Servicing automotive battery

COMPETENCY BASED LEARNING MATERIAL

Sector:

AUTOMOTIVE

Qualification:

Automotive Servicing NC I

Unit of Competency:

Service Automotive Battery

Module Title:

SERVICING AUTOMOTIVE BATTERY

Technical Education and Skills Development Authority

East Service Road, South Superhighway, Taguig, Metro Manila

NATIONAL CERTIFICATE LEVEL 1

QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Basic Competencies Module Title Code
1. Receive and Respond to 1. Receiving and Responding to 500311101

Workplace Communication Workplace Communication 500311102
2. Work with Others 2. Working with Others 500311103
3. Demonstrate Work Values 3. Demonstrating Work Values 500311104

4. Practice Housekeeping 4. Practicing Housekeeping
Procedures Procedures

No. Common Competencies Module Title Code
1. Apply Appropriate 1. Applying Appropriate ALT723201
ALT723202
Sealant/Adhesive Sealant/Adhesive ALT311201
2. Move and Position Vehicle 2. Moving and Positioning ALT311202

3. Perform Housekeeping Vehicle ALT311203
4. Perform Mensuration and 3. Performing Housekeeping ALT723203

Calculation 4. Performing Mensuration and ALT723204
5. Perform Safety Practices Calculation
6 Read, Interpret and Apply ALT723205
5. Performing Safety Practices
Specifications and Manual
6. Reading, Interpreting and
7. Use and Apply Lubricant/Coolant Applying Specifications and
Manual
8. Perform Shop Maintenance
7. Using and Applying Lubricants/
Coolants

8. Perform Shop Maintenance

No. Core Competencies Module Title Code
ALT723301
1. Perform Diesel Engine Tune Up 1. Performing Diesel Engine
ALT723302
Tune Up
ALT723303
2. Perform Gas Engine Tune Up 2. Performing Gas Engine Tune
ALT723304
Up ALT723305

3. Service Automotive 3. Servicing Automotive ALT723306

Battery Battery9

4. Service Ignition System 4. Servicing Ignition System

5. Test and Repair Wiring/Lighting 5. Testing and Repairing Wiring/

System Lighting System

6. Perform Underchassis Preventive 6. Performing Underchassis

Maintenance Preventive Maintenance

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the Module “Servicing Automotive Battery”. This module contains
training materials and activities for you to complete.

The unit of competency “Service Automotive Battery” contains the knowledge,
skills and attitudes required for an Automotive Servicing course. This is one of the
common modules for National Certificate level I (NC I).

You are required to go through a series of learning activities in order to complete
each of the learning outcomes of the module. In each learning outcome there are
Information Sheets, Operation Sheets and Job Sheets (Reference Materials for further
reading to help you better understand the required activities. Follow these activities on your
own and answer the self-check at the end of each learning activity.

If you have questions, don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this
module because you have:

• been working for some time
• already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill or
skills, talk to him/her about having them formally recognized so you don’t have to do the
same training again. If you have a qualification or Certificate of Competency from previous
trainings show it to your trainer. If the skills you acquired are still current and relevant to this
module, they may become part of the evidence you can present for RPL. If you are not sure
about the currency of your skills, discuss this with your trainer.

After completing this module ask your trainer to assess your competency. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.

Inside this module you will find the activities for you to complete and at the back are
the relevant information sheets for each learning outcome. Each learning outcome may have
more than one learning activities.

At the end of this module is a Learner Diary. Use this diary to record important dates,
jobs undertaken and other workplace events that will assist you in providing further details to
your trainer or an assessor. A Record of Achievement is provided for you by your trainer to
accomplish once you complete the module.

This module is prepared to help you achieve the required competency, in servicing
automotive battery. This will be the source of information that will enable you to acquire the
knowledge and skills in this particular trade independently at your own pace or with
minimum supervision or help from your instructor.

- Talk to your trainer and agree on how you will both organize the training of this
unit. Read through the learning guide carefully. It is divided into sections which
cover all the skills and knowledge you need to successfully complete this module.

- Work through all the information and complete the activities in each section and
complete the self-check. Suggested references are included to supplement the
materials provided in this module.

- Most probably your trainer will also be your supervisor or manager. He/she is
there to support you and show you the correct way to do things. Ask for help.

- Your trainer will tell you about the important things you need to consider when you
are completing activities and it is important that you listen and take notes.

- Talk to more experienced work mates and ask for their guidance.

- Use the self-check questions at the end of each section to test your own progress.

- When you are ready, ask your trainer to watch you perform the activities outlined
in the learning guide.

- As you work through the activities, ask for written feedback of your progress from
your trainer. After completing each element, ask your trainer to mark on the report
that you are ready for assessment.

- When you have completed this module (or several modules) and feel confident
that you have had sufficient practice your trainer will arrange an appointment with
you to asses you. The result of your assessment will be recorded in your
Competency Achievement Record.

Program /Course Automotive Servicing NC I
Unit of Competency SERVICE AUTOMOTIVE BATTERY
Module SERVICING AUTOMOTIVE BATTERY

INTRODUCTION:

This module contains information and suggested learning activities on servicing
automotive batteries. It includes instructions and procedure on how to identify/ explain the
operation and safe handling of different types of battery, removing, replacing, servicing and
charging batteries.

Completion of this module will help you in the understanding of succeeding modules on
ignition system and wiring/ lighting system.

This module consists of five learning outcomes. Each outcome contains learning
activities for both knowledge and skills, supported with information sheets, self-check activities
and job/operation sheets, gathered from different sources. Before you perform the manual
exercises, read the information/operation sheet and answer the self activities provided to
ascertain to yourself and your instructor that you are equipped with the knowledge necessary to
perform the skill portion of the particular learning outcomes.

Upon completion of this module, please report to your instructor for assessment to check
your understanding of the knowledge and skills requirements of this module. If you pass the
assessment, you will be given a certificate of completion.

SUMMARY LEARNING OUTCOMES

Upon completion of the module the trainees/students should be able to:

LO1 Identify and explain the operation and safe handling of different types of battery.
LO2 Demonstrate the testing of an automobile battery.
LO3 Demonstrate the correct procedure for removing and replacing batteries.
LO4 Demonstrate the correct procedure for servicing and charging batteries.
LO5 Demonstrate the correct procedure of jump starting a battery.

ASSESSMENT CRITERIA

Refer to assessment criteria of learning outcomes # 1-5 of this module (total of 27 criteria).

PREREQUISITES

Before you read this module, please ensure that work area and equipment are set up and
ready.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Aug. 15, 2003 March 1, 2006 1

Program /Course Automotive Servicing NC I
Unit of Competency SERVICE AUTOMOTIVE BATTERY
Module SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME #1

Identify and explain the operation and safe handling of different types of battery.

ASSESSMENT CRITERIA

1. Main Components of battery are identified.
2. Kinds of battery according to composition and function are differentiated.
3. Uses of different batteries according to vehicle classification are explained.
4. Safe handling and hazards associated with batteries are observed

RESOURCES

• Automotive Mechanics 10th Edition by Crouse- Anglin
• AutoTech CD
• Preventive Maintenance Manual
• Safety presentation chart

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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LEARNING EXPERIENCE

Learning Outcome #1: Identify and explain the operation and safe handling of different
types of battery.

Learning Activities Special Instructions

• What kind of battery have you already
seen?

• How does it differ from an automotive
battery?

1.1 Secure from your trainer information sheet Read Information sheet LO1-1. “Parts of a
of a cutaway 12V battery showing its Lead-Acid Battery”
internal construction. Refer this to the
mock-up conventional battery provided.

a. Read Battery Construction Read Information sheet LO1-2. “Battery
Construction”
b. After reading, proceed to your trainer
and ask what chemicals the battery
components are made of.

c. After doing a & b, answer a self-check Answer Self-Check LO1-1.
sheet #1.

d. Read Electrochemical process and Read Information Sheet LO1-3.
chemical reaction in a lead-acid “Electrochemical Process and Chemical
battery. Reaction in a Lead-Acid Battery”

• What is electromotive force? Refer to “Fundamentals of Environmental
Chemistry” pp. 281-282
• How do you measure the
electrochemical force of a battery?

• Approach your trainer for more Refer to “Conceptual Physics” Eight Edition
clarification about electrochemistry by Paul Hewitt pp. 388-389
and electromotive force if
necessary.

e. After doing c & d answer self check Answer Self-check LO1-3
correctly.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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LEARNING EXPERIENCE

Learning Outcome #1: Identify and explain the operation and safe handling of different
types of battery.

Learning Activities Special Instructions

1.2 Ask for the next handout from your
trainer on type of batteries.

• Which battery would you prefer to Read Information Sheet LO1-4.”Conventional

use? Why? and Maintenance-Free Battery”.

a. Read on the kinds of battery according
to composition and function.

1.3 Read: Working Safely Around Batteries. Read Information Sheet LO1-4.” Working
Safely Around Batteries”.

Things to do:

Make at least 5 rules on the Safe Refer to “Automotive Mechanics” by Crouse
Handling of Batteries. Write one rule on top and Anglin p. 356
of each sheet of bond paper with illustration
at the middle. Below it, write the Hazards
associated with mishandling a battery.

1.4 Research activity: Uses of Different Sample Form
Batteries According to Vehicle
Classification.
a. Answer the self-check sheet form
from your trainer.

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Information Sheet LO1-1. Parts of a Lead-Acid Battery

CONVENTIONAL BATTERY

DEEP CYCLE BATTERY

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Information Sheet LO1-2. Battery Construction

1. Battery Operation

The automotive battery supplies electric current to operate the starting motor and ignition
systems while starting the engine. It also acts as a voltage stabilizer by supplying current for
the lights, radio and other electrical accessories when the alternator is not handling the load.
In addition, the battery supplies a small current to the volatile memory in the electronic
control module (ECM) while the ignition key is off.

The battery is an electrochemical device. It uses chemicals to produce electricity. The
amount of electricity it can produce is limited. As the chemicals in the battery are depleted,
the battery runs down and is discharged. It can be recharged by supplying it with electric
current from the vehicle alternator or from a battery charger. The depleted chemicals are
restored to their original condition as the battery becomes recharged.

2. Chemicals in Battery

The battery is a lead-acid storage
battery. The chemicals in it are sponge
lead (a solid), lead oxide (a paste), and
sulfuric acid (a liquid). These three
substances can react chemically to
produce a flow of current. The lead
oxide and sponge lead are held in plate
grids to form the positive and negative
plates. The grids are made of lead with
other elements, such as calcium,
added.

The sulfuric acid is mixed with water to Figure LO1-2.1 Two types of automotive batteries. Left,
form the electrolyte. This is the liquid in caps can be removed to check the battery state of charge
a battery. The electrolyte is about 60
percent water and 40 percent sulfuric and to add water if needed. Right, a maintenance-free
acid in a fully-charged battery. As the battery that requires no additional water. The charge
battery discharges, the electrolyte loses
sulfuric acid and becomes mostly water. indicator in the top shows the state of charge.

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3. Battery Construction

The battery case is molded plastic. The
plates are welded to plate straps to form
plate groups. To make a battery cell, a
positive plate group fits into a negative
plate group. Porous separators are placed
between the plates. This prevents positive
and negative plates from touching while
allowing electrolyte to circulate between
the plates.

Figure LO1-2.2 Cutaway 12-volt battery showing its
internal construction.

The assembly of plate groups and
separators is an element. The elements fit
into compartments in the battery case to
form cells. Heavy lead connectors attach
to the cell terminals and connect the cells
in series. A plastic cover forms the top of
the battery. Some batteries have openings
in the cover from which filler plugs or vent
caps are removed to add water.
Maintenance-free batteries do not have
the removable vent caps.

Figure LO1-2.3 Partly assembled battery elements.

Some batteries are top-terminal batteries. They have the two main terminals or posts in the
cover. The positive terminal post is larger than the negative terminal post. Other batteries
are side-terminal batteries. They have the terminals on the side of the battery.

4. Connecting Cells

The 12-volt battery has six cells connected in series. This means the cell voltages add
together to produce the battery voltage. Each cell has a voltage of about 2.15 volts at full
charge. A fully charged battery has a voltage of about 12.9 volts.

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5. Battery Ratings

Two methods of rating batteries are reserve capacity and cold-cranking rate. An older
battery rating is ampere-hour capacity. This is the amount of current that a battery can
deliver for 20 hours without the temperature-corrected cell voltages dropping below 1.75
volts per cell.

• Reserve Capacity – This is the length of time that a fully-charged battery at 80ºF
(27ºC) can deliver 25 amperes. A typical rating is 125 minutes. This indicates the
battery can be discharged at 25 amperes for 125 minutes if the alternator is not
working.

• Cold-Cranking rate – This is a measure of the ability of a battery to crank an engine
when the battery is cold. There are two ratings. One is a number of amperes the 12-
volt battery can deliver for 30 seconds when it is at 0ºF (-18ºC) without the battery
voltage falling below 7.2 volts. A typical rating for a battery with a reserve capacity of
125 minutes is 430 amperes.

A second cold-cranking rating starts with the battery temperature at -20ºF (-29ºC). This
rating allows the final voltage to drop to 6 volts. A typical rating for a battery with a reserve
capacity of 125 minutes is 320 amperes.

6. Battery Efficiency

The ability of a battery to deliver current on its state of charge, temperature and discharge
rate. A partly discharged battery or a battery at low temperature can deliver less current.

7. Variations in Terminal Voltage

When the battery is being charged, terminal voltage increases with:

a. Increasing charging rate. Voltage must go up to increase the charging rate.
b. Increasing state of charge. It takes a higher voltage to force current through a fully-

charged battery.
c. Decreasing battery temperature. The lower temperature reduces chemical activity,

requiring a higher voltage to maintain the charging rate.

When the battery is being discharged, terminal voltage decreases with:

a. Increasing discharge rate.
b. Decreasing state of charge
c. Decreasing battery temperature

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Self-Check LO1-1

Select the best answer.

1. The battery is an electrochemical device. This means the battery
a. makes chemicals by electronic means
b. uses chemicals to provide electricity
c. has non-chemical plates
d. does not use an electrolyte

2. The battery performs the following EXCEPT
a. supplies current to crank the engine
b. supplies current when the charging system cannot handle the load
c. supplies current to the ignition system with the engine off
d. supplies current to the ECM while the engine is off

3. On a top-terminal battery, the negative terminal post is
a. smaller than the positive terminal post
b. the same size as the positive terminal post
c. larger than the positive terminal post
d. none of the above

4. The time in minutes that a fully charged battery at 80ºF (27ºC) can deliver 25 amperes is the
a. charging time
b. reserve capacity
c. cold-cranking rate
d. ampere-hour rate

5. The number of amperes that the battery can deliver for 30 seconds at 0ºF (-18ºC) without
cell voltages falling below 7.2 volts is called the
a. charging time
b. reserve capacity
c. cold-cranking rate
d. ampere-hour rate

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Answer Key LO1-1

1. B
2. C
3. A
4. B
5. C

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Information Sheet LO1-3. Electrochemical Process and Chemical
Reaction in Lead-Acid Battery

ELECTROCHEMICAL PROCESS

1. Cell Operation

Two dissimilar metals placed in an acid
bath produce electrical potential across the
poles. The cell produces voltage by a
chemical reaction between the plate and
the electrolyte. The positive plate is made
of reddish-brown material such as Lead
Dioxide (PBO2) while the negative plate is
made of grayish material called Sponge
Lead (PB). The acid bath is a mixture of
sulfuric acid and water cell electrolyte.
Together a cell element is formed.

2. Cycling

The battery stores electricity in the form of
chemical energy. Through a chemical
reaction process the battery creates and
releases electricity as needed by the
electrical system or devices. Since the
battery loses its chemical energy in this
process, the battery must be recharged by
the alternator. By reversing electrical
current flow through the battery the
chemical process is reversed, thus
charging the battery. The cycle of
discharging and charging is repeated
continuously and is called “battery cycling”.

3. Deep Cycling

Although batteries do cycle continuously, they do not cycle deeply. Deep cycling is when the
battery is completely discharged before recharge.

Automotive batteries are not designed as deep cycle batteries. Automotive batteries are
designed to be fully charged when starting the car; after starting the vehicle, the lost charge
is replaced by the alternator. So the battery remains fully charged. Deep cycling an
automotive battery will cause damage to the plates and shorten battery life.

Marine or golf cart batteries (Deep Cycle Batteries) on the other hand are designed to be
completely discharged before recharging. Because charging causes excessive heat which
can warp the plates, thicker and stronger plate grids are used. Normal automotive batteries
are not designed for repeated deep cycling and use thinner plates.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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ELECTROCHEMICAL REACTION

A lead-acid storage battery can be partially
discharged and recharged many times. There
are four stages in this discharging/charging
cycle.

1. CHARGED: A fully charged battery contains
a negative plate of sponge lead (Pb), a
positive plate of lead dioxide (Pb02), and
electrolyte of sulfuric acid (H2SO4) and water
(H20).

2. DISCHARGING: As the battery is
discharging, the electrolyte becomes diluted
and the plates become sulfated. The
electrolyte divides into hydrogen (H2) and
sulfate (S04) . The hydrogen (H2) combines
with oxygen (0) from the positive plate to form
more water (H20). The sulfate combines with
the lead (Pb) in both plates to form lead sulfate
(PbS04)

3. DISCHARGED: In a fully discharged
battery, both plates are covered with lead
sulfate (PbSO4) and the electrolyte is diluted
to mostly water (H2O).

4. CHARGING: During charging, the chemical
action is reversed. Sulfate (S04) leaves the
plates and combines with hydrogen (H2) to
become sulfuric acid (H2SO4). Free oxygen
(02) combines with lead (Pb) on the positive
plate to form lead dioxide (Pb02). Gassing
occurs as the battery nears full charge, and
hydrogen bubbles out at the negative plates,
oxygen at the positive.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Self-Check LO1-3

1. Voltage can be defined as:

A. Electrodynamic force
B. Electropotential force
C. Electrochemical force
D. Electromotive force

2. Current is the

A. Build up of electrons
B. Flow of electrons
C. Division of electrons
D. Passing of electrons

3. Resistance is the ___________ of/to current flow.

A. Opposite
B. Opposition
C. Result
D. Reverse

4. Voltage compares to __________ in a gas system.

A. Flow of gas
B. Restriction of gas flow
C. Pressure
D. Orifice effect

5. Current compares to ________ in a liquid piping system.

A. Orifice effect
B. Flow of product
C. Pressure pushing the product
D. Friction of the inside pipe wall

6. Resistance compares to ___________ in a gas or liquid piping system.

A. Build up of pressure
B. Flow of product
C. Orifice effect
D. Pipe’s outside diameter Text.

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Answer Key LO1-3

1. C
2. B
3. B
4. C
5. C
6. C

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Information Sheet LO1-4. Conventional and Maintenance-Free Battery

When selecting a battery type, it is extremely important that you select one that will match the
voltage output of your charging system. The easiest way to accomplish this is to replace your
battery with the same or compatible type of battery that originally was installed. If you change
your replacement battery to another battery type, you might have to adjust the charging voltage
to prevent undercharging or overcharging that could damage or reduce the service life of your
new battery. For example, replacing an Original Equipment Manufacturer (OEM) wet sealed
Maintenance Free (Ca/Ca) with a wet non-sealed Low Maintenance (Sb/Ca) battery (with filler
caps) might cause the Low-Maintenance (Sb/Ca) battery to be slightly overcharged and
consume more water. If you charge a Maintenance Free (Ca/Ca) battery with a charging system
or charger designed for a Low Maintenance (Sb/Ca) battery (with filler caps), you could
undercharge the Maintenance Free (Ca/Ca) battery. Replacing any other non-Gel Cell type of
battery with a Gel Cell could overcharge it. When in doubt, replace with an AGM or spiral wound
AGM battery.

Deep Cycle batteries are broadly divided into motive and stationary applications.

• Motive applications are where the battery is discharged in operations that will consume
between 20% and 80% of the battery's capacity and then recharged (which is considered to
be one cycle). Some examples of motive (also known as "cycling" or "traction") applications
are for batteries used in recreational vehicles (RV), motor homes, caravans, trailers, boats,
wheelchairs, golf carts, solar, floor sweepers, folk lift trucks and other electric vehicles (EV)
and typically have 200-500 cycles per year. Non-sealed wet Standard (Sb/Sb), wet Low-
Maintenance (Sb/Ca), VRLA AGM or VRLA Gel Cell batteries with pasted, tubular or
Manchester ("Manchex") positive plates or VRLA Spiral Wound AGM batteries are
recommended for motive deep cycle applications.

• Stationary (also known as "float", "reserve", "backup" or "standby") applications are where
stationary batteries are used to provide backup or standby power during loss of the primary
source of power such as uninterruptible power systems (UPS), emergency lighting systems,
security systems, telecommunications systems, etc., and typically have 2-12 cycles per
year. Generally, stationary batteries have longer service lives, more life cycles and cost
more than motive batteries. The chargers for motive and stationary batteries are different as
well. Non-sealed wet Standard (Sb/Sb), wet Low-Maintenance (Sb/Ca), wet Maintenance
Free (Ca/Ca) batteries with pasted or solid (Planté) positive plates are recommended for
stationary applications.

Wet Deep Cycle batteries, such as Marine/RV,
leisure and some golf cart, that use pasted
positive plates are less expensive to
manufacturer and have fewer life cycles and
shorter service lives at 50% average Depth-of-
Discharge (DoD) level than the Deep Cycle
batteries with solid (Planté), tubular or
Manchester (or "Manchex") positive plates.

They also have significantly fewer life cycles at the 80% average DoD level. Be aware that
some starting battery manufacturers have added handles and stud type terminals to their
cheaper starting batteries and sell them as Marine/RV Deep Cycle. The major disadvantage of
VRLA (AGM or Gel Cell) Deep Cycle batteries are their high initial cost (up to three times over
the cost of wet Standard (Sb/Sb) batteries), but arguably can have an overall lower total cost of

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ownership due to a longer service life, no "watering" and other labor costs, and faster
recharging. The total cost of ownership should be considered when buying Deep Cycle
batteries.

Advantages and disadvantages of the different types of batteries

ƒ Conventional or Wet Standard (Sb/Sb). Standard or "Conventional" (Sb/Sb) non-sealed
lead-acid batteries (with filler caps) have Lead-Antimony (Sb)/Antimony (Sb) plates and
have been commercially available for almost 100 years. They have a:

ƒ Tolerance for a wide range of charging current (to 25% of the battery's capacity) and
voltage.

ƒ Long service life (if properly maintained).

ƒ Increased water consumption.

ƒ Low tolerance for heat (they will lose half of their service life for every Increase of 15° F
(8.3° C) over 80° F (26.7° C).

ƒ High self discharge rate (depending on the temperature up to 50%-60% per month).

ƒ Charging losses of 15%-20% and maximum continuous discharge rate 25% of their
capacity.

Summary
For these reasons, they have almost been completely replaced by wet Low Maintenance
(Ca/Sb) batteries for high temperature under hood starting applications, but are still used for
many Deep Cycle motive applications. Wet Standard (Sb/Sb) batteries are generally the least
expensive lead-acid batteries.

Flooded, Wet or Low Maintenance (Sb/Ca)

The wet (or "flooded" cell) Low Maintenance
batteries (with filler caps) have a Lead-
Antimony (Sb)/Calcium (Ca) dual alloy or
hybrid plate formulations.They have most of
the same characteristics as wet Standard
(Sb/Sb) batteries, except they can handle the
high under hood heat better. Some battery
manufacturers,such as Johnson Controls,
build "North" and "South" Car battery versions
to make up for the differences in cold and hot
climates. Some also construct special Car
batteries that have a higher tolerance to heat
by changing plate or connecting strap
formulations or providing for more electrolyte.

For off road applications in trucks, recreational vehicles (RV's), motor caravans, 4x4s, vans or
SUV's (Sport Utility Vehicles), some battery manufacturers build "high vibration", "heavy duty",
"commercial", or "RV" battery versions designed to reduce the effects of moderate vibration. A
wet Low Maintenance(Sb/Ca) battery will typically cost a little more than a similar sized wet
Standard (Sb/Sb) battery.

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Wet or Maintenance-Free (Ca/Ca)
Wet Maintenance Free batteries have a Lead-Calcium (Ca)/Calcium (Ca) plate chemistry or
formulation, for example, Delphi 's ACDelco. The advantages of Maintenance Free (Ca/Ca)
batteries over Low Maintenance (Sb/Ca) are:

• Less preventive maintenance due to less water loss.

• Greater overcharge resistance.

• Reduced terminal corrosion.

• Up to 400% less self discharge.

• Less risk to consumers because there is less to service.

Summary
However, they are more prone to deep discharge ("dead" or "flat" battery) failures due to
increased shedding of active plate material and development of a barrier layer between the
active plate material and the grid metal. If a Maintenance Free (Ca/Ca) battery is sealed, water
can not be added when required. For that reason, in hot climates, using non-sealed wet
batteries (with filler caps), so you add distilled water, for under the hood or a sealed AGM
battery inside the passenger compartment or trunk is highly encouraged for longer battery
service life. Wet Maintenance Free (Ca/Ca) batteries are generally more expensive than wet
Low Maintenance (Sb/Ca) batteries.

AGM, or Absorbed Glass Mat
It is true that AGM batteries are more
expensive than Maintenance Free (Ca/Ca)
batteries. AGM batteries offer the following
advantages over conventional batteries:

ƒ Safer. Due to the much lower
production of hydrogen gas during
charging.

ƒ Maintenance-free. Sealed
maintenance-free design means you
never have to worry about checking
water levels. You'll never have to check
or add electrolyte again, unlike
conventional batteries which require
periodic fluid checks, do not require
water.

ƒ Sealed. Spill proof. They can be mounted in virtually any position (because they are
sealed).

ƒ No corrosion. Liquid-free AGM design will not leak or corrode on paint and chrome. It
also eliminates corrosion around the battery terminals.

ƒ They have less internal resistance that offers more CCA amperage than wet batteries.

ƒ Heat & vibration resistant. By nature AGM batteries are more heat and vibration resistant
than conventional batteries, both which contribute to the large majority of failures in
motorcycle & competition auto applications.

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ƒ Slower self-discharge rate. Slower self-discharge rate (longer shelf life) means battery
can sit for extended periods of time without constant monitoring. A wet battery
discharges 15% a month, where our AGM batteries discharge only 2-3% a month. AGM
batteries have less internal resistance which allows them to produce more discharge
current (cold cranking amperage) vs. comparable conventional "wet" batteries, and AGM
batteries also recharge faster

ƒ Longer service life.

ƒ Lower deep discharge failure.

ƒ Higher bulk charge acceptance rate (which means up to a 15% shorter recharge time).

ƒ Do not require special hazardous shipping and can be used near saltwater.

Gel Cell
Sealed VRLA (Valve Regulated Lead-
Acid) Gel Cell batteries use GRT
(Recombinant Gas Technology) and
use a thickening agent like fumed silica
gel to immobile the electrolyte instead
of a liquid electrolyte like the wet
batteries. They have a lot of the same
advantages of AGM batteries. When
comparing Gel Cell to AGM and Spiral
Wound AGM batteries, Gel Cells will
typically:

ƒ Have greater ability to withstand
a deep discharge, but not
temperatures over over 100°F
(37.8° C) because of the
possibility of "thermal runaway".

ƒ 10 to 15 cycle preconditioning or "break-in" period.

ƒ Less Cold Cranking Amps.

ƒ 80% of the capacity of a similar sized AGM battery and physically larger.

ƒ Slower recharging times and intolerant of higher charging voltages.

ƒ Lower capacity in cold temperatures.

ƒ Up to 20% more life cycles.

ƒ Cost more to manufacture.

ƒ Charging losses of 4% and maximum continuous discharge rate 25% of their capacity.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Additional Information:

General Battery Types

1. PRIMARY CELL: The chemical reaction totally destroys one of the metals after a period of
time. Small batteries for flashlights and radios are primary cells.

2. SECONDARY CELLS: The metals and acid mixture change as the battery supplies voltage.
The metals become similar, the acid strength weakens. This is called discharging. By
applying current to the battery in the opposite direction, the battery materials can be
restored. This is called charging. Automotive lead-acid batteries are secondary cells.

3. WET-CHARGED: The lead-acid battery is filled with electrolyte and charged when it is built.
During storage, a slow chemical reaction will cause self-discharge. Periodic charging is
required. For Toyota batteries, this is every 5 to 7 months.

4. DRY-CHARGED: The battery is built, charged, washed and dried, sealed, and shipped
without electrolyte. It can be stored for 12 to .18 months. When put into use, it requires
adding electrolyte and charging.

5. LOW-MAINTENANCE: Most batteries for Toyota vehicles are considered low-maintenance
batteries. Such batteries are built to reduce internal heat and water loss. The addition of
water should only be required every 15,000 miles or so.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Information Sheet LO1-5. Working Safely Around Batteries

When testing or servicing a battery, safety should be your first consideration. The electrolyte
contains sulfuric acid. It can eat your clothes. It can burn your skin. It can blind you if it gets in
your eyes. It can also ruin a car's finish or upholstery. If electrolyte is splashed on your skin or in
your eyes, wash it away immediately with large amounts of water. If electrolyte is spilled on the
car, wash it away with a solution of baking soda and water. When a battery is being charged,
either by the charging system or by a separate charger, gassing will occur. Hydrogen gas is
explosive. Any flame or spark can ignite it. If the flame travels into the cells, the battery may
explode.

Safety precautions include:

• Wear gloves and safety glasses.
• Remove rings, watches, other jewelry.
• Never use spark-producing tools near a battery.
• Never lay tools on the battery.
• When removing cables, always remove the ground cable first.
• When connecting cables, always connect the ground cable last.
• Do not use the battery ground terminal when checking for ignition spark.
• Be careful not to get electrolyte in your eyes or on your skin, the car finish, or your clothing.
• If you have to mix battery electrolyte, pour the acid into the water - not the water into the

acid.
• Always follow the recommended procedures for battery testing and charging and for jump

starting an engine.

CARE OF ELECTRONICS

Disconnecting the battery will erase the memory on electronic devices. Write down trouble
codes and programmed settings before disconnecting the battery.

Also, to prevent damage to electronic components:

• Never disconnect the battery with the ignition ON.
• Never use an electric welder without the battery cables disconnected.
• Never reverse battery polarity.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Program /Course Automotive Servicing NC I
Unit of Competency SERVICE AUTOMOTIVE BATTERY
Module SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME #2

Demonstrate on how to test an automotive battery.

ASSESSMENT CRITERIA

1. Different types of battery testing are performed.
2. Battery is tested without causing damage to workplace, property or vehicle.
3. Battery information is assessed and interpreted based on manufacturer specification.
4. Appropriate test equipment is selected and used.
5. Tests are performed and result analyzed.
6. Findings are reported to direct supervisor.
7. Personal safety is observed.

RESOURCES

• Automotive mechanics 10th edition by Crouse- Anglin
• Preventive maintenance manual

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Aug. 15, 2003 March 1, 2006 21

LEARNING EXPERIENCE

Learning Outcome #2: Demonstrate on how to test an automotive battery.

Learning Activities Special Instructions

2.1 What is an electrolyte?

An electrolyte is 36% H2SO4 and 64%
distilled water

Things to do:

a. Write a procedure in preparing 150 ml of Answer Self Check LO2-1.
electrolyte solution and show it to your
trainer. With your trainer’s approval,
prepare the solution and set it aside for
future use.

b. What is a chemical symbol? A chemical
formula? Give examples of the elements
and compounds involved in the study of
battery chemistry.
• After doing a & b, answer the self
check correctly.

2.2 Examine the hydrometer carefully. How Read Information Sheet LO2-1
many interval does the scale have? Try
to suck as much tap water using this Refer to “Automotive Mechanic” by Crouse
instrument. What do you observe? Try it and Anglin p 358
with the electrolyte you prepared earlier • Determine the specific gravity of distilled
and make a comparison.
a. Read about specific gravity and draw a water.
table showing the specific gravity of • Determine the specific gravity electrolyte
common substances.
b. Read the procedure on testing battery you have prepared?
using a hydrometer.
c. Test the battery using a hydrometer
and tabulate your observation. Report
this to your trainer.

2.3 Examine the voltmeter. Refer to “Automotive Mechanic”. pp 350-351
• How is it calibrated?
• What maximum and minimum unit Things to do:
of measure does it have?
• What is the unit of measurement • Using this instrument, test your battery
used? voltage following proper procedure.
Interpret your findings and make a report
it to your trainer.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Self-Check LO2-1
1. Write a procedure in preparing 150 ml of electrolyte solution and show it to your trainer.

With your trainer’s approval, prepare the solution and set it aside for future use.

2. What is a chemical symbol? A chemical formula? Give examples of the elements and
compounds involved in the study of battery chemistry.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Information Sheet LO2-1. Battery Testing

Battery testing has changed in recent years; although the three areas are basically the same,
the equipment has improved.

1. Visual Inspection
2. State of Charge

a. Specific Gravity
b. Open Circuit Voltage
3. Capacity or Heavy Load Test

Note: This does not include the Midtronics battery tester which has a different test procedure
and will be discussed later in this module.

VISUAL INSPECTION

Battery service should begin with a thorough visual inspection. This inspection may reveal
simple, easily corrected problems.

1. Check for cracks in the battery case and
broken terminals. Either may allow
electrolyte leakage, which requires battery
replacement.

2. Check for cracked or broken cables or
connections. Replace, as needed.

3. Check for corrosion on terminals and dirt
or acid on the case top. Clean the
terminals and case top with a mixture of
water and baking soda. A battery wire
brush tool is needed for heavy corrosion
on the terminals.

4. Check for a loose battery hold-down or
loose cable connections. Clean and
tighten, as needed.

5. Check the electrolyte fluid level. The level
can be viewed through the translucent
plastic case or by removing the vent caps
and looking directly into each cell. The
proper level is 1/2" above the separators
(about 1/8" below the fill ring shown
below). Add distilled water if necessary.
Do not overfill.

6. Check for cloudy or discolored electrolyte
caused by overcharging or vibration. This
could cause high self discharge. Correct
the cause and replace the battery.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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STATE OF CHARGE

The state of charge of a battery can be easily checked in one of two ways:

Specific Gravity Test

Open Circuit Voltage Test

Note:

1: A state of charge test is required to determine if there is sufficient charge in the battery to
properly perform a capacity test (explained later).

2: The only exception to this is the MIDTRONICS Battery Tester. This new state of the art
capacitance tester will be discussed later in this module.

SPECIFIC GRAVITY

Specific gravity means exact weight. A
"Hydrometer" or a "Refractometer" compares
the exact weight of electrolyte with that of
water. Strong electrolyte in a charged battery
is heavier than weak electrolyte in a
discharged battery. By weight, the electrolyte
in a fully charged battery is about 36% acid
and 64% water. The specific gravity of water is
1.000. The acid is 1.835 times heavier than
water, so its specific gravity is 1.835. The
electrolyte mixture of water and acid has a
specific gravity of 1.270, usually stated as
"twelve and seventy."

SPECIFIC GRAVITY READINGS

By measuring the specific gravity of the
electrolyte, you can tell if the battery is fully
charged, requires charging, or must be
replaced. It can tell you if the battery is
sufficiently charged for a capacity (heavy-load)
test. The battery must be at least 75%
charged to perform a heavy load test. (The
heavy load test will be discussed later). In
other words, each cell must have a specific
gravity of 1.230 or higher to proceed.

If the battery is less than 75% charged, it must be fully recharged before proceeding. If the
battery is 75% or higher proceed to a heavy load test. A battery not sufficiently charged will fail
because it is discharged.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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SPECIFIC GRAVITY - EXCESSIVE CELL
VARIATION READINGS
Variation in specific gravity among cells
cannot vary more than 0.050. The variance is
the difference between the lowest cell and the
highest cell. A battery must be condemned for
excessive cell variation if more that 0.050. In
the example below, the highest SG reading is
cell #1 (shown in green) while the lowest SG
reading is cell #5 (shown in blue); the
difference is 0.070 which requires battery
replacement. Cell #5 if failing.

Many factors contribute to cell variation; for example, if water was just added to that cell, the cell
is then diluted with water resulting is a lower specific gravity reading. Recharging the battery
would correct this false reading. In some cases if a battery that has cell variation slightly over
the specification and is only about 50% charge, charging the battery at a slow rate of charge
(5A) may reduce the cell variation, thus saving the battery.

SPECIFIC GRAVITY TEST PROCEDURE (HYDROMETER)

1. Wear suitable eye protection.

2. Remove vent caps or covers from the
battery cells.

3. Squeeze the hydrometer bulb and insert
the pickup tube into the cell closest to the
battery's positive (+) terminal.

4. Slowly release the bulb to draw in only
enough electrolyte to cause the float to
rise. Do not remove the tube from the cell.

5. Read the specific gravity indicated on the float. Be sure the float is drifting free, not in
contact with the sides of top of the barrel. Bend down to read the hydrometer at eye level.

Disregard the slight curvature of liquid on the float.

6. Record your readings and repeat the procedure for the remaining cells

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ADJUSTED SPECIFIC GRAVITY READINGS

Temperature correction is needed because specific gravity changes with temperature. Cold
thickens the electrolyte and raises the specific gravity. Heat thins the electrolyte and lowers
the specific gravity. Hydrometers are calibrated at 80'F (26.7'C). Electrolyte temperatures above
or below 80'F must be adjusted. For every 10'F increment below 80'F, subtract 0.004 to the
hydrometer readings, and for each 10'F increment above 80'F, add 0.004 to the readings. See
the examples below.

SPECIFIC GRAVITY TEST PROCEDURE (REFRACTOMETER)

A Refractometer optically measures the
specific gravity. No temperature correction is
needed.

1. Wear suitable eye protection.

2. Remove vent caps or covers from the
battery cells.

3. Place one drop of electrolyte on the
refractometer lens and close the prism.

4. Hold the refractometer up to the light and
reading chart from view finder.

5. Record your readings and repeat the procedure for the remaining cells.

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SPECIFIC GRAVITY TEST PROCEDURE
(AC Delco Battery with built- in Hydrometer)
1. Wear suitable eye protection.
2. Observe the built-in hydrometer.
Green Dot is visible: the battery is sufficiently charged for further testing (Heavy Load Test).
Dark Green Dot is visible: the battery needs to be recharged before further testing.
Light or Yellow Dot is visible: replace the battery

OPEN CIRCUIT VOLTAGE

A digital voltmeter must be used to check the
battery's open-circuit voltage. Analog meters
are not accurate and cannot be used.

1. Turn on the headlamps' high beam for
several minutes to remove any surface
charge.

2. Turn headlamps off, and connect the digital
voltmeter across the battery terminals.

3. Read the voltmeter. A fully charged battery
will have an open-circuit voltage of 12.6
volts.

On the other hand, a totally dead battery will
have an open-circuit voltage of less than 12.0
volts.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Note: If the battery is 12.4v or higher, proceed to heavy load test. If the battery is less than
12.4v, the battery must be fully recharged before testing. Be sure to remove the surface
charge completely; this is the number one mistake technicians make. If need be, place a load
tester on the battery and load the battery for 10 seconds at approximately 200 amps. Allow a
few minutes for the battery to recover then measure the open circuit voltage. This should
remove the surface charge and allow an accurate open circuit voltage measurement.
(Remember: a reading of 12.4 volts or higher load test the battery, 12.3 volts or less, recharge
the battery.)

HEAVY LOAD TEST

While a State of Charge test determines the battery's state of charge, it does not measure the
battery's ability to deliver adequate cranking power. A capacity, or heavy-load test measures
the battery's ability to deliver current. A battery load tester such as a Sun VAT-40 is used.
(Note: the battery must be at least 75% charged before a heavy test can be performed.)

DETERMINE CAPACITY RATING

The capacity rating is located on the battery label. Ratings can be expressed in CCA (Cold
Cranking Amps), AH (Amp-Hour), or JIS (Japanese Industrial Standard.) JIS uses a six digit
code (not shown). A conversion table is offered below that can be printed. If no rating is found
on the battery, then use the OEM battery rating found in most repair manuals.

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HEAVY LOAD TEST PROCEDURE
1. Install the load tester as shown in an earlier slide.
2. Load the battery by turning the Load Increase control until the ammeter reads 3 times the

amp-hour (AH) rating or one-half the cold-cranking ampere (CCA) rating.
3. Maintain the load for no more than 15 seconds, and note the voltmeter reading.
4. If the voltmeter reading during the test is

9.6 volts or higher, the battery is good.
9.5 volts or below, the battery is defective and needs replacement.

Note: Results will vary with temperature. Low temperatures will reduce the voltage reading, so
the electrolyte should be at 70'F or above. If not, use the following conversion table:

Voltage Temperature
9.6 70'F or above
9.5
9.4 60'F
9.3 50'F
9.1 40'F
8.9 30'F
8.7 20'F
8.5 10'F
0'F

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OPERATION SHEET LO2-1

Operation Title: Testing and Servicing Automotive Battery

Purpose: Ensure proper functioning and prolong the life of the
automotive battery

For the Operation: Automotive battery supplies electric current to operate
the starting motor and ignition system while starting the
engine. It also acts as a voltage stabilize by supplying
current for the lights, radio and other electrical
accessories when the alternator is not handling the load.

Equipment, Tools and Materials: Battery, cell tester, load tester, multi-tester, volt meter,
hydro meter and thermometer.

Procedure:

Conventional testing of Battery Using a Hydrometer

1. Open vent plugs.

2. Take a look at every cell for electrolyte level.

3. Add to cell where electrolyte level is low.

4. Measure the specific gravity of battery electrolyte.

5. List test result.

6. If the reading differs, use thermometer for battery electrolyte temperature.

7. After the measurement of electrolyte temperature, dip the thermometer on every cell for
electrolyte temperature. If the reading shows that the solution is above 80 F add .002 to the
reading of the thermometer. If the reading shows that the solutions is below 80°F subtract
.002 from the hydrometer reading.

Precautions: Never install a battery backward. The reversed polarity may cause high-
current flow which would damage electrical components.

Quality Criteria: 1. Use a battery charger to charge the battery.
2. Inspect, clean and replace the battery and cables after using.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Aug. 15, 2003 March 1, 2006 31

Program /Course Automotive Servicing NC I
Unit of Competency TEST, SERVICE AND REPLACE AUTOMOTIVE BATTERY
Module TESTING AND SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME #3

Demonstrate the correct procedure on how to remove and replace batteries.

ASSESSMENT CRITERIA:

1. Battery is removed without causing damage to the workplace, property or vehicle.
2. Proper procedure is followed in removing/ replacing battery.
3. Proper procedure is followed to prevent loss of vehicle electronics memory as per

manufacturer’s standards (if applicable.)
4. Appropriate tools and equipment are used.
5. Personal safety in removing and replacing battery is observed.

RESOURCES

• Automotive Mechanics 10th edition by Crouse- Anglin
• Preventive Maintenance manual

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Aug. 15, 2003 March 1, 2006 32

LEARNING EXPERIENCE

Learning Outcome #3: Demonstrate the correct procedure on how to remove and replace
batteries.

Learning Activities Special Instructions

3.1 Can you tell where the battery is found in
cars? In jeepneys or in ten wheeler
trucks?
• Why are batteries preferably placed
outside the vehicle bodies?

a. Read corrosion of metals. Refer to “Fundamentals of Environmental
• What is corrosion? Chemistry” by Stanly Manahan. Pp 296
• What are the causes of corrosion?
• Refer to the Service Manual

b. Write a procedure in removing battery Things to do:
from the vehicle. Repair/ replace damage • Inspect some vehicles where corrosion
parts and identify the tools to be used.
Show this to your trainer for approval. around the battery area is evident.

c. Read Electrical circuit safety
• After doing a, b, & c your instructor will
now tell you to remove the battery from
the vehicle following the procedure
you have prepared.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Information Sheet LO3-1 Battery Specifications

ORIGINAL EQUIPMENT BATTERIES Rating
50 Amp-Hours
Battery 60 Amp-Hours
50 D 20 70 Amp-Hours
55 D 23
N 70 Z

REPLACEMENT BATTERIES

BCI GROUP* TYPE PLATES RATINGS
(DIMENSIONS) (MONTHS) (NUMBER)
CCA RC
24, 24F 24 48
(10-3/16L x 6-3/16W x 9H) 36 54 (AMPERES) (MINUTES)
48 72
27, 27F 48 84 350 55
(12L x 6-3/16W x 8-15/16h)
400 60

525 100

560 115

BATTERY LOCATIONS:

Most batteries can be found under the hood and installed on battery holder with retaining straps
on most cars. Some other vehicles like jeepneys and European cars have them under the front
seat next to the driver’s seat. Others put them under the back seat of their car to improve weight
distribution on light vehicles. Putting batteries elsewhere other than under the hood can improve
their performance and life because they are far from high engine heat and vibration which
causes premature battery failure.

Batteries on light trucks can be found just under the hood or under the front seat next to the
driver’s seat. On heavy trucks, batteries are located under the cabin outside the vehicle. Some
trucks have them on battery boxes near the rear tires allowing for quick checking and servicing.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Operation Sheet LO3-1 Procedure in Removing and Replacing
Batteries

1. Connect a memory holder (a 9-volt battery
and adapter) to the cigarette lighter to keep
the volatile memories alive while the
battery is disconnected from the vehicle.
Follow the manufacturer’s instructions to
avoid overloading the 9-volt battery. If a
memory holder is not used, write down the
radio stations to which the push buttons
are preset. All data in this and other volatile
memories will be lost when the battery is
disconnected.

2. Disconnect the ground cable from the Loosening out and using battery-clamp puller to remove
battery. To remove a nut-and-bolt cable cable clamp from battery post.
clamp, use a box wrench or battery pliers.
Loosen the clamp bolt. Then pull the clamp
from the terminal.

3. Do not use other pliers or an open-end wrench. There is not enough room and they could
break the battery cover. If the clamp sticks, use a battery-clamp puller. Do not pry the clamp
off with a screwdriver or pry bar. You could break the cover. To detach the spring-ring cable
clamp, squeeze apart the ends of the rings with pliers.

4. Next, disconnect the insulated cable from the battery. Clean the terminals and cable clamps.
Loosen the hold-down clamps and remove the battery. Clean the battery tray and hold-down
clamps. If the parts are metal, clean them with a stiff brush and a solution of baking soda
and water. Open the water drain holes in the bottom of the tray. After rinsing and drying,
paint the tray and other metal parts with acid-resistant paint.

5. When installing the battery, do not reverse the terminal connections. Reconnect the
insulated cable first, then the ground cable. Tighten the hold-down clamps. Do not over-
tighten. Then reset the radio presets. Follow the procedure to restore data to the ECM and
volatile memories.

Caution: Be careful when installing the battery. Never install a battery backward. The reversed
polarity may cause high-current flow which would damage electrical components.

Wet batteries are new batteries that are shipped already filled with electrolyte. These batteries
periodically require recharging. Do not stack batteries on top of each other without additional
support. The weight can collapse the case and the plates in the bottom batteries.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Aug. 15, 2003 March 1, 2006 35

Self-Check LO3-1

Select the best answer.

1. To disconnect the battery, first
a. remove the vent plugs
b. disconnect the insulated cable from the battery
c. disconnect the ground cable from the battery
d. put the transmission in PARK or REVERSE

2. Technician A says a battery with and open-circuit voltage of 12.40 or higher can be load-
tested. Technician B says that an OCV of less than 12.40 means the battery must be
charged first. Who is right?
a. A only
b. B only
c. both A and B
d. neither A nor B

REVIEW QUESTION:

• Discuss the possible causes and troubles from battery overcharging and undercharging.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Program /Course Automotive Servicing NC I
Unit of Competency TEST, SERVICE AND REPLACE AUTOMOTIVE BATTERY
Module TESTING AND SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME #4

Demonstrate the correct procedure on how to service and charge batteries.

ASSESSMENT CRITERIA:

1. Battery is charged using appropriate battery charger.
2. Electrolyte levels are checked and topped up as necessary.
3. Battery and its terminals are cleaned.
4. Multiple connectors are used in accordance with manufacturer’s specification.
5. Leads are connected/disconnected in sequence and in correct polarity as indicated in

the manual.
6. Personal safety in servicing and charging battery is observed.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Aug. 15, 2003 March 1, 2006 37

LEARNING EXPERIENCE

Learning Outcome #4: Demonstrate the correct procedure on how to service and charge
batteries.

Learning Activities Special Instructions

4.1 What do you do to a vehicle that fails to
start?

• What are the causes of battery
failures?

A discharged battery will fail to supply the
required electric current to start a vehicle

• Read: Jump starting a battery. Ref. Automotive Mechanics p.373

After reading the procedure, answer

the self-check sheet. Complete the

connection on the battery terminals for

jumpstarting.

Ask your trainer to let you perform the Self-Check # 4

jumpstarting procedure in the actual battery.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Operation Sheet LO4-1 Charging Batteries

Two methods of battery charging are the slow
charge and the quick or fast charge. With slow
charging, the battery is given a charge of a
few amperes for several hours. A typical fast
charge is a 30-amp charging rate for up to 30
minutes. For further charging, reduce the
charging rate to 20 amps or less for up to 3
hour longer.

Charge a maintenance-free battery until the
green dot appears. To connect the charger to
a side-terminal battery, it may be necessary to
install bolts or adapters in the terminal bolt
holes.

When charging a battery in a vehicle, Battery charger connected to battery in a car.
disconnect the ground cable from the battery. Disconnect the negative or ground cable from the battery
This protects electrical and electronic
components from the high charging voltage. before connecting the battery-charger cables.

Caution: Never connect the battery charger backward. The reversed polarity may cause high-
current flow which would damage the vehicle electrical equipment.

Charge a battery with a charger:

1. Remove all the battery cell caps (if the battery is not maintenance free) and cover the holes
with a clean cloth to prevent spattering electrolyte.

2. Disconnect the negative battery cable and hook the battery charger cable clamps to the
battery posts (positive to positive, negative to negative), then set the charger to 12V if it has
a selector and plug in the charger.

3. Turn on the charger and check it regularly for the first couple of hours.

4. Continue to monitor a higher-amp (faster) charger. Let a trickle charger run for several hours
or overnight. A full charge on a trickle charger could take 8 to 16 hours.

5. If the battery has removable cell caps, measure the specific gravity with a hydrometer every
hour during the last few hours of the charging cycle (follow the instructions on the
hydrometer). Consider the battery charged when there's no change in the specific gravity
reading for two hours and the electrolyte in the cells is bubbling freely. The specific gravity
reading of each cell should be nearly the same; if not the battery probably has one or more
bad cells.

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Information Sheet LO4-1 Causes of Battery Failure

All batteries have a limited life, but some conditions can shorten battery life.

ELECTROLYTE LEVEL: A low electrolyte
level exposes active material, and any sulfate
hardens and resists chemical action. Loss of
electrolyte may be caused by a cracked case,
poor maintenance (not adding water when
needed), or severe overcharging which causes
high internal heat and excessive gassing. Too
much electrolyte is just as bad. Overfilling
dilutes the electrolyte and spillage may
corrode battery terminals.

OVERCHARGING: Overcharging by the
vehicle’s charging system or separate battery
charger causes excessive gassing and high
internal heat. Too much gassing can wash
active materials off the plate, as well as cause
excessive water usage. Too much heat can
oxidize the positive plate material and warp
the plates.

UNDERCHARGING: A faulty charging system will not maintain the battery at full charge.
Severe undercharging allows sulfate on the plates to become hard and impossible to remove by
normal charging. The weak electrolyte freezes easier. The undercharged battery may fail to
crank the engine.

CORROSION: Spilled electrolyte and condensation from gassing may cause corrosion on
terminals, connectors, and metal holddowns/carriers. Such corrosion increases electrical
resistance, which reduces available voltage and charging effectiveness. It may also create a
current leakage path to allow self-discharge.

CYCLING: Repeated cycling – from fully charged to fully discharged and back – may cause
loss of active material from the positive plates. This reduces battery capacity and its useful life.

TEMPERATURE: High temperatures from overcharging or engine heat can shorten battery life.
Low temperatures can cause freezing or weak electrolyte. At 0F (-17.8ºC), a fully charged
battery provides less than half its normal power. At the same time, the cold engine requires
twice as much cranking power as it does with normal temperatures. The electrolyte in a fully
charged battery will not freeze until -60ºF or lower, while the electrolyte in a fully discharged
battery will freeze at +18ºF.

VIBRATION: A battery must be mounted securely. Vibration can loosen connections, crack the
case, and damage internal components.

FACTORS AFFECTING CHARGING

Five factors affect battery charging by increasing its internal resistance and CEMF (counter-
electromotive force produced by the electrochemical reaction):

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1. TEMPERATURE: As the temperature decreases the electrolyte resists charging. A cold
battery will take more time to charge; a warm battery, less time. Never attempt to charge a
frozen battery.

2. STATE OF CHARGE: The condition of the battery’s active materials will affect charging. A
battery that is severely discharged will have hard sulfate crystals on its plates. The vehicle’s
charging system may charge at too high of a rate to remove such sulfates.

3. PLATE AREA: Small plates are charged faster than large plates. When sulfation covers
most of the plate area, the charging system may not be able to restore the battery.

4. IMPURITIES: Dirt and other impurities in the electrolyte increase charging difficulty.

5. GASSING: Hydrogen and oxygen bubbles form at the plates during charging. As these
bubble out, they wash away active material, cause water loss, and increase charging
difficulty.

Code No. Servicing Automotive Battery Date: Developed Date: Revised Page #
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Program /Course Automotive Servicing NC I
Unit of Competency TEST, SERVICE AND REPLACE AUTOMOTIVE BATTERY
Module TESTING AND SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME #5

Demonstrate the correct procedure on how to jumpstart battery.

ASSESSMENT CRITERIA:

1. Vehicle is jump started without causing damage to the workplace, property or vehicle.
2. Appropriate jumper leads are used to prevent spark and protection is employed when

necessary.
3. Leads are connected/disconnected in correct sequence and polarity.
4. PPE/safe practices are observed.

PREREQUISITES

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LEARNING EXPERIENCE

Learning Outcome #5: Demonstrate the correct procedure for jumpstarting battery.

Learning Activities Special Instructions

5.1 What happens to a cell phone battery
after it is used for quite sometime? Just
like the cell phone battery or any other
battery, an automotive battery needs to
be charged.

a. Examine the battery charger and write Ref. Automotive Mechanics p.357
down all its specifications. Show this Service Manual
to your trainer.

b. Read: Topping the Battery with
Distilled Water.

Cleaning the Battery and its Terminals

Things to do:

Check the battery provided by your trainer as
to:
1. Electrolyte level- (top as necessary)
2. Clean battery terminals

a. Read: Battery charging Ref. Automotive Mechanics p.360
b. With your trainer’s approval perform Battery charging instructions.

the task of battery charging and record
your observation.

• Write down the chemical reaction
resulting from the charging
process.

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Information Sheet LO5-1 Jump Starting a Dead Car Battery: A Few
Precautions

• Line both cars up so the batteries are as close as can be. Make sure the cars are in park,
and both cars are turned off, and not touching each other before you connect the cables.
Actually one of them is already off, or you wouldn't be in this predicament right? Make sure
all headlights, blinkers, car radios and A/C's are off, radar detectors are unplugged, cell
phones unplugged, everything off. Unplug all accessories from cigarette lighters and other
power sockets from both cars. Jump starting a battery can crank 300+ volts through your
system and the transients can destroy equipment. These voltage spikes are caused by
inrush current, into the inductances in your electrical system.

• Familiarize yourself with the Positive (+) and Negative (-) terminals of both car batteries so
you know exactly which one is which. All batteries are clearly marked so if you can't find it,
it's probably under 1/8" of caked on corrosion around the terminals. Wipe off any battery
acid that may have leaked.

• If the battery is cracked and liquid is leaking out, DO NOT go further! Bite the bullet and go
buy another battery and swap it out. If you try to jump start a battery with a crack in it, it will
explode, and battery acid will dissolve your eyes (on the positive side though, it does get the
red out). It makes no sense to jump a cracked battery, it will die in a few minutes.

• Try to clean off any corrosion around the dead battery terminals, and if you have tools,
loosen the wires from the terminals, clean them off, then retighten the wires to the shiny
posts. Corroded posts prevent the power from getting through the cables and into your
battery to revive it. If you have a file handy, try to file the metal battery posts until they are
nice and shiny. In a pinch use pliers to clamp down and scrape off corrosion too as the
metal is somewhat soft.

• Usually the positive battery cable is red or orange, and usually the Negative (-) or ground
cable is black, but always check for yourself to be sure.

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Operation Sheet LO5-1 Jump Starting Car Battery

The cables must be connected in this exact order listed below, 4 easy steps. Wear protective
eyewear.
1. Connect one end of the Positive (+) cable

to the Positive (+) post of the dead battery.

2. Connect the other end of the Positive(+)
cable to the Positive(+) post of the good
battery.

3. Connect one end of the Negative(-) cable
to the Negative(-) post of the good battery.

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4. Connect the other end of the Negative (-)
cable to a good solid SHINY, NON
PAINTED metal part of the engine on the
dead car. Usually a giant shiny nut on the
engine block will do. A painted, dirty, or oily
nut will not work. You usually want to avoid
placing the Negative (-) cable directly on
the dead battery to minimize the chance for
explosions. You should only use the
ground post on the dead battery as a last
resort. On this step you'll get a normal
spark as you connect the ground and
complete the circuit.

Why do the battery charger cables have to be connected in this order?

The reason why you connect the battery cables to the dead car battery first is you have 3 metal
cable ends dangling and potentially touching metal car parts, so a dead battery is less likely to
cause any sparking, since it has little or no voltage. So that is the safest starting point for your
jumper cables. The 2nd battery cable clamp goes to the positive end of the good battery instead
to minimize completing any circuits until we are ready to. Then the 3rd end of the battery cable
goes to the ground of the good battery. Remember, we still have not completed the circuit yet,
until the 4th battery cable clamp is attached to ground. This is why this order of attaching the
battery cables to your car batteries is the safest way to do it. It minimizes unnecessary sparking
until the charging circuit is completed. This is good practice because excessive and
unnecessary sparking could cause car batteries to fail.

Since the bad battery is weak, and to prevent exploding, it's ground clamp gets connected last,
but not directly to the ground battery post. To prevent sparking directly on the battery, you
connect the 4th battery cable clamp to a metal frame part of the dead car, which is connected to
the minus pole of the battery. Many people are easily confused by this step. They cannot figure
out how this completes the circuit to the battery. Car batteries have their ground cable also
wired to the chassis of the car, so by clamping to a good metal chassis point, this is electrically
equivalent to connecting to the ground post of your car battery.

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