Service Batteries

 

COMPETENCY-BASED CURRICULUM

Sector:

 AUTOMOTIVE  Automotive Servicing NC II

Unit of C omp ompet etency: ency:

Service Automotive Battery Module Title:

SERVICING AUTOMOTIVE BATTERY   TECHNICAL EDUCATION

AND

SKILLS DEVELOPMENT AUTHORITY  

MADDELA INSTITUTE OF TECHNOLOGY Dipintin, Maddela, Quirino  

 

Unit of Competencies comprising this Qualification

CODE NO.

BASIC COMPETENCIES

500311105 500311106 500311107 500311108

Participate in Workplace Communication Work in Team Environment Practice Career Professionalism Practice Occupational Health and Safety Procedures

CODE NO.

COMMON COMPETENCIES 

ALT723201 ALT723202 ALT311202 ALT723203

Apply Appropriate Sealant/Adhesive Move and Position Vehicle Perform Mensuration and Calculation Read, Interpret and Apply Specifications and Manuals

ALT723204 ALT723205

Use and Apply Lubricant/Coolant Perform Shop Maintenance

`CODE NO. ALT723301

CORE COMPETENCIES  Perform Diesel Engine Tune Up

ALT723302

Perform Gas Engine Tune Up

ALT723303 ALT723304 ALT723305 ALT723306 ALT723307 ALT723308 ALT723309 ALT723310 ALT723311 ALT723312

Service Automotive Battery Service Ignition System Test and Repair Wiring/Lighting Wiring/Ligh ting System Perform Underchassis Preventive Maintenance Service Starting System Service Charging System Service Engine Mechanical System Service Clutch System Service Differential and Front Axle Service Steering System

ALT723313 ALT723314 ALT723315

Overhaul Manual Transmission Service Brake System Service Suspension System

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology

Date Developed January 30, 2010

Page # 2

 

HOW TO USE THIS COMPETENCY BASED LEARNING MODULE

Welcome to the Module: Tuning Up Gasoline Engine. This module contains training materials and activities for you to complete.  The unit of competency competency "   Tune of Gasoline Engine"   contains the knowledge, skills and attitudes required for Automotive Servicing NC II . It is one of the Core Modules at National Certificate Level I (NC II ) . You are required to go through a series of learning activities in order to complete each learning outcome of the module. In each learning outcome there are Information Sheets, Resource Sheets and 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 outcome. Get the answer key from your instructor instructor and check your work honestly. If you have questions, please don’t hesitate to ask your facilitator for assistance.  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 someone already completed training in this area

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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 won’t have to do the same training again. If you have qualifications or Certificates of Competency from previous trainings, show them to your trainer. If the skills you acquired are still relevant to this module, they may become part of the evidence you can present for RPL. At the end of this learning material is a Learner’s Diary, use this diary to record important dates,  jobs undertaken undertaken and other workplace events that will assist you in providing providing further details to your trainer or assessors. A Record of Achievement is also provided for your trainer to complete once  you completed completed the module. module.  This learning material material was prepared to help you achieve the required comp competency, etency, in Tuning Up Gasoline Engine. This will be source of information for you to acquire the knowledge and skills in this particular trade independently and your own pace with minimum supervision or help from  your instructor. instructor. In doing the activities to complete the requirements of this module, please be guided by the following:    Talk

to your trainer and agree on how you will both organize the training under this module. Read through the module carefully. It is divided into sections that cover all the skills skill s and and knowledge you need to successfully complete

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology

Date Developed January 30, 2010

Page # 3

 

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Work through all information and complete the activities in each section. Read the information sheets and complete the self-check provided in this module.

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

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

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You will be given plenty of opportunities to ask questions and practice on the job. Make sure  you practice your new skills during regular work shifts. This way you will improve both your speed and memory and also your confidence.

   Talk

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

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

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When you are ready, ask your trainer to watch you perform the activities outlined in this module.

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As you work through the activities, ask for written feedback on your progress. Your trainer keeps feedback/pre-assessment reports for this reason. When you have completed this learning material and feel confident that you have had sufficient knowledge and skills, your trainer will arrange an appointment with a registered assessor to assess you. The results of the assessment will be recorded in your Competency Achievement Record.

Developed By: Edward P. Alip

Perform Gas Engine Tune -up  TESDA-Maddela Institute of Technology

Date Developed January 30, 2010

Page # 3

 

TABLE OF CONTENTS QUALIFICATION

:

Automotive Servicing NC II 

UNIT OF COMPETENCY

:

SERVICE AUTOMOTIVE BATTERY

MODULE TITLE

:

SERVICING AUTOMOTIVE BATTERY

CORE COMPRETENCY

ELEMENTS 1.  Explain the purpose, types, operation, and safe handling of batteries 

2. Test automotive batteries

PERFORMANCE CRITERIA

PAGE

1.1 Main components of batteries are identified 1.2 Differentiate batteries according to designs and usage 1.3 Tests  Tests carried out according to vehicle classification are explained 1.4 Safe handling of batteries observed 1.5 Hazards associated with batteries are identified 2.1 Different methods of battery testing are performed 2.2 Battery is tested without causing damage to workplace, property, or vehicle.

2.3 Correct information is accessed and interpreted 2.4 Appropriate test equipment is selected and used 2.5Tests are performed and results are analyzed 2.6 Personal safety is observed 3. Remove and and replace batteries batteries   3.1 Proper procedure is followed in removing and replacing battery 3.2 Battery is removed and replaced without causing damage to workplace, property or vehicle 3.3 Proper procedure is followed to prevent loss of vehicle’s electronic memory as per manufacturer’s standard (if applicable) 3.4 Appropriate tools and equipment are selected and used 3.5 Personal safety in removing and replacing batteries observed 4. Service and and charge batteries batteries  4.1 Battery is charged using the appropriate battery charger

5. Jump-start batteries 

Developed By: Edward P. Alip

4.2 Electrolyte level is checked and corrected 4.3 Battery and its terminals are cleaned 4. 4 Battery cables are disconnected and connected in right sequence 4.5 Personal safety in servicing and charging battery is observed  5.1 Vehicle is jump started without causing damage to workplace, property or vehicle 5.2 Appropriate cables are used in jump starting 5.3 Cables are disconnected and connected in right sequence 5.4 Personal safety is observed

 TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

5

 

QUALIFICATION: 

AUTOMOTIVE SERVICING NC II

COMMON COMPETENCY UNIT:

SERVICE AUTOMOTIVE BATTERY SERVICING AUTOMOTIVE BATTERY  

MODULE TITLE:

MODULE DESCRIPTOR : This module covers the ability to carry out the knowledge, skills, and attitude required in battery maintenance.

NOMINAL DURATION: 24 Hours CERTIFICATE LEVEL: NC II

SUMMARY OF LEARNING OUTCOMES: Upon completion of the module, trainees/students should be able to:

LO 1: Explain the purpose, types, operation, and safe handling of batteries LO 2: Test automotive batteries LO 3: Remove and replace batteries LO 4: Service and charge batteries LO 5: Jump-start batteries

PERFORMANCE CRITERIA:

All standards of performance for Servicing Automotive Batteries is in accordance with company standard operating procedure and manufacturer’s specification manuals using specified tools and equipment. LO 1: Explain the purpose, typ types, es, operation, and safe handling of batteries 1.6 Main components of batteries are identified 1.7 Differentiate batteries according to designs and usage 1.8 Tests  Tests carried out according to vehicle classification are explained 1.9 Safe handling of batteries observed 1.10 

Hazards associated with batteries are identified

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

3

 

LO 2: Testing Batteries 2.1 Different methods of battery testing are performed 2.2 Battery is tested without causing damage to workplace, property, or vehicle. 2.3 Correct information is accessed and interpreted 2.4 Appropriate test equipment is selected and used 2.5 Tests are performed and results are analyzed 2.6 Personal safety is observed

LO 3: Removing and replacing batteries 3.1 Proper procedure is followed in removing and replacing battery 3.2 Battery is removed and replaced without causing damage to workplace, property or vehicle 3.3 Proper procedure is followed to prevent loss of vehicle’s electronic memory as per manufacturer’s standard (if applicable)  applicable)   3.4 Appropriate tools and equipment are selected and used 3.5 Personal safety in removing and replacing batteries observed

LO 4: Servicing and charging batteries 4.1 Battery is charged using the appropriate battery charger 4.2 Electrolyte level is checked and corrected 4.3 Battery and its terminals are cleaned 4. 4 Battery cables are disconnected and connected in right sequence 4.5 Personal safety in servicing and charging battery is observed LO 5: Jump starting batteries 5.1 Vehicle is jump started without causing damage to workplace, property or vehicle 5.2 Appropriate cables are used in jump starting 5.3 Cables are disconnected and connected in right sequence 5.4 Personal safety is observed

PREREQUISITE : Must have finished basic competencies

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

 

Date Developed  January 30, 2010

Page #

4

 

QUALIFICATION:  

AUTOMOTIVE SERVICING NC II

COMMON COMPETENCY UNIT:

MODULE TITLE: 

SERVICE AUTOMOTIVE BATTERY

SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME NUMBER 1 : EXPLAIN THE PURPOSE, TYPES, OPERATION, AND SAFE HANDLING OF BATTERIES

ASSESSMENT CRITERIA: 1.  Main components of batteries are identified 2.  Differentiate batteries according to designs and usage 3.   Tests carried out according to vehicle classification are explained 4.  Safe handling of batteries observed 5.  Hazards associated with batteries are identified

LEARNING CONTENTS: 1.  2.  3.  4.  5.  6. 

Purpose of battery Battery types and designs Battery ratings and sizes Hazards associated with use of batteries Safe handling of batteries Factors affecting battery life

RESOURCES:

  Automotive Technology; Tech Manual; 4th Edition; ERJAVEC   Automotive Technology; 4 th  Edition; ERJAVEC   Computer Set   Communication Module    Tool/Equipment   Reference Books    Toyota Training Manual   Auto Mechanics, Theory and Service By: de Kryger, Kobacik.Bono

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Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

5

 

LEARNING EXPERIENCES/ACTIVITIES   LO 1: Explain the purpose, types, operation, and safe handling of batteries LEARNING ACTIVITIES Are you ready to perform the knowledge and skills activities?      

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SPECIAL INSTRUCTIONS

Observe safety precautions Wear protective equipment Always perform 5’S  5’S   1.  In the contextual learning laboratory, with the help of your instructor, gather information/data on the:    

Purpose of battery Automotive battery types and designs   Chemical reaction that takes place inside the battery during charging and discharging process  

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Check your knowledge

Battery ratings and size selection

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Check your knowledge

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Safety precautions in handling batteries   Battery routine inspection

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Check your knowledge

Factors affecting battery life

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Check your knowledge

 

Read Information Sheet LO11‖Purpose, construction, and types of batteries‖.  batteries‖. 

 

Answer self-check

 

Read Information Sheet LO1-2 ―Battery Rating methods and size selection‖.  selection‖. 

 

Answer self-check

 

Read information sheet LO1-3 ―Hazard, safe handling, and battery routine inspection‖.  inspection‖.  

 

Answer Self-check

 

Read information sheet LO1-4 ―Factors affecting battery life‖.  life‖. 

 

Answer Self-check

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Ask your instructor for assessment. If you passed the assessment,  your instructor will tell you to proceed to the next module.→→→  module.→→→ 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

6

 

INFORMATION SHEET LO1-1 PURPOSE, CONSTRUCTION AND TYPES OF BATTERIES

PURPOSE OF THE BATTERY  The battery supplies electricity when the:

1.  Engine is off - Electricity from the battery is used to operate lighting, accessories, or other electrical systems when the engine is not running.  

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

7

 

2.  Engine is Starting-Electricity from the battery is used to operate the starter motor and to provide current for the ignition system during engine cracking. Starting the car is the battery’s  most important function. 

3.  Engine is running-Electricity from the battery may be needed to supplement the charging system when the vehicle’s electrical load requirements exceed the charging system’s ability to produce electricity. Both the battery and the alternator supply electricity electr icity when demand is high. 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

8

 

CONSTRUCTION AND OPERATION OF THE BATTERY  The automotive battery supplies electric current to operate the starting motor and ignition system 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) when 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. limit ed. As the chemicals in the battery ar are e depleted, the battery runs down and is discharged. It can be recharged by supplying it with electric current from the vehicle’s alternator or from a battery charger. The depleted chemicals are restored to t o their original condition as the battery becomes recharged.

COMPONENTS OF THE BATTERY

• 

Grids

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Positive plates

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Negative plates 

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Electrolyte

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A container

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Cell covers

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Vent covers

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Cell containers

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Separators

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Elements

 The battery case is a 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.  The assembly of plate groups and separators is an element. The 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 removable vent caps.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

9

 

Battery Terminals  The battery has two external terminals: a positive (+) and a negative negative (-).These two terminals are either two tapered posts, L terminals, threaded studs on top of the case, or two internally threaded connectors on the side. The terminals have either a positive or negative marking, depending on which end of the series they represent.  Tapered terminals have a given dimension in accordance with standards standards agreed upon by the Battery Council International (BCI) and Society of Automotive Engineers (SAE).  This ensures that all positive and negative cable clamps would fit any corresponding battery terminal, regardless of the battery’s manufacturer.  The positive terminal is slightly larger, usually around 11/16 inch in diameter at the top, while the negative terminal has 5/8 diameter. This design minimizes the danger of installing the battery cables in reverse rever se polarity. Side terminals are positioned near the top of the battery case. These terminals t erminals are threaded and require a special bolt to connect the cables. c ables. Some batteries are fitted with both top and side terminals to allow them to be used in many different vehicles.

Battery terminals

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

11

 

Battery Hardware In order to connect the battery to the vehicle’s electrical system, Battery cables are used. Battery hold downs are used to prevent damage to the battery, and heat shields are sometimes sometime s used to keep battery temperatures low.  

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Battery Cables-Battery cables must be of sufficient capacity to carry the current required to meet all demands. The normal 12- volts cable size is 4 or 6 gauge . Various forms of clamps are used to ensure a good electrical connection at each end of the cable. Connections must be clean and tight to prevent arcing between the terminal and clamp, corrosion, and high voltage drops.  The positive cable is normally red and the negative cable is black . The positive cable fastens to the battery and the starter solenoid or relay. The negative cable fastens to a good ground on the engine block or chassis.

Battery Cables

 

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Battery Hold – DownsDowns-All batteries must be held securely in the vehicle to prevent the possibility of shorting across the terminals if they move or fall. Normal vibrations cause the plates to shed their active materials. Hold-downs reduce the amount of vibration v ibration and help increase the life of the battery. Battery hold-downs are made of metal or plastic.

Battery Hold-downs

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

12

 

 

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Heat Shield-Some vehicles have a heat shield made of plastic or another metal to protect the battery from high underhood temperatures. While heat shields do not need to be removed for most testing and inspection procedures, they must be removed and then correctly corr ectly installed during battery replacement. Vehicles operating in extremely cold climates may have a battery blanket or heater to keep the battery warm.

Battery Designs In many lead acid batteries, the grids are made of lead alloyed with approximately 6% antimony for strength. Antimony added to the lead grids acts as a catalyst but makes gassing worse (the loss of hydrogen and oxygen during use). In this case, frequent water replenishing is required.

1.  Maintenance free and Low maintenance batteries - Most batteries sold and installed today are either low-maintenance or free maintenance batteries. A maintenance-free battery is similar in design to a conventional battery, but many of the components have thicker construction. Different, more durable materials are used in low-maintenance batteries and the amount of antimony is reduced to about 3%. In maintenance-free batteries, the antimony is eliminated and replaced with calcium or strontium.  This reduces both the batteries internal heat and the amount of gassing that occurs during charging. Since heat and gassing are the principal reasons for battery water loss, these t hese changes reduce or eliminate the need to periodically add water. Maintenance-free battery has about 20% higher cold cranking power rating than a comparably sized conventional battery. Maintenance-free batteries are equipped with small gas vents that prevent gas pressure build-up in the case. Water is never added to these batteries.  Low-maintenance batteries are still equipped with vent holes and caps, which allow water to be added to the cells. A low-maintenance battery requires additional water substantially less often than a conventional battery.

Construction of a maintenance-free battery

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

13

 

2.  Hybrid Batteries-A hybrid battery can withstand six deep cycles and still retain r etain 100% of its original reserve capacity. The grid construction of a hybrid battery consists of approximately 2.75% antimony alloy on the positive plates and a calcium alloy on the negative plates. This allows the battery to withstand deep cycling while retaining reserved capacity for improved cranking performance. Also, the use of antimony alloys reduces grid growth, corrosion, corros ion, and water loss.   Grid construction differs from other batteries in that the plates have a lug located near the center of the grid. In addition, the vertical and horizontal grid bars are arranged in a radial design. With this grid design, current has less resistance and a shorter path to follow, which means the battery is capable of providing more current at a faster rate.  The separators used are constructed of glass covered with a resin or fiber glass. glass. The separators offer low electrical resistance with high resistance to chemical contamination. This type of construction provides for increased cranking performance and battery life.

Hybrid battery grid and separator construction

3.  Recombination Batteries- This  This battery is a completely sealed maintenance-free battery that uses electrolyte in gel form. In a gel-cell battery, gassing is minimized and vents are not needed.   During charging, the negative plates never reach a fully-charged condition and therefore cause little or no release of hydrogen. Oxygen is released at the positive plates, but it passes through the separators and recombines with the negative plates. Because the oxygen released by the electrolyte is forced to recombine with the negative plates, these batteries are called recombination batteries.

4.  Absorbed Glass Mat Batteries (AGM) - The  The electrolyte in these batteries is held in moistened fiber glass matting instead of existing as a liquid or gel. The matting is sandwiched between the battery’s lead plates, where it also serves as a vibration v ibration dampener. Rolls of high-purity lead plates are tightly compressed into six spiral s piral wound-cells. The plates are separated by acid-permeated vitreous separators. Vitreous separators s eparators absorb acid the same way a paper towel absorbs water. A small amount of silver is added to the plates and some sodium sulfate is added to the electrolyte.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

14

 

  Each of the six spiral cells is enclosed in its own cylinder within the battery battery case, forming a sealed sealed,, closed system that resembles a six-pack of soda. During normal use, hydrogen and oxygen within the battery are captured and recombined to form the water supply within the bound electrolyte, eliminating the need to over add water to the battery. Even if cracked, broken, or punctured, AGM batteries will never leak. These batteries have also als o short recharging times and low internal resistance, which provides increased incre ased output. AGM batteries also have exceptional durability in both high heat and subzero climates.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

15

 

Chemical Reaction in the Battery   The battery is a lead-acid storage battery. The chemicals in it are sponge sponge lead (a solid), lead peroxide (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. A chemical reaction between active materials on the positive and negative plates and the acid in the electrolyte produces electrical energy. When a battery discharges, lead in the lead peroxide of the positive plate combines with the sulfate radical (SO4) to form lead sulfate (PbSO4).

Discharging process (a bulb consumes electricity from a battery) A similar reaction takes place at the negative plate. In this plate, Lead (Pb) combines with sulfate (SO4) to also form lead sulfate (PbSO4). As the chemical reaction occurs, the oxygen from the lead peroxide and the hydrogen from the sulfuric acid combine to form water (H2O). During discharge, the electrolyte becomes weaker and the positive and negative plates become like one another. Since the charge of a battery depends on the difference between the two plate materials and the concentration of the electrolyte and this difference decreases during discharging, the battery loses power.  The recharging process is just the reverse of the discharging process. Electricity from an outside source such as the vehicle’s generator (alternator) or a battery recharger is forced into the battery. The lead sulfate (PbSO4) on both plates separate into lead (Pb) and sulfate (SO4). As the sulfate leaves both plates, it combines with hydrogen in the electrolyte to form sulfuric acid (H2SO4). At the same time, the oxygen (O2) in the electrolyte combines with the lead le ad (Pb) at the positive plate to form lead peroxide (PbO2). As a result, the negative plate returns to its original form of lead (Pb), and the positive plate reverts to lead peroxide.

Recharging process

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

16

 

  An unsealed battery gradually loses water due to its conversion into hydrogen and oxygen. These gases escape into the atmosphere through the vent caps. If the lost water is not replaced, the level of the electrolyte falls below the tops of the plates. This results in a high concentration of sulfuric acid in the electrolyte and permits the exposed material of the plates to dry and harden. In this situation, premature failure of the battery is certain. The electrolyte level in the battery must be checked frequently.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

16

 

SELF-CHECK MULTIPLE CHOICES

DIRECTIONS 1. Read each statement carefully. 2. This is a multiple choice type of test. Choose the correct or the best answer and write ONLY THE LETTER that corresponds to your choice on the space provided before each item. 3. Avoid erasures, make your module neat and clean. Good luck!

 _____1. An unsealed battery gradually gradually loses _____ due to its conversion into hydrogen and oxygen. A. power B. gas C. temperature D. water

 _____2. It supplies electric current to operate the starting motor and ignition system while starting the engine. engine. A. alternator B. battery C. dry cell battery D. wet cell battery

 _____3. The battery uses _______ to produce produce electricity. A. water B. electrolyte C. liquid D. chemicals

 _____4. The cells inside a battery are connected in______. A. parallel B. series-parallel C. series D. vertical

 _____5. The positive terminal is always ________ in diameter compared to the negative terminal. A. smaller B. the same C. bigger D. slightly smaller

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

16

 

   _____6. The normal 12 volts battery cable size A. gauges 4 or 5 B. gauges 4 or 6 C. gauges 6 or 8 D. gauges 10 or 12

 _____7. The loss of hydrogen and oxygen during use A. evaporation B. gassing C. drying D. discharging

 _____8. Battery terminals are designed and constructed with different different diameter A. because battery clamps are different in sizes also B. to make installation faster C. for better connection D. to minimize the danger of installing the cables in reverse r everse the polarity

 _____9. Color of cables for battery positive terminal are usually A. black B. blue C. green D. red

 higher cold cranking power rating  than a comparably  _____10. Maintenance-free battery has about about _____  higher sized conventional battery. A. 15 % B. 20 % C. 25 % D. 30 %

SCORE:

 Trainee’s Signature:  Signature: 

Date:

Assessor’s Signature:  Signature: 

Developed By: Edward P. Alip

Date:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

16

 

INFORMATION SHEET LO1-2 BATTERY RATING METHODS and SIZE SELECTION Rating Methods  The BCI (Battery Council International) rates batteries according to reserve capacity and coldcranking power. When replacing a battery, always refer to an application chart to select the battery with the correct BCI group number. Vehicle options, such as air conditioning and a number of major electrical accessories, may indicate the need for an optional heavy-duty battery with a higher rating. To handle cranking power and the vehicle’s other electrical needs, need s, the replacement battery should never have a lower rating than the original battery.

1.  Reserve Capacity (RC)-A reserve capacity rating represents the approximate time in minutes it is possible to travel at night with battery ignition and minimum electrical load, but without a charging system in operation. The time in minutes is based on a current draw of 25 amperes while maintaining a minimum battery terminal voltage of 10.5 volts (for 12 volts batteries) at 80 F (26.7 C). A battery with a reserve capacity of 100 would be able to deliver 25 amperes for 100 minutes before the voltage would drop below 10.5 volts. This rating represents the electrical load that must be supplied by the battery in the event of a charging system failure.  

2.  Ampere-Hour Rating- The  The ampere-hour rating is the amount of steady current that a fully charged battery can supply for 20 hours at 80 F (26.7 C) without the cell voltage falling below 1 -75 volts or 10.5 volts at the terminals. For example, if a battery can be discharged for 20 hours at a rate of 4.0 amperes before its terminal voltage v oltage reads 10.5 volts, it would have a rating of 80 ampere-hours.  

3.  Cold Cranking Amperes (CCA)- A cold cranking amperes rating specifies the minimum amperes available at 0 F (-17.7 C) and at -20 F (-28.8 C). CCA is the common standard for low-maintenance batteries. The ampere-hour rating is no longer used except with some imported vehicles. The CCA allows cranking capability to be related to such significant variables as engine displacement, compression ratio, temperature, cranking time, condition of engine and electrical system, and lowest practical voltage for cranking and ignition. The rating indicates the amperes that a fully charged battery will maintain for 30 seconds without the terminal voltage falling below 7.2 volts for a 12 volt battery. The cold-cranking rating is given in total amperage and is identified as 300 CCA, 400 CCA and so on. The usual range for passenger cars and light trucks is between 300 and 600 CCA. Some batteries have a rating as high as 1,100 CCA.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

17

 

Size Selection Besides selecting a battery based on capacity and rating, the proper battery is also one that fits. The battery should fit the battery holding fixture and the hold down must be able to be installed. It is also important that the height of the battery not allow a llow the terminals to short across the vehicle’s v ehicle’s hood when it is closed. BCI group numbers are normally given on the battery and are used to indicate the physical size and i ndicate the current capacity of a other features of the battery. The size of the battery does not always indicate battery.  The label may also include the date the battery was shipped shipped from the manufacturer. This information may also appear on a label on the side of the battery. The letter on the label corresponds with the month, starting with A for January, B for February and so on. The letter I is skipped so September is for letter J.  The number represents the year, with 8 standing for 1998, 1 for 2001 and so on.

BCI battery group numbers

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

18

 

SELF-CHECK

IDENTIFICATION Directions: Identify what is being asked in each statement. Write your answer in capital letters on the space provided before each item. Avoid erasures. Good luck!

 __________________________1.. It rates batteries according to reserve capacity and cold-cranking power.  __________________________1  __________________________2. This battery rating represents the approximate time in minutes it is possible to  __________________________2. travel at night with battery ignition and minimum electrical load, but without a charging system in operation.  __________________________3. The amount of steady current that a fully charged battery can supply for 20  __________________________3. hours at 80 F (26.7 C) without the cell voltage falling below 1-75 volts or 10.5 volts at the terminals.  __________________________4.. Battery rating which is the common standard for low-maintenance batteries.  __________________________4  __________________________5.. It pertains to the length, width, and h  __________________________5 height eight of the battery.

SCORE:  Trainee’s signature:  signature: 

Date:

Assessor’s Signature:  Signature: 

Developed By: Edward P. Alip

Date:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

18

 

INFORMATION SHEET LO1-3 HAZARDS, SAFE HANDLING AND BATTERY ROUTINE INSPECTION

 The potential dangers caused by the sulfuric acid in the electrolyte and the explosive gases  generated during battery charging charging require that battery service and troubleshooting must be conducted under absolute safe working conditions. Sulfuric acid also cause severe skin burns. If electrolyte contacts your skin or eyes, flush the area with water for several minutes. When eye contact occurs, force your eyelid open. Always have a bottle of neutralizing eye wash on hand and flush the affected areas with it. Do not rub skin or eyes affected.

Careless use of charger caused this battery to EXPLODE

When a battery is charging or discharging, it gives off quantities of highly explosive hydrogen gas. Some hydrogen gas is present in the battery at all times. Any flame or spark can ignite this gas, causing the battery to explode violently, propelling the vent caps at a high velocity and spraying acid in a wide area. To prevent this dangerous situation, take the following precautions:   Do not smoke near the top of a battery; and never use a lighter or match as a flashlight Remove wrist watches and rings before servicing any part of the electrical system. This helps to prevent the possibility of electrical arcing and burns

Even sealed, maintenance-free batteries have vents and can produce dangerous quantities of hydrogen if severely overcharged Always disconnect the battery’s ground cable when working on the electrical system or engine.  engine.  

A battery that has been overworked should be allowed to cool down and let air circulate around it before attempting to jump-start the vehicle Never connect or disconnect charger leads le ads when the charger is turned ON. Doing so generates a dangerous spark

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

19

 

  Never lay metal tools or other objects on the battery. Short circuit across the terminal can result.

Improper connection of charger cables to the battery can reverse the current flow and damage the generator.

When removing a battery from a vehicle, always disconnect the battery ground cable first. When installing, connect the ground cable last. Never reverse the polarity of the battery connections. All vehicles use negative ground. Rever Reversing sing the polarity will adversely damage the alternator and circuit wirings

Never attempt to use a fast charger as a boost to t o start the engine Never try to charge a battery that has ice in i n the cells. Passing current through a frozen battery can cause it to rupture or explode Never force-charge a dead battery. It may explode Acid from the battery damages vehicle’s paint and metal surfaces and harms shop equipment. Immediately neutralize any electrolyte spills during servicing

CONDUCTING A ROUTINE INSPECTION Visually inspect the battery cover and case for dirt and grease   Check the electrolyte level. When adding water to the cells, use distilled or clean, soft water. Fill each cell to just above the top of the plates  

Inspect the case for cracks, loose terminal posts, and other signs of physical damage   Check for missing cell plug covers and caps  

Inspect all cables for broken or corroded corr oded wires, frayed insulation, or loose or damaged connectors   Visually check battery damage or build up   terminals, cable connectors, metal parts, hold-downs, and trays for corrosion

Check the heat shield for proper installation on vehicles equipped with

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

20

 

SELF-CHECK TRUE OR FALSE

Directions Read and analyze each statement carefully. Write TRUE if the statement is CORRECT, and write FALSE if it is WRONG. Write your answer on the space provided before each item. Good luck!

 ________1. If electrolyte contacts your skin or eyes, flush the area with water for several minutes.  ________2. Careless use of charger can cause battery to EXPLODE   ________3. Maintenance-free batteries do not produce dangerous quantities of hydrogen if severely

overcharged  ________4. Battery cables can be disconnected and connected whichever comes first.  ________5. Battery chargers can be disconnected even when it is still ON.  ________6. Battery chargers can be used to start an engine.  ________7. A dead battery battery can still be used by charging it for many hours.  ________8. Each cell of the battery must be filled filled below the plates.  ________9. All clear water can be used on batteries.  _________10. Sulfuric acid in the battery battery is not potentially dangerous since it is only a liquid.

SCORE:

 Trainee’s signature:  signature: 

Date:

Assessor’s Signature:  Signature: 

Developed By: Edward P. Alip

Date:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

20

 

INFORMATION SHEET LO1-4 FACTOR AFFECTING BATTERY LIFE

All storage batteries have a limited service life, but many conditions can decrease service life.

Improper electrolyte levels —   With non-sealed batteries, water should be the only portion of the electrolyte lost due to evaporation during hot weather and gassing during charging. Maintaining an adequate electrolyte level is the basic step in extending battery life for these designs.

Temperature — B Batteries atteries do not work well when they are cold. At 0 F, a battery is only capable of working at 40% of its capacity. Like everything else, the electrons find it hard to move when they are cold. Also in the cold, the engine’s oil is thicker and is harder to crank the engine; therefore, the demands on the starter and battery are much higher. There is a possibility that the battery will freeze when it is low on charge and subjected to very cold weather. When the weather is extremely hot, the electrons get hyperactive and there is a possibility of boiling over as the electrons move rapidly. Plus, at high temperatures, the water tends to evaporate and heat causes the positive plate grids to corrode more rapidly. Batteries used in hot climates need to have their electrolyte level checked often and distilled water added if necessary.

Corrosion —   Battery corrosion is commonly caused by spilled electrolyte or electrolyte condensation from gassing. In either case, the sulfuric acid from the electrolyte corrodes, attacks, and can destroy not only connectors and terminals but hold-down straps and the battery tray as well. Corroded connections increase resistance at the battery terminal, which reduces the applied voltage to the vehicle’s electrical system. Corrosion on t he battery cover can also create a path of current, which allow the battery to slowly discharge. Finally, corrosion can totally destroy the hold-down straps and battery tray, which can result to physical damage to the battery.

Overcharging —   Batteries can be overcharged by either the vehicle’s charging system or a battery charger. In either case, the result is a violent chemical reaction within the battery that causes a loss of water in the cells. This can permanently reduce the capacity of the battery. Overcharging can also cause excessive heat, which oxidize the positive plates grid material and even buckle the plates, resulting in a loss of cell capacity and early battery failure. The vehicle’s charging system might not fully recharge recha rge the battery due to a Undercharge/Sulfation —   The stop-and-go driving or a fault in the charging system. In these cases, the battery operates in a partially discharged condition. A battery in this condition will become sulfated when the sulfate normally formed on the plates becomes dense, hard, and chemically irreversible. This happens because the sulfate has been allowed to remain in the plates for a long period. peri od. Sulfation of the plates causes two problems: First, it lowers the specific gravity levels and increases the danger of freezing at low temperatures. Second, in cold weather, a sulfated battery often fails to crank the engine because of its lack of reserve power.

Poor mounting —   Loose hold-down straps allow the battery to vibrate or bounce during vehicle operation. This vibration can shake the active materials off the grid plates, severely shortening battery life. It can also loosen the plate connections to the plate strap, loosen cable connections, or even crack the battery case.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

21

 

SELF-CHECK

Answer the following questions:

1. How can you extend the life of non-sealed batteries?

2. What are the two causes of battery electrolyte level getting low?

3. How does temperature affect battery performance?

4. Why corrosion prevents conduct of electricity?

5. What are the causes of sulfation?

SCORE:

 Trainee’s signature:  signature: 

Date:

Assessor’s Signature:

Developed By: Edward P. Alip

Date:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

21

 

QUALIFICATION:  

AUTOMOTIVE SERVICING NC II

COMMON COMPETENCY UNIT:

SERVICE AUTOMOTIVE BATTERY

MODULE TITLE: 

SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME NUMBER 2 : TESTING AUTOMOTIVE BATTERY

ASSESSMENT CRITERIA: 1. Different methods of ba battery ttery testing a are re performed 2. Battery is tested without causing damage to workplace, property, or vehicle. 3. Correct information is accessed and interpreted 4. Appropriate test equipment is selected and used 5. Tests are performed and results are analyzed 6. Personal safety is observed

LEARNING CONTENTS: 1.  Different methods of battery testing 2.   Testing tools and equipment 3.  Procedure in testing batteries 4.  Personal safety in testing battery

RESOURCES:

  Automotive Technology; Tech Manual; 4th Edition; ERJAVEC   Automotive Technology; 4 th  Edition; ERJAVEC   Computer Set   Communication Module    Tool/Equipment/Testing instruments   Reference Books    Toyota Training Manual   Auto Mechanics, Theory and Service By: de Kryger, Kobacik.Bono

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Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

23

 

LEARNING EXPERIENCES/ACTIVITIES   LO 2: Testing automotive battery LEARNING ACTIVITIES Are you ready to perform the t he knowledge and skills activities?      

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SPECIAL INSTRUCTIONS

Observe safety precautions Wear protective equipment Always perform 5’S  5’S   1.  In the contextual learning laboratory, with the help of your instructor, gather information/data on the:  

 

Safety in Testing Batteries  



 

Check your knowledge

 

Conducting visual inspection

 

Methods of battery testing



 

Follow Operation Sheet LO2-1 ―Conducting visual inspection‖.  inspection‖.  

 

Read Information Sheet ―Specific gravity test‖.  test‖. 

 

Answer self-check

 

Follow procedure in Operation sheet LO2-2A LO22A ―Conducting specific gravity test with a hydrometer‖.  hydrometer‖.  

 

Read Information Sheet ―Open circuit voltage test‖. test‖.  

 

Answer Self-check

 

Follow procedure in Operation Sheet

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

 

Read Information Sheet LO2-1‖Safety LO2-1‖Safety in testing batteries‖.  batteries‖.  Answer self-check

Specific gravity Test



Check your knowledge



LO2-2A

Conduct specific gravity test

Open circuit voltage Test

 

Check your knowledge Conduct open voltage test

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

circuit



LO2-2B ―Conducting LO2-2B voltage test‖.  test‖.  Battery leakage Test

 

Check your knowledge Conduct battery leakage test Capacity Test

 

Check your knowledge

circuit

 

Read Information Sheet ―Battery leakage test‖.  test‖.  

 

Answer questions

 

Follow procedure in Battery Leakage Test‖.  Test‖. 

 

Read Information ―Capacity Test‖.  Test‖.  

 

Answer Self-check

 

Follow procedure in Operation sheet Lo2-2D Lo22D ―Conducting capacity test‖.  test‖. 

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







Conduct capacity test

open

LO2-2B



LO2-2C

―Conducting

Sheet

LO2-2D

 

 

Ask your instructor for assessment. If you passed the assessment, your instructor will tell you to proceed to the next module.→→→ module.→→→  

INFORMATION SHEET LO2-1 

SAFETY IN TESTING BATTERIES Personal safety  Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:          

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

Work clothing –  clothing –  such  such as coveralls and steel-capped footwear Eye protection –  protection –  such  such as safety glasses and face masks Ear protection –  protection –  such  such as earmuffs and earplugs Hand protection - such as rubber gloves and barrier cream Respiratory equipment - such as face masks and valved valv ed respirators

If you are not certain what is appropriate or required, ask your supervisor.

Safety check     

Make sure that the hood is secure with a hood stay rod. Always make sure that you wear the appropriate personal protection equipment before starting the job. Remember that batteries contain acid and it is very easy to hurt  yourself even when the most exhaustive protection measures are taken.   Always make sure that your work area/environment is as safe as you can make it. Do not use damaged, broken or worn out workshop equipment.   Always follow any manufacturer's personal safety instructions to prevent damage to the vehicle you are working on.   Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

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

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

Points to note   

Batteries come in many sizes and power ratings, so always check the rating of the battery you are servicing. The rating provides a testing benchmark for battery performance.    The hydrometer used to measure the specific gravity of the ele electrolyte ctrolyte must be handled carefully and safely.

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

 



 



Developed By: Edward P. Alip

Store the hydrometer in a safe receptacle before and after use. Small amounts of electrolyte in the hydrometer can leak out and damage the vehicle paintwork. Do not remove electrolyte from one cell to another when testing; this will cause incorrect readings. Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

27

 

SELF-CHECK TRUE OR FALSE

Directions Read and analyze each statement carefully. Write TRUE if the statement is CORRECT, and write FALSE if it is WRONG. Write your answer on the space provided before each item. Good luck!

 ________1. Safety is everybody’s concern. concern.  ________2.Working  ________2. Working with batteries don’t need much attention.  ________3. Manufacturer’s Manufacturer’s personal safety instructions are important especially when working with hazardous materials.  ________4. The hydrometer is used to measure voltage in each cell.  ________5. Working with batteries batteries can always be done in any workplace workplace situation.

SCORE:

 Trainee’s signature:  signature: 

Assessor’s Signature:  Signature: 

Developed By: Edward P. Alip

Date:

Date:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

27

 

OPERATION SHEET LO2-1 CONDUCTING A VISUAL INSPECTION

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

25

 

 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

26

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. When servicing batteries, what must you do first to be able to easily e asily trace the problem? Q2. Why do you need to charge the battery after adding water? Q3. ischeck meantbattery by parasitic loadsacross and battery Q4. What How to discharge the topdrain? of the battery? Q5. How does an alternator belt affect battery charging? The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:  

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

26

 

INFORMATION SHEET LO2-2 METHODS OF BATTERY TESTING  Testing batteries is an important part of electrical system service. Depending on the design of the battery, state of charge and capacity can be determined in several ways.

INFORMATION SHEET LO2-2A

Specific Gravity Test- On unsealed batteries, the specific gravity of the electrolyte can be measured to give a fairly good indication of the battery’s state of charge. A hydrometer consists of a glass tube or barrel, rubber bulb, rubber tube, and a glass float or hydrometer with scale built into its upper stem. The glass tube encases the float and forms a reservoir for the test electrolyte. Squeezing the bulb pulls electrolyte into the reservoir. When filled with test electrolyte, the sealed hydrometer float bobs in the electrolyte. The glass float sinks in the test electrolyte indicates its relative weight compared to water. The reading is taken off the scale by sighting along the level of the electrolyte. electr olyte.

Hydrometers

A. When the scale sinks in the electrolyte The specific gravity is LOW B. When it floats high, the specific gravity is HIGH  The electrolyte of a fully charged battery is usually about 64% water and 36% sulfuric acid, which corresponds to a specific gravity of 1.270 . Specific gravity is the weight of a given volume of any liquid divided by the weight of an equal volume of water. Pure water has a specific gravity gr avity of 1.000 while battery electrolyte should have a specific gravity of 1.260 to 1.280 at 80F (26.7C (26.7C). ). In oth other er words, the electrolyte should be 1.260 to 1.280 times heavier than water.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 28

 

  Specific gravity of electrolyte decreases as the battery discharges. This is why measuring the specific gravity of the electrolyte with a hydrometer can be a good indicator of how much charge a battery has lost.  The table below lists specific gravity gravity readings in various stages of charge with respect to a battery’s ability to crank an engine at a temperature of 80F (26.7C).

ELECTROLYTE SPECIFIC GRAVITY AS RELATED TO CHARGE

Specific Gravity

Percent of charge

1.265

100%

1.225

75%

1.190

50%

1.155

25%

1.120 or lower

discharged

On some sealed maintenance-free batteries, a special temperature-compensated temperature -compensated hydrometer is built into the battery cover.

A quick visual check indicates the battery’s state of charge. It is important when observing the hydrometer that the battery has a clean top to see the correct indication. A flashlight maybe required in dark areas. Always look straight down when viewing the hydrometer.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 29

 

SELF-CHECK MATCHING TYPE Directions: Match the concepts found in column A with the corresponding words or technical terms found in column B. Choose your answer by writing the letter only on the space provided before each item. Write your answer in capital letters. Good luck!

Column B

Column A 1. Used to read specific gravity of a battery

A. 64% sulfuric acid and 36% water

2. The scale sinks in the electrolyte

B. high specific gravity

3. The scale floats high

C. hydrometer

4. Electrolyte composition of a fully-charged

D. 1.265

battery

E. specific gravity tester

5. Specific gravity of a fully-charged battery F. 1.290 6. Specific gravity of pure water G. Low specific gravity 7. Specific gravity of a half-charged battery H. 64% water and 36% sulfuric acid 8. low level electrolyte I. 1.500 9. 65% to 100% state of charge  J. 1.000 K. 1.190 L. 1.019 M. green N. clear O. dark

SCORE: __________  Trainee’s Signature:_________ Signature:_________ Date:________  Date:________   Assessor’s Signature:________ Date:_____  

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 29

 

OPERATION SHEET LO2-2A CONDUCTING A SPECIFIC GRAVITY TEST USING A HYDROMETER

Things you will need:  

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Safety goggles Rubber gloves Flat screwdriver Battery hydrometer Distilled water

1.  Step 1 Disconnect the negative lead on your battery, then disconnect the positive one.

2.  Step 2 Put on safety goggles and rubber gloves. Using a flat screwdriver, pry open the cover on your first cell.  The covers are round pieces of plastic inserted into the top of your battery. If you have a maintenance maintenance free battery, the covers to the cells are hidden beneath the paper labeling on the top of your battery.

3.  Step 3 Insert the tube or syringe part of your battery hydrometer into the liquid in the cell. Depending on what type of hydrometer you have, you will either squeeze and release the bulb at the end to draw liquid into the body of the hydrometer, or you will operate it like a syringe and pull the plunger up to draw liquid. Draw liquid into the hydrometer until you see se e the float in the body (usually a colored plastic ball) begin to rise. Note the reading on the gauge or scale printed on the side of the hydrometer, then release the liquid back into the cell.

4.  Step 4 Repeat step 3 for all of the cells in your battery, drawing in liquid until the ball floats, and noting the measurement on the side. A good battery will only have a difference of 0.5 ml between the measurements from all the cells. A bad cell will exceed that difference.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 30

 

5.  Step 5 Add a small amount of distilled water (no more than a cap full at a time) to the bad cell, and test it with the battery hydrometer again. Keep adding water and testing until the float measurement is within the acceptable range.

Temperature correction (see example)

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 31

 

CHECKING SPECIFIC GRAVITY FOR BATTERY WITH BUILT-IN HYDROMETER  

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 32

 

ANALYZING SPECIFIC GRAVITY TEST RESULT

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 33

 

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. Why negative lead or cable is always disconnected first and connected c onnected last? Q2. In a maintenance-free battery, how can you remove the cell covers c overs for you to be able to measure the specific gravity? Q3. When can you say that a battery must be replaced based on the specific gravity test result? Q4. When the temperature changes, what will happen to the gravity of the electrolyte? Q5. How do you know if a battery has a built-in hydrometer? The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology

Date Developed January 30, 2010

Page # 33

 

INFORMATION SHEET LO2-2B Open Circuit Voltage Test —   An open circuit voltage check can be used as a substitute for the hydrometer specific gravity test. As the battery is charged or discharged, slight changes occur in the battery’s voltage. So battery voltage with no load applied can give some indication of the state of charge.  The battery’s temperature should be between 60 and 100F (15.5 and 37.7C. The voltage mus mustt be allowed to stabilize for at least ten t en minutes with no load applied. On vehicles with high drains (vehi (vehicles cles with parasitic loads: clocks, computer controls, and other accessories that use small amount of current), it may be necessary to disconnect the battery ground cable. On batteries that have just been recharged, apply a heavy load for 15 seconds to remove the surface charge. Then allow the battery to stabilize. Once voltage has stabilized, use a voltmeter to measure the battery voltage to the nearest one-tenth of a volt.

Measuring open circuit voltage across battery terminals using a Voltmeter

BATTERY OPEN CIRCUIT VOLTAGE AS AN INDICATOR OF STATE OF CHARGE

Open Circuit Voltage

State of Charge

12.6 or greater

100%

12.4 to 12.6

75% - 100%

12.2 to 12.4

50% - 75%

12.0 to 12.2

25% - 50%

11.7 to 12.0

0 to 25 %

11.7 or less

0%

If the open circuit voltage test indicates a charge of below 75% of full charge, recharge the battery and perform capacity test to determine battery condition. Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology

Date Developed January 30, 2010

Page # 34

 

OPERATION SHEET LO2-2B CONDUCTING OPEN CIRCUIT VOLTAGE TEST

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology

Date Developed January 30, 2010

Page # 35

 

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. Why do you need to apply a heavy load for at least 15 seconds on a newly recharged battery before performing an open circuit voltage test? Q2. If you have taken an open circuit voltage of 11.9 or lower, what is the state of charge of the battery? Q3. What type of volt meter is best to use in taking open circuit voltage? Q4. In conducting open circuit voltage, when do you need to load test the battery and when do you need to recharge it? Q5. What is the setting of the instrument when measuring open circuit voltage for automotive batteries? The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 35

 

INFORMATION SHEET LO2-2C

Battery Leakage Test —   To To perform a battery leakage test, set a voltmeter on a low DC volt range. Connect the negative test lead to the battery negative terminal. Then move the positive lead across the top and sides of the battery case. If some voltage is read on the voltmeter, current is leaking out of the battery cells. The battery should be cleaned, then rechecked. If the battery again has some leakage, it should be replaced because the case is excessively porous or cracked.  

Conducting a battery leakage test

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 36

 

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. What is the setting of the voltmeter in conducting battery leakage test? Q2. What do you think are the causes of voltage leakage on a battery? Q3. When do you need to replace the battery, performing the voltage leakage test? The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 36

 

INFORMATION SHEET LO2-2D Capacity Test —   The The load or capacity test determines how well any type of battery, sealed or unsealed, functions under a load. In other words, it determines the battery’s ability to furnish starting current and still maintain sufficient voltage to operate the ignition system.    The load or capacity test can be performed with the battery either in or out of the vehicle. The battery must be at or very near a full state of charge. For best results, the electrolyte should be as close to 80F (26.7C) as possible. Cold batteries show considerably co nsiderably lower capacity. Never load test a sealed battery if its temperature is below 60 F (15.5C).

OPERATION SHEET LO2-2D CONDUCTING A BATTERY LOAD/CAPACITY TEST Procedure: 1.  Connect the tester as illustrated. The inductive pick-up (GREEN) must surround the negative cable of the tester itself. 

Typical tester hook-up for conducting a battery load/capacity test

2.  Observe the correct polarity and make sure the test leads are making good contacts with the battery posts.  3.   Turn the lead control knob (if the tester is so equipped) to draw current at the rate of three times the battery’s ampere-hour ampere-hour rating or ½ (one half) of its CCA rating.   4.  Maintain the load for 15 seconds. Observe the tester’s voltmeter.   5.  Discontinue the load after 15 seconds of current draw.   6.  At 70F (21C) or above or on testers that are temperature compensated, voltage at the end of 15 seconds should not fall below 9.6 volts. If the tester is not temperature compensated, use the table below to determine the adjusted minimum voltage v oltage reading for a particular temperature.  

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Page # 37

 

 

MINIMUM LOAD TEST VOLTAGES AS AFFECTED BY TEMPERATURE Battery Temperature (F)

Minimum Test Voltage

70F (21C)

9.6 volts (GOOD)

60 (15.5C)

9.5 volts (DEFECTIVE)

50 (10C)

9.4 volts (DEFECTIVE)

40 (4.4C)

9.3 volts (DEFECTIVE)

30 (-1C)

9.1 volts (DEFECTIVE)

26 (-6.6C)

8.9 volts (DEFECTIVE)

10 (-12.2C)

8.7 volts (DEFECTIVE)

0 (-17.7C)

8.5 volts (DEFECTIVE)

How to interpret the result If the voltage reading exceeds the specification by a volt or more, the battery is supplying sufficient current with a good margin of safety. If the reading is right on the spec, the battery might not have the reserve necessary to handle cranking during low temperatures. If the battery was at 75% charge and fell right on load specifications, it is probably in good shape. If the voltage reads below the temperature-corrected minimum, continue to observe the voltmeter of the tester after removing the load. If it rises 12.4 volts, the battery is bad. It can hold a charge but has insufficient cold cranking amperes (CCA). The battery can be recharged and retested, but the results are likely to be the same. If the voltage tests below the minimum and the voltmeter does not rise above 12.4 volts when the load is removed, the problem may only be a low state of charge. c harge. Recharge the battery and load test again. If a volt- ampere tester is not available, the starter motor can be used as a loading device to conduct a capacity test. By observing a voltage reading before and after the starting motor has run, the condition of the battery can be determined. Connect the voltmeter across the battery. Make sure the ignition is disabled to prevent engine starting.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

38

 

SELF-CHECK TRUE OR FALSE

Directions Read and analyze each statement carefully. Write TRUE if the statement is CORRECT, and write FALSE if it is WRONG. Write your answer on the space provided before each item. Good luck!

 ________1. It determines the battery’s ability to furnish starting current and still maintain sufficient voltage to operate the ignition system.  ________2. The load or or capacity test can be performed with the battery either in or out of the the vehicle vehicle..  ________3. Never load test a sealed battery if its temperature is below 80 F.  ________4. Do not disconnect the ignition system when cond conducting ucting battery load/capacity test using the starter motor as a loading device.  ________5. If the voltage reading exceeds the specification by a volt or more, the battery is not supplying sufficient current.

SCORE:

 Trainee’s signature:  signature: 

Date:

Assessor’s Signature:  Signature: 

Developed By: Edward P. Alip

Date:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

38

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. If the voltage tests b below elow the minimum and the voltmeter does not rise above above 12.4 volts when the load is removed, what will you do to the battery for a more reliable test result? Q2. When can you say that the battery is good, performing the battery load/capacity test? Q3. Do you need to consider the temperature of the electrolyte when performing battery load/capacity test? Why? Q4. What must you observe when using electrical testing te sting instruments? The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:

 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

38

 

QUALIFICATION:  

AUTOMOTIVE SERVICING NC II

COMMON COMPETENCY UNIT:

MODULE TITLE: 

SERVICE AUTOMOTIVE BATTERY

SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME NUMBER 3: REMOVE AND REPLACE BATTERIES

ASSESSMENT CRITERIA:

1. Proper procedure is followed in removing and replacing battery 2. Battery is removed and replaced without causing damage to workplace, property or vehicle v ehicle 3. Proper procedure is followed to prevent loss of vehicle’s electronic memory as per manufacturer’s standard (if applicable)  applicable)   4. Appropriate tools and equipment are selected and used 5. Personal safety in removing and replacing batteries observed

LEARNING CONTENTS: 1.  2.  3.  4. 

Safety procedure in removing and replacing battery Correct tools and equipment in removing removin g and replacing battery Hazards in removing and replacing battery Procedure in removing and replacing battery   Conventional   Electronic control

RESOURCES:

  Automotive Technology; Tech Manual; 4th Edition; ERJAVEC   Automotive Technology; 4 th  Edition; ERJAVEC   Computer Set   Communication Module    Tool/Equipment   Reference Books    Toyota Training Manual   Auto Mechanics, Theory and Service By: de Kryger, Kobacik.Bono

  











Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

41

 

LEARNING EXPERIENCES/ACTIVITIES   LO 3: Removing and replacing battery LEARNING ACTIVITIES Are you ready to perform the knowledge and skills activities?      

  

SPECIAL INSTRUCTIONS

Observe safety precautions Wear protective equipment Always perform 5’S  5’S  

1. In the contextual learning laboratory, with the help of  your instructor, gather information/data on the:    

safety in working with batteries inspecting batteries

 

Read Information Sheet LO3

 

Follow operation sheet LO3

 

Complete the assessment task



Ask your instructor for assessment. If you passed the assessment,  your instructor will tell you to proceed to the next module.→→→  module.→→→  





Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

INFORMATION SHEET LO3-1 BATTERY SAFETY

1. Do not allow battery acid to come in contact with skin, eyes, or clothing. 2. Observe polarity when making connections to the battery. 3. Always disconnect the negative cable first. 4. Avoid any arcing or open flames near a battery. 5. Follow manufacturer’s recommendations when charging.  charging.   6. Add only distilled water when low. 7. Do not wear jewelry when servicing a battery. 8. Never lay tools on a battery. 9. Always wear safety glasses when servicing a battery. 10. If frozen, allow the electrolyte to defrost before doing any service. 11. Never work on a battery with a lit cigarette in your mouth 12.

BATTERY INSPECTION TIPS

           

Developed By: Edward P. Alip

Check Check Check Check Check Check

the the the the the the

case for damage, dirt, and corrosion. electrolyte level, color, and odor. case for cracks and loose terminal posts. condition of the cables. battery hold-down fixture. heat shield for proper installation

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

OPERATION SHEET LO3-1

CHECKING BATTERY

A battery,  battery, like  like other parts of your vehicle, is subject to wear and tear and should be checked regularly. IIn n particular, pay attention to the battery ’’s s trouble spots, shown here. A battery that’s kept clean lasts longer than a cruddy one.

The parts of the battery to check

It’s easy to check your battery. Just locate it and follow these steps:   1.  Clean off powdery deposits on the positive and negative terminals. ter minals.  The deposits that form in lovely colors on the top of your terminals are made by battery acid. Before  you clean it, remove the cables (negative first) from both terminals by undoing the nut nut on each cable clamp and wiggling the cable until the clamp comes off the terminal post.  To brush the deposits off the terminal posts and cable cable clamps, sprinkle some baking soda onto each terminal, dip an old toothbrush or disposable brush in water, and scrub the deposits away.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

 

You can use a battery terminal brush (inside the cap) and clamp cleaner. If your cables and clamps won’t clean up completely with baking soda and water, rotate an inexpensive battery terminal brush on each terminal termi nal to shine it and ensure a good, solid electrical connection. You can also shine the insides of the cable clamps with the clamp cleaner that’s usually sold as one unit with the brush. A soapless steel wool pad may also do the job. 2.  Dry everything with a clean, disposable, lint-free rag.  Try to avoid getting the powdery stuff on your hands or clothes. If you do, wash it off with water right away. 3.  Reconnect the terminals to the battery, replacing the positive cable first and the negative cable last. After the battery terminals are reconnected, coat the terminals with thick automotive grease or petroleum jelly to prevent corrosive deposits from forming again. 4.  Exami Examine ne the battery cables and clamps to see whether they’re frayed or corroded.   If the damage looks worse, the cables and clamps may need to be replaced; otherwise, the battery may short-circuit, which could damage onboard computers. If you’ve been having trouble tro uble starting your engine, if your headlights seem dim, or if the battery is old, check to see whether the electrolyte in the battery is strong enough. If it’s weak, the battery may need to be recharged or replaced before it dies and leaves you stranded.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

5.  Check the battery case and the terminals. If you see major cracks in the battery case or obvious terminal damage, replace the battery regardless of its electrical performance.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. Q2. Q3. Q4. Q5. The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:  

Developed By: Edward P. Alip

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA Maddela Institute of   Technology  Technology  

 January 30, 2010

42

 

OPERATION SHEET LO3-2 REMOVING AND INSTALLING A CAR BATTERY No matter how well your vehicle is working, if your battery dies and can’t be recharged, you’re stranded in a vehicle that you can’t drive dr ive in for service. A battery usually has a sticker on it that shows when  you bought it and how long you can expect it to survive. To prevent being stuck on the road with a dead battery, enter that information in your owner's manual and have the battery replaced before it comes to the end of its life expectancy. Prepare your tools and materials —  materials —  an  an adjustable wrench, a couple of clean lint-free rags, a pair of disposable latex gloves, some water and baking soda, a battery brush, and an inexpensive pair of safety goggles .

PROCEDURE: 1.   Turn off your engine. Make sure that your vehicle is in Park, with the engine shut off and the parking brake on. 2.  Open the hood and place a blanket or pad over the fender.  This protects your car from corrosive battery acid. 3.  Remove the cables from the battery terminals. Look in your owner’s manual to see whether your vehicle vehicle has negative ground (most do). If it does, use an adjustable wrench to first loosen the nut and bolt on the clamp that holds the battery cable on the negative terminal. (That’s the post with the little ―–‖ or ―NEG‖ on it.) If your vehicle has positiv e ground, loosen the cable with ―+‖ or ―POS‖ on it first. Remove the cable from the post and lay it out of your way. Then remove the other cable from its post and lay that aside. If you have trouble loosening the bolt, grab it with one wrench and the nut with another, and move the wrenches in opposite directions. In this case, you don’t want to remove the bolts; just loosen them enough to release the cable clamps. 4.  Remove whatever devices are holding the battery in place. When you’re removing a bolt or screw, after you’ve loosened it with a tool, turn it the last few turns by hand so that you have a firm grip on it when it comes loose and it doesn’t drop and roll into obscurity.   5.  Remove the battery. When the battery is free, lift it out of its seat and place it out of your way. 6.  If the tray on which the battery was standing is rusty or has deposits on it, clean it with a little baking soda dissolved in water. Wear your gloves because the battery stuff is corrosive, and be sure the battery tray is completely dry before taking the next step!

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

7.  Place the new battery on the tray. Make sure it is facing in the same direction as the old one was. 8.  Replace the devices that held the old battery in place.  Try to wiggle the battery to make sure it’s completely secure.  secure.  9.  Replace the battery cables on the terminals in reverse order from which you removed them. If your vehicle has negative ground, the positive cable goes back first. Make certain that the clamps holding the cables on the battery terminals are gripping the posts tightly. 10. Take   the old battery to a recycling center that accepts batteries. batteries. Batteries are filled with a toxic, corrosive corros ive liquid and must be disposed of properly. What’s more, old batteries are usually rebuilt into new ones, so just throwing one in the trash is doubly bad for the environment. If you have your new battery installed when you buy it, the shop will recycle the old one for you.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

ORAL INTERVIEW SATISFACTORY RESPONSE YES NO

QUESTIONS Q1. Q2. Q3. Q4. Q5. The Candidate’s underpinning knowledge was:  

Satisfactory

Not satisfactory

Feedback to Candidate:

Trainee’s Signature: 

Date:

Assessor’s Signature:  

Date:

 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

42

 

QUALIFICATION:  

AUTOMOTIVE SERVICING NC II

COMMON COMPETENCY UNIT:

MODULE TITLE: 

SERVICE AUTOMOTIVE BATTERY

SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME NUMBER 4: SERVICE AND CHARGE BATTERIES

ASSESSMENT CRITERIA:  1. Battery is charged using the appropriate battery charger 2. Electrolyte level is checked and corrected 3. Battery and its terminals are cleaned 4. Battery cables are disconnected and connected in right sequence 5. Personal safety in servicing and charging battery is observed

LEARNING CONTENTS: 1. 2. 3. 4. 5.

Battery charger parts and their function Repair/clean/replace connectors Procedure in cleaning battery case, tray, and cables Topping, filling electrolyte/distilled water Procedure in battery charging   Fast charging   Slow charging

6. Proper connection of battery terminals 7. Safety in servicing and charging batteries RESOURCES:

  Automotive Technology; Tech Manual; 4th Edition; ERJAVEC   Automotive Technology; 4 th  Edition; ERJAVEC   Computer Set   Communication Module    Tool/Equipment   Reference Books    Toyota Training Manual   Auto Mechanics, Theory and Service By: de Kryger, Kobacik.Bono

  











Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA-Maddela Institute of   Technology  Technology  

 January 30, 2010

49

 

LEARNING EXPERIENCES/ACTIVITIES   LO 4: Servicing and replacing batteries LEARNING ACTIVITIES Are you ready to perform the knowledge and skills activities?      

  

SPECIAL INSTRUCTIONS

Observe safety precautions Wear protective equipment Always perform 5’S  5’S   1.  In the contextual learning laboratory, with the help of your instructor, gather information/data on the following and then perform:  

Cleaning battery case, tray, and cables

 

Cleaning Battery Terminals

 

Filling, topping electrolyte/distilled water

2.  Gather information/data on the safety procedure in using battery chargers and perform the following:  

Fast charging Slow charging    Trouble shooting

 

Follow Operation Sheet LO4-1

 

Follow Operation Sheet LO4-2

 

Follow Operation Sheet LO4-3

 

Read Information Sheet LO4-1

 

Follow Operation Sheet LO4-4

 

Complete the assessment task











 

3.  Check your knowledge and skill in this learning outcome.



Ask your instructor for assessment. If you passed the assessment, your instructor will tell you to proceed to the next module.→→→  module.→→→ 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

50

 

OPERATION SHEET LO4-1 CLEANING BATTERY CASE, TRAY, AND CABLES

Procedure: CAUTION: Always wear safety glasses and goggles when working with batteries and electrical system, no matter how small the job!

1.  Loosen the battery negative terminal clamp  

2.  Use a terminal clamp puller to remove the negative cable  

3.  Loosen the battery positive terminal clamp 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

51

 

4.  Use a terminal clamp puller to remove the positive clamp  

5.  Remove the battery hold –  hold  – down down hardware and any heat shields  

6.  Remove the battery from the tray  

CAUTION: When lifting a battery, excessive pressure pressure on the the end walls could cause acid to spew through the vent caps, resulting in personal injury. If possible, lift with a battery carrier or with your hands on opposite corners.

Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA Maddela Institute of   Technology  Technology  

 January 30, 2010

52

 

7.  Mix a solution of baking soda and water 

8.  Brush the baking soda solution over the battery case, but don’t allow the solution to enter the cells of the battery  

9.  Flush the baking soda off with water 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

53

 

10. Use a scraper and wire brush to remove corrosion from the hold-down hardware  

11. Brush the baking soda solution over the hold-down hardware and then flush with water  

12. Allow the hardware to dry then paint it corrosion-proof paint  

13. Use a terminal cleaner brush to clean the battery cables 

Developed By: Edward P. Alip

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA Maddela Institute of   Technology  Technology  

 January 30, 2010

54

 

14. Use a terminal cleaner brush to clean the battery posts  

15. Install the battery back into the tray. Don’t forget to install the battery hold-down hold -down hardware 

16. Install the positive battery cable first, and then the negative cable. Be sure to install the cables firmly.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

55

 

OPERATION SHEET LO4-2 CLEANING BATTERY TERMINALS  The problem arises more often if you don’t drive your car regularly. When the engine engine is not running and the battery is sitting, the terminals oxidize at a faster rate. This means you need to check the battery terminals more often for corrosion. corrosi on. Corrosion appears as a white, ashy deposit around one or both battery posts. Sometimes there is also a bit of color c olor mixed in. These deposits are the result of one of several possi possible ble chemical exchanges involving vapors and the battery post.  

Corroded battery terminal and connector

Supplies:  

           

A combination tool –  tool –  battery  battery post brush and battery clamp brush, obtainable at any auto parts store. These generally come in two designs, one employing wire brush elements and the other using two cutting blades and a reamer. Locking pliers (vice grips).  Toothbrush. Baking soda. Water. Clean, lint-free cloth. Wrench. Grease or petroleum jelly.

Directions: 1.  Remove the battery cables from the battery terminals by loosening the nut on each cable clamp. Once they are loose, always remove the cable clamp from f rom the negative terminal first . It’s marked with a minus (-) sign; the positive terminal has a plus (+) sign. Reverse the procedure, positive first, negative second, when replacing the cables. The cable may not come off easily. You will have to wiggle it and lift it upward until the clamp comes off the terminal post. Sometimes, Sometim es, especially if there is a lot of corrosion,  you may need the assistance of pair of locking pliers. pliers. Be careful not to short any tools you use against the car when they’re in contact with the battery. 2.  Examine the battery cables and clamps for excess wear or corrosion. Should damage appear extensive, replace the cables and clamps to avoid future problems.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

56

 

3.  Check the battery case for cracks and the terminals for damage. If you find either, replace the battery.

4.  Secure the loose cables so that they don’t accidentally flop back onto the terminals.

5.  Pour some baking soda directly onto the posts.

6.  Dip a toothbrush in water and use it to scrub the baking soda into the terminal posts and cable clamps. Skin and eye protection is recommended.

7.  If the toothbrush isn’t doing the job, Use a battery terminal cleaner brush on it. Also shine up the insides of the cable clamps by using the clamp cleaner that usually comes attached to the terminal brush or use a plain, soap-free steel wool pad.

8.  Dry everything off with a clean, disposable, lint-free rag.

9.  Smear grease or petroleum jelly je lly on the posts to slow down the formation of corrosive corrosiv e deposits. Cover all exposed metal surfaces on the battery posts, battery cables, and clamps.

10. Replace the positive clamp first and then replace the negative clamp. Tighten them down with the proper sized wrench.

11. Replace the rubber boot or plastic shield that covers the positive terminal. If you don’t have one, go and buy some from your local auto parts store.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

57

 

OPERATION SHEET LO4-3 CHECKING/FILLING ELECTROLYTE AND MAINTENANCE Battery Maintenance Periodic battery maintenance should be performed even when there is no vehicle starting problem. The following simple procedures will help prevent premature battery failure.

Check level.Refill Do not allow the level to to fallthe below the LOWER  line or below any of the LEVEL  line tops of electrolyte plates in cells. with distilled water UPPER LEVEL  line.  line. Low electrolyte levels may cause malfunction in the charging system Keep battery clean of all dirt and acid spillage, especially around terminals. Keep the exhaust tube free of kinks and dirt build-up If vehicle is not in frequent use, additional charging WILL be required. Before recharging be sure filler plugs are loosened. DO NOT REMOVE THE PLUGS Charging rates will vary depending on… - Battery’s electrical capacity   - Temperature of electrolyte - Battery’s state of charge at start of charging - Battery’s age and condition - Type of charger  

FILLING THE BATTERY WITH ELECTROLYTE (NEW BATTERY)

Remove the battery from packaging and place on a level stable surface Use 1.27 specific gravity electrolyte (diluted sulphuric acid) - NOT SUPPLIED Remove the filling plugs Remove the rubber cap and replace with the exhaust tube provided Fill the battery with the electrolyte to the UPPER LEVEL indicated on the battery casing

NOTE: Electrolyte temperature must be between 15oC and 30oC when filling  !

Leave the battery to stand for at least 30 minutes after filling. If the electrolyte level dro drops ps in this time, refill to the UPPER LEVEL before charging  The battery is now filled and ready to charge 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

58

 

INFORMATION SHEET LO4-1 SAFETY PRECAUTIONS IN BATTERY CHARGING

INSTRUCTIONS FOR YOUR SAFETY BATTERY WARNINGS DANGER! RISK OF BATTERY EXPLOSION FROM HYDROGEN GAS MAY RESULT IN BLINDNESS, SERIOUS INJURY, PERMANENT DISFIGUREMENT AND SCARRING. Batteries generate explosive hydrogen gas, even during normal operation. People have been injured by battery parts flying in an explosion. They can explode under normal operating conditions, such as starting your car. They can explode under abnormal conditions, such as jump starting, or if short circuited by a tool. They can explode in a parked car or sitting on a table.  To help reduce the risk of these dangers and injury, it is of the utmost importance that each time before using your charger, you read and understand this manual, and any warnings and instructions by the battery manufacturer. Follow these instructions exactly.

TO HELP REDUCE THIS RISK:   1.  Wear Personal Protective Equipment  ALWAYS wear complete eye protection (THAT PROTECTS EYES FROM ALL ANGLES). o  2.  Avoid Flames and Sparks Near Battery and Fuel   ALWAYS keep flames, matches, lighters, cigarettes or other ignition sources away from battery. o  o  DO NOT put flammable material on or under charger. DO NOT use near gasoline vapors. o  Make sure charger clips make good contact by twisting or rocking them back and forth several times. The second clip connection MUST ALWAYS be made away from the battery. ALWAYS  plug charger into an electrical outlet AFTER all connections have been made. See OPERATING INSTRUCTIONS. o  If necessary to remove battery from vehicle to charge, ALWAYS turn off all accessories in the vehicle. Then ALWAYS remove grounded terminal (connected to car frame) from battery first. o  A tool touching both batteryposts or battery post and car metal parts is a short circuit and will spark. When using metal tools on or near battery be extra cautious to reduce risk of short circuit, possibly causing a battery explosion. DO NOT drop a tool on battery. 3.  Reduce Explosive Gas (hydrogen)   o  Before connecting charger, ALWAYS add water to each cell until battery acid covers plates to help purge extra gas from cells. DO NOT overfill. Battery acid expands during charge. After charging fill to level specified by battery manufacturer. For a battery without removable caps (maintenance free battery), carefully follow manufacturer's instructions on charging. Some sealed maintenance free batteries have a battery condition indicator. A light or bright o  colored dot indicates low water. Such a battery needs to be replaced, re placed, not charged or jump started. o  Charge battery with caps in place. Most U.S. batteries are made with flame arresting caps. DO NOT pry caps off sealed batteries. Place wet cloth on batteries with non-flame arresting caps.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

59

 

  Be sure area around battery is well ventilated before and during charging process. NEVER  charge in a closed-in or restricted area. 4.  Stay Away From Battery When Possible  NEVER put face near battery. o  ALWAYS locate charger as far from fr om battery as DC cables permit. o  ALWAYS keep other people away from the battery. They are not wearing safety glasses like you o  are. 5.  Avoid Contact With Battery Acid   o  Battery posts may have acid corrosion. DO NOT get corrosion in your eyes. Avoid touching eyes while working near battery. o

o

 use to a battery carrier. Carrying   causing ALWAYSacid be forced out vent caps. a battery by hand may put pressure on its ends, ALWAYS have plenty of fresh water and soap nearby in case battery acid contacts o  c ontacts eyes, skin or clothing. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with cold running water for at least fifteen (15) minutes and get medical help immediately. In very cold weather a discharged battery may freeze. NEVER charge a frozen battery. Gases o  may form, cracking the case, and spray out battery acid. 6.  Avoid Overcharging Batteries  o   The non-automatic (manual) battery charger models can overcharge a battery if left connected for an extended period of time, resulting in loss of water and creation of hydrogen gas. 7.  Follow Other Manufacturers' Recommendations   o  Before using charger, read all instructions for, and caution markings on: (1) charger, (2) battery, and (3) related product using battery. Follow their recommended rate of charge.

ELECTRICAL WARNINGS DANGER! RISK OF ELECTRICAL AND FIRE HAZARD. MAY RESULT IN DEATH, SERIOUS INJURY, SHOCK OR BURNS.

TO HELP REDUCE THIS RISK:  This charger, like all electrical products, MUST be treated with respect. Follow these instructions to reduce electrical hazard risk. 1.  PROPER GROUNDING AND AC POWER CONNECTION   o  Charger MUST be grounded to reduce risk of electric shock. Charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug. The plug MUST be plugged into an outlet that is properly installed and GROUNDED in accordance with all local codes and ordinances. If you ever feel even a slight shock from this or any electrical appliance, stop, walk away. Turn off electricity to outlet, and have it inspected by an electrician. You may have a dangerous, improperly wired outlet. DANGER - NEVER alter AC power cord or plug provided - if it will not fit outlet, have proper o  outlet installed by a qualified electrician or proceed as shown in the t he illustration below. Improper connection can result in a risk of an electric shock. This battery charger is for use on a nominal 120 volt circuit (common household current), cu rrent), and has a grounding plug as illustrated. A temporary adapter may be used, USA only, to connect this plug to a two-pole receptacle, as shown, if properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician.

Developed By:

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

60

Edward P. Alip

 

  DANGER - Before using adapter as illustrated, be certain that center screw of outlet plate is grounded. The green colored rigid ear or lug extending from adapter MUST be connected to a properly grounded outlet - make certain it is grounded. If necessary, replace original outlet cover plate screw with a longer screw that will secure adapter ear or lug to outlet cover plate and make ground connection to grounded outlet. 2.  Remove Jewelry  ALWAYS remove personal metal items (such as rings, bracelets, necklaces and watches) when o  working with a battery. A short circuit through one of these items can melt it causing a severe burn. 3.  Avoid Charger Abuse  o

o

reduce risk of electric shock, unplug fromrisk. outlet before attempting any maintenance maintenance    To or cleaning. Turning off controls will not charger reduce this DO NOT disassemble charger. Take it to a qualified service person when service or repair is o  required. Incorrect reassembly may result in a risk of electric shock or fire. o  DO NOT expose charger to rain, snow, water, gas, oil, etc. DO NOT operate charger if it has received o  receiv ed a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified service person. o  DO NOT block air holes in top or bottom of charger. DO NOT put charger on vehicle seat. DO NOT set a battery on top of charger. DO NOT operate charger with clips shorted together. o  the battery MUST ALWAYS match to avoid damage to battery o   The polarity of the charger and the and charger. The second clip connection MUST ALWAYS be made away from the battery. (See OPERATING INSTRUCTIONS below.) 4.  Proper Use of Charger and Wiring  o  An extension cord should not be used unless absolutely necessary. ne cessary. Use of improper extension cord could result intype a risk of fire and electric shock.cord If extension cord must becord used, use  be ONLY  a grounded, 3-wire cord. NEVER  use a 2-wire and an adaptor! The MUST plugged into a grounded outlet. Make sure it is properly wired, in good electrical condition, and wire size is large enough for AC ampere rating of charger as specified below. AWG = American Wire Gauge RECOMMENDED PROPER WIRE SIZE (AWG) IN EXTENSION CORDS FOR BATTERY CHARGERS Charger's AC Input Rating equal to or greater than

Length of Cord (feet)

but less than

25 ft

AMPERES

50 ft

100 ft

150 ft

Wire Size of Cord (AWG)

0

2

18

18

18

16

2

3

18

18

16

14

3

4

18

18

16

14

4

5

18

16

14

12

You may use heavier size wire - NEVER lighter.

Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA-Maddela Institute of   Technology  Technology  

 January 30, 2010

61

 

    DO NOT modify charger circuitry. o   To reduce risk of damage to plug and cord when disconnecting charger, ALWAYS pull on plug NEVER on cord. o  Locate cord so that it will not be stepped on, tripped over, or otherwise subject to damage or stress. DO NOT lay extension cord on battery or charger. DO NOT operate charger with damaged cord or plug - replace them immediately. o  Determine battery voltage by referring to vehicle or equipment owner's manual and make sure it matches DC output voltage shown on charger nameplate. o

   This battery charger is designed specifically for charging automotive lead-acid batteries. DO NOT use with dry-cells that are commonly used with home appliances, flashlights, etc. These batteries may burst and cause injury to persons and damage to property. applications other than battery o   This charger is not intended to supply low-voltage power for applications charging. Charging a battery on board a boat floating in water requires a battery charger specially o  designed to marine charging standards. Move the battery to dry land for charging with this charger. o

AUTOMOTIVE WARNINGS DANGER! RISK OF FLYING PARTS IF USED NEAR MOVING ENGINE PARTS. MAY RESULT IN DEATH, BLINDNESS, SERIOUS INJURY, PERMANENT DISFIGUREMENT AND SCARRING.

TO HELP REDUCE THIS RISK:  

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

 



ALWAYS keep charger, DC clips and wires, and AC power cord and plug away from any movable parts of the vehicle including fan belts, fan blade, alternator or generator, etc. ALWAYS avoid the radiator cooling fan. On some cars it may start up without the engine running, when you least expect it. If your charger does not have an engine starting feature, ALWAYS disconnect the charger before starting the engine . If your charger has engine starting feature, AVOID MOVING ENGINE PARTS   when starting engine.

Developed By: Edward P. Alip

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA Maddela Institute of   Technology  Technology  

 January 30, 2010

62

 

OPERATION SHEET LO4-4 BATTERY CHARGING

Operating Instructions Instructions

A spark near the battery may cause a battery explosion. To reduce risk of a spark near the battery when you connect the charger clips, ONLY connect one clip to the battery. Then, take the second clip and connect it to the car frame or engine block. If I f a spark should occur then, it will be far away fr om the battery.  This type of connection works because every car battery has one cable cable which is connected to the body or car frame. This is called the ground cable. On most cars this cable is connected to the NEGATIVE terminal of the battery. This is called a NEGATIVE GROUND. Most cars made in the U.S.A., Europe, and Asia in the last twenty years have negative grounds. Battery Polarity: A battery has two poles or posts. The positive positiv e battery post is usually marked POS, P, or + and is larger than the negative post which is usually marked NEG, N, or ——   —— .   The polarity of the charger and the battery battery MUST ALWAYS match to avoid damage to battery and charger. On a negative ground car: connect the positive (red) charger clip to the positive battery post first; then connect the negative (black) clip to negative ground (car frame or engine block). If you are not sure what type of ground your car has, have it checked before using charger.

PROCEDURE STEP 1. CONNECTING THE CHARGER TO BATTERY

   

 

If charger has switch with OFF position, it MUST be set to OFF. AC power cord MUST be unplugged.

A. CHARGING BATTERY IN VEHICLE If car has negative ground: (Most cars do, but if you are not sure have it checked.) 1.  Connect POSITIVE (RED) charger clip to POSITIVE post of battery. Some newer cars have a remote positive terminal located away from the battery. Use this remote terminal for charging connections. See your car's owners manual. 2.  Next connect NEGATIVE (BLACK) charger clip to car frame or engine block away from battery.

CAUTION: DO NOT connect clip to carburetor, fuel lines, or sheet metal body parts. Connect to a heavy gauge metal part of the frame or engine block. bl ock. DO NOT face battery when maki making ng final connection.  Go to STEP 2 . > 

If car has positive ground: (MOST CARS DO NOT HAVE A POSITIVE GROUND)   1.  Connect NEGATIVE (BLACK) charger clip to NEGATIVE ungrounded post of battery. 2.  Next connect POSITIVE (RED) charger clip to car frame or engine block away from battery. Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

63

 

CAUTION: DO NOT connect clip to carburetor, fuel lines, or sheet metal body parts. Connect to a heavy gauge metal part of the frame or engine block. DO NOT face battery when making final connection.  Go to STEP 2. B. CHARGING BATTERY OUTSIDE VEHICLE    

 

Check polarity of battery posts. See above. Attach a jumper cable or a 6 gauge (AWG) insulated battery cable c able at least 24 inches long, to NEGATIVE battery post.

1.  Connect POSITIVE (RED) charger clip to POSITIVE post of battery. 2.  Position yourself and free end of cable as far away from battery as possible - then connect NEGATIVE (BLACK) charger clip to free end of cable. DO NOT face battery when making final connection. Go to STEP 2.

STEP 2 . TURNING THE CHARGER ON

     

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If equipped with voltage switch, set switch to voltage of battery: 6, 12 volts. If equipped with rate switch, set switch for charge rate desired: 2, 6, 12, 30 Amps. If equipped with automatic/manual charge mode switch, set switch to battery type for automatic charging of conventional batteries, maintenance free batteries, or manual f or non-automatic charging of all battery types. If equipped with timer, set to charge time desired. Plug the AC cord in a grounded outlet. Stand away from battery. DO NOT touch charger clips when the charger is on.  The charger should now be on and the ammeter showing the rate at which the battery is charging. T The he initial rate may be somewhat higher or lower than the charger's nameplate rating depending on battery condition and AC voltage at the outlet. See CHARGING TIME table for length of charge.

STEP 3 . TURNING THE CHARGER OFF

     

Unplug the AC power cord from the outlet. Set the selector switch to OFF. Remove charger clip connected to car frame: If charging battery outside a vehicle, remove clip

 

connected away from battery. Remove clip connected to battery post.

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ENGINE STARTING    

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For models with Engine Starting Feature. Connect in the same manner as for battery charging, following STEP 1. Make sure cords are away from moving engine parts. Charge the battery, following STEP 2, for at least 3 minutes before trying to start the engine. Set the selector switch to the proper start position and crank the engine in the normal manner. DO NOT CRANK FOR MORE THAN 15 SECONDS. Check car's owners manual for recommended cranking time limit. If car does not start or the charger's overload circuit breaker trips, allow the charger to cool for at least 3 minutes before trying again. When the engine has started, turn off charger following STEP 3 >. USE CARE TO AVOID MOVING ENGINE PARTS. 

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

64

 

 

C H A R G I N G T I M E  Time To Charge Fully- Discharged Battery   Battery Type

Battery Rating

Charger Output Rating (Amps) 2

6

10

12

30

Cars/Trucks etc.

RC 

315 CCA

60

20

7

4

3

1

450 CCA

70

23

8

5

4

2

550 CCA

85

NR

9

6

5

2

850 CCA

140

NR

16

9

8

3

1050 CCA

165

NR

18

11

9

4

Note change in ratings below to AH

AH 

small Motorcycle Garden Tractor

12

7

NR

NR

NR

NR

large Motorcycle Garden Tractor

32

18

6

4

3

NR

Deep Cycle

55

NR

10

6

5

NR

Deep Cycle

80

NR

15

9

7

3

Deep Cycle

105

NR

20

12

10

4

Time to charge your battery (hours)

Time to charger your battery (hours)

NR = Not Recommended for this size battery.

Charging times for your battery may be different from these. If your battery is only half discharged you will need only half the time to charge. Some old batteries may not accept a charge and will heat up on charging. CAUTION: If at any time the battery gets hot (above 125 degrees F) or acid comes out of vent caps, STOP charging. Have your battery checked. Charging may not be possible. possibl e. It may have to be replaced.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

65

 

 

Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA-Maddela Institute of   Technology  Technology  

 January 30, 2010

66

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

 

 

67

 

Fast and Slow Charging

Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA-Maddela Institute of   Technology  Technology  

 January 30, 2010

68

 

TROUBLE SHOOTING 1.  No DC Output On Ammeter When Charger Is On.   a) Unplug the charger and make sure connections are secure. b) Check for wall outlet for power. c) DC circuit breaker is tripped. See "Charger Overload" below. d) A dead battery (Specific Gravity near 1.000) shows very low output on ammeter. After 15 to 20 minutes the indicated current rises and normal charging occurs. 2.  Charger Overload. o   The charger is protected against overloads by a self-resetting DC circuit breaker. An overload is indicated when a full scale ammeter reading abruptly falls to zero accompanied accom panied by a distinct "click" of the DC circuit breaker as it trips. A 3 to 5 minute cooling off period is required before the breaker will reset itself. If the overload ov erload condition still exists, the cycle will repeat.

Listed below are the conditions that can cause the circuit breaker to trip:   A deeply discharged battery (Specific Gravity near 1.120). If the battery is in otherwise good condition, the circuit breaker may trip on and off several times until the battery recovers enough to allow a normal charge rate. If the tripping continues after 30 minutes, a larger charger should be used. A battery with a shorted cell. A battery in this condition may cause the breaker to trip o  continuously. It will not accept a charge and should be replaced. o  Charger leads are connected in reverse causing the breaker to trip continuously. May damage battery and charger. o

o

charger leads and together the charger on. This causes a spark which is on.    Touching dangerousthe if near a battery couldwith severely damageturned the charger. If proper hookup is observed and sparking does occur between charger charge r clips and frame o  connection, DO NOT use the charger. Have it checked by a qualified service person. CAUTION: Regardless of what is causing the overload, unattended or routine operation in this o  manner could result in serious damage to the charger and the battery. 3.  Charge Rate Does Not Go To Full Amp Rating Of Charger And/Or Falls Quickly When Charger Is Turned On.  o  Battery is partially charged. Battery is cold. o  o   The AC outlet voltage is less than 120 volts. o  Corroded clips and/or battery posts. 4.  Current Indicated On Ammeter Falls Slightly Showing No Further Change. Worn out battery with sulfated plates, replace battery. o 

STORAGE  



Clean clips. Repack charger and instruction manual. Store in a dry place not subject to sub-zero temperatures which could cause the cord insulation to become stiff and possibly crack when uncoiled.

Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA-Maddela Institute of   Technology  Technology  

 January 30, 2010

69

 

ASSESSMENT TASKS

 These assessment tasks should be completed when you are confident that you you can SERVICE ANMD CHARGE BATTRIES CORRECTLY. Assessment needs to conform to the rules of evidence. Therefore;

 

You will participate and complete the learning activities

   

You will demonstrate tasks to the required standards You will answer oral and written questions

 

You will complete the assessment tool

   

OBSERVATION CHECKLIST:

COMPONENT SELF CHECK

TRAINER’S CHECK  COMPETENT NOT YET COMPETENT

Battery is charged using appropriate battery charger Electrolyte levels are checked and topped up as necessary Battery case, terminals, trays, posts, and cables are cleaned Battery is charged following the correct procedure Charging problems troubleshooted Personal safety servicing and charging batteries applied

 ______________________ Signature

Developed By: Edward P. Alip

_______________ Date

____________________ Instructor’s Signature  

Service Automotive Battery  TESDA-Maddela Institute of Technology Technology

Date Developed January 30, 2010

Trainee’ s

Page # 70

 

QUALIFICATION:  

COMMON COMPETENCY UNIT:

MODULE TITLE: 

AUTOMOTIVE SERVICING NC II

SERVICE AUTOMOTIVE BATTERY

SERVICING AUTOMOTIVE BATTERY

LEARNING OUTCOME NUMBER 5: JUMP-STARTING A BATTERY

ASSESSMENT CRITERIA:  1. Vehicle is jump started without causing damage to workplace, property or vehicle 2. Appropriate cables are used in jump starting 3. Cables are disconnected and connected in right sequence 4. Personal safety is observed observed

LEARNING CONTENTS: 1.Jump-starting procedure 2.Polarity connections 3.Safety precautions 

RESOURCES:

 



Automotive Technology; Tech Manual; 4th Edition; ERJAVEC

  Automotive Technology; 4 th  Edition; ERJAVEC   Computer Set   Communication Module    Tool/Equipment   Reference Books    Toyota Training Manual   Auto Mechanics, Theory and Service By: de Kryger, Kobacik.Bono

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

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Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

71

LEARNING EXPERIENCES/ACTIVITIES   LO 5:Jump-start Battery LEARNING ACTIVITIES Are you ready to perform the knowledge and skills activities?      

  

SPECIAL INSTRUCTIONS

Observe safety precautions Wear protective equipment Always perform 5’S  5’S   1.  In the contextual learning laboratory, with the help of your instructor, gather information/data on the following and then perform:  

 Jump-starting a battery

2.  Check your knowledge and skill in this learning outcome.

 

Follow operation sheet

 

Complete the assessment task





Ask your instructor for assessment. If you passed the assessment, your instructor will tell you to proceed to th the e next module.→→→  module.→→→ 

Developed By:

Service Automotive Battery

Date Developed

Page #

Edward P. Alip

 TESDA Maddela Institute of   Technology  Technology  

 January 30, 2010

72

 

OPERATION SHEET LO5 JUMP-STARTING A BATTERY NOTE: When it is necessary to jump-start a car with a discharged battery using a booster battery and  jumper cables, follow instructions carefully to avoid damaging the charging system or creating a hazardous situation! CAUTION: Always wear eyes protection when making or breaking jumper cable connection! WARNING! Consult the manufacturer’s service manual for procedures and precautions when jumpstarting late model vehicles with electronic control systems. systems . Excessive battery voltages can damage sensitive electronic components.

Procedure:

Step 1.Make sure the two vehicles are not touching each other. The excessive current flow through the vehicle’s bodies can can damage the small ground straps that attach the engine block to the frame. These small wires are designed to carry only 30 amperes. If the vehicles are touching, as much as 400 amperes maybe carried through them.

Step 2.For each vehicle, engage the parking brake and put the transmission in neutral or park.

Step 3. Turn  Turn OFF the ignition switch and all all accessories on BOTH vehicles.

Step 4.Attach one end of the positive jumper cable to the weak battery’s positive terminal.  

Step 5.Connect the other end of the positive jumper cable to the booster battery’s positive terminal. t erminal. Meaning ―positive to positive‖.  positive‖.  

Step 6.Attach one end of the negative jumper cable to the booster battery’s negative terminal.  

Step 7.Attach the other end of the negative jumper cable to an engine ground of the vehicle with weak battery.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

73

 

Step 8. Try  Try to start the vehicle with weak battery. If the the vehicle does not readily start, start the jumper vehicle and accelerate it at fast idle to prevent excessive current draw.

Step 9.Once the disabled vehicle (vehicle with weak battery) starts. Disconnect the ground connected negative  jumper cable from its engine block.

Step 10.Disconnect the negative jumper cable from the booster battery.

Step 11.Disconnect the positive jumper cable from the booster battery, then from the other battery.

Developed By: Edward P. Alip

Service Automotive Battery  TESDA-Maddela Institute of   Technology  Technology  

Date Developed  January 30, 2010

Page #

74

 

ASSESSMENT TASKS

 These assessment tasks should be completed when you are confident that you you can PERFORM JUMPSTARTING A BATTERY CORRECTLY. Assessment needs to conform to the rules of evidence. Therefore;

 

You will participate and complete the learning activities

   

You will demonstrate tasks to the required standards You will answer oral and written questions

 

You will complete the assessment tool

   

OBSERVATION CHECKLIST:

COMPONENT SELF CHECK

TRAINER’S CHECK  COMPETENT NOT YET COMPETENT

Vehicle is jump-started without causing damage Appropriate jumper cables or leads are selected Proper procedure in  jump-starting is performed Personal safety in  jump-starting a battery observed

 ______________________ Signature

Developed By:

_______________ Date

Service Automotive Battery

____________________ Instructor’s Signature  

Date Developed

Trainee’ s

Page #

Edward P. Alip

 TESDA Maddela Institute of Technology Technology

January 30, 2010

75

 

PERFORMANCE TEST

Student’s Name:  Name:  Unit of Competency: SERVICE AUTOMOTIVE BATTERY

Name: Test Attempt:

1st 

2nd 

3rd 

OVERALL EVALUATION

Directions Level

Call your instructor. Ask him/her to assess your performance in the

PERFORMANCE LEVELS

Achieved

4.Can

perform

this

skill

without

supervision and with initiative and adaptability to problem situation 3.Can perform this skill satisfactorily without assistance or supervision.  2.Can perform this skill but needs some assistance and/or supervision. 1.Can perform parts of this skill satisfactorily, but requires considerable assistance and/or supervision. Instructor will initial level achieved

following critical tasks and  performance criteria below. You will be rated based on the overall evaluation on the right side.

YES

PERFORMANCE STANDARDS

NO

N/A

For acceptable achievement, all items should should receive a “YES” or “N/A” respons response. e.   1.Safe handling of batteries are observed 2.Different methods of battery testing performed 3.Appropriate testing equipment identified and used properly 4.Battery is removed and replaced without causing damage to any 5.Proper procedure in removing and replacing batteries performed 6.Appropriate tools and equipment in removing and replacing batteries used 7.Battery is charged efficiently 8.Battery is serviced properly 9.Vehicle is jump-started without without any damage 12.Occupational health and safety observed

 _______________________ Trainee’ Signature

Developed By: Edward P. Alip

_______________

_____________________ Date

Service Automotive Battery

Instructor’s Signature  

Date Developed

Page #