Service Batteries

COMPETENCY-BASED
CURRICULUM

Sector:
AUTOMOTIVE

Automotive Servicing NC II
Unit of Competency:
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

Developed By:
Edward P. Alip
Service Automotive Battery Date Developed Page #
TESDA-Maddela Institute of Technology January 30, 2010 2

CODE NO.
BASIC COMPETENCIES
500311105 Participate in Workplace Communication
500311106 Work in Team Environment
500311107 Practice Career Professionalism
500311108 Practice Occupational Health and Safety Procedures
`CODE NO. CORE COMPETENCIES
ALT723301 Perform Diesel Engine Tune Up
ALT723302 Perform Gas Engine Tune Up
ALT723303 Service Automotive Battery
ALT723304 Service Ignition System
ALT723305 Test and Repair Wiring/Lighting System
ALT723306 Perform Underchassis Preventive Maintenance
ALT723307 Service Starting System
ALT723308 Service Charging System
ALT723309 Service Engine Mechanical System
ALT723310 Service Clutch System
ALT723311 Service Differential and Front Axle
ALT723312 Service Steering System
CODE NO. COMMON COMPETENCIES
ALT723201 Apply Appropriate Sealant/Adhesive
ALT723202 Move and Position Vehicle
ALT311202 Perform Mensuration and Calculation
ALT723203 Read, Interpret and Apply Specifications and Manuals
ALT723204 Use and Apply Lubricant/Coolant
ALT723205 Perform Shop Maintenance
ALT723313 Overhaul Manual Transmission
ALT723314 Service Brake System
ALT723315 Service Suspension System
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 " 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 and check your work honestly. If you have
questions, please dont hesitate to ask your facilitator for assistance.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills covered in this module because
you have:
been working for someone
already completed training in this area

If you can demonstrate to your trainer that you are competent in a particular skill or skills, talk
to him/her about having them formally recognized so you wont 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 Learners Diary, use this diary to record important dates,
jobs undertaken and other workplace events that will assist you in providing further details to your
trainer or assessors. A Record of Achievement is also provided for your trainer to complete once
you completed the module.
This learning material was prepared to help you achieve the required competency, 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.
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 and
knowledge you need to successfully complete

Developed By:
Edward P. Alip
Work through all information and complete the activities in each section. Read the information
sheets and complete the self-check provided in this module.

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

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

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 experienced work mates and ask for their guidance.

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

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

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 Date Developed Page #

TABLE OF CONTENTS
QUALIFICATION : Automotive Servicing NC II
UNIT OF COMPETENCY : SERVICE AUTOMOTIVE BATTERY
MODULE TITLE : SERVICING AUTOMOTIVE BATTERY
CORE COMPRETENCY

ELEMENTS

PERFORMANCE CRITERIA

PAGE
1. Explain the purpose, types,
operation, and safe handling
of batteries
1.1 Main components of batteries are identified
1.2 Differentiate batteries according to designs and
usage
1.3 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. Test automotive 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
2.5Tests are performed and results are analyzed
2.6 Personal safety is observed

3. Remove and replace 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 vehicles
electronic memory as per manufacturers 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 charge 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

5. Jump-start 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

Developed By:
Edward P. Alip
Date Developed Page #
TESDA-Maddela Institute of Technology January 30, 2010
5
QUALIFICATION: AUTOMOTIVE SERVICING NC II
COMMON COMPETENCY UNIT: SERVICE AUTOMOTIVE BATTERY
MODULE TITLE: SERVICING AUTOMOTIVE BATTERY

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 manufacturers specification manuals using specified tools and
equipment.
LO 1: Explain the purpose, types, 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 carried out according to vehicle classification are explained

1.9 Safe handling of batteries observed

1.10 Hazards associated with batteries are identified

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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


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 vehicles electronic memory as per
manufacturers standard (if 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
PREREQUISITE: Must have finished basic competencies

Developed By:
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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. Purpose of battery
2. Battery types and designs
3. Battery ratings and sizes
4. Hazards associated with use of batteries
5. Safe handling of batteries
6. Factors affecting battery life

RESOURCES:

Automotive Technology; Tech Manual; 4
th
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
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LEARNING EXPERIENCES/ACTIVITIES
LO 1: Explain the purpose, types, operation, and safe handling
of batteries

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS
Are you ready to perform the knowledge and skills activities?

Observe safety precautions
Wear protective equipment
Always perform 5S

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

Check your knowledge

Battery ratings and size selection


Safety precautions in handling batteries
Battery routine inspection


Factors affecting battery life


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

Read Information Sheet LO1-
1Purpose, construction, and
types of batteries.

Answer self-check

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

Answer self-check

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

Answer Self-check

Read information sheet LO1-4
Factors affecting battery life.

Answer Self-check

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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.

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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 batterys most
important function.

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

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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. As the chemicals in the battery are depleted, the battery runs down and is
discharged. It can be recharged by supplying it with electric current from the vehicles alternator or from a
battery charger. The depleted chemicals are restored to their original condition as the battery becomes
recharged.

COMPONENTS OF THE BATTERY

Grids
Positive plates
Negative plates
Electrolyte
A container
Cell covers
Vent covers
Cell containers
Separators
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 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.

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Battery Terminals
The battery has two external terminals: a positive (+) and a 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 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 batterys 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
polarity.
Side terminals are positioned near the top of the battery case. These terminals are threaded and
require a special bolt to connect the cables. Some batteries are fitted with both top and side terminals to allow
them to be used in many different vehicles.

Battery terminals

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

Battery Hold Downs-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 and help increase the life of the battery.
Battery hold-downs are made of metal or plastic.

Battery Hold-downs

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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 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 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

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2. Hybrid Batteries-A hybrid battery can withstand six deep cycles and still retain 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, 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. 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 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 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 batterys
lead plates, where it also serves as a vibration dampener.

Rolls of high-purity lead plates are tightly compressed into six spiral wound-cells. The plates are
separated by acid-permeated vitreous separators. Vitreous separators 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.

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Each of the six spiral cells is enclosed in its own cylinder within the battery case, forming a 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
short recharging times and low internal resistance, which provides increased output. AGM batteries
also have exceptional durability in both high heat and subzero climates.

Developed By:
Edward P. Alip
15
Chemical Reaction in the Battery
The battery is a lead-acid storage battery. The chemicals in it are 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 vehicles 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 (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

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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.

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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 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.

A. alternator
B. battery
C. dry cell battery
D. wet cell battery

_____3. The battery uses _______ to 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

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_____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 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 the polarity

_____9. Color of cables for battery positive terminal are usually

A. black
B. blue
C. green
D. red

_____10. Maintenance-free battery has about _____ higher cold cranking power rating than a comparably
sized conventional battery.

A. 15 %
B. 20 %
C. 25 %
D. 30 %

SCORE:

Trainees Signature:

Date:

Assessors Signature:

Date:

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BATTERY RATING METHODS and SIZE SELECTION
Rating Methods
The BCI (Battery Council International) rates batteries according to reserve capacity and cold-
cranking 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 vehicles other electrical needs, 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 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 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.

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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 the terminals to short across the vehicles hood when it is
closed. BCI group numbers are normally given on the battery and are used to indicate the physical size and
other features of the battery. The size of the battery does not always indicate the current capacity of a
battery.
The label may also include the date the battery was 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

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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.
__________________________2. This battery 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.
__________________________3. 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.
__________________________4. Battery rating which is the common standard for low-maintenance batteries.
__________________________5. It pertains to the length, width, and height of the battery.

SCORE:

Trainees signature:

Date:


Date:

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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 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 batterys ground cable when working on the electrical system or 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 when the charger is turned ON. Doing so generates a
dangerous spark

Developed By:
Edward P. Alip
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. Reversing the
polarity will adversely damage the alternator and circuit wirings

Never attempt to use a fast charger as a boost to start the engine

Never try to charge a battery that has ice in 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 vehicles 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 wires, frayed insulation, or loose or damaged connectors

Visually check battery terminals, cable connectors, metal parts, hold-downs, and trays for corrosion
damage or build up

Check the heat shield for proper installation on vehicles equipped with

Developed By:
Edward P. Alip
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 can still be used by charging it for many hours.
________8. Each cell of the battery must be filled below the plates.
________9. All clear water can be used on batteries.
_________10. Sulfuric acid in the battery is not potentially dangerous since it is only a liquid.

SCORE:

Trainees signature:

Date:


Date:

Developed By:
Edward P. Alip
20

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.

TemperatureBatteries 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 engines 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 vehicles electrical system. Corrosion on the 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 vehicles 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.

Undercharge/Sulfation The vehicles charging system might not fully recharge the battery due to a
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.

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
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:

Trainees signature:

Date:


Date:

Developed By:
Edward P. Alip
21



LEARNING OUTCOME NUMBER 2: TESTING AUTOMOTIVE BATTERY

1. Different methods of battery testing are 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:

th
Edition; ERJAVEC
th
Edition; ERJAVEC
Computer Set
Tool/Equipment/Testing instruments
Reference Books

Developed By:
Edward P. Alip
23
LO 2: Testing automotive battery

Always perform 5S

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

Safety in Testing Batteries


Conducting visual inspection

Methods of battery testing

Specific gravity Test


Conduct specific gravity
test

Open circuit voltage Test


Conduct open circuit
voltage test

Battery leakage Test


Conduct battery leakage
test

Capacity Test


Conduct capacity test

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

Follow Operation Sheet LO2-1
Conducting visual inspection.

Read Information Sheet LO2-2A
Specific gravity test.

Answer self-check

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

Read Information Sheet LO2-2B
Open circuit voltage test.

Answer Self-check

Follow procedure in Operation Sheet
LO2-2B Conducting open circuit
voltage test.

Read Information Sheet LO2-2C
Battery leakage test.

Answer questions

Follow procedure in Conducting
Battery Leakage Test.

Read Information Sheet LO2-2D
Capacity Test.

Answer Self-check

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

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


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:
Work clothing such as coveralls and steel-capped footwear
Eye protection such as safety glasses and face masks
Ear protection such as earmuffs and earplugs
Hand protection - such as rubber gloves and barrier cream
Respiratory equipment - such as face masks and valved 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.
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 electrolyte must be handled
carefully and safely.
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.
Developed By:
Edward P. Alip
27
SELF-CHECK
TRUE OR FALSE

Directions

________1. Safety is everybodys concern.
________2.Working with batteries dont need much attention.
________3. Manufacturers 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 can always be done in any workplace situation.

SCORE:

Trainees signature:

Date:


Date:

Developed By:
Edward P. Alip
27

OPERATION SHEET LO2-1
CONDUCTING A VISUAL INSPECTION

Developed By:
Edward P. Alip
25

Developed By:
Edward P. Alip
26

Developed By:
Edward P. Alip
26

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
Q1. When servicing batteries, what must you do first to be able to easily trace
the problem?

Q2. Why do you need to charge the battery after adding water?
Q3. What is meant by parasitic loads and battery drain?
Q4. How to check battery discharge across the top of the battery?
Q5. How does an alternator belt affect battery charging?

The Candidates underpinning knowledge was:

Satisfactory Not satisfactory

Feedback to Candidate:

Trainees Signature:

Date:


Date:

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 batterys 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.

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 of 1.000 while battery
electrolyte should have a specific gravity of 1.260 to 1.280 at 80F (26.7C). In other words, the electrolyte
should be 1.260 to 1.280 times heavier than water.

Developed By:
Edward P. Alip
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 readings in various stages of charge with respect to a batterys 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 hydrometer is built into
the battery cover.

A quick visual check indicates the batterys 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

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 A

1. Used to read specific gravity of a battery

2. The scale sinks in the electrolyte

3. The scale floats high

4. Electrolyte composition of a fully-charged
battery

5. Specific gravity of a fully-charged battery

6. Specific gravity of pure water

7. Specific gravity of a half-charged battery

8. low level electrolyte

9. 65% to 100% state of charge

Column B

SCORE: __________
Trainees Signature:_________ Date:________
Assessors Signature:________ Date:_____

Developed By:
Edward P. Alip

A. 64% sulfuric acid and 36% water

B. high specific gravity

C. hydrometer

D. 1.265

E. specific gravity tester

F. 1.290

G. Low specific gravity

H. 64% water and 36% sulfuric acid

I. 1.500

J. 1.000

K. 1.190

L. 1.019

M. green

N. clear

O. dark
OPERATION SHEET LO2-2A

CONDUCTING A SPECIFIC GRAVITY TEST USING A HYDROMETER

Things you will need:
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
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 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
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
CHECKING SPECIFIC GRAVITY FOR BATTERY WITH BUILT-IN HYDROMETER

Developed By:
Edward P. Alip

ANALYZING SPECIFIC GRAVITY TEST RESULT

Developed By:
Edward P. Alip

Developed By:
Edward P. Alip

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
Q1. Why negative lead or cable is always disconnected first and connected last?
Q2. In a maintenance-free battery, how can you remove the cell covers 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?




Trainees Signature:

Date:


Date:

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
batterys voltage. So battery voltage with no load applied can give some indication of the state of
charge.

The batterys temperature should be between 60 and 100F (15.5 and 37.7C. The voltage must be
allowed to stabilize for at least ten minutes with no load applied. On vehicles with high drains (vehicles
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

OPERATION SHEET LO2-2B

CONDUCTING OPEN CIRCUIT VOLTAGE TEST

Developed By:
Edward P. Alip

Developed By:
Edward P. Alip

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
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?




Trainees Signature:

Date:


Date:

INFORMATION SHEET LO2-2C

Battery Leakage Test 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

Developed By:
Edward P. Alip

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
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?




Trainees Signature:

Date:


Date:

INFORMATION SHEET LO2-2D

Capacity Test 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 batterys 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 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
batterys ampere-hour rating or (one half) of its CCA rating.

4. Maintain the load for 15 seconds. Observe the testers 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 reading for a particular temperature.

Developed By:
Edward P. Alip

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. 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
38

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)


40 (4.4C)


30 (-1C)


26 (-6.6C)


10 (-12.2C)


0 (-17.7C)

SELF-CHECK
TRUE OR FALSE

Directions

________1. It determines the batterys ability to furnish starting current and still maintain sufficient voltage to
operate the ignition system.
________2. The load or capacity test can be performed with the battery either in or out of the vehicle.
________3. Never load test a sealed battery if its temperature is below 80 F.
________4. Do not disconnect the ignition system when conducting 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:

Trainees signature:

Date:


Date:

Developed By:
Edward P. Alip
38

Developed By:
Edward P. Alip
38

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
Q1. If the voltage tests below the minimum and the voltmeter does not rise 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 instruments?




Trainees Signature:

Date:


Date:




LEARNING OUTCOME NUMBER 3: REMOVE AND REPLACE BATTERIES


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

LEARNING CONTENTS:
1. Safety procedure in removing and replacing battery
2. Correct tools and equipment in removing and replacing battery
3. Hazards in removing and replacing battery
4. Procedure in removing and replacing battery
Conventional
Electronic control

RESOURCES:

th
Edition; ERJAVEC
th
Edition; ERJAVEC
Computer Set
Tool/Equipment
Reference Books

Developed By:
Edward P. Alip
41
LO 3: Removing and replacing battery

Always perform 5S

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

safety in working with batteries
inspecting batteries

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

Read Information Sheet LO3

Follow operation sheet LO3

Complete the assessment task

Developed By:
Edward P. Alip
42
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 manufacturers recommendations when 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

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

Developed By:
Edward P. Alip
42

CHECKING BATTERY

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

The parts of the battery to check

Its easy to check your battery. Just locate it and follow these steps:
1. Clean off powdery deposits on the positive and negative terminals.
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 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 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
42

You can use a battery terminal brush (inside the cap) and clamp cleaner.
If your cables and clamps wont clean up completely with baking soda and water, rotate an
inexpensive battery terminal brush on each terminal to shine it and ensure a good, solid electrical
connection. You can also shine the insides of the cable clamps with the clamp cleaner thats 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. Examine the battery cables and clamps to see whether theyre 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 youve been having trouble 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 its weak, the battery may need
to be recharged or replaced before it dies and leaves you stranded.

Developed By:
Edward P. Alip
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
42

Developed By:
Edward P. Alip
42

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
Q1.
Q2.
Q3.
Q4.
Q5.




Trainees Signature:

Date:


Date:

REMOVING AND INSTALLING A CAR BATTERY
No matter how well your vehicle is working, if your battery dies and cant be recharged, youre
stranded in a vehicle that you cant drive 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 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 owners manual to see whether your 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. (Thats the post with the little or NEG on it.) If your vehicle has positive 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 dont 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 youre removing a bolt or screw, after youve 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 doesnt 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!

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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 its completely 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 are filled with a toxic, corrosive liquid and must be disposed of properly. Whats 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.

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Developed By:
Edward P. Alip
42

ORAL INTERVIEW

QUESTIONS

SATISFACTORY
RESPONSE
YES NO
Q1.
Q2.
Q3.
Q4.
Q5.




Trainees Signature:

Date:


Date:




LEARNING OUTCOME NUMBER 4: SERVICE AND CHARGE BATTERIES

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. Battery charger parts and their function
2. Repair/clean/replace connectors
3. Procedure in cleaning battery case, tray, and cables
4. Topping, filling electrolyte/distilled water
5. Procedure in battery charging
Fast charging
Slow charging
6. Proper connection of battery terminals
7. Safety in servicing and charging batteries

RESOURCES:

th
Edition; ERJAVEC
th
Edition; ERJAVEC
Computer Set
Tool/Equipment
Reference Books

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

Always perform 5S

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

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

assessment, your instructor will tell you to proceed to
the next module.




Read Information Sheet LO4-1



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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

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

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

6. Remove the battery from the tray

CAUTION: When lifting a battery, excessive pressure on 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.

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7. Mix a solution of baking soda and water

8. Brush the baking soda solution over the battery case, but dont allow the solution to enter the
cells of the battery

9. Flush the baking soda off with water

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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

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

15. Install the battery back into the tray. Dont forget to install the battery hold-down hardware

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

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CLEANING BATTERY TERMINALS
The problem arises more often if you dont drive your car regularly. When the 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. Corrosion appears as a white, ashy deposit around one or both battery
posts. Sometimes there is also a bit of color mixed in. These deposits are the result of one of several possible
chemical exchanges involving vapors and the battery post.

Corroded battery terminal and connector

Supplies:
A combination tool 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 the negative terminal first. Its 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, especially if there is a lot of corrosion,
you may need the assistance of pair of locking pliers. Be careful not to short any tools you use against
the car when theyre 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.

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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 dont 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 isnt 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 on the posts to slow down the formation of corrosive 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 dont have one, go
and buy some from your local auto parts store.

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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 electrolyte level. Do not allow the level to fall below the LOWER LEVEL line or below any of the
tops of plates in cells. Refill with distilled water to the UPPER LEVEL 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
- Batterys electrical capacity
- Temperature of electrolyte
- Batterys state of charge at start of charging
- Batterys 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 drops in this time,
refill to the UPPER LEVEL before charging

The battery is now filled and ready to charge

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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
o ALWAYS wear complete eye protection (THAT PROTECTS EYES FROM ALL ANGLES).
2. Avoid Flames and Sparks Near Battery and Fuel
o ALWAYS keep flames, matches, lighters, cigarettes or other ignition sources away from battery.
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.
o Some sealed maintenance free batteries have a battery condition indicator. A light or bright
colored dot indicates low water. Such a battery needs to be replaced, 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.

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o 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
o NEVER put face near battery.
o ALWAYS locate charger as far from battery as DC cables permit.
o ALWAYS keep other people away from the battery. They are not wearing safety glasses like you
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 ALWAYS use a battery carrier. Carrying a battery by hand may put pressure on its ends,
causing acid to be forced out vent caps.
o ALWAYS have plenty of fresh water and soap nearby in case battery acid contacts 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.
o In very cold weather a discharged battery may freeze. NEVER charge a frozen battery. Gases
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.

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.
o DANGER - NEVER alter AC power cord or plug provided - if it will not fit outlet, have proper
outlet installed by a qualified electrician or proceed as shown in the 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), 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.

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o 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
o ALWAYS remove personal metal items (such as rings, bracelets, necklaces and watches) when
working with a battery. A short circuit through one of these items can melt it causing a severe
burn.
3. Avoid Charger Abuse
o To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance
or cleaning. Turning off controls will not reduce this risk.
o DO NOT disassemble charger. Take it to a qualified service person when service or repair is
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.
o DO NOT operate charger if it has received 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.
o DO NOT operate charger with clips shorted together.
o The polarity of the charger and the battery MUST ALWAYS match to avoid damage to battery
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. Use of improper extension
cord could result in a risk of fire and electric shock. If extension cord must be used, use ONLY
a grounded, 3-wire type cord. NEVER use a 2-wire cord and an adaptor! The cord MUST be
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 Length of Cord (feet)
equal to or
greater than
but less
than
25 ft 50 ft 100 ft 150 ft
AMPERES 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.

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o 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.
o This charger is not intended to supply low-voltage power for applications other than battery
charging.
o Charging a battery on board a boat floating in water requires a battery charger specially
designed to marine charging standards. Move the battery to dry land for charging with this
charger.

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

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BATTERY CHARGING
Operating 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 a spark should occur then, it will be far away from the battery.
This type of connection works because every car battery has one 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 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 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. DO NOT face battery when making 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.
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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 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
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 for 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. The
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.
ENGINE STARTING
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.
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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 Time to charge your battery (hours)
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 Time to charger your battery (hours)
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

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. It may have to be replaced.

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Fast and Slow Charging

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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 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 condition still exists, the cycle will repeat.
Listed below are the conditions that can cause the circuit breaker to trip:
o 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.
o A battery with a shorted cell. A battery in this condition may cause the breaker to trip
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 Touching the charger leads together with the charger turned on. This causes a spark which is
dangerous if near a battery and could severely damage the charger.
o If proper hookup is observed and sparking does occur between charger clips and frame
connection, DO NOT use the charger. Have it checked by a qualified service person.
o CAUTION: Regardless of what is causing the overload, unattended or routine operation in this
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.
o Battery is cold.
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.
o Worn out battery with sulfated plates, replace battery.

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.

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ASSESSMENT TASKS

These assessment tasks should be completed when you are confident that 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:

SELF CHECK

COMPONENT TRAINERS 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

______________________ _______________ ____________________ Trainees
Signature Date Instructors Signature

Developed By:
Edward P. Alip




LEARNING OUTCOME NUMBER 5: JUMP-STARTING A BATTERY

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

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

RESOURCES:

th
Edition; ERJAVEC
th
Edition; ERJAVEC
Computer Set
Tool/Equipment
Reference Books

Developed By:
Edward P. Alip
71
LO 5:Jump-start Battery
Are you ready to perform the knowledge and skills
activities?

Always perform 5S

information/data on the following and
then perform:

Jump-starting a battery

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

assessment, your instructor will tell you to proceed to
the next module.

Follow operation sheet


Developed By:
Edward P. Alip
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 manufacturers service manual for procedures and precautions when jump-
starting late model vehicles with electronic control 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
vehicles bodies 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 OFF the ignition switch and all accessories on BOTH vehicles.

Step 4.Attach one end of the positive jumper cable to the weak batterys positive terminal.

Step 5.Connect the other end of the positive jumper cable to the booster batterys positive terminal. Meaning
positive to positive.

Step 6.Attach one end of the negative jumper cable to the booster batterys 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
73
Step 8.Try to start the vehicle with weak battery. If 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
74
ASSESSMENT TASKS

These assessment tasks should be completed when you are confident that you can PERFORM JUMP-
STARTING 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:

SELF CHECK

COMPONENT TRAINERS 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

______________________ _______________ ____________________ Trainees
Signature Date Instructors Signature

Developed By:
Edward P. Alip

PERFORMANCE TEST

Students Name: Name:
Unit of Competency: SERVICE AUTOMOTIVE BATTERY Test Attempt: 1
st
2
nd
3
rd

Directions

Call your instructor. Ask him/her to
assess your performance in the
following critical tasks and
performance criteria below.

You will be rated based on the overall
evaluation on the right side.
OVERALL EVALUATION
Level
Achieved
PERFORMANCE LEVELS
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

PERFORMANCE STANDARDS

For acceptable achievement, all items should receive a YES or N/A response.
YES NO N/A
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 any damage
12.Occupational health and safety observed

_______________________ _______________ _____________________
Trainee Signature Date Instructors Signature

Developed By:
Edward P. Alip

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