OperationServiceDiagnosis

Battery

Battery Electro Chemical Device

• 4 Functions - Source, Reserve & Stabilizer• 1. Provides electrical energy to start car.• 2. Provides electrical energy to ignition system• 3. Provides electrical energy to accessories when

demands exceed alternators output• 4. Voltage stabilizer absorbs abnormal voltages created by

electrical components

Converts chemical energy into electrical energy

Top post Side post

side and top post

• A side and top post is becoming very common today because it will fit so many cars.

Batteries a little history

• Up to 1955 most batteries were 6 volt• General Motors started the move to 12 volts,

Volkswagen was the last in 1966 to switch over.• Some day cars may have a 42V/14V System.

Several problems lie in wait such as cost of the components. Life of batteries & arcing between components.

Battery Construction• Elements consist of two groups of plates• One more negative plate than positive with

insulated separators in between • Usually 9, 11, or 13 plates. 54, 66, or 78

total. • Case is made of hard rubber (rough service)

or plastic (light service)

Battery Construction

• One element in each cell, connected to the adjoining element, connected in series, each cell produces about 2.1 volts

• Case is divided into 6 cells (12.6 volts) • Case is divided into 4 cells (8.4 volts) Golf carts• Case is divided into 3 cells (6.3 volts)

Electrolyte64% water 36% Sulfuric acid

• H20-water 64% specific gravity 1.00

• H2S04-sulfuric acid 36% specific gravity 1.835 - caution

• Electrolyte 100% specific gravity 1.270

• Specific gravity is the ratio of the density of a substance to the density (mass of the same unit volume) of a reference substance. Water is the reference for specific gravity 1.00

Charged• positive plate negative plate

+ electrolyte - H2S04

Pb02 Pblead peroxide Sponge lead

Discharge• Oxygen and hydrogen form water, lead and sulfate form

lead sulfate. It is often seen in the plates/electrodes of car batteries, as it is formed when the battery is discharged.

• PbSO4 H20 PbSO4

• Charging sends electrons through in the opposite way reversing the cycle

• Sulfated plates refer to plates harden with lead sulfate

• Slow long charge to correct sulfated plates sometimes it cannot reverse the affects.

• 2 amps 24 hours

Things to remember

• Little brown particles floating around can short out battery (flakes off of the sulfated plates )

• Batteries can freeze if discharged H2O is water• Charging battery emits oxygen and hydrogen gas -

can explode • When you need to add fluid to a battery, use

distilled water (H2O it replaces the gas that is released H & O2 during gassing.)

Battery Gassing

During dischargeDuring charge

releases H & O2 during gassing

Batteries do blow up

Precautions

• When jumping a battery• When using a charger• When disconnecting a cable• When using any flame source

Precautions

• Always remove ground terminal first• Connect ground last– Jumper cable/battery charger on block of engine

• Corrosive (Sulfuric acid)

Battery types• WET CHARGE shipped with electrolyte must

charged during storage• DRY CHARGE shipped empty with no

electrolyte. Manufacture gives forming charge dries the cell elements and seals it. If you keep moisture out it will remain fully charged for long time. When needed just add electrolyte.

Group size• Batteries come in many different group sizes. A

battery's group size simply determines it's length, width, height, and terminal configuration

• Will have a number like group 75,78 or 24 or 24F, 26, 34

Battery capacity• 1) Plate size, the case is the same size, plates

are different size. Larger plates more amps• 2) Number of plates• 3) Amount of acid in electrolyte and battery

additives increase the sulfuric acid content of battery.

Battery capacity rating• Cold Cranking Amperes CCA most common

“Number of amperes load of battery will maintain at 0 degrees Fahrenheit for 30 seconds without battery voltage falling below 7.2 volts” (1.2 volts per cell)

• Size of engine should be smaller than cold cranking ampere rating.

• Do not be misled by CA that’s just Cranking Amps. It will give you a higher reading but it misleads you because it is tested at a higher temperature.

• Cranking amps are the numbers of amperes a lead-acid battery at 32 degrees F (0 degrees C) can deliver for 30 seconds and maintain at least 1.2 volts per cell (7.2 volts for a 12 volt battery).

Recommended Minimum battery size to buy when you replace it.

• 4-cylinder 400 CCA

• 6-cylinder 500 CCA

• 8-cylinder 575 CCA

Battery checking visual Inspection

Battery checking visual Inspection

• Cracked or leaking caseliquid level, add water use distilled water preferred (No minerals) or ice melted out of a freezer

• Voltage can discharge across top from post to post

• Clean battery top and post and cables, battery hold downs

Visual Inspection

• Mix baking soda and water to clean batteries• clean post and cable with a terminal brush or

post cutter• coat all connections with grease or use a spray

like NOCO NCP-2 Battery corrosion spray• Safety Glasses

Cleaning The Battery

Battery leakage test • Voltmeter (– negative) lead at negative post• Voltmeter (+ positive) lead drag across battery– No voltage should be present anywhere. If it is clean

the battery.

Battery Open Circuit Voltage Test• Measure what the voltage is with the key off Find

out it’s state of charge. It is a good starting point, should be at least 12.66 volts

• 12.66 = fully charged• 12.4 = 3/4 charged• 12.2 = 1/2 charged• 12.0 = 1/4 charged

Battery Terminals & Bolts• Post or top terminal• Side terminal• L terminal used on import• Marine• Stud

Terminal Test• This is the first step.• Take a voltmeter• DVOM (Digital volt ohm

meter)• Turn to DC Volts• Hook up like picture on

next page.

Terminal Test

• This is just a voltage drop test done on the battery terminals. You must disable the ignition and crank over the engine.

• Should be under .2 volts. Make sure you do both terminals Positive & Negative

Battery Drain test

or System drain testThis is done When a battery goes

dead for no apparent reason. Charging system seems to work OK Yet after charging the battery it is dead after several nights.

Battery Drain test

or System drain test• Ammeter is hooked in series at the

battery post with everything off Make sure you close the door or the courtesy lights will be on

Battery Drain test

Make sure you change the leads

Battery Drain test

• Battery Drain Key off• Hook up a ammeter in series reading should

not exceed the following• 77 older cars .01 amps, 10 ma (milliamps)• 78-85 .02 amps-.025 amps, 20-25 ma• 1986 & newer .05 amps, 50 ma

Open Circuit Voltage Test

• Sealed batteries• Remove surface charge• 12.66 = fully charged• 12.4 = 3/4 charged

Battery Voltage with the car off.

A battery Must be 3/4 charged before doing a battery capacity test

Before load testing - Check the temp.

Before load testing you must know what the battery is, or

should be rated at

The right battery for the vehicle

Ratings

• Cold cranking Amperes rating CCA• Cranking Amperes rating CA• Ampere-hour rating • Reserve capacity rating• Watt hour rating

P - L130 Capacity Test

Three times theampere-hour rating

Formula for load testing

Cold cranking amps

divided by 2

Formula for load testing

Three minute charge test

Tests for a sulfated battery• 40 amps for three minutes• Should be below 15.5 volts

Testing specific gravity

• Hydrometer check before adding water fully charged battery should read 1.270 should not vary more than 50 points between cells if it does recharge and check again

• Maintenance free batteries are sealed, cannot get into some. No way to add water or check specific gravity.

State of charge testing

Hydrometer• Ball Style

Hydrometer• float Style

Battery Refractometer

Charging batteries• Clean up Battery first• Unhook cables - check liquid level• Don't charge over 16 volts. If plates are sulfated

or if battery has been discharged for some time• Slow charge for a long period 24 hours

don't allow temperature to exceed 100 • Never fast charge batteries• Make sure that the battery charger is shut off or

unplugged when hooking up and removing the charger.

•Temperature• 0’ = 40%

•Charge•Plate area•Impurities•Gassing

Factors Affecting Charging

Causes of battery failure

Causes of failure

• Electrolyte level• Overcharging• Undercharging• Corrosion

• Cycling• Temperature• Vibration

• Most batteries in cars are 12 volt with negative ground.

• 6 volt older cars and 18 wheelers may have positive ground

SAFETY: do not allow battery acid to contact eyes skin or

fabrics if you do flush with lots of water, and get teacher or medical

help flush eyes for 15 minutes

Jump starting cars• positive to positive • negative to negative• Hook up negative cable last on car with dead

battery on a good ground. Not on the battery. If sparks occur no Hydrogen to blow up

battery date tags

Did You Know Batteries Lose Power While Sitting on the Shelf?

A battery can permanently lose some of its capacity when it's stored in a partly or fully discharged state. Periodic charging during storage can minimize the deterioration, but not all battery distributors and dealers do the necessary charging. That's why you may want to know how to read the date codes, which show when the product was manufactured, on a new product, to help you make sure you're really buying a fresh battery.

So, how do you read a date code?

Most Brands of BatteriesJOHNSON CONTROLS, INC. - INTERSTATE BATTERIES, Motorcraft, East penn - Deka, GNB -Champion, Stowaway:

The letters and numbers are on a sticker affixed to the battery or hot-stamped into the case cover along the top edges of the battery. The ship date codes begin with a letter: A stands for January, B for February and so on (some shipping codes skip the letter I, so it cannot be confused with the number 1. In those cases, J would represent September, K - October, L - November and M - December). The next digit is a number which represents the year the battery was shipped. Therefore, an A6 would mean the battery was shipped in January of 1996.

Exceptions DELCO - Freedom, Voyager, and some Sears brands:The code dates are stamped on the cover, usually near the posts. The first character represents the year (0-9) and the second shows the month (A-M, skipping I). For example, 4CN1 would stand for 1994, March.

EXIDE - Napa Legend, Edge, Power-Tron and Titan:

The fourth or fifth character may be a letter code for the month and the following character a number code for the year (i.e. RO8F3B stands for June 1993)

Last 3 pages © 2000 Interstate Battery System of America, Inc.

• Always Disconnect the ground cable first. (Negative Cable on cars)

• Always hook up the ground cable last

• If you disconnect the positive first and touch ground you will have sparks.

Removing Batteries

• Always make sure you have a way to keep the memory alive (Computer, radio, etc) when you replace the battery.

Removing Batteries

Hooking batteries in series Voltage goes up

Hooking batteries in parallel Voltage stays the same

Amperage goes up

The EndThat's all for this battery