Program / Course: Automotive Servicing NC 1

Unit of Competency Service Automotive Battery

Module Title Servicing Automotive Battery

This module contains information and suggested learning activities on Servicing Automotive
Batteries. It includes instructions and procedure on how to test automotive battery, remove and
replace batteries, service and charge batteries and jump start vehicle.

Completion of this module will help you understand the succeeding module on Test and Repair
Wiring and Lighting System.

This module consists of four learning outcomes. Each learning outcome contains learning
activities with instruction sheets. Before you follow the instruction, read the information sheets
and answer the self-check and activities provided to assess your competence by your teacher.
He/she will check if you have acquired the knowledge necessary to perform the skill portion of the
particular learning outcome.

SUMMARY OF LEARNING OUTCOMES

Upon completion of the module, you should be able to:

LO1. Test Automotive Battery;

LO2. Remove and Replace Batteries;
LO3. Service and Charge Batteries; and
LO4. Jump Start Vehicle
 Pre-Test

Select the correct answer to each question and write the letter on the blank provided.
1. The battery in an electro chemical device, means the battery----
a. makes chemicals by electronic means
b. uses chemicals to provide electricity
c. has non-chemical plates
d. does not use an electrolyte
2. The battery performs the following EXCEPT
a. supplies current to crank the engine
b. supplies current when the charging system cannot handle the lead
c. supplies current to the ignition system when the engine is off.
d. supplies current to the ECM while the engine is off
3. When working around the battery be sure to----
a. Disconnect the negative first
b. Disconnect the positive first
c. Never disconnect the terminals
d. a and b
4. A type of battery with no removable caps.
a. maintenance free battery
b. battery with caps
c. 3A battery
d. b and c
5. This type of hydrometer which is similar to ball type coolant
hydrometer.
a. ball hydrometer
b. flat hydrometer
c. barometer
d. a and b
6. A type of hydrometer which the state of charge marks on the float stem to
show electrolyte specific gravity.
a. ball type hydrometer
b. float hydrometer
c. a and b
d. none of the above
7. The indication if the battery is in full charge in using ball hydrometer.
a. all balls float
b. no balls float
c. a and b
d. none of the above
8. The more fully charge the battery is, the higher the float is indicating the
state of charge.
a. float hydrometer
b. ball hydrometer
c. a and b
d. all of the above
 Learning Outcome No 1. Test Automotive Battery

An automotive battery is a type of rechargeable battery that supplies electric energy to an

automobile. Usually this refers to an SLI battery (starting, lighting, ignition) to power the starter
motor, the lights, and the ignition system of a vehicle’s engine. An automotive battery may also be a
traction battery used as the main power source of an electric vehicle so preventive maintenance
procedures must be performed frequently to avoid automobile malfunctions.

Assessment Criteria
1. Battery is tested to avoid damage to the vehicle or to any property within the work area.
2. Battery is tested to avoid damage to any workplace property or vehicle.
3. Appropriate test equipment and instrument are selected.
4. Test results are analyzed and interpreted.
5. Findings are reported to immediate supervisor or automotive instructor.

Definition of Terms

BATTERY CELL - the active unit of the battery

BATTERY HOLD DOWNS - brackets that secure the battery to the chassis of
the vehicle.

BATTERY LEAKAGE TEST – test used to determine if current is discharging

across the top of the battery fuse.

BATTERY TERMINAL TEST - test that checks for poor electrical

connections between the battery cables and
terminals.

BATTERY TERMINALS - terminals of the battery where the positive and the
negative battery cables are connected. The
terminals may be posts or threaded insert.

BATTERY CHARGER - an equipment that is use to charge battery capacity

given in ampere hours.

ELECTROLYTE - Any solution that conducts electric current.

 INFORMATION SHEET No.1
Battery Construction and Operation

An automotive battery is a type of rechargeable battery that supplies electric energy to an

automobile. Usually this refers to an SLI battery (starting, lighting, ignition) to power the starter
motor, the lights, and the ignition system of a vehicle’s engine. An automotive battery may also be
atraction battery used as the main power source of an electric vehicle.

Automotive SLI batteries are usually lead-acid type, and are made of six galvanic cells in
series to provide a 12 volt system. Each cell provides 2.1 volts for a total of 12.6 volt at full charge.
Heavy vehicles, like highway trucks or tractors, often equipped with diesel engines, may have two
batteries in series for a 24-volt system, or may have parallel strings of batteries.

Lead-acid batteries are made of plates of lead and separate plates of lead dioxide, which are
submerged in electrolyte solution of 35% sulfuric acid and 65% water. This composition causes a
chemical reaction that releases electrons which flow through conductors to produce electricity.
When the battery discharges, the acid of the electrolyte reacts with the materials of the plates,
changing their surface to lead sulfate. When the battery is recharged, the chemical reaction is
reversed: the lead sulfate converted into lead oxide and lead.

Recycling automotive batteries reduce resources required to manufacture new batteries. It

also prevent improper disposal of toxic waste.

TYPES OF BATTERY - The following are two types of automotive batteries. The battery on left has
removable caps so the battery state of charge can be checked; adding water if needed. The battery
is a "Maintenance Free" battery (lead acid or alkaline) which is sealed and does not require adding
with distilled water because the electrolyte level does not change because they do not produce much
gas. The charge indicator in the top shows the state of change.

Fig. 1 Two types of Automotive Battery (left) ordinary wet

battery (right) maintenance free battery.

(www. goggle. com.ph.)

BATTERY CONSTRUCTION

The battery case is molded plastic. The plates are molded 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 make-up prevents positive and negative plates from touching one another, 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 are attached to the cell
terminals that connect the cells in series. A plastic cover forms the top of the battery.

Some batteries have openings in their cover with filler plugs or vent caps that are removable
for adding water. Maintenance-free batteries do not have removable caps.

Fig. 2. Parts of
Automotive Battery.
(Toyota Motor Sales,
U.S.A. ,Inc.)

WORKING SAFELY ON BATTERIES

Observe the following safety measures when working with batteries, testing or charging.

1. The sulfuric acid in the electrolyte is very corrosive. It can make holes in cloth. It can
cause serious burns on human skin. It can cause blindness if it gets into the eyes. Wear
eye protector when testing or charging a battery. If you get battery acid on your skin,
flush it off at once with water. If you get battery acid (electrolyte) into your eyes, flush
them with water at once then go to the school nurse, doctor or hospital emergency room.

2. When disconnecting a battery, always disconnect the negative or ground cable first.

3. If the battery has vent caps, make sure the vent holes are open before charging. Cover
the caps with a damp cloth. Discard the cloth after the battery is charged.

4. Never lean over a charging battery.

5. Do not charge a frozen maintenance-free battery because when the charge indicator dot
shows light, yellow or clear, the battery could explode.
 SELF – CHECK No.1

Select the correct answer to each question and write the letter on the blank provided for.
________1. The battery in an electro chemical device means the battery
a. makes chemicals by electronic means
b. uses chemicals to provide electricity
c. has non-chemical plates
d. does not use an electrolyte
________2. The battery performs the following EXCEPT
a. supplies current to crank the engine
b. supplies current when the charging system cannot handle the lead
c. supplies current to the ignition system when the engine is off.
d. supplies current to the ECM while the engine is off
________3. When working around the battery, be sure to;
a. disconnect the negative first
b. disconnect the positive first
c. never disconnect the terminals
d. a and b
________4. A type of battery with no removable caps.
a. maintenance-free battery
b. battery with caps
c. 3A battery
d. b and c
 INFORMATION SHEET No. 2
Testing the Battery

TWO WAYS OF TESTING THE BATTERY

Batteries are tested in two ways: the state of its charge and performance. The state of charge
of a vent–cap battery is determined by a hydrometer. The built-in battery provides this information.
The battery load test is performed to determine the serviceability of the battery.

HYDROMETER TEST

Two types of hydrometer:

1. Ball hydrometer
2. Float hydrometer

Ball hydrometer is similar to the ball type coolant hydrometer. To perform hydrometer
testing using ball hydrometer, insert the rubber tube into the vent hole of the battery, then squeeze
and release the bulb. Electrolyte will be drawn into the tube. If all balls float, the battery is fully
charged. If none, the battery is discharged. The more balls that floats, the higher the battery state
of charge.

The float hydrometer is used in the same way as the ball hydrometer. It will float as the
electrolyte is drawn from the battery. Marks on the float stem show the electrolyte specific gravity.
This indicates the battery state of charge. The more fully charged the battery, the higher the float.

As a precaution, make sure no electrolyte drips on the car or on you. Electrolyte will damage
the car paint or your clothes.

The following table shows the relationship between specific gravity and state of charge.

SPECIFIC GRAVITY STAGE OF CHARGE

1.265 -1.299 Fully charged battery
1.235 -1.265 Three – fourths charged
1.205 -1.235 One-half charged
1.170 -1.205 One-fourth charged
1.140-1.170 Barely Operative
1.110-1.140 Completely discharged

While the next table provides the specific gravities and freezing temperatures for battery
electrolytes.
SPECIFIC GRAVITY STAGE OF CHARGE
1.100 18 [-8.2]
1.160 1 [-7.2]
1.200 -17 [-27.3]
1.220 -31 [-35]
1.260 -75 [-59.4]
1.300 -95 [-70.5]
 SELF- CHECK No. 2

Write the correct letter of your choice on the blank provided for.

_________1. This type of hydrometer which is similar to ball type coolant

hydrometer.
a. ball hydrometer
b. flat hydrometer
c. barometer
d. a and b
_________2. A type of hydrometer which the state of charge marks on the
float stem to show electrolyte specific gravity.
a. ball type hydrometer
b. float hydrometer
c. a and b
d. None of the above
_________3. The indication if the battery is fully charged using a ball
hydrometer.
a. all balls float
b. no balls float
c. a and b
d. none of the above
_________4. The more fully charged the battery is, the higher the float is
indicating the state of its charge.
a. float hydrometer
b. ball hydrometer
c. a and b
d. all of the above
_________5. The more balls float, the higher the battery state of charge.
a. ball hydrometer
b. float hydrometer
c. a and b
d. None of the above
 OPERATION SHEET No. 1

Testing Automotive battery using hydrometer

Procedure:
Your teacher will discuss the procedure with you with the aid of pictures and actual battery.

1. Remove all battery vent caps.

2. Check the electrolyte level, it must be high enough to withdraw the correct amount of
solution into the hydrometer.
3. Squeeze the bulb and place the pick-up tube into the electrolyte of a cell.
4. Slowly release the bulb. Draw in enough solution until the float is freely suspended in the
barrel. Hold the hydrometer in vertical position.
5. Read the electrolyte level on eye level as shown in the figure below.
6. List the test result.

Fig. 3A. Drawing electrolyte from the battery

Fig. 3B. Checking specific gravity of electrolyte using float
hydrometer.(Toyota Motor Sales, U.S.A)