1

Battery Safety, Servicing & TestingBattery Safety, Servicing & Testing

R. BortignonR. Bortignon

2

Slideshow ContentsSlideshow Contents

battery function & related informationbattery function & related information

safe battery handling proceduressafe battery handling procedures

battery servicebattery service

battery testingbattery testing

alternator testingalternator testing

how to safely charge a batteryhow to safely charge a battery

jump starting a vehiclejump starting a vehicle

3

Purpose of the Battery…Purpose of the Battery…

• provides the electrical power needed to start the engine provides the electrical power needed to start the engine

• powers the starter motor and ignition & fuel systempowers the starter motor and ignition & fuel system

Starter FunctionStarter Function

4

5

Purpose of the Battery…Purpose of the Battery…

• once the engine is started, the once the engine is started, the alternatoralternator provides all the electrical provides all the electrical energy for the ignition system, computers, lights, radio, horn and other energy for the ignition system, computers, lights, radio, horn and other accessoriesaccessories

• alternator converts mechanical energy (belt-driven pulley) to electrical alternator converts mechanical energy (belt-driven pulley) to electrical energyenergy

6

Important info about automotive batteries…Important info about automotive batteries…• they converts chemical energy into electrical energythey converts chemical energy into electrical energy• they produce they produce 12.6 volts12.6 volts

• 6 individual cells produce 2.1 volts each6 individual cells produce 2.1 volts each

• they cost approximately $50 to $120they cost approximately $50 to $120

• battery warranties range from 3 to 6 yearsbattery warranties range from 3 to 6 years

• average battery life expectancy is 3 to 6 yearsaverage battery life expectancy is 3 to 6 years

• battery power is rated in battery power is rated in cold cranking ampscold cranking amps or or CCACCA’s’s

7

Battery SafetyBattery Safety

• Batteries contain a liquid called Batteries contain a liquid called electrolyteelectrolyte which contains which contains sulphuric acidsulphuric acid

• You must be careful not to splash the You must be careful not to splash the electrolyte in your eyes or get it on your electrolyte in your eyes or get it on your skin!skin!

• Batteries give off Batteries give off hydrogenhydrogen gas thru gas thru vents in the top of the batteryvents in the top of the battery

• Keep sparks & flames away from the Keep sparks & flames away from the battery!!!battery!!!

8

9

Servicing & Safe Battery HandlingServicing & Safe Battery Handling

First step in a battery service…First step in a battery service…

1. Disconnect & clean battery terminals and posts1. Disconnect & clean battery terminals and posts

a)a) alwaysalways remove remove negativenegative first, thenfirst, then positivepositive NegativeNegative is usuallyis usually blackblack or marked withor marked with – – and itand it

connects to groundconnects to ground PositivePositive is usuallyis usually redred or marked withor marked with ++ and it connects and it connects

to the starter motor or starter relayto the starter motor or starter relay

terminal puller

Wear eye protection!!!Wear eye protection!!!

10

• replace any bolt/nut, terminal or cable if damagedreplace any bolt/nut, terminal or cable if damaged

11

Use gloves when servicing batteries…Use gloves when servicing batteries…

12

13

14

b) always reinstall b) always reinstall positivepositive first, then negative first, then negative

• remember:remember: NPPNNPPN

• ensure the terminals cannot be moved by handensure the terminals cannot be moved by hand

• coat the terminals with spray paint or terminal protector to coat the terminals with spray paint or terminal protector to

reduce further corrosionreduce further corrosion

15

Step 2 in Battery Service…Step 2 in Battery Service…

2. Check the electrolyte level in 2. Check the electrolyte level in each celleach cell

• some vent caps are not some vent caps are not removable – ask Roger if you removable – ask Roger if you are unsure!are unsure!

• the electrolyte should cover the electrolyte should cover the platesthe plates

• add water if needed, butadd water if needed, but do do not overfillnot overfill!!

16

fill cells slowly - normally, very little water is required!

17

Step 3 in Battery ServiceStep 3 in Battery Service

3) use a rag & clean the top of the battery so current won’t 3) use a rag & clean the top of the battery so current won’t leak between the terminalsleak between the terminals

18

Battery ChargingBattery Charging

• next 2 slides…next 2 slides…

19

Battery ChargingBattery Charging1. Service the battery.1. Service the battery.

2. Connect the battery charger cables. 2. Connect the battery charger cables.

(red to positive, black to negative)(red to positive, black to negative)

3. Set the charge rate to LOW.3. Set the charge rate to LOW.

4. Set the timer to 60 minutes.4. Set the timer to 60 minutes.

5. Plug the charger in.5. Plug the charger in.

monitor battery temperature by placing your hand on the case – if it gets too hot, turn off the charger – the battery may be defective!

20

Unhooking the Battery ChargerUnhooking the Battery Charger

1. Unplug the charger!!!1. Unplug the charger!!!

2. Disconnect the cables.2. Disconnect the cables.

3. Check the battery’s voltage. 3. Check the battery’s voltage.

(should be 12 volts)(should be 12 volts)

21

Battery TestingBattery Testing

• next 4 slides…next 4 slides…

22

Battery TestingBattery Testing

• To test a battery you will use the VAT-40 to perform a To test a battery you will use the VAT-40 to perform a load load testtest

• load test tells us if the battery can deliver the power needed load test tells us if the battery can deliver the power needed to start the engineto start the engine

• beforebefore you perform a load test… you perform a load test…

• service the batteryservice the battery• ensure the battery is fully charged (12 volts)ensure the battery is fully charged (12 volts)

• to do this, connect a voltmeter {+ to +, - to -}to do this, connect a voltmeter {+ to +, - to -}• if the voltage is <12 volts, it will have to be chargedif the voltage is <12 volts, it will have to be charged

23

Using the VAT-40Using the VAT-40

1. Connect the cables as follows…1. Connect the cables as follows…

• 2 large load leads red to positive, black to negative2 large load leads red to positive, black to negative

• set the volt selector to set the volt selector to INT 18VINT 18V

• green inductive pick-up around one of the load leadsgreen inductive pick-up around one of the load leads

24

VAT-40 Step #2VAT-40 Step #2

2. Determine the CCA of the battery2. Determine the CCA of the battery

• look for a sticker on the battery that indicates the CCAlook for a sticker on the battery that indicates the CCA

• or look in “Mitchell” to determine the CCA of the original or look in “Mitchell” to determine the CCA of the original battery battery

• if all else fails, assume it is a 500 CCA batteryif all else fails, assume it is a 500 CCA battery

25

VAT-40 Step #3VAT-40 Step #3

3. Pull out 3. Pull out ½ the CCA½ the CCA or or 3 times the amp/hour rating3 times the amp/hour rating out of the out of the battery for battery for 10 seconds 10 seconds

(e.g. on a 650 CCA battery, pull 325 amps out during the load test)(e.g. on a 650 CCA battery, pull 325 amps out during the load test)

• the voltage should stay above 9.6 voltsthe voltage should stay above 9.6 volts• if the voltage drops below 9.6 volts, the battery will have to if the voltage drops below 9.6 volts, the battery will have to

be replacedbe replaced

26

Alternator TestingAlternator Testing

1. Check the belt tension 1. Check the belt tension (≈1/2” or 13mm slack)(≈1/2” or 13mm slack)

2. Are the wires on the back of 2. Are the wires on the back of the alternator corroded, the alternator corroded, loose or burned?loose or burned?

27

Alternator TestingAlternator Testing

3. Hook up the VAT-40 3. Hook up the VAT-40

Do not turn the load control knob!Do not turn the load control knob!

4. Start the engine.4. Start the engine.

Alternator should produce betweenAlternator should produce between 13.5 & 14.5 volts13.5 & 14.5 volts

28

Jump Starting a Battery Jump Starting a Battery

Connect the jumper cables in this order…Connect the jumper cables in this order…

1.1. connect positive to positiveconnect positive to positive

2.2. connect negative to groundconnect negative to ground Ground is any solid, unpainted metal part such as the Ground is any solid, unpainted metal part such as the frame or a bracket that is bolted to the engineframe or a bracket that is bolted to the engine

3.3. start the enginestart the engine

4.4. use a battery charger to recharge the dead batteryuse a battery charger to recharge the dead battery• Do not allow the clamps to touch each otherDo not allow the clamps to touch each other• Do not jump the battery if you suspect there is a fuel leakDo not jump the battery if you suspect there is a fuel leak