Service Training

CONSTRUCTION OF A BATTERY: Components

CAUSES OF BATTERY FAILURE

• Electrolyte Level• Overcharging• Undercharging• Corrosion• Cycling• High Temperatures• Vibration• Stratification

BATTERY CARE &

MAINTENANCE

DIAGNOSIS & BATTERY TESTING• Visual Inspection• State of Charge Inspection• Heavy Load Test

VISUAL INSPECTION: 1

• Cracks on Container or broken terminals.• Cracked or broken cables or connections.• Corrosion on terminals dirt or acid on top case,

clean with a mixture water & backing soda. Wire brush the terminals.

• Check for loose battery hold downs & loose battery connections.

• Check Electrolyte level should be between Max & Min.

• Check for Cloudy or discolored electrolyte caused by over charging or vibration.

• Check condition of plates & separators alt. Should be dark & light. If all are light – severe undercharging

• Check condition and tension of alt. belta) If Loose tighten – leads to proper chargingb) If too Tight – Reduces alt. Lifec) Frayed or glazed will fail – Replace it

• Check for Battery drain or parasitic loads. JIS standards permit a drain of 0.020amps >0.030amps identify the cause and correct

• Check for Battery drain across the Top of the battery – should not cross 0.5 Volt

VISUAL INSPECTION: 2

STATE OF CHARGE TEST

• This checks the chemical condition of the Battery

• Methods are as follows:a) Use Hydrometer: Check Sp. Gr.

b) Use Voltmeter: Check OCVc) Use Magic Eye (if available): Check color changed) Check brightness of HL during cranking,

STRATIFICATION

Normal batteryThe acid is equally distributed from the top to the bottom in the cell and provides maximum CCA and capacity

Stratified batteryThe acid concentration is light on top and heavy on the bottom. High acid concentration artificially raises the open circuit voltage. The battery appears fully charged but has a low CCA. Excessive acid concentration induces sulfation on the lower half of the plates.

SPECIFIC GRAVITY/STATE OF CHARGE

MAGIC EYEThe Magic Eye makes it easy to ascertain the state of charge or the electrolyte level without having to open the service plugs.

MAGIC EYE

MAGIC EYE

The variation in the height of electrolyte in a fully charged battery affects the Magic Eye as follows: