1. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Publisher The Goodheart-Willcox Co., Inc. Tinley Park, Illinois by Russell Krick

2. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only

3. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Battery principles  Battery functions  Battery construction  Wet- and dry-charged batteries  Maintenance-free battery  Battery ratings  Battery temperature and efficiency

4. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  An automotive battery is an electrochemical device  It produces and stores direct current electricity

5. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Parts

6. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Discharging  Changes chemical energy into electrical energy  Stored energy is released

7. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Charging  Electrical energy is converted to chemical energy  Energy is stored until needed

8. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Cycling  Repeated charging and discharging  Deep cycling  going from a very low charge to full charge  can shorten service life

9. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Basic Battery Cell  Contents:  negative plate  positive plate  container  electrolyte (battery acid)  When a load is connected to the cell, current will flow through the load

10. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Lead-Acid Battery Cell Electrolyte causes a chemical reaction between the plates, producing 2.1 volts

11. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cell Action (Charging)  Alternator causes free electrons to be deposited on the negative (–) plate  This causes the plates to have a difference in potential (electrical pressure or voltage)

12. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cell Action (Discharging)  Load is connected across the terminals  Current flows through the load to equalize the difference in charges on the plates  Excess electrons (current) move from the negative plate through the load to the positive plate

13. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Cycling

14. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Operate the starting motor, ignition system, fuel injection, and other electrical devices during cranking  Supply electrical power when the engine is not running  Supply electrical power when current demands exceed alternator output  Act as a capacitor (voltage stabilizer)  Store energy for extended periods

15. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Batteries must be built to withstand harsh conditions:  severe vibration  extreme temperatures  corrosive chemicals  high current discharge  prolonged periods without use

16. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Battery plates  grid coated with porous lead  several in each cell  Lead strap  one connects several negative plates  another connects several positive plates  Separators  insulating material between plates that keep them from touching each other Battery Element

17. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Element Most automotive batteries have six elements

18. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Battery case  high-quality plastic  holds the elements and electrolyte  Battery cover  bonded to the top of the case  seals the top  Battery caps  keep electrolyte from splashing out  serve as spark arrestors Case, Cover, and Caps

19. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Case, Cover, and Caps Case holds the elements and electrolyte

20. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Electrolyte  Mixture of sulfuric acid and distilled water  Poured into each cell until plates are covered  Also known as battery acid  Warning: electrolyte causes serious burns or blindness if it comes in contact with your skin or eyes!

21. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Electrolyte Electrolyte should just touch the split ring in the top of the case

22. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Charge Indicator Changes color to show the general state of charge of the battery

23. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Terminals Means of connecting the battery to the vehicle’s electrical system

24. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Open circuit cell voltage is 2.1 volts  Cells are connected in series  Battery voltage depends on the number of cells  A 12-volt battery has 6 cells and an open circuit voltage of 12.6 volts  A 6-volt battery has 3 cells and an open circuit voltage 6.3 volts Battery Voltage

25. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Voltage

26. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Two-Battery Systems  Parallel  connected negative to negative  connected positive to positive  two 12-volt batteries produce 12 volts, high current  Series  connected positive to negative  two 12-volt batteries produce 24 volts

27. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Cables A. Post-type B. Side terminal C. Braided ground D. 90º post-type E. Solenoid-to- starter

28. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cable Connections The negative cable grounds on the engine block and the positive cable connects to the starter solenoid

29. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Battery Tray and Retainer Holds battery securely in place. May house a battery temperature sensor.

30. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Protects battery from excess engine heat by routing air between heat shield and battery case Battery Tray and Heat Shield

31. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  No difference in the materials used in each  Only difference is in how they are prepared for service

32. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Wet- and Dry-Charged Batteries  Wet-Charged Battery  filled with electrolyte and charged at the factory  very common in many locations  Dry-Charged Battery  contains fully charged elements  does not contain electrolyte  leaves the factory in a dry state  has a long shelf life

33. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Does not use removable filler caps  Calcium is used to make the plates, which reduces gassing  Reduced water loss decreases service requirements  Less gassing results in less chemical loss, which results in increased battery life

34. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Works like a lead-acid battery  Contains a pastelike electrolyte  The electrolyte will not leak out if the case is cracked or broken, and the battery will continue to function

35. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Gel Battery  A complete seal eliminates gassing and reduces the risk of explosion  Improper charging can burn a void in the electrolyte gel  Burning can permanently lower power output  A specific charging rate is required, which is not required with a lead-acid battery

36. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Also known as an AGM battery  Contains a fiber matting that absorbs the liquid electrolyte  Battery has only enough electrolyte to wet the matting

37. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Absorbed Glass Mat Battery  Vibration and impact resistant and will not leak, even if the case is damaged  Sealing does not allow gassing, reducing the risk of explosion  Not as sensitive to improper charging as gel batteries

38. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Cold cranking rating  Reserve capacity rating  Amp-hour rating

39. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Cold Cranking Rating  Determines the current a battery can deliver for 30 seconds at 0ºF (-18ºC) while maintaining terminal voltage of 7.2 volts (1.2 volts per cell)  Expressed as cold cranking amps (CCA)  Indicates ability to crank the engine at cold temperatures  Typical applications:  305 CCA for small 4-cylinder engine  450 CCA for 8-cylinder engine

40. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Reserve Capacity Rating  Time needed to lower battery terminal voltage below 10.2 volts (1.7 volts per cell) at a discharge rate of 25 amperes at 80ºF (27ºC)  Expressed in minutes  example: If a battery is rated at 90 minutes and the charging system fails, the driver has approximately 90 minutes of driving time with a current use of 25 amperes before the battery goes completely dead

41. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Amp-Hour Rating  Once used to indicate battery power  Measures the current that the battery could produce for 20 hours at 80ºF (27ºC) with the battery voltage above 10.5 volts

42. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  As battery temperature drops, output is reduced  chemical process is slowed  battery cannot produce as much current

43. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Temperature versus Efficiency

44. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Parasitic Loads  Current draw present when engine and ignition are shut off  Computers and clock require constant power  Over prolonged periods, these may discharge the battery enough to prevent starting