1. Service Training

2. CONSTRUCTION OF A BATTERY: Components

3. CAUSES OF BATTERY FAILURE Electrolyte Level Overcharging Undercharging Corrosion Cycling High Temperatures Vibration Stratification

4. BATTERY CARE & MAINTENANCE

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

6. 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

7. Check condition and tension of alt. belt a)If Loose tighten – leads to proper charging b)If too Tight – Reduces alt. Life c)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

8. 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 OCV c) Use Magic Eye (if available): Check color change d) Check brightness of HL during cranking,

9. STRATIFICATION Normal battery The acid is equally distributed from the top to the bottom in the cell and provides maximum CCA and capacity Stratified battery The 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.

10. SPECIFIC GRAVITY/STATE OF CHARGE

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

12. MAGIC EYE

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