Inspecting and Cleaning the Battery Cables and Connections
Contents
1. Fender cover Battery charger Protective Clothing Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on PROCEDURE 1 Place the fender covers on the fender closest to the battery Task Completed 172 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 44 173 2 If equipped remove the battery caps and check the fluid level Fill the battery with clean distilled water do not use tap water if needed and reinstall the battery caps do not overfill the battery Warning Do not charge the battery if the fluid inside is frozen Note If the battery is a sealed design use a noncontact thermometer or a temperature probe to get an indica tion if the battery is frozen Task Completed Tim Gilles ea Pea KiE EASE Figure 3 28 Careless use of the battery charger caused this battery to explode 3 Remove the battery terminals and move the cables to the side Task Completed 4 What is the open circuit voltage of the battery Figure 27 32 Reading open circuit voltage with a digital voltmeter 5 Check that the charger is turned off and connect the battery charger cables to the battery Warning Be sure that you have a good connection so that you do not produce a spark Batteries produce a hydrogen gas when charging Task Completed 2012 Cengage Learning Inc Licensed2. battery Auxiliary power supply booster pack Protective Clothing Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on vin __Engine type ands PROCEDURE 1 What are the gauge size and length of the battery jumper cables you are using 2 Position the vehicle with the live battery so that the jumper cables will not be stretched Task Completed 3 Open the hood of both vehicles Task Completed 4 Make sure that the ignition is in the off position on both vehicles Task Completed 175 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted 176 Job Sheet 45 5 Connect one end of the positive jumper cable to the dead car s positive battery terminal Task Completed Make last connection 4 away from battery Smaller Larger i Top terminal batteries Figure 3 29 Correct connections for jump starting a car 6 Connect the other end of the positive jumper cable to the live car s positive battery terminal Task Completed 7 Connect one end of the negative jumper cable to the live car s negative battery terminal Task Completed 8 Connect the other end of the negative jumper cable to the dead car s engine ground Task Completed 9 Start the engine on the live car and wait a minute Task Completed 10 Attempt to start the dead car Once the dead car starts remove t
3. for one time use by the purchaser only no additional copying or retransmission is permitted 174 Job Sheet 44 6 Turn the charger on to the setting for a slow charge What is the amperage on this setting and how long would you leave it on 7 Turn the charger on to the setting for a fast charge What is the amperage on this setting and how long would you leave it on 8 Explain the situations in which you would use a slow charge or a fast charge Problems Encountered INSTRUCTOR EVALUATION oO oO Oo m m Mastered Task Able to Perform Task Independently Some Additional Training Suggested Able to Perform Task with Close Supervision Requires Additional Training Unable to Perform Task Not Attempted Comments Instructor Name S S S S Date Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Jump Starting a Battery Name S Motion Date NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 6 Start a vehicle using jumper cables or an auxiliary power supply P 2 Performance Objective s Upon completion of this Job Sheet you will be able to understand how to properly jump start a vehicle using a live battery in a vehicle and an auxiliary power supply booster pack Tools and Materials Battery jumper cables Vehicle with a live battery Vehicle with a dead
4. the battery open circuit is less than 12 4 volts recharge it before performing the capacity test 5 Connect the battery capacity tester clamps to the battery Make sure they are on tight Task Completed Ammeter Cengage Learning 2012 Figure 27 41 Parts of a volt amp tester 6 Based on the battery rating how much load should be applied to the battery during the capacity test 7 Conduct the battery capacity load test Voltage dropped to CFV ts Load was held for _ __E seconds 8 Did the battery pass the capacity load test 9 Is there enough power current capacity to meet the minimum requirements for this vehicle Note Steps 10 13 are for performing a conductance test 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted 180 Job Sheet 46 10 Connect the battery conductance tester to the battery terminals Task Completed 11 Follow the tester s instructions by entering the CCA into the tester screen Task Completed__ 12 Conduct the battery conductance test Task Completed 13 What were the results of the test 14 If this Job Sheet is for a live customer do you think that this testing series provides sufficient infor mation to determine the customer s problem Why or why not Problems Encountered INSTRUCTOR EVALUATION 4 Mastered Task Able to Perform Task Independently Some Additional Train
5. 1 Remove the battery caps and check the fluid level Warning Do not use a flame light to look inside the battery Use a flashlight Batteries emit hydrogen gas which is explosive Task Completed 168 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 43 169 amp 2 Does the battery have a built in hydrometer If yes describe what you see in the sight glass Top of Green dot Dark battery Sight glass ball F 65 or above Below 65 Low level 3 state of charge state of charge electrolyte 4 Figure 27 27 A builtin hydrometer in a sealed battery indicates the condition of the battery 3 What is the temperature of the battery case 4 Measure the specific gravity of each cell using the hydrometer or refractometer and record it below Tim Gilles Figure 27 24 Draw electrolyte into the hydrometer 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted 170 Job Sheet 43 b Figure 27 30 a Removing an electrolyte sample from the battery b Reading the strength of the sample with the refractometer Tim Gilles Tim Gilles 5 With respect to the temperature list the corrected specific gravity of each cell 6 Fill the battery with clean distilled water do not use tap water and do not overfill T
6. B SHEET 42 Inspecting and Cleaning the Battery Cables and Connections Name C CSSf aTHISM Le C COCCCCCCCCCC i DS Cle NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 4 Inspect clean fill and or replace battery battery cables connectors clamps and holddowns P 1 Performance Objective s Upon completion of this Job Sheet you will be able to understand how to inspect clean remove and install a battery the cables and holddown apparatus Tools and Materials Voltmeter Battery terminal cleaner brush Service manual Technician s tool set Vehicle Baking soda or battery cleaning solution Battery terminal remover Wire brush Protective Clothing Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on PROCEDURE 1 Describe the general appearance of the battery 164 Engine type and size 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 42 4165 2 Describe the general appearance of the battery terminals and cables 3 Check the tightness of the battery cables Are they tight 4 With the ignition in the on position use the voltmeter to measure the amount of voltage drop from the battery positive terminal to the battery positive cable while it is still attached 5 Do your answers from steps 3 and 4
7. ask Completed S 7 What is the open circuit voltage of the battery 8 Do your corrected specific gravity readings correlate to the open circuit voltage Water level Acid content Cengage Learning 2012 1 260 1 195 1 250 Figure 27 26 Hydrometer readings should vary no more than 0 050 This battery has a defective cell 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 43 171 9 Based on your testing does the battery require replacement or recharging Problems Encountered INSTRUCTOR EVALUATION O 4 Mastered Task 3 Able to Perform Task Independently Some Additional Training Suggested 2 Able to Perform Task with Close Supervision Requires Additional Training 1 Unable to Perform Task 0 Not Attempted oood Comments Instructor Name _ CD attr Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Charging a Battery Name CC C CSfatti coos CL CC CSCSCCCCSCO attr NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 5 Perform battery charge P 1 Performance Objective s Upon completion of this Job Sheet you will be able to understand how to perform a battery state of charge test Tools and Materials Voltmeter Service manual Technician s tool set
8. e _ ee S Date Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Perform a Battery Capacity and Conductance Test Name i UUUUUUCOC SSH Cnpt lgMn LW tT C i UUC C C TO NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 2 Perform battery capacity test confirm proper battery capacity for vehicle application determine necessary action P 1 6 A 2 Identify and interpret electrical electronic system concern determine necessary action P 1 Performance Objective s Upon completion of this Job Sheet you will be able to understand how to perform a battery test using both the capacity and conductance methods e Tools and Materials Capacity load tester Conductance tester Protective Clothing Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on Engine type and size PROCEDURE 1 Explain the difference between a conductance test and a capacity test Note Steps 2 8 are for performing a capacity test 178 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 46 179 2 What is the battery CCA 3 What is the open circuit voltage of the battery 4 Does the battery require charging before testing Note If
9. he negative jumper cable from the engine ground Task Completed 11 Remove the negative jumper cable from the live car Task Completed 12 Remove the positive jumper cable from the live car Task Completed 13 Remove the positive jumper cable from the dead car Task Completed 14 Now connect the auxiliary power supply booster pack to the dead vehicle s battery in the same manner as you did before but skipping the live car steps Task Completed 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted 15 16 17 18 19 Job Sheet 45 177 If the auxiliary power supply booster pack has an on off switch turn it on now Task Completed Start the engine of the dead car Task Completed Turn the engine off and turn the switch on the auxiliary power supply booster pack off Task Completed Remove the cables from the auxiliary power supply booster pack and remove it from the vehicle Task Completed Explain what could possibly happen if you connected the dead car s battery jumper cables to both the positive and negative terminals Problems Encountered INSTRUCTOR EVALUATION ooood OerN Ww 4 Mastered Task Able to Perform Task Independently Some Additional Training Suggested Able to Perform Task with Close Supervision Requires Additional Training Unable to Perform Task Not Attempted Comments Instructor Nam
10. indicate that there might be a problem 6 Describe the condition of the battery holddown Battery case Hoiddown bolt a Holddown J bolts z 8 E 8 g b 5 Figure 26 21 Different types of battery hold downs 7 Turn the key off and remove the battery cables and holddown apparatus Note You may have to use the battery terminal remover to remove some stuck cables i Task Completed 8 Remove the battery and place it on a bench Task Completed 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted 166 Job Sheet 42 9 Describe the condition of the battery tray 10 Using the wire brush a baking soda and water solution or a battery terminal cleaning solution clean the battery cables holddown and tray Task Completed Cengage Learning 2012 Figure 27 4 A battery terminal cleaner that cleans both the inside of the clamp and the outside of the post 11 After cleaning inspect the battery cables Do they still have corrosion on them 12 If the battery has removable caps on it remove them and check the fluid level Warning Do not use a flame light to look inside the battery Use a flashlight Batteries emit hydrogen gas which is explosive Task Completed Cengage Learning 2012 Figure 26 8 This battery has removable cell caps 13 Fill the battery with clean distilled water do not use tap
11. ing Suggested Able to Perform Task with Close Supervision Requires Additional Training Unable to Perform Task Not Attempted oooaoo orN Ww Comments Instructor Name _ o o o Date Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Battery Removal and Installation Name S CS fattitcos CL _ _ Date NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 3 Maintain or restore electronic memory functions P 1 6 B 8 Identify electronic modules security systems radios and other accessories that require reinitialization or code entry following battery disconnect P 1 6 B 4 Inspect clean fill and or replace battery battery cables connectors clamps and holddowns P 1 Performance Objective s Upon completion of this Job Sheet you will be able to understand how to remove and reinstall a battery and how to use a memory saving device Tools and Materials Service manual Technician s tool set Vehicle Memory saving device Protective Clothing Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on PROCEDURE 1 Record the radio station presets 181 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is per
12. mitted 182 Job Sheet 47 2 Refer to the owner s or service manual Does the vehicle you are working on have a security system on the radio Note If the vehicle does have a security system installed on the radio you may need to reinitialize the system or enter a code following a battery disconnect Refer to the service manual for instructions on retrieving and entering the code 3 Install the memory saving device Note Some memory saving devices are installed in the cigarette lighter and others use the battery terminals Task Completed E OURACELL E o Figure 27 10 A tool for keeping computer memory alive while a battery is removed for service 4 Remove the battery negative cable Task Completed 5 Remove the battery positive cable Task Completed 6 Remove the battery holddown apparatus Task Completed 7 Clean the battery holddown tray and cables as needed Note See Job Sheet 42 for the procedures for cleaning Task Completed 8 Reinstall the battery and holddown apparatus Task Completed 9 Connect the positive cable to the battery Task Completed 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 47 183 10 Connect the negative cable to the battery Task Completed 11 Remove the memory saving device Did the memory saving device work 12 If the memory saving device did not work you will need to set the
13. radio station presets clock s and seat memory positions Task Completed Problems Encountered INSTRUCTOR EVALUATION 4 oooagoda 3 2 1 0 Mastered Task Able to Perform Task Independently Some Additional Training Suggested Able to Perform Task with Close Supervision Requires Additional Training Unable to Perform Task Not Attempted Comments Instructor Name __ ee Cs lt D atte Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted B SHEET Identifying Hybrid Electric Vehicle High Voltage Circuits Safety and Precautions Name gt totion _ _ __ Date NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 7 Identify high voltage circuits of electric or hybrid electric vehicle and related safety precautions P 3 6 B 9 Identify hybrid vehicle auxiliary 12v battery service repair and test procedures P 3 8 F 7 Identify hybrid vehicle internal combustion engine service precautions P 3 Performance Objective s Upon completion of this Job Sheet you will be able to describe how to safely handle and identify a hybrid electric vehicle and related components Tools and Materials Service manual High voltage gloves Protective Clothing Equipment Goggles or safety glasses with
14. side shields Describe the vehicle being worked on PROCEDURE 1 Describe the location of the high voltage service plug also known as the disconnect plug 2 Gain access to the service switch 184 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 48 185 3 Compare those readings to what the manufacturer specifies Is there a difference 4 Do the pressure readings indicate that the warning light should be on 5 Gain access to the service manual Describe how this specific type of TPMS works Task Completed Problems Encountered INSTRUCTOR EVALUATION 4 oaao o 3 2 1 0 Mastered Task Able to Perform Task Independently Some Additional Training Suggested Able to Perform Task with Close Supervision Requires Additional Training Unable to Perform Task Not Attempted Comments Instructor Name _ S S Date Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted
15. water and do not overfill Task Completed 14 Reinstall the battery cables and holddown Task Completed 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Job Sheet 42 167 Problems Encountered INSTRUCTOR EVALUATION 4 Mastered Task Able to Perform Task Independently Some Additional Training Suggested Able to Perform Task with Close Supervision Requires Additional Training Unable to Perform Task Not Attempted ooood ORN Ww Comments Instructor Name _ en S Date Instructor Signature 2012 Cengage Learning Inc Licensed for one time use by the purchaser only no additional copying or retransmission is permitted Perform a State of Charge Battery Test Name gt Z gt Z Satoni Date NATEF Correlation This Job Sheet addresses the following NATEF task s 6 B 1 Perform battery state of charge test determine necessary action P 1 Performance Objective s Upon completion of this Job Sheet you will be able to understand how to perform a battery state of charge test Tools and Materials Voltmeter Service manual Hydrometer or refractometer Technician s tool set Battery with removable caps Infrared temperature gun Protective Clothing Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on Engine type and size Model vN PROCEDURE
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