21-22 September 2023

Facilitator : Le Roi Jones S. Aquitania

• Understand the Basic SLI Battery and Theories
– SLI Battery Structure and Technologies
– How SLI Battery Works
– Vehicle Electrical Systems
• Identify Improper Vehicle and SLI Battery
Maintenance Practices that causes premature battery
failures
– Apply Proper SLI Battery Maintenance and Care
• Hands On Activities:
– “Activation” and Testing of Dry-charged Batteries
– Hydrometer and Load Testing Basics and other practical
procedures
PRE TRAINING BASIC
BATTERY TEST
(3 Minutes)
BATTERY BASICS & THEORY
 WHAT IS A CELL AND
A BATTERY?
• An electrochemical cell is a device that stores
chemical energy and releases it as electricity
• A battery is a series of electrochemical cells
 TYPES OF BATTERIES

• According to recharge-ability
– Primary
• Converts chemical energy to
electrical energy through
irreversible chemical reactions
• Non-rechargeable
– Secondary
• Converts chemical energy to
electrical energy by reactions that
are essentially reversible
• Rechargeable
One of the Foundations of Modern Electricity
 WIRING CONNECTIONS
Series & Parallel

Series Circuit
• Voltage is additive
• Current/Capacity remains the
same

Parallel Circuit
• Voltage remains the same
• Current/Capacity is additive
 6v / 9Ah 12v / 4.5Ah 12v / 9Ah

2 x 4.5AH (6V) 2 x 4.5AH (6V)

4 x 4.5AH (6V)

6v / 9Ah 12v / 4.5Ah 12v / 9Ah

4.5AH and 10AH (6V)

4.5AH and 10AH (6V)

3x 3AH & 2x4.5AH (6V)

 Automotive Electrical Systems
(Voltage and Current
A. Classifications: Voltage B. Classification: Current
1. 6V 1. Direct Current
2. 12V 2. Alternating Current
3. 24V
4. 48V
Why do modern cars have 12V-DC (and Trucks 24V)
Systems?
– It has something to do with the (1) increasing power requirements
resulting in changes in battery specifications and (2) associated
aftermarket infrastructure of parts & components manufacturers
and distribution outlets
– Cost and Distribution Complications
Why DC Power:
A Lead Acid Batteries provides DC power, and DC
power is generally more useful / efficient than AC
power for most automotive electrical needs.

Why 12V Systems for Cars: 3Cell - 6V Battery

– A 6 Cell Lead Acid Battery has a
nominal voltage of 12 Volts
– Higher voltages are more efficient
and thus generally more desirable.
>> Switch from 6V to 12V system in
the 50’s – 60’s as power needs
were rapidly increasing
Why 24V Systems for Trucks
• The advantages of higher
voltage battery systems are
significant.
– Reduced cost in wiring (reduced
voltage drops) and electrical
components such as starter
motors and alternators
– Reduce the stress on the battery
(as the current demand decreases
for the same amount of power
delivered)
– Reduced stress to components
such as relays and motor brushes
last longer (if properly designed)
• Act as portable or standby power/energy
source
Automotive / Truck / Motorcyle Batteries are called Starting,
Lighting and Ignition (SLI) Batteries
1. Supply power to the starter and ignition system so the
engine can be cranked and started

2. Supply the extra power required should the vehicle’s

electrical load requirements exceed the electrical supply
from the charging system / alternator
3. Act as a voltage stabilizer in the electrical system.
– The battery smoothens or reduces temporarily
high voltage spikes (transient voltages) that
occur in the vehicle electrical system.
4. Supply power to accessories when engine is off
 Differences between lead – acid
battery types – by application
Type Automotive Traction Stationary
Applications/Uses •Passenger Car •Electric Forklift •Communication
•Trucks •Mine Locomotives •Switchgears
•Motorcycle •Industrial Trucks •Uninterruptible Power
Supply
Main Function Engine Starting Power Source Standby Power

Duty Cycle
Discharge Current •High current for engine •Relatively low Moderate to high,
starting depending on specific
application
Discharge Duration •Approximately 2-3 •Continuous or •Only for the duration of
seconds intermittent discharge a power interruption
lasting 6-8 hours
Discharge Frequency •Depends on vehicle •Daily •Only when there is
usage power interruption
Re-Charge Frequency •Battery is recharged •Daily •Battery is normally on
once the engine is float charge, with
running*** periodic equalizing
charge
2. Classification of Lead –Acid Batteries
(according to grid alloy chemistry)

2.1 Standard Antimonial Batteries

2.2 Low Maintenance Batteries
2.3 Maintenance-Free Batteries
2.3.1 Hybrid Batteries
2.3.2 Calcium Batteries
 Differences between lead acid battery
types – by Grid alloy
Type Positive Grid Negative Grid

Conventional Lead-antimony alloy Lead-antimony alloy

4.0 % - 6.0 % Antimony 4.0 % - 6.0 % Antimony

Low Maintenance Lead-antimony alloy Lead-antimony alloy

1.5 % - 3.0 % Antimony 1.5 % - 3.0 % Antimony

Maintenance Free( Hybrid) Lead-antimony alloy Lead-calcium alloy

1.5 % - 3.0 % Antimony 0.09% - 0.14 % Calcium

Maintenance Free Lead-calcium-tin alloy Lead-calcium alloy

(Calcium + / - Grids) 0.06% - 0.09% Calcium 0.09% - 0.14 % Calcium
0.7% - 1.50 % tin
3. Classification of Lead –Acid Batteries
(according to fluid “distilled
water” maintenance)
3.1 Low Maintenance
Batteries
• Needs periodic checking
and top-up of fluid
3.2 Maintenance-Free
Batteries
• No need to fill up fluid
over the entire service
life of the battery
• Battery Capacity -- a measure of the
amount of available energy in the storage
battery

An automotive battery must be able to

crank the engine for starting and still
have enough capacity to operate the
vehicles electrical systems, while the
engine starts
• Otherwise known as the
20 Hour or 5 Hour Rate

• A battery having 100 AH

rating must be able to
carry a 5 ampere load
for 20 hours, and still
maintain a terminal
voltage of 10.5 volts at
27º C (80º F).
• (100AH / 20 Hours = 5
Amps)
• This rating measures the
batteries ability to carry a 25
amp load at 27C.
• The Reserve Capacity is how
many minutes it takes the battery
terminal voltage to reach 10.5
volts.
• It provides the motorist an
approximation of time in
minutes the battery will support
a vehicle operating at night, if
(1) the battery is fully charged,
and (2) the vehicle charging
system has failed.
• The ability of a new fully
charged battery to
continuously deliver the
rated amps (CCA Battery
Rating) for 30 seconds at -18º
C and still maintain a
minimum voltage of 7.2 volts.
• The purpose of the CCA Rating is to
provide the motorist a reference to
compare the battery’s ability to crank
a particular size engine vs vehicle
manufacturer’s battery
recommendations for temperate
climate conditions
 BATTERY RATINGS ON LABEL

36Ah 12V

AMPERE HOUR (20HR)

1. Reinforced PP Body Construction
2. Grids and Active Materials
(Plates)
3. Plate separators made of HDPE
envelopes. 7
4. Electrolyte, a dilute solution of 5
sulfuric acid and water better 4 6
known as battery acid.
5. Straps and Inter Cell Connectors.
Connect same polarity plates and 2 3
one cell to the other in series. 1
6. Terminal posts, the connection
point between the battery and
whatever it powers.
7. Gas Venting System
Container & Cover
• Safely holds the
plates / active
materials and
electrolyte within
the battery

• Must not degrade

under extreme
conditions
experienced during
its entire service
life
Grids
The “foundation” for the
positive and negative active
material
• Bonds to the active material
• “High” Mechanical strength
to withstand the normal
handling and processing
• Moderately resistant to
acidic corrosion
• Good electrical conductivity
• Has low electrical resistance
 Active Materials

Each grid is pasted with an

lead based paste lead
dioxide (PbO2) in positive
plates and spongy lead (Pb)
Positive Paste
in negative plates

This active material

generates electrical energy
via chemical reaction with
the battery electrolyte
Negative Paste
Separator
Electrical insulator- it
insulates the positive active
material from the negative
active material , preventing a
short circuit in the cell

Ionic Conductor – it allows

the exchange of ions
between the battery plates,
allowing the current-
generating chemical reaction
to proceed
 Electrolyte (Sulphuric Acid + Water)

Directly participates
in the chemical
reaction that
generates electricity,
in this sense, it is
also an active
material
 Straps
• Connect the plates of
the same polarity all
positive and all negative
plates

• Compatible with grid

material

• Low electrical resistance

• Adequate mechanical
strength
Intercell Connectors
Interconnect the cells
in the battery;

• Same alloy as the

strap

• Connected through
the partition wall
reduces resistance
Terminal Posts

Provide a means for

connecting the battery to
an electrical load outside
of the battery
• Adequate mechanical
strength
• Low electrical resistance
• Resistant to corrosion
• Leak Free
• Lead Acid Batteries are governed by the following
electrochemical reaction:
PbO2 + Pb + 2 H2SO4  2 PbSO4 + 2 H2O
• Has a nominal electrochemical potential of 2.03 V; can
give 2.11V when full charge.
 Charged State Discharged State
PbO2 + 2H2 SO4 + Pb Pb SO4 + 2H2SO4 + Pb SO4
Sp. Gravity =1.255 – 1.280 Sp. Gravity =1.200
(Lead Dioxide) (Sulfuric Acid) (Sponge Lead) (Lead Sulphate) (Sulfuric Acid) (Lead Sulphate)
Positive Electrolyte Negative Positive Electrolyte Negative
Active Active Active Active
Material Material Material Material

Discharged
Charged
 DISCHARGING PROCESS

PbO2 + Pb + 2H2SO4 → 2PbSO4 + H2O

- +

Charging Process Process)

2PbSO4 + H2O → PbO2 + Pb + 2H2SO4

 Automotive Electrical
Trends and the Alternator
 Modern / Latest Vehicle 12V
Electrical Network Architecture
Automotive Electrical Load Trend
Typical Modern / Latest 12V Vehicle
Accessories Electrical Load
Typical Modern Alternator

Alternator
Assembly
 Alternator
• An alternator is a practically maintenance-free yet
one of the most important unit of the car’s engine.
• The alternator works by converting mechanical
energy to electrical energy, from alternating current
to the direct current.
• The primary function of an alternator is to work jointly
with the battery to supply energy to the electrical
components, i.e., lights, fan, windshield wipers, etc. as
well recharges the battery.
• An alternator is a current controlled – current source.
– I (Output) = K x I (Field)
• The voltage regulator “senses” the battery voltage
– Turns ON the field of current when the voltage is < 14.2V-
14.4V
– Turns OFF the field of current when the voltage is > 14.2V-
14.4V
Relationship of Alternator Output
and Battery Charging

The Charging Rate of the

alternator to the battery
depends on (1) Engine
Speed / Alternator speed
and (2) Electrical Load of
the vehicle
Relationship of Alternator Output
and Battery Voltage

1. Charged 2. Discharged
Condition: Condition:
Battery Battery
Resistance Resistance is
is HIGH LOW
Proton Preve 1.6L Alternator
Output vs Engine Speed

Alternator Rating:
90AH
Alternator – Engine
Crankshaft Speed
Ratio – 2:1
ALTERNATOR ACCESSORIES
A/C
AV /MM System
Head lights
Park lights
Defogger
Engine off
Horn
Accessories on Aux fan
Power Amplifier

With engine off , the

battery supplies 100%
BATTERY of the power
requirements to
accessories
ALTERNATOR ACCESSORIES
A/C
AV / MM System
Head lights
Park lights
Defogger
Horn
Engine on ( idling )
Aux fan
Full Accessories on
Power Amplifier

With engine on and idling,

the battery helps the
alternator in supplying the
power to accessories if the
BATTERY
load cannot totally be
supplied by the alternator ,
thereby discharging the
battery
 ACCESSORIES
ALTERNATOR
A/C
AV / MM System
Head and fog lights
Park lights
Defogger
Horn
Engine on ( high speed )
Aux fan
Accessories on
Power amplifiers
Note: Capacity of
alternator should be With engine on and in high speed
enough to power (2000 rpm or more), the
the added electrical alternator supplies all the power
accessories. BATTERY needed by the accessories and
also send current to the battery
to recharge or maintain the
optimum charge as needed
ALTERNATOR ACCESSORIES A/C
AV /MM System
Head and Fog Lights
Defogger
Horn
Aux fan
Charging Phone/Tablets
Sub-woofer / Amplifiers
Additional Halogen - Xenon
Engine on, high speed foglamps
Other “high amp”
Full Accessories on
accessories

With engine on and at high

speed , the battery will still
help the alternator in
BATTERY supplying the power to
accessories, should the rated
capacity of the alternator is
exceeded
“ ”
 “

• If the vehicle won’t start , what is the first

thing that you would think that caused the
problem?
• “ The battery is always the culprit “

NOT EVERY STARTING PROBLEM IS DUE TO

THE BATTERY !
 UNDERCHARGING

• Undercharging is the
condition wherein the
charging system is
supplying too little/ not
enough to properly charge
the battery
• A faulty (under)charging
system will not charge the
battery to full capacity.
• Depending on the at rest
battery state of charge
(SOC) and engine speed,
charging voltage normally
ranges from 13.5V up to
14.7V (also depending on
battery chemistry).
 CAUSES OF UNDERCHARGING

• On Board Vehicle Battery Charging

– Voltage Regulator (VR) Issues
• Worn out components / Wrong Setting
– Alternator Problems
• Faulty IC sensor, Diode / worn carbon brushes
– Loose Alternator Belt Setting or damaged
alternator belt / pulley
• External Battery Charging
– Faulty Battery Charger
• Worn out components, wires and clamps
– Improper Battery Charger Usage
• Not following manufacturers / manual
instructions
 EFFECTS OF UNDERCHARGING

• Hassle of not able to reliably start the engine

– Need to have the battery “recharged” more
frequently if the root cause of the problem is
not properly diagnosed

• Decreased Battery Lifespan /Premature Failure

– Severe undercharging allows sulfate crystals to
form on the plates / become hard (crystallized) and
impossible to remove by normal charging. This
phenomenon is called “Sulfation”
• Sulfation is the electro-chemical
phenomenon that leads to a buildup
of lead sulfate crystals to the surface of
battery plates and is one of the top
causes of premature battery failure
in lead-acid batteries.
• The damaged caused by
battery sulfation is easily preventable and
in some cases, can be reversible.
 Normal /
“Good” Plate

Lead Sulfate
Crystals
• Sulfation occurs when a battery is deprived of
a full charge, it (lead sulfates) builds up and
remains on battery plates.
• When too much sulfation occurs, it can impede
the chemical to electrical conversion and
greatly impact battery performance. When
your battery has a buildup of sulfates, the
following can happen:
– longer charging times
– excessive heat build-up
– shorter running times between charges
– dramatically shorter battery life
– complete battery failure
 DISCHARGING PROCESS

PbO2 + Pb + 2H2SO4 → 2PbSO4 + H2O

Recharging ProcessPocess)

2PbSO4 + H2O → PbO2 + Pb + 2H2SO4

• All lead acid batteries will accumulate
sulfation in their lifetime as it is part of the
natural chemical process of a battery.
• Sulfation builds up and causes problems
when;
• A battery is stored without a full charge
• A battery is stored above 80F / 27C and not
properly maintained (OCV below 12.4V) for an
extended period of time
• For every 10F / 3C above room temperature, the rate
of self-discharge doubles.
• Electrolyte solution levels is already way below
the plate top border / 50% of plate area
already exposed to air
• Practice FIFO or First in – First out
– This rule is very important, regardless if the
battery is MF or LM, more importantly if the
battery is already activated (Dilute Sulfuric
Acid / Electrolyte is already in the battery).
• All batteries will lose charge when not in service .
This is known as self discharge
• Allowing the batteries to stand for an extended
period of time , without proper / scheduled
recharging will result to reduced performance and
impact negatively the service life.
• Periodic Checking of Open Circuit Voltage
(OCV) / Part of Inventory Maintenance
– One of the easiest ways to prevent battery
sulfation is proper battery storage and
maintenance.
– When a battery is stored, even if it’s stored at
a full charge, a battery must be charged
enough after periodic inspection to prevent it
from dropping below 12.4 volts.
– Applying this maintenance charge will prevent
sulfates from building up.
• Make sure the electrolyte level is at least “mid to
top” of the acid indicator level in the event that
the batteries are going to be stored for some
time - especially for activated LM “ Low
Maintenance” batteries

Top up with
distilled water
as needed
before storage
• Sulfation of Batteries starts when specific
gravity falls below 1.220 or open circuit
voltage measures less than 12.40V (70% SOC).
• Check the battery voltage (wetcharged /
activated ) after 3 to 4 months in storage
(depending on ambient temperature of
storage area).
• Avoid letting the battery voltage fall below
12.40V for extended period of time
Using 1.280 SG Dilute Sulfuric Acid (Ca-Ca MF) and 1.260 (Low SB LM) as Initial Fill
 Recommended
Recharging
Voltage Point

Using 1.260 - 1.280 SG Dilute Sulfuric Acid as Initial Fill

 OVERCHARGING
• Overcharging is the condition
wherein the charging system is
supplying too much charge to
the battery
• Overcharging by the battery
charging system causes
excessive gassing and high
internal heat, resulting to
accelerated water loss.
• Too much gassing can lead to
the premature shedding of
active material from the
plates.
• Too much heat can also
oxidize the positive plate
material and warp the plates.
 CAUSES OF OVERCHARGING

• On Board Vehicle Battery Charging

– Voltage Regulator (VR) Issues
• Worn out components / Wrong Setting
– Alternator Problems
• Faulty IC sensor / diodes
• External Battery Charging
– Faulty Battery Charger
• Worn out components
– Improper Battery Charger Usage
• Not following manufacturers / manual instructions
– Leaving it on a Battery Charger for Too Long
• Usually happens to manual set chargers
EFFECTS OF OVERCHARGING
 EFFECTS OF OVERCHARGING

• Battery Lifespan Decrease or Dead Battery

– Extreme heat stress on plates causing grid buckling,
active material shedding leading to lower capacities
and eventually short circuit
• Battery Swelling and Melting
– Extreme heat causes excessive gas generation /
pressure build up
 EFFECTS OF OVERCHARGING

• Battery Leaking
– Extreme heat and pressure forcing acid to leak out of
the vents
• Battery Exploding
– Extreme heat and pressure causing battery cover / case
to fail
 REPEATED CYCLING

• Repeated cycling from fully charged to

(almost) fully discharged and back may
cause loss or deterioration of active
materials from the positive plates. This
reduces battery capacity and its useful
life.
• SLI batteries are designed for short but
high current discharges and once engine
starts, the alternator automatically
recharges the battery.
 Elevated Battery
Temperatures
• Anticipated battery life is
specified by the manufacturer for
batteries installed in an
environment at or near the
reference temperature of 25°C
(77°F).

• Above this temperature, battery

life is reduced. The chief aging
mechanism is accelerated
corrosion of the positive plates,
grid structure, and strap, which
increases exponentially as a
function of temperature.

• Elevated temperatures
accelerates battery life. An
increase of 8.3°C (15°F) can
reduce lead-acid battery life by
30% - 50% or more.
Elevated Battery
Temperatures
 EFFECTS OF ABNORMALLY
ELEVATED BATTERY TEMPERATURES

• Battery Lifespan Decrease or Dead Battery

– Extreme heat stress on plates causing grid buckling,
active material shedding leading to lower capacities
and eventually short circuit
• Battery Swelling and Acid Leaks
– Extreme heat causes
excessive gas generation
/ pressure build up resulting to
Bulging container and possibly
Acid leaking out the vents
• Battery Explosion
– Extreme heat and pressure
causing battery cover / case
to fail
 How to Check For and Fix an
Overcharged Battery?

• There are only two fixes for overcharging

batteries.
– The first is not as much of a fix as it is a
precaution: do not overcharge the battery.
– The second fix for an overcharged battery is to
replace it. If the battery melts, swells, or
explodes, it is obvious that a replacement is
necessary.
• If your vehicle’s alternator or voltage
regulator is to blame for an overcharged
battery, a fix for those components may
accompany a battery replacement if the
damage is too extensive for the battery.
UNWANTED / EXTREME VIBRATION

• Extreme Vibration can loosen

internal connections (Intercell
Welds), crack the terminal post
or case and damage internal
components of the batteries.

• Common causes of unwanted

vibration damage to the battery
are loose fitting or missing /
non-existence of battery hold-
down clamps.

• Not only the battery is in danger

but also engine components near
the battery are subject to
unwanted contact with the “loose
battery”, causing damage the
nearby engine components.
 HOW TO AVOID UNWANTED VIBRATION
DAMAGE TO THE BATTERY

• Properly secure the battery using OE / Proper

Replacement Battery Hold Down Clamps

• Do not over torque the

horizontal clamp bar nuts
to avoid damaging the
cover
- This may cause cracks
on the cover or damage
the weld between the
cover and container
 IMPROPER USAGE OR
MISAPPLICATIONS

• Not all batteries are

created “equal”
• Batteries are
commonly designed
for a specific use.
• If the battery is not
designed for a given
application, it might
not meet its life or
performance
expectations.
 IMPROPER USAGE OR
MISAPPLICATIONS
• Never use a SLI battery for deep cycle
applications.
• Deeper than designed discharge/charge
cycles will result to premature active
material shedding / shorter service life.
– Starting and deep cycle applications
• Starting – 5 to 20 % DOD or depth of discharge
• Deep cycle – up to 60% - 80 % DOD
• For deep discharge applications – use
deep cycle batteries
 IMPROPER USAGE OR
MISAPPLICATIONS
• Avoid using a “smaller battery” for “bigger
battery” applications
• Heavier than normal discharge (relative to the standard battery) will
result to accelerated active material shedding / shorter service life.
• Use “OEM” Standard Specification Batteries, i.e. if OE Spec is 100AH –
use 100AH

• Example: Using 2x70AH

batteries in an application
requiring 2x100AH batteries
 IMPROPER USAGE OR
MISAPPLICATIONS
• Avoid using a “smaller battery” and a
“bigger battery” together (12V - 24V Applications)
• The “smaller” battery will wear out faster vs the “bigger
battery” due to unequal charging rates causing premature active
material shedding / shorter service life.
• Use “OEM” and Same Size / Specification Batteries, i.e. if
OE Spec is 100AH >> use 100AH

– Example: Using 2x80AH

And 2x120AH batteries in an
application originally specified
requiring 4x100AH Batteries
for 24V / 200AH
• A weak car battery doesn’t necessarily mean it is
already dead. It could be that the battery is just
on a discharge state approaching 50% or lower
(12.25V or lower)
• Hard starting – a healthy or fully charge battery
will give the starter that normal spin the first time
you turn on the ignition. Two or more attempts
is considered hard starting
• Vehicle non starting – you will hear just a clicking
sound . This would mean that the battery is too
weak ( low voltage ) or dead-flat to turn the
starter motor
• Headlights – dimming headlights can be a sign of a weak
battery
• Electrical accessories – with the engine off, try using the
accessories (radio / AV , power window etc..) . If the
battery charge is low, some or all of the accessories will
be sluggish / operating slower than normal.
• An engine running at idle suddenly dies when a “high
amp” component such as aircon or AV system is turned
on.
• Check the battery icon on the dashboard – the battery
icon usually appears / illuminated when there is problem
in your battery.
• Battery icon in dashboard also appears / illuminated
when there is problem with the alternator belt tension or
alternator itself
Technicians should check these , as these may affect performance of the battery
• Failure to PERIODICALLY check and add distilled
water or Topping Up using Sulfuric Acid instead of
Distilled Water for Low Maintenance (LM) Batteries
– Higher specific gravity leads to accelerated corrosion /
short life

USE DISTILLED
WATER ONLY
• Ignoring “dirty” or corroded terminal posts
• Higher Resistance on the terminal post due to corrosion.
– Wash affected terminal(s) with Warm Water and Baking
Soda and brush away the corrosion
• When terminal corrosion happens even after frequent
cleaning – it is time to change your battery
• Ignoring “loose” terminals clamps – may lead to
engine not starting and even possibly -explosion of
the battery
– Ensure “tight fit” but do not overtighten clamp bolts
– Use the right tools
– Check out for worn-out terminal posts / terminal clamps / nut & bolt
• Always having very short trips and leaving the
vehicle unused for long periods of time
– Short trips will not properly charge the battery to optimum state
of charge levels
– Not using the vehicle for extended period of time, i.e. 4 – 12 weeks
will drain the battery, resulting to battery plate sulfation
• Use the vehicle for at least 30 minutes continuously
running with at least 2000 rpm for 15mins or more to
charge the battery in the morning so only the basic load
are used at least once a week. The more time on the road
– the better opportunity to fully charge the battery.
• If you have a battery charger – check properly the
charger settings and charge the battery before installing
to the vehicle
For Illustration Purposes only – use
correct hydrometer scale
 Rubber Bulb

SG variance per cell should not

exceed 25 points (0.025)
 CORRECT ACID LEVEL
1. Maintain Acid level within the “MIN – MAX” lines.
2. Check electrolyte level at least -3mm to -5 mm below the vent
well. DO NOT OVERFILL Cover

Vent
hole

Vent
Acid Level Lines
well
•Install in upright position
•Always connect the positive before the negative
–Connect the positive cable to the positive terminal
•When removing the battery, disconnect the
negative cable before the positive
• Avoid installing the battery cables in Reverse .
Even for a short time , it will damage the wiring and
electronic parts.
• For extra precaution, make sure the key is not in
the key hole when installing or removing a battery.
• Use Auxiliary “Jumper” Batteries

Eliminate possibilities of resetting the ECU and other memory dependent

electrical components such as radio, etc.
LOAD TESTER
• Use proper tools & testers
when checking a battery. Do
not “short” the battery when
checking for “Charge
Strength”
24V-12V DC-DC CONVERTER

• For a 24 volt system, do not

connect 12 volts accessories
to a single battery. This will
shorten the life of the battery
 NOTE : FOR ILLUSTRATION
PURPOSES ONLY

“Wire Tap”

24 VOLT SYSTEM

12 volt Cab Fan

• Use the right tools for installing &
removal of the battery

• Do not Force Fit the Terminal Clamps

• Do not store the battery in discharged condition

• Avoid using electrical accessories for an extended

period of time with the engine turned off

• Use the correct charger. Carefully read and

understand the instruction manual prior to
using the charge.
Keep Away From
Flames, Sparks,
No Smoking when Explosive – Emits
working with Hydrogen Gas
batteries

Corrosive – Keep Away From

Sulphuric Acid, Children
Can cause severe
burns and
blindness Wear Safety Goggles Read and Understand
when working with Carefully Battery and
Batteries Equipment Manuals
 PROPER STORAGE OF
NEW / RE-USABLE BATTERIES
• Proper usage and replenishment
planning needed to minimize
battery storage time
• Store SLI batteries in a cool, well
ventilated and covered area away
from direct sunlight / rain
• Store SLI batteries in either racks
and / or in pallets to minimize
space vis a vis single layer on
floor
• Segregate old but serviceable
batteries to another location
• If possible, store batteries with
the same size / classification in
one location and other sizes in
another location
• Maintain FIFO storage
procedures
 PROPER STORAGE OF
NEW / RE-USABLE BATTERIES
New and (Old but re-usable) Batteries Storage in Racks
 PROPER STORAGE OF
NEW / RE-USABLE BATTERIES
Used and Tested Batteries for Re-Use in Battery Rack
 PROPER STORAGE OF
USED LEAD ACID BATTERIES
Used Batteries in pallets for Disposal
Any more questions?
RSR
 POST TRAINING
BASIC BATTERY TEST
(2 Minutes)
Happy to be of Service to You