MECHANICAL ENGINEERING DEPARTMENT

DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)

ELECTRICAL (BATTERY)
CONDUCT AUTOMOTIVE BATTERY TEST, SERVICING, MAINTENANCE AND
TITLE
JUMP START PROCEDURES

CLO 1. Proceed troubleshooting method of automotive systems.

2. Follow skill for servicing automotive systems.
3. Demonstrate the ability to work as individual and as a team to complete assigned task.

At the end of the session the students will be able to:

OBJECTIVE 1. Execute voltage measurement using multimeter
2. Execute high discharge rate test using high discharge rate tester
3. Execute specific gravity measurement of electrolyte using hydrometer
4. Clean corrosion from terminal using hot water
5. Fasten battery terminals to torque
6. Correct electrolyte level
7. Execute correct procedure for battery charging using a battery charger
8. Connect jump start cable from weak battery to fully charged battery

INTRODUCTION / BASIC THEORY

Automotive battery have three main function to a vehicle which is to :

a) Supply current to the vehicle electrical system.
b) Store and receive current that supplied from charging system.
c) Stabilize voltage for the entire vehicle electrical system.
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)
Battery consists of several parts such as battery case, terminals, vents, separator, plates and electrolyte.

 Battery Case
Battery case holds battery components and electrolyte. It is made from plastic. Every cell in the case is
separated by a separator. The amount of separator is depends to the battery voltage. For example, 12 V
batteries have six separators which mean every cell is 2V.

 Vent caps
When battery is charged, the vent caps release hydrogen gases that produced due to chemical reaction
that happens in the battery.

 Terminal
Terminals function acts as source to supply electricity. It is made from plumbum. Positive terminal is
marked by (+) or red cable. While negative terminal is marked (-) or black/green cable. Positive terminal
is bigger than the negative terminal.

 Plate
Positive plates are made from plumbum peroxide (PbO2). Negative plates are made from plumbum (Pb).
Both plates react with the electrolyte to produce electricity. In every battery cell, the negative plates are
one more from positive plates. Battery ability depends on the amount of plates, plates size and electrolyte
density.

 Separator
Separator is made from paper and plastic mixture. It is placed between the positive plates and negative
plates so that the plates will not attached together.

 Electrolyte
Consists of a solution of about 35% sulfuric acid and 65% distilled water. It reacts with plumbum plates
to produce electricity. A new battery usually have electrolyte filled

Hydrometer Test Table

Specific
State of Charge Colour
Gravity
1.265-1.299 Fully Charged battery Green
1.235-1.265 Three-fourths Charged Yellow
1.205-1.235 One-half Charged Red
1.170-1.205 One-fourth Charged
1.140-1.170 Battery operative
1.110-1.140 Completely discharged

APPARATUS / MATERIALS / TOOL /EQUIPMENT

(either one)

 Combination spanner set

 Screw driver set
 Multimeter
 Hydrometer
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)
 Battery Charger
 Load Tester
 Sand Paper
 Goggle
 Battery Wire Brush
 Distilled Water
 Automotive Battery – 12 V

SAFETY

1. Understand the safety procedures specified by the lecturer.

2. Always aware, any machine or tool used in the practical task.
3. Perform your task in an organized manner as this can minimize the risk of accident occur.
4. Read and follow the experimental method and check with the lecturer if any problem occurs.
5. If electrolyte contact to the exposed to body parts, wash with lot of clean water. If contact with eyes,
wash with a lot of clean water and get medical attention immediately.
6. Never charged a battery in a vehicle using battery charger.

PROCEDURES:

1. Execute Voltage Measurement Using Multimeter

 Select a random battery in the workshop.

 Prepare multimeter for the voltage measurement.
 Change to suitable range.
 Connect the multimeter positive terminal to battery positive terminal.
 Connect the multimeter negative terminal to battery negative terminal.
 Observe the readings on the multimeter.
 Fill in the measurement table in result.
 If voltage less than 9.5 V, the battery need to be
charged.
 Charge the battery if necessary and conduct the
test again.

2. Execute High Discharge Rate Test Using High Discharge Rate Tester

 This test is conduct to test battery condition.

 Voltage is measured after battery highly discharged.
 Prepare a load tester.
 Connect the load tester positive terminal to battery positive terminal.
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)
 Connect the load tester negative terminal to battery negative
terminal.
 Switch ON load tester for 10 second.
 Observe the readings on the load tester.
 Fill in the measurement table in result.
 If voltage less than 9.5 V, the battery need to be charged.
 Charge the battery if necessary and conduct the test again.

3. Execute Specific Gravity Measurement Of Electrolyte Using

Hydrometer

 Check the electrolyte level.

 Wear suitable eye protection
 Open all the vent caps.
 Use hydrometer to test the specific gravity and measure the readings.
 Squeeze the hydrometer bulb and insert the pickup tube into the cell closest to the battery positive
terminal.
 Slowly release the bulb to draw in only enough electrolytes to cause the float to rise. Do not remove
the tube from the cell

 Read the specific gravity indicated on the float. Be sure the float is
drifting free, not in contact with the sides of top of the barrel.
 Bend down to read the hydrometer at eye level. Disregard the slight
curvature of liquid on the float.
 Compare it to the Hydrometer Test Table
 Repeat the test to every cell.
 Fill in the measurement table in result.
 Charge the battery if necessary and conduct the test again.
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)

4. Clean Corrosion From Terminal Using Hot Water

 Do a visual inspection on the physical condition of the battery installed on the engine stand.
 Check for cracks in the battery case and broken terminals.
 Check for cracked or broken cables or connection.
 Observe the battery terminal, clamp and hold down for sulfuric acid corrosion or dirt.
 Clean the corrosion with mild solution of baking soda and water or hot water
 Clean the terminal post and inside of the clamp with a battery wire brush

5. Fasten Battery Terminals To Torque

 Check for loose battery hold-down or loose cable

connections. Tighten every connection.
 Clean and tighten the battery terminal tightly
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)
6. Correct Electrolyte Level

 Check electrolyte fluid level. The level can be viewed

through the translucent plastic case or by removing the
vent caps and looking directly into each cell.
 The proper level is 0.5 inch above the separators.
 Add distilled water if necessary. Do not overfill

7. Execute Correct Procedure For Battery Charging Using A

Battery Charger

 Prepare the battery charger.

 Put the battery on a board and open the vent caps
 Connect the jumper cable according to the series or parallel connection.
 Adjust the charger according to suitable voltage and current.
 Switch ON the battery charger.
 Let the battery charged for the duration that set in the battery charger.

8. Connect Jump Start Cable From Weak Battery To Fully Charged Battery

 Jump starting a dead battery with booster cable or battery a car can be dangerous.
 Proper sequence connections will prevent sparks.
 Connect the two positive terminals, one from the good battery and the other to the dead battery.
 Connect one end of the jumper cable to the negative terminal of the booster (Good) battery.
 Connect the other end to a good ground on the engine away from the dead battery.
 If a spark occurs, it won’t near the battery,thus reducing the chance for explosion.
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)

 If the jump starting from another vehicle, start the engine and run the engine at 1500 rpm for a few
minutes.
 While the engine is running, start the dead vehicle

RESULT, ANALYSIS AND DISCUSSION

1. Battery Cross-Section Sketching

2. Draw charging system circuit in automotive vehicles
3. Voltage measurement using multimeter and high discharge rate tester:

TESTER Voltage Readings (V) Before Charged Voltage Readings (V) After Charged
1 2 3 Average 1 2 3 Average
Multimeter
Load Tester

4. Specific gravity measurement

i) Before Charged

Specific Gravity Readings Comment

Value Colour
Vent Cap Code
1
2
3
4
5
6
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)

ii) After Charged

Specific Gravity Readings Comment

Value Colour
Vent Cap Code
1
2
3
4
5
6

5. Explain the battery voltage and specific gravity measurement test result that conducted in this practical
task.
6. Describe the chemical reaction that happens when battery is charged.
7. Explain how to charge battey in series connection and parallel connection using battery charger. Sketch
the circuit involved in the connection.
8. Decsribe how to check electrolyte fluid level and condition.
9. Explain the service and maintenance that involved in ensuring battery life is longer
10. List the safety precautions needed when performing jump start procedure

CONCLUSION

Do a conclusion about the task performed.

REFERENCES

List out all the sources of references

1. Automotif Elektrik dan Diesel. Terbitan Dewan Bahasa dan Pustaka. Edisi 2005
2. Battery Service by Kevin R Sullivan, Skyline College. (www.autoshop101.com)
 MECHANICAL ENGINEERING DEPARTMENT
DJA20032 – AUTOMOTIVE
WORKSHOP PRACTICE 1 (LABSHEET /
WORKSHEET)