OBJECTIVES
After studying Chapter 16, the reader should be able to:
1. Prepare for ASE Electrical/Electronic Systems (A6)
certification test content area (Battery Diagnosis
and Service).
2. Describe how a battery works.
3. List battery ratings.
4. Describe deep cycling.
5. Discuss how charge indicators work.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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PURPOSE OF A BATTERY
• Everything electrical in a vehicle is supplied current
from the battery.
• The battery is one of the most important parts of a
vehicle because it is the heart or foundation of the
electrical system.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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BATTERY CONSTRUCTION
• Most automotive battery cases (container or covers)
are constructed of polypropylene, a thin
(approximately 0.08 in. [0.02 mm]thick), strong, and
lightweight plastic.
• Built into the bottom of many batteries are ribs that
support the lead-alloy plates and provide a space
for sediment to settle, called the Sediment
Chamber.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
BATTERY CONSTRUCTION
FIGURE 16-1 A typical polypropylene plastic battery case.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
GRIDS
• Each positive and
negative plate in a
battery is constructed
on a framework, or
grid, made primarily of
lead.
FIGURE 16-2 The grid provides support for the
plate active material.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Maintenance-Free versus Standard Battery Grids
• Maintenance-free batteries use calcium instead of
antimony, because 0.2% calcium has the same
strength as 6% antimony.
• Low-maintenance batteries use a low percentage of
antimony(about 2% to 3%), or use antimony only in
the positive plates and calcium for the negative
plates.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Radial-Grid Design
• Some batteries use a grid
design with only vertical
and horizontal strips.
• The current must move
over and up along the grid
strips to reach point A.
FIGURE 16-3 Current created at point B must
travel to point A to be able to reach the battery
terminals.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Radial-Grid Design
• With a radial grid design
(radial means branching
out from a common center),
the current generated near
point B can travel directly to
point A.
FIGURE 16-4 Radial design battery grids
permit lower resistance for current flow by
joining the branches of the grids.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Positive Plates
• The positive plates have lead dioxide (peroxide)
placed onto the grid framework.
• This active material can react with the sulfuric acid
of the battery and is dark brown in color.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Negative Plates
• The negative plates are pasted with a pure porous
lead,called sponge lead, and are gray in color.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Separators
• The positive and the negative plates must be
installed alternately next to each other without
touching.
• Many batteries use envelope-type separators that
encase the entire plate and help prevent any
material that may shed from the plates from causing
a short circuit between plates at the bottom of the
battery.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Cells
• Cells are constructed of
positive and negative plates
with insulating separators
between each plate.
• Most batteries use one
more negative plate than
positive plate in each cell.
FIGURE 16-5 Two groups are interlaced
to form a battery element.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Partitions
• Each cell is separated from
the other cells by
partitions,which are made
of the same material as that
used for the outside case of
the battery.
FIGURE 16-6 A cutaway battery showing
the connection of the cells to each other
through the partition.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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GRIDS
Electrolyte
• The electrolyte used in automotive batteries is a
solution (liquid combination) of 36% sulfuric acid
and 64% water.
• This electrolyte is used for both lead-antimony and
lead-calcium(maintenance-free) batteries.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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HOW A BATTERY WORKS
• A fully charged lead-acid battery has a positive plate
of lead dioxide (peroxide) and a negative plate of
lead surrounded by a sulfuric acid solution
(electrolyte).
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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HOW A BATTERY WORKS
During Discharging
• The positive plate lead
dioxide (PbO2) combines
with the SO4, forming
PbSO4 from the electrolyte
and releases its O2 into the
electrolyte, forming H2O.
FIGURE 16-7 Chemical reaction for a lead-acid
battery that is fully charged being discharged by
the attached electrical load.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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HOW A BATTERY WORKS
The Fully Discharged State
• When the battery is fully discharged, both the
positive and the negative plates are PbSO4 (lead
sulfate) and the electrolyte has become water
(H2O).
Diagnosis and Troubleshooting of Automotive Electrical,
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By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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HOW A BATTERY WORKS
During Charging
• During charging, the sulfate
(acid) leaves both the
positive and the negative
plates and returns to the
electrolyte, where it
becomes normal-strength
sulfuric acid solution.
FIGURE 16-8 Chemical reaction for a lead-acid
battery that is fully discharged being charged by
the attached generator.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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SPECIFIC GRAVITY
• The amount of sulfate in the
electrolyte is determined by
the electrolyte’s specific
gravity, which is the ratio of
the weight of a given
volume of a liquid to the
weight of an equal volume
of water.
FIGURE 16-9 As the battery becomes discharged, the
specific gravity of the battery acid decreases.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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SPECIFIC GRAVITY
Charge Indicators
• Some batteries are
equipped with a built-in
state-of-charge indicator.
• When the ball floats, it
appears in the
hydrometer’s sight glass,
changing its color.
FIGURE 16-10 Typical battery charge
indicator. If the specific gravity is low (battery
discharged), the ball drops away from the
reflective prism. When the battery is charged
enough, the ball floats and reflects the color
of the ball (usually green) back up through
the sight glass, and the sight glass is dark.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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SPECIFIC GRAVITY VERSUS STATE OF CHARGE AND
BATTERY
• VOLTAGE
– Values of specific gravity,
state of charge, and battery
voltage at 80°F (27°C) are
given in the following list.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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VALVE REGULATED LEAD-ACID BATTERIES
• There are two basic types of valve regulated leadacid (VRLA), also called sealed valve-regulated
(SVR) or sealed lead-acid (SLA), batteries.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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VALVE REGULATED LEAD-ACID BATTERIES
Absorbed glass mat (AGM).
• The acid used in an
absorbed glass mat (AGM)
battery is totally absorbed
into the separator, making
the battery leak-proof and
spill proof.
FIGURE 16-11 An absorbed glass mat battery
is totally sealed and is more vibration resistant
than conventional lead-acid batteries.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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VALVE REGULATED LEAD-ACID BATTERIES
Gelled electrolyte batteries.
• In a gelled electrolyte battery, silica is added to the
electrolyte, which turns the electrolyte into a
substance similar to gelatin.
• This type of battery is also called a gel battery.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CAUSES AND TYPES OF BATTERY FAILURE
• Most batteries have a
useful service life of three
to seven years; however,
proper care can help
increase the life of a
battery, but abuse can
shorten it.
FIGURE 16-12 Battery that was accidentally
left over the weekend on a battery charger
that was set for a high charge rate. Note how
the plates warped and the top blew off.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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BATTERY HOLD-DOWNS
• All batteries must be attached securely to the
vehicle to prevent battery damage.
• Battery hold-down clamps or brackets help reduce
vibration, which can greatly reduce the capacity and
life of any battery.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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BATTERY RATINGS
• Batteries are rated according to the amount of
current they can produce under specific conditions.
–
–
–
–
–
Cold-Cranking Amperes
Cranking Amperes
Marine Cranking Amperes
Reserve Capacity
Ampere Hour
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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DEEP CYCLING
• Deep cycling is almost fully discharging a battery
and then completely recharging it.
• Charging is hard on batteries because the internal
heat generated can cause plate warpage, so these
specially designed batteries use thicker plate grids
that resist warpage.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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BATTERY COUNCIL INTERNATIONAL GROUP SIZES
• The Battery Council International (BCI) organization has
established battery group size designations.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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BATTERY COUNCIL INTERNATIONAL GROUP SIZES
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
Pearson Prentice Hall - Upper Saddle River, NJ 07458
BATTERY COUNCIL INTERNATIONAL GROUP SIZES
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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WHAT CAN CAUSE A BATTERY TO EXPLODE?
• Batteries discharge hydrogen gas and oxygen when being
charged. If there happens to be a flame or spark, the
hydrogen will burn.
FIGURE 16-13 (a) A small spark inside the battery was the most likely cause of this
battery explosion. Parts of the battery were thrown 30 ft (10 m); luckily, no one was
around the vehicle at the time. (b) Because battery acid was spilled and sprayed
around the battery, the entire area was rinsed with water after unplugging the
battery charger.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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SUMMARY
1. Maintenance-free batteries use lead-calcium grids
instead of lead-antimony grids to reduce gassing.
2. When a battery is being discharged, the acid
(SO4) is leaving the electrolyte and being
deposited on the plates. When the battery is being
charged, the acid (SO4) is forced off the plates
and back into the electrolyte.
3. Batteries are rated according to CCA and reserve
capacity.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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REVIEW QUESTIONS
1. Explain why discharged batteries can freeze.
2. Identify the three most commonly used batteryrating methods.
3. Explain why a battery can explode if exposed to an
open flame or spark.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
1. When a battery becomes completely
discharged, both positive and negative
plates become _____ and the electrolyte
becomes _____.
a)
b)
c)
d)
H2SO4 /Pb
PbSO4 /H2O
PbO2 /H2SO4
PbSO4 /H2SO4
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
1. When a battery becomes completely
discharged, both positive and negative
plates become _____ and the electrolyte
becomes _____.
a)
b)
c)
d)
H2SO4 /Pb
PbSO4 /H2O
PbO2 /H2SO4
PbSO4 /H2SO4
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
2. A fully charged 12 volt battery should
indicate _____.
a)
b)
c)
d)
12.6 volts or higher
A specific gravity of 1.265 or higher
12 volts
Both a and b
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
2. A fully charged 12 volt battery should
indicate _____.
a)
b)
c)
d)
12.6 volts or higher
A specific gravity of 1.265 or higher
12 volts
Both a and b
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
3. Deep cycling means _____.
a) Overcharging the battery
b) Overfilling or underfilling the battery with water
c) The battery is fully discharged and then
recharged
d) The battery is overfilled with acid (H2SO4)
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
3. Deep cycling means _____.
a) Overcharging the battery
b) Overfilling or underfilling the battery with water
c) The battery is fully discharged and then
recharged
d) The battery is overfilled with acid (H2SO4)
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
4. What makes a battery “low maintenance” or
“maintenance free”?
a)
b)
c)
d)
Alloy is used to construct the grids.
The plates are constructed of different metals.
The electrolyte is hydrochloric acid solution.
The battery plates are smaller, making more
room for additional electrolytes.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
4. What makes a battery “low maintenance” or
“maintenance free”?
a)
b)
c)
d)
Alloy is used to construct the grids.
The plates are constructed of different metals.
The electrolyte is hydrochloric acid solution.
The battery plates are smaller, making more
room for additional electrolytes.
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
5. The positive battery plate is _____.
a)
b)
c)
d)
Lead dioxide
Brown in color
Sometimes called lead peroxide
All of the above
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
5. The positive battery plate is _____.
a)
b)
c)
d)
Lead dioxide
Brown in color
Sometimes called lead peroxide
All of the above
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
6. Which battery rating is tested at 0°F (18°C)?
a)
b)
c)
d)
Cold-cranking amperes (CCA)
Cranking amperes (CA)
Reserve capacity
Battery voltage test
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
6. Which battery rating is tested at 0°F (18°C)?
a)
b)
c)
d)
Cold-cranking amperes (CCA)
Cranking amperes (CA)
Reserve capacity
Battery voltage test
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
7. Which battery rating is expressed in
minutes?
a)
b)
c)
d)
Cold-cranking amperes (CCA)
Cranking amperes (CA)
Reserve capacity
Battery voltage test
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
7. Which battery rating is expressed in
minutes?
a)
b)
c)
d)
Cold-cranking amperes (CCA)
Cranking amperes (CA)
Reserve capacity
Battery voltage test
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
8. What battery rating is tested at 32°F
(0°C)?
a)
b)
c)
d)
Cold-cranking amperes (CCA)
Cranking amperes (CA)
Reserve capacity
Battery voltage test
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
8. What battery rating is tested at 32°F
(0°C)?
a)
b)
c)
d)
Cold-cranking amperes (CCA)
Cranking amperes (CA)
Reserve capacity
Battery voltage test
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
9. What gases are released from a battery
when it is being charged?
a)
b)
c)
d)
Oxygen
Hydrogen
Nitrogen and oxygen
Hydrogen and oxygen
Diagnosis and Troubleshooting of Automotive Electrical,
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CHAPTER QUIZ
9. What gases are released from a battery
when it is being charged?
a)
b)
c)
d)
Oxygen
Hydrogen
Nitrogen and oxygen
Hydrogen and oxygen
Diagnosis and Troubleshooting of Automotive Electrical,
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CHAPTER QUIZ
10. A charge indicator (eye) operates by
showing green or red when the battery is
charged and dark if the battery is
discharged. This charge indicator detects
_____.
a)
b)
c)
d)
Battery voltage
Specific gravity
Electrolyte water pH
Internal resistance of the cells
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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CHAPTER QUIZ
10. A charge indicator (eye) operates by
showing green or red when the battery is
charged and dark if the battery is
discharged. This charge indicator detects
_____.
a)
b)
c)
d)
Battery voltage
Specific gravity
Electrolyte water pH
Internal resistance of the cells
Diagnosis and Troubleshooting of Automotive Electrical,
Electronic, and Computer Systems, Fifth Edition
By James D. Halderman
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END
Diagnosis and Troubleshooting of Automotive Electrical,
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By James D. Halderman
© 2010 Pearson Higher Education, Inc.
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