Repair Area, Built-In Test & Battery Visual Inspection Information
VEHICLES IN THE REPAIR AREAIf a vehicle is going to be in the repair area for a prolonged period of time, the technician should disconnect the battery except when battery use is required for the repair. This will avoid battery drains from an open hood, deck lid, doors, etc.
The battery is the primary component in the vehicle's electrical system. It is very important that the battery be capable of delivering the current when necessary, as well as accepting current under charging conditions.
Another important function of the battery is as a giant capacitor (shock absorber) in the electrical system. It absorbs surges and acts as a buffer to the electrical system under short-term high-load conditions.
All vehicles are equipped with maintenance-free batteries. They have nonremovable battery caps, and never require the addition of water. The battery is sealed except for small vent holes in the cover. The ability to seal the battery is a result of special chemical composition changes made within the battery and the plates. These changes allow only very small amounts of gasses to be generated under normal conditions.
BUILT-IN TEST INDICATOR
The battery contains a visual test indicator, or hydrometer, molded into the top of the battery case. The test indicator will visually display the "state of charge" of the battery. When the battery is at an adequate state of charge (100% to 75%), the indicator will be GREEN. When charging is required, the indicator will be BLACK or dark (75% to 50%) or RED (50% to 0%). Replacement of the battery will be necessary if the test indicator is YELLOW or bright in color. This would be an indication of low fluid level.
The test indicator is a built-in hydrometer on top of the battery case. it provides visual information for battery testing. The test indicator is to be used with accepted diagnostic procedures only. It should not be used to determine if the battery is good or bad.
It is important when observing the test indicator that the battery be relatively level, and the indicator itself be clean. A light may be required to view the indicator.
Under normal operating conditions, one of four conditions can be observed with a maintenance-free battery
1. GREEN DOT
Any green appearance is interpreted as a "GREEN DOT" (100% to 75% state of charge), and the battery is adequately charged for testing. On rare occasions following prolonged cranking, the green dot may still be visible with a low battery voltage (below 12.4 volts) indicated on your voltmeter. Should this condition occur, charge the battery as described in the shop manual under "Battery Charging Procedures."
2. DARK OR BLACK DOT
A DARK or BLACK DOT (50% to 75% state of charge) indication is a result of the battery being partially discharged, but not below the 45% level. The battery should be checked and charged until the GREEN DOT visible prior to performing a load test.
3. RED DOT
A RED DOT visible in the viewing port will be an indication that the battery is BELOW a 50% state of charge and it will be necessary to charge the battery until the GREEN DOT is visible, PRIOR to performing any testing. DO NOT let the battery remain in a discharged state as internal damage may occur.
WARNING: ON RARE OCCASIONS, THE TEST INDICATOR MAY TURN A "LIGHT YELLOW" OR "BRIGHT" COLOR. THIS INDICATES A LOW ELECTROLYTE LEVEL. THE VEHICLE'S CHARGING SYSTEM SHOULD BE THOROUGHLY CHECKED FOR AN OVERCHARGING CONDITION. ALTHOUGH THE BATTERY MAY BE CAPABLE OF FUTURE SERVICE, REPLACE IT. DO NOT ATTEMPT TO CHARGE, TEST, OR JUMP START THE VEHICLE.
BATTERY VISUAL INSPECTION
1. Make sure the ignition switch is in the "OFF" position and all battery feed accessories are off.
2. Disconnect the battery cables at the negative cable first.
3. Remove battery hold-down clamp and remove battery from vehicle.
WARNING: CARE SHOULD BE TAKEN, IN THE EVENT THE BATTERY CASE IS CRACKED OR LEAKING, TO PROTECT HANDS FROM THE ELECTROLYTE. A SUITABLE PAIR OF NON-ABSORBENT GLOVES SHOULD BE WORN WHEN REMOVING THE BATTERY BY HAND.
4. Clean the top of the battery with a solution of clean warm water and baking soda. Scrub area with a stiff bristle brush and wipe off with a cloth moistened with ammnonia or baking soda and water.
5. Inspect battery case and cover for cracks. If cracks are present, the battery must be replaced.
6. Inspect the battery tray for damage caused by loss of acid from the battery. If acid damage is present, it will be necessary to clean the area with the same solution as described in Step 4.
7. Clean the battery posts with a suitable battery post cleaning tool.
8. Clean the inside surfaces of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables and broken terminal clamps.
9. Inspect the battery for damage around the hold-down ledge. If damage is present, replace the battery.
10. Install the battery in the vehicle, making sure that the battery is properly positioned in the battery tray. Install the hold-down clamp and bolt. Tighten the battery hold-down clamp bolt (refer to the service manual for proper torque specification).
11. Connect the cable clamps to the battery posts, making sure that the clamps are flush with the tops of the battery posts. Tighten the clamps securely, and coat all connections with mineral grease after tightening.
WARNING: WHEN BATTERIES ARE BEING CHARGED, AN EXPLOSIVE GAS MIXTURE FORMS BENEATH THE BATTERY COVER OF EACH CELL. DO NOT SMOKE NEAR BATTERIES ON CHARGE OR WHICH HAVE RECENTLY BEEN CHARGED. DON'T BREAK LIVE CIRCUITS AT THE TERMINALS OF THE BATTERY ON CHARGE, A SPARK WILL OCCUR WHERE THE LIVE CIRCUIT IS BROKEN. KEEP ALL OPEN FLAMES AWAY FROM THE BATTERY.
When it is necessary to charge a sealed battery, the following safety procedures must be followed:
1. Do not charge the battery if "GREEN" except immediately following prolonged cranking.
2. Do not charge the battery if the test indicator is a "LIGHT YELLOW" or "BRIGHT" color. REPLACE THE BATTERY.
3. If the battery feels HOT (125 degrees F, 52 degrees C) or if excessive gassing occurs through the vent holes, discontinue charging or reduce the charging rate IMMEDIATELY.
CAUTION: CHARGE THE BATTERY ONLY UNTIL THE GREEN DOT APPEARS. DO NOT OVERCHARGE.
Slight tapping or shaking of the battery may be necessary to make the-GREEN DOT appear.
There are many types of battery charging equipment available. Be sure to follow the instructions of the equipment manufacturer for the necessary preparations and precautions. However, the following items should be observed when slow charging the battery with any type of equipment:
1. If the battery is to remain in the vehicle, disconnect the cables at the battery negative cable first to prevent damage to the electrical system during charging.
2. Thoroughly clean the battery. Refer to "Battery Visual Inspection."