T: 03 9492 5878

M: [email protected]
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A: 17 Jeffcott Street West Melbourne VIC 3004

AURETR125 Test, charge and replace batteries and jump-start.

Assessment 1 – Questioning – Written Assessment

Student Name Zhiyang Xu Student ID Number PC001997

Unit Start Date Unit End Date

Assessment Due Date Date Submitted

This cover sheet is to be completed by the student and assessor and used as a record to determine student
competency in this assessment task

The assessment process and tasks were fully explained. Yes / No

I am aware of which evidence will be collected and how. Yes / No

I am aware of my right to appeal an assessment decision. Yes / No

I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their Yes / No
website at Insert Website Link

I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy Insert Website Link

I have access to all required resources? Yes / No

Cheating & Plagiarism Declaration

Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this
declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit
of competency except where the work has been correctly acknowledged.
NOTE: Student MUST sign this prior to submitting their assessments to the assessor

__19____ / __04____ /
Signature Zhiyang XU Date:
2024____

Satisfactory or Not Yet Satisfactory

Assessment Results
(Please circle the assessment result for this task)

Feedback to Student - Please provide general feedback on the Student’s performance

Student Declaration: - I verify that the work completed Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the explained and negotiated the assessment tasks with the
assessment process prior to commencing this student prior to commencing assessment.
assessment task.

Student Name: Zhiyang Xu Assessor’s Name:

Student Signature Date Assessor Signature Date

Zhiyang Xu

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AURETR125 Test, charge and replace batteries and jump-start.

19.04.2024

Student Guide for Written Knowledge Assessment

Overview of This is a written assessment task you will be assess on your knowledge of testing, charging
Assessment and replacing batteries and jump-starting vehicles.
The topics that will be covered in the assessment are:
1. Prepare to test, charge and replace batteries and jump-start vehicle.
2. Test battery.
3. Charge battery.
4. Carry out jump-start procedures.
5. Remove and replace battery
6. Complete work processes
This assessment will ensure that the elements, performance criteria, performance evidence
and knowledge evidence required, and conditions are adhered to demonstrate competency
in this unit assessment task.
 Read the assessment carefully before commencing.
 Your Assessor will use the assessment criteria in this document and will provide
feedback / comment.
 You MUST answer all the questions in the assessment tasks in your own words and
own handwriting.
 This is an “Open Book” assessment, and students can use the resources listed in
the “Resources Required” section below.

Task/s to be To complete this written assessment, you will need to answer the 75 questions comprising
assessed of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.

Time allowed On average, the Assessment should take 4 – 6 hours to complete.

Location This theory assessment will be completed in a classroom under the supervision of a
trainer/assessor.

Decision making The candidate MUST be able to demonstrate knowledge to complete the tasks outlined in
rules the elements, performance criteria and foundation skills of this unit, including knowledge of:
 Methods to locate and interpret information required to test, charge and replace
batteries and jump-start vehicles, including:
o Battery and vehicle manufacturer specifications
o Safety data sheets (SDS)
 Workplace procedures required to test, charge and replace batteries and jump-start
vehicles, including:
o Testing batteries
o Charging batteries
o Replacing batteries
o Jump-starting vehicles
o Establishing serviceability of tools and equipment
o Documentation procedures
o Housekeeping procedures, including:
‒ Examination of tools and equipment
‒ Storage of equipment
‒ Identification, tagging and isolation of faulty equipment
‒ Disposal of excess materials
‒ Recycling procedures
 Workplace health and safety (WHS) policies and procedures relating to testing,

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charging and replacing batteries and jump-start vehicles, including procedures for:
o Safely operating:
‒ Battery testing equipment
‒ Battery charging equipment
o Selecting and using personal protective equipment (PPE), including safety
glasses
o Identifying hazards and controlling risks associated with:
‒ Battery, vehicle and machinery movement before carrying out work
‒ Wearing jewellery while working around high current wiring
systems
o Identifying hybrid vehicles
o Identifying battery electric vehicles
 Environmental requirements relating to testing, charging and replacing batteries and
jump-starting vehicles, including procedures for:
o Following safety data sheets (SDS) to trap, store and dispose of toxic and
corrosive substances
o Disposing of or recycling batteries
 Tools and equipment required for testing, charging and replacing batteries and
jump-starting vehicles, including:
o Load testing devices
o Hydrometers
o Multimeters
o Jumper leads
o Battery chargers
o Battery cleaning materials
 Difference between voltage and current
 Key features and uses of batteries, including:
o Lead acid batteries, including deep cycle batteries
o Gel batteries
o Absorbed glass mat batteries
o Calcium batteries
o Lithium ion and lithium-ion phosphate batteries
 Battery connection methods for 6-volt, 12-volt, 24-volt and 48-volt, including:
o Series
o Parallel
o Series parallel
 Battery classification methods, including:
o Cold cranking amps (CCA)
o Reserve capacity (RC)
o Amp hour rating
 Battery testing procedures, including:
o Testing safety requirements
o Visual inspection procedures
o Voltage drop testing
o Hydrometer testing
o High-rate discharge testing
 Battery charging procedures, including:
o Charging safety requirements
o Slow, fast and trickle charging
o Battery memory retention
 Battery replacement procedures, including:
o Determining battery specifications to suit vehicle or machinery
manufacturer specifications, including correct:
‒ Voltage
‒ CCA and RC ratings
o Replacement safety requirements

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AURETR125 Test, charge and replace batteries and jump-start.

o Terminal disconnection
o Battery selection
o Battery installation and terminal connection
o Securing battery in vehicle
o System recalibration procedures
 Battery jump-start procedures, including:
o Vehicle and personnel safety requirements
o Battery terminal disconnection
o Jumper lead connection and disconnection

Assessment Competency is to be assessed in the workplace or a simulated environment that accurately

conditions reflects performance in a real workplace setting.
Assessment MUST include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals MUST provide
evidence that links them to the batteries that they have tested, charged, replaced and jump-
started, e.g., repair orders.
Assessors MUST verify performance evidence through questioning on skills and knowledge
to ensure correct interpretation and application.
The following resources MUST be made available:
 Automotive repair workplace or simulated workplace
 Workplace instructions
 Manufacturer battery specifications
 PPE for testing, charging, removing and replacing batteries and jump-starting
vehicles and machinery, including safety glasses
 Two [2] different types of serviceable batteries
 Two [2] different vehicles or machinery requiring jump-starting
 Tools, equipment and materials appropriate for battery testing, charging and
replacement, including:
o Load testing device
o Hydrometer
o Multimeter
o Jumper leads
o Battery charger
o Battery cleaning materials

Resources required Learning Resources available to students include:

 Automotive Technology (A System Approach) 7th Edition – Chapters 2, 5, 6, 7, 15,
17 & 35
 Websites –
http://www.centurybatteries.com.au/home
 Trainer Handouts

Results/Re-  The Assessor will grade the assessment and record the result on the front page of
assessment this document (S) – Satisfactory if all observable behaviours are correct and (NS)
not satisfactory if any areas are left incorrect
 Feedback will be provided on either result
 Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss
the area of the non-compliant observable behaviour and an opportunity given for re-
assessment. This may be through direct observation or a different method of
assessment e.g. verbal/oral questioning, problem solving exercise.
 If the outcome is again not satisfactory the student result will be deemed (NYC) not
yet competent. Additional feedback will be given, and a time agreed upon for further
assessment after additional training and skills practice has taken place, this
information will be recorded, dated and signed in the re-assessment area on the

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last page of this document
 Where all the assessment tasks have been graded (S) Satisfactory, the student will
be deemed C – Competent for the practical component and the result recorded and
signed in the area indicated on the last page of this document

Reasonable If the participant is unable to undertake the written assessment as designed, an interview
Adjustment (verbal questioning) may be used as an alternate approach.

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AURETR125 Test, charge and replace batteries and jump-start.

Assessment 1 – Questioning

Written Assessment

1. Why should special care be taken when working with batteries?

Special care is needed because the chemicals inside batteries, such as sulfuric acid, and the
potential high currents pose hazards including chemical burns, electrical shocks, and explosion
risks.

Multiple Choice question. Selected the correct answer. D

2. The safest way to fully charge a discharged battery quickly would be to:

A. Use a low current over 30 minutes.

B. Trickle charge only.
C. Use a high current over 2 hours.
D. Use high current for 30 minutes and then adjust to a trickle.

Multiple Choice question. Selected the correct answer. D

3. When disconnecting batteries.

A. Always connect the positive lead last.

B. Never join both leads together with the battery removed.
C. Always remove the positive lead first.
D. Always remove the earth lead first.

Multiple Choice question. Selected the correct answer. D

4. Important items of personal safety when working around batteries include.

A. PVC gloves or other suitable hand protection.

B. Eye and face protection.
C. Protective clothing.
D. All the answer are correct.

5. Rings, necklaces, bracelets and watches should not be worn while working around high current wiring
systems. Why?

They should not be worn because they are conductive materials that could lead to electric currents
passing through the body, causing electric shocks or severe burns.

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Multiple Choice question. Selected the correct answer.

6. Safety hazards associated with vehicle movement including a running engine may include. E

A. Engine moving parts such as fans, belts and pulleys.

B. Hot engine coolant, hot exhaust manifolds and engine exhaust gases.
C. High voltage ignition system that may cause electrical shock.
D. Petrol and LPG leaks causing a risk of fire.
E. All the answer are correct.

Fill in the missing words

7. First reading the SDS for an ‘Acid filled Battery’, then place the missing words to complete the following
related Acid filled Battery’ Safety Data Sheet environmental requirements information.
Missing Words: dilute, preventing, correctly, sand, recycling, stored, wash, neutralise, battery, labelled,
disposal, well-ventilated, reuse and shovel.

Following a ____battery___________ Acid Spill, you should first contain using ____sand___________ or
inert material such as dirt/earth.
Carefully _____wash__________ with water (fine spray or fog) then _____neutralize__________ with lime or
soda ash.
Then with a clean _____shovel__________, transfer spilled material into clean _____labelled__________
containers for ____disposal___________.
Finally, _____wash__________ area down with excess water ____preventing___________ from entering
drains, sewers, and streams
Batteries must be _______stored________ in their original containers and stored in a cool, dry, ____ well-
ventilated ___________ area in the workplace?
Batteries need to be disposed _____ correctly __________ by returning to the supplier or waste contractor for
recycling and or _____ reuse __________?

Multiple Choice question. Selected the correct answer.

8. What important information can be found within an SDS. D

A. Manufactures details and product name Eye and face protection.

B. Dangerous goods classification, physical properties and hazard information.
C. Precautions for use, safe handling, storage, and emergency information.
D. All the answer are correct.

True False question. Select the correct answer

9. SDS information should be stored only where they are accessible by the supervisor or workplace manager.
or
True ✘ False
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10. What is the purpose of the battery?

The purpose of a battery is to store electrical energy for use when needed. It is commonly used to
start vehicles, power the vehicle's electronic devices, or provide backup power when generator/AC
power is unavailable.

Fill in the missing words

11. There are seven (7) different lead acid battery design types, place the missing words to complete the following
battery types.

Missing Words: free, glass, hybrid, regulated, sealed, low and gel.

1 _______Low________ maintenance,
2 Maintenance-______free_________,
3 ________hybrid_______ maintenance-free,
4 ______gel_________,
5 Recombination _________regulated______,
6 Absorbed _______glass________ mat,
7 Valve _______regulate________ lead acid

12. Name the ten [10] parts of a lead acid battery below.

1 Terminal Post

2 Cell Caps

3 Vent Cap

4 Positive Terminal

5 Case

6 Positive Plate

7 Negative Plate

8 Separator

9 Electrolyte

10 Cell Connector

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Multiple Choice question. Selected the correct answer.

13. Why is a section of the battery referred to as a lead-acid cell? D

A. Each lead-acid cell contains rolls of high-purity lead plates, acid-permeated vitreous separators.
B. Each lead-acid cell contains sulphuric acid, spongy lead and lead oxide.
C. Each lead-acid cell contains lead-tin-calcium alloy with porous lead dioxide.
D. All the answer are correct.

14. What are ‘Deep Cycle’ batteries designed to do?

Deep cycle batteries are designed to provide a steady amount of power over a long period. They are built to
be discharged up to 80% or more of their capacity repeatedly, compared to starter batteries (like those
used in cars) which are designed for short, high-current bursts to start an engine and then quickly recharge.
Deep cycle batteries are commonly used in applications such as marine vessels, recreational vehicles,
solar power storage, and electric vehicles, where sustained power is needed over a longer time. They have
thicker plates and a different chemical composition to endure the stress of deep discharging and recharging
cycles.

Multiple Choice question. Selected the correct answer.

15. The electrolyte in a fully charged lead acid type battery is a solution of __A______?

A. 36 percent sulphuric acid and 64 % percent water.

B. 40% percent hydrochloric acid and 60 percent water.
C. 30% percent potassium hydroxide and 70 percent water.
D. 40% percent hydrogen peroxide and 50 percent water.

True False question. Select the correct answer

16. The function of the separators is to hold the positive and negative plates apart to prevent internal shorts.

✘ True or False

Fill in the missing words

17. Place the missing words to complete the following statement. A ‘Gel Battery’ is different to a ‘Lead Acid
Battery’s.

Missing Words: one-way, electrolyte, internal, water, movement, gassing, and gelling

A _____ gelling __________ agent is added to the _______ electrolyte ________ to reduce _____ movement
__________ inside the battery case.

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Gel batteries also use _____ one-way __________ valves in place of open vents, which help the normal
_____ gassing __________ gasses to recombine back into ____ water ___________ in the battery, reducing
_______ gassing ________.

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Multiple Choice question. Selected the correct answer. C

18. What does ‘AGM’ short for in regard to batteries?

A. Aufecht, GroBaspach and Melcher.

B. Australian Battery Group Maintenance.
C. Absorbed Glass Matt.
D. Annual General Meeting.

19. What are the key internal features of ‘AGM’ batteries?

Absorbed Glass Mat Separator， Spill-Proof Design， Tightly Packed Plates，

Low Internal Resistance， Valve Regulated， Charge Retention and Long Shelf Life

20. How do “Valve-Regulated Lead-Acid (VRLA) batteries (Also known as Calcium Batteries) work?
Valve-Regulated Lead-Acid (VRLA) batteries, also known as sealed lead-acid (SLA) batteries, are a
subtype of lead-acid batteries that include a safety valve. Here's how they work and function:

### Design and Function:

1. **Sealed Construction**: Unlike traditional flooded lead-acid batteries, VRLA batteries are sealed, which
means the electrolyte (sulfuric acid) is contained within the battery casing and cannot spill. This design also
prevents the need for regular maintenance such as water top-up.

2. **Safety Pressure Relief Valve**: Each cell in a VRLA battery has a built-in pressure relief valve. The
valve is designed to activate only under abnormal conditions (like overcharging) to release excess gas and
maintain internal pressure, preventing the battery from bursting.

3. **Absorptive Glass Mat (AGM) or Gel Electrolyte**: VRLA batteries are further classified into two types
based on the electrolyte used:
- **AGM Batteries**: These use a fiberglass mat to absorb and immobilize the electrolyte. The close
contact between the electrolyte and battery plates enhances the efficiency of the charge and discharge
reactions.
- **Gel Batteries**: These contain a silica gel that immobilizes the electrolyte. The gel form reduces
electrolyte evaporation and spillage, allowing the battery to operate in various orientations.

### Chemical Reactions:

- **Charging Process**: During charging, electrical energy is converted into chemical energy. The lead
dioxide (PbO2) on the positive plate and sponge lead (Pb) on the negative plate react with the sulfuric acid
(H2SO4) electrolyte to form lead sulfate (PbSO4) and water (H2O).
- **Discharging Process**: During discharge, the chemical reaction reverses. Lead sulfate and water react

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to produce lead dioxide, sponge lead, and sulfuric acid, releasing electrical energy.

### Key Features:

- **Maintenance-Free**: Since the batteries are sealed and the electrolyte is immobilized, they do not
require the addition of water throughout their life cycle.
- **Lower Self-Discharge**: VRLA batteries have a lower self-discharge rate compared to traditional lead-
acid batteries.
- **Durability and Safety**: The sealed construction makes them safer to use in various positions and less
susceptible to leakage, even if the outer case is damaged.

VRLA batteries are widely used in applications where maintenance access is difficult or where safety and
reliability are critical, such as in UPS systems, telecommunications, and emergency lighting systems.

True False question. Select the correct answer

21. Lithium-ion batteries are the safest type of battery to use in a hybrid vehicle because lithium is not reactive or
explosive.

True or ✘ False

Multiple Choice question. Selected the correct answer. D

22. Lithium-based batteries have?

A. High energy density.

B. Suffer less from the memory effect.
C. Environmentally friendlier.
D. All the answer are correct.

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23. What are the benefits and negatives of using lithium ion and lithium-ion phosphate batteries on vehicles
today?
Lithium-ion and lithium-ion phosphate batteries are widely used in vehicles today, especially in electric and
hybrid cars. Here’s a breakdown of their benefits and negatives:

### Benefits of Lithium-ion and Lithium-ion Phosphate Batteries

1. **High Energy Density**: Lithium-ion batteries store a lot of energy for their size and weight, which is
particularly valuable in electric vehicles that need to maximize range.

2. **Long Lifespan**: These batteries can endure hundreds to thousands of charge cycles with minimal
degradation, making them suitable for the daily demands of automotive use.

3. **Low Self-Discharge**: Lithium-ion batteries have a much lower self-discharge rate compared to other
rechargeable batteries like NiMH or lead-acid.

4. **No Memory Effect**: They don’t suffer from the memory effect, meaning they don’t lose their maximum
energy capacity from being recharged before they are fully depleted.

5. **Fast Charging**: Lithium-ion batteries can be charged relatively quickly compared to other battery
types, which is essential for electric vehicle usability.

6. **Safety and Stability**: Lithium-ion phosphate batteries, in particular, offer improved thermal and
chemical stability, which enhances safety by reducing the risk of overheating and subsequent fires or
explosions.

### Negatives of Lithium-ion and Lithium-ion Phosphate Batteries

1. **Cost**: While prices have been decreasing, lithium-ion batteries are still significantly more expensive to
manufacture than traditional lead-acid or NiMH batteries. This affects the overall cost of electric vehicles.

2. **Temperature Sensitivity**: Lithium-ion batteries can be sensitive to extreme temperatures, performing

poorly in very cold weather and risking overheating in hot climates.

3. **Aging**: Despite having a long lifespan, lithium-ion batteries do degrade over time and their capacity
diminishes whether they are used or not.

4. **Environmental Impact**: The mining of lithium, cobalt, and other metals used in these batteries raises
environmental and ethical concerns. Additionally, recycling of lithium-ion batteries is not yet widespread or
fully efficient.

5. **Safety Risks**: While lithium-ion phosphate batteries are generally safer, standard lithium-ion batteries
can pose fire and explosion risks if damaged or improperly managed due to their high energy density and
chemical properties.

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In vehicles, these batteries offer substantial benefits in terms of efficiency and environmental impact but
come with challenges that need to be managed through technology, regulation, and improvements in
battery chemistry and recycling technologies.

24. Explain why batteries are connected in ‘Series’?

Batteries are connected in series to increase the total voltage output of the assembly. This arrangement
involves connecting the positive terminal of one battery to the negative terminal of another battery. Here’s a
detailed explanation of how this works and why it’s done:

### How Series Connections Work:

- **Voltage Addition**: In a series configuration, the voltages of all the individual batteries add up. For
example, if four 12-volt batteries are connected in series, the total voltage output becomes 48 volts.
- **Current Stays Constant**: While the voltage sums up, the current capacity (ampere-hour rating) remains
the same as that of a single battery in the series. Thus, the battery pack can deliver the summed voltage at
the same current capacity as one of the individual batteries.

### Why Connect Batteries in Series?

- **Increased Voltage Requirements**: Many applications require a higher voltage than what a single
battery can provide. Connecting batteries in series allows for achieving the necessary voltage for these
applications without altering the battery chemistry or design.
- **Compatibility with Electrical Systems**: Many electric and hybrid vehicles, as well as other types of
machinery and equipment, require electrical systems operating at higher voltages for efficient power
transmission and performance. Series connections make it possible to match the battery output to the
system requirements.
- **Simpler Design Adjustments**: It is often more practical or economical to use multiple standard voltage
batteries in series for achieving a high-voltage setup than to develop and manufacture a high-voltage
battery specifically for each application.

### Example:
If an electric vehicle requires a 48-volt electrical system, engineers can achieve this by connecting four 12-
volt batteries in series. This setup will provide the necessary voltage while utilizing widely available 12-volt
batteries, simplifying design and potentially reducing costs.

Connecting batteries in series is a fundamental technique in battery configuration that allows for flexible
design choices to meet specific voltage requirements across various technologies and applications.

Multiple Choice question. Selected the correct answer.

25. If connect four (4) 12-volt batteries were connected in together in ‘Series’, what would be the total voltage be?

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A. 12-volts.
B. 36-volts.
C. 48-volts.
D. 64-volts.

26. Show by drawing how the cells of a battery are connected together for the following methods:
 Series.
 Parallel
 Series parallel

Series

Parallel

Series-Parallel

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Multiple Choice question. Selected the correct answer.

27. If connect four (4) 12V 100Ah (amp-hour) batteries were connected together in ‘Parallel’, what would be the
total Ah (amp-hour) be?

A. 100Ah (amp-hour).
B. 200Ah (amp-hour).
C. 300Ah (amp-hour).
D. 400Ah (amp-hour).

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Multiple Choice question. Selected the correct answer.

28. If connect six [6] 6V 100Ah (amp-hour) batteries connected together in ‘Series - Parallel, what would be the
total voltage and Ah (amp-hour) be?

A. 12V 100Ah (amp-hour).

B. 24V 200Ah (amp-hour).
C. 6V 600Ah (amp-hour).
D. 48V 400Ah (amp-hour).

Multiple Choice question. Selected the correct answer.

29. A cold-cranking amperes (CCA) rating specifies the minimum amperes available for 30 seconds at ________
degrees Fahrenheit?

A. 0.
B. 32.
C. 50.
D. 100.

Fill in the missing words

30. Place the missing words to complete the following statement about battery Reserve Capacity.
Missing Words: amperes, minutes, number, reserve
The reserve capacity (RC) rating represents the ______number_________ of minutes that a fully charged
battery can be discharged at 25 _____amperes__________ before battery voltage drops below 10.5 volts. A
battery with a _______reserve________ capacity of 120 would be able to deliver 25 amps for 120
____minutes___________ before its voltage drops below 10.5 volts.

31. Describe the ampere-hour rating.

Definition: The ampere-hour rating is defined as the number of amperes a battery can deliver for one hour
before its voltage falls below the level necessary to operate a device. It essentially measures the amount of
energy the battery can store and subsequently deliver.
Calculation: For instance, if a battery has a rating of 100 Ah, it can theoretically provide 100 amperes of
current for one hour, 50 amperes for two hours, 20 amperes for five hours, and so forth, under ideal
conditions.
Usage: This rating is crucial for determining how long a battery will operate a device before needing a
recharge. It is particularly important in applications like backup power systems, electric vehicles, and
portable electronic devices, where endurance and longevity are critical.
Implications in Real-world Use: The actual performance can be influenced by several factors including the
age of the battery, the temperature at which it operates, and the rate at which it discharges (also known as
the discharge rate). Higher discharge rates can reduce the effective ampere-hour capacity of the battery.
Standard Conditions: The ampere-hour rating is typically measured under specific standard conditions of
temperature and discharge rate, which are often specified by the manufacturer. For example, a common
standard is to measure the battery’s capacity at a 20-hour discharge rate at a temperature of 25 degrees

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Celsius.

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Fill in the missing words

32. Place the missing words to complete the following statement about what precautions MUST you follow when
working with, or near, a battery.
Missing Words: burns, explosive, flush, safety, spark

Always wear ____ safety ___________ glasses or goggles when working with batteries. When a battery is
charging or discharging, it gives off highly _______ explosive ________ hydrogen gas. Some hydrogen gas
is present in the battery at all times. Any flame or _ spark ______________ can ignite this gas, causing the
battery to violently explode, propelling the vent caps at a high velocity and spraying acid in a wide area.

Sulfuric acid can cause severe skin ____ burns ___________. If electrolyte contacts your skin or eyes,
_____ flush __________ the area with water for several minutes. When eye contact occurs, force your
eyelids open and flush your eyes with eyewash solution. Do not rub your eyes or skin and call a doctor
immediately.

33. Identify five [5] steps you would take to inspection the battery?

1 Visual Inspection

2 Check Terminal Connections:

3 Measure Voltage Levels:

4 Test the Battery State of Charge:

5 Check the Electrolyte Levels and Specific Gravity

Multiple Choice question. Selected the correct answer.

34. Corrosion on or near the battery must be minimized because _____.

A. Corrosion on the battery terminals increases resistance in the battery circuit.

B. Corrosion on the battery cover can create a path that will allow the battery to slowly discharge.
C. Corrosion can destroy the hold-down straps and battery tray.
D. All answers are correct.

35. How is a voltage drop test performed on the battery cables and connections?

Performing a voltage drop test on battery cables and connections is crucial for diagnosing electrical issues
in a vehicle's electrical system. Here's how to perform the test:
Tools Needed:
Digital multimeter (set to DC voltage)

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Wire brush or sandpaper (for cleaning terminals if needed)
Steps to Perform the Voltage Drop Test:
Prepare the Vehicle:
Ensure the vehicle is turned off and in park or neutral with the parking brake engaged.
Open the hood and locate the battery and the cables connected to it.
Set Up the Multimeter:
Turn on the multimeter and set it to measure DC voltage.
Select an appropriate voltage range on the multimeter, typically around 20 volts DC.
Test the Battery Voltage:
Measure the voltage across the battery terminals with the multimeter. This gives you the baseline voltage of
the battery.
Test Voltage Drop Across Positive Cable:
Keep the black probe of the multimeter on the negative terminal of the battery.
Place the red probe on the positive terminal of the battery.
Crank the engine (or turn on the headlights if the engine can't be started).
Read the voltage displayed on the multimeter. This is the voltage drop across the positive cable and
connections.
Test Voltage Drop Across Negative Cable:
Keep the red probe of the multimeter on the positive terminal of the battery.
Place the black probe on a clean, unpainted metal surface on the engine block or chassis (a good
grounding point).
Crank the engine (or turn on the headlights).
Read the voltage displayed on the multimeter. This is the voltage drop across the negative cable and
connections.
Interpretation of Results:
A voltage drop of more than 0.2 volts across either the positive or negative cable indicates a potential issue
with that cable or its connections.
If the voltage drop is excessive, further inspection of the cables, terminals, and connections is necessary.
Cleaning corroded or dirty terminals and tightening loose connections can often resolve voltage drop
issues.
Performing a voltage drop test helps identify areas of high resistance in the electrical system, which can
cause starting problems, charging issues, and other electrical malfunctions in the vehicle.

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Multiple Choice question. Selected the correct answer.

36. Batteries with removable vent caps should have the specific gravity of the electrolyte checked. The
electrolyte’s specific gravity can be measured with a battery hydrometer that uses a glass float in a glass tube
to measure the electrolyte’s specific gravity. The electrolyte of a fully charged battery is usually about 64
percent water and 36 percent sulfuric acid. This corresponds to a specific gravity of ________ at 80OC or
26.7OC.

A. 1.000.
B. 1.150.
C. 1.270.
D. All answers are correct.

Multiple Choice question. Selected the correct answer.

37. Which method of testing for battery state of charge (SOC) can be used on maintenance-free batteries?

A. Built-in hydrometer.
B. Open circuit voltage test.
C. Battery hydrometer.
D. Both “built-in hydrometer” and “open circuit voltage test”.

Multiple Choice question. Selected the correct answer.

38. Which of these statements from a battery load or high-rate discharge test is FALSE?

A. The battery needs to be replaced if the voltage dropped below 9.6 volts while under a load but rose above
12.4 volts when the load was removed.
B. The battery should be charged and then retested because it dropped below 9.6 volts and didn’t rise above
12.4 volts when the load was removed.
C. The battery should be charged and then retested because it dropped below 9.6 volts and rose above 12.4
volts when the load was removed.
D. The battery is good because the voltage dropped only to 10.3 volts while under load.

Multiple Choice question. Selected the correct answer.

39. How many volts are present in a fully charged 12-volt battery?

A. 12.0.
B. 12.2.
C. 12.4.
D. 12.6.

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40. How do you remove the surface charge on a battery prior to open circuit voltage testing?
Rest the Battery: Allow the battery to sit idle, disconnected from any charging source or load, for a minimum
of 6 hours. This resting period allows the surface charge to dissipate naturally.
Apply a Load: Connect a moderate electrical load to the battery for a brief period to discharge any
remaining surface charge. You can achieve this by turning on the vehicle's headlights or interior lights for a
few minutes. Alternatively, you can use a resistor or other load device if the battery is not installed in a
vehicle.
Wait for Stabilization: After applying the load, allow the battery to rest for an additional 5-10 minutes to
ensure that the voltage stabilizes.
Measure Open Circuit Voltage: Once the battery has rested and stabilized, use a digital multimeter to
measure the open circuit voltage (OCV) across the battery terminals. This measurement provides an
accurate indication of the battery's state of charge without interference from surface charge.

Multiple Choice question. Selected the correct answer.

41. All the following are good safety precautions to follow when charging batteries EXCEPT:

A. Always wear safety glasses.

B. Make sure the area is well ventilated.
C. Never charge a frozen battery or one with damaged plates.
D. Never allow the charging voltage to exceed 12.6 volts.

Multiple Choice question. Selected the correct answer.

42. Battery charging should be done in a well-ventilated area because the gases produced during recharging are
_____.

A. Highly toxic [poisonous].

B. Explosive.
C. Both “highly toxic [poisonous]” and “explosive”.
D. Neither “highly toxic [poisonous]” nor “explosive”.

Multiple Choice question. Selected the correct answer.

43. When charging a battery that has been completely discharged, the most important item to monitor is _____.

A. Gassing.
B. Charging voltage.
C. Charging current.
D. Battery temperature.

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44. Explain ‘Slow or Trickle’ charging?
Low Charging Current: The charging current used in slow or trickle charging is intentionally kept low,
usually ranging from around 0.1 to 0.3 times the battery's capacity in ampere-hours (Ah). This low current
ensures that the battery is charged gradually and gently.
Extended Charging Time: Due to the low charging current, the charging process takes an extended period
of time compared to fast charging methods. Trickle charging can take anywhere from several hours to
several days to fully charge a battery, depending on its size, capacity, and state of charge.
Continuous Maintenance: Trickle charging is often used for battery maintenance purposes, especially for
batteries that are not in regular use or are stored for long periods. By providing a continuous, low-level
charge, trickle charging helps prevent self-discharge and sulfation, which can occur when batteries are left
in a discharged state for too long.
Safety and Longevity: Slow or trickle charging is considered a safe and gentle charging method that
minimizes the risk of overcharging and overheating, which can shorten the lifespan of a battery. It is
particularly suitable for sensitive battery chemistries, such as lead-acid batteries, and can help prolong their
service life.
Applications: Trickle charging is commonly used for maintaining the charge of automotive, marine, RV, and
deep-cycle batteries during storage periods, as well as for charging small electronic devices like
rechargeable batteries in flashlights, remote controls, and portable radios.

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45. Explain ‘Fast’ charging?

Fast charging, also known as rapid charging or quick charging, is a charging method that replenishes the
energy in a battery at a much faster rate compared to traditional charging methods. This approach is
designed to significantly reduce the time required to charge a battery to its full capacity, making it
convenient for users who need quick access to their devices or vehicles.

### Key Characteristics of Fast Charging:

1. **High Charging Current**: Fast charging utilizes a higher charging current compared to slow or trickle
charging methods. This higher current allows for the rapid transfer of energy to the battery, enabling it to
charge more quickly.

2. **Advanced Charging Technology**: Fast charging often employs advanced charging technologies such
as Qualcomm Quick Charge, USB Power Delivery (USB PD), or proprietary fast charging standards
developed by device manufacturers. These technologies optimize the charging process by dynamically
adjusting voltage and current levels to maximize charging efficiency while minimizing heat generation.

3. **Reduced Charging Time**: The primary advantage of fast charging is its ability to significantly reduce
the time required to charge a battery. Depending on the battery capacity and the specific fast charging
technology used, charging times can be reduced from several hours to just minutes, allowing users to
quickly top up their devices or vehicles' batteries.

4. **Compatibility**: Fast charging is becoming increasingly common in various electronic devices, including
smartphones, tablets, laptops, electric vehicles (EVs), and power banks. Many modern devices support fast
charging standards, allowing users to take advantage of faster charging speeds with compatible chargers
and cables.

5. **Heat Generation**: While fast charging offers the benefit of reduced charging time, it can also generate
more heat compared to slower charging methods. Excessive heat can potentially degrade the battery over
time and may affect its long-term performance and lifespan. Therefore, it's essential to use fast charging
technologies responsibly and ensure adequate heat dissipation during the charging process.

6. **Battery Health Considerations**: Frequent use of fast charging, especially at high charging currents,
can accelerate battery degradation over time. Therefore, some users may choose to balance fast charging
with regular slower charging to maintain optimal battery health and longevity.

Overall, fast charging provides a convenient solution for quickly replenishing the energy in batteries,
offering users the flexibility to power their devices or vehicles more efficiently, especially when time is of the
essence. However, it's essential to consider factors such as battery compatibility, heat generation, and
long-term battery health when utilizing fast charging technologies.

True False question. Select the correct answer

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46. Before servicing the battery or battery cables, a memory saver should be connected to the vehicle’s electrical
system to prevent erasure of data in the vehicle’s computer and setup information in the entertainment and
accessory systems.

✘ True or False

Multiple Choice question. Selected the correct answer.

47. When a battery needs to be replaced, several things need to be considered when selecting the new battery
like?

A. Battery capacity.
B. Battery voltage and ratings.
C. Battery size.
D. All answers are correct.

48. Before replacing a 12-volt battery, you should check the service information for any specific safety precautions
or procedure that need to be followed. What are the ten [10] common safety precautions or procedure to
follow for battery replacement?

1 Review Service Information

2 Wear Personal Protective Equipment (PPE)

3 Turn Off Ignition and Electrical Systems

4 Locate and Disconnect Battery

5 Remove Battery Hold-Down Bracket

6 Lift Out Old Battery

7 Clean Battery Tray

8 Install New Battery

9 Secure Battery Hold-Down Bracket

10 Connect Battery Cables

Fill in the missing words

49. Place the missing words to complete the following statement about system recalibration procedures?
Missing Words: charging, monitors, PCM, performance, registration, scan tool

Replacing a battery may require performing a battery _____ registration __________ or entering a battery
energy management (BEM) code into the powertrain control module (PCM). On many vehicles, the engine

computer _____ monitors __________ and tracks electrical system operation, _____ charging
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__________ system status, and the age of the battery. A new original equipment (OE) battery should have a

BEM decal. Program the code into the computer using a ______ scan tool _________. If a new but non-OE
battery is installed and the system not reset, the _____ PCM __________ may not self-calibrate to the new
battery. This can affect charging system _____ performance __________ and affect the life of the new
battery.

50. Explain the proper procedure below to jump-start a typical vehicle with the battery of another vehicle.

1 Get the necessary equipment

2 Position the vehicles

3 Turn off both vehicles

4 Open the hoods

5 Identify the batteries

6 Connect the jumper cables

7 Start the working vehicle

8 Attempt to start the dead vehicle

9 Remove the jumper cables

10 Keep the engine running

11 Drive the vehicle

12

13

14

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True False question. Select the correct answer

51. Consult the manufacturer’s service manual for procedures and precautions when jump-starting late model
vehicles with electronic control systems.

✘ True or False

True False question. Select the correct answer

52. Jump-starting a battery can damage the vehicle electronic components.

✘ True or False

53. What is the difference between “Voltage” and “Current”?

voltage is the "pressure" or potential difference that drives the flow of electricity, while current is
the actual flow of electric charge through a conductor in response to that voltage. Voltage can be
thought of as the cause of electrical flow, while current is the effect of that voltage causing charge
to move.

True False question. Select the correct answer

54. A battery hydrometer is used to measure the specific gravity of the electrolyte.

✘ True or False

Multiple Choice question. Selected the correct answer.

55. Before you remove an old battery, the battery should be inspected and cleaned. What should you use to clean
the battery?

A. Alcohol.
B. Baking soda and water.
C. Water.
D. All answers are correct.

Multiple Choice question. Selected the correct answer.

56. A conductance tester measures the battery condition by ________?

A. Sending a small AC signal through the battery and measuring the current response.
B. Applying a load of 125 amps on the battery and measuring how fast the battery voltage returns to 12.4
volts when the load is turned off.
C. Measuring how fast the voltage drops when a 100-amp load is applied.
D. Measuring the voltage drop between cells as a load is applied.

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True False question. Select the correct answer

57. A battery strap or carrier should be used whenever a battery is lifted.

✘ True or False

58. Which function of the multimeter is used to test for parasitic draw?

A. Ohmmeter.
B. Voltmeter.
C. Ammeter.
D. Voltage drop.

59. A volt/ampere tester (VAT) is used to test ________?

A. Batteries.
B. Starting systems.
C. Charging system.
D. All answers are correct.

60. Which tool and equipment below, is used to jump-start a vehicle?

A. Hydrometer.
B. Multimeter.
C. Jumper leads.
D. All answers are correct.

61. What is the combination external/internal wire brushes used for?

External Brush: The external brush is used to clean
the battery terminals, which are the metal
connections where the battery cables attach. These
terminals can accumulate corrosion, dirt, or other
contaminants over time, which can hinder the flow of
electricity between the battery and the cables. The
external brush is used to scrub away these
contaminants, ensuring a clean, solid connection
between the terminal and the cable.
Internal Brush: The internal brush is designed to
clean the inside of the battery cable connectors.
These connectors, which attach to the battery
terminals, can also accumulate corrosion or
oxidation, which may hinder the flow of electricity.
The internal brush is used to clean the inside surface
of the connector, ensuring good electrical contact
with the battery terminal.

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True False question. Select the correct answer

62. Battery chargers are designed to supply a specific amount of constant voltage or constant current to the
battery to charge the battery.

✘ True or False

63. Referring to the Mitsubishi Pajero Workshop Manual Handout. Locate and interpret the manufacturers
specification for the specific gravity of the battery fluid including what the battery temperature must be.

64. Referring to the Mitsubishi Pajero Workshop Manual Handout. Locate and interpret the manufacturers
procedures for charging the battery with the battery still installed in the vehicle.

65. Referring to the Nissan 350Z Workshop Manual Handout. Locate and interpret the manufacturers torque
specifications for tightening the battery fix frame mounting nut and battery terminal nut.

66. Why is it very important that the Job Card is completed correctly?
Accurate Documentation: The job card serves as an official record of the work performed on the vehicle. It
includes details such as the customer's information, vehicle identification, services performed, parts used,
labor hours, and any additional notes. Accurate documentation ensures transparency and accountability for
both the service provider and the customer.
Legal and Regulatory Compliance: In many jurisdictions, automotive repair shops are required by law to
maintain detailed records of the services they provide. Properly completed job cards help ensure
compliance with legal and regulatory requirements, protecting both the shop and the customer in case of
disputes or legal issues.
Quality Control: A well-completed job card provides a clear outline of the work that was done on the vehicle.
This helps ensure that all necessary tasks were completed according to the service schedule or the
customer's specific requirements. It also allows for easy tracking of warranty information and ensures that
the customer receives the quality of service they expect.
Communication: The job card serves as a communication tool between different departments within the
automotive repair shop, including technicians, service advisors, and parts departments. Clear and accurate
documentation helps facilitate effective communication, ensuring that everyone involved in the service
process understands what needs to be done and can coordinate their efforts accordingly.
Customer Satisfaction: A properly completed job card provides transparency and reassurance to the

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customer. It demonstrates that the service provider has taken the time to document the work performed on
their vehicle and ensures that they have a clear understanding of the services provided, the associated
costs, and any recommendations for future maintenance or repairs. This can help build trust and confidence
in the service provider and enhance overall customer satisfaction.

True and False

67. An automotive technician must adhere to workshop safety guidelines and procedures when using all tools and
equipment to test, charge, replace batteries and jump-start vehicles.

✘ True or False

True and False

68. An automotive technician is required to document the work that was performed on a vehicle. Writing or typing
in the description of the steps performed during the testing and repair of the vehicle battery system should be
worded as if the technician is talking to the customer.

True or ✘ False

True and False

69. Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them. Never use
broken or damaged tools.

✘ True or False

True and False

70. For best results and long tool life, each tool used must be cleaned and checked before placing it back into the
toolbox or tool storage room.

✘ True or False

Multiple Choice question. Select the correct answer.

71. Lockout/tagout practices and procedures are intended to reduce the risk of automotive technicians’
inadvertently using battery tools, equipment or materials that have been determined to?

A. Be unsafe or potentially unsafe.

B. That are in the process of being serviced.
C. Both “Be unsafe or potentially unsafe” and “That are in the process of being serviced”.
D. Neither “Be unsafe or potentially unsafe” and “That are in the process of being serviced”.

True and False

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72. Most of the battery system electrical system components such as the battery, wiring, and terminals can be
recycled or used.

✘ True or False

Multiple Choice question. Select the correct answer.

73. Referring to the Hummer H3 Owner’s Manual Handout. What section and page number will you locate and
interpret the manufacturers procedure for Jump Starting the Hummer? (E.g., the first number is the section,
and second is the page number 1-10)

A. 5-94.
B. 2-44.
C. 5-34.
D. 1-26.
True and False
74. An automotive technician must adhere to workshop safety guidelines and procedures and follow the
manufactures procedures in the workshop manual for testing, charging, replacing batteries and jump-start
vehicles.

✘ True or False

Multiple Choice question. Select the correct answer.

75. Apart from badges on the vehicle identifying electric-powered passenger cars and hybrid vehicles, the
vehicles number plate is another way. What is on the number plate that identifies the vehicle being electric-
powered and hybrid passenger vehicles?

A. LPG.
B. H.
C. Hybrid.
D. EV.

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