Diagnosis Master Technician - Electrical Course

Discharged Battery

Outline

Flow of Troubleshooting 1. Discharged battery The following are malfunctions and complaints concerning the discharged battery. The battery is discharged. The starter does not turn, preventing the engine from starting. The engine can be started now, even though the battery was previously discharged.The customer thinks that the battery should be checked. 2. The main cause of malfunction The following are causes of discharged battery malfunctions. The switches are left turned on (light control switches, etc.). A malfunction problem in the battery or in the charging system. An imbalance between the amount the customer habitually uses and the alternator generates. 3. Handling method for discharged battery The following knowledge and skills are necessary for handling the discharged battery. Understanding of the customers habitual usage. Correct technical knowledge regarding discharged batteries.

(1/2) 4. Flow of troubleshooting Handle the discharged battery malfunction by following these three steps.
Engine start possible

Verify the symptom and diagnostic questioning.

Customer problem analysis check

The battery is

charged

Engine start impossible

are left turned on. Cranking state inspection

(1) Verify the symptom and diagnostic questioning Perform diagnostic questioning with the customer and verify the information regarding the vehicle. Understand the customers habitual usage of the vehicle. (2) Judge and inspect the malfunction symptom Inspect the battery and the charging system, etc. to judge whether the malfunction problem is caused by a problem on the vehicle side or is due to the customers habitual usage. (3) Inspect the charge and discharge balance Offer appropriate advice to the customer by ascertaining the true cause of the malfunction based on the charge and discharge balance inspection, and try to prevent the malfunction from recurring. REFERENCE: Flow of troubleshooting (See Discharged Battery of Electrical on PDF (2 to 2) Attachment A-1) (2/2)

Diagnostic questioning

Judge and inspect the malfunction symptom.

Vehicle inspection

Judged to be a malfunction

Judged not to be a malfunction [Example] Drives the vehicle only at night because works night shift. The charge and discharge balance is bad because of low-speed driving in traffic jams.

Systematic troubleshooting Repair Inspect the charge and discharge balance.

Ascertain the cause of the malfunction. Explain to the customer so that they can understand the situation.

2003 TOYOTA MOTOR CORPORATION. All right reserved.

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Verifying the Symptom and Diagnostic Questioning

1

Points for Troubleshooting For troubleshooting concerning the discharged battery, it is necessary to keep the following points in mind. 1. The battery degrades even if it has not been used. The degree of degradation will greatly differ depending on the conditions under which the vehicle has been used. 2. While the engine is running, if the electrical output that the alternator generates is greater than that consumed, the battery will be charged.

3. Conversely, if the electricity expended is greater than the amount the alternator generates, the battery will also supply electricity, causing it to become discharged. HINT: The amount the battery can charge and the amount it discharges is called the charge and discharge balance. If this balance signicantly worsens, the battery becomes discharged.

Charge and discharge balance is good: the battery charges.

Charge and discharge balance is bad: the battery discharges.

(1/1) Verifying the Symptom and Diagnostic Questioning Diagnostic Questioning Concerning the specic diagnostic questioning about the discharged battery, the following conditions should be known. 1. Previous battery maintenance history and maintenance condition In addition to questioning the customer, also check the inspection and maintenance booklet. History of battery change Frequency of relling the battery uid History of charging the battery, change in the specic gravity, etc.

(1/1) 2. How the electrical devices for the charge and discharge balance have been used Not only at the time when the battery became discharged, but also verify the electrical load that the customer uses on a daily basis. Headlights and fog lamps (the lights are turned off when the vehicle stops at an intersection, etc.) A/C (AUTO position, ECNO mode, etc.) Whether or not post-installed parts or components are used and how they are used How other electrical devices are used

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Verifying the Symptom and Diagnostic Questioning

Diagnostic Questioning 3. When the customer leaves the vehicle Check whether the switches have remained turned on or not, when the customer leaves the vehicle. (Check the condition when the vehicle was brought in.) Check the ignition key condition when the customer leaves the vehicle.

(1/1) Judge and Inspect Malfunctions

Verify the symptom and diagnostic q questioning. 2. Judge and inspect the malfunction symptom. Vehicle inspection -Inspect battery function -Inspect connection of circuits -Inspect charging function -Inspect parasitic current 3-(1) ( ) Judged to be a malfunction 3-(2) ( )

Outline 1. Outline of judgement and inspection of malfunctions To troubleshoot for a discharged battery, it is necessary to judge whether the malfunction symptom is caused by a problem on the vehicle side or not by inspecting the related electrical devices including the charging system while accurately determining whether the battery is good or not. 2. Vehicle inspection items Inspect battery function: If the battery is degraded, the electromotive force becomes smaller and the voltage drop when it is received some load becomes greater, which may cause the starter not to turn correctly. Inspect connection of circuits: If looseness or poor contact exists in the circuit connection, the current does not ow correctly, which could cause the alternator or IC regulator not to operate correctly. Inspect charging function: If the charging system does not correctly generate electricity, the battery charge becomes insufcient and will be discharged. If the battery is overcharged, the amount of battery uid decreases and may cause the amount of battery charge to be insufcient or promote its degradation. Inspect parasitic current: Even if all the switches are turned off, current ows into every electrical device. If this current is large, the battery discharge becomes larger, which causes a discharged battery. 3. Post inspection consultation (1) When the symptom is judged as a malfunction: If the malfunction problem is on the vehicle side based on the result of the inspection, the problem is judged to be a malfunction. Therefore, troubleshoot to determine the malfunction cause. (2) When the symptom is not judged as a malfunction: If the malfunction problem is not on the vehicle side based on the result of the inspection, and there is no other cause that leads to the malfunction symptom, it is necessary to consult with the customer from a different view point regarding the malfunction. This is because the malfunction is considered to be a result of the customers habitual usage. (1/1)

Judged not to be a malfunction [Example] Drives the vehicle Systematic troubleshooting only at night because works Repair night shift. The charge and dis scharge balance Ascertain the cause of the is bad because of b malfunction. low w-speed driving in Inspect the charge and th h Explain to the customer so that traf jams. ffic discharge balance. they can understand the situation. y

A A

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Judge and Inspect Malfunctions

REFERENCE Battery Life 1. Factors that determine battery life Battery life changes depending on the using conditions or environment. (1) Frequency that the battery is charged and discharged If the battery is frequently charged and discharged, the battery life becomes shorter and if the battery is not frequently charged and discharged, the battery life becomes longer. (2) Difference in load of the vehicle Heavy loads will need to be supplied with a large amount of electrical power upon ignition. Therefore, even if the battery performance slightly drops, it can easily reach the limit of its use. (3) Difference in temperature When the temperature decreases, the batterys amount of electrical power decreases. During winter, upon engine starting the battery requires a large amount of power, so the battery can easily become discharged. 2. Judge the life of the battery The life of the battery can also be determined by the following. (1) Cloud of the electrolyte, the amount of precipitate The electrolyte cloud becomes signicant or the quantity of precipitate increases. (2) Change in electrolyte quantity The amount of electrolyte signicantly decreases. (An increase in the uid lling frequency) The difference in the decreasing rate between each cell is large. (3) Conditions while charging Fluid temperature abnormally increases while charging. Even when charging has nished, gas generation is abnormally insufcient. (1/1) Inspect Battery Function

Gas generation is insufficient.

Inspect battery function Check the amount of electrolyte fluid

1. Check the amount of electrolyte uid Check the amount of uid in each cell.

OK Check specific gravity

Low Refill

OK

Large difference in the specific gravity of each cell

Small specific gravity (all cells)

Inspect recharging and charging condition OK Load test (High-discharge) NG

OK

NG

Judge the battery as degraded and replace it

(1/4)

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Judge and Inspect Malfunctions

Inspect Battery Function Criterion The uid level should be between the UPPER and the LOWER levels. HINT: If the uid level is below the LOWER level, rell the battery uid. However, if water is lled, the specic gravity cannot be correctly measured. So, recharge before checking the specic gravity.

ER UPP LO R WE

LEV

EL EL

LEV

(1/4) 2. Check specic gravity Check the specic gravity in each cell.

Inspect battery function Check the amount of electrolyte fluid

OK Check specific gravity

Low Refill

OK

Large difference in the specific gravity of each cell

Small specific gravity (all cells)

Inspect recharging and charging condition OK Load test (High-discharge) NG

OK

NG

Judge the battery as degraded and replace it

(2/4) Criteria (1) The specic gravity should be in the specied range shown in the Repair Manual. (2) The difference in the specic gravity of each cell should be 0.04 or less.
Float Hydrometer

HINT: Specic gravity only shows the battery charged (discharged) condition. Therefore, with only a specic inspection, the batterys degradation cannot be judged. If there is a great difference in the specic gravity of each cell, the following conditions are presumed. Inside short circuit in the battery The concentration increases due to the uid shortage (water evaporation) The concentration decreases due to water lling (2/4)

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Judge and Inspect Malfunctions

Inspect battery function Check the amount of electrolyte fluid

Inspect Battery Function 3. Inspect recharging and charging condition When the specic gravity is high or low, after recharging the battery, inspect the voltage and specic gravity. The batterys degradation can be judged by this method.
Low Refill

OK Check specific gravity

HINT: As preparation for the load voltage measurement, recharging is performed to adjust specic gravity.

OK

Large difference in the specific gravity of each cell

Small specific gravity (all cells)

Inspect recharging and charging condition OK Load test (High-discharge) NG

OK

NG

Judge the battery as degraded and replace it

(3/4) Criteria (1) Voltage The voltage at the beginning of charging should be 15 V or less. The voltage at the end of charging should be 15 V or more. (If the voltage is abnormal, the possibility of sulfation is high) (2) Specic gravity After charging, specic gravity should be in the specied range shown in the Repair Manual. The difference in the specic gravity of each cell should be 0.04 or less. CAUTION: Charge the battery with the normal charge. (The charging current should be set at approximately 1/10 of the battery capacity.) (3/4)

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Judge and Inspect Malfunctions

Inspect battery function Check the amount of electrolyte fluid

Inspect Battery Function 4. Load test (High-discharge) After the engine is warmed up, make it impossible to start. Then, measure the battery voltage when the engine is cranked with the ignition switch in the ST position (the starter is turned) for 5 seconds.

OK Check specific gravity

Low Refill

OK

Large difference in the specific gravity of each cell

Small specific gravity (all cells)

Inspect recharging and charging condition OK Load test (High-discharge) NG

OK

NG

Judge the battery as degraded and replace it

(4/4) Criterion The standard value is not set, compare the value with the same models. HINT: If the battery receives any load, the voltage decreases even when it is 12 V because current consumption increases. Therefore, measure the voltage with load and judge the battery capacity based on how much it decreases. When the current that is approximately four times as much as the battery capacity passes into the circuit (example: in the case of a 50 Ah battery, approximately 200 A), if a battery tester indicates 9 V or more after a period of 5 seconds, the voltage can be judged as good.

(4/4) Judge and Inspect Malfunctions Inspect the Connection in Each Circuit Inspect the connecting condition in each circuit. Connection in each terminal of the alternator Connection of the battery terminal Fuse Fusible link condition Criterion (1) There is no looseness or poor contact in any of the connections. (2) There is no burning, cutting of the fuses or fusible links.

(1/1) -7-

Diagnosis Master Technician - Electrical Course

Discharged Battery

Judge and Inspect Malfunctions

Inspect Charging Function Perform the following inspection about charging. 1. Inspect the alternator and V-belt

1.
Criterion (1) The V-belt tension, and deection should be in the specied range shown in the Repair Manual. (2) There are no abnormal sounds from the alternator while the engine is running.

(1/1) 2. No load test (adjusting voltage inspection) Inspecting condition Inspect with the minimum electrical load (the output is 10 A or less). Criterion The generated voltage should be kept constant (adjusting voltage).

2.

(1/1) 3. Load test (output current inspection) Inspecting condition Use the electrical equipment as much as possible to apply a large load (apply 30 A or more). Criterion The alternator should output depending on the load.

3.
A V

Headlight HI beam Heater blower HI Rear window defogger ON

(1/1)

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Judge and Inspect Malfunctions

Inspect Parasitic Current Inspect parasitic current Turn all the switches off and measure the discharged current from the battery. Criterion The standard value is not set, compare with the same model. HINT: When measuring the parasitic current, connect the tester without cutting the battery negative (-) terminal circuit. If the battery negative (-) terminal circuit on the vehicle side is cut, connect the tester between the battery negative (-) terminal on the vehicle side to that on the battery, and leave until the parasitic current becomes stable and measure the parasitic current.

(1/1) REFERENCE Parasitic Current 1. What is parasitic current? In general, parasitic current is the current owing when no electrical devices are used. For the vehicle, parasitic current is the current that ows when the ignition switch is off. In the vehicle, the following current ows as parasitic current to retain the memory in the system. Stand-by current of the microcomputer, etc. that arranges the preparation and waits to restart. Current for the diagnostic system memory or radio channel selection information, etc. Current necessary for clock operation, etc. 2. Examples of parasitic current owing into various equipment
Clock ECT ECU Airbag sensor assembly ABS ECU The key left in the ignition key cylinder(With key unlock warning switch) approx. 2.0 mA approx. 3.0 mA approx. 0.1 mA approx. 2.0 mA approx. 3.0 mA

:00

Charge and Discharge Balance

3. Malfunction cause in the parasitic current Usually, parasitic current ows only a few mA to 50 mA, which does not affect the battery function. However, the following causes, etc. may result in several hundred mA of parasitic current, which could result in a discharged battery. The switches are left on or the lights in the luggage room, etc. remain on. The malfunction of equipment or wiring. Power supplying method to the post-installed parts are not correct (always pass electricity when the ignition switch is off). (1/1) The customer always inserts the key into the ignition key cylinder. Outline of Charge and Discharge Balance 1. Inspect charge and discharge balance If any malfunction cannot be found on the vehicle side according to the vehicle inspection, the customers habitual usage may be severe. In this case, inspect the charge and discharge balance based on the information from the diagnostic questioning. 2. Important point about the charge and discharge balance The alternators output performance has a characteristic which is shown in the illustration. When the electrical load exceeding the alternators output performance is used, the battery discharge compensates for the alternators output current. If such conditions continue for a long period of time, the battery will become discharged. To prevent this, it is necessary to inspect the current, which is owing into the electrical device, and the alternators output performance when the battery is discharged and to judge whether or not the charge and discharge balance is good, that is, whether the battery is in a charged or discharged state. -9(1/1)

(A)

Engine: at approximately 2,000 rpm

Output current

0 2

4 6 8 10 Alternator speed (x1,000 rpm)

Diagnosis Master Technician - Electrical Course

Discharged Battery

Charge and Discharge Balance

Inspection Procedure for Charge and Discharge Balance 1. Inspect current consumption (1) After the engine is warmed up, keep the speed at approximately 2,000 rpm and wait until the current stops owing into the battery.
XX A

Current consumption of electrical load = a + b

a
A Current "a" Current "b" A

+b
XX A

-b
XX A

HINT: An alternator can reach the maximum rating output at around 2,000 rpm. Inspect with the battery fully charged. (2) While keeping the engine speed at approximately 2,000 rpm, apply the electrical load that the customer used in the same order and measure each current consumption and all the current consumption (a + b in the illustration). Measure the battery voltage (c in the illustration) at this time. HINT: Add up the current load. When the alternators generating voltage cannot be maintained constant, the current consumption of the electrical load can be judged as more than the alternators maximum output. (1/3)

XX A

XX A Voltage "c"

Current "a"
A

2. Inspect the alternator's output (1) After the engine is warmed up, keep the speed at approximately 2,000 rpm and wait until the current stops owing into the battery.
A

HINT: Inspect with the battery fully charged. (2) While keeping the engine speed at approximately 2,000 rpm, apply the total electrical load that the customer used. (3) Change the engine speed to obtain the engine speed at the point where the alternators output current (a in the illustration) becomes equal to the total consumption current measured at 1. Inspect current consumption.
4 5

3 2 1 0

6 7 8

Apply the total electrical load that the customer used

X1000rpm

HINT: This engine speed is the minimum engine speed that can keep the charge and discharge balance against the consumption current used by the customers electrical load. This engine speed is dened as N rpm. (2/3)

Judge the charge and discharge balance < A=B : good A>B : bad Charge Engine speed B

3. Judge the charge and discharge balance (1) Obtain the ratio of the engine speed when the battery is discharged while driving and the engine speed N as calculated in 2. Alternator output inspection. Criterion If the ratio when driving at the engine speed that the alternators output current exceeds the consumption current is more than half, the charge and discharge balance can be judged as good. (2) If the judgement is difcult using the above procedure, correctly measure the amount of the batterys charge and discharge (Ah) using a charger counter (VF-600), etc. 4. Recurrence prevention Since the true cause of the discharged battery frequently depends on the customer s using conditions, it is important to accurately advise and explain to the customer. It is necessary to give advice in order to let the customer know how to prevent the battery from becoming discharged by explaining the result of the charge and discharge balance (gain his understanding of the situation). If the technician fails to offer advice, the customer will not understand the true cause of the discharged battery and will continue the same habitual usage. As a result, the possibility of a malfunction recurrence is likely.

"N" rpm A

Discharge

Time

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Exercises
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Diagnosis Master Technician - Electrical Course

Discharged Battery

Question-1 The following statements refer to points for troubleshooting the battery. Which statement is true?

j k l m n 1. j k l m n 2. j k l m n 3. j k l m n 4.

A battery does not degrade regardless of whether it has been used or not. A battery definitely degrades. When the battery is discharged, it should be replaced with a new one. If the amount of electricity consumed is greater than the amount the alternator generates, the battery will also supply electricity, causing it to become discharged. When the battery is discharged, there is a high possibility that the starter has a malfunction.

Question-2 "Inspect battery function" is included among the inspection items for the discharged battery. For each of the following blanks (1 to 6), choose the correct description (a to f) in relation to "Inspection procedure" and "Criterion," respectively. Inspection procedure Check the amount of electrolyte fluid Check specific gravity Inspect recharging and charging condition Load test (High-discharge) Criterion

1
Check the specific gravity in each cell.

2 3 5
Compare the battery voltage with that of vehicles the same model, the voltage should be the equal.

4 6

a. b. c. d. e. f.

The fluid levels in all cells should be between the "UPPER" and "LOWER" levels Specific gravity should be within the specified range shown in the Repair Manual. Also, the difference of specific gravity in each cell should be 0.04 or less. After the engine is warmed up, make it impossible to start. Then, inspect the battery voltage when the engine is cranked with the ignition switch in the ST position for 5 seconds. The voltage should be 15 V or less at the beginning of charging, and 15V or more at the end of charging. Also, the difference of specific gravity in each cell should be 0.04 or less. Check the amount of fluid in each cell. When specific gravity is low, that is, the difference of specific gravity is large, after recharging the battery, inspect the voltage and specific gravity.

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Diagnosis Master Technician - Electrical Course

Discharged Battery

Question-3 The following statement refers to the description about the charge and discharge balance of the battery. Fill in the blank spaces (1 to 4) by choosing the correct term from the list (a to d). When ( 1 ) exceeding the alternator's ( 2 ) is used, the battery ( 3 ) compensates for the alternator's output current. If such conditions continue for a long period of time, the battery will become discharged. To prevent this, it is necessary to inspect the current, which is flowing into ( 1 ), and the alternator's ( 2 ) under the condition where the battery is discharged and to judge whether or not the charge and discharge balance is good, that is, the battery is in a ( 3 ) or ( 4 ) state.

a) charge (or charged) b) discharge (or discharged) c) the electrical load (the electrical device) d) output performance

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