MOTIVE POWER BATTERY

SERVICE MANUAL

THEORY CONSTRUCTION MAINTENANCE SERVICE PRECAUTIONS

TM

INTRODUCTION
With todays expanding industrial world, storage batteries and associated equipment must fill a vital power requirement. Storage batteries are the most dependable and economical source of power to satisfy power requirements. This manual contains information concerning the theory, construction, maintenance, service repair, and hazards of lead-acid storage batteries used in motive power requirements.

TABLE OF CONTENTS
SECTION I - THEORY AND CONSTRUCTION OF LEAD-ACID STORAGE BATTERIES 1-1 Fully Charged Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2 Charging the Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3 Battery Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1-4 Battery Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SECTION II - RECEIVING AND INSTALLATION 2-1 Receiving Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-2 Placing A Wet Battery In Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-3 Placing A Dry Battery In Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-4 A Battery Is Fully Charged When . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2-5 Operation Of The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION III - ROUTINE MAINTENANCE 3-1 Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3-2 Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3-3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3-4 Storing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3-5 Battery Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION IV - TROUBLE SHOOTING 4-1 Interpretation Of Cell Voltage Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4-2 Acid Replacement And Adjustment Of Specific Gravity . . . . . . . . . . . . . . . 13 4-3 Test Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4-4 Calculate Discharge Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4-5 Cadmium Electrode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4-6 Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4-7 On-Site Battery Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4-8 Causes Of Sulfated Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SECTION V - HEALTH AND SAFETY 5-1 Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5-2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MOTIVE POWER CELL PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION I THEORY AND CONSTRUCTION OF LEAD-ACID STORAGE BATTERIES

1-1 FULLY CHARGED CELL
Storage batteries do not store electrical energy, but convert electrical energy into chemical energy which is slowly accumulated as the charge progresses. A battery in use is said to be on discharge. During discharge, the chemical energy stored in the battery is converted into usable electrical energy. A lead-acid storage battery consists of cells with positive and negative electrodes called plates, which are physically separated from each other and immersed in an electrolyte of sulfuric acid solution. The active materials of the electrodes are lead peroxide (PbO2) for the positive plates, and sponge lead (Pb) for the negatives as shown in Fig. 1-1. In a fully charged cell, the electrolyte may have a specific gravity that varies from 1.240 to 1.330, depending on application. When fully charged, each cell has a voltage of approximately two volts on open circuit. However, a cell may have a voltage from 2.12 to 2.70 volts while being charged.
Fig. 1-1

(lead sulfate). As the sulfuric acid is removed from the electrolyte solution, the specific gravity of the electrolyte decreases and approaches the specific gravity of water (1.000). This condition is shown in Fig. 1-3. Specific gravity is the weight of electrolyte as compared to an equal amount of water.
Fig. 1-2

Decreasing Sulfuric Acid Increasing Water Decreasing Sponge Lead Increasing Lead Sulfate Decreasing Lead Peroxide Increasing Lead Sulfate

Electrolyte (Sulfuric acid and water) Maximum sulfuric acid

Discharging Cell

1-2 CHARGING THE CELL

Positive Plate

Negative Plate

Sponge Lead Charged Cell

Lead Peroxide

A cell develops a voltage potential when two dissimilar metals are immersed in a suitable electrolyte. The two metals used in lead-acid cells result in a voltage potential of two volts per cell and their potential ability to deliver this voltage under varying load and varying periods of time. During cell discharge, lead peroxide and sponge lead combine with sulfuric acid to form lead sulfate (PbSO4) on both plates as shown in Fig. 1-2. This reaction decreases cell voltage as the two plates approach being of the same chemical composition

The reaction that occurs in discharging the cell can be reversed, and it can be restored to its former charged condition by sending direct current through it in an opposite direction to the current flow on discharge as shown in Fig. 1-4. The active materials are restored to their respective conditions, and the electrolyte again becomes a more concentrated sulfuric acid solution. Cell voltage rises as the two plates become increasingly different in composition and the specific gravity of the electrolyte increases. As an operating guide, to obtain the best performance and life from a motive power storage battery, the depth of discharge should not regularly exceed 80% of the batterys rated capacity in amperehours. It should be charged after each shift of use or whenever the specific gravity of the electrolyte falls below 1.230. It is very important that proper ventilation be provided during charging to make certain that (1) the hydrogen gas, given off toward the end of the charging process is dissipated, and (2) that individual cell electrolyte temperatures during normal operations do not exceed 115F/46C.

Fig. 1-3

decreasing the size of cells or the number of cells in the battery. POSITIVE PLATE CAPACITY. Positive plate capacity is the ampere delivery for a fixed period of time (usually six hours) for a particular size positive plate. A 160G type positive plate has the capability of delivering 26.7 amperes for six hours or 160 amperes hours (26.7x6=160 AH) to a final voltage of 1.70. This ampere hour rating or capacity can be varied by increasing or decreasing the number of positive plates in the cell. In the previous examples, the battery is a 12 cell, 160G-13 plate unit. To determine the number of positive plates in each cell, subtract one from the total number of plates in the cell and divide by two. EXAMPLE: 13 - 1 = 12 2 = 6 positive plates per cell; 6 positive plates x 160 ampere-hours each = 960 AH. The use of a different type of positive plate, such as a General Battery 75GL or 160G will respectively decrease or increase the ampere hour capacity. The above ratings are based on a temperature of 77F with a fully charged specific gravity acid (see battery nameplate).
Fig. 1-4 Battery Charger

Minimum Sulfuric Acid Maximum Water Minimum Sponge Lead Maximum Lead Sulfate Minimum Lead Peroxide Maximum Lead Sulfate

Discharged Cell

1-3 BATTERY RATINGS

A single lead-acid cell does not have sufficient power to handle most requirements. However, connecting a number of cells together in series results in a battery capable of supplying higher power demands. BATTERY VOLTAGE. The number of cells is determined by the required nominal operating voltage of the equipment. Since each cell has a nominal voltage of two volts, a 24 volt industrial truck will require a 12 cell battery (12 cells x 2 volts/cell = 24 volts). AMPERE HOUR (AH). The electrical capability of a storage battery is usually expressed in ampere-hours. The ampere-hour capacity is the number of amperehours which can be delivered under specified conditions of temperature, rate of discharge and final voltage. Basically, ampere-hours are determined by multiplying the number of amperes which the battery will deliver by the number of hours during which the current is flowing. Example: 160 amperes x 6 hours =960 ampere-hours (six-hour rate). Total cell or battery capacity is then determined by the size and number of plates which make up the element. Due to the variety of job requirements, batteries are produced with many different sizes of cells. KILOWATT HOURS (KWH). Battery capacity is also expressed in kilowatt hours (KWH), which is the product of amperes x time x average volts per cell. Example: 160 amps x 6 hours x 1.932 average volts per cell = 1,855 watt hours 1000 = 1.85 KWH. For a 12 cell battery, the capacity would be 1.85 x 12 = 22.20 KWH. The kilowatt hour rating can be varied by increasing or

Typically 2.44 Volts

Increasing Sulfuric Acid Decreasing Water Increasing Sponge Lead Decreasing Lead Sulfate Increasing Lead Peroxide Decreasing Lead Sulfate

Charging Cell

SPECIFIC GRAVITY. The term which describes the ratio of the density of electrolyte to the density of water. Electrolyte weighing 1.2 times as much as the same volume of water has a specific gravity of 1.200. The full charge gravity of a cell is a matter of design and depends on several factors. The specific gravity must be high enough to contain the amount of sulfuric acid necessary to meet the chemical needs of a cell. If the sulfuric acid content is too high, damage may result to the cell. The standard full charge gravity for lead acid batteries used in motive power requirements is normally 1.275 to1.320. Specific gravities in railway-diesel cells may be as low as 1.240.

Since the acid content of the electrolyte decreases linearly as the cell is discharged, the decrease in gravity is directly proportionate to the amount in ampere-hours taken out. (Refer to Fig. 1-5.) The specific gravity at any point in the discharge indicates the depth of discharge, and can be translated into ampere-hours taken out. A cell having a full charge specific gravity of 1.280 and a final specific gravity of 1.130 will have a gravity drop of 150 points. EXAMPLE: assume the specific gravity is 1.180 at the end of a discharge. That is 100 points specific gravity below the full charge gravity, therefore, 100/150 = 67% discharged of rated capacity. Allow at least a half hour after end of discharge for the electrolyte to diffuse and give a true reading. The linear relation of gravity to state of discharge can be used in tests to determine power consumption or capacity required. Tests of this kind can be made to demonstrate that a truck requires a larger capacity battery to do the job, and can lead to the solution of a problem. GRAVITY DURING RECHARGE. The rise in gravity on recharge is not uniform or proportional to the amount of charge returned in ampere hours. During the early part of the charge, there is no gassing action to mix the electrolyte with the heavier acid being released from the plates. The heavier sulfuric acid will lie on the bottom. A hydrometer reading which draws electrolyte from the top of the cell does not indicate the true gravity or actual state of charge. During the gassing portion of the charge the sulfuric acid mixes, and the specific gravity rises rapidly to full charge value. (Refer to Fig. 1-5).

CASTING GRIDS. A pasted plate is a cast lead grid supporting framework around which chemical pastes have been applied. (Refer to Fig. 1-6). Lead alone is extremely soft and inclined to warp or lose form. A strengthening agent must be added to the lead. A quantity of antimony is added to the lead under very rigid control to secure the strengthening necessary. Temperature control is very critical as uncontrolled heat would cause the antimony to rise in the melting pot surface and evaporate. After heating, the molten alloy is poured into the grid molds. Only Enersys utilizes a computer controlled casting system which optimizes casting variables, resulting in larger lead crystals. Larger lead crystals mean fewer points for corrosion to attack the grid. PASTING THE GRIDS. After casting the grids, lead oxide pastes (active material) are applied to the grids.The negative grid, a lead oxide material, is applied containing an expander to produce the sponge lead condition. The positive plate is pasted with a compound of lead oxide, sulfuric acid, and water mixed to a putty-like consistency. These pastes are mechanically applied to the grids, and evenly distributed by rollers. The rolling process results in complete penetration of the paste as shown in Fig. 1-7. Only Enersys uses HUP, a patented positive paste process which optimizes both the active material utilization and virtually eliminates shedding, the leading cause of battery failure.

1-4 BATTERY CONSTRUCTION

The following is a brief description of the steps involved in the production of a lead acid cell which will help familiarize the reader with the various parts and their functions.

Fig. 1-6

Fig. 1-7

Fig. 1-8

Fig. 1-9

Positive Plate Wrapped Positive Grid

Positive grids are of heavier construction than negative grids. This is necessary because the chemical action resulting from charging and discharging a cell is more pronounced on the positive plate than on the negative. Gases formed during charging are Oxygen and Hydrogen, with the Oxygen forming on the positive plate and Hydrogen on the negative.

Burned Group

Pasted Plate

ASSEMBLY OF POSITIVE AND NEGATIVE GROUPS. A specified number of positive and negative plates are joined together to make up positive and negative groups. Each group of plates is assembled by joining the top (lug end) of each plate together and adding one or more terminal posts. This weld forms a solid bar connection between all plates in each group and their respective terminal posts. (Fig. 1-9) SEPARATORS. The negative and positive plates are insulated by a high-porosity Daramic separator. As shown in Fig. 1-10, separators are flat on one side and grooved on the other. The grooved side is faced to the positive plate to allow free circulation of a large volume of electrolyte to the positive active material. The flat side faces the negative plates. Since the negative material is sponge lead, grooves in the negative side of the separator would tend to fill with expanded material. ASSEMBLY OF AN ELEMENT. An element is one group of assembled positive and negative plates meshed together with a plastic separator protector positioned on top of the groups, and with separators inserted between each plate. The separator protector serves the following function: a. Protects the plates and separators from damage by any foreign object entering the cell through the vent opening. b. Prevents damage by careless use of a hydrometer or thermometer. c. Acts as a baffle to reduce sloshing of the electrolyte within the cell.(Refer to Fig. 1-11) ASSEMBLY OF THE COMPLETE CELL. The next step in cell assembly is the installation of a sediment leveling bridge (Fig. 1-12) in a high impact jar.

CURING AND DRYING PLATES. After pasting, the unformed plates are ready for drying. The wet pasted plates are cured and dried under tightly controlled conditions of temperature and humidity. This process produces a smooth, uniform plate in which the active material attains exceptional porosity and is bonded securely to the grid. This results in maximum cell efficiency. POSITIVE PLATE INSULATION. Retent-A-Tape is a fine glass mat. This is placed vertically against the positive plate surface. A one-piece plastic boot protector completely encases the bottom of the positive plate. A protective heat sealed perforated retainer envelops the entire plate and completes the wrapping. (Refer to Fig. 1-8) The plastic envelope is heavily perforated in the area covering the active material, permitting a free flow of electrolyte to the plate. However, in the area covering the plate edge, the envelope has no perforations and this provides a solid, insulated barrier. This prevents moss build-up and moss shorts between the plate edges. The combination of retainers, mats and bottom shields produces a positive plate assembly which retains the active material in the grid, provides insulation where required, and allows for a free flow of electrolyte to the plate interior.

A completed element is then installed in the jar and a tough, shockproof cover with lead-insert bushings (Refer to Fig. 1-13) is positioned on the posts and heat sealed to the jar. The terminal posts are welded to the lead cover inserts. The cell is then pressure tested to confirm a perfect bond between the cell cover to jar and post to cover insert. The assembled cells consist of cured, dry, unformed plates which have no electrical characteristics and capacity.

PLATE FORMATION. Electrolyte (sulfuric acid) at a specific gravity is now added to each cell. The initial charge given to a cell is known as the forming charge. The forming charge produces the electrical characteristics (positive and negative polarity) on each group of plates. COMPLETED BATTERY ASSEMBLY. At the completion of the forming charge, the cells are assembled into a suitable steel tray and connected in accordance with the buyers layout specifications. The battery is tested, inspected, and made ready for shipment.

Fig. 1-10

Fig. 1-12

Bridge

Fig. 1-13

Cover

Fig. 1-14
Separator

Fig. 1-11

Separator Protector Complete Cut-Away of Cell

SECTION II RECEIVING AND INSTALLATION

2-1 RECEIVING BATTERY
When receiving a new battery, immediately examine the exterior of the packing. Examine for wet spots on the sides or bottom which may indicate leaking jars broken in shipment or that the battery has been tipped over during transit. If there is visible evidence of damage, the receipt should be marked SHIPMENT RECEIVED DAMAGED. The carrier should be called immediately and asked to make a damage report. When a shipment is received and there is no visible evidence of damage, but during the unpacking damage is found, the carrier should be called immediately and requested to make a concealed damage report. Contact your local Enersys representative to assist you in evaluating the extent of the damage. Spilled electrolyte must be replaced immediately or permanent damage will occur to the affected area of the plates resulting in loss of the batterys ability to deliver its rated capacity. Broken jars must be replaced at once for the reason mentioned above. Contact your local Enersys representative immediately to make the proper repairs. (E) Lift the battery with an insulated battery lifting beam or insulated spreader bar with the lifting hooks set in the proper position to place a vertical pull on the lifting eyes (Fig. 2-2). (F) Install the battery in the compartment firmly blocking it to position. All vent caps must be tightly secured to prevent electrolyte spillage from occurring that could cause tray corrosion or battery compartment corrosion.

2-3 PLACING A DRY CHARGED BATTERY IN SERVICE

Batteries shipped in a dry charged condition should be stored in a cool dry place with vent caps securely in place. (A) Remove and discard plastic film seals (if present) from each cell vent hole. (B) Fill the cells using dilute battery grade sulfuric acid with a specific gravity 0.010 to 0.015 lower than nameplate specification, corrected to 77F and cooled down to 90F or less, to the level indicator. (C) Allow the cells to soak for 2 to 3 hours after filling. If the electrolyte level falls slightly because of absorption into the plates and separators, add acid of the same specific gravity to restore level. (D) With the use of a voltmeter, check the voltage of all cells for a correct polarity (Fig. 2-3), then start the initial charge after the electrolyte temperature has fallen below 95F. (E) Connect positive and negative terminals of the battery to corresponding positive and negative leads of the DC power source. (F) The initial charging current is 1/20 of the six hour capacity (finish rate). The time required for an initial charge is approximately 8 hours. (G) During the initial charge, the volume of the electrolyte decreases through electrolysis and evaporation. Therefore, water approved for use in lead acid storage batteries should be added when the electrolyte level falls below the level indicator. If the cell temperature rises higher than 110F, either reduce the charging current to half the specified value or stop charging until the temperature falls below 110F. In this case, prolong the charging time proportionately.

2-2 PLACING A WET BATTERY IN SERVICE

(A) Remove the vent caps from each cell and determine that the electrolyte level in each cell is at the bottom of the level indicator. If electrolyte has been lost, replace it with electrolyte of the same specific gravity. (B) A freshening charge should be given to the battery and will require about three to five hours to complete. The battery should be charged at its finish rate (about 4-5 amperes per 100 ampere hours of the batterys 6 hour rate capacity). (C) Vent caps should be secured in place during charging cycle. Charging is complete when the specific gravity levels off for a 3 hour period. General and Hup batteries have a normal fully charged specific gravity of 1.280-1.290 at 77F (Fig. 2-1). 55GL an 75GL batteries have a normal specific gravity of 1.305-1.320 at 77F. D) Battery compartment drain holes in the floor of the lift truck should be open, and the battery should be clean and dry prior to installation. Fig. 2-1

Fig. 2-2

(H) At the end of charge period, the cell voltages and specific gravity rises to about 2.55 volts and 1.280 (77F) respectively. Continue charging until the cells gas freely and the cell voltages and specific gravities remain constant over a three hour period. (I) Just before completion of the charge, read exact specific gravity of all cells and adjust to battery nameplate specification 0.005. (Refer to 4-2, Page 13). Fig. 2-3

CONSISTENT UNDERCHARGING of a battery will gradually run down the cells and result in one or more cells becoming completely discharged before the others, and may become reversed. Capacity and life expectancy are greatly reduced by undercharging. Equalizing charges to return the cells to a normal condition should be part of a weekly maintenance schedule when required. OVERDISCHARGING can also cause permanent damage
to the battery. Recharging is more difficult and more time consuming. Often complete recharge is not attained and the undercharged battery is placed into service. Consequently, it is overdischarged to a lower limit resulting in loss of capacity and premature battery failure. Optimum battery life can be aided by limiting discharge to 80% of its rated capacity.

A GOOD BATTERY MAINTENANCE PROGRAM is necessary to protect life expectancy and capacity of the battery. A more detailed discussion of Battery Maintenance can be found in Section III of this manual.

2-4 A BATTERY IS FULLY CHARGED WHEN:

(A) The charging voltage has stabilized. Voltage increases slowly during charging and levels off when the battery is fully charged.Refer to Fig.1-5 on Page 3 of Theory & Construction. (B) The battery is gassing freely. CAUTION: An explosive mixture of hydrogen and oxygen is produced in a lead acid battery while it is being charged. The gasses can combine explosively if a spark or flame is present to ignite them. Keep open flames, matches, and smoking away from the charging area. (C) The specific gravity of the electrolyte stops rising. Readings will stabilize when the battery is fully charged and may even drop due to a temperature rise in the electrolyte (Refer to Fig. 1-5, Page 3). (D) Charger current readings will level off (Refer to Fig. 1-5, Page 3).NOTE: Correct all voltages and specific gravities for temperature (see Chart 2-1 and 2-2 on charge or open circuit).

Chart 2-1

Cell Voltage Correction Factors

Electrolyte Temperature F Correction Factor Electrolyte Temperature F Correction Factor
NONE REQUIRED

49-51 52-54 55-57 58-60 61-63 64-66 67-69 70-72 73-75

-0.09 -0.08 -0.07 -0.06 -0.05 -0.04 -0.03 -0.02 -0.01

76-78 79-81 82-84 85-87 88-90 91-93 94-96 97-99 100-102

Subtract From Measured Volts

+0.01 +0.02 +0.03 +0.04 +0.05 +0.06 +0.07 +0.08

Chart 2-2
Electrolyte Temperature
39-41 42-44 45-47 48-50 51-53 54-56 57-60 61-63 64-66 67-69 70-72 73-75 76-78 79-81 82-84 85-87 88-91 92-94 95-97 98-100

Correction Factor
-0.012 -0.011 -0.010 -0.009 -0.008 -0.007 -0.006 -0.005 -0.004 -0.003 -0.002 -0.001 0 +0.001 +0.002 +0.003 +0.004 +0.005 +0.006 +0.007

Electrolyte Temperature
101-103 104-106 107-109 110-112 113-115 116-118 119-121 122-124 125-127 128-130 131-133 134-136 137-139 140-142 143-145 146-148 149-151 152-154 155-157 158-160

Correction Factor
+0.008 +0.009 +0.010 +0.011 +0.012 +0.013 +0.014 +0.015 +0.016 +0.017 +0.018 +0.019 +0.020 +0.021 +0.022 +0.023 +0.024 +0.025 +0.026 +0.027

2-5 OPERATION OF THE BATTERY

There are several factors which affect the operation of the battery concerning its ability to deliver capacity and life expectancy. Many chemical reactions are affected by temperature, and this is true of the reaction that occurs in a storage battery. The chemical reaction of a leadacid battery is slowed down by a lowering of temperature which results in less capacity. A battery that will deliver 100% of capacity at 77F will only deliver at 74% of capacity of 20F (Chart 2-3). EXCESSIVE HEAT will contribute greatly to reducing battery life by corroding the positive grids and excessive gassing which loosens active material in the plates, especially the positive plates. Overcharging is the most common contribution to excessive temperatures and gassing in a battery. A General Battery Ferro-Resonant charger, matched to the proper ampere-hour requirements of the battery, will help to avoid the problem of overcharging.

CELL SPECIFIC GRAVITY CORRECTION FACTORS

Temperature correction factor to be added or subtracted to the observed specific gravity to obtain corrected specific gravity @ 77F.

Chart 2-3
Electrolyte Temperature
F 77 60 50 40 30 20

Percent Capacity @ 6-Hour Rate

100 95 91 87 81 74

Percent Capacity @ 3-Hour Rate

100 93 87 83 76 67

Add To Measured Volts

Chart 3-3

BATTERY MAINTENANCE
FOLLOW THESE SIMPLE RULES FOR LONG LIFE AND TOP PERFORMANCE.

DAILY Connect battery to an automatic-start charger. If using manual start, press the start or daily button. After charge and before the work-shift, take a hydrometer reading on a single pilot cell to make certain of a full charge on the battery (see specific gravity ranges below). WEEKLY 1. Add pure water to all cells. While the battery is gassing at the end of the charge cycle, top off the water level to approximately 1/4 below the bottom of the vent well. 2. Provide an Equalize charge on the battery to properly mix the electrolyte and water. MONTHLY 1. Take a specific gravity reading on all cells with a hydrometer after charge. a. b. If the readings average less than the specific gravity ranges below, check the charger output. If one or two cells read more than 20-points less than the average, circle those readings and check for improvement at the next monthly reading. If the low cells do not improve, contact your local EnerSys Inc. representative

2. Wipe down the top of the battery with a neutralizing cleaning agent such as PRO Wash Light, part number 94883-4QT. 3. Inspect cable leads and connector for fraying, loose connectors or burned contact areas. Contact your local Enersys representative for repair or replacement as needed. 4. Refer to this manual for a more detailed description of maintenance and service.

Specific Gravity at 77F General Hup 55GL and 75GL 1.280 - 1.290 1.280 - 1.290 1.305 - 1.320

10

Chart 3-4

Specific Gravity @ 77F

77F

Chart 3-5

The recommendation for battery replacement water is shown in this listing below including the maximum allowable impurities in parts per million NEMA standards. Total Solids Fixed Solids Organic & Volatile Matter Iron Chloride Ammonia as NH4 Nitrites as HO2 Nitrates as HO3 350 200 150 4 25 5 10 10 PPM PPM PPM PPM PPM PPM PPM PPM

11

Chart 3-6

TM

BATTERY CHARGING LOG

USER #

TYPE

S/N

START OF CHARGE
DATE TIME TRUCK SP. GR.
CHARGER

END OF CHARGE
CELL TEMP. W E C* BY DATE TIME SP. GR. CELL TEMP. BY

* INSERT W WHEN WATER IS ADDED INSERT E WHEN EQUALIZING CHARGE IS GIVEN INSERT C WHEN BATTERY IS CLEANED OR WASHED

EVERY MONTH RECORD GRAVITY AFTER EQUALIZING CHARGE TEMP.

CELL 1 2 3 4 5 6
REMARKS

DATE.
CELL 25 26 27 28 29 30 SP. GR. CELL 31 32 33 34 35 36 SP. GR.

SP. GR.

CELL 7 8 9 10 11 12

SP. GR.

CELL 13 14 15 16 17 18

SP. GR.

CELL 19 20 21 22 23 24

SP. GR.

FORM NO. IND.010 (REV. A)

PRINTED IN U.S.A.

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SECTION IV TROUBLE SHOOTING

4-1 INTERPRETATION OF CELL VOLTAGE READINGS
The condition and health of a battery can be revealed in a study of its cell voltages. There are two factors to consider: the value of the voltage readings in relation to the battery function at that time, and the uniformity of the voltage readings throughout the battery. The nominal voltage value of a lead acid cell is 2.00 volts. It is not uncommon to encounter cell voltages anywhere from 1.00 volts or less to 2.75 volts depending on the function of the battery at the time of the readings. The interpretation of the voltage values is a matter of comparison with normal battery characteristics, and the knowledge as to the reason for any deviation. OPEN CIRCUIT READINGS. There is a definite relationship between the cell voltage and the specific gravity of a cell that is open circuit. Open circuit readings are useful in determining uniformity. For example, a fully charged battery on open circuit, with a specific gravity of 1.260 to 1.280 will read 2.10 to 2.12 volts or a spread of 0.02 volts. This 0.02 volt spread would be considered normal for a new battery. As the battery ages, the voltage spread will increase to about 0.03 volts. The reason for the spread to widen with age is due to inequalities in plate wear and possibly some acid loss. ON-CHARGE VOLTAGE READINGS. On charge voltage readings are the most informative and the best indicators of battery condition. These readings should be taken at the normal finish rate, and be corrected to the base of 77F. New batteries, at normal finish rate, will have cell voltages between 2.55 volts and 2.65 volts. Older batteries on charge at the normal finish rate, will have cell voltages about 2.45 to 2.55 volts VARIATIONS IN CHARGE VOLTAGE. If all cells of a battery show similar full-charge voltages, they are equally healthy. The uniformity and value of the individual cell voltage readings vary with the overall condition of the battery. A battery with an on-charge voltage of 2.45 to 2.50 volts per cell has more uniformly healthy cells than a battery having an on-charge voltage spread of 2.40 to 2.50 volts per cell. The batterys age and service duty must be considered in the interpretation of the on-charge voltage readings. An example would be an older battery which has on-charge cell voltage readings of 2.45 volts to 2.65 volts. The reason may very well be that the inside cells operate at higher than average temperatures causing higher local action, which would result in lower voltage. Regular equalize charge will compensate for the higher self-loss of the inside cell. Any wide spread on-charge voltage that could not be attributed to the batterys service life or age, is a sign that something is wrong and attention is necessary. Some causes of abnormally wide spread or charge voltages are: 1. Abnormal temperature differential 2. Internal shorts 3. Acid loss causing overdischarge 4. Insufficient charging

4-2 ACID REPLACEMENT AND ADJUSTMENT OF SPECIFIC GRAVITY

Under normal circumstances, a battery should never require the addition of acid to increase the specific gravity of the electrolyte. However, when upsets, jar breakage, overfilling, or careless use of the hydrometer cause a loss of electrolyte and a corresponding loss of battery capacity, the lost acid should be replaced. CAUTION: Before adding acid to a cell or to an entire battery with low specific gravity readings, try to raise the specific gravity by charging as described on page 17 Causes of Sulfated Batteries. Only if the charging is unsuccessful should an attempt be made to increase the specific gravity with acid. Never perform acid adjustment on a cell with an on-charge cell voltage less than 2.45 volts and that does not gas vigorously. To replace acid, use the following procedure with a sulfuric acid having a specific gravity of 1.400. (A) Battery must be in a fully charged condition topped off with an equalizing charge (see page 8 for definition and description), with the electrolyte freely gassing. (B) Remove electrolyte from the low reading cell or cells until the level reaches the separator protector. (C) Slowly add the 1.400 specific gravity sulfuric acid to the proper electrolyte level while it is still charging and gassing so that the adjusting acid mixes thoroughly. If added to fast, the adjusting acid will drop to the bottom of the cell and not diffuse immediately, resulting in an inaccurate specific gravity reading. Further additions of acid can be harmful, especially when the battery is returned to service and complete diffusion results in a high specific gravity. About 1/4 of 1.400 specific gravity will increase a cells specific gravity about 5 points (0.005) (D) After adding high specific gravity acid, leave the battery on charge for one hour so that the higher specific gravity acid is thoroughly mixed with the electrolyte. Read and record the specific gravity of the adjusted cell(s) and correct for temperature (refer to temperature correction chart 2-2 on page 7). If the specific gravity readings are too low, repeat steps 2 through 4 until the cell(s) attain a temperature corrected specific gravity specified on the battery nameplate 0.005. (E) If the specific gravity in cell(s) is too high, remove the electrolyte and replace it with approved water to proper electrolyte level (refer to chart 3-5 page 11). Charge the battery for one hour at the finish rate. Read the specific gravity of the cell(s) and correct for temperature if necessary. If the specific gravity is still too high, repeat the process until it reaches the proper full charge specific gravity. If the electrolyte level is low after the specific gravity has been adjusted, final electrolyte level adjustment must be made with the same strength sulfuric acid in order to maintain the proper specific gravity.

13

14

NOTE: If electrolyte temperature exceeds 110F during the above mentioned procedures, stop the charge and allow the battery electrolyte temperature to cool to 90F or less before continuing. CAUTION: Never add acid with a specific gravity higher than 1.400. When mixing or cutting acid, always add the acid to the water. NEVER POUR water into acid because a violent reaction could result, possibly causing personal injury. Always wear a face shield, rubber gloves, and an acid resistant apron.

4-3 TEST DISCHARGE

A capacity test is sometimes desirable to determine a batterys actual discharge capability as compared to its six hour rated capacity. The discharge test can be a significant diagnostic tool when equipment does not operate as expected, and it can help determine when the battery should be replaced. When a battery consistently delivers less than 80% of its rated 6 hour capacity, either some cells are substandard or the battery has reached the end of its useful life and should be replaced. Equipment: 1. Discharge apparatus 2. Voltmeter 3. Ammeter and shunt (calibrated) 4. Charge-test-discharge form (Section 87.86) 5. Thermometer 6. Hydrometer PROCEDURE: (A) Prior to the start of the test discharge, complete the general information section at the top of the charge-testdischarge form, Section 87.86. Calculate the desired discharge current rate from the procedure given below. (B) Record the open circuit voltage and specific gravity of each cell as received. Charge the battery and equalize charge. (C) Record the on-charge, end of equalize charge, voltage and specific gravity of each cell, and the charging current rate in amps. The end of equalize charge specific gravity should be according to battery nameplate specification. (D) If acid adjustment is necessary, follow the procedure set forth above for acid adjustment and record the adjusted specific gravity readings in the space provided. Maintain a temperature of 90F or less throughout the charging, equalize charge, and acid adjustment. If the temperature exceeds 90F, terminate charging and acid adjustment until battery has cooled down to 90F or less. Start discharge, maintain discharge current within plus or minus 1% of the calculated discharge rate. (E) After a few minutes, when discharge current stabilizes, record the voltage of each cell. (F) Install a thermometer in a center cell and record the temperature in the space provided. (G) Fill in the start time when discharge current was applied and record the time elapsed as start. Also, record the battery terminal voltage. Complete the remaining portion of the charge-test-discharge form Section 87.86 in the following manner: Record cell voltages every 60 minutes until an average voltage of 1.80 volts per cell is reached. Between 1.80 volts per cell and 1.75 volts per cell, readings of each cell voltage should be taken every 30 minutes. Between 1.75 volts per cell and 1.72 volts per cell, readings should be taken of each cell voltage every 15 minutes. Caution should be taken not to allow any cells to

reverse during discharge. To avoid allowing a cell to reverse, isolate the cell from the battery by cutting the intercell connector; and with a jumper cable, jump across the isolated cell. The time, temperature, and specific gravity should be recorded at termination. Recharge the battery as soon as possible after the test discharge. The actual capacity in ampere-hours obtained during the test discharge is the product of the discharge rate amperes times the time in hours required to reach termination voltage of 1.70 volts per cell. Further guidelines such as performance requirements, test conditions, test equipment, and test methods for conducting a test discharge should be obtained from Battery Council International publication BCI-I2 titled Determination of Capacity of Lead Acid Industrial Storage Batteries for Motive Power Service.

4-4 CALCULATE DISCHARGE RATE

To calculate the 6 hour discharge rate, multiply the rated ampere-hour capacity of the battery times 0.167. The product will be the amount of amperes necessary to discharge the battery 100% in a 6 hour period. To calculate the 3 hour discharge rate, multiply the rated ampere hour capacity of the battery times 0.280. The chart below is battery terminal voltage for termination of test discharge: Chart 4-1

Number of cells
6 9 12 15 18 24 30 32

Terminal Voltage
10.2 15.3 20.4 25.5 30.6 40.8 51.0 54.4

4-5 CADMIUM ELECTRODE TESTING

When a battery is not performing satisfactorily, it is useful to know if the positive or negative plates are at fault. A third electrode is introduced into the cell and the portion of the total voltage contributed by each plate group is measured. An analysis of these measurements between this third electrode and the positive or negative groups can be made; and by comparing each with the total cell voltage, the relative condition of each group is determined. The most commonly used third electrode in lead acid batteries is the cadmium electrode. Chart 4-3 shows three sets of cadmium readings taken on three cells at one half hour intervals at the end of a 6 hour discharge. The chief value of the cadmium electrode test is to determine the condition of positive and negative plates separately. The electrode consists of a rod about 5/16 in diameter; it may be from one to several inches long. Before the electrode is used for the first time, it should be soaked for several days in a sulfuric acid solution of about the strength of battery electrolyte, and before each test it should be immersed in the solution for several hours before it its used. The cadmium must be insulated so that it cannot come in contact with the plates of the cell. The separator protector in the cell will usually protect the cadmium rod from coming in contact with the plates. If the separator protector is

15

missing, the cadmium rod should be encased in a perforated hard rubber cover. A flexible rubber insulated wire is attached to the cadmium to serve as a voltmeter lead. The cadmium electrode is inserted into the electrolyte immediately above the center of the plate. The readings must be taken when the cell is either discharging or charging. Open circuit readings are meaningless. During the discharge cycle, the potential between the cadmium electrode and the positive plates decreases from about 2.2 to 2.0 volts, depending on the state of charge. If the battery is further discharged, this potential drops rapidly. The potential between the cadmium and the negative plates is about 0.15 to 0.2, volts, and the rate of increase in potential becomes greater if the cell is discharged below its normal rating. When the battery is on-charge, the potential between the cadmium and the negative plates reverses as the battery approaches the end of the charging cycle. The readings near the end of the charge are about 2.45 volts between the cadmium and the positive plates. A high resistance voltmeter must be used with the cadmium electrode because the current drawn by a low resistance voltmeter will cause polarization at the cadmium and error in the readings. At 77F the following would represent a healthy cell at finish rate: Positive Cadmium = 2.43 Negative Cadmium = -0.20 Cell Voltage = 2.63 The cell voltage is the algebraic difference between the two cadmium readings. Both the positive and negative cadmium readings under fully charged conditions will be uniform in a normal battery. If there is a cell voltage variation of more than 0.05 volts below the other cells, cadmium readings will indicate which plates are affected. An internal cell inspection should be made to determine the cause of the trouble. CELL NUMBER 1 shows normal readings. CELL NUMBER 2 has low terminal voltage. The positive and negative cadmium readings are low. Internal inspection of the cell will reveal the defect. CELL NUMBER 3 has low terminal voltage, but normal positive readings. The negative cadmium reading is low, indicating either undercharging or contamination of the negative plate. Chart 43 shows three negative cadmium readings taken on three cells at one half hour intervals at the end of a 6 hour discharge. CELL#1 - Both the positive and negative cadmiums are decreasing uniformly as the cell voltage decreases, and both sets of plates are losing capacity together indicating that they are in a healthy condition. At the end of the 6 hour discharge the cell had delivered capacity to 1.70 volts. This cell is performing satisfactorily. CELL #2 This cell delivered capacity; however the positive cadmium readings changed rapidly and contributed to most of the voltage drop since the negative cadmiums remained practically unchanged. This cell appears to be limited in its ability to deliver capacity by the positive plates at the present time.

CELL #3 - The terminal voltage of this cell decreased very rapidly towards the end of the discharge. The negative cadmium values changed by a large amount (0.32), whereas the positive values only showed a minimal change (0.05). This cell appears to be limited in its ability to deliver capacity by the negative plates which contributed to the bulk of the voltage drop. Failure of the negative plates will usually cause a more rapid decline in cell voltage than failure of the positives.
Chart 4-2 On Positive Negative Cell Cad. # Charge Cad. Cell Voltage Value Value

Probable Cause of Condition

2.63

2.43

-0.20

No internal shorts. Healthy negative plates. Typical readings for a new cell.

2.38

2.38

Low terminal voltage. Positive cadmium value below normal. Check for internal shorts. Could be a broken separator.

2.38

2.43

+0.05

Normal positive cadmium value indicates absence of internal shorts. Unhealthy negative plates indicated by low negative cadmium value. Negative plates could be failing.

Chart 4-3 Cell #1 5 Hours & 30 Min. Positive Cadmium Value Negative Cadmium Value Cell Voltage 6 Hours Positive Cadmium Value Negative Cadmium Value Cell Voltage 5 Hours & 7 Min. Positive Cadmium Value Negative Cadmium Value Cell Voltage 2.02 0.22 1.80 Cell #2 1.97 0.17 1.80 Cell #3 2.03 0.23 1.80

1.98 0.23 1.75

1.92 0.17 1.75

2.00 0.40 1.60

1.91 0.24 1.67

1.84 0.18 1.66

1.98 0.55 1.43

4-6 INTERNAL INSPECTION

If the test discharge previously explained indicates that the battery was not capable of delivering more than 80 percent of rated capacity, an internal inspection should be made. The positive plates, which wear first, should be examined. If it is discovered that the positive plates are falling apart or that the grids have many frame fractures, a replacement battery is needed. If the positive plates are in good mechanical condition and the cells contain little sediment, the battery may be sulfated.

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4-7 ON SITE BATTERY INSPECTIONS

On-site battery inspections are performed for various reasons. The customer may be experiencing battery problems or just require an annual battery inspection to determine the condition of all batteries and chargers. Many times the on-site inspection is a good sales tool for developing new customers as well as obtaining replacement battery orders. On-site inspections are not just a visual inspection, but also a factual inspection. Battery cell voltages and gravities should be recorded. Battery temperature and specific gravity before and after charge should be recorded. The number of cycles a battery receives during a 24 hour period, charger rates, and timer settings should be recorded, as well as the general condition of the charging area, ambient temperature, and battery charging schedule. Upon compiling the recorded data, an intelligent view of the customers operation can be made along with the proper recommendations. Consequent follow-up inspections and repair work can be accomplished. Form IND-441 should be used in an on-site battery inspection. The required information can be accumulated easily on this form for review (Refer to Chart 4-4).

4-8 CAUSES OF SULFATED BATTERIES

All lead acid batteries sulfate when discharged. The active material must convert to lead sulfate in order for the cells to produce energy. This sulfation process is called normal sulfation. The term sulfated battery means that the battery has developed abnormal sulfate and has its capacity impaired as a result. The most common causes of sulfation are: 1. Undercharging or neglect of equalizing charge. 2. Standing in a partially or completely discharged condition. No batteries should be allowed to stand in a completely discharged condition for more than 24 hours, or when temperatures are below freezing. 3. Low electrolyte level. 4. Adding acid. 5. High specific gravity. 6. High temperature.

Cells of a sulfated battery give low specific gravity and voltage readings and the battery will not become fully charged after a regular equalizing charge. Before assuming that the battery is sulfated, rule out the possibility that low gravity may be due to acid loss. If the specific gravity is low due to acid loss, the negative plates are likely to be in good condition, with the active material a spongy lead showing a metallic luster when stroked. Abnormally sulfated material is hard and gritty and feels sandy when rubbed. If the negative active material is mushy and sandy, coming off like mud when stroked, too much acid is indicated. A sulfated positive material is a lighter brown color than a normal positive plate. If the sulfation has not progressed too far, it may be possible to restore the battery to a serviceable condition by paying careful attention to the following procedure: (A) Clean the battery (neutralize, wash and dry). (B) Adjust electrolyte by adding approved water to the proper level. (C) Change the battery at the proper finish rate until the full ampere-hour capacity has been put in the battery, based on the six-hour rate. If the temperature rises above 110F during these procedures, reduce the charge rate accordingly, or stop the charge and allow the battery to cool to 90F or less before continuing. Charge the battery until the specific gravity shows no change during a 3 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge 2 or 3 times. (D) Discharge the battery to its rated capacity or lower without causing any cell to reverse. (E) Recharge again until the specific gravity shows no change during a 3 hour period. (F) Repeat the cycling process until the specific gravity remains constant. If the battery gives at least 80% capacity, recharge and put into service. (G) If the battery has not responded to steps A through F, it is sulfated to the point where it is impractical to attempt further treatment. The battery should be replaced.

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CHART 4-4 BATTERY INSPECTION REPORT INSPECTED BY:

TM

(AGENT OR BRANCH) DATE USER NAME LOCATION OF BATTERIES TYPE OF CHARGING EQUIPMENT USER # TYPE S/N CHARGE RATE TEMP.
CELL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
REMARKS & RECOMMENDATIONS

ADDRESS TYPE OF SERVICE CONDITION

C.V.

SP. GR.

C.V.

SP. GR.

C.V.

SP. GR.

C.V.

SP. GR.

C.V.

SP. GR.

FORM NO. IND. 441 (REV. A)

PRINTED IN U.S.A.

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SECTION V HEALTH AND SAFETY

5-1 BATTERY HAZARDS
GENERAL - A lead-acid battery can be a very useful, safe source of electrical power. While installing, using, maintaining, or repairing a motive power battery, opportunities exist, however, for exposure to potentially dangerous situations. This section identifies those hazards which could result from improper handling or use. HAZARDS (A) A sulfuric acid solution is used as the electrolyte in lead-acid batteries and has a concentration of approximately 37% by weight, of sulfuric acid in water. In this diluted state it is not as hazardous or as strong as concentrated sulfuric acid; but it acts as an oxidizing agent, and can burn the skin or eyes and destroys clothing made of many common materials such as cotton or rayon. (B) An explosive mixture of hydrogen and oxygen is produced in a lead-acid battery while it is being charged. The gases can combine explosively if a spark or flame is present to ignite them. Because hydrogen is so light, it normally rises and diffuses into the air before it can concentrate into an explosive mixture. If it accumulates into gas pockets, as can occur within a cell, it might explode if ignited. Hydrogen formula =0.00027 x (finish rate) x (number of cells)=cu.ft. of hydrogen produced per minute. (C) Electricity is produced by the batteries on discharge and, while most persons cannot feel voltages below 35 to 40 volts, all motive power batteries should be regarded as potentially dangerous. A lead-acid battery is capable of discharging at extremely high rates and, under conditions of direct shortage, can cause severe damage and serious injury. (D) The weight of these heavy batteries can easily cause painful strains or crushed hands or feet if improperly lifted or handled. Batteries can be damaged if dropped. The average motive power battery weighs more than one ton, so proper equipment must be provided when changing or handling batteries. (E) Burns can result from contact with molten lead or hot compounds while repairing a battery. Lead can splash when intercell connectors are being reburned, and hot compounds can be spilled when resealing covers to jars. Protective gear, if worn, will help prevent such burns. SAFETY PROCEDURES WHILE HANDLING BATTERIES (A) Lift batteries with mechanical equipment only, such as an overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should always be used with overhead lifting equipment. Do not use chains attached to a hoist at a single central point forming a triangle. This procedure is unsafe and could damage the steel tray. (B) Always wear safety shoes, safety glasses, and a hard hat made of a nonconducting material. (C) Tools, chains and other metallic objects should be kept away from the top of uncovered batteries to prevent possible short circuits. (D) Battery operated equipment should be properly positioned with switch off, break set, and battery unplugged when changing batteries or charging them while in the equipment. (E) Personnel who work around batteries should not wear jewelry made from conductive material. Metal items can short circuit a battery and could cause severe burns and electrocution. (F) Only trained and authorized personnel should be permitted to change or charge batteries. (G) Reinstalled batteries should be properly positioned and secured in the truck, tractor, or crane. Before installing a new or different battery, check with the truck or tractor name plate and battery service weight to make sure that the proper weight battery is being used. A battery of the wrong weight can change the center of gravity and cause equipment to upset.

SAFETY PROCEDURES WHILE CHARGING BATTERIES

(A) Specific areas should be designated for charging batteries. These areas should be equipped with overhead hoists or cranes for handling batteries. (B) Charging areas should be adequately ventilated. The actual amount of ventilation will depend upon such factors as number and size of batteries being charged at the same time, room size, ceiling height and airtightness of the building. Hydrogen concentrations above 4% can be explosive. Hydrogen Formula = 0.00027 x (finish rate) x (number of cells)=cu.ft. of hydrogen produced per minute. (C) Smoking, open flames, and sparks must be prohibited in the charging area. Post placards Hydrogen, Flammable Gas, No Smoking and No Open Flames. (D) Barriers (posts) should be provided to protect charging equipment from physical damage by trucks, tractors, and cranes. (E) Eyewashes and showers are required in areas where batteries are serviced. OSHA regulation 29 CFR 1910.151(c) has clear guidelines for eyewash and shower use. Safety equipment should be clearly identified and readily accessible.

5-2 SAFETY PROCEDURES

FEDERAL STANDARDS - In 1970, Congress passed the Occupational Safety and Health Act (OSHA). This act established the minimal acceptable standards for safe and healthful working conditions. The safety procedures outlined in this manual have been compiled from standards developed over the years by professional and technical organizations. The safety procedures have been grouped by functional area of most logical application or need.

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(F) Before connecting a battery to, or disconnecting it from, a charger, the charger should be turned off. Live leads can cause arcing and pitting of battery connector contact surfaces. (G) Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power. (H) At a minimum, a face shield or goggles, rubber gloves, apron and boots should be worn when checking, filling, charging or repairing batteries during periods of possible exposure to acid or electrolyte. (I) When batteries are charged on racks, the racks should be insulated to prevent any possibility of shortage. (J) When charging an enclosed or covered battery, always keep the battery tray cover, or compartment cover, open during the charging period. This will help to keep the battery cool and disperse the gases. (K) Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells. (L) Shut off and disconnect both input and output connections to the charger before repairing charging equipment. SAFETY PROCEDURES WHILE HANDLING BATTERY ACID (A) The splashing of acid into the eyes is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte. If this should happen, the eyes should be gently flooded with fresh, clean running water for at least 15 minutes followed as quickly as possible with a physicians examination. If the person is wearing contact lenses, they should be removed before rinsing the eyes. (B) Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin, but if a burn develops, it should be treated medically. (C) When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda as soon as possible, to neutralize the acid. (D) A carboy filter or safety siphon should be provided for handling acid from a carboy container. Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. Use only glass or acid resistant plastic containers when storing acid or electrolytes. (E) When mixing acid to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well. Never pour water into acid. Never use sulfuric acid solutions which are over 1.400 specific gravity. (F) Apply a neutralizing solution, such as a bicarbonate of soda and water, when acid is spilled on floor and clean up promptly. A mixture of one pound of soda to one gallon of water is recommended.

SAFETY PROCEDURES WHILE SERVICING OR REPAIRING BATTERIES (A) Disconnect the battery from the truck, tractor, or crane when servicing or repairing either the battery or the equipment. Also make certain the battery is disconnected from the charger before handling or repairing the battery. (B) Before repairing a battery, remove all of the vent caps and blow out each cell with a low pressure air hose to remove any residual gas. Use only a gentle stream of air to avoid splashing electrolyte. (C) Open or break the circuit before repairing damaged or dirty terminal plugs or receptacles connected to a battery, by removing and insulating one terminal lead at a time. (D) When melting sealing compound in preparation for resealing cells, be careful not to puncture the top section of unmelted compound with a screwdriver or other pointed object. A build-up of pressure from the melted compound in the bottom could cause liquid compound to squirt and inflict a severe burn. Do not allow compound to ignite by overheating. Compound becomes workable at 400 to 425F. (E) Check batteries frequently for acid leakage or signs of corrosion. (F) Use insulated tools whenever possible when working on batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or other insulating material to prevent short circuits. (G) When taking specific gravity readings, use a face shield or goggles and read the hydrometer with eye at about the same level as the electrolyte. See Fig. 5-1.

There may be additional regulatory requirements, depending on the specific application, as well as federal, state, and local requirements.
Fig. 5-1

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Chart 5-1 TROUBLE SHOOTING CHART Problem

Battery not working a full shift.

Probable Cause
1. Battery is undersized. 2. Battery not fully charged at beginning of shift. 3. Weak or defective cells. 4. Grounds or Shorts. 5. Battery has exceeded useful operating life. 6. Vehicle has electrical or mechanical problems.

Remedy
1. Replace with a battery of adequate capacity for the work load required. 2. Check chargers and charging schedules. Fully charged gravity is 1.275-1.285 for a standard battery. 3. Repair or replace battery. 4. Clean battery and remove any visible corrosion. 5. Replace battery. 6. Troubleshoot and repair vehicle.

Battery overheats on charge.

1. Charged equipment not operating correctly. 2. Charging equipment incorrectly adjusted. 3. Weak or defective cells. 4. Battery worn out. 5. High resistance connection. 6. Low electrolyte level. 7. Battery too warm when placed on charge. 8. Battery being charged in truck compartment with cover closed. 9. Battery too deeply discharged. 1. Excessive load. 2. Battery not fully charged prior to work assignment. 3. Battery overdischarged. 4. Electrolyte levels low. 5. High current draws due to worn-out equipment. 6. Operating truck in high ambient temperatures.

1. Repair or replace charger. 2.Adjust starting and finishing rates. 3. Repair or replace battery. 4. Replace. 5. Check for hot cables, poor plug solder joints, bad connector burns. 6. Water battery to correct level. Allow to cool and recharge. 7. Cool battery with fans or water to below 90F before starting charge. 8. Remove from truck and open cover while charging. 9. Limit discharge to 80% of rated capacity. 1. Do not exceed capacity of equipment. 2. Give full charge before returning to truck. 3. Limit discharge to 80% of rated capacity. 4. Water battery to correct level, allow to cool and recharge. 5. Repair brakes, worn out bearings etc. 6. Provide cool charging facilities for recharge. 1. Replace jars. 2. More care required. Electrolyte level must always cover the top of the batterys plates. 3. Check charging equipment. 4. Add water, give equalizing charge and adjust gravities. 1. Give equalizing charge. 2. Repair or replace battery. 3. Give equalizing charge and adjust gravities. 4. Neutralize and clean top. 5. Clean battery. 6. Add only distilled or approved water. 7. Give deep discharge and equalizing charge. 8. Give equalizing charges periodically. 1. All remedies listed under Unequal Cell Voltages. 2. Charge at finish rate for 1 hour after gassing begins. 3. Adjust gravity.

Battery overheats on discharge.

Low Electrolyte Level.

1. Cracked or broken jars. 2. Lack of watering.

3. Frequent overcharging. 4. Battery tipped over.

Unequal Cell Voltages.

1. Overdischarging. 2. Weak or defective cells. 3. Acid loss due to tipping or overwatering. 4. Corroded or dirty battery top. 5. Grounds in battery. 6. Impurities in cell electrolyte. 7. Battery used infrequently. 8. Lack of equalizing charges.

Unequal specific gravities.

1. All probable causes listed under Unequal Cell Voltages. 2. Battery recently watered and insufficient time allowed for mixing. 3. Improper gravity adjustment after cell replacement.

21

GENERAL SERIES MOTIVE POWER CELL PARTS LIST

INTERCELL CONNECTORS & INSULATORS SIDE TO SIDE END TO END Over Partition Insulator Standard Over Partition -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09")

Cell 55GL-5 55GL-7 55GL-9 55GL-11 55GL-13 55GL-15 55GL-17 55GL-19 55GL-21 55GL-23 55GL-25 55GL-27 55GL-29 55GL-31 55GL-33 75GL-5 75GL-7 75GL-9 75GL-11 75GL-13 75GL-15 75GL-17 75GL-19 75GL-21 75GL-23 75GL-25 75GL-27 75GL-29 75GL-31 75GL-33 75G-5 75G-7 75G-9 75G-11 75G-13 75G-15 75G-17 75G-19 75G-21 75G-23 75G-25 75G-27 75G-29 75G-31 75G-33 85G-5 85G-7 85G-9 85G-11 85G-13 85G-15 85G-17 85G-19 85G-21 85G-23 85G-25 85G-27 85G-29 85G-31 85G-33 100G-5 100G-7 100G-9 100G-11 100G-13 100G-15 100G-17 100G-19 100G-21 100G-23 100G-25 100G-27 100G-29 100G-31 100G-33

6 Hr. Ah 110 165 220 275 330 385 440 495 550 605 660 715 770 825 880 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 170 255 340 425 510 595 680 765 850 935 1020 1105 1190 1275 1360 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

Cable #2 #2 #2 #2 #2 #2 #2 #2 #2 1/0 1/0 1/0 1/0 2/0 2/0 #2 #2 #2 #2 #2 #2 #2 1/0 1/0 2/0 2/0 3/0 3/0 4/0 4/0 #2 #2 #2 #2 #2 #2 #2 1/0 1/0 2/0 2/0 3/0 3/0 4/0 4/0 #2 #2 #2 #2 #2 #2 1/0 1/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 #2 #2 #2 #2 #2 1/0 1/0 2/0 3/0 4/0 4/0 4/0 4/0 4/0 4/0

Cell 93478-CW 93479-CW 93480-CW 93481-CW 93482-CW 93483-CW 93484-CW 93485-CW 93486-CW 93487-CW 93488-CW 93489-CW 93490-CW 93491-CW 93492-CW 83623-CW 90000-CW 90001-CW 90002-CW 90003-CW 90004-CW 90005-CW 90006-CW 90007-CW 90008-CW 90009-CW 90010-CW 90011-CW 90012-CW 90013-CW 84301-CW 84302-CW 81113-CW 81114-CW 81115-CW 81116-CW 81117-CW 81118-CW 81119-CW 81120-CW 81121-CW 81122-CW 81123-CW 88137-CW 87300-CW 99231-CW 99232-CW 99233-CW 99234-CW 99235-CW 99236-CW 99237-CW 99238-CW 99239-CW 99240-CW 99241-CW 99242-CW 99243-CW 99244-CW 99245-CW 99261-CW 99262-CW 99263-CW 99264-CW 99265-CW 99266-CW 99267-CW 99268-CW 99269-CW 99270-CW 99271-CW 99272-CW 99273-CW 99274-CW 99275-CW

Cover 804080 804081 804082 804083 804084 804085 804090 804091 804092 804093 804094 804095 804940 804941 804942 804080 804081 804082 804083 804084 804085 804090 804091 804092 804093 804094 804095 804940 804941 804942 804080 804081 804082 804083 804084 804085 804090 804091 804092 804093 804094 804095 804940 804941 804942 804100 804101 804102 804103 804104 804105 804110 804111 804112 804113 804114 804115 804116 804117 804118 804100 804101 804102 804103 804104 804105 804110 804111 804112 804113 804114 804115 804116 804117 804118

Jar 804310 804311 804312 804313 804314 804315 804316 804317 804318 804319 804320 804321 804322 804323 804324 804360 804361 804362 804363 804364 804365 804366 804367 804368 804369 804370 804371 804372 804373 804374 804180 804181 804182 804183 804184 804185 804186 804187 804188 804189 804190 804191 804192 804193 804194 853440 853441 853442 853443 853444 853445 853446 853447 853448 853449 853450 804171 804172 804173 804174 804200 804201 804202 804203 804204 804205 804206 804207 804208 804209 804210 804211 804212 804213 804214

Standard 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54")

Insulator 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509

22

Cell 125G-11 125G-13 125G-15 125G-17 125G-19 125G-21 125G-23 125G-25 125G-27 125G-29 125G-31 125G-33 160G-9 160G-11 160G-13 160G-15 160G-17 160G-19

6 Hr. Ah 625 750 875 1000 1125 1250 1375 1500 1625 1750 1875 2000 640 800 960 1120 1280 1440

Cable 1/0 1/0 2/0 3/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 1/0 2/0 3/0 4/0 4/0 4/0

Cell 290343-CW 290344-CW 290345-CW 290346-CW 290347-CW 290348-CW 290349-CW 290350-CW 290351-CW 290352-CW 290353-CW 290354-CW 97811-CW 97812-CW 97813-CW 97814-CW 501456-CW 97815-CW

Cover 804103 804104 804105 804110 804111 804112 804113 804114 804115 804116 804117 804118 804911 804912 804913 804930 804931 804932

Jar 503835 503836 503837 503838 503839 503840 503841 503842 503843 503844 503845 503846 804571 804572 804573 804574 804575 804576

Standard 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54")

INTERCELL CONNECTORS & INSULATORS SIDE TO SIDE END TO END Over Partition Insulator Standard Over Partition 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09")

Insulator 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509

HUP SERIES HUP SERIES MOTIVE POWER CELL PARTS LIST MOTIVE POWER CELL PARTS LIST
Cell 85P-5 85P-7 85P-9 85P-11 85P-13 85P-15 85P-17 85P-19 85P-21 85P-23 85P-25 85P-27 85P-29 85P-31 85P-33 100P-5 100P-7 100P-9 100P-11 100P-13 100P-15 100P-17 100P-19 100P-21 100P-23 100P-25 100P-27 100P-29 100P-31 100P-33 125P-5 125P-7 125P-9 125P-11 125P-13 125P-15 125P-17 125P-19 125P-21 125P-23 125P-25 125P-27 125P-29 125P-31 125P-33 6 Hr. Ah 170 255 340 425 510 595 680 765 850 935 1020 1105 1190 1275 1360 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 250 375 500 625 750 875 1000 1125 1250 1375 1500 1625 1750 1875 2000 Cable #2 #2 #2 #2 #2 #2 1/0 1/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 #2 #2 #2 #2 #2 1/0 1/0 2/0 3/0 4/0 4/0 4/0 4/0 4/0 4/0 #2 #2 #2 1/0 1/0 2/0 3/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 4/0 Cell 290210-CW 290211-CW 290212-CW 290213-CW 290214-CW 290215-CW 290216-CW 290217-CW 290218-CW 290219-CW 290220-CW 290221-CW 290222-CW 290223-CW 290224-CW 290300-CW 290301-CW 290302-CW 290303-CW 290304-CW 290305-CW 290306-CW 290307-CW 290308-CW 290309-CW 290310-CW 290311-CW 290312-CW 290313-CW 290314-CW 290320-CW 290321-CW 290322-CW 290323-CW 290324-CW 290325-CW 290326-CW 290327-CW 290328-CW 290329-CW 290330-CW 290331-CW 290332-CW 290333-CW 290334-CW Cover 804100 804101 811582 811583 811584 811585 811586 811587 811588 811589 811590 811591 811592 811593 811594 804100 804101 811582 811583 811584 811585 811586 811587 811588 811589 811590 811591 811592 811593 811594 804100 804101 811582 811583 811584 811585 811586 811587 811588 811589 811590 811591 811592 811593 811594 Jar 804160 804161 804162 804163 804164 804165 804166 804167 804168 804169 804170 804171 804172 804173 804174 804160 804161 804162 804163 804164 804165 804166 804167 804168 804169 804170 804171 804172 804173 804174 804160 804161 804162 804163 804164 804165 804166 804167 804168 804169 804170 804171 804172 804173 804174 Standard 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") INTERCELL CONNECTORS & INSULATORS SIDE TO SIDE END TO END Over Partition Insulator Standard Over Partition -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") Insulator 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509

23

RENEGADE SERIES MOTIVE POWER CELL PARTS LIST

INTERCELL CONNECTORS & INSULATORS SIDE TO SIDE END TO END Over Partition Insulator Standard Over Partition -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") -(--) 201507 79374 (3.01") 79375 (3.09") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09")

Cell 75GS-5 75GS-7 75GS-9 75GS-11 75GS-13 75GS-15 75GS-17 75GS-19 75GS-21 75GS-23 75GS-25 75GS-27 75GS-29 75GS-31 75GS-33 110GS-5 110GS-7 110GS-9 110GS-11 110GS-13 110GS-15 110GS-17 110GS-19 110GS-21 110GS-23 110GS-25 110GS-27 110GS-29 110GS-31 110GS-33

6 Hr. Ah 150 225 300 375 450 525 600 675 750 825 900 975 1050 1125 1200 220 330 440 550 660 770 880 990 1100 1210 1320 1430 1540 1650 1760

Cable #2 #2 #2 #2 #2 1/0 1/0 2/0 3/0 4/0 4/0 4/0 4/0 4/0 4/0 #2 #2 #2 #2 #2 1/0 1/0 2/0 3/0 4/0 4/0 4/0 4/0 4/0 4/0

Cell 290830-CW 290831-CW 290832-CW 290833-CW 290834-CW 290835-CW 290836-CW 290837-CW 290838-CW 290839-CW 290840-CW 290841-CW 290842-CW 290843-CW 290844-CW 290810-CW 290811-CW 290812-CW 290813-CW 290814-CW 290815-CW 290816-CW 290817-CW 290818-CW 290819-CW 290820-CW 290821-CW 290822-CW 290823-CW 290824-CW

Standard 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54") 79371 (2.01") 79372 (2.81") 79377 (3.56") 79379 (4.32") 79382 (5.07") 79384 (5.82") 79280 (3.54") 79282 (3.54") 79284 (4.29") 79286 (5.04") 79288 (5.79") 79290 (4.29") 805060 (5.04") 805062 (5.79") 805064 (6.54")

Insulator 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509 201509

24

ACCUMULATOR / BOOT
Accumulator Another term for a secondary battery based on the fact that electric energy is accumulated in the form of chemicals. This term, pertaining to a storage cell or battery, is employed today in countries outside USA. Acetic Acid (C2H4O2) An organic acid liberated by reaction between wood and dilute sulphuric acid. It is injurious to positive plates in large quantity. Acid In the lead acid storage battery industry, acid implies sulfuric acid, and is used to describe the electrolyte or liquid in the cell. Active Materials The materials in a battery which react chemically to produce electrical energy. In a lead-acid battery the active materials are lead peroxide (positive) and sponge lead (negative). Activation Process for making a dry charged cell functional by introducing electrolyte. Air Oxidized A charged negative plate that has been removed from the electrolyte and permitted to discharge in an air atmosphere with the evolution of heat. Plates so treated must be recharged before they are capable of producing any useful electrical energy. Alloy A combination of two or more metals, as a mixture, solution, or compound. See ANTIMONIAL LEAD ALLOY, CALCIUM LEAD ALLOY. Ambient Temperature Ambient temperature is the temperature of the surrounding cooling medium, such as gas or liquid, which comes into contact with the heated parts of the apparatus, usually refers to room or air temp. Alternating Current An electric, pulsating current, in which the direction of flow is rapidly changed, so that a terminal becomes in rapid succession positive then negative. Ammeter An ammeter is an instrument for measuring electrical current. See also AMPERE-HOUR METER. Ampacity Current carrying capacity in amperes. Ampere The practical unit of electric current that is equivalent to the steady state current produced by one volt applied across a resistance of one ohm. It is one tenth of an abampere. Ampere-Hour A measure of the volume of electricity, being one ampere for one hour, or 3600 coulombs. It is used to express battery capacity, and is registered by an ampere-hour meter, or is obtained by multiplying the current in amperes by the length of time that the current is maintained. Ampere-Hour Capacity The ampere-hour capacity of a storage battery is the number of amperehours which can be delivered under specified conditions as to temperature, rate of discharge, and final voltage. Ampere-Hour Efficiency The ampere-hour efficiency of a storage battery is the electrochemical efficiency expressed as the ratio of the ampere-hours output to the ampere-hours input required for the recharge. Ampere-Hour Meter An amperehour meter is an instrument that registers the quantity of electricity in ampere-hours. Anode An anode is an electrode through which current enters any conductor of the nonmetallic class. Specifically, an electrolytic anode is an electrode at which negative ions are discharged, or positive ions are formed or at which other oxidizing reactions occur. Antimonial Lead Alloy Leadantimony alloy is the most common alloy used in battery castings. The percentage of antimony varies from 1/2 percent to 12 percent. Other substances are also included in small quantities either by way of a certain amount of inescapable impurity, or by design, to improve castings or to improve the properties of the cast part. Antimony (Sb) A silver-white metal of the arsenic family with a high luster, hard and brittle. Assembly 1. The process of combining the various parts of cells and batteries into the finished product. 2. Any particular arrangement of cells, connectors, and terminals to form a battery suited for a desired application. Automotive Battery (SLI) Battery of 3 or 6 cells used for starting, lighting, and ignition of automobiles, trucks, buses, etc. Average Voltage The average voltage of a storage battery is the average value of the voltage during the period of charge or discharge. Baffle (1) Partition in a cell. (2) Labyrinth arrangement for venting cells, especially in maintenance-free batteries. Barium Sulfate An inorganic component of many expander formulations. Barton Oxide Leady litharge produced in a Barton Mill or Pot. Battery (Storage) A storage battery is a connected group of two or more storage cells (common usage permits this term to be applied to a single cell used independently). Batteries are sometimes referred to as Accumulators since electric energy is accumulated by chemical reaction. Battery Additive A preparation sold to the public that allegedly rejuvenates worn-out, sulfated, or socalled dead batteries. Bayonet Vent A term originally applied to a design of quarter turn vent plug, the lower portion of which resembles a bayonet, both in appearance and locking arrangement. Boost Cells Cells with higher capacity than the test cells which are used to help maintain constant discharge current in a manual discharge test. Boost Charge A partial charge given to a storage battery usually at a high rate for a short period. It is employed in motive power service when the capacity of a battery is not sufficient for a full days work. Boot Plastic piece used at foot of plate, especially a wrapped plate, for retention and insulation.

25

BOTTOM POUR / COMMUNICATION BATTERY

Bottom Pour A term that describes a method of introducing molten metal into a bottom gated mold, the molten metal being withdrawn from the pot from a point below the surface of the melt. Bridge The ribs or elements supporting structure, molded, or cut to fit into the bottom of a ribless jar or container in order to provide sediment space under the element thereby preventing short circuits. Burning The welding together of two or more lead or lead alloy parts such as plates, straps, connector by means of heat and in some cases, additional metal supplied by a stick called a burning strip. Burning Center The center-to-center distance between adjacent plates of the same polarity. Burning Stick A lead or lead alloy stick of convenient size used as a supply of joining metal in lead burning. Button The finished button shaped area produced on the top surface of a connector or terminal by the post burning operation. Cadmium (Cd) A metallic element highly resistant to corrosion, used as a protective plating on certain steel parts and fittings. Cadmium Electrode A third electrode for separate measurements of the electrode potential of positive and negative plate groups. Calcium Lead Alloy A lead base alloy that in certain applications can be used for battery parts in place of antimonial lead alloys. Most common use is in stationary cells. Capacity See AMPERE HOUR CAPACITY. Capacity Test A test wherein the battery is discharged at constant current at room temperature to a cutoff voltage of usually 1.70 volts/cell. Carbon Black Finely divided carbon obtained by burning a gaseous hydrocarbon under controlled conditions and used as an ingredient in negative expanders. Carbon Burning Outfit A metallic rod and insulated handle, mounting a pointed carbon rod; used for lead burning on service locations where the usual gas flame equipment is not available. Carbon Puddling Rod A pencil like carbon rod used in lead burning to break up any oxide film, dirt, or dross particles that may be present in the molten metal. Carboy A large cylindrical container or bottle of plastic or glass used to ship acid. Car Lighting Battery An auxiliary storage battery designed to supply the lighting and air conditioning requirements of railroad cars while running at low speeds. An axle driven generator charges the battery and supplies the load requirements when the train operates at normal speeds. Cast To form a molten substance into a definite shape by pouring or forcing the liquid material into a mold and allowing it to solidify (freeze). Casting A metallic item, such as one or more grids, straps or connectors produced by pouring or forcing molten metal into a mold and allowing it to solidify. Cast-On Strap A multiplate connector which has been cast onto the plates directly in a combination mold/burning jig; contrasts with burning of plates and prefabricated straps. Cathode A cathode is an electrode through which current leaves any conductor of the nonmetallic class. Specifically, an electrolytic cathode is an electrode at which positive ions are discharged, or negative ions are formed, or at which other reducing reactions occur. Cell (Primary) A primary cell is a cell designed to produce electric current through an electrochemical reaction which is not efficiently reversible and hence the cell, when discharged, cannot be efficiently recharged by an electric current. Cell (Storage) A storage (secondary) cell is an electrolytic cell for the generation of electric energy in which the cell after being discharged may be restored to a charged condition by an electric current flowing in a direction opposite to the flow of current when the cell discharges. CEMF Counter Electromotive Force. Charged The condition of a storage cell when at its maximum ability to deliver current. The positive plate contains a maximum of lead peroxide and a minimum of sulfate, while the negative plates contain a maximum of sponge lead and a minimum of sulfate, and the electrolyte will be at maximum specific gravity. Charged and Dry A battery assembled with dry, charged plates, and no electrolyte. Charged and Wet A fully charged battery containing electrolyte and ready to deliver current. Charging The process of converting electrical energy to stored chemical energy. In the lead-acid system, charging converts Lead Sulfate (PbSO4) in the plates to Lead Peroxide (PbO2) (positive) or Lead (Pb) (negative plate). Charging Plug The male half of a quick connector which contains both the positive and negative leads. Charging Rate The charging rate of a storage battery is the current expressed in amperes at which the battery is charged. Charging Receptacle The female half of a quick connector housing both positive and negative leads. Circuit A system of electrical components through which an electric current is intended to flow. The continuous path of an electric current. Cold Crank Test SLI battery test wherein a high rate discharge, up to 300 amperes, is applied to a battery at 0F, and the 30 second cell voltage must be above 1.2 volts/cell. Communication Battery See TELEPHONE BATTERY.

26

COMPOUND / ELECTROLYTE
Compound An asphaltic, pitchlike material used as a cover-to-jar battery sealant. Constant-Current Charge A constant-current charge of a storage battery is a charge in which the current is maintained at a constant value. (For some types of lead-acid batteries this may involve two rates called a starting and a finishing rate.) Constant Potential Charge See CONSTANT VOLTAGE CHARGE. Constant Voltage Charge A constant-voltage charge of a storage battery is a charge in which the voltage at the terminals of the battery is held at a constant value. Container Housing for one or more cells, commonly called a JAR. Control Battery A float service battery designed for switchgear and circuit breaker operation in electric generating or distributing stations. Counter EMF Cells (CEMF CELL) Counter electromotive force cells, frequently called counter-cells, are cells of practically zero ampere-hour capacity used to oppose the line voltage. Unlike non-electrolytic resistors, which absorb voltage in proportion to the current flowing in the circuit, CEMF cells maintain a nearly constant voltage regardless of the current. Cover The lid or cover of an enclosed cell generally made of the same material as the jar or container and through which extend the posts and the vent plug. Cover Inserts Lead or lead alloy rings which are molded or sealed into the cell cover, and to which are burned the element posts thereby creating an effective acid-creep resistant seal. Creepage Creepage is the travel of electrolyte up the surface of electrodes or other parts of the cell above the level of the main body of electrolyte. Curing Chemical conversion process which changes lead oxides and sulfuric acid to mixtures of tetrabasic lead sulfate, other basic lead sulfates, basic lead carbonates, etc., which consequently will form desired structures of Pb or PbO2 on negative or positive plates during formation. Current The time rate of flow of electricity, normally expressed as amperes, like the flow of a stream of water. Cut-Off Voltage See FINAL VOLTAGE. Cutting (of acid) The dilution of a more concentrated solution of sulfuric acid to a lower concentration. Cycle A discharge and its subsequent recharge. Cycle Service A type of battery operation in which a battery is continuously subjected to successive cycles of charge and discharge, e.g., motive power service. Deep Discharge Removal of up to 80% of the rated capacity of a cell or battery. Dead Top A system of encapsulating intercell connectors with compounds, such as epoxy, or polyurethane, to prevent accidental intercell shorts from external sources. Dielectric Test An electric test performed on certain jars, containers, and other insulating materials to determine their dielectric breakdown strength. Diesel Starting Battery Batteries used to crank diesel engines. This function is similar to gasoline engines applications, except that greater demands are made for cranking power, and ignition is accomplished by the engines heat, without any further need for electric current. Diffusion The intermingling or distribution of the particles or molecules of a liquid. Direct Current (DC) A direct current is a unidirectional current in which the changes in value are either zero or so small that they may be neglected. Discharge Discharge of a storage battery is the conversion of the chemical energy of the battery into electrical energy. Discharged The condition of a storage cell when as the result of delivering current, the plates are sulfated. The electrolyte is exhausted, and there is little or no potential difference between the terminals. Discharge Rate Batteries discharged to meet any time rate between 3 hours and 8 hours are considered as having been normally discharged. Dope Battery treatment compound, usually consisting of sulfuric acid and/or metallic sulfate. Dross The layer of various oxides and impurities which forms on the surface of molten metal. Dry Charged A negative plate which has been subjected to the dry charging process. Dry Charging Manufacturing process whereby tank-formed negatives (or elements) are washed free of acid and then dried. Specific methods include use of vacuum, superheated steam, combustion gases, hot kerosene, etc. Efficiency The efficiency of a storage battery is the ratio of the output of the cell or battery to the input required to restore the initial state of charge under specified conditions of temperature, current rate and final voltage. Electrode A conductor through which a current passes in or out of a cell, apparatus or body. Electrode (Electrolyte) Potential An electrode potential is the difference in potential between the electrode and the immediately adjacent electrolyte, expressed in terms of some standard electrode potential difference. Electrolysis Electrochemical reaction which causes the decomposition of a compound, either liquid, molten or in solution. Electrolyte Any substance which disassociates into two or more ions when dissolved in water. Solution of electrolyte conducts electricity and is decomposed by it. In the battery industry the word electrolyte implies a dilute solution of sulfuric acid.

27

ELECTROMOTIVE FORCE (EMF) / HYDRATION (LEAD)

Electromotive Force (EMF) Electrical pressure or potential, expressed in terms of volts. Element Assembly of a positive plate group, a negative plate group, and separators. Emergency Lighting Service Float service batteries used in places of public assembly, hospital operating rooms, bank vaults, etc. which supply light in the event of power failures. End Cells End cells are cells of a storage battery which may be cut in or cut out of the circuit for the purpose of adjusting the battery voltage. End Gravity The specific gravity of a cell at the end of a prescribed (usually a 6 to 8 hour) discharge. End to End (E to E) Referring to method of assembling cells in relation to one another. Energy Density Ratio of battery energy content in watt hours to battery weight or volume. Envelope See PERFORATED RETAINER. Equalizing Charge An equalizing charge of a storage battery is an extended charge which is given to a storage battery to insure the complete restoration of active materials in all the plates of all the cells. Expander An addition agent either organic or inorganic or a mixture of both to be blended with the other ingredients for negative paste. The purpose of expanders is to delay shrinking and solidifying of the sponge lead of the finished plate, thereby enhancing negative plate capacity. Ferroresonant Charger A constant voltage power supply containing a special transformercapacitor combination, which changes operating characteristics as current draw is varied, so that the output voltage remains constant. Filling Gravity The specific gravity of acid used in the filling of batteries. Final Voltage The cut-off voltage of a battery; the prescribed voltage reached when the discharge is considered complete. Finishing Rate The finishing rate for a storage battery is the rate of charge expressed in amperes to which the charging current for some types of lead batteries is reduced near the end of charge to prevent excessive gassing and temperature rise. Fixed Resistance Discharge A discharge in which the cell or battery is discharged through a fixed resistive load. The current being allowed to fall off as the terminal voltage decreases. Flaming A method used to improve the surface of a cast lead or lead alloy part or of trimmed battery sealing compound in which a flame is passed over the surface causing the material to melt and flow smoothly together. Flat Plate A general term referring to pasted plates. Float Charging Application of a recharge at a very low rate and accomplished by connection to a buss with a voltage slightly higher than the open circuit voltage of the battery. Flush To add water to a cell. Flying Leads Any fixed terminal cable in which the terminal or plug end of the cable is unsupported and allowed to hang freely along the side of the battery. Foot Portion(s) of the grid projecting from the bottom edge, used for support of the plate group. Formation of Forming Charge An initial charging process during which the raw paste within the plates is electrochemically converted into charged active material, lead peroxide being formed in the positive plates and sponge lead in the negative plates. Formed Plates that have undergone formation are known by this term. Freshening Charge A charge given batteries in storage to replace the standing loss and to ensure that every plate in every cell is periodically brought to a full state of charge which gives form and strength to the grid and serves to conduct current to the lug. Full Charge Gravity The specific gravity of the electrolyte with the cells fully charged and properly leveled. Gang Vent Vents for usually three adjacent cells which are connected to a common manifold. Typically used on SLIs. Gassing Gassing is the evolution of gases from one or more of the electrodes during electrolysis. Gelled Electrolyte Electrolyte which has been immobilized by addition of silica powder or other gelling agent. Glass Mat Fabric made from glass fibers with a polymeric binder, such as styrene, acrylic, furfural, starch, used to help retain positive active material. Gravity Refers to specific gravity. Gravity Drop The number of points reduction or drop of the specific gravity of the electrolyte upon discharge of the cell. Grid A grid is a metallic framework employed in a storage cell or battery for conducting the electric current and supporting the active material. Group One or more plates of a type (positive or negative) which are burned to a post and strap. Hand Stand Manually operated casting mold into which lead or alloy is manually poured. High Impact Rubber See RESIN RUBBER. High Rate On charge, any rate higher than the normal finishing rate. H2SO4 Chemical symbol for Sulfuric Acid. H.U.P. High Utilization Positive. Patented process which optimizes both the active material utilization and the longevity of the positive paste. Hydration (Lead) Reaction between water and lead or lead compounds. Lead does not react with strong solutions of sulfuric acid, but gravities lower than those found in discharged cells are apt to produce hydration. Hydration is observed as a white coating on both plate groups and separators in a cell.

28

HYDROMETER / MILLIVOLT
Hydrometer Device used to indicate density or specific gravity of electrolyte solutions. Hydroset Curing process for negative and positive plates, wherein free lead in the paste is oxidized and total free lead is reduced to a few percent. Indicator Device employed to show a batterys state of charge, or its water level. Initial Voltage The initial voltage of a battery is the closed-circuit voltage at the beginning of a discharge. It is usually measured after the current has flowed for a sufficient period for the rate of change of voltage to become practically constant. Insert A bushing of lead or lead alloy molded or sealed into cell covers forming the post hole to which the post is burned to create a creep-resistant cover-to-post seal. Intercell Connector Conductor of lead, lead alloy, or lead plated copper which is used to connect two battery cells. Internal Resistance The internal resistance of a cell or battery is the resistance within the cell or battery to the flow of an electric current, and is measured by the ratio of the change in voltage at the terminals of the cell or battery corresponding to a specific change in current for short time intervals. Jackstraw Mats See GLASS MATS. Jar Cell container made by injection molding, roto-molding or thermo-forming. Jar Formation The forming of plates in the cell jar or container, after they have been assembled. Jumper A short length of conductor used to connect or cut out part of an electrical circuit. Kilovolt (KV) One thousand volts. Kilowatt (KW) One thousand watts. Kilowatt-hours (KWH) A measure of energy or work accomplished equal to 1000 watt-hours. Lamp Black Finely powered carbon used as an ingredient in negative plate expander. Lead (Pb) Chemical element used in lead-acid batteries (with sulfuric acid and other materials). Lead Burning Welding of lead or lead alloy parts. Lead Hydrate A white compound of lead of indefinite composition formed by the reaction of very dilute electrolyte or water on metallic lead or lead alloys. Lead Oxide A general term used to describe any of the finely divided lead oxides used to produce paste for storage batteries. Lead Peroxide A brown oxide of lead which is the active material in a fully formed positive plate. Its formula is PbO2. Lead Plated Part A metallic part that has had a thin protective layer of metallic lead electrodeposited on its surface. Lead Sponge (Pb) The chief component of the active material of a fully charged negative plate. Lead Sulfate (PbS04) A compound resulting from the chemical action of sulfuric acid on oxides of lead or lead metal itself. Level Indicator A float mounted in a float tube or similar indication of the electrolyte level. Level Lines Horizontal lines molded and/or painted near tops of battery jars which indicate minimum and maximum electrolyte level. Life Number of years of satisfactory float operation or number charge-discharge cycles for motive power operation. Lifting Ear An extension on the side walls of a battery tray provided with a hole or slot with which the battery can be lifted. Lignin Generic name for noncellulosic wood fraction which, as lignin sulfonic acid or desulfonated LSA, acts as an organic expander for lead-acid batteries. Litharge (PbO) A yellowish-red oxide of lead (monoxide), sometimes used in making active material. Local Action The loss of otherwise usable chemical energy by currents which flow within the cell of a battery regardless of its connections to an external circuit. Loss of Charge The capacity loss occurring in a cell or battery standing on open circuit as a result of local action. Lug Portion of grid used for support of the plate group, usually along top edge of grid, as hanging lug. Also, tab on grid used for connection of plate to strap and other plates. Machine Casting A fully or semi-automatic grid or small parts casting operation. Maintenance-FreeBattery Battery which requires no addition of water, no boost charges, etc. This typically requires a non-antimonial or lowantimonial grid alloy, sealed cell design, or low-loss venting. Manual Discharge Capacity test wherein the connection and disconnection of the battery and the test load are done by the operator and the disconnection is made after all cells have reached the prescribed final voltage. With fixed resistance loads, boost cells are used to keep the discharge rate fairly constant as the test cell voltages drop rapidly near the final voltage. Electronic load manual discharges generally do not require boost cells. Marine Battery A battery designed for shipboard installation to provide energy for cranking service and the operation of emergency lighting, alarm, and communication equipment. Microporous Separator Either a veneer-or a grooved-type separator made of any material in which the pores are numerous and microscopic. Mine Locomotive Battery A cycle service battery designed to operate mine locomotive, trammer, shuttle cars, and tunnel haulage equipment. Millivolt (MV) One thousandth part of a volt.

29

MODIFIED CONSTANT-VOLTAGE CHARGE / POSITIVE TERMINAL

Modified Constant-Voltage Charge A modified constantvoltage charge of a storage battery is a charge in which the voltage of charging circuit is held substantially constant, but a fixed resistance is inserted in the battery circuit producing a rising voltage characteristic at the battery terminals as the charge progresses. Mold A cast iron or steel form which contains the cavity into which molten metal is introduced to produce a casting of definite shape and outline. Mold Coat A preparation applied to metal molds in spray form which acts both as a mold release agent and as an insulator against rapid heat transfer. Mold Spray See MOLD COAT. Moss Dendritic crystals of lead (Pb) which sometimes grow at highcurrent density areas of negative plates, e.g. along edges, at feet, or at plate lugs. May cause a short circuit within cell. Moss Shield Plastic or hard rubber perforate sheet which insulates the gaps between negative plates and the positive strap, and between positive plates and the negative strap. Motive Power Battery A cycle service battery designed to supply the energy necessary to propel and operate electrically powered industrial trucks, street vehicles, and mine locomotives. Negative Plate The negative plate of a storage battery consists of the grid and active material to which current flows from the external circuit when the battery is discharging. Negative Terminal The negative terminal of a battery is the terminal toward which current flows (as ordinarily conceived) in the external circuit from the positive terminal. OHM A unit of electrical resistance. Oil of Vitriol Concentrated commercial sulfuric acid commonly referred to as OV. One Shot Formation Jar formation under conditions where end of formation specific gravity is equal to the operating specific gravity. Open-Circuit The state of a battery when it is not connected to either a charging source or to a load circuit. Open Circuit Voltage The opencircuit voltage if a battery is the voltage at its terminals when no appreciable current is flowing. Organic Expander An expander formulation which typically contains barium sulfate and a lignin type organic compound with small amounts of other materials. O.V. See Oil of Vitriol Oxide (of lead) A compound of lead and oxygen in one of several proportions such as gray oxide, litharge, red lead, or lead peroxide used to prepare battery paste. Panel Casting consisting of two or more grids which have been made simultaneously in a single mold. Parallel Assembly The arrangement of cells within a battery in which two or more cells are connected across a common terminal so that any current flow divides itself between the connected cells. Parallel Connection See PARALLEL ASSEMBLY. Partition An interior dividing wall in a tray or container. Paste Mixture of lead oxide with water, sulfuric acid, and sometimes other ingredients. Paste Consistency A term used to include all of the physical characteristics of the paste density, plasticity and texture. Pasting Battery assembly operation wherein paste is applied to grids by hand or by a machine. Pb Chemical symbol for lead. PbO Chemical symbol for litharge. PbO2 Chemical symbol for lead peroxide (dioxide). Pellet That portion of pasted material contained in a grid section framed by adjacent horizontal and vertical members exclusive of forming bars. Perforated Retainer A thin sheet of perforated plastic material installed to cover each face of a positive plate to prevent the loss of active material. It is normally used in conjunction with one or more layers of glass insulating material. Peroxide See LEAD PEROXIDE. Pig A cast bar of lead or lead alloy. Pig Lead A grade of highly refined unalloyed lead. Pilot Cell A pilot cell is a selected cell of a storage battery whose temperature, voltage, and specific gravity are assumed to indicate the condition of the entire battery. Plante Plates Plates, usually positives, made by machining or casting multiple slots in a thick Pb sheet, and consequent formation of active material from the thin webs of Pb or Pb alloy remaining. Plate A pasted grid, either formed or unformed. Plate Centers The distance between center lines of adjoining plates of opposite polarity in a cell. The plate center is, therefore, onehalf of the size of a strap center upon which the plates of a like polarity are burned. Polarity The polarity of a battery is an electrical condition determining the direction in which current tends to flow. By common usage the discharge current is said to flow from the positive electrode through the external circuit. Polarization Polarization in a battery is the change in voltage at the terminals of the cell or battery when a specified current is flowing and is equal to the difference between the actual and the equilibrium (constant open circuit condition) potentials of the plates exclusive of the IR drop. Porosity The ratio of interstices (voids) in a material to the volume of its mass. Positive Plates The positive plate of a storage battery consists of the grid and the active material from which current flows to the external circuit when the battery is discharging. Positive Terminal The positive terminal of a battery is the terminal from which current flows (as ordinarily conceived) through the external circuit to the negative terminal when the cell discharges.

30

POST / SPINE
Post Terminal or other conductor which connects the plate group strap to the outside of the cell. Post Builder A ring shaped mold used to repair damaged battery posts. Potential See VOLTAGE. Primary Cell See CELL PRIMARY. Puddling The process in which two or more lead or lead alloy parts are welded together within the confines of a suitably shaped dam. It is usually necessary to add extra metal from a burning strip in order to completely fill the dammed area. Pure Lead See PIG LEAD. Rated Capacity The amperehours of discharge that can be removed from a fully charged secondary cell or battery at a specific constant discharge rate at a specified discharge temperature and at a specified cut-off voltage. Rate of Charge See STARTING RATE, FINISHING RATE. Raw Plate An unformed plate. Rectifier A rectifier is a device which converts alternating current (AC) into unidirectional current (DC) by virtue of a characteristic permitting appreciable flow of current in only one direction. Red Lead (Pb3O4) A red oxide of lead used in making active material. Resin Rubber A rubber compound that has been modified by the addition of plastic resin to improve its impact strength. Reference Electrode Electrode used to measure acid concentration or plate state of charge. Typical examples: cadmium electrode, Hg/HgSO4 electrode, Hydrogen electrode, Pb electrode, PbO2 electrode. Resistance The opposition that a conductor offers to the passage of an electrical current, usually expressed in ohms. Resistor A device used to introduce resistance into an electrical circuit. Retainer A sheet of glass mat, perforated or slotted rubber, plastic, or some other satisfactory material installed on each face of the positive plates in certain types of cells to deter the loss of active material. Reversal Reversal of a storage battery is a change in normal polarity of the cell or battery. Rib A vertical or nearly vertical ridge of a grooved separator or spacer. Rib Block Bridge used in some smooth bottom jars to evenly support the element. Rib to Top A reference to the height dimension from the top of the supporting rib to the top edge of the jar or container. Run Down A small portion of metal that has dropped onto a plate, group or element in the course of burning. It may result in a short circuit. Sealing Manufacturing operation for attaching covers to jars by cement, sealing compound, or thermal fusion. Sealing Compound An asphalt mixture of several types differing in heat resistance, adhesion, and resistance to shearing. It is used for sealing cell covers to the jars or containers. See COMPOUND. Seal Nut A round notched alloy nut threaded onto certain types of strap posts for fastening and sealing the element and cover together. Secondary Lead Reclaimed lead as opposed to virgin lead. Sediment The leady sludge or active material shed from the plates and found in the bottom of cells. Sediment Space The portion of a jar or container compartment beneath the element provided to accommodate a certain amount of sediment from the wearing of the plates without short circuiting. Self-Discharge Loss of charge due to local action. Separator A separator is a device employed in storage battery for preventing metallic contact between the plates of opposite polarity within the cell, while allowing passage of electrolyte. See MICROPOROUS SEPARATOR. Separator Protector See MOSS SHIELD. Series Cells All cells in a battery other than pilot cells. The term became common since the cells are usually connected in series. The name would still apply to distinguish the difference between cells even if the cells are connected in multiple. Series Parallel Connection The arrangement of cells within a battery in which two or more strings of series connected cells each containing the same number of cells are connected in parallel in order to increase the capacity of the battery. Service Life See LIFE. Shedding Loss of active material from the plates. Short Circuit Current The current which flows when the two terminals of a cell or battery are inadvertently connected to each other. Side Terminal SLI battery design with two through-the-container current connectors on one side of the case instead of two posts on top. SLI Battery Battery for automotive use in starting, lighting, and ignition. Sliver, Slyver Extremely fine, parallel glass fibers used next to positive plate in retainers to retard shedding. Smelting The process by which the major portion of lead and antimony are recovered from spent batteries. Soaking A process whereby certain types of plates are soaked in sulfuric acid after pasting. Soaking provides a protective surface, and also a supply of sulfate helpful in jar formation and tank formation. Soda Ash Sodium Carbonate (Na2CO3), used to neutralize effluents containing sulfuric acid or acid spills. Spalling Shedding of active material, usually from positives, during formation due to incomplete or improper plate curing. Spine Cast Pb alloy conductor for tubular positive plate.

31

SPONGE LEAD / VACUUM CELL FILLER

Sponge Lead (Pb) The chief material of a fully charged negative plate. It is a porous mass of lead crystals. Stacking Cell assembly operation wherein plates and separators are alternately piled in a burning box prior to cast-on or burning-on of straps and posts. Stacking Fixture or Stacking Jig The fixture or device used to stack and burn elements. Standing Loss The loss of charge by an idle cell or battery resulting from local action. Starting Rate The number of amperes at which the charging of a storage battery may begin without producing gassing or bubbling of the electrolyte or a cell temperature in excess of 110F (43C). State of Charge The amount of electrochemical energy left in a cell or battery. Stationary Battery A stationary battery is a storage battery designed for service in a permanent position. Strap Precast or cast-on piece of lead or lead alloy used to connect plates into groups and to connect the groups to the post. Strap center Spacing between centers of adjacent plates in a group. Stratification As applied to electrolyte it is layers of high-gravity acid in the lower portions of a cell, where they are out of touch with the ordinary circulation of the electrolyte and thus of no use. Submarine Battery Battery usually used for main underwater propulsion of conventional submarines and for reactor control on nuclear submarines. Batteries usually operated in trickle discharge mode. Sulfated A term used to describe any plate or cell whose active materials contain an appreciable amount of lead sulfate. Sulfation The formation of lead sulfate on a plate or cell as a result of discharge, self discharge, or pickling. Sulfuric Acid (H2SO4) The principal acid compound of sulfur. Sulfuric acid of a high purity and in dilute form is the electrolyte of leadacid storage cells. Switchgear Battery See CONTROL BATTERY. Tack Burn A shallow burn used to tack together two lead parts. Tank Formation The electrolytic processing of plates in large tanks of acid at a point of manufacture prior to assembly. See also FORMATION Telephone Batteries Storage batteries of a wide range of capacities and types which are used in most of the operations involved in telephone communication. Often they are floated across generators or rectifiers, and serve for voltage stabilization, noise reduction, and emergency power. Temperature Correction In storage cells, the specific gravity and charging voltage vary inversely with temperature, while the open circuit voltage varies directly (though slightly) with temperature. Terminals The terminals of a battery are the points at which the external circuit is connected. Terminal Cable A length of insulated cable, one of which is connected to the terminal post of a battery, the other end being fitted with a suitable device (plug, receptacle, lug, etc.) for connection to an external circuit. Tinning The process of coating a metal surface with a thin layer of molten tin or tin alloy. Top Pour A term that describes a method of casting in which the molten metal is poured, usually by hand, into a top gated mold. Tray Steel enclosure for motive power battery cells. Treeing Growth of a lead dendrite or filament through a hole, crack, or large pore of a separator, whereby the cell is short-circuited. Trickle Charge A trickle charge of a storage battery is a continuous charge at a low rate approximately equal to the internal losses and suitable to maintain the battery in a fully charged condition. Tubular Plate Positive battery plate made from a cast spine and porous tubes which are filled with paste or dry oxide. TVR A temperature compensating voltage relay used in charging equipment. Two-Rate Charging An automatically controlled constant current or modified constant potential charging procedure. The charge is begun at a fairly high rate and is automatically reduced to a lower rate when the counter voltage rises to a predetermined level. Unactivated Storage Life The period of time before a dry charged cell deteriorates to have less than a specified capacity. Uncharged The condition of a battery assembled with formed plates but not yet having received its initial charge, is classified either uncharged and moist, or uncharged and dry. Uncharged and Dry A condition in which a battery or cell may be shipped to a customer. This indicates that the battery is assembled with formed plates and dry separators without electrolyte. Filling and a charge are required. Uncharged and Moist A condition in which a battery or cell may be shipped to a customer. Adopted by Battery Council International and indicates that the battery is assembled with formed plates and moist or wet wood separators without electrolyte. Filling and a long charge are required. Unformed A term used to describe any plate which has not been electrolytically formed. It may be dry or moist, cured or uncured, soaked or unsoaked. Useful Acid The volume of acid above the lower edges of the plates which takes part in the discharge reactions that occur within the cell. Vacuum Cast A machine casting technique in which a vacuum is applied to the top gate of a bottom-pour mold to increase venting. Vacuum Cell Filler A device used to fill cells in the charging room in which a vacuum is used to withdraw the air displaced by the filling electrolyte.

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VENT / WRAPPING
charging room in which a vacuum is used to withdraw the air displaced by the filling electrolyte. Vent An opening provided to permit the escape of gas from a cell or mold. Vent Assembly A cell venting device consisting of a ceramic vent stone and filler funnel assembled on a threaded or a quarter-turn bayonet base. Vent Baffle A thin disc located in a vent cap or plug to deflect spray back into the cell. Vent Cap SEE VENT PLUG. Vent Plug The piece or assembly of pieces employed to seal the vent and filling well of a cell cover except for a small hole in the plug itself which permits the escape of gas. Vent plugs are usually held in place either by threads or by a quarterturn catch (bayonet vent plug), or by a snap-in fit. Vent Well The hole or holes in a cell cover through which gas escapes, fluids are added or the electrolyte level is checked. The vent plug or vent assembly fits into the vent well. Verticals The vertical bars of members or members in a pasted plate grid. Volt The practical unit of measurement of electromotive force or potential difference required to send a current of one ampere through a resistance of one ohm. Volt Efficiency The ratio of the average voltage of cell or battery during discharge to the average voltage during its subsequent recharge. Voltage The difference of potential which exists between the terminals of a cell or battery, or any two points of an electrical circuit. Voltage Range The difference between the maximum and minimum cell voltages that exist within a battery or string of cells when all of the cells are charging or discharging. Voltmeter An instrument for measuring voltage. Watering Adding water to battery electrolyte to replace electrolysis and evaporative losses. Watt A measure of electric power. The product of amperes and volts. Watt-hour A measure of energy or work accomplished equal to the product of the rate of work in watts and the time in hours, or the product of ampere-hours and the average voltage. Watt-hour Capacity The watt-hour capacity of a storage battery is the number of watt-hours which can be delivered under specific conditions as to temperature, rate of discharge and final voltage. Watt-hour Efficiency The watthour efficiency of a storage battery is the energy efficiency expressed as the ratio of the watt-hour output to the watt-hours of the recharge. Watt-hour Meter A watt-hour meter is an electric motor that measures and registers electrical energy in watt-hours (or kilowatt-hours). Wet Shelf Life The period of time a wet secondary cell can be stored before its capacity has fallen to the point that the cell cannot be easily recharged. Wrapping Assembly operation wherein motive power positive plates are covered by silver, glass mat, and retainer.

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