MOTIVE POWER BATTERYSERVICE MANUAL

THEORY

CONSTRUCTION

MAINTENANCE

SERVICE

PRECAUTIONS

TM

™

INTRODUCTIONWith today’s expanding industrial world, storage batteries and associatedequipment must fill a vital power requirement. Storage batteries are the mostdependable 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 usedin motive power requirements.

TABLE OF CONTENTS

SECTION I - THEORY AND CONSTRUCTION OF LEAD-ACID STORAGE BATTERIES1-1 Fully Charged Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Charging the Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Battery Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-4 Battery Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION II - RECEIVING AND INSTALLATION2-1 Receiving Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-2 Placing A Wet Battery In Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-3 Placing A Dry Battery In Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-4 A Battery Is Fully Charged When . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-5 Operation Of The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION III - ROUTINE MAINTENANCE3-1 Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-2 Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-4 Storing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-5 Battery Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION IV - TROUBLE SHOOTING4-1 Interpretation Of Cell Voltage Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . 134-2 Acid Replacement And Adjustment Of Specific Gravity . . . . . . . . . . . . . . . 134-3 Test Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-4 Calculate Discharge Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-5 Cadmium Electrode Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-6 Internal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164-7 On-Site Battery Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174-8 Causes Of Sulfated Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION V - HEALTH AND SAFETY5-1 Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195-2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

MOTIVE POWER CELL PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1

SECTION ITHEORY AND CONSTRUCTION

OF LEAD-ACID STORAGE BATTERIES

Charged Cell

Fig. 1-2

Electrolyte(Sulfuric acid

and water)

Maximumsulfuric acid

NegativePlate

SpongeLead

PositivePlate

LeadPeroxide

DecreasingSulfuric

Acid

IncreasingWater

DecreasingSponge Lead

IncreasingLead Sulfate

DecreasingLead Peroxide

IncreasingLead Sulfate

Discharging Cell

Fig. 1-1

1-1 FULLY CHARGED CELLStorage batteries do not store electrical energy, but

convert electrical energy into chemical energy which isslowly accumulated as the charge progresses. A battery inuse is said to be on discharge. During discharge, thechemical energy stored in the battery is converted intousable electrical energy.

A lead-acid storage battery consists of cells with positive and negative electrodes called plates, which arephysically separated from each other and immersed in anelectrolyte of sulfuric acid solution. The active materials of the electrodes are lead peroxide (PbO2) forthe positive plates, and sponge lead (Pb) for the negativesas 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, dependingon application. When fully charged, each cell has a volt-age of approximately two volts on open circuit. However, acell may have a voltage from 2.12 to 2.70 volts while beingcharged.

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 voltagepotential of two volts per cell and their potential ability todeliver this voltage under varying load and varying periodsof time.

During cell discharge, lead peroxide and spongelead 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 platesapproach being of the same chemical composition

(lead sulfate). As the sulfuric acid is removed from theelectrolyte 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 ascompared to an equal amount of water.

1-2 CHARGING THE CELLThe reaction that occurs in discharging the cell can

be reversed, and it can be restored to its former chargedcondition by sending direct current through it in an opposite direction to the current flow on discharge asshown in Fig. 1-4. The active materials are restored totheir respective conditions, and the electrolyte againbecomes a more concentrated sulfuric acid solution. Cellvoltage rises as the two plates become increasingly different in composition and the specific gravity of the elec-trolyte increases.

As an operating guide, to obtain the best performance and life from a motive power storage battery, the depth of discharge should not regularlyexceed 80% of the battery’s rated capacity in ampere-hours. It should be charged after each shift of use orwhenever the specific gravity of the electrolyte falls below1.230. It is very important that proper ventilation be provided during charging to make certain that (1) thehydrogen gas, given off toward the end of the chargingprocess is dissipated, and (2) that individual cell electrolyte temperatures during normal operations do not exceed 115˚F/46˚C.

2

1-3 BATTERY RATINGSA single lead-acid cell does not have sufficient

power to handle most requirements. However, connecting a number of cells together in series resultsin a battery capable of supplying higher powerdemands.

BATTERY VOLTAGE. The number of cells is determined by the required nominal operating voltage ofthe equipment. Since each cell has a nominal voltage of two volts, a 24 volt industrial truck will requirea 12 cell battery (12 cells x 2 volts/cell = 24 volts).

AMPERE HOUR (AH). The electrical capability of astorage battery is usually expressed in ampere-hours.The ampere-hour capacity is the number of ampere-hours which can be delivered under specified conditions of temperature, rate of discharge and finalvoltage. Basically, ampere-hours are determined bymultiplying the number of amperes which the batterywill deliver by the number of hours during which the current is flowing. Example: 160 amperes x 6 hours =960ampere-hours (six-hour rate). Total cell or batterycapacity is then determined by the size and number ofplates which make up the element. Due to the variety of job requirements, batteries are produced withmany different sizes of cells.

KILOWATT HOURS (KWH). Battery capacity is alsoexpressed 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 percell = 1,855 watt hours ÷ 1000 = 1.85 KWH. For a 12 cellbattery, the capacity would be 1.85 x 12 = 22.20 KWH.The kilowatt hour rating can be varied by increasing or

decreasing the size of cells or the number of cells in thebattery.

POSITIVE PLATE CAPACITY. Positive plate capacity isthe ampere delivery for a fixed period of time (usually six hours) for a particular size positive plate. A160G type positive plate has the capability of delivering26.7 amperes for six hours or 160 amperes hours(26.7x6=160 AH) to a final voltage of 1.70. This amperehour rating or capacity can be varied by increasing ordecreasing the number of positive plates in the cell. Inthe previous examples, the battery is a 12 cell, 160G-13plate unit. To determine the number of positive plates ineach cell, subtract one from the total number of platesin 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 aGeneral Battery 75GL or 160G will respectivelydecrease or increase the ampere hour capacity.

The above ratings are based on a temperature of77˚F with a fully charged specific gravity acid (see battery nameplate).

SPECIFIC GRAVITY. The term which describes the ratioof 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 fullcharge gravity of a cell is a matter of design and dependson several factors. The specific gravity must be highenough to contain the amount of sulfuric acid necessaryto meet the chemical needs of a cell. If the sulfuric acidcontent is too high, damage may result to the cell. Thestandard full charge gravity for lead acid batteries used inmotive power requirements is normally 1.275 to1.320.Specific gravities in railway-diesel cells may be as low as1.240.

Fig. 1-3

Fig. 1-4Discharged Cell

Charging Cell

MinimumSulfuric

Acid

MaximumWater

Battery Charger

Typically2.44 Volts

IncreasingSulfuric

Acid

DecreasingWater

IncreasingSponge Lead

DecreasingLead Sulfate

IncreasingLead Peroxide

DecreasingLead Sulfate

MinimumSponge Lead

MaximumLead Sulfate

MinimumLead Peroxide

MaximumLead Sulfate

3

Since the acid content of the electrolyte decreases linear-ly as the cell is discharged, the decrease in gravity isdirectly proportionate to the amount in ampere-hourstaken out. (Refer to Fig. 1-5.)

The specific gravity at any point in the discharge indicates the depth of discharge, and can betranslated into ampere-hours taken out. A cell having afull charge specific gravity of 1.280 and a final specificgravity of 1.130 will have a gravity drop of 150 points.EXAMPLE: assume the specific gravity is 1.180 at theend of a discharge. That is 100 points specific gravitybelow the full charge gravity, therefore, 100/150 = 67%discharged of rated capacity. Allow at least a half hourafter end of discharge for the electrolyte to diffuse andgive a true reading.

The linear relation of gravity to state of dischargecan be used in tests to determine power consumption orcapacity required. Tests of this kind can be made todemonstrate 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 onrecharge is not uniform or proportional to the amount ofcharge returned in ampere hours. During the early part ofthe charge, there is no gassing action to mix the electrolyte with the heavier acid being released from theplates. The heavier sulfuric acid will lie on the bottom. Ahydrometer reading which draws electrolyte from the topof the cell does not indicate the true gravity or actual stateof charge. During the gassing portion of the charge thesulfuric acid mixes, and the specific gravity rises rapidly tofull charge value. (Refer to Fig. 1-5).

1-4 BATTERY CONSTRUCTIONThe following is a brief description of the steps

involved in the production of a lead acid cell which willhelp familiarize the reader with the various parts and theirfunctions.

CASTING GRIDS. A pasted plate is a cast lead grid supporting framework around which chemical pasteshave been applied. (Refer to Fig. 1-6).

Lead alone is extremely soft and inclined to warp orlose form. A strengthening agent must be added to thelead. A quantity of antimonyis added to the lead undervery rigid control to securethe strengthening neces-sary. Temperature control isvery critical as uncontrolledheat would cause the anti-mony to rise in the meltingpot surface and evaporate.After heating, the moltenalloy is poured into the gridmolds. Only Enersys utilizesa computer controlled casting system which optimizescasting variables, resulting in larger lead crystals. Largerlead crystals mean fewer points for corrosion to attack thegrid.

PASTING THE GRIDS. After casting the grids, lead oxidepastes (active material) are applied to the grids.The negative grid, a lead oxide material, is applied containingan expander to produce the sponge lead condition. Thepositive plate is pasted with acompound of lead oxide, sulfuric acid, and watermixed to a putty-like consis-tency. These pastes are mechanically applied to thegrids, and evenly distributedby rollers.The rolling processresults in complete penetra-tion of the paste as shown inFig. 1-7. Only Enersys usesHUP, a patented positivepaste process which optimizes both the active materialutilization and virtually eliminates shedding, the leadingcause of battery failure.

4

CURING AND DRYING PLATES. After pasting, theunformed plates are ready for drying. The wet pastedplates are cured and dried under tightly controlled conditions of temperature and humidity. This processproduces a smooth, uniform plate in which the activematerial attains exceptional porosity and is bondedsecurely to the grid. This results in maximum cell efficiency.

POSITIVE PLATE INSULATION. Retent-A-Tape® is afine 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 perforatedretainer envelops the entire plate and completes thewrapping. (Refer to Fig. 1-8)

The plastic envelope is heavily perforated in thearea covering the active material, permitting a free flowof 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 betweenthe plate edges. The combination of retainers, mats andbottom shields produces a positive plate assemblywhich retains the active material in the grid, providesinsulation where required, and allows for a free flow ofelectrolyte to the plate interior.

ASSEMBLY OF POSITIVE AND NEGATIVE GROUPS.A specified number of positive and negative plates arejoined together to make up positive and negativegroups. Each group of plates is assembled by joiningthe top (lug end) of each plate together and adding oneor more terminal posts. This weld forms a solid bar con-nection between all plates in each group and theirrespective terminal posts. (Fig. 1-9)

SEPARATORS. The negative and positive plates areinsulated by a high-porosity Daramic® separator. Asshown in Fig. 1-10, separators are flat on one side andgrooved on the other. The grooved side is faced to thepositive plate to allow free circulation of a large volumeof electrolyte to the positive active material. The flat sidefaces the negative plates. Since the negative material issponge lead, grooves in the negative side of the separator would tend to fill with expanded material.

ASSEMBLY OF AN ELEMENT. An element is onegroup of assembled positive and negative platesmeshed together with a plastic separator protector positioned on top of the groups, and with separatorsinserted between each plate.

The separator protector serves the following function:

a. Protects the plates and separators from damage by any foreign object entering the cellthrough the vent opening.

b. Prevents damage by careless use of ahydrometer or thermometer.

c. Acts as a baffle to reduce sloshing of theelectrolyte within the cell.(Refer to Fig. 1-11)

ASSEMBLY OF THE COMPLETE CELL. The next stepin cell assembly is the installation of a sediment leveling bridge (Fig. 1-12) in a high impact jar.

Positive Plate Wrapped Burned Group

Positive grids are of heavier constructionthan negative grids. This is necessarybecause the chemical action resultingfrom charging and discharging a cell ismore pronounced on the positive platethan on the negative. Gases formed during charging are Oxygen andHydrogen, with the Oxygen forming on the positive plate and Hydrogen on the negative.

Positive Grid Pasted Plate

Fig. 1-6 Fig. 1-7 Fig. 1-8 Fig. 1-9

5

A completed element is then installed in the jar and atough, shockproof cover with lead-insert bushings(Refer to Fig. 1-13) is positioned on the posts and heatsealed to the jar. The terminal posts are welded to thelead cover inserts. The cell is then pressure tested toconfirm a perfect bond between the cell cover to jar andpost to cover insert.

The assembled cells consist of cured, dry,unformed plates which have no electrical characteristicsand capacity.

PLATE FORMATION. Electrolyte (sulfuric acid) at aspecific gravity is now added to each cell. The initialcharge given to a cell is known as the forming charge.The forming charge produces the electrical characteristics (positive and negative polarity) on eachgroup of plates.

COMPLETED BATTERY ASSEMBLY. At the completion of the forming charge, the cells are assembled into a suitable steel tray and connected inaccordance with the buyer’s layout specifications. Thebattery is tested, inspected, and made ready for shipment.

Fig. 1-10 Fig. 1-12

Fig. 1-13

Fig. 1-14

Fig. 1-11

Separator

Complete Cut-Away of Cell

Cover

Bridge

Separator Protector

6

SECTION IIRECEIVING AND INSTALLATION

2-1 RECEIVING BATTERYWhen receiving a new battery, immediately

examine the exterior of the packing. Examine for wet spotson the sides or bottom which may indicate leakingjars broken in shipment or that the battery has been tippedover during transit.

If there is visible evidence of damage, the receiptshould be marked “SHIPMENT RECEIVED DAMAGED.” Thecarrier should be called immediately and asked to make adamage 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 immediatelyand requested to make a concealed damage report.

Contact your local Enersys representative to assist youin evaluating the extent of the damage.

Spilled electrolyte must be replaced immediately or permanent damage will occur to the affected area of theplates resulting in loss of the battery’s ability to deliver itsrated capacity.

Broken jars must be replaced at once for the reason mentioned above. Contact your local Enersys representative immediately to make the proper repairs.

2-2 PLACING A WET BATTERY IN SERVICE(A) Remove the vent caps from each cell and determine thatthe electrolyte level in each cell is at the bottom of the levelindicator. If electrolyte has been lost, replace it with elec-trolyte of the same specific gravity.(B) A freshening charge should be given to the battery andwill require about three to five hours to complete. The battery should be charged at its finish rate (about 4-5amperes per 100 ampere hours of the battery’s 6 hour ratecapacity).(C) Vent caps should be secured in place during chargingcycle. Charging is complete when the specific gravity levelsoff for a 3 hour period. General and Hup batteries have a nor-mal fully charged specific gravity of 1.280-1.290 at 77˚F (Fig.2-1). 55GL an 75GL batteries have a normal specific gravi-ty of 1.305-1.320 at 77˚F.D) Battery compartment drain holes in the floor of the lifttruck should be open, and the battery should be clean anddry prior to installation.

(E) Lift the battery with an insulated battery lifting beam orinsulated spreader bar with the lifting hooks set in the prop-er position to place a vertical pull on the lifting eyes (Fig. 2-2).(F) Install the battery in the compartment firmly blocking it toposition. All vent caps must be tightly secured to prevent electrolyte spillage from occurring that could causetray corrosion or battery compartment corrosion.

2-3 PLACING A DRY CHARGED BATTERY INSERVICE

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

Fig. 2-1

Fig. 2-2

7

(H) At the end of charge period, the cell voltages and specific gravity rises to about 2.55 volts and 1.280(77˚F) respectively. Continue charging until the cells gasfreely and the cell voltages and specific gravities remainconstant over a three hour period.(I) Just before completion of the charge, read exact specific gravity of all cells and adjust to battery name-plate specification ±0.005. (Refer to 4-2, Page 13).

2-4 A BATTERY IS FULLY CHARGED WHEN:(A) The charging voltage has stabilized. Voltage increas-es slowly during charging and levels off when the bat-tery is fully charged.Refer to Fig.1-5 on Page 3 of Theory& Construction.(B) The battery is gassing freely. CAUTION: An explo-sive mixture of hydrogen and oxygen is produced in alead acid battery while it is being charged. The gassescan combine explosively if a spark or flame is present toignite them. Keep open flames, matches, and smokingaway from the charging area.(C) The specific gravity of the electrolyte stops rising.Readings will stabilize when the battery is fully chargedand may even drop due to a temperature rise in theelectrolyte (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 specificgravities for temperature (see Chart 2-1 and 2-2 oncharge or open circuit).

2-5 OPERATION OF THE BATTERYThere are several factors which affect the operation ofthe battery concerning its ability to deliver capacity andlife expectancy. Many chemical reactions are affected bytemperature, and this is true of the reaction that occursin a storage battery. The chemical reaction of a lead-acid battery is slowed down by a lowering of temperature which results in less capacity. A battery thatwill deliver 100% of capacity at 77˚F will only deliver at74% of capacity of 20˚F (Chart 2-3).

EXCESSIVE HEAT will contribute greatly to reducing battery life by corroding the positive grids and excessivegassing which loosens active material in the plates, especially the positive plates. Overcharging is the most common contribution to excessive temperatures andgassing in a battery. A General Battery Ferro-Resonantcharger, matched to the proper ampere-hour require-ments of the battery, will help to avoid the problem ofovercharging.

CONSISTENT UNDERCHARGING of a battery will gradually run down the cells and result in one or more cellsbecoming completely discharged before the others, and maybecome reversed. Capacity and life expectancy are greatlyreduced by undercharging. Equalizing charges to return thecells to a normal condition should be part of a weekly maintenance schedule when required.

OVERDISCHARGING can also cause permanent damageto the battery. Recharging is more difficult and more time consuming. Often complete recharge is not attained and theundercharged battery is placed into service. Consequently, itis overdischarged to a lower limit resulting in loss of capacityand premature battery failure. Optimum battery life can beaided 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 Maintenancecan be found in Section III of this manual.

Fig. 2-3

Chart 2-1

Chart 2-2

Chart 2-3

Cell Voltage Correction FactorsElectrolyte

Temperature˚F

CorrectionFactor

CorrectionFactor

ElectrolyteTemperature

˚F

49-5152-5455-5758-6061-6364-6667-6970-7273-75

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

76-7879-8182-8485-8788-9091-9394-9697-99

100-102

NONE REQUIRED

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

ubtr

act

From

Mea

sure

d V

olts

Add

To

Mea

sure

d V

olts

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

CELL SPECIFICGRAVITY

CORRECTIONFACTORS

CorrectionFactor

ElectrolyteTemperature

ElectrolyteTemperature

CorrectionFactor

39-4142-4445-4748-5051-5354-5657-6061-6364-6667-6970-7273-7576-7879-8182-8485-8788-9192-9495-9798-100

-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

101-103104-106107-109110-112113-115116-118119-121122-124125-127128-130131-133134-136137-139140-142143-145146-148149-151152-154155-157158-160

+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

ElectrolyteTemperature

˚F

776050403020

PercentCapacity

@ 6-Hour Rate1009591878174

PercentCapacity

@ 3-Hour Rate1009387837667

10

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. If the readings average less than the specific gravity ranges below, check the charger output.

b. 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.

Chart 3-3

General

Hup

55GL and 75GL

Specific Gravity at 77˚F

1.280 - 1.290

1.280 - 1.290

1.305 - 1.320

11

The recommendation for battery replacement wateris shown in this listing below including the maximumallowable impurities in parts per million NEMA standards.

Total SolidsFixed SolidsOrganic & Volatile MatterIron ChlorideAmmonia as NH4Nitrites as HO2Nitrates as HO3

350 PPM200 PPM150 PPM

4 PPM25 PPM5 PPM

10 PPM10 PPM

Chart 3-5

Chart 3-4

Specific Gravity @ 77˚F

77˚F

12

BATTERY CHARGING LOGTM

Chart 3-6

USER # TYPE S/N

START OF CHARGE END OF CHARGE

DATE TIME TRUCK SP. GR. CHARGERCELLTEMP.

CELLTEMP.W E C* BY DATE TIME SP. GR. BY

* INSERT W WHEN WATER IS ADDEDINSERT E WHEN EQUALIZING CHARGE IS GIVENINSERT C WHEN BATTERY IS CLEANED OR WASHED

EVERY MONTH RECORD GRAVITY AFTER EQUALIZING CHARGE TEMP. DATE.

FORM NO. IND.010 (REV. A) PRINTED IN U.S.A.

REMARKS

CELL

1

2

3

4

5

6

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. CELL

25

26

27

28

29

30

SP. GR. CELL

31

32

33

34

35

36

SP. GR.

13

SECTION IVTROUBLE SHOOTING

4-1 INTERPRETATION OF CELL VOLTAGE READINGS

The condition and health of a battery can be revealedin a study of its cell voltages. There are two factors to consider: the value of the voltage readings in relation to thebattery function at that time, and the uniformity of the volt-age readings throughout the battery. The nominal voltage value of a lead acid cell is 2.00 volts. It is notuncommon to encounter cell voltages anywhere from 1.00volts or less to 2.75 volts depending on the function of thebattery at the time of the readings. The interpretation of thevoltage values is a matter of comparison with normal battery characteristics, and the knowledge as to the reasonfor 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 readingsare useful in determining uniformity. For example, a fullycharged battery on open circuit, with a specific gravity of1.260 to 1.280 will read 2.10 to 2.12 volts or a spread of0.02 volts. This 0.02 volt spread would be considered normal for a new battery. As the battery ages, the voltagespread will increase to about 0.03 volts. The reason for thespread to widen with age is due to inequalities in plate wearand possibly some acid loss.

ON-CHARGE VOLTAGE READINGS. On charge voltagereadings are the most informative and the best indicators ofbattery condition. These readings should be taken at the normal finish rate, and be corrected to the base of 77˚F.New batteries, at normal finish rate, will have cell voltagesbetween 2.55 volts and 2.65 volts. Older batteries oncharge at the normal finish rate, will have cell voltagesabout 2.45 to 2.55 volts

VARIATIONS IN CHARGE VOLTAGE. If all cells of a battery show similar full-charge voltages, they are equallyhealthy. 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 2.50volts per cell has more uniformly healthy cells than a battery having an on-charge voltage spread of 2.40 to 2.50volts per cell. The battery’s age and service duty must beconsidered in the interpretation of the on-charge voltagereadings. An example would be an older battery which hason-charge cell voltage readings of 2.45 volts to 2.65 volts.The reason may very well be that the inside cells operate athigher than average temperatures causing higher localaction, which would result in lower voltage. Regularequalize charge will compensate for the higher self-loss ofthe inside cell. Any wide spread on-charge voltage thatcould not be attributed to the battery’s service life or age, isa sign that something is wrong and attention is necessary.Some causes of abnormally wide spread or charge voltages are:

1. Abnormal temperature differential2. Internal shorts

3. Acid loss causing overdischarge4. Insufficient charging

4-2 ACID REPLACEMENT AND ADJUST-MENT OF SPECIFIC GRAVITY

Under normal circumstances, a battery should neverrequire the addition of acid to increase the specific gravityof the electrolyte. However, when upsets, jar breakage, overfilling, or careless use of the hydrometer cause a lossof 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 thespecific 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 thespecific gravity with acid. Never perform acid adjustmenton a cell with an on-charge cell voltage less than 2.45 voltsand that does not gas vigorously. To replace acid, use the following procedure with a sulfuric acid having a specificgravity of 1.400.(A) Battery must be in a fully charged condition topped offwith an equalizing charge (see page 8 for definition anddescription), with the electrolyte freely gassing.(B) Remove electrolyte from the low reading cell or cellsuntil the level reaches the separator protector.(C) Slowly add the 1.400 specific gravity sulfuric acid to theproper electrolyte level while it is still charging and gassingso that the adjusting acid mixes thoroughly. If added to fast,the adjusting acid will drop to the bottom of the cell and notdiffuse immediately, resulting in an inaccurate specific gravity reading. Further additions of acid can be harmful,especially when the battery is returned to service and com-plete diffusion results in a high specific gravity. About 1/4” of1.400 specific gravity will increase a cell’s specific gravity about 5 points (0.005)(D) After adding high specific gravity acid, leave the batteryon charge for one hour so that the higher specific gravityacid is thoroughly mixed with the electrolyte. Read andrecord the specific gravity of the adjusted cell(s) and correct for temperature (refer to temperature correctionchart 2-2 on page 7). If the specific gravity readings are toolow, 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 theelectrolyte and replace it with approved water to properelectrolyte 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 theprocess 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 adjustmentmust be made with the same strength sulfuric acid in orderto maintain the proper specific gravity.

14

15

NOTE: If electrolyte temperature exceeds 110˚F during theabove mentioned procedures, stop the charge and allow thebattery electrolyte temperature to cool to 90˚F or less beforecontinuing.CAUTION: Never add acid with a specific gravity higher than1.400. When mixing or cutting acid, always add the acid to thewater. 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

battery’s actual discharge capability as compared to its sixhour rated capacity. The discharge test can be a significantdiagnostic tool when equipment does not operate as expected, and it can help determine when the battery shouldbe replaced. When a battery consistently delivers less than80% of its rated 6 hour capacity, either some cells are substandard or the battery has reached the end of its usefullife and should be replaced.Equipment:

1. Discharge apparatus2. Voltmeter3. Ammeter and shunt (calibrated)4. Charge-test-discharge form (Section 87.86)5. Thermometer6. Hydrometer

PROCEDURE:(A) Prior to the start of the test discharge, complete the general information section at the top of the charge-test-discharge 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 eachcell as received. Charge the battery and equalize charge.(C) Record the on-charge, end of equalize charge, voltageand specific gravity of each cell, and the charging current ratein amps. The end of equalize charge specific gravity should beaccording to battery nameplate specification.(D) If acid adjustment is necessary, follow the procedure setforth above for acid adjustment and record the adjusted specific gravity readings in the space provided. Maintain a temperature of 90˚F or less throughout the charging, equalize charge, and acid adjustment. If the temperatureexceeds 90˚F, terminate charging and acid adjustment untilbattery has cooled down to 90˚F 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 appliedand record the time elapsed as start. Also, record the batteryterminal voltage. Complete the remaining portion of thecharge-test-discharge form Section 87.86 in the followingmanner:

Record cell voltages every 60 minutes until an averagevoltage of 1.80 volts per cell is reached. Between 1.80 voltsper cell and 1.75 volts per cell, readings of each cell voltageshould 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 isolatedcell. The time, temperature, and specific gravity should berecorded at termination. Recharge the battery as soon as possible after the test discharge.

The actual capacity in ampere-hours obtained duringthe test discharge is the product of the discharge rateamperes times the time in hours required to reach terminationvoltage of 1.70 volts per cell. Further guidelines such as per-formance requirements, test conditions, test equipment, andtest methods for conducting a test discharge should beobtained from Battery Council International publication BCI-I-2 titled “Determination of Capacity of Lead Acid IndustrialStorage 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. Theproduct will be the amount of amperes necessary to discharge the battery 100% in a 6 hour period.To calculate the3 hour discharge rate, multiply the rated ampere hour capacity of the battery times 0.280. The chart below is batteryterminal voltage for termination of test discharge:

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. Athird electrode is introduced into the cell and the portion of thetotal voltage contributed by each plate group is measured. Ananalysis of these measurements between this third electrodeand 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 commonlyused third electrode in lead acid batteries is the cadmiumelectrode.

Chart 4-3 shows three sets of cadmium readings takenon three cells at one half hour intervals at the end of a 6 hourdischarge.

The chief value of the cadmium electrode test is todetermine the condition of positive and negative plates separately. The electrode consists of a rod about 5/16” indiameter; it may be from one to several inches long. Before theelectrode is used for the first time, it should be soaked for sev-eral days in a sulfuric acid solution of about the strength ofbattery electrolyte, and before each test it should beimmersed 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 inthe cell will usually protect the cadmium rod from coming in contact with the plates. If the separator protector is

Chart 4-1

Number of cells Terminal Voltage

69

121518243032

10.215.320.425.530.640.851.054.4

16

missing, the cadmium rod should be encased in a perforated hard rubber cover. A flexible rubber insulatedwire is attached to the cadmium to serve as a voltmeterlead.

The cadmium electrode is inserted into the electrolyte immediately above the center of the plate. Thereadings must be taken when the cell is either discharging or charging. Open circuit readings are meaningless.

During the discharge cycle, the potential betweenthe cadmium electrode and the positive plates decreasesfrom about 2.2 to 2.0 volts, depending on the state ofcharge. If the battery is further discharged, this potentialdrops rapidly.The potential between the cadmium and thenegative plates is about 0.15 to 0.2, volts, and the rate ofincrease in potential becomes greater if the cell is discharged below its normal rating. When the battery ison-charge, the potential between the cadmium and thenegative plates reverses as the battery approaches theend of the charging cycle. The readings near the end ofthe 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 77˚F the following would represent a healthy cell at finish rate:

Positive Cadmium = 2.43Negative Cadmium = -0.20Cell Voltage = 2.63

The cell voltage is the algebraic difference betweenthe two cadmium readings. Both the positive and negative cadmium readings under fully charged conditions will be uniform in a normal battery. If there is acell voltage variation of more than 0.05 volts below theother cells, cadmium readings will indicate which platesare affected. An internal cell inspection should be made todetermine 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 ofthe cell will reveal the defect. CELL NUMBER 3 has lowterminal voltage, but normal positive readings. The negative cadmium reading is low, indicating either under-charging or contamination of the negative plate. Chart 4-3 shows three negative cadmium readings taken on threecells at one half hour intervals at the end of a 6 hour dis-charge.

CELL#1 - Both the positive and negative cadmiums aredecreasing uniformly as the cell voltage decreases, andboth sets of plates are losing capacity together indicating that they are in a healthy condition. At the endof the 6 hour discharge the cell had delivered capacity to1.70 volts. This cell is performing satisfactorily. CELL #2 -This cell delivered capacity; however the positive cadmium readings changed rapidly and contributed tomost of the voltage drop since the negative cadmiumsremained practically unchanged. This cell appears to belimited in its ability to deliver capacity by the positiveplates at the present time.

CELL #3 - The terminal voltage of this cell decreased veryrapidly towards the end of the discharge. The negativecadmium values changed by a large amount (0.32),whereas the positive values only showed a minimalchange (0.05). This cell appears to be limited in its abilityto deliver capacity by the negative plates which contributed to the bulk of the voltage drop. Failure of thenegative plates will usually cause a more rapid decline incell voltage than failure of the positives.

4-6 INTERNAL INSPECTION If the test discharge previously explained indicates

that the battery was not capable of delivering more than80 percent of rated capacity, an internal inspection shouldbe made. The positive plates, which wear first, should be examined. If it is discovered that the positive plates arefalling apart or that the grids have many frame fractures,a replacement battery is needed. If the positive plates arein good mechanical condition and the cells contain little sediment, the battery may be sulfated.

Cell#

1 2.63 2.43 -0.20

2 2.38 2.38 0

3 2.38 2.43 +0.05

OnCharge

CellVoltage

PositiveCad.Value

NegativeCad.Value Probable Cause of Condition

No internal shorts. Healthynegative plates. Typicalreadings for a new cell.

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

Normal positive cadmium valueindicates absence of internalshorts. Unhealthy negativeplates indicated by low negative cadmium value.Negative plates could be failing.

Chart 4-3

Chart 4-2

Cell #1 Cell #2 Cell #3

5 Hours & 30 Min.Positive Cadmium Value

Negative Cadmium Value

Cell Voltage

6 HoursPositive Cadmium Value

Negative Cadmium Value

Cell Voltage

5 Hours & 7 Min.Positive Cadmium Value

Negative Cadmium Value

Cell Voltage

2.02 1.97 2.03

0.22 0.17 0.23

1.80 1.80 1.80

1.98 1.92 2.00

0.23 0.17 0.40

1.75 1.75 1.60

1.91 1.84 1.98

0.24 0.18 0.55

1.67 1.66 1.43

17

4-7 ON SITE BATTERY INSPECTIONSOn-site battery inspections are performed for

various reasons. The customer may be experiencingbattery problems or just require an annual batteryinspection to determine the condition of all batteries andchargers. Many times the on-site inspection is a goodsales tool for developing new customers as well asobtaining replacement battery orders.

On-site inspections are not just a visual inspection,but also a factual inspection. Battery cell voltages andgravities should be recorded. Battery temperature andspecific gravity before and after charge should berecorded. 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 con-dition of the charging area, ambient temperature, andbattery charging schedule. Upon compiling the record-ed data, an intelligent view of the customer’s operationcan be made along with the proper recommendations. Consequent follow-up inspectionsand repair work can be accomplished.

Form IND-441 should be used in an on-site batteryinspection. The required information can be accumulated easily on this form for review (Refer toChart 4-4).

4-8 CAUSES OF SULFATED BATTERIESAll lead acid batteries sulfate when discharged.

The active material must convert to lead sulfate in orderfor the cells to produce energy. This sulfation process iscalled “normal sulfation.” The term “sulfated battery”means that the battery has developed abnormal sulfateand has its capacity impaired as a result.The most com-mon 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 arebelow 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 fullycharged after a regular equalizing charge. Beforeassuming that the battery is sulfated, rule out the possibility that low gravity may be due to acid loss. If thespecific gravity is low due to acid loss, the negativeplates are likely to be in good condition, with the activematerial a spongy lead showing a metallic luster whenstroked. Abnormally sulfated material is hard and grittyand feels sandy when rubbed. If the negative activematerial is mushy and sandy, coming off like mud whenstroked, too much acid is indicated. A sulfated positivematerial is a lighter brown color than a normal positiveplate. If the sulfation has not progressed too far, it maybe possible to restore the battery to a serviceable condition by paying careful attention to the followingprocedure:(A) Clean the battery (neutralize, wash and dry).(B) Adjust electrolyte by adding approved water to theproper level.(C) Change the battery at the proper finish rate until thefull ampere-hour capacity has been put in the battery,based on the six-hour rate. If the temperature risesabove 110˚F during these procedures, reduce thecharge rate accordingly, or stop the charge and allowthe battery to cool to 90˚F or less before continuing.Charge the battery until the specific gravity shows nochange during a 3 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge 2or 3 times.(D) Discharge the battery to its rated capacity or lowerwithout causing any cell to reverse.(E) Recharge again until the specific gravity shows nochange during a 3 hour period.(F) Repeat the cycling process until the specific gravityremains constant. If the battery gives at least 80%capacity, recharge and put into service.(G) If the battery has not responded to steps A throughF, it is sulfated to the point where it is impractical toattempt further treatment. The battery should bereplaced.

18

TM

BATTERY INSPECTION REPORT

CHART 4-4

INSPECTED BY:

REMARKS & RECOMMENDATIONS

(AGENT OR BRANCH)

DATE

USER NAME ADDRESS

TYPE OF SERVICE

CONDITION

LOCATION OF BATTERIES

TYPE OF CHARGING EQUIPMENT

USER #

TYPE

S/N

CHARGERATE

TEMP.

CELL 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.

123456

789101112

131415161718

192021222324

252627282930

313233343536

19

SECTION VHEALTH AND SAFETY

5-1 BATTERY HAZARDS

GENERAL - A lead-acid battery can be a very useful, safesource 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. Inthis 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 madeof 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 ispresent 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 intogas pockets, as can occur within a cell, it might explode ifignited. Hydrogen formula =0.00027 x (finish rate) x (num-ber of cells)=cu.ft. of hydrogen produced per minute.(C) Electricity is produced by the batteries on dischargeand, while most persons cannot feel voltages below 35 to40 volts, all motive power batteries should be regarded as potentially dangerous. A lead-acid battery iscapable of discharging at extremely high rates and, underconditions of direct shortage, can cause severe damageand serious injury.(D) The weight of these heavy batteries can easily causepainful strains or crushed hands or feet if improperly liftedor handled. Batteries can be damaged if dropped. Theaverage motive power battery weighs more than one ton,so proper equipment must be provided when changing orhandling batteries.(E) Burns can result from contact with molten lead or hotcompounds while repairing a battery. Lead can splashwhen intercell connectors are being reburned, and hotcompounds can be spilled when resealing covers to jars.Protective gear, if worn, will help prevent such burns.

5-2 SAFETY PROCEDURES

FEDERAL STANDARDS - In 1970, Congress passed theOccupational Safety and Health Act (OSHA). This actestablished the minimal acceptable standards for safe andhealthful working conditions. The safety procedures outlined in this manual have been compiled from standards developed over the years by professional andtechnical organizations.

The safety procedures have been grouped by functional area of most logical application or need.

SAFETY PROCEDURES WHILE HANDLING BATTERIES(A) Lift batteries with mechanical equipment only, such asan overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should alwaysbe used with overhead lifting equipment. Do not use chainsattached to a hoist at a single central point forming a trian-gle. This procedure is unsafe and could damage the steeltray.(B) Always wear safety shoes, safety glasses, and a hardhat made of a nonconducting material.(C) Tools, chains and other metallic objects should be keptaway from the top of uncovered batteries to prevent possi-ble short circuits.(D) Battery operated equipment should be properly positioned with switch off, break set, and batteryunplugged when changing batteries or charging themwhile in the equipment.(E) Personnel who work around batteries should not wearjewelry made from conductive material. Metal items canshort circuit a battery and could cause severe burns andelectrocution.(F) Only trained and authorized personnel should be permitted to change or charge batteries.(G) Reinstalled batteries should be properly positioned andsecured in the truck, tractor, or crane. Before installing anew or different battery, check with the truck or tractorname plate and battery service weight to make sure thatthe proper weight battery is being used. A battery of thewrong weight can change the center of gravity and causeequipment to upset.

SAFETY PROCEDURES WHILE CHARGING BATTERIES(A) Specific areas should be designated for charging batteries. These areas should be equipped with overheadhoists or cranes for handling batteries.(B) Charging areas should be adequately ventilated. Theactual amount of ventilation will depend upon such factorsas number and size of batteries being charged at the sametime, 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 chargingequipment from physical damage by trucks, tractors, andcranes.(E) Eyewashes and showers are required in areas wherebatteries are serviced. OSHA regulation 29 CFR1910.151(c) has clear guidelines for eyewash and showeruse. Safety equipment should be clearly identified andreadily accessible.

20

(F) Before connecting a battery to, or disconnecting itfrom, a charger, the charger should be turned off. Liveleads can cause arcing and pitting of battery connectorcontact surfaces.(G) Make sure that all electrical connections are tight andmechanically 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 possibleexposure to acid or electrolyte.(I) When batteries are charged on racks, the racks shouldbe insulated to prevent any possibility of shortage.(J) When charging an enclosed or covered battery, alwayskeep 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 thecells.(L) Shut off and disconnect both input and output connections to the charger before repairing charging equipment.

SAFETY PROCEDURES WHILE HANDLINGBATTERY 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 run-ning water for at least 15 minutes followed as quickly aspossible with a physician’s examination. If the person iswearing contact lenses, they should be removed beforerinsing the eyes.(B) Acid or electrolyte splashed onto the skin should bewashed 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 weaksolution of bicarbonate of soda as soon as possible, to neutralize the acid.(D) A carboy filter or safety siphon should be provided forhandling acid from a carboy container. Use the protectivebox when moving a carboy. Store acid in a cool place outof 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 pourthe acid slowly into the water and stir constantly to mixwell. Never pour water into acid. Never use sulfuric acidsolutions which are over 1.400 specific gravity.(F) Apply a neutralizing solution, such as a bicarbonate ofsoda and water, when acid is spilled on floor and clean uppromptly. A mixture of one pound of soda to one gallon ofwater is recommended.

SAFETY PROCEDURES WHILE SERVICING OR REPAIRING BATTERIES(A) Disconnect the battery from the truck, tractor, or cranewhen servicing or repairing either the battery or the equipment. Also make certain the battery is disconnectedfrom the charger before handling or repairing the battery.(B) Before repairing a battery, remove all of the vent capsand blow out each cell with a low pressure air hose toremove any residual gas. Use only a gentle stream of airto avoid splashing electrolyte.(C) Open or “break” the circuit before repairing damagedor dirty terminal plugs or receptacles connected to a battery, by removing and insulating one terminal lead at atime.(D) When melting sealing compound in preparation forresealing cells, be careful not to puncture the top sectionof unmelted compound with a screwdriver or other point-ed object. A build-up of pressure from the melted com-pound in the bottom could cause liquid compound to squirtand inflict a severe burn. Do not allow compound to igniteby overheating. Compound becomes workable at 400 to425˚F.(E) Check batteries frequently for acid leakage or signs ofcorrosion.(F) Use insulated tools whenever possible when workingon batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or otherinsulating material to prevent short circuits.(G) When taking specific gravity readings, use a faceshield or goggles and read the hydrometer with eye atabout the same level as the electrolyte. See Fig. 5-1.

Fig. 5-1

There may be additional regulatory requirements,depending on the specific application, as well

as federal, state, and local requirements.

21

Chart 5-1

TROUBLE SHOOTING CHART

Problem Probable Cause Remedy

Battery notworking a fullshift.

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 usefuloperating life.

6. Vehicle has electrical ormechanical problems.

1. Replace with a battery of adequatecapacity for the work load required.

2. Check chargers and chargingschedules. Fully charged gravity is1.275-1.285 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.

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 90˚F 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 battery’s 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 aftergassing begins.

3. Adjust gravity.

1. Charged equipment notoperating correctly.

2. Charging equipment incorrectlyadjusted.

3. Weak or defective cells.4. Battery worn out.5. High resistance connection.

6. Low electrolyte level.

7. Battery too warm when placedon charge.

8. Battery being charged in truckcompartment 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 highambient temperatures.

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

3. Frequent overcharging.4. Battery tipped over.

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.

1. All probable causes listed under“Unequal Cell Voltages.”

2. Battery recently watered andinsufficient time allowed formixing.

3. Improper gravity adjustment aftercell replacement.

Batteryoverheats on charge.

Batteryoverheats on discharge.

Low ElectrolyteLevel.

Unequalspecificgravities.

Unequal CellVoltages.

22

GENERAL SERIESMOTIVE POWER CELL PARTS LIST

Cell 6 Hr. Ah Cable Cell Cover Jar Standard Over Partition Insulator Standard Over Partition Insulator55GL-5 110 #2 93478-CW 804080 804310 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 20150955GL-7 165 #2 93479-CW 804081 804311 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 20150955GL-9 220 #2 93480-CW 804082 804312 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 20150955GL-11 275 #2 93481-CW 804083 804313 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 20150955GL-13 330 #2 93482-CW 804084 804314 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 20150955GL-15 385 #2 93483-CW 804085 804315 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 20150955GL-17 440 #2 93484-CW 804090 804316 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 20150955GL-19 495 #2 93485-CW 804091 804317 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 20150955GL-21 550 #2 93486-CW 804092 804318 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 20150955GL-23 605 1/0 93487-CW 804093 804319 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 20150955GL-25 660 1/0 93488-CW 804094 804320 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 20150955GL-27 715 1/0 93489-CW 804095 804321 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 20150955GL-29 770 1/0 93490-CW 804940 804322 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 20150955GL-31 825 2/0 93491-CW 804941 804323 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 20150955GL-33 880 2/0 93492-CW 804942 804324 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 20150975GL-5 150 #2 83623-CW 804080 804360 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 20150975GL-7 225 #2 90000-CW 804081 804361 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 20150975GL-9 300 #2 90001-CW 804082 804362 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 20150975GL-11 375 #2 90002-CW 804083 804363 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 20150975GL-13 450 #2 90003-CW 804084 804364 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 20150975GL-15 525 #2 90004-CW 804085 804365 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 20150975GL-17 600 #2 90005-CW 804090 804366 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 20150975GL-19 675 1/0 90006-CW 804091 804367 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 20150975GL-21 750 1/0 90007-CW 804092 804368 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 20150975GL-23 825 2/0 90008-CW 804093 804369 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 20150975GL-25 900 2/0 90009-CW 804094 804370 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 20150975GL-27 975 3/0 90010-CW 804095 804371 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 20150975GL-29 1050 3/0 90011-CW 804940 804372 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 20150975GL-31 1125 4/0 90012-CW 804941 804373 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 20150975GL-33 1200 4/0 90013-CW 804942 804374 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 20150975G-5 150 #2 84301-CW 804080 804180 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 20150975G-7 225 #2 84302-CW 804081 804181 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 20150975G-9 300 #2 81113-CW 804082 804182 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 20150975G-11 375 #2 81114-CW 804083 804183 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 20150975G-13 450 #2 81115-CW 804084 804184 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 20150975G-15 525 #2 81116-CW 804085 804185 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 20150975G-17 600 #2 81117-CW 804090 804186 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 20150975G-19 675 1/0 81118-CW 804091 804187 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 20150975G-21 750 1/0 81119-CW 804092 804188 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 20150975G-23 825 2/0 81120-CW 804093 804189 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 20150975G-25 900 2/0 81121-CW 804094 804190 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 20150975G-27 975 3/0 81122-CW 804095 804191 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 20150975G-29 1050 3/0 81123-CW 804940 804192 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 20150975G-31 1125 4/0 88137-CW 804941 804193 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 20150975G-33 1200 4/0 87300-CW 804942 804194 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 20150985G-5 170 #2 99231-CW 804100 853440 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 20150985G-7 255 #2 99232-CW 804101 853441 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 20150985G-9 340 #2 99233-CW 804102 853442 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 20150985G-11 425 #2 99234-CW 804103 853443 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 20150985G-13 510 #2 99235-CW 804104 853444 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 20150985G-15 595 #2 99236-CW 804105 853445 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 20150985G-17 680 1/0 99237-CW 804110 853446 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 20150985G-19 765 1/0 99238-CW 804111 853447 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 20150985G-21 850 2/0 99239-CW 804112 853448 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 20150985G-23 935 3/0 99240-CW 804113 853449 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 20150985G-25 1020 3/0 99241-CW 804114 853450 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 20150985G-27 1105 4/0 99242-CW 804115 804171 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 20150985G-29 1190 4/0 99243-CW 804116 804172 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 20150985G-31 1275 4/0 99244-CW 804117 804173 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 20150985G-33 1360 4/0 99245-CW 804118 804174 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509100G-5 200 #2 99261-CW 804100 804200 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509100G-7 300 #2 99262-CW 804101 804201 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509100G-9 400 #2 99263-CW 804102 804202 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509100G-11 500 #2 99264-CW 804103 804203 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509100G-13 600 #2 99265-CW 804104 804204 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509100G-15 700 1/0 99266-CW 804105 804205 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509100G-17 800 1/0 99267-CW 804110 804206 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509100G-19 900 2/0 99268-CW 804111 804207 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509100G-21 1000 3/0 99269-CW 804112 804208 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509100G-23 1100 4/0 99270-CW 804113 804209 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509100G-25 1200 4/0 99271-CW 804114 804210 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509100G-27 1300 4/0 99272-CW 804115 804211 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509100G-29 1400 4/0 99273-CW 804116 804212 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509100G-31 1500 4/0 99274-CW 804117 804213 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509100G-33 1600 4/0 99275-CW 804118 804214 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509

END TO ENDSIDE TO SIDEINTERCELL CONNECTORS & INSULATORS

23

Cell 6 Hr. Ah Cable Cell Cover Jar Standard Over Partition Insulator Standard Over Partition Insulator125G-11 625 1/0 290343-CW 804103 503835 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509125G-13 750 1/0 290344-CW 804104 503836 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509125G-15 875 2/0 290345-CW 804105 503837 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509125G-17 1000 3/0 290346-CW 804110 503838 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509125G-19 1125 4/0 290347-CW 804111 503839 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509125G-21 1250 4/0 290348-CW 804112 503840 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509125G-23 1375 4/0 290349-CW 804113 503841 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509125G-25 1500 4/0 290350-CW 804114 503842 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509125G-27 1625 4/0 290351-CW 804115 503843 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509125G-29 1750 4/0 290352-CW 804116 503844 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509125G-31 1875 4/0 290353-CW 804117 503845 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509125G-33 2000 4/0 290354-CW 804118 503846 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509160G-9 640 1/0 97811-CW 804911 804571 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509160G-11 800 2/0 97812-CW 804912 804572 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509160G-13 960 3/0 97813-CW 804913 804573 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509160G-15 1120 4/0 97814-CW 804930 804574 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509160G-17 1280 4/0 501456-CW 804931 804575 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509160G-19 1440 4/0 97815-CW 804932 804576 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509

Cell 6 Hr. Ah Cable Cell Cover Jar Standard Over Partition Insulator Standard Over Partition Insulator85P-5 170 #2 290210-CW 804100 804160 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 20150985P-7 255 #2 290211-CW 804101 804161 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 20150985P-9 340 #2 290212-CW 811582 804162 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 20150985P-11 425 #2 290213-CW 811583 804163 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 20150985P-13 510 #2 290214-CW 811584 804164 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 20150985P-15 595 #2 290215-CW 811585 804165 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 20150985P-17 680 1/0 290216-CW 811586 804166 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 20150985P-19 765 1/0 290217-CW 811587 804167 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 20150985P-21 850 2/0 290218-CW 811588 804168 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 20150985P-23 935 3/0 290219-CW 811589 804169 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 20150985P-25 1020 3/0 290220-CW 811590 804170 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 20150985P-27 1105 4/0 290221-CW 811591 804171 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 20150985P-29 1190 4/0 290222-CW 811592 804172 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 20150985P-31 1275 4/0 290223-CW 811593 804173 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 20150985P-33 1360 4/0 290224-CW 811594 804174 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509100P-5 200 #2 290300-CW 804100 804160 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509100P-7 300 #2 290301-CW 804101 804161 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509100P-9 400 #2 290302-CW 811582 804162 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509100P-11 500 #2 290303-CW 811583 804163 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509100P-13 600 #2 290304-CW 811584 804164 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509100P-15 700 1/0 290305-CW 811585 804165 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509100P-17 800 1/0 290306-CW 811586 804166 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509100P-19 900 2/0 290307-CW 811587 804167 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509100P-21 1000 3/0 290308-CW 811588 804168 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509100P-23 1100 4/0 290309-CW 811589 804169 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509100P-25 1200 4/0 290310-CW 811590 804170 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509100P-27 1300 4/0 290311-CW 811591 804171 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509100P-29 1400 4/0 290312-CW 811592 804172 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509100P-31 1500 4/0 290313-CW 811593 804173 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509100P-33 1600 4/0 290314-CW 811594 804174 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509125P-5 250 #2 290320-CW 804100 804160 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509125P-7 375 #2 290321-CW 804101 804161 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509125P-9 500 #2 290322-CW 811582 804162 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509125P-11 625 1/0 290323-CW 811583 804163 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509125P-13 750 1/0 290324-CW 811584 804164 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509125P-15 875 2/0 290325-CW 811585 804165 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509125P-17 1000 3/0 290326-CW 811586 804166 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509125P-19 1125 4/0 290327-CW 811587 804167 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509125P-21 1250 4/0 290328-CW 811588 804168 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509125P-23 1375 4/0 290329-CW 811589 804169 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509125P-25 1500 4/0 290330-CW 811590 804170 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509125P-27 1625 4/0 290331-CW 811591 804171 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509125P-29 1750 4/0 290332-CW 811592 804172 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509125P-31 1875 4/0 290333-CW 811593 804173 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509125P-33 2000 4/0 290334-CW 811594 804174 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509

INTERCELL CONNECTORS & INSULATORSSIDE TO SIDE END TO END

HUP SERIES

MOTIVE POWER CELL PARTS LISTINTERCELL CONNECTORS & INSULATORS

SIDE TO SIDE END TO END

HUP SERIESMOTIVE POWER CELL PARTS LIST

24

RENEGADE SERIESMOTIVE POWER CELL PARTS LIST

Cell 6 Hr. Ah Cable Cell Standard Over Partition Insulator Standard Over Partition Insulator75GS-5 150 #2 290830-CW 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 20150975GS-7 225 #2 290831-CW 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 20150975GS-9 300 #2 290832-CW 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 20150975GS-11 375 #2 290833-CW 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 20150975GS-13 450 #2 290834-CW 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 20150975GS-15 525 1/0 290835-CW 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 20150975GS-17 600 1/0 290836-CW 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 20150975GS-19 675 2/0 290837-CW 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 20150975GS-21 750 3/0 290838-CW 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 20150975GS-23 825 4/0 290839-CW 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 20150975GS-25 900 4/0 290840-CW 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 20150975GS-27 975 4/0 290841-CW 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 20150975GS-29 1050 4/0 290842-CW 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 20150975GS-31 1125 4/0 290843-CW 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 20150975GS-33 1200 4/0 290844-CW 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509110GS-5 220 #2 290810-CW 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509110GS-7 330 #2 290811-CW 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509110GS-9 440 #2 290812-CW 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509110GS-11 550 #2 290813-CW 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509110GS-13 660 #2 290814-CW 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509110GS-15 770 1/0 290815-CW 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509110GS-17 880 1/0 290816-CW 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509110GS-19 990 2/0 290817-CW 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509110GS-21 1100 3/0 290818-CW 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509110GS-23 1210 4/0 290819-CW 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509110GS-25 1320 4/0 290820-CW 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509110GS-27 1430 4/0 290821-CW 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509110GS-29 1540 4/0 290822-CW 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509110GS-31 1650 4/0 290823-CW 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509110GS-33 1760 4/0 290824-CW 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509

INTERCELL CONNECTORS & INSULATORSSIDE TO SIDE END TO END

25

Accumulator Another term for asecondary battery based on the factthat electric energy is accumulatedin the form of chemicals. This term,pertaining to a storage cell or battery, is employed today in countries outside USA.Acetic Acid (C2H4O2) An organicacid liberated by reaction betweenwood and dilute sulphuric acid. It isinjurious to positive plates in largequantity.Acid In the lead acid storage battery industry, “acid” implies “sulfuric acid”, and is used todescribe the electrolyte or liquid inthe cell.Active Materials The materials in abattery which react chemically toproduce electrical energy. In a lead-acid battery the active materialsare lead peroxide (positive) andsponge lead (negative).Activation Process for making adry charged cell functional by introducing electrolyte.Air Oxidized A charged negativeplate that has been removed fromthe electrolyte and permitted to discharge in an air atmosphere withthe evolution of heat. Plates so treat-ed must be recharged before theyare capable of producing any usefulelectrical energy.Alloy A combination of two or moremetals, as a mixture, solution, orcompound. See “ANTIMONIALLEAD ALLOY,” “CALCIUM LEADALLOY.”Ambient Temperature Ambienttemperature is the temperature ofthe surrounding cooling medium,such as gas or liquid, which comesinto contact with the heated parts ofthe apparatus, usually refers toroom or air temp.Alternating Current An electric,pulsating current, in which the direction of flow is rapidly changed,so that a terminal becomes in rapidsuccession positive then negative.Ammeter An ammeter is an instrument for measuring electricalcurrent. See also “AMPERE-HOURMETER.”Ampacity Current carrying capacityin amperes.

Ampere The practical unit of electric current that is equivalent tothe steady state current producedby one volt applied across aresistance of one ohm. It is onetenth of an abampere.Ampere-Hour A measure of thevolume of electricity, being oneampere for one hour, or 3600coulombs. It is used to express battery capacity, and is registeredby an ampere-hour meter, or isobtained by multiplying the currentin amperes by the length of time thatthe current is maintained.Ampere-Hour Capacity Theampere-hour capacity of a storagebattery is the number of ampere-hours which can be delivered underspecified conditions as to temperature, rate of discharge, andfinal voltage.Ampere-Hour Efficiency Theampere-hour efficiency of a storagebattery is the electrochemical efficiency expressed as the ratio ofthe ampere-hours output to theampere-hours input required for therecharge.Ampere-Hour Meter An ampere-hour meter is an instrument that registers the quantity of electricity inampere-hours.Anode An anode is an electrodethrough which current enters anyconductor of the nonmetallic class.Specifically, an electrolytic anode isan electrode at which negative ionsare discharged, or positive ions areformed or at which other oxidizingreactions occur.Antimonial Lead Alloy Lead-antimony alloy is the most commonalloy used in battery castings. Thepercentage of antimony varies from1/2 percent to 12 percent. Othersubstances are also included insmall quantities either by way of acertain amount of inescapableimpurity, or by design, to improvecastings or to improve the properties of the cast part.Antimony (Sb) A silver-white metalof the arsenic family with a high luster, hard and brittle.

Assembly 1. The process of combining the various parts of cellsand batteries into the finished prod-uct. 2. Any particular arrangement ofcells, connectors, and terminals toform a battery suited for a desiredapplication.Automotive Battery (SLI) Batteryof 3 or 6 cells used for starting, lighting, and ignition of automobiles,trucks, buses, etc.Average Voltage The average volt-age of a storage battery is the aver-age value of the voltage during theperiod of charge or discharge.Baffle (1) Partition in a cell. (2)Labyrinth arrangement for ventingcells, especially in maintenance-freebatteries.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 twoor more storage cells (commonusage permits this term to beapplied to a single cell used independently). Batteries are some-times referred to as “Accumulators”since electric energy is accumulatedby chemical reaction.Battery Additive A preparationsold to the public that allegedly reju-venates worn-out, sulfated, or so-called “dead” batteries.Bayonet Vent A term originallyapplied to a design of quarter turnvent plug, the lower portion of whichresembles a bayonet, both inappearance and locking arrangement.Boost Cells Cells with highercapacity than the test cells whichare used to help maintain constant discharge current in a manual discharge test.Boost Charge A partial chargegiven to a storage battery usually ata high rate for a short period. It isemployed in motive power service when the capacity of a battery is not sufficient for a full dayswork.Boot Plastic piece used at foot ofplate, especially a wrapped plate,for retention and insulation.

ACCUMULATOR / BOOT

26

Bottom Pour A term that describesa method of introducing moltenmetal into a bottom gated mold, themolten metal being withdrawn fromthe pot from a point below the surface of the melt.Bridge The ribs or elements supporting structure, molded, or cutto fit into the bottom of a ribless jaror container in order to provide sediment space under the elementthereby preventing short circuits.Burning The welding together oftwo or more lead or lead alloy partssuch as plates, straps, connector bymeans of heat and in some cases,additional metal supplied by a stickcalled a burning strip.Burning Center The center-to-cen-ter distance between adjacentplates of the same polarity.Burning Stick A lead or lead alloystick of convenient size used as asupply of joining metal in lead burning.Button The finished “buttonshaped” area produced on the topsurface of a connector or terminalby the post burning operation.Cadmium (Cd) A metallic elementhighly resistant to corrosion, usedas a protective plating on certainsteel parts and fittings.Cadmium Electrode A third electrode for separate measure-ments of the electrode potential ofpositive and negative plate groups.Calcium Lead Alloy A lead basealloy that in certain applications canbe used for battery parts in place ofantimonial lead alloys. Most common use is in stationary cells.Capacity See “AMPERE HOURCAPACITY.”Capacity Test A test wherein thebattery is discharged at constantcurrent at room temperature to acutoff voltage of usually 1.70volts/cell.Carbon Black Finely divided carbon obtained by burning agaseous hydrocarbon under controlled conditions and used asan ingredient in negative expanders.Carbon Burning Outfit A metallicrod and insulated handle, mountinga pointed carbon rod; used for leadburning on service locations where

the usual gas flame equipment isnot available.Carbon Puddling Rod A pencil likecarbon rod used in lead burning tobreak up any oxide film, dirt, ordross particles that may be presentin the molten metal.Carboy A large cylindrical container or bottle of plastic or glassused to ship acid.Car Lighting Battery An auxiliarystorage battery designed to supplythe lighting and air conditioningrequirements of railroad cars whilerunning at low speeds. An axle driven generator charges the battery and supplies the loadrequirements when the train operates at normal speeds.Cast To form a molten substanceinto a definite shape by pouring orforcing the liquid material into amold and allowing it to solidify(freeze).Casting A metallic item, such asone or more grids, straps or connectors produced by pouring orforcing molten metal into a mold andallowing it to solidify.Cast-On Strap A multiplate connector which has been cast ontothe plates directly in a combinationmold/burning jig; contrasts withburning of plates and prefabricatedstraps.Cathode A cathode is an electrode through which currentleaves any conductor of the nonmetallic class. Specifically, anelectrolytic cathode is an electrodeat which positive ions are discharged, or negative ions areformed, or at which other reducingreactions occur.Cell (Primary) A primary cell is acell designed to produce electriccurrent through an electrochemicalreaction which is not efficientlyreversible and hence the cell, whendischarged, cannot be efficientlyrecharged by an electric current.Cell (Storage) A storage (secondary) cell is an electrolyticcell for the generation of electricenergy in which the cell after beingdischarged may be restored to acharged condition by an electric

current flowing in a direction opposite to the flow of current whenthe cell discharges.CEMF Counter ElectromotiveForce.Charged The condition of a storage cell when at its maximumability to deliver current. The positive plate contains a maximumof lead peroxide and a minimum ofsulfate, while the negative platescontain a maximum of sponge leadand a minimum of sulfate, and theelectrolyte will be at maximum specific gravity.Charged and Dry A battery assembled with dry, charged plates,and no electrolyte.Charged and Wet A fully chargedbattery containing electrolyte andready to deliver current.Charging The process of converting electrical energy tostored chemical energy. In thelead-acid system, charging convertsLead Sulfate (PbSO4) in the platesto Lead Peroxide (PbO2) (positive)or Lead (Pb) (negative plate).Charging Plug The male half of aquick connector which contains boththe positive and negative leads.Charging Rate The charging rateof a storage battery is the currentexpressed in amperes at which thebattery is charged.Charging Receptacle The femalehalf of a quick connector housingboth positive and negative leads.Circuit A system of electrical components through which an electric current is intended to flow.The continuous path of an electriccurrent.Cold Crank Test SLI battery testwherein a high rate discharge, up to300 amperes, is applied to a battery at 0˚F, and the 30 secondcell voltage must be above 1.2volts/cell.Communication Battery See“TELEPHONE BATTERY.”

BOTTOM POUR / COMMUNICATION BATTERY

27

Compound An asphaltic, pitchlikematerial used as a cover-to-jar battery sealant.Constant-Current Charge A constant-current charge of a storage battery is a charge in whichthe current is maintained at a constant value. (For some types oflead-acid batteries this may involvetwo 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 whichthe voltage at the terminals of thebattery is held at a constant value.Container Housing for one or morecells, commonly called a “JAR.”Control Battery A float service battery designed for switchgear andcircuit breaker operation in electricgenerating or distributing stations.Counter EMF Cells (CEMF CELL)Counter electromotive force cells,frequently called “counter-cells,” arecells of practically zero ampere-hourcapacity used to oppose the linevoltage. Unlike non-electrolyticresistors, which absorb voltage inproportion to the current flowing inthe circuit, CEMF cells maintain anearly constant voltage regardlessof the current.Cover The lid or cover of anenclosed cell generally made of thesame material as the jar or container and through which extend the posts and the vent plug.Cover Inserts Lead or lead alloyrings which are molded or sealedinto the cell cover, and to which areburned the element posts therebycreating an effective acid-creepresistant seal.Creepage Creepage is the travel ofelectrolyte up the surface of electrodes or other parts of the cellabove the level of the main body ofelectrolyte.Curing Chemical conversionprocess which changes lead oxidesand sulfuric acid to mixtures of tetra-basic lead sulfate, other basic leadsulfates, basic lead carbonates,etc., which consequently will form

desired structures of Pb or PbO2 on negative or positive plates duringformation.Current The time rate of flow ofelectricity, normally expressed asamperes, like the flow of a stream ofwater.Cut-Off Voltage See “FINAL VOLT-AGE.”Cutting (of acid) The dilution of amore concentrated solution of sulfuric acid to a lower concentration.Cycle A discharge and its subsequent recharge.Cycle Service A type of batteryoperation in which a battery is continuously subjected to successive cycles of charge anddischarge, e.g., motive power service.Deep Discharge Removal of up to80% of the rated capacity of a cell orbattery.Dead Top A system of encapsulating intercell connectorswith compounds, such as epoxy, orpolyurethane, to prevent accidentalintercell shorts from externalsources.Dielectric Test An electric test performed on certain jars, containers, and other insulatingmaterials to determine their dielectric breakdown strength.Diesel Starting Battery Batteriesused to crank diesel engines. Thisfunction is similar to gasolineengine’s applications, except thatgreater demands are made forcranking power, and ignition isaccomplished by the engine’s heat,without any further need for electriccurrent.Diffusion The intermingling or distribution of the particles or molecules of a liquid.Direct Current (DC) A direct current is a unidirectional current inwhich the changes in value areeither zero or so small that they maybe neglected.Discharge Discharge of a storagebattery is the conversion of thechemical energy of the battery intoelectrical energy.

Discharged The condition of astorage cell when as the result ofdelivering current, the plates aresulfated. The electrolyte is exhausted, and there is little or no potential difference between the terminals.Discharge Rate Batteries discharged to meet any time ratebetween 3 hours and 8 hours areconsidered as having been normallydischarged.Dope Battery treatment compound, usually consisting of sulfuric acid and/or metallic sulfate.Dross The layer of various oxidesand impurities which forms on thesurface of molten metal.Dry Charged A negative platewhich has been subjected to the drycharging process.Dry Charging Manufacturingprocess whereby tank-formed negatives (or elements) are washedfree of acid and then dried. Specificmethods include use of vacuum,superheated steam, combustiongases, hot kerosene, etc.Efficiency The efficiency of a storage battery is the ratio of the output of the cell or battery to theinput required to restore the initialstate of charge under specified conditions of temperature, currentrate and final voltage.Electrode A conductor throughwhich a current passes in or out of acell, apparatus or body.Electrode (Electrolyte) PotentialAn electrode potential is the difference in potential between theelectrode and the immediately adjacent electrolyte, expressed interms of some standard electrodepotential difference.Electrolysis Electrochemical reaction which causes the decomposition of a compound,either liquid, molten or in solution.Electrolyte Any substance whichdisassociates into two or more ionswhen dissolved in water. Solution ofelectrolyte conducts electricity andis decomposed by it. In the batteryindustry the word “electrolyte”implies a dilute solution of sulfuricacid.

COMPOUND / ELECTROLYTE

28

Electromotive Force (EMF)Electrical pressure or potential,expressed in terms of volts.Element Assembly of a positiveplate group, a negative plate group,and separators.Emergency Lighting ServiceFloat service batteries used inplaces of public assembly, hospitaloperating rooms, bank vaults, etc.which supply light in the event ofpower failures.End Cells End cells are cells of astorage battery which may be cut inor cut out of the circuit for the purpose of adjusting the batteryvoltage.End Gravity The specific gravity ofa cell at the end of a prescribed(usually a 6 to 8 hour) discharge.End to End (E to E) Referring tomethod of assembling cells in relation to one another.Energy Density Ratio of batteryenergy content in watt hours to battery weight or volume.Envelope See “PERFORATEDRETAINER.”Equalizing Charge An equalizingcharge of a storage battery is anextended charge which is given to astorage battery to insure the complete restoration of active materials in all the plates of all thecells.Expander An addition agent eitherorganic or inorganic or a mixture ofboth to be blended with the otheringredients for negative paste. Thepurpose of expanders is to delayshrinking and solidifying of thesponge lead of the finished plate,thereby enhancing negative platecapacity.Ferroresonant Charger A constant voltage power supply containing a special transformer-capacitor combination, whichchanges operating characteristicsas current draw is varied, so that theoutput voltage remains constant.Filling Gravity The specific gravityof acid used in the filling of batteries.Final Voltage The cut-off voltage ofa battery; the prescribed voltagereached when the discharge is considered complete.

Finishing Rate The finishing ratefor a storage battery is the rate ofcharge expressed in amperes towhich the charging current for sometypes of lead batteries is reduced near the end of charge to preventexcessive gassing and temperaturerise.Fixed Resistance Discharge Adischarge in which the cell or battery is discharged through a fixedresistive load. The current beingallowed to fall off as the terminalvoltage decreases.Flaming A method used to improvethe surface of a cast lead or leadalloy part or of trimmed battery sealing compound in which a flameis passed over the surface causingthe material to melt and flowsmoothly together.Flat Plate A general term referringto pasted plates.Float Charging Application of arecharge at a very low rate andaccomplished by connection to abuss with a voltage slightly higherthan the open circuit voltage of thebattery.Flush To add water to a cell.Flying Leads Any fixed terminalcable in which the terminal or plugend of the cable is unsupported andallowed to hang freely along theside 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 Aninitial charging process during whichthe raw paste within the plates iselectrochemically converted intocharged active material, lead peroxide being formed in the positive plates and sponge lead inthe negative plates.Formed Plates that have undergone formation are known by this term.Freshening Charge A chargegiven batteries in storage to replacethe standing loss and to ensure thatevery plate in every cell is periodi-cally brought to a full state of chargewhich gives form and strength to thegrid and serves to conduct currentto the lug.

Full Charge Gravity The specificgravity of the electrolyte with the cells fully charged and properly leveled.Gang Vent Vents for usually threeadjacent cells which are connectedto a common manifold. Typicallyused on SLI’s.Gassing Gassing is the evolution ofgases from one or more of the electrodes during electrolysis.Gelled Electrolyte Electrolytewhich has been immobilized byaddition of silica powder or othergelling agent.Glass Mat Fabric made from glassfibers with a polymeric binder, suchas styrene, acrylic, furfural,starch, used to help retain positiveactive material.Gravity Refers to specific gravity.Gravity Drop The number of pointsreduction or drop of the specific gravity of the electrolyteupon discharge of the cell.Grid A grid is a metallic frameworkemployed in a storage cell or batteryfor conducting the electric currentand supporting the active material.Group One or more plates of a type(positive or negative) which areburned to a post and strap.Hand Stand Manually operatedcasting mold into which lead or alloyis manually poured.High Impact Rubber See “RESIN RUBBER.”High Rate On charge, any ratehigher than the normal finishing rate.H2SO4 Chemical symbol forSulfuric Acid.H.U.P. High Utilization Positive.Patented process which optimizesboth the active material utilizationand the longevity of the positivepaste.Hydration (Lead) Reaction betweenwater and lead or lead compounds.Lead does not react with strong solu-tions of sulfuric acid, but gravitieslower than those found in dischargedcells are apt to produce hydration.Hydration is observed as a whitecoating on both plate groups andseparators in a cell.

ELECTROMOTIVE FORCE (EMF) / HYDRATION (LEAD)

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Hydrometer Device used to indicate density or specific gravity ofelectrolyte solutions.Hydroset Curing process for negative and positive plates, wherein free lead in the paste is oxidized and total free lead isreduced to a few percent.Indicator Device employed to showa battery’s state of charge, or itswater level.Initial Voltage The initial voltage ofa battery is the closed-circuit volt-age at the beginning of a discharge. It is usually measuredafter the current has flowed for asufficient period for the rate ofchange of voltage to become practically constant.Insert A bushing of lead or leadalloy molded or sealed into cell covers forming the post hole towhich the post is burned to create acreep-resistant cover-to-post seal.Intercell Connector Conductor oflead, lead alloy, or lead plated copper which is used to connect twobattery cells.Internal Resistance The internalresistance of a cell or battery is theresistance within the cell or batteryto the flow of an electric current, andis measured by the ratio of thechange in voltage at the terminals ofthe cell or battery corresponding toa specific change in current for shorttime intervals.Jackstraw Mats See “GLASSMATS.”Jar Cell container made by injection molding, roto-molding orthermo-forming.Jar Formation The forming ofplates in the cell jar or container,after they have been assembled.Jumper A short length of conductor used to connect or cut outpart of an electrical circuit.Kilovolt (KV) One thousand volts.Kilowatt (KW) One thousand watts.Kilowatt-hours (KWH) A measureof energy or work accomplishedequal to 1000 watt-hours.Lamp Black Finely powered carbon used as an ingredient innegative plate expander.

Lead (Pb) Chemical element usedin lead-acid batteries (with sulfuricacid and other materials).Lead Burning Welding of lead orlead alloy parts.Lead Hydrate A white compoundof lead of indefinite compositionformed by the reaction of very diluteelectrolyte or water on metallic leador lead alloys.Lead Oxide A general term used todescribe any of the finely dividedlead oxides used to produce pastefor storage batteries.Lead Peroxide A brown oxide oflead which is the active material in afully formed positive plate. Its formula is PbO2.Lead Plated Part A metallic partthat has had a thin protective layerof metallic lead electrodeposited onits surface.Lead Sponge (Pb) The chief component of the active material ofa fully charged negative plate.Lead Sulfate (PbS04) A compound resulting from the chemical action of sulfuric acid onoxides of lead or lead metal itself.Level Indicator A float mounted ina float tube or similar indication ofthe electrolyte level.Level Lines Horizontal lines molded and/or painted near tops ofbattery jars which indicate minimum and maximum electrolytelevel.Life Number of years of satisfactory float operation or number charge-discharge cycles formotive power operation.Lifting Ear An extension on theside walls of a battery tray providedwith a hole or slot with which thebattery can be lifted.Lignin Generic name for non-cellulosic wood fraction which, aslignin sulfonic acid or desulfonatedLSA, acts as an organic expanderfor lead-acid batteries.Litharge (PbO) A yellowish-redoxide of lead (monoxide), sometimes used in making activematerial.

Local Action The loss of otherwise usable chemical energyby currents which flow within the cellof a battery regardless of its connections to an external circuit.Loss of Charge The capacity lossoccurring in a cell or battery standing on open circuit as a resultof local action.Lug Portion of grid used for support of the plate group, usually along top edge of grid, as “hanginglug.” Also, tab on grid used for connection of plate to strap andother plates.Machine Casting A fully or semi-automatic grid or small partscasting operation.Maintenance-FreeBattery Batterywhich requires no addition of water,no boost charges, etc. This typicallyrequires a non-antimonial or low-antimonial grid alloy, sealed celldesign, or low-loss venting.Manual Discharge Capacity testwherein the connection and disconnection of the battery and thetest load are done by the operator and the disconnection ismade after all cells have reachedthe prescribed final voltage. Withfixed resistance loads, boost cellsare used to keep the discharge ratefairly constant as the test cell voltages drop rapidly near the finalvoltage. Electronic load manual discharges generally do not requireboost cells.Marine Battery A battery designedfor shipboard installation to provideenergy for cranking service and theoperation of emergency lighting,alarm, and communication equipment.Microporous Separator Either aveneer-or a grooved-type separatormade of any material in which thepores are numerous and micro-scopic.Mine Locomotive Battery A cycleservice battery designed to operatemine locomotive, trammer, shuttlecars, and tunnel haulage equip-ment.Millivolt (MV) One thousandth partof a volt.

HYDROMETER / MILLIVOLT

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Modified Constant-VoltageCharge A modified constant-voltage charge of a storage batteryis a charge in which the voltage ofcharging circuit is held substantiallyconstant, but a fixed resistance isinserted in the battery circuit producing a rising voltage charac-teristic at the battery terminals asthe charge progresses.Mold A cast iron or steel formwhich contains the cavity into whichmolten metal is introduced to produce a casting of definite shapeand outline.Mold Coat A preparation applied tometal molds in spray form whichacts both as a mold release agentand as an insulator against rapidheat transfer.Mold Spray See “MOLD COAT”.Moss Dendritic crystals of lead(Pb) which sometimes grow at high-current density areas of negative plates, e.g. along edges, atfeet, or at plate lugs. May cause ashort circuit within cell.Moss Shield Plastic or hard rubber perforate sheet which insulates the gaps between negative plates and the positivestrap, and between positive platesand the negative strap.Motive Power Battery A cycleservice battery designed to supplythe energy necessary to propel andoperate electrically powered industrial trucks, street vehicles, andmine locomotives.Negative Plate The negative plateof a storage battery consists of thegrid and active material to whichcurrent flows from the external circuit when the battery is discharging.Negative Terminal The negativeterminal of a battery is the terminaltoward which current flows (as ordinarily conceived) in the externalcircuit from the positive terminal.OHM A unit of electrical resistance.Oil of Vitriol Concentrated commercial sulfuric acid commonlyreferred to as OV.One Shot Formation Jar formation under conditions whereend of formation specific gravity is equal to the operating specific gravity.

Open-Circuit The state of a battery when it is not connected toeither a charging source or to a loadcircuit.Open Circuit Voltage The open-circuit voltage if a battery is the voltage at its terminals when noappreciable current is flowing.Organic Expander An expanderformulation which typically containsbarium sulfate and a lignin typeorganic compound with smallamounts of other materials.O.V. See Oil of VitriolOxide (of lead) A compound oflead and oxygen in one of severalproportions such as gray oxide,litharge, red lead, or lead peroxideused to prepare battery paste.Panel Casting consisting of two ormore grids which have been madesimultaneously in a single mold.Parallel Assembly The arrangement of cells within a battery in which two or more cellsare connected across a commonterminal so that any current flowdivides itself between the connected cells.Parallel Connection See “PARALLEL ASSEMBLY.”Partition An interior dividing wall ina tray or container.Paste Mixture of lead oxide withwater, sulfuric acid, and sometimesother ingredients.Paste Consistency A term used toinclude all of the physical characteristics of the paste density,plasticity and texture.Pasting Battery assembly operation wherein paste is appliedto grids by hand or by a machine.Pb Chemical symbol for lead.PbO Chemical symbol for litharge.PbO2 Chemical symbol for leadperoxide (dioxide).Pellet That portion of pasted material contained in a grid sectionframed by adjacent horizontal andvertical members exclusive of forming bars.Perforated Retainer A thin sheetof perforated plastic materialinstalled to cover each face of a pos-itive plate to prevent the loss ofactive material. It is normally used inconjunction 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 refinedunalloyed lead.Pilot Cell A pilot cell is a selectedcell of a storage battery whose temperature, voltage, and specificgravity are assumed to indicate thecondition of the entire battery.Plante Plates Plates, usually positives, made by machining orcasting multiple slots in a thick Pbsheet, and consequent formation ofactive material from the thin webs ofPb or Pb alloy remaining.Plate A pasted grid, either formedor unformed.Plate Centers The distancebetween center lines of adjoiningplates of opposite polarity in a cell.The plate center is, therefore, one-half of the size of a strap centerupon which the plates of a like polar-ity are burned.Polarity The polarity of a battery isan electrical condition determiningthe direction in which current tendsto flow. By common usage the discharge current is said to flowfrom the positive electrode throughthe external circuit.Polarization Polarization in a battery is the change in voltage atthe terminals of the cell or batterywhen a specified current is flowingand is equal to the differencebetween the actual and the equilibrium (constant open circuitcondition) potentials of the platesexclusive of the IR drop.Porosity The ratio of interstices(voids) in a material to the volume ofits mass.Positive Plates The positive plateof a storage battery consists of thegrid and the active material fromwhich current flows to the externalcircuit when the battery is discharging.Positive Terminal The positive terminal of a battery is the terminalfrom which current flows (as ordinarily conceived) through theexternal circuit to the negative terminal when the cell discharges.

MODIFIED CONSTANT-VOLTAGE CHARGE / POSITIVE TERMINAL

31

Post Terminal or other conductorwhich connects the plate groupstrap to the outside of the cell.Post Builder A ring shaped moldused to repair damaged batteryposts.Potential See “VOLTAGE.”Primary Cell See “CELLPRIMARY.”Puddling The process in which twoor more lead or lead alloy parts arewelded together within the confines of a suitably shaped dam. Itis usually necessary to add extrametal from a burning strip in order tocompletely fill the dammed area.Pure Lead See “PIG LEAD.”Rated Capacity The ampere-hours of discharge that can beremoved from a fully charged secondary cell or battery at a specific constant discharge rate at aspecified discharge temperatureand at a specified cut-off voltage.Rate of Charge See “STARTINGRATE,” “FINISHING RATE.”Raw Plate An unformed plate.Rectifier A rectifier is a devicewhich 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 oflead used in making active material.Resin Rubber A rubber compound that has been modifiedby the addition of plastic resin toimprove its impact strength.Reference Electrode Electrodeused to measure acid concentrationor plate state of charge. Typicalexamples: cadmium electrode,Hg/HgSO4 electrode, Hydrogenelectrode, Pb electrode, PbO2electrode.Resistance The opposition that aconductor offers to the passage ofan electrical current, usuallyexpressed in ohms.Resistor A device used to introduce resistance into an electrical circuit.

Retainer A sheet of glass mat, per-forated or slotted rubber, plastic, orsome other satisfactory materialinstalled on each face of the positive plates in certain types ofcells to deter the loss of active material.Reversal Reversal of a storage bat-tery is a change in normal polarity of the cell or battery.Rib A vertical or nearly verticalridge of a grooved separator orspacer.Rib Block Bridge used in somesmooth bottom jars to evenly support the element.Rib to Top A reference to theheight dimension from the top of thesupporting rib to the top edge of thejar or container.Run Down A small portion of metalthat has dropped onto a plate, groupor element in the course of burning.It may result in a short circuit.Sealing Manufacturing operationfor attaching covers to jars bycement, sealing compound, or thermal fusion.Sealing Compound An asphaltmixture of several types differing inheat resistance, adhesion, andresistance to shearing. It is used forsealing cell covers to the jars or containers. See “COMPOUND.”Seal Nut A round notched alloy nutthreaded onto certain types of strapposts for fastening and sealing the element and covertogether.Secondary Lead Reclaimed leadas opposed to virgin lead.Sediment The leady sludge oractive material shed from the platesand found in the bottom of cells.Sediment Space The portion of ajar or container compartmentbeneath the element provided to accommodate a certain amount ofsediment from the wearing of theplates without short circuiting.Self-Discharge Loss of charge dueto local action.Separator A separator is a deviceemployed in storage battery for preventing metallic contact betweenthe 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 batteryother than pilot cells. The termbecame common since the cells areusually connected in “series.” Thename would still apply to distinguish the difference betweencells even if the cells are connectedin “multiple.”Series Parallel Connection Thearrangement of cells within a battery in which two or more stringsof series connected cells eachcontaining the same number of cellsare connected in parallel in order toincrease the capacity of the battery.Service Life See “LIFE.”Shedding Loss of active materialfrom the plates.Short Circuit Current The currentwhich flows when the two terminalsof a cell or battery are inadvertentlyconnected to each other.Side Terminal SLI battery designwith two through-the-container current connectors on one side ofthe case instead of two posts on top.SLI Battery Battery for automotiveuse in starting, lighting, and ignition.Sliver, Slyver Extremely fine, parallel glass fibers used next topositive plate in retainers to retardshedding.Smelting The process by which themajor portion of lead and antimonyare recovered from spent batteries.Soaking A process whereby certain types of plates are soaked insulfuric acid after pasting. Soakingprovides a protective surface, andalso a supply of sulfate helpful in jarformation and tank formation.Soda Ash Sodium Carbonate(Na2CO3), used to neutralize effluents containing sulfuric acid oracid spills.Spalling Shedding of active material, usually from positives, during formation due to incompleteor improper plate curing.Spine Cast Pb alloy conductor fortubular positive plate.

POST / SPINE

32

Sponge Lead (Pb) The chief material of a fully charged negativeplate. It is a porous mass of leadcrystals.Stacking Cell assembly operationwherein plates and separators arealternately piled in a burning boxprior to cast-on or burning-on ofstraps and posts.Stacking Fixture or Stacking JigThe fixture or device used to stackand burn elements.Standing Loss The loss of chargeby an idle cell or battery resultingfrom local action.Starting Rate The number ofamperes at which the charging of astorage battery may begin withoutproducing gassing or bubbling of theelectrolyte or a cell temperature inexcess of 110˚F (43˚C).State of Charge The amount ofelectrochemical energy left in a cellor battery.Stationary Battery A stationarybattery is a storage batterydesigned for service in a permanentposition.Strap Precast or cast-on piece oflead or lead alloy used to connectplates into groups and to connectthe groups to the post.Strap center Spacing betweencenters of adjacent plates in agroup.Stratification As applied to electrolyte it is layers of high-gravityacid in the lower portions of a cell,where they are out of touch with theordinary circulation of the electrolyte and thus of no use.Submarine Battery Battery usually used for main underwaterpropulsion of conventional sub-marines and for reactor control onnuclear submarines. Batteries usually operated in trickle dischargemode.Sulfated A term used to describeany plate or cell whose active materials contain an appreciableamount of lead sulfate.Sulfation The formation of lead sulfate on a plate or cell as a resultof discharge, self discharge, or pickling.Sulfuric Acid (H2SO4) The principal acid compound of sulfur.

Sulfuric acid of a high purity and indilute form is the electrolyte of lead-acid storage cells.Switchgear Battery See “CONTROL BATTERY.”Tack Burn A shallow burn used totack together two lead parts.Tank Formation The electrolyticprocessing of plates in large tanksof acid at a point of manufactureprior to assembly. See also “FORMATION”Telephone Batteries Storage batteries of a wide range of capacities and types which are usedin most of the operations involved intelephone communication. Oftenthey are floated across generatorsor rectifiers, and serve for voltage stabilization, noise reduction, andemergency power.Temperature Correction In storage cells, the specific gravityand charging voltage vary inverselywith temperature, while the open circuit voltage varies directly(though slightly) with temperature.Terminals The terminals of a battery are the points at which theexternal circuit is connected.Terminal Cable A length of insulated cable, one of which is connected to the terminal post of abattery, the other end being fittedwith a suitable device (plug, receptacle, lug, etc.) for connectionto an external circuit.Tinning The process of coating ametal surface with a thin layer ofmolten tin or tin alloy.Top Pour A term that describes amethod of casting in which themolten metal is poured, usually byhand, into a top gated mold.Tray Steel enclosure for motivepower battery cells.Treeing Growth of a lead dendriteor filament through a hole, crack, orlarge pore of a separator, wherebythe cell is short-circuited.Trickle Charge A trickle charge ofa storage battery is a continuouscharge at a low rate approximatelyequal to the internal losses and suit-able to maintain the battery in a fullycharged condition.Tubular Plate Positive battery platemade from a cast spine and porous

tubes which are filled with paste ordry oxide.TVR A temperature compensatingvoltage relay used in charging equipment.Two-Rate Charging An automatically controlled constantcurrent or modified constant potential charging procedure. Thecharge is begun at a fairly high rateand is automatically reduced to alower rate when the counter voltagerises to a predetermined level.Unactivated Storage Life Theperiod of time before a dry chargedcell deteriorates to have less than aspecified capacity.Uncharged The condition of a battery assembled with formedplates but not yet having received itsinitial charge, is classified eitheruncharged and moist, or unchargedand dry.Uncharged and Dry A condition inwhich a battery or cell may beshipped to a customer. This indicates that the battery is assembled with formed plates anddry separators without electrolyte.Filling and a charge are required.Uncharged and Moist A conditionin which a battery or cell may beshipped to a customer. Adopted byBattery Council International andindicates that the battery is assembled with formed plates andmoist or wet wood separators with-out electrolyte. Filling and a longcharge are required.Unformed A term used to describeany plate which has not been electrolytically formed. It may be dryor moist, cured or uncured, soakedor unsoaked.Useful Acid The volume of acidabove the lower edges of the plateswhich takes part in the dischargereactions that occur within the cell.Vacuum Cast A machine castingtechnique in which a vacuum isapplied to the top gate of a bottom-pour mold to increase venting.Vacuum Cell Filler A device used to fill cells in thecharging room in which a vacuum isused to withdraw the air displacedby the filling electrolyte.

SPONGE LEAD / VACUUM CELL FILLER

33

charging room in which a vacuum isused to withdraw the air displaced by the filling electrolyte.Vent An opening provided to permit the escape of gas from a cellor mold.Vent Assembly A cell ventingdevice consisting of a ceramic ventstone and filler funnel assembledon a threaded or a quarter-turn bayonet base.Vent Baffle A thin disc located in avent cap or plug to deflect sprayback into the cell.Vent Cap SEE “VENT PLUG.”Vent Plug The piece or assembly ofpieces employed to seal the ventand filling well of a cell cover exceptfor a small hole in the plug itselfwhich permits the escape of gas.Vent plugs are usually held in placeeither by threads or by a quarter-turn catch (bayonet vent plug), or bya snap-in fit.Vent Well The hole or holes in acell cover through which gasescapes, fluids are added or theelectrolyte level is checked.The ventplug or vent assembly fits into thevent well.Verticals The vertical bars of members or members in a pastedplate grid.

Volt The practical unit of measurement of electromotive forceor potential difference required tosend a current of one amperethrough a resistance of one ohm.Volt Efficiency The ratio of theaverage voltage of cell or batteryduring discharge to the averagevoltage during its subsequentrecharge.Voltage The difference of potentialwhich exists between the terminalsof a cell or battery, or any two pointsof an electrical circuit.Voltage Range The differencebetween the maximum and minimum cell voltages that existwithin a battery or string of cellswhen all of the cells are charging ordischarging.Voltmeter An instrument for measuring voltage.Watering Adding water to batteryelectrolyte to replace electrolysisand evaporative losses.Watt A measure of electric power.The product of amperes and volts.Watt-hour A measure of energy orwork accomplished equal to theproduct of the rate of work in wattsand the time in hours, or the product of ampere-hours and theaverage voltage.

Watt-hour Capacity The watt-hourcapacity of a storage battery is thenumber of watt-hours which can bedelivered under specific conditionsas to temperature, rate of dischargeand final voltage.Watt-hour Efficiency The watt-hour efficiency of a storage batteryis the energy efficiency expressedas the ratio of the watt-hour outputto the watt-hours of the recharge.Watt-hour Meter A watt-hour meteris an electric motor that measuresand registers electrical energy inwatt-hours (or kilowatt-hours).Wet Shelf Life The period of time awet secondary cell can be storedbefore its capacity has fallen to thepoint that the cell cannot be easilyrecharged.Wrapping Assembly operationwherein motive power positiveplates are covered by silver, glassmat, and retainer.

VENT / WRAPPING

34

NOTES

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NOTES