MOTIVE POWER BATTERY
SERVICE MANUAL
THEORY
CONSTRUCTION
MAINTENANCE
SERVICE
PRECAUTIONS
TM™
INTRODUCTION
With today’s expanding industrial world, storage batteries and associated
equipment must fill a vital power requirement. Storage batteries are the most
dependable and economical source of power to satisfy power requirements.
This manual contains information concerning the theory, construction,
maintenance, service repair, and hazards of lead-acid storage batteries used
in motive power requirements.
TABLE OF CONTENTS
SECTION I - THEORY AND CONSTRUCTION OF LEAD-ACID STORAGE BATTERIES
1-1 Fully Charged Cell . . . 1
1-2 Charging the Cell . . . 1
1-3 Battery Ratings . . . 2
1-4 Battery Construction . . . 3
SECTION II - RECEIVING AND INSTALLATION
2-1 Receiving Battery
. . . 6
2-2 Placing A Wet Battery In Service . . . 6
2-3 Placing A Dry Battery In Service . . . 6
2-4 A Battery Is Fully Charged When . . . 7
2-5 Operation Of The Battery . . . 7
SECTION III - ROUTINE MAINTENANCE
3-1 Adding Water . . . 8
3-2 Charging. . . 8
3-3 Cleaning . . . 8
3-4 Storing Batteries . . . 8
3-5 Battery Records . . . 9
SECTION IV - TROUBLE SHOOTING
4-1 Interpretation Of Cell Voltage Readings . . . 13
4-2 Acid Replacement And Adjustment Of Specific Gravity . . . 13
4-3 Test Discharge . . . 15
4-4 Calculate Discharge Rate . . . 15
4-5 Cadmium Electrode Testing . . . 15
4-6 Internal Inspection . . . 16
4-7 On-Site Battery Inspections. . . 17
4-8 Causes Of Sulfated Batteries . . . 17
SECTION V - HEALTH AND SAFETY
5-1 Battery Hazards
. . . 19
5-2 Safety Procedures . . . 19
MOTIVE POWER CELL PARTS LIST
. . . 22
1
SECTION I
THEORY AND CONSTRUCTION
OF LEAD-ACID STORAGE BATTERIES
Charged Cell Fig. 1-2 Electrolyte (Sulfuric acid and water) Maximum sulfuric acid Negative Plate Sponge Lead Positive Plate Lead Peroxide Decreasing Sulfuric Acid Increasing Water Decreasing Sponge Lead Increasing Lead Sulfate Decreasing Lead Peroxide Increasing Lead Sulfate Discharging Cell Fig. 1-1
1-1 FULLY CHARGED CELL
Storage batteries do not store electrical energy, but convert electrical energy into chemical energy which is slowly accumulated as the charge progresses. A battery in use is said to be on discharge. During discharge, the chemical energy stored in the battery is converted into usable electrical energy.
A lead-acid storage battery consists of cells with positive and negative electrodes called plates, which are physically separated from each other and immersed in an electrolyte of sulfuric acid solution. The active materials of the electrodes are lead peroxide (PbO2) for the positive plates, and sponge lead (Pb) for the negatives as shown in Fig. 1-1.
In a fully charged cell, the electrolyte may have a specific gravity that varies from 1.240 to 1.330, depending on application. When fully charged, each cell has a volt-age of approximately two volts on open circuit. However, a cell may have a voltage from 2.12 to 2.70 volts while being charged.
A cell develops a voltage potential when two dissimilar metals are immersed in a suitable electrolyte. The two metals used in lead-acid cells result in a voltage potential of two volts per cell and their potential ability to deliver this voltage under varying load and varying periods of time.
During cell discharge, lead peroxide and sponge lead combine with sulfuric acid to form lead sulfate (PbSO4) on both plates as shown in Fig. 1-2. This reaction decreases cell voltage as the two plates approach being of the same chemical composition
(lead sulfate). As the sulfuric acid is removed from the electrolyte solution, the specific gravity of the electrolyte decreases and approaches the specific gravity of water (1.000). This condition is shown in Fig. 1-3. Specific gravity is the weight of electrolyte as compared to an equal amount of water.
1-2 CHARGING THE CELL
The reaction that occurs in discharging the cell can be reversed, and it can be restored to its former charged condition by sending direct current through it in an opposite direction to the current flow on discharge as shown in Fig. 1-4. The active materials are restored to their respective conditions, and the electrolyte again becomes a more concentrated sulfuric acid solution. Cell voltage rises as the two plates become increasingly different in composition and the specific gravity of the 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 regularly exceed 80% of the battery’s rated capacity in ampere-hours. It should be charged after each shift of use or whenever the specific gravity of the electrolyte falls below 1.230. It is very important that proper ventilation be provided during charging to make certain that (1) the hydrogen gas, given off toward the end of the charging process is dissipated, and (2) that individual cell electrolyte temperatures during normal operations do not exceed 115˚F/46˚C.
2
1-3 BATTERY RATINGS
A single lead-acid cell does not have sufficient power to handle most requirements. However, connecting a number of cells together in series results in a battery capable of supplying higher power demands.
BATTERY VOLTAGE. The number of cells is
determined by the required nominal operating voltage of the equipment. Since each cell has a nominal voltage of two volts, a 24 volt industrial truck will require a 12 cell battery (12 cells x 2 volts/cell = 24 volts). AMPERE HOUR (AH). The electrical capability of a storage battery is usually expressed in ampere-hours. The hour capacity is the number of ampere-hours which can be delivered under specified conditions of temperature, rate of discharge and final voltage. Basically, ampere-hours are determined by multiplying the number of amperes which the battery will deliver by the number of hours during which the current is flowing. Example: 160 amperes x 6 hours =960 ampere-hours (six-hour rate). Total cell or battery capacity is then determined by the size and number of plates which make up the element. Due to the variety of job requirements, batteries are produced with many different sizes of cells.
KILOWATT HOURS (KWH). Battery capacity is also expressed in kilowatt hours (KWH), which is the product of amperes x time x average volts per cell. Example: 160 amps x 6 hours x 1.932 average volts per cell = 1,855 watt hours ÷ 1000 = 1.85 KWH. For a 12 cell battery, the capacity would be 1.85 x 12 = 22.20 KWH. The kilowatt hour rating can be varied by increasing or
decreasing the size of cells or the number of cells in the battery.
POSITIVE PLATE CAPACITY. Positive plate capacity is the ampere delivery for a fixed period of time (usually six hours) for a particular size positive plate. A 160G type positive plate has the capability of delivering 26.7 amperes for six hours or 160 amperes hours (26.7x6=160 AH) to a final voltage of 1.70. This ampere hour rating or capacity can be varied by increasing or decreasing the number of positive plates in the cell. In the previous examples, the battery is a 12 cell, 160G-13 plate unit. To determine the number of positive plates in each cell, subtract one from the total number of plates in the cell and divide by two.
EXAMPLE: 13 - 1 = 12 ÷ 2 = 6 positive plates per cell; 6 positive plates x 160 ampere-hours each = 960 AH. The use of a different type of positive plate, such as a General Battery 75GL or 160G will respectively decrease or increase the ampere hour capacity.
The above ratings are based on a temperature of 77˚F with a fully charged specific gravity acid (see battery nameplate).
SPECIFIC GRAVITY. The term which describes the ratio of the density of electrolyte to the density of water. Electrolyte weighing 1.2 times as much as the same volume of water has a specific gravity of 1.200. The full charge gravity of a cell is a matter of design and depends on several factors. The specific gravity must be high enough to contain the amount of sulfuric acid necessary to meet the chemical needs of a cell. If the sulfuric acid content is too high, damage may result to the cell. The standard full charge gravity for lead acid batteries used in motive power requirements is normally 1.275 to1.320. Specific gravities in railway-diesel cells may be as low as 1.240. Fig. 1-3 Fig. 1-4 Discharged Cell Charging Cell Minimum Sulfuric Acid Maximum Water Battery Charger Typically 2.44 Volts Increasing Sulfuric Acid Decreasing Water Increasing Sponge Lead Decreasing Lead Sulfate Increasing Lead Peroxide Decreasing Lead Sulfate Minimum Sponge Lead Maximum Lead Sulfate Minimum Lead Peroxide Maximum Lead Sulfate
3
Since the acid content of the electrolyte decreases linear-ly as the cell is discharged, the decrease in gravity is directly proportionate to the amount in ampere-hours taken out. (Refer to Fig. 1-5.)The specific gravity at any point in the discharge indicates the depth of discharge, and can be translated into ampere-hours taken out. A cell having a full charge specific gravity of 1.280 and a final specific gravity of 1.130 will have a gravity drop of 150 points. EXAMPLE: assume the specific gravity is 1.180 at the end of a discharge. That is 100 points specific gravity below the full charge gravity, therefore, 100/150 = 67% discharged of rated capacity. Allow at least a half hour after end of discharge for the electrolyte to diffuse and give a true reading.
The linear relation of gravity to state of discharge can be used in tests to determine power consumption or capacity required. Tests of this kind can be made to demonstrate that a truck requires a larger capacity battery to do the job, and can lead to the solution of a problem.
GRAVITY DURING RECHARGE. The rise in gravity on recharge is not uniform or proportional to the amount of charge returned in ampere hours. During the early part of the charge, there is no gassing action to mix the electrolyte with the heavier acid being released from the plates. The heavier sulfuric acid will lie on the bottom. A hydrometer reading which draws electrolyte from the top of the cell does not indicate the true gravity or actual state of charge. During the gassing portion of the charge the sulfuric acid mixes, and the specific gravity rises rapidly to full charge value. (Refer to Fig. 1-5).
1-4 BATTERY CONSTRUCTION
The following is a brief description of the steps involved in the production of a lead acid cell which will help familiarize the reader with the various parts and their functions.
CASTING GRIDS. A pasted plate is a cast lead grid supporting framework around which chemical pastes have been applied. (Refer to Fig. 1-6).
Lead alone is extremely soft and inclined to warp or lose form. A strengthening agent must be added to the lead. A quantity of antimony
is added to the lead under very rigid control to secure the strengthening neces-sary. Temperature control is very critical as uncontrolled heat would cause the anti-mony to rise in the melting pot surface and evaporate. After heating, the molten alloy is poured into the grid molds. Only Enersys utilizes
a computer controlled casting system which optimizes casting variables, resulting in larger lead crystals. Larger lead crystals mean fewer points for corrosion to attack the grid.
PASTING THE GRIDS. After casting the grids, lead oxide pastes (active material) are applied to the grids.The negative grid, a lead oxide material, is applied containing an expander to produce the sponge lead condition. The positive plate is pasted with a
compound of lead oxide, sulfuric acid, and water mixed to a putty-like consis-tency. These pastes are mechanically applied to the grids, and evenly distributed by rollers. The rolling process results in complete penetra-tion of the paste as shown in Fig. 1-7. Only Enersys uses HUP, a patented positive
paste process which optimizes both the active material utilization and virtually eliminates shedding, the leading cause of battery failure.
4
CURING AND DRYING PLATES. After pasting, the unformed plates are ready for drying. The wet pasted plates are cured and dried under tightly controlled conditions of temperature and humidity. This process produces a smooth, uniform plate in which the active material attains exceptional porosity and is bonded securely to the grid. This results in maximum cell efficiency.POSITIVE PLATE INSULATION. Retent-A-Tape® is a
fine glass mat. This is placed vertically against the positive plate surface. A one-piece plastic boot protector completely encases the bottom of the positive plate. A protective heat sealed perforated retainer envelops the entire plate and completes the wrapping. (Refer to Fig. 1-8)
The plastic envelope is heavily perforated in the area covering the active material, permitting a free flow of electrolyte to the plate. However, in the area covering the plate edge, the envelope has no perforations and this provides a solid, insulated barrier. This prevents moss build-up and moss shorts between the plate edges. The combination of retainers, mats and bottom shields produces a positive plate assembly which retains the active material in the grid, provides insulation where required, and allows for a free flow of electrolyte to the plate interior.
ASSEMBLY OF POSITIVE AND NEGATIVE GROUPS. A specified number of positive and negative plates are joined together to make up positive and negative groups. Each group of plates is assembled by joining the top (lug end) of each plate together and adding one or more terminal posts. This weld forms a solid bar con-nection between all plates in each group and their respective terminal posts. (Fig. 1-9)
SEPARATORS. The negative and positive plates are insulated by a high-porosity Daramic® separator. As
shown in Fig. 1-10, separators are flat on one side and grooved on the other. The grooved side is faced to the positive plate to allow free circulation of a large volume of electrolyte to the positive active material. The flat side faces the negative plates. Since the negative material is sponge lead, grooves in the negative side of the separator would tend to fill with expanded material. ASSEMBLY OF AN ELEMENT. An element is one group of assembled positive and negative plates meshed together with a plastic separator protector positioned on top of the groups, and with separators inserted between each plate.
The separator protector serves the following function:
a. Protects the plates and separators from damage by any foreign object entering the cell through the vent opening.
b. Prevents damage by careless use of a hydrometer or thermometer.
c. Acts as a baffle to reduce sloshing of the electrolyte within the cell.(Refer to Fig. 1-11) ASSEMBLY OF THE COMPLETE CELL. The next step in cell assembly is the installation of a sediment leveling bridge (Fig. 1-12) in a high impact jar.
Positive Plate Wrapped Burned Group
Positive grids are of heavier construction than negative grids. This is necessary because the chemical action resulting from charging and discharging a cell is more pronounced on the positive plate than on the negative. Gases formed during charging are Oxygen and Hydrogen, with the Oxygen forming on the positive plate and Hydrogen on the negative.
Positive Grid Pasted Plate
5
A completed element is then installed in the jar and a tough, shockproof cover with lead-insert bushings (Refer to Fig. 1-13) is positioned on the posts and heat sealed to the jar. The terminal posts are welded to the lead cover inserts. The cell is then pressure tested to confirm a perfect bond between the cell cover to jar and post to cover insert.The assembled cells consist of cured, dry, unformed plates which have no electrical characteristics and capacity.
PLATE FORMATION. Electrolyte (sulfuric acid) at a specific gravity is now added to each cell. The initial charge given to a cell is known as the forming charge. The forming charge produces the electrical characteristics (positive and negative polarity) on each group of plates.
COMPLETED BATTERY ASSEMBLY. At the
completion of the forming charge, the cells are assembled into a suitable steel tray and connected in accordance with the buyer’s layout specifications. The battery 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
6
SECTION II
RECEIVING AND INSTALLATION
2-1 RECEIVING BATTERY
When receiving a new battery, immediately examine the exterior of the packing. Examine for wet spots on the sides or bottom which may indicate leaking jars broken in shipment or that the battery has been tipped over during transit.
If there is visible evidence of damage, the receipt should be marked “SHIPMENT RECEIVED DAMAGED.” The carrier should be called immediately and asked to make a damage report.
When a shipment is received and there is no visible evidence of damage, but during the unpacking damage is found, the carrier should be called immediately and requested to make a concealed damage report.
Contact your local Enersys representative to assist you in evaluating the extent of the damage. Spilled electrolyte must be replaced immediately or permanent damage will occur to the affected area of the plates resulting in loss of the battery’s ability to deliver its rated capacity.
Broken jars must be replaced at once for the reason mentioned above. Contact your local Enersys representative immediately to make the proper repairs.
2-2 PLACING A WET BATTERY IN SERVICE
(A)Remove the vent caps from each cell and determine that the electrolyte level in each cell is at the bottom of the level indicator. If electrolyte has been lost, replace it with elec-trolyte of the same specific gravity.
(B)A freshening charge should be given to the battery and will require about three to five hours to complete. The battery should be charged at its finish rate (about 4-5 amperes per 100 ampere hours of the battery’s 6 hour rate capacity).
(C)Vent caps should be secured in place during charging cycle. Charging is complete when the specific gravity levels off for a 3 hour period. General and Hup batteries have a 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 lift truck should be open, and the battery should be clean and dry prior to installation.
(E)Lift the battery with an insulated battery lifting beam or insulated spreader bar with the lifting hooks set in the prop-er position to place a vprop-ertical pull on the lifting eyes (Fig. 2-2).
(F)Install the battery in the compartment firmly blocking it to position. All vent caps must be tightly secured to prevent electrolyte spillage from occurring that could cause tray corrosion or battery compartment corrosion.
2-3 PLACING A DRY CHARGED BATTERY IN SERVICE
Batteries shipped in a dry charged condition should be stored in a cool dry place with vent caps securely in place. (A)Remove and discard plastic film seals (if present) from each cell vent hole.
(B)Fill the cells using dilute battery grade sulfuric acid with a specific gravity 0.010 to 0.015 lower than nameplate specifi-cation, corrected to 77˚F and cooled down to 90˚F or less, to the level indicator.
(C)Allow the cells to soak for 2 to 3 hours after filling. If the electrolyte level falls slightly because of absorption into the plates and separators, add acid of the same specific gravity to restore level.
(D)With the use of a voltmeter, check the voltage of all cells for a correct polarity (Fig. 2-3), then start the initial charge after the electrolyte temperature has fallen below 95˚F. (E) Connect positive and negative terminals of the battery to corresponding positive and negative leads of the DC power source.
(F) The initial charging current is 1/20 of the six hour capacity (finish rate). The time required for an initial charge is approximately 8 hours.
(G) During the initial charge, the volume of the electrolyte decreases through electrolysis and evaporation. Therefore, water approved for use in lead acid storage batteries should be added when the electrolyte level falls below the level indicator. If the cell temperature rises higher than 110˚F, either reduce the charging current to half the specified value or stop charging until the temperature falls below 110˚F. In this case, prolong the charging time proportionately.
Fig. 2-1
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 gas freely and the cell voltages and specific gravities remain constant over a three hour period.
(I) Just before completion of the charge, read exact specific gravity of all cells and adjust to battery 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 a lead acid battery while it is being charged. The gasses can combine explosively if a spark or flame is present to ignite them. Keep open flames, matches, and smoking away from the charging area.
(C)The specific gravity of the electrolyte stops rising. Readings will stabilize when the battery is fully charged and may even drop due to a temperature rise in the electrolyte (Refer to Fig. 1-5, Page 3).
(D)Charger current readings will level off (Refer to Fig. 1-5, Page 3).NOTE: Correct all voltages and specific gravities for temperature (see Chart 2-1 and 2-2 on charge or open circuit).
2-5 OPERATION OF THE BATTERY
There are several factors which affect the operation of the battery concerning its ability to deliver capacity and life expectancy. Many chemical reactions are affected by temperature, and this is true of the reaction that occurs in a storage battery. The chemical reaction of a lead-acid battery is slowed down by a lowering of temperature which results in less capacity. A battery that will deliver 100% of capacity at 77˚F will only deliver at 74% of capacity of 20˚F (Chart 2-3).
EXCESSIVE HEAT will contribute greatly to reducing battery life by corroding the positive grids and excessive gassing which loosens active material in the plates, especially the positive plates. Overcharging is the most common contribution to excessive temperatures and gassing in a battery. A General Battery Ferro-Resonant charger, matched to the proper ampere-hour require-ments of the battery, will help to avoid the problem of overcharging.
CONSISTENT UNDERCHARGING of a battery will gradually run down the cells and result in one or more cells becoming completely discharged before the others, and may become reversed. Capacity and life expectancy are greatly reduced by undercharging. Equalizing charges to return the cells to a normal condition should be part of a weekly maintenance schedule when required.
OVERDISCHARGING can also cause permanent damage to the battery. Recharging is more difficult and more time consuming. Often complete recharge is not attained and the undercharged battery is placed into service. Consequently, it is overdischarged to a lower limit resulting in loss of capacity and premature battery failure. Optimum battery life can be aided by limiting discharge to 80% of its rated capacity.
A GOOD BATTERY MAINTENANCE PROGRAM is
necessary to protect life expectancy and capacity of the battery. A more detailed discussion of Battery Maintenance can be found in Section III of this manual.
Fig. 2-3
Chart 2-1
Chart 2-2
Chart 2-3
Cell Voltage Correction Factors
Electrolyte Temperature ˚F Correction Factor Correction Factor Electrolyte Temperature ˚F 49-51 52-54 55-57 58-60 61-63 64-66 67-69 70-72 73-75 -0.09 -0.08 -0.07 -0.06 -0.05 -0.04 -0.03 -0.02 -0.01 76-78 79-81 82-84 85-87 88-90 91-93 94-96 97-99 100-102 NONE REQUIRED +0.01 +0.02 +0.03 +0.04 +0.05 +0.06 +0.07 +0.08 Subtr act F rom Measured V olts Add T o Measured V olts
Temperature correction factor to be added or subtracted to the observed specific gravity to obtain corrected specific gravity @ 77˚F.
CELL SPECIFIC GRAVITY CORRECTION FACTORS Correction Factor Electrolyte
Temperature TemperatureElectrolyte CorrectionFactor
39-41 42-44 45-47 48-50 51-53 54-56 57-60 61-63 64-66 67-69 70-72 73-75 76-78 79-81 82-84 85-87 88-91 92-94 95-97 98-100 -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 +0.007 101-103 104-106 107-109 110-112 113-115 116-118 119-121 122-124 125-127 128-130 131-133 134-136 137-139 140-142 143-145 146-148 149-151 152-154 155-157 158-160 +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 Electrolyte Temperature ˚F 77 60 50 40 30 20 Percent Capacity @ 6-Hour Rate 100 95 91 87 81 74 Percent Capacity @ 3-Hour Rate 100 93 87 83 76 67
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 water
is shown in this listing below including the maximum
allowable impurities in parts per million NEMA
standards.
Total Solids
Fixed Solids
Organic & Volatile Matter
Iron
Chloride
Ammonia as NH4
Nitr
i
tes as HO2
Nitrates as HO3
350 PPM
200 PPM
150 PPM
4 PPM
25 PPM
5 PPM
10 PPM
10 PPM
Chart 3-5 Chart 3-4Specific Gravity @ 77˚F
77˚F12
BATTERY CHARGING LOG
TM
Chart 3-6
USER # TYPE S/N
START OF CHARGE END OF CHARGE
DATE TIME TRUCK SP. GR. CHARGER CELL
TEMP.
CELL TEMP.
W E C* BY DATE TIME SP. GR. BY
* INSERT W WHEN WATER IS ADDED
INSERT E WHEN EQUALIZING CHARGE IS GIVEN INSERT C WHEN BATTERY IS CLEANED OR WASHED
EVERY MONTH RECORD GRAVITY AFTER EQUALIZING CHARGE TEMP. 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 IV
TROUBLE SHOOTING
4-1 INTERPRETATION OF CELL VOLTAGE
READINGS
The condition and health of a battery can be revealed in a study of its cell voltages. There are two factors to consider: the value of the voltage readings in relation to the battery function at that time, and the uniformity of the volt-age readings throughout the battery. The nominal voltage value of a lead acid cell is 2.00 volts. It is not uncommon to encounter cell voltages anywhere from 1.00 volts or less to 2.75 volts depending on the function of the battery at the time of the readings. The interpretation of the voltage values is a matter of comparison with normal battery characteristics, and the knowledge as to the reason for any deviation.
OPEN CIRCUIT READINGS. There is a definite relationship between the cell voltage and the specific gravity of a cell that is open circuit. Open circuit readings are useful in determining uniformity. For example, a fully charged battery on open circuit, with a specific gravity of 1.260 to 1.280 will read 2.10 to 2.12 volts or a spread of 0.02 volts. This 0.02 volt spread would be considered normal for a new battery. As the battery ages, the voltage spread will increase to about 0.03 volts. The reason for the spread to widen with age is due to inequalities in plate wear and possibly some acid loss.
ON-CHARGE VOLTAGE READINGS. On charge voltage readings are the most informative and the best indicators of battery condition. These readings should be taken at the normal finish rate, and be corrected to the base of 77˚F. New batteries, at normal finish rate, will have cell voltages between 2.55 volts and 2.65 volts. Older batteries on charge at the normal finish rate, will have cell voltages about 2.45 to 2.55 volts
VARIATIONS IN CHARGE VOLTAGE. If all cells of a battery show similar full-charge voltages, they are equally healthy. The uniformity and value of the individual cell voltage readings vary with the overall condition of the battery. A battery with an on-charge voltage of 2.45 to 2.50 volts per cell has more uniformly healthy cells than a battery having an on-charge voltage spread of 2.40 to 2.50 volts per cell. The battery’s age and service duty must be considered in the interpretation of the on-charge voltage readings. An example would be an older battery which has on-charge cell voltage readings of 2.45 volts to 2.65 volts. The reason may very well be that the inside cells operate at higher than average temperatures causing higher local action, which would result in lower voltage. Regular equalize charge will compensate for the higher self-loss of the inside cell. Any wide spread on-charge voltage that could not be attributed to the battery’s service life or age, is a sign that something is wrong and attention is necessary. Some causes of abnormally wide spread or charge voltages are:
1. Abnormal temperature differential 2. Internal shorts
3. Acid loss causing overdischarge 4. Insufficient charging
4-2 ACID REPLACEMENT AND
ADJUST-MENT OF SPECIFIC GRAVITY
Under normal circumstances, a battery should never require the addition of acid to increase the specific gravity of the electrolyte. However, when upsets, jar breakage, overfilling, or careless use of the hydrometer cause a loss of electrolyte and a corresponding loss of battery capacity, the lost acid should be replaced.
CAUTION: Before adding acid to a cell or to an entire battery with low specific gravity readings, try to raise the specific gravity by charging as described on page 17
“Causes of Sulfated Batteries.” Only if the charging is unsuccessful should an attempt be made to increase the specific gravity with acid. Never perform acid adjustment on a cell with an on-charge cell voltage less than 2.45 volts and that does not gas vigorously. To replace acid, use the following procedure with a sulfuric acid having a specific gravity of 1.400.
(A)Battery must be in a fully charged condition topped off with an equalizing charge (see page 8 for definition and description), with the electrolyte freely gassing. (B) Remove electrolyte from the low reading cell or cells until the level reaches the separator protector. (C)Slowly add the 1.400 specific gravity sulfuric acid to the proper electrolyte level while it is still charging and gassing so that the adjusting acid mixes thoroughly. If added to fast, the adjusting acid will drop to the bottom of the cell and not diffuse immediately, resulting in an inaccurate specific gravity reading. Further additions of acid can be harmful, especially when the battery is returned to service and com-plete diffusion results in a high specific gravity. About 1/4” of 1.400 specific gravity will increase a cell’s specific gravity about 5 points (0.005)
(D)After adding high specific gravity acid, leave the battery on charge for one hour so that the higher specific gravity acid is thoroughly mixed with the electrolyte. Read and record the specific gravity of the adjusted cell(s) and correct for temperature (refer to temperature correction chart 2-2 on page 7). If the specific gravity readings are too low, repeat steps 2 through 4 until the cell(s) attain a temperature corrected specific gravity specified on the battery nameplate ± 0.005.
(E) If the specific gravity in cell(s) is too high, remove the electrolyte and replace it with approved water to proper electrolyte level (refer to chart 3-5 page 11). Charge the battery for one hour at the finish rate. Read the specific gravity of the cell(s) and correct for temperature if necessary. If the specific gravity is still too high, repeat the process until it reaches the proper full charge specific gravity. If the electrolyte level is low after the specific gravity has been adjusted, final electrolyte level adjustment must be made with the same strength sulfuric acid in order to maintain the proper specific gravity.
15
NOTE: If electrolyte temperature exceeds 110˚F during the above mentioned procedures, stop the charge and allow the battery electrolyte temperature to cool to 90˚F or less before continuing.CAUTION
:
Never add acid with a specific gravity higher than 1.400. When mixing or cutting acid, always add the acid to the water. NEVER POUR water into acid because a violent reaction could result, possibly causing personal injury. Always wear a face shield, rubber gloves, and an acid resistant apron.4-3 TEST DISCHARGE
A capacity test is sometimes desirable to determine a battery’s actual discharge capability as compared to its six hour rated capacity. The discharge test can be a significant diagnostic tool when equipment does not operate as expected, and it can help determine when the battery should be replaced. When a battery consistently delivers less than 80% of its rated 6 hour capacity, either some cells are substandard or the battery has reached the end of its useful life and should be replaced.
Equipment:
1. Discharge apparatus 2. Voltmeter
3. Ammeter and shunt (calibrated)
4. Charge-test-discharge form (Section 87.86) 5. Thermometer
6. Hydrometer PROCEDURE:
(A) Prior to the start of the test discharge, complete the general information section at the top of the charge-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 each cell as received. Charge the battery and equalize charge. (C) Record the on-charge, end of equalize charge, voltage and specific gravity of each cell, and the charging current rate in amps. The end of equalize charge specific gravity should be according to battery nameplate specification.
(D)If acid adjustment is necessary, follow the procedure set forth above for acid adjustment and record the adjusted specific gravity readings in the space provided. Maintain a temperature of 90˚F or less throughout the charging, equalize charge, and acid adjustment. If the temperature exceeds 90˚F, terminate charging and acid adjustment until battery 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 applied and record the time elapsed as start. Also, record the battery terminal voltage. Complete the remaining portion of the charge-test-discharge form Section 87.86 in the following manner:
Record cell voltages every 60 minutes until an average voltage of 1.80 volts per cell is reached. Between 1.80 volts per cell and 1.75 volts per cell, readings of each cell voltage should be taken every 30 minutes.
Between 1.75 volts per cell and 1.72 volts per cell, readings should be taken of each cell voltage every 15 minutes. Caution should be taken not to allow any cells to
reverse during discharge. To avoid allowing a cell to reverse, isolate the cell from the battery by cutting the intercell connector; and with a jumper cable, jump across the isolated cell. The time, temperature, and specific gravity should be recorded at termination. Recharge the battery as soon as possible after the test discharge.
The actual capacity in ampere-hours obtained during the test discharge is the product of the discharge rate amperes times the time in hours required to reach termination voltage of 1.70 volts per cell. Further guidelines such as per-formance requirements, test conditions, test equipment, and test methods for conducting a test discharge should be obtained from Battery Council International publication BCI-I-2 titled “Determination of Capacity of Lead Acid Industrial Storage Batteries for Motive Power Service”.
4-4 CALCULATE DISCHARGE RATE
To calculate the 6 hour discharge rate, multiply the rated ampere-hour capacity of the battery times 0.167. The product will be the amount of amperes necessary to discharge the battery 100% in a 6 hour period. To calculate the 3 hour discharge rate, multiply the rated ampere hour capacity of the battery times 0.280. The chart below is battery terminal voltage for termination of test discharge:
4-5 CADMIUM ELECTRODE TESTING
When a battery is not performing satisfactorily, it is useful to know if the positive or negative plates are at fault. A third electrode is introduced into the cell and the portion of the total voltage contributed by each plate group is measured. An analysis of these measurements between this third electrode and the positive or negative groups can be made; and by comparing each with the total cell voltage, the relative condition of each group is determined. The most commonly used third electrode in lead acid batteries is the cadmium electrode.
Chart 4-3 shows three sets of cadmium readings taken on three cells at one half hour intervals at the end of a 6 hour discharge.
The chief value of the cadmium electrode test is to determine the condition of positive and negative plates separately. The electrode consists of a rod about 5/16” in diameter; it may be from one to several inches long. Before the electrode is used for the first time, it should be soaked for sev-eral days in a sulfuric acid solution of about the strength of battery electrolyte, and before each test it should be immersed in the solution for several hours before it its used. The cadmium must be insulated so that it cannot come in contact with the plates of the cell. The separator protector in the cell will usually protect the cadmium rod from coming in contact with the plates. If the separator protector is
Chart 4-1
Number of cells Terminal Voltage 6 9 12 15 18 24 30 32 10.2 15.3 20.4 25.5 30.6 40.8 51.0 54.4
16
missing, the cadmium rod should be encased in a perforated hard rubber cover. A flexible rubber insulated wire is attached to the cadmium to serve as a voltmeter lead.The cadmium electrode is inserted into the electrolyte immediately above the center of the plate. The readings must be taken when the cell is either discharging or charging. Open circuit readings are meaningless.
During the discharge cycle, the potential between the cadmium electrode and the positive plates decreases from about 2.2 to 2.0 volts, depending on the state of charge. If the battery is further discharged, this potential drops rapidly. The potential between the cadmium and the negative plates is about 0.15 to 0.2, volts, and the rate of increase in potential becomes greater if the cell is discharged below its normal rating. When the battery is on-charge, the potential between the cadmium and the negative plates reverses as the battery approaches the end of the charging cycle. The readings near the end of the charge are about 2.45 volts between the cadmium and the positive plates. A high resistance voltmeter must be used with the cadmium electrode because the current drawn by a low resistance voltmeter will cause polarization at the cadmium and error in the readings. At 77˚F the following would represent a healthy cell at finish rate:
Positive Cadmium = 2.43 Negative Cadmium = -0.20 Cell Voltage = 2.63
The cell voltage is the algebraic difference between the two cadmium readings. Both the positive and negative cadmium readings under fully charged conditions will be uniform in a normal battery. If there is a cell voltage variation of more than 0.05 volts below the other cells, cadmium readings will indicate which plates are affected. An internal cell inspection should be made to determine the cause of the trouble.
CELL NUMBER 1 shows normal readings. CELL NUMBER 2 has low terminal voltage. The positive and negative cadmium readings are low. Internal inspection of the cell will reveal the defect. CELL NUMBER 3 has low terminal voltage, but normal positive readings. The negative cadmium reading is low, indicating either under-charging or contamination of the negative plate. Chart 4-3 shows three negative cadmium readings taken on three cells at one half hour intervals at the end of a 6 hour dis-charge.
CELL#1 - Both the positive and negative cadmiums are decreasing uniformly as the cell voltage decreases, and both sets of plates are losing capacity together indicating that they are in a healthy condition. At the end of the 6 hour discharge the cell had delivered capacity to 1.70 volts. This cell is performing satisfactorily. CELL #2 -This cell delivered capacity; however the positive cadmium readings changed rapidly and contributed to most of the voltage drop since the negative cadmiums remained practically unchanged. This cell appears to be limited in its ability to deliver capacity by the positive plates at the present time.
CELL #3 - The terminal voltage of this cell decreased very rapidly towards the end of the discharge. The negative cadmium values changed by a large amount (0.32), whereas the positive values only showed a minimal change (0.05). This cell appears to be limited in its ability to deliver capacity by the negative plates which contributed to the bulk of the voltage drop. Failure of the negative plates will usually cause a more rapid decline in cell voltage than failure of the positives.
4-6 INTERNAL INSPECTION
If the test discharge previously explained indicates that the battery was not capable of delivering more than 80 percent of rated capacity, an internal inspection should be made. The positive plates, which wear first, should be examined. If it is discovered that the positive plates are falling apart or that the grids have many frame fractures, a replacement battery is needed. If the positive plates are in good mechanical condition and the cells contain little sediment, the battery may be sulfated.
Cell # 1 2.63 2.43 -0.20 2 2.38 2.38 0 3 2.38 2.43 +0.05 On Charge Cell Voltage Positive Cad. Value Negative Cad.
Value Probable Cause of Condition
No internal shorts. Healthy negative plates. Typical readings for a new cell.
Low terminal voltage. Positive cadmium value below normal. Check for internal shorts. Could be a broken separator.
Normal positive cadmium value indicates absence of internal shorts. Unhealthy negative plates indicated by low negative cadmium value. Negative plates could be failing.
Chart 4-3 Chart 4-2
Cell #1 Cell #2 Cell #3
5 Hours & 30 Min.
Positive Cadmium Value Negative Cadmium Value Cell Voltage
6 Hours
Positive Cadmium Value Negative Cadmium Value Cell Voltage
5 Hours & 7 Min.
Positive Cadmium Value Negative Cadmium Value Cell Voltage 2.02 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 INSPECTIONS
On-site battery inspections are performed for various reasons. The customer may be experiencing battery problems or just require an annual battery inspection to determine the condition of all batteries and chargers. Many times the on-site inspection is a good sales tool for developing new customers as well as obtaining replacement battery orders.
On-site inspections are not just a visual inspection, but also a factual inspection. Battery cell voltages and gravities should be recorded. Battery temperature and specific gravity before and after charge should be recorded. The number of cycles a battery receives during a 24 hour period, charger rates, and timer settings should be recorded, as well as the general con-dition of the charging area, ambient temperature, and battery charging schedule. Upon compiling the record-ed data, an intelligent view of the customer’s operation can be made along with the proper recommendations. Consequent follow-up inspections and repair work can be accomplished.
Form IND-441 should be used in an on-site battery inspection. The required information can be accumulated easily on this form for review (Refer to Chart 4-4).
4-8 CAUSES OF SULFATED BATTERIES
All lead acid batteries sulfate when discharged. The active material must convert to lead sulfate in order for the cells to produce energy. This sulfation process is called “normal sulfation.” The term “sulfated battery” means that the battery has developed abnormal sulfate and has its capacity impaired as a result. The most 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 are below freezing.
3. Low electrolyte level. 4. Adding acid.
5. High specific gravity. 6. High temperature.
Cells of a sulfated battery give low specific gravity and voltage readings and the battery will not become fully charged after a regular equalizing charge. Before assuming that the battery is sulfated, rule out the possibility that low gravity may be due to acid loss. If the specific gravity is low due to acid loss, the negative plates are likely to be in good condition, with the active material a spongy lead showing a metallic luster when stroked. Abnormally sulfated material is hard and gritty and feels sandy when rubbed. If the negative active material is mushy and sandy, coming off like mud when stroked, too much acid is indicated. A sulfated positive material is a lighter brown color than a normal positive plate. If the sulfation has not progressed too far, it may be possible to restore the battery to a serviceable condition by paying careful attention to the following procedure:
(A) Clean the battery (neutralize, wash and dry).
(B) Adjust electrolyte by adding approved water to the proper level.
(C)Change the battery at the proper finish rate until the full ampere-hour capacity has been put in the battery, based on the six-hour rate. If the temperature rises above 110˚F during these procedures, reduce the charge rate accordingly, or stop the charge and allow the battery to cool to 90˚F or less before continuing. Charge the battery until the specific gravity shows no change during a 3 hour period while taking hourly readings. With automatic charging equipment, the battery may have to be placed on equalizing charge 2 or 3 times.
(D)Discharge the battery to its rated capacity or lower without causing any cell to reverse.
(E)Recharge again until the specific gravity shows no change during a 3 hour period.
(F)Repeat the cycling process until the specific gravity remains constant. If the battery gives at least 80% capacity, recharge and put into service.
(G)If the battery has not responded to steps A through F, it is sulfated to the point where it is impractical to attempt further treatment. The battery should be replaced.
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 CHARGE RATE 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.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
19
SECTION V
HEALTH AND SAFETY
5-1 BATTERY HAZARDS
GENERAL - A lead-acid battery can be a very useful, safe source of electrical power. While installing, using, maintaining, or repairing a motive power battery, opportunities exist, however, for exposure to potentially dangerous situations. This section identifies those hazards which could result from improper handling or use. HAZARDS
(A) A sulfuric acid solution is used as the electrolyte in lead-acid batteries and has a concentration of approximately 37% by weight, of sulfuric acid in water. In this diluted state it is not as hazardous or as strong as concentrated sulfuric acid; but it acts as an oxidizing agent, and can burn the skin or eyes and destroys clothing made of many common materials such as cotton or rayon. (B) An explosive mixture of hydrogen and oxygen is produced in a lead-acid battery while it is being charged. The gases can combine explosively if a spark or flame is present to ignite them. Because hydrogen is so light, it normally rises and diffuses into the air before it can concentrate into an explosive mixture. If it accumulates into gas pockets, as can occur within a cell, it might explode if ignited. Hydrogen formula =0.00027 x (finish rate) x (num-ber of cells)=cu.ft. of hydrogen produced per minute. (C) Electricity is produced by the batteries on discharge and, while most persons cannot feel voltages below 35 to 40 volts, all motive power batteries should be regarded as potentially dangerous. A lead-acid battery is capable of discharging at extremely high rates and, under conditions of direct shortage, can cause severe damage and serious injury.
(D)The weight of these heavy batteries can easily cause painful strains or crushed hands or feet if improperly lifted or handled. Batteries can be damaged if dropped. The average motive power battery weighs more than one ton, so proper equipment must be provided when changing or handling batteries.
(E)Burns can result from contact with molten lead or hot compounds while repairing a battery. Lead can splash when intercell connectors are being reburned, and hot compounds can be spilled when resealing covers to jars. Protective gear, if worn, will help prevent such burns.
5-2 SAFETY PROCEDURES
FEDERAL STANDARDS - In 1970, Congress passed the Occupational Safety and Health Act (OSHA). This act established the minimal acceptable standards for safe and healthful working conditions. The safety procedures outlined in this manual have been compiled from standards developed over the years by professional and technical organizations.
The safety procedures have been grouped by functional area of most logical application or need.
SAFETY PROCEDURES WHILE HANDLING BATTERIES
(A)Lift batteries with mechanical equipment only, such as an overhead hoist, crane or lift truck. A properly insulated lifting beam, of adequate capacity, should always be used with overhead lifting equipment. Do not use chains attached to a hoist at a single central point forming a trian-gle. This procedure is unsafe and could damage the steel tray.
(B)Always wear safety shoes, safety glasses, and a hard hat made of a nonconducting material.
(C)Tools, chains and other metallic objects should be kept away from the top of uncovered batteries to prevent possi-ble short circuits.
(D) Battery operated equipment should be properly positioned with switch off, break set, and battery unplugged when changing batteries or charging them while in the equipment.
(E)Personnel who work around batteries should not wear jewelry made from conductive material. Metal items can short circuit a battery and could cause severe burns and electrocution.
(F) Only trained and authorized personnel should be permitted to change or charge batteries.
(G)Reinstalled batteries should be properly positioned and secured in the truck, tractor, or crane. Before installing a new or different battery, check with the truck or tractor name plate and battery service weight to make sure that the proper weight battery is being used. A battery of the wrong weight can change the center of gravity and cause equipment to upset.
SAFETY PROCEDURES WHILE CHARGING BATTERIES
(A) Specific areas should be designated for charging batteries. These areas should be equipped with overhead hoists or cranes for handling batteries.
(B) Charging areas should be adequately ventilated. The actual amount of ventilation will depend upon such factors as number and size of batteries being charged at the same time, room size, ceiling height and airtightness of the building. Hydrogen concentrations above 4% can be explosive. Hydrogen Formula = 0.00027 x (finish rate) x (number of cells)=cu.ft. of hydrogen produced per minute. (C) Smoking, open flames, and sparks must be prohibited in the charging area. Post placards “Hydrogen”, “Flammable Gas”, “No Smoking” and “No Open Flames”. (D)Barriers (posts) should be provided to protect charging equipment from physical damage by trucks, tractors, and cranes.
(E)Eyewashes and showers are required in areas where batteries are serviced. OSHA regulation 29 CFR 1910.151(c) has clear guidelines for eyewash and shower use. Safety equipment should be clearly identified and readily accessible.
20
(F) Before connecting a battery to, or disconnecting it from, a charger, the charger should be turned off. Live leads can cause arcing and pitting of battery connector contact surfaces.
(G)Make sure that all electrical connections are tight and mechanically sound to prevent any arcing or loss of power. (H)At a minimum, a face shield or goggles, rubber gloves, apron and boots should be worn when checking, filling, charging or repairing batteries during periods of possible exposure to acid or electrolyte.
(I)When batteries are charged on racks, the racks should be insulated to prevent any possibility of shortage. (J)When charging an enclosed or covered battery, always keep the battery tray cover, or compartment cover, open during the charging period. This will help to keep the battery cool and disperse the gases.
(K) Keep vent caps in place at all times except while servicing or repairing cells. This minimizes the loss of electrolyte and prevents foreign matter from entering the cells.
(L) Shut off and disconnect both input and output connections to the charger before repairing charging equipment.
SAFETY PROCEDURES WHILE HANDLING BATTERY ACID
(A) The splashing of acid into the eyes is the most dangerous condition which can be encountered while handling sulfuric acid or electrolyte. If this should happen, the eyes should be gently flooded with fresh, clean run-ning water for at least 15 minutes followed as quickly as possible with a physician’s examination. If the person is wearing contact lenses, they should be removed before rinsing the eyes.
(B)Acid or electrolyte splashed onto the skin should be washed off under running water. Battery electrolyte will usually only cause irritation of the skin, but if a burn develops, it should be treated medically. (C)When electrolyte is splashed on clothing, use a weak solution of bicarbonate of soda as soon as possible, to neutralize the acid.
(D)A carboy filter or safety siphon should be provided for handling acid from a carboy container. Use the protective box when moving a carboy. Store acid in a cool place out of the direct rays of the sun. Use only glass or acid resistant plastic containers when storing acid or electrolytes.
(E)When mixing acid to prepare electrolyte, always pour the acid slowly into the water and stir constantly to mix well. Never pour water into acid. Never use sulfuric acid solutions which are over 1.400 specific gravity. (F)Apply a neutralizing solution, such as a bicarbonate of soda and water, when acid is spilled on floor and clean up promptly. A mixture of one pound of soda to one gallon of water is recommended.
SAFETY PROCEDURES WHILE SERVICING OR REPAIRING BATTERIES
(A)Disconnect the battery from the truck, tractor, or crane when servicing or repairing either the battery or the equipment. Also make certain the battery is disconnected from the charger before handling or repairing the battery. (B)Before repairing a battery, remove all of the vent caps and blow out each cell with a low pressure air hose to remove any residual gas. Use only a gentle stream of air to avoid splashing electrolyte.
(C)Open or “break” the circuit before repairing damaged or dirty terminal plugs or receptacles connected to a battery, by removing and insulating one terminal lead at a time.
(D) When melting sealing compound in preparation for resealing cells, be careful not to puncture the top section of unmelted compound with a screwdriver or other point-ed object. A build-up of pressure from the meltpoint-ed com-pound in the bottom could cause liquid comcom-pound to squirt and inflict a severe burn. Do not allow compound to ignite by overheating. Compound becomes workable at 400 to 425˚F.
(E)Check batteries frequently for acid leakage or signs of corrosion.
(F) Use insulated tools whenever possible when working on batteries. If possible, also cover the terminals and connectors of a battery with a sheet of plywood or other insulating material to prevent short circuits. (G) When taking specific gravity readings, use a face shield or goggles and read the hydrometer with eye at about the same level as the electrolyte. See Fig. 5-1.
Fig. 5-1
There may be additional regulatory requirements,
depending on the specific application, as well
21
Chart 5-1TROUBLE SHOOTING CHART
Problem Probable Cause Remedy
Battery not working a full shift.
1. Battery is undersized. 2. Battery not fully charged at
beginning of shift. 3. Weak or defective cells. 4. Grounds or Shorts. 5. Battery has exceeded useful
operating life.
6. Vehicle has electrical or mechanical problems.
1. Replace with a battery of adequate capacity for the work load required. 2. Check chargers and charging
schedules. Fully charged gravity is 1.275-1.285 for a standard battery. 3. Repair or replace battery. 4. Clean battery and remove any
visible corrosion. 5. Replace battery.
6. Troubleshoot and repair vehicle.
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 after gassing begins.
3. Adjust gravity. 1. Charged equipment not
operating correctly.
2. Charging equipment incorrectly adjusted.
3. Weak or defective cells. 4. Battery worn out.
5. High resistance connection. 6. Low electrolyte level. 7. Battery too warm when placed
on charge.
8. Battery being charged in truck compartment with cover closed. 9. Battery too deeply discharged.
1. Excessive load.
2. Battery not fully charged prior to work assignment.
3. Battery overdischarged. 4. Electrolyte levels low.
5. High current draws due to worn-out equipment.
6. Operating truck in high ambient temperatures. 1. 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 and
insufficient time allowed for mixing.
3. Improper gravity adjustment after cell replacement. Battery overheats on charge. Battery overheats on discharge. Low Electrolyte Level. Unequal specific gravities. Unequal Cell Voltages.
22
GENERAL SERIES
MOTIVE POWER CELL PARTS LIST
Cell 6 Hr. Ah Cable Cell Cover Jar Standard Over Partition Insulator Standard Over Partition Insulator
55GL-5 110 #2 93478-CW 804080 804310 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509 55GL-7 165 #2 93479-CW 804081 804311 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509 55GL-9 220 #2 93480-CW 804082 804312 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509 55GL-11 275 #2 93481-CW 804083 804313 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509 55GL-13 330 #2 93482-CW 804084 804314 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509 55GL-15 385 #2 93483-CW 804085 804315 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509 55GL-17 440 #2 93484-CW 804090 804316 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509 55GL-19 495 #2 93485-CW 804091 804317 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509 55GL-21 550 #2 93486-CW 804092 804318 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509 55GL-23 605 1/0 93487-CW 804093 804319 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509 55GL-25 660 1/0 93488-CW 804094 804320 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509 55GL-27 715 1/0 93489-CW 804095 804321 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509 55GL-29 770 1/0 93490-CW 804940 804322 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509 55GL-31 825 2/0 93491-CW 804941 804323 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509 55GL-33 880 2/0 93492-CW 804942 804324 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509 75GL-5 150 #2 83623-CW 804080 804360 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509 75GL-7 225 #2 90000-CW 804081 804361 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509 75GL-9 300 #2 90001-CW 804082 804362 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509 75GL-11 375 #2 90002-CW 804083 804363 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509 75GL-13 450 #2 90003-CW 804084 804364 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509 75GL-15 525 #2 90004-CW 804085 804365 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509 75GL-17 600 #2 90005-CW 804090 804366 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509 75GL-19 675 1/0 90006-CW 804091 804367 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509 75GL-21 750 1/0 90007-CW 804092 804368 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509 75GL-23 825 2/0 90008-CW 804093 804369 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509 75GL-25 900 2/0 90009-CW 804094 804370 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509 75GL-27 975 3/0 90010-CW 804095 804371 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509 75GL-29 1050 3/0 90011-CW 804940 804372 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509 75GL-31 1125 4/0 90012-CW 804941 804373 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509 75GL-33 1200 4/0 90013-CW 804942 804374 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509 75G-5 150 #2 84301-CW 804080 804180 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509 75G-7 225 #2 84302-CW 804081 804181 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509 75G-9 300 #2 81113-CW 804082 804182 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509 75G-11 375 #2 81114-CW 804083 804183 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509 75G-13 450 #2 81115-CW 804084 804184 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509 75G-15 525 #2 81116-CW 804085 804185 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509 75G-17 600 #2 81117-CW 804090 804186 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509 75G-19 675 1/0 81118-CW 804091 804187 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509 75G-21 750 1/0 81119-CW 804092 804188 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509 75G-23 825 2/0 81120-CW 804093 804189 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509 75G-25 900 2/0 81121-CW 804094 804190 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509 75G-27 975 3/0 81122-CW 804095 804191 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509 75G-29 1050 3/0 81123-CW 804940 804192 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509 75G-31 1125 4/0 88137-CW 804941 804193 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509 75G-33 1200 4/0 87300-CW 804942 804194 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509 85G-5 170 #2 99231-CW 804100 853440 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509 85G-7 255 #2 99232-CW 804101 853441 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509 85G-9 340 #2 99233-CW 804102 853442 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509 85G-11 425 #2 99234-CW 804103 853443 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509 85G-13 510 #2 99235-CW 804104 853444 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509 85G-15 595 #2 99236-CW 804105 853445 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509 85G-17 680 1/0 99237-CW 804110 853446 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509 85G-19 765 1/0 99238-CW 804111 853447 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509 85G-21 850 2/0 99239-CW 804112 853448 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509 85G-23 935 3/0 99240-CW 804113 853449 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509 85G-25 1020 3/0 99241-CW 804114 853450 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509 85G-27 1105 4/0 99242-CW 804115 804171 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509 85G-29 1190 4/0 99243-CW 804116 804172 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509 85G-31 1275 4/0 99244-CW 804117 804173 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509 85G-33 1360 4/0 99245-CW 804118 804174 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509 100G-5 200 #2 99261-CW 804100 804200 79371 (2.01") -- (--) 201507 79374 (3.01") 79375 (3.09") 201509 100G-7 300 #2 99262-CW 804101 804201 79372 (2.81") 79373 (2.97") 201508 79374 (3.01") 79375 (3.09") 201509 100G-9 400 #2 99263-CW 804102 804202 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509 100G-11 500 #2 99264-CW 804103 804203 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509 100G-13 600 #2 99265-CW 804104 804204 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509 100G-15 700 1/0 99266-CW 804105 804205 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509 100G-17 800 1/0 99267-CW 804110 804206 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509 100G-19 900 2/0 99268-CW 804111 804207 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509 100G-21 1000 3/0 99269-CW 804112 804208 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509 100G-23 1100 4/0 99270-CW 804113 804209 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509 100G-25 1200 4/0 99271-CW 804114 804210 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509 100G-27 1300 4/0 99272-CW 804115 804211 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509 100G-29 1400 4/0 99273-CW 804116 804212 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509 100G-31 1500 4/0 99274-CW 804117 804213 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509 100G-33 1600 4/0 99275-CW 804118 804214 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509 END TO END SIDE TO SIDE
23
Cell 6 Hr. Ah Cable Cell Cover Jar Standard Over Partition Insulator Standard Over Partition Insulator
125G-11 625 1/0 290343-CW 804103 503835 79379 (4.32") 79380 (4.44") 201511 79374 (3.01") 79375 (3.09") 201509 125G-13 750 1/0 290344-CW 804104 503836 79382 (5.07") 79383 (5.19") 201512 79374 (3.01") 79375 (3.09") 201509 125G-15 875 2/0 290345-CW 804105 503837 79384 (5.82") 79385 (5.94") 201513 79374 (3.01") 79375 (3.09") 201509 125G-17 1000 3/0 290346-CW 804110 503838 79280 (3.54") 79281 (3.70") 201514 79374 (3.01") 79375 (3.09") 201509 125G-19 1125 4/0 290347-CW 804111 503839 79282 (3.54") 79283 (3.70") 201515 79374 (3.01") 79375 (3.09") 201509 125G-21 1250 4/0 290348-CW 804112 503840 79284 (4.29") 79285 (4.45") 201516 79374 (3.01") 79375 (3.09") 201509 125G-23 1375 4/0 290349-CW 804113 503841 79286 (5.04") 79287 (5.20") 201517 79374 (3.01") 79375 (3.09") 201509 125G-25 1500 4/0 290350-CW 804114 503842 79288 (5.79") 79289 (5.98") 201518 79374 (3.01") 79375 (3.09") 201509 125G-27 1625 4/0 290351-CW 804115 503843 79290 (4.29") 79291 (4.45") 201519 79374 (3.01") 79375 (3.09") 201509 125G-29 1750 4/0 290352-CW 804116 503844 805060 (5.04") 805061 (5.20") 201520 79374 (3.01") 79375 (3.09") 201509 125G-31 1875 4/0 290353-CW 804117 503845 805062 (5.79") 805063 (5.95") 201521 79374 (3.01") 79375 (3.09") 201509 125G-33 2000 4/0 290354-CW 804118 503846 805064 (6.54") 805065 (6.70") 201522 79374 (3.01") 79375 (3.09") 201509 160G-9 640 1/0 97811-CW 804911 804571 79377 (3.56") 79378 (3.68") 201510 79374 (3.01") 79375 (3.09") 201509 160G-11 800 2/0 97812-CW 8049
