Ironclad Automobile Parts Guide

INSTRUCTIONS FOR INSTALLATION,
OPERATION, AND MAINTENANCE OF
LEAD-ACID BATTERIES IN MOTIVE POWER
SERVICE
Section 28.00
Instructions for Installation,
Operation, and Maintenance of
Lead-Acid Batteries in
Motive Power Service
TABLE OF CONTENTS
SECTION
SAFETY PRECAUTIONS 1
SPILLS AND RECYCLING 2
INTRODUCTION 3
FUNDAMENTALS OF A STORAGE BATTERY 4
CONSTRUCTION 5
INSPECTION OF BATTERY UPON RECEIPT 6
DRY CHARGED BATTERIES 7
INSTALLATION OF THE BATTERY 8
FAST CHARGING AND OPPORTUNITY CHARGING 9
OPERATION 10
TEMPERATURES 11
DISCHARGE CHARACTERISTICS 12
CHARGING EQUIPMENT 13
CHARGING CHARACTERISTICS 14
MAINTENANCE AND RECORDS 15
DETERMINATION OF CAPACITY 16
TROUBLESHOOTING 17
WATERING 18
CLEANING 19
ADJUSTING SPECIFIC GRAVITIES 20
STORAGE OF BATTERIES 21
ACCESSORIES 22
TOOLS 23
1. SAFETY PRECAUTIONS
a. Explosion can result from the gases produced by a
battery:
1. Do not smoke, use an open flame, or create arcs or
sparks in the vicinity of a battery.
2. Only charge a battery in a well-ventilated area with
the cover of battery or compartment raised for maximum
ventilation.
3. Do not charge the battery at a current greater than
5amps per 100 amp-hours capacity at the end of charge.
4. Every battery gives off hydrogen and oxygen during
recharge. Most of the gassing occurs after the 80%
point has been reached. As the breakdown of water
occurs oxygen and hydrogen are produced. The
concentration of the gasses is proportional to the current
being delivered to the battery.
Tocalculate the hydrogen produced use the following
formula, and ventilate the area as required. Hydrogen
must be ventilated in order to avoid an explosion.
Hydrogen concentrations of 4% or greater will cause an
explosion. When calculating assume all chargers in finish
rate at same time.
The National Fire Protection Association (NFPA) allows
up to 1% concentration. Make sure the ventilation system
can remove the hydrogen before it reaches
concentrations of 1% within the charging area.
Formula
0.00027 x (finish rate) x (number of cells) = cu. ft. of
hydrogen produced per min.
5. The ventilation system must also be designed to provide
removal of hydrogen and excess heat from the area directly
above charging batteries. Inlet air ducts should be placed
at shoulder height or lower so as to provide air movement
across the charging room and across batteries. Failure to
properly ventilate charging areas may result in employee
complaints of heat and “battery odor”.
b. Severe burns can be caused by the sulfuric acid contained
in the batteries covered by these instructions:
1. Do not get acid in eyes, on skin or clothing. In case of
contact, flush immediately and thoroughly with clean
water for at least 15 minutes. Obtain medical attention when
eyes are affected.
2. In handling sulfuric acid, wear a face shield, plastic or
rubber apron, and gloves. Avoid spilling acid.
3. PRO WASHTM neutralizing and cleaning solution or
bicarbonate of soda solution (one pound to a gallon
water) will neutralize any acid accidentally spilled. Apply
the PRO Wash solution until it turns yellow (bicarbonate
of soda solution stops bubbling), then rinse with clear
water. Do not allow any of this solution to enter the cells.
When diluting concentrated acid, always add acid to
water, never vice versa. Pour slowly and stir constantly,
to avoid excessive heat or violent chemical reaction.
4. Batteries and sulfuric acid should be handled only by
persons who have been instructed on the potential
chemical hazards, in accordance with the OSHA 29 C.F.R.
1910.1200, Hazard Communication Standard. Refer to
EnerSys Material Safety Data Sheet (MSDS) for
lead-acid batteries.
c. The battery is electrically live at all times:
1. Keep the top of the battery clean and dry to prevent
ground shorts and corrosion.
2. Do not lay metallic objects on the battery; insulate all
tools used in working on the battery to prevent short circuits.
Also remove all jewelry before working on the battery.
TUBULAR SINCE 1910 TM

3. Be especially careful when working on battery
terminal connections. Do not connect any two or more
terminals together unless the connection is a proper
and correct electrical one.
d.When lifting the battery, observe the following
precautions:
1. Unless completely insulated lifting beams are available,
temporarily cover the exposed metal components
of the cells with an insulating material (plywood, thick
rubber, etc.) to reduce the risk of a short circuit from the
chain or hooks.
2.Use a lifting device with two hooks which are
electrically insulated from each other to prevent short
circuits.
3. Follow the instructions on handling loads covered in
OSHA 29 C.F.R. 1910.179(n).
e.Keep the vent plugs firmly in place at all times except
when adding water or taking hydrometer and temperature
readings.
f. Only personnel who have been trained in battery
installation, charging and maintenance should be allowed to
work on the battery.
2. SPILLS AND RECYCLING
a. Spills of sulfuric acid should be handled with
consideration for the following:
1. Do not touch spilled material without appropriate personal
protective equipment (e.g., face shield, acid resistant gloves,
etc.).
2. If possible, stop the flow of spilled acid with sand or
other non-combustible absorbent and/or neutralize with
bicarbonate of soda, lime or other neutralizing agent.
3. Place spill residue into compatible containers. If spill
occurs from a battery, waste should be tested for presence
of hazardous constituents prior to disposal.
4. Do not allow the discharge of any electrolyte or acid
into sanitary or storm sewers.
5. Spills which enter the environment (through sewers,
waterways or soil) must be reported, as applicable, to
city,state, or federal environmental agencies as necessary.
6. Spills which occur during transportation of batteries
should be reported to CHEMTREC (1-800-424-9300) a
24-hour service for emergency assistance.
b. Handling and storage of new and used (spent) batteries:
1. Batteries and battery components should be handled
only in accordance with the safety procedure outlined in
Section 1.
2. All batteries, as well as other hazardous substances,
should be stored under cover and on an impervious surface
with adequate containment to prevent dispersion of
contaminants to the environment.
3. Batteries and acids should be stored away from sewer and
storm drains and from sources of heat (see Section 19).
4. Leaking or cracked batteries and cells should be contained
to prevent further leakage.
5. Generally, there are no storage time restrictions for batteries
or for spent lead-acid batteries which are destined for recycling.
However, state regulations and local fire and health ordinances
should be consulted for special restrictions on the storage of
hazardous substances, including batteries and acid.
6. Sulfuric acid is listed as an extremely hazardous
substance under the federal Emergency Planning and
Community Right-to-Know Act (EPCRA). Notification
and/or reporting to federal, state and local agencies may be
The threshold planning quantity (TPQ) for sulfuric acid is 1,000 pounds.
c. Recycling:
1. Spent lead-acid batteries which are destined for recycling are not
regulated under federal hazardous waste regulations or by most
state regulations. Contact your state environmental agency for
additional information.
2. Under federal land ban restrictions and individual state battery
recycling laws, spent lead-acid batteries can be disposed of only by
recycling/reclamation at permitted secondary lead smelters or other
authorized recycling facilities. Spent batteries should be sent only
to facilities which have obtained EPA or state hazardous waste
permits for the storage of spent batteries prior to recycling. Call
800-538-3627, x 1652 to reach the Recycling help desk.
3. Acid which is removed from spent batteries may be regulated
hazardous waste. Facilities which generate spent acid may be
subject to state or federal regulations for large or small quantity
generators applicable to labeling, manifesting, transportation and
reporting.
3. INTRODUCTION
The battery-operated electric vehicle fills a unique position
in the constantly enlarging field of materials handling.
Whether it be in a manufacturing plant, on a railway platform, in a mine,
or in airline ground support equipment, these battery-propelled vehicles
have advantages over other means of transporting equipment.
The vital power source of these vehicles is a storage battery.
The most reliable, yet simple, portable power package.
The purpose of this manual is to provide a better understanding
of the characteristics, operation, and care of this battery so that all of
its advantages and economies may be realized.
4. FUNDAMENTALS
Battery: A device for converting chemical energy into electrical
energy. All batteries are made up of individual compartments called
cells ,connected in series, so their individual voltages add up. Size,
internal design and materials used control the amount of energy
available from each cell. A
lead-acid battery is a number of cells or
containers filled with a mixture of sulfuric acid and water called
electrolyte. The
electrolyte covers vertical plates made of two types of
lead. Chemical action between the acid and the lead creates electrical
energy.
Volt, V :Afork lift’s running speed and its lifting speed are
determined by a battery’s voltage. And since each cell in a lead-acid
battery has 2 volts, multiply the number of cells by two and you
know the voltage. Thus, it automatically follows: the more cells,
the higher the voltage, the faster the fork lift’sspeed.
Ampere, A :An ampere is the standard measure of the
amount of electric current. The amount or flow can be large
(amperes) or small (milliamperes). Flashlight batteries are
measured in milliamperes. Lift truck batteries are measured in amperes.
While it’s important to match battery amperage with the total amperage
requirements of a fork lift truck, you still won’t know if you have enough
current to keep a truck running a full shift. You will know if you next
consider a battery’s ampere-hour rating.
Ampere-hour, A.H. :The higher a battery’s ampere-hour capacity, the
longer a fork lift will run. How long is always specified along with the
ampere-hour rating on the battery label. For example, 680
ampere hours (A.H.)
at the six hour rate means three things: First, 680
A.H. is the total capacity of the battery.Second, if the fork lift’smotor
and attachments draw 113 amperes continuously for six hours, the
battery will be completely drained of usable power in six hours. And
third, if the forklift’s motor and attachments draw only 90 amperes
continuously, the battery will provide energy for almost 8 hours and
have a power to spare. Obviously, a battery that’s not completely
drained during its work shift has an improved life span over a battery
that is. (To maximize the life of your battery it should not be discharged
below 80% depth of discharge.) Now,by taking
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what you know about a battery’s volts, amps, and ampere-hours,
you’re ready to easily change those numbers into the final key
concept, watts.
Watt, W. :Using battery voltage or amperage alone doesn’t tell you
enough about the battery. Multiplying those two values together
does. The answer you get is a battery’s wattage: the electrical power
abattery can provide. Every 1,000 watts is a kilowatt, or KW. Then,
for example, when your forklift needs 10KW of continuous power for
a6-hour shift, you need a battery that provides 60 kilowatt-hours
(60KWH) of energy.
OTHER IMPORTANT
BATTERY CONCEPTS
Cycle: Every time a battery is charged and then discharged in use is
one cycle. Battery life is usually measured in cycles. 1,200 to 1,500
cycles, or 5 to 6 years, is about the average battery’s life. However,
battery maintenance and charging procedures will either prolong or
shorten battery life, depending on how well recommended
procedures are followed. EnerSys will provide training aids and
materials whenever asked. Also, when a battery’s average voltage
measures less than 2.08 volts (open circuit - after a full charge) times
the total number of cells, the battery either needs repair or has
reached the end of its life. To be sure the situation isn’t the result of a
maintenance problem, call your lift truck dealer or EnerSys
representative.
Specific Gravity: As a battery is used, the sulfuric acid in the
electrolyte changes into another chemical when it combines with
the active material. As a result there’sless and less
power-generating sulfuric acid as the battery is discharged.
When the battery is recharged, the sulfuric acid returns.
FIGURE 1
CHARGED/
RECHARGED DISCHARGING DISCHARGED
1.300 Specific
1.200 Specific
1.120 Specific
Gravity
Gravity
Gravity
Sponge Lead Water
Lead Peroxide Lead Sulfate
Sulfuric Acid
The hydrometer detects the chemical change by measuring the
ratio of sulfuric acid to water. In addition, temperature also affects a
battery’s specific gravity. Temperatures above and below 77° F
require correction of the hydrometer reading. EnerSys can provide
athermometer which shows how much to correct for the
temperature at your location.
Gassing: Gassing occurs when chemical activity and heat build up
during overcharge, the last 20% of a normal charging cycle. The
water in the electrolyte inside the battery breaks down into hydrgen
and oxygen. When this happens, electrolyte will bubble and
expand, causing the battery to overflow if any cell was previously
filled with too much water.Inexperienced maintenance personnel
should never try to replace lost sulfuric acid. In addition, even
worse than overwatering is underwatering. If electrolyte isn’t at
least up to the battery’ssplash plate during charging and use, part
of the plates will be unused. The battery will then overheat, gas
more violently, and the exposed plates will eventually dry out and
be damaged. Scheduled maintenance must be done if a battery is
5. CONSTRUCTION
Fig. 2 illustrates the construction of a typical motive power
cell of the tubular design.
Figure 2
Call-outs as follows:
1. Positive Post 07. Separator
2. Negative Post 08. Vent Cap
3. Positive Plate 09. Jar
4. Negative Plate 10. Cover
5. Negative Grid 11. Bridge
6. Positive Spine 12. Vent Well
6. INSPECTION OF THE
BATTERY UPON RECEIPT
a. Examine for physical damage or loss of electrolyte.
b. Report actual or suspected damage to carrier.
c. Give battery an equalizing charge. (See Section 13.)
d. Check electrolyte levels IMMEDIATELY after charge and
add water if needed.
e. When adding water, the electrolyte height should be as
specified in Section 17.
7. MOIST/DRY CHARGED
BATTERIES
1. Moist charged batteries are electrically live upon receipt, even
before filling with electrolyte. Do NOT lay any metallic objects on the
battery.
2. Moist charged batteries or cells should be activated (unsealed,
filled with electrolyte and charged) only when ready to be placed in
service. Until ready for use, they must be stored in a cool, dry,low
humidity location with the pressure relief valves/vent plugs tightly in
place. Moist charged cells must be activated within 24 hours of the
loosening/breaking of the seal of the pressure relief valves/vent plugs.
CAUTION: IF THE EXISTING VENT PLUG HAS A LABEL
MARKED “DO NOT REMOVE”, STOP ALL ACTIVITY AND
CALL YOUR LOCAL ENERSYS REPRESENTATIVE.
3. To prepare for use carefully remove the sealed PRV
(pressure relief valve) using an approved tool or if necessary a
widegrip pliers, taking care not to damage the cell vent well
exteri-or. THROW AWAY THE PRESSURE RELIEF
VALVE/VENTPLUG. Fill all cells with electrolyte 0.015 sp. gr.
lower than the nominal operating gravity.
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4. Give the battery an equalizing charge but keep resetting
the charger to the equalize position until the specific gravities
remain constant for a period of three hours. At no time should
battery temperature be allowed to exceed 110°F (43°C).
5.At the completion of the charge, the specific gravities of all
cells corrected to 77°F (25°C) should be as specified on the
battery nameplate or shown in Table 3. If the specific gravity is
higher, remove some electrolyte and replace with water; if
lower, remove some electrolyte and replace with higher specific
gravity electrolyte. Any specific gravity adjustments should be
made with the charger on equalize in order to mix the
electrolyte properly. Removed electrolyte must be disposed of in
strict accordance with all environmental regulations. CAUTION:
ELECTROLYTE CONTAINS SULFURIC ACID WHICH CAN
CAUSE BURNS AND IS CORROSIVE.
6. Upon completion of the above steps, apply a standard vent
cap to all cells.
8. INSTALLATION OF
BATTERIES
a. The battery compartment in the vehicle should be ventilated
and designed in a manner to keep out water, oil, dirt and other
foreign matter. Drainage holes should be located in the floor of
the battery compartment. Consult with your vehicle dealer if
any question arises.
b. When lifting the battery, use an EnerSys PRO Series
Adjustable Lifting Beam which exerts a vertical pull on the
lifting tabs only.
c. The battery should be blocked, not wedged, to allow 1/8"
minimum clearance on all sides for easy removal from the
battery compartment.
d. During transit and storage a battery may have lost some of its
charge. Give it an equalizing charge before putting the battery in
service. (See Section 14.)
e. If any connections on the battery itself are bolted together, make
them clean and bright, using care not to remove the lead coating
from any lead-plated copper parts. Coat the surfaces to be bolted
together with No-Oxide grease. Due to vibration, handling and
heating during operation bolted connections loosen over time.
Re-tighten them at least twice yearly using an appropriately set
torque wrench.
No intermediate “taps” or connections should be made at other than
the main terminal of the battery. Any lower voltage device should
be supplied through a series resistor or from a separate source.
Any such device connected to an intermediate point of a battery
and/or overcharging the remainder can void your warranty.
TAPPING THE BATTERY SHORTENS ITS LIFE BY UP TO
THREE YEARS.
f. Storage - see Section 21.
9. FAST CHARGING AND OPPORTUNITY
CHARGING PROCEDURES
If a single battery is being used in a lift truck for multiple shifts or is
partially recharged during breaks, lunches, and other idle periods, it
may be in a fast charge or opportunity charge mode of operation.
Opportunity charging can be used to keep the battery’s state of
charge above 50% during the daily discharge cycle thereby allowing
the battery to maintain higher voltages during the shift and improve
truck performance. The total accumulated discharged ampere-hours
should not exceed 80% of the batteries designed capacity rating.
Discharge of more than 80% of the batteries designed capacity
rating in a 24-hour period will shorten battery life. If engaging in
opportunity charging, the battery must be returned to nameplate
specific gravity at least once per week. However,more frequent
recharges to nameplate specific gravity is desirable. Charge rates
during opportunity charging should not exceed 25 amps per 100
amps of a battery’s nameplate capacity. Under the opportunity
charging procedures outlined in this paragraph, standard battery
warranties apply.
Fast charging is intended to extend a battery’s run-time diring a shift
or day. A typical fast charging system will provide charge rates from 25
to 50 amps per 100 amps of a battery’s nameplate capacity. Fast
charging requires special chargers that can monitor and manage
battery temperatures during charge, assure a battery is recharged to at
least 90% state of charge on a daily basis, and provide an equalizing
charge at least once per week. Also, a fast charge battery should be
designed to accept higher charge current and to manage heat that
may be created by higher charging rates. A fast charge system,
including the battery and charger, should be designed to accept no
more than 160% of the battery’s 6-hour capacity rating on a shift day.
Under fast charging procedures outlined in this paragraph, fast
charging warranties apply.
Consult your EnerSys representative to avoid problems or very short
battery life.
10. OPE RATION
a.Full charge gravity of a new battery will be specified on the
nameplate located on the side of the battery tray. Full charge gravity
will be affected by temperature, acid level, and battery age. If acid is
lost from overfilling, full charge gravity and capacity will be lowered.
b. Under normal conditions, only add water. NEVER add acid or
other solutions to the cells.
c. Keep the plugs and receptacles in good condition. When
disconnecting battery from the truck or charger, pull on the receptacle
not the cable.When disconnecting from a charger, assure that the
charger is off first otherwise arcing will result. Arcing can cause battery
explosion, sulfation damage to connector contacts, and charger
components.
11. TEMPERATURES
a. Low Temperatures. The capacity of a storage battery is
reduced at low temperatures due to the increased viscosity
and resistance of the electrolyte. An approximation of this
reduction in capacity for batteries of these types is shown below.
TABLE 1
Internal Temperature of Cell (°F) Percent Capacity
77 100
60 095
40 087
20 073
This, of course, refers to the actual temperature of the cell and not
the ambient temperature. Thus a battery may be operated in quite
low ambient temperatures for short periods without the actual
battery temperature falling to a point where the capacity is seriously
curtailed. For example, batteries used in cold storage plants or
similar locations will deliver close to normal capacity if they are
moved into warmer areas for charging and whenever not in
actual use.
Low temperatures also increase the battery voltage on charge,
resulting in lower charge currents, and a longer recharge time.
Undercharging could occur unless charger adjustments are made
to compensate for it.
There is little danger of freezing of the battery electrolyte in
temperate climates unless the battery is completely discharged.
At the temperatures shown in the following table, the electrolyte
will not freeze unless the specific gravity is lower than indicated.
TABLE 2
Battery
Specific Gravity Freezes @ or Below
(Corrected to 77°F) Degrees F.
1.080 +20
1.130 +10
1.160 0
1.180 -10
1.200 -20
1.215 -30
1.225 -40
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Insub-freezing temperatures, water should be added just
before charging is completed to insure prompt mixing
with the electrolyte. Otherwise it may freeze on the surface
before mixing. No permanent harm results from low
temperature operation as long as freezing is avoided.
b.High temperatures have an adverse effect and all
practical means should be employed to keep the battery
temperature at normal values:
-Avoid overdischarging
-Charge in cool location
-Supply ample ventilation during charge by always opening
battery compartment or battery cover and circulating air by
fans if necessary
-Allow battery to cool down before starting charge.
The effect of temperature on battery life on any lead acid
truck battery is shown below.
AVERAGE LIFETIME BATTERY TEMPERATURE, °F
Figure 3 - Temperature vs. Battery Life Curve
EXAMPLE: If the average lifetime temperature of the battery
is 100°F,it will result in a battery life of
approximately 53% as compared to 100% at
77°F.
12. DISCHARGE
CHARACTERISTICS
a. In general, a battery may be discharged without harm at
any rate of current it will deliver,but the discharge should not
be continued beyond the point where the cells approach
exhaustion, or where the voltage falls below a useful value.
b. Discharging at a constant current value, the initial voltage
will depend on the rate of discharge and the normal
characteristic of the cell. As the discharge continues, the cell
voltage will slowly decrease during the first 70 to 80 percent
of the total time period. It will then fall more rapidly, passing
over the “knee” of the curve to the “final” voltage as full time
and capacity are reached. This “knee” is more pronounced
at low rates of discharge.
c. During discharge there is normally a rise in battery
temperature, depending on the ambient temperature, on the
rate of discharge and the type of battery assembly from the
standpoint of heat dissipation. The higher the ampere dis-
charge rate, the greater the temperature rise effect. During
discharge, a battery’stemperature will normally rise. The
speed and magnitude of this temperature rise is dependent
on the following conditions:
-ambient temperatures
-battery design and layout,
-and battery discharger rate.
Batteries subject to high discharge rates will
incur higher temperature increases.
d.As mentioned, a battery should not be discharged beyond the
point where the cells approach exhaustion. This is
referred to as “overdischarging” and can have very harmful
results, particularly if repeated for several days or cycles.
Overdischarge can be avoided by using a lift interrupt device.
When installed on the vehicle, the lift interrupt device gives a
constant readout of battery condition and locks out the lift
mechanisms as the battery approaches 80% depth of discharge.
TABLE 3
SPECIFIC GRAVITIES @ 77°F
Cell Type Fully Charged 80% Discharge* 100% Discharge*
E-55L 1.315 1.160 1.120
E-75L 1.315 1.160 1.120
E-75 1.280 1.160 1.130
E-460 1.280 1.140 1.105
E-85 1.280 1.150 1.120
E-85D 1.280 1.140 1.110
E-100 1.315 1.155 1.115
E-100X 1.280 1.130 1.090
E-110 1.315 1.155 1.115
E-100D 1.280 1.145 1.115
E-125 1.280 1.140 1.105
E-125D 1.280 1.130 1.100
E-140 1.280 1.140 1.105
E-140X 1.280 1.140 1.105
E-155 1.315 1.150 1.100
*These values are for discharging at the 6 Hr. rate, read immediately
at the completion of the discharge and corrected to 77°F.
13. CHARGING EQUIPMENT
a. Battery charging should be accomplished with an
electronically controlled charger.
b. When the discharged battery is placed on charge, the
battery will draw a relatively high current which will be at or
close to the capacity of the charger. Within a few minutes,
the current will adapt itself to the state of discharge of the
battery,remaining high if the battery is considerably
discharged or decreasing to a low rate if the battery is only
partially discharged. The charging rate should be controlled by
acontrol unit.
c. When charging any industrial battery, only use an approved
charger that is capable of returning a discharged battery’s
specific gravity back to it’s nameplate rating within an 8 hour
period. Several chargers offered by EnerSys will accomplish
this requirement. Some charger technologies, such as
ferro-resonant, will not adequately charge and EnerSys
Ironclad tubular battery and will result in undercharging and
short life. Please consult an EnerSys representative for more
information.
d. Although a number of chargers meet the mentioned
general requirements above, not all chargers are equal.
Contact your local EnerSys representative for more details.
5
PERCENT OF NORMAL BATTERYLIFE
(100% AT 77°F)

14. CHARGING
CHARACTERISTICS
a. Only EnerSys approved charging methods should be
used. To maximize life, charging should not result in
excessive gassing during the initial stages of charge. In
addition, the charging method should keep end-of-charge
temperature below 110˚F.
b. Every effort should be made to ensure that the battery
receives the proper amount of charge. Consistent undercharge
and/or excessive overcharge will contribute to internal battery
problems with a loss of capacity and reduction of life.
c. 1. Sulfation - Residual sulfation remains in the plates
ifthe battery is not fully charged to nameplate specific
gravity or allowed to remain partially discharged for an
extended period of time. This results in reduced
performance and life. All motive power batteries must be
returned to nameplate specific gravity at least once per
week. However,more frequent recharges to nameplate
specific gravity is desirable.
2. Stratification - Caused by insufficient gassing at end of
charge. Little or no mixing of electrolyte will thus create a
higher concentration of electrolyte at the bottom of the cell
compared to the top. This will eventually lead to sulfation
of the bottom of the negative plate with subsequent fall off
of performance and capacity.
d. Overcharge
1. It is uneconomical from a power standpoint and wastes
electrical energy while running the risk of permanent dam-
age to the battery.
2. Excessive gassing, producing hydrogen and oxygen,
not only increases the frequency of water additions to
the battery but also increases an explosion hazard
significantly over normal and safe charge conditions.
3. It creates dangerously high battery temperature which
significantly shortens normal battery life if repeated
instances occur above 110°F. (See Figure 3 in Section 11.)
Higher temperatures, that is 15-20°F above the maximum
allowable temperature at the start of the charge, tend to
reduce the battery voltage on charge permitting higher
current flow from the charger and further raising the cell
temperatures. Battery temperature at the end of charge
should not exceed 110°F. To assure this, batteries should
not be put on charge above 90°F.
Should excessive battery temperature occur with some
frequency, contact the EnerSys Service Center nearest
you (see back page) for an analysis of its cause and
charger output adjustment, if necessary.
4. Unless charging under an opportunity or fast charging
method as described in Section 9 of this manual, make
sure the battery is not being charged more then once per
day. When the battery reaches full charge, the charge
should be stopped. No amount of overcharging can
increase battery capacity.
e.When charging batteries while they are in the vehicle,
assure proper ventilation and follow the manufacturers
instructions. Open the battery cover, if so equipped, as well as
the battery compartment cover of the vehicle. Not following these
recommendations can cause gaspockets to remain in the vehicle
or battery giving rise to possible explosions when the vehicle is
put into use.
f. Extra care spent in proper charging is effort well worth it in
trouble free battery performance, reduced maintenance and long
battery life. For information regarding charging room
layouts, refer to EnerSys Form 8041.
g. Equalizing charge. It is necessary that a battery be brought
toastate of full charge in order to avoid excess sulfation, yet
appreciable overcharge must also be avoided.
1. Light Depth of discharge (50% or less) equalize bi-weekly.
2.Medium Depth of discharge (60%) equalize weekly and
recharge every 48 hours.
3. Heavy Depth of discharge (80% or greater) or battery
temperature exceeding 100°F equalize weekly, but allow
sufficient time for battery temperature to drop below 100°F.
15. MAINTENANCE AND
RECORDS
Specific records should be maintained for each battery in
your fleet. These records will provide a means of identifying
batteries which may need repair adjustment, charger
problem or which have reached the end of their useful life.
Such records also help assure warranty protection.To assist
your record keeping, EnerSys has developed Form 5847
(see sample on page 16 of this manual). You may copy
Form 5847 to establish your own “Battery Log Book.”
a. Where more than several batteries are in use, each one
should be identified with a permanent number assigned
when received. That number should be plainly painted or
stamped on the battery. If a large number of batteries are
involved, including several sizes or types, various groups can
be given prefixes or suffixes to identify size, voltage or shift.
b. After each battery is received and equalized, record the
corrected specific gravity of each cell. This serves as
reference for comparison with later readings.
c. In a new application the depth of discharge should be
checked for several weeks to determine whether it is within a
safe range. This is done by reading the specific gravity of a
particular cell (or cells) at the beginning and end of the
discharge. This daily discharge should not exceed 80% (see
Table 3). If final corrected specific gravity is below 80%, there
is a problem. Call your vehicle dealer or local EnerSys
representative. The “pilot cell(s)” used for such purposes
should be changed at monthly intervals, as frequent
hydrometer readings may noticeably reduce their specific
gravity through inadvertent losses.
d. While the record sheet can accommodate daily specific
gravity readings for up to a month, EnerSys recommends
quarterly specific gravity readings once the duty cycle and
depth of discharge meet the criteria contained herein. When a
gravity reading indicates an irregularity, then more frequent
readings can be initiated. The final determination for frequence
of hydrometer readings should depend on your past
experience and advice from your local EnerSys representative.
6

16. DETERMINATION OF
CAPACITY
a. A battery's capacity will, of course, decrease toward the
end of its life. Assuming no specific cause of trouble, this
will be a gradual decrease and ample warning of limiting
capacity will be evidenced by the slowing of the truck or
other vehicle toward the end of the day's work.
b. A battery is usually considered to be at the end of its
usefulness when its capacity decreases below 80% of
normal rating. However, it can sometimes be transferred to a
smaller job and thus give additional life and service.
18. WATERING
a. Use only approved water. That is 1) distilled water; or
2) de-mineralized water; or 3) local water that has been
approved for use in batteries. Never add acid, commercial
additives or other foreign material to the battery. Addition of
acid, commercial additives or foreign material may void
your warranty.
b. If there is some doubt as to whether the water being
used is suitable for use in lead-acid storage batteries, an
analysis should be obtained from a qualified laboratory,
otherwise, distilled or deionized water should be used.
Deionized water is available by using the EnerSys
PRO Clear Deionizer #94866.
c. Table 5 shows the maximum allowable impurities.
d. An EnerSys Watering Gun is a convenient and accurate
tool to aid in watering as it fills to a pre-selected height and
automatically shuts off; however, care must be taken to
adjust the watering gun so it will water cells to levels in
accordance with Figure 6.
c. Since the average motive power battery passes a “test”
every day by performing its regular work, it is seldom
necessary to conduct a formal test of its capacity. Also, most
users do not have the facilities to do this conveniently or
accurately. If any such testing is desired, consult your EnerSys
Representative regarding equipment and procedure.
17. TROUBLESHOOTING
The following conditions are usually indications of
approaching trouble.
*Contact your local EnerSys Service Representative
CONDITION CAUSE SOLUTION*
Unequal or low specific gravities a. Electrolyte spillage during watering a. Avoid overwatering, neutralize & clean.
b. Electrolyte flooding b. Water cells during end of charge.
c. Insufficient charge c. Extend charging time.
d. Internal short d. Replace cell.
Excessive water requirement a. Overcharging a. Select a properly sized charger.
Check charging time and average
battery temperature.
b. Jar leakage b. Replace or repair cell.
Excessive cell temperatures a. Overcharging a. Check charger size and charging time.
b. Battery overworked b. Reduce to one cycle/day or 300/year
maximum.
c. Battery being charged more than c. Reduce charging to once per day.
once per day.
d. Battery temperature too high at d. Allow battery to cool down before
start of charge. starting charge.
e. Shorted cell(s) e. Replace defective cell(s).
Poor truck performance a. Battery undersized a. Install higher capacity battery.
b. Undercharged battery b. Extend charging time.
c. Discharge indicator malfunction c. Reset discharge indicator for 80%.
d. Defective charging connector d. Replace or repair cable and/or
connector.
e. Excessive loss of electrolyte e. Adjust gravities at state of full charge.
Check for leakage.
7
Maximum
Allowable
Requirements Limits
Total Solids* 350.0
Fixed Solids* 200.0 Parts
Organic and Volatile* 150.0
Iron 4.0 Per
Chloride 25.0
Ammonium (NH4) 5.0 Million
Nitrites (NO2) 10.0
Nitrates (NO3) 10.0 (P.P.M.)
Manganese 0.07
Calcium and Magnesium 40.0
TABLE 5 - WATER IMPURITY CHART
*ASTM Spec. D-1888-67 Method A, or equal.
TABLE 4 - TROUBLESHOOTING CHART

e. Another convenient way to ensure proper fill levels is the
use of a single point watering (SPW) system. The EnerSys
Battery Irrigation System or EZ Fill System are effecient
methods of watering a battery. These reliable quality
systems allow the operator to fill to the proper level each
and every time.
f.Water should only be added to the battery when it is near
the end of charge and gassing or as closely as possible to
the end of charge time. As the electrolyte is at its maximum
level during this time, it is a certainty that the leve
established by the addition of water will not be exceeded at
any other time and overflow of the electrolyte (flooding) will
never occur. Fill to 1/4” below the bottom of the vent well at
the end of charge. See Figure 6 for details.
g. It is often inconvenient or impossible to be present at the
end of charge to perform watering. In this case, it is
recommended that the battery be watered as soon as
possible after the termination of charging, as in this way
levels will still be near the maximum and the danger of
over- or under-watering is minimized. Fill to the lower limit in
this case.
h. In Motive Power Service the real need to add water may
vary from weekly to quarterly depending on application,
battery temperature, and battery design. To extend this
interval to the maximum period possible follow these steps:
1. Adjust cell filler to fill to maximum possible height.
2. Water while battery is on charge and gassing.
3. Do not add water until actual visual inspection shows
top of separators/plates is visible.
4. A Battery Water Monitor is an excellent way to indicate
when water is needed.
5. Once a repetitive routine is established, water your
battery at that interval.
i. Should the battery start to use excessive water look for
any of the following problems: charger not shutting off
automatically, charging rate exceeds rate on battery
nameplate, one cell shorted or weakened.
j. Caution - Avoid overfilling as it will cause overflow
(flooding) of electrolyte resulting in loss of electrolyte, tray
corrosion, ground paths, and loss of capacity or working
ability.
Figure 6 - Sketch showing permissible high and low
limits of electrolyte level. High level marker indicates
proper level immediately after charging. Low level
marker indicates immediately after charging watering
is required.
19. CLEANING
a. Check the battery for cleanliness at regular intervals.
When necessary,dust or other material which has
accumulated should be removed by cleaning the battery.
b. Electrolyte spilled on the battery cell covers, trays or
battery compartment, never dries or evaporates. It causes
grounds and corrodes any metal parts. For light cleaning,
regular use of a neutralizing cloth such as PRO Wipes
#853638 may help remove these harmful deposits.
c. To both clean and neutralize your battery use EnerSys
PRO Wash Cleaner/Neutralizer #94883. This spray on
premixed cleaning solution changes color as it neutralizes
electrolyte or acid. Use this cleaner or bicarbonate of soda and
water (1.0 lb./1.0 gal.) any time you see electrolyte on the
battery top. (MAKE SURE VENT PLUGS ARE IN PLACE
WHEN CLEANING OR NEUTRALIZING YOUR BATTERY.)
If any corrosion exists on metal parts of the tray or
compartment, clean as above and repaint with acid-resistant
paint.
d. For large installations a “washstand” should be provided
with water hose and adequate drainage. It should include a
container for the cleaner, brushes, etc.
A periodic washing is recommended at least twice yearly. A
clean battery is an indication of good maintenance and
increases battery life.
e. Be sure to keep vent plugs in place and tight at all times,
to avoid loss of electrolyte due to gassing or spillage. The
gas-escape holes in the vent plugs should be examined to
see that they are not clogged with dirt. Wash all vent plugs
yearly or as needed by immersing in a bucket of water and
wiping clean.
20. ADJUSTING SPECIFIC
GRAVITY
Acid or electrolyte should never be added to a cell without first
making sure that charging will not restore the gravity to normal
values. Therefore, a cell or a battery should first be given a
thorough equalizing charge. See Section 14.g. The equalizing
charge should continue until there is no change in specific
gravity for 3 consecutive hourly readings. Never make a
gravity adjustment on a cell which does not gas freely on
charge.
If after the equalizing charge, the specific gravity (corrected for
temperature) of any cells is lower than the normal gravity
shown on the nameplate or in the instruction book, the specific
gravity of the low cells should be adjusted to normal in the
following manner:
a. Put battery on charge again at the finish rate, so as to have
the cells gassing for thorough mixing. Make sure all cells are
gassing before starting a gravity adjustment.
b. From the low reading cells draw offelectrolyte down to the
splash cover. Replace slowly with electrolyte of 1.400 specific
gravity.NEVER USE ACID OF HIGHER SPECIFIC GRAVITY
THAN 1.400. In adding acid to the cells, pour it in slowly.
c. Wait 20 minutes for the added electrolyte to become
thoroughly mixed by the gassing charge and then read the
specific gravities. If the gravity of any cell is still below
normal, repeat the process. Repeat as many times as
necessary to restore gravity to normal. When gravity has
apparently been adjusted to within the proper limits, continue
the charge at the finishing rate for an additional hour for
thorough mixing of the electrolyte.
d. If the corrected specific gravity of any cells is higher than
normal, proceed as follows:
As the battery charges, withdraw from the cell a small amount
of the electrolyte and replace with water, repeating at
20-minute intervals, if necessary, until the desired reading
is obtained.
On completion of the gravity adjustment, record the voltage of
all cells while still on charge at the finishing rate, and then stop
the charge. In about 20 minutes after stopping the charge
record the gravity of all cells and the electrolyte temperature
of at least two or three cells.
8
1/4” BELOW
VENT WELL

i.EnerSys Pro-Meter #94870. This shirt pocket sized
meter is versatile for 13 ranges in AC, DC and OHM readings.
Ithas an audible continuity signal and is accurate to 0.75%.
Ideal for the person who wants to do basic battery
orcharger troubleshooting.
j. EnerSys Battery Lifting Beam. Adjusts to fit batteries from
28" TO 43" long. Necessary in any shop where batteries are
charged or where the user needs a safe method to lift the
battery out of the vehicle.
k. EnerSys Portable Watering Cart #502056. Our portable
watering cart is ideal for locations with no pressurized water or
where a method is needed to quickly water batteries with
distilled water. Cart comes complete with DC motor, battery,
charger, and 10 gallon tank.
23. TOOLS
BURN CUTTERS
9
1. BURN CUTTER 3/4 IN. - cat. #41039
2. BURN CUTTER 1 IN. - cat. #80298
HYDROMETERS
a. EnerSys Hydrogen Detector #801550.
*1. SHORT STEM Sp. Gr. 1100-1300 - cat. #13142
*a. FLOAT - 1100-1300 Sp. Gr. - cat. #13090
*b. FLOAT - 1050-1380 Sp. Gr. - cat. #84599
*2. LONG STEM Sp. Gr. 1050-1380 - cat. #84598
*a. FLOAT-1050-1380 Sp. Gr. - cat. #84599
*b. BARREL - cat. #84600
*3. LONG STEM Sp. Gr.1100-1300 - cat. #81332
*a. FLOAT - 1000-1300
*NOT SHOWN
SERVICE TOOLS
NOTE: Specific gravity changes with temperature. Normal
values are at 77°F . This should be kept in mind
when reading specific gravity and proper correction
should be made to judge normal values. For each
3° above 77°F ADD 0.001 to the measured Sp. Gr.
For each 3° below 77°F SUBTRACT 0.001.
21. STORAGE OF
BATTERIES
a. Batteries should be stored in a clean, cool, dry and well
ventilated location away from radiators or heating ducts,
etc., and protected from exposure to direct sunlight.
b. Before storing, it is necessary that the battery be fully charged
and the electrolyte at the proper level. Disconnect
leads or cable connections to prevent use or possible
added loss of charge during prolonged storage period. Do
not remove electrolyte or dismantle the battery.
c. If storage temperature is 80°F or higher, check gravity at
least monthly, if 50°F, or lower, every two months. Whenever
gravity falls to about 1.240 or below, give equalizing charge as in
Section 13.g and also before returning to service.
22. ACCESSORIES
Certain Accessories (tools) are necessary or desirable for routine
work in the charging room. We feel the following are the minimum
number of tools for every charging room.
a. EnerSys PRO Alarm Hydrogen Detector #801550. This alarm
will monitor the hydrogen emitted from batteries while gassing
during charge, and provide for ventilation and warning before
explosive levels are reached (as the National Fire Protection
Agency recommends).
b. EnerSys Hydrometer #13142 (up to 1.300 Sp. Gr.). These
devices accurately and quickly measure the concentration of acid
in the electrolyte. Required to properly check full recharge, depth
of discharge or freezing points as shown in Tables 2 and 3. Special
floats available for different specific gravity scales.
c. EnerSys Thermometer #88330. Quickly takes the internal
temperature of single cell. Assures that you have a method to
check that charge temperatures have not exceeded 110°F (see
para. 10.a).
d. EnerSys Watering Guns EZ Fill #50092755 or PRO Fill #92755.
This tool allows manual pre-selection of internal watering height
and when connected to a standard pressurized watering system
automatically shuts off water flow. Flip Top Vent Cap #811112
makes watering a snap when used with watering guns.
e. EnerSys PRO Wash Light #94883-4QT.This unique
cleaner/neutralizer solution is a pre-mixed liquid in a spray bottle
which neutralizes spilled electrolyte (acid) as it cleans and
degreases your battery.In addition, the liquid turns from red to
yellow giving a positive indication any corrosive acid has been
neutralized.
f. EnerSys PRO Safety Kit #85879 provides all the personal
protective equipment necessary to satisfy OSHA regulations.
g. EnerSys PRO Clean Battery Maintenance Kit #85363 and PRO
Wipes #85368. These products will help to maintain a clean
battery.
h. EnerSys Emergency Spill Kits meet OSHA requirements
1910.178 (g)(2). Available in three convenient sizes: 853610 30
gallon, 853615 15 gallon, or 853620 6 gallon.
OTHER OPTIONAL ACCESSORIES:
Other tools may be needed in your operation because of the way
your company uses batteries. EnerSys also offers the following:
i. EnerSys Pro-Meter #94870. This shirt pocket sized
meter is versatile for 13 ranges in AC, DC and OHM readings. It
has an audible continuity signal and is accurate to 0.75%. Ideal for
the person who wants to do basic battery
or charger troubleshooting.

SERVICE TOOLS
0*1. CELL LIFTER - Belt type cat. #SS-5746
*02. CROSS LINK PUDDLING DAM - cat. #SS-5749
*03. CABLE LUG PUDDLING DAM - cat. #SS-5747
0*4. CONNECTOR PUDDLING DAM - cat. #SS-5745
(2 hole)
*05. CONNECTOR PUDDLING DAM - cat. #SS-5745-1
(4 hole)
*06. CONNECTOR PUDDLING DAM - cat. #SS-5745-2
(4 hole)
*07. CONNECTOR PUDDLING DAM - cat. #SS-5745-3
(4 hole)
*08. POST BURNING RING DAM - cat. #SA-60485
*09. BURNING DAM - cat. #SS-60321
*10. TOTE WELD OUTFIT - cat. #TW840-4474
*11. PORTABLE PLASTIC WELDER - cat. #Vari-FL-SFT
*12. CELL PRESSURE TESTER MP - cat. #83763
*13. PLASTIC WELDING ROD 1/8
*14. PLASTIC WELDING ROD 5/32
*15. CELL PULLER Pos. 76669
*16. CELL PULLER Neg. 76670
*NOT SHOWN
10

™
Section 28.00 Rev. H 11/06 © 2006 EnerSys All Rights Reserved.
Trademarks are the property of EnerSys and its affiliates unless otherwise noted.
Grafika
2366 Bernville Road, Reading, PA19605
1-800-EnerSys
www.enersysmp.com
[email protected]
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9000
™