THE ASSOCIATION OF AMERICAN BATTERY MANUFACTURERS ‘The Association of American Battery Manufacturers had its beginning in 1924 and has served the automotive industry +0 constructively that today it includes in its active membership the most important battery manufacturers in the United States, aswell as many others in countries throughout the world, ‘The public interest is admirably served by the Association through the sound policies established by its members, These policies have encouraged high standards of battery quality, have established fair and lawful practices in sales and service and have fostered improved safeguards for the health and economic welfare of those engaged in the manufacture of storage batteries. In addition to the Active Membership of battery mamufac- turers, the Assaciation includes ax Associate Members a large group of companies engaged in the distribution, sale and servicing of batteries as well as a group who supply the ma- terials related to storage buttery manufacture. The Associa- tion can therefore be said w be truly representative of the entire Storage Battery industry.2 ee ATTERY SERVICE MANUAL SIXTH EDITION PUBLISHED BY THE ASSOCIATION OF AMERICAN BATTERY MANUFACTURERS HEADQUARTERS: 19 NORTH HARRISON STREET, EAST ORANGE, N. J. 07017FOREWORD ‘The Association of American Battery Manufacturers presents this Re- vised Sixth Edition of the Battery Service Manual wi onsiderable pride and the hope that it will be useful in solving many of your probs lems. It represents the best t ng of the most capable engineers in battery industry. It is authori is simple—it is under ndable, indebted to the Technical Committee of our Association, and particularly those who have uridertaken the resp lity for preparing and revising this M. al to keep it abreast of the many battery in rovements and refinements as they develop. They have performed a tedious, time-consuming: task in an outstanding manner. Our sincere appreci fon is extended to cach and every one of these extremely capable Battery Engineers THE ASSOCIATION OF AMERICAN BATTERY MANUFACTURERS, INC.BATTERY CONSTRUCTION TERMINAL POSTS VENT PLUGS SEALING COMPOUND rune CONNECTOR NEGATIVE PLATE ELEMENT RESTS # Sve a = ee SEPARATORS SEDIMENT SPACE E PLATEThe ead far sering. enceEy eased as ele PARTS OF A BATTERY 2voll The parts of abecel, and, ‘are labeled far ident frie acid electrolyte i part i BATTERY CONSTRUCTION LEAD-ACID BATTERY DEFINED aitery ie an electrochemical chemical form s0 that it ean be te re illustrated in Fig. 1d reference. The sub CHEMICALS USED ‘There are four eswntial chemicals in a battery. ESSENTIAL. FOUND CHEMICALS ELLS Lead Peroxide tive Plates Sulfurie Avid trolyte Water cls Lend ive Plates GRIDS plates of a lead-acid storage Fig. 2—Positive pl attery consist of un elec: [Framework i the meshes of whieh 1 by cletro-chemical mt ta anal fe with part of active meteril to show grid structure. POSITIVE PLATES Positive platca are filled with lead peroxide active m ‘This ic a dark brown crystalline wa i very small particles, disposed so as to provide a Nigh degree of porasity in order to allow the electrolyte to ppenctrale the plate freely. See Fig. 2. NEGATIVE PLATES t Negative plates, Fig. 3, ate filed with # porous:mass of Teall in spongy farm, which electrolyte cam penetrate freely. The active material alan contains sa ealled “expanders” in prevent the sponge lead from contracting. and 10 the dence inactive state during the Life of the Microporous Bushing Attached.SEPARATORS [No positive plate may touch = negative plate or ee all the Pines inthe call will love that stored emcega” Thin sheets Sf non-conducting roan satel called 9 4, must therefore be inserted between the plates, ‘Thes sluste resin. inpreghated cellulose Biber types, also a pordus ber and Sebinntia the side facing the posi clume nett Ue’ pos ‘and to feciitte acid circa: leo. minimise the aren of ntact withthe positive plate which has a highly oxidizing secon st sprain Glo i inter a ate sometimes placed between the postive plate nnd the sepa tator to retard the lou of active material fd te protec he separator fom wxation. ELEMENT CONSTRUCTION In one method of construct plates are welded together, Pig. and the negative plates ire: si negative group. The tw cated in Fig, 5 plates with the positive plates ing a oups are pul together as indi- parators are thee inserted Between the owed Fares of the eeparatets next to the Ins second method af comtrstion, a stack, of aerate Ponies ard wegaive plate, Wiha separator between cock Plate fs bot up, wth the rooved faces of the separator dain In contact withthe porte pats. The fuga tet of plates are then welfed together as shown’ Fig, 6 Each group of platens prone with pst far connedting the laments serene the bay. “Tae taupe of plats anerabled with separators, prepared by her method, are called an “stement” Fig. 6. One ede ed per el. : Vig a | r za S—Negstive ond Positive Grow (Groups of 11-Plate Element). SS Fig. 6—Assombled Element (Assembled 11-Plate Element). There-may be any desired number or sine af plates osed én an element. depending pom how mach energy te to. be Sorel Iu thee i always one more negative plate than there are positives for reasons of muproved petformante, The greater the plate surface area used per elen higher willbe the voliage daring and Tow teriperatures Tiomever, the open circuit vollage of 9 fully charged sell 1 what the site of the eel or the member of plates inthe element, i only litle over 2vcls, The battery volt age is the sm of the vollage of Tis cells, ELECTROLYTE ‘The sponge lead and lead perowide which fill the respective plates ave referred to as the “active” materials of the bat. tery, Kut these rnsterials cannot become active until. they are covered by a water salution of aulfurie acid called the “electralste.” The sulfuric acid of the clectrolyte supplics the sulfation. which tin each of the plate materials and rel -lesteical energy. The sulfuric acid electrolyte is also the carrier for the alee. tele current inaide the battery: Between the positive and negative plates through the separators. The anttmonial lead alloy of the grid frazpework ofthe placs carries the electric 19 and from the active materials ta the outside ‘The electrolyte of a fully-charged battery usually eomtains shout 36% rafurie ack by. weleht-or about 257 by valk ‘ume. This carresponds to a specific gravity of 1.270 ‘at a po specific gravity ‘CONTAINER Jor automotive batteries are of the one piece ig 7, and are uranly made of hard rubber, ‘of bitunineus composition. These rnast withstand Extremes of heat and caidas well es mechanieal shot and tis Be resistant to the absorption of acid In the botiost 5 molded type, plray te show partitions and oloment rests. clement rete or i. plates are provided with stub feet on th the feet of the positives sit on Balers | of the negative plates sit om bridges 2 ‘mizes the danger of short circuits duc to sedlisient which falls from the plates onto the bridges wbece the plates res ischarging and charging of a battery seill tha ale ie the ive materia ae. bee te fal cn between the brid the cient epaces the life of the cal x naterial will gradually i een te tattery, The battery min af ve and negative plates ancl wil and rtetin of hag of ‘shoud te ke tion containers as they wi ‘avy [rom bitaminons eu ‘often the bituminous bind CELL COVERS AND VENT PLUGS Cell ed hard eri iy Ferthewo peas aed the I thick prorade through the cover. Th Vided with vent openings of va ‘constructions, ‘There are three types of onepiece cover hattery construe nolded in covers with mpi m2), ected for ell cor 6 Fig. 8—Ce plugs of rarious designs cooperate with ie to hfe the gases and electrolyte rl against the underside af the caver, to prevent lose i acd irom the elle CELL CONNECTORS In ler to connect the cells off» battery in series, the ele- iments are placed in ¢gel cell 2 tat the negative termine of one eell will be adjacent to the fest cell and 0 on throughout the Fig. 10, are placed over the protruding cell tor snd welded oem to connect the ais ne rust be hear « {or starting, without overbeating I pos = Coanettne ie igh carr required Fig. 9—One-Piece Battery Covers.Fig. 10—Various Cell Connectors, ction techniques have been slevetoped whereby cells are connected in series through the partitions oF over PART CHEMICAL ACTION OF DISCHARGE When » discharged by completing an external on the igh, the nd negative plate active materiale to fore sew henizal compound called lat sulfate, The salfae i Sap. ied by the acid soluion (eeetrolyr¥, which brooms weaker in copoesication ne the diechayge proseeths The mount of sei consumed in im dinect proportion ta the mount of electricity remoned from the cei When the eid ams ree srscnano the top of the partitions prior to placing the ever on the attry. This type of construction provides an acid seal between ceils and isa shorter conection ‘minionum voltage lose, TAPERED TERMINALS Atomotive batter: terminate are of special design, bein tapered to specified dimnrain in accordance wih stand ands agreed pen by the indart i penitive and feguve cables srcspuadiog battery crminalsterchangeably. ‘The postive terminal slighty larger (88, diameter at the“op than the nega tive terminal (4 ameter at the danger af intalling » battery length of taper is specified ax SEALING COMPOUND Sealing compound ne used bo frm an adh jin ben tween sll covers tnd containers They are eek of eee aly prseed Laundcots botnet fow'alMgh renner empenaanes tol ipa i nt teen tlm ghd vein scalar goed wilcPare soeasee cannot Ee esared by healegs Uh Me a 8M) 1 ey in the electrolyte ix partially used yp h plates, tiseful nbn with the tletecty at tery esl to be ditebarged This gradual weak the elect allows u ofthe electrolyte in proportion tp dia very well active becayne mneter treasure how much 9p the water inthe siecle aa ts sto judge about how much ectical ry i eft inthe eel ‘Betnio Wit nano aaa TohiGtw aa Fig. 11—Electro.Chomicel action in « battery.CHEMICAL ACTION OF CHARGE By pasting an electric curren and S07 of tr spel fed ‘capacity fn minutes when tee at °F, unediately ill the battery u6 Adyar ates vg er eed sone Shoah ten hs ally Changed os fein emperee Wha Sheer S2dares aus, Trecho asd Cad ‘Tests may then be made. ursction of dry-charged batteries tial 2haur capacities. Therefore. 59. of the minimum 20-hour ratings should be deducted ston Acting drhacged baleen Ite following the initial a = motive Engineers specifies an Activation and eketrolyte at 80°F. Other proce: stove, The per. Formance requitements under the SAE Specification state that the tine and volkage attained under Qe test condition hall be the same ax specified for the high rate discharge ao CURRENT ACCEPTANCE TESTS iri vied to ees he iy of siously untested batter to accept charge wr tollge ayes wih to bascry Ie a pastaly condition a1 30°F ‘The fully ‘ceiving the propor charging eurrent and gradually starve it, causing an aundercharged, sulfated hattery Corroded contact surfaces of all clamp terminals andl by tery. terminal poste should alseaye be cleaned bright with a. wire brush in order to make a perfect enstact each tine they are replaced, Fig. 20 shows & convenient taal for this parpene. IL is good practice when replacing terminals to grease therm with a heavy bodied mineral grease ar petrolaium, Dom apply an excessive quanlity as it may flow onte the sealing frampound and se clamp terminals onto: battery poets. To do n severe damage to the brittle harbrubleer ‘and sealing compound. INSTALL NEW BATTERY FULLY CHARGED ‘When # eustomer buys a new battery he is pay is entitled to receive one which is fully char fully-charged bi anteed performance, which is the bas eying for and ( Oni ot the wale trout trouble and costly tw Wis cus m the case of Deys tomers are Fully charged sehen installed Charged Batteries the adherence to the suggeatione oul inthe section an “Activation of Dry-Charged Batteries” on Page 17, shold result in trouble Replacement cables should ie of sulicient lengih to reach the terminal posts without causing undue strain on the posts and weavers. Cables thit ate too taut will enue damage to Posts an cause realing compound to crack and acid to les The battery should rest level in the eradle and be farkned securely fa place by a suitable holdalown, wing care to Tighten hold owns evenly from csch end, a thea 0 tise, fa not Wo distort or break the container, Do not drax Hrolddovens too tight. Where a hold-down is fixed at one dy care tant be eutivlod Ue tare prefer silane battery prioc to applying pressare to the roveable portion. Before connecting the cables, check the polarity of the ter- tamale of the bot oe sure it is hat reversed, Note tbe battery is %«" sand that the f Do pot drop termin the eon terminal a careful to it ts imperative that the palarity connection af the bs "ce ifthe engine is sared withthe battery eveted. the rectifier diodes and wiring harness will he inreparably damaged. In origed raionAsm matter af policy, the radio should always be when working. the battery. Tn any case, as an added safety meastte a final cheek of the able connections should be made with particular attention paid fo matching the lange cable clamp the larger rina post deflects to diechurge side of the scale tndieatee tte thot the battery is properly installed with regard te polar. ity. On ears without amimeters thia proeedare is impessible fara reliance must be placed in the cable checking 1 fcribed in the previows paragraph, in the ear manufacturer's manual CHECK CHARGING CIRCUIT rent a anilable for cheeking the cha wit, Follow the manufacturer’ pracedase in the we af the iestruments. Cheng af charging citeute without auch fjuipment fe not recommended PaRT vint EFFECT OF CABLE SIZE ON CRANKING Fig. 2%—Cable Sizes. mse the aed of Taade wiabe tthe lopeadent starting motor. Cables fo of the stan special a ssenget cars having L2-vol systems are Number 4 or Number 6 gauge exeept for ns where heavier eables may Ie used, ary having 6-voll systems are usually aber Q or Number 1 gauge, the Number O being the larger. In the preceding chart, Fig. 29, « comparison of full size ‘eres tndensize © en, Voltage ean be lost ly the use of eables which ate undersize wid alio by clamp terminals which are corroded. 2PART ay ast ss) et tg EARLY DISCHARGE NOT UNCOMMON Tee quite common to erie int expecially during vory cold weather, about new batteries returned for e a few dase or weeks after tale which ads thot there rmat fe something wrong. with ther, pe of complaint began when the automotive battery industry iret care int existence and lent jan tong am automotive bteries are sold. Actually very few ee meas are eis weg oa them, bat because they ate new, the inexperienced person, and same timer even the ont wo should know better, bckievs them torbe defective becanse be cannot find the reason for their becoming dischatged A very impor trouble is ene the installation of new batteries insered ia the paliey Tollowed in regard to Was the battery fully charged whe imalled? tyomely tion of partially discharged battery may set only lead te it returs. for charging bot may aba veult thor Hie and an adn tment. The gravity and temperature of the batery should thereforeerecuzded at Uh Lime of sale for future referees be kept char regulated sy Te is a fact that many neur batteries will eome back for hes they become discharged and, provided they ‘were: fully cha perly insalled. they may be Considered legitimate recharge joba for which full peice should be collected. Too often they are recharged gratis heeause of a desire to Keep = goad customer xis. Inccanse of a lick of knowledge af the trie circumstances tan how to deal with them, but they are legitizaate recharge jabs just the same, The battery is usually invalved In any starting failure, hut the fact that it is discharged does mot hnacessovily point to a defective or faulty battery. Tnvathe cient hours of driving, worn cables, rouble im the electrical system, such an volase rexalator out of adjustment, cor: Somnections of alternator or generator in need. of sepa Spies drive bel can cure baley tbe some dcharged andthe condition cannot be Hamed oy the batters. me "Car Alternator of Generator System,” BATTERY TESTS FOR DEFECTS A properly equipped dealer has threo ways of testing 4 bat- tery to determine its condi st—He can put it on charge to see whether it takes a charge satisfactorily. If it does, it has pasted onc teat mc- cessfully and is probably in. good condition. See "Charging Storage Batteries” Past XV, page 2 Second "y hale If 9 discharge testor is available he may test the for ‘charge, and if this tet shows ‘in good condition, the alley TESTS MUST BE BELIEVED 1 the foraging tests show the battery és be tn goed con. dition, the rls met be belfeed. Ths soame Beton, ba is erpained becatne aan ho are experienced tn han ing baltris and Who fall to learn the reason forthe di charge eondition are fable to-and by baring tho b hhecause they feel that since they cannot find any fause, It must be the battery. ther ey will slowly di. will not beeorme fully harged fi a week of twa, Hit comes hack discharged {2 week or two, there must be some reason for ‘ther than te battery ite, It may also help to remember that for every new battery returned for charging, many rose old batteries came back far the same reason: Nobody complain about the old Batterie, Never forget that there are ways to prove whether a battery Jor is mot at faull, and when these show it to be in good weit. the attery is completely absolved sa camePART X ea good grade cell will lower the specific gravity of the is does not mean that the cel as lost any Watch for batteries for excensive water system which The need nthe inaication oat of adjustment and indica to the damaging effects The larger proportion of present-day ba with liquid-level indicators in the vent open covers. Where such provisions ate nat present te level should be 4 to 1 inches above the top oo the 9 level, correcth a warm tempe using, may drop as meh a3 This in dive to the contraction of the shrinkage of the gas bubbles and beneath the eleinent, PART Xi RC TeCRL TG Le oaa) Ucn COT i) TROPICAL CLIMATES Batteries operated at high temperatures in tropical climates lly provided with elearolyte of about 1.225 Sp, Gi ‘when fllychargod, This inilder strength of acid js Jess deteriorating te. separators and. plates, which results. ger battery life. A tropical «limite is considered one which water never freeres, Attention is called to the fact that batteries can be fully charged and yet have different values af specific pravil ‘The following table gives the specific gravity values f typical batteries in various states of charge, these batteries Thaving indicated gravitis in the fully-chagged state. Values tre shown for batteries with a fullycharged gravity of 1.280 and 1-260 as used for cold and ternperate climtten, and in the last column values are showa for a battery 1 fully-eharged gravity of L225, a0 might be used ia ‘tropical cli Specie Gris soe of chores” ‘sO aid ant Tempra Ces Folly Charged 1,280 1,260 75% Charged vas 50% Charged 25% Charged Discharged leu ypc spwcte iy teneshat depriog bat se Bal cen SPECIAL CONSTRUCTIONS Some types of batteries ate constructed with an exira-lar space for wates above the eleme the usual water reserve i provided shove the Sj As a result of the extra waler used, the spocifie gravity of the electrolyte at fall level and with celly fully charged 1.250 Sp. Gr which is sometimes stated an the vent gl of these special batteries, ‘The same quantity of sully acid in used im these batter milder seid strength and requires that the battery be re nalered one-third ax often a8 the earventional battery. EFFECT OF REDUCING FULL-CHARGE ACID GRAVITY Most manufacturers have reduced the gravity of their bat- ies af starlard constrction Irom 1-280, containing SES. HSO. by weight, to 1.260, containing 35.6% FSO, by weeight, in order ta obtain ‘the. bovetis of the somesbet milder seid strength daring the life of the battery. TBs reelacing the initial capacity of the the expat of & ater depends up the the eleetolyte may have the effre hnatery tof ‘The amount of cleetrolyte in a batter its capacity since battery capacity ie components — (1} weight of positive acti ht of ocgative active material and (3) weight the electrolyte, This required wei will strongly affectfuric acid to: yield 2 specified elocteical cap: provided cither — (a) in smaller yelame uf ity or ib) Iargee volume of lower spec her cwinbination will enable a battery to meet its pub Tished ratings he spect exampl tion with harged gravity of 1. he 2shour capa and th tes och as 5 per ott, erty af sich a bat ery cannot be lowered without redacing se canoe I bowers; lover-praviy forert pier gions cn Dhar capacity and fine ald gravity of electrelyia used Aheclone.caeily cael Promise between capacity and hatery ie Tost ot in aude! tna battery after it leaves can be ade tin referring to the above tx bie of ebics to determine slate of charge Irom hydromcler ecesenry to fully-charge n battery to determine accurately. what is fally-charge gravity ie less the "fully-charged™” wravity is marked on the battery ‘eran the accompanying instruction tag. MIXING BATTERY ELECTROLYTE Diluting concentrated acid of 1.035 is not recommended because of the dangers involved. When undertaken as a re- ull of circumstances, extreme care must be taken in. pre- paring electralyte by diluting L435 Sp. Gr. Battery Grade ftlfarie eid ith w reood stick while acid fe being added, after which throw stick away, Because considerable heat is. generated suchen strong. sell is mined with water. take specific gravity readings andl make final adjustment of gravity after elec- trolyte has cvoled to room temperature, Never fill batt ‘ith electrolyte rmuch hotter than rem temperature Ue nothing bot alas, glazed earthenware, hard rubber, oF lend containers to rie store rkrtrolste, Une, cars or the hea ‘of ining may crack. plas containers. Ta. prepare slectrlyte al ony spel gravity between 1100 and 110, {ald one part by volume of concentrated 1.885 Sp. Gr. Bat tery-grade sulfuric ace tothe approximate nutaber of pats sf water show tm the follwing tall, SE orerrern Grae ‘Gronty ‘re Rs 67 Volume 1.100 9.8 ports water by volume 1.200 4.3 parts water by volume 1AS0 2. porte woter by vole 1.300 2.5 parts water by volume 1.400 1.6 parts water by volume So wear gouules ae ier working wil [Spy Gey ach gets on lathes, dilute ft ‘with clean water first, then neutralize, PART XII ACCIDENTAL IMPURITIES Colorless uids like gasoline, kerosene, turpentine, anti- freem, ur eathan tetrachloride (fire extinguisher Bid) are ry. aso tine and come other Liquide lighter hot readily sometimes mistaken for water and added to a b line, keroee than wa is th seater, will, we cach coll careh tes Alter this, the sted, Suck Maids in time often od the resulting: mixture is cleaned off promptly. Soluble like sea or salt water, vinegar, aleohol or harmful 5c, hydrochloric oF acetic acide of the electrolyte rust soften the sealing: comp dll I te remove ess ie such & the batteryParr XII SERVICING BATTERY IN CAR ‘with mineral grease or vaseline before the terminals are eeannected, © lespoet eral 11 adjust haldedowns. Urge replace battery top with a tif brash, beng earefl rosion predocs. Wipe off with a @_— Make hydrometer or sinner Finaly 9p the electrolyte er level with rent {fumerviceable. ater and change the battery sufbeiently to mix the electron to sre that they are not Ivte. or request the uwner to tetum the following day for hi posts and the inside sur Add wate ng the te level te the proper je tec camps toa lig moatees fae te oar Serna eat er fice, whenever they ate removed, Coal the eintatt surfaces page 2h Part XIV TESTING BATTERY FOR SERVICEABILIBITY INSTRUMENTS teers at east 10) ohime pe vol eee eaere Calter of at Fast. 100 shacs per va atrarents of unquestia meter accurate to atleast 1 pre 30:23,/10, oer ) ampere sh to bain 8500 ampere range, would be satisfactory for accurate teat work, . = OPEN-CIRCUIT VOLTAGE BATTERY TESTERS should be of the mercary inglass TH open-circuit voltage of « s high a» 125°F- and bie de- over a Linch ull immersion, A stable sirytype thermometer may prove satisfactory for the parpore, Shop electrical meters for buttery testing should be acewrate ‘within 2 percent over the entire eeale range. Laon y meters should be accurate within of L percent over the entire seale range and should he of the permane wpe, the va cfetably is calibrated, 0 correction factor of 01 volt equals U6 in Swale divi full scale for ng 15 yolts in overall Battery el he = 126 Volts/12. Example: 1.260 Sp Gr, = 2.10 Volts Cell = 62) Volta Vole Battery oh Batery 25BATTERY TESTING CHART—Fig, 30 (1215 59.07. (1) Prebetly Good (1) No soretion roma 9 omeng cl net ever £30. ‘Gr Ghe high fo dichorge copay fea ta! OX ck op. ‘roton ond satin Of rotoge fgvice Make 9 Porough the ‘ihe lca! sytem tor than teat, oo conechany, se tednd terminate (te hon 1215 5p a. 1) Guentonadin (epee be cared, Aer chen pet Mot (2) Cate owing more Hon 30 Felte GA. Shots in fw cl ©) Top mchorge bart Ge mate “W030 SG, vriion (B80 Spar) season in grewey. |” 8 Lente wlsctyeylaahage or |” paraty bay sold be rpiocd H attary acep Fach (ome ps ‘Se wrltion Jes aot pelt pea! wes Me. 1. rod toe ponon. (6 oer teas Soni more on Fabby emt (Api vamedy oten for Me. 1 shone (§) Reney being ln than 1 chore Guevara, (2) Any raed olan Tor Ne. 2 shown ‘er alt shoving lu has i har Tet tetimers ham 03 vl alain 6 Weal ernecan are acorn th Aevicg mr em BF ren joes for Ho, 3 bow, See Ho. 3 bere 8 oy em NOTE, Aor becenhorng aenal Fll-harond pate gravy of 1240 or abave at RIP. alec lar! shald eho 1 are separ serve eo ake reodigy te aber adie rater Sut thar antl sta amid. Hydrometers abel sree tr Yee Forel tmpertenn ae ey fo hae BOF for amet wih apni! Fly hare grey onder ent eae pa Fe proper shoriegpresures er fo “Charaeg Serene Pris” Poge 27nd eon! horging equipment manclacre'ipasenans GU High vate dicharge meter ie ‘tatters blow SHORT CIRCUTTS The proven of she sn in wing coe dternad by sching aM wl slat oquipmant and, we ths ground rep eamaced topping the CRETE cad agate Lamary pat Spaning wtb podeesd Mare a's scbteal at sec sta siting Batre fet ene owe mo TEEASSITS Wet mating hice Ore auld hack tn peaiby f= tuck stp lighter etch afore ocping he ene el spark at Tons inatan sf-s shar ech Te det very Shp ert sea oun oa ean ena nea cal HIGH RESISTANCE A slg sap (tie eronding) of mare th 7 wat (2/10) benean thy tating eto cable ord he cor frame cn cori hod sartng renerdlen of tery tennn Tis con be toned by poor catia! betwee elle fermi! ond ca fone, of between Czmp hermione bay ott sar inh ihe hgh eats by tinting he warn angina rok te ignitor ef Where hw ware ad Sorion (St tawcesuatted onthe sme mich the high eaten we fom fe ewer fo dire cop wil hows ts be dacumededtmpeculy ond rounded ‘S'teome domo tthe Ign col. Th procedure vl prvent tb engine fe werig during te crating te Repl epee compro! ‘Retigh reunion o a watoge 26perature correction factor i +s indicated by O. owever, the instru: anna be used an batietien and/or celle which have just come off charge, as the gates held on, the plats cause the instrument to give a falsely high rons are useful used with caution ta be applied to the off or turning on nutes before testing will remove the ee) from the readings, Letting bat ies sland on open circuit for several hours after charging will dissipate the gases from the plates and enable eutrect readings to be obtained. HIGH-RATE DISCHARGE EQUIPMENT High-rate discharge equipiest is available in a variety of forms. Most of these work on the principle of dlscharging the battery through a fixed resistance, for about 1S seconds, tand measuring the battery and /ar cell voltages while shuarging ats high rate to determine the cranking ability of the battery. Te ter ithe be . ie pemtap or lillng deb ring voltage as the criterion BATTERY TESTING CHART roredure based on hydrometer_ and, vet 13+ & shown in the "Battery Testing Chart™ Fig 30, This chart wall be helpful im rendering correct batlery No longer be used and procedure based ¢ cavity and overall terminal voltage (open circuit and under lead) must be followed. PART XV HARGING STORAGE BATTERIES PREPARING BATTERY FOR CHARGING pattery and clean its terminals before nat do not allow dirt to get into 8 the liquid level in the ells to the correct level battery is extremely eold, let it warns up before adding, wa- Tevel will rise as it Whey higherate Fast charger is used for charging it may be necessary to rem: electrolyte to V4 to 4, inch ahove the separ ‘overflowing. jar and retarnes pleted. The proper level ai CHARGING CURRENT Use only Direct Current from a charging source controlled Fate to the battery will not be excessive, ined ia a clean heen come to the Several methods for converting Alternating Garrent rect Carrent are commercially available for service Die HIGH-RATE FAST CHARGING A battery may be charged at any rate wich doce not exuse the electrolyte temperature of sny cll ts exceed 125°F, and does not eause excensive lon of the electrolyte. ‘Thi thoes not apply to Badlyaulfa hater. Such bal Ould be charged al specified low rales High-ae tat eaprgers chee very higineu rates of 50-t while for 6 Higherae fa handling bath 12 and eval re thatthe proper st fing in uaed for the particular battery tnvobysd swvid damage to tee charger and the batiory boing changed, Wher tan te pond a ar ed contol he em loko of gassing, Iie proctical to boost imal batteries in thie 93. Seine vf these chargers are quipped with w inediniing or temperature Limiting de, a peotect the batlery from exceeding temperature of BSF, High-rate chargers cannot be expect leries within an hours but they ciently well xo that it can cont Surate with its condition and to fully charge bat- Te charge the battery mul te of charges " ‘More than one battery, either all 12:Vol or all 6-Volt, can be charged on high-rate fast chargers. When this is sone connect the baltris in pale; that sonnet pontine franca! fo Reler to the charger Ihighrate chargers ithe salezuards rrovided by the ma by the aperator, Operating #n- rzers, as issued by each mamas facturer, should be carefully followed, aCONSTANT-POTENTIAL CHARGING -Constant-potenial chargers start the charge fl at a high and as the batery voltage builds up, the charge rate tapers oll te a lower value depending oh the design of tho charger and on the condition, age, and temperature of the A 'battry in good condition isnot harmed by this ‘ype of charging. badly sulfated Battery, however, may not come up to fullchary eharger. Temp ‘oethod of charging a it CONSTANT-CURRENT SLOW CHARGING The constant-current method of charging ie the old and vellestablished method for charging batteries where the n is tat hnawn and where» diagnosis Being made. internal cell cont of trouble i raw af batteries fs connected, there will be a positive a agate battery terminal fee for connecting the pos and negative charger leads respectively. ‘The positive terminal ofa hottery is ueually marked with a Sto B® or “POS” an it has a slightly larger top dian (GTS safe rate for bench Charging i b arpere per st per ell. For exam dese baitery Geving Tf plats per cell 5 of them would De ponkives, so the charge fate weuld be S amperes for abe Frttery, Tf several batteries of diferent ines are charged in serbon the rate for th line mest be deter iy cooaidered sale te Wotch temperature of batteries carefully and if the tem. re of any oneal them reaches 125°P., lower the rate. ietrolyte will expandl and the liquid level vise due tr eat and displacement of Tiquid by gas bubbles fering. at the plates while the battery is om charge, Hydrometer readings should be recorded hourly for exch sel of cach ‘tery sano appresches’ he fly rr charged state. A battery ix fally charged ben the cells are ll gassing Freely and the gravity ceases to vise for three succesive readings taken at hourly. intervals. Excessive iassing of the elertralyte may cause the quid to ex altelysow gravity due to the amall gas bubbles disp the fiquid, 40 allow the gas bubbles to rise to the surface in the hydrometer burtel hefore reading the float sale. tne chang og, leon charge othe pet rigs tno ag tet aa Mine ‘any particular battery is a. eee ieee ore ber 28 the cla may edict delet sch ma broken separate ran internal short. Stop chargin ery cals are: passin aod gravity will not tue farther ‘when tested at recharged ot sharging 3 of current, decomposes water, and ihsrmful to the positive plates. Do not stop short of the fully harged state, however, os outlined above, even IF i takes 24 hours or longer. badly sullaied battery will requiee longer than a normal battery. Unless electrolyte has een loat through spilling or raking. 1 shoul aol Be necessary oad acid 1 Tattory dung He ife: Rerenterr te make the tempera Tere cartoon lor rvrtncder roalingn mw warn heise: Ite wil read Tow ahs ight be mitten fr fare of the battery to rise normally im gravity. It might also be ‘mistakenly concludes that the hattery would at full charge. TRICKLE CHARGERS Trickle chargers are eflceivaly used for keeping dep Intterics feet, charged and fend forsake, Avon eo mteus crorehirgs fr Ling purtede of nk. haweree tech churgerp mich here ot eatpat of aw than ono ti fore ore See, le wey inpertéar tit Tey by ard fn ‘le eemdce ih diction, since continua cre Shneging or an indefinite time cyen trou ot ery ig ca nr ete i ep ies caesing ew nd egret: By eae large arr ther of al sight lo avold orerhargiog BATTERY GASES EXPLOSIVE The af cet Feng charged Wagon therfore clara The polly of ietion of Undone gx be See StT cumulated on the car, aa ‘om one's person, aiid liaharging near dhe vent openings cam be tain cimmnediitely before warkdng ow Une bat- texy, 5 rectal red or wile utied fo fe car Puapes nd'te the greens et use of a “Rooster” battery to start a ce te presents definite hazard he following fare Ts suggested.tide with the “bowntea” Battery. exercise extreme tare inthe handling of the cable epi, In disconnecting, al ways break the conpection atthe “Booster” batery Bist. PART FACTORS AF OVERCHARGING Charging a battery greatly in excess of what fs req harmful in several ways, a follow dite Severely es conduction, © _Becomposs wate of detelye into bydengen and oxygen gas (ax bubbles tend to wash setive: ma torial from the plates and carry moisture and ackd fromm the Sib ieee Docs ef tr ice itt move sao © Pe eecitael cat tamales cao ponent patcry a igh pera ¢peleaged period of time High internal heot is Dremel pak I dainages separators and negative, Ale te softened and distorted ard sealing compound placed ids with conse: es the positive plate fous of electrical nical weakening ‘and harging alone of in combination with a pre: ‘vious condition of undercharsing may cause revere bucking and searping of positive plates with accompanying perforation of separators, My. caus. damage hy corroton te cru, cables sil oer tal lcrical and egies patsy forcing liquid fm the cll chap sates in exces UNDERCHARGING fe battery operated eta . oe pated lies oar devaen ape al leat ie SEE is denne, hurd and comedy craw end inet be 1 ome Hite, belog aw om which it was formed ater 40 tha ditt ti te, may reval Pil [cay Va 8 Another sour plosion | nection of ehiarging ee|uipme ‘aie aly pes of charges: Pat the High Fate equipment. ‘careful checking of the conneetione before throwing the operating switch. reason acid electrolyte eyes, wash Ht out imi cok water cupped in xvi nged overcharging, as might be ced on along trip.ar by an alternator of generator real ican whieh has gotten out of wdljustr Scveroly buckled piates will panch tse separators at the Plate corners or ehufe the center of the separators, Thi may result in perforations of the separators and sev ort creat In the cell, e an undercharged condition fe re deliver fll powery bat {rover daring severe winter weathe ing of Electrolyte”, page 30. on the plates during discharge eas lang as the specific gravity antially charged condi- rep rmich Below sulfate Tee rr ture fluctuations of the electrolyte, may migrate ver dara into the pores of the separators id deposit as a white crystalline macs, Subeeijuent charg. ing may © ine deposits to metallic lead which may “short” the positive and negative plates through the areas of the separators affected, These smull sorts snay eauie a condition of low coll voltage when the battery te charged. For this reason automotive battery cells shoal Ihe allowed to stand idle in a disthargrd condition, LACK OF WATER ‘Water is one af the essential chemi battery and wader normal ‘component of the battery wh Is of @ leadeacid storage te of eperaiion the is at asthe rest of Sharcing, Wt sbould be replncsh au soon as the fut ove falls to the top of the aparatere I alee i wok weplaced, and the pales are exposed, the sci! will reach a danger: h concentration hat may hor ab disintetate the separators ind may permanently sulfate and impale the performance of the plates. Plates cannot take fall part in fhe attery ction unless they are completely cover by the electrolyte, Sulfuric acid must never he added tia ell unlews it is ‘Anawn to have been lst. 29LOOSE HOLD-DOWNS Hold-downs, if not properly adjusted, may allow the battery tw bounce around in the cradle. This may cause the bridige= ox which the elements rest to noleh the Battom of the sep- atators and may cause the plates to antch the bridge tops, cong ser eatetof ihe semen, Te Brounen of the battery many abo crock or wear the con yaad cause Sally oompeund te op aed oak nk acid corrodes terminals and cables and re- reby weak- high-resistance battery cone cing the battery's power and sho downs, + Rand, ean be too ti the container, allowing loss of acid fro will cause logs of battery capacity. the eells, and this BATTERY ELECTROLYTE SUBSTITUTES ontistaetory substitute electrolyte has been found for the simple misiure of sulfuric avid im water. Use no substitutes. EXCESSIVE LOADS A battery should never be used to propel the car by the use of the starting matar with clutch engaged except in a great amonguacy, This taay produce extoensiy high fntarnal bat tery temperatere an] none the starting rotor, FREEZING OF ELECTROLYTE ‘The electrolyte of u battery in varios states of charge will start to freeze at temperatures indicatnl below. The given femperaturcs indicate the ajproximate points at which the fiat Tee ceyuals begin to appear fn the soluilon, The sole Tot freeze solid until a lower temperature is a reached. Solid freexing of the lect container and damage the positive plates. may crack the A. charged automotive battery is in no. dan ‘age from freezing, Therefore, Keep batteries st charge (or more, especially during w' PART XVII Ss aS eV Wil) ae of defective batteries is not justified, The high cost of parts and labor at compated to the cost of replace- rent with new battery make any projected repairs un economical. Batteries having one-piece cavers tealed to the Containers with permanent cements canal fn any case be ‘opened for repair, ‘The following diseusion in presente for its informations! aly and is illsteative of Some of the points covered im Part XVI, “Factors Affecting Battery Life.” INSPECTION FOR SHORT CIRCUITS ‘This condo may re for materi Ealing Irom the plates aed cing in saficient quaetity to short Ehrcake the plates ot the bottom vt edges. Or it may be the frank of lend growing. ("irecing”) from plate to, plate thro hee oli yw eerste, ora rou edge ob te inay have eit ‘ough the parte, Lead ay te ron tang the el brag f tart lt {ee pst srps the connector the poms Sach ¢ “rundown” may not shortcircult the clement uatil later fr has occurred. One plate oF several plates in the clement may have “buekled”, causing exces- five wear and failure of separators resulting in a short ireuit af the elera 20 EXAMINATION OF POSITIVE PLATES FINELY DIVIDED SHEDDING Ay divided, even shedding tive plates, Fig. 31 tire surface of the mic of a battery after Fig. 31—Positive Plate oxhibiting shedding after lona service.GRID OXIDATION Long continued overcharging & always accompanied by ‘oxidation of the positive grid, which reduces the metals ‘gecacton of th eid wires and weakens the plate, Fig 32 oo that it is easily brokem under sli Vibratiois, Over-choewing Adjustment of the voltage regulator to meet di nb cores aly by Lover ing te consed by t20 trite rar also mabe be eaused by the battery freeziy while discharged. Too high « charging rate wold sbubly be accarnparsed by oxidation of the plate frame. Ghanky shedding may also be indoced by weston d Toote mounting af the baltery im the caries 32—Positive Plate, showing severe disinteg- ration due te collapse of grid mesh, correded by ‘overcharging. CRACKED OUTSIDE GRID FRAMES Thin indicates severe expansion due to the postive platce having been in a pertly-dlicharged condition nd Raving es etl land wl conde arden ation ie lace. This condition is aggravated By ‘over- charging afer plan have become sulfated, HARD PLATES ‘When the material in the plate is hard when scratched, Ike the surface of an unglased tile, iis indicative of beayy sallation. It may be corrected Ey ts BUCKLED PLATES Buckling of pli platen may be caused by plates stand. ing in en untlrcharged state for s condone peried of Use, or maybe the raul f excensive charging. expecially after plates nce’ previsusy Tecoma: deel Sulfted”B faning nan under charge state: See Fig. 38, Fig. 33 Severely buckled Pesitive Plate, DISCOLORATION Low electrolyte level will sometimes result ‘of a distinet area oF tone of the positive plates whic the ares covered by ele See Fi the formation Fig. 34 —Hladly slfcted positive, plate resulting ‘Glectralyte level, Discoloration of pairs with white lead sulfate may ako appear in elements which have stood for cansiderable time im adischarged condition in electrolyte of very low specific sravity. EXAMINATION OF NEGATIVE PLATES GLOSSY NEGATIVE MATERIAL Foly-charged ma Tule vat nge lead negative material normally has ‘and glosses toa metallic sheen whem {hack of the tharbna, 31SANDY NEGATIVE MATERIAL ais may real from operation of the batery when the ‘Tat dd ot sny be cans y phar a marae hy high temperatures I then eheiions of TEE rarity dnd igh temperature prevail for eomme the negative sponge lead may tec voft and mesh. Teck ef the thon ye dae ony to's diochrged Cn Th ue oh a ny te he seprtive pate i ony partially charged We rateral sa Tete an tppeareeo tnaler to w ey nepatir, Hy aftr Tor at lense 24 houre and unill the gravity stops ‘andy fesling pBmes may Be LOSS OF ACTIVE MATERIAL Lae f nage ative mati fram te gd mae the result of Righ-speeific-zray of hi clement is shortcircutied, is to continuous charging at DISCOLORATION A white discoloration may: he due to 0 wt Kea walle, esting rom low standing in a semicharged may be doe to small depos Lintimony or copper, ef may be due to the battery havin heen accidentally charged in reverse for a prolonged pesioa, EXAMINATION OF SEPARATORS NORMAL CONDITION Soparators which are firm but Bexible, not bl fund without splite or holes, are considered nor in color SOFT OR EXTREMELY BRITTLE ‘This condition is caused hy prolonged ex aperture [above LOE iighape ove E300) resulting from water lem Thee ores eal Ieaost black in ealor. Microporous re are umvally nt so aflete. rubber ot plastic sepa WORN SEPARATORS with rile alos destroyed and th back sforoted, Fig. 38, are ebaractertle of ed to cxcetie premare camel by bottled ive temperatures or highapecificaravity sor much darker in-color than wl 35_feporator soverely-onidized, ribs worn "Acad perforated near common, doa ts buckled positive. plore. PITTED SEPARATORS Ping of seater seals, ops pressure doe to conta wth Faosene active. material ss late. When caused By poitive mitra, the aie ried dg fie wparenr mad mae da slored carbonived rpote When due lo negative material thc piting saris onthe side of the separator in contact iri the a acterized by “Nomvholed™ appearance dae to movement of low part hes of active enteral FRINGED AT BOTTOM ¥ ‘This may be caused by excomiza wear duc to buckling of positive plates, of may result from oxidation of the sep ie by the shedled! positive active material, Fig, 36—Severely-netched separator due te vibra- tion of loose oloment, or battery loose in cradle.NOTCHED AT BOTTOM om separators to chafe on the bridges, Soo Fg. 26, TE the hatte tainer may. the battery ars loose fis the car, the outside af the con: abrasion where it carne in contact with supports. Ifthe container does not ¢how possible thatthe clement was asec 70 loosely in the eell without shina. Excessive and pro- longed vibration cam alse eaute this condition in corscclly ‘assemble aa installed batteries, EXAMINATION OF CONTAINERS teotion of the battery ed cletried cimpowentt 4 sith alter: e BATTERY AND REGULATOR SYSTEM sd performance of the battery are ob greatly i pced by the regulator that it in rally neteseary to ed ow they depen on each athe fr satefactory on, Whatnay sppear ta ea batery fre mote stttbatchle t's regeictor which ‘hed pet boa propery free a car from bat The following facts shin ewer tery amd Fp studied.* is meant the conteal of electrical pressure current flow (amperes) in the charging ‘he baery, generating unit and repute mst work an a team, The battery's ably fo resol charge Inerenen a the tottery approaches fallcharge and decrease when the banery feos discharged, We call his batery cha tae em vag or A cen Sa force). This bhatt vitally iaptant and ever a selena Ma Bee tan ‘he Charging Systim By lis Change In Courter Voleage, Fig. 39 pets ot hw the “CEM set batey ha system. Thus the Prevented by tse ‘whith tape fs the wor minal ‘ofthe regulator, gave of theaters. Halley te Hg oad on the ft of he cart. the bottom represent the charging from the alternator or C psicrato. ‘The heavy black lines marked with various’ states of charge are called Charge Vole Curves Tho curve ll ws what charge rate a healthy hattory at 20°F. may he expected to accept at various voltages and at wariom tater of charge. To ase the chi et a yetge apd move right cows the ti we intern: the charg voltage forthe par telar state of charge we are intercaled in. Moving straight down from i Soret we can rend the ares ‘rate in 7 petes If we ike, ne can revrre this proceda restarting wit charge rate and reading ‘off the corresponding vellage. ‘The eurves shove that-abatlery in tho more discharged con: Alito will accdpt hier charge rates at fairly low velioges For instance, the 1 charge, curve shows that a baitery in this condition wl ty 3, at 3h vas a at sre a ke oot hs wee We sen ae Bat ee ie vollages the current would'be Fimited to the generator or aliemator capacity, In the gare of the D.C. generator this ‘wold be Eimited by the regulator, and in the ease of the alternator, by the self-imiting. feature of the alternator iteef, We have assumed the limit to be $5 amperes. in Fig. 39. ne As the battery bosons more neatly charged, higher and Niger andl ghar gpkunie etter ied ree at liage regulator steph nto lini eis reduced. This we se that Mt volts can be charged at 13 ropes: a fall charge avenge of Tk gic nly about seer We-can state this principle of regulation it simple terma by saying — IP THE CHARGING VOLTAGE IS LIMITE THE CHARGING KATE WILL RE REDUCED BY THE BATTERY AS IT COMES. UP TO CHARGE. This i reason that batteries must be considered in any, discus cof regulation, Tt also brings up anoth HOW BATTERY VOLTAGE VARIES WITH CHARGE RATE AND STATE OF CHARGE AT 40°F. AS INDICATED ON CURVES ON A 12-VOLT SYSTEM BATTERY TERMINAL VOLTS HOW BATTERY VOLTAGE VARIES WITH CHARGE RATE, SHOWING EFFECT OF TEMPERATURE AND STATE OF CHARGE ON A 12-VOLT SYSTEM xct No, 2 — Anything that Afteets the Battery or Regulator Affects Regulation We have soon how much the STATE OF CHARGE of the bawery ailecte charge voltages. There ix another ariahle aebich has alnst as auch elloot, That variable i TE PEATURE. Pig. 40 abones graphically the effects of both sas of charge and leraperatute on charge velkage, Again tee concern ourselves seth a HZ-volt system. fote that. hallicharged bartery at 0°F. will accopt sorne- ng in the order of 2 amperes at 14h volts, Uer the same conditions the batiery will accept about 27 a at D0°F, asd full alternator oF generator octput at 1 Fe Raia bo clo taoertlle spear as parte of ont country are subject to. wide ‘ariations in temperature, “The effect of teraperoture on regtlalion is further detees fied bythe fact thatthe regulator, too, ix affected. To com for the changing termjeratites under which th hhave eompooents and ch hange the syste ‘hs the ambient temperature decreases, the charging voltaze is ineremsed ‘the higher battery CEMF, and eroitfecharsi tre increases, age is reduced to avoid overcharging the battery Because the limits actually held by the regulator are de iden is togulaon ig vey im, ‘adjustments raust be male nt ander, carefully contcled ithout obsersing. these eondic salt to reproduce, False settings joc mony dorms of cheated pho too Tow ‘operating temperature’ conditions, Settings made tions are erratic and thos obtained 9 i esntally a ceria product chase ing properties are often altered by chemical chaniey tatery tell Change of this ki Bre rought about deliberately by the maaufactoree of Uiey way result from long uve, prolonged operation at high temapecatures, and the Addition of impurities. Any significant change made inthe chargevoltage characteristics of a battery will definitely fleet rogulation and tany be teaponsle for early talure iWoverlonked. Sulfation, while normal, may be troublesome {Hi iallowed to became exceasive. Since tulfation is likely {occur whenever batteries arc nogketed for «long of time, it can occur in new batteries in stock as wl tnd ones. A battery which i ulated afen wil oe accept fin adequate charge raie from the alteeantor oF peperater god rap sarves to death onthe jab Raley gen can "efter argument for systematic caze of Batlries 3 the neseety for retain the al charge ee ar aera es anct exiet lose valkage a modern automobile. . ‘This brings us to a third fundamen! regula Fact No, 3 — Regulater Settings Must Be Correct for the Battery ond Type of Service ‘We have sern how the battery charge rate when the voltage tually control its own alton fimits the charge 38 voltage. We have also wen how muck the battery charge ‘ollage and the wogulator age silected by changes in tera reser Pang eo Keg tnt, it ick ‘ose that the seting of the Yallage tekalor is extremely he prope adjustment of the veltaze i ie largely Seteriines the success or fa ile. An incorrect ¥ age re i damage ranging trom borped-at omplete de- ‘equipment. Changes im selling, of course, raust be made ‘nly by a qualified automotive electrician, ng thatthe voltage regulator aeiing is very impor- tant, Uke question thew: hecomies, "what iv the proper set ting?" The seal scting say be defined ay “that setting tehich will keep the battery. at or near fall charge with 2 tninimunn use of water hen the nekike is sed tie cue thmary wag." Such dedinition makes it eany to sew hal tm be done, We simply nek the regulate thin the range fad moe frequent chicka of the atery one Several days or a few hundred miles of tervie, the bat- tery lous wate rap, the acting fs ton igh and sould Ter Tedeed, (A usage af | to ottnes of water fer eel per 101 tiles Bis cen found to be acceptable.) TE the hat tery falls Below Unree fourths sate af charge, the setting toa low andl should be When designing autornotive equipment, the manufacturers select a voltage apectication which wil satisfactorily main- any x Baki we lca The econ Thased on th ul the type of service. Because of ee netescary to a. ‘alialactors” range regulator and ear mamufoctorers. regulator ix temperaturccompensated, sormal changes in lemparataredo not require tha the is ecto ee Ubud by a regent oa fete he manatee Js specified. Occasionally, Literal ensayo ee te te tle to imriaint Eo isnt saw of chase When seb o he baler, reese ped thine ‘or overcharged, the tet aches a ene eae to the mant ‘Setnetdtnne i te! tener to elngy sting fr tet prtly pti Seca masel at Fangs cornet te gedechrging OF vechryng Oy inary tf fe prtedbety wear hg even at faisly low cutaide the “nia the hattery’s counters ‘lee or bly is greatly reduced as i Ineats up. When in this condition, the battery is unable to argng ate o sla vahasand thas sontnoet to get cven hotter. This condition normally indicates the feel far a ill To wr valtaze regulator, Teter va (or oth) ti ally be ter to rede the vollage setting first fo correct overcharging licationsx this ie often all that ie loos not prevent overheating, thea battery -venl should he checked, I bntlery continues to overcharge seriously after ads uate version ot been proved and the wokage setting has been reduced, jt is likely that the battery already has cen permanently damaged by continued werhening el? dr overcharging: or how an icra “shor” fn such cone, st coura, the only remedy may be anew battery. Mininwon voltage regulator fabio hon foot ence say be required for high speed with imedecats mead Incl, for exe ing salesmen’s cara. erou-country buses, and nicks, Here the problem is one of holding ch down tot value’ which will mot AL the oppotite end of the seale are the vehicles which are driven too litle, tow slowly, or which excounter low bate es regularly. When a battery ir sould, i eases rapidly. In extreme cases the gent haring current tnt i Mill ‘cases of ade lo. Mild cases of undeccharging My higher voltage regulator settings, but severe and persistent upderchaging requires periodic wo ‘charging froman outside source. In vey severe sub-rero low-rate changer to vearm enough to ise when driven tn the daytime, Appi hich permstent undercharging poste, Frequent tate tery os ) tiem, almost any veel net Sith apecial charpestile generator wil ge teabie driven slowly and continuously, as im very heavy trafic, Somoning up, ve fn that wo ean site Eight Rules for Good Regulstion which cover the minimum essential. a EIGHT RULES FOR GOOD REGULATION 1. Remember that the Ihatery is the basis of regulation 2 Remember that anything which affects the ballery or regulator affects regulation. ~ 3, Strive for low_watee-cansutns proper regulator acting. 4. Watch battery ventilation. ideation of | ght, and wires 6 Remomber that all sqgulator checks and adjustments avant be made ueder ‘specified condition 1. When ununca! erie condleonn require diy adjust the regular to the job. 8 Whenever possi tery. Aeep a followup record on the bat porta in Keeping the Battery inp satsfe Slate wf charges PRECAUTIONS TO BF OBSERVED WHEN SERVICING SYSTEMS USING ALTERNATORS 1. REVERSED BATTERY CONNECTIONS MAY DAM- AGE THE RECTIFIERS, YE! ‘WIRING, OR OTHER COMPONENTS OF THE CHARGING SYS. TEM. — Tattery polarity should be checked with a ollwieter to assure that it eouforms to that required, ich terminal post is connected fo ground before ling a battery. 2. TF ROOSTER BATTERIES ARE USED FOR START- ING THEY MUST BE CONNECTED PROPERLY TO PREVENT DAMA THE SYSTEM. — Always make cert (=) negative terminal of haoster battery fs connected to the (—¥ negative tet. ininal of the vehicle battery and that the (+) positive terminals are connected together. 8. CARE SHOULD BE TAKEN WHEN CONNECTING AGPAST CHANCE” Tusa to remove tt Ihattery ground strap before charging. It is not adieab ler apy condition te attempt to start the vehicle by Using the “fast charger” as a Booster, 4. DO NOT ATTEMPT TO POLARIZE THE ALTERNA. TOR. — No pol ad, 0 may resul ‘THE FIELD CIRCUIT MUST NOT BE GROUNDED AT ANY POINT. — Grounding of the field sill damage the regulator, Extra care must be taken bei wor near this electrical system. GROUNDING OF THE ALTERNATOR OUTPUT TERMINAL MAY DAMAGE THE ALTERNATOR AND/OR CIRCUIT COMPONENTS. — Unless the reae 41 cireuit breaker, this termina the system is pot in operation. is cam eause considerable damage 7. DO NOT GROUND THE ADJUSTING TOOT. TO THE, REGULATOR BASE WHEN ADJUSTING VOLTAGE UNIT Olt OTHER REGULATOR COMPONENTS, — ‘The adjusting: tool should be insilated, 8 CARE SHOULD BE TAKEN IN THE USE OF BAT. ERIES OF HICHER-THAN.SYSTEM VOLTAGE THER TO BOOST A BATTERY OF LOWER VOLT- AGE, OR IN STARTING. — Never leave the higher voltage battery in the system. When used for boosting, scone he eb butery ground When wed for starting, disconnect the higher-voltage balery as sen as voaieaanele ALTERNATORS MUST NOT BE OM OPEN CIRCUIT WITH THE, FIELD WINDING ERGIZED, High voltages wil result, causing possible rectifier failure, Make sure all connections are secure, damage to the alternator, regulator of 6 % ATED 6: 7PART XIX at sy ee ait DIRECT CURRENT (DC) continuous, undicectional ard non-pubsating current duced by storage hatteries. If produced hy # gener rectifier, there may be some slight variation due to co outators of generators, or due to the rectification chara: teristics af rectifiers Volt The unit of measure for electrical pressute or eleee tromotive fozee, measured Ampero—The 6 for current Bow, measured by an ammeter, it oa A unit of measure for battery: capaci ‘obtained by multiplying the current flow in amperes by 1 in hours during which the eurtent flows. For example, 2 battery which delivers 3 amperes for 20 hours came said Lo huve delivered 3.x 201 aF 60 ampere-hours Ampere-Hour WettThe unit of electrical A by slip ing the amperes flowing by th which forces it to flow. Watts amperes > volts 38 Wart-Hour—The unit of electrical energy obtained by F oulput by the average voltage the discharge. Wattshoure = nce opposing eurtent eal whem current flows whip between volte, The law may be Volts — Amperes x Ohms Vol ‘Amperes — elts Knowing any two of the three values of voltage (Volts) Current (Amperes) or Resistance (Olime)., the third vale be ealeulated from one of the-sbore three expressions lav.TABLE OF CONTENTS rat mms pact I Battery Construction 4 " How the Battery Works m Battery Capacity u W t Shipments before Acceptance 5 v Wet fitery Stork Maintenanee 5 vr Diy Charge " vit New Bat wo vi Elect of Cable Size on Cranking al x Now Daticriee Returned for Charging 2 x Water a Nt Acid Gravity for Tropical Climates and Special Consnee a xt Accidental [mpprities an xe Servicing Battery Fe XIV Testing Battery for Serviceability 25 XV Gharging Storage Batietien at WE, Féciots a\Geeting Watery Life » vir Fprernfl Exaitination of Coll x0 “XVII Gar Generatar Spates 0 sax Eteftricnl “Tips: Defined 33‘ Page Na Page No E . hecrcal Terms Pantie Pitre Trt 2 Boar reporter Scparatr 3 Heine Pope Croup 3 fens Hisnert Comartion Phe tt Mising Elche a cur Neatly Split 12,34 2 Aahation Fes ine Diy Chased ig aes wit 5 lial Syren sae A a = F ‘ Antangn, Ect ca ischarts t Se ete res Daca tt se Sens u Bal iat aa avi ng fener taeelioe Wels Batiseys Capacity Samtarde He Fete of Btetne ert ace u cen Taecin Posines an i Chemicals Used in 4 s Pane 2 {rtoes for Shpeeat 5 s Hae Conte ‘ chemical tien ia Sen : Foca Afrtng Life ae fare 43 Hol Dowat Titallation 8 es SAE Sttads mg Sittey Cone : ma 1 Shimer ap as Scteiay Sie rr Soe Special Cancroetisn, Tats for Detects ves Pat le eat Si 4 fares (| Ce asl serie i a a3 ; 3 EB tone # ren =f y & ioanivin « ae ae ey 3 Iniral Eeunnation of Gls Sots “Eager Corrmton “Ee 8 te 2 Taina Caper Se 7 ke Pale Do ee : 1 gil 3 2 eg eg ge ue ab ae Fie seventy ME ab HONE i B Sires te Bee | OE rl Devs BE Troll Cheat 3 2 : Vit aes 3 hn To ts a Se Fae ; 3 Ear fee eens LJ gee eae ate Giutlioe Te ae Notes defer Chen De i Malian er Ating tea af Hotere Ca mea Regulater # BL apes. Claim for ; ign, Riera Tees A Bina tar tines ie B ecied Medel fa Atrting a Determining Condition 8 correiant 1964 oy % THE ASSOCIATION OF AMERICAN BATTERY MANUFACTURERS, INC. HEapaual 19 NORTH HARRISON STREET, EAST ORANGE, N. J. 07017 a