REV.

BCI Battery
Technical BCIS-00 MAY15
Manual

Issued 1993-05
Current Revision: 2015-05

BCI TECHNICAL MANUAL INTRODUCTORY MATERIAL

1. DISCLAIMER STATEMENT

Battery Council International publishes technical information in this manual as an aid to

its members and to the public. The information in this manual is based on sound
engineering principles, research, extensive field experience and technical judgments of
industry members, and is subject to change in light of developments in technology and
field experience. Use or adoption of the information contained in this manual is
voluntary. Battery Council International expressly denies any warranties or guarantees,
express or implied, in connection with the information in this manual.

2. INTRODUCTION

This technical manual was prepared for all users of lead acid batteries with specific
reference to laboratory analyses and test methods for evaluation of battery performance,
major component parts and raw materials used to manufacture these batteries.

Industry technical personnel who are members of the BCI Technical Committee wrote all
BCI outlined test procedures. The procedures are intended to provide a common means
for the manufacturer and their customer to describe and compare desired battery
performance. They apply in total to batteries manufactured for the automotive, truck &
heavy duty, deep cycle, marine starting, lawn & garden, standby, powersports and other
applications where lead-acid batteries can be found.

Those specifications, tests, and procedures outlined under the „SAE‟ heading are those
which represent batteries manufactured for Original Equipment (OE) purposes and are a
result of the report of the Electrical Equipment Division approved January 1914. The
revisions as prepared by the SAE Storage Battery Subcommittee approved by the
Electrical Equipment Committee, June 1986, with subsequent revision when published.

To each and every individual who contributed to this third edition, we extend our sincere
appreciation.

3. SAFETY FIRST
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3.1. Explosion Warnings

3.2. Danger of Exploding Batteries

Batteries contain sulfuric acid and they produce explosive mixtures of hydrogen and
oxygen. Because self-discharge action generates hydrogen gas even when the battery
is not in operation, make sure batteries are stored and maintained in a well-ventilated
area. ALWAYS wear the appropriate safety gear, such as safety glasses and a face
shield, when working on or near batteries. When working with batteries:

Always wear proper eye, face and hand otection.

Keep all sparks, flames and cigarettes away from the battery.

Do not remove or damage vent caps.

Cover vent caps with a damp cloth to minimize gas seepage. (Note: This does not apply to Valve
Regulated Lead Acid (VRLA) batteries)

Make sure work area is well ventilated.

Never lean over battery while boosting, testing or charging.

3.3. Safe Battery Installation

To assure safe installation and proper operation, follow these installation procedures:

Warning: Most late model vehicles contain computerized engine controls. Disconnecting your
battery may result in the loss of memory contained in the powertrain control module. The memory
loss could affect, for example, the engine, transmission, brake and suspension systems and other
systems. In some instances, the anti-theft and sound system will be disabled and require security
codes to reactivate. CONSULT YOUR VEHICLES OWNERS MANUAL, VEHICLE DEALERSHIP
OR YOUR LOCAL MECHANIC REGARDING THE SAFE AND PROPER INSTALLATION OF A
NEW BATTERY.

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Disconnect ground cable first (this is usually the negative cable, however, older vehicles may have a
positive ground).

Remove old battery – note position of positive (+) terminal and negative (-) terminal. Mark the cables
for correct connection to new battery. In most vehicles, the positive will have a red cable or molded
end, and the negative will have a black cable or molded end.

Clean terminals and cable connections with a wire brush. Broken connections or frayed or cut cables
should be replaced.

Install the new battery in the same position as the old one, be sure to secure it with the hold-down
assembly.

Make sure battery terminals do no touch any metal mounting, engine or body parts.

Connect cables tightly. Reconnect the cables in the opposite order they were removed, i.e. ground
cable connection should be made last to avoid sparks.

3.4. Safe Charging

Before beginning the charging operation, read the instructions that come with the
charger. Never attempt to charge a battery without first reviewing the instructions for the
charger being used. In addition to the charger manufacturer‟s instructions, these general
precautions should be followed:

Always charge batteries in a well-ventilated area and wear proper eye protection.

Turn the charger and timer “OFF” before connecting the leads to the battery to avoid dangerous
sparks.

Never try to charge a visibly damaged or frozen battery.

Connect the charger leads to the battery; red positive (+) lead to the positive (+) terminal and black
negative (-) lead to the negative (-) terminal. If the battery is still in the vehicle, connect the negative
lead (after connecting to the positive) to the engine block to serve as a ground. (If the vehicle is
positive grounded, connect the positive lead to the engine block.)

Make certain that the leads to the connections are tight.

Follow the recommended charging instructions found in the charger manual. Consult the with the
battery manufacturer or point of battery purchase if you have additional questions. If the charger has
a timer, turn the charger on and slowly increase the charger rate until the desired ampere value is
reached. Or select the correct charging function based on the manual recommendation.

If the battery becomes hot or if violent gassing or spewing of electrolyte occurs, reduce the charging
rate or temporarily halt the charger.

Always turn the charger “OFF” before removing charger leads from the battery to avoid dangerous
sparks.

3.5. Handling Battery Acid

Battery acid, or electrolyte, is a solution of sulfuric acid and water that can destroy
clothing and burn the skin. Use extreme caution when handling electrolyte and keep an

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acid neutralizing solution – such as baking soda or household ammonia mixed with
water – readily available. In the event of a spill:

Always wear proper eye protection.

If electrolyte is splashed into the eye, immediately force the eye open and flood it with clean cool
water. Get prompt medical attention.

If electrolyte is taken internally, drink large quantities of water or milk. DO NOT induce vomiting. Call
a physician immediately.

Neutralize with baking soda any electrolyte that spills on a vehicle or in the work area, rinse
contaminated area with clean water.

To prepare electrolyte of a certain specific gravity, always pour the concentrated acid slowly into the
water; DO NOT pour water into the acid. Always stir the water while adding small amounts of acid. If
noticeable heat develops, allow the solution to cool before continuing to add acid.