TECHNICAL INFORMATION

CROSS REFERENCE
Click here to view a table of cross references

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REGISTRATION DATES
Click here to view a table of registration dates

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GUARANTEE
Yuasa batteries sold as replacement are guaranteed against failure caused by faulty material or workmanship. In the event of such failure, the battery will be exchanged free of charge by a Yuasa Distributor in the UK provided that the battery is accompanied by a proof-of-purchase.

Important – Exclusions
This guarantee excludes batteries fitted as Original Equipment or used on the following applications:

• Taxi cabs (including private cars used as taxis or for private-hire).
  
• PSVs (Passenger Service Vehicles)
  
• Ambulances.
  
• Police cars.
  
• Fire-engines.
  
• Cars (but not CV’s) used on a 2 or 3 shift/day basis.
  
• Trailers and caravans.
  
• Lawnmowers.
  
• Electrically-powered wheelchairs.
  
• Televisions.
  
• Golf-trolleys and ‘buggies’.
  
• Emergency lighting.
  
• Marine usage.
  
• Electrically-powered bicycles and tricycles.
  
• Other non-automotive usage including standby.

However, batteries used in these applications carry a full one-year Guarantee against faulty material and workmanship.

This Guarantee is valid only for the purchaser of the battery, and is not transferable.
This obligation excludes:

1. Failure resulting from wear-and-tear, misuse, and negligence either before or during use. Examples are overcharge, deep cycling, sulphation and undercharge.
   
2. Failure resulting from the use of any fluids other than distilled or deionised water, or from any action not recommended for Yuasa batteries.
   
3. Use of a battery-type on a vehicle or unit for which it is not recommended or on which it has been installed and commissioned incorrectly.
   
   

The guarantee-period is deemed to start:

• Original battery. From date-of-purchase.
  
• Free replacement battery. From date-of-purchase of the original battery.

This Guarantee does not affect the statutory rights of the consumer in any way.
This Guarantee is subject to the Terms and Conditions of Sale of Yuasa Battery Sales (UK) Ltd

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HOW A BATTERY WORKS

What Is a Battery?
A battery is a device for storing electrical energy in a chemical form, and then releasing it as direct current in a controlled way.

All types of batteries contain a positive and a negative electrode immersed in an electrolyte, the whole assembly being within a container

All Yuasa batteries are lead-acid batteries, which means that they have positive and negative electrodes made of lead compounds in a dilute sulphuric acid electrolyte.

Lead-acid batteries are secondary batteries, which means that they can be recharged after they have been discharged. Primary batteries can be discharged only once and then have to be thrown away; examples are some types of torch and radio batteries.

How a Yuasa Battery Works
The positive electrode is made of lead dioxide and the negative electrode is made of porous lead.
When an electrical load (for example, lights or a starter-motor) is connected across the battery, a current flows through the electrolyte in the battery and through the external load. This causes the battery to discharge, which results in the chemical composition of both the electrodes changing to lead sulphate.
A battery can be charged by putting a current through the battery from an outside source of electricity such as an alternator, dynamo or charging unit. This converts the lead sulphate back to the original materials of lead dioxide and porous lead.
As the battery becomes charged, the electricity begins to decompose (hydrolyse) the water in the electrolyte into its constituent elements of hydrogen and oxygen, which are released as gas. This is why a battery gases when it is charged.

What is a Battery Made of?
Grids
As the positive and negative electrodes are made of weak materials, they need a mechanical support which is provided by a grid made from a lead alloy; lead on its own would be too soft.
In addition to providing a support for the electrodes (the active material), the grid also conducts electricity from the electrodes to the outside load.

Electrodes
The electrodes are initially made from a mixture of lead oxide and lead sulphate, and this is converted into lead dioxide in the positive plate and porous lead in the negative plate when the battery is initially charged.
The negative electrode also contains small amounts of additives to give the battery a good discharge performance at low temperatures to improve starting.
The combination of grid and electrode is normally called a plate.

Electrolyte
The electrolyte is dilute sulphuric acid. This acts as a conductor to transport electrical ions between the positive and negative plates when the battery is being charged or discharged.
The acid also takes part in the discharge as the sulphate ions react chemically at the electrodes to produce lead sulphate.

Separator
The separator is an insulator placed between the positive and negative plates to prevent them shorting together.
The separator needs to be microporous with very small holes to allow the ions to flow through the separator from one plate to another. It also needs to be able to resist the high temperatures and strongly acidic oxidising conditions that occur in a battery.
Most modern separators are made of microporous polyethylene, which has the right properties to meet the demanding conditions within the battery.

Container and Lid
These are normally made of polypropylene, which is a light but strong plastic. Unlike some plastics, it does not become brittle when it is cold, and so can resist knocks during handling. It is not attacked by acid and it can also withstand the fluids (petrol, diesel, brake-fluid, antifreeze) normally found on a vehicle.

What Makes a Battery Maintenance-Free?
30 years ago, batteries lost water at a high rate, and motorists were advised to check the acid level as one of their weekly checks; modern maintenance-free batteries need no water addition throughout their life under normal operating conditions. Incidentally, during the same period, battery life has doubled from 2 years to 4-5 years.
In the past, battery grids were made of an alloy of lead with 10 per cent of antimony; the purpose of the antimony was to give rigidity as pure lead would be too soft on its own. Unfortunately, some of the antimony dissolved in the acid and resulted in the battery losing water.
With improvements in battery technology, we have been able to reduce the antimony content from 10 per cent to 1.5 per cent, and this reduction has resulted in batteries that are low maintenance, needing only yearly attention.
The latest improvement has been the use of 0.1 per cent of calcium as a hardening agent in grids in place of antimony; this causes less contamination of the acid and much reduced water loss, making the battery maintenance-free so no water needs to be added during its operational life.

Service Problems
Overcharge
Modern car charging systems allow only a small current to flow into the battery when it is fully charged. If there is a fault in the alternator, however, a much higher current will pass through the battery all the time that the car is running. This current will cause the battery to lose water rapidly, destroying the maintenance free characteristics of the battery, and will also reduce the life of the battery by damaging the positive grids.

A dark brown/black colour on the bottoms of the vent-plugs is a strong sign of overcharge.
If an alternator has a voltage above about 14.7 – 14.8 Volts at normal temperatures, this is a sign that the charging system is faulty.

Deep Cycling
Modern charging systems keep the battery in a high state-of-charge while the car is running under most operating conditions. However, the battery will discharge under abnormal conditions or if the car is allowed to stand with a load on, for example, lights. On modern cars when parked, there is normally a constant drain on the battery caused by such components as the computer, alarm system, clock etc, and this will cause the battery to become discharged. Depending on the vehicle, this can take weeks or months.

Vehicle batteries are designed to accept some cycles of discharge and recharge, but are not designed for applications in which there are constant cycles of charge and discharge (deep cycling). Leisure batteries have been designed for these types of application, and have a special construction to enable them to be deep cycled on a continuing basis.

Continual deep cycling of vehicle batteries will cause failure as the positive active material will gradually fall to the bottom of the battery, reducing the ability of the plates to store electricity.
A large number of small black/brown particles in the electrolyte are a strong indication that the battery has been deep cycled.

Sulphation
As explained earlier, sulphation is a normal part of the operation of a battery, and occurs whenever a battery is discharged. When the battery is recharged, the sulphation (lead sulphate) is changed back into active material.

If a battery is left flat for a period of time, this sulphation slowly changes its form into one that cannot be changed back into active material on charging, so, after charge, the battery will not return to give its original performance. If the sulphation is bad enough, the car will not start. This is the problem normally referred to as sulphation.

Undercharge
Undercharge occurs if the battery is not receiving enough charge to return it to a full state-of-charge; this will slowly cause sulphation. This fault can occur if the car is being used only occasionally for short journeys, or for stop-start urban motoring. Undercharge will also occur if the alternator voltage is in the region of 13.6 - 13.8 Volts

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UNDERSTANDING THE SPECIFICATIONS
Cold Cranking Performance (Amps) – SAE
The Cold Cranking Performance (CCA) measures the starting performance of the battery. In simple terms, the higher the CCA, the easier it will be to start the vehicle.

This is the starting test according to the SAE (Society of Automotive Engineers). The test specifies that the battery at a temperature of –18°C will deliver a current equal to the Cold Cranking Amps for 30 seconds with the voltage staying above 7.2 volts (3.6 volts for a 6 volt battery).
Battery performance drops off quickly with temperature, so this test is a good check of a battery’s starting ability.

Some other manufacturers use other CCA standards, for example, DIN, the German standard, JIS, the Japanese standard, ETN, the European standard etc. These will give different values to the SAE value.

Reserve Capacity (Minutes)
The Reserve Capacity is the amount of time in minutes that a battery at 25°C can deliver a current of 25 Amps until the voltage drops to 10.50V (5.25V for a 6 volt battery).

25 Amps represents a typical electrical load on a car under normal running conditions, so the Reserve Capacity gives an indication of the time that a vehicle with a normal electrical load will run with a broken alternator or fan-belt. This is a good, practical test.

Obviously, the more electrical accessories you turn off, the further you can drive the car.

Ampere-Hour Capacity at 20 Hour Rate (Ah)
The Ampere-Hour Capacity measures the total amount of electricity stored in a battery.
An Ampere-hour represents the amount of electricity when a current of 1 Ampere passes for 1 hour.
The Ampere-Hour Capacity varies with the rate at which the battery is discharged; the slower the discharge, the greater the amount of electricity that the battery will deliver.

The Ampere-Hour Capacity is the amount of electricity that a battery will deliver during 20 hours before the voltage falls to 10.50V. For example, a 60Ah battery will deliver a current of 3A for 20 hours.

Recommended Charge Rate (Amps)
This is the recommended current for charging batteries with a constant-current charger.
For more details, see Section G of ‘Information about Batteries’ in this Catalogue.

Dimensions – Length (mm)
This is the dimension over the longest part of the battery, including the hold-down if fitted.

Dimensions – Width (mm)
This is the dimension over the widest part of the battery, including the hold-down if fitted.

Dimensions – Height (mm)
This is the overall height of the battery to the tops of the terminals if these are proud of the lid.

Weight with Acid (kg)
This is the average weight of the battery as supplied.

Cell Layout
See the diagram on page 6 showing cell layouts and polarity.

Terminal
The diagram on page 6 shows the types of terminal fitted to each type of battery.

Container Features
The diagram on page 6 shows information about container hold-downs and other features.

Handles
A * in this column shows that the battery is fitted with carrying handles.

End-Venting
There are now several batteries in the range that have end-venting, rather than the normal venting through the individual vent-plugs.

A * in this column shows that the battery is fitted with end-venting at the negative end.

Japanese True-Fit
A * in this column shows that the battery has the same dimensions, features and performance-level as an original Japanese battery.

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HEALTH & SAFETY INFORMATION

Handling and the proper use of Lead Acid Batteries are not hazardous providing sensible precautions are observed, appropriate facilities are available and personnel have been given adequate training.

In accordance with the Consumer Protection Act 1987, the purpose of this guide is to :-
1. Indicate the main hazards which may arise
2. Outline the precautions to be taken to minimise such hazards
3. Indicate the emergency actions to be taken in the event of the occurrence of a hazard

A - Label Information
The following symbols are being used on all batteries and mean the following:

	Note Operating Instructions
	Shield eyes – eye protection must be worn
	Keep away from children
	Battery acid – corrosive and poisonous
	No smoking – no naked flames – no sparks
	Explosive gases
	Contains lead
	Never dispose of as domestic waste – take to a designated waste reclamation site
	Battery is recyclable – follow local recycling & reclaiming procedures

B - Battery Acid
The Hazard
Batteries contain Sulphuric Acid which may leak for various reasons. Also acid may be given off as droplets and/or spray/mist during recharge.

Sulphuric Acid is a corrosive and poisonous liquid which will cause burns and irritation to the skin and eyes and could severely damage clothing.

Refer to Health & Safety Executive Guidance Note EH40 for the latest occupational exposure limits for acid mist in air.

Precautions

• Always handle batteries with care
  
• Never overfill with acid
  
• Always store upright
  
• Never allow children access to a battery
  
• Always charge in a well ventilated area
  
• Never allow battery vents to become blocked
  
• Always wear eye protection
  
• Always wear protective clothing

Accident or Emergency Action & Treatment

Skin contact –
Immediately soak the affected area with copious amounts of clean water, remove any contaminated clothing and seek medical attention if irritation persists.

Eye contact –
Immediately irrigate eyes for at least 10 minutes with clean water, seek medical attention

Ingestion –
Immediately drink as much water as possible – do NOT induce vomiting, seek urgent medical attention

Spillages –
For small spillages wash away with large quantities of water. For larger volumes dispose of in suitable acid resistant containers, clearly labelled – see section H

C - Electrical Energy
The Hazard
Accidental short circuit of battery terminals by a conductive object, such as a metal tool or item of jewellery etc. may generate sufficient heat to cause severe burns, create arcing or cause any metal to melt and splash.

Severe electrical shocks may be received from faulty mains electrical charging equipment and during the recharge of high voltage battery systems or the recharge of a number of batteries connected in series i.e. 5 or more 12V batteries in series = 60V nominal.

Precautions
Always remove metal objects from hands, wrists & neck e.g. rings, bracelets, watches & necklaces.

Always, when working on vehicle electrical systems, disconnect the battery, but before disconnection :-

• Switch off all electrical loads
  
• Refer to vehicle manufacturer’s handbook
  
• Make the first disconnection and the last reconnection the earth point as far from the battery as possible

Always take great care to avoid shorting the live terminal to earth

Never place tools or metal objects near to or on top of a battery

Accident or Emergency Action & Treatment
Burns –
Apply a dry sterile dressing and seek medical treatment

Electric shock
Approach person with care. If the individual is clear of the conductor then, with caution, switch off equipment or break the current. If the individual is still attached to the conductor do not touch with bare hands. If possible use a suitable insulating material e.g. wood, rubber, plastic or rolled paper, to detach the conductor from the victim. If necessary, summon assistance then give artificial respiration until it arrives.

D - Emission of Gases
The Hazard
Hydrogen gas emitted during charging is explosive at concentration levels above 4%. Hydrogen & oxygen gases are both evolved during battery recharging. These gases may also be emitted at other times, for example, if the battery is moved or shaken

Precautions

• Always charge in a well ventilated area
  
• Always ensure the charging leads are correctly fitted before switching on the mains
  
• Always ensure the mains is switched off before disconnecting the charging leads
  
• Always use eye protection and protective clothing
  
• Always wait at least 5 minutes after ceasing recharge before disconnection
  
• Always take care to ensure that cables and connections are handled in a way that avoids accidental sparking

Never smoke near a battery

Never allow naked flames near a battery

Never create sparks near a battery

Accident or Emergency Action & Treatment

Seek medical advice as appropriate to injury
In an explosion acid will have been sprayed and ejected and plastic & metal parts may have caused severe lacerations.

E - Jump Starting
The Hazard
Use of an incorrect procedure when “jump starting” a vehicle could result in a battery explosion, fire and burns to the individual as well as damage to the vehicle electrical system

Precautions
Always follow the correct procedure as defined in the vehicle manufacturers handbook.

In the absence of this information, for a negatively earthed vehicle :-

1. Make sure the vehicles are not touching and that the ignition in both vehicles is turned off. Ensure both vehicles are in neutral or “park”
   
2. Connect the positive (red) cable from positive terminal on one vehicle battery to positive terminal on the other vehicle battery
   
3. Connect the negative (black) cable to the negative terminal of the vehicle with the “flat” battery – keeping clear from fuel lines and brake pipes.
   
4. Connect the negative cable to the negative terminal of the current supplying vehicle, or to an earthed point on the vehicle away from the battery e.g. engine casing.
   
5. Ensure all connections are tight and away from moving or rotating components
   
6. Start the engine of the vehicle with the “good” battery and allow to run for one minute.
   
7. Start the engine of the vehicle with the “flat” battery and allow to run for at least one minute.
   
8. Stop the engine of the vehicle with the “good” battery
   
9. Remove the cables in the opposite order keeping them well away from any moving or rotating components on the vehicle.

Accident or Emergency Action & Treatment
Seek medical advice as appropriate to the injury

F - Weight
The Hazard
Batteries are awkward and heavy to handle resulting in possible strains to the human body as well as potential for dropping the battery, with resultant acid spillage, injury etc.

Precautions
Always use correct lifting procedures to minimise strain to the human body
Always use lifting handle or lifting ledges if available on the battery

Accident or Emergency Action & Treatment
Seek medical advice as appropriate to the injury. Remember that acid may have been spilled.

G - Repairing of Damaged Batteries
No attempt should ever be made to renovate or repair a damaged battery.

This work involves all of the hazards detailed in sections A to F above and should only be carried out by suitably trained personnel with appropriate facilities and in accordance with the manufacturer’s instructions.

H - Disposal of Batteries & Associated Waste
All spent batteries and waste arising from spillages and fires must be disposed of in conformance with the Environmental Protection Act, the Special Waste Regulations 1996 and the Environmental Protection (Duty of Care) Regulations 1991.

G & P BATTERIES offer a complete battery disposal service.

For further information please contact G & P BATTERIES directly at the address below :-

Crescent Works Industrial Park
Willenhall, Road, Darlaston, Wednesbury
WS10 8JR
Tel : 0121 568 3200 Fax: 0121 568 3201

I - Fire
Since batteries contain combustible materials, the local Fire Authority should be consulted where a quantity of batteries are stored together.

J - Safety Data Sheet
More detailed Health & Safety information is available in the following publication:- SAFETY DATA SHEET – Batteries, Wet, Filled with Acid,
This is available from :-
Yuasa Battery Sales (UK) Ltd
Unit 22, Rassau Industrial Estate
Ebbw Vale, Gwent
U.K.
NP23 5SD
Tel: 08708 500 259 Fax: 08708 500 265

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ALL YOU NEED TO KNOW ABOUT BATTERIES

Contents
A - Storage.
B - Maintenance of Stock.
C - Commissioning.
D - Electrolyte-Levels (Acid-Levels) in Service.
E - Selecting the Correct Battery for the Application.
F - Removing Batteries and Installing Batteries on Vehicles.
G - Charging Off-Vehicle.
H - Checking Battery-Performance.
I - Maintenance in Service.

A - Storage

1. Always rotate your stock. Practise FIFO (First In, First Out). Batteries slowly lose their charge, and good stock-rotation stops batteries going flat in storage and makes sure that the customer buys a good battery.
   There is a label on the battery showing the number of the week in which the battery was charged. This makes it easy to tell which are the oldest and newest batteries.
   
   
2. Store batteries in a cool, dry, well-ventilated area.
   
3. Protect batteries from excessive heat. (Heat causes batteries to lose charge more quickly, and excessive heat can damage batteries).
   
4. Store batteries in an upright position. (To stop them falling over or leaking).
   
5. Do not stack batteries on top of other batteries. (To avoid scratching, and tearing labels. To avoid damaging terminals that stand proud of the lid).
   
6. Store shrink-wrapped batteries up to 3 high. (Any higher and there is a risk of them falling over and injuring people).
   
7. Do not remove any seals from dry-charged batteries until you are ready to commission the battery by filling it with acid. (The seal preserves the charge in the battery. If it is broken, air will enter and cause the battery to lose charge).
   
8. Store batteries on racks or on pallets, not on the floor. (Small stones or sharp points on a concrete floor can damage the base of the battery and cause leakage).
   
9. Make sure handles are left in the flat (down) position. Upright handles are more likely to be damaged.
   

B - Maintenance of Stock
Wet-Charged Batteries

1. Check the open-circuit voltage of the batteries in your stock every month using a digital voltmeter or a multimeter. If any have a voltage below 12.40V (6.20V for 6V batteries), give them a refreshing charge.
   (See Section G).
   
2. Scrap any batteries that drop below 11.00V. (These batteries will have developed a sulphation that cannot be completely reversed by charging, and so will not give the expected performance and life to the customer).

Dry-Charged Batteries

1. If you keep the batteries cool and dry, and do not remove the seal, dry-charged batteries do not need any other attention.
   
2. The maximum storage time of dry-charged batteries before they are commissioned by filling with acid is 24 months.

C - Commissioning
Wet-Charged Batteries

1. Do not supply a battery to a customer (end-user) if the voltage is below 12.40V (6.20V for 6V batteries). Charge any batteries with voltages below these values.
   
2. We recommend you check the condition of the battery before selling it using one of the methods described in Section H.

Dry-Charged Batteries

1. Only commission a dry-charged battery when it is needed for a customer.
   
2. If fitted, remove and discard any sealing plugs, tape or foil.
   
3. If fitted, remove and keep normal vent-plugs and terminal covers (usually red and black).
   
4. For filling, use battery-grade dilute sulphuric acid of specific gravity 1.270 – 1.280 at 25°C conforming to BS3031 or better. (Note: contaminated acid with impurities can seriously damage the life of the battery, in some cases reducing this to a few days. Do not use acid from old batteries).
   
5. The temperature of the acid and the battery should both be at room-temperature in the range 15 - 30°C.
   
6. Fill each cell with acid to a level of 3 – 6mm above the tops of the separators. Fill each cell one after the other and complete the filling in one operation.
   
7. Leave the battery for 20 – 30 minutes and then measure the open-circuit voltage. If it is below 12.50V, charge the battery. (See Section G). If it is above 12.50V, adjust the acid-levels to the correct operating levels with dilute sulphuric acid of specific gravity 1.270 – 1.280.
   (See Section D).
   
8. Fit the normal vent-plugs and terminal covers.
   
9. Wash the battery with hot water and dry it.
   
10. Note that performance checks on newly-commissioned dry-charged batteries with modern electronic digital testers using conductance technology are not recommended. Examples are testers supplied by Midtronics or Bosch. The results can be misleading until the battery has undergone some service use.

D - Electrolyte-Levels (Acid-Levels) in Service
Notes: Please read before adjusting acid-levels.

• Do not top up to the maximum levels a battery that needs charging. (Levels rise on charging). However, if the levels are below the tops of the separators, top up with distilled or deionised water until the separators are just covered.
  
• Adjust levels to the maximum levels only after the battery has stood for at least an hour after charging.
  
• Never overfill a battery. (The acid may come out of the vent-plugs when the battery is being charged).
  
• Use only distilled or deionised water for topping up. (Sulphuric acid should never be used except for the initial filling of a battery).

1. When the battery is in service, the electrolyte levels should be checked and adjusted to the levels given below.
   
2. If the battery has a maximum level line on the side of the container, fill to this maximum level.
   
3. If there is no maximum line, but there are filling tubes projecting from the bottom of the lid, fill to the bottom of the tubes.
   
4. If there is not a maximum line nor filling tubes in polypropylene batteries, fill to 7mm (0.25 inches) below the bottom edge of the lid-skirt.
   
5. If there are no filling tubes in hard-rubber batteries, fill to 15mm (0.5 inches) above the tops of the separators.

E - Selecting the Correct Battery for the Application
Car and Commercial Vehicle (CV) Batteries

1. Select the specified battery from the Application Section of this Catalogue.
   
2. On 24 Volt systems, or when 2 off 12 Volt batteries are fitted in parallel, both batteries should be replaced at the same time. Failure to do this will result in a greatly reduced battery life for the new battery that has been fitted.
   
   When batteries are joined in series, the negative terminal of one battery is connected to the positive terminal of the other, giving a total voltage of 24 Volts. The Ampere-hour capacity of the system is the same as that of the individual batteries.
   
   When batteries are joined in parallel, the positive terminals of the 2 batteries are connected together, and the negative terminals of the 2 batteries are also connected together. The voltage of the system remains unchanged at 12 Volts, but the Ampere-hour capacity of the system is double that of the individual batteries.
   

Leisure Batteries
1 Use the battery with the performance and size recommended by the equipment supplier.
2 We recommend that a leisure battery in a cycling application should be sized so that it is not normally discharged to more than 50 per cent state-of-charge. This will ensure that the battery gives a good life. The life of a battery regularly discharged by 50 percent is about 5 times that of a battery regularly discharged to 100 per cent. For example, a load of 3A for 10 hours will discharge a battery by 30Ah. If this represents 50 per cent state-of-charge, we would recommend a 60Ah battery.

F - Removing Batteries and Installing Batteries on Vehicles
Removing Batteries

1. It is good practice to tell the customer that, while you will do your best to keep the memory settings, it is possible these might be lost.
   
2. Make sure the hand-brake is on, and that the car is in neutral or park. Switch off all electrical loads and remove the ignition key from the car. Note: On some cars, the doors will lock when the battery is disconnected so this is why the key should be removed from the car. Also switch off any non-factory-fitted alarms.
   
3. Check that the cigar lighter is still working. If not, turn the ignition key to the auxiliary position. Install a Computer Memory Saver (CMS).
   
4. Disconnect the earth-connector first. (This is normally the negative on modern vehicles). This can result in the loss of memory settings; please refer to the vehicle handbook.
   
5. Disconnect the live-connector second. If a CMS is used, the connector will still remain live after it has been disconnected. To prevent the connector shorting against the car, place an insulator such as a rubber glove over the connector.
   
6. Remove the hold-down clamps.
   

Preparation of a Battery for Fitting

1. Check that the battery has the correct polarity for the vehicle.
   
2. Check that the battery has the correct height for the vehicle. (If a battery is too high, it can short out on the bonnet or the bottom of a seat, or it can damage the bonnet).
   
3. It is good practice to place the old and new battery side by side to compare polarities, hold-downs and performance-levels. Some batteries have hold-downs at both the sides and ends. Only the ones used for securing the battery on the vehicle need to be checked.
   
4. Check that the battery is clean and dry.
   
5. Check that the vent-plugs or manifolds are firmly in position.
   
6. Check that the battery has a voltage above 12.40V. If not, charge the battery or use another that has a voltage above 12.40V.
   
7. Ensure the 2 terminal caps are still fitted at this stage.

Preparation of the Vehicle

1. Clear away any items on the battery-tray which might damage the battery. (Placing a heavy battery on a piece of sharp grit can puncture the bottom of the battery).
   
2. Check that the connectors, the hold-down clamps and the tray are clean and corrosion-free. (If there is any corrosion, hot water will instantly remove this). If there is severe corrosion which might affect the stability of the battery or has affected other parts of the engine compartment, have the vehicle checked by an authorised distributor.
   
3. Check that the alternator drive-belt tension is correct. Refer to the vehicle handbook or service manual.
   
4. It is recommended that the electrical system, and particularly the charging system, of the vehicle be checked to make sure it is operating correctly. Refer to the vehicle handbook or service manual.
   

Installing the Battery

1. Fit and tighten the hold-down clamps. These should be tight enough to secure the battery and not allow it to move. DO NOT OVERTIGHTEN.
   
2. Connect the live-connector first to the correct battery-terminal (normally the positive) after removing the terminal cap. DO NOT OVERTIGHTEN.
   
3. Connect the earth-connector to the other terminal after removing the terminal cap. DO NOT OVERTIGHTEN.
   
4. Place the 2 terminal caps on the old battery that has been removed from the vehicle to avoid the possibility of short-circuits.
   
5. Replace onto the new battery any components that have been taken from the old battery such as exhaust tubes, vent-elbows, terminal covers, removable hold-down strips (widgets) etc.
   
6. The use of petroleum-jelly (Vaseline) is not necessary on modern polypropylene batteries, but there is no disadvantage in using it. Smear lightly on the terminals. It is still recommended for hard-rubber batteries. Do not use grease.
   
7. Remove the CMS.
   
8. Start the engine
   
9. For non-automotive applications, install the battery in line with the equipment-supplier’s recommendation.

G - Charging Off-Vehicle
Note: Please read before charging batteries

• Do NOT charge a battery if its temperature is below 3°C as the electrolyte may have frozen.
  
• Charging the battery on the vehicle is not recommended.
  
• Refer to Section F for information about removing the battery from the vehicle.
  
• ‘Sealed’ vehicle batteries should be charged only on constant potential chargers or ‘smart’ chargers. Do not charge on constant current chargers or boost chargers.
  ‘Sealed’ vehicle batteries do not allow any access to the electrolyte, and so cannot be topped up. There are no removable vent-plugs or manifolds. The battery is able to vent gases through breathing holes, and so it is not strictly sealed.
  
• A new, unused battery with a voltage below 11.00V should be scrapped and not charged. See Section B above.
  

General Procedure for All Types of Chargers
This section gives common information for all types of chargers. The sections below give details for different types of charger.

1. Check the electrolyte-levels in all the cells. If these are below the tops of the separators, top up with distilled or deionised water to the tops of the separators. Do not fill to a higher level before charging, but adjust the levels after charging. See Section D.
   
2. If you are using a constant-current charger or a boost-charger, remove the vent-plugs or manifolds before charging. (See below). There is no need to remove the vent-plugs or manifolds if you are using a constant-potential or a ‘smart’ charger.
   
3. Check that the charger is switched off.
   
4. When fitting the charger to the battery, connect the positive lead to the positive terminal and the negative lead to the negative terminal.
   
5. Switch on the charger. See below for the correct charging conditions depending on your type of charger.
   
6. Stop charging if the battery begins to gas freely (some gassing is normal during the last stages of charging) or if the battery temperature rises above 50°C.
   
7. Switch off the charger.
   
8. It is good practice to wait for about 20 minutes for the gases to clear before removing the leads from the battery as some chargers remain ‘live’ and can cause a spark.
   
9. Check the electrolyte-levels in all the cells and top up if necessary. See Section D.
   
10. Refit vent-plugs or manifolds if these have been removed.
    
11. Wash the battery with hot water and dry it.
    
12. Note. Many customers severely underestimate the amount of time necessary to charge a flat battery. This results in customers returning batteries saying that they have charged the battery but that it is still not holding charge.

Types of Charger and how to Use these.
There are many types of charger available; their working principles and the procedure for using these is given below.

Index

1 CONSTANT CURRENT CHARGERS.
These maintain a fixed, constant, preset current throughout the charging period irrespective of the battery on-charge voltage.

Charging Procedure with Constant Current Chargers

A Ideally, charge each battery on a separate charger unit. If this is not possible, charge batteries in series. We do not recommend charging batteries in parallel because it is not possible to control the amount of current passing through each battery.
If batteries in different states-of-charge are being charged in series, each battery should be removed as soon as it is charged. (If you wait until the last battery is charged, some of the batteries will be overcharged).

B Measure the open-circuit voltage of the battery. To obtain a stable voltage, the battery should not have been used or charged for a minimum of 3 hours before checking the voltage.

C Charge the battery at the recommended charge rate (See Battery Specifications section of the Catalogue). If you cannot set the recommended rate, extend or reduce the charging time on a pro rata basis.
For example, if the recommendation is to charge the battery at 4.0A for 6 hours (24Ah = 4.0 x 6), charge the battery for 12 hours if you can only set the charger at 2.0A (24Ah = 2.0 x 12).

D Charge the battery for the number of hours shown in the table below depending on the open-circuit voltage.
For example, if the battery has a voltage of 12.16V, charge it for 10 hours at the recommended charge rate.

E If you are charging a battery below 11.00V (overdischarged) that has been in service, a specialised charger capable of providing a very high charging voltage may be necessary, and the recommended current may not be obtainable at first. In this case, monitor the current and adjust as necessary during the charge.
If a battery has become overdischarged, it will have lost both life and performance because of irreversible sulphation. Charging may reduce further its potential life.

2 CONSTANT POTENTIAL CHARGERS.
These maintain a fixed, constant, preset voltage throughout the charging period. The current cannot be set and will fall as the battery state-of-charge increases.

Charging Procedure with Constant Potential and Modified Constant Potential Chargers.

A These chargers are normally designed to charge one battery at a time.
B Stop charging when the battery is gassing freely and the battery-voltage shows no increase over a period of at least 2 hours.
C Note. The majority of constant potential chargers are incapable of charging a severely overdischarged (below 11.00V) battery in a realistic period of time. A minimum of 24 hours is normal.
It might be impossible to charge an overdischarged battery.

3 MODIFIED CONSTANT POTENTIAL CHARGERS.
The majority of commercial chargers , particularly home-chargers, are of this type, and allow neither the voltage nor the current to be preset.

Charging Procedure with Modified Constant Potential Chargers.
A Use the same procedure as for Constant Potential Chargers in the paragraph above.

4 ‘SMART’ CHARGERS.
The latest generation of chargers is able to check the battery condition, and to supply automatically a controlled charge that will charge the battery in the fastest time without damaging it and without overcharging it at the end of the charge. Some ‘smart’ chargers have a special setting for all-calcium batteries and will charge these from flat, which most other chargers are unable to do.
Charging Procedure with ‘Smart’ Chargers
A Follow the manufacturer’s instructions.
B These chargers should be able to charge overdischarged (below 11.00V) batteries. Note that some have a special setting for all-calcium batteries.

5 BOOST CHARGERS.
These provide a very high initial current, and are used mainly to put some charge into a flat battery when it is needed urgently by the customer. The current falls as the battery state-of-charge increases, and the battery temperature is monitored to make sure it does not overheat.

Charging Procedure with Boost Chargers

A Boost charging is not recommended except in exceptional circumstances eg a stranded customer, as this will reduce battery life, especially if a battery is boost-charged more than once.
B Never boost-charge any battery that is below 11.00 Volts as it will be too sulphated to accept a charge; scrap the battery or charge normally.
C Only use a boost-charger that limits the charging voltage to a maximum of 14.2 Volts and that has a temperature monitor.
D Follow carefully the charger-manufacturer’s instructions.

H - Checking Battery-Performance
Electronic Testers Using Conductance Technology

1. The latest generation of testers is digital. Examples are Midtronics and Bosch testers. These will give an immediate decision on about 80 per cent of batteries in service, including flat ones. In the remaining 20 per cent of cases, the batteries need recharging before testing.
   
2. These testers show whether the battery is in a good, charged condition, whether it is discharged or whether it needs replacing.
   
3. Note. This is the preferred method of checking batteries as it does not take any charge out of the battery. It is also easier, quicker and safer.

Open-Circuit Voltage and High-Rate Discharge Testers

1. Measure the open-circuit voltage of the battery using a digital voltmeter or a multimeter. To obtain a stable voltage, the battery should not have been used or charged for a minimum of 3 hours before checking the voltage.
   
2. If the voltage is below 12.40V, charge the battery in accordance with Section G above.
   Note. This type of tester will only give an accurate result on a fully-charged battery. A common mistake is to use this type of tester on a discharged battery, and to judge that the battery is faulty if a cell is seen to ‘boil’. A ‘boiling’ cell on a flat battery does not mean that the battery is faulty.
   
3. Apply a current-load equal to half the SAE CCA cold cranking Amps for 15 seconds. For example, discharge a 600A battery at 300A. Observe the voltage during this time and record the voltage after 15 seconds. You will find the CCA in the Battery Specifications section of the Catalogue or on the label. Use an approved, calibrated tester.
   
4. If the voltage after 15 seconds is stable and above 9.60V, the battery is in a satisfactory condition with no faults.
   
5. If the voltage is below 9.60V after 15 seconds and it is unstable, normally falling quickly, the battery should be replaced.

‘Drop Testers’

1. ‘Drop testers’ have 2 spikes that are pressed into the tops of the battery terminals and a simple voltmeter to check the discharge voltage.
   
2. We do not recommend the use of these testers as:

• They are potentially unsafe to use as most types produce a spark when the spikes are first pressed into the terminals.
  
• The discharge rate is similar for all sizes of battery, and so they do not give a good indication of battery-condition.
  
• They give misleading results on discharged batteries.

I - Maintenance in Service
General

1. Always refer to the information contained in the handbook or brochure supplied with the vehicle or equipment.

Definition of Maintenance-Free

1. Our starter batteries for cars and commercial vehicles conform to the relevant sections of BS EN 50342-1: 2006 for maintenance-free characteristics.
   This means that in normal vehicle applications in temperate climate operation, it is not necessary to add water.
   
2. Our batteries are designed to be topped up with water if water should be lost owing to, for example, a charging system fault, prolonged operation in hot climates, excessive off-vehicle charging etc.
   
3. Note. The term maintenance-free applies only when the battery is used in an approved automotive or commercial vehicle application.

Definition of Low Maintenance

1. Low maintenance batteries in normal vehicle applications in temperate climate operation need water-addition only at yearly intervals.
   
2. Our batteries are designed to be topped up with water if water should be lost owing to, for example, a charging system fault, prolonged operation in hot climates, excessive off-vehicle charging etc.
   
3. Note. The term low maintenance applies only when the battery is used in an approved commercial vehicle application.

Battery Maintenance in Automotive Applications

1. Carry out the checks below at the recommended vehicle service intervals.
   
2. Check the electrolyte-level and top up with water if necessary. See Section D above for details about how to do this. (As explained above, it should not be necessary to add water unless the battery has encountered exceptional conditions).
   
3. Check that the battery is clean and dry and that the vents are not obstructed.
   
4. Check that the terminal-connectors and the hold-down clamps are securely-connected and corrosion-free.
   
5. If the battery is on a vehicle that is not to be used for an extended period (more than 1 month), disconnect it from the vehicle. Refer to Section F for information about removing the battery from the vehicle. Modern cars have electrical accessories that slowly discharge the battery even when the ignition key has been removed.
   Some accessories such as alarms, trackers, and phones can cause a battery to become discharged in a few weeks.
   
6. Fully charge the battery before storage and give it a refreshing charge every 3 months. See Section G above.
   

Battery Maintenance in Non-Automotive Traction and Deep Discharge Applications

1. Typical applications are lawnmowers, electric wheelchairs, caravans etc. The Leisure Battery range is recommended for these applications; standard vehicle batteries are not suitable.
   
2. Ensure that the battery is always kept in as high a state-of-charge as possible. Always recharge immediately after use.
   
3. Check the electrolyte-levels on a regular basis dependent upon use. Charging batteries regularly on a non-vehicle charging system may result in a higher rate of water-loss.
   
4. Check that the battery is clean and dry and that the vents are not obstructed.
   
5. If the battery is not to be used for an extended period (more than 1 month), fully charge it before storage, and give it a refreshing charge every 3 months. See Section G above.
   

Battery Maintenance in Non-Automotive Float Applications

1. Typical applications are motor-generators, stand-by applications etc. The Leisure Battery range is recommended for these applications; standard vehicle batteries are not suitable.
   
2. Batteries used in these applications should be changed every 2 years or more frequently. (Continuous charging, even from a well-controlled charging system, will result in internal degradation of the battery. This could result in the battery not giving its predicted output when required even though the battery appears to be fully-charged).
   
3. Ensure that the battery is always kept in as high a state-of-charge as possible without causing excessive overcharge. Always recharge immediately after use.
   
4. Check the electrolyte-level on a regular basis dependent upon use, but not less frequently than monthly. Charging batteries continuously on a non-vehicle charging system may result in a higher rate of water-loss.
   
5. Check that the battery is clean and dry and that the vents are not obstructed.
   
6. If the battery is not to be used for an extended period (more than 1 month), fully charge it before storage, and give it a refreshing charge every 3 months. See Section G above.
   
7. Best practice is to define a regular maintenance-routine, and to record the results.
   This should include such variables as the amount of water added to each cell, specific gravities in each cell, battery voltage etc.
   

Use of Battery Additives

1. We do not recommend the use of battery additives.
   
2. The use of these invalidates the guarantee.

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TERMS AND CONDITIONS

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