TM 10-6140-200-14
Section II. REPAIRING BATTERIES
remain for rebuilding later. (See Figure 3-1). The drills
3-5. General
come in different sizes. When using them be careful to
cut only as deeply as necessary, usually 1/4" to 3/8".
a. Storage batteries which have been damaged or which
Make certain vent plugs are in place. During drilling try to
contain defective cells may, if the rebuilding cost and
center on the cover bushing and make sure any lead curl
time are justified, be restored to a serviceable condition.
produced does not short across other connectors. After
drilling, the intercell connectors can be lifted off with a
b. It is important to check a battery thoroughly if it has
pair of pliers.
been involved in an accident or if it is believed to be
defective. A neglected battery will continue to deteriorate
even when not in use. Usually rebuilding is justified if the
majority of cells are in good condition.
c. This section explains how to remove cells from a
battery and how to repair them if they are to be salvaged.
Some special tools and parts will be required depending
upon the work to be done. Reference will be made to the
use of such special devices but they will not be further
identified in this manual. Although there is much simi-
larity of tools and battery parts among the various
battery manufacturers, the differences that exist are
critical. For this reason you must, when replacing or
repairing cells, refer to the applicable battery manu-
facturers listing of special tools, accessories and replace-
ment parts. These will be referenced in the General
Services Administration, Federal Supply Catalog, FSC
Group 61, part 11, Class 6140-Batteries-Heavy Duty,
Electric Storage. Each manufacturer identifies all tools,
accessories and replacement parts by an appropriate part
number. Use this number when making reference to them.
d. The General Services Federal Supply Catalogs can be
requisitioned from: General Services Administration, Cen-
tralized Mailing Lists Services, Building 41, Denver Fed-
eral Center, Denver, CO 80225.
Figure 3-1. Drilling cell connector
3-6. Purging of Gas
Before starting any repairs, remove all vent caps from
3-8. Removing a Complete Cell
cells to be repaired as well as from all surrounding cells.
The space above the electrolyte must be cleared of
hydrogen gas before proceeding with repairs. This can be
isolate the cell from adjacent cells. This may require
accomplished by introducing a low volume air stream
cutting of compound or removal of spacers. Use a long
(volume and force equal to that produced by fanning
spatula or similar tool to free the cell from top to
each cell with a stiff piece of cardboard or other suitable
bottom When the jar walls are free the cell can be lifted
from the battery tray. All cells are heavy so a suitable
nonconducting material) into each cell for at least 30
seconds. Be very careful when using air so that the
lifting device, such as an electric hoist, is recommended.
electrolyte is not splashed out of the cell. Do not blow
Threaded post clamps or cell pullers are available which
breath into cells. Wear protective face shield or goggles,
can be burned or clamped to the posts, as shown in
rubber gloves and apron. After cells have been purged,
cover all vent openings with several layers of water
ing bar between the loops of the post clamps and hook
dampened cloth before starting repairs.
the hoist to this bar.
b. After removing the cell, neutralize any acid in the tray
3-7. Removing Intercell Connectors
with a soda solution and clean up the residue.
Each battery manufacturer offers special intercell con-
nector drills designed to cut the bond between the cell
c. When a cell or element is being pulled, it is advisable
post and the connector while permitting the post to
to have on hand both a replacement jar and a cover in
3-4
