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TR 1170-85
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TECHNICAL REGULATIONS WAR DEPARTMENT,

No. 1170-85 } WASHINGTON, September 2, 1930.

AIR CORPS

BATTERIES FOR USE IN AIRCRAFT

Prepared under direction of the

Chief of the Air Corps

Paragraphs
SECTION I. Description and operation__. 1- 5
II. Maintenance 6-15
III. Repair---. 16-19

SECTION I

DESCRIPTION AND OPERATION

Paragraph
Purpose . 1
Construction_ 2
Operation 3
Air Corps requirements 4
Aircraft storage batteries- 5
1. Purpose. The aircraft storage battery furnishes electric current for the
ignition system, engine starter, lighting system, heating system, radio trans-
mission, certain cameras, bomb sights, and other electrically operated aircraft
equipment.
2. Construction. -a. The unit of a storage battery is the cell. An active
storage cell consists of electrodes ( negative and positive plates ) submerged in
electrolyte ( solution of sulphuric acid and distilled water ) .
(1) The positive electrode or plate is a lead grid or frame holding lead
peroxide. This lead peroxide is of reddish-brown color and the positive plates
may be identified in this way. The negative electrode or plate is a lead grid
holding soft metallic (spongy ) lead which is gray in color. Both the lead
peroxide and spongy lead, which are sometimes referred to as pastes, are
slightly soluble in sulphuric acid and are, therefore, active materials.
(2 ) The electrolyte is concentrated sulphuric acid added in sufficient
quantity to pure distilled water to form a solution whose density or specific
gravity is 1.275 to 1.285. ( The reading on the scale of the hydrometer omits
the decimal point. ) The specific gravity of water is 1.000 ; that of sulphuric
acid is approximately 1.835.
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2-3 AIR CORPS

Sulphuric acid solutions (electrolytes)

[Based on one part acid of 1.835 specific gravity at 60° F.]

Parts of water Percent- Freez- Parts of water Percent- Freez-

Specific to one part acid age of ing Specific to one part acid age of ing
gravity of sul- point in gravity of sul- point in
solution, phuric degrees solution, phuric degrees
70° F. By By acid in Fahren- 70° F. By By acid in Fahren-
volume weight solution heit volume weight solution heit

1100. 9.8 5.4 14. 65 +18 1260_ 3.05 1.66 35.0

1120. 8.0 4.4 17.4 +14 1280 . 2.75 1.49 37.3
1140. 6.68 3. 63 20. 1 +8 1300 . 2.47 1.34 39.65
1160_ 5.7 3. 11 22.7 1320_ 2.24 1.22 42.0
1180. 4.95 2.7 25. 2 -6 1340. 2.04 1.11 44. 1
1200- 4.33 2.36 27.7 -16 1360 1.86 1.01 46.3
1220_ 3.84 2.09 30.2 -31 1380. 1.70 92 48.4
1240. 3.4 1.86 32.5 -51 1400 1.56 .84 50.5

b. The negative and positive plates are constructed in separate groups and
then interleaved so there are alternately a positive plate and negative plate.
To prevent the plates from touching, separators of wood or rubber material
are used. These separators prevent metallic contact of the plates of opposite
polarity (negative and positive ) but do not interfere with passage of the
electric current through the electrolyte from one plate to the other. The
grooved side of the separator is always placed next to the positive plate.
Since a negative plate is always placed at either side of a positive plate,
there is an odd number of plates to each cell. This is an advantage, as it
gives action on each side of the positive plate. ( See fig. 1. )

CELL CONNECTION
SEALING NUT VENT PLUG GASKET

POSITIVE POST CELL COVER

ACID CHAMBER WHILE -NEGATIVE POST

BATTERY IS INVERTED
POST GASKET
PROPER ELECTROLYTE
LEVEL WITH BAFFLE FILLER CAP AND
PLATE VENT PLUG

POSITIVE STRAP- PROPER ELECTRO-

LYTE LEVEL WITH-
POSITIVE PLATE- OUT BAFFLE PLATE

WOOD SEPERATOR- NEGATIVE PLATE

BRIDGE SEDIMENT OR MUD SPACE

FIGURE 1.- Component parts of storage battery

3. Operation. -a. With the electrodes and electrolyte properly placed in a

nonmetallic container, the changes that take place in an active storage cell
during charge and discharge will be considered. A storage cell is in reality an
accumulator which is reversible in action. It breathes in acid and discharges
electricity or, conversely, breathes in electricity and discharges acid. The
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BATTERIES FOR USE IN AIRCRAFT 3-5

plates, therefore, may be termed the lungs of the battery. When the battery
is charged, the plates are full of electricity. When the battery is discharging,
the electricity is dispelled from the plates or lungs and the acid enters them.
This is the fundamental process which takes place and any departure from
these normal conditions in the cell shortens its life.
b. When a storage cell is discharging, electrical energy is released by the
action of the sulphuric acid on the active material of the positive ( lead per-
oxide ) and negative ( spongy lead ) plates. The sulphuric acid of the electro-
lyte is the conductor of the current between the negative and positive plates.
In effect what happens is that the sulphuric acid separates from the distilled
water and unites with the active materials of the positive and negative plates,
forming a sulphate on them and releasing hydrogen and oxygen. In normal
discharges the hydrogen and oxygen gases unite, forming water. As the water
is lighter than the acid, the density or specific gravity of the solution is
lowered during discharge of the cell.
c. The action that takes place in a cell which is being charged is just the
opposite of that taking place during discharge. An electric current is passed
through the cell from an outside source, in a direction opposite to that flowing
on discharge, the sulphate on the plates returns to the electrolyte, uniting
with the water to form sulphuric acid, and the active materials of the plates
return to their normal state. In charging a storage battery, the positive
terminal of the battery is connected with the positive of the generator and the
negative terminal of the battery with the negative of the generator.
d. The storage cell is completely charged when all of the sulphate is off
the plates and has combined with the water to make sulphuric acid. As the
acid is heavier than water, this causes the specific gravity of the electrolyte
to rise as charging continues and this explains why a hydrometer will indicate
the condition of the battery.
e. Since the plates act as the lungs of the cell to breathe in acid before
they can discharge electricity, only that portion of the plates which is covered
with the electrolyte bears any share of the burden of producing current.
The plates will crystallize above the points at which they are submerged in the
electrolyte. The term for this condition is " sulphation," the formation being
a hard crystalline one that closes up the pores and destroys the active sections
of the plates. It follows that a battery having only half the plate area covered
with electrolyte can work at but half capacity.
4. Air Corps requirements.-The essential requirements of an aircraft
battery are that it have a large capacity, be compact in size and light in
weight, and that it be capable of being turned in any position without spilling
the electrolyte and capable of being stored for twelve months without injury.
The battery must be able to withstand a high rate of discharge occasioned by
the use of engine starters.
5. Aircraft storage batteries. -a. The nonspill feature.-The aircraft storage
battery is so constructed that the electrolyte will not spill out, regardless of
the position of the battery if the proper electrolyte level is maintained . ( See
fig. 1.) This is necessary because of the various positions of an airplane in
flight. This nonspill feature is accomplished by having sufficient space above
the plate baffles with suitable vents in the ends of the baffles, so that regardless
of the position of the battery, the electrolyte level will always be below the air
vent of the plug which projects into the upper chamber from the top and center
of the cell.

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b. Capacity. To increase the capacity of the battery and also its rate of dis
charge, a large number of thin plates is used. This enables the battery to be
charged at higher rates for a given heating, thus shortening the time of charg
ing. In effect, by making the plates as thin as possible, more plates can be
used in a given space and more active material ( lead peroxide and spongy lead)
exposed to the electrolyte, giving a greater chemical reaction of the active mate
rials and producing a greater output of electrical energy. Thus a given capac
ity for the battery is obtained with a lower weight and greater compactness
than would be the case if thicker plates were used.
c. Bone-dry and semimoist batteries.—An advantage of the charged bone-dry
or semimoist batteries is that either can be shipped or stored without the elec
trolyte. The difference between these batteries is that the charged bone-dry
batteries have the plates fully charged, have rubber or wood and rubber separa
tors, and are ready for use as soon as the electrolyte is added, while the semi
moist batteries have separators which are moist and the plates are not what
is known as fully charged. The capacity of the charged bone-dry battery when
so formed (see par. 9 a ) is approximately 60 to 70 per cent of its full rated
capacity. The capacity of the semimoist battery is 95 per cent or more of its
full rated capacity after being formed (see par. 9b ) . Semimoist storage bat
teries can be shipped without electrolyte or stored for periods of time not to
exceed 15 months, provided the cells are sealed to prevent the escape of mois
ture or access of air, which would cause the formation of the crystalline
sulphate on the plates.
• SECTION II

MAINTENANCE
Paragraph
General instructions 6
When to add electrolyte--. 7
Gravity readings of electrolyte 8
Charging battery-. 9
Charging rates. 10
Charging methods 11
Gassing of battery . 12
Prevention of freezing 13
Cleaning 14
Sources of trouble___ 15
6. General instructions. a. In describing the action of the battery it was
stated that the plates must always remain covered with electrolyte. This
is most important in the care of the battery, as periodic refilling is required
to make up for evaporation. This refilling will be done with pure distilled
water at least once each week to keep the electrolyte at proper level, as shown
in Figure 1. The level of the electrolyte must not be allowed to get below
the top of the plates. Care will be taken not to add too much distilled water,
as the nonspill device requires that the highest level of electrolyte in the
battery be beneath the end of the vent plug . The electrolyte level should be
about one-eighth to three-eighths inch above the top of the separators. When
a baffle is present the level should not be above the baffle. Prior to installa
tion in an airplane the electrolyte, if present, will be drained off the top of
the baffle plates to prevent its escape in case the battery is inverted.
b. The terminals and connections of the battery will be kept coated with
vaseline to prevent corrosion, which is caused by the combination of the

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BATTERIES FOR USE IN AIRCRAFT 6-8

electrolyte and terminal material. A little ammonia or baking soda will

neutralize any acid that may be on the terminals. Excess corrosion must be
scraped off. The connections at the terminals will also be kept tight to insure
a good contact and coated with vaseline to prevent acid from getting to the
metal. Only clean glass or earthenware vessels will be used for storing
distilled water.
c. A battery found to be discharged will be immediately recharged. If there
is a marked difference in the reading of the cells, and especially if the reading
in one of the cells seems to be increasing, that cell is not in good order. Should
one cell regularly require more water than others, thus lowering the specific
gravity, a leaky jar may be the cause. A slow leak will rob a cell of all its
electrolyte in time, and a leaky jar should, therefore, be replaced immediately.
If there is no leak and the reading of a cell becomes 50 to 75 points lower than
the remaining cells , a partial short circuit or other trouble is indicated within
that cell. This, if neglected, will seriously injure the battery.
7. When to add electrolyte. -a. Add 1350 specific gravity electrolyte only
when the battery is fully charged and it is known that some of the electrolyte
has been spilled from the battery. If the battery has been subjected to severe
gassing during charging or discharging, part of the electrolyte is lost, and this
must be replaced by adding a little 1350 specific gravity electrolyte, using a
battery syringe filler. Never add electrolyte the temperature of which is over
90° F.
b. When mixing the acid with water to make electrolyte the acid should
always be poured slowly into the water, never the water into the acid, because
of danger to the person making the mixture. The solution should be stirred
continuously while the acid is being poured slowly into the water, to prevent
the heavier acid from flowing to the bottom of the vessel without mixing with
the water. See paragraph 2 a ( 2 ) for sulphuric acid solution. After diluting
the acid it is necessary to wait until the mixture has cooled before pouring it
into the battery, to avoid injury of the plates and separators.
c. The carboy containing the sulphuric acid should not be left exposed to
the air, as the acid absorbs water vapor from the air, and the carboy will soon
overflow if nearly filled with acid. Only such sulphuric acid as conforms to
specification 4-74 will be used.
8. Gravity readings of electrolyte.-a. Gravity readings will not be taken
immediately after adding distilled water. Water, being lighter than the
electrolyte, will float on top of the electrolyte until thoroughly mixed, giving
a false indication of the specific gravity of the electrolyte. When a battery is
brought in for charge, measure the specific gravity of each cell with a hydrom
eter. Where the electrolyte level is low a reading can usually be obtained
by tilting the battery about an axis perpendicular to the plate surfaces. Any
marked variations of a cell from the average of all cells will be noted.
b. The gravity reading on the hydrometer is expressed in points. The fol
lowing gives the condition of a battery for various readings :
(1 ) Gravity reading below 1.150 indicates battery is completely discharged
or run down.
(2 ) Gravity reading between 1.150 and 1.200 indicates battery is less than
half charged.
(3) A maximum gravity reading between 1.275 and 1.285 after charging
indicates that the battery is fully charged.

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8-11 AIR CORPS

c. After taking the reading with the hydrometer, the electrolyte must be
returned to the cell from which it was taken.
9. Charging battery.-a. New, charged, bone-dry batteries are formed by
the addition of electrolyte of proper gravity. The instructions for forming
these batteries as supplied with the battery by the manufacturer will be fol-
lowed. Usually this consists of adding the proper amount of approximately
1.290 specific-gravity electrolyte.
b. The forming of new semimoist batteries will be done in accordance with
instructions of the manufacturer furnished with the battery. Various manu-
facturers recommend slightly different procedure. Usually the procedure is to
add a liberal amount of electrolyte varying from 1.275 specific gravity to 1.375
specific gravity. The batteries are then allowed to stand for a given period of
time and placed on charge at a low charging rate for periods from 42 to 96
hours. In most cases this charging is done at about 2 amperes. It is to be
understood that the directions furnished by the manufacturer apply only to the
batteries furnished by such manufacturer.
c. For recharging batteries that have been previously formed the following
procedure will be followed : Add pure distilled water until electrolyte comes up
to the proper level of the battery ( one-fourth inch above separators or to top of
baffle plate ) .
d. A battery that has a cell or cells whose specific gravity remains very low
on repeated chargings should be replaced by a battery in good condition. Care
must be taken that such low specific gravity is not a result of spilling of the
electrolyte. The trouble will usually be due to a leaky jar or an internal short
circuit, and necessitates repair of the battery.
e. If a formed battery stands for over two weeks without use it will be fully
recharged. A storage battery will not be allowed to stand in a discharged con-
dition for more than one day. If possible, it will be placed “ on charge ” imme-
diately after being discharged.
10. Charging rates. -Charging rates depend largely upon the capacity of
the battery. In case the charging instructions have become detached from
the battery, the following instructions can be followed :
A safe value to start with is, roughly, one-sixth of the ampere-hour capacity
rating. For example, if the battery is rated at 36 ampere-hours, a 6 ampere
charging rate is safe to start with. The battery should be watched and the
charging rate reduced as soon as noticeable gassing occurs.
11. Charging methods. -a. There are various methods or practices of charg-
ing a storage battery. The more commonly known are constant current, con-
stant ( or modified ) potential, and trickle charge.
(1) Constant current charging.- In this method the charging current is
maintained at a constant value and lowered to another constant value as soon
as free gassing occurs. This is the system used so widely on automobiles. In
this method of charging, the battery must be watched in order to prevent over-
heating of battery and excessive gassing.
(2 ) Constant (or modified ) potential charging.-In this method of charging,
a fixed voltage source is used, so that when the battery reaches a full charge
the battery voltage is very nearly equal to that of the source and a very
small charging current will flow. This is the system used on airplanes.
A constant potential system is one where a given voltage is held at the
battery terminals. In practice there is a certain amount of resistance in the

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BATTERIES FOR USE IN AIRCRAFT 11-12

wires between the generator and battery. This resistance serves to reduce
a very high charging rate when a discharged battery is placed on charge.
With the resistance of the feeder lines taken into consideration , this method
of charging is known as the " modified constant potential." The characteristic
of a modified constant potential charge is a high initial charging rate which
automatically decreases as the battery becomes charged. This system, because
of the automatically decreasing charging rate, requires little attention and
charges the battery rapidly without gassing or overheating. For aircraft
batteries, the modified constant potential system is used. The voltage may
be held at about 2.35 to 2.40 volts per cell and a discharged battery almost
fully charged in five hours. With the proper choice of charging voltage, be-
tween 2.3 to 2.5 volts per cell, a battery may become fully charged in from
5 to 24 hours. If it is found that the battery is being overcharged, as evi-
denced by gassing or heating, the voltage held by the generator should be
reduced 0.1 to 0.2 volt. The effect of this reduction is to require a longer time
for a complete charge. At a charging voltage of 2.3 volts per cell at the
generator, or charging source, a battery can be left on the line a long time,
since after being completely charged there is only a trickle charge flowing.
With a higher charging voltage per cell a greater charging current will be
flowing through the battery when completely charged. For the shorter charg-
ing time corresponding to 2.5 volts per cell or greater the battery should
not be kept on charge too long, as overcharging may result, due to an excessive
finishing rate.
(3) Trickle charge.—A trickle charge is used to maintain a storage battery
in a fully charged condition over long periods of time while the battery is not
being used and is stored in a wet condition. The value of this charging cur-
rent is that it will just compensate for the leakage and internal discharges
while the battery is standing. The trickle-charging rate depends upon the
capacity of the battery and is roughly 1 per cent of the normal charging rate.
Distilled water should be added every month.
b. In charging the battery, the positive battery terminal will be con-
nected to the positive charging wire and the negative battery terminal to the
negative charging wire. If reversed, serious injury will result. A simple
method of determining the polarity of the wires is by testing with a voltmeter,
or by dipping the ends of the wires in a glass of water containing a few drops
of the electrolyte. In the latter test bubbles will form on the negative wire.
12. Gassing of battery. -a. The point at which gassing of a storage battery
begins while on charge is determined by the voltage, but the quantity of gas
depends on the current which is not absorbed by the battery. The gases
liberated are oxygen, evolved at the positive plates during charge, and hydrogen,
evolved at the negative plates. It is not uncommon, however, for one plate
to begin gassing before the other, and therefore the gas liberated from a storage
cell, in the early stages at least, does not always correspond to the proportions
of oxygen and hydrogen which form water. The gassing begins when the
voltage at the terminal of the battery has reached about 2.3 volts per cell. Dur-
ing the early stages of charging, the gas consists of almost equal parts of
oxygen and hydrogen, but as the charge approaches the end, when the cell
voltage has risen to 2.5 per cell, the gas has a composition of 2 parts hydrogen
to 1 of oxygen. Since oxygen and hydrogen unite with explosive violence to
form water from the gases liberated from a storage battery during charge, it is

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12-15 AIR CORPS

necessary that certain precautions be taken to avoid accident. Open flames of

any kind in a storage battery room are not permissible, and suitable ventila
tion should be provided to prevent an accumulation of hydrogen.
b. Storage cells of the lead acid type do not gas during discharge or when
standing idle under ordinary conditions. There is, however, often a slight
liberation of hydrogen from the negative plates, because of local action which
takes place when the cell is idle. It should always be presumed, therefore,
that hydrogen is present within the space over the electrolyte, and precautions
necessary to avoid explosions should be observed at all times. It is particularly
dangerous to use a lighted match or open flame over the vent of cell to see
how high the liquid stands.
13. Prevention of freezing.-a. A battery showing a reading of 1.220 or
more on the hydrometer will not freeze even at temperatures as low as 30°
below zero Fahrenheit. See paragraph 2 a ( 2) for sulphuric acid solutions
and freezing points.

FIGURE 2. -Effect of heating due to overcharging

b. Under freezing conditions, water will not be added and the battery remain
unused, as the water will remain on top of the solution until it is mixed with
it by gassing of the battery. If not mixed with the solution, it will freeze
almost as readily as if outside the battery.
14. Cleaning.-If electrolyte or acid is accidentally spilled over the top and
sides of the battery it will be removed by a clean cloth saturated with a solu
tion of ammonia and water, or soda and water, care being taken not to get it
in the cells.
15. Sources of trouble.-The most frequent sources of trouble with storage
batteries are as follows :
a. Overcharging.-Overcharging produces excessive gassing ( release of hydro
gen and oxygen which bubble up through the solution ) and this action loosens
the active material ( lead peroxide and spongy lead ) of the plates, particularly
the lead peroxide of the positive plate. This material sifts down between the
separators and the plates and is deposited in the bottom of the jar as a fine
sediment. Overcharging also increases the heat in the battery and in some

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BATTERIES FOR USE IN AIRCRAFT 15

cases of excessive heating the negative plates and separators are damaged.
(See fig. 2. ) Overcharging sometimes causes buckling of the plates due to
their overheating. (See fig. 3. )
b. Undercharging.-Consistent undercharging of the battery results in a
gradual running down of the cells. This is indicated by a progressively
lower density of the electrolyte and a tendency of the plates to become lighter
in color. The sediment deposited in the bottom of the jar when under
charging has been prolonged is usually a fine white powder, consisting prin

FIGURE 3.- Broken-down separator which causes a " short "

cipally of lead sulphate. Insufficient charging is one of the most common

causes of buckling of the plates. The lead sulphate occupies more space
than the original material and an excessive amount of it strains the plates.
(See fig. 4. )
c. Cracked or broken jars.-Cracked or broken jars of batteries can ordi
narily be detected by leakage of the electrolyte, or if the crack is slight by
the necessity of periodically adding more water to one cell than to the others .
In such a case the electrolyte of the cell will gradually become diluted by the
additions of water, and this will result in diminishing the capacity of the cell.
The only remedy is to replace the broken jar as soon as it is discovered.
d. Short circuits.- (1 ) Short circuits within the cell may be caused by a
breakdown of one or more of the separators between the positive and negative
plates and by the accumulation of sediment in the bottom of the jars. The
evidences of short circuits within the battery are

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15 AIR CORPS

(a) Continued low readings of the specific gravity of the electrolyte

even though the battery is receiving a normal amount of charge ;
(b ) Rapid loss of capacity after a full charge ;
(c) Abnormally low open circuit voltage.
(2 ) The remedy for this condition is to disassemble the cells, wash out the
accumulated sediment in the bottom of the jars, and replace the old separators
with new ones. The sediment in the bottom of the cell is a conductor, and
if enough of it accumulates to touch the bottom of the plates a short circuit
develops.
e. Worn-out plates.-Worn-out plates are ordinarily detected by a marked
decrease in the capacity of the battery when it is receiving an adequate amount

FIGURE 4. - Short circuit at corner of buckled plates

of charge. If the solution in the cells rises to its proper density ( 1.275 to
1.285 specific gravity ) when the cells are on charge, but only a small capacity
can be obtained on discharge, the battery is worn out. This may be due either
to age or poor material used in the construction of the plates. There is no
remedy except to replace the plates.
f. Excessive sulphation. - Excessive sulphation is generally caused by neglect
or misuse. The sulphation becomes excessive if the acid is too strong or if
proper charging is neglected . The final density of the electrolyte after the
charge is complete depends on the total amount of sulphuric acid in the cell.

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BATTERIES FOR USE IN AIRCRAFT 15

If all the lead sulphate in the plates ( except a few per cent- 1 to 4 per cent
that always remains ) has been reduced by charging to sulphuric acid, and the
specific gravity is still too low, the cell needs acid, but this is a rare occurrence.
On the other hand, if acid is added to a cell which already contains the normal
amount two things may happen. First, the rate of sulphation of the negative
plates will be increased. This means that the plates will lose their charge
faster than normal by local action. If the battery is in run-down condition
when the electrolyte is added it may be spurred on to give a little more
capacity at the expense of the remaining active material, but the additional
capacity obtained will in any case be small and accompanied by the formation

FIGURE 5.- Method of packing batteries for shipment

of an excessive amount of sulphate. As the pores of the plates become more

completely clogged with the sulphate the active material may be pushed out
of the grids, the plates buckled, and the difficulties in charging the plates
increased . Secondly, if a battery in this condition is charged fully the density
of the electrolyte will rise to an abnormally high value, which further acceler
ates the rate of sulphation of the negative plates and burns the separators.
To pour the solution out of the battery, whatever its state of charge, and add
another solution of some other density, will result in diminished capacity,
if the total amount of acid is too small , or in excess sulphation, if the amount is
too great. The latter more generally happens.

SECTION III

REPAIR
Paragraph
General . 16
Disassembly of battery. 17
Assembly of battery 18
Lead burning. 19

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16-18 AIR CORPS

16. General. The plates and separators of batteries are exceedingly thin ;
consequently, care must be used in the repairs to batteries.
17. Disassembly of battery.-a. First, clean the top of the battery thor
oughly. Note the relative location of cells, intercell connectors, and terminals
to insure a correct reassembly.
b. Bore out the connector, using a brace and bit centered over the post. The
bit may be either a wood bit or a twist drill, the former preferred, and should
be at least as large as the post. The filling plug should be in position while
boring out to prevent lead chips from getting into the cell. When the hole has
been bored down to the post the connector can be pried loose by inserting a
screw driver between the connector and the sealing nut. Care should be taken
not to put pressure on the cover of the cell. If boring out the connector is not
done properly-for instance, if the hole is not directly over the post-heat can
be applied gradually to the connector until the lead is softened sufficiently to
permit pulling up the connector with a pair of pliers. In all of the above
operations care should be taken not to short circuit the cell by allowing pliers
or other tools to come in contact with both posts at the same time.
c. Removal of plate groups. Remove the sealing nuts, using pliers in pref
erence to a monkey wrench or pipe wrench. Remove filling plug and blow gases
out of cell to avoid possibility of an explosion. Warm the inside of the jar
with steam and then insert a hot putty knife or similar tool around the inner
edge of the jar, melting out the sealing compound. This operation should be
performed as rapidly as possible, as the compound cools quickly. Remove cover
by pulling up with finger in filler opening. Clean cover with cloth damp with
a solution of dilute ammonia or soda. If present, lift the spacer on which the
cover rests by means of two special tools which are bent at the end to be in
serted under the lower edges of the spacer and pulling vertically. The plate
groups of the cell can then be lifted out by pulling vertically on the terminal
posts. Permit the plates to drain for a few minutes before lifting them entirely
out of cell .
d. Removal of separators.—Place the element ( negative and positive plate
groups ) on the edge of a table or bench. When it is necessary to use the sepa
66
rators again, a special tool called a separator inserter," which slips over the
separator, should be used. The broad side is used next to the negative plate to
loosen the separators so they can be pushed and pulled at the same time from
between the plates. In case the separators are not to be used again, a putty
knife may be inserted between each separator and the negative plate to loosen
them, and then they may be pushed from the top and pulled from the bottom
until freed from the plates. Separate the positive and negative groups of plates
and soak each of them in distilled water for about 20 minutes. They are then
ready to be placed away on a shelf if the battery is to be stored. Pour the
electrolyte out of the jar and wash the jar with distilled water..
18. Assembly of battery.-To install new separators, place the elements
(positive and negative plate groups ) on edge as for removal of separators.
Insert the separators from the bottom. The smooth side of the separator
is placed next to the negative plate. In case a combination wood and rubber
separator is used, the wood part is placed next to the negative plate and the
rubber part next to the wood part with the ridges or corrugations facing the
positive plate. The baffle for over the plates is slipped over the terminal posts
and placed in position and the element lowered into the jar. Then push the

12
 TR 1170-85
BATTERIES FOR USE IN AIRCRAFT 18-19

spacer, if used, down into position, and place the soft rubber gaskets, if used,
over the posts. The cover should be replaced while the jar is cold, unless it
will not fit readily, in which case warm the outside of the jar with a flame
until it becomes flexible enough to allow the cover to fit properly. Care should
be taken not to burn the jar. Heat the sealing compound and pour it into
position ; then trim with a hot putty knife until a level, smooth surface is
obtained. Clean off all compound not needed to seal the cover. Always have
the cover firmly in place and sealed before putting on the connector. If the
intercell connector is not of the right length it should be adjusted , and in no
case should it be forced into position over the posts, as the jar or cover may
be broken on account of undue strains. Whenever it is necessary to remove the
spilled acid from the jar, cover, or terminals, a cloth damp with a dilute solution
of ammonia or soda is used. It is necessary to have the jar and cover free from
acid, as otherwise the sealing compound will not adhere properly to the surfaces.
In case the electrolyte is added to the cell before plates are placed in position,
care should be taken that the ammonia or soda solution does not get into the
electrolyte.
19. Lead burning.-This is a welding process for making a good mechanical
and electrical connection between the plates and the strap holding them to
gether and between the posts and the connector. The heat at the tip of the
flame from the torch will fuse the lead of the post and connector together, and
other lead is added until the lead is flush with the top of the connector. The
surface can then be finished with a file.
[A. G. 062.12 (5-24-30) . ]

BY ORDER OF THE SECRETARY OF WAR :

C. P. SUMMERALL,
General,
Chief of Staff.
OFFICIAL :
C. H. BRIDGES,
Major General,
The Adjutant General.
139

U. S. GOVERNMENT PRINTING OFFICE : 1930