Swapping out my batteries.

[MattH]

Thought I would put a couple of pics up of progress so far:

New batteries ready and waiting:


Old batteries have copper bussbars that are soldered in place:



Junior hacksaw goes through easily:



Not quite as smart looking as the new batteries:



I'll be finishing the job tomorrow, I just got a head start on it this evening to see if I was going to need anything to be able to finish the job over the weekend.

 

[MattH]

Finished pulling all the old cells out and cleaned out the battery box:





Inserting the new cells, I had to pop the caps on the cells to allow the air out so they would fit:



New cells are a perfect fit in the box:



All the bussbars and filling caps installed:



I just need to fit lugs onto the ends of the battery cables then I'm good to go.

 

[eSCHEn]

So nice when it all just fits and works without hassle

 

[MattH]

Indeed. Now I've just got to find some lugs for 50mm/sq cable.

 

[Psychosaffa]

Local electrical wholesalers will have crimp lugs, and you should be able to hire a crimping tool as well.
What voltage is each battery cell?

 

[The_Yellow_Ardvark]

@MattH

http://bae-bristol.co.uk/auto-electrical-service-car-commercial-auto-electrician/

Try them, I used them in the past to supply crimps for central battery systems.
They did:
Bolt/screw fixings onto a copper sleeve.
Solder.
Crimp.
Hammer crimp.

Plus, local.

 

[MattH]

Local electrical wholesalers will have crimp lugs, and you should be able to hire a crimping tool as well.
What voltage is each battery cell?

Cells are 2v each, totalling 48v.

 

[Spark plug]

Did they come pre filed with electrolyte or do you have to fill them?

 

[MattH]

Did they come pre filed with electrolyte or do you have to fill them?

Pre-filled. Hooked them together and measured 50.4v across them.

 

[Spark plug]

Good stuff, you'll not know yourself now probably only have to charge it once a week.

 

[MattH]

Good stuff, you'll not know yourself now probably only have to charge it once a week.

If that, gets used for about an hour at a time once a week or so.
Trouble was on the old batteries it would be on red and once the pump cut activated.
It's a good truck and is in nice condition so deserved some new cells.

 

[Psychosaffa]

Do you have any idea what the capacity is of the cells, and the maximum current they can supply?

 

[MattH]

Old ones were 460ah when new, new ones are 550ah.

No idea on the current capacity but the truck has a 160a connector.