Replacing a battery cell is possible in many of the Series 5000 4V, 6V, 8V or 12V models.  This should only be done when the condition of the remaining cells in the battery will compliment and support the new cell.  Specific gravity and voltage readings should be taken and assessed before replacement of any cell or battery in a bank.


Safety Items:

1. Always wear rubber gloves and safety goggles.
2. Never struck battery with metal objects or tools.
3. Do not remove vent caps from cells.

Tools needed:

1. Wire brush
2. 2 wrenches (using black tape to cover the extremity not to be used during installation will prevent shorts)
3. Black 100% silicone sealant
4. Rubber mallet
5. Lubricant (to facilitate cell insertion)

Instructions:

1. Remove terminal protection rubber boots.
2. Disconnect battery and clean terminals. Remove black silicone around terminals (use wire brush).
3. Remove red plastic cover by pulling upwards from each side. It is fairly hard to remove. If rubber grommet around cell vent opening comes off, do not worry. Take a picture of the battery without its red cover. Make sure to clearly see the inter-cell connections.
4. Replace terminal protection rubber boots.
5. Using the 2 wrenches, disconnect the cells by un-bolting the connections between the cells. BE CAREFUL NOT TO SHORT THE POSITIVE AND NEGATIVE CONNECTIONS OR TERMINALS WITH THE WRENCHES.
6. Pull the bad cell out of the outer red casing. However, if the cell is large (KS, YS models), you should consider asking for help or use a lifting device.
7. Clean connections on cell(s) remaining in battery using wire brush as well as the connection on the new replacement cell.
8. Drop new replacement cell into casing, making sure it is dropped facing the proper polarity. Again, for large cells, you should consider asking for help or use a lifting device. Also, rubbing a lubricant on the sides of the cell would help inserting it inside the red container.
9. Connect the cells together using the same nuts, bolts, washers and lock washers that were removed at step 5. Tighten connections until lock washers are completely flattened (see picture taken at step 3).
10. Apply preferred corrosion prevention grease to the connections.
11. Check battery voltage, to ensure the cell has been installed correctly.
12. Remove terminal rubber protection boots.
13. Using rubber mallet, snap back on the red outer cover.
14. Clean off black silicone from vent rubber grommet and apply small bead of new black silicone sealant all around rubber grommet, inside crack.
15. Insert rubber grommet on vent and using the rubber mallet, tap it back onto the cover.
16. Apply bead of black silicone around both terminals. Let dry for 30 minutes.
17. Clean cables and re-connect batteries. Don't forget to slide the terminal rubber protection boots on the cables before making the connections! Tighten until lock washers are flattened. Make sure that there is no washer, nut or lock washer between the cables and the terminals.
18. Replace terminal protection rubber boots.
19. Verify that good voltage is reading on charger/inverter.
20. Verify liquid level on new replacement cell.