Supplemental Information & Instructions for Reproduction Lucas Type 6 Volt Battery Austin Healey 100 BN1, BN2; BN6, BN7 Jaguar XK120

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1 Created by Michael Grant on 5/20/2011 8:43:00 AM Revised by Eric Wilhelm Page 1 of Supplemental Information & Instructions for Reproduction Lucas Type 6 Volt Battery Austin Healey 100 BN1, BN2; BN6, BN7 Jaguar XK120 Moss offers two 6 volt batteries for the Healey and early Jaguar. This battery is for those looking for a vintage Lucas tar-top type battery with the original type mounting ears that will accept the fixing rods. These batteries are made for this specific purpose in small quantities, and they are costly to produce. The manufacturer (in Ohio) makes vintage batteries for a living, and they are the source when it comes to this kind of battery. This is a dry charged A battery, meaning the battery is built, charged, washed and dried, sealed, and shipped without electrolyte. The procedure on the C following pages is designed to help you protect your investment. You can seriously damage the battery and void the warranty if you do not follow these detailed instructions. Read through them carefully. Dimensions: A: 7 B: 7 5/8 C: 8 1/8 B

2 Created by Michael Grant on 5/20/2011 8:43:00 AM Revised by Eric Wilhelm Page 2 of IF YOU HAVE ANY TECHNICAL QUESTIONS ABOUT THE BATTERY CALL THE MANUFACTURER AT BEFORE FILLING OR CHARGING THE BATTERY Unpack the battery and carefully inspect it for shipping damage. If the box was damaged, and the battery inside is also damaged, contact Moss Motors as soon as possible. We will arrange to have the shipper inspect the packaging to determine if they are responsible, in which case they will replace the battery. If the battery is undamaged, install the dry battery in your car. Make sure it fits properly, and that the LUCAS imprint faces the right direction. Pay attention to the orientation of the terminals. If you determine that the battery is not going to work, contact Moss. Please note that once you have added fluid to the battery, it can only be returned for a defect in the battery it cannot be returned for any other reason It is your responsibility to verify that the battery is in fact correct for your particular application. AFTER TEST FITTING THE BATTERY Regardless of whether you are ready to use the battery immediately test fit it in your car. If there is a problem, we need to know about it as soon as possible. If you have determined that the battery is correct for your application the terminals are correctly placed, and the LUCAS name & Information are correctly oriented Remove the battery from the car and either store it, or proceed with the activation process. STORAGE OF A DRY CHARGED BATTERY If you are not quite ready to use the battery, it must be stored in a clean, cool and dry location. You must keep the vent caps unopened and intact until you are ready to fill the battery. Unlike wet-charged batteries, dry-charged batteries do not undergo serious deterioration, sulfation or corrosion during storage. Shelf life of a dry charge battery is five years plus if properly stored. The positive plate has an unlimited shelf life. The negative plate will revert to lead oxide in the presence of water and oxygen. If this should happen (say, by disturbing the sealed caps while being stored) the battery is not ruined, but activation will take considerably longer! Filling the battery to proper electrolyte level and bringing it to a full-charged state makes it a fully-charged battery. BUYING ELECTROLYTE Each battery will take about 2.5 pints of electrolyte, also known as battery acid. You can buy electrolyte at an auto parts store. For both batteries you will need about 5 pints, or 2 quarts (2.4 liters). Electrolyte is not distilled water it is a mixture of 35% sulfuric acid and 65% distilled water. If you do not have a battery hydrometer, you can buy one at the parts store when you pick up the electrolyte. A good one will cost $10-$15. Typical example is shown in photo at right. BATTERY SAFETY Wear complete eye protection, gloves, and old clothes. Avoid touching eyes while working near batteries. Wash your hands when done. If acid contacts skin or clothing, wash immediately with soap and water. If acid enters eyes, immediately flood eyes with running cool water for at least 15 minutes and get medical attention immediately. Use baking soda to neutralize spilled battery electrolyte. Mix 2 tablespoons with 2 pints of water. NEVER smoke or allow a spark or flame in vicinity of a battery (hydrogen gas creates a risk of explosion). Be extra cautious when working with metal tools around batteries. An accidental shortcircuit may result in a spark which could cause an explosion. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short-circuit current high enough to weld a ring or watch, causing severe burns

3 Created by Michael Grant on 5/20/2011 8:43:00 AM Revised by Eric Wilhelm Page 3 of ACTIVATION OF A DRY CHARGED BATTERY Do not fill and/or charge the battery in the car remove it and place it on a suitable work bench. Take off the caps and leave them off until the battery is fully charged and ready to be placed in your vehicle. Look in the battery and identify the plates. You will be adding electrolyte until the level of the electrolyte reaches a level inch above the top of the plates. ***DO NOT OVERFILL*** Overfilling will increase the chance that the acid will boil over during charging, and the acid will damage the exterior of the battery. Let your filled battery stand for two (2) hours to allow the electrolyte to be absorbed by the plates. Check the level of the electrolyte. If necessary, add electrolyte to the battery to fill it above the top of the plates. Most battery charges can be set to 6V or 12V- set yours to 6V. A slow charge overnight (8-12 hours) at 4 amps is ideal. Do not run the charger over 10 amps. Do not try and rush this process. Read the specific gravity with a hydrometer. All cells should read to If one cell reads down and the rest read up, then the battery is faulty. If all the cells read down, the battery is discharged and needs more charging. After sufficient charging and all cells are reading to 1.275, put the battery in the car and connect the cables, paying strict attention to the polarity. Start your engine. Check your charging system to make sure that it is working properly. If the car is not going to be driven regularly, disconnect one terminal while the car is inactive. During the off season, to avoid sulfation, one of the battery cables should be disconnected and the battery should be charged every thirty (30) days or put it on an automatic float charger like the on-board battery charger (aka battery tender ) like the Moss This will automatically keep the battery charged, prolonging the useful life of the battery. Understanding Why Batteries Go Bad -Sulfation Sulfation will happen if the battery sits for long periods of time. There are two problems that occur simultaneously. As the electrolyte begins to break down, sulfur in the battery acid solution actually leaves the electrolyte. This makes the electrolyte weaker-problem #1. This sulfur is converted to lead sulfate crystals, which form a layer or coating on the lead plates-problem #2. This process reduces the ability of the battery to deliver electricity to start the car, and it reduces that ability of the battery to accept a charge. Sulfation is a slow chemical process with three identifiable stages. Stage 1: In the beginning, as sulfur leaves the electrolyte, the thin film of small crystals on the lead plates will tend to make it harder to crank the engine over, meaning it will take longer to start the car, especially when it is cold. At this low level, the sulfation is reversible by charging the battery because the sulfur will be driven off the lead plates, back into the electrolyte. If the battery is charged soon enough, the stage 1 sulfation is totally reversible and the battery should suffer no permanent damage. Stage 2: If the vehicle remains inactive, more lead sulfate crystals begin to form on the plates. When enough of the plates are covered, the battery will not be able to generate enough electricity to start the vehicle. Stage 2 sulfation is still reversible by charging the battery, but it will take much more time on a battery charger to break the crystals free and return the sulfur to the electrolyte. Stage 3: If the battery sits long enough without being charged, the layer of lead sulfate crystals on the plates will become so thick and hard that they are permanent. The battery at this point will not take a charge no matter what you do. The battery is well and truly dead, and it must be replaced. There are several factors that can contribute to the process of sulfation. Some of the most common: "Deep cycling". Draining a battery of nearly all its energy, then recharging it. This pattern of use is common on boats, and they use specially designed batteries engineered for this type of use. Normal batteries can't stand a deep discharge/recharge cycle for long. Incomplete recharge. Recharging a battery to 90% of its capacity will allow sulfation of the battery using the 10% of the electrolyte not reactivated by the charging cycle.

4 Created by Michael Grant on 5/20/2011 8:43:00 AM Revised by Eric Wilhelm Page 4 of Sulfation (continued) Heat. As temperatures rise, the rate of internal discharge will go up. For example, after 30 days at 110ºF, a brand new, fully charged battery would probably not be able to start a car. Low electrolyte level. Battery plates exposed to air will immediately sulfate. To prevent sulfation, a battery needs to be maintained in a fully charged state. For vehicles used daily, (or at least weekly) this isn t a problem. However, your classic British sports car is probably not your daily driver, and sulfation will occur unless you take steps to prevent it. Completely charging the battery every 30 days is probably a minimum, but this is a chore that can easily be forgotten or postponed. That is why automatic chargers that maintain the battery in a fully charged state are popular. Protect Your Investment Battery Maintenance Most of us accept routine maintenance as part of the British Car Experience. However, so many of us drive cars with sealed or maintenance free batteries that we sometimes overlook the simple steps required to keep a vintage type battery in good working order. Clean the battery using a solution of baking soda and water. Mix 2 tablespoons of baking soda in a pint of water. Use a soft bristle brush. Rinse with distilled water. Dry it off with paper towels, and dispose of the paper towels in a plastic bag. Wear gloves and eye protection. Gas venting from the battery is a natural result of charging the battery. Most corrosion of the battery connections is caused by the gas venting from the battery. If you can keep the air (and therefore the battery gasses) away from the surface of the metal, you can prevent most corrosion. Run a small bead of silicone sealant at the base of the battery terminal and place a felt battery washer (the red & green ones they sell at your local auto parts store) over it. Coat the washer with high temperature grease or petroleum jelly (Vaseline). Coat the exposed cable end with grease or Vaseline then replace cable on the terminal and tighten. Remove and inspect the battery cable connections when you clean the battery. Check both ends, especially of the ground strap. Dirty (or loose) cable connections can cause battery problems. Re-coat with Vaseline as needed. Check the fluid level in the battery after cleaning it and drying it off. o Add distilled water only, and only as needed. o Do not add electrolyte. o Do not add tap water. o Do not overfill battery cells! The natural expansion of the electrolyte as it warms up (especially if the weather is hot) can force electrolyte from the battery. MOST IMPORTANT! Keep the battery fully charged. The battery should be charged every thirty (30) days or put it on an automatic float charger like the Moss This will automatically keep the battery charged, prolonging the useful life of the battery and preventing sulfation. Although every effort has been made to ensure the accuracy and clarity of this information, any suggestions that you may have that will improve the information (especially detailed installation notes) are welcome. Please use the simple form on the Contact Us page on the Moss website: If you prefer, you may call our Technical Services Department at So many people call us for help that we are often not able to answer the calls as fast as we d like, and you may be asked to leave a message. We apologize in advance for the inconvenience. We will get back to you within 2 business days. Moss Motors, Ltd. 440 Rutherford Street, Goleta, California In the US & Canada Toll Free (800) FAX (805) (805) Moss Europe Ltd. Hampton Farm Industrial Estate, Hampton Road West, Hanworth Middlesex, TW13 6DB In the UK: FAX: Instruction Sheet November 2010

5 Created by Michael Grant on 5/20/2011 8:43:00 AM Revised by Eric Wilhelm Page 5 of Warranty Information & Instructions for Reproduction Lucas Type 6 Volt Battery Austin Healey 100 BN1, BN2; BN6, BN7 Jaguar XK120 What is covered under warranty? A DEFECTIVE BATTERY IS DEFINED AS ONE THAT HAS A DEAD CELL OR WILL NOT HOLD A CHARGE. What is NOT covered under warranty? A BATTERY RENDERED INOPERABLE DUE TO SULFATION. PHYSICAL DAMAGE TO THE CASE (CRACKS AND/OR HOLES) A BATTERY THAT HAS BEEN SHORTED OUT. How does the warranty work? Should the battery fail to hold a charge due to a manufacturer s defect (not sulfation) within ninety (90) days of purchase, Antique Auto Battery will reimburse you the return shipping cost by UPS GROUND UP TO $30.00, and you will receive a replacement battery. If your battery is found to be defective after ninety (90) days from the purchase date, you will receive a "Pro-Rated" adjustment on a replacement battery. THERE ARE NO CASH REFUNDS IF YOU FEEL THAT YOU HAVE A DEFECTIVE BATTERY Most batteries that are returned as faulty are merely discharged. So, please charge them first. With old cars the problem of discharging frequently results from a very slow current drain in the car. That is why we have stressed removing one terminal from the battery when in storage. The second cause for the return of a battery is sulfation, which is caused by improper maintenance. Check to see if the acid level is 1/2" above the top of the plates. If not, add distilled water. Give the battery a long slow charge. Four (4) to ten (10) amps for eight (8) to twelve (12) hours on a home type charger. Read the specific gravity of the electrolyte with a hydrometer. All cells should read to o If all the cells read down, the battery is discharged and needs more charging. o If one cell reads down and the rest read up, then the battery is faulty you have a dead cell and you should contact the manufacturer-refer to the next page. After sufficient charging and all cells are up, put the battery in the car, it should start your engine. If the battery starts your engine and appears okay, disconnect one terminal and leave the battery sit for one week. After one week, take a hydrometer reading: o if there is no change the battery is okay. Look for the problem elsewhere, such as: Faulty wiring or wrong battery cable size. o If there is a change in the hydrometer readings, you may have a defective battery and you should contact the manufacturer-refer to the next page.

6 Created by Michael Grant on 5/20/2011 8:43:00 AM Revised by Eric Wilhelm Page 6 of CONTACTING ANTIQUE AUTO BATTERY The battery warranty is handled directly with the source: ANTIQUE AUTO BATTERY (AAB) 2320 Old Mill Road Hudson, OH If you have followed the procedures (lines ), and you have a dead cell or the change in hydrometer readings after one week of storage (disconnected) indicates a defective battery: Call Antique Auto Battery at and explain the situation. Ask for a PRO number. Once a PRO number has been issued to you, you only have two weeks to return the battery. Preparing the battery for shipment DO NOT SHIP A BATTERY WITH ELECTROLYTE! IT MUST BE DRY. Drain the battery electrolyte into a plastic container Contact your local agency responsible for Hazardous Material they will tell you where to take the electrolyte for disposal. After the battery has drained completely, replace the caps and rinse the outside with water, then dry it off. Wrap the battery in plastic or place it in a large plastic bag and tape the plastic/bag shut. Place the battery in the original box and add sufficient padding to protect the battery in shipment. If you do not have the original box, use a stiff corrugated cardboard box and pack the battery well enough to protect it in shipment. I the battery is damaged in shipment, the warranty is void. Ship the battery by UPS GROUND to ANTIQUE AUTO BATTERY, 2320 Old Mill Road, Hudson, OH On the UPS paperwork, indicate the type of material being shipped as auto parts. The PRO number must be on the outside of the package when it is returned. Freight must be PREPAID Antique Auto Battery will not accept C.O.D. shipments. NO EXCEPTIONS OR WARRANTY WILL BE NULL AND VOID. NO ADJUSTMENT ON BATTERIES THAT ARRIVE BROKEN Although every effort has been made to ensure the accuracy and clarity of this information, any suggestions that you may have that will improve the information (especially detailed installation notes) are welcome. Please use the simple form on the Contact Us page on the Moss website: If you prefer, you may call our Technical Services Department at So many people call us for help that we are often not able to answer the calls as fast as we d like, and you may be asked to leave a message. We apologize in advance for the inconvenience. We will get back to you within 2 business days. Moss Motors, Ltd. 440 Rutherford Street, Goleta, California In the US & Canada Toll Free (800) FAX (805) (805) Moss Europe Ltd. Hampton Farm Industrial Estate, Hampton Road West, Hanworth Middlesex, TW13 6DB In the UK: FAX: Instruction Sheet _Warranty Information November 2010