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JLG batteries

Replacement Batteries For JLG Electric Scissor Lifts

Choosing The Right Deep-Cycle Batteries for JLG 24-Volt ES, RS-Series, and JLG 48-Volt LE, E-Series Lifts

JLG is one of the leading manufacturers of scissor lifts and aerial work platforms that are used globally. The company has several lines of battery-powered vehicles that have improved duty-cycles due to their use of deep-cycle batteries.

Many of the company’s ES and RS Series scissor lifts feature a 24-volt system that takes a Group Size GC2 deep-cycle battery. Most of these lifts utilize four 6-volt batteries, so when it comes time to replace them, there are a couple of options that can keep these lifts running at optimum efficiency while also lowering annual operating costs. U.S. Battery’s US 2000XC2 offers 220 amp-hours at a 20-hour rate, offering an excellent value for JLG ES and RS Series lifts to provide excellent life and reliability when maintained.

When work crews need a battery that can keep up with long work cycles and want a longer-lasting battery, U.S. Battery’s US 2200XC2 is perhaps one of the best and hardest working deep-cycle GC2 sized batteries on the market. The US 2200XC2 has 232 amp-hours at a 20-hour rate, giving JLG lifts more runtime and longer life, especially with regular charging and maintenance.

JLG’s larger LE and E Series platform lifts have a 48-volt system and utilize eight Group Size 903 batteries. For these applications, U.S. Battery manufactures the US L16XC2 deep-cycle battery, which provides exceptional value with extended runtime and long life. The US L16XC2 produces 385 amp-hours at a 20-hour rate, making it one of the most popular batteries in this size range for these applications. U.S. Battery’s US L16EXC2 battery is also a Group 903 and is a cost-effective solution for platform lifts, which supplies 360 amp-hours at a 20-hour rate. The US L16HCXC2 is a high-capacity model in the same Group Size 903, that provides 420 amp-hours at a 20-hour rate, offering JLG LE and E Series lifts the maximum runtime available.

Proper Maintenance Makes The Difference 

To get the most performance from your new battery, you must develop a regular maintenance schedule that consists of:

  1. Checking and replenishing the electrolyte levels. Installing a BWT or Flow-Rite single-point-watering kit can make this an easy and quick process.
  2. Performing an equalization charge
  3. Checking and Cleaning battery terminals and connections
  4. Performing an opportunity charge when possible

For a full list of proper Deep Cycle Battery Care & Maintenance procedures, please see our page or download our Care & Maintenance brochure.

U.S. Battery Deep Cycle batteries are handcrafted in the U.S.A. The batteries also feature our exclusive XC2 formulation that produces increased initial capacity, fastest cycle-up time to full-rated capacity, improved recharge-ability, and the highest total energy delivered than any battery in their class. For a complete list of Flooded Lead-Acid or AGM batteries for work platforms visit U.S. Battery’s Aerial Work Platform Battery page to see all of the models, sizes, and specifications available to fit your particular vehicle.

 

TTBLS structure grown with additives

Improving Deep-Cycle Batteries Through Additives

Battery manufacturers have improved deep cycle battery performance through the use of additives, but not all of them result in the same benefit to customers. At the core of all deep-cycle flooded lead-acid (FLA) battery technology is a basic design that has undergone continuous improvement over more than 100 years. Lead battery chemistry is one of the most reliable and cost-effective technologies over any other type of battery used in a variety of global industries. While these batteries have historically been the most widely used and the most recycled, a variety of additives and technologies have been introduced over the last few years to improve their efficiency to an even greater extent.

Grid Alloys

Historically, the primary failure mode of deep-cycle lead-acid batteries has been positive grid corrosion. The grid alloys used to manufacture deep-cycle flooded lead-acid battery plates typically consist of lead with additions of antimony to harden the soft lead, and to improve the deep cycle characteristics of the battery. Additional metals are often added to the lead-antimony alloys to improve strength and electrical conductivity. Another additive that is used to enhance lead-antimony alloys is selenium. Selenium acts as a grain refiner in lead-antimony alloys. This fine-grain alloy provides additional strength and corrosion resistance over conventional lead-antimony alloys. The effect of these improvements is that positive grid corrosion is no longer the primary failure mode, and the cycle life of FLA deep cycle batteries has been significantly increased.

Active Materials

The starting materials for deep cycle FLA positive active materials are made from a mixture of lead oxide, sulfuric acid, and various additives. These materials improve the performance and life of the positive electrodes in a finished battery. Historically, positive electrodes have been processed using a procedure called hydroset. This procedure is designed to ‘grow’ tetrabasic lead sulfate (TTBLS) crystals in the plates to provide the strength to resist the constant expansion and contraction of the active materials during cycling. This crystal growing process has limitations in its ability to control the range of sizes of the TTBLS crystals. Through the use of crystal seeding additives, the range of crystal sizes can be controlled to the most desirable sizes. These uniform crystal sizes in the TTBLS structure result in increased initial capacity, faster cycle-up to rated capacity, higher peak capacity, and improved charging using the wide range of charger technologies used in various applications.

Concurrent with the improvements in deep cycle FLA positive active materials, improvements in the performance of deep-cycle FLA negative active materials are needed. Carbon additives have been used in the negative active materials of lead-acid batteries for many years. These additives have been used in lead-acid battery expanders to prevent the natural tendency of the negative active material to shrink or coalesce during cycling. Negative active material shrinkage can reduce the capacity and life of deep-cycle FLA batteries. Recent improvements in these carbon materials have opened up new opportunities to improve several performance limitations of lead-acid batteries. New structured carbon materials such as graphites, graphenes, and nanocarbons have been used to control sulfation and improve chargeability in a partial state of charge (PSOC) applications such as renewable energy.

Although the basic structure of an FLA battery hasn’t changed for more than 100-years, manufacturers are continually searching for ways to improve efficiency while maintaining their cost-effectiveness. Additives are one of the ways FLA batteries are becoming more efficient, and new technologies to further enhance them are on the horizon.

White golf club car.

Replacement Batteries For Club Car Golf Carts

Club Car golf carts have been around for nearly 60-years, producing a variety of battery-powered golf cars, utility, and personal use vehicles. As most owners of these vehicles know, proper battery maintenance is key to longevity and reliability, but eventually, the batteries will need to be replaced. 

 

When it comes time to get a new set of deep-cycle batteries for your Club Car, it’s important to make sure you select the right ones for your particular application, and most importantly, the type of use it will see. Club Car’s battery specifications are different for the various model vehicles they produce. Most utilize a 48-volt electric engine but depending on the model, have different amperage and power requirements.

 

As an example, Club Car DS and Precedent models (2in1, 2Plus2, Cargo, Professional), XF (2in1, 2Plus2) and XF Cargo models take six BCI Group Size GC8 eight-volt batteries. Choosing the right one depends on if you use the vehicle daily or if it says in storage at your vacation home. For each of these types of scenarios, there are different battery ratings to choose from that might better match your usage needs. U.S. Battery’s US 8VGC XC2 (with a 20-hour rate of 170) is a great choice for those who want a longer-lasting battery for this application. The US 8VGCE XC2 (with a 20-hour rate of 155) offers less overall runtime for applications where the vehicle won’t be used daily, offering a more cost-effective solution.

 

Club Car Precedent Champion models also use a 48-volt system but utilize four BCI Group Size GC12, 12-volt batteries. U.S. Battery’s 12VRX XC2 (20-hour rate of 155) provides a great compromise between daily and occasional use. 

 

Proper Maintenance Makes The Difference 

 

To get the most performance from your new battery, you must develop a regular maintenance schedule that consists of:

 

1. Checking and replenishing the electrolyte levels. Installing a BWT or Flow-Rite single-point-watering kit can make this an easy and quick process.

2. Performing an equalization charge

3. Checking and Cleaning battery terminals and connections

4. Performing an opportunity charge when possible

 

For a full list of proper Deep Cycle Battery Care & Maintenance procedures please see our page or download our Care & Maintenance brochure.

 

U.S. Battery Deep Cycle batteries are handcrafted in the U.S.A. The batteries also feature our exclusive XC2 formulation that gives them the highest initial capacity, fastest cycle-up time to full-rated capacity, improved recharge-ability, and the highest total energy delivered than any battery in their class. For a complete list of Flooded Lead-Acid or AGM batteries for golf cars and utility vehicles visit U.S. Battery’s Golf and Utility Vehicle Battery page to see all of the models, sizes, and specifications available to fit your particular vehicle.

8V batteries with watering kit

5 Benefits To Using A Single Point Watering System

Anyone using deep-cycle flooded lead-acid batteries in their electric vehicle or other equipment knows the importance of routinely watering the batteries. During charging, the water content of the electrolyte will decrease due to the electrolysis of water into hydrogen and oxygen gases. If left unchecked, the electrodes inside each cell can become exposed, resulting in a loss of battery performance. Regular watering is essential to the continued life and performance of any flooded deep cycle battery.

Electric vehicles and other equipment using deep cycle batteries typically have from four to eight individual batteries – each with multiple cells. Watering each cell can take a significant amount of time, especially if you are maintaining a fleet of vehicles. Battery packs are often located in areas that are not easily accessible, increasing the time required for watering.U.S. Battery offers two single-point watering systems (SPWS), Battery Watering Technologies and Flow-Rite, that can make battery maintenance quick and easy while offering several other benefits.

  1. You Can Fill All Your Batteries At Once                                                                                                                                                                                                                                              A SPWS connects to all of the cells in each of the batteries within the pack allowing you to fill them with water from a single point.
  2. Save Time During Regular Maintenance                                                                                                                                                                                                                                         On a single battery-powered vehicle, you can water all of the batteries in about a minute, versus what would normally take 45-60 minutes per vehicle.
  3. No Chance Of Over Watering                                                                                                                                                                                                                                                            With an SPWS, the battery cells fill up to the proper level and shut off to prevent overfilling.
  4. Monitoring Systems Can Tell You When To Water                                                                                                                                                                                                                        Some SPWS offer a sensor that can monitor water levels in the battery and indicate when they need watering.
  5. Extended Battery Life                                                                                                                                                                                                                                                                    Frequent maintenance extends the life of your batteries which in turn lowers your annual operating costs.

Click here for more information and installation instructions for our SPWS

AGM and Flooded Deep-Cycle Batteries

Understanding the Differences Between AGM And Flooded Deep-Cycle Batteries

When it comes to powering electric vehicles like golf carts, deep-cycle lead-acid batteries are the industry standard. The reason is that they are designed to provide the most cost-effective energy storage and delivery over the life of the battery.

Over the years, there have been two main types of deep-cycle lead-acid batteries that many golf car owners and fleets have used, the Flooded Lead-Acid (FLA) battery and the Absorbed Glass Mat (AGM) battery. While both provide optimum performance in a wide variety of applications, their design difference can offer various advantages depending on the application.

Engineering

The main design difference between FLA and AGM batteries is how the electrolyte is managed. In FLA batteries, the battery plates are submerged in the liquid electrolyte. During use, water in the electrolyte is broken down into oxygen and hydrogen gases and water is lost. This requires regular additions of water to be replaced to keep the battery plates fully submerged in the electrolyte.

In AGM batteries, the electrolyte is absorbed in special glass mat separators that retain all the electrolyte needed for the life of the battery.  Since there is no free electrolyte, the oxygen generated on a charge is recombined at the negative plate.  In normal operation, hydrogen is not generated and no water is lost.  This eliminates the need to add water and also allows the battery to be sealed with a one-way valve that prevents leakage of the electrolyte.

Performance Differences

FLA batteries have been used in a wide variety of applications for well over 150 years. Their popularity comes from their safety, reliability, and cost-effectiveness when compared with other types of rechargeable batteries.   According to Fred Wehmeyer, U.S. Battery Senior VP of Engineering, FLA batteries deliver the lowest cost per watt-hour both in acquisition cost and in overall cost per charge/discharge cycle.  “This is why they are the best choice for fleets of vehicles or equipment that are used heavily on a daily basis,” says Wehmeyer. “Also, both FLA and AGM batteries offer an environmental advantage over other types of batteries because they are essentially 100 percent recyclable and enjoy the highest recycling rate of any commercial product.”

AGM batteries offer the advantage of being maintenance-free. This can be significant in applications where regular maintenance is difficult or costly, such as when the batteries are located in remote or hard to access locations. Even though AGM batteries cost more per watt-hour, the elimination of maintenance costs reduces the overall battery operational costs.  Also, since the battery is sealed and does not emit gases in normal use, it can be used in sensitive areas such as food or pharmaceutical storage facilities.

Selecting between FLA or AGM deep cycle batteries ultimately depends on the type of use and the capability to provide regular maintenance in the application.

AGM = No Maintenance + Higher Cost + Susceptible to abuse like overcharging

FLA = Requires Watering + Lower Cost + Susceptible to abuse from poor maintenance

No matter what type of battery you use, it is always best to target the depth of discharge to 50 percent or less for both FLA or AGM battery types. This will optimize battery life cycle cost vs acquisition cost over the life of the battery system.

 

Connected 8v Batteries

Deep-Cycle Battery Terminals And Cable Maintenance Tips

When battery-powered vehicles and equipment suffer from intermittent performance issues, one of the most common reasons for this is poor battery cable connections. Ironically, loose connections can be caused by both under-tightening and over-tightening of the battery terminal connectors, as well as corrosion that can occur over time. Deep-cycle battery terminals are made from lead, which is a soft metal that creeps over time. The result is that they must be retightened regularly to maintain proper torque levels. If too much torque is applied when attaching cables to battery terminals, however, it can cause damage to the lead terminals preventing them from making a proper connection.  Battery manufacturers recommend terminal torque specifications that vary with the different types of terminals used for deep-cycle batteries.

Deep cycle batteries can come with UTL, UT, large and small L, Offset S, and SAE tapered post terminals, among others.  For UTL and UT battery terminals with threaded studs, the recommended torque is 95 – 105 in-lb (7.9 – 8.8 ft-lb).  For bolt-thru terminals such as large and small L and Offset S, the recommended torque is 100-120 in-lb (8.3 – 10 ft-lb).  SAE terminals have a recommended terminal torque of 50-70 in-lb (4.2 to 5.8 ft-lb). For other terminal types, consult the battery manufacturer’s recommendations. When measuring terminal torque, use a torque wrench with settings or readings in the 0 – 200 in-lb (0 – 16 ft-lb) range. Larger torque wrenches can inadvertently exceed the recommended settings or readings.

It is also important to consult the battery manufacturer’s recommendations for the proper type and assembly of the terminal hardware. Most manufacturers provide stainless steel nuts and lock washers or plated bolts, nuts, and lock washers with the batteries depending on the type of terminal used. The correct method is to position a lock washer between the nut and the connector (never between the connector and the lead terminal) and apply the recommended torque to completely compress the lock washer without deforming the lead terminal.

Clean terminals will maintain the best connection, so if corrosion is observed on the battery terminals and connectors, they should be cleaned with a wire brush and a solution of baking soda and water to neutralize any electrolyte that may be on the surfaces. To reduce the formation of corrosion on the terminals, battery manufacturers recommend using a corrosion inhibitor after making proper connections. Never apply grease or other lubricants between the terminals and connectors since they can interfere with the connection.

Check the cables to determine if they are corroded and need to be replaced.  Corrosion can extend under the cable insulation but is often not visible. A good ‘tug’ on the cables can expose weak connections. If new cables or connectors were added during the life of the vehicle, make sure the wire connectors are properly crimped and soldered to the cable ends.  Studies have shown that wire cables with crimped connectors that are not soldered to the cable ends can corrode faster and create a high resistance connection between the wire cable and crimped connector. This high resistance can cause excessive heating during discharge and melt the lead terminal, causing a loss of connection and permanent damage to the battery.  If any of the cables show signs of melted insulation, corrosion under the insulation, or have bare wire showing replace the cables and connectors.

While faulty connections are often the cause of battery terminal meltdowns resulting in poor performance, using appropriately sized wires with properly crimped and soldered connectors and the proper torque settings will reduce the chances that poor connections will adversely affect battery performance.

US L16HC XC2 Deep Cycle Battery

A Solar Energy Battery Storage Bank Made To Last 16 Years

Low Amperage Draw And Impeccable Maintenance Kept A Battery Energy Storage Bank Operable For More Than A Decade

Grover, Wyoming resident Jody Jenson, isn’t living “off-grid,” but his home is in a rural part of the state, where water comes from a well and delivered to the home by electric pumps. After several power outages, he didn’t want to rely on the city’s power grid to have fresh water, so he built a 48-volt solar system with U.S. Battery Deep-Cycle batteries for energy storage that have provided 16-years or reliable service.  “I did not like the vulnerability of relying on the grid for our drinking water,” said Jenson. “I spent over $12,000 on this system, including digging a new 100-ft. well. It definitely wasn’t to reduce costs, but more about having freshwater availability.”

To supply power to the pump system Jenson utilizes four 120-watt solar panels mounted together and wired to provide 24-volts and is connected to a circuit breaker and charge controller.  To store energy, he uses eight US L16HC XC2 batteries. “The system powers the well-pump that draws 4-amps, depending on groundwater level, but it’s pretty consistent,” he says. “It takes about 18-hours to fill the 1200 gallon cistern. The system normally runs about 12-hours between low and full tank levels.  From the cistern, there’s another pressure pump that draws six amps for approximately three minutes after starting, providing roughly 30-gallons between cycles.”

 Even though the system doesn’t draw huge amounts of amperage, Jenson never expected that the US L16HC deep-cycle batteries would last 16-years. “When I bought them, I remember being told that with proper maintenance, they should last something like five years,” said Jensen. “I knew with care, they would last longer.”

Jenson has taken exceptionally good care of his deep-cycle batteries, demonstrating how cost-effective flooded lead-acid batteries can be with proper maintenance. His routine includes weekly and monthly procedures. “Every week I go to check the system, including the water level in the cistern, corrosion on the battery posts, charging rate,  and battery voltage,” he says. “The batteries are still showing 26.5-volts fully charged. Once a month, I also check battery water levels and the amperage draw of the two pumps. This gives me any clues as to any problems that might be occurring. Quarterly, I add distilled water to the 24 individual cells.” 

While most people would consider this an impeccable maintenance routine, Jenson also includes periodic equalizing charges. “After adding water, I equalize the bank of batteries with the charge controller for a period of two hours at a maximum of 16-amps,” says Jensen. “I have never equalized without the batteries being fully charged. I’ve totaled up all the water I have added over the years, and as of today, from February of 2003 to now, I’ve added 63-gallons of water to the 24-cells!”

In addition to Jensen’s unique system and maintenance procedures, U.S. Battery L16 HC deep-cycle batteries feature the company’s XC2 formulation that uses Diamond Plate technology, highly efficient synthetic tetrabasic lead sulfate (TTBLS) crystal structures that enhanced performance, charging, and extend battery life. U.S. Battery also manufactures a line of Renewable Energy Batteries that are specifically designed for energy storage and feature Defender Moss Shields that reduce mossing and sulfation conditions, and Outside Positive Plates that mitigate the effects of plate sulfation.

While receiving 16-years of service from a set of deep-cycle batteries is not common, Jenson’s theory of having a large battery bank with a relatively low amperage draw, does demonstrate what low depth-of discharge and proper maintenance procedures can do to extend the life of deep-cycle batteries used for energy storage.

Skyjack-SJ-12 Vertical Lift

Replacement Deep-Cycle Batteries For Vertical Lifts 

Battery-powered vertical lifts are becoming increasingly popular with construction crews, as they are more compact, easily maneuverable, and provide a higher degree of safety than traditional ladders and scaffolding. 

To ensure reliable operation, it’s important for crews and rental facilities to utilize the proper deep-cycle batteries that power them. Some companies like Skyjack, JLG, Snorkel, and others, come equipped with four of our 6V flooded lead-acid batteries that feature quick fill caps that allow for easy inspection and water replenishing.  Over several years of operation, vertical lift manufacturers recommend utilizing the same type of replacement batteries to ensure proper operation. 

Deep Cycle BatteryModels such as Skyjack’s popular SJ12 feature U.S. Battery model US2200 XC2 6V deep-cycle batteries that provide a 232 amp-hour rating at a 20-hour rate, that is also designed to provide the highest rated capacity and fastest time to cycle up to rated capacity than any other deep-cycle battery in its class. These batteries also feature U.S. Battery’s SpeedCap design, making it easy to check water levels and to conduct routine maintenance, which includes checking water levels and topping off each cell to the battery manufacturer’s recommended levels as needed. 

Proper maintenance also includes visual inspections that require looking for clean terminals and wiring, then making repairs as necessary. Performing regular equalization charges at least once per month is also an important part of a proper maintenance routine that can prevent stratification and extend the service life of your batteries.

In addition to getting the right replacement batteries, the depth of discharge and regular maintenance are also key to making your vertical lift’s batteries last longer. Starting with a higher quality battery, such as what the vertical mast originally was equipped with, is a good start. It’s best to follow-up with ensuring that the batteries are limited to being discharged at no less than 50-percent. A 50-percent Depth Of Discharge (DOD), can be determined by first applying a full charge to the batteries, and the run time increases, regularly check the state of charge with a simple hydrometer. Battery manufacturers typically have a specific gravity chart that shows what the hydrometer will read at full charge, and also identify when it reaches various percentages of discharge. Periodically checking the hydrometer readings will give you a good idea of how much run-time the batteries can operate before reaching 50-percent discharge. Charging the batteries at this level, or before 50-percent DOD, will greatly promote longer service life.

With the right set of replacement batteries and routine maintenance, many construction crews and equipment rental facilities report that they have averaged five to seven years out of their batteries.

Children participating in Physics Bus experiments

U.S. Battery Manufacturing Continues Support For Physics Factory’s Efforts To Educate Students Using Renewable Energy

RV Batteries, Getting The Most Power Storage

Most RVs have an electrical system that simply plugs into a power source. When you’re at a more primitive site that has no power or water, your RV’s deep-cycle batteries had better be in top shape to power everything from your fridge, lights, stove and more. Many RV owners don’t always think about their batteries until they stop working, so it’s always important to make sure you have enough energy storage to power all your RV’s accessories. 

The way to ensure your RV has plenty of standby power is to ensure the batteries have enough capacity to handle the power load of all of your RV’s accessories. First, It’s important to know that RVs require a deep-cycle battery for this purpose. These batteries provide longer lasting power compared to regular car starter batteries that are designed to provide maximum power for short periods (to start the engine). Each deep-cycle battery is rated in amp-hours (AH), a measurement of the battery’s capacity. Most are indicated in the amount of current in amps that the battery can provide for 20-hours. 

For example, a deep-cycle battery with a 100 AH rating can deliver 5 amps for 20 hours, or 20 amps for 5 hours, before being discharged. Discharging deep-cycle batteries more than 50-percent will dramatically shorten their life. This is one reason why many experienced RV owners use batteries with the most AH rating they can get. When comparing batteries, make sure you compare them by the same 20-hour standard.

RV owners also switch to using multiple batteries to provide extra capacity. In many instances, this is done by using two smaller 12-volt deep-cycle batteries wired in parallel that will increase the AH capacity rating and leave the voltage at 12-volts. If you really want to dramatically increase your power storage, you can also switch to using two 6-volt batteries that need to be wired in series to produce 12-volts. This can more than double your AH capacity if you have the battery storage space to do so. 

Keeping your batteries from being discharged below 50-percent is key to making them last longer, as can checking the water levels in the batteries. In some RVs, it’s difficult to access the batteries for monthly maintenance so some RV owners also install a single-point watering system that makes it easy to add water to each battery from one access point. 

For more information on selecting the right RV batteries and maintenance tips on making them last longer, visit www.usbattery.com