Battery Post Repair

TM 9-6140-200-14

c. Repair of broken or damaged battery filler ports. Repair broken or damaged

battery filler ports as follows:

WARNING

Battery electrolyte can be harmful if it contacts the eyes,

skin or clothing. Flush immediately with large amount of

cold water. Also, in case of eye or skin contact, see a

physician immediately. Wear eye/face shield and other

protective clothing during all battery repair operations.

(1) Obtain an unserviceable battery. Remove all battery filler caps and

thoroughly drain electrolyte from battery.

(2) Using a two or three hole saw, drill the unbroken filler ports and remove all

undamaged filler ports from the unserviceable battery. Cut these

replacement undamaged filler ports from the unserviceable so that they are

large enough to overlap the holes of the battery where they will be installed

by 1/4 to 1/2 inches.

(3) Grind down the bottom side of the replacement filler ports using a disc-type

grinder.

(4) Remove the damaged filler ports from the battery to be repaired.

(5) Thoroughly clean the battery surface where the epoxy for the replacement

filler ports is to be applied.

(6) Apply epoxy cement in small amounts to the battery surface where the repair

is to be made.

(7) Install replacement filler ports on the battery and apply epoxy cement to the

outer bottom edges of the ports.

(8) Allow epoxy to cure for at least one hour before returning battery to service.

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