The Automobile Storage Battery: Its Care And Repair

Chapter 16 (2)

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Ampere Hours Ampere Ampere Length Weight at Usual Rate for Rate for in Inches in Type Part No. Lighting Rate 20 Minutes 5 Hours L. Pounds ---- -------- ------------- ---------- -------- --------- ------ 6-C-7 100001 45 54 7.3 5-7/8 34 6-C-9 100002 65 73 9.7 7 39 6-C-11 100003 85 91 12.1 8-1/8 44 6-C-13 100004 105 109 14.6 9-1/4 50 6-C-15 100005 125 127 17.0 10-3/8 56 6-C-17 100006 145 145 19.4 11-11/16 63 6-C-19 100007 165 163 21.8 13 70 6-C-21 100008 185 181 24.3 14-5/16 77 6-C-23 100009 205 199 26.7 15-5/8 85 6-C-25 100010 225 218 29.2 17-1/8 93 12-C-7 100011 45 54 7.3 10-9/16 59 12-C-19 100012 65 73 9.7 12-13/16 72 12-C-11 100013 85 91 12.1 15-1/16 84 12-C-13 100014 105 109 14.6 17-5/16 96 12-C-15 100015 125 127 17.0 19-8/16 110

Plates

Width Height Thickness ----- ------ --------- 5-5/8 4-1/4 0.1 inch

Type "E" Batteries

The type "E" series was designed for replacement work on a few old model cars now in service where a narrow, high battery was necessary. The design is not as efficient as the "B" and "C" lines, due to a lack of space and further, it has been necessary to omit the Westinghouse Post Seal for the same reason.

Ampere Hours Ampere Ampere Length Weight at Usual Rate for Rate for in Inches in Type Part No. Lighting Rate 20 Minutes 5 Hours L. Pounds ---- -------- ------------- ---------- -------- --------- ------ 6-E-13 100058 79 82 11.0 9-1/8 40 6-E-15 100062 94 96 12.8 10-1/4 44 6-E-17 100065 109 109 14.6 11-9/16 50 6-E-21 100067 139 136 18.2 14-3/16 62 12-E-11 100088 64 68 9.1 14-15/16 70 12-E-13 100060 79 82 11.0 17-3/16 79 12-E-15 100069 94 96 12.8 19-7/16 90 18-E-9 100070 49 54 7.3 15-5/16 75

Plates

Width Height Thickness ----- ------ --------- 4-1/8 5-5/8 .098

Type "H" Batteries

The type "H" battery is built with heavier plates than the type "C" and "B" batteries for use in cars where the necessary increased space is available and where the weight per ampere output is not a consideration. Under the same use the battery will give a greater life than the type "C" or "B" battery having the same positive area.

This battery has a greater space between the plates than the "C" or "B" battery and will therefore have less internal discharge when standing on open circuit, and is more desirable for miscellaneous use where open circuit discharge is of consideration.

Plates

Width Height Thickness ----- ------ --------- 5-5/8 5 .19

Type "J" Batteries

The type "J" battery is an extremely heavy construction battery with thick plates, and it was designed primarily for use on trucks and other vehicles of this type where there is excessive vibration and other possibility of mechanical abuse. This battery will give a greater life than either the "H", "C" or "B" battery with the same plate area. It is provided with wood separators and rubber sheets.

Plates

Width Height Thickness ----- ------ --------- 5-5/8 5 .19

Type "0" Batteries

The "0" type battery sacrifices some capacity in obtaining a rugged strength. It is a special battery made only with nineteen plates per cell where the percentage of sacrificed capacity is not great as compared with the twenty-one plate "C" type. It fills the same space as does a 6-C-21. It has greater life and strength. It has less capacity but it is built for conditions requiring less capacity than a twenty-one plate cell.

Plates

Width Height Thickness ----- ------ --------- 5-5/8 5-1/4 .123

Type "F" Batteries

There is only one type "F" battery. It is of big heavy construction exactly the same dimensions as the battery used for a number of years on the Cadillac and certain other cars. This battery is heavier than type "C" of the same capacity and it has a greater life.

Plates

Width Height Thickness ----- ------ --------- 4-3/4 5-1/4 .17

WILLARD BATTERIES

Since 1912, when the Willard Storage Battery Co. began to manufacture storage batteries for starting and lighting work, various types of Willard batteries have been developed. The original Willard starting and lighting batteries used two-piece, or "double" covers. These are shown in the cuts used to illustrate the sealing of double-cover covers in the preceding chapter, and no further description will be given here. The doublecover batteries are no longer made, but the repairman will probably be called upon to repair some of them. The instructions given in the preceding chapter should be used in making such repairs.

Following the double cover batteries came the single cover battery, of which a number of types have been made. One type used a rectangular post, and was very difficult to repair. Fortunately, this type was not used extensively, and the battery is obsolete.

Willard Batteries With Compound Sealed Posts

The oldest type single-cover Willard battery which the repairman will be called upon to handle is the compound sealed post type, illustrated in-Fig. 277. This battery includes types SEW, SER, SJW, SL, SLR, SM, SMR, STR, SXW, SXR, SP, SK, SQ, EM, and EMR. As shown in Fig. 277, there is a well around each post which is filled with: sealing compound. On the under side of the cover is a corresponding well which fits into the post well, the sealing compound serving to make the seal between the cover and the post.

[Fig. 277 Willard Battery cross section]

Aside from this post seal, no special instructions are required in rebuilding this type of Willard battery. A 3/4 inch drill is needed for drilling off the connectors. When the plates have been lifted out of the jars, and are resting on the jar to drain, and while the compound and cover are still hot, remove the cover by placing your fingers under it and pressing down on the posts with your thumbs.

With a narrow screw driver or a knife, clean out all of the old compound from the wells around the posts, and also remove the compound from the under side of the cover which fits into the post wells.

In reassembling the battery first try on the covers to see that they will fit in the post wells. Then remove the covers again and heat them with a soft flame. Then heat the post wells perfectly dry with a soft flame. Pour the post wells nearly full of compound, and quickly press the cover into position.

Willard Batteries With Lead Inserts In Covers

The types SJWN and SJRN Willard batteries have lead inserts in the cover post holes, as shown in Mg. 278, the inserts being welded to the posts. For removing the connectors and for separating the post from the cover insert, the Willard Company furnishes special jigs and forms. The work may also be done without these jigs and forms, as will be described later.

When the special jigs and forms are used, the work is done, as follows:

1. Place Willard drill jig Z-72 (Fig. 279) over the connector, and with a 13/16 inch drill, bore down far enough to release the connector from the post (Fig. 279).

[Fig. 278 lead insert used on Willard Batteries; Fig. 279
Willard Drill Jig Z-72; Fig. 279 Willard Drill Jig Z-72 and
how it is used]

2. File off the post stub left by drilling. This will give a flat surface on top of the cover insert and will make it easier to center the drill for the next operation.

3. With a 57/64 inch drill, and Willard jig Z-94 (Fig. 280), drill down to release the post from the cover insert.

[Fig. 280 Willard Jig Z-94; Fig. 281 Willard Post-Builder Z-93]

4. In reassembling, build the post up to a height of 1-5/16 inches above the top of the plate strap, using Willard post builder Z-93 (Fig. 281).

5. After removing the post builder, bevel the top edge of the post with a file, as indicated at "A" (Fig. 281). Then replace plates in the jars.

6. File off tops of cover inserts at "A" (Fig. 282), to a height of 3/16 inch above the cover. Also remove any roughness on surface "B" caused by pliers when cover was removed.

[Fig. 282 Willard Battery cross section of cover insert;
Fig. 283 Willard burning form Z-87 and how it is used]

7. Put on the covers so that their tops will be 1/32 inch above the top edge of the jars, tapping them lightly with a small hammer.

8. Place Willard burning form Z-87 (Fig. 283) over the post and cover insert and burn the post to the insert.

9. Remove form Z-87 and thoroughly brush off the top of the post stub. Then build up the stub post, using Willard burning form Z-88 on the positive posts and form Z-89 on the negative posts (Fig. 284).

[Fig. 284 Willard burning forms Z-88 and Z-89]

10. Now seal the covers with sealing compound as usual, and burn on the connectors.

11. If the terminal posts are made for clamp terminals, build up the posts by using Willard burning form Z-90, for the positive posts and Z-91 for the negative posts (Fig. 285).

[Fig. 285 Willard burning forms Z-90 and Z-91]

To work on the post seals of Willard types SJWN and SJRN without the special Willard jigs and forms:

1. Remove the connectors and terminals as usual.

2. Saw off the posts close to the covers, taking care not to injure the covers; This will separate the posts from the cover inserts, and the covers may be removed.

3. In reassembling, Ale off the top of the cover insert at "A" (Fig. 292).

4. Put covers on so that their tops will be 1/32 inch above the top edge of the jars, tapping the covers lightly with a small hammer.

5. Brush the top of post and cover insert perfectly clean. Now make a burning form consisting of a ring 1-1/8 inside diameter and 1-5/8 inch outside diameter and 3/16 to 1/4 inch high. Set this over the stub post and cover. With a hot lead burning flame melt the top of the post and cover insert together. Then melt in lead up to the top of the special burning form (Fig. 286). Then remove the form.

[Fig. 286 Cross section Willard Battery Posts Types SJWN and SJRN]

6. Set post builders on the part of the posts which has been built up and build up the posts as usual, Fig. 286. Then burn on the connectors and terminals.

Willard Gasket Type Batteries

Fig. 287 shows this type of construction, used on types SJRG and SLWG.

Fig. 288 shows the seal in detail. A soft rubber gasket is slipped over the post, and the cover is pushed down over the gasket. For removing the covers, have a cover removal frame made as shown in Fig.

289. Fasten the frame to a solid wall or bench so that it will withstand a strong pull. In rebuilding this type of battery proceed as follows:

[Fig. 287 Willard Gasket Seal Battery cross section]

1. Drill off the connectors and terminals, leaving the post stubs, as high as possible, since the only way of removing the plates is by grasping the post stubs with pliers.

[Fig. 288 Details of Willard Gasket Seal]

2. Steam the battery to soften the sealing compound and lift out the plates as usual.

3. To remove covers. Saw the post stubs off flush with the covers. Place the element in the cover removal frame (Fig. 289) and pull steadily on the element. A little swaying motion from side to side may help in loosening the covers. If any of the gaskets remain on the posts when the covers are removed, replace them in the cover and thoroughly dry the inside with a rag.

[Fig. 289 Cover removal frame for Willard Gasket Seal Battery]

4. To replace covers. With a rag or tissue paper wipe off the posts and then dry them thoroughly with a soft flame.

With a 3/4 inch bristle bottle brush apply a thin coating of rubber cement to the inside surfaces of the gaskets. Do this to one cover at a time and apply the cover quickly before the cement dries. The cement acts as a lubricant, and without it, it will be impossible to replace the covers.

Willard Separators

Fig. 290 shows the Willard Threaded Rubber Separator which is made of a rubber sheet pierced by thousands of threads which are designed to make the separator porous. This separator is not injured by allowing it to become dry, and makes it possible for the Willard Company to ship its batteries fully assembled without electrolyte or moisture, the parts being "bone-dry."

[Fig. 290 Willard threaded rubber separator]

UNIVERSAL BATTERIES

Types. The Universal Battery Co. manufactures batteries for (a) Starting and Lighting, (b) Lighting, (c) Ignition, (d) Radio, (e) Electric Cars and Trucks, (f) Isolated, or Farm Lighting Plants, and (g) General Stationary Work.

Construction Features. The Universal Starting and Lighting Batteries embody no special or unique constructions. The boxes are made of hard maple, lock cornered and glued. The jars have single rubber covers. The separators are made of Port Orford white cedar wood, this wood being the same as that used in some of the other standard makes of batteries. The space between the covers and connectors is sufficient to permit lifting the battery by grasping the connectors.

[Fig. 291 Universal Battery Cover cross section]

Fig. 291 shows the Universal Co. Post Seal construction. A soft rubber washer (A) is first slipped over the post. The cover (B) is then put in place, and rests on the washer (A) as shown. A second washer (C) is then slipped over the post, resting on the upper surface of the shoulder of the cover. The lead sleeve washer (D) is then forced down over the post, pressing washer (C) down on the cover, and pressing the cover down on washer (A). The two rubber washers serve to make a leak proof joint between post and cover. The lead sleeve-washer (D) "freezes" to the post, and holds cover and washers in position.

In rebuilding Universal batteries the cover need not be removed unless it is desired to replace plate groups. To remove the cover, after the cell connectors have been drilled off, drill down through the post-stub until the drill has penetrated to the shoulder (E). This releases the seal and the cover may be lifted off. To save time, the post-stub may be cut off flush with the top of the cover with a hack saw after the cell connectors have been drilled off. The drill is then used as before to release the grip of the washer. Using a drill to release the grip of the washer makes it necessary to build up the posts when the battery is reassembled. Instead of using an ordinary twist drill, a special hollow drill may be obtained from the Universal Battery Co. This drill cuts away the lead sleeve gasket without injuring the post. If an ordinary drill is used, a 3/4 inch drill is required for the seven plate battery and a 13/16 inch drill for all other sizes.

ONE-PIECE BATTERY CONTAINERS

The standard practice in battery assembly has always been to place the plates of each cell in a separate, hard rubber jar, the jars being set in a wooden box or case. Each six-volt battery thus has four containers. When a wooden case is used, jars made of rubber, or some other nonporous, acid-resisting material are necessary.

[Fig. 292 One-piece battery container]

Wooden cases have been fairly well standardized as to the kinds of wood used, dimensions, constructional features, and to a certain extent, the handles. The disadvantage of both the wooden case and the iron handles is that they are not acid proof. Acid-proof paint protects them from the action of the acid to a certain extent, but paint is easily scraped off, exposing the wood and iron to the action of the acid. It is practically impossible to prevent acid from reaching the case and handles, and corroded handles and rotted cases are quite common.

A recent development is a one-piece container which takes the place of the jars and wooden case. Such a container is made of hard rubber or a composition of impregnated fibre which uses a small amount of rubber as a binder. These cases are, of course, entirely acid proof, and eliminate the possibility of having acid soaked and acid rotted cases. Painting of cases is also eliminated. The handles are often integral parts of the case, as shown in Fig. 292, being made of the same material as the case.

The repairman should not overlook the possibilities of the one-piece containers. In making up rental batteries, or in replacing old cases, the one-piece containers may be used to advantage. These containers are suitable for Radio batteries, since they have a neater appearance than the wooden cases, and are not as likely to damage floors or furnishings because the acid cannot seep through them.

THE TITAN BATTERY

The Titan Battery is built along standard lines, as far as cases, plates, separators, and jars are concerned. The ribs of the grids not arranged at right angles but are arranged as shown in Fig. 293. Each pellet of active material is supported by a diagonal rib on the opposite face of the grid.

[Fig. 293a Titan Battery grid]
[Fig. 293b Titan Post Seal construction]

The Titan Post Seal is shown in Fig. 293. A soft rubber gasket (G) is slipped over the post, and rests on a shoulder (F) on the post. The cover has a channel which fits over the gasket and prevents the gasket from being squeezed out of place when the cover is forced down on the gasket. The post has two projections (DD), as shown, the lower surface of each of which is inclined at an angle to the horizontal. A lock nut (H), which has corresponding projections (IJ) is slipped over the post as shown at (0), and is given a quarter turn. The top surfaces of the projections on the lock-nut are inclined and as the locknut is turned, the projections on the post and nut engage, and the cover is forced down on the gasket (G). To lock the nut in place, a lock washer (L) is then slipped over the post, the projections (MM) fitting into spaces (KK) between the projections on the post and nut, thus preventing the nut from turning. A special wrench is furnished for turning the lock-nut. The cell connectors rest on the tops of the lock washers and keep them in place.

The overhauling of Titan batteries should be done as described on pages 328 to 374.

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The Automobile Storage Battery: Its Care And RepairChapter 16 (2)

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