t.

-l
The Battery Man's
Handy Book

Co!]rigIl, 19:1, !x
Willard Storage Brrterj Co.
Clerelnnd, Ohio
 TI.ID BATTERY MAN'S HANDY BOOK

METHOD OF REPAIRING GASKET TYPE BATTERIES

Fig. 1

Figure No. 1 shorvs clcsign of batterl' top construction. This par-

ticular section covcrs the connectol pos1, rttbbcr scalirg g:lsket, seal-
ing compourrl bett.ecn cover ancl case ancl top conllector hrtrnccl into
placc. 'fo repair this batter), procee('l as follorvs:

Have a Covcr Rernoval Frame (illustr ated in F ig. 2) macle at a

local michine shop. Fasten thc frarrc to a soli.l u.all or hench that
rvill r.ithstand a strong pull.

Fig.2

2
 THE BATTDRY NIAN'S HAIDY BOAK

I. Drill Off Top and Terminal Connectors.

Drill off the top and ter minal connectors in the usual manncr, lear-
ing as much oi the post as is pr,.sit,le. The only uav in rtich the
elerrerts and covers car.r lrc liftcd out is by means o[ grasping the
posts. You u,ill thus see that it is desirablc to have high posts
remaining above the covers.
2. Soften the Sealing Compound.
A-With Steam.
Placc the steam jet in the
vent hole ancl lehve long
cnougl.r to allorv the com-
pound to become very. soft
and r.ith a narrour heatcd
chisel remove thc compound
from betu.ecn the covers
down to the top edge of the
iars as indicated at point A,
Fig.3.

B-With a Flame and

Hot Chisel.
With an ordinary gas
flame heat the com-
pound around the edge
of the cover, keepirg
the flame moving so as
not to concentrate the
flame in one place and
burn the rubber Take
out the compound while
hot with a narrow
heated chisel or scre$'-
driver until practically
clean.
 THE BATTERY MAN'S HANDY BOOK

3. Draw Out Element and Allow to Drain.

Remove thc element b1' lifting

from the jar rvith element pliers
ancl set it at an angle in the jar to
clrai n.

4. Remove Covers from Elements.

(Note.) Ii the tratter) is to be opened for inspection onl1,, or i[
the nature of the repair is such that the elements need not be disas-
sembled, do not remo\.e the colers.
Before attempting to remole the covers, see that tlrere is no lead
projecting at tbe poirts indicated at A, Fig. 4.
Place the cover in the Corcr Removal Frame and pull steadilv on
the element (See Fig. 4). A little swaying motion from side to side
ma), hasten the looseling.

Fig. 4
 TLl[, BATTERY I,TAN'S HA\'Df BOOK

_
Replace Gaskets in CoYer and Dry,

Ii an-v of the gaskeis remaired

on the posts, replace them in the
cover and then thoroughll. dr1'
the insicle rvith a rag or tissue
paper.

6, Make Necessary Repairs.

After suf6cient draining the element can be separated for necessary l

repairs and prepared for reassembling in the jars.

7. Clean Off Compound Around Top Edge of Jars.

ll
After removing the elements
from the jars, clean off the sur- I
plus compound that has adhered
to top inside edge of the jar r,r,ith
a putty knife so that the element
and cover will lit in easily u'hen
replaced.

8. Clean Out Sediment.

If all cells har.c been
removed, place the
lr,ood case u.ith the jars
on the $.ash tank shelf
and turn a stream of
water into the jars u'ith
enough lorce to loosen
the scdiment and then
wash out thoroughly.
 THE BATTERY MAN'S HANDY BOOK

9. Replace Elements.
Reassemble thc elements and place then.r in the jar so that the
positir-e terminal is to the front when thc nameplate end of the case
is to the right.

10. Dry the Posts.

\\rith a rag or tissue paper

u'ipe off the posts and then dr1-
thoroughly u.ith a light gas
flame.

I1. Cement the Gaskets.

\\'ith a 94" bristle bottle
bmsh insert a small quantity
of rubber cement around the
inside of thc gashet. Do tl.ris
rvith one cover at a time and
applv the cover quickly so as
not to allot' the cement to
dry. This cement u.ill ilct as
a Iubricant and, r,itl.rout it,
it rvil1 be impossible to put on
thc covers.

12. Replace Covers.

Place the covers o\-er the post
and press dol\'n until thc top
edge of the covers is Yro of an
inch above the the top edge
of the case.
 THE BATTERY ]IA.\'S H.1\'D\- BOOK

13. Thoroughly Dry and Warm Space Between Cover and Jar.

The space bet\,\'cen the

cover and jar should be
perlectll' driecl, using an
ordinarl- gas flame. This
till insure a pcrfect seal
of rubbcr and ccmpound,

14. Seal the Battery.

\Vith a pouring dipper

lill the space between the
cover and jar about half
lull o{ rathcr'thickmelted
compound, allorving this to
thoroughly cool and hard-
en. Then 6nish pouring
lrith r.ery hot and thin
compound until it is level
u''ith thc top eclge of the
case.

15. Smooth the Compound.

Play a light flame over

the compound so as to ha\.e
it run together and prcscnt
a smooth 6nish.
 .THE BATTERY MAN'S HANDY BOOK

Burn on the Connectors.

Clcan ofi thc tops of the posts

u-ith a rvire brush. Lay the toP
conlr.'clors irr place and L.,utn on in
the usual way. If burned on
terminal connectors are used theY
should be placed over the Posts
and burned on in the usual n-'anner.

Fill the Battery with Electrolyte.

Fill the battery rvith electrolyte

of the proper specific gravity, be-
ing carelul to have pl€nty of solu-
tion above the plates, but do not
fill too full.

Removing One Cell Only.

\Uhen removing
one cell only, drill
thc top connector or
conlectors on the
arljacent cell, or cells,
leaving the connector
()1 connectols on the
clcmclt to be rc-
moved without dis-
turbing the connect-
ors or posts.

If, afterward, it is found necessary to remoyc the cover, rcplace

I
the element in the jar ancl drill out the posts in the regular u'a1'.
 THE BATTERY IIAN'S 114}IDY BOOK

TYPES "SJWN'' AND "SJRN''

Cross Section of Terminal Post Burned to Cover Insert

Cross Section of Connecting Strap Post, Cover Insert and

Top Connector Welded Together

9
 THE BATTERY MAN'S HAAIDY BOOR

METHOD OF REPAIRING NEW TYPE "SJWN'' AND

BATTERY.
1. Cut Off Terminal Post.
If clamp terrninals are Llsed. cllt
ofl top oI tcrnrin.rl l,osrs rr-irrg
large end cutters or a hack sar.r..
It
I
If burnecl on terminals are usecl ;
drill off l'ith a 13210,, drill to a
depth suflicient to release t he
terminal from thc post assemtrlr-.

2. Remove Top Connectors,

z-72

Place drill jig Z-72 over the top

connector head and drill rvith n \
191e" drill, Z-t-l, to a depth
suf-
ficient to release thc connect()r I
Irom the post assembll'.

3, Smoothing Ofi Top of posts.

Smooth off extension o[ posts
left b]. cuttirg and drilling, by
means of a file. This u,ill expose
a flat surface on top of tlte insert t
and nake it casier to center the
drill for the next operation. l
10
 TIIE BATTERY I,TAN'S HANDY ]]AOK

4. Releasing Post from Insert.

t#
^@- ,___\e:i--..-:

N\ \,
:\-_l:=*-l+ \ lc-
I:.i&
a,iw,
z-94 z_95

\\rith a n16+,' dri1l, iZ_95, ancl

drill jig, Z-9,1, release the con-
nector post lrom the insert as
shou'n. The internal cliametcrs of
rhe enrl' o[ rhe r]rill jiq rrrrv
sliqhrll. I sc rlro crrrl u
fits over the insert. "t, t,"ri

5. Soften the Sealing Compound Around the Covers-

A-With Steam.
Placc the steam jet in
the vent hole ilncl le:n,e
long enough to allorv
the compound to bc-
come r-cry soft.

B-With a Flame and

Hot Chisel.
\Vith an ordirary gas '
flame heat the com-
pound around the cdge
of the covcr, kcsping
the flanc mor.ing so as
not to concentrate the
flame in onc place arnd
burn the rubber. 'lake
out the compound l'hile
hot rvith a trarro\\ hcat-
ed-chisel or screrv-driler
until practicallv clean.

,_1
 THE BATTERI/ MAN'S HANDY BOOR

6. Remove Covers.

Liit off thc covers r,itl.r a pair

o[ plicrs on each insert. The com-
pound, rvhile soft, shoulcl be
cleanecl off immediately after re-
mor"al of thc colcrs.

7. Draw Out Element and Allow to Drain.

Remove the elernent by lifting

lrom thc jar r,ith element pliers
and set it at an angle in the jar to
rlra in.

8. Make Necessary Repairs.

After sufEcient drainir.rg the element c&lr l)c separated for uecessaty
repairs and prepared for reassernbling in the jars.
(Note.) Il the batterl' is to be opened for inspection only, or if
the rature of thc rcpair is such that the elcments neecl not bc dis-
assembled, do not release the rvekl tretrveetr thc posts ancl insert.
Remove the top cor[ectors as shorvn in paragraph 2, altcr thich thc
compound can l-re soltened or renloved and thc elemcnt ard cover
drarvn out together.
I
9. Clean Off Compound Around Top Edge of Jars. 1
(See paragraph 7, pagc .5.)

12
 THI' BATTERY MAN'S HANDY BOOK

10. Clean Out Sediment.

(See paragraph 8, page .5.)

11. Build Up Connecting Strap Posts.

z-93
I
\Yith post buildcr, Z-93, build
up thc post to a height of 1-11a''
above the top of the connecting
strap.

12. Bevel Top Edge of Post.

After rcmoving the post builder

belel the top edge of the post rvith
a file as indicated at "A" in orclcr
to alloiv the cover to go on easily.

13. Replace Elements.

Reassen.rble the elements, place thcm in the jars so that thc positile
terminal is to the Iront u'hen the name-plate end of the case is to the
right.

14. File and Clean CoYer Inserts.

File ofl thc top of the covcr in-
serts at the point "A" to a height
o[ 9jc" abovc the coter. Also re-
lttove arny roughness on surface
"B" causecl b-v pliers l.hen cover
tvas removed.

15. Replace Covers.

Put on the covers so that their

tops will be %2" above the top
edge of the jars, tapping Jightly
with a small hammer.

13
 t
TLID BATTERY MAN'S HANDY BAOK

16. Weld Post and Insert Together,

z-87
Place burning form Z-87 over
the post ar.rd insert and burn the
tir.o parts togcther making a pcr-
fect seal.

17. Build Up Stub Post.

Z-88 (Pos.) Z-89 (Ne9.)

Thoroughll' brush ofI the top of
the post l.ith a rire brush and
build up a stub post using burning
form Z-88 on positive posts and
Z-89 on negativc posts.

18. Thoroughly Dry and Warm Space Between Cover and Jar.
(See paragraph 13, page 7.)

19. Seal the Battery.

\Vith a pouring dip-
per 611 thc space
betu.een the jar and
cover about half full
of nelted No. 7 seal-
ing compound, allow-
ing this to cool. Then
finish pouring r.ith
No. 7 con=pound a
little more than full.
Let all compound cool :

Ior several minutes. ,

J
 THE BATTERY ]1It,'S IJ-I.\'D]- BOOfi

20. Clean Off All Surplus Compound.

Clealr off all the surplus compound

from the top of thc batter.v, using a
hot putty knife or clrisel 'r.hich will
leave a smooth finish.

21. Burn on the Connectors.

(See paragrapl.r 16, pagc E.)

22. Build Up Terminal Posts.

Z-90 (Pos.) Z-91 (Neg.)

lf the terminal posts arc made
for clarmp tcrminals, Jtuild up lty
u-ing burrring lonn Z-()0 lor po"i-
tive posts tLncl Z-91 for negative
posts. \\ihcn burning terminal
posts antimon]' lead llurning bars
should be uscd.

23. Fill the Battery with Electrolyte.

Fill the battery r.ith electrol-vte

of the proper spccific gravitl', be-
ing careful to have plenty of solu-
tion above the plates, but do not
fill too full.
 THE BATTERY MAN'S HANDY BOOK

Removing One Cell OnIy.

Whcn removing
one cell only, drill
the top connector or
connectors on the
adjacent cell, or cells,
leaving the connector
or connectors on the
element to be re-
movecl rvithout dis-
turbing the con-
nectors or posts.

If, afterward, it is found necessary to remove thc cover

replace the element in the jar and drill out the posts in
the regular rvay.
 THL BATTER)' 11,1.\'S l1-.r-\-,D )- aoo.(

METHOD OF DISMANTLING AND REASSEMBLING

SINGLE COVER BATTERIES WITH COMPOUND
SEALED POSTS OF TYPES
SEW, SER, SJW, SJR, SL, SLR, SM, SMR, STR, SXW, SXR,
SP, SK, SQ, EM and EMR

1. Remove the Top and Terminal Connectors.

Center punch a hole in the exact center

of the connector hcad. Drill a hole fully
)f " dccp into the post using a 3f" machite
clrill.The connectors should then be lifted
off easilv t'ith a pair of-plicrs. If tl.rey do
not come off readily apply a small lead-
burning flame to softcn the lead at the joint
of thc post and. connector.

2. Soften the Sealing Compound Around the Covers'

(See paragraph .5, page 11 .)

t7
 THE BATTERY MAN'S HANDY BOOK

3. Draw Out the Battery Element.

After thc compr,'rind has softcncd or

been removed, lift the elcmcnt from
the jar rith a p:rir o{ elcment pliers
on cach pcst. II thc clcment fits tiglrt
.lnd a batter) r isc is llct usccl. it Drtr.1'
be necessarl' to Put one Ioot on the
case u.hile ltulling tlre elernent.

4. Allow the Element to Drain and Remove the Cover.

Immccliately aftcr the elemcnt is rerroved

place it at an angle in the jar to drain. \\'hile
the co:rpound is still hot and soft, rcmor.e the
cover by placing tlre fingers under the cover
and the thumbs on the posts and lilt the covcr
rvith the fingcrs.

Clean Covers and Wells of Compound.

\\,'ith a putt) knifc clean off all tl.re
cornpould from around the edge of the
cover. \\rith a narror\r screu.driver or a
kni{c clean out all of thc old con.rpound
that is found on the under side of thc
cover in tlre part that fits into the rvell
of thc post. Also r enlove the con-rpound
that is in tl.re r.ells of the posts.

6. Clean Off the Compound Around the Top EdSe of Jar.

(See paragraph 7, page 5.)
18
 THE BATTERY MAN'S I.IANDY BOOK

7. Clear Out Sediment.

(:ce l,Jragraph 8. page 5.

8. Replace Elements in the Jar and Fit the CoYers.

In order th.rt the coYcrs
n.ray be placed in position
quickly for sealing, thby
should first be fittecl in tl.reir
respective cells. After again
ren-roving thc covers see that
the u.ells are dried by the use
o[ an ordinary gas flarue.
Good results can only be ob-
tained lYheii all parts to bc
sealcd :rrc thoroughly dry.

9. Sealing Cover Around the Connecting Strap Post.

After rvar ming the rvell of tl.re

's'ith the flanre pour in:.r.relted
No. 7 sealing compouncl until thc
l'ell is ncatrly lull and thcn quickly
prcss thc cover into position.

10. Thoroughly Dry and Warm the Space Between Cover and
Jar.
(See piiragralth 13, pagc 7.)

11. Sealing the Battery.

(Scc paragrapl.r 19, Pagc i4 t

t2. Clean Off AII Surplus Compound.

(Sce paragraph 20, page 15.)
 THIJ BATTERY ]VIAN'S HANDY- BAOK

13. Burning On the Connectors.

(See paragraph l6, page 8.)

14. Filling the Battery with Electrolyte.

Yl:T:xrs ir::,,:,l".

Fill the l)irtter) rvith clcctrolltc of

tl're propcr spccihc gralitl'. Be carc-
Iul to har-e pleltl ol solution alrole
the plates, i)ut (lo not lill trxr lrrll.

The strength of the electrolyte used for hlling an-v batter]'u.ith neu'
wood separators largely depends upon the condition of the plates. If
they are.nerv platcs the electrolyte used for lilling should be 1.3.35
specilic gravity;if they are old plates and in a baclly sulphated concli-
tion, it is advisable to Ii11 with 1.150 specific gravity electrolyte;if thc-v
are old plates and not badly sulphated, use 1.250 spccific gravitl-
electrolyte; if tl.rey ass o1d plates and you are in doullt as to their con-
dition, use 1.200 specific gravity electrolyte. Regardless of what
strength electrol-vte has been used, the gravity of the electrolyte t hcn
the batterl is completely charged should be between 1.280 and 1.300
in eacl.r cell. If thc specific gravity is not between 1.280 and 1.300 in
each cell, adjustment must be n.rade by remor.ing a portion of thc
electrolyte and rcplacing with a like anlount of cither distillecl r.r''atcr,
or 1.400 specific grar.ity electrolyte, depending upon t'hether the
electrolyte in the cells is belorr or above thc specilied limits.
Note-Electrolyte oI difiercnt spccifrc gravities is madc up accorcl-
ing to the following porportions by volune, of pure sulphuric acid
(1.84 specific gravity) and distilled water:
1.150 Sp. Gr. equals ore part Sulphuric Acid to 6 parts dis-
tilled water.
1.200 Sp. Gr. equals one part Sulphuric Acid to 4 parts dis-
tilled li'ater.
1.2.50 Sp. Gr. equals one part Sulphuric Acid to 3 parts dis-
tilled water.
1.285 Sp. Gr. equals onc part Sulphuric Acid to 2.5 parts dis-
tilled water.
1.32.5 Sp. Gr. equals one part Sulphuric Acicl to 2 parts dis-
ti1led water.
Note-\,Vhen mixing electrolyte always pour the pure Sulphuric
Acid into the distilled water and allorv the solutiorr to cool trelolv'
90 degrees F. before putting into the batteqr.