The Automobile Storage Battery Part 55

1. Drilling Off the Top Connectors. Do this as described on page 329.

For type KZ batteries use a 3/8 inch drill. For all other types use a 5/8 inch drill.

2. Removing Plates from Jars. Follow the general instructions on page 333.

Types DX, LX, LXR, LXRV, PHC, XC, XX, and XXV. In opening these batteries, all of which have the single f.l.a.n.g.e cover, you may remove each cell complete from the case, and then draw out the plates; or you may draw out the plates without taking out the jars. To remove the complete cell, heat a thin bladed putty knife and work it down all around the outside of the jar. Then lift out the complete cell by pulling steadily on the cell posts with two pairs of gas pliers. The battery should be placed on the floor when you do this, and you should stand with one foot pressed against the side of the case.

If you do not wish to remove the complete cells, or should the jars fit too tight in the case, unseal the covers and remove the plates according to the instructions given on page 333.

Types KZ and MHA. These batteries have the double f.l.a.n.g.ed cover.

Several methods may be used in removing the plates from the jars. In each case, the top of the cell is cleaned, gas blown out of the vent holes, and the sealing nuts removed before opening the cells.

[Fig. 240 Removing double f.l.a.n.g.e exide cover]

First, a flame may be used to soften the sealing compound which is placed in the slot formed by the two f.l.a.n.g.es of the cover. If you wish to use a flame, first remove each complete cell from the case, loosening the tie bolts that pa.s.s through the case to release the jars. Then hit out each complete cell. Now get two strong boards which are about one fourth inch longer than the height of the jar. See Fig.

240. Support the jar on these boards by resting the lower edge of the sides of the cover on the top edge of the boards. Then run a moderate flame around the outside of the f.l.a.n.g.e until the cover is soft, and the compound melting. Then press down on the cell posts with your thumbs, and the jar and plates will drop free of the cover. The plates are then drawn out and rested on the top of the jars to drain, as usual.

Another method is to remove the cells from the case and put them in the battery steamer for ten minutes as described on page 332. Instead of first taking the complete cells out of the case and then steaming them separately, you may steam the entire battery for about ten minutes, and then draw out the plates and cover of each cell with gas pliers without removing the jars. This method must be used in opening types KXD, LXRE, and XE, which have sealing compound under the jars.

Work on Plates, Separators, Jars, and Case

Having opened the battery, follow the instructions given on pages 335 to 361 for examination of plates and separators, and all work on plates, jars, separators, and case.

Rea.s.sembling Plates

[Fig. 241 Upsetting threads to prevent nut from turning]

First slip the positive and negative groups together without separators. Then wipe the posts with a rag moistened with ammonia, rinse them with water, and dry thoroughly with a clean rag. Next slip the soft rubber washers over the posts and place the cover in position. Lubricate the lead sealing nuts with graphite that has been mixed to a paste with water. Do not use grease or vaseline to lubricate these nuts. Then put on the sealing nuts and tighten them partly with your fingers.

You are now ready to insert the separators as directed on page 361.

Types MHA, PHC, KXD, KZ, LXR, LXRE, LXRV, XX, and XXV have, in addition to the usual wooden separators, perforated rubber sheets, which should be placed against the grooved side of each wooden separator before inserting, and insert with rubber sheet against the positives.

Make a careful examination to see that you have not left out any separators.

When the separators are all in place, even them up on each side. Then tighten the sealing nuts with the special Exide wrench. When you have turned the nuts down tight, lock them in place by driving a center punch on the threads on the post just above the nut, Fig. 241. This will damage the thread and prevent the nut from turning loose.

Putting Plates In Jars

The next step is to lower the plates into the jars, as described on page 362. In types KXD, LXRE, and XE be sure to first replace the two soft rubber buffers in the bottom of the jar, one over each ridge.

Filling Jars With Electrolyte

As soon as you have an element in place in the jar, fill the jar with electrolyte of the proper strength, as described on page 364, to prevent the separators and plates from drying. The negatives, especially, must be covered with electrolyte to prevent them from heating and drying.

Sealing Exide Battery Covers

[Fig. 242 Laying "worm" of sealing compound]

[Image: Chart showing capacity of Exide batteries]

For Types DX, LX, LXR, LXRV, PHC, XC, XX, and XXV, which have the single f.l.a.n.g.e type of cover, slowly heat the sealing compound until it runs, but do not get it so thin that it will run down into the cell between the cover and jar. Then pour it into the channel between cover and jar walls. Allow it to cool and finish it off flush with a hot knife. When pouring, be sure the compound is liquid and not lumpy, as in such a case a poor seal will result. A glossy, finished appearance may be given to the compound by pa.s.sing a flame over it after the job is finished.

For Types KXD, KZ, LXRE, MHA, and XE, which have the double f.l.a.n.g.e type of cover, have ready a string or worm of sealing compound about 3-16 inch in diameter, made by rolling between boards some of the special compound furnished for the purpose. The cover may or may not have been attached to the element, depending on how repairs have been made. In either case the procedure is the same as far as sealing is concerned. a.s.suming the element is attached, stand it upside down, with the cover resting upon two strips, Fig. 242. Lay the string of compound all around the cover channel. Now turn right side up and insert in the jar, taking care that the jar walls enter the cover channels at all points. Apply heat carefully to the edges of the cover and gently force cover clown. If too much compound has been used, so that it squeezes out around the cover, sc.r.a.pe off the excess with a hot knife while forcing cover down.

Putting Cells In Case

When the covers have all been sealed, put the cells in the case, taking care to put the negative and positive posts in their proper positions, so that each cell connector will connect a positive to a negative post.

In Types MHA, KXD, LXRE, and XE, which have wooden s.p.a.cers between the cells, take care that the s.p.a.cers are in position and then, after cells are in place, tighten the tie bolts with a screw driver to clamp the jars.

In Types DX, LX, LXR, LXRV, SX, XC, XX, and XXV the cells should fit tight in the case; pack them in with thin boards if necessary.

Burning on the Cell Connectors

See instructions on pages 213 to 216.

Charging After Repairing

See also instructions on page 373.

Not sooner than ten to fifteen hours after filling battery with electrolyte, add electrolyte to restore level if it has fallen.

U. S. L. BATTERIES

The instructions for rebuilding batteries which have already been given, pages 328 to 374, apply also to all U. S. L. batteries. In working on the old U. S. L. batteries, ill.u.s.trated in Fig. 243, draw out the electrolyte down to the tops of the plates so that the electrolyte is below the lower end of the vent tube. Then blow out any gas which may have collected under the cover with compressed air or bellows. Never fail to do this, as there is only a small vent hole in the cover through which the gas can escape, the vent tubes extending down into the electrolyte when the cells are properly filled.

[Fig. 243 Cross section of old type USL battery]

[Fig. 244 Cross section of new type USL battery]

Fig. 244 shows the new U. S. L. cover construction. Note that the special cell filling device is no longer used. U. S. L. batteries have lead bushings moulded into the cover. These bushings fit around the posts, and are burned to the posts and top connectors, Figs. 243 and 244, thus giving leak proof joints between the cover and the posts. In burning on the connectors, melt bottom edge of hole first, then top of post and cover bushing, and melt in your burning lead slowly.