The Automobile Storage Battery Part 61

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, ill.u.s.trated 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 rea.s.sembling 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 rea.s.sembling, 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 rea.s.sembling, 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.