MANUAL "JExibe” Batteries IN >^TOMOBILB STARTING C& LIGHTING SERVICE theeiectricstomg^ PHII.ADEl.PUfA. PA. FORM 1299 Seventh Edition FEBRUARY. 1919 OipVrffrW, IM, tin Thi einlrw.Sioi-nge BaiU>'v.&- MANUAL sf “jExibe” Batteries IN AUTOMOBILE STARTING C& LIGHTING SERVICE This Manual consists of two sections. Section I, which is also issued Section II deals with the repair of above batteries together with other CONTENTS—Section I—Page 6 CONTENTS—Section II—Page 27 the Electric storage batteryCo. PHILADELPHIA, PA. FORM 1296 FEBRUARY, 1919 PHILADELPHIA ATLANTA DETROIT ' 3 North 15th St.’ ATLANTA DETROIT t. ATLANTA WASHINGTON 1823-1833 L St., N.W: ROCHESTER 184 Clinton Ave., South ST. LOUIS 21st and Walnut Sts. SAN FRANCISCO 1536-1556 Bush St. 17th and Walnut Sts. ROCHESTER 184 Clinton Ave., South SAN FRANCISCO DENVER 1424 Wazee St. CHICAGO Marquette Building NEW YORK 100 Broadway ST. LOUIS PITTSBURGH Keystone Building CHICAGO 18-24 E. 25th St. MINNEAPOLIS KANSAS CITY 17th and Walnut Sts. CHICAGO 333 West 35th St. MINNEAPOLIS 3 North 15th St. DENVER 1424 Wazee St. WASHINGTON 1823-1833 L £ EXIDE BATTERY DEPOTS, Inc. NEW YORK CITY PHILADELPHIA BOSTON West End Ave. and 64th St. The Electric Storage Bat. Co. 718-720 Beacon St. 671-673 N. Broad St. CLEVELAND 1536-1556 Bush St. TORONTO, CANADA 105 Bond St. SERVICE STATIONS OFFICES THE ELECTRIC STORAGE BATTERY CO. ------ -------- BOSTON 718-720 Beacon St. CLEVELAND Citizens Building 1508 Federal Reserve Bank Bldg. KANSAS CITY DENVER ” " *• ' " D. Luther. Soliciting Agt. 1424 Wazee St. WASHINGTON 1823-1833 LSt., N.W. MINNEAPOLIS theelectric STORAGE BATTERYCO. GENERAL OFFICES AND WORKS Allegheny Avenue and Nineteenth Street PHILADELPHIA, PA. DEPOTS AND STORE ROOMS To which out of town shipments should be made of batteries to be repaired EXIDE BATTERY DEPOTS, INC. NEW YORK CITY PHILADELPHIA BOSTON West End Ave. and 64th St. The Electric Storage Bat. Co. 718-720 Beacon St. Allegheny Ave. and 19tl CLEVELAND 5121 Perkins Ave. ROCHESTER 184 Clinton Ave., South ST. LOUIS 21st and Walnut Sts. ---------- SAN FRANCISCO lozo-roou l. St., N. W. 1536-1556 Bush St. Communications from all countries outside of the United States, and from outlying territories of the United States, should be addressed to THE ELECTRIC STORAGE BATTERY CO. EXPORT DEPARTMENT 100 BROADWAY, NEW YORK CITY, U. S. A. (2) Cor. Peachtree ana ma DETROIT THIS book is entirely devoted to the care and operation of a storage battery used for automo bile starting, lighting and ignition. Section I has been issued separately as Form 1369 for the use of the owner or chauffeur of an automobile, but is given in the following pages together with Section II, which deals with repairs to batteries and care of batteries in storage, for the guidance of the garage man and bat tery repair man. In just a few words, let us first tell you how the “lEXfbe” Battery is particularly adapted to the start ing, lighting and ignition of automobiles. At the start, let us impress upon you the fact that the design and manufacture of a battery for starting and lighting service is no easy problem. It requires a lot of ability and experience to design a battery that will satisfactorily meet the conditions of starting and lighting service. A battery must have a great amount of power in order to crank an engine for perhaps thousands of revolutions, in addition to lighting the lamps on the car and furnishing current for ignition, electric horn, etc. Do you realize that an “lExibe” Auto Battery which measures only 12^4 inches long, 7% inches wide and 9% inches high, and weighs only 63*4 pounds, can deliver over 2,000,000 foot pounds of energy—sufficient to raise its own weight to a vertical height of over 6 miles? Do you realize that in cranking an engine, a 50 or 60 pound storage battery must often develop power at the rate of over two electrical horse power? Power is not all. A storage battery, to be success ful, must do its work instantly, automatically and unfailingly month in and month out and at tempera tures ranging from below zero to 100 degrees F. Again, it must be so designed as to require a minimum of care and to be easily kept in first class condition. (3) The “EXlbe” Battery is manufactured by the oldest, largest and most experienced battery manu facturer in the country. Seven years ago there arose a demand for storage batteries for automobile starting, lighting and ignition. At that time this Company, with over twenty-three years’ experience in storage battery design, and with unequaled manufacturing facilities, undertook to develop the best starting and lighting battery possible. It possessed a great advantage in the fact that as a foundation it had the “Extbe” Battery, which for years had shown such successful results in electric vehicle and other allied services. It was with the “EXlbe” Starting and Lighting Bat tery, put into service in 1912, that the commercial practicability of electric cranking was definitely es tablished. Each year since 1912 has seen an enormous increase in the use of “ExlbC” Batteries until at the time this is written more than 1,110,000 “ExlbC” Bat teries have given and are giving satisfaction in starting and lighting service. This number is being added to at the rate of many thousands each month. The following are some of the many exclusive “EXlbe” features that are responsible for its success: First. The Unit Cell Assembly—a really notable forward step in battery construction—dispensing with bulky and troublesome sealing and packing com pound, saving space and weight and making the bat tery clean, dry and attractive in appearance. Second. Non-Flooding Filling Plug and Vent preventing in a simple and practical way the over filling of cells with its attendant evils. Third. Improved Methods of Sealing—secur ing a tight and perfect closure of the cells without waste of space or weight and facilitating opening of cells for inspection or repair when necessary. Fourth. Rubber Jars of Special Compound— tough and semi-flexible, making jar breakage in ser vice very rare. (4) Fifth. Increased Power for a Given Weight and Size—obtained by the use of thin plates of large area, yet so designed as to be rugged and long-lived. Sixth. Cases of Improved Construction—hav ing lock-jointed corners and handles anchored in case ends. “lEXl&e” construction makes the “lExi&C” Bat tery the highest priced starting and lighting battery on the market. But while it costs the most to make, it is the least expensive to use. The higher price is more than compensated for by the longer life, greater reli ability and the high quality of service generally which it gives to a car owner. In addition to manufacturing a battery of the very highest quality, this Company is further serving its customers by maintaining a Service Organization which makes it easy for a car owner to obtain an “jEx(J>e” Battery or any battery help or information or to have his battery renewed or repairs made when such are necessary. This Company has fifteen Sales Offices in this country and one in Canada, as shown on page 2. In addition there are fourteen “lExibe” Depots and hundreds of “lExi&e” Service Stations equipped to give prompt and reliable service in the larger cities and towns throughout the country. Ascertain the location of the “lExi&C" Service Station nearest you arid go there the next .time you wish any information on batteries. Our nearest office will gladly furnish you with a list of the “jExfbe” Service Stations. Adding Water. How to Add Waler. 12 AND 22 (6) 10 10 10 10 13 13 13 14 14 15 15 16 16 16 16 19 19 20 20 20 20 18 18 19 How to Charge Indications of Complete Charge. Length of Charge Add Nothing but Waler Hydrometer Readings Hydrometer Syringe Method of Use DESCRIPTION OF NON-FLOODING VENT FILLING PLUG GLOSSARY To Charge One Battery from a Direct Current Polarity Resistance Required Cleanliness CONTENTS (Section I) (For Contents of Section II, see page 27) FOREWORD TABLE OF CHARGE RATES FIRST CARE OF A NEW BATTERY BATTERY IN SERVICE How to Take Readings. . What Readings Indicate Charging General Special Charging BATTERIES USED IN TROPICAL CLIMATES BATTERY IN NEED OF REPAIRS Packing for Shipment CARE OF BATTERY OUT OF SERVICE Adding Water Periodic Charge HYDROMETER AND ITS USE. Care of Battery Case Care of Connections Battery Not Giving Satisfactory Service. How to Locate Trouble Additional Tests Failure to Start FOREWORD The storage battery is an exceedingly important part of the equipment of the modern automobile. It is the “heart” of the electrical system, supplying the power for starting the engine, lighting the lamps and often current for ignition as well. The average car owner or chauffeur is fairly familiar with the engine and its care, but is apt to regard the battery as mysterious and therefore to ignore it. A storage battery, like the tires, will eventually wear out with use. The normal life, however, can be very much shortened by neglect, the result of which is the same as abuse. The object of this book is to give information which will enable the garage man or battery repair man to obtain the best results and is not intended for the owner or chauffeur. Although the whole subject is covered in con siderable detail, it will be found that the actual care, while essential, amounts to very little and is easily understood. It may be summed up in four rules: 1. Add nothing but pure water to the cells and do it often enough to keep the plates cov ered. 2. Take frequent hydrometer readings. 3. Give the battery a special charge when ever the hydrometer readings show it to be necessary. 4. Keep the filling plugs and connections tight and the battery clean. P) TABLE OF CHARGE RATES TYPE OF CELL A XC-5 X-55 X-5............................................... XC-7 X-75 X-7..................JX-7................... XC-9 X-95 X-9............................................... XC-11 X-115 X-ll................ JX-11.................. XC-13 X-135 X-13................ JX-13.................. XC-15 X-155 X-15 XA-15 JX-15................. XC-17 X-175 X-17........................................... XC-19 X-195 X-19...............JX-19................... XC-21 X-215 X-21........................................... XC-23 X-235 X-23 ........................................... XC-25 X-255 X-25 ........................................... PH-13 PHA-13 PHB-13 PH-135..................... MH-11 MHA-11 MH-115................................. . .T” 8 .. 9 ..10 ..11 ..12 * Note.—To identify type of cell, note the marking on the name plate, but disregard the first and last numerals, which refer respectively to the number and arrangement of cells in the battery. For instance, with name plate marked 3-XC-15-1 look for XC-15 in table. FIRST CARE OF A NEW BATTERY from an outside source (page 13). If the gravity is above 1.250 (1.180*), note the level of the electrolyte. If the level is below the bottom of the filling tube (Fig. 1), add pure water until the level rises into the tube; then replace the filling plugs and tighten by turning to the right. Examine battery carefully to see that it is firmly secured in place. Examine connections to see that they are tight and If battery is installed in an enclosing box, be sure that any ventilating holes are not clogged. *The lower gravity refers to batteries used in tropical climates (see page 17). <« Remove filling plugs, and read the specific gravity of the electrolyte in each cell with the hydrometer syringe (page 20). If the gravity is below 1.250 (1.180*), and running the car will not charge the battery sufficiently to raise the gravity to BATTERY IN SERVICE GENERAL following rules, which, if observed with reasonable care, will result in the best service being obtained: i. Add nothing but pure water to the cells and do it often enough to keep the plates covered. 2. Take frequent hydrometer readings. 3. Give the battery a special charge whenever the hydrometer readings show it to be necessary. 4. Keep the filling plugs and connec tions tight and the battery clean. ADDING WATER 1 Water must be added often enough to keep the plates ' covered. If the plates are exposed for any length of time, they may be seriously damaged. The length of time a battery can go without the addition of water will depend upon the season of the year, water being required more frequently in summer than in winter. The best plan is to make it an invariable rule to remove the filling plugs once each week and add water if level of elec trolyte is below bottom of filling tube. battery. Use an electric lamp for inspection. Never add water while the battery is charging. If wateris added while charging the gassing may cause flooding. Always add the water regularly, though the battery may seem to work all right without it. In freezing weather, when necessary to add water, always do it just before running the car. The reason for this is that water being lighter than electrolyte will remain on the surface and will freeze in cold weather. If the engine is run, however, the gassing, due to the charging current, will thoroughly mix the water with the electrolyte; the motion of the car when running will have a similar effect. Thoroughly mixed electrolyte will not freeze solid except at very low temperatures. The electrolyte in a fully charged battery (gravity above 1.270)freezes at about 80 degrees below zero Fahrenheit; while in a normally discharged battery (giavity 1.150 to 1.175) it freezes at about zero Lrlren nei u Th,ere,fore> it is especially important to have thff- battery. well charged when the car is standing in a very cold place. (10) Add Water Hydrometer Readings If hydrometer readings are taken after adding water and before trolyte will be drawn into the syringe. This is due to the water being lighter than the electrolyte, and therefore remaining on the surface until thoroughly mixed by running the car. The electrolyte in a cell consists of a mixture of sulphuric acid and water. Sulphuric acid does not evaporate, water does. When the level of the electrolyte in a cell becomes low, it is due, under normal conditions, to the evaporation of water, which should be replaced with water only. There being no loss of acid, it is never necessary, during normal service, to add any acid to a battery. If electrolyte has been spilled from the battery by accident the loss may be replaced with electrolyte of 1.250 (1.180*) specific gravity. HYDROMETER READINGS Take frequent hydrometer readings, for they show Value of whether the battery is receiving sufficient charge. When the battery is used in connection with a charging generator system, the system is so designed and adjusted that the amount of charging current received by the battery from the charging genera tor (dynamo) should about compensate for the discharge current used when starting the engine or when lighting the lamps from the battery. At medium or high speeds, the current for lamps does not It sometimes happens, due to unusual conditions, such as ex cessive use of lamps, especially when car is driven at low speed, that the battery will not receive enough charge from the dynamo and Take a hydrometer reading of each cell with the hydrometer when syringe (page 20) at least once a week and just before adding to take water. Readings Remove filling plugs by turning to the left, and if level of How to electrolyte is found to be below bottom of filling tube (Fig. 1), Add Water add water by means of the hydrometer syringe (page 20) or a very small pitcher until the level begins to rise in the tube. After adding water, be sure to replace filling plugs and tighten by turning to the right. If filling plugs are not tight ened, the electrolyte will flood out of the battery and cause damage (page 22). Wipe off the top of the battery after adding water. The water used must be of reasonable purity, as the use Kind of of impure water, if persisted in, will injure the plates. Dis- Water to Use tilled water, melted artificial ice or rain water collected in clean receptacles is recommended. Nothing but water must be put into the cells. If acid Add of any kind, alcohol, or in fact anything but water, is added jer to the cells, it will result in very serious injury to the (11) How to Take (12) If the hydrometer reading of one cell should be considerably lower than the readings of the other cells in the battery, and if this difference should increase from week to week, it is an indica tion of trouble in that cell. The trouble may be due to a short circuit (glossary), causing the cell to discharge itself, or it may be due to an impurity in the cell or to a leaking jar. A slight leak will allow electrolyte to escape, and if not noticed, the addition of water to replace its loss will lower the gravity. Whatever the cause of low gravity, it should be attended to at once (page 18). together with slow running of the car, which cuts down the charg ing current from the generator, or it may be due to trouble in the system. The remedy is to use lights sparingly until the gravity rises above 1.200 (1.130*). If gravity will not rise above 1.200 (1.130*) within a reasonable time, look for trouble in the system. Gravity of 1.150 (1.080*) or below indicates battery com pletely discharged (exhausted). An exhausted battery should be removed from the car and given a full charge at once (page 13). If, after the battery has been fully charged, the gravity again falls to 1.150 (1.080*), it indicates there is trouble some where in the system which must be located and corrected. The specific gravity readings of all cells of a battery should normally rise and fall together, as all cells of a battery as used with most systems are connected in series so that the charging rhe electric system on the car does not work properly, as they may indicate the trouble. The method of taking hydrometer readings is fully explained on page 20. Specific gravity above 1.225 (1.155*), indicates that the battery is more than half charged. Gravity below 1.200 (1.130*), but above 1.150 (1.080*), indicates battery less than half charged, i.e., is approaching exhaustion. Fig. 2 Fig. 3 Normal Position of Valve when Valve Turned to Prevent Flooding while Charging Filling Plug is Removed with Filling Plug Removed Special Charging When the hydrometer readings indicate the battery to be When exhausted, or approaching exhaustion, it should be charged. Necessat When lamps burn dimly (running on battery), the battery should be charged. When voltage with lamps burning has fallen below 1.80 volts per cell, the battery should be charged. When the car is not in use, the battery should be charged at least once every two months if practicable to do so (page 19). If battery is not giving satisfactory service, and, owing to low level of electrolyte, it is not possible to obtain a hydrom eter reading, water should be added and the battery charged. by low voltage and dim lights, but the hydrometer8 readings will show the gravity jo be .well above 1.200 (1.130*). This is one of the battery at once, and reduce the specific gravity to between 1.270 and1.300 (1.200* and 1.230*). Remove the filling plugs and add water if necessary. Then How to replace and tighten filling plugs to prevent flooding. Never Charge charge a battery with the filling plugs removed. An ^exception to this rule is that in order to observe the gassing be removed from one or more cells, but care should be taken^cTturn the valve inside the filling tube so that it will be at right angles to its normal that only the tip engages the valve. If the valve is not turned, electrolyte may flood out-of the cell.^ After the charge, the filling plug CHARGING A battery charge is complete when, with charging current General flowing at the normal rate, all cells are gassing (bubbling) freely and evenly and the specific gravity and voltage of all cells have reached a maximum; that is, have shown no further rise during a period of 5 hours. Such a charge, as above described, can be given by running the engine idle if in connection with charging generator system. On account of the length of time required, however, it is usually preferable to remove battery from the car and give the charge from an outside source. In either case, such a charge is termed a “Special Charge.” (13) to batteries with low (14) perature of electrolyte above 110 [125*] degrees Fahrenheit), either stop the charge or reduce the rate until temperature lowers. After the charge is completed, take and record the hydrom eter reading of each cell, as these readings taken at full charge are useful as a standard for comparison when subsequent readings are taken. need of repairs (page 18). Replace and tighten filling plugs, wipe off top and sides of battery. When connecting to car circuit, be sure that all connections are clean and tight. Charging Circuit A storage battery must be charged with direct current; never use alternating current for this purpose as it will ruin the battery. If alternating current only is available, it will be necessary to provide apparatus for converting it into direct current. Several forms of apparatus are on the market for this purpose, either motor generator sets or rectifiers. Connect the battery to the charging circuit (page 15) The positive terminal of the battery marked “+” or “POS” must be connected to the positive wire from the charging source. Charge at the rate given in the table (page 9) for the type of battery in question. Indications Continue the charge until the gravity has risen to a maxi- of Complete mum, that is, shows no further rise over a period of 5 hours, Charge successjve hourly hydrometer readings taken on the same cell being alike. The battery voltage should likewise rise to a maximum. Near the end of charge, remove the filling plugs to make sure that the cells are all gassing (bubbling) freely, as this is also an indication of full charge. Be careful to quickly replace very urgent to charge the battery in quicker time than this, the first to reduce the voltage of the circuit to that of the battery. The carbon filament lamps connected in parallel with each other, this arrangement, each lamp will allow one ampere of charging current to pass through the battery, so that the number of lamps required will depend upon the charge rate of the battery (table, page 9). For instance, for Type XC-13, charge rate 6 If 32 candle power lamps are not available, then double the number of 16 candle power lamps will be required. If tungsten or other high efficiency lamps are used, more will be required than if carbon filament lamps are used, owing to the lower current rating of the former. If the battery is to be charged from a 220 volt circuit, use two lamps in series in place of each of the lamps necessary when charging from 110 volts. If only a 500 to 600 volt circuit is available, it is necessary to use five lamps in series in place of each of the lamps used when charging from 110 volts. (15) To Charge One Battery From a Direct Current Circuit Always connect the positive terminal of the battery poiarity to the positive wire of the charging circuit and the negative ■ battery terminal to the negative wire of the circuit. If only one battery is to be charged from a 110 volt direct Resistance CLEANLINESS Necessity As with mechanical apparatus, cleanliness is essential to obtain the best results. Care must be taken to keep exposed portions of the battery and its connections clean and dry. If reasonable attention is given to this requirement, much annoyance from trouble with the starting, lighting and ignition system will be avoided. If water or electrolyte is spilled upon the battery or in in any quantity, use waste moistened with weak ammonia in order to neutralize the acid in the electrolyte. Do not allow electrolyte to collect upon the woodwork as it will cause deterioration. Once a week, when adding water, inspect all the battery connections and make sure that they are tight and clean. A loose or dirty connection may cause trouble when least expected. If signs of corrosion of any brass or copper parts should appear, clean the parts thoroughly with weak ammonia and apply vaseline. Connections throughout the system must be examined periodically and kept tight and clean. Someti mes a connection, even if tight, will give trouble, due to foreign matter, such as paint or varnish, on the contact surfaces. This must be removed with a file or sand paper. The connections to the generator and the grounding connections to the frame of the car (if car is equipped with a grounded system) must not be neglected. “JSxfoe” Starting and Lighting Battery Typo 3-XC-13-1 BATTERY NOT GIVING SATISFACTORY SERVICE If trouble should develop, as shown by the engine not How to cranking properly, lights burning dimly or “missing" of the Locate If a broken jar or short circuited cell is indicated (gravity considerably lower than in other cells), have the battery repaired (page 18). indicated below. Make sure that all connections are tight and that all con tacts are clean. Take a hydrometer reading of each cell. If battery is found to be exhausted (gravity 1.150 [1.080*] or thereabout), give a special charge (page 13). Examine battery. If there is a broken connection, ter minal, jar or cover, have the battery repaired. Additional Tests they continue to burn brightly, the trouble is in the motor or meter is at hand, turn on all the lamps and read the voltage of each cell or of the battery. If the voltage per cell is 2 volts or thereabout, the trouble is in the connections. If voltage is low (1.80 volts per cell or lower), the trouble is in the battery. When lamps burn brightly, but engine will not crank, notice, when attempting to start engine, whether lamps become cables at the battery terminals. Then strike the cable terminal against its battery terminal; if sparks are noticed, there is a ground in the wiring which must be looked for and removed. The wiring may have become grounded to the frame of the car, and cause a leakage of current which in time may completely discharge the battery. This may be tested for as follows: At BATTERIES USED IN TROPICAL CLIMATES Batteries used in tropical climates give better results with low gravity electrolyte. Places where freezing of water never occurs are regarded as having tropical climate. With low gravity electrolyte the high temperature limit may be raised to 125 degrees Fahrenheit. <17> BATTERY IN NEED OF REPAIRS Any repairs necessitating taking cells apart should not usually be attempted by the individual owner, but should be done by a competent repair man (preferably one of the “JEXIDC” Battery Depots or an “jExtDe” Distributor). Ship ping instructions for batteries to be repaired will be forwarded upon application to the nearest office of the Company (page 2). In countries outside of the United States and in outlying territories of the United States, if a reliable repair shop cannot be located, apply to the agent from whom the car was obtained, or to The Electric Storage Battery Co., Export Dept., 100 Broadway, New York City, U. S. A. PACKING FOR SHIPMENT about 2 inches thick, and on this place the battery. Over the tops of the cells place paper, preferably paraffined, and then cover the whole battery with stout wrapping paper, folding it down over the sides to keep off packing material and dust. It is not safe to ship a battery without proper packing, as the rough handling received is almost sure to do damage. The following procedure is recommended: 1. Procure a strong box made with steeple shaped top (Fig. 5) to prevent the package from being placed upside down. The 3. Fill the space around the sides and ends of battery with excelsior, shavings, coarse saw dust or even twisted and crumpled balls of paper, ramming down tight. 4. Leave the top of the battery free of packing material and covered only with the paper. 5. Nail slats on the box for a cover; never make a solid cover. The slatted cover enables the freight handlers to see the contents of the package and helps toward careful handling. A stout strip of wood nailed on each side and projecting beyond the ends for handles will prevent the package from being stood on end. 6. Label the box "Handle with Care” and “Do Not Drop.” 7. In addition to the address of destination, as given in shipping instructions, be sure to mark with name of shipper for identification upon arrival. 8. When shipping by freight, the proper freight classifica tion IP t le United States is "Electric Storage Batteries, Assem bled. No railroad caution labels are required. 9. When shipping by express in the United States, “Acid” caution labels must be attached to each package. (18) CARE OF BATTERY OUT OF SERVICE electrolyte reading between 1.270 and 1.300 (1.200* and 1.230*). Disconnect the wires of the battery, as even a slight leak in the wiring will cause the battery to discharge. When a car is likely to be out of service for two months or When a car is to stand idle for any considerable period, as when it is laid up for the winter months, the battery should not be left on the car without attention. When a car is likely to be out of service as long as one month, but less than two, be careful to add water to the cells just before the last time the car is used and endeavor then to run the car (using lamps sparingly) so that the battery will be the electrolyte in all cells, as shown by the hydrometer syringe, has held at a maximum (ceased to rise) for a period of 5 hours and all the cells are gassing freely. When fully charged, place the battery where it will be dry, cool and free from dust. proper attention. If this is not practicable, the battery should be taken out of the car and treated as follows: Remove filling plugs and add pure water until the level reaches the bottom of the filling tube. Replace filling plugs, turning them as far as they will go to insure their being firmly seated. Never charge a battery with the filling plugs out, as the automatic vents are then closed and flooding may result. See exception to this rule at bottom of page 13. Put on charge at the proper current rate as given in table Once every two months during the out of service period, remove filling plugs and add water, replace plugs and give battery what is known as a "freshening charge”; that is, charge Always add water and charge the battery before putting back in service. If the periodic charges have not been given during the out of service period, charge for at least 24 hours at normal rate before putting battery into service again. Then the battery may be allowed to stand for another two months. If it is not practicable to have the battery charged at periodic intervals as above described, or sent to a reliable garage where it will receive attention, it can be allowed to stand (provided it has first been fully charged) for a period not exceeding six months, but better results will be obtained if the freshening charge every Adding Periodic Charge THE HYDROMETER AND ITS USE The specific gravity or density of the electrolyte is measured by an instrument called the "hydrometer,'' ■) (Fig. 6), S-l type. This consists of a closed ! longer stem of small diameter. Inside of the stem is a graduated scale. The hydrometer floats upright in the liquid and the point on the scale at the surface of the liquid shows the specific gravity, usually called "gravity.” For greater convenience, the hydrometer isusually placed inside of a larger glass tube pro- known as the "hydrometer syringe” (Fig. 7). Bydm- By sdueczing the bulb, inserting the nozzle ei« into the electrolyte and releasing the bulb, elec trolyte is drawn up into the glass tube. Sufficient elec trolyte should.be drawn up to float the hydrometer clear of the rubber plug in the bottom (Fig. 8). Fig. 8. Taking Hydrometer Readings (20) should.be To prevent the hydrometer from sticking to the side of the tube, it is necessary that the syringe be held in a vertical position. The reading is taken at the surface of the electrolyte and when there is no compression on the bulb. electrolyte back into the same cell from which it was taken. Failure" to do this often leads to trouble; that is, electrolyte is often taken out of one cell, the gravity noted and the elec trolyte put back into another cell. The result is that the amount of electrolyte taken out of the first cell is eventually replaced with water, leaving the electrolyte weaker; whereas the elec trolyte which was taken out and put into another cell would make the electrolyte of that cell stronger, resulting in irregularity in the different cells. In recording the gravity of the different cells, it is customary to begin with the cell at the positive end. <2t) DESCRIPTION OF NON-FLOODING VENT AND FILLING PLUG Fig. 11 From the illustrations (Fig. 11) of the vent and filling plug, it will be seen that they provide both a vented stopper (vents F, G, H) and an automatic device for the preventing of over filling and flooding. In a simple and effective manner, the amount of water that can be put into the cells is limited to the exact amount needed to replace that lost by evaporation. This is accomplished by means of the hard rubber valve (A) within the battery cover and with which the tip of the filling plug (E) engages, as shown in the illustrations. The action of removing the plug (E) turns this valve (A), closing the air passage (BB), and forming an air tight chamber (C) in the top of the cell. When water is poured in, it cannot rise in this air space (C) so as to completely fill the cell. As soon as the proper level is reached, the water rises in the filling tube (D) and gives a positive indication that sufficient water has been added. Should, however, the filling be continued, the excess will be pure water only, not acid. On replacing the plug (E), the valve (A) is auto matically turned, opening the air passages (BB), leaving the air chamber (C) available for the expansion of the solution, which occurs when the battery is working. (22) GLOSSARY Cover. The rubber cover which closes each individual cell; it is flanged for sealing compound to insure an effective Battery Terminals. Devices attached to the positive post of one end cell and the negative of the other, by means of which the battery is connected to the car circuit. Buckling. Warping or bending of the battery plates. Burning Strip. A convenient form of lead, in strips, for filling up the joint in making burned connections. Case. The containing box which holds the battery cells. Cell. The battery unit, consisting of an element complete with electrolyte, in its jar with cover. Cell Connector. The metal link which connects the positive post of one cell to the negative post of the adjoining cell. Charge. Passing direct current through a battery in the direction opposite to that of discharge, in order to put back the energy used on discharge. Charge Rate. The proper rate of current to use in charging a battery from an outside source. It is expressed in amperes and varies for different sized cells. Corrosion. The attack of metal parts by acid from the elec- verses its direction or “alternates” in polarity so that it will not charge a battery. Ampere. The unit of measure of the rate of flow of electric current. Ampere Hour. The unit of measure of the quantity of electric Discharge. The flow of electric current from a battery through a circuit. The opposite of "charge.” Electrolyte. The fluid in a battery cell, consisting of specially pure sulphuric acid diluted with pure water. Element. One positive group and one negative group with separators, assembled together. Acid. As used in this book refers to sulphuric acid (H2SO4), the active component of the electrolyte. Active Material. The active portion of the battery plates; on the negatives. Alternating Current. Electric current which does not flow (23) means the density compared to water as a standard. Grid. The metal framework of a plate, supporting the active material and provided with a lug for conducting the current and for attachment to the strap. Group. A set of plates, either positive or negative, joined to a strap. Groups do not include separators. Hold-down Clips. Brackets for the attachment of bolts for holding the battery securely in position on the car. Hydrogen Flame. A very hot and clean flame of hydrogen gas and compressed air used for making burned connec- Filllng Plug. The plug which fits in and closes the orifice of the filling tube in the cell cover. Flooding. Overflowing through the filling tube. With the “jExi&e” automatic filling tube, this can usually occur only when a battery is charged with the filling plug out. Freshening Charge. A charge given to a battery which has been standing idle, to insure that it is in a fully charged condition. Gassing. The bubbling of the electrolyte caused by the rising of gas set free toward the end of charge. Generator System. An equipment including a generator for automatically recharging the battery, in contradistinc tion to a straight storage system where the battery has to be removed to be recharged. Hydrogen Generator. An apparatus for generating hydrogen gas for lead burning. Hydrometer. An instrument for measuring the specific gravity of the electrolyte. Hydrometer Syringe. A glass barrel enclosing a hydrometer and provided with a rubber bulb for drawing up electrolyte. Jar. The hard rubber container holding the element and electrolyte. Lead Burning. Making a joint by melting together the metal of the parts to be joined. Lug. The extension from the top frame of each plate, con necting the plate to the strap. Maximum Gravity. The highest specific gravity which the electrolyte will reach by continued charging, indicating that no acid remains in the plates. Oil of Vitriol. Commercial name for concentrated sulphuric acid (1.835 specific gravity). This is never used in a battery and would quickly ruin it. Plates. Metallic grids supporting active material. They are alternately positive (brown) and negative (gray). Polarity. Electrical condition. The positive terminal of a cell or battery, or the positive wire of a circuit, is said to have positive polarity; the negative, negative polarity. (24). Voltage. Electrical potential or pressure, of which the volt is the unit. Sulphated. The condition of plates having an abnormal amount of lead sulphate caused by “starvation” or by allowing battery to remain discharged. Tie Bolts. Bolts which, in some types, extend through the battery case between the cells and clamp the jars in position. Top Nut. The hexagon nut which, in batteries with bolted connections, screws on the post and holds the connectors Spacers. Wood strips used in some types to separate the cells in the case, and divided to provide a space for the tie bolts. Specific Gravity. The density of the electrolyte compared to water as a standard. It indicates the strength and is measured by the hydrometer. Starvation. The result of giving insufficient charge in relation to the amount of discharge, resulting in poor service and injury to the battery. Post. The portion of the strap extending through the cell cover, by means of which connection is made to the adjoin ing cell or to the car circuit. Rectifier. Apparatus for converting alternating current into direct current. Resistance. Material (usually lamps or wire) of low con ductivity inserted in a circuit to retard the flow of current. By varying the resistance, the amount of current can be regulated. Rubber Sheets. Thin, perforated hard rubber sheets used in combination with the wood separators in some types of batteries. They are placed between the grooved side of the wood separators and the positive plate. Sealing Compound. The acid proof compound used to seal the cover on the jar. Sealing Nut. The notched round nut which screws on the Sediment. Active material which gradually falls from the plates and accumulates in the space below the plates pro vided for that purpose. Separators. Sheets of grooved wood, specially treated, inserted between the positive and negative plates to keep them out of contact. Short Circuit. A metallic connection between the positive and negative plates within a cell. The plates may be in actual contact or material may lodge and bridge across. If the (25) SECTION II REPAIRS TO BATTERIES CARE OF BATTERIES IN STORAGE The preceding chapters deal with the care and operation of batteries and are intended primarily for the user. The following pages, dealing with repairs to batteries and care of batteries in storage, are for the guidance of garage and repair men, since work of this nature should be undertaken only by those who have the necessary equipment and experience. (26) . 29 . 29 . 29 . 30 CONTENTS (Section II) (For Contents of Section I, see page 6) RECEIVING A NEW BATTERY......................... Battery Received Installed on Car Battery Shipped Separately from Car.............. GENERAL DESCRIPTION OF BATTERY 31 Plates .... Grid Material... Group Separators. Element... Electrolyte. Jar Case1'.’.'.'.'.'.’.'..'.". Handles Hold-down Clips. ELECTROLYTE 34 Composition 34 Concentrated Sulphuric Acid 34 Preparing Electrolyte 34 Chemically Pure Electrolyte 34 Specific Gravity 34 Temperature Correction 34 Freezing Point 36 OUTLINE OF THE ACTION IN A STORAGE BATTERY 3S General Formation of Lead Sulphate Drop in Voltage Drop in Specific Gravity During Discharge. Charging Action of Current Object of Charging Gassing Normal Sulphate Abnormal Sulphate High Rates of Discharge Over Discharge Starvation Overcharge Low Temperature 38 38 38 38 38 38 39 39 39 39 39 39 39 39 39 40 SPECIAL INSTRUCTIONS FOR BATTERIES USED WITHOUT GENERATOR SYSTEM 41 (Continued on next page) (27) CONTENTS (concluded) Taking Battery Apart Disconnecting Removing Cell from Case Removing Element from Jar. . Removing Sealing Nats Removing Cover from Element. Taking Element Apart Inspection of Parts Broken Jar Broken Cover Loose Post Positive Plates Negative Plates Wood Separators Perforated Rubber Sheets Sediment Electrolyte Reassembling Battery. . A ssembling Element. Hydrogen Gas Outfit. . Carbon Burning Outfit Toolsand Equipment BATTERIES IN STORAGE Wet Storage Location Temperature A djusting Gravity.. Temperature Correa Lead Burning Cleaning Surfaces.. Method of Burning. Locking Sealing Nuts. Sealing Placing Cells in Case. Connecting Filling with Electrolyte.. Specific Gravity Purity Charging... Preliminary Stand... Periodic Charge Lamp Resistance Unit Resistance Rheostat Dry Storage Polarity Alternating Current BATTERIES SHIPPED UNFILLED. Directions for Putting into Service. TABLES OF RATINGS .. 53 .. 53 .. 53 .. 53 .. 54 .. 54 .. 54 . . 54 .. 54 .: 55 . . 55 ..' 55 .. 57 . . 59 .. 60 .. 61 . . 61 . . 61 .. 61 . . 62 .. 63 .. 63 .. 63 .. 64 .. 64 .. 64 .. 65 .. 65 .67, 68 43 43 43 47 48 48 48 48 48 48 48 49 49 49 49 50 50 50 50 51 51 52 (28) RECEIVING A NEW BATTERY BATTERY RECEIVED INSTALLED ON CAR See page 9—“First Care of Battery.” BATTERY SHIPPED SEPARATELY FROM CAR (This refers to batteries shipped filled. For batteries shipped unfilled see page 65). In unpacking a battery, keep the packing case right side up to avoid spilling the electrolyte (battery solution). First remove all packing material from the top and sides of the battery in order to insure nothing getting into the cells when the filling plugs are removed. Examine battery case carefully to see if there is any evidence of a cell leaking due to a broken jar, or other indication of injury received in transit. If such is found, claim should be made Batteries with bolted connections are shipped with a metal strip underneath the top nuts of the cell terminal posts to keep the sealing nuts from loosening. These strips should be dis carded. Remove filling plugs, giving a quarter turn to the left, and examine height of electrolyte; if it is below the bottom of the filling tube (Fig. 1), add pure water until the level of the solu tion is even with the bottom of the tube. from the cellsjn transit, ^use electiolyce of 1.250 specific After adding water, replace and tighten filling plugs by turning to the right and give the battery a charge (page 13) at the proper rate for the type of battery as given in the table (pages 67 and 68). Continue charge until voltage of battery and specific gravity of electrolyte of each cell (as read by the hydrom eter syringe) show no rise over a period of 5 hours. At the end of this charge, take a careful gravity reading of each cell. The specific gravity should be between 1.270 and 1.300 (1.200* and 1.230*); if it is not, continue the charge and proceed as follows: If the specific gravity is low, withdraw some of the solu tion with the hydrometer syringe and add 1.300 (1.230*) specific gravity electrolyte. If gravity is too high, withdraw some solution and add water. Repeat until gravity is within the proper limits. Never add electrolyte to a cell after the gravity has been adjusted to the proper point, unless to replace actual loss by spilling. Wipe off the top and sides of the battery case, being care ful to remove any water or electrolyte that may have been spilled. If the connections are bolted, tighten all the top nuts, as they may have worked loose during shipment. The battery is then ready to be installed on the car. * The lower gravity refers to batteries used in tropical climates (see page 17). (29) Installing Battery on Car It is very important that the battery be properly installed on the car, and considerable attention has been given by car manufacturers to providing for the battery a suitable battery compartment in a reasonably accessible location. The battery must be securely fastened in place by means of holding devices which grip the case or case handles, so that this strain is not put upon the cells or terminals. In making connections to the car wiring, be sure to follow the diagram as given in the car or system instruction book. Clean the wire terminals before inserting in the battery terminals and make sure that the connections are secure so they will not 30) GENERAL DESCRIPTION OF BATTERY The positive and negative plates in “E.XlOe” Starting Plates and Lighting Batteries are of the same general design as the “lExlbe" plates so well known in vehicle bat teries. A grid made of a stiff lead alloy supports the active material iff' the form of a series of ver tical strips held between the grid bars and locked in place by horizontal surface ribs which are stag gered on the opposite sides. Fig. 12 shows a section through the horizontal ribs and makes clear their staggered relation. After the grids are cast, they are “pasted” with oxides of lead made into a paste of special composition which sets in drying, like cement. The plates then go through an electro-chemical process which converts the material of the positives into brown peroxide of lead and that of the negatives into gray, spongy lead. Fig. 13 shows the finished positive plate and Fig. 14 the negative. Both the positive and negative plates are provided with Lug an extension or “lug,” and they are so assembled that all the positive lugs come at one side of the jar and all the negative lugs at the other, thus enabling each set to be burned together with a connecting strap, giving one positive and one negative pole. The burning is done by a hydrogen flame, which melts ■ the metal of both lugs and strap into an integral union. A set of plates burned to a strap is known as a “group" Group (Fig. 15), either positive or negative. The straps (Fig. 15) are made of a hard lead alloy and are straps provided with posts to which the cell connections are made. When the positive and negative groups are assembled Separators together, the adjoining plates are kept out of contact by means of wood separators ribbed on the side against the positive. The separators (Fig. 16) are made of tough wood particularly Electrolyte the method of making a tight seal where the post goes through the cover (Fig. 1). The strap post has an alloy collar which supports the jar cover, a soft rubber gasket being placed between. The post is threaded where it comes age. The plates rest on stiff ribs or bridges in the bottom of the jar (Fig. 1), allowing space for the gradual accumulation of "sediment." Cover The jar cover and method of sealing and venting represent a radical improvement over previous practice. The cover is flanged in such a way as to give a more perfect seal to the jar than the old flat type of cover, and each cell is a separate sealed unit. adapted for the purpose and given a special treatment to remove harmful substances. Element A positive and a negative group, together with the separators, constitute an "element” (Fig. 17). The fluid, known as “electrolyte” (page 34), is dilute sulphuric acid. The cell container is a rubber jar of special composition which will withstand the vibration of the car and any ordinary handling without break- Fig. 16. Separacor keeps the case from becoming weakened and unsightly. So by means of bolts engaging the hold-down clips. over the entire battery, as is general in other types, is required. This fact adds greatly to the ease with which the battery can be taken apart. through the cover and the sealing nut clamps the cover tight, the soft rubber gasket underneath giving a very effective seal. For description of vent see page 22. The case is substantially built of hard wood thoroughly It is absolutely essential that the battery be securely held in position on the car, and for this purpose brackets which (33) In this connection, the expression "chemically pure” acid (3« 1.230*) for a fully charged battery. Stronger electrolyte than this is injurious. To prepare electrolyte from sulphuric acid of 1.835 specific gravity, mix with water in the proportions indicated in Fig. 18 for the desired specific gravity, taking the following precautions: Concentrated sulphuric acid is a heavy, oily liquid having a specific gravity of about 1.835. A battery will not operate if the acid is too strong, and it is therefore diluted with sufficient full strength (approximately 1.835 sp. gr.) and at the same time chemically pure. If this chemically pure acid of full strength be mixed with chemically pure water, the mixture would still be chemically pure, but not of full strength. On the other hand, if a small quantity of some impurity be introduced into chemically pure acid, it would not materially reduce the strength, but would make it impure. The usual method of determining the strength of elec trolyte is by taking its specific gravity. The method is possible on account of the fact that sulphuric acid is heavier than water. Therefore the greater the proportion of acid contained in the electrolyte the heavier the solution or the higher its specific Specific By specific gravity is meant the relative weight of any Gravity substance compared with water as a basis. Pure water, there fore, is considered to have a specific gravity of 1, usually written 1.000 and spoken of as “ten hundred.” One pound of water is approximately one pint. An equal volume of concentrated sulphuric acid (oil of vitriol) weighs 1.835 pounds. It there fore has a specific gravity of 1.835 and is spoken of as “eighteen thirty-five.” empcraturc Since electrolyte, like most substances, expands when Correction heated, its specific gravity is affected by a change in temperature. ELECTROLYTE Electrolyte, as used in all “lExtbC” types of batteries, con sists of a mixture of pure sulphuric acid and distilled or other Chemically Both the water and the sulphuric acid used in making Elect roT to e'ectro'yte should be chemically pure to a certain standard. This is the same standard of purity as is usually sold in drug stores as “CP” (chemically pure) or by the chemical manu- J V r Parts of Water Fift. 18 (35) there is little danger of freezing except with a discharged battery. perature. For instance, if electrolyte has a gravity of 1.275 at 70 degrees Fahrenheit and the temperature be raised to 73 degrees Fahrenheit, this increase in the gravity to drop from 1.275 to 1.274. On the other hand, if the temperature has been lowered from 70 degrees to 67 degrees, this -would cause the gravity to rise from 1.275 to 1.276. Since the change of tem perature does not alter the actual strength of the reading should be corrected one point for each three degrees change in temperature. For convenience, 70 degrees Fahrenheit is considered as normal, from which point the corrections are made. For the convenience of the user, a thermometer If electrolyte has a certain gravity at a temperature of 70 degrees Fahrenheit and be heated, the heat will cause the electrolyte to expand, and, although the actual strength of the solution will remain the same as before heating, yet the expansion will cause it to have a lower gravity, of approximately amount of correction is indicated. This is on the opposite side of the mercury column and parallel to the temperature scale; that is, opposite to the tem perature 70 degrees is figure 0, showing that no cor- rection is made at that temperature. Three degrees jogp-' below 70 degrees is shown minus 1, indicating that the "Bps gravity should be corrected at that temperature by deducting one point. Three degrees above 70 degrees -M — is shown plus 1, which indicates that the gravity at Wa few that temperature should be corrected by adding one • Wj fe? point to the reading, as shown by the hydrometer. VsfiJ The thermometer is shown in Fig. 19. V H When the temperature is considerably above or ( ) below normal, the hydrometer readings should be cor- 'Sz' rected as explained above. KU- 1’ The freezing point of electrolyte depends upon its h11™™'11' Specific Graviiy Fiji. 20 (37) retarded; and since the acid cannot then get into the plates fast enough to maintain the normal action, the battery becomes less A storage battery consists of one or more cells. A cell consists essentially of positive and negative plates immersed in electrolyte. The electrolyte of the “ExtOe” cell consists of a mixture OUTLINE OF THE ACTION IN A STORAGE BATTERY direction opposite to that of discharge. This current, passing through the cells in the reverse direction, will reverse the action which took place in the cells during discharge. It will be remem bered that during discharge the acid of the electrolyte went into and combined with the active material, filling its pores with sulphate and causing the electrolyte to become weaker. Action Reversing the current through this sulphate in the plates restores ot Current the active material to its original condition and returns the acid to the electrolyte. Thus, during charge, the electrolyte ♦.The lower gravity refers to batteries used in tropical climates (see page 17). (38) by the amount of acid that is used in the plates, producing the electric current and incidentally producing the compound of acid and lead called "lead sulphate.” This sulphate con- Drop in tinues to increase in quantity and bulk, thereby filling the pores The voltage of one cell is about two volts. The voltage of a battery (with cells in "series”) is the number of cells multiplied by two. When a cell is put on discharge, the current is produced by the acid in the electrolyte going into and combining with the lead of the porous part of the plates called “active material.” In the positive plate, the active material is lead peroxide, and in the negative is metallic lead in a spongy form. emotion When the sulphuric acid in the electrolyte combines with of Lead j ; t|lc actjve material, a compound, lead sulphate, isSulphate formed. Drop During a normal complete discharge, the amount of acid ravISPI)urC used from the electr0'yte !n “JExlOe” cells will cause the ^Discha^ge sPccific gravity to drop about 150 points (0.150 sp. gr.). Thus if the gravity of a fully charged cell is 1.300 (1.230*), it will, at the end of discharge, be about 1.150 (1.080*). The battery should receive charge before it is discharged below this point. gradually becomes stronger as the sulphate in the plates decreases, until no more sulphate remains and all the acid has been returned to the electrolyte. It will then be of the same strength as before the discharge and the same acid will be ready to be used over again during the next discharge. Since there is no loss of acid, none should ever be added to the electrolyte. The acid absorbed by the plates during discharge is, Object during charge, driven from the plates by the charging of Charging current and restored to the electrolyte. This is the whole object of charging. work without giving out shows that it is not injured thereby. this is the abnormal condition usually referred to as “sulphated.” This condition is usually the result of "starvation” of the battery. A very general misapprehension has existed in the past as to the effect on a lead storage battery of discharging at very high rates. The fact that a starting battery will spin one of the big modern engines which a strong man can scarcely turn over shows what its capabilities are; and the length of time charge is entirely normal. If, however, charging is insufficient, the sulphate increases and becomes hard and the plates become When a battery is fully discharged, it can absorb current at the highest rate. As the charge progresses, the plates can no longer absorb current at the same rate and the excess current goes to form gas. Ina battery which is charged or nearly charged, the plates can absorb current without excessive gassing only at a low rate, and a high charge rate will be almost entirely used in forming gas, resulting in high temperature and wear on the plates. In starting and lighting systems, the aim is to provide sufficient current under average running conditions so that the battery will not be “starved," and yet the charge will be at but overdischarge, or, what in time amounts to the same thing, undercharge or “starvation." If a car is so run that the battery gets insufficient charge and is “starved,” it cannot be expected to do its work properly. Persistent overcharging not only tends to wash out the positive active material, but also acts on the positive grids, giving them a scaly appearance. Temperature has quite a marked effect on a battery. Low temperature temporarily both lessens the ampere hour capacity which can be taken out of the battery and lowers the discharge voltage. It is as if the battery were numbed by the cold and unable to make the same effort as at normal temperature. The effect of cold is only temporary, the battery returning to its normal state upon its return to normal temperature even without charge. Starting batteries are usually designed with sufficient margin over the ordinary requirements so that they will still perform their functions under reasonably low tem perature conditions. It is just as well, however, to bear in mind the effect of cold weather and to aim. to keep the battery unusually well charged in winter and not expose it unnecessarily to low temperatures. There is no danger of the electrolyte freezing in a fully charged cell; but in one which is overdis charged or has had water added without subsequent charging this is likely to occur in cold climates. High High temperature is to be avoided from the standpoint of Temperature life. 110 degrees Fahrenheit (125 degrees F. in tropical climates with low gravity electrolyte; see page 17), is usually given as the limiting temperature, and even this would be harmful if maintained steadily. Heating is ordinarily the result of charging at too high a current rate. If the temperature of the electrolyte in a battery is found to run consistently high, the system should be inspected; it may be out of adjustment and be charging the battery at too high a rate. The effects of continued high temperature are to distort and buckle the plates, to char and weaken the wood separators, to solten and sometimes injuriously distort the jars and covers. («) SPECIAL INSTRUCTIONS FOR BAT TERIES USED WITHOUT GEN ERATOR SYSTEM If the battery is used alone (without generator) to supply about and by lamps burning dimly or voltage falling below 1.8 Give the battery a charge at least once every two months whether the hydrometer readings show this to be necessary should be removed from the car and charged (page 13). Do not allow the battery to discharge until completely water except when the battery is removed from the car for charging. ' Add water just before charging, not during or imme diately after charge. Frequent hydrometer readings should be taken, however, * The lower gravity refers to batteries used in tropical climates (see page 17). Fig. 21. Section of Battery—Burned Connections, Single Flange Cover (42) REPAIRS modern types of “JEXtOc” Starting and Lighting Batteries. There are three general types, differing in minor details, which are clearly set forth in Figs. 21, 24 and 28. Fig. 21 shows the burned connection type with the single flange cover. Fig. 24 shows the burned connection type with the double flange cover. Fig. 28 shows the bolted connection type, which always takes the double flange cover. TAKING BATTERY APART The first step is to remove the filling plugs, to give more room to work upon the battery terminals. Then disconnect the terminals and intercell connectors. Disconnecting trally over each post a brace with a inch wood bit and bore the a. Burned Conneclions(Types XA, XC, LX, SX, ZA, JX, PHA, MHA). Remove the connectors, which are solid lead links (Fig. method is to play a burning flame on the joint, at the same time pulling the connector with a pair of pliers until it comes loose. b. Boiled Connections (Types X, PH, PHB, MH, ZB). Remove the alloy covered top nuts, using a properly fitting socket wrench (Fig. 25). Take off the connectors without bend ing. These are lead-coated copper strips. Save the alloy washers, of which there are three—one above, one between and one below the connectors (Fig. 26). The complete cell can now be lifted out of the case. Removing Cell from Case Types X, XA, PH, MH have the jars separated in the case by painted wood spacers divided horizontally, and between the two sections runs a tie bolt (Figs. 24 and 28). These should now be unscrewed one or two turns with a screw driver, thus releasing the jars. If the jars stick to case, loosen by running a Removing Element from Jar will loosen the com pound, and the ele ment with the cover on it can be lifted out This type of cover (Fig. 27) has sloping sides flanged out wardly at the base to fit the inside of the jar snugly, while at the top it clears the jar, giving a space of aboutX inch for scal ing (Fig. 21). To unseal, heat a flat-bladed knife (a putty knife will answer) in a flame and run it through the sealing compound close to.-ko low ...oil nil tko Single Flang b. Double Flange Type of Cover (Types X, XA, PH, MH, ZB, ZA). This type of cover is made with two flanges projecting downward, one fitting inside and the other outside of the jar walls. The two flanges form a channel or slot, holding jar walls and sealing compound between the flanges (Fig. 28). The scaling nuts must be removed (see below) before un sealing the cover. To unseal, procure two stout boards about % inch longer than the height of the jar and rest the side flanges of the cover on these so that the cell is raised. Now warm the cover all around the edges, and the compound will soften so that by pressing down on the posts the jar with the ele- ment in it will readily drop free from the cover (Fig. 29). The warming may be accomplished by pass ing a moderate flame quickly around the cover, taking care not to hold it on one spot long enough to burn the rubber. After removing cover the element can be lifted out of the jar. Removing Sealing Nuts purpose. Do not use gas pliers or any thing except the proper wrench in Fig. 30. Scaling Nut Wrench This is done by unscrewing with the special wrench (Fig. removing the sealing nuts. Removing Cover from Element Loosen and remove sealing nuts (see above) and lift off the cover. For double flange type the cover must be unsealed and removed (Fig. 29) before removing element from jar. Taking Element Apart After removing the cover, lay the element down with the plates on edge and, slightly spreading the plates, withdraw the separators one at a time. The positive and negative groups can then be separated, and the dismantling is complete. If the negative plates are to be used again, do not let them dry, but place the group in water or electrolyte. This will save time in the length of charge required after reassembling. INSPECTION OF PARTS If a jar is broken, but the cell is otherwise in good condition, it is not necessary to remove the sealing nuts, as the cover may be unsealed and the element with cover attached removed from If the cover is cracked or broken, a new one should be If a post is loose or in bad condition, it is advisable to have without undue strain (Fig. 31). If the battery has been badly abused, “starved" or neglected, the negatives may have shed material; in this case it is best to use a new group. If the negative material is very hard and not spongy, it is "sulphated,” and particular care should be used that the subsequent charge The positive plates should be examined particularly for washing out of material and buckling (warping). If the material has washed out on the surface to a depth below the base of the horizontal ribs, a new group should be substituted. If the plates are only slightly buckled, they can be replaced as they are, since this generally does no harm. If they are badly buckled, a new group should be substituted. The negative plates are nearly always in good condition mechanically, as they arc not affected by abuse as readily as the positives. If the positives arc buckled, the negatives will be also; but if in a charged condition, can be readily straightened as follows: Place boards of suitable thickness between the plates and outside of the group and slowly apply a gradual pressure. This (48) carding, as this determines the proper gravity of the new electrolyte (49) The wood separators should be examined as to their physical Wood condition—wearing off of the ribs, splits or perforations and Separa mechanical strength. As a rule, however, unless a battery is comparatively new, it will be found advisable to install new separators whenever a cell is dismantled for repairs, since it is of vital importance in a battery to have the separators in good condition. No wood separators should be used except the specially treated separators furnished by this Company. These should Sometimes impurities get into the electrolyte through care- Electrolyte lessness or ignorance, but their detection is not practicable except by an expert chemist. As a precautionary measure, the use of new electrolyte of known purity is recommended when repairing a battery. handling. It is advisable to carry a small stock of these for emergencies. The sediment in the bottom of the jars will rarely be found Sediment to have reached the plates, but whenever a cell is taken apart for any purpose it is advisable to wash the sediment out of the Perforated rubber sheets, when used (Types PH and MH), Perforated When the positive plates are badly disintegrated, it is ruining the new positives in a short time. Unless there have been broken jars or abuse of some sort, the battery case will usually be found to be in good condition. If the case has become acid soaked and rotted, a new one should be used. When the old case is to be used again, it should be soaked in a solution of baking soda and water. This will neutral ize any acid and prolong the life of the wood. Rinse with water and allow to dry thoroughly. Repaint the case inside and out with asphaltum or other acid proof paint. case it is safer to discard the negatives and separators as well, and place the cover in position, being sure not Lubricate the sealing nuts with a little graphite mixed to a paste with grease or vaseline. Put on the sealing nuts and tighten them only par- thoroughly with clean Slip the positive and negative groups together Now place the groups on edge (Fig. 32) and insert the sepa rators, being sure that the flat side of the wood goes against the negative plate. Where rubber sheets are used (Types PH and MH), place one against the grooved side of each wood sepa rator before inserting. When the separators are all in place (count them to be sure none are missing), stand the element up again and tap the edges of the wood separators with a wood block until they project equally on each side of the plates. Tighten up the sealing nuts, using the special wrench (Fig. 27). REASSEMBLING BATTERY After the necessary repairs have been made, as described above, the battery should be reassembled as follows: Wipe the posts with a piece of waste moistened with ammonia, (so) Locking Sealing Nuts With burned connections, the thread of the post extends slightly above the sealing nut. When the nuts are tight, take a center punch (a sharp nail will answer) and carefully drive it on the thread in a few spots just above each nut (Fig. 33). This will slightly upset the alloy thread on the post and prevent the nut from coming loose. Fig. 33. (st) With bolted connections, the thread of the post does not extend above the sealing nut. The top nut, when in position, prevents the sealing nut from coming loose, so that no further locking is necessary. Sealing Before sealing always wipe the surfaces to be sealed with ammonia, and then allow to thoroughly dry, otherwise the compound will not stick and a leak may result. a. Single Flange Type of Cover (Types XC, LX, SX, JX). Slip the element with cover attached into the jar, and then place hot compound in the channel, finishing it off flush with a hot knife. b. Double Flange Type of Cover (Types X, XA, PH, MH, ZB, ZA). Have ready a string or worm of sealing compound about inch in diameter, made by rolling between boards some of the special compound furnished in tubes for the purpose. Stand the element upside down, with the cover resting upon two strips (Fig. 34). Lay the string of compound all around the cover channel. Now turn the element right side up and insert it in the jar, taking care that the jar walls enter the cover channels at all points. Apply heat carefully to the edges of the scrape off the excess with a hot knife. cover and gently force cover and clement down until the latter is seated on the ribs in the bottom of the jar. If too much com Placing Cells in Case When all the cells are assembled, place them in the case, taking care that the wood spacers are in position in types which have them (X, XA, PH, MH). These types also have the tie bolts through the case, and these should now be tightened to clamp the jars. In types without tie bolts, the cells should be tight in the case; pack them in with thin boards if necessary. (S2) Connecting b. Bolted Connections. First grease the studs well with vaseline. Slip one of the connector links over the posts of adjoining cells, then an alloy washer over each post, followed by a second connector and second washer. Put on the top nuts and pull up tight with a a. Burned Connections. First see that the posts and the eyes of the lead connectors are clean and bright. If the disconnecting has been carefully done, the posts and connectors will be in good condition and need only washing with ammonia followed, when dry, by slight polishing with sand paper or scraping with a knife. Place the connectors over the posts, lightly tapping them to a firm seat, and burn the joint, using a burning outfit (page 54), or, if nothing better is available, a soldering iron. Do not use any soldering If old plates and new separators are used, fill with electrolyte 50 points (.050 sp. gr.) higher than the old electrolyte. When the old separators are put back, use the same gravity as the old electrolyte (page 49). The electrolyte must be of proper purity (page 34). trolyte of any higher gravity can be diluted with pure water (page 11). To mix electrolyte from strong sulphuric acid, see pages 34 and 35. FILLING WITH ELECTROLYTE Fill the cells with new electrolyte until the level rises in the filling tubes, and be sure to replace and tighten the filling plugs before starting to charge. The specific gravity of electrolyte to use will depend upon Specific the condition of the plates. Gravity If new elements are used, fill with 1.350 (1.260*) gravity CHARGING Do not start the charge until at least 10 hours after filling Prellm]narJ with electrolyte. This is to give the cells a chance to cool, and stand in very hot weather a longer stand may be necessary. Charge at about two-thirds the normal charge rate (pages 67 Maximum and 68) until the specific gravity and voltage show no rise over a Gravity » The lower gravity refers to batteries used in tropical climates (see page 17). (S3) by melting the parts to be joined and forming a solid weld. The process is called “lead burning,” and is carried out by means of illuminating or hydrogen gas and compressed air, illuminating or natural gas and oxygen, or by an electrically heated carbon. period of 10 hours and all the cells are gassing freely. This will require at least 60 hours in the case of new elements, while with old plates, which are badly sulphated or have dried out, con siderably more time may be necessary. Take occasional temperature readings, and if the tempera ture reaches 110 (125*) degrees F., either lower the current rate for the effect of the old solution held in the cells. A little experi ence will enable the operator to gauge this quite accurately. After any adjustment, charge for some minutes to allow the gassing to thoroughly mix the solution before taking hydrom eter readings. If the temperature is far from normal, correct the hydrom eter readings by adding one point (.001 sp. gr.) for each 3 degrees When the charge is complete, adjust the electrolyte to the proper level (Fig. 1), continuing the charge to allow the gassing to thoroughly mix the solution. Take a hydrometer reading on of between 1.270 (1.200*) and 1.300 (1.230*). If the adjustment necessary is slight, this may be accom plished by removing some of the solution and adding water or stronger electrolyte as required. If the adjustment necessary is considerable, it will be found more convenient to empty out the solution and refill with elec- Surfaces t0 good workmanship. Lead is soft and very readily cleaned with a scraper or file. In the case of a battery which has had electrolyte in it, the surfaces to be burned should first be wiped with ammonia to neutralize the acid and then allowed to dry before scraping. Before starting to burn, the connector or terminal should first be lightly tapped to a snug fit on the post. The top of the post should be '/» inch below the top of the connector to allow space for burning. If the post is too long, remove the connector and trim off the post. degrees F. (page 36). Always wipe off the top and sides of battery with weak ammonia after adjusting electrolyte. LEAD BURNING (54) to the connector, after which lead from a piece of burning strip can be run in until the joint is flush. fuls of wet waste may be packed around and over the vents. A large piece of burlap or a towel thoroughly soaked in water is suitable. The wet cloth is recommended for two reasons. First, it prevents the burning flame or arc from communicating to the interior of the cell, and, second, if an explosion should occur, the cloth will prevent the solution and small parts from being thrown lowing precautions should be taken: The filling plugs should be in place, and the entire battery, with the exception of the part on which the burning operation is to be performed, should be covered by a cloth thoroughly wet with water. The cloth should The Illuminating Gas Outfit The outfit (Fig. 36) consists of a special burning tip and mixing valve. Sufficient inch hose should be provided, and the hose wired to the apparatus in making connections. The com paratively high air pressure renders this precaution advisable. A supply of compressed air is necessary, the proper pressure ranging from 5 to 10 pounds, depending upon the length of hose and the size of parts to be burned. When air from a compressor for pumping tires is used, a suitable reducing valve must be introduced. (S5> This outfit is designed for use with the ordinary city gas supply; natural gas cannot be used. Connect the air hose to cock A, the gas hose to cock B. The leader hose, which should not be more than 5 or 6 feet long, is connected to the pipe C and to the burning tip at D. When the air pressure at the source is properly adjusted, close the air cock (A) and turn the gas cock (B) on full. Light the gas at the tip and then turn on the air. If the flame blows out, the air pressure is too high and must be reduced, preferably at the source. Fig. 36. E. S. B. Co. Illuminating Gas Outfit appearance and show a waist about X inch from the end of the tip, the flame converging there and spreading out beyond. This flame is not suitable for burning. Slowly turn off the gas until the outer portion at the waist breaks and spreads, with an inner tongue of flame issuing through If the gas is turned off further, or too much air is turned on, the flame assumes a blue color, gradually becoming invisible, and is then deficient in heating power. When properly adjusted, the hottest part of the flame is just past the end of the inner point. Do not hold the flame too close to the work when burning, as its heating effect is greatly reduced and the flame is spread so as to make control difficult. The burning tip is provided with an outer sleeve and lock nut (E). The sleeve is removable and can be taken off in case any of the holes in the tip become clogged. The position of this sleeve is adjustable, the best position varying with the pressure of the flame, etc. This position should be determined by (56) 1 wash bottle. 2 rubber stoppers. A still better method of burning is by use of illuminating niumlni gas. either artificial or natural, and oxygen in tanks for which orNatur suitable apparatus has been recently developed. Detailed in- Gas and formation regarding the procuring of proper apparatus and full Oxygen instructions for its use will be furnished upon request. The Hydrogen Gas Outfit Hydrogen gas, while more expensive and troublesome than illuminating gas, gives a hotter flame and therefore permits of more rapid work. Some garages doing a large amount of work may still prefer its use, although in most cases the use of illumi nating gas offers more advantages. Hydrogen gas may be made with a hydrogen outfit, or, in most localities, it may be procured in tanks under pressure. Instructions for using hydrogen from tanks will be furnished upon request. The portable hydrogen outfits supplied by The Electric Parts Storage Battery Company each consist of the following parts: 1 finger pipe and set of tips. 1 length 50 ft. ft in. rubber tubing. 1 length 2 ft. % in. rubber tubing. 1 triangular scraper. The material required for charging is as follows: Type j Zinc Water || Vitriol p 5 lbs. 1 7 pts. 1 1J^ pts. E 15 lbs. 7 pts. . pts. D 15 lbs. | 12 qts. 2^ qts. stamped “L” of the wash bottle. closing both cocks "S” and “N.” Take the kink out of the hose connected to outlet “E” of the gas chamber, and allow the air to escape until the charge of grating in gas chamber. Replace hand hole cover “X,” being sure that it is screwed down tight on its gasket. Put the required amount of water in reservoir “A,” and then pour into the water the required amount of vitriol, being sure always that the water is placed in the reservoir first; then rinse wash bottle gas cock at “N," hold a lighted match or candle to the finger pipe until the gas burns, then add air and adjust both cocks until the flame, when tried on a piece of lead, melts the metal hose on the outlet “E” coming from gas chamber “F” and kink this hose so as to prevent anything passing through it. Put rubber stopper in outlet "H” of gas chamber “F,” and be sure that it is tight. Remove hand hole cover “X” from gas The thoroughly flush the drain with water at the same time, and allow the water to run for a few minutes. If solution is spilled, its action can be stopped by using Gold Dust, Pearlinc, washing soda, lime or ammonia. A new charge of water and vitriol should not be put in until just before the generator is to be used again. The following precautions should be observed when han dling vitriol: The vitriol must invariably be poured into the water; never pour the water into the vitriol. When pouring the vitriol into reservoir “A,” stand on a box or platform, which will bring the top of the reservoir about to the waist line, and in pouring it To avoid danger of an explosion, never bring an exposed flame near the generator. When a charge is exhausted or the generator is to be laid up for the night, proceed as follows: Remove the hose at the nipple “E" and then pull out the stopper at “H.” After the solution has run out, thoroughly flush with water poured into the reservoir “A,” and continue until the water emerges at “H" in a clear state. This is highly important, as otherwise the gas chamber may clog. Care should be taken not to allow the solution to come in contact with any- (58) care should be taken not to splash the vitriol. If burned by vitriol, immediately apply oil to the burn, not water. The Carbon Burning Outfit The number of cells used should be sufficient to heat the carbon The carbon should be sharpened to a long point like a should be used that the surfaces are clean and a good contact secured. The cable attached to the carbon holder is then attached to the spare battery, either at the other terminal or on the con nector of the cell adjoining, depending upon whether the battery is partially discharged or fully charged. In the latter case, three The method of using it for reburning connectors is as follows: One terminal of a spare six volt battery is connected by a piece of cable with the connector to be burned. The cable The advantage of this outfit lies in the fact that a spare six volt battery can be used as the source of current for the operation, rendering unnecessary the use of further accessory apparatus, like the hydrogen generator. This outfit (Fig. 38), as supplied by The Electric Storage Battery Co., consists of the following parts: Carbon holder with lead pencil and should project about one inch from the holder. The latter should be cooled off occasionally by plunging it, carbon and all, into a pail of water. After being used for a short time, it will be found that the carbon will not heat prop erly, due to a film of scale formed on the surface. This should be cleaned off with a knife or file, as occasion requires. As in the case of flame burning, additional leadjo make a flush joint should not be added until the metal of the pieces to be joined has melted. The carbon should be moved around to insure a solid joint at all points. TOOLS AND EQUIPMENT (1) To read battery or cell voltage (portable voltmeter, (8) To handle sealing compound (receptacles in which to 8 inch gas pliers). (7) To prepare surfaces for lead burning (knife, scraper, Anyone undertaking to care for or repair batteries must, in time, gather the equipment he considers necessary or desirable for the work. Many of the tools are questions of personal taste or present equipment but there are four things absolutely es- (1) Suitable charging apparatus (for suggestions see ’ pages 61 to 64). (2) A hydrometer syringe (Type S-l is made for this work). (3) A battery thermometer (illustrated on page 36). (4) A lead burning outfit (pages 54 to 59). In addition tools and equipment must be available for the following purposes, and suggestions are here given along with (2) To remove connectors (for burned connectors a brace with % inch wood bit—see Fig. 23. For bolted connectors, a special ratchet socket wrench—see Fig. 25). (3) To tighten or loosen sealing nuts (a special wrench, Fig. 30. There are three sizes). (9) To handle electrolyte (non-metallic or lead vessels for storing, mixing and pouring. Rubber gloves or fingers for protection. Soda or ammonia solution for neutralizing effects of spillage or stoppage). A stock of spare battery parts should, of course, be kept on hand and with these should be included: (1) Sealing compound for resealing cells. (2) Burning strip for lead burning. (3) Electrolyte for replacing actual spillage or loss and never for normal operation (see rule 1, page 10). (4) Acid-resisting paint for painting cases. (5) Petroleum grease for terminals to prevent corrosion. providing it will not soon require repairs necessitat- Batteries may be kept in wet storage by means of either "trickle” charge or periodic charge. Trickle Charge When a number of batteries are to be held in wet storage, the most satisfactory results can be obtained by charging con tinuously at a very low rate. This charge is termed a "trickle” charge and in many cases will be found more convenient to arrange for than the periodic charges at a higher rate. Connect not more than fifteen 3-cell batteries (45 cells) in series (positive terminal of one battery to negative terminal of the next battery and so on) across a 110-volt direct current cir cuit and in series with a 110-volt incandescent lamp (Fig. 39) and charge- continuously. If only from one to ten batteries are to be taken care of, use a 25-watt lamp; if from eleven to fifteen batteries, use a 40-watt lamp. (61) DRY STORAGE (1) Any battery out of commission for longer than a year, no matter what its condition. (2) Any battery on which repairs necessitating dis mantling are, or soon will be, required. WET STORAGE Provide a bench or shelf in a convenient location and with Location sufficient space for all the batteries not in cars. Place the batteries upon wood strips in order to keep the bottom of the cases clear of the bench, and allow a little air space between adjacent batteries. Install the necessary wiring, etc., so that batteries can be easily connected up and charged where they stand on the bench. Apply vaseline freely to battery terminal and exposed copper BATTERIES IN STORAGE When a car is to stand idle for any considerable period, as When when it is held for future delivery, or laid up for the winter Necessary months, or when batteries are kept in stock, the batteries should be put into storage. There are two general methods of putting a battery into Two storage, one known as “wet storage” and the other as “dry Methods storage,” the method adopted depending upon the condition of the battery and the length of time the battery is to be out of commission, thus: WET STORAGE enough charge is given to maintain the batteries in good condition. Before going on "trickle” charge and at intervals during the charge, the filling plugs should be removed and water added Soon after the charge is started, take a gravity reading of each cell in order to ascertain whether any cells are in need of repairs. Gravity readings are also advisable from time to time in good condition. Periodic Charge In cases where it is not practicable to arrange for the "trickle” charge, the batteries should be charged periodically, as given under “Care of Battery Out of Service," page 19. It may be more convenient to charge all the batteries at the same time, even if they have stood for different periods, or they may be charged in groups at different times. wired up to snap switches in groups containing two, four, eight Reeistam and sixteen lamps respectively. A suitable main switch, fuse cutout, ammeter and terminal block complete the outfit. Any good electrician will understand this layout and can make it up and install it quickly and at moderate expense. With this equipment from one to twelve 3-cell batteries can be connected in series (the positive terminal of one connected to the negative terminal of the next and so on) and charged at one time. The lamps which are in series with the batteries make it possible to regulate the current passing through the battery to the proper value. Different combinations of the switches permit current to pass through two, four, six and eight and so on up to all thirty lamps and then through the batteries in series with them. Instead of lamps, resistance units of approximately 35 Unit ohms resistance and 3.3 amperes capacity each may be used. Resistanc This equipment will occupy less space than the lamps and serve the same purpose, each resistance unit replacing two lamps. Instead of either a lamp resistance or unit resistance panel, Rheostat a special form of rheostat may be used for charging. The Elec tric Storage Battery Company will be glad to furnish prices upon application to its nearest office. (63) DRY STORAGE Putting When putting the battery back into commission proceed Battery into as instructed on pages 50 to 54, being sure to charge in accord- Commission ance with the instructions on page 53. .ocatlon Provide a dry place for storage free from dust. Take the battery out of the car, remove the filling plugs and add pure water until the level reaches the bottom of the filling tube. Replace filling plugs, turning them as far as they will go to insure their being firmly seated. Never charge a battery with the filling plugs out, as the automatic vents are then closed and flooding may result. (See exception to this rule at bottom of page 13). iminary Put on charge at the proper current rate in table (pages Charge 57 anc] 6g) and continue the charge until the specific gravity of the electrolyte in all cells, as shown by the hydrometer syringe, has held at a maximum (ceased to rise) for a period of five hours and all cells are gassing freely. Record the specific gravity for future use when putting the battery back into commission. Have on hand enough pure water to fill all the cells, remove the filling plugs and empty the electrolyte as soon as possible after the charge is completed by tilting and turning over the battery and immediately replace the electrolyte with water. After electrolyte has been removed do not allow battery to stand without water as the negative plates may become hot. Should any of the electrolyte be spilled on the case it should be wiped off with a rag moistened with ammonia. Allow the battery to stand filled with water for approxi- POLARITY Always be sure that the positive terminal of the series of batteries is connected to the positive terminal of the line and the negative battery terminal to the negative of the To determine the polarity of the charging circuit, if a suit able voltmeter is not at hand, dip the end of the two wires from the charging circuit into a glass of water, in which a teaspoonful of salt has been dissolved, but do not allow ends of wires to touch. Then close the switch. Fine bubbles of gas will be given off from the negative wire. Open the switch, and connect the negative wire to the negative battery terminal and the positive wire to the positive battery terminal. The connections are now com- ALTERNATING CURRENT When only alternating current is available, it is necessary to provide apparatus to change it into direct current, since only direct current can be used to charge batteries. For this pur pose a motor generator set or rectifier can be used. (64) BATTERIES SHIPPED UNFILLED Batteries shipped to far distant countries are generally shipped unfilled with electrolyte to eliminate spillage and loss of charge during shipment. The following special instructions are applicable to these batteries for putting them into service and should be carefully followed: Object of Shipping Unfilled scribed on page 34. Examine battery case carefully to see if there is any evidence of a cell leaking due to a broken jar, or other indication of injury received in transit. If such is found, claim should be made Directions for Putting into Service As soon as practicable after receipt, the cells must be filled Fining with electrolyte and given an initial charge. To fill, remove filling plugs and pour electrolyte of 1.350 (1.260*) specific gravity EIectrol or its equivalent 38 degrees (30* degrees) Baume carefully into cells until level with bottom of filling tubes, using a china or glass pitcher or rubber syringe. Then replace and tighten filling plugs and allow battery to stand not less than 10 hours before Batteries with bolted connections are shipped with a metal strip underneath the top nuts of the cell terminal posts to keep the sealing nuts from loosening. These strips should be discarded. For connecting up charging circuit, follow instructions at Charging bottom of page 14 and all of page 15, except that the resistance Circuit or lamps should be arranged so that the charging rate will be as near as possible the rate given in the table on the next page. For instance, for Type XC-13, a charge of 4 amperes instead of 6 should be used. For charging more than one battery, use diagram and instructions under Periodic Charge (page 62). On account of the length of charge required it is not advisable to attempt charging with the generator on an automobile. Not less than 10 hours after filling, remove filling plugs, add Initial water to restore level of electrolyte if it has fallen, and replace Charge filling plugs screwing them tight. Never charge with filling plugs out or loose as flooding may result. Start charging and continue for at least four days (96 hours) or until the battery has received at least the number of ampere hours given in the table on the next page. „ If temperature of electrolyte approaches 110 degrees r. (125 degrees F. in tropical climates with low gravity electrolyte) (65) ful to remove any water or electrolyte that may have been to this rule at bottom of page 13). At the end of this charge take a careful gravity reading of each cell. The specific gravity should be between 1.270 and as they may have worked loose during shipment. The battery is then ready to be installed on the car (see page 30). plugs are out. Throughout the charge keep filling plugs turned to the stop charging or reduce rate until it lowers. Add water, if necessary’, during this charge to keep the plates covered. When proceed as follows: If the specific gravity is low, withdraw some of the solution with the hydrometer syringe and add 1.300 specific gravity electrolyte. If gravity is too high, withdraw some solution and add water. Repeat until gravity is within the proper limits. Never add electrolyte to a cell after the gravity has Adjusting been adjusted to the proper point, unless to.replace actual INITIAL CHARGE TABLE XC-19 6Yz XC-25 XC-11 XC-13 625 675 720 120 190 240 290 385 430 480 (66) ‘E xt be ” S TA RT IN G AN D LI G H TI N G BA TT ER IE S (68) “E xf oe ” L IG H TI N G AN D IG N IT IO N BA TT ER IE S u < s 0 g 0 saSslife s 3 X S S 3 S X hb <=<* s « g - « - |1|| J* &co 'O co h Tf< socm o o in *n co iiF P> ' IQ O\ °° x: cs x s:VO O O -+ CM o mco co CO co o o hhe s st§<=< o \o o oo o o' r-CO CO CO CO O O v-4 —< sllfe fe'SO x«" o o o o g co life o o o o o o lit 1 2 2 7 -jj ; 3 22 2S ) cn NN NN > CO cJjJs coco

1919 Manual of Exide Batteries in Automotive Starting and Lighting Service

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