BY

Third Edition

Completely Revised and Enlarged

Fourth Impression

Published 1922 by

THE AMERICAN BUREAU OF ENGINEERING, INC. CHICAGO, ILLINOIS, U. S. A.

Completely Revised and Enlarged

Fourth Impression

Published 1922 by

THE AMERICAN BUREAU OF ENGINEERING, INC. CHICAGO, ILLINOIS, U. S. A.

Plates

Separators

Electrolyte

Jars

Covers

Case

Assembling and Sealing

Preparing Batteries for Dry Shipment

Terminal Connections

HOMEMADE BATTERIES

Relations Between Chemical Actions and Electricity.

Design and Construction.

Operating Conditions.

Age of Battery.

"Dope" Electrolytes

PLATE TROUBLES

Buckling

Shedding, or Loss of Active Material

Loose Active Material

Impurities

Corroded Grids

Granulated Negatives

Heating of Negatives Exposed to the Air

Negatives With Very Hard Active Material

Bulged Negatives

Negative With Soft, Mushy Active Material

Negatives With Roughened Surface

Frozen Positives

Rotted, Disintegrated Positives

Buckled Positives

Positives That Have Lost Considerable Active Material

Positives With Soft Active Material

Positives With Hard, Shiny Active Material

Plates Which Have Been Charged in Wrong Direction

SEPARATOR TROUBLES

JAR TROUBLES

BATTERY CASE TROUBLE

TROUBLE WITH CONNECTORS AND TERMINALS

ELECTROLYTE TROUBLES

GENERAL TROUBLES

Open Circuits

Battery Discharged

Dead Cells

Loss of Capacity

Loss of Charge in An Idle Battery

Equipment Which is Absolutely Necessary

Equipment Needed In Opening Batteries

Equipment for Lead Burning (Welding)

Equipment for General Work on Cell Connectors and Terminals

Equipment for Work on Cases

Tools and Equipment for General Work

Stock

Special Tools

DESCRIPTIONS OF TOOLS AND EQUIPMENT NAMED IN FOREGOING LIST

Charging Equipment

Constant Current Charging

Using Lamp Banks, or Rheostats

Using Motor-Generator Sets

A few suggestions on Motor-Generator Sets

Operating the Charging Circuits

Care of Motor-Generator Set

Constant-Potential Charging

The Tungar Rectifier

A. Two Ampere Rectifier

B. The One Battery Rectifier

C. The Two Battery Rectifier

Catalogue No. 195530

Fig. 55. The Two Battery Tungar Rectifier

D. The Four Battery Tungar

E. The Ten Battery Rectifier

F. The Twenty Battery Tungar

General Instructions and Information on Tungars

Installation

Line Connections

Battery Connections

Operation

Troubles

Tungar Rectifiers

Mercury Arc Rectifier

Mechanical Rectifiers

Stahl Rectifier

Other Charging Equipment

CHARGING BENCH

Fig. 65. Charging Bench with D.P.D.T. Switch for Each Battery

WORK BENCH

SINK OR WASH TANK

LEAD BURNING (WELDING) OUTFIT

EQUIPMENT FOR HANDLING SEALING COMPOUND

SHELVING AND RACKS

BINS

BATTERY STEAMER

EQUIPMENT FOR LEAD BURNING (WELDING) Plate Burning Rack

The Burning Lead Mould

EQUIPMENT FOR GENERAL WORK ON CONNECTORS AND TERMINALS

Moulds for Casting Inter-Cell Connectors, Terminals, Terminal Screws, Taper Lugs, Plate Straps, Etc.

EQUIPMENT FOR WORK ON CASES

TOOLS FOR GENERAL WORK

CADMIUM TEST SET AND HOW TO MAKE THE TEST

How Cadmium Tests Are Made

When Cadmium Readings Should Be Made

Open Circuit Voltage Readings Worthless

What the Cadmium Test Set Consists of

The AMBU Cadmium Voltmeter

Testing a Battery on Discharge

Testing a Battery on Charge

HIGH RATE DISCHARGE TESTERS

PARAFFINE DIP POT

WOODEN BOXES FOR BATTERY PARTS

Fig. 130. Boxes for Holding Parts of Batteries Being Prepaired

EARTHENWARE JARS

ACID CARBOYS

SHOP LAYOUTS

Concerning Light

TROUBLES

Suggestions

LEAD BURNING (WELDING)

General Lead Burning Instructions

Burning on the Cell Connectors and Terminals

Burning Plates to Strap and Post

Post Building

Extending Plate Lugs

Making Temporary Charging Connections

MOULDING LEAD PARTS

HANDLING AND MIXING ACID

PUTTING NEW BATTERIES INTO SERVICE

Batteries Shipped Fully Charged, or "Wet." All Makes

BATTERIES SHIPPED "DRY"

Exide Batteries

Table of Initial and Repair Charging Rates

Vesta Batteries

Philadelphia Diamond Grid Batteries

Charging Rates

TABLE — No. 1

TABLE NO.2

Willard Bone-Dry Batteries

Unfilled Willard Wood Insulated Batteries

Preparing Westinghouse Batteries for Service

The Prest-O-Lite Assembled Green Seal Battery

Initial Charge---52 Hours

INSTALLING A BATTERY ON A CAR

STORING BATTERIES

"Wet" Storage

Series on 115 Volt Line

Dry Storage

DETERMINING AGE OF BATTERY

Exide Age Code.

Prest-O-Lite Age Code.

Prest-O-Lite Factory Marks.

Titan Age Code.

RENTAL BATTERIES

Terminals for Rental Batteries

RADIO BATTERIES

VESTA RADIO BATTERIES

EXIDE RADIO BATTERIES

WILLARD RADIO BATTERIES

WESTINGHOUSE RADIO BATTERIES

PHILADELHIA RADIO BATTERIES

Initial and Recharge Charging Rate

U. S. L. RADIO BATTERY

PREST-O-LITE RADIO BATTERIES

Table of Prest-O-Lite Radio Batteries

UNIVERSAL RADIO BATTERIES

"DRY" STORAGE BATTERIES

DISCHARGE TESTS

The 15 Seconds High Rate Discharge Test

Lighting Ability Discharge Tests

Starting Ability Discharge Tests

"Cycling" Discharge Tests

Discharge Apparatus

PACKING BATTERIES FOR SHIPPING

STORING SEPARATORS

REINSULATION

SAFETY FIRST FOR THE BATTERY REPAIRMAN

TESTING THE ELECTRICAL SYSTEM

Tests to Be Made by the Repairman

Troubles

ADJUSTING GENERATOR OUTPUTS

How and When to Adjust Charging Rates

TESTING AND FILLING SERVICE

SERVICE RECORDS

Purchasing Methods.

The Use and Abuse of Credit.

Proper Bookkeeping Records.

A Daily Exhibit of Your Business.

Expenses and Profits.

Invaluable Monthly Comparative Information.

Battery Tests

General Inspection

Operation Tests

Trouble Charts

All Cells Show Low Gravity or Low Voltage

Gravity Readings Unequal

High Gravity

Low Electrolyte

Battery Overheats

Electrolyte Leaking Out at Top

Summary

How to Open a Battery

What Must Be Done with the Battery?

Examining the Plates

When to Put In New Plates

When the Old Plates May be Used Again

What To Do With the Separators

Find the Cause of Every Trouble

Eliminating "Shorts"

Charging

Washing and Pressing the Negatives

Washing Positives

Burning on Plates

Work on the Jars

Testing Jars

Removing Defective Jars

Repairing the Case

REASSEMBLING THE BATTERY

Reassembling the Elements

Putting Elements in Jars

Filling Jars with Electrolyte or Putting on the Covers

Use 1.400 Acid

Putting on The Covers

Sealing Compounds

Sealing Double Cover Batteries

Sealing Single Cover Batteries

Burning-on the Cell Connectors

Marking the Battery

Cleaning and Painting the Case

Charging the Rebuilt Battery

Adjusting the Electrolyte

High Rate Discharge

EXIDE BATTERIES

Type Numbers

Methods of Holding Jars in Case

Opening Exide Batteries

Work on Plates, Separators, Jars, and Case

Reassembling Plates

Putting Plates In Jars

Filling Jars With Electrolyte

Sealing Exide Battery Covers

Putting Cells In Case

Burning on the Cell Connectors

U. S. L. BATTERIES

PREST-O-LITE BATTERIES

Prest-O-Lite Type "N" Post Locking Outfit

To Remove Cell Covers from Elements

To Rebuild Posts

To Lock or Peen Posts

Precautions in Post Locking Operations

General Instructions

THE PHILADELPHIA DIAMOND GRID BATTERY

Old Type

New Development in the Philadelphia Battery

The Philadelphia Separator

THE EVEREADY STORAGE BATTERY

Description of Parts

Repairing Eveready Batteries

VESTA BATTERIES

The Vesta Type "D" Battery

Type "DJ"

Vesta Separators

Vesta Post Seal

WESTINGHOUSE BATTERIES

Westinghouse Plates

TYPES OF WESTINGHOUSE BATTERIES

Type "A" Batteries

Plates

Type "B" Batteries

Plates

Type "C" Batteries

Plates

Type "E" Batteries

Plates

Type "H" Batteries

Plates

Type "J" Batteries

Plates

Type "0" Batteries

Plates

Type "F" Batteries

Plates

WILLARD BATTERIES

Willard Batteries With Compound Sealed Posts

Willard Batteries With Lead Inserts In Covers

Willard Gasket Type Batteries

Willard Separators

UNIVERSAL BATTERIES

ONE-PIECE BATTERY CONTAINERS

THE TITAN BATTERY

Selection of Plant

Location of Plant

Wiring

Installation

Connecting Cells

Initial Charge

Instructing Users

Care of the Plant in Operation

Care of Battery

Charging

Discharge

Battery Troubles

PREST-O-LITE FARM LIGHTING BATTERIES

Rebuilding Prest-O-Lite Farm Lighting Batteries

EXIDE FARM LIGHTING BATTERIES.

Batteries with Sealed Glass Jars.

Battery Gauges and Instruments for Testing.

The Ampere-Hour Meter

Hydrometers

When and How to Charge Battery

Plants with Average Loads

Carry Heavy Loads Greater Than 10 Amperes.

Where Small Load Is Used.

INSPECTION TRIPS

Sediment Space Filled.

Check Ampere-Hour Meters

Voltage Readings

REPAIRS

Disassembling a Cell

Assembling

Inserting Locking Pin

Sealing Covers

Filling Cell with Electrolyte

Charging

Adjusting Gravity of Electrolyte

HOW TO REPAIR DELCO-LIGHT CELLS

Treating Broken Cells

Treating Spilled Cells

Treating Badly Sulphated Cells That Have Been in Service

Treating Reversed Cells

Removing Impurities

Clearing High Resistance Short Circuits

Clearing Lug Shorts

Putting Repaired Cells Back in Service

Charging Outside Negative Plates

Pressing Negative Plates

Salvaging Replaced Cells

Repairing Lead Parts

Repairing Broken Posts.

Burning on Straps

How to Eliminate Burning on Straps by Use of an Auxiliary Strap

Burning on New Plates

Keeping Wood Separators In Stock

Freezing Temperature of Electrolyte

Care of Cells in Stock

Taking Batteries Out of Commission

Putting Batteries Into Commission After Being Out of Service

General Complaints from Users and How to Handle Them.

OTHER EXIDE FARM LIGHTING BATTERIES

Batteries with Open Glass Jars

Batteries with Sealed Rubber Jars

WESTINGHOUSE FARM LIGHTING BATTERIES

Opening and Setting-Up Westinghouse Farm Lighting Batteries

The Relation Between Various Sizes of Westinghouse Farm Light Batteries and Work to be Done

Table A

Table B

WILLARD FARM LIGHTING BATTERIES

Glass Jar Batteries. Fully Charged and Filled With Electrolyte

Unpacking

Inspection of Cells.

Connecting the Cells

Willard Glass Jar Batteries Shipped "Knock-Down."

Cleaning the Glass Jars

Preparing the Covers

Assembling the Element and Separators

Sealing Element Assembly in Jar

Filling with Electrolyte

Initial Charge

Wilard Rubber Jar Batteries Shipped Completely Charged and Filled with Electrolyte

Willard Rubber Jar Batteries Shipped Dry (Export Batteries)

Installing Counter Electromotive Force Cells