Document 8OeQzbb14N4bGVVx9ojq5wGoo

BEFORE: Removing the Cell . '-V Follow These Tips,-j For Your Storage Klry Repairs AFTER: Sealing and Welding u g{ f i I Here are the steps to follow when replacing B cr Special tool drill* art annular hole, permit! removal of connector! end covers without disturbing terminol post storage-battery cover or taking out the cell for general tenance. The technique is simple--just a straight job of cutting, sealing and rebuilding. Cutting. The hard-rubber battery covers have post inga lined wilh lead inserts. These inserts are welded |< lead terminal posta to prevent leaks. In a nutshell, the ccdure for taking out a damaged cover is to cut metal between the post end its opening. One way is to use a special toot, Fig. 1, that eu annular hole around ihe post. With this tool, the lead remain solid, upright and ol normal height. You ot off the cell connector and battery cover when your deep enough. The other way is to cut out the metnl in the posts' 15/16-in. drill. Fig. 2. When you get down to % lnn intercell connector w(U be free. Drilling down through cover frees it in turn. Sometimes the bsttery is designed so there is el* between the intercell connector and tbe top of the In this case you can eliminate the first drilling by a horizontal saw cut under the connector. s} If cover is ondomaged, but you want to remove the bitui elements from the jar for basic cell repair, remove the cell connector and lift out both cover and elements unit. Fig. 3. Altemote method of disassembling storage battery Is to drill out the posts with an ordinory )5/]6-ln.>dJa drill Cover ond element may be pulled simultaneously If cover Is undamaged. Clips and cholns hold down the bottery jar Dy making a saw cut through tbs connector above junction line between battery cells, you do not even have to remove connector. The lifting tool can be a post cutter with dull cutting edges or any other suitable instrument. An easy way to hold down the battery jar is with clips and chains, as shows ' this photo. Sealing. To assure .a proper seat between cover and when reassembling the cell unit, use a good sealing cotthj pound and apply it properly. Fig. 4. Battery manufacturer*! ordinorily supply compound in packaged form, ready for uifc; Melt sealing compound over a burner or blowtorch in an|< metal saucepan or pot with a good pouring lip. Keep tenf peroture at the lowest point that will permit easy pouring,, as too rapid heating ond loo high temperatures causa It to catch on fire. Burning consumes oil and impairs effective; ness. The melting pot should be about one-quart size. Do not use too large a pot because more tlmo wilt be required to melt the compound completely. > If eomo compound remains after pouring a seal, it may l* cooled, stored and reused. But when it Is being reheated, de not puncture the unmelted lop layer with a screwdriver of; other pointed tool because pressure in the lower melted see tlon may cause hot, melted compound to squirt through lb*, hole. The hands, face or body of persons nearby may** severely burned. u"pVtWdl0br ' " KW-tU> lUHftMS. Mppil* Sf Urn anlN Dwirtmmt H Otlld-Kiiltnil hUrl*i, l*onrut ISP*tf^M)rI>cei to be sealed, neutralize with ammonia PBjSpjfflfwda, and dry corefully. Be sure cover is properly P^1?K?op *ce|1 *nd ,eve* *ilh other cover*in bB,,eryl^^vfflesUng compound into space between cover and jar, IS^flfeefui K> avoid spilling- Space rouat be, Ailed to some BEr ImilRc*other cells so there are no recesses where acid ftSvfci^colleci. Use a sharp knife to smooth over rough BSftfed rtmc.tf excess after compound has solidified. IjSsiwl'idi'og-. Next step in reassembling the battery is to Sfad'THe'drilled posts. This is a simple `'puddling" opera-' a carbon electrode to apply heel within the ks^tyHfla-simple post mold that can be made in the shop IgKSrehaied outside. Take core that the carbon rod does gnofljoueinside ol mold. KjeSrSn-electrode can also be used for burning (welding) Bufconnectlons. A carbon burner consists of an electrode Vj,V3epnd a carbon rod. It is designed for 6-v power supply of a battery), and can use power from the bat- mftyltieini repaired. To insure a good weld, use exactly BtSrtacells, as less is inadequate for a good weld, ond more TlSujllyVendBngers bsttery, operator and joint. If battery rfftfeVepalr is entirely discharged, connect the carbon burner RTmm.'oeU* of so adjacent unit. HiTo'd'should be pointed to a Win. tip and extended about` jl^Smffrom ihe holder. If possible, connect it to the power fBpTcffso the carbon rod has negative polarity. This makes Reklmt'caticf as it tends to keep joint and working surface Cl&rp^* . OTtesd-surfaces to he welded or built up should be nett- njayed: and cleaned with a wire brush. Clean inside hole Mflcoiweetoi with a knife, and wire-brush tip of the carbon. jEtTo-make a joint, thoroughly heat center of the part being awjrtked.umil you have a puddle of molten metol. Then add luai|[oiia( lead. Fig. 5. working rapidly to complete the perjsponifefore entire part melts. When possible,' surround lS''"w'`d on with a damp rag. Uae molds made for EtaeMkirpoie when building up posts or splicing a connector. lR,add new lead, touch it to the carbon rod and let it flow Ljgufhibe puddle rather titan plunging cold lead into the IMqdlarinelf. Kwhcn burning a connector to a post, one slow trip around do tlte job. This is also true of burning a lead-insert of a new cover. But joint is so deep Jed will be removed from the post in the ,r0und ihe joint. To build it up, return carbon point |?v"!CT ihe post and add new lend to raise post height otleyel of the top of post mold. j?AJf.er asking the burn, let joint cool undisturbed. Mov- Mt/it-during cooling may cause lead crystallization and Jjtt)lt>in a poor weld. After cooling, you can determine ff^ther weld has been made properly by testing with o pair ujiPheri. gangly resist separation. plU'^paraiion occurs, examine the two surfaces to de- ,bc I'finis and nature of weakness so the situation viJl^ correccted on the second try. Pour seol'ing compound Into spoce between cover ond |or. Space must be filled to some level os the odlocent calls Burn joints with a carbon rod connected to throe bottery colls. Apply fresh leod so it Hows Into molted puddle Use o mold when building up bottery posts, but be coreful thot tho corbon rod does not touch side o the mold tSjj plant operation and maintenance section