Willard Batteries With Lead Inserts in Covers
The types SJWN and SJRN Willard batteries have lead inserts in the cover post holes, as shown in Mg. 278, the inserts being welded to the posts. For removing the connectors and for separating the post from the cover insert, the Willard Company furnishes special jigs and forms. The work may also be done without these jigs and forms, as will be described later.
When the special jigs and forms are used, the work is done, as follows:
1. Place Willard drill jig Z-72 (Fig. 279) over the connector, and with a 13/16 inch drill, bore down far enough to release the connector from the post (Fig. 279).
2. File off the post stub left by drilling. This will give a flat surface on top of the cover insert and will make it easier to center the drill for the next operation.
3. With a 57/64 inch drill, and Willard jig Z-94 (Fig. 280), drill down to release the post from the cover insert.
4. In reassembling, build the post up to a height of 1-5/16 inches above the top of the plate strap, using Willard post builder Z-93 (Fig. 281).
5. After removing the post builder, bevel the top edge of the post with a file, as indicated at “A” (Fig. 281). Then replace plates in the jars.
6. File off tops of cover inserts at “A” (Fig. 282), to a height of 3/16 inch above the cover. Also remove any roughness on surface “B” caused by pliers when cover was removed.
7. Put on the covers so that their tops will be 1/32 inch above the top edge of the jars, tapping them lightly with a small hammer.
8. Place Willard burning form Z-87 (Fig. 283) over the post and cover insert and burn the post to the insert.
9. Remove form Z-87 and thoroughly brush off the top of the post stub. Then build up the stub post, using Willard burning form Z-88 on the positive posts and form Z-89 on the negative posts (Fig. 284).
10. Now seal the covers with sealing compound as usual, and burn on the connectors.
11. If the terminal posts are made for clamp terminals, build up the posts by using Willard burning form Z-90, for the positive posts and Z-91 for the negative posts (Fig. 285).
To work on the post seals of Willard types SJWN and SJRN without the special Willard jigs and forms:
1. Remove the connectors and terminals as usual.
2. Saw off the posts close to the covers, taking care not to injure the covers; This will separate the posts from the cover inserts, and the covers may be removed.
3. In reassembling, Ale off the top of the cover insert at “A” (Fig. 292).
4. Put covers on so that their tops will be 1/32 inch above the top edge of the jars, tapping the covers lightly with a small hammer.
5. Brush the top of post and cover insert perfectly clean. Now make a burning form consisting of a ring 1-1/8 inside diameter and 1-5/8 inch outside diameter and 3/16 to 1/4 inch high. Set this over the stub post and cover. With a hot lead burning flame melt the top of the post and cover insert together. Then melt in lead up to the top of the special burning form (Fig. 286). Then remove the form.
6. Set post builders on the part of the posts which has been built up and build up the posts as usual, Fig. 286. Then burn on the connectors and terminals.