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Price $15.00
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1920 EDITION
PUBLISHED BY
This Manual the original and official compilation of blueprint wiring dia-
is
grams in book form. All diagrams are authentic and accurate, the sources or data from which
made being the original shop or working blueprints of the car and equipment manufacturers, and
not photographic reproductions from instruction books, trade periodicals, etc., the usual source
from which inaccurate diagrams are frequently compiled and offered to the trade.
By reading the General Instructions one can understand how easily electrical circuits
may be traced, and appreciate the simplicity of trouble finding, making tests, etc.
THE PUBLISHERS.
CIRCUIT DIAGRAMS OF CARS
Starting A Generator No. Battery Ignition Coil
Car Year Model System ,,r Type Voltage or Wiring Page
Abbott-Detroit 1916-1917... t>44 Remy 254 6... Remy 8. C. . . . 1
Acme Truck 1919-1920. . . All Models Gray 4 Davis Eisemann . . .
Mag. . 8. C. . . . 2
Ahrens-Fox Fire Engine All Models Delco MG-79 12... Delco 8. C. . . . :<
Auburn. . .
1918 6-44 Delco MG-83 6. . . Delco. 2142. S. C. . . 34
Auburn. . . .
1917-18-19-20 6-39 Remy 168-E-230C 6. . .
Remy 8. C. . . . 35
Austin 1917-1918... HK12 Delco G-87 6... Delco 2123. 8. C. . . . 36
Bell 1916 16 Ward-Leonard RM 12... AK II... 8. C. . . . 37
Bethlehem Truck 1918-19-20.. DX, EX, FX Gray 4 Davis 6... G4D 8. C. . . . 38
Biddle. . . 1919-1920. . . All Models Gray 4 Davis 220 6... Conn s.c 39
Bour-Davis. . 1918-19-20.. All Models. .
Remy 166, 240, 241 6. .
Remy S. C. . 40
CIRCUIT DIAGRAMS OF CARS Continued
CIRCUIT DIAGRAMS OF CARS Confin
Car
CIRCUIT DIAGRAMS OF CARS Continual
Car
CIRCUIT DIAGRAMS OF CARS Continued
CIRCUIT DIAGRAMS OF CARS Continud
Car
CIRCUIT DIAGRAMS OF CARS Continued
Car
CIRCUIT DIAGRAMS OF CARS-Continu.d
Car
CIRCUIT DAGRAMS OF CARS Continued
Car
CIRCUIT DIAGRAMS OF CARS Continued
Car
CIRCUIT DIAGRAMS OF CARS Continued
CIRCUIT DIAGRAMS OF CARS Continued
Car
CIRCUIT DIAGRAMS OF CARS Continued
Car Year
CIRCUIT DIAGRAMS OF CARS-Continued
Car
CIRCUIT DIAGRAMS OF CARS Continued
CIRCUIT DIAGRAMS OF CARS-Continued
STANDARD AND INTERNAL DIAGRAMS
System Diagrams of System Diagrams of
. Standard Wiring 663 Detroit R-S Motor Generator, Installation for cars not originally
i
'halmrrs Standard Wiring 664 equipped 700
'
'liallliers Single I'nit (Early Model Inti>ni:il Wiring 665 Disco Standard Installation, Generator Model 100, Motor Model
i
AlliM 'Ii.'iliii.T- Internal Cireuits. Mnti>r-( ieiieratnr with Regulator. (Late 200 701
M.xleU 666 Disco Single Unit Standard Wiring 702
Vr-Kent Ignition SyMein 667 Disco Two Unit Standard, Models 30 U>39 703
Lite lard Wiring, Series Dimmer, Grounded System. Con- Disco Two Unit Standard, Models 40 to 49 704
neetieut Ignition, Ty|>o II A N-D Switch 668 Disco Internal Circuits, 12 Volt Motor Generator with Regulator. 705
Lit-- GB Generator, Field Winding Internals 669 Dyncto Standard Wiring for Entz Starting A Lighting System 706
GC-GD Generator, Field Winding Internals 670 Dyneto Single Unit, 4 Terminal Unit, Standard Wiring. Models
Auto Lite ( ',( ',
Generator, Internal Connections 671 AAB 707
Auto Ijte. GH Generator, Internal Connections 672 Dyneto Two Unit, DA Motor A GA Generator, Standard Wiring. 708 . .
Lite. (ill Generator, Internal Connections 673 Dyneto Internal Circuits, Motor Generator, Model B 740
Auto Lite M D-MC-M V Motors, Internal Circuits 674 Dyneto Internal Circuits, Generator and Controller, (Type CA Gen-
Auto Liic. Internal Model
( 'in -nit.*, GH
Generator and Model M Motor. 675 erator, 3 Brush Regulation) 709
Bijur Internal Circuits (L-61 and B-10, 3 Brush Regulation, K- Dyneto Motor Generator, Internal Connections 710
646, Gen. 11-75, Voltage Regulator 676 Dyneto-Enti Internal Circuits, Chalmers and White Installation 711
Bijur. Generator w th Regulator. Internal Circuits, Standard Eisemann Magnetos. . . . G-4 Internal, E-M External 712
( 'onneetions 677 Esterline Generator with Automatic Cutout 713
Bijur Two Terminal Type L-61 Generator, Internal Circuits .678
. . . Fischer Internal Circuits, Double Deck Model for Fords 714
Bijur Single Terminal Type L-61 Generator, Internal Circuits, Genemotor Type GSL-102 Standard Wiring and Internal Circuits .... 715
Grounded System 679 Gray A Davis Standard Grounded System 1913-14 716
Bijur Front Head Type L-61 Generator, Internal Circuits, Gray A Davis Standard 2 Wire System 1913-14 717
Grounded System 680 Gray A Davis Standard Grounded System 1915 718
Bijur 1918 Demountable Type, Voltage Regulator, Internal Cir- Gray A Davis Standard Grounded System 1915, Internal Wiring 719
cuits 681 Gray A Davis Two Unit, Internal Circuits 720
Bosch Standard Lighting System 682 Hoinze Magneto Circuits 721
Bosch Rushmorc. . . . Internal Circuits 683 Heinze-Springfield Two Unit, Internal Circuits. 722
Connecticut Automatic Ignition System 684 Jesco Internal Circuits 723-725
Connecticut Ignition Internal Circuits, Type O Switch, GA Coil, A No. 16 Igniter. 685 Lcece-Neville Internal Circuits, Cutout and Generator, Motor and Gener-
Connecticut. .
Igniter System, Type G or GJ, E or EJ Systems 686 ator with Cutout 726
Connecticut Internal Circuits, Type H Automatic Ignition Switch 687 National Standard Wiring 727
Deaco Internal C'ircuits, Voltage Regulator, Generator 688 North East Internal Circuits, Models A A B 72N
Delco Internal Circuits, Motors, Generators, & Motor Generators, North East Internal Circuits, ModelsGAD 729
All Models 689-696 North East Internal Circuit, Model L, Generator, Ground Return
Delco 1912-13 6-24 Volt System, Internal Motor & Generator System 730
Control 697 North East Internal Circuit,Model H, K or R, Starting Motor 731
Delco Control Panel 6-24 Volt System 698 Philbrin Duplex Ignition System, Internal and External Wiring 732
Delco Voltage Regulator, Internal Circuits 699 Remy Internal Circuits 733-736
xxv
STANDARD AND INTERNAL DIAGRAMS Continued
Rushmore Standard Wiring .- 737 Westinghouse Standard Wiring, Connections of Complete System with
Simms-Huff. . . . Internal Circuits 738 Separately Mounted Regulator 752
Simms-Huff. . . . 12 Volt, Motor Generator, Internal Circuit 739 Westinghouse Standard Wiring, Showing Single Reduction Motor and
Splitdorf Generator and Regulator, Internal Circuit .740
_.
. Vertical Ignition System 753
Splitdorf Internal Circuit, Motor Generator, Switch and Cutout. .741 . .
Westinghouse Internal Wiring and Mechanical Connections of Double
Splitdorf Internal Circuit, Generator and Regulator TU-1 742 Reduction Motors and Switch for Automatic Screw
Splitdorf-Apelco Internal Circuits, Generator with Cutout, Generator with Pinion Shift 754
Regulator 743 Westinghouse Internal Ignition Circuits, Horizontal Ignition System,
Splitdorf-Apelco Internal Circuits, 12 volt, Motor Generator with Cutout .... 705 Vertical Ignition System 755
U. S. A. Liberty Ignition 1919-1920, Aviation Circuit Diagram 742 Westinghouse Internal Circuits, 3rd Brush Generator with Separate Cut-
U. S. L... Internal Circuits, 12-24 Volt, External Regulator, External out, Starting Motor and 3rd Brush Generator with Self
Armature Type 744 Contained Cutout 756
Wagner. Internal Circuits, Motor and Generator with Regulator .666 . .
Westinghouse Internal Circuits, Generator Frame Nos. 150 and 750 (R. H.
Wagner. Internal Circuits, EM-165 Generator with Cutout 696 Rotation) 757
Wagner . Internal Circuits, 12 Volt, Single Unit, Motor Generator, Westinghouse Internal Circuits, Motors, Generators, Switches, Relay
Early Models 745 Regulators, Cutouts, etc 758-763
Wagner Internal Circuits, Model 36-T Motor, Model 45-T Generator. 746 Westinghouse Round Generator with Separate Regulator, Vertical Ignition
Wagner-Ward-Leonard 6-12 Volt, Two Unit as Installed on Various Motor Cars and SGL Reduction Motor, Ammeter, Fuse Block, Starting
Trucks not originally equipped 747 Switch, Rev. Lighting and Ignition, Switch 764
Ward-Leonard . Internal Circuits, Voltage Regulators 748 Westinghouse Standard Motor, Lighting and Ignition Generator, 2-Gang
Ward-Leonard . Internal Circuits, Generator with Regulator Cutout 749 Lighting and Ignition Switch, Ammeter, Fuse Block. .765 .
Westinghouse . . Internal Circuits, Connections for Separately Mounted Westinghouse 3rd Brush Generator, Separate Cutout, Starting Motor,
Regulator 750 Starting Switch 766
Westinghouse . Internal Circuits, Connections for 3rd Brush Gen. and Self Westinghouse Lighting and Ignition Frame No. 760, (R. H. Rotation) 767
Contained Cutout, Starting Motor, Starting Switch .751
. .
Westinghouse Starting Motor Connections 768
if eitheror both are effected by short circuit, open circuit, The commutator on the end of the armature shaft is for
poor contact, or ground, the strength of the machine will be reversing the current as it leaves the armature, since it is a
reduced proportionately. fluctuating or alternating current that is generated in the
coils. This can be readily seen because the number of lines of
force is increased during one-half of the revolution and de-
creased during the other half.
GENERATORS AND IGNITION COILS
One of the fundamental principles of electricity is that if
the number of magnetic lines of force passing thru any closed In the case of ignition systems, we have a similar con-
coil or closed electrical circuit be changed, a voltage will be dition, namely, the change in the number of lines of force
induced in this coil which will cause a current to flow, the threading the coil. Ignition coils, primary and secondary,
magnetic effect of which is to oppose the change in the orig- are wound about the same iron core so that any change in
inal number of lines of force. The voltage, as induced, depends magnetic influence of one is transmitted directly to the other
upon the length of time required to change the magnetic influ- with a minimum of loss. When current is flowing thru the
ence, the more rapid the change, the higher the voltage. The primary or low voltage coil of the system, from a battery, in
operation of all direct current generators, as well as gasoline the case of battery ignition, and self-generated by the mag-
motor ignition systems, depends upon this principle. nets, in magneto ignition, it builds up a heavy magnetic field,
the lines of force of which thread the secondary. When this
In the case of the generator, the number of magnetic lines current is cut off by the opening of the breaker points, this
of force threading any coil of the armature is a maximum magnetic influence ceases. The change in the number of lines
when the plane of the coil is at right angles to the path of the of force thru the primary causes a countervoltage to be
field force from the field coils. This can be readily seen if we induced in the primary, the current from which must be
take, as an example, a two-pole generator with a single coil absorbed or a bad arc develops at the breaker points. The
on the armature. If we imagine the poles to be in the hori- condenser, a vital part of all ignition systems, is employed for
zontal position and the plane of the coil in the vertical position this work, as further described herein.
we have a condition of maximum number of lines of force
threading the coil. Now, if we turn the coil thru any appreci-
able angle, the field coils and pole pieces remaining stationary, Inasmuch as both the primary and secondary coils are
the number of lines of force is decreased and a voltage is gener- wound on the same core, the effect of the change in the magnet-
ated (the amount depends upon the speed of rotation) in the ism of the primary has the same result in the secondary in
coils of the armature. By increasing the number of coils in that a voltage is induced. The coil relationship is such that
the armature the voltage is increased and kept more nearly this secondary voltage is very high and forces itself across
constant. the gap of the spark plug, causing the ignition spark.
IT ION sparking position. If the ignition takes place too early, the
motor will have a knock that is very characteristic, whereas
The internal combustion motor derives its power from it' it be too late, loss of power and excessive heating will be
the expansive force developed by the charge of gas which is
noted.
compressed in the explosion chamber being suddenly raised
i a low to a high temperature. To raise the temperature
df this gas one must supply heat This heat is generated by
In the majority of battery ignition systems the breaker
burning of a part of the gas (gasoline) which is com- cam is held to the drive shaft with some form of friction
ised. As in the case of any burning material, a definite
device. This cam can be easily moved and thus change the
length of time is required, depending upon the quantity,
before the material is entirely consumed. This last statement
sparking position beyond the limits of the control lever. In
the high tension magneto the breaker mechanism is perma-
must be borne in mind at all times when considering ignition
nently located on the armature shaft, usually with some form
problems. of key. For this reason the only method of altering the spark-
ing position beyond the range of the control lever is thru the
driving yoke or timing gears of the motor. Alteration of the
To start the burning of any combustible substance an ignit- relationship between the distributor gear and armature gear
ing flame or its equivalent, the heat value of which is measured does not affect the sparking position of the magneto, but does
by the inflammability of the substance, must first be applied. move the high tension conductor relative to the segments in
This igniting flame, in the case of the gas in an automobile the distributor when the magneto spark occurs..
engine, is supplied by the spark which occurs between the elec-
trodes of the spark plug. It is very essential that this spark
occur at the proper time relative to the position of the piston There are at present two distinctive types of ignition in
in the cylinder as .well as that the valves be in the
proper use on automobile engines, namely, battery ignition and mag-
position. The gas must be compressed to its highest point neto. The principle of operation of each is the same and it is
when the combustion is completed. AVere there no time ele- identical with that of the generators, i. e., the inducing of a
ment to be considered in the burning of the gas, ignition could voltage in a coil of wire by changing the number of magnetic
take place when the piston is at its highest point. However, in lines of force threading the coil. The ignition system is made
order to have the motor operate at its proper efficiency, the up of a primary and a .s> <<> mlnri/ coil, a primary circuit
spark is so set that the charge is ignited before the
piston breaker, a condenser and a distributing system for both the
reaches the top dead center. Since the amount of this advance primary and secondary current. The primary coil is one of
of the spark before center depends on the speed of the motor a comparative few number of turns of rather heavy wire
as well as its load, considering all forms of ignition the same,
wrapped around a core of soft iron. This coil, as its name
provision both manual and automatic is made for varying the implies, is 'the first one to function in the operation of the ,
ignition system. The secondary coil is composed of a greater opening the circuit of the primary coil this magnetic influence
number of turns of very small wire. Since the secondary ceases, which induces a high voltage in the secondary coil.
coil depends upon the changes in the magnetic influence of the In the design of the ignition unit the relationship between
primary coil, and in order to eliminate as much as possible the primary and secondary coils is such that this induced
the loss of this magnetic influence thru leakage, both the pri- voltage is sufficient to jump the gap at the plug. At the time
mary and secondary coils are wound upon the same core. of opening the primary circuit there is a considerable voltage
The primary circuit breaker is a mechanism used for opening induced in the primary coil itself and this voltage tends to
the primary circuit at regular predetermined intervals. The force current thru the gap at the breaker points even after
condenser functions in the ignition system in the same way as they have been slightly opened. Were this condition allowed
an air chamber on a water pump, that is, it absorbs the surge to exist the breaker points would very soon burn away. It
in the pressure at one interval and discharges the accumulated is at this point that the condenser functions. Instead of the
pressure at another interval. An electrical condenser is made arc forming at the breaker points the condenser, thru what
up of a number of sheets of electrical conducting material, we may term its elastic characteristic, absorbs the current
usually tin or aluminum foil, separated by sheets of insulating from this self-induced voltage and almost immediately dis-
material, such as paper or mica. Its complete operation is charges it back thru the primary coil. Since a reversal of
outlined below. The primary distribution system, in the case the direction of flow of the current reverses the direction of
of battery ignition, is that set of wires which feed the primary flow of the magnetic lines of force, the discharge of the con-
current from the battery to the coil and breaker points, and in denser reduces the length of time required for the number of
the magneto that wire or system of wires which are used to lines of force threading the secondary coil to change from
short circuit the magneto primary circuit breaker and thus maximum to zero. This reduction of the time element for
make it inoperative. The secondary distribution system is the change increases the secondary voltage because the induced
that which distributes the secondary or high voltage current voltage in any coil depends upon the time rate of change of
from the secondary coil to the spark plugs. In the case of the magnetic influence threading the coil.
multi-cylinder motors this secondary distribution system usu-
ally takes the form of a distributor head moulded from a high The action of the high tension magneto is identical with
tension insulation with inserts moulded in place. The high that of the battery ignition, altho the resultant operating
tension current is fed to the center of the distributor head characteristics differ. The high tension magneto, being a
and thru some form of rotor distributed to these inserts and self-contained unit, develops its own primary energy thru the
from them thru the spark plug wires to the plugs. rotation of the armature between the poles of the strong
horse shoe magnets. The generation of this primary current
-In both the single spark battery ignition and high tension is explained by again referring to the topic of generators in
magneto ignition the primary coil is first energized, its mag- that the number of magnetic lines of force is changed by the
netic field encircling and threading the secondary 'coil. Upon rotation of the armature in the magnetic field. The primary
XXXI 1
iker of the high tension magneto is so located that A cutout consists of an iron core having two windings
tlu- contact points open when the primary current is at its thereon, namely, a shunt and a series winding. The shunt
ttest value. The magneto armature, under this condition, winding is connected across the generator so as to receive the
-ually from one-eighth to live-thirtyseconds of an inch of 1'u 11 voltage of the generator across the terminals, and when
leaving the pole shoe, when the spark control lever is in the the machine attains a speed at which it develops a voltage over
fully retarded position. Since the primary voltage, together that of the battery, the shunt winding is sufficiently energized
with the primary current, increases with an increased speed to close the cutout. When the cutout is closed a small current
tat ion of the armature, it is possible to break the primary is caused to flow in the series winding connected in the main
nit earlier in the relative position of armature and pole circuit from the generator to the battery, and this coil is ener-
pit gized. The pull due to the series winding, which is much
greater than that of the shunt, reinforces the pull due to the
There is otic characteristic in high tension magneto ignition shunt winding and firmly holds the contacts of the cutout in
that is not found in battery ignition, due to the rotation of their closed position.
the secondary coil in the magnetic field. This causes what is
called the "after burning" of the spark. Also, since the cur-
rent as generated in the primary coil of the magneto is alter- When the speed of the generator is decreased to a value at
nating, the direction of flow thru the breaker points is reversed which itsvoltage is lower than that of the battery, or when
\ time that they separate. This fact reduces the tendency the generator is at rest, a momentary discharge of the battery
of burning of the points and eliminates the formation of a thru the series winding takes place and demagnetizes the coil.
cone and crater condition which is so often found on battery The instant the coil is demagnetized, the tension spring
iirnitioii systems which have no current reversing feature attached to the cutout pulls its contact arm away from the
rporated in the ignition switch. core and opens the circuit.
With increasing generator speed the voltage will tend to The amount of current generated depends primarily upon
riseabove 7.75. If, however, this value is exceeded by a very the speed at which machine is driven and the position of the
small amount, the increased pull on the vibrating reed of the regulating brush with respect to the two main brushes.
regulating unit will overcome the spring pull and it will be
drawn towards the core, thus opening the contacts and insert- Beginning at zero speed, the voltage is, of course, zero, and
ing the resistance in the generator field circuit. The added with increasing speed the voltage increases until the armature
resistance in the field circuit decreases the exciting current develops 6.5 volts, at which value the shunt coil of the cutout
in the field winding and the voltage developed by the armature is sufficiently energized to cause the cutout switch to close.
tends to drop below the normal value of the 7.75 volts. If
the voltage drops slightly below the normal, the pull of the After the cutout is closed, the generator begins to deliver
spring on the regulator reed predominates and it again moves current to the battery.
away from the core and closes the contacts which short cir-
cuits the resistance and permits the exciting field current to The constant current generator has a single shunt winding
increase. This cycle of operations is repeated at rapid inter- distributed over its poles and the regulation is effected by
vals and maintains the generator voltage constant at all speeds having this winding connected between one of the main gener-
above the critical value at which it develops 7.75 volts with ator brushes and an auxiliary or regulating brush. The
the resistance cut out of the field circuit. maximum current generated depends upon the location of
the third brush with respect to the main brush to which one
The rapidity of vibration depends, to a large extent, upon side of the shunt field is connected. Moving the third, or
speed, the regulator reed vibrating one hundred to one hun- regulating brush, in the direction of rotation of the armature,
dred and fifty times per second. The actual voltage developed increases the generator output, and in direction opposite to
by the generator is made up of a series of very fine ripples the rotation of armature decreases the output.
LOCATION AND CORRECTION OF FAULTS
To be able to fully understand and intelligently trace the
faults or trouble that occur from time to time in the electrical
;its and equipment on motor cars, it is essential that the
Drawing No. 2
post of the generator, the lamp will light if the circuit be con- can be made by inserting suitable insulation between the coil
tinuous, but not if the circuit be open. If this shunt field be and pole piece at that point where the insulation is broken.
!
there is no magnetic field thru which the armature must
Failure of the insulating bushings or washers that are used
re to generate any current. One usually finds an open with the binding post studs which act as the conductors
circuit of this nature in the leads connecting the different
coils of the field or that leading to the brush or brush through the machine frame or housings can be corrected only
pigtail.
Correction can be made by soldering intact and winding tape by replacement of the bushings or washers.
the connection. Supposing that the circuits are all com- The wear of the brushes leaves a carbon dust deposit on
plete, then test for short circuit or grounds. The blueprints all of the parts in the commutator end of the machine, and
show what these circuits should be and one can very readily, if this accumulation becomes sufficient, short circuit or ground
with the test points, determine whether or not will ensue which makes the machine inoperative. It is very
they be properly
connected to or insulated from each other. essential that the commutator end of the machine be kept
clean and free from this dust at all times as it tends to work
One of the more common troubles encountered is that of into the bearing points of the brush holder, causing the latter
grounds or failure of the insulation between the conductors to become so sluggish in its action that the brush cannot follow
XXTV11
the variations of the commutator. With this condition pres- condition would be caused by a loose or dirty connection in
ent excessive arcing at the brushes results, and the brushes the circuit which introduces a high resistance and causes an
and commutator will both burn away in a very short time, ne- excessive voltage drop at that point which, tho allowing cur-
cessitating new brushes, turning off the commutator and pos- rent to flow when the higher voltage of the test lamp circuit
sibly new brush springs. Another condition that will cause is employed, virtually opens the circuit on the lower
voltage.
excessive arcing at the brushes is that of high mica in the com- This condition is usually found more in the starting system
mutator. The copper may wear away faster than the insula- than the lighting or generating, and its location can some-
tion, the latter projecting above the surface somewhat. In times be determined by the heating of the connection. How-
all generator commutators the mica should be undercut about ever, the more satisfactory method is to measure the voltage
1-32 inch with a hack saw blade, which will eliminate this drop, with the current turned on, across all of the connections
difficulty. in the circuit, with a voltmeter of suitable scale and calibra-
No garage can be considered complete unless an ammeter tion. That which shows the greatest drop is, of course, the
and a voltmeter of suitable calibration be listed in their one that is giving the trouble. For example, a starting system
equipment. The electrical equipment of an automobile may fails to operate even tho the battery be fully charged and all
be satisfactory in every way, apparently, and still give the connections tight. The commutator of the starting motor is
owner of the car a great deal of trouble. For example, the inspected, sanded smooth if necessary and still the starter- will
generator may be charging the storage battery when the not crank the motor. By measuring with a voltmeter the drop
motor isrunning but still the battery does not hold its charge. across the various connections, we find that the voltage thru
One may suppose that the charging rate of the generator is the starting switch is very much lower than that of the bat-
not sufficient to keep the system in condition but without some tery. This condition would absolutely prohibit sufficient cur-
means of measuring the actual current flowing he remains rent reaching the starter to develop any appreciable power.
in the dark. Further it is very inconvenient, at times, to test Upon dissembling the switch a very unsatisfactory contact
for short or open circuit or ground with the test points. For surface would be found, either burned or dirty or, due to loss
example, it is desirable to determine whether an open circuit of tension of the springs, the contact surfaces are not held
exists on a lighting circuit on a car. By placing the ammeter together tight enough.
in that particular circuit with the switch in the "on" posi- A further use of the ammeter and voltmeter together is
tion one can determine whether current be flowing or not. to test for open or short circuits in armature coils. To test
If there is current flowing, which is in excess of that drawn for an open circuited coil, disconnect the field coils from the
by the lamp, a short circuit exists which permits the current machine, but leave the brushes in contact. Now connect a
to flow thrti the circuit, but not thru the lamp which is of dry cell in the circuit so that about eight amperes will flow
rather high resistance. thru the armature. With a pair of soft points as leads from
Again, the test points may show continuity of circuit but the voltmeter, measure the voltage drop between adjacent
still no current will flow when in its normal operation. This bars of the commutator. A sudden increase in this voltage
xxxvm
state, the same condition results. This is due to Breakage of a pillar post or strap connector is noticeable
the minute eryst.-ils of lead sulphate, which are formed on either by the wabble, or excessive heat generated at the faulty
both plates of all lead batteries during
discharge, slightly dis- connection when the battery is being discharged at a high rate.
solving in the electrolyte, and recrystalling out, one upon the
other, until there are appreciable crystals formed, making a One may confront the battery repair man
condition that
white and shiny layer over the whole plate. A
battery in this which very easily explained, but at times difficult to detect,
is
iition acts very similarly to one which is worn out, in is the failure of separator insulation due to
excessively strong
that its capacity in ampere hours has fallen far below the electrolyte. The strong acid very rapidly attacks the wood
manufacturer's rating, leading one to believe that a great deal fiber of the separator and makes it appear as mussy wet
of the active material has fallen out of the plates. The rem- chocolate. The specific gravity of the electrolyte in this case
edy for a sulphated battery is a long, slow over-charge, at is usually at least 1320 and the voltage on charge is normal
about one quarter the normal charging rate. This continued but falls off rapidly on discharge. Remedy for this fault, in
ovrr-char^o is necessary because of the difficulty of breaking case the plates have not been too heavily sulphated, is replace-
sulphate down by means of an electric current. In fact, ment of separators and very low electrolyte, bringing the
the fault is corrected in part only after the treatment pre- gravity back with a slow charge.
scribed. Great care should be exercised in this charge, as
well as for any other correction or in the operation of a stor-
bnttery, that the temperature of the electrolyte never REPAIRING BATTERIES
eds 100 degrees Fahrenheit. Temperatures above this
LEAD CONNECTOR-SEALED TYPE
point arc accompanied by a hardening of the plates, resulting
in lower terminal voltage on discharge, and carbonizing of the Before starting to dismantle a battery, a sketch should be
irators which reduce their insulating value and cause pre- made showing the inter-cell connections and position of termi-
mature failure. nals for guidance in re-assembling.
Evidence of a broken jar is very apparent through leakage To remove top connections after being drilled, place a flat
of the electrolyte. piece of steel along edge of case to prevent marring or crush-
xiiii
ing of edges; then use lever underneath connector
and pry at an angle on top of jars to drain. While the elements are
off. Brush off the accumulation of lead and dirt from top of draining, apply flame around the terminal posts and lift off
battery. Care should be exercised to keep foreign
substances covers.
/
from the inside of the battery, especially metal which may
become lodged between the plates and cause short circuiting. If separators are in good condition, and a jar replacement
only is necessary, set the element in electrolyte or water until
Remove vent plugs and blow in the holes in the covers. ready to replace. If separators are to be changed, separate
This should always be done before bringing an open flame the positive and negative groups by grasping the elements
near the battery, as an explosive gas, (hydrogen), is generated firmly by the posts and working slowly back and forth.
in the battery during both charge and discharge. Explosion
of this gas in the confined space of the battery cell usually The smallest opening in a separator may cause a short cir-
results in a broken jar. The moulded rubber vent plugs being
cuit which may not be discovered until the battery has been in
very brittle and easily broken, the use of pliers for their
re-
use again for some time. When separators have turned black,
moval is not advisable.
they are carbonized and their life is virtually gone. To re-
move separators, take a long bladed knife and run it between
Soften the sealing by playing a soft flame over the com- the plate and the separator. It is always best to renew the
not burn
pound. Care must be taken so that the flame does separators. Separators should never be allowed to become
the covers. It is. best to play the flame back and forth, not
dry, but should be kept immersed in a very weak solution of
steadily in one place as this will cause the compound to melt
electrolyte.
and run. Asmall flame used for several minutes brings better
results than a strong flame which melts only the surface com-
pound and leaves that below hard. Inspect plates to determine whether or not they require
replacement. If battery has been overheated through over-
charging or snort circuiting, this will be indicated by brittle
Use a heated screw driver (to prevent adhering) and dig
and buckled plates, with active material granular and falling
out the compound. After all the compound has thus been
removed apply the flame to the inside of the jar (through vent away from the grid. Plates in this condition will have to be
replaced.
tube) for an instant, then run a hot putty knife around the
edges between jar and cover.
The condition of the positive plates can be ascertained by
Place the battery on the floor and, holding firmly between using the blade of a knife. If they are fairly hard and have
the feet, grasp the terminal posts with two pairs of pliers and neither lost too much of their surface nor become extremely
lift the element and cover out together. Let the elements rest buckled they can be used again.
XL1V
The condition of the negative plates is very often such that To assemble an dement, place the positive and negative
they may be used attain with new positives. In this case the groups on a clean, tl.it Always make sure that it is
surface.
five' group should he immersed in water to prevent the free from lead scrapings or foreign substances of any kind,
mil drying out through heating by exposure to thP air. as these substances will adhere to wet separators, which will
cause short circuiting of the plates. Intermesh the positive
and negative group. As the negative group contains one
Occasionally it hap])ens that one or two plates in a group
more plate than does the positive, both outside plates will be
replaeement while the balance of the plates are in good
:re
iticii. In this ease ne\v plates may be used in replacement. negative.
To remove a jar fill it with boiling water and allow it to If the cover does not fit close to the terminal posts, or the
stand for a few minute's. This will loosen the sealing com- wall of the jar, the openings should be calked to prevent the
pound surrounding the jar. Grasp the edges of the jar with melted sealing compound from flowing into the jar.
two pairs of pliers and pull it straight up. Care should be
so as not to damage adjacent jars.
Pour the compound so that it will fill all spaces and reach
The new jar should be heated before being placed in the with the top of the case.
to a height level Also see that it flows
case. When the jar has been heated either with boiling water evenly over the whole surface.
or flame, it should be pushed into place, taking care that the
top of the jar is level with the others. If not lined up, the
top connectors will be uneven, and as a result present a very . Before applying connectors, ,see that the terminal posts
amateurish-looking job. are free of all compound and dirt.
XLV
Using an ordinary pocket knife, clean the inside of the 100 F., lower the charging rate, or discontinue charge until
connectors. Then clean the tops of the connectors with a file, the cell cools. The strength of the electrolyte used for filling
to remove dirt and oxide, so that they can be properly united. the battery largely depends upon the condition of the plates.
If all new plates are used, gravity should be 1.300 if positive
;
Before applying the terminal connectors, test all cells with renewal, 1.285 ; if old and sulphated plates, 1.100, and if old
a voltmeter to see if they are set up properly. The connectors and not sulphated plates, 1.250.
should be applied so that the positive of one cell is connected
to the negative of the next cell. If the battery has new plates, twice its rated capacity will
be required for the development charge. If the plates are old
In welding connectors and terminals to the posts, fuse the and badly sulphated, more time may be required.
top of the post with the edges of the hole in the connector.
Melt strips of lead and allow the molten metal to run into the
hole in the connector. Care must be taken to see that the top
Any cells which have not been repaired should be left out
of the circuit during the first half of the developing charge.
of post and the inside edges of the connectors are properly
melted together before adding additional lead. If this is not
They may then be connected into the circuit and the whole
battery brought to full charge.
done, poor contact will result. Care should be taken not to
melt the outer edges of the connectors.
After burning the connectors and terminals, mark the posi-
When the charge is complete, adjust the gravity of the
electrolyte to 1.280 to 1.300. To do this remove some elec-
tive terminal (+) and the negative ( ).
trolyte from the cell and replace with pure water until de-
sired gravity is reached or remove electrolyte from the cell
;
XLVl
ABBOTT' DETROIT MODEL 6-4+ /SJG-/9/7
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600
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602
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603
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640
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641
WILLYS -KNIGHT 1916
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642
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646
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WILLYS- KNIGHT 1 917-18
648
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649
WILLYS-KNIGHT'1327 88 -8 T IBIS
650
WILLYS- KNIGHT 1 SI 7 $18 88-G-TC
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WILLYS-KNIGHT 1318 - /8 T-
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652
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653
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659
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CONNECT/CUT /GN/TEf? SYSTEM.
'
i
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686
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688
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689
C/^CU/7~S
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699
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710
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INTERNAL CIRCUITS
713
CIRCUITS
714
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\\.
768
Library