Welcome to Handy Hints

These handy hints provide helpful tips for the most common queries that I receive.
If you don't find the answer you're looking for, please contact us.

What is the right level to fill my battery?

Remove the plugs from the top of the battery and fill the water so it's 1cm / 10mm over the lead plates.

What is the correct charging rate for my vehicle?

Charging rate output from an alternator should be between 13.6 volts with load on
( headlamps ) and 14.4 volts with load off.

What is the best way to clean battery terminals on the battery?

Mix hot water and a bit of bi-carb soda together, and pour over terminals. Alternatively,  pour hot water from a kettle onto the battery terminals. 
To stop corrosion, then apply grease or Vaseline to the terminals.

What is the red light that comes on in the instrument panel after the vehicle has been started and looks like a battery?

It means that your vehicle has something wrong with the charging system and your vehicle battery will go flat.
You should take it to an Auto Electrician to have the problem rectified.

What does the warning light which looks like a battery but has wave looking line running through it mean?

It means that the water level is running low in the battery.

What is that fast clicking sound that I hear when I try and start my vehicle?

The fast clicking sound means that your battery is flat.
You will need to jump start the vehicle or call an Auto Electrician to have the problem rectified.

what is the best way to jump start my vehicle?

Connect the positive jumper lead ( red lead ) onto the positive of the flat battery and the other end of the jumper lead to the positive terminal of the good battery ( the positive terminal is the one marked with an + on top of the battery ).
Now connect the negative jumper lead ( black lead ) to a clean part of the engine block in the vehicle with the flat battery and the other end of the jumper lead to the negative terminal of the good battery ( the negative terminal is marked with an -- on top of the battery ).
Start both vehicles and let run for about 5 - 10 mins together.
Stop vehicles and then remove jumper leads from vehicles.
Now both vehicle's should start by their own power.
Contact an Auto Electrician to have the electrical system checked out.

Headlamp Aiming Procedure:

The Road Safety ( Vehicles ) Regulations require that top of the beam of the light projected from a low headlamp is:

( a ) not higher than the center of the headlamp when measured at a point 8.0 metres in front of the vehicle: and,

( B ) not more than 1.o metre higher than the level on which the motor vehicle is standing when at a point 25.0 metres in front of the vehicle.

The normal procedure to test the low beam headlamps comply with the regulation is to:

• Ensure the test site is level and there is no load in the vehicle which affects it's normal ride height.

• Position the vehicle close to the screen and carefully mark the centre of each beam lamp on the screen.

• Move the vehicle directly back from the screen unlit the front of the headlamp are 8 metres from the screen.

• The low beam light should be at the same height and must not be higher then the marked centre of the headlamp.

High beam should be correct once low beam is correctly adjusted.

How do I wire driving lights?

What is an Auto Electrician?

An Auto Electrician is a person who is professionally trained technician in repairs to all electrical operating components on a motorizes vehicle. E.g. Starting system, charging system, lights, wiring, etc.

What is the wiring code for a seven / five pin plug socket for a caravan / trailer?

Five pin round plug & socket wiring code:

on the bottom of all sockets there are numbers in which the socket can be wired.

Seven pin round plug & socket wiring code:

Six pin plug & socket wiring code:

Seven pin heavy duty 70 amp round plug & socket wiring code:

Twelve pin flat plug & socket wiring code:

Seven pin flat plug & socket wiring code:

What is the wiring code for a standard relay?

Relay wiring code:

 Charging your battery

Before attempting to charge a battery, be aware of all the safety precautions you should observe during the charging operation.

• Always turn the charger off before attaching, rocking, or removing the terminal clamps.
• Keep open flames and sparks away from the battery.
• Keep vent caps in place.
• Charge in well ventilated area.
• Follow the battery charger manufacturer's instructions.

Specific charging rates or times are difficult to detail due to a number of other features such as:

• The electrical capacity of the battery.
• Temperature of the electrolyte.
• Battery state of charge at the start of the charging period.
• Battery age and condition.

Battery Charging Guide

6-Volt and 12-Volt batteries recommended charging rate and time from a Fully Discharged Condition (i.e. Flat, Discharged).  Fast Recharging is not Recommended.

Check the batteries specifications for the Reserve minutes.

"Calcium" Batteriers - What are they?

The Calcium in "calcium batteries" refers to the lead alloy used in the production of the grids for plate making.  The alloy is typically still 99% lead with alloying metals.

Lead acid starting batteries can be produced from a number of different lead grid alloys.  Pure lead is hardened by the addition of alloying metals, e.g..

Low Antimony Alloy = 1.75% antimony (+ tin, arsenic)
Calcium Alloy = 0.1% calcium (+ tin, aluminum)
Silver Alloy = 0.06% Silver with Calcium (+ tin, aluminum)

Grids can be produced by various methods such as:

• Gravity cast
• Expanded, from cast or wrought lead alloy strips
• Continuous cast

These types of batteries are commonly known according to their grid construction as:

Calcium lead alloys are not new, calcium having been considered as an alternate hardener for lead alloy in the 1930's.

Calcium alloy grids are used primarily

1. because of their low water loss and low self discharge characteristics, and
2. the rapid solidification point of the alloy allows the operation of continuous grid making process.

Calcium lead alloy grids were found to be prone to grid growth and cracking, leading to premature battery failure.  This has been controlled by modifying the alloy and roll hardening the positive grid, or the use of calcium/silver alloys.

Maintenance Free Batteries- truly maintenance free?

By definition, a Maintenance Free battery is one which, during its operating life and under normal operating conditions, will not require water addition (maintenance).

All three grid types listed above can be used to produce 'maintenance free batteries'. Regardless of the grid alloy combinations, all batteries will gas and lose water from the electrolyte.

The hydrogen over-voltage increases from antimonial to hybrid, and from hybrid to calcium / calcium construction.  This means that at a given rate of overcharge at the same temperature, an antimonial battery will consume more water than a hybrid, and a hybrid will consumer more water than a calcium / calcium build.

A healthy electrolyte reservoir (volume of electrolyte above the plates) in the battery is critical for maintenance free performance, regardless of the grid combination used.  Sealed cover type MF batteries (eg. AC Delco) will still gas during overcharging and lose water from the electrolyte reservoir.   The ability to still service an MF battery subjected to adverse conditions will extend operating life.

Calcium Alloy Batteries - the Pros and Cons

Some typical calcium alloy battery characteristics, when compared with low antimonial batteries are:

• Lower self discharge rate, which increases shelf life and extends the charge period during shipping of vehicles.  At the same temperature, shelf life periods are typically 2 months for low antimonial, 4 months for hybrid and 8 months for calcium / calcium.
• Lower water loss (gassing rate) under overcharging conditions.  Test by VW-Europe showed the following comparative water loss rates:

• Lower internal resistance which provides a small increase in CCA performance.
• Higher charge rate acceptance.
• Can result in reduced positive grid life under cycling conditions, and at elevated operating temperatures.  Positive plate failure can be through grid corrosion or loss of positive active material.
• 'Barrier Layer Sulphation' problems occur if fully discharged (flat).  The battery can then be difficult to recharge, requiring a higher voltage charge.  Battery life may be reduced as a result of 'barrier layer sulphation' as full capacity may not be regained.
• The key to the life and performance of calcium / calcium MF batteries is in the tight control of the manufacturing process and positive plate grid alloy specifications.
• OE manufacturers fitting calcium / calcium batteries look for benefits in a longer 'stand' life (lower self discharge).  This helps increase the probability of the vehicle starting after overseas shipment.   Lower self discharge can help to offset standing (parasitic) electrical loads of, typically, 10 to 30 milliamps.

Motor vehicle Charging system:

Voltage Control / set point

• While calcium alloy batteries can accept higher recharge voltages, the nominal charging voltage in modern cars is 14.2 volts. (Technically, to charge an antimonial battery, the effective charge voltage is 14.15 volts at 20?C, and 13.75 volts at 40?C).
• There is a trend developing, to reduce rather than increase voltage set points. (Many truck settings are now 14.2 volts for short distance vehicles, and 13.8 volts for long haul vehicles).

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