Archive for the ‘Electrical System’ Category.

General Inspection – BRAKE WARNING LAMPS

PURPOSE
A brake warning lamp may be a handbrake light, a master cylinder level indicator or a master cylinder losing excessive fluid which enables the switch to be activated.

THINGS TO LOOK FOR
The most serious light indicator is a brake light staying on because the system is leaking excessive fluid.  The first step is to check the fluid reservoir.  If it’s exactly at the full mark while you have the cap off, push the level indicator down to see if the light goes out.  Also check the hand brake lever to see if the light fades or goes out if you manipulate the on and off on the handbrake.  If either works, disconnect the connection to the master cylinder.  If the light goes out have your mechanic inspect it before you drive it anywhere as the light connected to the master cylinder, the warning brake light, is a brake fluid loss indicator.  This is a serious problem.

IS IT EXPENSIVE TO REPAIR?
Costs may vary, depending on the source of the problem.

TEMPORARY REPAIR AND LONG TERM REPLACEMENT
Disconnecting the warning lamp to prevent the light from coming on is not the way to go as it’s designed to prevent the brakes from failing.

This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

General Inspection – BRAKE LIGHTS

PURPOSE
Brake lights are designed to let other drivers know when you’re braking.

THINGS TO LOOK FOR
The problem with brake lights is that it’s hard for the driver to know if they are operating or not.  One way to check this is to reverse close to a wall at night and view the reflection of the brake lights in the rear vision mirror.  Also you can ask a friend to view the rear lights while you depress your brake pedal with the ignition on.

IS IT EXPENSIVE TO REPAIR?
Brake globes are cheap at under $2.00 each.  If you decide to fit a globe make sure  that the new globe has the same voltage and wattage as the old one as this will affect the brightness of the globe.

TEMPORARY REPAIR AND LONG TERM REPLACEMENT
If you find that the globe is out, give the assembly a light tap or remove the globe and refit it.  This may resecure the connections and the globe will become operational again.  A discoloured globe is a dead globe that needs to be replaced.  There is only one way to fit a globe.  It has offset mechanism.  This will be explained in the video.

 

This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

General Inspection – Loose fan belt

THE EFFECT
A loose fan belt is a fan belt screaming out for help.  Also a loose fan belt may perish or deteriorate rapidly depending on whether it’s a polyrib belt or a ‘V’ belt.  A loose fan belt will also affect the charge rate and the cooling system if the water pump pulley is connected to that fan belt.  Any fan belt that is loose will affect what it’s driving.

THINGS TO LOOK FOR
Check the belts for tension.  If they feel loose, tighten them up.

COST
Nothing; if you do it yourself!  When you check the fan belt make sure there is no oil around the fan belt and it isn’t cracked.  An oily or cracked fan belt is a fan belt that is no longer useable.  With an oily fan belt you will have to get the oil leak fixed ASAP as it will affect the belt until it is repaired.  Also the oil leaks onto the road and that can become a safety hazard.  Fan belts cost between $5.00-$65.00 depending on the make and model.  Some fan belts are difficult to changeover, so it might be a good idea to get your mechanic to fit a new fan belt.  When checking one belt, check all of them, as they all seem to go at the same time.
This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

General Inspection – Thermo fan not switching on

THE EFFECT
The car will overheat mainly when it’s idling.

THINGS TO LOOK FOR
A thermo fan should switch on periodically when idling.  If it does not, make sure the connection to the thermostatic fan switch is okay. A fan fuse might also have gone.  Check all the fuses. Find the thermo fan relay, wiggle the relay or swap that relay with an air conditioning relay, provided that the amperage on the relays are all the same.

COST
Depending on why it’s not switching on.  If it’s the fuse it will only cost 50 cents but if it’s the thermo fan switch it could cost around $90.00.  The thermo fan itself could cost $150.00.  The wiring could cost $30.00 to correct.  The thermo fan not switching on may be bypassed or bridged at the relay or at the connection, just to get you home.

 

This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

General Inspection – Thermo fan switching on

THE EFFECT
The cooling system will maintain normal operating temperature under all driveable conditions. 

THINGS TO LOOK FOR
It’s always a good idea to look at the thermostatic fan to understand how it operates.  Because thermostatic fans are thermostatically controlled, they should switch on and off.  A good thermostatic fan in a very good cooling system will switch on for between 20-40 seconds.  If the fan switches on for longer than 60 seconds this might be a cooling system that is unable to cool down with the thermostatic fan. If the fan stays on for 5 seconds then this is an excellent cooling system as it never requires a lot of effort from the thermo fan.

 
This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

General Inspection – BALLAST RESISTOR – if fitted

PURPOSE
The bells resistor lowers the operating voltage to the coil from 12 volts down to 9 volts to maintain a low voltage to the points and condenser.  The bells resistor is bypassed when the starter motor is cranking the engine.  The bells resistor has a working life of approximately 10 years. 

THINGS TO LOOK FOR
Most bells resistors are open circuit making it impossible to start ..The most effective indication of this is when cranking the engine, the engine nearly starts and as you release the key, the engine will stop.  Using a test light, a faulty resistor will only have power to one side with the ignition on. 

IS IT EXPENSIVE TO REPAIR?
The bells resistor is probably the most inexpensive component to replace costing between $5.00-$15.00.

TEMPORARY REPAIR AND LONG TERM REPLACEMENT
A faulty bells resistor may be bypassed but don’t leave it as it will affect the ignition system.  The only time to bypass a bells resistor is when it needs to be tested to prove that it is the bells resistor that is faulty by connecting and bypassing it.

 
This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

Battery Recycling

Protecting The Environment And Preserving Resources

Recently, business and individuals alike have all become more aware of the need to make every effort to protect our environment and preserve the earth’s vital resources.  History has shown that a number of products and practices that were taken for granted eventually proved to be of major concern to the future of the planet.  For example, air-conditioning and refrigeration contributed greatly to health and comfort the world over, yet escaped CFC’s are said to be damaging the earth’s protective ozone layer, creating a serious global problem.  Batteries need to be considered in a similar light.  While they are a necessary part of everyday living and vital to our way of life, they also represent a major challenge in terms of their environmental impact.

The car battery under your car bonnet contains around 10 kilos of lead, 4 litres of electrolyte, of which about one third is sulphuric acid, and about 1 kilo of durable plastic.  In other words, it’s bulky, it’s heavy and all of its components are either hazardous to humans and the environment or non biodegradable.

Now, the challenge for the battery industry is to harness the same technological ingenuity that has served us in the past to provide the answers for the environmental dilemmas facing us today and tomorrow.  Now, turning the environmental challenges of recycling batteries into opportunities is good business.

GNB Battery Technologies have led the way with the introduction of  ‘Total Battery Management’. It’s a great example of post-consumer recycling in which components of a consumer product – after its usefulness is exhausted – are recycled right back into more of the same product.

Taking care of problems in our own backyard
Based on recent surveys, it is estimated that throughout Australia there are about 1.4 million spent batteries lying in gardens and garages.  Acid spillages from these batteries are potentially dangerous to humans and can also pollute the ground itself.  Acid spillages onto the ground will contaminate soil, while in the case of concrete, acid spillage will cause severe damage.

So how do you get rid of it?  The answer is not to get rid of it, but to recycle it.  If spent batteries are just dumped they cause several problems.  Not only do they add volume to the ever growing landfills, but they represent a considerable environmental danger as the cases eventually deteriorate, crack and leak dangerous acids.  While recycling batteries has no easy or ready made solution, it is one that is a major priority if we are to make our environment a healthier and safer place for future generations.

Already, batteries lead the way in recycling terms, and unlikely as it first might seem, the percentage of batteries recycled is well ahead of paper, glass and aluminium.

Because the earth’s resources are not infinite it is becoming increasingly important to continue developing more efficient methods of recovering and recycling batteries.  This will enable us to rely less and less on having to mine the earth for the raw materials need to manufacture new batteries, placing less demands on existing resources and reducing the possible environmental concerns that may confront us in the future.

Simply following these steps when disposing of batteries will go a long way to protecting our environment and our future.

· Do not put them in household garbage
· Do not leave them around the home
· Do not throw them in the tip

Instead, they should be returned to:
· a retailer when making a battery purchase
· a service station or auto electrician
· a scrap metal merchant
· a GNB outlet

You can play your part in helping the environment by returning old batteries.  At the same time you’ll also be helping to keep the cost of new batteries down by reducing manufacturing costs.

· The same transportation network that distributes new batteries also takes responsibility for safely picking up spent batteries and trucking them from the point of exchange to GNB recycling plants which begin the resource recovery process.  Batteries are broken up and recyclable components are recovered.
· Plastic pellets recovered from old cases and covers are used to manufacture new battery cases and covers.
· Lead ingot recycled from old plates and lead oxide materials are used to manufacture new battery grids and lead oxide plate material.
· Sodium sulphate crystals chemically separated from old battery acid are recycled and sold to other industries as raw material for detergents, textiles and glass.

Battery Recycling

Battery Recycling

This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

Warranty Claim Procedure

· Check batteries for obvious damage such as cracked or broken cases, terminal damage or broken electrical leads.
· Check that the battery is secure in its compartment.  Tighten hold-down clamps if necessary.
· Check that the alternator drive belt is not loose and tighten if necessary.
· Check the vehicle charging system by starting the engine and adjust the engine revs to approximately half the normal throttle opening, then measure the battery voltage after is has stabilised.
· It should read between 14.1 and 14.4 volts to maintain the battery correctly.  If it reads less than 14.0 volts or more than 14.5 volts the regulator is faulty and will cause battery failure in time due to improper charging.  An auto electrician is needed to rectify this problem.
· Make sure that the top of the battery is clean.  Wash with a diluted solution of bicarbonate of soda and wipe dry with a clean cloth.
· Make sure the battery terminals and cable connections are clean and tight.  Coat terminals with Vaseline or petroleum jelly to stop corrosion.
· If the battery has removable vent caps, check the specific gravity of each cell with a hydrometer.  A good battery should have a specific gravity of 1240 or higher in all cells. Ifs the specific gravity is even in all cells but reads below 1220 the battery is probably serviceable but needs to be recharged.  If one or two cells are significantly lower in specific gravity reading than the others, the battery is suspect and could fail at any time.  Recharge the battery and carry out a load test to verify the battery’s condition.
· If the electrolyte level is low, top up each cell with distilled or deionised water to approximately 12mm above the top of the plates, then charge the battery.
· Check the open circuit of the battery with an accurate digital voltmeter.  Conventional low maintenance batteries should read 12.4 volts or higher and sealed maintenance free batteries should read 12.5 volts or higher.  If the reading is below these cut-off levels, the battery needs to be charged and then load tested to confirm whether it is faulty or not.
· Charge rates for various battery types are available from the manufacturer or your nearest battery service agent.
· Carry out load test to see if the battery is serviceable.

HRD testers are available as either fixed or variable load testers.  Operating instructions and procedures may vary from brand to brand.  The following procedures are indicative only.  When available, the manufacturer’s instructions should be followed.

Using a fixed load HRD tester
· Attach tester clamps to battery terminals in correct polarity (usually red to positive [+ve] and black to negative [-ve] ).
· Set selector switches on load tester to appropriate battery range.
· Apply load test for 10 seconds.
· Read load tester.
· If voltage is at or above the minimum voltage specified by the tester manufacturer then the battery is not faulty, and should be recharged and returned to service.
· If the voltage on load is below the minimum voltage specified by the tester manufacturer the battery is fault and should be replaced.

Using a variable load HRD tester
· Attach tester to battery terminals (usually red to positive [+ve] and black to negative [-ve] ).
· Set selector on load tester to 50% SAE cranking current or 3 times the 20 hour rate if SAE current is not known.
· Apply load test for 10 seconds.
· Read load tester.
· If the voltage is at or above 9.6 volts, then the batter is not faulty, should be recharged and returned to service.
· If the voltage on load is 9.5 volts or below, the battery is faulty and should be replaced.
Recommended Equipment

Battery Testers
For repeated operation:
 DURST 2003F
 6V/12V/24V, heavy duty carbon pile resistor, fan cooled, current up to 500 Amps
 DURST 3006
 6V/12V/24V, heavy duty carbon pile resistor, fan cooled, current up to 1000 Amps
 CHRISTIE CT800
 6V/12V, heavy duty carbon pile resistor, fan cooled, current up to 800 Amps
 For individual operation (not repeated tests).
 CHRISTIE BT900
 Fixed load tester 300 Amps for testing 12 volt batteries up to 900 CCA
 (Note: this machine cannot test 6 volt batteries).

Digital Voltmeters
Wattmaster KD567

Hydrometer
Use a good quality unit

 

This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

Jump Starting An Engine

Warning
Extreme care must be taken when jump starting an engine or serious bodily injury or damage to the vehicles may result.

If jump starting is not done correctly, expensive damage can be done to a vehicle’s electrical system, particularly to those fitted with electronic ignitions.  Check the vehicle operating manual, if there are no specific instructions, then follow these steps.
When jump started, flat batteries generate high volumes of hydrogen gas which is extremely explosive, so sparks and naked flames must be avoided at all times.  Do not lean over batteries during the operation.  As a precaution, wear safety goggles and a face shield to protect eyes.
First, check to ensure both batteries are the same voltage (6 or 12 volt) and that the two vehicles are not touching each other.  If the failed battery is open circuit do not attempt to jump start.

* Open circuit batteries can be detected by:
· battery volts reading zero immediately after a high rate discharge test is applied.
· when the battery will not accept charge current.

Carefully follow these steps in order:
Step 1
Warning: Jump starting can damage vehicle electronics.  Check the vehicle operating manual.  If there is no specific instructions then follow these steps.  If the failed battery is open circuit* do not attempt to jump start.

Step 2
· Be sure the batteries of both cars are the same voltage (6 volt or 12 volt).
· Drive the donor car close to the disabled car but ensure that the vehicles are not touching.
· Place both cars in neutral or park and apply hand brake.
Make sure both vehicle ignitions are switched to OFF and all electrical equipment is OFF.

Step 3
Connect the vehicles in the following EXACT sequence and make sure the jumper leads are clear of any moving parts.
· Take the RED jumper lead and connect to POSITIVE terminal (marked + or POS) of the discharged battery.
· Connect the other end of the RED jumper lead to the positive terminal of the charged battery.
· Take the BLACK jumper lead and connect one end to the NEGATIVE terminal (marked – or NEG) of the charged battery.
· Make the final connection to the engine block or chassis of the stalled vehicle (negative earth vehicles only).  Never use Air Conditioner, Brakes or Fuel Lines for engine earth.

Step 4
Start the engine of the stalled vehicle.

Step 5
After starting, allow engine of the stalled vehicle to fast idle for a minimum of 10 minutes before disconnecting the jumper leads (see step 6) to allow the cars electrical systems to balance.  This reduces the possibility of damage to vehicle electronics.

Step 6
Remove the BLACK cable first from the vehicle with the discharged battery then the opposite end from the charged battery.  Repeat for the RED cable.

Step 7
After your car has been jump started, the battery should be recharged with a battery charger.

 
This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

Automotive Battery Care And Maintenance

Keep batteries topped up
Maintaining a sufficient electrolyte level ensures the electrolyte is neither too high or too low.  Use distilled or deionised water and never over fill.

Maintenance free batteries do not require topping up and are fully sealed to resist tampering.  Low maintenance batteries require the addition of water only once per year.

Keep batteries clean and dry
Dirt on a battery’s surface leads to discharge and corrosion.  Avoid spilling oil or grease onto the top of the battery.  To remove dirt or moisture, wash with a solution of bicarbonate of soda and water.  Rinse afterwards with clear water.  Ensure vent plugs are in place at all times.

Check electrical connections
Make sure battery terminals and cable connections are clean and tight.  Coat terminals with Vaseline or petroleum jelly to stop corrosion.

Stop excessive vibration
Vibration reduces the structural integrity of a battery.  Ensure battery is correctly and firmly secured.

Avoid overcharging
Overcharging produces rapid deterioration and corrosion which shortens battery life.

A battery needing to be topped up continually with water is a sure sign that the car’s electrical system requires careful checking.

Precautions
To avoid shorting, metallic objects should not be placed on top of the battery.  Batteries contain hydrogen gas and air in a volatile mixture which is easily ignited.  Keep flames or sparks away from the battery at all times.  Batteries contain sulphuric acid.  Never add acid to cells and keep acid away from eyes, skin, clothing or any other material which may become damaged.  If contamination occurs, use large amounts of water to neutralise and flush acid away.  Batteries are heavy – ensure correct lifting procedures are used when moving batteries.

 

Battery Care And Maintenance

Battery Care And Maintenance

 

This article is found in the Virtual mechanic CD Rom
You can download it for the price of a latte, but you will learn not to buy a lemon
By Darren Gow-Brown, Melbourne Australia ©2009

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