01

INTRODUCTION

02-03
DEFINITIONS OF AUTOMOTIVE BATTERIES

04
BATTERY PERFORMANCE

05
BATTERY TEST PROCEDURE

06
POST ABUSE INDICATORS

07
BATTERY REMOVAL & FITTING CHART

08
JUMP START GUIDE

09
BATTERY CARE & MAINTENANCE

10-11
BATTERY SAFETY TIPS

12
BATTERY BAY SETUP

13
BATTERY LAYOUT

14-15
BATTERY SPECIFICATION SHEET
 WILLARD BATTERIES ®

Rooted in the hearts of South Africans, Willard® Batteries combines technology and a quest for
perfection to bring you a battery of unrivalled standing.

Our Willard® product range is manufactured in Port Elizabeth. With a presence in SA since the 1920s,
local production started in 1954. Today, the factory still reflects the true South African spirit of
combining imported state-of-the-art technology with solid South African ingenuity and know-how.

Over the years, Willard® Batteries has built a strong track record of service excellence and has
maintained the core attributes of the brand that has helped define it: its values, its culture and the
long-term relationships it has built with its customers. In the future, Willard® Batteries is looking to
continue to build and live its brand legacy as it strengthens its bonds with both its suppliers and its
customers.

01
VENTED (FLOODED) BATTERY

This is the most common of automotive battery types. This type of battery has a cover with one or more openings
through which gas generated by the battery may escape. The battery has “free” electrolyte which means that the acid
moves freely within the battery.

SEALED MAINTENANCE FREE BATTERY (SMF)

Some specifications use the term “maintenance free” to describe a battery that has a water loss below a certain level.
SMF batteries are flooded batteries that have a mechanism for water to condensate and return to the battery.

ENHANCED FLOODED BATTERY (EFB)

Enhanced Flooded Batteries were developed for use in stop-start vehicles. EFB’s are specifically designed for stop-start
loads, where the battery has to crank the engine several times more, due to frequent stop events, and must have
enough capacity to run vehicle loads while the engine is not running.

VALVE REGULATED (VRLA)

A battery that is closed under normal conditions and has an arrangement that only allows gas to escape if the internal
pressure exceeds a predetermined value. In this type of battery, the electrolyte is immobilised. This mean that the acid
is held in either a gel or a glass mat structure.

A. AGM (Absorbed Glass Mat) is a special design glass mat designed to wick the battery electrolyte between the
battery plates. If the battery is broken, no free liquid can leak out.

B. Gel Cell batteries contain a silica type gel that the battery electrolyte is suspended in; this thick paste like
material allows electrons to flow between plates but will not leak from the battery if the case is broken.

The valve regulated battery is often called a sealed battery because no addition of electrolyte or water is possible.

02
TERMINOLOGY

1. Capacity: is the ability of a fully charged battery to deliver a specific quantity of electricity
(current in amperes) over a definite period of time in minutes or hours.

2. Reserve Capacity: (Cr, n) (Minutes) is the time in minutes a fully charged battery will
supply 25 ampere continuously before the voltage falls to 10,5 volts. This rating
represents the time in minutes which a fully charged battery would continue to supply the
average (25 ampere) should the Alternator fail.

3. Cold Cranking Performance: (CCA) is the cold temperature discharge (-18°C) that a fully
charged battery can supply current in ampere over a predetermined period before the
voltage drops below a specified end-point. The various standards are as follows:

BATTERY RATINGS - ABBREVIATIONS

SANS
South African National Standard
1.4 volts per cell (or 8.4 volts on a 12 volt battery) after 60 seconds

SAE (BCI)
Society of Automotive Engineers
1.2 volt per cell (7.2 volts on a 12 volt battery) after 30 seconds

03
 Optimum performance

Malfunctions in the system

Or the opposite

04
Perform Test – Use Battery Diagnostic Tester

Out of Vehicle Test Perform in Vehicle - Test if required

Select Battery Type

Starter System Test
Regular
Gel
AGM
Charging System Test
Select Battery Standard for SAE
- Use Battery Diagnostic Tester.
CCA
EN - Refer to operating manual for decision
IEC and interpretation of results.
SAE
DIN
Select Battery Rating
Battery performs test:
Battery Test Results

Decision Interpretation

GOOD BATTERY Return the battery to service.

GOOD RECHARGE Fully charge the battery and return it to service.
CHARGE & RETEST Fully charge the battery and retest. Failure
to fully charge the battery before retesting
may cause inaccurate results. If CHARGE &
RETEST appears again after you fully charge
the battery, replace the battery.

REPLACE BATTERY Replace the battery and retest. A REPLACE

BATTERY result may also mean a poor
connection between the battery cables and the
battery. After disconnecting the battery cables,
retest the battery using the out-of-vehicle test
before replacing it.
BAD CELL REPLACE Replace the battery.

Test Messages

Conditions that prevent proper testing:

- Refer to Operating Manual.

VOLTAGE STATE OF
% RESULTS
CAPACITY CHARGE (S.O.C)
12.8 V 100% Charged Good Battery
12.6 V 100% Charged Good Battery
12.4 V 75% Discharged Charge & Retest
12.2 V 50% Discharged Charge & Retest
12 V 25% Over Discharged Charge & Retest
11.8 V 0% Over Discharged Charge & Retest

05
Look out for the following signs:

Perfect post.

Excessive force - Over tightening of post clamp.

Melted post - Caused from arc or short.

Bent post - Caused from excessive force and over

tightening.

Indented post - Caused from over tightening of post

clamp resulting in a poor connection.

Corroded post - Excessive corrosion resulting in

post damage.

Chipped post - Caused from reverse connectivity.

NOTE: In the event of any signs of abuse,

the warranty will be null and void.

06
Follow the steps below:

1 The negative(-) terminal must be

5
connected to the ground cable. Carefully place the new
battery into the battery tray.
The chassis of all modern cars are
earthed to the negative of the battery.

Ensure the battery terminals are in the same position

2 Disconnect the negative(-) cable first

in relation to the earth cable, to ensure correct polarity.

to prevent sparks/damage caused by

accidental short circuiting.
6 Replace battery
hold-downs. Secure
hold-down nuts
tightly.
Second, disconnect the positive (+) cable.
Remove the battery hold-downs.
Remove the battery from the vehicle.

3 Inspect and clean all 7

corrosion from the battery tray, Reverse the
hold-downs and clamps using connection
clean water. procedure.

First connect the positive.

Replace items damaged by excessive corrosion. Second connect the negative cable.
Neutralise and wash severely corroded components. Ensure cable connections are tight.
Use a solution of Bicarbonate of Soda mixed with warm Coat the terminals with petroleum jelly.
water (10grams, or 1 tablespoon, to 1 litre of water). Do not use grease which may contain

8
metal additives.

4 Use a post cleaner Installation

to clean post and complete.
clamp. Start vehicle.

Caution: Certain vehicles such as BMW, Mercedes Benz and Audi, require that a slave battery or alternative electrical supply be connected before removing and
installing a new battery:
• Damage to the vehicle’s electronic management system.
• Loss of all electronic management system coding for radios, windows, seats etc.

07
 When connecting the booster cables. In both cars, set handbrakes; turn off all
switches, and place gear selector in Neutral or Park position.
Discharged Booster

1
2

STEP 1: Connect one cable STEP 2: Connect other end of the

to the positive (+) post of the same cable to the positive (+) post
discharged battery. of the booster battery.

Booster Discharged

3
4
STEP 3: Connect the second cable
to the negative (-) post of the booster
STEP 4: Make final connection of
battery.
the second cable on engine block
or chassis of stalled vehicle
Ensure all booster cable connections are secure.

STEP 5: To remove
cables, reverse this
The engine of the stalled vehicle
may now be cranked
exact procedure.

08
For a battery to remain in good working order, it should be maintained in a fully charged state by the vehicle’s charging
system. Where a battery is used as a means of alternative power, it is generally charged by means of an independent
charger or rectifier which supplies controlled direct current (DC). An independent charger is also used to charge motor
batteries that have become discharged due to faulty alternators, charging systems or if left unused for prolonged
periods. If the following hints are adhered to, a battery will provide extended and trouble-free service.

WHAT TO DO
Store batteries in a clean and dry area (in order to prevent deterioration).

Store batteries in a fully charged state. (12V Battery above 12.6V).

Ensure a correct polarity connection when recharging and fitting.

Follow proper recharging schedules to prevent overcharging. Ensure charging is conducted in a

well ventilated area.

Ensure that the battery is always clean and dry, with the terminals coated with petroleum jelly
(Vaseline) or proprietary terminal protectors. Do not use greases which may contain metal
additives.

NB: Practice stock rotation and use a first-in, first-out system at all times.

Always wear protective clothing when working with batteries.

WHAT NOT TO DO
Do not store batteries in a discharged state.

Do not test batteries by shorting across terminal posts with wire, spanners, etc.

Do not allow open flames or sparks near a battery as it could explode (batteries give off
flammable gases).

Do not use a single spanner to use loosen or tighten the terminal clamp as this could damage to
post lid seal. Use a spanner to the nut and a second spanner to the bolt.

Do not use the starter motor to propel the vehicle or leave the vehicle parked with accessories
switched on for extended periods.

Do not lean over a battery when charging or testing.

Do not put any metal objects on top of a battery.

09
SULPHURIC ACID (SULPHURIC ACID EMERGENCY PROCEDURES)
Skin contact: Immediately drench the affected area with clean water and remove any
contaminated clothing. If any soreness or irritation persists seek medical advice.

Eye contact: Immediately wash out the eyes with clean water until initial burning subsides. Do
not use eye drops but do seek prompt medical attention.

Ingestion: DO NOT induce vomiting but make patient drink as much water or milk as possible,
followed by milk of magnesia, beaten eggs or vegetable oil and seek immediate medical
attention.

Spillage: Small spillages can be quite simply dealt with by rinsing away with plent of water and
neutralising using Bicarbonate of Soda mixed with water (10 grams Bicarb to 1 litre water).

Burns: Apply a dry sterile dressing and seek medical attention.

SULPHURIC ACID HANDLING TIPS

Sulphuric acid (H2SO4) is contained in batteries. Battery acid is a poisonous and corrosive liquid, which will cause burns
and irritation to the skin and eyes. Take precautions when charging as sulphuric acid is given off in a fine mist.

Always handle batteries with care and keep upright.

Disposal: Suitably labelled, acid resistant containers should be used for transporting,
neutralising and disposal of sulphuric acid.

Use eye protection and protective clothing where there is any risk of acid splashing or spillage.

Keep, charge, check and test batteries in a well ventilated area.

Do not place tools or conductive objects on top of batteries.

Before using a battery charger consult manufacturer’s literature.

Remember to switch the charger off before connecting or disconnecting the battery.

EMISSION OF GASES
Hydrogen and oxygen can be generated and emitted. An explosive atmosphere is created if the
concentration of hydrogen in air exceeds 4%.

10
 Keep, fill, charge, check and test batteries in a well ventilated area.

Avoid sources of ignition close to batteries. In particular: No smoking. No naked

flames. Switch off current before making or breaking electrical connection.
Avoid sparks caused by accidental short circuits.

EMERGENCY PROCEDURE FOR TREATING ELECTRIC SHOCKS

Electric Shock: Immediate action is essential in cases of severe electrical shock as the nerves
controlling breathing and heart action may be affected. Do not delay treatment by calling for a
doctor; this should be done quickly if help is available or when the casualty recovers.

Make sure it is safe to approach casualty. If the casualty is not clear of the electric source,
switch off the power. If this is not possible, attempt to separate the casualty from the conductor
using a dry, insulating object (wood, rubber, brick, thickly folded newspaper, cardboard) and try
to push or pull the casualty clear of contact. Do not touch casualty with bare hands.

Apply artificial respiration if necessary. Seek medical attention thereafter.

Explosion: Seek any necessary medical attention and remember that sulphuric acid may have
been ejected.

ELECTRICAL ENERGY HANDLING TIPS

Electrical energy can be supplied from batteries and charging equipment.

* Burns may occur from the heating effect of tools and conductive objects in contact with live
battery terminals or conductors. In addition, sparks and molten metal may be ejected and co
bustible materials, notably the gaseous fumes, ignited to cause potentially lethal explosions.

* It is possible to receive a severe electric shock from charging equipment and from a number of
batteries connected in series i.e. five or more 12 volt batteries (+60 volt nominal).

Before using conductive tools on a battery, remove metallic personal adornments from the
hands and wrists.

Before working on a vehicle’s electrical system, blow across the terminals and the vent holes to
disperse any fumes and disconnect the battery where there is any risk of accidental short
circuits. Always disconnect the earth terminal from a battery first and connect it last to prevent
short circuiting.

Use eye protection and protective clothing where there is any risk of acid splashing or spillage.

11
TEST & CHARGE
Z
EQUIPMENT
REQUIRED: Battery Charger Battery Analyser Work Bench

Eye Acid Proof Safety

Protection Overall Shoes

Apron Safety Gloves

SAFETY
EQUIPMENT:
TOOLS: RELATED
Terminal Cleaner
ACCESSORIES:
Battery Hold Downs
Battery Connectors

Jumper Cables J-Bolts

Booster Pack Positive & Negative

Cable
Required Spanners/
Size 10 and 13
Positive & Negative
Shifting Spanner Terminal Clamps

Hack Saw Battery Trays

12
12 VOLT CELL LAYOUT

4 5 6

7 TERMINAL TYPE A
17.4 mm 15.8 mm

SPECIAL FEATURES 19 mm 18 mm

1. One piece DIN type cover

2. One piece flat top cover
3. Single cell lids with exposed connectors TERMINAL TYPE B
4. Polypropylene container
5. With handles 12.7 mm 11.1 mm
6. 9mm Clip on side hold-downs optional
7. With clip on shoulders 19 mm 18 mm

CONTAINER HOLD-DOWNS
B0 B1 B3

10.5 mm
10.5 mm
10.5 front, back & ends
10.5 front, back & ends
No bottom hold-downs

B4 B5
10.5 mm

19 mm 29 mm
19 front, back & ends
10.5 front, back & 29 ends

B13 B6

29 mm 10.5 mm 29 mm 29 mm

29 ends
19 & 10.5 front & back, 29 & 10.5 ends

EXAMPLE: B5. 2. 4
(10.5 FRONT & BACK & 29 ENDS)
B5 = Container Hold-down
2 = One piece flat top cover
13 4 = Polypropylene
 +U 5HVHUYH 6$16 0D[ 2YHUDOO
6$%0$ ',1&&$ 6$(&&$ ,(&&&$ 2YHUDOO &HOO &RQWDLQHUKROG 6SHFLDO
:LOODUG&RYHU &DSDFLW\ &DSDFLW\ &&$ OHQJWK KHLJKW 7HUPLQDOOD\RXW
1XPEHU $PSV $PSV $PSV ZLGWKPP OD\RXW GRZQ IHDWXUH
$K 0LQXWHV $PSV PP PP
/LJKW
 )ODW           $ % 
 60)           $ % 
 60)           $ % 
 &9           $ % 
 )ODW           % %
 )ODW           % %
 &9(XUR           $ %* 
 60)           $ % 
 &9(XUR           $ % 
 60)           $ % 
 )ODW           $ % 
 60)           $ % 
 )ODW           $ % 
 60)           $ % 
 )ODW           $ % 
 )ODW           $ % 

14
 )ODW           $ % 
 60)           $ % 
 &9           $ % 
 60)           $ % 
 )ODW           $ % 
 60)           $ % 
 )ODW           $ % 
 60)           $ % 
 &9           $ % 
 &9(XUR           $ % 
 &9           $ % 
 60)           $ % 
 )ODW           $ % 
 )ODW           $ % 
6 )ODW           $ % 
 60)           $ % 
 60)           $ % 
 &9           $ % 
 &9           $ % 
 60)           $ % 
 +U 5HVHUYH 6$16 0D[ 2YHUDOO
6$%0$ ',1&&$ 6$(&&$ ,(&&&$ 2YHUDOO &HOO &RQWDLQHUKROG 6SHFLDO
:LOODUG&RYHU &DSDFLW\ &DSDFLW\ &&$ OHQJWK KHLJKW 7HUPLQDOOD\RXW
1XPEHU $PSV $PSV $PSV ZLGWKPP OD\RXW GRZQ IHDWXUH
$K 0LQXWHV $PSV PP PP
 &9           $ % 
 &9           $ % 
 (XUR       $ %
 (XUR       $ %
 &9(XUR           $ % 
 &9(XUR           $ % 
+HDY\'XW\
 )ODW           $ % 
 60)           $ % 
 60)           $ % 
 )ODW           $ % 
& 60)       $ %
&6 60)       7KUHDGHG3RVW %
 60)           $ % 
 60)           $ % 6
 )ODW           $ % 6
 60)           $ % 6

15
 )ODW           $ % 6
 )ODW           $ % 
 60)           $ % 
 60)           $ % 
 )ODW           $ % 
 )ODW           $ % 
 60)           $ % 
 )ODW           $ % 6
 60)           $ % 6
 )ODW           $ % 
 )ODW           $ % 
 60)           $ % 
 )ODW       $ %
 60)           $ % 
 &9           $ % 
 &9           $ % 
&9 &9           $ % 
 )ODW           $
 ^D&       ϯϰϱ ϭϳϱ Ϯϲϰ ϰ 
DEPENDABLE
IS A 7 LETTER WORD.
And that 7 letter word is Willard.

9 Tonnes of precious cargo. Another eight hours to reach your destination. Out on the open road you
need a reliable battery to get you there on time. Every time. With Willard Batteries you can depend
on the power of the technology to share some of your load.

Willard. The last word in start-up power.

willard.co.za