Engine JAC HFC4DA1-2C. Manual — part 55
SC
SC
SC
SC Battery
Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 10 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
Fault
Fault
Fault
Fault determination
determination
determination
determination of
of
of
of battery
battery
battery
battery
2.
Appearance inspection
Items of Inspection
Cause
Troubleshooting
Case
Damage
①
Battery case crash
②
Incorrect installation
Replace with a new one
Burn
①
Loose connection or poor contact of terminal post
②
External short circuit
Replace with a new one
Explosion
①
Internal short circuit
②
In the case of low electrolyte level, there will be internal spark.
③
Blocked vent
Replace with a new one
Deformation
①
Overcharge
②
Overcurrent charging
③
Blocked vent
Replace with a new one
Battery acid leakage
①
Damaged plastic case due to external impact
②
Inversion or too large tilt angle of battery
③
Unfirm heat seal
Replace with a new one
Terminal post melting loss
①
External short circuit
②
Poor contact
③
Poor welding
Replace with a new one
3.
Voltage inspection
Voltage
When it is above 12.5V,the electric
eye is green
Normal
Load test
When it is between 12.4 ~ 11V, the
electric eye is black
Undercharge
Boost charge
When it is equal to or under 10.5V
①
Overdischarge (Black electric)
②
Short circuit (in general, green electric eye)
③
Open circuit
Replace with a new one
Load test
Green area
Normal
—
Yellow area
Undercharge
Boost charge
Red area
①
Undercharge
②
Short circuit or open circuit
Replace with a new one
SC
SC
SC
SC Battery
Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 11 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
Fault
Fault
Fault
Fault determination
determination
determination
determination of
of
of
of Generator
Generator
Generator
Generator
Fault diagnosis of charging system
Fault symptoms
Fault diagnosis
Troubleshooting
No lightened charging indicator lamp
when the ignition switch is at the 2
nd
gear
① Bulb fault
② Looseness or oxidation of
generator
connectors or battery terminals, poor
connection of ground wire
③ Faults in voltage regulator, rotor or brush
circuit
④ Ignition switch fault
① Install a new bulb.
② Clean and tighten cables of battery or
generator and apply acid proof grease.
Inspect ground wire connectors, clean
and tighten if necessary.
③ Eliminate the open circuit fault
④ Install a new ignition switch
Incorrect
go-out
of
charging
indicator lamp when the engine is in
operation
① Loose drive belt
② Loose or oxidized generator connector,
poor connection of ground wire
③ Unable contact of brush with rotor ring,
stuck brush in conduction direction, wear
and oil stains of brush. Wear of bearing
and slip ring, faults in voltage regulator or
rectifier assembly
① Tension drive belt again
② Clean and tighten connectors
③ Inspect brush connector, clean/loosen
brush if necessary, install a new voltage
regulator or replace the faulted generator
Undercharge
① Loose drive belt
② Fault in welding points of generator
connector
③ Poor connection of ground wire between
voltage regulator and generator housing
① Tension drive belt again
② Install a new voltage regulator or replace
the faulted generator if necessary
③ Clean and tighten connectors
Overcharge
① Voltage regulator fault
① Install a new voltage regulator or replace
the faulted generator if necessary
Noise in operation
① Bearing wear
② Loose pulley
③ Belt wear
① Install a new generator
② Tension
the
pulley
according
to
specified torque. In the case of broken
shaft, replace the generator
③ Install a new belt
SC
SC
SC
SC Battery
Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 12 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
Operating
Operating
Operating
Operating principle
principle
principle
principle of
of
of
of generator
generator
generator
generator
The operating principle of generator: divide three-phase
alternating currents (AC) generated by the three-phase
windings into two paths: take one as field current to go
through 3 excitation diodes 1 to D+ end and voltage
regulator 5, then go through moving contacts and slip
rings to field winding, finally, return to the voltage
regulator through slip rings and sliding contacts; The
other one goes through positive rectifier diode of
three-phase full-wave velocity converter bridge to
electric appliances in the vehicle and then returns
through negative power diodes.
Terminal B+ is an output one and Terminal D+ is
connected to charging indicator lamp and ignition
switch in the external circuit and then is connected to
battery positive pole. When starting the engine, contact
points of the ignition switch are closed and form initial
field current in field winding with the charging indicator
lamps lightening simultaneously (lighting inspection). In
the case of engine in idling operation condition, the
indicator lamp goes out. During vehicle running, if the
charging indicator lamp is lightened, it indicates faults
in generator system.
The hybrid germanium transistor voltage regulator is
adopted in this generator, consisting of a ceramic wafer
with protective resistance and an integrated circuit
enclosed in seal housing. It plays a role in: keeping a
constant output current of AC generator in the case of
wide engine speed range and large output current
change.
SC
SC
SC
SC Battery
Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 13 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
Precautions
Precautions
Precautions
Precautions of
of
of
of generator
generator
generator
generator maintenance
maintenance
maintenance
maintenance
For the output current of generator is generated by
stators and rectified by rectifier diodes, please pay
attention to following aspects in generator inspection
and regulation:
1.
Pay attention to generator ground polarities and it
is not allowed to connect reversely. In the case of
reverse connection of generator and battery
polarities, it leads to positive conduction of
power diode and the diode is burnt by the large
current
goes
through
it.
Therefore,
correct
polarities are necessary in battery replacement.
2.
It is not allowed to use screw drivers or wires to
ground output terminal and housing of generator
for live wire test. For instant large current or high
voltage
electromotive
force
generated
by
induction may puncture or burn down the power
diode.
3.
It is not allowed to connect two terminal posts for
test with screw drivers or wires or there shall be
fast rise of generator voltage which may lead to
voltage regulator damage.
4.
In the case of fast charging with large current
from AC generator to battery, when the charging
current is discovered getting smaller or ever
being close to 0, please verify for the existence of
faults in charging part. In the case of voltage
regulator fault or excessively
high
voltage
regulation, please carry out maintenance as soon
as possible to avoid early damage in battery and
electric appliance of generator field winding.
5.
In the joint operation of generator and voltage
regulator, the output voltage is very stable.
However, in the case of their inspections and
applications,
they
should
be
connected
to
on-board battery in parallel for application. When
the generator is outputting a large current, sudden
disconnection with battery may generate an
excessively high peak voltage. In this case, even
there is only a short-time existence of the peak
voltage, it may lead to damage of other electronic
parts.
Therefore,
pay
attention
to
relevant
inspection and application, do not disconnect the
connection of generator in operation with battery
at any case.
6.
It
is
necessary
to
guarantee
the
reliable
connection
of
the
connecting
ground
wire
between the generator and chassis.
7.
It is not allowed to ground the power supply lead
in the operation of generator or it may lead to
harness burn.
8.
In generator inspection, it is necessary to fill the
generator sealed bearing with sufficient No.2
lithium base grease before the next maintenance.
9.
It is not necessary to maintain the voltage
regulator, In the case of its damage, replace the
voltage regulator assembly.
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