Engine JAC HFC4DA1-2C. Manual — part 54
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Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 6 -
charging current for battery can return to normal
gradually.
In the process of charging, if there is a large
quantity of acid spraying out from battery vent,
stop charging and identify the cause.
In the process of charging, when the battery
temperature exceeds 45 ℃, stop charging. When
the battery is cooled down to room temperature,
go on to charge it with half charging current.
In the process of battery boost charge, check the
status of electric eye once an hour. In the case of
green electric eye, it indicates that the battery is
charged completely and stop charging.
After charging completion and relevant test, it is
recommended
to
apply
grease
on
battery
terminals to avoid electrolytic corrosion.
3.
Correct Application of Battery
�
The discharging time of battery in large current
should not be too long or pole plate shall be
deformed due to overheating that may lead to
short circuit or battery capacity reduction caused
by active material shedding. In the case of vehicle
start, each start time should not exceed 5 seconds
and the interval between continuous starts should
not less than 10~15 seconds;
�
In capacity inspection with high rate discharging
gauge (discharging meter), the discharging time
should not exceed 5 seconds;
�
In normal vehicle running, battery is in charging
state generally; In the case of low power supply
capacity of generator due to improper regulation
of
regulator,
excessive
battery
power
consumption due to frequent vehicle start or
serious battery power loss due to short circuit in
electric appliance, it is necessary to carry out
battery boost charge.
�
After 3 months of battery service time, when the
battery
capacity
is
lower
than
50%
or
phenomenons like underpowered vehicle starting,
dim lighting, abnormal honk etc., off-board boost
charge for battery shall be carried out as well as
normal maintenance. At the same time, pay
attention to batteries in the process of charging
for batteries with the same capacity and different
voltages shall not be charged together. It is not
allowed the mixed use of new and old batteries.
�
The output voltage of vehicle voltage regulator
shall be measured after battery loading and shall
be regulated in the range of 13.8~14.8 V
according to vehicle service condition. The
recommended voltage is 14.4V. In the case of
frequent vehicle application, it is easy to cause
battery overcharge and the voltage should be
regulated to a lower one. On the contrary, in the
case of infrequent vehicle application or frequent
vehicle start, the voltage should be regulated to a
higher one. To avoid overcharge, the voltage
should be heightened while in summer it should
be lowered.
�
In the case of long-term parking, the negative
terminal should be disconnected with vehicle to
avoid
excessive
self
discharge
and serious
sulfating. Under the condition of no battery
power loss, recharge the maintenance-free battery
once every 3 months. In the case of instant power
loss at the beginning of parking, it is necessary to
recharge the battery timely according to the
voltage. In general, when battery voltage is under
12.6V, it is necessary to recharge the battery.
It is not allowed for the battery discharging current to
exceed
that
of
the
maximum
battery
of
the
manufacturer. In general, the discharging current is
4~5 times as large as that of 4~5C20 battery capacity.
It is not allows to test battery electrification with
short-circuit method.
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Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 7 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
1.
Fault diagnosis of Battery
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault symptoms
symptoms
symptoms
symptoms
Cause
Cause
Cause
Cause analysis
analysis
analysis
analysis
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Insufficient
battery power
① Voltage is approximately 12V
② Density is under 1.220dt
③ Underpowered vehicle starting, dim
lighting, low honk
④ The capacity test is in the yellow
area.
① Too low set value of vehicle
regulator
② Power consumption is larger than
that of charging.
③ High start frequency and short
driving distance
④ Insufficient power generation or
circuit fault
⑤ Terminal corrosion or unfirm
connection
① Replace the regulator
② Carry out the off-board
charging
③ Eliminate
generator
or
circuit faults
④ Clean
corrosions
on
terminals.
Overcharge
① Perpetual reddish yellow of battery
case inner wall (operating bolt)
② Separator carbonization or softening
③ Red brown and thick electrolyte
④ Pulpy shedding of positive active
material
① Too high set valve of vehicle
regulator
② Too large current in charging and
too long charging time
③ Closed operating bolt in charging
① Regulate or replace the
regulator
② Charge according to relevant
regulations
③ For mild overcharge, clean it
with water and recharge it
for application.
Overdischarge
① Voltage is under 10V
② Density (proportion) is 1.100g/cm
3
③ Tattletale gray and thick electrolyte
① Apply the undercharged battery
② V ehicle undercharge and too
long service time of battery
③ Short circuit in vehicle circuit
④ Forget to turn off electric switch
⑤ Impure electrolyte or serious self
discharge
① Replace the circuit regulator
② Guarantee the quality and
quantity
of
off-board
charging
③ Eliminate circuit faults
④ Keep a clear head in parking
(to turn off the switch)
⑤ Replace with a new battery
Short circuit
① Voltage is under 10V
② No voltage in faulted cell
③ No proportion in faulted cell
④ Smoking
and
bubbling
in
discharging
⑤ No response from the faulted cell in
charging
① Lead leakage or foreign matter
dropping in battery assembly
② Pole plate bending in battery
assembly
③ Burrs of cluster plate pins
④ Holes or cracks in separators.
⑤ Artificial damage
① Disassemble and analyze it
② Replace with a new battery
Open circuit
① Unusually instability of voltage
② Lead leakage and cavities at the
place 5mm upper than the terminal
top
③ Measure voltage is under 10V and
discharging returns zero
④ Unable current input in charging or
there is abnormal noise
① Poor welding of terminal posts
② Broken busbar
③ Open welding of wall weld
④ Broken intermediate terminal post
① Repair
② Replace with a new battery
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Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 8 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
1.
Fault diagnosis of Battery
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault symptoms
symptoms
symptoms
symptoms
Cause
Cause
Cause
Cause analysis
analysis
analysis
analysis
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Improper
electrolyte filling
① Peculiar smell of electrolyte
② Density
(proportion)
is
above
1.300dt
③ Density is about 1.100dt after filling.
④ Liquid color is light and whitish.
① Impure electrolyte
② Too high ratio of electrolyte
③ Insufficient density
④ Do not fill pure water
① Replace with a new battery
② Adjust the density and carry
out boost charge
③ After
changing
the
electrolyte, adjust charging
with acid of 1.400dt
Sulphating
of
pole plate
① Excessively low battery capacity in
discharging
② Too fast voltage descent speed in
discharging
③ Early bubble generation in charging
④ Too fast and high voltage rise in
charging
⑤ There are white granules and spots
on pole plate surface.
① Insufficient charging time and too
long service time
② Too long storage of battery with
electrolyte and
no timely boost
charge
③ Battery is in the status of liquid
loss and the exposure time of
terminal cluster is too long.
④ Too high electrolyte density
⑤ Too high electrolyte temperature
⑥ Impure electrolyte
① Overcharge method
② Repetitive charging method
③ Washing treatment
④ Replace with a new battery
Battery
cell
electrolyte
leakage
① Low voltage
② When connecting battery cells
are
tilted, electrolyte flows.
③ There is boiling in discharging.
1
Electrolyte flows among battery
cells and
cracks on battery case
2
There
is
vibration
in
transportation.
③ There is vibration in vehicle
running.
④ There are sparking and implosion.
⑤ The heat seal is not firm.
① Repair or replace the case
② Replace with a new battery
Excessive
shedding
of
active material
① Excessive sediments at the battery
bottom
② Excessive low battery capacity
③ Perpetual red brown of cell wall and
operating bolt
④ Red brown electrolyte
⑤ The electrolyte is reddish and there
is
pulpy shedding of pole plate
active materials, separators are in
softening state and negative pole
plate active materials are softening
expansion.
⑥ Massive shedding
① Too high set valve of vehicle
circuit regulator
② Too large current in charging and
too long charging time
③ Too large discharge capacity and
too long discharge time
④ High temperature and long service
time due to long-term vehicle
running
⑤ Unqualified
pole
plate
manufacture
① Clean the sediments with
washing method and charge
it for reuse
② Replace with a new battery
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SC Battery
Battery
Battery
Battery and
and
and
and Charging
Charging
Charging
Charging System
System
System
System
- 9 -
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Test
Test
Test
Test
1.
Fault diagnosis of Battery
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault symptoms
symptoms
symptoms
symptoms
Cause
Cause
Cause
Cause analysis
analysis
analysis
analysis
Troubleshooting
Troubleshooting
Troubleshooting
Troubleshooting
Excessive
shedding
of
active material
① Excessive sediments at the battery
bottom
② Excessive low battery capacity
③ Perpetual red brown of cell wall and
operating bolt
④ Red brown electrolyte
⑤ The electrolyte is reddish and there
is
pulpy shedding of pole plate
active materials, separators are in
softening state and negative pole
plate active materials are softening
expansion.
⑥ Massive shedding
① Too high set valve of vehicle
circuit regulator
② Too large current in charging and
too long charging time
③ Too large discharge capacity and
too long discharge time
④ High temperature and long service
time due to long-term vehicle
running
⑤ Unqualified
pole
plate
manufacture
① Clean the sediments with
washing method and charge
it for reuse
② Replace with a new battery
Reverse
installation
of
polarities
① For one reversed cell, 8V
② For two reversed cells, 4V
③ For the whole reversed cells-12V
Manufacturing quality
① Replace with a new battery
② Disassemble and reinstall
Reverse charging
of polarities
① The voltage is negative
② The colors of positive and negative
terminal posts are reversed.
③ The colors of pole plates are
reversed.
① Misconnection of positive and
negative polarities in charging
① Discharge the capacity of
battery
after
its
reverse
charging
of
polarities
completely
② Charge the battery with
small current and then with
normal current in the case of
response of every cell
③ For serious cases, replace
with a new battery
Battery
explosion
① Terminal post sparking
② Broken positive circuit
③ Holes and cracks in battery case and
cover
① Incorrect installation
② Aged and thin circuit
③ Faulted operation of generator
④ Interference of external sparks
⑤ Insufficient solder for terminal
post
⑥ Broken busbar
⑦ Dropped plate
⑧ Broken intermediate terminal post
⑨ Broken pole plate
① Firmly install
② Replace the circuit
③ Eliminate generator fault
④ Keep the battery away from
heat source
⑤ Always
keep
vent
unblocked.
⑥ Replace with a new battery
Low capacity in
early stage
① Underpowered start
② Low voltage value
③ Slow response
① Unfirm connection or circuit fault
② It exceeds the storage period.
③ Positive pole plate passivation
④ Negative pole plate oxidation
⑤ Slightly leaky separator
① Inspect the circuit carefully
② Carry out boost charge
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