DAF LF45, LF55 Series. Manual — part 335
5
LF45/55 series
Batteries
DIAGNOSTICS
1-1
1. BATTERIES
1.1 FAULT-FINDING TABLE
SYMPTOM: NEW BATTERY HEATS UP CONSIDERABLY DURING FILLING
Possible cause
Remedy
Inadequate formation because of storage in
unsuitable or damp conditions over a long period
Allow to cool
Charge fully
Check the relative density
SYMPTOM: BATTERY OVERFLOWS, BATTERY ACID SPILLS FROM PLUG HOLES
Possible cause
Remedy
Battery overfilled
Siphon off some of the fluid
Overcharging
Check charging voltage
Check/repair charging circuit
SYMPTOM: ACID LEVEL TOO LOW
Possible cause
Remedy
Leaking battery
Replace the battery
Excessive gas development due to charging
current being set too high
Check charging voltage
Check/repair charging circuit
SYMPTOM: RELATIVE DENSITY TOO LOW (<1.240)
STARTING TROUBLE
Possible cause
Remedy
Power consumer left on by mistake
Charge the battery
Insufficient charging
Check alternator drive
Check/repair charging circuit
SYMPTOM: RELATIVE DENSITY TOO HIGH (>1.290)
Possible cause
Remedy
Topped up with battery acid instead of distilled
water
Siphon off some of the fluid and top up with
distilled water
If necessary, repeat this after mixing (charging)
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DIAGNOSTICS
Batteries
LF45/55 series
1-2
SYMPTOM: STARTING TROUBLE
POOR STARTING TEST RESULT
POWER FAILS UNDER LOAD
Possible cause
Remedy
Discharged battery
Charge the battery
Worn battery (plates corroded and worn away)
Replace the battery
Defective battery (“dead cell”)
Replace the battery
Battery sulphated (plates have hardened)
Replace the battery
SYMPTOM: BURNT-IN BATTERY TERMINALS
Possible cause
Remedy
Cable clamps not securely fitted or poor contact
Have the battery terminals repaired, fit the cable
clamps properly and replace the cable clamps if
necessary
SYMPTOM: 1 OR 2 CELLS BUBBLE EXCESSIVELY UNDER HIGH LOAD
(STARTING OR STARTING TEST)
Possible cause
Remedy
Defective cells
Replace the battery
Leaking cell partition
Replace the battery
SYMPTOM: BATTERY DISCHARGES VERY FAST (DOES NOT RETAIN POWER)
Possible cause
Remedy
Insufficient charging
Check the charging. Is the charging time (driving
time) sufficient?
Short circuit in charging circuit
Check the charging circuit
Major self discharging, for example due to
contamination
Clean the battery
Battery sulphated (on examining the plates, they
are found to be hard and, in some cases,
whitened)
Replace the battery
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LF45/55 series
Batteries
DIAGNOSTICS
1-3
SYMPTOM: SHORT BATTERY LIFE
Possible cause
Remedy
Wrong type of battery chosen (for example if the
vehicle has a tail lift)
Replace with battery of a higher capacity
(170 Ah)
Often too deeply discharged
Intermediate charging with rectifier
Not recharged after deep discharge
(white deposits)
Always charge the battery after deep discharge
Alternator capacity too low
Use alternator with higher capacity (100 A)
SYMPTOM: THE BATTERY HEATS UP DURING USE AND CONSUMES A LOT OF FLUID
Possible cause
Remedy
Overloading, or charging voltage too high
Check the charging circuit (voltage regulator)
SYMPTOM: BATTERY HAS EXPLODED
Possible cause
Remedy
Fire or sparks during or just after charging
Ensure good ventilation and exercise due
caution as regards fire and sparks
Short circuit between the battery terminals
Exercise caution when storing conductive
material (for example, tools)
Internal defect (loose connection)
Replace the battery
SYMPTOM: DEFECTIVE ALTERNATOR AND/OR DIODES (RADIO AND OTHER
POLARITY SENSITIVE EQUIPMENT NOT WORKING)
Possible cause
Remedy
Reversed battery polarity, or incorrect charging
Discharge the battery and charge in the correct
direction
Replace the battery and/or alternator if
necessary
SYMPTOM: BATTERY HAS NO VOLTAGE
Possible cause
Remedy
Internal open circuit
Replace the battery
Battery very deeply discharged
Charge the battery and test it; replace if
necessary
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DIAGNOSTICS
Batteries
LF45/55 series
1-4
1.2 SERVICE LIFE
The service life of a battery is significantly
shortened if it used “cyclically”.
This means that the batteries are used a lot
without their being charged.
For example when using a tail lift, cab heater,
microwave oven or cooler box.
This is why batteries in commercial vehicles and
vehicles used for international transport often fail
prematurely (within 1.5 years).
The battery must be charged whenever the
voltage measured across one battery falls below
12.5 V. If the battery is not charged, the
“sulphating” process will begin.
This is a chemical reaction in the battery that
produces lead sulphate. Lead sulphate adheres
to the battery plates and can cause
short-circuiting between the plates, reducing the
capacity of the battery.
However, most lead sulphate breaks down when
the battery is recharged.
If a battery is used (discharged) while it is not
being charged by the alternator, short-circuiting
between the battery plates will occur sooner.
This reduces the capacity and consequently the
service life of the battery.
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