2.11  Starting  /  Charging  System
JL4G18-D

2.11.1 Specifications
2.11.1.1 Fastener Tightening Specifications

Applications

Model

Specifications

Metric (Nm)

US English (lb-ft)

Battery Cable Nut

M6

8.5-12

6.3-8.9

Battery Bracket To Battery
Stud Nut

M6

7.5-10.5

5.6-7.8

Battery Terminal Bolt

M6 × 34

8.5-12

6.3-8.9

Battery Upper Bracket Bolt

M10 × 1.5 × 20

13

9.6

Generator Drive Shaft Nut

M24

100

74

Generator Upper Mounting Bolt

M8 × 30

20-30

14.8-22.2

Generator Screw

M10 × 1.25 × 72

44-64

32.6-47.4

Starter Electromagnetic Switch
Assembly Screws

M6 × 28

8

5.9

Starter Solenoid Switch
Terminal To Battery Cable
Terminal Nut

M13

10

7.4

Starter To Engine Block
Mounting Bolt

M10 × 1.25 × 60

37

27.4

Starter To Transmission
Mounting Bolt

M10 × 1.25 × X80

37

27.4

2.11.1.2 General Specifications

Battery Specifications

Applications

Specifications

Cold Start Current

400 A

Rated Capacity

60 A/h

Rated Voltage

12 V

Start Motor Specifications

Applications

Specifications

Starter

No-Load Test (12.2 V )

40-90 A

No-Load Test Power Consumption

0.5 kW

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Applications

Specifications

Drive Gear Speed

2,600-4,800 rpm

Solenoid

Coil (12.2V)

35 A

Suction Coil (12.2V)

35 A

Generator Specifications

Applications

Specifications

Current

90 A

Model

JFZ1906

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2.11.2 Description and Operation
2.11.2.1 Battery Description and Operation

Warning!

Refer to "Battery Acid Fluid" in "Warnings and Notices".

This vehicle uses uses a maintenance-free battery, which is
different from a conventional battery. There is no vent plug in
this battery. Apart from a small vent on both sides of batteries,
the battery is completely sealed. Vent holes can discharge a
small amount of gas generated by the battery. The electrolyte
inside  the  battery  generates  a  small  amount  of  gas  after
chemical reactions. If there is no exhaust vent, battery internal
pressure increases as the gas pressure increases. When the
pressure is over limit that the battery shell can withstand, the
battery shell will break.

Compared  with  a  conventional  battery,  this  battery  has  the
following advantages:

–

No need to fill water during the life of the battery.

–

Overcharge protection.

–

Electricity leakage is less likely to happen as compared with
a conventional battery.

–

Lighter, smaller and capacity is larger.

In the entire electrical system, battery has main functions:

–

Provide energy to the starter for starting the vehicle.

–

Play a role as the electrical system voltage regulator.

–

When  the  generator  electrical  system  capacity  can  not
meet  the  demand,  the  battery  can  provide  power  in  a
certain period of time.

Battery technical parameters explained:

1. Rated capacity: Witt the minimum output of electrical loads

and without generator power, the time the vehicle drives at
night.

2. Cold  start  current:  Starting  current  when  the  battery

temperature is -18°C.

If  the  battery  test  is  normal,  but  the  battery  voltage  often
appears  inadequate,  the  vehicle  can  not  start  at  night  etc.,
consider the reasons from the following aspects:

–

Electrical  equipment  in  the  vehicle  remain  turned  on  all
night.

–

Driving speed is low, stop and start frequently.

–

Vehicle  electrical  load  exceeds  the  generator  output,
especially  if  the  vehicle  is  equipped  with  aftermarket
equipments.

–

Charging  system  fault,  such  as  electrical  short  circuit,
generators belt slipping, generator malfunction or voltage
regulator malfunction.

–

Improper  use  of  the  battery,  including  failed  to  maintain
battery  cable  terminals  clean  and  tighten,  or  the  battery
bracket is loose.

–

Mechanical failure in the electrical system, such as short
circuit or circuit damage.

2.11.2.2  Starting  System  Description  and
Operation

Starting  system  includes  the  battery,  ignition  switch,  starter,
starter  relays  and  related  circuits,  all  of  these  parts  are
connected by circuits. When the ignition switch is turned to "ST"
position, the starter relay pull-in and provides power to starter
motor magnetic switch, starter motor runs. For specific control
principle. Refer to 

2.11.3.1

 

Starting System Working Principle

.

2.11.2.3  Charging  System  Description  and
Operation

Charging  system  includes  the  battery,  generator,  instrument
cluster and relevant circuits. Generator consists of the voltage
regulator, rectifier, stator and rotor, which are all installed inside
the generator housing. When the engine rotates, the drive belt
drives the generator to rotate. The generator rotation generates
an alternating current, which is converted to a direct current by
the diode rectifier and then transmitted to the charging system.
Voltage  regulator  automatically  adjusts  the  generator  field
current to control voltage output to keep it within the appropriate
charging  range.  For  detailed  working  principle.  Refer  to
the

2.11.3.2

 

Charging System Working Principle

.

Charging Process:

1. Remove the sealed-type battery from the vehicle and install

proper  adapter  components.  Make  sure  that  all  the
charging cables are clean and firm. To achieve best results,
charge the battery when the electrolyte and electrode are
at room temperature. If the battery temperature is too low,
the charger may not start charging after a few hours.

2. Charge  the  battery  until  the  battery  is  full  or  the  tested

battery  voltage  is  close  to  full  load  capacity.  Check  the
battery every half an hour during charging.

3. Test  the  battery  load  after  charging.  Refer  to

2.11.7.9

 

Battery Discharging Current Parasitic Load Test

.

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Charge a fully discharged battery (off the vehicle):

Strictly  abide  by  the  following  procedure,  otherwise  a  good
battery might be mistakenly replaced .

Follow  the  following  procedures,  charge  a  fully  discharged
battery:

1. Measure  the  battery  terminal  voltage  with  a  precision

voltage meter. If the reading is less than 10 V, the charging
current will be low. The battery can only be charged with
more than a few mA of current after a certain period of time.

2. Set the battery charger at a high value.

3. Continue to charge the battery, with 16V charging voltage

for more than 4 hours:

•

If after 4 hours, there is still no charging current. The
battery should be replaced.

•

If  there  is  charging  current,  then  the  battery  intact.
Continue to charge the battery until it is fully charged.

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