JAC HFC4DA1-2C engine. Service Manual

SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 1 -

Battery

Battery and

and

and Charging

Charging

Charging System

System

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction and

and

and Operation

Operation

Battery..............................................................................................................................................................................2

Mounting Position....................................................................................................................................................... 2
Precautions.................................................................................................................................................................. 3

Generator..........................................................................................................................................................................4

Overview..................................................................................................................................................................... 4

Diagnosis

Diagnosis and

and

and Testing

Testing

Battery..............................................................................................................................................................................5

Maintenance................................................................................................................................................................ 5
Fault diagnosis.............................................................................................................................................................7

Generator........................................................................................................................................................................11

Fault determination....................................................................................................................................................11
Operating principle.................................................................................................................................................... 12

Removal

Removal and

and

and Installation

Installation

Battery............................................................................................................................................................................14

Removal of Battery....................................................................................................................................................14
Installation of Battery................................................................................................................................................ 16

Generator........................................................................................................................................................................18

Removal of Generator............................................................................................................................................... 18
Installation of Generator............................................................................................................................................ 21

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 2 -

Instruction

Instruction and

and

and Operation

Operation

Battery

Maintenance-free battery is adopted by Sunray series with characteristics in low electrolyte consumption. In the
service life of the battery, there is no need to replenish with distilled water. Moreover, other characteristics of the
battery are shock resistance, high temperature resistance and low self discharge. Therefore, the service life of this
battery is twice as long as that of general batteries.

Mounting

Mounting Position

Position

Position of

of Battery

Battery

The battery is mounted on the right side of the engine compartment.

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 3 -

Instruction

Instruction and

and

and Operatio

Operatio

Operation

Precautions

Precautions of

of Battery

Battery

Warning:

Warning: Keep the battery out of the reach of

children. Since there is sulfuric acid in the battery, the
contact of the sulfuric acid with the skin, eyes or
clothes should be avoided. In the case of working
close to the battery, it is necessary to protect your eyes
from being hurt by the spilled out acid solution. Once
the acid solution comes into contact with skin or eyes,
it is necessary to wash with clean water for 15 minutes
at least and go to a doctor immediately. In the case of
mistakenly swallow, it is necessary to go to a doctor
immediately or it may lead to personal injury.

Warning:

Warning: In general, explosive gas may be

generated by the battery. In the case of misconduct of
it, it may lead to personal injury. Therefore, keep the
battery out of flames, sparks or burning objects. In the
case of battery charging or working close to the battery,
it is necessary to protect your face and eyes and
maintain good ventilation. Please follow relevant
instructions or it may lead to personal injury.

Warning:

Warning: In the case of mistakenly short circuit

between the positive and negative terminal posts with
a metal conductor (eg.metal tools, metal wires, metal
parts, etc.), in other word, the external short circuit of
the battery occurs, the generated electric arc may
result in electrode erosion and melted lead alloy
splashing even the burning due to the generation of a
lot of heat.

Precautionary measure: Prevent direct short

circuit between the positive and negative terminal
posts of the battery in battery assembly with metal

tools or fault diagnosis with metal wires.

Warning:

Warning: It is necessary to connect the charger

with the battery properly before turning on the
charger or it may lead to personal injury.

Warning:

Warning: It is necessary to turn off the charger

before disassembling the battery or it may lead to
personal injury.

Attention:

Attention: It is avoided to carry out battery

charging onboard.

Attention:

Attention: It is not allowed to get close to the

battery being charged by the generator. If only
generator is applied in battery charging, it is required
continuous driving over 8 hours for complete charging
without any extra load on the charging system.

Warning:

Warning: In the process of charging equipment

application, it is necessary to follow the instruction of
the manufacture or it may lead to personal injury.

Protection: Please wear safety goggles and

gloves.

Emergency treatment: In the case of battery

burning, disconnect the external short-circuited metal
wire with the battery, using a monkey spanner or other
tools and it is not allowed to contact it with hands. At
the same time, put out the fire with extinguisher.

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 4 -

Instruction

Instruction and

and

and Operation

Operation

Generator

Air-cooled generator is adopted by Sunray series vehicle, conducting cooling via the air blowing from the fan behind
the pulley into the generator shell. The generator is the main power of the vehicle with the function of power
supplying to all electric equipments (except starter) in the normal operation of the starter (above the idle speed) as
well as battery charging.

Explosive

Explosive View

View

View of

of Generator

Generator

1. Stator

2.Rear bearing

3.Rotor assembly

4.Retainer

5. Front bearing

6.Front cover

7.Pulley

8.Pulley nut

9.Fan guider

10. Double labyrinth seal

11.IC voltage regulator assembly

12.Diode assembly

13. Rear cover

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 5 -

Diagnosis

Diagnosis and

and

and Testing

Testing

Maintenance

Maintenance of

of Battery

Battery

Battery status indicator (electric eye):

Green: There is sufficient electric quantity in the

battery for starting the vehicle normally.
Black: There is no sufficient electric quantity in
the battery and battery boost charge is needed.
White: The battery is scrapped and it is necessary
to carry out replacement.

Boost charge of Battery

Under the condition of vehicle starting, in the
case of abnormal applications like excessively
long-term operation of electricals, the electric eye
of the battery becomes darkened even the vehicle
fails to start because of the power loss of battery
due to the lack of normal battery charging caused
by long-term parking and vehicle electric leakage
or charging fault in vehicle generator. In this case,
it is necessary to carry out external charging
treatment to the battery.

�

Appearance inspection of the battery prior to
boost charge:
It is not allowed to charge the battery with a
broken case or acid leakage. Please replace the
battery after identifying the cause.
It is not allowed to carry out boost charge for the
battery with a broken terminal post. Please
replace the battery after identifying the cause.
It is not allowed to charge the battery with a
white electric eye. Please replace the battery.
Prior to boost charge, please clean the terminal
post, removing the oxide on the surface.

�

Precautions in charging:
Wear safety goggles.
Maintain ventilation in charging under normal
temperature.
It is not allowed to smoke in charging to prevent
the introduction of fire.
In the wire connection after charging, connect the
positive connecting wire firstly; in the wire
disconnection before charging, disconnect the
negative connecting wire firstly.

�

Battery boost charge:
Confirm that battery terminals are clean and
charging circuit is in good connection.
Connect the positive pole of the charger with that
of the battery while the negative pole of the
charger with that of the battery. Do not charge the
series connected battery (24V).

As dual-purpose charger, one with constant
voltage of 16.0V (maximum permitted voltage
is equal or under 16.2V or large quantity of
water shall be electrolyzed which may lead to
liquid level decrease, white electric eye and
scrapped battery) and rated current of 25 ampere
shall be applied in battery charging until the
electric eye becomes green. The green electric
eye indicates the battery is charged completely.
In the case of no constant voltage charger for
battery

charging,

charge

the

battery

with

constant

current

according

following

specifications:

(1)

Select the charging current with rated
capacity of 1/8 ～ 1/10 ampere for battery
charging and at the end of charging, the
voltage of battery shall reach 16V without
any exceedance (in the case of black electric
eye of the battery with voltage under 16V at
the end of battery charging, there is no
influence to battery application.) When it
can not guaranteed the charging voltage
limit of the charger is under 16V, it is
necessary to monitor the end voltage of
battery to be charged, or there shall be
battery

water

loss

due to

overvoltage

charging even battery failure.

(2)

After charging completion, verify the color
of battery electric eye. In the case of green
electric eye, it indicated that the battery is
charged completely. In the case of black
electric

eye,

verify

whether

charging

connecting wires are connected firmly,
connection points are clean and charging
voltage is 16V. Leave the battery as it is for
24 hours, measure its voltage and carry out
boost charge according to charging interest.

(3)

In the case of white electric eye, it indicates
that there are bubbles in the electric eye and
shake the battery slightly to remove these
bubbles. If the electric eye is still white after
battery shaking (indicating electrolyte loss),
replace the battery.

For battery with voltage lower than 11V, there
may be incapable charging phenomenon at the
beginning of battery charging. The proportion of
sulfuric acid in the battery is close to pure water
and battery internal resistance becomes very
large due to serious battery power loss. In this
case, reduce the charging current or use a
charger with a higher power instead, with the
battery charging goes on, the proportion of
sulfuric acid in the battery increases and the

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging 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

apply

grease

battery

terminals to avoid electrolytic corrosion.

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

lower

than

50%

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

the

maximum

battery

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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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 7 -

Diagnosis

Diagnosis and

and

and Test

Test

Fault diagnosis of Battery

Fault

Fault symptoms

symptoms

Cause

Cause analysis

analysis

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

circuit faults

④ Clean

corrosions

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 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

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

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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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 8 -

Diagnosis

Diagnosis and

and

and Test

Test

Fault diagnosis of Battery

Fault

Fault symptoms

symptoms

Cause

Cause analysis

analysis

Troubleshooting

Improper
electrolyte filling

① Peculiar smell of electrolyte

② Density

(proportion)

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

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.

Electrolyte flows among battery
cells and

cracks on battery case

There

vibration

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

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

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 and

and

and Charging

Charging

Charging System

System

- 9 -

Diagnosis

Diagnosis and

and

and Test

Test

Fault diagnosis of Battery

Fault

Fault symptoms

symptoms

Cause

Cause analysis

analysis

Troubleshooting

Excessive
shedding

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

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

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

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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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 10 -

Diagnosis

Diagnosis and

and

and Test

Test

Fault

Fault determination

determination

determination of

of battery

battery

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

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

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 11 -

Diagnosis

Diagnosis and

and

and Test

Test

Fault

Fault determination

determination

determination of

of 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

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

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

specified torque. In the case of broken
shaft, replace the generator

③ Install a new belt

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 12 -

Diagnosis

Diagnosis and

and

and Test

Test

Operating

Operating principle

principle

principle of

of 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.

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 13 -

Diagnosis

Diagnosis and

and

and Test

Test

Precautions

Precautions of

of generator

generator

generator 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:

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.

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

induction may puncture or burn down the power
diode.

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.

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.

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

connected

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

relevant

inspection and application, do not disconnect the
connection of generator in operation with battery
at any case.

necessary

guarantee

the

reliable

connection

the

connecting

ground

wire

between the generator and chassis.

It is not allowed to ground the power supply lead
in the operation of generator or it may lead to
harness burn.

In generator inspection, it is necessary to fill the
generator sealed bearing with sufficient No.2
lithium base grease before the next maintenance.

It is not necessary to maintain the voltage
regulator, In the case of its damage, replace the
voltage regulator assembly.

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 14 -

Removal

Removal and

and

and Installation

Installation

Removal

Removal of

of Battery

Battery

Warning:

Warning: In general, explosive gas may be

generated by the battery. In the case of
misconduct of it, it may lead to personal injury.
Therefore, keep the battery out of flames, sparks
or burning objects. In the case of battery
charging or working close to the battery, it is
necessary to protect your face and eyes and
maintain good ventilation. Please follow relevant
instructions or it may lead to personal injury.

Warning:

Warning: Since there is sulfuric acid in the

battery, the contact of the sulfuric acid with the
skin, eyes or clothes should be avoided. In the
case of working close to the battery, it is
necessary to protect your eyes from being hurt by
the spilled out acid solution. Once the acid
solution comes into contact with skin or eyes, it
is necessary to wash with clean water for 15
minutes at least and go to a doctor immediately.
In the case of mistakenly swallow, it is necessary
to go to a doctor immediately or it may lead to
personal injury.

The

sequence

battery

disconnection:

disconnect the negative connecting wire of the
battery and then the positive one.

Warning:

Warning: In the maintenance of auxiliary

restraint system or fuel system, do not apply the
audio hosting or the storage device of key
password. For the applications of these devices at
this moment, there is still a low current in vehicle
electric

system.

Please

relevant

instructions or it may lead to personal injury.

Notice

Notice:::: Prior to battery ground wire removal, it is

necessary to confirm that the engine is stopped in
order to avoid vehicle electric system damage.

Notice:

Notice: In the case of battery removal mentioned

maintenance

manual,

please

the

procedure for the removal.

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SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 15 -

Removal

Removal and

and

and Installation

Installation

Removal

Removal of

of Battery

Battery

Open the engine hood.

Unscrew mounting bolts of battery negative pole.

Remove the negative connecting wire of

battery.

Unscrew mounting bolts of battery positive pole.

Remove the positive connecting wire of

battery.

Take down the battery from vehicle.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

SC Battery

Battery

Battery and

and

and Charging

Charging

Charging System

System

- 16 -

Removal

Removal and

and

and Installation

Installation

Installation of

of Battery

Battery

Warning:

Warning: In general, explosive gas may be

generated by the battery. In the case of
misconduct of it, it may lead to personal injury.
Therefore, keep the battery out of flames, sparks
or burning objects. In the case of battery
charging or working close to the battery, it is
necessary to protect your face and eyes and
maintain good ventilation. Please follow relevant
instructions or it may lead to personal injury.

Caution: Prior to connection of battery ground

wire, it is necessary to confirm that all electric
systems are turned off in order to avoid vehicle
electric system damage.

Do not tilt the battery with an angle over 40°

It is not allowed to place the battery up side down

or place it laterally.

It is not allowed to install the battery with

electric leakage onto the vehicle.

Inspect the transportation tray for battery for the

existence of screws and nuts and remove them in
order to avoid secondary damage of the battery.

The sequence of battery connection: connect the

positive connecting wire of the battery and then
the negative one.

Warning:

Warning: Since there is sulfuric acid in the

Notice: In the case of battery removal mentioned

maintenance

manual,

please

the

procedure for the removal.

Prior to battery installation, it is necessary to

confirm that the electric eye is green.

It is not allowed to install the battery with a black

electric eye onto the vehicle.

It is not allowed to knock or twist terminal posts

in battery installation.

In battery installation, make sure that all electric

appliances are “OFF”.

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JAC HFC4DA1-2C engine. Service Manual - part 14