F300-HD_Engine-CH-Charging_System-Part1
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DAIHATSU
CHARGING SYSTEM
PRECAUTIONS CH- 2 TROUBLE SHOOTING CH- 2 IN-VEHICLE INSPECTION CH- 4 ALTERNATOR OH-12
WNSBE-CHO01
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PRECAUTIONS
1. Prior to the inspection, make sure that the battery cables are connected securely. 2. When a quick charging operation is carried out, first be sure to disconnect the battery cables.
TROUBLE SHOOTING
. Never use a high-voltage insulation resistance tester for the purpose of conducting tnis inspection. Under no circumstances should the battery cables be disconnected while the engine is rotating.
Problem
Possible causes
Remedies
Page
Charge warning lamp will not glow even if ignition switch is turned ON.
Fuse blown Lamp bulb burnt Poor connection of wiring Open wire IC regulator faulty
Check gauge fuse. Replace bulb.
Repair poor connection of wiring.
Repair or replace. Replace regulator assembly.
Charge warning lamp will not go out even if engine has started.
Drive belt loose or worn
Battery cables loose, corroded or worn
Fuse blown Fusible link blown IC regulator or altemator faulty Wiring faulty
Adjust or replace. Repair or replace cables. Check gauge fuse. Replace fusible link. Check charging system. Repair or replace.
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Ignition swltch Fuse block
ENGINE fuse
U.
Battery
Fusible | warning
Relay box
EFI No.1 fuse
1 sA
Charge
4; in
combination
__ 5 meter
D I gj I l Alternator
regulator
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IN-VEHICLE INSPECTION
CAUTION: - Never touch at the battery terminals immediately afterthe
vehicle has been operated. o .Be certain to turn OFF the ignition key switch during the
inspection.
Check the battery case for proper installing condition and cracks. If the batter case exhibits improper installing condition or cracks, replace or repair the battery, as required.
Check to see if the battery terminals exhibit corrosion and/or loose condition. lf the battery terminals exhibit corrosion and/or loose condi- tion, remove the battery cable terminals from the terminal of the battery. Remove any rust, using a wire brush or a fine abrasive paper.After the battery terminals have been con- nected, coat these terminal wlth a thin film of lithium grease. NOTE: Afterthe batteryterminals have been cleaned, make sure that no rust particle remains on the terminals.
Check of specific gravity of battery electrolyte
Measure the specific gravity of the electrolyte of each cell, /E
using a hydrometer. Ensure that the specific gravity is within the specified value.
Standard specific gravity: When fully charged at 20 °C (68 1.25 or more
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If the specific gravity is not within the specified value, check the electrolyte level and/or replenish distilled water. Then, charge the battery until the specific gravity reaches the specified value. (See page CH-4.)
<Reference> Specific gravity = Measured + 0.0007 (Electrolyte - 20) at standard specific temperature temperature gravity at time of
measurement °C CAUTION: Utmost care must be exercised as to the handling of electrolyte. Be very careful not to allow the electrolyte
to touch with your skin, clothes or any parts of the vehicle.
WN88E-CHIXJ4
v First-aid treatment for dilute sulfuric acid
Nature of accident First-aid treatment
. . Immediately flush the affected area using a large amount of clean running water, until Amd gets no acid content remains any more.
Immediately flush your eyes using a large amount of clean running water for at least
_ _ Immediately flush the affected area using a large amount of clean running water, until * Acid gets to your skin or clothes. no acid content remains any more. Afterwards, neutralize them with a soap. Finally flush them with water. _
Immediately flush the affected area using a largeamount of water, until no acid Acid is spilled. content remains any more. Afterwards, neutralize the area with slaked lime, sodium or
the like.
Immediately flush the mouth with clean water. Let him drink raw eggs, milk or a large
. . . .......-........, ........ ....,....,.... Amd 'S swalmwed' amount of water. Let him lie quietly.
* After the aforesaid first-aid treatment has _been done, call a physician immediately.
WRSB-OH011
4. lnspection of battery electrolyte level
Ensure that the battery electrolyte level is the highest level. £
If the battery electrolyte level of any cell isnot the highest level, replenish distilled water to the highest level. Q
. Never add city tap water or sulfuric acid, etc. instead of
distilled water. V Ve ~ lf the electrolyte level of each battery cell differs greatly,
it is advisable to inspect to see if any electrolyte leakage “T”
is present.
5. Inspection of drive belt
WR88-CHO12
(1) Visually check the belt for separation ofthe adhesive rub-
ber above and below the core, core separation from the Z adhesive rubber, cracking or separation of the ribs, torn l)& | (4 or worn ribs or cracks in the inner ridges of the ribs. , N k ' _ , or worn ribs or cracks in the inner ridges of the ribs. // J \\\\\ If necessary replace the drive belt. FTM
ga
WR88-CHO13
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(2) Measurement of amount of belt deflection
Push the midpoint of the drive belt between the alternator pulley and the water pump pulley by applying a force of 10 kg (22 lb). Measurefthe deflection of the drive belt. Specified Belt Deflection New belt: 5.0 - 7.0 mm (0.20 - 0.28 inch)
(With a pressed force of 10 kg (22 lb) applied to a point indicated in figure) Used belt: 6.0 - 8.0 mm (0.24 - 0.31 inch)
(With a pressed force of 10 kg (22 lb) applied to a point indicated in figure) Adjust the drive belt tension, if necessary.
NOTE: - “New belt" refers to a belt which has been used less than
5 minutes on a running engine. -' “Used belt" refers to a belt which has been used on a run
ning engine for 5 minutes or more. - After replacing the drive belt, check that it fits properly in the ribbed grooves, especially in the places difficult to see. o After installing a new belt, run the engine for about 5
minutes and then recheck the tension.
Check of fuses for continuity Fusible link Fusible link block EFI No.1 fuse Engine fuse Gauge fuse Checking alternator wiring and listening for abnormal noises (1) Check to see if the alternator wire is connected proper
ly to the alternator. (2) Ensure that the alternator emits no abnormal noise while
the engine is running.
Check of charge warning lamp circuit (1) Turn OFF all accessory switches. (2) Start the engine and warm up the engine thoroughly.
Turn OFF the ignition switch. (3) When the ignition switch is turned ON, ensure that the
charge warning lamp goes on. (4) After the engine has started, ensure that the charge
warning lamp goes out. If the warning lamp does not function as specified, troubleshoot the warning lamp circuit.
CH-6
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Check of charging circuit under no-loaded state NOTE: If a battery/altemator tester is available, connect such tester to the charging circuit according to the manufacturer’s in- structions.
(1) If such a tester is not available, connect a voltmeter and
an ammeter to the alternator wiring and alternator as fol- lows: 0 Disconnect the battery ground cable from the negative
(-) terminal of the battery. 0 Ccnnect an ammeter in series between the alternator wire terminal B and the alternator as indicated in the right figure. Connect the positive (-) terminal of a voltmeter to the ter
minal B as indicated in the right figure. 0 Connect the negative (-) terminal of the voltmeter to the
. engine ground. 0 Wind vinyl tape around each connection section so as
to prevent short. 0 Reconnect the battery ground cable tothe negative (-)
terminal of the battery. (2) Check the charging circuit as follows:
(1) Start the engine and warm it up. (2) Raise the engine speed from the idle speed to
2000 rpm. Take the readings of the ammeter and voltmeter. Standard Amperage: Not to exceed 10 A Standard Voltage: Standard Amperage14.2 - 14.8 V
If the voltage reading is greater than the standard voltage, replace IC regulator.
If the voltage reading is less than the standard voltage, ground the terminal F as indicated in the right figure. Proceed to start the engine. If the voltage reading becomes greater than the standard voltage under this setting, replace the IC regulator. If the voltage reading is still less than the standard voltage under this setting, check the alternator.
Check of charging circuit under loaded state (1) Start the engine. Maintain the engine speed at
2000 rpm. Tum ON the high beams of the headlamps and set the blower fan motor switch to the Hi position. Take the reading of the ammeter. Standard Amperage: 30 A or more
If the ammeter reading is less than 30A, repair the alternator. (See page CH-15.) NOTE: When the battery is in a fully charged state, the ammeter
CH-7
Terminal B
UE
reading may be léss than 30 A durinvg the afofesaid test. I f
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BATTERY REMOVAL
CAUTION:
v Never touch at the battery terminals immediately after the vehicle has been operated
o Be certain to turn OFF the ignition key. ~ Never allow any fire to be brought near the battery. NOTE:
Be very careful not to drop the battery or apply strong vibration to the battery
terminal of the battery
Disconnect the positive terminal from the positive (+) ter
W
Disconnect the ground cable terminal from the negative (-)
a
Remove the battery hold-down clamp Remove the battery.
CLEANING, INSPECTION & CHARGING OF BATTERY
Remove any rust from the battery terminals by means of a wire brush or a fine abrasive paper, or sodium water and a soft brush. NOTE: After the battery terminals have been cleaned, make sure that no rust particle remains on the terminals.
Using 'adhesive tape or the like,' seal the vent hole of each cell plug. Flush the battery with clean water, using a soft brush.
3. Wipe off the battery surface using a cloth dampened by
clean water. Proceed to dw the battery.
CH-8
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4. Battery capacity check
(1) Check by hydrometer
Measure the specific gravity of the electrolyte of each cell, using a hydrometer. Ensure that the specific gravity is within the specified value. Standard Specific Gravity: When fully charged at 20 °C (68
If the specific gravity is not within the specified value, check the electrolyte level and/or replenish distilled water. Then, charge the battery until the specific gravity reaches the specified value. lf the battery is prone to be discharged (the specific gravity drops) even after the battery has been charged, despite the fact that the charging system of the vehicle has no malfu nction, it is necessary to replace the battery. . However, make sure that the wiring harness of the
vehicle has no defect.
Reference Specific gravity = Measured + 0.0007 at standard specific temperature gravity [Temperature of electrolyte at time of measurement :
20 °C (68
(2) Reserve capacity check by battery tester
Connect a battery tester to the battery so as to check the capacity. NOTE: The battery tester should be operated in accordance with the operating instructions set forth by the manufacturer.
lf the battery capacity is not within the specified value, check the electrolyte level and/or replenish distilled water. Then, charge the battery until the battery capacity reaches the specified level. (See page CH-4.)
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Battery recharging CAUTIQN: o Never perform quick charging for the MF (Maintenance Free) battery.
o Care must be exercised to ensure that the electrolyte temperature *will not rise above 45 °C (113 during the charging. If the electrclyte will likely exceed this level, suspend the charging or
reduce the charging current to a half level. o Never allow any fire to be brought near the battery.
o Make sure thatthe charging side is well ventilated during the charging or immediately after the charg
o If the battery is charged vi/ith_ the battery mounted on the vehicle, be certain to turn OFF the ignition
eyvitch. ffbenf disconnect the battery ground cable from the battery negative (-) terminal.
- The switch of the battery charger should be turned OFF first, whehever it is cehnected or disconnected
from the battery. - Do not use a battery tester or a hydrometer during the charging.
o -If it is necessary to approach the battery during the charging or immediately after the charging, be sure to wear goggles. Also, keep your face away from the battery, whenever possible.oAs for the removal
V type battery oell plugs, remove them. Care must be exercised not to loose them. q If the electrolyte level is law, be sure te replenish distilled water. (See page CH-5.)
o Under no circumstences sneulq the be connected to thevbattery réversely. Upon com
pletion of the charging, positively install each cell plug. Flush the battery with cléan water:
( 1) Determination of charging current
The charging should be carried out using a current that is one tenth of the five-hour rate capacity.
Example: 50 AH(5-hour rate)
Battery capacity (5-hour rate)
1 0
Charging current (A) =
(2) Determination of charging time
The charging time can be determined, using the following formula given below:
Charging time (hour) =
(3) Connection of battery charger
(1) Ensure that the charger switch is turned OFF. (2) Insert a thermometer into the battery. (3) Connect the charger tothe battery. (4) Set the timer ofthe charger. Turn ON the switch. CAUTION Care must exercised to ensure that the electrolyte tempera- ture will not rise above 45 °C (113 during the charging.
CH-10
