Battery
Batteries are sealed as standard on all vehicles. There are no ventilation plugs in the lid. The battery is completely sealed, with the exception of two small ventilation holes on the sides. These vents are used to vent battery gases. The rechargeable battery has the following advantages over conventional ones:
- During the entire service life, water is not topped up.
- Overcharge protection. If too high voltage is applied, the battery will take less current than a normal battery. In a conventional battery, excess voltage causes it to boil and lose fluid.
- A rechargeable battery is not as prone to self-discharge as a conventional one. This is especially important when the battery is idle for a long time.
- More capacity in a lighter and smaller package.
The battery has three main functions in the electrical system. First of all, the battery is a source of energy to start the engine. Then, the battery acts as a voltage stabilizer for the electrical system. And besides this, for a limited time, the battery provides energy if the performance of the generator becomes insufficient.
Ratings
The battery has two ratings: (1) reserve tank at 27°С (80°F), this is the time during which a fully charged battery provides a current of 25 A at a voltage above 10.5 V; (2) cold start current determined at -18°C (0°F), which defines the capacity for cold start.
Reserve capacity
Reserve capacity is the maximum time to travel at night with minimal electrical load and no generator output. Expressed in minutes, reserve capacity (or RC parameter) is the time required for a fully charged battery to reach a terminal voltage of 10.5 V at 27°C (80°F) and when discharging with a current of 25 A.
Cold start current
The cold start current test is expressed at a battery temperature of -18°C (0°F). The current rating is the minimum current that the battery must deliver for 30 seconds at a given temperature, meeting the minimum voltage requirement of 7.2V. This is a measure of cold cranking power.
The battery is not designed to last forever. However, with proper maintenance, the battery will last for many years.
If the battery passes the test, but for unknown reasons does not perform well, then the following factors may be the basis for this:
- Additional devices in the car are not turned off at night.
- The vehicle is operated at a slow average speed for short periods of time.
- The electrical load is greater than the generator output, especially due to the additional equipment.
- Faults in the charging system such as short circuits, a slipping alternator belt, a faulty alternator, or a faulty voltage regulator.
- Incorrect maintenance, including dirty and loose terminals or a loose battery clamp.
- Mechanical problems in the electrical system, such as shorted or pinched wires.
Built-in hydrometer
The sealed battery has a built-in, temperature-compensated hydrometer on top of the battery. The hydrometer is used for the following diagnostic procedure:
1. When inspecting the battery, make sure it has a clean top.
2. During normal operation, two indicators are visible:
- VISIBLE GREEN POINT - any green color is interpreted as "green dot", this means that the battery is ready for testing.
- DARK GREEN POINT NOT VISIBLE - if there is a problem with starting, the battery must be checked. At the same time, the charging system and electrical system should be checked.
3. Sometimes another indication is visible:
- TRANSPARENT OR LIGHT YELLOW COLOR - this means that the liquid level is below the hydrometer. The cause may be excessive or too long charging, a broken housing, excessive tipping, or normal battery wear. The battery in this state indicates overcharging due to a malfunction in the charging system. Therefore, in case of difficulties with starting, it is necessary to check both the charging system and the electrical system. If starting problems are caused by the battery, replace it.
Charging procedure
1. Batteries with a green dot do not need to be charged unless they have just been discharged (like when starting an engine).
2. When charging a removed battery with sealed terminals, install an adapter. Make sure all charging contacts are clean and tight. Best results are achieved when the electrolyte and plates are at room temperature. An extremely cold battery may not accept charging current for several hours.
3. Charge the battery until the green dot appears. During charging, check the battery every half hour. You may need to tilt or shake the battery for the green dot to appear.
4. After charging, the battery must pass a load test. follow the paragraph «Starter» in this section.
Required charging time
The time required to charge the battery depends on the following factors:
- Battery size - A fully discharged battery running under heavy load can take twice as long as a battery in a light passenger car.
- Temperature - Temperature - at a temperature of -18°С (0°F) any battery will take longer to charge than at 27°C (80°F). When express charging a cold battery, the current consumption will be very low at first. The battery will draw higher current only after heating.
- Charger performance - A charger with 5A charging current will take longer than a charger with 30A or more.
- Charge level - A fully discharged battery takes twice as long to charge as a half-discharged battery. Since the electrolyte is almost pure water, it is a poor conductor in a fully discharged battery and therefore the charging current draw will be very low at first. Later, with more acid from the charging process, the charging current will increase.
Charging a fully discharged battery
If you do not follow these instructions, you can damage a perfectly serviceable battery. The following procedure is used to charge a fully discharged battery:
1. Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10V, the charging current will be very low and it will take some time for the battery to accept more than a few milliamps of current. See «Required charging time» in this section, focusing on the factors that affect both the required charging time and the approximate calculated figures in the table below. Such low currents are not readable by all ammeters.
2. Set the charger to high.
Important: Some chargers have reverse polarity protection to prevent incorrect connection of the battery terminals. A fully discharged battery may not have enough voltage to activate the protection circuit, even if the cable is connected correctly. This may be due to the fact that the battery does not draw charging current. Follow the manufacturer's instructions to bypass the protection circuit to turn on the charger and charge the battery at low voltage.
3. Continue charging until the charging current can be measured. Chargers differ in voltage and current strength. The time required for the battery to accept the measured charging current at different voltages can be:
1. Continue charging until the charging current can be measured. Chargers differ in voltage and current strength. The time required for the battery to accept the measured charging current at different voltages can be:
| Voltage | Watch |
| 16.0 or more | Up to 4 hours |
| 14.0-15.9 | Up to 8 hours |
| 13.9 or less | Up to 16 hours |
- If the charging current cannot be measured before the end of the specified charging time, replace the battery.
- If the charging current is measured within the specified time, the battery is OK and charging should continue in the normal way.
Important: It is important to remember that a fully discharged battery must be charged to a sufficient number of amp-hours (a/h), to restore it to an acceptable state. In general, it is enough to charge up to the parameters of the reserve capacity (RC), so that a green dot appears on the hydrometer.
- If the charging current cannot be measured using the charging time calculated above, replace the battery.
Procedure for starting the engine from an external source of current
1. Put the car with good (charged) battery so that the connecting cables are long enough.
2. Turn off the ignition, all headlights, and all electrical loads in both vehicles. Install beacons if the traffic situation requires it, as well as lighting for the work area.
3. Set the parking brakes on both vehicles.
Note: To avoid damage, route cables away from pulleys, fans, and other parts that move when the vehicle is started.
4. Install the automatic transaxle assembly to PARK and the manual transaxle to NEUTRAL.
1. Install the automatic transaxle assembly to PARK and the manual transaxle to NEUTRAL.
Attention! To avoid accidents, do not use cables with damaged or missing insulation.
5. Attach one end of the cable to the positive battery terminal. Make sure it does not come into contact with other metal parts. Attach another cable to the positive terminal of another battery. Do not connect the other end of the negative terminal of a dead battery.
Attention! To avoid personal injury, do not connect the cable directly to the negative terminal of a dead battery. In this case, sparks may occur and the battery may explode.
6. Connect one end of the second cable to the negative terminal of the starter battery. Make final connection to engine ground (e.g. to the support bracket) not less than 450 mm (18 inches) from a dead battery.
7. Start the engine on a car with a good battery. Let the engine run for a few minutes at medium speed. Then start the engine on the vehicle with the dead battery.
8. Remove the cables in the exact reverse order. First remove the negative cable from the vehicle with the dead battery. When removing each clamp, make sure it does not touch other metal parts while the other end remains attached.
Generator
Vehicle charging system type - KDAC AD237. The number indicates the outer diameter in millimeters of the stator core laminations.
AD type generators are equipped with internal regulators. The Delta stator, bridge rectifier, and slip ring and brush rotor are electrically similar to previous generators. A conventional pulley and fan are used. There is no test hole.
Unlike three-wire generators, AD 237 models can only be used with two connections: Terminals "L" And "F" connected to the electronic engine management system controller (ECM).
As with other charging systems, the charge indicator lamp is controlled by the ECM when the ignition switch is in the ON position and goes out when the engine is running. If the charging indicator lamp lights up while the engine is running, this indicates a malfunction in the charging system.
The warning lamp lights up brightly for various types of faults, and also when the system voltage is too high or too low.
The voltage setting of the regulator changes with temperature and limits the voltage in the system by controlling the rotor current.
Charging system
AD type generators use a new type of regulator with three diodes. The Delta stator, bridge rectifier, and slip ring and brush rotor are electrically similar to previous generators. A conventional pulley and fan are used. There is no test hole.
Starter
Coil starter motors have pole strips around the armature that are energized by the coils.
Encapsulated lever start rotary motors have a starting mechanism and a moving coil in the drive housing which protects them from the effects of dirt, frost and spray.
In the main circuit, the windings of the electromagnetic relay are energized when the switch is closed. The movement of the moving coil and the starting lever causes the gear to go into the engine flywheel. The main contacts of the electromagnetic relay are closed. The engine starts.
Once the engine is started, the pinion freewheel protects the armature from over-revving until the switch disengages when the return spring forces the pinion back. To avoid unnecessary overtravel, the switch should be turned off immediately after starting the engine.
Engine start system
The engine electrical system includes the battery, ignition, starter, alternator and all associated wiring. The diagnostic tables will help you find and fix problems.
If the problem is with a specific component, refer to the service manual section for that component. The engine starting system includes the battery, starter motor, ignition switch and all related wiring. All of these components are electrically connected.