- Batteries with the green dot showing do not require charging unless they have just been discharged, such as in cranking a vehicle.
- When charging sealed-terminal batteries out of the vehicle, install the adapter kit. Make sure all the charger connections are clean and tight. For best results, batteries should be charged while the electrolyte and the plates are at room temperature. A battery that is extremely cold may not accept current for several hours after starting the charger.
- Charge the battery until the green dot appears. The battery should be checked every half-hour while charging. Tipping or shaking the battery may be necessary to make the green dot appear.
- After charging, the battery should be load tested. Refer to Battery Inspection/Test.
Charging Time Required
The time required to charge a battery will vary depending upon the following factors:
| • | Size of Battery--A completely discharged large heavy-duty battery requires more than twice the recharging as a completely discharged small passenger car battery. |
| • | Temperature--A longer time will be needed to charge any battery at -18°C (0°F) than at 27°C (81°F). When a fast charger is connected to a cold battery, the current accepted by the battery will be very low at first. The battery will accept a higher current rate as the battery warms. |
| • | Charger Capacity--A charger which can supply only 5 amperes will require a much longer charging period than a charger that can supply 30 amperes or more. |
| • | State-of-Charge--A completely discharged battery requires more than twice as much charge as a one half charged battery. Because the electrolyte is nearly pure water and a poor conductor in completely discharged battery, the current accepted by the battery is very low at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current will likewise increase. |
Charging a Completely Discharged Battery (Off The Vehicle)
Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced.
The following procedure should be used to recharge a completely discharged battery:
- Measure the voltage at the battery terminals with an accurate voltmeter. If the reading is below 10 volts, the charge current will be very low, and it could take some time before the battery accepts the current in excess of a few milliamperes. Refer to the paragraph above to Charging Time Required which focuses on the factors affecting both the charging time required and the rough estimates in the table below. Such low current may not be detectable on ammeters available in the field.
- Set the battery charger on the high setting.
- Battery chargers vary in the amount of voltage and current provided. The time required for the battery to accept a measurable charger current at various voltages may be a follows:
Note: Some charges feature polarity protection circuitry, which prevents charging unless the charger leads are correctly connected to the battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly, making it appear that the battery will not accept charging current. Therefore, follow the specific charger manufacturer's instruction for bypassing or overriding the circuitry so that the charger will turn on and charge a low-voltage battery.
Voltage | Hours |
|---|---|
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 charge current is not measurable at the end of the above charging times, the battery should be replaced. |
| • | If the charge current is measurable during the charging time, the battery is good, and charging should be completed in the normal manner. |
| Note: It is important to remember that a completely discharged battery must be recharged for a sufficient number of ampere hours (AH) to restore the battery to a usable state. As a general rule, using the reserve capacity (RC) rating as the number of ampere hours of charge usually brings the green dot into view. |
| • | If the charge current is still not measurable after using the charging time calculated by the above method, the battery should be replaced. |
| • | If the charge current is measurable during the charging time, the battery is good, and charging should be completed in the normal manner. |
Jump Starting Procedure
- Position the vehicle with the good (charged) battery so that the jumper cables will reach from the one battery to the other.
- Turn off the ignition, all the lights, and all the electrical loads in both vehicles. Turn on the hazard flashers if jump starting where there is traffic. In addition, turn on any other lights needed for the work area.
- In both vehicles, apply the parking brake firmly.
- Shift an automatic transaxle to PARK, or a manual transaxle to NEUTRAL.
- Clamp one end of the first jumper cable to the positive terminal on the battery. Make sure it does not touch any other metal parts. Clamp the other end of the same cable to the positive terminal on the other battery. Never connect the other end to the negative terminal of the discharged battery.
- Clamp one end of the second cable to the negative terminal of the booster battery. Make the final connection to a solid engine ground, such as the engine lift bracket, at least 450 mm (18 in) from the discharged battery.
- Start the engine of the vehicle with the good battery. Run the engine at a moderate speed for several minutes. Then start the engine of the vehicle which has the discharged battery.
- Remove the jumper cables by reversing the above sequence exactly. Remove the negative cable from the vehicle with the discharged battery first. While removing each clamp, take care that it does not touch any other metal while the other end remains attached.
Caution: Refer to Ignition OFF When Disconnecting Battery Caution in the Preface section.
Caution: Route the accelerator cable through the groove in throttle body lever. Securely seat the accelerator cable.
Warning: Cables that have missing or loose insulation should be replaced. Failure to properly maintain cables could result in personal injury or vehicle damage.
Warning: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases.
Generator
The charging system has several models available, including the 0114D (ValeoMando) or the CS-121D (Delphi). The number denotes the outer diameter, in millimeters of the stator lamination.
CS generators are equipped with internal regulators. The Y connection (ValeoMando) or Delta (Delphi) stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar to earlier generators. A conventional pulley and fan are used. There is no test hole.
Unlike three-wire generators, the 0114D (ValeoMando) or CS-121D (Delphi) may be used with only two connections; battery positive and an L terminal to the charge indicator lamp. Use of the "P", "I", and "S" terminals is optional. The "P" terminal is connected to the stator and may be connected externally to a tachometer or other device.
As with other charging systems, the charge indicator lamp lights when the ignition switch is turned to ON, and goes out when the engine is running. If the charge indicator is on with the engine running, a charging system defect is indicated. This indicator light will glow at full brilliance for several kinds of defects, as well as when the system voltage is too low.
The regulator voltage setting varies with temperature and limits the system voltage by controlling the rotor field current. The mono regulator having 2-3 pins in the terminal can be applied for generator. The regulator maintains the system voltage by controlling field current on-off without typically fixed frequency.
Charging System
The generator provides DC voltage to operate the vehicle's electrical systems and to recharge the battery. Built-in regulators control the voltage output of the generator. When the ignition switch is turned to the ON position, battery voltage is applied through the F4 fuse, and the charge indicator to the regulator in the generator. When the generator is not rotating, the regulator provides a good ground and causes the charge indicator to light. Voltage from the F7 fuse also generates a magnetic field around the field coil. As the engine starts and the generator begins to rotate, a voltage is also generated in the stator. The voltage regulator senses this voltage and takes control of the field current. AC voltage is generated in 3 stator coils. This AC voltage is converted to DC voltage in the rectifier bridge. The DC output, after being regulated by the voltage regulator, is applied to the vehicle's battery and electrical supply circuits at the BAT terminal of the generator. A separate output voltage is provided to the charge indicator. Since equal voltage is now being provided to both sides of the charge indicator, the lamp loses its ground and goes out. The voltage regulator is also connected to battery voltage through the generator BAT terminal. When the battery is fully charged, the voltage regulator decreases field excitation. This reduces the output of the generator to prevent overcharging. When the battery has been discharged or is heavily loaded, the voltage regulator increases the field excitation and voltage output of the generator.
