Chapter III Malfunction Diagnosis and Troubleshooting
Great Wall Baoding Internal Combustion Engine
Manufacturing Company Limited
109
(3) Insufficient electrolyte in the storage
battery or sulphation or ageing of polar
plates
(3) Add electrolyte to the required level or
replace the storage battery when the
capacity can not recover in case of
sulphation of polar plates.
19. Insufficient Capacity, Difficulty in Starting or Overhigh Self Discharge of the
Storage Battery
Phenomenon and Cause of Malfunction
Troubleshooting
Insufficient
capacity of the
storage battery
and hard to
start the diesel
engine
(1) Low level of electrolyte
(2) Short circuit between polar plates
(3) Sulphation of polar plates
(4) Poor contact of circuit connectors, too
much oxide on the terminal pole or
undercharge
(1) Add distilled water or dilute sulphuric
acid with the density of 1.1 as required.
(2) Clear the sediment and replace the
electrolyte.
(3) Charge and discharge repeatedly to
clear the sulphation.
(4) Fasten the connecting circuit, clear
the oxide on the terminal pole or charge
the storage battery if necessary.
Overhigh self
discharge of the
storage battery
(1) Foreign matters in the electrolyte
(2) Short circuit of the storage battery
outer wire
(3) Short circuit of positive/negative poles
due to electrolyte spilled out on the
storage battery surface
(4) Serious short circuit due to metal tools
or bars left between the positive and
negative poles.
(5) Short circuit of pole plates due to
active substance falling off from the pole
plates and excessive sediment; short
circuit of pole plates due to damage of the
baffle plate; short circuit between positive
and negative poles due to warpage of
pole plates.
(1) Add electrolyte mixed up with pure
sulphuric acid and distilled water as
required.
(2) Check the part with short circuit and
clear the malfunction.
(3) Use alkaline water or warm water to
clean the storage battery surface and
pole end and keep the outer surface
clean (Don’t get the alkaline water or
warm water entered the storage battery).
(4) It is prohibited to leave metal tools or
bars on the surface of storage battery.
(5) Repair or replace the storage battery.
Warning
(1) The gas from the storage battery can be easily ignited by sparks, so ignition, naked fire or smoking
should be forbidden during repair and maintenance for the storage battery. During maintenance, don’t
get your skin or cloth spilled by the electrolyte of storage battery and make sure to wear goggles.
(2) Never get the two terminal poles in short circuit, or the storage battery may heat up quickly, which
may lead to explosion.
(3) To avoid short circuit, the storage battery earthing wire should be removed before the electrical
equipment is removed; but to replace a bulb, you need only disconnect the relevant switches.
(4) Remove the storage battery in the sequence of earthing wire, positive pole wire, storage battery
baffle plate and then the storage battery. Installation the storage battery in the opposite sequence.
