Chapter 10 Electrical system

Content
Section 1 power-supply system………………………………………………………………399
I 、 overview………………………………………………………………………399
II、fault diagnosis……………………………………………………………………404
III、maintenance………………………………………………………………………406
IV、overhaul…………………………………………………………………………409
Section 2 Body electrical system……………………………………………………………417
I、overview……………………………………………………………………………417
II、fault diagnosis……………………………………………………………………424
III 、 maintenance……………………………………………………………………429
IV 、 Circuit diagram…………………………………………………………………441
attached drawing I………………………………………………………………………………444

attached drawing II………………………………………………………………………………445

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 Section 1 Power-supply system
I、 Overview
The vehicle power supply system composed by battery, generator (three
phase alternator), rectifier (Three-phase ac full-wave rectifier), and voltage
regulator (Built-in) and charging indicator, provides 12 V dc power to electrical
equipments of vehicle.

1．Battery
Battery has three main functions in electrical equipments system:
·It’s a power for engine starting
·It’s
a Rated power 45AH／5HR，12V
Electrolyte specific gravity In 20 C full charged 1.28
o

voltage stabilizer for electrical

equipments system,
·When power load more than generator output, it can provide power with generator together for a certain
period.
The types of battery for vehicles as follows:

Battery installation brackets and linking piece

Battery installation brackets should be in good condition to make sure it fixed firmly and maintaining
horizontal.
Before install the battery, the installation brackets and linking piece should be cleaned, without corrosion.
Make sure no spare parts inside the bracket.
In order to avoid swing of battery inside the bracket, the holding down bolt should be tightened properly,
and do not tightened too tight.
Electrolyte freeze
The electrolyte freezing point depends on the proportion of the electrolyte. The freeze will damage the
battery, but in all the charging conditions will prevent freezing. if the battery freeze accidentally, unfreeze it
before charging.
Sulphating
If the battery is in discharging condition and with a long time, Wires sulfate can become hard crystalline
substance, and It is not easy to transfer to the active materials during the charging. “Sulphating” indicated the
reaction result and process. The light sulphating can be recovered by the way of devulcanization charging,
however the capacity may decreased as result.

Battery maintaining (For ordinary wires batteries, according to the below steps; For free maintenance
wires battery please refer to the part of Free maintenance wires battery)
Caution ：
·Battery can't close to the fire or electric spark, because the gases produced from battery are

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inflammable and explosive.
·Never let a battery liquid contact with eyes, skin, fiber and paint surface. Because it is a corrosive
acid, in case of contacted, wash the interface with water immediately and fully.
·Battery should be kept in place where children unable to touch.
1) Battery is a very reliable component but still need regular maintenance.

Battery box should be kept clean to avoid terminal corrosion. The battery electrolyte level should be kept
above the minimum liquid level.
Please pay attention if the vehicle is stopped of using for a long time:：
·Start the engine weekly, keep running at the speed of 2000 ～3000 rpm until the vehicle achieve the normal
working temperature. Make sure all electric switch turned off before vehicle stored.
·Charging twice per month, prevent over discharge, especially with cooling temperature. When vehicle was
stored, the battery will keep discharging even without the using. In a cold temperature conditions, improper
charging may cause electrolyte freeze and battery box may crack as well.
2) The Wire connectors should be kept clean
The wire connector, especially the positive (+) terminal is easy to be corrupted. The corrosion products or
rust will hinder the current conducting. Clean the terminals and accessories regularly, to ensure that the
positive joint and the positive terminal have good contact condition.
3) To learn the charging condition the battery at all time
The simplest method to identify the charging condition of battery is hygrometry. Hydrometer is a
instrument which may measure the liquid proportion of battery. Please refer to “battery diagnosis”.

Maintenance free battery

When use ordinary wires batteries, it need regular maintenance, such as wipe the surface, check liquid
surface level, charging distilled water, regular charging, etc, which bring a lot of inconvenience to user, in
addition, the ordinary battery service life is short, the corrosive action is strong, have to install in a position
where well-ventilated and easy to dismounting and maintenance.。
Free maintenance battery also said non-maintenance battery; it’s also a wires battery, but due to the
improvement of structures, materials and processing, so it overcomes the above-mentioned drawbacks and
developed quickly and applied broadly, and will gradually replace the existing ordinary wires batteries.
Free maintenance battery without the add liquid hole which may avoid moisture volatilizes and dust
falling; it reserved enough amount of the electrolyte and Do not need to add distilled water during the service,
so it’s no need to maintaining; Free maintenance battery without the Safety vent which may avoid high
pressure inside and Acid gas emissions, Reduce the corrosion function for electrode pile and organism; only a
few Self-discharge and can be used around two
years; small internal resistance, good starting
performance; long service life, its’ 2-4 times to
ordinary wires batteries.

Maintenance Free Battery technical condition

checking methods
Charging indicator observation Charging level over 65%
Maintenance Free Battery has a Charging indicator
Charging level lower than limit valve
(electrolyte density meter eye)to show the charging
conditions. Refer to the picture; put the bottom

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straight pipe of charging indicator into the electrolyte from top of battery, and the indicator is green; if the
charging condition lower than 65%, the indicator turn to black color; if the electrolyte lower than the limit
Electrolyte Allowed Electrolyte Allowed Electrolyte Allowed
temperature (oC) voltage (V) temperature (oC) voltage (V) temperature (oC) voltage (V)
21 9.6 —1 9.1 -18 8.5
10 9.4 —9.5 8.8 <-18 8.0

valve, the indicator turn to transparent color, and which means it should be scrapped.

Identify the battery technology conditions through observe the charging indicator.

①If it displayed as green, the battery is in good condition, use voltage gauge to test the further battery
technology condition.
②If it displayed as green but Starting is not strong enough or starting time is too long, charge the battery.
③If it displayed as black, the battery is in the serous power-lack, charge the battery.
④If it displayed as transparent color, the surface of electrolyte is too low, and if unable to start the starter,
replace the battery or identify the reason for low liquid surface. The low liquid surface maybe caused by
cracks of box, or over charged seriously; check the charging system as well.
Measure the terminal voltage of battery
①Fully Charged, connect Carbon meter as adjustable load between positive and negative poles, load
current adjusted to specified valve and Continuous discharge 15 s.
②Test the terminal voltage, if it higher than 9.6V, the battery in good condition and can be used after
charging; if it lower than 9.6V, the battery cannot be used anymore.
The above testing applied with temperature 21 oC, the allowed voltage in difference temperature please refer to
the below table. To measure the loading current of terminal voltage shall be according to the factory
specification.

Free maintenance battery charging method

take charging when the color turned to black, the charging steps as follows:：
①Connect the circuit between battery and charger
②Adjust the voltage of charger to 14.4V, the current to maximum and start the charging.
③General use of the rated current for charging, during the charging, if the electrolyte leaked from vent,
or Gas emitted or temperature of electrolyte over 45oC, check the charging indicator every 1H, keep
charging if not turn to green. In case the temperature of electrolyte over 50oC, stop charging and wait until
the temperature of electrolyte fall down.
④When indicator turns to green, the charging finished.

Notice: The Charging current value should be based on the factory specification.

Caution：
Should pay attention to safety when use or maintain the battery, take glasses if possible and keep Away from the
flame and spark source to avoid exploding of battery and injured.

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 2．Generator
This is a three-phase ac generator with three groups (6 diodes) of diodes, which composed three groups of
the wave rectifier. The structure please refer to the below pricture.

1. Built-in adjustable generator assembly 2. LC regular 3. stator coil 4. diode 5.excitation coil
6. charging indicator 7. general switch 8. battery
Generator characteristics：
·Regulator fixed on the inside of the generator
·Voltage (IC) regulator is integrated circuit, control the voltage produced by generator can cannot adjust
the setting voltage.
·Generator rotor bearing keep enough lubricant without regular lubrication. Two Brushes send current to
excitation coil which fixed on rotor through two slip rings. In normal conditions, it needs little
maintenance in long term.
·Stator armature assembled inside of Stacked iron core, the iron core is a Machine box components.
·Capacitor which fixed on the rear housing can restrain radio interference
The functions of generator as follows:
1）To powering the electric equipments when engine in proper functioning
2）To powering the battery when the battery short of electric and with large power consumption of vehicle

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 1 belt pulley 2 belt pulley nut 3 rotor fan 4 stator coil
5 stator coil 6 excitation coil 7 regulator 8 carbon brush
B: output of generator (terminal of battery)
D: Hypothetical terminals
E:Ground
F: field coil terminal
IG: ignition terminal
L: Charging indicator terminal

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II、fault diagnosis

1．Battery
Visual inspection
Check if there is significant damage, such as Electrolyte leakage. If it damaged, replace or repair it.
Liquid hydrometer testing
Notice：
The direct way of identify the charging condition is high discharge current test with precision voltmeter.
When the temperature of battery is 20oC:
Full charged, the specific gravity is 1.280
Half charged, the specific gravity is 1.22
Discharged condition, the specific gravity is 1.150, it can be frozen.
If the temperature of battery is not 20oC, the specific gravity vary with temperature, the specific gravity
reading (from hydrometer) should be amended based on 20"C
The way of amendment, refer to the left picture which shows the relation between specific gravity and
temperature.
Method of application：
Assume the reading of specific gravity is 1.28, the temperature of battery is -5 oC, find the crossed point of
line -5o and 1.28, this area is charging condition. How to identify the degree of charging condition? To obtain
the answer, first draw a line from A point and paralleled to area boundary, and extend to the right to get a cross
point in the percentage line, this point in the percentage line is the answer. In this case, the parallel crossed
percentage line in the point of 85%, which means the battery is 85% of full charged.。
2. Generator Dummy terminal Ignition terminal
Light terminal
Caution： Generator output terminal
·Do not fault the polarity of ignition terminal and indicator Ground

terminal.
·Do not make short circuit between ignition
terminal and light terminal, these two terminals
connected through the indicator.
·No charge between light terminal and ground.
·If connect the charger to the battery, refer to the
part of “battery charging”.
The following condition appeared means the
charging system have problem：
1) When the ignition switch turned on, charging
indicator lighting, when the engine start to running
normally, the indicator still lighting, which means there
have the fault.
2) Engine started slowly or indicator doesn’t work,
which mean the battery charged insufficiently.
3) Lot of electrolyte leaked from the hole, means over
charged.
the noise from generator may caused by belt loosed, nut loosed, bearing wear, have dirt, diode damaged
or stator damaged。

404
Fault indicate lamp

Bat
Problems Causes Approaches
tery
·fuse burned check fuse
·light burned replace light
·wires loosened tighten the joint
Ignition connected, engine not started, the
·Voltage (IC) regulator or magnetic check the generator
charging light doesn't work coil fault repair or replace it
· Brush and slip ring contacted
badly
·driving belt loose or wear adjust or replace the
·Voltage (IC) regulator or magnetic driving belt
charging light doesn't put out when engine running coil fault check the charging
(battery need charging frequently) ·wires fault system
Repair circuit
charged insufficiently
Even the indicator in proper working, the engine
started slowly may cause by below causes:
It can be used for vehicle which with voltmeter and
ampere meter
1) Check the tensity of driving belt
2) Check the battery for failures; refer to the part
“battery”
3) Check the damage effects, tensity, and cleanness of
circuit, battery, stator, ignition and ground
terminals connectors, check the wires connection
of battery.
4) Connect the voltmeter and ampere meter as right
picture shown
Voltmeter
Connect the voltmeter between generator B terminal and ground terminal.
Ampere meter
Connect the ampere meter between generator B terminal and battery positive(+) terminal.
Notice：
Use full charging battery
6) Testing current and voltage
Un-load checking
1) Engine running at the speed of 2000rpm, read the
indication.
Notice：
Shut accessory devices down (wiper, heater, etc.)
standard current Mix 10A

standard voltage 25oC，14.2～14.8V

Notice：
The voltage may change due to the changing of
regulator housing temperature.

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 Over high voltage
If the voltage higher than standard, check the ground condition
if the ground is no problem, replace the voltage regulator
Over low voltage
If the voltage lowers than standard, check with following steps
2) Connect the field coil terminal to the ground, start the engine, and measure the voltage from output terminal
of generator as left picture shown.
·Voltage higher than standard
The generator is ok, but the regulator is failed and need to be replaced.
·voltage lower than standard
Some problem with generator and check it to find the problem.
Load checking
1) Turn on the front lamp and heater, with engine running at the speed of 2000rpm
2) Measure the current, if it smaller than 20A, replace or repair the generator.
Over charging
1) Refer to the “battery” part to identify if it over charged.
2) If there have obvious signs like electrolyte leaked, dismount the generator and check the ground condition
and short circuit condition. And replace the stator as necessary.
3) Measure the voltage with engine running at the speed of 2000rpm.
4) If the measured voltage is not within standard range, then check the ground or regulator condition.

III、Maintenance

1. Battery

Cross-connect starting in emergency

When cross connect the wires, handle the assist battery and discharge battery carefully, follow the below
steps to avoid spark produced.

Warning：
·Any violated may cause:
1) Battery exploding, battery acidify or fire, and result in severe injury (especially the eyes) or Machine
damaged
2) Vehicle electric units damaged
·Wearing goggles when remove spare parts。
·Should be careful to avoid metal tools or cross wiring contact with battery positive terminals and other metal,
otherwise, the short circuit may caused.
1) The parking brake and automatic transmission set in the stop position (Manual transmission neutral
position), turn off ignition device, lights and all other power loads.
2) Check the electrolyte level, if it lower than lowest liquid level, adding distilled water.
3) Connect one end of cross connect wires to assist battery positive terminal, another end to discharge battery
positive terminal (12V battery only can use cross connection to start the engine).

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4) Connect one end of cross connect wires to assist battery negative terminal, another end to the ground part of
engine (like exhaust manifold) but keep distance at least 45cm(18inch) between vehicle battery
Caution：
Do not connect the negative wires to the discharged battery negative terminal directly.
5) Start the engine which with assist battery shut down all electric accessories. And then start the engine which
with discharge battery.
6) Disconnect the cross wires as the opposite order.
2. Charging device (charging without engine running)
Caution：
When starts the engine which with charging device by cross-connection, make sure all voltage is 12V and
negative pole connected with ground. Do not use 24V charging device, otherwise, the electric system or units
may damaged badly.
Dismounting
1) Open the engine housing cover.
2) Disconnect the negative pole
3) Disconnect the positive pole
4) Remove the fixing band
5) Remove the battery
Handling
When handle the battery, the following
safety precaution need to be noted.
·The battery may produce hydrogen, so the fire
or spark may kindle the hydrogen if too close.
·The electrolyte is highly acid, Should avoid
contact in clothing or other fiber, and in case of
contacted, use plenty of water to wash immediately.

Installation
1) Install it as the opposite order of dismounting；
2) Tighten the wires of battery
Notice：
·Make sure there are enough space between ground wires and engine shield plate
·No contacts between vehicle body and battery wires.
·Put insulation paste cover after tightened the positive
terminal firmly.。 1 Battery
2 Positive wires
3 Negative wires
4 Fixing belt

Generator dismounting
1) Remove the negative wires from battery
2) Remove the Bracket strengthen pieces of
compressor
3) Disconnect the B terminal and articulator from

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generator.
4) Remove the belt adjusting bolt. Remove the adjusting arm after removed up bolt and pivot bolt.
5) Remove the generator

Installation
Install it as the opposite order of dismounting. And adjust the driving belt to specified tensity.
Notice：
The tensity of driving belt please refer to the engine chapter
Tightening torque
(a)：23N·m
1 Generator 4 Base
(b)：50N·m
2 Belt adjusting bolt 5 Adjusting stiffening frame of generator
(c)：8N·m 3 Adjusting bolt 6 Adjustor of generator belt
Generator belt
Belt tensity checking
1) Check the craze, cut, deformation, wear, cleanness condition of belt.
2) Check the tensity of belt, use thumb press it (about 10KG), if belt settled about 6—8mm, the tensity is
properly.
Belt tensity “a”：6～8mm
Notice：
adjust the belt tensity to 5～6mm when replace a new belt
3) If the belt is too tight or too loose, loose the adjusting bolt and pivot bolt, and then adjust the tensity of belt
by rotate the adjusting bolt.
4) Tighten the adjusting bolt and pivot bolt
Tightening torque
(a)：23 N·m
(b)；50 N·m
5) Connect the negative wires to battery terminal
Replace belt
Refer to the engine chapter, the section of “water pump belt”

IV、Generator Overhaul

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 1 Pulley
2 Pulley bearing
3 Nut
4 Driving end cover
assembly
5 engine front bearing
6 bearing retainer
7 bolt
8 stub bolt
9 rotor assembly
10 engine rear bearing
11 bearing cover
12 voltage regulator
13 brush bracket
assembly
14 bolt
15 rectifier
16 terminal insulator
17 rear end cover

Dismounting
1) Dismount the output terminal nut and isolation

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 parts of generator.；
2) Remove the rear cover.；

Rear cover 3. B binding post bolt

Insulator

3) Loose two bolts; pull out the brush

Positioning frame assembly；
4) Loose 2# bolt, remove the voltage
regulator.；
5) Remove the brush Positioning frame cover
from the brush Positioning frame.

6) remove the rectifier positioning frame；

7) Clamp the shaft by internal hexagonal
wrench, loose belt nut and remove the belt
pulley.；
Caution：
·Only use the internal hexagonal wrench,
because internal dodecagon wrench may slip
and cause damaged.
·Do not use vice or pipeline wrench to fix the
belt pulley. Otherwise, may cause distortion in
the belt pulley.
1 Rectifier positioning bracket

8) Loose two rear cover nuts and bolts；

9) Use plastic hammer hit the rear frame gently, and
remove the rear frame which fixed with rotor 1. Rear frame 3 Rear cover nut
2 rotor shaft 4 Rear cover bolt
tapping shaft；
10) Separate the rear cover and rotor with plastic
hammer.；

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Caution：
Do not hit the shaft when rotor and cover separated.

11) Remove the end cap shaft and cover by shaft

bearing replacer as necessary.；
Caution：
Do not damage the coolant fan blades when use
replacer.
End cover bearing
bearing remover
bearing cover

12) If necessary, loose four bolts, batter board, and

then remove the driving shaft；
13) If necessary, loose stud bolt and then pull out
the stator.
Notice：
Stator dismounting may much easy if with warm
temperature.

1. stub bolt 3 driving end bearing

2 positioning plate 4 stator
Check rotor open circuit
Use ohmmeter to check the conduction
condition between two slip rings. If cannot
be conducted, replace the rotor
standard resistance: about 2.9 ohm

Ground connection (short circuit)

Use ohmmeter to check the conduction
condition between rotor and slip rings. If it
conducted, replace the rotor.

Slip Ring
·If slip ring have scratches or unsmooth,
replace the rotor

1 Rotor
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·Use slide caliper to measure the slip ring diameter.
standard diameter：14.4mm
minimum diameter：14.0mm
If the measured valve less than minimum diameter, replace the rotor.

Stator open circuit

Use ohmmeter to check the conduction condition
between all wires. If cannot be conducted, replace the
stator.

Ground connection (short circuit)

Use ohmmeter to check the conduction condition
between coil wires and stator iron core. If it conducted,
replace the stator.

Brush
Exposed brush length
Measure the length of brush to identify the wear condition.
If the wear condition exceed the operating limit, replace it. Refer to
the part of “replace brush”.
Exposed brush length “a”
standard value：10.5mm
limit value：4.5mm

Rectifier
Positive rectifier
1) Use ohmmeter, one end connect with generator output terminal, another connect with rectifier terminal (P 1

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—P4).
2) Exchange the ends and repeat the step 1)。
3) Check the conduction directions, if both directions are
conducted, replace the rectifier positioning frame.

B: positive terminal E: negative terminal

P2-P1: Rectifier terminal

B: positive terminal
E: negative terminal
P2-P1: Rectifier terminal

Bearing
Driving end bearing
Check whether bearing damage or wear.

Cover end bearing

Check whether bearing damage or wear.

Replace brush
1) Sealing-off, remove the brush and spring.
2) Let the new brush wire shift to brush positioning frame hole.
Plug the spring and brush into frame.

3) Weld the brush wires to frame with specified length of

exposed.
Exposed length of“a”：10.5mm
4) Check whether the brush can move smoothly in the brush
positioning frame.
5) Cut off the excess wires.
6) Put insulated paint on the welding spot.

Assembling

413
assembling
1) If the end cover bearing has been removed, install it.
2) Check whether the end cover bearing can smooth rotating.

1 End cover bearing 3 Bearing cover

2 rotor

3) If the stator has been removed, install it and tighten the

stud bolt.
4) If the driving end bearing has been removed, install it. 1 stub bolt 3 driving end bearing
5) Check whether the driving end bearing can smooth rotating. 4 positioning plate 5 stator
tightening torque
(a)：8.8 N·m
(b)：2.6 N·m

6) Put distance ring and driving end frame on the belt

pulley, and then install the rotor to the driving end frame.

1 rotor 2 driving end cover

7) Install the rear frame to driving end frame.

8) Tighten the nut and bolt with specified torque.
Tightening torque
(a)：4.5 N·m

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9) Install the belt pulley and tighten pulley nut with specified torque.
Tightening torque
(b)：45～60N·m

10) Install rectifier positioning frame as picture shows, fix the stator wires.

Caution：
When installing rectifier, make sure there have
enough space between stator wires and cooling fan
blades.
Tightening torque
(c)：2.0 N·m

11) Install the brush positioning frame cover to the brush

positioning frame.

12) Install voltage regulator and brush positioning

frame to rear machine frame flatly.
1 IC regulator
13) Install five bolts and make sure the gap between 2 Brush positioning bracket
brush positioning frame and joint is 1mm. 3 Rear frame

Ttightening torque
(d)：2.0 N·m

14) Install rear cover

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Tightening torque
(a)：4.5 N·m
15) Install insulation parts, tighten inside nut of B terminal with specified torque.
Tightening torque
(b)：8.0 N·m

1 Rear end cover

2 Insulator 3 B terminal inside nut
16) Make sure the rotor can rotating smoothly.
Technical requirements

rated voltage 12V

allowed working
-30～90oC
60A(at 13.5V) temperature
Standard output
negative pole contact with
allowed mix speed 18，000rpm polarity
ground
Un-load speed l，180rpm clockwise rotation from belt pulley
Rotating direction side
output voltage 14.2～14.8V

Tightening torque

Tightening torque
fastening piece
N·m Kg·m
1.ground bolt 8 0.8
2.gine driving belt adjusting bolt 23 2.3
3.engine bearing bolt 50 5.0
4.engine bracket bolt 23 2.3
5．engine output terminal inside
4.2 0.42
nut
6 ． engine output terminal
8 0.8
outside nut
7．pulley nut 113 11.3
8．rear machine frame nut
4.5 0.45
9．rear cover nut
10．negative rectifier bolt 4.0 0.4

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