Foton Series Light Bus. Instruction — part 17
OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
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5. Battery quality assessment procedure
White Zone
Fully Charged
Green Zone
Normal
Yellow Zone
Insufficient Charged
Supplementary
Charging
Liability of User
Red Zone
No Power
Charging Inspection
Liability of User
>1.30
Faulty fluid filling
Specific gravity to be
adjusted
1.250-1.280
Normal
1.220-1.100 以下
Over discharged or failure
Charging Inspection
Liability of User
Single-frame
S.G.
Difference >0.04
There may be failure in
battery.
Charging Inspection
Above 12.5V
Normal
For direct use
12.5-11.5V
Insufficient Charge
Supplementary Charge
Liability of User
<11.5
There may be failure
Charging Inspection
Liability of User
Fault Diagnosis Effect Treatment
1. Low set value of regulator
1. Voltage below 12V
1. Charger to be
adjusted
2. Vehicle power consumption is larger
than charging amount
2. Specific gravity of
electrolyte below 1.220
2. Supplementary
charging
3. Frquent starting and short driving
distance
3. Difficult to be started,
weak lighting
4. Insufficient power generation or circuit
short
In
su
ff
ic
ie
n
t
C
h
ar
g
ing
5. Plate or connection corroded
4. Capacity tester
displayed in yellow or red
3. Replace a new one
for customer
1. High set value of regulator
1. Cell or vent plug turns
black and yellow
Charger to be
adjusted
2. Long time charging
2. Carbonized battery
separator
3. Long time long distance driving
3. Positive corrosion,
crack and floating
4. Too large current during charging
4. Wet acid on cell surface
5. Liquid level frequently
dropped and contaminated
O
v
er
C
h
ar
g
ing
6. Plate shadding unevenly
1. Continue to use undercharged battery
1. Voltage is below 10V
1. Charger to be
adjusted
2. Vehicle electric circuit in short circuit
2. S.G of electrolyte is
below 1.100
2. Supplementary
charging
O
v
er
D
is
ch
ar
g
in
g
3. Electrical devices used by vehicle have
not turned off
3. Low S. G. after
supplementary charging
Ba
tt
ery
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Cause Analysis Liability
1. Battery is damaged
Damaged during delivery or during use
2.Battery in bad conditon or rubber case is
distorted
Liability of manufacturer
Battery is
damaged
3. Improper installation (fitting is loose)
Liability of user
1. Terminal joint loose or in bad contact
Liability of user
2. Spark presence during charging
Liability of user
3. External short circuit
Liability of user
Battery is
blown up
or
damanged
4. Vent hole has blocked or perforated
Liability of user
1. Over charging
Liability of user
2. Too large current for charging
Liability of user
Battery
Distortion
3. Vent hole is blocked
Liability of user
1. External short circuit
Liability of user
2. Bad connection wire
Liability of user
Terminal is
melted and
damaged
3. Bad welding
Liability of manufacturer
11.4.2 Starter
Main Technical Parameters of Starter (BJ491EQ1 Gasoline Engine)
S/N
Items
Parameters
1
Model
QDY1253 Permanent-Magnet Reduction Starter
2
Graound polarity
Negative
3
Rated Voltage (V)
12
4
Rated Power (KW)
1.4
5
Rotating Direction (Viewing from the driving
terminal)
Clockwise
6
Gear Ratio
Pinion 9 Teeth and Gear 108 Teeth
1. Structure Overview
This starter is an enclosed-type DC motor in 4-pole series excitation with instantaneous rated working brush.
Starting is electromagnetically controlled, and roller-type isolator is adopted for torque transfer for mechanical
driving. After the motor has started, it would prevent gears of starter from being damaged at their high-speed
rotation along with flywheel, as the one way clutch would not transfer torque at the moment.
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Fig 11-2 Gasoline Engine Starting System
2. Notes to starter application
(1) Before starter is activated, check if engine can work normally. And check if starter and and its
connection are correctly installed, if lead contact is in good condition, and if power level of battery is sufficient.
(2) Engine cranking shall not exceed 15 seconds each time to protect starter and battery. There should be at
least 2 minutes interval between a fail start-up to second cranking. If 3 attempts cannot start up engine, one has to
turn to find the cause before next cranking.
(3) After engine has been started, release ignition key immediately, so that the gear of starter can be
detached. It is called low-temperature starting when starter is activated under the environment of temperature
below -5℃.
3. Starter Faults and troubleshooting
(1) Starter fails to rotate, see table 11-9.
Table 11-9 Starter Fails to Rotate
Causes
Solutions
1. Battery is under charged
2. No power at starter connector (wire to starter has
disconnected , poor contact at magnetic switch or
terminals)
3. Poor brush contact
4. Starter itself in short circuit or open circuit
1. Battery to be charged or replaced after check
2. (Test light or voltmeter) test and repair circuit,
replace battery and clean contacting points if
necessary
3. Clean brush bracket, replace brush spring or brush
4. Repair after checking
(2) Starter can not start up the engine , see table 11-10
Starter runs but is unable to start up engine
Terminal 30
Terminal 50
Fuse
Battery
Starter
Ignition Switch
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Table 11-10 Starter can not start up the engine
Causes
Solutions
Battery undercharged; short battery fluid or wrong
electrolyte gravity
Poor contact between brush and cummutator
Armature coil in short circuit
Dewelded between armature coil and reverser
Loosened connector or oxidized damages
Burnt electro-magnetic switch contacts
Excessive shaft bush wear, worn armature
One-way clutch is skipping
High engine oil resistance in winter
1. Check battery, add right electrolyte; charge battery
fullly and adjust fluid gravity
1、 Repair or replace brush, brush box or spring
2、 Repair or replace armature
3、 Weld at dewelded spots
4、 Fasten nut and remove oxidants
5、 Grind contacts with sand paper for better contacting
6、 Replace new shaft bush
7、 Repair or replace one-way clutch
8、 Preheat engine at cranking, use winter oil
(3) Starter gear fails to disengage, see table 11-11.
Starter keeps running after engine has been started. Starter gear does not disengage
Table 11-11 Starter gear fails to disengage
Causes
Solutions
Electro-magnetic switch contactsh has melted
together
Gasket lost between switch and drive cover, core’s
travel becomes short
1. Repair switch contacts, grind burnt spots with file
or sand paper
2. Add gasket, adjust clearance between gear and
thust ring to 0.2-4mm (switch is closed).
(4) Repair a starter
① Check and repair of carbon brush. Use wire hook to lift brush spring, and remove brush from bracket.
Brush wear should not exceed 1/3 of a new brush (14mm). Otherwise replace it with new brush of same
specification. Mating area between brush and reverser should be larger than 75%, otherwise glaze the brush.
Brush wiring should be secured, and brush isolated (test with 220V test light).
②Check magnetizing coil connectors for any loosening or dewelded, followed with short circuit and cut-off
checks. Check can be performed with 220V AC test light.
③ Check and repair of armature. Armature shaft jurnal and bush should be snug. One can use 00 rated sand
paper to grind burnt surface on armature. If its out-of-round exceeds 0.05mm, armature should be put into
machining. Do not deep cut mica between bronze plates to avoid brush powder from triggering reverser to short
circuit. Bronze plates should be welded firmly
11.4.3 Alternator (matched with BJ491EQ1 alternator)
1. Main Specifications and Technical Parameters
S/N
Description
Parameters
1
Model
JFZ1977
JF1615
2
Rated Output
14V 90A
14V 65A
3
Rated Rpm
6000r/min
6000r/min
4
Operating Rpm (Continuous)
1000~18000r/min
1000~18000r/min
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S/N
Description
Parameters
5
Overspeed Test
22000r/min 30S
22000r/min 30S
6
Rpm at Zero Current
≤1000r/min
≤1000r/min
7
Regulator Adjusting Voltage
14.1±0.2V
8
Regulator Temperature Compensation Coefficient
-7±3mV/℃
9
Weight of Alternator (kg)
6
5.1
JFZ1977 and JF615 automobile AD alternators are synchronous Lundell and silicon rectifying alternators
with built-in electronic regulator. The alternator is provided with a continuous rated operating system with
negative grounding. Alternator rotates clockwise when viewing from the driving terminal. The alternator is
installed in an angle, hanged on two points. The surrounding media temperature is ranging between -40~+100
,
℃
and the monthly average relative humidity is not higher than 90%.
2. Charging System Circuit
The circuit of charging system for gasoline engine is indicated in Figure 11-3.
Fig 11-3 Charging System Circuit of Gasoline Engine
3. Notes to use an AD alternator
(1) Grounding polarity of alternator must be consistent to that of battery, namely negative. If mistaken
connection occurs, the battery will discharge through silicon diode to burn out diode.
(2) After alternator has started running, it is not allowed to check alternator output with spark test method
as the silicon diode may get damaged. Do this with bulb or multimeter.
(3) When alternator is turned off, disconnect the ignition switch. Otherwise battery will be grounded
through magnetic field coil of rotor and voltage regulator, keeping discharging till gets drained.
(4) Operator should eliminate immediately the faulties such as non-power generation or very low current.
In this case, alternator is not allowed perform long time opeartion, or other parts may get damaged.
4. Maintenance, Check, and Repair of Alternator
Frequently check the fixing nuts of alternator, tighten them if there is any loosening. It is not allowed to
Flexible
Connection of
Battery
Fuse (5A)
Fuse Box
Charging
Indicator Light
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check alternator output with live wire and magnetic field shorting methods. Alternator diode and insulation cannot
be checked with megohmmeter and 220V AC current, otherwise diode may get burnt. While the alternator has not
been dismantled, operator can use a multimeter to measure resistance values between alternator posts to
primarily judge if there is any faulty in an alternator. Current collector, brush, and brush spring should be checked
once every half year. All faulty should be eliminated timely.
(1) Check and replace diode
Disconnect diode from rotor winding to check resistance between diode’s two poles with a multimeter (R x 1)
as indicated in figure 11-4. Diode is in short circuit if no resistance has been measured on both terminals; and
diode is in open circuit if infinite resistance has been measured
Fig 11-4 Check Silicon Diode with Multimeter
Replace diode when internal open circuit or short circuit occurs on it. Followings are notes when to replace a
diode:
① Replace a new diode with same specificaiton.
② Be careful to mount negative tube (black) to end cover; positive red tube is to be mounted on element
panel.
③ Do not knock diode during replacing. Use special tools to press diode in place. Diode tube and hole must
be tightly matched. Precisely mount two diodes with an interference within the range of 0.07~0.09.
(2) Check and repair a rotor
Check and repair excitation winding. Open circuit and short circuit of excitation winding can be checked
with a multimeter (R x1). Touching the two ends with test probe as indicated in figure 11-5. The measured
resistance should comply with specification in table 18-14. If resistance is smaller than regulated value, it
indicates that there is turn-to-turn fault with excitation winding; if resistance is infinitely great, it means that the
excitation winding has been in open circuit.
Figure 11-5 Check Excitation Winding
More than 10000Ohm
More than 10000Ohm
Back End Cover of Alternator
Element Panel
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Open circuit of excitation winding generally occurs in the connecting part of winding lead and slip ring,
which can be corrected by re-welding. Rotor must be dismantled for re-coiling if turn-to-turn fault of grounding is
due to burnout of excitation winding.
The surface of rotor slip ring should keep clean, flat, and smooth, without any obvious burnout or uneven
wear. Slight burnout can be polished with fine sandcloth, and it is allowed to have slight surface damage. After
repair, the error on roundness of slip ring should not be larger than 0.25mm, the surface coarseness should not be
higher than Ra1.6μm, and the thickness of copper collar on slip ring should not be smaller than 1.50mm.
Otherwise, the slip ring should be replaced.
(1) Check and repair stator winding. Open circuit can be checked with a multimeter (R x 1), use multimeer
probes to touch three outlet stubs respectively as indicated in figure 11-6. It is normal if pointer stays below 1Ω.
But there must be an open circuit if the pointer remains still.
Figure 11-6 Check Stator Winding
For grounding check, touch the two test probes of multimeter with leads of winding and iron core of stator
respectively. The measured resistance shall be infinitely great, or it indicates that stator winding has grounded.
If open circuit or grounding in stator winding is found, the neutral point of the three-way winding should be
sealed off to further locate the failure point.
When the turn-to-turn ( inter-phase short circuit) happens that could burnout coil, or when there is severe
grounding that could not be corrected, the original winding shall be disassembled for re-coiling.
(2) Check and repair carbon brush. Carbon brush should move freely inside of the brush yok free from
obstruction. Replace severe worn-out brush. Carbon brush yoke should be free from damage and distortion.
Spring pressure should be between 1.5~2.0N.
11.4.4 Lighting System
1. Refer to the connection diagram for connection of electrical devices for the whole vehicle. The
connection of lighting system see figure 11-1
2. Lights
(1) Refer to table 11-12 for types of lights and the bulbs.
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Table 11-12 Lights List
S/N
Description
Spec (W)
Bulbs number
1
Headlight
55/60
2
2
Front
21
4
3
Corner Light
5
4
4
Front Fog Light
55
2
5
Rear
21
2
6
Backup Light
21/5
2
7
Rear Fog Light
21
2
8
Brake Light and Tail Light
21/5
2
9
License Light
5
2
10
Dome Light
5
1
All the lights should be complete, effective, and reliable during vehicle operation. The light form and
brightness of front headlight shall comply with vehicle checking and measuring regulations.
3. Vehicle signals
① Headlight relay
Lighting relay is a mini- electromagnetic relay, fitted on the fuse box. When combination switch lever is on
the headlight position, relay for headlight is connected to control the change of high and low beams. High beam is
displayed on instrument panel with a blue indicatort.
② Flash relay and directional indication:
When control lever is on the corresponding directional position, the power supply for flash relay is switched
on, the will flash. At the same time the directional indicator on instrument panel should also be turned on.
When the bulb of is broken, a bulb of same specification shall be replaced, otherwise the speed of lighting
flash will be inconsistent. If turing light refuses to flash, operator should check if flash relay is loosened, and then
short-test flash relay. If turns on now, it indicates that the flash relay is broken, use a flash relay of the same
specification to replace.
4. Faults in Lighting System and troubleshooting
① Fuse is burned out immediately once the light switch is turned on. This indicates a short circuit between
fuse and light.
② All lights keep off when light switch is turned on: no connection with power supply; the light fuse is
broken.
③ Failure corner lights:
Bulb filament is burn out; there is open circuit in the line; bad grounding or bad contacts.
④ Failure headlight: open circuit between light switch and beam selector, or failure beam selector; Coil of
lighting relay curcuit is open; fuses of left and right headlights are broken; and bulb filament is burned out.
⑤ Failure backup/brake light: switchs for backup / brake lights are damaged; bulb filament is burned out; or
there is bad contact or open circuit in the line.
3. Control Mechanism
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Fig 11-7 Complex instrument and Control Switch
Note:
Do not turn steering wheel when the vehicle is parking, and don’t move the vehicle when steering
wheel is locked. These would damage steering wheel.
(1) Switches used by BJ6536 series of light buses are listed in table 11-13.
Table 11-13 Switch List
Switch
Qty per Vehicle
Remarks
Ignition Switch
1
Combination Switch
1
Including light switch, switch, front headlight beam
selecting switch, PASS light switch, windshield wiper
switch, and windshield washer switch
Rear Fog Light Switch
1
Hazard light switch
Side window glass defrosting vent
Wiper and washer switch
Outside left rearview mirror
Radio and cassette player
Front air conditioner control switch
Central vent
Doors main control switch
Side vent
Ignition switch
Ashtray
Cigarette lighter
Inside
dome
light switch
Rear heater switch Rearview adjusting switch
Rear defrosting switch
Front dome light
Side window glass defrosting vent
Brake fluid tank
Side vent
Gloves case
Outside right rearview mirror
Front corner light, front headlight and
turning signal light switch
Front fog light switch
Parking brake lever
Gearshift control lever
Inner anti-dazzle rearview
Complex instrument
Rear fog light switch
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Chapter 11 Structure, Application and Service of Electrical Devices & Instrument
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Switch
Qty per Vehicle
Remarks
Front Fog Light Switch
1
Hazard Switch
1
Dome light switch
1
A/C Switch
1
▲Headlight Switch
Release this switch each time when this switch is lifted and the lighting switch is on “OFF” or 1
st
shift
position, the high beam of headlight will turn on or turn out. To send the overtaking signal, repeat the operation
crank, and thus the light will flash during daytime, while during nighttime the high beam and low beam will
alternatively turn on.
▲ Switch
When the lever of this combination switch is turned to the intended direction, the will flash, and at the same
time, the indicator on instrument panel will also flash. When steering wheel is returned to the middle position,
the switch lever will automatically resume to neutral position.
▲Light Control Switch
This switch is divided into two shifts to control following lights: 1
st
Shift: corner light, tail light, license
light, instrument panel illumination, low beam; 2
nd
Shift: High beam
▲Front Headlight Beam Selector
When switch lever is pulled up and down, the beam of front headlight will be alternatively switched from
high beam to low beam or from low beam to high beam. When front headlight is on high beam, the high-beam
indicator instrument panel will turn on.
(3) Other Switches
① Hazard Switch: When switch is pressed, front, rear, left, and right 4 s will all turn on.
② Steering gear linked lockpin: as long as ignition key is in the switch, the lockpin will not lock up the
steering gear. During driving process, the key can only be turned to “ON” position. Only when vehicle has
stopped driving, the key will return to “LOCK” position to be removed. At the same time, as linked lockpin can
lock the directional mechanism, it also can be used for theft –proof purpose.
③ Horn Button: The button is mounted in steering wheel center. Its sound lasts less than 2 seconds each
time.
④ Auto returning mechanism: Control lever for will return to middle shift from either “left” or “right”
postion along with steering wheel’s returning to center pistion. A return cam makes this possible.
(4) Ignition Switch
① Ignition switch performance is indicated in table 11-14.
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Table 11-14 Ignition switch performance
General
Power
Supply
Preheating
Receiving
Player
Start
Circuit of
Accessories
Remarks
LOCK
●
Ignition key can be inserted
or pulled out on this position.
Steering wheel will be locked
and fixed when key has taken
out. Engine will stop rotating
when key is turned to
“LOCK” position.
ACC
●
●
●
On this position, the circuit
of accessories is switched on
while engine has turned off.
ON
●
● When atmospheric
temperature is from
15℃
to
-15℃,
preheating
circuit
automatically turned
on and automatically
disconnected
in
30~140
second
(BJ483 engine)
●
●
Circuit for the whole vehicle
is switched on, and the key is
to be kept on this position
when engine is running
START
●
●
After engine has been started,
release your hand, and the
key switch will automatically
return to “ON” position.
Note: ● indicates “on”. When engine coolant temperature is lower than 0
, electronic preheating device
℃
is
activated. .
② Ignition Switch Function and Rated Current
Table 11-15 Ignition Switch Function and Rated Current
Name
Switch Function
Rated Current (A)
Service Life (Times)
Working Time
Start
10
50000
15 Seconds
≯
Igniting
15
50000
Continuous
Accessory
10
50000
Continuous
Ignition switch
Preheating
26
≯
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11.5 Complex instrument and Auxiliary Electrical Devices
1. Complex instrument
Complex instrument include water temperature meter, odometer, speedometer, fuel meter and reset button,
etc. Print circuit board is adopted by complex instrument. Each corresponding electrical devices comes with
standard plug connector. Refer to figures 11-8 and 11-9.
Fig 11-8 Luxurious and Superior Series Complex Instrument.
Fig 11-9 Standard Series Complex Instrument
2. Speedometer
① Technical parameters of speedometer
Structure and model Magnetic induction type
Max indicated speed (km/h) 180
Fuel meter
Odometer
Trip counter
Harzard indicator
Speedometer
Engine Rpm meter
Trip counter reset knob
Water temperature meter
Trip counter reset knob
Fuel meter
Hazard indicator
Odometer
Speedometer
Water temperature meter
Trip counter
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Max indicated mileage (km) 99999.9
Speedometer: Speedometer indicates the vehicle speed in km/h.
Odometer: Odometer records vehicle accumulated driving distance in km.
Mileage counter and reset button: Reset button of odometer is located on the lower corner of
speedometer.
I. Odometer with single-row liquid crystal display
1. Liquid crystal display of accumulated mileage;
2. Press reset button less than 1 second to show journey mileage;
3. Press reset button again less than 1 second to return to total vehicle mileage;
4. While journey mileage is displaying, press the button longer than 2 seconds will zero the display.
(Vehicle total mileage cannot be reset to “0”) .
II. Odometer with double-row liquid crystal display
When reset button is pressed longer than 2 seconds, travelled mileage will be cleared into “0”.
Coolant temperature meter and fuel meter
When starting switch is turned to “ON” position, coolant temperature meter will indicate the temperature of
cooling water. The letters “C” and “H” on meter represent “Low Temperature” and “High Temperature”,
respectively. If coolant temperature meter pointer is under the red line, it indicates that coolant temperature is
normal. The letters “E” and “F” on fuel meter stand for fuel “empty” and “ful” respectively. On some type of
instrument panel, when ignition key is turned to “OFF” position, fuel metr pointer will not return to “E” mark, it
still indicates the approximate oil level.
① Coolant temperature meter and its sensor
▲ Refer to table 11-16 for technical data of coolant temperature meter and its sensor.
▲ Check coolant temperature meter and sensor. Unplug the sensor and connect a 40Ohm resistor. Ground
one resistor end. Turn on ignition switch, coolant temperature meter and its circuit are normal if the meter
indicates around 100℃.
▲ Refer to table 11-17 for coolant temperature meter fault diagnosis.
Table 11-16 Technical Data of Coolant temperature meter and Its Sensor
Coolant temperature meter (Moving Magnetic Type)
Sensor (Heat Sensitive Resistor)
Indicated Value
(℃)
50
105
125
50
85
115
Applicable
Voltage
(V)12
Equivalent
Resistance(Ω)
226±5
26.4±4.5
19
226±36~36.6
64±8
1.71~2.21
Note: Equivalent resistance means a stabilized resistance during the coolant temperature sensor’s
operating.
Table 11-17 Coolant temperature meter Fault Diagnosis
Symptom
Cause and elinmination
Instrument
indicator does not
work
1. Instrument socket is loosened or with bad contact
2. Open circuit inside coolant temperature meter, and the core of coolant temperature meter
should be replaced if resistance is infinitely great when checked with above-mentioned
method
3. There is failure inside sensor, sensor should be replaced if measured resistance is
significantly different from the specified one when checked with above-mentioned method.
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Chapter 11 Structure, Application and Service of Electrical Devices & Instrument
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Symptom
Cause and elinmination
Incorrect
Indication of
Instrument
1. Check the coolant temperature meter with above-mentioned method, and if its pointer is
excessively deviated, it indicates the meter has not been well calibrated and should be
replaced.
2. Check the sensor with above-mentioned method, and if values vary significantly, it
indicates there is sensor failure, sensor should be replaced.
② Fuel meter and its sensor
▲Refer to table 11-18 for technical data of fuel meter and its sensor.
Table 11-18 Technical Data of Fuel Meter and Its Sensor
Fuel Sensor (Slip Resistance Type)
Applicable
Voltage (V)
Fuel Level
0(E)
1/2
1(F)
12
Fuel Meter
(Moving Magnetic
Type)
Output Resistance (Ω)
110(-8,0)
32.5±13
3(0,+10)
▲Check fuel meter. Remove the sensor connecting wire and connecte with a 32.5±13 Ω (12V) resistor.
Ground one end of resistor. Turn on ignition switch, if fuel meter stays around 1/2 scale mark, it indicates that fuel
meter and its circuit are under normal condition.
▲Check fuel sensor
Take the fuel sensor out from fuel tank. Measure resistance between the two contacts of sensor with a
multimeter and move the float position from 0 to 1/2, and to 1. Observe the readings of multimeter, if the
measured resistance complies with specifications in table 18-23, the sensor is in good condition.
Notes to user:
1. Generally fill fuel to the lower edge of the filler to prevent fuel from splashing out of. For this reason,
the fuel quantity is theoretically less than that in the fully filled state. Therefore, fuel meter does not indicate the
full (F) level.
2. When fuel meter indicates zero (E), there is still a remaining fuel of 6~9L inside the fuel tank. The
vehicle can still drive for about 50-~100km.
▲Refer to table 11-19 for fuel meter fault diagnosis and troubleshooting.
Table 11-19 Fuel Meter Fault Diagnosis And Troubleshooting
Symptom
Cause and Elimination
Instrument Fails to Work
1. Instrument socket of print circuit board lis oosened or with bad contact
2. There is open circuit inside fuel meter, and the core of meter should be replaced if
resistance is infinitely great. check with above-mentioned method.
Meter pointer moves
more than one scale
mark when meter is
powered on.
Slip resistor contact of sensor is loosened or resistor disconnected, and the sensor
should be repaired or replaced. Check with above-mentioned method
Incorrect Indication
1. Fuel meter should be replaced if pointer has deviated too much. Check with
above-mentioned method
2. Sensor contact position has changed, and output resistance is incorrect; adjust
contact position or replace sensor. Check with above-mentioned method
3. Length of sensor rod is inconsistent to height of fuel tank. Select matching sensor
rod.
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5. Auxiliary Electrical Devices
Auxiliary electrical devicess include horn, Radio/casette player, windshield wiper/washer, cigarette lighter,
and heating device, etc.
(1) Horn
When horn’s volume is turned down or does not work, turn the adjusting screw on the back of horn until
suitable volume is achieved, and then tighten and lockup the nut.
(2) Windshield Wiper
Wiper is used for cleaning windshield when vehicle is driving in raining or snowing days or days. Two shifts
of wiping speeds are provided during use as per different requirements. Wiper motor is a permanent magnetic
double-speed motor. Wiper is controlled (on/off/speed) by a lever under steering wheel. The first shift is low speed
and the second shift is high speed. Do not use wiper dryly. Operated wipe only when fluid is present either with
rain or windshield fluid. Otherwise, windshied glass could be scrached or motor could be damaged.
(3) Windshield washer
Washer is generally used together with wiper. Washer motor is designed for short-term working only, its
working duration for each time should not exceed 5 seconds. Nozzle of washer can be adjusted. Insert a pin into
nozzle, and gently toggle it to desired direction so that sprayed fluid could land on the middle upper part of
windshield. If nozzle is blocked, use a metal wire to clear it.
Use special windshield fluid, and use antifreezing fluid in winter.
(4) Cigarette Lighter
Cigar lighter can be use only when ignition switch is on “ACC” or “ON” position. Press inward the cigarette
lighter and the lighter will heat up, and pop up to normal position after heating up.
Please pay attention to the following items when cigarette lighter is used:
Make sure to push on its handle knob. Never hold the lighter body to avoid scalding. If cigar lighter will not
pop up in 18 seconds, this indicates it is failure. Press again could help it to get out. Do not leave vehicle attended
after having pushed down cigar lighter to avoid fire accident. Sometimes the cigarette lighter fails to eject dut to
parts distortion, and fitting for the lighter should then be replaced.
(5) Heating Device
Heating device is used in cold weather. Turn the knob to activate it after engine coolant temperature has gone
up. Temperature switch and fan switch can be used to control interior temperature. They also help to defrost
/defog windshield by applying recycling air.
(6) Dome Light
Dome lights operate can be operated no matter which position the ignition switch is on. There are
controlled by their own switches.
11.6 Air Conditioner
Vehicle air-conditioning system is the equipment to realize the ventilation, cooling and heating,
dehumidifying and air cleaning within the vehicle. It provides the driver and passengers with a comfortable
environment, relieve the driver from fatigue to ensure a safe driving. Air-conditioning equipment has already
become a vital functional component of a vehicle, and is an important indicator for assassing the integrity of a
vehicle’s functions.
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Chapter 11 Structure, Application and Service of Electrical Devices & Instrument
·263·
Fig11-10 AC System
1-Nut M6;2-Blower Assembly;3-Bolt;4-Big Washer;5-Self Tapping Screw;6-Front Evaporator Assembly;7-Hexagon Flange
Nut;8-Bolt;9-Front Heating Radiator Assembly;10-Hexagon Flange Nut;11- Front Evaporator Suction Pipe Assembly;12-Bolt;
13-Receiver Assembly;14-Bolt;15-Rear Evaporator Suction Pipe Assembly A;16-Pipe Clip;17-Pipe Clip;18-Complex Pipe
Assembly;19-Bolt;20-Three holes Cover Assembly;21-Bolt;22-Three Holes Cover Water Pipe Rubber Ring;23- Three Holes
Cover Small Rubber Ring;24- Three Holes Cover Big Rubber Ring;25-Rear Evaporator Water Dropping Pipe Assembly and Rear
Evaporator Water Dropping Pipe;26-Rear Evaporator Suction Pipe Assembly B;27- Rear Evaporator Exhaust Pipe Assembly A;
28-Nut;29-Bolt;30- Rear Evaporator Assembly;31-Upper Block of Water Pipe;32-Lower Block of Water Pipe;33- Front
Evaporator Exhaust Pipe Assembly B;34-Pipe Clip;35-Bolt;36-Pipe Clip Assembly;37-Bolt Assembly;38-Low Pressure Pipe
Assembly;39-Low Pressure Pipe Assembly;40- Rear Evaporator Exhaust Pipe Assembly B;41-Bracket Assembly;42-Bolt;43-Nut;
44-Condenser Assembly;45-Bolt and High Pressure Pipe Assembly;46-High Pressure Pipe Assembly
11.6.1 Principle & Structure
1. Refrigeration Cycle
Refrigerant in vehicle air-conditioner is vaporized from liquid to gas and condensed from gas to liquid. The
cycle repeates continuously. This cycle is called the refrigeration cycle.
Usually gas temperature will rise when gas is compressed; and gas will turn into liquid if the temperature
drops; and the liquid shall turn into gas again when pressure drops. In the refrigeration cycle, compressor
compresses the refrigerant gas, the compressed high-pressure and high-temperature gas is condensed into liquid
through condenser. The liquid refrigerant is vaporized by means of the orificing effect of the expansion valve.
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