the starter relay pulls-in and provides power to starter motor magnetic switch. After that, the 
starter motor runs. For specific control principle, refer to 2.11.3.1 Start System Operating 
Principle. 

2.11.2.3 Charging System Description and Operation 

Charging system includes the battery, generator, instrument and relevant circuits. Generator 
consists of the voltage regulator, rectifier, stator and rotor, which are all installed inside the 
generator. When the engine rotates, the drive belt drives the generator to rotate. The generator 
rotation generates an alternating current, which is converted to a direct current by the diode 
rectifier and then transmitted to the charging system. Voltage regulator automatically adjusts the 
generator field current to control voltage output to keep it within the appropriate charging range. 
Refer to 2.11.3.2 “Charging System Operating Principle” for the detailed operating principle. 

Charging Process: 

1.  When charging sealing type battery after dismantling from vehicle, it is necessary to equip 

joint tool components. Make sure that all the charging cables are clean and firm. To achieve 
best results, charge the battery when the electrolyte and electrode are at room temperature. If 
the battery temperature is too low, the charger may not start charging after a few hours. 

2.  Charge the battery until the battery is full or the tested battery voltage is close to full load 

capacity. Inspect the battery every half an hour during charging. 

Refer to 2.11.7.9 "Battery Discharge Current and Parasitical Load Tests" to carry out the load test 
on the battery after charging. 

Charge a fully discharged battery (off the vehicle): 

Strictly bey the following procedure, otherwise a good battery might be mistakenly replaced. 
Follow the following procedures, charge a fully discharged battery: 

1.  Measure the battery terminal voltage with a precision voltage meter. If the reading is less than 

10 V, the charging current will be low. The battery can only be charged with more than a few 
mA of current after a certain period of time. 

2.  Set the battery charger at a high value. 

3.  Continue to charge the battery with 16 V charging voltage for more than 4 hours: 

• 

If there is still no charging current after reaching above time, it is necessary to replace 
battery. 

• 

If there is charging current measured during charging period, it indicates that the battery is 
intact and can continue to be charged fully. 

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2.11.3 System operating principle 

2.11.3 .1 Start System Operating Principle 

When the ignition switch is at the "ST" position: 

z  Power passes through the under hood fuses EF40 and EF29 to the starter relay ER03 terminal 

No.30. 

z  Power passes through the under hood fuses EF40 and EF14 to the ignition switch wiring 

harness connector IP45 terminal No.5. 

z  When the ignition switch is at the “ST” position, the power passes through the ignition switch 

wiring harness connector IP45 terminal No.4 to the starter relay ER03 terminal No. 86. 

z  After energizing, the starter motor solenoid switch closes to provide the close loop between 

the battery and the starter motor. The starter motor is grounded via the engine cylinder block. 
Wen the two requirements of power supply and grounding are met, the starter motor begins to 
run and the engine starts up. 

Start motor operating principle: The motor is a DC reduction motor. The stator is a permanent 
magnet and the rotor is coil windings located in the armature. Through the magnetic field the coil 
excites the windings. Solenoid core is located inside the drive cover to avoid dust, ice and splash 
of water. When the switch is closed, the electromagnetic switch coil power results in a magnetic 
field, causing the core and fork to move and driving gear and the engine flywheel ring gear to 
mesh. When the electromagnetic switch main contacts are closed, the battery to starter motor 
circuit is connected. The armature rotates and through a reduction mechanism increases the torque 
to drive the engine to rotate. With the starter motor rotating, due to the driving gear and the engine 
flywheel ring gear mesh, so the engine rotates. When the engine starts, the driver gear overdrive in 
order to prevent the armature speed is too high to damage the starter, at this moment the return 
spring separates the drive gear. In order to prevent the high speed which may damage the starter, 
the ignition switch should be immediately released after the engine starts. 

2.11.3.2 Charging System Operating Principle 

Generator provides DC voltage to the vehicle electrical system and maintains the battery charged. 
The voltage output is controlled by the regulator integrated inside the generator: 

z  When the ignition switch is at "OFF" position: battery voltage passes through the I/P fuse 

EF03 to the generator harness connector EM12 terminal No.1. This voltage is the working 
power supply of generator. 

z  When the ignition switch is at "ON" position and the engine is not running: 

A.  Generator harness connector EM12 terminal No.1 still has voltage. When the ignition switch is at 

"ON" position, it provides IG1 relay terminal No.85 voltage. The relay pulls in. 

B.  Battery voltage passes through the I/P fuse EF40, EF35 and cab fuse IF02 to IG1 relay terminal 

No.87. Due to relay pull-in, relay terminal #30 output passes the battery voltage through the cab fuse 
IF25 to the generator harness connector EM12 terminal No.1. After the magnetizing coil is provided 
with power, this voltage produces a good magnetic field around the coil. 

C.  Generator harness connector EM11 terminal No.1 is connected with the instrument connector IP02 

terminal No.10, so the EM11 terminal controls the generator charging indicator lamp. When the 
engine is not running, the terminal provides a good ground, so the charging indicator lamps. 

z  When the engine operates: a stator coil generates induction alternating voltage because an 

exciting coil generates a magnetic field; thus, a voltage regulator inducts the voltage and 
control current and alternating voltage in the magnetic field that are generated by 3 stator 
coils. The AC voltage is converted into DC voltage through a current rectifier built in the engine.  
Adjusted by the voltage regulator, the generator output voltage is applied to the vehicle battery and the 
battery terminals power circuit. With the generator working, generator harness connector EM11 terminal 

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No.1 voltage and the voltage at both sides of charging indicators in the instrument is the same, thus the 
charging indicator loses ground and off.   

z  Because the generator harness connector EM12 terminal No.1 and the battery is connected, 

when the battery is fully charged, the regulator will reduce the magnetic field excitation 
current, thereby reducing the generator output voltage to prevent overcharging. When the 
battery discharging or load is big, the voltage regulator increases the magnetic field excitation 
current to increase the generator output voltage. 

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2 . 11 . 4 Part position figure 

2.11.4.1 Component position 

1

2

NL02-1003e

 

1. Generator 

2. Starter 

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