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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

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

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

3. Electrical devices used by vehicle have

not turned off

3. Low S. G. after

supplementary charging

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

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

Model

QDY1253 Permanent-Magnet Reduction Starter

Graound polarity

Negative

Rated Voltage (V)

Rated Power (KW)

1.4

Rotating Direction (Viewing from the driving

terminal)

Clockwise

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

Model

JFZ1977

JF1615

Rated Output

14V 90A

14V 65A

Rated Rpm

6000r/min

Operating Rpm (Continuous)

1000~18000r/min

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S/N

Description

Parameters

Overspeed Test

22000r/min 30S

Rpm at Zero Current

≤1000r/min

Regulator Adjusting Voltage

14.1±0.2V

Regulator Temperature Compensation Coefficient

-7±3mV/℃

Weight of Alternator (kg)

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

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

Headlight

55/60

Front

Corner Light

Front Fog Light

Rear

Backup Light

21/5

Rear Fog Light

Brake Light and Tail Light

21/5

License Light

Dome Light

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

Combination Switch

Including light switch, switch, front headlight beam

selecting switch, PASS light switch, windshield wiper

switch, and windshield washer switch

Rear Fog Light Switch

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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Switch

Qty per Vehicle

Remarks

Front Fog Light Switch

Hazard Switch

Dome light switch

A/C Switch

▲Headlight Switch

Release this switch each time when this switch is lifted and the lighting switch is on “OFF” or 1

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

Shift: corner light, tail light, license

light, instrument panel illumination, low beam; 2

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.

●

● When atmospheric

temperature is from

15℃

-15℃,

preheating

circuit

automatically turned

on and automatically

disconnected

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

℃

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

50000

15 Seconds

≯

Igniting

50000

Continuous

Accessory

50000

Continuous

Ignition switch

Preheating

≯

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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

（℃）

105

125

115

Applicable

Voltage

（V）12

Equivalent

Resistance（Ω）

226±5

26．4±4.5

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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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)

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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Foton Series Light Bus. Service Manual - part 17