Basic Knowledge of

Loader Electrical System

February 2011
Main Content

 Suitable Group

 Training Objectives

Contents

24/01/12
Suitable Group

This course is suitable for domestic and foreign

junior technical service personnel
It also applies to…

24/01/12
Main Content

 Suitable Group

 Training Objectives

Contents

Evaluation Topics

24/01/12
Training Objectives

1. This training course is expected to have 6 hours.

2. After training of this course, students should master the following
main knowledge points:
（ 1 ） Circuit diagram and failure analysis methods
（ 2 ） Storage battery diagnosis
（ 3 ） Structure of generator
（ 4 ） Failure diagnosis of starter
（ 5 ） Instrument and sensor
（ 6 ） Electrical system structure and principle of Lingong loader
（ 7 ） Common failure diagnosis and troubleshooting of loader
electrical system

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 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
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 Circuit Diagram and Failure Analysis Methods of
Engineering Machinery
Expression Methods of Loader Circuit Diagram: In circuit diagram, power supply,
cranking system, lighting, instrument and auxiliary device are connected by switches,
wires and insurance devices according to their respective working characteristics and
mutual inner link to make a whole.
Ⅰ. Expression Methods of Loader Circuit Diagram
Expression methods include circuit diagram, principle diagram, wiring diagram and
electrical component distribution map.
Ⅱ. Circuit Analysis
Principles followed by circuit:
1. Single wire system
2. Electrical equipments are in parallel and controlled by their respective switches.
3. Low pressure. Appliances are designed under 24V (output voltage of generator is
28V).
4. All the vehicles are equipped with insurance devices to prevent electrical equipment
and wires from burning due to short circuit.
5. Negative electrode of storage battery is 24/01/12
connected to the ground.
 Circuit Diagram and Failure Analysis Methods of
Engineering Machinery
Ⅲ. Main Points in Reading Circuit Diagram
1. Read drawing statements vehicleefully for several times
Drawing statements indicate name and number of all electrical equipments of the vehicle. By
reading drawing statements, you can preliminarily understand electrical equipments equipped
by the vehicle. And then find the electrical equipments in the circuit diagram with their number.
And further explore mutual connections and control relationship.
2. Remember graphical symbols for electrical diagrams
Circuit diagram shows structure and working principle with graphical symbols for electrical
diagrams. Therefore, to understand schematic circuit diagram, you must remember meaning of
graphical symbols for electrical diagrams.
3. Remember circuit mark symbols

To draw and read electric circuit diagram, some electrical devices or their terminals are given
different symbols.
4. Remember circuit characteristics ⑴ Single wire system ⑵ Negative earth ⑶
Electrical equipments are in parallel

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 Circuit Diagram and Failure Analysis Methods of
Engineering Machinery
5. Remember closed-loop principle
Any complete circuits consist of power supply, fuse, switch, control device, electrical
equipment, wires, etc. Current must start from positive terminal of power supply. It reaches
electrical equipment through fuses, switches, control devices, wires, etc. A return circuit can
be formed after it goes back to negative electrode of power supply through wires (or by earth).
Therefore, there are three kinds of ideas when reading circuit diagram.
Idea 1: Along current flow of circuit, start from positive electrode of power supply. Find electric
equipment, switches, control devices, etc. And then return to negative electrode of power
supply.
Idea 2: Against current flow of circuit, start from negative electrode of power supply (earth). Go
back to positive electrode of power supply through electric equipment, switches, control
devices, etc.
Idea 3: Start from electric equipment. Find its control switches, wires and control units in turn.
Reach positive electrode of power supply and earth (or negative electrode of power supply).
In practical application, different ideas can be selected for circuit. However, it's worth noting
that with extensive use of electronic control technology, most circuits of electrical equipment
has main circuit and control circuit at the same time. Both of the two circuits have to be given
consideration to when reading diagram.

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 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
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Storage Battery

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（ 1 ） Classification of Storage Battery
Storage battery is a chemical power, which stores electricity or
supplies power to electrical equipment with its internal chemical
reactions. Currently there are basically two kinds of storage batteries
used in fuel automobile, which are lead-acid storage battery
(hereinafter referred to as lead storage battery) and nickel-iron
storage battery. Meanwhile, because of higher requirements to
emission of fuel automobile and impact of energy crisis, all the
countries are continuously exploring and developing electric
vehicles, whose main power supply is new high-energy battery. The
table below lists features of various batteries.

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（ 1 ） Classification of Storage Battery
Type Features

Common Electrode plates of new storage battery are uncharged. Before using electrolyte should be added and
lead storage first charge should be conducted according to provisions. First charge needs a long time. Regular
battery maintenance is needed in use.

Dry-charged Electrode plates of new storage battery are in dry charging status. There is no electrolyte in the
lead storage storage battery. If you want to use it within the specified preservation period, you just have to add
battery electrolyte according to provisions. It can be used after standing for 20 ~ 30min. Regular maintenance
is needed in use.

Drained and Electrode plates of new storage battery are charged. There is little electrolyte in the storage battery. If
charged you want to use it within the specified preservation period, you just have to add electrolyte according
lead storage to provisions. It can be used after standing for 20 ~ 30min. Regular maintenance is needed in use.
battery

Maintenance Maintenance is not needed in use. It can be used for 3 to 4 years. Distilled water doesn’t need to be
free storage added. There is very little pile corrosion and self discharge.
battery

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（ 2 ） Functions of Storage Battery
Amper Start
e meter button
Loader is equipped with two dc
power supply, which are Regulator

storage battery and generator. Generator

Sto Starter
The two power supply are in Ele rag
ctri e
parallel. Electric equipments of c bat
equ ter
the entire vehicle are in parallel.
ipm y
Functions of Storage Battery: ent

1 ） When engine starts, storage battery will supply power to starting system and ignition
system. 2 ） When engine is running at low speed and voltage of generator is below charging
voltage of storage battery, storage battery will supply power to electrical equipment.
3 ） When engine is running at middle or high speed and voltage of generator is higher than
charging voltage of storage battery, storage battery will store the rest electricity of generator.
4 ） When generator overloads, storage battery will help generator supply power to electrical
equipment. 5 ） Storage battery can also absorb transient overvoltage in the circuit, keep
voltage of vehicle electrical system stable and protect electronic components.

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 1. Structure of Lead Storage
Battery
Lead storage battery is generally
formed by the series connection
of three or six single batteries.
See figure for its structure
1 － Negative pole
2 － Liquid adding port lid
3 － Positive pole
4 － Wall connection
5 － Bus bar
6 － Shell
7 － Negative electrode plate
8 － Division plate
9 － Positive electrode plate

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1. Structure of Lead Storage Battery
1 ） Electrode Plate
Electrode plate is the core part of storage battery.
Charging and discharging chemical reactions of
storage battery mainly rely on active materials and
electrolyte on the plate. There are positive and negative
electrode plates, both consisting of grid frame and
active substances.
Function of grid frame is consolidation of active
substances. Grid frame is generally cast by antimony
alloy. It has good conductivity, corrosion resistance
and mechanical strength. Structure of grid frame is
shown in the top right figure. In order to reduce internal
resistance and improve starting performance of storage
battery, some lead storage batteries use radiate grid
frame. The bottom right figure is radiate grid frame
structure of storage battery for Santana vehicle.

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1. Structure of Lead Storage Battery
Active substance on positive electrode plate is dark brown
1 － Plate group
PbO2. Active substance on negative electrode plate is Grid Frame assembly 2 －

spongy and grey pure lead (Pb) . Tune active substances into Negative
a paste, fill in space of grid frame and dry. Electrode plate is electrode plate
3 － Division
formed. As shown in the top right figure.
plate
Active
Put a piece of positive electrode plate and a piece of 4 － Positive
Substances
negative electrode plate in electrolyte. About 2V of electrode plate
electromotive force can be obtained. In order to increase 5 － Connector of
capacity of storage battery, many pieces of positive and
electrode plate
negative electrode plates are often installed in parallel
respectively to form positive and negative electrode plate
group. As shown in the bottom right figure. In each single
battery, positive electrode plate is 1 piece less than
negative electrode plate, so that each piece of positive
electrode plate is between two pieces of negative electrode
plate. Discharging on both sides of positive electrode plate
can be even to avoid bending of electrode plate due to
uneven discharging.

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1. Structure of Lead Storage Battery
2 ） Division Plate
Division plate is inserted between positive and negative electrode plate, to avoid
short circuit caused by contact of positive and negative electrode plate. Division
plate should be anti-acid and porous for electrolyte penetration. Commonly used
materials for division plate include wood, microporous rubber, microporous plastic,
etc. Among them, wooden division plate has poor acid resistance. Microporous
rubber has the best division plate performance but high cost. Microporous plastic
division plate has small hole diameter, high hole rate and low cost. Therefore, it is
widely used.
3 ） Electrolyte
In chemical reaction of storage battery, electrolyte conducts electricity among ions
and participate in chemical reactions. Electrolyte is made of pure sulfuric acid
(H2SO4) and distilled water in a certain proportion. Its density is generally from 1.24
to 1.30 g/cm3.
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1. Structure of Lead Storage Battery
Density of electrolyte has important influence on work of storage battery. Big density can reduce the
danger of freezing and improve the capacity of storage battery. But if the density is too high,
viscosity will increase, capacity of storage battery will decline, and its service life will be shortened.
Density of electrolyte should be determined by region and climate conditions. The table below lists
density of electrolyte in different regions and under different temperature. In addition, purity of
electrolyte is also one of the important factors influencing on performance and service life of storage
battery .
Density of electrolyte of fully charged storage battery at
Weather Conditions 25℃ （ g/cm3 ）
Winter Summer

Regions where temperature is below 1.30 1.26

－ 40℃ in winter
Regions where temperature is above 1.28 1.25
－ 40℃ in winter
Regions where temperature is above 1.27 1.24
－ 30℃ in winter
Regions where temperature is above 1.26 1.23
－ 20℃ in winter
Regions where temperature is above 1.24 1.23
0℃ in winter

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 1. Structure of Lead Storage Battery
4 ） Shell
Shell is used as container of electrolyte and electrode plate
group. It should acid-proof, heat resistant and shock-proof.
Shell is usually made of hard rubber or polypropylene plastic. It
is integral structure. There are raised ribs at the bottom for
electrode plate group. The shell is divided by walls into three or
six single compartments that are not connected. Single
compartments are installed in series with lead chains. As
shown in the right figure. Upper part of shell is sealed with
battery cover of the same material. Battery cover is equipped
with liquid adding holes corresponding to every single
compartment to add electrolyte and distilled water, and
measure density and temperature of electrolyte and height of
liquid surface. Air vent on the liquid adding cover can smoothly
discharge gas produced in chemical reaction of storage
battery.
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 2. Features of Maintenance Free Storage
Battery
Maintenance free storage battery is also called MF storage battery. Maintenance free means during
reasonable use period of vehicle, there is no need of adding distilled water for storage battery,
detection of liquid surface height of electrolyte, detection of electrolyte density and other maintenance
activities. Features of maintenance free battery include:
1 ） Grid frame is made of lead calcium alloy, which not only improves mechanical strength of grid
frame, but also reduces water consumption and self discharge of storage battery.
2 ） Bag microporous PVC division plate is used. Positive electrode plate is put in the division plate
bag, which can prevent active substances on the plate from falling off and avoid short circuit of
electrode plate. Therefore bottom of shell doesn’t need raised ribs, which lowers the height of plate
group, increases volume of upper part of electrode plate, and increases storage capacity of electrolyte.
3 ） Electrolyte density meter installed in storage battery can automatically display energy of storage
battery and surface height of electrolyte. If observation window of density meter is green, storage
battery is fully charged and can be used normally. If it is dark green or black, storage battery doesn’t
have enough energy and needs additional charge. If it is light yellow, storage battery will be declared
worthless. As shown in the figure.

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2. Features of Maintenance Free Storage
Battery

1 － Green （ Charging degree is 65 ％ or above ） 2 － Black （ Charging degree is

below 65 ％） 3 － Light yellow （ Storage battery has failure ） 4 － Cover of storage
battery 5 － Observation window 6 － Optic charge indicator 7 － Small green ball
4 ） New security ventilation device and gas collector are used. a alumina filter installed in
the port lid can prevent vapor and sulphuric acid gas from passing through, and allow
hydrogen and oxygen to escape smoothly. Catalyst palladium installed in catalyst
palladium can make hydrogen and oxygen ions to combine into water and return to the
storage battery. 24/01/12
3. Capacity and Influencing
Factors of Storage Battery
C, capacity of storage batter, is equal to the product of discharge current I f and
discharge time tf.
C ＝ If ·tf
1 ） Rated Capacity
According to GB5008.1-91 Lead-acid Starter Batteries—Technical Conditions, when
fully charged new storage batteries continuously discharge with the discharge
current of 20 hourly rate (0.05C20 amps) until average voltage of single battery
reduces to 1.75 V under electrolyte temperature of 25 + 5 ℃, the output electric
quantity is called rated capacity of storage batteries, represented with C 20, whose
unit is A · h.
eg ：
When 6 - Q - 120 storage batteries continuously discharge with the discharge
current of in 6A (0.05 C20 = 0.05 x 120 = 6A) until average voltage of single battery
reduces to 1.75 V, if the discharge time is greater than or equal to 20h, the capacity
C ＝ If·tf≥120A·h, and rated capacity has been reached, it is qualified product. If
discharge time is less than 20h and capacity is less than rated capacity, it is
unqualified product.
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3. Capacity and Influencing
Factors of Storage Battery
2 ） Reserve Capacity
According to GB5008.1-91 Lead-acid Starter Batteries—Technical Conditions, when storage
batteries continuously discharge with the constant current of 25A until average voltage of single
battery reduces to 1.75 V, the discharge time is called reserve capacity of storage batteries, whose
unit is minute.
Reserve capacity represents the capacity of storage batteries to provide constant current of 25A
for lighting, start motor and other electric equipments in failure of charging system of vehicle.
3 ） Starting Capacity
Starting capacity represents lead storage battery’s capacity of electric power supply when the
engine starts. It is one of the most important indexes for detection of quality of storage battery.
Starting capacity is largely influenced by temperature. Therefore, it is divided into low-temperature
starting capacity and normal-temperature starting capacity.
（ 1 ） Low-temperature starting capacity: Under the electrolyte temperature of - 18 ℃, when
storage batteries continuously discharge with 3 times of rated capacity until voltage of single
battery reduces to 1V, the discharged electric quantity is low-temperature starting capacity. The
duration should be above 2.5 min.
（ 2 ） Normal-temperature starting capacity: Under the electrolyte temperature of 30 ℃, when
storage batteries continuously discharge with 3 times of rated capacity until voltage of single
battery reduces to 1.5V, the discharged electric quantity is normal-temperature starting capacity.
The duration should be above 5min.

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 3. Capacity and Influencing
Factors of Storage Battery
1 ） Structural Factors
If surface area of storage battery electrode plate is larger and the number of electrode plate is great, more
active substances will participate in reactions and capacity will be greater. In addition, if the plate is thin,
active substances will have better porosity, electrolyte will be easier to penetrate into plate, active
material is higher, utilization ratio of active substances will be higher, and output capacity will be bigger.
2 ） Use Factors
（ 1 ） Discharge current
（ 2 ） Temperature of electrolyte （ see the right figure ）
（ 3 ） Density of electrolyte
Increasing the density of electrolyte properly can
increase penetration rate of electrolyte and improve
electromotive force and capacity of storage battery. But
if density of electrolyte is too big, viscosity will be increased,
resistance will increase, and capacity of storage battery will be
reduced.

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3. Capacity and Influencing
Factors of Storage Battery
（ 1 ） Discharge Current
Electro
motive Starting
The greater discharge current is, Force Voltage

the smaller capacity of battery is. Ending

As shown in the right figure. Voltage

When discharge current

increases, the speed of chemical
reactions will increase, and the
speed for PbSO4 to block holes
will increase, so that many active
substances in the inner layer of
plate cannot participate in
chemical reactions. Actual output
Discharge Time (h or min)
capacity of storage battery will
Meanwhile, electrolyte density will reduce rapidly. Voltage of storage battery will also drop sharply.
decrease.

Discharge time will be shortened. Therefore, in actual use, starting time must be strictly controlled.
Starting time should not exceed 10s, and interval between two successive starting shall not be less
than 2 minutes.

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4. Charging of Storage Battery
1 ） Charging Equipment

Storage battery is dc power, which must be charged with dc power. When

charging, positive electrode of charging power supply shall be connected to
positive electrode of storage battery, and negative electrode of charging
power supply shall be connected to negative electrode of storage battery.
Charging device on vehicle is ac generator driven by engine. Silicon rectifier
charger, thyristor rectifier charger and intelligent charging machine are often
used for charging.

2 ） Charging Method
（ 1 ） Constant-voltage charge
（ 2 ） Constant-current charge
（ 3 ） Quick charge

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5. Common Failure of Storage Battery
Failure 1: Vulcanization of Electrode Plate
Failure A layer of white coarse grain PbSO4 is generated on the plate, which cannot turn into PbO2 and Pb in normal
Symptom charging.
（ 1 ） When sulfuretted batteries discharge, voltage sharply reduces and drops to end voltage too early.
Capacity of batteries decrease.
（ 2 ） When storage battery is charged, voltage of single compartment increases too fast, and temperature of
electrolyte increases quickly, but density increases slowly, and bubbles are produced too early. There are
even bubbles immediately the batteries are charged.
Failure （ 1 ） Storage battery is undercharged for a long time or fails to be charged timely after discharge. Part of
Cause PbSO4 on the plate dissolves in electrolyte. The higher environment temperature is, the larger solubility is.
When environment temperature decreases, solubility will decrease. Dissolved PbSO4 will separate out,
crystallize again on the plate, and form vulcanization.
（ 2 ） Liquid surface of electrolyte is too low. Upper part of the plate contacts with air and be oxidated. When
the vehicle is running, electrolyte fluctuates and contacts with oxidation part of the plate. Big grain PbSO4
hardening layer is generated, and upper part of the plate is vulcanized.
（ 3 ） Because of long-term over-discharge or deep discharge of small current, PbSO 4 is generated in holes of
active substances deep in the plate.
（ 4 ） New storage battery is not completed charged. Active substances are not fully restored.
（ 5 ） Density of electrolyte is too high. Composition is pure. External temperature changes dramatically .

Troubles Mild vulcanized storage battery can be treated with long charging of small current . Vulcanization of Serious
hooting vulcanized storage battery can be removed with desulphurization charging method. Particularlly serious
Method vulcanized storage battery should be scrapped.

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5. Common Failure of Storage Battery
Failure 2: Falling of Active Substances
Failure Mainly refers to falling off of PbO2, the active substance on the positive electrode plate.
Sympt Battery capacity reduces. Brown substance can be seen in liquid adding hole while charging. Electrolyte is
om
turbid.

Failure （ 1 ） Charge current of storage battery is too large. Temperature of electrolyte is too high. Active
substances become expanded, soft and easy to fall off.
Cause
（ 2 ） Storage battery is often overcharged. A large amount of gas escapes from holes on the plate, making
active substances fall off.
（ 3 ） Electrode plate bents and deforms due to frequent low-temperature high-current discharge, which
makes active substances fall off.
（ 4 ） Bumping and vibration while vehicle is running.

Troubl If there are few sediments on lead storage battery whose active substances fall off, the battery can be used
eshoot after removing. If there are many sediments, electrode plate and electrolyte should be replaced.
ing
Metho
d

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 5. Common Failure of Storage Battery
Failure 3: Corrosion of Grid Frame on Electrode
Failure
Sympt Plate
Mainly corrosion of grid frame on positive electrode plate. Plate is rotten. Active substances accumulate
between division plates in the form of bulk. Output capacity of storage battery reduces.
om

Failure （ 1 ） Storage battery is often overcharged. O2 generated on positive electrode plate oxygenizes grid frame.
Cause （ 2 ） Density and temperature of electrolyte is too high. Charging time is too long. Corrosion of plates will be
accelerated.
（ 3 ） Electrolyte is not pure.

Troubl For storage battery with lighter corrosion, if there are impurities in electrolyte, electrolyte shall be poured out,
eshoot and cleaned with distilled water repeatedly. And then new electrolyte shall be added. The battery can be used
ing after charging.
Metho For storage battery with relatively severe corrosion, if density of electrolyte is too high, it can be adjusted to
d specified value. The battery can be used when it is not charged.
For storage battery with severe corrosion, if grid gram is broken and active substances fall off in bulk , electrode
plate needs to be replaced.

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5. Common Failure of Storage Battery
Failure 4: Short Circuit of Electrode Plate
Failure Positive and negative electrode plate of storage battery directly contacts with each other or gets overlapped
Sympt by other conductive materials. This is called short circuit of electrode plate.
om For storage battery with short-circuit electrode plate, voltage is very low or zero while charging.
Temperature of electrolyte soars. Density rises slowly. There are few bubbles while charging.

Failure （ 1 ） Division plate is broken. Positive and negative electrode plate directly contacts with each other.
Cause （ 2 ） Active substances largely fall off. Positive and negative plate are connected after sedimentation.
（ 3 ） Electrode plate group bends.
（ 4 ） Conductive objects fall in the pool.

Troubl During short circuit of electrode plate, storage battery must be opened for inspection.
eshoot Change damaged division plate, eliminate deposition of active substances, correct or replace bended plate
ing
Metho group, etc.

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 5. Common Failure of Storage Battery
Failure 5: Self Discharge
Failure Under no-load condition, energy of storage battery disappears automatically. This is called self discharge.
Sympto Capacity of fully charged storage battery reduces by more than 2% every day within 30 days. This is called fault
m self discharge.

Failure （ 1 ） Electrolyte is not pure. There is potential difference between impurities and plates, and between different
impurities on the plate. Partial discharge is produced through electrolyte.
Cause
（ 2 ） Storage battery has been stored for a long time. Sulfuric acid sinks. Upper and lower part of electrode plate
have potential difference, which causes self discharge.
（ 3 ） Electrolyte overflowing from storage battery accumulates on the surface of battery cover. Close circuit is
formed between positive and negative pole.
（ 4 ） Active substances on electrode plates fall off. There is too much sediment on the lower part, which causes
short circuit of electrode plate.

Trouble Storage battery with a little self discharge can be normally discharged. And then pour out electrolyte, wash with
shootin distilled water repeatedly, and add new electrolyte. It can be used after fully charged. If self discharge is relatively
g severe, battery should be completely discharged. Pour out electrolyte, remove plate group, pull out division plate,
wash with distilled water, reassemble and add new electrolyte. It can be used after charging.
Method

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5. Common Failure of Storage Battery
Failure 6: Polarity Reversal of Single
Failure Original positive electrode plate of single battery changes into negative electrode plate. Negative electrode
Sympt Battery
plate changes into positive electrode plate. At this time, voltage of storage battery drops rapidly. It cannot be
used.
om

Failure Faulted single battery is not found timely (such as short circuit of plate, falling of active substances, etc.).
When storage battery is discharged, the single battery will be discharged to zero first due to its small
Cause
capacity. When discharge is continued, discharge current of other single batteries will charge it and
reserves its polarity.

Troubl Electrode plates of single battery with polarity reversal should be replaced.
eshoot
ing
Metho
d

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 6. Use, Maintenance and Inspection of
Storage Battery
Storage of Storage Battery
（ 1 ） Storage of New Storage Battery
The following points should be paid attention to during storage of storage
batteries.
①Keep at room temperature of 5 ～ 30℃. Dry, clean and ventilated.
②Avoid from direct sunlight. More than 2m away from heat source.
③Avoid from contact with any liquid and harmful gas.
④Shall not be inverted or lay. shall not be put together. Shall not bear heavy
pressure
⑤New storage battery shall not be stored for more than 2 years.
（ 2 ） Storage of Unused Storage Battery
Wet storage method is used. Fully charge first. During this period color of
electric eye shall be checked regularly. If capacity reduces by 25%, the battery
shall be immediately charged. It shall 24/01/12
be fully charged before using.
 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
01/24/12 24/01/12
Integrated Generator

24/01/12
 （ 1 ） Overview
1. Functions of Generator and Regulator
As the main power supply of engineering machinery, generator has the
following main functions:
（ 1 ） Supply power for electrical equipments when engine operates with
speed above idling speed.
（ 2 ） Charge storage batteries
Need for installation of regulator
In the process of operation, speed of engine and working conditions of
electrical equipments change, so that rotate speed and load of generator
change. To ensure that electrical equipments work normally during operation
of engine, regulator must be installed.
Basic functions of alternator regulator:
When load of generator and rotate speed of engine are within the normal
range, keep average output voltage of generator within the prescribed scope.

37
24/01/12
 （ 1 ） Overview

2. Basic Requirements to Generator and Regulator

（ 1 ） When engine is idle running, output voltage of generator shall not be
lower than terminal voltage of batteries and it shall have a certain load
capacity.
（ 2 ） When engine runs with middle or high speed, generator shall be able to
satisfy electricity requirements of most electrical equipments.
（ 3 ） When load of generator and rotate speed of engine change within the
normal range, output voltage of generator shall not below voltage of storage
battery or above voltage allowed by electrical equipments.
（ 4 ） When armature voltage of generator is below the voltage of storage
battery, armature discharge of storage battery through generator shall be
prevented.
38
24/01/12
 （ 1 ） Overview
3. Classification of AC Generator
Engineering machinery generator is divided into DC generator and AC generator. DC
generator rectifies with rectifier. AC generator rectifies with diode rectifier. DC
generator has been basically eliminated.
1 ） By overall structure
（ 1 ） Common AC generator. This generator doesn’t have special device or special
functional features. When using, it needs to be equipped with voltage regulator.
（ 2 ） Integral AC generator. Generator and regulator are made into a whole
generator.
（ 3 ） AC generator with pump. Generator and brake system of vehicle are installed
together with vacuum booster.
（ 4 ） Brushless AC generator. Generator without electric brush.
（ 5 ） Permanent magnet AC generator. Rotor poles are made of permanent magnet.

39
24/01/12
 （ 1 ） Overview

Common AC Generator Integral AC Generator AC Generator with Pump

Figure 3.19

40
24/01/12
 （ 1 ） Overview

2 ） By structure of rectifier
（ 1 ） 6-tube AC Generator
Notes ：
（ 2 ） 8-tube AC Generator AC generators with different
（ 3 ） 9-tube AC Generator earth type have different regulator
（ 4 ） 11-tube AC Generator and wiring method. Failure
3 ） By type of magnet winding inspection method of charging
system is also different. It should
earth
noticed when using, or generator
（ 1 ） Internal-earth AC Generator will not generate electricity and
（ 2 ） External-earth AC regulator will not work.
Generator

41
24/01/12
 （ 1 ） Overview

Positive Diode

Electric Diode

Negative Diode
Output Stud
(earth)

Excitation
Stud

Positive
electrode
plate

Negative
Stator
electrode
winding stud
plate

Structure of Rectifier of 11-tube AC Generator Structure of Rectifier of 8-tube AC Generator

42
24/01/12
 （ 2 ） Structure of
Generator
1. Structure of Common AC Generator
1 ） Rotor
2 ） Stator
3 ） Rectifier
4 ） End cover and brush components

Figure 3.1

43
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 （ 2 ） Structure of
Generator
1 ） Rotor
The function of rotor is generating magnetic
field.
Rotor consists of claw pole, magnetic yoke,
magnet winding, slip ring, rotor spindle, etc.
When two slip rings are energized with direct
current, electric current will flow through
magnet winding. Axial magnetic flux will be
produced axial magnetic flux, magnetizing one
claw pole into of N pole and the other into S
pole. Six (or eight) pairs of interlinked poles will
be formed.
When rotor rotates, rotating magnetic field will
be formed. 44
24/01/12
 （ 2 ） Structure of
Generator

2 ） Stator
Connected to diode
Neutral contacts of stator
The function of stator is Connected to diode
Connected to diode
generating alternating current.
Stator core is made of insulating Stator
Winding

silicon steel plates with groove in Iron Core

the inner circle.

Stator winding has three groups
of coils, inlaid in groove of stator
core symmetrically. Three phase
winding is connected with star
connection and delta connection.
Figure 3.5

45
24/01/12
 （ 2 ） Structure of
Generator

3 ） Rectifier
The function of rectifier is
changing three-phase
alternating current of
stator winding into direct
current.

Figure 3.6

46
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 （ 2 ） Structure of
Generator
4 ） End Cover and Brush Components
End cover general has 2 parts (front end cover
and back end cover), which support rotor, stator,
rectifier and brush components.
Brush components consist of brush, brush
holder and brush spring. As show in Figure 2-11.
Function of brush is bringing power supply into
magnet winding through slip ring. 2 brushes
installed in holes of brush holder keep
contacting with slip rings with the pressure of
spring.
Brushes and slip rings shall be connected Brush
电刷组件
Components
properly. Otherwise, generator will not generator
enough electricity because field current is too
small.
47
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（ 2 ） Structure of
Generator

Figure 3.10

48
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 3. Other Types of AC Generators
1 ） Brushless AC Generator
Due to lack of brush and slip ring, poor unstable excitation, no generation of power from
generator and other failure will not be caused by wear and bad contact of brush and slip
ring. At the same time, there is no spark while working, which also reduces radio
interference.
Brushless AC Generator is divided into claw pole type, exciter type and permanent magnet
type.
（ 1 ） Structure and Working Principle of Claw Pole Brushless AC Generator
As show in the figure below, magnet winding of claw pole Brushless AC Generator is static.
It is fixed on back end cover by a magnetic yoke bracket. Therefore, it doesn’t need brush.
In two claw poles, only one claw pole is directly fixed on rotor spindle of motor. The other
claw pole is welded on the first claw pole with non magnetic material. When the rotor
rotates, a claw pole will make the other claw pole rotate in the stator. When direct current
passes through magnet winding, claw pole will be magnetized. Rotating magnetic field is
formed. Magnetic circuit is shown as arrow in Figure 2-23. 49
24/01/12
 3. Other Types of AC Generators

Armature B
Magnetic field F
Neutral N
Earth E

Structure of Claw Pole Brushless AC Generator

1 － Exterior 2 － Back bearing 3 － Hood 4 － Rectifier 5 － Shell 6 － Stator 7 － Magnet yoke
8 － Connector of magnet winding 9 － Magnet winding 10 － Claw pole 11 － Front end over
12 － Fan 13 － Belt wheel

50
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 3. Other Types of AC Generators
（ 2 ） Features of Claw Pole
Brushless AC Generator
Advantages of Claw Pole Brushless
AC Generator include simple
structure, convenient maintenance,
and reliable working. Generator will
not generate unstably or fail to
generate electricity due to poor
contact of brush and slip ring.
Disadvantage is connection difficulty
between claw poles. Because gaps in
magnetic circuit increase, excitation
Structure and Magnetic Circuit of Claw Pole Brushless AC Generator
current should be increased under 1 － Rotor spindle 2 － Magnet yoke bracket 3 － End cover 4 － Claw pole
5 － Stator core 6 － Non-magnetic coupling link 7 － Magnet winding
the same output power of generator. 8 － Rotor magnet yoke

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 （ 4 ） Regulator
1. Electronic Regulator
With the development of electronic technology, at present almost all the AC
generators use electronic regulators. Its advantage include high voltage
control accuracy, no spark, light weight, small volume, long service life, high
reliability, small radio frequency interference, etc.
Electronic regulator includes transistor regulator and integrated circuit
regulator.

Transistor Regulator and Integrated Circuit Regulator

a) Transistor Regulator b) Integrated Circuit Regulator

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 2. Classification of Electronic Regulator

Electronic regulator can be divided into two kinds by type of AC generator

earth.
（ 1 ） Internal Earth Regulator
Electronic regulator suitable for internal earth AC generator is called internal
earth electronic regulator.
（ 2 ） External Earth Regulator
Electronic regulator suitable for external earth AC generator is called external
earth electronic regulator.
For transistor regulator, during use, it is best to use the regulator specified in
vehicle manual. If replaced with other types, nominal voltage, power and
other required parameters shall be same to those of the original regulator.
The replaced regulator must have the same type of earth with the original
53
regulator. Otherwise, generator may24/01/12
not work normally due to blocking of
 3. Working Principle of Electronic Regulator
1 ） Working Principle of External Earth Electronic Regulator
（ 1 ） Basic Circuit
Electronic regulator has many types. They have different internal circuits,
but working principle can be understood with the basic principle of basic
circuit.
Electronic Regulator AC Generator

Storag Load
e
Batter
y

54
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 3. Working Principle of Electronic Regulator
2 ） Basic Circuit of Internal Earth Electronic Regulator

In basic circuit of internal earth electronic regulator, RNP VT1 and VT2 of transistor are used.
Magnet winding of generator is connected between collector of VT2 and earth end, which is
quite different from external earth electronic regulator. Working principle and structure are
similar to those of external earth electronic regulator.

Electronic Regulator AC Generator

Storag
e Load
Batter
y

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（ 5 ） Fault Detection of AC Generator

When AC generator fails to generate electricity or fails to generate enough

electricity, first we should decide whether the failure happens in external
circuit or in generator. If it is preliminarily determined that the failure is
inside generator, AC generator should be removed from the vehicle for
inspection and repairing.
AC generator should be tested first. The purpose is to determine whether
AC generator has failure and where the failure occurs, in order to repair
with a purpose.
Machine test includes measurement of resistance between wiring
terminals, no-load voltage and load current test on universal engine stand,
and observation of waveform output by generator with an oscilloscope.

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（ 5 ） Fault Detection of AC Generator
1. Measurement of Resistance between Wiring
Terminals
（ 1 ） Measure the resistance between output
terminal B+ and earth end E of generator (shell or
earth wiring terminal)
Through measurement we can decide whether
rectifier of AC generator has failure. If there is
failure, the generator should be further
disassembled for detection.
（ 2 ） Measure the resistance between F terminal
Measurement of Resistance
of positive brush and negative brush E of generator between Wiring Terminals

Through measurement of resistance between wiring

terminals, we cannot decide whether the generator
has failure. Bench test shall be conducted. 57
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（ 5 ） Fault Detection of AC Generator

2. Bench Test
（ 1 ） No-load Test
No-load test is a test conducted when AC generator has no load (no external
output of current). The purpose of no-load test is to preliminarily decide
whether generator has failure.
（ 2 ） Load Test
Load test is a test conducted when AC generator has load (external output of
current). The purpose of no-load test is to further decide whether generator
has failure.
Some failures of AC generator cannot show without current output.
Therefore, if generator is normal in no-load test, load test shall be conducted.

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（ 5 ） Fault Detection of AC Generator

3. Inspection of Rotor
(1) Inspection of Magnet Winding
Measurement of resistance of magnet winding with multimeter shall
be up to standard
Resistance between each slip ring and rotor spindle should be
infinite.

Inspection of short circuit Inspection of earth of magnet winding

and open circuit of magnet
59
winding
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（ 5 ） Fault Detection of AC Generator
(2) Inspection of Rotor Spindle and Slip Ring
Bending of rotor spindle will make the gap
between rotor and stator too small and cause
friction or collision. If it is found that resistance is
too large or there is abnormal sound during
operation of generator, we should check whether
rotor spindle bends.
Surface of slip ring should be smooth and without
erosion. The thickness shall be greater than
1.5mm.
(3) Inspection of Bearing
If abnormal sound is found during operation of
generator, we should check vehicleefully whether
Inspection of Radial Run-out Tolerance of Rotor Spindle
it is caused by damage of bearing.

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（ 5 ） Fault Detection of AC Generator

4. Inspection of Stator
（ 1 ） Inspection of open circuit and earth of stator winding
（ 2 ） Inspection of short circuit of stator winding

Inspection of open circuit of stator Inspection of earth of stator

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 （ 5 ） Fault Detection of AC Generator
5. Inspection of Rectifier
(1) Inspection of Common Rectifier
Separate lead wires of diode from
other connection. Connect two
probes of pointer multimeter
respectively to lead wire and shell Inspection of positive Inspection of positive
resistance of positive resistance of reverse
of diode to measure positive and
diode
reverse resistance of diode. diode

Positive resistance of diode shall

conform to the standard value.
Reverse resistance shall be above
Inspection of positive Inspection of reserve
10k Ω. resistance of negative resistance of negative
diode diode
Inspection of Commutation Diode
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 （ 5 ） Fault Detection of AC Generator
（ 2 ） Inspection of Rectifier with Integral Structure
Current plate, positive and negative diode of rectifier with
integral structure are welded together and inseparable .
The right figure is rectifier of AC generator of Honda
Motor.
In detection of positive diode, red probe of pointer
(Earth)
multimeter shall be connected to B. Black probe shall be
connected to P1, P2, P3 and P4 in turn, which should be
all conductive. Measure after exchanging two probes.
They should be all infinite. Otherwise, positive diode is
damaged. Rectifier assembly needs to be changed.
In detection of negative diode, black probe of pointer
multimeter shall be connected to P1, P2, P3 and P4 in
turn, which should be all conductive. Measure after
exchanging two probes. They should be all infinite.
63
Otherwise, negative diode is damaged. Rectifier assembly
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（ 5 ） Fault Detection of AC Generator
6. Inspection of Brush Components
Brush and brush holder should not be damaged or cracked. Brush
should move freely in brush holder. There should be no blocking.
Length of brush exposed from brush holder is called brush length.
Brush length should not exceed wear limit (1/2 of original length), or
the brush should be replaced.
Pressure of brush spring shall conform to the standards, which is
generally 2 ~ 3N. Press brush into brush holder. The exposed part
shall be about 2mm long. If spring pressure is too small, it should be
replaced.

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 （ 6 ） Use and Maintenance of Charging System
AC generator and regulator with simple structure are convenient to maintain. If they are
used correctly, there will be little failure and they will have long service life. If they are
not used correctly, they will be damage soon. Therefore, in use and maintenance the
following points should be paid attention to.
1. Negative electrode of storage battery must be connected to earth. Otherwise,
electronic components of generator or regulator may be burned.
2. Generator should be firmly connected to storage battery. If it is suddenly
disconnected, overvoltage will damage electronic components of generator or
regulator.
3. During operation of generator, generator cannot be inspected with fire test. Otherwise,
rectifier diode may be burned.
4. Once failure of AC generator or regulator is found, they shall be inspected and repaired
immediately to eliminate malfunction timely. Otherwise, greater failure or power lack of
battery will be caused, so that vehicle can't run.
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 （ 6 ） Use and Maintenance of Charging
System
5. When choosing regulator for AC generator, voltage level of AC generator must be same
to that of regulator. Earth type of AC generator must be same to that of regulator. Power
of regulator shall be no less than power of generator. Otherwise, the system can not
work normally.
6. Circuit must be connected correctly. Currently different vehicles have different
installation position of regulator and wiring method. Therefore, special attention has to
be paid while wiring.
7. Regulator must be controlled by ignition switch. When generator stops turning, ignition
switch shall be opened. Otherwise, magnetic circuit of generator will always be
connected. Magnetic coil will be burned, and power lack of storage battery will be
caused.
8. When failure is found and generator or regulator has to be removed from vehicle for
inspection, ignition switch and all electrical equipments shall be closed first. Cables on
negative electrode of storage battery shall be removed. And then wiring connectors on
generator shall be removed.
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6 ） Use and Maintenance of Charging
System

Maintenance of Charging System

1. Check drive belt of generator
2. Check connection of wires
3. Check whether there is noise during
operation
4. Check whether generator generates
electricity normally
5. Check whether storage battery is
overcharged

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 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
01/24/12 24/01/12
 Starter

Contact

Terminal

Contact

24/01/12
24/01/12
 （ 1 ） Starting Principle of Engine

To make the engine change from static to working state, bent axle of
engine must use rotated with external force, so that air cylinder will
absorb (or form) flammable gas mixture, burn and expand. Working cycle
will be conducted automatically. Under the action of external force, bent
axle begins to turn. Engine starts idle running automatically. This process
is called starting of engine.
Engine has many starting methods. Commonly used motor starting of
automobile engine uses motor as mechanical power. When gear on motor
shaft and gear ring around flywheel of engine engage with each other,
motive power will be delivered to flywheel and bent axle to make them
rotate. Motor itself uses storage battery as energy. At present, most
automobile engines use motor to start.

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 （ 2 ） Composition of Starter
Composition of Starter
Starter generally consists of 3 parts.
1. The function of DC series motor is to produce torque.
2. The function of transmission mechanism (or engaging mechanism) is to make
gear driving of starter and ring gear of flywheel engage with each other and deliver
torque of starter to bent axle of engine when the engine starts; make driving gear slip
and gear ring of flywheel automatically disconnect after the engine starts.
3. Control device (switch) is used to connect and clear the circuit between starter
and storage battery. Some vehicles also have access and screening function of
additional resistance of ignition coil.
Function of Starter
Function of starter is to deliver the electric energy of storage battery into mechanical
energy with starter, and start the engine through transmission mechanism.

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 （ 2 ） Composition of
Starter

1-moving core 2-electromagnetic switch 3-return spring 4-spiral groove

5,11-sliding bearing 6-pinion check ring 7-overruning coupler 8-auxillary spring
9-exciting winding 10-armature 12-insulation ring 13-contact disc
14-insulating vehiclebon brush holder 15- vehiclebon brush spring 16-
vehiclebon brush holder connected to earth 17- vehiclebon brush

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 1. DC Motor （ Series ）
1 ） Structure of DC Motor
DC motor consists of armature, pole,
shell, brush, brush holder, etc.
(1) Armature Assembly
The armature is used to produce
electromagnetic torque. It consists of
core, armature winding, armature
shaft and commutator. Armature
Figure 4-6 Armature
core is made up with many pieces of 1- armature shaft 2-armature core 3-
armature winding 4-commutator
insulating silicon sheets. Armature
winding is made of thick and flat
copper wires with wave winding
method. Copper sheets of
commutator are thick. Adjacent Figure 4-7 Commutator

copper sheets are insulated with 1-copper sheet 2-mica sheet

mica sheets. 74
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 1. DC Motor （ Series ）
（ 2 ） Magnetic Pole
Magnetic pole consists of core and armature winding. Its function is to produce
magnetic field in motor. Pole core is generally made of low vehiclebon steel, and
fixed on shell of motor with screws. There are generally 4 poles. 4 exciting windings
form two pairs of opposite poles. Common exciting winding is generally installed in
series with armature winding in the circuit. Therefore, it is called series DC motor.
（ 3 ） Brush and Brush Holder
Function of brush and brush holder is to bring current into armature and make
armature continuous rotate. Brush is generally suppressed with copper and graphite,
which can reduce resistance and increase abrasion resistance. Brush is installed on
brush holder, suppressed tightly on commutator with spring pressure, and connected
to the shell to form circuit earth, which is called earth brush. It is connected to
exciting winding and armature winding, and insulated with shell, which is called
insulation brush. 75
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 1. DC Motor （ Series ）

（ 4 ） Shell
Shell is made of low vehiclebon steel coil or cast iron. Working
time of starter is very short, so sliding bearing is usually used.
Because armature of reduction starter has high rotate speed,
armature uses rolling bearing.

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 2. Transmission Mechanism of Starter

Transmission mechanism of starter is actually a one-way clutch. The

function of one-way clutch is one-way delivery of torque, which means
torque of starter is delivered to bent axle of engine when the engine starts.
After the engine starts, it can automatically slip. Ring gear of flywheel will
not make armature of starter rotate to prevent damages to starter.
One-way clutch includes roller type, friction plate type, spring type, ratchet
type, etc. Among them, one-way clutch of friction plate type is usually
used in high-power starter.

77
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 2. Transmission Mechanism of Starter
1 ） Roller Type One-way Clutch
Make use of wedging and relaxing in
w
e
d
g
e

s
l
o
t

b
e
t Figure 4-8 Roller Clutch Mechanism
w
Start engagement b) break away from engagement c) profile chart
e of starter 2-outer race 3-inner race 4-roller 5-plunger 6-spline
1-driving gear
sleeve 7-gear ring of flywheel
e
n 78
24/01/12
 3. Control Device of Starter

Control device usually consists of master switch, shifting fork, switching

element, return spring, etc.
Connection or disconnection of main circuit of starter is controlled by master
switch through switching element and return spring. One-way clutch is
controlled by shifting fork. gearshift fork to make driving gear enter and exit
engagement with flywheel.
1 ） Control Principle
（ 1 ） The principle of engagement before connection
（ 2 ） The principle of high starting rotate speed
（ 3 ） After disconnection of main circuit, driving gear can quickly demesh.

79
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 3. Control Device of Starter
2 ） Structure and Principle
Control device is divided
into mechanical type and
electromagnetic type.
（ 1 ） Mechanical control
device
（ 2 ） Electromagnetic
control device
Electromagnetic control
mechanism of starter
mainly consists of sucking Figure 4-10 Circuit Diagram of Electromagnetic Control Mechanism of Starter
1-starting relay 2-starter 3-wiring terminal of storage battery on starter 4-contact
coil, holding coil, driving piece 5-sucking
coil 6-holding
lever, starter switch coil 7-iron core
8-driving lever
contact, etc. 9-small gear8010-
wiring terminal
24/01/12 of motor 11-
（ 3 ） Inspection, Test and Maintenance of
Starter

3. Use and Maintenance of Starter

1) Each starting time of starter shall not exceed 10s. The second starting
shall be made after 1min, so that storage battery can recover. Three
consecutive starting shall be made after 2min on the basis of inspection
and troubleshooting.
2) Heat preservation measures shall be taken for storage battery while
starting in winder or under low temperature.
3) After the engine starts, starter control circuit must be cut off
immediately to stop starter.

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（ 3 ） Failure Diagnosis and Inspection of
Starting System
Case 1 Starter doesn’t turn
1. Failure Symptom and Failure Cause
While starting, starter doesn’t turn. Possible failures include:
(1) Power failure
Serious power lack, vulcanization on plate, or short circuit of storage battery. Pole of storage
battery doesn’t contact well with cable clamp. Wire connection of starting circuit becomes
loosen, which causes poor contact.
(2) Starter failure
Commutator and brush doesn’t contact well. Exciting winding or the armature winding has
open circuit or short circuit. Insulation brush is connected to earth. Electromagnetic switch
coil has open circuit, short circuit, earth connection or erosion of contacts, etc.
(3) Starter relay failure
Coil of starter relay has open circuit, short circuit, earth connection or erosion of contacts.
(4) Ignition switch failure
Poor wiring or internal poor contact of ignition switch
(5) Circuit failure of starting system
Starting circuit has open circuit, poor wiring or loosing.
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2. Failure Diagnosis Method
(1)Check power
Sound the horn or open headlight. If sound of horn is small or hoarse and light is darker than
usual, it shows power has problems.
(2)Check starter
Make wiring terminal connected to storage batteries and conducting plate of motor on
electromagnetic switch of starter short circuit with screw driver. If starter doesn’t turn, it shows
motor has problems. Starter should be overhauled.
(3)Check electromagnetic switch
Make wiring terminal connected to wiring terminal of starter relay and storage batteries on
electromagnetic switch short circuit with screw driver. If starter doesn’t turn, it shows
electromagnetic switch of starter has problems. Electromagnetic switch should be overhauled.
(4)Check starter relay
Make wiring terminals of battery and starter on starter relay short circuit with screw driver. If
starter turns, it shows starter relay has problems. Otherwise, further inspection should be
conducted.
(5)Check ignition switch and circuit
Directly connect battery of starter relay and ignition switch with wires. If starter can operate
normally, it shows starter relay or ignition switch has failure. They can be inspected.
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 Case 2 Poor starting of starter
1. Failure Symptom and Failure Cause
While starting, rotate speed of starter is obviously low or it even stops. Possible failures
include:
(1)Power failure
Power lack of storage batteries, vulcanization and short circuit on plate, poor contact of
starting power wiring, etc.
(2)Starter failure
Poor contact between commutator and brush, poor contact between contact disc and
contacts of electromagnetic switch, local short circuit of motor exciting winding or
armature winding, etc.
2. Failure Diagnosis Method
If starter operates weakly, starter power should be checked first. If starter power doesn’t
have problem, starter should be overhauled. First contact of electromagnetic switch contact
disc, commutator and brush. And then check exciting winding and armature winding.

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 Case 3 Idling of starter
1. Failure Symptom and Failure Cause
After starting switch is on, only starter rapidly rotates and bent axle of engine doesn’t turn.
Such symptom shows starter circuit is unblocked. Transmission device of starter or gear
ring of flywheel have failure.
2. Failure Diagnosis Method
（ 1 ） If there is crash of gear during idling of starter, it shows gear ring tooth of flywheel
or small gear tooth of starter are badly worn or damaged, causing incorrect engagement.
（ 2 ） Failures of starter transmission device include one-way engage switch spring
damage, serious wear of roller of one-way engage switch, and corrosion of spline groove of
one-way engage switch sleeve. These failures will stop normal movement of small gear, so
that it cannot be engage with gear ring of flywheel.
（ 3 ） Some starter transmission devices use level-1 planet gear reducing device, which
compact structure, large transmission ratio and high efficiency. But in use it is often burned
or blocked due to excessive load. Some use friction plate clutch. If pressure spring is
damaged, spline is blocked due to corrosion or friction plate clutch slides, idling of starter
85
can also be caused. 24/01/12
 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
01/24/12 24/01/12
Lighting and Auxiliary Equipments

24/01/12
 Lighting and Auxiliary Equipments

Preheat Oil Pressure Alarm Charging Power off

Lamp I I
n n
d d
i i
c c
a a
t t
o o
r r

Braking Low Pressure Distance Light Fuel Colating

Alarm Lamp Indicator Indicator

24/01/12
Lighting and Auxiliary Equipments

24/01/12
Lighting and Auxiliary Equipments

24/01/12
 Lighting and Auxiliary Equipments
Work
L
i
g
h
t

Front Group Lamp

24/01/12
Lighting and Auxiliary Equipments

Flameout Relay Starting Relay

24/01/12
Lighting and Auxiliary Equipments

24/01/12
 Lighting and Auxiliary Equipments

Float
Drop Lean Forward

Swing Arm Controller

Lean
Backwa
Bucket Controller
rd

24/01/12
Lighting and Auxiliary Equipments

24/01/12
 Lighting and Auxiliary Equipments

Termina
Position Position l

24/01/12
 （ 1 ） Lighting Equipments
vehicle lighting is necessary lighting equipment in driving and work at night of vehicles. In order to
improve speed and ensure the safety in driving and work at night, the vehicle is equipped with various
lighting equipments. vehicle lighting can generally be divided into external lighting device and internal
lighting device by installation position and use.
Headlight should have anti-dazzling device to prevent accidents due to dazzling of other drivers in work at
night or vehicle meeting.

External Lighting Internal Lighting

Type
Baggage
Headlight Foglight License plate lamp Toplight Gauge lamp
compartment lamp

White
Yellow or white
Features when Normally on White White White White
Single cathode
working Distance and near Normally on Normally on Normally on Normally on
Normally on
light

Ensure effective Used for

Used for lighting of Used for
Provide security for lighting and provide lighting of Used for lighting of
Use license plate at rear of interior lighting
safe driving signal when it is gauge at baggage at night
vehicle at night
wet, snowy or foggy night

24/01/12
（ 2 ） Signal Lamp
Except lighting, there are light signals to indicate other vehicles or pedestrians on the vehicle. These
lights are called signal lamp.
Signal lamp is also divided into external signal lamp and internal signal lamp. External signal lamp
refers to turning indicator, brake light, taillight, width lamp, and reversing lamp. Internal signal lamp
refers to indicators of dashboard, mainly including steering, oil pressure, charging, braking, closing
hint and other meter lamps. See the table below for features and use of signal lamps.

External signal lamp Internal signal lamp

Type
Parking Reversing Turning
Steering lamp Width lamp Brake light Other indicators
light lamp indicator

White or
Features White or Red
Amber yellow White
when red Normally White White
Shine Normally Normally on
working Normally on Shining Normally on
alternately on
on

Inform
Inform Indicate
Indicate passers-by
passers-by or Mark that Tell driver
has slowed or other Tell driver
Use other vehicle vehicle driving direction
down or vehicles status of vehicle
vehicles width has of vehicle
will stop about
about turning stopped
reserving

24/01/12
（ 3 ） Electric Horn
Currently most loaders use electric horn, which is mainly used for warning of
pedestrians and other vehicles to attract attention and ensure safety.
Electric horn can be divided into spiral, cylinder and basin by appearance; high pitch
and low pitch by audio frequency; single wire system and double wire system by wring
method.
Electric horn makes metal film vibrate and produce sound with electromagnetic force.
With agreeable voice, it is widely used in various automobiles and engineering
machinery.
Electric horn can be divided into common electric horn and electronic horn by existence
of contacts. Common electric horn controls vibration of magnetic coil incentive film and
produce sound with connection and disconnection of contacts. Electronic horn doesn’t
have contacts. It produces sound with incentive film in transistor circuit.

24/01/12
（ 3 ） Electric Horn
In small and medium-sized vehicles, due to the limit of installation position, spiral electric horn is
mostly used. Basin electric horn has small size, light weight, good directing and small noise.
Small sound of basin electric horn is even better. Without trumpet projector, it still can have large
sound. Due to these advantages, it is also widely used currently in engineering machinery.

24/01/12
（ 4 ） Alarm Lamp and Alarm Switch
steering indicator

Alarm lamp is usually

oil charging indicator distance
installed on dashboard in fuel (water)
pres light
t
sure
cab. Its power is 1 ~ 3W. e
m
There is light filter in front passing p
foglight hand braking braking invalidsafety belt oil temperature
light e
of the bulb, so that the light r
a
bulb is yellow or red. Light t
engine baggage u
vacuum degree parking light
filter is often marked with compartment
room r
e
graphic symbols to show
its functions. See their fan wiper/ wiper sprayer
meanings in figure, At
present LED gradually
lighting choke horn back wiper back
replaces common light switch v spray
a er
bulb. l
v
e
24/01/12
1. Oil Pressure Alarm
Pressure Alarm: Whether oil pressure is normal directly Influences on performance and work reliability
of vehicles. So, many vehicles are equipped with oil pressure alarm lamp. Spring oil pressure alarm
lamp switch and film oil pressure alarm lamp switch are shown in the figure. When ignition switch is on
but the engine has not started, hydraulic switch is connected and alarm lamp will be on. After the
engine starts, pressure of main oil gallery will increase, contact of switch will be disconnected, and
alarm lamp will be off. It shows that lubrication system works normally. If oil gallery is blocked or
leaked during operation, which makes oil pressure below a certain value, switch will be connected and
alarm lamp will be on to remind the driver to stop immediately for repairing. In addition, some vehicles
have low pressure and high pressure. When oil pressure is below low pressure or above high pressure,
low-pressure normally-off switch or high-pressure normally-on switch will be connected and alarm
lamp will be on.

24/01/12
2. Coolant temperature Alarm

The function of coolant temperature alarm lamp is that the alarm lamp will be automatically on to
alarm when coolant temperature rises to a certain limit. The circuit diagram is shown in Figure
5.37. Bar bimetallic strip is installed in enclosed tubular of sensor. Its free end is welded with
movable contacts, which are connected to earth directly. When the temperature rises to limit
value, due to different expansion coefficient of bimetallic strip, it bends to stationary contacts.
Once the two contacts contact with each other, alarm lamp circuit will be connected. Red alarm
light will be on. Loaders generally display with instrument.

24/01/12
3. Reversing Switch and Back-Up Buzzer
When the vehicle reserves, to warn pedestrians and vehicles, vehicle drivers behind the
vehicle, reversing light, back-up buzzer or voice reversing alarm device is installed at the
rear of vehicle. They are automatically controlled by reversing switch on the transmission.
When the gear lever is moved to reverse gear, reversing light, back-up buzzer or voice
reversing alarm device will be connected to the power. Reversing light will give off
flashing signal. Buzzer will continuously call. Voice reversing alarm device will send out
alarm prompt.
Back-up buzzer is a audible device producing sound intermittently. Its voice part is
equipped with a electric horn with small power. A switch circuit consisting of an astable
circuit and an inverter controls the circuit.

24/01/12
（ 5 ） Traditional Instruments
1. Oil Pressure Gauge
Function: Oil pressure gauge is used to detect and display oil pressure of main
oil gallery of engine, in order to prevent major faults of cylinder bore scuffing
and burning due to lack of oil
Composition: It consists of oil pressure sensor and oil pressure indicator.
Classification: Oil pressure indicator can be divided into electrothermic type,
electromagnetic type and spring type.
Oil pressure sensor can be divided into bimetallic strip type and variable
resistance type. Electrothermic oil pressure indicator with bimetallic strip oil
pressure sensor or electromagnetic oil pressure indicator with variable
resistance oil pressure sensor are commonly used.
1 ） Electrothermic oil pressure indicator and bimetallic strip oil pressure
sensor
2 ） Electromagnetic oil pressure indicator and variable resistance oil pressure
sensor
24/01/12
（ 5 ） Traditional Instruments
1 ） Electrothermic oil pressure indicator and electrothermic oil pressure
sensor
（ 1 ） Structure
Electrothermic oil pressure indicator is also called bimetallic strip oil
pressure indicator. Basic structure of electrothermic oil pressure indicator
and electrothermic sensor are shown in the figure.

Lubricating
Oil

24/01/12
（ 5 ） Traditional Instruments
2 ） Electromagnetic oil pressure indicator and electromagnetic oil pressure sensor
（ 1 ） Structure. Structures of electromagnetic oil pressure indicator and variable
resistance oil pressure sensor are shown in the figure.
Electrothermic oil pressure indicator is also called bimetallic strip oil pressure
indicator. Basic structure of electrothermic oil pressure indicator and electrothermic
sensor are shown in the figure.

24/01/12
（ 5 ） Traditional Instruments
2. Coolant Temperature Gauge
Function: Coolant temperature gauge is used to test and display working
temperature of coolant in engine jacket, in order to prevent overheat of
engine caused by excess temperature of coolant.
Classification: Coolant temperature gauge can be divided into electrothermic
type, electromagnetic type and moving-magnetic type. Coolant temperature
sensor can be divided into bimetallic strip type and thermistor type.
Electrothermic coolant temperature gauge with bimetallic strip sensor,
electrothermic coolant temperature gauge with thermistor sensor and
electromagnetic coolant temperature gauge with thermistor sensor are
commonly used.
1 ） Electrothermic coolant temperature gauge and bimetallic strip sensor
2 ） Electrothermic coolant temperature gauge and thermistor sensor
3 ） Electromagnetic coolant temperature gauge and thermistor temperature
sensor
24/01/12
（ 5 ） Traditional Instruments
1 ） Electrothermic coolant temperature gauge and bimetallic strip sensor
（ 1 ） Structure
Basic structures of electrothermic coolant temperature gauge and
bimetallic strip sensor are shown in the figure.

24/01/12
（ 5 ） Traditional Instruments
2 ） Electrothermic coolant temperature gauge and thermistor
sensor
(1)Structure. Basic structure is shown in the figure. Main element of
thermistor sensor is thermistor with negative temperature
coefficient.

24/01/12
（ 5 ） Traditional Instruments
3 ） Electromagnetic coolant temperature gauge and thermistor sensor
(1)Structure. Basic structure is shown in the figure. Main element of
thermistor sensor is thermistor with negative temperature coefficient.

24/01/12
 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
01/24/12 24/01/12
（ 1 ） Overview

In order to improve working conditions and comfort of driver, a

growing number of engineering machinery are equipped with air
conditioning system. Automotive air conditioning system
generally includes cooling device, heating device and ventilation
device. Cooling device is used for air cooling and
dehumidification in vehicle in hot weather. Heating device is
used for heating in vehicle and defrosting of cab windscreen in
cold weather. Ventilation device changes air to keep air in
vehicle fresh and clean.

24/01/12
（ 2 ） Structure

Air conditioning
system consists of
compressor,
condenser, low
pressure switch,
liquid storing drying
chamber, high-
pressure valve,
evaporator, thermal
control switch, and
expansion valve.

24/01/12
 （ 3 ） Working Principle
Working process: Driven by the engine with belt, compressor
absorbs low-temperature (5 ℃) and low-pressure refrigerant vapor
which gasifies due to heat absorption in the evaporator,
compresses it into high-temperature (70-80 ℃) and high-pressure
gas, delivers into condenser through high-pressure pipeline, and
conducts heat exchange (release heat) with outside air. When the Liquid
Liqui expansi
temperature drops to about 50 ℃, it will condensate into liquid. d on
Heat (enter coolant Liqui Heat (discharg
device
After moisture and impurities are removed in the liquid storage pot, from air) d into air)

it is delivered to expansion valve through high-pressure tube,

Condense
whose throttling effect will make high-temperature and high- r

pressure cooling fluid into low-temperature (about 5 ℃) and low-

pressure (about 0.15 Mpa) mist. And then it is sprayed into Gas Gas
Compresso
evaporator, boiled and gasified by absorbing heat of surrounding
Low pressure side High pressure
atmosphere, which will decrease the temperature of ambient air. For
coolant gas at outlet of evaporator, because heat absorption
temperature rises to about 5℃, when blower blows air around to
evaporator surface, air will be delivered to cab and carriage after
cooling. Coolant gasified after heat absorption is absorbed by
compressor. As the above process continues, the place around
evaporator will always remain low temperature.

24/01/12
（ 4 ） Failure Diagnosis

Common failures of refrigerating machinery are generally caused by

electrical, mechanical, coolant and refrigerating machine oil. Its performance
includes no refrigeration of refrigerating machinery , insufficient refrigerating
output, abnormal noise, etc.

Case 1: No refrigeration

1 ） Fan of evaporator doesn’t rotate due to failure of fuse, internal switch,

connection, etc
2 ） Fan of evaporator rotates. Whether compressor rotates, belt is loosen,
there is coolant, pipes are blocked, etc.

24/01/12
（ 4 ） Failure Diagnosis

Case 2: Insufficient refrigerating output

1 ） Coolant flow at outlet of expansion valve decreases.
Temperature is too high or pressure is too low at high-
pressure of low-pressure side of refrigerating machinery.
2 ） Lack of coolant.
3 ） Belt of compressor slide because it is too loosen.
Case 3: Abnormal noise
Generally mechanical failures, such as loosening of
fastener, excessive wear of moving parts or bad lubrication.

24/01/12
 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and
Troubleshooting of Electrical
System
01/24/12 24/01/12
24/01/12
（ 1 ） Power Supply
1. Storage Battery
20-hour discharge capacity of maintenance free storage battery is 120Ah.
2. Generator
JFZ2517A integral AC generator
3. Regulator
PNP transistor regulator is used
4. Main switch
Electromagnetic main switch
Some types are equipped with
mechanical main switch.

24/01/12
 Starting
s
w
Connected i
to upper t
c
end of fuse h
block

Starter relay Connected

to charging
indicator
Connected
Storage batteries
Power switch Storage to
Starting stopwatch
battery motor
Generato
relay r

24/01/12
（ 2 ） Starting Section
1. Starter
Series DC generator is used, whose power is above 7.5KW. So the starter has
short-time design. Each starting time shall not be too long. 10s shall not be
exceeded. Interval between two starting shall not less than 1 minute. If the vehicle
cannot be started after three starting, please start after identifying causes.
2. Starting Switch. JK406C can prevent error restart. It must be opened after the
vehicle is closed by key and engine misses. Otherwise, it will be locked. Staring
position cannot obtained.
3. Starter Relay
JN3A-24
Power and starting system are shown as the figure below.

24/01/12
（ 2 ） Starting Section Intermediate
To

Starting relay
switch (starting
chain)

Connected
to
control unit

toplight

Starter To charging

relay indicator
Storage To stopwat
Insurance
battery
Storage battery
Power Insurance relay
Generato
switc Starting
h m
o
t
o
r
24/01/12
（ 3 ） Lighting and Auxiliary Circuit
1. Front and back headlights
2. Working light and toplight of in cab
3. Dashboard and wiring
4. Instrument and sensor
1 ） Oil pressure of engine. Low-pressure alarm. Pressure
switch is used. Switch will connect alarm circuit when pressure is below
specified value. Alarm lamp will be on. The machine must be stopped
and can be used after identifying causes.
2 ） Water temperature gauge and sensor
Electromagnetic meter and electrothermic sensor
are used.

24/01/12
（ 3 ） Lighting and Auxiliary Circuit
3 ） Torque converter oil temperature gauge and sensor
Electromagnetic meter and electrothermic sensor
are used.
4 ） Gas pressure sensor and gas pressure meter
Electromagnetic meter and electrothermic sensor
are used.
5 ） Shifting pressure gage and sensor
Direct feeling pressure gage is used. Durable, reliable and low-cost.
6 ） Wiper
7 ） Horn——Double basin electric horn is used
8 ） Back-Up buzzer and switch; Alarm lamp
9 ） Radio cassette recorder——Optional

24/01/12
（ 4 ） Pilot Control Section

1. Pilot
electromagnet
2. Approach
switch

24/01/12
 Floating
magnetic valve

Bucket
magnetic valve

Swing arm
magnetic valve

Approach switch (swing

arm)
Blue

Brown

Black

Approach switch
Blue (bucket)

Brown

Black

24/01/12
Gearbox Control Connected to
control unit

Intermediate Intermediate
Intermediate
relay relay
relay
(starting chain) (reversing)
(cut power)

Parking brake indicator switch

Connected to signal Connected to

end of starter relay reversing light

Connected to
Brake switch starting switch
(left) Connected to indicatorG2
of
Connected to control unit
stoplight

Brake switch (right)

24/01/12
 Lingong Maintenance Free Storage Battery
Ⅰ. Use Electric Eye and Open-circuit Voltage Technology
Electric eye indicating state on VARTA maintenance free storage battery is closely related to
and consistent with its open-circuit voltage, but they should meet the following requirements:
1. Let battery settle down for a period of time after charging or discharging to allow full mixing
of sulfuric acid;
2. Shake batteries to expel bubbles in electric eye;
3. Charged battery should discharge with load for 15 seconds to eliminate discharge on the
surface. And then measure open-circuit voltage.
（ 1 ） Electric Eye:
（ 2 ） Open-circuit Voltage:
Color of
Electric Quantity
Electric Eye

Electric quantity is above 65%.

Normal

Electric quantity is below 65%.

Charging needed

Overcharge. Should be replaced

24/01/12
Lingong Maintenance Free Storage Battery

Green electric eye indicates ：

1 ） When the vehicle is delivered to distributor, batteries have sufficient
electricity. During transport process, vehicle can be started for several
times;
2 ） Dealer-Under normal circumstances, battery can start vehicle within
one week;
3 ） Service personal-Batteries have sufficient electricity. Load test can be
conducted.
4 ） Service personal-Batteries with sufficient electricity can be installed on
vehicle or stop charging.
5 ） Service personal and driver-Charging system of vehicle operates
normally.
6 ） Diver-Vehicle cannot start not because
24/01/12
of batteries.
Lingong Maintenance Free Storage Battery

Black electric eye indicates ：

1 ） Vehicle manufacturer - during production, vehicle has been
significantly discharged. When the vehicle is delivered to distributor,
batteries don’t have sufficient electricity to start the vehicle.
2 ） Vehicle dealer-Before vehicle is sold, batteries must be recharged.
Otherwise, client cannot start the vehicle.
3 ） Service personal-Batteries don’t have sufficient electricity. Load test
cannot be conducted or they cannot be installed on vehicle until batteries
are recharged.
4 ） Service personal/Driver-Charging system of vehicle may have problem
(loosen belt or poor earth);
5 ） Driver-Vehicle cannot start because of insufficient electricity of
batteries. 24/01/12
Lingong Maintenance Free Storage Battery

White electric eye indicates ：

1 ） Service personal/Driver-Charging system has problems.
2 ） Service personal/Driver-Batteries have to be replace (no need of test).
3 ） Service personal-If electric eye is black before charging, batteries are
overcharged.

24/01/12
Lingong Maintenance Free Storage Battery
（ 2 ） Open-circuit Voltage:
Can decide whether batteries are in good load state and whether
vehicle can be delivered according to OCV test. Agents, service
station, and user can also decide load state of batteries by
measuring OCV.

24/01/12
Lingong Maintenance Free Storage Battery
Combination of Open-circuit Voltage and Electric Eye Technology
1. When electric eye is black and OCV>12.2V, battery can be fully charged
with charging voltage of 16V and charging current of 25A within 4 hours;
2. When electric eye is black and OCV>11.0V, battery can be fully charged
with charging voltage of 16V and charging current of 25A within 8 hours;
3. When electric eye is black and OCV ＜ 11.0V, battery can be fully charged
with charging voltage of 16V and charging current of 25A within 16 hours;
4. When electric eye is green and voltage is below 11.0V, battery has short
circuit and has to be replaced.

24/01/12
Lingong Maintenance Free Storage Battery

（ 3 ） Self Discharge of Battery

Storage battery has self discharge in storage process, which
increases as the temperature increases. Self-discharge rate will be
doubled when the temperature increased by 10 degrees. Self-
discharge rate is 6% ~8%, 3% ~ 4% and 1.5% ~ 3% monthly under
35 degrees, 25 degrees and 15 degrees. Under normal
temperature, self discharge rate of large capacity battery is 4% and
self discharge rate of small capacity battery is 3%.

24/01/12
Lingong Maintenance Free Storage Battery

（ 4 ） Load Discharge of Auxiliary Electric Elements

Load of auxiliary elements are mainly caused by vehicle clock,
acoustics, alarm system and other auxiliary appliances. This load
exists forever. Even if starting key is disconnected, the load still
exists. If the vehicle is not used for a period of time, the vehicle
may not be started.
Transition leakage of storage battery shall not reach 50% of battery
capacity. If the vehicle is parked for a long time, negative electron
ode connections of batteries shall be pulled up.

24/01/12
Lingong Maintenance Free Storage Battery

（ 5 ） Charging of Storage Battery

Storage batteries stored for too long (eg, unused more than 6 months after leaving
factory), vehicle charging system failure or other improper operation may cause
excessive discharge of storage battery. When state indicator of storage battery is
black, storage batteries shall be charged according to the following methods.
Under room temperature, positive and negative electrode of storage battery shall be
connected to positive and negative electrode of DC charger respectively, Storage
battery shall be charged with constant voltage of 16.0 + 0.1 V for 16 ~ 24 hours. If
during constant charging process, temperature of storage battery exceeds 45
Celsius or charging current exceeds 25A, charging voltage shall be lowered or
charging time shall be extended properly.
Notes ： Storage battery shall be charged in the area with good ventilation. Ensure
safe electrical operation.

24/01/12
Lingong Maintenance Free Storage Battery

How shall we correctly check and judge maintenance free storage

battery? Most of service personnel are facing these questions.
why can't the vehicle start? Many people may misjudge due to
lack of suitable tools and methods, which will cause unnecessary
battery replacement without finding out root causes. This problem
appears constantly.

24/01/12
 Contents
Circuit Diagram and Failure Analysis
1 Methods of Engineering Machinery
2 Storage Battery
1
3 Generator and Regulator

4 Starter
Lighting Equipment, Auxiliary Circuit
5
and Instrument
6 Air-conditioning System
Electrical System Structure and Principle
7
8 of Lingong Loader
Common Failure and Troubleshooting of
Electrical System

01/24/12 24/01/12
（ 1 ） Judgment Idea and Method
Begin
ning
General flow is good for
Step 1 Listen to client’s
cultivation of good fault statement about failure
diagnosis and inspection idea
Step 2 Determine failure
for beginners. Maintenance symptom

personnel with reasonable Step 3 Analyze related

knowledge and working circuit principle

experience doesn’t need to Step 4 Analyze failure

causes
exactly follow the process steps
in actual work. They can skip Step 5 Diagnose and repair
circuit
some steps according to actual
situation or by experience, and Verify whether No
Step 6
overhaul the fault point directly, circuit
recovers
which can effectively improve Ye
s
work efficiency. End

24/01/12
（ 2 ） Common Failures
Figure 1
1. Open circuit （ disconnectio
n ） failure （ Figure 1 ）
2. Short circuit failure （ Figure
2）
3. Poor contract （ contact Storage battery

Figure 2
resistance is too
large ） failure Short circuit
Short circuit Short circuit
of earth

Storage battery Storage battery Storage battery

24/01/12
 （ 3 ） Use of Common Inspection
Equipments
1. Objectives
Master common inspection tools of automobile : correct use of jumper, testing
lamp, multimeter (mechanical and digital), oscilloscope, malfunction
diagnosis machine, etc.
2. Instruments and Tools
Jumper, testing lamp, multimeter (mechanical and digital), oscilloscope,
malfunction diagnosis machine, etc.
3. Content Electrical
Fuse equipment
Jumper
Switch Connector Jumper

Storage battery Jumper

Warning: Don’t connect jumper directly to two ends of storage battery or

between positive electrode and earth of storage battery.

24/01/12
（ 3 ） Use of Common Inspection
Equipments
2 ． Testing Lamp 12V testing lamp

⑴ Passive Testing Lamp

Light is on
handle Probe
Limit of testing lamp is that it cannot
display voltage of detected circuit.
Warning ： It is not suggested to
detect circuit controlled by Connector clip

computer with testing lamp.

Storage battery

24/01/12
（ 3 ） Use of Common Inspection
Equipments
Battery on Light is on
handle the top
⑵ Active Testing Lamp
Active testing lamp is similar to passive testing lamp. It
has a battery supply. When connected to two ends of a
wire, bubble in the testing lamb will be on. It can be used
to test connection or disconnection of circuit.
Warning: Alive circuit cannot be tested with active testing
lamp, or the lamp will be damaged.

24/01/12
 （ 3 ） Use of Common
Inspection Equipments
3. Use steps of digital multimeter:
Choose the appropriate test gear.
Put probe of multimeter in proper input end.
⑴ Black probe is usually inserted in common
port （ COM ） . Digital multimeter can
measure:1. DC voltage; 2. AC
⑵ When measuring voltage, resistance or voltage; 3. oil injection pulse; 4.
diode; 5. resistance; 6. current;
diode, red probe is usually inserted in the 7. frequency; 8. rotate speed; 9.
closed angle; 10. TECK; 11. fault
position end with mark of VΩ. code; etc.
⑶ When measuring current, red probe is
usually inserted in the position end with
mark of A or mA.
Choose the appropriate measuring range

Read correctly according to selected gear.

24/01/12
 （ 3 ） Use of Common Inspection
Equipments
4. Universal Analogue Multimeter
Because analogue multimeter has higher output than
high-resistance digital multimeter, analogue multimeter is
more accurate than digital multimeter when measuring
resistance of diode and electronic components.
Note 1 ： At present most circuits on vehicle are
transistor circuits. Meter of 10M Ohm or higher resistance
should be used to measure voltage of these circuits.
Note 2 ： At present most circuits on vehicle are
transistor circuits. Ohmmeter of 10M Ohm or higher
resistance should be used to measure voltage of these
circuits. In addition, decide whether the measured circuit
is disconnected. Otherwise, circuit supplied by automotive
electrical system may damage equipment or provide false
readings
24/01/12
 Reliability
bears great
trust!

24/01/12