JAC S2. Elctrical Wiring diagrams - part 1
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Starting and Charging System
Starting and Charging System
1
Starting and Charging System
I、Summary
（I）Structure outline
Starting system mainly includes battery, ignition switch, starter, starter relay and related lines.
Main components of charging system include: generator assembly (inbuilt voltage regulator), battery, battery
charging indicator light.
Starting System
As main component of starting system, starter consists of direct current motor, electromagnetic switch and
transmission mechanism. Direct current motor lead in current from battery and make driving gear wheel to turn;
transmission mechanism makes driving gear wheel mesh into flywheel gear ring, and also can automatically
disconnect after engine starting; starter circuit is controlled by electromagnetic switch.
Starting system has 2 separate circuits: one is to provide high current to starter, the other is low current control
circuit which controls starter relay.
Charging System
Main function of generator is to provide power to all electrical equipment (except starter) when engine running
normally, and also charge battery. Generator mainly consists of 5 parts: rotor, stator, voltage regulator, end cover.
The rotor and stator generate alternating current with electromagnetic cutting principle, generated alternating current
is transformed into 14V stabled direct current by rectification and voltage stabilization of voltage regulator.
Generator is driven by engine through engine belt and pulley device.
Battery
The vehicle uses free-maintenance battery, whose difference with traditional battery is there is no vent plug on
battery cover, and battery is completely sealed except small vent holes on both sides of battery. Small quantity of
gas produced by battery can be released from vent holes, small amount of gas will be released when electrolyte
inside battery has chemical reactions, and if there is no exhaust vent, internal pressure will increase continuously
along with air increase, and battery shell will crack down when pressure exceeds its limitation.
Compared to regular battery, free-maintenance battery has following advantages:
- No need to add water during battery service life.
- Overcharge protection.
- Power leakage is not as easy as regular battery.
- Smaller weight and volume, large capacity.
Battery has 3 main functions in whole electrical system:
- Supply starting power when engine starting.
- Work as electrical system voltage stabilizer.
- When generating capacity of generator can’t satisfy need of electrical system, battery can supply power in a
certain period of time.
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Starting and Charging System
Starting and Charging System
2
Component Position
1. Battery 2. Starter 3. Generator
（II）Operating Principle
Operating principle of starter: Turn ignition switch to “START” → Contact plate connects electromagnetic
switch bolt (at the same time shifting fork knockout gear wheel and mesh with flywheel) → Battery positive
electrode (+) supplies power, main current flows into commutator from positive electrode brush → Rotor rotates
under the action of magnetic field → (Drive planet wheel to turn) → small gear wheel move forward along drive
shaft spline → Gear drive flywheel to turn → engine starts to work.
Operating principle of generator: Generator provides direct current voltage power to vehicle electrical system
and keep battery in charging state. Output of voltage is controlled by voltage regulator. When turn ignition switch
to “START”, current flows into excitation coil, which is initially motivated. When stator coil starts generating
electricity after engine starting, excitation coil is activated by output current from stator coil. Terminal “B” supplies
power to vehicle electrical system, and supply charge power to battery. Voltage regulator checks input voltage at
“S” terminal, and controls output voltage accordingly. If excitation current increases, output power of alternating
current generator increases, otherwise it decreases. When battery voltage (voltage of “S” terminal of alternating
current generator) reaches about 14.4V regulating voltage, excitation current is cut off. When battery voltage drops
below regulating voltage, voltage regulator regulates output voltage by controlling excitation current to maintain it
in constant level.
When ignition switch is turned on and engine not start, power supply connect to terminal of combination meter
charging indicator light through indoor electrical box, to combination meter terminal, through “L” terminal of
generator to “E” terminal to grounding joint, at the same time charging indicator light will be on.
After starting engine, when generator can work normally, voltage of power supply terminal of charging
indicator light is close to “L” terminal of engine, charging indicator light is off. If charging indicator light is still on
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Starting and Charging System
Starting and Charging System
3
when engine running, it indicates there is fault. If there is no voltage or too high voltage when engine working,
indicating function of voltage regulator will start, and charging indicator light will be on.
Electrical Schematic Diagram
（III）Technical Parameter
Battery Specification
No.
Application
Description
1
Cool starting current
433A （SAE）
2
20 hours rate capacity
55Ah
3
Rated voltage
12V
Starter Specification
No.
Application
Description
1
Voltage
12V
2
Power
1.2KW
Generator Specification
No.
Application
Description
1
Current
90A
2
Voltage
14V
（IV）Torque Parameter
No.
Tighten part name
Torque （N·m）
1
Generator regulating nut
20~25
Battery
Starting
switch
Generator
Combinati
on meter
Anti-theft
relay
Neutral
gear
sensor (MT)
Starting
relay
Starter
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Starting and Charging System
Starting and Charging System
4
2
Generator square-head bolt tighten nut
42~52
3
Battery pressing plate fixed nut
5~8
4
Generator power supply wiring harness fixed nut
10~14
（V）Maintenance Caution
Before maintaining any electrical component, ignition switch should be in “OFF”, and all electrical load must
be “OFF”, unless there is other description in operating procedure. If tool or device is easy to contact with exposed
energized electrical terminals, battery negative electrode should be disconnected. Violation of these security notice
could lead to personal injury or vehicle component damage.
1. Start with auxiliary battery
1). If need to use auxiliary and cross-wiring to start engine, please ensure to use 12V auxiliary battery. After
connecting battery cross-wiring, ensure cross-wiring is clamped to battery terminal and in good connection.
2. Method to prevent battery over-charging
1). Should always keep battery surface (especially top) clean and dry, connecting part of terminal should be
clean and tightened; if not use vehicle for a long period, battery negative electrode should be disconnected, and
check battery charging state periodically.
II、Troubleshooting
（I）Troubleshooting List
1. Check whether there is after-sales installation which will affect starting, charging or ignition system.
2. Check system components those are easy to be seen or contacted to check whether there is obvious damage
or easy to cause damage.
3. Check whether battery is installed correctly.
4. Test condition of battery, whose voltage should not be less than 11.5V.
5. Check whether there is damage on relevant wire, and check whether connections of starter motor, starter
electromagnetic switch, starting switch, battery and all relevant ground are reliable.
6. Check whether installation of generator is loosen or improperly installed, and whether driving belt tension
is normal or there is possibility for slip.
No.
Fault
phenomenon
Fault reason analysis
Solution
Remark
1
Starting
abnormal
Engine ignition, fuel system fault
Check engine ignition, fuel system
Refer to “Starter
not work”
Starter power supply fault
Check starter power supply
Starter fault
Replace starter
Starter electromagnetic switch fault
Replace starter electromagnetic switch
Engine mechanical binding
Check related machinery components
of engine
Starter electromagnetic switch power
supply circuit fault
Check related circuit
Starter ground wire fault
Check ground circuit
Starter control power supply circuit fault
Check related circuit
Starting relay fault
Replace starting relay
Anti-theft control system fault
Maintain anti-theft control system
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Starting and Charging System
Starting and Charging System
5
Starting switch fault
Replace starting switch
2
Starter can’t
stop working
Starting relay fault
Replace starting relay
Starter fault
Replace starter
Starter switch fault
Replace starting switch
3
Starter noise
Flywheel gear ring damage (Gear crack,
missing or abrasion etc.)
Replace flywheel
Flywheel damage (flywheel deformation)
Replace flywheel
Starter fault (gear crack or abrasion, axle
sleeve abrasion)
Replace starter
4
Charging
indicator light
always on
Generator L terminal circuit fault
Check related circuit
Ground wire of combination meter power
supply fault
Check related circuit or replace
combination meter
Generator power supply circuit fault
Check related circuit
Generator fault
Replace generator
5
Charging
indicator light
not on
Generator L terminal circuit fault
Check related circuit
Generator fault
Replace generator
Ground wire of combination meter power
supply fault
Check related circuit or replace
combination meter
6
Generator noise
Generator fault
Replace generator
Generator installation fault
Install generator again
Generator belt fault
Install again or replace
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Starting and Charging System
Starting and Charging System
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（II）Troubleshooting Flow Chart
Starter not work (MT)
Fault phenomenon:
Starter not work
Check voltage of starter B+
terminal voltage
Standard
voltage
value:
11V-14V
Whether
accord
with standard value
Whether
accord
with standard value
Whether
accord
with standard value
Whether
accord
with standard value
Ignition switch to “ST”, check
voltage of starter wiring
harness
connector
B03-1
terminal
Voltage standard value: 11V-
14V
Check voltage of starter relay
ER01-30 terminal voltage
Standard voltage value: 11V-
14V
Check voltage of starter relay
ER01-85 terminal voltage
Standard voltage value: 11V-
14V
Short circuit starting relay
ER01-30/ER01-87 by special
short
connector.
Observe
working condition of starter
Check wiring harness between
starting relay ER01-86 and ECU
and ECU control fault
Fault removed
Check wiring harness fault
between starting relay ER01-
87 and starter wiring harness
connector
Check state of fuse EF02 and
circuit between starting relay
ER01-85 terminal and main
relay
Check state of fuse ESF07 and
circuit between starting relay
ER01-30 terminal and B+
Replace starter
Maintain circuit between
starter B+ terminal and
battery
Whether starter works
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
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Starting and Charging System
Starting and Charging System
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Starter not work (CVT)
Fault phenomenon:
Starter not work
Check voltage of starter B+
terminal voltage
Standard voltage value: 11V-14V
Ignition switch to “ST”, check
voltage of starter wiring harness
connector B03-1 terminal
Voltage standard value: 11V-
14V
Check voltage of starter relay
ER01-30 terminal voltage
Standard voltage value: 11V-
14V
Whether
accord
with standard value
Whether
accord
with standard value
Maintain circuit between
starter B+ terminal and
battery
Replace starter
Check state of fuse ESF07 and
circuit between starting relay
ER01-30 terminal and B+
Yes
Yes
No
No
No
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