Great Wall. Service manual for chassis and body (2006) - page 21

 

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Great Wall. Service manual for chassis and body (2006) - page 21

 

 

BE-1

Body Electric System

Protective box Location and content ............................ BE-6

Power Supply System .................................................. BE-16

Starting System ............................................................ BE-17

Lighting System ........................................................... BE-19

Combination Instrument ............................................... BE-32

Backup Radar System ................................................. BE-39

Wiping and Washing System ....................................... BE-40

Central control lock and Power regulator System ......... BE-50

Acoustical Equipment System ..................................... BE-61

Wire Harness Arrangement.......................................... BE-68

BE

Page

BE-2

Brief Introduction

1. Power supply system

The power supply system includes accumulator, generator and its adjustor. Generator is the main power supply; the

accumulator is the auxiliary power supply. The generator, parallel with the accumulator, is equipped with the

adjustor, which is used to maintain the voltage of generator stable when the rotating velocity and the load varies.

2. Starting System

Which includes the direct current motor, drive mechanism and control device, etc. its performance is to start the

engine.

3. Lighting system

Which includes various lighting lamps inside and outside of the body and their control device; they are used mainly

to guarantee safety driving in night.

4. Alarming System

Which includes the electric horn, flasher and various service signal indicating lamps, etc. they are mainly used to

guarantee the physical and driving safe when driving.

5. Auxiliary Electric Appliance System

It includes the electric wiper, air-conditioner, recorder and cigarette lighter, etc.

R

red

R/G

red

green

socket plugging element

plug plugging element

N

2

3

4

5

6

1

2

3

4

5

S

s o c k e t   p l u g g i n g

element

plug plugging element

1.

The codes of sockets of socket plugging element are

complied from left to right.

2.

The codes of sockets of socket plugging element are

compiled from right to left.

Remark: all of plugging elements are watched from the in-

wiring direction.

3.

Comparison between plug and socket plugging elements

The plug and socket plugging elements are classified accord-

ing to their in-built socket shape.

(a)

All of plugging element are marked according to the

opening end and are locked at their tops.

(b)

When pulling the plugging element, pull the plugging

element itself instead of wire.

Remark: before pulling the plugging element, check the

plugging element that you want to disconnect first to verify

their classifications.

English letters for wiring colors code:

B =black    Bl =blue   R =red    Br =brown

Lg =reseda V  =purple   G =green    O =orange

W =white    Gr =gray   P =pink  Y =yellow

First letter stands for the basic color, while the second for the

stripe color.

Body Electric System

Brief Introduction

BE-3

Body Electric System

Brief Introduction

pull up

pull up

press down

press down

Change of fuse and maxi-fuse

Remark: in case of exchanging the fuse or maxi-fuse, the fuse

or maxi-fuse with same rated current should be used.

Notice:

1.

Before exchanging the fuse or maxi-fuse, all electric

appliances and ignition switches should be turned off

firstly. And the rated current of fuse or maxi-fuse should

not be exceeded.

2.

When disassembling or assembling the fuse, the

disassembly and assembly tools must be used. And they

must be pulled out or plugged in vertically. No bend is

allowed because the bend will make the connecting

terminals depart away, and thus poor connection will

occur. In case the fuse or maxi-fuse is burned, it shows

there is short circuit. In such situation, the systematic

inspection should be conducted by the qualified

technician.

Remark: the disassembly and assembly tools are put on the

protective box cover.

same  rated current

10A

10A

BE-4

How to make systematic inspection

The inspection order is a simple troubleshooting approach, which is used to check and diagnose the failure on vehicle

when there is part (wiring and plugging elements excluded) failure in the systematic operation or presupposed

system.

Following items should be considered firstly when checking the failure.

 

wiring failure

 

open circuit or short circuit of electric wiring

 

failure in plugging element connection or terminal connection

 

failure of fuse or maxi-fuse

Notice:

1.

The inspection is conducted on vehicle when the system is in operation, therefore, security should be

taken into account when checking.

2.

Care should be paid not to make short circuit in the system under the condition that the accumulator is

directly connected, and the applicable voltage should be selected correctly.

Voltage inspection

(a)

Verify the voltage situation at the inspection spots.

For example:

Put the ignition switch at

ON

 position

Put the ignition switch and SW1 at 

ON

position;

Put the ignition switch of SW, SW1 and the relay at

ON

 position (SW2 at 

OFF

 position)

(b)

Connect the cathode lead (-) to the normal grounding

place or the cathode terminal of accumulator with the

voltmeter; while connecting the positive lead (+) to the

plugging element or part terminal. Such inspection can

be conducted with the test bubble instead of voltmeter.

Inspection on Conductance and Resistance

(a)

Disconnect the terminal or wire of accumulator to guar-

antee there is no voltage between the inspection sports.

(b)

Connect the two measuring leads of ohmn meter with the

inspection spots.

ohmn meter

SW

SW2

electromagnetic coil

relay

SW1

fuse

IG terminal connected to ignigtion

switch of SW

12

0

0

V

Body Electric System

Brief Introduction

BE-5

If there is diode in the circuit, connect the two leads in reverse

polar and make another inspection. When the cathode lead (-)

is connected with the positive (+) side of diode, and the

positive (+) lead should be connected with the cathode (-) lead

of diode, the diode should conduct, while the two leads

connected to the reverse polar, the diode should not contact.

Remark: the specification may be not same due to different

testing meter types; therefore, the application instruction for

testing meter should be referred before the inspection.

Check the light emitting diode (LED) according to the same

approach for diode inspection.

Remark:

The testing meter should be used the one with 3V voltage or the

one has larger resistance than that in circuit.

If no suitable testing meter is applied, the voltage of accumu-

lator may be added to check the LED to see whether it is

lighted.

(c)

Use the voltage or ohmn meter with high-impedance

(min voltage of 10 KV) to diagnose the failure in electric

circuit.

Body Electric System

Brief Introduction

0

0

K

K

ohmn meter

diode

0

0

K

K

ohmn

LED

digital type

 analogue type

DC

D
C

V

LG terminal of ignition switch

testing bubble

fuse box

short circuit

SW1

short circuit

disconnection

electromagnetic

coil

short circuit

disconnection

disconnectiong

Check to see whether there is short circuit

(a)

Tear down the burned fuse and remove all loads from

the fuse.

(b)

Connect the testing bubble at the fuse position;

(c)

Verify the situation of testing bubble position:

For example:

Put the ignition switch of SW at

ON

 position;

Put the ignition switch of SW and SW1 at

ON

 position;

Put the ignition switch of SW, SW1 and Relay at

ON

 position (which connects with the relay), and put

SW2 at 

OFF

) position (or disconnect the SW2).

(d)

Disconnect or re-connect the plugging elements when

observing the testing bubble. In case the testing bubble

keeps lighting, which shows there is short circuit between

the plugging elements; if the testing bubble extinguishes,

there is short circuit between the plugging elements.

(e)

Shake the trouble wire alongside the body to locate the

SW2

electromagnetic

coil

BE-6

Position and content of protective box

 Parts mounting Position

Body Electric System

Protective Box Position and Content

time-delay relay

protective box I

protective box III

horn relay

SL diesel

SY diesel

pre-heating timer

SL diesel

SY diesel

flasher relay

protective box I

rear defrost relay SY

rear air-conditioning relay SY

SL SK SY SJ

Dr SF

BE-7

Body Electric System

Protective Box Position and Content

protective box II

preheating relay

diesel

air-conditioner relay

fuel pump relay

ECU relay

Parts Mounting Position (Continued)

BE-8

Body Electric System

Protective Box Position and Content

Content of Protective Box

1 protective box I

fuse

1.Small lamp

10A

2.Rain brus

20A

3.Ceiling lamp

10A

4.(Cigarette lighter)

15A

5.Back -u

15A

6.Brake

10A

7.electric window

30A

8.Instrument

10A

fuel delivery/break electromagnetic valve10A(diesel

9.Central control lock

15A

Dr

A

B

C

1

2

3

4

5

6

7

8

9

SL SK

U

N

O

V

P

Q

R

NM

NN

NO

S

T

NP

NQ

FUSE

1. Protection

10A

2. Unload

3. Charging

10A

4. Back-up

10A

5. ECU

10A

6. Unload

7. Rain wiper

10A

8. Stop lamp

10A

9. Ceiling lamp

10A

10. Central control lock 15A

11. Dual flasher

10A

12. EC

10A

13. Fuel pump

10A

14. Cigarette lighter

15A

relay

A electric window relay

B. small lamp relay

C.(flasher)

(plugging elements of ceiling

lamp wire harness)

(plugging elements of wire

harness in engine room)

BE-9

Body Electric System

Protective Box Position and Content

fuse

relay

1. Small lamp

10A

A. electromagnetic fan relay

2. Brake

5A

B. lasher

3. Ceiling lamp

5A

C. electromagnetic fan relay

4. Central control lock

15A

D. small lamp relay

5. Electric rocker gear

30A

E. electric window relay

6. Dual flasher

10A

7. Cigarette lighter

15A

8. Rear vision mirror

5A

(1) plugging elements of ceiling lamp wire harness

9. Unload

(2) plugging elements of wire harness at front left door

10. Acoustic device

15A

(3)plugging elements of wire harness in engine room

11. Rear window

20A

12. Electromagnetic fan

10A

13. Instrument

 5A

14. Back-up lamp

5A

15. Rain brush

10A

16. Steering

5A

17. Unload

18. Unload

A

B

C

E

D

1

2

3

4

5

6

7

8

9

10 11 12

13 14 15

16 17 18

SF

Protective bos I (continued)

BE-10

Body Electric System

Protective Box Position Content

Fuse

V e h i c l e

Model

1. Standby

30A

Standby

20A

SJ

2. Standby

15A

SY

Standby

10A SJ

3. Standby

10A

SY SJ

4. Unload

SY

Bass bubble

10A

SJ

Power amplification

10 A

top SY

5. Unload

SY SJ

6. Unload

SY SJ

7. Unload

SY SJ

8. Air-conditioner

10A

SY SJ

9. Charging

10A

SY

Instrument

10A

SJ

10.ECU

10A

SY SJ

11.Back-up lamp

10A

SY SJ

12.Cigarette lighter

30A

SY SJ

receiver

13.Unload

SY

Refrigerant

10A

SJ top SY

14.Unload

SY SJ

15.Steering electric window

10A

SY

Humid display of steering

10A

SJ

sindicating lamp

16.Stop lamp

10A

SY SJ

17.Power aerial of inside lamp

10A

SY SJ

18.Central control lock

20A

SY SJ

19.Dual flasher

10A

SY SJ

20.Front rain brush

10A

SY SJ

21.Rear air-conditioner

15A

SY

Unload

SJ

22.Rear defroster

15A

SY

Unload

SJ

23.Rear rain brush

10A

SY

Unload

SJ

1Protective box I (continued)

pv=pg

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

BE-11

Body Electric System

Protective Box Position and Content

Fuse

Vehicle model

1. Standby

10A

(SL diesel)(SY diesel)

2. Standby

15A

(SL diesel) (SY diesel)

3. Standby

30A

(SL diesel) (SY diesel)

4. Unload

(SL diesel) (SY diesel)

5. Unload

(SL diesel) (SY diesel)

6. Unload

(SL diesel) (SY diesel)

7. Unload

(SL diesel) (SY diesel)

8. Start

10A

(SL diesel) (SY diesel)

9. Rear defroster

15A

(SY diesel)

Unload

(SL diesel)

10.Cigarette lighter

 and 

receiver

30A

(SY 

diesel)

 Cigarette 

lighter

15A

(SL 

diesel)

11.Rear rain brush

10A

(SY diesel)

 Unload

(SL 

diesel)

12.Front rain brush

15A

(SY diesel)

 Rain 

brush

5A

(SL 

diesel)

13.Steering

10A

(SY diesel)

 Dual 

flasher

10A

(SL 

diesel)

14.Preheating

15A

(SL diesel)(SY diesel)

15.Electric window

30A

(SL diesel)(SY diesel)

16.Small lamp

10A

(SL diesel)(SY diesel)

17.Stop lamp

10A

(SL diesel)(SY diesel)

18.Inside lamp

and electric aerial

15A

(SY diesel)

eiling lamp

10A

(SL diesel)

19.Central control lock

20A

(SY diesel)

 

Central control lock

15A

(SL diesel)

20.Rear air-conditioner

15A

(SY diesel)

 Unload

(SL 

diesel)

21.Unload

(SL diesel)(SY diesel)

 

Refrigerant

10A (top SY diesel)

22.Unload

(SL diesel )(SY diesel)

 

Power amplification

10A

(top SY diesel)

23.Unload

(SL diesel)(SY diesel)

1.Protective box I (continued)

SLDiesel  SYDiesel

1

2

3

4

5

6

7

8

9

NM

11

12

13

14

15

16

17

18

19

20

21

22

23

BE-12

Protective box II

Body Electric System

Protective Box Position and Content

Dr SF

Fuse

Vehicle

Relay

vehicle

1. Front fog lamp

15A

Dr

A. electromagnetic fan relay

Dr

Unload

SF

charging relay

Dr diesel

2. Electromagnetic fan

15A

Dr

electric horn relay

SF

ECU1

10A

SF

B. large lamp

Dr SF

3. Large lamp

10A

Dr

C. frost relay

Dr SF

Horn

15A

SF

4. Horn

15A

Dr

Lower beam

10A

SF

5. ECU1

10A

Dr

(1) plugging elements of

 

wire harness in engine room

Dr

Charging

10A

Dr diesel

 none

SF

Rear frost

5A

SF

(2) plugging elements of

 

wire harness in engine room

Dr SF

6. Large lamp

10A

Dr

(3) plugging elements of

 

wire harness in engine room

Dr SF

ECU2

10A

SF

7. Rear frost

10A

Dr

Upper beam

10A

SF

8. ECU2

10A

Dr

Preheating

10A

Dr diesel

Front fog lamp

10A

SF

9. Fuel pump

10A

Dr SF

Unload

Dr diesel

A

B

C

1

2

3

4

5

6

7

8

9

BE-13

Body Electric System

Protective Box Position and Content

Protective box II (continued)

Fuse

Vehicle

Relay

Vehicle

1. Standby

10A

SL SK

A.electromagnetic fan relay

SL SK

2. Standby

10A

SL SK

small lamp relay

(SL diesel)

3. Standby

30A

SL SK

B.electric window relay

SL SK

20A

(SL diesel)

cold start relay

(SL diesel)

4. Rear fog lamp

10A

SL SK

C.frost relay

SL SKLeft 

large lamp

10A

(SL diesel)

charging relay)

(SL diesel)

5. Front fog lamp

10A

SL SK

D.blower relay)

SL SK

Right large lamp

10A

(SL diesel)

thermostatic relay

(SL diesel)

6. Small lamp

10A

SL SK

E.small lamp relay

SL SK

Air-conditioner

10A

(SL diesel)

heating relay

(SL diesel)

7. Electric horn

10A

SL SK

F.large lamp relay

SL SK

Warm air

20A

(SL diesel)

G.air-conditioner relay

SL SK

8. Electric window

30A

SL SK

frost relay

(SL diesel)

Unloa

(SL diesel)

H.rain-brusher intermissive relay

SL SK

9. A/C

10A

SL SK

I.diod

SL SK

Charging

10A

(SL diesel)

10.Air blower

30A

SL SK

Electric horn

10A

(SL diesel)

11.Electronic fan

10A

SL SK

Dual flasher

10A

(SL diesel)

12.Right large lamp

10A

SL SK

Unload

(SL diesel)

13.Left large lamp

10A

SL SK

Fog lamp

 10A

(SL diesel)

14.60A fuse

SL SK

15.60A fuse

SL SK

16.30A fuse

SL SK

17.30A fuse

SL SK

Unload

SL diesel

1

2

3

H

4

5

6

7

14

15

G

E

F

C

D

A

B

8

9

10

11

12

13

SL SK

17

16

I

BE-14

Fuse

Vehicle

Relay

Vehicle

1. Standby

10A

SY SJ

A. electromagnetic fan relay

SY SJ

2. Standby

10A

SY SJ

small lamp relay

(SY diesel)

3. Standby

30A

SY SJ

B. electric window relay

SY SJ

4. Rear fog lamp

10A

SY SJ

cold start relay

(SY diesel)

Left large lamp

10A

(SY diesel)

air-conditioner relay

SJ

5. Front fog lamp

10A

SY SJ

C. frost relay

SY SJ

Right large lamp

10A

(SY diesel)

 charging relay

(SY diesel)

6. Small lamp

10A

SY SJ

D. blower relay

SY SJ

Air-conditioner

10A

(SY diesel)

 thermostatic relay

(SY diesel)

7. Electric horn

10A

 SY SJ

E. small lamp relay

SY SJ

Warm air

20A

 (SY diesel)

heating relay

(SY diesel)

8. ECM

10A

SY SJ

rear defrost relay

SJ

Unload

(SY diesel)

F. large lamp

SY SJ

9. Fuel pump

10A

SY SJ

H. rain-brusher intermissive relay

SY SJ

Charging

10A

(SY DIESEL)

I. diode

SY SJ

10. Air blower

30A

SY SJ

Electric horn

10A

(SY diesel)

11. Electronic fan

10A

SY SJ

Dual flasher

10A

(SY diesel)

12. Right large lamp

10A

SY SJ

Rear fog lamp

10A

(SY diesel)

13. Left large lamp

10A

SY SJ

Front fog lamp

10A

(SY diesel)

14. 60A fuse

SY SJ

15. 60A fuse

SY SJ

16. 30A fuse

SY SJ

17. 30A fuse

SY SJ

Unload

(SY diesel)

Protective box II (continued)

Body Electric System

Protective Box Position and Content

1

2

3

4

17

16

14

15

I

H

G

E

F

C

D

A

B

5

6

7

8

9

10

11

12

13

SY SJ

BE-15

 Body Electric System

Protective Box Position and Content

Protective box III

Fuse

Vehicle model

1. Compressor

10A

Dr SF

2. Unload

SF

A/C

10A

Dr

3. Warm air

30A

Dr SF

Dr SF

A

1

2

3

BE-16

Power supply system

  Body Electric System

Power Supply System

The power supply system includes the accumulator and the generator, the latter is the main power supply while the

accumulator is the auxiliary power supply. The two power supplies are in paralleling connection.

fuse

ignition switch

ACC

ON

ST

4

5

 

 

 

generator

fuse

ignition switch

SL SK SY SJ

Dr SF

4

3

2

8

7

6

5

1

5

4

3

1

10

9

8

7

6

2

vehicle models in parenthesis belongs to Dr and SF

battery

fuse

charging indicating lamp

 

 

 

 

 

 

 

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