TÀI LIỆU mạch điện xe KIA k2700

IGN2

IGN2

Washer Motor

Washer S/W

M

Wiper Motor Electrical System

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M
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INT.
Wiper
Relay

Electrical
System
MF S/W

IGN2 S/W

B+

Published by
Chonan Technical Service Training Center

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Electrical System

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Electrical System

Contents
1. Starting System

5

1.1 Features

5

1.2 Operating Principle

5

1.3 Structure and Operation
1.4 Schematic Diagram

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11

1.5 Inspection

12

1.6 Troubleshooting

18

2. Charging System

19

2.1 Features

19

2.2 Operating Principle

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2.3 Structure and Operation
2.4 Schematic Diagram

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2.5 Inspection

28

2.6 Troubleshooting

35

3. Preheating System

37

3.1 Features

37

3.2 Operating Condition

38

3.3 Components
3.4 Schematic Diagram

39

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3.5 Inspection

41

3.6 Troubleshooting

44

4. ETACS

47

4.1 Features

47

4.2 Operating Conditions by Function

57

5. Component Location

73

5.1 K2700

73

5.2 PREGIO

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Electrical System

1. Starting System
1.1 Features
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Electrical System

The purpose of the starting system is to use electricity from the battery and an electric
motor to turn over the engine during starting. The starting system consists of the battery, a
starting motor, a magnetic switch, an ignition switch, and related electrical wiring.
A typical starting motor is made up of a frame and field coil assembly, an armature, a drive
mechanism, a brush and holder assembly, and a magnetic switch.

1.1.1 Specification
Model
Item

POONG SUNG
Output

Test condition
No-load
characteristics Performance
Magnetic
switch

J2, JT, D4BH
MANDO
12V – 2.2 kW
11V (20℃)
130A, MAX. 4,500 rpm

Rush current

45A (12V, 20℃)

52A (12V, 20℃)

Holding current

12A (12V, 20℃)

12A (12V, 20℃)

1.2 Operating principle
Electric motors of the type used in “start motor” operate on the principle that a currentcarrying conductor will tend to move from a strong magnetic field to a weak magnetic field.
If a single current-carrying conductor is placed in a magnetic field created by a permanent

magnet, as in figure #1, the flow of current in the conductor will cause a magnetic field to
encircle the conductor in a clockwise direction.

This circular magnetic field will tend to cancel out and weaken the lines of force between
the poles of the permanent magnet below the conductor. At the same time, both fields will
combine above the conductor to create strong magnetic field. In effect, there is more
magnetism above the conductor and less below it. Then, as the distorted lines of force tend
to straighten out, they exert a downward thrust on the conductor.
<Rotary Motion>
In a start motor, the downward thrust is converted into rotary motion. Assume that the
conductor in figure #1 is bent into a loop, as shown in figure #2. This will be the rotating part,
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which is known as the armature. The ends of the armature are connected to two semicircular
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Electrical System

brass bars called the commutator.
The magnetic field of the two magnetic poles (marked N and S) is created by two
electromagnets. Current for the electromagnets called field coils in this setup is provided by a
battery. The current flowing through the field coils, figure #2, produces a strong magnetic field
that flows from the north pole (N) to the south pole (S).

Figure #3

Figure #2

At the same time, current flowing through the armature coil produces a circular magnetic
field that surrounds the armature, as shown by the arrows in figure #2. This circular magnetic

field is in a clockwise direction on the left-hand conductor of the armature and a
counterclockwise direction around the right conductor. Note that the current in the left-hand
side of the armature coil is flowing toward the commutator, which is the same direction shown
in figure #1.
This results in a downward thrust on the armature. Since the current is flowing in the
opposite direction in the right-hand side of the armature coil, the thrust will be in the opposite
direction, or upward, figure #3.
The combination of the two thrusts causes the armature to rotate. This rotation will
continue because each time the armature coil passes the vertical position, the commutaotr
(which rotates with the armature) will automatically connect the armature coil so the current
will continue to flow away from the commutator in the right-hand coil and toward the
commutator in the left-hand coil.

1.3 Structure and operation
The start motor is mounted under the injection pump, in front of engine. The start motor
is a device that rotates the crankshaft through the flywheel ring gear to start the engine.

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Electrical System

When the start motor is activated by the ignition switch, the magnetic switch operates
and meshes the pinion with the outer ring gear of the flywheel through lever action. The
engine is then rotated by the motor and starts. When the ignition switch is returned to ON
after the engine has started, the pinion release the ring gear and motor revolution stops.
Major parts in the assembly are the motor to generate torque, the overrunning clutch to
transmit power and to prevent start motor overrun, the magnetic switch to turn on/off motor

current and mesh the pinion with the ring gear and the internal gear to amplify armature
torque.

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Magnetic switch
Lever
Front bracket
Spacer

Brush holder assembly

Cover

Through bolt
Rear bracket
Yoke assembly
Armature

Start Motor (D4BH)

8 (J2, JT, JTA)
Start Motor
1. Field frame assembly
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6. Clutch assembly


Electrical System

2. Armature

7. Retainer and roller

3. Brush holder

8. Pinion gear

4. Brush spring

9. Idle gear

5. Magnetic switch assembly

10. Starter housing

1.3.1 Motor
The current passes through the armature, with the result, the motor generates high
torque that is required to start the engine.

1.3.2 Overrunning clutch
The overrunning clutch transmits cranking torque from the start motor to the fly wheel
gear, but permits the pinion gear to run faster than, or overrun, the armature once the engine
has started. This protects the armature from excessive speed during the brief period that the

start motor pinion gear remains meshed and the engine has started.
Overrunning clutch of the roller type is used. The roller is installed into a wedge-shaped
groove formed by outside and inside race (sleeve) and pressed by a spring. In igniting the
start motor, the roller is pressed into the narrow side of groove and acts as a key transmitting
the revolution of outside race to the pinion.
However, because the roller compresses the spring and moves into the wide side of
groove when the pinion revolves by the engine, the effect of the key disappears and the
revolution of pinion isn’t transmitted to the outside race.

Overrunning Clutch
When the starter switch turns ON, the
battery current flows from the terminal S of the 1.3.3 Magnetic Switch
magnetic switch to the pull-in coil (P) and hold-in
The magnetic switch makes the load
coil(H).
The feebler current then flows from the terminal current of the motor ON/OFF, and the
M to the motor. The plunger is attracted by the pinion engages with the ring gear.
magnetic force of the pull-in and hold-in coils,
1.3.4 Operation
pushing out the pinion via the lever.
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Electrical System

As the pinion comes into complete mesh
with the ring gear, the contact P2, closes allowing
a large current to directly flow from the battery

to motor to turn the pinion. At the same time,
no current flows to the pull-in coil(P), the
plunger being retained by the hold-in coil(H) alone.

The moment the starter switch is turned OFF,
battery current flows from the terminal B to the
pull-in(P) and hold-in(H) coils, canceling the
magnetic fluxes of the plunger. This causes the
plunger to be returned spring force, opening the
contact P2 to shut off current to the motor.

1.4 Schematic Diagram

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Electrical System

The battery B+ current stands by at the start motor magnetic switch(A-01), ignition
switch, and starter relay terminal 5(A-07) through fusible link. When a driver sets the ignition
switch to the start position, the ignition current flows to ground through the starter relay
excitation coil. The standing by current of starter relay terminal 5(A-07) flows from the start
motor magnetic switch terminal (A-02)) to the hold-in coil and pull-in coil. Then the magnetic
switch gets closed and the standing by current of magnetic switch(A-01) flows to the motor.
The plunger is pulled by the strength of the pull-in coil and holding the coil pushes out
the pinion through the lever. When the pinion engages with the ring gear completely, the
contact point is closed and the large current flows directly from the battery to the motor to
rotate the pinion. At this time, the plunger is kept only by hold-in coil (H) as the current

doesn’t flow in the pull-in coil (P).

1.5 Inspection
11 ANALYZER
1.5.1 Battery Inspection with MICRO 570

Let’s check the battery capacity, which is one of the most important external factors,
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Electrical System

using the tester.

MICRO 570 Analyzer
<Procedure>
① Connect the tester to the battery
- Red clamp to battery positive (+) terminal
- Black clamp to battery negative (-) terminal

※ CAUTION
Connect clamps securely. If “CHECK CONNECTION” message is displayed on the screen,
reconnect clamps securely.
② The tester will ask if the battery is connect “IN A VEHICLE“ or “OUT OF A VEHICLE”. Make
your selection by pressing the arrow buttons; then press ENTER.

③ Choose either CCA or CCP and press the ENTER button.
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※ NOTE
- CCA : Cold cranking amps, is an SAE specification for cranking batteries at -0.4 ℉ (-18 ℃).

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Electrical System

- CCP : Cold cranking amps, is an SAE specification for Korean manufacturer’s for cranking
batteries at -0.4℉ (-18℃).

④ Set the CCA value displayed on the screen to the CCA value marked on the battery label
by pressing up and down buttons and press ENTER.

※ NOTE
The battery ratings(CCA) displayed on the tester must be identical to the ratings marked on
batter label.

⑤ The tester displays battery test results including voltage and battery ratings. A relevant
action must be given according to the test results by referring to the battery test results as
shown in the table below.

<Battery test results>

RESULT ON

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REMEDY

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Electrical System

PRINTER
Good battery

No action is required.

Good recharge

Battery is in a good state.
Recharge the battery and use.

Battery is not charged properly.
Charge & Retest Charge and test the battery again (Failure to charge the battery fully
may read incorrect measurement value)
Replace battery and recheck the charging system. (Improper
Replace battery

connection between battery and vehicle cables may cause “REPLACE
BATTERY”, retest the battery after removing cables and connecting
the tester to the battery terminal directly prior to replacing the battery)

Bad-cell replace

Charge and retest the battery. And then, test results may cause
“REPLACE BATTERY”, replace battery and recheck the charging
system.

※ WARNING
Whenever filing a claim for battery, the print out of the battery test results must be attached.

⑥ To conduct starter test, continuously, press ENTER.

1.5.2 Starter Inspection with MICRO 570 ANALYZER
<Procedure>
① After the battery test, press ENTER immediately for the starter test.

② After pressing ENTER key, start the engine.

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Electrical System

③ Cranking voltage and starter test results will be displayed on the screen. Take a relevant
action according to the test results by referring to the starter test results as given below.

<Starter test results>

RESULT ON
PRINTER

REMEDY

Cranking
System shows a normal starter draw.
voltage normal
Cranking
voltage low

Charge battery

Replace
battery

Cranking voltage is lower than normal level  Check starter.
The state of battery charge is too low to test  Charge the battery and
retest.
Replace battery.
If the vehicle is not started though the battery condition of “Good and
fully charged” is displayed.
Check wiring for open circuit, battery cable connection, starter and
repair or replace as necessary.
If the engine does crank, check fuel system.

※ NOTE
When testing the vehicle with old diesel engines, the test result will not be favorable if the
glow plug is not heated. Conduct the test after warming up the engine for 5 minutes.
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Electrical System

④ To continue charging system test, press ENTER.

1.5.3 Magnetic Switch Inspection
<Pull-in voltage>
1 Inspect the battery voltage.

 Voltage : above 12.4V
② After starting the engine, check if the starter rotates smoothly.
③ If the starter does not rotate, check the “S” terminal voltage during cranking engine.
 Voltage above 8V : Inspect the starter
 Voltage below 8V : Inspect wiring(main fuse, ignition switch)

Poong Sung(J2, JT)

Mando (J2, JT)

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Electrical System

<Pull-in coil>
※ NOTE
Remove the battery negative cable.
Remove the “M” terminal of starting motor.
① Do the continuity test between “S” and “M” terminal.

② If it is opened, replace the magnetic switch.
<Hold-in coil>
① Do the continuity test between “S” and switch body.

2 If it is opened, replace the magnetic switch.

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Electrical System

1.6 Troubleshooting
Problem

No
engine
cranking

Starter
rotates
slowly

Possible causes

Action

Insufficient battery charge

After checking specific
Charge or Replace

Loosed, corroded or worn
battery cable

Repair or Replace

Malfunction of fuse and wiring

Repair or Replace

Malfunction of starter

Repair or Replace

Malfunction of ignition switch

Repair or Replace

Insufficient battery charging

After checking specific
Charging or Replace

Loosed, corroded or worn battery
cable

Repair or Replace

Malfunction of starter

Repair or Replace

Malfunction of magnetic switch
Starter
rotates

continuousl
y

Starter spins
�No engine
cranking

Repair or Replace

Malfunction of ignition switch

Repair or Replace

Shorted wiring

Repair

Worn pinion
malfunction

gear

or

starter

Repair or Replace

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Worn ring gear
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Replace


Electrical System

2. Charging System
2.1 Features
The purpose of the charging system is to recharge the battery after it cranks the engine
and to provide all electrical power to the vehicle after the engine has started.
The typical automotive charging system consists of the alternator (generator), voltage
regulator, alternator drive belt, battery, and related wiring.

2.1.1 Specification
Model
Item
Alternator

Type

J2, JT

D4BH

Built-in IC regulator and silicon-diode rectifier

Output
Regulator

setting voltage
Battery

Type

12V / 75A
14.4 ± 0.3V
PT80-33HL 100AH

MF 100 AH

2.2 Operating Principle
An alternator is an electromagnetic device that converts the mechanical energy supplied
by the engine into electrical energy. In operation, the generator maintains the storage battery
in fully charged condition and supplies electrical power for the electrical system and
accessory equipment.
The operation of the automotive alternator is based on the principle of electromagnetic
induction. That is, when a coil of wire is moved through a magnetic field, a voltage will be
induced, or generated, in the coil.
Actually, voltage can be induced in either to two ways :
● By moving a coil of wire through a magnetic field.
● By keeping the coil stationary and moving the magnetic field.
The old DC(direct current) alternator operated on the first principle. The DC alternator
induced voltage in coils of wire as the assembly (armature) rotated in a stationary magnetic
field. The AC (alternating current) alternator19
operates on the second principle. The magnetic
field, or rotor, is rotated and voltage is generated in the stationary coils, or stator.
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Electrical System

In general, then, voltage is induced in a coil whenever there is a change in the lines of
force passing through the coil. Figure #1 illustrates what happens when lines of force are cut
by a rotating coil.
When the coil is in the vertical position, as shown at A in Figure #1, the lines of force
surrounding the conductor are balanced. For that instant, no lines of force are being cut.
Therefore, no voltage will be induced in the coil. As the coil approaches position B, an
increasing number of lines of force will be cut. The generated voltage will continue to
increase until it reaches a maximum at position B.
After passing position B, the voltage will start to decrease as fewer lines of force are
being cut. It will become zero when position C is reached. As rotation continues, another
maximum will be reached at position D. However, the lines of force are now being cut in the
opposite direction to that of position B. Therefore, the current generated will flow in the
opposite direction.

Figure #1
Because the current keeps changing its direction as the loop of wire is rotated, it is called
an alternating current. The variations in the value and direction of the generated voltage are
shown in the lower portion of Figure #1. To make use of the electrical energy being
generated, each end of the coil is connected to a ring that rotates with the coil of wire.
Contact with these rotating slip rings is made by brushes that bear against the rings.
All automotive generators produce alternating current that, in turn, must be rectified
(converted) to direct current to satisfy the needs of the storage battery in the various
electrical systems and accessories.
In an ac generator, or alternator, Figure #2, the magnetic field is rotated and voltage is
generated in the stationary coils. Rectifiers, or diodes, are built into the alternator to limit
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current flow to one direction only to provide direct
current at the output terminal.

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Electrical System

2.3 Structure and Operation
The alternator is driven by the V-belt, acting to charge the battery and supply power to
other electrical equipment. The alternator is driven, and connected with the engine by a belt
and the quantity of power generation is different according to the rotational frequency of
engine. If the quantity of power generation is more than the load, the power is supplied for all
electric devices only by the generator and the battery is charged by it. An alternator mainly
consists of a rotor to generate a magnetic field, a stator to generate power, a rectifier to
rectify the generated current and a regulator to stabilize the generated voltage.

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Alternator (D4BH)

2.3.1 Rotor
The rotor is composed of the rotor core, the coil, the slip ring and the rotor shaft and
connected with a crank pulley by the V belt for revolution.
The rotor coil generates the magnetic field by current and is inputted through the slip ring
from the brush, and the end of coil is connected with a slip ring made of stainless steel.
Rotor core

Rotor shaft

Rotor coil
Slip ring

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Electrical System

2.3.2 Stator
Together with the rotor core, the stator core forms the magnetic flux path. The magnetic
flux lines in the stator core are affected by the passage of the rotor core field and generate
electricity. The stator core is made by overlapping several steel plates or silicon steel plates
to reduce the loss of magnetic field, and forms the magnetic circuit with the rotor core.

Stator coil

Stator core

The stator has three sets of windings that are assembled around the inside
circumference of a laminated core. Each winding of the stator generates a separate voltage,
making the alternator a three-phase unit. One end of each winding is connected to a positive
diode and a negative diode. The other ends of the stator windings are connected to form a
“Y”(120˚) arrangement.

2.3.3 Rectifier
The rectifier mainly consists of 3 diode trios, 6 diodes and 2 heat sinks. It rectifies the AC

stator output to DC power. Each heat sink has the (+) or (-) leads from 3 diodes attached to it,
performing full wave rectification for 3-phase AC.
The diodes are connected to the stator leads and serve as one-way valves that permit
current to flow through in one direction only. Each phase of the three-phase output of the
alternator ranges from positive to negative and back to positive again. The diodes convert
this alternating current to direct current at the alternator output terminal.
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Electrical System

Note in Figure that while the voltage of each phase ranges from zero to maximum, the
effective voltage of all phases maintains a reasonably even current output.

In diagram ②, high voltage is generated between I
and III, so current passes through diode 1 to the
load and returns through diode 6.

Following the process sequentially, it can be seen that the current always flows to the load,
while each phase passes current to a different pair of diodes for rectification.

2.3.4 Regulator
The regulator is integral with the brush holder. The assembly combines the IC regulator,
the brushes and the brush springs. The regulator controls the input of current flowing in the
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rotor coil of the alternator and the output current
of the generator. The IC regulator cuts off
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Electrical System

the current of the rotor coil by the semiconductor circuit. In addition, if the output voltage of
the generator is low, it will turn the charging warning lamp ON.

<IC regulator operation>
When the Ignition switch is turned on, base current flows from the battery to the power
transistor (Tr1), turning it on. Current then flows to the field coil, lighting the charge lamp.

When the engine is started and the alternator begins to generate electricity, the base current
is supplied by the alternator itself. The field current comes from the diode trio, exciting the
field coil. The output voltages at B and L terminals are the same, extinguishing the charge
lamp.

When alternator voltage rises, Zener diode ZD is energized, and supplies a base current
to transistor Tr2, turning it on. This causes the base current of power transistor to short to
ground through Tr1. The power transistor is turned off and the current flow stops,
When output voltage drops, Zener diode ZD shuts off, turning on the power transistor, and
raising the voltage by supplying field current again.
Adjustment of the voltage generated by the alternator is thus achieved by the IC
regulator is constantly repeating this operating cycle.

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