Hyundai Chonan Technical Service Trainng Center Electrical System
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Electrical System
Electrical
System
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Chonan Technical Service Training Center
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Electrical System
Chonan Technical Service Training Center 2
Electrical System
Foreword
This training guide has been published to help all the service personnel of
HYUNDAI distributors, authorized HYUNDAI workshops and commercial
vehicle fleet companies be familiar with the electrical system of HYUNDAI
vehicles.
The applicable vehicles are all kinds of Hyundai Truck and Bus.
All the contents of this guide, including, drawings and specifications are the
latest available at the time of publication.
All the contents of this guide will be helpful when you provide efficient and
correct service on electrical system.
For detailed service specifications and service procedures, please refer to the
relevant shop manuals.ⓒ2003. Hyundai Motor Company
Chonan Technical Service Training Center
All rights reserved.
This publication may not be reproduced in whole or in part without the written consent of
HMC.
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Electrical System
Contents
1. Battery ······································· 7 7. Power Window System ················· 97
1.1 Functions ································ 7 7.1 Operating conditions ················· 97
1.2 Structure ································· 7 7.2 Components ···························· 97
1.3 Characteristic··························· 10 7.3 Analysis of schematic diagram ···· 98
1.4 Service ··································· 13 7.4 Troubleshooting (HD65, 72) ······ 99
7.5 Schematic diagram ··················· 101
2. Starting System ··························· 23
2.1 Operating principle ···················· 23 8. Central Door Lock / Unlock System ········ 103
2.2 Structure ································· 24 8.1 Operating conditions ················· 103
2.3 Operation ································ 27 8.2 Components ···························· 103
2.4 Schematic Diagram ··················· 31 8.3 Analysis of schematic diagram ···· 104
8.4 Troubleshooting (HD65, 72) ········ 105
3. Charging System ························· 39 8.5 Schematic diagram ··················· 107
3.1 Operating principle ···················· 39
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Electrical System
3.2 Structure ································· 41 9. Mirror Defogger System ··············· 109
3.3 Operation ································ 46 9.1 Operating conditions ················· 109
3.4 Schematic Diagram ··················· 47 9.2 Components ···························· 109
9.3 Analysis of schematic diagram ···· 110
4. Lighting System ·························· 53 9.4 Troubleshooting (HD65, 72) ········ 111
4.1 Features ································· 53 9.5 Schematic diagram ··················· 113
4.2 Lighting system ························ 54
4.3 Head lamps ····························· 58 10. Engine Preheating System ·········· 115
4.4 Turn and hazard lamps ·············· 62 10.1 Operating conditions ················ 115
10.2 Components ·························· 125
5. Gauge & Warning System ············· 67 10.3 Analysis of schematic diagram ··· 125
5.1 Features ································· 67 10.4 Troubleshooting (HD 65, 72) ····· 127
5.2 Gauge system·························· 67 10.5 Schematic diagram·················· 129
5.3 Warning system························ 78
6. Wiper & Washer System ··············· 87
6.1 Wiper system ··························· 87
6.2 Washer related wiper ················· 90
6.3 Schematic diagram ··················· 94
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Electrical System
1. Battery
The lead-acid storage battery used in automobiles and other vehicles is an
electrochemical device that converts chemical energy into electrical energy. When the battery
is connected to an external load, such as a starting motor, the energy conversion takes place
and electricity flows through the circuit.
1.1 Functions
The lead-acid battery has several important functions as follows;
It serves as a source of power for the starting motor, ignition system, electronic fuel
injection system, and other electrical devices for the engine when cranking and
starting an engine.
It supplies all of the electrical power for the vehicle when the engine is not running.
It acts as a stabilizer of voltage for the entire electrical system.
It furnishes current for a limited time when electrical demands exceed alternator
output.
It stores electricity for extended periods.
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Electrical System
1.2 Structure
The lead-acid storage battery is built to withstand severe vibration, cold weather, engine
heat, corrosive chemicals, high current discharge, and prolonged periods without use. To test
and service batteries properly, you must understand battery construction. The construction of
basic lead-acid cell-type battery is as follows;
Battery element
Battery case, cover, and caps
Battery terminals
Electrolyte
Cell connector lead strap Filler cap
Terminals
Element Cell divider
Figure 1.1 Cross section of a battery
1.2.1 Battery element
The battery element is made up of negative plates, positive plates, separators, and
straps (figure. 1.2). The element fits into a cell compartment in the battery case. Most
automotive batteries have six elements.
Negative group 2 Volts
Positive group
Negative plate
Separator
Positive plate
Figure 1.2 Battery element.
Each cell compartment contains two kinds of chemically active lead plates, known as
positive and negative plates. The battery plates are made of GRID (stiff mesh framework)
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Electrical System
coated with porous lead. These plates are insulated from each other by suitable separators
and are submerged in a sulfuric acid solution (electrolyte).
Charged negative plates contain spongy (porous) lead (Pb) which is gray in color.
Charged positive plates contain lead peroxide (PbO2 ) which has a chocolate brown color.
These substances are known as the active materials of the plates. Calcium or antimony is
normally added to the lead to increase battery performance and to decrease gassing (acid
fumes formed during chemical reaction). Since the lead on the plates is porous like a sponge,
the battery acid easily penetrates into the material. This aids the chemical reaction and the
production of electricity.
Lead battery straps or connectors run along the upper portion of the case to connect the
plates. The battery terminals (post or side terminals) are constructed as part of one end of
each strap.
To prevent the plates from touching each other and causing a short circuit, sheets of
insulating material (microporous rubber, fibrous glass, or plastic-impregnated material), called
separators, are inserted between the plates. These separators are thin and porous so the
electrolyte will flow easily between the plates. The side of the separator that is placed against
the positive plate is grooved so the gas that forms during charging will rise to the surface
more readily. These grooves also provide room for any material that flakes from the plates to
drop to the sediment space below.
1.2.2 Battery case, cover, and caps
The battery case is made of hard rubber or a high- quality plastic. The case must
withstand extreme vibration, temperature change, and the corrosive action of the electrolyte.
The dividers in the case form individual containers for each element. A container with its
element is one cell.
Stiff ridges or ribs are molded in the bottom of the case to form a support for the plates
and a sediment recess for the flakes of active material that drop off the plates during the life
of the battery. The sediment is thus kept clear of the plates so it will not cause a short circuit
across them.
The battery cover is made of the same material as the container and is bonded to and
seals the container. The cover provides openings for the two battery posts and a cap for each
cell.
Battery caps either screw or snap into the openings in the battery cover. The battery
caps (vent plugs) allow gas to escape and prevent the electrolyte from splashing outside the
battery. They also serve as spark arresters (keep sparks or flames from igniting the gases
inside the battery). The battery is filled through the vent plug openings. Maintenance-free
batteries have a large cover that is not removed during normal service.
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Electrical System
CAUTION
Hydrogen gas can collect at the top of a battery. If this gas is exposed to a flame or spark,
it can explode.
1.2.3 Battery terminals
Battery terminals provide a means of connecting the battery plates to the electrical
system of the vehicle. Either two round post or two side terminals can be used.
Battery terminals are round metal posts extending through the top of the battery cover. They
serve as connections for battery cable ends. Positive post will be larger than the negative
post. It may be marked with red paint and a positive (+) symbol. Negative post is smaller,
may be marked with black or green paint, and has a negative (-) symbol on or near it.
Side terminals are electrical connections located on the side of the battery. They have
internal threads that accept a special bolt on the battery cable end. Side terminal polarity is
identified by positive and negative symbols marked on the case.
1.2.4 Electrolyte
The electrolyte solution in a fully charged battery is a solution of concentrated sulfuric
acid in water. This solution is about 60 percent water and about 40 percent sulfuric acid.
The electrolyte in the lead-acid storage battery has a specific gravity of 1.28, which
means that it is 1.28 times as heavy as water. The amount of sulfuric acid in the electrolyte
changes with the amount of electrical charge; also the specific gravity of the electrolyte
changes with the amount of electrical charge. A fully charged battery will have a specific
gravity of 1.28 at 26.7℃.
As storage battery discharges, the sulfuric acid is depleted and the electrolyte is
gradually converted into water. This action provides a guide in determining the state of
discharge of the lead-acid cell. The electrolyte that is placed in a lead-acid battery has a
specific gravity of 1.280.
The specific gravity of an electrolyte is actually the measure of its density. The electrolyte
becomes less dense as its temperature rises, and a low temperature means a high specific
gravity. The hydrometer that you use is marked to read specific gravity at 26.7℃ only. Under
normal conditions, the temperature of your electrolyte will not vary much from this mark.
However, large changes in temperature require a correction in your reading.
1.3 Characteristic
1.3.1 Battery capacity
The capacity of a battery is measured in ampere-hours. The ampere-hour capacity is
equal to the product of the current in amperes and the time in hours during which the battery
9 Chonan Technical Service Training Center
Hyundai Chonan Technical Service Trainng Center Electrical System
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Electrical System
is supplying current. The ampere-hour capacity varies inversely with the discharge current.
The size of a cell is determined generally by its ampere-hour capacity. The capacity of a cell
depends upon many factors, the most important of which are as follows:
The area of the plates in contact with the electrolyte
The quantity and specific gravity of the electrolyte
The type of separators
The general condition of the battery (degree of sulfating, plates buckled, separators
warped, sediment in bottom of cells, etc.)
The final limiting voltage
1.3.2 Battery ratings
Battery ratings were developed by the Society of Automotive Engineers (SAE) and the
Battery Council International (BCI). They are set according to national test standards for
battery performance. They let the mechanic compare the cranking power of one battery to
another. The two methods of rating lead-acid storage batteries are the cold-cranking rating
and the reserve capacity rating.
1.3.3 Cold-cranking rate
The cold-cranking rating determines how much current in amperes the battery can
deliver for thirty seconds at –17.8℃ while maintaining terminal voltage of 7.2 volts or 1.2
volts per cell. This rating indicates the ability of the battery to crank a specific engine (based
on starter current draw) at a specified temperature.
For example, one manufacturer recommends a battery with 305 cold-cranking amps for
a small four-cylinder engine but a 450 cold-cranking amp battery for a larger V-8 engine. A
more powerful battery is needed to handle the heavier starter current draw of the larger
engine.
1.3.4 Reserve capacity rating
The reserve capacity rating is the time needed to lower battery terminal voltage below
10.2 V (1.7 V per cell) at a discharge rate of 25 amps. This is with the battery fully charged
and at 80?F. Reserve capacity will appear on the battery as a time interval in minutes.
For example, if a battery is rated at 90 minutes and the charging system fails, the
operator has approximately 90 minutes of driving time under minimum electrical load before
the battery goes completely dead.
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