Automotive Electrical Course - Service Training 1999

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Course

Introduction

Automotive

Electrical Course

S E R V I C E T R A I N I N G

Student Learning Guide

BEC



m o d u l e A E C

COURSE INTRODUCTION

This three day course provides an opportunity

for hands-on electrical diagnosis practice.

ur ng s course, you w :

• Analyze automotive circuits using circuit

agrams.

• Learn to use the Kia 5-Step

Troubleshooting Process to locate faults.

• Gain experience using the DVOM.

• en y norma sys em opera on o

electrical system components.

• nspect for normal operation of the vehicle’s

basic electrical systems.

To provide the Kia technician with the skillsan now e ge require to iagnose an

repair a ve ic e t at as an e ectrica systemma unction.

AEC-2

COURSE GOAL

REREQUISITES one

We come to Kia Automotiveectrica

ectrica princip es anan s-on iagnostics or Kia

Tec nicians

eview o avai a eesources

Course length is 3 days

AEC-1

1



m o d u l e A E C

COURSE INTRODUCTION

MODULAR FORMAT

As a Kia service professional, you understand

e mpor ance o s ay ng curren w o ay s

complex automotive technology. The amount

of training that a technician needs dependson factors like technical background, product

knowledge and practical experience. To meet

your needs, we have developed a modular

training system to help you focus your efforts in

the areas that are of the most value to you.

TWO TYPES OF MODULES

. Student Learnin Guide and Workbook

This module explains subjects from basicconcepts to the most complex technology

we offer. Obtaining a working knowledge of

any sys em or componen s a prerequ s e

to effectively diagnose system malfunctions.

There may also be classroom exercises that

you w comp e e as a group.

2. Guided Practice

s mo u e prov es an s-on exper ence a

will build on the theory and diagnosis topics

discussed in the classroom.

These modules will also help develop your

troubleshooting skills. This course will involve

the use of service manuals, ETMs, technical

service bulletins, newsletters and other

resources as an integral approach to your

overall diagnostic strategy.

o u ar ormat wi e p youocus your e orts in t e areasthat are of the most value to

you.

AEC-3

. Stu ent Learning Gui e anWor oo :

- Exp ains t eory

- Can e use or se stu y

2. Gui e Practice

- Provi es an s-onexperience

- He ps eve optrou es ooting s i s

AEC-4

2



Several symbols have been designed to keep

you on rac as you comp e e eac mo u e.

These symbols are shown in the illustration

above.

When you see this symbol, view the appropriate videosegment for important concepts or procedures.

Activities support critical learning objectives. Performing

ese proce ures w e p you mas er e ma er a .

This symbol shows when you must refer to additional

publications to complete the questions or module activity.

Most modules contain a Self-Test or an

Instructor Sign-Off to give you feedback on your strengths

and weaknesses. Gauge your level of expertise by your

ability to answer the questions and instructor’s feedback.

ev ew appropr a e areas as nee e .

AEC-5

m o d u l e A E C

COURSE INTRODUCTION

3



m o d u l e A E C

COURSE INTRODUCTION

e

a o

TIME OCATION INST. TYPE SUBJECT MATTER

8:00-8:30 Classroom

Discussion

Course Introductions

: - :

9:00-10:0 : - : 10:15-10: 10:30-11:30 Classroom Discussion/Activity Introduction to Multimeters

11:30-12:30 UNCH

12:30-2:30 Classroom Discussion/Activity Electrical Circuits

: - :

2:45-4:00 Classroom Discussion/Activity Electrical Circuits

: - : assroom va uat on ev ew a es

-

TIME LOCATION INST. TYPE SUBJECT MATTER

: - : assroom scuss on ct v t

Electrical Circuits

9:30-9:45 : - : 12:00-1:0 1:00-1:45

1:45-2:45 Classroom/Shop Discussion/Activity Electrical Dia nosis

2:45-3:00 BREAK

: - : assroom scuss on ct v ty ec r ca a nos s

4:00-4:30 Classroom Evaluation Review / Da 2 Test

AEC-7

4



GETTING THE MOST OUT OF THE COURSE

Use the course materials in any way that will

help you remember the material. Make notes

or raw ngs on ese ma er a s o e p you

remember details.

One of Kia’s main goals is to provide as much

individual instruction as possible. If you do not

understand something in the classroom, askyour instructor to clarify the point.

During hands-on practice sessions, you will

often be part of a working team. You will

on y earn rom e exper ence you ac ve y

participate.

Ta e notes an ma erawings

Wor as a team

earn rom mista es

As questions

e an active participant

AEC-9

IME OCATION NST. TYPE SUBJECT MATTER

:

8:

9: 9: 0:45-11:15 Classroom Video atter Char in and Startin

S stems

1:15-12:00 Classroom/Shop iscussion/Activity attery, Charging and Starting

S stems

: - ::00-2:30 Classroom/Shop iscussion/Activity atter Char in and Startin

S stems

2:30-2:45 REAK

2:45-4:00 Classroom/Shop iscussion/Activity atter Char in and Startin

S stems

: - : assroom va uat on ev ew na es

AEC-8

m o d u l e A E C

COURSE INTRODUCTION

5



m o d u l e A E C

COURSE INTRODUCTION

COURSE CREDIT

Course credit will be granted by a Kia Service

ra n ng ns ruc or w en a o e cr er a or

course completion has been met.

Because our technical training is performance-

based, hands-on practice will make up 45%

of your course credit. Each Guided Practicemodule lists specific performance objectives

that are the basis for scoring. The instructor

will observe and evaluate your performance,

coaching you when necessary.

Additional factors that may affect this score

are safe and appropriate use of tools and

equipment and following written and verbal

instructions.

Each Guided Practice Module is assigned arelative “point” value, depending on the difficulty

of the material.

e ay an ay es s are eac . e

Final Test is 25% of your grade.

e ns ruc or w eva ua e e egree o

which you contribute to discussions, offer your

experience, or simply ask questions about

something you don’t understand. Participation

also takes into account your professional

conduct and working with teammates during

c assroom an s op prac ce ac v es. s

counts for 10% of your course credit.

The sum of the above scores will determine

your course ac evemen per ormance.

minimum score of 80% is required for course

credit.

Gui e Practice = 45%

Day 1 Test = 10%

Day 2 Test = 10%

+ Fina test = 25%

+ C ass participation = 10%

Tota = 100%

80% require or course cre it

EC-10

This training course is an opportunity to learn

advanced skills successfully in a controlled

env ronmen un er e gu ance o a ra ne

Kia instructor. Have a good experience here,

and return to your dealership with confidence in

your own abilities as a trained Kia professional.

6



___________________________________

_____________________ _______

______________ ____________

_________ _______________________

___________________________________

___________________________________

m o d u l e A E C

COURSE INTRODUCTION

7



m o d u l e A E C

COURSE INTRODUCTION

__________________________________

___________ ______________

__________________________________

8



KIA MOTORS AMERICA, INC

o part o t s pu cat on may e repro uce , store e ectron ca y, or trans-

m tte n any orm or y any means w t out pr or wr tten approva rom a

otors mer ca, nc. reserves t e r g t to ma e c anges n t e escr p-

t ons, spec cat ons or proce ures w t out pr or not ce or o gat on.

Copyright © 1999 Kia Motors America, Inc. Corporate Service Training

epartment

/99

Part Number: KC-BEC



Electrical

Fundamentals

Automotive

Electrical Course



EF1



Each year there is an increased use

of electronics in the automobile. With

e emp as s pu on as an accura e

diagnosis it is important for the technician

to understand what electricity is and how it

wor s.

m o d u l e E F 1 1

ELECTRIC FUNDAMENTALS

LEARNING OBJECTIVES

ODULE DIRECTIONS

THINGS YOU WILL NEED

Carefully read this material. Study each

illustration as you read the material. Feel

ree o as ques ons any me some ng s

not clear. Be sure to answer the questions

in the spaces provided as you perform the

ac v es.

After successfully completing this module,you s ou e a e to:

Exp ain w at e ectricity is an ow itwor s

De ine vo tage, amperage, resistancean watts

De ine magnetism, in uctance,capacitance an impe ance

• The materials in this module

• The electrical project board

• A digital multimeter

EF1-1




m o d u l e E F 12

DISCOVERY OF ELECTRICITY

The first recording of electricity was around

600 BC. It was found that by rubbing certain

su s ances ey wou a rac g er o ec s

to them. Later in the 18th century it wasdiscovered that there were two kinds of

forces, or charges, caused by rubbing certain

ma er a s. was oun a e c arges wou

repel and opposite charges would attract.

THE FAMOUS KITE EXPERIMENT

In the mid 1800’s Benjamin Franklin proved that

lightning was a form of electricity. He flew a

kite into a thunderstorm and found that sparks

jumped to the ground from a metal key attached

to the wet string.

An assumption was made that there was

current coming down the string from a high

level of energy to a lower level. The high

eve o energy was ca e os ve an e

low level of energy was called egative. The

assumption that electrical current flowed from

pos ve o nega ve was accep e un

when the discovery of the electron proved that it

was actually the electrons, or negative particles

of electricity, that move through a circuit.

WHAT IS ELECTRICITY?

ec r c y s a orm o energy w ere e ec rons

move from one atom to another. The

movement of these electrons can be explained

y e ec ron eor . ec r c y ex s s

when a voltage source creates a current flow

by pushing electrons with enough force to

overcome the resistance of the circuit. Voltage,

current and resistance are the three basic

elements of a circuit. Electricity itself is invisible

but its effects can be seen in the forms of light,

heat, noise and motion. Examples: We can

see the light that a lamp gives off. We can see

a motor turn. We can hear the buzzer’s sound

and we can feel the heat from an electric heater

element.

irst recor e in 600 BC

Some materia s w en ru etoget er wi attract ot ermateria s

18t century iscovery ounthat like charges repel andopposite c arges attract

enjamin Fran in proves t atightning is a form of electricity- mi 1800 s

ectrica current is t oug t toow rom positive to negative

Conventiona Current F ow

T e e ectron is iscovere in1897

A orm o energy w ereelectrons move from one atomto anot er

xists w en a vo tage sourcecreates a current ow yus ing e ectrons wit

enough force to overcome theesistance o t e circuit

Vo tage, current an resistanceare t e t ree asic e ements oa circuit

Invisi e, ut e ects can eseen

F1-2

F1-4

EF1-3




m o d u l e E F 1 3

ELECTRON THEORY

The Electron Theory states that all matter

so , qu or gas s ma e up o a oms o ne

together. Each atom is made up of a nucleus

and electrons. The electrons orbit around thenuc eus. e ou er or ng e ec rons can move

from one atom to another when the number of

electrons in the atom become unbalanced. This

movement of electrons is known as electricity.

THE ATOM

The atom is like a tiny solar system. The atom

has a nucleus at its center which is made up

of protons and neutrons. The protons are

positively charged. The neutrons have no

electrical charge but are of the same weight

as the protons. Orbiting at a very high rate

of speed around the nucleus are negatively

charged electrons. When the number of

electrons equals the number of protons the

atom is balanced. These electrons weigh about

1/1845 as much as a proton. Energy withine a om causes e e ec rons o sp n aroun

e nuc eus n r ngs or s e s. s ey sp n,

centrifugal force pulls the electrons away from

the nucleus but an electrostatic force within

e nuc eus a ances e cen r uga orce an

keeps the electrons at a specific distance from

the nucleus. When more energy is added to

the atom, such as heat, the electrostatic force

within the nucleus decreases and the centrifugal

force of the electrons increases. The electrons

then move further away from the nucleus untilthe two forces become equal again.

• A matter is ma e up o atoms

• Eac atom as a nuc eussurrounded by orbitinge ectrons

T e outer or iting e ectronscan move to neig oringatoms w en t e atom ecomesunbalanced

• The movement of electronsrom atom to atom is e ectricity

Protons ave a positive c arge

Neutrons ave no c arge

Negative y c arge e ectronsor it t e nuc eus

• Com ination o e ectrostaticforce and centrifugal force keep

t e e ectrons in or it

T e istance etween t ee ectrons an t e nuc eus isincrease w en more energy isa e to t e atom

EF1-5

F1-6

EF1-7




m o d u l e E F 14

IONS

An electrical force outside the atom can

a rac e ec rons rom e ou er r ng an eave

the atom in an unbalanced condition. An

unbalanced atom is called an ion. When ana om ga ns an e ec ron an as more e ec rons

than protons it is a negative ion. When an

atom loses an electron and has more protons

an e ec rons s a pos ve on an w a rac

an electron from a nearby balanced atom.

The electrons are constantly moving within a

material from one atom to another. This causes

electron flow.

The electrons in the outer ring are not as

s rong y a rac e o e pro ons as e nner

rings of electrons. The inner electrons are

called bound electrons and the outer electrons

are ca e free electrons. When a force such

as heat, pressure, friction, light, chemical action

or magnetic action is applied to the material,

the free electrons can move from one atom

to the next. Electrical current can be formed

by a stream of these free electrons along a

con uc or.

DIRECTION OF FLOW

ere are wo ways a we can cons er e

flow of electrical current. The electron flow

which is from negative to positive and the flow

of conven ona curren w c , w e ac ua y

a myth, flows from positive to negative. It

is easier to think in terms of conventional

current flow since most electrical drawings and

semiconductor symbols are marked with arrows

indicating the conventional current flow. It is

also easier to use the conventional current flow

because we can relate the flow of electricity

to the rules of hydraulics in that there is a

pressure, flow and opposition.

EF1-8

EF1-9

EF1-10




m o d u l e E F 1 5

MEASUREMENT OF ELECTRICITY

QuantityThe electron is such a small particle of

e ec r c y a a very arge quan y are requ re

to have a measurable unit. The basic unit ofelectrical quantity is the coulomb. A coulomb

is equal to 6.28 billion, billion electrons (6.28 x18 . e sym o or quan y s

FlowWhen one coulomb flows past a given point in

one second, there is a flow of one ampere, or

one amp. It will be the same whether we think

of electron flow or conventional current. This

flow is normally called current and its symbol is

I for intensity.

ressure

The volt s the standard unit of electrical

pressure and is the amount of pressure required

o orce one ampere o ow roug one o m o

resistance. The symbol for voltage (electrical

pressure) is E for electromotive force.

OppositionEvery electrical circuit or component has

res s ance. es s ance s w a opposes curren

flow. It is this resistance that changes the

electrical energy into another form of energy

such as heat, light or motion. There are five

factors that affect the resistance of a conductor

- the conductor’s type of material, length,

diameter, temperature and physical condition.

e s an ar un o res s ance s e o

One ohm is the resistance through which a

pressure of one volt can force a flow of one

ampere. The symbol for resistance is

PowerThe end result of electricity is power. The wa

is the unit of electrical power. One watt is the

amount of power used when one amp of current

flows under a pressure of one volt. The symbol

for power is .

Quantity

• Basic unit is the coulomb

One cou om = 6.28 x 1018

e ectrons

• Sym o or quantity is Q

Flow

Basic unit is t e ampere

• The flow of one coulomb past agiven point in one secon

Norma y ca e current

• Sym o or current is I

Intensity

Pressure

Basic unit is t e vo t

• Amount o pressure require toorce one ampere o ow t rougone o m o resistance.

• Symbol for voltage is EE ectromotive orce

Opposition

Basic unit is t e o m

• T e resistance t at opposescurrent ow

C anges e ectrica energy intoanother form of energy eg: heat,ig t or motion

T e sym o or resistance is R

Power

• Basic unit is the watt

T e amount o e ectrica poweruse w en one amp o currentflows under a pressure of onevo t

T e en resu t o e ectricity

• The symbol for power is P

F1-11 thru EF1-16



m o d u l e E F 16


MAGNETISM / ELECTROMAGNETISM

Magnetism

Like electricity, you cannot see magnetism, but

you can feel its effects. It is an invisible forcethat acts on certain types of metals, such as

iron and steel, causing them to pull together or

push away from each other.

There is a definite area around every magnet

where the magnet force exerts its power. This

power is called the magnetic field or flux. The

further away from the magnet, the weaker the

field. The magnetic force always completes a

loop that leaves one end of the magnet (North-

seeking) and re-enters the other end (South-seeking). These ends of the magnet are the

magne c po es an are e wo s ronges areas

of the field. Because the magnet is polarized,

unlike poles attract and like poles repel.

e ear se s an ex reme y arge magne

with its magnetic lines of flux extending 50,000

miles from its surface. If a bar magnet is

suspen e y a s r ng e ear s magne c

field will cause the magnet to orient itself in a

north-south direction. We are able to use thisp enomenon o ma e a compass.

agnetism is an invisi e orce

Causes certain meta s to repeor attract

agnets ave a ie ux t atoops rom t e N po e to t e So e

i e po es repe an un i eoles attract F1-17

8

EF1-19



m o d u l e E F 1 7


INDUCTANCE

us as e ec r c curren s can pro uce magne c

fields, so too can magnets produce electric

currents. If a magnet is moved near a coil

of wire a current is generated in the wire. A

current can also be generated if the coil of wire

is moved near the magnet. The magnetic lines

of flux passing through the conductor forces

the electrons to flow through the conductor.

The amount of electricity generated depends

on the rate at which the lines of flux are cut.

The rate can be increased by increasing the

number of lines of flux by making the magnet

s ronger, or y mov ng e con uc or roug

e nes o ux as er. s pr nc p e s use

in the alternator to recharge the battery andprovide the vehicle with the electricity it needs

o opera e.

A wea magnetic ie wit nopo arity surroun s a con uctorwith current flowing through it

• If the conductor is coiled theie ecomes stronger an nowas a nort an sout po e

T e coi s magnetic ie isirect y proportiona to t e

current an t e num er oturns on the coil

• An iron rod down the middleo t e coi strengt ens t emagnetic ie

Electromagnetism

n e ear y s, e re a ons p e ween

magnetism and electricity was discovered when

it was found that the needle of a magnetic

compass was deflected when it was placednear a current carrying conductor.

This deflection was caused by an invisible

magnetic field that surrounds the conductor

when an electrical current flows through it.

This magnetic field is relatively weak and has

no po ar y. u e w re s woun n o a co

the field becomes stronger and has a definite

north and south pole. The strength of the coil’s

magne c e s rec y propor ona o e

current and the number of turns on the coil. It

was soon discovered that the magnetic field

cou e ma e even s ronger y p ac ng an ron

rod down the middle of the coil.

EF1-20

F1-21



m o d u l e E F 18


CAPACITANCE

Conductors are able to pass electrical current

because the electrons within their atoms are

loosely held in orbit. Insulators block the flow of

curren ecause e r e ec rons are e g y

within the atom. In certain types of insulators

called dielectrics the electrons can be pulled

n o a s or e or . s perm s a vo age o

exist across the dielectric or you could say the

storage of an electrical charge. Some materials

used as dielectrics are: waxed paper, glass,

m ca, o an a r.

Capacitors are made up of two parallel

con uc ng p a es separa e y a e ec r c.

When a DC voltage is applied to the terminals

of the capacitor the build up of electrons on

the negative plate distorts the orbits of the

dielectric’s electrons in the direction of the

positive plate causing the capacitor to become

charged. If the voltage source is removed the

charge still remains. If a path for the current

is provided outside the capacitor the current

will then flow from the capacitor discharging

. apac ors oc e ow o rec curren

since current only flows during the charging ordischarging of the capacitor. Capacitors don’t

pass a erna ng curren u ey ac e ey

do. Because the current is constantly rising

and falling the capacitor is always either being

c arge or sc arge .

Capacitance is t e storage oan e ectrica c arge

Capacitors consist o twoarallel conductors separatedy a ie ectric

W en DC is app ie to t ecapacitor t e ie ectric storest e c arge unti a pat isrovided for the current to flow

Capacitors oc t e ow o DC

Capacitors seem to pass AC;the current constantly risesan a s so t e capacitor isconstant y eing c arge or

isc arge F1-22



m o d u l e E F 1 9


ELF-TEST

This self-test will enable you toeasure the knowledge that you

ave gained about Fundamentals of

lectricity. Circle the one best answer

a comp e es e s a emen or

answers the question.

. lectricity is an invisible form of

energy where electrons move from

one atom to another.

a. True

b. alse

2. Which of the following is a factor

hat would affect the resistance of a

conductor?

. The type of material the

conductor is made of.

b. The length of the conductor.

. The physical condition of theconductor.

. All of the above.

3. What is the relationship between

magnetism and electricity?

a. Magnetism is required to make

electricity.

b. A magnetic field surrounds a

conductor with current flowingroug .

c. A magnet requires electrical

current flow.

d. A magnet has the same atomic

structure as copper, making it a

goo con uc or.

. nductance is the generation of

electrical current by rubbing two

con uc ors aga ns eac o er.

. True

b. False



m o d u l e E F 110


___________________ ________

___________________________________



m o d u l e E F 1 11


__________________ ________

__________________________________









epartment

/99

Part Number: KC-EF1



Introduction to

Multimeters

Automotive

Electrical Course



IM1



er comp e ng s mo u e, you w e a e o

identify the uses of multimeters for diagnosing

and testing electrical circuits. You will also be

able to identify the differences between analog

and digital multimeters.

now ng ow o proper y use a mu me er

will enable you to diagnose and repair Kia

automotive electrical problems faster and more

effectively.

m o d u l e I M 1 1

INTRODUCTION TO MULTIMETERS

I enti y t e precautions necessary toprotect t e mu timeter an t e circuit

er orm unit conversions rom w o eunits to t ousan t s

roper y connect t e mu timeter ea san se ect t e proper unction an sca efor circuit measurement

easure voltage, amperage andres stance

-

ODULE DIRECTIONS



illustration as you read the material. Feel free

o as ques ons any me some ng s noclear. Be sure to answer the questions in the

activities and at the end of the module.

• A digital multimeter

• Electrical project board with accessories




m o d u l e I M 12

MULTIMETERS

One of the most important and versatile pieces

of test equipment you will use in diagnosing

electrical system faults is the multimeter. As

e name mp es ese ns rumen s are capa eof measuring voltage, current and resistance.

More sophisticated models can measure

frequency, duty cycle and temperature. Some

models, called scope meters, have a built in

oscilloscope.

Mu tip e unctions in onemeter

Basic Functions:vo tage, current an

resistance

• A vance Functions:requency, uty cyc e,temperature an osci oscope

IM1-2

DVOMs are easier to rea

DVOMs ave auto ranging

DVOMs are more accurate

Low impe ance o ana ogmeters can amage so istate circuitry

IM1-4

Types of Multimeters

ere are wo ypes o mu me ers:

analog and digital.

na og me ers use a nee e an ca ra e

scale to indicate values.

Digital meters, called DVOMs or DMMs, display

the values on a digital display.

Analog vs. Digital Meters

The DVOM is recommended over the analog

meter for several reasons:

• VOMs are easier to read.

• ost DVOMs have auto-ranging.

• VOMs are generally more accurate

because their high impedance circuitry

does not take power from the circuit.

• The low impedance, or internal

resistance, of analog meters can cause

naccura e rea ngs an can amage

solid state circuits.

1-3




m o d u l e I M 1 3

Because digital multimeters are designed

to measure voltage, current and resistance,

you mus proper y se up e me er o avo

damaging the meter or the circuit and to

ensure that you are making an accurate

measurement. Since there is a wide variety ofme ers ava a e, a ways rea e opera or s

manual before using the meter. There are

three important steps to follow when using most

g a mu me ers.

SETTING UP THE MULTIMETER ETER SETUP

1. Connect t e test ea s to t eroper jacks.

. Se ect t e proper range anunction.

. nsure t at you un erstanw at is eing s own in t eigita isp ay.

IM1-6

IM1-5

anuaange n cator

gta spay

Mode Selector Switch

10 Ampere fused

input terminal

300ma fused inputterminal

Mode Indicator

o t m nput erm na

ommon nput erm na

Manual/Auto Range Button

~ or AC = A ternating Current ) ) = Au i e Continuity Test

… or DC = Direct Current = Dio e Test

A = Amperes = Ki o or t ousan

Ω = O ms = Mega or mi ion

V = Vo ts m = Mi i or one-t ousan t

= Micro or one-mi iont IM1-7

Multimeter Symbols

Become familiar with

the display symbols

used for the different

types of measurement

an un s o measure.

The illustration shows

the most common

sym o s.



…

Most meters have a rotary selector switch that allows you to set the function

and range for the type of reading that you wish to make.

Volts AC for measuring alternating current voltages

Volts DC for measuring direct current voltages

DC millivolts for measuring very low direct current voltages

Ohms for measuring the resistance in conductors.

Continuity for checking for shorts or opens in conductors

o e es or c ec ng e orwar an reverse as vo age o o es or o er

semiconductor junction

Amps AC for making series current measurements in alternating current circuits

Amps DC for making series current measurements in direct current circuits

METER FUNCTIONS


m o d u l e I M 14

IM1-8

Manual Range Indicator

Mode Selector Switch

mps angesDiode/

ContinuityTest

Ohms Ranges

Volts Ranges

o e n cator

Digital Reading

m

Ω

) )

~

anua uto ange utton




m o d u l e I M 1 5

USING THE MULTIMETER

The most desirable method of probing

connec ors s y us ng a es ea a ap er rom

a kit supplied by most DVOM manufacturers. If

a kit is not available, use a mating connector or

a ma ng p n rom a connec or repa r .

f you need to test a connector while the circuit

s opera ng, a ways pro e e connec or

from the back side, never puncture the wire

insulation. Check the reading on both sides

of the connector because dirt and corrosion

between contact surfaces can cause electrical

problems.

se a test lead adapter fromVOM manu acturer w enro ing connectors

se mating connector orin w en a apter it is not

available

robe connectors onoperating circuits rom rear

easure ot si es oconnector

e er to Owner s Manuae ore using meter.

IM1-9

PRECAUTIONS

To ensure that the meter is used safely, follow these instructions:

1. ever use the meter if the meter or test leads look damaged.

2. e sure the test leads and rotary switch are in the correct positions for the

desired measurement.

3. Always insert the meter in the circuit in parallel for voltage and in series for

curren measuremen s.

4. ever use the meter in a circuit of higher voltage or amperage than the meter is

capable of measuring safely.

. ways s ar measur ng w e amme er on e g es sca e an wor your

way down.

. ever measure resistance in a circuit with power applied (do not forget to

discharge all capacitors).

. eep your fingers behind the finger guards on the test probes when making

easurements.

V E R Y

I M P O R T A N T




m o d u l e I M 16

The voltmete function is used to measure

e e ec r ca pressure or vo age erence

between two points. A voltmeter reads voltage

available from a power source or the voltage

rop across a c rcu componen or connec on.

To measure available voltage or voltage drop in

a circuit, place the selector switch in the VAC,

VDC or mVDC mode. Then connect the meterin parallel with the load device or the circuit with

the red lead (positive) connected closest to the

positive side of the battery and the black lead

(negative) connected to ground or closest to the

negative side of the battery.

Unit Conversions

On an automotive electrical circuit, voltage

readings are usually displayed as volts or

millivolts. Refer to the illustration to make unitconvers ons.

MEASURING VOLTAGE

1 vo t = 1000 mi ivo ts

To convert vo ts to mi ivo ts,move t e ecima pointt ree p aces to t e rig t.

xamp e: 12 V = 12,000 mV

To convert mi ivo ts to vo ts,move the decimal pointt ree p aces to t e e t.

xamp e: 120 mV = 0.120 V

-

1-10



m o d u l e I M 1 7


The ohmmete function is used to check

con nu y an o measure res s ance n a c rcu .

A zero resistance reading indicates continuity

or a short circuit. An out of limits (OL) reading

indicates that there is an infinite amount of

resistance or an open in a circuit.

To measure continuity or resistance, set the

se ec or sw c n e Ω mo e. en connec

one test lead to one end of the circuit you are

testing and the other test lead to the other end

o e c rcu . en measur ng e res s ance o

a component, the component must be isolated

or disconnected from the rest of the circuit.

Ohmmeters can be connected to the circuit

without regard to polarity unless the circuit

con a ns a o e. ey ave e r own n ernabattery and should never be connected to an

operating circuit.

n t onvers ons

efer to the illustration to make unit

convers ons.

MEASURING RESISTANCE

1 Ki o - o m = 1000 o ms

1 Mega - o m = 1,000,000 o ms

To convert Ω to Ω, movet e ecima point to t eig t t ree p aces.

xamp e: 10 Ω = 10,000 Ω

To convert MΩ to Ω, movethe decimal point to theig t six p aces.

xamp e: 10MΩ = 10,000,000 Ω

IM1-13

IM1-12

0.01




m o d u l e I M 18

The ammete function is used to measure the

current flow between two points in the circuit.

To measure current flow, remove power from

the circuit. Set the selector switch in the AAC

or ADC mode and place the red lead in either

e or m ac . en connec e

ammeter in series with the circuit or component

with the red lead closest to the positive

a ery erm na . pp y power o e c rcu .

Compare the current flow (amperage) to the

specifications. If the amperage is low, check

for high resistance or a discharged battery. Ifthe amperage is high, check for a short or faulty

componen .

MEASURING CURRENT FLOW

1 Amp = 1,000 mi iamps

o convert amps tomi iamps, move t e ecimapoint t ree p aces to t erig t.

xamp e: 15 A = 15,000 mA

To convert mi iamps toamps, move the decimal

p ace t ree p aces to t ee t.

xamp e: 1,677 mA = 1.677 A

IM1-15

-14

Unit Conversions

Refer to the illustration to learn how to make

unit conversions.

12.3



m o d u l e I M 1 9


There are several different types of accessories

available for DVOMs. These include test leads,

probes and inductive ammeter clamps. In

some cases, the multimeter comes in a kit that

includes some of these accessories.

Most accessories are available from the

manufacturer or at your local electronics store.

MULTIMETER ACCESSORIES

CURRENT CLAMPS

IM1-16




m o d u l e I M 110

MULTIMETER ACTIVITIES

Using your assigned multimeter, follow the

rec ons or eac ac v y an answer e

questions that describe how you set up the

multimeter. Have the instructor check each

ac v y e ore you move on o e nex one.

Activity A

nstall the test leads and select the proper

range and function to measure 200 millivolts

DC.

1. Which jack did you plug the red lead into?

2. Which jack did you plug the black lead into?

_______________________________

3. What is the Mode Selector Switch position?

_______________________________

. What position is the MANUAL RANGE/

AUTO RANGE switch in?

Activity B

ns a e es ea s an se ec e proper

range and function to measure 2 kilo-ohms.


_______________________________

. Which jack did you plug the black lead into?

_______________________________

. a s e e ec w c pos on

_______________________________

4. What position is the MANUAL RANGE/


_______________________________



m o d u l e I M 1 11


Activity C

ns a e es ea s an se ec e proper

range an unc on o measure amps .


_______________________________

. Which jack did you plug the black lead into?

_______________________________

. What is the Select Switch position?

_______________________________

4. What position is the MANUAL RANGE/





m o d u l e I M 112

ELF TEST

This self-test will enable you tomeasure e now e ge a you ave

gained about using a multimeter. Circle

the one best answer that completes the

s a emen or answers e ques on.

1. To help keep the internal DVOM

battery from running down while

ma ng res s ance c ec s, ma e

sure that the circuit you are

checking has power applied to it.

a. True

b. False

2. 2 kilo-ohms is equal to _____ohms.

.

b. 200

. ,

d. 20,0003. To measure current flow, how

should the meter be connected?

. n ser es w e c rcu

b. In parallel with the load device

c. Across the power source

. It doesn’t matter

4. Most multimeters are capable of

measuring up to ___ amps without

a ng ex erna accessor es.

a. 5

.

. 50

d. 100

. f the red lead is placed in the 10 amp

ac , ow wou m amps e

displayed?

. .

b. 27.0

. .

d. .270



m o d u l e I M 1 13


___________________________________

________________ __________

__________ ________________

___________________________________

___________________________________




m o d u l e I M 114

__________________________________

_______________ __________

_________ ________________

__________________________________

__________________________________









epartment

/99

Part Number: KC-IM1



Electrical

Circuits

Automotive

Electrical Course



EC1



AUTOMOTIVE ELECTRICAL CIRCUIT ANALYSIS

m o d u l e E C 1 1

er comp e ng s mo u e, you w e a e

to identify how different types of automotive

electrical circuits are designed to operate

an e me o s use n con ro ng e ec r ca

behavior in a circuit.

o ena e you o agnose an repa r a

automotive electrical problems faster and more

effectively.



o as ques ons any me some ng s noclear. Be sure to answer the questions at the

end of the module.

• o u e

• Electrical project board and accessories

• DVOM

I enti y circuit e ements: power source,oa , protection evice an groun

I enti y t e i erent types o circuitsan circuit contro met o s

Determine w at is require to ma e t ecircuit operate

• App y t e re ations ip etween vo ts,amps and ohms to diagnose a faultye ectrica circuit

C1-1

LEARNING OBJECTIVES

MODULE DIRECTIONS





m o d u l e E C 12

ELECTRICAL CIRCUITS

e pa a e ec r c y ows roug s ca e

a circuit. The circuit must form a complete

loop from the positive side of the power source

o e nega ve s e o e power source.Electrical behavior in a circuit is determined by

the design of the circuit, the number and types

of load devices, the size of the conductors and

the types of control devices used by the circuit.

Electrical Circuit Components

as c au omo ve e ec r ca c rcu cons s s

of a voltage source (battery, generator),

conductors (usually wires or the vehicle body)and one or more load devices that perform

some type of useful work such as lamps,

mo ors, e c.

os e ec r ca c rcu s ave a eas one

protection device such as a fuse, a circuit

breaker or a fusible link and one or more

con ro ev ces nc u ng sw c es, re ays an

solid-state devices such as transistors.

Component Descriptions

o a e (Power) Source - The device that

provides the potential or pressure to move

electrons through the circuit.

on uc ors - rov e a con ro e pa or

current flow from and back to the power source.

oa ev ces - Convert electrical energy into

another form such as heat, light or mechanical

energy so the circuit can perform useful work.

Protection Devices - Provide an intentional

open circuit when current exceeds specified

m s.

Control Devices - can control the amount and

direction of current flow through a circuit.

• Vo tage source provi espressure to move electrons

• Conductors provide acontro e pat or currentow

Loa evices converte ectrica energy intoanother form so the circuitcan perform useful work

• Intentional opening ofprotection evices protectt e circuit

C1-4

EC1-3

A circuit is a pat or currentto ow

• E ectrica e avior in acircuit is influenced by:

- esign of the circuit

- umber and types of loaddevices

- Size of the conductors

- Types of control devices

C1-2

WITCH(CONTROL

DEVICE)




m o d u l e E C 1 3

ypes of Control Devices

The most common types of control devices used

in automotive electrical circuits are shown in the

illustration.

Switch - A device that mechanically opens and

closes an electrical circuit. Some switches are

controlled by pressure, temperature or light.

elay - An electromechanical device thatutilizes a small amount of current to energizean e ec romagne a c oses e con ac s n acircuit carrying a higher amount of current. Theelectromagnet in a relay has a fixed core thata rac s a movea e arma ure.

ransistor Semiconductor devices that functionas switches with no moving parts. As the namemp es, sem con uc ors con uc e ec r c y parof the time and do not conduct at other times.These qualities let transistors function like electricre ays.

lectronic Control Unit (ECU) - Often referredo as “the computer”, these units are nothingmore an sop s ca e sw c es. e any o erswitching device, an ECU can be the control

device in ground or power controlled circuits.

Other Types of Devices

Solenoid An electromechanical device thatutilizes a small amount of current to energizean electromagnet that closes the contacts in acircuit carrying a higher amount of current. Thee ec romagne n a so eno as a movea e corehat is pulled into the hollow coil.

iode - Semiconductor devices that work like an

e ec r ca one way va ve y a ow ng curren oflow in only one direction. Commonly used whenchanging alternating current into direct current.

Capacitor An electrical component that cans ore a sma c arge an en re ease asneeded. They can be used to store and releasea g vo age, pro ec a c rcu aga ns surges orsmooth out current fluctuations

• Sw tc

Mec anica evice t atopens or c oses t e circuit

• Relay

An electromagnet with aixe core t at attracts amovea e armature

Trans stor

Wor s i e a re ay ut asno moving parts

• E ectron c Contro Un t

Sop isticate switc

Receives signa s romsensors then controlsactuators

-

• So eno

n e ectromagnet wit amoveable core that is pullednto t e coi

o e

semicon uctor evice t ata ows current to ow in on y

one irection

Capac tor

Can store a sma c arge w iccan e re ease w en nee eto make a current flow for as ort perio

C1-7

• Turn electrical circuit on or off

• se on eit er power si e orground side of circuit

C1-5




m o d u l e E C 14

elationship between voltage,amperage an resistance in ane ectrica circuit

Current is irect y proportionato vo tage an inverse yroportional to the resistancen a c rcu t

u is e y George SimonO m in 1826

One vo t o pressure wi causeone ampere o current to own a circuit with a resistance ofone o m EC1-8

E = Voltage measured inVolts

I = Current measured inAmps

R = Resistance measuredin Ohms

The relationship between voltage, current andres s ance s suc a any one va ue can e

found when there are two known values. To

make this easier to understand we can put

Ohm’s law in the form of the formula

E = I X R.

n this formula, E represents voltage, I

represents current and R represents resistance.

To find current, we use the formula

= E/R

and to find resistance we use the formula

R = E/I.

Using the divided circle method makes it easier

to remember the formulas.

OHM’S LAW

In 1826 a German scientist named George

Simon Ohm published his findings of the

relationship between voltage, amperage andresistance in an electrical circuit. These

findings were proved to be true and were

named “Ohm’s Law.” Ohm’s Law states that

the current that flows in a circuit is directly

proportional to the voltage and inversely

propor ona o e res s ance n e c rcu .

One volt of pressure will cause one ampere of

current to flow in a circuit with a resistance of

one o m.

Ohm’s Law Relationship

f the resistance stays constant...current goes

up as voltage goes up and current goes down

as voltage goes down.

vo age s ays cons an ...curren goes up as

resistance goes down and current goes down

as resistance goes up.

C1-13




m o d u l e E C 1 5

E

R

12v

4

12

4

Ohms

RI =4

=3 A

=3

I= Amps E = Volts R = Ohms

E

I=3

12v

12

3=4Ohms3X 4 =12V

P = Power measured inWatts

I = Current measured inAmps

E = Voltage measured inVolts

The same relationship may be found between

power, current and voltage. To find the power

or wattage used in a circuit we can use the

formula = . We can also find current by

using the formula I = P/E or find voltage using

the formula E = P/I. To remember the formulas

use the divided circle method.

1-14



ERIFYING OHM’S LAW

n this activity you will be able to observe the

re a ons p e ween curren an vo age an

between current and resistance. Make the

circuit shown in the picture below connecting- w ea w res. urn e po en ome er

knob to set the voltage at 4.0v. Measure and

record the current of the circuit. Then do the

same measuremen w - an - .

Next, adjust the voltage up to 8V with the

po en ome er an measure e curren w en

R-1, R-2 and R-3 are alternately placed in the

circuit.

na y, measure e curren w e vo age seat 12 volts and alternately R-1, R-2 and R-3 in

the circuit.


m o d u l e E C 16




m o d u l e E C 1 7

4V 8V

R-1 (100 ohm)

R-2 (200 ohm)

R-3 (300 ohm)

A A

A A

A

12V

In the space below explain what you have foundabout the relationship between voltage, current

and resistance.

___________________




m o d u l e E C 18

Series Circuit

A series circuit has only one path for the current

o flow. All the components are connected

in-line. The same amount of current will flowhrough each component but the voltage will

drop as current flows through each load device.

an open occurs anyw ere n e pa ere

will be no current flow.

An example of a series circuit would be the old

ype of christmas tree lights. When one bulb

burns out or is removed, the rest of the lights go

out also. A common example of an automotive

series circuit is the cigarette lighter.

TYPES OF CIRCUITS

lectrical circuits must form a complete

loop, but they can be connected in different

ways. There are three basic types of circuits,

each with its own characteristics. How thecomponen s are connec e w n e c rcu

determines the type of circuit.

ach type of circuit causes voltage and current

o v e accor ng o spec c ru es.

Series circuit is a vo tage ivi ercircuit.

Current is t e same anyw ere int e circuit.

Tota resistance is t e sum oeach load resistance.

• Tota vo tage rop equa s app iesource vo tage.

EC1-17

Series

One pat or current ow

ara e

ore t an one pat orcurrent ow

Series - Para e

Com ination o series anarallel circuits

Circuit behavior isetermine y t e type o

circuit

EC1-16




m o d u l e E C 1 9

SERIES CIRCUIT EXAMPLE

n s ser es c rcu examp e, w en e gn on

switch is in the ACC or ON position current

coming from the battery flows from the ignition

switch through the cigar lighter 15A fusehrough connectors C230 and C248 to the

cigarette lighter heater element.

hen the cigarette lighter is pressed in,

he circuit is completed from terminal #1 of

connector C248 to terminal #2 of connector

. urren can en ow rom erm na

of connector C248 to ground, completing the

circuit back to the battery.

n this type of circuit, any break (intentional or

nintentional) in the circuit will cause current

low to stop.

SSENGERMPARTMENTSEBOX

CIGARETTE

LIGHTER

1

C1-18




m o d u l e E C 110

Measuring Voltage in a Series Circuit

n s ac v y, we are measur ng e ava a e

source voltage and the voltage drop of a

normally operating circuit with the loads

arrange n ser es.

Complete the table on the following page

using information obtained by taking voltage

measuremen s a e po n s us ra e n e

diagram.




m o d u l e E C 1 11

V1 Source Voltage V

V2 Lamp 1 V

V3 Lamp 2 V

V4 Lamp 3 V

OLTAGE : LOADS CONNECTED INSERIES

n e space e ow exp a n w a e vo age

measurements you obtained tell us about

voltage in a series circuit.

___________________

___________________

+

-

L1V2 V3

V4

L2

L3

V1

-




m o d u l e E C 112

Measuring Current in a Series Circuit

n s ac v y, we are measur ng e curren a

different locations within a normally operating

circuit with the loads arranged in series.

Complete the table and questions on the

following page using information obtained by

taking current measurements at the points

us ra e n e agram.

CAUTION

A ways start measur ng w tt e ammeter on t e g estscale and work your way

own to prevent amage tot e meter.

C1-21





CURRENT: LOADS CONNECTED INSERIES

Source Current

A Lamp 1 A

amp

A Lamp 3 A

n the space below explain what the current

easuremen s you o a ne e us a ou

current in a series circuit.

________________________ ________________________

________________________

________________________

________________________

________________________

________________________

________________________ ________________________

________________________

________________________

+

-

L1 L2

L3

A 1 A 2

A 3

A 4

C1-23




m o d u l e E C 114

Measuring Resistance in a SeriesCircuit

In this activity, we are measuring the resistance

at different locations within a series circuit

w more an one oa ev ce an e o aresistance of the entire circuit.

Complete the table and questions on the

o ow ng page us ng n orma on o a ne y

taking resistance measurements at the points

illustrated in the diagram.





RESISTANCE: LOADS CONNECTEDIN SERIES

Ω es s or Ω

Ω2 esistor 2 Ω

Ω esistor 3 Ω

Ω4 Total Resistance Ω

n the space below explain what the resistance

measuremen s you o a ne e us a ou

resistance in a series circuit.

________________________

________________________

________________________

________________________

________________________ ________________________

________________________

________________________

________________________

Ω

R1 R2 R3

1 Ω2

Ω3

Ω4

Ω es s or Ω

Ω6 esistor 5 Ω

Ω o a es s ance Ω

Ω amp Ω

Ω9 Lamp 2 Ω

Ω amp Ω

Ω11 Total Resistance Ω

R4 R5

Ω5

Ω6

Ω7

Ω

L2 L3

8 Ω9 Ω10

Ω11

L1

EC1-25

C1-26

C1-27




m o d u l e E C 116

PARALLEL CIRCUITS

A parallel circuit has more than one path for

e curren o ow. ac ranc rece ves e

same voltage. If the load in each branch hashe same resistance then the current will be

he same in each branch. If the load in each

branch has a different resistance then the

current will be different for each branch.

f an open occurs in one or more of the

branches, the remaining branches will continue

o have current flow.

A back-up light circuit is one example of a

parallel circuit.

• Current divider circuit

• Independent branches

• oltage applied to each branch ist e same

-

Vo tage app ie to eac oaequals the source voltage

oad resistance determinest e current t roug eacoa

Tota circuit resistance isess t an t e owest oa

esistance

Tota current equa s t e sumo t e ranc currents

-

ara e Circuit Ru es

lectrical behavior in all parallel circuits is

governe y e ru es s own n e us ra on.

These rules apply to all parallel circuits

regardless of the type and number of load

devices.





ara e Circuit Examp e

n this parallel circuit example, current flows

from the battery through the ignition switch (ON

or pos on an e amp me er use

to either the back-up light switch (M/T) or thetransmission range switch (A/T).

When the transmission shift lever is moved

to the reverse position, current flows through

either the back-up light switch (M/T) or the

transmission range switch (A/T) to splice S250.

Current splits at the splice and travels to each

o e wo ac -up g s.

On the ground side of the circuit, current flows

from the back-up lights through splice S404 togrounding point G400 and back to the battery

through the vehicle body.

f either bulb burns out or either parallel branch

develops an open, the unaffected bulb will

continue to operate.C1-30







V1 Source Voltage V

V2 amp 1 V

V amp 2 V

4 amp

OLTAGE: LOADS CONNECTED INPARALLEL

n the space below explain what the voltage

easuremen s you o a ne e us a ou

oltage in a parallel circuit.

__________________

+

-

V4V3V2V1

C1-32




m o d u l e E C 120

Measuring Current in a Parallel Circuit

n s ac v y, we are measur ng e curren a

different locations within a normally operating

circuit with the loads arranged in parallel.

se e p c ure e ow o e p you u e

parallel circuit. Then complete the table

and questions on the following page using

n orma on o a ne y a ng curren

measurements at the points illustrated in the

diagram.

CAUTIONA ways start measur ng w tt e ammeter on t e g est

sca e an wor your wayown to prevent amage to

t e meter.EC1-33





CURRENT: LOADS CONNECTED INPARALLEL

A Source Current A

A2 amp 1 A

A3 amp 2 A

4 amp

5 o a

n e space e ow exp a n w a e curren


current in a parallel circuit.

___________________

+

-

A5

A1

A3 A4 A2

EC1-35




m o d u l e E C 122

Measuring Resistance in a Para eCircuit

In this activity, we are measuring the resistance

at different locations within a parallel circuit and

the total resistance of the entire circuit.

Measure the resistances of R1, R2 & R3.

Connect R1, R2 & R3 in parallel as shown in

e us ra on p c ure e ow an measure

the combined resistance. Then complete the

table and questions on the following page

using information obtained by taking resistance


diagram.





RESISTANCE: LOADS CONNECTEDIN PARALLEL

Ω esistor 1 Ω

Ω es s or Ω

Ω3 esistor 3 Ω

Ω o a es s ance Ω

In the space below explain what the resistance


res s ance n a para e c rcu .

___________________

R1

Ω1

R2

Ω2

R3

Ω3

Ω4 R1 R2 R3

EC1-37




m o d u l e E C 124

T h i s

p a g e l

e f t i n t e n

t i o n a l

l y b l a

n k .





SERIES-PARALLEL CIRCUITSCurrent in t e series sectionequa s sum o para eranc circuits

• Tota circuit resistanceequals parallel resistancep us series resistance

Vo tage app ie to t epara e portion equa sapp ie source vo tage minusvoltage drop across seriesport on

C1-39

orma y n a ser es-para e c rcu , e powersource, control and protection devices are in

series and the loads are in parallel.

If an open occurs in the series portion, the

whole circuit will lose current flow.

If an open occurs in a parallel branch, the

current flow will remain in the series portion and

e rema n ng para e ranc es.

The instrument panel lighting circuit is one

example of a series-parallel circuit.

Series Para e Circuit Ru es

Electrical behavior in all series-parallel circuits is

governed by the rules shown in the illustration.

These rules apply to all series-parallel circuits

regardless of the type and number of load

ev ces.

Com ines c aracteristics o seriesan para e circuits

Some components are in seriesan ot ers are in para e

Power source, contro anprotection evices are norma yin series

• Loads are normally in parallel

C1-38




m o d u l e E C 126

Series-Para e Circuit Examp e

In the series-parallel circuit shown on the

previous page, current flows from the battery

roug e g sw c ar or ea pos on ,

and the 10 amp tail fuse to the instrument paneldimmer switch. This is the series portion of the

c rcu .

On the output side of the dimmer switch,

current flows to splice S251 where it divides

and travels to all of the instrument panel lights.

All instrument panel lights are connected on

e groun s e o sp ce . rom sp ce

S219 the current flow path is through grounding

points G200 and G201 back to the battery

roug e ve c e o y.

The circuitry between splice S251 and S219

is considered to be the parallel portion of the

circuit.

When diagnosing a series-parallel circuit,

remem er:

• f an open occurs in the series portion the

whole circuit will lose current flow.

• f an open occurs in a parallel branch the

current flow will remain in the series portion

and the remaining parallel branches.





INSTRUMENT PANEL LIGHTING

(Partial View)




m o d u l e E C 128

Measuring Vo tage in aSeries-Para e Circuit

In this activity, we are measuring the available

source voltage and the voltage drop of a

norma y opera ng c rcu w e oa sarranged in series-parallel.

Use the picture below to help you build the

ser es-para e c rcu . en comp e e e

table on the following page using information

obtained by taking voltage measurements at

e po n s us ra e n e agram.





V1 Source Voltage V

V otentiometer V

Lamp 1

V4 Lamp 2 V

V Lamp 3 V

OLTAGE: LOADS CONNECTED INSERIES-PARALLEL

n e space e ow exp a n w a e vo age


voltage in a series-parallel circuit.

____________________

____________________

____________________

____________________

____________________

____________________

____________________

+

-

V1 V2

V3 V4 V5

C1-42




m o d u l e E C 130

Measuring Current in a

Series-Parallel Circuit

n this activity, we are measuring the current at

eren oca ons w n a norma y opera ng

circuit with the loads arranged in series-parallel.

se e p c ure e ow o e p you u e

series-parallel circuit. Then complete the

table and questions on the following page

using information obtained by taking current


diagram. Remove a load from the parallel

por on an no e w a appens o e o a

curren .

CAUTIONAlways start measuring witht e ammeter on t e g est

sca e an wor your wayown to prevent amage to

the meter.

EC1-43





CURRENT: LOADS CONNECTED INSERIES-PARALLEL

A Source Current A

o en ome er

A Lamp 1 A

4 amp

amp

A Total Current A

In the space below explain what the currentmeasurements you obtained tell us about

curren n a ser es-para e c rcu .

+

-

A1 A2

A5

A6

A4 A3

C1-45




m o d u l e E C 132

Measuring Resistance in aSeries-Para e Circuit

n this activity, we are measuring the resistance

at different locations within a series-parallel

circuit and the total resistance of the entirecircuit.

se the picture below to help you build the

ser es-para e c rcu . en comp e e e a e

and questions on the following page using

information obtained by taking resistance

measuremen s a e po n s us ra e n e

diagram.






m o d u l e E C 134

CIRCUIT CONTROL METHODS

u omo ve e ec r ca c rcu s can e power

controlled, ground controlled or reverse polarity.

Some circuits use a combination of control

me o s.

ower contro e

Groun contro e

eversi e

Com ination o two or moretypes o contro

EC1-48

-

EC1-50

Power Contro e Circuits

In a power controlled circuit, the control device

is located between the voltage source and the

oa .

Current to the load is controlled by completing

or interrupting the path between the voltage

source an e oa .

The load is always connected to ground in this

type of circuit.

Groun Contro e Circuits

In a ground controlled circuit, the control device

is located between the load and ground.

The load is controlled by completing or

interrupting the path to ground.

e power s e o e c rcu s a ways powere

and voltage is always available at the positive

side of the load device.





EC1-52

REVERSIBLE POLARITY CIRCUITS

Reversible polarity circuits are normally two

separate series circuits that share a common

groun an a common power supp y. ey are

used when actuators must be able to run in twodirections, like power door lock, power mirror

and power window motors.

These circuits are wired so that either side of

the motor or actuator can be connected to the

vo age source. opera es n one rec on

when one lead is positive and in the other

direction when the other lead is positive.

Reversible Polarity CircuitExamp e

Most reversible polarity circuits

nc u e wo re ays a s are a

common ground. One motor lead

connects to the first relay and the

o er mo or ea connec s o e

second relay. Each side of the motor

is grounded when its relay is de-energ ze .

When one relay is energized, it

switches one motor lead connection

rom groun o e pos ve s e o e

voltage source. The other motor lead

remains grounded.

orma y two series circuitst at s are a common grounand power supply

or actuators or motorsoperating in 2 irectionse.g. power oor oc

irection o operationac ieve y c angingolarity of applied voltage

EC1-51

Current flows from the voltage source through the closed contacts of the energized

relay, through the motor and finally to ground through the de-energized relay.

everse po ar y c rcu s norma y ave a pro ec on ev ce w c can e a c rcu

breaker or a positive temperature coefficient (PTC) resistor. These devices protect the

circuit in the event that the device being moved by the motor reaches its stop and power

s e ng app e .







Functions o Re ays

A relay is simply just a remote control switch.

A small amount of current is allowed to

flow through an electromagnetic coil. The

e ec romagne c e ec pu s an arma ure

towards the coil causing a set of contacts to

close. Once the contacts are closed a higher

amoun o curren s a owe o ow roug e

contact points.

Build the circuit shown in the picture below

using the relay, switch and buzzer and describe

s opera on.

________________________

________________________

________________________

________________________

+

-

RELAY

C

O

N

TR

O

L

D

C1-5




m o d u l e E C 138

Functions o Capacitors

A capacitor is a device for storing an electrical

charge. A capacitor consists of two plates made

of an electrically conducting material separated

by a nonconducting material or dielectric. Ifvoltage is applied to the capacitor plates, the

plates will become charged, one positively and

one negatively. If the externally applied voltage

is then removed, the capacitor plates remain

charged, and the electric charge induces an

electric potential between the two plates. The

capac or s a y o s ore a c arge can e

increased by increasing the area of the plates,

by decreasing their separation or by varying

e su s ance use as an nsu a or. en e

charged capacitor is shorted, discharge currentwill flow from the capacitor.

u e c rcu s own n e

p c ure e ow. ow e capac or

to charge then remove the powersource. Describe what happens.

+

-+-

CAPACITOR

EC1-56





+-

u e c rcu s own n e p c ure e ow.

Close the switch and allow the capacitor to

discharge. Describe what happens.

C1-58







ELECTRONIC CIRCUIT CONTROLMETHODS

e a vancemen s n o ay s ec no ogy

the automobile has become much more

complex. Computerized systems consisting ofe ec ron c or so s a e ev ces are now e ng

used to control emissions, deploy airbags,

monitor engine operation, control alarm systems

an many o er opera ons a ng p ace n e

vehicle. The most common of the electronic

control devices that the technician may become

nvo ve w are o es an rans s ors. ese

ev ces are nown as sem con uc ors.

Semiconductors

sem con uc or s a so ma er a w ose

e ec r ca con uc v y a room empera ure es

between that of a conductor and that of an

insulator. At high temperatures its conductivity

approac es a o a me a an a ow

temperatures it acts as an insulator.

e e emen s s con an german um are

typically used as semiconductor material. Both

have only 4 electrons in their outer valence

s e . en cer a n mpur es suc as arsen c,bismuth or antimony, which have 5 electrons

in their outer shells, are alloyed with them the

resu an ma er a ecomes an - ype ma er a .

N-Type semiconductors have extra electrons

free to move about so they are called donors.

en s con or german um s a oye w

boron, indium or gallium, which have only 3

electrons in their outer shells, there will be

holes formed in the outer ring which will accept

electrons from an outside source. The materialis now a P-Type material and is an acceptor.

The N-Type materials are negative charged

and the P-Type materials are positive charged.

Just like magnets, the “likes” repel and the

oppos es a rac .

Dio es

Transistors

Part con uctor; part insu ator

• Usually made of silicon orgermanium

Can e N-Type or P-Type

W en joine toget er currentcan move on y in one irection

P

N

++++

++++

++++

++++

+++

+++

+++

+++

+++

+

+

__

_

________

__

___

__

_

___

_

_

(-)

GND

LIKE

CHARGES

REPEL

LIKE

CHARGES

REPEL

LOAD

B+

JUNCTION

FILLED

STRIPE

+

_

FORWARD

BIASED

(-)

GND

OPPOSITE

CHARGES

ATTRACT

B+

JUNCTION

EMPTY

STRIPE +

_

REVERSED

BIASED

OPPOSITE

CHARGES

ATTRACT

P

+

+++

+

+++

++++

++++

+

+

N

___

___

___

___

_

_

+

+

+

+

EC1-62

EC1-63

EC1-6




m o d u l e E C 142

Functions o Dio es

A diode is a semiconductor device with one N-

Type and one P-Type material joined together

w c a ows curren ow n one rec on on y.

It can be compared to a check valve whichpermits a fluid to pass in one direction and

s ops n e o er. e mos common p ace

that the automotive technician will find the use

of diodes is in the alternator to rectify or change

the AC voltage into DC voltage. A diode is also

used in the alternator to prevent the battery

from discharging back through the windings in

e a erna or.

Using the diode, Switch 1 and Lamp L2,

build the circuit shown in the picture belowan escr e s opera on. everse e

connections to the diode and check again.

_________________________

+

-

12V

5W

+

-

12V

5W

DIODE

EC1-65





EMITTER

BASE

COLLECTOR

P

N

P

P PN

EMITTER

BASE

COLLECTOR

RANSISTOR

Funct ons o Trans stors

A transistor is similar to a diode in that it uses

N-Type and P-Type materials but rather than

check the flow of current the transistor can

control the flow of current much like a relay.

The transistor is essentially a sandwich of N-

Type material between two pieces of P-Type

material or a P-Type material between two N-

ype ma er a s. e cen er p ece s ex reme y

n an s ca e e ase an s e con ro

element of the transistor. One end piece is the

emitter and the other is the collector. When

curren s a owe o pass roug e ase, e

emitter and collector materials react and allow

current to pass through them.

EMITTER

BASE

COLLECTOR

P

N N

PN N

EMITTER

BASE

COLLECTOR

C1-67

C1-67




m o d u l e E C 144

sing the PNP transistor, Switch 1 and Lamp L2, build the circuit shown in the picture

e ow an escr e s opera on.

______________________________________________

______________________________________________

______________________________________________

______________________________________________

B

C

E

A 2 A 1

OFF

1 A 2

EC1-68





E

C

B

E

E C B

C

E

C

C

B

B

B=

P

N

P

PNP

INSPECTION OF PNP TRANSISTOR

NO

POSITIVE (RED) NEGATIVE (BLACK) CONTINUITY




m o d u l e E C 146

sing the NPN transistor, Switch 1 and Lamp L2, build the circuit shown in the picture

e ow an escr e s opera on.

B

12v5w

C

E

A 2 A 1

S - 1

ON

1 A 2

C1-70





C

E

B

E

E C B

C

C

E

C

E

B

B

B=

N

P

N

NPN

INSPECTION OF NPN TRANSISTOR

C YES

NO

POSITIVE (RED) NEGATIVE (BLACK) CONTINUITY




m o d u l e E C 148

. As the resistance in a 12-volt

automotive circuit increases, whathappens to current flow in the circuit?

a. t stops

. ecreases

. t increases

. o ng

. When current is allowed to pass

through the base of a transistor, theemitter and collector materials react

and allow current to pass through them.

a. True

b. False

6. What happens to the total current

in a parallel circuit, when one of the

branches are removed?

. Stays the sameb. Goes up

. Goes down

d. Changes to equal the resistance

. What law of electricity states that the

current that flows in an electrical circuit

is directly proportional to the voltage

an nverse y propor ona o e

res s ance n e c rcu

. Coulomb’s Law

b. Kirchoff’s Law

. Ohm’s Law

d. Faraday’s Law

SELF-TEST

This self-test will enable you to

measure the knowledge that you have

ga ne a ou u omo ve ec r ca

Circuit Analysis. Circle the one best

answer that completes the statement or

answers the question.

1. hich of the following is a load

device?

a. attery

. Circuit breaker

. lower motor

d. og lamp switch

2. hich of the following circuits is an

examp e o a ser es-para e c rcu

. nstrument panel lights

. ack-up lights

. orn

d. eadlamps

. ec n c an says a a wor ng

circuits must have a power source,

a load device and a ground.

ec n c an says a mos

automotive circuits have a control

device.

ho is correct?

. ec n c an on y

. Technician B only

c. oth A and B

. e er nor





______________________ _________

_______ _____________________

__________________________________









epartment

/99

Part Number: KC-EC1



Electrical

Diagnosis

Automotive

Electrical Course



ED1



ELECTRICAL DIAGNOSIS

m o d u l e E D 1 1

er comp e ng s mo u e, you w e a e

to use a good diagnostic thought process to

identify the correct sequence of steps to follow

w en agnos ng an repa r ng a a ve c e.

This will enable you to diagnose and repairsystem or component problems faster and more

effectively.

• Use a goo iagnostic t oug t processwhen diagnosing and repairing system orcomponent pro ems

I enti y t e Kia 5 Step trou es ootingprocess

Use vo tage rop testing to iso ate circuitau ts

Use a DVOM an an E ectricaTrou es ooting Manua to iagnose aparasitic current draw problem

D1-1

LEARNING OBJECTIVES

ODULE DIRECTIONS

WHAT YOU WILL NEED


illustration as you read the material. Feel freeto ask questions any time something is not

c ear. e sure o answer e ques ons n e

activity and at the end of the module.

• One red marker

• One green marker

• Digital Multimeter

• 1999 Sephia or Sportage




m o d u l e E D 12

DIAGNOSTIC THOUGHT PROCESS

Diagnosis is more than simply following a series

o s eps o so ve a spec c pro em. agnos s

is a thought process that causes you to look

at a system that is not functioning properlyand discover the reasons. If you use a good

diagnostic thought process, many possible

causes can be eliminated before you even open

your oo ox. n s mo u e, you w earn o

develop good habits by following the Kia 5 step

troubleshooting process.

. Veri y t e pro em

2. Ana yze t e pro em

3. Fin t e cause

. Repair t e pro em

. C ec t e repair

-

• Not simply following steps

• Thinking critically aboutma unctioning system aniscovering reasons or

pro ems

• E iminate o vious pro emsbefore opening tool box

• Fo ow Kia 5 steptrou es ooting process

D1-2

Norma or a norma ?

Be sure t at you un erstant e pro em

Experience t e pro em irstan wit t e customer

present

• Don t start isassem y ortesting until problem areaas een narrowe own

C ec or ma unctionin icator ig ts

D1-4

Five Step Troubleshooting Process

Effective diagnosis requires knowledge of how

a system is supposed to operate in order to

e erm ne w en s no opera ng correc y.

There are five basic steps for diagnosis and

repair. If you follow these steps in a systematic

manner, you will usually find the cause of the

problem the first time.

VERIFY THE PROBLEM

e an accura e escr p on o e cus omer s

complaint. Determine if the concern is a

normal condition or a valid failure. Sometimes

a va comp a n ex s s, u e cus omer may

describe the problem in a way that leads you

down the wrong diagnostic path.

Note the symptoms, but do not begin

disassembly or testing until you have narrowed

own e pro em area.

Check to see if any warning or malfunction

indicator lights are on.






m o d u l e E D 14

reliminary Checks

Do the preliminary checks. Based on the

symptoms and your understanding of the

systems operation, identify one or more

possible causes. Use the troubleshootinginformation in the Service Manuals and ETMs

as a gu e.

C ec or unusua con itionsappearance, o ors, noise,

vi ration or ea s

• Retrieve iagnostic trou e

codes, pending codes andreeze rame ata

Visua y inspect or ooseconnections or urnt wiring

C ec or own uses

C ec t e operation o t esuspect system

Investigate t e ve ic e sistory

• C ec service manua orpossible causes

• Review all schematics for thepro em system

Loo or app ica e Tec nicaService Bu etins anNews etters

D1-7

Ana yze t e possi i ities

Prioritize t e possi i ities

Use t e Service Manuaan or ETM to etermine t econnection t at is easiest toaccess an wi provi e t emost use u in ormation

• Perform the tests andinspections iste in t eService Manua an or ETM

D1-8

IND THE CAUSE

ormu a e a s mp e an og ca proce ure o

diagnose the condition. Check the diagnosis

you made by doing tests. Test for the most

likely cause of failure first. Isolate electrical

c rcu s.




m o d u l e E D 1 5

R EPAIR THE PROBLEM

Once the specific problem is identified, make

the repair following all recommended repair

procedures in the service manual and/or ETM.

eplace parts using theecommen e Serviceanua proce ures

ep ace connectors an

wire termina s usingecommended proceduresescri e in t e ETM

se genuine Kia rep acementarts

ED1-9

ec ec , eva uate resu ts

C ec re ate systems orroper operation

Check for any new problems

ED1-10

CHECK THE R EPAIR

Verify that the repair corrected the problemby performing the system checks under

e con ons ocumen e n e cus omer

complaint. Operate any related systems. Make

sure no new problems turn up and the original

pro em oes no recur.



ELECTRICAL SYSTEM MALFUNCTIONS

All electrical malfunctions can be categorized

in one of three types of faults: high resistance,

ow res s ance or componen .

High Resistance Faults

e err ng ac o m s aw, we now a

when resistance in a circuit increases the

available current will decrease. High resistance

n a c rcu can e cause y an open n e

circuit or a loose, dirty or corroded connection.

In order for the circuit to have current flow a

comp e e pa s nee e . n open n e c rcu

will stop current flow and unwanted resistance

will reduce the current flow. High resistance

problems are very common and often

over oo e w en o ng e ec r ca agnos s.

When lamps flicker or motors run slow check

the connections in the circuit for being loose,

r y, or corro e . orma y, a g res s ance

fault does not cause the fuse to blow.

Open circuit

irty connections

Corroded connections

Will not cause blown fuse

D1-12


m o d u l e E D 16

igh Resistance Faults

ow Resistance Faults

Component Fau ts

D1-11

DIAGNOSING AN OPEN CIRCUIT

To discover the location of an open in a circuittwo methods can be used: a voltage test or a

continuity test.

Voltage Test

e vo age es can e one us ng e er a es

lamp or a digital volt meter. Start by checking

for the proper voltage at the power source.

Connect the negative lead of the test lamp

or volt meter to a known good ground. Then

connect the positive lead to the point where

you want to check. If the proper voltage is

presen move e es amp or vo me er o e

next point along the conductor where a device

or connector is located and check for voltage

aga n. on nue o move a ong e con uc or

until no voltage is detected. The open will be

located between the last two points checked.

The two methods for locating anopen in a circuit are:

Vo tage Test

Continuity Test

ED1-13

ED1-1




m o d u l e E D 1 7

- 6

REMOVE

FUSE OPEN

Continuity Test

The continuity test is nothing more than just

checking for a continuous path for the current to

flow. The best tool for this test is the ohmmeter.

With the ohmmeter you will also be able to

locate areas of high resistance. The circuit or

component should be isolated or removed from

the power source prior to testing. Connect

the ohmmeter to the circuit or component with

e pos ve ea a one en an e nega ve

lead at the other. Polarity will only matter if

a diode is in the circuit. Check to see if the

res s ance measuremen s w n spec ca on.

f the resistance is high or an “OL” (out of

limits) reading is obtained continue to take

measuremen s w e s or en ng e c rcu ownuntil the problem area or component is found.

VOLTAGE DROP

As current flows through a resistance, electrical

energy is converted to other forms of energy

such as heat, light or motion.

e e or o pus ng e ec rons roug a

resistance uses up voltage. This reduction in

voltage is called voltage drop. In automotive

circuits even the smallest loss of voltage will

cause poor performance.

Voltage drop is the difference between the

voltage on the power side of a load (applied

voltage) and the voltage on the ground side

(closest to the negative battery terminal).

n mos cases vo age rop es s are

recommended over resistance checks because

you are measuring the circuit while it is in

opera on.

You can measure the resistance through the

starter cable and as long as one strand of

wire is complete the resistance will be within

specifications. But, after applying power to

e c rcu an measur ng e vo age rop,

becomes more evident that there is a problem

in the circuit.

D1-15




m o d u l e E D 18

iagnosing Using Voltage Drop

en you measure e vo age rop across

a load, you are measuring the actual voltage

applied to that load.

Voltage drop occurs whenever current flowsthrough a resistance. There is no voltage drop

without current flow.

The sum of all of the voltage drops in a circuit,

will always be equal to the source voltage.

In a multi-device circuit, if the voltage drop

across any one device is equal to the source

vo age, e ev ce as an open c rcu ecause

no voltage is being consumed.

f the voltage drop across any one load device isero, e oa ev ce s s or e an s e er no

consuming voltage or there is no voltage drop

ecause there is no current flow in the circuit.

o age rops s ou no excee e o ow ng:

200mV Wire or cable

300 mV Switch

100 mV Ground

0mV to <50mV Sensor connections

0.0V Connections

On longer wires or cables, the drop may be slightly higher. In any case, a voltage drop

of more than 1.0 volt usually indicates a problem.

Diagnosis Procedure

1. Connect the positive lead of a voltmeter to the end of the wire (or to the side of the

connector or switch) closest to the battery.

2. Connect the negative lead to the other end of the wire (or the other side of the

connector or switch).

3. Operate the circuit.

4. The voltmeter will show the difference in voltage between the two points.

erence, or vo age rop o more an . vo , may n ca e a pro em.

DIAGNOSING HIGH R ESISTANCE FAULTS

igh resistance malfunctions result in reduced or improper operation of the circuit.

Suspect a high resistance malfunction if a bulb turns on but remains dim or a motor

Vo tage rops s ou not exceet e o owing:

200mV Wire or ca e300 mV Switch100 mV Groun0mV to <50mV Sensor connections0.0V Connections

ED1-18a




m o d u l e E D 1 9

• Result in reduced ormproper operat on

Usua y cause y oose orcorro e connections

Vo tage rop s ou enear y zero across controdevice or connection

ED1-19

operates at a reduced speed. Loose

connections, corrosion and partially broken

w res are e y o cause g res s ance n a

c rcu . o age rops across a con ro ev ce

or connection should be ideally zero if not very

low.

Using Voltage Drops to Find High Resistance

When you compare this circuit to the normally

operating circuit on the previous page, you will

see the effect that high resistance has on a

circuit.

e sw c n s c rcu as r y con ac s

which causes the voltage drop across the

switch to be 3.9 volts as opposed to the 0.1 volt

drop across the switch in the normally operating

c rcu .

Notice also that because the switch is dropping

3.9 volts and the fuse contacts are dropping 0.1

volt, there are only 8 volts left to operate the

bulb. In this circuit the bulb would burn dimmer

an norma .

High resistance is very critical in ECU controlled

circuits because the reference voltage is only

vo s. g res s ance n an con ro ecircuit can cause false readings from sensors

and may even prevent the circuit from

opera ng.

ED1-20

Low Resistance Faults

A low resistance fault will allow too much

current flow or current to flow to a portion of

e c rcu w ere oes no e ong. e ow

resistance can be caused by a short to ground

or a short to another circuit. Check for barew res ouc ng o groun or o o er w res.

Also be aware that sometimes an aftermarket

accessory may have been installed incorrectly.

Usually a fuse will blow or a circuit breaker

w open ecause e ow res s ance con on

increases the current flow in the circuit to more

than the circuit is capable of handling.

Too muc current ow

Wire s orte to groun

Wire to wire s ort

• Check part installation

• Will blow fuse or open breaker

D1-21




10

Short circuits that result in excessive current

flow will normally blow the circuit protection

device. Because the circuit will not operate,

voltage drop tests cannot be made.

There is a commercially available short detector

that pulses current intermittently through the

s or e c rcu . n n uc ve amme er, nc u e

with the kit, traces this flow of current through

the faulty circuit. The ammeter needle will

move with each of the current pulses as it is

moved along the circuit. When it gets to the

short, the needle will stop.

e mos common use or s es er s or

wiring harness shorts to ground.

ARASITIC RAW

Parasitic current draw flows when all the

switches on the vehicle are in the off position.

A small amount of current is necessary to

enable the various electronic control units and

a arm sys ems o re a n e r programm ng

w en e gn on sw c s urne o .

Parasitic current draw is normally less than 20

m amps u may e g er w an a ermar e

alarm system installed.

ED1-22

DIAGNOSING SHORT CIRCUITS

lows when all switches areo

ecessary to reta ncomputer memory

A ove 20 mi iamps may

in icate a pro em

D1-23




11

Diagnosing a Parasitic Draw Pro em

en paras c raw excee s approx ma e y

20 milliamps (100 milliamps with aftermarket

alarm), it may be an indication that the vehicle’s

e ec r ca sys em as a groun e c rcu a sbypassing its control device. This can cause

the vehicle battery to discharge over a period of

me.

Parasitic current draw is measured by turning

OFF all accessories, closing all the doors, the

run , e c. an connec ng an amme er e ween

the negative battery cable and the negative

battery post as shown in the illustration.

Diagnosis Procedure

Connect the red lead to the battery cable and

the black lead to the battery negative post.

If the current reading on the meter exceeds

50mA (100mA with aftermarket alarm), refer

to the Power Distribution Schematic Diagram

n ec on o e ec r ca rou es oo ng

Manual (ETM) and remove one fuse or fusible

link at a time until the ammeter reading is

norma .

Once the malfunctioning circuit has been

identified, refer to the Circuit Diagram for that

circuit to further isolate the problem to the wiring

or a circuit component.

1. Connect ammeter to batteryca e an attery negativepost

2. Re er to Power Distri utionin ETM

3. Remove one use or usi ein at a time unti t eammeter reading is normal

D1-25

ED1-24

.013

CAUTION

A ways start measur ng w tt e ammeter on t e g est

scale and work your wayown to prevent amage to

t e meter.

ED1-26




m o d u l e E D 112

USE FAILURES

A fuse will normally fail for one of three

reasons: excessive current in the circuit, fatigue

or poor contact. By inspecting the failed fuse

we can often determine the cause of the failure.

• xcessive current can be caused by a

s or c rcu or y an excess ve oa e ng

mposed on a motor. Examples:

Wiper blade frozen to the windshield

Window too tight in the runner

A fuse that has failed due to excessive

current will have a 2 to 3mm section

elted away at the center. The circuit and

components should be checked and anyepa rs nee e s ou e one pr or o

eplacing the fuse.

• use fatigue is caused by the fluctuations in

current when the power is switched ON and

OFF. The ON/OFF current will heat and

cool the fuse and eventually the fuse will

urn out.

A fuse that has failed due to fatigue will

ook like the center of the fuse was cut with

a thin knife.

• oor contact between the fuse and the fuse

o er causes res s ance w c genera es

eat. If the fuse gets too hot it burns and

ails.

On bladed fuses the plastic may melt

and the element will melt much like with

excessive current. On tube fuses, the

con ac s a e cap o e emen w me .

rior to replacing the fuse, the holder

should be cleaned and repaired to provideetter contact with the fuse.

Excessive Current

Fatigue

Poor Contact

ED1-27

ED1-28

-






m o d u l e E D 114

INDICATORS AND GAUGES CLUSTER




m o d u l e E D 1 15

DIAGNOSTIC EXAMPLE

ollow the steps in this activity using the

sc ema c agram s own n e us ra on.

Answer the questions in the space provided.

The owner of a 1996 Sportage stated that the

coolant temperature gage does not work.

You have verified the problem and found that all

o e o er gauges are wor ng .

You have located the INDICATORS AND

GAUGES CLUSTER diagram in the ETM and

are ready to analyze the problem.

. Trace the power side of the coolant

temperature gauge circuit with a red marker.

2. Trace the ground side of the circuit with a

green mar er.

3. dentify the following components:

Load Devices: _______________________

Control Devices

Protection devices____________________

Since the other gauges worked OK, all of thewiring from the ignition switch to terminal #5 of

connector C252 is good.

This limits the suspect area to the gauge and

the ground return path through the sending unit.

ou ave us re uce a comp ex agram o

a small section without even opening your tool

box.

Now you can isolate the problem by dividing the

circuit at the easiest point where you will get themost useful information, in this case connector

C127, and continue your diagnosis.




m o d u l e E D 116

CURRENT FLOW MEASUREMENT

1. isconnect the negative battery cable.

. onnec e mu me er e ween e

negative battery terminal and the negative

battery post.

3. Close all doors, trunk, etc.

. easure e paras c curren raw.

ultimeter reading ___ ___________ amps

. Select the 20 Amp range on the multimeter.

6. Open the driver’s door.

. Check the dome light switch to ensure it is

in the “door” position.

8. easure the parasitic current draw

u me er rea ng ___ ___________ amps

9. Close the driver’s door. The ammeter

s ou re urn o e rea ng you a n s ep

.

. Connect the negative battery cable.

.013

VOLTAGE DROP MEASUREMENT

ve c e comes n o your s op w

the complaint that the passenger

compartment dome light glows dim.

e cus omer s a es a e u

as een rep ace u e con on

remains.

agnose s pro em us ng vo agedrop. In the space provided to the

right explain what you did to locate

e pro em an w a s caus ng e

problem.

________________________

________________________

________________________





SELF-TEST

This self-test will enable you to measure

e now e ge a you ave ga ne a ou

Diagnostic Techniques. Circle the one best

answer that completes the statement oranswers e ques on.

1. Diagnosis is simply following a series of

steps to solve a specific problem.

a. True

b. alse

. Checking for trouble codes is part of .

. 1. Verifying the problem

b. 2. Analyzing the problem

c. 3. Finding the cause

. . epa r ng e pro em

. 5. Checking the repair

3. Technician A says that there is no voltage

drop without current flow.

Technician B says that the voltage drop

across a control device should always equal

e app e vo age.

Who is correct?

a. Technician A only

b. Technician B only

. o an

d. either A nor B

4. On a 12 volt automotive electrical system,

parasitic current draw must be at least 300milliamps to retain the ECM’s memory.

. True

b. alse




m o d u l e E D 118

__________________________________

_______ ___________________

__________________________________





___________________________________

________ ___________________

___________________________________









epartment

/99

Part Number: KC-ED1



Electrical

Repairs

Automotive

Electrical Course



ER1



ELECTRICAL R EPAIRS

m o u e 1

o ay s ve c es are us ng more e ec ron cs

than ever before. With computerized

management systems and more electronic

con ro e ev ces, w r ng pro ems ave

become a major concern. Most common

electrical circuit malfunctions in today’sve c es can e race own o a pro em a

the connectors. Loose or corroded connectors

can cause high resistance in a circuit. These

conditions may require the replacement of a

w re erm na or e en re connec or.

Other times a wire may become pinched or

chafed and cause a short circuit. When this

happens it may become necessary to replace or

repair the wire or complete harness.

n this module, you will become familiar with

repairing wiring, terminals and connectors.

I enti y terms re ate to wiring arnessrepair.

• Perform a satisfactory wire repair.

• Per orm a satis actory termina

replacement.

R1-1

LEARNING OBJECTIVES

ODULE DIRECTIONS

are u y rea s ma er a . u y eac


to ask questions any time something is not

c ear. e sure o answer e ques ons n e

activity and at the end of the module.

• erm na repa r

• Soldering iron with stand

• Solder

• Heat shrink gun



ELECTRICAL R EPAIRS

m o u e2

Connector Terminal

HARNESSES

To provide current flow throughout the vehicle

w re arnesses are use . re arnesses are

bundles of wires that are bound together in

plastic tubing or wrapped with tape. Bundlingthe wires together offers protection for the wires

as well as organization. A vehicle will have

several wire harness sections so that a section

can e rep ace w ou rep ac ng a e w re n

the vehicle. The sections are attached to each

other with connectors.

R1-3

• Provide current to all pointso t e ve ic e

Bun es o wire

Boun in tu ing or tape

Attac e to eac ot er yconnectors

R1-2

CONNECTORS AND TERMINALS

Every wire in a vehicle ends up in some type of

connector or terminal. A connector is usually

a p as c p ece a ouses e w re erm naor terminals. A terminal is a device attached

to the end of a wire or component to make the

e ec r ca con ac po n remova e. ar ous

types of connectors, terminals and junction

blocks are used on Kia vehicles. The Electrical

Troubleshooting Manual can be used to identify

each type used in a circuit. The connector is

an excellent point for conducting tests because

e c rcu can e opene w ou amage o

the wires. Connectors can also be a major

source of electrical problems. The connector

can be improperly connected, corroded or have

m ss ng or en erm na s.

Connector Replacement

Connectors can be replaced in one of two

ways:

y sp c ng a comp e e connec or w

erminals and wire pigtail to the harness

y removing all the terminals and replacingus e connec or ous ng

If replacing a complete connector, be sure to

s agger e sp ces so a ey are no a n e

same area. If replacing the empty connector,

ensure that the replacement connector is

en ca o e or g na connec or.

- Splice complete connectorwit termina s an wirepigtai to t e arness

- Stager sp ices

R1-4



ELECTRICAL R EPAIRS

m o u e 3

Connector Inspection

Check for signs of damage or corrosion to the

outside and inside of the connector. Check

for bent or missing terminals. Check for good

terminal tension. When a tester is used tocheck the continuity or to check the voltage,

insert the tester probes from the wire harness

s e.

Check for:

• Damage

• Corrosion

• Bent/missing terminals

• Terminal tension

Always insert test lead probes fromt e wire si e

-

Connector Terminal Identification

Most male connectors will have female

terminals and most female connectors willhave male terminals. The cavities (and wire

terminals) in each connector are numbered

starting from the upper right looking at the male

terminals from the terminal side or looking at

the female terminals from the wire side. Both

views are in the same direction so the numbers

are e same. cav es are num ere , even

if they have no wire terminals in them.

e connec or cav y num er s s e nex oeach terminal on the circuit schematic. The

cavity/terminal shown is #4.

3 2 1

6 5 4

WireSideOfFemale Terminals

SideOfTerminals

- - -

MaleTerminal

FEMALETERMINAL

MALETERMINAL

CA VITY/TERMINAL 4

4 C103

ER1-6

ER1-7



ELECTRICAL R EPAIRS

m o u e4

Disconnecting the Connector

The connector can be disconnected by pressing

the lock lever. Do not pull on the wires when

disconnecting the connector. Be careful to hold

the connector housing itself when disconnectingit.

Terminal Replacement

Terminal replacement is easy if done correctly.

The first step is to identify the type of connectorand terminal. Check for the position of the lock

tab and direction of unlocking.

e secon s ep s o remove e erm na

from the connector. This is done by inserting a

push- tool into the connector against the locking

tab while pulling the wire, with terminal, out of

the connector. Some connectors may have a

secondary locking device that will need to be

remove pr or o remov ng e erm na s.

The third step is to replace the terminal.

Select the correct replacement terminal from

e erm na repa r . r p a ou nc o

insulation from the end of the wire. Insert the

stripped end of the wire into the replacement

erm na . s ng a cr mp ng oo , cr mp e rs

tab of the terminal over the bare wire. Then

crimp the second tab over the insulated portion

of the wire.

The fourth step is to install the terminal intothe connector. Check that the locking tab is

in good condition and in the correct position.

Push the terminal into the connector until you

hear or feel the “click”. Gently pull on the

w re ea o ensure a e erm na s sea e

correctly in the connector. If needed, install the

secondary locking device.

Step 1. I enti y t e connectoran termina type

Step 2. Remove t e termina romthe connector

Step 3. Replace the terminal

Step 4. Install the terminal intot e connector

ER1-9

R1-8

WARNING

o not repa r a r agharnesses or connectors.

ER1-10







ELECTRICAL R EPAIRS

m o u e 7

Splicing a Wire

In this activity you will splice two pieces of

w re oge er w an n ne so er sp ce o n .

Follow the steps outlined on the previous page

for splicing a wire. When finished have yourns ruc or c ec your wor .



ELECTRICAL R EPAIRS

m o u e8

ELF-TEST

This self-test will enable you tomeasure the knowledge that you

ave ga ne a ou ec r ca

Repairs. Circle the one best answer

that completes the statement or

answers e ques on.

1. The plastic piece attached to

the end of a wire that houses

e w re erm na or erm na s s

the:

. erm na

b. Plug

. onnec or

d. Socket

2. What should always be done

prior to any wire repair?

a. Remove the harness from

the vehicle

. ean e w res o e

repaired

. Replace blown fuses

d. Disconnect the vehicle’s

battery

3. When checking the continuity

through a connector,

e connec or s ou edisconnected and the test lead

probes should be inserted from

e erm na s e.

. True

. a se

. a s e a recommen e me o or

doing a wire splice?

. w s e w res oge er an ape

b. Use an inline solder joint

. ep ace e arness

d. nstall a connector at the damaged

por on o e w re

5. n the connector shown below, into

w c cav y wou erm na um er e

inserted?

d



ELECTRICAL R EPAIRS

m o u e 9

__________________________________

__________________ ________

_______ ___________________

__________________________________

__________________________________



ELECTRICAL R EPAIRS

m o u e10

___________________________________

___________________ ________

________ ___________________

___________________________________

___________________________________









epartment

/99

Part Number: KC-ER1



Battery, Charging

and StartingSystems

Automotive

Electrical Course



Stator

Coil

Rotor

Coil

arning Lamp

Diode

IC Regulator

METER

IGNBTN

AIN

Battery

AC Voltage

Rectifier

DC Voltage

ES1



n this module you will examine the operation

and function of the battery, starting system

and charging system used on Kia vehicles.

You will also become familiar with the service

and test procedures of these systems. Hands

on exerc ses w e use o re n orce einformation.

m o d u l e E S 1

BATTERY, CHARGING AND STARTING SYSTEMS

1

A ter success u y comp eting t is mo u e yous ou e a e to comp ete t e o owing.

For t e attery, c arging system an startingsystem:

I enti y terms

I enti y various parts an t eir unctions

Per orm operationa tests

ES1 - 1

Carefully follow the procedures and answer

the questions in this module. Study each

us ra on as you rea e ma er a . ee ree

to ask questions any time something is not

clear.

When you have completed all of the activities,

see your instructor for module sign off.

• Digital multimeter

• A starter

• An alternator

• 1998 or later Sephia or Sportage

• Service Manual for the vehicle

• a ery es er

LEARNING OBJECTIVES

ODULE DIRECTIONS




m o d u l e E S 12


THE BATTERY

The battery converts chemical energy into

electrical energy. The battery stores chemicals

a w reac o crea e e ec r c y. ere are

two types of metals in the battery and when

an acid is added a reaction takes place that

pro uces an e ec r ca vo age. e a ery

provides the energy for the starter system and

acts as a voltage stabilizer for the electrical

sys em. en e e ec r ca sys em oa

exceeds the generator output, the battery can

also provide extra power for a limited time.

Battery Functions

1. hen the engine is off the batteryrovides energy to operate the lighting and

accessory sys ems.

2. hen the engine is starting the battery

rov es energy o opera e e s ar er mo or

an e gn on sys em ur ng cran ng.

3. The charging system is unable to provide

or the extra energy needed to operate the

electrical loads when the engine is running.

The battery supplies this extra energy

ee e o opera e e e ec r ca oa s. e

attery also works as a voltage stabilizer by

absorbing abnormal, transient voltages in

he vehicle’s electrical system.

Battery Type

The battery used in Kia vehicles are of the lead-

acid type. The battery is a conventional, low

maintenance type, 12 volt 48 amp-hour battery.

There is no built-in hydrometer. The electrolytelevel and specific gravity should be checked

ocassionally. The Sephia battery has a reserve

capac y o m nu es an a co cran ng

amperage rating of 460 amps. The Sportage

battery has a reserve capacity of 99 minutes

an a co cran ng amperage ra ng o

amps.

Stores c emica s

C emica reaction createse ectricity

rovides energy for starter

Voltage stabilizer for electricalsystem

W en engine o , provi esenergy for accessories

nergy to ignition & startermotor uring cran ing

Supplements energy duringig oa perio s

A sor s transient vo tages

Conventiona

ea aci

12 vo t, 48 amp- our

ow maintenance

ES1 - 2

ES1 - 3

ES1 - 4





m o d u l e E S 14


How a Battery Works

A lead-acid battery has two different metals,

lead dioxide and sponge lead, in a container of

electrolyte (water and acid). The lead dioxide

has a positive electrical charge and the spongelead has a negative electrical charge. The two

different metals and the acid solution create a

chemical reaction which produces an electrical

voltage.

curren w ow w en a con uc or an a

load are connected between the two metals. If

the current is allowed to flow the battery will

sc arge un e me a s ecome a e an e

acid is used up. If a current is applied to the

battery in the opposite direction, it will chargee a ery un e ma er a s are re urne o

their original condition. The partial discharging

and recharging of the battery can occur many

mes.

attery nspect on

• Check for cracks in the case and loose or

ro en erm na s. ep ace a ery.

• Check for cracked or broken cables or

connec ons. ep ace as nee e .

• Check for corrosion on terminals and dirt or

acid on the case top. Clean with a mixture

o wa er an a ng so a. se a w re

rush on terminals.

• Check the rubber protector on the positive

erminal for proper coverage.

• Check for loose battery hold down and

oose cable connections. Tighten aseeded.

• ec e e ec ro y e eve . s ou e

etween the UPPER LEVEL and LOWER

EVEL. If not, add distilled water to bring

evel up to UPPER LEVEL. Do not overfill.

ead dioxide (+) & sponge lead-

ectro yte

ischarge - Current flows from- to + until both - & + platesave a a ance num er o

e ectrons

ec arge - Vo tage is app ie ina reverse irection unti p ateseturn to their original condition

ischarging/Recharging canoccur many t mes

Crac s in case

Tig t termina s

Crac e or ro en ca es

Corro e termina s

irt or aci on case top

oose attery o own

A quate e ectro yte eve

-

ES1 - 10

ES1 - 11



• State of chargec emica con ition

y rometer speci ic gravityOpen circuit vo tage testc ec s avai a e attery

vo tage wit no oa

• bility to deliver currenta equate cran ing power

oa test c ec s attery sa i ity to provi e currentnder a load

m o d u l e E S 1 5


attery Testing

a er es can e es e o e erm ne

s a e o c arge an a y o e ver curren e

state of charge test checks the battery’s chemical

condition while the ability to deliver current test

easures e a ery s a y o e ver a equa e

cranking power.

STATE OF CHARGE

State of charge can be measured by two methods:

. ea e spec c grav y an empera ure o e

electrolyte.

. ecord your readings and repeat the procedure for

the remaining cells.

echarge the battery if the specific gravity is below thestandard of 1.280 at 77oF. Replace the battery if the

with a hydrometer or with an open-circuit voltage test.

Hydrometer

As a battery discharges, the acid becomes weaker as some of it combines with the plate

material. The hydrometer test is used to check the specific gravity, or exact weight, of

the electrolyte. By weight the electrolyte in a fully charged battery is about 36% acid

and 64% water. Water’s specific gravity is 1.000 and sulfuric acid’s specific gravity is

. . en com ne e e ec ro y e m x ure as a spec c grav y o . .

By measuring the specific gravity of the electrolyte, you can tell if the battery is fully

c arge , nee s c arg ng or mus e rep ace .

In icator Eye

• Green - Goo

• B ac - Lowe ectro yte eveor ow c arge

ES1 - 12

specific gravity varies more than 0.05 between any two cells.

o e: a rep acemen a er es may ave an n ca or eye u

into the battery. This is a reference only; a more thorough visual

inspection and state of charge test should be used.

Test Procedure:

. emove e caps rom e a ery ce s.

2. Squeeze the hydrometer bulb and insert the pickup

u e n o e ce neares o e pos ve erm na .

3. Slowly release the bulb allowing the electrolyte to

flow into the hydrometer only enough to cause the

oa o r se.



m o d u l e E S 16


Open-Circuit Voltage Test

n open-c rcu vo age es s mp y c ec s

ava a e a ery vo age w no oa . g a

voltmeter is used to check the battery’s open-

circuited voltage. The voltage reading indicates

e a erys s a e o c arge.

If the battery has just been charged, turn

the headlamps on for one minute to remove

any surface charge. Turn the headlamps off

and connect a voltmeter across the battery

terminals. A fully charged battery will have a

voltage reading of at least 12.6 volts. A dead

battery will have a voltage reading of less than

12.0 volts.

APACITY OR OAD EST

The capacity or load test is used to check the

a ery s a y o e ver a equa e cran ng

power. This test simulates a load on the battery

such as that provided by the starter motor.

A battery load tester, such as the Snap-On

MT1590 or the Sun VAT-40 is needed. Follow

the manufacturer’s recommended procedures

for the tester that you are using.

Before load testing a battery be sure to visuallyinspect the battery for defects and make sure

e a ery mee s or excee s e m n mum

state of charge requirement.

s ng e oa es er, s ow y app y a oa o

the battery until the ammeter reads 3 times

the amp-hour (AH) rating or one-half the cold

cranking ampere (CCA) rating. Maintain the

load for no more than 15 seconds.

If the voltmeter reading is above 10.0 voltse a ery s goo . e rea ng s . o .

volts, the battery is serviceable, but requires

charging and retesting. If the voltage reading is

e ow . vo s, e a ery s e er sc arge

or defective.

S1 - 15



m o d u l e E S 1 7


Battery Charging

o rec arge a a ery, curren mus e app e

o e a ery n e oppos e rec on o e

discharge flow. This restores the imbalance of

electrons in the battery. There are two basic

me o s o c arg ng e a ery: as c arg ng

and slow charging

as c arg ng s one y app y ng a g ra e

of current to the battery for a short period of

time. The fast charge method should not be

use on a comp e e y sc arge a ery, o

prevent damage to the battery. The maximum

recommended charging current is 20 amperes.

e s ow c arge me o w comp e e y

recharge the battery by charging with a lowercurrent for a longer period of time. The

max mum c arg ng curren s ou e ess an

1/10th of the battery capacity. For instance,

a 40 AH battery should be slow charged at 4

amps or ess.

CHARGE RATE CHART*

RC Rating AH Rating 5A 10A 20A 30A 0A

less than 75 ess than 48 10 hrs 5 hrs 2.5 hrs 2 hrs

2.5 hrs 2 hrs

115 - 160 75 - 100 20 hrs 10 hrs 5 hrs 3 hrs 2.5 hrs

- - rs rs . rs rs . rs

or u y sc arge a er es

ast c arg ng

Hig rate o current or s orttime

ax. current = 20 amps

S ow c arg ng recommen e

• Comp ete rec argeCurrent = 1/10 of battery’srat ng

CAUTION

emember that a battery may lose its chargew e t e ve c e s s tt ng on t e ot wa t ngor sa e ot rot . To avo an em arrass ngoment w t a customer or t e rep acement

of a battery, be sure to start vehicle inventoryo ten enoug to ma nta n a u c arge on t eattery. S1 - 18

Kia Specifications

ES1 - 16

-





m o d u l e E S 1 9


THE CHARGING SYSTEM

Components

The charging system consists of the ignition

switch, generator, voltage regulator, drive belt,

a ery an warn ng amp.

peration

When the ignition switch is turned to ON

or START, battery voltage is applied to the

charge indicator and terminals B and S of the

genera or. er e eng ne as s ar e an

Charging System

Ignition switc

enerator

• oltage Regulator

• rive Belt

• attery

• Warning Lamp

is running, the drive belt transfers a portion of the mechanical energy of the engine to

the generator to produce an alternating current. The alternating current flows through

a series of rectifier diodes within the generator and is converted to direct current. The

direct current and voltage keeps the battery fully charged and provides power to operatethe vehicle’s electrical systems. The amount of direct current and voltage the generator

outputs is controlled by the voltage regulator. On Kia vehicles, the voltage regulator is

built into the generator. If the voltage regulator senses that the output of the generator

is not sufficient for charging the battery, it will ground terminal L of the generator and the

c arge n ca or w um na e.

Stator

-

S1 - 22

erm na s

“B” Battery voltage

“L” arning lamp

circuit

“S” attery vo tage

o the regulator

egu ate e

o tage





m o d u l e E S 1 11


n opera on, e ro or urns ns e e s a or.

As the rotor turns, it induces an alternating

current or AC in the windings of the stator.

Automotive electrical systems are not designed to use alternating current. The

genera or uses a ev ce nown as a rec er o conver o . rec er s ma e

up of three sets of diodes. Diodes are semiconductors that allow current to pass in onedirection only. You can think of rectifier diodes as switches, operated by voltage polarity.

They turn on and conduct current when you apply one polarity; they turn off and block

current when you apply the opposite polarity. This is the process that converts AC to

DC.

B

L

SE

DC VoltageRectifier

AC Voltage

Diode

Stator Coil

Rotor

Coil

Battery

Ignition

switch

Warning Lamp

IC Regulator

Meter

BTN

Main

-







Charging System Warning Lamp

The Charging System Warning Lamp should

come on w en e gn on sw c s urne

ON. Current flows from the ignition switch to

the warning lamp. The ground is completed

roug e genera or erm na an con ro

circuit to the generator case that is grounded to

the engine.

BL

S

- +

Generator

Instrument

Panel

Meter FuseIGN SW

Main Fuse

Battery

If the warning lamp does not come on when the ignition is turned to ON, check for an

open n ca or u , own use or an open c rcu e ween e erm na an e

ignition switch.

When the ignition switch is turned to START and the engine starts the light will go out.

The generator control circuit opens the warning lamp ground and applies current to the“L” terminal. The diode in the warning lamp assembly protects the electrical system

from unwanted current flow in this mode.

If there should be a generator or control circuit malfunction, the “L” terminal will switch

ac o groun an urn e warn ng amp on.

-

31



m o d u l e E S 114


rior to iagnosis, c ec or:

u y c arge attery

Tig t connections

roper y a juste rive e t

Common pro em con itions:

o c arge

ow c arge

Overc arge

Charging System Diagnosis

Before attempting to troubleshoot the charging

sys em ma e sure a e a ery s u y

charged and will hold a charge. Then check

that all connections at the battery, generator,

ng ne ompar men use e ay ox, an

also throughout the charging circuit are correct

and making good electrical contact. Once you

ave e erm ne a e c arg ng sys em s

at fault the problem can be further diagnosed

by checking for the charge condition. Most

charging system problems come under one of

the following conditions: no charge, low charge

or overcharge.

Indication = Brightly lit warning lamp with engine running

robable cause

Loose drive beltDe ective generatorWiring pro em

ction

emove S L connectorNote warning amp, i :

• OFF - C ec generator output• ON - Check “L” terminal wire for short to ground

O CHARGE

If the charge warning lamp remains brightly lit with the engine running, the generator

s no c arg ng a a . ro en or ex reme y oose r ve e cou cause a no-

charging condition. If the belt is okay, the problem is in the charging system. Remove

the connector containing the “S” and “L” wires. If the warning lamp goes off, check

generator output. If the warning lamp stays on, check the “L” terminal wire for a short to

ground.

ES1 - 32

-





LOW CHARGE

If the charge warning lamp glows slightly, it means that the generator is charging, but

s ou pu s ow. e r ve e cou e oose. owever, e r ve e s ens one

correctly and is in good condition the problem is in the charging system. Check the

battery and its connections. If no problem is found, check the generator’s output

curren .

In ication = Warning amp g ows s ig t y

ro a e cause ction

oose rive e t A just rep ace rive e t• ow attery c arge Check battery state of charge• oose/dirty connections Check/clean connections ow generator output C ec generator output

In ication = requent burning out of fuses or lights apid depletion of electrolyte solution

robable cause Action

• Wiring/connector problem • Check for shorted/open wires &connector pro ems

irt or corrosion on t e attery C ean attery & termina s• e ective attery • C ec attery state o c arge• efective generator • Check generator output

VERCHARGE

requent burning out of fuses or lights or the repeated addition of water to the battery

may be an indication of a generator that is overcharging the system. Make sure all the

connections on the generator are clean, tight and correct. If everything is okay, the

charging system is at fault.

emove the connector containing the “S” and “L” wires from the generator. Turn the

ignition switch to ON but do not start the engine. Connect a voltmeter between the “S”

erm na an groun . no vo age s presen , e c rcu e ween e erm na an e

battery is either grounded or open. Repair as required.

e- ns a e connec or. un e eng ne a a mo era e spee w a accessor es

off and measure the battery voltage. If the voltage is above 16.0 volts replace the

genera or.

ES1 - 34

ES1 - 35



m o d u l e E S 116


Charging System Troubleshooting

Problem Possible Cause Action

Warning lamp does

not go out with engine

runn ng; no c arge, ow

charge or overcharge.

o se

1. Blown fuse

2. Lamp burned out

3. Open circuit between

he “L” terminal and the

gn on sw c

1. Loose or worn drive

belt

2. Defective battery or

battery connections

3. Defective wiring

4. Defective generator

. oose or worn r ve

belt

. orn genera or

bearings

3. Defective diode in the

generator

1. Check METER fuse;

replace if needed

. ec amp; rep ace

needed

3. Check for open in

circuit; repair as needed

1. Check drive belt; adjust

or replace if needed

2. Check battery and

connections; charge or

rep ace as nee e

3. Check voltage drop on

c rcu

4. Check charging system

ou pu

1. Check drive belt; adjust

or rep ace as nee e

2. Replace generator

3. Replace generator

arn ng amp oes no

light, with ignition ON

and engine off.





THE STARTING SYSTEM

One of the most important functions of the vehicle’s electrical system is starting the

eng ne. s s accomp s e y e s ar ng sys em w c cons s s o wo ma or

components, the starter motor and the battery. Other related components that make up

the starting system are the ignition switch and the automatic transmission range switch

or s ar er c u c pe a pos on sw c .

The starter motor converts electricity from the battery into rotational movement to turn

the flywheel connected to the engine’s crankshaft. The starter must crank the engine

fast enough and for a sufficient length of time until the Engine Control Module has

ensured the proper fuel and ignition are provided in order to keep the engine running.

Once the engine is running the starting system’s job is done and is no longer needed

until the next time the engine needs to be started.

tarter Motor Types

Two different types of starter motors are

used on Kia vehicles, a direct drive s ar er

mo or or a gear re uc on s ar er mo or. e

conventional starter motor is used on Kia

models with manual transmission/transaxle.

e gear re uc on s ar er mo or s es gne

o re uce e spee an ncrease e orquerequired to start vehicles with automatic

transmission/transaxles.

The two starter motors are different

mechanically but electrically they operate

identically. Both starters consist of a motor, a

solenoid, a drive pinion and a housing.

• Direct drive (manual)

• Gear reduction (automatic)

ES1 - 37



m o d u l e E S 118


The Starter Motor Assembly

e s ar er mo or s an assem y a nc u es

a s an ar mo or an a so eno . e

motor does the actual work of changing the

electrical energy into mechanical energy. The

so eno s an e ec romagne c sw c a

performs two functions. It actuates a lever that

slides the pinion drive gear forward to engage

with the flywheel. It also serves as a heavy

duty relay for current to flow to the starter

mo or.

The Starter Clutch Pedal Position Switch(Manual Transmission/Transaxle Vehicles)

The clutch pedal position (CPP) switch is asafety switch which closes the circuit between

the starter and the ignition switch when the

clutch pedal is depressed.

The Transmission/Transaxle Range Switch(Automatic Transmission/Transaxle Vehicles)

The transmission/transaxle range switch

per orms e same unc on as e c u c

pedal position switch. When the transmission/

transaxle is in NEUTRAL or PARK, the

c rcu o e s ar er so eno s c ose . e

transmission/transaxle is in any other position

the circuit is open and the starter will notopera e.

-

-





This page is intentionally blank.



m o d u l e E S 120


Starting System Operation

IGNITION IN OFF POSITION

• attery voltage is applied at all times from

he positive battery terminal to the ignition

sw c an e norma y open s ar ersolenoid contacts.

IGNITION IN START POSITION

• Current flows through the STARTER fuse

(Sephia Only) to the transmission/transaxle

ange sw c u oma c or e s ar er

clutch pedal position switch (Manual).

• f the range switch is in either PARK or

EUTRAL or the clutch pedal position

switch is closed, the current will flow

roug e s ar er so eno o - n an

ull-in coils.

• e s ar er so eno co s energ ze, w c

c ose e s ar er so eno con ac s an

he battery voltage is applied to the starter

otor. At the same moment, the solenoid

unger pu s e r ve ever o mes e

inion drive gear with the flywheel. The

starter motor engages to crank the engine.

IGNITION IN ON POSITION

• Current no longer flows to the starter

solenoid.

• The magnetic fields in the coils diminish

a ow ng e s ar er so eno con ac s o

open.

• Current to the motor is cut off and the

solenoid plunger is pushed back by spring

ressure that causes the pinion drive gear

o disengage from the flywheel.





m o d u l e E S 122


TROUBLESHOOTING

Symptom Possible Cause Action

ng ne w no cran ,

u s ar er sp ns

Cranks slowly

• ea a ery

• Blown STARTER fuse(Sephia Only)

• Loose connections

• au y gn on sw c

• Faulty CPP switch or TR

switch

• Open circuit in harness

• au y s ar er so eno

• Faulty starter motor

• ec an ca pro em n eng ne

• Starter drive pinion gear

no engag ng

• Weak battery

• oose or corro e

connections

• Faulty starter motor

• Mechanical problems

with engine or starter

• Charge or replace battery

• Replace fuse

• Check connections at

battery, starter and harness

• ep ace gn on sw c

• Replace CPP or TR switch

• Check harness

• Replace starter solenoid

• Replace starter motor

• Check engine

• Check for starter drive

p n on gear movemen .

Replace starter if needed

• Check for damaged teeth

on flywheel and pinion gear.

Replace as needed

• Check battery and charge

as needed

• Clean and tighten

connections

• Test starter

• Check engine and starter,

epair or replace as needed

ng ne w no cran ,

starter motor does

no opera e

Starter keeps running • Damaged pinion or ring gear

• Faulty plunger in solenoid

• au y gn on sw c

• Short to battery in starter

circuit

• Check gears for wear ordamage

• es s ar er so eno

• Check ignition switch

• Check harness





1. A battery’s reserve capacity ismeasured in:____

.

b. wa s

c. amp-hours

d. minute

2. When doing an Open-Circuit

Voltage Test on a fully charged

battery, an acceptable voltage

rea ng wou e:____

. 9.6 voltsb. 11.5 volts

. . vo s

d. 15.3 volts

. o ge e es c arge you

should fast charge a completely

discharged battery.

. rue

b. alse

4. The generator works on theprinciples of:____.

a. mechanical induction

b. electromagnetic induction

. ermo ynam c n uc on

d. semiconductors

. n w c o e o ow ng genera or

components is the electrical

current produced?

. s a or

b. ro or . rec er

d. regulator

6. What is used to change the AC voltage, that thegenerator produces, to DC voltage so that the

ve c e can use .

a. voltage regulator

b. relay

. stator and rotor

d. rectifier

. c o e o ow ng s a pro a e cause or a

low charge on a battery?

a. loose drive belt

. corro e a ery connec onsc. defective wiring

. a o e a ove

8. Which of the following is not a function of the

starter solenoid?

a. Serves as a heavy duty relay for current to flow

to the starter motor

b. Sends a signal to the ECM when the starter is

urn ng

c. Actuates the lever that slides the pinion drive

gear forwardd. ouses the pull-in coil and hold-in coil

. a causes e so eno p unger o re urn o

its normal position when voltage is stopped to

the starter motor?

. magne c orce

b. gravity

. spr ng pressure

d. centrifugal force

10. A mechanical problem within the engine couldcause e s ar er o con nue o opera e a er

the engine has already started.

a. rue

. a s e

This self-test will enable you to measure the

now e ge a you ave ga ne a ou a

Electrical Systems. Circle the one best answer

that completes the statement or answers the

ques on.









epartment

/99

Part Number: KC-ES1



Battery, Charging

and Starting

Systems

APPLICATIONS

Automotive

Electrical Course



ES2

Stator

Coil

Rotor

Coil

Warning Lamp

Diode

IC Regulator

ETER

IGNBTN

MAIN

Battery

AC Voltage

Rectifier

DC Voltage





BATTERY, CHARGING

AND STARTING SYSTEMS APPLICATIONS

m o d u l e E S 22

Battery Testing

In this exercise you will be assigned to a vehi-

cle and will do the following checks.

• attery visual inspection

• pec c rav y es

• Open Circuit Voltage Test

• Capacity or Load Test

VISUAL INSPECTION

Check Condition Recommendation1. Case _____________________ __________________________

2. Terminals _____________________ __________________________

3. Cables

4. Connectors _____________________ __________________________

. o - own

6. Drive Belt _____________________ __________________________

7. Electrolyte _____________________ __________________________

8. Plates



BATTERY, CHARGING


m o d u l e E S 2 3

HYDROMETER TEST

Cell pecific Gravity emperature Adjusted S.G. % Charge

1 _______________ ____________ ____________ _________

2 _______________ ____________ ____________ _________

3

4 _______________ ____________ ____________ _________

6 _______________ ____________ ____________ _________

BATTERY CONDITION: ____ Good

____ Needs Charge

____ a

____ Requires Further Testing



BATTERY, CHARGING


m o d u l e E S 24

PEN-CIRCUIT VOLTAGE TEST:

1. Set voltmeter to read DC volts.

. onnec pos ve ea o vo me er o pos ve erm na o a ery.

3. Connect negative lead of voltmeter to negative terminal of battery.

. ecord reading. _________ volts

. s the voltage reading at least 12.6 volts? ____ es ____ o

6. s the voltage reading less than 12.0 volts? ____ Yes ____ No

EAVY-LOAD TEST

1. Visually inspect battery and ensure that battery meets or exceeds the minimum state

of charge requirement.

2. nsure that the engine and all accessories are OFF.

. Connect the positive (red) clamp of the battery tester to the positive (+) battery post.

. Connect the negative (black) clamp of the battery tester to the negative (-) battery

pos .

5. etermine the battery load test specification. (1/2 of battery’s CCA or 3 times thebattery’s amp-hour rating). What is the battery’s load test specification? _____

6. Set the load on the battery tester.

. Set the timer on the battery tester for 15 seconds.

8. ress the LOAD TEST start button.

. e oa w re ease an e sp ay w reeze w en e mer reac es . a

was the voltage reading at the end of the 15 seconds? _____

. s the battery within specifications?____ es ____ o



BATTERY, CHARGING


m o d u l e E S 2 5

Charging System Voltage Check

1. Turn the ignition ON but do not start the

eng ne.

2. easure the voltage at the generator ter-

inals B, L and S.

3. ecord the voltages in the table below.

. ar e eng ne an a ow o e.

. easure the voltage at the generator ter-

inals B, L and S.

6. ecord the voltages in the table below.

Are the voltage measurements that

you got within specifications?

____ Yes ____ No

Specification

Terminal

B

S

Ign: On (V) dle (V)

Terminal

B

S

Ign: On (V)

pprox.

Approx. 1

Approx. 12

dle (V)

. - .

14.1 - 14.7

14.1 - 14.7

erm na

“S” Terminal

“L” Terminal



BATTERY, CHARGING


m o d u l e E S 26

Charging System Test Using thenap- n - ester

Using the Snap-On MT-1590 tester, check the

c arg ng sys em.

Alternator Current Output Test

. e ore per orm ng e a erna or ou pu es ensure e a ery s u y c arge

and passes the load test. Also visually inspect the alternator, drive belt and wir-

ing.

2. The engine should be at operating temperature and all electrical accessories

should be turned OFF

3. Connect the load leads across the battery (red to positive and black to negative).

4. Zero the AMPS DISPLAY and make sure the ALTERNATOR

s on.

5. Make sure tester is in BATTERY VOLTS FUNCTION.

6. Clamp the AMPS PROBE around the alternator output wire at least 6” from alter-

nator.

. us e o secon s.

8. Press the ALTERNATOR OUTPUT TEST START key, start engine and set RP

e ween , an , .

9. Observe MAXIMUM AMPS reading. Kia minimum specification is 65A.

. serve or con on o e a erna or

diodes.

Voltage Regulator Test

1. Perform steps 1 - 6 of Alternator Current Output Test.

2. Operate engine at moderate speed as required with all accessories off. Allow

some running time for the charging system to stabalize (charging system should

be at operating temperature).

3. Observe VOLTS and AMPS readings. Charging system voltage should be

e ween . o . vo s w ess an amps c arg ng curren .



BATTERY, CHARGING


m o d u l e E S 2 7

Starting System Test Using theSnap-On MT-1590 Tester

Using the Snap-On MT-1590 tester, check the

starting system.

Starting System Test

1. Perform pre-test: Check battery, wiring, connections and mounting of starter and

solenoid.

2. Turn off all the vehicle’s electrical accessories. Ensure battery is fully charged

and that the engine is at shop temperature.

3. Disable the ignition or fuel system.

4. Connect LOAD LEADS across the battery, red to positive and black to negative.5. Zero AMPS DISPLAY, if it does not read zero.

. Make sure tester is in BATTERY VOLTS FUNCTION.

7. Connect the AMPS PROBE around the starter cable.

. ress e o a us e eng o me or e es e ween

15 to 20 seconds.

. Press the STARTER DRAW TEST START KEY. The TIMER DISPLAY will begin

counting down automatically.

. Engage the starter when about 7 seconds are left on the TIMER DISPLAY and

continue cranking until the TIMER DISPLAY reads “0”, which freezes amps and

volts readings.

. ar er raw or a rec r ve s ar er s ou e o amps. ar er

draw for a gear reduction (AT) starter should be 150 to 250 amps.



BATTERY, CHARGING


m o d u l e E S 28

UICK GENERATOR BENCH TEST

ngs you w nee :

1. Generator

2. Work bench

3. Power source (i.e.: Fully charged 9v b

4. Ammeter

. re es ea

6. 1 black test lead

ns ruc ons:

1. Place generator on bench.

2. Make sure ammeter is set to highest scale.

3. Connect the positive (red) lead of ammeter to the B terminal of the generator.

4. Connect the negative (black) lead of the ammeter to the negative (-) terminal of

the battery or negative post of the power supply.

5. Connect the black test lead between the generator housing and the negative (-)

terminal of the power source.

6. Connect the red test lead between the L terminal of the generator and the posi-

tive (+) terminal of the power source.

. urn e genera or pu ey y an an o serve e curren rea ng on e

ammeter.

“B” Terminal

“S” Terminal

“L” Terminal





BATTERY, CHARGING


m o d u l e E S 210

GENERATOR STATOR INSPECTION

en e genera or s oun o e e ec ve a enc es can e one on e compo-

nents of the generator to determine the exact problem within the generator.

con nu y c ec o e s a or s ou e one o e erm ne s serv cea y. An ohmmeter will be needed to complete these tests.

Continuity Between Coil Leads

Check for continuity between the stator coil leads.

s there continuity between the leads?_____ Yes _____ o

The stator is defective if no continuity.

Continuity Between Stator CoilLeads and Core

Check for continuity between the sta-

tor coil leads and the core.

s ere con nu y e ween e co

ea s an e core

_____Yes_____No

The stator is defective if continuity

exists.



BATTERY, CHARGING



Negative (Black) Positive (Red) Continuit

When the generator is found to be defective, a bench test can be done on the compo-

nents of the generator to determine the exact problem within the generator.

A continuity check of the rectifier should be done to determine its serviceability.n o mme er w e nee e o comp e e ese es s.

Continuity Between Diodes

Using the table below, check for continuity between each of the terminals.

, , o

P1, P2, P3 Yes

, , es

1, P2, P3 E Yes

1, P2, P3 B No

2, P3 T No

as the rectifier you checked good or bad?_____ Good _____

ad



BATTERY, CHARGING


m o d u l e E S 212

1. Check continuity between commutator and core with ohmmeter.

s continuity present?

Replace armature if there is continuity.

2. Check continuity between commutator and shaft with ohmmeter.

s continuity present? ______________ Yes ____ No

Replace armature if there is continuity.



BATTERY, CHARGING



1. Check for continuity between S and B terminals

w an o mme er.

Is continuity present? ____ Yes ____ Noep ace so eno ere s con nu y.

2. Check for continuity between S terminal and

solenoid body with ohmmeter.

Is continuity present? ____ Yes ____ No

Replace solenoid if there is no continuity.

3. Check for continuity between M and B termi-

na s w o mme er.


Replace solenoid if there is continuity.

4. Check for continuity between S and M terminals

w an o mme er.


ep ace so eno ere s no con nu y.







Documents

Automotive Electrical Course - Service Training 1999