Daewoo 1.6 + ++2 +n+s + ( Ú )

TRUCK
ELECTRIC TRAINING
Maintenance training 2011 . 2
CONTENTS
1. ElECTRICAL SERVICE MANUAL ------------------------- 5
2. ElECTRICAL PARTS (Relays, switches) ---------------- 15
3. GROUND -------------------------------------------- 35
4. POWER LINE --------------------------------------- 43
5. CIRCUIT OF ELECTRIC SYSTEM --------------------- 51
6. METER CLUSTER ----------------------------------- 65
7. ECU OF DE Engine (Semi-electronic) ---------------- 75

1. ElECTRICAL SERVICE MANUAL
Learning Objectives
1. Understanding service manual

Note
Electric Circuit Diagram
-7- Customer Service Team, TDCV

Electric Circuit Diagram
Main color line color
Violet
Connector : Male Connector : Female

Terminal : Female Terminal : Male

Locations of Electrical Harnesses






2. ElECTRICAL PARTS
(Relays, switches)
Learning Objectives
1. Understanding Type of relay and operation principle
2. Understanding Type of switches and operation principle

Note
Understanding Relays
Relay front Relayed back

1. What is relay?
▶ Relay can control big current and voltage by small signal or voltage.
“Relay is switch controlled by small electrical signal”
2. How to operate
▶ Contact point is disconnected by power of spring usually.
When the power is supplied into relay, induced electromotive force is created on coil.
And electromagnet pull a piece of iron and contact point is connected..
(Relay is same as mechanical switch except electromagnetic function)

3. Type of Relay
1) “A” Type relay (Normal open type)
Contact point is disconnected usually.
But if signal (voltage) is supplied into relay, contact point is connected
(※Caution : direction of diode)

2) “B” type relay (Normal close type)
Contact point is connected usually.
But if signal (voltage) is supplied into relay, contact point is disconnected.

3) “C” type relay

“A” type relay and “B” type relay are combined

30
Terminal location of relay
86 87A 85
(Bottom view of relay)
87
Motor
87a
(4)
Fuse
30
(3)
Lamp
20A 87
(5)
Valve
85 86
Fuse (1) (2)
10A
Switch
- + - +
24V BATT 24V BATT
Battery

Circuit of Relay
“Circuit type1 Circuit type 2 Circuit type 3
30 30 30
58 F2 F2
F2 15A 15A
15A
85 30 85 30 85 30
86 87 86 87 86 87 87a
Switch Switch
Operating Parts Operating Parts Part is working

Ex) Light, Temperature, Ex) Light, Temperature, Ex) Relay, Motor, ECM
31 31 31

Understanding Switch
Switch side view Bottom of switch

Circuit of Switch
Circuit type 1 Circuit type 2 Circuit type 3
30
58 58 58
Green, Red Green, Red White Green, Red
C131
F31
1
15A
1 4 1 4 1 4
Caution :
Some switches are
LED type
3 2 5 3 2 5 3 2 5
F31
15A
Operating Parts Operating Parts Operating Parts

Ex) Light, Temperature, Ex) Light, Temperature, Ex) Control Unit, ECM
31 31 31

Circuit of Switch
Circuit type 4 Circuit type 5 Circuit type 6
15b 15b
58
Green, Red
C131
F31
1
15A
1 4 1 1
3 2 5 2 2
Operation Parts Operation Parts Operation Parts

Ex) Unit, ECM Ex) Light, Temperature, Ex) Control Units, ECM
31 31

Understanding of Fuse
1. What is “Fuse”
▶ Fuse is wire which is made of lead and tin. If current is higher than allowed current,
it is melted and disconnect electricity flow to protect a wiring harness damage.
Normal Bad (Short circuit)

Fuse and relay box
▶ Fuse & relay box layout

Fuse and relay box
▶ Fuse & relay box located in the center consol of Cabin

and supply electric power to electric device.
Fuse
Blinker unit
Relay
Controller unit

Auxiliary Fuse box and Symbol
See enlarged

Sub relay Symbol and Controller (Vehicle Type 1)
Inside the stowage
Rear
panel
Front
panel

Inside the stowage

Rear
panel
Front
panel

Inside the stowage
Rear
panel
Front
panel

Note
3. GROUND
Learning Objectives
1. Understanding the ground of vehicle

(-)
Note
Understanding of ground
1. Purpose of Ground
▶ To reduce the material cost of wire harness and to reduce the rate of w/harness problem
▶ If ground (-) is located at near parts, abnormal power and electromagnetic waves can be reduced.
It can be protected the abnormal electric phenomenon of electronic parts .
2. Ground Position
▶ Ground positions are located on side frame of rear side of battery, Radiator Side frame,
Front Lid Inside (Bottom of Multi Connector)

Locations of Frame Ground

Locations of Frame Ground
Right
G100
G312
G110
G108
G103 G109
G312
Front
G200 G312
G106
G107
G312
－＋
Left

Position of Ground Connections
See enlarged
inside front Lead
Electrical Maintenance

Locations of Cabin Ground

Note
4. POWER LINE
Learning Objectives
1. Understanding Power line

Note
Fuse and relay Layout
Power : Bat (+) Power : ACC
Power(+) supply from battery
Power : Key on Head lamp
Aircon relay ABS relay Wiper high relay
H / lamp low relay ACC relay Wiper on/off relay
Horn relay Converter relay E.C.U relay
Red wiring
Blue wiring
H / lamp high relay F / fog lamp relay Tail lamp relay
F US E CA P A FUS E CA P A
DE S CR IP T IO N DE S CR IP T IO N
NO CIT Y NO C IT Y
1 6
2 30(A) THE ROOM FUSE #31 ~ #33 B+ (라이트) 7 30(A) CAB TILT BOX B+
3 20(A) TRAILER ABS B+ 8 30(A) M IXER SWITCH BOX B+
4 50(A) STARTER SWITCH "IG" RELAY #30 9 15(A) CONDENSER FAN M OTER RELAY #30
Wiper intermitent relay Timer Unit Auto-Door Lock Unit Mirror Heat Unit THE ROOM FUSE #1 ~ #11, #23,24＃
B+ 29
5 50(A)
ACCESSARY RELAY(30) B+
F US E CA P A F US E CA P A
D ES C R IP T IO N D ES C R I P T IO N
NO CI T Y NO C IT Y
1 15 IGNITION SWITCH , METER 18 20 AIR CON, , BLOWER MOTER , FRE&REC SW

White wiring White wiring
2 10 ROOM LAMP , DOOR STEP LAMP , KEY HOLE UNIT 19 10 CAB TILT , CAB LOCK SW
3 15 DC-DC CONVERTER 20 10 PREHEATER UNIT
4 10 CLOCK(B+) , CASSETTE(B+) 21 10 CASSETTE , CLOCK
5 15 ENGINE STOP MOTER , KEY BOX 22 10 BED HEATER , CIGAR , SEAT HEATER 2-7. THE OTHERS RELAY ( inside the stowage )
6 15 ABS C1-8 23 20 CUSTOMER SERVICE
7 10 ABS C1-9 24 15 CUSTOMER SERVICE
8 15 BLINKER UNIT 25 10 AUTO GREASE UNIT
9 15 DOOR LOCK , HORN , KEY LESS LAMP 26 5 ABS C1-7
10 10 FOG LAMP RELAY 27 5 TRAILER ABS(IGN+)
11 20 P / WINDOW SWITCH 28 15 WIPER SYSTEM , COMBI SW
12 10 MIRROR HEATER 29 15 DE12TIS POWER R #30
13 10 PTO , DIFF LOCK(L/R) , SPLIT 30 30 ECM MEMORY CIEAR , ECM POWER R #85 , IG relay
14 10 LOCK BRAKE S/W 31 15 HEAD LAMP HIGH R #30 / #85
15 10 STOP LAMP 32 15 HEAD LAMP LOW R #30 / #85
16 10 B / UP LAMP 33 10 TAIL LAMP R #30 / #85
17 15 WORKING LAMP

Locations of Power
Right
To inside cabin
Head Light Power

Constant Power
Relay power of Key “On”
Starter Motor
Front
－＋
보조 FUSE 박스
Left

Photo of Power Wiring
Relay : ignition Auxiliary Fuse and Relay
※ If vehicle long time parking or need to cut the main power,

disconnect No 5 connector. (red wire connector)
Because of preventing of battery discharging

Position of Ground and Power Connections
See enlarged
inside front Lead
Electrical Maintenance

Key Box Connector
Key Box “Close” 24V output

(Red / Yellow)
FUSE No 5
(Blue / Yellow)
Key “ACC” 24V Output

(Blue / Red)
Fuse No1 24V

(White/ Red)
Key “Start” 24V output Key “On” 24V Output

(Blue / Orange) (Black / White)
Ignition Key Box

Note
5. CIRCUIT OF ELECTRIC SYSTEM
Learning Objectives
1. Understanding electric circuit

Note
Startup Concepts
Alternator rotation
Charge
Alternator
Engine rotation
Starter Motors
DE12TI DV15TI
Starter motor and battery charging
DE12TIS
Starting signal
Injection Pump
Injection pipe Injection Nozzle
Ignition switch
Cylinder piston
Injection Flanger
- + - +
24V BATT 24V BATT

circuit diagram - Starter motor and starter switch
start
Starter switch Transmission neutral switch
Starter relay Sub starter switch

circuit diagram – Battery Charging
Warning Battery charge G (Alternator)

circuit diagram - Lighting
Head lamp low
start
Head lamp S/W Head lamp high relay C202 Connector

circuit diagram – Air con & Heater

circuit diagram – Air con
old
Bloewr switch Air con switch Temperature

switch new
Air con relay Dual pressure switch Air con compressor
FAN motor relay Fan motor

(MICRO)

circuit diagram - Split system (ZF / T14 Transmission)
T/M Split low
T/M Split high
T/M high S/W
start
T/M Split S/W Split low / high M/V Split air supply

ZF-16S Sensor location
Reverse Switch
Neutral switch
Split switch
Range low / high switch
LH side of transmissions
Top of Transmissions

T-14 Sensor location
Split switch
Neutral switch
Reverse Switch
Transmissions at the top

circuit diagram – Cap Tilt
start

Operating of Cap Tilt
1. After Key
“ACC”
2. Pull hoot lever. 3. Push cab tilt operate switch.

Then cab lock switch is working.
Cab lock S/W Diode array

Exhaust Brake circuit diagram
Key “on” 24V supply
start
Head lamp S/W
Head lamp S/W Head lamp S/W Split low / high M/V

6. METER CLUSTER
Learning Objectives
1. Understanding Meter Cluster

Note
circuit diagram – Meter cluster

Photo of Meter cluster
Meter Cluster Front View
32P “B”
CONNCTOR
32P “C”
CONNCTOR
16P “A”
CONNCTOR
Rear View

circuit diagram – Meter cluster

Pin position of Meter cluster
Meter Cluster Rear

View

Warning symbol of Meter cluster

Gauge of Meter cluster

Function of Warning Buzzer

Note
7. ECU OF DE Engine (Semi-
electronic)
Learning Objectives
1. Understanding Semi-electronic ECU

Note
Semi-electronic Startup Concepts
Alternator rotation
Charge
Alternator
Engine rotation
Starter Motors
DE12TI
Starter motor and battery charging
DE12TIS
Semi-electronic control is
Starting signal
Key ON 24V in put
ECU
Injection Pump
Injection pipe Injection Nozzle
Ignition switch
Cylinder piston
Injection Flanger
- + - +
24V BATT 24V BATT

Semi-electronic Sensor location
Water Temp sensor
RH direction LH direction
of the engine of the engine
Air heater relay
Rack sensor (and)
(※ Not applied on tropical regions)
Pre-stroke actuator
NE sensor
(Engine speed sensor)

Semi-electronic Sensor location
2 5
1
4
3
RH direction LH direction Back direction
of the engine of the engine of the engine
1. Pre-stroke actuator 2. Rack sensor 3. NE sensor
4. Air heater relay 5. Water Tempe sensor

(※ Not applied on tropical regions)
※Material / Source : Engine Maintenance Manual

Function of DE engine ECU sensor
Water Tempe sensor

Engine warning lights
NE sensor
(Engine speed sensor)
(Air heater relay ON/OFF)

ECU output
input Rack sensor
Pre-stroke actuator
Pre-stroke sensor
◈ Water Tempe sensor

→ Check coolant temperature and adjust inject timing and preheat
◈ NE sensor
→ Check engine rpm and decide fuel inject timing.
◈ Rack sensor
→ Check rack position
◈ Pre - stroke sensor
→ Check stroke actuator position
◈ Engine warning lights
→ To flash warning lamp of meter cluster, if occurred problem

circuit diagram – Semi electronic

circuit diagram – Semi electronic
Engine harness
Dash harness
Separation
ECU

DE - Fault code
Fault
Fault information Solution
code
11 Normal code
12 Pre-stroke control servo error Check Wiring harness of Actuator and ECU Power
13 Pre-stroke sensor error Check Wiring harness of Actuator and ECU Power
14 Pre-stroke offset learning error Check Wiring harness of Actuator and ECU Power
Check voltage between ECU connector and

15 Pre-stroke actuator power error
27.47 terminal
16 NE sensor error Check NE Sensor and Wire harness
21 Water Temp sensor error Check coolant sensor and wiring harness
22 Fuel Rack sensor error Check rack sensor and wiring harness
23 Intake Air heater relay error Check relay and wiring harness ※ Not applied on tropical regions

Engine self-diagnostic and repair hint








circuit diagram – DE12TIS ECU
Rack Sensor
Temperature sensor NE(Pick-up) Sensor

circuit diagram – DE12TIS ECU
Prest Sensor
Prest Actuator

Order of How to diagnose
1. After Key off (Engine stop), 2. Check position of failure diagnose connector which 3. Separate white connector of failure
Open the stowage box of passenger side located above ECM. (Covered by black tape) diagnose connector.
▶ diagnostics
①. Using Diagnose tool. (SCAN 200)

②. Check flash signal of warning lamp(DIAG)
a. Failure code displays two digits,
First code is 10-digit number and flash for 1 second.
Second code is 1-digit number and flash for 0.5 second and pause 3 second
b. If more than two failure were occurred on vehicle, latest failure code is displayed
and remaining failure codes will be displayed two times.
4. After Key on, check “CEL” lamp.
1sec 1sec 1sec 1sec ON
 Normal conbition (11 code) 1sec 1sec 1sec
OFF
1sec 1sec 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
ON
 Failure Code (16 ode)
OFF

Order of diagnose Code deleted
1. Key off after

vehicle repair
2. Separate black connector of diagnose connector 3. After Key On, failure code is deleted soon.
which located on ECM.
▶ How to delete
①. To use diagnose (SCAN 200)

②. To separate black connector of diagnose connector and Key On
4. Re-assemble connector after deleting failure code.

Note
To produce world-class quality
Thank you

Daewoo 1.6 + ++2 +n+s + ( Ú )

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TRUCK

1. ElECTRICAL SERVICE MANUAL ------------------------- 5

2. ElECTRICAL PARTS (Relays, switches) ---------------- 15

4. POWER LINE --------------------------------------- 43

5. CIRCUIT OF ELECTRIC SYSTEM --------------------- 51

6. METER CLUSTER ----------------------------------- 65

7. ECU OF DE Engine (Semi-electronic) ---------------- 75

1. Understanding service manual

-7- Customer Service Team, TDCV

Main color line color

Connector : Male Connector : Female

-8- Customer Service Team, TDCV

-9- Customer Service Team, TDCV

-10- Customer Service Team, TDCV

-11- Customer Service Team, TDCV

-12- Customer Service Team, TDCV

-13- Customer Service Team, TDCV

-14- Customer Service Team, TDCV

2. Understanding Type of switches and operation principle

Relay front Relayed back

-17- Customer Service Team, TDCV

“Relay is switch controlled by small electrical signal”

▶ Contact point is disconnected by power of spring usually.

And electromagnet pull a piece of iron and contact point is connected..

(Relay is same as mechanical switch except electromagnetic function)

-18- Customer Service Team, TDCV

(※Caution : direction of diode)

-19- Customer Service Team, TDCV

2) “B” type relay (Normal close type)

Contact point is connected usually.

But if signal (voltage) is supplied into relay, contact point is disconnected.

-20- Customer Service Team, TDCV

3) “C” type relay

-21- Customer Service Team, TDCV

-22- Customer Service Team, TDCV

“Circuit type1 Circuit type 2 Circuit type 3

Operating Parts Operating Parts Part is working

-23- Customer Service Team, TDCV

Switch side view Bottom of switch

-24- Customer Service Team, TDCV

Circuit type 1 Circuit type 2 Circuit type 3

Green, Red Green, Red White Green, Red

Operating Parts Operating Parts Operating Parts

-25- Customer Service Team, TDCV

Circuit type 4 Circuit type 5 Circuit type 6

Operation Parts Operation Parts Operation Parts

-26- Customer Service Team, TDCV

it is melted and disconnect electricity flow to protect a wiring harness damage.

Normal Bad (Short circuit)

-27- Customer Service Team, TDCV

▶ Fuse & relay box layout

-28- Customer Service Team, TDCV

▶ Fuse & relay box located in the center consol of Cabin

-29- Customer Service Team, TDCV

-30- Customer Service Team, TDCV

Inside the stowage

-31- Customer Service Team, TDCV

Inside the stowage

-32- Customer Service Team, TDCV

Inside the stowage

-33- Customer Service Team, TDCV

1. Understanding the ground of vehicle