light FORD KUGA 2011 1.G Owner's Manual

Charging System
Refer to Wiring Diagrams Section 414-02, for
schematic and connector information.
General Equipment
Midtronics EXP-1050 battery tester
Midtronics GR590-2
Ford diagnostic equipment
Inspection and Verification
WARNINGS: Batteries contain sulphuric acid. Avoid
contact with skin, eyes, or clothing. Also,
shield your eyes when working near
batteries to protect against possible
splashing of the acid solution. In case of
acid contact with skin or eyes, flush
immediately with water for a minimum of
15 minutes and get prompt medical
attention. If acid is swallowed, call a
physician immediately. Failure to follow
these instructions may result in personal
injury.
Batteries normally produce explosive
gases which can cause personal injury.
Therefore, do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near a
battery, always shield your face and
protect your eyes. Always provide
ventilation. Failure to follow these
instructions may result in personal injury.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
or electrical damage.
Visual Inspection Chart Electrical
Mechanical
– Fuse(s)
– Wiring harness(es)
– Generator
– Electricalconnector(s)
– Battery junction box (BJB)
– Battery
– Battery cables
– Battery monitoring sensor (BMS)
– Charging system warning indicator
–
Accessory drive belt
– Generator
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. Check the operation of the charging system warning indicator lamp, located in the instrument
cluster. Normal operation is as follows:
Normal Charging System Voltages Charging System
Warning Indicator Operation
Engine to
battery ground
Battery
Gener-
ator B+ Circuit
I Circuit
Ignition Switch
Position
OFF
0V
10-12V
10-12V
0V
Position 0
Illuminated
0V
10-12V
10-12V
0V
Position II
OFF
0V
13-15V
13-15V
13-15V
Position II with
the engine
running
5. If the cause is not visually evident, verify the symptom and refer to the Component Tests. Component Tests
Generator On-Vehicle Tests - No-Load Test
1. Turn off all electrical loads and the ignition
switch. G1055063en
2008.50 Kuga 8/2011 414-00-2
Charging System - General Information
414-00-2
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Battery Disconnect and Connect
Disconnect
WARNINGS:
Batteries normally produce explosive
gases which may cause personal injury,
therefore do not allow flames, sparks or
lighted substances to come near the
battery. When charging or working near
the battery always shield your face and
protect your eyes. Always provide
adequate ventilation. Failure to follow
these instructions may result in personal
injury.
The supplemental restraint system (SRS)
is active for a certain length of time after
the power supply has been disconnected.
Wait for a minimum of 3 minutes before
disconnecting or removing any SRS
components.
Audio unit key code saving devices must
not be used when working on
supplemental restraint or fuel systems.
When using these devices the vehicle
electrical system is still live but with a
reduced current flow. Failure to follow this
instruction may result in personal injury.
CAUTION: Make sure the engine is not
running before disconnecting the battery
ground cable to avoid damage to the
vehicle electrical system.
NOTE: Disconnecting the battery will erase fault
codes, drive values and customer data stored in
the modules.
NOTE: This procedure should be used to
disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Refer to: Battery and Battery Charging Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. Obtain and record the audio unit keycode and
preset radio frequencies. 3.
G1062389en
2008.50 Kuga 8/2011 414-01-2
Battery, Mounting and Cables
414-01-2
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Direct Current/Alternating Current (DC/AC) Inverter – Overview
Function indicator
WARNING: For workshop repairs, it is only
permissible to replace the converter as a
complete unit together with the wiring
harness and the socket. The component
must not be opened, as charged capacitors
inside can still carry dangerously high
residual voltages.
The LED in the socket lights up orange when the
converter is supplying a voltage.
In the event of a fault the system switches off and
indicates the cause of the fault by flashing a trouble
code via the LED in the socket:
• 1x flash – High temperature
• 2x flashes – Overload
• 3x flashes – Internal overvoltage
• 4x flashes – Internal undervoltage
• Continuous flashing – Short circuit to power
If the converter switches off due to high
temperature then it switches back on again
automatically once the temperature has cooled
down sufficiently.
With all of the other faults which are displayed, the
converter can be reset by switching the ignition off
and back on again or by unplugging and reinserting
the consumer in the socket.
If these measures are unsuccessful then there are
no further options for directly influencing the
function yourself. G1055637en
2008.50 Kuga 8/2011 414-05-3
Voltage Converter/Inverter
414-05-3
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Component Description
DC/AC converter
The converter operates with a series connection
of two power converter circuits. The primary power
converter here is a push-pull converter. It converts
the 12 V supply from the electrical system of the
vehicle to an intermediate direct current link of
approx. 320 V.
From this intermediate direct current link, the
downstream full H-bridge circuit generates a
pulse-width modulated output voltage with 230
V/50 Hz.
A controller modulates the pulse width of the
square-wave output voltage and maintains an
effective output voltage of 230 V under varying
load conditions and under different input voltages.
Here, the rising and falling edge of the positive and
negative square wave pulse are controlled
symmetrically to the ideal shape of a sine wave,
which - among other things - also makes a positive
contribution to electromagnetic compatibility.
DC/AC converters which supply a modified square
wave output voltage are referred to as 'Modified
Sine Wave Inverters".
With this type of system there is no need for a
residual current operated device for protection in
the event of accidental contact, as all of the 230 V
lines are double-insulated. Potential-free separation
of the entire 230 V voltage part from the vehicle is
provided (electrical isolation).
The output voltage of 230 V/50 Hz is not generated
until the switching voltage is present at terminal 1
of the converter via the AC mains outlet switch.
The converter operates with the ignition switched
on and a vehicle electrical supply of between 11
V and 16 V. Internal voltage monitoring in the converter deactivates the system if the input
voltage is outside this range.
AC mains outlet
Description
Item
230 V/50 Hz outlet
1
LED (light emitting diode)
2
Cover3 Description
Item
230 V/50 Hz outlet (for UK vehicles)
1
LED2
Cover3
In order to prevent accidents and the risk of
electrical shock, the outlet is protected with a child
safety device and the AC outlet switch.
In order to make the system safer for children, the
safety catches for the 230 V contacts can only be
pushed to one side by pressing a Euro plug evenly
into both of the connector openings.
The AC mains outlet switch only activates the
system when a consumer is connected to the
outlet. G1055639en
2008.50 Kuga 8/2011 414-05-5
Voltage Converter/Inverter
414-05-5
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The contacts of the outlet exert a more powerful
grip on the plug so that it does not shake loose on
poor road surfaces. An orange LED lights up to
show that the unit has been activated.
G1055639en
2008.50 Kuga 8/2011 414-05-6
Voltage Converter/Inverter
414-05-6
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SECTION 417-01 Exterior Lighting
VEHICLE APPLICATION:
2008.50 Kuga
PAGE
CONTENTS
SPECIFICATIONS
417-01-3
Specifications ......................................................................................................................
417-01-3
Headlamp adjustment.....................................................................................................
DESCRIPTION AND OPERATION 417-01-4
Exterior Lighting (Component Location).............................................................................
417-01-5
Exterior Lighting (Overview)...............................................................................................
417-01-5
Front headlamps.................................................................................................................
417-01-5
Conventional Headlamps................................................................................................
417-01-5
Xenon headlamp.............................................................................................................
417-01-6
Headlamp levelling.........................................................................................................
417-01-7
Combined rain sensor/light sensor.....................................................................................
417-01-7
autolamps ...........................................................................................................................
417-01-7
Headlamp switch-off delay.................................................................................................
417-01-7
Turn signals........................................................................................................................
417-01-7
Door entry illumination........................................................................................................
417-01-8
Rear Lighting......................................................................................................................
417-01-9
Exterior Lighting (System Operation and Component Description)....................................
417-01-9
System Diagram.................................................................................................................
417-01-10
System Operation...............................................................................................................
417-01-10
Headlamp levelling.........................................................................................................
417-01-10
Xenon headlamp.............................................................................................................
417-01-10
Conventional Headlamps................................................................................................
417-01-11
Turn signals....................................................................................................................
417-01-11
Combined rain sensor/light sensor.................................................................................
417-01-11
Component Description......................................................................................................417-01-11Combined rain sensor/light sensor.................................................................................
DIAGNOSIS AND TESTING 417-01-12
Fog Lamps..........................................................................................................................
417-01-12
Description of operation......................................................................................................
417-01-13
Inspection and Checking....................................................................................................
417-01-15
Headlamps..........................................................................................................................
417-01-15
Description of operation......................................................................................................
417-01-16
Inspection and Checking....................................................................................................
417-01-17
Headlamp Leveling.............................................................................................................
417-01-17
Description of operation......................................................................................................
417-01-18
Inspection and Checking....................................................................................................
417-01-19
Parking, Rear and License Plate Lamps............................................................................
417-01-19
Description of operation......................................................................................................
417-01-20
Inspection and Checking....................................................................................................
417-01-21
Reversing Lamps................................................................................................................
417-01-21
Description of operation......................................................................................................
417-01-22
Inspection and Checking.................................................................................................... 417-01-1
Exterior Lighting
417-01-1
.
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417-01-24
Stoplamps ...........................................................................................................................
417-01-24
Description of operation......................................................................................................
417-01-25
Inspection and Checking....................................................................................................
417-01-26
Turn Signal and Hazard Lamps..........................................................................................
417-01-26
Description of operation......................................................................................................
417-01-27
Inspection and Checking....................................................................................................
GENERAL PROCEDURES 417-01-29
Front Fog Lamp Adjustment...............................................................................................
417-01-30
Headlamp Adjustment........................................................................................................
REMOVAL AND INSTALLATION
417-01-32
Headlamp Switch................................................................................................................
417-01-34
Stoplamp Switch.................................................................................................................
417-01-35
Trailer Module.....................................................................................................................
417-01-36
Front Fog Lamp..................................................................................................................
417-01-37
Headlamp Assembly........................................................................................................... 417-01-2
Exterior Lighting
417-01-2
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Headlamp adjustment
X value
Component
X = 10 cm/10 m = 0°34' = 1.0%
Headlamp
X = 22 cm/10 m = 1°16' = 2.2%
Front fog lamp G1209238en
2008.50 Kuga 8/2011 417-01-3
Exterior Lighting
417-01-3
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Exterior Lighting – Component Location
Description
Item
Vehicle level sensors on the front and rear
axles
1
Side lamp/stoplamp, turn signal lamp
2
Reversing Lamp
3
Additional high-mounted stoplamp
4
Number plate lamp
5
Rear fog lamp
6
Front side turn light
7 Description
Item
Door entry illumination (courtesy lamps)
8
Lighting switch
9
Control module for the automatic
headlamp leveling system
10
Dipped beam headlamp, main beam
headlamp, turn signal lamp, side lamp
11
Fog lamp
12
Combined rain sensor/light sensor
13 G1079625en
2008.50 Kuga 8/2011 417-01-4
Exterior Lighting
417-01-4
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The turn signal lamps and side lights are the same as in conventional headlamps.
Bulb color
Current draw
Bulb
Lamp
Clear
35W
D1S
Low-beams
Clear
55W
H1
High beam headlamp
Clear
21W
H21W
Turn signal indicator
Clear
5W
W5W
Side lamp
Headlamp levelling
Vehicles with conventional headlamps are
equipped with a manual headlamp leveling system. An automatic headlamp leveling system is a legal
requirement for vehicles with gas discharge
headlamps.
The automatic headlamp levelling system is a
dynamic system which provides additional benefits
for the driver in terms of improved illumination of
the road due to improved control over the
headlamp beam.
In a static system, the vehicle is only considered
as a stationary object, whereas a dynamic system
also takes into account the dynamic changes to
the inclination of the vehicle whilst driving.
In order to prevent unnecessary changes in the
height of the headlamp beam, the system filters
out surface irregularities and any pitching of the
vehicle under braking and acceleration.
The system is designed to respond to changes in
the inclination of the vehicle caused by load
changes or long-term effects of aerodynamic forces
acting on the vehicle (e.g. due to continuous driving
at high speeds).
Accordingly, the system needs to be set up with
the aid of WDS (Worldwide Diagnostic System)
after any components are replaced or any other
repairs are carried out.
G1079626en
2008.50 Kuga 8/2011 417-01-6
Exterior Lighting
417-01-6
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