EM030761-0 en

March 2021

Service Manual
for Fundamental
Principles of Electricity
6015 - 6090
 3 842 950.00 en

Issued by: Caterpillar Global Mining HMS GmbH

© Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2021. Unless expressly permitted, the
transfer and reproduction of this manual/file and the sale and disclosure of its content is prohibited.
Contraventions are liable to compensation. All rights reserved in the event of patent, utility model, or
registered design registration.
Printed in Germany
 3 842 950.00 en

CONTENTS

FOREWORD__________________________________________________________________________ 1

SAFETY INSTRUCTIONS _______________________________________________________________ 1

Personnel Requirements ............................................................................................................................1
Observe the hazard warnings on the machine...........................................................................................1
Observe the warnings and safety instructions in the instructions ..............................................................1

GENERAL INFORMATION ON ELECTRICITY _______________________________________________ 2

Atoms .............................................................................................................................................2
Atomic Structure.............................................................................................................................2
Free Electron..................................................................................................................................2
Electromagnetic Field.....................................................................................................................3
Alternating Current – Display .........................................................................................................4
Electric Power Generation, Principle..............................................................................................4
Electric Power Generation in Motor Vehicles .................................................................................5
Function of an Alternator ............................................................................................................................5
Rectification – Three-Phase Bridge Circuit ....................................................................................6
Construction of an Alternator......................................................................................................................8
Type Identification.......................................................................................................................................8
Maintenance ...............................................................................................................................................8
Charging Batteries..........................................................................................................................9
Circuit with error indicator when excitation circuit is interrupted.....................................................9
Testing the Charging System .......................................................................................................10

COMPONENTS USED IN VEHICLE ELECTRICAL SYSTEMS__________________________________ 11

Battery ..........................................................................................................................................11
Battery Design..............................................................................................................................12
Maintenance-Free Starter Battery ............................................................................................................12
Low Maintenance Batteries ......................................................................................................................13
Battery Testing..........................................................................................................................................13
Acid values for diluted sulfuric acid ..........................................................................................................13
Mixing Fresh Battery Electrolyte...............................................................................................................14
Mixing Instructions ....................................................................................................................................14
Maintenance .............................................................................................................................................14
Faults ........................................................................................................................................................15
Electric Motors..............................................................................................................................17
Electric Motors..............................................................................................................................17
Electric Motor Operation...............................................................................................................17
Starter motor ................................................................................................................................18
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Starting Engine Operation ........................................................................................................................18

Engaging...................................................................................................................................................18
Engaged ...................................................................................................................................................18
Checking Vehicle Starter System .............................................................................................................19
Starting Engine .........................................................................................................................................19
Maintenance .............................................................................................................................................20
Carbon brushes ........................................................................................................................................20
Commutator ..............................................................................................................................................20
Lubrication ................................................................................................................................................21

BASIC PRINCIPLES OF VEHICLE ELECTRICAL SYSTEMS __________________________________ 21

Current, Voltage, Resistance, and Power ....................................................................................21
Current (I) .................................................................................................................................................21
Voltage (V)................................................................................................................................................21
Resistance (R) ..........................................................................................................................................21
Power (P)..................................................................................................................................................22

MEASUREMENTS USING A MULTIMETER ________________________________________________ 22

Multimeter Settings.......................................................................................................................22
Voltage Measurements ................................................................................................................22
Testing diodes ..............................................................................................................................23
Current Measurements.................................................................................................................23
Ohm Measurements (Resistance)................................................................................................23
Check cable continuity .................................................................................................................23

SERIES AND PARALLEL CONNECTION OF COMPONENTS _________________________________ 24

Batteries .......................................................................................................................................24
Series Connection ....................................................................................................................................24
Parallel Connection ..................................................................................................................................24
Resistors ......................................................................................................................................24
Series Connection ....................................................................................................................................24
Parallel Connection ..................................................................................................................................24
Capacitors ....................................................................................................................................24
Series Connection ....................................................................................................................................24
Parallel Connection ..................................................................................................................................24
Electrolytic Capacitor....................................................................................................................25

VOLTAGE LOSS AND LINES ___________________________________________________________ 26

LINE CALCULATION __________________________________________________________________ 27

Parameters and Units...................................................................................................................27
Calculation: ...............................................................................................................................................27

LINES FOR VEHICLE ELECTRICAL SYSTEMS_____________________________________________ 28

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Calculation Example.....................................................................................................................29

LIGHTING ___________________________________________________________________________ 30
Instructions for Adjusting Headlights ............................................................................................30
Requirements ...........................................................................................................................................30
Working Lights ..........................................................................................................................................30
Incandescent Lamps ................................................................................................................................30
Sources of Error and Reasons for Lighting ..................................................................................30
Transition Resistances in a Line Circuit ...................................................................................................30

SPECIAL CIRCUITS IN VEHICLE ELECTRICAL SYSTEMS ___________________________________ 31

Diode ............................................................................................................................................31
“Recovery Diode” .........................................................................................................................31
Varistor .........................................................................................................................................32
Generator Regulator.....................................................................................................................32
Vehicle Fuses...............................................................................................................................33

MARKING INDIVIDUAL PARTS _________________________________________________________ 34

STANDARD TERMINAL DESIGNATIONS _________________________________________________ 35

Terminal Designations..................................................................................................................35
3 842 950.00 en

FOREWORD
The purpose of this manual is to share knowledge
of the most essential basic principles in the field of
electricity. Knowing these fundamentals will make
it easier for maintenance personnel to understand
the electrical systems used in Caterpillar Global
Mining HMS GmbH machines.
This manual is also intended to be a reference
work for trained electricians working in customer
service or workshops.
It does not describe actual repair or maintenance
work. Descriptions of this work can be found in the
operation and maintenance instructions or in the
technical manual for the machine.
Notice:
The article numbers listed here should not be used
to order replacement parts. The article numbers
used in this manual are only intended to serve as
documentation of the parts to which the data listed
below refer.
Please use the replacement parts list associated
with a specific machine when ordering spare parts.
This replacement parts list is available in hard copy
form, as well as in digital format and online. Please
contact your Caterpillar dealer for more information.
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SAFETY INSTRUCTIONS
Personnel Requirements
All work performed on electrical or electronic
components and systems of the machine must be
carried out by trained and qualified professionals
only, or by personnel undergoing training under the
supervision and guidance of a qualified person.
If personnel do not have the required expertise,
then in-depth training must be provided by
experienced personnel, e.g. by Caterpillar Global
Mining HMS GmbH.
Electrical systems may be installed with varying
levels of high voltage in the machines that
have to be operated. This also calls for different
requirements regarding the qualifications of the
personnel who will be responsible for carrying
out maintenance or repair work.
For example, an electrician may not work on
systems operating at 6000-7200 V without further
training and instruction if he only has experience
with 24 V wiring systems.
Detailed information on personnel requirements can
be found in the “Electrics and Electronics” section of
the technical manual for a specific machine.
In all cases, the applicable national legislation
and the accident prevention regulations for your
respective country must be observed. These are
not included in this manual.
Observe the hazard warnings on the
machine
Observe all safety instructions and hazard
warnings on the machine.
Keep all safety instructions and hazard warnings
at and on the machine in place, and make sure
they are complete and in legible condition.
Replace any illegible or missing warning signs
or information immediately.
Observe all national laws, regulations
and guidelines that apply in your country.
Observe the warnings and safety
instructions in the instructions
Descriptive and instructive text contains warnings
and safety information. This information alerts the
operator to potential risks and is thus provided for
your safety. For this reason, always observe all
warnings and safety information.
1
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GENERAL INFORMATION
ON ELECTRICITY
To make the concept of electricity more
understandable, we are going to make a brief
sidestep into the field of electrical engineering.

Atoms
All substances are made up of atoms.
An atom consists of a nucleus, which has a positive
charge, and electrons. These electrons have a
negative charge and orbit the nucleus at great
speed. The nucleus itself is composed of protons,
which are positively charged, and neutrons, which
have a neutral charge. The number of protons and
neutrons is based on the given atomic structure. If
the nucleus has the same number of electrons as
protons, the atom acts neutrally to the outside, in
terms of electrical charge. All electrons are bonded
magnetically at their core. If an electron is missing,
for whatever reason, i.e. there is one more proton
in the nucleus than there are electrons orbiting it,
the atom is positive.
Fig. 2
The electron from nucleus A has reached a neutral
orbit. Since atom B is electrically neutral and atom
C is not (it's missing an electron), the electron is
attracted by nucleus C and nucleus A is therefore
no longer neutral. Another atom attracts another
electron that has reached a neutral orbit. If an
electron from nucleus C, which is now neutral,
reaches a neutral orbit again, it is likewise
attracted by a non-neutral nucleus (and so on).

Atomic Structure
The number of protons corresponds to the number
of electrons, e.g. it is electrically neutral
(see Fig. 1).

Fig. 3

Precious metals and nonferrous metals contain

a relatively large number of free electrons. If
Fig. 1 you move a conductor (e.g. a copper wire) into
a magnetic field, free electrons will be pulled
Because substances contain a multitude of atoms, in one direction or another.
it often occurs that an electron exists at an equal
distance to another nucleus as to its own nucleus.
In this case, the magnetic attraction from its own
nucleus increases. Such an electron is no longer
bound to its own nucleus, in other words it is free.
Electrons of this type are called “free electrons.”

Free Electron
If an electron leaves its orbit and is at the same
distance to another nucleus as to its own, it is no
longer bound to its nucleus – it is free (see Fig. 2).

2

Electromagnetic Field
When current flows through a conductor,
a magnetic field then forms around the
conductor (see Fig. 4).
Fig. 4
The resistor “R” serves only to prevent a short in
the circuit. If a conductor is formed into a coil with
several windings, a magnetic field will spread
around the coil (see Fig. 5). The strength of the
magnetic field depends on the current that flows
through the coil and on the number of windings.
Fig. 5
An iron core with preferred magnetic orientation
is normally used to support the windings in order
to increase the intensity of the magnetic field.
Consequently, the electromagnetic force is
sufficient to, e.g. pull the core of a solenoid valve.
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The result is that an electrical potential is built
up alternatingly at the ends of the conductor. This
potential is called electrical voltage (V), measured
in volts (V). If this conductor is now formed as
a closed circuit, the electron current that moves
through the conductor can be measured. This
flow of electrons is called electrical current
(I) and is measured in amperes (A).
Fig. 6
The formation of a continuously alternating
potential in a conductor is called AC voltage. The
current flowing in this process is called alternating
current, i.e. the current constantly changes its
direction and strength. The alternating current
and AC voltage can be made visible by means
of a display unit. Current and voltage are normally
synchronized. If current is not synchronized with
voltage, this is known as a phase shift.
3
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Alternating Current – Display Electric Power Generation, Prin-

The waveform of the alternating current or AC
voltage is a sine curve. If the current and voltage
are in phase, both achieve their peak value at the
same time. The oscillations that occur in one
second are known as the frequency (f). The
number of oscillations that occur in one second are
specified in hertz (Hz). A few important physical
parameters are listed below (see Fig. 7):
ciple
It then becomes relatively easy to construct a
power generator based on the fact that a magnetic
field is formed around a conductor when a current
is made to flow through the conductor. This
principle is described in Fig. 8. Windings (2) are
mounted on a rotor (1) and are supplied with direct
current (3). This produces a magnetic field (4). The
rotor magnetic field runs through the windings (6)
mounted to the stators (5) of the generator when
the rotor turns. Electrical voltage is thereby
generated in the stator winding.

Fig. 7

T Duration of a complete oscillation (period)

in s
f Frequency in Hz
(f = 1/T)
î Peak value (amplitude) of current
û Peak value (amplitude) of voltage
ω Angular frequency in 1/s
(ω = 2 * f = 2 π/T)
Fig. 8
φ Phase shift angle between current and
voltage; phase-shifted means: current and
voltage achieve their threshold or their zero
crossing at different points
t Time axis (time in s)

4
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Electric Power Generation in

Motor Vehicles
Function of an Alternator
The purpose of a generator is to cover the energy
needs of electrical consumers. It must also ensure
that the battery itself is charged when permanent
consumers are connected at low engine speeds
(low idle). The generator must supply constant
voltage at all operational and load conditions. A
regulator helps the generator in this process by
regulating voltage between 13 and 14.5 V,
regardless of the load and speed of the generator.

An alternator (also generator, Fig. 9) generates Fig. 10

three alternating currents, each phase-shifted by
120° (Fig. 10). This three-phase current is rectified
by the controller electronics by means of diodes and
converted into direct current. A controller is used
to adjust the DC voltage to the nominal charging
voltage. The direct current that is produced as
a result is required for recharging the battery,
i.e. the battery is recharged as the motor runs.
Current flows when voltage is applied to the field
winding mounted to the magnet wheel. This current
produces a magnetic field.
AC voltage is generated in each coil when the
magnet wheel turns. Three equal voltages are
produced in the three coils. However, these
voltages are shifted in time to each other by 1/3 of
a period, i.e. the phase shift amounts to 120°. If the
coils are loaded equally, the phase angle between
currents is also 120°. Three alternating currents that
are each phase-shifted by 120° are called three-
phase alternating current or three-phase current.

Fig. 9

5
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Rectification – Three-Phase
Bridge Circuit
Since three-phase alternating current is
generated in motor vehicles, it must be rectified
in order to recharge the battery. If the three-
phase AC voltage produced by the generator
is made visible, this results in three sine curves
that are each phase-shifted by 120°, based on
the design of the generator.
Consider a curve: It rises to “V+ max (plus)”,
the highest voltage value, then falls through the
“0 point” to “V-max (minus)”, the lowest voltage
value. If AC voltage is now applied to the anode
side of a diode, the negative half-wave is blocked
and the positive one can pass through. Fig. 11

Fig. 12

Only positive (plus) voltage exists at the cathode side (cathode output voltage) and no longer the full anode
input voltage (Fig. 12).

If we examine the direction of the three-phase current, several diodes are connected in parallel to a bridge
(see Fig. 13). The individual diodes of this bridge are known as main diodes.

6
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Fig. 13

Only positive waves still exist at the output of the rectifier bridge, i.e. direct current or DC voltage still exists.
This direct current is used to back up the battery.

7
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Construction of an Alternator Type Identification

Fig. 15

Note:
24 V generators are installed in equipment.
Maintenance
The alternators installed in current CAT machines
are largely maintenance-free. V-belt tension should
Fig. 14 be checked about once a month, depending on
how the machine is used. Carbon brushes should
1 Slip-ring end shield be checked once a year. A visual examination
2 Rectifier – Heat sink of slip rings should also be performed, and, if
necessary, these components should be sanded
3 Power diode
down using a very fine emery cloth.
4 Exciter
5 Transistor regulator using hybrid
technology (= electronic regulator)
6 Stator with three-phase winding
7 Claw-pole rotor
8 Fan
9 Belt pulley
10 Drive end shield with mounting flanges

Note:
The battery should not be disconnected from the
generator while the generator is running; this would
endanger semiconductor components in the
generator and in electronic control units.

8

Charging Batteries
Since the generator in motor vehicles is used for
backing up (recharging) batteries, the three-phase
current must be transformed into direct current.
This is achieved by means of rectifier diodes
(see Fig. 16).
Fig. 16
1 Field diodes
2 Main diodes
3 Regulator
Field diodes are responsible for transforming three-
phase current into direct current. This direct current
is then routed to the field winding by means of the
regulator, and this component is responsible for
limiting or shutting off field current after charging
voltage is reached. The main diodes are
interconnected by means of a so-called bridge.
The output (B +) of this diode bridge is permanently
connected to the battery terminal (+).
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Circuit with error indicator when
excitation circuit is interrupted
Fig. 17
1 Generator
2 Generator indicator lamp
3 Resistor R
4 Ignition or driving switch
5 Battery
The only function of the charge alarm indicator
is to ensure the generator is premagnetized and
to monitor the excitation circuit. If the charge alarm
indicator is lit while the generator is running, this
means there is no excitation current and therefore
no battery charge.
The functions of the charge controller are based
on the principle described in Fig. 17. When the
ignition switch (4) is closed, current flows from the
battery (5) through the indicator lamp (2) over
a resistor (3) to the ground. The resistor (3) is
calculated so that the indicator lamp is lit. If the
diesel engine is then started so the generator is
powered up, a positive voltage is supplied to the
terminal (D +) of the generator. Because a positive
voltage is now being supplied to both sides of the
indicator lamp, the charge alarm indicator goes
out. The resistor must be connected in the
immediate vicinity of the indicator lamp.
9
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Testing the Charging System

Note:
The voltage gauge must be switched to direct
current operation.

The voltage gauge must be connected directly to

the battery for the charging system to be tested.
The engine must then be brought to full speed.
The nominal charging voltage must be
reached after approx. 2 minutes. This voltage
should be between 13-14.5 V in a 12 Volt
system, or 26-29 V in a 24 Volt system.
If the voltage gauge shows an extremely high
value, the regulator is probably defective. On the
other hand, if the voltage value is too low, there
is probably a fault in the charging system.

10
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COMPONENTS USED IN VEHICLE ELECTRICAL SYSTEMS

Battery
The battery is only used for starting the vehicle
and for the lights when the machine is parked.
During operation, the generator takes over the
supply of power to the vehicle and simultaneously
recharges the battery.

The batteries most frequently used in vehicles

are 12 volt batteries. They are constructed from
individual cells (see Fig. 19) (Basic Lead Cell
Construction). A nominal voltage of 12 V is realized
by interconnecting (serial connection) six cells
(2 V cells) (see Fig. 18).

Fig. 19

Fig. 18

The nominal voltage of a battery is based on the

number of cells connected in series.
UB  n  U Z
n Number of cells
UB Nominal voltage of battery
UZ Nominal voltage of cells (= cell voltage)

11
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Battery Design Maintenance-Free Starter Battery

Metallurgical measures ensure that electrolysis of
water during normal operation under wiring system
conditions (V = constant) is reduced sufficiently
so that the electrolyte supply via the plates is
adequate for the full working life of the battery.

If a battery of this type needs to be recharged

outside of the wiring system, make sure the
charging voltage per cell is limited to
a maximum 2.3–2.4 V.

Fig. 20

1 Block cover
2 Terminal cover cap
3 Direct cell connector
4 End terminal
5 Safety valve
6 Plate connector
7 Battery casing
8 Base hold-down
9 Positive plates immersed in foil separators
10 Negative plates

Note:

The description “maintenance-free in accordance

with DIN” only means that a battery must remain
under a prescribed limit in terms of water
consumption. This by no means ensures that
water refilling can be dispensed with over the
entire lifetime of the battery. In addition, the
remaining maintenance aspects are generally
not affected by this definition. For these reasons,
some advertising statements regarding freedom
from maintenance are misleading.

12
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Low Maintenance Batteries Battery Testing

The electrolyte level in low maintenance batteries Acid density is the key characteristic that indicates
should be checked at least once a year. If the the state of charge for a battery. Acid density can
electrolyte level lies below the level line set by the be measured to see how fully a battery is charged.
manufacturer, the battery's chambers should be A hydrometer is used to measure acid density. The
refilled with distilled water. If the battery needs scale of the hydrometer shows the acid density.
to be recharged away from the wiring system,
it should be charged using a tenth of the current Acid values for diluted sulfuric acid
of the nominal capacity of the battery.
Acid Freezing
State of Battery
Battery charging results in the density threshold
charge design
production of highly explosive kg/l °C
oxyhydrogen. Batteries should only
be charged in well-ventilated areas charged normal 1.28 -68
specifically provided for that
for 1.23 -40
purpose. Working with fire and open
tropics
flames, and smoking are prohibited.
Relevant safety regulations must half- normal 1.16/1.20 -17…-27
always be observed. charged
for 1.13/1.16 -13…-17
tropics

discharged normal 1.04/1.12 -3…-11

for 1.03/1.08 -2...-8

tropics
Table 1

The start test involves measuring voltage under

load by means of a battery tester.

Battery testers for 12 V are used for block

cover batteries. The battery tester is used to
simulate a battery charge for approximately
5 seconds with a fixed resistance of 300 A.
The voltage is then measured during this
process and approximates a benchmark of the
battery's ability to start. The permissible limit
voltage is set at 8 V for 6 cells = 1.33 V/cell.
When using a battery tester, you must ensure
that there is good contact between the needle
tips of the tester and battery terminals.

Finally, the measurement is evaluated. If the acid

density is too low but the start test was acceptable,
the battery generally only needs to be recharged.

If both acid density and the start test were

unsatisfactory, the battery is usually no longer
usable. If cell acid densities or battery voltages in
charged batteries deviate significantly in the start
test or are unsatisfactory, the battery should be
taken out of service.

13
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Mixing Fresh Battery Electrolyte Maintenance

This term includes all maintenance measures
When mixing fresh battery required to ensure that the battery functions
electrolyte, make sure that the optimally during its lifetime:
concentrated sulfuric acid is always
poured into distilled water and
 Refilling water
never the other way around! Risk
of splashing acid! Always wear
 Periodic recharging when battery is stored
safety glasses and protective
clothing! Accident prevention
 Immediate recharging after discharge
regulations must always be
observed while working.
 Avoiding overcharging

The following table (Table 2) shows the volume ratio  Avoiding deep discharges
of concentrated sulfuric acid (96%) to distilled water.

Mixing Instructions
Required Volume ratio of concentrated
acid density sulfuric acid (96%) to
kg/l distilled water

1.23 1 : 3.8
1.26 1 : 3.2
1.28 1 : 2.8
1.30 1 : 2.6
1.34 1 : 2.3
Table 2

14
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Faults
Faults Cause Remedy

1. Acid level is too low Overcharging, evaporation Refill with distilled or desalinated water
(especially in summer) (in charged batteries)

2. Acid flows out of Charging voltage is too high Test voltage regulator, then adjust or
sealing plug replace

Acid level is too high Draw off excess acid with hydrometer

3. Acid density is too low Battery is discharged Charge battery

Generator is not working Have generator checked

properly

Short circuit in power network Have electrical system checked

Acid is diluted because Correct acid balance

of a maintenance error

4. Acid density is too high Excessive acid content Correct acid balance
after refilling

5. Effective output is too Battery is discharged Recharge battery

low; voltage is dropping
too quickly Charging voltage is too low Adjust or replace voltage regulator

Connection terminals are loose Clean connection terminals and lightly

or oxidized grease terminals, especially underside,
using anti-corrosion grease “Ft 40 v 1”;
tighten connection screws

Battery capacity is too low Use larger battery; also install larger
(too many consumers) generator if necessary; best to consult
specialist workshop

Battery self-discharge too high Replace battery

because of impurities in battery
electrolyte

Battery may be “sulfated” Charge battery with low current so

(grayish-white film on positive film slowly recedes; replace battery
and negative plates) if effective output is still too low after
repeated charging and discharging

Battery is exhausted, active Replace battery

plate ground has failed

Acid level is below the Refill with distilled or desalinated water

upper edge of the plates up to prescribed height

15
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Faults Cause Remedy

6. Battery lifetime is too Battery was discharged too Use battery with greater capacity;
short frequently and too deeply if necessary, use special
model “S” battery

Battery is becoming too warm Select a better installation location

Vibration stress too high Select a better installation location

Battery may be “sulfated” See item 5.6

(grayish-white film on positive
and negative plates)

Battery electrolyte Replace battery

is contaminated

7. Battery charges are Fault in generator, voltage Increase generator output or

consistently too low regulator or line connections repair/replace generator and voltage
regulator; make sure lines are fastened
correctly

V-belt is loose Tighten or replace V-belt

Too many consumers Install larger battery. Also use larger

are connected generator if necessary; best to consult
specialist workshop

8. Continual overcharging Fault in voltage regulator, Replace or otherwise adjust voltage

possibly also in generator regulator; check generator

9. Switch contacts in Battery is incorrectly connected Connect battery with correct polarity,
voltage regulator (incorrect polarity) Replace voltage regulator
charred (in direct
current generators)

10. Diode rectifier Battery is incorrectly connected Connect battery with correct polarity,
is destroyed (incorrect polarity) replace diode rectifier
(in alternators)
Table 3

16
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Electric Motors The torque is equal to zero when the conductor is

positioned between pole shoes (see Fig. 22).
Normally only direct current motors (starters,
windshield wiper motors, fan motors, etc.) are
used in vehicles. We therefore present a brief
overview on how motors of this type work.

Electric Motor Operation

An electric motor transforms electrical capacity
(product of voltage times current) into mechanical
capacity (product of speed times torque). This
process is based on the fact that a force is exerted
on a current-carrying conductor in a magnetic field.
The size of this force is proportional to the strength
of the magnetic field and the amperage, and is at
its maximum when the magnetic field and current
are aligned perpendicularly to one another. It is
useful to form the conductor as a rotatable loop
(see Fig. 21).
Fig. 22
If it is ensured that the direction of current is
changed, or turned, after every half turn in the
conductor loop, the torque then has the same
direction of rotation and can cause a constant
spinning of the loop. This reversal of current occurs
in a commutator that consists of two segments,
shaped like half-rings and isolated from one
another, to which the two conductor ends of the
loop are connected. Two current collectors, called
carbon brushes, are connected to the power
source and rub against the segments (Fig. 21 and
Fig. 23). A large number of wire loops are used in
order to achieve a steady torque (see Fig. 23; this
example shows three conductor loops).

Fig. 21

The magnetic lines of force run from pole to pole,

i.e. from pole shoe to pole shoe. If the conductor is
located under the pole shoes (i.e. in the area of the
magnetic field) the torque acting on the conductor
loop is constant and has a specific direction. When
the conductor is given a half turn and is in the area
of the opposing magnetic field, the torque has the
same value, but the reverse direction.

Fig. 23

17

Fig. 24 shows the separate torques and resulting
total torque for three loops arranged symmetrically.
The commutator used here has six individual
segments, also called laminations. In reality the
number of loops is much higher, since torque also
increases along with the number of loops.
Fig. 24
18
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Starter motor
Starting Engine Operation
When the starter switch is activated, the solenoid
plunger and the actuating lever cause the bevel
pinion to be inserted into the ring gear through the
action of the helix (Fig. 25, “engaging”). Contacts
for main current are connected to the end of the
pinion travel of the engagement relay (Fig. 26,
“Engaged”). The pull-in winding is de-energized
and the pinion is held by means of the holding
winding. When the motor starts, the bevel pinion
is returned to the rest position by the return spring
after the starter switch is let go.
Engaging
Fig. 25
Engaged
Fig. 26
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Checking Vehicle Starter System

 Test battery.

 Check to make sure battery cable and connections have proper contact.

 Measure voltage drop (0.5 V).

 Measure minimum pull-in voltage at magnetic switch (8.0 V).

Starting Engine
1 Return spring 14 Armature
2 Holding winding 15 Exciter developer
3 Pull-in winding 16 Armature winding
4 Solenoid plunger 17 Guide ring
5 Contact 18 Control stop
6 Connection bolts 19 Roller freewheel
7 Contact bridge 20 Armature shaft
8 Commutator bearing 21 Bevel pinion
9 Brush spring 22 Cam
10 Commutator 23 Brake disc
11 Carbon brush 24 Engaging spring
12 Pole housing 25 Actuating lever
13 Pole shoe

Fig. 27

19
 3 842 950.00 en

Maintenance
Note:
The risk of short circuiting exists whenever work is
performed on the electrical components in installed
starting engines.
The ground lead to the battery must be
disconnected before working on the electrical
components of the starting engine.
Tools must not be placed on the battery itself!
Carbon brushes
Carbon brushes should be inspected from time
to time to ensure they are in flawless condition
(see Fig. 28).

 Remove the seal cap.

 Use a hook to lift up the spring that is pressing
the carbon brush onto the commutator. While
doing so, you should always make sure you Fig. 28
don't bend the spring to the side, or lift it more
than necessary.
 Now check to see if the carbon brushes
can move easily as they are fed into the
brush holder.

Commutator
The commutator should have a regularly smooth,
grayish-black surface and must be free of oil
and grease.

 Clean dirty commutators with a clean cloth

moistened with gas (not steel wool), then dry
them well.
 Worn commutators (ridged or out-of-center)
must be skimmed in a workshop equipped
for this purpose.
Note:
Under no circumstances may sandpaper or files
be used to work on commutators.

20

Lubrication
Both of the screw push starter bearings are fitted
with self-lubricating bearings (composite bushing)
so that these do not require lubrication. These
bearings must not be treated with degreasing
cleaning agents.
In addition, the following instructions must
always be observed:
Carbon brushes and brush holders must be free
of oil and grease.
Clean dirty brushes and holder using a clean cloth
moistened with gas (not with steel wool, since this
frays easily), then dry them well.
Always wear gloves in order to avoid injuries
through skin contact with aggressive substances.
Do not use sandpaper, files or knives to work on
bare carbon brush grinding surfaces.
Blow out the brush holder well.
Always wear safety glasses when working in order
to prevent injuries caused by flying dust particles.
If a carbon brush is broken, unsoldered, or so worn
that the spring or strands soldered in the brush
threaten to contact the brush holder, it should
be replaced.
When inserting carbon brushes, make sure the
spring does not hit the brush.
Always replace carbon brushes each time the
motor is completely overhauled.
Skim the commutator every time carbon brushes
are replaced.
3 842 950.00 en
BASIC PRINCIPLES OF
VEHICLE ELECTRICAL
SYSTEMS
Current, Voltage, Resistance, and
Power
Current (I)
Electrical current is understood to mean the
flow of free electrons in a conductors. Current
measurements are carried out by means of an
ammeter, which must be connected in the path
of the current. The amount of electrical current is
specified using “I” and the unit with “A” (ampere).
Voltage (V)
Electrical voltage is the difference in potential
between two conductors (using the same reference
point). Voltage is measured by means of a voltage
gauge, which must be connected in the shunt path
to the consumer of between potential points. The
amount of voltage is specified using “V” and the
units with “V” (volt).
Resistance (R)
Electrical resistance is understood to mean the
resistance that is brought against the electrical
flow of current and slows it down. The amount
of resistance depends upon the material in use
as well as its dimensions. The amount of electrical
resistance is specified using “R” and the unit with
“Ω” (ohm).
21
 3 842 950.00 en

Power (P) MEASUREMENTS USING

Power is understood to mean the current that flows
through a consumer at constant voltage. Its amount
is specified using “P” and the unit with “W” (watt).
The relationship between current (I), voltage (V),
resistance (R), and power (P) are summarized in
Fig. 29. This section also includes conversion
formulas you can use to calculate different
quantities.
A MULTIMETER
Multimeter Settings
Follow the instructions below before connecting the
multimeter:
 Set direct current/alternating current
and/or DC/AC voltage.
 Select as large a measuring range as possible.
 Connect the multimeter then reset the
measuring range until it shows the highest
possible reading.

Voltage Measurements

Fig. 29

Fig. 30

Note:
A voltage gauge is always connected in parallel
to the consumer or voltage.

22
 3 842 950.00 en

Testing diodes Ohm Measurements (Resistance)

A voltage measurement can also be used to check Ohm meter
diodes. The structure of an diode is always as
shown in the figure below. Here, the “positive side”
is the anode and the “negative side” is the cathode.
The direction of flow is from “positive” to “negative.”

The following values can be measured in the test:

Measured voltage Diode condition
0.637 V Diode is working properly
0 volts Diode is not working properly

Current Measurements Fig. 32

Note:
The component to be measured in an ohm
resistance measurement must always be
voltage-free. Components in a circuit may
be measured only if they are removed.
Check cable continuity
An ohm resistance measurement can also be used
to check cable continuity. The following situations
may arise in this case:

Measured resistance Cable condition

Fig. 31 0 ohms Cable assembly is ok
(has continuity)
Infinite ohms Cable assembly is not ok
Note:
(break in cable)
The current-carrying line must always be
disconnected and the meter connected to the
circuit before measuring current. Current
must flow through the meter.

23
 3 842 950.00 en

SERIES AND PARALLEL

CONNECTION OF
COMPONENTS
Batteries
Capacitors
Series Connection
When two or more batteries (C) are connected
Series Connection
in series, the voltages of each battery are When capacitors (C) are connected in series, the
added together. total capacity (Ctot) is less than the smaller
individual capacity.

Parallel Connection
When two or more batteries – these must be of the Parallel Connection
same voltage – are connected in parallel, the
voltage remains the same. When capacitors (C) are connected in parallel, the
capacity value is added up, i.e. total capacity (Ctot)
However, the capacity of each is added together is the sum of all individual capacities.
(i.e. the amount of electrical charge that can
be output).

Note:
Proper polarity must always be observed
when batteries are interconnected.
Note:
Capacitors connected in series and in parallel have
the opposite behavior of resistances.

Resistors
Series Connection
When two or more resistors (R) are connected in
series, the resistance value is added up. The sum of
the resistances produces the total resistance (Rtot).

Parallel Connection
When two or more resistances (R) are connected
in parallel, the total resistance value (Rtot) is less
than the smaller individual resistance value. If two
equal resistances (equal resistance value) are
connected in parallel, the total resistance is then
half of each individual resistance.

24
 3 842 950.00 en

Electrolytic Capacitor
Electrolytic capacitors behave exactly like the
capacitors described above, but they are installed
polarized. The polarity is imprinted on the
capacitor.

Series connection:

Parallel connection:

Risk of accident!
Electrolytic capacitors must never
be installed the wrong way. Other
components and circuit symbols
can be found in section 12.1.

25
 3 842 950.00 en

VOLTAGE LOSS AND LINES

The values specified in Table 4 for voltage loss in a The Vvg values specified are test values and can
line (Vvl) and for total voltage drop (Vvg) are used also include contact resistances of switches, fuses,
to calculate plus wires. The voltage drop from the etc. for line calculation.
ground return remains unconsidered. However, the
forward and return lines are normally used as
a line length in case the ground lead is isolated.

Power type Permissible voltage drop Permissible voltage drop Comments

of positive line in overall power circuit
Vvl Uvg

Light Lines
Terminal 30 from light switch up to lighting 0.1 V 9.6 V Current at nominal voltage
> 15 W up to trailer socket and nominal power
From trailer socket
up to lighting

Terminal 30 from light switch 0.5 V 0.9 V

up to lighting > 15 W
up to trailer socket

Terminal 30 from light switch 0.3 V 0.6 V

up to headlights

Charging line
From alternator
Terminal B 0.1 V at 12 V Current at nominal voltage
and nominal power
up to battery 0.8 V at 24 V

Control Line up to maximum

From alternator 0.1 V at 12 V excitation current (note 1)
up to regulator
(terminal D+, D-, DF) 0.2 V at 24 V

Main Starter Line 0.5 V at 12 V Starter short circuit current

at +20 °C
1.0 V at 24 V (notes 2 and 3)

Starter Control Line

Terminal 50 from starter switch up to 1.4 V at 12 V 1.7 V at 12 V Maximum control current
starting motor (notes 4 and 5)
Solenoid plunger with basic winding 2.0 V at 24 V 2.5 V at 24 V
Solenoid plunger with pull-in and 2.4 V at 12 V 2.8 V at 12 V
holding winding 2.8 V at 24 V 3.5 V at 24 V

Other Control Lines 0.5 V at 12 V 1.5 V at 12 V Current at nominal voltage

From switch to relays, horn etc. 1.0 V at 24 V 2.0 V at 24 V
Table 4

26
 3 842 950.00 en

Note: LINE CALCULATION

All three control lines should have equal length and
equal resistance as far as possible. Parameters and Units
If start limit temperature is decreased, the Vvl
value may be exceeded if necessary in special Parameter Unit
cases, using a very long main starter line.
If the return of the main starter line is isolated, the I Amperage A
voltage loss in the return line should not exceed l Line length m
that of the forward line; the permissible value P Power required by W
consumer
is 4% of the nominal voltage, giving 8% altogether. 2
q Conductor cross-section mm
Vvl values apply for solenoid plunger temperatures
of 50-60 °C R Resistance (consumer) Ω
If necessary, include the line in front of the starter S Line current density A/mm
2

switch in calculations. VN Nominal voltage V

Vvl Permissible voltage V
drop of isolated line
Vvg Permissible voltage V
drop around overall
power circuit
ρ Specific electrical Ωmm
resistance
Table 5

Calculation:
Include voltage drop and heating when determining
conductor cross-section.
 Determine amperage I of consumer

I  P / UN

 Calculate conductor cross-section

q with Uvl – value from Table 6
(for copper = 0.0185 Ω mm/m)

q = I * l/Vvl

 Round off q to next-highest conductor cross-

section as per Table 6. Individual lines under 1
mm are not recommended because their
mechanical strength is too low.

 Calculate actual voltage drop Vvl

Vvl = I * l/q

 To avoid excessive heating, check

current density S (during short-term
operation S < 30 A/mm2, for values
during continuous operation see
Table 6).

S = I/q

27
 3 842 950.00 en

LINES FOR VEHICLE ELECTRICAL SYSTEMS

One-wire, untinned, PVC-insulated

Nominal Resistance per Conductor Line diameter Permissible continuous current Permissible
cross-section meter diameter (guideline value) current
density

mm at 20 °C Maximum Maximum at +30 °C at +50 °C Continuous

m Ω/m dimension mm dimension mm A A operation
A/mm

0.5 37.1 1 2.3 11 7.8 10

0.75 24.7 1.2 2.5 15 10.6 10
1 18.5 1.4 2.7 19 13.5 10
1.5 12.7 1.6 3 24 17 10
2.5 7.6 2.1 3.7 32 22.7 10
4 4.71 2.7 4.5 42 29.8 10
6 3.14 3.4 5.2 54 38.3 6
10 1.82 4.3 6.6 73 51.8 6
16 1.16 6 8.1 98 69.6 6
25 0.743 7.5 10.2 129 91.6 4
35 0.527 8.8 11.5 158 112 4
50 0.368 10.3 13.2 198 140 4
70 0.259 12 15.5 245 174 3
95 0.196 14.7 18 292 207 3
120 0.153 16.5 19.8 344 244 3
Table 6

28

Calculation Example
The line cross section must be determined if an
electrical unit is to be added as well.
Example: Adding a work light (two lamps)
The following parameters must be known: Vehicle
operating voltage and power consumption of flood
light. In our example operating voltage is 24 volts
(28 volts), power consumption of a work light
is 70 W.
We must first calculate the current of
the incandescent lamp (see Section 4
“Ohmic Range”).
P 70W
J   2,9 A
U 24V
A current of approx. 3 A would therefore flow for
one lamp bulb, but since two bulbs are being used,
the doubled amperage must be used (i.e. 6 A).
3 842 950.00 en
According to Table 6, a cable assembly with a
conductor cross section of 0.5 mm2 can be used at
an assumed ambient temperature of 50 °C. This
temperature value is always used when you cannot
rule out the fact that cable assemblies will be
routed through the engine compartment.
Note:
Lay cable assemblies in a protective sleeve so that
they cannot become chafed or jammed.
Be sure to note the cable color when laying cable.
This is especially important when installing units
at a later time. “Brown” is always “ground” or
“negative” here.
All circuits must be protected with
appropriate fuses.
Any switches that are used must be able
to connect the expected current.
29
 3 842 950.00 en

LIGHTING Sources of Error and Reasons

A crucial factor in vehicle operational safety is
vehicle lighting. Vehicle headlights must be
installed or constructed and divided up in
accordance with German Road Traffic Registration
Ordinance (StVZO). If this is not the case, this can
lead to a dazzling effect on oncoming traffic.
Instructions for Adjusting Head-
lights
Requirements
 The vehicle must be on a level surface.
 Tire air pressure must be checked.
Working Lights
Working lights may only be switched on when
work is being carried out. These units are usually
installed so as to be movable and can be adjusted
as needed.
for Lighting
Note:
Please remember that lighting is an essential
component in vehicle operational safety. The
lighting system must be inspected and made ready
before beginning a trip. The most common sources
of error lie in the fact that headlights shine
“yellowish” and do not radiate “white light”
as usual. This effect is then caused by an
impermissibly high ground transition resistance
when the voltage supply system is functioning
perfectly. The permissible voltage loss is then
exceeded.
Transition Resistances in a Line
Circuit
In most cases, transition resistances occur in
cable connections, ground connection and
defective switches. A transition resistance
results in voltage loss.

Incandescent Lamps
Incandescent lamps are constructed for 2 volt,
12 volt, and 24 volt systems. The socket shape
of each lamp type is different in order to make
confusion impossible. The voltage and power
of incandescent lamps are specified on the lamp
itself. Halogen lamps are designated by means
of symbols H1-H4. Their light output over
conventional incandescent lamps is improved
by 70% on average.

Note:
Incandescent lamps may only be replaced by
those types specified in the wiring diagram.

30

SPECIAL CIRCUITS IN VEHICLE ELECTRICAL SYSTEMS
Diode
The “Voltage Measurements” section above
included some discussion on diodes. Following are
descriptions of additional information and special
configurations with diodes.
Diodes are components that allow current to flow in
only one direction – comparable to the non-return
valves used in hydraulic systems. The two
connections are designated using “anodes”
and “cathodes”.
Fig. 33
If a positive voltage is applied to the cathode of
a diode, the diode blocks the current, i.e. no
current may flow to the anode (blocking direction).
Conversely, if a positive voltage is added to the
anode, the current may flow through to the cathode
(flow direction). If a negative voltage is applied,
the diode has the opposite behavior as with
a positive voltage.
Note:
 Positive voltage at cathode:
Diode blocks.
 Negative voltage at cathode:
Diode lets current through.
 Positive voltage at anode:
Diode lets current through.
 Negative voltage at anode:
Diode blocks.
3 842 950.00 en
“Recovery Diode”
The term “recovery diode” is only seen in
connection with a circuit in which coils (inductance)
are connected. Fig. 34 shows an example of
a possible circuit diagram in which a diode
is connected as a “recovery diode.”
Fig. 34
1 Solenoid valve
2 Recovery diodes
3 Switch
4 Fuse
When the solenoid valve is switched off, an
induction voltage is then generated in the coil. The
potential of the induction voltage is directed against
the feed voltage. This voltage is so high that when
the switch is opened, an electric arc is produced
which is capable of fusing the switch contact. Since
the voltage induced when the valve is switched off
is negative and is applied to the cathode of the
diode, the diode is connected in the forward
direction for the voltage. The inductive voltage is
therefore short-circuited to the ground. As a result,
this voltage at the switch contact is no longer so
powerful that it can fuse the contacts of the switch.
31

Varistor
A varistor is a voltage-dependent resistor (Fig. 35).
In principle, it fulfills the same function as a
recovery diode and is added to a circuit in the
same manner.
Fig. 35
The following is always true of varistors: The
higher the voltage, the lower the resistance.
32
3 842 950.00 en
Generator Regulator
The function of a generator regulator is to regulate
the field current of the generator so that a constant
voltage, based on the condition of the battery,
is always available for charging the battery (see
Fig. 36). The regulator ensures the voltage
remains constant no matter what the speed of the
generator is. The field current is generated by the
main windings of the generator (4) and
transformed into direct current by means of so-
called field diodes. This DC voltage is then applied
to the regulator (1) that controls the generator's
field current.
Fig. 36
1 Voltage regulator
2 Charge indicator
3 Ignition switch
4 Generator
5 Field diode
The ends of generator windings (4) are designated
using U, V, and W (see Fig. 36).
 3 842 950.00 en

Vehicle Fuses
Type Nominal current Color
A
Round 5 Yellow
fuses 8 Black
8 White
16 Red
25 White
25 White
Fuse strips 25 White
30, 50, 100 Gray
125, 150, 250
35, 60, 100 Gray
Plug 3 Violet
fuses 4 Pink
5 Beige/clear
7,5 Brown
10 Red
15 Blue
20 Yellow
25 Neutral/white
30 Green

Glass 5 Red
fuse 10 Yellow
15 Blue
20 Green
25 Silver

Radio 2 Clear
Table 7

33
 3 842 950.00 en

MARKING INDIVIDUAL PARTS

Extract from DIN EN 81346-2 (replaces DIN 61346-2 and DIN 40719-2)

Letter Name Examples

A Structural component, structural sub-component Amplifier, magnetic amplifier, device combination

B Conversion from non-electrical to electrical Measuring transducers, thermoelectric sensors, thermocells,

quantities (and vice versa) photoelectric cells, dynamometers, quartz crystals, rotating field
sensors, angle transmitters

C Capacitors —

D Delay devices, storage devices, binary elements Combination elements, bistable elements, monostable elements

E Various lighting devices, heating devices

F Protective devices Fuses, surge arresters, locking devices, circuit breakers,

protection relays, trips

G Generators, power supply Rotating generators, rotating frequency converters, battery,

power supply device, oscillators

H Alarm systems Visual and acoustic alarm devices

I DO NOT USE DUE TO RISK OF CONFUSION —

WITH “AMPERAGE”

K Relays, contactors Power contactors, auxiliary contactors, servo relays, turn signal
flashers, timer relays

L Inductances Inductance coils

M Motors —

P Measuring devices, test equipment Display, recording and metering measuring devices, pulse
generators, clocks

Q Power current switching relay Circuit breakers, disconnect switches, safety switches, engine
protection switches, automatic switches, fuse switches

R Resistors Adjustable resistors, potentiometers, regulating resistors

S Switches, selector switches Push buttons, limit switches, control switches, signal generators

T Transformers Voltage converters, current transformers

U Modulators, converters Frequency converters, transducers, inverters, converters,

inverted rectifiers

W Transmission paths, waveguides Jumper wires, cable assemblies, busbars

X Terminals, plugs, sockets Disconnect plugs and disconnect sockets, test plugs, terminal
strips, soldering strips

Y Electrically activated mechanical devices Brakes, clutch, valves

Z Terminator, compensation devices, filters, Cable reproductions

limiters, yoke connections
Table 8

34
 3 842 950.00 en

STANDARD TERMINAL DESIGNATIONS

Terminal Designations
(extract from DIN 72552)
Terminal designations are not identical to line designations, since devices with different terminal descriptions
may be connected to both ends of a line. If the terminal designations are no longer adequate (multiple plug
connection), terminals get consecutive number or letter designations that have no standardized functional
assignment.

Terminal Meaning Terminal Meaning

1 Ignition coil, Electric Motors

1)
ignition distributor 32 Return line
1)
Low voltage 33 Main connection
Ignition distributor with two separate power 33 a Self-parking
1a circuits 33 b Shunt field
1b to contact breaker I 33 f for second smaller speed step
to contact breaker II 33 g for third smaller speed step
33 h for fourth smaller speed step
2 Short circuit terminal
33 L Rotation direction left
(magneto ignition)
33 R Rotation direction right
4 Ignition coil, ignition distributor high voltage
45 Starting engine
Separate start relay, output; starting engine,
Ignition distributor with two separate power
input (main current)
4a circuits
from ignition coil I 45 a Two-starter parallel operation
4b terminal 4 45 b Start relay for engagement current
from ignition coil II, Output starting engine I,
terminal 4 Input starting engines I and II
Output starting engine II
15 Switched positive terminal downstream of
battery, (output of ignition [driving] switch) 48 Terminal on the starting engine and on the
repeating start relay
15 a Output at series resistor to ignition coil and
starting engine for monitoring the start procedure

Glow plug and starter switch 49 Turn-signal flasher

17 Start 49 a (pulse generator)
19 Preheat 49 b Input
49 a Output
Battery Output, 2nd turn signal flasher
30 Input from battery positive terminal, direct Output, 3rd turn signal flasher
30 a Battery changeover relay 12/24 V 50 Starting engine
Input from battery II positive terminal Starter control
31 b Return line to battery negative or ground, (direct)
via switch or relay (switched negative)
50 a Battery changeover relay
Battery changeover relay 12/24 V return line Output for starter control
31 a to battery II negative terminal return line
to battery I negative terminal 50 b Starter control
31 c
for parallel operation of two starters with
sequential control
50 a Start relay for sequential control of the
50 d engagement current for parallel operation
of two starting engines
Input at start relay for starting engine I
Input at start relay for starting engine II

Note:

1) Polarity change possible in terminal 32–33

35
 3 842 950.00 en

Terminal Meaning Terminal Meaning

Start-locking relay AC generator

50 e Input (Magneto generator)
50 h Output 59 AC voltage, output, rectifier, input
59 a Charging armature, output
AC generator
59 b Taillight armature, output
51 DC voltage at rectifier
59 c Brake light armature, output
51 e DC voltage at rectifier with choke
coil for daytime driving 61 Generator indicator lamp

Trailer signals Tone sequence control

52 Additional signals from trailer 71 Input
to traction vehicle 71 a Output to horn 1 + 2 low
71 b Output to horn 1 + 2 high
53 Wiper motor,
input (+) 72 Alarm switch
53 a (rotating beacon)
Wiper (+), self-parking
53 b Wiper (shunt winding) 75 Radio, cigarette lighter
53 c Electric windshield washer pump 76 Loudspeakers
53 e Wiper
(brake winding) 77 Door valve control
53 i Wiper motor with permanent magnet and third Switches
brush (for higher speed) Normally closed and changeover switches
Brake light 81 Input
54 for lighting combinations and trailer plug 81 a Output 1, normally closed switch side
connections 81 b Output 2, normally closed switch side
Trailer signal Normally open switch
54 g Pneumatic valve for brakesaver, solenoid 82 Input
operated 82 a Output 1
55 Fog lamp 82 b Output 2
82 z Input 1
56 Headlamp 82 y Input 2
56 a High bean and high-beam indicator lamp
Multi-position switches
56 b Low beam
83 Input
56 d Headlamp flasher contact
83 a Output, position 1
57 Parking light for motorcycles (abroad also for 83 b Output, position 2
passenger cars, commercial vehicles etc.) 83 L Output, position left
57 a Parking lamp 83 R Output, position right
57 L Parking lamp, left Current relays
57 R Parking lamp, right 84 Input
58 Clearance lamp, taillight, license plate and Actuator and relay contact
instrument panel lamps 84 a Output
58 b Taillight changeover for two-wheel tractors Actuator
84 b Output
58 c Trailer plug fitting for one-wire taillight with Relay contact
fuse in trailer Switching relays
85 Output, actuator
58 d Variable intensity instrument illumination, (end of winding to negative or ground)
taillight and clearance lamp Input, actuator
58 L left 86 start of winding
58 R right, 86 a Start of winding or 1st winding
License plate lamp 86 b Winding tap or 2nd winding

36
 3 842 950.00 en

Terminal Meaning

Relay contact for normally closed and

changeover switches,
87 Input
87 a Output 1 (normally closed switch side)
87 b Output 2
87 c Output 3
87 z Input 1
87 y Input 2
87 x Input 3
88 Relay contact for normally open switches,
Input
Relay contact for normally open
and changeover switches
88 a (normally open switch side)
88 b Output 1
88 c Output 2
Output 3
Relay contact for normally open switch
88 z Input 1
88 y Input 2
88 x Input 3

Generator and generator regulator

B+ Battery positive
B- Battery negative
D+ Dynamo positive
D- Dynamo negative
DF Dynamo field
DF 1 Dynamo field 1
DF 2 Dynamo field 2
Alternator
U, V, W Alternator terminals

Direction indicator lamp (turn-signal flasher)

C First indicator lamp

C0 Main connection for indicator control circuits
separated from the direction indicator
C2 Second indicator lamp
C3 Third indicator lamp (e.g. when towing
two trailers)
L Turn-signal lamps, left
R Turn-signal lamps, right

37
© Copyright The reproduction, distribution and utilization of this manual / file as well as the
Caterpillar Global communication of its content to others without express authorization is prohibited.
Mining HMS GmbH Offenders will be held liable for the payment of damages. All rights reserved in the event of
2021 the grant of a patent, utility model or design.
Printed in Germany