This document provides information on electrical systems, components, and testing techniques. It discusses how to use multimeters to measure voltage, current, resistance, and check for continuity. It also describes electrical components like switches, relays, and motors. Proper use of wiring diagrams, diagnostic equipment, and safety procedures for working with high and low voltage systems are emphasized. Electrical problems are discussed along with starting, charging, and battery systems.
This document provides information on electrical systems, components, and testing techniques. It discusses how to use multimeters to measure voltage, current, resistance, and check for continuity. It also describes electrical components like switches, relays, and motors. Proper use of wiring diagrams, diagnostic equipment, and safety procedures for working with high and low voltage systems are emphasized. Electrical problems are discussed along with starting, charging, and battery systems.
This document provides information on electrical systems, components, and testing techniques. It discusses how to use multimeters to measure voltage, current, resistance, and check for continuity. It also describes electrical components like switches, relays, and motors. Proper use of wiring diagrams, diagnostic equipment, and safety procedures for working with high and low voltage systems are emphasized. Electrical problems are discussed along with starting, charging, and battery systems.
This document provides information on electrical systems, components, and testing techniques. It discusses how to use multimeters to measure voltage, current, resistance, and check for continuity. It also describes electrical components like switches, relays, and motors. Proper use of wiring diagrams, diagnostic equipment, and safety procedures for working with high and low voltage systems are emphasized. Electrical problems are discussed along with starting, charging, and battery systems.
AGR MEM2 M07 1117 INTRODUCTION Use of electrical testing equipment and electrical testing techniques When and where to use voltage, ohm, amp and specific gravity measurements and simple circuit testing techniques. How to use voltage, ohm, amp, specific gravity measuring and simple circuit testing techniques. How to use the electrical testing equipment required. How to conduct tests following electrical safety and workplace procedures. How to calculate amps, ohms, and volts to determine component condition. How to make recommendations based upon the results of your tests. How to interpret the results of your tests. Electrical Terminology Current is the movement of electricity through a wire or circuit Voltage is the pressure that pushes the electricity through the wire or circuit Resistance is the obstacle to current flow and a conductor carries current to the parts of a circuit “Hot wires” connect the battery positive to the components of each circuit Insulation stops the current flow and keeps the current in the metal wire conductor Electric Circuits An electrical circuit contains a power source, conductors, and a load The load is part of a circuit that converts electrical energy into another form of energy A series circuit has only one conductor path or leg for current through the circuit If any part of the circuit is “opened”, all of the series circuit stops working A parallel circuit has two or more legs or paths for current One path can be closed and the other opened, and the closed path will still operate A series-parallel circuit has both series and parallel branches in it Ohm's Law calculates an unknown electrical value when two values are known Figure 26–2. Ohm’s Law is a simple formula for calculating electrical values in a circuit Magnetism Magnetism involves the study of how electric fields act upon ferrous objects A flux or magnetic field is present around permanent magnets and current-carrying wires An electromagnetic field is a set of windings or wires wrapped around an iron core Electric motors, solenoids, relays, and other parts use this principle Diagnostic Equipment Locating an electrical fault is not possible without using diagnostic tools A multimeter (VOM) is a voltmeter, ohmmeter, and ammeter combined into one case A digital multimeter (DVOM) has a number readout for the test value An analog multimeter (AVOM) has a pointer that moves across the face of a scale Use of an AVOM can damage sensitive electronic components Test Light, Jumper Wires Test light can determine if current is flowing through a circuit Jumper wires are used to temporarily bypass circuits or components for testing Figure 26–4. Jumper wires can be used to bypass resistive parts or to connect power directly to parts to check their operation. For example, if a motor runs when connected directly to voltage, you would know the circuit might not be providing power or a ground to the motor. Using Multimeters A multimeter must never be connected to a circuit in which current is flowing To measure resistance with a multimeter: Set the range selector switch on the highest range Connect the test leads to opposite ends of the circuit Reduce the range setting until the meter shows a reading near the middle of the scale Checking Continuity A circuit remains closed and operational when it has continuity The continuity check determines if the electrical circuit has a complete path without any opens Set the range selector switch on the highest resistance range position Connect the multimeter test leads to the opposite ends of the wire or part being tested Read the meter An infinite reading shows an open circuit and a zero reading shows continuity Measuring Voltage The multimeter allows you to select either alternating current voltage (ACV) or direct current voltage (DCV) AC current is the current found in your home DC current is normally measured in an automobile Some signals from sensors can be AC Current or amperage is sometimes measured to check the consumption of power by a load Measuring Voltage (continued)
Modern ammeters have an inductive pickup
that slips over the wire or cable to measure current A high current draw indicates a low resistance A low current draw indicates a high resistance Checking for Shorts
When checking for a short between two
adjoining wires in a harness: Set the range selector as for a continuity check Connect the test leads to the opposite ends of the adjoining wires The multimeter should read almost infinity Wiring Diagrams
Wiring diagrams are used to determine and
isolate problems Abbreviations are used on wiring diagrams so that more information can be given Electrical symbols are graphic representations of electrical-electronic components Wire color coding allows you to find a specific wire in a harness or in a connector Wiring Diagrams (continued) Circuit numbering specifies which part of the circuit the service manual is referring to Wiring harness has several wires enclosed in a protective covering Service manual gives illustrations with code numbers for locating parts and connections May also give a part location diagram for finding electrical parts Electric Components
A switch turns a circuit on or off manually
A solenoid is an electromagnet with a movable core or plunger A relay is a remote control switch A bad relay will often have burned points that prevent current flow to the load Motors use permanent and electromagnets to convert electrical energy into a rotation motion Circuit Protection Devices
Prevent excess current from burning wires
and components With an overload or short, too much current tries to flow Without a fuse or breaker, the wiring in the circuit would heat up Fuses
Fuses burn in half with excess current to
protect a circuit from further damage The cartridge fuse is found on most older domestic vehicles and a few imports Domestic vehicles use blade or spade fuses; European imports may use ceramic fuses A blown fuse has infinite resistance Fuse ratings are current at which a fuse will blow A fuse box holds various circuit fuses, breakers, and flasher units for turn and emergency lights Fuse Links
Fuse links (fusible links) are smaller-
diameter wire spliced into the larger circuit wiring Ensures over-current protection Normally in engine compartment near battery Often installed in the positive battery lead that powers the ignition switch Covered with a special insulation that bubbles when it overheats Circuit Breakers
Circuit breakers heat up and open with
excess current to protect the circuit Many circuits are protected by circuit breakers Each circuit breaker conducts current through an arm made of two types of metal bonded together The arm heats up if it carries too much current As one metal expands farther than the other, the arm bends, opening the contacts and breaking the current Electrical-Electronic Systems
Ignition system produces an electric arc in a
gasoline engine to cause the fuel to burn Ignition coil is a step-up transformer that produces high voltage needed to make the current jump the spark plug gap Spark plug wires are high-tension wires that carry coil voltage to each spark plug Spark plugs ignite the fuel mixture in the engine's combustion chambers Starting and Charging Systems
Starting system has a large electric motor
that turns the engine flywheel Ignition switch connects battery voltage to a starter solenoid or relay Starter solenoid, when energized, connects the battery and the starting motor Starting motor is a large DC motor for rotating the engine flywheel Flywheel ring gear meshes with the starter- mounted gear while cranking Starting and Charging Systems (continued)
Charging system recharges the battery and
supplies electrical energy to the running engine Voltage regulator controls alternator output and charging system voltage is 13 to 15 volts To check for spark Pull off one spark plug wire, install an old spark plug; lay the spark plug on the engine ground When you crank the engine a bright spark should jump across the spark plug gap To check for fuel, a pressure gauge on the engine's fuel rail should read within specs Electrical Problems Open circuit is an unwanted break in a circuit Short circuit is an unwanted wire-to-wire connection in a circuit In a grounded circuit the current flows to ground without flowing to the part Abnormal resistance is due to a bad connection or partial short Diagnostic charts give possible causes for electrical problems and symptoms Batteries Battery stores electrical energy chemically Voltage spikes are voltage surges that can destroy may microcircuits in electronic systems Good idea to remove the battery before doing any kind of collision repair work Once the battery has been placed on a bench, it should be checked for damage A voltmeter or a specialized battery tester checks battery condition Batteries (continued) Follow an eleven-step procedure for charging a battery using a battery charger Avoid jump starting whenever possible Jumper cables connect two batteries when one is “dead” Special care is necessary when charging or jump starting to avoid damaging computer circuits Before reinstalling the battery after body work, clean its terminals Figure 26–13. Jumper cables or a battery charger must be connected carefully to prevent sparks or electronic component damage. Connect positive to positive and negative to negative in the proper sequence: red to red, then black to any metal ground away from the Battery Safety Keep batteries away from the welding operations, open flames, sparks, or heat sources Do not charge batteries with cracked case -Do not smoke near batteries Ventilate the area around dead or damaged batteries to avoid explosion Do not charge a frozen battery Electrolyte in the battery is a mixture of water and sulfuric acid and must be kept in mind Lighting and Other Electric Circuits
Lighting system feeds electricity to the light
bulbs throughout the vehicle When lights fail to function, check the bulb first -If the bulb is good, trace for an open feeding current to the dead bulb Other electrical circuits (horn, power windows, etc) use the same principles just discussed Repairing Wiring and Connections
When servicing electrical wiring, never tug
on the connectors Route wiring in the same location as the OEM Protect the electrical connectors from moisture and corrosion by using dielectric grease Use the same size and type of wiring for repairs Solder Repair
Soldering uses moderate heat and solder to
join wires or other parts All copper wire joints should be soldered Use rosin-core solder, not acid-core, when soldering electrical connections Acid fluxes create corrosion and can damage electronic components Electrical tape can be used around wire splices when they will not be exposed to moisture Electrical Connector Service An automotive electrical connector includes two plastic, snap together fittings -Allow several wires to connect together securely Various connector designs are used on vehicles -Each requires a different method for disconnection If needed, inspect electrical connectors when trying to find opens When electrical trouble is experienced in any circuit it is advisable to start with the battery. Battery 1. A visual inspection and a few quick electrical checks with a voltmeter, ammeter, ohmmeter and hydrometer will reveal the condition of the power source. 2. The battery posts and cables must be clean and free of deposits. 3. The use of undersize batteries will result in poor performance or early failure. A new battery should be at least of equal ampere- hour rating to the original battery. 4. A 12-volt dry charged battery needs to be activated with electrolytes at a temperature under 60 degrees F for a 10-minute period at warm up charge of 15 amperes. 5. Always install a battery with the same positive and negative posts in proper position. Hold down bolts should be tight to prevent movement and damage to the battery case. 6. The ground strap should be connected last to prevent arcing. A coating of spray-on battery corrosion preventative, petroleum jelly or grease should be applied to post and cable clamps. 7. For batteries which have discharged and require charging, a slow charge is best. ( Example, 4-amps for 24 hours is better than 50 amps for 1 ½ hours.) This is for a 100 amp/hour capacity battery. 8. When checking a battery with a hydrometer the temperature of the electrolyte should be considered. 9. When reading a hydrometer the barrel must be held vertically and just the right amount of acid be drawn up into the barrel to float the tube freely. 10. The following table illustrates the specific gravity for a cell in various stages of charge to crank an engine at 80 degrees F. 1.280 Specific Gravity 100% charged 1.220 " " 50% charged 1.190 " " 25% charged 1.160 " " very little good 1.130 " " discharged 11. Pouring acid into a discharged battery will cause early failure. Generator The generator supplies electricity when driven mechanically by the engine. It should supply current to the battery, to keep it in a charged condition and to any connected electrical load. However, the regulator and the wiring has its part to play in the system. If the ammeter gauge is working properly on the tractor it should indicate the charging rate. 1. A system that has an overcharge will require excessive water usage and a high ammeter indication. 2. Check visually the wiring connections and make sure they are clean and tight. Repair or replace wires that are faulty or bare on insulation. 3. Periodically check the fan belt for wear, glazing, or bottoming on the pulley. 4. Hold generator pulley with fingers and feel for side play and freeness of rotation to determine condition of bearings. 5. Each bearing has grease supply which eliminates the need for periodic lubrication. 6. If in doubt of proper operation the alternator may be taken off and put on a test stand to check diodes, starter and rotor. 7. When connecting a booster battery, connect negative posts together and positive posts together. If leads are hooked wrong the diodes can be damaged. When you have sparks and high flow current there is danger of the wiring harness being burned. 8. Do not short across or ground any of the terminals on the regulator. An attempt to polarize an alternator can cause damage to the diodes, wiring harness and other components. 9. Complaints or troubles involving the charging circuit are either overcharging or undercharging of the battery. 10. An undercharged battery or one that “runs down” is the fault of a short, heavy usage, or faulty battery. Voltage Regulator 1. The regulator has a battery, generator, and field terminal. The operation or rate of charge is controlled by the cutout relay. The cutout is a magnetically operated switch that controls the flow or current. 2. Care must be exercised when cleaning points. Some points are soft and some very hard, requiring different methods. All oxides should be removed so the pure metal is exposed, although it is not necessary to file the surface perfectly flat. 3. Contact points may be cleaned with a strip of 400 silicon carbide paper and then cleaned with a strip of trichloroethylene paper 4. Never use emery cloth or sandpaper to clean contact points. Cranking Circuits The cranking motor converts electrical energy from the battery into mechanical energy which is used to crank the tractor engine for starting. 1. The cranking circuit consists of a battery, cranking motor, wiring and control switches. 2. The solenoid switch engages the pinion gear to mesh with the engine flywheel and reverse the process after the engine has started. 3. No periodic lubrication is needed and the cranking motor will have to be disassembled to inspect brushes and bearings. 4. The wiring circuit to the starting motor must have tight fittings and proper size wire to carry current due to high energy demands during cranking.