- Install, Test and Repair
Electrical/Electronic
Units/Assemblies and Low Voltage
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.
