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    48549360-12V24V-ELECTRICAL-SYSTEMS(1)

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    41 views26 pages

    12V24V Electrical Systems

    Uploaded by

    Abo Achraf Laalawi

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Service Training STUDENT Course Materials REFERENCE MATERIALS CATERPILLAR TPL RELAY _TP2 START qs STARTER 1P10—" MOTOR. BATTERIES TPs DISCONNECT ‘SWITCH 12-V AND 24-V ELECTRICAL SYSTEMS Service Training 5/198 Reference Materials Service Training 5/198 TABLE OF CONTENTS Maintenance-Free Batteries Require Different Troubleshooting Procedures ... af Preventive Maintenance For Batteries 5 Alterator/Generator Output Test On The Engine... 6 ‘Testing The Starter On The Engine 7 Jump Starting Procedures. How To Determine If Relays Are Functioning Comtectly......connevnnnnnnnnnnnnnnnned Be Sure Battery Cable To Starter Connection Has Correct Torque... Electrical System Damage From High Voltage ..... Understanding Four Wire Windshield Wiper Motors (12. & 24V) .occnveneennnnnennendT Procedure For Replacing Batteries Or Battery Cables Procedure For Replacing Batteries Battery Cables Or Disconnect Switches ...0--oe--u18 Procedure For Replacing Batteries, Battery Cables Or Disconnect Switches Understanding Causes Of Blown Fuses And Tripped Circuit Breakers .. Understanding Circuit Breakers... ees or 20 ‘Understanding "Shorts," "Opens" and "Intermittents’, How To Troubleshoot A Short-To-Ground In Power Wiring 22 Limitations On Engine Cranking Time. Description Of Service Code Information. 23 Explanation of "Pull Up Voltage” . Machine Electrical Systems Schematics with New Format. Reference Materials Service Training 5/198 June 20, 1988 Maintenance-Free Batteries Require Different ‘Troubleshooting Procedures 1401 Many new Cat products are now using maintenance free batteries, These batteries require different test procedures from conventional batteries. Since there are no vent plugs ‘on maintenance-free batteries, there is no way to check the specific gravity of the electrolyte. A hydrometer cannot be used. Instead, the voltage of the battery must be checked to ‘determine the state of charge. Measure the open circuit voltage ofthe battery: Use a digital volt meter such as 67070 Multimeter Group. Set the meter ‘on the 20 volt DC seule and touch the probes tothe battery terminals. Ifthe battery voltage is 12.40 or above, the battery is ready for use, if below 12.40 volts, it must be recharged for satisfactory performance. Ifa maintenance-free battery is being considered for ‘warranty, the same voltage check must be done before performing a Toad test. Maintenance-free batteries below 12.40 volts will fail a load test, but still may be good, serviceable batteries when recharged, Reference Materials ‘When maintenance-free batteries are deeply discharged, they may not recharge if you just jump-start dhe engine. Cat alternators produce 13.8 volts on 12 volt products and 27.5 volts on 24 volt products. But 16 volts (32 volts on 24 volt systems) may be requited for charging to begin. Recharge with a battery charger capable of supplying 16 volts so that the batteries will accept a charge. Once they accept charging current, indicated by an increase inthe charger ammeter reading, the voltage must then be reduced. Its important not to let the charging voltage exceed 16.0 volts, especially as the battery becomes fully charged. ‘The Cat maintenance-free battery used in original equipment (375760) is designed and built to rigid Cat specifications. It can be deeply discharged, such as by leaving the lights on over a weekend, and still be a good serviceable battery when fully recharged. For complete testing and charging information, refer to Special Instruction, Form SEHS7633, "Battery Procedur Service Training 5/198 ‘Mareh 27, 1989 Preventive Maintenance For Batteries 1401 ‘The battery is often overlooked in many preventive maintenance programs. This is unfortunate because, with a litle care, battery life can be substantially extended, Caterpillar suggests some relatively simple steps to ensure steater reliability and longer battery life. ‘The most important is to make sure electrolyte levels are ‘checked at appropriate intervals. Standard, or conventional, batteries should be checked every 100 hours. Electrolyte levels should be checked in low maintenance batteries at ‘each 250-hour interval. No acid level check is required or ‘can be performed on the maintenance-free design. the electrolyte level is low, add only distilled water to keep possible contaminants out ofthe battery. While checking the electrolyte, make a few other visual inspections: 1. Is there any indication of damage or corrosion on the battery terminals, the battery box or wiring? If so, clean or replace the necessary components. Cleaning can best be done with a solution of baking soda and water (I 1/2 cups baking soda per gallon of water). Visual inspection could also alert you to the possibility of a cracked battery which ‘could only be identified by corrosion inthe battery tay. 2, Are the hold-downs tightened correctly? Vibration will ‘destroy a battery faster than anything else. 3: there debris under the battery? This must be removed \when hold-downs ate tightened as this can cause holes to be Worn in the ease and result in loss of electrolyte. 4. Are all vent caps correctly in place? Loss of vent caps ‘can pose a potential hazard and permit contamination of the battery. '5, Are the alternator belts tight? Ifnot, the battery will not ‘charge correctly and poor performance will result, (6, What is the alternator output voltage? Use a voltmeter to ‘cheek it. Tis will identify both low charging voltages due to loose Fan belt and also high charging voltages which ean ‘damage a battery. Altemator charging voltage should be 13.5 to 14.5 volts fora 12 volt system and 27.0 to 29.0 for a 24 vole system, While the maintenance-free batteries do not require electrolyte checks, do steps 1, 2,3, Sand 6 every 1,000 hours for maximum battery life. Reference Materials Another important factor in prolonging battery life is proper Storage, Bateries are perishable items and can lose efficiency when notin use. Batteries discharge faster in high temperatures so they should be stored in the coolest place possible. Small, constant electrical current loads like brushless alternators, electronics, clocks, etc, can run a battery down when not in use, if a machine will not be used for 30 days or more, open the disconnect switch or remove the ground (negative) cable from the battery ‘The next step isto check the batteries’ state of charge. This is called checking the open-circuit voltage. Use a digital volt meter such as 6V7070 Multimeter. An analog meter (moving needle type) is not accurate enough for battery use Ser the voltmeter on the 20volt DC state and touch the probes tothe battery terminals withthe engine off. A reading of 12.40 or more (for a 12 volt battery) means the battery is charged sufficiently. Any reading less than 12.40 ‘means the battery needs charging, If the battery has been recently charged, the surface charge ‘must be removed before making this test, To remove the surface charge, crank the engine for about 5 seconds with the fuel shut off, or turn on the headlights for about one ‘minute, The open ciecuit voltage can then be accurately checked. Ifthe battery is below 12.40 open circuit voltage, then it should be changed. The slow change method for charging battery will provide the best results. The battery should be charged at the manufacturer's recommended rate or 3% of the Cold Cranking Amps (CCA) rating. For example, Catespllar’s 8D battery is rated at 1250 CCA, thus the charge rate should be approximately 37 amps. ‘The charging voltage should never exceed 16 volts. Too ‘much voltage will cause serious damage to the batery Charge time could be as little asa few hours fora battery near 12.40 open-circuit voltage t approximately 8 hours for a fully discharged battery. For more complete information on charging a battery, see either Special Instruction, SEHS9014, "Battery Charging Rate/Time Tables", or SEHS7633 "Battery Test Procedure" ‘To assure the battery will function correctly, it should be load-tested, To do this, see Special Instruction SEHS7633 Battery Test Procedure’ Preventive maintenance and appropriate checking and charging can increase battery life. There are two most significant problems with batteries brought in for service: they have been discharged or they have been subjected to use (for example: lack of water, loose hold-downs, etc.) Rogular preventive maintenance can reduce the possibility of throwing away a good battery. You can obtain more information on batteries and assistance in battery testing from any Caterpillar dealer. Service Training 5/198 May 4, 1987 Alternator/Generator Output Test On The Engine 1401, 1404, 1405, 1406 All Caterpillar Engines REFERENCE ARTICLE: "Testing The Starter On The Engine, inthis isue, ‘Servicemen often need a procedure to follow to determine if ‘an altemator or generator is working, or if it needs to be replaced. This general procedure is valid for any type of system. voltage, or charge rating, ‘Tools Needed: 6¥7070 Digital Multimeter (or 67800 or 6V3030 or ‘equivalent 870900 AC/DC Clamp-on Ammeter or equivalent 1, Put the multimeter positive (+) lead on the B+ terminal of the alternator. Put the negative (-) lead on the negative (-) terminal of the alternator. Put the clamp-on ammeter around the positive output wire ofthe alternator, 2, Tun offal electrical accessories. With the fuel off, crank the engine for 30 seconds. Wait wo minutes to let the starter cool. IFthe system appears to be up to specifications, cerank the engine again for 30 seconds, NOTE ‘Cranking the engine for 30 seconds partially discharges the batteries in order to do a charging test if bateries are already low in charge, skip this step. Jump-start engine or charge batteries as required Reference Materials 3. Start the engine and run at approximately 1/2 throt. 4, Immediately check output current, This initial charging current should be equal to or greater than the full output current shown in the Service Manual. The most common alternators are 24V Systems ‘6N9294- 35, ‘589088 - SOA '8N999 -75A 61139535, 712095 - 35, 12V Systems, "TNAT84- 408, 6T1396- 55, 712096- 55, 5. Within approximately 10 minutes at 1/2 throttle (possibly longer depending upon battery size, condition and alternator rating), the alternator output voltage should be 27.5 plus or ‘minus 1 Vol indicating the alternator is performing within spec. See Fault Condition Chart *12V System - 13.8+.5V +30V System - 34.4 13V +52 System - 36.7 + 13V 6. The charging current during this period should taper off to less than approximately 10 Amps, depending again upon battery and alternator capacities. See chart. Fault Conditions and Possible Causes Voltage After About 10 Min, is Below Spec. Voltage Alter About 10 Min. is In Spec. Voltage After About ‘Replace alternator (defective regulator, open stator phase, and/or rectifier) ‘Current at Startup Below Specification “Tum on all accessories. I'vollage drops below spec., replace alternator (open rectifier and/or stator phase ‘Current at Startup Reached spec. and then tapered off ‘Replace alternator (defective regulator ‘Alternator and batteries in spec. Turn on all acessories to verify. Voltage must say in spee Replace alternator (shorted regulator) ‘Cheek batteries per Form SEHS7633. Do alternator test again if necessary (Current at Startup Exceeds spec, and stays high ‘Check batteries per Form SEHS7633, Do alternator test again if necessary Replace alternator (shorted regulator) Check batteries for possible damage English SEHS 7633 is also available in French (SFHS7633) «Spanish (SSHS7633), and German (SGHS7633) 10 Min, is Above Spec. Service Training 5/198 May 28, 1990 ‘Testing The Starter On The Engine 1453, 1450, 1401 ‘This article replaces the article with the same ttle on Page 12 of the May 4, 1987 Service Magazine REFERENCE ARTICLE: Service Magazine; May 4, 1987; Page 10; "Alternator/Generator Output Test On The Engine.” Service Magazine; December 10, 1984; "Starters That Remain Engaged After Engine Is Running, Service Magazine: April 24, 1989: "Page 1; "Causes And Exfects Of Low Battery Voltage On Electric Starters Reference Materials REFERENCE: Special Instruction, SEHS7768, "Use of (6¥2150 Starting/Charging Analyzer Group." This is a general procedure to help aid the serviceman determine ita starter needs replacement. I is NOT intended to cover all possible problems and conditions, but to serve only asa guide. The most common 24V circuit is discussed and 12V circuits are indicated as applicable. On engines with a diagnostic connector, the 6V2150 Starting/Charging Analyzer Group helps you to do the following procedure in seconds. General Information Starting systems usually have four major components «Start switch «Star relay _ Starter solenoid . Starter motor TP1 TP2 STARTER MOTOR TP10 TPS START TPs BATTERIES DISCONNECT ‘SWITCH —y Service Training 5/198 ‘The only exception to this typical cranking circuit is that some small engines do not require the start relay. In this ‘case the start switch is connected directly tothe starter solenoid, ‘Start switches are relatively low current devices. They are rated to switch approximately 5 to 20 amps. Because the coil ofa start relay between TP2 (Test Point 2) and TPI in lustration 1 draws about 1 amp, the start switch can easily turn on the start relay and have long life. ‘The switch contacts ofa typical stat relay are rated t0 switeh between 100 and 300 amps, Because a starter solenoid requires only 5 t0 50 amps, the start relay can ‘easily switch this load, ‘The starter solenoid has two functions: it engages the pinion withthe flywheel, and it isa high current switch rated about 1000 amps that actually turns on the starting motor. ‘The starter solenoid has two coils: the pull-in coil (W) «draws about 40 amps and holdin coil (X) requires about $ amps. The instant the start relay closes, both eoils (W and X) receive power. Battery voltage is applied tothe high end ‘ofboth coils, at Test Point (3) which is the "stat" terminal (S). The low end of hold-in coil (X) is permanently ‘connected to the ground post ofthe starter motor. Grounding forthe low end, Test Point (4), of pull-in coil (OW) is momentary, and takes place through the DC resistance ofthe starter motor. When magnetic force builds in both coils, the starter pinion is moved to engage the ring gear. Only then will the solenoid contacts close to power the starter motor. This temporarily removes the ground from pull-in coil (W), and puts battery voltage on both ends of it while the motor cranks. During this period, the pull-in coil is out of the circuit and draws no current, Cranking ‘continues until power to the motor solenoid is turned off by the start swite ‘The result ofthese switches and relays i to permit aS amp ‘dash-mounted switch to turn on a 500 to 1000 amp motor for cranking an engine. Battery voltage (power) available during cranking depends ‘on the temperature of the bateries. See Chart A. This chart is only a GUIDE as to what to expect from a NORMAL system, ‘Chart A-Typieal System Voltage During Cranking Versus Ambient Temperature axctere [rete | were Temp. |C10°F o20°F) [20°F 10 50°F) _|(60°F To 80°F) 2avor | 1aVel6v | Viiv | 16Veo20¥ Systm ravi | 6vosv Tio BVI 1OV System Reference Materials Chart B shows maximum allowable voltage drops in the high current battery cicuit to the starter. These Values are ‘maximums for engines with more than about 2000 SMH. Newer engines have less voltage drops ‘Chart B-Maximum Allowable System ‘Voltage Drops During Cranking ‘Absolute Maximum Voltage Reading Cireuit av BV Batt. Pos. Postto Starner _0.5V 03V Pos. Post (TP10 to TP6) Batt, Neg, Post to Starter | _14V OV Neg. Post (TP7 to TPS) Drop Across Only Tov 3 Disconnect Switch (TPS to TP9) ‘Start Relay Contacts ORV oav (TP3 to TPO) ‘Solenoid Contacts ORV Dav (TP6 to TPA) Voltage drops greater than those listed are usually caused by loose and/or corroded connections or bad switch contacts. ‘The entire diagnostic procedure can be reduced to:

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