Tractor & Equipment

AIMS & OBJECTIVES

Course title Basic Electrics

Proposed date (s)
Max No of Students 10
Course duration 5 Days
Audience All Trainee Service Engineers
Prerequisites Technical background and practical Engine experience
Course Aims and Objectives At the completion of the course, given the necessary Caterpillar Service
literature, the Student will be able to:
1. State Ohm’s law and describe, to the Instructor’s satisfaction, the relationship between
resistance, current, voltage and Power
2. Describe to the Instructor’s satisfaction the function and operation of the following:
a) Resistors
b) Conductors
c) Batteries
d) Switches
e) Relays
f) Alternators
g) Starter Motors
3. Use diagnostic tooling, such as Multimeters and continuity lights
4. Describe to the Instructor’s satisfaction basic troubleshooting techniques
5. Use Component Rebuild Record sheets and Procedures sheets to inspect and record the
condition and measurement of 10 given engine components
6. Use Special Instruction REHS0126 to state the cause of 10 fault codes

Subjects covered include :-

a) Electrical and Electronic fundamentals
b) Series and Parallel circuits
c) Direct and Alternating current
d) Switches
e) Sensor, senders and PWM (Pulse Width Modulation)
f) How to read Caterpillar Electrical drawings
g) An introduction to ECM (Electronic Control Modules)
h) CID (Component Identifiers) FMI (Failure Model Identifiers) and MID (Module Identifiers)

Comments Electronic controls of Hydraulic systems will not be included

Suggested Handouts / reference material

Media No Title
SEKV3001 Acronyms and Glossary of Electrical / Electronic terms
SENR6910 777D Wiring schematic (3PR1 – Up)
SENR5392 D9R (7TL1 - 851)
SENR8459 D9R with 3408E (7TL852 – Up)
REHS0126 Caterpillar Electronic Controls Service Code Information Description List

Appendices 2g) Trainee Service Engineer – Basic Electrics Course Revision 1.0 23-02-01
 Introduction to Electricity
Basic Electrical
Fundamentals
COURSE OVERVIEW

OVERVIEW

This course introduces the student to basic electrical and electronic

fundamentals needed by a technician to properly diagnose and repair
the complex electrical systems installed in Caterpillar machines. The
course does not teach specific machine systems unless otherwise
stated in the lesson description.
The following course curriculum has been developed using the
reference materials and tooling listed on the following pages.
Substitute materials and tooling may be used at the discretion of the
instructor.
Course exercises and lab assignments may require modification(s) if
substitute materials and tooling are used.

© 2000 Caterpillar Inc.

Revision August 1, 2000 Property of Caterpillar Inc.
 Table of Contents
Table Of Contents
UNIT 1: Introduction to Electricity
Lesson 1: Electricity--How It Works
Lesson 2: Magnetism

UNIT 2: Electrical Circuits

Lesson 1: Ohm's Law
Lesson 2: Basic Circuit Theory
Lesson 3: Digital Multimeter
Lesson 4: Electrical Measurement
Lesson 5: Circuit Faults
UNIT 3: Electrical Components
Lesson 1: Basic Electrical Components
Lesson 2 : Solid State Electrical Components
Lesson 3: Component Symbols
UNIT 4: Machine Electrical Systems
Lesson 1: Battery
Lesson 2: Charging System
Lesson 3: Starting System
 Objectives
Basic Electrical
Fundamentals
OBJECTIVES

At the completion of this course, the student will have working

knowledge of basic electrical theory, components and basic electrical
systems. Using Caterpillar electrical schematics, test equipment and
other reference literature the student will be able to operationally test
Caterpillar machine systems. The student will also be able to
troubleshoot, diagnose and repair electrical components and
electrical systems.
 Course Reference Material
Basic Electrical
Fundamentals
Reference Materials

Other reference materials may be used at the

discretion of the instructor.
Service Publications:
Special Instruction--Use of 6V3000 Sure Seal Kit--SMHS7531
Special Instruction--Use of CE/VE Connector Tools--SEHS9065
Special Instruction--Servicing DT Connectors--SEHS9615
Special Instruction--Battery Procedures--SEHS7633
Special Instruction--Battery Charging Rate/Time Tables--SEHS9014
Special Instruction--4C4911 Battery Load Tester--SEHS9249
Service Manual Module--Starting and Charging Systems Operation
Testing and Adjusting (For Machines Equipped With Diagnostic
Connector) Individual Circuit Description
Tool Operating Manual--9U7560 Field Soldering Iron
Group--NEHS0601

Videos:
Basic Wire Maintenance--SEVP3197
How to Test a CAT Battery--SEVP1590
Testing the Alternator on the Engine--SEVP1591
Testing the Starter on the Engine--SEVP1592
Using the 9U7330 Digital Multimeter--SEVP3198
The Intelligence of Powerful Connections--AEVP2974

Miscellaneous:
Booklet--Battery Service Manual--SEBD0625
Service Magazine Articles: 3/27/89, 3/28/90, 5/4/87, 3/27/89, 6/28/88
Ugly's Electrical Reference - SEBD0983
 Course Tooling
Basic Electrical
Fundamentals
Tooling Requirements

Suggested Labs and exercises for this course require the following tools.
Substitute tooling may be used at the discretion of the instructor.
Compass/iron filings/pane of glass
9U7330 Digital Multimeter or equivalent
Fluke User's Manual, Fluke P/N 834218
7X1710 Multimeter Probe Group
6V3000 Sure-Seal Repair Kit
6V3001 Crimping Tool
6V3008 Insertion Tool
4C3406 Deutsch Connector Kit
9U7246 Deutsch Connector Kit
1U5804 Deutsch Connector Crimp Tool
9U7560 Field Soldering Iron Group (optional)
4C9024 Battery Group (optional)
Small bottle of denatured alcohol
8T9170 Electrical Components Group (if available)
1278087 Battery Analyzer
4C4911 Battery Load Tester
6V2150 Starting/Charging Analyzer
8T0900 AC/DC Clamp-On Ammeter, or
9U5795 AC/DC Current Probe
 Unit 1: Introduction to Electricity
UNIT 1
Introduction to Electricity

Unit Objectives:

At the completion of this unit each student will be able to: explain
how electricity and magnetism work.
Unit References:

Student Worktext
Tooling:

None Required
 Lesson 1: Electricity How It Works
Lesson 1: Electricity--How It Works
Lesson 1 Objective
At the completion of this lesson, the student will be able to:
Demonstrate an understanding of electrical theory by selecting the
correct responses on to basic questions on a multiple-choice quiz.

Fig. 1.1.1

Introduction
What is electricity? We say that flashlights, electric drills, motors,
etc. are "electric." However, we often refer to computers,
televisions, etc. as "electronic." What is the difference?
Anything that works with electricity is electric, including both
flashlights and electric drills, but not all electric components are
electronic. The term electronic refers to semiconductor devices
known as "electron devices." Electron devices are named such,
because they depend on the flow of electrons for their operation.
Unit 1 1-1-2 Electrical Fundamentals
Lesson 1

To better understand electricity, it is necessary to have a basic

knowledge of the fundamental atomic structure of matter. Matter is
anything that has mass and occupies space. It can take several forms
or states, such as, the three common forms being solid, liquid and
gas. This course will provide a basic understanding of the theoretical
principles needed to develop a foundation for studying and working
with electrical circuits and components as a Caterpillar technician.
Matter and Elements
We define matter as anything that takes up space, and that - when
subjected to gravity - has weight. Matter consists of extremely tiny
particles grouped together to form atoms. There are approximately
100 different naturally, occurring atoms called elements. An element
is defined as a substance that cannot be decomposed any further by
chemical action. Most elements have been found in nature.
Examples of some of the natural elements are: copper, lead, iron,
gold and silver. Other elements (approximately 14) have been
produced in the laboratory. Elements can only be changed by an
atomic or nuclear reaction. However, they can be combined to make
the countless number of compounds which we experience every day.
The atom is the smallest particle of an element that still has the same
characteristics as the element. Atom is the Greek word meaning a
particle too small to be subdivided.
Atoms
Although nobody has even seen an atom, its hypothetical structure
fits experimental evidence that has been measured very accurately.
The size and electric charge of the invisible particles in an atom are
indicated by how much they are deflected by known forces. Our
present "solar system" models, which has the sun at its center and the
planets rotating around it was known as the "atomic model", was
proposed by Niels Bohr in 1913.
Unit 1 1-1-3 Electrical Fundamentals
Lesson 1

NEUCLEUS

++
+ +++
+
+ +

ELECTRONS

Fig. 1.1.2 Electrons

The center of an atom is called the nucleus and is composed

principally of particles called protons and neutrons. Orbiting around
every nucleus are small particles called electrons. These electrons
are much smaller in mass than either the proton or neutron.
Normally, an atom has an equal number of protons in the nucleus and
electrons around the nucleus. The number of protons or electrons is
called the "atomic number". The "atomic weight" of an element is
the total number of particles--protons and neutrons--in the nucleus

NUMBER OF
ORBITING ELECTRONS
1 2
NUCLEUS
ORBITING ELECTRONS (2 PROTONS
2 NEUTRONS)
1P 2P
+ 2N
+
SHELL

NUCLEUS
(1 PROTON)

HYDROGEN ATOM HELIUM ATOM

(a) (b)

Fig. 1.1.3 Neutron, Proton, and Electron

Fig. 1.1.3 shows the structure of two of the simpler atoms. Fig.
1.2.3(a) is an atom of hydrogen, which contains 1 proton in its
nucleus balanced by 1 electron in its orbit or shell. The atomic
number for a hydrogen atom is 1. Fig. 1.1.3(b) shows a simple atom
of helium, which has 2 protons in its nucleus balanced by 2 electrons
in orbit. The atomic number for helium is 2 and it's atomic weight
would be 4 (2 protons + 2 neutrons).
Scientists have discovered many particles in the atom, but for the
purpose of explaining basic electricity, we need to discuss just three:
electrons, protons and neutrons. To better understand the basics of
electricity we will use an atom of copper as an example.
Unit 1 1-1-4 Electrical Fundamentals
Lesson 1

18

8
FIRST SHELL NECLEUS
2 (29 PROTONS,
35 NEUTRONS)

29 P
35 N

SECOND SHELL

THIRD SHELL
ATOMIC NUMBER =29
ATOMIC WEIGHT = 64
FOURTH SHELL

Fig. 1.1.4 Copper Atom

Fig. 1.1.4 shows a typical copper atom. The nucleus of the atom is
not much bigger than an electron, so you cannot really tell how big
they are. In the copper atom the nucleus contains 29 protons (+) and
35 neutrons and has 29 electrons (-) orbiting the nucleus. The atomic
number of the copper atom is 29 and the atomic weight is 64. What
happens when a length of copper wire is connected to positive and
negative source, such as a dry cell battery?

NEGATIVE POSITIVE
CHARGES CHARGES

ELECTRON FLOW

BATTERY

Fig. 1.1.5 Battery

An electron (-) is forced out of orbit and attracted to the positive (+)
end of the battery. The atom is now positive (+) charged because it
now has a deficiency of electrons (-). It in turn attracts an electron
from its neighbor. The neighbor in turn receives an electron from
the next atom, and so on until the last copper atom receives an
electron from the negative end of the battery.
The result of this chain reaction is that the electrons move through
the battery from the negative end to the positive end of the battery.
The flow of electrons continues as long as the positive and negative
charges from the battery are maintained at each end of the wire.
Unit 1 1-1-5 Electrical Fundamentals
Lesson 1

Electrical Energy
There are two types of forces at work in every atom. Under normal
circumstances, these two forces are in balance. The protons and
electrons exert forces on one another, over and above the forces of
gravitational or centrifugal. It has been determined that besides mass,
electrons and protons carry an electric charge, and these additional
forces are attributed to the electric charge that they carry. However,
there is a difference in the forces. Between masses, the gravitational
force is always one of "attraction" while the electrical forces both
"attract" and "repel." Protons and electrons attract one another, while
protons exert forces of repulsion on other protons, and electrons exert
repulsion on other electrons.

OPPOSITE LIKE + LIKE –

CHARGES CHARGES CHARGES
ATTRACT REPEL REPEL

Fig. 1.1.6 Force between charges

Thus, it appears to be two kinds of electrical charge. Protons are said

to be positive (+) and the electrons are said to be negative (-). The
neutron as the name implies, is neutral in charge. The directional
quality of the electricity based on the type of charge is called
"polarity." This leads to the basic law of electrostatics which states,
UNLIKE charges attract each other, while LIKE charges repel each
other.
Unit 1 1-1-6 Electrical Fundamentals
Lesson 1

ELECTROSTATIC
LINES OF FORCE

NEGATIVE POSITIVE
OBJECT OBJECT

Fig. 1.1.7 Electrostatic Field between Two Charged Bodies

Charges and Electrostatics

The attraction or repulsion of electrically-charged bodies is due to an
invisible force called an electrostatic field, which surrounds the
charged body. Fig. 1.1.7 shows the force between charged particles
as imaginary electrostatic lines from the positive charge to the
negative charge. The conventional method of representing the lines
of force is for the arrowheads to point away from the positive charge
and point toward the negative charge.
When two like charges are placed near each other, the lines of force
repel each other as shown below

Fig. 1.1.8 Electrostatic Field between Two Negatively

Charged Particles

Potential Difference
Because of the force of its electrostatic field, an electric charge has
the ability to move another charge by attraction or repulsion.
The ability to attract or repell is called its "potential." When one
charge is different from the other, there must be a difference in
potential between them.
Unit 1 1-1-7 Electrical Fundamentals
Lesson 1

The sum difference of potential of all charges in the electrostatic field

is referred to as electromotive force (emf). The basic unit of potential
difference is the "volt" (V) named in honor of Alessandro Volta, an
Italian scientist and the inventor of the "voltaic pile," the first battery
cell. The symbol for potential is V indicating the ability to do the
work of forcing electrons to move. Because the volt unit is used,
potential difference is called "voltage".
There are many ways to produce voltage, including friction, solar,
chemical, and electromagnetic induction. The attraction of bits of
paper to a comb that has been rubbed with a wool cloth is an example
of voltage produced by friction. A photocell, such as on a calculator,
would be an example of producing voltage from solar energy.
Coulomb
A need existed to develop a unit of measurement for electrical charge.
A scientist named Charles Coulomb investigated the law of forces
between charged bodies and adopted a unit of measurement called the
"Coulomb." Written in scientific notation is expressed as One
Coulomb = 6.28 x 1018 electrons or protons. Stated in simpler terms,
in a copper conductor, one ampere is an electric current of 6.28
billion billion electrons passing a certain point in the conductor in one
second.
Current
In electrostatic theories as earlier discussed, the concern was mainly
the forces between the charges. Another theory that needs explained
is that of "motion" in a conductor. The motion of charges in a
conductor is defined as an electric current. An electron will be
affected by an electrostatic field in the same manner as any
negatively charged body. It is repelled by a negative charge and
attracted by a positive charge. The drift of electrons or movement
constitutes an electric current.
Unit 1 1-1-8 Electrical Fundamentals
Lesson 1

The magnitude or intensity of current is measured in "amperes." The

unit symbol is "A". An ampere is a measure of the rate at which a
charge is moved through a conductor. One ampere is a coulomb of
charge moving past a point in one second.

POTENTIAL DIFFERENCE CONVENTIONAL

IN VOLTS CURRENT

ELECTRONS

CONDUCTOR
A B

Fig. 1.1.9 Current Flow

Conventional versus Electron Flow

ELECTRON CONVENTIONAL
THEORY THEORY

Fig. 1.1.10 Electron and Conventional Current

There are two ways to describe an electric current flowing through a
conductor. Prior to the use of "atomic theory" to explain the
composition of matter, scientists defined current as the motion of
positive charges in a conductor from a point of positive polarity to a
point of negative polarity. This conclusion is still widely held in
some engineering standards and textbooks. Some examples of
positive charges in motion are applications of current in liquids,
gases and semiconductors. This theory of current flow has been
termed "conventional current."
With the discovery of using atomic theory to explain the composition
of matter, it was determined that current flow through a conductor
was based on the flow of electrons (-), or negative charge.
Therefore, electron current is in the opposite direction of
conventional current and is termed "electron current."
Unit 1 1-1-9 Electrical Fundamentals
Lesson 1

Either theory can be used, but the more popular "conventional"

theory describing current as flowing from a positive (+) charge to a
negative (-) charge will be used in this course.
Resistance
Georg Simon Ohm discovered that for a fixed voltage, the amount of
current flowing through a material depends on the type of material
and the physical dimensions of the material. In other words, all
materials present some opposition to the flow of electrons. That
opposition is termed "resistance." If the opposition is small, the
material is labeled a conductor. If the opposition is large, it is labeled
an insulator.
The Ohm is the unit of electrical resistance and the symbol to
represent an Ohm is the Greek letter omega, ½ A material is said to
have a resistance of one ohm if a potential of one volt results in a
current of one ampere.
It is important to remember that electrical resistance is present in
every electrical circuit, including components, interconnecting wires,
and connections. Electrical circuits and the laws relating to them will
be discussed later in this unit.
As resistance works to oppose current flow, it changes electrical
energy into other forms of energy, such as, heat, light or motion. The
resistance of a conductor is determined by four factors:
1. Atomic structure (how many free electrons). The more free
electrons a material has, the less resistance it offers to current
flow.

FREE ELECTRONS

NEUTRONS

++
+ ++ +
+
+ +

PROTONS

Fig. 1.1.11
Unit 1 1-1-10 Electrical Fundamentals
Lesson 1

RΩ 6Ω
A.

Resistance
2XRΩ
C.
5Ω

R
B. RΩ Ω
2 80°F 125°F
Temperature

Fig. 1.1.12 Resistance

2. Length. The longer the conductor, the higher the resistance.

If the length of the wire is doubled as shown in Fig. 1.1.12 (a)
the greater the resistance between the two ends.
3. Width (cross sectional area). The larger the cross sectional
area of a conductor, the lower the resistance (a bigger
diameter pipe allows for more water to flow). If the cross
section area is reduced by half as shown in Fig. 1.1.12 (b), the
resistance for any given length is doubled.
4. Temperature. For most materials, the higher the temperature,
the higher the resistance. The chart shown in Fig. 1.1.12(c)
shows the resistance increasing as the temperature rises.
Please note, there are a few materials whose resistance
decreases as temperature increases.
Unit 1 1-1-11 Electrical Fundamentals
Lesson 1

Electrical Circuits and Laws

An electrical circuit is a path, or group of interconnecting paths,
capable of carrying electrical currents. It is a closed path that
contains a voltage source or sources. There are two basic types of
electrical circuits-series and parallel. The basic series and parallel
circuits may be combined to form more complex circuits, but these
combinational circuits may be simplified and analyzed as the two
basic types. It is important to understand the laws needed to analyze
and diagnose electrical circuits. They are Kirchoff's Laws and Ohm's
Law.
Gustav Kirchoff developed two laws for analyzing circuits. They are
stated as:
1. Kirchoff's Current Law (KCL) states that the algebraic sum of
the currents at any junction in an electrical circuit is equal to
zero. Simply stated, all the current that enters a junction is
equal to all the current that leaves the junction. None is lost.
2. Kirchoff's Voltage Law (KVL) states that the algebraic sum of
the electromotive forces and voltage drops around any closed
electrical loop is zero. Simply stated, if we started at a
particular point in a closed circuit and went around that circuit
adding the individual differences in potential until all were
considered and the starting point was reached, there would be
no extra voltage, and none would be left unaccounted for.
Georg Simon Ohm discovered one of the most important laws of
electricity. It describes the relationship between three electrical
parameters: voltage, current and resistance. Ohm's is stated as
follows: The current in an electrical circuit is directly proportional to
the voltage and inversely proportional to the resistance. The
relationship can be summarized by a single mathematical equation:
Current = Electromotive Force
Resistance

or, stated in electrical units:

I = Volts
Ohms
Unit 1 1-1-12 Electrical Fundamentals
Lesson 1

When using mathematical equations to express electrical

relationships, single letters are used to represent them. Resistance is
represented by the letter R or the Omega symbol (Ω). The voltage or
difference in potential is represented by the letter E or V
(electromotive force). Current is represented by the letter I (intensity
of charge). Using these laws to calculate circuits will be discussed
later in this course.
Electrical Conductors
In electrical applications, electrons travel along a path called a
conductor or wire. They move by traveling from atom to atom.
Some materials make it easier for electrons to travel and they are
called "good conductors." Examples of good conductors are: silver,
copper, gold, chromium, aluminum and tungsten. A material is said to
be a good conductor if it has many free electrons. The amount of
electrical pressure or voltage, it takes to move electrons through a
material depends on how free its electrons are.
Although silver is the best conductor it is also expensive. Gold is also
a good conductor, but not as good as copper. The advantage gold has
is it will not corrode like copper. Aluminum is not as good as copper,
but it is less expensive and lighter.
The conductivity of a material determines how good a conductor that
material is. Fig. 1.1.13 shows some of the common conductors and
their relative conductivity to copper.

CONDUCTIVITY CHART
Conductor Conductivity (to copper)
Silver 1.064
Copper 1.000
Gold 0.707
Aluminum 0.659
Zinc 0.288
Brass 0.243
Iron 0.178
Tin 0.018
Fig.1.1.13 Conductivity Chart
Unit 1 1-1-13 Electrical Fundamentals
Lesson 1

Other materials make it difficult for electrons to travel and they are
called "insulators." A good insulator keeps the electrons tightly
bound in orbit. Examples of insulators are: rubber, wood, plastics,
and ceramics. It is also important to know that it is possible to make
an electric current flow through every material. If the applied voltage
is high enough, even the best insulators will break down and allow
current flow. The following chart Fig. 1.1.14 list some of the more
common insulators.

COMMON INSULATORS
Rubber Plastics
Mica Glass
Wax or Paraffin Fiberglass
Porcelain Dry Wood
Bakelite Air

Fig.1.1.14 Common Insulator Chart

There is one other item that should be considered when discussing

insulators. Dirt and moisture may serve to conduct electricity around
an insulator. If an insulator is dirty or there is moisture present, it
could cause a problem. The insulator itself is not breaking down, but
the dirt or moisture can provide a path for electrons to flow. It is
therefore important to keep the insulators and contacts clean.
Unit 1 1-1-14 Electrical Fundamentals
Lesson 1

Wires
A wire in an electrical circuit is made up of a conductor and an
insulator. The conductor is typically made up of copper and the
insulator (outside covering) is made of plastic or rubber. Conductors
can be a solid wire or stranded. In most earthmoving applications the
wire is stranded copper with a plastic insulation covering the
conductor.
There are many sizes of wire. The smaller the wire the larger the
identification number. The numbering system is known as the
American Wire Gage (AWG). The chart below, Fig. 1.1.15 describes
the AWG wire size standard.

AWG Diameter (mils) Ohms per 1000 ft

10 102.9 .9989
12 80.8 1.588
14 64.1 2.525
16 50.8 4.016
18 40.3 6.385
20 32.0 10.15
22 25.4 16.14
24 10.0 103.2
26 3.10 1049.0
Fig. 1.1.15 AWG (American Wire Gauge) Wire Size Standard

Resistance can also be affected by other conditions, such as,

corrosion, etc., which need to be considered when making resistance
measurements.