SIX-STEP TROUBLESHOOTING PLAN

WORKSHEET 1-1
Electrical Basics Worksheet

Body Electrical Definitions and Rules

Definitions:

Electricity is the flow of electrical charges through simple materials and devices.

Automotive electrical systems use the flow of electrical charges to do work.

The pressure that pushes the electrical charges is called voltage. The unit of measure for electrical
pressure is Volts (V).

The amount of electrical charges flowing is called current. The unit of measure for current is Amps
(A). 1 Amp equals 6.28 x 1018 (6,280,000,000,000,000,000) electrons per second.

Resistance opposes current, converts the flow of electrical charges into work and causes voltage to
be used up. The unit of measure for resistance is Ohms (W).

Rules:

1. Current (A) can only flow when there is a complete path (circuit) between power and ground (or between a
higher voltage and a lower voltage). No complete path = an “open” circuit = 0 flow

2. The resistance of the load limits current in the circuit and converts current flow into work. In a perfect circuit
the only resistance would be the load.

3. Whenever current flows in a circuit, voltage drops (DV - D is the Greek letter Delta, which means change in,
so DV represents change in voltage or Voltage drop.) will happen. Voltage drops happens anywhere there is
resistance. The larger the resistance the larger the voltage drop.

4. Every circuit will use up all the source voltage (total DV will equal source voltage).

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Current Path Tracing:

Current tracing is a technique that will be used throughout this course to analyze electrical circuits. Current
path tracing allows you to identify the critical components in the circuit, predict voltage levels at any point in the cir-
cuit and predict the locations of voltage drops (DV).

1. a. Using components from the 622 kit, build the following circuit:

+ 1 2 1 2 1 2
–
1210 1500 1187

b. Turn the switch on and make sure the lamp lights.

c. Turn the switch off.

Using the diagram below:

+ 1 2 1 2 1 2
–
1210 1500 1187

2. a. Use a pink (P for power) highlighter to trace from the voltage source to the open in the circuit.

b. Use a green (G for ground) highlighter to trace from ground to the open in the circuit.

No, the circuit is open

c. Does current flow in this circuit? ______________________________________________________

Rule#1 No complete circuit

d. Which body electrical rule helps answer this question? ____________________________________

Because the switch is open no current flows, but

e. Why did we change colors at the switch? _______________________________________________

voltage is present up to terminal 1 of the switch. Connection to ground is present at terminal

2 of the switch.

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3 a. Draw the switch in the closed position and trace from the voltage source to terminal 1 of the #1187
lamp with a pink highlighter.

+ 1 2 1 2 1 2
–
1210 1500 1187

b. Trace from terminal 2 of the load to ground with a green highlighter.

c. Source V, 12V, +B
Pink represents a part of the circuit where the voltage level is ________________

d. Green represents a part of the circuit where the voltage is level isGround, 0V, -B
_____________

e. Yes, the circuit is complete.

Does current flow in this circuit? ________________________________________

f. The load uses up the voltage, causes DV

Why did we change colors at the load? __________________________________

Open Circuit Voltage, Voltage Drop and Available Voltage Tests

Open Circuit Voltage

4. a. Verify that the circuit built in step 1 is still assembled correctly;

+ 1 2 1 2 1 2
–
1210 1500 1187

b. Turn the switch on and verify that the lamp lights.

c. Turn the switch off.

5. a. Place the red lead of the voltmeter at terminal 1 of the #1500 switch and the black
lead on terminal 2 and record the reading.
Source Voltage, 12 volts, +B_(actual = 14.06V)
_______________________________________________________

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 6. a. Trace the current path for Step 5 on the diagram below:
Instructor Note: Because the circuit is open there is no current flow, so you really can't
trace a current path. What you are actually tracing is voltage present. Pink = 12V
present and green = ground present.

+ 1 2 1 2 1 2
–
1210 1500 1187
b. Why did the meter read battery voltage on Step 5?
HINT: A voltmeter reads the voltage difference between the red and the black test lead. Voltage at
the red (+) test lead minus voltage at the black (-) test lead equals the voltage reading displayed
on the meter
+ test lead has source voltage present, - lead has ground. 12V - 0V = 12V reading

c. Is this an open circuit voltage test or a voltage drop test? Open circuit voltage test.
_____________________

HINT: See the Technician Handbook, page 8.

Instructor Note: Voltage present confirms continuity only, not the quality of the circuit.
See Step 18 for an example.

Voltage Drop (DV)

7. a. Turn the switch on and verify that the lamp is illuminated.

b. Place the red test lead on terminal 1 of the #1500 switch and the black test lead on
terminal 2 and record the reading.

Very low volts, should be less than .1Volts (Actual = .002V)

_________________________________________________________________

8. a. Trace the current path for Step 7 on the diagram below:

+ 1 2 1 2 1 2
–
1210 1500 1187

b. Why was the voltage reading on Step 7 very low ? 12V - 12V = 0V
_________________________

c. Is this test an open circuit voltage test or a voltage drop (DV) test? voltage drop
_____________
Instructor Note: If the entire circuit is not traced (see Step 6a trace) the circuit is open
and any voltage tests will be open circuit voltage. DV tests require a complete circuit
with current flowing.
d. When testing DV on a non load (conductor, control device, circuit protection device etc.) what
does a low voltage reading confirm?

Good component and connections.

_____________________________

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9. a. Verify that the circuit built in step 1 is still assembled correctly;

+ 1 2 1 2 1 2
–
1210 1500 1187

b. Turn the switch on and verify that the lamp lights.

c. Remove the lamp from the socket.

10. Measure and record the open circuit voltage between terminals 1 and 2 of the empty lamp socket.

Battery voltage, source voltage, 12 Volts, +B voltage (Actual = 14.0V)

____________________________________________________________________

11. Install the lamp. Measure and record the voltage drop between terminals 1 and 2 of the #1187 lamp.

Battery voltage, source voltage, 12 Volts, +B voltage (Actual = 13.88V)

____________________________________________________________________

12. What is the key difference between an open circuit voltage test across an open (step 10) and a voltage drop
(DV) test across an operating load (step 11)?
HINT: It is not the meter reading. It was the same for both Steps 10 and 11.

The lamp is lit. Step 10 is open circuit, Step 11 is voltage drop DV

_____________________________________________________________________

13. What does a battery voltage drop across an operating load indicate?

Entire circuit is performing correctly. Load receiving and using correct voltage. The only way to
___________________________________________________________________________________

get a battery voltage drop across an operating load is to have a good circuit. To quote Allen
___________________________________________________________________________________

Woodrum, "If you see a battery voltage reading across a load and the load is not working, the
___________________________________________________________________________________

problem is between the test leads." A battery voltage DV reading across an operating load
___________________________________________________________________________________

confirms everything about the circuit. A battery voltage open circuit reading across a load
___________________________________________________________________________________

indicates an open load.

___________________________________________________________________________________

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 Available Voltage and Voltage Drop (DV)

14. a. Measure and record Available Voltage(with the switch closed) at the points listed:
Hint: Red (+) test lead to the test point, Black (-) test lead to ground.

+ 1 2 1 2 1 2
–
1210 1500 1187

Source voltage, +B, 12 volts (Actual = 13.9V)

1. Source Voltage ___________________________________________
Source voltage, +B, 12 volts (Actual = 13.9V)
2. Terminal 1 of the #1210 fuse ___________________________________________

3. Terminal 2 of the #1210 fuse

Source voltage, +B, 12 volts (Actual = 13.88V)
___________________________________________

4. Terminal 1 of the #1500 switch

5. Terminal 2 of the #1500 switch
6. Terminal 1 of the #1187 lamp
7. Terminal 2 of the #1187 lamp
Source voltage, +B, 12 volts (Actual = 13.87V)
___________________________________________
Source voltage, +B, 12 volts (Actual = 13.87V)
___________________________________________
Source voltage, +B, 12 volts (Actual = 13.87V)
___________________________________________
Ground, low voltage, .1V or less (Actual = .002V)
___________________________________________

b. What does reading 6 (terminal 1 of the #1187 lamp) indicate?

Good connections and power supply from source to lamp
_____________________________________________________

c. What does reading 7 (terminal 2 of the #1187 lamp) indicate?

Good ground connection
______________________________________________________

15. a. Measure and record the Voltage drop across the components listed:
HINT: Red (+) test lead to terminal 1 of the component and the Black (-) test lead to terminal 2 of the
component.
Very low voltage, .1 volt or less(Actual = .019V)
#1210 fuse ________________________________________
#1500 switch Very low voltage, .1 volt or less (Actual = .002V)
________________________________________
#1187 lamp +B, source voltage, 12 volts (Actual = 13.86V)
________________________________________

b. What is indicated by a low Voltage Drop at the #1210 fuse and the #1500 switch and a high Voltage drop at
the #1187 lamp?Good components at the fuse and the switch shown by very low voltage
_____________________________________________________________

drops. Good lamp and power supply shown by +B DV across the lamp.
_________________________________________________________________________________

c. Do both types of tests (Step 14 Available Voltage & Step 15 DV) give you the same information?
Yes. Step 14 requires subtraction to calculate DV measured in Step 15.
_________________________________________________________________________________

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16. a. Add a #1152 lamp to the circuit as indicated below:

+ 1 2 1 2 1 2 1 2
–
1210 1152 1500 1187

b. Turn the switch on and make sure both lamps light.

c. The #1152 lamp will simulate unwanted resistance between the fuse and the switch in an otherwise
normal lamp circuit. In a normal circuit this unwanted resistance would not be visible (so pretend that you
can’t see the #1152 lamp). The next few steps will use Available Voltage and Voltage Drop tests to locate
the unwanted resistance.

17 a. The customer concern is a dim lamp in this circuit. Can you verify the condition?

yes, the 1187 lamp is dim and since I can't see the invisible 1152 I don't know why.
______________________________________________________________________________

b. Trace the current path for a normal circuit using the diagram below. When using current path tracing as a
diagnostic method you always trace the circuit as it appears in the EWD. The purpose of current path
tracing is to learn how a normal circuit works. Then you use your circuit knowledge to find out where the
problem circuit is different.

c. Use this trace to predict normal voltage levels for this circuit in the steps below.

invisible
1152

+ 1 2 1 2 1 2
–
1210 1500 1187

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 18. a. Based on your current path trace from Step 17b predict the voltage at terminal 1 of the #1187 lamp.
+B, Source voltage, 12 volts
_________________________________________________________________

b. Remove the #1187 lamp. Measure and record the Open Circuit Voltage at Terminal 1 of the empty
socket.
+B, Source voltage, 12 volts (Actual = 13.97V)
__________________________________________________________________

Continuity only. An open circuit voltage test will NOT

c. What does this reading indicate? _____________________________________________________

show high resistance problems in circuits. Meter impedance is too high to load the circuit
__________________________________________________________________________________
so no DV happens at invisible 1152.
__________________________________________________________________________________

d. Install the lamp.

19. a. Based on the trace from step 17b, predict the Voltage Drop (DV) across the #1187 lamp.
+B, source voltage
___________________________________________________________________

12V, +B , source voltage (Actual = 13.97V)

b. Measure and record source voltage. _____________________________________

Approx 3.0V (Actual = 3.24V).

c. Measure and record DV across #1187 lamp. _______________________________

Note: Leave the meter leads connected to the circuit after taking this reading.

High resistance in the circuit. A good circuit

d. What does this reading indicate? ________________________________________
would show approximately source voltage DV across the only load in the circuit.
_____________________________________________________________________

20. a. Based on the current path trace from Step 17b, predict the Available Voltage (for a normal circuit) at
terminal 1 of the #1187 lamp.
Based on the normal circuit trace, there should be 12V, +B, source voltage available.
_____________________________________________________________________

b. Move the Black (-) test lead to ground, measure and record Available Voltage at terminal 1 of
the #1187 lamp.
Approximately 3.0 Volts (Actual = 3.24V), same reading as Step 19c.
_____________________________________________________________________
Instructor Note: As a generic test procedure the following method is very effective.
Step 1 - Trace current path and predict the DV of the load. Step 2 - Voltage drop the
load. Full source V with an operating load indicates a good, normal circuit. Full source
V with no load operation indicates an open load. Less than full source DV indicates
high resistance in the circuit. 0V indicates an open. Step 3 - Move the negative test
lead to ground to find out if the problem is in the power supply side of the circuit.
Less than source V indicates high resistance in the supply side of the circuit. 0V indi-
cates an open. If Step 3 shows source V go to Step 4. Step 4 - Move the positive
test lead to the ground side of the load. Anything over 0.1V indicates a problem in the
ground side of the circuit.
c. What does this reading indicate? High resistance in the power supply side of the
________________________________________
circuit causes the #1187 lamp to be dim.
_____________________________________________________________________

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21. a. Based on the current path trace from Step 17b, predict the available voltage (for a normal circuit) at
the following points.

Source voltage, +B, 12 Volts

Terminal 2 of the #1500 switch. ________________________________
Source voltage, +B, 12 Volts
Terminal 1 of the #1500 switch. ________________________________
Source voltage, +B, 12 Volts
Terminal 2 of the #1210 fuse. _________________________________
Source voltage, +B, 12 Volts
Terminal 1 of the #1210 fuse. __________________________________

b. Measure and record Available Voltage at these points.

Approximately 3 Volts (Actual = 3.25V)

Terminal 2 of the #1500 switch. ________________________________

Approximately 3 Volts (Actual = 3.25V)

Terminal 1 of the #1500 switch. ________________________________

Source voltage, +B, 12 Volts

Terminal 2 of the #1210 fuse. _________________________________

Source voltage, +B, 12 Volts

Terminal 1 of the #1210 fuse. __________________________________

Voltage is lost between the fuse and the

c. What do these readings indicate? ___________________________________
switch. High resistance located between the fuse and the switch.
_________________________________________________________________

22. a. Based on the trace from Step 17b, predict DV from terminal 2 of the #1210 fuse to terminal 1 of
the #1500 switch.
Should be very low, probably less than .01V, definitely less than .1V.
_____________________________________________________________________

b. Measure the DV from terminal 2 of the #1210 fuse to terminal 1 of the #1500 switch.
Approximately 10 Volts. (Actual = 10.66V)
____________________________________________________________________

High resistance between the the fuse and

c. What does this reading indicate? ________________________________________
the switch.
_____________________________________________________________________

d. Do both types of tests (Step 21b Available Voltage and Step 22b DV) give you the same
information?
Yes. Step 21b Available Voltage requires subtraction to determine the amount of voltage
________________________________________________________________________________
drop, while Step 22b DV shows the voltage drop directly.
________________________________________________________________________________

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 Series Circuits

Hint: See the Series Circuit rules on pages 6 and 7 of this handbook.

23. a. Using components from the L622 kit, build the following circuit:

+ 1 2 1 2 1 2
–
1210 1500 1187

b. Close the switch and make sure the lamp lights.

c. Trace the current path for this circuit.

d. Measure and record voltage readings at the following points:

Source voltage »13.9 V

____________

DV between terminals 1 and 2 of the #1500 switch ».001 V

____________

DV between terminals 1 and 2 of the #1187 lamp

»13.9 V
____________

e. Do the meter readings match your current path trace predictions? YES
___________

If there is only one load in the circuit, all the voltage is used up
in that load.

24. a. Add a #1152 bulb to the circuit as shown below:

b. Close the switch and verify that both lamps light, then turn the lamps off.

c. Disconnect the lamps from the circuit, then measure and record the resistance of each lamp.

»6 W
#1187 __________________

»12 W
#1152 __________________

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d. Why is it necessary to disconnect the components before measuring resistance?

Components must be isolated from circuit for accurate ohmeter readings
___________________________________________________________________

e. Connect the lamps to the circuit and close the switch.

The 1152 is much brighter than the 1187

f. Which lamp is brighter? ______________________________________________

g. Measure and record the DV of each lamp:

» 3.2V
#1187 _________________

» 10.7V
#1152 _________________

h. Trace the current path for this circuit.

i. What is the voltage between the lamps (the part of the circuit traced in blue)?

» 10.7V
_____________________________________________________________________

If there are multiple loads in the circuit, voltage is divided ac-

cording to the resistance of the loads. The load with the most
resistance will use the most voltage, the load with the least re-
sistance will use the least voltage. The voltage used is directly
proportional to the resistance.

25. Using the circuit built for Step 24, measure and record the current (A) at the following points:

» 92 mA
Between terminal 2 of the #1500 switch and terminal 1 of the #1187 lamp. ________

» 92 mA
Between terminal 2 of the #1187 lamp and terminal 1 of the #1152 lamp. __________

» 92 mA
Between terminal 2 of the #1152 lamp and ground. ___________

Amperage is the same throughout the circuit. This means that

an ammeter can be connected anywhere in the circuit and
measure the Amperage.

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26. a. Using components from the L622 kit, build the circuit shown below:

b. Close the switch and verify that all three lamps light.

c. Trace the current path for this circuit.

d. Measure and record the following readings:

Current (A) » 81 mA
______________

DV across the first #1187 lamp » 2.6 V

______________

DV across the #1152 lamp » 8.7 V

______________

DV across the second #1187 lamp » 2.6 V

______________

e. Compare the current (A) for this circuit with the reading from Step 25.

Total resistance is the sum of all the resistance in the circuit.

Adding a resistance in series will increase total circuit resis-
tance and decrease current (A).

Parallel Circuits
Hint: See the parallel circuit rules on page 7 of the Technician Handbook
27. a. Using components from the L622 kit, build the circuit shown below:

1 2

1187 #1

+ 1 2 1 2 1 2
–
1210 1500 1187 #2

b. Trace the current path for this circuit.

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c. Measure and record the Available Voltage at terminal 1 of each #1187 lamp:

» 13.8 V
1187 #1 __________________

» 13.8 V
1187 #2 __________________

The voltage applied to each branch is the same.

28. Using the circuit built for Step 27, measure and record the current between the following points:

» 440 mA
Terminal 2 of the #1210 fuse and terminal 1 of the #1500 switch. _________________

» 220 mA
Terminal 2 of the #1500 switch and terminal 1 of 1187 #1. ______________________

» 220 mA
Terminal 2 of the #1500 switch and terminal 1 of 1187 #2. ______________________

29. a. Using components from the L622 kit, build the circuit shown below:

1 2

1187 #1

+ 1 2 1 2 1 2
–
1210 1500 1187 #2

1 2

1152

b. Trace the current path for this circuit.

c. Disconnect the lamps from the circuit and measure and record their resistances:

»6W
1187 #1 _______________________

»6W
1187 #2 _______________________

» 12 W
1152 ________________________

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 d. Why is it necessary to disconnect the lamps to measure their resistance?
» To isolate each lamp from parallel connections in the circuit
__________________________________________________________________

e. Install the lamps and close the switch. Verify that all 3 lamps light.

f. Measure and record the current between the following points:

Terminal 2 of the #1210 fuse and terminal 1 of the #1500 switch. » 540 mA
__________

Terminal 2 of the #1500 switch and terminal 1 of 1187 #1. » 220 mA

__________

Terminal 2 of the #1500 switch and terminal 1 of 1187 #2. » 220 mA

__________

» 100 mA
Terminal 2 of the #1500 switch and terminal 1 of the #1152 lamp. __________

The current in a branch is determined by the branch’s

resistance. The branch with the least resistance will have
the most current.

31. a. Compare total current for Step 28 and Step 29:

» 440 mA
Total current for Step 28. ______________________

» 540 mA
Total current for Step 29 ______________________

Total resistance decreases as branches are added. Adding a

branch lowers total resistance and increases current.
The total circuit resistance is always lower than the lowest
branch resistance.

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Series-Parallel Circuits

32. a. Using components from the L622 kit, build the following circuit:
Note: This circuit is a simulation of the horn circuit for the 1998 ES 300. Lamps are substituted for
horns, otherwise the circuit is functionally identical.

b. Which meter function would help to identify the terminals of the relay?
Ohmeter, the coil will show » 70w and all other terminals infinite resistance
_________________________________________________________________ (OL)

c. Turn the switch on and off and verify that the lamps light.

33. a. Using the diagram below, trace the current path for this circuit when the lamps are off.

b. Predict the voltage at terminal 1 of the #1500 switch when the lamps are off.

Battery voltage, +B, source voltage (Actual » 13.9 V)

_________________________________________________________________

c. Measure and record the voltage at terminal 1 of the #1500 switch when the lamps are off.
Battery voltage, +B, source voltage (Actual » 13.9 V)
___________________________________________________________________

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34. a. Using the diagram below, trace the current path for this circuit when the lamps are on.

b. Predict the voltage at terminal 1 of the #1500 switch when the lamps are on.
Ground, very low voltage, less than .1V
________________________________________________________________

c. Measure and record the voltage at terminal 1 of the #1500 switch when the lamps are on.
Ground, very low voltage, less than .1V (actual » .002V)
_________________________________________________________________

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35. Using the 1998 ES300 horn circuit diagrams provided below:
a. Trace the current path with the horns off.
b. Trace the current path with the horns on.

a. Horns off b. Horns on

10A 10A
HORN HORN

1 5 1 5
HORN HORN
RELAY RELAY

2 3 2 3

10 2K 1 2F 10 2K 1 2F
G-B

G-B
J2 A J2 A
G-W

G-W
JUNCTION JUNCTION
CONNECTOR CONNECTOR
A A
G-B

G-B

G-W G-W

6 1 1 6 1 1
H7 H8 H7 H8
C12 HORN HORN C12 HORN HORN
HORN SW LH RH HORN SW LH RH
[COMB. SW] [COMB. SW]

36. Refer to the current path traces from Step 35 to answer the following questions:
a. Why is there battery voltage at connector C12, terminal 6 of the switch when the horns are off?
There is no connection to ground through the switch, so no DV happens at
_____________________________________________________________________
the relay coil.
_____________________________________________________________________

b. What does a battery voltage reading at connector C12, terminal 6, horns off, tell you about
the circuit?
There is no continuity between the fuse and connector C12, terminal 6. No
_____________________________________________________________________
information on circuit quality, but continuity exists.
_____________________________________________________________________

c. Where would your next test point be if you did not measure battery voltage at connector C12,
terminal 6, with the horns off?

Multiple acceptable answers. Junction connector 2, Connector 2K,

_____________________________________________________________________
pin 10 etc.
_____________________________________________________________________

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 d. Why is there low voltage at connector C12, terminal 6, when the horns are on?

Grounding the control side of the horn relay causes to flow. The coil in
_____________________________________________________________________
the relay uses up the voltage.
_____________________________________________________________________

e. If both horns were inoperative, where would you test first?

Multible acceptable answers. Most likely are the fuse or the relay.
_____________________________________________________________________

f. If only one horn was inoperative, would you test the relay or the switch?
No. One operating horn confirms the relay and the switch. The problem would
_____________________________________________________________________
have to be in the branch with the inoperative horn.
_____________________________________________________________________

Problems in the series portion of a series-parallel circuit affect

the entire circuit. Problems in a parallel branch of a series par-
allel circuit affect only the branch where the problem is.

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