Technical Systems Training - Electrical Systems.pdf

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Technical Service Training
Global Fundamentals
Curriculum Training – TF1010011S
Electrical Systems
Student Information
FCS-13197-REF
CG7967/S 05/2001
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Introduction
Preface
Global fundamentals training overview
The goal of the Global Fundamentals Training is to provide students with a common knowledge base of the
theory and operation of automotive systems and components. The Global Fundamentals Training Curriculum
(FCS-13203-REF) consists of nine self-study books. A brief listing of the topics covered in each of the self-study
books appears below.
Shop Practices (FCS-13202-REF) explains how to prepare for work and describes procedures for lifting
materials and vehicles, handling substances safely, and performing potentially hazardous activities (such as
welding). Understanding hazard labels, using protective equipment, the importance of environmental policy,
and using technical resources are also covered.
Brake Systems (FCS-13201-REF) describes the function and operation of drum brakes, disc brakes, master
cylinder and brake lines, power-assist brakes, and anti-lock braking systems.
Steering and Suspension Systems (FCS-13196-REF) describes the function and operation of the power-
assisted steering system, tires and wheels, the suspension system, and steering alignment.
Climate Control (FCS-13198-REF) explains the theories behind climate control systems, such as heat transfer
and the relationship of temperature to pressure. The self-study also describes the function and operation of the
refrigeration systems, the air distribution system, the ventilation system, and the electrical control system.
Electrical Systems (FCS-13197-REF) explains the theories related to electricity, including the characteristics
of electricity and basic circuits. The self-study also describes the function and operation of common
automotive electrical and electronic devices.
Manual Transmission and Drivetrain (FCS-13199-REF) explains the theory and operation of gears.
The self-study also describes the function and operation of the drivetrain, the clutch, manual transmissions
and transaxles, the driveshaft, the rear axle and differential, the transfer case, and the 4x4 system.
Automatic Transmissions (FCS-13200-REF) explains the function and operation of the transmission and
transaxle, the mechanical system, the hydraulic control system, the electronic control system, and the transaxle
final drive. The self-study also describes the theory behind automatic transmissions including mechanical
powerflow and electro-hydraulic operation.
Engine Operation (FCS-13195-REF) explains the four-stroke process and the function and operation of the
engine block assembly and the valve train. Also described are the lubrication system, the intake air system,
the exhaust system, and the cooling system. Diesel engine function and operation are covered also.
Engine Performance (FCS-13194-REF) explains the combustion process and the resulting emissions.
The self-study book also describes the function and operation of the powertrain control system, the fuel
injection system, the ignition system, emissions control devices, the forced induction systems, and diesel
engine fuel injection. Read Engine Operation before completing Engine Performance.
To order curriculum or individual self-study books, contact Helm Inc.
Toll Free:
1-800-782-4356 (8:00 am – 6:00 pm EST)
Mail:
14310 Hamilton Ave., Highland Park, MI 48203 USA
Internet:
www.helminc.com (24 hours a day, 7 days a week)
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Contents
Introduction
Introduction ................................................................................................................................. 1
Preface ..................................................................................................................................................................... 1
Global fundamentals training overview ...................................................................................................... 1
Contents ................................................................................................................................................................... 2
Lesson 1 – Theory and operation of electriciy .......................................................................... 4
General ..................................................................................................................................................................... 4
Objectives ....................................................................................................................................................... 4
At a glance ............................................................................................................................................................... 5
Introduction .................................................................................................................................................... 5
Components of electricity ............................................................................................................................. 5
Theory ...................................................................................................................................................................... 7
Electron movement ........................................................................................................................................ 7
Operation ................................................................................................................................................................. 8
Condutors and insulators .............................................................................................................................. 8
Lesson 2 – Charateristics of electricity ..................................................................................... 9
General ..................................................................................................................................................................... 9
Objectives ....................................................................................................................................................... 9
Theory .................................................................................................................................................................... 1 0
Characteristics of electricity ........................................................................................................................ 1 0
Factors that affect resistance ....................................................................................................................... 1 5
Operation ............................................................................................................................................................... 1 6
Ohm’s Law ................................................................................................................................................... 1 6
Watts .............................................................................................................................................................. 2 1
At a glance ............................................................................................................................................................. 2 2
Units of measurements ................................................................................................................................22
Lesson 3 – Complete electrical circuit ..................................................................................... 23
General ................................................................................................................................................................... 2 3
Objectives ..................................................................................................................................................... 2 3
At a glance ............................................................................................................................................................. 2 4
Complete electrical circuit .......................................................................................................................... 2 4
Components ........................................................................................................................................................... 2 5
Components of a complete electrical circuit ............................................................................................. 2 5
Generator ...................................................................................................................................................... 2 9
Voltage regulator .......................................................................................................................................... 2 9
Power distribution system ........................................................................................................................... 3 0
Operation ............................................................................................................................................................... 3 1
Series circuits ............................................................................................................................................... 3 1
Parallel circuits ............................................................................................................................................. 3 5
At a glance ............................................................................................................................................................. 3 8
Common circuit faults ................................................................................................................................. 3 8
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Introduction
Contents
Lesson 4 – Basic control devices .............................................................................................. 40
General ................................................................................................................................................................... 4 0
Objectives ..................................................................................................................................................... 4 0
Components ........................................................................................................................................................... 4 1
Control devices ............................................................................................................................................ 4 1
At a glance ............................................................................................................................................................. 4 9
Circuit protection ......................................................................................................................................... 4 9
Components ........................................................................................................................................................... 5 0
Circuit protection (continued) .................................................................................................................... 5 0
At a glance ............................................................................................................................................................. 5 4
Electromagnetic devices ............................................................................................................................. 5 4
Components ........................................................................................................................................................... 5 5
Electromagnetic devices (continued) ......................................................................................................... 5 6
Lesson 5 – Wiring diagrams ..................................................................................................... 58
General ................................................................................................................................................................... 5 8
Objectives ..................................................................................................................................................... 5 8
At a glance ............................................................................................................................................................. 5 9
Wiring diagrams ........................................................................................................................................... 5 9
Wire color codes .......................................................................................................................................... 5 9
Components ........................................................................................................................................................... 6 0
Schematic symbols ...................................................................................................................................... 6 0
Reading a wiring diagram ........................................................................................................................... 6 1
Lesson 6 – Diagnostic process .................................................................................................. 62
General ................................................................................................................................................................... 6 2
Objective ...................................................................................................................................................... 6 2
At a glance ............................................................................................................................................................. 6 3
Symptom-to-system-to-component-to-cause diagnostic procedure diagnosis ...................................... 6 3
Workshop literature ..................................................................................................................................... 6 4
List of abbreviations .................................................................................................................. 65
Service Training
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