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[object Object],[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 36, the reader should be able to:
[object Object],[object Object],[object Object],[object Object],[object Object],KEY TERMS:
WIRING SCHEMATICS ,[object Object],Continued
[object Object],Figure 36–1  The center wire is a solid color wire, meaning that the wire has no other identifying tracer or stripe color. The two end wires could be labeled “BRN/WHT,” indicating a brown wire with a white tracer or stripe. Continued Chart on Page 370 of your textbook.
Figure 36–2 Typical section of a wiring diagram. Notice that the wire color changes at connection C210. The “.8” represents the metric wire size in square millimeters. ,[object Object],The diagram also shows the color of the wire changes at C210. This stands for “connector #210” and is used for reference purposes, and can vary depending on the manufacturer.  Continued The color change from purple (PPL) to purple with a white tracer (PPL/WHT) is not important except to know where the wire changes color in the circuit. Wire gauge remained the same on both sides of the connection
[object Object],Figure 36–3  This figure shows typical electrical and electronic symbols used in automotive wiring and circuit diagrams. See the chart on Page 371 of your textbook.
Wiring diagrams indicate connections by symbols that look like arrows. Do  not  read these “arrows” as pointers showing the direction of current flow. Also observe that the power side (positive side) of the circuit is usually the female end of the connector.  If a connector becomes disconnected, it will be difficult for the circuit to become shorted to ground or to another circuit because the wire is recessed inside the connector. Read The Arrows Figure 36–4 In this typical connector, note that the positive terminal is usually a female connector.
SCHEMATIC SYMBOLS ,[object Object],Continued Figure 36–5  The symbol for a battery. The positive plate of a battery is represented by the longer line and the negative plate by the shorter line. The voltage of the battery is usually stated next to the symbol. Battery  The plates of a battery are represented by long and short lines. The longer line represents the positive plate of a battery and the shorter line represents the negative plate of the battery. Each pair of short and long lines represents one cell of a battery.
[object Object],Figure 36–6 The ground symbol on the left represents earth ground. The ground symbol on the right represents a chassis ground. Continued
[object Object],Continued ,[object Object],[object Object],[object Object]
Figure 36–7  Starting at the top, the wire from the ignition switch is attached to terminal B of connector C2, the wire is 0.5 mm 2 (20-gauge AWG) and is yellow. The circuit marker is 5. The wire enters connector C202 at terminal B3. Continued
[object Object],[object Object],[object Object],[object Object],Continued
Figure 36–8 The electrical terminals are usually labeled with a letter, as shown on this cooling fan motor. Figure 36–9 Two wires that cross at the dot indicate that the two are electrically connected. Figure 36–10 Wires that cross, but do not electrically contact each other, are shown with one wire bridging over the other. Continued
[object Object],100  to  199   Under the hood 200  to  299   Under the dash 300  to  399   Passenger compartment 400  to  499   Rear package or   trunk area 500  to  599   Left-front door 600  to  699   Right-front door 700  to  799   Left-rear door 800  to  899   Right-rear door Even-numbered connectors are on the  right  (passenger side) of the vehicle, odd-numbered connectors on the  left  (driver’s side). Continued
Figure 36–11 Connectors (C), grounds (G), and splices (S) are followed by a number, generally indicating the location in the vehicle. For example, G209 is a ground connection located under the dash. C - 102  is a  connector  located  under the hood  (between 100 and 199) on the  right side  of the vehicle (even number 102). Continued
Figure 36–12  The ground for the battery is labeled G305 indicating the ground connector is located in the passenger compartment of the vehicle. The ground wire is black (BLK), the circuit number is 50, and the wire is 32 mm 2 (2-gauge AWG). ,[object Object],A ground located under the dash on the driver’s side could be labeled  G-201 (G means ground). A splice indication is an “S” followed by three numbers, such as  S-301 .  Continued
[object Object],Figure 36–13  The symbol for light bulbs shows the filament inside a circle, which represents the glass ampoule of the bulb. Continued ,[object Object]
[object Object],Continued
Figure 36–14  An electric motor symbol shows a circle with the letter “M ” in the center and two black sections that represent the brushes of the motor. This symbol is used even though the motor is a cross-flow design. Figure 36–15 Resistor symbols vary depending on the type of resistor. Continued
[object Object],Figure 36–16  A rheostat uses just two wires—one is connected to a voltage source and the other is attached to the movable arm. Continued
[object Object],Continued
Figure 36–17 Symbols used to represent capacitors. If one of the lines is curved, this indicates that the capacitor being used has a polarity, while the one without a curved line can be installed in the circuit without concern about polarity. Figure 36–18 The grid-like symbol represents an electrically heated element. Continued
Figure 36–19 A dashed outline represents a portion (part) of a component. Figure 36–20 A solid box represents an entire component. Continued
[object Object],Continued ,[object Object],[object Object],[object Object],Figure 36–21 This symbol represents a component that is case grounded.
[object Object],Continued ,[object Object],[object Object],NOTE:   All switches are shown on schematics in their normal position. This means that the headlight switch will be shown normally off, as are most other switches and controls.
[object Object],Continued
Figure 36–22  (a) A symbol for a single-pole, single-throw (SPST) switch. This type of switch is normally open (N.O.) because nothing is connected to the terminal that the switch is contacting in its normal position. (b) A single-pole, double-throw (SPDT) swtich has three terminals. (c) A double-pole, single-throw (DPST) swtch has two positions (off and on) and can control two separate circuits. (d) A double-pole, double-throw (DPDT) switch has six terminals—three for each pole. Note: “c ” and “d ” also show a dotted line between the two arms indicating that they are mechanically connected. (a) (b) (c) (d) Continued
[object Object]
RELAY TERMINAL IDENTIFICATION ,[object Object],Continued
Figure 36–23  A relay uses a movable arm to complete a circuit whenever there is a power at terminal 86 and a ground at terminal 85. A typical relay only requires about 1/10 ampere through the relay coil. The movable arm then closes the contacts (#30 to #87) and can relay 30 amperes or more. Continued
Figure 36–24  A cross-sectional view of a typical four-terminal relay. Current flowing through the coil (terminals 86 and 85) causes the movable arm (called the armature) to be drawn toward the coil magnet. The contact points complete the electrical circuit connected to terminals 30 and 87. Continued
[object Object],Figure 36–25 A typical relay showing the schematic of the wiring in the relay. Terminals #30 and #87 are electrically connected when the relay is energized. Continued The relay coil can be controlled by supplying either power or ground to the relay coil winding.  Most relays use four or five terminals as follows:
[object Object],Continued
Figure 36–27  A typical horn circuit. Note that the relay contacts supply the heavy current to operate the horn when the horn switch simply completes a low current circuit to ground, causing the relay contacts to close. Figure 36–26  All schematics are shown in their normal, nonenergized position. Continued
[object Object],Figure 36–28  When the relay or solenoid coil current is turned off, the stored energy in the coil forward biases the clamping diode and effectively reduces voltage spike. This induced voltage can be as high as 100 volts or more and can cause problems with other electronic devices in the vehicle. The short high-voltage surge can be heard as a “pop ” in the radio. To reduce the induced voltage, some relays contain a diode connected across the coil in the reverse bias direction. Continued
[object Object],Figure 36–29 A resistor used in parallel with the coil windings is a commonly used spike reduction method used in many relays. Continued
COMMON POWER OR GROUND ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],For a customer complaint involving one or more of the items listed, check the fuse and the common part of the circuit that feeds all of affected lights. Check for a common ground if several components that seem unrelated are not functioning correctly. Continued See Figure 36–30 for an example where all of the following lights are powered by one fuse (power source).
Figure 36–30 A typical wiring diagram showing multiple switches and bulbs powered by one fuse. Schematic on Page 376 of your textbook.
[object Object],Often, a customer will notice just one fault while other lights or systems may not be working correctly. For example, a customer noticed that the electric mirrors stopped working. The service technician checked all electrical components in the vehicle and discovered that the interior lights were also not working. Check Everything The service technician found the interior light and power accessory fuse blown. Replacing the fuse restored the proper operation of the electric outside mirror and the interior lights. However,  what  caused the fuse to blow? A visual inspection of the dome light, next to the electric sunroof, showed an area where a wire was bare. Evidence was seen where the bare wire had touched the metal roof, which could cause the fuse to blow. The technician covered the bare wire with a section of vacuum hose and then taped the hose with electrical tape to complete the repair.
Often the owners of vehicles, especially of pickup trucks and sport utility vehicles (SUVs), want to add additional electrical accessories or lighting. It is tempting in these cases to simply splice into an existing circuit. However, whenever another circuit or component is added, the current that flows through the newly added component is also added to the current for the original component. This additional current can easily overload the fuse and wiring. Do not simply install a larger-amperage fuse; the wire gauge size was not engineered for the additional current and could overheat. The solution is a relay, which uses a small coil to create a magnetic field that causes a movable arm to switch on a higher-current circuit.  Do It Right — Install a Relay - Part 1
Figure 36–31  To add additional lighting, simply tap into an existing light wire and connect a relay. Whenever the existing light is turned on, the coil of the relay is energized. The arm of the relay then connects power from another circuit (fuse) to the auxiliary lights without overloading the existing light circuit. The typical relay has 50 to 150 ohms (usually 60 to 100) of resistance and requires just 0.24 to 0.08 amp when connected to a 12-volt source. This small additional current will not be enough to overload the existing circuit.  Do It Right — Install a Relay - Part 2
USING SCHEMATICS FOR TROUBLESHOOTING ,[object Object],Continued
Figure 36–32  Always check the simple things first. Check the fuse for the circuit you are testing. Maybe a fault in another circuit controlled by the same fuse could have caused the fuse to blow. Use a test light to check that both sides of the fuse have voltage. ,[object Object],If voltage is available at the socket, the problem is either a defective bulb or a poor ground at the socket or a ground wire connection to the body or frame.  If no voltage is available at the socket, consult a wiring diagram.  The wiring diagram should show all of the wiring and components included in the circuit.
[object Object],The common question is, where does a technician start troubleshooting when using a wiring diagram (schematic)? Where to Start? The easiest first step is to locate the unit on the schematic that is not working at all or not working correctly. Often a ground is used by more than one component. Therefore, ensure that everything else is working correctly. If not, then the fault may lie at the common ground (or power) connection.. Divide the circuit in half by locating a connector or a part of the circuit that can be accessed easily. Then check for power and ground at this midpoint. This step could save you much time. HINT 1 HINT 2 HINT 3 a . Trace where the unit gets its ground connection. b . Trace where the unit gets its power connection.
LOCATING A SHORT CIRCUIT ,[object Object],Continued
[object Object],[object Object],NOTE:   A heavy-duty (HD) flasher can also be used in place of a circuit breaker to open and close the circuit. Wires and terminals must be made to connect the flasher unit where the fuse normally plugs in.
[object Object],Continued
[object Object],CAUTION:   Connecting the lead to the power side of the fuse holder will cause current flow through and damage to the ohmmeter. ,[object Object],[object Object],[object Object],Continued
[object Object],Continued
Figure 36–33  (a) After removing the blown fuse, a pulsing circuit breaker is connected to the terminals of the fuse. (b) The circuit breaker causes current to flow, then stop, then flow again, through the circuit up to the point of the short-to-ground. By observing the Gauss gauge, the location of the short is indicated near where the needle stops moving due to the magnetic field created by the flow of current through the wire. Continued
Figure 36–34  A Gauss gauge can be used to determine the location of a short circuit even behind a metal panel. ,[object Object],Continued
[object Object],Figure 36–35  A tone generator-type tester used to locate open circuits and circuits that are shorted-to-ground. Included with this tester is a transmitter (tone generator), receiver (probe), and headphones for use in noisy shops. The tone will be generated while there is a continuous electrical path along the circuit. The signal will stop if there is an open (break) or short-to-ground in the circuit.  The windings in the solenoids and relays will increase the strength of the signal in these locations. See Figures 36–36 and 36–37.  Continued
Figure 36–36  To check for a short-to-ground using a tone generator, connect the black transmitter lead to a good chassis ground and the red lead to the load side of the fuse terminal. Turn the transmitter on and check for tone signal with the receiver. Using a wiring diagram, follow the strongest signal to the short-to-ground. There will be no signal beyond the fault. Continued
Figure 36–37 To check for an open (break), connect the red lead of the tone generator to the load side of the fuse terminal and the black lead to a good chassis ground. Turn on the transmitter an then listen for the tone signal with the receiver set in the open position. Using a wiring diagram, follow the signal along the circuit until the tone stops, indicating the location of the open.
Electrical shorts are commonly caused either by movement, which causes the insulation around the wiring to be worn away, or by heat melting the insulation. When checking for a short circuit, first check the wiring that is susceptible to heat, movement, and damage: Heat or Movement ,[object Object],[object Object],[object Object]
Intermittent electrical problems are common yet difficult to locate. To help locate these hard-to-find problems, try operating the circuit and then start wiggling the wires and connections that control the circuit. If in doubt where the wiring goes, try moving all the wiring starting at the battery. Pay particular attention to wiring running near the battery or the windshield washer container. Corrosion can cause wiring to fail, and battery acid fumes and alcohol-based windshield washer fluid can start or contribute to the problem. If you notice any change in the operation of the device being tested while wiggling the wiring, look closer in the area you were wiggling until the actual problem is located and corrected. Wiggle Test
ELECTRICAL TROUBLESHOOTING GUIDE ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],STEP-BY-STEP TROUBLESHOOTING PROCEDURE ,[object Object],[object Object],[object Object],[object Object],[object Object],HINT:   Split the circuit help isolate the problem and start at the relay.
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],A customer complained that after driving for a while, he got a static shock whenever the door handle was grabbed when exiting the vehicle. The customer thought that there must be an electrical fault and that the shock was coming from the vehicle itself. In a way, the shock was caused by the vehicle, but it was  not  a fault.  Shocking Experience Obviously, a static charge was being created by movement of the driver’s clothing on the seats and discharged when the driver touched the metal door handle. Figure 36–38 Antistatic spray can be used to stop customers from being shocked when they touch a metal object like the door handle.
SUMMARY ,[object Object],[object Object],[object Object],Continued
SUMMARY ,[object Object],[object Object],[object Object],( cont. )
end

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Chapter 36

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  • 8. Wiring diagrams indicate connections by symbols that look like arrows. Do not read these “arrows” as pointers showing the direction of current flow. Also observe that the power side (positive side) of the circuit is usually the female end of the connector. If a connector becomes disconnected, it will be difficult for the circuit to become shorted to ground or to another circuit because the wire is recessed inside the connector. Read The Arrows Figure 36–4 In this typical connector, note that the positive terminal is usually a female connector.
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  • 12. Figure 36–7 Starting at the top, the wire from the ignition switch is attached to terminal B of connector C2, the wire is 0.5 mm 2 (20-gauge AWG) and is yellow. The circuit marker is 5. The wire enters connector C202 at terminal B3. Continued
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  • 14. Figure 36–8 The electrical terminals are usually labeled with a letter, as shown on this cooling fan motor. Figure 36–9 Two wires that cross at the dot indicate that the two are electrically connected. Figure 36–10 Wires that cross, but do not electrically contact each other, are shown with one wire bridging over the other. Continued
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  • 16. Figure 36–11 Connectors (C), grounds (G), and splices (S) are followed by a number, generally indicating the location in the vehicle. For example, G209 is a ground connection located under the dash. C - 102 is a connector located under the hood (between 100 and 199) on the right side of the vehicle (even number 102). Continued
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  • 20. Figure 36–14 An electric motor symbol shows a circle with the letter “M ” in the center and two black sections that represent the brushes of the motor. This symbol is used even though the motor is a cross-flow design. Figure 36–15 Resistor symbols vary depending on the type of resistor. Continued
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  • 23. Figure 36–17 Symbols used to represent capacitors. If one of the lines is curved, this indicates that the capacitor being used has a polarity, while the one without a curved line can be installed in the circuit without concern about polarity. Figure 36–18 The grid-like symbol represents an electrically heated element. Continued
  • 24. Figure 36–19 A dashed outline represents a portion (part) of a component. Figure 36–20 A solid box represents an entire component. Continued
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  • 28. Figure 36–22 (a) A symbol for a single-pole, single-throw (SPST) switch. This type of switch is normally open (N.O.) because nothing is connected to the terminal that the switch is contacting in its normal position. (b) A single-pole, double-throw (SPDT) swtich has three terminals. (c) A double-pole, single-throw (DPST) swtch has two positions (off and on) and can control two separate circuits. (d) A double-pole, double-throw (DPDT) switch has six terminals—three for each pole. Note: “c ” and “d ” also show a dotted line between the two arms indicating that they are mechanically connected. (a) (b) (c) (d) Continued
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  • 31. Figure 36–23 A relay uses a movable arm to complete a circuit whenever there is a power at terminal 86 and a ground at terminal 85. A typical relay only requires about 1/10 ampere through the relay coil. The movable arm then closes the contacts (#30 to #87) and can relay 30 amperes or more. Continued
  • 32. Figure 36–24 A cross-sectional view of a typical four-terminal relay. Current flowing through the coil (terminals 86 and 85) causes the movable arm (called the armature) to be drawn toward the coil magnet. The contact points complete the electrical circuit connected to terminals 30 and 87. Continued
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  • 35. Figure 36–27 A typical horn circuit. Note that the relay contacts supply the heavy current to operate the horn when the horn switch simply completes a low current circuit to ground, causing the relay contacts to close. Figure 36–26 All schematics are shown in their normal, nonenergized position. Continued
  • 36.
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  • 39. Figure 36–30 A typical wiring diagram showing multiple switches and bulbs powered by one fuse. Schematic on Page 376 of your textbook.
  • 40.
  • 41. Often the owners of vehicles, especially of pickup trucks and sport utility vehicles (SUVs), want to add additional electrical accessories or lighting. It is tempting in these cases to simply splice into an existing circuit. However, whenever another circuit or component is added, the current that flows through the newly added component is also added to the current for the original component. This additional current can easily overload the fuse and wiring. Do not simply install a larger-amperage fuse; the wire gauge size was not engineered for the additional current and could overheat. The solution is a relay, which uses a small coil to create a magnetic field that causes a movable arm to switch on a higher-current circuit. Do It Right — Install a Relay - Part 1
  • 42. Figure 36–31 To add additional lighting, simply tap into an existing light wire and connect a relay. Whenever the existing light is turned on, the coil of the relay is energized. The arm of the relay then connects power from another circuit (fuse) to the auxiliary lights without overloading the existing light circuit. The typical relay has 50 to 150 ohms (usually 60 to 100) of resistance and requires just 0.24 to 0.08 amp when connected to a 12-volt source. This small additional current will not be enough to overload the existing circuit. Do It Right — Install a Relay - Part 2
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  • 51. Figure 36–33 (a) After removing the blown fuse, a pulsing circuit breaker is connected to the terminals of the fuse. (b) The circuit breaker causes current to flow, then stop, then flow again, through the circuit up to the point of the short-to-ground. By observing the Gauss gauge, the location of the short is indicated near where the needle stops moving due to the magnetic field created by the flow of current through the wire. Continued
  • 52.
  • 53.
  • 54. Figure 36–36 To check for a short-to-ground using a tone generator, connect the black transmitter lead to a good chassis ground and the red lead to the load side of the fuse terminal. Turn the transmitter on and check for tone signal with the receiver. Using a wiring diagram, follow the strongest signal to the short-to-ground. There will be no signal beyond the fault. Continued
  • 55. Figure 36–37 To check for an open (break), connect the red lead of the tone generator to the load side of the fuse terminal and the black lead to a good chassis ground. Turn on the transmitter an then listen for the tone signal with the receiver set in the open position. Using a wiring diagram, follow the signal along the circuit until the tone stops, indicating the location of the open.
  • 56.
  • 57. Intermittent electrical problems are common yet difficult to locate. To help locate these hard-to-find problems, try operating the circuit and then start wiggling the wires and connections that control the circuit. If in doubt where the wiring goes, try moving all the wiring starting at the battery. Pay particular attention to wiring running near the battery or the windshield washer container. Corrosion can cause wiring to fail, and battery acid fumes and alcohol-based windshield washer fluid can start or contribute to the problem. If you notice any change in the operation of the device being tested while wiggling the wiring, look closer in the area you were wiggling until the actual problem is located and corrected. Wiggle Test
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  • 64. end