Introduction:
This lesson describes and explains the information that is available to
help the technician in diagnosing and troubleshooting electrical and
electronic systems.
Objectives:
At the completion of this lesson, the student will be able to:
Demonstrate an understanding of electrical circuit symbols by
matching the name of the symbol with the symbol graphic and
demonstrate the ability to read and interpret schematic information.
References:
The schematic used for this lesson is 950G--Electrical Schematic
Form No. RENR2140. The lecture and quiz for this exercise is
developed from the above schematic. The reference materials can be
easily adapted to another product by ordering a machine specific
schematic and then tailoring the quiz to match the schematic.
Tooling:
None
Lesson 3: Electrical Schematics
Lesson 3: Electrical Schematics
Unit 3
Lesson 3
3-3-2
Electrical Fundamentals
POS NEG
MOTOR
SOLENOID
DISCONNECT
SWITCH
10 A
MOTOR
TRANSISTOR
TEMPERATURE
SWITCH
BATTERY
CIRCUIT
BREAKER FUSE
PRESSURE SWITCHES
LIGHT
TOGGLE SWITCH
RESISTORS
REOSTAT POTENTIOMETER RESISTOR
G
IGN
ALT
+
SEND
MOTOR
GRD
ALTERNATOR
MTR BAT
GAUGE
RELAY
GROUND
STARTER
Fig. 3.3.1 Electrical Schematic Symbols
Schematics
Schematics are basically line drawings that explain how a system
works by using symbols and connecting lines. Symbols are used to
represent devices or components of both simple and complex
electrical and electronic systems. Schematic symbols are used
extensively in Caterpillar publications for diagnosing electrical
concerns.
Schematics are used by technicians to determine how a system works
and to assist in the repair of a system that has failed.
Schematic symbols present a great deal of information in a small
amount of space and the reading of schematic symbols requires
highly developed skills and practice. A logical, step-by-step approach
to using schematic diagrams for troubleshooting begins with the
technician's understanding of the complete system. Although there are
many electrical symbols used in circuit diagrams, Figure 3.3.1 shows
the some of the more common Caterpillar electrical symbols.
Unit 3
Lesson 3
3-3-3
Electrical Fundamentals
Schematic Features
Caterpillar electrical schematics contain very valuable information.
The information is printed both on the front and reverse side of the
schematic. The technician needs to become very skilled in reading
and interpreting all the information contained on both sides of the
schematic.
Some of the features on the front of the schematic include:
Color codes for circuit identification
Color abbreviation codes
Symbol descriptions
Wiring harness information
Schematic notes and conditions
Grid design for component location
Component part numbers
The following is a recommendation for clearing up the confusion
associated with dashed lines:
Dashed "colored" lines represent attachment circuits. Use the
color identification code located on the schematic to determine
the circuit.
The heavy "double-dashed" lines identify the circuitry and
components located in the operator station.
A dashed (thin black) line is used to identify an attachment, wire,
cable or component. (See the symbol description on the
schematic).
Unit 3
Lesson 3
3-3-4
Electrical Fundamentals
OLD FORMAT
COLOR CODE
WIRE SIZE
WIRE LABEL
169 - PK - 18
NEW FORMAT
COLOR CODE
WIRE LABEL
WIRE SIZE
169 - H5 PK - 18
WIRE #5 in HARNESS "H"
Fig. 3.3.2 Wire Identification Labels
Machine Electrical Schematics with New Format
Some Caterpillar machines use a new format for electrical system
schematics. The new format is called PRO/E and provides additional
information for wire, connector, component and splice symbols. The
following information describes the new format.
Wire Identification Labels
This slide shows the new wire identification format. The label
includes the circuit identification wire label number (169), harness
identification code (H), the wire number in the harness (5), color code
(PK) and the wire size (18).
NOTE: The codes shown are examples of the new identification
system. Consult the appropriate electrical schematic for more
detailed and accurate information.
Unit 3
Lesson 3
3-3-5
Electrical Fundamentals
.
OLD FORMAT
CONNECTOR LABEL
CONNECTOR LABEL
CONNECTOR LABEL
H G
NEW FORMAT
CONNECTOR LABEL
G-C1
P/N
H-C7
P/N
"H" is the harness identification, "C" stands for connector,
"7" is the connector number in the harness,
and P/N is the receptacle connector part number
Fig. 3.3.3 Connector Identification
Connectors
The new connector identification format includes the harness
identification code (H), identifies the assembly as a connector (C),
identifies the number of the connector within the harness (7), and lists
the connector part number (3E3382).
NOTE: The codes shown are examples of the new identification
system. Consult the appropriate electrical schematic for more
detailed and accurate information.
OLD FORMAT
FUSE
P/N
10 A
NEW FORMAT
H-P12
P/N
10 A
Fig. 3.3.4 Components
Components
The previous method of component labeling on a schematic shows
the descriptive name and the component part number. The
schematics drawn in PRO/E format contain a harness identification
letter (H), a serializing code (P-12) where "P" stands for part and
"12" stands for harness position (number "12" part in harness "H",
and the component part number (113-8490).
NOTE: The codes shown are examples of the new identification
system. Consult the appropriate electrical schematic for more
detailed and accurate information.
Unit 3
Lesson 3
3-3-6
Electrical Fundamentals
OLD FORMAT
10 A
405-GY-16
Splice
405-GY-18
NEW FORMAT
10 A
405-G9 GY-16
Splice
405-G7 GY-18
Splice
405-G14 GY-18
Fig. 3.3.5 Splices
Splices
The PRO/E format for splices uses two connection points to indicate
which side a given wire exits. The previous splice symbol used a
simple filled-in dot to indicate a splice.
The new format shows that in harness "G", wire 405-G9 GY-16 is
spliced into two wires, "405-G7 GY-18" and "405-G14 GY-18."
NOTE: The codes shown are examples of the new identification
system. Consult the appropriate electrical schematic for more
detailed and accurate information.
Some of the features on the back of the schematic include:
Harness and wire electrical schematic symbols and identification
Electrical schematic symbols and definitions
Wire description chart
Related electrical service manuals
Harness connector location chart
Off machine switch specifications
Machine harness connector and component locations, identified as
a machine silhouette
Component Identifier (CID) list and flash code conversion
Component location chart
Resistor and solenoid specifications
Failure Mode Identifier (FMI) list
