Fundamental Electrical Troubleshooting Dan Sullivan Pdf 153
Gaspard Xenos
Relays and Solenoids
Rheostats and Potentiometers
How to REALLY Read Schematics
Meter Reading Tricks and Little-known facts
Multiplexing and Sensors
Voltage, Resistance and Current in Troubleshooting
Diodes, Transistors and Multiplexing
Motors and Alternators
Troubleshooting Methods and Tricks of the Trade
One popular course, Fundamental Electrical Troubleshooting (FET), is a fully-integrated, hands-on electrical troubleshooting class designed specifically for technicians and mechanics who work on heavy trucks and heavy equipment.
Sullivan explained that STS methods make it possible for techs to fully understand how electricity and electrical systems work, making them much more effective on the job. The company trains technicians of all skill and experience levels.
Online Training - One hour of multimeter training and advice on many aspects of electrical troubleshooting by Dan Sullivan - leading electrical trainer. Compass - used for alternator and solenoid diagnostics. See Youtube for training videos.
In previous articles for Construction Equipment magazine, I've detailed specific skills and practices that can be used to speed up and streamline electrical troubleshooting. In this article I'll be doing the same, but I'll also try to suggest a few ways you can alter your thinking about the way you approach troubleshooting.
Attaining these goals is not as difficult (or impossible) as it might seem. The issues involved here are the knowledge, thought processes and confidence of the technician. First and fundamental, the technician must have a detailed understanding about how the voltmeter works and a disciplined approach to reading electrical schematics. My experience has taught me that these are absolutely critical skills. We've touched on these subjects before, but we'll cover a few more tricks in these areas in our present discussion.
But just as important is the technician's thought process. Electrical troubleshooting is a logical exercise that requires logical thinking. Too many technicians start out with hasty, incorrect assumptions; they're doomed to fail before they start. But take heart; it's a situation that can be reversed, and you'll find your confidence growing as you learn to thoughtfully exercise basic skills.
But actually, you're saving time. As an electrical troubleshooter, you must keep track of time and not let it get the better of you. Without question, most technicians have a misplaced sense of time when working on electrical problems. I've seen them waste two or three hours walking around, changing parts (without knowing for certain if the parts are faulty), pulling wire harnesses apart just to look at them, and doing other "little" things that add up to hours of effort.
Schematic reading is a skill that is central to the troubleshooting process, and if you try to avoid it, you'll be working on the machine as if blind. It's crucial that technicians get into the books and get the system figured out before starting the troubleshooting process. Doesn't it make sense to gain some idea of what could be causing the problem before you attempt to make the repair?
My approach to troubleshooting is first to make a simple drawing of the suspect circuit in order to figure out what it does (and what it doesn't do) and, then, to repair the wires. Technicians can waste a lot of time, because they think they need to see the wiring in order to figure out what's going on. So, they rip open harnesses, cut tie-wraps and unravel wire looms. Nothing could be more unproductive. The redrawing process forces technicians to slow down and to analyze, resulting in intelligent decisions.
Dare I say it? The ohmmeter is really a terrible troubleshooting tool. Now, don't misinterpret this to mean that using the digital meter is a mistake. What I'm saying is that the OHM function on the meter is not anywhere as effective and useful as most people assume.
But that said, the voltmeter is often misused. For instance, some technicians round off readings, instead of using the exact number: 13.3V is not 12V and 11.8V is not 12V. If you don't take advantage of the meter's accuracy, you'll miss the diagnosis. And for all of its virtues, the voltmeter can mislead you in certain situations; but if you're aware of this, you won't be tripped up. But unfortunately, some technicians haven't yet learned to use the voltmeter to its full potential, often ignoring valuable readings that they don't understand.
When making this investigation and you're looking for voltage at a component you have unplugged, the voltmeter will register ghost voltage if the wire is not complete (open) to the component, or exact system voltage if the wire is complete to where you are. If you do read exact voltage, you then know that something after the component is open.
Believe me, a great many parts are replaced needlessly because of this error. Since the technician reads full system voltage when testing the circuit to the component, the usual assumption is that the circuit is capable of carrying proper current; therefore, the component itself is bad. This problem is very frustrating, because you change the part with confidence after following the manufacturer's instructions, but it still doesn't work.
Technicians who understand the problem of high-resistance faults and the voltmeter's inability to find the fault in a static test (that is, without current flowing) sometimes work around it by devising a dynamic test (with current flowing) by using a headlight that can be placed in the circuit to "load" it. Or, another possibility is using a testing tool capable of performing a dynamic test, such as TESlite Voltmeter Leads, which allow you to determine if the circuit is free of resistance by loading the circuit during the voltage test.
In conclusion, the best way to think about all of this is to understand that troubleshooting is a brain game, not a wrench-turning, meter-reading, parts-changing game. Once you've read the schematic, redrawn the circuit, determined what the circuit is supposed to do and, finally, have taken meter readings to see what the circuit is (or isn't) actually doing, then you troubleshoot.
Some schematics are drawn as a straight line, called "ladder diagrams." If not, you should take the time to read the schematic and learn how the circuit works. Then, redraw the whole circuit as a straight line. Reading the schematic and then redrawing is a very critical rule.
Find the load component first (for instance, light, horn, coil, solenoid or backup alarm), then find its ground, and then find the battery. Trying to read a schematic from positive to negative doesn't work. Always work back toward the battery from the load. This rule is important because it gives you a correct direction. All grounds must eventually end at the battery (not inputs).
Construction Equipment thanks Dan Sullivan for sharing excerpts from his book, Fundamental Electrical Troubleshooting. Sullivan is a full-time trainer, helping technicians understand and apply electrical theory and problem diagnosis. He also is the inventor of the TESlite, a diagnostic instrument for troubleshooting electrical problems. Text and drawings are used with permission. You can reach Sullivan at Sullivan Training Systems, 877-WRENCH2, or at www.brighterideas.com.
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Jorge Garcia has over 20 years of experience in the electrical field as both a practicing and electrical instructor. He has been a licensed electrician since 2000 and currently holds an Electrical Contractor and Master Electrician license from Texas. Jorge currently serves as the Department Chair for Construction, Manufacturing, Transportation Technology at Texas Southmost College. Additionally, he has over 15 years in business as an Electrical Contractor for Exit Light Services. Jorge has an Associate degree in Electrician Technology, a Bachelor of Science in Criminal Justice, a Master of Science in Management and Leadership, and is currently in a Learning Technology Ph.D. program. He also holds a Fire Suppression License from the State Fire Marshal Office, Licensed Irrigator, Limited License Electrician from Tennessee, License in Bilingual & Technology Education from Texas Education Agency, National Center for Construction Education & Research (NCCER) Electrical Instructor Certification, and an Occupational Safety and Health Administration (OSHA) Authorized Trainer license.
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