Automotive Electrical and Electronic Systems Classroom Manual Fifth Edition Update by John F. Kershaw
www.TechnicalBooksPDF.comContentsChapter 1 — Tools, Fasteners, and Safety 1Learning Objectives 1Key Terms 1Threaded Fasteners 1Metric Bolts 2Grades of Bolts 2Nuts 3Washers 4Basic Tool List 4Tool Sets and Accessories 10Brand Name Versus Proper Term 10Safety Tips for Using Hand Tools 11Measuring Tools 11Safety Tips for Technicians 13Safety in Lifting (Hoisting) a Vehicle 15Electrical Cord Safety 17Fire Extinguishers 19Summary 20Review Questions 20Chapter 2 — Introduction to Electricity 21Learning Objectives 21Key Terms 21What is Electricity? 22Atomic Structure 22Sources of Electricity 25Historical Figures in Electricity 30Summary 31Review Questions 32Chapter 3 — Electrical Fundamentals 35Learning Objectives 35Key Terms 35Conductors and Insulators 36Characteristics of Electricity 36Complete Electrical Circuit 40Ohm’s Law 42Power 44Capacitance 45Summary 49Review Questions 50Chapter 4 — Magnetism 53Learning Objectives 53Key Terms 53Magnetism 54Electromagnetism 55Electromagnetic Induction 60Transformers 65Electromagnetic Interference (EMI)Suppression 65Summary 68Review Questions 70Chapter 5 — Series, Parallel, and Series-Parallel Circuits 71Learning Objectives 71Key Terms 71Basic Circuits 71Series Circuit 72Parallel Circuit 72Series Circuit Voltage Drops 73Parallel Circuit Voltage Drops 75Calculating Series Circuit TotalResistance 76Calculating Parallel Circuit TotalResistance 78Series-Parallel Circuits 79Series and Parallel Circuit Faults 82Summary of Series Circuit Operation 84Summary of Parallel Circuit Operation 84Review Questions 85Chapter 6 — Electrical Diagrams andWiring 89Learning Objectives 89Key Terms 89Wiring and Harnesses 90Wire Types and Materials 92Wire Size 93Connectors and Terminals 96Ground Paths 99Multiplex Circuits 100ix
www.TechnicalBooksPDF.comxContentsElectrical System Polarity 103Common Electrical Parts 103Wire Color Coding 109The Language of Electrical Diagrams 111Diagrams 112Summary 124Review Questions 126Chapter 7 — Automotive BatteryOperation 129Learning Objectives 129Key Terms 129Electrochemical Action 130Battery Electrolyte 134State-of-Charge Indicators 135Wet-Charged and Dry-ChargedBatteries 136Battery Charging Voltage 136Battery Selection and Rating Methods 136Battery Installations 138Battery Installation Components 140Battery Life and Performance Factors 142Summary 144Review Questions 145Chapter 8 — Charging System Operation 147Learning Objectives 147Key Terms 147Charging System Development 148DC Generator 148Charging Voltage 148Diode Rectification 150AC Generator (Alternator) Components 152Current Production in an AC Generator 156Voltage Regulation 161Electromagnetic Regulators 162Solid-state Regulators 163Charge/Voltage/Current Indicators 168Charging System Protection 170Complete AC Generator Operation 170AC Generator (Alternator) DesignDifferences 171Summary 179Review Questions 181Chapter 9 — Starting System Operation 183Learning Objectives 183Key Terms 183Starting System Circuits 184Basic Starting System Parts 184Specific Starting Systems 188Starter Motors 192Frame and Field Assembly 192DC Starter Motor Operation 194Armature and Commutator Assembly 197Permanent-Magnet Fields 197Starter Motor and Drive Types 198Overrunning Clutch 203Summary 204Review Questions 206Chapter 10 — Automotive Electronics 209Learning Objectives 209Key Terms 209Semiconductors 210Electrostatic Discharge (ESD) 213Diodes 213Photonic Semiconductors 215Rectifier Circuits 216Transistors 217Silicon-Controlled Rectifiers (SCRs) 221Integrated Circuits 222Using Electronic Signals 222Summary 223Review Questions 224Chapter 11 — The Ignition Primary andSecondary Circuits and Components 227Learning Objectives 227Key Terms 227Need for High Voltage 228High Voltage Through Induction 228Basic Circuits and Current 229Primary Circuit Components 230Switching and Triggering 230Monitoring Ignition Primary CircuitVoltages 234Primary and Secondary Circuits 236Ignition Coils 237Distributor Cap and Rotor 247Ignition Cables 250Spark Plugs 250Spark Plug Construction 252Summary 255Review Questions 256Chapter 12 — Automotive LightingSystems 257Learning Objectives 257Key Terms 257Headlamp Circuits 258Common Automotive Bulbs 268Taillamp, License Plate Lamp, and ParkingLamp Circuits 269Stop Lamp and Turn Signal Circuits 270Hazard Warning Lamp (Emergency Flasher)Circuits 274Backup Lamp Circuits 275Side Marker and Clearance LampCircuits 276
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Contents
Electrical System Polarity 103
Common Electrical Parts 103
Wire Color Coding 109
The Language of Electrical Diagrams 111
Diagrams 112
Summary 124
Review Questions 126
Chapter 7 — Automotive Battery
Operation 129
Learning Objectives 129
Key Terms 129
Electrochemical Action 130
Battery Electrolyte 134
State-of-Charge Indicators 135
Wet-Charged and Dry-Charged
Batteries 136
Battery Charging Voltage 136
Battery Selection and Rating Methods 136
Battery Installations 138
Battery Installation Components 140
Battery Life and Performance Factors 142
Summary 144
Review Questions 145
Chapter 8 — Charging System Operation 147
Learning Objectives 147
Key Terms 147
Charging System Development 148
DC Generator 148
Charging Voltage 148
Diode Rectification 150
AC Generator (Alternator) Components 152
Current Production in an AC Generator 156
Voltage Regulation 161
Electromagnetic Regulators 162
Solid-state Regulators 163
Charge/Voltage/Current Indicators 168
Charging System Protection 170
Complete AC Generator Operation 170
AC Generator (Alternator) Design
Differences 171
Summary 179
Review Questions 181
Chapter 9 — Starting System Operation 183
Learning Objectives 183
Key Terms 183
Starting System Circuits 184
Basic Starting System Parts 184
Specific Starting Systems 188
Starter Motors 192
Frame and Field Assembly 192
DC Starter Motor Operation 194
Armature and Commutator Assembly 197
Permanent-Magnet Fields 197
Starter Motor and Drive Types 198
Overrunning Clutch 203
Summary 204
Review Questions 206
Chapter 10 — Automotive Electronics 209
Learning Objectives 209
Key Terms 209
Semiconductors 210
Electrostatic Discharge (ESD) 213
Diodes 213
Photonic Semiconductors 215
Rectifier Circuits 216
Transistors 217
Silicon-Controlled Rectifiers (SCRs) 221
Integrated Circuits 222
Using Electronic Signals 222
Summary 223
Review Questions 224
Chapter 11 — The Ignition Primary and
Secondary Circuits and Components 227
Learning Objectives 227
Key Terms 227
Need for High Voltage 228
High Voltage Through Induction 228
Basic Circuits and Current 229
Primary Circuit Components 230
Switching and Triggering 230
Monitoring Ignition Primary Circuit
Voltages 234
Primary and Secondary Circuits 236
Ignition Coils 237
Distributor Cap and Rotor 247
Ignition Cables 250
Spark Plugs 250
Spark Plug Construction 252
Summary 255
Review Questions 256
Chapter 12 — Automotive Lighting
Systems 257
Learning Objectives 257
Key Terms 257
Headlamp Circuits 258
Common Automotive Bulbs 268
Taillamp, License Plate Lamp, and Parking
Lamp Circuits 269
Stop Lamp and Turn Signal Circuits 270
Hazard Warning Lamp (Emergency Flasher)
Circuits 274
Backup Lamp Circuits 275
Side Marker and Clearance Lamp
Circuits 276
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