3/31/25, 12:24 AM SIS 2.

2007/07/26 Electrical System (SENR9832-72)

SMCS - 1400, 1550, 1900 i02809245

Grounding Practices PSP

202 -000C
Proper grounding for the machine electrical system and the engine electrical system is
necessary for proper machine performance and reliability. Improper grounding will result in

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uncontrolled electrical circuit paths and unreliable electrical circuit paths.

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SEN 4:02+ 0
Uncontrolled engine electrical circuit paths can result in damage to main bearings, crankshaft
bearing journal surfaces, and aluminum components.

© 2 R983 05:30
To ensure proper functioning of the machine and engine electrical systems, an engine-to-frame
ground strap with a direct path to the negative battery post must be used. This may be provided
025 2
by way of a starting motor ground, a frame to starting motor ground, or a direct frame to engine
ground.
Cat
erp
An engine-to-frame ground strap must be used in order to connect the grounding stud of the
illa
engine to the frame of the vehicle and to the negative battery post.
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c.

Illustration 1 g01028488
Typical example
Grounding Stud To Battery Ground ("-")

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Illustration 2 g01028479
Typical example
Alternate grounding stud to battery ground ("-")

The engine must have a wire ground to the battery.

Ground wires or ground straps should be combined at ground studs that are only for ground use.
All of the grounds should be tight and free of corrosion.

All of the ground paths must be capable of carrying any likely current faults. An AWG #0 or larger
wire is recommended for the grounding strap to the cylinder head.

The engine alternator should be battery ground with a wire size that is capable of managing the
full charging current of the alternator.

NOTICE
When boost starting an engine, the instructions in Systems
Operation, "Engine Starting" should be followed in order to
properly start the engine.

This engine may be equipped with a 12 volt starting system or a

24 volt starting system. Only equal voltage for boost starting
should be used. The use of a higher voltage will damage the
electrical system.

The Electronic Control Module (ECM) must be disconnected at

the "J1/P1" and "J2/P2" locations before welding on the vehicle.

The engine has several input components which are electronic. These components require an
operating voltage.

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Unlike many electronic systems of the past, this engine is tolerant to common external sources
of electrical noise. Buzzers that use electrical energy can cause disruptions in the power supply.
If buzzers are used anywhere on the machine, the engine electronics should be powered directly
from the battery system through a dedicated relay. The engine electronics should not be
powered through a common power source with other activities that are related to the keyswitch.

Engine Electrical System

The electrical system has the following separate circuits:

Charging

Starting (If equipped)

Accessories with low amperage

Some of the electrical system components are used in more than one circuit. The following
components are common in more than one circuit:

Battery or batteries

Circuit breakers

Battery cables

Ammeter

The charging circuit is in operation when the engine is running. An alternator makes electricity for
the charging circuit. A voltage regulator in the circuit controls the electrical output in order to keep
the battery at full charge.

The starting circuit is activated only when the start switch is activated.

The accessory circuit with the low amperage and the charging circuit are connected through the
ammeter. The starting circuit is not connected through the ammeter.

Charging System Components

Alternator
The alternator is driven by a belt from the crankshaft pulley. This alternator is a three-phase, self-
rectifying charging unit, and the regulator is part of the alternator.

The alternator design has no need for slip rings and the only part that has movement is the rotor
assembly. All conductors that carry current are stationary. The following conductors are in the
circuit:

Field winding

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Stator windings

Six rectifying diodes

Regulator circuit components

The rotor assembly has many magnetic poles that look like fingers with air space between each
of the opposite poles. The poles have residual magnetism. The residual magnetism produces a
small magnetic field between the poles. As the rotor assembly begins to turn between the field
winding and the stator windings, a small amount of alternating current (AC) is produced. The AC
current is produced in the stator windings from the small magnetic field. The AC current is
changed to direct current (DC) when the AC current passes through the diodes of the rectifier
bridge. The current is used for the following applications:

Charging the battery

Supplying the accessory circuit that has the low amperage

Strengthening the magnetic field

The first two applications use the majority of the current. As the DC current increases through
the field windings, the strength of the magnetic field is increased. As the magnetic field becomes
stronger, more AC current is produced in the stator windings. The increased speed of the rotor
assembly also increases the current and voltage output of the alternator.

The voltage regulator is a solid-state electronic switch. The voltage regulator senses the voltage
in the system. The voltage regulator switches ON and OFF many times per second in order to
control the field current for the alternator. The alternator uses the field current in order to
generate the required voltage output.

NOTICE
Never operate the alternator without the battery in the circuit.
Making or breaking an alternator connection with heavy load on
the circuit can cause damage to the regulator.

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Illustration 3 g01241796
Typical alternator components
(1) Regulator
(2) Roller bearing
(3) Stator winding
(4) Ball bearing
(5) Rectifier bridge
(6) Field winding
(7) Rotor assembly
(8) Fan

Starting System Components

Starting Solenoid

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Illustration 4 g00317613
Typical starting solenoid

Illustration 5 g01241797
Typical starting motor components
(9) Field
(10) Solenoid
(11) Clutch
(12) Pinion
(13) Commutator
(14) Brush assembly
(15) Armature

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The starting solenoid (10) is an electromagnetic switch that performs the following basic
operations:

The starting solenoid (10) closes the high current starting motor circuit with a low current
start switch circuit.

The starting solenoid (10) engages the pinion for the starting motor (4) with the ring gear.

Solenoid (10) has windings (one or two sets) around a hollow cylinder. A plunger with spring
pressure(core) is inside of the cylinder. The plunger can move forward and backward. When the
start switch is closed and electricity is sent through the windings, a magnetic field (9) is made.
The magnetic field (9) pulls the plunger forward in the cylinder. This moves the shift lever in
order to engage the pinion drive gear with the ring gear. The front end of the plunger then makes
contact across the battery and motor terminals of solenoid (10). Next, the starting motor begins
to turn the flywheel of the engine.

When the start switch is opened, current no longer flows through the windings. The spring now
pushes the plunger back to the original position. At the same time, the spring moves the pinion
gear away from the flywheel.

When two sets of solenoid windings are used, the windings are called the hold-in winding and
the pull-in winding. Both sets of windings have the same number of turns around the cylinder, but
the pull-in winding uses a wire with a larger diameter. The wire with a larger diameter produces a
greater magnetic field (9). When the start switch is closed, part of the current flows from the
battery through the hold-in windings. The rest of the current flows through the pull-in windings to
the motor terminal. The current then flows through the motor to ground. Solenoid (10) is fully
activated when the connection across the battery and the motor terminal is complete. When
solenoid (10) is fully activated, the current is shut off through the pull-in windings. At this point,
only the smaller hold-in windings are in operation. The hold-in windings operate for the duration
of time that is required in order to start the engine. Solenoid (10) will now draw less current from
the battery, and the heat that is generated by solenoid (10) will be kept at an acceptable level.

PSP-000CB74D
2025/03/30
18:53:53+05:30
i00854556
© 2025 Caterpillar Inc.

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