9

Technical Vocational Livelihood

(TVL)
Automotive Servicing 9
Quarter 4 - Week 1 -8

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 WEEKLY LEARNING ACTIVITY SHEETS
TVE-AUTOMOTIVE 9 Quarter 4 Week 1-2

Name: ___________________________________________ Section: ____________________

Learning Objective:
 Tests are carried out to determine faults using appropriate tools and techniques.
 Faults are identified and preferred repair action determined.
TLE_IAAS9- 12DT- Ia-jIIa-j-2

 Time Allotment: 16 hours

INFORMATION SHEET No.1

TITLE: Starting System Service Cautions

Before beginning any service on the starter system, some

precautions must be observed.

1. Refer to the manufacturer’s manual for correct procedures for

disconnecting a battery. Some vehicles with onboard computers
must be supplied with an auxiliary power source.
2. Disconnect the battery ground cable before disconnecting any of
the starter circuit’s wires or removing the starter motor.
3. Be sure the vehicle is properly positioned on the hoist or on safety
jack stands.
4. Before performing any cranking test, be sure the vehicle is in park
or neutral and the parking brakes are applied.
5. Follow manufacturer’s directions for disabling the ignition system.
6. Be sure the test leads are clear of any moving engine components.
7. Never clean any electrical components in solvent or gasoline. Clean
with low pressure compressed air, denatured alcohol or wipe with
clean rags only.

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Starting System Principles and Components

The internal combustion engine must be rotated before it will

run under its own power. The starting system is a combination of
mechanical and electrical parts that work together to start the engine. The
starting system is designed to convert electrical energy into mechanical
energy. To accomplish this conversion, a starter or cranking motor is used.
The starting system includes the following components: battery, cable and
wires, ignition switch, starter solenoid or relay, starter motor, starter drive
and flywheel ring gear, and starter safety switch.

Fig. 26 Starting system major components.

Major components of the starting system. The solid line represents the
starting circuit. The dashed line indicates the starter control circuit.

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 INFORMATION SHEET No. 2

TITLE: TESTING THE STARTING SYSTEM

Insulated circuit resistance test

The insulated circuit resistance test is a voltage drop test that is used to locate high
resistance in the starter circuit. An electrical resistance will have a different pressure or
voltage on each side of the resistance. Voltage is dropped when current flows through
resistance. Most manufacturers design their starting systems to have very little resistance to
the flow of current to the starter motor. Most have less than 0.2 volt dropped on each side of
the circuit. This means the voltage across the starter input terminal to the starter ground
should be within 0.4 volt of battery voltage.
Voltage drops are measured by connecting a voltmeter in parallel with the circuit
section being tested. In order to obtain a voltage drop reading, a load on the circuit must be
applied. The following is the test procedures:
1. Set the volt selector to the 3V position.
2. Connect the test leads depending the type of system being tested.
3. The voltmeter should read off the scale to the right until a load is put on the circuit.
If the meter reads zero, reverse the leads.
4. Disable the ignition system to prevent the vehicle from starting. This may be done
by removing the ignition coil secondary wire from the distributor cap and putting
it to ground.

Fig. 27 Disabling ignition system

5. Crank the engine and observe the voltmeter scale.

This test for voltage drop in the entire circuit, so if voltage drop is excessive the
cause of the drop must be located. To locate cause of the excessive voltage drop,
move the voltmeter lead on the starter toward the battery. With each move of the test
lead, crank the engine while observing the voltmeter reading. Continue to test each
connection until a noticeable decrease in voltage drop is detected. The cause of the
preceding point.

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Ground Circuit Test

A ground circuit test is performed to measure the voltage drop in the ground side of
the circuit. If the starter motor connection to ground is broken or loose, the circuit would be
opened. This could cause an intermediate starter system problem, or a starter motor that will
crank the engine. To perform the ground circuit test, connect the voltmeter leads across the
ground circuit and read voltage drop while cranking the engine. Follow these directions:

1. Set the volt selection to 3V.

2. Connect the positive volt test lead to the starter motor case and the negative test
lead to the ground battery terminal. Make sure any paint removed from the area
where the lead is connected to the case.
3. Crank the engine while observing the voltmeter.

Less than 0.2 volt indicates the ground circuit is good. If more than 0.2 volt is
observed, then there is a poor ground circuit connection. A poor ground circuit connection
could be the result of loose starter mounting bolts, paint on the starter motor case, or a bad
battery ground terminal post connection. Also check the ground cable for high resistance or
for being undersized.

Fig. 28 Connection of voltmeter in circuit ground test.

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 Activity 1

Draw a diagram on the alternator terminal identification

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 WEEKLY LEARNING ACTIVITY SHEETS
TVE-AUTOMOTIVE 9 Quarter 4 week 3-4

Name: ___________________________________________ Section: ____________________

Learning Objective:
* Starting systems are repaired without causing damage to any workplace property or vehicle.
 Information is assessed and interpreted from appropriate manufacturer’s specification.
 Starting systems are repaired without causing damage to any workplace

property or vehicle.

 Information is assessed and interpreted from appropriate manufacturer’s specification.

TLE_IAAS9- 12DT- Ia-jIIa-j-2

 Time Allotment: 16 hours

OPERATION SHEET No.1

Procedure in Disassembling Starter Motor

1. Always have a clean and organized work area. Prepare tools and materials needed
2. Clean the case and scribe reference marks at each end of the starter and housing
and the frame.

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3. Disconnect the field coil connection at the solenoids terminal.

4. Remove the two screws that attach the solenoid to the starter drive housing.

5. Rotate the solenoid until the locking flange of the solenoid is free, then remove
the solenoid.

6. Remove the through bolts from the end frame.

7. Remove screw from the cap.

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8. Pull out lock and spring

9. Remove the end frame.

10. Pull out magnetic field

11. Remove the armature from the drive housing. Note: on some units it may be
necessary to remove the shift lever from the drive housing before removing the
armature.

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 12. Remove snap ring from the shaft.

13. Pull out retainer.

14. Pull out over running clutch

15. Remove bushing with a hammer and a special service tool (SST)

Note: In assembling starter motor, perform the reverse procedures in

disassembling.

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INFORMATION SHEET No. 3

PARTS OF STARTER MOTOR

Fig. 29 Component parts of starter motor

BRONZE BUSHING

FRONT OR NOSE HOUSING

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 ARMATURE

FIELD COIL ASSEMBLY

REAR HOUSING

SHIFT LEVER

MAGNETIC SWITCH

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CARBON BRUSH HOLDER

CARBON BRUSH

THROUGH BOLTS

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 OPERATION SHEET No.2

Commutator Tests

If a growler is not available, the armature commutator can be tested

for opens and grounds using an ohmmeter. The following procedures should
be followed:
Testing the armature for opens.
1. Set the selector knob of multitester to Rx1.
2. Connect the test leads to any two commutator sectors.
3. Note the reading. There should be zero ohms of resistance.
Note: The armature will have to be replaced if there is resistance.

Fig. 30 Testing the armature for opens.

Testing the armature for shorts to ground.

1. Place the multitester on the Rx2K.
2. Connect one of the test leads to the armature shaft.
3. Connect the other lead to the commutator segments.
4. Check each sector. There should be no continuity to ground.
Note: The armature will have to be replaced if there is continuity.

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 Self Check No. 1

Answer each of the following answer with the word TRUE if the statement is
correct or FALSE if the statement is wrong. Answer before the number.

1. The starting system is a combination of mechanical and

electrical parts that work together to start the engine.
2. An electrical resistance will have a same pressure or
voltage on each side of the resistance.
3. Voltage drops are measured by connecting a voltmeter
in series with the circuit section being tested.
4. A ground circuit test is perform to measure the voltage drop
in the ground side of the circuit.
5. Less than 0.4 volt indicates the ground circuit is good.

Self Check No. 2

Direction: On the blank provided for, write the correct letter of your choice.

1. No cranking and no lights when the key is turned to start

may be caused all by the following EXCEPT
a. burned out light bulbs
b. an open circuit
c. a dead battery
d. an open fusible link
2. Voltage is dropped when current flows through .
a. Ohms
b. resistance
c. current
d. power
3. An electrical resistance will have difference pressure or
.
a. voltage
b. resistance
c. flow
d. current
4. A ground circuit test is performed to measure the .
a. pressure drop
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 b. resistance drop
c. voltage drop
d. heat drop
5. If the engine cranks slowly but does not start, a possible
cause
a. a discharged battery
b. low temperature
c. driver has row down the battery trying to start
d. any of the above

Self Check No. 3

Direction: Select the one correct, best or most probable answer to each
question.

1. Technician A says the starting system includes a low

current control circuit and a high – current motor circuit.
Technician B says the starting system includes a relay or
solenoid switch and a safety switch. Who is right?
a. A only
b. B only
c. both A and B
d. neither A and B
2. The overrunning clutch performs all the following except
a. transmits cranking torque to the engine
b. damage the armature if it fails to lock
c. prevents the engine from driving the pinion
d. acts as one – way clutch
3. The flow of battery connect in the starting motor circuit may
be controlled by means of a .
a. mechanical switch
b. electrical switch
c. dimmer switch
d. lock switch
4. A solenoid is an electromagnetic switching .
a. Device
b. Gadget
c. Tools
d. equipment

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 WEEKLY LEARNING
WEEKLY LEARNING ACTIVITY SHEETS
TVE-AUTOMOTIVE 9 Quarter 4 week 5-8

Name: ___________________________________________ Section: ____________________

Learning Objective:
1. Test and understanding charging system component and diagram.
2. Disassemble alternator based on the procedures stated in the service manual
3. Repair/replace and assemble alternator components/parts in accordance to service
manual
TLE_IAAS9- 12DT- Ia-jIIa-j-2

 Time Allotment: 35 hours

INFORMATION SHEET No.4

TITLE: Understanding charging System

• FUNCTION OF CHARGING SYSTEM

The system that is used to charge the batter Supplies current to all electrical circuits
Converts the mechanical energy into electrical energy to be use for all the electrical circuits of
the automobile.

• COMPONENT OF CHARGING SYSTEM

1. Battery
2. Ignition switch
3. Charge indicator (ammeter or charge indicator light)
4. Fuse
5. Voltage regulator
6. Alternator
1. External regulated
2. Internal regulated or built-in
voltage regulator

FUSE AND FUSIBLE LINK: Fusible link and a separate fuse are use to
protect the charging system circuit.
FUSE – the weakest point of the circuit. The fuse breaks when short circuit occur.

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CHARGING SYSTEM

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 Charging System
Alternator

• The charging system has three

major components. The Battery,
Alternator, and the Regulator.
• This alternator works together
with the battery to supply power
when the vehicle is running.
• The output of an alternator is
direct current, however AC
voltage is actually created and
then converted to DC as voltage
leaves the alternator on its way to
the battery and the electrical
loads.

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 The alternator contains:
• A rotating field winding called the rotor.
• A stationary induction winding called the stator.
• A diode assembly called the rectifier bridge.
• A control device called the voltage regulator.
• Two internal fans to promote air circulation.
• Most regulators are on the inside the alternator. Older models have externally mounted
regulators.
• Unlike other manufacturers, this model can be easily serviced from the rear on the unit.
• The rear cover can be removed to expose internal parts.
• However, today’s practice is to correctly diagnose the problem and replace the alternator as
a unit, should one of it’s internal components fail.

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 Activity:1

Draw the following in a separate sheet:

1.Draw a circuit diagram of charging system.

2. Draw an alternator diagram.

Activity:2

1. Namely the parts of rotor assembly.

2. Namely the parts of alternator assembly.

3. Namely the alternator terminal identification.

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