Internal Use Only

Professor -
MPT 4 AST L2 – 3.3.3, 3.4.2, 3.7.3
CRN

Motive Power Programs

Name: ________________________________________________

Student ID: ____________________

Class: ______ Group: ______ Date: __________________

Cranking Systems; Charging Systems and Control Circuits, Diagnostics and Testing –
Electrical and Fuel Systems 2 (ELFL002)

Learning Outcome(s):

Upon successful completion, the learner has reliably demonstrated the ability to:

• Explain the purpose, construction, and operating principles of cranking systems

according to accepted manufacturers’ standards
• Explain cranking system operations according to manufacturers’ standards
• Perform diagnosis according to manufacturers’ standards
• Explain the construction, principles of operation, inspection and testing of charging
systems according to manufacturers’ standards

Performance Objective(s):

3.3.3 Disassemble and re-assemble cranking motors

o Inspect and test major components of cranking motors
• Armature for shorts, opens, ground, alignment
• Field coils for shorts, opens, ground
• Identify type of winding
• Pole shoes
• Bushings and bearings
• Brushes and springs

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 1

3.4.2 Perform inspection, testing, and diagnostic procedures on cranking motors
o Analyze the results
• Cranking system visual inspection
• Battery load test and verify capacity and performance to application
• Cranking circuit voltage drop tests
• Cranking system current draw test
• Perform ring gear tooth inspection
• Slow cranking
• No cranking

3.7.3 Inspect, test and diagnose alternator and voltage regulation systems
o Perform charging system visual inspection
• Belt tension
• Connections and wiring

o Perform charging system current and voltage output tests

o Disassemble, test and re-assemble alternator

• Rotor field tests
• Rectifier diodes
• Stator

Completion Timeline: 12 Hours

Tools & Materials required:

Tools/Equipment Qty.
DVOM 1
AVR tester 1
Growler 1
Hack saw blade 1
Shop Key Pro 1

Materials Qty.
Starter motor 1
Crocus cloth 1
Alternator

Vehicle #: Repair Order #:

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 2

 Key # Returned: Yes No Tool Box # Tool Box Inventory: Yes No

Shop
Completed: Yes No Vehicle Condition Satisfactory: Yes No
Clean Up

***Read ENTIRE shop practicum before proceeding to Shop Activities***

In-Class Shop Activities:

--- Cranking Systems and Control Circuits, Diagnostics and Testing ---

1. Using Shop Key, a DVOM meter, battery load tester, your assigned vehicle and following
manufacturer’s service procedures, follow the inspection and test steps listed below.
Record your results.

a) Perform a visual inspection on a battery and report the following:

Battery Specifications

Manufacturer

Battery Model

Battery Group

Serial Number

Cold Cranking Amps (CCA)

Ampere-Hour Rating (AH)

Cranking Ampere (CA)

Reserve Capacity (RC)

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 3

 b) Perform a battery load test.

Connect the carbon pile load tester, as per the test equipment manufacturers’ instructions.

Determine the correct amount of load = __________ amps.

***3X amp/hour of the battery OR 1/2 CCA of the battery***

Remove the surface charge by applying load of one-half of the CCA rating of the battery for 15
seconds. Let the battery “recover” for 15 seconds.
Apply the same amperage load for 15 seconds. With the load still applied, read and record the
battery voltage.

Battery Voltage = __________ V

Is the battery within specifications for you to proceed with the test? __________

2. Visually inspect the starter motor electrical circuit and starter motor mountings. Record your
findings.
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

3. Using Shop Key, retrieve the wiring diagram of the starting system of the vehicle you are
working on and PRINT IT OFF. Highlight the positive side of the system in YELLOW.
Highlight the negative side of the system in GREEN. Identify the control circuit in ORANGE.
Attach to shop sheet.

4. Using Shop Key, an AVR, and your assigned vehicle, perform a starter current draw test.
Follow the testing procedure listed below. Record your results.

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 4

 Record the vehicle system specifications in table below.

Voltage should not drop below: __________ volts

Expected amperage draw is: __________ amps

a) How would you prepare the vehicle before initializing an amp draw test?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

b) What method would you use and why?

____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

Connect AVR tester and perform an amp draw test. Be sure to zero the ammeter.
Do not crank starter motor for more than 10 seconds!

Initial amperage draw is: __________ amps

Continued amperage draw is: __________ amps

Voltage after 10 seconds is: __________ volts

5. Using a DVOM meter and a shop vehicle, perform a starter system insulated circuit
resistance test. Follow the testing procedure listed below. Record your results.

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 5

 a) Connect voltmeter to battery terminals and measure voltage. Record test result in table
below.

Voltage across battery: __________ volts

b) Using a voltmeter, connect positive lead to battery positive and negative lead to starter
motor input terminal. Crank engine for 10 seconds and measure voltage. Record test
results in the table below.

Voltage across terminal on starter motor: __________ volts

6. Using a DVOM meter and a shop vehicle, perform a starter system ground circuit test.
Follow the testing procedure listed below. Record your results.

a) Connect the voltmeter positive lead to the starter motor housing and the negative lead to
the battery ground terminal. Crank engine for 10 seconds and record measurement.

Voltage across starter motor case and battery ground: __________ volts

7. Using a DVOM meter and a shop vehicle, perform a starter solenoid circuit resistance test.
Follow the testing procedure listed below. Record your results.

a) Connect the voltmeter positive lead to the BAT terminal on the starter solenoid and
connect the negative lead to the starter motor input terminal. Crank engine for 10
seconds and record measurement.

Voltage across starter solenoid BAT terminal and

__________ volts
starter motor input terminal:

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 6

8. Using a DVOM meter and a shop vehicle, perform a starter system open circuit test. Follow
the testing steps listed below. Record your results.

a) Connect the voltmeter positive lead to the starter motor input terminal and the negative
lead to ground. Turn ignition key to the Start position. Measure and record voltage
reading.

Voltage at starter motor input terminal and ground: __________ volts

b) Connect the voltmeter positive lead to the starter solenoid terminal B+ and the negative
lead to ground. Turn ignition key to the OFF position. Measure and record voltage
reading.

Voltage at starter solenoid terminal B+ and ground: __________ volts

c) Connect the voltmeter positive lead to the starter solenoid terminal B+ and the negative
lead to ground. Turn ignition key to the START position. Measure and record voltage
reading.

Voltage across starter solenoid terminal B+ and

__________ volts
ground:

Reconnect ALL components and verify the vehicle STARTS!

9. Using a disassembled bench starter motor, perform a field coil circuit test. Record test
findings in table below. Knowing how the field coils are wired is critical. Determine the
power and ground side of the field coil circuit.

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 7

 a) Open circuit testing. Using an ohmmeter, place one lead on the starter motor input
terminal and connect the other lead on the insulated brushes. Measure and record
resistance.

Field coil resistance: __________ ohms

b) Short to ground circuit testing. Using an ohmmeter, place one lead on the starter motor
input terminal and connect the other lead on the starter case. Measure and record
resistance.

Field coil resistance: __________ ohms

10. Using the disassembled bench starter motor, a growler and hack saw blade, perform an
armature short test.

a) Place armature on growler, hold hack saw blade parallel to the core of the armature,
observe blade and record test findings in table below. Slowly rotate the armature.

Hack saw blade action: No vibration/pull: _____ Vibration/pull: _____

11. Using the disassembled bench starter motor, a DVOM meter, perform an armature ground
test.

a) With the DVOM on the resistance setting, place one lead on a commutator bar and the
other on the armature core. Record test findings in table below.

Commutator to armature core resistance: __________ ohms

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 8

12. Using the disassembled bench starter motor and a DVOM meter, perform a commutator
open circuit test.

a) Clean the commutator with crocus cloth. With the DVOM on the lowest ohms scale,
place each lead on a commutator bar. Record test findings in table below.

Commutator resistance: __________ ohms

13. Using the disassembled bench starter motor and a DVOM meter, perform an armature short
to ground circuit test.

a) Clean the commutator with crocus cloth. With the DVOM on the lowest resistance scale,
place one lead on a commutator bar and the other lead on the armature machined shaft.
Check each commutator segment. Record test findings in table below.

Commutator segment to armature shaft resistance: __________ ohms

Commutator segment to armature shaft resistance

__________ ohms
variance:

14. Using the disassembled bench starter motor and a DVOM meter, perform a brush continuity
test.

a) With brushes placed in brush holders and using a DVOM meter, place one lead on
positive brush and the other lead on the negative brush. Record test findings in table
below.

+ Brush to – brush resistance: __________ ohms

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 9

15. Using the disassembled bench starter motor, perform an overrunning clutch inspection.

a) Slide overrunning clutch onto the armature shaft. Attempt to rotate clutch in both
directions. Record inspection findings in table below.

Overrunning Clutch Operation Inspection Condition Found

Clutch rotated smoothly in one direction

only and locked in the opposite direction

Clutch rotated rough

Clutch failed to lock

Clutch locked in both directions

16. Reassemble the starter motor.

Summarize and record ‘Key’ learning’s for Cranking Systems and Control Circuits, Diagnostics
and Testing:

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 10

 ---------- Charging Systems and Control Circuits -----------

1. Using a shop vehicle/engine stand, perform a preliminary charging system visual inspection.
Record results in table below.

Check the Following Items: Condition Recommendations

Drive Belt Condition

Drive Belt Tension/Alignment

Electrical Connections to AC
Generator
Electrical Connections to
Regulator
Ground Connections at the
Engine and Chassis

Battery Cables and Terminals

Fuses and Fusible Links

2. Using an AVR machine, your assigned vehicle, perform a Voltage Output test. Follow the
testing procedure listed below. Record your results.

a) Key OFF, measure and record voltage across battery terminals.

Base Voltage: __________ volts

b) START engine run to 1500 RPM, measure and record voltage across battery terminals.

Voltage Output: __________ volts

(Typically, 13.5v – 14.5v)

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 11

3. Using the AVR machine, your assigned vehicle, perform a Voltage Drop test on the charging
system. Follow the testing procedure listed below. Record your results.
a) Insulated circuit. Using small red and black test leads, connect red lead to AC generator
output terminal and black lead to battery positive terminal.

Voltage drop across AC generator output

__________ volts
terminal battery positive terminal:

b) Ground circuit. Using small red and black test leads, connect red lead to battery negative
terminal and black lead to AC generator housing.

Voltage drop across negative battery terminal

__________ volts
and AC generator housing:

4. Continuing with your AVR and assigned vehicle, perform a Charging System Requirement
test*. Record your results.

Maximum current requirement: __________ amps

*Connect the LARGE red and black cables across the battery. Connect the inductive pickup
around ALL battery ground cables. With the ignition switch in the RUN position, engine NOT
running, observe the ammeter reading. This reading indicates how much current is required to
operate any full-time accessories.

5. What precautions must you take into consideration when testing the alternator for maximum
current output?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 12

____________________________________________________________________________
____________________________________________________________________________

6. Continuing with your AVR and assigned vehicle, perform a Current Output test* of the
charging system. Record your results.

Maximum current output: __________ amps

*Maximum Output Testing: Clamp the ammeter around the BAT+ wire leading from the
alternator to the battery. Bring the vehicle to a fast idle of around 2000 rpm and apply a load to
the charging system to produce maximum output.

7. Continuing with your AVR and assigned vehicle, perform a Voltage Regulator test. Record
your results.

Regulated voltage reading: __________ volts

8. Using a bench component AC generator, MARK the two housing halves and disassemble
each main component. Follow the testing procedure listed below. Record your results.

a) Visually inspect the rotor. Check rotor windings for signs of discoloration or overheating.
Do the rotor windings show any of these signs? YES or NO
If YES, describe.
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

b) Visually inspect the slip rings. Check slip rings to ensure they are flat, smooth and free of
damage.

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 13

Do the slip rings show any of these signs? YES or NO
If YES, describe.
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

9. Using a DVOM, test the rotor for OPENS in the rotor windings. Follow the testing procedure
listed below. Record your results.

Resistance between slip rings: __________ ohms

10. Using a DVOM, test the rotor for SHORT TO GROUND in the rotor windings. Follow the
testing procedure listed below. Record your results.

a) Place one DVOM test lead on each slip ring and one on the rotor shaft. Reading should
be: OL ohms. Record resistance.

Resistance between slip ring and rotor shaft: __________ ohms

11. Using a DVOM, test the stator for OPENS in the stator windings. Follow the testing
procedure listed below. Record your results.

a) Place DVOM test leads on each pair of stator leads. Record resistance on each
combination of stator leads.

Resistance between stator leads combination 1: __________ ohms

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 14

 Resistance between stator leads combination 2: __________ ohms

Resistance between stator leads combination 3: __________ ohms

12. Using a DVOM, test the stator for SHORT TO GROUND in the stator windings. Follow the
testing steps listed below. Record your results.

a) Place one DVOM test lead on stator lead and the other lead on the stator frame.
Reading should be: OL ohms. Record resistance on each combination of stator leads.

Resistance between stator lead and frame

__________ ohms
combination 1:

Resistance between stator lead and frame

__________ ohms
combination 2:

Resistance between stator lead and frame

__________ ohms
combination 3:

Testing the Diodes

(Rectifier Bridge)
13. Using a DVOM, test each diode for CONTINUITY in both directions. Record your results.
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 15

(Diode Trio)
14. Using a DVOM, test each diode for CONTINUITY in both directions. Record your results.
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

15. Explain to your instructor how the rotor works; how the stator works; and how AC voltage is
rectified.

Rotor Operation - Task Completed _____

Stator Operation - Task Completed _____

AC Voltage Rectification - Task Completed _____

16. Reassemble the AC generator (if applicable use a paper clip/pin to hold brushes in place).

AC generator correctly reassembled - Task Completed _____

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 16

Shop Homework:

1. A vehicle is towed into the shop due to a no-start (no-crank) condition. The headlights are
turned on, and when the ignition key is placed in the START position, the lights remain
bright, but the starter does not crank the engine.
Technician A says that the starter may be binding internally.
Technician B says that the battery may be discharged.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

2. A vehicle is being tested for a slow-crank condition. The starter current draw is 525 amps.
Technician A says that the field windings in the starter may be shorted.
Technician B says that the starter drive gear may be slipping.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

3. The starter draw of a vehicle with a slow-crank condition is 75 amps. The battery had a
good state of charge and it passed the capacity test.
Technician A says that a starting circuit voltage drop test should be performed.
Technician B says that the neutral safety switch may have excessive resistance.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 17

4. A voltmeter that is connected across a starter solenoid’s battery and motor terminals
indicates 12 volts when the ignition key is turned to the START position. A distinct click is
heard from the solenoid when this occurs, but the engine does not crank.
Technician A says that there is excessive voltage drop in the circuit between the battery and the
starter solenoid.
Technician B says that the starter solenoid probably needs to be replaced.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

5. Technician A says that incorrect pinion gear to ring gear clearance can result in noisy
cranking and high starter draw.
Technician B says that starting circuit voltage drop should be checked before performing a
starter draw test.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

6. A vehicle’s battery discharges in a very short period of time due to a shorted cell. Before
replacing the battery, a charging system test is performed. The engine is started, and all
accessories are turned off.
Technician A says that the charging system’s amperage output will be lower than normal.
Technician B says that the alternator’s field current will be high when the engine is running.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 18

7. The charging system voltage of a vehicle equipped with an external voltage regulator is 15.5
volts at 1500 rpm.
Technician A says that the voltage regulator sensing circuit may have excessive resistance.
Technician B says that the alternator’s field circuit may have excessive resistance.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

8. Charging system voltage is being measured at 2 places at the same time with the engine
running. Connecting the voltmeter’s leads across the battery terminals results in a 12.8-volt
reading, while connecting the voltmeter to the AC generator output terminal and the AC
generator case results in a 14.2-volt reading.
Technician A says that there may be excessive resistance on the ground side of the charging
system.
Technician B says that there may be excessive resistance on the positive side of the charging
system.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 19

9. A customer says that his battery completely discharges every few days even though he
drives his car about 80 KMs every day. A test of his charging system is performed, and the
following measurements are recorded with all accessories turned on. At 1300 rpm the
charging system voltage and amperage are 12.4 volts and 60 amps. A replacement
alternator produces the same measurements.
Technician A says that there may be excessive electrical demand on the alternator.
Technician B says that the charging system output circuit may have excessive voltage drop.
Who is correct?
a) A only
b) B only
c) Both A and B
d) Neither A nor B

10. Which of the following could result in battery overheating and eventual premature failure?
a) Open field circuit
b) Shorted stator windings
c) Open diode
d) High resistance in the voltage regulator sensing circuit

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 20

 Summarize and record ‘Key’ learning’s for Charging Systems and Control Circuits:

Evaluation

Advanced Intermediate Beginner

10 9 8 7 6 5 4 3 2 1
0 Mark
(100%) (90%) (80%) (70%) (60\50 (50%) (40%) (30%) (20%) (10%)

Practicum
Performance

Practicum
Homework (%)

Shop
Preparedness

Instructor summative feedback:

Electrical and Fuel Systems L2 – 3.3.3, 3.4.2, 3.7.3 Page 21