VEHICLE SERVICING

LEVEL - I

Learning Guide - 42
Unit of Competence: - Apply Automotive
Electrical System Fundamentals
Module Title: - Applying Automotive Electrical
System Fundamentals
LG Code: EIS VHS1 M13 LO-1LG- 42
TTLM Code: EIS VHS1 TTLM 09 19v1

LO 1:- Identify and apply

Electrical/electronic fundamentals

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 Instruction Sheet Learning Guide

This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics –
 Locating suitable and relevant sources of information
 Identifying elements of electricity
 Applying Elements of electricity/electronic common terminology
 Applying elements of electricity/electronic
This guide will also assist you to attain the learning outcome stated in the cover page. Specifically,
upon completion of this Learning Guide, you will be able to –

 Locate to assist suitable and relevant sources of information with electrical fundamentals
research.
 Identify elements of electricity
 Apply to common elements of electricity/electronic terminology for automotive electrical
circuits, systems and components
 Apply to common elements of electricity/electronic calculations for automotive electrical
circuits, systems and components

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described in number 1 to 7.
3. Read the information written in the “Information Sheets 1”. Try to understand what are being
discussed. Ask you teacher for assistance if you have hard time understanding them.
4. Accomplish the “Self-check 1” in page 4
5. Ask from your teacher the key to correction (key answers) or you can request your teacher to
correct your work. (You are to get the key answer only after you finished answering the Self-
check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if your rating
is unsatisfactory, see your teacher for further instructions or go back to Learning Activity #1.
7. Submit your accomplished Self-check. This will form part of your training portfolio.

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 Information Sheet-1.1 Locating suitable and relevant sources of information

Electrical circuits require different components depending on the type of work they do and how
they are to perform it. A light may be wired directly to the battery, but it will remain on until the
battery drains. A switch will provide for control of the light circuit. However, if variable dimming of
the light is required, a rheostat is also needed.
There are several electrical components that may be incorporatedinto a circuit to achieve the
desired results from the system. These components include switches, relays, buzzers, and
various types of resistors, Capacitor, Inductor and Transformer.
There is often confusion concerning the terms electrical and electronic. In this Learning Guide,
electrical and electrical systems refer to wiring and electrical parts, such as generators, lights, and
voltage regulators. Electronics means computers and other black box-type items used to control
engine and vehicle systems. A good understanding of electrical principles is important to proper
diagnosis of any system that is monitored, controlled, or operated by electricity.
BASICS OF ELECTRICITY
Perhaps the one reason why some people find it difficult to understand electricity is that they
cannot see it. By actually knowing what it is and what it is not, you can easily understand it.
Electricity is not magic! It is something that takes place or can take place in
everything you know. It not only provides power for lights, TVs, stereos, and refrigerators, it is also
the basis for the communications between our brain and the rest of our bodies.

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 Self-Check -1.1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
1. Whtat is the diference between electericty and electronics?(3point)
2. Write several electrical components? (3point)

Answer Sheet

1. _______________________________________________________________________
___________________________________.
2. _______________________________________________________________________
___________________________________.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Score = ___________

Rating: ____________

Name: _________________________ Date: ______________

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 Information Sheet-1.2 Identifying elements of electricity

Electricity is the movement of electrons from atom to

atom through a conductor.

Electricity can flow only if there is a complete circuit from the

battery through wires to components and back to the battery again.

The diagram shows a simple circuit of a battery, wires, a switch

and a lamp. The switch works by breaking the circuit. Fig 1.1 siple electrical circuit
With the switch open the circuit is broken - so electricity
cannot flow and the lamp is off.

With the switch closed the circuit is complete - allowing electricity to flow and the lamp is on. The
electricity is carrying energy from the battery to the lamp.
We can see, hear or feel the effects of electricity flowing such as a lamp lighting, a bell ringing, or
a motor turning - but we cannot see the electricity itself, so which way is it flowing?

Which way does electricity flow?

We say that electricity flows from the positive (+) terminal of a battery to the negative (-) terminal
of the battery. We can imagine particles with positive electric charge flowing in this direction
around the circuit, like the red dots in the diagram.

This flow of electric charge is called conventional current. This direction of flow is used
throughout electronics and it is the one you should remember and use to understand the operation
of circuits.
Elements of electricity
Elements of electricity are:-1. Electric Current
2. Voltage and Electro Motive Force
3. Resistance
1. Electric Current:- Current can be defined as the rate (intensity) of electron flow and is
measured in amperes.

Fig 1.2 flow of electrns

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 There are 6 laws that regulate this electrical behavior:-
1. Like charges repel each other.
2. Unlike charges attract each other.
3. A voltage difference is created in the conductor when an EMF is acting on the
Conductor.
4. Electrons flow only when a voltage difference exists between the two points in a
Note: Satisfactory rating - 3 points
Conductor. Unsatisfactory - below 3 points
5. Current tends to flow to ground in an electrical circuit as a return to source.
You can ask you teacher for the copy of the correct answers.
6. Ground is defined as the baseline when measuring electrical circuits,
and is the point of Lowest voltage. Also, it is the return path to the source for an
Electrical circuit.The ground circuit used in most automotive systems is through
the vehicle chassisand/or engine block.
Conductors and Insulators
Insulators are materials that don’t allow electrons to flow through them easily.
 Insulators are atoms that have 5 to 8 electrons in their valence ring.
 The electrons are held tightly around the atom’s nucleus and they can’t be moved easily.
 Some atoms are not good insulators or conductors; these are
called semiconductors.
3 or fewer electrons—conductor.
5 or more electrons—insulator.
4 electrons—semiconductor.
2. Voltage and Electro Motive Force: - Voltage can be defined as an electrical pressure and
is the electromotive force (EMF) that causes the movement of the electrons in a conductor.

Fig 1.3 Applied voltag (EMF) in aconductor

Voltage: - Voltage will exist between any two

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 points in that circuit. The only time voltage does not exist
is when the potential drops to zero.
3. Resistance: - Resistance is the opposition to current flow
and is measured in Ohms.

Fig 1.4 Asiplified light circuit ilustration

 A complete electrical circuit consists of the following:

1. a power source,
2. a load or resistance unit,
3. conductors.
 There are 5 basic characteristics that determine the amount of resistance in any part of a
circuit.
1. The atomic structure of the material: The higher the number of electrons in the outer
valence ring, the higher the resistance of the material.
2. The length of the conductor: The longer the conductor, the higher the
resistance.
3. The diameter of the conductor: The smaller the cross-sectional area of the
Conductor, the higher the resistance.
4. Temperature: Normally an increase of temperature of the conductor causes an
Increase in the resistance.
4. Physical condition of the conductor: If the conductor is damaged by nicks or
cuts, the resistance will increase because the conductor’s diameter is decreased by these

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 Self-Check -1.2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
Part 1. Chose(1point)
1. One of from the following is not acomplete electrical circuit
A. a power source B. a load or resistance unit
C. conductors D. non
2. Which one is from the following true about insulator?
A. Insulators are materials that allow electrons to flow through them easily.
B. Insulators are materials that don’t allow electrons to flow through them easily.
C. Some atoms are not good insulators or conductors
A. all
Part 2. Write the correct answers for the following questions.(1point)
1. Write way of electricity flow?
2. List 6 laws that regulate electrical behavior?
3. Write elements of electricity and differeciat them?
4. Difine Conductors, Insulators and semi Conductors?

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

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 Answer Sheet
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

Part 1 1. ______
2. ____
Part 2.
1.____________________________________________________________________________________
______________________________________________________________________
2,
_____________________________________________________________________________________
_______________________.
3,
_____________________________________________________________________________________
____________________________.
4,
_____________________________________________________________________________________
______________________________________________________.

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 Information Sheet-1.3 Applying Elements of electricity/electronic common
terminology

Elements of electrical/ common terminology may include:

Electrical loads

Load device: - A load converts current flow into heat, light, or motion. Examples of
loads include rear window defoggers (heat), light bulbs (light), and motors (motion).

Fig 1.5 Electrical loads

Voltage
Voltage:- is measured in volts. One volt can push a certain amount of current, two
volts twice as much, and so on. A voltmeter measures the difference in
electrical pressure between two points in volts. A voltmeter is used in parallel.

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 Fig 1.6 voltmeter conection
Amperage
Current:- is measured in amperes, or amps, for short. An ammeter measures current flow
in amps. It is inserted into the path of current flow, or in series, in a circuit.

Fig 1.7 Ameter conection in series

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 Resistance
Resistance is measured in ohms. A special meter, called an ohmmeter, can
Measure the resistance of a device in ohms when no current is Flowing.

Fig 1.8 OHM’S meter conection

Wire resistance

A car's wiring has to distribute power from the battery to

devices located all over the car. It also has to transmit
data on a data bus, as well as a variety of digital and
analog signals from switches and sensors.

When the resistance stays the same current

goes up as voltage goes up, and current goes
down as voltage goes down. A discharged battery
has low voltage which reduces current. Some
devices may fail to operate (slow motor speed). An
unregulated alternator may produce too much
voltage which increases current. Some devices
may fail early (burned-out lamps).

If too much current goes through a wire, it can overheat

and melt. The amount of current that a wire can handle
depends on its length, composition, size and how it is
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bundled. Let's take a quick look at how each of these properties affects the wire's current-
carrying capacity:
Ohms law
1) What is ohms Law?

When voltage is applied to the electrical

circuit, current flows in the circuit.
The following special relationship exists
among the voltage, current and resistance
within the circuit:

The size of the current that flows in a circuit

varies in proportion to the voltage which is
applied to the circuit, and inverse proportion
to the resistance through which it must pass.

This relationship is called Ohm's law, and can

be expressed as follows.

1 ohm (Ω) refers to a resistance that permits

1 A of current to flow in a circuit when 1 V of
voltage is applied to the circuit.
I= V / R or
Current = voltage / resistance
Where:
I: Current flowing in the circuit, in ampere (A)
V: Voltage applied to the circuit, in volts (V)
R: Resistance in the circuit, in ohm's (Ω)
In practical terms "I =V/R" therefore means "A =V/Ω".

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2) Applications’ of Ohm’s Law
As an application of Ohms law , any
voltage V , current I or resistance R in
an Electric circuit can be
determined without actually
measuring it if the two others
values are known.

The relationship between voltage,

current, and resistance can be
substituted with the water flow as
illustrated.

(a) Voltage and current

The device in the illustration shows how the
speed of the waterwheel changes by
changing the water volume in the left tank.
This means that the speed of the water
flowing to the waterwheel changes with the
change in the water pressure in the tank.

When this phenomenon of water is

substituted with electricity, the water volume
(water pressure) is the voltage, and the water
flow is the electrical current.

(b) Current and resistance

The force of the water flow changes with the
open area of the gate that is located between
the tank and the waterwheel.

As a result, the speed of the waterwheel

changes. This gate is equivalent to the
resistance in an electrical circuit.

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c) Current, voltage, and resistance
It is possible to operate the waterwheel at a
desired speed by adjusting the water
pressure and the height of the gate.

Similarly, in an electrical circuit, the desired

amount of work is allocated to various devices
by changing the value of the resistance or
voltage.

Example: - if we have 2 amps of current and 6 ohms of resistance in a circuit, we must

have 12volts?
Volts of electrical pressure.
V=IxR
V= 2 Amps × 6 Ohms
V=2×6
V= 12 Volts

Example: The circuit had 12

volts and the resistance of the
bulb was 3 Ω, then Current?
Watt’s Law
 Power (P) is the rate of doing electrical work.
 A watt is equal to 1 volt multiplied by 1 ampere.
 Power measurements are measurements of the rate at
which electricity is doing work.

P =V × I Fig 1.9 simpl electrical circuit to help ohms low

Example: - A 100-watt bulb is brighter and uses more

Electricity than a 60-watt bulb.
P =V × I
P = 12V× 4 A
P = 48w
Fig 1.10 drop voltage mesurment
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P =V × I

I = P/V

V = P/I

Example: The power output of the bulb is 75 watts.

The circuit current is 5A, about Voltage?

Fig 1.11 power output of the bulb

Resistor circuits
CONNECTED RESISTANCE IN WATER FLOW FORM
(a) Series connection in water flow form
With this method, multiple electric devices are
Connected serially with a single electric wire.

Figure represents a series connection in the

Form of a water flow. The uniqueness of this
Water flow is that an equal volume of water
Flows through each of these waterfalls, which
is also equal to the volume of water that flows
From the source. (I = I1 = I2 = I3) Moreover, the
Sum of the height of the three individual
Waterfalls equals the height of the entire
Waterfall.
(V0 = V1 + V2 + V3)

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(b) ParaIIeI connection in water flow form
With this method, multiple electric devices are
connected to a single electric wire. Figure
represents a parallel connection in the form
of water flowing. All the waterfalls have the
same height. (V0 = V1=V2 = V3) Moreover, the
sum of the volume of the water that flows
through the waterfalls is equal to the total
volume of water.(I0 = I1 + I2+ I3)

Electrical Circuits

There are 3 different types of electrical circuits:

(1) the series circuit

(2) the parallel circuit

(3) the series-parallel circuit.

CHARACTERISTICS OF CONNECTED RESISTANCE

(a) Series connection

If, for example two or more lamp (resistance R1
and R2, etc.) are connected in a circuit as follows,
there is only one route that the current can take.
This type of circuit is called a series connection.
The value of current is always same at any point
in a series circuit.

The combined resistance R0 in this circuit fig 1.12 Series connection

is equal to the sum of individual resistance
R1 and R2.
R0 = (R1+R2)

Therefore the strength of current I flowing in

the circuit can be found as follows;
I = V/R0 = V/ (R1+R2)
Combined resistance R0 can be
determined as follows;
R0=R1+R2+R3+------- + Rn Fig. 1.12 Series connection

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Example: The total resistance of this circuit ?

(b) ParaIIeI connection

In parallel connection, two or more resistance

(R1, R2, etc.) are connected in a circuit as follows.
Since battery voltage V is applied equally to all
resistances, the strength of current I1 and I2 can be
determined from Ohm's law
Follows; I1 = V / R1 I2 = V / R2 the total current I is
also equal to the sum of current I1 and I2 flowing
through individual resistance R1 and R2. Resistance
R0 (a combination of resistance
R1 and R2) in a parallel connection can be
determined as follows; I = I1 + I2
R0 = V/ I = V / (I1+ I2) = V/ {(V / R1) + (V/R2)} R0=1/
(1/R1+1/R2)
R0=1/ (R1+R2)/ (R1xR2) fig 1.14 parallel cconection
R0=R1 x R2/ (R1+ R2)

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Series parallel circuit
 Current in the series portion of the circuit equals the sum of branch currents
 Circuit resistance is the sum of the parallel equivalent resistance and any series resistances.
 Voltage applied to the parallel branch is the source voltage minus any voltage drop across
loads wired in series.
1. Total Voltage: V=?
2. Total Current I=?
3. Total Resistance RT=?
4. Total P=?
5. Current through R1: V1=? I1=?
6. Current through R2: V2=? I2=?
7. Current through R3: V3=? I3 =?

Relays circuits
Relays
Some circuits utilize electromagnetic switches called relays (Figure 3-7). The
coil in the relay has a very high resistance, thus it will draw very low current. This
low current is used to produce a magnetic field that will close the contacts. Normally
open relays have their points closed by the electromagnetic field, and normally closed
relays have their points opened by the magnetic field. The contacts are designed to
carry the high current required to operate the load component. When current is
applied to the coil, the contacts close and heavy battery current flows to the load
component that is being controlled.

Fig 1.15 Relay opration

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 The illustration below shows a relay application in a horn circuit. Battery voltage
is applied to the coil. Because the horn button is a normally open–type switch, the
current flow to ground is open. Pushing the horn button will complete the circuit,
allowing current flow through the coil. The coil develops a magnetic field, which closes
the contacts. With the contacts closed, battery voltage is applied to the horn (which is
grounded). Used in this manner, the horn relay becomes a control of the high current

necessary to blow
the horn. The
control circuit may
be wired with very
thin wire because it will have low current fl owing through it. The control unit may
have only 0.25 ampere flowing through it, and the horn may require 24 or more
amperes.

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 Electricity/electronic
Atomic Structure
An atom is the smallest part of a chemical element that
still has all the characteristics of that element.

The nucleus contains positively

charged particles called protons
Electrons are negatively and particles that have no
charged particles. charge, which are called
neutrons.

Atoms attempt to have the same number of electrons as there are protons in the nucleus.

A specific number of electrons are in each of the electron orbit paths. The outer orbit, or shell as
it is sometimes called, is referred to as the valence ring.
For example, a copper atom contains 29
Electrons; 2 in the first orbit, 8 in the second, 18 in
the third orbit, and 1 in the fourth

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The only concern is with the electrons that are in the valence ring. Since an atom seeks to be
balanced: An atom missing, attempt to gain other electrons from neighboring atoms.
The atom excess amount of electrons, try to pass them on to neighboring atoms.
CURRENT FLOW THEORIES

Two theories describe current flow. The conventional theory, commonly used for
automotive systems, says current flows from (+) to (-) ... excess electrons flow from an
area of high potential to one of low potential (-). The electron theory, commonly used for
electronics, says current flows from (-) to (+) ... excess electrons cause an area of
negative potential (-) and flow toward an area lacking electrons, an area of positive
potential (+), to balance the charges. While the direction of current flow makes a difference
in the operation of some devices, such as diodes, the direction makes no difference to the
three measurable units of electricity: voltage, current, and resistance.
Terms Of Electricity
Electricity cannot be weighed on a scale or measured into a container. But, certain
electrical "actions" can be measured. These actions or "terms" are used to describe
electricity; voltage, current, resistance, and power.

Voltage is pressure
Current is flow.
Resistance is opposes flow.
Power is the amount of work performed. It depends on the amount of pressure and the
volume of flow.
Measuring unit & devices
Current is measured in amperes or “amps." Current is sometimes called amperage.
Current is present in a circuit When.

 There is sufficient available voltage.

 There is a continuous path from the source, through the load, to ground.
Converting amperage values - Automotive system currents vary from large to small:
• Large currents (up to 100 A) - charging and starting system.
• Small currents (less than an amp) - electronic control circuits.
Large current values typically display in amperes. Smaller current values may be expressed as
milliamps. To convert from one to the other, simply move the decimal point three places:
• Amperes to milliamps - decimal point moves 3 places to the right.
1.000 ampere = 1,000 milliamps
• Milliamps to amperes - decimal point moves 3 places to the left.
0.001 ampere = 1.000 milliamp

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Resistance is measured in Ohmmeter or “ohms”. Make sure the circuit or component to be
tested is isolated and not connected to any power source.
Other Ohmmeter Functions - The ohmmeter function of a DMM can also be used for other
tests and Measurements:
• Circuit continuity (with audible beep to confirm continuity)
• Conductance (very high resistance)
• Diode test (some DMM’s cannot test)
• Capacitance (some DMM’s cannot)
Converting resistance values - Automotive system resistance values vary from large too
small. Low resistance levels are expressed in ohms. Large resistance values are expressed
in kilo-ohms and very large values are expressed in mega-ohms.

 Kilo-ohm = 1,000 ohms (1.0 k)

 mega-ohm = 1,000,000 ohms (1.0 M)
Convert ohm readings as follows:

• Kilo-ohms to ohms - decimal point moves 3 places to the right.

• Ohms to kilo-ohms - decimal point moves 3 places to the left.
• Mega-ohm to ohms - decimal point moves 6 places to the right.
• Ohms to Mega-ohms - decimal point moves 6 places to the left.
Voltage is measured in Voltmeter or “volt”.
You can measure voltage …
• Between any two points in a circuit
• Between any point in a circuit and ground
• Across any component in the circuit: - Switches, Relay contacts and coils, Connectors,
Wires, Cables
Converting Voltage Values - Automotive voltage values vary from around 14 volts to very small
values under 50 mV. Hybrid vehicles such as the Prius use circuits with high voltage and current
(over 100 volts). Follow all safety precautions and service procedures when working on high
voltage circuits. Values under 1 volt are often expressed as millivolts.
1 volt is equal to 1,000 millivolts.
Convert the values as follows:-
• Volts to millivolts, move the decimal point 3 places to the right.
(Example: 1.34 V = 1,340 mV)
• Millivolts to volts, move the decimal point 3 places to the left.
(Example: 289 mV = .289 V)

Measuring Units - To the right of the measured value number, the display shows letters that
represent units:
V volts
A amperes
Ω ohms

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 Actions Of Current

Current flow has the following effects; motion, light or

heat generation, chemical reaction, and
electromagnetism.
HEAT GENERATION
When current flows through a lamp filament, defroster
grid, or cigarette lighter, heat is
generated by changing electrical energy to thermal
energy. Fuses melt from the heat generated when too
much current flows. Fig 1.16 heat generation

CHEMICAL REACTION
In a simple battery, a chemical reaction between two
different metals and a mixture of acid and water causes
a potential energy, or voltage. When the battery is
connected to an external load, current will flow. The
current will continue flowing until the two metals become
similar and the mixture becomes mostly water. When
current is sent into the battery by an alternator or a
battery charger, however, the reaction is reversed. This
is a chemical reaction caused by current flow. The
current causes an electrochemical reaction that restores Fig 1.18 chemical reaction
the metals and the acid-water mixture.
ELECTROMAGNETISM
Electricity and magnetism are closely related.
Magnetism can be used to produce electricity.
And, electricity can be used to produce
magnetism. All conductors carrying current
create a magnetic field. The magnetic field
strength is changed by changing current ...
stronger (more current), weaker (less current).
With a straight conductor, the magnetic field
surrounds it as a series of circular lines of
force. With a looped (coil) conductor, the lines
of force can be concentrated to make a very
strong field. The field strength can be
increased by increasing the current, the number of Fig 1.19 Electromagnetism
coil turns, or both. A strong electromagnet can
be made by placing an iron core inside a coil. Electromagnetism is used in many ways.

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 Types of electricity

There are two kinds of electricity; static and

dynamic. Dynamic electricity can be further
divided into direct current (DC) and alternating
current (AC).
1. STATIC ELECTRICITY
When a non conductive substance such as
a glass rod is rubbed with a silk cloth, the
surfaces of both the rod and the cloth
become charged with electricity, one positively
and one negatively. Unless the two materials
touch, or are connected by a conductor, the electrical charge will remain in the glass rod and silk
cloth. Since it does not move, this type of electricity is called static electricity. In terms of free
electrons, static electricity refers to a state in which free electrons are separated from their
atoms and do not move about on the surface of the substance.
2. DYNAMIC ELECTRICITY
When electrons are freed from their atoms and flow in a material, this is called dynamic
electricity. If the free electrons flow in one direction, the electricity is called direct current (DC).
This is the type of current produced by the vehicle's battery. If the free electrons change
direction from positive to negative and back repeatedly with time, the electricity is called
alternating current (AC). This is the type of current produced by the vehicle's alternator. It is
changed to DC for powering the vehicle's electrical system and for charging the battery.

Fig 1.20 Types of electricty

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 Self-Check -1.2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
Part 1. Write the correct answers for the following questions.
1. What is OHM`S low?
2. Write types electrical circuit differeciat them?
3. What is the function of relay in electrical circuit?
4. Write the instruments that used to measure current, voltage and resistance?
5. Define the terms of load, atom and watt`s low?
6. What are thactoins of current?

Short Answer Questions

1. ______________________________________________________________________.
2. _______________________________________________________________________
.
3. _______________________________________________________________________
_________________________________________________.
4. _______________________________________________________________________
_______________________________________________________________________
________________________.
5. _______________________________________________________________________
_______________________________________________________________________
______________________________.
6. _______________________________________________________________________
_____________________________.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

26 | P a g e
 Information Sheet-1.4 Applying elements of electricity/electronic

An open circuit is any circuit that is not complete, or that lacks continuity, such as a broken
wire. Open circuits have the following features:
1. No current at all will flow through an open circuit.
2. An open circuit may be created by a break in the circuit or by a switch that opens (turns off)
the circuit and prevents the flow of current.
3. In any circuit containing a power load and ground, an opening anywhere in the circuit will
cause the circuit not to work.
Ohm’s Law Applied to a Series Circuit
So now that we know the current in the loop is 10A and in a series circuit that current is constant
throughout, we can use Ohm’s law to calculate the voltage supplied to the speaker: V(speaker)
= I(loop) x R(speaker) or V(speaker) = (4A) x (2Ω) or ~ 8VDC. The LEDs will in turn have a
supply voltage of: V (LED) = (4A) x (1Ω) or ~ 4VDC. This circuit is known as a voltage divider
circuit. The supply voltage was divided among the loads in proportion to the resistance each
load carries. R1 had a higher resistance and received 8VDC of the total 12VDC supply and R2
received the rest or 4VDC. It can otherwise be stated that R1 has a voltage drop of 8VDC and
R2 has a voltage drop of 4VDC

Fig 1. 21 aplication of series circuit

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Ohm’s Law Applied to a Parallel Circuit
Now let’s take the same toy and rewire it so that the speaker and LEDs are in parallel with the
power source, as se below.

Fig 1.22 Ohm’s Law Applied to a Parallel Circuit

Let’s also use the same values as before with R1 = 430Ω, R2 = 284Ω, V (source) = 5VDC,
I(source) = 5A. This time let’s find out how much current each branch is pulling from the source.
As mentioned previously, with parallel circuits the voltage across each branch will be equal to
the supply voltage. So right away, I can tell you that the voltages across R1 and R2 are both
5VDC. Using Ohm’s law, I can also calculate the current in each loop or branch. Set up the
formula for current or I (R1) = V (R1)/R1 which is solved to be, I (R1) = 5VDC/430Ω = 11.63mA.
Doing the same for the other loop, we get I (R2) = V (R2)/R2, I (R2) = 5VDC/284Ω = 17.6mA.
Let’s also find the total current draw by the whole circuit. No, we’re not going to add the two
branch currents together (smart, but too easy); we’ll use Ohm’s law and the parallel resistance
calculation. First we need to find the total resistance in the circuit. In series circuits we would just
add all of the resistance values together. In parallel, you have to add the reciprocals of all the
resistance values together and then reciprocate back. Here we go, 1/R (total) = 1/R1 + 1/R2 =
1/430Ω + 1/284Ω = 0.0058467… Now reciprocate back to get R (total) = 171Ω. Using this value
we can now find I (total) = V (total)/R (total) = 5VDC/171Ω = 29.23mA. You can see that if we
had added the two loop currents together we would have gotten the same result, I (R1) + I (R2)
= 11.63mA + 17.6mA = 29.23mA. High fives all around! One quick note, current will always try to
take the path of least resistance. I was taught to think that current flows much the same as
water. If you have two channels in a river and one is partially blocked by logs, then most of the
water will flow through the clear channel. Same is true with current. In a parallel circuit, the
branch with the least amount of blockage or resistance will receive the majority of the current. In
our example both channels are partially blocked but the one that is most clear (R2) will receive
the most current. Pop Quiz, what if R2 was to short out? Well, in a short there is no resistance,
so all of the current would flow though that branch. The wire could overheat causing the worm to
lose its glow and quite possibly everything else. Fusing that branch would save little Suzie’s
favorite toy and fusing is a very important part of design both in circuits and in systems as a
whole.
28 | P a g e
 Self-Check -1.4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
Part 1. Write the correct answers for the following questions.(2point)
1. What is open circuit?
2. What are futures of open circuit?
3. Drow the ciruit of voltage which is applied in series and parallal?

Answer Sheet

1. ____________________________________________________________________
________________________________________________.
2. ____________________________________________________________________
________________________________________________.
3.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

29 | P a g e
 Operation Sheet 1 Identify and apply electrical/electronic fundamentals

Task1. Method of: performing series circuit

 Wear appropriate clothes, shoe ...
 Ensure the work shop hazard free
 Ensure the working area is bright / good
 visibility make workstation comfortable OPERATIONS:
Step1-prepare components/materials
of electrical circuit
Step 2- connect lamps each other
In series
Step 3- Attach each ends of wire to the
battery +ve terminal and –ve terminal
Step 4- If the lamps gives a light the circuit is ok, but no light recheck the
circuit.
Task2. Method of: performing parallel circuit
 Wear appropriate clothes, shoe ...
 Ensure the work shop hazard free
 Ensure the working area is bright / good
 visibility make workstation comfortable
Step1-prepare components/materials
of electrical circuit
Step 2- connect lamps each other
In parallel
Step 3- Attach each ends of wire to the battery +ve
terminal and –ve terminal
Step 4- If the lamps gives a light the circuit is ok, but no light recheck the circuit.

30 | P a g e
Task2. Apply OHM’s low in Series and ParaIIeI connection
 Wear appropriate clothes, shoe
 Ensure the work shop hazard free
 Ensure the working area is bright / good
 visibility make workstation comfortable
Step1-prepare components/materials
of electrical circuit
Step 2- connect lamps each other in Series
And In parallel
Step 3- Attach each ends of wire to the battery +ve
terminal and –ve terminal
Step 4- If the lamps gives a light the circuit is ok, but no
light recheck the circuit...
Step 5- connect the volt meter in parallel and measure the drop of valtage in laps.
Step 5- connect the Ammeter in series and measure the input current to laps.
Step 7- calculate the recorded data by using OHM`S low
 equipment tools and materials : lamps,fuse, multi- meter - paper and pen [for recording
the data] wire, plaster ,pliers electrical tap, wire

31 | P a g e
 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the
following tasks within 1hour.
Project 1. Identify and apply electrical/electronic fundamentals
Task 1. Install circuit of shown on the figure.

Task 2. Apply OHM’s low in Series and ParaIIeI connection

A. Series circuite

B. Parallel circuite

32 | P a g e
 List of Reference Materials

1- Advanced Automotive Electricityand Electronics

http://www.cdxauto.com/mastadvelectrfeatures
2- AUTOMOTIVE TECHNOLOGY 5 t h E d i t i o n by Jack Erjavec
www.cengage.com.
3- Basic Auto EIectronics and EIectricaI Systems[AT-1035] Honda manual
4- Basic Auto EIectronics and EIectricaI Systems TOYOTA manual
5- AUTOMOTIVE ELECTRICAL TESTING by TECH A.V
www.techav.co.za
1. Different lerning guids
2. MANAGING ELECTRICAL RISKS IN THE WORKPLACE by safe work austria
www.safeworkaustralia.gov.au

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 VEHICLE SERVICING
LEVEL - I

Learning Guide - 43
Unit of Competence: - Apply Automotive Electrical
System Fundamentals
Module Title: - Applying Automotive
Electrical System
Fundamentals
LG Code: EIS VHS1 M13 LO-2 LG- 43
TTLM Code: EIS VHS1 TTLM 09 19v1

LO 2: Research and identify systems and

components
34 | P a g e
This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics –
 Identify component or system
 Locate suitable and relevant sources of information
 Research reference information
 Identify potential for unsafe conditions or safety hazards
 Apply workplace Health and Safety (WHS)
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –

 Identify component or system to be research

 locate suitable and relevant sources of information to assist with identification of systems
and components
 Research reference information to ensure sufficient understanding of component or system
to assist with identifying how the circuit functions
 Identify potential for unsafe conditions or safety hazards
 Apply Workplace Health and Safety (WHS) requirements

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described in number 1 to 7.
3. Read the information written in the “Information Sheets 1”. Try to understand what are being
discussed. Ask you teacher for assistance if you have hard time understanding them.
4. Accomplish the “Self-check 1” in page 40
5. Ask from your teacher the key to correction (key answers) or you can request your teacher
to correct your work. (You are to get the key answer only after you finished answering the
Self-check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if your
rating is unsatisfactory, see your teacher for further instructions or go back to Learning
Activity #1.
7. Submit your accomplished Self-check. This will form part of your training portfolio.

35 | P a g e
 Identify component or system
Information Sheet-2.1

Automotive Electrical System Basics

In the early days of the modern automobile, most cars didn’t use electricity. Lights were powered
by gas, bells were used instead of horns, and engines were started by crank. However, by the
1920s, rechargeable batteries were quite commonplace. And as manufacturers installed these
batteries, they wondered how else electricity might be used in a car: convenient electric starters,
helpful instruments and gauges, headlights and wipers for safety, air conditioning and music . .
. One thing’s for sure: cars have come a long way in the past century! To recognize and
troubleshoot electrical issues with your car, it is important to understand automotive electrical
system basics.

Fig 2.1 Ignition switch

Automotive Electrical System Basics

The battery is the backbone of your vehicle’s electrical system. It provides the electrical current
that allows the vehicle to start and powers the other components, like the ignition and fuel
systems, which in turn create the combustion needed for the engine to operate.

Although the battery supplies the car’s power, the starter is what actually activates the engine.
It is connected to the ignition switch, which is typically activated by key. Receiving a punch of

36 | P a g e
energy from the battery, the starter rotates the flywheel, which turns the crankshaft, which
moves the pistons of the engine.

The alternator is necessary for endurance; without it, the battery would not be able to run for an
extended period of time. The alternator keeps the battery charged and the electrical system
running, but it isn’t necessary for the car to start. Some older cars have a generator instead, but
modern alternators are preferable because they are lighter, stronger, and more efficient.

The Starting System

The starting system is a combination of mechanical and electrical parts that work together to
start the engine. The basic starting system includes the following components.
1. Battery.
2. Cable and wires.
3. Ignition switch.
4. Starter solenoid or relay.
5. Starter motor.
6. Starter drive and flywheel ring gear.
7. Starting safety switch.

Fig 2.2 starting system circuite

37 | P a g e
The Charging System
The purpose of the charging system is to convert the mechanical energy of the engine into
electrical energy to recharge the battery and run the electrical accessories. When the engine is
first started, the battery supplies all the current required by the starting and ignition systems. The
entire charging system consists of the following components:
1. Battery.
2. AC generator or DC generator.
3. Drive belt.
4. Voltage regulator.
5. Charge indicator (lamp or gauge).
6. Ignition switch.
7. Cables and wiring harness.
8. Starter relay (some systems).
9. Fusible link (some systems).

Fig 2.3 charging circuite

38 | P a g e
The Lighting System
2.4). This includes
headlights, front and rear park lights, front and rear turn signals, side marker lights, daytime
running lights, cornering lights, brake lights, back-up lights, instrument cluster backlighting, and
interior lighting.
n consist of more than 50 light Bulbs and hundreds of
feet of wiring. Incorporated within these circuits are circuit protectors, relays, switches, lamps, and
connectors. In addition, more sophisticated lighting systems use computers and sensors.

Fig 2.4 vehicle lighting system

Vehicle Instrumentation Systems
Vehicle instrumentation systems (Figure 2.5 ) monitor the various vehicle operating systems and
provide information to the driver about their correct operation. Warning devices also provide
information to the driver; however, they are usually associated with an audible signal. Some
vehicles use a voice module to alert the driver to certain conditions.

Vehicle Instrumentation Systems

39 | P a g e
 Self-Check -2.1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next
page:
Part 1. Write the correct answers for the following questions. (2point)
1. Write basic automotive electrical systems?
2. What is the functions of basic automotive electrical systems?
3. Write the component/indicaters on vehicle instrumentation system?

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

40 | P a g e
 Answer Sheet
Score = ___________
Name: _________________________ Date: _______________
Short Answer Questions Rating: ____________

1. ____________________________________________________________________
________________________________________________.
2. ____________________________________________________________________
___________________________________________________.
3.

41 | P a g e
 Information Sheet-2.2 Locate suitable and relevant sources of information

FINDING SOURCES
Finding books and articles for your cours can be quite a challenge - especially if you've
Not yet familiarized yourself with the library and its resources. The homepage of the UW
Library homepages is a good place to start. There you will find links to the library catalog,
Electronic resources like online databases, and information on the library and its services.
If you're not sure where to start, try the following resources:

Circulation, helpful handouts, reference assistance, access to library computers, room

Reservations, interlibrary loan and copy/duplication of materials.

The Student Consultation Service is designed for UW students needing research

Assistance with course- and degree-related projects and assignments. Meet with a
Librarian one-on-one to discuss focusing a topic, identifying & evaluating sources,
And searching library databases and the Internet effectively. Subject librarians are
on hand to provide you with even more specialized assistance.

Chat with a librarian 24/7 for all of your research need!

Overgaard Library Walk-in Workshops (www.lib.washington.edu/ougl/walkins):
Obtain helpful information on a variety of topics, including how to effectively
research using a variety of online resources!
Research 101 is an
interactive online tutorial for students wanting an introduction to research skills. The
tutorial covers the basics, including how to select a topic and develop research
Questions, as well as how to select, search for, find, and evaluate information
Sources.

42 | P a g e
Workshop resources
Every workshop has many resources. You need to be aware of
what they are, and how you can make best use of them.
Resources include:
• special workshop tools and equipment fixtures, such as
vehicle lifts, the air compressor, the wheel-balancer,
steering alignment tools, the headlamp aligner, and so on
• Stock in the stores – different types of tyres, exhausts, shock
absorbers, batteries, oil, and so on
• Fixtures and fittings in the reception area, the staff dining area,
and elsewhere
• Utilities, such as electricity, gas, water and the telephone
• space available – to work, to store parts, to park and display
vehicles
• Time – often the firm’s most valuable resource.
Use resources to the best advantage

Tools
Use tools and equipment safely and properly. Avoid damage, and don’t risk
your own health and safety, or anyone else’s.
Utilities
Electricity, gas and telephone calls are costly. Waste will reduce the firm’s
profit. To save energy, your firm will probably have some automatic timing
controls fitted.
Consumable items
Do not waste consumable items, even if they are small. After fitting an exhaust system, for instance,
return to stock any unused components such as nuts, brackets or rubber mounting rings.

Vehicle maintenanc
Security
Make sure that parts are kept as safe as possible. If visitors wander
around the workshop and are not observed, they could steal things. Theft
by staff may also occur. Taking goods, equipment or money without
permission is always theft. Theft by staff is gross misconduct, and can
lead to dismissal. Do not leave keys in unattended cars. It is not
uncommon to have cars driven away from the forecourt.

43 | P a g e
Using resources economically
Avoid wasting power
 Turn off lights when they are not needed.
 Keep workshop doors shut, to keep heat in.
 Report faulty components – for example, a leaking air line that causes the compressor
to keep switching on.
 Turn off water when you are not using it, especially when washing cars. Use space
sensibly Workshop space is expensive. Costs include rates, taxes, heating and lighting.
Do not waste this space!
 Place vehicles so that you can work properly, but so that they take up minimum space.
 Keep the working space around ramps and in gangways clear of obstructions.
 Clear away quickly when a job is finished.
Time
You rightly expect to be paid for your time at work. So you
must play your part and help the firm to make a profit.
 As a newcomer to the trade you are unlikely to work as
quickly as a skilled technician. But aim to build up your
speed.
 Work steadily, but not slowly. Time wasted is almost
impossible to make up. You may have a bonus at stake!
 Organise yourself. Gather tools, information and
equipment before you start a job.
 Complete jobs properly. Putting things right later is costly

CATEGORIZE YOUR SOURCES

Once you've done a summary of your sources, see if you can place your sources into
various categories. Remember: writing an academic essay is like taking part in a large,
ongoing conversation. While everyone has his own point of view, it is also safe to say that
no one is entering the conversation as a lone wolf. Everyone is speaking from a certain
critical perspective. These perspectives might be classified into different groups.
Categorizing your sources might be as simple as looking for similarities among your
sources. Which of these sources seem to share a point of view? Which seem to arrive at
similar conclusions? You will also discover differences among your sources. Try to define
these differences and see if they seem to fall into different categories: side A seems to
believe X, while side B seems to believe Y. Or side A attempts to understand the problem
from a feminist perspective, while side B is inter

44 | P a g e
INTERROGATE YOUR SOURCES
In most of the papers you will write in college, it will not be enough simply to review what
other people have said about a topic. Instead, you will be asked to present your own point
of view. In order to do this, you will need to interrogate your sources. To interrogate your sources it is
not necessary to be contentious. You don't have to search like a bloodhound for the weak spot in an
argument. You are not required to "take on" your source.
Instead, you'll want to ask questions of your sources. Initiate a conversation. Challenge,
Interrogate, rebut, confirm. Is the writer offering evidence for her claims? Is this evidence sufficient?
Why or why not? Is there something that the writer is overlooking? Omitting? Is this omission a matter
of carelessness, or does it seem to you purposeful? Why?
places?
Where the reason seems to break down? Can you locate and identify any logical fallacies?
Do these fallacies undermine the writer's argument, or not? Is the writer's language appropriate? Does
she sometimes rely on a pretty phrase or a passionate claim to cover up a lack of evidence? What can
you determine about the writer's perspective? Does she seem to have any biases that are important to
note? Does she seem to belong to a particular critical?
School? Does the writer's perspective help or hinder the argument she is trying to
Make? Why?
Where do you stand in relation to the writer? Do you give her a round of applause?
Do you feel like booing her off the stage? Are you sitting with your arms crossed?
Feeling skeptical? Keep notes of your personal responses to the writer, and try to
Translate those responses into comments or questions.

45 | P a g e
 Self-Check -2.2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions.(1point)
1. Write work shop resources?
2. What is the library hompage good place to start?
3. What is the challenging to find boocks and articles?
4. If you are not required “to take on” your resources, What kind of question you are asking?
5. How can avoiding wasts in vehicle electrical system?
Answer Sheet

1. ___________________________________________________________________________
________________________________________________________________________.
2. ___________________________________________________________________________
______________________________________________________________________.
3. ___________________________________________________________________________
___________________________________________________________________________.
4. ___________________________________________________________________________
_____________________________________________________________________.
5. ___________________________________________________________________________
___________________________________________________________________________
__________________________________________________________

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

46 | P a g e
 Information Sheet-2.3 Research reference information

SUPPLEMENTS
The Automotive Technology package offers a full complement of supplements.
Student Online Companion
Each textbook provides access to the new Student Online Companion, which
includes the following components:
■ PowerPoint—Study outlines with images for each textbook chapter.
■ ASE-Style Practice Questions—self check questions to help students review
chapter material and get familiar with the question types they will see on certification exams.
■ Web Links and Activities—Links to industry Web resources/reference material
with related research activities for many.
■ Challenging Concepts— videos, narration, and questions to help students
comprehend more challenging topics.
■ Interactive Online Game—A self-review Q&A game to help students comprehend the chapter
material.
Tech Manual
The Tech Manual (ISBN 1428311505) offers students opportunities to strengthen
their comprehension of key concepts and to develop their hands-on, practical shop
experience. Each chapter includes Concept Activities and Job Sheets, many of
which are directly correlated to specific NATEF tasks. Service manual report sheets,
case studies, and review questions also are included to offer a rounded approach to
each lesson.
Instructor Resources
The Instructor Resources DVD (ISBN 1428311521) for the fifth edition includes the
following components to help minimize instructor prep time and engage students:
■ PowerPoint—Chapter outlines with images, animations, and video clips for
each textbook chapter.
■ Computerized Test Bank in Exam View—Hundreds of modifiable questions
for exams, quizzes, in-class work, or homework assignments. All applicable
questions are correlated to the 2008 NATEF Automobile Standards.
■ Image Library—A searchable database of hundreds of images from the textbook that can be used
to easily customize the PowerPoint outlines.
■ Challenging Concepts—45 videos, narration, and questions help students
comprehend more challenging topics.
■ End-of-Chapter Review Questions—Word files of all textbook review questions are provided on
the DVD.
47 | P a g e
■ Instructor’s Manual—an electronic version of the Instructor’s Manual is
included in the Instructor Resources.
■Operation Sheet Template—for instructors who develop their own job sheets, a template is
provided to help with their formatting.
Instructor’s Manual

This comprehensive guide provides lecture outlines with teaching hints, answers
to review questions from the Learning guide, and answers to Tech Manual questions, as
well as guidelines for using the Tech Manual. A correlation chart to the 2008 NATEF
Task List provides refers

Self-Check -2.3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions.(3point foreach)
1. Write methods of to access new topic on line?
2. What are instructer resources?
Answer Sheet

1. ___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
_____________________________________.
2. ___________________________________________________________________________
___________________________________________________________________________
_____________________________________________________________.

Note: Satisfactory rating – 3 points Unsatisfactory – below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: ______________

48 | P a g e
 Information Sheet-2.4 Identify potential for unsafe conditions or safety
hazards

Workshop Hazards Over the next few screens you will see various videos showing a
technician whose actions could easily cause hazards. Of course the common fault in each of
the videos is that he is not wearing overalls or using any personal safety equipment!
Carelessness Carelessness of any kind but particularly whilst
moving vehicles.

 Drinking/drugs Drinking or taking drugs - these badly

affect your ability to react to dangerous situations.
 Your health Tiredness or sickness - these will affect your
abilities to think and work safely.
 Fooling about Messing about - most accidents are caused
by people fooling about.
Safety equipment
It is important to always use safety equipment such as trolleys, cranes, etc. and to be
competent in using them. As with the use of any equipment and all aspects of work if you
are in any doubt it is important to ask. If it involves a person’s health or safety then it is vital.
Inexperience and lack of supervision are potential hazards
Your surroundings
The surroundings, in which you work, may have:
 Bad ventilation
 Poor lighting
 Noise
 Dangerous substances stored incorrectly
 Broken or worn tools and equipment
 Faulty machinery
 Slippery floors
 Untidy benches and floors
 Unguarded machinery
 Unguarded pits.

49 | P a g e
Hazards in the workshop
The following tables list some of the hazards you will come across in a vehicle workshop.
Also listed are the problems these can cause, together with ways we can reduce the risks.
This is called risk assessment. Please study the tables and add notes above about the five
hazards that you think are most important.
Moving loads
Never try to lift anything beyond your capability - get a mate to help. Over 40 kg and
you really should get help.
 Whenever possible use an engine hoist, a transmission jack or a trolley.
 Lift correctly, using the legs and keep your back straight.
 When moving heavy loads on a trolley, get help and position
yourself so you will not be run over if you lose control.
 The ideal option in all cases is simply to avoid manual handling where possible.

Fig 2.2 Moving loads below the standard

Vehicle Safety
Vehicle safety and the associated regulations can be very complicated. However for our
purposes we can consider the issue across two main areas:
1. Construction of the vehicle
2. Driving and operating the vehicle.
50 | P a g e
Construction of the vehicle
Before a vehicle can be constructed a prototype has to be submitted for type approval. When
awarded this means the vehicle has passed very stringent tests and that it meets all current
safety requirements. Different countries have different systems, which mean some
modifications to a car may be necessary if it is imported or exported. The European Union
(EU) has published many
‘directives’, which each member country must incorporate into its own legislation. This has
helped to standardise many aspects. In the UK the ‘Road Vehicles (Construction & Use)
Regulations 1986’, is the act which ensures certain standards are met. If you become
involved in modifying a vehicle e.g. for import, you may need to refer to the details of this act.
Environmental Laws
Many other laws exist relating the motor vehicle and the environment. These are about
emissions and pollution. Environmental laws change quite often and it will be important to
keep up to date.
The MOT
The Department Of Transport states that all vehicles over three
years old must undergo a safety check which ensures the vehicle
continues to meet the current legislation. First set up by the Ministry
Of Transport, it continues to be known as the MOT test. This test
now includes checks relating to environmental laws.

51 | P a g e
Electrical Equipment Safety
Precautions Incorrect handling of electrical
equipment can
cause a short and a fire. Therefore, learn to use it
correctly and carefully observe the following
precautions: If any irregularity is detected in
electrical equipment, immediately turn OFF the
switch and contact the controller / foreman. In case
of a short or accidental fire in an electrical circuit,
turn OFF the switch first before taking fire
extinguishing measures. Report any improperly
routed wiring or improperly installed electrical
equipment to the controller /foreman. Report any
blown fuse to your supervisor because a blown
fuse indicates some sort of electrical problem.
Never perform the following actions because they fig 2.3 Electrical Equipment Safety
Are extremely dangerous:
• Do not go near broken or dangling electrical
wires.
• To prevent electrical shocks, never touch any
electrical equipment with wet hands.
• Never touch switches that are labeled "Out of
Order".
• When disconnecting a plug, do not pull on the
cord; pull on the plug itself.
• Do not route an electrical cord through wet or oil
soaked areas, through heated surfaces,
Or around sharp corners.
• Do not use the combustibles near switches,
switchboards or motors etc., which are easy to fig 2.4 electric hazards
Spark.

52 | P a g e
 Self-Check -2.4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Choise the correct answer ffrom the given alternatives(1point)
1. __________is the behavior of derty surrounding?
A. noise C. foulty machinery
B. dangerous materials stored incorrectly D. all
2. Elements of hazard in the work shop includes_______?
A. Moving heavy load B. Foulty machinery
B. Ungrounded machinery D. All
3. How could occur hazard in the work shop?
A. Carlessnes C. Miss handling surrounding
B. unsafe handling of equipments D. All
4. What is the alowable lifting weight of materials?
A. Over 50kg C. Over 30kg
B. Below 45kg D. Below 35
5. Which on is from the following included under vehicle safety?
A. Construction of vehicle C. only A is answer
B. Driving and oprating the vehicle D. A & B

Answer Sheet

1. _______________
2. _______________
3. _______________
4. _______________
5. _______________

Note: Satisfactory rating - 2 points Unsatisfactory - below 2points

You can ask you teacher for the copy of the correct answers.
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

53 | P a g e
 Information Sheet-2.5 Apply workplace Health and Safety (WHS)

Safety caps
Bump caps protect your head from banging on the
underside of a vehicle when you work under a ramp.
Soft caps keep your head and hair clean. They also
prevent long hair from catching in revolving parts, such
as drills on the bench, or engine drive belts under the
bonnet.
Goggles

Soft caps

Spectacles

Eye protectors Welding goggles

An accident to the eyes can be very painful and may result in

blindness.
Spectacles protect you from rust or dirt falling off thecar. Some
have side shields and can be adjusted to fit your face.
Goggles protect you from dust and chemicals. They are used, for
example, when sanding body filler off bumped car wings.
Welding goggles protect your eyes from the bright glare of the
welding flame.
Ear protectors Earmuffs Earplugs
Ear muffs protect your ears from damage when there is a loud, continuous noise.
Earplugs are as effective as, and in some cases more effective than, ear muffs!

Hands
Everyday life is difficult without good hands. Be aware of sharp object, chemicals and hot metals.
Wear appropriate gloves when necessary to protect your hands. You need to wash your hands before
eating.
54 | P a g e
Masks
Face masks protect your lungs from dust. (Some of the
dust may be toxic.) They use special moulded pads,
made from cotton gauze or special filter paper.
Gas respirators are used in vehicle paint shops.
The paint fumes may be toxic.

Fig 2.5 Masks High grade dust mask Valved,

dust/mist mask

Hand protection
Industrial gloves should be used when moving rough
or heavy parts. They protect your hands and wrists from
cuts, scratches and burns.
Heat-resistant gloves should be worn when working
on items such as a hot exhaust or radiator.

Heat-resistant gloves

Plastic-coated gloves Leather-faced fabric gloves

Fig 2.6 safety gloves

55 | P a g e
 Figure 2. 7 Untidy and Tidy Workbench

ORDERLY WORKSHOP HABITS

Personal Cleanliness
Personal cleanliness is of the utmost importance and is a fair indication of the attitude of trade’s
people to their work. When technicians are not clean and tidy in personal appearance and habits,
they are unlikely to be any different in their approach to work. A bad approach results in the
production of inferior work and is frequently a contributing factor in serious accidents.

Industrial Housekeeping
Where a workshop has been allowed to become dirty and untidy, general inefficiency, poor work
practice and frequent accidents often result (Figure 2).
Remember, workshop cleanliness is a function of both management and staff for the benefit of both.
Fundamentally, then, tradespeople make their own working conditions by the attitude they adopt.

EQUIPMENT SAFETY
Hand Tools
Never use defective tools, for example those with broken handles, chisels with mushroom heads,
spanners with spread jaws, files without handles (especially on the lathe) and tools of the wrong size
for the job.

56 | P a g e
Machinery

Figure 2.8 - Safety when grinding

(Note the eye protection and the safety shield around the wheel)
Many accidents are caused by the operation of inadequately guarded machines or where the guards
supplied have been removed irresponsibly. Your personal safety is largely dependent on the attitude
you adopt towards the use and the maintenance of the safety guards and devices supplied. (Figure3).

USING ELECTRIC POWER EQUIPMENT

Safety Check
■ Do not stand on wet floors or in puddles when using electrical equipment.
■ Always wear eye protection when using any drill.
■ Before connecting the drill to the power supply, check the power cord for splits or chafing. If there
are any exposed wires, the cord will need to be replaced. Refer this to your supervisor.
■ Always disconnect the power supply before plugging or unplugging the drill.
■ Do not use electrical power equipment near flammable liquids and gases.
■ Remove the chuck key from the chuck before you start drilling.
■ Never use a drill that has a known fault.
■ Never operate a portable power drill unless it is grounded.

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 Self-Check -2.5 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions. (3point)
1. _________ is used when moving rough or heavy parts?
2. What are electrical safetys?
3. Write workplace Health and Safety tools?

Answer Sheet
1. ___________________________________________.
2. ____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________.
3. ____________________________________________________________________________
____________________________________________________________________________
___________________________________________________________________________.

Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

58 | P a g e
 List of Reference Materials

6- Advanced Automotive Electricityand Electronics

http://www.cdxauto.com/mastadvelectrfeatures
7- AUTOMOTIVE TECHNOLOGY 5 t h E d i t i o n by Jack Erjavec
www.cengage.com.
8- Basic Auto EIectronics and EIectricaI Systems[AT-1035] Honda manual
9- Basic Auto EIectronics and EIectricaI Systems TOYOTA manual
10- AUTOMOTIVE ELECTRICAL TESTING by TECH A.V
www.techav.co.za
3. Different lerning guids
4. MANAGING ELECTRICAL RISKS IN THE WORKPLACE by safe work austria
www.safeworkaustralia.gov.au

59 | P a g e
 VEHICLE SERVICING
LEVEL - I

Learning Guide - 44
Unit of Competence: - Apply Automotive Electrical
System Fundamentals
Module Title: - Applying Automotive
Electrical System
Fundamentals
LG Code: EIS VHS1 M13 LO-3 LG-44
TTLM Code: EIS VHS1 TTLM 09 19v1

LO 3: Locate systems and components

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This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics –
 Source suitable automotive systems or components
 Confirm location of system or component
 Identify alternative methods of system or component
This guide will also assist you to attain the learning outcome stated in the cover page. Specifically,
upon completion of this Learning Guide, you will be able to –
 Source suitable automotive systems or components to assist with task
 Confirm location of system or component in relation to modern vehicle configuration
 Identify Alternative methods of system or component location in relation to possible light
vehicle configuration (where applicable)

Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described in number 1 to 7.
3. Read the information written in the “Information Sheets 1”. Try to understand what are being
discussed. Ask you teacher for assistance if you have hard time understanding them.
4. Accomplish the “Self-check 1” in page 66
5. Ask from your teacher the key to correction (key answers) or you can request your teacher to correct
your work. (You are to get the key answer only after you finished answering the Self-check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if your rating is
unsatisfactory, see your teacher for further instructions or go back to Learning Activity #1.
7. Submit your accomplished Self-check. This will form part of your training portfolio.

61 | P a g e
 Information Sheet-3.1 Source suitable automotive systems or components

Today, most manufactures network their electrical systems together through computers. This
means that information gathered by one system can be used by another. The result may be that a
faulty component may cause several symptoms. Consider the following example. The wiper system
can interact with the headlight system to turn on the headlights whenever the wipers are turned on.
The wipers can interact with the vehicle speed sensor to provide for Speed-sensitive wiper operation.
The speed sensor may provide information to the antilock Brake module. The antilock brake module
can then share this information with the transmission control module, and the instrument cluster can
receive vehicle speed information to operate the speedometer. If the vehicle speed sensor should fail,
this could result in no antilock brake operation and a warning light turned on in the dash. But it could
also result in the speedometer not functioning, the transmission not shifting, and the wipers not
operating properly
Battery

Battery

The battery is a rechargeable device that

serves as a power supply for the electrical
parts when the engine is stopped. When
the engine is running, it stores the used
electricity.
HINT:
A battery inspection consists of checking the
level and the specific density of the electrolyte.

Fig 3.1 Battery components

Negative Terminal :- The portion of the battery to which the negative cable is connected.

Vent Plug :- Discharges gas vapors during charging. Plug to supply the electrolyte.
Indicator:- Used for checking the state of charge or the electrolyte level.
Positive Terminal :- The portion of the battery to which the positive cable is connected.
Electrolyte:- Chemically reacts with the pole plates to charge and discharge electricity.
Cell :- Each cell generates approximately 2.1V of electricity.
Pole Plate:- Consists of positive and negative plates.

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 REFERENCE
Charging and discharging principle
A battery charges and discharges electrical energy through
the chemical reaction of the electrolyte.

A, Discharging
Electrical energy is generated when the sulfuric acid of the
electrolyte reacts with lead and turns into water. At this time,
the sulfuric acid combines with the pole plates, causing the
positive and negative pole plates to turn into lead sulfate.
H2SO4:SulfuricH2O: Water H2: Hydrogen O2: Oxygen

B, .Charging
Because sulfuric acid is discharged from the pole plates, the electrolyte turns into sulfuric acid,
and the specific gravity of the electrolyte increases.The positive pole plates turn into lead dioxide
and the negative pole plates turn into sponge lead.
1. Discharging amperage
2. Charging amperage
Starting System
Starting System
The starting system forces the engine to crank
with an electric motor, and starts the engine.
1. Battery
2. Ignition switch
3. Starter

Fig 3.2 starting system circuits

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REFERENCE:

There are four types of starters, as shown on the left.

A, Conventional type a type of starter in
which the armature and pinion gear
rotate in an identicalmanner.

B, Reduction type a type of starter that has

an idler gear between the drive and
driven gears in order to reduce the
rotation of the Armature and transmit it
to the pinion gear.

C, Planetary type A type of starter that has

planetary gears to reduce the rotation
of the armature. It is more compact and
lightweight than the reduction type.

Fig 2.3 starting motor types

D, Planetary reduction-Segment conductor motor type

Permanent magnets are used in the field coil.
The armature coil has been made more compact,
resulting in a shorter overall length.
1. Pinion gear
2. Armature
3. Idler gear
4. Planetary gear
5. Permanent magne

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 Charging System

The charging system produces electricity to

supply the electrical components with the
amount of electricity required, and to charge the
battery while the vehicle's engine is in operation.
As soon as the engine starts, the drive belt
causes the alternator to operate.
1, Alternator
2, Battery
3, Discharge warning light
4, Ignition switch

Fig 3.4 charging system circuit Alternator

As the engine starts, the drive belt causes the pulley
of the alternator to rotate. As a result, the rotor
rotates, and an electric current emits in the coil of
the stator
1, Pulley
2, Rotor (Coil)
3, Stator (Coil)
4, Rectifier (diodes)
5, IC regulator
6, Terminal "B"

Fig 3.5 alternator components Ignition System

The ignition system generates sparks at high- voltage,
and ignites the air-fuel mixture, which is compressed in
the cylinders, at the optimal timing. Based on the signals
received from the sensors, the engine ECU (Electronic
Control Unit) effects control to achieve optimal ignition
timing.
1, Ignition switch
2, Battery
3, Ignition coil with igniter
4, Spark plug
5, Engine ECU
Fig 3.6 Ignition System 6, Camshaft position sensor

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 7, Crankshaft position sensor

Lighting system circuit:-includes the battery, vehicle frame, all the lights, and various switches that
control their use. The lighting circuit is known as a single-wire system since it uses the vehicle frame
for the return.
Self-Check -3.1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions. (1point)
1. State the main purpose of a charging system in a motor vehicle??
2. What are the various electrical systems in an automobile?
3. Write the few purpose of battery?
4. What is starting motor?
5. What is the function of the ignition system?

Answer Sheet
1. ___________________________________________________________________________
___________________________________________________________.
2. ___________________________________________________________________________
___________________________________________________________.
3. ___________________________________________________________________________
__________________________________________________________.
4. ___________________________________________________________________________
___________________________________________________________.
5. ___________________________________________________________________________
___________________________________________________________.
Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.
Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

66 | P a g e
 Information Sheet-3.2 Confirm location of system or component

The location of vehicle electrical system or component are differ from vehicle design to design and
company to company.
1. Location of battery is commonly under the hood for light duty trucks and for heavy duty trucks it
lives under the middle part of vehicle.

Fig 3.7 location battery

2. Location of starter motor is commonly attached on the engine near to fly wheel.

Fig 3.8 location of starte

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 3. Location of charging circuit is commonly positioned on the engine attached or connected to
crank shaft pulley with belt.

Fig 3.9 location of vehicle electrical system

1. Battery
2. Starting System
3. Charging System
4. Ignition System
5. Ignition Switch
6. Combination Meter (Discharge Warning Light)
7. Sensors
 Body Electrical
The body electrical components consist of electrical parts that are
Attached to the vehicle body
1. Wire harness
2. Switches and relays
3. Lighting system
4. Combination meter and gauges
5. Wipers and washers
6. Air conditioning

68 | P a g e
 Self-Check -3.2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions.(1point)
1. Identify the loction of starter motor?
2. The body electrical components attached to the vehicle body consist of electrical parts
are______?
3. Identify the loction of igniton system?
4. Identify the loction of charging system?

Answer Sheet
1. ___________________________________________________________________________
_____________________________
2. ___________________________________________________________________________
____________________________________.
3. ___________________________________________________________________________
___________________________________________.
4. ___________________________________________________________________________
___________________________________________________.

Note: Satisfactory rating - 2 points Unsatisfactory - below 2 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

69 | P a g e
 Information Sheet-3.3 Identify alternative methods of system or component

In the quest to improve fuel economy, decrease emission levels, and make vehicles more reliable,
engineers have applied advanced electronics to starters and generators.
Alternatives of battery:-
 NICKEL-BASED BATTERIES
Batteries have a positive plate that contains nickel.
Two types of nickel-based rechargeable batteries are commonly used: the nickel-metal hydride
(NiMH) and nickel-cadmium (NiCad).nickel-metal hydride (NiMH)

 Lithium-Polymer Batteries
The lithium-polymer (Li-Poly or LiPo) battery is not a liquid; rather, the lithium salt is held in a solid
polymer composite (such as poly acrylonitrile).
Alternatives of starting systems:-
REFERENCE:
There are four types of starters, as shown on the left.
Conventional type A type of starter in
which the armature and pinion gear
rotate in an identicalmanner.
Reduction type A type of starter that has
an idler gear between the drive and
driven gears in order to reduce the
rotation of the Armature and transmit it
to the pinion gear.
Planetary type A type of starter that has
planetary gears to reduce the rotation
of the armature. It is more compact and
lightweight than the reduction type.
fig 3.10 types of starters Planetary reduction-Segment conductor
70 | P a g e
 motor type
Permanent magnets are used in the field
coil. The armature coil has been made
more compact, resulting in a shorter
overall
length.
Alternatives of ignition system systems:-
1. Magneto Ignition System:- is popular on motorcycles
because it is lighter than a battery-operated system
and requires less maintenance

2. Contact (Breaker) Point Ignition System battery-powered

ignition systems with mechanical switches

3. Electronic Ignition Systems have used sensors, such as a

pickup coil and reluctor (trigger wheel), to trigger or signal
an electronic module that switches the primary ground
circuit of the ignition coil
A. Distributor ignition (DI) is the term
Specified by the Society of Automotive
Engineers (SAE) for an ignition system
That uses a distributor.
B. Electronic ignition (EI) is the term
Specified by the SAE for an ignition
System that does not use a distributor.
Types of EI systems include:
1. Waste-spark system. This type of
system uses one ignition coil to
fire the spark plugs for two
cylinders at the same time.
2. Coil-on-plug system. This type of system uses a single ignition coil for
each cylinder with the coil placed above or near the spark plug.

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 Alternatives of charging system:-
The charging system has two essential functions:-
1. Generate electrical power to run the vehicle's electrical systems
2. Generate current to recharge the vehicle's battery
Types of charging circuit
1. Charging circuit using electromagnetic regulator

Fig 3.11 Charging circuit using electromagnetic

2. Charging circuit using integrated circuit regulator

Fig 3.12 Charging circuit using integrated circuit regulator

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 3. Charging circuit modulated control

Fig 3.13 Charging circuit modulated control

Alternatives of lightning system is light emitting diodes
The light emitting diode (LED) is an active light element. If an electrical voltage is applied, current
flows through the chip. The electrons of the atoms of the LED chip are highly energized by the
voltage. As light is emitted, they return to their initial state of
Low energy charge. The 0.1 to 1 mm small semiconductor crystal is seated on a reflector that directs
the light with pin-point precision. LEDs are commonly used as light sources for lights on the rear of
the vehicle, especially the additional stop lamps located in the center.

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 Self-Check -3.3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions.(1point)
1. What is the alternatives of battery?
2. Write types of starting system?
3. Classify electronic ignition system?
4. What are the alternatives of ignition system?
5. What is the essential function of charging system?

Answer Sheet
1. ___________________________________________________________________________
__________________________________________________________________.
2. ___________________________________________________________________________
__________________________________________________________________.
3. ___________________________________________________________________________
___________________________________________________________________.
4. ___________________________________________________________________________
____________________________________________________________________.
5. ___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________.
Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

74 | P a g e
 Operation Sheet 2 Confirm location of system or component

 wear appropriate clothes, shoe ...

 Ensure the work shop hazard free
 Ensure the working area is bright / good
 visibility make workstation comfortable
Task1. Confirm location of system or component
Step 1- Make ready live vehicle if it is hot let to cool
Step 2- Identifying Location of battery is commonly under the hood for light
duty trucks and for heavy duty trucks it lives under the middle part of
vehicle.
Step 3- Identifying Location of starter motor is commonly attached on the
engine near to fly wheel.
Step 4. Identifying Location of charging circuit is commonly positioned on
the engine attached or connected to crank shaft pulley with belt.

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the following
tasks within 1 hour.
Project 2. Locate systems and components
Task 1. Confirm and locate vehicle electrical system or component
Task 2. Identify alternatives of vehicle electrical system or component

76 | P a g e
 List of Reference Materials

11- Advanced Automotive Electricityand Electronics

http://www.cdxauto.com/mastadvelectrfeatures
12- AUTOMOTIVE TECHNOLOGY 5 t h E d i t i o n by Jack Erjavec
www.cengage.com.
13- Basic Auto EIectronics and EIectricaI Systems[AT-1035] Honda manual
14- Basic Auto EIectronics and EIectricaI Systems TOYOTA manual
15- AUTOMOTIVE ELECTRICAL TESTING by TECH A.V
www.techav.co.za
5. Different lerning guids
6. MANAGING ELECTRICAL RISKS IN THE WORKPLACE by safe work austria
www.safeworkaustralia.gov.au

77 | P a g e
 VEHICLE SERVICING
LEVEL - I

Learning Guide - 45
Unit of Competence: - Apply Automotive Electrical
System Fundamentals
Module Title: - Applying Automotive
Electrical System
Fundamentals
LG Code: EIS VHS1 M13 LO-4 LG- 45
TTLM Code: EIS VHS1 TTLM 09 19v1

LO 4: Determine method of system or component

operation

78 | P a g e
This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics –
 Identifying and applying appropriate electrical/electronic test equipment
 Examine system or component
 Determine and analyze operational principles of circuit, component and system functions
 Determine system or component relationship to light vehicle operation
 Identify potential for unsafe conditions
 Identify potential common faults with system or component
This guide will also assist you to attain the learning outcome stated in the cover page. Specifically,
upon completion of this Learning Guide, you will be able to –

 Identify and apply appropriate electrical/electronic test equipment for the purpose of testing
circuit diagram, system or component
 Examine system or component and sub-assembly components
 Determine and analyze operational principles of circuit, component and system functions
 Determine system or component relationship to light vehicle operation
 Potential for unsafe conditions or associated risk factors with system or component operation or
testing is identified
 Identify and apply potential common faults with system or component
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Follow the instructions described in number 1 to 7.
3. Read the information written in the “Information Sheets 1”. Try to understand what are being
discussed. Ask you teacher for assistance if you have hard time understanding them.
4. Accomplish the “Self-check 1” in page 99
5. Ask from your teacher the key to correction (key answers) or you can request your teacher to correct
your work. (You are to get the key answer only after you finished answering the Self-check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However, if your rating is
unsatisfactory, see your teacher for further instructions or go back to Learning Activity #1.
7. Submit your accomplished Self-check. This will form part of your training portfolio.

79 | P a g e
 Information Sheet-4.1 Electrical/electronic test equipment.

Test lamp
A circuit tester is a useful and inexpensive tool for making electrical tests.
Checking a simple circuit is straightforward - the lighting circuits are among the simpler ones - but the
electrical wiring in a car contains many interlinking and branching circuits, which bring complications.
All car wiring is colour-coded;
unfortunately there are no national or
international standards for colors. Color
codes for individual cars can be found
in wiring diagrams, in the car handbook or
in a service manual. How to use a circuit
tester Connect the tester clip to
the negative terminal of the battery and
touch the probe to the positive one. If the
tester lamp does not light, the battery is
dead (or the bulb in the tester has blown).
If it lights, try again with the clip earthed to
the car body: if the lamp fails to light, the
battery negative terminal is not earthed properly.
Fig 4.1 circuit tester
Earth the clip near the switch of the circuit
being tested and touch the probe to the 'live'
(battery) side of the switch. If the lamp does
not light, the wiring between the battery and
the switch is faulty, or a fuse has blown.
When checking a component operated by the
ignition switch, be sure that the switch is on.
If the lamp lights, turn the switch on and probe
its other Side: if the lamp does not light, the
switch is faulty.
If the switch works, leave it on, earth the clip
near the component and probe the live side of
the component. If the lamp does not light, the wiring from switch to component is faulty, or a fuse has
blown. If all of the checks so far are satisfactory, transfer the clip to the live side of the battery.

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Now probe the earthed side of the component (it may be earthed by its metal body being fixed to the
car body). If the lamp does not light, the component is badly earthed. If it does light, the component
itself is faulty.

Multti meter
A multi-meter is has three parts:
 Display
 Selection Knob
 Ports
 The display usually has four digits and the ability to display a negative sign. A few multi-
meters have illuminated displays for better viewing in low light situations.
 The selection knob allows the user to set the multi-meter to read different things such as
milliamps (mA) of current, voltage (V) and resistance (Ω).
 Two probes are plugged into two of the ports on the front of the unit. COM stands for common
and is almost always connected to Ground or ‘-’ of a circuit.
 The COM probe is conventionally black but there is no difference between the red probe and
black probe other than color. 10A is the special port used when measuring large currents (greater
than 200mA). mA V Ω is the port that the red probe is conventionally plugged in to. This port
allows the measurement of current (up to 200mA), voltage (V), and resistance (Ω). The probes
have a banana type connector on the end that plugs into the multi-meter. Any probe with a
banana plug will work with this meter. This allows for different types of probes to be used.
Measuring Voltage
 To start, let’s measure voltage on a AA battery: Plug the black probe into COM and the red
probe into mAVΩ. Set the multi-meter to “2V” in the DC (direct current) range. Almost all portable
electronics use direct current), not alternating current. Connect the black probe to the battery’s
ground or ‘-’ and the red probe to power or ‘+’. Squeeze the probes with a little pressure against
the positive and negative terminals of the AA battery. If you’ve got a fresh battery, you should
see around 1.5V on the display (this battery is brand new, so its voltage is slightly higher than
1.5V).

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What happens if you switch the red and black probes?
The reading on the multi-meter is simply negative.
Nothing bad happens! The multi-meter measures
voltage in relation to the common probe. How much
voltage is there on the ‘+’ of the battery compared to
common or the negative pin? 1.5V. If we switch the
probes, we define ‘+’ as the common or zero point. How
much voltage is there on the ‘-’ of the battery compared
to our new zero? -1.5V!

Fig 4.2 multtimeter

Oscilloscope
An oscilloscope, previously called oscillograph, is a type of electronic test instrument that allows
observation of constantly varying signal voltage, usually as a two-dimensional graph of one or more
electrical potential difference using the vertical or Y-axis, plotted as a function of time (horizontal X-
axis).
 Oscilloscopes are used to observe the change of an electrical signal over time.
 An oscilloscope displays voltage waveforms
 Oscilloscopes display the waveform of a signal and allow quantities such as phase to be
measured.

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 Fig 4.3 oscilloscope
Clamp Meter
In electrical and electronics engineering a current clamp or current probe is an electrical device
having two jaws which open to allow clamping around an electrical conductor.
This allows properties of the electric current in the conductor to be measured, without having to make
physical contact with the wire

Fig 4.4 Clamp Meter

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Electrical and electronic circuits
An Application of Series Circuit
Principles On a typical Lexus Electric
Radiator Fan Circuit, the fan motors are
connected in series to get a low speed.
Note all of the connections, switches
and relay contacts that are connected in
series with each other. Reference the
“Radiator Fan and Condenser Fan”
circuit in the EWD, System Outline,
“Low Speed Operation” for a complete
description.

Fig 4.5 Electrical and electronic

circuits

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 Fundamental of control units, basic parameters, signals of actuators and sensors
Normally:

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Mercury switches
If the capsule is moved so the mercury touches both of the electrical contacts, the circuit is
completed.

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Testing circuit diagram, system or component

Type of Circuit Diagram

1. Block Diagram – This type of diagram uses rectangular or triangle to represent a component,
a group of components or a group of units and arrows to show the connection and flow of a
certain device.

fig 4.6

2. Pictorial Diagram – It shows the picture of actual components and wiring connections.
Although, it does not provide the exact size of the components, it shows the exact shape in
proportion to the actual component.

87 | P a g e Fig 4.7 Pictorial Diagram of a fuel pump switch is

incorporated into the air flow meter to prevent the fuel
pump from running unless the engine is running.
 3. Schematic Diagram – A schematic diagram is actually a map showing the path of current that
takes through the various components. This type of diagram is a graphically representation
(represented by a symbols) which shows the electrical construction of a system or circuit.
However, it does not give the exact shape or size of the entire circuit.

Fig 4.8 Schematic Diagram

Elements of electronic system:
An ECU is an electronic device that stores and processes data. It relies on semiconductors and is a
group of integrated circuits (IC).
There are four basic functions of an ECU:
Input: A signal sent from an input device. The device can be a sensor or a switch activated by the
driver, technician, or a mechanical part.
Processing: The ECU uses the input information and compares it to programmed instruction. This
information is processed by logic circuits in the computer.
Storage: The program instructions are stored in the computer’s memory.

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 Some of the input signals are also stored for processing later.

Fig 4.9 elements of electronic contro unit

Output: After the computer has processed the inputs and checked its
programmed instructions, it will issue commands to various output devices.
These output devices may be instrument panel displays or output actuators.
The output of one computer may also be an input to other computers.

Electronic Device
Diodes
A diode is an electrical one-way check valve that will allow current to flow in one direction only.
E.g. Zener Diodes, Light-Emitting Diodes etc.

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 Fig 4.10 Light-Emitting Diodes
Zenier Diodes
Resistor
Series Resistor for limiting current flow

Transistors
Transistor=transfer + resist
-layer semiconductor. It is used as a very fast switching device.

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Fuses
, is a replaceable element that contains a metal strip that will
melt when the current flowing through it exceeds its rating.

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 Tools and equipment
BASIC HAND TOOLS

Wrenches
The word wrench means twist. A wrench is a tool for twisting and/or holding bolt
heads or nuts. Nearly all bolt heads and nuts have six sides; the jaw of a wrench fits
around these sides to turn the bolt or nut. All technicians should have a complete
collection of wrenches.
This includes both metric and SAE wrenches in a variety of sizes and styles. The
width of the jaw opening determines its size. For example, a 1⁄2-inch wrench has a jaw
opening (from face to face) of 1⁄2 inch. The size is actually slightly larger than its
nominal size so the wrench fits around a nut or bolt head of equal size.
K
The following is a brief discussion of the types
of wrenches used by automotive technicians.

Open-End Wrench The jaws of the open-end

wrench allow the wrench to slide around two
sides of a bolt or nut head where there might be
insufficient clearance above or on one side of
the nut to accept a box wrench.

Box-End Wrench The end of the box-end

wrench is boxed or closed rather than
open. The jaws of the wrench fit
completely around a bolt or nut, gripping
each point on the fastener. The box-end
wrench is not likely to slip off a nut or
bolt. It is safer than an open-end wrench.
Box-end wrenches are available as 6 point
and 12 point. The 6-point box end grips the
screw more securely than a 12-point box-end
wrench can and avoids damage to the bolt
head.
A. Six-point Box Wrench
B. Twelve-point Box Wrench

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Sockets and Ratchets
A socket wrench is much safer,
faster, and easier to use than any other
wrench. In fact, sometimes it is the only
wrench that will work.

The basic socket wrench set consists

of a ratchet handle and several barrel-
shaped sockets. Sockets are available in 6,
8, or 12 points. A 6-point socket has
stronger walls and improved grip on a bolt
compared to a normal 12-point socket. Six-
point sockets are mostly used on fasteners
that are rusted or rounded. Eight-point
sockets are available to use on square nuts
or square-headed bolts.

The square hole is the size of the

hole and handle lug (1⁄4 inch, 3⁄8 inch, 1⁄2 fig 4.12 Sockets and Ratchets
inch, and so on) indicates the drive size of
the socket wrench.

Deep-well sockets are made extra-long

Impact Socket
to fit over bolt ends or studs. Deep-well
sockets should not be used when a regular-size
socket will do the job. The longer socket
develops more twist torque and tends to slip off Deep Socket
the fastener. Heavier-walled sockets are
designed for use with an impact wrench and
are called impact sockets. Most sockets are
chrome-plated, except for impact sockets.
Special Sockets Screwdriver (including
Torx® driver) and Allen wrench attachments
are also available for use with a socket wrench.
A typical set of specialty socket drivers. These
socket wrench attachments are very handy

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when a fastener cannot be loosened with a
regular screwdriver. The leverage given by the
ratchet handle is often just what it takes to
break a stubborn screw loose.

Standard Tip Screwdriver: A slotted screw

accepts a screwdriver with a standard or blade-
type tip. The standard tip screwdriver is
probably the most common type. It is useful for
turning carriage bolts, machine screws, and
sheet metal screws. The width and thickness of
the blade determine the size of a standard
screwdriver. Always use a blade that fills the
slot in the fastener.

■ Phillips Screwdriver: The tip of a Phillips

screwdriver has four prongs that fit the four
slots in a Phillips head screw. The four surfaces
enclose the screwdriver tip so it is less likely
that the screwdriver will slip out of the fastener.
Phillips screwdrivers come in sizes #0 (the
smallest), #1, #2, #3, and #4 (the largest).

Pliers
Pliers are gripping tools used
for working with wires, clips,
and pins. At a minimum, an
auto technician should own
several types: standard pliers
for common parts and wires,
needle nose for small parts,
and large, adjustable pliers for
large items and heavy-duty
work.

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Stethoscope
A stethoscope is used to
locate the source of engine and other
noises. The stethoscope pickup is
placed on the suspected component,
and the stethoscope receptacles are
placed in the technician’s ears.

Fig 4.13 Stethoscope

ELECTRICAL / ELECTRONIC SYSTEM TOOLS

Circuit Tester
Circuit testers are used to check for voltage in an
electrical circuit. A circuit tester commonly called a test-
light. Its handle is transparent and contains a light bulb. A
probe extends from one end of the handle and a ground clip
and wire from the other end. When the ground clip is
attached to a good ground and the probe touched to a live
connector, the bulb in the handle will light up. If the bulb
does not light, voltage is not available at the connector.

Fig 4.14 Circuit TesterMulti-meters

A multi-meter is a must for diagnosing the individual
components of an electrical system. A digital multi-meter
(DMM) can measure volts, ohms, and low current such as direct
current (dc) and alternating current (ac) amperes, diode
continuity, frequency, temperature, engine speed, and dwell,
and/or duty-cycle. DMMs provide great accuracy by measuring
volts, ohms, or amperes in tenths, hundredths, or thousandths of
a unit. Several test ranges are usually provided for each of these
functions. Some meters have multiple test ranges that must be
manually selected; others are auto-ranging.

Fig 4.15 Multti-meters

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Lab Scopes

An oscilloscope or lab
scope is a visual voltmeter. A
lab scope converts electrical
signals to a visual image
representing voltage changes
over a specific period of time.
This information is displayed in
the form of a continuous voltage
line called a waveform or trace.
With a scope, precise
measurement is possible. A
scope displays any change in fig 4.16 lab Scopes
voltage as it occurs.
Hand-Held Engine Analyzer

With the help of powerful functions,

MT3500 Hand-held Engine Analyzer
supplies serial testing items, and meets
serial testing demands.

Fig 4.17 Hand-Held Engine Analyzer

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ENGINE PERFORMANCE TOOLS

Scan Tools

A scan tool is a microprocessor designed

to communicate with the vehicle’s computer.
Connected to the computer through diagnostic
connectors, a scan tool can access diagnostic
trouble codes (DTCs), run tests to check
system operations, and monitor the activity of
the system. Trouble codes and test results are
displayed on a
screen or printed out on the scanner printer.
The scan tool is connected to specific
diagnostic connectors on the vehicle. It must be programmed fig 4.18 scan tool for the model
year, make of vehicle, and type of engine. With OBD-II,
the diagnostic connectors (commonly called Data Link
Connector or DLCs) are located in the same place on all
vehicles. Most OBD-II scan tools have the ability
to store, or “freeze,” data during a road test and
then play back this data when the vehicle is returned to
the shop. Scan Tool may have the following capabilities:

■ Retrieve DTCs.
■ Monitor system operational data.
■ Reprogram the vehicle’s electronic control modules.
■ Perform systems diagnostic tests.
■ Display appropriate service
information,including electrical diagrams.
■ Display TSBs.
■ Display troubleshooting instructions.
■ Perform easy tool updating through a
personal computer (PC).

Injector Circuit Test light

A special test light called a noid light can be

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used to determine if a fuel injector is receiving its proper
voltage pulse from the computer. The wiring harness
connector is disconnected from the injector and the noid
light is plugged into the connector. After disabling the
ignition to prevent starting, the engine is turned over by
the starter motor. The noid light will flash rapidly if the
voltage signal is present. No flash usually indicates an
open in the power feed or ground circuit to the injector.

Soldering Equipment
The Soldering Iron/Gun

The first thing you will need is a soldering iron, which is the heat source used to melt solder. Irons of
the 15W to 30W range are good for most electronics/printed circuit board work. Anything higher in
wattage and you risk damaging either the component or the board. If you intend to solder heavy
components and thick wire, then you will want to invest in an iron of higher wattage (40W and above)
or one of the large soldering guns. The main difference between an iron and a gun is that an iron is
pencil shaped and designed with a pinpoint heat source for precise work, while a gun is in a familiar
gun shape with a large high wattage tip heated by flowing electrical current directly through it.

fig 4.20 A 300W Soldering Gun

fig 4.19A 30W Watt Soldering Iron

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 A variation of the basic gun or iron is the soldering station,
where the soldering instrument is attached to a variable power
supply. A soldering station can precisely control the
temperature of the soldering tip unlike a standard gun or iron
where the tip temperature will increase when idle and decrease
when applying heat to a joint. However, the price of a soldering
station is often ten to one hundred times the cost of a basic iron
and thus really isn't an option for the hobby market. But if you
plan to do very precise work, such as surface mount, or spend
8 hours a day behind a soldering iron, then you should
consider a soldering station.

Fig 4.21 soldering station

Solder

The choice of solder is also important. There several kinds of solder available but only a few are
suitable for electronics work. If acid core solder is used on electronics, the acid will destroy the traces
on the printed circuit board and erode the component leads. It can also
form a conductive layer leading to shorts. For most printed circuit
board work, a solder with a diameter of 0.75MM to 1.0MM is desirable.
Thicker solder may be used and will allow you to solder larger joints
more quickly, but will make soldering small joints.

Large joints, such as soldering a bracket to a chassis using a high

wattage soldering gun, will require a separate application of brush on
flux and a thick diameter solder of several millimeters.

Remember that when soldering, the flux in the solder will release
fumes. Therefore, always work in a well-ventilated area and avoid
breathing the smoke created. Hot solder is also dangerous. Eye
protection is also advised

Fig 4.22 solder

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 Self-Check -4.1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Choise the correct answer ffrom the given alternatives (1point)
1. __________ is a circuit testers are used to check for voltage in an
electrical circuit?
A. Test light C. volt meter
B. OHM`s meter D. all
2. It is type of diagram uses rectangular or triangle to represent a component, a group of
components?
A. Schematic Diagram C. Block Diagram
B. Pictorial Diagram D. All
3. What is the alowable included under electrical testing tool?
A. Test light C. oscilloscope
B. OHM`s meter D. all
4. Which on is safer, faster, and easier to use than any other wrench?
A. Open-End Wrench C. Sockets and Ratchets
B. Box-End Wrench D. Screwdriver
5. _________ is an electrical one-way check valve that will allow current to flow in one
direction only?
A. Diode C. fuse
B. Transistor D. All

Answer Sheet

1. ______
2. ______
3. ______
4. ______
5. ______
Note: Satisfactory rating - 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Information Sheet-4.2 Examine system or component

A source, protection device, control device, load (component that does the work) and
ground path are found in every automotive circuit. Customers do not bring in their
vehicles for circuit checkups or maintenance; they come to the shop or, even worse, are
towed in when an electrical system fault has occurred. The technician must be up for
the task. Unlike a fluid leak or an abnormal noise, electrons flowing in a circuit cannot
be seen or heard. Technicians must be proficient at using service information, circuit
wiring diagrams, and the digital multi-meter (DMM) for electrical system diagnosis. Like
any task, repetition and practice allow technicians to identify the cause of electrical

Measuring Voltage
Measuring voltage is the most frequently performed electrical system diagnostic test.
Measuring source voltage should be one of the first inspection points of any electrical system.
Measure source voltage at the battery with the vehicle off all electrical loads off. A fully charged
battery should indicate very close to 12.6 volts on the digital multi-meter (DMM). Perform a battery
test if source voltage is 12.4 volts or less before continuing diagnosis. The concern may be due to a
faulty battery or a problem with the charging system.

The DMM on the volt setting is measuring the difference in voltage (potential or pressure) between
the positive test lead and the negative test lead. Using the battery as an example,
the positive post of the battery has a potential of 12.6 volts and the negative post of the battery has a
potential of 0 volts when fully charged. In simple terms, the DMM takes the voltage measured on the
positive lead and subtracts it from the negative lead:

12.6V – 0.0V = 12.6V.

Looking at the voltage predicted in the circuit in, the technician has predicted source voltage before
the load and after the load when the circuit is off: 12.6V – 12.6V = 0.0V.
There is no potential difference between these two test points when the circuit is off so the
DMM displays 0.00V. Measuring available voltage and voltage drop in the circuit is part of the
diagnostic process. Perform these tests once you have reviewed the service information, traced
circuit current paths, and predicted circuit voltages at applicable test points. It is usually best to start
with available voltage tests as the results are shown on the DMM display even if no current is present
in the circuit. Available voltage tests are made by placing the DMM negative test lead on a known
good ground location. Place the DMM positive test lead at the desired test point in the circuit.
Compare the test result to your predicted voltage on the wiring diagram.
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Fig 4.23 Source voltage is measured at the battery and should be fig 4.24 A battery with 12.4V or less should be tested
very close to 12.6 volts. and, if OK, charged to 100% using a
“Smart” charging system.

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A circuit fault is noted when the voltage is not close to what should be
present. The available voltage test can quickly narrow your search for
the cause of a circuit
fault, like an open circuit concern (FIGURE 6-4). Voltage drop tests
require that current is present in the circuit. Remember,
voltage only drops in the presence of current. The
voltage drop test is the best test for isolating high
resistance faults in a circuit (FIGURE 6-5). A voltage drop
test is performed by placing the positive lead of the DMM
on the
Most positive portion of the circuit and the negative lead on the most
negative portion of the circuit with the test circuit energized (on). A
voltage drop can be performed on any portion of the circuit—across
the load where most of the voltage should be used to perform work, a
connector, a switch, a section of wiring, or the ground (TABLE 6-1).
You can apply one of Kirchhoff ’s laws to verify your voltage drop
testing was done correctly. Kirchhoff stated that the sum of the
voltage drops in a circuit must equal source voltage. After you note
your voltage drops, add them up to verify they equal source voltage.
This ensures that you did not misinterpret a voltage reading or have
one or both of the test leads in the wrong location.

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Resistance Testing
A resistance test is best used when testing a circuit
component as part of the service
information’s diagnostic procedure. You may need to
measure a relay coil, thermistor,
solenoid, or a fuel injector for resistance and then compare
your DMM reading with the
service information specification (FIGURE 6-6).
Resistance tests are made with the circuit off and isolating
the component or
portion of the circuit you will be testing. Isolate the
component by disconnecting the

FIGURE 4.24 Available voltage tests do not

require current to be present in the circuit and
can quickly pinpoint that there is an open circuit
fault.

Measuring Amperage
Using the DMM to measure circuit amperage is not often performed in automotive circuits. Most
DMMs can only measure up to 10 amps of current, and most automotive body
electrical circuits require more amperage than this to operate (note the fuse rating for the
circuit you are diagnosing). The most common use for the ammeter function of the DMM

FIGURE 4.25 An inductive clamp can be used to

measure amperage values that exceed the limit of the
DMM or if you want to view the signal on a DSO.

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 Self-Check -4.2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Part 1. Write the correct answers for the following questions.
1. What method is applicable used to examine vehicle electrical system(4point)

Answer Sheet

1. ___________________________________________________________________________
___________________________________________________________________________
_______________________________________.

Note: Satisfactory rating - points Unsatisfactory - below 2points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

105 | P a g e
 Determine and analyze operational principles of
Information Sheet-4.3
circuit, component and system functions

Circuit Faults
Circuit faults result in a customer concern. These faults can be categorized as an open circuit, high
resistance in a circuit, a short circuit, a shared voltage fault, or parasitic draw.
It is important to determine the type of circuit fault you are dealing with during your diagnosis
as it will affect the strategy and test methods used to isolate the cause of the fault.
Open Circuit
An open circuit no longer has a continuous path for current in the circuit and is the most
common electrical system fault. Causes of an open circuit include disconnected connectors,
a bad switch, damaged terminal connectors, cut wires, or a defective or blown fuse. When
there is no observable sign of circuit operation, there may be an open circuit (FIGURE 4.26).
Begin by testing the available voltage in the circuit that is the easiest to reach of those
that are the most likely cause of the concern. For the stop light circuit shown, you can test at
left stop light connector pin 3. If source voltage is present, then the circuit open is after this
point. If no voltage is present, the open is before this point in the circuit. With continued
circuit testing, you find that there is source voltage at left stop light connector pin 1. This
indicates the bulb should be OK. The next test location is the circuit ground point, L3—the

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DMM indicates 0 volts. Since there is source voltage at the ground side of the stop light bulb
connector (L31 pin 1) and no voltage at the circuit ground point, the open is between these
fig 4.26 open circuit test
two points. Further testing should be performed by visually inspecting this section of the
harness to determine the where the open is located.

High Resistance in a Circuit

In some cases high resistance faults may appear to be open circuit faults. The difference
is that current is present in the circuit with a high resistance fault. Additionally, instead of
infinite resistance like an open circuit, there is a resistance that is causing an excessive voltage drop
at some point before or after the circuit load (FIGURE 4.27).
The strategy for isolating the location of the high resistance fault is very similar to
open circuit voltage testing. If the circuit load functions, but does not function correctly,
you know that current is present. Therefore you can perform available voltage tests and
voltage drop tests throughout the circuit to isolate the high resistance. If you are unable to
determine whether current is present because the load does not appear to operate, begin
with available voltage testing at the load at both the positive and ground pins of the connector. Source
voltage at the load indicates the resistance is after the load, which should be confirmed when you
obtain a reading that exceeds 100mV or greater on the ground side of the load (with the circuit on)
(FIGURE 4.28). Voltage that is much less than source voltage indicates the high resistance is before
the load. Once you have isolated which part of the circuit has excess resistance, you can continue to
use available voltage tests or voltage drop tests to isolate where the high resistance is.

Short Circuit
A short circuit occurs when current bypasses the load and goes directly to ground or
when there is some fault in a circuit component (usually the load) that reduces resistance
and increases current beyond normal levels. A relay coil that has failing wire insulation
increases current, for example. Fuses, fusible links, and circuit breakers serve as circuit protection
devices in case of a short circuit. Fuses and fusible links are designed to have their conductor melt
from the excess current of a short circuit. When the conductor melts away, it opens the circuit and
prevents overheating wiring, switches, and the load device which could lead to a vehicle fire.
Diagnosing a short circuit can seem like a daunting task since you cannot power the circuit on and
then use your DMM to find the cause. There are a couple of methods that you can use to locate the
fault. The first method involves using an incandescent light as a short-finding tool. Create the short-
finding tool by using a 12-volt 1156 light socket, a fuse

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 FIGURE 4.27 Measure voltage at the load. Less than FIGURE 4.28 Locate the short using an 1156 lamp and socket ith
source voltage on the source side indicates resistance a fuse. Disconnect connectors in the circuit before the load ntil
before the load.Voltage that is greater than 100–300mV the light turns off to isolate the short location. Using an
incandescent lamp with fused leads connected to the fuse holder
after the load indicates excess resistance after the load.
is one method for locating a short circuit.

holder, and 16 gauge wire. Assemble as shown in FIGURE 4.28. Remove the circuit fuse and install
the short-finding tool. Turn the affected circuit on and the 1156 bulb will illuminate.
Begin disconnecting circuit connectors in the affected circuit one at a time. When the 1156
bulb goes out, you know the short is in that section of the circuit. You can then inspect the
harness or component further to determine what repair is required. Another option is to use a short-
detecting tool. There are two basic types. The first uses a circuit breaker to power up the circuit for
very short intervals. While it is energized, you use a hand-held tool that detects the magnetic field in
the wiring harness. If the needle on the tool moves, there is current present. When the needle stops
moving, you have found where the short to ground is. The second type of short detector uses a signal
generating device connected to the affected circuit. Once it is connected, you leave the circuit off and
then use the signal detector along the harness. As long as there is a signal, the wiring is OK. The
signal stops where the short is. The difficulty with both of these methods is in the amount of the
harness you must expose to find the short location, especially where the harness is difficult to reach

108 | P a g e
behind the instrument panel. Whichever method you use to find the cause of the short circuit, once
found, perform the recommended repair and then thoroughly retest the circuit to ensure all is OK.
Shared Voltage
A shared voltage fault is one of the most confusing faults to diagnose. A shared voltage fault
occurs when one circuit shares its voltage with another causing it to operate at the same
time. A shared voltage fault can occur when one circuit joins with another circuit causing
the two circuits to operate when one or the other is energized. This may be caused when
two wires chafe through the insulation and the bare wire touches, when damage to a connector
causes adjacent pins to touch, when a fault or damage inside a junction block allows two distinct
circuit paths to intersect and connect, or when a damaged dual filament light
bulb allows voltage in one filament to touch the other filament and turn that
part of the circuit on. An open ground in one circuit can also allow current to
seek a path to ground through another related component like a light bulb or
shared fuse (FIGURE 4.29). Isolate the cause of a
shared voltage fault by first checking for a blown
fuse. The blown fuse may cause the lack of
voltage in one circuit to seek a path
through another circuit where they intersect in a
junction block or junction connector. Shared
voltage concerns in incandescent lighting circuits
can be diagnosed by removing each bulb one at a
time. Inspect the bulb to be sure it is the correct
type and there is no damage to the bulb base or
socket in the vehicle harness. If the other circuit
turns off when you remove the bulb, you have
isolated the cause to either the bulb or that part of
the harness and bulb socket. Do this for each bulb
in the circuit until you locate the cause of the fault? Fig 4.29 Shared Voltage
It ispossible that a damaged harness or connector is allowing one circuit to power another due to
exposed wires touching each other or two or more connector pins touching. Isolating where the short
to voltage is should begin with where the two (or more) circuits have wiring in the same connector(s).
Check for continuity between the two suspected wires. It should be an open circuit, but a resistance
reading near 0 ohms indicates the two wires have made contact. Carefully inspect connectors for
damage. If OK, move on to the harness sections and carefully inspect the individual wires for damage
to insulation that would allow the circuits to share voltage from one to the other. Lastly, some circuits
use diodes to isolate one part of the circuit from another. Refer to the wiring diagram; if there is an

109 | P a g e
isolation diode present, locate the diode and check its operation with your DMM. Replace the diode if
it fails the forward or reverse bias tests.
Parasitic Draw
A parasitic draw is always present in the modern
vehicle. ECUs have keep alive memory
functions, and ECUs related to alarm and keyless entry
systems remain active while the
vehicle is locked and off. The typical vehicle should
have less than 50mA (milliamps) of
parasitic or ignition-off draw and should have little effect
on battery voltage over a vehicle
storage period of two to four weeks. Excessive parasitic
draw usually presents as a customer
concern that the battery has low or no charge to start fig 4.30 Parasitic Draw
the vehicle after it has been parked for
a period of a few hours to a day or so. Your diagnosis should begin with a thorough battery and
charging system test. A failing battery or charging system that does not fully charge the battery can
cause symptoms that may seem like a parasitic draw concern but are not. If the battery and charging
system are OK, check for parasitic draw (FIGURE 4.30).
Parasitic current draw can be measured in several ways, the most common being the
process of using an ammeter capable of measuring milliamps and inserting it in series

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 Self-Check -4.3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Choise the correct answer ffrom the given alternatives (1point)
1. __________ is faults may appear current and presents open circuit?
A. Parasitic Draw C. full circuit
B. Open circuit D. High Resistance in a Circuit
2. Which circuit fault is one of the most confusing faults to diagnose?
A. High Resistance in a Circuit C. full circuit
B. Parasitic Draw D. shared voltage
3. The fault that is presented always in the modern vehicle?
A. High Resistance in a Circuit C. full circuit
B. Parasitic Draw D. All
4. A foult circuit occurs when current bypasses the load and goes directly to ground?
A. Open circuit C. High Resistance in a Circuit
B. Parasitic Draw D. A short circuit
5. It is has no longer a continuous path for current in the circuit and is the most
Common electrical system fault?
C. Open circuit C. High Resistance in a Circuit
D. Full circuit D. A short circuit

Answer Sheet
1. ____
2. ____
3. ____
4. ____
5. ____

Note: Satisfactory rating – 3 points Unsatisfactory - below 3 points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

111 | P a g e
 Determine system or component relationship to light
Information Sheet-4.4
vehicle operation

Testing Switches, Connectors, and Wiring

Switches, connector pins, and wiring from one part of a circuit to the next are often tested as
part of the electrical system diagnosis. Service information often provides resistance specifications to
check these components; however, the best test for component resistance is the voltage drop test, as
discussed earlier in this chapter. Switch contacts should have infinite resistance when off and very
close to 0 ohms when in the on position. Wiring and connector pins should have very close to 0 ohms
of resistance. Also, wiring that delivers voltage to the load should have no continuity to ground (OL on
the DMM). Voltage drop testing is a dynamic test. The component is tested when current is present in
the circuit. A switch, wire, or harness connector pins may have very little resistance when tested by
the DMM and its very small current present during the resistance test. Applying full circuit current will
cause resistance to show in the form of a voltage drop. Perform a voltage drop across a switch by
measuring at the connector pins. The voltage drop should be less than 100mV for most circuits.
Circuits with high current may have a higher voltage drop. For example, an incandescent stop light
circuit may have 200–300mV drop across the brake light switch. Switch contacts can corrode or be
damaged from repeated on to off cycling. A voltage drop of more than 500mV usually indicates the
switch is faulty and should be replaced. Connectors join sections of the harness together and allow
for easier assembly or disassembly of the vehicle and related repairs that may be required.
Connector pins are really only designed to be connected and disconnected three or four times in their
vehicle life. Every time a connector is disconnected and reconnected, its pins may be damaged or
there may be wear and damage to the housing and the retaining lock mechanism. Use caution when
disconnecting the connectors and avoid repeated removing and installing. Tools are available to test
for connector pin fit. An excessive voltage drop across a connector may be caused by a damaged
pin. The use of this tool can help identify whether pin fit is the cause. A damaged connector or
damaged pin usually requires a harness replacement if the vehicle is under warranty. Customer pay
may require you repair or replace the connector pin or entire connector if the components are
available. Some vehicle manufacturers provide terminal repair kits and a catalog of replacement
connectors that are a direct replacement or can be adapted to fit, like using a 6 pin connector in place
of a 4 pin.

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Wiring can be damaged due many factors including high heat environments, flexing as the powertrain
moves, chafing from road vibration and heat expansion and contraction, rubbing and flexing when
doors and the deck lid or hatch open/close, and physical damage due to an accident or improperly
installed accessories. The service information usually provides
harness testing specifications in the related circuit diagnosis where required. Usually the information
relates to resistance tests from connector to connector and to chassis ground. Unfortunately, a
resistance test can miss diagnosing a damaged wire that can handle the full circuit current. For this
reason a voltage drop test is recommended. The wiring should have very little resistance and a
voltage drop that is less than 100mV for most body electrical circuits. Wiring that exceeds voltage
drop limits or has a short to ground must be repaired by harness replacement or repair.

FIGURE 4.31 Terminal pin test tools can be used to

Verify the correct pin fit tension is

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 Self-Check -4.4 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions.
1. What method we use to measure/Test foults of switches, connectors, and wiring?(4point)

Answer Sheet

1. ___________________________________________________________________________
___________________________________________________________.

Note: Satisfactory rating – ½ points Unsatisfactory - below ½ points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Information Sheet-4.5 Identify potential for unsafe conditions

All workers a right to work in place where risks to their health and safety are properly controlled.
Health and safety about stooping you getting hurt at work or ill through work. Your employer is
responsible health and safety. But you must help.
Working in a motor vehicle workshop is a dangerous occupation, if you do not take care.
The most important thing is to be aware of the hazards and then it is easy to avoid the
danger. The hazards in a workshop are from two particular sources: you and your
surroundings.
Hazards due to you may be caused by:
 carelessness – particularly while moving vehicles
 drinking or taking drugs – badly affects your ability to react to dangerous situations
 tiredness or sickness – affects your ability to think and work safely
 messing about – most accidents are caused by people fooling about
 not using safety equipment – you have a duty to yourself and others to use
safety equipment
 inexperience – or lack of supervision: if in doubt – ask.
The surroundings in which you work may have:
bad ventilation
poor lighting
noise
dangerous substances stored incorrectly
broken or worn tools and equipment
faulty machinery
slippery floors
untidy benches and floors
unguarded machinery
unguarded pits.

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What you must do:

1. Follow the training you have received when using any work items your

employer has given you.

2. Take reasonable care of your own and other people’s health and safety.

3. Co-operate with your employer on health and safety.

4. Tell someone (your employer, supervisor, or health and safety

representative) if you think the work or inadequate precautions are putting anyone’s health
and safety at serious risk.

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 Table 4.1 hazards and actions to reduce

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 Self-Check -4.5 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answers for the following questions. (2point for each)

1. List examples that can cause hazards?

2. What method you must follow to minimize hazard?

Answer Sheet

1. ___________________________________________________________________________
___________________________________________________________________________
_________________________________________.
2. ___________________________________________________________________________
___________________________________________________________________________
____________________________________.

Note: Satisfactory rating – ½ points Unsatisfactory - below ½ points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: ______________

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 Information Sheet-4.6 Identify potential common faults with system or
component
TROUBLESHOOTING CIRCUITS
When troubleshooting an electrical problem, in any system, it is very important that a
logical approach is taken. Making assumptions or jumping to conclusions can be very
expensive and a total waste of time. The basic steps for diagnosis given in Chapter 2
should be followed. Here they are again, only modified to fit electrical problems:
Open
An open is simply a break in the circuit (Figure 3-52). An open is caused by turning a
switch off, a break in a wire, a burned-out light bulb, a disconnected wire or connector,
or anything that opens the circuit. When a circuit is open, current does not flow and
the component doesn’t work. Because there is no current flow, there are no voltage
drops in the circuit. Source voltage is available everywhere in the circuit up to the point
at which it is open. Source voltage is even available after a load, if the open is after
that point.

Opens caused by a blown fuse will still cause the circuit not to operate, but the cause
of the problem is the excessive current that blew the fuse. Nearly all other opens are
caused by a break in the continuity of the circuit. These breaks can occur anywhere in
the circuit.
Shorts
A short results from an unwanted path for current. Shorted circuits cause an increase
in current flow by bypassing part of the normal circuit path. This increased current
flow can burn wires or components.
An example of a shorted circuit could be found in a faulty coil. The windings within a
coil are insulated from each other; however, if this insulation breaks down, a copper-

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to-copper contact is made between the turns. Since part of the windings will be

bypassed, this reduces the number of windings in the coil through which current will

flow. This results in the effectiveness of the coil being reduced. Also, since the current
bypasses a portion of the normal circuit resistance, current flow is increased and
excess heat can be generated.

Another example of a shorted circuit is if the insulation of two adjacent wires breaks

down and allows a copper-to-copper contact (Figure 3-53). If the short is between

points A and B, light 1 would be on all the time. If the short is between points B and
C,both lights would illuminate when either switch is close

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Another example is shown in Figure 3-54. With the two wires shorted together, the

horn will sound every time the brake pedal is depressed. Also, if the horn button is

pressed, the brake lights will come on.

Another type of electrical defect is a short to ground. A short to ground allows current

to flow an unintentional path to ground (Figure 3-55). To see what happens in a circuit

that has a short to ground, refer to Figure 3-56. If normal resistance of the two bulbs

is 3 ohms and 6 ohms, since they are in parallel, the total circuit resistance is 2 ohms.

The short makes a path from the power side of one bulb to the return path, and to the

battery. The short creates a low- resistance path. If the low-resistance path has a

resistance value of 0.001 ohms, it is possible to calculate what would happen to the

current in this circuit.

The short becomes another leg in the parallel circuit. Since the total resistance of a

parallel circuit is always lower than the lowest resistance, we know the total resistance

of the circuit is now less than 0.001 ohms. Using Ohm’s law we can calculate the

current flow through the circuit.

I = V/R or I = 12/.001 or I = 12,000 Amps

Needless to say, it would take a large wire to carry that kind of amperage. Our 10-amp

fuse would melt quickly when the short occurred. This would protect the wires and
light bulbs.

High Resistance
High-resistance problems occur when there is unwanted resistance in the circuit. The
high resistance can come from a loose connection, corroded connection, corrosion in
the wire, wrong size wire, and so on. Since the resistance becomes an additional load
in the circuit, the effect is that the load component, with reduced voltage and current
applied, operates with reduced efficiency. An example would be a taillight circuit with

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a load component (light bulb) that is rated at 50 watts. To be fully effective, this bulb
must draw 4.2 amperes at 12 volts (I = P ÷ V). This means a full 12 volts should be
applied to the bulb. If resistance is present at other points in the circuit, some of the
12 volts will be dropped. With less voltage (and current) being available to the light
bulb, the bulb will illuminate with less intensity.

Figure 3-57 illustrates a light circuit with unwanted resistance at the power feed for
the bulb and at the negative battery terminal. When the circuit is operating properly,
the 2-ohm light bulb will have 6 amps of current fl owing through it and drop 12 volts.
With the added resistance, the current is reduced to 3 amps and the bulb drops only
6 volts. As a result, the bulb’s illumination is very dim.

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 Self-Check -4.6 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the next page:
Part 1. Write the correct answer for the following question.

1. What method is applicable used to examine vehicle electrical system, why?(4point)

Answer Sheet

1. ___________________________________________________________________________
___________________________________________________________________________
________________________________________________.

Note: Satisfactory rating – ½ points Unsatisfactory - below ½ points

You can ask you teacher for the copy of the correct answers.

Score = ___________

Rating: ____________

Name: _________________________ Date: _______________

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 Operation Sheet 3 Determine method of system or component operation

 wear appropriate clothes, shoe ...

 Ensure the work shop hazard free
 Ensure the working area is bright / good
 visibility make workstation comfortable
Task1. Examine system or component
Step 1- Make ready live vehicle if it is hot let to cool
Step 2- Identifying Location of battery: - it is commonly under the hood for
Light duty trucks and for heavy duty trucks it lives under the
Middle part of vehicle
Step 3- Identifying Location of starter motor is commonly attached on the
engine near to fly wheel.
Step 4. Identifying Location of charging circuit is commonly positioned on
the engine attached or connected to crank shaft pulley with belt.
Task 2. Examine system or component
OPEN-CIRCUIT VOLTAGE TEST
 An accurate digital voltmeter is used to check the battery's open-
circuit voltage
Step 1. If the battery has just been charged,
turn on the Head lamps for one minute
to remove any surface charge.
Step 2- Turn headlamps off and connect the

voltmeter across the battery terminals.

Step 3- Remove either battery cable or only

negative battery cable to have valid result.

Step 4- Read the voltmeter. A fully charged battery will have an open-circuit
voltage of at least 12.6 volts. A dead battery will have an open-circuit
voltage of less than 12.0 volt.
Task3. Charging System Diagnosis and Service

Step . CHECK BATTERY TERMINALS, FUSIBLE LINKS AND FUSES

(a) Check that the battery terminals are not loose or corroded.
(b) Ch e ck t he f u sib le lin k a nd f u se s f o r co n t inu it y.
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Step 2. INSPECT DRIVE BELT
(a) Visually check the drive belt for cracks, oiliness or wear. Check that the belt does
not touch the bottom of the pulley groove.
If necessary, replace the drive belt.
(b) [Canada]
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020) or
Borroughs No. BT -33-73F
Dri ve belt tension: New belt 125 ± 25 lb
Used belt 115 ± 15 lb
If the belt tension is not within specification, adjust it.

NOTE:
- When checking the tension, be sure the gauge is on the belt protrusion.
- “New belt" refers to a new belt which has been used less than 5 minutes on a
running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5
minutes or more.
- After installing a new belt, run the engine for about 5 minutes and recheck the
tension.

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 (c) [Others]
Check the drive belt deflection by pressing on the belt at the points indicated in the
figure with 10 kg (22.0 lb, 98 N) of pressure.
Drive belt deflection:
New belt 8 - 9 mm (0.31 - 0.35 in.)
Used belt 10 - 13 mm (0.39 - 0.51 in.)
If the belt deflection is not within specification, adjust it.
NOTE:
- "New belt" refers to a new belt which has been used less than 5 minutes on
a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5
minutes or more.
- After installing a new belt, run the engine for about 5 minutes and recheck the
deflection.

Step 3. VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL

NOISES
( a ) Che ck th at the wirin g is in go od cond it io n.
( b ) Check that there are no abnormal noises from the alternator while the engine is
running.

Step4. INSPECT CHARGE WARNING LIGHT CIRCUIT

( a ) W arm up the engine and then turn it off .
(b) T u r n o f f a l l a c c e s s o r i e s .
( c ) Turn the starter switch to "ON." Check that the charge warning light is lit.
( d ) Start the engine. Check that the light goes out. If the light does not operate as
specified, troubleshoot the warning light circuit.

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 Step5. CHECK CHARGING CIRCUIT WITHOUT LO AD
NOTE: If a battery/alternator tester is available, connect the tester to the charging circuit as per
the manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as
follows:
- Disconnect the wire from terminal B of the alternator and connect it to the negative (—)
probe of the ammeter.
- Connect the test probe from the positive (+) terminal of the ammeter to terminal B of the
alternator.
- Connect the positive (+) probe of the voltmeter to terminal B of the alternator.
- Ground the negative (—) probe of the voltmeter.

(b) Check the charging circuit as follows:

Task 4. STARTER REMOVAL

PROCEDURE After testing has confirmed that a starter motor may need to be replaced; most vehicle
manufacturers recommend the following general steps and procedures.
STEP 1 Disconnect the negative battery cable.
STEP 2 Hoist the vehicle safely.

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 STEP 3 Remove the starter retaining bolts and lower the starter to gain access to the wire(s)
connection(s) on the starter.
STEP 4 Disconnect and label the wire(s) from the starter and remove the starter.
STEP 5 Inspect the flywheel (flexplate) for ring gear damage. Also check that the mounting holes
are clean and the mounting flange is clean and smooth. Service as needed.
NOTE: This step may not be necessary. Check service information for the specified procedure
for the vehicle being serviced. Some starters are located under the intake manifold. SEE
FIGURE .

Task 5. PERFORMANCE TEST

N.B.
 Before being to disassemble the starter motor first roughly pinpointing the source of the
problem by the performance test is recommended since it helps speed up the overhaul. Also
perform this test after assembly is completed to make sure that the starter motor is operating
correctly.

 Complete each test as quickly as possible (within approximately 3-5 seconds). Other wise, the
coil in the starter motor may burn out.
Stap1.PULL-IN TEST
(a) Disconnect the field coil lead from Terminal C.
 What is/are the reason/s of disconnecting terminal
C____________

______________________________________________________

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 (b) Connect the battery to the magnetic switch as shown. Check that the pinion moves
outward.
OBSERVATION___________________________________________
If the pinion gear does not move outward, check for (a)_____________
(b)___________________
(c)___________________
CONCLUSION____________________________________________

Step 2. HOLD-IN TEST

With the battery connected as above and with the pinion out,
disconnect the negative lead from ________________________.
Check that the pinion remains out.

OBSERVATION___________________________________________
If the pinion gear retracts, check for (a) ______________________
(b)______________________
(c)______________________
CONCLUSION____________________________________________

Step 3. PINION RETURN TEST

Disconnect the negative lead from
_____________________________
Check that the pinion reacts

OBSERVATION___________________________________________
If the pinion gear does not immediately retract, check for
(a)______________________

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 (b)______________________
(c)______________________
CONCLUSION____________________________________________
4. CHECK PINION CLEARANCE
(Except Reduction Type)
(a) Connect the battery to the magnetic switch as shown.

(b) Move the pinion gear toward the armature to remove slack,
then measure the clearance between
______________________and ___________________
Standard clearance: 0.1 –0.4mm

OBSERVATION___________________________________________
CONCLUSION____________________________________________

5. NO-LOAD TEST

(a) Securely fix the starter motor with a vice

(b) Connect the field coil lead to Terminal C. Make sure the lead
is not grounded
(c) Connect the battery and ammeter to the starter as shown.
(d) Check, that the starter rotates smoothly and steadily, and
that the pinion moves out.
(e) Check that the ammeter reads the specified current.
Specified Current: Less than 50 A at 11V
OBSERVATION___________________________________________
CONCLUSION____________________________________________

N.B.
The amount of electrical current flowing through the circuit in the no-load test varies depending
with the starter motor, but as much as 200-300 amperes flows in some starter motors. Refer
beforehand to the vehicle's repair manual for the amount of current and be sure to use an
ammeter with the appropriate capacity. Be sure to use heavy-duty cables as well.
(f) Check that the pinion gear retracts and the motor stops as soon as the cable is
disconnected from Terminal _____________. (This is necessary only for the
conventional type starter motor.) If the motor does not stop immediately, the probable
cause/s is/are (a)_________________________
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 (b)_________________________
(c)__________________________

Task 6. CHECK lighting CIRCUIT RESISTANCE

Step1. Disconnect the section of the circuit that you are testing.
Step 2. Connect the DMM leads and note the resistance reading on the display.
Step 3. Measure resistance of the harness
Step 4. Wiring resistance should be very close to 0 ohms.
Task 7. CHECK LIGHTING CIRCUIT OPEN
Step 1. Connect the section of the circuit that you are testing.
Step 2. Connect the DMM leads and note the reading on the display.
Step 3. If source voltage is present, then the circuit open is after this point.
Step 4. If no voltage is present, the open is before this point in the circuit.
Step 5. With continued circuit testing, you find that there is source voltage at left stop light connector
pin 1. This indicates the bulb should be OK.

Resistanc Test Open circuit test

Operation Sheet 1 Identify and apply electrical/electronic fundamentals

 Material/ equipment: - lamps,fuse,

multi- meter - paper and pen [for recording the data] wire,pliers electrical
tap, wire ,belt tension guage connecter terminals…….

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform the following
tasks within 2hour.
Project 3. Determine method of system or component operation
Task 1. Examine vehicle electrical system or component
Task 2. Diagnosis Charging System

Step 3. Inspect charge warning light circuit

Task 4. Remove starter motor from the vehicle
Task 5. PERFORMANCE TEST
N.B.
 Before being to disassemble the starter motor first roughly pinpointing the source of the
problem by the performance test is recommended since it helps speed up the overhaul. Also
perform this test after assembly is completed to make sure that the starter motor is operating
correctly.

 Complete each test as quickly as possible (within approximately 3-5 seconds). Other wise, the
coil in the starter motor may burn out.
Stap1.PULL-IN TEST
(c) Disconnect the field coil lead from Terminal C.
 What is/are the reason/s of disconnecting terminal
C____________

______________________________________________________
(d) Connect the battery to the magnetic switch as shown. Check that the pinion moves
outward.
OBSERVATION___________________________________________
If the pinion gear does not move outward, check for (a)_____________
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 (b)___________________
(c)___________________
CONCLUSION____________________________________________

Step 2. HOLD-IN TEST

With the battery connected as above and with the pinion out,
disconnect the negative lead from ________________________.
Check that the pinion remains out.

OBSERVATION___________________________________________
If the pinion gear retracts, check for (a) ______________________
(b)______________________
(c)______________________
CONCLUSION____________________________________________

Step 3. PINION RETURN TEST

Disconnect the negative lead from
_____________________________
Check that the pinion reacts

OBSERVATION___________________________________________
If the pinion gear does not immediately retract, check for
(a)______________________
(b)______________________
(c)______________________
CONCLUSION____________________________________________
4. CHECK PINION CLEARANCE

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 (Except Reduction Type)
(c) Connect the battery to the magnetic switch as shown.

(d) Move the pinion gear toward the armature to remove slack,
then measure the clearance between
______________________and ___________________
Standard clearance: 0.1 –0.4mm

OBSERVATION___________________________________________
CONCLUSION____________________________________________

5. NO-LOAD TEST

(g) Securely fix the starter motor with a vice

(h) Connect the field coil lead to Terminal C. Make sure the lead
is not grounded
(i) Connect the battery and ammeter to the starter as shown.
(j) Check, that the starter rotates smoothly and steadily, and
that the pinion moves out.
(k) Check that the ammeter reads the specified current.
Specified Current: Less than 50 A at 11V
OBSERVATION___________________________________________
CONCLUSION____________________________________________

N.B.
The amount of electrical current flowing through the circuit in the no-load test varies depending
with the starter motor, but as much as 200-300 amperes flows in some starter motors. Refer
beforehand to the vehicle's repair manual for the amount of current and be sure to use an
ammeter with the appropriate capacity. Be sure to use heavy-duty cables as well.
(l) Check that the pinion gear retracts and the motor stops as soon as the cable is
disconnected from Terminal _____________. (This is necessary only for the
conventional type starter motor.) If the motor does not stop immediately, the probable
cause/s is/are (a)_________________________
(b)_________________________
(c)__________________________

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 List of Reference Materials

1. Advanced Automotive Electricityand Electronics

http://www.cdxauto.com/mastadvelectrfeatures
2. AUTOMOTIVE TECHNOLOGY 5 t h E d i t i o n by Jack Erjavec
www.cengage.com.
3. Basic Auto EIectronics and EIectricaI Systems[AT-1035] Honda manual
4. Basic Auto EIectronics and EIectricaI Systems TOYOTA manual
5. AUTOMOTIVE ELECTRICAL TESTING by TECH A.V
www.techav.co.za
6. Different lerning guids
7. MANAGING ELECTRICAL RISKS IN THE WORKPLACE by safe work austria
www.safeworkaustralia.gov.au

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