Servicing Starting System

COMPETENCY BASED LEARNING MATERIAL

Sector:

AUTOMOTIVE

Qualification:

Automotive Servicing NC II

Unit of Competency:

Service Starting System

Module Title:

SERVICING STARTING SYSTEM

Technical Education and Skills Development Authority

East Service Road, South Superhighway, Taguig, Metro Manila

NATIONAL CERTIFICATE LEVEL 2

QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

1. Service Starting System • Servicing Starting ALT723307
System
2. Service Charging System ALT723308
3. Service Engine Mechanical • Servicing Charging System ALT723309a
• Servicing Cooling System ALT723309b
System • Servicing Lubricating System ALT723309c
• Servicing Gasoline Fuel System ALT723309d
4. Service Clutch System • Servicing Air Induction System ALT723309e
5. Service Differential and Front • Servicing Diesel Fuel Injector ALT723310
• Servicing Clutch System ALT723311
Axle • Servicing Differential and Front
6. Service Manual Steering System ALT723312
7. Overhaul Manual Transmission Axle
• Servicing Manual Steering ALT723313a
8. Service Brake System
System ALT723313b
9. Service Suspension System • Pulling-out, Disassembling and
ALT723314a
Checking Manual Transmission
• Assembling and Testing ALT723314b
ALT723314c
Manual Transmission ALT723315
• Identifying and Explaining

Hydraulic Brake System
Operations and Functions
• Servicing Brakes
• Overhauling Brake Systems
• Servicing Suspension System

How to use this Competency-Based Learning Material

Welcome to the Module Servicing Starting System. This module contains training
materials and activities for you to complete.

The unit of competency "Service Starting System" contains the knowledge, skills
and attitudes required for an Automotive Servicing. It is one of the specialized modules at
National Certificate II (NC II) level.

You are required to go through a series of learning activities in order to complete
each learning outcomes of the module. In each learning outcome there are Information
Sheets and Resource Sheets (Reference Materials for further reading to help you better
understand the required activities. Follow these activities on your own and answer the self-
check at the end of each learning outcome. You may remove a blank answer sheet at the
end of each module (or get one from your facilitator/trainer) to write your answers for each
self-check. If you have questions, don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this
learner's guide because you have:

• been working for some time
• already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular outcome,
you don't have to do the same training again.

Talk to your trainer about having them formally recognized. If you have a qualification
or Certificate of Competence from previous training, show it to you r trainer. If the skills you
acquired are still current and relevant to the unit/s of competency they may become part of
the evidence you can present for RPL. If you are not sure about the currency of your skills,
discuss this with your trainer.

After completing this module ask your trainer to assess your competency. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.

Inside this learner's guide you will find the activities for you to complete and at the
back are the relevant information sheets for each learning outcome. Each learning outcome
may have more than one learning activities.

At the back of this learner's guide is a Learner Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you in providing
further details to your trainer or an assessor. A Record of Achievement is also provided for
your trainer to complete once you complete the module.

Program /Course Automotive Servicing NC II
Unit of Competency Service Starting System

Module Servicing Starting System

INTRODUCTION:

The starting system is a combination of mechanical and electrical parts that work
together to start the engine. A technician must be aware of the principles surrounding
the starting system in order to identify the source of the problem.

In this module you will learn how to test and repair starting systems/direct current
motors appropriate to vehicles. You will be performing activities to develop your skill in
testing starting system components and identify faults, disassemble starter,
repair/replace parts and reassemble starter components.

You will also review underpinning knowledge such as electrical principles, repair
procedures, electrical measuring and testing procedures and vehicle safety
requirements.

After doing the learning activities in this learner's guide you will be assessed by
your facilitator/instructor on repairing starting system, and direct current motors.

LEARNING OUTCOMES

Upon completion of this module you should be able to:

• Test starting system components and identify its faults;

• Disassemble starter motor; and

• Repair/Replace and assemble starter components/parts.

ASSESSMENT CRITERIA

All standard of performance for Repairing Starting Systems is in accordance with
company standard operating procedure and manufacturer’s specification Manuals using
specified tools and equipment.

1. Test starting system/components and identify faults:

1.1. Work is completed without causing damage to any workplace property or
vehicle.

1.2. Correct information is accessed and interpreted from appropriate
manufacturer specifications.

1.3. Tests are carried out to determine faults using appropriate tools and
techniques.

1.4. Faults are identified and preferred repair action is determined.

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2. Repair starting systems/direct current motors and/or associated
components

2.1. Starting systems/direct current motors are repaired without causing
damage to any workplace property or vehicle.

2.2. Correct information is accessed and interpreted from appropriate
manufacturer specifications.

2.3. Necessary repairs, component replacement and adjustments are carried
out using appropriate tools, techniques and materials.

PREREQUISITES

1. NC I certification

2. Modules on the following:
- Testing, Servicing and Replacing Automotive Battery
- Drawing/Reading Basic Technical Drawings
- Using and Maintaining Volt-Ohm Milliammeter
- Solving Basic Trade-Related Mathematics Problems

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LEARNING EXPERIENCES

Learning Outcome # 1 : TEST STARTING SYSTEM AND IDENTIFY FAULTS

Learning Activities Special Instructions

1. Identify starting system components, • Read Information Sheet # 1a
types and classification - Components and Functions of the
Starting System.
2. Scale reading of analog/digital - Answer Activity #1a questions.
Voltmeter/Ammeter
• Read Information Sheet # 1b -
3. Conducting starting system - Starter Motor Operation.
components failure analysis - Answer Activity #1b questions.

• Read Information Sheet # 1c
- Types of Starter Motor.
- Answer Activity #1c question.

• Read Information Sheet # 1d.
- Classification of Starter Motor Drives
- Answer Activity #1d questions.

• Follow procedures on Operation
Sheet # 2.

• Answer the Self-Check on pages 18-
19.

• Read the information on Activity # 3a.
• Perform the procedures on Operation

Sheet # 3a.
• Read the Information Sheet # 3b.
• Read the information on Activity # 3b.
• Fill-up the Data table on page 34.
• Fill-up job-order form on page 35.
• Participate in a role play described on

Activity # 3d on page 38.

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LO 1 - Test Starting System and Identify Faults

LEARNING OUTCOME 1:

At the end of these learning activities you should be able to test starting system
components and identify faults.

EQUIPMENT AND MATERIALS:

• Running condition engine
• Starting system (simulated mock-up)
• Multi-tester
• Service manual (Repair manual)
• Starter motor
• Set of wrenches
• Vernier caliper
• Sand paper
• Growler

LEARNING ACTIVITIES:

Activity # 1: IDENTIFY STARTING SYSTEM COMPONENTS, TYPES
AND CLASSIFICATION

Do you know the working components of the starting system and their
functions?

a. Read Information Sheet 1a, and then answer these questions.

• How does a starting motor operate?
• What are the types of starting motor and their working drive

mechanism?

b. Read Information Sheet 1b before answering these questions.

• Do you know how a starting motor operates?
• What are the principles involved in a motor operation?

c. Read Information Sheet 1c before answering this question.

• How is each type of starter motor differs from each other?

d. Read Information Sheet 1d before answering these questions.

• How are starter motor drives differs from each other according to
operation?

• What distinct type is commonly used at present?

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INFORMATION SHEET # 1a: COMPONENTS AND FUNCTIONS OF THE
STARTING SYSTEM

Starting the engine is possibly the most important function of the vehicle's electrical
system. The starting system performs this function by changing electrical energy from
the battery to mechanical energy in the starting motor. This motor then transfers the
mechanical energy, through gears, to the flywheel on the engine's crankshaft. During
cranking, the flywheel rotates and the air-fuel mixture is drawn into the cylinders,
compressed, and ignited to start the engine. Most engines require a cranking speed
of about 200 rpm.

Starting Systems

Two different starting systems are used on vehicles. Both systems have two separate
electrical circuits ... a control circuit and a motor circuit. One has a conventional
starting motor.

1. Automotive Battery - is a device that converts chemical energy into electric
energy. It supplies electric current to the starter motor and to the ignition switch
when the engine is being cranked.

2. Starting Motor -
is a device that
converts electric
energy into
mechanical
energy. It is
designed to
produce a large
amount of torque
for a short period
of time. It operates
when the ignition
switch is turned to
the start position.
Its purpose is to
crank the engine
for starting.

3. Starter Cables - a cable wiring that carries direct current from the battery to the
starting motor.

4. Ignition Switch - a mechanical switch which connect and controls electrical
current from the battery to the starting motor.

5. Fusible Link - a safety device installed in a circuit that interrupts short-circuit and
maintains constant flow of voltage.

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INFORMATION SHEET 1b: STARTER MOTOR OPERATION

1. CONVENTIONAL STARTER MOTOR

IGNITION SWITCH IN “ST”

• Current flows from the battery through
terminal “50” to the hold-in and pull-in
coils. Then, from the pull-in coil, current
flows through terminal “C” to the field
coils and armature coils.

• Voltage drop across the pull-in coil limits
the current to the motor, keeping its
speed low.

• The solenoid plunger pulls the drive
lever to mesh the pinion gear with the
ring gear.

• The screw spline and low motor speed
help the gears mesh smoothly.

PINION AND RING GEARS ENGAGED

• When the gears are meshed, the
contact plate on the plunger turns on the
main switch by closing the connection
between terminals “30” and “C.”

• More current goes to the motor and it
rotates with greater torque (cranking
power).

• Current no longer flows in the pull-in
coil. The plunger is held in position by
the hold-in coil's magnetic force.

IGNITION SWITCH IN “ON”

• Current no longer flows to terminal “50,”
but the main switch remains closed to
allow current flow from terminal “C”
through the pull-in coil to the hold-in coil.

• The magnetic fields in the two coils
cancel each other, and the plunger is
pulled back by the return spring.

• The high current to the motor is cut off
and the pinion gear disengages from the
ring gear.

• A spring-loaded brake stops the
armature.

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2. GEAR-REDUCTION STARTER MOTOR

IGNITION SWITCH IN “ST”

• Current flows from the battery through
terminal "50" to the hold-in and pull-in
coils. Then, from the pull-in coil, current
flows through terminal "C" to the field
coils and armature coils.

• Voltage drop across the pull-in coil
limits the current to the motor, keeping
its speed low.

• The magnetic switch plunger pushes
the pinion gear to mesh with the ring
gear.

• The screw and low motor speed help
the gears mesh smoothly.

PINION AND RING GEARS ENGAGED

• When the gears are meshed, the
contact plate on the plunger turns on the
main switch by closing the connection
between terminals “30” and “C.”

• More current goes to the motor and it
rotates with greater torque.

• Current no longer flows in the puff-in
coil. The plunger is held in position by
the hold-in coil's magnetic force.

IGNITION SWITCH IN “ON”

• Current no longer flows to terminal “50,”
but the main switch remains closed to
allow current flow from terminal “C”
through the pull-in coil to the hold-in coil.

• The magnetic fields in the two coils
cancel each other, and the plunger is
pulled back by the return spring.

• The high current to the motor is cut off
and the pinion gear disengages from the
ring gear.

• The armature has less inertia than the
one in a conventional starter. Friction
stops it, so a brake is not needed.

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INFORMATION SHEET 1c: TYPES OF STARTER MOTOR

1. CONVENTIONAL STARTER MOTOR
2. GEAR-REDUCTION STARTER MOTOR
3. PLANETARY-TYPE STARTER

The starter motors used on Toyota vehicles have a magnetic switch that shifts a rotating
gear (pinion gear) into and out of mesh with the ring gear on the engine flywheel. Two
types of motors are used: conventional and gear reduction. Both are rated by power
output in kilowatts (KW) ... the greater the output, the greater the cranking power.

CONVENTIONAL STARTER MOTOR

The conventional starter motor contains the components shown, The pinion gear is on
the same shaft as the motor armature and rotates at the same speed. A plunger in the
magnetic switch (solenoid) is connected to a shift lever. When activated by the
plunger, the shift lever pushes the pinion gear and causes it to mesh with the flywheel
ring gear. When the engine starts, an over-running clutch disengages the pinion gear
to prevent engine torque from ruining the starting motor.

This type of starter was used on most 1975 and older Toyota vehicles. It is currently
used on certain Tercel models. Typical output ratings are 0.8, 0.9, and 1.0KW. In most
cases, replacement starters for these older motors are gear-reduction motors.

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GEAR-REDUCTION STARTER MOTOR

The gear-reduction starter motor contains the components shown. This type of starter
has a compact, high-speed motor end a set of reduction gears. While the motor is
smaller and weighs less than conventional starting motors, it operates at higher speed.
The reduction gears transfer this torque to the pinion gear at 1/4 to 1/3 the motor speed.
The pinion gear still rotates faster than the gear on a conventional starter and with much
greater torque (cranking power).

The reduction gear is mounted on the same shaft as the pinion gear. And, unlike in the
conventional starter, the magnetic switch plunger acts directly on the pinion gear (not
through a drive lever) to push the gear into mesh with the ring gear.

This type of starter was first used on the 1973 Corona MKII with the 4M, six cylinder
engine. It is now used on most 1975 and newer Toyotas. Ratings range from 0.8KW on
most Tercels and some older models to as high as 2.5KW on the diesel Corolla, Camry
and Truck, The cold-weather package calls for a 1.4KW or 1.6KW starter, while a 1.0KW
starter is common on other models.

The gear-reduction starter (shown below) is the replacement starter for most
conventional starters.

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PLANETARY-TYPE STARTER MOTOR

The planetary type starter uses a
planetary gear to reduce the rotational
speed of the armature, as with the
reduction type, and the pinion gear
meshes with the ring gear via a drive
lever, as with the conventional type.

1. Speed Reduction Mechanism

Reduction of the armature shaft's
speed is accomplished by three
planetary gears and 1 internal gear.

When the armature shaft turns, the
planetary gears turn in the opposite
direction, which attempts to cause the
internal gear to turn. However, since
the internal gear is fixed, the
planetary gears themselves are
forced to rotate inside the internal
gear.

Since the planetary gears are
mounted on the planetary gear shaft,
the rotation of the planetary gears causes the planetary gear shaft to turn also. The
gear ratio of the armature shaft gear to the planetary gears and internal gear is
11:15:43, which results in a reduction ratio of approximately 5, reducing the rotational
speed of the pinion gear to approximately 1/5 of its original speed.

2. Damping Device

The internal gear is normally fixed,
but if too much torque is applied to
the starter, the internal gear is
caused to rotate, allowing the excess
torque to escape and preventing
damage to the armature and other
parts. The internal gear is engaged
with a clutch plate and the clutch
plate is pushed by a spring washer. If
excess torque is brought to bear on
the internal gear, the clutch plate
overcomes the pushing force of the
spring washer and turns, causing the internal gear to rotate. In this way, the excess
torque is absorbed.

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INFORMATION SHEET 1d: CLASSIFICATION OF STARTER MOTOR
DRIVES

1. Armature Shift Type

Both pinion and armature are
shifted into mesh with ring gear.

2. Inertia Drive Type

The pinion is fitted to the
armature shaft on which helical
splines are machined. In this
type, as the pinion rotational
inertia produces the difference
of revolutions between pinion
and armature shaft, the pinion
is slided on the helical splines
into mesh with ring gear.

3. Chain Drive Type

This type of starter is employed
for motor cycles and small
engines. The reduction device
is built-in. Starter pinion drives
the engine crank-shaft by the
chain. An over-running clutch is
installed on engine crank-shaft.

4. Starter-generator type

This type starter is employed for
motorcycles and small engines.
The armature is directly
connected into engine crank-
shaft. This type starter operates
as a starter only when starting
the engine, and operates as a
generator after the engine has
started.

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5. Magnetic switch type

This type starter is widely
used in recent automobiles.
Only the pinion with over-
running clutch is shifted by
solenoid-operated drive lever,
into mesh with the ring gear.

6. Reduction type starter

This newly developed starter
includes high-speed compact
motor and reduction gears.
The required torque is
obtained by reducing the
motor speed to approximately
one third.

The plunger in the magnetic
switch pushes the pinion shaft
through the plunger shaft,
and the pinion engages with
the ring gear.

The transition concerning the
ratio of output-to-weight is
shown in the chart.

It can be found the reduction
type starter presents an
outstanding improvement with
respect to the ratio of output
to weight.

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ASSESSMENT TASKS:

These assessment tasks should be completed when you are confident that you can
identify starter motor components, types and classification. Assessment needs to
conform to the rules of evidence. Therefore:
• You will need to participate and complete the learning activities
• You will demonstrate tasks to the required standard

• You will answer oral and written questions
• You will complete the assessment tool

OBSERVATION CHECKLIST:

Self Component Trainer’s check
check
Competent Not yet
competent

System components and starter drive
properly identified.

Starter motor types and its operation properly
understood.

Utilized the service (repair) manual.

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Activity # 2: PREPARING REPAIR MANUAL AND VOM

SCALE READING OF ANALOG/DIGITAL VOLTMETER/AMMETER

Scale reading is very important in testing the starting system of automobile. The
problem can be identified using any of these instruments:

EQUIPMENT/INSTRUMENTS:

• Digital meter
• Analog meter
• Voltmeter
• Ammeter
• Ohmmeter
• Analog Multi meter

PARTS OF AN ANALOG TESTER

Ask your facilitator to provide you a working analog tester which you will use for this
activity. Observe the figure below and note the position of each part.

Note: The placement of parts on some testers may be different from the one shown
below, ask the facilitator to identify the equivalent parts.

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OPERATION SHEET # 2: MEASURING CURRENT, VOLTAGE AND
RESISTANCE

1. Turn the zero position adjuster so that the pointer may align right to the zero position.

2. Select a range proper for the item to be measured, set the range selector knob
accordingly.
NOTE: When determining a measuring range, select such one for higher voltage than
the value to be measured as well as where the pointer of a meter moves to a
considerable extent. However, select the maximum range and measure in case the
extent of value to be measured cannot be predicted.

MEASURING DCV (Direct Current Voltage)
1. Set the range selector knob to an appropriate DCV range.
2. Apply the black test pin to the minus potential of measured circuit and the red test pin

to the plus potential.
3. Read the move of the pointer to V and A scale.

(Refer to SCALE READINGS figure on page 17)

MEASURING ACV (Alternating Current Voltage)
1. Turn the range selector knob to an appropriate ACV range.
2. Apply the test leads to measured circuit.
3. Read the move of the pointer by V and A scale. (Use AC 10V scale for 10V range

only.)
• Since this instrument employs the mean value system for its AC voltage

measurement circuit, AC waveform other than sine wave may cause error.
• There occurs error under such frequencies other than specified in the

specification.

MEASURING DCA (Direct Current Amperes)
1. Turn the range selector knob to an appropriate DCA range.
2. Take out measured circuit and apply the black test pin to the minus potential of

measured circuit and the red test pin to the plus potential.
3. Read the move of the pointer by V and A scale.

MEASURING OHMS (Ω)

NOTE: Do not measure resistance in a circuit where a voltage is present.
1. Turn the range selector knob to an appropriate Ω range.

2. Short the red and black test pins and turn the ∞ adjustment so that the pointer may
align exactly to ∞. (If the pointer fails to swing up to ∞ even when the ∞ adjuster is

turned clockwise fully, replace the internal battery with a fresh one.)
3. Apply the test pin to measured resistance.
4. Read the move of the pointer to Ω scale.

Note: The polarity of + and - turns reverse to that of the test leads when
measurement is done in Ω range.

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Code No. Aug. 15, 2003 15

ALT723307

1. Loosen the screws fixing the rear case and remove it.
2. Take out the battery and replace it with new.
3. Put back the rear case and fix it with the screws.

Note: Be sure to use the same type of battery to replace the drained one.

MEASURING CAPACITOR (C)

1. Set the range selector knob to C(µF).
2. Measure the capacitance by applying the test pin to the capacitor to be measured

after ∞ adjustment made in the same manner as in the resistance measurement.

3. The pointer moves full scale by the charge current to the capacitor. However, the
pointer starts gradual returning from a certain point. Read the then indicated
maximum value on C(µF) scale.
Note: Be sure to short circuit both ends of the capacitor for discharge prior to the
initial measure after the measurement was once made.
Pay due attention to the polarity (+ and -) of the capacitor. (Connect + side of the
capacitor to - side of the tester.)

MEASURING AF OUTPUT (dB)

1. dB (decibel) is measured in the same way as ACV measurement reading the dB
scale instead. For measurement on the 10V range, the dB scale (-10dB - +22dB) is
read directly, but when measured on the 50V range, 14dB is added. On the 250V
range, 28dB is added.
Thus, the maximum dB readable is 22 + 40 = 62(dB) measured on the 1000V range.
Note: Cut direct current with a capacitor of 0.1µF or more when measuring such
signal as having direct current.

MEASURING OF ICEO (Leak Current) FOR TRANSISTOR

1. Adjust 0Ω by setting the range selector knob to a proper range
from X1~X1k.

2. For NPN transistor, apply a black test pin to the collector and
the black one to the emmiter.

3. Determine the leak current by ICEO scale indicated on the
scale plate. (Unit in µA, mA)

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MEASURING OF DIODE (Including LED)

1. Adjust 0Ω by setting the range selector knob to a
proper range from X1 (150mA)~ X100k (1.5µA).

2. Apply the black test pin to anode side and the red one
to cathode side when measuring IF (forward current).
Apply the black test pin to cathode side and the red
one to anode side when measuring IR (reverse
current).

3. Read the indicated value by LI scale. (The pointer
moves to a considerable extent for IF, and little extent for IR)

4. Value indicated on LV scale during the measurement is the forward voltage of diode.

Note: Additional information is available in the supplemented Learning Element entitled
"Measuring Electrical Voltage Using a Multimeter".

SCALE READINGS

Range Multiplied Range Multiplied
Ω X 100K X 100K DCV 10 X1
1 X1k X1k 4 DCV 1000 X100
X10 ACV 1000 X100
X10 X1 5 ACV 10 X1
X1 X1 6 C (µF) X1
DCV 250 X0.01 150mA at X1 X10 (mA)
DCV 2.5 X0.001 15mA at X10 X1 (mA)
DCV 0.25 X1 7 15µA at X1k X10 (µA)
2 ACV 250 X0.001 1.5µA at X100k X0.1 (µA)
DCA 0.25 X0.1 8 LV X1
DCA 25m X0.01 9 hFE X1
DCA 2.5m X1 ACV 10 X1
DCV 50 X1 ACV 50 14dB added
3 ACV 50 X1 10 ACV 250 28dB added
DCA 50µ X0.01 40dB added
4 DCV 0.1 ACV 1000

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SELF-CHECK:

Read the instructions carefully, be sure to answer the questions fully before going to the
next activity.

Reading an Analog Multimeter

1. In the analog multimeter shown above, the range switch is set to take DC voltage
readings. Assuming that four different voltage measurements were taken (switch
positions 1, 2, 3, and 4) and the needle moved to the same position for each
measurement, the voltage readings would be as follows:

Setting 1: 1.85 V
Setting 2: 7.4 V
Setting 3: 37 V
Setting 4: 185 V

• Explain the significance of needle (pointer) movement of the multimeter.

• How do you detect if the battery of the multimeter is defective?

• What are the parts of the analog multimeter?

• What does it measure?

2. Determine the correct reading for each indicated position (1, 2, 3, and 4) of the
analog multimeter below.

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3. Convert each of the following digital multimeter readings.

a. 340 mV to volts
b. 0.75 V to millivolts
c. 2 A to milliamps
d. 1950 mA to amps
e. 7.5 ohms to kilohms
f. 2.2 kilohms to oms
g. 1.5 Megohms to ohms

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ASSESSMENT TASKS:

These assessment tasks should be completed when you are confident that you can
read analog/digital multimeter properly. Assessment needs to conform to the rules of
evidence. Therefore:
• You will need to participate and complete the learning activities
• You will demonstrate tasks to the required standard

• You will answer oral and written questions (Self-Check)
• You will complete the assessment tool

OBSERVATION CHECKLIST:

Self Component Trainer’s check
check
Competent Not yet
competent

Types of analog/digital voltmeter/ammeter
properly identified.

Analog/digital voltmeter/ammeter operation
properly understood.

Digital multimeter readings converted to
equivalent values

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Optional Activity:

Ask your instructor/facilitator to provide you the Starter Repair Manual and a VOM
to start working on Activity 3.

Parts of the Volt-Ohm Milliammeter (VOM)

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ALT723307 Aug. 15, 2003 21

Activity # 3a: CONDUCTING STARTING SYSTEM COMPONENTS
FAILURE ANALYSIS

Starting problems can be classified into two broad categories:

• The engine cranks normally but fails to start.
• The cranking speed is too low to start the engine.

If the engine cranks normally but fails to start, the defect lies in the engine ignition,
fuel, or compression system. If the cranking speed is too low to start the engine, on
the other hand, the problem usually lies in the starting system though it could also lie
in the engine itself. At extremely low temperatures, for example, a much greater
torque is necessary to crank the engine because of higher oil viscosity.

In troubleshooting, careful observation of the conditions under which the trouble
arises will aid you greatly in accurately locating the source of the problem.

1. OUTLINE OF ON-VEHICLE INSPECTION

If it is thought that the cause of In the case of vehicles with a
the trouble is not in the engine, but in clutch start system (manual
the starting system, first check to see transmission), a clutch starter relay
whether normal voltage is being and clutch start switch are installed to
applied to the starter motor with the prevent starting if the clutch pedal is
starter motor mounted in the vehicle. not depressed.

Although the starter circuits
used on actual automobiles vary
in configuration from one model to
another, they may be roughly
broken down into two types: those
having a starter relay and those
without one. As the diagrams
illustrate, however, in both cases,
Terminal 30 always remains
connected to the battery while
Terminal 50 is connected only
when the ignition switch is in the
START position. The starter
circuit for automatic transmission
vehicles also has a neutral start
switch, which prevents the circuit
from closing, thus activating the
starter motor, unless the shift
lever is in the neutral (N) or park
(P) position.

Figure 1. Starting system circuit diagram

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Figure 2. Starting system circuit diagram with starter relay
*1 For automatic transmission vehicles
*2 For clutch start system

2. Turning the ignition switch to the START position causes the pinion gear to move
outward with a click, but the starter motor remains deactivated or does not speed
up.

The problem in this case probably lies in the starter motor, the engine itself, or in
the electrical system up to terminal 30.

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a. Check the engine rotational resistance. Check to see if unusually large torque
is required to crank the engine by rotating the crankshaft manually using a
box-end wrench, etc.

b. Measure the battery terminal voltage. When the ignition switch is in the START
position, the terminal voltage should be 9.6 V or higher.
If the measured value falls below this level, recharge or replace the battery.
Check for stains or corrosion on the battery terminals as well.

c. Measure the voltage between Terminal 30 of the starter motor and ground.
When the ignition switch is in the START position, the voltage should be 8 V or
higher. If the measured value falls below this level, check the starter cable
between the battery and Terminal 30 and repair or replace it if necessary.

d. Before disassembling the starter motor, roughly pinpoint the source of the
problem so that the job may proceed more smoothly. (In this case, the trouble
may originate with poor main switch contact, excessively large electrical
resistance between the brushes and the commutator, slipping of the starter
clutch, etc.)

ON-VEHICLE INSPECTION

• Make sure to put the shift lever in either the neutral (N) or the park (P)
position when checking an automatic transmission vehicle.

• In the case of vehicles with a clutch start system, check with the clutch
pedal depressed.

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CHECK BATTERY TERMINAL VOLTAGE

1. Turn the ignition switch to the START position and measure the voltage at the
battery terminals.

Standard 9.6 V or higher

2. Replace the battery if the voltage is lower than 9.6 V.

IMPORTANT:
• If the starter does not operate, or if

it turns slowly, be sure to check first
to see whether the battery is normal
or not.

• Even if the measured terminal
voltage is at the normal level,
stained or corroded terminals may
cause poor starting due to
increased resistance, leading to a
decrease in the voltage when the
ignition switch is turned to START
position.

CHECK TERMINAL 30 VOLTAGE

1. Turn the ignition switch to the START
position and measure the voltage
between starter terminal 30 and the
body.

Standard: 8.0 V or higher

2. Check the starter cable and repair or
replace it if necessary if the voltage is
lower than 8.0 V.

IMPORTANT!
Since the location and appearance of
Terminal 30 may differ depending on
the type of starter motor, make sure of
these by checking the repair manual.

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CHECK TERMINAL 50 VOLTAGE

1. Turn the ignition switch to START and
measure the voltage between starter
terminal 50 and the body.

Standard: 8.0 V or higher

2. If the voltage is lower than 8.0 V,
check the fusible link, ignition switch,
neutral start switch, starter relay clutch
starter switch, etc., one at a time,
referring to the wiring diagram. Repair
or replace any parts which are faulty.

IMPORTANT:

Since the location and appearance of
terminal 50 may differ depending on
the type of starter motor, make sure of
these by checking the repair manual.

CLUTCH STARTER RELAY

If the clutch start system is abnormal,
carry out the following checks and
adjustments.

INSPECTION OF STARTER RELAY

1. INSPECT CLUTCH STARTER
RELAY

NOTE: The relay is located in the No. 1
junction block in the left cowl side.

Inspect Relay Continuity

a) Using an ohmmeter, check that there
is continuity between terminals 1 and
3.

b) Check that there is no continuity
between terminals 2 and 4.

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If continuity is not as specified, replace
the relay.

Inspect Relay Operation

a) Apply battery voltage across
terminals 1 and 3.

b) Check that there is continuity
between terminals 2 and 4.

If operation is not as specified, replace the relay.

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OPERATION SHEET # 3a - PERFORM STARTER MOTOR TESTS

IMPORTANT:
• Before beginning to disassemble the starter motor first roughly pinpoint 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.
• The test procedures for the conventional and reduction type starter motors are
essentially the same. This section, therefore, discusses the conventional type only.
• Complete each test as quickly as possible (within approximately 3-5 seconds).
Otherwise, the coil in the starter motor may burnout.

1. PULL-IN TEST
(a) Disconnect the field coil lead
from Terminal C.
(b) Connect the battery to the
magnetic switch as shown.
Check that the pinion moves
outward.
If the pinion gear does not move
outward, check for damage to the
pub-in coil, sticking of the plunger,
and other possible causes.

2. HOLD-IN TEST
With the battery connected as above
and with the pinion out, disconnect
the negative lead from Terminal C.
Check that the pinion remains out. If
the pinion gear retracts, check for
damage to the hold-in coil, improper
grounding of the hold-in coil, and
other possible causes.

3. PINION RETURN TEST
Disconnect the negative lead from
the switch body. Check that the
pinion retracts. If the pinion gear
does not immediately retract, check
for fatigue of the return spring,
sticking of the plunger, and other
possible causes.

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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
the pinion end and stop collar.

Standard clearance: 0.1 - 0.4 mm
(0.004 -- 0.016 in.)

5. NO-LOAD TEST
(a) Securely fix the starter motor with
a vise, etc.
(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 11 V

IMPORTANT!
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 50. (This is necessary only for the conventional type
starter motor.) If the motor does not stop immediately, the armature brake is
defective.

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INFORMATION SHEET 3b: USING THE VERNIER CALIPER

The Vernier caliper is a precision measuring instrument. It is used to measure internal
and external dimensions to an accuracy of 0.02mm (0.001"). Vernier calipers are
available in different sizes but the most common are the 150mm (6 inch) and 300mm (12
inch) calipers. The measuring range of these instruments can be up to 50mm (2") less
than the quoted size.

Parts of the Vernier Caliper

Clamping

The adjustable jaw of the Vernier caliper is locked in position by tightening the
clamping screw. The facility to lock the adjustable jaw is also of particular advantage
when a dimension has been gauged and removal of the Vernier caliper from the
workpiece may cause a movement of the adjustable jaw.

If the Vernier caliper is to be used as a fixed gauge, the caliper is pre-adjusted to the
specified dimension and locked into position.

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Always ensure that the clamping screws are released before attempting to move the
adjustable jaw.

Example 1, Measuring external dimensions on a small component.
The workpiece should be deburred and the Vernier caliper clamping screws unlocked.

1. Hold the Vernier caliper in the right hand as shown. Ensure that the clamping screws
are slack.

2. Slide the adjustable jaw away from the fixed jaw until the component slides in
between the jaws.

3. Slide the adjustable jaw towards the fixed jaw until the component is in contact with
the two jaws.

4. Lock the fine adjustment
clamp with the left hand.

Note: It may be necessary to rest the
component on the workbench to avoid
removing it from the jaws.

5. Move and rock the Vernier caliper while adjusting
the adjustable jaw against the component to find
the minimum dimension and to ensure that the
jaws are square to the component.

6. Lock the main clamping screw.

7. Check the 'feel' of the jaws against the component for
squareness.

8. Read the Vernier caliper.

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Example 2, Measuring internal dimension on a large component.
The workpiece should be deburred and the Vernier caliper clamping screws unlocked.

1. Hold the Vernier caliper in both hands as
shown. Ensure that the clamping screws are
slack.

2. Slide the adjustable jaw towards the fixed jaw until
the jaws slide in between the two faces to be
measured.

3. Hold fixed jaw firmly against the inside face.

4. Slide the adjustable jaw outwards towards the other
face.

5. Lock the fine adjustment clamp.

6. Rock the adjustable jaw against the component whilst adjusting the
adjustable jaw until the ,jaw passes against the component with a slight drag.

7. Lock the main clamping screw.

8. Check the feel of the jaws against the component.

9. Read the Vernier caliper.

10. Add the combined thickness of the nibs to the reading.

Note: When first using the instrument check the combined thickness of the nibs with
a micrometer.

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Reading the Vernier Caliper Scale (metric)

Note: Workings for the example
A magnifying glass is a useful aid for reading the shown
scales on a Vernier caliper accurately.
3 cm= 30.00 mrn
1. Determine the number of whole centimeters to the
left of the zero on the Vernier scale.

2. Determine the number of whole millimeters 9 mm = 9.0 mm
between the last whole figure obtained in (1) and
the zero on the Vernier scale.

3. Determine whether a 0.5 millimeter is between the Yes = 0.50 mm
last whole millimeter obtained in (2) and the zero

on the Vernier scale.

4. Find the line on the Vernier scale that lines up 6 .12mm
with a line on the main scale. 6 x .02 =

(a) If the Vernier scale has 25 divisions: multiply
the number by .02

(b) If the Vernier scale has 50 divisions: multiply
the number by .01.

TOTAL 39.62 mm

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Activity No. 3b: MEASURING CURRENT, VOLTAGE, RESISTANCE IN
SERIES, PARALLEL AND COMBINED SERIES-
PARALLEL

EQUIPMENT / RESOURCES:

• Voltmeter
• Ammeter
• Circuit board
• Battery (12 V)
• Conducting wire with alligator clip
• 3 bulbs (2Ω, 4Ω & 6Ω)

At the end of these learning activities you should be able to measure current, voltage,
and resistance of electrical circuits.

1. Using the given
equipment/materials connect
the three bulbs in series.
(Refer to the diagram 1).

Diagram 1. Series Circuit

When the switch is closed what is the:

a) Total resistance of the circuit;
b) Current across each resistor and;
c) Voltage across each resistor;
d) Relationship between current voltage and resistance;

Data

Resistance (Ω) Voltage Current
(V) (A)
a.
b.
c.
d.

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2. Using the same equipment, Diagram 2. Parallel Circuit
connect the 3 bulbs in parallel
and make the same
measurements.

3. Now connect the bulb in
series-parallel and repeat the
measurement.

Diagram 3. Series-Parallel Circuit

ASSESSMENT: (APPLICATION)
1. The courtesy light or dome light in a car is rated at 2.0 candle-power. Using a
12-volt car system, determine the current and resistance of the lamp.
2. Calculate the current and the resistance in a starter motor rated at 700 candle-
power and 12 volts.

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Activity No. 3c: FILLING-UP JOB-ORDER FORM

Indicating the proper data may help you as a technician to get additional information
about repairing a starting system. It is a must to get the following information.

Fill-up the needed data in the following form.

Customer’s Name: Date: Car No.
Street Address:
City Technician Name:
Fax/Cell/Tel no.:
Vehicle Identification Supervisor’s Name:
Number:
Engine Year: Make: Model:
License
Color Mileage:

Technician Findings & Recommendations:

____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________

Date Accepted: ________________ Action Taken: ___________________________
Date Released: ________________ Signature of Technician: ___________________

Checked by:

________________________
Supervisor’s Signature

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ASSESSMENT:
Without looking back at the previous page, try to answer the following questions.
1. What are the data found in the job-order form?
2. Why is it very important for you as technician to fill-up this form?
3. Who is responsible for checking this job order form?
4. Why are your findings/recommendations important?

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Activity No. 3d: ROLE PLAY

Everyday we follow and give instructions. Instructions are given orally and in written
form. If the instructions are accurate and specific you can easily follow them.

1. Assuming that you are already a technician. Get a partner and act-out a situation; one
will act as the supervisor giving instructions to a technician in repairing a starting
motor.

2. Let each group write their dialogue, first, then call one group to represent while others
listen while answering the following questions:

• What were the instructions given to the technician to follow?

• Why did the technician follow the instructions easily?

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ASSESSMENT TASKS:

These assessment tasks should be completed when you are confident that you can
conduct starting system components failure analysis properly. Assessment needs to
conform to the rules of evidence. Therefore:
• You will need to participate and complete the learning activities
• You will demonstrate tasks to the required standard

• You will answer oral and written questions
• You will complete the assessment tool

OBSERVATION CHECKLIST:

Self Component Trainer’s check
check
Competent Not yet
competent

Starting problems identified and methods of
inspection properly understood.

Starting components properly checked.

Procedures in starter motor testing properly
understood and performed

Measurement of values using VOM correctly
performed and recorded

Job-order form properly filled-up

Participated in role play

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LEARNING EXPERIENCES

Learning Outcome # 2 : DISASSEMBLE STARTER MOTOR

Learning Activities Special Instructions

2. Prepare tools, area and • Read instructions in Activity #1
tester/equipment needed
• Study and perform Activity #2a
2a. Pull-out the starter motor • Study and perform Activity #2b

2b. Using floor jack and stands • Study and perform Activity #3a
3a. Disassemble the starter motor
• Identify parts of the starter by writing
3b. Parts and function of starter motor the numbered parts on the space
provided.

4. Perform starter motor • Perform Activity #4
inspection/measurement and record
reading

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LO2 - DISASSEMBLE STARTER MOTOR

LEARNING OUTCOME 2:

At the end of these learning activities you should be able to:
- prepare tools, area and tester/equipment needed;
- pull-out starter motor;
- disassemble a starter motor; and
- perform starter motor inspection/measurement and record readings

EQUIPMENT AND MATERIALS:

• Caliper/Outside micrometer
• Growler
• VOM
• Dial gauge with magnetic stand
• V-block
• Surface plate
• Spring scale

LEARNING ACTIVITIES:

Activity No. 1 - PREPARE TOOLS, AREA AND TESTER/EQUIPMENT
NEEDED

1. For your safety, read Information Sheet on "Safety Precautions and Care in Using
Hand tools, Machines and Portable Electric Power Tools"

2. Also read the Learning Element on "Measuring Electrical Voltage Using a Multimeter"

Do the assignments at the end of the learning element.
Check your performance using the progress check.

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Activity No. 2a - PULL-OUT THE STARTER MOTOR

1. Review Learning Outcome 1, Learning Activity 1. Study the illustration to be familiar
with the location of the starter motor.

After taking a series of tests on starting motor and all the test conducted indicates
the starter motor must be removed, how would you perform pulling-out starter motor
from the system? What precautionary safety measures would you observe in
performing the task?

2. Prepare the necessary tools/equipment needed. There are two ways of pulling-out a
starter from the vehicle. Select from the available facilities in your workshop.
a. Using a lift (steps 3-12)
b. Using a floor jack and stands (refer to activity #2b on page 41)

3. Set the vehicle on a hoist lift.

4. Raise hoist lift for proper pad-to-frame contact.

5. Raise vehicle a few inches above the ground

Note: Shake vehicle while observing for signs of any movement if there are any
unusual noises or movement of the vehicle, lower it down and reset the pads, then
follow step #4.

6. Disconnect negative cable clamp of the battery.

7. Disconnect positive cable and lead wire from the magnetic switch terminal.

8. Raise vehicle at the desired height and lock the hoist.

Caution: Do not get under the vehicle until the hoist lock has been set.

9. Loosen the starter mounting bolts and remove all but one.

Caution: The starter motor is heavy, make sure it is secured and supported before
removing the last bolt.

10. Support the starter motor and remove the remaining bolt.

11. Remove the starter motor.

12. Release the hoist lock and lower the vehicle.

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Activity No. 2b - USING FLOOR JACK AND STANDS

Have you checked the condition of the floor jack? Does it have sufficient rating to lift and
sustain the weight of the vehicle. Have you inspected for proper lubrication and hydraulic
fluid level? What course of action will you do if the jack does not pass any one of these
inspections? What is your recommendation?

1. Prepare the necessary tools/equipment needed.

2. Move the vehicle to a flat and level ground.

3. Shift the vehicle's transmission to
NEUTRAL for an automatic feed
transmission. Shift the
transmission to first gear on
vehicle with manual transmission.

4. Set the parking brake.

5. Place wheel blocks
around the rear
wheels.

6. Position the floor jack under the
front of the vehicle at a location
strong enough to support the
weight.

Note: The jack should be
centered between the front tires
and positioned so that the lift will
be straight up and down.

Caution: (Do not lift the front-
two-wheels of the vehicle too
high that it can slip off of the jack
saddle.)

7. Operate the jack until the jack
saddle contacts the lift points.

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Note: (Check for good contact if things look good, lift the front of the vehicle a couple
of inches off the floor. Recheck the position of the jack.)

8. Disconnect the negative cable clamp of the battery.

9. Disconnect positive lead wire from the magnetic
switch upper terminal.

10. Raise the vehicle to the required height.

11. Place two safety stands under the vehicle in a
location that will support the weight.

12. Slowly lower the vehicle onto the stands.

Caution: (Make sure the safety stands are located where they will not lean or slip).

13. Get beneath the vehicle using a creeper and locate the starter motor.

14. Loosen the starter mounting bolts and remove all but one.

Caution: (The starter motor is heavy, make sure it is secured before removing the
last bolt).

15. Support the starter motor and remove the remaining bolt.

16. Pull-out the starter motor.

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Activity No. 3a - DISASSEMBLE STARTER MOTOR
CONVENTIONAL STARTER MOTOR

Components of a Conventional Type Starter Motor

Procedure:

1. Prepare the necessary tools needed.

2. Disconnect the lead wire from the magnetic
switch lower terminal.

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3. Loosen two screws , unhook the moving stud
from the drive lever by tilting the switch end
as shown and pull out the magnetic switch.

4. Remove the end frame cover, armature shaft
lock plate, brake spring and rubber ring.

5. Separate the commutator end frame from
the yoke by removing two through bolts.

6. Take off the brushes and pull out the brush
holder from the armature shaft.

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7. Separate the yoke from the drive housing

8. Remove the drive lever set bolt, then take off
the rubber and plate from the drive housing.
Pull out the armature with overrunning clutch
and drive lever.

9. Tap in the stop collar, using a socket
wrench. Then take off the pinion after
removing snap ring.

10. Remove the snap ring, using a snap ring
expander.

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