Test Project Automobile Technology

Task B - Electrical System

TP33_ RSC 2017_25%

Submitted by: All Coaches/Experts

Member Region: NCR

TP33_ RSC 2016_pre_NCR

 Skill 33 - Automobile Technology

COMPETITOR INSTRUCTIONS

Competitor Country
Task
Name Code
B

Competitor Instructions

Task Electrical Systems

Familiarization Time 15 minutes

Task Duration 3 hours
Break 15 minutes

Marking Summary

Possible
Section
Mark
1 Preparation, Safety, and Housekeeping 3.00

2 Body Electrical, Lighting System 6.00

3 Body Electrical, Signaling System 6.00

4 Starting system 5.00

5 Charging system 5.00

Total 25.00

You are required to

- Observe occupational health & safety standards
- Only ask necessary questions
- Not speak to the public while competition
- Comply with Experts instructions
- Ensure Competitor Number on all forms
- Use appropriate tools and procedures
- Complete all instructions on the next page

Remark: Vehicle/Model: Toyota 1994-97 Model Year /

Body and Engine Electrical Simulator

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 Skill 33 - Automobile Technology

Competitor Instructions - Automobile Technology

Competitor Country
Task
Name Code

Install lighting system circuit

1.
Such as: Park light, tail light, instrument panel light, and license plate light.
NOTE: Lighting system is “NOT CONTROLLED” by ignition switch.

Install signaling system circuit

Such as: Brake light, reverse light, horn, turn signal, and hazard light
2.
NOTE: Signaling system is “CONTROLLED” by ignition switch except hazard
light”

Perform starter motor performance test before disassembly

Install starting system circuit controlled by starter relay
Disassemble starter motor as per manual
3. Perform starter motor component inspection as per manual
Assemble starter motor as per manual
For repairs refer to the expert
Fill in report form

Perform alternator performance test before disassembly

Install charging system circuit
Disassemble alternator motor as per manual
4. Perform alternator component inspection as per manual
Assemble alternator as per manual
For repairs refer to the expert
Fill in report form

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 Skill 33 - Automobile Technology

COMPETITOR - REPORT SHEET

Competitor Country
Task
Name Code

Report Sheet

STARTING SYSTEM

Did the starting operate normally? [ ] yes [ ] no

Fault(s) found:

Rectify:

STARTER PERFORMANCE TEST

Specification Actual Serviceable Unserviceable

Description

1. Pull-in test

2. Hold-in test

3. Clutch pinion return

test

STARTER INSPECTION
Specification Actual Serviceable Unserviceable
Description

1. Commutator for open

circuit

2. Commutator for ground

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 Skill 33 - Automobile Technology

Competitor Country
Task
Name Code

Report Sheet

STARTER INSPECTION
Specification Actual Serviceable Unserviceable
Description

1. Commutator diameter

2. Field coil for open

circuit

3. Field coil for ground

4. Brush length

5. Brush holder insulation

6. Starter clutch

7. Pull-in coil

8. Hold-in coil

9. Planet carrier shaft

diameter

CHARGING SYSTEM

CHARGING SYSTEM PERFORMANCE TEST

1. Did the charging operate normally? [ ] yes [ ] no

Alternator output :_____________ Volts ( with load )

Alternator output :_____________ Volts ( without load )

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 Skill 33 - Automobile Technology

Competitor Country
Task
Name Code

Report Sheet

CHARGING SYSTEM

ALTERNATOR INSPECTION
Specification Actual Serviceable Unserviceable
Description

1. Inspect rotor for open

circuit

2. Inspect rotor for ground

3. Measure slip ring diameter

4. Inspect stator for open

circuit

5. Inspect stator for ground

6. Measure exposed brush

length

7. Inspect positive rectifier

8. Inspect negative rectifier

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 Skill 33 - Automobile Technology

FORM 5 – MARKING SUMMARY FORM

Competitor Country Marking Scheme

Task
Name Code

B Electrical Systems

Marking Summary

Possible Actual
Section
Mark Mark

1 Preparation, Safety, and Housekeeping 3.00

2 Lighting System 6.00

3 Signaling System 6.00

4 Starting system 5.00

5 Charging system 5.00

Total 25.00

Time Keeping

Familiarization Competition Breaks

Start Start Start

Stop Stop Stop

Experts Signatures

1 2 3 4

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 Skill 33 - Automobile Technology

Competitor Country Marking Scheme

Task
Name Code
B Electrical Systems

MARKING FORM

Preparation, Safety, and

1. Yes No Actual Comments
Housekeeping
1.01 Select the correct common tools 0.40 0
1.02 Check all instructions 0.40 0
1.03 Use workshop manual correctly 0.40 0
1.04 Apply logical working procedure 0.60 0
1.05 Calibrate Multimeter 0.40 0
1.06 Clean up the working area 0.40 0
1.07 Clean up tools and equipment 0.40 0

Sub Total 3.00 0

2. Body Electrical, Lighting System Yes No Actual Comments

2.01 Head light hi-beam properly installed 0.70 0 Report condition

2.02 Head light lo-beam properly installed 0.70 0

2.03 Passing light properly installed 0.60 0
2.04 Check head light relay operation 0.50 0
2.05 Park and tail lights properly installed 0.70 0
2.06 Check park/tail relay operation 0.60 0
2.07 License plate properly installed 0.50 0
2.08 Park and tail lights controlled by relay 0.60 0
2.09 Head lights controlled by relay 0.60 0
2.10 Lighting system not controlled by ignition
0.50 0
switch

Sub Total 6.00 0

Body Electrical Signaling System

3. Yes No Actual Comments
Installation
3.01 Brake light properly installed 0.80 0 Report condition

3.02 Reverse light properly installed 0.80 0

3.03 Horn properly installed 0.80 0

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 Skill 33 - Automobile Technology

Competitor Country Marking Scheme

Task
Name Code

B Electrical Systems

MARKING FORM

3. Signaling System Installation Yes No Actual Comments

3.04 Horn is controlled by relay 0.70 0
3.05 Turn signal properly installed 0.80 0
3.06 Turn signal is controlled by ignition switch 0.70 0
3.07 Hazard light properly installed 0.80 0
3.08 Hazard is not controlled by ignition switch 0.60 0

Sub Total 6.00 0

4. Starting System Yes No Actual Comments

4.01 Perform starter motor function (no load test) 0.70 0 Report condition

4.02 Perform pull-in test 0.30 0

4.03 Perform hold-in test 0.30 0
4.04 Perform pinion drive return test 0.30 0
4.05 Disassemble starter motor 0.40 0
4.06 Check armature for open circuit 0.40 0
4.07 Check armature for short circuit 0.40 0
4.08 Check armature for grounded 0.40 0
4.09 Check field coil for open 0.40 0

4.10 Check field coil for grounded 0.40 0

4.11 Check overrunning clutch condition 0.30 0
4.12 Assemble starter motor 0.70 0

Sub Total 5.00 0

Charging System Yes No Actual Comments

5.
5.01 Check function of charging system 0.50 0 Report condition

5.02 Dismantle altenator Assembly 0.40 0

5.03 Check Positive Diodes condition 0.40 0

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 Skill 33 - Automobile Technology

Competitor Country Marking Scheme

Task
Name Code

B Electrical Systems

MARKING FORM

5. Charging System Yes No Actual Comments

Check Continuity between Slip Rings to Rotor
5.04 0.40 0
Body
Check Rotor Body and both Bearings Physical
5.05 0.30 0
Condition
5.06 Check Resistance of Rotor Winding 0.30 0
5.07 CheckCarbon Brushes condition 0.40 0
5.08 Check Continuity of all Stator Coils 0.30 0
5.09 Check negative Diodes condition 0.40 0

5.10 Check alternator output voltage 0.60 0

5.11 Assemble alternator 0.70 0
5.12 Calibrate measuring instruments 0.30 0

Sub Total 5.00 0

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