Automechanics

Fourth Year
Module 4
Working Together

What this module is about

This module includes four systems namely: charging, ignition, lighting and horn systems. They have
different functions in vehicle operation. You will know more about the operation of the different systems by
trying out all the activities in this module. Consult your teacher if there are some doubts in interpretations.
Bring your portfolio to recheck answers with your teacher.

This module aims to do the following:

1. Discuss the purpose and functions of the charging system.

2. Explain the types of charging systems.
3. Identify the parts included in the charging system.
4. Discuss the troubles of a charging system and the corresponding remedies.
5. Identify the parts of the ignition system.
6. Explain the purpose and functions of the ignition system.
7. Discuss the two circuits of the ignition system and identify their parts.
8. Describe the wiring installation of the ignition system.
9. Explain the construction of the spark plug.
10. Discuss the function of the spark plug.

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PRETEST
Directions: Select the letter of the best answer to each question. Write your answer on your answer sheet.

1. It is a device that converts chemical energy to electrical energy.

a. armature
b. commutator
c. battery
d. generator

2. A device that maintains battery charge.

a. alternator
b. voltage regulator
c. ammeter
d. commutator

3. Produces alternating currents and supplies the current to the battery.

a. commutator
b. alternator
c. ammeter
d. battery

4. The alternator fails to charge and the possible causes are:

a. loose or slipping belt
b. defective regulator
c. worn-out fuse box
d. all of the above

5. A trouble in the charging system causing noisy generator.

a. grounded field coil
b. current regulator setting too high
c. faulty regulator assembly
d. dragging armature

6. A device that ignites air fuel mixture inside the combustion chamber.
a. electrode
b. diode
c. spark plug
d. ammeter

7. A device that absorbs excess current supplied by the ignition coil.

a. diode
b. condenser
c. spark plug
d. contact point

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8. It provides a larger dwell period to induce the saturation of the coil.
a. contact point
b. condenser
c. diode
d. ammeter

9. It is a device that multiplies current and supplies this to the gap of the spark plug.
a. condenser
b. contact point
c. ignition coil
d. diode

10. A kind of circuit operated through an air compressor to produce sounds.

a. air horn circuit
b. horn relay
c. horn switch
d. electric horn circuit

Lesson 1
The Charging System

The purpose and function of the charging system is to supply current to all of the lighting devices in the
vehicle. Below are the different devices and parts which constitute the charging system.

1. Alternator
It is a device that produces alternating current and supplies this to the battery.

Starting
Motor
Solenoid
(Relay)

Battery

Alternator Ignition Charge

Switch Indicator Light

Alternator Assembly

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 2. Voltage Regulator
It is a device that maintains constant voltage and a fully charged battery.

Cutout Current Voltage

Battery Relay Regulator Regulator

Shunt Winding

Series Winding
Shunt Winding
Generator
Field
Battery
Generator
Ammeter
Resistance

Voltage Regulator

3. Ammeter
This is a device that indicates the flow of current from the alternator to the battery.

Pointer

Permanent Magnet
Terminal

Pivot

Terminal Armature
Conductor
Permanent Magnet
Armature

Ammeter Gauge

Types of Charging Systems

There are two types of charging systems namely: direct current and alternating current.

1. Generator
Winding is parallel to the armature that produces direct current. This type of charging
equipment has been replaced today by the alternator due to traffic increase which requires the
engine to run at idle speed often.

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 d - df
bearing plate armature

commutator

carbon brush
casing
pole shoe

Generator Assembly

2. Alternators
These are widely used today in automobile because of the current needed through the carbon
brushes, and they require a good charging rate to the battery.

three-phase winding
stator
diode
claw-pole magnet
frame (rotor)

slipping
fan

ring winding

Alternator Assembly

3. Battery
It is a device that converts chemical energy to electrical energy.

Positive Plate

Separator

Negative Plate

6
 Volt bat

12 Volt Battery

Activity 1

1. Dismantle the alternator assembly.

2. Replace the carbon brush and bushing.
3. Place a small amount of grease on the newly installed bushing.
4. Clean all the parts of the alternator assembly.
5. Check the alternator before installing the engine.

Activity 2

1. Dismantle the terminal from the battery to the alternator.

2. Disconnect the terminal of the voltage regulator and check the clearance of the cutout relay connection.
3. Rub with sandpaper to remove the ridges in the contact of a cutout relay.
4. Tighten the nut of the ammeter gauge.
5. Check the terminal of the ammeter gauge.
6. Draw and label the ammeter gauge.

Activity 3

1. Check the level of the battery solution.

2. Remove the dirts in the negative and positive terminals.
3. Check the positive terminal connected to the starter and remove the ridges.

Self-check:

I.
1. Did you dismantle an alternator assembly?
2. Did you replace a carbon brush and bushing of an alternator?
3. Did you notice a new bushing with grease as lubricant?
4. Did you clean the parts of the alternator before you installed it in the engine?
5. Did you check the alternator if the connection is properly installed?

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6. Did you adjust the voltage regulator assembly for better charging performance?
7. Did you inspect the positive and negative terminals of the ammeter gauge?

II.
1. Did you experience dismantling the terminal of the battery to the alternator?
2. Did you check the terminal of the voltage regulator? The clearance of the cutout relay?
3. Is there any contact after removing the ridges on the cutout relay?
4. Did you tighten the nut of the ammeter gauge?
5. Did you check the terminal of the ammeter gauge?
6. Did you draw and label the parts of the ammeter gauge?

III.
1. Did you check the level of the battery solution?
2. Did you remove the dirt in the negative and positive terminal?
3. Did you check the positive terminal connected to the starter?

Lesson 2
Troubles in the Charging System, Causes and Remedies

1. The alternator or generator fails to charge

Causes Possible Remedies

a. Loose, broken or slipping belt a. Tighten or replace fan belt.

b. Loose connection and poor wiring b. Clean and tighten
and brush contact all connections.
c. Defective regulator c. Replace the regulator.
d. Worn-out fuse box d. Replace the fuse box.

2. Charging rate too high or not steady

Causes Possible Remedies

a. High current resistance a. Locate resistance, clean tighten or

replace the wire and connections.
b. Too high current regulator setting b. Replace the unit.
c. Grounded field coil c. Check or correct the grounds.

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3. Excessive rate of charge

Causes Possible Remedies

a. High circuit resistance a. Tighten the connections and check resistance.

b. Faulty regulator assembly b. Replace the regulator assembly.

4. Noisy generator (DC)

Causes Possible Remedies

a. Dragging armature a. Replace the bearing/armature.

b. Dry bearing b. Lubricate the bearing.
c. Defective bearing c. Replace the bearing.
d. Belt slipping d. Tighten the belt.

5. Regulator points oxidized, pitted or burned

Causes Possible Remedies

a. Incorrect regulator a. Replace the regulator and connect properly.

b. Shorted field winding b. Replace the generator.
c. Shorted condenser c. Replace the condenser.
d. Air gap is incorrect d. Adjust air correctly.
e. Point gap is incorrect e. Adjust point gap correctly.

6. Undercharged Battery

Causes Possible Remedies

a. No charge or low battery rate a. Adjust the charging rate.

b. Excessive use of the starter b. Time the engine for fast starting.
c. Defective battery c. Replace the battery.
d. Excessive resistor in charging circuit d. Test and check resistance.

7. Overcharged Battery

Causes Possible Remedies

a. Excessive resistance in the voltage a. Clean and tighten connections.

regulator circuit
b. Defective regulator b. Repair and replace the regulator.
c. Defective battery c. Recharge or replace the battery.

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8. Excessive use of battery water or electrolytes

Causes Possible Remedies

a. Battery cranked-case housing defective a. Replace battery housing.

b. Voltage regulator setting too high b. Lower the voltage setting.
c. Loose battery sealing compound c. Reseal the battery sealing compound.

Activity 4

1. Check the carbon brush of the alternator assembly.

2. Check the troubles of the generator assembly.
3. Check the ground connection of the battery.
4. Check the fan belt of the alternator.

Self-check:

1. Did you check the carbon brush of the alternator assembly?

2. Did you check the troubles of the generator assembly?
3. Did you check the ground connection of the battery?
4. Did you check the fan belt of the alternator and the generator?

Lesson 3
The Parts and Function of the Ignition System

The ignition system consists of the primary or low voltage circuit and the high voltage circuit. The
function of the ignition system is to ignite the fuel mixture inside the cylinder.

1. The Ignition Coil

It is a step-up transformer that multiplies current from 20,000 to 30,000 such that the current
will jump to the gap of the spark plug.

distributor cap

distributor spark plug

12 - volt battery

ignition coil

The Ignition Coil

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2. Distributor
The breaker points are supported by the breaker plate which is positioned to enable the cam
to open the point. The function is to open and close the breaker points through the action of the
cam.

breaker plate
assembly

cam

breaker points

The Distributor

3. Condenser
It has the capacity to store electrical energy and absorb excess current supplied by the ignition
coil.

The Condenser

4. Spark Plug
This is a device inserted into the combustion chamber of an engine containing an insulated
center electrode for conducting high tension current from the ignition distributor.

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 creepage current barriers

terminal pin
insulator

spark plug body

fused glass

sealing ring
sealing ring
thread base of insulator
center electrode
earth electrode

The Spark Plug Assembly

5. Breaker Point (contact point)

It provides a longer dwell period to induce the saturation of the coil.

condenser

contact point

Breaker Point Installation

The two circuits of the ignition system are the electrical ignition circuit and the electronics ignition
circuit.

1. Electrical Ignition Circuit

This is connected to a negative grounded battery, the “AM” terminal of the ignition switch
which is connected to the positive terminal.

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 battery battery

ignition switch
high-voltage
ignition switch
primary winding cable
ignition rotor
laminations coil
primary winding ignition coil
spark
coil wire plug
secondary
distributor distributor cam
winding
condenser
distributor rotor points
cap
wiring
plugs coil

battery ignition
switch
cable starting
solenoid motor

2. The Electronic Ignition Circuit

It uses transistors and other semiconductor devices as an electric switch to turn the primary
current on and off.

primary winding distributor

ignition
battery ignition
switch
coil contact
points
Contact Point Ignition System
Primary Circuit

electronic distributor
primary winding control unit

ignition sensor
battery ignition
switch coil armature
coil

Electronic Ignition System

Primary Circuit

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Activity 5

1. Conduct a spark test, using the ignition coil and the contact point in the distributor assembly.
2. Remove the ridges on the tip of the contact point by using sandpaper.
3. Remove the carbon deposits in the spark plug, using the sandpaper.

Self-check:

1. Did you conduct a spark plug test in the ignition system?

2. Did you remove the ridges at the tip of the contact point?
3. Did you remove the carbon deposits in the spark plug?

Lesson 4
The Lighting System

The main source of current in an automotive engine is the battery. The current is stored in the battery
and supplied to all the lighting systems of a vehicle. The battery is very important, particularly at night when light
has to be projected several meter in front of the vehicle to enable the driver to see the road ahead.

1. Headlight - a unit in front of the vehicle for purposes of projecting light several meters ahead of
the vehicle.

2. Tail light - a unit indicating the rear of the vehicle by means of red light.

3. Instrument light - this is coated inside the instrument board which illuminates the fuel gauge, oil
gauge and speedometer.

4. Dome light - a unit located at the ceiling of the vehicle. It illuminates its interior.

5. Signal light - a device which blinks and flashes to indicate the attention of the driver of a motor
vehicle to change direction or stop the vehicle.

6. Stop light - a unit mounted on the rear end of a vehicle, intended primarily to indicate that the
vehicle is slowing down or stopping.

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 head light tail light
battery

steering wheel

ammeter

plate no. light

ignition switch
ampere
park light
start ignition
panel and gauge light
amperes accessory

fuse

relay

Headlight Circuit with Main Switch and Relay

Activity 6

1. Check the headlight switch and the stop light switch and the signal light switches.
2. Check the panel instrument switch of the vehicle.

Self-check:

1. Did you check the switches of the stop, signal and headlight switch?
2. Did you check the panel instrument switch of the vehicle?

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 Lesson 5
The Horn System, Its Parts and Functions

This device is installed in automotive vehicles to warn pedestrians and other motorists. The horn
system consist of the battery, horn relay and horn switch.

1. Horn relay - a magnetically operated switch used to carry current directly from the battery to the
horn without having the current pass through the horn switch.

2. Battery - a device that converts chemical energy to electrical energy.

3. Horn switch - a device used to open or cut off current throughout the circuit.

relay

horns
battery

fuse box

start ignition
air horns relay amperes accessory
ammeter

ignition switch

motor horn button

change over switch

Horn Circuit with Air Horn

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 4. Electric horn circuit - a kind of circuit that is operated by electric current.

5. Air horn circuit - a kind of circuit operated through an air compressor to produce sounds.

Activity 7

1. Check on the fuel and the push button of the electric horn circuit.
2. Check on the air compressor, air hose of the air horn circuit.

Self-check:

1. Did you check on the fuel and push button of the electric horn circuit?
2. Did you check on the air compressor and the air hose of the air horn circuit?

LET’S SUMMARIZE

This module dwells on the parts and functions of the charging, ignition, lighting and horn systems. The
various systems of the vehicle have their respective functions in car operation. If one system malfunctions, this
has a great effect on car operation, particularly in regard to the ignition system, because automatically, the
engine will stop operating.

Other system like charging, lighting and the horn system will not drastically affect the engine operation
since function is outside the engine. You will know more about the troubles if these, occur and remedial
measures are applied. You will soon experience applying the knowledge and skills learned in automechanic
shop.

POSTTEST
Directions: Select the letter corresponding to the best answer to each question. Write the letter on your answer
sheet.

1. A kind of circuit operated through an air compressor to produce sounds.

a. air horn circuit
b. horn relay
c. horn switch
d. electric horn circuit

2. It is a device that multiplies current and supplies it to the gap of the spark plug.
a. condenser
b. ignition coil
c. contact point
d. diode

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3. It provides a longer dwell period to induce the saturation of the coil.
a. contact point
b. condenser
c. diode
d. ammeter

4. It is a device that absorbs excess current supplied by the ignition coil.

a. diode
b. spark plug
c. condenser
d. contact point

5. It is a device that ignites the air-fuel mixture inside the combustion chamber.
a. electrode
b. spark plug
c. diode
d. ammeter

6. A trouble in the charging system causing noisy generator.

a. grounded field coil
b. current regulator setting too high
c. faulty regulator assembly
d. dragging armature

7. The alternator fails to charge and the possible causes are

a. loose or slipping belt
b. defective regulator
c. worn-out fuse box
d. all of the above

8. Produces alternating current and supplies the current surge to the battery.
a. commutator
b. alternator
c. ammeter
d. battery

9. It is a device that maintains the charging of the battery.

a. alternator
b. voltage regulator
c. ammeter
d. commutator

10. This device converts chemical energy to electrical energy.

a. armature
b. commutator

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 c. battery
d. generator

KEY TO CORRECTION

Pretest

1. c
2. b
3. b
4. d
5. d
6. c
7. b
8. a
9. c
10. a

Posttest

1. a
2. b
3. a
4. c
5. b
6. d
7. d
8. b
9. b
10. c

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