Ok Task B - Electrical System

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
RSC, September 2017, National Capital Region, Philippines 2

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

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
Description
1. Commutator for open

circuit
2. Commutator for ground

Competitor Country
Task
Name Code
Report Sheet
STARTER INSPECTION
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 )

Competitor Country
Task
Name Code
Report Sheet
CHARGING SYSTEM
ALTERNATOR INSPECTION
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

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


Task
Name Code
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


Task
Name Code
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


Task
Name Code
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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Test Project Automobile Technology

Task B - Electrical System

TP33_ RSC 2017_25%

Submitted by: All Coaches/Experts

TP33_ RSC 2016_pre_NCR

Task Electrical Systems

Familiarization Time 15 minutes

2 Body Electrical, Lighting System 6.00

3 Body Electrical, Signaling System 6.00

4 Starting system 5.00

5 Charging system 5.00

You are required to

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

RSC, September 2017, National Capital Region, Philippines 2

Competitor Instructions - Automobile Technology

Install lighting system circuit

Install signaling system circuit

Perform starter motor performance test before disassembly

Perform alternator performance test before disassembly

RSC, September 2017, National Capital Region, Philippines 3

COMPETITOR - REPORT SHEET

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

STARTER PERFORMANCE TEST

Specification Actual Serviceable Unserviceable

3. Clutch pinion return

1. Commutator for open

2. Commutator for ground

RSC, September 2017, National Capital Region, Philippines 4

2. Field coil for open

3. Field coil for ground

5. Brush holder insulation

9. Planet carrier shaft

CHARGING SYSTEM PERFORMANCE TEST

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

Alternator output :_____________ Volts ( with load )

RSC, September 2017, National Capital Region, Philippines 5

1. Inspect rotor for open

2. Inspect rotor for ground

3. Measure slip ring diameter

4. Inspect stator for open

5. Inspect stator for ground

6. Measure exposed brush

7. Inspect positive rectifier

8. Inspect negative rectifier

RSC, September 2017, National Capital Region, Philippines 6

FORM 5 – MARKING SUMMARY FORM

Competitor Country Marking Scheme

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

Familiarization Competition Breaks

Start Start Start

Stop Stop Stop

RSC, September 2017, National Capital Region, Philippines 7

Competitor Country Marking Scheme

Preparation, Safety, and