Learner Guide - AURETR030 - Diagnose and Repair Starting Systems PDF

Diagnose and repair
starting systems
AURETR030
Diagnose and repair starting systems
Application
This unit describes the performance outcomes required to diagnose and repair
faults in the starting systems of vehicles, vessels or machinery. It involves preparing
for the task, selecting the correct diagnostic procedure, carrying out the diagnosis
and the repair, performing post-repair testing, and completing workplace
processes and documentation.
It applies to those working in an automotive service and repair industry. The

starting systems include those in agricultural machinery, heavy commercial
vehicles, light vehicles, marine vessels, mobile plant machinery, motorcycles or
outdoor power equipment.
No licensing, legislative, regulatory or certification requirements apply to this unit at

the time of publication.
Pre-requisite Unit
NIL
Competency Field
Electrical
Unit Sector
Technical – Electrical and Electronic
ii
Elements and Performance Criteria

ELEMENTS PERFORMANCE CRITERIA MAPPING
INFORMATION
(Describe the (Performance criteria describe the
essential performance needed to demonstrate
outcomes) achievement of the element)
1.1. Job requirements are determined from Page 3 - 15

workplace instructions.
1.2. Diagnostic information is sourced and Page 16 - 23

interpreted.
1. Prepare to
1.3. Diagnostic options are analysed and those Page 55 - 64
diagnose and
most appropriate to the circumstances are
repair starting
selected.
system
1.4. Hazards associated with the work are Page 4 - 7
identified and risks are managed.
1.5. Diagnostic tools and equipment are Page 20 - 23

selected and checked for serviceability.
2.1. Diagnostic tests are carried out according Page 55 - 64

to workplace procedures and safety
requirements without causing damage to
components or systems.
2. Diagnose 2.2. Faults are identified from diagnostic test Page 55 - 64

starting system results and causes of faults are determined.
2.3. Diagnosis findings and recommendations Page 73, 74

for necessary repairs or adjustments are
reported according to workplace
procedures.
3.1. Repair information is sourced and Page 16 - 20

interpreted.
3.2. Repair options are analysed and those Page 65 - 68

3. Repair starting
most appropriate to the circumstances are
system
selected.
3.3. Repair tools, equipment and materials are Page 10 – 13, 20 - 23

selected and checked according to
manufacturer specifications and
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workplace procedures.
3.4. Repairs and component replacements Page 65 - 68

and adjustments are carried out according
to manufacturer and component
specifications, workplace procedures and
safety requirements, and without causing
damage to components or systems.
3.5. Post-repair testing is carried out according Page 69, 70

to workplace procedures to confirm fault
rectification, and any further problems
detected as having been introduced
during the repair process are rectified.
4.1. Final inspection is made to ensure work is to Page 69, 70

workplace expectations and vehicle,
vessel or machinery is presented ready for
use.
4.2. Work area is cleaned, waste and non- Page 10, 70

recyclable materials are disposed of, and
4. Complete work recyclable material is collected.
processes
4.3. Tools and equipment are checked and Page 10, 70
stored and any faulty electrical equipment
is identified, tagged and isolated
according to workplace procedures.
4.4. Workplace documentation is processed Page 71, 72

according to workplace procedures.
iv
Knowledge Evidence
MAPPING
KNOWLEDGE OUTCOMES
INFORMATION
• Work health and safety (WHS) and occupational health

and safety (OHS) requirements, including procedures for:
Page 10 – 13, 20 -
o using specialised tools and equipment
23
o using appropriate personal protective equipment (PPE) Page 8 - 10
o identifying hazards and controlling risks associated with:
 working on high voltage ignition systems Page 5, 6
 wearing jewellery while working around high current Page 6, 7

wiring systems
• Operating principles of starting systems and associated

components, including :
o producing movement due to the force between Page 26 - 29

magnetic fields
o producing magnetic fields due to the current flow Page 29

through conductors
o basic direct current motor operation, including simple Page 32 - 37

armature, magnetic field and commutator
• Application, purpose and operation of starting systems

and components, including:
o starter motors, including:
 internal component function and operation, Page 32 - 37

including armature, commutator field windings
 starter motor windings, including series wound, shunt Page 38, 39

wound and compound wound
 permanent magnet starter motors Page 46, 47
 direct drive and reduction-type starter motors Page 43 - 46
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o starting electrical systems, including:
 solenoids Page 33
 shift levers Page 53, 54
 overrunning clutch flywheel ring gears Page 37
 ignition switching, including key start, push-button Page 49 - 51

start, remote start and start-stop systems
 safety switches, including inhibitor switches and Page 51 - 53

clutch neutral switches
• Diagnostic testing procedures for starting systems,

including:
o accessing and interpreting scan tool system data,

including:
 Diagnostic trouble codes (DTCs) Page 59, 60
 live data Page 60
 freeze frame data Page 60, 61
 waveforms Page 61, 62
o using diagnostic flow charts Page 55, 56
o testing electrical systems, including procedures for:
 accessing electrical terminals and using test probes Page 56, 57

without damaging connectors, fuse holders or wiring
 resistance, current flow and voltage drop checks of Page 57

starting system circuits
 field winding tests Page 62
 armature tests, including using a growler Page 62
 commutator tests Page 63
 brushes and holder tests Page 63
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 overrunning clutch and pinion tests Page 63
 flywheel ring gear tests Page 63, 64
 starter motor bench tester operation Page 64
• Repair procedures for starting systems, including:
o tightening connections Page 65 - 68
o replacing faulty or damaged cable connections Page 65 - 68
o removing and replacing faulty or damaged Page 65 - 68

components
• Post-repair testing procedures for starting systems,

including:
o DTC clearing procedures Page 69
o checking for electrical connector mating Page 69, 70
o static and dynamic performance tests of starting Page 70

systems.
vii
Table of Contents
1 Introduction ..................................................................................................... 1
2 Hazards and safety ........................................................................................ 3
2.1 Work health and safety (WHS) ............................................................................... 3
2.2 Hazards ...................................................................................................................... 4
2.2.1 Safety while working on vehicle starting system ..........................................................4
2.2.2 Hazards and safety while working on the high voltage system ...............................5
2.2.3 Hazards and safety while wearing jewellery and watches .......................................6
2.3 Safety ......................................................................................................................... 7

2.3.1 Personal safety ...................................................................................................................8
2.3.2 Tools and equipment safety ......................................................................................... 10
2.3.3 Vehicle safety .................................................................................................................. 14
2.3.4 Work area safety ............................................................................................................. 14
3. Diagnosis preparation and planning ........................................................ 16

3.1 Diagnostic process ................................................................................................ 16
3.2 Diagnostic flow chart ............................................................................................ 16
3.3 Service information ................................................................................................ 17
3.4 Tools and equipment ............................................................................................ 20
3.4.1 Usage of tools .................................................................................................................. 21
3.4.2 Precision of test equipment .......................................................................................... 21
3.5 Special tools and equipment............................................................................... 21

3.5.1 Multimeter ........................................................................................................................ 21
3.5.2 Basic code reader .......................................................................................................... 22
3.5.3 OBD II scanners and readers or scan tool ................................................................. 22
3.5.4 Oscilloscope .................................................................................................................... 23
4 Starting system .............................................................................................. 24

4.1 Operation................................................................................................................ 25
4.2 Operating principles .............................................................................................. 25
4.2.1 Field around an electrical conductor ........................................................................ 25
4.2.2 Magnetic field of a coil ................................................................................................. 26
4.2.3 Current produced through magnetism ..................................................................... 26
4.2.4 Producing rotating magnetic field .............................................................................. 29
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4.3 Internal circuit ......................................................................................................... 29

4.4 Starter circuit........................................................................................................... 31
5 Starter motor ................................................................................................. 32

5.1 Components........................................................................................................... 33
5.1.1 Solenoid ............................................................................................................................ 33
5.1.2 Brushes............................................................................................................................... 34
5.1.3 Commutator .................................................................................................................... 34
5.1.4 Armature........................................................................................................................... 35
5.1.5 Field coils .......................................................................................................................... 36
5.1.6 Flywheel ring gear .......................................................................................................... 37
5.2 Starter motor characteristics ................................................................................ 38

5.2.1 Series-wound motors ...................................................................................................... 38
5.2.2 Shunt-wound motors ...................................................................................................... 39
5.2.3 Compound-wound motors ........................................................................................... 39
5.3 Types according to method used to engage the pinion with engine gear
Error! Bookmark not defined.
5.3.1 Inertia type drives ........................................................................................................... 40
5.3.2 Pre-engaged type .......................................................................................................... 41
5.3.3 Overrunning clutch drive .............................................................................................. 42
5.4 Types ........................................................................................................................ 43

5.4.1 Direct drive starters ......................................................................................................... 43
5.4.2 Gear reduction starters.................................................................................................. 44
5.4.3 Positive engagement starters ....................................................................................... 45
5.4.4 Permanent magnet starters .......................................................................................... 46
5.5 Starter torque.......................................................................................................... 47
6 Ignition switch system .................................................................................. 49

6.1 Key start ................................................................................................................... 49
6.2 Push-button start .................................................................................................... 50
6.3 Remote start ........................................................................................................... 50
6.4 Start-stop ................................................................................................................. 51
6.5 Safety switches ....................................................................................................... 51
6.5.1 Inhibitor switches ............................................................................................................. 51
6.5.2 Clutch neutral systems ................................................................................................... 52
6.6 Shift levers................................................................................................................ 53
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7 Diagnosis of starting system ........................................................................ 55

7.1 Preliminary checks ................................................................................................. 55
7.2 Starter fault diagnostic table................................................................................ 55
7.3 Accessing electrical terminals using test probes............................................... 56
7.4 Resistance and current flow check .................................................................... 57
7.5 Starter current draw test ....................................................................................... 57
7.5.1 Starter voltage drop test across the supply line........................................................ 57
7.5.2 Starter voltage drop test across earth line................................................................. 58
7.5.3 Starter voltage drop test across starter solenoid contacts..................................... 58
7.6 Diagnostic procedure using a scan tool ............................................................ 58

7.7 Access and interpret scan tool system data ..................................................... 59
7.7.1 Diagnostic Trouble Codes (DTCs) ................................................................................ 59
7.7.2 Live data ........................................................................................................................... 60
7.7.3 Freeze frame data .......................................................................................................... 60
7.7.4 Waveforms ....................................................................................................................... 61
7.8 Component test ..................................................................................................... 62

7.8.1 Field winding test ............................................................................................................ 62
7.8.2 Armature test using growler .......................................................................................... 62
7.8.3 Commutator test............................................................................................................. 63
7.8.4 Brushes and holder test .................................................................................................. 63
7.8.5 Overrunning clutch and pinion test ............................................................................ 63
7.8.6 Flywheel ring gear test ................................................................................................... 63
7.8.7 Stater motor bench tester operation .......................................................................... 64
7.8.8 Drive pinion test ............................................................................................................... 64
8 Repair of starting system ............................................................................. 65

8.1 Starter motor removal ........................................................................................... 65
8.2 Starter motor disassembly ..................................................................................... 65
8.3 Starter motor assembly ......................................................................................... 66
8.4 Repair procedure of battery ................................................................................ 67
8.5 Remove and replace starting system solenoid battery terminal .................... 67
8.5.1 Precautions ...................................................................................................................... 68
9 Post repair inspection and documentation............................................. 69

9.1 Post service checks................................................................................................ 69
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9.2 DTC clearing procedure ....................................................................................... 69

9.3 Electrical connector mating ................................................................................ 69
9.4 Static and dynamic performance tests.............................................................. 70
9.5 Workshop procedures ........................................................................................... 70
9.6 Documentation ...................................................................................................... 71
9.6.1 Repair Order (RO) ........................................................................................................... 71
9.6.2 Diagnosis report .............................................................................................................. 73
10 References .................................................................................................... 75
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1 Introduction
Engine starting system allows for the rotation of the vehicle’s internal combustion
engine (ICE) that helps to start the combustion cycle. In the older version of vehicles,
rotation of the combustion engine was done by the hand-crank handle. Modern
vehicles use electric starter motor to draw electrical power from the battery of the
vehicle.
Figure 1: Vehicle engine starting system
Engine starter can work only for short period of time and need to crank the engine
at the right speed in order to start. In terms of effectiveness, modern starting systems
prove to be very effective, as the starting system and battery are well maintained.
Engine starting system consist of –
• Battery
• High and low-amperage wires
• Solenoid
• Starter motor assembly
• Ring gear
• Ignition switch
1
Figure 2: Starter motor components
During cranking process, two actions occur. The pinion of the starter motor engages
with the flywheel ring gear and the starter motor then rotates to turn over or crank
the engine.
Starter motor is the electric motor powered by the storage battery. 12-volt storage
battery is sufficient to power the starter motor, while some of the starter motors
operate with high-voltage battery. Starter motors have high torque at low speeds.
Starter cables are heavy in the vehicle because they carry high current required by
the starter motor.
Starter motor allows for the rotation of the engine flywheel and crankshaft to rotate
from a resting position and keeps them turning till the engine fires and runs on its
own.
Basic motor principles
The force produced between two magnetic fields operates all the electric motors
including the alternator and starter system. The north and south poles of the
permanent magnet produce one of the magnetic fields while the current flow in
conductor produces the other magnetic field (electromagnetic field).
2
2 Hazards and safety
2.1 Work health and safety (WHS)
Work health and safety (WHS) governs the safety, health and well-being of people
involved in work or employment. Irrespective of the nature of their work, employees
must be able to carry out their responsibilities in a safe and secure working
environment which is free from hazards.
Figure 3: Work health and safety
The objectives of WHS are to:
• Ensure health, safety and welfare of employees and other people at work;
• Protect the public from the health and safety risks of business activities;
• Emilimate workplace risks at the source and
• Involve employers, employees and the organisations that represent them in the
formulation and implementation of health, safety and welfare standards.
WHS play an important role in providing a safe workplace for both employers and
employees.
• Work health and safety act 2004 and the Work health and safety regulations 2007
seek to improve the level of safety in automotive industry.
• WHS Regulations 2017 involves the safe operation of major hazard facilities,
training for high risk work, managing and removing asbestos and licenses for
specific activities
For further information on WHS regulations, visit

www.worksafe.vic.gov.au/automotive.
3
2.2 Hazards
Hazard identification is an important step in the safety management process. This

helps in identifying, assessing every hazard related to work in order to control and
find the solution at the earliest.
Some of the hazards related to the starting system are:
• Battery explosion risk
• Burns from high current flowing from the battery cables
• Injuries from lifting heavy starters and batteries
• Burns from battery electrolyte
• Fire hazards
• Engine cranking hazard
2.2.1 Safety while working on vehicle starting system
• Wear appropriate PPE to protect from injuries.
• Ensure to disconnect the battery while working with battery (connecting or

disconnecting to the starting system).
• Avoid wearing jewellery while working on starting or charging system to eliminate

the possibility of electric shocks.
• To remove a starter, ensure that the battery terminals are disconnected to avoid
accidental arcing of battery cable to the ground.
• Usually the worn gears have very sharp edges. Wear gloves to avoid cutting of
fingers from sharp edges.
• For most of the alternators, the positive terminal of the battery is connected to
the back of alternator. Avoid contact of the air cleaner or any other grounded
component with the hot wire.
• Avoid engine from starting by restricting the current flow only to the starting
system and not to the ignition system.
• Ensure transmission is out of gear while setting for cranking and parking brake.
• When a starter is disassembled, make sure that battery should not arc from the
battery cable to the ground, by disconnecting the negative terminal of the
battery first.
4
• Wear appropriate PPE like hand gloves while working with worn-out pinion gear
or the flex plate ring gear, as they have sharp edges.
• Avoid pinching of the fingers between block and starter frame, while working
with heavy starters.
2.2.2 Hazards and safety while working on the high voltage system
Figure 4: High voltage hazards signage
Starting system generates a very high voltage which ignites the air-fuel mixture. Care
must be taken as these systems run on very high voltages. Contact with live parts
causes shocks, burns, fires or explosion.
Hazards
• Contact with live parts causing shocks and burns
• Faults which may cause fires
• Fire or explosion
Safety
• While working on the high voltage systems, the technician should be qualified in
handling high voltage systems in vehicles and must follow appropriate
procedures instructed by the manufacturer.
• One should be trained in identifying high voltage components and wiring.
• The technician should be trained in using and maintaining protective equipment

suitable for high voltage systems. They must refer to manufacturer information
while using protective equipment.
5
o Personal protective clothing: dry-electrical high voltage safety rubber gloves,

safety goggles, electrical hazard safety shoes and acid resistant apron.
o High voltage rubber insulation mats
o High voltage insulated tools
o High voltage insulated stick.
• The high voltage system may remain powered for up to 10 minutes after being
disabled. The method of disabling the high voltage system is manufacturer
specific.
• Never touch, cut or open any orange high voltage power cable or high voltage
components without personal protective equipment.
• Never use equipment with frayed cords, damaged insulation or broken plugs.
• Do not cause any physical impact on the battery as the electrolyte is flammable.
The electrolyte may be toxic and can damage human tissue.
• Never use equipment with frayed cords, damaged insulation or broken plugs.
• Do not have any metal objects nearby while working on the batteries.
• Components with a strong magnetic field are used in the vehicles. Operators with
a medical electric device such as pacemakers must not carry out electronic
diagnosis as strong magnetic fields can affect the function of the device.
• Never spray water or any liquids on to the electrical systems.
• Never wear jewellery while working on high voltage system since it causes electric
shocks as jewellery is good conductor of electricity.
• Always disconnect battery ground connections (negative terminal) before

servicing or testing electrical system components.
• Hybrid vehicles have higher voltages. Follow safety precautions and service
procedures when working with high voltage circuits for avoiding personal injury.
2.2.3 Hazards and safety while wearing jewellery and watches
Hazards
• Jewellery and watches are made of electricity conducting materials hence may
cause electrical shocks.
• The jewellery and watches are prone to heating quickly while working on the
electrical systems, this leads to burning and catching up fire.
6
• The jewellery will melt when exposed to the high voltage currents.
Figure 5: Jewellery and watches
• Imagine leaning over a running engine with a dangling necklace; it could get
caught in the fan belt and be ripped from the neck; not only will it get destroyed,
but it could seriously injure the technician.
• A ring or watch could inadvertently short out an electrical circuit, heat up quickly
and severely burn the technician, or cause a spark that may explode the
battery.
• A ring can also get caught on moving parts, breaking the finger bone or even
ripping the finger out of the hand.
Safety
• To be safe, always remove watches, rings, and jewellery before starting work. Not
only is it safer to remove these items, but your valuables will not get damaged or
lost.
2.3 Safety
It is essential to follow safety precautions while removing or working on a starting

system. The safety instructions inform the operator with regards to:
• Operation of starting system according to safety requirements
• Maintenance of the system according to guidelines
• Cleaning of the starter system according to guidelines
• Considering appropriate measures to safe guard against the faults.
7
Figure 6: Personal protective equipment
The safety in the WHS is classified into 4 categories, namely:
• Personal safety
• Tools and equipment safety
• Vehicle safety
• Work place safety
2.3.1 Personal safety
Personal protective equipment (PPE) is designed to protect the technician or the

person working on the vehicle systems from specific hazards. Some of the
equipment is supposed to be mandatory before entering the shop floor and the rest
are used for specific operations.
The types of personal protective equipment are below listed ones:
PPE Purpose Image
Safety glasses and face To protect from splashes and

shields any damage to the eyes
8
To protect from inhalation of

Air respirators and face
harmful gases, asbestos,
masks
brake dusts, etc.
To protect from any head

Safety helmets injury or impact or
penetration
To protect from any

Safety shoes or steel damage to the foot due to
toed boots heavy materials, chemicals
at high temperatures
To avoid any contact with

Workshop uniforms or
hot and toxic fluids or from
overalls
fire sparks.
To avoid high decibel noise

Ear plugs or muffs from the machinery which
may affect hearing abilities.
9
To avoid contact with hot

Safety rubber gloves or
fluids or from high current
sleeves
shocks
2.3.2 Tools and equipment safety
An automotive technician must adhere to the following safety guidelines when using
tools and equipment.
 Hand tool safety
Hand tools such as wrenches, screwdrivers, and hammers must be carefully used to
prevent any accidents. The following tips must be considered while using hand tools:
• Keep the tools away from the oil and grease as these may turn slippery and may
cause injuries while working.
• Inspect the tools for the cracks or damages and never use the tool if found faulty.
• Use the appropriate tools for the purpose they are designed.
• Make sure the tool is of appropriate size and of professional quality.
• When using an air impact wrench, always use impact sockets.
• Never use a wrench or pliers as a hammer.
Figure 7: Hand tools
10
• Always be aware of striking an object with the full-face hammerhead.
• Be careful when using sharp or pointed tools.
• Do not place sharp tools or other sharp objects into pockets.
• If a tool is supposed to be sharp, make sure it is sharp as dull tools can be more
dangerous than sharp tools.
 Power tool safety
Figure 8: Power tools
Power tools are operated by an outside power source, such as electricity,

compressed air, or hydraulic pressure. Improper use may result in serious injury.
Always wear safety glasses when using power tools. Never try to use a tool beyond
its stated capacity.
 Electrical tool safety
Electrical tools are powered by electricity. Electrical equipment that is not properly
earthed or maintained can lead to electric shock, serious burns or even death.
11
Figure 9: Electrical tools
• Always read and follow the operating procedures before using electrical
equipment.
• Ensure that the electrical tools are properly grounded before operating.
• Keep your hands, loose gloves, and loose clothing away from moving parts of
electrical tools.
• Check the wiring for insulation cracks, as well as bare wires, before using it.
• Avoid contact with electrical tools using wet hands and water surrounding as it
leads to electrical shock. Never stand on a wet or damp floor when using
electrical power tools.
• Before plugging in an electric tool, make sure its switch is in the off position.
• Always turn off the tool before unplugging the tool.
• Never leave a running power tool unattended.
• When using a bench or floor grinding wheel, check the machine and the grinding
wheels for signs of damage before using them. If the wheels are damaged, they
should be replaced before using the machine.
• Although the safety guards are designed to prevent injury, one should still wear
safety glasses and/or a face shield while using the machine.
• Make sure there are no people or parts around the machine before starting it.
• Keep hands and clothing away from the moving parts.
• Maintain a balanced posture while using the machine.
12
 Compressed air tool safety
Power tools that use compressed air are called pneumatic tools.
• Pneumatic tools must always be operated at the pressure recommended by the

manufacturer.
• Before using a pneumatic tool, check all the hose connections for leaks. Also,
check for any airline damage.
Figure 10: Pneumatic tools
• When using an air nozzle, always wear safety glasses or a face shield as the dirt
particles and metal pieces blown by high-pressure air can penetrate the skin or
get into eyes.
• Never use compressed air to blow dirt from clothes or hair or to clean the floor or
workbench.
• Never spin bearings with compressed air. If the bearing is damaged, one of the
steel balls or rollers might fly out and can cause serious injury.
13
2.3.3 Vehicle safety
Figure 11: Safety while lifting vehicle
• Always be careful while lifting the vehicle on a lift or hoist. Place the hoist plates at
the jacking points only.
• Make sure the underbody of the vehicle is not damaged while lifting.
• Always use the appropriate jack to lift the vehicle and place the jack at the
jacking points only.
• Never hold the vehicle on the jack for a longer time. Always use safety stands to
support the jack for a longer time.
• Apply the parking brake and shift the gear to Parking, before the vehicle is lifted
on the hoist.
• Lock the wheels using the wheel stoppers and wheel chokes.
2.3.4 Work area safety
• The floor and benchtops of the work area must be kept clean, dry and orderly.
• Any oil, coolant, or grease on the floor can make it slippery and can result in
serious injuries.
14
Figure 12: Work area safety
• To clean up oil, use commercial oil absorbent.
• Keep the water off the floor as water is slippery on smooth floors, and electricity
flows well through water.
• Aisles and walkways should be kept clean and wide enough to easily move
through.
• Make sure the work areas around machines are large enough to safely operate
the machine.
• Keep an up-to-date list of emergency telephone numbers clearly posted next to

the telephone. These numbers should include a doctor, hospital, fire and police
departments.
• The work area should have a first-aid kit and eye flushing kits readily available.
15
3. Diagnosis preparation and planning
Figure 13: Vehicle diagnosis
The diagnostic preparation and requirements make the job easy and quick.
This involves:
• Service and diagnostic information
• Tools and equipment for the diagnosis
• Hazards and safety analysis
• Diagnostic process and methods.
3.1 Diagnostic process
Diagnostics is an important part of an automotive technician’s work. The concept of

diagnostics depends on one’s knowledge of vehicle systems combined with the use
of logical and analytical process for determining the fault. The technician must also
be aware of the manufacturer and service information.
3.2 Diagnostic flow chart
The step by step flow in diagnosing a complaint is very important for quick diagnosis;
this is also called as diagnosis routine.
1. Collect the information about the problem - Find out when and where the
problem happened and what exactly happened.
2. Verify the problem - Take the vehicle for a road test and try to identify the
problem, if possible.
3. Thoroughly define what the problem is and when it occurs - Pay strict attention to
the conditions present when the problem happens. Pay attention to the entire
16
vehicle; another problem that was not evident to the customer may be evident
to you.
4. Research all available information to determine the possible causes of the

problem. Try to match the exact problem with a symptoms chart or think about
what is happening and match a system or some components to the problem.
5. Separate the problem by testing. Narrow down the probable causes of the
problem by checking the obvious or easy-to-check items and eliminate the
possibility of problem with them.
6. Continue testing to pinpoint the cause of the problem. Once you know where the
problem could be, test until you find it!
7. Locate and repair the problem, then verify the repair. Never assume that your
work solved the original problem. Make sure the problem is resolved before
returning it to the customer.
Figure 14: Diagnostic flow chart
3.3 Service information
The manufacturer specifications, workplace procedures and other technical

information relating to vehicle repair and diagnosis in a workplace can be obtained
from the organization’s website or Manager’s office.
17
Figure 15: Service manuals and records
Manufacturer specifications with regard to inspection and service include:
• Systems and system wiring diagrams
• Safety precautions to be exercised while working on a specific system
• System diagnostic procedures
• Repair instructions
• Installation procedures
• Final inspection procedures
Vehicle service history records
It is very important for the technician to check the service history of the vehicle in
case of unusual problems. A previous repair may lead to the current problem or the
previous problem which is not attended to and carried forward can also be tracked
in the service history. This record simplifies the current diagnosis and repairs.
Service history records are maintained by the workshop or service department for a
specified time period to comply with federal law.
Service manuals
Factory and aftermarket service manuals, also called workshop manuals contain
vehicle specifications and service procedures. Factory service manuals cover one or
more models of the same vehicle for a year, while aftermarket service manuals
cover multiple years and/or models in one manual.
Service manuals include the following:
• Capacities and recommended specifications for all fluids.
• Specifications including engine and routine maintenance items.
18
• Testing procedures.
• Service procedures including the use of special tools when needed.
• Component location information.
• Diagnosis symptoms and flow charts.
While some factory service manuals are printed in one volume, most factory service
information is printed in several volumes due to the amount and depth of
information presented. The typical factory service manual is divided into 2 sections.
a. General information
General information includes topics such as:
• Warnings and cautions
• Vehicle identification numbers on the engine, transmission/transaxle, and body

parts
• Fastener information and Lock cylinder coding
• Decimal and metric equivalents
• Abbreviation and standard nomenclature.
b. Technical service bulletins
The manufacturer provides information to technician or service staffs on unexpected

problems, updates, or changes in the repair procedures that occur with a vehicle
system, part, or component as an update in a bulletin called the Technical service
bulletins (TSBs).
Technical service bulletins are different from the service information and the repair
procedure as service information and repair manuals are prepared by the
manufacturer while manufacturing the vehicles and includes the information of
service requirements of the vehicle. TSB consists of the service procedures of the
unexpected failures which need the changes in the service procedure.
Note:
• The technician with the right skill and knowledge on the vehicle has to know
where to exactly stop the diagnosis.
• The technician should be aware of the seriousness of damage that may be

caused while working on the critical system.
• The person should know his limitations in dealing with every component as it may
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cause huge damage to the system.
3.4 Tools and equipment
Tools and equipment are very useful to test and diagnose the fault with the vehicle
or system. So, the diagnosis and test equipment or tools are linked and, in most
cases, it is difficult to interpret the results of the test. Hence, the comparison of the
test result is being done from the service books and other source of information.
Figure 16: Tools and equipment
The following are some of the diagnostic tools:
• Hand tools: The basic tools like spanners, wrenches, the sockets, screwdrivers etc.
• Special tools: The special tools are tools which are used for the specific job.
• Precision measuring equipment: The test equipment is used for specific purpose of
measuring and testing. These may include measuring tools like ruler, dial gauge
and some analysing tools like engine analyser.
• Dedicated test equipment: These are also similar to special tools but these are
dedicated to a single operation in the system. These are similar to the diagnostic
tools or scan tools which are meant to diagnose an individual component.
• Accuracy test equipment: These are free from the clutter of regular instruments
and have very precise work standards.
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3.4.1 Usage of tools
Using tools effectively comes only by practice and cannot be acquired just by
reading or references. However, the general guidelines outlined here will certainly
help with recommendations from the manufacturers. There is a wide range of tools
available that can be harmful. The manufacturer can assist for general advice on
using hand tools.
• Tools should be used only for a suitable purpose.
• Use the right tool for the right job.
• Follow the manufacturer’s instructions for better performance.
• Never use a broken tool or wrong tool for the repair.
• Take care of tools; they will take care of you.
3.4.2 Precision of test equipment
For every diagnosis there should be a definite point to understand the precision of
the measurement or the limit of the job to be done. Hence the precision measuring
equipment play a prominent role in comparing the manufacturer's inputs and the
different outcomes during the job.
If the diagnosis is done precisely and cautiously, without any mistakes and errors,
then it is said to be accurate. This should follow the values of the manufacturer
requirements. This sort of diagnosis or actions need some special equipment called
the accurate test equipment.
3.5 Special tools and equipment
3.5.1 Multimeter
The multimeter is a significant tool used to perform electric and electronic tests in
vehicles. Digital multimeters (DMM) are affordable, extraordinary and provide
accurate reading. They are very easy to operate and have numeric display.
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Figure 17: Multimeter
3.5.2 Basic code reader
A basic code reader monitors a variety of sensor inputs and outputs. They are used
to perform the checks on the safety systems like ABS and ESC. The system sets a
trouble code that corresponds to a specific fault. There are different types of codes
(i.e. hard, soft) that represent both ongoing and intermittent problems.
Figure 18: Basic code reader
3.5.3 OBD II scanners and readers or scan tool
Figure 19: OBD II Scanner
Scan tools can read and display live data, show what the code means, display
freeze frame data, display readiness, monitor status, and reset readiness monitors.
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Scan tools can also graph data, send it to other devices such as a computer or
phone, provide information that can be printed out, and even read pending codes.
The software that measures the diagnostics of the car takes regular readings of
different systems in the car.
3.5.4 Oscilloscope
An oscilloscope or lab scope is a visual voltmeter that converts an electrical signal 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. The time is displayed along the X-axis (horizontal axis) and amplitude is
displayed along the Y-axis (vertical axis). Precise measurement is possible with a
scope.
Figure 20: Oscilloscope
Safe operating procedure for multimeter and scan tool
Multimeter
• Do not use wrong polarity while testing the battery.
• Connect the black probe into the COM port on multimeter and connect the
negative terminal, connect the red probe into the V port on multimeter and
connect the positive terminal of the battery.
Scan tool
• Some tools contain an internal 250V, 8A Fuse that is factory replaceable only.
Incorrect replacement may cause an explosion.
• Do not use scan tools in environments where explosive vapour may collect,
such as in below-ground pits, confined areas, or less than 18 inches above the
floor.
• Do not expose tester to rain, snow or wet conditions. Do not allow the battery
gases or acid or contact tester housing.
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4 Starting system
Starting system is a combination of mechanical and electrical parts that work
together to start the engine. The starting system is designed to change the electrical
energy, which is being stored in the battery, into mechanical energy. A starter motor
is used to serve the purpose.
A starter system includes the following components –
• Battery
• Cable and wires
• Ignition switch
• Starter solenoid or relay
• Starter motor
• Starter drive and flywheel ring gear
• Starting safety switch (Inhibitor switch)
Figure 21: Vehicle starter system
The basic requirements for the staring system of an automotive engine are that the
engine has to be turned ON at a speed of approximately 50 to 90 rpm for ignition to
occur.
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4.1 Operation
To produce a turning effect, two magnetic fields are required to be placed in close
proximity to one another. If one of the magnets is pivoted, it will move as the
magnetic lines of force try to straighten themselves.
This produce restricted movement, only at maximum half a turn, and to produce
continuous movement, one of the magnetic fields have to be able to be reversed
when required.
One way to continue the movement is to reverse the magnetic field in the rotating
magnet.
Figure 22: Vehicle starter system operation
4.2 Operating principles
4.2.1 Field around an electrical conductor
In earlier days it was discovered that when an electrical current was passed through
a wire, a magnetic field was produced around the wire, when current flows.
Field around a wire
The lines of force consist of circles around the wire and are formed into a definite
pattern depending on the direction of the current flow.
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Direction of current
The direction of the magnetic field can be determined by knowing the direction of
the current. If the current is flowing away from the magnetic field, then the direction
of current is clockwise. If the current is flowing towards the magnetic field, then the
direction of current is anti-clockwise.
4.2.2 Magnetic field of a coil
Magnetic field is reinforced if the conductor is formed into a loop.
Coil
• The lines of force in a coil combine to form a field many times stronger than that
of a single conductor.
• The strength of the field is increased as the number of coils is increased, or as the
amount of current flowing in the coils is increased.
• Using a coil of wire instead of a single conductor greatly increases the magnetic
effect.
• Inserting a soft iron into the centre of the coil intensifies the magnetic field even
more.
Solenoids
• The iron core becomes magnetised and behaves like a permanent magnet as
long as the current is flowing.
• The polarity of the magnetic field varies with the direction of the current flow.
• The current flowing from the battery positive terminal through the coil to the
negative terminal produces a north pole at the positive end and a sound pole at
the negative end.
Reversing current flow
• If the battery is connected the other way around, the polarity of the field will also
be reversed.
4.2.3 Current produced through magnetism
Induction
When a conductor is moved through a magnetic field or magnetic lines of force are
moved through a conductor, an electric current is generated. The electric current
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that is produced is called as “induced Electromagnetic Field (EMF) and the method
is known as “induction”.
To induce an electrical current, either the magnetic field or the conductor must be
moving. This can be achieved by –
• Conductor moving through the stationary magnetic field.
• Magnetic field moving through a stationary conductor.
• A magnetic field building (current switched on) or collapsing (current switched

off) through a conductor.
Current direction
The direction of the induced current flow depends on the polarity of the magnetic
field (whether north or south pole) and the direction of the movement.
Fleming’s right-hand rule is used to determine the direction of the induced voltage.
• The first, second and third fingers of the right hand are held at right angles to one
another.
• The thumb is pointed in the direction of the movement.
• If the first finger is pointed in the direction of magnetic field, second finger will
indicate the direction of the induced voltage.
Figure 23: Fleming's right-hand rule
Induction between coils
When two conductors are placed side by side and current passes through one
conductor, the magnetic field produced around it will also influence the other
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conductor. Current is induced into the second conductor when the magnetic field,
produced in the first conductor, is building or collapsing.
Induction between wires - It implies that the voltage will only be induced while the
magnetic lines of force are moving through the second conductor, either building
up or collapsing. This will happen when the current in the first conductor is turned on
or off. There is no current flow induced in the second conductor when the field is
stabilised.
If the conductors are formed into coils, the current induced is much higher than in a
straight conductor. This type of current in one coil by the action of another is called
mutual induction. It is the principle behind transformers, ignition coil and the
alternator.
Mutual induction - The coil that carries the current into the inductive system is called
the primary winding of the coil. The coil in which the EMF is induced is called the
secondary winding of the coil.
Mutual induction in a transformer
A transformer consists of two coils – primary coil and secondary coil, placed side by
side. Current can be induced in the secondary coil by building up and collapsing
the magnetic field in the primary coil. A soft iron core is used to wind these coils,
intensifying the strength of the magnetism.
When the primary coil is connected to a battery and current is turned on, a
magnetic field is built up around the coil. As it builds up, the magnetic field cuts
across the windings of the secondary coil.
This movement of magnetism through the secondary coil induces a positive charge
in the coil.
Figure 24: Mutual induction of a transformer
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Field stabilises
When the magnetic field of the primary coil reaches its maximum, the magnetic
field stabilises and no voltage is induced in the secondary coil.
Primary current turned off
If the current through the primary coil is turned off, its magnetic field will collapse.
The collapsing magnetic field cuts through the windings of the secondary coil and
this moving field induces a negative voltage in the secondary coil.
4.2.4 Producing rotating magnetic field
The rotating magnetic field is generally termed the “armature magnetic field”. It
consists of a loop of wire that when battery current flows through it, a magnetic field
is produced around it whose plane is at right angles to the loop.
When this loop of wire is placed between the poles of the field, the coils will rotate.
When the loop has moved through half a turn the current through the coil must be
reversed to continue rotation.
This requires a commutator and brushes.
The commutator consists of metal segments, one connected to each end of the
coil. The brushes are connected to the battery and slide on the commutator
segments.
When the black half of the loop is at the top, its end is connected through the
commutator segment to the battery positive terminal.
In this position, the current flowing through the loop produces a north-pole opposite
the fixed north pole of the field coil, and a south-pole opposite the fixed south pole
of the field coil. Repulsion occurs and the loop begins to rotate.
Rotating field
When the loop has moved through half a turn, the white section is on the top. The
magnetic field produced by this section is still north in polarity because the current
through the coil has been reversed.
This reversal is achieved because the commutator segments have moved under the
opposite brushes to connect the coils to the opposite terminals of the battery.
4.3 Internal circuit
The starter motor is series wound as this type of motor produces its maximum torque
at times when it is most needed.
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This means that the internal arrangement of the starter motor consists of field coils
that are electrically in series with the armature windings.
Figure 25: Sectional view of vehicle starter motor
Series circuit
The field coils are wound in series with one another so as to produce alternate north
and south poles.
The insulated brushes then connect with the armature commutator. The circuit
continues through the armature windings to the pair of non-insulated or earth
brushes that are connected to the starter end-bracket, and the engine earth.
Two basic winding patters are used in the armature – lap winding and wave
winding.
Lap winding
In the lap winding, the two ends of the winding are connected to adjacent
commutator segments. In this pattern, the wires passing under a pole field have their
current flowing in the same direction.
Wave winding
In the wave winding pattern, each end of the winding connects to commutator
segments that are 90 or 180 degrees apart. In this pattern, some windings will have
no current flow at certain positions of armature rotation.
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This occurs because the segment ends of the winding loop are in contact with
brushes that have the same polarity.
4.4 Starter circuit
The starter circuit consist of a supply direct to the starter from the battery, with a
return path through the vehicle engine and chassis.
Solenoid switch
The circuit is controlled by a solenoid switch, either on the starter motor or separate
to it. The solenoid switch is energised from the start position on the ignition switch.
Figure 26: Vehicle starter circuit
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5 Starter motor
The starter motor incorporates a solenoid switch that shifts a pinion gear into and out
of mesh with the ring gear around the circumference of the flywheel.
The pinion gear of the starter motor is located on the armature and rotates at the
same speed as the armature. The lever connected to the solenoid plunger pushes
the pinion gear out and causes it to mesh with the ring gear.
Figure 27: Starter motor
The equipment required to crank the engine comprises of starter motor, together
with its switch, a battery of sufficient capacity to produce the current necessary to
develop the torque of the starter motor, and the connecting cables.
The outstanding characteristic of the starter motor is that the turning power of
“torque” is maximum at minimum speed.
Figure 28: Exploded view of starter motor
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Maximum power
When the starter motor is engaged to the engine flywheel, current is applied and is
exerted to maximum power. This engagement requires more battery current.
This may vary from approximately 250 amperes up to 100 amperes according to the
size of the engine, its temperature, the number of cylinders and the compression
ratio.
Figure 29: Starter motor components
5.1 Components
5.1.1 Solenoid
The solenoid is a magnetic switch that has two coils. A pull in the coil operates while
the pinion is being pushed into mesh with the ring gear, and a hold in coil that
maintains the pinion in mesh while the starter is operating. Solenoid also serves as the
main switch for the heavy starter current.
Figure 30: Vehicle starter solenoid
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5.1.2 Brushes
Brushes slide on the armature commutator and allow the starter current to pass from
the field coils to the armature windings and from the armature to the earth return
circuit.
Figure 31: Vehicle starter system brushes
5.1.3 Commutator
The flow of the current in the conductor generates an electromagnetic field around
it. The reverse direction of the current flow allows the conductor to move in the
opposite direction.
Figure 32: Vehicle starter system commutator
This is known as motor effect and makes the loop to rotate at 90 degrees to the
magnetic field. In order to continue the rotation of the conductor, the current flow
direction must be reversed at the static neutral point.
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Figure 33: Starter system commutator components
Commutator is used to continually reverse the current flow for maintaining loop
rotation. Commutator has two semi-circular segments which are connected to
either ends of the loop that are isolated from each other. Brushes allow for the
commutator to slide in order to complete the circuit and allow the current flow
through the loop.
5.1.4 Armature
Armature is rotated by the magnetic field and this creates the torque for cranking
the motor. The armature shaft has provision for the pinion to slide along it to engage
and disengage from the engine ring gear.
Figure 34: Starter system armature
Eddy currents
The armature is constructed with a core made of several thin iron stampings that are
attached to each other. Laminated construction is used because in a solid iron core
the magnetic fields would generate eddy currents and the associated energy loss.
By using laminated construction, and insulating the laminations, eddy currents in the
core are minimised.
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The slots on the outside diameter of the laminations hold the armature windings. The
windings loop around the core and are connected to the commutator. Each
commutator segment is insulated from the adjacent segments.
Figure 35: Starter system armature components
A typical armature can have more than 30 commutator segments. A steel shaft is
fitted into the centre hole of the core laminations. The commutator is also insulated
from the shaft.
5.1.5 Field coils
The field coils are electromagnets constructed of wire coils wound around a pole
shoe. The field coils are attached to the inside of the starter housing. The iron pole
shoes and the iron starter housing work together, to increase and concentrate the
field strength of the field coils.
Figure 36: Starter system field coils
When the current flows through the field coils, strong stationary electromagnetic
fields are created. The fields have a north and south magnetic polarity based on the
direction the windings are wound around the pole shoes.
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Figure 37: Sectional view of field coils
The polarity of the field coil alternates to produce opposite magnetic fields. In any
DC motor, there are three methods of connecting the field coils to the armature – in
series, in parallel (shunt) and a compound connection that uses both series and
shunt coils.
5.1.6 Flywheel ring gear
Figure 38: Starter system flywheel ring gear
The flywheel ring gear is also named as starter ring or ring gear. It is a medium
carbon steel ring that is used to transfer the starter motor torque from pinion to the
flywheel.
Figure 39: Standard flywheel rotation
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5.2 Starter motor characteristics
When the field windings and armature windings connect in series, they create high
torque. Starter provides lower torque needed when the crankshaft is rotating.
Heavy load is imposed on the starter allowing high current to flow from the battery
through the field and armature windings. The same current flows through the
windings, by creating strong magnetic fields.
When one of the crankshafts start turning, less load is applied to the starter allowing
for dropping of current, making the fields weak and ultimately less torque.
Starter motor series windings provide with the required characteristics.
Series and compound windings
Arrangement of electric motor windings can be done in three different ways – series-
wound, shunt-wound or compound-wound.
5.2.1 Series-wound motors
Most of the starter motors are series-wound with current flowing first to the field
windings, then to the brushes at that time, then through the grounded brushes back
to the battery source.
Figure 40: Series-wound starter motor
Initial start
This design permits all of the current that passes through the field coils to pass
through the armature. A series-wound motor will develop its maximum torque output
at the time of initial start. As the motor speed increases, the torque output of the
motor will decrease. This decrease of torque output is the result of the counter
electromotive force.
38
5.2.2 Shunt-wound motors
Electric motors, or shunt motors, have the field windings wired in parallel across the
armature. A shunt motor does not decrease in its torque output as speed increases.
Figure 41: Stunt-wound starter motor
Due to its inability to produce high torque, the shunt wound motor is not used as a
starter motor. However, shunt motors may be found as wiper motors, power window
motors, power seat motors and so on.
5.2.3 Compound-wound motors
In a compound wound motor some of the field coils are connected to the armature
in series and some field coils are connected in parallel with the battery and the
armature.
Figure 42: Compound-wound starter motor
This arrangement allows the compound motor to develop good starting torque and
constant operating speeds. The field coil that is shunt wound is used to limit the
speed of the starter motor.
39
5.3 Starter classification
Stater motors are classified according to the method used to engage the pinion
with the engine ring gear.
Gears must mesh
A starter drive includes a pinion gear set that meshes with the flywheel ring gear on
the engine’s crankshaft. To prevent damage to the pinion gear or the ring gear, the
pinion ear must mesh with the ring gear before the starter motor rotates.
To help assure smooth engagement, the end of the pinion gear is tapered. Also, the
action of the armature must always be from the motor to the engine. The engine
must not be allowed to spin the armature.
The ratio of the number of teeth on the ring gear and the starter drive pinion gear is
usually between 15:1 and 20:1. This means the starter motor is rotating 15 to 20 times
faster than the engine.
Cranking ratio
Normal cranking speed for the engine is about 200 rpm. If the starter drive had a
ratio of 18:1, the starter would be rotating at a speed of 3,600 rpm. If the engine
started and was accelerated to 2,000 rpm, the starter speed would increase to
36,000 rpm. This would destroy the starter motor if it was not disengaged from the
engine.
Starter motors used on passenger and light commercial vehicles are either inertia
type or pre-engaged type.
5.3.1 Inertia type drives
The inertia drive depends on inertia to provide meshing of the drive pinion with the
ring gear. The screw shaft threads are a part of the armature, and will turn at
armature speed.
Screw shaft
At the end of the pinion and barrel is the pinion gear that will mesh with the ring
gear. The pinion and barrel have internal threads that match those of the screw
shaft.
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Figure 43: Inertia type starter drive
Operating principles
When current flows through the starter motor, the armature will begin to spin. Torque
from the armature is transmitted via a shock-absorbing spring and drive head to the
screw shaft. This causes the screw shaft to rotate. However, the barrel does not
rotate.
Torque transfer
The barrel has weight on one side to increase its inertia effect. The barrel tends to
stay at rest, and the screw shaft rotates inside the barrel. As a result, the barrel is
threaded down the length of screw shaft to the end. At the end of the screw shaft,
the pinion gear engages the ring gear. Here the pinion gear locks to the screw shaft
and transfers the torque from the armature to the ring gear and engine.
When the engine starts and is running under its own power, it will rotate faster than
the armature. This causes the barrel to screw back down the screw shaft and bring
the pinion gear out of engagement with the ring gear.
5.3.2 Pre-engaged type
Turning the ignition switch to the start position connects to the battery to the starter
solenoid pull-in coil.
41
Figure 44: Pre-engaged type starter drive
A magnetic field is created in the solenoid windings and the iron plunger is drawn
into the solenoid coil and a lever connected to the drive assembly engages the
drive pinion gear into the flywheel ring gear.
Contact disk
When the pinion is fully engaged with the ring gear a contact disk closes the main
circuit between the battery and the starter motor. This allows full current to the motor
and the drive pinion gear cranks the flywheel to start the engine.
When the current flows to the motor, the solenoid pull-in coil is bypassed and the
hold-in coil keeps the drive pinion gear engaged with the flywheel until the ignition
switch is released from the start position.
Pull in and hold in coils
An overrunning clutch in the drive assembly protects the starter from excessive
speeds during the brief period before the driver releases the ignition switch from the
start position as the engine starts.
5.3.3 Overrunning clutch drive
The most common type of starter drive is the overrunning clutch. The overrunning
clutch is a roller-type clutch that transmits torque in one direction only and
freewheels in the other direction. This allows the starter motor to transmit torque to
the ring gear, but prevents the ring gear from transferring torque to the starter motor.
In an overrunning-type clutch, the clutch housing is internally splined to the starter

armature shaft. The drive pinion turns freely on the armature shaft within the clutch
housing.
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Figure 45: Overrunning clutch starter drive
Operating principles
When torque is transmitted through the armature to the clutch housing, the spring-
loaded rollers are forced into the small ends of their tapered slots. They are then
wedged tightly against the pinion barrel. The pinion barrel and clutch housing are
now locked together and torque is transferred through the starter motor to the ring
gear and engine.
When the engine starts and is running under its own power, the ring gear attempts to
drive the pinion gear faster than the starter motor. This unloads the clutch rollers and
releases the pinion gear to rotate freely around the armature shaft.
5.4 Types
The most common type of starter motor used today incorporates the overrunning
clutch starter drive instead of the old inertia-engagement drive. There are four basic
types of starter motors:
• Direct drive
• Gear reduction
• Positive-engagement (movable pole)
• Permanent magnet
5.4.1 Direct drive starters
The most common type of starter motor is solenoid-operated direct drive unit.
Although there are construction differences between applications, the operating
principles are the same for all solenoid-shifted starter motors.
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Figure 46: Direct drive starter motors
Plunger
When the ignition switch is placed in the start position, the control circuit energizes
the pull-in and hold-in windings of the solenoid. The solenoid plunger moves and
pivots the shift lever, which in turn locates the drive pinion gear into mesh with the
engine flywheel.
When the solenoid plunger is moved all the way, the contact disc closes the circuit
from the battery to the starter motor. Current now flows through the field coils and
the armature. This develops magnetic fields that cause the armature to rotate, thus
turn the engine.
5.4.2 Gear reduction starters
Some of the manufacturers use gear reduction starters to provide increased torque.
The gear reduction starter differs from most other designs in that the armature does
not drive the pinion directly. The armature drives a small gear that is in constant
mesh with a larger gear.
Figure 47: Gear reduction starter motors
44
Depending on the application, the ratio between these two gears is between 2:1
and 3.5:1. The additional reduction allows for a small motor to turn at highest speeds
and greater torque with less current draw.
Figure 48: Sectional view of gear reduction starter motor
The solenoid operation is similar to that of the solenoid-shifted direct drive starter in
that the solenoid moves the plunger, which engages the starter drive.
Gear reduction starters are of two types –
a. Spur reduction gears
For this type of starter motor, spur gears are arranged in s schematic pattern. Both,
the small gear of the armature shaft and the large gear of the drive shaft mesh
together, with the normal operations of the solenoid and shift lever.
b. Planetary reduction gears
Starter motors with planetary reduction gears allow for a gear reduction between
the armature and drive shaft by mounting pinions on the drive shaft carrier and
making the pinion movement stationary. The pinion walks around inside the
stationery internal gear allowing for a gear reduction.
5.4.3 Positive engagement starters
Positive engagement starters use the shunt coil windings of the starter motor to
engage the starter drive. The high starting current is controlled by a starter relay
mounted close to the battery. When the relay is closed, current flows through a drive
coil.
45
Figure 49: Positive engagement starter motor
Drive coils creates an electromagnetic field that attracts a movable pole shoe. The
movable pole shoe is attached to the starter drive through the plunger lever. When
the movable pole shoe moves, the drive gear engages the engine flywheel.
As soon as the starter drive pinion gear contacts the ring gear, a contact arm on the
pole shoe opens a set of normally closed grounding contacts. When the ground
circuit opens, all the starter current flows through the remaining three field coils and
through the brushes to the armature. The starter motor then begins to rotate.
Holding coil
To prevent the starter drive from disengaging from the ring gear if battery voltage
drops while cranking, the movable-pole shoe is held down by a holding coil. The
holding coil is a smaller coil inside the main drive coil and is strong enough to hold
the starter pinion gear engaged.
5.4.4 Permanent magnet starters
Figure 50: Permanent magnet starter motor
46
Commutator and brushes
The permanent magnet starter design provides for less weight, simpler construction
and less heat generation as compared to the conventional field coil starters. As
there are no field coils, current is delivered directly to the armature through the
commutator and brushes. The permanent magnet starter also uses gear reduction
through a planetary gear set.
Figure 51: Exploded view of permanent magnet starter motor
Planetary gear
The planetary gear train transmits power between the armature and the pinion
shaft. This allows the armature to rotate at greater speed and increased torque. The
planetary gear assembly consist of a sun gear on the end of the armature, and
three planetary carrier gears inside a ring gear. This ring gear is held stationary.
Reduces demand for current
When the armature is rotated, the sun gear allows the carrier gears to rotate about
the internal teeth of the ring gear. The planetary carrier is attached to the output
shaft. The gear reduction provided for by this gear arrangement is 4.5:1. By providing
for this additional gear reduction, the demand for high current is lessened.
5.5 Starter torque
Torque is the turning effect that the starter motor applies to the engine crankshaft.
The starter motor torque is lower than that required by the engine.
The gear ratio of the starter pinion and engine ring gear is used to multiply the
torque to that required for the starting system.
47
Figure 52: Starter motor torque
48
6 Ignition switch system

Ignition switch, starter switch activates the main electrical systems of the vehicle.
Ignition switch provides power to the starter solenoid and ignition system
components. Ignition switch is usually connected with the starter switch to activate
the starter motor.
Figure 53: Starter motor ignition switch
Ignition switches were used as the key switches that requires appropriate key to
unlock the switch function. These mechanical switches remain to be pervasive in
modern vehicles. They have to be combined with an immobiliser in order to activate
the switch function.
Figure 54: Ignition switch connectivity to starter motor
6.1 Key start
Key start switches require the correct key to be inserted to unlock the functions of
the switch. They are mostly used in situation where access needs to be restricted to
the switch’s functions.
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Figure 55: Key start switch
Location – On the steering column
Applicable – Vehicles with manual key
6.2 Push-button start
New vehicles use the upgraded technology and are equipped with keyless systems
by replacing the key switch with a push button. The vehicles with this switch system
come with a fob. The fob transmits the low-frequency signal to the vehicle system.
Upon validation and ensuring that correct signal is sent, it allows to push a button on
the dashboard to start the engine.
Figure 56: Push-button start switch
Location – On the dashboard
Applicable – Vehicles with key less go
6.3 Remote start
The remote start switch allows to ‘turn over’ or to ‘crank’ the engine without actually
running the engine. They turn useful for conduction certain tests like compression
tests, identifying the high side of the engine cylinder.
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Location – Remote operation
Applicable – Vehicle with remote start-stop
6.4 Start-stop
The start stop system automatically shuts off the engine when the vehicle stops. The
system allows for automatic engine restart when the car is ready to drive off.
The start stop system cuts down the engine idle time and reduces emissions. The
vehicle with start-stop system enhanced the fuel efficiency by shutting the engine
during idle and saves fuel.
Figure 57: Start stop switch
Location – Remote operation
Applicable – Vehicle with remote start-stop
6.5 Safety switches
Safety switch, usually called as the neutral safety switch is a normal open switch that
stops the starting system to operate when transmission is in gear. Safety switches can
be found between the ignition and the relay or solenoid or between relay and
ground.
Location – Brake pedal/ clutch pedal
Applicable – Automatic transmission/ manual transmission
6.5.1 Inhibitor switches
Most of the starter motor circuits have an automotive safety switching mechanism
which prevents the engine to start at specific situations. The automatic transmission
51
systems integrate an inhibitor switch on the gear selector. This inhibitor switch allows
the engine to start at park and neutral positions only.
Figure 58: Starter motor inhibitor switch
This avoids the engine to start with transmission in gear and thus avoid unexpected
pulling by the vehicle. Carefully examine and adjust the inhibitor switch to avoid risk
of incorrect operation.
Location – Between the starter switch and solenoid switch
Applicable – Automatic transmission
6.5.2 Clutch neutral systems
A park/ neutral position switch is the safety switch that is used with an automatic
transmission. The switch contacts are wired in a series with the control circuit,
stopping the current flow through relay or solenoid till the shift lever turn neutral or
park. This switch can be found mounted on the transmission housing.
Figure 59: Starter motor clutch neutral system
52
When the automatic transmission is in the gear, the movement of the ignition key is
stopped by the mechanical safety switches. To turn the ignition key, the shift selector
should reach to neutral or park position. These systems are referred as interlock
systems.
Figure 60: Neutral safety switch
Clutch pedal controls the safety switches used with the manual transmissions. The
clutch start performs similar to that of a park/ neutral position switch. The clutch start
switch keeps the starter control circuit open until the clutch pedal is depressed.
Location – Clutch pedal/ clutch housing
Applicable – Vehicles with manual transmission
6.6 Shift levers
Shift lever allows switching on the starter motor. The lever pushes the pinion into the
starter gear ring. An electromagnet component known as starter relay controls the
shift lever.
On activating the starter relay, the relay core shift to the left leading the coupling
lever to insert the pinion into starter gear ring. Movement of pinion allows the shift
lever to turn.
Figure 61: Starter motor switch lever
53
When there is no current flow to the coil of the starter relay, the relay core shift back
to right allowing the coupling lever to retract the pinion from the starter gear ring.
As the starter motor draws huge amount of current, heavy duty switch needs to be
used for turning the starter motor on and off.
54
7 Diagnosis of starting system

It is essential to diagnose vehicles’ starter problems, thoroughly and systematically.
Starter system diagnosis includes checking the primary areas which are responsible
for majority of the vehicle electrical problems.
7.1 Preliminary checks
• Check the condition and state of battery charge.
• Disconnect the ignition coil lead and earth to the vehicle body to prevent
starting.
• Connect a remote-control starting switch between the solenoid “Bat” terminal

and the solenoid “Switch” terminal.
• Connect the voltmeter leads as indicated for each test and read the voltage
drop while cranking engine, when the ignition switch is OFF.
7.2 Starter fault diagnostic table
Symptom Possible cause Action
Engine not cranking • Gear selector not in • Required battery

(starter does not turn) correct position. diagnosis
• Battery • Examine DTCs and

follow manufacturer
• Harness/ connectors manuals.
• Starter motor
• Starter relay
• Start switch
• Transmission control
module (TCM)
• Engine control module

(ECM)
• Engine seized
Engine not cranking • Installation of the starter • Examine the ring gear
55
(starter motor does motor teeth.

turn)
• Starter motor
• Ring gear
Slow cranking of the • Battery • Examine the condition

engine of the battery and
• Harness/ connectors state of the charging.
• Starter motor
• Incorrect grade of the

engine oil
Excessive noise from • Starter motor • Examine the starter

the starter motor motor installation.
• Starter motor installation/
casing
• Ring gear
7.3 Accessing electrical terminals using test probes
Test lamps can be used to test the circuit electricity. Ensure that the test light is tested
on the power ground before using. When one end of the test light is connected to
power and the other end to the ground, test light illuminates. If this does not happen,
the test light fails to illuminate.
Electrical terminal
Wiring connections can be checked by back probing. For water proof plugs, back
probing turns out to be difficult and instead metal probes are used for the purpose.
Metal probes can be easily inserted from the back of the connector. By using a
multimeter, required values can be measured.
Fuse holder
Detach the fuse holder by loosening the screw fittings. By removing the screws, the
fuse holder can be completely removed and tested.
56
Steps involved to examine the circuit with test probes are –
• Connect the light to the negative battery terminal and the probe end of the test
light to the positive battery terminal.
• Connect the clip to the ground close to the test area. Ground should be an
unpainted metal surface of the vehicle, fixed to the battery ground return system.
• Place the probe in parallel to the test light circuit.
• Light turns on, if voltage is present.
7.4 Resistance and current flow check
For resistance and current flow, a voltmeter and an ammeter give more precise
check.
• Connect the voltmeter between the alternator output terminal and earth.
• Disconnect the cable from the starter motor output terminal and connect the
ammeter into the circuit.
• Alternatively, an induction-type ammeter can be used avoiding removal of the

alternator positive cable.
• Check the alternator voltage and record the readings of the ammeter current.
• When the engine is idle, the voltage readings of 14 volts or higher readings
indicate correct operation of the system.
7.5 Starter current draw test
Starter current draw test measures the number of amps used by the starter during
cranking.
• Connect an ammeter into the circuit and pick up the gauge over the main starter
battery lead.
• Test with the starter cranking and the ignition disabled to prevent starting.
• The current reading should be within 125-175 A for a light vehicle and 150-250A for
the vehicles over two litres.
7.5.1 Starter voltage drop test across the supply line
• Connect the positive lead of the voltmeter to the battery “+” terminal.
• Connect the negative lead to the starter main terminal.
57
• With the engine cranking, the reading should be no more than 0.5 volts.
7.5.2 Starter voltage drop test across earth line
• Connect the negative lead of a voltmeter to the battery negative terminal.
• Connect the positive lead to the starter ground.
• With the engine cranking the reading should be not more than 0.5 volts.
7.5.3 Starter voltage drop test across starter solenoid contacts
• Connect the positive lead of the voltmeter to the solenoid “Bat” terminal.
• Connect the negative lead to solenoid “Starter” terminal.
• With the engine cranking, the reading should be no more than 0.5 volts.
7.6 Diagnostic procedure using a scan tool
Scan tool can be used for diagnosis of the starting system’s electrical faults. Scan
tool allows for measuring various parameters. Scan tool allows for reading out and
erase and reprogram software. Scan tool provides information on DTC, live data and
freeze data.
It is recommended that when scan tool is used for diagnosis, it is important to follow
manufacturer procedures to retrieve DTCs and to get the live data or freeze frame
data.
Diagnosis of the starting system can be done by using a scan tool, which measures
different parameters. Diagnosis steps includes the following steps –
• Follow manufacturer specifications to retrieve Diagnostic Trouble Codes (DTCs)

and obtain live data or freeze frame data.
• Clear all the fault codes and re-examine for DTCs.
• Use the scan tool and carefully observe the live/ freeze frame data at different
instances –
o Battery voltage before starting
o Battery voltage when engine is ON and with no accessories ON
o Battery voltage when engine is ON
o Conditions under which the voltage fluctuates
o Amount and speed at which the battery is charged

58
7.7 Access and interpret scan tool system data
Follow manufacturer specifications for accessing and interpreting scan tool data to
obtain live data or data freeze-frame to detect the fault codes. Once the data is
captured, codes need to be re-checked for DTCs.
If DTCs continue, examine by following DTC system. DTCs do not always indicate a
faulty component but also indicate a system fault. Conduct further tests accordingly
to remove the problem. Always follow manufacturer procedures for repairing the
parts.
7.7.1 Diagnostic Trouble Codes (DTCs)
DTC’s are automotive computer codes stored by the on-board computer diagnostic
system (OBD) in a vehicle. These codes are intended to help determine the root
cause of the failure.
Figure 62: Diagnostic trouble codes
The faults generated by a component in the system or its associated circuit

generates the code, fault code generated is stored in the ECU memory for the
further reference of the user. These codes are described into two – fast and slow,
some systems in an ECU produce both types.
Procedure for interpreting DTCs and Scan tool data
1. Locate the data link connector (DLC), and connect the scan tool.
2. Power on the scan tool, and turn the ignition on, without starting the engine.
3. Establish scan tool communications with the vehicle.
59
4. Retrieve and record the DTCs.
5. Look up the DTCs' definitions in code books or in the manufacturer's service

information.
6. Interpret the results, referencing the manufacturer's service information.
7. Power off the scan tool, turn the ignition off and disconnect the scan tool.
7.7.2 Live data
In the advanced scan tools to diagnose the vehicle systems, there is a special
feature to read the real-time measurement of the system inputs and outputs. This is
called the live data. These also provide real-time data to understand the
environment of the vehicle.
Figure 63: Sample Live data
The following are some of the live data provided by scan tool:
• Running engine speed in Revolutions per Minute (rpm).
• Ignition time, based on valve timing.
• Absolute throttle position
7.7.3 Freeze frame data
When an emission related fault occurs in a vehicle, the OBDII system not only sets the
code but also records a snapshot of the vehicle operating parameters which helps
to identify the problem. These set of values are referred as freeze frame data.
60
Figure 64: Sample Freeze frame data
As per the regulations related to the OBDII system, freeze frame buffer will capture
and store the engine operating conditions whenever the malfunction indicator lamp
is glowing. The data can be assumed as a single record for a particular set of
operating conditions.
7.7.4 Waveforms
In modern electronics, signals change millions of times per second. When you plot
these changes on an oscilloscope, the graph will take on some shape. This shape is
called as a waveform, and its characteristics can tell many things about a signal
including:
Figure 65: Sample Oscilloscope waveforms
• The minimum and maximum voltages of a signal
• The frequency of an oscillating signal
• How a circuit changes a signal as it moves through the circuit
• How the frequency or timing of the signal changes over time
61
• Whether or not a malfunctioning component is distorting the signal
• How much of the signal is noise and whether the noise is changing with time?
7.8 Component test
The root causes behind the failure of the starter system can be determined by
inspecting and checking the all the individual components.
To start with, examine armature and field coil for all the open and short circuits. It is
advised to replace the starter motor if diagnosed with faulty armature or field coils.
7.8.1 Field winding test
Steps involved in performing a field winding test are –
• Use a good quality Digital Multimeter for the test and examine for coil continuity
and shorts.
• Examine the winding pattern of the field coils and identify the earth and power in.
• This helps to get correct and accurate readings.
• Detach the coils from the starter yoke and break the continuity between the coils
and the body.
• Any readings on the ohmmeter, indicated leakage from the field coils.
7.8.2 Armature test using growler
• Induce a magnetic field into the armature by using a growler.
• When the armature is rotating, run a small hacksaw blade across its top.
• The vibrations of hacksaw blades indicate shorts in the armature.
• This happens because growler acts like a primary stage of a transformer and
armature as the secondary windings.
• A magnetic field is created by the winding shorts of the armature.
• For an electrically safe armature, ensure that the commutator end of the
armature is cleaned neatly.
• For worn-out commutator, determine the possibility of it getting serviced.
• It serviceable, machine it or clean with emery paper as required.
• Avoid skipping of brushes by undercutting the insulation in the commutator.
62
7.8.3 Commutator test
• Examine the surface of the commutator for any dirt or burning. The traces of dirt
need to be cleaned and the burnt part can be cut using an armature lathe.
• Examine and measure the commutator diameter and if diameter is less than
manufacturer specifications, replace the armature.
• Check the measure the commutator runout.
• If the runout is within the manufacturer specifications, inspect the commutator for
carbon dust or brass ships.
• Replace the commutator if the runout is beyond manufacturer specifications.
• Examine and compare the depth of the insulating material between the
commutator segments, with manufacturer specifications.
• Examine continuity between the segments of the commutator, if any open circuit
identified, replace the armature.
7.8.4 Brushes and holder test
• Connect the DMM to the brush holder by connecting one end to the positive
terminal and other end to the earth.
• Ensure breaking of continuity.
• Brush holder needs to be replaced, if continuity persists.
• Examine the brush length by using a Vernier and check the technical data for
determining the minimum length of the brush.
7.8.5 Overrunning clutch and pinion test
• Examine the drive pinion overrunning clutch by holding the pinion body with one
hand and teeth with the other hand.
• Turn pinion in different directions.
• There should be smooth turning on one direction and should not turn in the other
direction.
• Examine and inspect for damaged teeth.
7.8.6 Flywheel ring gear test
• Usually ring gears do not wear evenly over all the teeth.
63
• Only a few teeth or few places of the gear appear to be worn-out.
• Usually the teeth where the pinion gets engaged with the engine gets worn-out.
• Start the engine and analyse the spot where the teeth are worn out.
• Replace the ring gear with worn out teeth.
7.8.7 Stater motor bench tester operation
Detach the starter motor from the vehicle to perform no-load and torque test.
Torque tests can be performed by using s starter test bench or jig. Maximum torque is
produced by loading the starter test bench. Simultaneously check the current draw
and voltage drop.
Bench test are performed only after the starter overhaul. The normal-size starter
under test will produce 14 Nm and draw around 300 amps.
No-load test
Hold the starter securely against the reaction that will occur when the starter rotates.
• Connect the battery to the starter, along with an ammeter with 100 amps
capacity.
• Operate the starter by connecting a jumper lead between the B and S terminals
of the solenoid.
• Ensure that pinion moves along the full travel and free spinning of the starter.
• Readings on the ammeter should be around 50 amps.
Test result
Faults or problems can be recognised by the decreasing sped levels and increased
drawings of the current. This may be either due to worn-out bearings, bent shaft or
ground in armature windings.
Non-operating starter and no current draw specify some form of open circuit.
Examine the starter switch, connections and the starter brush.
7.8.8 Drive pinion test
The drive pinion over running clutch can be checked by taking the pinion body in
one hand and pinion teeth on the other hand trying to turn the pinion in both
directions. By doing this, it should turn smoothly in one direction and not turn in
opposite direction.
64
8 Repair of starting system

Starter motor repair includes removal, disassembly and re-assembly.
8.1 Starter motor removal
The steps involved in removing the starter motor are –
• Disconnect the battery.
• Disconnect the two starter motor cables.
• Disconnect the two wiring loom connectors from the solenoid.
• Remove the starter motor securing bolts from the bell housing of the gearbox and
lift the starter motor clear of the vehicle.
8.2 Starter motor disassembly
The steps involved in disassembling the starter motor are –
• Clamp the starter motor into a vise and remove the commutator end plate.
• Remove the retaining clip from the armature shaft.
• Disconnect the starter motor main feed wire from the solenoid.
• Disconnect the solenoid securing screws from the starter motor.
• Withdraw the solenoid from the drive end housing by lifting the solenoid upward
to disengage the solenoid armature from the pinion actuator fork.
• Remove the two-end housing securing bolts and guide and end housing from the
starter centre housing.
• Replace the brushes by removing the end plate securing screws.
• To replace the field winding brushes, unsolder each brush from its field winding
and solder replacement brushes.
• To replace the earth brush, remove the securing rivets from the end plate and
rivet the replacement brush.
• Remove the central field housing from the armature.
• Unlock the armature from the actuating fork and front housing and withdraw the
armature.
65
• Inspect the actuating fork for damage and replace if required.
• Service the drive pinion and one way clutch as one single unit.
• If damaged, replace both together. To replace, withdraw the snap ring from the
armature and remove the unit.
• Clear all starter motor components and inspect for signs of damage or excessive
wear. Noisy bearings, won bushes and brushes worn to 8 mm in length must be
replaced.
8.3 Starter motor assembly
Starter motor can be assembled by the following steps –
• Install the pinion shift fork into the front housing.
• Position the pinion shift fork onto the one-way clutch.
• Locate the armature shaft into the front housing bush.
• Carefully slide the central housing over the armature and position the central
housing onto the front housing.
• Position the brush plate onto the armature slip ring.
• Fit the field winding brushes and retaining springs onto the end plate.
• Position the end housing onto the central housing.
• Align the brush holder end plate and fit the securing screws.
• Align the end housing with the central and front housing, install the starter motor
through bolts and secure.
• Locate the solenoid plunger onto the pinion shift fork.
• Align and secure the solenoid mounting bolts.
• Bench test the starter motor before installing into the vehicle.
• Reconnect the starter motor main feed wire to the solenoid. Refit the starter motor
to the vehicle and carry out starter motor tests.
66
8.4 Repair procedure of battery
Repair of battery includes the following steps –
• Remove the terminals of the battery and clean all the terminals from corrosion.
• Maintain the desired fluid level in the battery.
• By using a cleaning brush, clean the battery terminal.
• Carry the battery by using a battery tool.
• Avoid the removed terminals, to touch the vehicle ground.
• Radio pre-sets can be secured by installing memory saver devices on the vehicle.
• Tightly secure the battery terminals by applying correct force.
• Once the terminals are fixed, apply contact spray to the terminals.
• To disconnect the battery, remove the negative terminals first.
8.5 Remove and replace starting system solenoid battery

terminal
• Detach the terminals of the battery and clean all the terminals.
• Slip-joint pliers can be used to hold the battery terminal when it is disconnected.
• Cut about ½ in. of insulation from each of the cable.
• Use a solution of baking soda mixed with water for cleaning the copper strands
that turn green.
• Allow the cable to dry by providing compressed air.
• Slip the tubing over the cable and slide it down, removing it from its way.
• Enclose the main cable along with all the required smaller cables into the
compression nut.
• Fix the battery terminal and secure it till it snugs.
• Slide the heat-shrink tubing over the connection and shrink it.
67
8.5.1 Precautions
• Put the markings while disconnecting the connectors.
• Disconnect the solenoid connection by pressing and pulling back the release clip
on the plastic harness.
• Ensure not to pull on the wiring as it may lead to tearing of the plastic harness.
• Place the set of connectors safely.
• Use the markings while connecting the wirings.
• Use relevant nuts with proper torque to tighten securely the solenoid plastic
casing.
• After connecting, reconnect the battery and try starting the vehicle.
68
9 Post repair inspection and documentation

Upon completion of the service/ repair, post-service inspection and documentation
include the following steps –
• Clean the work area, tools, equipment and vehicle to workplace requirements.
• Material that can be reused should be collected and stored.
• Waste and scrap should be removed following workplace procedures.
• Unserviceable equipment should be tagged and faults are identified in

accordance with workplace procedures.
• Complete the relevant service and repair documentation.
9.1 Post service checks
Post service checks include the following –
• Examine and ensure the condition of the battery charge.
• Examine the voltage drop readings while cranking engine, when the ignition
switch is OFF.
• Make sure that a remote-control starting switch is connected between the

solenoid bat terminal and switch terminal.
• Restart the engine and re-examine the voltage settings.
9.2 DTC clearing procedure
• Ensure that all the battery terminals are fit securely and tightly.
• Examine the alternator belt tension.
• DTCs can be cleared by connecting a scan tool.
• Examine all the related systems and ensure all the systems are operating correctly.
9.3 Electrical connector mating
• Examine the starting system circuit connectors and ensure that all the connectors
are removed and the route is properly wired.
• Securely bolt the retaining device to firmly place the connector.
69
• Resistance test can be performed to ensure that the connecting pins are tightly
secured.
• Resistance test can be performed by back-probing the plug from each side and
twisting the connector plug.
9.4 Static and dynamic performance tests
• Examine the battery voltage.
• Observe for any cranking noise while starting.
• Ensure that starter motor connectors are locked properly.
• Ensure that the battery terminal is tightly secured.
Perform road test and examine if the warning lamp turns off at correct intervals and
when the vehicle is turning.
Ensure that all the functions are synchronised once the battery is removed.
9.5 Workshop procedures
Once the automotive systems are inspected and repaired, follow the below house-
keeping rules:
• Ensure the work area is cleaned and there is no waste lying on the floor.
• Clean and wipe all the oil spills on the floor to avoid slips, trips and falls.
• Do not leave the tools on the workshop floor.
• Clean the tools and equipment after completion of the task.
• Inspect the tools for physical damages and tagout any faulty tools and report to
the supervisor.
Tagout: The tagout is a safety practice to reduce the risk of technicians using tools
and equipment which are found unsafe or that are in the process of being serviced.
The tagged-out tool avoids the accidental usage of the faulty tools.
70
Figure 66: Tagout of faulty equipment
• The tools must be stored back in the designated place.
• Precision measuring equipment like dial gauges, Vernier calipers, screw gauges,
etc. and specialist diagnostic tools such as scan tools and multimeter should be
stored in the moisture free manufacturer provided containers in line with the
manufacturer’s procedure.
• Adhere to the safe environmental procedures for cleaning and disposing of non-
recyclable materials.
• The recyclable materials must be disposed to the authorized dealer.
9.6 Documentation
It is very important to document the procedure performed on the system before and
after a service or a diagnosis.
9.6.1 Repair Order (RO)
A repair order (RO) is written for every vehicle brought into the shop for service. RO is
also called as service or work orders. ROs contain information about the customer,
the vehicle, the customer’s concern or request, an estimate of the cost for the
services, and the time the services should be completed.
RO is a legal document used for many other purposes, such as payroll and general
record keeping. Legally, RO protects the shop and the customer. Every shop may
enter different information onto the original RO, most ROs contain the following
information:
• Complete customer information
• Complete vehicle identification
71
• The service history of the vehicle
• The customer’s complaint
• The preliminary diagnosis of the problem
• An estimate of the amount of time required for the service
• An estimate of the costs of the parts involved in the service
• The time the services should be completed
• The name or other identification of the technician assigned
• The actual services performed with their cost
• The parts replaced during the services
• Recommendations for future services
• The total cost of the services
Figure 67: Sample repair order
72
9.6.2 Diagnosis report
The diagnosis report is a report of diagnosis generated or manually prepared by the

technicians which consist of the following information:
• Complete vehicle information
• The service history of the vehicle
• Concern being diagnosed
• The diagnosis tool and equipment used
• The diagnosed fault codes generated
• The live data, the freeze frame data for the diagnosis done
• The technician’s observations
• The procedure involved to resolve the generated concern
• The conclusion and summary of the diagnosis
This data helps the technician in understanding and registering the diagnosis,
making the customer understand the repairs and diagnosis done on the vehicle. This
also helps as a quick reference for the workshop if any complaint arises. And as per
the law, the reports must be procured in the workshop for further assistance.
Figure 68: Sample diagnosis report
73
Importance of documenting diagnostic process
• The technician can keep track of the process e.g. the details of the tests and their
results.
• The technician can see the build-up of information which will help them
eventually recognize the fault.
• The business can communicate accurately with the customer from the start of the
diagnostic procedure until the repair is completed and paid for.
• The business can obtain authority to repair at the appropriate stages as the
procedure is worked through.
• There is an accurate record if there is any dispute over the work done.
• There is a service record that helps as a reference for future jobs.
74
10 References
Erjavec, J. Automotive Technology: A Systems Approach. [Cengage]. Retrieved
from https://cengage.vitalsource.com/#/books/9781337794404/
May and Simpson, Automotive mechanics: 10th Edition, McGraw-Hill Education.
CDX Automotive, Light Vehicle: Jones and Bartlett Learning.
https://www.safeworkaustralia.gov.au/chemicals
* All images are taken from Google and clipart.
75

Learner Guide - AURETR030 - Diagnose and Repair Starting Systems PDF

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Diagnose and repair

It applies to those working in an automotive service and repair industry. The

No licensing, legislative, regulatory or certification requirements apply to this unit at

Elements and Performance Criteria

1.1. Job requirements are determined from Page 3 - 15

1.2. Diagnostic information is sourced and Page 16 - 23

1.5. Diagnostic tools and equipment are Page 20 - 23

2.1. Diagnostic tests are carried out according Page 55 - 64

2. Diagnose 2.2. Faults are identified from diagnostic test Page 55 - 64

2.3. Diagnosis findings and recommendations Page 73, 74

3.1. Repair information is sourced and Page 16 - 20

3.2. Repair options are analysed and those Page 65 - 68

3.3. Repair tools, equipment and materials are Page 10 – 13, 20 - 23

3.4. Repairs and component replacements Page 65 - 68

3.5. Post-repair testing is carried out according Page 69, 70

4.1. Final inspection is made to ensure work is to Page 69, 70

4.2. Work area is cleaned, waste and non- Page 10, 70

4.4. Workplace documentation is processed Page 71, 72

• Work health and safety (WHS) and occupational health

o using appropriate personal protective equipment (PPE) Page 8 - 10

o identifying hazards and controlling risks associated with:

 working on high voltage ignition systems Page 5, 6

 wearing jewellery while working around high current Page 6, 7

• Operating principles of starting systems and associated

o producing movement due to the force between Page 26 - 29

o producing magnetic fields due to the current flow Page 29

o basic direct current motor operation, including simple Page 32 - 37

• Application, purpose and operation of starting systems

o starter motors, including:

 internal component function and operation, Page 32 - 37

 starter motor windings, including series wound, shunt Page 38, 39

 permanent magnet starter motors Page 46, 47

 direct drive and reduction-type starter motors Page 43 - 46

o starting electrical systems, including:

 shift levers Page 53, 54

 overrunning clutch flywheel ring gears Page 37

 ignition switching, including key start, push-button Page 49 - 51

 safety switches, including inhibitor switches and Page 51 - 53

• Diagnostic testing procedures for starting systems,

o accessing and interpreting scan tool system data,

 Diagnostic trouble codes (DTCs) Page 59, 60

 live data Page 60

 freeze frame data Page 60, 61

 waveforms Page 61, 62

o using diagnostic flow charts Page 55, 56

o testing electrical systems, including procedures for:

 accessing electrical terminals and using test probes Page 56, 57

 resistance, current flow and voltage drop checks of Page 57

 field winding tests Page 62

 armature tests, including using a growler Page 62

 commutator tests Page 63

 brushes and holder tests Page 63

 overrunning clutch and pinion tests Page 63

 flywheel ring gear tests Page 63, 64

 starter motor bench tester operation Page 64

• Repair procedures for starting systems, including:

o tightening connections Page 65 - 68

o replacing faulty or damaged cable connections Page 65 - 68

o removing and replacing faulty or damaged Page 65 - 68

• Post-repair testing procedures for starting systems,

o DTC clearing procedures Page 69

o checking for electrical connector mating Page 69, 70

o static and dynamic performance tests of starting Page 70