Starting System and Engine Cooling Inspection Procedure

4.1. STARTING AND CHARGING SYSTEM

OBJECTIVES
After completing this experiment, you will be able to:
1. Test and safely charge the battery
2. Understand how the cranking/starting works.

DISCUSSION
The starting system includes the battery, starter motor, solenoid, ignition switch, and in some
cases, a starter relay. An inhibitor (neutral safety) switch is included in the starting system
circuit to prevent the vehicle from being started while in gear. When the ignition key is turned
to the start position, the current flows and energizes the starter's solenoid coil. The energized
coil becomes an electromagnet which pulls the plunger into the coil, the plunger closes a set
of contacts which allow high current to reach the starter motor.
The charging system, like the starting system is a series circuit with the battery wired in
parallel. After the engine is started and running, the alternator takes over as the source of
power and the battery then becomes part of the load on the charging system.
A “dead battery” (discharged battery) is a very common problem. The engine will usually fail
to crank and start. Even though the lights and horn may work. There is not enough current in
the battery to operate the starting motor. Thus, it is important to inspect and test vehicle
battery. In this experiment, you will study to inspect the battery visually and by measuring the
voltage to determine the battery condition, thus preventing failure in the starting and charging
system.

EQUIPMENT
1. EFI Petrol Engine Test Bed (EP-TBS-E) Trainer
2. EFI Petrol Engine Test Bed (EP-TBS-E) Experiment Manual
3. Battery Tester (not supplied)

Figure 4.1-1 A battery tester.

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 Starting System and Engine Cooling Inspection Procedure

PROCEDURE
1. Prepare the required equipment for this experiment.
2. Be sure that the procedure of Using the Trainer (Sub-chapter 2.5) has been followed
correctly.
3. Find the engine battery which is located on the bottom side of the trainer next to the fuel
tank.
4. Visually inspect the battery condition for a dirt buildup on the battery top, damaged case,
and loose or corroded connections.
Note: Those are common sources that can cause starting problems.
5. If necessary test the battery by using a battery tester.
Note:
Ways to use a battery tester: connect the appropriate cables of the tester to battery
terminal (+) and (-), and observe the tester reading. Activate the LOAD ON by pushing
the toggle switch left/right and notice how much the voltage is dropped (Figure 4.1-2). If
the needle is lied on yellow or red area, that means that the battery is weak or bad, thus,
it should be replaced with a new one.

(a) (b)

(c)

Figure 4.1-2 (a) Initial battery tester reading, (b) Battery tester reading when switching the LOAD ON
(c) LOAD ON toggle switch.
6. Observe engine instrument and control panel.
7. Switch ON the control panel and crank the engine by turning the ignition switch key
clockwise (ST. position). While in cranking, observe and record the voltmeter and
ampere-meter reading on the control panel (Figure 4.1-3).

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 Starting System and Engine Cooling Inspection Procedure

Note: In this step, the power cable of ignition coil can be removed so the engine will start
but not run (Figure 4.1-4), however, do not crank the engine for more than 15-30 seconds
or starter may damage. Once you have got the data, instal back the power cable and
start the engine (make sure engine can run normally).

Figure 4.1-3 The two parameters for cranking/starting observation.

Ignition Coil
Power Cable

Figure 4.1-4 A way to prevent the engine starts running.

8. Connect ignition coil power cable and then start the engine.
9. When the engine is running, record the voltmeter and ampere-meter reading on idle speed
(800 Rpm), 1500 Rpm, and 2000 Rpm. Adjust the throttle control to get those variation
of engine speed.
Note: In this step, the engine is charging the battery. Battery voltage should be about
13.8V (higher) than the normal voltage when the engine is off.
10. Discuss the experiment results with your instructor.
11. Clean up the trainer when experiment is done.
12. Return all equipment that used during the experiment.
13. Keep the trainer in a proper place.

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 Starting System and Engine Cooling Inspection Procedure

QUESTION AND TASK

1. Fill your observation results into Table 4.1-1 below.
Table 4.1-1 Starting system diagnosis results

No Condition Voltage (Volt) Ampere (Amp.)

1 Control panel is ON …............ VDC …............ Amp

2 Cranking the engine …............ VDC …............ Amp

3 Engine at idle speed …............ VDC …............ Amp

4 Engine at 1500 Rpm …............ VDC …............ Amp

5 Engine at 2000 Rpm …............ VDC …............ Amp

2. What will happen if the engine is low battery?

3. Mention starting system components and describe how the system can start the engine
running!

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 Starting System and Engine Cooling Inspection Procedure

4.2. ENGINE COOLING SYSTEM

OBJECTIVES
After completing this experiment, you will be able to:
1. Recognize the corresponding components of cooling system.
2. Understand the work principles of cooling system.
3. Understand the function of radiator.

DISCUSSION
Combustion of the air-fuel mixture in the cylinders generates heat which produces high
pressure, to force the piston down in the power stroke. Not all of this heat can be converted
into useful work on the piston, and it must be removed to prevent seizure of moving parts.
This is the role of the cooling system. Most engines are liquid-cooled.
A liquid-cooled system uses water coolant. Basically, coolant flows through passages in the
engine, and through a radiator. The radiator accepts hot coolant from the engine, and lowers
its temperature. Air is flowing around, and through the radiator takes heat from the coolant.
The lower-temperature coolant is returned to the engine through a pump.

EQUIPMENT
1. EFI Petrol Engine Test Bed (EP-TBS-E) Trainer
2. EFI Petrol Engine Test Bed (EP-TBS-E) Experiment Manual

PROCEDURE
1. Prepare the required equipment for this experiment.
2. Be sure that the procedure of Using the Trainer (Sub-chapter 2.5) has been followed
correctly.
3. Fill in reservoir with water coolant until it reaches maximum level (upper line in radiator
reservoir). Figure 4.2-1 shows the radiator reservoir.

Figure 4.2-1 The dotted line is the maximum level of reservoir.

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 Starting System and Engine Cooling Inspection Procedure

4. Also, fill in the radiator with water coolant until it is full. See Figure 4.2-2 below.

Figure 4.2-2 The water coolant when it is on maximum level in the radiator.
5. Observe the water temperature sensor, it is located at engine water outlet to radiator
(Figure 4.2-3). Be sure that there is no leak or water drops.

Figure 4.2-3 Water temperature sensor is connected to water temperature display on control panel
6. Observe the engine water Outlet temperature sensor (Figure 4.2-4). Be sure that the
sensor (thermocouple) connector is tight.

Figure 4.2-4 The thermocouple is connected to Engine Water Outlet reading on control panel.

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 Starting System and Engine Cooling Inspection Procedure

7. Observe the radiator hose (inlet and outlet), be sure the clamp is tight and no leakage. See
Figure 4.2-5.

Engine water outlet

(radiator inlet)

Engine water inlet

(radiator outlet)
Figure 4.2-5 Radiator Hoses. Red arrows show those inlet and outlet.
8. Observe the cooling fan and try to turn the cooling fan clockwise using your hand (Figure
4.2-6). In condition of the engine is off before running, how do you feel when turning the
fan? compare your result later when the engine is off after warming up.
Note: This engine cooling fan is mechanically system (bi-metals spring coil)

Cooling Fan

Figure 4.2-6 Cooling Fan investigation.

9. Start the engine by turning the ignition switch key clockwise to ST. position. The engine
should be run.
10. Set the engine speed to 1000 Rpm by adjusting the throttle control and let the engine run
for about 3 minutes.
11. Observe the water temperature gauge on control panel and record the temperature reading.
12.Observe also temperature display on control panel. Record the temperatures of Engine
Water Inlet and Engine Water Outlet by selecting T3 and T4 respectively.

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 Starting System and Engine Cooling Inspection Procedure

13. Gradually increase engine speed to 2000 Rpm for 2 minutes and 2500 Rpm for 1 minutes.
Record all necessary temperatures as previous step for comparison.
14. Keep the engine run until thermostat is fully opened and water temperature gauge reading
is approximately (±90°C). The opening of thermostat is indicated by temperature reading
almost same of T4 and T3.
Note: When thermostat is close, the temperature difference between T4 and T3 is more
than 5ºC, but when the thermostat is open, the temperature difference will be less than
2ºC.
15.After considering the thermostat is fully opened, you can turn Off the engine.
16.Observe the cooling fan and try to turn the cooling fan clockwise using your hand. In
condition of the engine is off after warming up, how do you feel when turning the fan?
compare your result when the engine was off before running. When engine is warm, the
fan is connected to the engine shaft so it will be hard to turned.
17. Discuss the experiment results with your instructor.
18. Clean up the trainer when experiment is done.
19. Return all equipment that used during the experiment.
20. Keep the trainer in a proper place.

QUESTION AND TASK

1. Fill your observation results into Table 4.2-1 below.
Table 4.2-1 Temperature engine observation results

No Engine Time Water (T3) Engine (T4) Engine (T6)

speed Temperature Water Inlet Water Outlet Ambient
Gauge (ºC) (ºC) (ºC) Temp. (ºC)

1 1000 Rpm 3 minutes ….... ºC ….... ºC ….... ºC ….... ºC

2 2000 Rpm 2 minutes ….... ºC ….... ºC ….... ºC ….... ºC

3 2500 Rpm 1 minutes ….... ºC ….... ºC ….... ºC ….... ºC

2. Describe cooling system components and their function for cooling down the engine!
3. Why does the cooling fan speed is slower when the engine is cold compare to the fan
speed when the engine is fully warmed up?
4. Explain the work principles of thermostat!