Student Assignments for EC-510HV_052964 Functional cutaway diesel starter EC-510HV_052964-95_V2025-5 © 2025 ConsuLab Educatech Inc. All rights reserved. EC-510HV_052964-95 Table of contents 400-6330 Zéphirin-Paquet St. QUEBEC QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 © 2025 ConsuLab Educatech Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053334 and above. Table of Contents Product Description 3 Warnings and Cautions 3 Educational Advantages: 3 Items needed to use the product: 3 Application 3 Technical Support 3 Component Identification 4 Operation Instructions 5 Learning Modules 6 Theory Theory and practices: For clear understanding of concepts 8 Definition and Relationships 9 Student Assignments SA-1 — Wiring Diagram Analysis 13 SA-2 — Starter Cranking Voltage Test 14 SA-2 — Student Answer Sheet 16 SA-3 — Starter Cranking Amperage Test 17 SA-3 — Student Answer Sheet 19 SA-4 — Result Analysis using Ohm’s Law 20 SA-5 — Solenoid Activation with Booster Cables 21 SA-5 — Student Answer Sheet 24 consulab.com info@consulab.com 3 EC-510HV_052964-95 Product Description Product Description The EC-510HV cutaway model demonstrates the operation and internal components of a typical diesel starter. Students can easily visualize the internal operation of the starter and safely operate it. Warnings and Cautions The trainer must be connected to a fully charged 12 volt battery with a minimum CCA capacity of 850 CCA.. The protective cover should never be removed during demonstrations, as moving components may cause injury or elec- tric shock. Educational Advantages: • Fully functional cutaway diesel starter • Allows students to clearly see the internal components and their operation in real time • Protective plexiglass cover • Power requirements: 12 VDC Items needed to use the product: • Fully charged battery with a minimum capacity of 850 CCA • Booster cables • Digital multimeter • Inductive ammeter, which is available in two types. Type 1: This type of inductive ammeter is equipped with a digital readout screen which reads the current being mea- sured directly on the ammeter. No other equipment is needed. Type 2: This type of inductive ammeter requires interfacing with a digital voltmeter with adjustments being selected based on the amount of current being measured. Be sure to follow the equipment instructions to ensure accurate readings. • Safety gloves Application The starter mounted on the EC-510HV is a Delco brand. Delco starters are used on a wide variety of diesel engines. Technical Support Contact the ConsuLab technical support for any damage or defect of the trainer components. +1 (800) 567-0791 Ext 1 support@consulab.com mailto:support@consulab.com consulab.com info@consulab.com 4 EC-510HV_052964-95 Component Identification Component Identification 1. Starter Solenoid 2. Starter Motor 3. Crank Relay 4. Crank Relay Contacts Fuse (60A) 5. Ignition Switch 6. Starter Relay Coil Fuse (10A) 7. Solenoid Primary Terminals 8. S Terminal 9. Battery 350A Main Fuse 10. Ground Terminal 11. Main Fuse Test Points 12. 12VDC Power Supply Cables with Alligator Clamps 3 8 7 12 465 2 11 9 9 10 1 consulab.com info@consulab.com 5 EC-510HV_052964-95 Operation Instructions Operation Instructions The EC-510HV starter has been designed to operate in the same way as those starters installed a “real-life” vehicle: 1. Connect the positive (red) alligator clamp to the positive terminal of a fully charged 12V battery. This must first be charged at full capacity 2. Connect the negative (black) alligator clamp to the battery negative terminal. 3. Turn the ignition key to the START position. 4. The starter solenoid should activate to operate the starter. 5. It is also possible to bypass the solenoid circuit using a specialized jump-start tool by connecting it to its primary terminals. Do not use a screwdriver. 6. The EC-510HV trainer is equipped with an OCP (Over Crank Protection) thermal device. During periods of long cranking the OCP system may interrupt the circuit allowing “cool-down” time to occur and it will automatically reset after a short time. If restarting is necessary, turn the ignition key to OFF and then back to START. 7. Do not crank the starter motor for more than 5 seconds during each use. 8. Wait 15 seconds between starting sequences. 9. Disconnect the trainer from battery when not in use. Warning Thermal Over-Crank Protection (OCP) The starter motor is equipped with a protective switch that activates when the starter motor temperature becomes too high. This protection is also called an Over-Crank Protection (OCP) switch. Starter OCP switch consulab.com info@consulab.com 6 EC-510HV_052964-95 Learning Modules Learning Modules The EC-510HV-95 student manual contains learning modules, information, and resources to help students master various basic electrical and electronics skills and concepts. Each module provides instructional support information, student assignments and a student answer sheet. The student assignment procedures and answer sheets may be reproduced and distributed within the school only. Duplication of these documents for external sources is prohibited by law. The corrected answer sheets may be fillable in student records to track progress. Teachers are encouraged to follow the chronological order of the activities, but each module may be addressed individually. The EC-510HV learning modules topics are: 1. Wiring diagram analysis. 2. Starter initial voltage test. 3. Using an inductive ammeter. 4. Results analysis using Ohm’s law. 5. Starter activation with booster cables. consulab.com info@consulab.com 7 EC-510HV_052964-95 Theory Theory consulab.com info@consulab.com 8 EC-510HV_052964-95 Theory — Practices Theory and practices: For clear understanding of concepts Theory is essential. It allows you to understand how the starter and the electrical circuit work. In the heavy vehicle industry, you also need to know how to adapt your knowledge in order to properly diagnose and repair HV starting systems. The realities of the field require simple, fast, and effective methods. Very often, managers or team leaders purchase a new starter before the truck even arrives at your shop. Even without a diagnosis, the decision to replace a starter simply to ensure its optimal functioning can be a good one. The internal bearings and gear teeth wear out, and the moderate price of the starter means that often the first decision the department manager makes is to replace the part. Diagnosis of a starter, field approach 1. Record the mileage or engine hours: When you begin working on a vehicle, first get into the habit of recording the vehicle’s hours of work or mileage. This practice will certainly be greatly appreciated by your manager and will allow you to learn more about the vehicle. A 400 000mi (700 000km) history may be a valid reason to replace the part first, without question. 2. Check the battery: A weak, discharged, or improperly connected battery is often the cause of the problem. This is the basic step before any other checks. Most batteries should be tested using either a load tester or battery conductance tester 3. Preliminary check of the starter: After a starting sequence, if one of the starter components smokes, is hotter than normal, or if, upon approaching the starter, you notice a foul odor, this may be a clear sign that the component needs to be replaced. Ask your manager about your observations. 4. Previous Repairs If the vehicle is having trouble starting, the starter looks new, and the connections are freshly cleaned, there’s a good chance that a previous repair may be the cause of the problem. Connection errors, among other things, are common and can affect the power supply system. When replacing the starter, use color-coded zip ties or other identification means to clearly identify the wires for each terminal. EC-510HV_052964-95 Theory — Definition and Relationships consulab.com info@consulab.com 9 Definition and Relationships Assignments SA-2 and SA-3 cover the basics of Ohm's Law and the understanding of electrical circuits. Technicians who want a success in all their electrical tasks must understand and know how to apply Ohm’s Law concepts when perform- ing circuit diagnosis and repair. A lack of understanding of the relationships between volts, ohms and amps explained in the student assignments often leads to an error in diagnosing the original problem and unnecessary replacement of expensive components. What is Ohm's Law? A German physicist named Georg Ohm (1787-1854) conducted many different experiments with electricity. Around 1827, he developed a formula to explain the behavior of this science. Basically, Ohm’s Law describes the direct relationship that occurs between voltage, current and resistance. Ohm used mathematics to define the operational links between these three “elements” of electricity. We previously understood that electricity was the flow of electrons flowing through one conductor, but Georg Ohm was able to explain how each element affected the others. The formula A = V ⁄ R was his conclusion on how electricity operates in a circuit. Looking at the formula, "A" or "I" is the intensity or amount of current or electrons moving in a circuit. Mostly in technical documents, A is used instead of I. the letter V represents the electrical pressure that pushes the electrons into the circuit. It is expressed in volts. As for the letter R, it corresponds to the resistance which is the opposition to current flow and it is expressed in ohms. The Greek symbol Ω is used to represent the ohm value. Understanding how to use these principles is critical to diagnosing electrical system problems. Ohm’s Law can be taught using several different methods. Some teachers use extensive mathematical calculations to "validate" the system. For the purposes of this manual, we will keep this module as simple as possible. The instructor will be able to provide his students with additional resources if necessary to properly use Ohm’s Law in learning activities on the basic principles of electricity. Several teachers now believe that using voltage drop to explain Ohm’s Law to students provides a better understanding than using mathematical formulas. This is a personal choice for each instructor. Relationships Let's analyze this statement that explains Ohm's Law: It takes one volt of electrical pressure to push one ampere of elec- trons through one ohm of resistance. Voltage and resistance are the main factors in the presence of current. Amperage cannot be created in itself, because it is the result of changes in voltage or resistance. Thinking about the water hose, if the pressure is somehow increased, the amount of water flowing out of the hose increases. If there is a twist or blockage in the hose, less water will flow. The increase in water flow corresponds to an increase in current or amperage as voltage or pressure gets higher. Elec- tric current is the flow of electrons resulting from the amount of voltage and resistance in a circuit. consulab.com info@consulab.com 10 EC-510HV_052964-95 Theory — Definition and Relationships We can establish some rules that explain the efficiency of the electrical system: • If the voltage or pressure increases and the resistance remains the same, the amperage or flow increases propor- tionally. This is because there is a greater amount of "push" of electrons through the same resistor, which results in a greater electrical flow. • If the voltage decreases and the resistance remains the same, the current also decreases. Less pressure reduces the flow of electrons, because there is less "push" that forces them to move. • If the resistance in ohms increases and the voltage in volts remains the same, the current in amps decreases. If we increase the restriction in the flow, it will decrease. When we twist the water hose a little, what happens? There's less water coming out. • If the resistance decreases and the voltage remains the same, the current increases. If we lower the resistance, it results in a higher flow. Increasing the diameter of the hose would result in a greater flow of water. Use Ohm's Law to understand the behavior of the circuit Technicians diagnosing electrical system problems must must understand and be abe to apply Ohm’s Law concepts in troubleshooting techniques. They also must be able to apply their understanding of Ohm’s Law in the diagnosis of any circuit that is malfunctioning. For example, suppose that one of the headlights of a vehicle malfunctions when it is switched on. A dim headlamp indicates that the circuit current is lower than expected. What is the cause of this reduc- tion in intensity? Thinking about Ohm’s Law, an increase in resistance or a reduction in voltage will cause that condition. If the vehicle operating voltage remains unchanged, the problem is probably caused by the increase in resistance some- where in the circuit. This unwanted increase in resistance may be on the power (positive) or ground (negative) side of the circuit. The technician should then test the circuit for unwanted resistance. Corrosion, rust, dirty electrical terminals, and corroded wires can often be causes of unwanted increased resistance in headlamp circuits. With Ohm’s Law if two of the three circuit values (volts, amps or ohms) are known, we can calculate the third unknown value. There are formulas that help calculate this value. For the purposes of this manual, we will use the following mea- surement units: Ohms = R, amps = A and voltage = V. To calculate the resistance of the circuit in ohms: R = V ⁄ A to calculate the current in amps: A = V ⁄ R to calculate the voltage in volts: V = A × R. We can use a simpler method to remember the above formulas. It is a question of visualizing them in a circle as shown on the right. Simply place a finger on the value to be found and perform the calculation from the operation of the other remaining values. If we want to calculate the resistance, we place a finger on R and divide V, the voltage by A, the current. This calculation makes it possible to determine the resistive value in ohms. For example: If the vehicle blower motor has a resistance of 2 Ω, how many amps will be drawn when operating at high speed with 14.5 volts? Answer: 7.25 A as calculated: 14.5 V ⁄ 2 Ω = 7.25 A.. R. V A consulab.com info@consulab.com 11 EC-510HV_052964-95 Theory — Definition and Relationships In recent years, many instructors no longer want to use complex mathematical formulas to explain Ohm’s Law to stu- dents. They prefer to demonstrate and measure the voltage drop present at each resistor. Voltage drop measurements tend to give students a better understanding of electrical circuit behaviors. The basics and learning activities related to VOLTAGE DROP will be covered in the upcoming activities. Voltage drop testing involves measuring the amount of volt- age between two specific points in a circuit. For example, if we wanted to know if a wire between Point A and Point B. In this case, the desired voltage drop would be “0”, but if the voltmeter indicates a voltage, there is unwanted resistance in the wire being measured. The electrical system What is an electrical circuit? A typical automotive electrical system contains the following: • A power source (usually the battery); • Certain types of overcurrent protection (fuse, circuit breaker or fusible link); • A certain type of switch that must be controlled when the circuit is activated (the switch can be on the positive or ground side of the circuit). • A certain type of resistance that has a useful function in the circuit (bulb, motor, horn, etc.). This resistance is commonly referred to as LOAD. • Positive wires that allow current to flow from the battery to the resistance. • Ground wires that allow current to flow back to the battery from the resistance. consulab.com info@consulab.com 12 EC-510HV_052964-95 Student Assignments Student Assignments consulab.com info@consulab.com 13 EC-510HV_052964-95 SA-1 — Wiring Diagram Analysis Instructor grade : Comments : A. Key Ignition Switch B. Crank Relay C. Starter Solenoid D. Starter Motor E. 350A Fuse F. 60A Fuse G. 10A Fuse 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 FO LI O 1/ 1 D ES SI N E : VE R IF IE : D AT E D E C R EA TI O N : IN D IC E D AT E M O D IF IC AT IO N D ES . Lo gi ci el S EE 3. 70 v. ST A RT ER S YS TE M C IR C U IT EC -5 10 H V BAT + 350A 60A IGNITION SWITCH OFF START IGN. CRANK RELAY Model 39MT STARTER SOLENOID Delco #8300084 STARTER MOTOR 10A # 10 AWG # 1 6 A W G # 16 # 1 6 M Thermal over-crank protection 06 /0 4/ 20 22 D C TEST POINT # 10 AWG # 2 A W G # 2 A W G # 1 6 A W G #8 AWG B SC S D1 D2 R ev 2 .0 1 2 RE V 2 .3 0 30 /1 0/ 20 25 D C 25 22 5 FS 2. 30 Boucle mesure courant #8 AWG Boucle mesure courant Boucle mesure courant # 1 6 A W G SA-1 — Wiring Diagram Analysis Name : Group : Date : • Observe the starter system wiring diagram. • Put the correct letter (A through G) next to each component on the diagram for identification. consulab.com info@consulab.com 14 EC-510HV_052964-95 SA-2 — Starter Cranking Voltage Test SA-2 — Starter Cranking Voltage Test Perform all tests and procedures below as required. Do not write on this page. Use the student answer sheet to record your readings and answers. The Starter Cranking Voltage Test is widely used in industry and is designed to measure the battery’s ability to maintain a minimum electrical pressure (voltage) during starter operation. If the starter has internal operating problems, it will draw more amperage than normal, which will require more battery voltage. If the battery cannot provide the required voltage, the starter voltage will drop below the minimum acceptable level, usually 10.5 volts. If it drops below this minimum, it could be due to one of the following causes: 1. Battery status fails to supply sufficient current to the starter circuit caused by an internal problem, shorted battery plates, low charge level or other factors. 2. Poor battery cable connections in the starter circuit due to dirt, corrosion, loose cables, or poor conductivity. 3. Faulty starter or solenoid that creates a partial short circuit, resulting in higher-than-normal current draw and lower- ing the initial cranking voltage. 4. Excessive internal mechanical friction of the engine due to several stresses that can sometimes increase the amper- age demand on the starting system. Equipment required: • Multimeter set up to read DC voltage • Fully charged battery with a terminal voltage of 12.6 VDC • EC-510HV Functional Cutaway Diesel Starter Procedure: 1. Place a fully charged battery on a stable and secure surface. 2. Measure the voltage across the battery terminals and record your readings on the student answer sheet. 3. Connect the starter 12VDC power supply RED and BLACK cables to the battery (RED to + and BLACK to -). 4. Set the multimeter in voltmeter mode and connect probes to the battery terminals (RED to + and BLACK to -). 5. Turn the EC-510HV ignition key to the START position, and the starter should begin to operate. 6. While the starter is running, observe the CRANKING VOLTAGE when cranking and record your readings on the stu- dent answer sheet. consulab.com info@consulab.com 15 EC-510HV_052964-95 SA-2 — Starter Cranking Voltage Test 7. Repeat the STARTER CRANKING VOLTAGE TEST three times and record each reading on the student answer sheet. NOTE: Observe the following safety precautions: - Do not exceed 5 seconds when cranking the starter; - Wait a minimum of 15 seconds between each crank cycle. 8. Evaluate the voltage measurements taken on the trainer. Are they within specifications or not? 9. List some reasons why the STARTER CRANKING VOLTAGE may be significantly lower than the minimum specifications. 10. Explain why you can measure a starter cranking voltage of 11.80 V, for example. Use the student answer sheet. 11. Ask the instructor to correct your answer sheet and make sure the EC-510HV trainer is in its original condition, after disconnecting the battery. Test Result and Analysis: • Voltage before stater cranking: If the battery terminal voltage is below 12.6 V, this may indicate that the battery is not fully charged or has other internal problems. An initial voltage test should not be performed on a starting system if the battery voltage does not reach 12.6 V. • Cranking voltage during starter cranking: If the initial voltage drops significantly during cranking, this may indicate excessive current in the starter circuit or, on a real vehicle, excessive internal mechanical friction in the engine. • Specifications: When performing an STARTER CRANKING VOLTAGE TEST on a vehicle, always check the test speci- fications. However, it is generally accepted in the industry that the voltage should not drop below 10.5 V during the test. • Test Conclusions: If the cranking voltage remains near 10.5 V, this indicates that the battery and starting system are functioning properly. If the voltage drops below 10.5 V, additional specific tests of the starter’s internal parts are required to identify the cause of the excessive cranking voltage. Educational Objectives: • Understanding the STARTER CRANKING VOLTAGE TEST: Students will learn how to perform this type of test during starter cranking and how to interpret the test results. • Proper Use of a Voltmeter: This assignment allows students to practice setting up, adjusting, measuring and correctly evaluating voltmeter readings. • Test Result Analysis: Students will learn the different conditions and causes of abnormal voltage noted during an STARTER CRANKING VOLTAGE TEST and will be able to evaluate their results. consulab.com info@consulab.com 16 EC-510HV_052964-95 SA-2 — Starter Cranking Voltage Test SA-2 — Student Answer Sheet Correctly complete all steps of the SA-2 Starter Cranking Voltage Test procedure and record your readings and answers on this page. Name : Group : Date : 2. What is the measured battery voltage across terminals? V 6. What is the measured CRANKING VOLTAGE of the starter? V 7. Initial Voltage Test 1: V Initial Voltage Test 2: V Initial Voltage Test 1: V 8. Were the results within specifications or not? 9. List some of the causes of the starter cranking voltage test results being below specifications: 10. Explain why a cranking voltage test result of 11.80 volts is good or bad: Instructor grade : Comments : consulab.com info@consulab.com 17 EC-510HV_052964-95 SA-3 — Starter Cranking Amperage Test SA-3 — Starter Cranking Amperage Test Complete all tests and procedures below as required. Do not write on this page. Use the student answer sheet to record your readings and answers. Objective: Learn how to use an inductive ammeter to measure cranking amperage in a diesel starter circuit and understand current variations during starting. Introduction: The inductive ammeter allows you to measure current intensity safely thanks to its insulating jaws. The current flow- ing through the conductor is detected through the generated magnetic field. The measurements are displayed on the ammeter’s digital screen when equipped or interfaced with a voltmeter or oscilloscope to read the high current draw of HV starters. The higher the number of amperes, the stronger the magnetic field. AC and DC current measurements are carried out without danger of short circuits. Equipment required: • Inductive ammeter (see comment above) • Fully charged battery with a terminal voltage of 12.6 VDC • EC-510HV Functional Cutaway Diesel Starter Procédure: 1. Place a fully charged battery on a stable and secure surface. 2. Check the battery voltage (V) with a multimeter. Record your reading on the student answer sheet. 3. Connect the RED and BLACK diesel starter cables to the battery (red + and black -). 4. Correctly position the inductive ammeter around the starter red power supply cable. Looking at the meter, you can see an arrow indicating the direction it should be installed. 5. Make sure all components are properly connected and ready to operate. 6. Turn the ignition key to the START position to activate the starter solenoid. 7. Observe and record the current values measured by the clamp-on ammeter during cranking. 8. Repeat the measurement three times, observing safety instructions (do not exceed 5 seconds during a cranking sequence and space each sequence 15 seconds apart). Record your readings on the student answer sheet. 9. The results obtained previously will allow you to continue the tests of the other activities in the manual. By following this procedure and analyzing the results thoroughly, you will be able to effectively diagnose the condition of your starter and identify possible problems EC-510HV_052964-95 SA-3 — Starter Cranking Amperage Test consulab.com info@consulab.com 18 Test Result and Analysis: The results obtained with the inductive ammeter allow us to determine the starter wear and its ease of turning the en- gine. It is possible that engine components cause a higher or lower voltage than average in the measurement reading. In our case, the readings should be reduced because the starter operates without causing the rotation of an engine. • Normal current: A starter in good condition should draw a specific current depending on the size and type of the engine. Follow manufacturers specifications for the amount of specified cranking current. • High current: If the measured current is significantly higher than normal, this may indicate a problem with the starter, such as an internal short circuit, worn bearings, or excessive resistance in the circuit. • Low current: A lower than expected starting current may indicate a weak battery, corroded or loose electrical con- nections, or a problem with the engine itself. • Analysis of current variations: Observe current variations during startup. Large changes of current may indicate intermittent problems in the electrical circuit or starter components. Educational Objectives Know why it is essential to measure cranking current: • Current value: The value measured by the inductive ammeter represents the intensity of the current flowing through the conductor surrounded by the meter. • Safety: Measuring current with a clamp-on ammeter is non-intrusive, which ensures increased safety for the user. There is no need to interrupt the circuit to take the measurement. Conclusion: The clamp-on ammeter is an essential tool for technicians, allowing them to safely diagnose and analyze electrical systems. By understanding the readings of the clamp meter, you can identify potential problems in the circuit and take the necessary steps to resolve them. consulab.com info@consulab.com 19 EC-510HV_052964-95 SA-3 — Starter Cranking Amperage Test SA-3 — Student Answer Sheet Correctly perform all steps of the procedure for measuring the cranking current of activity SA-3 and record your read- ings and answers on this page. Name : Group : Date : 2. What is the terminal voltage of the battery you are using? V 8. Cranking amperage test 1: A Cranking amperage test 2: A Cranking amperage test 3: A Question : Normally, a starter should be subjected to an amperage ranging from 150 A to 400 A. Were the results within specifications or not? List some causes of incorrect cranking current readings: 1. 2. 3. Instructor grade : Comments : EC-510HV_052964-95 SA-4 — Result Analysis using Ohm’s Law consulab.com info@consulab.com 20 SA-4 — Result Analysis using Ohm’s Law Name : Group : Date : Equipment Required: • Multimeter • 12V Battery • EC-510HV Functional Cutaway Diesel Starter Procedure: 1. Result analysis. - Compare the current and voltage values measured during three different start sequences of the previous activi- ties : • SA-2 Results Cranking voltage test 1: V Cranking voltage test 2: V Cranking voltage test 3: V • SA-3 Results Cranking amperage test 1: A Cranking amperage test 2: A Cranking amperage test 3: A - Discuss current and voltage variations and their significance in terms of starter operation. - Using Ohm’s law with the results of activities SA-2 and SA-3, calculate the resistance of the circuit in ohms: • Cranking test 1 : Ω • Cranking test 2 : Ω • Cranking test 2 : Ω Confirmation: With a multimeter in Ω mode, check the starter motor to see if the tests performed gave plausible answers. It is possi- ble that the measurements made in Ω do not perfectly match the calculations, as this may be due to the battery charge changing with each start. In addition, the values may not reflect reality because the starter motor of the EC-510HV train- er is not subject to force to crank an actual diesel engine. • Multimeter reading: Ω Instructor grade : Comments : consulab.com info@consulab.com 21 EC-510HV_052964-95 SA-5 — Solenoid Activation with Booster Cables SA-5 — Solenoid Activation with Booster Cables Complete all tests and procedures below as required. Do not write on this page. Use the student answer sheet to record your readings and responses. Educational Objectives This assignment helps students understand why the starter motor can turn even though the solenoid is not engaged and helps them understand the current path in the starter motor’s electrical circuit. SA-5 provides a practical and interactive approach to strengthening their knowledge of electricity and stater circuit operation. Introduction: The starter solenoid plays a crucial role in the operation of a vehicle’s starter. Below are its main functions. Starter activation: To activate the solenoid, the starter relay uses the signal from the ignition switch to initiate a higher current circuit to the solenoid. This acts like an electromagnetic switch. When you turn the ignition key to the START position, the output current from the relay is sent to the solenoid. This current creates a magnetic field that attracts the plunger inside the solenoid. Pinion engagement: The movement of the solenoid plunger pushes the pinion lever (or gear) outward from the starter. This pinion mates with the engine’s flywheel to allow the starter to rotate the engine. Closing the power circuit: As the pinion engages, the solenoid closes a power circuit that allows a high current to flow from the battery to the starter motor. This provides the energy needed to rotate the engine. Summary: The ignition switch sends an electrical signal to the relay, which initiates a higher intermediate current flowing to the starter solenoid signal terminal. The power of this current creates a magnetic field at the solenoid, causing the in- ternal plunger to move, which pushes the solenoid lever and pinion gear into mesh with the flywheel. As the gear engag- es with the flywheel, the solenoid closes a power circuit, allowing a high current to flow from the battery to the starter motor and the starter now begins to rotate the engine. Equipment Required: • EC-510HV Functional Cutaway Diesel Starter • Fully charged 12V battery • Booster cables (minimum 4-Gauge) • Multimeter or voltmeter • Safety gloves consulab.com info@consulab.com 22 EC-510HV_052964-95 SA-5 — Solenoid Activation with Booster Cables Procedure: 1. Place a fully charged battery on a stable and secure surface. 2. Check the battery voltage (V) with a multimeter and record your reading on the student answer sheet. 3. Connect the RED and BLACK booster cables to the battery (red + and black -). 4. Make sure all components are properly connected and ready to use. 5. Relay operation: A. Remove the 60 A fuse from the module. B. Use a multimeter in ohms mode to measure the resistance across the relay’s left and right terminals when the ignition key is turned to the OFF and START positions. Record your measurements on the student answer sheet. C. Use a multimeter in ohms mode to measure the resistance between the Relay Left Terminal (Figure 1) and the Solenoid Signal Terminal (Figure 2) when the ignition key is turned to the OFF and START posi- tions. Record your measurements on the student answer sheet. D. Use a multimeter in voltage (V) mode with the probes on the signal terminals on top of the relay. Take the mea- surement readings when the ignition key is turned to the OFF and START positions. Record your measurements on the student answer sheet. E. Explain how the relay system works and which relay terminals are connected to the starter primary circuit con- nections. Write your answer on the answer sheet. 6. Solenoid Operation: A. At this point, be sure the 60 A fuse is functional. B. Use a multimeter in voltage (V) mode to measure the voltage across the solenoid’s primary and signal terminal when the ignition key is turned to the OFF and START positions, and record your results. Place the black probe of the multimeter on the ground terminal of the battery or starter motor. C. After your analysis, describe the function of the solenoid’s primary terminals. Record your answer on the student answer sheet. 7. Starter activation with booster cables: Pay special attention to the booster cable connection between the battery and the starter, which will instantly acti- vate the starter. Be sure to wear safety gloves and safety glasses for the next steps. A. Disconnect the cables from the diesel starter. B. Connect the booster cables to the battery (red + and black -). C. Connect the black booster cable (negative) to the starter ground terminal. D. Pay close attention to the results obtained in the next step. E. Connect the red booster cable (positive) to the right primary terminal. F. Do not exceed 5 seconds for the starter to crank. Relay Left Terminal Relay Signal Terminals Figure 1 Solenoid Signal Terminal Figure 2 Right Primary terminal Left Primary Terminal consulab.com info@consulab.com 23 EC-510HV_052964-95 SA-5 — Solenoid Activation with Booster Cables G. What happens to the starter when the right primary terminal is energized? Write your answer on answer sheet. H. What does the starter solenoid do? Write your answer on the answer sheet. 8. Describe the complete operation of the starter, specifying the path taken by the current to operate the starter mo- tor from the ignition switch to its ground terminal. Use the student answer sheet. 9. Submit your answer sheet to the teacher for corrections EC-510HV_052964-95 SA-5 — Solenoid Activation with Booster Cables consulab.com info@consulab.com 24 SA-5 — Student Answer Sheet Correctly complete all steps of the SA-5 procedure for activating the starter with booster cables and record your read- ings and answers on this page. Name : Group : Date : 2. What is the terminal voltage of the battery you are using? V 5. Relay operation: B. Measure the relay resistance when the ignition key is turned to OFF: Ω Measure the relay resistance when the ignition key is turned to START: Ω C. Measure the resistance between the relay left terminal and solenoid signal terminal to OFF position: Ω Measure the resistance between the relay left terminal and solenoid signal terminal to START position: Ω D. Measure the voltage across the relay signal terminals when the ignition key is turned to OFF: V Measure the voltage across the relay signal terminals when the ignition key is turned to START: V E. Explain how the relay system works and which relay terminals are connected to the starter primary circuit con- nections: 6. Solenoid operation: B. Solenoid’s Left Primary Terminal: OFF position V / START position V Solenoid’s Right Primary Terminal: OFF position V / START position V Solenoid’s Signal Terminalïde : OFF position V / START position V C. After your analysis, describe the function of the solenoid’s primary terminals. Solenoid’s Left Primary Terminal: Solenoid’s Right Primary Terminal: Solenoid’s Signal Terminal: 7. Starter activation with booster cables. G. What happens to the starter when the right primary terminal is energized? H. What does the starter solenoid do? EC-510HV_052964-95 SA-5 — Solenoid Activation with Booster Cables consulab.com info@consulab.com 25 8. Describe the complete operation of the starter, specifying the current path taken to operate the starter motor from the ignition switch to its ground terminal: Instructor grade : Comments : 400-6330 Zéphirin-Paquet St. QUEBEC QC G2C 0M3 Canada © 2024 ConsuLab Educatech Inc. All rights reserved. Product Description Warnings and Cautions Educational Advantages: Items needed to use the product: Application Technical Support Component Identification Operation Instructions Learning Modules Theory Theory and practices: For clear understanding of concepts Definition and Relationships Student Assignments SA-1 — Wiring Diagram Analysis SA-2 — Starter Cranking Voltage Test SA-2 — Student Answer Sheet SA-3 — Starter Cranking Amperage Test SA-3 — Student Answer Sheet SA-4 — Result Analysis using Ohm’s Law SA-5 — Solenoid Activation with Booster Cables SA-5 — Student Answer Sheet
