9/10 TLE

AUTOMOTIVE

LEARNER’S MATERIAL
PIVOT 4A CALABARZON
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standards prescribed by the DepEd Region 4A and Curriculum and Learning
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use of existing NC-Based TESDA Materials.

The Editors

PIVOT 4A CALABARZON
 Technology
and Livelihood
Education
Automotive

Regional Office Management and Job S. Zape, Jr.,

Development Team:
Jhonathan S. Cadavido, Romyr L. Lazo, Fe M. Ong-Ongowan, Lhovie A. Caui-
lan, Eugene Ray F. Santos and Philips T. Monterola

Schools Division Office Management Team: Merthel M. Evardome, Nadine C.

Celindro, Nicolas M. Burgos, Macaria Carina C. Carandang, Rosalinda A. Mendoza, Nel-
son M. Arisga, Nilo M. Vanguardia, Herman M. Sinohin, Edwin B. Romulo

TLE (Automotive)- Grade 9/10

PIVOT IV-A Learner’s Material
Quarter 1
First Edition, 2020

Published by: Department of Education Region IV-A CALABARZON

Regional Director: Wilfredo E. Cabral
Assistant Regional Director: Ruth L. Fuentes

PIVOT 4A CALABARZON
 Battery Construction and Operation
Lesson
I
All Automotive batteries operate because of the chemical ac-
tion which takes place when two dissimilar materials are placed in a
conductive and reactive solution called electrolyte. In this lesson, you will
learn about the functions, chemical actions and construction of a battery. Al-
so, you will know how to test the battery and work safely in handling the bat-
teries.
Functions of the battery:
The functions of the battery are to:
1. Operate the starter motor
2. Provide current for the ignition systems and electrical accessories when
the engine is not operating.
3. Supply power for the lighting systems and electrical accessories
when the engine is not operating.
4. Act as a voltage stabilizer for the complete electrical system.
5. Provide current when the electrical demand of the vehicle exceeds the
output of the charging system.
Electrochemical Action
Two dissimilar metals in the presence of a conductive and reactive
solution called an electrolyte cause automotive batteries to operate from the
chemical action. Because this chemical action produces electricity, it is called
electro – chemical action. The chemical action of the electrolyte causes elec-
trons to be removed from one metal and added to the other. This loss and gain
of electrons causes the metals to be oppositely charged, and a potential differ-
ence, or voltage, exists between them. The metal piece which has lost electrons
is positively charged, and is called the positive plate. The piece which has
gained electrons is negatively charge, and is called the negative plate. If a con-
ductor and a load are connected between the two plates, current will flow
through the conductor, For simplicity, battery current flow is assumed to be
conventional (+ to -) current flow through the external circuit connected to the
battery.
Classification of Battery
A. “Low Maintenance” battery has removable caps so the battery’s state of
charge can be checked; adding distilled water if needed.
B. "Maintenance Free" battery (lead acid or alkaline) is sealed and does not re-
quire adding with distilled water. Its electrolyte level does not change because
they do not produce much gas. The charge indicator in the top shows the state
of charge.
Battery Construction
The battery case is a molded plastic that provides enclosure to the battery
parts. Inside the battery are number of plates molded to plate straps to form
plate groups. The negative plate group and positive plate group with porous
separator in between them. The porous separator prevents the positive and
negative plates from touching one another. It also allows electrolyte to circulate
between them. When these two plate groups are assembled together, it
forms an element. The elements fit into compartments or partitions in the bat-
tery case. When this elements are immersed in a battery solution called elec-
trolyte (water and sulfuric acid), it can form into a voltaic cell of two volts. Some
batteries have openings in their cover with filler plugs or vent caps that are re-
movable for adding water. Maintenance-free batteries do not have removable
caps.

4 PIVOT 4A CALABARZON
 Automotive batteries are made of a number of electrochemical cells.
Each cell produces electrical energy through the reaction of two dissimilar met-
als in the presence of an electrolyte. Each lead-acid cell generates about 2.1
volts regardless of the number of positive and negative plates. Current output
of a cell depends on the total surface area of all the plates. Batteries with high-
er current or capacity ratings have a larger plate areas. Automotive batteries
are secondary batteries and can be charge.

Parts of the Battery

Proper Safe Handling of Batteries

Observe the following safety measures when working with batteries. The
sulfuric acid in the electrolyte is very corrosive. It can damage clothes. It can
cause serious burns on human skin. If you get battery acid on your skin, flush
it at once with water. Wear eye protector when testing or charging a battery. If
the battery acid (electrolyte) gets into your eyes, flush them with water at once.
It can cause blindness if it gets into the eyes. Go to the school physician or
nearest hospital for medical attention.
1. When disconnecting a battery, always disconnect the negative or ground
terminal/ cable first.
2. If the battery has vent caps, make sure the vent holes are open before
charging. Cover the vent hole with a damp cloth. Discard the cloth
after the battery is charged.
3. Never lean over a charging battery, gas or fumes emitted and inhaled
are hazardous to your health.
4. Do not charge a frozen maintenance- free battery because when the charge
indicator dot shows light yellow or clear the battery could explode
5. Lift the case straight up. Tipping it to one side may allow the electrolyte to
leak out.
6. Carry the battery case; put both hands under the case.
7. Do not overtighten the battery hold-down clamp through bolt and nut. This
may lead the battery clamp to compress the battery and may cause damage
to it.

5 PIVOT 4A CALABARZON
Four main Hazards Associated with Battery
1. Battery acid: the electrolyte in a battery is corrosive and it can burn the skin
or eyes, eat holes in clothing or even etch on concrete floor.
2. Flammable gases: batteries emit hydrogen gas, this is flammable. It ignites
easily and can cause a fire or explosion if allowed to accumulate in a small
place.
3. Electric shock: many of us aware of this danger, because we may have seen
sparks fly when jumper cables are attached to car battery.
4. Weight: Batteries like those used in a heavy duty vehicles, are heavy and re-
quire proper material handling equipment to lift them safely.

Two Ways of Testing Battery

Ball hydrometer is similar to the ball type coolant hydrometer. To
perform this test, insert the rubber tube into the vent hole of the battery,
then squeeze and release the bulb. Electrolyte will be drawn into the tube. If all
balls float, the battery is fully charged. If none, the battery is discharged. The
more balls that floats, the higher the battery state of charge.
The float hydrometer is used in the same way as the ball hydrometer. It
will float as the electrolyte is drawn from the battery. Marks on the float stem
show the electrolyte specific gravity. This indicates the battery state of charge.
The more fully charged the battery, the higher the float.
Battery Maintenance
1. Make a visual inspection of the battery. – Battery maintenance
should always begin with thorough visual inspection.
a. corrosion around the terminals
b. sign of leakage – cracked case, missing cap, and
loose hold down clamps c. electrolyte level
2. Clean the battery top terminals, and cable clamps.
3. Test the battery.
4. Charge the battery.

A battery should be treated with respect. The acid of the battery electro-
lyte can damage the cars paint or corrode metal parts if spilled. The acid can
also cause serve burns if it contacts your skin. Wear safety glasses to protect
your eyes when servicing a battery.

6 PIVOT 4A CALABARZON
Procedure in Cleaning the Battery Terminals
Materials: Protective gloves, like dish gloves / Baking soda / Water
Used toothbrush / Rags / Petroleum jelly/grease
1. Mix the homemade battery cleaner

- mix one tablespoon of baking soda into one cup of water, and
stir it together until its thoroughly mixed.
2. Remove the cables from the battery and inspect it.

- Be sure that the engine is off, open the hood and remove the two
cable terminals (negative
and positive ). Make visual inspection for build-ups corrosion, and
grimes. If you notice of
battery case leaking, swollen, or bloated case, skip cleaning and
bring your battery to the battery shop for major check –up.
3. Dip a toothbrush in your cleaner tub and start scrubbing the terminals.

4. Rinse off the residue with water and dry.

5. Rub light amount of petroleum jelly/grease onto the terminals and connect
the cables. Connect first the positive terminal followed by the negative ter-
minal.
6. Inspect the connection thoroughly, and start the engine to check your task
if working.
Procedures for Charging Batteries Safely

1. Be sure the proper charger is being used for the particular kind of bat-
tery.

2. Check that vent caps are in place to prevent overflow and spilling of elec-
trolyte.

3. Shut off the charger when connecting or disconnecting the battery.

4. Before charging a battery while it is still in a forklift, open the bat-

tery compartment and allow it to cool down following lift truck oper-
ation.
5. After charging, again allow the battery to cool down—it prolongs battery
life.

6. Never overcharge a battery—that’s another way to prolong battery life.

Remember that battery maintenance is very important task in order to

maintain the condition of vehicle electric energy performance and to prolong
the life of the automotive battery. Always follow the procedures to meet the en-
vironmental safety standard.

7 PIVOT 4A CALABARZON
D
Learning Task 1: Identify the parts of the battery. Write your answers in your
notebook.

Learning Task 2: Using a Venn Diagram, compare and contrast Ordinary Wet
battery and Maintenance-Free Battery.

Low Maintenance Battery Maintenance-Free Battery

E
Learning Task 3: Arrange the letters to spell out the correct word which is de-
scribed by the clues . Write your answer to the answer sheet.

1. L A L B T R E H Y M E D Y R O- To perform testing, insert the rubber

tube into the vent of the battery.

2. L O A F T R O D M E R E T Y H- It will float as the electrolyte is drawn

from the batteries.

3. R E Y T A R T B- Source of the electricity and can be tested in two ways.

4. N A C I O N P R U T E - Make sure no electrolyte drips on the car or on you.

5. F I C P E C I S T Y G R A V I– Show the table and its relationship with the

state of charge.

8 PIVOT 4A CALABARZON
 A
Learning Task 4: Read each item very carefully and choose the letter of the cor-
rect answer. Write it in your notebook.

1.This type of hydrometer which is similar to ball type coolant hydrometer.

A. ball hydrometer C. barometer
B. flat hydrometer D. a and b

2. A type of hydrometer which the state of charge marks on the float stem to
show electrolyte specific gravity.
A. ball type hydrometer C. a and b
B. float hydrometer D. None of the above

3. The indication if the battery is fully charged using a ball hydrometer.

A. all balls float C. a and b
B. no balls float D. none of the above

4. The more fully charged the battery is, the higher the float is indicating the
state of charge.
A. float hydrometer C. a and b
B. ball hydrometer D. all of the above

5. The more balls float, the higher the battery state of charge.
A. ball hydrometer C. a and b
B. float hydrometer D. None of the above

9 PIVOT 4A CALABARZON
 How to Test an Automotive Battery
Lesson

I
In this lesson, you will learn one of the essential task in battery opera-
tion is testing the state condition of battery, such as rating capacity, good con-
dition of battery, if need recharging, and if already malfunction or defective the
need for replacement.
You will also study how to select appropriate test equipment in testing
the automotive batter, test Automotive battery, and analyze test results of test-
ing automotive battery.
Two Ways of Testing the Battery
Batteries are tested in two ways: the state of charge and performance. A
hydrometer identifies the state of charge of a vent–cap battery. Information is
built-in the actual battery.
The ball hydrometer is similar to the ball type coolant hydrometer.
To perform hydrometer testing using ball hydrometer, insert the rubber tube
into the vent hole of the battery, then squeeze and release the bulb. Electrolyte
will be drawn into the tube. If all balls float, the battery is fully charged. If
none, the battery is discharged. The more balls that floats, the higher the bat-
tery state of charge.
The float hydrometer is used in the same way as the ball hydrometer. it
will float as the electrolyte is drawn from the battery. Marks on the float stem
show the electrolyte specific gravity. This indicates the battery state of charge.
The more fully charged the battery, the higher the float.
The following table shows the relationship between specific gravity and
state of charge.

Specific Gravity Stage of Charge

1.265 -1.299 Fully charged battery

1.235 -1.265 Three – fourths charged
1.205 -1.235 One-half charged
One-fourth charged
1.170 -1.205
1.140-1.170 Barely Operative
Completely Charged
1.110-1.140

Meanwhile, the table below provides the specific gravities and freezing
temperatures for battery electrolytes.
Specific Gravity Stage of Charge

1.100 18 [-8.2]

1.160 1 [-7.2]

1.200 -17 [-27.3]

-31 [-35]
1.220

1.260 -75 [-59.4]

-95 [-70.5]
1.300

10 PIVOT 4A CALABARZON
Demonstrating the Testing of an Automotive Battery
Modern measuring instruments evolved in a very fast and changing
time. Year after year, from human to non-human use, new and sophisticated
measuring instruments are innovated.
In automotive application, vehicles are innovated and modified year af-
ter year. Measuring instruments used from engine output testing like dy-
namometer to engine tune-up like engine analyzer are used even in small
auto shop industry. In automotive battery, several instruments evolves to
check or to test the capacity or performance of battery the in producing elec-
trical even without pulling it from the vehicle.
Supplies and Materials: Apron / Safety goggles / Gloves / Distilled water
Tools/Instruments: Float type hydrometer / Battery cell tester / Multi-tester/
Load tester
Equipment: Charged and discharged battery
A. Hydrometer Test
Procedure:
a. Remove all battery vent caps.
b. Check the electrolyte level, it must be high enough to draw the
correct amount of battery solution (electrolyte) into the hydrometer.
b. Squeeze the suction rubber bulb and insert the pick-up tube into the bat-
tery hole just enough to draw the electrolyte solution.
c. Slowly release the suction rubber bulb. Draw in enough solution
until the float is freely suspended in the hydrometer glass barrel. Hold
the hydrometer in vertical position. d. Read the electrolyte level on eye lev-
el as shown in the figure below.
e. List the test result.
B. Battery Cell Test
Procedure:
1. Disconnect the negative and positive terminals of the battery.
2. Remove the battery from the vehicle and place it on the bench.
Note: The battery can also be tested on the vehicle but safety precautions
must be observed.
3. Cover the battery vent plugs with a damp cloth.
4. Place the battery cell tester on the cell connector of the battery.
Note: This test can be performed in a low-maintenance battery.
5. Read the cell tester indicator if the battery cell being tested is good
(usually green color) or bad (usually red color).
6. Replace the battery if cells are defective.

C. Battery Load Test

1. Connect a battery/starter tester as shown below.
2. With the load control knob in the off position, set the voltmeter selector
switch to the range closest to 12 volts.
3. Adjust the control knob clockwise until the ammeter reads three times the
battery’s ampere
hour rating.
4. Hold the load constant for 15 seconds, read the voltmeter scale and reduce
the load by turning the knob to off.
Note: a similar test can be made using a voltmeter across the battery while cranking
the engine with the starter motor to provide a load.

11 PIVOT 4A CALABARZON
 Safety precaution: Ignition should be isolated.
5. A voltmeter reading of not less than 9.5 volts for a 12-volt battery indicates
that the battery’s output capacity is good and that the battery can be
placed back in the service.
6. If the reading is below 9,5 volts for a 12-volt battery, a possible defective
condition is indicated.
Connecting and Disconnecting A Battery
Supplies and Materials: Memory holder ( for vehicles with electronics controlled
system) / Baking soda and water / Rags / Brush/Copper brush
Tools : Box wrench / Battery pliers / Combination wrench / Vice grip plier
Equipment: Vehicle trainer with battery or live vehicle
Procedure:
1. Connect a memory holder (a 9-volt battery and adaptor) to the cigarette
lighter to keep the volatile memories alive, while the battery is disconnected
from the vehicle.
Note: This step is for the battery equipped with electronic/computer controlled system. Fol-
low the manufacturer’s instruction to avoid overloading the 9-volt battery.
2. Disconnect the ground cable clamp using a box wrench or battery pliers.
3. Loosen the battery clamp with the use of appropriate wrench.
Note: Some battery clamp are snap-fitted to lock. It needs hand pressure to unlock the
clamp from the battery terminal).
4. Pull the battery clamp slowly from the battery terminal.
Note: Do not use other pliers or open-end wrench. If the clamp sticks, use a battery clamp
puller, do not pry the clamp off with screw driver or pry bar. This may break the cover.
5. Disconnect the insulated cable from the battery.
Note: Some vehicles have wires connected to the insulated side of the battery cable. Be sure
not to separate the wires. Wrapped it together with the insulated side of the battery cable.
6. Remove the hold-down clamps and remove the battery.
7. Clean the battery tray and hold-down clamps. If these parts are made of
metal, clean them with stiff brush and a solution of baking soda and wa-
ter.
8. When connecting the battery, be careful not to connect the battery cable
connections in wrong polarity with the battery terminals. The wrong polari-
ty may cause high current flow which will damage the vehicle’s electrical
components.
9. Coated with lithium grease or petroleum jelly, reconnect and tighten the in-
sulated cable first then the ground cable.
10. Install and tighten the hold down clamps.
11. Removed the memory holder.
12. Test run the engine for battery operation.

Removing and Replacing Battery

Supplies and Materials : Apron / Safety goggles / Gloves / Soda solution /
Lithium grease
Tools: Box wrench(12x13) / Screw drivers / Battery clamp puller / Wire brush
Equipment : Engine mock-up / Vehicle / Replacement battery
Procedures in Removing Battery
1. For electronic equipped vehicle. Remove the cigarette lighter and plug the
memory keeper into the lighter socket. A complementary metal–oxide–
semiconductor (CMOS) will keep the PIN codes and settings for radios and
navigation systems from getting erased when you disconnect the battery. If

12 PIVOT 4A CALABARZON
 you don't have a memory keeper make sure you have all the PINs for your
electronic equipment before you start working. You may wish to check your
car manual to see what devices may be affected.
2. Open the hood and use the prop rod to keep it open. Most of the latest
model cars have hoods that hold themselves up.
3. Locate the battery. The battery should be located in an accessible part on
either side of the vehicle's frame. The battery is a rectangular box with
two cables attached to it. Some cars have battery under the metting in the
trunk, or inside the fender of the wheel well (The latter is often very diffi-
cult to remove).
4. Identify battery terminals. Locate the positive and the negative terminals.
The positive terminal will have a plus sign and the negative terminal will
have a minus sign. These signs are inscripted on the battery post termi-
nals.
5. Disconnect the negative terminal. Loosen the negative cable clamp with a
wrench (Usually 8mm or 10mm) and slide it off from the battery terminal.
If the cables are unmarked, label them so that they don't get mixed up
(otherwise you may ruin your car's electric system later on). It is also im-
portant that you disconnect the negative terminal socket before the positive
terminal socket. Otherwise, you may short circuit the positive terminal to a
grounded part of the car.
6. Disconnect the positive terminal.
7. Remove the car battery by unfastening the battery holder
and remove any screws,clamps or bars holding the battery in place.
Carefully lift the battery out of the car. Remember that a battery can
weigh30 to 60 pounds, or 13.5 to 27 kilos, so if you have any back prob-
lems, get a helping hand.
8. Clean the terminal clamps and the battery tray. You can use a baking soda
solution and a wire brush. If there's any severe corrosion, consider replace-
ment by a mechanic. Otherwise, let the area dry before moving onto the
next step.
Procedures in Replacing Battery
1. Replace the battery - Place the new battery where you just removed the old
battery out, with the positive and negative terminals on the correct sides.
Connect all the screws, clamps or bars that may hold the battery in place.
2. Reconnect the positive terminal. Tighten the clamps using a wrench.
3. Reconnect the negative terminal.
4. Tighten the clamp with the wrench. Apply battery lithium grease. Spray the
terminals with lithium grease to prevent corrosion.
5. Close the hood - Shut the hood of your car firmly and start your car. Check
that all the electronic devices are working properly.
6. Dispose used battery at service garages, auto supply stores, and recycling
centers. There may be a small fee for the service, but throwing the battery
away as normal garbage is not an option.

D
Learning Task 1: Present the following process in a process diagram.
A. Testing Battery
B. Connecting and Disconnecting Battery
C. Removing and Replacing Battery

13 PIVOT 4A CALABARZON
 E
Learning Task 2: Rate yourself in terms of performing/doing the following
tasks.
1-I can do this well 2–I am learning how to do this 1–I cannot do this yet

_____ Using the hydrometer properly and accurately

_____ Reads the discharge state of the battery
_____ Adds distilled water to the battery
_____ Uses the tools/materials and equipment appropriately
_____ Observes safety measures in testing the battery

A
Learning Task 3: Read the following items. Choose only the letter of the best
answer. Write your answer in your notebook.
1. When disconnecting the battery, the correct tools to use are:
A. box wrench B. open wrench C. battery pliers D. A and C
2. The tool to remove the clamp of the battery is:
A. battery clamp puller C. screw driver
B. pry bar D. b and c
3. In cleaning the corrosion and foreign matters on the battery tray, use:
A. brush with baking soda and water B. oil
B. gasoline D. none of the above
4. To first step to disconnect the battery is:
A. remove the vent plug
B. disconnect the insulated cable from the battery
C. disconnect the ground cable from the battery
D. put the transmission in park or reverse
5. In order to be sure that the battery is connected properly , it must be:
A. cleaned B. displayed C. tested D. Transferred
6. In disconnecting the battery the correct tools used are:
A. box wrench B. open wrench C. battery pliers D. a and c
7. The tool used in removing the battery clamp is:
A. battery clamp puller C. screw driver
B. pry bar D. b and c
8. In cleaning the corrosion and foreign matters on the battery tray, clean
with:
A. brush with baking soda and water C. oil
B. gasoline D. none of the above
9. The first step to disconnect the battery is:
A. remove the vent plug
B. disconnect the insulated cable from the battery
C. disconnect the ground cable from the battery
D. put the transmission in park or reverse
10. Some battery have wires connected to the battery:
A. grounded cable C. insulated cable
B. neutral cable D. none of the above
14 PIVOT 4A CALABARZON
Explaining the Principles of Auto-Electricity
Lesson
I
This lesson contains information and suggested learning activities
on Testing and Repairing Wiring/Lighting System. It includes explain
the principle of auto electricity, explain automotive lighting system
and its functions, install wiring/lighting system, test electrical system and de-
termine preferred action, and carry out necessary repair in the electrical sys-
tem.

The word electricity comes from the Greek word elektron,

meaning “amber” (a fossil resin). The ancients produced electric charg-
es by rubbing amber with wool. This produced static electricity, which
was the first known type of electricity. It is called “static” (motionless) be-
cause the charge is at rest and not moving through a wire.
Atom is the smallest particle of a mater.
There are three particles of an atom:
1. Proton is positively charged.
2. Neutron is no charge or neutral particles.
3. Electron is negatively charged particles.
Two types of electric current:
1. Direct Current (DC) – when the free electrons are mov-
ing in a constant direction.
2. Alternating Current (AC) – when the direction and motion
and the size of the current vary periodically with time.
Three types of circuit:
1. Series Circuit – circuit in which the devices are connected end
to end, positive terminal to negative terminal. The same current
flows through all the devices in the circuit.
2. Parallel Circuit – circuit wherein the load or devices are
connected across each other. The current flows in different directions.
3. Series/Parallel Circuit – a combination of series and parallel circuit.

OHM’S LAW
A German physicist, Georg Simon Ohm (1787-1854), established
that electric pressure (EMF) in volts, electrical resistance in ohms, and the
amount of current in amperes flowing through any circuit are all related.
As the electric pressure goes up, more electrons flow. Increasing
the voltage increases the ampere of current. However, increasing the re-
sistance decreases the amount of current that flows. These relation-
ships can be summed up in a statement known as Ohm’s law.
Ohm’s law can also be stated as a simple
formula that can be used to calculate one value of

E
an electrical circuit if the other two are known:

Voltage is equal to current times resistance:

E (Electromotive force in volts) = I (Current in am-

I R
peres) x R (Resistance in ohms)
Where
I = current in amperes (A)
E = electromotive force (EMF) in volts (V)
R = resistance in ohms ( Ω ) Ohm’s Law Formula
15 PIVOT 4A CALABARZON
 LAW OF MAGNETISM
Magnet – is a piece of iron that attracts metallic steel. It has two mag-
netic poles called north magnetic pole and south magnetic pole. The north
magnetic pole is the exit point of the magnetic lines of force and the
south magnetic pole is the point where the magnetic lines of force enter.

South S N North

Magnet with magnetic poles

Magnetism – is a force that has ability to attract iron either by means of
electromagnet or by a natural magnet.

Magnetic Lines of Force

N
M
A
G
Magnet N
E
T
S

Nail Iron Filings

A natural magnet is a permanent magnet whereas electromagnet a temporary or

a man-made magnet. Electromagnet can be made when a coil of wire is wounded
around an iron core. When electric current is allowed to pass through the coil,
the iron core produces magnetism.

N S

Coil of Wire Iron Core

The Electromagnet
16 PIVOT 4A CALABARZON
 It was also found out that a magnet of the same poles ( S-S, N-
N) repel each other and a magnet of different poles ( N-S, S-N) attract each
other.

AUTOMOTIVE ELECTRICAL CICUITS

CIRCUIT – is the complete path of an electric current including

the current source. When the path is continuous, the circuit is closed and
current flows. When the path is broken, the circuit is open and no current
flows.
In an automotive electrical circuit, one of the wires from each
load returning to battery is connected to the vehicle body or frame. There-
fore, the vehicle body or frame itself functions as a conductor, allowing cur-
rent to flow through the body or frame and back to battery. The body or
frame is then referred to as the ground or earth of the circuit (meaning
that part of the circuit that returns the current to the battery). There-
fore, the two wiring diagrams below have the same meaning, but in
this manual, they be presented as shown in the wiring diagram below.

PATH

CONTROL (Switch)
CURRENT CONSUMING
SOURCE DEVICE (Load)
Fuse

Typical Complete Electrical Circuit

17 PIVOT 4A CALABARZON
 PARTS OF A COMPLETE CIRCUIT
Every complete circuit contains the following parts:
1. The source of electrical energy such as the battery used in a car.
2. Control such as switch is used to open and close the flow of cur-
rent flowing in a circuit. In times of excessive current flow or
overload, a device called fuse or fusible link used in a car protects
the circuit from electrical harm.
3. A conductor is usually an insulated copper wire that allows the passage
of current to flow from the power source such as the car’s battery to the
load such as light bulb and other electrical consuming device.
4. The electrical “load” or resistance is a consuming device that which the
electrical current is operating or lighting.

AUTOMOTIVE ELECTRICAL TERMS AND SYMBOLS, SIZES OF WIRES, PO-

LARITY, CONDUCTOR AND INSULATOR

Acquaintance with the electrical terms and symbols, sizes of wires, and
the knowledge about the polarity, conductors and insulators is of utmost
important with the one working with automotive electricity. This will facilitate
the work easily and accomplish the tasks on time.
Below are some of the various electrical terms and symbols usually
encountered when one is looking for electrical diagrams of a vehicle.

1. Ammeter – measures the flow of cur-

rent.

2. Battery –stores chemical energy and

converts it into electrical energy.

3. Wire connected - crossed wires

with a block dot at the junction are
joined
4. Connector with plug and socket –
the connection maybe temporary, or
serve as a permanent electrical joint be-
tween two wires or devices.
5. Light – current flow through a fila-
ment causes the filament to heat up
and emit light.
6. Transistor – a solid state device typi-
cally used as an electronic relay, it stops
or passes current depending on applied

7. Capacitor (Condenser) – a small hold-

ing unit for temporary storage of electrical
charge.

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8. Wire not connected – crossed wires with-
out a block dot at the junction are not
joined.
9. Diode – a semiconductor which
allows current flow in only one di-
rection.
10. Fuse – a thin metal strip which burns
through when too much current flows
through it.
11. Ground – the point at which wiring
attaches to the chassis, thereby provid-
ing a return path for an electrical cir-
cuit, without a ground for other return
path, current cannot flow.
12. Horn – an electric device which sounds
a loud audible signal.

13. Relay – an electrically operated

switch where the current flow through
a small coil creates a magnetic field which
either opens or closes an attached switch.
14. Switch – continuously passes current
through one set of contacts or the other.

15. Motor – a power unit which converts

electrical energy into mechanical energy,
especially rotary motion.
DIFFERENT SIZES OF WIRE, CONDUCTOR, INSULATOR AND
POLARITY
The electrical units in the automobile are connected by wires of different
sizes. The size of each wire depends on the amount of current the wire
must carry. The heavier the current, the larger the wire must be. The
wires are gathered together to form wiring harnesses.
Each wire is identified by the color of its insulation. For example, wires
are light green, dark green, blue, red, black with a white tracer, and so
on. The car manufacturer’s shop manuals have illustrations that
show the various wires and their colors. If you ever have to trace a particular
wire, refer to the shop manual to determine its color.

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 Electrical wire used in automotive application is stranded in type.
It means it is composed of strip of wires bounded together to form a
solid-like cord called conductor. It is usually made of copper metal to
provide an excellent conduction of electrical flow, and has a great re-
sistance to high temperature. Remember that engine itself produces high
temperature during operation. Electrical wires within the engine compart-
ment must withstand this high heat and not melt easily to avoid electrical fail-
ure.
Aluminum, silver, iron, steel, and gold are examples of metals but
copper because of its reasonable price is an excellent conductor of them all.
Automotive wires come in various sizes depending on the kind of circuit and
load used. Usually, number 16 wire is used in small current carrying
loads of around 10 amperes such as courtesy or dim light. Number 14 wire is
used in lamps like headlights, stop lights and signal lights because it
could carry a higher current to about 15 amperes. Numbers 12 and 10
wires are used in high current carrying loads to about 20 to 30 amperes
respectively such as the main ignition- starter switch, main fuse box, al-
ternator output circuit. The number 0/00 is a very thick wire and used as ca-
ble from battery positive terminal to starter motor and battery negative
terminal to vehicle ground. This thick cable could carry a capacity of
150 amperes to 300 amperes during engine starting. If thin wire is used,
the high current flowing in a wire will melt. It will result in electrical
fault such as fire because of a high current that thin wire cannot with-
stand.
Automotive wires must be made also of a very good plastic polyvi-
nyl chloride (PVC) covering called insulator. It must be made of a
very high resistance to heat. Insulator provides protection to the conduc-
tor to avoid grounding of the wire to the engine and vehicle
ground. If in case the conductor gets in contact to the ground, elec-
trical failure will result such as grounded circuit and frequent discharging
of the battery happen. Insulators is also made of various materials such as
fiberglass used in fuse base holder; ceramic as used in spark plugs; and
glass as used in cartridge type of fuse. Insulator comes in different colors
for easy identification in a circuit. Common insulator color such as red is used
in ‘live’ or ‘hot’ wire. Black color is typically used as ‘ground’. Commonly, in-
sulator consist of one solid or single based color. Insulators of modern
vehicle consists of a combination of two to three thin line colors with
one based color. Car manufacturers produced this kind of color coding for
easy identification and installation of wires in a circuit.

Polarity
In automotive application, polarity is the identification of positive (+)
‘live’ or ‘hot’ wire. The negative (-) polarity on the other hand is the
‘earth’ or ‘ground’ side where the flow of electricity returns to complete the cir-
cuit.
When disconnecting the battery cable from the battery, it is im-
portant that correct removal must be observed to ensure safety. The
‘negative’ cable is removed first from the negative battery post usually
marked (-) or has a smaller diameter. The positive battery cable is removed
next from the positive battery post usually marked (+). This is to ensure
that the flow of current is disconnected at once. The positive battery

20 PIVOT 4A CALABARZON
post is bigger than the negative post. The negative post has usually
green colored ring inserted on it or with black or green plastic protector.
The positive post has a red colored ring or with red colored plastic protec-
tor. These markings are very important for easy and correct identification of
polarity. When reinstalling the battery cables to the post. it should not
be reversed to avoid damage to the alternator diodes and electrical wir-
ings.
NOTE: Modern cars are equipped with microcomputers. They have Random Ac-
cess Memories (RAMs) – data that could be erased when battery is discon-
nected. Therefore, if it becomes necessary to disconnect the battery cable, the data
stored in each memory should first be written down so that it will not be lost.

D
Learning Task 1: In a short bond paper, accomplish the following checklist.
This checklist determines your level of knowledge and mastery about connect-
ing parts of a circuit.

SELF-RATING COMPETENCY CHECKLIST IN CONNECTING PARTS OF A CIRCUIT

COMPETENCY I cannot do this I am learning I can do this but I can do this
yet . (1pt) how to do I need to learn very well . (4pts)
this. (2pts) more and improve.
(3pts)
Identify and cite
the function of
different parts of
a circuit on a
board
Connecting the
wire on its
parts.
Operate the
circuit if done
successfully
Uses the tools/
materials and
equipment appro-
priately.
Observes safety
measures in con-
necting parts of a
circuit.
Self-Rating Rubric in Connecting Parts of a Circuit:

LEGEND:

20 - Advance
17-19 - Proficient
13-16 - Approaching Proficiency
8- 12 - Developing
1- 7 - Beginning

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 E
Learning Task 2: In a short bond paper, do the following performance task proce-
dures.

CONNECTING PARTS OF A CIRCUIT A.

Supplies and Materials:
• Automotive wires
• Lamp (12V)
• Fuse
• Ignition switch
• Fuse box
B. Tools:
• Electrical pliers
• Long nose pliers
• Test light
• Screw driver
C. Equipment:
• Battery 12 volts

Working Plan Drawing:

PATH

CONTROL CURRENT CONSUMING

SOURCE
Fuse

Sample plan used in the parts of a circuit.

Procedure:
1. Prepare the necessary tools, materials and equipment.
2. Connect a wire from the positive terminal of the lamp to the ACC
terminal of the ignition switch.
3. Connect a wire from the AM/BATT terminal of the ignition switch to the posi-
tive terminal of the battery.
4. Connect the negative terminal of the battery to the ground of a lamp.

NOTE:

• Check for the looseness of connection of wires, it can cause an open

circuit or high resistance.
• Always check the work of students before operating the circuit.
• A major cause of electrical troubles is excessive resistance in
circuits, which can be due to poor connections, defective wires,
or bad switch contacts.

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 A
Learning Task 3: Match Column A with Column B. Write only the letter of
the correct answer on a separate sheet of paper.

Column A Column B

1. A thin metal strip which burns A.

through when too much
current flows through it.
2. A semiconductor which allows cur- B.
rent flow in only one
direction.
3. A small holding unit for temporary C.
storage of electrical charge.

4. A power unit which converts electri- D.

cal energy into mechanical energy, es-
pecially rotary motion.
5. Current flow through a filament E.
causes the filament to heat up and emit
light.
6. Includes plastics, wood, glass, rub- F. 20 Ampere
ber, and ceramics.

7. According to signs, color of rings, G. Conductor

and sizes.

8. Metals. iron, steel, copper, alumi- H. 10 Ampere

num, silver, and gold are examples.

9. Amount of current the wire must I. Insulator

carry in size no. 12.

10. Amount of current the wire must J. Polarity

carry in size no. 16.

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 References

Chilton’s Easy Car Care: Chilton Book Company. 3rd Ed. Chilton

Oxford Dictionary of Current English. New Revised Ed. Oxford University Press,
1998
Popular Mechanics Guide to Auto Basic Repair and Maintenance. Book Division
The Heart, Corporation, New York, NY Electronics Resources
Swing Crispin, Frederick, Dictionary of Technical Terms the Buce Publishig Co:
1998.
Stockel, Martin W. Auto Mechanics Fundamentals. The Goodheart Willcox
Company, Inc, 1978
Way, Radnar, PA 19089

24 PIVOT 4A CALABARZON
Para sa mga katanungan o puna, sumulat o tumawag sa:

Department of Education Region 4A CALABARZON

Office Address: Gate 2 Karangalan Village, Cainta Rizal

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