LAB MANUAL

1
STARTER SERVICE

• CHAPTER 5
• LAB MANUAL

2
STARTING SYSTEM COMPONENTS

• BATTERY
• CABLES AND WIRING
• IGNITION SWITCH
• NEUTRAL SAFETY SWITCH
• STARTER RELAY/SOLENOID
• STARTER MOTOR

LAB 155
3
TROUBLESHOOTING

• Problems fall into Four categories
• No Crank
• Slow Crank
• Starter spins but does not engage
• Excessive noise

4
PROCEDURES

• VERIFY PROBLEM
• DEVELOP CONSISTENT METHOD
• PERFORM VISUAL INSPECTION
• CHECK BATTERY PERFORMANCE
• VERIFY ENGINE CONDITION IF NO CRANK OR SLOW CRANK
• (BE CAUTIOUS!)

5
TROUBLE CHARTS

• FIND NORMAL AMPERAGE STARTER DRAW SPECS.
• BY SYMPTOM, CAN SOMETIMES DIAGNOSE PROBLEM IN
  STARTING SYSTEM
• TESTING EQUIPMENT MUST BE ACCURATE

LAB 157-159
6
QUICK TEST

• TURN HEADLIGHTS ON
• CRANK ENGINE
• NOTE RESULTS
• DONT OVERCRANK ENGINE

LAB 161
7
CURRENT DRAW TEST

• DISABLE IGNITION
• VISUAL INSPECT
• HOOK UP EQUIPMENT
• TURN OFF ALL ELECTRICAL LOADS
• PERFORM TEST

LAB 162
8
CURRENT DRAW TEST

• VOLTAGE SHOULD NOT GO BELOW 10 VOLTS
• AMPERAGE SHOULD BE ABOUT
• 4 CYL. 125-150
• 6 CYL. 140-160
• 8 CYL. 160-200 small block
• 8 CYL. 200-240 large block

9
CURRENT DRAW TESTUse ARBST
10
VOLTAGE DROP TEST

• A CIRCUIT RESISTANCE TEST IS ALSO CALLED A
  VOLTAGE DROP TEST
• YOU HAVE TO TEST BOTH THE POSITIVE AND THE
  NEGATIVE SIDES

LAB 164
11
VOLTAGE DROP TEST INSULATED CIRCUIT

• VOLTMETER ON LOW SCALE
• HOOK UP EQUIPMENT
• CRANK ENGINE
• NOTE VOLTAGE
• LESS THAN 0.5 VOLT
• ALSO CALLED A INSULATED CIRCUIT RESISTANCE TEST

LAB 164
12
VOLTAGE DROP INSULATED CIRCUIT
LAB 164
13
VOLTAGE DROP GROUND CIRCUIT

• SELECT LOW SCALE
• HOOK UP EQUIPMENT
• CRANK ENGINE
• NOTE RESULTS
• LESS THAN 0.2V VOLTAGE DROP

LAB 165
14
VOLTAGE DROP GROUND CIRCUIT
LAB 165
15
SOLENOID CIRCUIT TEST

• DISABLE IGNITION
• LOW VOLT SCALE
• CONNECT ACROSS SOLENOID
• CRANK ENGINE
• VOLTAGE LESS THAN 0.2 VOLT

LAB 166
16
SOLENOID CIRCUIT TEST
17
FREE SPEED TEST

• TESTS STARTER FREE LOAD
• AMPS
• RPM
• CAUTION!
• COMPARE RESULTS TO SPECS

LAB 168-169
18
Bench testing a starter
19
STARTER R R

• DISCONNECT BATTERY!
• IDENTIFY WIRES
• PAY ATTENTION TO SHIMS, ETC.
• ADJUST DRIVE GEAR CLEARANCE
• RE-CHECK OPERATION

LAB 170
20
THE END