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CHAPTER 5 LAB MANUAL

STARTER SERVICE. CHAPTER 5 LAB MANUAL. STARTING SYSTEM COMPONENTS. BATTERY CABLES AND WIRING IGNITION SWITCH NEUTRAL SAFETY SWITCH STARTER RELAY/SOLENOID STARTER MOTOR. LAB 155. TROUBLESHOOTING. Problems fall into Four categories No Crank Slow Crank

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CHAPTER 5 LAB MANUAL

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  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 • DON’T 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

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