CHAPTER 5

LAB MANUAL

• BATTERY

• CABLES AND WIRING

• IGNITION SWITCH

• NEUTRAL SAFETY SWITCH

• STARTER RELAY/SOLENOID

• STARTER MOTORLAB 155

TROUBLESHOOTING

• Problems fall into Four categories– No Crank

– Slow Crank

– Starter spins but does not engage

– Excessive noise

PROCEDURES

• VERIFY PROBLEM

• DEVELOP CONSISTENT METHOD

• PERFORM VISUAL INSPECTION

• CHECK BATTERY PERFORMANCE

• VERIFY ENGINE CONDITION IF NO CRANK OR SLOW CRANK

• (BE CAUTIOUS!)

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

QUICK TEST

• TURN HEADLIGHTS ON

• CRANK ENGINE

• NOTE RESULTS

• DON’T OVERCRANK ENGINE

LAB 161

CURRENT DRAW TEST

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

LAB 162

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

CURRENT DRAW TESTUse ARBST

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

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

VOLTAGE DROP INSULATED CIRCUIT

LAB 164

VOLTAGE DROP GROUND CIRCUIT

• SELECT LOW SCALE

• HOOK UP EQUIPMENT

• CRANK ENGINE

• NOTE RESULTS• LESS THAN

0.2V VOLTAGE DROPLAB 165

VOLTAGE DROP GROUND CIRCUIT

LAB 165

SOLENOID CIRCUIT TEST

• DISABLE IGNITION• LOW VOLT SCALE• CONNECT ACROSS

SOLENOID• CRANK ENGINE• VOLTAGE LESS

THAN 0.2 VOLT

LAB 166

SOLENOID CIRCUIT TEST

FREE SPEED TEST

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

LAB 168-169

Bench testing a starter

STARTER R & R• DISCONNECT BATTERY!

• IDENTIFY WIRES

• PAY ATTENTION TO SHIMS, ETC.

• ADJUST DRIVE GEAR CLEARANCE

• RE-CHECK OPERATION

LAB 170

THE END