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STARTER SYSTEM DIAGNOSIS AND SERVICE

STARTER SYSTEM DIAGNOSIS AND SERVICE. STARTING SYSTEM COMPONENTS. BATTERY CABLES AND WIRING IGNITION SWITCH NEUTRAL SAFETY SWITCH STARTER TEMPERATURE SWITCH (if used) STARTER RELAY STARTER SOLENOID STARTER MOTOR. TYPICAL STARTER MALFUNCTIONS. FOUR CATEGORIES NO CRANK SLOW CRANK

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STARTER SYSTEM DIAGNOSIS AND SERVICE

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  1. STARTER SYSTEM DIAGNOSIS AND SERVICE

  2. STARTING SYSTEM COMPONENTS • BATTERY • CABLES AND WIRING • IGNITION SWITCH • NEUTRAL SAFETY SWITCH • STARTER TEMPERATURE SWITCH (if used) • STARTER RELAY • STARTER SOLENOID • STARTER MOTOR

  3. TYPICAL STARTER MALFUNCTIONS • FOUR CATEGORIES • NO CRANK • SLOW CRANK • STARTER SPINS BUT NO CRANK • EXCESSIVE NOISE WHILE CRANKING

  4. TROUBLESHOOTING • PERFORM BATTERY TESTING • CLEAN BATTERY TERMINALS AND CABLE ENDS • VERIFY ENGINE CONDITION IF NO CRANK OR SLOW CRANK • PERFORM CRANKING CIRCUIT VOLTAGE DROP TEST • PERFORM CRANKING CONTROL CIRCUIT VOLTAGE DROP TEST • MEASURE STARTER CURRENT DRAW, AND CRANKING SPEED

  5. CRANKING CIRCUIT TEST • USE BATTERY LOAD TESTER AND CONNECT TO BATTERY TERMINAL ON STARTER SOLENOID AND STARTER GROUND TERMINAL • CONNECT DMM ACROSS POSITIVE CIRCUIT • CONNECT DMM ACROSS NEGATIVE CIRCUIT • DO NOT CONNECT DMM LEADS TO LOAD TESTER CLAMPS, DMM WILL NOT READ ACCURATELY • SET LOAD TESTER TO 500 AMPS FOR MULTIPLE BATTERIES OR ½ CCA RATING OF SINGLE BATTERY • VOLTAGE DROP TOTAL ALLOWED IS .5 VOLT MAXIMUM

  6. PG 234 IN TEXT

  7. TYPICALCRANKING CONTROL CIRCUIT PG 236 IN TEXT

  8. CRANKING CONTROL CIRCUIT TESTING PG 237 IN TEXT • USE DMM TO TEST FOR VOLTAGE AT RELAY BATTERY TERMINAL, SHOULD READ BAT VOLTS • HOLD KEY IN CRANK POSITION, USE DMM TO TEST FOR VOLTAGE AT RELAY CONTROL TERMINAL, SHOULD READ BATTERY VOLTS • HOLD KEY IN CRANK POSITION, USE DMM TO TEST FOR VOLTAGE AT RELAY CONTROL GROUND TERMINAL, SHOULD READ 0 VOLTS • HOLD KEY IN CRANK POSITION, USE DMM TO TEST FOR VOLTAGE AT RELAY OUTPUT TERMINAL, SHOULD READ BATTERY VOLTS

  9. TESTING NUETRAL START CIRCUIT PG 238 IN TEXT • DISCONNECT NUETRAL START SWITCH, HOLD KEY IN CRANK POSITION AND MEASURE VOLTAGE BETWEEN CONNECTOR AND GROUND, SHOULD READ BATTERY VOLTS • WITH SWITCH STILL DISCONNECTED CAN MEASURE OHMS WITH TRANS IN NUETRAL SHOULD READ NEAR 0, IF OL SWITCH IS BAD

  10. TESTING STARTER TEMPERATURE SWITCH • STARTER MOTOR AT ROOM OR OUTSIDE TEMPERATURE • USE DMM AND MEASURE RESISTANCE BETWEEN THE TWO TERMINALS OF THE SWITCH • SWITCH IS GOOD IF RESISTANCE IS NEAR 0 • IF RESISTANCE IS HIGH SWITCH IS BAD

  11. SOLENOID TESTING • CONNECT DMM ACROSS SOLENOID BATTERY TERMINAL AND STARTER MOTOR TERMINAL • DMM SHOULD BE READING BATTERY VOLTAGE • WATCH DMM, TURN IGNITION SWITCH TO CRANK POSITION, WHILE CRANKING DMM SHOULD READ LESS THAN .1 VOLT • IF VOLTAGE IS HIGHER THAN .1 VOLT SOLENOID DISC IS NOT MAKING GOOD CONNECTION TO BATTERY AND/OR MOTOR TERMINALS

  12. STARTER TESTING ON THE VEHICLE • PERFORM STARTER CURRENT DRAW AND CRANKING SPEED TEST • RESULTS WILL VARY DEPENDING ON CONDITION OF ENGINE, BATTERIES, OUTSIDE TEMPERATURE, AND OIL VISCOSITY • USE INDUCTIVE CLAMP AMMETER • USE LASER TACHOMETER TO MEASURE CRANKSHAFT SPEED • CRANK ENGINE AND COMPARE MEASURMENTS TO SPECS IN SERVICE MANUAL

  13. STARTER REMOVAL AND REINSTALLATION • DISCONNECT ALL BATTERY NEGATIVE CABLES! • IDENTIFY WIRES FOR RECONNECTION • PAY ATTENTION TO ANY MOUNTING SHIMS • CLEAN ALL WIRE TERMINALS, HARDWARE, AND STARTER MOUNT • INSTALL STARTER AND TEST FOR PROPER OPERATION, (ALSO CHECK FOR NUETRAL START, SHOULD NOT CRANK IN GEAR)

  14. STARTER TESTING ON THE BENCH • SET OR CHECK PINION CLEARANCE • CONNECT STARTER WITH BATTERY CABLES, MUCH THE SAME AS ON THE VEHICLE • MAKE SURE ALL CONNECTIONS ARE TIGHT • USE REMOTE STARTER SWITCH TO ACTIVATE SOLENOID • USE INDUCTIVE CLAMP AMMETER TO MEASURE AMPERAGE DRAW AND LASER TACHOMETER TO MEASURE RPM • COMPARE READINGS TO SPECIFICATIONS IN SERVICE MANUAL

  15. THE END

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