Ford Falcon. Manual — part 193
303-06-9 Starting
System 303-06-9
DIAGNOSIS AND TESTING (Continued)
Test Step
Result / Action to Take
D2
CHECK FLYWHEEL
Remove the starter motor. Refer to procedure in this section.
Yes
REPLACE as necessary.
Inspect the starter drive and flywheel for damage.
No
Is the starter drive or flywheel damaged?
Perform Bench Test procedures this section.
PINPOINT TEST E : UNUSUAL STARTER NOISE DURING STARTER OVERRUN
Test Step
Result / Action to Take
E1
CHECK STARTER MOTOR MOUNTING
Inspect the starter motor mounting.
Yes
Go to E2
Check the starter motor mounting bolts for looseness.
No
Is the starter motor mounted properly?
REMOUNT or REPLACE the starter motor.
E2
CHECK STARTER DRIVE ENGAGEMENT
Remove the starter motor.
Yes
PERFORM the Bench Test procedures in this
Inspect the starter drive and flywheel for damage. Refer to inspection
section.
procedure in this section.
No
Are the starter drive and flywheel OK?
REPLACE as necessary.
PINPOINT TEST F : STARTER MOTOR REMAINS ENGAGED AND RUNS WITH ENGINE
Test Step
Result / Action to Take
F1
CHECK STARTER MOTOR TERMINALS
Inspect the starter motor connectors for corrosion and incorrect
Yes
installation.
PERFORM the Bench Test procedures in this
section.
Are the starter motor connectors clean and installed properly?
No
CLEAN or ADJUST starter motor connectors.
starter switch, and determine exact reading on
Component Tests
voltmeter.
Starter Motor Load Test
NOTE: Ensure ignition switch is in the off position
and the solenoid terminal 50 connector has been
Conduct this test if the starter cranks slowly and it is
removed so that the engine does not start.
desired to compare current draw to specifications.
This test is performed with the starter motor fitted to
4. Disconnect battery to vehicle cables and reduce
the vehicle.
resistance of carbon pile until voltmeter indicates
1. Connect the starter motor tester equipment to the
the same reading as that obtained while the
vehicle’s battery. Ensure that current is not
starter cranked the engine. The ammeter will
flowing through the ammeter and heavy duty
indicate starter current draw under load. Check
carbon pile rheostat portion of starter tester
this value with value listed in specifications.
circuit, (rheostat at maximum counter clockwise
Starter Motor No Load Test
position).
The starter motor no load test will uncover such
2. Disconnect the push on connector at the starter
conditions as open or shorted windings, rubbing
solenoid (terminal 50) and connect a remote
armature, and bent output shaft. The starter can be
control starter switch from the positive battery
tested, at no load, on the test bench only.
terminal to solenoid terminal 50.
1. Clamp the starter motor securely in a starter test
3. Place transmission in neutral or park. With the
bench.
ignition off crank the engine using the remote
G86730 en
303-06-10 Starting
System 303-06-10
DIAGNOSIS AND TESTING (Continued)
2. Connect Starter Tester to a fully charged battery
starter motor should operate smoothly. Determine
(Specific Gravity > 1260) and connect the battery
the exact reading on the voltmeter.
positive to the battery supply (terminal 30) of the
NOTE: The duration of this test should be as
starter motor and battery negative to the starter
short as possible.
motor case. Starter motor connection cables
5. Disconnect starter from battery then reduce
should be large enough to carry high currents,
resistance of rheostat until voltmeter indicates the
(equivalent to those used on the vehicle).
same reading as that obtained while the starter
3. Connect a remote starter switch between the
was running. The ammeter will indicate starter no
solenoid terminal 50 and the power supply on
load current draw. Refer to specifications for a
terminal 30.
comparative value.
4. Ensure that no current can flow through the
6. If the current exceeds Specification, check for
ammeter (rheostat at maximum counter clockwise
rubbing armature, bent output shaft, binding
position). Engage the remote starter switch, the
bearings, or shorts in armature or brush
pinion should shift to the crank position and the
assembly.
Starter Solenoid
Armature
Inspect the solenoid for damage and test the winding
The commutator should be examined for any sign of
dc resistance.
burned or darkened segments as this is usually an
indication of open circuited windings. Check for short
Hold-in Winding
1.16 - 1.3 Ohms.
circuits using an armature growler or similar tester.
Pull-in Winding
0.248 - 0.281 Ohms.
Test the insulation resistance to earth using a megger
or similar tester. A reading 1 MegaOhm or greater
Test temperature
+20
°C
should be expected.
During hold in and pull in tests the solenoid is held
vertically, ie plunger uppermost. It is recommended
that a rubber band be installed to prevent the plunger
from flinging out during testing.
G86730 en
303-06-11 Starting
System 303-06-11
DIAGNOSIS AND TESTING (Continued)
Inhibitor Switch Test
On vehicles equipped with an automatic transmission,
apply the brakes and attempt to start the engine while
moving the selector lever through all ranges. This may
determine if the problem is caused by a maladjusted
or defective neutral-start switch. Refer to Section
307-01 for the adjustment of this switch.
G86730 en
303-06-12 Starting
System 303-06-12
GENERAL PROCEDURES
2. Press the plunger fully home, it will be held by the
Starting System
hold-in winding.
3. Now decrease the voltage until the winding will no
Cleaning Components
longer hold the plunger.
Brushes and brush holder Inspection
CAUTION: The Armature, solenoid switch
and drive assembly components must not be
1. Check the brush holder for shorts to ground using
cleaned with spirit based agents, only clean rags
an insulation tester with a minimum AC voltage of
and compressed air must be used.
40 volts.
NOTE: All other mechanical components may be
2. Ensure that the brushes move freely in their
cleaned using non volatile or low inflammable agents
holders and that the brushes are free from chips
in a well ventilated area, it is important that the parts
and burn marks.
are thoroughly dried before assembly, take care not to
3. Check brush length if shorter than the minimum
breath in the vapours.
length (7mm) replace the brush set.
Please observe the safety regulations and precautions
Armature Inspection
issued by the manufacturer of the cleaning agent in
use.
1. Clean and inspect the armature for broken or
burned insulation and unwelded or open
Pull-In Voltage Testing
connections.
1. Using a power supply capable of supplying 30
2. Inspect armature shaft and bearing surfaces for
amperes, set the voltage to 3.0 volts. A battery
scoring and excessive wear.
and variable resistor may also be used.
3. Check commutator for runout using a dial
2. Connect the solenoid. Connect a 12 volt test lamp
indicator. If commutator is rough, or out of round,
between terminal 30 (main battery supply input)
turn it down to Specification or replace.
and +12 volt supply and a voltmeter between
terminal 50 and ground.
Item
Description
3. Fully press in solenoid plunger until lamp lights.
1
Rotate armature chafts on bearing
Allow the plunger to spring out by approximately
surfaces
8-10mm and hold in this position.
2
Dial indicator
4. Slowly increase the voltage on terminal 50 until
3
“V” blocks
the plunger pulls in; note voltmeter reading. At the
Machining and undercutting the commutator
same time the lamp must light fully (main contact
continuity).
1. If worn segments are evident on the commutator it
NOTE: The voltage should be between 3.0 - 6.5
must be machined until the working surface is
volts. Test duration should NOT exceed 2
clean, note that the minimum size for the
seconds.
commutator is 31.2mm. When machining the
armature it must not be held by the laminations.
Hold-In Voltage Testing
The Armature must be held at the drive end and
NOTE: The voltmeter reading, this is the release
supported at the commutator end bearing surface.
voltage which should be between 0.2 - 2.0 volts.
1. Set the power supply to 12 volts, connect the
positive lead to terminal 50 of the solenoid and
connect the negative lead to the case of the
solenoid.
G86731 en
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