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