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Group 14 Starting System
Group 14 Starting System
PART 14-1
PART 14-2
PAGE .14-10
STARTER. . . . . . . . . . . . . . . . . . . . . .14-8 ..
Section Page Armature andField GroundedCircuit Test-OnTest Bench 14-3 Starter Cranking Circuit Test. . . . . . . . . . . . . .14-5 2 CommonAdjustmentsand Repairs. . . . . . . . . .14-6 Brush Replacement 14-6 Armature Replacement .14-6 3 Cleaning and Inspection .14-6
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the starter relay, the starter (lgnltion) switch, and the necessary cables and wiring to connect the components. Vehicles equipped with an automatic transmission employ a neutral-start switch in the system which prevents operation of the starter in all selector positions except N (neutral) and P (park). A schematic diagram of the starting circuit is shown in Fig. 1. The majority of starting problems usually fall into one of the following situations: the starter will not crank the engine; the engine will crank at normal speed but will not start; and the starter cranks the engine very slowly. If the engine will crank but will not start, the trouble is usually in the engine, fuel system or ignition system rather than in the starting system. Following are road map type charts which may be followed to determine the cause of the difficulty and the corrective action. ROAD SERVICE
On road service calls. connect a
BATTERY
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booster battery to the system for casesof a starter thai will not crank the engine or a starter that cranks the engine very slowly. If the starter turns the engine over, but the engine still will not start, even with the booster battery attached, refer to the following charts. Be certain that correct battery polarity is observed when using a booster battery; positive to positive, and negative to negative connection of the auxiliary cables. STARTER WILL NOT CRANK THE ENGINE Refer to Fig. 2 for this symptom. NOTE I-NEUTRAL START 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 neutralstart switch. Refer to Group 7 Part 3 for the adjustment of this switch.
1_0_00 -
- - --AUTOMATIC
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,
TRANSMISSION ONLY STARTER NEUTRAL SWITCH CLOSED WITH SELECTOR IN N OR P POSITION Stripe SWITCH
---STARTER
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14-2
GROUP 14
STARTINGSYSTEM
CHECK THE BATTERY AND STARTER CABLES FOR GOOD ELECTRICAL CONTACT. . LOOK FOR BROKEN OR CORRODEDCONNECTIONS. IN PARTICULAR' ASSUREGOOD GROUND CONNECTIONS. CLEAN AND TIGHTEN THE CABLE CONNECTIONSAS NECESSARY. CHECK THE BATTERY SPECIFIC GRAVITY.
OK
LOW
PERFORM THE BATTERY TESTS, CHARGE OR REPLACE THE BATTERY AS NECESSARY. CHECK THE BATTERY AND STARTER CABLES AND STARTER RELAY FOR EXCESSIVE RESISTANCE.
RELAY CLICKS
* I
BY.PASS THE IGNITICI-I SWITCH, NEUTRAL START SWITCHAND WIRING. SEE NnTE NO.3.
... REMOVE THE STARTING MOTOR AND DRIVE. CHECK AND CLEAN THE STARTER DRIVE AS REOOIRED. CHECK FOR DAMAGED FLYWHEEL RING GEAR TEETH. WHEN INSTALLING THE S"JARTER. PROPERLY ALIGN IT TO THE FLYWHEEL HOUSING.
ENGINE
CRANKS
* REPLACE RELAY
CHECK THE WIRING TO THE IGNITION SWITCH,NEUTRAL START SWITCH AND WIRING TO STARTER RELAY. SEE NOTE NO.4.
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REMOVE AND TEST THE STARTER. REPAIR AS REQUIRED.
REOOIRED.
PART 14-1
from the battery terminal of the relay to the starterterminal of the relay (Fig. 3, connectionNo.1). NOTE 3--STARTER RELAY TEST Connect a jumper from the battery terminal of the relay to the starter (ignition) switch terminal of the relay (Fig. 3, connectionNo.2) If the engine does not crank, thc starter relay probably is at fault. NOTE 4-STARTER CONTROL CIRCUIT TEST On vehiclesequippedwith an automatic transmission,if the engine cranks, connect a jumper from the relay side of the neutral-startswitch battery terminal of the relay to the (Fig. 3, connection No.3). If the enginedoesnot crank, the wiring betweenthe neutral-startswitch and the relay is at fault. If the enginecranks, relay side of the neutral-startswitch connect a jumper {rom the battery terminal of the relay to the starter (ignition) switch side of the neutralstart switch (Fig. 3, connectionNo. 4). If the enginedoesnot crank, the neutral-start switch is out of adjustment or defective. If the engine cranks,check for voltage at the battery terminal of the starter (ignition) switch wiring harnessconnectorwith a test light or a voltmeter. If voltage is not available,the wiring between the battery terminal of the starter relay and the battery terminal of the starter (ignition) switch is at fault. If voltage is available,substitutean ignition switch from stock. If the engine cranks, replace the ignitior. switch. If the engine still will not crank, the trouble is in the wiring or connections between the ignition switchand the starter-neutralswitch.
STARTER CRANKS ENGINE SLOWLY Refer to Fig. 4 for this symptom.
GENERALSTARTINGSYSTEMSERVICE
14-3
meter will indicatethe startercurrent draw under load. STARTERNO-LOAD TEST The starter no-load test will uncover such faults as open or shorted windings,rubbing armature,and bent armature shaft. The starter can be tested,at no-load, on the test bench only. Make the test connections as shownin Fig. 6. The starterwill run at no-load.Be sure that no current is flowing through the ammeter (rheostat at maximum counterclockwise position). Determine the exact reading on the voltmeter. Disconnect the starter from the battery, and reducethe resistance of the rheostatuntil the voltmeterindicates the same reading as that obtained while the starter was running. The ammeterwill indicate the starter no-load current draw. ARMATURE OPEN CIRCUIT TEST-ON TEST BENCH An open circuit armature may sometimes detectedby examining be the commutator for evidence of burning. The spot burned on the commutator is caused by an arc formed every time the commutator segment,connectedto the open circuit winding, passes under a brush.
ARMATURE AND FIELD GROUNDED CIRCUIT TESTON TEST BENCH This test will determine if the winding insulation has failed, permitting a conductor to touch the frame or armature core. To determine if the armature windings are grounded, make the connections as shown in Fig. 7. If the voltmeter indicates any voltage, the windings are grounded. Grounded field windings can be detected by making the connections as shown in Fig. 8. If the voltmeter indicates any voltage, the field windings are grounded.
TO BATTERY
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14-4
GROUP 14
STARTINGSYSTEM
STARTER CRANKS ENGI NE SLOWLY-ROADMAP * CHECK THE BATTERY AND S,ARTER CABLES FOR GOOD ELECTRICAL CONTACT. LOOK FOR CORRODED OR LOOSE CONNECTIONS. IN PARTICULAR, ASSURE GOODGROUND CONNECTIONS. CLEAN AND TIGHTEN THE CABLES AS NECESSARY. CHECK BATTERY SPECIFIC GRAVITY
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PERFORM BATTERY TESTS. CHARGE OR REPLACE THE BATTERY AS NECESSARY. CHECK THE BATTERY AND STARTER RELAY FOR EXCESSIVE RESISTANCE.
REFER TO GROUP 8
J 1317-A
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HOLDING GROUND
- --COIL LEAD
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FIG. 8-Field
Test
Grounded Circuit
and the positivelead connected the to battery positiveterminal (Fig. 9, connectionCD) 0.5 volt. 2. With the voltmeter negative lead connectedto the battery terminal of the starter relay and the positive lead connectedto the positive terminal of the battery (Fig. 9, connection C!J) 0.1 volt. 3. With the voltmeter negative lead connectedto the starter terminal of the starter relay and the positive lead connectedto the positive terminal of the battery (Fig. 9, connection<! 0.3 volt. 4. With the voltmeter negative lead connected the negativetermito nal of the battery and the positive lead connectedto the engineground (Fig. 9, connection 0) 0.1 volt. .
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STARTERCRANKING CIRCUIT TEST Excessive resistancein the starter circuit can be determinedfrom the resultsof this test. Make the test connections as shown in Fig. 9. Crank the engine with the ignition OFF. This is accomplished disconnectby ing and grounding the high tension lead from the spark coil and by connecting a jumper from the battery terminal of the starter relay to the ignition switch terminal(s),of the relay. The voltagedrop in the circuit will be indicatedby the voltmeter (0 to 2 volt range). Maximum allowable voltage drop shouldbe: 1. With the voltmeter negative lead connected the starterterminal to
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FIG.
Test
9-Starter
14-6
GROUP 14
STARTINGSYSTEM
4. Remove the starter drive plunger lever pivot pin and lever, and remove the armature. 5. Remove the front end plate.
6. Remove the ground brush retaining screws from the frame and remove the brushes (cut the ground brush nearest the starter terminal from the brush terminal block, as close to the brush lead terminal as possible). 7. Cut (or unsolder) the insulated brush leads from the field coils, as close to the field connection point as possible. 8. Clean and inspect the starter motor. 9. Replace the front end plate if the insulator between the field brush holder and the end plate is cracked or broken. 10. Position the new insulated field brushes lead on the field coil terminal. Install the clip provided with the brushes to hold the brush lead to the terminal. Solder the lead, clip, and terminal together, using rosin core solder (Fig. 4, Part 14-2). Use a 300watt iron. 11. Install the ground brush leads to the frame with the retaining screws. 12. Clean the commutator with #00 or #000 sandpaper. 13. Position the front end plate to the starter frame, with the end plate boss in the frame slot. 14. Position the fiber washer on the commutator end of the armature shaft and install the armature in the starter frame. 15. Install the starter drive gear plunger lever to the frame and starter drive assembly, and install the pivot pin. 16. Position the return spring on the plunger lever, and the rear end housing to the starter frame. Install the through bolts and tighten to specified torque (55-75 inch pounds). Be sure that the stop ring retainer is seated properly in the rear end housing. 17. Install the commutator brushes in the brush holders. Center the brush springs on the brushes. 18. Position the plunger lever cov-
er and the brush cover band, with its gasket, on the starter. Tighten the band retaining screw. 19. Connect the starter to a battery to check its operation. ARMATURE REPLACEMENT 1. Loosen the brush cover band retaining screw and remove the brush cover band, gasket, and the starter drive plunger lever cover. Remove the brushes from their holders. 2. Remove the through bolts, the rear end housing, and the drive plunger lever return spring. 3. Remove the pivot pin retaining the starter gear plunger lever, and remove the lever. 4. Remove the armature. If the starter drive gear assembly is being reused, remove the stop ring retainer and the stop ring from the end of the armature shaft, and remove the assembly. S. Place the drive gear assembly on the new armature with a new stop ring. 6. Install the fiber thrust washer on the commutator end of the armature shaft and install the armature. 7. Position the drive gear plunger lever to the frame and drive gear assembly and install the pivot pin. 8. Position the drive plunger lever return spring, the rear end housing, and the front end plate to the starter frame, and then install and tighten the through bolts to specification. Be sure that the stop ring retainer is seated properly in the drive gear housing. If the starter has needle bearings apply a small amount of grease to the needles before installing the starter ends. 9. Place the brushes in their holders, and center the brush springs on the brushes. 10. Position the plunger lever cover and the brush cover band, with its gasket, and then tighten the retaining screw. 11. Connect the starter to a battery to check its operation.
2. Inspect the armature windings for broken or burned insulation and unsolderedconnections. 3. Check the armature for open circuits and grounds.
4. Check the commutatorfor runout (Fig. 10). Inspect the armature shaft and the two bearingsfor scoring and excessive wear. On a starter with needle bearings apply a small
PART 14-1 -
GENERAL STARTINGSYSTEMSERVICE
14-7
amount of greaseto the needles.If the commutator is rough, or more than 0.005 inch out-of-round,turn it down. 5. Check the brush holders for broken springs and the insulated brush holders for shorts to ground. Tighten any rivets that may be loose. Replace the brushesif worn to 1/4 inch in length.
6. Check the brush spring tension. Replace the springs if the tension is not within specified limits (40 ounces minimum). 7. Inspect the field coils for burned or broken insulation and continuity. Check the field brush connections and lead insulation.
14-8
STARTER
Section 1 DescriptionandOperation. . . . . . 2 Removaland Installation. . . . . . 3 Major Repair Operation. . . . . . .
Page Section
Disassembly
Assembly
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.14-9 .14-9
2. Disconnectthe starter cable at the starter terminal. 3. On a Comet with power steering (8-cyl. engine), disconnect and lower the idler arm from the frame.
Push the bolts back through the frame. 4. Remove the starter mounting bolts. Removethe starter assembly.
5. Position the starter assembly to the flywheel housing, and start the mounting bolts.
6. Snugall bolts, then torque them to specification. 7. Connect the starter cable. 8. Install the idler arm (if removed), and lower the car.
Use the following procedure when it becomes necessary to completely overhaul the starter. Fig. 2 illustrates a partially disassembledstarter. DISASSEMBLY
1. Loosen the brush I.;overband retainingscrewand reinovethe brush cover band and the starter drive plungerlever cover.Observe lead the positions for assemblyand then re-
move the commutator brushesfrom the brush holders. 2. Remove the through bolts, starter rear end housing, and the starter drive plunger lever return spring. 3. Removethe pivot pin retaining the starter gearplungerlever and removethe lever and the armature. 4. Removethe stop ring retainer. Removeand discardthe stopring re-
taining the starter drive gear to the end of the armature shaft, and re!Dovethe starter drive gear assembly. 5. Removethe front end plate. 6. Removethe two screwsretaining the ground brushes the frame. to 7. On the field coil that operates the starter drive gear actuating lever, bend the tab up on the field retainer and remove the coil retainer. 8. Removethe three coil retainin2
PART 14-2
STARTER
14-9
screws,using tool lOO44-A and an arbor press(Fig. 3). The arbor press prevents the wrench from slipping out of the screw. Unsolder the field coil leads from the terminal screw, and removethe pole shoesand coils from the frame (use a 300-watt iron).
USE Arbor Press TO HOLD Toot-IOO44-A
turning it down. A brush kit and a contact kit are available. All other assemblies are to be replaced rather than repaired. If the starter has needle bearings, apply a small amount of greaseto the needles before assembly. ASSEMBLY
Too/IN SCREWSOCKET
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1. Install the starter terminal, insulator,washers, retaining nut in and the frame (Fig. 4). Be sure to position the slot in the screwperpendicular to the frame end surface. 2. Position the coils and pole pieces,with the coil leadsin the terminal screwslot, and then install the retaining screws(Fig. 3). As the pole shoe screwsare tightened,strike the frame several sharpblowswith a softfaced hammer to seat and align the pole shoes,then stake the screws. 3. Install the solenoidcoil and retainer and bend the tabsto retain the coils to the frame. 4. Solder the field coils and solenoid wire to the starter terminal using rosin core solder.Use a 300-watt iron. 5. Check for continuity and grounds in the assembled coils. 6. Positionthe new insulatedfield brushes lead on the field coil terminal. Install the clip providedwith the brushes hold the brush lead to the to terminal. Solder the lead, clip, and termil'~l together, using rosin core solder (Fig. 4). Use a 300-watt iron. 7. Position the solenoid coil ground terminal over the nearest ground screwhole. 8. Position the ground brushesto
14-10
SPECIFICATIONS
Vendor
Minimum Brushes Stall Maximum rus Load No.Load Mfg. Wear Spring Torque@ 5 Volts Tension (Amperes)(Amperes) length limit (FootPounds) (Inches) (Inches) (Ounces)
250 100-150
15.5 9
670 460
70 70
0.5 0.5
0.25 0.25
40 40
Maximumcommutator runout in inches is 0.005. Maximumstarting circuit voltage drop (battery + terminal to starter terminal @ normal engine temperature)0.5 volt. Starter through-bolt torque 55-75 inch pounds. Starter mounting-bolttorque 3/8 inch bolt two-holemounting15-20foot pounds,5/16 inch bolt three-hole mounting 12-15 foot pounds.
SPECIAL TOOLS
Tool Number Tool lOO44-A
Description GeneratorPoleScrewWrench