BSBT College

434 MAGSAYSAY AVENUE BAGUIO CITY

NAME: ________________________________________________ ___________________ DATE:____________________

JOB ORDER: PERFORM STARTER TESTING AND INSPECTION

ACTIVITY 5.3: STARTER INSPECTION AND TESTING
TASK I. STARTER COMPONENTS INSPECTION AND TESTING.
Starter Type: _______________________________________________________________________________
STEPS DIAGRAM/ILLUSTRATION TEST RESULT RECOMMENDATION
1. PREPARE TOOLS, EQUIPMENT,
AND MATERIALS

2. PERFORM STARTER
PERFORMANCE OR NO LOAD
TEST

3. DISASSEMBLE STARTER
See repair manual for the
specific procedures
4. CHECK PULL-IN COIL OPEN
CIRCUIT TEST

5. CHECK HOLD IN COIL

6. CHECK PLUNGER OPERATION

7. CHECK STARTER DRIVE

HOUSING FOR CRACKS/
DAMAGE

8. CHECK OVERRUNNING
CLUTCH
9. CHECK PINION GEAR TEETH
AND CHAMFER FOR WEAR OR
DAMAGE

10. CHECK ARMATURE FOR

GROUND

11. CHECK ARMATURE FOR

OPEN CIRCUIT

12. CHECK ARMATURE FOR

SHORT CIRCUIT

13. MEASURE COMMUTATOR

DIAMETER
Std. Diameter: ______mm
Minimum diameter:_____mm

14. MEASURE COMMUTATOR

RUNOUT

Maximum circle runout or Limit

= ______________mm

15. CHECK DEPTH OF MICA

SEGMENT

Standard :_________mm
Limit: _____________mm
16. CHECK FIELD COIL FOR OPEN
CIRCUIT

17. CHECK FIELD COIL FOR

GROUNDED CIRCUIT

18. MEASURE BRUSH LENGTH

STD: ________________mm

Limit: _______________mm

19. CHECK INSULATED BRUSH

(POSITIVE BRUSH FOR
GROUNDED CIRCUIT)

20. CHECK BRUSH SPRINGS FOR

CRACK/ DAMAGE

21. ASSEMBLE STARTER

22. PERFORM NO LOAD

PERFORMANCE TEST (See Repair
Manual for the procedures)
 CHECK YOUR PERFORMANCE BY ANSWERING THE CHECKLIST BELOW

Performance Criteria Checklist 5.3

CRITERIA
YES NO
Did I….
1. Prepared tools, equipment and materials to be used?

2. Performed starter performance test or No load test?

3. Disassembled the starter motor as per repair manual instructions?

4. Checked the pull-in coil?
5. Checked the hold-in coil?
6. Checked plunger operation?
7. Checked starter drive housingfor cracks, damage
8. Checked the overrunning clutch?
9. Checked pinion gear teeth and chamfer for wear or damage?
10. Checked the armature for ground?
11. Checked the armature for open circuit?
12. Checked armature for short circuit?
13. Checked commutator diameter?
14. Checked commutator runout?
15. Checked depth of mica segment?
16. Checked field coil for open circuit?
17. Checked field coil for ground circuit?
18. Measured brush length?
19. Checked insulated brush for ground?
20. Checked brush springs?
21. Assembled the starter motor?
22. Performed bench test/Performance test/No load test?

TASK II. Gasoline engine starting circuit

Step 1. Prepare connecting wires with clips, test lamp or digital multi tester, battery and gasoline engine starting system wiring
diagram.
Step 2. Connect the starting system wiring circuit of a gasoline engine.
Step 3. Turn ignition switch to start position and check for proper starter operation. If starter does not operate properly, DO
inspection and diagnosis.
Step 4.If starter operation is OK, Call your instructor for checking and recording of the task completed.

TASK III. Connect the diesel engine starting circuit

Step 1. Prepare connecting wires with clips, test lamp or digital multitester, battery and diesel engine starting system wiring
diagram.
Step 2. Connect the starting system circuit of a diesel engine.
Step 3. Turn ignition switch to start position and check for proper starter operation. If starter does not operate properly, DO
inspection and diagnosis.
Step 4. If starter operation is OK, call your instructor for checking and recording of the task completed.

PROGRESS REVIEW

TEST I. Identify the starter components parts shown on the mock-up board
1. _ 6. 11. 16.

2. 7. 12. 17.

3. 8. 13. 18.

4. 9. 14. 19.

5. 10. 15. 20.

TEST II. Encircle the letter of the correct answer.

1. Which component allows the driver to trigger ignition?

A. Wiring relay B. Inhibitor switch C. Ignition switch D. Ignition relay

2. The _______ motor is more common because it allows for reduced power demand and increased torque
A. Straight drive B. Orbital reduction C. Elliptical D.Planetary gear reduction
3. Technician A states that adjusting the transmission range sensor on automatic transmissions may affect the starting system
operation. Technician B states that on manual transmission adjusting the clutch pedal may affect starting system operation.
Who is correct?
A. Technician A B. Technician B C. Both technician D. Neither technician
4. How does an undercharged battery affect vehicle start?
A. The vehicle will not start
B. The vehicle will start and run for a short period only
C. The starter motor will burn out
D. There is no effect
5. Under normal conditions the starter solenoid engages the __________.
A. Contact plate B. Starter housing C. Starter drive D. Contact relay
6. Technician A states that engine rotation begins when the pinion gear engages the flywheel. Technician B states that the
engine rotation begins after the charging system starts. Which is correct?
A. Technician A B. Technician B C. Both technician D. Neither technician
7. The ignition switch is NOT normally located ____________________.
A. On the console C. Near the steering column
B. On the key D. On the steering column
8. On a vehicle with manual transmission the inhibitor switch will prevent starting if the ______________.
A. Gear selector is not in neutral or park C. Clutch is not depressed
B. Vehicle has been hot wired D. Battery is overcharged
9. The purpose of the starting system is to ____________.
A. Convert torque into electrical energy C. Charge the battery to start the engine
B. Use power from the battery to start the engine D. Keep the engine running at all times
10. Technician A states that the starter gear retracts after the starter drive gear overruns. Technician B states that the starter
gear retracts when current is removed from the starter solenoid winding. Which is correct?
A. Technician A B. Technician B C. Both Technicians D. Neither Technician
11. The two components capable of carrying system are the _______________.
A. Ignition solenoid and inhibitor relay C. Starter relay and starter solenoid
B. Starter switch and inhibitor D. Inhibitor switch and ignition switch
12. What is another name for the inhibitor switch
A. Neutral interrupter C. Ignition switch
B. Neutral safety switch D. Clutch casing
13. The inhibitor switch is not normally located on the ___________________.
A. Transmission B. Clutch pedal C. Pinion gear D. Shift linkage
14. The inhibitor switch will prevent starter on vehicles with automatic transmission unless the gear selector is in which gears
A. Park or reverse B. Neutral or park C. Neutral and drive D. Reverse and park

15. Which of the following step occurs during normal operation of the starting system?
A. Voltage is sent to the inhibitor switch
B. Engine flywheel engages, engine rotation begins
C. Starter gear retracts
 D. Starter drive gear overruns
16. During starting the pinion gear drive assembly engages the _____________.
A. Crankshaft B. Battery C. Engine flywheel D. Starter drive gear
17. Which of the following provides energy to the starter?
A. Inhibitor switch B. Starter motor C. Starter relay D. Battery
18. Starting system wiring is normally between what two gauges?
A. 2 to 4 B. 8 to 28 C. 6 to 20 D. 4 to 6
19. When inspecting wiring, all connections shoul be clean and ___________.
A. Frayed B. Black C. Insulated D. Secure
20. The two types of starter motors are _________________.
A. Straight and orbital reduction C. Circular and planetary gear reduction
B. Straight and planetary gear reduction D. Planetary and gear reduction

21. The ______________ moves the starter gear outward.

a. relay b. armature c. field coil d. solenoid

22. The picture shown below is testing for armature _______.

A. Ground circuit b. open circuit c. short circuit

23. The picture shown below is testing armature for

A. ground circuit b. open circuit c. short cicuit

24. The picture shown below is testing field coil for

A. ground circuit b. open circuit c. short cicuit

25. The picture shown below is testing field coil for

A. ground circuit b. open circuit c. short cicuit