Starting system basic fundamentals & its testing methods

presentation explore the basic principle of starting system and testing methods in order verify the performance of system

1. STARTING SYSTEM

2. STARTING SYSTEM

3. STARTING SYSTEM
Batteryprovides the current to turn
the starter motor.
Fuseprotects the circuit.
Ignition switchcloses the circuit.
Relayuses small amount of current to control large amount.
Neutral safety switchopens the circuit until the vehicle is in neutral
(manual transmission), or park (Automatic). (Can be adjusted)
Solenoiddoes the same thing as relay, but performs
mechanical operation. It is an electromagnetic switch.
Starter motorengages pinion gear to ring gear (mounted on flywheel,
Or torque converter).

4. STARTING SYSTEM
•Starting system uses battery power and an electric DC motor to turn
engine crankshaft for engine starting.
•Changes electrical energy to mechanical.
•Provides gear reduction/torque multiplication (16:1 to 20:1).
•When the ignition key is turned on the current flows through the
solenoid coil. This closes the contacts, connecting battery to the
starter motor.

5. STARTING SYSTEM
Inside the starter motor.
1.Starter solenoid
2.Starter drive/bendix
3.Starter armature
4.Starter brushes
5.Starter bearings

6. STARTING SYSTEM
COMMUTATOR sliding electrical connection between the motor
windings and the brushes.
•Insulated from each other.
•Several loops of wire and a
commutator with many segments
are used to increase motor power
and smoothness.

7. STARTING SYSTEM
BRUSHESride on top of the commutator to carry battery current
to spinning windings.
•Replaced during starter rebuilding.

8. STARTING SYSTEM
Starter Armatureconsists of the armature shaft, armature core,
commutator and armature windings.
•Armature must produce high torque and high speeds.

9. STARTING SYSTEM
Field windingis a stationary insulated wire wrapped in a circular
shape. It creates a strong magnetic field around the motor armature.

10. STARTING SYSTEM
Pinion Gearis attached to the starter drive and when starting the
vehicle the pinion gear engages with flywheelor
ring gear. It is moved by the YOKE.

11. STARTING SYSTEM
Overrunning Clutch Starter
•Locks it in one direction and unlocks it in another.
•It allows the pinion gear to run free when engine begins to run.

12. STARTING SYSTEM
Gear Reduction Starter
•Has an extra gear on the armature to further increase the rotating force
•Gear ratio between flywheel and armature is 45:1
•Hence, the armature turns 45 times to turn the flywheel (engine) once.
•This provides high cranking torque for starting.

13. STARTING SYSTEM
DC electric motors have three common types of internal connections:
Series-wound motorsdevelop maximum torque at initial start-up.
Torque decreases as motor speed increases.
Shunt-wound motorshave less starting torque but more constant
torque at varying speeds.
Compound-wound motorshave both series and shunt windings.
They have good starting power with fairly consistent operating speeds.

14. STARTING SYSTEM
Starting Solenoid
•Is a high current relay (controlled by
low current)
•Works as an electromagnet switch
•If faulty it will simply make a
clickingsound when one is attempting
to start the vehicle.

15. STARTING SYSTEM
Neutral safety switchprevents the vehicle from starting while in
gear. (can be adjusted)
Clutch Safety Switchprevents the vehicle from starting, unless the
clutch pedal is pressed. (adjustable)

16. STARTING SYSTEM
When replacing a starter motor, make sure
the spacer shims are of correct thickness
are installed.
•Shims sit in between the starter
housing and the engine block.
If these shims are left out, the pinion
gear may not mesh with the
flywheel gear properly, and might
cause damage to the ring-gear.
•Starter metallic grinding
sound.

17. STARTING SYSTEM
QUICK TESTING
No crank with no headlights
•Dead Battery(corroded terminals)
or an open in electrical circuit.
•Burned fuse.
•Burned or broken wire.

18. STARTING SYSTEM
QUICK TESTING
Head lights go out when cranking
•Battery may be weak.
•Indicates heavy current draw.
•Starter motor may be shorted.

19. STARTING SYSTEM
QUICK TESTING
Lights stay bright but, no crank
•High resistance or an open in starting circuit.
•Possibly Ignition switch
•Wiring , solenoid, cable connections, relay, fuse.

20. STARTING SYSTEM
Current Draw Testmost of the starters draw over 200 Amps.
•Hookup the VAT
•Disconnect Fuel/ignition
•Crank engine for 5-10 seconds and note the voltage.
•Load the battery until same voltage is obtained
and record the Amp.
•The Amps will equal the current drawn by
the starting motor.
4 Cylinder –150/200 amps
6 Cylinder –175/250 amps
8 Cylinder –225/300 amps

21. STARTING SYSTEM
Voltage Drop Test checks for high resistance across a cable/connection
•Disable ignition/fuel
•Hook voltmeter between +ve battery post and +ve starter terminal
•Hook voltmeter between -ve battery post and starter ground.
•Crank the engine (5-10Sec.), Voltmeter should not read more
then 1volts.
If greater:
•Loose electrical connections.
•Burned or pitted solenoid contacts.