How The Starting System Works - Blog - Teknisi

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7/11/23, 7:30 PM How the Starting System Works - Blog.Teknisi
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The starting system converts electrical energy from the battery into
mechanical energy in order to start the engine.
#A basic starting system has four parts:

Battery - Supplies energy for the circuit
Starter switch - Activates the circuit
Solenoid (motor switch) - Engages the starting motor
drive with the flywheel
Starting Motor - Drives the flywheel to crank the
engine
When the starter switch is activated a small amount of current

flows from the battery to the solenoid and back to the battery
through the ground circuit.
The solenoid performs two functions. The solenoid engages the

pinion with the flywheel and closes the switch inside the solenoid
between the battery and starting motor, which completes the circuit
and allows high current to flow into the starting motor.

3V6V 9V12V 24V 36V DC Motor
The starting motor converts the electrical energy from the battery
into rotary mechanical energy in order to crank the engine. The
starting motor is similar to other electric motors. All electric motors
produce a turning force through the interaction of magnetic fields
inside the motor.
Starting Motor
Illustration 2
A review of some basic rules of magnetism is needed, to

understand the basic operating principles of starting motors.
The following information is the basic rules of magnetism:
Like poles repel. Unlike poles attract. 

Magnetic flux lines are continuous and exert force.

DuriCurrent-carrying conductors have a magnetic field
that surrounds the conductor in a direction that is
determined by the direction of the current flow.
If a conductor has a current that has passed through the

conductor, there will be a magnetic field that is formed. A
permanent magnet has a field between the two poles. When the
current carrying conductor is placed in the permanent magnetic
field, there will be a force that is exerted on the conductor because
of the magnetic field. If the conductor is formed in a loop and
placed in the magnetic field, the result is the same. Since current
flow is in opposite directions in the coil, one side will be forced
upward while the other side is forced downward. This will provide a
rotational effect or a torque effect on the coil.
Starting Motor Principles
Illustration 3
The pole pieces in the field frame assembly can be compared to

the ends of a magnet. The space between the poles is the
magnetic field.

Illustration 4
If a wire (field winding) is wrapped around the pole pieces and

current is passed through the wire, the strength of the magnetic
field between the pole pieces increases.
Illustration 5
If you feed current from the battery into a loop of wire, a magnetic
field is also formed around the wire.

Illustration 6
If the loop of wire is placed in the magnetic field between the two
pole pieces and current is passed through the loop, a simple
armature is created. The magnetic field around the loop and the
field between the pole pieces repel each other, causing the loop to
turn.
Illustration 7
A commutator and several brushes are used to keep the electric

motor spinning by controlling the current that is passing through
the wire loop. The commutator serves as a sliding electrical
connection between the wire loop and the brushes. The
commutator has many segments, which are insulated from each
other.
The brushes ride on top of the commutator and slide on the

commutator in order to carry battery current to the spinning wire
loops. As the wire loops rotate away from the pole shoes, the
commutator segments change the electrical connection between
the brushes and the wire loops. This reverses the magnetic field
around the wire loops. The wire loop is again pulled around and
passes the other pole piece. The constantly changing electrical
connection keeps the motor spinning. A push-pull action is set up
as each loop moves around inside the pole pieces.

Several loops of wire and a commutator with many segments are

used to increase motor power and smoothness. Each wire loop is
connected to the wire loops own segment on the commutator in
order to provide current flow through each wire loop as the brushes
contact each segment. As the motor spins, many wire loops
contribute to the motion in order to produce a constant and smooth
turning force.
Illustration 8
A starting motor, unlike a simple electric motor, must produce very

high torque and relatively high speed. Therefore, a system to
support the wire loops and to increase the strength of each wire
loop's magnetic field is needed.
A starter armature consists of the following components:

Armature core
Armature shaft
Commutator
Armature windings (wire loops)
The starting motor shaft supports the armature as the armature

spins inside the starter housing. The commutator is mounted on

one end of the armature shaft. The armatures core holds the
windings in place. The core is made of iron in order to increase the

strength of the magnetic field that is produced by the windings.
Illustration 9
A field winding is a stationary insulated wire that is wrapped in a

circular shape, which creates a strong magnetic field around the
motor armature. When current flows through the field winding, the
magnetic field that is between the pole pieces becomes vary large.
The magnetic field can be 5 to 10 times that of a permanent
magnet. As the magnetic field between the pole shoes acts against
the field that is developed by the armature, the motor spins with
extra power.
Starting Motor Characteristics

Starters are high capacity intermittent duty electric motors that tend
to behave with the followign specific characteristics:
If starting motors are required to power a certain

mechanical component (load), the starting motor will
consume a specific amount of power in watts.
If the load is removed, speed increases and current
draw will go down.
If the load is increased, speed decreases and current
draw will go up.
The amount of torque that is developed by an electric motor
increases as the current flowing through the motor increases. The
starting motor is designed to operate for short periods of time
under an extreme load. The starting motor produces a very high
horsepower for the size.
Counter Electromotive Force (CEMF) is responsible for changes in

current flow as the starter speed changes. CEMF increases the
resistance to current flow from the battery, through the starter, as
the starter speed increases. This occurs because, as the
conductors in the armature are forced to spin, the conductors are 
cutting through the magnetic field that is created by the field
windings. This induces a counter voltage in the armature that acts

against battery voltage. This counter voltage increases as the
armature speed increases. This acts as a speed control, and
prevents high free running speeds.
Although, most electric motors have some form of current

protection device in the circuit, most starter motors do not. Some
starters have thermal protection. This is provided by a heat
sensitive thermostatic switch. The thermostatic switch will open
when the starter temperature rises due to excessive cranking. The
switch will automatically reset when the starter temperature cools.
The electric motor is classified as an intermittent operating motor. If
the electric motor were a continuous operating motor, the electric
motor would need to be almost as large as the engine. Because of
the high torque demands on the starter motor, a great deal of heat
is produced during operation. Extended operation of the starter
motor will cause internal damage due to this high heat. All the parts
of the starter motor's electrical circuit are very heavy. This enables
the handling of the heavy current flow that is associated with the
operation.
If higher loads require more power to operate, then each starter

motor must have sufficient torque in order to provide turning speed
that is necessary to crank the engine. This power is directly related
to the strength of the magnetic field, since the strength of the field
is what creates the power.

Illustration 10
As previously described, starting motors have a stationary member

(field windings) and a rotating member (armature). The field
windings and the armature are usually connected together so that
all current that enters the motor passes both the field and the
armature. This is the motor circuit.
The brushes are a means of carrying the current from the external
circuit (field windings) to the internal circuit (armature windings).
The brushes are contained in brush holders. Normally, half the

brushes are grounded to the end frame. The other half of the
brushes are insulated and connected to the field windings.
Starter motor fields can be wired together in four different

configurations in order to provide the necessary field strength:
Series
Compound (shunt)
Parallel
Series-parallel

Series wound starters (Illustration 9) are capable of producing a

very high initial torque output when the starters are first engaged.
This torque then decreases as the starters operate due to counter-
electromotive force. This decreases the current flow since all the
windings are in series.
Compound motors have three windings in series and one winding

in parallel. This produces good initial torque for starting and the
benefit of some load adjustment due to the parallel winding. This
type of starter also has the added benefit of speed control due to
the parallel field.
Parallel wound motors provide higher current flow and greater

torque, by dividing the series windings into two parallel circuits.
Series-parallel motors combine the benefits of both the series and

the parallel motors.
Many starters have four fields and four brushes. Starters that are
required to produce very high torque, may have up to six fields and
brushes. Some light duty starters may have only two fields.
Many heavy-duty starter motors are not grounded through the case
of the starter. This type of starter motor is grounded through an
insulated terminal that must be connected to the battery ground for
the starter to work. A ground wire for the solenoid and other engine
electrical devices must also be attached to the starter ground
terminal for proper electrical operation.
Illustration 11
After electrical power is transmitted to the starting motor, some

type of connection is needed to put this energy to work. The
starting motor drive makes it possible to use the mechanical
energy that is produced by the starting motor.

Although torque that is produced by the starter motor is high, the

torque does not have the ability to crank the engine directly. Other
means must be used to provide both adequate cranking speed and
the necessary torque.
To provide adequate torque for cranking the engine, the speed of

the starter is altered by the ratio between the pinion gear on the
starter and the engine flywheel. This ratio varies from 15:1 to 20:1.
For example, if the starter drive gear had 10 teeth, the ring gear
might have 200 to provide a ratio of 200:10 or 20:1.
Starter Drive Mechanism

If the starter were left engaged to the flywheel after the engine
started, damage would occur to the armature due to very high
speeds that are created as the engine rpm increased. At high
speed, the armature would throw the windings due to centrifugal
force.
The gear that engages and drives the flywheel is called a pinion
gear. The gear on the flywheel is called a ring gear. How the starter
pinion gear engages with the flywheel ring gear depends on the
type of drive that is used.
Starter pinion gears and starter drive mechanisms can be of two

different types:
Inertia drive
Overrunning clutch
Inertia drives are actuated by rotational force when the armature
turns. This type engages after the motor begins to move. The drive
sleeve has a very coarse screw thread that is cut into the drive
sleeve, which corresponds to threads that are on the inside of the 
pinion.
As the motor begins to turn, the inertia that is created at the drive
causes the pinion to move up the threads until the pinion engages
with the ring gear on the flywheel. You can recreate this action by
spinning a heavy nut on a bolt and watch the rotary motion change
to linear motion as the nut moves up or down.
One disadvantage of inertia starters is that the pinion is not

positively engaged before the starter begins to turn. If the drive
does not engage with the flywheel, the starter will spin at a high
speed without cranking the engine. If the pinion lags the pinion will
strike the gear with heavy force. This will damage the teeth.
Illustration 12
The overrunning clutch drive is the most common type of clutch

drive. The overrunning clutch drive requires a lever to move the
pinion into mesh with the flywheel ring gear. The pinion is engaged
with the flywheel ring gear before the armature starts to rotate.
With this type of drive system, a different method must be used in

order to prevent armature overspeeding. A lever pulls the drive out
of engagement while an overrunning clutch prevents
overspeeding.

eromni
Kinmore Motor
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3V6V 9V12V 24V 36V DC
Motor
Open
The overrunning clutch locks the pinion in one direction and

releases the pinion in the other direction. This allows the pinion
gear to turn the flywheel ring gear for starting. The overrunning
clutch also allows the pinion gear to freewheel when the engine
begins to run.
The overrunning clutch consists of rollers that are held in position

by springs against a roller clutch. This roller clutch has tapered
ramps that allow the roller to lock the pinion to the shaft during
cranking.
The torque travels through the clutch housing. The torque is

transferred by the rollers to the pinion gear. When the engine starts
and the speed of the drive pinion exceeds the speed of the
armature shaft, the rollers are pushed down the ramps. This
permits the pinion to rotate independently from the armature shaft.
Once the starter drive pinion is disengaged from the flywheel and
is not operating, spring tension will force the rollers into contact
with the ramps in preparation for the next starting sequence. There
are various heavy duty designs of this drive.
Starting Circuit Controls

Illustration 13
The starting circuit contains control and protection devices. The

control and protection devices are necessary to allow the
intermittent operation of the starter motor and to prevent operation
during some machine operation modes for safety reasons.
The starter electrical circuit may consist of the following devices:

Battery
Cables and wires
Key start switch
Neutral safety switch and clutch safety switch (if
equipped)
Starter relay
Starter solenoid
Battery
The battery supplies all of the electrical energy to the starter which
enables the battery to crank the engine. It is important that the
battery be fully charged and in good condition if the starting system
is to operate at full potential.
Read More:
Battery Voltage Test
How a Battery Works?
Cables and Wires

The high current flow through the starter motor requires cables that
must be large enough to have low resistance. In a series circuit,
any added resistance in the circuit will affect the operation of the
load due to a reduction in the total current flow in the circuit.

In some systems, the cables will connect the battery to the relay
and the relay to the starter motor. In other systems the cable will
go directly from the battery to the starter.
Ground cables must also be large enough to handle the current

flow. All connectors and connections in the starting system must
have as little resistance as possible.
Keystart Switch
The key start switch activates the starter motor by providing power
to the starter relay from the battery. The key start switch can be
operated directly by a key, a button, or remotely by linkage from a
key activated control. The key start switch can be mounted in the
dashboard assembly or on the steering column.
Neutral Safety Switch or Clutch Safety Switch

All vehicles that are equipped with a power shift or an automatic
transmission require a neutral safety switch that will only permit
starter operation in park or in neutral. This switch can be mounted
on the transmission, at the shifter or in the linkage. The switch
contacts are closed when the transmission selector is in park or in
neutral. The switch contacts are open when the transmission
selector is in any gear.
Some vehicles may use a clutch safety switch that is open when
the clutch is in the engaged position and closed when the operator
depresses the clutch pedal. This prevents starter operation as long
as the clutch is engaged. Some transmissions also use a neutral
gear switch that will prevent starter operation, unless the
transmission is placed in the neutral position.
All safety switches of this type should be maintained in good

operating condition. All safety switches should never be bypassed
or removed.
Starter Relay

Illustration 14
The starter relay (magnetic switch) may be used in some starting

systems. The starter relay is located between the key start switch
and starter solenoid. The starter relay is a magnetic switch that is
activated by power from the battery that is supplied through the
key start switch. Relays are usually placed so that the cables
between the starter and the battery are as short as possible.
The starter relay uses a small current from the key start switch to
control the larger current to the starter solenoid, which reduces the
load on the key start switch. Energizing the relay windings will
cause the plunger to be pulled up due to the magnetism that is
caused by the current flow through the windings. The contact disk
will also be pulled up and will contact the battery and starter
terminal ends. Current will flow from the battery to the starter
solenoid.
Illustration 15
Solenoids combine the operation of a magnetic switch (relay) with

the ability to perform a mechanical task (engage the drive). The
starter solenoid produces a magnetic field that pulls the solenoid
plunger and disc into the coil windings, which completes the
starting system circuit. The solenoid is mounted on the starter 
motor so that linkage may be attached to the overrunning clutch
drive in order to engage the drive.
Solenoids contain two different windings for effective operation.

When the ignition switch is turned to the start position, current from
the battery flows through a pull-in winding and a hold-in winding.
These windings contain many coils of wire and produce a strong
magnetic field to pull the heavy plunger forward and engage the
starter drive.
When a plunger reaches the end of the travel through the solenoid,
the plunger engages a contact disk that will operate like a relay
and allow current to flow to the starter motor from the battery. This
also serves to disconnect the series pull-in winding from the circuit
and allows current to flow through a shunt hold-in winding only.
Only the lighter magnetic field that is created by the hold-in winding
is required to hold the plunger in position. This reduces the amount
of control current that is required to eliminate heat buildup and
provides more current for the starter motor.
Illustration 16
When the ignition switch is closed, battery current flows in two

directions. Current flows from the battery to the start switch and
then through the pull-in winding, field winding, armature, brushes
and to ground.
The activation of the pull-in winding and the hold-in winding

produces a magnetic force. The magnetic force pulls the plunger to
the left, which moves the overrunning clutch and the pinion toward
the flywheel ring gear.

Illustration 17
When the plunger is pulled to the left, the solenoid contacts close.
At this point the pinion begins to mesh with the flywheel ring gear
and the pull-in winding is shorted. This causes current flow through
the solenoid contacts to the field winding, armature, brushes and to
ground. Current still flows through the hold-in winding to ground.
The starting motor is energized. The pinion engages the flywheel
ring gear. The engine begins to crank. At this time the plunger is
kept in the pull-in position only by the magnetic force of the hold-in
winding.
Illustration 18
As soon as the engine starts, the flywheel ring gear turns the
pinion faster than the starting motor is rotating. The overrunning
clutch breaks the mechanical connection between the clutch and
the starting motor. When the ignition switch is released, current
flow through the hold-in winding and the pull-in winding is in the
same direction, which causes the hold-in winding magnetic force to
be reduced. The solenoid contacts are opened. The plunger and
overrunning clutch are pulled back to the original position by the
return spring force. The armature stops and the motor is OFF.
Series-Parallel Systems 
Machines with larger diesel engines require high power starters to

provide adequate cranking speed for the engine. To achieve this
some machines use 24V starters. Using 24V allows the starter to
produce the same power with less current flow.
In a series-parallel system the starter operates on 24V but the rest

of the machine electrical system operates on 12V. A special series-
parallel switch is used that connects two or more batteries in
parallel for normal accessory and charging operation and then
connects the batteries in series with the starter when cranking. 12V
accessories are preferred because they are much less expensive
than 24V lights and accessories.
12/24 Electrical Systems

In another system of this type, the starter is connected in series
with two 12V batteries. The alternator charges the batteries with
24V.
Starter System Testing

Accurate testing of a starting system begins with an understanding
of how the system functions. If your knowledge of the operation is
complete, you can logically determine the fault through visual
inspection and electrical testing.
Inspecting and Troubleshooting

An organized procedure for testing and inspection is necessary to
prevent the replacement of good parts or the unnecessary repair of
operational components.
Verify the Complaint

Operate the system yourself to see how the system functions.
Starter system problems will normally fall into the following
categories:
The starter spins but does not crank the engine.
The engine cranks very slowly.
The engine does not crank at all.
The starter motor is too noisy.
Do not crank the engine for more than 30 seconds at a time. Allow
the starter motor to cool between cranking periods in order to
prevent damage.

Define the Problem

Determine whether the problem is mechanical or electrical. For
instance, if the starter rotates but does not crank the engine, the
problem is most likely mechanical, since the drive does not seem
to be engaging.
Mechanical problems can be corrected by repairing the component

or by replacing parts.
Electrical problems require additional testing to determine the

cause of the fault and the repair that will be required.
Isolate the Problem

Regardless of whether the problem is mechanical or electrical, you
will have to determine where the problem is occurring, so that you
can quickly and accurately make your repairs.
The steps involved in testing and isolating a starting circuit are:
Test the battery in order to determine if the battery is
fully charged and capable of delivering sufficient
current.
Test the wiring and switches to determine if both are in
good operating condition.
If the engine, battery and wiring are all OK, but the
starter is not operating correctly, the fault must be with
the starter.
Visual Inspection
Begin all starting system testing with a thorough visual inspection.
Check for the following problems:
Loose or corroded battery terminals
Worn or frayed insulation on the battery cables
Corroded solenoid or relay connections
A damaged starter solenoid or relay
Cracked or broken insulators on the starter relay
Loose engine or chassis grounds
Damaged neutral safety switches
Damaged ignition switch or actuating mechanisms
Loose starter
Battery Test
Continue the inspection with a complete test and service of the
battery.

Preform all required tests in order to verify that the battery is in

good operating condition. Correct battery output is vital for good
starting system operation and for correct diagnosis of the starting
system.
Starting System Tests

On machine starting motor tests should be performed first in order
to determine whether the starter must be removed and tested
further.
The following test should be preformed while the starting motor is

still on the machine:
Starting system voltage during cranking
Current draw during cranking
Voltage drops during cranking
Engine rotation
Starter motor pinion and flywheel ring gear inspection
Bench tests will determine if the starter must be repaired or
replaced. Bench tests include a no load test and starting motor
component tests.
Read More:
Capacity Rating pada Battery
Charging Time (Waktu Pengisian) pada Battery
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7/11/23, 7:30 PM How the Starting System Works - Blog.

ABOUT CONTACT US PRIVACY POLICY DISCLAIMER     

 HOME FAULT CODES  DIAGNOSTIC SOFTWARE CAT ELECTRONIC TECHNICIAN

 Fault Codes CUMMINS ISB

How the Starting System Works CM2150 (168)

2023 Global Threat Report

 Basic Hydraulics (12)

#A basic starting system has four parts:

When the starter switch is activated a small amount of current

The solenoid performs two functions. The solenoid engages the

3V6V 9V12V 24V 36V DC Motor

A review of some basic rules of magnetism is needed, to

The following information is the basic rules of magnetism:

Like poles repel. Unlike poles attract. 

Magnetic flux lines are continuous and exert force.

If a conductor has a current that has passed through the

Starting Motor Principles

The pole pieces in the field frame assembly can be compared to

If a wire (field winding) is wrapped around the pole pieces and

A commutator and several brushes are used to keep the electric

The brushes ride on top of the commutator and slide on the

Several loops of wire and a commutator with many segments are

A starting motor, unlike a simple electric motor, must produce very

A starter armature consists of the following components:

The starting motor shaft supports the armature as the armature

windings in place. The core is made of iron in order to increase the

A field winding is a stationary insulated wire that is wrapped in a

Starting Motor Characteristics

If starting motors are required to power a certain

Counter Electromotive Force (CEMF) is responsible for changes in

windings. This induces a counter voltage in the armature that acts

3V6V 9V12V 24V 36V DC Motor

Although, most electric motors have some form of current

If higher loads require more power to operate, then each starter

As previously described, starting motors have a stationary member

3V6V 9V12V 24V 36V DC Motor

The brushes are contained in brush holders. Normally, half the

Starter motor fields can be wired together in four different

Series wound starters (Illustration 9) are capable of producing a

Compound motors have three windings in series and one winding

Parallel wound motors provide higher current flow and greater

Series-parallel motors combine the benefits of both the series and

After electrical power is transmitted to the starting motor, some

Although torque that is produced by the starter motor is high, the

3V6V 9V12V 24V 36V DC Motor

To provide adequate torque for cranking the engine, the speed of

Starter Drive Mechanism

Starter pinion gears and starter drive mechanisms can be of two

One disadvantage of inertia starters is that the pinion is not

The overrunning clutch drive is the most common type of clutch

With this type of drive system, a different method must be used in

The overrunning clutch locks the pinion in one direction and

The overrunning clutch consists of rollers that are held in position

The torque travels through the clutch housing. The torque is

Starting Circuit Controls

The starting circuit contains control and protection devices. The

The starter electrical circuit may consist of the following devices:

Cables and Wires

Ground cables must also be large enough to handle the current