Introduction

 Electric motors are used to start the engine and to move the vehicle.

 The vehicle’s starting system is designed to turn or crank the engine over fast
enough until it can start and operate under its own power.

 To do this, the starter motor receives electrical power from the battery.

 The starter motor then converts this energy into mechanical energy, it transmits
through the drive mechanism to the engine’s flywheel.

 Among the various means available, automobile now use:

i. Electrical cranking system

ii. Manual cranking system

iii. Air cranking system

iv. Hydraulic cranking system

 Basic Starting System component
 Starting system components and their function

a) Battery: provides current to turn the starter motor.

b) Ignition Switch : controls the circuit.

c) Relay : uses small amount of current to control large amount.

d) Neutral Safety Switch: opens the circuit until the vehicle is in neutral

e) Solenoid: performs mechanical operation. It is an electromagnetic switch.

f) Starter Motor: engages pinion gear to ring gear which is mounted on

flywheel.

g) Flywheel assembly: used to turn engine crankshaft for engine starting.

 Starting System
 Changes electrical energy to mechanical.
 An electric DC motor is used to turn engine crankshaft for engine
starting.
 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.
 Average starter motor draws about 250 Amps or more.
 This current flows through the large cables that connect the battery to the
starter and ground.
The starter circuit has 2 separate circuits.
1) The starter circuit: Carriers the heavy current from
the battery to the starter motor
2) The control circuit: controls the high current to the
starter motor
Starter Motor Overview
 Starter Motor Assembly
Starter Solenoid or magnetic switch

o Makes an electrical connection between the battery and the starting motor.

o Allows the low current ignition switch circuit to control the high current starting

motor.

o Pushes the starter pinion gear into mesh with the flywheel ring gear.

o Receives a large electric current from battery and a small electric current from

the ignition switch.

o When the ignition switch is turned on, a small electric current is sent to the starter

solenoid. This causes the starter solenoid to close a pair of heavy contacts.

 It is activated by the magnetic forces generated in the coil

 Starter Relay
• Opens or closes one circuit by responding to an

electrical signal from another circuit.

• Uses a small current from the ignition switch to

control a larger current through the starter

solenoid.

• Reduces the load on the ignition switch.

• Used on today's vehicle.

Fig. Starter relay circuit
 Starter Motor Construction
 The starter is a special type of electric motor designed to operate under great
electrical overloads.

 The starter motor consists of:

 A housing
 Field coils
 An armature
 A commutator
 Starter drive
 Starter Brushes
 End frames
 Starter Bearings
 Types of Starter Motor

 There are two major types of starter motor used on cars:

1. Conventional Type Starter Motors

2. Reduction Type Starter Motors

Convectional type
Reduction type
 Operation of the Conventional Type Starter Motor
i. Ignition Switch In Start Position
 When the ignition switch is turned to the start position, terminal 50 passes
electrical current to the hold in and pull in coil.

 Then current passes from the pull in coil to the armature by terminal "C"

 The voltage drop across the pull in keeps the amount of electrical current flow
through the armature coil becomes small and the motor rotates at lower speed.

 The magnetic field generated by the hold in and pull in coils pull the plunger
against the return spring by the drive to mesh with the ring gear.

 The low starter speed 'meshes the pinion and the ring gear smoothly.
 Ignition Switch In Start Position

Hold in Ground
coil
Battery Ignition Terminal
switch 50
Pull in Terminal
coil C Field coil

Armature Ground
 ii. Pinion And Ring Gear Engaged

 When the magnetic switch and screw splines have pushed the pinion gear to
mesh with the ring gear, the contact plate attached to the plunger turns the main
switch on by short circuiting the connection between terminal 30 and terminal 'C'.

 As a result a larger electrical current passes through the starter motor to

rotate with a greater torque the screw splines helps the pinion gear mesh more
securely with the ring gear.

 At the same time, the voltage levels at both ends of the pull in coil becomes
equal so that no current flows through this coil the plunger is therefore held in
position only by the magnetic force exerted by the hold in coil.
Pinion and Ring Gear Engaged

Ignition Terminal Hold in Ground

Battery Switch 50

Terminal Contact
30 Terminal Field
Plate C Armature Ground
coil
 iii. Ignition Switch In On Position

 When the ignition switch is returned to on position from start, the voltage applied to
terminal 50 is cut off.

 The main switch remains closed, however, the current that flows from terminal" C" to
the hold in coil via the pull in coil since current flow through the hold in coil in the
same direction as when the ignition switch is in start position in generates a magnetic
force which pulls the plunger.

 In the pull in coil; on the other hand, current flows in the opposite direction
generating a magnetic force, which tires to return the plunger to its original position.

 The magnetic fields set up these two coil cancel each other. so the plunger is
pulled back by the return spring.

 Therefore the heavy current which has been applied the motor is cut off and the
plunger disengages the pinion gear from the ring gear at about the same time.
Ignition switch in on position

Pull in Hold in Ground

Battery Terminal Terminal

30 "C" Field Armature Ground
coil
 Starter Performance Test

• Before being to disassemble the starter motor first roughly pin pointing the

source of the problem by the performance test is recommended

• Also perform this test after assembly is completed to make sure that the starter

motor is operating correctly.

• Complete each test as quickly as possible (within approximately 3-5 seconds).

Other wise, the coil in the starter motor may burn out.

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 I. Pull In Test
 Disconnect the field coil lead from Terminal C.
 Connect the battery to the magnetic switch as shown. Check that the pinion moves
outward.

 If the pinion gear does not move outward, check for:

A. Battery voltage
B. Pull in coil and hold in coil resistance
C. Drive lever

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 II. Hold In Test
• With the battery connected as pull in test and with the pinion out, disconnect the
negative lead from terminal C.
• Check that the pinion remains out.
 If the pinion gear retracts, check for:
 Hold in coil resistance
 Ground connection

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 III. Pinion Return Test

• This test is done after hold in test, disconnect the negative lead from body ground
as figure below.

• If the pinion gear does not immediately retract, check for:

 Return spring

 Plunger

 Drive lever

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 Iv. Check Pinion Clearance
A. Starter should be on the bench

B. Connect the battery to the magnetic switch as shown.

C. Move the pinion gear toward the armature to remove slack, then measure the
clearance between retainer and pinion gear by feeler gauge or vernier calliper.

• Standard clearance: 0.1 –0.4mm  If starter motor on the engine

 Check pinion to flywheel
ring gear clearance.
 Excessive clearance
Starter can be loud and
teeth can be damaged
 Too little clearance
Starter could bind and
amp draw will be higher

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 V. No load Test
a) Securely fix the starter motor with a vice

b) Connect the field coil lead to Terminal C. Make sure the lead is not grounded

c) Connect the battery and ammeter to the starter as shown.

d) Check, that the starter rotates smoothly and steadily, and that the pinion moves
out.

e) Check that the ammeter reads the specified current.

f) Check that the pinion gear retracts and the motor stops as soon as the cable is
disconnected from Terminal 50.
 If the motor does not stop immediately, the
probable causes are:
(a) stacked contact point
(b) damaged return spring
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(c) defective plunger or drive lever
 Disassembling Of Starter Motor

i. Remove the magnetic switch

ii. Remove the end cover iii. Remove the lock plate

iv. Remove the end frame

v. Remove the brush

vi. Remove the yoke vii. Remove the drive lever & armature
viii. Remove the starter clutch

ix. Assemble the removed parts

 Starter Component Tests

1. Check the field coil for continuity

• Use ohmmeter or continuity tester.

• If the tester shows continuity the coil is normal, if
not the coil is open.

2. Check the field coil for insulation

• Using ohmmeter or continuity tester check
continuity between field coil and body.
• If the tester shows no continuity the insulation
is normal, if it shows continuity repair or
replace the field coil.
 3. Check armature coil for insulation

 Hold one ohmmeter lead to a commutator segment and the other on the
armature core.
 Check between the armature shaft and the commutator.
 If there is continuity at either of these 2 test points, the armature needs to be
replaced.
 4. Check the armature coil for short circuit
 Clean and Armature short test

 With the armature in an armature tester (growler), hold a hacksaw blade

on the armature core.

 If the blade is attracted to the armature’s core or

vibrates while the core is turned, the armature is shorted and must be
replaced or repaired.

continued…
5. Check the armature coil for continuity
 With an ohmmeter, check for continuity between the segments of the commutator.

If an open circuit exists between any segments, replace the armature.

6. Check the commutator for roundness

 7. Measure the wear on the commutator out side diameter

8. Measure the brush length

 9. Check the brush spring

10. Check the brush holder for insulation

 11. Check the starter clutch

12. Check the bearing