RANAGHAT GOVERNMENT POLYTECHNIC

DEPARTMENT OF AUTOMOBILE ENGINEERING

AUTOMOTIVE ELECTRICAL & ELECTRONICS LAB (AEPC504)

EXPERIMENT NO: 03

TITLE: Starter Motor – Component identification, starter current draw test and voltage drop
test.
OBJECTIVE: To identify the various components of starter Motor.
To know the basic working of different components of starter motor.
To understand the stater motor current draw test and voltage drop test.

TOOLS REQUIRED:

Spanners, screw drivers, pliers etc.

APPARATUS REQUIED:

Battery, solenoid switch, starting motor, starting switch etc.

DESCRIPTION:

It is a high-torque series wound electric motor used for the purpose of starting the engine,
typically through a high ratio geared drive connected to the flywheel ring gear.
Starter motor is a series-wound direct current electric motor with a solenoid switch mounted on
it. When low-current power from the starting battery is applied to the solenoid, usually through a
yellow key-operated switch, it pushes out a small pinion gear on the starter motor's shaft and
meshes it with the ring gear on the flywheel of the engine. The solenoid also closes high-current
contacts for the starter motor and it starts to run. Once the engine starts, the key-operated switch is
opened, a spring in the solenoid assembly pulls the pinion gear away from the ring gear, and the starter
motor stops.

CONSTRUCTONAL DETAILS:

1. Yoke:
The yoke provide mechanical support for the pole and act as protecting cover for the whole
machine. It is made up of cast iron or cast steel is employed large machines.
2. Pole:
The poles consist of copper windings which the current passed through it and it magnetized the
poles.
3. Armature
The armature is the heart of an electric motor. It rides on the central shaft, which also contains
the commutator and two bearings front and rear. The armature runs in the field created by the
coils and is essentially a moving magnet when the coils are energized. Current flowing through
the windings and commutator bars create a magnetic field which rotates the armature. The force
of the rotating armature transfers through the starter drive mechanism to crank the engine.

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4. Commutator
The commutator is a section of the shaft at the rear of the starter housing on which the brushes
run to conduct electricity. The brushes are two pieces of carbon attached to wires. These wires
are connected to the battery through the starter switch. When the switch is thrown, they conduct
electricity to the coils and armature causing the starter to spin.
5. Bendix
The Bendix drive is a unique combination of a spring and a gear. When the starter is engaged,
the gear extends into the housing on the front of the unit, engages the flywheel and spins the
engine to begin the combustion process. The Bendix is sometimes activated by a solenoid and a
wishbone-shaped lever, depending on manufacturer.

6. Electromagnetic Field Coils and Housing

A field frame is the starter housing. A core holds the starter fields in the frame with screws. Cars
have two to four field coils, connected in a series. Energized by the battery, the coils turn into an
electromagnet, which forces the armature to turn.
7. Solenoid
The solenoid consists of two coils of wire wrapped around a movable core. The starter solenoid
acts as a switch by closing an electrical circuit and connects the starter motor to the battery. A
key inserted and turned in the ignition switch to the start position opens a current flow from the
battery through a neutral switch to the solenoid. The current in the solenoid creates a magnetic
field that pulls a movable core linked to the starter drive gear. The solenoid pushes the starter
gear into mesh with the ring gear. When the engine starts, a clutch disengages the starter drive
gear. The driver then releases the start key, which removes the battery power to the armature.

8. Shift Fork
The solenoid has a plunger, which pulls or pushes the shift fork attached to the starter drive gear.
This engages the starter gear.

9. Starter Drive Gear

When the shift fork engages the starter gear, it engages the ring gear on the engine's flywheel.
The flywheel, connected to the crankshaft, moves the pistons in the cylinders to start the engine.

10. The Pinion

A small gear with a number of teeth that mesh with another gear, the pinion of a starter motor, in
turn, meshes with the flywheel. If a driver continues to turn a key in an ignition for an extended
period of time, the pinion will simply spin on the driveshaft, and will not fire the starter motor.

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 PINNION & BARREL ASSEMBLY

Fig. Starter Motor Components.

TESTS CONDUCTED ON STARTER MOTOR:

To start the engine, the crankshaft must turn fast enough for air- fuel mixture to enter the
cylinder. An electric starter or starting motor does the job. It converts electrical energy from the
battery into mechanical energy that rotates the crankshaft. When the driver turns the ignition

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 key to start, the control circuit causes contacts to close in a starter relay or solenoid switch.
High current then flows from the battery to the starter motor. As the starter motor shaft turns, it
turns the crankshaft fast enough to start the engine. To ensure the proper functioning of starer
motor the following two testes are important from the subject point of view.
1. Voltage Drop Test.
2. Current Draw Test.

Voltage Drop Test:

A voltage drop test is the only effective way to find excessive resistance in high amperage
circuits. It's a quick and easy test that doesn't require any disassembly and will quickly show you
whether or not you've got a good connection or a bad one.

To do a voltage drop test, you create a load in the circuit that's being tested. Then you use a
digital volt meter (DVM) to measure the voltage drop across the live connection while it is under
the load. Voltage always follows the path of least resistance, so if the circuit or connection being
tested has too much resistance some of the voltage will flow through the DVM and create a
voltage reading.
If a connection is good, you should find little or no voltage drop and see less than 0.4 volts for
most connections, and ideally less than 0.1 volts. But if you find more than a few tenths of a
voltage, drop across a connection, it indicates excessive resistance and a need for cleaning or
repair.
To check the starter circuit for excessive resistance, you need to measure the voltage drop at the
battery, battery cable connections and starter while the engine is being cranked.
The first check is "available battery voltage." For the starter to crank at normal speed, the battery
must be at least 75% charged (12.4 volts or higher). Low battery voltage can not only affect the
starter but every other electrical system in the vehicle.
i. Set your DVM to the 20volt scale, then connect meter positive (+) lead to battery positive (+)
post (not the clamp or cable), and the meter negative (-) lead to battery negative (-) post.
ii. Disable the engine so it will not start when it is cranked. (Ground the ignition coil wire, or
disable the ignition circuit or fuel pump relay.) Limit cranking time to 15 seconds or less.
iii. While cranking the engine, record the volt reading on the DVM.
iv. Next, connect your meter positive (+) lead to the battery terminal stud on the starter, and the
meter negative (-) lead to the starter housing.
v. While cranking the engine, record the volt reading.
vi. Compare the two voltage readings. If both are the same, there are no excessive voltage drops
on the positive feed side.
vii. If available voltage at the starter is not within one (1) volt of battery voltage, there is
excessive voltage drop in the circuit.
The next test is for voltage drop on the positive side of the starter circuit.
i. Make sure the battery is fully charged.
ii. Disable ignition.
iii. Set DVM on 2 volt scale.
iv. Connect meter positive (+) lead to positive (+) battery post, and the meter negative (-)
lead to the battery terminal stud on the starter. While cranking the engine, record the
voltage reading.

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The maximum allowable voltage drops including the solenoid or external relay in the
starter circuit should be 0.6 volts or less.
If you find more than a 0.6 volt drop in the starter circuit, you can isolate the bad
connection by using the following voltage drop tests.

The negative side of the starter circuit. To check the entire circuit, connect the meter positive
lead to a clean spot on the starter motor case and the meter negative lead to the negative battery
post. Crank the engine and note the reading. The voltage drop on the negative side should be 0.3
volts or less.

2. Current Draw Test.

i. This test measures the current flow to the starter motor while it cranks the engine.
ii. Disable the ignition coil and connect ammeter to the battery cable.
iii. Turn ignition key to start and read the current draw and note down it. Check whether it is
according to manufacturer specification. If not, find and rectify the fault.

PRECAUTION:

 Keep work area clean and organize.

 Pick up appropriate tools and use tool cabinets.
 Never wear loose clothing or clothing that is ripped or torn.
 Never touch any moving components.
 Do not touch any live wire.
 Avoid water and any other conducting materials when working with electricity.
 Take the reading carefully.

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