ST-1

Starting system

Structure /circuit diagram of starter .................................... ST-2

Disassembly of starter ....................................................... ST-3

Inspection on starter ......................................................... ST-4

Assembly of starter ........................................................... ST-7

Testing on starter.................................................................ST-9

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ST-2 Starting system-Structure /circuit diagram of starter

The exterior force of petrol engine comes from one starter, which receives power supply from the battery,
and drives the engine to rotate. The starter is of one special DC electrical motor, which has following features
during operation: with a large starting torque, a large staring current, and subject to an intermittent operation.

Structure /circuit diagram of starter

The structure of starter as shown in the figure below:

felt sealing-gasket
armature
excitation winding(excitation frame)
brush bracket
end cover

rear bearing

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front bearing
brush spring bearing
solenoid switch
idler wheel
steel ball
release spring

starting pinion
starter shell
clutch assembly

The one with mark

 Starting system-Disassembly of starter ST-3

Circuit diagram of starter as shown in the figure below:

ignition switch

fuse

terminal 30 terminal 50

battery

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starter

Disassembly of starter
1. Dismantle thearmature assembly inside the excitation
frame.
(a)Remove nuts from the terminal of solenoid switch, and remove
the lead-wire as well.
(b)Two through-bolts need to be taken out.
(c)Take out the excitation frame together with the armature.
(d)Remove the felt sealing-gasket.

2. Removal of starter shell, clutch assembly, and gear

(a)Remove two screws.

(b)Following spare parts shall be removed from the solenoid switch:

a Starter shell
b Idler wheel and bearing
c Clutch assembly
d Release spring
ST-4 Starting system-Inspection on starter

3. Removal of steel ball

A magnetic rod may be used to take steel ball out from the axle hole of
clutch.
magnetic rod

4. Removal of brush frame

Two screws and end cover will be removed from the excitation frame.

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Using screwdriver, spring could be taken out from the brush holder, and
the brush holer could be removed, followed by a removal of four brushes
and brush holders.

Inspection on starter

Armature winding
1. Check whether the rectifier is in an opened loop.
Use an ohmmeter to check whether conduction exists on the
discofrectifier. The armature needs to be changed if the conduction
fails.

conduction

2. Check whether the rectifier has been grounded.

Use an ohmmeter to check whether noncon duction exists between rectifier
and the core of armature windings.
The armature needs to be changed if the conduction works.

non-conduction
 Starting system-Inspection on starter ST-5

Rectifier
1. Check whether the surface of rectifier has been
contaminated or damaged by burning.
If it does occur, sand paper (No.400) or lathe may be used for a repair or
correction purpose.
2. Check the circumferential radial runout of rectifier
Max. circumferential radial runout 0.05 mm
Lathe may be used for a repair or correction purpose if the radial runout
exceeds Max. value.

3. Check the diameter of rectifier

Standard diameter 30 mm
Min. diameter 29 mm
The rectifier needs to be changed if the actual diameter is less than Min.
value.

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4. Check the depth of cutting groove
Check whether it’s clean or has foreign materials on the bottom of groove,
and whether the edge of groove is round and smooth.
Standard depth of groove (0.5 0.8)mm
Min. depth of groove 0.2 mm
If the depth of groove is less than Min. value, saw blades may be used
for a repair or correction purpose.

Excitation winding (excitation frame)

1. Check whether the excitation winding is in an opened loop.Use
an ohmmeter to check whethe rconduction exis tsbetween the lead-
wire and the lead-wire of brush on excitation winding.
The excitation frame needs to be changed if the conduction fails.

conduction

2. Check whether the excitation winding has been

grounded.
Use an ohmmeter to check whether non conduction exists between
excitation winding and the excitation frame.
The excitation frame needs to be repaired or changed if the conduction
works.

non-conduction
ST-6 Starting system-Inspection on starter

Brush
Check the length of brush
Standard length 13.5 mm
Min. length 8.50 mm
The brush frame, and the excitation frame must be changed if the length
is less than Min. Value.

Brush spring
Check the load of brush spring using a Pull up balance.
Standard spring load (17.56-23.64) N
Note Read the load produced at the moment when the spring isleaving
the brush while the brushs pring is being pulled up by a Pull-up balance;
If the read value is not within the specified scope, the brush spring shall
be changed.

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Brush holder
Check the insulation of brush holder.
An ohmmeter may be used to check whether nonconduction exists
between positive brush and negative brush.
The brush holder must be repaired or changed if conduction works.

Clutch and gear

rotating 1. Check the gear teeth.
Check whether the teeth of small gear &idler wheel, andthe clutch assembly
have been abraded or damaged.
locked They may be changed if any damage is found. In case of any damage,
check whether the gear ring of flywheel has been abraded or damaged.
2. Check the small gear on clutch
Have the small gear rotating in clockwise direction to check

Bearing
1. Check bearing
Manually push each bearing inward, and have it rotating at the same
time.
The bearing may be changed if any resistance has beenmet, or the rotation
is not flexible.
 Starting system-Assembly of starter ST-7

2. The bearing may be changed if necessary.

(a)Use SST to remove the bearing

(b)Use SST and press tool to press new front bearing.

SST 09285-76010

(c)Use a press tool to press into rear bearing

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Solenoid switch
terminal 50 1. Perform a pull-in winding test in an open circuit
An ohmmeter may be used to check whether conduction exists between
terminal 50 and terminal C.The solenoid switch needs to be changed
if non-conduction exists.

terminal C

2. Perform a holding-power winding test in an open circuit

switch unit An ohmmeter may be used to check whether conduction exists between
terminal 50 terminal 50 and the switch unit.
The solenoid switch needs to be changed if non-conduction exists.

Assembly of starter
Note During the assembly of starter, bearings
and gears may be lubricated using high temperature
grease.
1. Installation of armature into the excitation frame
After the armature bearing is applied with greasete ar mature may be
inserted into the excitation frame.
ST-8 Starting system-Assembly of starter

2. Installation of brush holder

(a)Put the brush holder on armature.
(b)To connect armature with the holder, screw tap may be used to press
the brush spring on the back. Beside, four brushes must be connected.
Note: Check and verify that the positive lead-wire
has not been connected with ground.

End cover may be installed using two screws.

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3. Installation of steel ball into the axle hole of clutch
(a)Grease needs to be applied to steel ball.
(b)Steel ball shall be installed into the axle hole of clutch.

4. Installation of clutch assembly

(a)Grease needs to be applied to the release spring.
(b)Release spring shall be installed into the hole of solenoid switch.

(c)Following spare parts shall be installed into the starter shell.

a Clutch assembly
b Idler wheel and bearing
 Starting system-Testing on starter ST-9

(d)Using two screws, the starter shell and solenoid switch may be
assembled together.

5. Installation of the excitation frame and the armature

assembly
(a)A new felt sealing-gasket needs to be installed on the armature.

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(b)Have the convexity of excitation frame aligned with the tangent
plane of solenoid switch.
(c)Two through-bolts will be installed.
(d)Install the lead-wire with the terminal of solenoid switch,followed
by an installation of nut.

Testing on starter
Note: to avoid any damage on winding due to burning,
terminal C the test must be completed within (3-5s).
1. Perform a pull-in test
(a)Remove the lead-wire of excitation winding from terminal C.
(b)Connect the battery onto solenoid switch as shown in the figure, and
check while small gear is moving outward.
The solenoid switch assembly needs to be changed if small gear does not
terminal 50 move.

2. Perform a holding-power test

Subject to above wire connection, remove the negative leadwire from
terminal C when small gear is going out, and check whether small gear is
able to keep its status when going out.
The solenoid switch assembly needs to be changed if small gear goes back
to the inside.
ST-10 Starting system-Testing on starter

3. Check the return status of plunger piston

After a removal of negative lead-wire from the switch unit, check whether
small gear is able to go back to the inside.
The solenoid switch assembly needs to be changed if small gear does not
return to the inside.

4. Perform a zero-load performance test

(a)As indicated in the figure, have the battery and armature connected
terminal 50 respectively with the starter
(b)Check whether the rotation of starter is smooth or flexible when small
gear goes out, and whether the current value is within the limit of
specification.
Specified current 90A when at 11.5V

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terminal 30