Starting system
Contents
1. 86 or 1 amp 2 then measure the continuity between the switch terminals of the relay 30 amp 87 or 3 amp 4 If there in no continuity replace relay 17 Starting system faults possible causes and action Malfunction of P position switch CVT model Starting motor not running No operating sound of magnetic switch Malfunction of clutch pedal position switch M T model Battery voltage is too low Charging faulty due to deteriorated battery Poor battery terminal connection Poor ground cable connection Blown fuse Faulty magnetic switch Poor magnetic switch lead wire connector connection Open circuit between battery and magnetic switch Open circuit in pull in coil Faulty brushes and or brush springs Poor sliding of plunger and or pinion Faulty starting motor control relay Faulty ECM and its circuit Faulty keyless start system ENO5 Engine Auxiliary System Starting system Check P position switch Check clutch pedal position switch Replace battery Check terminal connection or replace battery Tighten ground cable Replace fuse Check magnetic switch Check connector connection Repair circuit Check pull in coi circuit Check brushes and brush springs Check plunger and pinion Check starting motor control relay Check ECM and its circuit Check keyless start system 18 Starting motor not running Operating sound of magnetic switch heard Starting motor running but to2. e Describe the function of a starter motor e Identify and name the different parts of a starter motor e Describe the functions of the different parts of a starter motor Operating principle of the DC motor The starter motor converts electrical energy to mechanical energy In the motor vehicle a starter motor is used to start the internal combustion engine The starter motor is a DC motor that is series wound It produces greater torques at low speed The electrical energy required for starting is generally drawn from the battery An armature is positioned inside a powerful magnetic field crated by either permanent magnets or field coils When current is supplied to the commutator it flows through the armature windings The coil in the N side receives a force in the left direction and the coil in the S side receive a force in the right direction This creates a turning force ENO5 Engine Auxiliary System Starting system Figure 1 Starter motor operating principle a Commutator b Current flow c Battery d Direction of rotation of armature e Armature coil inside magnetic lines N North pole of magnet field coil S South pole of magnet field coil pears Magnetic lines of force N ae 2 28 ae Betpas Starter motor components ENO5 Engine Auxiliary System Starting system Figure 3 Starter motor components Suzuki Kizashi 1 Armature housing 2 Bushing 3 Pinion stop ring 4 Overru
3. of ring gear Noise Abnormally worn bushing Worn teeth of pinion Worn teeth of ring gear ENO5 Engine Auxiliary System Starting system Replace overrunning clutch Check overrunning clutch Replace overrunning clutch Replace flywheel M T model or drive plate CVT model Replace bushing Replace overrunning clutch Replace flywheel M T model or drive plate CVT model 20 Summary e The starting system consists of the starter motor relay wiring ignition switch battery and the starter motor e In some Suzuki models the ECM monitors the condition of the starting system and outputs a DIC in the event of faults e Modern starter motors are of the reduction gear type which is small and lightweight The torque required to turn the engine is achieved via use of a planetary gear mechanism e The magnetic switch is like a relay A small current is used to connect the battery to the starter motor which have much large current e The starter motor is a series wound type which enables it to produce great torque at low speeds e Permanent magnets or field coil magnets can be used to create the magnetic field e Simple on vehicle starter circuit tests can be used to determine the condition of the starting system These tests include voltage drop tests current draw tests and even relay test and even DTC read out using the SDT EAr T l aji a A 7 971 CMAC Cruncainn A Z ri CUa tArA Startins ouctanam f Well
4. 0 A maximum 6 17 Nem 0 63 kgf m 5 0 Ibf ft minimum Around at 20 C 66 F Figure 1 Starter specification Suzuki Alto AMF310 Direction of rotation CC C ClOCKWwise as viewed from pinion side Number of pinion teeth N32A 12 teeth J24B 8 teeth No load characteristic OV 0AMax 2000rpmMiN Loaded characteristic 11 0 Nem 1 1 kgf minimum Locked charactenstic 20 0 Nem 2 0 kgf m 15 0 IbF ft minimum Magnetic switch operating voltage 6 V or less Figure 2 Starter specifications Suzuki Grand Vitara JB632 ENO5 Engine Auxiliary System Starting system 14 Starter circuit symptom diagnosis Possible symptoms of starting system trouble would be as follows e Starting motor does not run or runs slowly e Starting motor runs but fails to crank engine e Abnormal noise is heard Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery wiring harness starting motor including magnetic switch or engine Before removing the starting motor to perform inspection check the following items to narrow down the possible causes of trouble e Before removing the starting motor to perform inspection check the following items to narrow down the possible causes of trouble e Discharge of battery e Mounting of starting motor ENO5 Engine Auxiliary System Starting system On vehicle starter system test Q This test checks the s
5. The internal gear 2 is fixed and the drive is supplied by the armature and it drives the planetary gears 1 The overrunning clutch and pinion is driven by the planetary gears The transmission ratio between the armature and the pinion is variable across a wide range from approximately 3 1 to 6 1 ENO5 Engine Auxiliary System Starting system Figure 11 Planetary gear set 1 Planetary gears 2 Fixed internal gear ring gear starting circuit In this lesson we will study the starting system circuit components and the starting process Objectives At the end of this lesson you will be able to e Name and describe the tasks and functions of the components of the starting systems e Describe the starting process ENO5 Engine Auxiliary System Starting system Starting system components Figure 1 Starting system circuit components A basic starting system circuit consists of the following components Battery 10 Supplies the electrical energy to the starter Starter switch 9 closes the starter circuit to energise the Starter relay Starter relay 11 controls the opening and closing of the circuit from the battery to the magnetic switch Magnetic switch 3 Actuates the shift fork and closes the contacts supplying current to the armature and field coils Starter motor 8 Generates the turning force Pinion 2 Transfers turning force of the armature to the ring gear Overr
6. ages the pinion from the armature once the pinion is rotating more quickly to protect the starter motor from excessive speeds which can cause damage 11 Suzuki starting system circuit The following components are also part of the starting system depending on the model Refer to the service manuals for model specific starting circuits e Engine Control Module e Keyless start control module e CPP switch M T model or TR sensor A T model GRN BLE GRN BLK Figure 3 Suzuki Swift keyless push start model 1 Battery 2 Main fuse box 3 Starter motor 4 ST fuse 5 Keyless start control module 6 Engine Start switch 7 Starting motor control relay 8 ST SIG2 fuse 9 Engine control module 10 TR sensor or CPP No 1 switch ENO5 Engine Auxiliary System Starting system Operation of the keyless push start model In the keyless push start models the push start button is connected to the keyless start control module When the keyless push start button 6 is pressed a start signal is sent to the keyless start control module which then actuates the starter relay 7 The solenoid circuit of the starter relay is grounded via the TR sensor or CPP switch 10 which ensures the transmission is in the P position or the clutch pedal is depressed The starter relay is then energised closing the circuit to the magnetic switch allowing current to flow from the battery to the pull in and hold in coils En
7. done you have now completed the Starting system training course Please complete the online exam ENO5 Engine Auxiliary System Starting system ZZ
8. e Non Suzuki Technician to Suzuki Technician curriculum The curriculum consists of the following modules GEO1 Suzuki Introduction GE02 Electrical and Electronics Diagnostics ENO2 Engine Mechanical part En03 Engine Mechanical part II ENO4 Engine Mechanical part III ENO5 Engine Auxiliary systems DS01 Driveshaft Axle DSO2 Driveshaft Axle transfer case 10 BRO2 Brake control systems 11 Manual transmission transaxle 12 CS02 Control system body electrical 13 CS03 Communication bus systems oS at oe oe Se oe SS You are currently studying ENO5 Engine Auxiliary Systems This module consists of the following courses e Charging systems e Starting systems e Exhaust system Click on the other training modules to view their training contents Table of contents Starter motor DC motor operating principles Starter motor components Armature Brushes amp brush holder Magnetic switch Pinion amp overrunning clutch Field coils amp Magnets Reduction gear Starting circuit Starting process Starting circuit diagnosis On vehicle starter system test Voltage drop on cables Starter motor relay testing Starting system symptom troubleshoot table ENO5 Engine Auxiliary System Starting system CO CON DO OO FF A e e ee ee ee A CO N MD O W FE O Starter motor In this lesson we will study the basic construction and operation of a starter motor Objectives At the end of this lesson you will be able to
9. gine control module 9 The ECM monitors the starter circuit operation and stores DTC s in the event a signal is not received from the starter relay Possible ECM DTC s DTC detecting condition P0616 Starter Relay Circuit Low Starter switch signal is undetectable even if engine has been started 2 D C detection logic PO617 Starter Relay Circuit High Starter switch ON signal is high level ON for 180 sec after engine has been started 2 D C detection logic 12 starting circuit diagnosis In this lesson we will study possible starting system troubles and their possible causes We will also look at how to perform Starter motor testing Objectives At the end of this lesson you will be able to e Describe starting system volt drop and current draw test e Perform voltage drop on the positive cable negative cable and battery posts ENO5 Engine Auxiliary System Starting system 13 Starter motor specifications Vehicle starting systems are generally equipped with pre engaged starters up to a rated output of approximately 2 5 kW The nominal voltage is 12V The starter performance range depends on the combustion system and the size of the internal combustion engine The tables below indicate the starting system specifications The service manual must always be used to obtain starting system specifications 20 A maximum 6000 r min minimum o 2 84 N m 0 29 kgf m 2 0 Ibf ft minimum 1950 r min minimum 43
10. led and record voltage reading If the voltage measured rises above 0 5V there is excess resistance in the circuit Check the circuit for loose connections corroded terminals etc ENO5 Engine Auxiliary System Starting system System Ok Starter circuit connections faulty Battery discharged Starter Motor faulty Negative cable volt drop test Connect the negative probe of a voltmeter to the negative terminal and the positive probe to the starter mounting frame Crank the engine starting system disabled and record the voltage reading If the voltage rises above 0 5V there is excessive resistance in the circuit Check the cable for loose connections corrosion etc 16 Battery terminals volt drop test Poor contacts and corrosion on the battery terminals and cable Can cause excessive resistance in the cables The battery terminals can be checked for high resistance by following this procedure Connect the voltmeter as shown in figure 5 Crank the engine Starting system disabled and record the voltage reading If the voltage rises above 0 5 volts disconnect the battery cable and clean the contact points Figure 5 Battery post resistance 1 Battery post 2 Voltmeter positive probe 3 Voltmeter negative probe 4 Cable end ENO5 Engine Auxiliary System Starting system Testing the starter motor relay Figure 6 Relay testing Connect a battery to the solenoid terminals of the relay 85 amp
11. nning clutch 5 Drive lever assembly 6 Magnetic switch 7 Internal gear 8 Planetary carrier shaft 9 Planetary gear 10 Yoke 11 Armature 12 Brush assembly 13 End housing 14 bushing Armature amp The armature is the central rotating part of a starter motor To provide constant rotation and steady torque many wire loops windings coils are required The coils are wound in slots formed in a laminated soft metal core The end of each coil is soldered to the commutator Each segment of the commutator is insulated by mica Figure 4 Armature 1 Armature shaft 2 Armature coils 3 Armature core 4 Commutator ENO5 Engine Auxiliary System Starting system Brushes and brush holder Current is delivered to the commutator using carbon brushes The brushes are housed in a brush holder The positive brushes are connected to the vehicle battery via the field coil and terminal M and they are insulated from the housing The negative complete the electrical circuit as they are mounted on the brush holder which is grounded via the housing Figure 10 Brushes 1 Brushes 2 Negative brushes 3 Positive brushes 4 Terminal M connection Magnetic switch The magnetic switch also known as a solenoid acts as a relay and connects the battery to the starter motor field coils and armature A small current is used to energize the pull in and hold in windings of
12. o slowly small torque If battery and wiring are satisfactory inspect starting motor Battery voltage is too low Charging faulty due to deteriorated battery Poor battery terminal connection Poor ground terminal connection Faulty magnetic switch Faulty brushes and or brush springs Faulty brush holder Burnt commutator Short circuit between commutator and armature Poor starting motor cable connection Open circuit between battery and magnetic switch Obstructed crankshaft rotation Faulty magnetic switch Low battery voltage Charging faulty due to deteriorated battery Poor battery terminal connection Short circuit between commutator and armature Burnt commutator Faulty brushes and or brush springs Faulty brush holder ENO5 Engine Auxiliary System Starting system Check battery Replace battery Check terminal connection or replace battery Tighten ground cable Check magnetic switch Check brushes and brush springs Check brush holder Check commutator Check commutator Check starting motor cable connection Repair circuit Repair engine assembly Check magnetic switch Check battery Replace battery Check terminal connection or replace battery Check commutator Check commutator Check brushes and brush springs Check brush holder 19 Starting motor running but not Worn pinion tip ki i e ia cia Poor sliding of overrunning clutch Slipping overrunning clutch Worn teeth
13. rrunning clutch is designed to rotate in one direction Field coils are insulated copper wires wrapped around tron only When the pinion is engaged to the flywheel ring gear and cores They are connected in opposite pairs to provide North the engine has started the starter motor armature will rotate and South poles Current flowing through the field coils together with the flywheel The overrunning clutch prevents produces a powerful magnetic field over speeding of the armature In figure 5 permanent magnets are used to create the magnetic field The permanent magnets are positioned to create North and South poles The armature rotates inside the yoke Field coil Figure 9 Pull in amp hold in coils Figure 5 Yoke with Figure 6 Yoke with field permanent magnets coils 1 Pinion 2 Overrunning clutch 3 Spring ENO5 Engine Auxiliary System Starting system Reduction gear type starters Conventional direct drive starter motor have a pinion that rotates at the same speed as the armature The pinion and the overrunning clutch are mounted directly on the armature shaft In order to deliver high torque at low temperatures a large Starter motor would be required In a reduction gear type starter motor a planetary gear set is used to transfer the drive to the pinion and overrunning clutch A smaller and faster electric motor is used and it achieves the Same torque developed by the conventional direct drive starter motor
14. s Way of Life SUZUKI Starting system oa f 7 Engine Auxiliary Systems SUZUKI Course code EN05 re S SUZUKI Student training manual TRAINING ACADEMY Suzuki Online Training TECHNICIAN Foreword This training manual contains basic operating principles of the Starting system in a motor vehicle The main starting system in a motor vehicle includes the starter motor the wiring harness the battery In this manual we will look at the basic operating principles of the starter motor and starting system basic diagnosis After you have carefully studied this lesson you must complete the on line lesson exam on Suzuki Online Training before continuing to the next course Smart manuals Co Some sections of this training manual contain videos with detailed information on the topics you are studying If you are studying this training manual on a PC look out for the green play video symbol on any photo or picture in this manual click on the green button to watch a video providing you with detailed information on that topic Note Internet connection required This document Is intended solely for training purposes only All vehicle repairs and adjustments must be carried out according to the procedures stipulated in current service manuals and technical bulletins ENO5 Engine Auxiliary System Starting system Suzuki Technician curriculum This training manual is part of th
15. tarter system for voltage drop and current draw It is a good indication of the condition of the Starter motor and cables To perform an on vehicle test of the starter circuit e Connect a voltmeter and inductive type ammeter to the vehicle battery as shown if figure 3 e Note the voltage reading of the battery e Disconnect the ignition system so the vehicle will not start when the engine is being cranked e Crank the engine and record the lowest reading measured by the voltmeter and the highest reading recorded by the ammeter Caution Do not crank the engine for more than 20 second otherwise the starter motor could overheat Figure 3 1 Amp clamp 2 Negative cable 3 Negative terminal 4 Positive terminal 15 Starting circuit troubleshooting chart Use the table below to determine the condition of the stating system Cranking voltage Cranking current Voltage OK Current OK Voltage OK Current Low engine cranks Slowly Voltage low Current Low engine cranks Slowly Voltage low Current High Figure 4 Starter system troubleshooting chart Cable voltage drop tests These tests will quickly locate a cable with high resistance and it provides an easy way of checking the condition of the cables and their connections Positive cable volt drop test Connect the positive probe of the voltmeter to the positive terminal and the negative probe to the starter solenoid terminal B Crank the engine starting system disab
16. the solenoid enabling large current to be passed from the battery to the starter motor A shift lever is also connected to the solenoid As the plunger is pulled towards the contacts the shift lever is moved forward to engage the pinion the flywheel ring gear Figure 7 Magnetic switch 1 Terminal M 6 Shift lever 2 Terminal B 7 Pull in coil 3 Contact switch 8 Plunger 4 Hold in coil 5 Overrunning clutch amp pinion ENO5 Engine Auxiliary System Starting system Pull in winding The pull in winding this winding is energized when the ignition is turned to the start position The magnetic field generated attracts the plunger towards the contact switches Hold in winding This winding keeps the contacts closed until the ignition Switched is switched back to ON position Figure 8 Pull in amp hold in coils 1 Terminal B 2 Terminal S 3 Pull in coil 4 Hold in coil 5 Terminal M Pinion and overrunning clutch Field coils amp Permanent magnets WF The pinion is splined to the armature and rotates together with Depending on the type of starter motor the yoke houses the the armature during the starting process The pinion meshes field coils figure 6 or sets of permanent magnets figure 5 with the ring gear on the flywheel and transfers the starter These are used produce the magnetic lines in which the torque to the flywheel armature is positioned The ove
17. unning clutch 2 Protects the armature from excessive speeds if the starter switch is not released 10 Starting circuit and starting process When the ignition switch 9 is turned to start position the Starter relay 11 is energised and the relay switch is closed allowing current to flow from the battery 10 to terminal S of the magnetic switch 3 The current flows through the pull in coil 7 creating a magnetic field around the coil The plunger 5 is then pulled backwards forcing the pinion 2 forwards to mesh with the ring gear on the flywheel When the contacts 6 are closed current flows from the battery to terminal B of the magnetic switch because the contacts are closed current flows out via terminal M of the magnetic switch to the field coil if equipped and then to the armature commutator ENO5 Engine Auxiliary System Starting system Figure 2 Starting circuit Suzuki Jimny gt Current flow to terminal S gt Current flow to terminal B thick starter cables gt Current flow to starter relay solenoid Mechanical movements This causes the armature to rotate When the armature rotate it rotates with the pinion which is already engaged to the flywheel ring gear In this way the engine is cranked Once the engine has started the ignition switch must be returned to ON position to cut the power to the magnetic Switch The overrunning is a one way clutch that diseng
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