Carolina CAT Construction Equipment

Fall 1. HET 127 Shop Rules and regulations 1 2. HET 110C Diesel Engines 6 3. HET 112C Diesel Electrical Systems 5 4. HET 125C Preventive Maintenance 2 5. ENG 111 Expository Writing 3 Spring 6. HET 116C Heating /Air conditioning Systems 2 7. HYD 112C Hydraulics/Medium/Heavy Duty 2 8. HYD 134C Hydraulic/Hydrostatic Construction 4 9. AUB 134C Auto body MIG welding 3 10. MAT 115 Mathematical Models 3 Summer 11. HET 114C Power Trains 5 12. HET 115C Electronic Engines 3 13. HYD 210C Advanced Hydraulics 2 Fall 14. COE 112R Co-op work Experience I* (or HET128C) 2 15. HET 128C Med/Heavy duty tune up* (or COE112r) 2 Graduation Requirements: 43

Cranking Systems
HET112C Diesel Electrical Systems

Objectives
Identify the components in a Construction cranking circuit. Explain the operating principles of magnetic switches, solenoids, and starter motors. Describe the operating principles of lightweight, planetary gear reduction starter motors. Test and troubleshoot a cranking circuit using voltage drop testing

( Objectives cont.)
Disassemble a heavy-duty Construction starter motor. Test an armature for shorts using a growler. Test an armature for grounds and opens. Use a test light to check out field coils. Outline the procedure required to rebuild a DelcoRemy 42MT starter motor.

INTRODUCTION
The cranking system in any vehicle is designed to turn the engine over until it can operate under its own power. A cranking system can be divided into two sub-circuits known as the control circuit and the starter circuit. The objective of the cranking system is to energize a starter motor using energy from the vehicle batteries.

STARTING CIRCUIT COMPONENTS

Battery Key switch (or starter button) Battery cables Magnetic switch Starter motor A starter motor draws high current from the batteries, typically 300 to 400 amperes.

GROUND AND INSULATED CIRCUITS

Almost all current highway vehicles use negative chassis ground electrical circuits. In such a system, the entire chassis is used as the ground or negative path for current flow. This is known as the ground circuit. An advantage of chassis negative ground systems is that only the positive side of the current path to components has to be insulated.

CRANKING CIRCUIT COMPONENTS

BATTERY TERMINALS CABLES STARTER MOTOR MAGNETIC SWITCH CONTROL CIRCUIT

MAXIMUM VOLTAGE DROP SPECIFICATIONS

Insulated circuit voltage drop (VD) maximums:

Cranking Circuit Component Max VD Starter cable 0.2 volt Each cable connection 0.1 volt Starter solenoid 0.3 volt Maximum total permissible voltage loss 0.5 volt

IGNITION SWITCH
The ignition switch gets its name from the automobile key circuit. The term ignition switch is commonly used to describe the switch that energizes the control circuit in the cranking system. There are two types. The first type is integral with the ignition key: To close the control circuit to initiate cranking, the key is turned. The second type is a push-button and requires that the ignition key circuit be closed before the push-button starter is powered.

STARTER RELAY

STARTER MOTORS

Shop Talk
Starter motors can only operate for short periods without rest. The high current needed to operate the starter creates considerable heat, and continuous operation will cause overheating. A starter motor should never operate for more than 30 seconds at a time and should rest for 2 minutes between cranking cycles. This permits the heat to dissipate without damage to the unit.

STARTER MOTOR CONSTRUCTION

Field Coils

Armature

Commutator

OPERATION

Current Flow

STARTER SOLENOIDS

Solenoid Windings

Shop Talk
In almost all diesel engine starters, the solenoid performs the function of a relay. The control circuit is wired to the windings of the solenoid. Battery current is routed directly to the starter motor through the drive solenoid.

Initiating Cranking

Overrunning Clutches

Thermostats
Some starter motors are equipped with a thermostat (see Figure 9-2B). The thermostat monitors the temperature of the motor. If prolonged cranking causes the motor temperature to exceed a safe threshold, the thermostat opens and the starter current is interrupted. The starter motor, then, will not operate until the motor cools and the thermostat closes.

CONTROL CIRCUIT
The control circuit allows the driver to use a small amount of battery current to control the flow of a large amount of current in the starting circuit. It consists of the following components.

 Ignition Switch Neutral Safety Switch Starter Relays

REDUCTION-GEARING STARTER MOTORS

Shop Talk
The starter should not be operated if the voltage at the battery is below 9.6 volts. Some leasing companies now use a voltage sensing module to prevent starter operation if voltage is below 9.6 volts to prevent drivers from destroying starters.

Testing Cranking Current

Shop Talk
If the analyzer uses an inductive pickup (amp clamp), ensure that the arrow on the inductive pickup is pointing in the right direction as specified on the ammeter. Then crank the engine for 15 seconds and observe the ammeter reading.

WARNING:
When performing this test, do not operate the solenoid for extended periods because severe overheating will result.

Starter Circuit Testing

Shop Talk
When testing starter circuits, use the OEM recommended method of preventing the engine from starting. When performing voltage drop tests, make sure you record the results to two decimal places. Record the results by writing them down so you can easily check them to spec afterwards.

NO-LOAD TESTS

STARTER REBUILD
DISASSEMBLY INSPECTION REASSEMBLY

ADJUSTING PINION CLEARANCE

Summary
The vehicle cranking circuit functions to crank the engine until it can operate under its own power. A cranking circuit is managed by a control circuit that uses low current to switch and energize a highcurrent starter motor circuit. A starter motor converts the electrical energy of the vehicle batteries into mechanical energy for cranking the engine.

Summary (cont.)
A powerful electromagnetic field in the starter motor field coils is used to rotate the armature assembly in a typical starter motor. Most starter motors are series wound, so there is only one path for current flow through the assembly. This means that all of the current flowed through the field coils also flows through the armature, providing the conditions that along with the absence of CEMF produce peak torque at close to stall speeds.

Summary (cont.)
CEMF works in opposition to battery current in an armature. It rises proportionally with armature speed. For this reason, CEMF helps limit starter overspeed. A new generation of lightweight, high-torque starter motors uses planetary gear reduction to multiply cranking torque and greatly reduce motor weight.

Summary (cont.)
Voltage drop testing should be used to troubleshoot a cranking circuit malfunction because it does so dynamically. A heavy-duty Construction starter motor found to be defective should be removed from the engine and either rebuilt or replaced.

Summary (cont.)
A growler is used to test an armature for shorts: A steel strip such as a hacksaw blade is placed on top of the armature during testing and if it vibrates, a short is indicated. A test light is used to test an armature for grounds and opens.

Summary (cont.)
Field coils should be checked using a test light. After reassembling a starter motor, the pinion clearance should be checked with thickness gauges and adjusted if necessary.

Any Questions ?