303-06A-1 Starting System – Gasoline Engine 303-06A-1

Section 303-06 A Starting System - Gasoline Engine

Applicable Model: Boomday

CONTENTS PAGE
Specifications
Specifications...............................................................................................................................303-06A-2
Descriptions and Operations
Starting System.............................................................................................................................303-06A-3
Diagnosis and Testing
Starting System...........................................................................................................................303-06A-4
General Procedures
Inspection of Drive Gear and Flywheel Ring Gear of Starter .................................................303-06A-9
Removal and Installation
Starter.........................................................................................................................................303-06A-10

2011 Boomday & Boarding Workshop manual

303-06A-2 Starting System – Gasoline Engine 303-06A-2
Specifications

Torque Parameters

Item Nm
Terminal nut of electromagnetic switch B 20 ± 2
Starter retaining nut 90 ± 1

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303-06A-3 Starting System – Gasoline Engine 303-06A-3
Diagnosis and Testing

Starting System
The starting system includes: Electromagnetic switch
● Starter. ● Is an electromagnetic body.
● Starter switch, a part of the ignition switch. ● Makes the starter drive mechanism engages
● Starter relay. with the flywheel.
● Electromagnetic switch. ● With power on, the contacts close and the
battery is connected to the starter, rotating the
● Starter drive mechanism.
starter armature.
Starter
● Keeps power on with a retaining coil until the
● It is a wound field motor and it decelerates ignition switch is released.
through the drive mechanism. It is a12V DC
motor.
● It integrates a starter solenoid.
● There is a one-way clutch in the starter drive
mechanism.
The functions of the starter are listed as follows:
● When the ignition switch is at the "ST (starting)"
position, current flows through the pull-in coil
of solenoid switch until the iron core of the
solenoid coil reaches its maximum stroke. The
iron core pulls the lever to drive the pinion to
engage with the flywheel.
● The touch plate in front of the pushrod
switches on the main circuit of the starter
through the attraction of the pull-in coil. The
flux direction of the pull-in coil is the same as
that of the retaining coil energized, and the
combination of their electromagnetic suctions
makes the pinion of the starter engage with the
flywheel in a better way and rotate the engine
with enough speed to start it.
● When ignition switch returns to the "ON
(operation)" position, the relay switches off
the current to the electromagnetic switch and
the flux direction of the pull-in coil is opposite
to that of the retaining coil energized, so
the attraction disappears and the pinion is
detached from the flywheel as a result.
Starter drive mechanism
● Is controlled by the pull-in coil and retaining
coil of the solenoid coil.
● Engages with the flywheel to drive the engine.
● Has an inner one-way clutch to detach the
engine when the engine starts.

2011 Boomday & Boarding Workshop manual

303-06A-4 Starting System – Gasoline Engine 303-06A-4
Diagnosis and Testing

Starting System
Universal Tool 3. If the obvious cause of the problem observed
or raised has been discovered, then the
Car multimeter
problem must be corrected (if possible) before
the next step.
Working principles 4. If the cause of the problem can not be
When ignition switch is at the "ST" position, the found through visible inspection, then after
current flows through the ignition switch to shut confirmation of the phenomenon of fault,
continue the diagnosis in reference to the
off the starter relay; then the battery current flows
failure symptom table.
through the starter relay to the electromagnetic
switch on the starter. The pull-in coil and retaining
coil of the electromagnetic switch are energized
to engage the pinion of the starter with the
ring gear of the flywheel, and meanwhile the
large current of the battery flows through the
electromagnetic switch to the starting motor to
rotate the generator.
When the ignition switch is at the "ON"
position, the current from the starter relay to
the electromagnetic switch disappears; the
magnetic force of the pull-in coil is opposite to
that of the retaining coil, so the magnetic force
is neutralized. The large current of the starter is
interrupted and the starter stops working.
Inspection and Verification
ATTENTION: There is a protection cover
or shield on the battery input terminal and
it must be installed after maintenance.
ATTENTION: Make sure the battery ground
wire is disconnected before maintaining
the starter.
1. Confirm the questions of the customer.
2. Inspect the appearance of the equipment for
visible mechanical or electric damages.
Appearance check list

Mechanical Electrical
● Installation of the ● Battery
starter. ● Wire harness
● Installation of the ● Electrical connector
starter relay
● Fuse: 10A
● Relay
● Ignition switch
● Starting motor

2011 Boomday & Boarding Workshop manual

303-06A-5 Starting System – Gasoline Engine 303-06A-5
Diagnosis and Testing

Symptom List

Symptoms Possible Causes Measures

● Battery. ● Refer to section 414-01.
● Refer to the wiring diagram and
T h e e n g i n e c a n n o t ● Relay. carry out test over relay com-
rotate, but the relay works ponents.
properly.
● Starter.
● Refer to Accuracy Test A.
● Circuit.
● Battery. ● Refer to section 414-01.
● Replace it with a new fuse if
necessary. If the new fuse blows
● Fuse.
out again, check the engine for
ground short circuit.
The engine can not
rotate, and the relay does ● Refer to the wiring diagram and
not work properly. ● Relay. carry out test over relay com-
ponents.

● Ignition switch.
● Starter. ● Refer to Accuracy Test B.
● Circuit.
● Battery. ● Refer to section 414-01.
The engine starts slowly. ● Starter.
● Refer to Accuracy Test C.
● Circuit.
● Check the pinion of the starter for
● Starter. damages and replace the starter
if necessary.
Abnormal starting noise
● Remove the starter. Check the
● Ring gear of the flywheel. ring gear of the flywheel for
damage.

● Check the pinion of the starter

and one-way clutch for damage
● Starter.
The starter is idling at and replace it with a new starter if
a high speed, but the necessary.
engine crankshaft does
not rotate. ● Remove the starter. Check the
● The ring gear of the flywheel. ring gear of the flywheel for
damage.

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303-06A-6 Starting System – Gasoline Engine 303-06A-6
Diagnosis and Testing

Accuracy Test
ATTENTION: Use a digital multimeter to
complete all electrical measurements.
Accuracy Test A: The engine can not rotate,
but the relay works properly.

Testing Conditions Details / Results / Measures

A1: Check the voltage on the starter provided by the electromagnetic switch
1. Shift the ignition switch to the position of ST.
2. Measure the voltage between S terminal of the
electromagnetic switch of the starter and the
ground.
Is the voltage greater than 12.5V?
Yes
Go to A2.
No
Go to A3.
A 2: Check the power supply to the starter
1. Measure the voltage between B terminal of the
starter and the positive electrode of the battery.
Is the voltage less than 0.5V?
Yes
Refer to the removal and installation of the starter
in this chapter to check the working condition of the
circuit inside and replace the starter if necessary.
No.
Clean and connect electrical and cable connectors
of the positive electrodes of all batteries, and test
the system. If the problem still exists, replace it
with a new starter.
A3: Check the voltage applied on the starter relay.
1. Shift the ignition switch to the position of
"LOCK".
2. Remove the starter relay.
3. Measure the voltage between pin 30 of the
relay and the ground.
Is the voltage greater than 12.5V?
Yes
Repair the line between the relay and terminal S
of the starter.
No
Repair the line and Check the fuse. Replace it
with a new fuse if necessary. If the fuse blows out
again, check for any short circuit to ground.

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303-06A-7 Starting System – Gasoline Engine 303-06A-7
Diagnosis and Testing

Accuracy Test B: The engine can not rotate / The relay does not work.

Testing Conditions Details / Results / Measures

B1: Check the voltage between the starter relay and ignition switch.
1. Remove the starter relay.
2. Shift the ignition switch to the position of ST.
3. Measure the voltage between? pin of the relay
and the ground.
Is the voltage greater than 12.5V?
Yes
Replace it with a new relay. Test the system to
see if it works properly.
No
Go to B2.
B2: Check the voltage of the ignition switch line.
1. Remove the electrical connector of the ignition
switch.
2. Test the voltage between port ? and the ground.
Is the voltage greater than 12.5V?
Yes
Replace it with a new ignition switch assembly
and test the system to see if it works properly.
No.
Check the fuse. If the replaced fuse blows out
again, check if there is short circuit to ground.
Repair the line and test the system to see if it
works properly.

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303-06A-8 Starting System – Gasoline Engine 303-06A-8
Diagnosis and Testing
Accuracy Test C: The engine starts slowly.

Testing Conditions Details / Results / Measures

ATTENTION: Ensure the battery has been tested and charged fully before this test.
C1: Check the voltage of the starter
Measure the voltage between terminal B of the
starter and the ground.
Is the voltage greater than 12.5V?
Yes
Go to C2.
Repair the line between the battery and terminal
B of the starter. Clean and tighten the connection
at the terminal. Test the system to see if it can run
properly.
C2: Check the ground wire of the starter
1. Shift the ignition switch to the position of ST.
2. Measure the voltage between the super shell of
the starter and the ground wire of the battery.
Is the voltage less than 0.5V?
Yes
Replace the starter assembly. Test the system to
see if it works properly.
No.
Clean and tighten up the electrical connector of
cathode cables of all batteries and the connection
of the ground wire of the starter. Test the system
to see if it works properly.

2011 Boomday & Boarding Workshop manual

303-06A-9 Starting System – Gasoline Engine 303-06A-9
General Procedures

Inspection of Drive Gear and Flywheel Ring Gear of Starter

1. Check the components for wearing.
1 The abrasion of the drive gear of starter.
2 The abrasion of the flywheel ring gear.

2. If the pinion of the starter does not engage

with the flywheel ring gear fully, or the
pinion or the flywheel ring gear has been
worn or damaged, replace the starter and
the flywheel with new ones.

2011 Boomday & Boarding Workshop manual

303-06A-10 Starting System – Gasoline Engine 303-06A-10
Removal and Installation

Starter
Removal and Installation
1. Remove the ground wire of the battery.
Reference: Battery, Bracket and Cable
(Section 414-01 Battery, Bracket and Cable
- Removal and Installation).
2. Remove the electrical cable of the electrom-
agnetic switch of the starter.
● Tighten the nut up to the torque of 20 ± 2
Nm during installation.

3. Remove the starter.

Remove the two nuts of the starter.
● Tighten them up to the torque of 90 ± 1 Nm
during installation.

4. For installation, reverse the removal procedures.

2011 Boomday & Boarding Workshop manual