Isuzu Cars and Trucks 1981-1991

Battery and Starting System


The battery is the first link in the chain of mechanisms which work together to provide cranking of the engine. In most modern vehicles, the battery is a lead-acid electrochemical device consisting of six 2 volt (2V) subsections connected in series so the unit is capable of producing approximately 12V of electrical pressure. Each subsection (cell) consists of a series of positive and negative plates held a short distance apart in a solution of sulfuric acid and water. The two types of plates are of dissimilar metals. A chemical reaction takes place which produces current flow from the battery, when it's positive and negative terminals are connected to an electrical appliance such as a lamp or motor. The continued transfer of electrons would eventually convert the sulfuric acid in the electrolyte to water and make the two plates identical in chemical composition. As electrical energy is removed from the battery, it's voltage output tends to drop. Thus, measuring battery voltage and battery electrolyte composition are two ways of checking the ability of the unit to supply power. During the starting of the engine, electrical energy is removed from the battery. However, if the charging circuit is in good condition and the operating conditions are normal, the power removed from the battery will be replaced by the alternator which will force electrons back into the battery, reversing the normal flow and restoring the battery to it's original chemical state.

The battery and starting motor are linked by very heavy electrical cables designed to minimize resistance to the flow of current. Generally, the major power supply cable that leaves the battery goes directly to the starter, while other electrical system needs are supplied by a smaller cable. During the starter operation, power flows from the battery to the starter, then is grounded through the vehicle's frame and the battery's negative ground strap.

The starting motor is a specially designed, direct current electric motor capable of producing a very great amount of power for it's size. One thing that allows the motor to produce a great deal of power is it's tremendous rotating speed. It drives the engine through a tiny pinion gear (attached to the starter's armature), which drives the very large flywheel ring gear at a greatly reduced speed. Another factor allowing it to produce so much power is that only intermittent operation is required of it. Thus, little allowance for air circulation is required and the windings can be built into a very small space.

The starter solenoid is a magnetic device which employs the small current supplied by the starting switch circuit of the ignition switch. This magnetic action moves a plunger, which mechanically engages the starter and electrically closes the heavy switch which connects it to the battery. The starting switch circuit consists of the starting switch (contained within the ignition switch), a transmission neutral safety switch or clutch pedal switch and wiring necessary to connect these with the starter solenoid or relay.

The pinion (small gear) is mounted to a one-way drive clutch. This clutch is splined to the starter armature shaft. When the ignition switch is moved to the Start position, the solenoid plunger slides the pinion toward the flywheel ring rear via a collar and spring. If the teeth on the pinion and flywheel match properly, the pinion will engage the flywheel immediately. If the gear teeth butt one another, the spring will be compressed and will force the gears to mesh as soon as the starter turns far enough to allow them to do so. As the solenoid plunger reaches the end of its travel, it closes the contacts that connect the battery to the starter, then the engine is cranked.

As soon as the engine starts, the flywheel ring gear begins turning fast enough to drive the pinion at an extremely high rate of speed. At this point, the one-way clutch allows the pinion to spin faster than the starter shaft so that the starter will not operate at excessive speed(s). When the ignition switch is released from the starter position, the solenoid is de-energized, the spring (contained within the solenoid assembly) pulls the pinion out of mesh and interrupts the current flow to the starter.