Forklift Alternators and Starters

Forklift Starter and Alternator - The starter motor of today is normally either a series-parallel wound direct current electric motor which has a starter solenoid, which is similar to a relay mounted on it, or it can be a permanent-magnet composition. Once current from the starting battery is applied to the solenoid, basically via a key-operated switch, the solenoid engages a lever that pushes out the drive pinion that is situated on the driveshaft and meshes the pinion utilizing the starter ring gear which is seen on the flywheel of the engine.

As soon as the starter motor begins to turn, the solenoid closes the high-current contacts. Once the engine has started, the solenoid has a key operated switch which opens the spring assembly to pull the pinion gear away from the ring gear. This action causes the starter motor to stop. The starter's pinion is clutched to its driveshaft by an overrunning clutch. This permits the pinion to transmit drive in only a single direction. Drive is transmitted in this particular way through the pinion to the flywheel ring gear. The pinion remains engaged, like for instance as the operator fails to release the key as soon as the engine starts or if there is a short and the solenoid remains engaged. This actually causes the pinion to spin separately of its driveshaft.

The actions mentioned above would prevent the engine from driving the starter. This significant step stops the starter from spinning very fast that it will fly apart. Unless modifications were done, the sprag clutch arrangement will preclude using the starter as a generator if it was used in the hybrid scheme discussed prior. Normally an average starter motor is designed for intermittent use that will prevent it being utilized as a generator.

Hence, the electrical components are meant to function for more or less less than thirty seconds to avoid overheating. The overheating results from too slow dissipation of heat because of ohmic losses. The electrical parts are intended to save weight and cost. This is the reason the majority of owner's manuals for vehicles suggest the driver to pause for at least ten seconds right after each and every ten or fifteen seconds of cranking the engine, when trying to start an engine that does not turn over at once.

During the early part of the 1960s, this overrunning-clutch pinion arrangement was phased onto the market. Before that time, a Bendix drive was used. The Bendix system operates by placing the starter drive pinion on a helically cut driveshaft. When the starter motor starts spinning, the inertia of the drive pinion assembly enables it to ride forward on the helix, hence engaging with the ring gear. As soon as the engine starts, the backdrive caused from the ring gear allows the pinion to exceed the rotating speed of the starter. At this moment, the drive pinion is forced back down the helical shaft and thus out of mesh with the ring gear.

In the 1930s, an intermediate development between the Bendix drive was developed. The overrunning-clutch design which was made and introduced in the 1960s was the Bendix Folo-Thru drive. The Folo-Thru drive has a latching mechanism along with a set of flyweights in the body of the drive unit. This was better as the average Bendix drive used to disengage from the ring when the engine fired, even though it did not stay functioning.

Once the starter motor is engaged and starts turning, the drive unit is forced forward on the helical shaft by inertia. It then becomes latched into the engaged position. When the drive unit is spun at a speed higher than what is achieved by the starter motor itself, like for example it is backdriven by the running engine, and afterward the flyweights pull outward in a radial manner. This releases the latch and enables the overdriven drive unit to become spun out of engagement, thus unwanted starter disengagement can be avoided before a successful engine start.

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