Clark January 2nd, 2017
Voice Mail: “Hi Clark, it’s (name withheld). I was out sailing today with my daughter and we had an electrical fire on the new starter you installed. Because of the fire we lost the engine and hit the south tower on the Golden Gate Bridge, called the Coast Guard, and had to be towed back to our berth. When I opened the engine compartment there were six inch flames rising from the starter, but I was able to blow them out. I don’t know where that leaves us, but I’d sure like to speak with you.”
Not what a marine electrician wants to hear. After my initial panic, I reflected that this was a basic R&R (remove and replace) of an old starter for a new one. I’d tested it several times, by cranking and starting the engine, and all seemed well. Various scenarios flew through my mind – defective starter, defective solenoid, some sort of shorted wire, stuck solenoid or stuck starter button, or, eh gads, installer error. I called the owner, who was very understanding, and was back on his boat the next day. If you look at the photo above, all the insulation on all the wires leading to the starter is fried, and was burning until he blew it out.
After an initial check, I called the owner and told him that no matter whose fault it was, the damage was probably less than the deductible on his insurance, and that I might as well remove the starter and start the replacement process. He agreed. I pulled the starter and found it well-burnt, and the solenoid completely melted, with both of the studs loose. The main linkage between the solenoid and the starter motor had acted as a fuse, melted through, and ended the fireworks:
I took it back to the starter store, where they were very understanding and agreed to replace it under warranty, but also opined that something had probably got stuck, and that the starter probably wasn’t at fault. They noted some damage to the pinion gear, which I hadn’t noticed.
I installed the (second) new starter and continued my postmortem, finding very quickly that the cranking circuit was closed, as in, if I’d connected it the starter would have started cranking and wouldn’t have stopped. In this instance the boat had a starter button, separate from the key switch that energized the circuit, and the button was stuck:
Blessed sweet mother of God, it wasn’t my fault! I replaced the button, and the burnt wires, tested it all out, and all was well, for the second time. The owner was very understanding, ended up buying my wife and me a nice bottle of wine, and we decided we owed the guys at the starter store a case of beer.
There are some interesting things that happen with a stuck starter, one of which I didn’t know about. I knew about shorts, of course, and 98% of high amperage starter circuits aren’t protected with fuses, so these can be spectacular. And I knew about all kinds of unintended open circuits, as with bad motors, bad solenoids, etc. But I always thought that a stuck starter, as in, a starter that stays engaged after the engine starts, would just burn out its innards or strip its pinion gear.
Nay. A starter that stays engaged after an engine starts gets spun continually, much faster than its intended rotation speed, and actually becomes a generator, sending high current back into the electrical system. In most cases the batteries and cabling can handle the current, but the starter can’t. It gets very hot and finally burns up (from high current, rather than friction, overheated brushes, or whatever). Even in normal use a starter is an intermittent duty motor: With a recalcitrant engine you should only crank it for ten seconds or so at a time, then give it thirty seconds to cool off, and to allow the surface voltage to come back on the battery.
So, it is very important to make sure your starter disengages after your engine starts. In most cases this is obvious, as in your car, where if you held the key in the cranking position, or the starter got stuck this way, you’d hear it. But on many boats it’s not so obvious, since the engine panel might be some distance from the engine, and once started the engine noise can drown everything else out.
This boat happened to be a Catalina, and on Catalinas it’s standard to have a starter indicator light on the instrument panel. This is a good feature, and not common on other boats, but you’ve got to know it’s there:
On this boat it was there and still worked, but the owner didn’t know about it, plus it’s hard to see in daylight, and easy to miss in full combat mode (they were close to the south tower of the Golden Gate Bridge in an outgoing tide, after all). But also on Catalinas, and many other sailboats, the engine panel is exposed to the elements in the cockpit, sometimes gets kicked a lot, and generally takes a beating. In this case the starter button saw constant rain and spray, and eventually corroded and got stuck.
On my boat I’m standing right over the engine when I start it, so I’d hear it in a nanosecond if my starter got stuck, but not so on many boats. If it wouldn’t be obvious to you if your starter got stuck, you should consider an indicator light or buzzer. When you consider that it would result in not only a destroyed starter, but in not being able to start your engine again, and maybe an electrical fire, it’s worth some thought.