STARTER(for TMC Made Cold Area Specification Vehicles) INSPECTION

PROCEDURE

1. INSPECT STARTER ASSEMBLY

   Note

   Perform each of the following tests within 3 to 5 seconds.

   
   

   1. Perform pull-in test.

      
      

      1. Disconnect the field coil lead wire from terminal C.

      2. 

         Text in Illustration

         *1	Terminal C
         *2	Terminal 50
         *3	Body

         Connect the battery to the starter magnetic switch as shown in the illustration and check that the pinion gear is extended.

   2. 

      Text in Illustration

      *1	Terminal C
      *2	Terminal 50
      *3	Body

      Perform holding test.

      
      

      1. Check that the pinion gear does not return inward after the cable of terminal C is disconnected.

   3. 

      Text in Illustration

      *1	Terminal C
      *2	Terminal 50
      *3	Body

      Inspect the clutch pinion gear return.

      
      

      1. Move the pinion gear toward the armature.

   4. Perform the operation test without load.

      
      

      1. Connect the field coil lead wire to terminal C.

         Torque:

         9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      2. Clamp the starter in a vise.

      3. 

         Text in Illustration

         *1	Terminal 30
         *2	Terminal 50
         *3	Body

         Connect the battery and ammeter to the starter as shown in the illustration.

      4. Check that the ammeter indicates the specified current.

         Standard Current

         Tester Connection	Condition	Specified Condition
         Battery positive terminal - Terminal 30 - Terminal 50	11.5 V	Below 90 A

         If the result is not as specified, replace the starter assembly.

2. INSPECT STARTER ARMATURE ASSEMBLY

   

   
   

   1. Check the commutator for open circuits.

      
      

      1. Using an ohmmeter, check the resistance between the segments of the commutator.

         Text in Illustration

         *1	Commutator

         Standard Current

         Tester Connection	Condition	Specified Condition
         Segment - Segment	Always	Below 1 Ω

         If the result is not as specified, replace starter armature assembly.

   2. 

      Text in Illustration

      *1	Armature Coil Core
      *2	Commutator

      Check the commutator for ground.

      
      

      1. Using an ohmmeter, check the resistance between the commutator and armature core.

         Standard Current

         Tester Connection	Condition	Specified Condition
         Commutator - Armature coil core	Always	10 kΩ or higher

         If the result is not as specified, replace the starter armature assembly.

   3. Check the commutator for dirt and burns on the surface.

      If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

   4. 

      Check the commutator circumference runout.

      
      

      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the circumference runout.

         Maximum runout
         0.4 mm (0.0157 in.)

         If the runout is greater than the maximum, replace the starter armature assembly.

   5. 

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      28.0 mm (1.1024 in.)

      Minimum diameter
      27.0 mm (1.0630 in.)

      If the diameter is less then the minimum, replace the starter armature assembly.

   6. 

      Using a vernier calipers, measure the undercut depth of the commutator.

      Standard depth
      0.6 mm (0.0236 in.)

      Minimum depth
      0.2 mm (0.0079 in.)

      If the undercut depth is less then the minimum, adjust it with a hacksaw blade.

3. INSPECT STARTER YOKE ASSEMBLY

   

   Text in Illustration

   *1	Brush
   *2	Terminal C

   
   

   1. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection	Condition	Specified Condition
      Terminal C - Brush	Always	Below 1 Ω

      If the result is not as specified, replace the starter yoke assembly.

   2. 

      Text in Illustration

      *1	Brush
      *2	Starter Yoke

      Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection	Condition	Specified Condition
      Starter yoke - Brush	Always	10 kΩ or higher

      If the result is not as specified, replace the starter yoke assembly.

4. INSPECT BRUSH

   

   
   

   1. Using a vernier caliper, measure the brush length.

      Standard length
      14 mm (0.5511 in.)

      Minimum length
      9 mm (0.3543 in.)

      If the length is less than the minimum, replace the starter yoke assembly.

5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   

   
   

   1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

      Standard Resistance

      Tester Connection	Condition	Specified Condition
      Positive (+) - Negative (-)	Always	10 kΩ or higher

6. INSPECT STARTER CLUTCH SUB-ASSEMBLY

   

   Text in Illustration

   *a	Free
   *b	Lock

   
   

   1. Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

      If necessary, replace the starter clutch sub-assembly.

7. INSPECT MAGNET STARTER SWITCH ASSEMBLY

   

   
   

   1. Check the plunger.

      
      

      1. Push in the plunger and check that it returns quickly to its original position.

         If necessary, replace the magnet starter switch assembly.

   2. 

      Text in Illustration

      *1	Terminal C
      *2	Terminal 50

      Check the pull-in coil for an open circuit.

      
      

      1. Measure the resistance according to the value(s) in the table below.

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Terminal 50 - Terminal C	Always	Below 1 Ω

         If the result is not as specified, replace the magnet starter switch assembly.

   3. 

      Text in Illustration

      *1	Terminal 50

      Check whether the holding coil has an open circuit.

      
      

      1. Using an ohmmeter, check the resistance between terminal 50 and the switch body.

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Terminal 50 - Body	Always	Below 2 Ω

         If the result is not as specified, replace the magnet starter switch assembly.