СТАРТЕР (для моделей мощностью 1,6 кВт) ПРОВЕРКА


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.

    Note

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


    1. Perform a pull-in test.


      1. Disconnect the lead wire from terminal C.

      2. A01CBSYE02
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal C

        Connect the battery to the magnet starter switch assembly as shown in the illustration and check that the pinion gear moves outward.

        If the clutch pinion gear does not move, replace the magnet starter switch assembly.

    2. Perform a hold-in test.


      1. A01CC5KE02
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal C

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

        If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

    3. Inspect the clutch pinion gear return.


      1. A01CDJ6E02
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal C

        Disconnect the negative (-) lead from the switch body.

        Check that the pinion gear moves inward.

        If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

    4. Perform an operation test without load.


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. A01CFQAE02
        Text in Illustration
        *1 Body
        *2 Terminal 50
        *3 Terminal 30

        Clamp the starter in a vise.

        Note

        Ensure that the starter is secured firmly in the vise to prevent it from falling out.

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

        Note

        Do not allow any lead to get caught as the pinion gear operates.

      4. Check that the starter operates smoothly and steadily with the clutch pinion gear extended.

        Check that the ammeter indicates the specified current.

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

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01CEF4

      Check the plunger.


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

        If necessary, replace the magnet starter switch assembly.

    2. A01CDNUE02
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C

      Inspect the resistance of the pull-in coil.


      1. Using an ohmmeter, measure the resistance between terminal 50 and terminal C.

        Standard resistance
        Below 1 Ω

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

    3. A01CFG9E02
      Text in Illustration
      *1 Switch Body
      *2 Terminal 50

      Inspect the resistance of the hold-in coil.


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

        Standard resistance
        Below 2 Ω

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Remove the claws of the springs, then remove the 4 brushes.

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

      A01CCQ0E04
      Text in Illustration
      *1 Brush *2 Spring
      *3 Length - -
      Standard length
      14.4 mm (0.567 in.)
      Minimum length
      9.0 mm (0.354 in.)

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

    3. A01CGF6E05

      Check the brush holder.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        A - B Always 10 kΩ or higher
        A - C Always 10 kΩ or higher
        A - D Always Below 1 Ω
        B - C Always Below 1 Ω
        B - D Always 10 kΩ or higher
        C - D Always 10 kΩ or higher

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

  4. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for contamination and burns on its surface.

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

    2. A01CE46E06
      Text in Illustration
      *1 Commutator

      Check if the commutator has an open circuit.


      1. Measure the resistance between the segments of the commutator.

        Standard resistance
        Below 1 Ω

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

    3. A01CE4LE08
      Text in Illustration
      *1 Commutator
      *2 Armature Coil Core

      Check if the commutator is grounded.


      1. Measure the resistance between the commutator and armature coil core.

        Standard resistance
        10 kΩ or higher

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

    4. A01CB14E02
      Text in Illustration
      *1 Armature Shaft

      Check the commutator circle for runout.


      1. Place the shaft of the starter armature assembly on V-blocks.

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

        Standard runout
        0.02 mm (0.000787 in.)
        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. A01CBP8E02

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29.0 mm (1.14 in.)
      Minimum diameter
      28.0 mm (1.10 in.)

      If the diameter is less than the minimum, replace the armature assembly.

    6. A01CCCT

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard undercut depth
      0.7 mm (0.0276 in.)
      Minimum undercut depth
      0.2 mm (0.00787 in.)

      If the diameter is less than the minimum, replace the armature assembly.

  5. INSPECT MOTOR TERMINAL STARTER KIT


    1. Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

      If necessary, replace the motor terminal starter kit.

      Also check the planetary gears for wear or damage.

    2. A01CDWME10
      Text in Illustration
      *1 Lock
      *2 Free

      Inspect the starter clutch.


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

        If necessary, replace the motor terminal starter kit.