1Gd-Ftv Starting. Starter (For 2.0 Kw Type) Inspection

INSPECT STARTER ASSEMBLY
INSPECT MAGNET STARTER SWITCH ASSEMBLY
INSPECT STARTER BRUSH HOLDER ASSEMBLY
INSPECT STARTER ARMATURE ASSEMBLY
INSPECT REPAIR SERVICE STARTER KIT

Starter (For 2.0 Kw Type) -- Inspection

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.

NOTICE:

These tests must be performed within 3 to 5 seconds to prevent the coil from burning out.

Mount the starter assembly in a vise between aluminum plates.

Perform a pull-in test.
1. Remove the nut and disconnect the lead wire from terminal C.
2. Connect the battery to the starter assembly as shown in the illustration. Check that the clutch pinion gear extends.
  Text in Illustration
  *a
  Terminal C
  *b
  Terminal 50
  
  Extends
  If the clutch pinion gear does not extend, replace the magnet starter switch assembly.

Text in Illustration
*a	Terminal C
*b	Terminal 50
	Extends

Perform a holding test.
1. Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the clutch pinion gear remains out.
  Text in Illustration
  
  Disconnect
  If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

Text in Illustration
	Disconnect

Inspect the clutch pinion gear return.
1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
  Text in Illustration
  
  Disconnect
  
  Return Inward
  If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

Text in Illustration
	Disconnect
	Return Inward

Perform an operation test without load.
1. Connect the lead wire to terminal C with the nut.
  Torque:
  10 N*m{102 kgf*cm, 7 ft.*lbf}
2. Connect the battery and an ammeter (AC/DC 400A probe) to the starter assembly as shown in the illustration.
  Standard current:
  150 A or less at 11.5 V
  Text in Illustration
  *a
  Terminal 30
  *b
  Terminal 50
  *c
  AC/DC 400A Probe
  If the result is not as specified, replace the starter assembly.

Text in Illustration
*a	Terminal 30
*b	Terminal 50
*c	AC/DC 400A Probe

2. INSPECT MAGNET STARTER SWITCH ASSEMBLY

Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

Push in the plunger and check that it returns quickly to its original position.
If the result is not as specified, replace the magnet starter switch assembly.

Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Starting.Starting System.Starter (For 2.0 Kw Type) Inspection

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
Terminal 50 - Switch Body
Below 2 Ω
Text in Illustration
*a
Terminal C
*b
Terminal 50
*c
Switch Body
If the result is not as specified, replace the magnet starter switch assembly.

Text in Illustration
*a	Terminal C
*b	Terminal 50
*c	Switch Body

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

Inspect the load of the brush spring.
1. Take a pull scale reading immediately after the brush spring separates from the brush.
  Standard spring load:
  22.3 to 27.3 N (2.3 to 2.8 kgf, 5.0 to 6.1 lbf)
  Minimum spring load:
  13.8 N (1.4 kgf, 3.1 lbf)
  If the load is less than the minimum, replace the starter brush holder assembly.

Check the resistance.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  A - B
  A - C
  B - D
  C - D
  Always
  10 kΩ or higher
  A - D
  B - C
  Below 1 Ω
  If the result is not as specified, replace the starter brush holder assembly.

Check the brush length.
1. Using a vernier caliper, measure the brush length.
  
  Text in Illustration
  *a
  Brush
  *b
  Spring
  *c
  Length
  -
  -
  Standard length:
  14.4 mm (0.567 in.)
  Minimum length (convex part):
  9.0 mm (0.354 in.)

Text in Illustration
*a	Brush	*b	Spring
*c	Length	-	-

4. INSPECT STARTER ARMATURE ASSEMBLY

Check the commutator surface for dirt and burns.
If the surface is dirty or burnt, replace the starter armature assembly.

Check the resistance.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  Segment - Segment
  Always
  Below 1 Ω
  Segment - Coil Core
  10 kΩ or higher
  Text in Illustration
  *a
  Segment
  *b
  Coil Core
  If the result is not as specified, replace the starter armature assembly.

Text in Illustration
*a	Segment
*b	Coil Core

Check the commutator for circle runout.
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the circle runout.
  Maximum runout:
  0.05 mm (0.00197 in.)
  If the runout is more than the maximum, replace the starter armature assembly.

Check the commutator.
1. Using a vernier caliper, measure the commutator diameter.
  Standard diameter (convex part):
  29.0 mm (1.14 in.)
  Minimum diameter (convex part):
  28.0 mm (1.10 in.)
  HINT:
  Be sure to measure the commutator diameter at the ridges.
  If the diameter is less than the minimum, replace the starter armature assembly.

Using a vernier caliper, measure the undercut depth of the commutator.
Standard undercut depth (convex part):
0.7 mm (0.0276 in.)
Minimum undercut depth (convex part):
0.4 mm (0.0157 in.)
HINT:
Be sure to measure the commutator diameter at the ridges.
If the undercut depth is less than the minimum, replace the starter armature assembly.

5. INSPECT REPAIR SERVICE STARTER KIT

Check the clutch pinion gear teeth for wear or damage.
If the clutch pinion gear teeth are damaged, replace the repair service starter kit and also inspect the flywheel ring gear for wear or damage.

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

Free

Lock
If the result is not as specified, replace the repair service starter kit.

Tester Connection	Condition	Specified Condition
Terminal 50 - Terminal C	Always	Below 1 Ω
Terminal 50 - Switch Body	Always	Below 2 Ω

Text in Illustration
	Free
	Lock