5L-E Starting. Starter Inspection

INSPECT STARTER ASSEMBLY
INSPECT MAGNET STARTER SWITCH ASSEMBLY
INSPECT BRUSH
INSPECT STARTER BRUSH HOLDER ASSEMBLY
INSPECT STARTER YOKE ASSEMBLY
INSPECT STARTER ARMATURE ASSEMBLY
INSPECT STARTER CLUTCH SUB-ASSEMBLY

Starter -- 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 became hot and cause injury.

NOTICE:

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

Mount the starter in a vise between aluminum plates.

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

Text in Illustration
*1	Terminal C
*2	Terminal 50

Perform a holding test.
1. Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains extended.
  Text in Illustration
  *1
  Terminal C
  If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

Text in Illustration
*1	Terminal C

Inspect the clutch pinion gear return.
1. Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward.
  If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

Perform an operation test without load.
1. Connect the field coil lead wire to terminal C.
  Torque:
  5.9 N*m{60 kgf*cm, 52 in.*lbf}
2. Connect the battery and an ammeter to the starter as shown in the illustration.
  Text in Illustration
  *1
  Terminal 30
  *2
  Terminal 50
3. Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current.
  Specified current:
  120 A or less at 11.5 V
  If the result is not as specified, inspect the starter assembly.
  HINT:
  Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

Text in Illustration
*1	Terminal 30
*2	Terminal 50

2. INSPECT MAGNET STARTER SWITCH ASSEMBLY

Inspect the pull-in coil.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  Terminal C - Terminal 50
  Always
  Below 1 Ω
  Text in Illustration
  *1
  Terminal C
  *2
  Terminal 50
  If the result is not as specified, replace the magnet starter switch assembly.

Text in Illustration
*1	Terminal C
*2	Terminal 50

Inspect the holding coil.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  Switch body - Terminal 50
  Always
  Below 2 Ω
  Text in Illustration
  *1
  Switch Body
  *2
  Terminal 50
  If the result is not as specified, replace the magnet starter switch assembly.

Text in Illustration
*1	Switch Body
*2	Terminal 50

3. INSPECT BRUSH

Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.5L-E Starting.Starting System.Starter Inspection

Using a vernier caliper, measure the brush length.
Text in Illustration
*1
Length
*a
Brush Holder Side
*b
Starter Yoke Side
Standard brush length:
16.5 mm (0.650 in.)
Minimum brush length:
9.0 mm (0.354 in.)
1. If the length is less than the minimum, replace the brush holder and starter yoke assembly.

Text in Illustration
*1	Length
*a	Brush Holder Side
*b	Starter Yoke Side

4. INSPECT STARTER BRUSH HOLDER ASSEMBLY

Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Tester Connection
Condition
Specified Condition
Positive (+) brush holder - Negative (-) brush holder
Always
10 kΩ or higher
1. If the result is not as specified, replace the starter brush holder assembly.

Check the brush spring load.
1. Take a pull scale reading immediately after the brush spring separates from the brush.
  Standard spring load:
  27 to 32 N (2.7 to 3.3 kgf, 6.0 to 7.3 lbf)
  Minimum spring load:
  18 N (2 kgf, 4.0 lbf)
  Text in Illustration
  *1
  Brush Spring
  *2
  Brush
  If the spring load is less than the minimum, replace the brush holder assembly.

Text in Illustration
*1	Brush Spring
*2	Brush

5. INSPECT STARTER YOKE ASSEMBLY

Inspect for an open circuit.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  Lead wire - Brush
  Always
  Below 1 Ω
  If the result is not as specified, replace the starter yoke assembly.

Inspect for a short circuit.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  Starter yoke body - Brush
  Always
  10 kΩ or higher
  If the result is not as specified, replace the starter yoke assembly.

6. INSPECT STARTER ARMATURE ASSEMBLY

Check the commutator for dirt and/or burns on the surface.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. Replace the armature if necessary.

Inspect the commutator for an open circuit.
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
  Text in Illustration
  *1
  Segment
  If the result is not as specified, replace the starter armature assembly.

Text in Illustration
*1	Segment

Inspect the commutator for a short circuit.
1. Measure the resistance according to the value(s) in the table below.
  Standard Resistance:
  Tester Connection
  Condition
  Specified Condition
  Segment - Coil core
  Always
  10 kΩ or higher
  Text in Illustration
  *1
  Segment
  *2
  Coil Core
  If the result is not as specified, replace the starter armature assembly.

Text in Illustration
*1	Segment
*2	Coil Core

Inspect the commutator circle runout.
1. Place the armature on V-blocks.
2. Using a dial indicator, measure the circle runout.
  Maximum circle runout:
  0.05 mm (0.00197 in.)
  If the runout is more than the maximum, correct it with sandpaper (No. 400) or replace the starter armature assembly.

Using a vernier caliper, measure the commutator diameter.
Standard diameter:
35.0 mm (1.38 in.)
Minimum diameter:
34.0 mm (1.34 in.)
If the diameter is less than the minimum, replace the starter armature assembly.

Measure the undercut depth of the commutator.
Standard depth:
0.7 mm (0.0276 in.)
Minimum depth:
0.2 mm (0.00787 in.)
If the undercut depth is less than the minimum, correct it with a hacksaw blade.

Inspect the bearings.
1. Check that the bearing rotates smoothly.
  If the result is not as specified, replace the starter armature assembly.

7. INSPECT STARTER CLUTCH SUB-ASSEMBLY

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

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

Free

Lock
If the result is not as specified, replace the starter clutch sub-assembly.

Text in Illustration
	Free
	Lock

Turn the pinion gear by hand while applying inward force and check the movement of the bearing.
If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.

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

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