Scribd Logo
Upload

Welcome to Scribd!

  • 33 views

    Starter Assy (1.3Kw) (1Az-Fe) : Overhaul

    Uploaded by

    Henry Silva
    This document provides instructions for overhauling a starter assembly. It describes removing parts like the commutator end frame, yoke assembly, armature plate and planetary gear. It then details inspecting components like the armature, commutator end frame and repair service starter kit. Specific checks include continuity tests and measuring dimensions. The instructions conclude by describing reinstallation of the planetary gear and armature plate.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Starter Assy (1.3Kw) (1Az-Fe) : Overhaul

    Uploaded by

    Henry Silva
    33 views6 pages
    This document provides instructions for overhauling a starter assembly. It describes removing parts like the commutator end frame, yoke assembly, armature plate and planetary gear. It then details inspecting components like the armature, commutator end frame and repair service starter kit. Specific checks include continuity tests and measuring dimensions. The instructions conclude by describing reinstallation of the planetary gear and armature plate.

    Original Title

    m_19_0009

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides instructions for overhauling a starter assembly. It describes removing parts like the commutator end frame, yoke assembly, armature plate and planetary gear. It then details inspecting components like the armature, commutator end frame and repair service starter kit. Specific checks include continuity tests and measuring dimensions. The instructions conclude by describing reinstallation of the planetary gear and armature plate.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    33 views6 pages

    Starter Assy (1.3Kw) (1Az-Fe) : Overhaul

    Uploaded by

    Henry Silva
    This document provides instructions for overhauling a starter assembly. It describes removing parts like the commutator end frame, yoke assembly, armature plate and planetary gear. It then details inspecting components like the armature, commutator end frame and repair service starter kit. Specific checks include continuity tests and measuring dimensions. The instructions conclude by describing reinstallation of the planetary gear and armature plate.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    19–9

    STARTING & CHARGING – STARTER ASSY(1.3KW) (1AZ–FE)

    STARTER ASSY(1.3KW) (1AZ–FE)


    1906L–01

    OVERHAUL

    1. REMOVE REPAIR SERVICE STARTER KIT

    (a) Remove the nut, and disconnect the lead wire from the re-
    pair service starter kit.

    A57559

    (b) Remove the 2 screws holding the repair service starter kit
    to the starter housing.
    (c) Remove the repair service starter kit.
    (d) Remove the return spring and plunger.

    A57560

    2. REMOVE STARTER COMMUTATOR END FRAME COVER

    (a) Using a screwdriver, remove the cover.

    3. REMOVE STARTER COMMUTATOR END FRAME


    ASSY

    (a) Using snap ring pliers, remove the snap ring and plate
    washer.

    A58582

    (b) Remove the 2 through bolts, and pull out the starter yoke
    assy together with the commutator end frame assy.
    4. REMOVE STARTER YOKE ASSY

    (a) Remove the starter armature assy from starter yoke assy.

    A57561

    1AZ–FE ENGINE REPAIR MANUAL (RM865E)


    19–10
    STARTING & CHARGING – STARTER ASSY(1.3KW) (1AZ–FE)

    5. REMOVE STARTER ARMATURE PLATE

    6. REMOVE PLANET GEAR

    (a) Remove the 3 planetary gears.

    A58370

    7. INSPECT STARTER ARMATURE ASSY


    Continuity

    (a) Check the commutator for open circuit.


    (1) Using an ohmmeter, check that there is continuity
    between the segments of the commutator.
    If there is no continuity between any segments, replace the ar-
    mature.

    A58372

    No Continuity (b) Check the commutator for ground.


    (1) Using an ohmmeter, check that there is no continu-
    ity between the commutator and armature coil core.
    If there is continuity, replace the armature.

    A58373

    (c) Check the commutator for dirty and burn on surface.


    If the surface is dirty or burnt, correct it with sandpaper (No.400)
    or a lathe.
    (d) Check for the commutator circuit runout.
    (1) Place the commutator on V–blocks.
    (2) Using a dial indicator, measure the circle runout.
    Maximum circle runout: 0.05 mm (0.0020 in.)
    If the circle runout is greater than maximum, replace the arma-
    A58371 ture.

    1AZ–FE ENGINE REPAIR MANUAL (RM865E)


    19–11
    STARTING & CHARGING – STARTER ASSY(1.3KW) (1AZ–FE)

    (e) Using vernier calipers, measure the commutator length.


    Standard length: 3.3 mm (0.1299 in.)
    Maximum length: 4.0 mm ( 0.1575 in.)
    If the length is greater than maximum, replace the armature.
    Length

    A58584

    8. INSPECT STARTER COMMUTATOR END FRAME


    No Continuity
    ASSY

    (a) Check the brush holder.


    (1) Using an ohmmeter, check that there is no continu-
    ity between the positive (+) and negative (–) brush
    holders.
    If the there is continuity repair or replace the starter commutator
    A58583 end frame assy.

    (b) Using vernier calipers, measure the brush holder length.


    Standard length: 9.0 mm (0.3543 in.)
    Maximum length: 4.0 mm ( 0.0787 in.)
    If the length is greater than maximum, replace the starter com-
    Length
    mutator end frame assy.
    9. INSPECT MOTOR TERMINAL STARTER KIT

    (a) Check the gear teeth on the planetary gear, internal gear
    A56443 and starter clutch for wear or damage.
    If the gear is damaged, replace it.
    If damaged, replace the gear or clutch assembly. If damaged,
    also check the drive plate ring gear for wear or damage.

    (b) Check the starter clutch.


    Free
    (1) 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.
    If necessary, replace the starter clutch.

    Lock
    A58585

    1AZ–FE ENGINE REPAIR MANUAL (RM865E)


    19–12
    STARTING & CHARGING – STARTER ASSY(1.3KW) (1AZ–FE)

    10. INSPECT REPAIR SERVICE STARTER KIT

    (a) Check the plunger.


    (1) Push in the plunger and check that it returns quickly
    to its original position.
    If necessary, replace the repair service starter kit.

    A58586

    (b) Check the pull–in coil for open circuit.


    Terminal C (1) Using an ohmmeter, check that there is continuity
    between terminals 50 and C.
    If there is no continuity, replace the repair service starter kit.

    Terminal 50
    Continuity

    A58375

    (c) Check the hold–in coil for open circuit.


    (1) Using an ohmmeter, check that there is continuity
    between terminal 50 and the switch body.
    If there is no continuity, replace the repair service kit.

    Terminal 50 Continuity

    A58376

    11. INSTALL PLANET GEAR

    (a) Apply grease to the planetary gears and pin parts of the
    planetary shaft.
    (b) Install the 3 planetary gears.
    (c) Align the cutout of the plate with the protrusion inside the
    shock absorber.

    A58370

    12. INSTALL STARTER ARMATURE PLATE

    (a) Apply grease to the planetary gears and pin parts of the
    planetary shaft.
    (b) Align the cutout of the plate with the protrusion inside the
    shock absorber, and install the plate.

    A58808

    1AZ–FE ENGINE REPAIR MANUAL (RM865E)


    19–13
    STARTING & CHARGING – STARTER ASSY(1.3KW) (1AZ–FE)

    13. INSTALL STARTER ARMATURE ASSY

    (a) Apply grease to the washer plate and armature shaft.


    (b) Install the armature shaft to the starter commutator end frame assy.
    (c) Using snap ring pliers, install the plate washer and new snap ring.

    (d) Using vernier calipers, mesure the snap ring.


    Length Maximum length: 5.0 mm ( 0.1969 in.)
    If the length is greater than maximum, replace the new snap
    ring.

    A58810

    14. INSTALL STARTER COMMUTATOR END FRAME COVER

    15. INSTALL STARTER YOKE ASSY

    (a) Align the starter commutator rubber end frame with the
    cutout of starter yoke.
    (b) Install starter yoke assy to starter commutator end frame.

    A58587

    16. INSTALL STARTER COMMUTATOR END FRAME


    ASSY

    (a) Align the starer yoke assy with the cutout of motor termi-
    nal starter kit.

    A58806

    1AZ–FE ENGINE REPAIR MANUAL (RM865E)


    19–14
    STARTING & CHARGING – STARTER ASSY(1.3KW) (1AZ–FE)

    (b) Install the starter yoke assy with the 2 through bolts.
    Torque: 6.0 Nm (61 kgfcm, 52 in.lbf)

    A57561

    17. INSTALL REPAIR SERVICE STARTER KIT

    (a) Apply grease to the plunger and hook.


    (b) Hang the plunger hook of the repair service starter kit to
    the drive lever.
    (c) Install the plunger and return spring.
    (d) Install the repair service starter kit with the 2 screws.
    Torque: 7.5 Nm (80 kgfcm, 69 in.lbf)
    A58807 (e) Apply grease to the nut of the lead wire.

    (f) Connect the lead wire to the terminal with the nut.
    Torque: 6.5 Nm (66 kgfcm, 58 in.lbf)

    A57559

    1AZ–FE ENGINE REPAIR MANUAL (RM865E)

    You might also like