Starter Chevrolet Hi-Cube G30

DESCRIPTION

Enclosed housing starter has a solenoid pinion shaft (overrunning clutch) with entire mechanism enclosed within housing. Permanent Magnet Gear Reduction (PMGR) starter has small permanent magnets mounted inside the field frame. The magnets take place of current-carrying field coils mounted on iron pole pieces. Internal gear reduction is achieved through planetary gear assembly.

TROUBLE SHOOTING

Note. See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

SOLENOID WINDING TESTS

Tests are performed with all leads disconnected from solenoid. Complete tests in minimum amount of time to prevent solenoid from overheating.

Hold-In Winding

1. Connect an ammeter, voltmeter, carbon pile and battery into starter circuit. (Scheme 1) Using carbon pile, decrease battery voltage to 10 volts.
2. Refer to «SOLENOID HOLD-IN WINDING SPECIFICATIONS»(/chevrolet/hi-cube-g30/1985-1993/remont/starter/#starter) table for correct amperage reading. Higher reading indicates winding is shorted or grounded. Lower reading indicates excessive resistance.

Pull-In Winding

Using the solenoid test connections as identified by the dashed lines, decrease battery voltage to 5 volts. (Scheme 1) Refer to the SOLENOID PULL-IN WINDING SPECIFICATIONS table for correct amperage draw. Higher reading indicates winding is shorted or grounded. Lower reading indicates excessive resistance.

Note. To prevent overheating of pull-in winding, do not energize more than 15 seconds. Current draw will decrease as winding temperature increases.

Scheme 1

1. Connect a tachometer, ammeter and voltmeter into start circuit. (Scheme 2) Using carbon pile, adjust voltage to 10 volts and engage starter motor.
2. Read amperage draw and armature speed to ensure they are within specification. Refer to the «STARTER NO-LOAD SPECIFICATIONS»(/chevrolet/hi-cube-g30/1985-1993/remont/starter/#starter) table. If exact voltage cannot be obtained, raise voltage slightly higher. RPM should be slightly higher. DO NOT apply excessive voltage, as too much voltage may cause damage to armature.
3. Low free speed and high current draw indicates too much friction, shorted armature, or grounded armature or fields. Failure to operate with high current draw indicates a direct ground in terminal or fields, or frozen bearings.
4. Failure to operate with no current draw indicates an open field, open armature coils, broken brush springs, worn brushes, or high commutator insulation.
5. If no-load speed is low and there is low current draw, suspect high internal resistance due to poor connection, defective leads, or dirty commutator. A high free speed and high current draw usually indicates shorted fields.

Scheme 2

ARMATURE

Test armature for shorted coils with a growler. Check for grounded coils using a self-powered test light. Place one test lead on armature core or shaft, and other test lead on commutator. Light should not illuminate. If light illuminates, armature is grounded and should be replaced.

FIELD COILS (ENCLOSED HOUSING)

1. Using self-powered test light, place one test lead on field coil terminal strap, and touch other test lead to field coil brush lead (check series coils and shunt coils separately at appropriate terminals).
2. Light should illuminate. If light does not illuminate, coils are open. Check for grounds by placing one test lead on field armature strap, and touch other lead to armature core or shaft. If light illuminates, one or more coils are grounded.
3. On 5MT starter, coils cannot be replaced separately. The frame and field assembly must be replaced. On 10MT and 27MT a pole shoe spreader and pole shoe screwdriver can be used to replace a defective field coil.

Note. Shunt coil ground lead must be disconnected and all field terminals insulated from frame when making this test.

BRUSHES, SPRINGS & HOLDERS

Replace brushes if worn to 1/2 original length, oil-soaked or pitted. Check brush spring tension and replace springs if weak or distorted.

DRIVE & PINION

Pinion should turn freely in overrun direction and should not slip in drive direction. Check spring for correct tension and drive collar for wear (these parts can be removed for replacement by forcing collar toward clutch and removing lock ring from end of tube). Replace drive assembly if pinion teeth are worn, chipped, or cracked.

PINION CLEARANCE

1. Disconnect motor field coil connector and insulate it carefully. Connect a battery from solenoid switch terminal to solenoid frame. Momentarily flash a jumper lead from motor terminal to solenoid frame.
2. This shifts pinion into cranking position. Push pinion back toward commutator end to eliminate slack. Distance between pinion and pinion stop should be .010-.160" (.25-4.5 mm). Clearance is not adjustable. If clearance is not to specification, check for proper assembly.

Scheme 3

REMOVAL & INSTALLATION

Note. If shims are installed between starter and engine, note and record the arrangement for installation reference.

ALL MODELS EXCEPT "T" & "U" SERIES

1. Disconnect negative battery cable. Raise and support vehicle. Remove starter braces and shields (if equipped). Disconnect electrical wiring from starter solenoid.
2. Remove starter mounting bolts. Remove shims and note arrangement for reassembly. Remove starter. To install, reverse removal procedure. Ensure shims are installed in original location. Tighten bolts or nuts to specifications. See «TORQUE SPECIFICATIONS»(/chevrolet/hi-cube-g30/1985-1993/remont/starter/#starter__torque-specifications) at end of article.

"T" SERIES

1. Disconnect negative battery cable. Raise and support vehicle. Disconnect electrical wiring from starter solenoid. Remove mounting bracket and wiring from brush end of starter. Remove skid plate. Remove 2 brake line-to-crossmember brackets.
2. Remove 6 crossmember bolts and remove crossmember. Remove transmission cooler line-to-flywheel housing bracket. Remove brace rod to flywheel housing. Remove lower flywheel housing cover (if necessary).
3. Remove starter bolts. Note location and number of shims for reassembly. Remove starter. To install, reverse removal procedure. Tighten bolts and nuts to specifications.

"U" SERIES

1. Disconnect negative battery cable. Raise and support vehicle. Remove nut from A/C bracket. Remove engine bracket nut and bracket. Place drain pan under oil pan. Remove oil pressure sending unit. Remove oil filter.
2. Disconnect electrical wiring from starter. Remove starter bolts. Note location and number of shims for reassembly. Remove starter. To install, reverse removal procedure. Tighten bolts and nuts to specifications.

DISASSEMBLY & REASSEMBLY

Overhaul information is not available. Refer to the figures for disassembly and reassembly reference. (Scheme 4)and (Scheme 5).

Scheme 4

Scheme 5

CLEANING

Clean all parts with a clean cloth. DO NOT clean armature, field coils, or drive assembly in any type of grease dissolving solvent as this will damage insulation and wash lubricant out of drive assembly.

SOLENOID HOLD-IN WINDING SPECIFICATIONS

SOLENOID PULL-IN WINDING SPECIFICATIONS

STARTER NO-LOAD SPECIFICATIONS

TORQUE SPECIFICATIONS

STARTER TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• SOLENOID HOLD-IN WINDING SPECIFICATIONS
• TORQUE SPECIFICATIONS