DESCRIPTION
Starter is a brush-type, series-wound electric motor with an overrunning clutch (drive assembly). Field frame is enclosed by commutator end frame and drive bushing and carries pole shoes and field coils. A spline armature shaft drive end carries drive assembly.
STARTER LOAD (LOCK) TEST
With starter on bench, lock starter drive pinion. Voltmeter and ammeter readings should be within specification. See STARTER LOAD (LOCK) TEST SPECIFICATIONS table.
| Application | Volts | Amps | |
|---|---|---|---|
| Bosch | |||
| 0 001 218 0 | 3 | 720-950 | |
| 0 001 311 1 | 7.4 | 480-560 | |
| " | 6.5 | 410-490 | |
| 0 001 362 | 4.5 | 700-880 | |
| 0 001 108 | 4.5 | 625-800 | |
| Hitachi | |||
| S 114-232 | 6 | 650 | |
| S 13-91 | 8.8 | 300 | |
| " | 3 | 880 | |
STARTER LOAD (LOCK) TEST SPECIFICATIONS
STARTER NO LOAD TEST
With starter on bench, operate starter and check ammeter, voltage, and RPM. Readings should be within specification. See STARTER NO LOAD TEST SPECIFICATIONS table.
| Application | Volts | Amps. | RPM | |
|---|---|---|---|---|
| Bosch | ||||
| 0 001 218 0 | 10.5 | 95 | 4200 | |
| 0 001 311 1 | 11.5 | 70 | 7500 | |
| 0 001 362 | 11.5 | 95 | 6500 | |
| 0 001 108 | 11.5 | 75 | 2900 | |
| Hitachi | ||||
| S 114-232 | 12 | 60 | 7000 | |
| S 13-91 | 11 | 140 | 3900 | |
STARTER NO LOAD TEST SPECIFICATIONS
SOLENOID TEST
Connect battery negative lead to starter solenoid terminal "M". Connect battery positive lead to solenoid terminal No. 50. (Scheme 2) If plunger does not extend firmly, replace solenoid.
Scheme 1
TROUBLE SHOOTING
| Problem & Possible Cause | Action | |
|---|---|---|
| No Start Condition | ||
| Dead Battery | Check/Replace Battery | |
| Bad Cable Connections | Clean/Replace Cables | |
| Ignition Switch/Circuit Fault | Check Switch/Circuit | |
| Charging System Warning Light Stays On | ||
| Loose/Worn Alternator Belt | Tighten/Replace Belt | |
| Loose Alternator Connections | Check/Repair Connections | |
| Warning Light Wiring | Check/Repair Wiring | |
| Faulty Stator/Diodes | Test/Repair Alternator | |
| Faulty Voltage Regulator | Test/Repair Regulator | |
| Warning Light Off With Ignition Switch On | ||
| Blown Fuse | Check/Replace Fuse | |
| Faulty Alternator | Test Alternator | |
| Bad Warning Light Bulb | Test/Replace Bulb | |
| Warning Light On With Ignition Switch Off | ||
| Alternator Wiring Short | Check/Repair Wiring | |
| Faulty Rectifier Bridge | Test/Repair Alternator | |
| Ammeter Indicates Discharge | ||
| Loose/Worn Alternator Belt | Tighten/Replace Belt | |
| Loose Alternator Connections | Check/Repair Connections | |
| Faulty Ammeter | Test/Replace Ammeter | |
| NOISY Defective Battery | Replace Battery | |
| Defective Alternator | Test/Repair Alternator | |
| Defective Regulator | Test/Repair Regulator | |
CHARGING SYSTEM TROUBLE SHOOTING
OVERHAUL
Note. For starter overhaul (Scheme 2)-5. View of Bosch starter (0 001 218 0) is not available from manufacturer.
Scheme 2
Scheme 3
Scheme 4
Scheme 5
STARTER SPECIFICATIONS
| Application | Specification | |
|---|---|---|
| Armature Core Runout | ||
| Bosch (0 001 218 0) | .0019" (.050 mm) | |
| Bosch (0 001 311) | .002" (.05 mm) | |
| Bosch (0 001 362) | .002" (.05 mm) | |
| Bosch (0 001 108) | .002" (.05 mm) | |
| Hitachi (S 114-232, S 13-91) | .002" (.05 mm) | |
| Armature End Play | ||
| Bosch (0 001 218 0) | .0118-.023" (.300-.60 mm) | |
| Bosch (0 001 311) | .004-.012" (.10-.30 mm) | |
| Bosch (0 001 362) | .004-.012" (.10-.30 mm) | |
| Bosch (0 001 108) | .004-.012" (.10-.30 mm) | |
| Hitachi (S 114-232, S 13-91) | .0012-.039" (.03-.10 mm) | |
| Carbon Brush Minimum Length | ||
| Bosch (0 001 218 0) | .27" (7 mm) | |
| Bosch (0 001 311) | .500" (13 mm) | |
| Bosch (0 001 362) | .33" (8.5 mm) | |
| Bosch (0 001 108) | .500" (13 mm) | |
| Hitachi (S 114-232, S 13-91) | .44" (11 mm) | |
| Cold Cranking Test Voltage | ||
| Bosch (0 001 218 0) | 10.5 | |
| Bosch (0 001 311) | 11.5 | |
| Bosch (0 001 362) | 11.5 | |
| Bosch (0 001 108) | 11.5 | |
| Hitachi (S 114-232, S 13-91) | 12.0 | |
| Commutator Diameter | ||
| Bosch (0 001 218 0) | 1.30" (33.5 mm) | |
| Bosch (0 001 311) | 1.30" (33.5 mm) | |
| Bosch (0 001 362) | 1.60" (42.5 mm) | |
| Bosch (0 001 108) | 1.60" (42.5 mm) | |
| Hitachi (S 114-232, S 13-91) | 1.5" (39 mm) | |
| Commutator Runout | ||
| Bosch (0 001 218 0) | .0004" (.010 mm) | |
| Bosch (0 001 311) | .002" (.05 mm) | |
| Bosch (0 001 362) | .002" (.05 mm) | |
| Bosch (0 001 108) | .002" (.05 mm) | |
| Hitachi (S 114-232, S 13-91) | .002" (.05 mm) | |
STARTER SPECIFICATIONS
See also:
• STARTER LOAD (LOCK) TEST SPECIFICATIONS