STARTER 02 01 srm0106 PDF
STARTER 02 01 srm0106 PDF
STARTER 02 01 srm0106 PDF
DELCO
DELCO STARTERS USED ON HYSTER
LIFT TRUCKS
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Starter Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Description and Operation .................................................................................................................................. 1
Starter Repair ...................................................................................................................................................... 3
Remove ............................................................................................................................................................. 3
Disassemble ..................................................................................................................................................... 3
Clean ................................................................................................................................................................ 4
Assemble .......................................................................................................................................................... 4
Install ............................................................................................................................................................... 5
General Checks and Adjustments....................................................................................................................... 5
Troubleshooting.................................................................................................................................................... 8
HYSTER
APPROVED
PARTS
2200 SRM 106 Description and Operation
General
This section has a description and the service proce- NOTE: Information on starters manufactured out-
dures for the starter, the solenoid, and the solenoid side the United States is in the SRM sections for lift
switch. trucks that use those starters.
Description and Operation
The positive battery cable is connected to the "BAT" the START position. The solenoid switch closes the
terminal on the starter solenoid. See Figure 1, Fig- contacts that energize the solenoid of the starter.
ure 2, and Figure 3. Battery voltage is not applied
to the starter until the ignition switch, the solenoid
switch (diesel units only), and the transmission neu-
tral switch close. The solenoid moves the linkage and
the drive clutch to engage the starter pinion with the
ring gear. At the end of its stroke, the plunger of the
solenoid closes the main solenoid contacts. The cur-
rent then flows to the starter windings. The starter
pinion turns the flywheel ring gear.
The starter is a linkage type with a drive clutch
mechanism. The solenoid is fastened to the starter.
The pinion is part of the drive clutch. The drive
clutch is moved on the armature shaft by the linkage
connected to the solenoid plunger. When the engine
starts, the pinion is still engaged with the ring gear.
The pinion turns freely when driven by the ring gear.
When the key is released, the pinion moves away
from the ring gear and the starter circuit opens.
When energized, the starter solenoid moves the link-
age, closes the contacts, and energizes the starter.
The solenoid has two windings. When energized, one
winding pulls the solenoid plunger to close the con-
tacts. The other winding holds the plunger in that
position. The current for the winding that pulls must
flow through the starter brushes to a ground. The
ground for the winding that holds the plunger in po-
sition is the solenoid frame. When the key switch
is closed, the current flows through both windings.
When the plunger moves the linkage, the contacts
close, which causes the winding that pulls to have
a short circuit. That winding is deenergized, but
the current continues to flow through the winding 1. BATTERY
that holds the plunger. The winding that holds the 2. IGNITION SWITCH
3. NEUTRAL START SWITCH (CAN CONSIST OF
plunger is deenergized when the key switch is re- SEVERAL RELAYS)
leased. 4. STARTER SOLENOID
5. STARTER
The solenoid switch is a relay that is used in the 6. SOLENOID SWITCH (NOT ON ALL UNITS)
diesel starter circuit. The solenoid for the starter of
the diesel engine uses more current than does the so- Figure 1. Starting Circuit
lenoid for the starter of the gasoline engine. The so-
lenoid switch is actuated by turning the key switch to
1
Description and Operation 2200 SRM 106
666#
7///.//£
HM080020
Figure 2. Starter
2
2200 SRM 106 Starter Repair
HM080021
Starter Repair
REMOVE 1. Install labels on the starter wires and cables for
correct connection during installation. Discon-
NOTE: If the starter does not operate correctly, refer nect the wires and the cables to the starter.
to General Checks and Adjustments before beginning
any repair procedures. 2. Remove the capscrews that hold the starter to
the flywheel housing.
WARNING 3. If used, remove the spacers and the gaskets.
Always disconnect the battery ground cable be-
fore making repairs to prevent possible dam- 4. Remove the starter from the lift truck.
age and injury. Install a tag on the battery ter-
minal so that no one connects the cable on the DISASSEMBLE
terminal.
1. Remove the screw and lock washer connecting
the field coil strap to the "M" terminal of the so-
lenoid. See Figure 2 and Figure 4.
3
Starter Repair 2200 SRM 106
2. Remove the two screws that hold the solenoid to 4. Install the shaft assembly in the drive end hous-
the drive end housing. Turn the solenoid 1/4 turn ing. Make sure the linkage is engaged in the
and remove it from the starter. drive clutch. Install and tighten the four screws
for the bearing plate.
3. Remove the two bolts that hold the commutator
end frame and the field frame to the drive hous- 5. Install the field frame over the armature. Re-
ing. Make alignment marks on the end frame tract the brush springs and slide the brushes on
and on the field frame for easy assembly. Pull the the commutator.
end frame from the field frame. On some models
it is necessary to pull the brushes from the hold- 6. Align the marks and install the thrust washer
ers. Remove the field frame. and the commutator end frame. Install and
tighten the through bolts.
4. If used, remove the four screws holding the cen-
ter bearing plate to the drive end housing. 7. Make sure the solenoid cover is not damaged. In-
stall the plunger spring and the solenoid. Install
5. Remove the armature from the drive end hous- and tighten the solenoid mount screws. Connect
ing. Tilt the armature to disengage the linkage the field coil strap to the "M" terminal with the
from the drive clutch. On some models it is nec- screw and lock washer.
essary to remove the linkage before removing the
armature.
CLEAN
CAUTION
Never use solvent on the drive clutch, arma-
ture, or field windings. Use a cloth to clean
these parts.
ASSEMBLE
1. Install a new seal in the center bearing plate. See
Figure 2 and Figure 5.
HM080022
4
2200 SRM 106 General Checks and Adjustments
INSTALL
1. Make sure the surfaces of the flywheel housing,
the spacer, and the starter are clean and smooth.
Install the gaskets or use a sealant (Hyster part
number 264159) that forms a gasket between
metal parts.
4. Connect the ground cable to the battery. 1. THRUST COLLAR 3. SNAP RING
2. RETAINER
c. Inspect all the connections to the battery, b. Check the pinion gear (on the drive clutch)
starter solenoid, key switch, and neutral for damage. The pinion must turn in one
start switch. Clean and tighten, if necessary. direction and lock in the other. Replace the
complete assembly if any part has damage.
d. Check the resistance of the connections with
a voltmeter. See Figure 7. Each connection c. Check the clearance of the armature bush-
must not have more than a 0.5 volt loss for ings.
a 12-volt system or 1.0 loss for a 24-volt sys-
tem. d. Check for cracks in the drive end housing.
5
General Checks and Adjustments 2200 SRM 106
HM080024
3. When the starter is disassembled, make the fol- g. Check that the brush springs have enough
lowing checks: tension.
a. Check that the seals are good on units that h. Check the brushes for wear. The brushes
use an oil clutch or a powershift transmis- must be at least one half the length of new
sion. ones.
6
2200 SRM 106 General Checks and Adjustments
HM080027
HM080028
1. INSULATED 2. GROUND BRUSH
BRUSH
1. FIELD COIL STRAP 2. GROUND BRUSH
Figure 9. Field Coil Ground Test
Figure 10. Field Coil Open Circuit Test
CAUTION
Remove only enough metal to clean the surface
on the commutators with the plastic insulation.
See Figure 11. Do not cut the insulation be-
tween the bars on the commutator. The plastic
material is necessary to support the bars. The
plastic material is softer than the bars and will
wear at the same rate.
7
Troubleshooting 2200 SRM 106
Troubleshooting
The starter will not turn; no Battery is discharged or has damage. Recharge or replace battery.
noise at the solenoid.
The starter will not turn; the The battery is discharged or has Recharge or replace battery.
solenoid makes noise. damage.
The cable connections have too much Clean or install new parts.
resistance.
The starter will not turn. The control circuit has a short cir- Check wiring for damage and repair.
The ammeter indicates a cuit.
large current draw.
The pinion is not engaging the ring Check the clutch on the starter for
gear. damage and repair.
8
2200 SRM 106 Troubleshooting
The cables get too hot. The battery is discharged or has Recharge or replace the battery.
damage.
The pinion is not disengaging from Check the clutch on the starter for
the ring gear. damage and repair.
The starter turns too slowly. The battery is discharged or has Recharge or replace battery.
damage.
The cable connections have too much Repair or install new parts.
resistance.
The starter turns, but the The drive clutch has damage. Install new parts.
engine will not turn.
The pinion is not disengaging from Check the clutch on the starter for
the ring gear. damage and repair.
9
Troubleshooting 2200 SRM 106
The starter makes too much The solenoid has damage. Replace solenoid.
noise.
10
Hyster Easy Language Program
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