Service Manual

38
GTS 200
Electric Starter
Electric Starter
Contents
General Information 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T roubleshooting 12 V olt Starting System 38 . . . . . . . . . . . . . .
T est Equipment 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Multimeter 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Shunt 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter T est Bracket 39 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Equipment 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling Instructions 40 . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Battery 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Battery T erminal 40 . . . . . . . . . . . . . . . . . . . . . .
Starter 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Starter Motor Drive and Clutch 41 . . . . . . . . . . . .
W iring Diagrams 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check 12 V olt Starter Motor 41 . . . . . . . . . . . . . . . . . . . .
Starter Motor Specifications 41 . . . . . . . . . . . . . . . . . . . .
T roubleshoot Starter Motor 41 . . . . . . . . . . . . . . . . . . . . .
Check Brake Switch 42 . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Brake Switch W iring 42 . . . . . . . . . . . . . . . . . . . .
Disassemble Starter Motor 42 . . . . . . . . . . . . . . . . . . . . .
Clean and Inspect Starter 43 . . . . . . . . . . . . . . . . . . . . . . .
Assemble Starter Motor 43 . . . . . . . . . . . . . . . . . . . . . . .
Install Starter 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information
The T oro GTS 200 electric start system consists of a 12V
battery , starter motor , switch, and alternator . In addition, the
1999 and newer models have a brake switch and a fuse for the
char ging system. A separate trickle char ger is also standard.
The starter motor uses a gear type engagement method,
similar to an automobile starter . The starter motor shaft drives
a pinion gear into engagement with a ring gear attached to the
engine flywheel and cranks the engine. See Fig. 84 for
location of starter motor .
1
2
Fig. 84 – Electric Start Engine
1. Connector 2. 12 volt starter motor
When the starter switch is activated, the battery supplies
power to the starter motor , cranking the engine. On 1999 and
newer models, the brake switch must also be activated to
power the starter . When the engine is running, the alternator
rechar ges the battery . It will take approximately 15–20
minutes of running to replace the battery char ge used to start
the engine one time.
Should the battery need additional rechar ging, the trickle
char ger is plugged into a 120 volt AC household outlet, and
then connected to battery . The battery will be fully char ged
within a 72 hour period. It is not recommended that battery be
rechar ged if temperatures are below 40 ° F (4 ° C). For best
results, char ge battery within temperature limits of 40 ° F
(4 ° C) to 105 ° F (41 ° C). When long periods of storage are
encountered, battery should be char
ged overnight every two
months. This type of battery will lose its char ge when not in
use. This may shorten battery life.
Troubleshooting
12 V olt Starting System
The following list is given to aid in diagnosing problems for
12 volt starting systems.
Note: If a starting problem is encountered, the engine itself
should be thoroughly checked to eliminate it as the cause of
starting dif ficulty . It is a good practice to check engine for
freedom of rotation by removing spark plug and turning
crankshaft over by hand, to be sure it rotates freely .
1.
Engine Cranks Slowly
A. Additional load af fecting performance.
B. Dischar ged battery .
C. Faulty electrical connection (battery circuit).
D. Dirty or worn starter motor commutator , bearing, weak
magnets, etc.
E. W orn brushes or weak brush springs.
F. W rong oil viscosity for temperature expected.
G. Flywheel brake mis-adjusted.
2. Engine W ill Not Crank
A. Dischar ged or defective battery .
B. Faulty electrical connections.
C. Faulty starter motor switch (open circuit).
D. Open circuit in starter motor .
E. Brushes sticking, etc.
3. Starter Motor Spins,
But Does Not Crank Engine
A. Sticking pinion gear due to dirt or damaged spline.
B. Damaged pinion or ring gear .
C.
Starter pinion clutch slipping.