Checking the brushes
Using a caliper, measure the height of the brushes.
Nominal brush height:
- starter 0.8 kW - 14.0 mm
- starter 1.2 kW - 15.5 mm
- starter 1.4 kW - 15.0 mm
- starter 2.2 kW - 16.5 mm
Minimum allowable brush height:
- starter 0.8 kW - 9.0 mm
- starter 1.2 kW - 11.0 mm
- starter 1.4 kW - 10.0 mm
- starter 2.2 kW - 9.0 mm
If the height of the brush is less than the minimum allowable value, then replace the brushes and touch up with sandpaper.
Checking brush springs
Use the steelyard to measure the tension of the brush springs at the moment of their separation from the brush.
Nominal force of brush springs:
- starter 0.8 kW - 13.7-17.7 N
- starter 1.2 kW - 15.0-19.0 N
- starter 1.4 kW - 18-24 N
- starter 2.2 kW - 30 N
Minimum brush spring force:
- starter 0.8 kW - 9 N
- starter 1.2 kW - 10N
- starter 1.4 kW - 12 N
- starter 2.2 kW - 18 N
If the force of the springs is less than the minimum value, then replace the brush springs.
Checking the brush holder
Check brush holder insulation. Using an ohmmeter, verify that there is no continuity between the positive "+" and negative brush holders. Otherwise, replace the brush holder.