Usage:
Removal of Electrical System
Disassembly, Inspection and Reassembly Of Electrical System
Starter
Disassembly and Inspection of Starter
Inspection of Starter
Armature coil short-circuit test
(1) Armature coil short-circuit test
Place the armature on the growler. Set an iron piece parallel to the armature, and rotate the armature slowly by hand. If the iron piece is attracted to the coil or vibrates, there is a short-circuit; replace the armature.
(2) Armature coil grounding test
If there is continuity between the commutator and shaft (or core), replace the armature.
Armature coil grounding test
(3) Measurement of commutator runout
Measure the commutator runout using a dial gage. If the amount of runout exceeds the limit value, replace the armature. If the commutator surface is rough, refinish the surface with sand paper (#300 to #500). If the surface has ridges due to abrasion, replace the armature since it is not repairable.
Measurement of commutator runout
(4) Measurement of commutator outside diameter
Measure the outside diameter of the commutator, and, if the limit is exceeded, replace the armature.
Measurement of commutator outside diameter
(5) Measurements of mold depth between segments
Clean the grooves between segments, and measure the mold depths between segments. If the limit value is exceeded, repair.
Measurement of mold depth between segments
(6) Inspection of armature gear
If the inspection of the armature gear finds abnormal wearing or chipped teeth, replace the armature.
(7) Yoke coil open-circuit test
Check to see if there is continuity between the terminal lead wire and brush (positive). If there is no continuity, there is an open-circuit; replace the yoke assembly.
Yoke coil open-circuit test
(8) Yoke coil grounding test
Check to see if there is continuity between the yoke and brush (positive). If there is continuity, the yoke coil is grounded. Check the insulation, and replace the yoke assembly if the problem cannot be corrected.
Yoke coil grounding test
(9) Inspection of magnetic switch
Conduct the following the following continuity tests, and, if there is any problem, replace the magnetic switch.
(a) Coil open-circuit test
Check to see if there is continuity between terminal M and ground (case). There should be no continuity between terminal B and ground.
Inspection of magnetic switch
(b) Inspection of contact adhesion
Check to make sure there is no continuity between terminal B and terminal M.
(10) Measurement of brush length
Measure the length of each brush, and, if the limit value is exceeded, replace the brush. If the brush is unevenly worn or has a rough contact surface, refinish with sand paper (#300 to #500).
Measurement of brush length
(11) Measurement of brush spring tension
Measure the installation tension of each brush spring. Read the tension at the moment when the spring detaches from the brush. If the tension value is near the limit value, replace the brush spring.
Measurement of brush spring tension
(12) Inspection of brush holders for insulation
Using a tester, check to make sure that there is no continuity between the positive-side brush holder and negative-side brush holder plate. If there is continuity, replace the brush holder.
Inspection of brush holder for insulation
(13) Inspection of overrunning clutch
Make sure that the pinion shaft rotates smoothly in one direction, and locks in place when it is turned in the opposite direction. If the pinion shaft does not rotate properly, replace the overrunning clutch (pinion shaft assembly).
Inspection of overrunning clutch
Reassembly of Starter
Reassemble the starter by following the disassembly sequence in reverse, and observe the following during reassembly.
(1) Application of grease
In the case the starter has been overhauled, apply grease to the following sliding sections, gears and bearings.
Inspection and Adjustment After Reassembly
After reassembly, conduct the following inspections and test.
(1) Adjustment of pinion gap
Adjustment of pinion gap (1)
(a) Since connecting the wires of the reassembled starter as shown in the diagram causes the pinion to extend and rotate slowly, disconnect the connector from terminal M to stop rotation.
(b) Lightly push the tip of the extended pinion shaft with a finger, and measure the distance of the shaft movement to obtain the pinion gap measurement. Adjust the pinion gap by varying the number of packings installed at the magnetic switch section so that it conforms to the standard value. When the number of packings is increased, the pinion gap decreases. If proper adjustment cannot be achieved by varying the number of packings, replace the lever assembly.
Adjustment of pinion gap (2)
NOTE: To prevent the switch coil from overheating during inspection, do not supply electricity for more than 10 continuous seconds.
(2) No-load test
After the pinion gap adjustment, connect measurement instruments between the starter and battery as shown in the diagram to check no-load characteristics.
No-load test
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Use thick wires, and firmly tighten the connections at the terminal. |
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Alternator
If a problem occurs in the charge system, check the following conditions to locate the cause of the problem. Only when inspection cannot be conducted on the alternator in the installed condition, dismount the alternator for inspection and repair.
On Vehicle Inspection
(1) Cautions for handling
Handle the alternator carefully, as incorrect handling can result in alternator damage or malfunctions.
(a) Do not connect the battery cables in reverse. Note the negative (-) cable is a grounding wire.
(b) Do not use a high-voltage tester such as a megger.
(c) When charging the battery, disconnect the cables from the battery terminals.
(d) Do not disconnect the lead wire from terminal B of the alternator while the engine is operating.
(e) Do not ground terminal B of the alternator since it is constantly applied with battery voltage.
(f) Do not short-circuit or ground terminal L. (unit with integrated IC regulator)
(g) When using a steam cleaner, do not allow steam to directly contact the alternator.
(2) Inspection of adjustment voltage (unit with integrated IC regulator)
Inspection of adjustment voltage
(a) Disconnect the cable from the positive (+) terminal of the battery, and connect an ammeter between the terminal and cable.
(b) Connect a voltmeter between terminal L and ground.
(c) Make sure that the voltmeter indicates "0" when the starter switch is turned off. Make sure that the voltmeter indicates a voltage level significantly lower than the battery voltage when the starter switch is turned on (without starting the engine).
(d) Short-circuit the terminal of the ammeter, and start the engine.
(e) Read the indication (adjustment voltage) on the voltmeter with the ammeter indicating 5A or lower, the engine operating at 1500 to 2500 min-1, and the lamp switches turned off.
(3) Inspection of output (unit with integrated IC regulator)
Wiring for output test
(a) Disconnect the grounding cable from the battery.
(b) Disconnect the wire from terminal B of the alternator, and connect an ammeter, then connect a voltmeter between B and ground.
(c) Reconnect the grounding cable to the battery.
(d) Start the engine.
(e) Immediately after the engine starts, turn on all load devices such as lamps.
(f) Increase the engine speed, and read the maximum current at the specified alternator rotation speed when the voltmeter indicates 27.0 V. If the measured value conforms to the standard value, the alternator is normal.
Disassembly of Alternator
(1) Separation of front bracket from stator core
Insert the tip of a slotted screwdriver into the gap between the stator core and front bracket, and pry open.
Separation of front bracket from stator core
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Do not insert the screwdriver too far into the assembly to prevent damaging the stator core. |
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(2) Removal of the pulley
Removal of pulley
(a) After wrapping the rotor with a cloth for protection and holding it with a vice, unscrew the pulley nut, then remove the pulley and spacer.
(b) Remove the rotor from the front bracket.
(3) Removal of stator core and rectifier
Removal of stator core
(a) Disconnect the lead wires between the stator core and the rectifier at the soldered sections, and remove the stator core.
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Melt the soldered sections as quickly as possible. Prolonged heating cam damage the diodes. |
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(b) Unscrew the rectifier mounting screws, and dismount the rectifier.
Inspection and Repair of Alternator
(1) Inspection of diodes
Inspection of diodes
Conduct a continuity test with each diode in the rectifier.
(a) Using a tester, check continuity between each diode lead terminal and its case. If the resistance value is large in one direction and small in the opposite direction, the diode is normal.
(b) If the resistance measurements are the same in both directions, replace the rectifier. Be sure to check all diodes.
(2) Inspection of field coil
Field coil continuity test
(a) Check continuity between snap rings. If there is no continuity, there is an open-circuit; replace the field coil.
Field coil grounding test
(b) Check continuity between the slip ring and shaft (or core). If there is no continuity, the circuit is grounded; replace the field coil.
(3) Inspection of Stator Core
Stator core continuity test
(a) Check continuity between lead wires. If there is no continuity, there is an open circuit; replace the stator core.
Stator core grounding test
(b) Check the continuity between the stator core and each lead wire. If there is continuity, the stator core is grounded; replace the stator core.
(4) Inspection of brushes
Inspection of brush
(a) If the brushes are worn close to the wear limit (service limit), replace the brushes.
Replacement of brushes (1)
(b) To remove the brushes and springs, disconnect the brush lead wires at the soldered sections.
(c) To install new brushes, press them into the brush holders as shown in the diagram, then solder the lead wires.
Replacement of brushes (2)
Reassembly of Alternator
Reassembly of alternator
To reassemble, follow the disassembly sequence in reverse, and observe the following during reassembly.
(1) Locate the eccentric groove on the periphery of the rear bearing. Insert the rotation retaining snap ring so that the highest protruded section of the ring is positioned at the deepest section of the groove.
(2) When replacing the rear bearing, press-fit the rear bearing so that the groove on the periphery of the bearing faces the snap ring side.
(3) When press-fitting the rear bearing into the rear bracket, heat the rear bracket to 50 to 60 °C [122 to 140 °F) first.
(4) Before installing the rotor to the rear bracket, lift the brushes by inserting a wire through a small hole in the rear bracket, then remove the wire after completing the reassembly.
Glow Plugs
Inspection of Glow Plugs
Inspection of glow plug
As shown in the diagram, check the continuity between the terminal and body, and, if there is no continuity or resistance is high, replace the glow plug.
Installation
Installation of Electrical System
Installation of Alternator
(1) Install the fan belt on the alternator, and mount the alternator on the engine. Temporarily tighten all bolts.
Installation of alternator
(2) Insert a bar between the alternator and crankcase, and adjust the belt tension by using the bar as leverage. While keeping the alternator at that position, tighten the bolt that secures the alternator to the adjusting plate.
(3) Check the belt tension, and, if it deviates from the standard value, loosen the bolt and repeat above step (2).