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SECTION 1E

ENGINE ELECTRICAL

REPAIR INSTRUCTIONS

UNIT REPAIR



D102E701
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STARTER MOTOR

Inspection / Measurement (Before the Overhaul)

  1. Remove the starter. Refer to "Starter" in this section.
  2. Pinion clearance inspection.
  3. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds)



    D102E702
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    D102E703
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  4. Magnetic switch pull-in test.
  5. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid. (in 10 seconds)



    D102E704
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    D102E705
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  6. Solenoid hold-in test.
  7. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.



    D102E706
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    D102E707
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  8. Solenoid return test.
  9. Notice : Complete the testing in a minimum amount of time to prevent overheating and damaging the solenoid.



    D102E708
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    D102E709
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    1. No-road test.
      • Connect the 12-volt battery lead to the starter circuit.
      • Connect the current and the voltage (1).
      • Install the starter motor rpm gage (2).
      • Start the starter motor with the switch on (3).
      • Measure the speed of pinion gear and the current.
      • If the measurement satisfy the limit, the starter motor is normal.


    D102E710
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    Desciption
    Limit
    The speed of pinion gear
    Minimum: 2,000 rpm
    Condition: Voltage/Current
    Maximum: 9V / 150A


D102E711
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Disassembly Procedure

  1. Remove the starter contact end frame.


  2. D102E712
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  3. Remove the brush holder assembly.


  4. D102E713
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  5. Remove the field frame assembly from the armature set (1).


  6. D102E714
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  7. Remove the solenoid assembly.


  8. D102E715
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  9. Remove the armature set and solenoid from the starter housing.


D102E716
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Inspection / Measurement (After the Overhaul)

  1. Ground test for armature coil.


  2. D102E717
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  3. Short circuit test for armature coil.


  4. D102E718
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  5. Open circuit test for armature coil.


  6. D102E719
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  7. Inspect the brushes wear.
  8. a. Brushes wear limit.
    Desciption
    Standard
    Limit
    Brushes wear
    11.3-11.5 mm
    (0.445-0.453 in)
    7.0-7.25 mm
    (0.275-0.285 in)


D12E720A
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Install the bolts / nuts.
  3. Tighten
    Tighten the starter motor terminal M nut to 9-12 N•m (80-106 lb-in) (a).
    Tighten the through-bolts to 4-6 N•m (35-53 lb-in) (b).



D102E721
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GENERATOR (A-TYPE : MANDO)

Disassembly Procedure

  1. Remove the generator. Refer to "Generator" in this section.
  2. Remove the front bracket and rear bracket.


  3. D102E722
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    D102E723
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  4. Remove the pulley and rotor assembly from the front bracket.


  5. D102E724
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  6. Remove the front bracket, rotor and collar.


  7. D102E725
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  8. Remove the front bearing.


  9. D102E726
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  10. Remove the battery positive terminal nut from the rear bracket.


  11. D102E727
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  12. Remove the stator assembly from the rear bracket.


  13. D102E728
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  14. Remove the rectifier / brush holder / regulator from the stator.
  15. Notice : If the stator connections are welded, melt the lead. Avoid overheating as it can damage the diodes.



D102E729
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Inspection / Measurement

  1. Inspect the rotor assembly.


  2. D102E730
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    Desciption
    Limit
    The measured resistance
    2.9Ω


    D102E731
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  3. Inspect the stator.


  4. D102E732
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    D102E733
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  5. Inspect the rectifier.
  6. Inspect the open circuit for stator coil lead terminals using the ohmmeter (1).
    Replace the rectifier if necessary.


    D102E734
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    Inspect the open circuit for stator coil lead terminals using the ohmmeter (2).
    Replace the rectifier if necessary.


    D102E735
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  7. Inspect trio diodes.


  8. D12E736A
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  9. Inspect the brush wear.
  10. Desciption
    Standard
    Limit
    Brushes wear
    18.5 (0.73)
    13.5 (0.53)


D102E737
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. a. Brushes.
    b. Hole.


    D12E738A
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  3. Install the bolts / nuts / screws.
  4. Tighten
    • Tighten the brush holder / regulator / rectifier screws to 9-12 N•m (80-106 lb-in) (a).
    • Tighten the battery positive terminal nut to 4-7 N•m (35-62 lb-in) (b).



    D102E739
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    D12E740A
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D102E741
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GENERATOR (B-TYPE: DAC)

Disassembly Procedure

  1. Remove the generator. Refer to "Generator" in this section.
  2. Remove the cover from the generator.
  3. a. Cover.


    D102E742
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  4. Remove the regulator / brush holder / rectifier assembly.


  5. D102E743
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    D102E744
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  6. Remove the regulator / brush holder / rectifier.
  7. a. Rectifier.
    b. Regulator.
    c. Brush holder.


    D102E745
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  8. Remove the shield before the drive end bracket and the frame.


  9. D102E746
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  10. Remove the pulley and rotor assembly from the drive end bracket.


  11. D102E747
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  12. Remove the drive end bracket, rotor and space.


  13. D102E748
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  14. Remove the stator assembly from the frame.


D102E749
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Inspection / Measurement

  1. Inspect the rotor assembly.


  2. D102E750
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    D102E751
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  3. Inspect the stator.


  4. D102E752
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    D102E753
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  5. Inspect the rectifier.
  6. Inspect the open circuit for stator coil lead terminals using the ohmmeter (1).
    Replace the rectifier if necessary.


    D102E754
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    Inspect the open circuit for stator coil lead terminals using the ohmmeter (2).
    Replace the rectifier if necessary.


    D102E755
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  7. Inspect trio diodes.
  8. Replace the heat sink if necessary (a).


    D12E756A
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  9. Inspect the brush wear
  10. a. Brush wear limit.
    Desciption
    Standard
    Limit
    Brushes wear
    20 (0.79)
    14 (0.55)


D12E757A
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Assembly Procedure

  1. Install in the reverse order of removal.
  2. Install the screws / nuts / bolts.
  3. Tighten
    • Tighten the regulator screw to 9-12 N•m (80-106 lb-in) (a).
    • Tighten the rectifier / regulator screw to 9-12 N•m (80-106 lb-in) (b).
    • Tighten the brush holder / regulator screw to 9-12 N•m (80-106 lb-in) (c).



    D12E758A
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    D12E759A
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    D12E760A
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D102E761
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DISTRIBUTOR ASSEMBLY

Disassembly Procedure

  1. Remove the distributor. Refer to "Distributor" in this section.
  2. Remove the cap, seal and rotor from the distributor housing.


  3. D102E762
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    D102E763
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  4. Remove the inner / outer cover from the distributor housing.


  5. D102E764
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  6. Remove the optical sensor cover and adaptor from the distributor housing.


  7. D102E765
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  8. Remove the optical sensor unit from the distributor housing.


  9. D102E766
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  10. Remove the bearing plate from the distributor housing.


  11. D102E767
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  12. Remove the coupling, shaft and bearing from the distributor housing.


D102E768
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Assembly Procedure

  1. Install in the reverse order of removal.

SCHEMATIC AND ROUTING DIAGRAMS

STARTING SYSTEM


D12E2011
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CHARGING SYSTEM


D12E2021
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IGNITION SYSTEM CIRCUIT - TYPICAL


D12E2031
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IGNITION SYSTEM CIRCUIT - EURO III


MAA1E010
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SPECIFICATIONS

STARTER SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Starter Motor
Type
-
SD 80
-
Output(Capacity)
kW
0.8
-
No Load Test @ 9 volts Drive Pinion Speed
A RPM
150 2,000
-
Brushes Length
mm (in.)
11.3-11.5 (0.445-0.453)
7.0-7.25 (0.275-0.285)

GENERATOR SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Generator
Type
A-Type
B-Type
-
J114D(MANDO)
CS114D(DAC)
-
Regulator
Voltage
A-Type
B-Type
V
14.4-15.0
14.3-4.9
-
Brushes
Length
A-Type
B-Type
mm (in.)
18.5 (0.728)
20.0 (0.787)
13.5 (0.531)
14 (0.551)
Output
(Capacity)
A-Type
B-Type
-
12V, 65A
12V, 65A
-

IGNITION SYSTEM SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Ignition Coil
Type
-
Closed
Magnetic Type
-
First Coil Resistance
1.2±10%
-
Second Coil Resistance
KΩ
12.1 ± 15%
-
Distributor
Type
-
Optical Sensor
Type
-
Spark Plug
Type
Unlead
-
BPR5EY-11
1.0 - 1.1 mm
WR8DCX
1.1 - 1.2 mm
Type
Lead
-
BPR5EY
0.7 - 0.8 mm
WR8DC
0.7 - 0.8 mm
Spark Plug
Gap
Unlead
mm (in.)
1.1 (0.043)
-
1.2 (0.047)
-
Lead
mm (in.)
0.8 (0.031)
-
Ignition Wire
Ignition Wire Resistance
KΩm
2.5-12.0
-

BATTERY SPECIFICATIONS

Application
Description
Unit
Standard
Limit
Battery
Type
-
MF
-
Capacity
AH
35
-
Cold Cranking Amps
CCA
275
-

FASTENER TIGHTENING SPECIFICATIONS

Application
N•m
Lb-Ft
Lb-In
Distributor Bolts
10-16
-
89-142
Battery Retainer Clamp-to-Battery Rod Nuts
6-8
-
53-71
Battery Carrier Tray Bolts
9-12
-
80-106
Battery Cable Nuts
9-12
-
80-106
Starter field Connector Nut
9-12
-
80-106
Starter Through-Bolts
4-6
-
35-53
Starter Mounting Bolts
55-65
41-48
-
Starter Solenoid Assembly Screws
6-8
-
53-71
Starter Solenoid Nuts
9-12
-
80-106
Spark Plug
20-30
15-22
-
Generator Through-Bolts
4-6
-
35-53
Generator Drive End Nut
80-110
59-81
-
Generator Battery Lead Connector Nut
4-7
-
35-62
Generator Bearing Plate Bolt
6-8
-
53-71
Generator Brush Holder / Rectifier Screw
9-12
-
80-106
Generator Belt Tension Adjusting Bolt
18-28
13-21
-
Generator Shackle Bracket Bolt
45-55
33-41
-
Generator Lower Bracket-to-Generator Bolt/Nut
18-28
13-21
-
Ground Bolt
35-41
26-30
-
Ignition Coil Screw
4-7
-
35-62
Ignition Coil Bracket Bolt
9-12
-
80-106


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