12-1
ELECTRICAL SYSTEM
1. Removing electrical system ..........12-2
1.1 Removing starter.................................... 12-2
1.2 Inspection before removing alternator ... 12-3
1.2.1 Inspecting alternator operation.................12-3
1.2.2 Handling precaution .................................12-3
1.2.3 Inspecting regulated voltage
(IC regulator integral type) .......................12-4
1.2.4 Inspecting output
(a built-in IC regulator type)......................12-4
1.3 Removing alternator............................... 12-5
1.4 Removing stop solenoid......................... 12-6
1.5 Removing glow plug............................... 12-7
2. Disassembling, inspecting and
reassembling electrical system .....12-8
2.1 Inspection before disassembling starter 12-8
2.1.1 No load test..............................................12-8
2.2 Disassembling and inspecting starter .... 12-9
2.2.1 M008T70471A (12V-2.0kW),
M008T81071A (24V-3.2kW) ....................12-9
2.2.2 M001T68281(12V-1.7kW)......................12-10
2.3 Preparation before disassembling ....... 12-11
2.3.1 Removing pinion set...............................12-11
2.3.2 Removing magnetic switch ....................12-11
2.3.3 Removing rear bracket...........................12-12
2.3.4 Removing brush holder and
brush assembly......................................12-12
2.3.5 Removing armature and yoke................12-12
2.3.6 Removing overrunning clutch.................12-13
2.3.7 Removing gear shaft..............................12-13
2.4 Inspecting and repairing starter ........... 12-14
2.4.1 Inspecting brushes for wear...................12-14
2.4.2 Measuring brush spring load..................12-14
2.4.3 Inspecting brush holder for insulation ....12-14
2.4.4 Measuring commutator radial runout .....12-15
2.4.5 Measuring commutator outside diameter12-15
2.4.6 Measuring undercut depth .....................12-15
2.4.7 Checking armature coil ..........................12-16
2.4.8 Inspecting rear bracket...........................12-16
2.4.9 Inspecting overrunning clutch ................12-17
2.4.10 Inspecting continuity of yoke assembly..12-17
2.4.11 Inspecting insulation between yoke body
and brush ...............................................12-17
2.4.12 Inspecting pinion ....................................12-18
2.4.13 Inspecting front bracket..........................12-18
2.4.14 Inspecting gears of starter......................12-18
2.4.15 Inspecting continuity of magnetic switch
(between M terminal and case)..............12-18
2.4.16 Inspecting insulation of magnetic switch
(between M terminal and B terminal)..... 12-18
2.5 Reassembling starter ........................... 12-19
2.5.1 Applying grease..................................... 12-20
2.5.2 Installing pinion...................................... 12-20
2.5.3 Installing gear shaft ............................... 12-21
2.5.4 Installing yoke and armature ................. 12-21
2.5.5 Installing brush holder and
brush assembly ..................................... 12-22
2.5.6 Installing rear bracket ............................ 12-22
2.5.7 Installing magnetic switch...................... 12-22
2.5.8 Inspecting pinion clearance................... 12-23
2.6 Disassembling, inspecting and
reassembling alternator (12V-50A) ...... 12-24
2.6.1 Separating front bracket from stator...... 12-25
2.6.2 Removing pulley................................... 12-25
2.6.3 Removing stator .................................... 12-25
2.6.4 Inspecting rectifier ................................. 12-26
2.6.5 Inspecting rotor...................................... 12-26
2.6.6 Inspecting stator .................................... 12-27
2.6.7 Inspecting brushes for wear .................. 12-27
2.6.8 Replacing brushes................................. 12-28
2.6.9 Reassembling alternator........................ 12-28
2.7 Inspecting glow plug.............................12-29
3. Installing electrical system.......... 12-30
3.1 Installing glow plug............................... 12-30
3.2 Installing stop solenoid.........................12-31
3.3 Installing stop solenoid (ETR type) ......12-32
3.3.1 Procedure for installing stop solenoid
(ETR type) ............................................. 12-32
3.3.2 Verification after reassembling
(ETR type) ............................................. 12-32
3.4 Installing stop solenoid (ETS type)....... 12-33
3.4.1 Procedure for installing stop solenoid (
ETS type)............................................... 12-33
3.4.2 Verification after reassembly (ETS type)12-34
3.5 Installing alternator............................... 12-35
3.6 Installing starter.................................... 12-36
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