12-1
ELECTRICAL SYSTEM
1. Removing electrical system ..........12-2
1.1 Removing starter.................................... 12-2
1.2 Inspection before removing alternator
(A007TA0171B (12V-40A),
A007TA8271A (24V-25A))..................... 12-3
1.2.1 Inspecting alternator operation.................12-3
1.2.2 Handling precaution .................................12-3
1.2.3 Inspecting regulated voltage ....................12-4
1.2.4 Inspecting output......................................12-4
1.3 Removing alternator............................... 12-5
1.4 Removing stop solenoid......................... 12-5
1.5 Removing glow plug............................... 12-6
2. Disassembling, inspecting and
reassembling electrical system .....12-7
2.1 Inspection before disassembling starter
(M000T60481 (12V-1.2kW),
M001T68381 (12V-1.7kW)) ................... 12-7
2.1.1 Inspecting pinion clearance......................12-7
2.1.3 No load test..............................................12-9
2.2 Disassembling and inspecting starter
(M000T60481 (12V-1.2kW),
M001T68381 (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
(M000T60481 (12V-1.2kW),
M001T68381 (12V-1.7kW)) ................. 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 pinion ....................................12-17
2.4.11 Inspecting front bracket..........................12-17
2.4.12 Inspecting gears of starter......................12-17
2.4.13 Inspecting continuity of magnetic switch
(between M terminal and case)..............12-17
2.4.14 Inspecting insulation of magnetic switch
(between M terminal and B terminal)..... 12-17
2.5 Reassembling starter
(M000T60481 (12V-1.2kW),
M001T68381 (12V-1.7kW)).................. 12-18
2.5.1 Applying grease..................................... 12-18
2.5.2 Installing pinion...................................... 12-19
2.5.3 Installing gear shaft ............................... 12-19
2.5.4 Installing yoke and armature ................. 12-20
2.5.5 Installing brush holder and
brush assembly ..................................... 12-20
2.5.6 Installing rear bracket ............................ 12-20
2.5.7 Installing magnetic switch...................... 12-20
2.5.8 Inspecting pinion clearance................... 12-21
2.6 Inspection before disassembling starter
(M002T66071 (24V-3.2kW)) ................12-22
2.6.1 Inspecting pinion clearance................... 12-22
2.6.3 No load test ........................................... 12-24
2.7 Disassembling and inspecting starter
(M002T66071 (24V-3.2kW)) ................12-25
2.7.1 Preparation before disassembling......... 12-26
2.7.2 Removing magnetic switch.................... 12-26
2.7.3 Removing rear bracket .......................... 12-26
2.7.4 Removing brushes, brush holder, yoke
and armature ......................................... 12-27
2.7.5 Removing ball bearing........................... 12-27
2.7.6 Removing cover set............................... 12-27
2.7.7 Removing center bracket....................... 12-28
2.7.8 Removing reduction gear and
spring set............................................... 12-28
2.7.9 Removing pinion set.............................. 12-28
2.7.10 Removing lever and pinion shaft ........... 12-28
2.8 Inspecting and repairing starter
(M002T66071 (24V-3.2kW)) ................12-29
2.8.1 Inspecting brushes for wear .................. 12-29
2.8.2 Measuring brush spring load ................. 12-29
2.8.3 Inspecting brush holder for insulation.... 12-29
2.8.4 Measuring commutator radial runout..... 12-30
2.8.5 Measuring commutator outside diameter12-30
2.8.6 Measuring undercut depth..................... 12-30
2.8.7 Checking armature coil.......................... 12-31
2.8.8 Inspecting continuity of yoke assembly . 12-32
2.8.9 Inspecting insulation between yoke body
and brush............................................... 12-32
2.8.10 Inspecting center bracket ...................... 12-32
2.8.11 Inspecting overrunning clutch................ 12-33
2.8.12 Inspecting pinion.................................... 12-33
2.8.13 Inspecting front bracket ......................... 12-33
2.8.14 Inspecting gears of starter..................... 12-33
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