ELECTRICAL SYSTEM

CONTENTS
SERVICE DATA ............................................. EE-1-1 ADJUSTMENT ............................................... EE-2-8
SPECIFICATIONS ......................................... EE-1-1 PERFORMANCE TEST (NO LOAD) ............ EE-2-8
SERVICE DATA ............................................. EE-1-2 ALTERNATOR ............................................... EE-3-1
TIGHTENING TORQUE ................................ EE-1-4 = MODEL NAME 0202 102 1943, 0202 152 0044
STARTING MOTOR ..................................... EE-2-1 AND 0201 152 1130, 0201 102 4510 =
= MODEL NAME 0350 602 = CONSTRUCTION .......................................... EE-3-1
CONSTRUCTION .......................................... EE-2-1 TROUBLESHOOTING ................................... EE-3-2
TROUBLESHOOTING ................................... EE-2-2 DISASSEMBLY .............................................. EE-3-4
DISASSEMBLY .............................................. EE-2-3 INSPECTION ................................................. EE-3-5
INSPECTION ................................................. EE-2-4 PERFORMANCE TEST ................................ EE-3-7
 SERVICE DATA

SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model
0350 602 0381 0350 602 0460
Item
Type Shift
Output V-kW 24 - 6.0
Rated time Second 30
Manufacturer Sawafuji

ALTERNATOR
Model 0202 152 0044
0202 102 1943 0201 152 1130 0201 102 4510
Item (0202 152 0043)
Output V-A 24 - 40 24 - 50 24 - 40
Type of regulator IC-transistor type
Vacuum pump model 1290 009 00 (VD-30) —
Manufacturer Sawafuji

AIR HEATER
Type Ribbon
Rated current V-A 11.0 - 85
Rated time Second Less than 60

EE-1-1
 SERVICE DATA

SERVICE DATA
STARTING MOTOR
Model 0350 602
Unit: mm (in)
Maintenance Service
Item Remarks
standard limit
Brush height 20.0 (0.787) 14.0 (0.551)
Brush
Brush spring tension N {kgf, lbf} 29.4 {3.0, 6.6} 20.6 {2.1, 4.6} When spring is set
Outside diameter 40.0 (1.575) 38.0 (1.496)
Less than
Runout 0.1 (0.004)
Commutator 0.05 (0.0020)
0.5 - 0.8
Undercut depth 0.2 (0.008)
(0.020 - 0.031)
Less than
Shaft runout 0.1 (0.004)
0.05 (0.0020)
Gear shaft
0.1 - 0.5
Thrust gap —
(0.004 - 0.020)
Front bearing (metal) inside diameter 17.0 (0.669) 17.2 (0.677)
Center bearing (metal) inside diameter 28.0 (1.102) 28.2 (1.110)
Bracket Commulator bearing fit section inside di-
32.0 (1.260) 32.1 (1.264)
ameter
Gear bearing fit section inside diameter 52.0 (2.047) 52.1 (2.051)
Armature, field
Insulation resistance MΩ More than 1.0 0.5
coil
Brush holder Insulation resistance MΩ More than 1.0 0.5
Series coil resistance Ω 0.12 - 0.15 —
Magnetic Shunt coil resistance Ω 0.6 - 0.8 —
switch 1.0 - 2.0
Contactor point deflection —
(0.039 - 0.079)
Clearance between pinion gear and pinion 0.5 - 3.0
Pinion gear —
stopper (0.020 - 0.118)
0.3 - 1.5
Adjustment Dimention L —
(0.012 - 0.059)
Current A Less than 120 —
Performance Terminal voltage 24V
test Motor speed rpm More than 3,500 —
(no load) Pinion pop out voltage V Less than 16 —

EE-1-2
 SERVICE DATA

ALTERNATOR
Model 0202 102 1943, 0202 152 0044 (0202 152 0043) and 0201 152 1130, 0201 102 4510
Unit: mm (in)
Item Maintenance standard Service data Remarks
0202 102 1943 0.36 - 0.44 —
0202 152 0044
0.19 - 0.24 — Between two phases
Stator coil Resistance Ω (0202 152 0043)
[At 20°C (68°F)]
0201 152 1130 0.18 - 0.22 —
0201 102 4510 0.285 - 0.315 —
0202 102 1943 7.0 - 9.0 —
0202 152 0044
5.0 - 7.0 —
Field coil Resistance Ω (0202 152 0043) At 20°C (68°F)
0201 152 1130 5.6 - 6.8 —
0201 102 4510 7.5 - 8.3 —
Less than
Shaft outside diameter of the front part 25.0 (0.9843)
24.98 (0.9835)
0202 102 1943
Rotor Less than
0202 152 0044 16.0 (0.6299)
assembly 15.98 (0.6291)
Shaft outside diam- (0202 152 0043)
eter of the rear part
0201 152 1130 Less than
17.0 (0.6693)
0201 102 4510 16.98 (0.6685)

More than
Front cover Inside diameter of front bearing fitting hole 62.0 (2.441)
62.1 (2.445)
More than
Housing Inside diameter of rear bearing fitting hole 23.8 (0.937)
23.80 (0.9370)
0202 102 1943 More than 40 —
0202 152 0044
More than 50 — 28V, 5,000 rpm
Output current A (0202 152 0043)
[At 20°C (68°F)]
0201 152 1130 More than 50 —
0201 102 4510 More than 40 —
Performance
test Regulating voltage V 28.0 - 29.0 — At 20°C (68°F)
0202 102 1943
Speed required to 0202 152 0044
Less than 900 —
increase voltage to 27 (0202 152 0043) At 20°C (68°F)
volts rpm 0201 102 4510
0201 152 1130 Less than 950 —

EE-1-3
 SERVICE DATA

TIGHTENING TORQUE
STARTING MOTOR
Model 0350 602
Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque
C terminal 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
B and M terminals 16.2 - 22.1 {1.65 - 2.25, 11.9 - 16.3}
Magnetic switch mounting bolt 14 - 16 {1.4 - 1.6, 10 - 12}
Through bolt 14 - 16 {1.4 - 1.6, 10 - 12}
Brush holder mounting bolt 3.6 - 4.9 {0.37 - 0.50, 2.7 - 3.6}

ALTERNATOR
Model 0202 102 1943, 0202 152 0044 (0202 152 0043) and 0201 152 1130, 0201 102 4510
Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque
Screw Size M5 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
0202 102 1943
0202 152 0044
96 - 127 {9.8 - 13.0, 71 - 94}
Pulley mounting nut (0202 152 0043)
0201 102 4510
0201 152 1130 127 - 157 {13.0 - 16.0, 94 - 116}
M6 3.2 - 4.4 {0.33 - 0.45, 2.4 - 3.3}
Terminals
M8 8 - 11 {0.8 - 1.1, 5.8 - 8.0}
Through bolt 6 - 9 {0.6 - 0.9, 4.3 - 6.5}

EE-1-4
 STARTING MOTOR 0350 602

STARTING MOTOR
= MODEL 0350 602 =
CONSTRUCTION

WEE043A

EE-2-1
 Engine does not
start.

. *A
No
Does engine turn No Does starting motor N.G. + Charge or replace battery.
c Check battery for charging condition
c c
by cranking? turn? and battery terminals for connections + Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
. .
Yes
Does gear shaft turn? Can you hear starter relay operating? No Check and repair wiring system of
c Check pinion roller
TROUBLESHOOTING

c
clutch for damage. (Block relay equipped model only) block relay.
No Replace if neces- + Key switch.
sary. Yes + Starter relay.
+ Connections.
. .
Check reduction gear Can you hear magnetic switch operat- No + Check and repair wiring up to mag-
c
parts (armature, gear ing sound? netic switch.
shaft). Replace if neces- + Repair or replace magnetic switch.
sary. Yes
. N.G. .
(Turns N.G. N.G.
Does starting mo- Check battery for charg- Is meshing condition of pinion and ring + Check lever assembly for deforma-
slowly) c *A c
tor turn normally? ing condition and battery gear normal? tion, weak return spring and pinion
c
terminals for connections for sliding condition.
O.K. and corrosion. O.K. + Correct meshing condition of pinion
and ring gear. Replace if necessary.
O.K.
. . .

EE-2-2
Check ignition Check engine oil viscos- N.G. Replace engine Remove starting motor from engine. No Replace motor (field coil or armature).
c c
system and fuel ity. oil. Does starting motor turn under no load
system. by connecting battery (+) terminal to M
O.K. terminal of starting motor and battery
STARTING MOTOR

(−) terminal to starting motor body?

Yes
. .
Does engine turn by re- Yes Repair or replace Check magnetic switch contacts.
c
placing starting motor starting motor. Replace if necessary.
with a new one?
No
. EEE1-003
Check inside of engine.

Starting motor does not Repair or replace key switch, : Check item : Problem or corrective action
c
stop when key switch is block relay or magnetic
turned off. switch. If any abnormality is found, immediately disconnect battery negative terminal.
0350 602
 STARTING MOTOR 0350 602

DISASSEMBLY

ZEE057A

j
1 Magnetic switch assembly j8 Gear case j
15 Lever assembly
j
2 Rear bracket j9 Packing j
16 Center holder
.j
3 Brush holder assembly j
10 Retaining ring j
17 Shim washer
j
4 O-ring j
11 Hook j
18 Pinion assembly
j
5 Yoke assembly .j
12 Pinion stopper j
19 Pinion case
j
6 Armature assembly j
13 Holder j
20 Cover
j
7 O-ring j
14 Shaft j
21 Metal
Marks ‘‘.’’ and ‘‘>’’ indicate that key points of operation are explained in the text.
NOTE
+ Numbers before part names do not indicate the disassembly sequence.

EE-2-3
 STARTING MOTOR 0350 602

Key point of disassembly

3 Brush holder assembly
j
+ Raise the brush spring and remove the brush from the brush
holder.
+ Remove the brush holder from the armature commutator.

ZEE055A

12 Pinion stopper
j
+ Remove the clip from inside the stopper. (Push the clip inward
from the groove in the stopper using a flat-blade screwdriver
and pry off the clip.)
+ Push the stopper and remove the two hooks.
+ Remove the stopper from the shaft.

ZEE056A

INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has exceeded,
repair or replace faulty parts.

BRUSH
Brush height
Unit: mm (in)
Maintenance standard Service limit
20.0 (0.787) 14.0 (0.551)

EP10-37

Brush spring tension

Unit: N {kgf, lbf}
Maintenance standard Service limit Remarks
29.4 {3.0, 6.6} 20.6 {2.1, 4.6} When spring is set

EEE1031A

EE-2-4
 STARTING MOTOR 0350 602

COMMUTATOR
Outside diameter
Unit: mm (in)
Maintenance standard Service limit
40.0 (1.575) 38.0 (1.496)

NOTE
+ If the commutator surface is rough, grind with No. 500 to
600 sandpaper and then measure the outside diameter.
EP10-76

Runout
Unit: mm (in)
Maintenance standard Service limit
Less than 0.05 (0.0020) 0.1 (0.004)

EEE3-002

Undercut depth
Unit: mm (in)
Maintenance standard Service limit
0.5 - 0.8 (0.020 - 0.031) 0.2 (0.008)

ZEE007A

GEAR SHAFT
Shaft runout
Unit: mm (in)
Maintenance standard Service limit
Less than 0.05 (0.0020) 0.1 (0.004)

EEE2-007

Thrust gap
Unit: mm (in)
Maintenance standard Service limit
0.1 - 0.5 (0.004 - 0.020) —

EE-2-5
 STARTING MOTOR 0350 602

BRACKET
Front bearing (metal) inside diameter
Unit: mm (in)
Maintenance standard Service limit
17.0 (0.669) 17.2 (0.677)

Center bearing (metal) inside diameter

Unit: mm (in)
Maintenance standard Service limit
28.0 (1.102) 28.2 (1.110)

Commutator bearing fit section inside diameter

Unit: mm (in)
Maintenance standard Service limit
32.0 (1.260) 32.1 (1.264)

Gear bearing fit section inside diameter

Unit: mm (in)
Maintenance standard Service limit
52.0 (2.047) 52.1 (2.051)

ARMATURE COIL
Continuity test
Make sure there is no continuity between the commutator and
armature assembly.

EEE3-003

Insulation test (Insulation resistance)

Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5

ES10-23

EE-2-6
 STARTING MOTOR 0350 602

FIELD COIL
Continuity test
Make sure there is continuity between the field coil terminals.

EP10-35

Insulation test (Insulation resistance)

Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5

EP10-36

BRUSH HOLDER
Insulation test (Insulation resistance)
Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5

EP10-39

MAGNETIC SWITCH
Continuity test (Series coil resistance)
Perform the continuity test between the M and C terminals.
Unit: Ω
Maintenance standard Service limit
0.12 - 0.15 —

EEE3002A

Continuity test (Shunt coil resistance)

Check the continuity between the C terminal and coil case.
Unit: Ω
Maintenance standard Service limit
0.6 - 0.8 —

EEE1075A

EE-2-7
 STARTING MOTOR 0350 602

Contactor point deflection

Check deflection when the contactor makes contact.
Unit: mm (in)
Maintenance standard Service limit
1.0 - 2.0 (0.039 - 0.079) —

PINION GEAR
Clearance between pinion gear and pinion stopper
Unit: mm (in)
Maintenance standard Service limit
0.5 - 3.0 (0.020 - 0.118) —

ADJUSTMENT
Measure dimension L moved towards the thrust direction of the
pinion when the magnetic switch pushes out the pinion.
1. Connect the S terminal to the battery positive terminal through
the magnetic switch. Ground the M terminal midway and then
connect it to the battery negative terminal.

EP10-49

2. Turn on the switch and make sure the magnetic switch pushes
out the pinion. Then, push back the pinion lightly and measure
dimension L.
Unit: mm (in)
Item Maintenance standard Service limit
Dimension L 0.3 - 1.5 (0.012 - 0.059) —

3. If dimension L exceeds the maintenance standard, replace the

starting motor assembly with a new one.
E11-17

PERFORMANCE TEST (NO LOAD)

1. Connect as shown in the illustration. Turn off the key switch and
turn the starting motor. Under these conditions, measure the
current and the number of rotations. (Terminal voltage: 24
volts)
Item Maintenance standard Service limit
Current A Less than 120 —
Motor speed rpm More than 3,500 —
ZEE058A

EE-2-8
 STARTING MOTOR 0350 602

2. Check that the pinion gear pops smoothly out and in when the
switch is turned on and off.

3. Measure the minimum voltage which is necessary for the pinion

to pop out. Prepare a variable resistor and battery voltmeter as
testing equipment. Set the resistance higher at first so that a
lower voltage applies to the starting motor. Then, slowly lower
the resistance and measure the voltage when the pinion pops
out.
Unit: V
Maintenance standard Service limit
Less than 16 —

ZEE059A

EE-2-9
 ALTERNATOR 0202 102, 0202 152, 0201 152, 0201 102

ALTERNATOR
= MODEL 0202 102 1943, 0202 152 0044 (0202 152 0043), 0201 152 1130, 0201 102 4510 =
CONSTRUCTION
MODEL 0202 102 1943 AND 0202 152 0044 (0202 152 0043)

ZEE013A

MODEL 0201 152 1130 AND 0201 102 4510

WEE044A

EE-3-1
 The battery runs down.

No Check the battery relay. Abnormal Replace the battery relay.

c c

Normal Check the wiring. Abnormal Repair the wiring.

c c

. c To *A

Is the voltage across alternator ter- No Does voltage exist? No j Is the fuse blown? Abnormal j Replace the fuse.
TROUBLESHOOTING

c c c
minals B and E above 22V? j Is the wiring between the alter- j Repair the wiring.
(When the key switch is ON and Yes nator and battery normal?
engine is stopped.)
Normal
Yes .
. To *A
*A Abnormal
Is the belt broken? j Change the belt.
c
Is the belt slipping? j Adjust the belt tension.

Normal
.
. To *A
Does voltage exist across alternator No Is the key switch normal? Abnormal j Replace the key switch.
c c
terminals IG and E?
(Key switch is ON) Normal
Abnormal j Replace the fuse.
c Is the fuse blown?
c
Yes

EE-3-2
Normal
*B .
. To *B
ALTERNATOR

Is the voltage across alternator ter- No Faulty alternator j Repair the alternator.
c c
minals B and E over 27V? (Replace the diode, stator or
(Engine speed: 1,000 rpm) regulator.)

Yes
.
Measure the alternator charging No Increase the electrical load (Turn on No Faulty alternator
c c c
current at B terminal. Is it over all the lights.)
45A? Is the charging current over 45A?
(Engine speed: 2,000 rpm)
Yes
. Yes
Normal alternator b

.
(Check the battery and its related
parts.)
0202 102, 0202 152, 0201 152, 0201 102
 The battery becomes overcharged. (Battery fluid decreases)
(The battery fluid decreases.)

.
Is the voltage across alternator ter- Yes Faulty alternator (Regulator) j Repair the alternator
c c
minals B and E over 29V? (Faulty regulator)
(Engine speed: 1,000 rpm) (Broken internal wiring)

. No
Normal alternator
.
(Check the battery and its related : Check item : Problem or corrective action
parts.)

EE-3-3
ALTERNATOR
0202 102, 0202 152, 0201 152, 0201 102
 ALTERNATOR 0202 102, 0202 152, 0201 152, 0201 102

DISASSEMBLY

WEE052A

j
1 Nut j9 Ball bearing j
17 Rubber cap
j
2 Lock washer j
10 Washer j
18 Heat sink
j
3 Washer j
11 Oil seal j
19 Terminal
.j
4 Pulley assembly j
12 Cover j
20 Through bolt
j
5 Spacer j
13 Rotor assembly j
21 Charge light circuit assembly
.j
6 Front cover j
14 Stator assembly j
22 Cover
j
7 Oil seal j
15 Field coil assembly j
23 Regulator
j
8 Washer j
16 Housing
Marks ‘‘.’’ and ‘‘>’’ indicate that key points of operation are explained in the text.
NOTE
+ Numbers before part names do not indicate the disassembly sequence.

EE-3-4
 ALTERNATOR 0202 102, 0202 152, 0201 152, 0201 102

Key point of disassembly

j6 Front cover
To separate the front cover assembly, insert a screwdriver into
the clearance between the front cover and stator core.
NOTE
+ Be careful not to damage the stator coil with the screw-
driver tip.

EF10-036

j
4 Pulley assembly
When separating the pulley assembly, secure the rotor periph-
ery with a vise. Then, remove the pulley nut, pulley assembly
and spacer. If the pulley assembly is difficult to remove, use a
general-purpose puller.

EEE3-006

INSPECTION
STATOR COIL
Continuity test of the stator coil
Unit: Ω
Maintenance
Item Service limit Remarks
standard
0202 102 1943 0.36 - 0.44 —
0202 152 0044 Between two
0.19 - 0.24 — phases EEE1-080
Resistance (0202 152 0043)
[At 20°C
0201 152 1130 0.18 - 0.22 — (68°F)]
0201 102 4510 0.285 - 0.315 —

If there is no continuity, the stator coil may be broken. Replace the

stator coil as an assembly.

Insulation test of the stator coil

Make sure there is no continuity. If there is continuity, the stator coil
may be shorted. Replace the stator coil as an assembly.

EEE3034A

EE-3-5
 ALTERNATOR 0202 102, 0202 152, 0201 152, 0201 102

FIELD COIL
Continuity test of the field coil
Unit: Ω
Maintenance
Item Service limit Remarks
standard
0202 102 1943 7.0 - 9.0 —
0202 152 0044
5.0 - 7.0 — At 20°C
Resistance (0202 152 0043)
(68°F)
0201 152 1130 5.6 - 6.8 — EEE2-016

0201 102 4510 7.5 - 8.3 —

If there is no continuity, the field coil may be broken. Replace the

field coil as an assembly.

Insulation test of the field coil

Make sure there is no continuity. If there is continuity, the field coil
may be shorted. Replace the field coil as an assembly.

EEE2-017

ROTOR ASSEMBLY
Shaft outside diameter of the front part
Unit: mm (in)
Maintenance standard Service limit
25.0 (0.9843) Less than 24.98 (0.9835)

Shaft outside diameter of the rear part

Unit: mm (in)
Item Maintenance standard Service limit
0202 102 1943
0202 152 0044 16.0 (0.6299) Less than
(0202 152 0043) 15.98 (0.6291)

0201 152 1130 17.0 (0.6693) Less than

0201 102 4510 16.98 (0.6685)

EE-3-6
 ALTERNATOR 0202 102, 0202 152, 0201 152, 0201 102

FRONT COVER
Inside diameter of front bearing fitting hole
Unit: mm (in)
Maintenance standard Service limit
62.0 (2.441) More than 62.1 (2.445)

HOUSING
Inside diameter of rear bearing fitting hole
Unit: mm (in)
Maintenance standard Service limit
23.8 (0.9373) More than 23.80 (0.9370)

PERFORMANCE TEST
NOTE
+ Use leads with a cross-sectional area greater than 8 mm2
(0.0124 sq in) and a length less than 2.5 m (8.2 ft) to
connect the line between the alternator’s B terminal and
positive battery terminal, the E terminal and battery
ground terminal, and the L terminal and battery ground
terminal.
+ Use switches with as small a contact resistance as pos-
sible in the circuit. ZEE012A
+ Conduct performance test in areas where ambient tem-
perature is maintained at 20°C (68°F).
Start-up revolution
1. Install the alternator on a vehicle or connect to a variable
velocity motor and connect the leads as shown in the figure.
2. Turn switches SW1 and SW2 ‘‘ON’’, then gradually increase
alternator speed.
3. When the voltmeter registers a voltage higher than the voltage
when the alternator is stopped, turn switch SW1 ‘‘OFF’’.
4. While observing the voltmeter, increase alternator speed.
5. Read alternator speed (rpm) when the voltmeter registers 27
volts.
Unit: rpm
Maintenance Service Re-
Item
standard limit marks
0202 102 1943
Speed required to 0202 152 0044 At
Less than 900 —
increase voltage to (0202 152 0043) 20°C
27 volts 0201 102 4510 (68°F)
0201 152 1130 Less than 950 —

EE-3-7
 ALTERNATOR 0202 102, 0202 152, 0201 152, 0201 102

Measuring of regulating voltage

Turn switch SW1 off and turn switch SW2 on. Increase the
alternator speed up to the rated rpm of 5,000. Then, measure the
voltage.
Unit: V
Maintenance standard Service limit Remarks
28.0 - 29.0 — At 20°C (68°F)

Measuring output current

1. Adjust the variable resistor to zero and turn switches SW1 and
SW2 on.
2. Keep the alternator speed at the rated rpm and adjust the
variable resistor so that the terminal voltage is at the specified
value. Then, read the current.
Terminal voltage: 28V - 5,000 rpm
Unit: A
Maintenance
Part number Service limit Remarks
standard
0202 102 1943
More than 40 —
0201 102 4510
0202 152 0044 At 20°C (68°F)
(0202 152 0043) More than 50 —
0201 152 1130

EE-3-8