Text preview for : Avviamento e Alternatore.pdf part of NISSAN Almera Tino Info. General - Accelerator Control, Fuel, Exaust System - Axle Front e Rear - Starting Charging - Clutch - Fuse Box - Maintenance - Suspension - Steering System - Trasmission - pag. 260
Back to : Almera Tino_01.part1.rar | Home
STARTING & CHARGING SYSTEM SECTION
GI MA EM LC EC
SC
CONTENTS
PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) AIR BAG and SEAT BELT PRE-TENSIONER...............2 Wiring Diagrams and Trouble Diagnoses....................2 BATTERY.........................................................................3 How to Handle Battery ................................................3 METHODS OF PREVENTING OVER-DISCHARGE ......3 CHECKING ELECTROLYTE LEVEL ............................3 SPECIFIC GRAVITY CHECK ......................................4 Battery Test and Charging Chart.................................6 CHART I ...................................................................6 CHART II ..................................................................7 A: SLOW CHARGE ....................................................8 B: STANDARD CHARGE ..........................................10 C: QUICK CHARGE .................................................11 STARTING SYSTEM .....................................................13 System Description....................................................13 M/T MODELS ..........................................................13 A/T MODELS ...........................................................13 Wiring Diagram - START -.........................................14 M/T MODELS ..........................................................14 A/T MODELS ...........................................................15 Trouble Diagnoses.....................................................16 Construction...............................................................17 Removal and Installation ...........................................19 REMOVAL ...............................................................19 INSTALLATION........................................................19 Inspection...................................................................19 MAGNETIC SWITCH CHECK ...................................19 PINION/CLUTCH CHECK .........................................20
BRUSH CHECK .......................................................20 YOKE CHECK .........................................................21 ARMATURE CHECK ................................................21
FE CL MT AT AX SU BR ST RS BT HA
Assembly ...................................................................22 PINION PROTRUSION LENGTH ADJUSTMENT ........22 CHARGING SYSTEM ....................................................24 System Description....................................................24 Wiring Diagram - CHARGE -.....................................25 Trouble Diagnoses.....................................................26 WITH IC REGULATOR .............................................26 MALFUNCTION INDICATOR ....................................26 Construction...............................................................27 Removal and Installation ...........................................28 REMOVAL (QG ENGINE) .........................................28 REMOVAL (YD ENGINE)..........................................28 INSTALLATION........................................................28 Disassembly...............................................................28 REAR COVER .........................................................28 REAR BEARING ......................................................28 Inspection...................................................................29 ROTOR CHECK ......................................................29 BRUSH CHECK .......................................................29 STATOR CHECK .....................................................30 Assembly ...................................................................30 RING FITTING IN REAR BEARING ...........................30 REAR COVER INSTALLATION .................................30 SERVICE DATA AND SPECIFICATIONS (SDS) .........31 Battery........................................................................31 Starter ........................................................................31 Alternator ...................................................................31
EL IDX
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
NLSC0001
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER" used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL V10 is as follows (The composition varies according to the destination and optional equipment.): ¼ For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), front seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. ¼ For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side air bag (satellite) sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: ¼ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer. ¼ Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by intentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. ¼ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just before the harness connectors or for the complete harness are related to the SRS.
Wiring Diagrams and Trouble Diagnoses
When you read wiring diagrams, refer to the following: ¼ GI-11, "HOW TO READ WIRING DIAGRAMS" ¼ EL-12, "POWER SUPPLY ROUTING" for power distribution circuit When you perform trouble diagnoses, refer to the following: ¼ GI-32, "HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSES" ¼ GI-21, "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT"
NLSC0002
SC-2
BATTERY
How to Handle Battery
How to Handle Battery
NLSC0003
CAUTION: If it becomes necessary to start the engine with a booster battery and jumper cables, 1) Use a 12-volt booster battery. 2) After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. 3) Never add distilled water through the hole used to check specific gravity.
GI MA EM LC
METHODS OF PREVENTING OVER-DISCHARGE
NLSC0003S01
The following precautions must be taken to prevent over-discharging a battery. ¼ The battery surface (particularly its top) should always be kept clean and dry. ¼ The terminal connections should be clean and tight. ¼ At every routine maintenance, check the electrolyte level. This also applies to batteries designated as "low maintenance" and "maintenance-free".
MEL040F
EC FE CL MT
¼
When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal.
AT AX SU BR
MEL041F
¼
Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge.
ST RS BT HA
MEL042F
CHECKING ELECTROLYTE LEVEL
NLSC0003S02
WARNING: Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
EL IDX
SC-3
BATTERY
How to Handle Battery (Cont'd)
¼ ¼
Remove the cell plug using a suitable tool. Add distilled water up to the MAX level.
MEL043F
Sulphation
NLSC0003S0201
SEL709E
A battery will be completely discharged if it is left unattended for a long time and the specific gravity will become less than 1.100. This may result in sulphation on the cell plates. To determine if a battery has been "sulphated", note its voltage and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.
SPECIFIC GRAVITY CHECK
1.
NLSC0003S03
Read hydrometer and thermometer indications at eye level.
MEL042FA
2. Convert into specific gravity at 20°C (68°F). Example: ¼ When electrolyte temperature is 35°C (95°F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20°C (68°F) is 1.240. ¼ When electrolyte temperature is 0°C (32°F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20°C (68°F) is 1.196.
SC-4
BATTERY
How to Handle Battery (Cont'd)
GI MA EM LC EC FE
SEL007Z
CL MT AT AX SU BR ST RS BT HA
EL IDX
SC-5
BATTERY
Battery Test and Charging Chart
Battery Test and Charging Chart
CHART I
NLSC0017 NLSC0017S01
SEL754W
*1: SC-4 *2: SC-7
*3: SC-8 *4: SC-10
*5: SC-11
SC-6
BATTERY
Battery Test and Charging Chart (Cont'd)
CHART II
NLSC0017S02
GI MA EM LC EC FE CL MT AT
SEL755W
AX SU BR ST RS BT HA
*:
SC-6
¼ Check battery type and determine the specified current using the following table. Fig. 1 DISCHARGING CURRENT (Load Tester)
Type 28B19R(L) 34B19R(L) 46B24R(L) 55B24R(L) 079 [YUASA type code] 50D23R(L) 55D23R(L) 65D26R(L) 80D26R(L) 75D31R(L) 063 [YUASA type code] 95D31R(L) 115D31R(L) 025 [YUASA type code] Current (A) 90 99 135 135 135 150 180 195 195 210 210 240 240 240
EL IDX
SC-7
BATTERY
Battery Test and Charging Chart (Cont'd)
Type 065 [YUASA type code] 027 [YUASA type code] 075 [YUASA type code] 110D26R(L) 95E41R(L) 067 [YUASA type code] 130E41R(L) 096 [YUASA type code] 096L [YUASA type code] 010S [YUASA type code] Current (A) 255 285 300 300 300 325 330 375 375 360
A: SLOW CHARGE
NLSC0017S03
SEL756W
*1: SC-4
*2: SC-7
SC-8
BATTERY
Battery Test and Charging Chart (Cont'd)
Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)
BATTERY TYPE 010S [YUASA type code] 096L [YUASA type code] 079 [YUASA type code] 025 [YUASA type code] 027 [YUASA type code] 063 [YUASA type code] 067 [YUASA type code] 096 [YUASA type code] 065 [YUASA type code] 075 [YUASA type code]
GI
130E41R(L) 14.0 (A) 115D31R(L) 110D26R(L) 75D31R(L) 95D31R(L) 95E41R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
CONVERTED SPECIFIC GRAVITY
MA EM LC EC FE CL MT AT AX
Below 1.100
4.0 (A)
5.0 (A)
7.0 (A)
8.0 (A)
8.5 9.0 (A) (A)
10.0 (A)
11.0 (A)
¼ ¼
Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.
Fig. 3 ADDITIONAL CHARGE (Slow charge)
SEL757W
SU
*: SC-7
CAUTION: ¼ Set charging current to value specified in Fig. 2. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ¼ Keep battery away from open flame while it is being charged. ¼ When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ¼ If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).
BR ST RS BT HA
EL IDX
SC-9
BATTERY
Battery Test and Charging Chart (Cont'd)
B: STANDARD CHARGE
NLSC0017S04
SEL758W
*1: SC-4
*2: SC-7
Fig. 4 INITIAL CHARGING CURRENT SETTING (Standard charge)
BATTERY TYPE 010S [YUASA type code] 096L [YUASA type code] 079 [YUASA type code] 025 [YUASA type code] 027 [YUASA type code] 063 [YUASA type code] 067 [YUASA type code] 096 [YUASA type code] 065 [YUASA type code] 075 [YUASA type code]
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
1.100 - 1.130 1.130 - 1.160 1.160 - 1.190 1.190 - 1.220
4.0 (A) 3.0 (A) 2.0 (A) 2.0 (A)
5.0 (A) 4.0 (A) 3.0 (A) 2.0 (A)
6.0 (A) 5.0 (A) 4.0 (A) 3.0 (A)
7.0 (A) 6.0 (A) 5.0 (A) 4.0 (A)
8.0 (A) 7.0 (A) 6.0 (A) 5.0 (A)
95E41R(L)
CONVERTED SPECIFIC GRAVITY
9.0 (A) 8.0 (A) 7.0 (A) 5.0 (A)
10.0 (A) 9.0 (A) 8.0 (A) 6.0 (A)
13.0 (A) 11.0 (A) 9.0 (A) 7.0 (A)
¼ ¼
Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary.
SC-10
130E41R(L)
115D31R(L)
110D26R(L)
BATTERY
Battery Test and Charging Chart (Cont'd)
Fig. 5 ADDITIONAL CHARGE (Standard charge)
GI MA EM LC EC FE CL MT AT AX SU BR ST
SEL760W
SEL759W
*:
SC-7
CAUTION: ¼ Do not use standard charge method on a battery whose specific gravity is less than 1.100. ¼ Set charging current to value specified in Fig. 4. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ¼ Keep battery away from open flame while it is being charged. ¼ When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ¼ If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F).
C: QUICK CHARGE
NLSC0017S05
*:
SC-7
RS BT HA
EL IDX
SC-11
BATTERY
Battery Test and Charging Chart (Cont'd)
Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge)
010S [YUASA type code] 096L [YUASA type code] 079 [YUASA type code] 025 [YUASA type code] 027 [YUASA type code] 063 [YUASA type code] 065 [YUASA type code] 075 [YUASA type code] 067 [YUASA type code] 096 [YUASA type code]
BATTERY TYPE
CURRENT [A] CONVERTED SPECIFIC GRAVITY 1.100 1.130 1.130 1.160 1.160 1.190 1.190 1.220 Above 1.220
10 (A)
15 (A)
20 (A) 2.5 hours
25 (A)
30 (A)
40 (A)
2.0 hours
1.5 hours
1.0 hours
0.75 hours (45 min.)
¼ Check battery type and determine the specified current using the table shown above. ¼ After starting charging, adjustment of charging current is not necessary. CAUTION: ¼ Do not use quick charge method on a battery whose specific gravity is less than 1.100. ¼ Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ¼ Keep battery away from open flame while it is being charged. ¼ When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ¼ Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation. If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). ¼ Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery.
SC-12
130E41R(L)
115D31R(L)
110D26R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
STARTING SYSTEM
System Description
System Description
M/T MODELS
NLSC0004 NLSC0004S01
Power is supplied at all times ¼ through 40A fusible link (letter J, located in the fuse and fusible link box) ¼ to ignition switch terminal 1. With the ignition switch in START position, power is supplied ¼ from ignition switch terminal 5 ¼ to smart entrance control unit terminal 59 ¼ from smart entrance control unit terminal 58 ¼ to starter motor harness connector terminal 1. The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts.
GI MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA
A/T MODELS
NLSC0004S02
Power is supplied at all times ¼ through 40A fusible link (letter J, located in the fuse and fusible link box) ¼ to ignition switch terminal 1. With the ignition switch in the START position, power is supplied ¼ from ignition switch terminal 5 ¼ to park/neutral position relay terminal 5. With the ignition switch ON or START position, power is supplied ¼ through 10A fuse [No. 20, located in the fuse block (J/B)] ¼ to park/neutral position (PNP) relay terminal 1. With the selector lever in the P or N position, ground is supplied ¼ to park/neutral position relay terminal 2 through the park/neutral position switch ¼ from body ground F10. Then park/neutral position relay is energized and power is supplied ¼ from park/neutral position relay terminal 3 ¼ to starter motor harness connector terminal 1. The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts.
EL IDX
SC-13
STARTING SYSTEM
Wiring Diagram -- START --
Wiring Diagram -- START --
M/T MODELS
NLSC0005 NLSC0005S06
YEL052E
SC-14
STARTING SYSTEM
Wiring Diagram -- START -- (Cont'd)
A/T MODELS
NLSC0005S07
GI MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA
EL IDX
YEL053E
SC-15
STARTING SYSTEM
Trouble Diagnoses
Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
NLSC0018
SEL761W
SC-16
STARTING SYSTEM
Construction
Construction
NLSC0006
GI MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA
SEL027UC
EL IDX
YEL149E
SC-17
STARTING SYSTEM
Construction (Cont'd)
MEL136L
YEL150E
SC-18
STARTING SYSTEM
Removal and Installation
Removal and Installation
REMOVAL
1. 2. 3. 4. Remove intake air duct and air cleaner assembly. Disconnect starter harness. Remove starter bolts (two). Remove starter.
NLSC0007 NLSC0007S01
GI MA
INSTALLATION
To install, reverse the removal procedure.
NEL642
NLSC0007S02
EM LC EC FE CL
YEL151E
MT AT AX SU BR
YEL152E
Inspection
MAGNETIC SWITCH CHECK
¼ ¼ 1. ¼ 2. ¼
NLSC0019 NLSC0019S01
ST RS BT HA
Before starting to check, disconnect battery ground cable. Disconnect "M" terminal of starter motor. Continuity test (between "S" terminal and switch body). No continuity ... Replace. Continuity test (between "S" terminal and "M" terminal). No continuity ... Replace.
EL IDX
MEL138L
SC-19
STARTING SYSTEM
Inspection (Cont'd)
PINION/CLUTCH CHECK
1. ¼ 2. ¼ 3.
MEL139L
NLSC0019S02
¼
Inspect pinion teeth. Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) Inspect reduction gear teeth (If equipped). Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) Check to see if pinion locks in one direction and rotates smoothly in the opposite direction. If it locks or rotates in both directions, or unusual resistance is evident. ... Replace.
NLSC0019S03 NLSC0019S0301
BRUSH CHECK Brush
Check wear of brush. Wear limit length: Refer to SDS (SC-31). ¼ Excessive wear ... Replace.
SEL014Z
Brush Spring Check
NLSC0019S0302
Check brush spring pressure with brush spring detached from brush. Spring pressure (with new brush): Refer to SDS (SC-31). ¼ Not within the specified values ... Replace.
SEL015Z
Brush Holder
1. ¼ 2. ¼
NLSC0019S0303
Perform insulation test between brush holder (positive side) and its base (negative side). Continuity exists. ... Replace. Check brush to see if it moves smoothly. If brush holder is bent, replace it; if sliding surface is dirty, clean.
SEL016Z
SC-20
STARTING SYSTEM
Inspection (Cont'd)
YOKE CHECK
NLSC0019S04
Magnet is secured to yoke by bonding agent. Check magnet to see that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly. CAUTION: Do not clamp yoke in a vice or strike it with a hammer.
GI MA EM LC EC FE CL
SEL018Z
MT
ARMATURE CHECK
1. ¼ 2. ¼
NLSC0019S05
Continuity test (between two segments side by side). No continuity ... Replace. Insulation test (between each commutator bar and shaft). Continuity exists. ... Replace.
AT AX SU BR
SEL019Z
3. ¼
Check commutator surface. Rough ... Sand lightly with No. 500 - 600 emery paper.
ST RS BT HA
SEL020Z
4.
¼
Check diameter of commutator. Commutator minimum diameter: Refer to SDS (SC-31). Less than specified value ... Replace.
EL IDX
SEL021Z
SC-21
STARTING SYSTEM
Inspection (Cont'd)
5. ¼
Check depth of insulating mold from commutator surface. Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in)
SEL022Z
Assembly
NLSC0020
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the starter. Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT Clearance (QG engine models)
NLSC0020S01 NLSC0020S0101
With pinion driven out by magnetic switch, push pinion back to remove slack and measure clearance " " between the front edge of the pinion and the pinion stopper. Clearance " ": Refer to SDS (SC-31).
SEL026Z
Movement (YD engine models)
NLSC0020S0102
Compare movement " " in height of pinion when it is pushed out with magnetic switch energized and when it is pulled out by hand until it touches stopper. Movement " ": Refer to SDS, (SC-31).
MEL140L
SC-22
STARTING SYSTEM
Assembly (Cont'd)
¼
Not in the specified value ... Adjust by adjusting plate.
GI MA EM
SEL633BA
LC EC FE CL MT AT AX SU BR ST RS BT HA
EL IDX
SC-23
CHARGING SYSTEM
System Description
System Description
NLSC0009
The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. Power is supplied at all times to alternator terminal 4 (S) through: ¼ 10A fuse (No. 39, located in the fuse and fusible link box). Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected by the 100A fusible link. The alternator is grounded to the engine block. With the ignition switch in the ON or START position, power is supplied ¼ through 10A fuse [No. 30, located in the fuse block (J/B)] ¼ to combination meter terminal 2 Ground is supplied to terminal 46 of the combination meter through terminal 3 (L) of the alternator. With power and ground supplied, the charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated.
SC-24
CHARGING SYSTEM
Wiring Diagram -- CHARGE --
Wiring Diagram -- CHARGE --
NLSC0010
GI MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA
EL IDX
YEL054E
SC-25
CHARGING SYSTEM
Trouble Diagnoses
Trouble Diagnoses
NLSC0011
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table. ¼ Before starting, inspect the fusible link. ¼ Use fully charged battery.
WITH IC REGULATOR
NLSC0011S01
SEL338V
NOTE: ¼ If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection. (Check the tightening torque.) ¼ When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty parts with new ones.
MALFUNCTION INDICATOR
NLSC0011S02
The IC regulator warning function activates to illuminate "CHARGE" warning lamp, if any of the following symptoms occur while alternator is operating: ¼ Excessive voltage is produced. ¼ No voltage is produced.
SC-26
CHARGING SYSTEM
Construction
Construction
NLSC0012
GI MA EM LC EC FE CL MT AT AX SU BR ST RS BT HA
MEL141LA
EL IDX
MEL497L
SC-27
CHARGING SYSTEM
Removal and Installation
Removal and Installation
REMOVAL (QG ENGINE)
1. 2. 3. 4. 5.
NLSC0013 NLSC0013S01
Loosen drive belt idler pulley. Remove drive belt idler pulley (include tightening screw). Remove alternator harness. Remove alternator upper bolt and lower bolt. Remove alternator.
MEL145L
REMOVAL (YD ENGINE)
1. 2. 3. 4. 5. 6. Remove alternator harness. Loosen alternator upper nut and lower bolt. Loosen drive belt. Remove alternator bracket bolts (two). Remove alternator upper nut and lower bolt. Remove alternator.
NLSC0013S03
NEL645
INSTALLATION
To install, reverse the removal procedure.
NLSC0013S02
Disassembly
REAR COVER
NLSC0021 NLSC0021S01
CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat just bearing box section with a 200W soldering iron. Do not use a heat gun, as it can damage diode assembly.
SEL032Z
REAR BEARING
NLSC0021S02
CAUTION: ¼ Do not reuse rear bearing after removal. Replace with a new one. ¼ Do not lubricate rear bearing outer race.
SC-28
CHARGING SYSTEM
Inspection
Inspection
ROTOR CHECK
1. ¼ 2. ¼ 3.
SEL033Z
NLSC0022 NLSC0022S01
¼
Resistance test Resistance: Refer to SDS (SC-31). Not within the specified values ... Replace rotor. Insulator test Continuity exists ... Replace rotor. Check slip ring for wear. Slip ring minimum outer diameter: Refer to SDS (SC-31). Not within the specified values ... Replace rotor.
GI MA EM LC EC FE CL MT
BRUSH CHECK
1. ¼ 2. ¼ Check smooth movement of brush. Not smooth ... Check brush holder and clean. Check brush for wear. Replace brush if it is worn down to the limit line.
NLSC0022S02
AT AX SU BR ST RS BT HA
SEL034Z
EL IDX
SC-29
CHARGING SYSTEM
Inspection (Cont'd)
STATOR CHECK
1. ¼ 2. ¼ Continuity test No continuity ... Replace stator. Ground test Continuity exists ... Replace stator.
NLSC0022S03
SEL037Z
Assembly
RING FITTING IN REAR BEARING
¼
NLSC0023 NLSC0023S01
Fix ring into groove in rear bearing so that it is as close to the adjacent area as possible. CAUTION: Do not reuse rear bearing after removal.
SEL044Z
REAR COVER INSTALLATION
1.
NLSC0023S02
Fit brush assembly, diode assembly, regulator assembly and stator. 2. Push brushes up with fingers and install them to rotor. Take care not to damage slip ring sliding surface.
SEL048Z
SEL049Z
SC-30
SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
Battery
Applied model Type 025 Capacity V-AH 12-52 027 065 12-55 075 12-50 079 12-42 067 12-60 096 12-64 QG engine YUASA type code YD22 engine YUASA type code
NLSC0014
GI MA EM
NLSC0015
Starter
D7E31 Type VALEO make Non-reduction Applied model System voltage V Terminal voltage V No-load Current A Revolution rpm Minimum diameter of commutator mm (in) Minimum length of brush mm (in) 11.0 45 12,000 28.2 (1.110) 6.15 (0.242) 16.2 - 19.8 (1.65 - 2.02, 3.64 - 4.45) 0.05 (0.002) 11.0 Less than 90 More than 2,700 28.0 (1.102) 10.5 (0.413) 12.7 - 17.7 (1.3 - 1.8, 2.9 - 4.0) Less than 0.2 (0.008) 0.3 - 2.5 (0.012 - 0.098) -- -- QG engine 12 11.0 Less than 145 More than 3,400 11.0 S114-800B HITACHI make Reduction M8T75371 M008T71471 MITSUBISHI make Reduction YD22 engine
LC EC FE
Less than 145 More than 3,300
CL MT AT
31.4 (1.236) 11.0 (0.433) 26.5 - 36.1 (2.7 - 3.7, 6.0 - 8.2) --
Brush spring tension N (kg, lb)
Clearance between bearing metal and armature shaft mm (in) Clearance " " between pinion front edge and pinion stopper mm (in) Movement " " in height of pinion assembly mm (in)
AX SU BR
NLSC0016
Max. 1 (0.039)
-- 0.5 - 2.0 (0.020 - 0.079)
--
Max. 12.2 (0.480)
Max. 13 (0.512)
Alternator
LR180-762 Type HITACHI make Applied model Nominal rating V-A Ground polarity Minimum revolutions under no-load (When 13.5V is applied) rpm More than 23/1,300 More than 65/2,500 More than 87/5,000 14.1 - 14.7 6.0 (0.236) 1.0 - 3.43 (102 - 350, 3.60 - 12.34) 6.0 (1.024) 2.67 2.31 QG engine 12-80 Negative Less than 1,000 More than 34/1,300 More than 83/2,500 More than 91/5,000 YD engine 12-100 LR1100-724
ST RS BT HA
Hot output current (When 13.5V is applied) A/rpm
Regulated output voltage V Minimum length of brush mm (in) Brush spring pressure N (g, oz) Slip ring minimum diameter mm (in) Rotor coil resistance at 20°C (68°F)
EL IDX
SC-31
NOTES