SERVICE DATA

SERVICE DATA
SPECIFICATIONS
STARTING MOTOR
Model 0350 602 0260
S210-112
Item 0350 602 0330
Type Shift
Output V-kW 24-6.0
Rated time Second 30
Manufacturer Hitachi Sawafuji

ALTERNATOR
0201 102 0201 152
Model LR240-602 LR250-602 2920 0020
Item LR240-603 LR250-603 0201 102 0201 152
2973 0053
Output V-A 24-40 24-50 24-40 24-50
Type of regulator IC type
Manufacturer Hitachi Sawafuji

AIR HEATER
Type Ribbon
Rated current V-A 11.2-85
Rated time Second Less than 60

SERVICE DATA
STARTING MOTOR
Model S210-112
Unit: mm (in)
Maintenance Service
Part Item Remarks
standard limit
Runout 0.05 (0.0020) 0.4 (0.016)
Commutator 0.5 - 0.8
Undercut depth 0.2 (0.008)
(0.020 - 0.031)
Brush height — 14.0 (0.551)
Brush
Brush spring tension N {kgf, lbf} 34.3 {3.5, 7.7} 24.5 {2.5, 5.5} When spring is set
Shaft diameter — 14.9 (0.587)
Armature
shaft Clearance between rear cover side bushing
— 0.2 (0.008)
and calculate armature shaft diameter
Clearance between pinion sliding shaft and
— 0.2 (0.008)
pinion
Clearance between pinion side bushing and
— 0.2 (0.008)
Gear shaft shaft
Shaft outside diameter — 17.9 (0.705)
Less than
Shaft runout 0.1 (0.004)
0.5 (0.020)

Performance Current A Less than 170 — Terminal voltage

test Motor speed rpm More than 2,000 — 24V
(no load) Pinion pop out voltage V Less than 18 —

EE-1-1
 SERVICE DATA

Model 0201 102 2920, 0201 102 2973, 0201 152 0020 and 0201 152 0053
Unit: mm (in)
Maintenance Service
Part Item Remarks
standard limit
0201 102 2920
0.36 - 0.44 — Between two
0201 102 2973
Starter coil phases
0201 152 0020 [At 20°C (68°F)]
0.19 - 0.24 —
0201 152 0053
Coil Resistance Ω
0201 102 2920
7.0 - 9.0 —
0201 102 2973
Field coil At 20°C (68°F)
0201 152 0020
5.0 - 7.0 —
0201 152 0053
Less than
Shaft outside diameter of the front part 25.0 (0.9843)
24.98 (0.9835)
Rotor
Less than
Shaft outside diameter of the rear part 17.0 (0.6693)
16.98 (0.6685)
More than
Inside diameter of front bearing fitting hole 62.0 (2.441)
62.1 (2.445)
Bracket
More than
Inside diameter of rear bearing fitting hole 23.8 (0.937)
23.80 (0.9370)
0201 102 2920
More than 40 —
0201 102 2973 28V, 5,000 rpm
Output current A
0201 152 0020 [At 20°C (68°F)]
More than 50 —
0201 152 0053
Regulating voltage V 28.0 - 29.0 — At 20°C (68°F)
Speed required to increase voltage to 27 volts rpm Less than 900 — At 20°C (68°F)

TIGHTENING TORQUE
STARTING MOTOR
Model S210-112
Unit: Nzm {kgfzm, ftzlbf}
Part Tightening torque Remarks
C terminal 2.5 - 2.9 {0.25 - 0.30, 1.8 - 2.2}
B terminal 20 - 22 {2.0 - 2.2, 15 - 16}

Model 0350 602 0260 and 0350 602 0330

Unit: Nzm {kgfzm, ftzlbf}
Part Tightening torque Remarks
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 3.9 - 4.9 {0.40 - 0.50, 2.9 - 3.6}

EE-1-4
 SERVICE DATA

ALTERNATOR
Model LR240-602, LR240-603, LR250-602 and LR250-
603
Unit: Nzm {kgfzm, ftzlbf}
Part Tightening torque Remarks
Alternator mounting nut 13.7 - 25.5 {1.40 - 2.60, 10.1 - 18.8}
B and E terminals 3.9 - 4.9 {0.4 - 0.5, 2.9 - 3.6}

Model 0201 102 2920, 0201 102 2973, 0201 152 0020 and 0201 152 0053
Unit: Nzm {kgfzm, ftzlbf}
Part Tightening torque Remarks
Size M4 1.0 - 1.4 {0.10 - 0.14, 0.7 - 1.0}
Screw
Size M5 1.9 - 2.5 {0.19 - 0.25, 1.4 - 1.8}
Pulley mounting nut 96 - 127 {9.8 - 13.0, 71 - 94}
B and E terminals 3.2 - 4.4 {0.33 - 0.45, 2.4 - 3.3}
Through bolt 6 - 9 {0.6 - 0.9, 4.3 - 6.5}

EE-1-5
 Engine does not
start.

▼ *A
No
Does engine turn No Does starting motor © Check battery for charging condition N.G. Charge or replace battery.
© ©
by cranking? turn? and battery terminals for connections Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
▼ ▼
Yes
No
TROUBLESHOOTING

Does gear shaft turn? © Check pinion roller Can you hear starter relay operating? Check and repair wiring system of
©
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 magnetic
©
parts (armature, gear ing sound? switch.
shaft). Replace if neces- Repair or replace magnetic switch.
sary. Yes
▼ N.G. ▼
(Turns N.G. N.G. Check lever assembly for deformation,
Does starting mo- Check battery for charg- Is meshing condition of pinion and ring
slowly) © *A ©
tor turn normally? ing condition and battery gear normal? weak return spring and pinion for slid-
©
terminals for connections ing condition.
O.K. and corrosion. O.K. Correct meshing condition of pinion
and ring gear. Replace if necessary.

EE-2-2
O.K.
▼ ▼ ▼

Check ignition Check engine oil viscos- N.G. Replace engine Remove starting motor from engine. No Replace motor (field coil or armature).
© ©
system and fuel ity. oil. Does starting motor turn under no load
system.
STARTING MOTOR

by connecting battery (+) terminal to M

O.K. terminal of starting motor and battery
(−) terminal to starting motor body?

▼
Yes
▼

Does engine turn by re- Yes Repair or replace Check magnetic switch contacts.
©
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
©
stop when key switch is block relay or magnetic
turned off. switch. If any abnormality is found, immediately disconnect battery negative terminal.
S210-112
 STARTING MOTOR S210-112

BRUSH HOLDER
Insulation test
Check for continuity between the positive (insulated) and the
negative (base) sides of the brush holder, using an insulation
tester. If continuity exists, it indicates faulty insulation, and the
brush holder should be replaced.

EP10-39

MAGNETIC SWITCH
Continuity test (Series coil resistance)
Check the continuity between the magnetic switch terminal C
and terminal M and replace when there is no continuity.

EEE3002A

Continuity test (Shunt coil resistance)

Check the continuity between magnetic switch terminal C and
the coil case (metal part) and replace when there is no
continuity.

EEE1075A

PINION
1. Check the pinion teeth for wear or damage. If necessary,
replace the pinion assembly.
2. Ensure that the pinion slides smoothly. Replace when the
pinion bushing is scratched, burned or otherwise damaged.
BALL BEARING
Check the ball bearing for noise, play, thermal discoloration or
damage. If there is any abnormality, replace the ball bearing
together with the armature as an assembly.

ADJUSTMENT

The pinion position dimension pushed out by the magnetic

switch is called dimension L.
1. Pass current between the magnetic switch terminal C and
ground.

EP10-49

EE-2-7
 Engine does not
start.

▼ *A
No
Does engine turn No Does starting motor © Check battery for charging condition N.G. Charge or replace battery.
© ©
by cranking? turn? and battery terminals for connections Repair connections and corrosion of
and corrosion. battery terminals.
Yes Yes
O.K.
▼ ▼
Yes
No
TROUBLESHOOTING

Does gear shaft turn? © Check pinion roller Can you hear starter relay operating? Check and repair wiring system of
©
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 magnetic
©
parts (armature, gear ing sound? switch.
shaft). Replace if neces- Repair or replace magnetic switch.
sary. Yes
▼ N.G. ▼
(Turns N.G. N.G. Check lever assembly for deformation,
Does starting mo- Check battery for charg- Is meshing condition of pinion and ring
slowly) © *A ©
tor turn normally? ing condition and battery gear normal? weak return spring and pinion for slid-
©
terminals for connections ing condition.
O.K. and corrosion. O.K. Correct meshing condition of pinion
and ring gear. Replace if necessary.

EE-3-2
O.K.
▼ ▼ ▼

Check ignition Check engine oil viscos- N.G. Replace engine Remove starting motor from engine. No Replace motor (field coil or armature).
© ©
system and fuel ity. oil. Does starting motor turn under no load
system.
STARTING MOTOR

by connecting battery (+) terminal to M

O.K. terminal of starting motor and battery
(−) terminal to starting motor body?

▼
Yes
▼

Does engine turn by re- Yes Repair or replace Check magnetic switch contacts.
©
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
©
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

EEE012A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1 Magnetic switch assembly

j j8 Gear case j15 Lever assembly

2 Rear bracket
j j9 Packing j16 Center holder

.j3 Brush holder assembly j

10 Retaining ring j17 Shim washer

4 O-ring
j 11 Hook
j j18 Pinion assembly

5 Yoke assembly
j 12 Pinion stopper
.j j19 Pinion case

6 Armature assembly
j 13 Holder
j j20 Cover

j
7 O-ring j
14 Shaft j21 Metal

Marks ‘‘.’’ and ‘‘>’’ indicate that key points of operation are explained in the text.

EE-3-3
 STARTING MOTOR 0350 602

Key point of disassembly

j3 Brush holder assembly
Contact the negative side of the brush spring to the side of the
brush. Lift the brush from the armature commutator surface.
Extract the positive side of the brush from the brush holder.
Then, remove the brush holder assembly.

EEE1-024

12 Pinion stopper
j
Move the pinion stopper toward the pinion. Using a screwdriver,
pry off the pinion stopper clip. Then, extract the pinion assembly
and center plate.

EF10-015

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 ex-
ceeded, 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-3-4
 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-3-5
 STARTING MOTOR 0350 602

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

Metal inside diameter (Holder)

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

Inside diameter at bearing (Commutator side)

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

Inside diameter at bearing (Gear side)

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
Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5

ES10-23

EE-3-6
 STARTING MOTOR 0350 602

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

EP10-35

Insulation test
Unit: MΩ
Maintenance standard Service limit
More than 1.0 0.5

EP10-36

BRUSH HOLDER
Insulation test
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
0.13 - 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-3-7
 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 CHECK

1. Connect as shown in the illustration. Turn off the key switch

and turn the starting motor. Under these conditions, mea-
sure the current and the number of rotations. (Terminal
voltage: 24 volts)
Item Maintenance standard Service limit
Current A More than 100 —
Motor speed rpm More than 4,000 —
WEE005A

EE-3-8
 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 —
EEE1078A

EE-3-9
 OFF OFF Replace the charge lamp.
Turn the key switch © Does the charge lamp come on with the chassis coupler removed © Inspect or replace the
ON. and the wiring harness terminal ‘‘L’’ grounded to the chassis? charge lamp relay.
Does the charge lamp
come on? ON NOTE:
Charge lamps are
ON ▼
available from the chassis
▼
maker.
Put the coupler into ALT.
Turn the key switch to
START position.
(Engine starts.)

▼
ON
Does the charge lamp come on with the ALT terminal ‘‘F’’ grounded © Replace RG.
to the chassis?

OFF Check the field coil and di-

© ode.
▼

Does the charge lamp © ON © Check the fan belt and

go out? ALT.

OFF

EE-4-2
Check the diode
© Lamp flashes. © (positive side).
▼
ALTERNATOR

Engine speed: 1,500 rpm

Determine VB. © VB 〉 28.5 © Replace the RG.

© VB = 28 - 29 © All in order

* Remarks ABBREVIATION:
1) Full charged battery must be used. ALT: Alternator
2) DC voltmeter: 0 to 75V, class 0.5 RG: Regulator
3) Checking method also applies to the bench test. VB: Voltage at the battery terminal
LR240, LR250
 ALTERNATOR LR240, LR250

DISASSEMBLY
REMOVAL
Key point of removal
Before removing the alternator from the engine, be sure to
turn the key switch off, then disconnect the battery cable
from the negative terminal of the battery.

EE-4-3
 ALTERNATOR LR240, LR250

5. Read alternator speed (rpm) when the voltmeter registers 27

volts.
Unit: rpm
Maintenance standard Service limit
Less than 950 —

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
28.0 - 29.0 —

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: 27V
Unit: A
Item Maintenance standard Service limit
LR240-602
More than 40 —
LR240-603
LR250-602
More than 50 —
LR250-603

EE-4-9
 The battery runs down.

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

c ©

Normal Check the wiring. Abnormal Repair the wiring.

c ©

▼ c To *A
No No
TROUBLESHOOTING

Is the voltage across alternator ter- Does voltage exist? j Is the fuse blown? Abnormal j Replace the fuse.
© © ©
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.
©
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.
© ©
terminals IG and E?
(Key switch is ON) Normal
Abnormal j Replace the fuse.
c Is the fuse blown?
©

EE-5-2
Yes
Normal
*B ▼
To *B
ALTERNATOR

Is the voltage across alternator ter- No Faulty alternator j Repair the alternator.
© ©
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
© © ©
current at B terminal. Is it over all the lights.)
35A? Is the charging current over 35A?
(Engine speed: 2,000 rpm)
Yes
▼ Yes

Normal alternator b

.
(Check the battery and its related
parts.)
0201 102, 0201 152
 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
© ©
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-5-3
ALTERNATOR
0201 102, 0201 152
 ALTERNATOR 0201 102, 0201 152

DISASSEMBLY
REMOVAL
Key point of removal
Before removing the alternator from the engine, be sure to
turn the key switch off, then disconnect the battery cable
from the negative terminal of the battery.

EE-5-4
 ALTERNATOR 0201 102, 0201 152

DISASSEMBLY

WEE011A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

1 Cover
j j8 Oil seal j14 Field coil assembly

2 Housing
j 9 Washer j15 Charge light circuit assembly
j
j
3 Rotor assembly j
10 Ball bearing j16 Terminal

.j4 Front cover assembly Washer j17 Regulator

j
11

.j5 Pulley assembly Oil seal j18 Rubber cap

j
12
6 Spacer
j j19 Heat sink
13 Stator assembly
j
j
7 Cover
Marks ‘‘.’’ and ‘‘>’’ indicate that key points of operation are explained in the text.

EE-5-5
 ALTERNATOR 0201 102, 0201 152

Key point of disassembly

4 Front cover assembly
j
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

5 Pulley assembly
j
When separating the pulley assembly, secure the rotor
periphery 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
Part number Service limit Remarks
standard
0201 102 2902
0.36 - 0.44 — At 20°C (68°F)
0201 102 2973
Between two EEE1-080
0201 152 0020 phases
0.19 - 0.24 —
0201 152 0053

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-5-6
 ALTERNATOR 0201 102, 0201 152

Unit: rpm
Maintenance standard Service limit Remarks
Less than 900 — At 20°C (68°F)

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
0201 102 2902
More than 40 —
0201 102 2973 28V, 5,000 rpm
0201 152 0020 [At 20°C (68°F)]
More than 50 —
0201 152 0053

EE-5-9
 AIR HEATER

- MEMO -

EE-6-2
 AIR HEATER

- MEMO -

EA-6-3