GeneralTROUBLESHOOTINGCHARGING SYSTEM

Symptom Possible cause Remedy

Charge warning lamp is notturned on when ignition swit-ch is ON state.

Fuse is broken. Replace the fuse.

Bulb is broken. Replace the bulb.

Loose wiring connection Retighten the loose connection

Wrong connection of L-S terminals Check and replace wiring or replace the volt-age regulator

Charge warning lamp doesnot turn off even after the e-ngine is started.(When batte-ry needs to be charged freq-uently)

Drive belt is loose or worn. Replace the drive belt.

Fuse is broken. Replace the fuse.

Fusible link is broken. Replace the fusible link.

Voltage regulator or alternator is defective. Replace the alternator.

Wiring is defective. Repair or replace the wiring.

Battery cable is corroded or worn. Repair or replace the battery cable.

Battery is overcharged. Votage regulator is defective. (Charge war-ning lamp turns on.) Replace the voltage regulator.

Voltage sensing wiring is defective. Replace the wiring.

Battery is discharged. Drive belt is loose or worn. Replace the drive belt.

Wiring connector is loose or circuit is short. Retighten the loose connection or repair thewiring.

Fusible link is short. Replace fusible link.

Poor grounding Repair.

Voltage regulator is defective.(Charge war-ning lamp turns on.) Check the alternator.

Battery is exhausted. Check the battery.

PRE-HEATER SYSTEMSymptom Possible cause Remedy

Engine does not start whenthe coolant temperature is b-elow 0°C.

Wiring connection is loose or wiring is defe-ctive.Coolant sensor is defective.Air heater is defective.Pre-heater control uint is defective.

Repair the wiring or tighten the connection.Replace the coolant sensor.Replace the air heater.Replace the unit.

If engine stops after 1st expl-osion or idle is unstable wh-en the coolant temperature i-s below 0°C.

Connection is loose or wiring is defectiveAir heater is defective.Pre-heater plug relay is defective.Pre-heater control unit is defective.

Correct or tighten wiring or connection.Replace air heater.Replace the relay.Replace the unit.

Symptom Possible cause Remedy

Pre-heating indicator remai-ns off.

Lamp is short.Connection is loose or wiring is cracked.Wiring is short.Pre-heater control unit is defective.

Replace the lamp.Replace wiring or tighten connection.Repair or replace the wiring.Repalce the unit.

STARTER SYSTEMSymptoms Possible cause Remedy

Engine does not crank. Defective battery, excessive dischargeWiring fault of starter motorWiring fault of starter motor relayWiring fault of magnetic switchWiring fault of starter switchWiring fault of batteryDefective magnetic switchDefective starter motor relayWear or damage of brushDefective motorDefective starter switch

Charge or replace.Repair or replace.Repair or replaceRepair or replace.Repair or replace.Repair or replace.Repair or replace.Repair or replace.Repair or replace.Repair or replace.Repair or replace.

Starter motor operates but enginedoes not start.

Pinion gear is out of mesh with ring gear.Battery voltage is low.Ring gear, pinion wear or damageDefective heater relayContact pressure of brush is low.Defective overrunning clutchBattery cable is corroded or worn.

Repair or replace.Charge or replace.Repair or replace.Repair or replace.Repair or replace.Repair or replace.Repair or replace.

Starter motor keeps rotating. Defective starter switchDefective magnetic switch

Repair or replace.Repair or replace.

GENERALSTARTER MOTOR SPECIFICATION

Items Specification

Type Electronic push-in type

Rated output 24V- 5.5KW

Rotation direction Clockwise from pinion side

Number of pinion teeth 11

Number of ring gear 144(HD120, AEROTOWN)

Input angle of pinion 14.5°

Center distance between ring gear and pinion 234.5mm (HD120, AEROTOWN)

STARTER MOTOR OUTPUTItems Specification

No load test Terminal voltage 23.5 V

Max. current 120 A

Min. RPM 3,400 RPM or more

Magnetic switch operating voltage 16 V or less

Load test Terminal voltage 16 V

Terminal current 600 A

Min. RPM 900 RPM or more

Characteristics of ass-urance output

Terminal voltage 9 V

Max. current Less than 1,140 A

Min. rotation force 98 Nm or more

PRE-HEATING SYSTEMItems Specification

Air heater Capacity 2.1kW

Rated voltage, amperage 22V 95A ± 10%

Temperature increase It takes 19 sec. to reach 800°C when DC 22V is applied.

The temperature should be 1,010°C at 30 sec. after DC 22V is applied.

Isolation resistance 1MΩ or more when measuring with a megger tester at roo-m temperature

ALTERNATOR (HD120)Items Specification

Alternator(HD120,70A)

Type 3 phase alternator

Rated output 24V 70A

Rated RPM 5,000 rpm

RPM in use 8,000 rpm

Regulator type Regulator built-in IC

Regulator adjusting voltage[at 20°C] 28 ± 0.5V

SERVICE STANDARD (HD120)Items Reference value Limit value Remedy

Alternator outputcharacteristics

[at hot]

Voltage Output current RPM

70% or more Replace.27V

35A 1,500 rpm

70A 5,000 rpm

IC regulator adjustingvoltage

(5,000 rpm, 5A or less)28~29V - Replace.

ALTERNATOR SPECIFICATION (AEROTOWN)Items Specification

Type 3 phase alternate current commutator type

Rated output 24V, 140A

Rated RPM 5,000 rpm

RPM in use 7,000 rpm

Regulator type Regulator built-in IC

Regulator adjusting voltage(at 20°C) 28 ± 0.5V

SERVICE STANDARD (ALTERNATOR, AEROTOWN)Items Reference value Limit value Remedy

Alternator output characteristics[at hot]

Votage Output current RPM

70% or more Replace.27V

80A 1,900 rpm

140A 5,,000 rpm

IC regulator adjusting voltage(5,000 rpm, 5A or less) 28~29V - Replace.

Charging SystemAlternator(Truck)OUTLINEALTERNATORAlternator is of a built-in type with an IC regulator. Abrush holder is installed in the rear bracket.When IC regulator fails, regulator assembly should bereplaced because the voltage cannot be controlled.ROTORWhen the rotor is driven by the rotation of the pulley, thecurrent flows from the brush to rotor coil through slip ring.

Then, rotor core becomes an electromagnet.

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STATORStator core forms the magnetic flux path together withrotor core. The magnetic flux in the stator core is affectedby the passage of the rotor core field so that electricity isgenerated as each rotor core rotates.

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RECTIFIERRectifier comprises of 3 pairs of diodes(6 in total) and 1heat sinks. It converts AC output of the stator to DCpower.

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REGULATORRegulator assembly comprises of IC regulator, brush andbrush spring. It stabilizes the output varying according tothe engine rpm.

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COMPONENTS

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DISASSEMBLY1. Remove two nuts mounted on rear cover using ascrewdriver.

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2. Separate cover (A) using a screwdriver.

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3. Separate slip ring guide (A).

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4. Loosen two bolts and a stud bolt and then separateregulator (A).

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5. Remove four through bolts and disassemble statorand rectifier(A).

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6. Using a solder gun, remove 3 lead wires of stator anddisconnect stator.

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7. Using a compressed air tool, loosen nut anddisconnect front bracket.

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REASSEMBLYReassembly is the reverse order of disassembly.

INSPECTIONROTOR INSPECTION1. Check for continuity between slip rings (A). Replacethe rotor if there is no continuity.

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2. Check for the non-continuity between slip ring (A)and rotor (B), and between slip ring(A) and shaft (C).Replace the rotor if there is continuity each other.

STATOR INSPECTION1. Check for continuity between lead wires (A).Replace the stator if there is no continuity.

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2. Check for continuity between lead wire (A) and coil(B). Replace the stator if there is continuity.

BRUSH INSPECTIONReplace the brush if it is worn exceeding to the limit.REGULATOR INSPECTIONReplace the regulator if brush is worn and does notcontact with slip ring of rotor.

Alternator(Bus)OUTVIEWALTERNATOR (AEROTOWN)In brushless type of alternator, brush isn't used and acurrent is supplied for field coil.Main components are composed of field coil generatingmagnetic field, stator generating electric force, rectifierrectifying electric force and regulator allowing voltage togenerate constantly etc..1. Field coilField coil connected to front and rear bracketreceives current from terminal and generatesmagnetic field.

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2. RotorIf the rotor is turned around field coil by pulley,magnetic poles are formed by field coil due tomagnetic field generated.

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3. StatorVoltage in the stator coil which coil is wound will begenerated by alternating magnetic field produced byfield coil.

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4. RectifierMain components of rectifier are 3 diode trios, 8diodes and 1 heat sink. Commutator converts A.C.into D.C.Each heat sink has (+) or (-) lead of 4 diodes andconverts 3 phase alternating current into directcurrent by rectifying.

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5. RegulatorRegulator changes force of field coil and stabilizesoutput voltage according to variation of engine speed.

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6. Charging circuit

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1) When starting switch is set to ON.

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2) When starting engineAlternator begins to generate electricity whenstarting engine, voltage in alternator terminal "B"becomes higher than battery voltage and currentflows as follows:

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Battery charging begins in this way and chargingalarm lamp turns off at the same time.

COMPONENTS

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ON-VEHICLE INSPECTIONVOLTAGE DROP TEST OF ALTERNATOROUTPUT WIREThis test is performed to check whether the wiring isgood or not between the alternator "B" terminal and thebattery (+) terminal by the voltage drop test.1. PREPARATION

1) Turn the ignition switch to "OFF".2) Disconnect battery ground cable.3) Disconnect alternator output wire from alternator

terminal "B" .4) Connect a DC ammeter(0~250A) between

alternator terminal "B" and output wiredisconnected. Connect lead wire(+) of anammeter to terminal "B" and connect lead wire (-)to output wire disconnected.

CAUTIONIf clamp type ammeter is used, you canmeasure current without disconnectingharness.

5) Connect a digital voltmeter between alternatorterminal "B" and battery terminal (+).Connect the lead wire(+) of voltmeter to terminal"B" and connect lead wire (-) to battery terminal(-).

6) Connect battery ground cable.

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2. Test1) Start the engine.2) With turning ON/OFF the headlight, adjust the

engine speed so that the ammeter indicatorpoints 20A. Then, measure the voltage.

3. Result1) It is normal if the measured voltage is within the

specification.

Reference voltage : Max. 0.2V

2) If the measured voltage exceeds the reference,wiring may be defective. Therefore, check thewirings between terminal "B" of the alternatorand fusible link, and between alternator andterminal (+) of the battery.

3) In addition, before the secondary test, check thelooseness at the connection and the discolorationof harness due to the overheating etc. Repairthem.

4) Adjust the engine speed at idle after the test andturn the light and ignition switch to "OFF".

5) Disconnect the battery ground cable.6) Disconnect the ammeter and voltmeter connected

for the test.7) Connect the alternator output lead wire to the

terminal "B" of the alternator.8) Connect the battery ground cable.

OUTPUT CURRENT TESTThis test is to check whether the alternator output currentcoincides with the rated current.1. Preparation

1) Prior to test, check the followings and repair ifnecessary.

2) Check whether the battery installed to vehicle isnormal.

CAUTIONWhen the output current is measured, use thebattery discharged a little bit.It is difficult to perform the accurate test withthe fully charged battery because ofinsufficient load.a. Turn the ignition "OFF".b. Disconnect the battery ground cable.c. Disconnect the alternator output wire from

terminal "B" of the alternator.d. Connect a DC ammeter (0~250A) to terminal

"B" and the disconnected output wire.Connect lead wire (+) of ammeter to terminal"B" and connect lead wire (-) to output wire.

CAUTIONSince it has high current, make sure totighten the connection completely byusing not clip but bolt and nut.

e. Connect the voltmeter (0~40V) betweenterminal "B" and ground. And connect leadwire (+) to terminal "B" of alternator andconnect lead wire (-) to ground.

f. Connect battery ground cable.1) 140A ALTERNATOR

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2. Test1) Check to see if the voltmeter indicates voltage

value equivalent to battery voltage.If voltmeter indicates 0V, it means wire betweenterminal "B" of alternator and terminal (-) ofbattery may be disconnected, fusible link is shortor ground is poor.

2) Start the engine and turn the headlight switch"ON".

3) Set the headlight on "HIGH" and place the heaterblower switch at "HIGH". Measure the max.output current value displayed on the ammeter byaccelerating the engine speed up to 2,500rpm.

NOTICESince charging current drops down rapidly afterengine is started, perform this test quickly to getaccurate max. current.

3. Result1) Measured value from the ammeter should be

greater than the limit value. Despite that thealternator output wire is normal, if the measuredvalue is low, remove the alternator from thevehicle and check it.

Output current : 70% of the rated current

CAUTION• Rated output current is shown on the

identification plate attached on thealternator body.

• Since output current varies depending onthe electric load and temperature of thealternator itself, at test it is difficult to getthe rated output current if the electric loadof the vehicle is low. In that case, turn theheadlight on to result in the batterydischarge or increase the electric load byusing additional light from other vehicle.Since rated output current cannot bemeasured when the temperature ofalternator itself or ambient temperaturesare too high, you should lower thetemperature before the secondary test.

2) After completing the output current test, adjustthe engine speed at idle and turn the ignitionswitch “OFF.”

3) Disconnect the battery ground cable.4) Remove ammeter, voltmeter and tachometer.5) Connect alternator output wire to terminal “B” of

the alternator.6) Connect the battery ground cable.

ADJUSTING VOLTAGEThis test is to check to see whether the voltage regulatorcontrols the voltage properly.1. Preparation

1) Check the battery installed on the vehicle for fullycharged.

2) Turn the ignition switch “OFF.”3) Disconnect the battery ground cable.4) Connect a digital voltmeter between terminal "A"

of alternator and ground. Connect lead wire (+) ofvoltmeter to terminal "A" by using special tool“wire-harness connector.” Connect lead wire (-)of voltmeter to ground or terminal (-) of thebattery.

5) Disconnect alternator output wire from terminal“B” of the alternator.

6) Connect the DC ammeter (0~250A) in serialbetween terminal “B” and the disconnectedoutput wire. Connect lead wire (-) of ammeter tothe disconnected output wire.

7) Install engine tachometer. Connect batteryground cable.

[140A ALTERNATOR]

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2. Test1) Turn the ignition switch “ON” and check to see

whether voltmeter indicates the reference value.2) If voltmeter indicates 0V, which means wire

between terminal “B” of alternator and terminal(+) of battery is disconnected or fusible link isblown.

3) Start the engine. Turn the light and all otheraccessory switches “OFF”.

3. Result1) If the voltmeter reading agrees with the table of

the adjusting voltage, the voltage regulator isnormally operating. If the measured value ishigher than the reference value, the voltageregulator or alternator is defective.

Regulator temperature(°C)

Adjusting voltage(V)

Alternator 140A

20~30 28~29

2) After completing the test, adjust the engine speedat idle and turn the ignition switch “OFF.”

3) Disconnect the battery ground cable.4) Remove ammeter, voltmeter and engine

tachometer.5) Connect alternator output wire to terminal “B” of

alternator.6) Connect the battery ground cable.

DISASSEMBLY

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1. Remove four through bolts.

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2. Separate front from rear part by using a screwdriver.

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3. Disassembly of Field coil assembly1) Loosen field coil screws (five).

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CAUTIONAfter removing the mounting screw, removebolts after fixing at separating as field coilassembly can be apart.

2) Separate field coil assembly (A) after gentlyprying stator by using a screwdriver.

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4. Disassembly of stator assemblySeparate stator coil by unsoldering the lead wire ofstator coil from rectifier.(8 points)

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CAUTIONDo not use solder gun for 5 seconds or more at atime to prevent damage to rectifier due tooverheating.

5. Separating rectifier and regulator from rear bracket1) Remove mounting nut of terminal "B" bolt and

then remove terminal "B" bolt.

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2) Remove rectifier and regulator mountingbolt(6points) and then remove in order of washerfor insulating, rectifier A, B, regulator.

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6. Removal of pulleyUsing a compressed air tool, loosen hexagonal nutand remove in order of pulley, woodruff key, fan.1) Secure rotor does not turn and loosen nut.

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2) Using puller, remove pulley.

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3) Remove woodruff key by gently tapping its upperpart and then remove fan.

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7. Separate rotor from front bracket using puller.

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INSPECTION

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1. Stator check1) Continuity between lead wire

Check for continuity between lead wires of eachstator. Replace the stator if there is no continuity.

2) Check for continuity between stator lead wire andcore, replace the stator if there is continuity,which means that there is ground.

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2. Rectifier checkMeasure the resistance of each diode.Contact (+) and (-) of circuit tester to each diode andmeasure.• Contact infinite resistance to both sides of each

diode and measure.• If the resistance of both sides indicates zero,

which means diode is short.Replace the rectifier in the above cases.Measure it in the following order.

1) Measurement of diode which has heat sink:

Measure the resistance between heat sink andstator coil lead connecting part.

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2) Measure the resistance between sub-diodeconnecting part (3 points) and heat sink.

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3. Field coil check1) Measure the resistance between the field coil

terminals and if measured value is out ofspecification, replace the field coil.

2) Check for continuity between terminal of field coiland core, replace the field coil if there iscontinuity, which means that there is ground.

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4. Bearing checkIf faulty, replace the bearing.1) Removal of front bearing

a. Remove bearing cover.

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b. Strike wooden bar on spacer in front of thefront bracket to remove bearing.

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2) Reassembly of front bearinga. Apply engine oil to outer side of bearing lightly

and strike into the place of inner bearing ofthe front bracket using a press.Bearing seat surface should be flush withcover mounting part.

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b. Assemble the cover and strike the spacer withsoft hammer to contact bearing with cover.Otherwise, hit the spacer to contact thebearing for sure.

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3) Replacement of rear bearinga. Remove the rear bearing using a bearing

puller.

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b. Apply engine oil lightly to the inner side ofbearing and install bearing using a press.

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REASSEMBLYReassembly is the reverse order of disassembly.

Starting SystemOUTLINESTARTER MOTORThe starter motor is the system which converts electricalenergy of battery into mechanical rotation energy tosupply more than minimum rpm of crankshaft required bythe starting of internal combustion engine. Classifying thestarter motor, it is composed of such parts as electricalmotor part which turning force occurs, drive part whichtransmits power to the ring gear, the magnetic switch partwhich moves the pinion into the ring gear and sendscurrent to electrical motor.

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OPERATION1. The pinion is not in mesh with the ring gear if starterswitch is opened.

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2. When the starter switch is closed, current flows to thestarter relay and "B"(battery terminal) and "S"(switchterminal) of the starter relay are connected andcurrent begins to flow to the starter plunger.

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3. If current flows to the starter plunger, not only theplunger but also the lever is pulled. Therefore, thepinion moves to the ring gear side. As "B"(batteryterminal) and "M"(motor terminal) of magnet meetfrom the specific engaged distance, large currentflows to the starter motor and the pinion rotates thering gear.

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Starter MotorCOMPONENTS

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1. Hog ring2. Pinion retainer3. Pinion4. Pinion spring5. Housing assembly6. Clutch and output shaft assembly7. Gear support assembly8. Washer9. Retainer10. Drive shaft assembly11. Planetary gear assembly12. Dust cover13. Ball14. Armature assembly15. O-ring16. Frame field assembly17. O-ring

18. Brush holder assembly19. CE housing20. CE screw21. Through bolt22. Bolt23. Plate and connector assembly24. Shift lever assembly25. Shift lever pin26. Shift lever plug27. Outer jump spring28. Spring retainer assembly29. Bolt30. IMS assembly31. Solenoid screw32. Solenoid assembly33. Nut34. Nut

DISASSEMBLY1. Disconnect each nut from the magnet switchassembly.

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2. Remove the screw from the rear bracket.

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3. Remove the through bolt from the rear bracket.

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4. Remove the rear bracket.

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5. Remove the yoke assembly, the brush holderassembly and the armature.

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6. Remove the mounting screw of the starter motorrelay.

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7. Remove the mounting screw of the magnet switch.

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8. Remove the magnet switch (A).

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9. Remove the plug using a long nose plier.

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10.Remove the ball, the small gear and the shield.

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11.Remove the hog-ring with an awl.

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12.Remove the pinion and the spring.

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13.Remove the shaft assembly and the lever.

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14.Remove the lever pin.

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15.Remove the C-ring with a long nose plier.

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16.While the holding (A), turn 1/2 pitch of (B) toseparate.

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REASSEMBLYReassembly is the reverse order of disassembly.

INSPECTIONARMATURE CHECK1. Coil short test

a. Place the armature on a growler tester. Hold apiece of iron in parallel with the armature.

b. Slowly turn armature by hand. If the iron piece isattracted or vibrated, which means there is ashort circuit. Then, replace the armature.

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2. Coil ground testCheck for continuity between the commutator andshaft (or core). If there is continuity at the placewhere coil is grounded, replace the armature.

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3. Measure outer diameter of armature commutator.If the measured value is less than limit, replace thearmature.* Limit value : Ø 35.0mm

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4. Measure under cut (B) between segment (A). If out ofreference value, correct it.* Reference value : 0.7 ~ 0.9 mm

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5. Commutator checka. Place the armature on 2 V-blocks. Measure the

run-out of commutator using a dial indicator.b. If the run-out exceeds the limit, repair it as far as

outer diameter does not exceed the service limit.c. Repair the irregular wear on the commutator

surface by grinding with sand paper (No.300~500).* Commutator run-out : 0.06 mm

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FIELD COIL CHECK1. Coil open testCheck for continuity between the terminal lead andthe brush (+). If there is no continuity, the circuit isopened. Then, replace the yoke assembly.

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2. Coil short testCheck for continuity between the yoke and the brush(+). If there is continuity, the circuit is grounded.Then, replace the yoke assembly.

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BRUSH AND BRUSH HOLDER ASSEMBLY1. Measure the brush wear, and replace if it is less thanthe limit.When replacing the brush, take care not to damageholder.* Brush wear service limit : 12.0 mm

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2. Measure the installed load of the brush spring.If the measured spring pressure is less than the limit,replace the spring.* Reference value : 20 ~ 24 N(2.1~2.4kgf)

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3. Brush holder assembly insulation testCheck for continuity between brush holder (+) andbrush holder plate (-). If there is continuity, replacethe brush holder assembly.

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MOTOR INSPECTIONELECTRIC MOTOR OPERATION TEST1. Connect battery between terminal “M” of magneticswitch and motor body.

2. It is normal if the electric motor operates. Check theinternal parts if the electric motor does not operate. Do not try to connect continually longer than 10seconds.

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Pull-in coil test in the magnetic switch1. Pull-in coil is normal if the plunger goes in and thenthe pinion comes out when the battery is connectedbetween terminal “S” and “M” of magnetic switch.

2. If it does not come out, replace the magnetic switch.Disconnect connector from terminal "M" for the test. Do not try to connect continually longer than 10seconds.

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Holding coil support Test in the magneticswitch1. Pull out the pinion to 34mm by hand with batteryconnected between terminal “S” of magnetic switchand body. If pinion returns when it is released,holding coil is normally functioning. Do not try to connect continually longer than 10seconds.

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Magnetic switch return test1. Pull out the pinion to 34mm by hand with batteryconnected between terminal “M” of magnetic switchand body. If pinion returns immediately when it isreleased, both coils are normally functioning. Do not try to connect continually longer than 10seconds.

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Preheating SystemIntake Air HeaterCOMPONENTS

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1. Cylinder head2. Coupler intake gasket3. Intake coupler4. Pipe air heater

5. Air heater assembly6. Heater gasket7. Heater gasket(MESH)

REPLACEMENTAIR HEATER ASSEMBLY1. Disconnect air heater ground cable and cableconnected with air heater relay.

2. Remove air heater mounting bolts(four) and thenremove air heater assembly with the gasket.

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3. Installation is the reverse order of removal.AIR HEATER RELAY1. Disconnect air heater relay connector and cable.2. Disconnect air heater relay mounting bolts(two) andthen remove air heater relay.

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3. Installation is the reverse order of removal.

INSPECTION1. Check the cable connected to air heater for damage.2. Check the air heater ground cable for damage.