General

TROUBLESHOOTING
CHARGING SYSTEM
Symptom

Possible cause

Charge warning lamp is not Fuse is broken.

turned on when ignition switBulb is broken.
ch is ON state.
Loose wiring connection

Charge warning lamp does

not turn off even after the engine is started.(When battery needs to be charged frequently)

Battery is overcharged.

Battery is discharged.

Remedy
Replace the fuse.
Replace the bulb.
Retighten the loose connection

Wrong connection of L-S terminals

Check and replace wiring or replace the voltage regulator

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.

Votage regulator is defective. (Charge warReplace the voltage regulator.

ning lamp turns on.)
Voltage sensing wiring is defective.

Replace the wiring.

Drive belt is loose or worn.

Replace the drive belt.

Wiring connector is loose or circuit is short. Retighten the loose connection or repair the
wiring.
Fusible link is short.

Replace fusible link.

Poor grounding

Repair.

Voltage regulator is defective.(Charge warCheck the alternator.

ning lamp turns on.)
Battery is exhausted.

Check the battery.

PRE-HEATER SYSTEM
Symptom

Possible cause

Remedy

Engine does not start when Wiring connection is loose or wiring is defethe coolant temperature is b- ctive.
elow 0C.
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 explosion or idle is unstable when the coolant temperature is below 0C.

Correct or tighten wiring or connection.

Replace air heater.
Replace the relay.
Replace the unit.

Connection is loose or wiring is defective

Air heater is defective.
Pre-heater plug relay is defective.
Pre-heater control unit is defective.

Symptom

Possible cause

Pre-heating indicator remai- Lamp is short.

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

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

STARTER SYSTEM
Symptoms

Possible cause

Engine does not crank.

Defective battery, excessive discharge

Wiring fault of starter motor
Wiring fault of starter motor relay
Wiring fault of magnetic switch
Wiring fault of starter switch
Wiring fault of battery
Defective magnetic switch
Defective starter motor relay
Wear or damage of brush
Defective motor
Defective starter switch

Remedy
Charge or replace.
Repair or replace.
Repair or replace
Repair 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 engine Pinion gear is out of mesh with ring gear.
does not start.
Battery voltage is low.
Ring gear, pinion wear or damage
Defective heater relay
Contact pressure of brush is low.
Defective overrunning clutch
Battery 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.

Repair or replace.
Repair or replace.

Defective starter switch

Defective magnetic switch

GENERAL
STARTER 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 OUTPUT

Items
No load test

Load test

Specification

Terminal voltage

23.5 V

Max. current

120 A

Min. RPM

3,400 RPM or more

Magnetic switch operating voltage

16 V or less

Terminal voltage

16 V

Terminal current

600 A

Min. RPM

900 RPM or more

Characteristics of ass- Terminal voltage

urance output
Max. current

9V
Less than 1,140 A

Min. rotation force

98 Nm or more

PRE-HEATING SYSTEM
Items
Air heater

Specification

Capacity

2.1kW

Rated voltage, amperage

22V 95A 10%

Temperature increase

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

The temperature should be 1,010C at 30 sec. after DC 22
V is applied.
1M or more when measuring with a megger tester at room temperature

Isolation resistance

ALTERNATOR (HD120)
Items
Alternator
(HD120,70A)

Specification

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 20C]

28 0.5V

SERVICE STANDARD (HD120)

Items
Alternator output
characteristics
[at hot]
IC regulator adjusting
voltage
(5,000 rpm, 5A or less)

Reference value
Voltage
27V

Output current

RPM

35A

1,500 rpm

70A

5,000 rpm

28~29V

Limit value

Remedy

70% or more

Replace.

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 20C)

28 0.5V

SERVICE STANDARD (ALTERNATOR, AEROTOWN)

Items

Reference value
Votage

Alternator output characteristics

[at hot]
IC regulator adjusting voltage
(5,000 rpm, 5A or less)

27V

Output current

RPM

80A

1,900 rpm

140A

5,,000 rpm

28~29V

Limit value

Remedy

70% or more

Replace.

Replace.

Charging System
Alternator(Truck)
SDFEE7502D

OUTLINE
ALTERNATOR

RECTIFIER

Alternator is of a built-in type with an IC regulator. A

brush holder is installed in the rear bracket.

Rectifier comprises of 3 pairs of diodes(6 in total) and 1

heat sinks. It converts AC output of the stator to DC
power.

When IC regulator fails, regulator assembly should be

replaced because the voltage cannot be controlled.

ROTOR
When the rotor is driven by the rotation of the pulley, the
current flows from the brush to rotor coil through slip ring.
Then, rotor core becomes an electromagnet.

SDFEE7503D

REGULATOR
Regulator assembly comprises of IC regulator, brush and
brush spring. It stabilizes the output varying according to
the engine rpm.

SDFEE7501D

STATOR
Stator core forms the magnetic flux path together with
rotor core. The magnetic flux in the stator core is affected
by the passage of the rotor core field so that electricity is
generated as each rotor core rotates.

SDFEE7504D

COMPONENTS

SDGEE9001L

DISASSEMBLY
1. Remove two nuts mounted on rear cover using a
screwdriver.

4. Loosen two bolts and a stud bolt and then separate

regulator (A).

SDFEE7509D
SDFEE7506D

2. Separate cover (A) using a screwdriver.

SDFEE7507D

5. Remove four through bolts and disassemble stator

and rectifier(A).

SDFEE7510D

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

disconnect stator.

3. Separate slip ring guide (A).

SDFEE7508D
SDFEE7511D

7. Using a compressed air tool, loosen nut and

disconnect front bracket.

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

SDFEE7001D

REASSEMBLY

SDFEE7512D

Reassembly is the reverse order of disassembly.

INSPECTION

2. Check for continuity between lead wire (A) and coil

(B). Replace the stator if there is continuity.

ROTOR INSPECTION

BRUSH INSPECTION

1. Check for continuity between slip rings (A). Replace

the rotor if there is no continuity.

Replace the brush if it is worn exceeding to the limit.

REGULATOR INSPECTION
Replace the regulator if brush is worn and does not
contact with slip ring of rotor.

SDFEE7002D

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.

Alternator(Bus)
3. Stator

OUTVIEW
ALTERNATOR (AEROTOWN)
In brushless type of alternator, brush isn't used and a
current is supplied for field coil.

Voltage in the stator coil which coil is wound will be

generated by alternating magnetic field produced by
field coil.

Main components are composed of field coil generating

magnetic field, stator generating electric force, rectifier
rectifying electric force and regulator allowing voltage to
generate constantly etc..
1. Field coil
Field coil connected to front and rear bracket
receives current from terminal and generates
magnetic field.

SDFEE7003D

4. Rectifier

SDGEE9025L

2. Rotor
If the rotor is turned around field coil by pulley,
magnetic poles are formed by field coil due to
magnetic field generated.

Main components of rectifier are 3 diode trios, 8

diodes and 1 heat sink. Commutator converts A.C.
into D.C.
Each heat sink has (+) or (-) lead of 4 diodes and
converts 3 phase alternating current into direct
current by rectifying.

SDFEE7004D
SDGEE9026L

5. Regulator

2) When starting engine

Regulator changes force of field coil and stabilizes

output voltage according to variation of engine speed.

Alternator begins to generate electricity when

starting engine, voltage in alternator terminal "B"
becomes higher than battery voltage and current
flows as follows:

SDGEE9003L

Battery charging begins in this way and charging

alarm lamp turns off at the same time.
SDFEE7005D

6. Charging circuit

SDFEE7515D

1) When starting switch is set to ON.

SDGEE9002L

COMPONENTS

SDGEE9007L

3. Result

ON-VEHICLE INSPECTION
VOLTAGE DROP
OUTPUT WIRE

TEST

OF

ALTERNATOR

This test is performed to check whether the wiring is

good or not between the alternator "B" terminal and the
battery (+) 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 wire
disconnected. Connect lead wire(+) of an
ammeter to terminal "B" and connect lead wire (-)
to output wire disconnected.
CAUTION
If clamp type ammeter is used, you can
measure current without disconnecting
harness.
5) Connect a digital voltmeter between alternator
terminal "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.

1) 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 the
wirings between terminal "B" of the alternator
and fusible link, and between alternator and
terminal (+) of the battery.
3) In addition, before the secondary test, check the
looseness at the connection and the discoloration
of harness due to the overheating etc. Repair
them.
4) Adjust the engine speed at idle after the test and
turn 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 TEST

This test is to check whether the alternator output current
coincides with the rated current.
1. Preparation
1) Prior to test, check the followings and repair if
necessary.
2) Check whether the battery installed to vehicle is
normal.
CAUTION
When the output current is measured, use the
battery discharged a little bit.
It is difficult to perform the accurate test with
the fully charged battery because of
insufficient load.
a. Turn the ignition "OFF".
b. Disconnect the battery ground cable.

SDGEE9004L

2. Test
1) Start the engine.
2) With turning ON/OFF the headlight, adjust the
engine speed so that the ammeter indicator
points 20A. Then, measure the voltage.

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.
CAUTION
Since it has high current, make sure to
tighten the connection completely by
using not clip but bolt and nut.

e. Connect the voltmeter (0~40V) between

terminal "B" and ground. And connect lead
wire (+) to terminal "B" of alternator and
connect lead wire (-) to ground.
f. Connect battery ground cable.

1) 140A ALTERNATOR

3. Result
1) Measured value from the ammeter should be
greater than the limit value. Despite that the
alternator output wire is normal, if the measured
value is low, remove the alternator from the
vehicle and check it.
Output current : 70% of the rated current

CAUTION
Rated output current is shown on the
identification plate attached on the
alternator body.
Since output current varies depending on
the electric load and temperature of the
alternator itself, at test it is difficult to get
the rated output current if the electric load
of the vehicle is low. In that case, turn the
headlight on to result in the battery
discharge or increase the electric load by
using additional light from other vehicle.
Since rated output current cannot be
measured when the temperature of
alternator itself or ambient temperatures
are too high, you should lower the
temperature before the secondary test.

SDGEE9005L

2. Test
1) Check to see if the voltmeter indicates voltage
value equivalent to battery voltage.
If voltmeter indicates 0V, it means wire between
terminal "B" of alternator and terminal (-) of
battery may be disconnected, fusible link is short
or ground is poor.
2) Start the engine and turn the headlight switch
"ON".
3) Set the headlight on "HIGH" and place the heater
blower switch at "HIGH". Measure the max.
output current value displayed on the ammeter by
accelerating the engine speed up to 2,500rpm.
NOTICE
Since charging current drops down rapidly after
engine is started, perform this test quickly to get
accurate max. current.

2) After completing the output current test, adjust

the engine speed at idle and turn the ignition
switch 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.

2. Test

ADJUSTING VOLTAGE
This test is to check to see whether the voltage regulator
controls the voltage properly.

1) Turn the ignition switch ON and check to see

whether voltmeter indicates the reference value.

1. Preparation

2) If voltmeter indicates 0V, which means wire

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

1) Check the battery installed on the vehicle for fully

charged.
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 (+) of
voltmeter to terminal "A" by using special tool
wire-harness connector. Connect lead wire (-)
of voltmeter to ground or terminal (-) of the
battery.
5) Disconnect alternator output wire from terminal
B of the alternator.
6) Connect the DC ammeter (0~250A) in serial
between terminal B and the disconnected
output wire. Connect lead wire (-) of ammeter to
the disconnected output wire.
7) Install engine
ground cable.

tachometer.

Connect

battery

3) Start the engine. Turn the light and all other

accessory switches OFF.
3. Result
1) If the voltmeter reading agrees with the table of
the adjusting voltage, the voltage regulator is
normally operating. If the measured value is
higher than the reference value, the voltage
regulator or alternator is defective.
Regulator temperature
(C)
20~30

Adjusting voltage(V)
Alternator 140A
28~29

2) After completing the test, adjust the engine speed

at idle and turn the ignition switch OFF.
3) Disconnect the battery ground cable.

[140A ALTERNATOR]

4) Remove ammeter,
tachometer.

voltmeter

and

engine

5) Connect alternator output wire to terminal B of

alternator.
6) Connect the battery ground cable.

SDGEE9006L

DISASSEMBLY

SDGEE9008L

1. Remove four through bolts.

CAUTION
After removing the mounting screw, remove
bolts after fixing at separating as field coil
assembly can be apart.
2) Separate field coil assembly (A) after gently
prying stator by using a screwdriver.

SDFEE7517D

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

SDFEE7520D

4. Disassembly of stator assembly

Separate stator coil by unsoldering the lead wire of
stator coil from rectifier.(8 points)

SDFEE7519D

3. Disassembly of Field coil assembly

1) Loosen field coil screws (five).

SDFEE7521D

CAUTION
Do not use solder gun for 5 seconds or more at a
time to prevent damage to rectifier due to
overheating.

SDFEE7007D

5. Separating rectifier and regulator from rear bracket

1) Remove mounting nut of terminal "B" bolt and
then remove terminal "B" bolt.

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

SDFEE7522D

2) Remove rectifier and regulator mounting

bolt(6points) and then remove in order of washer
for insulating, rectifier A, B, regulator.

SDFEE7524D

2) Using puller, remove pulley.

SDFEE7525D
SDGEE9009L

SDGEE9010L

3) Remove woodruff key by gently tapping its upper

part and then remove fan.

SDFEE7526D

7. Separate rotor from front bracket using puller.

SDFEE7527D

INSPECTION

SDGEE9011L

1. Stator check

2. Rectifier check

1) Continuity between lead wire

Measure the resistance of each diode.

Check for continuity between lead wires of each

stator. Replace the stator if there is no continuity.
2) Check for continuity between stator lead wire and
core, replace the stator if there is continuity,
which means that there is ground.

Contact (+) and (-) of circuit tester to each diode and

measure.

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.

SDFEE7528D

1) Measurement of diode which has heat sink:

Measure the resistance between heat sink and
stator coil lead connecting part.

3. Field coil check

1) Measure the resistance between the field coil
terminals and if measured value is out of
specification, replace the field coil.
2) Check for continuity between terminal of field coil
and core, replace the field coil if there is
continuity, which means that there is ground.

SDFEE7529D

2) Measure the resistance between sub-diode

connecting part (3 points) and heat sink.
SDFEE7530D

4. Bearing check
If faulty, replace the bearing.
1) Removal of front bearing
a. Remove bearing cover.

SDFEE7529D

SDGEE9012L

b. Strike wooden bar on spacer in front of the

front bracket to remove bearing.

SDGEE9015L

3) Replacement of rear bearing

SDGEE9013L

2) Reassembly of front bearing

a. Remove the rear bearing using a bearing

puller.

a. Apply engine oil to outer side of bearing lightly

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

SDGEE9016L

b. Apply engine oil lightly to the inner side of

bearing and install bearing using a press.

SDGEE9014L

b. Assemble the cover and strike the spacer with

soft hammer to contact bearing with cover.
Otherwise, hit the spacer to contact the
bearing for sure.

SDGEE9017L

REASSEMBLY
Reassembly is the reverse order of disassembly.

Starting System
OUTLINE
STARTER MOTOR
The starter motor is the system which converts electrical
energy of battery into mechanical rotation energy to
supply more than minimum rpm of crankshaft required by
the starting of internal combustion engine. Classifying the
starter motor, it is composed of such parts as electrical
motor part which turning force occurs, drive part which
transmits power to the ring gear, the magnetic switch part
which moves the pinion into the ring gear and sends
current to electrical motor.

2. When the starter switch is closed, current flows to the

starter relay and "B"(battery terminal) and "S"(switch
terminal) of the starter relay are connected and
current begins to flow to the starter plunger.

SDGEE9019L

SDFEE7038D

3. If current flows to the starter plunger, not only the

plunger but also the lever is pulled. Therefore, the
pinion moves to the ring gear side. As "B"(battery
terminal) and "M"(motor terminal) of magnet meet
from the specific engaged distance, large current
flows to the starter motor and the pinion rotates the
ring gear.

OPERATION
1. The pinion is not in mesh with the ring gear if starter
switch is opened.

SDGEE9020L

SDGEE9018L

Starter Motor
COMPONENTS

SDGEE9024L

1. Hog ring
2. Pinion retainer
3. Pinion
4. Pinion spring
5. Housing assembly
6. Clutch and output shaft assembly
7. Gear support assembly
8. Washer
9. Retainer
10. Drive shaft assembly
11. Planetary gear assembly
12. Dust cover
13. Ball
14. Armature assembly
15. O-ring
16. Frame field assembly
17. O-ring

18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Brush holder assembly

CE housing
CE screw
Through bolt
Bolt
Plate and connector assembly
Shift lever assembly
Shift lever pin
Shift lever plug
Outer jump spring
Spring retainer assembly
Bolt
IMS assembly
Solenoid screw
Solenoid assembly
Nut
Nut

4. Remove the rear bracket.

DISASSEMBLY
1. Disconnect each nut from the magnet switch
assembly.

SDFEE7042D

SDFEE7039D

5. Remove the yoke assembly, the brush holder

assembly and the armature.

2. Remove the screw from the rear bracket.

SDFEE7043D
SDFEE7040D

3. Remove the through bolt from the rear bracket.

SDFEE7041D

6. Remove the mounting screw of the starter motor

relay.

SDFEE7044D

7. Remove the mounting screw of the magnet switch.

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

SDFEE7045D

8. Remove the magnet switch (A).

SDFEE7048D

11.Remove the hog-ring with an awl.

SDFEE7046D

9. Remove the plug using a long nose plier.

SDFEE7047D

SDFEE7049D

12.Remove the pinion and the spring.

SDFEE7050D

13.Remove the shaft assembly and the lever.

16.While the holding (A),

separate.

turn 1/2 pitch of (B) to

SDFEE7051D

14.Remove the lever pin.

SDFEE7054D

REASSEMBLY
Reassembly is the reverse order of disassembly.

INSPECTION
ARMATURE CHECK
1. Coil short test
SDFEE7052D

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

a. Place the armature on a growler tester. Hold a

piece of iron in parallel with the armature.
b. Slowly turn armature by hand. If the iron piece is
attracted or vibrated, which means there is a
short circuit. Then, replace the armature.

SDFEE7053D

SDFEE7055D

2. Coil ground test

5. Commutator check

Check for continuity between the commutator and

shaft (or core). If there is continuity at the place
where coil is grounded, replace the armature.

a. 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

SDFEE7056D

3. Measure outer diameter of armature commutator.

If the measured value is less than limit, replace the
armature.
* Limit value : 35.0mm

SDFEE7058D

FIELD COIL CHECK

1. Coil open test
Check for continuity between the terminal lead and
the brush (+). If there is no continuity, the circuit is
opened. Then, replace the yoke assembly.

SDFEE7057D

4. Measure under cut (B) between segment (A). If out of

reference value, correct it.
* Reference value : 0.7 ~ 0.9 mm

SDFEE7059D

SDGEE9022L

2. Coil short test

2. Measure the installed load of the brush spring.

Check for continuity between the yoke and the brush

(+). If there is continuity, the circuit is grounded.
Then, replace the yoke assembly.

If the measured spring pressure is less than the limit,

replace the spring.
* Reference value : 20 ~ 24 N(2.1~2.4kgf)

SDFEE7060D

BRUSH AND BRUSH HOLDER ASSEMBLY

1. Measure the brush wear, and replace if it is less than
the limit.
When replacing the brush, take care not to damage
holder.

SDFEE7062D

3. Brush holder assembly insulation test

Check for continuity between brush holder (+) and
brush holder plate (-). If there is continuity, replace
the brush holder assembly.

* Brush wear service limit : 12.0 mm

SDFEE7063D

SDFEE7061D

MOTOR INSPECTION
ELECTRIC MOTOR OPERATION TEST

Holding coil support Test in the magnetic

switch

1. Connect battery between terminal M of magnetic

switch and motor body.

1. Pull out the pinion to 34mm by hand with battery

connected between terminal S of magnetic switch
and body. If pinion returns when it is released,
holding coil is normally functioning.

2. It is normal if the electric motor operates. Check the

internal parts if the electric motor does not operate.
Do not try to connect continually longer than 10
seconds.

Do not try to connect continually longer than 10

seconds.

SDFEE7066D

SDFEE7064D

Pull-in coil test in the magnetic switch

1. Pull-in coil is normal if the plunger goes in and then
the pinion comes out when the battery is connected
between 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 10
seconds.

Magnetic switch return test

1. Pull out the pinion to 34mm by hand with battery
connected between terminal M of magnetic switch
and body. If pinion returns immediately when it is
released, both coils are normally functioning.
Do not try to connect continually longer than 10
seconds.

SDFEE7064D
SDFEE7065D

Preheating System
Intake Air Heater
COMPONENTS

SDGEE9023L

1.
2.
3.
4.

Cylinder head
Coupler intake gasket
Intake coupler
Pipe air heater

5. Air heater assembly

6. Heater gasket
7. Heater gasket(MESH)

REPLACEMENT

INSPECTION

AIR HEATER ASSEMBLY

1. Check the cable connected to air heater for damage.

1. Disconnect air heater ground cable and cable

connected with air heater relay.

2. Check the air heater ground cable for damage.

2. Remove air heater mounting bolts(four) and then

remove air heater assembly with the gasket.

SDFEE7101D

3. Installation is the reverse order of removal.

AIR HEATER RELAY

1. Disconnect air heater relay connector and cable.
2. Disconnect air heater relay mounting bolts(two) and
then remove air heater relay.

SDFEE7102D

3. Installation is the reverse order of removal.