Starting Charging System
Contents
1. 2 0 al Ul L O gF e 1 7 8 00143 3 Remove the V belt cover 4 Remove the front side V belt lt Ref to ME H4SO 43 FRONT SIDE BELT RE MOVAL V belt gt or lt Ref to ME H4DOTC 54 FRONT SIDE BELT REMOVAL V belt gt STARTING CHARGING SYSTEMS 5 Remove the bolts which install generator onto bracket SC 00032 B INSTALLATION Install in the reverse order of removal Tightening torque 25 N m 2 5 kgf m 18 1 ft lb CAUTION Check and adjust the V belt tension lt Ref to 450 44 INSPECTION V belt gt or lt Ref to ME H4DOTC 55 INSPECTION V belt gt SC 00032 C DISASSEMBLY 1 Remove the four through bolts SC 00078 SC H4S0 13 Generator STARTING CHARGING SYSTEMS 2 Heat portion A of rear cover to 50 C 122 F with a heater drier SC 00079 3 Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover Pry them apart to disassemble SC 00080 A Screwdriver 4 Hold the rotor with a vise and remove pulley nut SC 00035 CAUTION When holding the rotor with a vise place alumi num plates or wooden pieces on the vise jaws to prevent rotor from damage SC 00036 gt Front cover2. SC 00089 2 Remove the cover of terminal B SC 00090 3 Remove the nut of terminal B and then re move the rectifier 5 00091 D ASSEMBLY Assemble in the reverse order of disassembly 1 Pulling up brush Before assembling press the brush down into brush holder and then fix them in that position by passing a 1 mm 0 08 in dia 40 to 50 mm 1 6 to 2 0 in long wire through the hole as shown in the figure CAUTION Be sure to remove the wire after reassembly SC 00092 A Wire 2 Install the ball bearing 1 Set the ball bearing on the front cover and then securely install an appropriate tool Such as a fit socket wrench to the bearing outer race 2 Press the ball bearing into the specified po sition using a press 3 Install the bearing retainer 3 Press the bearing rear side into the rotor shaft using a press to install 4 Heat the bearing box in rear cover 50 to 60 C 122 to 140 F and then press the rear bearing into rear cover CAUTION Grease should not be applied to rear bearing Remove the oil completely if it is found on bear ing box 5 After reassembly turn the pulley by hand to check that rotor turns smoothly E INSPECTION 1 DIODE CAUTION Never use a mega tester designed for reading high voltage or any other similar instrument for this test otherwise the diodes may be dam aged SC H4S0 16 Generator ST
3. FUJI HEAVY INDUSTRIES LTD G1870GE2 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU H4SOw oOBD SPEED CONTROL SYSTEMS SP H4SOw oOBD IGNITION IG H4SOw 00BD STARTING CHARGING SYSTEMS SC H4SOw oOBD EN H4SOw 00BD ENGINE DIAGNOSTICS diag i G1870GE2 See STARTING CHARGING SYSTEMS _SC HASO eneral Description oS ee oe at RATION A a General Description STARTING CHARGING SYSTEMS 1 General Description A SPECIFICATIONS 1 NON TURBO MODEL Item Designation Type Reduction type Vehicle type MT 1 6 LAT 2 0 LAT 2 5 LAT Model MO000T30471 MO000T30571 000720171 Manufacturer Mitsubishi Electric Voltage and output 12 V 1 0 kW 12 1 4 kW Direction of rotation Counterclockwise when observed from pinion Number of pinion teeth 8 9 Voltage 11V No load charac teristics Current 95 A or less 90 A or less Starter Rotating speed 2 500 rpm or more 2 000 rpm or more Voltage 7 5 V 7 7 V Load character Current 300 A 400 A istics Torque 8 84 N m 0 90 kgf m 6 5 ft lb or more 16 7 N m 1 70 kgf m 12 3 ft lb more Rotating speed 870 rpm or more 710 rpm or more Voltage 4V 3 5 V Lock character Curre
4. SC 00045 5 Ball bearing rear side Check the rear ball bearing Replace if it is noisy or if the rotor does not turn smoothly 3 STATOR 1 Continuity test Inspect the stator coil for continuity between each end of the lead wires If resistance is 1 MQ or more the lead wire is broken and so replace the stator assembly NA 4 SC 00047 A Stator SC H4S0 17 Generator STARTING CHARGING SYSTEMS 2 Insulation test Inspect the stator coil for continuity between stator core and each end of lead wire If resistance is 1 Q or less the stator coil is grounded and so replace the stator assembly f h N 4 SC 00048 4 BRUSH 1 Measure the length of each brush If wear ex ceeds the service limit replace the brush Each brush has the service limit mark A on it Brush length Standard 18 5 mm 0 728 in Service limit 5 0 mm 0 197 in SC 00049 2 Checking brush spring for proper pressure Using a spring pressure indicator push the brush into the brush holder until its tip protrudes 2 mm 0 08 in Then measure the pressure of brush spring If the pressure is less than 2 648 N 270 g 9 52 02 replace the brush spring with a new one The new spring must have a pressure of 4 609 to 5 786 N 470 to 590 g 16 58 to 20 810 oz 5 BEARING FRONT SIDE Check the front ball bearing If the resistance is
5. B Pulley C Nut D Rotor 5 Remove the ball bearing as follows 1 Remove the bolt and then remove the bear ing retainer 2 Firmly install an appropriate tool such as a fit socket wrench to bearing inner race SC 00082 3 Push the ball bearing off the front cover us ing a press 5 45 14 Generator 6 Remove the bearing from rotor using a bearing puller SC 00046 7 Unsolder connection between rectifier and stator coil to remove the stator coil CAUTION Do not allow a 180 270 W soldering iron to contact the terminals for more than 5 seconds at once because the rectifier cannot withstand so much heat SC 00083 8 Remove the IC regulator as follows 1 Remove the screws which secure IC regula tor to rear cover SC 00084 STARTING CHARGING SYSTEMS 2 Unsolder the connection between IC regula tor and rectifier to remove the IC regulator SC 00085 9 Remove the brush as follows 1 Remove cover A SC 00086 A CoverA 2 Remove cover B SC 00087 A CoverB 3 Separate the brush from connection to re move SC 00088 SC H4S0 15 Generator STARTING CHARGING SYSTEMS 10 Remove the rectifier as follows 1 Remove the bolts which secure the rectifier
6. Current 90 A or less Starter teristics Rotating speed 3 000 rpm or more 2 000 rpm or more Voltage 8 V 7 7 V Load character Current 280 A 400 A istics Torque 16 7 N m 1 70 kgf m 12 3 ft lb 9 3 N m 0 95 kgf m 6 9 ft lb or more more Rotating speed 860 rpm or more 710 rpm or more Voltage 5V 3 5 V Lock character Current 515 less 960 A or less istics Torque 16 N m 1 63 kgf m 11 8 ft lb 31 N m 3 16 kgf m 22 9 ft lb or more more Type Rotating field three phase voltage regulator built in type with load response control system Model A2TB5391 A2TB6291 Manufacturer Mitsubishi Electric Voltage and outpu t 12 75 Generator Polarity on ground side Negative Direction of rotation Clockwise when observed from pulley side Armature connecti on Three phase Y type Output current 1 500 rpm 30 A or more 2 500 rom 64 A or more 5 000 rom 76 A or more Regulated voltage 14 1 14 8 V 20 68 F Battery Type and capac Europe and South America 12 V 48 AH 55D 231 12 V 52 AH 65D 231 ity For Australia and South America except STi Australia 12 V 40 AH 50D 20L SC H4S0 3 STARTING CHARGING SYSTEMS B COMPONENT 1 STARTER General Description EXCEPT FOR DOHC TURBO MT MODE
7. specifications Load test standards Voltage Load 1 6L MT 2 0L Non turbo MT 2 5L MT and 1 6L AT 7 5 V 8 84 0 90 kgf m 6 5 ft lb 2 0L Non turbo AT 2 5L AT 7 7 V 16 7 N m 1 70 kgf m 12 3 ft lb 2 0L Turbo MT 8 V 9 3 0 95 kgf m 6 9 ft lb 2 0L Turbo AT 7 7 V 16 7 N m 1 70 kgf m 12 3 ft lb Current Speed 1 6L MT 2 0L Non turbo MT 2 5L MT and 1 6L AT More than 300 A 870 rpm 2 0L Non turbo AT 2 5L AT More than 400 A 710 rpm 2 0L Turbo MT More than 280 A 860 rpm 2 0L Turbo AT More than 400 A 710 rpm 3 Lock test With the starter stalled or not rotating measure the torque developed and current draw when the volt age is adjusted to the specified voltage Lock test standards Voltage Current 1 6L MT 2 0L Non turbo MT 2 5L MT and 1 6L AT Less than 4 V 680 A 2 0L Non turbo AT 2 5L AT Less than 3 5 V 960 A 2 0L Turbo MT Less than 5 V 515 A 2 0L Turbo AT Less than 3 5 V 960 A Torque 1 6L MT 2 0L Non turbo MT 2 5L MT and 1 6L AT 17 N m 1 73 kgf m 12 5 ft lb 2 0L Non turbo AT 2 5L AT 31 N m 3 16 kgf m 22 9 ft lb 2 0L Turbo MT 16 N m 1 63 kgf m 11 8 ft lb 2 0L Turbo AT 31 N m 3 16 kgf m 22 9 ft lb 5 45 12 Generator 3 Generator A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the connector and terminal from generator e NON TURBO MODEL 9 NQ TDDS
8. 1 Rear cover 4 Bearing retainer 8 regulator with brush 12 Terminal careful not to burn your hands because each part on the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect the ground cable from battery SC H4SO 6 Starter 2 Starter A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the air cleaner case Non turbo model lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt 3 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercool er gt 4 Remove the air cleaner case stay Non turbo model MT MODEL STARTING CHARGING SYSTEMS 5 Disconnect the connector and terminal from starter Terminal B Connector 6 Remove the starter from transmission B INSTALLATION Install in the reverse order of removal Tightening torque 50 N m 5 1 kgf m 37 ft lb C DISASSEMBLY 1 STARTER ASSEMBLY 1 Loosen the nut which holds the terminal M of switch assembly and then disconnect the connec tor 2 Remove the bolts which hold the switch assem bly and then remove switch assembly plunger and plunger spring from starter as a unit SC H4S0
9. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 FUEL INJECTION FUEL SYSTEMS FU H4SO EMISSION CONTROL EC H4S0 AUX EMISSION CONTROL DEVICES INTAKE INDUCTION NTU SIO MECHANICAL 450 This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts EXHAUST EX H4SO COOLING 0 45 LUBRICATION LU H4SO SPEED CONTROL SYSTEMS SP H4SO IGNITION IG H4S0 STARTING CHARGING SYSTEMS SC H4S0 ENGINE DIAGNOSTICS 45 FUEL INJECTION FUEL SYSTEMS FU H4SOw oOBD EMISSION CONTROL EC H4SOw 00BD AUX EMISSION CONTROL DEVICES INTAKE INDUCTION IN H4SOw 00BD MECHANICAL 45 0 0 EXHAUST EX H4SOw oOBD All information illustration specifi cations contained in this manual are based on the latest product information available at the time of publication approval COOLING CO H4SOw 00BD
10. 7 Starter STARTING CHARGING SYSTEMS NOTE Be careful because the pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly SC 00169 A Switch ASSY B Plunger 3 Remove both through bolts and brush holder screws and then detach the rear cover and brush holder SC 00170 Brush holder B Rear cover 4 Remove the armature and yoke from front brack et The ball used as a bearing will come off from the armature end NOTE Before removal of the yoke put alignment marks on the yoke and front bracket SC 00171 A Front bracket B Yoke C Ball 0 Armature 5 Remove packing A planetary gears packing B and plate FN B SC 00172 Packing A Planetary gear 6 Remove the shaft assembly and overrunning clutch as a unit SC H4S0 8 Starter STARTING CHARGING SYSTEMS NOTE Note the direction of the lever before removing SC 00173 A Shaft ASSY Overrunning clutch C Lever 7 Remove the overrunning clutch from shaft as sembly as follows 1 Remove the stopper from ring by lightly tap ping the stopper with an appropriate tool such as a fit socket wrench 2 Remove the ring stopper and clutch from shaft SC 00014 Socket wrench Ring Shaft Stopper 2 BRUSH HOLDER NOTE Only the brush holder of turbo MT model starter ca
11. ARTING CHARGING SYSTEMS 1 Checking positive diode Check for continuity between the diode lead and positive side heat sink The positive diode is in good condition if resistance is 1 Q or less only in the direction from the diode lead to heat sink SC 00042 A Diode lead B Heat sink positive side 2 Checking negative diode Check for continuity between the negative side heat sink and diode lead The negative diode is in good condition if resistance is 1 Q or less only in the direction from the heat sink to diode lead SC 00043 A Diode lead B Heat sink negative side 2 ROTOR 1 Slip ring surface Inspect the slip rings for contamination or any roughness on the sliding surface Repair the slip ring surface using a lathe or sand paper 2 Slip ring outer diameter Measure the slip ring outer diameter If the slip ring is worn replace the rotor assembly Slip ring outer diameter Standard 22 7 mm 0 894 in Limit 22 1 mm 0 870 in 3 Continuity test Check the resistance between slip rings using cir cuit tester If the resistance is not within the specified range replace the rotor assembly Specified resistance Approx 1 8 2 2 56 00044 4 Insulation test Check the continuity between slip ring and rotor core or shaft If resistance is 1 or less the rotor coil is grounded and so replace the rotor assem bly
12. L 16 a A 5 02009 a Front bracket 1 2 Sleeve bearing 3 Lever set 4 Magnet switch ASSY 5 Stopper set 6 Overrunning clutch Internal gear ASSY Shaft ASSY Gear ASSY Packing Yoke ASSY Armature SC H4S0 4 13 14 15 16 Brush holder ASSY Sleeve bearing Rear cover Rear cover set General Description STARTING CHARGING SYSTEMS DOHC TURBO MT MODEL SC 00168 1 Sleeve bearing 7 Internal gear ASSY 13 Armature 2 Front bracket 8 Shaft ASSY 14 Brush holder ASSY 3 Lever set 9 Gear ASSY 15 Brush 4 Magnet switch ASSY 10 Ball 16 Sleeve bearing 5 Stopper set 11 Packing 17 Rear cover 6 Overrunning clutch 12 Yoke ASSY SC H4SO0 5 General Description STARTING CHARGING SYSTEMS 2 GENERATOR 12 C CAUTION Wear working clothing including cap protec tive goggles and protective shoes during operation Remove contamination including dirt and sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement SC 00144 1 Pulley 5 Rotor 9 Brush 2 Front cover 6 Bearing 10 Rectifier 3 bearing 7 gt Stator coil 1
13. ent value specified by manufacturer or at approx 1 10 of the battery s am pere hour rating 4 QUICK CHARGING Quick charging is a method in which the battery is charged in a short period of time with a relatively large current by using a quick charger Since a large current flow raises electrolyte temper ature the battery is subject to damage if large cur rent is used for prolonged time For this reason the quick charging must be carried out within a current range that will not increase the electrolyte temper ature above 40 C 104 F It should be also remembered that the quick charg ing is a temporary means to bring battery voltage up to a fair value and as a rule a battery should be charged slowly with a low current CAUTION Observe the items 3 NORMAL CHARGING e Never use more than 10 amperes when charging the battery because that will shorten battery life SC H4S0 20
14. felt while rotating or if abnormal noise is heard re place the ball bearing SC H4S0 18 Battery STARTING CHARGING SYSTEMS 4 Battery A REMOVAL 1 Disconnect the positive cable after discon necting the ground cable of battery 2 Remove the flange nuts from battery rods and then take off the battery holder SC 00053 3 Remove the battery B INSTALLATION Install in the reverse order of removal Tightening torque 3 4 0 35 kgf m 2 5 ft lb NOTE Clean the battery cable terminals and then apply grease to retard formation of corrosion e Connect the positive cable of battery and then the ground cable of battery C INSPECTION WARNING Electrolyte has toxicity be careful handling the fluid Avoid contact with skin eyes or clothing Es pecially at contact with eyes flush with running water for 15 minutes and get prompt medical at tention Batteries produce explosive gasses Keep sparks flame cigarettes away Ventilate when charging or using in enclosed space For safety in case an explosion does occur wear eye protection or shield your eyes when working near any battery Never lean over a bat tery Do not let the battery fluid contact eyes skin fabrics or paint work because battery fluid is corrosive acid To lessen the risk of sparks remove rings metal watch bands and other metal jewelry Never allow metal tool
15. ginal position even when it is pulled out with a screwdriver SC 00175 A Terminal S B Terminal M SC H4SO 11 Starter STARTING CHARGING SYSTEMS 7 PERFORMANCE TEST The starter should be submitted to performance tests whenever it has been overhauled to assure its satisfactory performance when installed on the engine Three performance tests no load test load test and lock test are presented here however if the load test and lock test cannot be performed carry out at least the no load test For these performance tests use the circuit shown in figure SC 00077 A Variable resistor B Magnetic switch C Starter body 1 No load test With switch on adjust the variable resistor to obtain 11 V take the ammeter reading and then measure the starter soeed Compare these values with the specifications No load test standards Voltage Current 1 6L MT 2 0L Non turbo MT 2 5L MT and 1 6L AT 11 95 2 0L Non turbo AT 2 5L AT MAX 11 V 90 A 2 0L Turbo MAX 11 V 90 A Rotating speed 1 6L MT 2 0L Non turbo MT 2 5L MT and 1 6L AT More than 2 500 rpm 2 0L Non turbo AT 2 5L AT More than 2 000 rpm 2 0L Turbo MT More than 3 000 rpm 2 0L Turbo AT More than 2 000 rpm 2 Load test Apply the specified braking torque to starter The condition is satisfactory if the current draw and starter speed are within the
16. n be disassembled Slightly open the metal fitting while holding the in sulating plate against the brush holder Remove the insulating plate The brush and spring can be easily removed from the brush holder at this time SC 00174 Brush holder B Insulating plate C Metal fitting D ASSEMBLY 1 Assemble in the reverse order of disassembly 2 Apply grease to the following parts before as sembly Front and rear bracket sleeve bearings Armature shaft gear Outer periphery of plunger Mating surfaces of plunger and lever Gear shaft splines Mating surfaces of lever and clutch Ball at armature shaft end Planetary gear E INSPECTION 1 ARMATURE 1 Check the commutator for any sign of burns of rough surfaces or stepped wear If wear is of a mi nor nature correct it by using sand paper 2 Run out test Check the commutator run out and then replace if it exceeds the limit SC H4S0 9 STARTING CHARGING SYSTEMS Starter Commutator run out Standard 0 05 mm 0 0020 in Service limit Less than 0 10 mm 0 0039 in A i 4 5 00021 Dial gauge V block 3 Depth of segment mold Check the depth of segment mold Depth of segment mold 0 5 mm 0 020 in SC 00022 A Depth of mold B Segment C Mold 4 Armature short circuit test Check the armature for short circuit by placing it on a growler tester Hold an i
17. nt 680 A or less 960 A or less istics Torque 17 N m 1 73 kgf m 12 5 40 31 N m 3 16 kgf m 22 9 ft lb more more Type Rotating field three phase voltage regulator built in type with load response control system Model A2TB5391 A2TB6291 Manufacturer Mitsubishi Electric Voltage and output 12 75 Generator Polarity on ground side Negative Direction of rotation Clockwise when observed from pulley side Armature connecti on Three phase Y type Output current 1 500 rom 30 A or more 2 500 rom 64 A or more 5 000 rpm 76 A or more Regulated voltage 14 1 14 8 V 20 68 F Type and capac Battery ity Europe and South America 1 61 12 48 550 23L 2 01 12 52 650 231 2 5 L 12 52 750 231 12 V 48 550 231 For Australia and general Others 12 V 27 AH 34D 191 SC H4S0 2 General Description STARTING CHARGING SYSTEMS 2 TURBO MODEL Item Designation Type Reduction type Vehicle type MT AT Model 228000 9270 001720171 Manufacturer DENSO Mitsubishi Electric Voltage and output 12 V 1 0 kW 12 V 1 4 kW Direction of rotation Counterclockwise when observed from pinion Number of pinion teeth 9 Voltage 11 5 V 11V No load charac
18. rge SC 00094 Specific gravity 20 C 68 F 2 Measuring the specific gravity of the electrolyte in battery will disclose the state of charge of bat tery The relation between specific gravity and state of charge is as shown in the figure D MEASUREMENT WARNING Do not bring an open flame close to the battery at this time CAUTION Prior to charging corroded terminals should be cleaned with a brush and common caustic soda solution SC H4S0 19 Battery STARTING CHARGING SYSTEMS Be careful since the battery electrolyte over flows while charging the battery Observe the instructions when handling bat tery charger Before charging the battery on vehicle dis connect battery ground terminal to prevent damage of generator diodes or other electrical units 1 JUDGMENT OF BATTERY IN CHARGED CONDITION 1 Specific gravity of electrolyte is held within the specified range from 1 250 to 1 290 for more than one hour 2 Voltage per battery cell is held at the specified range from 2 5 to 2 8 volts for more than one hour 2 STATE OF CHARGE CHECK USING A HYDROMETER Hydrometer indicator Green dot Above 65 Load test Dark dot Below 65 Charge battery Replace battery If cranking is difficult State of charge Corrective action Clear dot Low electrolyte Check electrical system before replacement 3 NORMAL CHARGING Charge the battery at curr
19. ring force Measure the brush spring force with a spring scale If it is less than the service limit replace the brush holder Brush spring force Standard Except DOHC turbo MT model 15 9 19 5 N 1 62 1 99 kof 3 57 4 38 16 when new DOHC turbo MT model 21 6 N 2 2 kgf 4 9 Ib when new Service limit Except DOHC turbo MT model 2 5 N 0 25 kgf 0 56 Ib DOHC turbo MT model 5 9 N 0 6 kgf 1 3 Ib 5 SWITCH ASSEMBLY Using a circuit tester set in check that there is continuity between terminals S and M and between terminal S and ground Also check to be sure there is no continuity be tween terminals M and B Terminal Specified resistance S M Less than 1 Q S Ground Less than 10 B More than 1 MQ STN 5 00075 6 SWITCH ASSEMBLY OPERATION 1 Connect the terminal S of switch assembly to positive terminal of battery with a lead wire and starter body to ground terminal of battery The pin ion should be forced endwise on shaft CAUTION With the pinion forced endwise on shaft the starter motor may rotate because current flows through the pull in coil to motor however this is not a problem 2 Disconnect the connector from terminal M and then connect the positive terminal of battery and terminal M using a lead wire and ground terminal to starter body In this test set up the pinion should return to its ori
20. ron sheet against the ar mature core while slowly rotating armature A short circuited armature will cause the iron sheet to vibrate and to be attracted to core If the iron sheet is attracted or vibrates the armature which is short circuited must be replaced or repaired SC 00023 Iron sheet Grower tester 5 Armature ground test Using a circuit tester touch one probe to the com mutator segment and the other to shaft There should be no continuity If there is continuity the ar mature is grounded Replace the armature if it is grounded SC 00024 2 YOKE Make sure the pole is set in position 3 OVERRUNNING CLUTCH Inspect the teeth of pinion for wear and damage Replace if it is damaged It is normal if the pinion ro tates smoothly in direction of rotation counter clockwise and does not rotate in the opposite direction CAUTION Do not clean the overrunning clutch with oil to prevent grease from flowing out SC H4S0 10 Starter STARTING CHARGING SYSTEMS 4 BRUSH AND BRUSH HOLDER 1 Brush length Measure the brush length and then replace if it is worn down to under the service limit Replace if abnormal wear or cracks are noticed Brush length Standard 12 3 mm 0 484 in Service limit 7 0 mm 0 276 in SC 00102 Service limit line B Brush 2 Brush movement Be sure the brush moves smoothly inside brush holder 3 Brush sp
21. s to contact the positive battery terminal and anything connected to it while you are at the same time in contact with any other metallic portion of the vehicle This may cause a short circuit 1 EXTERNAL PARTS Check for the existence of dirt or cracks on battery case top cover vent plugs and terminal posts If necessary clean with water and wipe with a dry cloth Apply a thin coat of grease on the terminal posts to prevent corrosion 2 ELECTROLYTE LEVEL Check the electrolyte level in each cell If the level is below MIN LEVEL bring the level to MAX LEVEL by pouring distilled water into the battery cell Do not fill beyond MAX LEVEL 3 SPECIFIC GRAVITY OF ELECTROLYTE 1 Measure the specific gravity of electrolyte using a hydrometer and a thermometer Specific gravity varies with temperature of electro lyte so that it must be corrected at 20 C 68 F us ing the following equation 520 St 0 0007 x t 20 520 Specific gravity corrected at electrolyte temperature of 20 C St Measured specific gravity t Measured temperature C Determine whether or not battery must be charged according to corrected specific gravity Standard specific gravity 1 220 1 290 at 20 C 68 F 1 28 1 26 1 244 1 22 1 1 20 4 1 1 1 184 1 1 1 164 1 i a 1 144 i 1 1 124 i l 100 75 50 22 0 Complete charge Charging condition Specific gravity and state of cha
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