NISSAN PATROL 1998 Y61 / 5.G Electrical System Repair Manual

Construction
Removal and Installation
Inspection
MAGNETIC SWITCH CHECK
+Before starting to check, disconnect battery ground cable.
+Disconnect ``M'' terminal of starter motor.
1. Continuity test (between ``S'' terminal and switch body).
+No continuity ... Replace.
MEL996DB
MEL609I
SEL036H
STARTING SYSTEM
EL-47

2. Continuity test (between ``S'' terminal and ``M'' terminal).
+No continuity ... Replace.
PINION/CLUTCH CHECK
1. Inspect pinion teeth.
+Replace pinion if teeth are worn or damaged. (Also check con-
dition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
+Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
+If it locks or rotates in both directions, or unusual resistance is
evident. ... Replace.
BRUSH CHECK
Brush
Check wear of brush.
Wear limit length:
Refer to SDS (EL-51).
+Excessive wear ... Replace.
Brush spring pressure
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SDS (EL-51).
+Not within the speci®ed values ... Replace.
Brush holder
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
+Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
+If brush holder is bent, replace it; if sliding surface is dirty, clean.
SEL038H
SEL630BA
SEL014Z
SEL015Z
SEL568B
STARTING SYSTEM
Inspection (Cont'd)
EL-48

YOKE CHECK
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunction-
ing parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.
ARMATURE CHECK
1. Continuity test (between two segments side by side).
+No continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
+Continuity exists. ... Replace.
3. Check commutator surface.
+Rough ... Sand lightly with No. 500 - 600 emery paper.
4. Check diameter of commutator.
Commutator minimum diameter:
Refer to SDS (EL-51).
+Less than speci®ed value ... Replace.
SEL305H
SEL019Z
SEL020Z
SEL021Z
STARTING SYSTEM
Inspection (Cont'd)
EL-49

5. Check depth of insulating mold from commutator surface.
+Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
Assembly
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT
Clearance ``!''
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance ``!'' between the front edge
of the pinion and the pinion stopper.
Clearance ``!'':
Refer to SDS (EL-51).
Movement ``!''
Compare movement ``!'' in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement ``!'':
Refer to SDS (EL-51).
SEL022Z
SEL026Z
SEL497D
STARTING SYSTEM
Inspection (Cont'd)
EL-50

+Not in the speci®ed value ... Adjust by adjusting plate.
Service Data and Speci®cations (SDS)
STARTER
TypeS13-502
HITACHI make
Reduction gear type
Applied model RD28
System voltage V 12
No-load
Terminal voltage V 11
Current A Less than 125
Revolution rpm 4,000
Minimum diameter of commutator
mm (in)35.5 (1.398)
Minimum length of brush mm (in) 11 (0.43)
Brush spring tension
N (kg, lb)28.4 - 34.3
(2.9 - 3.5,
6.4 - 7.7)
Clearance between bearing metal
and armature shaft mm (in)Ð
Clearance ``!'' between pinion
front edge and pinion stopper
mm (in)Ð
Movement ``!'' in height of pinion
assembly mm (in)0.3 - 2.0
(0.012 - 0.079)
SEL633BA
STARTING SYSTEM
Assembly (Cont'd)
EL-51

Wiring Diagram Ð CHARGE Ð
YEL782A
CHARGING SYSTEM
EL-52

Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test. The alternator can be checked easily by referring to the Inspec-
tion Table.
+Before starting, inspect the fusible link.
+Use fully charged battery.
WITH IC REGULATOR
Check the fol-
lowing:
+Warning
lamp bulb
+Fuse for
warning lamp
Ignition switch
``ON''Warning lamp
``OFF''Disconnect connector (S, L) and
ground L harness side.Warning lamp
``OFF''
Warning lamp
``ON''Damaged IC
regulator.
Replace.
Warning lamp
``ON''
Engine start.
Engine speed:
1,500 rpmWarning lamp
``ON''Check the following:
+Drive belt
+Fuse for S terminal
+Connector (S, L terminal) con-
nectionEngine idlingWarning lamp
``OFF''OK
Warning lamp
``ON''
Warning lamp
``OFF''OKEngine speed:
1,500 rpm
(Measure B
terminal volt-
age)More than
15.5VDamaged IC
regulator.
Replace.
No generationField circuit is
open.
Warning lamp: ``CHARGE'' warning lamp in combination meter
Note:
+If the inspection result is OK even though the charging system is malfunctioning, check the B ter-
minal connection. (Check the tightening torque.)
+When ®eld circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
MALFUNCTION INDICATOR
The IC regulator warning function activates to illuminate ``CHARGE'' warning lamp, if any of the following
symptoms occur while alternator is operating:
+Excessive voltage is produced.
+No voltage is produced.
CHARGING SYSTEM
EL-53

Construction
Removal and Installation
CAUTION:
+Start service operation after removing the negative termi-
nal from the battery.
+Also remove the undercover, if equipped, before servicing.
Disassembly
REAR COVER
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
YEL783A
MEL610I
SEL032Z
CHARGING SYSTEM
EL-54

REAR BEARING
CAUTION:
+Do not reuse rear bearing after removal. Replace with a
new one.
+Do not lubricate rear bearing outer race.
Inspection
ROTOR CHECK
1. Resistance test
Resistance: Refer to SDS (EL-56).
+Not within the speci®ed values ... Replace rotor.
2. Insulator test
+Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to SDS (EL-56).
+Not within the speci®ed values ... Replace rotor.
BRUSH CHECK
1. Check smooth movement of brush.
+Not smooth ... Check brush holder and clean.
2. Check brush for wear.
+Replace brush if it is worn down to the limit line.
STATOR CHECK
1. Continuity test
+No continuity ... Replace stator.
2. Ground test
+Continuity exists ... Replace stator.
SEL033Z
SEL631DA
SEL108E
SEL109E
CHARGING SYSTEM
Disassembly (Cont'd)
EL-55

Assembly
RING FITTING IN REAR BEARING
+Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
REAR COVER INSTALLATION
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with ®ngers and install them to rotor.
Take care not to damage slip ring sliding surface.
Service Data and Speci®cations (SDS)
ALTERNATOR
TypeA3TA4399
MITSUBISHI
Applied model RD28
Nominal rating V-A 12-100
Ground polarity Negative
Minimum revolution under no-load
(When 13.5V is applied) rpmLess than 1,300
Hot output current
(When 13.5V is applied)
A/rpmMore than 35/1,300
More than 72/2,500
Regulated output voltage V 14.1 - 14.7
Minimum length of brush mm (in) 5 (0.20)
Brush spring pressure
N (g, oz)4.6 - 5.8
(470 - 590, 16.58 - 20.81)
Slip ring minimum outer diameter
mm (in)22.1 (0.870)
Rotor (Field coil) resistanceW2.1 - 2.5
SEL044Z
SEL048Z
SEL049Z
CHARGING SYSTEM
EL-56