20412267 Volvo.Penta Plug

Disassembly and Inspection of Starter
Inspection of Starter
(1) Armature coil short-circuit testPlace the armature on the growler. Set an iron piece parallel to the armature, and rotate the armature slowly by hand. If the iron piece is attracted to the coil or vibrates, there is a short-circuit; replace the armature.
Armature coil short-circuit test(2) Armature coil grounding testIf there is continuity between the commutator and shaft (or core), replace the armature.
Armature coil grounding test(3) Measurement of commutator runoutMeasure the commutator runout using a dial gage. If the amount of runout exceeds the limit value, replace the armature. If the commutator surface is rough, refinish the surface with sand paper (#300 to #500). If the surface has ridges due to abrasion, replace the armature since it is not repairable.
Measurement of commutator runout(4) Measurement of commutator outside diameterMeasure the outside diameter of the commutator, and, if the limit is exceeded, replace the armature.
Measurement of commutator outside diameter(5) Measurement of mold depth between segmentsClean the grooves between segments, and measure the mold depths between segments. If the limit value is exceeded, repair. (6) Inspection of armature gearIf the inspection of the armature gear finds abnormal wearing or chipped teeth, replace the armature.
Measurement of mold depth between segments(7) Yoke coil open-circuit testCheck to see if there is continuity between the terminal lead wire and brush (positive). If there is no continuity, there is an open-circuit; replace the yoke assembly.
Yoke coil open-circuit test(8) Yoke coil grounding testCheck to see if there is continuity between the yoke and brush (positive). If there is continuity, the yoke coil is grounded. Check the insulation, and replace the yoke assembly if the problem cannot be corrected.
Yoke coil grounding test(9) Inspection of magnetic switchConduct the following the following continuity tests, and, if there is any problem, replace the magnetic switch.(a) Coil open-circuit testCheck to see if there is continuity between terminal M and ground (case). There should be no continuity between terminal B and ground.(b) Inspection of contact adhesionCheck to make sure there is no continuity between terminal B and terminal M.
Inspection of magnetic switch(10) Measurement of brush lengthMeasure the length of each brush, and, if the limit value is exceeded, replace the brush. If the brush is unevenly worn or has a rough contact surface, refinish with sand paper (#300 to #500).
Measurement of brush length(11) Measurement of brush spring tensionMeasure the installation tension of each brush spring. Read the tension at the moment when the spring detaches from the brush. If the tension value is near the limit value, replace the brush spring.
Measurement of brush spring tension(12) Inspection of brush holders for insulationUsing a tester, check to make sure that there is no continuity between the positive-side brush holder and negative-side brush holder plate. If there is continuity, replace the brush holder.
Inspection of brush holder for insulation(13) Inspection of overrunning clutchMake sure that the pinion shaft rotates smoothly in one direction, and locks in place when it is turned in the opposite direction. If the pinion shaft does not rotate properly, replace the overrunning clutch (pinion shaft assembly).
Inspection of overrunning clutchReassembly of Starter
Reassemble the starter by following the disassembly sequence in reverse, and observe the following during reassembly.(1) Application of greaseIn the case the starter has been overhauled, apply grease to the following sliding sections, gears and bearings. Inspection and Adjustment After Reassembly
After reassembly, conduct the following inspections and tests.(1) Adjustment of pinion gap(a) Since connecting the wires of the reassembled starter as shown in the diagram causes the pinion to extend and rotate slowly, disconnect the connector from terminal M to stop the rotation.
Adjustment of pinion gap (1)(b) Lightly push the tip of the extended pinion shaft with a finger, and measure the distance of the shaft movement to obtain the pinion gap measurement. Adjust the pinion gap by varying the number of packings installed at the magnetic switch section so that it conforms to the standard value. When the number of packings is increased, the pinion gap decreases. If proper adjustment cannot be achieved by varying the number of packings, replace the lever assembly. To prevent the switch coil from overheating during inspection, do not supply electricity for more than 10 continuous seconds.
Adjustment of pinion gap (2)(2) No-load testAfter the pinion gap adjustment, connect measurement instruments between the starter and battery as shown in the diagram to check no-load characteristics.
Use thick wires, and firmly tighten the connections at the terminal.
No-load testAlternator
If a problem occurs in the charge system, check the following conditions to locate the cause of the problem. Only when inspection cannot be conducted on the alternator in the installed condition, dismount the alternator for inspection and repair. On Vehicle Inspection
(1) Cautions for handlingHandle the alternator carefully, as incorrect handling can result in alternator damage or malfunctions.(a) Do not connect the battery cables in reverse. Note the negative (-) cable is a grounding wire.(b) Do not use a high-voltage tester such as a megger.(c) When charging the battery, disconnect the cables from the battery terminals.(d) Do not disconnect the lead wire from terminal B of the alternator while the engine is operating.(e) Do not ground terminal B of the alternator since it is constantly applied with battery voltage.(f) Do not short-circuit or ground terminal L. (unit with integrated IC regulator)(g) When using a steam cleaner, do not allow steam to directly contact the alternator.(2) Inspection of adjustment voltage (unit with integrated IC regulator)(a) Disconnect the cable from the positive (+) terminal of the battery, and connect an ammeter between the terminal and cable.(b) Connect a voltmeter between terminal L and ground.(c) Make sure that the voltmeter indicates "0" when the starter switch is turned off. Make sure that the voltmeter indicates a voltage level significantly lower than the battery voltage when the starter switch is turned on (without starting the engine).(d) Short-circuit the terminal of the ammeter, and start the engine.(e) Read the indication (adjustment voltage) on the voltmeter with