A: SLOW CHARGE
Determine initial charging current from speci®c gravity refer-
ring to Fig. 2.
+Charge battery.
+Check charging voltage 30 minutes after starting the bat-
tery charge.
12 to 15 volts
OKBelow 12 volts or above 15
voltsNG
Continue to charge for 12
hours.
Replace battery.
CHECKING SPECIFIC GRAVITY
Refer to ``Speci®c Gravity Check''.
Conduct additional charge as per Fig. 3, if necessary.
Go to ``CAPACITY TEST''.Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)
CON-
VERTED
SPECIFIC
GRAVITYBATTERY TYPE
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
115D31R(L)
95E41R(L)
130E41R(L)
Below
1.1004.0
(A)5.0
(A)7.0
(A)8.0
(A)9.0
(A)10.0
(A)14.0
(A)
+Check battery type and determine the speci®ed current using the table
shown above.
+After starting charging, adjustment of charging current is not necessary.
Fig. 3 ADDITIONAL CHARGE (Slow charge)
Below 1.150
1.150 - 1.2001.200 - 1.240Above 1.240
Charge for 5
hours at ini-
tial charging
current set-
ting.Charge for 4
hours at ini-
tial charging
current set-
ting.Charge for 2
hours at ini-
tial charging
current set-
ting.
Go to ``CAPACITY TEST''.
.
CAUTION:
+Set charging current to value speci®ed in Fig. 2. If charger
is not capable of producing speci®ed current value, set its
charging current as close to that value as possible.
+Keep battery away from open ¯ame while it is being
charged.
+When connecting charger, connect leads ®rst, then turn on
charger. Do not turn on charger ®rst, as this may cause a
spark.
+If battery temperature rises above 60ÉC (140ÉF), stop
charging. Always charge battery when its temperature is
below 60ÉC (140ÉF).
.
..
.
.
.
.
.
...
....
BATTERY
Battery Test and Charging Chart (Cont'd)
EL-42
B: STANDARD CHARGE
Determine initial charging current from
speci®c gravity, referring to Fig. 4.
Charge battery for 8 hours.
CHECKING SPECIFIC GRAVITY
Refer to ``Speci®c Gravity Check''.
Conduct additional charge as per Fig. 5, if
necessary.
Go to ``CAPACITY TEST''.Fig. 4 INITIAL CHARGING CURRENT SETTING
(Standard charge)
CON-
VERTED
SPECIFIC
GRAVITYBATTERY TYPE
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
115D31R(L)
95E41R(L)
130E41R(L)
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A)8.0
(A)9.0 (A)13.0
(A)
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A)7.0
(A)8.0 (A)11.0
(A)
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A)6.0
(A)7.0 (A)9.0
(A)
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A)5.0
(A)5.0 (A)7.0
(A)
+Check battery type and determine the speci®ed current using the table shown above.
+After starting charging, adjustment of charging current is not necessary.
Fig. 5 ADDITIONAL CHARGE (Standard charge)
Below 1.150
1.150 - 1.2001.200 - 1.240Above 1.240
Charge for 3.5
hours at initial
charging current
setting.Charge for 2.5
hours at initial
charging current
setting.Charge for 1.5
hours at initial
charging current
setting.
Go to ``CAPACITY TEST''.
.
CAUTION:
+Do not use standard charge method on a battery whose speci®c gravity is less than 1.100.
+Set charging current to value speci®ed in Fig. 4. If charger is not capable of producing speci®ed
current value, set its charging current as close to that value as possible.
+Keep battery away from open ¯ame while it is being charged.
+When connecting charger, connect leads ®rst, then turn on charger. Do not turn on charger ®rst,
as this may cause a spark.
+If battery temperature rises above 60ÉC (140ÉF), stop charging. Always charge battery when its
temperature is below 60ÉC (140ÉF).
.
.
.
.
...
....
BATTERY
Battery Test and Charging Chart (Cont'd)
EL-43
C: QUICK CHARGE
Determine initial charging current setting and charg-
ing time from speci®c gravity, referring to Fig. 6.
Charge battery.
Go to ``CAPACITY TEST''.Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick
charge)
BATTERY TYPE
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
115D31R(L)
95E41R(L)
130E41R(L)
CURRENT [A] 10 (A) 15 (A) 20 (A) 30 (A)40
(A)
CONVERTED SPECIFIC GRAVITY
1.100 - 1.130 2.5 hours
1.130 - 1.160 2.0 hours
1.160 - 1.190 1.5 hours
1.190 - 1.220 1.0 hours
Above 1.220 0.75 hours (45 min.)
+Check battery type and determine the speci®ed current using the table shown
above.
+After starting charging, adjustment of charging current is not necessary.
CAUTION:
+Do not use quick charge method on a battery whose speci®c gravity is less than 1.100.
+Set initial charging current to value speci®ed in Fig. 6. If charger is not capable of producing
speci®ed current value, set its charging current as close to that value as possible.
+Keep battery away from open ¯ame while it is being charged.
+When connecting charger, connect leads ®rst, then turn on charger. Do not turn on charger ®rst,
as this may cause a spark.
+Be careful of a rise in battery temperature because a large current ¯ow is required during quick-
charge operation.
If battery temperature rises above 60ÉC (140ÉF), stop charging. Always charge battery when its
temperature is below 60ÉC (140ÉF).
+Do not exceed the charging time speci®ed in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.
Service Data and Speci®cations (SDS)
Applied
modelRD28
Standard Cold areas for Europe
Type 95D31L 115D31L
Capacity
V-AH12-80 12-80
.
.
BATTERY
Battery Test and Charging Chart (Cont'd)
EL-44
Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
Starter does not stop.cReplace magnetic switch.
Engine does not start.
Does engine turn by cranking?
No
cYe s
Does engine turn normally?
No (Turns slowly.)
cYe s
Check ignition/fuel system.
Check battery as follows:
+Charging condition
+Terminal connections
+Terminal corrosion
NG
cOK
Repair starter motor.
jA
Does starter motor turn?
No
cYe s
Does gear shaft turn?
No
cYe s
Check pinion clutch.
Check reduction gear, armature
and gear shaft.
Check fuse and fusible link.
OK
cNG
Replace.
Check battery as follows:
+Charging condition
+Terminal connections
+Terminal corrosion
OKj
A
cNG
+Charge battery.
+Repair connections and corro-
sion of battery terminals.
Check starting system wiring.
OK
cNG
Repair.
Does magnetic switch operation
sound occur?
Ye s
cNo
Replace magnetic switch.
Check condition of pinion and ring
gear mesh.
NG
cOK
Does starter turn under no load by
connecting wires as follows?
SEL009Z
cYe s
Replace magnetic switch.
+Adjust pinion movement.
+Check pinion moving mecha-
nism.
+Check ring gear.cNo
Repair starter motor.
.
.
.
.
.
.
.
.
.
.
.
.
STARTING SYSTEM
EL-46
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
Trouble Diagnoses
DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE
Terminal No. ConnectionsINPUT (I)/
OUTPUT (O)Operated conditionVoltage (V)
(Approximate
values)
1Power source for illumi-
nation & tail lampÐÐ12
2Power source for head-
lamp LHÐÐ12
3Power source for head-
lamp RHÐÐ12
4 Headlamp RH OON (daytime light operating*) 12
OFF 0
5 Headlamp LH OON (daytime light operating*) 12
OFF 0
6 Start signal I Ignition switchSTART 12
ON, ACC or OFF 0
7 Power source Ð Ignition switchON or START 12
ACC or OFF 0
8 Alternator ``L'' terminal I EngineRunning 12
Stopped 0
9 Ground Ð Ð Ð
10 Illumination & tail lamp OON (daytime light operating*) 12
OFF 0
11 Lighting switch I1STz2ND position 12
OFF 0
*: Daytime light operating: Lighting switch in ``OFF'' position with engine running.
Bulb Replacement
Refer to ``HEADLAMP'' (EL-63).
Aiming Adjustment
Refer to ``HEADLAMP'' (EL-63).
HEADLAMP Ð Daytime Light System Ð
EL-69
System Description
CIRCUIT OPERATION
[Example]
Aiming switch ``0''
+When the aiming switch is set to ``0'', the motor will not start.
This is because the power terminals are positioned at the non-
conductive section of the sensor's rotary unit.
Aiming switch ``0''®``1''
+When the aiming switch is moved from ``0'' to ``1'', the sensor's
conductive section activates the relay. Power is supplied
through the relay to the motor. The headlamps will then move
in the ``DOWN'' direction.
+The motor continues to rotate while the rotary unit of the sen-
sor moves from point A to point B.
+The power terminals will then be positioned at the nonconduc-
tive section, disconnecting the power to the motor. The motor
will then stop.
Aiming switch ``1''®``0''
+When the aiming switch is moved from ``1'' to ``0'', the sensor's
conductive section activates the relay. Power is supplied
through the relay to the motor. The motor will rotate to move the
headlamps in the ``UP'' direction.
+When the rotary unit of the sensor moves from point B to point
A, the motor will stop.
SEL465M
SEL364P
SEL365P
HEADLAMP Ð Headlamp Aiming Control Ð
EL-70