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MAZDA M4-2.5D DIESEL ENGINE

H1.50-1.75XM (S/H25-35XM)

[C010, D001, D010, E001];

H2.00XMS (S/H40XMS)

[C010, D001, D010, E001]

PART NO. 897594

2200 SRM 550

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE:

The following symbols and words indicate safety information in this

manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

2200 SRM 550

Description

General

This section has the descriptions and service procedures for the electrical systems of the Mazda M4-2.5D diesel
engine. This section includes the starting and ignition systems. Troubleshooting information is included at the
end of this section.

Description

STARTING CIRCUIT

The starting system includes the starter circuit
and the circuit for cold start aid. See Figure 1 and
Figure 2. The starter circuit includes the battery,
starter, key switch, and neutral start switch. The
circuit for cold start aid includes a glow plug for each
cylinder, a relay, a controller, a thermal switch, the
key switch, a fuse, and the battery.

1.

BATTERY

2.

STARTER

3.

S TERMINAL

4.

BATTERY
TERMINAL

5.

KEY SWITCH

6.

NEUTRAL START
SWITCH

Figure 1. Starter Circuit

The starter has a drive gear and an idler gear to in-
crease starter torque. It also has a clutch assembly.
The clutch assembly magnetically pushes a small
gear out of the housing to engage the flywheel teeth.
The starter motor rotates the drive gear. The drive
gear engages and rotates the larger idler gear. The
idler gear engages the teeth on the clutch assembly
when the magnet of the solenoid is energized.

A

small gear on the end of the clutch assembly engages
the teeth on the flywheel.

When the starter is

energized, the solenoid magnet makes the clutch
assembly connect power from the idler gear to the
flywheel.

At approximately the same time, the

starter motor energizes to rotate the flywheel and
start the engine.

A. FROM STARTER S TERMINAL

1.

GLOW PLUG

2.

RELAY

3.

CONTROLLER

4.

THERMAL SWITCH

5.

KEY SWITCH

6.

FUSE

7.

BATTERY

Figure 2. Circuit for Cold Start Aid

Several conditions must exist to start the engine.
The direction control lever must be in the NEU-
TRAL position so the transmission is in NEUTRAL
and the neutral start switches are closed. Voltage
from the key switch is applied through the switches

1

Description

2200 SRM 550

to the S terminal of the starter to energize the
starter motor.

The glow plugs for the cold start aid heat the fuel
from the injectors. Heating the fuel lowers the com-
bustion point of the fuel. The glow plugs are resis-
tance heaters that have parallel electrical connec-
tions. The glow plugs are electrically in series with
the relay, fuse, and battery.

The relay is energized to complete the circuit to the
glow plugs when several conditions exist. The key
switch must be in the IGN or START position, there
must be a voltage signal to the controller from the S
terminal of the starter, and the thermal switch must
be closed. The thermal switch is closed when the en-
gine coolant is cold.

The relay is de-energized when the key switch is in
the OFF position, the controller has completed the
time cycle, or the engine coolant has warmed enough
so that the thermal switch contacts open. The glow
plugs are de-energized when the relay is de-ener-
gized.

CHARGING SYSTEM

The charging system includes the alternator, regu-
lator (inside the alternator case), and battery. See
Figure 3. The regulator controls the alternator to

charge the battery. The battery voltage decreases
as the starting circuit and other circuits use current
from the battery. The regulator senses this decrease
in battery voltage and increases the alternator out-
put to charge the battery. The alternator supplies
all the necessary current, within its maximum, when
the engine is operating. The alternator is either ON
or OFF.

The alternator generates full current at a given
rpm when it is ON. It generates no current if it is
OFF. The regulator switches the alternator between
ON and OFF to get the average charging current
needed.

Alternator output is directly changed by

engine speed and the rotor current. The regulator
controls the rotor current.

The alternator has four main parts: (1) the stator, (2)
the rotor, (3) the diode assembly, and (4) the regula-
tor. Mechanical power from the engine turns the ro-
tor inside the stator windings. The regulator controls
the flow of battery current to the rotor brushes, slip
rings, and rotor windings. A magnetic field that ro-
tates is the result of this current flow and mechanical
power. The magnetic field makes current flow in the
stator windings. This current is AC and is changed
to DC by the diodes to become the alternator output.
The output from the alternator connects to the posi-
tive terminal of the battery to charge the battery.

1.

ALTERNATOR

2.

CONNECTOR

3.

OTHER BATTERY CIRCUITS

4.

INDICATOR

5.

KEY SWITCH

6.

BATTERY

7.

REGULATOR

8.

STATOR

9.

ROTOR

Figure 3. Charging Circuit

2

2200 SRM 550

Starter Repair

Starter Repair

REMOVE AND DISASSEMBLE

WARNING

Always disconnect the battery ground cable be-
fore making repairs to prevent possible dam-
age and injury. Install a tag on the battery ter-
minal so that no one connects the cable on the
terminal.

NOTE:

Refer to Troubleshooting, General Checks and

Adjustments, Starter Checks, Cold Start Aid Checks,
and Charging Circuit Checks before starting any re-
pair procedures. Make sure that repair or replace-
ment of a part is necessary before removal and dis-
assembly.

1.

Disconnect battery cable at negative battery ter-
minal.

2.

Put labels on starter electrical leads for correct
connection during installation. Remove all elec-
trical leads fastened to starter terminals.

3.

Hold starter to keep it from falling. Remove two
capscrews that fasten starter to flywheel hous-
ing.

4.

Remove motor lead at solenoid terminal. Remove
capscrews that fasten solenoid to drive housing.
Remove solenoid. See Figure 4.

5.

Remove through-bolts that fasten end housing to
drive housing. Carefully remove end housing.
Remove brush holder, field housing, and arma-
ture.

6.

Remove retainers from center housing. Remove
center housing. Remove clutch lever and springs.

7.

Remove snap ring from end of idler gear. Remove
idler gear. Remove clutch assembly from drive
housing.

8.

Measure length of brushes. Measure from end
to end of each brush. Standard length is 18 mm
(0.71 in.).

Minimum brush length is 11 mm

(0.43 in.).

Replace positive brushes as shown

in Figure 5.

Replace brush holder to replace

negative brushes.

ASSEMBLE AND INSTALL

1.

Install bearings in drive housing and center
housing. Lubricate splines of clutch and pinion
shafts with high-temperature grease.

Install

clutch in drive housing. Install pinion, bushing,
and snap ring. See Figure 4.

2.

Install idler gear and washer.

Install center

housing and retainer.

3.

Install bearing in end housing.

4.

Install armature in center housing. Install seal
and field housing.

Install brushes in brush

holder. Install end housing and through-bolts.
Install brush holder in end housing.

5.

Install clutch lever and springs. Connect sole-
noid to clutch lever, then install solenoid on drive
housing.

6.

Connect motor wire to solenoid.

7.

Hold starter in position to connect electrical
leads to BATTERY and S terminals of starter.
Connect electrical leads.

8.

Install starter on flywheel housing. Connect bat-
tery cable to negative battery terminal.

3

Starter Repair

2200 SRM 550

1.

SOLENOID

2.

SPRING

3.

LEVER

4.

DRIVE HOUSING

5.

SNAP RING

6.

BUSHING

7.

PINION

8.

BEARING

9.

CLUTCH

10. IDLER GEAR
11. WASHER
12. CENTER HOUSING

13. RETAINER
14. ARMATURE
15. SEAL
16. HOUSING AND FIELD COIL
17. BRUSH HOLDER
18. END HOUSING

Figure 4. Starter Parts

4

2200 SRM 550

Alternator Repair

A. USE HAMMER TO BREAK BRUSH FROM WIRE.
B. USE A SOLDERING IRON TO REMOVE OLD SOLDER FROM WIRE. TWIST END OF BRUSH WIRE TO

PUT WIRES TOGETHER. PUT WIRE IN BRUSH AND SOLDER BRUSH TO WIRE. MAKE SURE SOLDER
SURFACE ON BRUSH IS FLAT.

Figure 5. Starter Motor Brushes

Alternator Repair

REMOVE AND DISASSEMBLE

WARNING

Always disconnect the battery ground cable be-
fore making repairs to prevent possible dam-
age and injury. Install a tag on the battery ter-
minal so that no one connects the cable to the
terminal.

NOTE:

Do only the steps that are necessary to replace

the part that has damage.

1.

Disconnect battery cable at negative battery ter-
minal.

2.

Put labels on wire connected to B terminal and
wire connected to ground terminal.

Remove

wires from terminals and disconnect connector
plug from alternator.

3.

Remove capsrews, washers, and nut that fasten
alternator to engine. Remove alternator.

4.

Remove bolts and nut sets that fasten end hous-
ings together.

5.

Put rotor in vise with soft jaws. (Do not tighten
vise to cause rotor distortion.)

Use a socket

wrench to remove nut set from pulley. Remove
pulley, fan, spacer, and front housing from rotor.
See Figure 6.

6.

Remove screws that fasten bearing retainer to
front housing.

Remove bearing retainer and

front bearing.

7.

Remove nuts that fasten stator and diode assem-
bly to rear housing. Remove stator and diode as-
sembly from rear housing.

8.

Mark stator to show position of brushes and con-
nector. Use pliers as a heat sink to keep heat
from diodes. Use a soldering iron to remove sta-
tor leads from diode assembly.

5

Alternator Repair

2200 SRM 550

1.

NUT SET

2.

PULLEY

3.

SPACER

4.

BOLT

5.

FRONT HOUSING

6.

FRONT BEARING

7.

BEARING RETAINER

8.

ROTOR

9.

REAR BEARING

10. STATOR

11. VOLTAGE REGULATOR AND

BRUSH ASSEMBLY

12. BRUSH (2)
13. SPRING (2)
14. DIODE ASSEMBLY
15. REAR HOUSING

Figure 6. Alternator Parts

ASSEMBLE AND INSTALL

1.

Hold diode assembly in position to connect stator
leads. Align brushes and connector at mark on
stator. Use pliers as a heat sink to keep heat from
diodes. Use a soldering iron to connect stator
leads to diode assembly. See Figure 6.

2.

Install bearing and bearing retainer on front
housing with screws.

3.

Put rotor (with threaded end of the shaft up)
in vise with soft jaws. (Do not tighten the vise
enough to cause rotor distortion.) Install front
housing, spacer, fan, pulley, and nut set on shaft.
Use a socket wrench to tighten nut.

4.

Install stator and diode assembly on rotor. Hold
brushes away from slip rings during installation.
Install pin or wire in hole of brush holder.

5.

If rear bearing next to slip rings was removed,
install it on armature shaft.

6.

Install rear housing over diode assembly. Make
sure all insulators for screws are correctly in-
stalled. (Positive half of diode assembly must not
touch rear housing. Screws must not touch rear
housing and positive half of diode assembly.) In-
stall bolts and nut sets that fasten end housings
together.

6

2200 SRM 550

Starter Checks

7.

Install alternator on engine using capscrews,
washers, and nut. Install belt on pulley. Adjust
belt tension as described in Periodic Mainte-
nance section.

8.

Connect plug to alternator connector. Connect
other wires to B and ground terminals as indi-
cated on labels. Connect negative cable on bat-
tery terminal.

General Checks and Adjustments

WARNING

To prevent movement of the lift truck, put the
transmission in NEUTRAL and apply the park-
ing brake.

CAUTION

Do not change the polarity of the circuits. Do
not connect any wires in the circuits except as
described in these instructions. Never connect
the wire from the terminal marked BAT to an
open circuit.

Remove battery cables and clean terminals and cable
connectors. Inspect insulation on wires. Make sure
all fasteners and connections are clean and tight. If
necessary, use a water-and-soda solution to clean top
of battery. Do NOT remove cell caps or permit the
water-and-soda solution to get in battery.

When connecting a charger or another battery, con-
nect the positive terminals to the positive terminal
of the battery, then connect the negative terminal
to a clean metal part of the engine. Disconnect the
charger or other battery in the reverse order. Prob-
lems in the charging circuit are indicated by one or
more of the following:
• The starter motor turns slowly. The battery voltage

is low because of low alternator output or a faulty
battery.

• The specific gravity readings are low. The battery

is not fully charged or is damaged.

• The battery uses more than 30 ml (1 oz) of water

per cell per month. The alternator output is too
high.

NOTE: There are no adjustments for the starter or
alternator.

Starter Checks

OPERATION CHECK

If the results of this check are within the specifica-
tions, the starter is in good condition, and repair is
not necessary.

1.

Put starter in vise so that it cannot move.

2.

Use a 12 V battery with full charge.

Use an

ammeter with minimum capacity of 60 amperes.
Connect circuit shown in Figure 7.

Attach

jumper wire to S terminal, but do not connect
negative lead of battery to starter yet.

3.

Briefly touch negative lead to starter housing
and check indications on meters. Remove neg-
ative lead.

1.

STARTER

2.

150 A AMMETER

3.

VOLTMETER

4.

12 V BATTERY

5.

NEGATIVE LEAD

6.

VISE

7.

S TERMINAL

8.

BATTERY
TERMINAL

Figure 7. Starter Check

7

Starter Checks

2200 SRM 550

The starter is in good condition if all of the following
occur:
• The clutch assembly moves so that it can engage

the flywheel.

• Smooth rotation occurs just after clutch movement.
• The ammeter indicates 53 amperes or less.
• The clutch assembly moves so that it can disengage

the flywheel after the jumper wire is removed from
the S terminal.

SOLENOID COIL CHECKS

The two parts of the solenoid coil work together to
push the pinion out of the housing. After the pinion is
out, one coil de-energizes and the other coil keeps the
assembly out. The pinion must return to the housing
when the second part of the coil is de-energized.

CAUTION

Do not take more than 3 to 5 seconds to do each
of these checks. If power is connected for a
longer period, the coil may burn.

1.

Put starter in vise so that it cannot move.

2.

Disconnect wire at M terminal at solenoid. Ap-
ply battery voltage across M and S terminals of
solenoid. When operating correctly, pinion will
extend from housing.

3.

Disconnect wire at M terminal at solenoid. Apply
battery voltage between M terminal and hous-
ing. Pull pinion out by hand. Operation is cor-
rect when pinion stays out. If pinion retracts, so-
lenoid coil is faulty.

4.

Disconnect wire at M terminal at solenoid. Apply
battery voltage between M terminal and hous-
ing. Disconnect power. Pinion will retract im-
mediately after power is disconnected.

BRUSH HOLDER CHECK

1.

Remove brush holder from motor housing.

2.

Remove brushes from brush holder.

3.

Connect ohmmeter between each bracket that
holds each brush and mount plate for brackets.
Indications for two positive brackets must be in-
finity. Indications for other two brackets must be
0 ohms. See Figure 8.

NOTE: BRUSH ASSEMBLY CAN BE DIFFERENT
THAN SHOWN.

1.

NEGATIVE BRACKETS

2.

POSITIVE BRACKETS

3.

MOUNT PLATE

Figure 8. Brush Holder Check

ARMATURE CHECK

1.

Remove armature.

2.

Use ohmmeter to check for indication of infin-
ity between any commutator bar and armature
shaft. Check for continuity (0 ohms) between any
two commutator bars.

3.

If either check is wrong, replace armature.

FIELD WINDINGS CHECK

1.

Remove motor, brush holder, and armature.

2.

Use ohmmeter to check for continuity between
positive brush and electrical lead of motor.
Check for indication of infinity between any
positive brush and motor housing. If indication
is not infinity, check that brush lead connections
are not touching housing.

3.

If either check is wrong, replace complete motor
housing.

CLUTCH AND BEARING CHECK

1.

Check teeth of gear. If teeth are worn or dam-
aged, replace clutch assembly.

2.

Check teeth of ring gear on flywheel. If teeth are
worn or damaged, replace ring gear. See section
for ENGINE.

8

2200 SRM 550

Cold Start Aid Checks

3.

Check that clutch bearing rotates freely and
smoothly. Bearing must not be loose. If pinion

rotates in both directions, replace clutch assem-
bly.

Cold Start Aid Checks

GLOW PLUGS

The glow plugs for the cold start aid are directly be-
low the injectors on the engine. See Figure 9.

Use an ohmmeter to check the glow plugs of the cold
start aid. See Figure 10. Check for 1.4 to 1.5 ohms
between the positive wire at the glow plug and the
cylinder head. If the ohmmeter indicates zero or in-
finity, replace the glow plug. Glow plugs cannot be re-
paired. New ones must be installed if they are faulty.

1.

Disconnect electrical wire at metal strip con-
nected to all glow plugs.

2.

Remove nuts from all glow plugs. Remove metal
strip.

3.

Use wrench to remove glow plugs. Install re-
placement glow plugs, metal strip, and wire.

1.

NUT

2.

CONNECTOR
PLATE

3.

POWER LEAD

4.

GLOW PLUG

5.

CYLINDER HEAD

Figure 9. Glow Plug

1.

CYLINDER HEAD

2.

POSITIVE WIRE

Figure 10. Glow Plugs Check

FUSE

1.

Find the fuse for the cold start aid on the fuse
panel. The fuse panel is on the left-hand side of
the cowl. Remove fuse.

2.

Use an ohmmeter to check fuse for continuity. If
there is no continuity, check for a short circuit
in the wires and connections between fuse and
relay.

3.

Replace fuse.

RELAY AND CONTROLLER

The relay is on a bracket on the battery tray. See
Figure 11.

1.

Remove wire connectors for BU and BZ wires.
Use an ohmmeter set to low scale to check for
continuity between terminals.

If there is a short circuit or infinity reading, the
relay coil is faulty. If there is a very low resis-
tance reading, the coil is good.

2.

Install wire connectors on terminals.

3.

Remove wire connector for the BT and BR wires.
Use an ohmmeter set to a low scale to check for
continuity between the BT and BR terminals.

9

Charging Circuit Checks

2200 SRM 550

If there is a short circuit, the relay contacts are
welded. Replace relay. If there is an infinity
reading, install wire connectors on terminals.

4.

Check wires and connectors at controller and be-
tween controller, starter, key switch, relay, in-
strument panel indicator, and thermal switch. If
all connections and wires are good, replace con-
troller.

1.

BRACKET

2.

CONTROLLER

3.

RELAY

Figure 11. Glow Plug Circuit Relay and

Controller

Charging Circuit Checks

CAUTION

NEVER operate the engine if the alternator
output B terminal is not connected to the
battery.

Do not short-circuit or connect jumper wires to
any of the alternator terminals unless specified
in procedures.

Make sure polarity is correct before connect-
ing a battery charger or another battery.

Always check the general condition of the complete
system before doing a complete check on each part.
Check the general condition of the battery, battery
cables and connections, and alternator wires and
connectors. Also check the condition and tension of
the drive belt for the alternator.

The two problems of the charging circuit are low
output and high output. Low output causes a low
battery and difficult starting. A high output causes
heating of the battery and evaporation of water
from the electrolyte. The following two checks will
determine whether the alternator, regulator, or
wiring has the charging fault. The two checks will
also determine whether the charging system has
the correct output.

Do the following two checks

before removal, disassembly, or replacement of the
alternator or regulator.

LOW-OUTPUT CHECK

WARNING

Do not connect the wire from the BAT terminal
to the electrical ground. A short circuit will oc-
cur and make sparks, which can cause injury.

NOTE:

Make sure the wire from the voltmeter makes

contact with each terminal on the alternator.

1.

Connect voltmeter between battery terminal B
and electrical ground. Turn key switch to ON
position and check indication. Turn key switch
to OFF position.

2.

Connect voltmeter to field terminal L and regu-
lator terminal R. Turn key switch to ON position
and check indication. Turn key switch to OFF
position.

3.

If there are no indications on voltmeter during
Step 1 and Step 2, check for open circuit between
each terminal and battery.

If there are indications on voltmeter during
Step 1 and Step 2, disconnect cable for electrical
ground on battery.

4.

Connect ammeter into circuit at battery terminal
B. See Figure 12.

10

2200 SRM 550

Charging Circuit Checks

5.

Connect cable for electrical ground to battery.

6.

Connect resistor (carbon pile) across terminals of
battery.

WARNING

During engine operation, be careful not to
touch pulleys, fans, or belts in the engine area.
Contact with these parts can cause personal
injury.

7.

Start and run engine at 2000 to 2500 rpm. Adjust
resistor until maximum charging rate is reached.

8.

Read maximum charging rate on alternator
frame. Read ammeter. Indication on ammeter
must be within 10% of amount shown on frame.

9.

If amount shown is within 10%, alternator is in
good condition. Check starter or wires for prob-
lems.

HIGH-OUTPUT CHECK

1.

Connect voltmeter from regulator terminal R to
electrical ground. Check indication on voltmeter.
See Figure 12.

2.

If there are no indications, check for open circuit
between regulator terminal and battery.

If there is an indication, connect voltmeter be-
tween BAT terminal and electrical ground.

3.

Increase engine speed until maximum voltage in-
dication is reached.

4.

If voltage shown is more than 15.5 volts, disas-
semble alternator and do remainder of checks.

DIODES CHECK

NOTE:

Disassemble the alternator for this check and

the remainder of the alternator checks. The stator
must be disconnected from the diode assembly to do
the following checks.

1.

Use an ohmmeter with a 1.5-volt cell. Use lowest
range scale to check positive and negative diodes
of rectifier bridge and diode set.

NOTE: ALTERNATOR CAN BE DIFFERENT THAN
SHOWN.

1.

RESISTOR
(CARBON PILE)

2.

BATTERY

3.

VOLTMETER

4.

STARTER

5.

ALTERNATOR

6.

BATTERY
TERMINAL (B)

7.

FIELD TERMINAL
(L)

8.

REGULATOR
TERMINAL (R)

9.

AMMETER

Figure 12. Alternator Output Check

NOTE:

Some ohmmeters use a reverse polarity. The

"correct indications" will be opposite for these ohm-
meters for Step 3 and Step 4.

2.

Find electrical connection points on diode assem-
bly for three terminals, BAT, L, and E.

3.

Connect positive ohmmeter lead to point A. Con-
nect negative ohmmeter lead to alternator BAT,
L, and E terminal connection points in sequence.
Do this check again with positive ohmmeter lead
at point B and again with positive lead at point
C. Correct indications are very low resistance or
short circuit between positive and negative ohm-
meter leads for each of nine checks. See Fig-
ure 13.

If there is an open circuit (infinity reading) at any
check, that diode is faulty and must be replaced.

11

Charging Circuit Checks

2200 SRM 550

4.

Do Step 3 again with negative ohmmeter lead
at test points A through C and positive lead at
connection points for ammeter terminals. Cor-
rect indications are open circuit between nega-
tive and positive ohmmeter leads for each of nine
checks. See Figure 13.

If there is a short circuit at any check, that diode
is faulty and must be replaced.

1.

POINT A

2.

POINT B

3.

POINT C

4.

TERMINALS FOR OTHER OHMMETER LEAD

Figure 13. Diodes Check

ROTOR FIELD WINDING CHECK

NOTE:

Make sure the needle in the ohmmeter always

returns to zero correctly. The indications will change
when the temperature of the winding changes.

1.

Connect ohmmeter to each slip ring and check for
open circuits.

If the indication is high (infinity), the winding has an
open circuit.

2.

To check resistance of rotor field, connect ohm-
meter to two slip rings. Correct indication is 4.0
to 4.5 ohms.

If the indication is less than specification, there is a
short circuit in windings. If the indication is greater
than specification, there is additional resistance in
the windings.

3.

To check electrical ground, connect ohmmeter be-
tween either slip ring and electrical ground as

shown in Figure 14. Replace rotor if indication
is less than infinity.

Figure 14. Rotor Coil Checks

12

2200 SRM 550

Charging Circuit Checks

STATOR WINDINGS CHECK

1.

Use a soldering iron to disconnect soldered ter-
minals (3) of stator lead wires. Separate stator
and rectifier.

2.

To check stator windings for electrical ground,
connect an ohmmeter as shown in Figure 15.
There must be no continuity between any stator
terminals and metal frame.

3.

To check for open circuits in stator, connect ohm-
meter or test lamp between each pair of wires to
stator as shown in Figure 15.

If the test lamp does not illuminate or the meter
indication is high, the windings have an open cir-
cuit.

Figure 15. Stator Checks

BRUSHES AND BEARINGS

1.

Check each brush for minimum length on short-
est side of 7 mm (0.3 in.).

2.

Check brush springs. If spring is broken, dis-
torted, or has rust, replace spring. If brushes
have changed color from heat or they are weak,
replace brushes.

3.

Check brush holder for cracks or damage.

4.

Check armature bearings for smooth operation.
Bearings must not be loose or have seal leaks.

VOLTAGE REGULATOR CHECK

Use a voltage regulator test device. Follow directions
that come with test device. Do not use an ohmmeter.

If voltage regulator is damaged, replace voltage reg-
ulator.

13

Troubleshooting

2200 SRM 550

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Starter does not run or has
slow speed.

The battery is not fully charged or is
damaged.

Charge battery or install new bat-
tery.

The connections at the battery or
starter are loose or they have corro-
sion.

Clean electrical terminals and con-
nectors.

Key switch is damaged.

Install new key switch.

Solenoid coil or switch contacts have
damage.

Install new solenoid.

Brush springs in starter are dam-
aged.

Install new brush springs.

Brush leads are broken or have a
short circuit.

Check and repair brush leads.

Commutator in starter is dirty or
worn.

Clean and repair commutator.

Armature winding in starter has
damage.

Install new armature winding.

Field windings in starter have dam-
age.

Install new field winding.

Worn or damaged starter gears.

Repair starter.

Bearings in starter are worn or dam-
aged.

Install new bearings.

Starter operates, but engine
crankshaft does not rotate.

Wiring

connections

are

broken,

loose, or have corrosion.

Repair wiring.

Starter clutch assembly has damage.

Repair or install new starter.

Solenoid has damage and will not
keep the clutch assembly engaged.

Install new solenoid.

Starter clutch assembly will not
move freely.

Repair or install new starter.

Gear teeth on starter clutch assem-
bly are damaged.

Repair or install new starter.

Gear teeth on ring gear are damaged.

Install new flywheel.

14

2200 SRM 550

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Starter continues to run.

Contacts of solenoid are welded to-
gether.

Install new solenoid.

Solenoid coil has a short circuit.

Install new solenoid.

Spring that disengages the starter
clutch is broken.

Repair or install new starter.

Key switch is damaged.

Install new key switch.

Battery

does

not

stay

charged.

Battery terminals have corrosion.

Clean battery terminals.

Battery has damage inside the case.

Install new battery.

Drive belt for alternator is loose.

Adjust drive belt.

Wiring

connections

are

broken,

loose, or have corrosion.

Repair wiring connections.

Short circuit between wiring connec-
tor(s).

Repair wiring connections.

Alternator brushes are worn.

Install new brushes.

Alternator

brushes

have

weak

springs.

Install new springs.

Alternator has dirty slip rings.

Clean slip rings.

Stator coil for alternator has a short
circuit.

Install new starter coil.

Voltage regulator has damage.

Install new voltage regulator.

Battery

is

charged

more

than necessary.

Wiring

connections

are

broken,

loose, or have corrosion.

Repair wiring connections.

Short circuit between wiring connec-
tor(s).

Repair wiring connections.

Field coil in alternator has damage.

Install new field coil.

Regulator in alternator has a dam-
age.

Install new regulator.

High resistance in the circuit.

Replace alternator.

15

Troubleshooting

2200 SRM 550

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery uses more water
than normal.

Battery is being charged more than
normal.

Replace voltage regulator.

Alternator has damage in the stator
windings, diodes, rectifier bridge, ro-
tor, or voltage regulator.

Install new parts.

Battery is damaged.

Install new battery.

There is no charge from the
alternator.

The indicator

light indicates a discharge
condition when the rpm is
high and the load is high.

Drive belt is not tight or is broken.

Adjust or replace drive belt.

The brushes are worn or damaged.

Install new brushes.

Weak brush springs. Brushes do not
move freely in the brush holders.

Inspect and repair brush springs.

Dirt on the slip rings.

Clean slip rings.

Discharge

indicator

indi-

cates a discharge condition
at all engine speeds.

There is an electrical ground in the
field winding.

Replace alternator.

There is a short circuit in the diodes.

Replace damaged diodes.

There is an electrical ground at the
end of the windings.

Replace alternator.

The voltage regulator has damage.

Replace voltage regulator.

Glow plugs do not operate.

Loose or broken wires or connectors
in glow plug circuit.

Repair or replace wires or connectors.

Glow plugs burned or damaged.

Install new glow plugs.

Relay or controller is damaged.

Install new relay or controller.

16