Mitsubishi 4M4 Service Manual
Pub.No.TWDE0911, NOVEMBER 2009
Shop Manual
diesel engine
diesel engine
Pub.No.TWDE0911
NOVEMBER 2009
Shop Manual
Pub.No.TWDE0911, NOVEMBER 2009
GROUP INDEX
FOREWORD
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of
Mitsubishi Fuso 4M4 series diesel engine, and includes
procedures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with
no wastage.
GENERAL..........................................
ENGINE .............................................
LUBRICATION...................................
FUEL AND ENGINE CONTROL .......
COOLING ..........................................
INTAKE AND EXHAUST ...................
EMISSION CONTROL.......................
HYBRID ELECTRIC VEHICLE
SYSTEM ............................................
00
11
12
13
14
15
17
18
For more details, please consult your nearest authorized
Mitsubishi dealer or distributors.
Kindly note that the specifications and maintenance service figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.
NOVEMBER 2009
Applicable models
4M42T3
©2009 Mitsubishi Fuso Truck & Bus Corporation
This Shop Manual contains the information classified into the following groups.
If any system or equipment has two or more variations with significantly different construction, the variations are
handled as different groups. These groups are identified by different alphabets preceded by the same number.
1. ENGINE volume
Group No. Group subject
11 ENGINE
12 LUBRICATION
13 FUEL AND ENGINE CONTROL
14 COOLING
15 INTAKE AND EXHAUST
17 EMISSION CONTROL
18 HYBRID ELECTRIC VEHICLE SYSTEM
2. CHASSIS volume
Group No. Group subject
21 CLUTCH
22 MANUAL TRANSMISSION
22E INOMAT-II
25 PROPELLER SHAFT
26 FRONT AXLE
27 REAR AXLE
31 WHEEL, TIRE
33 FRONT SUSPENSION
34 REAR SUSPENSION
35 BRAKE
35EA POWER ANTI-LOCK BRAKE SYSTEM
35EB HILL START ASSIST SYSTEM
36 PARKING BRAKE
37 STEERING
41 BUMPER, FRAME
42 CAB MOUNTING, TILT
43 DOOR
51 EXTERIOR
52 INTERIOR
55 HEATER, AIR-CONDITIONER
3. ELECTRICAL volume
Group No. Group subject
54 ELECTRICAL
GROUP 00 GENERAL
MODIFICATION SUMMARY ............................................................. 00-2
VEHICLE MODEL CODING SYSTEM .............................................. 00-4
EQUIPMENT TYPE CODING SYSTEM ............................................ 00-6
POWER TRAIN TABLE .................................................................... 00-7
HOW TO READ THIS MANUAL ....................................................... 00-8
CHASSIS NUMBER, ENGINE NUMBER, MOTOR NUMBER
AND NAME PLATE ......................................................................... 00-16
PRECAUTIONS FOR MAINTENANCE OPERATION .................... 00-18
JACKING UP THE VEHICLE .......................................................... 00-28
DIAGNOSIS CODES
1. Diagnosis Codes ...................................................................... 00-30
2. Reading and Erasing the Diagnosis Code ................................. 00-31
TABLE OF STANDARD TIGHTENING TORQUES ........................ 00-36
13A
13E
00-1
MODIFICATION SUMMARY
1. Characteristics of and Precautions for the ECO HYBRID Model
• The following are added to the characteristics of the CANTER ECO HYBRID.
• The CANTER ECO HYBRID is equipped with a dedicated high voltage battery (350 V) for the hybrid electric ve-
hicle system aside from the 24 V battery.
• High voltage is cut off when the starter switch is OFF and the vehicle is stationary.
• High voltage is generated in the high voltage circuit when the starter switch is ON or when the gear is engaged
and the wheels are rotating.
• High voltage in the high voltage circuit may be generated irrespective of the vehicle condition during the hybrid
electric vehicle system abnormalities (the hybrid electric vehicle warning lamp illuminates).
• Be sure to observe the regulations of your country or region regarding the qualifications or trainings required for
servicing the high-voltage equipment.
• The following are added to the precautions concerning high voltage cable and high voltage devices.
DANGER
• High voltage (350 V) may be generated in the high voltage circuit that consists of various high voltage devices (motor generator, motor electronic control unit and high voltage battery box) and cable (orange). Utmost care is required in handling these parts. When servicing, see Gr18 HYBRID ELECTRIC VEHICLE
SYSTEM.
• Improper use of the high voltage battery may cause electric shock, overheating or fire though it is safe
when properly handled. It may explode in the worst case.
• The following are added to the remedies against vehicle damage by collision or the like.
WARNING
• When the vehicle is on fire, use the ABC fire extinguisher to put out the fire. Since it is dangerous to fight
a fire with a small quantity of water, spray a large amount of water from a fire hydrant or wait for the arrival of the fire brigade.
• When the vehicle is soaked in water, do not touch the high voltage devices and high voltage cable including the safety plug of the high voltage battery box to prevent electric shock. Work on the vehicle after
pulling it out of water.
• Insulate any high voltage terminal that is exposed by damage with vinyl tape or the like to prevent electric
shock.
CAUTION
• The electrolyte in the high voltage battery is as flammable as kerosene. If there is any fluid leakage near
the high voltage box, wipe up the fluid while keeping fire away from it.
• Turn the starter switch to OFF to cut off the high voltage system. If it cannot be confirmed that the starter
switch is OFF, disconnect the negative side battery cable from the 24 V battery. Then, remove the safety
plug of the high voltage battery box with insulated gloves on while referring to Gr18 HYBRID ELECTRIC
VEHICLE SYSTEM.
• In the case of the abnormality described above, replace the defective part referring to Gr18 HYBRID
ELECTRIC VEHICLE SYSTEM.
00-2
M E M O
00
00-3
VEHICLE MODEL CODING SYSTEM
<For Hong Kong and Singapore>
1 743 52 986
FE84BE
1 Basic vehicle type F Cab-over engine truck
2 Load capacity, drive system E 2 ton class and over, 4 × 2
3 Cab type 8 Wide cab
4 Suspension 4 Independent axle
5 Engine B 4M42T
6 Wheelbase E 3350 mm
7 Chassis arrangement for use V Van use
8 Rear tire arrangement, payload 3
9 Vehicle specification H Hybrid
10 Engine output variation 6 4M42T3 (96 kW {130 PS})
11 Export specification EX
V3H6
11
10
EX
Low deck/rear double
Payload 3000 to 4000 kg
00-4
<For Australia and New Zealand>
00
1 743 52 986
FE84BE
1 Basic vehicle type F Cab-over engine truck
2 Load capacity, drive system E 2 ton class and over, 4 × 2
3 Cab type 8 Wide cab
4 Suspension 4 Independent axle
5 Engine B 4M42T
6 Wheelbase E 3350 mm
7 Chassis arrangement for use V Van use
8 Rear tire arrangement, payload 7
9 Steering position R Right-hand drive vehicle
10 Export specification FA
11 Vehicle specification H Hybrid
V7RFA
11
10
H
Rear double
Payload 3000 to 4000 kg
00-5
EQUIPMENT TYPE CODING SYSTEM
Component Name plate marking Code description
Engine
4M42T3 4 M 4 2 T 3
Classification of turbocharger
Turbocharged
Order of development within same series
Order of development among different series
Diesel engine
No. of cylinders (4)
Clutch
C3W28 C 3 W 28
Disc outside diameter
Facing material (W: Woven)
Load carrying capacity of truck class (ton nage) on which the clutch is primarily used
Initial letter of the clutch
Transmission
M036S5 M 036 S 5
Forward speeds
Type of mesh (S: Synchromesh)
Load carrying capacity of truck class (ton nage) on which the clutch is primarily used
Initial letter of the transmission
Propeller shaft
P3 P 3
Front axle
F200T F 200 T
Rear axle
R033T R 03 3 T
Reduction and differentioal
D033H D 03 3 H
Load carrying capacity of truck class (ton nage) on which the clutch is primarily used
Initial letter of the propeller shaft
Vehicle type (T: Truck)
Load carrying capacity of truck class (ton nage) on which the clutch is primarily used
Initial letter of the front axle
Vehicle type (T: Truck)
Order of development within same series
Load carrying capacity of truck class (ton nage) on which the clutch is primarily used
Initial letter of the rear axle
Tooth profile (H: Hypoid gear)
Order of development within same series
Load carrying capacity of truck class (ton nage) on which the clutch is primarily used
Initial letter of the reduction & differentioal
00-6
POWER TRAIN TABLE
00
Vehicle model Engine Clutch Transmission Propeller shaft Rear axle
FE84BEV3H6EX 4M42T3 C3W28 M036S5 P3 R033T D033H
FE84BEV7RFAH 4M42T3 C3W28 M036S5 P3 R033T D033H
Reduction and
differential
00-7
HOW TO READ THIS MANUAL
This manual consists of the following parts:
• Specifications
• Structure and Operation
• Troubleshooting
• On-vehicle Inspection and Adjustment
• Service procedures
On-vehicle Inspection and Adjustment
• Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedures
• Procedures for servicing components and parts off the vehicle are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
• Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.
• Some routine visual checks and cleaning of some reused parts are not described but must always be included in
actual service work.
Caution
• This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:
DANGER
WARNING
CAUTION
NOTE
Terms and Units
• Front and rear
The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred
to as the rear.
• Left and right
Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left
and right.
Precautions that should be taken in handling potentially dangerous substances
such as battery fluid and coolant additives.
Precautionary instructions, which, if not observed, could result in serious injury or
death.
Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.
Suggestions or supplementary information for more efficient use of equipment or
better understandings.
Standard value
• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
• When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
00-8
00
Tightening torque
• Values are directly specified for out-of-standard tightening torques for bolts and nuts.
• Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
(Values for standard tightening torques are based on thread size and material.)
• When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.
Units
• Tightening torques and other parameters are given in SI* units with metric units added in brackets { }.
*SI: Le Système International d’Unités
Example: 390 N·m {40 kgf·m}
Metric unit
SI unit
Item SI unit {metric unit} Conversion factor
Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}
Pressure
Volume dm
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Power kW {PS} 0.7355 kW {1 PS}
Vacuum pressure
kPa {mmHg} 0.133322 kPa {1 mmHg}
Pa {mmH
O} 9.80665 Pa {1 mmH2O}
2
3
{L} 1 dm3 {1 L}
00-9
HOW TO READ THIS MANUAL
1. Illustrated Parts Breakdown and Service Procedures
Symbol Denotation Application Remarks
Tightening torque
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or
sealant
Special tool
*a Associated part
Parts not tightened to standard torques
(standard torques specified where necessary for servicing)
Parts to be coated with lubricant or sealant
for assembly or installation
Parts for which special tools are required for
service operation
Parts associated with those removed/disassembled for servicing
Specified values shown in table
See Table of Standard Tightening Torques for
parts for which no tightening torques are specified.
Necessary lubricant and/or sealant, quantity required, etc. are specified in table.
Tool name/shape and part number are shown in
table.
00-10
00
00-11
HOW TO READ THIS MANUAL
2. How to Use Diagnosis Codes <Electronic Control System>
There are the diagnosis code and message displayed on Multi-Use Tester.
Numerical values in parenthesis are added only when a diagnostic code indicated in
the Multi-Use Tester display differs from the code indicated by the number of warning
lamp flashes.
P0475: Exhaust Brake PWR (Open) (warning lamp flashes: 93)
Generation condition Exhaust shutter 3-Way magnetic valve circuit is open
System recovers if any valid signal is input when starter switch is turned
Recoverability
Control effected by electronic control
unit
Service data C2: Auxiliary brake M/V1
Actuator test AA: Auxiliary brake M/V1
Inspection
Electronic control unit : Exhaust shutter 3-Way magnetic valve
Electrical equipment #565: Exhaust shutter 3-Way magnetic valve
Electric circuit diagram Exhaust shutter 3-Way magnetic valve circuit
from OFF to ON (the warning lamp does not extinguish unless 3 consecutive
valid signals are input).
Control of auxiliary brake function is deactivated.
White smoke reduction control is deactivated if idling condition is held
for an extended period of time.
Refer to
Refer to
Inspections Performed At Electronic Control Unit Connectors.
Refer to
Actuator Tests Performed Using Multi-Use Tester.
Refer to
Multi-Use Tester Service Data.
Refer to
Inspection of Electrical Equipment.
Electric Circuit Diagram.
00-12
3. How to Read Circuits
00
00-13
HOW TO READ THIS MANUAL
3.1 Index number: to
• Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its
own index number.
100 999
3.2 Key number: A01 to Z99
• Key numbers indicate electrical equipment installation locations. The installation location of a part can be easily
found using its key number shown in a circuit diagram.
All of the electrical equipment installation locations are listed in Gr54-10.
3.3 Part name
3.4 Connector type (type indication)
• A list of the connectors used is included in Gr54-14.
3.5 Connector terminal number
3.6 Major harness division
• Major harness divisions are shown.
3.7 Wiring variations between different specifications
• Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown.
3.8 Code number: #001 to #999
• Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec-
tion procedure for a electrical equipment can be found using its code number shown in a circuit diagram.
3.9 Grounding point: [1] to [99]
• Locations where wires are grounded to the vehicle. All of the grounding points are listed in .
130
3.10 Harness connection
• The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.
3.11 Circuit number, wire diameter, wire color
00-14
(1) Wire color
Wire color Base color + tracer
BBlackBW
Br Brown BrW
GGreenGW
Gr,
Gy
LBlueLW
Lg
O Orange OL
PPinkPB
Pu Purple
RRedRW
Sb Sky blue
VVioletVY
WWhiteWR
YYellow
green
Gray
Light
GrL,
GyL
LgR
YR
YP
Black/
white
Brown/
white
Green/
white
Gray/
blue
Blue/
white
Light
green/
Orange/
blue
Pink/
black
Red/
white
Violet/
yellow
White/
Yell ow /
Yell ow /
pink
BY
BrB
GR
GrR,
GyR
LR Blue/red LY
LgY
red
OB
PG
RB
VW
WB
red
YB
red
YV
Black/
yellow
Brown/
black
Green/
red
Gray/
red
Light
green/
yellow
Orange/
black
Pink/
green
Red/
black
Violet/
white
White/
black
Yell ow /
black
Yell ow /
violet
BR Black/red BG
BrY
GY
LgB
OG
PL
RY
VR Violet/red VG
WL
YG
Brown/
yellow
Green/
yellow
Blue/
yellow
Light
green/
black
Orange/
green
Pink/
blue
Red/
yellow
White/
blue
Yell ow /
green
BrR
GB
LB
LgW
PW
RG
WG
YL
Black/
green
Brown/
red
Green/
black
Blue/
black
Light
green/
white
Pink/
white
Red/
green
Violet/
green
White/
green
Yell ow /
blue
BL
BrG
GL
LO
RL Red/blue RO
WO
YW
Black/
blue
Brown/
green
Green/
blue
Blue/
orange
White/
orange
Yellow/
white
GO
LG
YO
00
Green/
orange
Blue/
green
Red/
orange
Yellow/
orange
00-15
CHASSIS NUMBER, ENGINE NUMBER, MOTOR NUMBER AND NAME PLATE
• Serial chassis and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every
vehicle and engine has its own number. These numbers are required for registration and related inspection of the
vehicle.
Chassis number
<Type 1>
• The chassis number is indicated on the left frame, near the left
front wheel.
Example: FE84BE – A
Chassis number
Vehicle number
<Type 2>
• The chassis number is included in the vehicle identification number (V.I.N), which is stamped on the left-hand frame near the left
front wheel.
Example: JLF FE84BE0K J
Chassis number
Vehicle number
Engine number
• The engine number is indicated on the right side of the crank-
case.
Example: 4M42 –
Engine number
Engine model
Motor number
• The motor number is indicated on the left below part of the
clutch housing.
Example: S10B12345
00-16
00
Name plate
<Type 1>
• Name plate contains the following information.
• MODEL
• Chassis number
• Engine number
• Wheel base
<Type 2>
• Vehicle compliance and date plate are attached to the assistant
driver’s side door opening. The compliance plate certifies that
your vehicle complied with Australian Design Rules at the time
of manufacture. In all correspondence related to your vehicle the
following information should be quoted.
• The engine number.
• The vehicle identification number (V.I.N.) – shown on compli-
ance plate.
• The S.O.A. No. (where applicable), option code, paint and
trim codes located on date plate.
00-17
PRECAUTIONS FOR MAINTENANCE OPERATION
• Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
about the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.
• Check the location of the fault, and identify its cause. Based on
your findings, determine whether parts must be removed or disassembled. Then, follow the service procedure given in this
manual.
• Perform service operations on a level surface. Before starting,
take the following preparatory steps:
• To prevent soiling and damage, place covers over the seats,
trim and floor in the cab and over the paintwork of the body.
• Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this manual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
• After manually tilting the cab, be sure to engage the stopper with
the lock lever to secure the cab stay in a rigid state.
• Take extreme care when removing/installing heavy items such
as engine, transmission and axle. When lifting heavy items using
a cable etc., observe the following precautions.
00-18
• Identify the mass of the item being lifted. Use a cable that is
strong enough to support the mass.
• When lifting the engine, always use the engine hanger.
00
• If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item’s center of
gravity.
• Do not allow anyone to pass or stay under a lifted item that
may fall.
• Never work in shoes that have oily soles.
When working with a partner or in a group, use pre-arranged signals and pay constant attention to safety. Be careful not to touch
switches and levers unintentionally.
• Inspect for oil leakage etc. before washing the vehicle. If the order is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
• Prepare replacement parts ready for installation.
00-19
PRECAUTIONS FOR MAINTENANCE OPERATION
• Oil seals, packings, O-rings and other rubber parts, gaskets, and
split pins must be replaced with new ones after removal. Use
only genuine MITSUBISHI replacement parts.
• When disassembling parts, visually check them for wear, cracks,
damage, deformation, deterioration, rust, corrosion, defective rotation, fatigue, clogging and any other possible defect.
• To facilitate correct reassembly of parts, make alignment marks
on them before disassembly and arrange disassembled parts
neatly. Make punch marks and other alignment marks where
they will not detract from parts’ functionality and appearance.
• After removing parts from the vehicle, cover the area to keep it
free of dust.
CAUTION
• Be careful not to mix up identical parts, similar parts and
parts that have left/right alignments.
• Keep new replacement parts and original (removed) parts
separately.
• Apply the specified oil or grease to U-seals, oil seals, dust seals
and bearings before reassembly.
• Always use the specified oils and greases when performing inspection or replacement. Immediately wipe away any excess oil
or grease with a rag.
00-20
• Wear safety goggles when using a grinder or welder. Wear
gloves when necessary, and watch out for sharp edges and other items that might wound your hands.
00
• Before working on the electrical system, disconnect the (–) bat-
tery cable to prevent short circuits.
CAUTION
• Make sure the starter switch and lighting switches are OFF
before disconnecting or connecting battery cable.
Semiconductor components may otherwise be damaged.
• Carefully handle sensors relays, and other items that are sensi-
tive to shock and heat. Do not remove or paint the cover of any
control unit.
• When applying a voltage to a part for inspection purposes,
check that the (+) and (–) cables are connected properly then
gradually increase the voltage from zero. Do not exceed the
specified voltage.
Remember that control units and sensors do not necessarily operate on the battery voltage.
• When separating connectors, grasp the connectors themselves
rather than the harnesses.
• To separate locking connectors, first push them in the direction
of the arrows. To reconnect locking connectors, push them together until they click.
• Before washing the vehicle, cover electrical parts to keep them
dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them.
00-21
PRECAUTIONS FOR MAINTENANCE OPERATION
1. Handling Precautions for Electric Circuits
CAUTION
• Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Doing so can,
particularly with the chassis harness, hasten corrosion.
1.1 Inspection of harnesses
(2) Inspections with connectors fitted together
(2.1) Waterproof connectors
• Connect an inspection harness and connector A between the
connectors B of the circuit to be inspected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry
sides of the waterproof connectors since this would damage
their waterproof seals and lead to rust.
(2.2) Non-waterproof connectors
• Perform the inspection by inserting a test probe C into the wire-
entry sides of the connectors. An extra-narrow probe is required
for control unit connectors, which are smaller than other types of
connector. Do not force a regular-size probe into control unit
connectors since this would cause damage.
(3) Inspections with connectors separated
(3.1) Inspections on female terminals
• Perform the inspection by carefully inserting a test probe into the
terminals. Do not force the test probe into the terminals since
this could deform them and cause poor connections.
00-22
(3.2) Inspections on male terminals
• Perform the inspection by applying test probes directly to the
pins.
.
CAUTION
• Be careful not to short-circuit pins together with the test
probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit’s internal circuitry.
00
• When using a multimeter to check continuity, do not allow the
test probes to touch the wrong terminals.
1.2 Inspection of connectors
(1) Visual inspection
• Check that the connectors are fitted together securely.
• Check whether wires have been separated from their terminals
due to pulling of the harness.
• Check that male and female terminals fit together tightly.
• Check for defective connections caused by loose terminals, by
rust on terminals, or by contamination of terminals by foreign
substances.
(2) Checking for loose terminals
• If connector terminal retainers become damaged, male and fe-
male terminals may not mate with each other when the connector bodies are fitted together. To check for such terminals, gently
pull each wire and see whether any terminals slip out of their
connector housings.
00-23
PRECAUTIONS FOR MAINTENANCE OPERATION
1.3 Inspections when a fuse blows
• Remove the fuse, then measure the resistance between ground
and the fuse’s load side.
Next, close the switch of each circuit connected to the fuse. If
the resistance measurement between any switch and ground is
zero, there is a short circuit between the switch and the load. If
the resistance measurement is not zero, the circuit is not currently short-circuited; the fuse probably blew due to a momentary short circuit.
• The main causes of short circuits are as follows:
• Harnesses trapped between chassis parts
• Harness insulation damage due to friction or heat
• Moisture in connectors or circuitry
• Human error (accidental short-circuiting of components)
1.4 Inspection of chassis ground
• A special ground bolt is used to tighten a ground terminal. When
servicing the ground point, be sure to follow the procedures described below:
• When reinstalling the ground bolt
• When relocating the ground point
2. Service Precautions for Alternators
• When servicing alternators, observe the following precautions:
• Never reverse the polarity of battery connections.
Tighten the ground bolt to the specified torque.
A special ground bolt must be used. Spot-weld a nut to a
frame and tighten the ground bolt to the specified torque. Be
sure to apply touch-up paint to the welded point.
If the polarity of the battery connections were to be reversed,
a large current would flow from the battery to the alternator,
damaging the diodes and regulator.
00-24
• Never disconnect the battery cables with the engine running.
Disconnection of the battery cables during engine operation
would cause a surge voltage, leading to deterioration of the diodes and regulator.
00
• Never perform inspections using a high-voltage multimeter.
The use of a high-voltage multimeter could damage the diodes
and regulator.
• Keep alternators dry.
Water on alternators can cause internal short circuits and damage.
• Never operate an alternator with the B and L terminals short-circuited. Operation with the B and L terminals connected together
would damage the diode trio.
• Disconnect the battery cables before quick-charging the battery
with a quick charger.
Unless the battery cables are disconnected, quick-charging can
damage the diodes and regulator.
00-25
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