Daihatsu F300 User manual

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DAIHATSU
F300
Service
111anual
SECTION INDEX
NAME
GENERAL INFORMATION
MAINTENANCE
ENGINE MECHANICAL
EMISSION CONTROL SYSTEM
EFISYSTEM
FUEL SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM
IGNITION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
CLUTCH
MANUALTRANSMISSION
TRANSMISSION & TRANSFER
PROPELLER SHAFT
FRONT & REAR DIFFERENTIAL
FRONT AXLE & SUSPENSION
REAR AXLE & SUSPENSION
BRAKE SYSTEM
STEERING
BODY
BODYELECTRICAL SYSTEM
HARNESS & WIRING DIAGRAM
APPENDIX
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Gl
MA
EM
EC
EF
FU
co
LU
IG
ST
CH
CL
MT
TR
PR
DF
FS
RS
BR
SR
80
BE
HW
AP

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DAIHATSU
F300
• STARTING SYSTEM
OUTLINE OF STARTING SYSTEM ••••••••••.. ST- 2
DESCRIPTION .............................................. ST- 5
PLANETARY TYPE STARTER
MOTOR ..................................................... ST-10
REDUCTION TYPE STARTER
MOTOR ..................................................... ST -24
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• ST-1

STARTING SYSTEM
OUTLINE OF STARTING SYSTEM
COMPONENTS
Planetary type staner motor
The starter motor consists of a solenoid switch and a motor.
The solenoid has electric contact points which supply power to the motor. The solenoid also has a shift fork
(driver lever) which
moves the motorpinion gear into meshwith the ring gear mounted on the engine flywheel.
The planetary type starter motor is a reduction type starter which employs a planetary gear set. Compared
with the conventional starter motors, this reduction type starter motor features a smaller size and lighter
weight
<D Bearing
® Drive housing
® Snap ring
@ Stop collar
® Clutch
® Snap ring
(t) Washer
® Drive lever
® Bearing
® Center bearing
@ Magnet switch
@ lntemal gear
@Washer
@ Planet carrier shaft
@Bearing
®End frame
@Bearing
@ Annature
ST-2
* :Non-reusable parts
.A : Asbestos parts
@ Brush holder
® Oring
@Yoke
@ 0 ring
@Plate
@ Planet gear
®Washer
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STARTING SYSTEM
Reduction type starter motor
The starter consists of a solenoid switch and a motor. The power generated at the motor is transmitted to
the clutch assembly through the idle gear. The rotation speed is reduced in accordance with the gear ratio
between the drive gear provided
at the motor and the clutch gear. On the other hand, the torque of the
rotation increases.
(j) Bearing
@ Armature
® Bearing
@ Field frame
®Spring
® Brush holder
<!> End frame
@ Magnet switch assembly
®Spring
@Ball
0 Clutch assembly
@Idle gear
@ Searing housing
G Bearing
@ Starter drive housing
..&. : Asbestos parts
ST-3

STARTING SYSTEM
STARTING SYSTEM CIRCUIT
Ignition switch
ECU
ST (EFI engine only)
0--+~--------------~------------~~
E
Reduction typePlanetary type
starter starter
ST
8
TROUBLE SHOOTING
Problem Possible cause
Remedies
Engine will not crank. Battery not fully charged.
Check specific gravity of battery electrolyte.
Charge or replace battery.
Battery cables loose, corroded or worn. Repair or replace cables.
Fusible link blown. Replace fusible
link..
Starter faulty. Repair starter.
Ignition switch faulty. Replace ignition switch.
Engine cranks Slowly.
Battery notfully charged. Check specific gravity
of battery electrolyte.
Charge
or replace battery.
Battery cables loose, corroded or worn. Repair or replace cables.
Starter faulty. Repair starter.
Starter keeps running. Starterfaulty. Repair starter.
Ignition switch faulty. Replace ignition switch.
Short in wiring. Repair
or replace wiring.
Starter spins. -Engine will Pinion
gear teeth broken or faulty starter. Repair starter.
not crank. Rywheel teeth broken. Replace flywheel.
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ST-4

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DESCRIPTION
PLANETARY TYPE STARTER MOTOR
The planetary starter motor consists of a motor and asolenoid
switch in the same
way as with the conventional starter motors.
However, the starter
motor of this type differs from the conven-
tional type startermotors in that the revolution speed generated
by the motor is reduced in the power train system.
STARTING SYSTEM
The following shows how the torque is transmitted in the power train system.
(Here, it should be notedthat the planetarycarriershaft, planetarycarrierandplanetary gearshaftis integral.)
<D The torque generated at the armature is transmitted to the sun gear.
® When the sun gear is turned, the planetary gear turns on its own planetary gear shaft.
® However, normally the internal gear is locked. As a result, the planetary gear starts to walk around
the sun gear, while the planetary gear itself is turning on its own shaft.
@ In as much as the planetary carrier is integral with the planetary gear shaft, the torque is transmitted.
Consequently,
the pinion gear starts to turn.
Furthermore,
the starter motor of this type is equipped with a bufferdevice. When an excessive torque
is applied,
it drives the internal gear, thereby relieving the excessive torque.
Planetary carrier shaft
The following is the description of the buffer function.
The internal
gear is meshed with the clutch plate provided
inside the shock absorber bearing.
Since the clutch plate is held in such a way that it turns when
a torque
in excess of a certain value is applied. Therefore, the
internal gearturnstogetherwith the clutch plate, thereby reduc-
ing the torque excessively applied.
ST-5
Armature shaft
Planetary gear
Planetary gear shaft
Planetary
carrier shaft
Clutch plate
Sun gear
Shock Planetary
absorber bearing gear

STARTING SYSTEM
PRINCIPLES OF OPERATION & STARTING SYSTEM
CIRCUIT
The starter motor operations can be divided into two opera-
tions. When tihe ignition switch is setto the START (ST) position,
currentfrom the battery flows to the motorthrough the solenoid.
The motor starts to rotate. Simultaneously, the pinion gear
meshes with the ring gear by the magnetic force.
When the pinion gear has shifted intoa complete mesh with the
ring gear, the solenoid
contact points are closed. The current
from
the batterynow directly goes to the motor. thus supplying
high povver enough for cranking the engine. In this way, the
starter motor begins cranking the engine.
The solenoid is composed
of two coils. One is a low-resistance
coil which moves the shiftfork (which corresponds to the pinion
shaft
·1n the case of the reduction type starter motor). The other
is a high-resistance coil which retains the solenoid at the ~start"
position.
The low-resistance coil is connected to the battery ground
through the motor brush (and armature coil) and filed coil. The
high-resistance coil
is directly grounded to the solenoid case.
During the engine cranking, the solenoid is energized at the
high-resistancecoil alone. Sincethe low-resistance coil has the
same potential
at its both ends, no currentflows. Consequently,
the solenoid is retained
at the "start~ position by means ofthe
high-resistance coil only. The right figure shows an equivalent
circuit
of the system.
ST..-<;
_[
T"
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.L.
r
Reduction type starter motor
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STARTING SYSTEM
During the starting period, the low-resistance coil provides the solenoid with a large amount of current to
move the shift fork
or the pinion shaft. Afterward, however, it is no longer necessary to use a large amount
of current to hold the solenoid. Therefore. the above-described circuit is employed in the starting system so
as to prevent burning.
The plunger
of the solenoid has two functions: One is to move the shift fork or the pinion shaft. The other is
to close the electric
contact points, which takes place simultaneously with the first function. For positive
contact, the contact points are connected
to the plunger through a spring.
When the ignition switch is
set to the start {ST) position, current from the battery goes to the low-resistance
coil, filed coil and armature coils. As a result, the motor start rotating. Simultaneously, the high-resistance
coil ·Is also energized. These two coils exert a drawing force on the plunger, thus making the plunger
overcome the force
of a spring (a spring which is provided toreturn the plunger and differsfrom theaforesaid
spring provided
at the contact points). The plunger then moves the shift fork or the pinion shaft strongly,
thereby making the pinion
gear mesh with the ring gear. Simultaneously, the starter contact points close and
current is directly
drawn from the battery. At this stage, the low-resistance coil has an equal potential at its
both ends, as previously
described~ Hence, no current flows to the motor through the low-resistance coil.
After the engine has started, when the ignition switch is returned to the lG position, current
to the solenoid
is cut off. (See the NOTE.) The spring built in the solenoid returns the plunger, thereby opening the contact
points and cutting the
current to the motor. At the same time, the shift fork orthe pinion shaft which has been
pushing the pinion
gear returns to the original position by meansof the aforesaid spring force. Consequently,
the pinion gear is
disengaged and separated from the ring gear.
This pinion gear's separation from the ring
gear can not be performed positively and assuredly by the spring
at the pinion shaft alone. To achieve positive separation, a screw-shaped spline is provided at the pinion
shaft gear. After start
of the engine, the rotation speed of the ring gearcontinues to increase. Consequently,
it becomes possible
for the ring gear to drive the pinion gear.
At this point, owing to
the screw-shaped spline, the pinion gear is moved in such a direction that it tends to
disengage from the ring gear. On the other hand, this screw-shaped spline helps the pinion gear to
be
pushed and moved into mesh with the ring gear during the starting period.
NOTE:
In fact, at this moment, the current to the solenoid goes to the starter contact points and passes in
series through the low-resistance coil and the high-resistance coil. Consequently, electromagnet
function continues and drawing forces are generated. However, the electromagnetic forces generated
at the low-resistance and high-resistance coils counteract, for the winding direction of the coil is
opposite
to each other. As a result, no drawing force is produced.
On the other hand, when the ignttion switch is set to the ON (ST/ON) position, a parallel circuit is
formed. The electromagnetic forces generated at both coils are in the same direction, resulting in an
increased drawing force.
Namely, the direction
of the current at the low-resistance coil changes reversely when the ignition
switch is switched between the ON and
OFF sta1es. (This explanation appfies only to the instance
when the ignition switch is changed from
the STposition to the IG position.)
ST-7

STARTING SYSTEM
SERVICING INSTRUCTIONS OF STARTER
(1) When connecting the starter terminal or battery terminal, perform positive tightening so as to avoid poor
connection.
If poor connection should exist, it presents the hazard of serious danger that a large amount of current
flowing
during starter operation can overheat the poor connection.
(2) When
removing the starter, first disconnect the negative 8 terminal of the battery. Then, disconnect the
terminals (+B, ST) at the starter side. Sincethe batteryvoltage is always applied to the starter +B terminal,
failure to observe this removing sequence may lead to battery short, which is extremely dangerous.
(3) When installing the starter, install the starter in the clutch housing positively and be sure to tighten the
attaching bolts to the specified torque. Improper installation can cause premature wear of the teeth of
the pinion gear or ring gear and also can cause breakage of the clutch housing.
IN-VEHICLE INSPECTION
(1) Place the shift lever to the neutral position. Apply the park-
ing brake lever.
(2) Disconnect the ignition coil coupler so that the engine will
not start.
(3) Setthe ignition switch
to the ST position. Check to see if the
engine cranks.
(4) If the
engine will not crank, perform the following checks.
• Inspect the battery for damage. Charge the battery.
Perform harness continuity test.
{5) If the
starter motor still will not rotate even after the checks
above have been performed, remove the starter motor and
periorm the unit check.
REMOVAL
(1} Disconnect the ground cable terminal from the negative(-)
terminal of the battery.
ST-8
WFE90-S'""017
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(2) Jack up the vehicle and support it with safety stands.
(3) Disconnect the starter terminals
STand 8 from the starter.
(4) Remove the starter motor from the clutch housing.
ST-9
STARTING SYSTEM
''"''"""'

STARTING SYSTEM
PLANETARY TYPE STARTER MOTOR
UNIT CHECK OF PLANETARY TYPE STARTER
MOTOR
CAUTION:
• Each of the following tests must be performed within
three to five seconds. If you fail to observe
this caution
and the starter should
be energized for more than this
duration, the coil may be burnt out.
(1) Pull-in test
<D Disconnect the lead wire form the magnetic switch ter-
minaL
® Connect the negative (-)terminal of the battery to the
starter body and magnetic switch terminal.
® Connectthe positive(+) terminal to the terminal ST.
Ensure that the pinion is pushed ouward.
If the drive pinion fails to moveout, replace the magnetic
switch.
(2) Hold-in test
After the check has been performed following the same
procedure as with the pu!l-in test, disconnect the negative
terminal ofthe magnetic switch terminal.
Ensure that the drive pinion '1s held in a pushed-out state.
Jf the drive pinion fails to be held, replace the magnetic
switch.
ST-10
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(3) Inspection of plunger return
After
the check has been performed follow·1ng the same
procedure as with the
hold-in test, disconnect the ground
terminal of the starter body. Ensure that the drive pinion is
drawn into the drive housing.
If the drive pinion fails to be drawn, replace the magnetic
switch.
(4) No--load performance
test
Connectthe battery and an ammeter to the starter as shown
in the right figure. Ensure
that the starter rotates smoothly
with the pinion moving out.
Measure
the current the starter is drawing.
Specified Current:
Less than 90A at 11.5V
NOTE:
• Prior to the test, be sure to connect the lead wire to the
magneticswitch.
DISASSEMBLY OF PLANETARY TYPE
STARTER MOTOR
(1) Disconnect the lead wire from the magnetic switch.
(2) Rem::we the attaching nut
of the magnetic switch from the
drive housing.
{3) Remove the
magnetic switch from the drive housing.
ST-11
STARTING SYSTEM

STARTING SYSTEM
(4) Remove the tiNO through bolts from the commutator end
frame.
(5) Remove the yoke with armatureand the driveleverfrom the
drive housing.
(6) Separate the yokewith armaturefrom the clutch with center
bearing.
(7) Remove the ·o· ring.
(8) Remove the end frame cover by removing the two screws.
(9) Remove the brushes from the brush holder by lifting the
brush springs by means of nose pliers or the like.
NOTE:
• Care must be exercised not to damage the brushes
during the removal.
(10) Then, remove the
armature from the yoke.
ST-12
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(11) Removal of planetary gear
<D Remove the plate for starter armature.
® Remove the three planetary gears.
® Remove the plate washer.
(12) Remove the stop collar from the snap ring by tapping the
collar with a screwdriver or the like placed on it.
(13) Detach the snap ring by prying it off with snap ring pliers.
Then, remove the collar.
(14) Remove the clutch.
(15) Detach the snap ring. Separate the center bearing from the
planetary carrier shaft .
ST-13
STARTING SYSTEM

STARTING SYSTEM
(16) Remove the internal gear by aligning the recessed section
provided at theouter periphery
of the internal gear with the
protruded section provided at the inner periphery of the
center bearing.
INSPECTION OF PLANETARY TYPE STARTER
MOTOR
Check of armature
(1) Check of armature insulation
Ensure that no continuity exists between the commutator
and the armature coil, using an ohmmeter.
If continuity exists, replace the armature.
(2) Check
of commutator continuity
Check continuity between each adjacent segment of the
commutator, using an ohmmeter.
If no continuity exists between any adjacent segments,
replace the armature.
Check of commutator
(1) Check each contact surface of the commutator segments
with the brushes for burning.
If the surfaces are dirty or burnt, correct the commutator
surfaces, using abrasive paper (No. 400) or a lathe.
(2) Check
of commutator for circle runout
Support the armature at its
both ends on a Vee block.
Check the commutatorfor circlerunout, using a dial gauge.
Circle Runout Limit: 0.05 mm
If the circle runout exceeds the allowable limit, turn down
the commutator on a lathe.
At this point, care must
be exercised to ensure that the
commutator diameter is not lessthan the minimum require-
ment diameter of
27 mm.
ST-14
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(3) Measurement of commutator diameter
Measure the commutator diameter by means of a
micrometer or vernier calipers.
Standard Diameter: 28 mm
Minimum Diameter: 27 mm
If the commutator diameter is less than the minimum
diameter, replace the armature.
(4) Check of commutator undercut
Measure the insulator groove depth between commutator
segments.
Minimum Depth: 0.2 mm
If the insulator groove depth becomes less than t1e limit
value, replace the commutator.
Check of field coil
(1) Reid coil continuity test
Perform
f1eld coil continuity test at a point between the lead
wire and the brush, using an
ohmmeter.
If no continuity exists, replace the yoke.
(2) Reid coil short test
Perform field coil short test at a point between the brush
and the yoke proper, using an ohmmeter.
If no continuity exists, replace the yoke.
Check of brushes
(1) Measurement of brush length
Measure the brush length, using vernier calipers.
Standard Length:
14 mm
Minimum Length: 9 mm
(2) Replacement of brush.
If the length is less than the minimum requirement, replace
the brush
holder or the yoke, as required.
ST-15
STARTING SYSTEM
Groove requiring correction
Improperly undercut groove
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A
Depth

STARTING SYSTEM
(3) Procedure for brush replacement
(i) Cut the brush lead wire at the terminal side.
NOTE:
Replacement can be made only for the two brushes at
the yoke side (posttive (+)side). The brush at the nega-
tive
(-) side should be replaoad together with the brush
holder.
® Remove welding traces with a file or the like to correct
the brush terminal to the specified dimensions.
Specified Dimensions:
NOTE:
Thickness: 1.5 mm -1 .7 mm
Width: 5
mm
• Be sure to remove the l!@tH¥1J section ofthe brush terminal
as indicated in the right figure. Since the section to be
removed is narrow, be very careful not to damage the
field coil.
® Stack the plate section of a replacement brush ontothe
welding sde of the lead wire. Make pressure connec-
tion
over the overlaid section by pinching it with pliers.
NOTE:
• Be sure to take out the brush lead wire in the correct
direction.
@ Solder the pressure connection section. Correct the
section, using a file or the like,
so that the section con-
forms to the dimensions,
as indicated in the right figure.
NOTE:
1. When performing the soldering, heat the section to be
soldered thoroughly.Be very careful not to allow any
solderto flow into the positive side lead wire.
2. Be sure to allow solderin a sufficientamountto flow into
the inside ofthe plate.
3. Ensure that no solder oozes to the field side.
Check of brush holder
(1) Check of brush holder for insulation
Measure
the insulation between the positive and negative
terminals of the brush holder, using an ohmmeter.
InsulationResistance: 0.1 M!l or more
(2) Replacement of brush holder.
If the insulation resistance is less than the specification,
replace
the brush holder.
ST-16
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~Cct M
J. ~~~~;~;' I \.m;,al at •
Section to Section to yoke Side
be removed be removed
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Check of brush spring
Measure the brush spring tension, using a spring scale.
Standard Tension: 15.7 N (1.6 kgf)
Check of clutch
(1) Inspection of pinion gear and spline teeth
Check the teeth of the pinion gear and spline for wear or
damage.
If the teeth exhibit any damage, replace the clutch. Also,
inspect the flywheel ring gear for wear or damage.
(2)
Check of starter clutch
While holding the clutch, turn the pinion clockwise. Ensure
that the pinion turns smoothly.
Turn the pinion counterclockwise. Ensure that the pinion is
locked.
If the check results are unsatisfactory, replace
the starter
clutch.
Check at magnetic switch
(1) Plunger check
Push in the plunger with your fingers and release your
fingers. Ensure that the plunger returns quickly to the
original position. If the plunger exhibits poor retuming or
fails to return, replace the magnetic switch.
(2) Pull-in coil
open circuit test
Using an ohmmeter, ensure that continuity exists between
the terminal ST and terminal C.
If no continuity exists, replace the magnetic switch.
ST-17
STARTING SYSTEM
Brush

STARTING SYSTEM
(3) Hold-in coil open circuit test
Ensure that continuity exists between
the terminal ST and
the switch body.
If no continuity exists, replace the magnetic switch.
Check of bearing
Center bearing
(1) Measure the outer diameter of the center bearing sliding
section of the planetary carrier shaft
Specified Value: 15 mm
(2) Measure the inner diameter of the center bearing so as to
determine the clearance.
Specified Value: 0.04 mm
Allowable Umit: 0.15 mm
If the clearance exceeds the allowable limit, replace the
oilless bearing or the planetary carrier shaft.
(3) Bearing replacement
<D Remove the bearing, using a suitable tool in combina-
tion
with a press or the like.
NOTE:
• When pulling out the bearing, be sure to remove it from
the inside.
® Install the bearing, using a suitable tool in combination
with a press or the like.
NOTE:
• When installing the bearing, be sure to install it from the
outside.
ST-18
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Terminal ST
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NOTE:
• The bearing should be driven into position in such a way
that the bearing is recessed within 0.5 mm from the edge
of the center bearing.
End frame bearing
(1) Measure the outer diameter of the end frame sliding section
of the armature shaft.
Specified Value: 7 mm
(2) Measure the inner diameter of the end frame bearing so as
to determine the clearance.
Specified Value: 0.04 mm
Allowable Umit: 0.15 mm
If the clearance exceeds the allowable limit, replace the
oilless bearing or the armature.
(3) Bearing
replacement
<D Remove the bearing, using a tap having an outer
diameter of 8 mm.
NOTE:
• Be certain to clamp the end frame in a vise with a cloth
interposed
so that no scratch may be made on the end
frame.
® Install a new bearing, using a suitable tool in combina-
tion with a press or the like.
ST-19
STARTING SYSTEM
Center h
bearing
Oilles(
-v®
IP
O.lmm
bearing