Professional Documents
Culture Documents
INSPECTION
1.
INSPECT STARTER ASSY
NOTICE:
These tests must be performed within 3 to 5 seconds to
prevent burnout of the coil.
(a) Perform the pullin test.
(1) Remove the nut, then disconnect the lead wire from
terminal C.
A83797
(2)
Battery
A84765
(b)
Disconnect
Terminal C
Battery
A84789
(c)
Disconnect
Battery
A84790
Author:
Date:
1210
192
STARTING & CHARGING
(d)
A83797
(2)
(3)
Terminal 30
Terminal 50
Ammeter
Battery
A84791
A32779
Specified Condition
12
Continuity
35
No Continuity
35
Continuity
(Apply battery voltage to terminals 1 and 2)
Author:
Date:
1211
193
STARTING & CHARGING
COMPONENTS
37 (378, 27)
Starter Assy
37 (378, 27)
Starter Connector
Starter Center Bearing
Clutch Subassy
Planetary Gear
Starter Armature Plate
Starter Yoke Assy
Starter Wire
9.8 (100, 7)
x2
x2
Washer
Snap Ring
Starter Commutator
End Frame Cover
10 (102, 7)
A84619
Author:
Date:
1212
194
STARTING & CHARGING
REPLACEMENT
1.
2.
3.
(a)
(b)
(c)
(d)
Terminal Cover
(d)
(c)
(a)
(d)
A51076
4.
5.
6.
Author:
Date:
1213
195
STARTING & CHARGING
OVERHAUL
1.
(a)
(b)
A83797
(c)
(d)
A83798
2.
(a)
(b)
A83799
A83800
Author:
Date:
1214
196
STARTING & CHARGING
3.
(a)
4.
A83803
(a)
A83801
Snap Ring
Pliers
5.
(a)
(b)
6.
(a)
7.
A83802
A83804
(a)
A83805
Author:
Date:
1215
197
STARTING & CHARGING
8.
(a)
A73990
9.
(a)
A58586
(b)
Terminal C
Continuity
Ohmmeter
Terminal 50
A84614
(2)
Switch Body
Continuity
Ohmmeter
Terminal 50
A84615
10.
(a)
Continuity
Segment
A79764
Author:
Date:
1216
198
STARTING & CHARGING
(2)
Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the starter armature.
(b) Check the commutator surface for dirt or burn.
If the surface is dirty or burnt, smooth the surface with 400grit
sandpaper or lathe.
No Continuity
Commutator
Coil Core
A79765
(c)
Depth
A58584
11.
Length
A76677
(b)
No Continuity
A79766
12.
Free
Lock
A83810
Author:
Date:
1217
199
STARTING & CHARGING
(b)
14.
A84665
(a)
A83805
15.
(a)
(b)
A83804
Author:
Date:
1218
1910
STARTING & CHARGING
16.
(a)
(b)
Snap Ring
Pliers
(c)
A83802
(d)
Length
A58810
17.
(a)
A84616
Key
Keyway
18.
(a)
19.
A73991
Rubber
Cutout
(a)
A79727
Author:
Date:
1219
1911
STARTING & CHARGING
Keyway Key
20.
(a)
(b)
21.
(a)
(b)
A84617
A83799
(c)
A84618
(d)
(e)
A83798
A83797
Author:
Date:
1220
1912
STARTING & CHARGING
CHARGING SYSTEM
CHARGING SYSTEM
190C801
PRECAUTION
1.
2.
3.
4.
5.
6.
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
Check that the charging cable is tightened on terminal B of the alternator and the fuse box.
Do not check whether the alternator generates or not with connecting terminal F to other terminal.
Author:
Date:
1221
1913
STARTING & CHARGING
CHARGING SYSTEM
190C901
ONVEHICLE INSPECTION
1.
(a)
(b)
2.
(a)
HINT:
If the specific gravity is less than specification, charge the battery.
A01259
3.
(a)
(b)
A01260
(c)
HINT:
If the voltage is less than specification, charge the battery.
Blue
White
Red
Z11580
4.
(a)
(b)
Author:
Date:
1222
1914
STARTING & CHARGING
5.
(a)
CHARGING SYSTEM
HINT:
B00543
B00540
6.
VISUALLY CHECK ALTERNATOR WIRING
(a) Check that the wiring is in good condition.
7.
LISTEN FOR ABNORMAL NOISES FROM ALTERNATOR
(a) Check that there is no abnormal noise from the alternator while the engine is running.
8.
INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on.
(b) Start the engine. Check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warning light circuit.
9.
INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) If a battery/alternator tester is available, connect the tester to the charging circuit as permanufacturers instructions.
(b)
Ammeter
Disconnect Wire
from Terminal B
Battery
Alternator
Voltmeter
CH0732
Author:
Date:
1223
1915
STARTING & CHARGING
CHARGING SYSTEM
(c)
10.
(a)
(b)
HINT:
If the ammeter reading is less than standard amperage, repair the alternator.
If the battery is fully charged, the indication will sometimes be less than standard amperage.
Author:
Date:
1224
1916
STARTING & CHARGING
GENERATOR ASSY
GENERATOR ASSY
190CA01
REPLACEMENT
1.
3.
(a)
(c)
(d)
4.
B00145
(b)
A65924
A65925
A65925
Author:
Date:
1225
1917
STARTING & CHARGING
GENERATOR ASSY
190CB01
COMPONENTS
Front Bearing
3.0 (31, 27 in.lbf)
Rotor
111 (1,132, 82)
Rear Bearing
Washer
2.9 (30, 26 in.lbf)
Terminal Insulator
Bearing Retainer Plate
Rectifier Holder
Bearing Cover
Brush Cover
Plate Seal
Rectifier
End Frame
Terminal Plate
Regulator
Cord Clip
Brush Holder
Terminal Insulator
A65928
Author:
Date:
1226
1918
STARTING & CHARGING
GENERATOR ASSY
190CC01
OVERHAUL
SST
1B
SST
1A
1.
HINT:
SST1 A, B
0982006010
SST2
0982006020
(a)
A62753
SST 2
A62754
(d)
SST
1A
A62755
(f)
(g)
SST
1A
SST
1B
A62756
Author:
Date:
1227
1919
STARTING & CHARGING
2.
(a)
(b)
(c)
(d)
(e)
(f)
3.
(a)
4.
(a)
GENERATOR ASSY
5.
(a)
(b)
(c)
SST
A62757
6.
(a)
(b)
7.
(a)
(b)
F
B
A62881
A62882
Author:
Date:
1228
1920
STARTING & CHARGING
Slip Ring
GENERATOR ASSY
8.
(a)
(b)
Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
(c)
9.
(a)
INSPECT BRUSH
Using a vernier calipers, measure the exposed brush
length.
Standard exposed length:
9.5 11.5 mm (0.374 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
10.
(a)
(b)
A62758
Rotor
Slip Ring
A62759
A62760
A62762
B00219
Author:
Date:
1229
1921
STARTING & CHARGING
Socket Wrench
29
GENERATOR ASSY
(c)
(d)
B00211
Cord Clip
11.
(a)
12.
(a)
A62763
13.
(a)
(b)
Protrusion
A62764
Author:
Date:
1230
1922
STARTING & CHARGING
SST
1B
SST
1A
14.
GENERATOR ASSY
HINT:
SST1 A, B
0982006010
SST2
0982006020
(a)
A62753
SST 2
(c)
(d)
(e)
A62754
SST
1A
(f)
A62765
(g)
(h)
SST
1A
SST
1B
A62756
Author:
Date:
1231