1. Alternators and
Starter Motors
TECHNICAL MANUAL
Alternators and Starter Motors
CTM77 18JUL05 (ENGLISH)
John Deere Power Systems
LITHO IN U.S.A.
2. Introduction
Foreword
This manual is written for an experienced technician. Component Technical Manuals are concise service
Essential tools required in performing certain service guides for specific components. They are written as
work are identified in this manual and are stand-alone manuals covering multiple machine
recommended for use. applications.
Live with safety: Read the safety messages in the Fundamental service information is available from
introduction of this manual and the cautions presented other sources covering basic theory of operation,
throughout the text of the manual. fundamentals of troubleshooting, general maintenance,
and basic types of failures and their causes.
CAUTION: This is the safety-alert symbol.
This manual covers alternator and starter motor
When you see this symbol on the machine
applications for all John Deere diesel engines—
or in this manual, be alert to the potential for
both older 300/400/500-Series and newer
personal injury.
POWERTECH® and PowerTech Plus™ 2.4 L—13.5 L
engines. This manual covers components for both
This Component Technical Manual (CTM) contains the
Deere OEM engines and Deere machine engine
latest available instructions necessary to repair engine
applications.
alternators and starter motors. It includes theory of
operation, and diagnostic and testing procedures to
NOTE: Remanufactured alternators and starter motors
help troubleshoot and understand potential failure
are available for replacement on most
modes.
applications listed in this manual. Refer to
John Deere’s “Remanufactured Components”
The information is organized in sections and groups by
catalogs PC2344 (Ag), PC2345 (CE) and
various suppliers. At the beginning of each repair
PC2346 (C&CE) to cross-reference your
group are summary listings of all applicable essential
original equipment part number and obtain a
tools, service equipment and tools, other materials
suitable remanufactured replacement starter or
needed to do the job, service parts kits, specifications,
alternator.
wear tolerances, and torque values.
POWERTECH is a registered trademark of Deere & Company. IFC,CTM77 –19–15JUL05–1/1
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3. Introduction
John Deere Dealers
IMPORTANT: Please copy this page listing changes
and route it through your service
department.
This CTM is a complete revision of CTM77, Alternators
and Starter Motors, dated 25 Sep 02. Discard CTM77
dated 25 Sep 02 and replace it with this new manual.
This manual covers alternators and starter motors on all
John Deere and OEM applications manufactured since
1972, except 40, 50 and 55 Series Utility Tractors.
Revised information includes:
1. Updated test specifications for all current alternators
and starter motors, including those adopted since the
25 Sep 02 edition.
2. Added new applications for all current alternators and
starter motors.
3. Added new Bosch alternator pulley removal procedure
to Section 30, Group 10.
4. Updated torque charts in Section 05, Group 10.
OURGP11,0000053 –19–15JUL05–1/1
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6. Contents
05
SECTION 75—Iskra Starter Motors
Group 05—Starting Circuit Theory of Operation
Group 10—Iskra AZE/AZF/AZJ-Type Starter Motor
Repair
Group 15—Iskra AZE-Type Starter Motor Repair
10
SECTION 80—Valeo Starter Motors
Group 05—Starting Circuit Theory of Operation
Group 10—Valeo Starter Motor Repair
15 SECTION 85—Magneton Starter Motors
Group 05—Starting Circuit Theory of Operation
Group 10—Magneton Starter Motor Repair
20
25
30
35
40
45
50
CTM77 (18JUL05) ii Alternators and Starter Motors
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7. Contents
55
60
65
70
75
80
85
INDX
CTM77 (18JUL05) iii Alternators and Starter Motors
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8. Contents
55
60
65
70
75
80
85
INDX
CTM77 (18JUL05) iv Alternators and Starter Motors
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11. Group 05
Safety
05
Handle Fluids Safely—Avoid Fires 05
1
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
–UN–23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 –19–03MAR93–1/1
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12. Safety
05
05 Handling Batteries Safely
2
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (—) battery clamp
first and replace it last.
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 15—30
–UN–23AUG88
minutes. Get medical attention immediately.
If acid is swallowed:
TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 2 L (2 quarts).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
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13. Safety
05
Wear Protective Clothing 05
3
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1
Work in Clean Area
Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
–UN–18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN –19–04JUN90–1/1
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE –19–04JUN90–1/1
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14. Safety
05
05 Work In Ventilated Area
4
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR –19–17FEB99–1/1
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1
Use Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1
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15. Safety
05
Remove Paint Before Welding or Heating 05
5
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 76 mm (3 in.) from area to
be affected by heating.
TS220
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding
will take place.
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–19JUL01–1/1
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16. Safety
05
05 Practice Safe Maintenance
6
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
–UN–08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR –19–17FEB99–1/1
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17. Safety
05
Dispose of Waste Properly 05
7
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1
Prevent Machine Runaway
Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals.
Machine will start in gear if normal circuitry is bypassed.
–UN–11JAN89
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.
TS177
DX,BYPAS1 –19–29SEP98–1/1
Live With Safety
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
–19–07OCT88
TS231
DX,LIVE –19–25SEP92–1/1
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19. Group 10
General Information
05
Unified Inch Bolt and Screw Torque Values 10
TS1671 –UN–01MAY03 1
Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c b c b c
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N•m lb-ft N•m lb-ft
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
TORQ1 –19–24APR03–1/1
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20. General Information
05
10 Metric Bolt and Screw Torque Values
2
–UN–01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N•m lb-ft
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 –19–24APR03–1/1
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21. Group 15
Electrical System Basic Information and Wiring Diagrams
05
Electrical Circuit Malfunctions 15
1
–19–27FEB92
T7713AD
A—Battery C—Switch D—Light E—Ground
B—Fuse
1. There are four common circuit malfunctions. • After the component.
• High-Resistance Circuit Component malfunctions can easily be confused with
• Open Circuit circuit malfunctions. Therefore, care must be exercised
• Grounded Circuit when isolating the cause of a problem.
• Shorted Circuit
Example: Light does not operate or is dim when switch
2. Three sections in a simple circuit where these is turned ON, until switch connector is disconnected
malfunctions can occur: and reconnected.
• Before the controlling switch (C). Reason: High resistance caused by a dirty switch
• Between the controlling switch and before the connector, caused a voltage drop which prevented the
component, light (D). proper amount of current from flowing to the light.
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22. Electrical System Basic Information and Wiring Diagrams
05
15 High Resistance Circuit
2
–19–26FEB92
T7713AG
A—Battery D—Switch Terminal F—Harness Connector H—Light
B—Fuse E—High Resistance G—Light Terminal I—Ground
C—Switch
A high resistance circuit can result in slow, dim or no If battery voltage is indicated, check closer to ground
component operation. to locate point of voltage drop. The example shows
high resistance (E) between switch and harness
Examples: Loose, corroded, dirty or oily terminals. connector.
Wire size too small. Strands broken inside the wire.
Poor ground connection to frame. Repair circuit as required. In the example, strands
were broken inside the wire. Replace that section of
To locate the cause of high resistance: wire.
With switch (C) ON, check for battery voltage between Repeat check-out procedure after repair.
switch and ground (I) at an easily accessible location,
like harness connector (F).
If less than battery voltage is indicated, check again
closer to switch.
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23. Electrical System Basic Information and Wiring Diagrams
05
Open Circuit 15
3
–19–27FEB92
T7713AF
A—Battery D—Switch Terminal F—Open Circuit H—Light
B—Fuse E—Harness Connector G—Light Terminal I—Ground
C—Switch
An open circuit will result in no components operating. If battery voltage is indicated, check for voltage closer
Fuse may or may not be blown. to ground at harness connector (E).
Example: Broken wire, disconnected component If no voltage is indicated, wire may be broken between
terminal, pins inside a connector not making contact, switch and connector.
blown fuse, open circuit breaker, failed switch or
component, or a disconnected ground wire. If battery voltage is indicated, inspect connector pins. If
pins are OK, check for voltage at light terminal (G).
To locate an open circuit:
In the example, zero voltage will be indicated at light
Check fuse. If blown, replace and operate circuit. If terminal, indicating a broken wire between harness
fuse blows a second time, continue check. connector and light terminal.
With switch (C) ON, check for battery voltage at switch If battery voltage had been indicated, the next check
terminal (D). for voltage would be at ground connection (I).
If no voltage is indicated, check switch, fuse and wiring Normal indicated voltage at a ground connection
to battery. should be 0.0 to 0.5 volts.
Continued on next page DPSG,OUO1004,661 –19–15MAR99–1/2
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24. Electrical System Basic Information and Wiring Diagrams
05
15 If battery voltage is indicated, poor connection to frame When problem is located, repair as needed, then
4
or broken wire is indicated. repeat last check.
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25. Electrical System Basic Information and Wiring Diagrams
05
Grounded Circuit 15
5
–19–27FEB92
T7713AE
A—Battery D—Switch G—Harness Connector J—Light
B—Fuse E—Switch Terminal H—Grounded Circuit K—Ground
C—Fuse Terminal F—Harness Connector I—Light (Component) Terminal
If no component operates, the fuse is blown and If continuity to ground is indicated, there is a pinched
replacement fuses blow immediately or the circuit or bare wire between fuse terminal (C) and harness
breaker is open and reopens when reset, a grounded connector (F).
circuit exists. (Example: power wire contacting frame
or other metal component). A wire may be pinched or If continuity to ground does not exist, disconnect
insulation may be worn from a wire. To isolate the ground (K) from frame. Measure continuity to ground
location of a grounded circuit: at harness connector (G). This checks harness from
harness connector to ground terminal. In the example,
If circuit is grounded between battery and fuse, wire continuity to ground will exist because circuit is
will be burned and circuit will be open. Fuse will not be grounded (wire is pinched) at (H).
blown.
If continuity exists, disconnect circuit at light terminal
If fuse is blown, remove fuse from circuit, disconnect (I) and measure continuity to ground on light terminal.
circuit near its center, such as harness connector (F). This checks harness from light to ground terminal. In
Turn switch (D) ON and check for continuity to ground the example, continuity will not exist, indicating a
at harness connector (F). This will check harness from grounded circuit between the light and harness
harness connector to fuse. connector (G).
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26. Electrical System Basic Information and Wiring Diagrams
05
15 Repeat check-out procedure after repair.
6
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27. Electrical System Basic Information and Wiring Diagrams
05
Shorted Circuit 15
7
–19–27FEB92
T7713AH
A—Battery E—Switch Terminal I—Harness Connector L—Light
B—Fuse F—Switch J—Light M—Ground
C—Fuse G—Harness Connector K—Light Terminal N—Ground
D—Switch H—Shorted Circuit
A shorted circuit causes components in separate Disconnect wire from switch of component that should
circuits to operate when a switch in either circuit is not be ON. In the example, disconnect wire from
turned ON. (Example: two harnesses rubbing together terminal (E) at switch (D). Light (J) remains ON.
until insulation is worn through, allowing bare wires to
touch). Components can also become shorted. Disconnect circuit at convenient places like harness
However, shorted components will usually blow the connectors (G) and (I) and light terminal (K) until light
fuse. (J) goes OFF.
To locate a shorted circuit: The short circuit will be between the last two places
the circuit was disconnected. In the example, it is
Turn switch (F) ON then OFF. Turn switch (D) ON between harness connectors (G and I). Light (J) will go
then OFF. Both lights (J and L) will be ON when either OFF when harness connector (I) is disconnected.
switch (D or F) is ON. Inspect harness between connectors (G and I).
Turn switch (F) ON. Both lights (J and L) will be ON;
only light (L) should be ON.
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28. Electrical System Basic Information and Wiring Diagrams
05
15 Repair or replace wires and harnesses as needed. Repeat check-out procedure after repair.
8
Install tie bands and clamps on harnesses as required
to prevent future problems.
DPSG,OUO1004,664 –19–15MAR99–2/2
Seven Step Electrical Test Procedure
–19–05MAR92
T7719AA
A—Battery Ground D—Fuse or Circuit Breaker G—Battery Side of Component I—Ground Side of Component
B—Battery E—Component Side of Fuse or Terminal Terminal
C—Battery Side of Fuse or Circuit Breaker H—Light (Component) J—Component Ground
Circuit Breaker F—Switch
Continued on next page DPSG,OUO1004,666 –19–15MAR99–1/2
CTM77 (18JUL05) 05-15-8 Alternators and Starter Motors
071805
PN=26
29. Electrical System Basic Information and Wiring Diagrams
05
Step 1—Switch ON 15
9
Check battery side of circuit breaker (C) for battery voltage. Battery voltage normal, go to Step 2.
Low voltage, repair high resistance. Open circuit from battery.
Step 2—Switch OFF
Check component side of circuit breaker (E) for battery voltage. Battery voltage normal, go to Step 4.
Low voltage, repair high resistance.
No voltage, go to Step 3.
Step 3—Switch OFF
Check component side of circuit breaker (E) for continuity to ground. Continuity to ground, repair grounded circuit at or before switch.
No continuity to ground, replace circuit breaker.
Step 4—Switch ON
Check component side of circuit breaker (E) for battery voltage. Battery voltage normal, go to Step 6.
Low voltage, repair high resistance.
No voltage, go to Step 5.
a
Step 5
Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.
wire at (G) for battery voltage. No voltage, repair grounded or open circuit at or after switch.
Step 6—Switch ON
Check lead to component at (G) for battery voltage. Battery voltage normal, go to Step 7.
Low voltage, repair high resistance in circuit between fuse and
component.
No voltage, repair high resistance or open circuit between fuse and
component.
Step 7—Switch ON
Check ground wire of component at (I) for voltage. No voltage, good continuity to ground, repair component.
Voltage, poor continuity to ground, repair high resistance or open
ground circuit.
a
A multimeter will not apply a load to the circuit at Step 5. The multimeter result is tested as a voltage condition in the result column.
DPSG,OUO1004,666 –19–15MAR99–2/2
CTM77 (18JUL05) 05-15-9 Alternators and Starter Motors
071805
PN=27
30. Electrical System Basic Information and Wiring Diagrams
05
15 Multimeter
10
The multimeter is an autoranging digital display that
allows very accurate readings to be taken.
A—Display
B—Voltage AC (Alternating Current)
C—Voltage DC (Direct Current)
D—Resistance
E—Diode Test/Continuity
F—Current AC (Alternating Current)
G—Current DC (Direct Current)
H—Voltage, Resistance, Diode/Continuity (Red Lead
Input)
I—Ground (Black Lead Input)
J—Current/Amps (Red Lead Input)
–19–03SEP93
T8074AA
DPSG,OUO1004,665 –19–15MAR99–1/1
CTM77 (18JUL05) 05-15-10 Alternators and Starter Motors
071805
PN=28
33. Group 05
Delco-Remy Alternator Theory of Operation
Delco-Remy (Delcotron) Alternator Operation
The drawing at right shows alternator circuitry. Schematic
of regulator (E) has been simplified. The regulator is a
non-adjustable, sealed, solid-state unit mounted inside the
10
alternator. 05
1
NOTE: To prevent battery run-down, R3 resistor has
extremely high resistance. It still allows a constant
drain on battery but this is insignificantly small. R3
and R4 are needed to provide voltage differential
for turning on transistors.
An alternator (unlike a generator) uses a rotating magnetic
field with stationary windings. The magnetic field is
externally excited. This means that it requires an outside
current source. The rotor (F) consists of two interlocking
soft iron sections and a wire coil wrapped around an iron
core. When current is passed through the wire coil, the
rotor becomes an electromagnet.
–UN–07APR89
The rotating magnetic field induces an alternating current
in the stator windings (G). This is converted to direct
current by six diodes in the rectifier bridge (H).
RW1010L
A capacitor inside rear housing protects rectifier bridge
and diode trio (D) from voltage surges. It also suppresses
radio interference. Delco-Remy (Delcotron) Alternator
A—Diode
This alternator uses an “A” field circuit with regulator
B—Switch
located after field. Full output is obtained by grounding C—Battery
field. D—Diode Trio
E—Regulator
F—Rotor (Field)
G—Stator
H—Rectifier Bridge
RG,RG34710,2025 –19–15MAR97–1/1
Delco-Remy (Delcotron) Regulator Operation
The solid-state regulator is mounted inside the alternator.
It controls output by controlling current through field. In
operation, regulator has the following three phases.
Continued on next page RG,RG34710,2026 –19–18OCT00–1/4
CTM77 (18JUL05) 10-05-1 Alternators and Starter Motors
071805
PN=31
34. Delco-Remy Alternator Theory of Operation
Phase I—Alternator Stopped
(Phase 1 also applies when alternator is running but only
if not running fast enough for output to exceed battery
voltage.)
10
05
2 1. Current flows from battery through key switch (B) and
diode (A) to terminal 1.
2. From there, current flows through resistor R1 to
transistor TR1 and turns it on.
3. Transistor TR1 then provides a path to ground so
current can flow through field, enabling alternator to
generate electricity.
4. Zener diode D2 prevents flow of current from terminal
2 to transistor TR2. A Zener diode is a special type of
diode which will not permit current to pass until voltage
reaches a certain preset level. If voltage exceeds that
level, current can pass through the Zener diode.
–UN–29NOV89
A—Diode
B—Key Switch
C—Battery
RW10107L
D—Diode Trio
E—Regulator
F—Rotor (Field)
G—Stator
Phase I—Alternator Stopped
H—Rectifier Bridge
Continued on next page RG,RG34710,2026 –19–18OCT00–2/4
CTM77 (18JUL05) 10-05-2 Alternators and Starter Motors
071805
PN=32
35. Delco-Remy Alternator Theory of Operation
Phase II—Generating Electricity
1. The diode trio, key switch, rectifier bridge, and terminal
1 all have equal voltage. Therefore no current flows
through diode.
10
05
2. Current, now coming from diode trio, still flows through 3
resistor R1 to turn on transistor TR1.
3. Transistor TR1 still provides a path to ground so
current can flow through field, enabling alternator to
generate electricity.
4. Since the field is rotating, it does generate electricity.
Alternating current is included in the stator windings.
The rectifier bridge converts it to direct current,
providing current to run electrical accessories and
charge batteries.
5. Output voltage still has not reached critical voltage of
Zener diode D2, so no current can flow from terminal 2
–19–28NOV89
to transistor TR2.
RW10108L
Phase II—Generating Electricity
Continued on next page RG,RG34710,2026 –19–18OCT00–3/4
CTM77 (18JUL05) 10-05-3 Alternators and Starter Motors
071805
PN=33
36. Delco-Remy Alternator Theory of Operation
Phase III—Shut-Off
1. Output voltage reaches critical voltage of Zener diode
D2.
10
05 2. Current can now pass through Zener diode D2 to turn
4 on transistor TR2.
3. Transistor TR2 now provides a direct path to ground
for any current coming through resistor R1.
4. This cuts off the current to transistor TR1, turning it off.
There is now no path to ground for current through
field.
5. Current through field is shut off instantly, and alternator
stops generating electricity.
6. Phase II and III are repeated many times per second
to maintain voltage at proper level.
–19–28NOV89
RW10131L
Phase III—Shut-Off
RG,RG34710,2026 –19–18OCT00–4/4
CTM77 (18JUL05) 10-05-4 Alternators and Starter Motors
071805
PN=34
37. Group 10
Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair
Essential Tools
NOTE: Order tools according to information given in the
U.S. SERVICEGARD™ Catalog or from the
European Microfiche Tool Catalog (MTC).
10
10
1
SERVICEGARD is a trademark of Deere & Company OUO1004,0000B4E –19–25APR02–1/5
Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791
Test electrical components for voltage, resistance, or
current flow. It is especially good for measuring low
voltage or high resistance circuits.
–UN–12DEC88
RW11274
JT05791
OUO1004,0000B4E –19–25APR02–2/5
Alternator, Generator, Starter and Battery Bench
Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JT01760
Test alternators and starters for voltage, resistance, or
current flow.
OUO1004,0000B4E –19–25APR02–3/5
RG12198 –UN–17JUL02
Alternator Pulley Tool Set . . . . . . . . . . . . . . . . JD306A
Remove and install alternator pulley retaining nut.
JD306A
Continued on next page OUO1004,0000B4E –19–25APR02–4/5
CTM77 (18JUL05) 10-10-1 Alternators and Starter Motors
071805
PN=35
38. Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair
Bushing, Bearing and Seal Driver Set . . . . . . D01045AA
Remove front bearing.
10
–UN–21SEP00
10
2
RG11162
D01045AA
OUO1004,0000B4E –19–25APR02–5/5
Other Material
Number Name Use
Delco-Remy Lubricant No. 1948791 Lubricate alternator bearings.
400-Grit Silicon Carbide Paper or 00 Polish slip rings.
Sandpaper
OUO1004,0000B50 –19–21SEP00–1/1
Delco-Remy (Delcotron) 10SI, 12SI, and 15SI
Charging Circuit Repair Specifications
Item Measurement Specification
Delco-Remy Model 12SI Alternator Torque 100 N•m (75 lb-ft)
Pulley Nut
Delco-Remy Model 10SI and 15SI Torque 80 N•m (60 lb-ft)
Alternator Pulley Nut
OUO1004,0000B51 –19–21SEP00–1/1
CTM77 (18JUL05) 10-10-2 Alternators and Starter Motors
071805
PN=36
40. Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair
Stator Winding Field Resistance
37-amp, 12-volt 0.23 ohm
40-amp, 24-volt 0.23 ohm
42-amp, 12-volt 0.28 ohm
10 55-amp, 12-volt 0.20 ohm
10
61-amp, 12-volt 0.20 ohm
4
63-amp, 12-volt 0.20 ohm
72-amp, 12-volt 0.10 ohm
75-amp, 12-volt 0.10 ohm
78-amp, 12-volt 0.10 ohm
105-amp, 12-volt 0.10 ohm
130-amp, 12-volt 0.04 ohm
RG,RG34710,2031 –19–07JUL05–2/2
Remove Pulley Nut
NOTE: Pulley nut need not be removed if you are certain
that front bearing is in good condition. Separate
housing as described and leave rotor in front
housing.
–UN–15DEC88
1. Install a 15/16 in. socket (A) on JD306A-1 Alternator
Pulley Nut Tool (B) to hold nut.
RW6036
2. Install JD306A-2 (C) on hex shaft of JD306A-1 to hold
rotor shaft.
Remove Pulley Nut
3. Hold rotor and remove nut. A—15/16 in. Socket
B—JD306A-1 Alternator Pulley Nut Tool
C—JD306A-2 Alternator Pulley Nut Tool
RG,RG34710,2032 –19–12SEP02–1/1
CTM77 (18JUL05) 10-10-4 Alternators and Starter Motors
071805
PN=38
41. Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair
Separate Housing
1. Remove washer (A), pulley (B), fan (C), and collar (D).
2. Before separating, make a chalk mark (E) across
10
separation between front and rear housings for
–UN–16NOV89
10
alignment when reassembling. Housings can be 5
indexed any one of four ways.
RW10657
A—Washer
B—Pulley
C—Fan
D—Collar Separate Housing
E—Chalk mark
F—Nut
G—Through Bolts
RG,RG34710,2033 –19–15MAR97–1/3
3. Remove four through bolts (A).
4. Separate front and rear housings. If necessary, pry
carefully with two screwdrivers on opposite sides to
force housings apart.
–UN–22FEB90
A—Through Bolts (4 Used)
RW6011
Separate Front and Rear Housing
Continued on next page RG,RG34710,2033 –19–15MAR97–2/3
CTM77 (18JUL05) 10-10-5 Alternators and Starter Motors
071805
PN=39
