John Deere Alternators & Starter Motors Technical Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere Alternators & Starter Motors Technical Manual – PDF DOWNLOAD
- This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. This Component Technical Manual (CTM) contains the latest available instructions necessary to repair engine alternators and starter motors.
- It includes theory of operation, and diagnostic and testing procedures to help troubleshoot and understand potential failure modes. The information is organized in sections and groups by various suppliers. At the beginning of each repair group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
TABLE OF CONTENTS:
John Deere Alternators & Starter Motors Technical Manual – PDF DOWNLOAD
Contents 5
Introduction and Safety Information 9
Safety 11
Handle Fluids Safely—Avoid Fires 11
Prevent Battery Explosions 11
Prepare for Emergencies 11
Handling Batteries Safely 12
Wear Protective Clothing 13
Work in Clean Area 13
Service Machines Safely 13
Work In Ventilated Area 14
Illuminate Work Area Safely 14
Use Proper Lifting Equipment 14
Remove Paint Before Welding or Heating 15
Practice Safe Maintenance 16
Use Proper Tools 16
Dispose of Waste Properly 17
Prevent Machine Runaway 17
Live With Safety 17
General Information 19
Unified Inch Bolt and Screw Torque Values 19
Metric Bolt and Screw Torque Values 20
Electrical System Basic Information and Wiring Diagrams 21
Electrical Circuit Malfunctions 21
High Resistance Circuit 22
Open Circuit 23
Grounded Circuit 25
Shorted Circuit 27
Seven Step Electrical Test Procedure 28
Multimeter 30
Delco-Remy Alternators 31
Delco-Remy Alternator Theory of Operation 33
Delco-Remy (Delcotron) Alternator Operation 33
Delco-Remy (Delcotron) Regulator Operation 33
Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair 37
Essential Tools 37
Other Material 38
Delco-Remy (Delcotron) 10SI, 12SI, and 15SI Charging Circuit Repair Specifications 38
Delco-Remy (Delcotron) 10SI, 12SI, and 15SI Charging Circuit Test Specifications 39
Remove Pulley Nut 40
Separate Housing 41
Remove Front Bearing 42
Install Front Bearing 43
Remove and Install Rear Bearing 44
Test Rotor for Grounds 44
Test Rotor for Open Circuit 45
Test Rotor for Short Circuit 45
Repair Slip Rings 46
Inspect Stator 46
Test Stator for Grounds 47
Test Stator for Short Circuit 47
Test Brush Assembly for Grounds 48
Test Diode Trio 48
Test Rectifier Bridge 49
Regulator Test 49
Assemble the Alternator 50
Delco-Remy (Delcotron) 21SI Alternator Repair 53
Essential Tools 53
Delco-Remy (Delcotron) 21SI Charging Circuit Repair Specifications 54
Delco-Remy (Delcotron) 21SI Charging Circuit Test Specifications 55
Disassemble Delco-Remy 21SI Alternator 56
Disassemble Alternator 57
Slip Ring End Housing and Components 58
Drive End Frame and Components 63
Assemble Alternator 65
Slip Ring End Housing Assembly 65
Final Assembly 71
Motorola Alternators 73
Motorola Alternator Theory of Operation 75
Motorola Alternator Operation 75
Motorola Regulator Operation 76
Motorola 8E-Series Alternator Repair 81
Essential Tools 81
Motorola 8E-Series Charging Circuit Repair Specifications 82
Motorola 8E-Series Charging Circuit Test Specifications 82
General Information 83
Remove Alternator for Repair 83
Disassemble and Test Motorola 8E-Series (12-Volt, 65 Amp) Alternator 84
Assemble Motorola 8E-Series (12-Volt,65Amp) Alternator 88
Motorola HC-, MA-, MR-Series Alternator Repair 89
Essential Tools 89
Service Equipment and Tools 90
Motorola HC-, MA-, MR-Series Charging Circuit Repair Specifications 90
Motorola HC-, MA-, MR-Series Charging Circuit Test Specifications 91
Disassemble and Test Motorola HC-, MA-, MR-Series Alternator 92
Assemble Motorola HC-, MA-, MR-Series Alternator108
Motorola A-, RA-, 8AR-Series Alternator Repair119
Essential Tools119
Motorola A-, RA-, 8AR-Series Charging Circuit Repair Specifications120
Motorola A-, RA-, 8AR-Series Charging Circuit Test Specifications120
Disassemble and Test Motorola A-, RA-, 8AR-Series Alternator121
Assemble Motorola A-, RA-, 8AR-Series Alternator129
Motorola SA-Series Alternator Repair131
Essential Tools131
Other Material132
Motorola SA-Series Charging Circuit Repair Specifications132
Motorola SA-Series Charging Circuit Test Specifications133
Remove Alternator for Repair133
Disassemble and Test Motorola SA-Series Alternator134
Assemble Motorola SA-Series Alternator144
Motorola TA-Series Alternator Repair151
Essential Tools151
Service Equipment and Tools152
Motorola TA-Series Charging Circuit Repair Specifications153
Motorola TA-Series Charging Circuit Test Specifications153
Remove Alternator for Repair154
Disassemble and Test Motorola TA-Series Alternator154
Assemble Motorola TA-Series Alternator164
Niehoff Alternators173
Niehoff Alternator Theory of Operation175
Starting the Niehoff Alternator175
Niehoff Alternator Operation175
Niehoff Alternator Load Dump Circuit178
Niehoff 12-Volt, 110-Amp Alternator Repair179
Essential Tools179
Other Material181
Niehoff 12-Volt Charging Circuit Repair Specifications181
Niehoff 12-Volt Charging Circuit Test Specifications182
Disassemble Niehoff 12-Volt, 110-Amp Alternator182
Test Niehoff 12-Volt, 110-Amp Alternator Components195
Assemble Niehoff 12-Volt, 110-Amp Alternator200
Establish Magnetic Field205
Niehoff 24-Volt, 50-Amp Alternator Repair207
Essential Tools207
Other Material209
Niehoff 24-Volt Charging Circuit Repair Specifications209
Niehoff 24-Volt Charging Circuit Test Specifications210
Disassemble Niehoff 24-Volt, 50-Amp Alternator and Test Components211
Assemble Niehoff 24-Volt, 50-Amp Alternator218
Re-Establish Magnetic Field224
Denso Alternators225
Denso Alternator Theory of Operation227
Denso Alternator Operation227
Denso Regulator Operation228
Denso Alternator with Add-On Regulator Repair231
Essential Tools231
Other Material232
Denso Charging Circuit Repair Specifications (Alternators with Add-On Regulator)232
Denso Charging Circuit Test Specifications (Alternators with Add-On Regulator)232
Disassemble Denso Alternator with Add-On Regulator and Test Components233
Separate Housing234
Separate Housing and Remove Rear Bearing235
Inspect Rear Bearing238
Install Rear Bearing238
Remove Stator, Rectifier Bridge and Brush Assembly238
Test Brush Assembly239
Install New Brushes241
Inspect Stator241
Test Stator for Grounds242
Test Stator for Open or Short242
Test Diodes in Rectifier Bridge243
Test Diodes for Open or Short Circuit243
Test Diode/Resistor Trio244
Connect Stator Windings245
Test Regulator245
Assemble Rear Frame246
Remove Pulley Nut247
Remove and Inspect Front Bearing247
Install Front Bearing Assembly248
Test Rotor for Grounds248
Test Rotor for Open or Shorted Circuits249
Recondition Slip Rings249
Install Rotor and Front Housing250
Install Pulley Assembly251
Install Regulator251
Denso Alternator with Built-In Regulator Repair253
Essential Tools253
Other Material254
Denso Charging Circuit Repair Specifications (Alternators with Built-In Regulator)255
Denso Charging Circuit Test Specifications (Alternators with Built-In Regulator)256
Disassemble and Test Denso Alternator with Built-In Regulator257
Disassemble Alternator258
Assemble Denso Alternator264
Bosch Alternators265
Bosch Alternator Theory of Operation267
Function of Alternator267
Bosch Alternator Repair269
Essential Tools269
Other Material270
Bosch Charging Circuit Repair Specifications271
Bosch Charging Circuit Test Specifications272
Alternator, Section View274
Alternator Removal275
Removing Brush Holder with Regulator275
Alternator Disassembly276
Stator Removal276
Diode Plate Removal277
Alternator Exploded View278
Testing Rotor for Short Circuit279
Testing Rotor for Ground279
Testing Slip Rings and Rotor Shaft for Radial Runout280
Turning Down Slip Rings280
Testing Stator Coil for Short Circuit281
Testing Stator Coil for Grounds281
Replacing Carbon Brushes282
Replacing Ball Bearings282
Checking Positive Diodes283
Checking Negative Diodes284
Testing Exciting Diodes285
Diode Plate Installation286
Soldering Stator Coils286
Pressing Ball Bearing onto Rotor Shaft287
Pressing Rotor into Drive End Frame287
Assemble Alternator288
Installing Brush Holder with Regulator288
Fan and Belt Pulley Removal and Installation289
Valeo Alternators291
Valeo Alternator Theory of Operation293
Valeo Alternator Operation293
Valeo Regulator Operation294
Valeo Alternator Repair299
Essential Tools299
Other Material300
Valeo Charging Circuit Repair Specifications300
Valeo Charging Circuit Test Specifications301
Disassemble Alternator and Test Components301
Assemble Alternator307
Valeo A13N-Series Alternator Repair311
Essential Tools311
Valeo A13N-Series Repair Specifications312
Valeo A13N-Series Test Specifications312
Disassemble and Test Valeo A13N-Series Alternator313
Assemble Valeo A13N-Series Alternator320
Magneton Alternators321
Magneton Alternator Theory of Operation323
Operation of Alternator323
Magneton Alternator Repair325
Essential Tools325
Magneton Charging Circuit Repair Specifications326
Magneton Charging Circuit Test Specifications327
Exploded View of Alternator328
Identification329
Troubleshooting330
Disassembly of Alternator331
Testing Brush/Regulator Assembly333
Testing Rotor334
Testing Stator/Rectifier Bridge Assembly335
Rectifier Bridge Replacement336
Reassembly of Alternator336
Installation of Alternator338
Leece-Neville Alternators339
Leece-Neville Alternator Theory of Operation341
Alternator Operation341
Leece-Neville Alternator Repair343
Essential Tools343
Leece-Neville Repair Specifications343
Leece-Neville Charging Circuit Test Specifications344
Repair Alternator344
Charging System Failure344
Alternator Troubleshooting345
Alternator Output Test345
Diode Trio Test346
Full Field Test347
Adjust Regulator348
Prestolite Alternators349
Prestolite Alternator Theory of Operation351
Alternator Operation351
Prestolite Alternator Repair353
Essential Tools353
Prestolite Charging Circuit Test Specifications354
Repair Alternator354
Charging System Failure355
Alternator Troubleshooting355
Test Alternator356
Iskra Alternators359
Iskra Alternator Theory of Operation361
Operation of Alternator361
Iskra Alternator Repair363
Essential Tools363
Iskra Charging Circuit Repair Specifications364
Iskra Charging Circuit Test Specifications365
Exploded View of Alternator366
Identification367
Troubleshooting368
Remove and Install Pulley369
Testing Brush/Regulator Assembly370
Install Brush/Regulator Assembly372
Installation of Alternator372
Delco-Remy Starter Motors373
Starting Circuit Theory of Operation375
General Information375
Typical Starting Circuit Operation375
Typical Starter Motor Operation376
Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair377
Essential Tools377
Service Equipment and Tools378
Other Material378
Delco-Remy 10MT, 20MT, 22MT, 25MT, 27MT, 28MT Starter Motor Repair Specifications379
Delco-Remy 10MT, 20MT, 22MT, 25MT, 27MT, 28MT Starter Motor Test Specifications380
Diagnosing Starter Motor Malfunctions382
Delco-Remy Starter Motor Cutaway View—Series 10MT, 20MT, 22MT, 25MT, 27MT, 28MT383
Check Operation of Motor Drive383
Make Solenoid Pull-In Test384
Make Solenoid Hold-In Test385
Make Solenoid No-Load Test385
Disassemble Starter Motor and Test Components386
Clean Starter Motor Components389
Inspect Armature390
Make Short Circuit Test390
Make Armature Ground Test391
Make Open Circuit Test391
Make Ground Circuit Test for Field Windings391
Make Open Circuit Test for Field Windings392
Remove Field Coils (If Necessary)392
Install Field Windings393
Disassemble Solenoid393
Inspect and Clean Solenoid Parts394
Assemble Solenoid395
Remove Drive End Bushing and Wick395
Install Drive End Bushing and Wick396
Inspect Drive Motor ID396
Inspect Center Bushing ID397
Inspect Commutator End Frame Bushing397
Assemble Starter Motor398
Check Pinion Clearance400
Make Solenoid No-Load Test401
Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair403
Essential Tools403
Service Equipment and Tools404
Other Material404
Delco-Remy 30MT, 35MT, and 37MT Starter Motor Repair Specifications405
Delco-Remy 30MT, 35MT, and 37MT Starter Motor Test Specifications406
Diagnosing Starter Motor Malfunctions408
Delco-Remy Starter Motor Cutaway View—Series 30MT, 35MT, and 37MT409
Test Starter Motor Before Disassembly410
Make No-Load Test for Solenoid412
Disassemble Delco-Remy Starter Motor (Series 35MT Illustrated)414
Install New Bushings During Disassembly419
Clean Starter Motor Components420
Inspect Armature421
Make Short Circuit Test421
Make Armature Ground Test422
Make Open Circuit Test422
Make Ground Circuit Test for Field Windings423
Make Open Circuit Test for Shunt Windings423
Make Open Circuit Test for Field Windings424
Remove Field Windings424
Inspect Brushes425
Test Brush Holder for Ground425
Inspect Brush Springs426
Inspect and Clean Solenoid426
Assemble Solenoid426
Inspect Plunger, Shift Lever, and Overrunning Clutch Assembly427
Assemble Starter Motor427
Check Armature End Play430
Check for Proper Pinion Clearance431
Make No-Load Test (After Assembly)432
Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair433
Essential Tools433
Other Material434
Delco-Remy 40MT, 41MT, 42MT, and 50MT Starter Motor Repair Specifications435
Delco-Remy 40MT, 41MT, 42MT, and 50MT Starter Motor Test Specifications436
Diagnosing Starter Motor Malfunctions437
Delco-Remy Starter Motor Cutaway View—Series 40MT, 41MT, 42MT, and 50MT438
Test Starter Motor Before Disassembly438
Test Pull-In and Hold-In Windings441
Make No-Load Test442
Disassemble Delco-Remy Starter Motor ( Series 50MT Illustrated)444
Make Ground Circuit Test for Field Windings449
Make Open Circuit Test for Shunt Windings449
Make Open Circuit Test for Field Windings450
Remove Field Windings450
Inspect Brushes451
Test Brush Holder for Ground452
Inspect Brush Springs452
Install New Bushings—40MT, 41MT, and 42MT453
Install New Bushings—50MT455
Clean Starter Motor Components456
Inspect Armature457
Make Short Circuit Test457
Make Armature Ground Test458
Make Open Circuit Test458
Inspect Solenoid Plunger and Shift Lever Assembly459
Inspect Overrunning Clutch and Pinion459
Inspect and Clean Solenoid460
Assemble Solenoid460
Assemble Starter Motor461
Check for Proper Pinion Clearance464
John Deere/Denso Starter Motors467
Starting Circuit Theory of Operation469
General Information469
Typical Starting Circuit Operation469
Starter Motor Operation (Conventional Type)470
Starter Motor Operation (Gear Reduction Type)471
Starter Motor Operation (Planetary Type)473
John Deere/Denso Conventional Starter Motor Repair475
Essential Tools475
Service Equipment and Tools476
Dealer Fabricated Tools477
Other Material478
John Deere/Denso Conventional Starter Motor Repair Specifications479
John Deere/Denso Conventional Starter Motor Test Specifications480
Test Starter Motor Before Disassembly482
Make Solenoid Pull-In Test482
Make Solenoid Return Test484
Make No-Load Test484
Diagnose No-Load Test485
Disassemble Starter Motor485
John Deere/Denso Conventional Starter Motor Exploded View489
Install New Bushings/Needle Bearings490
Clean Starter Motor Components490
Inspect Armature491
Make Short Circuit Test491
Make Armature Ground Test492
Make Open Circuit Test492
Repair Armature493
Inspect Overrunning Clutch and Pinion493
Make Grounded Circuit Test for Field Windings494
Make Open Circuit Test for Shunt Windings494
Make Open Circuit Test for Field Windings495
Remove Field Windings (If Necessary)495
Install Field Windings496
Inspect and Repair Brushes496
Test Brush Holder for Grounds497
Measure Brush Spring Tension497
Disassemble Solenoid498
Assemble Starter Motor499
Install Solenoid502
Make No-Load Test504
John Deere/Denso Gear Reduction Starter Motor Repair505
Essential Tools505
Service Equipment and Tools506
Other Material506
John Deere/Denso Gear Reduction Starter Motor Repair Specifications507
John Deere/Denso Gear Reduction Starter Motor Test Specifications508
Bench Test Starter Motor509
No-Load Test510
John Deere/Denso Gear Reduction Starter Motor Exploded View511
Disassemble Field Frame, Armature, and Brush Holder511
Inspect and Repair Armature513
Inspect Brushes and Brush Holder517
Inspect Field Coils519
Assemble Field Frame, Armature, and Brush Holder520
Disassemble Gear Train and Overrunning Clutch523
Assemble Gear Train and Overrunning Clutch526
Disassemble, Inspect, and Repair Starter Solenoid529
Assemble Solenoid Assembly531
John Deere/Denso Planetary Starter Motor Repair535
Essential Tools535
Other Material536
John Deere/Denso Planetary Starter Motor Repair Specifications536
John Deere/Denso Planetary Starter Motor Test Specifications537
Test Starter Motor Before Disassembly537
Make Solenoid Pull-In Test538
Make Solenoid Hold-In Test539
Make Return Test540
Make No-Load Test540
Diagnose No-Load Test541
Disassemble Starter Motor541
John Deere/Denso Planetary Starter Motor Exploded View548
Clean Starter Motor Components549
Inspect and Repair Brushes550
Test Brush Holder for Grounds550
Measure Brush Spring Tension551
Assemble Starter Motor551
Install Solenoid555
Make No-Load Test557
Bosch Starter Motors559
Starting Circuit Theory of Operation561
General Information561
Typical Starting Circuit Operation561
Typical Starter Motor Operation562
Bosch Conventional Starter Motor Repair563
Essential Tools563
Bosch Conventional Starter Motor Repair Specifications564
Bosch Conventional Starter Motor Test Specifications565
Make No-Load Test566
Diagnosing Starter Motor Malfunctions567
Bosch Conventional Starter Motor Cutaway View568
Bosch Conventional Starter Motor Exploded View569
Disassembly570
Solenoid Switch—Removal570
Carbon Brush Plate—Removal571
Armature—Removal571
Snap Ring—Removal572
Cleaning Parts572
Testing Armature for Grounds572
Testing Armature for Short Circuit573
Testing Armature for Open Circuit573
Turning Commutator Down574
Testing Commutator for Out-of-Roundness574
Testing Field Winding for Grounded Circuit575
Field Winding—Removal575
Make Open Circuit Test for Field Windings576
Lubrication of Starter Motor (Before and During Assembly)576
Field Winding—Installation577
Checking Carbon Brush Plate for Grounds577
Testing Carbon Brushes578
Replace Carbon Brushes578
Engaging Lever—Installation579
Checking Armature End Play and Torque579
Installing Starter Motor579
Bosch Planetary Gear Starter Motor Repair581
Essential Tools581
Bosch Planetary Gear Starter Motor Test Specifications582
Make No-Load Test582
Diagnosing Starter Motor Malfunctions583
Bosch Planetary Gear Starter Motor Cutaway View584
Disassemble Solenoid Switch585
Test Solenoid Switch586
Assemble Solenoid Switch587
Iskra Starter Motors589
Starting Circuit Theory of Operation591
General Information591
Typical Starting Circuit Operation591
Starter Motor Operation592
Iskra AZE/AZF/AZJ-Type Starter Motor Repair593
Essential Tools593
Dealer Fabricated Tools594
Iskra AZF-Type Starter Motor Repair Specifications597
Iskra AZJ-Type Starter Motor Repair Specifications597
Iskra AZE, AZF-Type Starter Motor Test Specifications598
Iskra AZJ-Type Starter Motor Test Specifications599
Exploded View of Iskra Starter Motor (AZF-Type)600
Exploded View of Iskra Starter Motor (AZJ-Type)601
Troubleshooting602
Identification603
Disassembly of Starter Motor603
Testing Solenoid Switch607
Testing Brushes607
Brush Replacement608
Testing Armature608
Testing Field Windings609
Checking Engaging Lever609
Checking Overrunning Clutch Pinion610
Reassembly of Starter Motor610
Iskra AZE-Type Starter Motor Repair615
Essential Tools615
Dealer Fabricated Tools616
Iskra AZE-Type Starter Motor Repair Specifications617
Iskra AZE-Type Starter Motor Test Specifications617
Exploded View of AZE (Noseless)-Type Starter Motor618
Troubleshooting619
Identification620
Removing Solenoid Switch620
Testing Solenoid Switch621
Installing Solenoid Switch622
Valeo Starter Motors623
Starting Circuit Theory of Operation625
General Information625
Typical Starting Circuit Operation625
Typical Starter Motor Operation626
Valeo Starter Motor Repair627
Essential Tools627
Valeo Starter Motor Repair Specifications628
Valeo Starter Motor Test Specifications628
Exploded View of Starter Motor629
Disassembly of Starter Motor630
Testing Solenoid Switch635
Testing Brushes636
Positive Brush Replacement636
Testing Armature637
Testing Field Winding637
Checking Overrunning Clutch Pinion638
Reassembly of Starter Motor639
Magneton Starter Motors641
Starting Circuit Theory of Operation643
General Information643
Typical Starting Circuit Operation643
Starter Motor Operation644
Magneton Starter Motor Repair645
Essential Tools645
Dealer Fabricated Tools646
Magneton Starter Motor Repair Specifications646
Magneton Starter Motor Test Specifications647
Exploded View of Starter Motor648
Identification649
Troubleshooting650
Disassembly of Starter Motor651
Testing Solenoid Switch655
Testing Brushes656
Brush Holder Replacement656
Testing Armature657
Testing Field Winding657
Checking Overrunning Clutch Pinion658
Reassembly of Starter Motor659
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V