I

fid
k
jf JW u
VOLTMETER
t
OHMMETER
t
AMMETER
SHORT DETECTOR
ELECTRICAL
SERVICE
GUIDE
BATTERY
STARTING
SYSTEM
CHARGING
SYSTEM
HOWTOTROUBLESHOOT
CIRCUITPROBLEMS
@Ni ssan Motor
Corporati on
i n USA
t
t
t
t
t
t
LOWSCALE
RED
POSITIVE
POSITIVE
HOW
TO
READ
AVOLTMETER
POS
NEG
READING
13VOLTS
HIGH
SCALE
SCALE
SELECTOR
BLACK
NEGATIVE
60
AH
NEGATIVE
VOLTAGE
DROPS
Turn
Page
t
M
VOLTAGE
DROPS IN
POSITIVESIDE
1 TURN
VOLTMETERTO LOWSCALE
2
CONNECT
POSITIVE
LEAD
TO
BAT
TERY
TERMINAL
3 TURN ON CIRCUIT TO BE
TESTED
4 CONNECT
NEGATIVE VOLTMETER
LEAD
TO HOT
WIRE ATAPPLI
ANCE LIGHT
MOTOR
ETC IN
CIRCUIT
TOBETESTED
0 3 0 18
o
POS NEG
5 READINGS
BELOW
2VOLTS
Posi ti ve
Si de of Ci rCUi t
OK
ABOVE
2VOLTS
Move
negati ve
lead back
along
Ci rcui t
toward
battery
andcheck at
each
Junc
tlon or connecti on
When
readi ng drops
below
2volts
you
wi ll f i nd
f ault be
tween
last
and
next to last
pOi nts
tested
M2
VOLTAGEDROPSIN
NEGATIVESIDE
OFCIRCUIT
TURN
VOLTMETERTO
LOWSCALE
2
CONNECT
NEGATIVELEADTOBAT
TERY TERMINAL
3 TURN ON CI RCUIT TO BE
TESTED
4
CONNECT POSITIVE
VOLTMETER
LEADTO
GROUND
WIRE AT
APPLI
o 3 O 18
ANCE LIGHT
MOTOR ETC IN
CI RCUITTOBE
TESTED
NEG
t
5 READINGS
BELOW
15
VOLT
Ground
si de of Ci rCUi t IS
OK
ABOVE
15
VOLT
BAD
GROUND
CONNECTION Move
posi ti ve
leadback
along ground
ci rcui t
toward
negati ve
termi nal of
battery
When
readi ng drops
below 15
volt
you
wi ll f i nd
f ault between last two
pOi nts
tested
M3
t
t
t
t
A
HOW
TO
USE THEOHMMETER
Set Scale
IF
READINGSHOULDBE
Up
to
100
Ohms
Use xl Scale
Up
to 1000Ohms
Use
xlO
Scale
or
xlOOScale
Over 1000Ohms
Use
xl000Scale
2 TURNOHMMETER
ON
3
CALIBRATE Touch
the two
leads
to
gether
turn
adjusti ng
knob
unti l
needle IS
at zero
4 MAKE
SURECIRCUITISTURNED
OFFI
5
CONNECT LEADS
to ei ther Si de
of
what
ever
you
re
testi ng
6 TAKE
READING MULTIPLY TIMES
SCALE SETTING
Of f
1
IS
x o
xoo
x
ooo
It
M4
Example
Readi ng
IS 75
Scale IS xlOO
Meter
readi ng
IS 75 x
100 750 Ohms
WHATTHE
OHMMETER
IS USED
FOR
USE
ITTOCHECK
SWITCHES
Set
to xI
Scale
Connect the leads across two
pOi nts
then workthe sWi tch
Ohmmeter
shouldmove f rom
open
Ci rcui t
hi gh
resi stance to no resi stance
SPAR
KPLUG ANDCOILWIRES
Set
to
x1000 Scale
Readi ng
shouldbe between 8and10thousandohms
per
f oot
IGNITION
COIL
240Z
Transi stor
Igni ti on
Other
Through
75
Pri mary Wi ndi ng
1 5 1
7
45
55 117 143
xI Scale
Ohms
Ohms Ohms
Secondary Wi ndi ng
95 116 85 127 11 2
168
xIOOOScale Thousand
Ohms ThousandOhms
Thousand
Ohms
BALLAST
RESISTOR
1
3
1 7
Ohms at
68
degrees
260
Z Ballast Resi stor
1
2 1 4Ohms
bothsecti ons
together
TRANSISTOR
IGNITION PICKUP
COIL
1974 620Ohms 19745
1975
720
Ohms
DIODES
Set to
x1000
Scale
Connect
the leads across the di ode then sWi tch the leads
In one
posi ti on you
should
get
a
readi ng
In the other
you
shouldhave ei ther
very
li ttle or no
readi ng
Foralternator
testi ng
see Alternator Overhaul secti on
In
thi S
manual
CROSSOVERS
INTHEWIRING HARNESS
Di sconnect
battery
andset to x1000scale Atharness connector connect one leadto
pi n
of Ci rcui t whi ch
IS
malf uncti oni ng
Touch the other leadto all the other
pi nS
In
the connector
If
you
f i nd
conti nUi ty
lookat the
wIri ng
di agram
to determi ne whether thi S
conti nUi ty
IS normal
If
It Isn t then
you
have located
a crossover See
Troubleshooti ng
Secti on
enti tled
Strange Thi ngs Happen
t
t
t
t
t
t
M5
HOWTO
USE
INDUCTIONAMMETER
ISOLATE
A
SINGLE
WIRE IN THE
CIRCUIT YOU WANT TO TEST
NOTE IF
YOU DON
T SEPARATE
THE
WIRES
YOU ARE LIKELYTO
GET
AFALSE
READING
2 HOLD
THE AMMETER OVER THE
WIRE SO
THAT THE WIRE FITS
INTHECLIPPROVIDED
3
TURNONTHE CIRCUIT
ANDREAD
THE METER
M
6
HOWTO
USE
AMMETER
NEG
MAKESURE
YOUR AMMETER CAN
HANDLE THE AMOUNT
OF
CUR
RENT FLOWING
IN THE
CIRCUIT
OTHERWISE
THE METER MAYBE
DAMAGEDWHEN
YOU
HOOKIT UP
t
2 BREAK THE CIRCUIT AT SOME
POINT THIS
COULD BE AT THE
BATTERY
TERMINAL THE COMPO
NENT
WHICH
THE CIRCUIT FEEDS
OR
ATA
CONNECTOR
t
3 CONNECT
THE POSITIVE LEADOF
THE AMMETER
TOWARDS
THEBAT
TERY
PLUS
SIDE CONNECTTHE
NEGATIVE LEAD TOWARDS THE
NEGATIVE SIDE OF THE CIR
CUlT
4 TURN ON
THE CI
RCUIT
IF THE
READING
IS DOWN SCALE RE
VERSETHE
AMMETERLEADS
5 NOWYOU CAN
READ THE AM
METER
M7
HOW
TOUSE
ASHORT
DETECTOR
1 Locate
wIri ng
harness
layout
In vehIcle
shop
manual
2 Determi ne
whi chf use IS
blowi ng
3
Cli p
leads
of
f lasher
uni t
across
f use
cli p
4
When f lasher
starts
cli cki ng
move
detector
along
wIri ng
harness
uSi ng
di agram
In
shop
manual
Needle
wi ll move when current
IS
f lOWi ng
5 When
you
pass
the shorted
pOi nt
the
needle
wi ll
stop pulsati ng
MB
HOWTOCHECK OUT THE BATTERY
FIRST KNOWTHE BASIC
SAFETY
RULES FOR
BATTERY
CHARGING
CHARGE
BATTERIESINAWELLVENTILATEDSHOP HAVE AFIRE
EXTINGUISHER
HANDY
2 LOOSENVENTCAPS
BEFORE
CHARGING
3
WHEN YOU CONNECT ACHARGER
HOOK UP THE LEADS
FIRST
THEN TURNON
THE CHARGER DONOTTURNONTHE
CHARGER FIRST YOU MAYGETASPARK
WHICH
COULD
MAKETHE BATTERY
EXPLODE
BATTERYTESTING Turn
Page
BATTERYRATINGS BYMODEL ORIGINAL EQUIPMENT
AMPERE
HOURS
1976 1975 1974 1973 1972
9971
1970 1969
1968
710 60 60 60
210 60 60 60
610
60 60 60
60
620 60 60 60 60 60
S30
60 60 60 60 60 50
510 60
60 60
50 50
50
B110
50 50
50
521 60 60 5060 40
40
520 40
SRL311
40
50 4050 4050
SPL311 40
50
4050
40
50
L60
60
M9
Howto check the
battery
PRELIMINARY
CHECKS Vi sual
Inspecti on
Check
battery rati ng agai nst
that
of
ori gi nal
f actory equi pment
see chart
b
Check
f or cracks and
warpage
of the
case
c Make sure cables are clean and
ti ght
d
Check
aCi d level 38 Inch above
plates
e
f
a
Make sure vents aren t
clogged
Make sure
top
of
battery
ISclean
t
t
o
Q
OVER
5 VOLT
CLEAN BATTERY
t
Ml0
o
o
PROPER
ACID
LEVEL
CLOGGED VENTS
CORROSION
CRACKS
CHECK
A
HRATING
WARPEDCASE
2 BATTERY
LEAKAGE TEST
Check
to make
sure the
battery
IS
not
di schargi ng
across the
top
between
the
two
posts
a Setvoltmeter
to low
range
b Touch
negati ve
leadof voltmeter
to
nega
ti ve
battery
post
c
Touch the
posi ti ve
leadof the voltmeter
to the
top
of the
battery
andmove It
around
If the
readi ng goes
over 5 volts then clean of f
the
top
of the
battery
and
retest
A
S VOLTS
o
o
0
Oll l
BOd
BATTERY
CAPACITY
TEST
LOADCONTROL
3 TIMES
o00 AMP HOUR RATING
15 SECONDHOLD
4 THREE
MINUTECHARGETEST
To be
perf ormed only
If
battery
has
f ai ledthe
Capaci ty
Test In
step
number
3
a Connect a
goodquali ty
bat
tery
Remove cell
caps
b Turn the
charger
to a
f ast
charge
rate not over40
amps
c Af ter three
mi nutes check
voltmeter
readi ng
If It IS over
15 5 volts
165 f or Mai nte
nance Free Batteri es
the bat
tery
shouldbe
replaced
If It
IS below15 5 volts
then
pro
ceedto
step
number
5
3 BATTERYCAPACITYTEST
a Wi th
battery
connectedtotester as shown
turn loadknob unti l a drawof 3ti mes the
battery rati ng
IS shown
Example Battery rati ng
60
Ampere
Hours
Turn loadto 180
Amps
draw
b Holdthi S draw
f or
15 seconds then look
at
voltage
If
voltage
remai ns at 96volts
or above THE BATTERYIS GOOD You
need
not
perf orm
any
f urther
tests
If
volt
age
drops
below96volts
then
proceed
to
the next
test
0
00
000
THREE MINUTE
BATTERY
CHARGE
TEST
t
t
ABOVE155V
REPLACEBATTERY
t
M11
5 CELL TEST UNDER CHARGE
Connect the
tester andthe
battery charger
as In
step
number
4 Settof ast
charge
rate 35 40
Amps
a Turn tolow
range
voltmeter
b Attach
speci al
cell
probes
to voltmeter
leads
c Touch
posi ti ve probe
to
battery posi ti ve
termi nal
d Sti ck the black
probe
In the
battery
cell
nearest the
battery posi ti ve post
WRITE
DOWN
the voltmeter
readi ng
e Now
put
the
posi ti ve probe
In the cell near
est the
posi ti ve post
Putthe
negati ve
probe
In the next cell down Record
the
readi ng
f
Conti nue on
down the
battery recordi ng
the
readi ng
eachti me
g
When
youget
to the
pOi nt
where the
POSI
ti ve
probe
IS In the last cell of the
battery
touch
the
negati ve probe
to the
negati ve
post
Record
thi S
readi ng
h You
shouldnowhave seven
readi ngs
Now
add
the f i rst
readi ng
to the last thi S Wi ll
gi ve
you
SIX
readi ngs They
should
all be wi thi n 2
two
tenths volt of each other
If
one
cell vari es
more than thi Samount f rom
any
other then the
battery
ISbadandmust be
replaced
24
26
26
24
26
2
26
26
26
2
M12
SATTERY CELL TEST UNDER
CHARGE
FAST CHARGE RATE ALL CELLS WITHIN
2VOLT
READING1
READING
2
READINGS
3 6
READING
7
t
t
t
M13
I
STARTINGSYSTEM
I
STARTERTESTING
STARTEROVERHAUL PROCEDURES
1200AND8210TO1975
STARTEROVERHAUL PROCEDURES
ALL LSERIES ENGINES
t
t
t
STARTING SYSTEM
Testi ng
I
Fi rst
CheckThe
Battery
I
I
Turn
Key
To Start
I
No
Cli ck Cli ck or Starter turns
See
Page
S
2
Pull
Igni ti on
Start Wi re
Usu
ally
Black Yellow Of f At
Starter
Connect Test
Li ght
Between Thi s
LeadAnd
Battery
Negati ve
Ter
mmal Have Someone
Turn
Key
No
Li ght
Li ght
See
Page
S5 See
Page
S
2
t
t
t
t
81
TESTING
STARTER CURRENT DRAW
Connect Tester Turn
SWi tch
To Starter
Pull Out COi l WIre
From
Di stri butor
Cap
Not
From
Coi l
AndGroundIt
I
Crank
Engme
ReadCurrent Draw
Amps
Less
than
150
Amps
Speed
slow
See
Page
S3
S 2
Speed
normal
Starter O
K
1Ik
Starter turns f ast
less
than
60
Amps
Ti ght Engi ne
Mechamcal
Problem
More
than150
Amps
Plug
COIl
Wi re Back In Start
Engme
But
Hold
Key
Over
To
Start
So
That
Starter Does Not
Stop
Starter
draws more
than 60
Amps
Short In
Sta
rter
Overhaul
I
TESTING
FOR
VOLTAGE
DROPS
IN
STARTER
POSITIVE
CIRCUIT
I
Turn
Voltmeter To LowScale
I
TouchPosi ti ve LeadToPosi ti ve Post Of
Battery
NotToCable
Connect
Negati ve
LeadTo
Solenoi d
M Termi nal Termi nal ConnectedToStarter
Pull COIl Wi re Out Of
Di stri butor
Cap
AndGroundIt
I
Crank
Engi ne
I
More
than
1 Volt Less
than 1
Volt
See
Page
S4
Move
Negati ve
LeadTo B Ter
mlnal Of Solenoi d
Termi nal Con
nectedTo
Battery
Crank
Engi ne
I
More
than
1
Volt
Less than 1
Volt
BadConnec Solenoi d
tlon
Between Bad R R
Battery
And Solenoi d
Solenoi d
t
t
t
t
53
t
t
TESTING FOR VOLTAGE
DROPS
IN
STARTER GROUNDCIRCUIT
I
Turn Voltmeter To
LowScale
I
Connect
Negati ve
LeadTo
Negati ve
Termi nal
Of
Battery
HoldPosi ti ve LeadToStarter
Housmg
Make
Good
Connecti on
I
I
Crank
Engme
I
More than
0 5
Volt Less than
0
5 Volt
Bad
Ground
Check
Battery
Ter
See
Page
S
5
mmal
Cable GroundConnecti ons
And
Starter
Bolts
84
TESTING FOR VOLTAGE DROPS
IN
IGNITION SWITCH STARTER SOLENOID CIRCUIT
I
Turn
Voltmeter To LowScale
I
Connect POSi ti ve LeadToPosi ti ve Termi nal
Of
Battery
Connect
Negati ve
LeadTo
Bayonet
Connector Black YellowAtSolenoi d
SWi tch
Leave BYWi re Connected
I
GroundCOi l Wi re
I
I
Crank
Engi ne
I
More
than 1 5 Volts Less
than
1 5 Volts
Open
In Starter
Connect
Jumper
Wi re Between
Overhaul
Battery
Posi ti ve Termi nal And
The S Termi nal
On SolenOId
11
Cli ck Starter
turns No cli ck
Starter
Open
In
Ci rcui t
Igni ti on
SWItch
does not
turn
Connectors
Neutral
Saf ety Relay
Bad
Solenoi d
Automati c Transmi ssi on
Inter
lock
Relay
11
L Seri es
Engi nes
Others
R
R
R R
Overhaul
SolenOi d
Starter
t
t
55
I I
1200ANDB210TO1975
D @ j
Gear housl
ng
2 Dust cover
3 Shi f t lever
4 Gasket
5 Shi f t lever
pIn
6 Sol enoldsWi tch
7 Center support
8 Armature
9Thrust washer
10 BushIng
11 PIni on stopper retai ner
12Snap ri ng
13PInIon stopper
14 PIni on
15
Overrunni ng
c1tuch Bendi x
16 Fi eldcOi l
17 Fi eld
hOUSIng
18 Brushband
19Brush
20 Rear cover
21
Through
bolt
00
6
@ j
@
@ @
I
J
0
SOLENOIDSWITCHTERMINALS
B Battery connectedtobattery
M Motor connectedtostarter f i eld
S Solenoi dacti vatedby Igni ti on
sWi tch In start posi ti on
t
81
B210
f
a
D
f l
Remove the nut
securi ng
the starter
f i eldlead
to the solenoi d M
termi nal
and
remove the
lead
Remove the brush
cover or
bandand
then re
move the screw whi ch
connects the
posi ti ve
brushtothe f i eld
Nowremove the two
through
bolts
and
pull
of f
the
end
plate
c
yr
L
Jlf
I
Nowremove the cotter
key
andthe
shi f t lever
locki ng pi n
then
remove the
solenoi d
Remove the two
screws whIch secure
the sole
nOi d
t
Now
remove
the
posi ti ve
brush Thi S Wi ll be
easi er to do If
you
make a
Si mple
tool
by
bendi ng
a nai l Nowhook the end
of
the tool
underneath the
brush
spri ng pull up
on the
spri ng
andremove the brush
t
Next
separate
the f i eld
housi ng
f rom
the starter
gear housi ng
You
may
have to
tap
li ghtly
on
the armature
shaf t
uSi ng
a
plasti C
hammer
t
B2
B210
Next
pull
the armature outof the
gear housi ng
I
I
I
Next
push
the
stop ri ng
down towardthe arma
ture Thi s wi ll
expose
the
snap ri ng
t
Preli mi nary
checks bef ore
cleani ng
Check the
ri ng gear
on the
engi ne
f or
chi pped
teethor excessi ve wear of the teeth You
may
have to
replace
the
ri ng gear
In
severe
cases
t
B3
To remove
the
overrunni ng
clutch f i rst remove
the
locki ng cli p
f rom
the
stop ri ng
Remove the
snap ri ng uSi ng
a tool as shown and
sli de the
overrunni ng
clutch of f
the armature
shaf t
Inspect
the f i eldcOi l leadwhere It
goes through
to
grommet
Into the starter Thi S of
n
pe
comes
grounded
out
causi ng
a SHORT
B210
Check the i nsi de of the brush cover andthe
f i eld
housi ng
aroundthe commutator You
mi ght
f i nd
a
ri ng
of solder here whi chwould
tell
you
that the armature has
spun
too f ast
overheated
andlost
some
of ItS solder It
mi ght
also tell
you
that the starter has been
hangi ng
up
on the
ri ng gear
because the
overrunni ng
clutch IS not
worki ng properly
Cleani ng
t
DO NOT USE SOLVENT
except
on the
gear
housi ng
I
If
you
do
youmi ght damage
the i nsul
ati on
on the f i eld
Wi ndi ngs
or di ssolve
the
grease
In the
overrunni ng
clutch
causi ng
It to
f all later on
USi ng
ai r
caref ully
blowall
parts
clean
CHECK
THE ARMATURE Avi sual
i nspecti on
shouldshow
you
whetherthe armature has been
draggi ng
on
the f i elds Thi s Wi ll
cause
shorts and
mi ght
have
permanently damaged
the armature
I
nspectl
on
t
Look at the solder
JOi nts
aroundthe commuta
tor Be sure to check
thi s If
you
f oundsolder
i nsi de
the f i eld
hOUSi ng
t
84
8210
Inspect
the
commutator Itshouldbe clean and
shi nY
when
youput
the starter back
together
so
It
wi ll be
necessary
to clean It
uSi ng
a
stri p
of
sandpaper
or commutator
paper
Check
to
make sure there IS a
groove
between the bars
of the
commutator If there Isn t
you
wi ll have
to
make
one
t
Now
place
the armature
on a
growler
andturn
the
growler
on
Lay
a hacksawblade on
top
of
the armature andturn the
armature If the
blade
sti cks to the armature then
you
have
a
short andthe armature wi ll have
to
be
replaced
I
Next check the
armature
f or
opens USi ng
the
test
li ght
secti on
of
the
growler
touch one lead
to
anyone
of the
commutator
segments
Take
the other leadand
run It aroundthe commu
tator
touchi ng
all of
the
segments
The
li ght
shouldbe li t on
every
segment
If It Isn tthen
there IS an
open
In
the solder
connecti on at that
segment
orthere IS an
open
i nsi de the armature
If
any opens
are
i ndi cated
replace
the armature
t
65
8
210
Next
touch one leadof the
conti nUi ty
tester
to the
shaf t andtouch the other leadto
any
segment
of
the commutator If there IS a short
the
li ght
Wi ll
go
on If It does
replace
the
armature
Inspect
the
spli nes
on the
armature shaf t If
there
are
any rough spots
or
burrs
they
wi ll
keep
the
bendlX f rom
sli di ng
one
way
or the
other and
cause the starter to
hang
up
on the
f lywheel
or else not to
engage
at all
Fi le of f
any
burrs
CHECK
THE
OVERRUNNING
CLUTCH Hold
the
outSi de of the clutch
andturn the
gear
It
should
turn wi th a
sli ght
smooth
drag
In one
di rectIOn In the other di recti on It shouldnot
turn If It does not
gi ve youposi ti ve
i ndi cati ons
replace
the
assembly
Also check the
gear
teeth
f or
chi pped
teeth and
replace
the
gear
If
you
f i nd
any
t
t
L
t
86
t
t
t
B
210
CHECK
THE
FIELDS Look
at
the
i nsulati on
around the
wi ndi ngs
and the
solder
JOi nt
between the
f i elds Checkthe f i elds f or
OPENS
by connecti ng
one lead of the tester
to the
mai n f i eld
leadand
touchi ng
the brush
Wi ththe
other lead
The
li ght should
turn on If
not
then there
ISan
open
In the
f i eld
andthe
f i elds
should
be
replaced
Check
the
f i elds
f or shorts
touch one leadof
the
conti nUi ty
tester
to
the f i eld
leadandthe
other leadtothe
f i eld
hOUSi ng
The
li ght
should
not
li ght
If It does
you
have
a
short and
Wi ll
have to
replace
the f Ields
r
q
To
replace
the
f i elds use
an
Impact
tool
Place
the
hOUSi ng
on a Vi se but
donot
ti ghten
as thi S
may
cause
warpage
of
the
hOUSi ng
Remove the
screws and
replace
the
f i elds
B 7
B210
CHECK THE BRUSH PLATE Fi rst checkthe
posi ti ve
brush holderto make sure ItISInsulated
f romthe
plate
Touch one leadof the tester to
the
plate
andthen touchthe other leadto the
brush holder If the
li ght
comes on then the
enti re brush
plate
Wi ll have tobe
replaced
Check the brush
plate negati ve
brush holder
f or
opens
touch one leadto the
plate
andthe
other leadto the
negati ve
brush If the
li ght
does not go
on then REPLACE THE BRUSH
PLATE
CHECK THE STARTER BUSHINGS In the
starter
gear hOUSi ng
Place the armature shaf t
In the
bushi ng
andcheck f or Si de
play
Too
much
play
here wi ll allowthe armature to
drag
on the f i elds
causi ng
a short Replace
the enti re
brush cover If that bushi ng IS bad The other
bushi ng
can be
replacedseparately
If
you
re
place
the
bushi ngs
be sure to checkthat the
armature shaf t turns f reely In thembef ore
putti ng
the starter back together
I
t
t
t
l
B8
8210
CHECK THE BRUSHESf or wear
They
should
be at least 34of thei r
ori gi nal length
If there IS
any doubt
replace
them
t
TESTINGTHESOLENOID Youwi ll needtwo
jumper
wi res Connect a
jumper
wi re f romthe
S termi nal to the
posi ti ve post
of a battery
Next connect a second
jumper
wi re tothe
nega
ti ve
post
of the
battery
andtouchthi s wi re to
the solenoi dhousi ng
The solenoi dshoulden
gage
wi tha weak
pu
II
youmay
have to
push
It
part
of the way
In Thi s ISatest f orthe holdIn
wi ndi ng
whi ch
keeps
the starter
engaged
wi th
the
f lywheel
If
you
f eel no
pull
at all
replace
the solenOi d
t
Next check the
pull In
Wi ndi ng
Leave the
pOSi ti ve jumper
leadhooked
up
and
si mply
move the
ground
wi re to the M termi nal
the
termi nal connectedto the starter f i eldwi re
When
youground
thi S termi nal the solenoi d
shouldbe acti vated andshould
pull In much
more
strongly
than It di dIn the f i rst test If
not
replace
the solenoi d
t
NOTE Even If the solenoi d
passes
these tests
replace It If earli er tests Indi catedIt to be
def ecti ve
89
J
i
i
8210
The solenoi dtravel shouldalso be
Inspected
Just
push
the
plunger agai nst
a hardsurf ace as
shown andmeasure the di stance between the
ti p
of
the
plunger
andthe f ace
of
the
solenoi d
The
di stance should
be
317323mi lli meters
or 1248 272
Inches
THISMEASUREMENT
IS VERY
IMPORTANT
If It
IS
Incorrect then
the solenoi dWi ll
not
engage properly
wi ththe
f lywheel
andWi ll ei ther
hang up causi ng
bendlx
damage
or else
gri nd
of f the teeth of
the
rI
ng gea
r
Re
Assembly
Install
the center
support
andthe bendlxon
the armature
shaf t
Next
place
the
stop ri ng
down on the shaf t andInstall the
snap ri ng
and
snap ri ng cli p
t
Install
the
armature andshi f t lever In the
gear
hOUSi ng
and
engage
the
solenoi d
In
the shi f t lever I
nstall
the shi f t lever
Pi n
t
I
I
1
A
I
t
810
t
8
210
Now
mstall
the cotter
key
Install
the two
solenoi d
attachmg
screws
Next
sli de the
f Ieldhousmg
over
the
armature
B
11
1
B
210
Install the brushes and
tIghten
the
screw
ter
mlnals
connecti ng
themto the
f i eld
andto
ground
Now Install the end
plate
Don t
f orget
to re
stall
any spacers
or
shIms whIch
you
mIght
have removedf romthi s
end
Next
replace the brushband
812
8210
Fi nally
Install the f i eldwi re on the
solenoi d M termi nal
Fi nal benchtest
Thi s test
requi res
some
experti se
so
perf orm
It
caref ully
Install
the
starter
f i rmly
In avi se
Connect the
negati ve clamp
of a
hi gh
quali ty
battery
charger
tothe starter
gear housi ng f lange
Connect the
posi ti ve
leadof the
battery
charger
to
the solenoi d 8 termi nal
Turn
the
charger
on
Connect a
Jumper
wi re between
the 8 termi
nal andthe solenoi d 5
termi nal The solenoi d
should
engage
andthe starter should
turn and
the currentdrawshouldnotexceed60
amps
B13
I
ALL LSERIES ENGINES
I
CD
CV @
@
j
@
l
rt
3
@@
@
0
1
Shi f t lever
pi n
o
2 Gear
hOUSIng
j3@ @
3 Dust cover
v
4 Shi f t lever @
5 Gasket
6 Solenoi dsWi tch ass
y
7 Armature
8 Thrust washer
9
BushIng
10 Thrust washer
11 Pi ni on
stopper
retaIner
cli p
12
Snap ri ng
13PIni on
stopper
14
PIni on
15
OverrunnIng
clutch Bendi x
16 FIeldcoi l
@
17 Fi eld
hOUSIng
j6
@
18 POSItIve brush
19
Negati ve
brush
20
Brush
spri ng
t
21 Brushholder ass
y
22
BushIng
23 Rear cover
24
Through
bolt
SOLENOIDSWITCHTERMINALS
B
Battery
connectedto
battery
M Motor connectedtostarter
f i eld
S Solenoi dacti vated
by
Igmtlon
SWi tch In start
posi ti on
L1
LSERIES
Di sassembly
Remove the nut
securi ng
the starter f i eldlead
to the solenoi d M termi nal andremove the
lead Remove the two screws whi chsecure the
solenoi dandremove the solenoi d
Remove the twosmall screws
securi ng
the brush
cover over the end
plate
Remove the two
through
bolts
holdi ng
the starter
together
Nowremove the two pOSi ti ve
brushes brushes
whi chare solderedto the f i elds Make a
Si mple
hook out of a nai l andhook It behi ndthe
spri ng
on each brush Pull
up
on the
spri ng
and
remove the brush
f
I
t
t
L2
t
t
LSERIES
Nowsli de the brush plate of f the commutator
Be caref ul not to lose any washers
or
spacers
Remove the f Ieldhousi ng
You
may
have to
tap li ghtly wi th a plasti c
hammer on the arma
ture shaf t to separate
the f i eld
housi ng
f rom
the gear housi ng
Now remove the
nut washer andthe shi f t lever
locki ng pi n
Next pull
the armature out of the
gear housi ng
l3
p
@
1
I
r
1
Ji J
1
Il
I
J J
I
CDI
J
L
SERIES
Nowremove the
overrunni ng
clutch Fi rst sli de
the
locki ng cli p
of f the
gear stop ri ng
Now
push
the
stop ri ng
towardthe
gear
Now
you
can see the
snap ri ng
Removal
of thi s
snap
ri ng
wi ll be
easi er
If
you
have a tool suchas the
one shown When the
snap ri ng
has been re
moved sli de the
overrunni ng
clutch of f the
armature
I
i
I
I
I
f
f
t
Preli mi nary
checks bef ore
cleani ng
Check the
ri ng gear
on the
engi ne
f or
chi pped
teeth or excessi ve wear
of
the teeth You
may
have to
replace
the
ri ng gear
In
severe
cases
t
L4
L
SERIES
Inspect
the f i eldcoi l leadwhere It
goes through
the
grommet
Into the starter Thi s of ten be
comes
grounded
out
causi ng
a SHORT
Check
the Insi de of the brush
cover andthe
f i eld
housi ng
aroundthe
commutator
You
mi ght
f i nda
ri ng
of solder here
whi ch wouldtell
you
that the armature
has been overheated
spun
too f ast andlost
some
of
ItS solder It
mi ght
also
tell
you
that the
starter has been
hangi ng
up
on
the
nng gear
because the
overrunni ng
clutch IS not
worki ng properly
t
Cleani ng
q
LL
DO NOT USE
SOLVENT
except
on the
gear
housi ng
OtherWi se
youmi ght damage
the i nsul
ati on on the f i eld
Wi ndi ngs
or di ssolve the
grease
In the
clutch
causi ng
It tof all later
on
USi ng
ai r
caref ully
blowall
parts
clean
t
L5
L
SERIES
InspectIOn
CHECK
THE
ARMATURE
A
vlsualmspectlon
shouldshow
you
whether
the armature has
been
draggi ng
on the f i elds
Thi s wi ll cause
shorts and
mi ght
have
permanently damaged
the armature
Look at the
solder
JOi nts
aroundthe commu
tator Be
sure to check thi s If
you
f ound
solder
Insi de the f i eld
housi ng
Inspect
the commutator
Itshouldbe
clean
and
sh
InY
bef ore
youput
the starter
back
together
so It wi ll be
necessary
toclean It
uSi ng
a
stri p
of
sandpaper
or commutator
paper
Check to
make
sure there IS a
groove
between the bars
of
the
commutator If there Isn t
you
Wi ll have
to make
one
t
t
L6
t
t
L
SERIES
Now
place
the
armature
on
a
growler
andturn
the armature If the blade
sti cksto the armature
then
you
have
a
short
and
the
armature wi ll
have
to
be
replaced
Next check the armature f or
opens USi ng
the
test
li ght
secti on of the
growler
touch one lead
to
anyone
of the commutator
segments
Take
the other leadandrun It aroundthe commuta
tor
touchi ng
all of the
segments
The
li ght
shouldbe li t on
every segment
If It Isn tthen
there
IS an
open
In
the solder connecti on at
that
segment
or there IS an
open
i nsi de the
armature
If
any opens
are i ndi cated
replace
the
armature
L7
LSERIES
Next touch one
leadof the
conti nui ty
tester
to the shaf t
andtouch the other leadto
any
segment
of the commutator If there
IS a short
the
li ght
wi ll
go
on If It does
replace
the
armature
Inspect
the
spli nes
on the armature shaf t If
there are
any rough spots
or burrs
they
wi ll
keep
the
overrunni ng
clutch f rom
sli di ng
one
way
or the other andcause the starter to
hang
up
on the
f lywheel
or else not to
engage
at all
Fi le of f
any
burrs
CHECK
THE OVERRUNNING
CLUTCH Hold
the outsi de of the clutch andturn the
gear
It
shouldturn wi th a
sli ght
smooth
drag
In one
di recti on In the other di recti on
It
should
not
turn If It does not
gi ve youposi ti ve
i ndi cati ons
replace
the
assembly
Also
checkthe
gear
teeth
f or
damage
and
replace
If
you
f i nd
any
JI
LS
LSERIES
CHECK THE FIELDS Look at the i nsulati on
aroundthe
wi ndi ngs
andat the solder
JOi nt
between the f i elds
Check
the f i elds f or
OPENS
by
con
nectlng
the lead of the tester to the
mai n
f i eld
leadand
touchi ng
each of the brushes
In turn The
li ght
should
go
on each ti me If
not there
IS an
open
andthe
f i elds must be
replaced
Check the f i elds
f or
shorts touch one
lead
of
the
conti nUi ty
tester
to
the f i eld
hOUSi ng
The
li ght
shouldnot
go
on If
It does
you
have a
shortandwi ll have to
replace
the f i elds
t
To
replace
the f i elds use
an
Impact
tool Place
the
hOUSi ng
on a Vi se but do
not
ti ghten
as
thi S
may
cause
warpage
of
the
hOUSi ng
Remove
the screws and
replace
the
f i elds
t
L9
I
I
I
I
LSERIES
CHECK
THE BRUSH
PLATE Fi rst check the
posi ti ve
brush holder to make sure It
IS i nsul
atedf romthe
plate
Touch one
leadof the
tester to the
plate
and
then
touch
the other
leadto each of the two
posi ti ve
brush holders
If the
li ght
comes on then the
enti re brush
plate
wi ll have to be
replaced
Check the
brush
plate
negati ve
brush holders
f or
opens
touch one lead
to
the
plate
andthe
other to
each of the
negati ve
brushes If the
li ght
does
not
go
on then REPLACE THE
BRUSH PLATE
CHECK THE STARTER
BUSHINGS In the
brush
cover andIn the starter
gear hOUSi ng
Place the armature shaf t
In
the
bushi ng
and
check
f or
si de
play
Too much
play
here wi ll
allowthe armature to
drag
on
the
f i elds
causi ng
a short
Replace
the enti re brush
cover
If that
bushi ng
IS bad The other
bushi ng
can be re
placedseparately
If
youreplace
the
bushi ngs
be sure to check that the armature shaf t
turns
f reely
In thembef ore
putti ng
the
starter
back
together
J
JI
4
J
L 10
LSERIES
CHECK
THE
BRUSHES
f or
wear and
If there
IS
any
doubt
replace
themWhen
you
solder In
newbrushes be
sure to use a well
ti nned
hot
solder Iron toensure a
goodJOi nt
NOTE
Brushes
should
be
replaced
when
they
are less than
3
4of thei r
Ori gi nal length
TESTINGTHE
SOLENOID YouWi ll
needtwo
jumper
wi res
Connect a
jumper
wi re f rom
the
S
termi nal to the
posi ti ve post
of
a
battery
Next connect
a second
jumper
wi re
to the
negati ve post
of the
battery
andtouch
thi s
wi re to the solenoi d
hOUSi ng
The solenoi d
should
engage
wi th
a weak
pull youmay
have
to
push
It
part
of the
way
In ThIS IS a test
f or
the hold
In
Wi ndi ng
whi ch
keeps
the starter
engaged
Wi th the
f lywheel
If
you
f eel
no
pull
at all
replace
the
solenoi d
Next
check the
pull
In
Wi ndi ng
Leave the
posi ti ve
Jumper
lead hooked
up
and
Si mply
move the
ground
wi re to the M
termi nal
the
termi nal connected to the starter
f i eld
wi re When
youground
thi S termi nal the
sole
nOi d
shouldbe acti vated and
should
pull
In
more
strongly
than It di d
In
the
f i rsttest If not
replace
the
solenoi d
NOTE
Even If the solenoi d
passes
these tests
replace
It If earli er
tests
i ndi cated
It too be
def ecti ve
L11
11
L
fh
r
I
I
I
I
LSERIES
Reassembly
Replace
the
overrunni ng
clutch
on armature
Be sure
cli p
IS
f i rmly
In
place
Rei nstall
the armature In the
gear housmg
whi le also
posi ti oni ng
the solenoi dshi f t
lever
core and
lockmg pm
Sli de the f i eld
housmg
overthe armature and
up
to the
gear housmg
Nowmstall the end
plate
pullmg up
on the
negati ve
brush
spri ngs
toallow
the
plate
to sli de ontothe commutator
Place
the
plate
partway
on the commutator
L
Jq
i
r
r
ol
0
r
l
I
r
Jf
F
t
t
L12
LSERIES
Now
place
the
posi ti ve
brushes
mthei r
holders
pulli ng
back
on the
sprmgs
to allow
the brushes
to sli de mto
place
Next push
the
brush
plate
all the
way
mto
place
1
Install the brush
cover Don
t
f orget
the
thrust
washer
sl
whi ch
youmay
have
removedupon
di sassembly
Install
the
through
bolts
andthe
small
cap
retai ner screws
Install
the solenoi d
and
ItS
gasket
L13
c f
j
lf r
r
4
Q
r
1
L
SERIES
Install the
f i eld
wi re
on the solenoi d M
termi nal
Measuri ng
Clearance
1
Wi th
the
solenoi d
energi zed push
the
dri ve
pi ni on
towardthe f rontof the
starter toremove
all slackandmeasure clearance between the
omlO 1 rear
edge
andthe
pi ni on stopper
The
clearance shouldbe between 3and 1 5mm
012and059In If
necessary adjust
clearance
1
by addi ng
or
removi ng
the
adjusti ng
washers
locatedbetween the solenoi dandthe
gear
case
AdJustmg
washers are avai lable In two Si zes
5mm 020
In and
8mm
031
NOTE
1978 models
only
Clearance
1
IS
3 25mm 012 098m
Fi nal BenchTest
Thi s test
requi res
some
experti se
so
perf orm
It
caref ully
Install the starter
f i rmly
In avi se
Connect the
negati ve clamp
of
a
hi gh quali ty
battery charger
to the starter
gear
housi ng
f lange
Connect the
posi ti ve
leadof the
battery charger
tothe solenoi d B termmal
Turn the
charger
on
Connect a
Jumper
wi re between the B termi
nal andthe solenoi d 5 termi nal The solenoi d
should
engage
andthe starter shouldturn on
andthe current
drawshouldnotexceed60
amps
o 310 I 5 mm
112 1 1
I
119
JIl
t
L14
SPECIFICATIONS
t
SCOPE
t
I
THECHARGINGSYSTEM
1 Check Battery
Make Sure ItIs OKBef ore
Goi ng On
2 CheckAlternator Belt
3 If YouHave
CHARGING
SYSTEM
TESTER
t
TESTING
TESTLIGHT
t
ANDVOLTMETER
ALTERNATOR
t
OVERHAUL
PROCEDURES
t
ALTERNATORSPECI FICATIONS
1 RATEDOUTPUT To Fi ndThe Rated
Output
Of The Alternator YouAre
Worki ng
On Look On The Alternator Front
Housi ng
You
Wi ll Fi ndASeri es Of Identi f i cati on Marks NowLook For
The Fi gures
LT1 The Next Two Numbers Are The
Amperage Rati ng
Of The Alternator
EXAMPLE LT160 60
Amperes
Rated
Output
t
2 OUTPUT
MEASUREMENT The Actual
Output Whi ch YouWi ll Be Able To ReadWi ll
Depend
On Whether Your Tester Is Connected
Di rectly
To
The Alternator OrToThe
Battery
Output
At A Termi nal
Same As Rated
Output
AMPSI
25
33
35
50
60
Output
At
Battery
Termi nals
AMPSI
18
24
28
375
45
t
NOTE Don t
Forget
ToAdd5To 10
Amps ToThe Meter
Readi ng
If YouAre
USi ng
A
Chargmg System
Tester SuchAs
The Vat28
I
t
3 VOLTAGESETTING NoLoadFullyChargedBattery
143 153Volts
All Models
t
t
Co1
20KV
15KV
10KV
5KV
OKV
40KV V
30KVV
20KV v
10KV v
5 40 35 30 25 20 15
10
5
1111ti ll I r I I I I I 11 I
90 80 70 60 50 40 30 20 10
I I 1 1 I I I I I I
60555045403530252015 10 5
OKV V
o
14
CYL
06CYL
rm 1
t
t
LOWVOLTAGEPICKUP LEAD
t
t
Co2
CHARGING
CIRCUIT
TESTING
WITH ASCOPE
1
TURN
SCOPEON
DISPLAYPATTERN1POSITION
2 SET
VOLTAGESWITCH
TO PRIMARY
3 TURNVOLTAGE TOLOW
SCALE
0
40VI
4 ATTACH LOWVOLTAGE PICKUP LEADS
REDTOALTERNATOR
BAT OR
A
TERMINAL
BLACKTOALTERNATORGROUND
OR E TERMINAL
5 START
ENGINE OBSERVE PATTERN ADJUSTPAHERN FORGREATEST
SPREAD HORIZONTAL CHECKPATTERNAGAINSTTHOSESHOWN
NORMAL
AI
PATTERNNORMAL
See
Page
C5
4
OPEN DIODE
Bl
PATTERNBAD
See
Page
C7
4
SHORTEDDIODE
OPEN STATOR
Cl
NO
PATTERN
See
Page
C9
rf tt rrr
SHORTEDSTATOR
C3
PATTERNNORMAL
ATTACH VOLTMETER TOBATTERYTERMINALS START ENGINE RUNAT 2000 RPM
FOR10SECONDS CHECKVOLTMETERREADING
LOWORHIGH
143 153VOLTS
SYSTEM0K
POSITIVECIRCUITRESISTANCETEST SETVOLTMETERTOLOWSCALE TOUCHPOSITIVE
LEADTOALTERNATOR A OR BAT TERMINAL TOUCHNEGATIVELEADTOBATTERY
POSITIVE TERMINAL TURNON HEADLIGHTS HIGH BEAM ANDHEATER FAN HIGH
SPEEDRUNENGINEAT2000RPM
BELOW2VOLTS
TOUCHNEGATIVE VOLTMETER LEADTOALTERNA
TOR E TERMINAL TOUCH POSITIVE VOLTMETER
LEAD TO BATTERY NEGATIVE TERMINAL LOW
SCALE RUNENGINE LIGHTSANDFANON
BELOW05VOLTS
LEAVE NEGATIVE LEADCONNECTEDAT ALTERNA
TOR TOUCH POSITIVE LEADTOOUTSIDE OFREG
ULATOR RUN ENGINE HEADLIGHTS ANDFAN ON
BELOW05VOLTS
I
REPLACEREGULATOR
NOTE MAKE SURE THAT THE BATTERY IS IN
ACHARGEDCONDITION FORTHISTEST OTHERWISE
VOLTAGEREADINGCOULDBEINCORRECT
I
ABOVE2VOLTS
CHECK FOR BAD CONNECTION IN WIRE BETWEEN
ALTERNATOR A TERMINAL ANDBATTERY 1973
1974610CHECKCONNECTORBLOCKATRIGHTKICK
PANELIN PASSENGERCOMPARTMENT
t
ABOVE05VOLTS
BADGROUNDCONNECTIONBETWEENALTERNATOR
ANDBATTERY
ABOVE05VOLTS
t
BADGROUNDCONNECTIONBETWEENALTERNATOR
ANDREGULATOR
t
t
C5
B WB
BW
or
WL
t
REGULATORCONNECTOR
HARNESS SIDE
B Ground
y Neuter toAlternator N termi nal
WB Fi eld
W From A Termrnal
t
BW From
Igni ti on
SWi tch
early
models WL
WR FromDash
Charge Warni ng Li ght
y W WR
t
CG
BAD
PATTERN
SET VOLTMETER TOLOWSCALE TOUCH POSITIVE LEADTO
ALTERNATOR A OR
BAT TERMINAL TOUCHNEGATIVE LEADTOBATTERYPOSITIVE
TERMINAL TURN
ONHIGH BEAM
HEADLIGHTS
ANDHEATER FAN HIGH
SPEED RUNENGINE AT 2000
RPM CHECKREADING
BELOW2
VOL
TS
ABOVE
2
VOLTS
TOUCH
NEGATIVE VOLTMETERLEADTOALTERNA
TOR E TERMINAL TOUCH POSITIVEVOLTMETER CHECK FOR BAD CONNECTION IN WIRE BETWEEN
LEADTOBATTERYNEGATIVE TERMINAL RUNEN ALTERNATOR A TERMINALANDBATTERY
GINEAT2000RPM
LIGHTS
ANDFANON
BELOW05VOLTS
ABOVE
0
5VOLTS
LEAVE NEGATIVE LEADCONNECTEDTOALTERNA
BAD
GROUNDCONNECTIONBETWEENALTERNATOR
TOR E TERMINAL TOUCH POSITIVE LEAD TO
ANDBATTERY
OUTSIDEOF
REGULATOR
RUN
ENGINE
LIGHTSAND
FANON
BELOW05VOLTS
ABOVE05
VOLTS
REMOVE FIELDWIRE AT ALT
TOUCHTEST LIGHT BAD
GROUND
CONNECTIONBETWEENALTERNATOR
TOTHISWIRE WHITE
BLACK ANDREGULATOR
LIGHTOFF
OR
FLICKERING
LIGHT
ON STEADY
AT REGULATORCONNECTOR KEYON TOUCHTEST
LIGHT TO
BLACKIWHITE
OR WHITEBLUE WIRE
REMOVEALTERNATORFORREPAIRS
LEAVECONNECTOR
PLUGGED
IN
Overhaul
LIGHTON
LIGHTOFF
TOUCHLIGHTTOWHITE BLACKWIRE
OPEN
CIRCUIT BETWEEN IGNITION SWITCH AND
REGULATOR
LIGHTOFF
LIGHTON
I
I
WHITE
BLACKWIRE BETWEENREGULATORANDAL
REPLACE
REGULATOR
TERNATORFIELDISOPEN
t
t
Co7
B
W
B W
B
or
W
L
y W
W
R
t
t
B
Y
WB
W
B
W
W
R
t
Coa
REGULATOR
CONNECTOR
HARNESS SIDE
Ground
Neuter
toAlternator
N termi nal
Fi eld
From
A Termi nal
From
Igni ti on
SWi tch
early
models WL
FromDash
Charge Warni ng
Li ght
NO
SCOPE
PATTERN
TURN KEY ON HOLD SCREWDRIVER
IN FRONT OF ALTERNATOR PULLEY CHECK
FORMAGNETISM
NOMAGNETISM
UNPLUGFIELDLEAD WHITEBLACK AT ALTERNA
TOR TOUCHTESTLIGHTTOTHIS LEAD KEYON
LIGHTOFF
AT REGULATORCONNECTOR
KEYON TOUCHTEST
LIGHT TO
BLACKIWHITE
OR WHITEBLUE WIRE
LIGHT
ON
TOUCH LIGHT TO WHITEBLACK WIRE
KEY
ON
LIGHT
ON
WHITEBLACKWIRE BETWEENREGULATORANDAL
TERNATORFIELDISOPEN
MAGNETISM
CHECKTOMAKE SUREYOUCONNECTEDTHE
SCOPE
PROPERLY IFYOUDIDTHENREMOVETHEALTER
NATORFORREPAIRS
Overhaul
LIGHT
ON
REMOVE
ALTERNATORFORREPAIRS
Overhaul
LIGHT
OFF
t
OPEN CIRCUIT
BETWEEN IGNITION
SWITCH AND
REGULATOR
LIGHTOFF
I
I
REPLACEREGULATOR
C
9
RATED
OUTPUT
2 ACTUAL
OUTPUT
ALTERNATORSPECIFICATIONS
To
Fi ndT1MI
Ratf tI
Output Of The
A1ternatOl
YouAre
Wonung
On
LookOn The
AlternatOl Front
Housmg
You
Wi ll FInd
A Si nn Of
IdentdlClltlon
Man
s
N01I I
lookFor
1M
FIIIS
LT1 The Next
Two Numbers A The
Amplll
Rati ng
Of The
Alternator
EXAMPLE LT160
60Ampern
R
Output
Thi s Is The Maxi mum
Output MumThe
Alternator
Is
Actually Capable Of Produang
AndWllIch You
Should
Look FOI When Yau
Test
The arglng
System
RATED
OUTPUT
AMPS
25
33
35
50
60
ACTUALOUTPUT
AMPS
24
28
n
45
NOTE Don t
Forgrrt
To
Add5Amps
ToThe
Mater
R
ng
If YouAre
1IIlng
A
ag
ng
System
Test lr
Sum
The Vat28
3
VOLTAGESETTING NoL
FuIIyCharg8d
143
153Volts
IAII
Model
t
t
B
Y
B
W
B
BW
or
WL
y W
R W
REGULATOR
CONNECTOR
HARNESS SIDE
Ground
Neuter to
Alternator N
termi nal
WB Fi eld
W From A Termi nal
t
BW
WR
Co10
From
Igni ti on
SWi tch
early
models WL
FromDash
Charge Warni ng Li ght
AMPS
o
o
0
000
i Hi Hi 9
CHECKING
THECHARGING
SYSTEM
WITHA
SPECIAL
TESTER
CONNECT TESTER
TOVEHICLE SEE SAMPLE
ILLUSTRATIONI
LEAVE ALLVEHICLE
ELECTRICALUNITS
TURNEDOFF
RUN
ENGINE AT 2500 RPM
TURN
LOAD
KNOB UNTIL AMMETER GETS TOHIGHEST
READING ADD5TO10AMPSTOTHISFIGURE
BELOWSPECIFIED
AMPERAGE
UNPLUG FIELDLEAD
WHITE BLACKI
FROM
AL
TER
NATOR PLUGTESTERFIELDLEADINTOALTERNA
t
TOR TURNTESTERTO INTERNAL GROUNDTYPE
FIELD RUNAT2500 RPM TURNLOAD KNOB TO
OBTAIN HIGHEST READING ADD 5 TO 10AMPS
CURRENTOUTPUT
NORMAL
TOUCHTHETESTLIGHTTOFIELD
LEAD
AT
ALTERNATOR
WHITE
BLACK IGNITIONON
NOLIGHT
REPLACEREGULATOR
LIGHT
IGNITION ON TESTLIGHTTOTHE
WHITEBLACK WIRE AT THE REG
ULATOR CONNECTOR LEAVE
CONNECTORPLUGGEDIN
NOLIGHT
LIGHT
OPEN IN FIELD WHITE BLACK
WIRE BETWEEN REGULATORAND
ALTERNATOR
ATREGULATORCONNECTOR TEST
LIGHTTOBLACKlWHITE ORWHITE
BLUE WIRE IGNITION ON CON
NECTORSTILLPLUGGEDIN
NOLIGHT
OPEN IN IGN
CIRCUIT TO REG
ULATOR
LIGHT
REPLACEREGULATOR
AT OR ABOVE WORKING
AMPERAGE
SEE
CHARTI
SYSTEM
0K
CURRENT
OUTPUT
LOW
RECONNECT FIELD TURNVOLTMETER
SELECTOR
TOLOWRANGE CONNECT POSITIVE LEADTOAL
TERNATOR A OR BAT TERMINAL CONNECT
NEGATIVE LEADTOPOSITIVE TERMINAL
OFBAT
TERY RUN ENGINE AT 2500 RPM TURNLOADTO
10AMPS CHECK
VOLTAGEREADING
ABO
OLTS
OPENIN WIRINGBETWEENALTER
NATOR A AND
BATTERY
TERMI
NAL
BELOW2
VOLTS
NOW
CONNECT NEGATIVE LEAD
OF VOLTMETER TO E
OR
GROUNDTERMINALOF
ALTERNA
TOR PUT POSITIVELEADON NEG
ATIVE TERMINAL OF BATTERY
RUN ENGINEAT 2500 RPM APPLY
A LOADOF10AMPS CHECKVOLT
AGEREADING
ABOVE
05VOLT
BAD GROUND CONNECTION
BE
TWEEN ALTERNATOR
AND BAT
TERY
BELOW
05
VOLT
t
MOVE POSITIVE LEADTO REGU
LATORCOVER REPEATTEST
ABOVE05VOLT
BAD GROUND CONNECTIONS AL
TERNATORREGULATOR
BELOW05VOLT
t
REMOVE
ALTERNATOR
FOR RE
PAIRS
t
Overhaul
C11
t
CHECKING
THE
CHARGING
CIRCUIT
WITHA
TEST LIGHT
ANDAVOLTMETER
NOTE BEFORE
STARTING
TEST
MAKESUREBATTERYISFULLYCHARGED
TEST LIGHT TO YELLOWWIRE AT
REGULATOR
CONNECTOR LEAVE CONNECTOR
t
PLUGGEDIN
ENGINERUNNING
LIGHT
ON
CHECK BATTERY VOLTAGE ENGINE
RUNNING AT 3000 RPM NO LOADAPPLIED
VOLTAGELOW
14
3 153VOLTS
VOLTAGEGOOD
POSITIVE CIRCUIT RESISTANCE TEST SET VOLT
IF BATTERY
PROBLEMS PERSIST CHECK
AGAIN TO
METER
TOLOWSCALE TOUCHPOSITIVE LEADTO
MAKE SURE
THAT BATTERY IS 0K AND
THAT
ALTERNATOR A OR BAT TERMINAL TOUCH
THERE IS NO
LEAKAGE CURRENT EITHER
ACROSS
NEGATIVE
LEADTOBATTERYPOSITIVETERMINAL
THE TOP OF
THE BATTERYORTHROUGH
ADEFEC
TURNON HIGH
BEAM HEADLIGHTS ANDHEATER
TIVE CIRCUIT
INTHE VEHICLE IF
PROBLEMSSTILL
FAN HIGHSPEED
RUNENGINEAT3000RPM CHECK
EXIST CHECKFOR
ANOPENDIODE
READING
I
ABOVE
2
VOLTS
BELOW
2
VOLTS
CHECK FOR BAD CONNECTION IN WHITE WIRE BE
TOUCH
NEGATIVE
VOLTMETERLEADTO
ALTERNA
TWEENALTERNATOR A TERMINALANDBATTERY
FOR E TERMINAL TOUCHPOSITIVE
VOLTMETER
LEADTOBATTERYNEGATIVE TERMINAL
RUNEN
GINEAT2000RPM LIGHTSANDFAN
ON
I
ABOVE
05
VOLTS
BELOW
0
5
VOLTS
BADGROUNDCONNECTION
BETWEEN
ALTERNATOR
LEAVE NEGATIVE LEADCONNECTEDTOALTERNA
ANDBATTERY
TOR E TERMINAL TOUCH POSITIVE LEAD
TO
OUTSIDEOFREGULATOR RUNENGINE
LIGHTSAND
FANON
I
ABOVE
05
VOLTS
BELOW05VOLTS
BAD
GROUND
CONNECTION
BETWEENALTERNATOR
HIGH
RANGEVOLTMETERTOBATTERYTERMINALS
ANDREGULATOR
UNPLUGALTERNATORFIELDLEAD CONNECTJUMP
ERWIRE FROMALTERNATOR A TOALTERNATOR
F FIELD TERMINAL RUNENGINE CAUTION DO
NOTAllOWVOLTAGETOEXCEED16VOLTS
I
VOLTAGE
NORMAL
143 15
3
OR
ABOVE
BELOW143
VOLTS
I
I
CHECK
CONNECTORS
REGULATOR
ALTERNATOR
REMOVE
ALTERNATOR
FOR
REPAIRS
FIELDWIRE WB IF0K REPLACE REGULATOR
Overhaul
t
t
C
12
LIGHT
OFF
tt
ENGINE OFF IGNITION ON HOLDSCREWDRIVERIN FRONTOF
ALTERNATORPULLEY
CHECKFORMAGNETISM
NOMAGNETISM MAGNETISM
PULLOFFFIELDWIREATALTERNATOR
TEST
LIGHT
TOFIELDWIRE WBI KEYON
TEST LIGHT PROBE YELLOW
NEUTER WIRE AT
ALTERNATOR LEAVE CONNECTOR
PLUGGED IN
ENGINERUNNING
LIGHT
ON
LIGHTON
OPEN CIRCUIT IN YELLOWNEU
TER WIRE ALTERNATORTOREG
ULATOR
REMOVE ALTERNATOR FOR RE
PAIRS
LIGHT
OFF
Overhaul
LIGHT
OFF
TEST LIGHT TO WHITE
BLACK
WIRE AT REGULATOR CONNEC
TOR KEY
ON CONNECTORPLUG
GEDIN
REMOVE ALTERNATOR FOR RE
PAIRS
Overhaul
LIGHT
ON
OPEN
IN
FIELD WIRE W
B
BE
TWEEN REGULATOR ANDALTER
NATOR
LIGHT
OFF
TEST
LIGHTTOBLACKWHITE OR
WHITEBLUE WIRE
KEYON CON
NECTORPLUGGEDIN
I
REPLACEREGULATOR
LIGHTON
LIGHT
OFF
I
OPEN IN IGNITION
CIRCUIT TO
REGULATOR
REGULATORCONNECTOR
HARNESS SIDE
BW
B Ground
or
y Neuter
to
Alternator
N termi nal
WL WB Fi eld
W FromA Termi nal
W
R
B W From
Igni ti on
SWi tch
early
models WL
WR FromDash
Charge Warni ng Li ght
t
B WB
t
y
W
C
13
ALTERNATOR
OVERHAULPROCEDURES
CD
A
mr
y
rID
I
Pulley
as embly
2
Front
cover
3
rront
be
nng
4 Rotor
5
Rear
beanng
6 Stator
7 Rear cover
8 Bru
h assembly
9 DIOde et
pi a
te embly
10
DIOde
cover
II
Through
bolts
A1
ALTERNATOROVERHAUL
Alternator
dlssassembly
bench test
Cali brate an Ohmmeter on the X1 scale Touchone
leadto the alternator F or f i eldtermi nal Touch
the other leadto the E or
ground
termi nal The
meter shouldread between 5 and200 ohms
Spi n
the
pulley
whi le
you
are
dOi ng
thi s andthe
readi ng
should
vary sli ghtly
If the
readi ng IS too
hi gh
then there IS an
open
In
the f i eldci rcui t brushes
sli p ri ngs
rotor wi ndi ngs
andtermi nals If the
readi ng
IS too low then there
ISa short
IIi
li lt
Remove the screws
securrng
the brush holder
and remove the brush holder cover Pull the
brush holder f orwardandremove the brushes
together
wi ththe brushholder
r
V
J
USi ng
a screwdri ver make a scratch mark
along
the si de of the alternator so
you
wi ll be able to
li ne
up
the secti ons when
you
reassemble them
p
Unscrewthe three
through
bolts
Tappi ng li ghtly
wi th a
plasti C
hammer
separate
the f ront hous
Ing
androtor f romthe rear
housi ng
andstator
as shown MAKESURE THATTHE STATOR
STAYS WITH THE REAR HOUSING If the
stator housi ng comes of f wi ththe f ront housi ng
the stator wi res wi ll be
damaged
A2
ALTERNATOROVERHAUL
Place the rotor In a Vi se
bei ng
sure to
protect
It wi thtwoblocks of wood
Remove the
pulley f an and
spacers Remember
the order In whi ch
you
removedthe
partsl
00
1lo
Now
you
can remove the
spacer
seal andseal
retaIner
I
Remove the di ode cover screwandloosen the
negati ve
di ode
plate f i Xi ng nut Remove the
di ode cover
A3
V
e
Remove the three screws f romthe f ront
bearrng
retai ner and
pull
the rotor out of the f ront
cover
Remove the
beari ngs
f romthe rotor shaf t uSi ng
a
bearrng puller
or
press
Nowuse a
solderrng gun todi sconnect the stator
coi l leadwi res f romthe di ode termi nals
ALTERNATOROVERHAUL
oQ
C
00
Remove
the A
termi nal
nut
andthe di ode
pack
i nstallati on
nut
Spread
the wi re
retai ni ng
clamps
and
remove
the
wi res
f romthe
clamps
Remove the di ode
pack
Cleani ng
t1
i i
Now
you
can
remove the stator f romthe f ront
hOUSi ng
Blowof f all
parts
wi th
compressed
ai r
DONOTUSE
SOLVENTI
If
you
do the solvent
mi ght
di ssolve the
i nsulati on on
the
rotor
and
stator
wi ndi ngs
InspectIOn
ROTOR TESTS
Fi rst
Inspect
the
sli p
ri ngs
They
shouldbe clean and
shi nY
If
they
aren t
then clean them
uSi ng
400
gri t
or
f i ner
paper
Check
the
solder
JOi nt
between
the rotor Wi nd
Ings
andthe
sli p ri ngs
Of ten
thi S connecti on
breaks loose andcauses alternator
f ai lure If
It
has broken loose
you
Wi ll have to resolder
the connecti on andre
glue
the leadto the rotor
uSi ng
epoxy
cement
t
A4
ALTERNATOROVERHAUL
Next check the rotor resi stance Cali brate the
ohmmeter on the X1 scale Touch one leadto
each
sli p ri ng
The
readi ng
shouldbe 4
5
ohms
If
It s too
hi gh
then check the connecti ons
between the
rotor
Wi ndi ng
andthe
sli p ri ngs
If It s
too
lowthen there
IS
a
short In the rotor
Wi ndi ngs
If
you
are
unable
to
repai r
the rotor
replace
It
Next check
the rotor f or
grounds
Cali brate
the ohmmeter on
the
X1000 scale
Touch one
lead to one
of the
sli p ri ngs
andtouch the
other leadto the
rotor shaf t The needle
should
not
move
at
all If It does then
replace
the
rotor It IS
shorted
to
ground
STATOR TESTS
Vi sually Inspect
the stator
f or broken connecti ons andburned
i nsulati on
Next check the stator f or
conti nui ty
Cali brate
the ohmmeter on the X1000 scale Touch an
ohmmeter
lead
to one
of
the stator Wi res and
touch the other leadto each of the other three
leads one at a ti me The needle shouldmove all
the
way
over each ti me
shOWi ng conti nui ty
If It
doesn
t
then lookf or
opens
In
the
stator
A
5
t
ALTERNATOROVERHAUL
Check the stator
f or
grounds
Leave
the ohm
meter cali bratedon the X1000
scale Touchone
leadto
anyone
stator
leadwi re Touch the
other leadto the stator
support
The needle
shouldnot move
If
It
does then
replace
the
stator as It IS
shorted
to
ground
DIODE
TESTS Fi rst
check
the
posi ti ve
di odes
Note
THE
STATOR
MUSTBEUNSOLDERED
FIRSTI Cali brate
the ohmmeter on the X1000
scale
Connect the
negati ve
blackl
lead
to the
posi ti ve
di ode
plate
Touch the
other leadto
each
of the three stator connecti on
termi nals
The needle
should
show
movement at each
termi nal Now reverse the
leads The meter
shouldnot move at
any
of the three termi nals
If the di odes f ai l
any
of these
tests then
replace
the enti re
pack
Check
the
negati ve
di odes Leave the
ohmmeter
cali brated
on the
X1000 scale
Connect
the
posi ti ve
redl
leadto the
negati ve
di ode
plate
the
plate
whi ch IS
groundedl
Touchthe ohm
meter
negati ve
lead
to each
of the three stator
connecti on
termi nals
The
needle shouldmove
at each
termi nal
If
the di odes f all
ei ther
of
these
tests then
replace
the enti re
pack
t
AG
ALTERNATOR
OVERHAUL
INSPECT
THE BRUSHES and
If
they
are worn
tonear the
brushwear li mi t li ne
replace
them
BEARINGS should
be
caref ully Inspected
If the
alternator
has
been used
f or
an extendedperi od
of ti me or If there
IS
any
questi on
about
the
condi ti on
of the
bearrngs
then
replace
them
Install the
stator In the
f ront
housi ng
li ni ng up
the
marks
you
made
durrng
assembly
t
A7
ALTERNATOROVERHAUL
h
Install
the di ode
pack
In
place
and
ti ghten
the
f i Xi ng
nut
Loosely
Install the A termi nal
nut
Resolder the three stator
coi l
lead
wi res to the
di ode termi nals Note DOTHIS
AS QUICKLY
AS POSSIBLEI Otherwi se
you
ri sk
damagi ng
the
di odes wi ththe heat
I
I
I
i i
Now Install the di ode cover and
ti ghten
the
negati ve
di ode
plate f i Xi ng
nut andthe di ode
cover screw
Rei nstall the rotor
beari ngs
on the shaf t
uSi ng
a
press
Adri ver IS not recommendedbecause It
mi ght
result In
beari ng damage
When
you
I
Install the
f ront
beari ng
don t
f orget
to
sli de
the
beari ng
retai ner onthe shaf t f lrstl
t
A8
ALTERNATOR
OVERHAUL
Rei nstall the
grease
seal
and
seal
retai ner
In the
f ront
housi ng
Next mount the
rotor In a
vi se Be sure to
protect
the rotor wi th two
blocks
of wood
Now
Install
the
f ront
spacer
pulley
andnut
assembly
and
ti ghten
the
nut to
25
29f t
Ibs
A
t
0
j
I
Now
sli de the rotor shaf t mto
the
f ront
housi ng
as
f ar
as It wi ll
go
and
ti ghten
the retai ner
f i xi ng
screws
Now
assemble the
f ront
housi ng
rotor
assembly
to the
rear
housi ng
stator
assembly
Be
sure
to
li ne
up
the
scratch
marks
you
made
when
you
di sassembled
the alternator Install
the
three
through
boltsand
ti ghten
securely
Frnally
Install the
brushes
Insulator and
brush
holder cover
Ti ghten cover screws
A9
HOWTOTROUBLESHOOT
HEATGENERATED
BUTFUSESDONOTBLOW
ORFUSESBLOW
AFTERCONSIDERABLETIME
ENGINEKEEPS
RUNNINGWITH
KEYOFF
SOMETHING DOESN T
WORK
4
4
4
STRANGETHINGS
HAPPEN
FUSEBLOWS
t
TROUBLESHOOTI
NG
HEATPRODUCED
BUT
FUSE
DOESNT
BLOW
THISCONDITION ISCAUSEDBYHIGHRESISTANCEIN A
CIRCUIT
1 LOCATETHEHEATEDAREA
t
2 LOOKFORPOORCONNECTIONS
A CORROSION
B PINSPUSHEDOUTOFCONNECTORS
C LOOSECONNECTIONS
D
FUSES LOOSE FUSECLIP ORFUSECLIP MOUNTINGONFUSEBOX
3 LOOKFORUNDERSIZEWIRE ESPECIALLYIN ADD ON INSTALLATIONS FOG
LIGHTS
ETC
I
WHEREWIREGAUGE INSTAllEDISTOOSMALLFORLOAD
PASSINGTHROUGH
IT
t
t
t
TR1
TROUBLESHOOTING
ENGINEKEEPS
RUNNINGWITHKEY
OFF
I
1Ik
ENGINESTOPS
PLUGCOIL WIRE BACK
IN START ENGINE
TURNKEYOFF UNPLUGIGNITION
SWITCH
ENGINE
KEEPS
RUNNING
I
UNPLUGVOLTAGEREGULATOR
ENGINEKEEPS
RUNNING
DOES CARBURETOR HAVEANTI
DIESELING
SOLENOID
NO
YES
I
UNPLUGCOILWIRE
I
I
ENGINEKEEPS
RUNNING
ENGINEIS DIESELING
CARBURETORPROB
LEM
I
I
UNPLUG
THIS
SOLENOIDAND
CONNECT
A
JUMPERWIRE FROMTHE BATTERY TER
MINALTOTHESOLENOIDRESTARTENGINE
AND
TURNKEYOFFAGAIN
UNPLUG
FUSES ONEATATIME
ENGINE
KEEPS RUNNING
WITH
FUSESOUT
See
Page
TR
4
ENGINESTOPS
REPLACEIGNITIONSWITCH
ENGINESTOPS
REPLACE REGULATOR
PROBLEMPERSISTS
CROSS
BETWEEN ALTERNATOR NEUTER
WIRE YELLOWAND IGNITION WIRE IN
HARNESS OR b AUTOMATIC CHOKE
RELAY
I
I
ENGINE
STOPS
See
Page
TR
5
I
t
t
t
TR2
TROUBLESHOOTING
ENGINE
KEEPS
RUNNING
WITHALLFUSES
OUT
NOWSTUDY
THE
WIRING DIAGRAM IN THE
VEHICLE SERVICE MANUAL DETERMINE WHAT
COMPONENTS GET CURRENT DIRECTLYFROMTHE IGNITION SWITCH WITHOUT FIRST
GOING
THROUGH
A
FUSE NOWUNPLUGTHESECOMPONENTS ONEATATIME
ENGINEKEEPSRUNNING
ENGINE
STOPS
REPLACETHESHORTEDCOMPONENT
THERE IS A CROSS IN THE HARNESS BETWEENTHE
IGNITION FEEDLINE ANDTHE
BATTERYFEEDLINE
1 USING THE SERVICE MANUAL MAKE A LIST OF ALL THE
CONNECTORS
AND
HARNESSESINVOLVEDINTHEIGNITION LINE
2MAKEA VISUAL INSPECTIONOFTHESECONNECTORS ANDTHE HARNESSESTHEM
SELVES LOOK
FOR
WIRES
WHICHHAVEBEENIMPROPERLYINSTALLEDOR
SHORTED
TOGETHER
REMOVETHE FUSE BLOCKANDINSPECT FORSHORTS SOMETIMES ON
NEW
CARS YOU
WILL FINDA WIRE INSERTED INTOTHE WRONGPIN OFACON
NECTOR CHECKALLWIRESAGAINSTTHEWIRINGDIAGRAM
PROBLEMPERSISTS
ONRAREOCCASIONSYOUWILLFIND
TWO
WIRESCROSSEDIN THE
HARNESS
TOCHECK
1
DISCONNECTBATTERY
2 UNPLUGALLCONNECTORSANDCOMPONENTS
3CALIBRATEOHMMETERONx1000SCALE
4 AT EACH CONNECTOR WHICH HAS BOTH BATTERY ANDIGNITION 1 1 WIRES
RUNNINGTHROUGH ITLOCATETHERELEVANTPINS
5
TEST FOR CONTINUITYACROSS THESE PINS WHEN YOU FINDCONTINUITY YOU
Wi ll KNOWWHERE YOUSHOULDEITHER REPLACE A HARNESS OR UNWRAP THE
HARNESSANDINSULATETHEWIRES
t
t
t
TR3
TROUBLESHOOTING
ENGINESTOPS
THE SHORT BETWEEN BATTERY ANDTHE IGNITION
CIRCUIT IS LOCATEDIN THE CIRCUITS
CONTROLLEDBY
THIS
FUSE
1 MAKEALISTOFALLTHECOMPONENTS
ANDRELAYSWHICHARECONTROLLEDBY
THISFUSE
2 UNPLUGTHESE
COMPONENTS ONEATATIME
ENGINE KEEPSRUNNING
ENGINESTOPS
I
REPLACETHESHORTEDCOMPONENT
THERE
IS ACROSSINTHECIRCUITSSERVEDBYTHISFUSE
MAKE A VISUAL INSPECTION OFALL
THE CONNECTORS INVOLVED LOOKING FOR
WIRES WHICHHAVE
BEEN IMPROPERLY INSTALLEDORSHORTED
TOGETHER
DONT
FORGET
TOCHECK THE FUSE BLOCK ITSELF SOMETIMES ONNEWCARS YOUWILL
FINDA WIRE INSERTED INTOTHE WRONG PIN OFACONNECTOR CHECKALL
WIRES
AGAINST
THEWIRINGDIAGRAM
NO
PROBLEM
FOUND
ONRARE
OCCASIONS YOUWILLFINDTWOWIRES
CROSSEDIN THEHARNESS
TOCHECK
1 DISCONNECT BATTERY
2 UNPLUGALLCONNECTORS
SERVINGCIRCUITS
CONTROLLED
BYTHISFUSE
3 CALIBRATEOHMMETERONx1000SCALE
4 AT EACHCONNECTOR WHICH
HAS BOTHBATTERY ANDIGNITION FUSE WIRES
RUNNINGTHROUGHIT LOCATETHE
RELEVANTPINS
5 TEST FOR
CONTINUITYBETWEENTHESEPINS WHEN YOUFINDCONTINUITYYOU
WILL KNOWWHERE YOU
SHOULDEITHER REPLACE A HARNESS ORUNWRAP THE
HARNESSANDINSULATETHEWIRES
I
t
t
t
TR
4
TROUBLESHOOTING
SOMETHINGDOESNTWORK
CHECK BATTERYVOLTAGE IT SHOULDBE FULLYCHARGED IF NOT THENCHARGE THE
BATTERYBEFOREPROCEEDINGWITHFURTHERTESTS
CHECKFUSES
1 TURNONTHECIRCUITYOUARETESTING
2TURNIGNITIONKEYTO IGNITIONON POSITION
3CONNECTTESTLIGHTCLIPTOGROUND
4 TOUCH LIGHT TOBOTH SIDES OFEACH FUSE ITSHOULDBE LIT ON BOTHSIDES
NOTE DONTFORGETANYINLlNEFUSESWHICHMAYBEINTHECIRCUIT
FUSES0K
GETOUT THESERVICEMANUALANDFINDTHESECTION DESCRIBING
THE CIRCUIT INVOLVEDCHECK TOSEE WHETHER THECIRCUITHAS
ARELAYIN IT
CIRCUITHAS RELAY
1 LOCATETHERELAYONTHECAR
2 STUDYTHE WIRING DIAGRAMTODETERMINEWHATTURNS THE
RELAYONANDOFF THIS CANBEDONE USINGA SWITCHIEG
INHIBITOR SWITCH USING THE IGNITION KEY OR USING A
SWITCHIN THE CONTROLLEDCIRCUIT IEG DIMMERSWITCHI
3 ACTIVATETHERELAY ANDLISTENTOIT
RELAYCLICKS
See
Page
TR10
RELAYDOESNTCLICK
See Page
TRl
FUSESBAD
See
Page
TR12
JI
NORELAY
See
Page
TR10
t
TR5
TROUBLESHOOTING
RELAYDOESNTCLICK
LOCATETHECONNECTOR
AT
THERELAY
IN
QUESTION
USING THE SERVICE MANUAL
DETERMINE WHICH PIN OF THE
CONNECTOR
SERVES TO
ACTIVATETHE RELAYWINDING
BECOMES
HOT WHEN THE RELAYACTIVATING SWITCH
ISTURNEDON
SET THE VOLTMETERTOLOWRANGE O3V CONNECTTHEPOSITIVE VOLTMETERLEADTO
THEBATTERYPOSITIVETERMINAL
NOWPROBE THE POSITIVE PIN OFTHECONNECTOR WITHTHENEGATNE VOLTMETERLEAD
CONNECTORPLUGGEDIN
ENERGIZE THE RELAYBYWORKING THE ACTIVATING SWITCH ANDOBSERVE THE VOLT
METER
BELOW2
VOLTS
ABOVE
2
VOLTS
See
Page
TR
B
1 NOWDETERMINE WHICH PIN OF THE CONNECTOR SERVES TO
GROUNDTHERELAY
2 PROBE THIS PIN WITH THE
POSITIVE VOLTMETER LEAD LEAVE
CONNECTOR PLUGGEDIN NOTE IF THEREIS NOGROUNDLEAD
THEN THE RELAYIS GROUNDED
THROUGH THE CHASSIS TOUCH
THEPOSITIVELEADTOTHERELAYHOUSING
3CONNECT THE NEGATIVE
VOLTMETER LEADTOTHE NEGATIVE
BATTERY TERMINAL
4
NOWENERGIZETHERELAYANDOBSERVETHEVOLTMETER
BELOW1
VOLT ABOVE
1 VOLT
I
I
See
Page
TR9
REPLACETHERELAY
t
TRG
TROUBLESHOOTING
RELAYPOSITIVECIRCUIT
RESISTANCETEST
USING
THE
SERVICE MANUALCIRCUITDIAGRAM DETERMINETHE LOCATIONOFTHE
RELAY
ACTIVATING SWITCH I E IS IT IN THE
POSITIVE
OR NEGATIVE
SIDE
OF THE
CIRCUIT
SWITCH IN
POSITIVE
SIDE
OFTHE CIR
CUIT BETWEENTHE
BATTERYPOSITIVE
POSTANDTHERELAY
SWITCH
IN NEGATIVE
GROUND
SIDE
OFCIRCUIT
FINDOPERATIONAL
DIAGRAMOFTHE
SWITCHIN THE SERVICEMANUAL TEST
THE SWITCH
USINGANOHMMETER SEE
OHMMETER
SECTION
OFTHISMANUAL
IF
SWITCH
IS 0K
1 LEAVE THE CIRCUIT TURNEDON AND
MALFUNCTIONING ALL
CONNECTORS
PLUGGEDIN
2LEAVE THE POSITIVE
VOLTMETER LEAD CONNECTED TO THE
POSITIVE
BATTERYTERMINAL
3 NOWTAKE THE
NEGATIVE VOLTMETER LEAD AND PROBE ALL
ALONG THECIRCUIT BACKINGUPTOWARDTHE BATTERY TAKE
YOUR
TIMEANDYOUWi ll LOCATE THE POINTOFHIGHRESIST
ANCEWHEN THE VOLTAGE
FINALLY
DROPS BACK TONORMAL
t
t
TR
TROUBLESHOOTING
RELAYNEGATIVE
CIRCUIT
RESISTANCETEST
USING THE SERVICE MANUALCIRCUIT DIAGRAM DETERMINE
THE LOCATION OFTHE
RELAY
ACTIVATING
SWITCH I E IS IT IN THE POSITIVE
OR NEGATIVE SIDE OF THE CIRCUIT
SWITCH IN
NEGATIVESIDEOFTHECIR
CUIT BETWEEN
RELAYAND
GROUNDI
SWITCH IN POSITIVE SIDE OFTHE CIR
CUIT BETWEENTHEBATTERYPOSITIVE
POST
ANDTHE
RELAYI
FINDTHE OPERATIONAL DIAGRAMOFTHE SWITCH
IN THE SERVICE MANUAL USING ANOHMMETER
TESTTHESWITCH SEE
OHMMETER
SECTIONOFTHIS
SERVICE
GUIDE
IF
SWITCHIS
OK
1
LEAVE
THE
NEGATIVEVOLTMETER LEAD CONNECTEDTOTHE BATTERY NEGATIVE TER
MINAL
2 PLUG IN THE RELAYSWITCHANDTURNITON RELAY
MALFUNCTIONING
3 NOWTAKETHE POSITIVE VOLTMETER LEADANDPROBE ALL
ALONG
THE
NEGATIVE SIDe
OF THE CIRCUIT FROM THE RELAYWINDING NEGATIVE TERMINAL
TO THE NEGATIVE
TERMINALOFTHEBATTERY IFYOUTAKEYOUR
TIME
YOU
WILL
FINDTHE
POINTOFHIGH
RESISTANCEWHENTHEVOLTAGEFINALLYDROPSBACKTONORMAL
NOTE
FOR ILLUSTRATION
ONVOLTAGE DROPS SEE
THE
SECTION
ON
VOLTMETERS
IN
THIS MANUAL
t
TR8
TROUBLESHOOTING
LOCATETHECONNECTORATTHECOMPONENTIN QUESTION IFTHECOMPONENTISAGAUGE
OR LIGHT IN THE INSTRUMENTCLUSTER THENYOUSHOULDPULLTHE CLUSTER OUT TO
GAINACCESSTOTHECONNECTOR
USINGTHESERVICEMANUAL DETERMINEWHICHPINOFTHECONNECTORSHOULDBE HOT
HAVECURRENTTOITl WHENTHECIRCUITISACTIVATED
SET VOLTMETERTOLOWRANGE IO3V CONNECT THE POSITIVE LEAD TOTHE POSITIVE
TERMINALSOFTHEBATTERY
I
TURNTHECIRCUITON
I
NOWPROBETHE POSITIVEWIREATTHECONNECTORWITHTHENEGATIVEVOLTMETERLEAD
LEAVETHECONNECTORPLUGGEDIN ANDCHECKTHEREADING
BELOW2VOLTS ABOVE2VOLTS
1 USING THE SERVICE MANUAL DETERMINE WHICH PIN OFTHE
See
Page
TR16
CONNECTORSHOULD BE GROUNDED NEGATIVE WHEN THECIR
CUITISACTIVATED
2 WITH THE VOLTMETER STILL SET TOTHE LOWRANGE O3VI
CONNECT THE NEGATIVE LEADTOTHE NEGATIVE TERMINAL OF
THEBATTERY
3 NOWPROBE THENEGATIVEWIRE ATTHECONNECTOR USINGTHE
POSITIVE VOLTMETER LEAD LEAVE THE CONNECTOR PLUGGED
IN ANDTURNONTHECIRCUIT
4 CHECKTHEREADING
BELOW1 VOLT
See
Page
TR14
REPLACETHECOMPONENT
t
t
TR9
TROUBLESHOOTING
STRANGE
THINGS HAPPEN
EXAMPLE ALL
PARKING LIGHTS
FLASHWHEN
TURNSIGNALSAREENERGIZED
I
PROBLEMSLIKETHESEARE
CAUSEDBY
1 BADGROUNDCONNECTIONS
2 BAD
CONNECTIONSIN
POSITIVESIDEOFCIRCUIT
3 CROSSOVERBETWEENPOSITIVESIDES OFTWOCIRCUITS
4
CROSSOVERBETWEENGROUNDOFONECIRCUITAND
POSITIVE
SIDEOFANOTHER
CIRCUIT
PRELIMINARY
ITEMS
TO
CHECK
1
GROUNDCONNECTIONS
2 IF
ONEOFTHE CIRCUITS
INVOLVED
IS
A
LIGHTCIRCUIT REMOVE
THE
TWOSTOP
LIGHTBULBS
TESTPROCEDURE
1 CHECK
BATTERYVOLTAGE
IT
SHOULD
BE
FULLYCHARGED IFNOT THEN
CHARGE
THEBATTERYBEFOREPROCEEDINGWITHFURTHERTESTS
2
CHECK
FUSES
A TURNONTHECIRCUITYOUARETESTING
B TURNIGNITIONKEYTO IGNITIONON POSITION
C CONNECTTESTLIGHTCLIP TOGROUND
D
TOUCHLIGHTTOBOTH
SIDES
OFEACHFUSE ITSHOULDBELITONBOTHSIDES
NOTE DONTFORGETANYINLINEFUSESWHICH
MAYBEIN THECIRCUIT
FUSES0
K
See
Page
TR
13
FUSESBAD
See
Page
TR
12
t
TR10
TROUBLESHOOTING
I
FUSE
BLOWS
I
FUSE
BLOWS ONLYWHEN ASPECIFIC
OTHER
CASES
COMPONENTIS TURNEDON
USINGWIRINGDIAGRAMIN VEHICLESHOPMANUAL
MAKE
A
LIST
OFALLTHE COMPONENTSCONTROL
UNPLUG THIS COMPONENT AND TRY NEWFUSE
LED
BY
THIS
FUSE
STEADYSHORTS FUSE
STILL
BLOWS
CONNECT
SHORT DETECTOR
FLASHER
SHORT IN WIRING BETWEEN
SWITCHAND
UNIT
ACROSS FUSE CLIP OR TERMINALS
COMPONENT
USE SHORT DETECTOR TO
FLASHER WILL START CLICKING
UNPLUG
TOTRACEIF
POSSIBLE OTHERWISE MAKE
ALL THE COMPONENTS ON THE CIRCUITS VISUAL INSPECTION OF ALL WIRING IN
ONEATATIME
VOLVED
INTERMITTENT
SHORTS YOU CANT
GET
THEFUSETOBLOW
FUSEDOESNTBLOW
FIRST TRYTODETERMINEWHENTHEFUSE
REPLACETHECOMPONENT SHORTED
BLOWS ASKOWNER FORDETAILS
HOWMANYPEOPLEINCAR
HOWMUCHCARGO
WASITRAINING
THENTRY
TOSIMULATE THECONDITIONS
FLASHER
STOPS
CLICKING
IF THIS IS NOT SUCCESSFUL THEN FIND
WIRINGHARNESS LAYOUTIN SERVICEMAN
UAL MAKE A CLOSE VISUALINSPECTION
I
REPLACE THE LAST UNITYOUDISCONNEC
OF ALL CIRCUITS INVOLVED YOU ARE
TED
AS
IT
ISSHORTED
lIKElYTOFINDWIRES SHORTEDONSEAT
TRACKS FOR EXAMPLE OR
AGAINST
CHASSIS RAILS
FLASHERCONTINUES
CLICKING
FINDWIRINGHARNESS LAYOUTIN SERVICE
MANUAL TRACE
ALONG
EACHCIRCUITIN
VOLVED USING SHORT
DETECTOR UNTIL
SHORT
IS FOUND
TR11
TROUBLESHOOTING
FUSESOK
MAKEALISTOFALLTHECIRCUITSWHICHARE ACTINGUP WRITETHISDOWN
1 NOWCHOOSEONE OFTHESECIRCUITS FINDTHE CIRCUIT DESCRIPTION ANDDIAGRAMIN
THESERVICEMANUAL FAMILIARIZEYOURSELFBRIEFLYWITHTHISCIRCUIT
2 NOWON THE CAR FIND THE PLUGCONNECTING THE COMPONENT LIGHTBULB HORN
RELAYETC CONTROLLEDBYTHISCIRCUIT
NOTE IFCOMPONENTISAGAUGEOR LIGHTIN THE INSTRUMENTCLUSTER YOUSHOULDPULL
THECLUSTEROUTTOGAINACCESSTOTHEPLUG
1 TURNVOLTMETERTOLOWSCALE
2 CONNECTNEGATIVELEADOFVOLTMETERTONEGATIVETERMINALOFBATTERY
3 TURN CIRCUIT ON AND SET UP MALFUNCTION THIS MAYNECESSITATE TURNING ON
ANOTHERCIRCUITATTHESAMETIME
4 TOUCH POSITIVE LEAD OF VOLTMETER TOGROUND TERMINAL OF COMPONENT LEAVE
ALLCONNECTIONSPLUGGEDIN
5 CHECKVOLTMETERREADING
ABOVE1 VOLT
See
Page
TR14
BELOW1 VOLT
See
Page
TR15
TR12
TROUBLESHOOTING
NEGATIVECIRCUIT RESISTANCE
ABOVE1 VOLT
USINGTHE SERVICE MANUALCIRCUITDIAGRAM DETERMINETHE LOCATIONOFTHESWITCH
I E ISITIN THEPOSITIVEORNEGATIVESIDEOFTHECIRCUIT
SWITCH IN NEGATIVE
SIDE OF THE
CIRCUIT BETWEEN THE COMPONENT
ANDGROUND
SWITCH IN POSITIVE SIDE OFTHECIR
CUIT BETWEENTHEBATTERYPOSITIVE
POSTANDTHECOMPONENT
FINDTHE OPERATIONAL DIAGRAMOFTHE SWITCH
IN THE SERVICE MANUAL USING ANOHMMETER
TESTTHESWITCH SEE OHMMETERSECTIONOFTHIS
MANUAL
IFSWITCH IS0K
1 LEAVE THE NEGATIVE VOLTMETER LEADCONNECTEDTOTHE NEGATIVE BATTERY TER
MINAL
2 LEAVE THE CIRCUITTURNEDON ANDMALFUNCTIONING ALLCONNECTORSPLUGGEDIN
3 NOWTAKE THEPOSITIVE VOLTMETERLEADANDPROBEALLALONGTHENEGATIVESIDEOF
THECIRCUITFROMTHECOMPONENT NEGATIVETERMINALTOTHENEGATIVETERMINALOF
THE BATTERY IFYOU TAKE YOURTIME YOUWILL FINDTHEPOINTOFHIGHRESISTANCE
WHENTHEVOLTAGEFINALLYDROPSBACKTONORMAL
FORILLUSTRATIONSEETHESECTIONONVOLTMETERSINTHIS MANUALI
TR13
TROUBLESHOOTING
BELOW1 VOLT
1 NOWCONNECT THE POSITIVE LEAD OF THE VOLTMETER TO THE POSITIVE BATTERY
TERMINAL
2 TOUCH THE NEGATIVE LEADTOTHE HOT POSITIVE WIRE ATTHECOMPONENT COMPO
NENTSTILLPLUGGEDIN TURNEDONANDMALFUNCTIONING
3 CHECKVOLTAGEREADING
ABOVE
2
VOLTS
See
Page
TR16
BELOW2
VOLTS
SeePage
TRll
TR14
TROUBLESHOOTING
POSITIVE
CIRCUIT RESISTANCE
ABOVE2VOLTS
IN THE
SERVICE
MANUAL FINDTHE
DIAGRAMFORTHECIRCUITON
WHICHYOUAREWORKING
NOWSTUDYITTOFINDTHE
LOCATIONOFTHESWITCH
SWITCH
IN POSITIVESIDEOFTHE CIR
CUIT BETWEEN
THEBATTERYPOSITIVE
POST
ANDTHE
COMPONENT
SWITCH
IN NEGATIVE GROUNDI SIDE
OFTHECIRCUIT
FINDOPERATIONAL
DIAGRAMOFSWITCHIN
SERV
ICE MANUAL
TEST THE SWITCH USING AN
OHMMETER SEE OHMMETER SECTION OF
THIS
MANUAL
1
LEAVETHECIRCUITTURNEDONAND
MALFUNCTIONING
2 LEAVETHEPOSITIVE
VOLTMETERLEADCONNECTEDTOTHEPOSITIVE
BATTERYTERMINAL
3 NOWTAKETHE NEGATIVE
VOLTMETERLEADANDPROBEALLALONGTHE
CIRCUIT BACKING
UP TOWARDTHE
POSITIVETERMINAL OFTHEBATTERY LEAVEALLCONNECTORS
PLUGGED
IN
TAKE
YOURTIME
ANDYOUWILL LOCATE THE POINT OF
HIGH RESISTANCEWHEN THE
VOLTAGEFINALLYDROPS
BACKTONORMAL
TR15
TROUBLESHOOTING
BELOW2VOLTS
THEREISACROSSBETWEEN
1 THEPOSITIVESIDESOFTWOCIRCUITS
2 THE POSITIVE SIDE OFONE CIRCUIT ANDTHE NEGATIVE SIDE OFANOTHER CIRCUIT
TOFINDTHECROSS FIRSTSETUPTHEMALFUNCTION
ENGINERUNNING
NO YES
WITH ENGINE OFF DISCONNECT BATTERYCABLES
RECONNECTCABLES
WITHIGNITION ON ENGINE OFF DISCONNECT AL
TERNATOR FIELD LEAD CHECK TOBE SURETHE
WIRES ARE IN THECORRECT PLACES IN THE FIELD
PLUG F TERMINAL WHITEBLACKWIRE
MALFUNCTIONHASSTOPPED
CONNECT JUMPER WIRE FROM BATTERY AND
NEUTER YEllOWWIREATCONNECTOR
THERE IS A RELAYMALFUNCTIONING
SHORTINGTWOCIRCUITSTOGETHER
MALFUNCTIONPERSISTS
MALFUNCTIONDOESNTRETURN
MALFUNCTIONRETURNS
1 UNPLUGAUTOMATICCHOKERELAY
2 UNPLUG ELECTRIC FUEL PUMP RELAY
1973 4S301
3 TRYNEWVOLTAGEREGULATOR
MALFUNCTIONPERSISTS
THEREISACROSS BETWEENTHENEUTER
YELLOWWIRE
ANDSOMEOTHERWIREINTHEHARNESS
DISCONNECTBATTERYCABLESAGAIN ENGINEOFF
See
Page
TRt8
TR1G
TROUBLESHOOTING
BELOW
2
VOLTSCONTINUED
1 DISCONNECTBATTERYCABLESANDUNPLUGCOILWIRE
2CALIBRATEANOHMMETERONTHExl000SCALE
3 USING THE SERVICE MANUAL LOCATE THE MAINWIRING
HARNESS
IN WHICH
THE COM
PONENT CONTROLLINGWIRESARELOCATED
4 UNPLUG THIS
HARNESS FROMTHEOTHERMAINHARNESS ES IN THECAR USUAllYTHERE
WILLBE
ONE
OR TWOMAIN
JUNCTION
BLOCKS NOTE
WHENYOUUNPLUGTHEHARNESS ES
MAKE A VISUALINSPECTIONOF
THE PINS SOMETIMES YOUWILL FINDTHAT THECONNEC
TORS HAVE HEATED UP AND MELTED ALLOWING TWO PINS TO TOUCH EACH OTHER
5
CONNECT ONEOHMMETER LEADTOTHE HOT WIRE AT THE COMPONENT ANDLEAVE IT
THERE
6 NOWATTHE MAINHARNESSCONNECTORS TOUCHTHEOTHEROHMMETERLEADTOEVERY
OTHERPIN ONEATATIMECHECKFORCONTINUITY
CONTINUITY
NO
CONTINUITY
CHECKTHE WIRING
DIAGRAM
TOFINDOUT
WHAT
CIRCUITTHISPIN
See
Page
TR
19
CONTROLS
DETERMINE
WHETHER THERE
SHOULD
BE CONTINUITY
BETWEENTHAT CIRCUITANDTHE ONEWHICHISMALFUNCTIONING
CONTINUITY
NORMAL
CONTINUE TESTING UNTIL ALL PINS HAVE BEEN
TESTED
CONTINUITYNOTNORMAL
PROBLEMNOTLOCATED
THERE
IS
A
CROSSOVER
BETWEENTHESETWOCIR See
Page
TR
19
CUlTS EITHERATA UNITWHICHPLUGS INTOTHE
HARNESS OR IN THE HARNESS ITSELF
TODECIDE
WHICH
IS THE CASE
ONEATATIME UNPLUGTHOSEUNITS COMPONENTS SWITCHES ETC WHICHARECONNECTED
TOTHESUSPECTCIRCUITS
CONTINUITYSTOPS CONTINUITYCONTINUES
I
REPLACETHEUNIT
I
THERE IS A CROSSOVER IN THE WIRINGHARNESS
BETWEEN THESE TWO WIRES YOUWILL HAVE TO
UNWRAP THE HARNESS TOFINDTHE CROSSOVER
OR
REPLACE
IT
TR
17
TROUBLESHOOTING
NOWDISCONNECT THE OHMMETER LEADFROMTHECOMPONENT HOT LEAD CONNECTITTO
THE COMPONENTGROUNDLEAD ATTHE HARNESS CONNECTORS ONCEAGAINPROBEEVERY
WIREWITHTHEOTHEROHMMETERLEAD LOOKINGFORCONTINUITY
CONTINUITY
CHECK
THE WIRINGDIAGRAM
TO
FIND
OUT WHATCIRCUITTHISPIN
CONTROLS
DETERMINE
WHETHER THERE
SHOULD
BE
CONTINUITY
BETWEENTHESECIRCUITS
NO
CONTINUITY
See
Page
TR20
I
CONTINUITY
NORMAL
CONTINUE TESTING UNTIL ALL PINS HAVE BEEN
TESTED
CONTINUITY
NOTNORMAL
THEREISACROSSOVERBETWEENTHESETWOWIRES
EITHERATAUNITWHICHPLUGSINTOTHEHARNESS
OR
IN
THE
HARNESS
ITSELF
TO
DECIDEWHICHISTHECASE
ONEATATIMEUNPLUGTHOSE UNITS COMPONENTS SWITCHES ETC
WHICHARECONNECTEDTOTHESUSPECTCIRCUITS
PROBLEMNOTLOCATED
See
Page
TR20
CONTINUITY
CONTINUES
CONTINUITY
STOPS
I
REPLACETHEUNIT
I
THERE
IS
A
CROSSOVER IN
THE
WIRING HARNESS
BETWEEN THESE TWOWIRES
YOU
WILL HAVE TO
UNWRAP THE
HARNESS
TOFINDTHE
CROSSOVER
OR
REPLACE IT
TR18
TROUBLESHOOTING
NOWDISCONNECT THE OHMMETER FROM THE COMPONENT LEAD
AT THE MAIN HARNESS CONNECTOR FINDTHE COMPONENT HOT
LEADON THE OTHERSIDEOFTHE CONNECTOR WHERETHECIRCUIT
CONTINUESINTOTHENEXTHARNESS
CONNECTANOHMMETER LEADTOTHIS PIN ANDCHECKEACHOTHER
PIN IN THE CONNECTORS ON THAT OTHER
HARNESS CONTINUE AS
BEFORE DISCONNECTINGEACH UNIT IN THIS HARNESS
ANDTHEN
CHECKING THE GROUND CIRCUIT FOR
CROSSOVERS
IF
YOU CON
TINUE TRACING THE CIRCUIT YOU WILL LOCATE THE PROBLEM
TR19