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I
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VOLTMETER
OHMMETER
AMMETER
SHORT DETECTOR ELECTRICAL
t t t t
SERVICE GUIDE
BATTERY
STARTING SYSTEM
CHARGING SYSTEM
HOW TO TROUBLESHOOT CIRCUIT PROBLEMS
@Nissan Motor Corporation
in U S A
t t t
t
HOW TO READ A VOLTMETER
READING 13 VOLTS
HIGH SCALE
t
VOLTAGE DROPS Turn Page LOW SCALE SCALE
SELECTOR POS
RED
POSITIVE
NEG
BLACK
NEGATIVE
NEGATIVE
POSITIVE
60 AH
M
VOLTAGE DROPS IN POSITIVE SIDE
1
TURN VOLTMETER TO
2
CONNECT POSITIVE LEAD TO BAT TERY
TERMINAL
3
TURN
4
CONNECT NEGATIVE LEAD ANCE
LOW SCALE
ON
TO
CIRCUIT TO
BE TESTED
VOLTMETER
HOT WIRE
LIGHT
MOTOR CIRCUIT TO BE TESTED
AT APPLI ETC
IN
0
3
READINGS BELOW 2 VOLTS
Positive Side of
CirCUit
OK
ABOVE 2 VOLTS Move toward
negative
battery
lead
below 2 volts tween
tested
M2
last
back along
Circuit
and check at each Junc
tlon or connection
you
and
When reading drops will find fault be
next
to
18
o POS
5
0
last
pOints
NEG
VOLTAGE DROPS IN NEGATIVE SIDE OF CIRCUIT
TURN VOLTMETER TO
2
LOW SCALE
CONNECT NEGATIVE LEAD TO BAT TERY
TERMINAL
3
TURN
ON
4
CONNECT
CI RCUIT TO BE TESTED
VOLTMETER
POSITIVE
LEAD TO GROUND WIRE AT APPLI ANCE
MOTOR
LIGHT
ETC
o
3
O
18
IN
CI RCUIT TO BE TESTED
NEG
t
5
READINGS
BELOW
15 VOLT
Ground side of
ABOVE BAD
CirCUit IS
15 VOLT
GROUND
positive
lead
toward
negative
When
OK
CONNECTION
back
along ground
terminal
reading drops
below
of
Move circuit
battery
15 volt you
will find fault between last
two
pOints
tested
M3
HOW TO USE THE OHMMETER
Set Scale IF READING SHOULD BE
Up
to 100
Ohms
Use xl Scale
Up Use
to
1000 Ohms
xlO Scale
or
xlOO Scale
Over 1000 Ohms Use xl000 Scale
2
TURN OHMMETER ON
3
CALIBRATE
gether
turn
Touch
adjusting
the two
leads
to
knob until needle
IS
at zero
t t
A
4
MAKE SURE CIRCUIT IS TURNED OFFI
5
CONNECT LEADS ever
you
re
to either Side
of what
testing
t 6
TAKE
READING SCALE SETTING
MULTIPLY
TIMES
Example Reading Off 1
IS
t
x x x
4 M
o
oo ooo
It
Scale
IS
IS
7 5
xlOO
Meter reading
IS
75
x
100
750 Ohms
WHAT THE OHMMETER IS USED FOR
USE IT TO CHECK
SWITCHES Set to
x
I Scale
should
move
Connect the leads
from open
Circuit
across
high
two
pOints
resistance
then work the sWitch
Ohmmeter
to no resistance
SPAR K PLUG AND COI L WI RES Set to
x1000
Scale
Reading should
be between
8 and 10 thousand ohms per foot
IGNITION COI L
240 Z
1 5
Primary Winding x
I Scale
Transistor Ignition
1 7
45
95
xIOOO Scale
55
116
85
Thousand Ohms
t
Through 75
117
Ohms
Ohms
Secondary Winding
Other
143
Ohms
127
11 2 168 Thousand Ohms
Thousand Ohms
t
BALLAST RESISTOR 1 3
1 7 Ohms at 68
degrees
260 Z Ballast Resistor
1 2
1 4 Ohms
both sections
together
t
TRANSISTOR IGNITION PICKUP COIL 1974
620 Ohms
19745
1975
720 Ohms
DIODES Set to x1000 Scale
Connect the leads
position you should get
reading
a
reading
For alternator testing
see
In
across
the diode
then sWitch the leads
the other you should have either very little
Alternator Overhaul
section
In
In
t
one
or no
thiS manual
CROSSOVERS IN THE WIRING HARNESS Disconnect
and set to x1000 scale
battery
of Circuit which
IS
pin the connector
malfunctioning
At harness connector
connect one lead to
Touch the other lead to all the other pinS
t
In
If you find continUity IS
normal
entitled
If
It
Isn
t
look at the wIring diagram to determine whether thiS continUity then you have located a crossover See Troubleshooting Section
Strange Things Happen
t M 5
HOW TO USE INDUCTION AMMETER
ISOLATE A SINGLE CIRCUIT NOTE THE
YOU IF
WIRES
WIRE
WANT
YOU
IN
TO
THE TEST
DON T SEPARATE
YOU ARE
LIKELY TO
GET A FALSE READING 2
HOLD
THE
WIRE
SO
AMMETER THAT
THE
OVER THE WIRE
FITS
IN THE CLIP PROVIDED
3
TURN ON THE THE METER
M 6
CIRCUIT AND READ
HOW TO USE AMMETER
MAKE SURE YOUR AMMETER HANDLE
THE
AMOUNT IN
FLOWING
RENT
THE
OTHERWISE
CAN CUR
OF
THE
CIRCUIT
METER
MAY BE
DAMAGED WHEN YOU HOOK IT UP
NEG
t
2
BREAK
POINT
THE
CIRCUIT COULD
THIS
BATTERY TERMINAL NENT WHICH
THE
BE
AT
THE
t
SOME
AT
THE
COMPO
CIRCUIT FEEDS
OR AT A CONNECTOR 3
POSITIVE LEAD OF
CONNECT THE
THE AMMETER TOWARDS THE BAT
SIDE
TERY PLUS NEGATIVE
LEAD
NEGATIVE
CONNECT THE TOWARDS
SI DE
OF
THE
THE CI R
CUlT
4
ON
TURN
READING
THE IS
CI RCUIT DOWN
IF
THE
SCALE
RE
VERSE THE AMMETER LEADS
5
NOW
YOU
CAN
READ
THE
AM
METER
M7
HOW TO USE A SHORT DETECTOR
1
Locate
wIring
harness
In
layout
vehIcle
shop
manual
2
Determine which fuse
3
Clip leads
4
When flasher starts
5
When you
of
IS
flasher
blowing unit
across
fuse
clip
clicking move detector along In shop manual wIring harness uSing diagram Needle will move when current IS flOWing
will stop
pass the shorted
pOint
the needle
pulsating
MB
HOW TO CHECK OUT THE
FIRST
KNOW THE
BATTERY
BASIC SAFETY RULES FOR BATTERY CHARGING
CHARGE BATTERIES IN A WELL VENTILATED SHOP HAVE A FIRE EXTINGUISHER HANDY
2
LOOSEN VENT CAPS BEFORE CHARGING
3
WHEN THE
YOU CONNECT A CHARGER
CHARGER
HOOK UP THE
DO NOT TURN ON THE CHARGER
LEADS FIRST
THEN TURN ON
FIRST YOU MAY GET A SPARK
WHICH COULD MAKE THE BATTERY EXPLODE
BATTERY TESTING
BATTERY RATINGS BY MODEL
Turn
Page
ORIGINAL EQUIPMENT
AMPERE HOURS
1976
1975
1974
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
B110
50
50
50
60
60
521
1973
1972
9971
1970
1969
1968
50
50
50
50 60
40
40
520
40
SR L311
40 50
40 50
40 50
SPL311
40 50
40 50
40 50
L60
60
M9
How to check the
battery
PRELIMINARY
CHECKS
Visual
battery rating against that factory equipment see chart
Inspection of original
a
Check
b
Check for cracks and warpage of the
c
Make
sure
d
Check
aCid
e
Make
sure
vents aren t
f
Make
sure
top of battery
cables level
are
clean
3 8 Inch
and
above
case
tight PROPER ACID LEVEL
plates
clogged IS
CLOGGED VENTS
clean
CORROSION
CHECK A H RATING
CRACKS
WARPED CASE
2
BATTERY LEAKAGE TEST sure
the
battery
IS
not
Check
discharging
to make
across
the
top between the two posts Set voltmeter
b
Touch negative lead of voltmeter to nega tive
c
t
to low range
a
battery post
Touch the positive to
the top
of the
lead of the voltmeter
battery
and
move
It
around If the
o
t
o
Q
OVER
5
VOLT
CLEAN BATTERY
t M l0
o
reading
the top of the
goes
over
battery and
5 volts retest
then clean off
BATTERY CAPACITY l BOd Oll
A
S
TEST
VOLTS
o
0
o
LOAD CONTROL
o0 0
AMP HOUR
3 TIMES
RATING
15 SECOND HOLD
3
BATTERY CAPACITY TEST
a
With
battery
turn
load knob until
connected to tester
battery rating Example
IS
Battery rating Amps
60
Ampere
voltage
or
above
If
voltage
Hours
draw
Hold thiS draw for 15 seconds at
shown
shown
Turn load to 180 b
as
draw of 3 times the
a
remains
then look
at 96 volts
THE BATTERY IS GOOD
You
need not
perform any further tests If volt age drops below 96 volts then proceed to the next test
4 THREE MINUTE CHARGE TEST To
be
performed only If battery Capacity Test In step
THREE
has failed the number 3 a
Connect
a
good quality
Turn
charge c
After
rate
three
voltmeter 15 5 volts nance
charger
the
0
to
a
If It
16 5 for
IS
below 15 5 volts
over
Mainte the bat
tery should be replaced IS
t
000
check
minutes
Free Batteries
00
fast
not over 40 amps
reading
t
bat
tery Remove cell caps b
MINUTE
BATTERY CHARGE TEST
If It
then pro
ABOVE 15 5V REPLACE BATTERY
ceed to step number 5
t M 11
5
Connect the
CELL TEST UNDER CHARGE tester and the
4 Set to fast
battery charger 40 35 charge rate
as In
Amps
a
Turn to low range voltmeter
b
Attach
special
cell
step number
probes
to
voltmeter
leads c
Touch positive probe
to
battery positive
terminal d
probe In the battery cell battery positive post WR ITE the voltmeter DOWN reading
Stick the black the
nearest
e
probe In the cell near positive post Put the negative probe the next cell down Record the reading
Now put the positive est the In
f
Continue the
g
on
down the
battery
reading
When you get to the pOint where the POSI tive
probe
IS In
the last cell of the battery
touch the negative probe post Record thiS reading h
recording
each time
You should
now
have
to the
seven
reading to the last readings They should all
readings
Now add
the first
thiS Will give you
SIX
be within 2
tenths more
volt of each other
If
one
cell
two varies
than thiS amount from any other then the
battery
IS
bad and must be
replaced
24 26 26
24
26
2
26
26
26 2
M12
negative
SA TTERY
CELL
TEST
UNDER
FAST CHARGE RATE ALL CELLS WITHIN
CHARGE 2 VOLT
READING 2
READING 1
t t READINGS 3
6
READING 7
t M 13
STARTER TESTING
STARTER OVERHAUL PROCEDURES 1200 AND 8 210 TO 1975
t
STARTER OVERHAUL PROCEDURES ALL L SERIES ENGINES
I
STARTING SYSTEM
I
t
t
STARTING
SYSTEM
Testing
I
First
I
Check The
Turn
No
Click
Key
To
I
Battery
Click
or
See Pull
ally
Ignition
Start
Black Yellow
Lead
Ter
No
Light Between Battery Negative
Have Someone Turn
Light
See Page S 5
Page S 2
Usu
Wire
This
mmal
Starter turns
Off At Starter
Connect Test And
t
I
Start
t
Key
Light See
Page
S2
t
t 81
TESTING STARTER CURRENT DRAW
Connect Tester Turn SWitch To
Pull Out COil WIre From Distributor
I
Crank
Engme
Cap
Speed See
Page
S3
Not From
Read Current Draw
Less than 150 Amps
slow
Starter
Coil
And Ground It
I
Amps
More than 150
Amps
Plug COIl Wire Back In Start Engme But Hold Key Over To
Speed normal
Start
Starter O K
So That Starter Does Not
Stop
1Ik Starter turns fast
Starter draws
less than 60
than 60 Amps
Tight Engine
Short In
Mechamcal
Sta rter
Problem
S 2
Amps
Overhaul
more
TESTING
FOR VOLTAGE DROPS IN STARTER POSITIVE CIRCUIT
I
I
Turn Voltmeter To Low Scale
Touch Positive Lead To Positive Post Of
Battery
Not To Cable
t Connect
Negative
Lead To Solenoid
M
Terminal
Pull COIl Wire Out Of Distributor
Terminal Connected To Starter
Cap
And Ground It
t
I
Crank
I
Engine
More than 1 Volt
Less than 1 Volt See
Move
Negative
Lead To
B
S4
Ter
mlnal Of Solenoid
Terminal Con
nected To
Crank
Battery
Page
Engine
I More than 1 Volt Bad Connec
Solenoid
tlon Between
Bad
Battery
And
t
Less than 1 Volt
R
R
Solenoid
Solenoid
t 53
TESTING
FOR VOLTAGE
I
DROPS
IN
STARTER
GROUND CIRCUIT
I
Turn Voltmeter To Low Scale
Connect Negative Lead To Negative Terminal Of Battery
t Hold Positive Lead To Starter
I
t
Crank
More than 0 5 Volt Bad Ground mmal
Check
Battery
Make Good Connection I
I
Engme
Less than 0 5 Volt Ter
Cable Ground Connections
And Starter Bolts
4 8
Housmg
See
Page
S 5
TESTING FOR VOLTAGE DROPS IN IGNITION SWITCH STARTER SOLENOID CIRCUIT
I
I
Turn Voltmeter To Low Scale
Connect POSitive Lead To Positive Terminal Of
Battery
t Connect
Negative
Lead To
Bayonet
Connector
Black Yellow
At Solenoid SWitch
Leave B Y Wire Connected
I
I
Ground COil Wire
I
I
Crank Engine
Less than 1 5 Volts
More than 1 5 Volts
Open Connect
Jumper
Wire
Battery
Positive
Terminal
The
S
Terminal
t
Between
In Starter
Overhaul
And
On SolenOId
11 Click Open
No click
Automatic
Ignition SWItch Neutral Safety Relay Transmission
Starter
does not turn
In Circuit
Connectors
lock
Starter turns
Bad Solenoid
Inter
11
Relay
L Series
R
Engines R
SolenOid
Ot hers
R
R
Overhaul
Sta rter
55
I
I
1200 AND B 210 TO 1975
@
D
@
j
@ I
Gear housl ng 2
Dust
cover J
3 Shift lever
0
4 Gasket 5 Shift lever pIn 6 Sol enold sWitch 7
00
6
Center support
8 Armature
@
9 Thrust washer
j
@
10 BushIng 11
PInion stopper retainer
12 Snap ring 13 PInIon stopper
t
14 PInion 15
Overrunning
c1tuch
Bendix
16 Field cOil 17
Field
18
Brush band
hOUSIng
19 Brush 20 Rear 21
cover
Through
bolt SOLENOID SWITCH TERMINALS
B
Battery connected
M
Motor
S
Solenoid sWitch
to
battery
connected to starter field
In
activated by Ignition start
position
81
B 210 f a
c
D
yr L
fl
Jlf key
the nut securing the starter field lead to the solenoid M terminal and remove the
Now
then
remove
lead
Remove the two
screws
Remove
remove
locking
pin
the cotter
I
and the shift lever
the solenoid whIch
secure
the sole
nOid
t Remove the brush move
the
screw
cover
or
band
which connects
and then
re
the positive
brush to the field
Now
remove
easier
to
bending
do
a
underneath spring and
nail
the positive If you
brush
make
a
ThiS Will
be
tool
by
Simple
Now hook the end of the tool
the brush remove
spring
pull
up
on
the
the brush
t
Now
remove
the end
plate
the two
through
bolts and
pull off
Next gear
separate the field housing from the
housing
You may have to tap
the armature shaft uSing a
plastiC
starter
lightly
t
on
hammer
B2
B 210
Next
the armature out of the gear
pull
To
remove
the
locking
the overrunning clutch first clip from the stop ring
remove
housing
I
I I
Next ture
push
the stop ring down toward the
arma
This will expose the snap ring
Remove the snap ring uSing a tool as shown and slide the overrunning clutch off the armature shaft
t Preliminary
checks before
Check the ring gear
on
teeth
or excessive wear
have
to
replace
cleaning
the engine for of the teeth
the ring gear
In
chipped
You may
severe
cases
Inspect
t
the field cOil lead where It goes
to grommet comes
B 3
Into
grounded
the starter
through
ThiS of
out causing a SHORT
n
pe
B 210
Check the inside of the brush field
housing around the might find a ring of solder
tell you
cover
commutator
and lost
some
has spun too fast of ItS solder It might
also tell you that the starter has been on
clutch
You
which would
here
that the armature
overheated
up
and the
the ring IS
not
gear
because
hanging
the overrunning
working properly
Cleaning DO
NOT USE
housing ation
grease
on In
fall later
USing
SOLVENT except
air
the field
t
the gear
on
I If you do you
the insul
might damage Windings or dissolve
the overrunning clutch
the
causing It to
on
carefully
blow all parts clean
I nspectl on
t CHECK THE ARMATURE
A visual inspection
Look at the solder JOints around the commuta Be
check this If you found solder
should show you whether the armature has been
tor
dragging on the fields This Will cause shorts and might have permanently damaged the armature
inside the field hOUSing
sure
to
t 84
8 210
Inspect the shinY when
commutator
It should be clean and
you put the starter back
so
It
of
sandpaper
will be necessary to clean It uSing or
commutator
I
together a
strip
Check
paper
to make sure there IS a groove between the bars
of the commutator to make
If there
you will have
t
Isn
one
t Now the
place the armature on a growler and turn growler on Lay a hacksaw blade on top of
the armature
blade sticks
and
turn
the armature
to the armature
If the
then you have
short and the armature will have to be
Next test
a
replaced
check the armature for opens USing the section of the growler touch one lead
light
to anyone of the commutator
the other lead tator
touching
should be lit there
IS
segment
an
65
all
run
segments Take
It around the commu
of the segments
The
light
every segment If It Isn t then the solder connection at that In open
or
If any opens
t
and
on
there
are
IS an
open inside the armature
indicated
replace the
armature
8 210
Next to
touch
one
the shaft
segment of the the
light
Will
lead of the continUity tester
and touch the other lead to any commutator
go
on
If
It
If there does
IS a
short
replace
the
armature
Inspect
t
the
splines on the armature shaft If are any rough spots or burrs they will keep the bendlX from sliding one way or the other and cause the starter to hang up on the or else not to at all flywheel File off engage there
any burrs
t
CHECK THE OVERRUNNING CLUTCH Hold the outSide of the clutch and turn the gear It should turn with a slight smooth drag In one directIOn turn
In the other direction
It should not
If It does not give you positive indications
replace the assembly Also check the gear teeth for chipped teeth and replace the gear If you find any
L
t 86
B 210
CHECK THE around
the
FIELDS
by connecting lead
then there
the
lead
of the tester
JOint
touching In
open
to the
the brush With the
The light should IS an
solder
Check the fields for OPENS
one
field lead and
other
and
windings
between the fields
main
Look at the insulation
turn
the field
on
If not
and the fields
should be replaced
Check the fields for shorts
t
touch
one
lead of
the continUity tester to the field lead and the other lead to the field not
have
If It does
light to replace
hOUSing The light should
you have
a
short and Will
the fIelds
r t
To the
replace the fields hOUSing on a Vise
may
cause
screws
t B 7
and
use an
warpage of the
replace
Impact tool
but do not
hOUSing
the fields
tighten
Place as
thiS
Remove the
q
B 210
CHECK THE BRUSH PLATE positive brush holder to make from the the
one
check the
It IS Insulated
lead of the tester to I
and then touch the other lead to the
plate
brush
Touch
plate
First sure
holder
entire brush
If the
plate
Check the brush for opens
touch
light
replaced
brush
plate negative one
then the
comes on
Will have to be
lead to the
plate
t
holder and the
other lead to the negative brush does not go
If the light then REPLACE THE BRUSH
on
PLATE
THE
CHECK starter In
check for Side
cover
bushing place the
play
a
short
If that bushing
Replace IS
bad
the shaft
t
Too
drag
the entire The other
replaced separately If you re bushings be sure to check that the shaft turns freely In them before
can
armature
In
allow the armature to
the fields causing
brush
BUSHINGS
Place the armature
hOUSing bushing and play here will gear
the
much on
STARTER
putting the
be
starter
back together
l
t B 8
8 210
CHECK THE BRUSHES for be at least 3 4 of their any doubt
wear They should original length If there IS
them
replace
TESTING THE SOLENOID
t
You will need two
jumper wire from the terminal to the positive post of a battery Next connect a second jumper wire to the nega
jumper
wires
Connect
a
S
tive
post of the battery and touch this
the solenoid
The solenoid
housing
wire
should
to en
gage with a weak pu II you may have to push It part of the way In This IS a test for the hold In
winding which keeps the starter engaged with If you feel no pull at all replace flywheel
the
J
the solenOid
t
Next
check the
pOSitive jumper move
the
ground
pull
hooked
wire
to the
terminal connected When
you
ground
should be activated more
not
than
strongly replace the
NOTE
replace
89
up
and did
In
simply the
terminal
starter
should
the
field
wire
the solenoid
pull
In
much
the first test
i
If
solenoid
Even If the solenoid passes these tests If earlier tests Indicated It to be It
defective
t
to the
and
M
thiS terminal
It
Leave
Winding
In
lead
i
8 210
The
solenoid
Just push the shown
and
travel
should
also be
plunger against
a
Inspected
hard surface
as
the distance between the
measure
tip of the plunger and the face of the solenoid The distance should be 31 7323 millimeters or
1248
272 Inches
THIS MEASUREMENT
IS VERY IMPORTANT
If It
IS
Incorrect
the solenoid Will
not engage properly flywheel and Will either hang up bendlx damage or else grind off the
the
rI
then
with the causing teeth of
ng gea r
t
Re Assembly Install
the center support and
the armature down
on
snap ring
Next
shaft
the bendlx
place
the stop
on
ring
the shaft and Install the snap ring and
clip
t Install the gear
armature
hOUSing
and shift lever
In
the
and engage the solenoid
the shift lever
In
I nstall the shift lever Pin I
I 1 A
I
t 810
8 210
Now mstall the
Install the
two
cotter
key
solenoid attachmg
screws
1
t Next
B 11
slide the fIeld housmg
over
the armature
B 210
Install the brushes and tIghten the screw ter mlnals connecting them to the field and to
ground
Now stall
Install the end any spacers
plate
or
Don t
forget
to
re
shIms whIch you mIght
have removed from this end
Next
replace the brush band
8 12
8 210
Finally solenoid
Install M
the
field
wire
on
the
terminal
Final bench test
This
test
some
requires
expertise
so
perform
carefully Install the starter
firmly
In a vise
Connect the negative clamp of
battery charger
to the starter gear
high quality housing flange a
Connect the positive lead of the battery charger to the solenoid
8
Turn the
charger
on
Connect
a
Jumper
terminal
wire
nal and the solenoid
5
between the
8
termi
terminal The solenoid
should engage and the starter should turn the current draw should not exceed 60 amps
B 13
and
It
I
I
ALL L SERIES ENGINES
CV
CD
@
@
j
@
l
rt 3@
@@ 0
2
Shift lever pin Gear hOUSIng
3
Dust
1
o
j3 @ @ v
cover
@
4 Shift lever 5
Gasket
6 Solenoid sWitch 7
ass
y
Armature
8 Thrust washer 9
BushIng
10 Thrust washer 11
Pinion stopper retaIner
12
Snap
clip
ring 13 PInion stopper 14 PInion 15
OverrunnIng
16
FIeld coil
clutch
@ j6 @
17
Field hOUSIng 18 POSItIve brush 19
Negative
brush
20 Brush spring 21 Brush holder 22
ass
t
y
BushIng
23 Rear 24
Bendix
cover
Through
bolt
SOLENOID SWITCH TERMINALS
B
Battery
M
Motor connected to starter field
S
Solenoid SWitch
In
connected to battery
activated by Igmtlon start
position
L1
L SERIES
Disassembly Remove the nut securing the starter field lead to
the solenoid
lead
M
terminal
Remove the two
solenoid and
remove
over
through
the
bolts
end
holding
and
remove
which
secure
the the
the solenoid
Remove the two small cover
screws
screws
securing the brush
plate
Remove
the starter
the two
together
f
t I
Now
which
remove are
hook out spring
on
remove
the two pOSitive brushes
soldered of
a
to the fields
nail
each brush
Make
and hook It Pull up
on
brushes a
Simple
behind the
the spring and
the brush
t L2
L SERIES
1 I r
Now slide the brush
plate off the
commutator
Be careful not to lose any washers
or
spacers
1
p
@
JiJ Remove
the fIeld
housing You plastic hammer
to
may have on the arma
1
Il I
tap lightly with a ture shaft to separate the field housing from the gear
housing
J
J
I
t Now
remove
locking pin gear housing
t l3
the
Next
nut
pull
washer and the shift lever the armature out of the
CDI J
L SERIES
Now
remove
the overrunning clutch
First slide I
the
locking clip
off the gear stop ring
iI I
f I
f
Now
ring toward the gear Now the snap ring Removal of this snap ring will be easier If you have a tool such as the one shown When the snap ring has been re you
push
the stop
can see
moved
slide
the
overrunning clutch
off the
armature
t Preliminary
checks before
Check the ring gear teeth
on
or excessive wear
have to
replace
cleaning
the engine
for
of the teeth
the ring gear
In
chipped
You may
severe
cases
t 4 L
L SERIES
q
the field coil lead where It goes
Inspect
the grommet comes
the starter
Into
grounded
out
Check the Inside of the brush find
a
cover
around the commutator
housing
of solder
ring
here
through
often
and the field You
fast
and
lost
some
also tell you that the up
on
clutch
the IS
not
nng gear
might
which would
you that the armature has been overheated too
of ItS solder
starter
be
SHORT
a
causing
This
tell spun
It
has been
might hanging
because the overrunning
working properly
LL
t Cleaning DO
NOT USE
SOLVENT except on the gear OtherWise housing you might damage the insul
t L 5
ation
on
grease
In
USing
air
the field
Windings
or
dissolve the
the clutch causing It to fall later
carefully
blow all parts clean
on
L SERIES
InspectIOn CHECK THE ARMATURE should been shorts
show
you
dragging and might on
A
vlsualmspectlon
whether the armature This
the fields have
will
has
cause
permanently damaged
the armature
Look at the solder JOints around the tator
Be
sure
to check this If you
Inside the field
Inspect
found solder
housing
the commutator
It should be clean and
sh InY before you put the starter back so It will be necessary to clean It uSing commutator
sandpaper
or
make
there
sure
IS
of the commutator to
make
commu
a
paper
t
together a
strip of
Check to
groove between the bars
If there
Isn
t you Will have
one
t L 6
L SERIES
Now
place
the armature
the armature
on a
growler
and turn
If the blade sticks to the armature
then
you have a short and the armature have to be replaced
Next test
will
check the armature for opens
light
section
of the
growler
to anyone of the commutator
the other lead and tor
touching
should be lit there
IS
an
all on
one
lead
segments Take
It around the commuta
of the segments The light If It Isn t then every segment
open
that segment
run
the
USing
touch
or
In
the solder connection
there
IS an
open
at
inside the
armature
t If any opens
t L7
are
indicated
replace
the armature
L SERIES
Next
touch
one
lead of the continuity tester
and touch the other lead to any of the commutator If there IS a short segment the light will go on If It does replace the to
the shaft
armature
JI
Inspect
the
splines on the any rough spots
armature
there
are
keep
the overrunning clutch
or
shaft
burrs
from
will
they sliding
one
way or the other and cause the starter to up on the
flywheel
or
If
hang
else not to engage at all
File off any burrs
CHECK THE OVERRUNNING CLUTCH the outside of the clutch should turn direction turn
with
a
slight
Hold
and turn the gear smooth
In the other direction
drag
In
It should
It one
not
If It does not give you positive indications
replace the assembly Also check for damage and replace If you find
the gear teeth any
L S
L SERIES
CHECK THE around
the
FIELDS
windings
between the fields
by
at
the solder JOint
Check the fields for OPENS
nectlng the lead of the tester to the field lead and touching each of the brushes
con
main In
Look at the insulation and
turn
not
The
there
IS
should go on each time If open and the fields must be
light an
replaced
Check the fields for shorts the continUity
light
should not go
on
short and will have to
t
touch
to the field
tester
If It does
one
lead of
hOUSing you
The
have
a
replace the fields
To
replace the fields use an Impact tool Place hOUSing on a Vise but do not tighten as thiS may cause warpage of the hOUSing Remove the screws and replace the fields the
I
I I
I
t L 9
L SERIES
BRUSH PLATE
CHECK THE positive ated tester
First check the
brush holder to make
from
It
IS
insul
lead of the
the
plate Touch one plate and then touch
the
to
sure
the other
lead to each of the two positive brush holders If the light comes on then the entire brush plate will have to be
replaced
JI
J Check the brush for opens other to
light
touch
lead to the
one
brush
holders
plate
and the
each of the negative brushes
does
BRUSH
plate negative
not
on
go
then
If the
REPLACE
THE
PLATE
4
CHECK brush Place
THE
cover
STARTER
and
the armature
check for side
the
In
shaft
play
allow the armature to a
short
Replace bad
bushing placed separately IS
be
sure
BUSHINGS starter In
on
If you
hOUSing bushing and play here will gear
the fields causing
the entire brush The other
the
the
Too much
drag
In
cover
If that
be re bushing the replace bushings can
to check that the armature shaft turns
freely In together
them before putting the starter back
J
L 10
L SERIES
CHECK THE BRUSHES for IS
any doubt
new
replace
brushes
solder
Iron
NOTE
be
wear
11
If there
and
them
sure
to ensure a
When you solder In to use a well tinned hot
good JOint
Brushes should be replaced when they are less than 3 4 of their Original length
L
TESTING THE SOLENOID
You Will need two
jumper wires Connect a jumper wire from the S terminal to the positive post of a battery Next
connect
wire
a
second
the
to
solenoid
should engage with to
push
It
the hold
a
hOUSing pull
The
this
solenoid
you may have
Th
In
r
the
to
and touch
weak
part of the way
wire
jumper
post of the battery
negative
h f
IS IS a
Winding which keeps engaged With the flywheel If you at all replace the solenoid In
test
for
the starter feel
no
pull
I I
Next
check the
pull
In
Winding
Leave
the
Jumper lead hooked up and Simply the ground wire to the M terminal
positive move
the terminal wire
connected
When you
nOid should
ground
be activated
strongly than replace the solenoid more
NOTE
replace
the starter
and
field
the sole
should pull
It did In the first test
I
In
If not
Even If the solenoid passes these tests It If earlier tests indicated It too be
defective
L 11
to
thiS terminal
I
L SERIES
Reassembly Replace Be
sure
the overrunning clutch
clip
IS
firmly
In
on
armature
place
Reinstall the armature
In
the gear
while also positioning
the solenoid shift
lever
pm
core
and
lockmg
F
housmg 0
rl
t
L Slide the field housmg to the gear
housmg
the armature and up
Now mstall the end
Jq i
r
plate
ol
the negative brush springs to allow
pullmg up the plate to slide the plate part way on
over
r
onto the commutator on
Place
the commutator
I r
t
f J
L12
L SERIES
1
holders
place the positive brushes m their pulling back on the sprmgs to allow the brushes to slide mto place Next push the brush plate all the way mto place Now
Install the brush washer
sl which
disassembly small cap
cover
you
Don t
forget the
thrust
may have removed upon
Install the
through bolts and the
retainer screws
c
j
f
Q
lf r r
4 Install the solenoid and
ItS
gasket
r
L13
1
L SERIES
Install
the
field
wire
on
the
solenoid
M
terminal
Measuring the
With pinion
solenoid
energized
omlO 1
rear
clearance
measure
edge
059
by adding
be
5mm
between
removing the
washers
020
NOTE
1978 3
are
1
mm
I
19 1
JIl
The
stopper
3 and
1 5mm
adjust clearance adjusting washers
available
8mm
and
In
1
remove
located between the solenoid and the gear
AdJustmg
I 5
If necessary
In or
10
112
between the
and the pinion
should
012 and
clearance
o 3
drive
the
push
toward the front of the starter to
all slack and
1
1
Clearance
models
only
25mm
012
two
In
case Sizes
031 Clearance
1
IS
098m
Final Bench Test
This
test
some
requires
expertise
so
perform
It
carefully Install the starter
Connect
battery flange
firmly
In a vise
the negative clamp of charger to the starter
Connect the positive lead of the to the solenoid
B
Turn the charger
on
Connect
a
Jumper
a
high quality housing
t
gear
battery charger
term mal
wire
nal and the solenoid
5
between the
B
termi
terminal The solenoid
should engage and the starter should turn on and the current draw should not exceed 60 amps
L14
SPECIFICATIONS
SCOPE
I
t
t
THE CHARGING SYSTEM
TESTING
CHARGING SYSTEM
1
Check Battery Going On
Make Sure It Is OK Before
2
Check Alternator Belt
3
If You Have
TESTER
TEST LIGHT AND VOL TMETER
ALTERNATOR OVERHAUL PROCEDURES
t
t
t t
ALTERNATOR SPECI FICATIONS
1
RATED OUTPUT
To
Find
Working Will
The On
Rated
Of The Alternator You
Find A Series Of Identification Marks LT1
Figures Amperage Rating The
EXAMPLE
2
Output
Look On The Alternator Front
The
Next
Two
Housing
Are You
Now Look For
Numbers
Are The
Of The Alternator
LT160
60
Amperes
Rated
t
Output
OUTPUT MEASUREMENT
The Actual
Output
Which You Will Be Able To Read Will
On Whether Your Tester Is Connected
Depend
The Alternator Or To The
At
Output
A
Terminal
Same As Rated
Directly
To
Battery Output
Output
At
Battery AMPSI
Terminals
AMPSI
NOTE
25
18
33
24
35
28
50
375
60
45
Don t
Reading
t
Forget To Add 5 To 10 Amps To The Meter USing A Chargmg System Tester Such As
If You Are
The Vat 28
I
t 3
VOLTAGE SETTING
No Load
Fully Charged Battery
143
153 Volts
All Models
t t Co1
20KV
40KV
15KV
30KV V
V
10KV
v 20KV
5KV
v 10KV
OKV
15 5 5 40 35 30 25 20 10 I r I I 1111 till I I I 11 I 30 10 90 80 70 60 50 40 20 I I I I I 1 1 I I I 60555045403530252015 10 5
r m
V OKV o
14
CYL
06
CYL
1
t
t
LOW VOLTAGE PICKUP LEAD
t t Co2
CHARGING CIRCUIT TESTING WITH A SCOPE
1
TURN SCOPE ON
2
SET VOLTAGE SWITCH TO
3
TURN VOLTAGE TO LOW SCALE
4
ATTACH LOW VOLTAGE PICKUP LEADS
DISPLAY PATTERN1POSITION PRIMARY
RED TO ALTERNATOR
0 40VI
BAT
OR
A
BLACK TO ALTERNATOR GROUND OR
5
START ENGINE SPREAD
OBSERVE PATTERN
HORIZONTAL
TERMINAL E
TERMINAL
ADJUST PAHERN FOR GREATEST
CHECK PATTERN AGAINST THOSE SHOWN
AI
PATTERN NORMAL
Bl
PATTERN BAD
See
4 Page
C 5
NORMAL
OPEN
DIODE
See
Page
C 7
4
SHORTED DIODE
Cl
NO PATTERN
See
Page
C 9
OPEN STATOR
ftt r r
r
r
SHORTED STATOR
C3
PATTERN NORMAL
ATTACH
VOLTMETER
TO BATTERY TERMINALS
START ENGINE
RUN AT
RPM
2000
FOR 10 SECONDS CHECK VOLTMETER READING
14 3
15 3 VOLTS SYSTEM 0 K
LOW OR HIGH POSITIVE CIRCUIT RESISTANCE TEST LEAD TO ALTERNATOR POSITIVE
TERMINAL
A
OR
TURN ON
BAT
SET VOLTMETER TO LOW SCALE TOUCH TERMINAL
HEADLIGHTS
POSITIVE
TOUCH NEGATIVE LEAD TO BATTERY
HIGH
BEAM
AND
HEATER
FAN
HIGH
SPEED RUN ENGINE AT 2000 RPM
ABOVE 2 VOLTS
BELOW 2 VOLTS TOUCH NEGATIVE VOLTMETER TOR
E
LEAD
TERMINAL
TO
SCALE
BATTERY
RUN ENGINE
LEAD TO AL TERNA
TOUCH POSITIVE NEGATIVE
CHECK
VOLTMETER
LOW
TERMINAL
LIGHTS AND FAN ON
ULATOR
RUN ENGINE
CONNECTION
IN
WIRE
BETWEEN
TERMINAL AND BATTERY
1973
t
COMPARTMENT
ABOVE 0 5 VOLTS BAD GROUND CONNECTION BETWEEN ALTERNATOR
LEAD TO OUTSIDE OF REG
AND BATTERY
HEADLIGHTS AND FAN ON
t
ABOVE 0 5 VOLTS
BELOW 0 5 VOLTS
I
A
PANEL IN PASSENGER
LEAVE NEGATIVE LEAD CONNECTED AT AL TERNA TOUCH POSITIVE
BAD
1974610 CHECK CONNECTOR BLOCK AT RIGHT KICK
BELOW 0 5 VOLTS
TOR
FOR
ALTERNATOR
I
REPLACE REGULATOR
BAD GROUND CONNECTION BETWEEN ALTERNATOR AND REGULATOR
t NOTE
MAKE
SURE
THAT
A CHARGED CONDITION
THE
BATTERY
FOR THIS TEST
IS
t
IN
OTHERWISE
VOLTAGE READING COULD BE INCORRECT
C 5
B W
B
W B
or
W L
y
t
W
W R
REGULATOR CONNECTOR HARNESS SIDE
B
Ground
y
Neuter
W B
Field
W
From
W B
t
W R
t C G
From
to
A
Alternator
terminal
Termrnal
Ignition
From Dash
N
SWitch
early
models W L
Charge Warning Light
BAD PATTERN
SET
VOLTMETER
BAT
TERMINAL
ON HIGH RPM
BEAM
TO LOW SCALE
TOUCH POSITIVE
TOUCH NEGATIVE
LEAD TO
LEAD TO ALTERNATOR
A
BATTERY POSITIVE TERMINAL
HEADLIGHTS AND HEATER FAN
HIGH SPEED
OR
TURN
RUN ENGINE AT
2000
CHECK READING
BELOW 2 VOL TS
ABOVE 2 VOLTS
TOUCH NEGATIVE VOLTMETER LEAD TO AL TERNA TOR
E
TERMINAL
TOUCH POSITIVE VOLTMETER
LEAD TO BATTERY NEGATIVE TERMINAL GINE AT 2000 RPM
CHECK
RUN EN
TERMINAL
OUTSIDE OF
A
CONNECTION
IN
WIRE
BETWEEN
TERMINAL AND BATTERY
ABOVE 0 5 VOLTS
LEAVE NEGATIVE LEAD CONNECTED TO AL TERNA E
BAD
LIGHTS AND FAN ON
BELOW 0 5 VOLTS
TOR
FOR
AL TERNATOR
TOUCH
REGULATOR
POSITIVE
RUN
ENGINE
LEAD
BAD GROUND CONNECTION BETWEEN ALTERNATOR
TO
AND BATTERY
LIGHTS AND
FAN ON
BELOW 0 5 VOLTS
REMOVE
FIELD WIRE
TO THIS WIRE
AT
TOUCH TEST LIGHT
AL T
BAD
WHITE BLACK
LIGHT
TO
BLACKIWHITE
LEAVE CONNECTOR
OR
GROUND CONNECTION BETWEEN ALTERNATOR
AND REGULATOR
LIGHT ON STEADY
LIGHT OFF OR FLICKERING AT REGULATOR CONNECTOR
t
ABOVE 0 5 VOLTS
KEY ON
TOUCH TEST
WHITE BLUE
REMOVE ALTERNATOR FOR REPAIRS
WIRE
PLUGGED IN
Overhaul LIGHT ON
LIGHT OFF OPEN TOUCH LIGHT TO WHITE BLACK WIRE
CIRCUIT
BETWEEN
IGNITION
SWITCH
AND
REGULATOR
LIGHT OFF LIGHT ON WHITE BLACK WIRE BETWEEN REGULATOR AND AL TERNATOR FIELD IS OPEN
I
REPLACE REGULATOR
I t
Co7
B W W B
B
or
W L
y
t
W R
W
REGULATOR CONNECTOR HARNESS SIDE
t t Coa
B
Ground
Y
Neuter
W B
Field
W
From
B W
From
W R
From Dash
to
A
Alternator
N
terminal
Terminal
Ignition
SWitch
early
models W L
Charge Warning Light
NO SCOPE PATTERN
TURN
KEY
ON
HOLD
SCREWDRIVER
IN
FRONT
OF
ALTERNATOR
PULLEY
CHECK
FOR MAGNETISM
NO MAGNETISM
MAGNETISM CHECK TO MAKE SURE YOU CONNECTED THE SCOPE
UNPLUG FIELD LEAD
WHITE BLACK
AT AL TERNA PROPERLY
TOR
TOUCH TEST LIGHT TO THIS LEAD
IF YOU DID THEN REMOVE THE ALTER
KEY ON NATOR FOR REPAIRS
Overhaul LIGHT ON LIGHT OFF REMOVE ALTERNATOR FOR REPAIRS AT REGULATOR CONNECTOR LIGHT
TO
BLACKIWHITE
KEY ON
OR
TOUCH TEST
WHITE BLUE
WIRE
Overhaul LIGHT OFF OPEN
LIGHT ON
TOUCH
LIGHT
TO
WHITE BLACK
CIRCUIT
BETWEEN
IGNITION
SWITCH
t
AND
REGULATOR
WIRE
KEY
ON
LIGHT OFF LIGHT ON WHITE BLACK WIRE
BETWEEN REGULATOR AND AL
TERNATOR FIELD IS OPEN
I
REPLACE REGULATOR
I
C 9
ALTERNATOR SPECIFICATIONS
RATED
OUTPUT
To
Find T1MI On
Wonung 1M
RatftI Look
A Sinn
Will FInd
L T1
FI IIS
Amplll
Output Of The A1ternatOl You Are On The AlternatOl Front Housmg You Of IdentdlClltlon Mans look For I N01I
EXAMPLE
The
Next
Two
Numbers
The
A
Of The Alternator
Rating
L T160
60 Ampern
R
Output
AMPS 2
ACTUAL OUTPUT
This
Is
The
Output
Mum The And
Actually Look
Maximum
Capable Of Produang au Test The a rglng
FOI When Y
RATED
OUTPUT
AMPS
WllIch
Alternator Is You Should
System
ACTUAL OUTPUT
AMPS
o
25
NOTE ng
33
24
35
28
50
n
60
45
Don
If You
t
Forgrrt
Are
To
1IIlng
A
Add 5 Amps
To The
ng System a g
o
000 Mater
l Test r
R
Sum
The Vat 28
3
VOLTAGE SETTING
NoL
FuIIyCharg8d
143
153Volts Model
IAII
i
B W
t
W B
B
or
W L
y
W R
W
REGULATOR CONNECTOR HARNESS SIDE
t
B
Ground
Y
Neuter
W B
Field
W
From
W B
t
W R
Co10
From
to
A
Alternator
terminal
Terminal
Ignition
From Dash
N
SWitch
0
early
models W L
Charge Warning Light
Hii
9
CHECKING THE CHARGING SYSTEM WITH A SPECIAL TESTER
CONNECT TESTER
TO VEHICLE
SEE SAMPLE
ILLUSTRATIONI
LEAVE ALL VEHICLE
ELECTRICAL UNITS TURNED OFF
RUN
ENGINE
AT 2500
RPM
TURN LOAD KNOB
UNTIL
AMMETER
GETS TO HIGHEST
READING ADD 5 TO 10 AMPS TO THIS FIGURE
AT
ABOVE
OR
WORKING
SEE
AMPERAGE
CHARTI SYSTEM 0 K
CURRENT OUTPUT LOW
BELOW SPECIFIED AMPERAGE UNPLUG FIELD LEAD NATOR TOR
WHITE
BLACKI FROM AL TER
RECONNECT FIELD
PLUG TESTER FIELD LEAD INTO ALTERNA
TURN TESTER TO
FIELD
RUN AT 2500
OBTAIN
HIGHEST
INTERNAL GROUND TYPE
RPM
TURN LOAD
READING
ADD
5 TO
KNOB
TO
10 AMPS
TO LOW
t
RANGE
TERNATOR NEGATIVE TERY
A
TURN VOLTMETER
CONNECT POSITIVE OR
BAT
TERMINAL
LEAD TO POSITIVE
RUN ENGINE
AT
SELECTOR
LEAD TO AL CONNECT
TERMINAL
2500 RPM
OF BAT
TURN LOAD
TO
10 AMPS CHECK VOLTAGE READING
CURRENT OUTPUT NORMAL ABO
TOUCH THE TEST LIGHT TO FIELD LEAD
AT
WHITE NATOR
BLACK
OLTS
OPEN IN WIRING BETWEEN ALTER
ALTERNATOR
AND BATTERY TERMI
A
IGNITION ON NAL
LIGHT NO LIGHT IGNITION
ON
WHITE BLACK ULATOR
REPLACE REGULATOR
TEST LIGHT TO THE WIRE
AT
THE
CONNECTOR
BE LOW 2 VOLTS CONNECT
NOW
REG
OF
LEAVE
TOR
LEAD OR
E
PUT POSITIVE LEAD ON
ATIVE
TERMINAL
RUN ENGINE AT
LIGHT WIRE
TO
GROUND TERMINAL OF ALTERNA
CONNECTOR PLUGGED IN
OPEN
NEGATIVE
VOL TMETER
IN
FIELD
BETWEEN
A LOAD WHITE BLACK
OF
NEG
BATTERY
2500 RPM
APPLY
OF10 AMPS CHECK VOLT
AGE READING
REGULATOR AND
ALTERNATOR
ABOVE 0 5 VOLT
NO LIGHT
BAD
GROUND
TWEEN AT REGULATOR CONNECTOR
TEST
LIGHT TO BLACKlWHITE
OR WHITE
BLUE
ON
WIRE
IGNITION
CON
MOVE
NO LIGHT IGN
CIRCUIT
t
BAT
BELOW 0 5 VOLT LIGHT
IN
AND
BE
TERY
NECTOR STILL PLUGGED IN
OPEN
CONNECTION
ALTERNATOR
POSITIVE
LEAD TO
REGU
LATOR COVER REPEAT TEST
REPLACE REGULATOR TO
REG
ABOVE 0 5 VOLT
ULATOR BAD
GROUND
CONNECTIONS
AL
TERNATOR REGULATOR
t
BELOW 0 5 VOLT REMOVE
ALTERNATOR
FOR
RE
PAIRS
t
Overhaul
C 11
CHECKING THE CHARGING CIRCUIT WITH A TEST LIGHT AND A VOLTMETER NOTE BEFORE
TEST
LIGHT TO
PLUGGED IN
STARTING TEST MAKE SURE BATTERY IS FULLY CHARGED
YELLOW WIRE
AT
REGULATOR
CONNECTOR
LEAVE
CONNECTOR
t
ENGINE RUNNING
LIGHT ON CHECK
BATTERY
VOLTAGE
ENGINE
RUNNING
AT
14 3
VOLTAGE LOW IF POSITIVE
CIRCUIT
RESISTANCE
TEST
TO LOW SCALE
TOUCH POSITIVE
A
OR
BAT
BATTERY
LEAD TO BATTERY
TURN ON
HIGH
FAN
TERMINAL
TOUCH THE
NEGATIVE
BEAM
POSITIVE TERMINAL
NO
PROBLEMS PERSIST
SURE
THAT
BATTERY
CHECK AGAIN
IS
0K
IS NO LEAKAGE CURRENT
TOP OF THE
BATTERY
TIVE CIRCUIT IN THE
HEADLIGHTS AND HEATER
LOAD APPLIED
15 3 VOLTS VOLTAGE GOOD
LEAD TO THERE
ALTERNATOR
RPM
SET VOLT MAKE
METER
3000
AND
TO
THAT
EITHER ACROSS
OR THROUGH A DEFEC
VEHICLE
IF
PROBLEMS STILL
EXIST CHECK FOR AN OPEN DIODE
HIGH SPEED RUN ENGINE AT 3000 RPM CHECK
READING
I
ABOVE 2 VOLTS
BELOW 2 VOLTS CHECK TOUCH FOR
NEGATIVE VOLTMETER LEAD TO AL TERNA
E
TERMINAL
TOUCH POSITIVE
BAD
CONNECTION A
IN
WHITE WIRE BE
TERMINAL AND BATTERY
VOLTMETER
LEAD TO BATTERY NEGATIVE TERMINAL GINE AT 2000 RPM
FOR
TWEEN ALTERNATOR
RUN EN
LIGHTS AND FAN ON
I
ABOVE 0 5 VOLTS
BELOW 0 5 VOLTS BAD GROUND CONNECTION BETWEEN LEAVE NEGATIVE TOR
E
LEAD CONNECTED TO AL TERNA
TERMINAL
TOUCH
OUTSIDE OF REGULATOR
t
POSITIVE
RUN ENGINE
LEAD
ALTERNATOR
AND BATTERY
TO
LIGHTS AND
FAN ON
I
ABOVE 0 5 VOLTS
BELOW 0 5 VOLTS BAD GROUND HIGH RANGE VOLTMETER TO BATTERY TERMINALS UNPLUG ALTERNATOR FIELD LEAD ER WIRE F
FROM ALTERNATOR
FIELD
TERMINAL
A
CONNECT JUMP
TO ALTERNATOR
RUN ENGINE
CAUTION
NOT AllOW VOLTAGE TO EXCEED 16 VOL TS
t
DO
I
VOLTAGE NORMAL 14 3
BELOW 14 3 VOLTS
CHECK
I
t C 12
REMOVE
ALTERNATOR
CONNECTION BETWEEN ALTERNATOR
AND REGULATOR
FOR
REPAIRS
I
Overhaul
CONNECTORS
FIELD WIRE
W B
15 3 OR ABOVE
REGULATOR
IF 0 K
REPLACE
ALTERNATOR REGULATOR
LIGHT OFF
tt
ENGINE OFF
IGNITION ON
FRONT OF ALTERNATOR PULLEY
HOLD SCREWDRIVER IN
CHECK FOR MAGNETISM
NO MAGNETISM PULL OFF FIELD WIRE AT ALTERNATOR TO FIELD WIRE
W
BI
MAGNETISM TEST
TEST LIGHT
LIGHT
ALTERNATOR
PROBE
NEUTER
YELLOW
LEAVE
WIRE
AT
PLUGGED
CONNECTOR
IN
KEY ON ENGINE RUNNING
LIGHT ON
LIGHT ON OPEN REMOVE
ALTERNATOR
FOR
TER
RE
Overhaul
LIGHT OFF LIGHT
WIRE TOR
AT
TO
IN
YELLOW
NEU
ALTERNATOR TO REG
LIGHT OFF
WHITE BLACK
REGULATOR
KEY ON
WIRE
ULATOR
PAIRS
TEST
CIRCUIT
REMOVE
CONNEC
ALTERNATOR
FOR
RE
PAIRS
CONNECTOR PLUG
Overhaul
GED IN
LIGHT ON OPEN
LIGHT OFF
TWEEN
TEST LIGHT TO BLACK WHITE WHITE BLUE
WIRE
KEY ON
IN
FIELD
WIRE
REGULATOR
W B
BE
AND ALTER
NATOR OR
CON
NECTOR PLUGGED IN
LIGHT ON LIGHT OFF OPEN
IN
IGNITION
CIRCUIT
TO
REGULATOR
I
I
REPLACE REGULATOR
REGULATOR CONNECTOR HARNESS SIDE
B
Ground
y
Neuter
W B
Field
W
From
B W
From
W R
From Dash
t
B W
B
W B
or
W L
y
W
W R
to
A
Alternator
N
terminal
Terminal
Ignition
SWitch
early models W L
Charge Warning Light
C 13
t
ALTERNATOR OVERHAUL PROCEDURES
CD A
mr y
rID I
Pulley
2
Front
3
rront be nng
4
Rotor
embly as cover
5
Rear
6
Stator
7
Rear
8
Bru
beanng
cover
h assembly
9
DIOde
10
DIOde
II
Through
et
pia te
em bly
cover
bolts
A 1
ALTERNATOR OVERHAUL Alternator
dlssassembly
bench
test
Touch
on
the X1 scale
lead to the alternator
F
or
field terminal
the other lead to the
E
or
ground
Calibrate
meter
the
an
Ohmmeter
should read
pulley
between
while you
are
one
Touch
terminal
The
5 and 200 ohms this and the
dOing
Spin reading
should vary slightly If the
reading
IS
the field circuit and terminals IS a
too
then there
high
brushes
If the
slip rings reading IS too
IS
an
low
open
In
windings
rotor
then there
J
short
IIi lilt
Remove
the
securrng the brush holder the brush holder cover Pull the
and remove brush holder forward and
together
USing
screws
remove
a
screwdriver
make
a
scratch mark
along
you will be able to line up the sections when you reassemble them
the side of the alternator
the brushes
so
with the brush holder
p
r
V
Unscrew the three with
a
plastiC
through
hammer
shown
the
rear
housing
and stator
MAKE SURE THAT THE STATOR
STAYS WITH THE stator
Tapping lightly
separate the front hous
Ing and rotor from the as
bolts
housing
REAR
HOUSING
comes off with the
stator wires will be
If the
front housing
damaged
A 2
ALTERNATOR OVERHAUL
V
e
Place the
rotor
It with two
order
being
a Vise
sure
Remove the three
protect
pulley fan
In
which
retainer
you
removed
can
remove
the
and
screws
from the front
bearrng
the rotor out of the front
pull
cover
and spacers Remember
00 Now you
to
blocks of wood
Remove the the
In
partsl
1lo
the spacer
seal and seal
Remove the bearings from the
reta Iner
a
bearrng puller
or
rotor
shaft uSing
press
I
Remove the diode negative diode
A 3
diode
cover
cover
screw
plate fiXing
and loosen the
nut
Remove
the
Now
use a
coil lead
solderrng
wires
gun to disconnect the stator
from the diode terminals
ALTERNATOR OVERHAUL
t1
oQ
C
00 ii Remove
the
A
terminal
nut
and
the diode
Now
pack installation nut Spread the wire retaining clamps and remove the wires from the clamps Remove the diode pack
you
can remove
the stator from the front
hOUSing
Cleaning Blow off all
parts with compressed air DO NOT USE SOLVENTI If you do the solvent might dissolve the insulation
on
the rotor and stator
windings
InspectIOn ROTOR
They
TESTS
First
Inspect the slip rings
should be clean and
then clean them
shinY
If
uSing 400 grit or Check the solder JOint between the Ings and the slip rings Often thiS breaks
loose
and
causes
they
aren
t
finer paper rotor Wind connection
alternator failure
If
It has broken loose you Will have to resolder the connection and re glue the lead to the rotor
uSing epoxy cement
t A 4
ALTERNATOR OVERHAUL
Next
check the rotor resistance
ohmmeter each If
slip
It s
the X1
on
ring The
too
reading then
high
between the rotor If It
s
too low
Next
check the
to
rotor
the connections
and the
IS a
short
slip
In
rings
the rotor
unable to repair the rotor
one
on
for
rotor
of the
slip
move at
all
rings
STATOR TESTS
Touch
one
touch
the
and
The needle should
If It does
It IS shorted to
Calibrate
grounds
the X1000 scale
other lead to the rotor shaft not
lead to
t
the ohmmeter lead
one
should be 4 5 ohms
Winding
are
Calibrate the
Touch
check
then there
If you
Windings replace It
scale
then
replace
the
ground
Visually
Inspect the
stator
for broken connections and burned insulation Next
check the stator for continuity
the ohmmeter
on
ohmmeter lead to
the X1000 one
of the
scale
Calibrate Touch
stator Wires
an
and
touch the other lead to each of the other three leads
one
at a time
The needle should
move
all
the way over each time shOWing continuity If It doesn t then look for opens In the stator
A 5
ALTERNATOR OVERHAUL
Check the stator for
grounds
X1000 scale Touch
meter calibrated on the
lead
to
anyone stator
other lead should
to
not
Touch
wire
one
the
The needle
support
If It does
stator as It IS shorted to
DIODE TESTS
lead
the stator
move
Leave the ohm
then
replace
the
ground
First check the positive diodes
THE STATOR MUST BE UNSOLDERED FIRSTI Calibrate the ohmmeter on the X1000
Note
blackl
Connect the negative
scale
positive
diode
plate
Touch
lead to the
the other lead to
each of the three stator connection terminals The
needle
terminal
should
Now
should not
show
reverse
move
movement
the leads
replace
pack
Check the negative diodes calibrated
meter
at any of the three terminals
If the diodes fail any of these tests then the entire
each
at
The
on
the X1000
Leave the ohmmeter
scale
Connect
the
positive redl lead to the negative diode plate the plate which IS groundedl Touch the ohm negative lead to each of the three stator connection terminals The needle should move at each terminal If the diodes fall either of these meter
tests then
replace
the entire
pack
t A G
ALTERNATOR OVERHAUL
INSPECT THE BRUSHES and If they to near
the brush
wear
limit line
are worn
replace
them
BEARINGS should be carefully Inspected If the alternator has been used for an extended period of time condition
the any question about of the bearrngs then replace them
or
If there
t A 7
the front
housing made durrng assembly
Install the stator the marks you
IS
In
lining
up
ALTERNATOR OVERHAUL
h Install the diode pack
fiXing
Loosely
nut
In
and
place
Install the
A
tighten
the
terminal nut
I I I
ii
Resolder the three stator coil lead diode terminals AS
POSSIBLEI
wires
to the
DO THIS AS QUICKLY
Note
Otherwise
you
risk
damaging
Now
Install
the diode
negative diode cover
cover
plate fiXing
and
nut
tighten
the
and the diode
screw
the diodes with the heat
Reinstall the rotor press
A driver
might
result
Install
the
the bearing
IS
bearings
on
the shaft uSing
a
not recommended because It
bearing front bearing
When you damage don t forget to slide
retainer on the
shaft flrstl
In
I
t A 8
ALTERNATOR OVERHAUL
0
I
Reinstall the grease seal and seal front
retainer In the
Now slide the
housing
as
far
as
j
rotor shaft mto the
It will go and
tighten
front
housing
the retainer
fixing
screws
Next
mount the
rotor In a vise Be sure to protect the rotor with two blocks of wood Now Install the front spacer pulley and nut
assembly
and
tighten
the nut
to
25 29 ft Ibs
Now assemble the front to the rear
housing
Frnally holder
A9
Install the brushes cover
Tighten
rotor
assembly
assembly
Be sure to
line up the scratch marks you made when you the alternator I nstall the three through bolts and tighten securely disassembled
A
t
housing
stator
Insulator and brush
cover screws
HEAT GENERATED BUT FUSES DO NOT BLOW OR FUSES BLOW AFTER CONSIDERABLE TIME
4
ENGINE KEEPS RUNNING WITH KEY OFF
HOW TO TROUBLESHOOT
SOMETHING
T DOESN
WORK
4
4
STRANGE THINGS HAPPEN
FUSE BLOWS
t
TROUBLESHOOTI NG
HEAT PRODUCED BUT FUSE DOESN T BLOW
THIS CONDITION
IS CAUSED BY HIGH RESISTANCE IN A CIRCUIT
1
LOCATE THE HEATED AREA
2
LOOK FOR POOR CONNECTIONS
3
A
CORROSION
B
PINS PUSHED OUT OF CONNECTORS
C
LOOSE
D
FUSES
CONNECTIONS LOOSE FUSE CLIP OR FUSE CLIP MOUNTING ON FUSE BOX
LOOK FOR UNDERSIZE WIRE ETC
t
ESPECIALLY IN
ON ADD
INSTALLATIONS
FOG LIGHTS
I WHERE WIRE GAUGE INSTAllED IS TOO SMALL FOR LOAD PASSING THROUGH
IT
t
t
t
TR 1
TROUBLESHOOTING
ENGINE KEEPS RUNNING WITH KEY OFF
I
I
UNPLUG COIL WIRE
1Ik
I
ENGINE STOPS PLUG COIL WIRE TURN KEY OFF
BACK
IN
ENGINE KEEPS RUNNING
START ENGINE ENGINE IS DIESELING
UNPLUG IGNITION SWITCH
CARBURETOR PROB
LEM
ENGINE KEEPS RUNNING
I
UNPLUG VOLTAGE REGULATOR
I
ENGINE STOPS
I
I
REPLACE IGNITION SWITCH
ENGINE KEEPS RUNNING DOES CARBURETOR
HAVE ANTI
DIESELING
t
ENGINE STOPS
SOLENOID
REPLACE REGULATOR
NO
YES UNPLUG THIS JUMPER WIRE
AND CONNECT A
SOLENOID FROM THE
BATTERY
PROBLEM PERSISTS
TER
MINAL TO THE SOLENOID RESTART ENGINE
CROSS
AND TURN KEY OFF AGAIN
WIRE
BETWEEN YELLOW
HARNESS
OR
ALTERNATOR AND b
IGNITION
NEUTER WIRE
AUTOMATIC
IN
CHOKE
t
RELAY
I
UNPLUG FUSES ONE AT A TIME
I I
ENGINE KEEPS RUNNING WITH FUSES OUT
ENGINE STOPS See
Page
TR 5
See Page TR 4
t
TR 2
TROUBLESHOOTING
ENGINE KEEPS RUNNING WITH ALL FUSES OUT
NOW
STUDY THE
WIRING
COMPONENTS GET
DIAGRAM
IN
THE
VEHICLE
CURRENT DIRECTLY FROM THE
SERVICE MANUAL
IGNITION SWITCH
DETERMINE
WITHOUT
FIRST
WHAT
GOING
THROUGH A FUSE NOW UNPLUG THESE COMPONENTS ONE AT A TIME
ENGINE STOPS REPLACE THE SHORTED COMPONENT
ENGINE KEEPS RUNNING THERE IS A CROSS
IN
THE
HARNESS
BETWEEN THE
IGNITION
FEED LINE
AND THE
BATTERY FEED LINE 1
USING
THE
SERVICE
MANUAL
MAKE
A
LIST
OF
ALL
THE
CONNECTORS
AND
HARNESSES INVOLVED IN THE IGNITION LINE
2
MAKE A VISUAL INSPECTION OF THESE CONNECTORS AND THE SELVES
TOGETHER
REMOVE THE
NEW CARS
YOU WILL
NECTOR
HARNESSES THEM
t
LOOK FOR WIRES WHICH HAVE BEEN IMPROPERLY INSTALLED OR SHORTED FUSE
BLOCK AND INSPECT
FIND A WIRE
INSERTED
FOR SHORTS SOMETIMES
INTO THE
WRONG PIN
ON
OF A CON
CHECK ALL WIRES AGAINST THE WIRING DIAGRAM
PROBLEM PERSISTS ON RARE OCCASIONS YOU WILL FIND
TWO WIRES CROSSED IN THE HARNESS
TO CHECK
1
DISCONNECT BATTERY
2
UNPLUG ALL CONNECTORS AND COMPONENTS
3
CALIBRATE OHMMETER ON x1000 SCALE
4
AT
EACH CONNECTOR
WHICH
HAS
t
BOTH BATTERY
AND
IGNITION
1 1 WIRES
RUNNING THROUGH IT LOCATE THE RELEVANT PINS
5
TEST
FOR
Will
KNOW WHERE
CONTINUITY
ACROSS THESE PINS
YOU SHOULD EITHER
WHEN YOU FIND CONTINUITY
REPLACE A HARNESS OR
YOU
UNWRAP THE
HARNESS AND INSULATE THE WIRES
t
TR 3
TROUBLESHOOTING
ENGINE STOPS
THE
SHORT BETWEEN
BATTERY
AND THE
IGNITION CIRCUIT
IS LOCATED IN
THE
CIRCUITS
CONTROLLED BY THIS FUSE
COMPONENTS AND RELAYS WHICH ARE CONTROLLED BY THIS FUSE
1
MAKE A LIST OF ALL THE
2
UNPLUG THESE COMPONENTS ONE AT A TIME
ENGINE STOPS
ENGINE KEEPS RUNNING
I
REPLACE THE SHORTED COMPONENT
I
THERE IS A CROSS IN THE CIRCUITS SERVED BY THIS FUSE MAKE WIRES
A VISUAL INSPECTION WHICH HAVE
BEEN
OF ALL THE
IMPROPERLY
FORGET TO CHECK THE
FUSE
FIND A WIRE
INTO THE
INSERTED
CONNECTORS
INVOLVED
INSTALLED OR SHORTED
BLOCK ITSELF WRONG
SOMETIMES
LOOKING FOR
TOGETHER
ON NEW CARS
PIN OF A CONNECTOR
DON T
YOU WILL
t
CHECK ALL WIRES
AGAINST THE WIRING DIAGRAM
NO PROBLEM FOUND ON RARE OCCASIONS YOU WILL FIND TWO WIRES CROSSED IN THE HARNESS
TO CHECK 1
DISCONNECT BATTERY
2
UNPLUG ALL CONNECTORS SERVING CIRCUITS CONTROLLED BY THIS FUSE
3
CALIBRATE OHMMETER ON x1000 SCALE
4
AT
EACH CONNECTOR WHICH HAS BOTH BATTERY
RUNNING THROUGH IT
5
TEST
FOR CONTINUITY BETWEEN THESE PINS
WILL KNOW
WHERE
AND IGNITION
FUSE
t
WIRES
LOCATE THE RELEVANT PINS
YOU SHOULD EITHER
WHEN YOU FIND CONTINUITY
REPLACE
YOU
A HARNESS OR UNWRAP THE
HARNESS AND INSULATE THE WIRES
t
TR 4
TROUBLESHOOTING
SOMETHING DOESN T WORK
CHECK BATTERY VOLTAGE
IT
SHOULD BE FULLY
CHARGED
IF
NOT
THEN CHARGE THE
BATTERY BEFORE PROCEEDING WITH FURTHER TESTS
CHECK FUSES
NOTE
1
TURN ON THE CIRCUIT YOU ARE TESTING
2
TURN IGNITION KEY TO
3
CONNECT TEST LIGHT CLIP TO GROUND
4
TOUCH
LIGHT
IGNITION ON
TO BOTH
SIDES
POSITION
OF EACH FUSE
IT SHOULD BE
LIT ON
DON T FORGET ANY INLlNE FUSES WHICH MAY BE IN THE CIRCUIT
FUSES 0 K
FUSES BAD See
GET OUT THE SERVICE MANUAL AND FIND THE SECTION DESCRIBING THE
BOTH SIDES
CIRCUIT INVOLVED
Page
TR 12
CHECK TO SEE WHETHER THE CIRCUIT HAS
A RELAY IN IT
JI CIRCUIT HAS RELAY 1
LOCATE THE RELAY ON THE CAR
2
STUDY THE
WIRING
DIAGRAM
RELAY ON AND OFF
3
INHIBITOR
SWITCH
SWITCH IN
THE
RELAY CLICKS See
Page
See
USING
TR 10
Page TR
10
TO DETERMINE WHAT TURNS THE
THIS CAN BE DONE USING A SWITCH THE
IGNITION
CONTROLLED CIRCUIT
ACTIVATE THE RELAY
NO RELAY
IE G
KEY
OR
DIMMER
t
IE G
USING
A
SWITCHI
AND LISTEN TO IT
RELAY DOESN T CLICK
See Page TR l
TR 5
TROUBLESHOOTING
RELAY DOESN T CLICK
LOCATE THE CONNECTOR AT THE RELAY IN QUESTION
USING
THE
SERVICE MANUAL
ACTIVATE THE
DETERMINE
RELAY WINDING
WHICH HOT
BECOMES
PIN
OF
WHEN
THE
THE
CONNECTOR SERVES TO
RELAY ACTIVATING SWITCH
IS TURNED ON
SET THE
VOLTMETER TO LOW RANGE
O 3V
CONNECT THE POSITIVE
VOLTMETER LEAD TO
THE BATTERY POSITIVE TERMINAL
NOW PROBE THE
POSITIVE
PIN OF THE CONNECTOR WITH THE NEGATNE VOLTMETER LEAD
CONNECTOR PLUGGED IN
ENERGIZE
THE
RELAY BY WORKING
THE
ACTIVATING
SWITCH
AND OBSERVE THE
VOLT
METER
BELOW 2 VOLTS
ABOVE 2 VOLTS See
1
NOW
DETERMINE
WHICH
PIN
OF
THE
CONNECTOR
SERVES
Page
TR B
TO
t
GROUND THE RELAY
2
PROBE
THIS
CONNECTOR THEN
THE
PIN
POSITIVE
WITH THE
PLUGGED IN
NOTE
IF
VOLTMETER
LEAD
LEAVE
THERE IS NO GROUND LEAD
RELAY IS GROUNDED THROUGH
THE
CHASSIS TOUCH
THE POSITIVE LEAD TO THE RELAY HOUSING
3
CONNECT THE BATTERY
4
NEGATIVE
VOLTMETER
NOW ENERGIZE THE RELAY
NEGATIVE
AND OBSERVE THE VOLTMETER
ABOVE 1 VOLT
BELOW 1 VOLT
I
LEAD TO THE
TERMINAL
REPLACE THE RELAY
I
See
Page
TR 9
TR G
TROUBLESHOOTING
RELAY POSITIVE CIRCUIT RESISTANCE TEST
USING THE
SERVICE MANUAL CIRCUIT DIAGRAM
ACTIVATING
SWITCH
I E
IS IT
IN
SWITCH IN POSITIVE SIDE OF THE CUIT
DETERMINE THE
LOCATION OF THE
POSITIVE OR NEGATIVE SIDE OF THE
THE
SWITCH
CIR
BETWEEN THE BATTERY POSITIVE
IN
NEGATIVE
RELAY
CIRCUIT
GROUND
SIDE
OF CIRCUIT
POST AND THE RELAY
FIND
OPERATIONAL
SWITCH IN THE
THE
DIAGRAM
OF THE
SERVICE MANUAL TEST
SWITCH USING AN OHMMETER
OHMMETER
SEE
SECTION OF THIS MANUAL
IF SWITCH 1
LEAVE
IS 0 K THE
CIRCUIT
TURNED ON
AND
MALFUNCTIONING
ALL
CONNECTORS PLUGGED IN
2
LEAVE
THE
POSITIVE
VOLTMETER
LEAD
CONNECTED
TO
THE
POSITIVE BATTERY TERMINAL
3
NOW
TAKE
ALONG
THE
NEGATIVE
THE CIRCUIT
YOUR TIME AND YOU Will ANCE WHEN
THE
VOLTMETER
LEAD
BACKING UP TOWARD THE
VOLTAGE
LOCATE THE
AND
PROBE
BATTERY
ALL
TAKE
POINT OF HIGH RESIST
FINALLY DROPS BACK TO NORMAL
t
t
TR
TROUBLESHOOTING
RELAY NEGATIVE CIRCUIT RESISTANCE TEST
USING THE
SERVICE MANUAL CIRCUIT DIAGRAM SWITCH
ACTIVATING
I E
IS
IT
IN
THE
DETERMINE THE
POSITIVE
OR
LOCATION
NEGATIVE
OF THE
SIDE OF
THE
RELAY
CIRCUIT
SWITCH IN NEGATIVE SIDE OF THE CIR
SWITCH
CUIT
CUIT BETWEEN THE BATTERY POSITIVE
BETWEEN RELAY AND
GROUNDI
IN POSITIVE SIDE OF THE CIR
POST AND THE RELAYI FIND THE IN
THE
OPERATIONAL
SERVICE
DIAGRAM OF THE
MANUAL
TEST THE SWITCH
SEE
USING
SWITCH
AN OHMMETER
OHMMETER SECTION OF THIS
SERVICE GUIDE
I F SWITCH IS 1
LEAVE
THE
K O
NEGATIVE VOLTMETER
LEAD
CONNECTED TO THE
BATTERY
NEGATIVE
TER
MINAL
2
PLUG
IN
3
NOW
TAKE THE
OF
THE
THE
RELAY SWITCH AND TURN IT ON
POSITIVE
CIRCUIT
FROM
VOLTMETER THE
TERMINAL OF THE BATTERY
RELAY
RELAY
MALFUNCTIONING
LEAD AND PROBE ALL ALONG THE WINDING
NEGATIVE
IF YOU TAKE YOUR TIME
TERMINAL
TO
NEGATIVE SIDe THE
NEGATIVE
YOU WILL FIND THE POINT OF HIGH
RESISTANCE WHEN THE VOLTAGE FINALLY DROPS BACK TO NORMAL
NOTE FOR ILLUSTRATION ON VOLTAGE DROPS VOLTMETERS IN THIS MANUAL
SEE THE SECTION ON
t
TR 8
TROUBLESHOOTING
LOCATE THE CONNECTOR AT THE COMPONENT IN QUESTION OR
LIGHT IN
THE
INSTRUMENT CLUSTER
GAIN ACCESS TO THE
IF THE COMPONENT IS A GAUGE
THEN YOU SHOULD PULL THE
CLUSTER OUT TO
CONNECTOR
USING THE SERVICE MANUAL DETERMINE WHICH PIN OF THE CONNECTOR SHOULD BE HAVE CURRENT TO ITl WHEN THE CIRCUIT IS ACTIVATED
SET VOLTMETER TO LOW RANGE
IO 3V
HOT
POSITIVE LEAD TO THE POSITIVE
CONNECT THE
TERMINALS OF THE BATTERY
I
I
TURN THE CIRCUIT ON
NOW PROBE THE LEAVE THE
POSITIVE WIRE AT THE CONNECTOR WITH THE NEGATIVE VOLTMETER LEAD
CONNECTOR PLUGGED IN
AND CHECK THE
READING
ABOVE 2 VOLTS
BELOW 2 VOLTS 1
USING
THE
SERVICE
MANUAL
DETERMINE
CONNECTOR SHOULD BE GROUNDED
WHICH PIN
NEGATIVE
WHEN
OF THE
See
Page
TR 16
THE CIR
CUIT IS ACTIVATED
2
WITH
THE
VOLTMETER
CONNECT THE
STILL
NEGATIVE
SET TO THE
LEAD TO THE
LOW
RANGE
O
3VI
t
NEGATIVE TERMINAL OF
THE BATTERY
3
NOW PROBE THE POSITIVE IN
4
NEGATIVE WIRE AT THE CONNECTOR
VOLTMETER
AND TURN
LEAD
LEAVE
THE
USING THE
CONNECTOR PLUGGED
ON THE CIRCUIT
CHECK THE READING
BELOW 1 VOLT
See
Page
TR 14
t
REPLACE THE COMPONENT
TR 9
TROUBLESHOOTING
STRANGE THINGS HAPPEN
EXAMPLE
ALL PARKING LIGHTS FLASH WHEN TURN SIGNALS ARE ENERGIZED
I
PROBLEMS LIKE THESE ARE CAUSED BY 1
BAD GROUND CONNECTIONS
2
BAD CONNECTIONS IN POSITIVE SIDE OF CIRCUIT
3
CROSSOVER BETWEEN POSITIVE SIDES OF TWO CIRCUITS
4
CROSSOVER BETWEEN GROUND OF ONE CIRCUIT AND POSITIVE
SIDE OF ANOTHER
CIRCUIT
PRELIMINARY ITEMS TO CHECK 1
GROUND CONNECTIONS
2
IF
ONE OF THE
CIRCUITS INVOLVED IS A LIGHT CIRCUIT
REMOVE THE
TWO STOP
LIGHT BULBS
TEST PROCEDURE 1
CHECK BATTERY VOLTAGE
IT SHOULD BE FULLY CHARGED
IF NOT
THEN
CHARGE
THE BATTERY BEFORE PROCEEDING WITH FURTHER TESTS
2
CHECK
FUSES
A
TURN ON THE CIRCUIT YOU ARE TESTING
B
TURN IGNITION KEY TO
C
CONNECT TEST LIGHT CLIP TO GROUND
D
TOUCH LIGHT TO BOTH
IGNITION ON
POSITION
SIDES OF EACH FUSE IT SHOULD BE LIT ON BOTH SIDES
NOTE DON T FORGET ANY INLINE
FUSES WHICH MAY BE IN THE CIRCUIT
t FUSES 0 K See
Page
TR 13
FUSES BAD See Page TR 12
TR 10
TROUBLESHOOTING
I
I
FUSE BLOWS
BLOWS
FUSE OTHER CASES
ONLY
WHEN
A SPECIFIC
COMPONENT IS TURNED ON
USING WIRING DIAGRAM IN VEHICLE SHOP MANUAL MAKE A LIST OF ALL THE
UNPLUG
COMPONENTS CONTROL
THIS
COMPONENT
AND
TRY
NEW
FUSE
LED BY THIS FUSE
FUSE STI LL BLOWS
STEADY SHORTS
CONNECT
SHORT
UNIT ACROSS
DETECTOR
FUSE
CLIP
OR
WILL START CLICKING
ALL
COMPONENTS ON
THE
IN
WIRING
COMPONENT
TERMINALS
FLASHER THE
SHORT
FLASHER
TO TRACE IF
UNPLUG CIRCUITS
VISUAL
ONE AT A TIME
USE
BETWEEN SWITCH AND SHORT
POSSIBLE
INSPECTION
DETECTOR
OTHERWISE
OF
TO
MAKE
ALL WIRING
IN
VOLVED
INTERMITTENT
SHORTS
YOU
CAN T
GET THE FUSE TO BLOW FIRST
FUSE DOESN T BLOW
TRY TO DETERMINE WHEN THE FUSE
BLOWS
REPLACE THE COMPONENT
SHORTED
ASK OWNER FOR DETAILS
HOW MANY PEOPLE IN CAR
HOW MUCH CARGO
WAS IT RAINING
THEN TRY
TO SIMULATE THE CONDITIONS
IF
THIS
UAL
I
REPLACE THE
IS
NOT SUCCESSFUL
THEN
FIND
WIRING HARNESS LAYOUT IN SERVICE MAN
FLASHER STOPS CLICKING LAST UNIT YOU DISCONNEC
OF
MAKE
ALL
A
CLOSE VISUAL INSPECTION
CIRCUITS
INVOLVED
lIKElY TO FIND WIRES
TED AS IT IS SHORTED
TRACKS
FOR
YOU
ARE
SHORTED ON SEAT
EXAMPLE
OR
AGAINST
CHASSIS RAILS
FLASHER CONTINUES CLICKING FIND WIRING HARNESS LAYOUT IN MANUAL
TRACE
VOLVED
USING
SHORT
SERVICE
ALONG EACH CIRCUIT IN SHORT
DETECTOR
UNTIL
IS FOUND
TR 11
TROUBLESHOOTI NG
FUSES O K
MAKE A LIST OF ALL THE CIRCUITS WHICH ARE
1
NOW CHOOSE ONE OF THESE CIRCUITS THE SERVICE MANUAL
2
NOW
ON
RELAY
NOTE
THE
ETC
CAR
FIND THE
ACTING UP
WRITE THIS DOWN
CIRCUIT DESCRIPTION
AND DIAGRAM IN
FAMILIARIZE YOURSELF BRIEFLY WITH THIS CIRCUIT
FIND
THE
PLUG CONNECTING
THE
COMPONENT
LIGHT BULB
HORN
CONTROLLED BY THIS CIRCUIT
IF COMPONENT IS A GAUGE OR
LIGHT IN THE
INSTRUMENT CLUSTER
YOU SHOULD PULL
THE CLUSTER OUT TO GAIN ACCESS TO THE PLUG
1
TURN VOLTMETER TO LOW SCALE
2
CONNECT NEGATIVE LEAD OF VOLTMETER TO NEGATIVE TERMINAL OF BATTERY
3
TURN
CIRCUIT
ON
AND
SET UP
MALFUNCTION
THIS
MAY NECESSITATE
TURNING
ON
ANOTHER CIRCUIT AT THE SAME TIME
4
TOUCH
POSITIVE
LEAD
OF
VOLTMETER
TO GROUND
TERMINAL
OF
COMPONENT
LEAVE
ALL CONNECTIONS PLUGGED IN
5
CHECK VOLTMETER READING
ABOVE 1 VOLT
BELOW 1 VOLT
See
See
Page
TR 14
Page
TR 15
TR 12
TROUBLESHOOTING
NEGATIVE CIRCUIT RESISTANCE
ABOVE 1 VOLT USING THE I E
SWITCH
SERVICE MANUAL CIRCUIT DIAGRAM
IS IT IN THE POSITIVE OR
IN
NEGATIVE
IN
OPERATIONAL DIAGRAM OF THE
TEST THE SWITCH
LOCATION OF THE SWITCH
THE
SWITCH IN POSITIVE SIDE OF THE CIR CUIT BETWEEN THE BATTERY POSITIVE
POST AND THE COMPONENT
SERVICE MANUAL
THE
OF
COMPONENT
THE
CIRCUIT BETWEEN AND GROUND
FIND THE
SIDE
DETERMINE THE
NEGATIVE SIDE OF THE CIRCUIT
SWITCH
USING AN OHMMETER
SEE OHMMETER SECTION OF THIS
MANUAL
I F SWITCH IS 0 K
1
LEAVE
THE
NEGATIVE
VOLTMETER
LEAD CONNECTED TO THE
NEGATIVE
BATTERY
TER
MINAL
2
LEAVE THE
CIRCUIT TURNED ON AND MALFUNCTIONING
3
NOW TAKE THE POSITIVE
ALL CONNECTORS
PLUGGED IN
VOLTMETER LEAD AND PROBE ALL ALONG THE NEGATIVE SIDE OF
THE CIRCUIT FROM THE COMPONENT NEGATIVE TERMINAL TO THE NEGATIVE TERMINAL OF THE
BATTERY
IF YOU TAKE YOUR TIME
WHEN THE VOLTAGE
YOU WILL FIND THE POINT OF HIGH RESISTANCE
FINALLY DROPS BACK TO NORMAL
FOR ILLUSTRATION SEE THE SECTION ON VOLTMETERS IN THIS
MANUALI
TR 13
TROUBLESHOOTING
BELOW 1 VOLT
1
NOW
CONNECT
THE
POSITIVE
LEAD
OF
THE
VOLTMETER
TO
THE
POSITIVE
BATTERY
TERMINAL
2
TOUCH THE
NEGATIVE LEAD TO THE
NENT STILL PLUGGED IN
3
HOT
POSITIVE
WIRE
AT THE COMPONENT
COMPO
TURNED ON AND MALFUNCTIONING
CHECK VOLTAGE READING
ABOVE 2 VOLTS See
Page
TR 16
BELOW 2 VOLTS
SeePage
TR ll
TR 14
TROUBLESHOOTING
POSITIVE CIRCUIT RESISTANCE
ABOVE 2 VOLTS IN THE
SERVICE MANUAL FIND THE DIAGRAM FOR THE CIRCUIT ON WHICH YOU ARE WORKING
NOW STUDY IT TO FIND THE LOCATION OF THE SWITCH
SWITCH CUIT
IN
POSITIVE SIDE OF THE
CIR
BETWEEN THE BATTERY POSITIVE
SWITCH
IN
NEGATIVE
GROUNDI SIDE
OF THE CIRCUIT
POST AND THE COMPONENT FIND
OPERATIONAL DIAGRAM OF SWITCH IN SERV
ICE
MANUAL
OHMMETER
TEST
SEE
THE
OHMMETER
SWITCH
USING
SECTION
OF
AN THIS
MANUAL
1
LEAVE THE CIRCUIT TURNED ON AND MALFUNCTIONING
2
LEAVE THE POSITIVE VOLTMETER LEAD CONNECTED TO THE POSITIVE
3
NOW TAKE THE
BATTERY TERMINAL
NEGATIVE VOLTMETER LEAD AND PROBE ALL ALONG THE CIRCUIT BACKING
POSITIVE TERMINAL OF THE BATTERY LEAVE ALL CONNECTORS PLUGGED TAKE YOUR TIME AND YOU WILL LOCATE THE POINT OF HIGH RESISTANCE WHEN THE
UP TOWARD THE IN
VOLTAGE FINALLY DROPS BACK TO NORMAL
TR 15
TROUBLESHOOTING
BELOW 2 VOLTS
THERE IS A CROSS BETWEEN
1
THE POSITIVE SIDES OF TWO CIRCUITS
2
THE
POSITIVE
SIDE OF ONE CIRCUIT AND THE
TO FIND THE CROSS
NEGATIVE SIDE OF ANOTHER
CIRCUIT
FIRST SET UP THE MALFUNCTION
ENGINE RUNNING
YES
NO WITH ENGINE OFF
WITH IGNITION DISCONNECT
BATTERY
CABLES WIRES ARE PLUG
F
ON
FIELD
TERNATOR
RECONNECT CABLES
IN
ENGINE OFF LEAD
DISCONNECT AL
CHECK TO BE SURE THE
THE CORRECT PLACES IN THE
TERMINAL
FIELD
WHITE BLACK WIRE
MALFUNCTION HAS STOPPED THERE
IS
A
RELAY
MALFUNCTIONING
SHORTING TWO CIRCUITS
CONNECT NEUTER
TOGETHER
JUMPER
WIRE
FROM
BATTERY
AND
YEllOW WIRE AT CONNECTOR
MALFUNCTION DOESN T RETURN MALFUNCTION PERSISTS MALFUNCTION RETURNS 1
UNPLUG AUTOMATIC CHOKE RELAY
2
UNPLUG 4 1973
3
ELECTRIC
FUEL
PUMP
RELAY
S301
TRY NEW VOLTAGE REGULATOR
MALFUNCTION PERSISTS THERE IS A YELLOW
CROSS BETWEEN THE NEUTER
WIRE
AND SOME OTHER WIRE IN THE HARNESS
DISCONNECT BATTERY CABLES AGAIN
See
Page
ENGINE OFF
TR t8
TR 1G
TROUBLESHOOTING
BELOW 2 VOLTS CONTINUED
1
DISCONNECT BATTERY CABLES AND UNPLUG COIL WIRE
2
CALIBRATE AN OHMMETER ON THE xl 000 SCALE
3
USING
THE
SERVICE MANUAL
LOCATE
THE
MAIN WIRING HARNESS
IN
WHICH THE
COM
PONENT CONTROLLING WIRES ARE LOCATED
4
UNPLUG THIS HARNESS FROM THE OTHER MAIN HARNESS ES WILL BE ONE OR TWO MAIN JUNCTION BLOCKS MAKE A VISUAL TORS
5
HAVE
INSPECTION OF THE PINS
HEATED
UP
AND
MELTED
SOMETIMES ALLOWING
CONNECT ONE OHMMETER LEAD TO THE
HOT
IN THE CAR
USUAllY THERE
NOTE WHEN YOU UNPLUG THE HARNESS ES
WIRE
YOU WILL FIND THAT THE CONNEC TWO
PINS
AT THE
TO
TOUCH
COMPONENT
EACH
OTHER
AND LEAVE
IT
THERE
6
NOW
AT THE
OTHER PIN
MAIN HARNESS CONNECTOR S
TOUCH THE OTHER OHMMETER LEAD TO EVERY
ONE AT A TIME CHECK FOR CONTINUITY
NO CONTINUITY
CONTINUITY CHECK THE
WIRING
CONTROLS
DETERMINE
See
DIAGRAM TO FIND OUT WHAT CIRCUIT THIS PIN WHETHER
BETWEEN THAT CIRCUIT AND THE
Page
TR 19
THERE SHOULD BE CONTINUITY ONE WHICH IS MALFUNCTIONING
CONTINUITY NORMAL CONTINUE
TESTING
UNTIL
ALL PINS
HAVE
BEEN
TESTED
PROBLEM NOT LOCATED
CONTINUITY NOT NORMAL
See Page TR 19
THERE IS A CROSSOVER BETWEEN THESE TWO CIR CUlTS
EITHER AT A
HARNESS
OR
TO DECIDE
IN
THE
UNIT WHICH PLUGS INTO THE HARNESS
ITSELF
WHICH IS THE CASE ONE AT A TIME
UNPLUG THOSE UNITS
COMPONENTS SWITCHES
ETC
WHICH ARE
CONNECTED
TO THE SUSPECT CIRCUITS
CONTINUITY STOPS
I
REPLACE THE UNIT
CONTINUITY CONTINUES
I
THERE IS A CROSSOVER BETWEEN THESE TWO UNWRAP THE OR
HARNESS
IN
THE
WIRES
WIRING HARNESS
YOU WILL HAVE TO
TO FIND THE
CROSSOVER
REPLACE IT
TR 17
TROUBLESHOOTING
NOW DISCONNECT THE THE
OHMMETER LEAD FROM THE COMPONENT
COMPONENT GROUND LEAD
AT THE
WIRE WITH THE OTHER OHMMETER LEAD
HARNESS CONNECTOR S
HOT
LEAD
LOOKING FOR CONTINUITY
NO CONTINUITY
CONTINUITY CHECK THE
WIRING DIAGRAM TO FIND OUT WHAT CIRCUIT THIS PIN
CONTROLS
DETERMINE
WHETHER
CONNECT IT TO
ONCE AGAIN PROBE EVERY
See
Page
TR 20
THERE SHOULD BE CONTINUITY
BETWEEN THESE CIRCUITS
I CONTINUITY NORMAL CONTINUE
TESTING
UNTIL
ALL
PINS
HAVE
BEEN
TESTED
CONTINUITY NOT NORMAL THERE IS A CROSSOVER BETWEEN THESE TWOWIRES EITHER AT A UNIT WHICH PLUGS INTO THE HARNESS
PROBLEM NOT LOCATED
OR IN THE HARNESS ITSELF
See
TO DECIDE WHICH IS THE CASE ONE AT A TIME UNPLUG THOSE UNITS COMPONENTS SWITCHES
Page
TR 20
ETC
WHICH ARE CONNECTED TO THE SUSPECT CIRCUITS
CONTINUITY CONTINUES THERE IS A CROSSOVER IN BETWEEN UNWRAP OR
