ELECTRICAL. Table of Contents. Specifications. Section 2B Charging & Starting System

Transcription

1 ELECTRICAL Section 2B Chrging & Strting System Tle of Contents Specifictions B-1 Specil Tools B-2 Bttery Cle Size B-3 Replcement Prts B-3 Recommended Bttery B-3 Bttery B-4 Precutions B-4 Chrging Dischrged Bttery B-4 Winter Storge of Btteries B-5 Flywheel Removl nd Instlltion B-6 Removl B-6 Instlltion B-7 Flywheel/Alterntor B-8 System Components B-10 Precutions B-10 Alterntor Description B-11 Dignosis of Alterntor System on Engine.. 2B-11 Alterntor System Circuitry Test B-12 Output Circuit B-12 Sensing Circuit B-13 Voltge Output B-14 Current Output B-15 Current Output Trouleshooting B-16 Repir B-16 Removl B-16 Instlltion B-17 Alterntor Belt Tension Adjustment B-18 Strter System B-18 Strter Motor Amperes Drw B-18 Strter System Components B-18 Description B-18 Strter Motor (Solenoid Driven Bendix) B-20 Trouleshooting the Solenoid Driven Bendix Strter Circuit B-22 Strter Circuit Trouleshooting Flow Chrt.. 2B-23 Strter Removl nd Instlltion B-25 Removl B-25 Instlltion B-26 Disssemly B-27 Clening nd Inspection B-30 Ressemly B-31 Strter Clening, Inspection nd Testing... 2B-34 Clening nd Inspection B-34 Testing Solenoid Driven Bendix Strters. 2B-35 Slve Solenoid Test B-37 Commnder 2000 Key Switch Test B-38 2 B Specifictions CHARGING SYSTEM STARTING SYSTEM Alterntor Output (Regulted) Brush Length Voltge Output Regultor Current Drw Strter Drw (Under Lod) Strter Drw (No Lod) Minimum Brush Length Bttery Alterntor Std Exposed Length: in. (10.5 mm) Min. Exposed Length: in. (1.5 mm) 13.5 to 15.1 Volts 0.15 ma (Ign. Switch Off) 30.0 ma (Ign. Switch On) 170 Amperes 60 Amperes 0.25 in. (65.4 mm) Bttery Rting 1000 (Minimum) Mrine Crnking Amps (MCA) 750 (Minimum) Cold Crnking Amps (CCA) 105 (Minimum) Amp Hour JANUARY 2001 Pge 2B-1

2 Specil Tools 1. Volt/Ohm Meter A1 or DMT 2000 Digitl Tchometer Multimeter A1 -Volt/Ohm Meter A1 -DMT 2000 Digitl Tchometer Multimeter A1 2. Ammeter (60 Ampere minimum) (Otin loclly) 3. Flywheel Holder Protector Cp Flywheel Puller A1 Pge 2B JANUARY 2001

3 Bttery Cle Size If stndrd (originl) ttery cles re replced with longer cles, the wire guge size must increse. See chrt elow for correct wire guge size. ÎÎ Wire Gge Size Bttery Cle Length Bttery Cle Wire Gge Size Mercury/Mriner Outords Bttery Cle Length 8 ft. 2.4m 9 ft. 2.7m 10ft. 3.0m 11ft. 3.4m 12ft. 3.7m 13ft. 4.0m 14ft. 4.3m 15ft. 4.6m 16ft. 4.9m 17ft. 5.2m 18ft. 5.5m 19ft. 5.8m 20ft. 6.1m 21ft. 6.4m 22ft. 6.7m 23ft. 7.0m 24ft. 7.3m Models Wire Gge Size No. SAE 6-25 Hp #8* #8 #6 #6 #6 #6 #4 #4 #4 #4 #4 #4 #4 #4 #2 #2 # Hp Hp (except DFI) DFI Models #6* #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0 #6* #6 #4 #4 #4 #4 #4 #4 #2 #2 #2 #2 #2 #2 #2 #4* #2 #2 #2 #2 #2 #2 #2 #2 #2 #0 #0 #0 * = Stndrd (originl) Cle Length nd wire gge size. Replcement Prts WARNING Electricl, ignition nd fuel system components on your Mercury Sport Jet re designed nd mnufctured to comply with U. S. Cost Gurd Rules nd Regultions to minimize risks of fire nd explosions. Use of replcement electricl, ignition or fuel system components, which do not comply with these rules nd regultions, could result in fire or explosion hzrd nd should e voided. Recommended Bttery A 12 volt mrine ttery with minimum Cold Crnking mperge rting of 750 mperes or 1000 (minimum) Mrine Crnking mperes should e used JANUARY 2001 Pge 2B-3

4 Bttery Precutions CAUTION If ttery cid comes in contct with skin or eyes, wsh skin immeditely with mild sop. Flush eyes with wter immeditely nd see doctor. When chrging tteries, n explosive gs mixture forms in ech cell. Prt of this gs escpes through holes in vent plugs nd my form n explosive tmosphere round ttery if ventiltion is poor. This explosive gs my remin in or round ttery for severl hours fter it hs een chrged. Sprks or flmes cn ignite this gs nd cuse n internl explosion which my shtter the ttery. The following precutions should e oserved to prevent n explosion. 1. DO NOT smoke ner tteries eing chrged or which hve een chrged very recently. 2. DO NOT rek live circuits t terminls of tteries ecuse sprk usully occurs t the point where live circuit is roken. Alwys e creful when connecting or disconnecting cle clmps on chrgers. Poor connections re common cuse of electricl rcs which cuse explosions. 3. DO NOT reverse polrity of ttery terminl to cle connections. Chrging Dischrged Bttery WARNING Hydrogen nd oxygen gses re produced during norml ttery opertion or chrging. Sprks or flme cn cuse this mixture to ignite nd explode, if they re rought ner the vent openings. Sulphuric cid in ttery cn cuse serious urns, if spilled on skin or in eyes. Flush or wsh wy immeditely with cler wter. The following sic rule pplies to ny ttery chrging sitution: 1. Any ttery my e chrged t ny rte (in mperes) or s long s spewing of electrolyte (from violent gssing) does not occur nd for s long s electrolyte temperture does not exceed 125 F (52 C). If spewing of electrolyte occurs, or if electrolyte temperture exceeds 125 F, chrging rte (in mperes) must e reduced or temporrily hlted to void dmge to the ttery. 2. Bttery is fully chrged when, over 2-hour period t low chrging rte (in mperes), ll cells re gssing freely (not spewing liquid electrolyte), nd no chnge in specific grvity occurs. Full chrge specific grvity is , corrected for electrolyte temperture with electrolyte level t 3/16 in. (4.8 mm) over plte, unless electrolyte loss hs occurred (from ge or over-filling) in which cse specific grvity reding will e lower. For most stisfctory chrging, lower chrging rtes in mperes re recommended. 3. If, fter prolonged chrging, specific grvity of t lest on ll cells cnnot e reched, ttery is not in optimum condition nd will not provide optimum performnce; however, it my continue to provide dditionl service, if it hs performed stisfctorily in the pst. Pge 2B JANUARY 2001

5 4. To check ttery voltge while crnking engine with electric strting motor, plce RED (+) led of tester on POSITIVE (+) ttery terminl nd BLACK ( ) led of tester on NEGATIVE ( ) ttery terminl. If the voltge drops elow 9-1/2 volts while crnking, the ttery is wek nd should e rechrged or replced. Winter Storge of Btteries Bttery compnies re not responsile for ttery dmge either in winter storge or in deler stock if the following instructions re not oserved: 1. Remove ttery from its instlltion s soon s possile nd remove ll grese, sulfte nd dirt from top surfce y running wter over top of ttery. Be sure, however, tht vent cps re tight eforehnd, nd low off ll excess wter thoroughly with compressed ir. Check wter level, mking sure tht pltes re covered. 2. When dding distilled wter to ttery, e extremely creful not to fill more thn 3/16 in. (4.8 mm) ove perforted ffles inside ttery. Bttery solution or electrolyte expnds from het cused y chrging. Overfilling ttery will cuse electrolyte to overflow (if filled eyond 3/16 ove ffles). 3. Grese terminl olts well with 2-4-C Mrine Luricnt nd store ttery in COOL- DRY plce. Remove ttery from storge every dys, check wter level nd put on chrge for 5 or 6 hours t 6 mperes. DO NOT FAST CHARGE. 4. If specific grvity drops elow 1.240, check ttery for reson nd rechrge. When grvity reches 1.260, discontinue chrging. To check specific grvity, use hydrometer, which cn e purchsed loclly. 5. Repet preceding chrging procedure every dys, s long s ttery is in storge, for est possile mintennce during inctive periods to ensure good servicele ttery in spring. When redy to plce ttery ck in service, remove excess grese from terminls ( smll mount is desirle on terminls t ll times), rechrge gin s necessry nd reinstll ttery JANUARY 2001 Pge 2B-5

6 Flywheel Removl nd Instlltion Removl 1. Remove flywheel cover from engine. WARNING Engine could possily strt when turning flywheel during removl nd instlltion; therefore, disconnect (nd isolte) sprk plug leds from sprk plugs to prevent engine from strting. 2. Disconnect sprk plug leds from sprk plugs. 3. While holding flywheel with flywheel holder ( ), remove flywheel nut nd wsher. -Flywheel Holder ( ) Instll crnkshft Protector Cp ( ) on end of crnkshft, then instll Flywheel Puller ( A2) into flywheel. 5. Hold flywheel tool with wrench while tightening olt down on protector cp. Tighten olt until flywheel comes free. -Flywheel Puller ( A2) Pge 2B JANUARY 2001

7 NOTE: Neither het or hmmer should e used on flywheel to id in removl s dmge to flywheel or electricl components under flywheel my result. 6. Remove flywheel. Inspect flywheel for crcks or dmge. Instlltion IMPORTANT: Clen flywheel/crnkshft tper with solvent nd ssemle dry. 1. Instll flywheel. 2. Instll flywheel wsher nd nut. 3. Hold flywheel with Flywheel Holder ( ). Torque nut to 125 l-ft (169.5 Nm). -Flywheel Holder ( ) JANUARY 2001 Pge 2B-7

8 Flywheel/Alterntor C With Teflon ( A12) Pge 2B JANUARY 2001

9 Flywheel/Alterntor TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. Nm 1 1 ALTERNATOR 2 1 SCREW (M10 x 100) SCREW (M10 x120) WASHER 5 3 MOUNT 6 1 BRACKET 7 3 WASHER 8 1 BRACKET 9 2 NUT SCREW (M10 x 55) CABLE 12 1 PIN 13 1 BRACKET 14 3 SCREW (5/16-18 x 1 IN.) SPRING 16 1 BELT TENSIONER ARM ASSY 17 1 STUD (M10 x 85) 18 1 NUT BUSHING 20 2 WASHER 21 1 PULLEY 22 1 SCREW (M10 x 35) BELT 24 1 FLYWHEEL 25 1 NUT (M16X1.5) WASHER 27 1 PLUG 28 1 NUT WASHER JANUARY 2001 Pge 2B-9

10 System Components The ttery chrging system consists of the lterntor, ttery, ignition switch, strter solenoid nd the wiring which connects these components. c d -Alterntor -Bttery c -20 Ampere Fuse d-strter Solenoid To Precutions The following precutions must e oserved when working on the lterntor system. Filure to oserve these precutions my result in serious dmge to the lterntor system. 1. Do not ttempt to polrize the lterntor. 2. Do not short cross or ground ny of the terminls on the lterntor, except s specificlly instructed. 3. Never disconnect the lterntor output led, regultor hrness or ttery cles when the lterntor is eing driven y the engine. 4. Alwys remove NEGATIVE ( ) ttery cle from ttery efore working on lterntor system. 5. When instlling ttery, e sure to connect the NEGATIVE ( ) (GROUNDED) ttery cle to NEGATIVE ( ) ttery terminl nd the POSITIVE (+) ttery cle to POSI- TIVE (+) ttery terminl. 6. When using chrger or ooster ttery, connect it in prllel with existing ttery (POSITIVE to POSITIVE; NEGATIVE to NEGATIVE). Pge 2B JANUARY 2001

11 Alterntor Description The lterntor employs rotor, which is supported in 2 end frmes y ll erings, nd is driven t 2.5 times engine speed. The rotor contins field winding enclosed etween 2 multiple-finger pole pieces. The ends of the field winding re connected to 2 rushes which mke continuous sliding contct with the slip rings. The current (flowing through the field winding) cretes mgnetic field tht cuses the djcent fingers of the pole pieces to ecome lternte north nd south mgnetic poles. A 3-phse sttor is mounted directly over the rotor pole pieces nd etween the 2 end frmes. It consists of 3 windings wound 120 electriclly out-of-phse on the inside of lminted core. The windings re connected together on one end, while the other ends re connected to full-wve rectifier ridge. The rectifier ridge contins 8 diodes which llows current to flow from ground, through the sttor nd to the output terminl, ut not in the opposite direction. When current is supplied to the rotor field winding, nd the rotor is turned, the movement of the mgnetic fields creted induces n lternting current into the sttor windings. The rectifier ridge chnges this lternting current to direct current which ppers t the output terminl. A diode trio is connected to the sttor windings to supply current to the regultor nd the rotor field during opertion. Voltge output of the lterntor is controlled y trnsistorized voltge regultor tht senses the voltge t the ttery nd regultes the field current to mintin lterntor voltge for properly chrging the ttery. Current output of the lterntor does not require regultion, s mximum current output is self-limited y the design of the lterntor. As long s the voltge is regulted within the prescried limits, the lterntor cnnot produce excessive current. A cutout rely in the voltge regultor lso is not required, s the rectifier diodes prevent the ttery from dischrging ck through the sttor. A smll mount of current is supplied y the excittion circuit in the regultor to the rotor field to initilly strt the lterntor chrging. Once the lterntor egins to produce output, field current is supplied solely y the diode trio. The lterntor is equipped with 2 fns which induce ir flow through the lterntor to remove het creted y the rectifier nd sttor. Dignosis of Alterntor System on Engine 1. If prolem is n underchrged ttery, verify condition hs not een cused y excessive ccessory current drw or y ccessories which hve ccidentlly een left on. 2. Check physicl condition nd stte of chrge of ttery. Bttery must e t lest 75% (1.230 specific grvity) of fully chrged to otin vlid results in the following tests. If not, chrge ttery efore testing system. 3. Inspect entire lterntor system wiring for defects. Check ll connections for tightness nd clenliness, prticulrly ttery cle clmps nd ttery terminls. IMPORTANT: RED output led from lterntor must e tight. A drkened RED sleeve indictes led ws loose nd ecoming hot. 4. Check lterntor drive elt for crcks nd frying. Replce if necessry. Check elt tension. Adjust if necessry, s outlined under Drive Belt Replcement nd Adjustment JANUARY 2001 Pge 2B-11

12 Alterntor System Circuitry Test Output Circuit Using 0-20 volt DC voltmeter, perform the following tests: 1. Connect POSITIVE (+) voltmeter led to lterntor terminl B (output terminl). Connect NEGATIVE ( ) led to cse ground on lterntor. 2. Shke lterntor wiring hrness. Meter should indicte ttery voltge nd should not vry. If proper reding is not otined, check for loose or dirty connections or dmged wiring. -Terminl B Pge 2B JANUARY 2001

13 Sensing Circuit 1. Unplug RED nd PURPLE led connector from lterntor. 2. Connect POSITIVE (+) voltmeter led to RED led nd NEGATIVE ( ) voltmeter led to ground. 3. Voltmeter should indicte ttery voltge. If correct voltge is not present, check sensing circuit (RED led) for loose or dirty connections or dmged wiring. -Sense Led (RED) JANUARY 2001 Pge 2B-13

14 Voltge Output 1. Using 0-20 volt DC voltmeter, connect POSITIVE (+) led of voltmeter to TERMINAL B of lterntor nd NEGATIVE ( ) led of voltmeter to engine ground. 2. Strt engine nd llow to wrm up. Increse engine RPM from idle to At mient temperture norml voltge output should e volts. NOTE: If lterntor is under-chrging check connections. If lterntor is over-chrging replce lterntor Terminl B Pge 2B JANUARY 2001

15 Current Output NOTE: Before conducting current output test, ssure tht ll ot electricl ccessories re turned OFF. 1. With engine shut off, instll mmeter with clmp-on current proe (cple of reding 60+ mperes) onto lterntor chrging conductor (10 AWG Red Wire). 2. Strt engine nd llow to wrm up. 3. Bttery voltge should e etween 14.2 nd 15.0 VDC for ll engine RPM s. Alterntor output current should correspond with grph elow. Exmple: If engine is revolving t 2000 RPM current meter should e pproximtely 14.5 ± 3 Amps. c 18.5 Current Consumed (mps) Ammeter (DMT 2000 Digitl Tchometer Multimeter A1) -Clmp-On Current Proe ( ) c -Alterntor Chrging Conductor (10 AWG Red Wire) Engine RPM JANUARY 2001 Pge 2B-15

16 Current Output Trouleshooting Current Output is Low Current Output is High Bttery Cles re loose or corroded Defective Bttery (Open Circuit) Defective Alterntor Accessories turned on Defective Bttery (Internl Short) Defective Alterntor Repir Removl 1. Remove top cowling. 2. Disconnect ttery cles from ttery. 3. Disconnect wiring hrness from lterntor. 4. Remove pivot olt nd tension olt. -Attching Bolt -Hrnesses Pge 2B JANUARY 2001

17 Instlltion 1. Secure lterntor to engine lock with ttching olts. Torque top olt to 40 l-ft (54 Nm). Torque ottom olt to 25 l-ft (34 Nm). 2. Instll lterntor elt in V-groove of flywheel nd lterntor pulley. 3. Reconnect electricl hrness to lterntor. c Top Bolt [Torque to 40 l-ft (54 Nm)] -Bottom Nut [Torque to 25 l-ft. (34 Nm) c -Hrnesses JANUARY 2001 Pge 2B-17

18 Alterntor Belt Tension Adjustment Correct lterntor elt tension is mintined y elt tensioner ssemly. -Belt Tensioner Assemly Strter System Strter Motor Amperes Drw STARTER MOTOR NO LOAD NORMAL PART NO. AMP. DRAW AMP. DRAW AMPS 165 AMPS AMPS 170 AMPS Strter System Components Bttery Neutrl Strt Switch Ignition Switch Slve Solenoid Description Strter Motor The ttery supplies electricity to ctivte the strter motor. When the ignition is turned to the START position, the slve solenoid is energized which in turn ctivtes the strter solenoid, thus completing the strter circuit etween the ttery nd strter. The neutrl strt switch opens the strter circuit when the shift control lever is not in neutrl thus preventing ccidentl strting when the engine is in ger. CAUTION The strter motor my e dmged if operted continuously. DO NOT operte continuously for more thn 30 seconds. Allow 2 minute cooling period etween strting ttempts. Pge 2B JANUARY 2001

19 Notes: JANUARY 2001 Pge 2B-19

20 Strter Motor (Solenoid Driven Bendix) Pge 2B JANUARY 2001

21 Strter Motor (Solenoid Driven Bendix) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 2 THRU BOLT SCREWS END CAP 4 1 BUSHING 5 1 BRUSH PLATE ASSEMBLY 6 1 ARMATURE 7 1 FIELD FRAME 8 1 SOLENOID 9 1 SHIELD 10 1 CUSHION 11 3 PLANETARY GEARS 12 1 PLUG 13 1 DISC 14 1 SHIFT FORK 15 1 GEAR/CLUTCH ASSEMBLY 16 1 BEARING 17 1 HOUSING 18 3 SCREW DRIVE GEAR 20 1 SNAP RING 21 2 MOUNTING COLLAR 22 2 STOP 23 2 NUT WASHER 25 1 NUT JANUARY 2001 Pge 2B-21

22 Trouleshooting the Solenoid Driven Bendix Strter Circuit Before eginning the trouleshooting flow chrt, verify the following conditions: 1. Confirm tht ttery is fully chrged. 2. Check tht control lever is in NEUTRAL position. 3. Check terminls for corrosion nd loose connections. 4. Check cles nd wiring for fryed nd worn insultion. 5. Check 20 mp fuse. Loction of Test Points (clled out in flow chrt) re numered elow. TO ALTERNATOR BATTERY STARTER STARTER SOLENOID SLAVE SOLENOID 20 AMP FUSE IGNITION SWITCH NEUTRAL START SWITCH (LOCATED IN CONTROL HOUSING) Solenoid Driven Bendix Strter Circuit Pge 2B JANUARY 2001

23 Strter Circuit Trouleshooting Flow Chrt (Solenoid Driven Bendix) Strter Motor Does Not Turn TEST 1 With ignition key in START position, check for ttery voltge t TEST POINT 1. Voltge indicted nd solenoid clicks No voltge indicted Voltge indicted nd solenoid does not click Voltge indicted t Test Point 9 is 9.5 volts or greter. Go to TEST 2 Check for strter motor ground t Test Point 10 Voltge indicted t Test Point 9 is less thn 9.5 volts. Good ground Bd ground clen cle ends or replce ground cle Defective strter motor Defective strter solenoid Defective strter solenoid SAFETY WARNING: Disconnect BLACK with RED sleeve (strter motor) cle from slve solenoid test point 7 BEFORE mking tests 1 thru 7 to prevent unexpected engine crnking. TEST 2 Use n ohmmeter (Rx1 scle) nd connect meter leds etween NEGATIVE ( ) ttery post nd common powerhed ground. No Continuity Indicted There is n open circuit in the BLACK NEGATIVE ( ) ttery cle etween the NEGATIVE ( ) ttery post nd the powerhed. Check cle for loose or corroded connections. Check cle for open. Continuity Indicted Proceed to TEST 3 No voltge reding: proceed to TEST 4. Test 3. Disconnect BLACK ground wire(s) from Test Point 3.. Connect voltmeter etween common engine ground nd Test Point 3. c. Turn ignition key to Strt position. TEST 4. Reconnect BLACK ground wire.. Connect voltmeter etween common engine ground nd Test Point 4. c. Turn ignition key to Strt position. 12 Volt Reding* Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to strter solenoid. Proceed to TEST JANUARY 2001 Pge 2B-23

24 No voltge reding: proceed to TEST 5 12 Volt Reding Defective strter solenoid No voltge reding: proceed to TEST 6 TEST 5. Connect voltmeter etween common engine ground nd Test Point 5.. Turn ignition key to Strt position. 12 Volt Reding* Neutrl strt switch is open or YELLOW/RED wire is open etween Test Points 5 nd 4. No voltge reding: proceed to TEST 7 TEST 6 Connect voltmeter etween common engine ground nd Test Point 6 12 Volt Reding* Defective ignition switch. TEST 7 Check for voltge etween common engine ground nd Test Point 7. No voltge reding: Check BLACK cle with RED sleeve etween ttery(+) POSITIVE terminl nd Test Point 8 nd Test Point Volt Reding* Check fuse in RED wire etween Test Points 6 nd 7. Check for open RED wire etween Test Points 6 nd 7. TEST 8. Connect voltmeter etween common engine ground nd Test Point 2.. Turn ignition key to Strt position. No voltge reding: Defective slve solenoid 12 Volt Reding* Should her solenoid click: proceed to TEST 9 TEST 9. Reconnect BLACK cle (with RED sleeve) to slve solenoid Test Point 7.. Connect voltmeter etween common engine ground nd Test Point 7. c. Turn ignition key to Strt position. No voltge reding: Check BLACK cle (with RED sleeve) for poor connection or open circuit. *Bttery Voltge Pge 2B JANUARY 2001

25 Strter Removl nd Instlltion Removl CAUTION Disconnect ttery leds from ttery efore removing strter. 1. Disconnect ttery cles from ttery. 2. Disconnect wires from strter solenoid terminls. 3. Remove strter trunion mounting olts nd remove strter from engine Strter Solenoid -Mounting Bolts JANUARY 2001 Pge 2B-25

26 Instlltion 1. Secure strter to engine with 4 olts. Use right top olt to ttch BLACK NEGATIVE. Torque top ttching olts to 18 l-ft (24 Nm). Torque ottom ttching olts to 18 l-ft. (24 Nm). 2. Secure BLACK cles (with RED sleeves) to POSITIVE (+) terminl on strter solenoid. Torque nut to 55 l-in (6 Nm). e c d -Top Bolts [Torque to 18 l-ft (24 Nm)] -Bottom Bolts [Torque to 18 l-ft (24 Nm)] c -BLACK Cles (with RED sleeves) d-nut (under RED oot) [Torque to 55 l-in (6 Nm)] e -Strter Solenoid Pge 2B JANUARY 2001

27 Disssemly (Solenoid Driven Bendix Strter) 1. Remove rush led from solenoid nd through olts from end frme. e c d -Brush Led -Through Bolts c -Strter Solenoid 2. Remove rmture nd field frme from drive housing d-brush Plte Screws e -End Frme NOTE: Permnent mgnets inside field frme will e holding rmture in plce. c d -End Frme nd Bering -Screws (2) [Internl Torx Snp On E6 Socket] c -Brush Holder d-armture e -Field Frme e JANUARY 2001 Pge 2B-27

28 3. Remove shield nd cushion from drive housing. c Shield -Cushion c -Drive Housing 4. Remove 3 screws retining strter solenoid. Remove solenoid from drive housing. 5. Remove snp ring nd ger from strter shft. c d e -Drive Housing -Strter Solenoid c -Screws (3) [ Internl Torx Snp On E6 Socket] d-snp Ring e -Pinion Ger Pge 2B JANUARY 2001

29 6. Remove plnetry ger nd clutch ssemly from drive housing. 7. Remove solenoid rm, metl disc nd plug from drive housing. e c d -Plnetry Ger nd Clutch Assemly -Drive Housing c -Plug d-metl Disc e -Solenoid Arm Inspect drive housing needle ering for roughness. If ering is worn or dmged, ering cn e removed y using n pproprite mndrel to drive/press ering from drive housing. NOTE: If ering hs spun in drive housing ore, drive housing must e replced. -Needle Bering -Drive Housing JANUARY 2001 Pge 2B-29

30 Clening nd Inspection IMPORTANT: Do not use grese dissolving solvents to clen electricl components, plnetry gers or drive clutch. Solvent will dmge insultion nd wsh the luricnt out of the clutch drive nd gers. Use clen rgs nd compressed ir to clen components. 1. Test over-running clutch ction of drive. Pinion should turn freely in over-running direction nd must not slip in crnking direction. 2. Inspect pinion teeth for wer. 3. Inspect spring for tension nd drive collr for wer. 4. Check tht erings roll freely. If ny roughness is felt, replce ering. 5. Inspect plnetry ger ssemly. Gers must mesh esily nd roll freely with no inding. Pge 2B JANUARY 2001

31 Ressemly (Solenoid Driven Bendix Strter) 1. Instll solenoid rm with plnetry ger nd clutch ssemly into drive housing. c Solenoid Arm -Plnetry Ger nd Clutch Assemly c -Drive Housing 2. Instll metl disc nd plug into drive housing Metl Disc -Plug JANUARY 2001 Pge 2B-31

32 3. Attch solenoid rm to strter solenoid. Instll strter solenoid in drive housing nd secure with 3 screws. Torque screws to 40 l-in (4.5 N.m). 4. Instll drive ger nd secure with snp ring. 5. Reinstll ruer umpers on housing. c e d f -Drive Housing -Strter Solenoid c -Screw (3) [Torque to 40 l-in (4.5 N.m) 6. Instll cushion nd shield in drive housing. c d-drive Ger e -Snp Ring f -Bumpers Shield -Cushion c -Drive Housing Pge 2B JANUARY 2001

33 7. Instll field frme over rmture. 8. While holding rushes ck, slide rush plte onto rmture while ligning rush led grommet with slot in field frme. 9. Secure end plte to rush ssemly with 2 screws. Torque screws to 30 l-in (3.4 Nm). NOTE: Prior to instlling field frme ssemly into drive housing, lign slot in field frme with plug in drive housing. g d c e f Armture -Field Frme Grommet Slot c -Brush Plte d-brush Led Grommet e -End Plte f -Screws [Torque to 30 l-in (3.4 Nm)] g-field Frme Plug Slot JANUARY 2001 Pge 2B-33

34 10. Instll field frme nd end frme in drive housing. 11. Instll through olts nd rush led. Torque through olts to 110 l-in (12.5 Nm). Torque rush nut to 55 l-in (6 Nm). d c e f -End Frme -Field Frme c -Drive Housing d-through Bolts [Torque to 110 l-in (12.5 Nm)] e -Brush Led f -Brush Nut [Torque to 55 l-in (6 Nm)] Strter Clening, Inspection nd Testing Clening nd Inspection 1. Clen ll strter motor prts. 2. Check pinion teeth for chips, crcks or excessive wer. 3. Replce the drive clutch spring nd/or collr if tension is not dequte or if wer is excessive. 4. Inspect rush holder for dmge or for filure to hold rushes ginst commuttor. 5. Replce rushes tht re pitted or worn to less thn 1/4 in. (6.4 mm) in length. 6. Inspect the rmture conductor (commuttor r junction) for tight connection. A loose connection (excessive het from prolonged crnking melts solder joints) results in urned commuttor r. 7. Resurfce nd undercut rough commuttor s follows: CAUTION Do not turn down the commuttor excessively.. Resurfce the commuttor nd undercut the insultion etween the commuttor rs 1/32 in. (0.8mm) to the full width of the insultion nd so tht the undercut is flt.. Clen the commuttor slots fter undercutting. Pge 2B JANUARY 2001

35 c. Snd the commuttor lightly with No. 00 sndpper to remove urrs, then clen the commuttor. d. Recheck the rmture on growler for shorts s specified in the following procedure ( Testing ). 8. Open-circuited rmtures often cn e repired. The most likely plce for n open circuit is t the commuttor rs, s result of long crnking periods. Long crnking periods overhet the strter motor so tht solder in the connections melts nd is thrown out. The resulting poor connections then cuse rcing nd urning of the commuttor rs. 9. Repir rs, tht re not excessively urned, y resoldering the leds in rs (using rosin flux solder) nd turning down the commuttor in lthe to remove urned mteril, then undercut the mic. 10. Clen out the copper or rush dust from slots etween the commuttor rs. 11. Check the rmture for ground. See the following procedure ( Testing ). Testing Solenoid Driven Bendix Strters Armture Test for Shorts Check rmture for short circuits y plcing on growler nd holding hck sw lde over rmture core while rmture is rotted. If sw lde virtes, rmture is shorted. Recheck fter clening etween commuttor rs. If sw lde still virtes, replce rmture Armture Test for Ground 1. Set ohmmeter to (R x 1 scle). Plce one led of ohmmeter on rmture core or shft nd other led on commuttor. 2. If meter indictes continuity, rmture is grounded nd must e replced JANUARY 2001 Pge 2B-35

36 Checking Positive Brushes nd Terminl Set ohmmeter to (R x 1 scle). Connect meter leds etween POSITIVE rushes. Meter must indicte full continuity or zero resistnce. If resistnce is indicted, inspect led to rush nd led to POSITIVE terminl solder connection. If connection cnnot e repired, rushes must e replced POSITIVE (+) Brushes Testing Negtive Brushes for Ground Set ohmmeter to (R x1 scle). Plce one led of the ohmmeter on the NEGATIVE rush nd the other led on the end cp (re metl). If the meter indictes NO continuity, replce the NEGATIVE rush. Repet this procedure on the other NEGATIVE rush NEGATIVE ( ) Brushes -End Cp Pge 2B JANUARY 2001

37 Slve Solenoid Test 1. Disconnect ll wires from solenoid. 2. Connect ohmmeter (R x1 scle) etween terminls 1 nd Connect 12-volt power supply etween terminls 3 nd 4. Solenoid should click nd meter should red 0 ohms (full continuity). 4. If meter does not red 0 ohms (full continuity), replce solenoid. DCV ACV DVA VOLT Supply -VOA Leds JANUARY 2001 Pge 2B-37

38 Commnder 2000 Key Switch Test 1. Disconnect remote control wiring hrness nd instrument pnel connector. 2. Set ohmmeter on R x 1 scle for the following tests. 3. If meter redings re other thn specified in the following tests, verify tht switch nd not wiring is fulty. If wiring checks ok, replce switch. IMPORTANT: Key switch must e positioned to RUN or START nd key pushed in to ctute choke for this test. KEY POSITION CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS: BLK BLK/YEL RED YEL/RED PUR YEL/BLK OFF RUN START CHOKE* Pge 2B JANUARY 2001