Professional Documents
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Hyster H1.50XM (D001) Electrical Systems
Hyster H1.50XM (D001) Electrical Systems
Hyster H1.50XM (D001) Electrical Systems
CAUTION 2
When using an arc welder, always disconnect the
ground lead from the lift truck battery to prevent
alternator or battery damage. Attach the welding
ground clamp as close to the weld area as possible to 6
prevent welding current from damaging the 7
bearings.
The diodes and resistors in the electrical system can
3
be damaged if the following cautions are not
followed: 5
• Do not disconnect the battery when the engine
is running. The voltage surge can damage the 4
diodes and resistors in the electrical system. 1. BATTERY
• Do not disconnect an electric wire before the 2. KEY SWITCH
engine is stopped and the switches are “OFF”. 3. NEUTRAL START SWITCH
4. STARTER
• Do not cause a short–circuit by connecting the 5. “S” TERMINAL
electric wires to the wrong terminals. Make 6. BATTERY TERMINAL
sure a correct identification is made of the wire 7. DISCONNECT SWITCH
(EEC ONLY)
before it is connected.
• Make sure a battery is the correct voltage and FIGURE 1. THE STARTING CIRCUIT
polarity before it is connected.
• Do not check for current flow by making a Ignition System (See FIGURE 2.)
spark because the electronic components can
The ignition system generates a spark at each spark plug
be damaged.
to start combustion in each cylinder. The ignition sys-
DESCRIPTION tem has the following main parts: battery, key switch,
coil, distributor, spark plugs, and wires.
Starting System (See FIGURE 1.)
If the starter is operating, current flows from the battery,
The starting system includes the starter, battery, key through the key switch and the neutral start switch to en-
switch, and neutral start switch. The starter solenoid is ergize the starter solenoid. Current also flows through
energized when current flows through the key switch, the key switch, coil primary, and distributor. The dis-
neutral start switch, and solenoid. The solenoid mag- tributor opens and closes the coil primary circuit as the
netically pushes the clutch out to engage the engine fly- starter rotates the engine crankshaft. The opening and
wheel teeth. The solenoid also closes contacts to ener- closing of the circuit causes the primary current and
gize the starter motor. These operations occur at ap- magnetic field in the coil to change. The changing mag-
proximately the same time. The motor torque is applied netic field generates a high voltage in the secondary
just as the teeth engage. The key switch must be in the winding of the coil. The distributor sends this high volt-
START position. The neutral start switch must also be age to each spark plug at the correct time for combus-
in the ON position to energize the starter. The neutral tion.
1
7 2 Charging System (See FIGURE 3.)
1
2 3
5
4
6
9542
8
10 7
9
1. ALTERNATOR 4. INDICATOR 7. REGULATOR 10. DIODE TRIO
2. CONNECTOR 5. KEY SWITCH 8. STATOR
3. OTHER BATTERY CIRCUITS 6. BATTERY 9. ROTOR
FIGURE 3. THE CHARGING CIRCUIT
2
The alternating current (AC) generated by the alternator tor connects to the positive terminal of the battery to
is changed to direct current (DC) by the diodes to be- charge the battery.
come the alternator output. The output from the alterna-
REPAIRS
GENERAL 8. Lift the brush springs and remove the brushes from
the brush holders. Remove the brush holder assembly
NOTE: Use the TROUBLESHOOTING and CHECKS from the field housing. Move the field housing from the
AND ADJUSTMENTS sections of this section before armature and drive housing.
starting any repair procedures. Make sure that repair or
replacement of that part is necessary before removal, 9. Measure the length of the brushes. Measure from
disassembly, or replacement of the part. end–to–end of each brush. The standard length is 17 mm
(0.67 in). The minimum brush length is 11.5 mm (0.45
WARNING in). Install new brushes as shown in FIGURE 4. Install a
Always disconnect the battery ground cable before new brush holder to replace the negative brushes.
making repairs to prevent possible damage and
injury. Install a tag on the battery terminal so that no
one connects the cable on the terminal.
STARTER
3
1. SOLENOID ASSEMBLY
2. LEVER
3. BUSHING 1
4. DRIVE HOUSING
5. WASHER
6. LOCK RING
7. SPACER 5
8. CLUTCH
9. ARMATURE 2
10. FIELD HOUSING
11. BRUSH
12. BRUSH SPRING
13. BRUSH HOLDER 9
14. COVER
7
6
5
4
11
3
14
3
10
13
12
11
2. Install the lever on the clutch assembly. Install the so- 5. Install the end cover, the two long bolts, and the two
lenoid plunger on the lever. Install the armature, clutch screws that fasten the end cover.
assembly, solenoid plunger, and lever in the drive hous- 6. Install the solenoid washers, spring, and solenoid on
ing. Install the washer springs and spring seat for the the drive housing using the screws. Connect the strap
lever in the drive housing. from the motor to the motor terminal of the solenoid. In-
4
stall the washer, lock washer, and nut on the motor ter- DISTRIBUTOR, H1.50–1.75XM, H2.00XMS
minal. Tighten the nut. (S/H25–35XM, S/H40XMS)
7. Install the starter on the flywheel housing using the Removal And Disassembly (See FIGURE 7.)
two capscrews. NOTE: Do only the steps that are necessary to replace
the part that has damage.
8. Install all the electrical leads to the correct solenoid
terminals as marked on the labels. Install the plate that 1. Loosen the screws that fasten the distributor cap to the
fastens to the engine between the fuel pump and starter. distributor. Remove the cap and heat sink. If the cap will
be replaced, remove the wires from the cap. Make a note
9. Connect the battery cable to the negative terminal of for correct installation of wires in the replacement cap.
the battery. 2. Disconnect the vacuum line from the vacuum control.
Remove the coil wire from the distributor cap.
H2.00–3.20XM (H40–65XM) SHOWN 3. Make alignment marks on the engine and distributor
housing for correct alignment during installation. Make
1 3 a mark on the edge of the distributor housing for rotor
2
alignment for correct installation. Remove the nut and
washers that fasten the flange of the distributor housing
to the engine block. Slowly remove the distributor hous-
ing from the engine without turning the housing.
NOTE: The rotor will turn as the distributor is removed.
Make a note of the direction and amount of rotation from
the mark on the edge of the distributor housing.
4. Remove the signal rotor and rotor. Remove the pick–
6
4 5 up assembly and cover.
5. Remove the screws for the electronic module. Re-
move the electronic module and breaker assembly.
4. IGNITION COIL
1. ENGINE 5. SCREW, NUT, 6. Disconnect the vacuum advance mechanism. Re-
2. DISTRIBUTOR AND WASHER (2) move the screws that fasten the vacuum advance mecha-
3. BATTERY 6. BATTERY BRACKET
nism to the distributor housing. Remove the vacuum ad-
FIGURE 6. COIL REPLACEMENT vance mechanism from the housing.
7. Put the drive gear in a vise that has soft jaws. Tighten
the vise just enough to keep the gear from turning in the
COIL REPLACEMENT vise. Do not damage the drive gear. Remove the screw
from the bore in the top end of the shaft. Remove the
The coil is installed on a bracket near the battery tray. timing advance parts.
8. Put the distributor housing on a block that is a support
1. Put labels on the wires connected to the coil for cor-
for the bottom shaft near the drive gear. Use a punch and
rect connection during installation.
hammer to carefully remove the roll pin. Do not damage
2. Remove the two capscrews, nuts and washers that fas- the drive gear. Remove the drive gear and oil seal. Re-
ten the coil to the battery bracket. move the shaft.
5
7
1
11
8
12
13 2
3
4
9
5
14
6
15
1. CAP
2. HEAT SINK 10
3. SIGNAL ROTOR
4. ROTOR
5. PICK–UP ASSEMBLY
6. COVER
7. ELECTRONIC MODULE 10. OIL SEAL 13. VACUUM ADVANCE UNIT
8. BREAKER ASSEMBLY 11. SEAL 14. ROLL PIN
9. TIMING ADVANCE UNIT 12. HOUSING 15. DRIVE GEAR
6
4. Remove the rotor, seal ring, and cover.
CAUTION
If the engine crankshaft has been moved since the 5. Remove the two screws that fasten the electronic
distributor was removed, see the repair procedures module and sensing coil assembly to the heat sink. Dis-
for the engine to correctly install the distributor. Do connect and remove the electronic module from the
not do Step 8. sensing coil assembly. Disconnect the two electrical
leads for the electronic module. Remove the wire and
7. Align the marks on the engine and distributor hous- grommet assembly from the slot in the side of the dis-
ing. Align the rotor with the mark on the distributor tributor housing.
housing and move the rotor to the position as described
6. Remove the snap ring that fastens the arm of the vac-
in the NOTE of the removal procedure. When the instal-
uum advance mechanism. Remove the two screws that
lation is correct, the rotor/distributor housing mark and
fasten the vacuum advance mechanism to the distributor
the distributor housing/engine marks will all be correct-
housing. Remove the vacuum advance mechanism from
ly aligned. Tighten the capscrews that fasten the housing
the housing.
to the engine.
7. Remove the two screws on the outside of the housing
8. Connect the wires to the distributor. If necessary, con- that fasten the heat sink. The heat sink is the base for the
nect the spark plug wires to the correct spark plugs. Con- electronic module and sensing coil assembly.
nect the vacuum line to the vacuum advance mecha-
nism. 8. Remove the two screws that fasten the breaker assem-
bly to the inside of the distributor housing.
DISTRIBUTOR,
9. Put the drive gear in a vise that has soft jaws. Tighten
S/H2.00–3.20XM (S/H40–65XM) the vise just enough to keep the gear from turning in the
vise. Do not damage the drive gear. Remove the screw
Removal and Disassembly (See FIGURE 8.)
from the bore in the end of the top shaft.
NOTE: Do only the steps that are necessary to replace
10. Hold the distributor housing upside down and care-
the part that has damage.
fully tap the outer edges on a soft wooden block. Tap the
1. Loosen the two screws that fasten the distributor cap housing until the breaker assembly comes loose from
to the distributor. Remove the cap. If the cap will be re- the housing. Remove the breaker assembly and top shaft
placed, remove the wires from the cap. Make a note for from the housing.
correct installation of wires in replacement cap.
11. If the sensing coil must be replaced, remove the roll
2. Disconnect the vacuum line from the vacuum ad- pin that locks the signal rotor to the top of the shaft. Re-
vance mechanism. Remove the coil wire from the dis- move the signal rotor and sensing coil assembly.
tributor cap.
12. If the weights must be replaced, remove the two
3. Make alignment marks on the engine and distributor springs and the snap rings from the two pin mounts. Pull
housing for correct alignment during installation. Make the weights from the shaft bracket.
a mark on the edge of the distributor housing for rotor
13. To remove the bottom shaft assembly, the drive gear
alignment for correct installation. Remove the nut and
must be removed. Put the distributor housing on a block
washers that fasten the flange of the distributor housing
to the engine block. Slowly remove the distributor hous- that is a support for the bottom shaft near the drive gear.
ing from the engine without turning the housing. Use a punch and hammer to carefully remove the roll
pin. Do not damage the drive gear. Remove the drive
NOTE: The rotor will turn as the distributor is removed. gear and oil seal. Remove the two screws that fasten the
Make a note of the direction and amount of rotation from shaft bracket inside the base of the distributor housing.
the mark on the edge of the distributor housing. Remove the bottom shaft.
7
on the breaker assembly is completely installed in the
CAUTION bore of the housing. Install the two screws and fasten the
Do NOT move the engine crankshaft before the dis- breaker assembly to the inside of the distributor hous-
tributor is installed. The distributor will not be ing. Install the screws that fasten the heat sink assembly
installed correctly and the engine will not operate to the distributor housing.
correctly. If the crankshaft is moved, see the section
for the ENGINE to correctly install the distributor. 6. Install the vacuum advance mechanism on the distrib-
utor housing with the hole in the arm over the pin on the
Assembly and Installation (See FIGURE 8.) breaker assembly. Install the snap ring on the pin to fas-
ten the arm. Install the two screws that fasten the vacu-
CAUTION um advance mechanism to the distributor housing.
Make sure both distributor shafts are clean and
7. Connect the electrical leads to the electronic module.
smooth. Make sure the bores for the shafts are clean.
Make sure the leads and the grommet are in the correct
position in the slot on the side of the distributor. Install
1. Put engine oil on the top and bottom shafts. Install the
the cover, seal ring, and rotor. If necessary, install the
bottom shaft in the distributor housing and fasten with
spark plug wires in the correct positions in the replace-
the two screws inside the base of the distributor housing.
ment distributor cap. Install the distributor cap.
Install the oil seal and drive gear. Align the hole in the
gear with the hole in the shaft and install the roll pin.
CAUTION
2. Assemble and install the timing advance mechanism If the engine crankshaft has been moved since the
as shown in FIGURE 8. Make sure the weights can distributor was removed, see the section for the EN-
move easily on the pins. If necessary, use fine abrasive GINE to correctly install the distributor. Do not do
cloth to polish the pins and the holes in the weights. The Step 8.
fine abrasive cloth must be number 500 to 600. Remove
8. Align the marks on the engine and distributor hous-
all dust and put a very thin layer of grease on each pin.
ing. Align the rotor with the mark on the distributor
3. Install the breaker assembly on the top shaft. Install housing and move the rotor to the position as described
the sensing coil, with the coil windings toward the in the NOTE of the removal procedure. The distributor
breaker assembly, on the heat sink. Put a thin coating of rotor MUST be correctly aligned with the engine crank-
special heat sink grease on the electronic module. Install shaft. If the installation is correct, the rotor/distributor
the electronic module on the heat sink. housing mark and the distributor housing/engine marks
will all be correctly aligned. Tighten the capscrews that
4. Put the heat sink assembly on the top shaft. Install the fasten the housing to the engine.
signal rotor correctly on the shaft and fasten it with the
roll pin. See FIGURE 8. 9. Connect the coil wire to the distributor. If necessary
connect the spark plug wires to the correct spark plugs.
5. Install the top shaft assembly onto the bottom shaft Connect the vacuum line to the vacuum advance mecha-
and into the distributor housing. Make sure the bearing nism.
8
1
5
7
12
11 2
8
13 6
15
9 3
14
16
10
17 4
12653
9
3. Remove the capsrews, washers, and nut that fasten the 7. Remove the nuts that fasten the stator and diode as-
alternator to the engine. Remove the alternator. sembly to the rear housing. Remove the stator and diode
assembly from the rear housing.
4. Remove the three bolts that fasten the end housing to- 8. Mark the stator to show the position of the brushes and
gether. connector. Use pliers as a heat sink to keep heat from the
diodes. Use a soldering iron to remove the stator leads
5. Put the rotor in a vise that has soft jaws. Do not tighten from the diode assembly.
the vise to cause rotor distortion. Use a socket wrench to
remove the pulley nut. Remove the pulley, fan, collar, Assembly and Installation (See FIGURE 9.)
and front housing from the rotor. 1. Hold the diode assembly in a position to connect the
stator leads. Align the brushes and connector at the mark
6. Remove the three screws that fasten the bearing re- on the stator. Use pliers to keep heat from the diodes.
tainer to the front housing. Remove the bearing retainer Use a soldering iron to connect the stator leads to the di-
and ball bearing. ode assembly.
3
2 1
14
10
13
12
11
9
12643
10
2. Install the ball bearing and bearing retainer on the 6. Install the rear housing over the diode assembly.
front housing. Use the three screws. Make sure all the insulators for the screws are correctly
installed. The positive half of the diode assembly must
3. Put the rotor, with threaded end of the shaft up, in a not touch the rear housing. The screws must not touch
vise that has soft jaws. Do not tighten the vise to cause the rear housing and the positive half of the diode assem-
rotor distortion. Install the collar, fan, pulley, lock wash- bly. Install the nuts and bolts that fasten the rear hous-
er, and nut on the shaft. Tighten the nut using a socket ings.
wrench.
7. Install the alternator on the engine using the
capscrews, washers, and nut. Make sure to install the
4. Install the stator and diode assembly on the rotor and
belt on the pulley. Adjust the belt tension as described in
rear housing. Hold the brushes away from the slip rings
the section for PERIODIC MAINTENANCE.
during installation. Use a pin or wire in the hole of the
brush holder. 8. Connect the plug to the alternator connector. Connect
the other wires to the B and ground terminals as shown
5. If the ball bearing next to the slip rings was removed, on the labels. Connect the negative cable on the battery
install it on the armature shaft. terminal.
CAUTION CAUTION
Do not change the polarity of the circuits. Do not con- Make sure the cables to the starter and ammeter are
nect any wires in the circuits, except as described in gauge 4 (25 mm2) minimum.
these instructions. Never connect the wire from the 1. Put the starter in a vise so that it cannot move.
terminal marked “BAT” to an open circuit.
2. Use a 12V battery that has a full charge. Use an amme-
ter that has a minimum capacity of 60 amperes. Connect
When connecting a charger or another battery, connect
the circuit shown in FIGURE 10. Attach the jumper
the positive terminals to the positive terminal of the bat-
wire (7) to the S terminal, but do not connect the nega-
tery. Then connect the negative terminal to a clean metal
tive lead (2) of the battery to the starter yet.
part of the engine. Disconnect the charger or other bat-
tery in the reverse order. Problems in the charging cir- 3. Touch the negative lead to the starter housing for only
cuit are indicated by one or more of the following: a short time and check the indications on the meters.
11
Now, remove the negative lead from the starter housing.
Remove the small jumper wire from the S terminal. NOTE: BRUSH ASSEMBLY CAN BE
DIFFERENT THAN SHOWN.
1 2
2
1
S
7 M
9553
2
3
1. NEGATIVE BRACKETS
2. POSITIVE BRACKETS
6
3. MOUNT PLATE
9568
5
4 3 FIGURE 11. CHECK THE BRUSH HOLDER
1. STARTER SOLENOID Check Armature
2. NEGATIVE LEAD (DO NOT CONNECT)
3. 12V BATTERY Remove the armature. Use an ohmmeter to check for an
4. AMMETER infinity indication between any commutator bar and the
5. STARTER armature shaft. Check for continuity (zero ohms) be-
6. POSITIVE LEAD
tween any two commutator bars. If either check is
7. JUMPER WIRE
wrong, replace the armature.
FIGURE 10. CHECK THE STARTER
Check Field Windings
Remove the motor, brush holder, and armature. Use an
4. The starter is in good condition if all of the following
ohmmeter to check for continuity between the positive
items are correct:
brush and electrical lead of the motor. Check for a indi-
a. Clutch assembly moves so that it can engage the cation of infinity between a positive brush and the motor
flywheel. housing. If the indication is not infinity, check that the
b. Smooth rotation occurs just after clutch move- brush lead connections are not touching the housing. If
ment. either check shows a wrong condition, replace the com-
plete motor housing.
c. Ammeter must indicate 53 ampere or less.
Check Clutch And Bearing
d. Clutch assembly moves so that it can disengage
the flywheel after jumper wire is removed from S Check the teeth of the gear. If the teeth are worn or dam-
terminal. aged, replace the clutch assembly. Check the teeth of the
ring gear on the flywheel. If the teeth are worn or dam-
aged, replace the ring gear. See the section for the EN-
Check Brush Holder (See FIGURE 11.) GINE. Check that the clutch bearing rotates freely and
smoothly. The bearing must not be loose.
Remove the brush holder from the motor housing. Re-
move the brushes from the brush holder. Connect an IGNITION SYSTEM
ohmmeter between each bracket that holds each brush
and the mount plate for the brackets. The indications for Adjust Engine Timing (See FIGURE 12.)
the two positive brackets must be infinity. The indica- Check that the distributor is adjusted for the correct tim-
tions for the two other brackets must be zero ohms. ing. Connect a timing light to the number one spark plug
12
wire. Disconnect and put a plug in the vacuum hose that
is connected to the vacuum advance unit. Operate the
WARNING
Make sure the timing light, and your hands and arms
engine at idle speed (725 rpm). Carefully hold the tim- stay clear of the fan blade area. The rotating blades
ing light in a position to illuminate the indicator. The of the fan can cause damage or injury.
correct degree mark on the pulley must be aligned with
the indicator on the engine. If the mark is not aligned,
Spark Plugs
loosen the clamp at the base of the distributor housing.
Adjust the position of the distributor to align the correct Check the spark plugs for the following conditions:
timing mark and the indicator. Tighten the clamp and • Burned Insulator
check that the timing is still correct. Carefully remove
the timing light, stop the engine, and disconnect the tim- • Cracked or Broken Insulator
ing light • Burned Electrodes (anode or cathode)
• Carbon Deposits
S/H2.00–3.20XM (S/H40–65XM) SHOWN
• Damaged Gasket
CHARGING CIRCUIT
13
Check For Low Output (See FIGURE 13.) 3. If there are no indications on the voltmeter during
Steps 1 and 2, check for an open circuit between each
WARNING terminal and the battery.
Do not connect the wire from the “BAT” terminal to
the electrical ground. A short–circuit will occur and 4. If there are indications on the voltmeter during Steps 1
make sparks, which can cause injury. and 2, disconnect the cable for the electrical ground on
the battery.
NOTE: Make sure the wire from the voltmeter makes
contact with each terminal on the alternator. 5. Connect an ammeter into the circuit at the battery ter-
minal B. See FIGURE 13.
1. Connect a voltmeter between the battery terminal B
and the electrical ground. Turn the key switch to the ON 6. Connect the cable for the electrical ground on the bat-
position and check the indication. tery.
2. Connect a voltmeter to the Field terminal L and the 7. Connect a resistor (carbon pile) across the terminals
Regulator terminal R. Follow the procedure in Step 1 of the battery.
and check the indication.
WARNING
NOTE: ALTERNATOR CAN BE During engine operation, be careful not to touch pul-
DIFFERENT THAN SHOWN. leys, fans, or belts in the engine area. Contact with
these parts can cause personal injury.
1
8. Start and run the engine at 2000 to 2500 rpm. Adjust
the resistor until the maximum charging rate is reached.
2 3
9. Read the maximum charging rate on the alternator
frame. Read the ammeter. The indication on the amme-
ter must be within 10% of the amount shown on the
frame.
8
6 10. If the amount shown is within 10%, the alternator is
in good condition. Check the starter or wires for the
7
problems.
14
1
2
3
1. POINT “A” 2. POINT “B” 3. POINT “C” 4. TERMINALS FOR OTHER OHMMETER LEAD
FIGURE 14. CHECK THE DIODES
Check The Diodes (See FIGURE 14.) 4. Do Step 3 again with the negative ohmmeter lead at
the test points “A” through “C”and the positive lead at
NOTE: Disassemble the alternator for this check and the connection points for the ammeter terminals. The
the remainder of the alternator checks. The stator must correct indications are an open–circuit between the neg-
be disconnected from the diode assembly to do the fol- ative and positive ohmmeter leads for each of the nine
lowing checks. checks. See FIGURE 14. If there is a short–circuit at any
1. Use an ohmmeter with a 1.5 volt cell. Use the lowest check, that diode is bad and must be replaced.
range scale to check the positive and negative diodes of
Check Field Winding For The Rotor
the rectifier bridge and the diode set.
(See FIGURE 15.)
NOTE: Some ohmmeters use a reverse polarity. The 1. Connect an ohmmeter to each slip ring and check for
“correct indications” will be opposite for these ohmme- open circuits. If the indication is high (infinity), the
ters for Steps 3 and 4. winding has an open circuit. To check the resistance of
the field, connect the ohmmeter to the two slip rings.
2. Find the electrical connection points on the diode as-
The correct indication is 4.0 to 4.5 ohms. If the indica-
sembly for the three terminals “BAT”, “L”, and “E”.
tion is less than the specification, there is a short circuit
3. Connect the positive ohmmeter lead to point “A”. in the windings. If the indication is greater than specifi-
Connect the negative ohmmeter lead to the alternator cation, there is additional resistance in the windings.
“BAT”, “L”, and “E” terminal connection points in se-
2. To check the electrical ground, connect the ohmmeter
quence. Do this check again with the positive ohmmeter
between either slip ring and the electrical ground as
lead at point “B” and again with the positive lead at point
shown in FIGURE 15. Replace the rotor if the indica-
“C”. The correct indications are a very low resistance or
tion is less than infinity.
a short–circuit between the positive and negative ohm-
meter leads for each of the nine checks. See NOTE: Make sure the needle in the ohmmeter always
FIGURE 14. If there is an open circuit (infinity reading) returns to zero correctly. The indications will change
at any check, that diode is bad and must be replaced. when the temperature of the winding changes.
15
9552
16
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Starter does not run or has slow The battery is not fully charged or Charge battery or install new battery.
speed. is damaged.
The connections at the battery or Clean electrical terminals and con-
starter are loose or they have cor- nectors.
rosion.
Key switch is damaged. Install a new key switch.
Solenoid coil or switch contacts Install a new solenoid.
have damage.
Brush springs in starter are dam- Install new brush springs.
aged.
Brush leads are broken or have a Check and repair brush leads.
short circuit.
Commutator in starter is dirty or Clean and repair commutator.
worn.
Armature winding in starter has Install new armature winding.
damage.
Field windings in starter have dam- Install new field winding.
age.
Worn or damaged starter gears. Repair starter.
Bearings in starter are worn or Install new bearings.
damaged.
Starter operates, but engine crank- Wiring connections are broken, Repair wiring.
shaft does not rotate. loose, or have corrosion.
Starter clutch assembly has dam- Repair or install a new starter.
age.
Solenoid has damage and will not Install a new solenoid.
keep the clutch assembly engaged.
Starter clutch assembly will not Repair or install a new starter.
move freely.
Gear teeth on starter clutch assem- Repair or install a new starter.
bly are damaged.
Gear teeth on ring gear are dam- Install a new flywheel.
aged.
Starter continues to run. Contacts of solenoid are welded Install a new solenoid.
together.
Solenoid coil has a short–circuit. Install a new solenoid.
Spring that disengages the starter Repair or install a new starter.
clutch is broken.
Key switch is damaged. Install a new key switch.
Engine will not start – no spark or Distributor has damage. Install a new distributor.
weak spark. Coil has damage. Install a new coil.
Key switch has damage. Install a new key switch.
Electronic module or sensing coil Install a new module or sensing coil.
has damage.
17
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Battery does not stay charged. Battery terminals have corrosion. Clean battery terminals.
Battery has damage inside the Install a new battery.
case.
Drive belt for alternator is loose. Adjust drive belt.
Wiring connections are broken, Repair wiring connections.
loose, or have corrosion.
Short–circuit between wiring con- Repair wiring connections.
nector(s).
Alternator brushes are worn. Install new brushes.
Alternator brushes have weak Install new springs.
springs.
Alternator has dirty slip rings. Clean the slip rings.
Stator coil for alternator has a Install a new stator coil.
short–circuit.
Voltage regulator has damage. Install a new voltage regulator.
Battery is charged more than nec- Wiring connections are broken, Clean or repair wiring connections.
essary. loose or have corrosion.
Short–circuit between wiring con- Clean or repair wiring connections.
nector(s).
Field coil in alternator has damage. Install a new field coil.
18