SECTION 6D3 - STARTING AND CHARGING SYSTEM

Starting System

General Description

Service Precaution

Diagnosis

Starter

Removal

Installation

Disassembled View

Inspection and Repair

Characteristic Test

Charging System

General Description

General On-Vehicle Inspection

Generator

Removal

Inspection

Installation

Diagnosis

Disassembly

Clean

Inspection

Reassembly

Inspection

Technical Data

Starting System

General Description

Cranking Circuit

The cranking system consists of a battery, starter, starter

switch, starter relay, etc. These main components are

connected.

Starter

The cranking system employs a magnetic type reduction

starter in which the motor shaft is also used as a pinion shaft.

When the starter switch is turned on, the contacts of magnetic

switch are closed, and the armature rotates. At the same time,

the plunger is attracted, and the pinion is pushed forward by

the shift lever to mesh with the ring gear.

Then, the ring gear runs to start the engine. When the engine

starts and the starter switch is turned off, the plunger returns,

the pinion is disengaged from the ring gear, and the armature

stops rotation. When the engine speed is higher than the

pinion, the pinion idles, so that the armature is not driven.

Service Precaution

CAUTION:

Always use the correct fastener in the proper location.

When you replace a fastener, use ONLY the exact part

number for that application. Holden will call out those

fasteners that require a replacement after removal. Holden

will also call out the fasteners that require thread lockers

or thread sealant. UNLESS OTHERWISE SPECIFIED, do

not use supplemental coatings (Paints, greases, or other

corrosion inhibitors) on threaded fasteners or fastener

joint interfaces. Generally, such coatings adversely affect

the fastener torque and the joint clamping force, and may

damage the fastener. When you install fasteners, use the

correct tightening sequence and specifications. Following

these instructions can help you avoid damage to parts and

systems.

Diagnosis

Condition Possible cause Correction

Starter does not run Charging failure Repair charging system

Battery Failure Replace Battery

Terminal connection failure Repair or replace terminal connector

and/or wiring harness

Starter switch failure Repair or replace starter switch

Starter failure Repair or replace starter

Starter

Removal

1.Remove the battery ground cable.

2.Remove harness connectors (1) and (2).

3.Remove bolts from starter.

Installation

1.Install starter assembly.

2. Install mounting bolts and tighten bolts to specified torque.

Torque: 51 N⋅

⋅⋅⋅m (5.2 kgf⋅

⋅⋅⋅m)

3. Connect harness.

4. Reconnect the battery ground cable.

Disassembled View

Legend

1 Bolt

2 Magnetic Switch

3 Gear Case

4 Piston

5 Piston Shaft

6 Center Bracket

7 Armature

8 Yoke Assembly

9 Brush and Brush Holder

10 Washer

11 Rear Cover

12 Through Bolt

Inspection and Repair

Repair or replace necessary parts if extreme wear or damage

is found during inspection.

Armature

Check for continuity between commutator and segment.

Replace commutator if there is no continuity (i.e.,

disconnected).

Check for continuity between commutator and shaft.

Also, check for continuity between commutator and armature

core, armature core and shaft. Replace commutator if there is

continuity (i.e., internally grounded).

Brush

Measure the length of brush.

Replace with a new one, if it is below the limit.

Brush Holder

Check for continuity between brush holder (+) (4) and base (-).

Replace, if there is continuity (i.e., insulation is broken).

Magnetic Switch

Check for continuity of shunt coil between terminals S and M.

Replace, if there is no continuity (i.e., coil is disconnected).

Continuity of Series Coil

Check for continuity between terminals S and M.

Replace, if there is no continuity (i.e., coil is disconnected).

Continuity of Contacts

With the plunger faced downward, push down the magnetic

switch. In this state, check for continuity between terminals B

and M. Replace, if there is no continuity (i.e., contacts are

faulty).

Pinion

Check if the pinion rotates smoothly in drive direction by hand,

or if it is locked when it is rotated in reverse. If not, replace the

pinion.

Characteristic Test

For easily confirming the characteristics, conduct the noload

test as follows:

Rating as short as 30 seconds requires rapid testing.

Fix the starter on the test bench, and wire as shown in

illustration. When the switch is closed, the current flows and

the starter runs under no load. At this time, measure current,

voltage and speed to check if they satisfy the standard.

Legend

1 Volt Meter

2 Revolution Indicator

3 Battery

4 Ammeter

5 Switch

Charging System

General Description

The charging system is an IC integral regulator charging

system and its main components are connected as shown in

illustration.

The regulator is a solid state type and it is mounted along with

the brush holder assembly inside the generator installed on the

rear end cover.

The generator does not require particular maintenance such as

voltage adjustment. The rectifier connected to the stator coil

has eight diodes to transform AC voltage into DC voltage.

This DC voltage is connected to the output terminal of

generator.

Legend

1 Startor assembly

2 Housing

3 Slipring

4 Screws (2)

5 Regulator

6.Bolt (4)

7 Rectifier assembly

8 Retaining assembly

9 B+ terminal nut and washer

10 Pulley

11 Rotor assembly

12 Ball bearing

General On-Vehicle Inspection

The operating condition of charging system is indicated by the

charge warning lamp. The warning lamp comes on when the

starter switch is turned to "ON" position. The charging system

operates normally if the lamp goes off when the engine starts.

If the warning lamp shows abnormality or if undercharged or

overcharged battery condition is suspected, perform diagnosis

by checking the charging system as follows:

1.Check visually the belt and wiring connector.

2.With the engine stopped, turn the stator switch to "ON"

position and observe the warning lamp.

If lamp does not come on:

Disconnect wiring connector from generator, and ground

the terminal "L" on connector side.

If lamp comes on:

Repair or replace the generator.

Generator

Removal

1.Disconnect battery ground cable.

2.Move drive belt tensioner to loose side using wrench then

remove drive belt.

3.Disconnect terminal "B" wiring connector and connector.

4.Remove generator assembly.

Generator Power and Circuit Diagram Inspection

Legend

1 Load resistor, set parallel to battery

2 Battery

3 Voltmeter

4 Ammeter

5 Ignition Lock

6 Charge Telltale

7 Generator

1. Disconnect battery.

2. Close off connecting cable from alternator terminal "B+".

3. Set ammeter (measuring range 100A) in disconnected line.

4. Connect controllable load resistor to battery terminal.

5. Set resistor in front of connection to "O"; connect first to

battery, then to resistor.

6. Connect tachometer.

7. Connect oscilloscope according to manufacturer's

instructions.

8. Connect battery.

9. Start engine and read off resulting current at various engine

speeds.

Generator Power

1. Adjust load resistor, if the required load currents are not

attained.

2. The shape of the voltage curves on oscilloscope curve

should be regular.

3. Test value: 5 to 7A.

4. If the required minimum current intensity is not attained, or if

the oscilloscope picture shows variations, the alternator

should be overhauled.

Regulated Voltage Circuit Diagram Legend

1 Battery

2 Ignition Lock

3 Charge Telltale

4 Resistor, for attainment of load current with the battery set in

series

5 Voltmeter

6 Ammeter

7 Generator

Installation

1. Install generator assembly and bring generator assembly to

the position to be installed.

2. Install generator assembly and tighten to the specified

torque.

Torque:

Long bolt: 35 N⋅

⋅⋅⋅m (3.6 kgf⋅

⋅⋅⋅m)

Short bolt: 20 N⋅

⋅⋅⋅m (2.0 kgf⋅

⋅⋅⋅m)

3. Connect wiring harness connector.

4. Move drive belt tensioner to loose side using a wrench, then

install drive belt to normal position.

5. Reconnect battery ground cable.

The generator has four external connections; the "B+" lead to

battery positive, "L" lead to the warning lamp circuit(max. 2

watts), "S" lead to battery positive terminal for battery sensing

and an earth connection.

Explanation of type inscripiton

Example:KC-A--> 14V 50-90A.

K = Code for Stator OD(126mm OD).

C = Compact Generator.

A = Ausland (countries other than Germany)

> = Direction of rotation(clockwise).

14V = Generator Operating Voltage.

50A = Stabilised output at 25 C at 1800 RPM./13.5

Volts.

90A = Stabilised output at 25 C at 1800 RPM./13.5

Volts.

Generator Connetions.

B+ : Battery Main Connection (battery positive)

S : Battery Sense Connection(battery positive)

L : Waring lamp(via warning lamp to Ignition switch)

BATT.SENSE

REGULATOR ASSEMBLY

HYBR10

ALTERNATOR ASSEMBLY

12V BATT.

1GN.SW.

300a*

WARN.LAMP

1.2 WATT

SUPPRESSOR

CAPACITOR

0.5µf

NOTE: * RESISTOR IS RECOMMENDED TO

ENSURE THAT THE GENERATOR

REMAINS FUNCTIONAL IN CASE OF

WARNING LAMP FAILURE

Warning

Do not reverse S and L connections as this will destroy the

warning lamp circuit of the regulator.

Ensure good electrical contact beween generator earth and

battery negative,

Operation

With the Iginiton switch turnded "ON", current is supplied via

the warning lamp to the "L" terminal of the regulator. Base

current is fed to T15 causing it to turn on, current then flows

from B+ through the rotor winding via the regulator brushes

and the collector emitter junction of T15 to earth completing the

circuit. The current in the rotor causes a magnetic field

between adjacent poles to be created, this field is rotated and

cuts the windings of the stator at right angles inducing a

voltage into them.

As the speed is increased this induced voltage increases and

results in curent being rectified in the 3 phase diode bridge and

supplied as DC to the B+ output and hence to the battery.

When the voltage at the B+ terminal of the battery reaches

around 14.2 volts, this voltage is monitored by the "S" lead and

turns the regulator Hybrid base current to T15 OFF removing

rotor current, resulting in a decrease in output voltage to below

the regulating voltage, T15 base current turns ON and the

whole cycle is repeated very rapidly.

D38 protects T15 and the regulator against the back voltage

developed across the rotor winding when T15 turns OFF.

The new generated EP regulators incorporate current limiting in

the warning lamp circuit.

Backup Regulation

The EP regulator will limit the output voltage to a safe level

should either the main B+ cable or the battery sense wire

become decoupled, the output voltage will be slightly above the

normal setting(1-3 volts).

Start up phase

When the Iginition switch is turned on and the engine is not

running, the current to the rotor is reduced by switching it on

and off at a 50% duty cycle, the frequency is approximately 4

KHz and may be audible at times.

This is quite normal, once the engine is started normal

regulation commences.

Warning lamp failure

Should the warning lamp fail, the generator will self excite by

deriving a small current from the phase connecion allowing the

voltage to build up to regulating level.

Note: no filed current will flow when the engine is cranking.

Diagnosis

The EP regulator incorporates diagnostics which will illuminate

the warning lamp as a result of fault conditions in the generator

and external circuitry.

These conditions include:

1.An open circuit in the regulator battery sensing wire (S

Terninal)

2.An open circuit or excessive voltage drop in the B+ cable.

3.An open circuit in the generator phase connection.

4.Overcharging of the battery.

5.Regulator output stage short circuit.

6.Open circuit rotor.

The regulator compares the voltage at B+ with the voltage at

the "S" terminal connceted to battery positive. If the voltage

differential exceeds a predetermined threshold, the regulator

will operate in backup mode to limit the output voltage to a safe

level. The warning lamp; will remain illuminated as along as

these conditions prevail.

Sources of high resistance which will trigger the warning lamp

are:

a.Poor contact in wiring harness connectors.

b.Poor contact between rectifier and regulator.

c.High resistance in fusible link assembly.

Caution:

When bench testing the generator it is important that the

warning lamp wattage of 2 watts is not exceeded.

Reversal of the "S" and "L" on the regulator will damage

the regulator.

The correct plug for the regulator is a 9 122 067 011 for the

Bosch tye and for the Shinagawa connector the number is

X02FW.

See appendix 1 for daignostic matrix.

Before testing or disassembling the generator please observe

the following points.

1. When testing the diodes with AC type testers the RMS.

Vlotage output must not exceed 12.0 volts, it is

recommended that the stator should be disconnected

during this test.

2. Where zener power diodes are used, the breakdown

voltage should be tested to ensure all diodes have the same

zener voltage.

3. Insulation tests on the rotor and stator should use a voltage

not exceeding 110v for a series test lamp. The rectifier

must be disconnected from the stator prior to testing.

4. When carrying out repairs to the charging system always

disconnected the battery negative first, and reconnect it last.

5.During current output tests please make sure that the

ammeter is securely connceted into the charge circuit.

6.Some battery powered timing lights can produce high

transient voltages when connected or disconnected. Only

disconnect or connect timing lights when the engine is

switched off.

7.Make sure the warning lamp circuit is functioning normally

before commencing tests.

8.Battery isolation switches must only be operated when the

engine is stopped.

9.To protect the charging system when using 240 volt

chargers it is recommeneded that the battery is

disconnected whilst charging.

10.Due to the very low resistance value of the stator winding it

may not be possible to obtain accurate readings without

special equipment.

11.12 volts must never be connected to the "L" terminal of the

regulator as this will damage the lamp driver circuit.

12.No loads apart from the warning lamp can be connected to

the "L" termainal. The "W" terminal is provided for this

purpose.

Disassembly

1. Mark the relative positions of the end housings in relation to

the stator assembly to aid reassembly. Use a permanent

marking pen do not use centre punched as this can cause

misalignmnet of the housings.

2. Remove the EP regulator from the slipring end housing by

removing the two screws. Tilt the regulator slightly from the

plug connection until the regulator clears the housing, then

lift clear.

3. Remove the four through bolts.

4. Carefully remove the stator assembly along with the slipring

end housing taking care not to put strain on the stator wires.

5. To disconnect the stator from the rectifier assembly, grasp

the stator wires close to the wire loop with a pair of long

nosed pliers, heat the joint with a soldering iron, when the

point becomes plastic apply a slight twisting motion to the

wires, then pull upwards to release the wires. Remove the

stator.

This procedure opens the wire loop to release the stator

connections easily.

6. To remove the rectifier remove the three retaining screw

and the B+ terminal nut and washers.

Note: the B+ bolt and the positive heatsink retaining screw are

fitted with mica insulating washers.

These must be discarded and replaced with new washers and

heatsink compound.

7. To remove the pulley, mount an 8mm Allen key in the vice

with the short end upwards, place a 24mm ring spanner on

the puley nut, position the internal hexagon of the rotor shaft

onto the Allen ken, loosen the nut and remove the pulley.

Note: the pulley has an integral boss which locks up against

the bearing,

therefore no thrust collar is provided.

8. Removing the rotor assembly. Remove the four retaining

screws from the drive end housing, withdraw the rotor

complete with the bearing.

Note: the rotor must not be pressed from the drive end housing

using a press as the bearing retaining plate and drive end

housing will be damaged or distorted. Parts removed in this

way must be replaced if the integrity of the generator is to be

maintained.

9. Remove the drive end bearing from the rotor shaft using a

chuck type puler, take care not to distort the fan assembly

during this process.

10.Remove the slipring end bearing using the same meghod

as in 9.

Clean

Thoroughly clean all components except the rotor and stator

with an approved cleaning agent. Ensure that all traced of oil

and dirt are removed. If an abrasive cleaner is used to remove

scale and paint from the housings take care not to abrade the

bearing and mounting spigot surfaces. The rotor and stator

must be cleaned with compressed air only, the use of solvents

could cause damage to the insulating materials.

Inspection

1. Rectifier assembly

The following test equipment is required.

The recitifier assembly is not repairable and must be replaced

if a faulty diode is detected during inspection.

(a) Adiode tester where the DC output at the test probes does

not exceed 14 volts or in the case of AC testers 12 volts

RMS. This is to ensue that when inspection rectifiers fitted

with zener power diodes the forward and reverse checks

are completer and are not masked by the diode turning on

due to the zener breakdown voltage.

(b) A zenere diode tester with a DC output in excess of 30

volts, the tester should also incorporate internal current

limiting set to 5 Ma. to prevent high currents during

inspection.

temperature and overload, open circuits are usually a result

of excessive voltage.

Positive heatsink

8 diode6 diode

Negative heatsink

AStarpoint F

B+Bolt

Diode connections

Stator connection

1.1 Power Diodes.

Apply the negative test probe of the diode tester or a

multimeter with a diode test feature to the positive heatsink and

the positive probe alternatevely to A,B,C, a low resistance

reading, or the forward voltage drop across the diode shoud be

obtained. Reverse the test probes, a high resistance reading or

a higher reverse voltage should be obtained.

Now connect the positive test probe to the negative heatsink

and the negative alternatively to D,E,F, a low resistance or

forward voltage drop across the diode should be obtained.

Reverse the test probes, a high resistance reading or a higher

reverse voltage should be obtained.

For 8 diode rectifier plates tests for G and H should be

included. When the reverse voltage test is done the applied

voltage should be less than 14 volts DC or 12 volts RMS for

AC testers.

1.2 Zener Diode

The basic tests in 1.1 should be undertaken first before the

diode zener voltage is tested. Diodes are grouped together

according to their zener voltag i.e. all diodes within a rectifier

must have the same zener voltage.

Connect the test probes as for the reverese test listed above

i.e. reverse biased apply the test voltage form the zener diode

tester (current limited to 5ma) and read to zener breakdown

voltage this should be a steady reading and not increase with

increased voltage from the tester.

Readings for Zener diode groups 011 to 042

Zener voltage at

5Ma.

Positive

diode

Negative

diode

Fordward

current Rating

17.8v-19.2v 011 012 25A

18.8v-20.2v 013 014 25A

19.8v-21.2v 015 016 25A

20.8v-22.2v 017 018 25A

21.8v-23.2v 019 020 25A

22.8v-24.2v 021 022 25A

17.8v-19.2v 031 032 35A

18.8v-20.2v 033 034 35A

19.8v-21.2v 035 036 35A

20.8v-22.2v 037 038 35A

21.8v-23.2v 039 040 35A

22.8v-24.2v 041 042 35A

Note: Diode number is stamped on the rear of the diode.

2. Stator

Inspect the stator insulation resistance to ground with an

insuation tester or a series test lamp up to 110 volts.

The insulation resistance must be greater than 1 megohm.

The winding reisistance is measured between phases using a

low reading ohmmeter designed for this purpose, the values

are given at the rear of this instruction.

3. Rotor

Inspect the rotor for insulation resistance to ground using an

insulation tester or a series test lamp up to 110 volts.

The insulation resistance must be grater than 1 megohm.

Measure the rotor resistance between the sliprings using an

ohmmeter or apply 12 volts across the sliprings and measure

the rotor current flow, then divide 12 by the measured current,

the results is the rotor resistance in ohms. values are given at

the rear of this instruction.

If the sliprings are worn or out of round they must be re-

machined to a minimum diameter or 26.7 mm and should have

a runout not exceeding 0.060mm. If the slipring is below these

limits it must be replaced with a new one.

Warning; extreme care must be exercised when machining

the slipring as it is possible for the turning tool to foul the fan.

4. Replacing the brushes (inbuilt regulator)

Check the brushes for length, this is measured from the brush

holder to the end of the brush along it's centre line. Also

inspect for any sideways wear. If worn replace both brushes.

The minimum length is 3.8mm. Inspect the brush springs for

signs of corrosion or loss of tension or uneven tension.

Replacing the brushes, using a soldering iron apply heat to the

soldered joints on the rear of the brush holder of the regulator,

using a small lever prise up the retaining tabs to release the

brush lead and spring. Thread the new brush lead up the

brush holder along with the spring, pull the lead through the

tabs until the brush is protruding 12mm from the holder.

Bend down the tabs and solder the brush lead taking care not

to allow the solder to run up the lead which will reduce

flexibility. Use 60/40 resin cored solder.

5. Ball bearing

Please note the bearings used in this KCA generator are a high

tolerance type, only fully sealed bearings of the same

specification are to be used as replacements. It is

recommended that the bearings be replaced during the

reconditioning process to restore the unit to original

specification.

6. Regulator

The regulator can only be tested when fitted into an altenator.

Warning: do not reverse"S" and "L" connections or put 12

volt supply to "L" terminal, this connection must not be

used as a supply source other than to supply the

requirements of the warning lamp 2(watts).

Such action will destroy the regulator warning lamp

circuit.

For test voltages refer to Generator output testing section.

See also additional information on regulator function earlier in

this instruction.

Reassembly

Generator

(a) Press new bearing onto slipring end of the rotor taking care

to aplly the force to the bearing inner race only, otherwise

the bearing will be noisy and it's life will be shortened.

(b) Fit a new bearing to the drive end housing, fit the bearing

plate, and four retaining screws, press the rotor into the

bearing, using a support tool to take the thrust against the

bearing inner.

The support is fitted from the pulley side of the bearing. In

this way the thrust is not taken by the drive end housing.

short end upwards, place a 24mm ring spanner on the shaft

nut, position the internal hexagon of the rotor shaft onto the

Allen key, tighten the nut to the required torque(See torque

chart)

(d) Inspect the bearing support ring for signs of damage, if in

doubt replace the ring by pressing it into the housing by

hand, do not use excessive force.

(e) To refit the rectifier, fit new mica washers to the positive

heatsink B+ bolt and retaining screw each washer must

have heatsink compound applied to both surfaces before

fitting.

Fit the three retaining screws to the rectifier then install into

slipring end housing. Tighten the B+ bolt to the reuired

torque.

(f) To refit the stator, make sure the spigot surface are clean

and free from damage, fit the stator into the slipring end

housing noting the correct lead connection positioning. Fit

the stator leads into the wire loops in the recrifier. Using a

pair of pliers squeeze the loop to retain the stator lead prior

to soldering. Repeat for each lead in turn, solder the leads

into position using 60/40 resin cored solder. Make sure the

leads will be clear of the internal fan when the rotor is

assmebled into the stator.

(g) Carefully install the rotor into the stator/slipring end housing

assembly, noting the alignment of the housings and through

bolt holes. Fit the through bolts making sure the stator is

seated correctly, tighten the through bolts to the correct

torque setting (uneven torque can produce magnetic noise

levels above normal).

(h) Fitting the regulator. Compress the brushes into the brush

holder by hand, slip the regulator through the opening in the

rear of the slipring end housing until the brushes come in

contact with the slipring. Press the regulator towards the

slipring until the holes are aligned then fit the retaining

screws and tighten.

Inspection

Generator

Before any in field testing can be undertaken it is important that

the battery's conditions is established and the terminals are

clean and tight.

Check the condition of the generator drive belt and ensure that

it is adjusted in accordance with the engine manufacturer's

recommnedations.

Battery conditions:

Note: This assessment may be difficult with maintenance free

assemblies.

Test the specific gravity of the individual cells the readings

should be within 10 points of each other, it is recommended

that the average SG should be 1.260 or higher.

A load test should be carried out to determine the ability of the

battery to supply and accept current. This is a good indicator

as to the general condition of the battery.

A load equal to the normal starting current should be placed

across the battery, the duration of this load test should not

exceed 10 seconds, during this time the terminal voltage

across the battery should not drop below 9.6 volts. Observe

each cell for signs of excessive gas liberation, usuall an

indication of cell failure.

If the battery test is clear proceed with the Generator tests as

follows.

Care should be taken when making the following connections.

It is recommended that the battery negative terminal be

disconnected before the test meters are connected, and

reconnecting the negative terminal when the meters are

inserted into the circuit under test. The warning lamp in the D+

circuit should not exceed 2 watts.

Regulating voltage test on the vehicle.

Connect a voltmeter to the generator, the positive lead to the

B+ terminal and the nagative lead to the generator casing.

Select the voltage range to suit the system, i.e. 20v for 12 volt

sysytems or 40v for 24 volt systems. Connect an ammeter in

series with the main output cable from the B+ terminal on the

generator, the range selected must be capable of reading the

maximum output from the generator.

Note the voltmeter reading before starting the engine. This

reading should increase when the engine is running indicating

generator output, start the engine and increase the engine

speed until the generator is running at 4000 rpm, switch on

vehicle loads of 5-10 A is indcated on the ammeter, the

voltmeter shoud read 14.0-14.2 v for a 12 volt system, for a 24

volt system the readings should be 5-10 A and 27.7-28.5 volts.

Load regulation test

Increase the engine speed until the generator is running at

6000 rpm, increase the load to 90% of full output a decrease in

the regulating voltage should not exceed 0.50 volts for 12 v

and 0.70 v for 24 v regulators of the readings obtained in the

previous test. If so, the regulator is defective.

Generator output test at full load

Increase engine speed until the altenator is running at 6000

rpm, switch on electrical loads until the generator voltage drops

to 13.5 volts for 12 v systems and 26 volts for 24 v systems, full

outut should be obtained under these conditions. It may be

necessary to adjust engine speed to maintain altenator speed.

If sufficient electrical loads are not available a carbon pile

resistance can be connected across the battery and adjusted

until maximum output is obtained.

Keep the time for this test to a minimum to avoid undue

heating and high engine speeds.

Technical Data

(mm)

Brush wear - Minimum Length 3.8

Sliprings - Minimum Diameter 26.7

Sliprings - Trueness <0.06

Pole claws - Trueness <0.05(93.25±0.05)

Torque

N.m(kgf⋅m)

Pulley retaining nut 54-68(5.5-6.9)

Capacitor retaining screw 2.7-3.8(0.3-0.4)

Capacitor whiz nut 1.5-2.2(0.1-0.2)

B+ terminal nut M8 7.5-8.5(0.8-0.9)

B+ terminal rectifier nut 6.0-7.5(0.6-0.8)

Regulator retaining screw 1.6-2.3(0.1-0.2)

Rectifier retaining screw 1.6-2.3(0.1-0.2)

Bearing retaining plate screw 2.1-3.0(0.2-0.3)

Through bolt 3.8-5.5(0.4-0.6)

Winding resistance(between phases)

(Ω)

Stator Rotor

70 Amp generator 0.086+10% 2.6±0.13

85 Amp generator 0.058+10% 2.6±0.13

90 Amp generator 0.056+10% 2.6±0.13

Warning lamp fault indication

Fault running Generator not

running Ignition ON

Generator

Iginiton ON

Generator out cable

O/C

ON ON

Battery "S" cable O/C ON ON

Battery overcharged ON ON

Positive diode short OFF ON

Negative diode short ON ON

Positive diode open ON OFF

Negative diode open ON OFF

Phase voltage sensing ON ON

cable open circuit

Power transistor

shorted

ON ON

Warnign lamp driver

O/C

OFF OFF

Output wave forms for phase and startpoint connections.

Note; the average of these two waveforms are identical from

no load to 100% output of rated load.

Voltage phase = Voltage startpoint

6.9v@ rated output 7.2v@ Zero output

Note: The phase frequency is one third of the startpoint

frequency.