Complete service technical manual with electrical wiring diagrams for John Deere Alternators & Starter Motors, with all the workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Alternators & Starter Motors workshop CTM technical service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CTM77 - John Deere Alternators & Starter Motors Component Technical Manual.pdf
CTM77 (30OCT00) - John Deere Alternators & Starter Motors Component Technical Manual.epub

Total Pages: 811 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle etc.
Language: English

Main Sections

Foreword

Introduction and Safety Information

Delco-Remy Alternators

Motorola Alternators

Niehoff Alternators

Denso Alternators

Bosch Alternators

Valeo Alternators

Magneton Alternators

Leece-Neville Alternators

Prestolite Alternators

Iskra Alternators

Delco-Remy Starter Motors

John Deere/Denso Starter Motors

Bosch Starter Motors

Iskra Starter Motors

Valeo Starter Motors

Magneton Starter Motors

 

Table of Contents - expanded view

Foreword

Introduction and Safety Information

Safety

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Handling Batteries Safely

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Prevent Machine Runaway

Live With Safety

General Information

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Electrical System Basic Information and Wiring Diagrams

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Seven Step Electrical Test Procedure

Multimeter

Delco-Remy Alternators

Delco-Remy Alternator Theory of Operation

Delco-Remy (Delcotron) Alternator Operation

Delco-Remy (Delcotron) Regulator Operation

Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Essential Tools

Other Material

Delco-Remy (Delcotron) 10SI, 12SI, and 15SI Charging Circuit Repair Specifications

Delco-Remy (Delcotron) 10SI, 12SI, and 15SI Charging Circuit Test Specifications

Remove Pulley Nut

Separate Housing

Remove Front Bearing

Install Front Bearing

Remove and Install Rear Bearing

Test Rotor for Grounds

Test Rotor for Open Circuit

Test Rotor for Short Circuit

Repair Slip Rings

Inspect Stator

Test Stator for Grounds

Test Stator for Short Circuit

Test Brush Assembly for Grounds

Test Diode Trio

Test Rectifier Bridge

Regulator Test

Assemble the Alternator

Delco-Remy (Delcotron) 21SI Alternator Repair

Essential Tools

Delco-Remy (Delcotron) 21SI Charging Circuit Repair Specifications

Delco-Remy (Delcotron) 21SI Charging Circuit Test Specifications

Disassemble Delco-Remy 21SI Alternator

Disassemble Alternator

Slip Ring End Housing and Components

Drive End Frame and Components

Assemble Alternator

Slip Ring End Housing Assembly

Final Assembly

Motorola Alternators

Motorola Alternator Theory of Operation

Motorola Alternator Operation

Motorola Regulator Operation

Motorola 8E-Series Alternator Repair

Essential Tools

Motorola 8E-Series Charging Circuit Repair Specifications

Motorola 8E-Series Charging Circuit Test Specifications

General Information

Remove Alternator for Repair

Disassemble and Test Motorola 8E-Series (12-Volt, 65 Amp) Alternator

Assemble Motorola 8E-Series (12-Volt, 65 Amp) Alternator

Motorola HC-, MA-, MR-Series Alternator Repair

Essential Tools

Service Equipment and Tools

Motorola HC-, MA-, MR-Series Charging Circuit Repair Specifications

Motorola HC-, MA-, MR-Series Charging Circuit Test Specifications

Disassemble and Test Motorola HC-, MA-, MR-Series Alternator

Assemble Motorola HC-, MA-, MR-Series Alternator

Motorola A-, RA-, 8AR-Series Alternator Repair

Essential Tools

Motorola A-, RA-, 8AR-Series Charging Circuit Repair Specifications

Motorola A-, RA-, 8AR-Series Charging Circuit Test Specifications

Disassemble and Test Motorola A-, RA-, 8AR-Series Alternator

Assemble Motorola A-, RA-, 8AR-Series Alternator

Motorola SA-Series Alternator Repair

Essential Tools

Other Material

Motorola SA-Series Charging Circuit Repair Specifications

Motorola SA-Series Charging Circuit Test Specifications

Remove Alternator for Repair

Disassemble and Test Motorola SA-Series Alternator

Assemble Motorola SA-Series Alternator

Motorola TA-Series Alternator Repair

Essential Tools

Service Equipment and Tools

Motorola TA-Series Charging Circuit Repair Specifications

Motorola TA-Series Charging Circuit Test Specifications

Remove Alternator for Repair

Disassemble and Test Motorola TA-Series Alternator

Assemble Motorola TA-Series Alternator

Niehoff Alternators

Niehoff Alternator Theory of Operation

Starting the Niehoff Alternator

Niehoff Alternator Operation

Niehoff Alternator Load Dump Circuit

Niehoff 12-Volt, 110-Amp Alternator Repair

Essential Tools

Other Material

Niehoff 12-Volt Charging Circuit Repair Specifications

Niehoff 12-Volt Charging Circuit Test Specifications

Disassemble Niehoff 12-Volt, 110-Amp Alternator

Test Niehoff 12-Volt, 110-Amp Alternator Components

Assemble Niehoff 12-Volt, 110-Amp Alternator

Establish Magnetic Field

Niehoff 24-Volt, 50-Amp Alternator Repair

Essential Tools

Other Material

Niehoff 24-Volt Charging Circuit Repair Specifications

Niehoff 24-Volt Charging Circuit Test Specifications

Disassemble Niehoff 24-Volt, 50-Amp Alternator and Test Components

Assemble Niehoff 24-Volt, 50-Amp Alternator

Re-Establish Magnetic Field

Denso Alternators

Denso Alternator Theory of Operation

Denso Alternator Operation

Denso Regulator Operation

Denso Alternator with Add-On Regulator Repair

Essential Tools

Other Material

Denso Charging Circuit Repair Specifications (Alternators with Add-On Regulator)

Denso Charging Circuit Test Specifications (Alternators with Add-On Regulator)

Disassemble Denso Alternator with Add-On Regulator and Test Components

Separate Housing

Separate Housing and Remove Rear Bearing

Inspect Rear Bearing

Install Rear Bearing

Remove Stator, Rectifier Bridge and Brush Assembly

Test Brush Assembly

Install New Brushes

Inspect Stator

Test Stator for Grounds

Test Stator for Open or Short

Test Diodes in Rectifier Bridge

Test Diodes for Open or Short Circuit

Test Diode/Resistor Trio

Connect Stator Windings

Test Regulator

Assemble Rear Frame

Remove Pulley Nut

Remove and Inspect Front Bearing

Install Front Bearing Assembly

Test Rotor for Grounds

Test Rotor for Open or Shorted Circuits

Recondition Slip Rings

Install Rotor and Front Housing

Install Pulley Assembly

Install Regulator

Denso Alternator with Built-In Regulator Repair

Essential Tools

Other Material

Denso Charging Circuit Repair Specifications (Alternators with Built-In Regulator)

Denso Charging Circuit Test Specifications (Alternators with Built-In Regulator)

Disassemble and Test Denso Alternator with Built-In Regulator

Disassemble Alternator

Assemble Denso Alternator

Bosch Alternators

Bosch Alternator Theory of Operation

Function of Alternator

Bosch Alternator Repair

Essential Tools

Other Material

Bosch Charging Circuit Repair Specifications

Bosch Charging Circuit Test Specifications

Alternator, Section View

Alternator Removal

Removing Brush Holder with Regulator

Alternator Disassembly

Stator Removal

Diode Plate Removal

Alternator Exploded View

Testing Rotor for Short Circuit

Testing Rotor for Ground

Testing Slip Rings and Rotor Shaft for Radial Runout

Turning Down Slip Rings

Testing Stator Coil for Short Circuit

Testing Stator Coil for Grounds

Replacing Carbon Brushes

Replacing Ball Bearings

Checking Positive Diodes

Checking Negative Diodes

Testing Exciting Diodes

Diode Plate Installation

Soldering Stator Coils

Pressing Ball Bearing onto Rotor Shaft

Pressing Rotor into Drive End Frame

Assemble Alternator

Installing Brush Holder with Regulator

Fan and Belt Pulley Removal and Installation

Valeo Alternators

Valeo Alternator Theory of Operation

Valeo Alternator Operation

Valeo Regulator Operation

Valeo Alternator Repair

Essential Tools

Other Material

Valeo Charging Circuit Repair Specifications

Valeo Charging Circuit Test Specifications

Disassemble Alternator and Test Components

Assemble Alternator

Valeo A13N-Series Alternator Repair

Essential Tools

Valeo A13N-Series Repair Specifications

Valeo A13N-Series Test Specifications

Disassemble and Test Valeo A13N-Series Alternator

Assemble Valeo A13N-Series Alternator

Magneton Alternators

Magneton Alternator Theory of Operation

Operation of Alternator

Magneton Alternator Repair

Essential Tools

Magneton Charging Circuit Repair Specifications

Magneton Charging Circuit Test Specifications

Exploded View of Alternator

Identification

Troubleshooting

Disassembly of Alternator

Testing Brush/Regulator Assembly

Testing Rotor

Testing Stator/Rectifier Bridge Assembly

Rectifier Bridge Replacement

Reassembly of Alternator

Installation of Alternator

Leece-Neville Alternators

Leece-Neville Alternator Theory of Operation

Alternator Operation

Leece-Neville Alternator Repair

Essential Tools

Leece-Neville Repair Specifications

Leece-Neville Charging Circuit Test Specifications

Repair Alternator

Charging System Failure

Alternator Troubleshooting

Alternator Output Test

Diode Trio Test

Full Field Test

Adjust Regulator

Prestolite Alternators

Prestolite Alternator Theory of Operation

Alternator Operation

Prestolite Alternator Repair

Essential Tools

Prestolite Charging Circuit Test Specifications

Repair Alternator

Charging System Failure

Alternator Troubleshooting

Test Alternator

Iskra Alternators

Iskra Alternator Theory of Operation

Operation of Alternator

Iskra Alternator Repair

Essential Tools

Iskra Charging Circuit Repair Specifications

Iskra Charging Circuit Test Specifications

Exploded View of Alternator

Identification

Troubleshooting

Remove and Install Pulley

Testing Brush/Regulator Assembly

Install Brush/Regulator Assembly

Installation of Alternator

Delco-Remy Starter Motors

Starting Circuit Theory of Operation

General Information

Typical Starting Circuit Operation

Typical Starter Motor Operation

Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Essential Tools

Service Equipment and Tools

Other Material

Delco-Remy 10MT, 20MT, 22MT, 25MT, 27MT, 28MT Starter Motor Repair Specifications

Delco-Remy 10MT, 20MT, 22MT, 25MT, 27MT, 28MT Starter Motor Test Specifications

Diagnosing Starter Motor Malfunctions

Delco-Remy Starter Motor Cutaway View—Series 10MT, 20MT, 22MT, 25MT, 27MT, 28MT

Check Operation of Motor Drive

Make Solenoid Pull-In Test

Make Solenoid Hold-In Test

Make Solenoid No-Load Test

Disassemble Starter Motor and Test Components

Clean Starter Motor Components

Inspect Armature

Make Short Circuit Test

Make Armature Ground Test

Make Open Circuit Test

Make Ground Circuit Test for Field Windings

Make Open Circuit Test for Field Windings

Remove Field Coils (If Necessary)

Install Field Windings

Disassemble Solenoid

Inspect and Clean Solenoid Parts

Assemble Solenoid

Remove Drive End Bushing and Wick

Install Drive End Bushing and Wick

Inspect Drive Motor ID

Inspect Center Bushing ID

Inspect Commutator End Frame Bushing

Assemble Starter Motor

Check Pinion Clearance

Make Solenoid No-Load Test

Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Essential Tools

Service Equipment and Tools

Other Material

Delco-Remy 30MT, 35MT, and 37MT Starter Motor Repair Specifications

Delco-Remy 30MT, 35MT, and 37MT Starter Motor Test Specifications

Diagnosing Starter Motor Malfunctions

Delco-Remy Starter Motor Cutaway View—Series 30MT, 35MT, and 37MT

Test Starter Motor Before Disassembly

Make No-Load Test for Solenoid

Disassemble Delco-Remy Starter Motor (Series 35MT Illustrated)

Install New Bushings During Disassembly

Clean Starter Motor Components

Inspect Armature

Make Short Circuit Test

Make Armature Ground Test

Make Open Circuit Test

Make Ground Circuit Test for Field Windings

Make Open Circuit Test for Shunt Windings

Make Open Circuit Test for Field Windings

Remove Field Windings

Inspect Brushes

Test Brush Holder for Ground

Inspect Brush Springs

Inspect and Clean Solenoid

Assemble Solenoid

Inspect Plunger, Shift Lever, and Overrunning Clutch Assembly

Assemble Starter Motor

Check Armature End Play

Check for Proper Pinion Clearance

Make No-Load Test (After Assembly)

Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Essential Tools

Other Material

Delco-Remy 40MT, 41MT, 42MT, and 50MT Starter Motor Repair Specifications

Delco-Remy 40MT, 41MT, 42MT, and 50MT Starter Motor Test Specifications

Diagnosing Starter Motor Malfunctions

Delco-Remy Starter Motor Cutaway View—Series 40MT, 41MT, 42MT, and 50MT

Test Starter Motor Before Disassembly

Test Pull-In and Hold-In Windings

Make No-Load Test

Disassemble Delco-Remy Starter Motor ( Series 50MT Illustrated)

Make Ground Circuit Test for Field Windings

Make Open Circuit Test for Shunt Windings

Make Open Circuit Test for Field Windings

Remove Field Windings

Inspect Brushes

Test Brush Holder for Ground

Inspect Brush Springs

Install New Bushings—40MT, 41MT, and 42MT

Install New Bushings—50MT

Clean Starter Motor Components

Inspect Armature

Make Short Circuit Test

Make Armature Ground Test

Make Open Circuit Test

Inspect Solenoid Plunger and Shift Lever Assembly

Inspect Overrunning Clutch and Pinion

Inspect and Clean Solenoid

Assemble Solenoid

Assemble Starter Motor

Check for Proper Pinion Clearance

John Deere/Denso Starter Motors

Starting Circuit Theory of Operation

General Information

Typical Starting Circuit Operation

Starter Motor Operation (Conventional Type)

Starter Motor Operation (Gear Reduction Type)

Starter Motor Operation (Planetary Type)

John Deere/Denso Conventional Starter Motor Repair

Essential Tools

Service Equipment and Tools

Dealer Fabricated Tools

Other Material

John Deere/Denso Conventional Starter Motor Repair Specifications

John Deere/Denso Conventional Starter Motor Test Specifications

Test Starter Motor Before Disassembly

Make Solenoid Pull-In Test

Make Solenoid Return Test

Make No-Load Test

Diagnose No-Load Test

Disassemble Starter Motor

John Deere/Denso Conventional Starter Motor Exploded View

Install New Bushings/Needle Bearings

Clean Starter Motor Components

Inspect Armature

Make Short Circuit Test

Make Armature Ground Test

Make Open Circuit Test

Repair Armature

Inspect Overrunning Clutch and Pinion

Make Grounded Circuit Test for Field Windings

Make Open Circuit Test for Shunt Windings

Make Open Circuit Test for Field Windings

Remove Field Windings (If Necessary)

Install Field Windings

Inspect and Repair Brushes

Test Brush Holder for Grounds

Measure Brush Spring Tension

Disassemble Solenoid

Assemble Starter Motor

Install Solenoid

Make No-Load Test

John Deere/Denso Gear Reduction Starter Motor Repair

Essential Tools

Service Equipment and Tools

Other Material

John Deere/Denso Gear Reduction Starter Motor Repair Specifications

John Deere/Denso Gear Reduction Starter Motor Test Specifications

Bench Test Starter Motor

No-Load Test

John Deere/Denso Gear Reduction Starter Motor Exploded View

Disassemble Field Frame, Armature, and Brush Holder

Inspect and Repair Armature

Inspect Brushes and Brush Holder

Inspect Field Coils

Assemble Field Frame, Armature, and Brush Holder

Disassemble Gear Train and Overrunning Clutch

Assemble Gear Train and Overrunning Clutch

Disassemble, Inspect, and Repair Starter Solenoid

Assemble Solenoid Assembly

John Deere/Denso Planetary Starter Motor Repair

Essential Tools

Other Material

John Deere/Denso Planetary Starter Motor Repair Specifications

John Deere/Denso Planetary Starter Motor Test Specifications

Test Starter Motor Before Disassembly

Make Solenoid Pull-In Test

Make Solenoid Hold-In Test

Make Return Test

Make No-Load Test

Diagnose No-Load Test

Disassemble Starter Motor

John Deere/Denso Planetary Starter Motor Exploded View

Clean Starter Motor Components

Inspect and Repair Brushes

Test Brush Holder for Grounds

Measure Brush Spring Tension

Assemble Starter Motor

Install Solenoid

Make No-Load Test

Bosch Starter Motors

Starting Circuit Theory of Operation

General Information

Typical Starting Circuit Operation

Typical Starter Motor Operation

Bosch Conventional Starter Motor Repair

Essential Tools

Bosch Conventional Starter Motor Repair Specifications

Bosch Conventional Starter Motor Test Specifications

Make No-Load Test

Diagnosing Starter Motor Malfunctions

Bosch Conventional Starter Motor Cutaway View

Bosch Conventional Starter Motor Exploded View

Disassembly

Solenoid Switch—Removal

Carbon Brush Plate—Removal

Armature—Removal

Snap Ring—Removal

Cleaning Parts

Testing Armature for Grounds

Testing Armature for Short Circuit

Testing Armature for Open Circuit

Turning Commutator Down

Testing Commutator for Out-of-Roundness

Testing Field Winding for Grounded Circuit

Field Winding—Removal

Make Open Circuit Test for Field Windings

Lubrication of Starter Motor (Before and During Assembly)

Field Winding—Installation

Checking Carbon Brush Plate for Grounds

Testing Carbon Brushes

Replace Carbon Brushes

Engaging Lever—Installation

Checking Armature End Play and Torque

Installing Starter Motor

Bosch Planetary Gear Starter Motor Repair

Essential Tools

Bosch Planetary Gear Starter Motor Test Specifications

Make No-Load Test

Diagnosing Starter Motor Malfunctions

Bosch Planetary Gear Starter Motor Cutaway View

Disassemble Solenoid Switch

Test Solenoid Switch

Assemble Solenoid Switch

Iskra Starter Motors

Starting Circuit Theory of Operation

General Information

Typical Starting Circuit Operation

Starter Motor Operation

Iskra AZE/AZF/AZJ-Type Starter Motor Repair

Essential Tools

Dealer Fabricated Tools

Iskra AZF-Type Starter Motor Repair Specifications

Iskra AZJ-Type Starter Motor Repair Specifications

Iskra AZE, AZF-Type Starter Motor Test Specifications

Iskra AZJ-Type Starter Motor Test Specifications

Exploded View of Iskra Starter Motor (AZF-Type)

Exploded View of Iskra Starter Motor (AZJ-Type)

Troubleshooting

Identification

Disassembly of Starter Motor

Testing Solenoid Switch

Testing Brushes

Brush Replacement

Testing Armature

Testing Field Windings

Checking Engaging Lever

Checking Overrunning Clutch Pinion

Reassembly of Starter Motor

Iskra AZE-Type Starter Motor Repair

Essential Tools

Dealer Fabricated Tools

Iskra AZE-Type Starter Motor Repair Specifications

Iskra AZE-Type Starter Motor Test Specifications

Exploded View of AZE (Noseless)-Type Starter Motor

Troubleshooting

Identification

Removing Solenoid Switch

Testing Solenoid Switch

Installing Solenoid Switch

Valeo Starter Motors

Starting Circuit Theory of Operation

General Information

Typical Starting Circuit Operation

Typical Starter Motor Operation

Valeo Starter Motor Repair

Essential Tools

Valeo Starter Motor Repair Specifications

Valeo Starter Motor Test Specifications

Exploded View of Starter Motor

Disassembly of Starter Motor

Testing Solenoid Switch

Testing Brushes

Positive Brush Replacement

Testing Armature

Testing Field Winding

Checking Overrunning Clutch Pinion

Reassembly of Starter Motor

Magneton Starter Motors

Starting Circuit Theory of Operation

General Information

Typical Starting Circuit Operation

Starter Motor Operation

Magneton Starter Motor Repair

Essential Tools

Dealer Fabricated Tools

Magneton Starter Motor Repair Specifications

Magneton Starter Motor Test Specifications

Exploded View of Starter Motor

Identification

Troubleshooting

Disassembly of Starter Motor

Testing Solenoid Switch

Testing Brushes

Brush Holder Replacement

Testing Armature

Testing Field Winding

Checking Overrunning Clutch Pinion

Reassembly of Starter Motor