Alternators and

Starter Motors

COMPONENT
TECHNICAL
MANUAL

Deere Power Systems Group

CTM77 (30OCT00)
LITHO IN U.S.A.
ENGLISH
 Introduction
Foreword

This manual is written for an experienced technician. Component Technical Manuals are concise service
Essential tools required in performing certain service guides for specific components. They are written as
work are identified in this manual and are stand-alone manuals covering multiple machine
recommended for use. applications.

Live with safety: Read the safety messages in the Fundamental service information is available from
introduction of this manual and the cautions presented other sources covering basic theory of operation,
throughout the text of the manual. fundamentals of troubleshooting, general maintenance,
and basic types of failures and their causes.
CAUTION: This is the safety-alert symbol.
This manual covers alternator and starter motor
When you see this symbol on the machine
applications for all John Deere diesel engines—
or in this manual, be alert to the potential for
both older 300/400/500-Series and newer
personal injury.
POWERTECH 2.9 L—12.5 L engines. This manual
covers components for both Deere OEM engines
This Component Technical Manual (CTM) contains the
and Deere machine engine applications.
latest available instructions necessary to repair engine
alternators and starter motors. It includes theory of
NOTE: Remanufactured alternators and starter motors
operation, and diagnostic and testing procedures to
are available for replacement on most
help troubleshoot and understand potential failure
applications listed in this manual. Refer to
modes.
John Deere’s “Remanufactured Components”
catalogs to cross-reference your original
The information is organized in sections and groups by
equipment part number and obtain a suitable
various suppliers. At the beginning of each repair
remanufactured replacement starter or
group are summary listings of all applicable essential
alternator.
tools, service equipment and tools, other materials
needed to do the job, service parts kits, specifications,
wear tolerances, and torque values.

POWERTECH is a registered trademark of Deere & Company. IFC,CTM77 –19–18SEP00–1/1

CTM77 (30OCT00) Alternators and Starter Motors

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 Introduction

John Deere Dealers

IMPORTANT: Please copy this page listing changes

and route it through your service
department.

This CTM is a complete revision of CTM77, Alternators

and Starter Motors, dated 15 MAR 97.

This manual covers alternators and starter motors on

most John Deere applications manufactured since 1972,
except 40, 50 and 55 Series Utility Tractors.

New information added to this manual includes:

• Section 45—Leece-Neville Alternators

• Section 50—Prestolite Alternators

Revised information includes:

1. Updated specifications for all current alternators and

starter motors, including those adopted since the 15
MAR 97 edition.
2. Added new applications and specifications for all
current alternators and starter motors.

OUO1004,0000B49 –19–15SEP00–1/1

CTM77 (30OCT00) Alternators and Starter Motors

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 Introduction

CTM77 (30OCT00) Alternators and Starter Motors

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 Contents
05
SECTION 05—Introduction and Safety Information SECTION 40—Magneton Alternators
Group 05—Safety Group 05—Magneton Alternator Theory of
Group 10—General Information Operation
Group 15—Electrical System Basic Information and Group 10—Magneton Alternator Repair
Wiring Diagrams
10
SECTION 45—Leece-Neville Alternators
SECTION 10—Delco-Remy Alternators Group 05—Leece-Neville Alternator Theory of
Group 05—Delco-Remy Alternator Theory of Operation
Operation Group 10—Leece-Neville Alternator Repair
Group 10—Delco-Remy (Delcotron) 10SI, 12SI and
15SI Alternator Repair SECTION 50—Prestolite Alternators 15
Group 15—Delco-Remy (Delcotron) 21SI Alternator Group 05—Prestolite Alternator Theory of Operation
Repair Group 10—Prestolite Alternator Repair
SECTION 15—Motorola Alternators
SECTION 60—Delco-Remy Starter Motors
Group 05—Motorola Alternator Theory of Operation
Group 05—Starting Circuit Theory of Operation
Group 10—Motorola 8E-Series Alternator Repair 20
Group 10—Delco-Remy 10/20/22/25/27/28MT
Group 15—Motorola HC-, MA-, MR-Series
Starter Motor Repair
Alternator Repair
Group 15—Delco-Remy 30MT, 35MT, 37MT Starter
Group 20—Motorola A-, RA-, 8AR-Series Alternator
Motor Repair
Repair
Group 20—Delco-Remy 40MT, 41MT, 42MT, 50MT
Group 25—Motorola SA-Series Alternator Repair
Starter Motor Repair 25
Group 30—Motorola TA-Series Alternator Repair

SECTION 20—Niehoff Alternators SECTION 65—John Deere/Denso Starter Motors

Group 05—Niehoff Alternator Theory of Operation Group 05—Starting Circuit Theory of Operation
Group 10—Niehoff 12-Volt, 110-Amp Alternator Group 10—John Deere/Denso Conventional Starter
Repair Motor Repair
30
Group 15—Niehoff 24-Volt, 50-Amp Alternator Group 15—John Deere/Denso Gear Reduction
Repair Starter Motor Repair

SECTION 25—Denso Alternators SECTION 70—Robert Bosch Starter Motors

Group 05—Denso Alternator Theory of Operation Group 05—Starting Circuit Theory of Operation
Group 10—Denso Alternator with Add-On Regulator Group 10—Robert Bosch Starter Motor Repair 35
Repair
Group 15—Denso Alternator with Built-In Regulator SECTION 75—Iskra Starter Motors
Repair Group 05—Starting Circuit Theory of Operation
Group 10—Iskra Starter Motor Repair
SECTION 30—Robert Bosch Alternators
40
Group 05—Robert Bosch Alternator Theory of SECTION 80—Valeo Starter Motors
Operation Group 05—Starting Circuit Theory of Operation
Group 10—Robert Bosch Alternator Repair Group 10—Valeo Starter Motor Repair
SECTION 35—Valeo Alternators
Group 05—Valeo Alternator Theory of Operation 45
Group 10—Valeo Alternator Repair
Group 15—Valeo A13N-Series Alternator Repair

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 50

COPYRIGHT  2000
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  1994, 1997

CTM77 (30OCT00) i Alternators and Starter Motors

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 Contents

05

10

15

20

25

30

35

40

45

50

CTM77 (30OCT00) ii Alternators and Starter Motors

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 Contents

60

65

70

75

80

INDX

CTM77 (30OCT00) iii Alternators and Starter Motors

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 Contents

60

65

70

75

80

INDX

CTM77 (30OCT00) iv Alternators and Starter Motors

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 05

Section 05
Introduction and Safety Information
Contents

Page

Group 05—Safety . . . . . . . . . . . . . . . . . . . . . .05-05-1

Group 10—General Information

Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-10-1
Metric Bolt and Cap Screw Torque Values . . . .05-10-2

Group 15—Electrical System Basic Information and

Wiring Diagrams
Electrical Circuit Malfunctions . . . . . . . . . . . . . .05-15-1
High Resistance Circuit . . . . . . . . . . . . . . . . . . .05-15-2
Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .05-15-3
Grounded Circuit . . . . . . . . . . . . . . . . . . . . . . . .05-15-5
Shorted Circuit . . . . . . . . . . . . . . . . . . . . . . . . .05-15-7
Seven Step Electrical Test Procedure . . . . . . . .05-15-8
Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-15-10

CTM77 (30OCT00) 05-1 Alternators and Starter Motors

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 Contents

05

CTM77 (30OCT00) 05-2 Alternators and Starter Motors

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 Group 05
Safety
05
Handle Fluids Safely—Avoid Fires 05
1

When you work around fuel, do not smoke or work near

heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.

–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

TS227
spontaneously.

DX,FLAME –19–29SEP98–1/1

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.

–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).

TS204
DX,SPARKS –19–03MAR93–1/1

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88

hospital, and fire department near your telephone.

TS291

DX,FIRE2 –19–03MAR93–1/1

CTM77 (30OCT00) 05-05-1 Alternators and Starter Motors

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 Safety

05
05 Handling Batteries Safely
2

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.

–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.

TS204
Always remove grounded (—) battery clamp
first and replace it last.

CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 15—30

–UN–23AUG88
minutes. Get medical attention immediately.

If acid is swallowed:

TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 2 L (2 quarts).
3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.

DPSG,OUO1004,2758 –19–11MAY00–1/1

CTM77 (30OCT00) 05-05-2 Alternators and Starter Motors

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 Safety

05
Wear Protective Clothing 05
3

Wear close fitting clothing and safety equipment

appropriate to the job.

Prolonged exposure to loud noise can cause impairment

or loss of hearing.

–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.

TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.

DX,WEAR –19–10SEP90–1/1

Work in Clean Area

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

–UN–18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.

T6642EJ
DX,CLEAN –19–04JUN90–1/1

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
–UN–23AUG88

Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.
TS228

DX,LOOSE –19–04JUN90–1/1

CTM77 (30OCT00) 05-05-3 Alternators and Starter Motors

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 Safety

05
05 Work In Ventilated Area
4

Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.

–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area

TS220
DX,AIR –19–17FEB99–1/1

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe

injury or machine damage.

Follow recommended procedure for removal and

installation of components in the manual.

–UN–23AUG88
TS226

DX,LIFT –19–04JUN90–1/1

CTM77 (30OCT00) 05-05-4 Alternators and Starter Motors

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 Safety

05
Remove Paint Before Welding or Heating 05
5

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.

–UN–23AUG88
Remove paint before heating:

• Remove paint a minimum of 76 mm (3 in.) from area to

be affected by heating.

TS220
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.

Do all work in an area that is ventilated to carry toxic

fumes and dust away.

Dispose of paint and solvent properly.

DX,PAINT –19–22OCT99–1/1

CTM77 (30OCT00) 05-05-5 Alternators and Starter Motors

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 Safety

05
05 Practice Safe Maintenance
6

Understand service procedure before doing work. Keep

area clean and dry.

Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.

Securely support any machine elements that must be

raised for service work.

Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems

–UN–23AUG88
or welding on machine.

On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or

TS218
welding on machine.

DX,SERV –19–17FEB99–1/1

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.

Use power tools only to loosen threaded parts and

fasteners.
–UN–08NOV89

For loosening and tightening hardware, use the correct

size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
TS779

wrenches.

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

CTM77 (30OCT00) 05-05-6 Alternators and Starter Motors

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 Safety

05
Dispose of Waste Properly 05
7

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.

–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.

TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

Prevent Machine Runaway

Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

–UN–11JAN89
NEVER start engine while standing on ground. Start
engine only from operator’s seat, with transmission in
neutral or park.

TS177
DX,BYPAS1 –19–29SEP98–1/1

Live With Safety

Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
–19–07OCT88
TS231

DX,LIVE –19–25SEP92–1/1

CTM77 (30OCT00) 05-05-7 Alternators and Starter Motors

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 Safety

05
05
8

CTM77 (30OCT00) 05-05-8 Alternators and Starter Motors

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 Group 10
General Information
05
Unified Inch Bolt and Cap Screw Torque Values 10
1

–UN–27SEP99
TORQ1A
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings

Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If
higher grade fasteners are used, these should only be tightened to
the strength of the original.

DX,TORQ1 –19–01OCT99–1/1

CTM77 (30OCT00) 05-10-1 Alternators and Starter Motors

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 General Information

05
10 Metric Bolt and Cap Screw Torque Values
2

–UN–07SEP99
TORQ2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.

DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.

Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.

DX,TORQ2 –19–01OCT99–1/1

CTM77 (30OCT00) 05-10-2 Alternators and Starter Motors

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 Group 15
Electrical System Basic Information and Wiring Diagrams
05
Electrical Circuit Malfunctions 15
1

–19–27FEB92
T7713AD
A—Battery C—Switch D—Light E—Ground
B—Fuse

1. There are four common circuit malfunctions. • After the component.

• High-Resistance Circuit Component malfunctions can easily be confused with

• Open Circuit circuit malfunctions. Therefore, care must be exercised
• Grounded Circuit when isolating the cause of a problem.
• Shorted Circuit
Example: Light does not operate or is dim when switch
2. Three sections in a simple circuit where these is turned ON, until switch connector is disconnected
malfunctions can occur: and reconnected.

• Before the controlling switch (C). Reason: High resistance caused by a dirty switch
• Between the controlling switch and before the connector, caused a voltage drop which prevented the
component, light (D). proper amount of current from flowing to the light.

DPSG,OUO1004,785 –19–19APR99–1/1

CTM77 (30OCT00) 05-15-1 Alternators and Starter Motors

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 Electrical System Basic Information and Wiring Diagrams

05
15 High Resistance Circuit
2

–19–26FEB92
T7713AG
A—Battery D—Switch Terminal F—Harness Connector H—Light
B—Fuse E—High Resistance G—Light Terminal I—Ground
C—Switch

A high resistance circuit can result in slow, dim or no If battery voltage is indicated, check closer to ground
component operation. to locate point of voltage drop. The example shows
high resistance (E) between switch and harness
Examples: Loose, corroded, dirty or oily terminals. connector.
Wire size too small. Strands broken inside the wire.
Poor ground connection to frame. Repair circuit as required. In the example, strands
were broken inside the wire. Replace that section of
To locate the cause of high resistance: wire.

With switch (C) ON, check for battery voltage between Repeat check-out procedure after repair.
switch and ground (I) at an easily accessible location,
like harness connector (F).

If less than battery voltage is indicated, check again

closer to switch.

DPSG,OUO1004,660 –19–15MAR99–1/1

CTM77 (30OCT00) 05-15-2 Alternators and Starter Motors

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 Electrical System Basic Information and Wiring Diagrams

05
Open Circuit 15
3

–19–27FEB92
T7713AF
A—Battery D—Switch Terminal F—Open Circuit H—Light
B—Fuse E—Harness Connector G—Light Terminal I—Ground
C—Switch

An open circuit will result in no components operating. If battery voltage is indicated, check for voltage closer
Fuse may or may not be blown. to ground at harness connector (E).

Example: Broken wire, disconnected component If no voltage is indicated, wire may be broken between
terminal, pins inside a connector not making contact, switch and connector.
blown fuse, open circuit breaker, failed switch or
component, or a disconnected ground wire. If battery voltage is indicated, inspect connector pins. If
pins are OK, check for voltage at light terminal (G).
To locate an open circuit:
In the example, zero voltage will be indicated at light
Check fuse. If blown, replace and operate circuit. If terminal, indicating a broken wire between harness
fuse blows a second time, continue check. connector and light terminal.

With switch (C) ON, check for battery voltage at switch If battery voltage had been indicated, the next check
terminal (D). for voltage would be at ground connection (I).

If no voltage is indicated, check switch, fuse and wiring Normal indicated voltage at a ground connection
to battery. should be 0.0 to 0.5 volts.

Continued on next page DPSG,OUO1004,661 –19–15MAR99–1/2

CTM77 (30OCT00) 05-15-3 Alternators and Starter Motors

103000
PN=21
 Electrical System Basic Information and Wiring Diagrams

05
15 If battery voltage is indicated, poor connection to frame When problem is located, repair as needed, then
4
or broken wire is indicated. repeat last check.

DPSG,OUO1004,661 –19–15MAR99–2/2

CTM77 (30OCT00) 05-15-4 Alternators and Starter Motors

103000
PN=22
 Electrical System Basic Information and Wiring Diagrams

05
Grounded Circuit 15
5

–19–27FEB92
T7713AE
A—Battery D—Switch G—Harness Connector J—Light
B—Fuse E—Switch Terminal H—Grounded Circuit K—Ground
C—Fuse Terminal F—Harness Connector I—Light (Component) Terminal

If no component operates, the fuse is blown and If continuity to ground is indicated, there is a pinched
replacement fuses blow immediately or the circuit or bare wire between fuse terminal (C) and harness
breaker is open and reopens when reset, a grounded connector (F).
circuit exists. (Example: power wire contacting frame
or other metal component). A wire may be pinched or If continuity to ground does not exist, disconnect
insulation may be worn from a wire. To isolate the ground (K) from frame. Measure continuity to ground
location of a grounded circuit: at harness connector (G). This checks harness from
harness connector to ground terminal. In the example,
If circuit is grounded between battery and fuse, wire continuity to ground will exist because circuit is
will be burned and circuit will be open. Fuse will not be grounded (wire is pinched) at (H).
blown.
If continuity exists, disconnect circuit at light terminal
If fuse is blown, remove fuse from circuit, disconnect (I) and measure continuity to ground on light terminal.
circuit near its center, such as harness connector (F). This checks harness from light to ground terminal. In
Turn switch (D) ON and check for continuity to ground the example, continuity will not exist, indicating a
at harness connector (F). This will check harness from grounded circuit between the light and harness
harness connector to fuse. connector (G).

Continued on next page DPSG,OUO1004,662 –19–15MAR99–1/2

CTM77 (30OCT00) 05-15-5 Alternators and Starter Motors

103000
PN=23
 Electrical System Basic Information and Wiring Diagrams

05
15 Repeat check-out procedure after repair.
6

DPSG,OUO1004,662 –19–15MAR99–2/2

CTM77 (30OCT00) 05-15-6 Alternators and Starter Motors

103000
PN=24
 Electrical System Basic Information and Wiring Diagrams

05
Shorted Circuit 15
7

–19–27FEB92
T7713AH
A—Battery E—Switch Terminal I—Harness Connector L—Light
B—Fuse F—Switch J—Light M—Ground
C—Fuse G—Harness Connector K—Light Terminal N—Ground
D—Switch H—Shorted Circuit

A shorted circuit causes components in separate Disconnect wire from switch of component that should
circuits to operate when a switch in either circuit is not be ON. In the example, disconnect wire from
turned ON. (Example: two harnesses rubbing together terminal (E) at switch (D). Light (J) remains ON.
until insulation is worn through, allowing bare wires to
touch). Components can also become shorted. Disconnect circuit at convenient places like harness
However, shorted components will usually blow the connectors (G) and (I) and light terminal (K) until light
fuse. (J) goes OFF.

To locate a shorted circuit: The short circuit will be between the last two places
the circuit was disconnected. In the example, it is
Turn switch (F) ON then OFF. Turn switch (D) ON between harness connectors (G and I). Light (J) will go
then OFF. Both lights (J and L) will be ON when either OFF when harness connector (I) is disconnected.
switch (D or F) is ON. Inspect harness between connectors (G and I).

Turn switch (F) ON. Both lights (J and L) will be ON;

only light (L) should be ON.

Continued on next page DPSG,OUO1004,664 –19–15MAR99–1/2

CTM77 (30OCT00) 05-15-7 Alternators and Starter Motors

103000
PN=25
 Electrical System Basic Information and Wiring Diagrams

05
15 Repair or replace wires and harnesses as needed. Repeat check-out procedure after repair.
8
Install tie bands and clamps on harnesses as required
to prevent future problems.

DPSG,OUO1004,664 –19–15MAR99–2/2

Seven Step Electrical Test Procedure

–19–05MAR92
T7719AA
A—Battery Ground D—Fuse or Circuit Breaker G—Battery Side of Component I—Ground Side of Component
B—Battery E—Component Side of Fuse or Terminal Terminal
C—Battery Side of Fuse or Circuit Breaker H—Light (Component) J—Component Ground
Circuit Breaker F—Switch

Continued on next page DPSG,OUO1004,666 –19–15MAR99–1/2

CTM77 (30OCT00) 05-15-8 Alternators and Starter Motors

103000
PN=26
 Electrical System Basic Information and Wiring Diagrams

05
Step 1—Switch ON 15
9
Check battery side of circuit breaker (C) for battery voltage. Battery voltage normal, go to Step 2.
Low voltage, repair high resistance. Open circuit from battery.
Step 2—Switch OFF
Check component side of circuit breaker (E) for battery voltage. Battery voltage normal, go to Step 4.
Low voltage, repair high resistance.
No voltage, go to Step 3.
Step 3—Switch OFF
Check component side of circuit breaker (E) for continuity to ground. Continuity to ground, repair grounded circuit at or before switch.
No continuity to ground, replace circuit breaker.
Step 4—Switch ON
Check component side of circuit breaker (E) for battery voltage. Battery voltage normal, go to Step 6.
Low voltage, repair high resistance.
No voltage, go to Step 5.
a
Step 5
Disconnect wire at battery side of component (G). Switch ON. Check Battery voltage, repair component.
wire at (G) for battery voltage. No voltage, repair grounded or open circuit at or after switch.
Step 6—Switch ON
Check lead to component at (G) for battery voltage. Battery voltage normal, go to Step 7.
Low voltage, repair high resistance in circuit between fuse and
component.
No voltage, repair high resistance or open circuit between fuse and
component.
Step 7—Switch ON
Check ground wire of component at (I) for voltage. No voltage, good continuity to ground, repair component.
Voltage, poor continuity to ground, repair high resistance or open
ground circuit.
a
A multimeter will not apply a load to the circuit at Step 5. The multimeter result is tested as a voltage condition in the result column.

DPSG,OUO1004,666 –19–15MAR99–2/2

CTM77 (30OCT00) 05-15-9 Alternators and Starter Motors

103000
PN=27
 Electrical System Basic Information and Wiring Diagrams

05
15 Multimeter
10

The multimeter is an autoranging digital display that

allows very accurate readings to be taken.

A—Display
B—Voltage AC (Alternating Current)
C—Voltage DC (Direct Current)
D—Resistance
E—Diode Test/Continuity
F—Current AC (Alternating Current)
G—Current DC (Direct Current)
H—Voltage, Resistance, Diode/Continuity (Red Lead
Input)
I—Ground (Black Lead Input)
J—Current/Amps (Red Lead Input)

–19–03SEP93
T8074AA
DPSG,OUO1004,665 –19–15MAR99–1/1

CTM77 (30OCT00) 05-15-10 Alternators and Starter Motors

103000
PN=28
 Section 10
Delco-Remy Alternators
Contents 10

Page Page

Group 05—Delco-Remy Alternator Theory of Slip Ring End Housing Assembly . . . . . . . . . .10-15-13
Operation Final Assembly . . . . . . . . . . . . . . . . . . . . . . . .10-15-19
Delco-Remy (Delcotron) Alternator
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .10-05-1
Delco-Remy (Delcotron) Regulator
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .10-05-1

Group 10—Delco-Remy (Delcotron) 10SI, 12SI and

15SI Alternator Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-2
Delco-Remy (Delcotron) 10SI, 12SI, and
15SI Charging Circuit Repair
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .10-10-2
Delco-Remy (Delcotron) 10SI, 12SI, and
15SI Charging Circuit Test Specifications . . .10-10-3
Remove Pulley Nut . . . . . . . . . . . . . . . . . . . . . .10-10-4
Separate Housing . . . . . . . . . . . . . . . . . . . . . . .10-10-5
Remove Front Bearing . . . . . . . . . . . . . . . . . . .10-10-6
Install Front Bearing . . . . . . . . . . . . . . . . . . . . .10-10-7
Remove and Install Rear Bearing . . . . . . . . . . .10-10-8
Test Rotor for Grounds . . . . . . . . . . . . . . . . . . .10-10-8
Test Rotor for Open Circuit . . . . . . . . . . . . . . . .10-10-9
Test Rotor for Short Circuit . . . . . . . . . . . . . . . .10-10-9
Repair Slip Rings . . . . . . . . . . . . . . . . . . . . . .10-10-10
Inspect Stator . . . . . . . . . . . . . . . . . . . . . . . . .10-10-10
Test Stator for Grounds. . . . . . . . . . . . . . . . . .10-10-11
Test Stator for Short Circuit. . . . . . . . . . . . . . .10-10-11
Test Brush Assembly for Grounds. . . . . . . . . .10-10-12
Test Diode Trio . . . . . . . . . . . . . . . . . . . . . . . .10-10-12
Test Rectifier Bridge . . . . . . . . . . . . . . . . . . . .10-10-13
Regulator Test . . . . . . . . . . . . . . . . . . . . . . . .10-10-13
Assemble the Alternator . . . . . . . . . . . . . . . . .10-10-14

Group 15—Delco-Remy (Delcotron) 21SI Alternator

Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .10-15-1
Delco-Remy (Delcotron) 21SI Charging
Circuit Repair Specifications . . . . . . . . . . . . .10-15-2
Delco-Remy (Delcotron) 21SI Charging
Circuit Test Specifications . . . . . . . . . . . . . . .10-15-3
Disassemble Delco-Remy 21SI Alternator . . . . .10-15-4
Disassemble Alternator . . . . . . . . . . . . . . . . . . .10-15-5
Slip Ring End Housing and Components. . . . . .10-15-6
Drive End Frame and Components . . . . . . . . .10-15-11
Assemble Alternator . . . . . . . . . . . . . . . . . . . .10-15-13

CTM77 (30OCT00) 10-1 Alternators and Starter Motors

103000
PN=1
 Contents

10

CTM77 (30OCT00) 10-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Delco-Remy Alternator Theory of Operation
Delco-Remy (Delcotron) Alternator Operation

The drawing at right shows alternator circuitry. Schematic

of regulator (E) has been simplified. The regulator is a
non-adjustable, sealed, solid-state unit mounted inside the
10
alternator. 05
1
NOTE: To prevent battery run-down, R3 resistor has
extremely high resistance. It still allows a constant
drain on battery but this is insignificantly small. R3
and R4 are needed to provide voltage differential
for turning on transistors.

An alternator (unlike a generator) uses a rotating magnetic

field with stationary windings. The magnetic field is
externally excited. This means that it requires an outside
current source. The rotor (F) consists of two interlocking
soft iron sections and a wire coil wrapped around an iron
core. When current is passed through the wire coil, the
rotor becomes an electromagnet.

–UN–07APR89
The rotating magnetic field induces an alternating current
in the stator windings (G). This is converted to direct
current by six diodes in the rectifier bridge (H).

RW1010L
A capacitor inside rear housing protects rectifier bridge
and diode trio (D) from voltage surges. It also suppresses
radio interference. Delco-Remy (Delcotron) Alternator

A—Diode
This alternator uses an “A” field circuit with regulator
B—Switch
located after field. Full output is obtained by grounding C—Battery
field. D—Diode Trio
E—Regulator
F—Rotor (Field)
G—Stator
H—Rectifier Bridge

RG,RG34710,2025 –19–15MAR97–1/1

Delco-Remy (Delcotron) Regulator Operation

The solid-state regulator is mounted inside the alternator.

It controls output by controlling current through field. In
operation, regulator has the following three phases.

Continued on next page RG,RG34710,2026 –19–18OCT00–1/4

CTM77 (30OCT00) 10-05-1 Alternators and Starter Motors

103000
PN=31
 Delco-Remy Alternator Theory of Operation

Phase I—Alternator Stopped

(Phase 1 also applies when alternator is running but only

if not running fast enough for output to exceed battery
voltage.)
10
05
2 1. Current flows from battery through key switch (B) and
diode (A) to terminal 1.

2. From there, current flows through resistor R1 to

transistor TR1 and turns it on.

3. Transistor TR1 then provides a path to ground so

current can flow through field, enabling alternator to
generate electricity.

4. Zener diode D2 prevents flow of current from terminal

2 to transistor TR2. A Zener diode is a special type of
diode which will not permit current to pass until voltage
reaches a certain preset level. If voltage exceeds that
level, current can pass through the Zener diode.

–UN–29NOV89
A—Diode
B—Key Switch
C—Battery

RW10107L
D—Diode Trio
E—Regulator
F—Rotor (Field)
G—Stator
Phase I—Alternator Stopped
H—Rectifier Bridge

Continued on next page RG,RG34710,2026 –19–18OCT00–2/4

CTM77 (30OCT00) 10-05-2 Alternators and Starter Motors

103000
PN=32
 Delco-Remy Alternator Theory of Operation

Phase II—Generating Electricity

1. The diode trio, key switch, rectifier bridge, and terminal

1 all have equal voltage. Therefore no current flows
through diode.
10
05
2. Current, now coming from diode trio, still flows through 3
resistor R1 to turn on transistor TR1.

3. Transistor TR1 still provides a path to ground so

current can flow through field, enabling alternator to
generate electricity.

4. Since the field is rotating, it does generate electricity.

Alternating current is included in the stator windings.
The rectifier bridge converts it to direct current,
providing current to run electrical accessories and
charge batteries.

5. Output voltage still has not reached critical voltage of

Zener diode D2, so no current can flow from terminal 2

–19–28NOV89
to transistor TR2.

RW10108L
Phase II—Generating Electricity

Continued on next page RG,RG34710,2026 –19–18OCT00–3/4

CTM77 (30OCT00) 10-05-3 Alternators and Starter Motors

103000
PN=33
 Delco-Remy Alternator Theory of Operation

Phase III—Shut-Off

1. Output voltage reaches critical voltage of Zener diode

D2.
10
05 2. Current can now pass through Zener diode D2 to turn
4 on transistor TR2.

3. Transistor TR2 now provides a direct path to ground

for any current coming through resistor R1.

4. This cuts off the current to transistor TR1, turning it off.

There is now no path to ground for current through
field.

5. Current through field is shut off instantly, and alternator

stops generating electricity.

6. Phase II and III are repeated many times per second

to maintain voltage at proper level.

–19–28NOV89
RW10131L
Phase III—Shut-Off

RG,RG34710,2026 –19–18OCT00–4/4

CTM77 (30OCT00) 10-05-4 Alternators and Starter Motors

103000
PN=34
 Group 10
Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
10
10
1

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B4E –19–21SEP00–1/4

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B4E –19–21SEP00–2/4

Alternator Pulley Tool Set . . . . . . . . . . . . . . . . JD306A

Remove and install alternator pulley retaining nut.

–UN–31JAN89
R26528

JD306A

Continued on next page OUO1004,0000B4E –19–21SEP00–3/4

CTM77 (30OCT00) 10-10-1 Alternators and Starter Motors

103000
PN=35
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Bushing, Bearing and Seal Driver Set . . . . . . D01045AA

Remove front bearing.

10

–UN–21SEP00
10
2

RG11162
D01045AA

OUO1004,0000B4E –19–21SEP00–4/4

Other Material

Number Name Use

(U.S.) Delco-Remy Lubricant No. 1948791 Lubricate alternator bearings.

(U.S.) 400-Grit Silicon Carbide Paper or 00 Polish slip rings.

Sandpaper

OUO1004,0000B50 –19–21SEP00–1/1

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

Charging Circuit Repair Specifications

Item Measurement Specification

Delco-Remy Model 12SI Alternator Torque 100 N•m (75 lb-ft)

Pulley Nut

Delco-Remy Model 10SI and 15SI Torque 80 N•m (60 lb-ft)

Alternator Pulley Nut

OUO1004,0000B51 –19–21SEP00–1/1

CTM77 (30OCT00) 10-10-2 Alternators and Starter Motors

103000
PN=36
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

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

Charging Circuit Test Specifications
Field Current Rated (Hot) Output
Cold Output
@27°C (80°F) at Rated Speed
10
John 10
Deere Delcotron 3
Part No. Model No. Series Type Amps Volts Amps RPM Amps RPM Amps
AR54793 1100490 10SI 106 4.0—4.5 12 25 2500 65 5000 72
AR54796 1104901 10SI 106 4.0—4.5 12 25 2000 51 5000 55
30
22
AR56728 1102359 10SI 106 4.0—4.5 12 22 2000 33 5000 37
AR84305 1102926 10SI 116 4.0—5.0 12 30 2000 57 5000 61
AR84306 1102932 10SI 116 4.0—5.0 12 25 2000 65 5000 72
AR93445 1103124 10SI 116 4.0—5.0 12 30 2000 57 5000 61
AR93446 1103128 10SI 116 4.0—5.0 12 25 2000 65 5000 72
AT117390 1105539 15SI 116 4.0—5.0 12 56 2000 110 5000 105
AT130930 1101285 10SI 100 1.2—1.6 24 25 2600 41 7000 40
AT142267 10479850 12SI 100 4.0—5.0 12 51 2000 81 7000 78
AT157177 10480058 10SI 116 4.0—5.0 12 51 2000 81 7000 78
AT157178 10480060 10SI 116 1.2—1.6 24 25 2600 41 7000 40
AT58321 1102936 10SI 116 4.0—5.0 12 30 2000 57 5000 61
AT64718 1103131 10SI 116 4.0—5.0 12 28 2000 42 7000 42
RE13797 1105175 10SI 116 4.0—5.0 12 25 2000 65 5000 72
RE13966 1105068 10SI 116 4.0—5.0 12 30 2000 57 5000 61
RE17379 1105422 10SI 116 4.0—5.0 12 32 2000 60 5000 63
RE20034 1105510 10SI 116 4.0—5.0 24 25 2600 41 7000 40
RE27109 1101268 12SI 100 4.2—5.0 12 30 1600 75 6500 75
RE31694 1101345 12SI 100 4.2—5.0 12 30 1600 78 6500 78
RE501112 — — — — 12 — — — — 105

Regulator Temperaturea Voltage

29°C (85°F) 13.8—14.9 volts
41°C (105°F) 13.6—14.7 volts
52°C (125°F) 13.4—14.6 volts
63°C (145°F) 13.2—14.4 volts
a
Measured 25.4 mm (1.0 in.) from regulator.

Continued on next page RG,RG34710,2031 –19–08SEP00–1/2

CTM77 (30OCT00) 10-10-3 Alternators and Starter Motors

103000
PN=37
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Stator Winding Field Resistance

37-amp, 12-volt 0.23 ohm
40-amp, 24-volt 0.23 ohm
42-amp, 12-volt 0.28 ohm
10 55-amp, 12-volt 0.20 ohm
10
61-amp, 12-volt 0.20 ohm
4
63-amp, 12-volt 0.20 ohm
72-amp, 12-volt 0.10 ohm
75-amp, 12-volt 0.10 ohm
78-amp, 12-volt 0.10 ohm
105-amp, 12-volt 0.10 ohm
130-amp, 12-volt 0.04 ohm

RG,RG34710,2031 –19–08SEP00–2/2

Remove Pulley Nut

NOTE: Pulley nut need not be removed if you are certain

that front bearing is in good condition. Separate
housing as described and leave rotor in front
housing.

–UN–15DEC88
1. Install a 15/16 in. socket (A) on JD306A-1 Alternator
Pulley Nut Tool (B) to hold nut.

RW6036
2. Install JD306A-2 (C) on hex shaft of JD306A-1 to hold
rotor shaft.
Remove Pulley Nut
3. Hold rotor and remove nut. A—15/16 in. Socket
B—JD306A-1 Alternator Pulley Nut Tool
C—JD306A-2 Alternator Pully Nut Tool

RG,RG34710,2032 –19–15MAR97–1/1

CTM77 (30OCT00) 10-10-4 Alternators and Starter Motors

103000
PN=38
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Separate Housing

1. Remove washer (A), pulley (B), fan (C), and collar (D).

2. Before separating, make a chalk mark (E) across

10
separation between front and rear housings for

–UN–16NOV89
10
alignment when reassembling. Housings can be 5
indexed any one of four ways.

RW10657
A—Washer
B—Pulley
C—Fan
D—Collar Separate Housing
E—Chalk mark
F—Nut
G—Through Bolts

RG,RG34710,2033 –19–15MAR97–1/3

3. Remove four through bolts (A).

4. Separate front and rear housings. If necessary, pry

carefully with two screwdrivers on opposite sides to
force housings apart.

–UN–22FEB90
A—Through Bolts (4 Used)

RW6011
Separate Front and Rear Housing

Continued on next page RG,RG34710,2033 –19–15MAR97–2/3

CTM77 (30OCT00) 10-10-5 Alternators and Starter Motors

103000
PN=39
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

5. Set alternator on rear housing (A) and slide front

housing (B) off. Lift out rotor (C).

6. Place a piece of masking tape over rear bearing to

keep trash out.
10
10

–UN–22FEB90
6 A—Alternator Rear Housing
B—Alternator Front Housing
C—Rotor

RW6012
Lift Out Rotor

RG,RG34710,2033 –19–15MAR97–3/3

Remove Front Bearing

Remove bearing retainer (A) and bearing (B).

NOTE: If bearing must be pressed in or out of housing,

carefully support housing near bearing diameter.

–UN–22FEB90
A 1-3/4 in. socket makes a suitable support. Use
disk No. 27494 from D01045AA Bushing Driver
Set to press on inner diameter of bearing. Press
from outside to inside.

RW6013
A—Bearing Retainer
B—Bearing Remove Bearing Retainer and Bearing

RG,RG34710,2034 –19–15MAR97–1/1

CTM77 (30OCT00) 10-10-6 Alternators and Starter Motors

103000
PN=40
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Install Front Bearing

Bearing may be reused if not damaged.

1. Clean bearing and fill it 1/4 full with Delco-Remy

10
Lubricant No. 1948791 before assembly. Do not 10

–UN–22FEB90
overfill. 7

NOTE: Lubrication is not required on sealed bearings.

RW6013
2. Install bearing (B).

A—Bearing Retainer Install Front Bearing

B—Bearing

RG,RG34710,2035 –19–15MAR97–1/2

3. Fill cavity between retainer plate (A) and bearing (B)

with Delco-Remy No. 1948791 Lubricant.

4. If felt seal (C) is hardened or worn, replace seal and

retainer.

–UN–22FEB90
A—Retainer Plate
B—Beraing
C—Felt Seal

RW6014
Replace Retainer

RG,RG34710,2035 –19–15MAR97–2/2

CTM77 (30OCT00) 10-10-7 Alternators and Starter Motors

103000
PN=41
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Remove and Install Rear Bearing

1. Replace rear bearing (A) if defective or its grease

supply is exhausted. Do not relubricate.
10
10 2. Support housing (B) near bearing diameter with a

–UN–22FEB90
8 1-1/4 in. socket and press bearing to inside.

3. Press new bearing in until flush with housing.

RW6015
NOTE: If seal is separate from bearing, install a new seal
whenever bearing is replaced. Install seal with lip
of seal toward rotor when assembled. Coat seal Rear Bearing
lip with oil when installing rotor shaft.
A—Rear Bearing
B—Support Housing

RG,RG34710,2036 –19–18OCT00–1/1

Test Rotor for Grounds

1. Use an ohmmeter (A) or test lamp to test for continuity.

2. Attach ohmmeter to rotor shaft (B) and each slip ring

(C).

–UN–10NOV88
3. Replace rotor if test shows continuity.

A—Ohmmeter

RW6017
B—Rotor Shaft
C—Slip Ring
Test Rotor for Grounds

RG,RG34710,2038 –19–15MAR97–1/1

CTM77 (30OCT00) 10-10-8 Alternators and Starter Motors

103000
PN=42
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Test Rotor for Open Circuit

1. Use ohmmeter (A) (or test lamp) to test for continuity

from one slip ring (B) to the other (C).
10
2. If test does not show continuity, replace rotor. 10

–UN–10NOV88
9
A—Ohmmeter
B—Slip Ring
C—Slip Ring

RW6018
Test Rotor for Open Circuit

RG,RG34710,2039 –19–15MAR97–1/1

Test Rotor for Short Circuit

1. Connect slip ring (A) to one terminal of 12-volt battery

(B).

2. Connect ammeter (C) to other terminal of battery and

–UN–25APR89
slip ring (D).

3. Current draw should be 4.0—4.5 amps at 12 volts.

RW6019
Excessive current draw indicates a short circuit.
Replace rotor if current draw exceeds 5.0 amps.
Test Rotor for Short Circuit

A—Slip Ring
B—12-Volt Battery
C—Ammeter
D—Slip Ring

RG,RG34710,2040 –19–18OCT00–1/1

CTM77 (30OCT00) 10-10-9 Alternators and Starter Motors

103000
PN=43
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Repair Slip Rings

NOTE: Rough or out-of-round slip rings can cause short

brush life.
10
10 1. Mount rotor assembly on plate.
10
2. If slip rings are rough or scored, turn them just enough
to eliminate roughness. If slip rings are out-of-round,
turn them to within 0.005 mm (0.002 in.) of total
indicator reading.

3. Polish slip rings sparingly with No. 00 sandpaper or

400-grit silicon carbide paper.

IMPORTANT: Clean rotor and stator with compressed

air only. Cleaning solvent will damage
insulation.

RG,RG34710,2041 –19–15MAR97–1/1

Inspect Stator

1. Inspect stator (A) for defective insulation.

2. Check for discoloration or a burned odor indicating a

short circuit.

–UN–10NOV88
3. Replace stator if you find any defect.

RW6020
A—Stator

Inspect Stator

RG,RG34710,2042 –19–15MAR97–1/1

CTM77 (30OCT00) 10-10-10 Alternators and Starter Motors

103000
PN=44
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Test Stator for Grounds

Connect an ohmmeter (A) (or test lamp) between each

stator (B) lead and stator frame (C). Replace stator if test
indicates continuity.
10

–UN–16NOV89
10
NOTE: The stator cannot be tested for an open circuit 11
unless terminals are disconnected from stator
windings.

RW10652
A—Ohmmeter
B—Stator
C—Stator Frame Test Stator for Grounds

RG,RG34710,2043 –19–15MAR97–1/1

Test Stator for Short Circuit

A short-circuit in the stator can be difficult to identify. Use

an ohmmeter that is sensitive to resistance of 0.0 to 1.0
ohm.

–UN–25APR89
Connect ohmmeter (A) between each pair of terminals
(B). Resistance should be approximately 0.1 ohm.
(Ohmmeter needle should deflect to zero if leads are
touched together.) If resistance is low, windings are

RW6022
shorted and must be replaced.

A stator will occasionally exhibit an open circuit or short Connect Ohmmeter Between Terminals
circuit only when hot, making the defect even more
A—Ohmmeter
difficult to diagnose. B—Terminals

If a stator defect cannot be confirmed, re-check all other

components. If problem is not found elsewhere, replace
stator.

RG,RG34710,2044 –19–15MAR97–1/1

CTM77 (30OCT00) 10-10-11 Alternators and Starter Motors

103000
PN=45
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Test Brush Assembly for Grounds

A grounded brush assembly results in either no output or

uncontrolled output, depending on where the ground is
located.
10
10

–UN–22FEB90
12 NOTE: A grounded brush assembly may also damage the
diode trio. Before assembling alternator, check
diode trio.

RW6023
1. Check insulating washers on screws holding brush
leads (A and B). Replace if necessary. If circuit is
grounded elsewhere, replace regulator. Test Brush Assembly for Grounds

A—Brush Contact from Diode Trio

2. Connect ohmmeter (or test lamp) between points (B B—Brush Contact from Regulator
and C) and between points (A and D). Replace brush C—Test Point
assembly if either check shows no continuity. D—Test Point

RG,RG34710,2045 –19–15MAR97–1/1

Test Diode Trio

1. Remove stator and diode trio attaching nuts (A). Note

position of any insulating washers.

2. Remove diode trio, noting insulator position.

–UN–22FEB90
A—Stator and Diode Trio Attaching Nuts (4 Used)

RW6024

Stator and Diode Trio

Continued on next page RG,RG34710,2046 –19–15MAR97–1/2

CTM77 (30OCT00) 10-10-12 Alternators and Starter Motors

103000
PN=46
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

3. Connect ohmmeter (or test lamp) to points (A and D).

Check for continuity. Reverse leads and test for
continuity between same points. A good diode trio will
have continuity only in one direction.
10
Repeat test between points (B and C) and (C and D). 10

–UN–22FEB90
13
Replace diode trio unless tests show continuity in only
one direction in each case.

RW6025
A—Terminal
B—Terminal
C—Terminal Connect Ohmmeter
B—Terminal

RG,RG34710,2046 –19–15MAR97–2/2

Test Rectifier Bridge

NOTE: Rectifier bridge has grounded heat sink (A) and

insulated heat sink (E).

Connect ohmmeter (or test lamp) to points A and B. Then

–UN–22FEB90
reverse leads between same two points. Continuity should
be in only one direction.

NOTE: On models 10-SI and 12-SI, connect ohmmeter

RW6026
lead to threaded stud of test points (B), (C), and
(D). On all other models, connect ohmmeter by
pressing down very firmly onto flat metal Test Rectifier Bridge
connector, and not onto threaded stud.

A—Grounded Heat Sink

B—Terminal
C—Terminal
D—Terminal
E—Insulated Heat Sink

RG,RG34710,2047 –19–15MAR97–1/1

Regulator Test

Regulator cannot be effectively tested. Replace regulator

if brush assembly tests indicate a failure.

RG,RG34710,2048 –19–15MAR97–1/1

CTM77 (30OCT00) 10-10-13 Alternators and Starter Motors

103000
PN=47
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

Assemble the Alternator

1. Install rectifier bridge (A). Be sure insulating washers

are in position.
10
10 A—Rectifier Bridge

–UN–22FEB90
14

RW6027
Install Rectifier Bridge

RG,RG34710,2049 –19–15MAR97–1/4

2. Install brush assembly (A) and diode trio (B). Be sure

brush assembly insulating screws (C) are in position.

3. Push brushes back to clear slip rings. Insert a wire

through hole in rear housing only far enough to hold
brushes back.

–UN–22FEB90
A—Brush Assembly
B—Diode Trio
C—Brush Assembly Insulating Screws (2 Used)

RW6028
Install Brush Assembly and Diode Trio

Continued on next page RG,RG34710,2049 –19–15MAR97–2/4

CTM77 (30OCT00) 10-10-14 Alternators and Starter Motors

103000
PN=48
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

4. Remove tape over rear bearing and carefully slip rotor

(C) into rear housing (A).

A—Rear Housing
B—Front Housing 10
C—Rotor 10

–UN–22FEB90
15

RW6012
Slip Rotor into Rear Housing

RG,RG34710,2049 –19–15MAR97–3/4

5. Carefully slip front housing over rotor shaft. Align

previously marked chalk mark (E).

6. Install four through bolts (G). Alternately tighten bolts

until secure.

–UN–16NOV89
7. Remove wire from housing.

8. Install collar (D), fan (C), pulley (B), washer (A) and nut
(F). Tighten pulley nut with JD306A Alternator Pulley

RW10657
Tool to specifications.

Specification Slip Front Housing Over Rotor Shaft

Delco-Remy Model 12SI
Alternator Pulley Nut—Torque ...................................... 100 N•m (75 lb-ft) A—Washer
Delco-Remy Model 10SI and B—Pulley
15SI Alternator Pulley Nut— C—Fan
Torque ............................................................................. 80 N•m (60 lb-ft) D—Collar
E—Chalk Mark
F—Nut
.
G—Bolts

RG,RG34710,2049 –19–15MAR97–4/4

CTM77 (30OCT00) 10-10-15 Alternators and Starter Motors

103000
PN=49
 Delco-Remy (Delcotron) 10SI, 12SI and 15SI Alternator Repair

10
10
16

CTM77 (30OCT00) 10-10-16 Alternators and Starter Motors

103000
PN=50
 Group 15
Delco-Remy (Delcotron) 21SI Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
10
15
1

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B52 –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B52 –19–21SEP00–2/2

CTM77 (30OCT00) 10-15-1 Alternators and Starter Motors

103000
PN=51
 Delco-Remy (Delcotron) 21SI Alternator Repair

Delco-Remy (Delcotron) 21SI Charging

Circuit Repair Specifications

Item Measurement Specification

10
15 Delco-Remy Model 21SI Alternator Torque 100 N•m (75 lb-ft)
2 Pulley Nut

Drive End Bearing Retainer Plate Torque 3.0 N•m (26 lb-in.)
Cap Screws

Slip Ring End Housing Components

Inside Output Terminal Nut Torque 5.5 N•m (50 lb-in.)

Rectifier Bridge Attaching Screws Torque 3.0 N•m (25 lb-in.)

Capacitor Attaching Screw Torque 2.5 N•m (22 lb-in.)

“R” Terminal Nut Torque 2.5 N•m (22 lb-in.)

Regulator Mounting Screws Torque 2 N•m (20 lb-in.)

Regulator Mounting Nut Torque 2.5 N•m (22 lb-in.)

Brush Holder Pivot Attaching Torque 2 N•m (20 lb-in.)

Screw

Stator Debris Shield Mounting Stud Torque 5.5 N•m (50 lb-in.)
Nut

Rectifier Bridge Nuts Torque 2.5 N•m (22 lb-in.)

Drive End-to-Slip Ring End Housing Torque 5.5 N•m (50 lb-in.)
Through Bolts

OUO1004,0000BB1 –19–28SEP00–1/1

CTM77 (30OCT00) 10-15-2 Alternators and Starter Motors

103000
PN=52
 Delco-Remy (Delcotron) 21SI Alternator Repair

Delco-Remy (Delcotron) 21SI Charging

Circuit Test Specifications
Field Current Cold Output Rated (Hot)
@ 27°C (80°F) Output at
Rated Speed 10
15
John Deere Delcotron Alternator Amps Volts Amps RPM Amps RPM Amps 3
Model No. Model No. Series Type
AT142246 1117909 21SI 355 6.7—7.1 12 50 1600 130 5000 130

Regulator Temperaturea Voltage

29°C (85°F) 13.8—14.9 volts
41°C (105°F) 13.6—14.7 volts
52°C (125°F) 13.4—14.6 volts
63°C (145°F) 13.2—14.4 volts
a
Measured 25.4 mm (1.0 in.) from regulator.

Stator Winding Field Resistance

130-amp, 12-volt 0.04 ohm

RG,RG34710,2052 –19–08SEP00–1/1

CTM77 (30OCT00) 10-15-3 Alternators and Starter Motors

103000
PN=53
 Delco-Remy (Delcotron) 21SI Alternator Repair

Disassemble Delco-Remy 21SI Alternator

10
15
4

–UN–30NOV93
RG6994
Delco-Remy 21SI Alternator

1—Slip Ring End Housing 12—Regulator Stud Connector 22—Pulley 29—Regulator Attaching
2—Slip Ring End Bearing 13—“I” Terminal Connector 23—Regulator Nut Screw (Insulated)
3—Rotor Assembly 14—Capacitor 24—Rectifier Bridge Nut 30—Capacitor Attaching Screw
4—Stator Assembly 15—Brush Holder Assembly 25—Shaft Nut 31—Bearing Retainer Plate
5—Drive End Frame 16—Brush and Arm 26—Rectifier Bridge Attaching Screw
6—Drive End Bearing 17—Drive End Retainer Plate Nut/Washer Assembly 32—Slip Ring End Frame
7—Rectifier Bridge Assembly 18—Hinge Bushing 27—Brush Holder Attaching Ground Screw and Load
8—Diode Trio 19—Regulator Terminal Cover Screw (Pivot) Washer
9—Regulator 20—Terminal Cap 28—Regulator Attaching 33—Shaft Nut Washer
10—BAT Terminal Assembly 21—Fan Screw (Ground) 34—Through Bolt
11—“I” Terminal Assembly

RG,RG34710,2053 –19–15MAR97–1/1

CTM77 (30OCT00) 10-15-4 Alternators and Starter Motors

103000
PN=54
 Delco-Remy (Delcotron) 21SI Alternator Repair

Disassemble Alternator

1. Place alignment mark across slip ring end housing (A),

stator housing (B), and drive end frame (C) for
assembly after repair.
10
15
A—Slip Ring End Housing 5
B—Stator Housing
C—Drive End Frame

–UN–30NOV93
RG6971
Alignment Mark

RG,RG34710,2054 –19–15MAR97–1/2

2. Remove four through bolts (A).

3. Separate drive end frame (B) (with rotor) from slip ring
end housing (C) (with stator). If necessary, carefully
pry drive end frame from edge of stator with
screwdriver (D). After separation, place tape over slip
ring end housing bearing inside unit to prevent dirt
from entering bearing.

–UN–30NOV93
A—Through Bolts
B—Drive End Frame
C—Slip Ring End Housing

RG6972
D—Screwdriver

Disassemble Alternator

RG,RG34710,2054 –19–15MAR97–2/2

CTM77 (30OCT00) 10-15-5 Alternators and Starter Motors

103000
PN=55
 Delco-Remy (Delcotron) 21SI Alternator Repair

Slip Ring End Housing and Components

1. Inspect slip ring end housing (A) for loose connections

or other obvious conditions. Correct as necessary. If
none are found, proceed with slip ring end housing
10
15 checks which follow.
6
2. Remove three rectifier bridge nuts (B) to disconnect
stator (C). If necessary, carefully pry stator (C) away
from slip ring end housing (A) with a screwdriver (D).

–UN–30NOV93
3. Inspect stator windings for dark, burned appearance.
View windings from inside of unit; black paint on

RG6973
outside of windings does not indicate burned windings.

If all windings are uniform in color and varnish covering Slip Ring End Housing and Components
is not flaking off, proceed with electrical check, step 4
below. A—Slip Ring End Housing
B—Rectifier Bridge Nuts
C—Stator
If some windings are dark and others are light, a D—Screwdriver
shorted, open, or grounded condition is indicated.
Replace the stator. The stator should also be replaced
if the windings are uniformly dark and burned, with the
varnish flaking off to expose bare wires.

Continued on next page RG,RG34710,2055 –19–18OCT00–1/7

CTM77 (30OCT00) 10-15-6 Alternators and Starter Motors

103000
PN=56
 Delco-Remy (Delcotron) 21SI Alternator Repair

4. Perform electrical check on stator. Use digital

multimeter on ohms setting (or a 110-volt test lamp).
There should be no continuity between any of the
stator leads (A) and the stator laminations (B).
10
If continuity is present, windings are grounded. 15
Replace stator. 7

If there is no continuity, stator is probably good.

However, there is no service electrical check for

–UN–30NOV93
shorted or open delta stator windings. If all other
electrical checks are normal and the generator did not
produce within 15 amps of the rated output, a shorted
or open stator is indicated and the stator should be

RG6974
replaced.
Stator Leads and Laminations
A—Stator Leads
B—Stator Laminations

RG,RG34710,2055 –19–18OCT00–2/7

5. Remove insulated regulator attaching screw (A) to

disconnect diode trio (B). Lift diode trio from slip ring
end housing assembly.

6. Place the negative ohmmeter lead on regulator strap

(C) and use positive ohmmeter lead to check for
continuity to each of the three rectifier bridge straps. All
three readings should indicate continuity. Reverse the
ohmmeter leads and perform the checks again.
Readings should all indicate open circuits.

If all readings are proper, diode trio is good. –UN–30NOV93

If any reading is wrong, replace the diode trio.

RG6975

A—Insulated Regulator Screws

B—Diode Trio
C—Regulator Strap Check Continuity
D—Rectifier Bridge Straps

Continued on next page RG,RG34710,2055 –19–18OCT00–3/7

CTM77 (30OCT00) 10-15-7 Alternators and Starter Motors

103000
PN=57
 Delco-Remy (Delcotron) 21SI Alternator Repair

7. Use the digital multimeter to check the rectifier bridge.

Rectifier bridge may also be checked while installed in
the slip ring end housing. Check rectifier bridge as
follows:
10
15 Place negative ohmmeter lead on grounded heat sink
8 (A). Touch positive ohmmeter lead firmly to metal

–UN–30NOV93
diode clips (B) that surround each of the three
threaded studs. All three readings should be the same
and indicate open circuits. Reverse the ohmmeter
leads and perform the checks again. All three readings

RG6976
should indicate continuity.

Repeat checks using insulated (positive) heat sink (C) Check Rectifier Bridge
in place of grounded heat sink. With negative
A—Grounded Heat Sink
ohmmeter lead on insulated heat sink (C), all three B—Metal Diode Clips
readings should indicate continuity. Reverse the C—Insulated (Positive) Heat Sink
ohmmeter leads and perform the checks again.
Readings should all indicate open circuits.

If readings are good, the rectifier bridge is good.

If any reading is wrong, an open or shorted diode is

indicated and the rectifier bridge should be replaced.

Continued on next page RG,RG34710,2055 –19–18OCT00–4/7

CTM77 (30OCT00) 10-15-8 Alternators and Starter Motors

103000
PN=58
 Delco-Remy (Delcotron) 21SI Alternator Repair

8. To remove rectifier bridge, remove inside BAT terminal

nut (A), regulator nut (B) and regulator stud connector
(C) from regulator stud. Remove inside “R” (relay)
terminal nut (D) and relay terminal connector (E) (if
used), two bridge attaching screws (F), and insulated
10
capacitor attaching screw (G). Lift capacitor (H) and 15
rectifier bridge (I) from slip ring end housing. 9

A—BAT Terminal Nut

B—Regulator Nut
C—Regulator Stud Connector
D—Relay Terminal Nut
E—Relay Terminal Connector
F—Bridge Attaching Screws

–UN–30NOV93
G—Capacitor Attaching Screw
H—Capacitor
I—Rectifier Bridge

RG6977
Remove Rectifier Bridge

Continued on next page RG,RG34710,2055 –19–18OCT00–5/7

CTM77 (30OCT00) 10-15-9 Alternators and Starter Motors

103000
PN=59
 Delco-Remy (Delcotron) 21SI Alternator Repair

9. Brush holder assembly must be removed to service

brushes or regulator. Hold brushes (A) in retracted
position and insert brush pin (B) to keep brushes in
retracted position. Remove insulated regulator
attaching screws (C). Remove regulator nut and stud
10
15 connector (D) (if used). Loosen or remove inside “I”
10 terminal nut (E) to move “I” terminal connector (F) (if
used) as necessary for clearance. Finally, remove
brush holder pivot screw (G). Lift brush holder
assembly (H) from housing without bending regulator
connector from diode trio or “I” terminal connector.

–UN–30NOV93
10. Check brushes and leads for excessive wear,
breakage, etc. If necessary to replace, note routing of
lead wires and position of brush lead clips (I) for later
assembly. (Brushes are identical but leads and clips

RG6978
are positioned differently.) Carefully remove brush pin
(B) to release brushes (A). Remove brushes and
Brush Holder Assembly
spacer (J) one at a time, placing fingers around
springs (K) to prevent loss. It may be necessary to A—Brush
spread the brush lead clips slightly to disengage B—Brush Pin
retaining tabs. C—Regulator Attaching Screws
D—Regulator Stud Connector
E—Inside “I” Terminal Nut
11. If previous checks lead to an instruction to replace the
F—“I” Terminal Connector
regulator (L), replace it. Remove remaining regulator G—Brush Holder Pivot
attaching (ground) screw (M). H—Brush Holder Assembly
I—Brush Lead Clip
J—Spacer
K—Brush Springs
L—Regulator
M—Regulator Attaching Screw

Continued on next page RG,RG34710,2055 –19–18OCT00–6/7

CTM77 (30OCT00) 10-15-10 Alternators and Starter Motors

103000
PN=60
 Delco-Remy (Delcotron) 21SI Alternator Repair

12. Remove protective tape and check bearing (B) in slip

ring end housing (A). If bearing is dry or damaged,
replace bearing.

NOTE: Bearings are permanently lubricated. Do not add

10
grease. 15
11
To remove bearing, use tube (C) slightly smaller than
opening in slip ring end housing and drive bearing
through to inside of housing.

–UN–30NOV93
NOTE: If bearing is being replaced without removing
brushes from slip ring end housing, use brush pin
to hold brushes in retracted position while bearing

RG6979
is removed.
Check Bearing
13. Place tape over bearing until reassembly of alternator.
A—Slip Ring End Housing
B—Slip Ring End Bearing
C—Tube
D—Hammer

RG,RG34710,2055 –19–18OCT00–7/7

Drive End Frame and Components

1. Use digital multimeter to check rotor field resistance.

Place ohmmeter leads on two slip rings (A) on the
rotor shaft to make this check. Proper resistance is
0.04 ohm.

–UN–30NOV93
Also check for a grounded field by touching one lead to
a slip ring and one lead to rotor frame (B) or shaft (C).
Reading should be infinite (open) to show that field is

RG6980
not grounded.

If field resistance is outside specifications, or if field is Drive End Frame and Components
grounded, replace rotor as described in the following
steps. A—Slip Rings
B—Rotor Frame
C—Rotor Shaft
2. Hold drive end frame (D) and spin rotor by hand to see D—Drive End Frame
that it spins freely in ball bearing. If bearing movement
is rough or loose, replace bearing in drive end frame
as described in the following steps.

NOTE: Bearing is permanently lubricated. Do not add

grease.

Continued on next page RG,RG34710,2056 –19–15MAR97–1/2

CTM77 (30OCT00) 10-15-11 Alternators and Starter Motors

103000
PN=61
 Delco-Remy (Delcotron) 21SI Alternator Repair

3. Remove shaft nut (A) by placing a 5/16-in. hex wrench

(B) in the end of the shaft to hold the shaft while
removing nut with a common wrench (C). Remove
shaft nut washer (D), pulley (E) and fan (F) from shaft.
10
15 4. Remove rotor (G) from drive end frame (H).
12

–UN–30NOV93
5. If rotor checked good electronically, inspect slip rings.
If rough or out of round, turn in lathe (removing only
enough material to make rings smooth and round).
Maximum indicator reading for roundness is 0.05 mm

RG6981
(0.002 in.). Finish with 400 grain polishing cloth. Blow
away all copper dust. Clean shaft of any accumulated
grease or copper dust. Inspect Bearing

6. Remove three attaching screws (I) and bearing retainer A—Shaft Nut
B—Hex Wrench
plate (J) from drive end frame. C—Common Wrench
D—Shaft Nut Washer
7. Inspect drive end bearing (K). If bearing appears dry, E—Pulley
or if rotor did not turn smoothly when checked during F—Fan
alternator disassembly, replace the drive end bearing. G—Rotor
H—Drive End Frame
I—Attaching Screws
NOTE: Bearing is permanently lubricated. Do not add J—Retainer Plate
grease. K—Drive End Bearing

RG,RG34710,2056 –19–15MAR97–2/2

CTM77 (30OCT00) 10-15-12 Alternators and Starter Motors

103000
PN=62
 Delco-Remy (Delcotron) 21SI Alternator Repair

Assemble Alternator

1. Install drive end bearing (K) and bearing retainer plate

(J) on drive end frame (H) with three attaching screws
(I). Tighten attaching screws to specifications.
10
15
Specification 13
Drive End Bearing Retainer Plate

–UN–30NOV93
Cap Screws—Torque .................................................... 3.0 N•m (26 lb-in.)

2. Install rotor shaft (G) into drive end bearing.

RG6981
3. Install fan (F), pulley (E) and shaft nut washer (D) and
shaft nut (A) onto rotor shaft. Hold rotor shaft with
Alternator Components
5/16-inch hex wrench (B) and tighten shaft nut with
common wrench (C). Tighten shaft nut to A—Shaft Nut
specifications. B—Hex Wrench
C—Common Wrench
Specification D—Shaft Nut Washer
Delco-Remy Model 21SI E—Pulley
Alternator Pulley Nut—Torque ...................................... 100 N•m (75 lb-ft) F—Fan
G—Rotor
H—Drive End Frame
I—Attaching Screws
J—Retainer Plate
K—Drive End Bearing

RG,RG34710,2057 –19–15MAR97–1/1

Slip Ring End Housing Assembly

1. Install slip ring end bearing (A) into slip ring end
housing (B) using appropriate size tube (C). Install
bearing flush with outside lip of housing. Cover
opening in bearing with tape to prevent entry of dirt.

A—Slip Ring End Bearing

B—Slip Ring End Housing
–UN–30NOV93

C—Tube
RG6982

Slip Ring End Housing Assembly

Continued on next page RG,RG34710,2058 –19–15MAR97–1/10

CTM77 (30OCT00) 10-15-13 Alternators and Starter Motors

103000
PN=63
 Delco-Remy (Delcotron) 21SI Alternator Repair

2. Install rectifier bridge assembly (A) in slip ring end

housing (B). Install one rectifier bridge attaching screw
(C) through grounded heat sink portion of rectifier
bridge as shown. Tighten attaching screw finger-tight.
10
15 A—Rectifier Bridge Assembly
14 B—Slip Ring End Housing
C—Rectifier Bridge Attaching Screw

–UN–30NOV93
RG6983
Install Rectifier Bridge Assembly

RG,RG34710,2058 –19–15MAR97–2/10

NOTE: Shape of “R” terminal connector determines

location of “R” terminal in slip ring end housing.

3. Install relay “R” terminal (A) in slip ring end housing

(B). Place inside insulating washer (C) over “R”
terminal stud. Place “R” terminal connector (D) over
rectifier bridge stud (E) and “R” terminal stud.

NOTE: Be sure inside insulating washer is between

–UN–30NOV93
connector and slip ring end housing at terminal
end. Connector must not touch housing. Also be
sure outside insulator is centered in hole to
ensure that terminal stud cannot touch housing.

RG6984
4. Install inside nut/washer assembly (F) on “R” terminal
stud. Tighten inside nut/washer assembly to Install Terminal Connectors
specifications.
A—“R” Terminal
Specification B—Slip Ring End Housing
“R” Terminal Stud Nut—Torque .................................... 2.5 N•m (22 lb-in.) C—Insulating Washer
D—“R” Terminal Connector
E—Rectifier Bridge Stud
F—Inside Nut/Washer Assembly

Continued on next page RG,RG34710,2058 –19–15MAR97–3/10

CTM77 (30OCT00) 10-15-14 Alternators and Starter Motors

103000
PN=64
 Delco-Remy (Delcotron) 21SI Alternator Repair

5. Install output (BAT) terminal (A) on slip ring end

housing (B). Be sure to seat square insulator flange in
hole.

6. Install inside (BAT) terminal nut/washer assembly (C)

10
on terminal stud and tighten finger-tight. 15
15
7. Position capacitor over holes in rectifier bridge and
install rectifier bridge attaching screw (E) through
capacitor connector and grounded heat sink into slip

–UN–30NOV93
ring end housing. Tighten screw finger-tight.

8. Install insulated capacitor attaching screw (F) through

capacitor connector and insulated heat sink into slip

RG6985
ring end housing. Tighten screw finger-tight.

Slip Ring End Housing

A—Output (BAT) Terminal

B—Slip Ring End Housing
C—Inside (BAT) Terminal Nut/Washer Assembly
D—Capacitor
E—Rectifier Bridge Attaching Screw (Ground)
F—Capacitor Attaching Screw (Insulated)

RG,RG34710,2058 –19–15MAR97–4/10

IMPORTANT: Do not immerse or wipe regulator with

solvent. Internal damage to regulator
could result.

9. Before installing voltage regulator, be sure regulator

and regulator mounting bosses in slip ring end housing

–UN–30NOV93
are free of all dirt and grease. Wipe all contact areas
with a clean, dry cloth.

10. Install regulator (A) to slip ring end housing (B) with

RG6986
regulator attaching screw (C) (ground). Tighten screw
finger-tight.
Install Regulator

A—Voltage Regulator
B—Slip Ring End Housing
C—Voltage Regulator Attaching Screw

Continued on next page RG,RG34710,2058 –19–15MAR97–5/10

CTM77 (30OCT00) 10-15-15 Alternators and Starter Motors

103000
PN=65
 Delco-Remy (Delcotron) 21SI Alternator Repair

11. Install brushes (A), springs (B) and spacer (C) on

brush holder (D).

NOTE: Brushes are identical, but bush leads and contact

clips (E) are positioned differently.
10
15
16 12. Pin brushes in retracted position with brush pin (F).

–UN–30NOV93
A—Brush (with Arm)
B—Brush Spring
C—Spacer
D—Brush Holder
E—Brush Contact Clip

RG6987
F—Brush Pin

Install Brushes, Springs and Spacer

RG,RG34710,2058 –19–15MAR97–6/10

13. With brushes pinned in retracted position, position

brush holder assembly (B) over holes in regulator (C)
and slip ring end housing (D). Install brush holder
attaching (pivot) screw (E) and one insulated
regulator attaching screw (F). Tighten both screws
finger-tight.

NOTE: Brush pin (A) must remain in place until final

assembly.

Ensure that contact surfaces of brushes are free

of grease and dirt.

–UN–30NOV93
14. Install diode trio (G) onto three threaded studs on
rectifier bridge assembly (H). Position long connector
strap on diode trio over mounting hole in brush holder

RG6988
and regulator.

Position Brush Holder Assembly

A—Brush Pin
B—Brush Holder Assembly
C—Regulator
D—Slip Ring End Housing
E—Brush Holder Attaching (Pivot) Screw
F—Regulator Attaching Screw (Insulated)
G—Diode Trio
H—Rectifier Bridge

Continued on next page RG,RG34710,2058 –19–15MAR97–7/10

CTM77 (30OCT00) 10-15-16 Alternators and Starter Motors

103000
PN=66
 Delco-Remy (Delcotron) 21SI Alternator Repair

15. Hold outside BAT terminal and temporarily remove

the inside BAT terminal nut/washer assembly (A).
Install regulator stud connector (B) to threaded
regulator stud (C) and to inside BAT terminal stud
(D). Reinstall inside BAT terminal nut/washer
10
assembly (A) and install regulator nut/washer 15
assembly (E) to regulator stud. Tighten two nuts 17
finger-tight.

–UN–30NOV93
16. Install “I” terminal with outside insulator (F) (if used) to
slip ring end housing and hold in place. Install inside
insulator (G) and “I” terminal connector (H) over “I”
terminal stud inside housing. Position other end of “I”

RG6989
terminal connector over mounting hole in brush
holder. Install “I” terminal nut/washer assembly (I)
BAT Terminal
onto “I” terminal stud. Tighten nut finger-tight.
A—Inside BAT Terminal Nut/Washer Assembly
17. Install insulated regulator attaching screw (K) to B—Regulator Stud Connector
mounting hole in brush holder, passing through diode C—Regulator Stud
D—BAT Terminal Stud
trio connector (J) and “I” terminal connector (if used).
E—Regulator Stud Nut/Washer Assembly
Tighten screw finger-tight. F—“I” Terminal with Outside Insulator
G—Inside Insulator
H—“I” Terminal Connector
I—Inside “I” Terminal Nut/Washer Assembly
J—Diode Trio Connector
K—Regulator Attaching Screw (Insulated)

Continued on next page RG,RG34710,2058 –19–15MAR97–8/10

CTM77 (30OCT00) 10-15-17 Alternators and Starter Motors

103000
PN=67
 Delco-Remy (Delcotron) 21SI Alternator Repair

18. Tighten the slip ring end housing components in the

following order to specifications listed below:

a. Inside output terminal nut (A).

10
15 b. Rectifier bridge attaching screws (B).
18
c. Insulated capacitor attaching screw (C).

d. “R” terminal nut (D). It may be necessary to hold

terminal on outside while tightening.

–UN–30NOV93
e. Regulator mounting screw (E).

f. Insulated regulator attaching screw.

RG6990
g. Regulator nut (G) (if used).

h. Brush holder attaching (pivot) screw (H). Slip Ring End Housing Components

A—Inside Output Terminal Nut

Slip Ring End Housing Components—Specification B—Rectifier Bridge Attaching Screws
Inside Output Terminal Nut (A)—
C—Insulated Capacitor Attaching Screw
Torque ........................................................................... 5.5 N•m (50 lb-in.) D—“R” Terminal Nut
Rectifier Bridge Attaching Screws
E—Regulator Mounting Screw
(B)—Torque ................................................................... 3.0 N•m (25 lb-in.) F—Insulated Regulator Nut (If Used)
Capacitor Attaching Screw (C)—
G—Regulator Nut
Torque ........................................................................... 2.5 N•m (22 lb-in.) H—Brush Holder Attaching (Pivot) Screw
“R” Terminal Nut (D)—Torque....................................... 2.5 N•m (22 lb-in.)
Regulator Mounting Screws (E)—
Torque .............................................................................. 2 N•m (20 lb-in.)
Regulator Mounting Nut (G)—
Torque ........................................................................... 2.5 N•m (22 lb-in.)
Brush Holder Pivot Attaching
Screw (H)—Torque........................................................... 2 N•m (20 lb-in.)

Continued on next page RG,RG34710,2058 –19–15MAR97–9/10

CTM77 (30OCT00) 10-15-18 Alternators and Starter Motors

103000
PN=68
 Delco-Remy (Delcotron) 21SI Alternator Repair

19. If used, install debris shield mounting stud in slip ring

end housing with inside washer to “I” terminal hole in
housing. Install outside washer, lock washer and
mounting stud on outside of housing. Tighten nut to
specifications.
10
15
Specification 19
Stator Debris Shield Mounting

–UN–30NOV93
Stud Nut—Torque ......................................................... 5.5 N•m (50 lb-in.)

20. Install stator (A) in slip ring end housing (B), placing
three phase leads (C) over threaded studs (D) on
rectifier bridge. Be sure stator is seated in register

RG6991
around edge of slip ring end housing.
Install Components on Housing
21. Install rectifier bridge nuts on threaded studs. Tighten
nuts to specifications. A—Stator
B—Slip Ring End Housing
Specification C—Phase Leads
Rectifier Bridge Nuts—Torque ...................................... 2.5 N•m (22 lb-in.) D—Threaded Studs on Rectifier Bridge
E—Rectifier Bridge Nuts

RG,RG34710,2058 –19–15MAR97–10/10

Final Assembly

1. Assemble drive end frame assembly (A) and slip ring

end housing assembly (B) using alignment marks (C)
to ensure proper alignment to parts. Install four through
bolts (D) and tighten bolts to specifications.

Specification

–UN–30NOV93
Drive End-to-Slip Ring End
Housing Through Bolts—Torque ................................... 5.5 N•m (50 lb-in.)

A—Drive End Frame Assembly

RG6992
B—Slip Ring End Housing Assembly
C—Alignment Marks
D—Through Bolts Final Assembly

Continued on next page RG,RG34710,2059 –19–15MAR97–1/2

CTM77 (30OCT00) 10-15-19 Alternators and Starter Motors

103000
PN=69
 Delco-Remy (Delcotron) 21SI Alternator Repair

2. Remove brush pin (A) from slip ring end housing (B) to
release brushes onto slip rings inside unit.

A—Brush Pin

–UN–30NOV93
10 B—Slip Ring End Housing
15
20

RG6993
Remove Brush Pin

RG,RG34710,2059 –19–15MAR97–2/2

CTM77 (30OCT00) 10-15-20 Alternators and Starter Motors

103000
PN=70
 Section 15
Motorola Alternators
Contents

Page Page

Group 05—Motorola Alternator Theory of Operation Motorola SA-Series Charging Circuit Repair
Motorola Alternator Operation . . . . . . . . . . . . . .15-05-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . .15-25-2 15
Motorola Regulator Operation . . . . . . . . . . . . . .15-05-2 Motorola SA-Series Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .15-25-2
Group 10—Motorola 8E-Series Alternator Repair Remove Alternator for Repair . . . . . . . . . . . . . .15-25-3
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .15-10-1 Disassemble and Test Motorola 8SA-Series
Motorola 8E-Series Charging Circuit Repair Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-25-3
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .15-10-2 Assemble Motorola 8SA-Series Alternator. . . .15-25-14
Motorola 8E-Series Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .15-10-2 Group 30—Motorola TA-Series Alternator Repair
General Information. . . . . . . . . . . . . . . . . . . . . .15-10-3 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .15-30-1
Remove Alternator for Repair . . . . . . . . . . . . . .15-10-3 Service Equipment and Tools . . . . . . . . . . . . . .15-30-2
Disassemble and Test Motorola 8E-Series Motorola TA-Series Charging Circuit Repair
(12-Volt, 65 Amp) Alternator . . . . . . . . . . . . .15-10-4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . .15-30-2
Assemble Motorola 8E-Series Motorola TA-Series Charging Circuit Test
(12-Volt, 65 Amp) Alternator . . . . . . . . . . . . .15-10-8 Specifications. . . . . . . . . . . . . . . . . . . . . . . . .15-30-3
Remove Alternator for Repair . . . . . . . . . . . . . .15-30-3
Disassemble and Test Motorola TA-Series
Group 15—Motorola HC-, MA-, MR-Series
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-30-4
Alternator Repair
Assemble Motorola TA-Series Alternator . . . . .15-30-14
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .15-15-1
Service Equipment and Tools . . . . . . . . . . . . . .15-15-1
Motorola HC-, MA-, MR-Series Charging
Circuit Repair Specifications . . . . . . . . . . . . .15-15-2
Motorola HC-, MA-, MR-Series Charging
Circuit Test Specifications . . . . . . . . . . . . . . .15-15-3
Disassemble and Test Motorola HC-, MA-,
MR-Series Alternator . . . . . . . . . . . . . . . . . . .15-15-4
Assemble Motorola HC-, MA-, MR-Series
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .15-15-20

Group 20—Motorola A-, RA-, 8AR-Series Alternator

Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .15-20-1
Motorola A-, RA-, 8AR-Series Charging
Circuit Repair Specifications . . . . . . . . . . . . .15-20-1
Motorola A-, RA-, 8AR-Series Charging
Circuit Test Specifications . . . . . . . . . . . . . . .15-20-2
Disassemble and Test Motorola A-, RA-,
8AR-Series Alternator . . . . . . . . . . . . . . . . . .15-20-3
Assemble Motorola A-, RA-, 8AR-Series
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .15-20-11

Group 25—Motorola SA-Series Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .15-25-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .15-25-1

CTM77 (30OCT00) 15-1 Alternators and Starter Motors

103000
PN=1
 Contents

15

CTM77 (30OCT00) 15-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Motorola Alternator Theory of Operation
Motorola Alternator Operation

In an alternator, the magnetic field of the rotor is moved

across stationary conductors in the stator. This permits
permanent connection between the stator windings and
the output terminal. Slip rings are used to transmit the
field current to the rotor field winding.

–UN–31MAY89
The alternator produces power in the form of three-phase
alternating current and voltage. The alternating current is
rectified to direct current by a three-phase full-wave 15
rectifier circuit using six silicon rectifier diodes. Since the 05

T52184
1
diode will pass current in only one direction (from
alternator to battery or load), the alternator does not Motorola Alternator Operation
require the use of cutout relay.
1—Stator
The entire DC output of the system passes through the 2—Rotor Winding (Field)
isolation diode. This provides the system with several 3—Rotor Slip Ring
4—Brushes
distinct advantages. It prevents the battery from 5—Regulator Terminal
discharging through the regulator and alternator field 6—Output Terminal
without the use of relays or switches. Electrically, the 7—Isolation Diode
indicator lamp is connected across the isolation diode. 8—Regulator
When the system is operating properly, the alternator
output voltage is very nearly the same as the battery
voltage. This means that the voltage potential across the
isolation diode is low and the indicator lamp shows that
the alternator is charging.

The alternator output current is controlled by the current

flow through the field coil (rotor). The amount of current
required is determined and controlled by the regulator.
Since there is very little residual magnetism in the
alternator, it is necessary to supply a small amount of
excitation current to the field (rotor) to start the process of
current generation. The excitation resistor supplies this
starting current when the key switch is turned on. This
resistor is enclosed in the sealed regulator case. Once the
alternator is excited, a voltage is developed at the
regulator terminal and the voltage regulator takes over
control of the system voltage.

RG,RG34710,2060 –19–15MAR97–1/1

CTM77 (30OCT00) 15-05-1 Alternators and Starter Motors

103000
PN=73
 Motorola Alternator Theory of Operation

Motorola Regulator Operation

The transistor regulator is an electronic switching device

composed principally of transistors, resistors, and diodes
to form a completely static unit containing no moving
parts.

The transistors are used to switch the alternator field

current on and off, and are controlled by the resistors and
the Zener diode.

–UN–02JUN89
15
05 A Zener diode is a special diode that will break down and
2
permit a reverse flow of current when the voltage reaches

T51537
a certain value, without damaging the semiconductor
material. This diode is the trigger which senses the
maximum desired voltage and turns the transistor on or Motorola Regulator Operation
off to limit charging system voltage.
1—Thermistor (RT)
2—Field Discharge Diode
The field discharge diode provides an alternator current 3—Transistor (T-2)
path to protect the transistors from induced high voltage 4—Transistor (T-1)
from the alternator field windings. The sudden stopping of 5—Zener Diode
field current by the transistor and subsequent collapsing of 6—Excitation Resistor
7—To Alternator Indicator Light
the magnetic field causes an induced voltage in the rotor
windings.

The thermistor (RT) is a temperature compensating

resistor. Its resistance varies with temperature and
controls the operating point of the Zener diode so that a
high system voltage is produced in cold weather, when
needed, and a lower system voltage in warm weather.

When the voltage appearing at the output terminal of the

alternator rises to a predetermined value (14.4 volts), the
voltage which appears across the Zener diode conducts.
This conduction of the Zener diode permits current to flow
in the base of transistor T-1. This causes transistor T-1 to
turn on and reverse bias transistor T-2, thus turning off
the current applied to the alternator field.

When the system voltage drops below the predetermined

value, the Zener diode stops conducting, T-1 turns off and
T-2 turns on. When transistor T-2 is switched on, field
current again is supplied to the alternator.

Continued on next page RG,RG34710,2061 –19–15MAR97–1/5

CTM77 (30OCT00) 15-05-2 Alternators and Starter Motors

103000
PN=74
 Motorola Alternator Theory of Operation

The operation of transistor T-2 is in effect like a switch,

turning the alternator field current on and off as the
electrical supply varies due to the varying electrical load.
This action occurs many times a second, so fast it cannot
be detected in the alternator output.

The solid-state regulator is either mounted on rear of

alternator or mounted internally. It controls output by
controlling current through field. In operation, regulator
has the following three phases.
15
05
Continued on next page RG,RG34710,2061 –19–15MAR97–2/5 3

CTM77 (30OCT00) 15-05-3 Alternators and Starter Motors

103000
PN=75
 Motorola Alternator Theory of Operation

Phase 1—Alternator Stopped

(Phase 1 also applies when alternator is turning but only if

not running fast enough for output to exceed battery
voltage.)

1. Current flows from battery (B) through key switch (C)

to regulator (A).

2. From there, current flows through resistors R8, R7, and

15 R1 to transistor Q2, turning it on.
05
4
3. Transistor Q2 then provides a path so current can flow
through field (E) to ground, enabling alternator to
generate electricity.

4. Zener diode D1 prevents flow of current to transistor

Q1. A Zener diode is a special type of diode which will
not permit current to pass until voltage reaches a
certain preset level. If voltage exceeds that level,
current can pass through the Zener diode.

A—Regulator
B—Battery
C—Key Switch
D—Rotor
E—Field Windings
F—Delta Stator
G—Rectifier Diodes
H—Diode Trio
I—Suppression Capacitor

–UN–02MAY89
N37761

Phase 1—Alternator Stopped

Continued on next page RG,RG34710,2061 –19–15MAR97–3/5

CTM77 (30OCT00) 15-05-4 Alternators and Starter Motors

103000
PN=76
 Motorola Alternator Theory of Operation

Phase II—Generating Electricity

1. The key switch (C) and rectifier bridge diodes (G) all
have equal voltage. Therefore, no current flows from
key switch to regulator.

2. Current, now coming from rectifier bridge diodes, flows

through resistors R7 and R1 to turn on transistor Q2.

3. Transistor Q2 still provides path to ground through field

(E), enabling alternator to generate electricity. 15
05
5
4. Since the field is rotating, it does generate electricity.
Alternating current is included in the stator windings
(F). The rectifier bridge converts it to direct current,
providing current to run electrical accessories and
charge the battery.

5. Output voltage still has not reached critical voltage of

the Zener diode D1.

A—Regulator
B—Battery
C—Kay Switch
D—Rotor
E—Field Windings
F—Delta Stator
G—Rectifier Diodes
H—Diode Trio
I—Suppression Capacitor

–UN–02MAY89
N37762
Phase II—Generating Electricity

Continued on next page RG,RG34710,2061 –19–15MAR97–4/5

CTM77 (30OCT00) 15-05-5 Alternators and Starter Motors

103000
PN=77
 Motorola Alternator Theory of Operation

Phase III—Shut-Off

1. Output voltage reaches critical voltage of Zener diode

D1.

2. Current can now pass through Zener diode D1 to turn

on control transistor Q1

3. Current from transistor Q1 cuts off voltage to transistor

Q2, turning it off. There is now no path to ground for
15 current through field (E).
05
6
4. Current through field is shut off instantly, and alternator
stops generating electricity.

5. With transistor Q2 off, system voltage starts to drop in

unrestricted fashion until it falls below the Zener diode
D1 critical voltage. When this occurs, Zener diode D1
and transistor Q1 switch off and Q2 turns on again.

6. Phase II and III are repeated many times per second

to maintain voltage at proper level.

A—Regulator
B—Battery
C—Key Switch
D—Rotor
E—Field Windings
F—Delta Stator
G—Rectifier Diodes
H—Diode Trio
I—Suppression Capacitor

–UN–02MAY89
N37763

Phase III—Shut-Off

RG,RG34710,2061 –19–15MAR97–5/5

CTM77 (30OCT00) 15-05-6 Alternators and Starter Motors

103000
PN=78
 Group 10
Motorola 8E-Series Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

15
10
SERVICEGARD is a trademark of Deere & Company OUO1004,0000B5A –19–21SEP00–1/2 1

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B5A –19–21SEP00–2/2

CTM77 (30OCT00) 15-10-1 Alternators and Starter Motors

103000
PN=79
 Motorola 8E-Series Alternator Repair

Motorola 8E-Series Charging Circuit Repair

Specifications

Item Measurement Specification

Brush (24-Volt, 42-Amp) Minimum Exposed Length 6.4 mm (0.25 in.)

Brush (12-Volt, 65-Amp) Minimum Exposed Length 4.8 mm (0.189 in.)

Motorola 8E-Series Alternator

15
10
Pulley-to-Shaft Nut Torque 60 N•m (45 lb-ft)
2

Rear Housing-to-Front Housing Torque 7.0—8.3 N•m (50—60 lb-in.)

Cap Screws

Bearing Retainer Cap Screws Torque 3.5—4.8 N•m (25—35 lb-in.)

Output Terminal Nut Torque 7 N•m (50 lb-in.)

Indicator Light Terminal Torque 2.3 N•m (20 lb-in.)

Slip Ring-to-Shaft Torque 40 N•m (30 lb-ft)

OUO1004,0000B59 –19–21SEP00–1/1

Motorola 8E-Series Charging Circuit Test

Specifications
John Deere Motorola Volts Rated Output Test Field Currentb Winding
Part No. Part No. Amps Amps (Hot)a Amps Resistancec
Ohms
AT103344 8EM2009NB 12 65 54—62 3.2—3.7 4.0—4.7
AT115049 8EM3002GB 24 42 37—42 1.8—2.3 12.0—13.0
AT125414 8EM2009ND 12 65 54—62 3.2—3.7 4.0—4.7
AT125430 8EM3002GC 24 42 37—42 1.8—2.3 12.0—13.0
RE28186 8EM3002GA 24 42 37—42 1.8—2.3 12.0—13.0
a
Output test @ 3000—4000 RPM.
b
Field current @ 20—27°C (70—80°F); @ 10V for 12V systems and 20V for 24V systems.
c
Winding resistance @ 20—27°C (70—80°F).

RG,RG34710,2066 –19–08SEP00–1/1

CTM77 (30OCT00) 15-10-2 Alternators and Starter Motors

103000
PN=80
 Motorola 8E-Series Alternator Repair

General Information

The Motorola 8E-Series charging systems are available in

two basic versions on John Deere Engines. One version
(12-volt, 65-amp) includes an integral, solid-state voltage
regulator. The other version (24-volt, 42-amp) is equipped
with a blade terminal for connection to a remote,
externally-mounted voltage regulator.

Refer to the proper repair procedure for the charging

system used on your John Deere Engine. 15
10
3

RG,RG34710,2067 –19–15MAR97–1/1

Remove Alternator for Repair

Refer to your machine technical manual for removal of

alternator.

IMPORTANT: Never immerse alternator in cleaning

solvent. Remove dirt and grease by
scraping and using a stiff brush with
solvent. Dry with compressed air.

ONLY rosin core solder should be used

for soldering operations. The use of
acid core solder will result in rapid
corrosion of the windings and eventual
failure of the complete alternator unit.

RG,RG34710,2068 –19–15MAR97–1/1

CTM77 (30OCT00) 15-10-3 Alternators and Starter Motors

103000
PN=81
 Motorola 8E-Series Alternator Repair

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

15
10
4

–UN–02NOV88
T6478AB

Motorola 8E-Series Alternator

1—Nut (2 Used) 10—Insulating Washer (2 18—Rear Housing 26—Front Bearing

2—Screw (2 Used) Used) 19—O-Ring 27—Front Housing
3—Rear Cover 11—AC Tap Strap 20—Stator Assembly 28—Fan Spacer
4—Felt Gasket 12—B + Nut 21—Slip Ring 29—Fan
5—Nut 13—Screw (4 Used) 22—Rear Bearing 30—Pulley
6—D + Strap 14—Diode Field 23—Rotor Assembly 31—Lock Washer
7—Brush Assembly 15—Screw (3 Used) 24—Woodruff Key 32—Nut
8—Screw (2 Used) 16—Rectifier Diode Bridge 25—Bearing Retainer Screw (3
9—Voltage Regulator 17—Through Bolt (4 Used) Used)

Continued on next page RG,RG34710,2069 –19–15MAR97–1/7

CTM77 (30OCT00) 15-10-4 Alternators and Starter Motors

103000
PN=82
 Motorola 8E-Series Alternator Repair

1. Inspect and test brush assembly. Brush set may be Brush (12-Volt, 65-Amp)—
reused if brush length is within specification. Minimum Exposed Length ..................................... 4.8 mm (0.189 in.)

Specification Brushes must not be oil soaked, cracked or grooved

Brush (24-Volt, 42-Amp)— on the sides. Replace defective brush assembly.
Minimum Exposed Length ....................................... 6.4 mm (0.25 in.)

15
10
RG,RG34710,2069 –19–15MAR97–2/7 5

2. Inspect and test diode trio. Test diode for continuity

from each of three terminals (A) to D+ stud (B).
Continuity must be observed in one direction only.

Replace entire diode trio if any one diode fails test.

–UN–02NOV88
A—Diode Terminals
B—D+ Stud

T6478AD
Diode Trio

RG,RG34710,2069 –19–15MAR97–3/7

3. Inspect and test rectifier bridge. Test for continuity

between plate (B) and each of three diode terminals
(A). Then test for continuity between terminal (C) and
each of the three diode terminals. Continuity should be
observed in one direction only, and all diodes should
check alike.
–UN–02NOV88

Replace entire rectifier bridge if any diode fails test.

T6478AE

A—Terminals
B—Plate
C—Terminal
Test Continuity

Continued on next page RG,RG34710,2069 –19–15MAR97–4/7

CTM77 (30OCT00) 15-10-5 Alternators and Starter Motors

103000
PN=83
 Motorola 8E-Series Alternator Repair

4. Inspect and test stator. Test for continuity between

terminals (A, B and C). There should be no continuity
from any terminals (A, B, or C) and laminations (D).

Replace stator if windings show any signs of

discoloration.

–UN–02NOV88
A—Terminal
B—Terminal
C—Terminal

T6478AF
15 D—Laminations
10
6 Inspect and Test Stator

RG,RG34710,2069 –19–15MAR97–5/7

5. Inspect and test rotor assembly. Test resistance

between each slip ring (A). Then test for no continuity
between each slip ring and pole finger (B).

Slip ring resistance should be 4.0—4.7 ohms @ 20—

27°C (70—80°F) for 12-volt systems and 12.0—13.0

–UN–02NOV88
ohm for 24-volt system.

A—Slip Ring
B—Pole Finger

T6478AA
Inspect and Test Rotor Assembly

Continued on next page RG,RG34710,2069 –19–15MAR97–6/7

CTM77 (30OCT00) 15-10-6 Alternators and Starter Motors

103000
PN=84
 Motorola 8E-Series Alternator Repair

6. If necessary to replace slip rings, unsolder rotor leads

(A) from slip ring terminals. Straighten rotor leads (A)
and insert a No. 10 x 1 in. cap screw (B) into center of
slip ring assembly. Remove slip ring assembly using a
bearing puller.

–UN–02NOV88
7. If necessary, remove rear bearing using a bearing
puller.

NOTE: Replace bearing if removed.

T6486AH
15
10
A—Rotor Leads 7
Unsolder Rotor Leads
B—No. 10 x 1 in. Cap Screw

RG,RG34710,2069 –19–15MAR97–7/7

CTM77 (30OCT00) 15-10-7 Alternators and Starter Motors

103000
PN=85
 Motorola 8E-Series Alternator Repair

Assemble Motorola 8E-Series

(12-Volt, 65 Amp) Alternator

For alternator assembly, the following is a list of special

reassembly requirements:

Replace bearings if removed.

Guide rotor leads through one of the oval passages in the

slip ring assembly. The oval passages must line up with
15 the groove in the rotor shaft. Solder rotor leads to
10
terminals on slip ring.
8

Tighten front bearing retainer screws (B) to specifications.

Press front housing down until inner bearing (D) race

contacts shoulder on the shaft.

Apply a thin film of heat sink compound to back of diode

rectifier bridge (A) and mating surface of rear housing.

–UN–09DEC88
Check to be sure felt gasket is installed.

Tighten shaft nut (C) to specifications.

T6493BC
Tighten through bolts (4 used) to specifications.
Assemble Motorola 8E-Series Alternator
Motorola 8E-Series—Specification
Pulley-to-Shaft Nut—Torque ........................................... 60 N•m (45 lb-ft) A—Diode Rectifier Bridge
Rear Housing-to-Front Housing B—Front Bearing Retainer
Cap Screws—Torque ................................... 7.0—8.3 N•m (50—60 lb-in.) C—Shaft Nut
Bearing Retainer Cap Screws— D—Inner Bearing
Torque .......................................................... 3.5—4.8 N•m (25—35 lb-in.)
Output Terminal Nut—Torque .......................................... 7 N•m (50 lb-in.)
Indicator Light Terminal—Torque .................................. 2.3 N•m (20 lb-in.)
Slip Ring-to-Shaft—Torque ............................................. 40 N•m (30 lb-ft)

RG,RG34710,2070 –19–15MAR97–1/1

CTM77 (30OCT00) 15-10-8 Alternators and Starter Motors

103000
PN=86
 Group 15
Motorola HC-, MA-, MR-Series Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

15
15
SERVICEGARD is a trademark of Deere & Company OUO1004,0000B5C –19–21SEP00–1/2 1

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B5C –19–21SEP00–2/2

Service Equipment and Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company OUO1004,0000BBE –19–18OCT00–1/2

Battery Load Tester . . . . . . . . . . . . . . . . . . . . JT28001

Test rotor windings.

OUO1004,0000BBE –19–18OCT00–2/2

CTM77 (30OCT00) 15-15-1 Alternators and Starter Motors

103000
PN=87
 Motorola HC-, MA-, MR-Series Alternator Repair

Motorola HC-, MA-, MR-Series Charging

Circuit Repair Specifications

Item Measurement Specification

Brush Minimum Exposed Length 6.4 mm (0.25 in.)

Slip Ring Retainer Cap Screw Torque 5.1 N•m (45 lb-in.)

Fan Pulley-to-Shaft Nut Torque 47—68 N•m (35—50 lb-ft)

15
15
Stator Stud Lock Nuts Torque 3.5—4.5 N•m (33—40 lb-in.)
2

Housing Through Bolts Torque 5.5—7.0 N•m (50—60 lb-in.)

Brush Assembly Mounting Screws Torque 2.5—3.5 N•m (20—30 lb-in.)

Regulator Mounting Cap Screws Torque 4.5—5.0 N•m (40—45 lb-in.)

Isolation Diode Nuts Torque 2.5—3.5 N•m (20—30 lb-in.)

Alternator Terminal Nuts Torque 2.5—3.5 N•m (20—30 lb-in.)

OUO1004,0000BB2 –19–28SEP00–1/1

CTM77 (30OCT00) 15-15-2 Alternators and Starter Motors

103000
PN=88
 Motorola HC-, MA-, MR-Series Alternator Repair

Motorola HC-, MA-, MR-Series Charging

Circuit Test Specifications
John Deere Motorola Rated Output Testa Field Currentb Winding Resistancec
Part No. Part No. Volts Amps Amps (Hot) Amps Ohms
AH112211 8MR2030T 12 90 79—82 4.10—4.40 2.3—2.4
AR40420 70D44110C01 12 55 — — —
AR43989 8MA2003PA 12 72 — 1.8—2.0 5.0—5.4
AR50909 8MR2012P 12 72 — 1.8—2.0 5.0—5.4
AR52077 8MR2012PS,MA12JD602 12 70 — 1.8—2.0 5.0—5.4 15
AR52078 8HC2003PS 12 72 — 1.8—2.0 5.0—5.4 15
3
AR53261 70D44086B05 12 35 — — —
AT21618 A12NJD454 12 35 — 1.95—2.55 4.2—5.5
AT28453 MA12NJD603 12 55 43—46 1.65—2.25 4.0—5.2
AT31668 70D44160B 12 22 — — —
AT31670 8MA2002KS 12 51 43—46 1.65—2.55 4.0—5.2
AT41951 70D44725C03 12 37 — — —
AT44644 8HC3010G 24 42 30 1.28—1.88 11.0—14.0
AT49446 8HC3010G 24 42 30 1.28—1.88 11.0—14.0
AT55539 8HC2015L, 8HC2012F 12 62 51—54 2.10—2.50 4.1—4.7
RE50811 8MR2069T 12 90 79—82 4.10—4.40 2.3—2.4
a
Output test @ 3000—4000 RPM.
b
Field current @ 20—27°C (70—80°F); @ 10V for 12V systems and 20V for 24V systems.
c
Winding resistance @ 20—27°C (70—80°F).

RG,RG34710,2072 –19–08SEP00–1/1

CTM77 (30OCT00) 15-15-3 Alternators and Starter Motors

103000
PN=89
 Motorola HC-, MA-, MR-Series Alternator Repair

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

15
15
4

–UN–22SEP88
N38152

HC-, MA-, MR-Series with Isolation Diode

1—Cover 11—Nut (6 Used) 21—Positive Ring 30—Rotor

2—Tie Strap 12—Lock Washer (5 Used) 22—Negative Ring 31—Key
3—Screw (2 Used) 13—Washer (4 Used) 23—Insulator 32—Retainer
4—Lock Washer 14—Diode, Isolation 24—Bolt 33—Housing
5—Regulator 15—Sleeve 25—Stator 34—Nut (4 Used)
6—Gasket 16—Washer (2 Used) 26—O-Ring 35—Spacer
7—Screws (2 Used) 17—Housing 27—Screw 36—Fan
8—Brush Holder 18—Capacitor 28—Ring 37—Lock Washer
9—Isolator 19—Bushing (2 Used) 29—Bearing (2 Used) 38—Nut
10—Through Bolts (4 Used) 20—Wiring Lead

Continued on next page RG,RG34710,2073 –19–15MAR97–1/30

CTM77 (30OCT00) 15-15-4 Alternators and Starter Motors

103000
PN=90
 Motorola HC-, MA-, MR-Series Alternator Repair

15
15
5

–UN–22SEP88
N38456
HC-, MA-, MR-Series With Diode Trio

1—Screen 10—Lock Washer (6 Used) 19—Rectifier Diode 28—Retainer

2—Tie Strap 11—Isolation Washer (7 Used) 20—Isolation Diode 29—Front Housing
3—Screw (4 Used) 12—Rear Housing 21—Bolt 30—Square Nuts
4—Regulator 13—Capacitor 22—Stator 31—Spacer
5—Gasket 14—Washer 23—Screw 32—Fan
6—Screws (2 Used) 15—Spacer 24—Slip Rings 33—Washer
7—Brush Holder 16—Nuts (2 Used) 25—Bearing (2 Used) 34—Nut
8—Through Bolts (4 Used) 17—Diode Plate 26—Rotor Assembly 35—O-Ring
9—Nuts (5 Used) 18—Diode Trio 27—Key

Continued on next page RG,RG34710,2073 –19–15MAR97–2/30

CTM77 (30OCT00) 15-15-5 Alternators and Starter Motors

103000
PN=91
 Motorola HC-, MA-, MR-Series Alternator Repair

IMPORTANT: Voltage regulator wires must be

disconnected before testing diodes to
obtain accurate results.

1. Disconnect voltage regulator wires on regulator (A),

negative output (B) and positive output (C) terminals.

–UN–02NOV88
A—Voltage Regulator
B—Negative Output Wire
C—Positive Output Wire

T6558AI
15
15
6 Output Terminals

RG,RG34710,2073 –19–15MAR97–3/30

IMPORTANT: The diode test position must be used

on meters to get accurate results.
Follow manufacturer’s instructions for
your meter to test diodes.

–UN–07NOV88
2. Test positive and negative diodes in both directions
using an ohmmeter. Put one probe on a diode lead (B)
and the other probe on diode plate (A) to get a
reading.

T84666
A diode with a high reading in one direction and a low Test Diodes
reading in the other direction is good. A diode with the
same reading in both directions is bad and should be A—Diode Plate
replaced. B—Diode Lead

Continued on next page RG,RG34710,2073 –19–15MAR97–4/30

CTM77 (30OCT00) 15-15-6 Alternators and Starter Motors

103000
PN=92
 Motorola HC-, MA-, MR-Series Alternator Repair

NOTE: Illustration shows alternator equipped with an

isolation diode plate. Some applications do not
use this plate.

3. Check isolation diode using volt-ohm-amp meter with

selector indicator in diode test position.

–UN–06APR90
The meter must register OL in one direction and
approximately 0.50 volts in the other. If it does not,
replace diode.

T6015BJ
15
15
Alternator with Isolation Diode Plate 7

RG,RG34710,2073 –19–15MAR97–5/30

4. Loosen regulator cap screws (A). Remove two nuts to

remove isolation diode plate, if equipped.

A—Regulator Cap Screws (4 Used)

–UN–06APR90
T6015AZ
Regulator Cap Screws

Continued on next page RG,RG34710,2073 –19–15MAR97–6/30

CTM77 (30OCT00) 15-15-7 Alternators and Starter Motors

103000
PN=93
 Motorola HC-, MA-, MR-Series Alternator Repair

5. Remove sleeve (C), insulator washer (B) and regulator

wires (A) from alternator terminals.

A—Regulator Wires
B—Insulator Washer
C—Sleeve

–UN–06APR90
T6015AT
15
15
8 Remove Sleeve, Washer, and Wires

RG,RG34710,2073 –19–15MAR97–7/30

6. Test the three negative diodes with selector in diode

test position.

Touch one probe to a diode and the other probe to the

ground terminal. Take reading. Reverse probes (A) and
take another reading.

–UN–06APR90
The meter must register OL in one direction and
approximately 0.50 volts in the other on all three
diodes. If it does not, replace the negative diode plate.

T6015AL
A—Meter Probes
Test Negative Diodes

Continued on next page RG,RG34710,2073 –19–15MAR97–8/30

CTM77 (30OCT00) 15-15-8 Alternators and Starter Motors

103000
PN=94
 Motorola HC-, MA-, MR-Series Alternator Repair

7. Test the three positive diodes (A) with selector in diode

test position.

Touch one probe to a diode (A) and the other probe to

diode plate post. Take reading. Reverse probes and
take another reading.

–UN–06APR90
The meter must register OL in one direction and
approximately 0.50 volts in the other on all three
diodes. If it does not, replace the negative diode plate.

T6015AM
15
15
A—Three Positive Diodes 9
Test Positive Diodes

RG,RG34710,2073 –19–15MAR97–9/30

8. Check the stator windings for continuity.

Touch one probe to a diode (A) and the other probe to

each of the other two diodes (B) attached to the same
diode plate. Repeat step for other diode plate.

–UN–06APR90
If there is no continuity in any of the connections, there
is an open circuit in the stator windings and the stator
must be replaced.

T6015AD
A—Diode
B—Two Diodes
Check Stator Windings

Continued on next page RG,RG34710,2073 –19–15MAR97–10/30

CTM77 (30OCT00) 15-15-9 Alternators and Starter Motors

103000
PN=95
 Motorola HC-, MA-, MR-Series Alternator Repair

9. Check stator for a grounded winding.

Touch one probe to a diode (A) and the other probe to

the rear alternator housing (B). Take reading. Reverse
probes and take another reading.

–UN–06APR90
The meter must register continuity in one direction
only. If continuity is registered in both directions, a
stator winding is grounded and the stator must be
replaced.

T6015BA
15
15
10 A—Diode
Check Stator for Grounded Winding
B—Rear Alternator Housing

RG,RG34710,2073 –19–15MAR97–11/30

10. Remove screws and disconnect wire (A) to remove

regulator.

11. Remove cap screws (B) to remove brushes.

A—Wire

–UN–06APR90
B—Cap Screws (2 Used)

T6015AY
Remove Regulator and Brushes

RG,RG34710,2073 –19–15MAR97–12/30

12. Check the condition of the springs, connections, and

for free movement of the brushes. If either brush is
worn to less than specified length, or is cracked or oil
soaked, replace the brush assembly.

Specification
–UN–07NOV88

Brush—Minimum Exposed Length ................................. 6.4 mm (0.25 in.)

T84656

Check Movement of Brushes

Continued on next page RG,RG34710,2073 –19–15MAR97–13/30

CTM77 (30OCT00) 15-15-10 Alternators and Starter Motors

103000
PN=96
 Motorola HC-, MA-, MR-Series Alternator Repair

13. Check for continuity between terminal (A) and brush

(B) and bracket (C) and brush (D). If there is no
continuity at either brush, replace the brush assembly.

14. Check for continuity between terminal (A) and bracket

(C). If there is continuity, replace the brush assembly.

–UN–23FEB90
15. Check for continuity between terminal (A) and brush
(D). If there is continuity, replace the brush assembly.

T87568
15
A—Terminal
15
B—Brush Check for Continuity
11
C—Bracket
D—Brush

RG,RG34710,2073 –19–15MAR97–14/30

16. Check rotor windings for continuity (a low resistance

reading will be seen) using an ohmmeter.

If there is no continuity (open circuit), check soldered

connections (A). If connections are good, replace

–UN–07NOV88
rotor.

NOTE: Place meter probes on edges of slip rings to

prevent scratching brush contact area.

T84674
A—Soldered Connections
Check Soldered Connections

Continued on next page RG,RG34710,2073 –19–15MAR97–15/30

CTM77 (30OCT00) 15-15-11 Alternators and Starter Motors

103000
PN=97
 Motorola HC-, MA-, MR-Series Alternator Repair

17. Check for grounded rotor windings. If there is

continuity (short circuit), replace rotor.

–UN–06APR90
T6015AE
15
15
12 Check for Grounded Rotor Windings

RG,RG34710,2073 –19–15MAR97–16/30

18. Remove nut and isolation washer. Disconnect wiring

lead (A).

19. Remove four cap screws to remove rear housing

cover.

–UN–06APR90
NOTE: Some units use square nuts with the through
bolts; others have threaded holes in the front
housing.

T6015AP
A—Wiring Lead

Disconnect Wiring Lead

RG,RG34710,2073 –19–15MAR97–17/30

IMPORTANT: Inserting screwdriver blades farther

than 1.6 mm (1/16 in.) may damage
stator windings.

20. Carefully insert two screwdriver blades (A) in opposite

–UN–23FEB90

openings between the stator and front housing and

separate the front housing from the rear.

A—Two Screwdriver Blades

T87572

Insert Screwdriver Blades

Continued on next page RG,RG34710,2073 –19–15MAR97–18/30

CTM77 (30OCT00) 15-15-12 Alternators and Starter Motors

103000
PN=98
 Motorola HC-, MA-, MR-Series Alternator Repair

21. Put identification tags on wiring leads to aid

assembly.

22. Unsolder wiring leads from diode leads, as necessary,

to replace diode assemblies, diode trio or stator. Use
needle-nose pliers as a heat sink on the leads of

–UN–21FEB90
good diodes to protect them from too much heat.

Remove nut and insulating washers from regulator

terminal stud to remove diode trio from positive diode

T89073
assembly plate. Note location of insulating washers 15
for reassembly. 15
Unsolder Wiring Leads 13

23. When soldering wiring leads to diodes, use needle

nose pliers as a heat sink to protect diodes from too
much heat. Use rosin core solder only.

24. Be sure to install insulating washer under nut when

diode trio is installed.

RG,RG34710,2073 –19–15MAR97–19/30

For alternators equipped with a diode trio:

25. Using a commercial diode tester, volt-ohm-amp meter

with diode test position, or 12-volt DC test lamp,
check for continuity from each lead separately to
center contact stud. Continuity should be observed in
one direction only. All three diodes should check
alike.

–UN–22SEP88
26. If any diode is defective, replace entire diode trio
assembly.
N38452

Commercial Diode Tester

Continued on next page RG,RG34710,2073 –19–15MAR97–20/30

CTM77 (30OCT00) 15-15-13 Alternators and Starter Motors

103000
PN=99
 Motorola HC-, MA-, MR-Series Alternator Repair

27. Clamp pulley in vise using an over-sized belt to

protect pulley. Remove nut to remove pulley and fan.

Inspect parts for wear or damage.

–UN–21FEB90
T89074
15
15
14 Remove Pulley and Fan

RG,RG34710,2073 –19–15MAR97–21/30

28. Remove the front bearing retainer (A) by compressing

ears of bearing retainer with a long-nosed pliers and
lifting retainer free of recess. On HC and MR units,
remove three front bearing retainer screws and lock
washers.

–UN–23FEB90
A—Front Bearing Retainer

T87605
Remove Front Bearing Retainer
RG,RG34710,2073 –19–15MAR97–22/30

29. Use a plastic hammer to remove rotor and bearing

from front housing. If front housing has felt dust seals
pressed in casting, replace with new seals.
–UN–23FEB90
T87606

Remove Rotor and Bearing

Continued on next page RG,RG34710,2073 –19–15MAR97–23/30

CTM77 (30OCT00) 15-15-14 Alternators and Starter Motors

103000
PN=100
 Motorola HC-, MA-, MR-Series Alternator Repair

30. Use a suitable bearing puller to remove front bearing.

–UN–23FEB90
T87607
15
Remove Front Bearing 15
Continued on next page RG,RG34710,2073 –19–15MAR97–24/30 15

CTM77 (30OCT00) 15-15-15 Alternators and Starter Motors

103000
PN=101
 Motorola HC-, MA-, MR-Series Alternator Repair

31. Connect a voltmeter (A) to slip rings. (Make sure slip

rings are clean.)

32. Connect an ammeter (D), a variable resistor (B), and

12-volt power source (C) in series. Attach to slip
rings.

NOTE: Use a second volt-ohm-amp meter for the

ammeter, and JT28001 Battery Load Tester as

–UN–22SEP88
the variable resistor.
15
15 33. Set battery load tester to maximum resistance.
16

N37053
34. Connect other slip ring to the power source.
Voltmeter and Ammeter
35. Adjust battery load tester to obtain full battery voltage.
A—Voltmeter
IMPORTANT: Do not remove rotor leads from slip B—Variable Resistor
C—12-Volt Power Source
rings at this time. It will cause an arc,
D—Ammeter
damaging slip ring surface.

ROTOR WINDING TEST SPECIFICATIONS [Measured at 21—27°C

(70—80°F)]
System Rated Current Draw Winding Resistance
Voltage Amps (Amps)a (Ohms)

12 37 1.95—2.55 4.2—5.5
12 51/55 1.65—2.55 4.0—5.2
12 62 2.1—2.5 4.1—4.7
12 72 1.8—2.0 5.0—5.4
12 90 4.1—4.4 2.3—2.4
24 42 1.28—1.88 11.0—14.0
a
Current draw at 10V for 12-Volt systems and 20V for 24-Volt
systems.

Shorted windings are indicated by excessive current

draw, and open windings by no current draw.

Continued on next page RG,RG34710,2073 –19–15MAR97–25/30

CTM77 (30OCT00) 15-15-16 Alternators and Starter Motors

103000
PN=102
 Motorola HC-, MA-, MR-Series Alternator Repair

36. Check rotor for grounds between each slip ring and
rotor shaft, using ohmmeter (A) or test lamp.

Ohmmeter resistance reading should be high (infinite)

or test lamp should not light. If resistance is low or
test lamp lights, short exists between field coil and
rotor. Replace rotor.

–UN–22SEP88
A—Ohmmeter

N35990
15
15
17
Ohmmeter or Test Lamp

RG,RG34710,2073 –19–15MAR97–26/30

37. Inspect rotor shaft and body for stripped threads on

shaft, worn key slot, worn bearing surface, scuffed
pole fingers, or worn or dry bearing.

Replace rotor assembly if any of the above faults are

found.

–UN–22SEP88
NOTE: New rotors include new rear bearings and slip
rings.

N85162O1
38. Unsolder rotor leads from slip ring terminals.

IMPORTANT: Do not overheat slip ring terminals. Inspect Rotor Shaft and Body

39. Carefully unwind ends of rotor coil leads from slip ring
terminals.

Continued on next page RG,RG34710,2073 –19–15MAR97–27/30

CTM77 (30OCT00) 15-15-17 Alternators and Starter Motors

103000
PN=103
 Motorola HC-, MA-, MR-Series Alternator Repair

40. Remove hex countersunk head screw (A) from end of

shaft.

41. Thread a 1/4 x 1 in. cap screw into slip ring hub. This
will back slip ring assembly (B) off shaft.

–UN–22SEP88
A—Hex Countersunk Head Screw
B—Slip Ring Assembly

N85162P1
15
15
18 Remove Screw and Slip Ring Assembly

RG,RG34710,2073 –19–15MAR97–28/30

42. Place rotor leads (B) away from bearing puller contact
area.

43. Using bearing puller (C), remove rear bearing (A).

–UN–03MAR89
NOTE: Remove bearing only if it will be replaced.

A—Rear Bearing
B—Rotor Leads

N29582NY
C—Bearing Puller

Remove Rear Bearing

Continued on next page RG,RG34710,2073 –19–15MAR97–29/30

CTM77 (30OCT00) 15-15-18 Alternators and Starter Motors

103000
PN=104
 Motorola HC-, MA-, MR-Series Alternator Repair

44. Examine stator for discoloration or a burned odor

indicating overheating from shorted windings. Stator
should be checked further with low resistance (0—1
ohm) ohmmeter before it is replaced.

45. Disconnect stator leads from diode assemblies and

check resistance from each lead to stator frame. If

–UN–15DEC88
reading is not infinite, a winding is grounded.

46. Carefully zero the ohmmeter and connect the leads

between A and B. 15

R15973
15
19
The meter reading should be 0.6 ohms. An infinite or Stator Leads
high reading indicates an open-circuited winding.
A—Stator Lead
B—Stator Lead
47. While measuring the resistance between A and B, C—Stator Lead
touch AA and BB leads together. If ohmmeter pointer AA—Stator lead
does not drop to 0, the windings are shorted. BB—Stator Lead
CC—Stator Lead
48. Repeat steps 3 and 4 with leads connected to A and
C, then to B and C.

49. When replacing stator, connect leads A to B, AA to C,

and BB to CC. Connect to diode assemblies.

RG,RG34710,2073 –19–15MAR97–30/30

CTM77 (30OCT00) 15-15-19 Alternators and Starter Motors

103000
PN=105
 Motorola HC-, MA-, MR-Series Alternator Repair

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

15
15
20

–UN–22SEP88
N38152

HC-, MA-, MR-Series with Isolation Diode

1—Cover 11—Nut (6 Used) 21—Positive Ring 30—Rotor

2—Tie Strap 12—Lock Washer (5 Used) 22—Negative Ring 31—Key
3—Screw (2 Used) 13—Washer (4 Used) 23—Insulator 32—Retainer
4—Lock Washer (2 Used) 14—Diode, Isolation 24—Bolt 33—Housing
5—Regulator 15—Sleeve 25—Stator 34—Nut (4 Used)
6—Gasket 16—Washer (2 Used) 26—O-Ring 35—Spacer
7—Screws (2 Used) 17—Housing 27—Screw 36—Fan
8—Brush Holder 18—Capacitor 28—Ring 37—Lock Washer
9—Isolator 19—Bushing (2 Used) 29—Bearing (2 Used) 38—Nut
10—Through Bolts (4 Used) 20—Wiring Lead

Continued on next page RG,RG34710,2074 –19–15MAR97–1/21

CTM77 (30OCT00) 15-15-20 Alternators and Starter Motors

103000
PN=106
 Motorola HC-, MA-, MR-Series Alternator Repair

15
15
21

–UN–22SEP88
N38456
HC-, MA-, MR-Series with Diode Trio

1—Screen 10—Lock Washer (6 Used) 19—Rectifier Diode 28—Retainer

2—Tie Strap 11—Isolation Washer (7 Used) 20—Isolation Diode 29—Front Housing
3—Screw (4 Used) 12—Rear Housing 21—Bolt 30—Square Nuts
4—Regulator 13—Capacitor 22—Stator 31—Spacer
5—Gasket 14—Washer 23—Screw 32—Fan
6—Screws (2 Used) 15—Spacer 24—Slip Rings 33—Washer
7—Brush Holder 16—Nuts (2 Used) 25—Bearing (2 Used) 34—Nut
8—Through Bolts (4 Used) 17—Diode Plate 26—Rotor Assembly 35—O-Ring
9—Nuts (5 Used) 18—Diode Trio 27—Key

Continued on next page RG,RG34710,2074 –19–15MAR97–2/21

CTM77 (30OCT00) 15-15-21 Alternators and Starter Motors

103000
PN=107
 Motorola HC-, MA-, MR-Series Alternator Repair

1. Support pulley end of rotor on base of press assembly.

NOTE: Use new front and rear bearings for reassembly of

alternator.

2. Using push-puller, leg extensions, and bearing puller

–UN–22SEP88
attachment, and pressing only on inner bearing race,
press bearing on shaft until inner race contacts the
shaft shoulder.

N38455
15
15
22 Install Bearing

RG,RG34710,2074 –19–15MAR97–3/21

3. Guide rotor windings through one passage in slip ring

hub.

4. Hand press slip rings (B) on shaft while maintaining

alignment of winding leads and passage.

–UN–22SEP88
5. Tighten hex countersunk head screw (A) to
specifications.

Specification

N85162P1
Slip Ring Retainer Cap Screw—
Torque ........................................................................... 5.1 N•m (45 lb-in.)
Slip Rings and Head Screw
A—Hex Countersunk Head Screw
B—Slip Rings

Continued on next page RG,RG34710,2074 –19–15MAR97–4/21

CTM77 (30OCT00) 15-15-22 Alternators and Starter Motors

103000
PN=108
 Motorola HC-, MA-, MR-Series Alternator Repair

6. Install a fiber washer on the non-soldered terminal of

slip rings. This is to prevent the inner slip ring from
touching the outer slip ring, causing a short.

7. Wrap leads (A) around slip ring terminals, and solder

with rosin core solder. Do not overheat.

IMPORTANT: ONLY rosin core solder should be used

for soldering operations. The use of
acid core solder will result in rapid
corrosion of the windings and eventual 15
failure of the complete alternator unit. 15
23

8. Secure wires to end of rotor with a synthetic sealer.

9. Retest rotor assembly to ensure that a ground or short

circuit did not develop during repair.

A—Wire Leads

–UN–22SEP88
N85162Q1
Wrap Leads around Slip Ring Terminals

RG,RG34710,2074 –19–15MAR97–5/21

10. For MA and MR units, install sleeve (A) into either

side of front ball bearing using a 32 mm disk. Push
flange of sleeve tight against bearing race.

A—Sleeve –UN–07NOV88
T84586

Install Sleeve
Continued on next page RG,RG34710,2074 –19–15MAR97–6/21

CTM77 (30OCT00) 15-15-23 Alternators and Starter Motors

103000
PN=109
 Motorola HC-, MA-, MR-Series Alternator Repair

11. Install felt seal (A) and washer (B) (if used) into front
housing.

A—Felt Seal
B—Washer

–UN–07NOV88
T84587
15
15 Install Felt Seal and Washer
24 RG,RG34710,2074 –19–15MAR97–7/21

12. Install front ball bearing (A) into front housing so

sleeve flange is toward rotor. Push bearing to the
bottom of bore.

A—Front Ball Bearing

–UN–07NOV88
T84588
Install Front Ball Bearing
RG,RG34710,2074 –19–15MAR97–8/21

13. Place bearing retainer in housing recess, with ears

upward and aligning them with opening in housing.
Use a wooden dowel to exert pressure on retainer
while locking retainer in recess.

–UN–23FEB90
T87609
Bearing Retainer in Housing Recess
Continued on next page RG,RG34710,2074 –19–15MAR97–9/21

CTM77 (30OCT00) 15-15-24 Alternators and Starter Motors

103000
PN=110
 Motorola HC-, MA-, MR-Series Alternator Repair

14. For HC and MR units, assemble front bearing and

sleeve as follows:

NOTE: There are two variations of assembly depending

on the dimension (A).

If the dimension of bore (A) is 35.6 mm (1.40 in.),

install the front bearing and sleeve assembly (B) in
the housing and secure with bearing retainer (C),
three retainer screws (D) and lock washers (E).
15

–UN–10DEC93
If the dimension of bore (A) is 46.9 mm (1.847 in.), 15
25
the felt seal (F) must be installed flush with outer
surface of housing. Remove outer bearing seal (G)
from bearing before installing bearing and sleeve

RG6995
assembly in housing. Place felt seal (H) against
bearing retainer (C). Secure bearing retainer (C) with
three retainer screws (D) and lock washers (E). 35.6 mm (1.40 in.)

NOTE: Extra grease may be placed between the outer

felt seal and the bearing.

A—Housing Bore Dimension

B—Bearing and Sleeve Assembly
C—Bearing Retainer
D—Retainer Screws
E—Lock Washers
F—Felt Seal
G—Outer Bearing Seal
H—Felt Seal

–UN–10DEC93
RG6996
46.9 mm (1.847 in.)

RG,RG34710,2074 –19–15MAR97–10/21

15. Using a hollow drive that contacts inner bearing race

only, press front housing onto rotor shaft until bearing
race contacts shaft shoulder.
–UN–23FEB90
T87610

Press Front Housing onto Rotor Shaft

Continued on next page RG,RG34710,2074 –19–15MAR97–11/21

CTM77 (30OCT00) 15-15-25 Alternators and Starter Motors

103000
PN=111
 Motorola HC-, MA-, MR-Series Alternator Repair

16. Install spacer (A) and woodruff key (B).

A—Spacer
B—Woodruff Key

–UN–21FEB90
T89075
15
15
26 Install Spacer and Woodruff Key

RG,RG34710,2074 –19–15MAR97–12/21

17. Install fan, pulley, lock washer, and hex nut. Clamp
pulley in vise using an old over-sized belt to protect
pulley and tighten nut to specifications.

Specification
Fan Pulley-to-Shaft Nut—Torque ..................... 47—68 N•m (35—50 lb-ft)

–UN–21FEB90
T89076
Tighten Nut

Continued on next page RG,RG34710,2074 –19–15MAR97–13/21

CTM77 (30OCT00) 15-15-26 Alternators and Starter Motors

103000
PN=112
 Motorola HC-, MA-, MR-Series Alternator Repair

18. Install O-ring. Lubricate the exposed area of the

O-ring with hydraulic brake fluid only.

DO NOT use oil.

–UN–06APR90
T6015AJ
15
15
Install O-Ring 27

RG,RG34710,2074 –19–15MAR97–14/21

19. Install insulator washer (A) and cap screw.

A—Insulator Washer

–UN–21FEB90
T89077
Install Insulator Washer and Cap Screw

Continued on next page RG,RG34710,2074 –19–15MAR97–15/21

CTM77 (30OCT00) 15-15-27 Alternators and Starter Motors

103000
PN=113
 Motorola HC-, MA-, MR-Series Alternator Repair

20. Install insulator washers (A) and sleeves (B).

IMPORTANT: To prevent shorting or grounding,

position stator leads away from through
bolts and sharp corners of diode
assemblies. Squeeze rear housing and

–UN–21FEB90
stator together to check wire positions.

A—Insulator Washers
B—Sleeves

T89089
15
15
28 Insulator Washers and Sleeves

RG,RG34710,2074 –19–15MAR97–16/21

21. Install rear housing on stator.

22. Install capacitor, if equipped.

23. Install insulating washers (B), wire lead (A) and four
nuts (C). Tighten nuts to specifications.

–UN–06APR90
Specification
Stator Stud Lock Nuts—Torque ................... 3.5—4.5 N•m (33—40 lb-in.)

T6015AR
24. Install rear housing and stator on the front housing.
Line up screw holes.
Rear Housing
25. Install four through bolts (D) and square nuts, if used.
Tighten bolts evenly to specifications. A—Wire Lead
B—Insulating Washers
C—Nuts ( 4 Used)
Specification
D—Through Bolts ( 4 Used)
Housing Through Bolts—Torque .................. 5.5—7.0 N•m (50—60 lb-in.)

NOTE: Spin rotor shaft by hand to ensure bearings are

not binding.

Continued on next page RG,RG34710,2074 –19–15MAR97–17/21

CTM77 (30OCT00) 15-15-28 Alternators and Starter Motors

103000
PN=114
 Motorola HC-, MA-, MR-Series Alternator Repair

26. Install brush assembly (HC/MR unit shown).

27. Install and tighten screws (B) to specifications.

Specification
Brush Assembly Mounting

–UN–06APR90
Screws—Torque ........................................... 2.5—3.5 N•m (20—30 lb-in.)

28. Connect regulator wire (A) to brush terminal.

T6015AC
A—Regulator Wire 15
B—Screws (2 Used) 15
HC/MR Unit Shown 29

RG,RG34710,2074 –19–15MAR97–18/21

29. Install regulator wires (A). Install insulator washer (B)

and sleeve (C).

A—Regulator Wires
B—Insulator Washer
C—Sleeve

–UN–06APR90
T6015AT
Install Wires, Washer, and Sleeve

Continued on next page RG,RG34710,2074 –19–15MAR97–19/21

CTM77 (30OCT00) 15-15-29 Alternators and Starter Motors

103000
PN=115
 Motorola HC-, MA-, MR-Series Alternator Repair

30. Install isolation diode plate and insulation washer (B)

at negative terminal, if equipped.

IMPORTANT: The negative terminal post must be

isolated from diode plate.

–UN–06APR90
31. Install and tighten regulator cap screws (A) to
specifications.

Specification

T6015AK
15 Regulator Mounting Cap
15 Screws—Torque ........................................... 4.5—5.0 N•m (40—45 lb-in.)
30 Isolation Diode Plate/Insulation Washer
A—Regulator Cap Screws (4 Used)
B—Insulated Washer

RG,RG34710,2074 –19–15MAR97–20/21

32. Install and tighten two isolation diode nuts to

specifications.

Specification
Isolation Diode Nuts—Torque ...................... 2.5—3.5 N•m (20—30 lb-in.)

33. Tighten alternator terminal nuts to specifications.

–UN–06APR90
Specification
Alternator Terminal Nuts—Torque ............... 2.5—3.5 N•m (20—30 lb-in.)

T6015BI
Tighten Nuts

RG,RG34710,2074 –19–15MAR97–21/21

CTM77 (30OCT00) 15-15-30 Alternators and Starter Motors

103000
PN=116
 Group 20
Motorola A-, RA-, 8AR-Series Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

15
20
SERVICEGARD is a trademark of Deere & Company OUO1004,0000B60 –19–21SEP00–1/2 1

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B60 –19–21SEP00–2/2

Motorola A-, RA-, 8AR-Series Charging

Circuit Repair Specifications

Item Measurement Specification

Used Brush Minimum Exposed Length 6.4 mm (0.25 in.)

Housing Through Bolts Torque 3.5—4.0 N•m (30—35 lb-in.)

Pulley Shaft Nut Torque 68 N•m (50 lb-ft)

OUO1004,0000B63 –19–21SEP00–1/1

CTM77 (30OCT00) 15-20-1 Alternators and Starter Motors

103000
PN=117
 Motorola A-, RA-, 8AR-Series Alternator Repair

Motorola A-, RA-, 8AR-Series Charging

Circuit Test Specifications
John Deere Motorola Volts Rated Output Testa Field Currentb Winding Resistancec
Part No. Part No. Amps Amps (Hot) Amps Ohms
A221618 A12NJD454 12 35 — — —
AR38458 RA12NJD453, 12 35 33 1.90—2.55 4.2—5.5
70D44120C01
AR40419 RA2AJD9025, 24 35 — 1.28—1.88 —
A24JD900
15 AR40420 RA12NJD604 12 55 52 1.65—2.25 4.0—5.2
20 a
2 Output test @ 3000—5000 RPM.
b
Field current @ 20—27°C (70—80°F); @ 10V for 12V systems and 20V for 24V systems.
c
Winding resistance @ 20—27°C (70—80°F).

RG,RG34710,2076 –19–08SEP00–1/1

CTM77 (30OCT00) 15-20-2 Alternators and Starter Motors

103000
PN=118
 Motorola A-, RA-, 8AR-Series Alternator Repair

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

15
20
3

–UN–02FEB89
RG5477
Motorola A-, RA-, 8AR-Series Alternator

1—Isolation Diode Plate 7—3/4 in. Insulating Washer 13—Slip Ring End Frame 18—Drive End Frame
2—1/2 in. Insulating Washer 8—Long Insulating Bushing 14—Slip Ring End Bearing 19—Spacer
3—Short Insulating Bushing 9—O-Ring Bearing Retainer 15—Rotor 20—Fan
4—Brush Return Wire 10—Positive Diode 16—Bearing Retainer 21—Pulley
5—Brush Holder 11—Stator 17—Drive End Bearing 22—Pulley Nut
6—Through Bolt 12—Negative Diode

The regulator (not shown) may be mounted directly to

end frame (13) or remotely mounted elsewhere on the
vehicle.

Continued on next page RG,RG34710,2077 –19–15MAR97–1/15

CTM77 (30OCT00) 15-20-3 Alternators and Starter Motors

103000
PN=119
 Motorola A-, RA-, 8AR-Series Alternator Repair

1. Check isolation diode plate using digital multimeter with

selector indicator in the diode test position.

The meter must register “OL” in one direction and

approximately 0.50 volts in the other. If it does not,
replace diode.

–UN–06APR90
T6015BJ
15
20
4 Check Isolation Diode Plate

RG,RG34710,2077 –19–15MAR97–2/15

2. Test the three negative diodes (A) with selector in

diode test position.

Touch one probe to a diode (A) and the other probe to

the ground terminal. Take reading. Reverse probes
and take another reading.

–UN–06APR90
The meter must register “OL” in one direction and
approximately 0.50 volts in the other on all three
diodes. If it does not, replace the negative diode plate.

T6015AL
A—Three Negative Diodes
Test Negative Diodes

Continued on next page RG,RG34710,2077 –19–15MAR97–3/15

CTM77 (30OCT00) 15-20-4 Alternators and Starter Motors

103000
PN=120
 Motorola A-, RA-, 8AR-Series Alternator Repair

3. Test the three positive diodes (A) with selector in diode

test position.

Touch one probe to a diode (A) and the other probe to

diode plate post. Take reading. Reverse probe and
take another reading.

–UN–06APR90
The meter must register “OL” in one direction and
approximately 0.50 volt in the other on all three diodes.
If it does not, replace the positive diode plate.

T6015AM
15
20
A—Three Positive Diodes 5
Test Positive Diodes

RG,RG34710,2077 –19–15MAR97–4/15

4. Check the stator windings for continuity.

Touch one probe to a diode (A) and the other probe to

each of the other two diodes (B) attached to the same
diode plate. Repeat step for other diode plate.

–UN–06APR90
If there is no continuity in any of the connections, there
is an open circuit in the stator windings and the stator
must be replaced.

T6015AD
A—Diode
B—Two Diodes
Check Stator Windings for Continuity

Continued on next page RG,RG34710,2077 –19–15MAR97–5/15

CTM77 (30OCT00) 15-20-5 Alternators and Starter Motors

103000
PN=121
 Motorola A-, RA-, 8AR-Series Alternator Repair

5. Check stator for a grounded winding.

Touch one probe to diode lead (A) and the other probe
to the rear alternator housing (B). Take reading.
Reverse the probes and take another reading.

–UN–06APR90
The meter must register in one direction only. If
continuity is registered in both directions, a stator
winding is grounded and the stator must be replaced.

T6015BA
15
A—Diode Lead
20
B—Rear Alternator Housing
6 Check Stator for Grounded Winding

RG,RG34710,2077 –19–15MAR97–6/15

6. Remove regulator from end frame, if so equipped.

Remove brush cover.

7. Remove two cap screws to remove brushes.

8. Check the condition of the springs and connections,

–UN–07NOV88
and for freedom of movement of brushes. If either
brush is worn beyond specification, or is cracked or oil
soaked, replace the brush assembly.

T84656
Specification
Used Brush—Minimum Exposed Brush Assembly
Length ............................................................................. 6.4 mm (0.25 in.)

Continued on next page RG,RG34710,2077 –19–15MAR97–7/15

CTM77 (30OCT00) 15-20-6 Alternators and Starter Motors

103000
PN=122
 Motorola A-, RA-, 8AR-Series Alternator Repair

9. Check for continuity between terminal (A) and brush

(B). Next check for continuity between bracket (C) and
brush (D). If there is no continuity at either brush,
replace the brush assembly.

10. Check for continuity between terminal (A) and bracket

–UN–23FEB90
(C). If there is continuity, replace the brush assembly.

A—Terminal
B—Brush

T87568
C—Bracket 15
D—Brush 20
Check for Continuity
7

RG,RG34710,2077 –19–15MAR97–8/15

11. Remove four through bolts and nuts.

IMPORTANT: Inserting screwdriver blades deeper

than 1.6 mm (1/16 in.) may damage
stator windings.

–UN–23FEB90
12. Carefully insert two screwdriver blades (A) in opposite
openings between the stator and front housing to
separate the front housing from the rear.

T87572
A—Two Screwdriver Blades Insert Screwdriver Blades

Continued on next page RG,RG34710,2077 –19–15MAR97–9/15

CTM77 (30OCT00) 15-20-7 Alternators and Starter Motors

103000
PN=123
 Motorola A-, RA-, 8AR-Series Alternator Repair

13. Remove stator and diode assembly from the slip ring
end frame.

14. If necessary to remove diodes from stator, carefully

note locations of insulators and washers for proper
reassembly. Do not unsolder stator-to-diode wire

–UN–21FEB90
junctions. Avoid bending stator wires at junction.

IMPORTANT: Do not use an acid-core solder when

soldering diode leads. Use rosin-core

T89073
15 solder only.
20
8 Soldering and Unscrewing Leads
15. Use needle-nose pliers as a heat sink when soldering
and unscrewing leads to and from diodes. Do not
exert excessive stress on diode leads.

16. Note diode assembly-to-stator connections. Be sure

replacement diode assembly connections are the
same as removed. The positive diode assembly has
red printing and the negative has black printing. DO
NOT INTERCHANGE.

RG,RG34710,2077 –19–15MAR97–10/15

17. Use a bearing puller to remove slip ring end bearing.

If bearing is to be reused, puller must contact inner
race only.

–UN–23FEB90
T87602
Remove Slip Ring End Bearing
Continued on next page RG,RG34710,2077 –19–15MAR97–11/15

CTM77 (30OCT00) 15-20-8 Alternators and Starter Motors

103000
PN=124
 Motorola A-, RA-, 8AR-Series Alternator Repair

18. Remove nut to remove pulley and fan. Clamp pulley

in vise using an old over-sized belt to protect pulley.
Remove woodruff key from shaft.

Inspect parts for wear or damage.

–UN–21FEB90
NOTE: Pulley nut need not be removed if front bearing
will not be replaced.

T89074
15
20
Remove Pulley and Fan 9

RG,RG34710,2077 –19–15MAR97–12/15

19. Remove the front bearing retainer (A) by prying it out

of its groove with an awl.

A—Front Bearing Retainer

–UN–23FEB90
T87605
Remove Front Bearing Retainer
RG,RG34710,2077 –19–15MAR97–13/15

20. Use a plastic hammer to remove rotor and bearing

from front housing.

–UN–23FEB90
T87606

Use Plastic Hammer

Continued on next page RG,RG34710,2077 –19–15MAR97–14/15

CTM77 (30OCT00) 15-20-9 Alternators and Starter Motors

103000
PN=125
 Motorola A-, RA-, 8AR-Series Alternator Repair

21. Use a suitable bearing puller to remove front bearing.

–UN–23FEB90
T87607
15
20 Remove Front Bearing
10 RG,RG34710,2077 –19–15MAR97–15/15

CTM77 (30OCT00) 15-20-10 Alternators and Starter Motors

103000
PN=126
 Motorola A-, RA-, 8AR-Series Alternator Repair

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

15
20
11

–UN–02FEB89
RG5477
Motorola A-, RA-, 8AR-Series Alternator

1—Isolation Diode Plate 7—3/4 in. Insulating Washer 13—Slip Ring End Frame 18—Drive End Frame
2—1/2 in. Insulating Washer 8—Long Insulating Bushing 14—Slip Ring End Bearing 19—Spacer
3—Short Insulating Bushing 9—O-Ring Bearing Retainer 15—Rotor 20—Fan
4—Brush Return Wire 10—Positive Diode 16—Bearing Retainer 21—Pulley
5—Brush Holder 11—Stator 17—Drive End Bearing 22—Pulley Nut
6—Through Bolt 12—Negative Diode

For alternator assembly, the following is a list of Be sure front bearing retainer is firmly seated in
special requirements: housing bore.

Replace bearings, if removed. Tighten housing through bolts to specifications.

Guide rotor leads through one of the oval passages in Specification

Housing Through Bolts—
the slip ring assembly. The oval passage must line up
Torque.................................................... 3.5—4.0 N•m (30—35 lb-in.)
with the groove in the rotor shaft.

Press front housing down until inner bearing race

contacts shoulder on shaft.

Continued on next page RG,RG34710,2078 –19–15MAR97–1/2

CTM77 (30OCT00) 15-20-11 Alternators and Starter Motors

103000
PN=127
 Motorola A-, RA-, 8AR-Series Alternator Repair

Tighten pulley shaft nut to specifications.

Specification
Pulley Shaft Nut—Torque ......................................... 68 N•m (50 lb-ft)

RG,RG34710,2078 –19–15MAR97–2/2

15
20
12

CTM77 (30OCT00) 15-20-12 Alternators and Starter Motors

103000
PN=128
 Group 25
Motorola SA-Series Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

15
25
SERVICEGARD is a trademark of Deere & Company OUO1004,0000B64 –19–21SEP00–1/2 1

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B64 –19–21SEP00–2/2

Other Material

Number Name Use

T43512 (U.S.) Thread Lock and Sealer (Medium Apply to front and rear bearing
TY9473 (Canadian) Strength) retainer cap screws.
242 (LOCTITE)

LOCTITE is a registered trademark of Loctite Corp. OUO1004,0000B66 –19–21SEP00–1/1

CTM77 (30OCT00) 15-25-1 Alternators and Starter Motors

103000
PN=129
 Motorola SA-Series Alternator Repair

Motorola SA-Series Charging Circuit Repair

Specifications

Item Measurement Specification

Brush Minimum Exposed Length 4.8 mm (0.189 in.)

Slip Ring Retainer Screw Torque 5.1 N•m (45 lb-in.)

Pulley Retaining Nut Torque 68 N•m (50 lb-ft)

15
25
Housing Through Bolts Torque 5.7—6.8 N•m (50—60 lb-in.)
2

OUO1004,0000B67 –19–21SEP00–1/1

Motorola SA-Series Charging Circuit Test

Specifications
John Deere Motorola Volts Rated Output Testa Field Currentb Winding Resistancec
Part No. Part No. Amps Amps (Hot) Amps Ohms
AT51042 8SA2016R 12 84 77—80 1.74—2.10 5.25
RE20486 8SA2035V 12 130 100—110 3.90—4.70 2.30
a
Output test @ 3000—4000 RPM.
b
Field current @ 20—27°C (70—80°F); @ 10V for 12V systems and 20V for 24V systems.
c
Winding resistance @ 20—27°C (70—80°F).

Item Specification
Stator Resistance 0.1—0.4 ohms
130 Amp Rotor Winding Resistance 2.0—3.0 ohms
84 Amp Rotor Winding Resistance 4.7—5.8 ohms

RG,RG34710,2080 –19–08SEP00–1/1

CTM77 (30OCT00) 15-25-2 Alternators and Starter Motors

103000
PN=130
 Motorola SA-Series Alternator Repair

Remove Alternator for Repair

Refer to your machine technical manual for removal of

alternator.

IMPORTANT: Never immerse alternator in cleaning

solvent. Remove dirt and grease by
scraping and using a stiff brush with
solvent. Dry with compressed air.

ONLY rosin core solder should be used 15

for soldering operations. The use of 25
3
acid core solder will result in rapid
corrosion of the windings and eventual
failure of the complete alternator unit.

RG,RG34710,2081 –19–15MAR97–1/1

Disassemble and Test Motorola 8SA-Series

Alternator

1. Remove alternator ground wire (A), regulator ground

lead (B) and regulator positive lead (C).

–UN–17NOV89
2. Remove regulator retaining cap screws (D).

3. Remove yellow wire leads from stator terminals and

green wire leads from brush terminals.

RW10855
A—Alternator Ground Wire Disassemble Motorola 8SA Alternator
B—Regulator Ground Lead
C—Regulator Positive Lead
D—Cap Screws

Continued on next page RG,RG34710,2082 –19–15MAR97–1/22

CTM77 (30OCT00) 15-25-3 Alternators and Starter Motors

103000
PN=131
 Motorola SA-Series Alternator Repair

4. Remove brush assembly retaining cap screws (A), then

remove brush assembly.

A—Brush Assembly Retaining Cap Screws (2 Used)

–UN–17NOV89
RW10856
15
25
4 Brush Assembly Retaining Cap Screws

RG,RG34710,2082 –19–15MAR97–2/22

5. Examine brushes for roughness, cracks or oil

contamination. If damaged, replace assembly.

6. Measure unused brush length. If brush length is not

within specification, replace brushes.

–UN–17NOV89
Specification
Brush—Minimum Exposed Length ............................... 4.8 mm (0.189 in.)

RW10857
Measure Brush Length

Continued on next page RG,RG34710,2082 –19–15MAR97–3/22

CTM77 (30OCT00) 15-25-4 Alternators and Starter Motors

103000
PN=132
 Motorola SA-Series Alternator Repair

7. Use ohmmeter to test continuity between each terminal

and attached brush.

8. Test continuity between the two brushes and between

each brush and ground. There should be no continuity.

–UN–17NOV89
9. If malfunction was indicated in regulator or brush
assembly, replace parts as necessary and reassemble.
If not, continue disassembly.

RW10858
15
25
Use Ohmmeter to Test Continuity 5

RG,RG34710,2082 –19–15MAR97–4/22

10. Remove four through bolts (A).

A—Through Bolts (4 Used)

–UN–17NOV89
RW10859
Remove Through Bolts

Continued on next page RG,RG34710,2082 –19–15MAR97–5/22

CTM77 (30OCT00) 15-25-5 Alternators and Starter Motors

103000
PN=133
 Motorola SA-Series Alternator Repair

IMPORTANT: Avoid inserting sharp tools between

stator and housing. Damage to stator
windings or laminations could occur.

11. Separate front housing from rear housing by

supporting rear housing at through bolt ears (A) with

–UN–17NOV89
wood or steel blocks. Use 25.4 mm (1.0 in.) ID soft
steel conduit (B) as a driver.

NOTE: Stator will stay with rear housing, rotor will stay

RW10860
15 with front housing.
25
6 Separate Front Housing from Rear Housing
A—Through Bolt Ears
B—Soft Steel Conduit Driver

RG,RG34710,2082 –19–15MAR97–6/22

12. Remove stator leads from the three stator tap

terminals (A).

13. Remove the “R” terminal stud (B).

14. Remove stator (C) from rear housing.

A—Stator Tap Terminals (3 Used)

B—“R” Terminal Stud
C—Stator

–UN–17NOV89
RW10862

Remove Stator Leads

Continued on next page RG,RG34710,2082 –19–15MAR97–7/22

CTM77 (30OCT00) 15-25-6 Alternators and Starter Motors

103000
PN=134
 Motorola SA-Series Alternator Repair

15. Inspect stator for physical damage. Look for broken

insulation, rotor striking laminations or foreign material
that may restrict circulation of cooling air.

Discoloration or burned odor may indicate

overheating, which may cause short circuits. Replace

–UN–17NOV89
stator if either condition exists.

16. Connect ohmmeter to each stator lead (A) and stator

frame (B). Replace stator if test indicated continuity.

RW10863
15
25
A—Stator Leads 7
Inspect Stator Lead and Frame
B—Stator Frame

RG,RG34710,2082 –19–15MAR97–8/22

17. A short-circuit in the stator can be difficult to identify.

Use an ohmmeter that is sensitive to resistance of 0
to 1 ohm.

Connect ohmmeter between each pair of terminals

(A). Resistance should be approximately 0.1 ohm.
(Ohmmeter needle should deflect to zero if leads are
touched together.) If resistance is above 0.4 ohm,
replace stator.

A stator will occasionally exhibit an open circuit or

short circuit only when hot, making the defect even
more difficult to diagnose.

A—Stator Terminals

–UN–17NOV89
RW10864

Ohmmeter

Continued on next page RG,RG34710,2082 –19–15MAR97–9/22

CTM77 (30OCT00) 15-25-7 Alternators and Starter Motors

103000
PN=135
 Motorola SA-Series Alternator Repair

18. Remove positive stud (A) and negative stud (B) nuts,
and leads to stator taps. Remove diode heat sink
assembly from rear housing.

A—Positive Stud
B—Negative Stud

–UN–17NOV89
RW10865
15
25
8 Remove Diode Heat Sink Assembly

RG,RG34710,2082 –19–15MAR97–10/22

19. Disconnect capacitor lead (A) from heat sink.

NOTE: Make sure that heat sink halves are insulated

from each other.

20. Connect ohmmeter to each lead (B) and heat sink.

–UN–17NOV89
Reverse leads and test for continuity between same
points. Perform this check on both (+) and (—) heat
sink assemblies. Good diodes will have continuity in
only one direction. Replace assembly if there is no

RW10866
continuity in either direction or continuity in both
directions.
Capacitor Leads

A—Capacitor Lead
B—Leads

Continued on next page RG,RG34710,2082 –19–15MAR97–11/22

CTM77 (30OCT00) 15-25-8 Alternators and Starter Motors

103000
PN=136
 Motorola SA-Series Alternator Repair

21. Set multimeter for highest resistance (ohms) scale of

diode test position to test capacitor.

22. Connect meter test leads to condenser lead (A) and

body (B) as shown. Charge condenser for 15 seconds
before disconnecting one test lead.

–UN–17NOV89
If the multimeter indicates continuity through the
condenser, it is leaking current and needs to be
replaced.

RW10867
15
23. Reset multimeter for a low voltage scale. 25
Condenser Lead and Body 9

24. Observe voltmeter needle (digital read-out) for a

A—Condenser Lead
voltage increase as you reconnect the test lead. B—Condenser Body

If there was no voltage reading, the condenser was

not charged and needs to be replaced.

25. Repeat the last four steps several times to verify

condenser performance.

RG,RG34710,2082 –19–15MAR97–12/22

26. Use an ohmmeter to test rotor for continuity.

27. Attach ohmmeter to rotor frame (A) and each slip ring
(B).

28. Replace rotor if test shows continuity.

–UN–16NOV89
A—Rotor Frame
B—Slip Ring

RW10871
Rotor Frame and Slip Ring

Continued on next page RG,RG34710,2082 –19–15MAR97–13/22

CTM77 (30OCT00) 15-25-9 Alternators and Starter Motors

103000
PN=137
 Motorola SA-Series Alternator Repair

29. Use ohmmeter to test for continuity from one slip ring
to the other or at soldered connections at end of
rotor.

If test does not show continuity, replace rotor.

–UN–16NOV89
30. Measure rotor winding resistance.

Rotor winding resistance should be 2.0—3.0 ohms for

130-amp circuits and 4.7—5.8 ohms for 84-amp

RW10872
15 circuits.
25
10 Ohmmeter

RG,RG34710,2082 –19–15MAR97–14/22

31. Inspect rotor slip rings (A) for excessive wear or

roughness. Use fine crocus cloth to remove minor
roughness.

32. Check front and rear bearings (B) for roughness.

–UN–16NOV89
33. Check fan (C) for loose or bent blades.

34. Check pulley (D) for excessive wear.

RW10873
If bearings, slip rings or pulley are rough or worn or
fan is damaged, continue with disassembly.
Inspect Components

A—Rotor Slip Ring

B—Rear Bearing
C—Fan
D—Pulley

Continued on next page RG,RG34710,2082 –19–15MAR97–15/22

CTM77 (30OCT00) 15-25-10 Alternators and Starter Motors

103000
PN=138
 Motorola SA-Series Alternator Repair

35. Unsolder rotor leads from slip ring terminals.

IMPORTANT: Do not overheat slip ring terminals.

36. Carefully unwind ends of rotor coil leads from slip ring
terminals.

–UN–22SEP88
N85162O1
15
25
Unsolder Rotor Leads 11

RG,RG34710,2082 –19–15MAR97–16/22

37. Remove hex countersunk head screw (A) from end of

shaft.

38. Thread a 1/4 x 1 in. cap screw into slip ring hub. This
will back slip ring assembly (B) off shaft.

–UN–22SEP88
A—Hex Countersunk Head Screw
B—Slip Ring Assembly

N85162P1
Shaft

RG,RG34710,2082 –19–15MAR97–17/22

IMPORTANT: Do not press on porcelain center of slip

rings.

39. Use three-jaw puller and slide hammer to remove rear

bearing from rotor.
–UN–16NOV89
RW10874

Continued on next page RG,RG34710,2082 –19–15MAR97–18/22

CTM77 (30OCT00) 15-25-11 Alternators and Starter Motors

103000
PN=139
 Motorola SA-Series Alternator Repair

40. Place pulley in vise using soft jaws to protect pulley.

Remove pulley nut and lock washer.

41. Remove pulley (A) and fan (B).

–UN–16NOV89
A—Pulley
B—Fan

RW10875
15
25
12 Remove Pulley and Fan

RG,RG34710,2082 –19–15MAR97–19/22

42. Remove spacer (A) and woodruff key (B).

43. Remove three bearing retainer screws (C).

A—Spacer
B—Woodruff Key

–UN–16NOV89
C—Retainer Screws

RW10876
Remove Spacer and Woodruff Key

Continued on next page RG,RG34710,2082 –19–15MAR97–20/22

CTM77 (30OCT00) 15-25-12 Alternators and Starter Motors

103000
PN=140
 Motorola SA-Series Alternator Repair

IMPORTANT: To prevent damage to front housing DO

NOT support housing at outer
circumference when removing rotor and
front bearing.

44. Using three-jaw puller, push rotor and front bearing

–UN–16NOV89
from front housing.

RW10877
15
25
Three-Jaw Puller 13

RG,RG34710,2082 –19–15MAR97–21/22

45. Remove front bearing only if bearing replacement is

necessary. Use a knife-edge, bearing pulling
attachment to remove front bearing from rotor shaft.

46. Inspect rotor shaft, body, and rear bearing for stripped
threads on shaft, worn key slot, worn bearing surface,

–UN–16NOV89
or scuffed pole finger. Replace rotor assembly if any
of the above defects are found.

RW10878
Inspect Rotor Shaft, Body and Bearing

RG,RG34710,2082 –19–15MAR97–22/22

CTM77 (30OCT00) 15-25-13 Alternators and Starter Motors

103000
PN=141
 Motorola SA-Series Alternator Repair

Assemble Motorola 8SA-Series Alternator

1. Install rear bearing spacer (A), sealing felt, rear bearing

(B), front bearing retainer (C), sealing felt and front
bearing (D).

–UN–16NOV89
2. Place assembly in small press. Using a 25.4 mm
(1.0 in.) ID soft steel conduit, push assembly together
until spacers and bearings are seated against rotor
frame.

RW10879
15
25
14 A—Rear Bearing Spacer
Motorola 8SA Alternator
B—Rear Bearing
C—Front Bearing Retainer
D—Front Bearing

RG,RG34710,2083 –19–15MAR97–1/13

3. Guide rotor windings through one passage in slip ring

hub.

4. Hand press slip rings (B) on shaft while maintaining

alignment of winding leads and passage.

–UN–22SEP88
5. Tighten hex countersunk head screw (A) to
specifications.

Specification

N85162P1
Slip Ring Retainer Screw—
Torque ........................................................................... 5.1 N•m (45 lb-in.)
Slip Rings and Head Screw
A—Hex Countersunk Head Screw
B—Slip Rings

Continued on next page RG,RG34710,2083 –19–15MAR97–2/13

CTM77 (30OCT00) 15-25-14 Alternators and Starter Motors

103000
PN=142
 Motorola SA-Series Alternator Repair

6. Install a fiber washer on the non-soldered terminal of

slip rings. This is to prevent the inner slip ring from
touching the outer slip ring, causing a short.

7. Wrap leads (A) around slip ring terminals and solder

with rosin-core solder. Do not overheat.

8. Secure wires to end of rotor with a synthetic sealer.

9. Retest rotor assembly to ensure that a ground or short

circuit did not develop during repair. 15
25
15
A—Leads

–UN–22SEP88
N85162Q1
Wrap Leads Around Terminals

RG,RG34710,2083 –19–15MAR97–3/13

IMPORTANT: Support front housing on bearing quill.

10. Press rotor with front bearing into front housing.

–UN–16NOV89
RW10880

Press Rotor Into Front Housing

Continued on next page RG,RG34710,2083 –19–15MAR97–4/13

CTM77 (30OCT00) 15-25-15 Alternators and Starter Motors

103000
PN=143
 Motorola SA-Series Alternator Repair

11. Apply LOCTITE 242 Thread Lock and Sealer to front

bearing screws (A) and reinstall.

12. Reinstall spacer (B) and woodruff key (C).

–UN–16NOV89
A—Front Bearing Screws (3 Used)
B—Spacer
C—Woodruff Key

RW10881
15
25
16 Reinstall Spacer and Woodruff Key

LOCTITE is a registered trademark of Loctite Corp. RG,RG34710,2083 –19–15MAR97–5/13

13. Install fan (B), pulley (A), lock washer and nut.

14. Tighten pulley nut to specifications.

Specification
Pulley Retaining Nut—Torque ......................................... 68 N•m (50 lb-ft)

–UN–16NOV89
A—Pulley
B—Fan

RW10875
Install Fan and Pulley

Continued on next page RG,RG34710,2083 –19–15MAR97–6/13

CTM77 (30OCT00) 15-25-16 Alternators and Starter Motors

103000
PN=144
 Motorola SA-Series Alternator Repair

15. Inspect rear housing bearing bore (A) for scuffs or

cracks. Replace as necessary.

16. Check and install all inside insulators (B).

–UN–11APR90
A—Rear Housing Bearing Bore
B—Inside Insulators

RW10868
15
25
Inspect Rear Housing 17

RG,RG34710,2083 –19–15MAR97–7/13

17. Check and install outside insulators (C).

NOTE: Do not attempt to remove rear bearing, nylon

retaining ring. Retaining ring does not normally
need to be replaced. Replace only if cracked or
gouged or if there is evidence of bearing spin.

–UN–17NOV89
C—Outside Insulators
RW10869

Outside Insulator

Continued on next page RG,RG34710,2083 –19–15MAR97–8/13

CTM77 (30OCT00) 15-25-17 Alternators and Starter Motors

103000
PN=145
 Motorola SA-Series Alternator Repair

18. Install “R” terminal bolt (A) through stator lead and
diode lead eyelets with three insulators (B).

19. Install diode heat sink into rear housing.

–UN–17NOV89
A—“R” Terminal Bolt
B—Insulators (3 Used)

RW10870
15
25
18 Terminal Bolt and Insulators

RG,RG34710,2083 –19–15MAR97–9/13

20. Install stator assembly into rear housing.

21. Install the “R” terminal stud (B).

22. Install leads on three stator terminals (A).

A—Stator Terminals (3 Used)

B—“R” Terminal Stud
C—Stator

–UN–17NOV89
RW10862

Install Terminal Stud and Leads

Continued on next page RG,RG34710,2083 –19–15MAR97–10/13

CTM77 (30OCT00) 15-25-18 Alternators and Starter Motors

103000
PN=146
 Motorola SA-Series Alternator Repair

23. Install rear housing assembly to front housing.

24. Apply LOCTITE 242 Thread Lock and Sealer to

through bolts (A) and install. Tighten evenly so rear
rotor bearing is pressed into rear housing. Tighten
until stator and housings are securely fastened

–UN–17NOV89
together.

25. Tighten through bolts to specifications.

RW10859
Specification 15
Housing Through Bolts—Torque .................. 5.7—6.8 N•m (50—60 lb-in.) 25
Through Bolts 19
NOTE: Lubricate rear retaining ring (in rear housing
bearing bore) with liquid soap. A—Through Bolts (4 Used)

LOCTITE is a registered trademark of Loctite Corp. RG,RG34710,2083 –19–15MAR97–11/13

26. Install brush assembly. Install and tighten brush

assembly retaining cap screws (A) securely.

A—Brush Assembly Retaining Cap Screws (2 Used)

–UN–17NOV89
RW10856
Brush Assembly Retaining Cap Screws

Continued on next page RG,RG34710,2083 –19–15MAR97–12/13

CTM77 (30OCT00) 15-25-19 Alternators and Starter Motors

103000
PN=147
 Motorola SA-Series Alternator Repair

27. Install gasket on voltage regulator.

28. Connect two regulator brush leads to brush assembly.

29. Install regulator and tighten retaining cap screws (D)

securely.

–UN–17NOV89
30. Install alternator ground wire (A) and regulator ground
lead (B). Install washer and tighten nut securely.

RW10855
15 31. Install regulator positive lead (C) with washer and
25 tighten nut securely.
20 Install Gasket
32. Refer to your machine technical manual for
A—Alternator Ground Wire
installation of alternator and proper adjustment of B—Regulator Ground Lead
V-belts. C—Regulator Positive Lead
D—Retaining Cap Screws

RG,RG34710,2083 –19–15MAR97–13/13

CTM77 (30OCT00) 15-25-20 Alternators and Starter Motors

103000
PN=148
 Group 30
Motorola TA-Series Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

15
30
SERVICEGARD is a trademark of Deere & Company OUO1004,0000B68 –19–21SEP00–1/3 1

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B68 –19–21SEP00–2/3

Bushing, Bearing and Seal Driver Set . . . . . . D01045AA

Install seal in front housing of alternator.

–UN–21SEP00
RG11162

D01045AA

OUO1004,0000B68 –19–21SEP00–3/3

CTM77 (30OCT00) 15-30-1 Alternators and Starter Motors

103000
PN=149
 Motorola TA-Series Alternator Repair

Service Equipment and Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.

15
30
2 SERVICEGARD is a trademark of Deere & Company OUO1004,0000B69 –19–21SEP00–1/2

17-1/2 Ton Puller Set . . . . . . . . . . . . . . . . . D01047AA

Remove alternator pulley.

OUO1004,0000B69 –19–21SEP00–2/2

Motorola TA-Series Charging Circuit Repair

Specifications

Item Measurement Specification

Brush Minimum Exposed Length 6.4 mm (0.25 in.)

Alternator Pulley Retaining Nut Torque 47—68 N•m (35—50 lb-ft)

Front-to-Rear Alternator Housing Torque 2.8—3.4 N•m (20—30 lb-in.)

Cap Screws

Brush Holder Retaining Screws Torque 2.8—3.4 N•m (20—30 lb-in.)

OUO1004,0000B6B –19–21SEP00–1/1

CTM77 (30OCT00) 15-30-2 Alternators and Starter Motors

103000
PN=150
 Motorola TA-Series Alternator Repair

Motorola TA-Series Charging Circuit Test

Specifications
John Deere Motorola Volts Rated Output Testa Field Currentb Winding Resistancec
Part No. Part No. Amps Amps (Hot) Amps Ohms
AN114058 8TA2009E 12 30 28—30 0.55—1.50 11.0—12.5
AT22870 TA12NJD400 12 30 28—30 0.55—1.50 11.0—12.5
AT31669 8TA2009EB 12 30 28—30 0.55—1.50 11.0—12.5
AT36220 8TA2003D 12 22 18—20 0.55—1.50 11.0—12.5
AT41070 8TA2006D 12 22 18—20 0.55—1.50 11.0—1.25 15
AT45618 8TA2017D 12 22 18—20 0.55—1.50 11.0—12.5 30
3
AT56246 8TA3025CS 24 16 10—14 0.08—1.20 27.0—29.0
AT56247 8TA3025C 24 16 10—14 0.08—1.20 27.0—29.0
a
Output test @ 3000—4000 RPM.
b
Field current @ 10V for 12V system and 20V for 24V systems; @ 20—27°C (70—80°F).
c
Winding resistance @ 20—27°C (70—80°F).

Item Specification
Rotor Current Draw @ 20—27°C (70—80°F) 0.55—1.56 amps

RG,RG34710,2085 –19–08SEP00–1/1

Remove Alternator for Repair

Refer to your machine technical manual for removal of

alternator.

IMPORTANT: Never immerse alternator in cleaning

solvent. Remove dirt and grease by
scraping and using a stiff brush with
solvent. Dry with compressed air.

ONLY rosin core solder should be used

for soldering operations. The use of
acid core solder will result in rapid
corrosion of the windings and eventual
failure of the complete alternator unit.

RG,RG34710,2086 –19–15MAR97–1/1

CTM77 (30OCT00) 15-30-3 Alternators and Starter Motors

103000
PN=151
 Motorola TA-Series Alternator Repair

Disassemble and Test Motorola TA-Series

Alternator

1. Remove voltage regulator (A) and capacitor (B) from

alternator.

–UN–14FEB90
A—Voltage Regulator
B—Capacitor

T91362
15
30
4 Remove Voltage Regulator and Capacitor

RG,RG34710,2087 –19–15MAR97–1/20

2. Remove brush cover (A) and gasket.

A—Brush Cover and Gasket

–UN–12APR90
T5916AG
Remove Brush Cover and Gasket

Continued on next page RG,RG34710,2087 –19–15MAR97–2/20

CTM77 (30OCT00) 15-30-4 Alternators and Starter Motors

103000
PN=152
 Motorola TA-Series Alternator Repair

3. Remove isolator (A) and brush assembly (B). Inspect

brushes. If either one is worn beyond specification,
cracked or oil soaked, replace the brush assembly.

Specification
Brush—Minimum Exposed Length ................................. 6.4 mm (0.25 in.)

–UN–14FEB90
A—Isolator
B—Brush Assembly

T91364
15
30
Remove Isolator and Brush Assembly 5

RG,RG34710,2087 –19–15MAR97–3/20

4. Check for continuity between terminal (A) and brush

(B) and bracket (C) and brush (D). If there is no
continuity at either brush, replace the brush assembly.

5. Check for continuity between terminal (A) and bracket

(C). If there is continuity, replace the brush assembly.

–UN–23FEB90
6. Check for continuity between terminal (A) and brush
(D). If there is continuity, replace the brush assembly.

T87568
A—Terminal
B—Brush Check for Continuity
C—Bracket
D—Brush

Continued on next page RG,RG34710,2087 –19–15MAR97–4/20

CTM77 (30OCT00) 15-30-5 Alternators and Starter Motors

103000
PN=153
 Motorola TA-Series Alternator Repair

7. Remove cap screws (A) to separate the housings.

Note horseshoe clip (B) at lower cap screw.

IMPORTANT: Inserting screwdriver blades farther

than 1.6 mm (1/16 in.) may damage
stator windings.

–UN–14FEB90
8. Carefully insert two screwdriver blades in opposite
openings between the stator and front housing and
separate the front housing from the rear.

T91366
15
30
6 A—Cap Screws (4 Used)
Separate Front Housing
B—Horseshoe Clip

RG,RG34710,2087 –19–15MAR97–5/20

9. Remove nuts and washers (A) to disconnect stator

leads (B).

NOTE: Remove diode leads from stud terminal.

A—Nuts and Washers (3 Used)

–UN–14FEB90
B—Stator Leads

T91367
Disconnect Stator Leads

Continued on next page RG,RG34710,2087 –19–15MAR97–6/20

CTM77 (30OCT00) 15-30-6 Alternators and Starter Motors

103000
PN=154
 Motorola TA-Series Alternator Repair

10. Use ohmmeter to check rotor windings by placing a

probe on each slip ring. If there is no continuity,
replace the rotor.

–UN–14FEB90
T91373
15
30
Check Rotor Windings 7

RG,RG34710,2087 –19–15MAR97–7/20

11. Use ohmmeter to check for grounded rotor windings.

If there is continuity, replace the rotor.

–UN–14FEB90
T91374
Check for Grounded Rotor Windings

Continued on next page RG,RG34710,2087 –19–15MAR97–8/20

CTM77 (30OCT00) 15-30-7 Alternators and Starter Motors

103000
PN=155
 Motorola TA-Series Alternator Repair

12. Use ohmmeter to check the stator for an open

winding. Check all the leads. If there is no continuity
in any of the connections, there is an open circuit in
the stator windings and the stator must be replaced.

–UN–14FEB90
T91375
15
30
8 Check Stator and Leads

RG,RG34710,2087 –19–15MAR97–9/20

13. Use ohmmeter to check the stator for a grounded

winding. Touch one probe to any of the leads and
one to the ground. The meter must not register
continuity. If it registers continuity, a stator winding is
grounded and the stator must be replaced.

–UN–14FEB90
T91376
Check Stator

Continued on next page RG,RG34710,2087 –19–15MAR97–10/20

CTM77 (30OCT00) 15-30-8 Alternators and Starter Motors

103000
PN=156
 Motorola TA-Series Alternator Repair

IMPORTANT: The diode test position must be used

on meters with test position to get
accurate results. Follow the
manufacturer’s instructions for your
meter to test diodes.

–UN–14FEB90
14. Test positive and negative diodes in both directions
using a volt-ohm-amp meter. Put one probe on a
diode lead and the other probe on the diode plate to
get a reading.

T91377
15
A diode with a high reading in one direction and a low 30
Test Diodes 9
reading in the other direction is good. A diode with
the same reading in both directions is defective and
should be replaced.

Test diode trio in both directions using a

volt-ohm-amp meter. Put probes on each end of
diode to get a reading.

–UN–12APR90
A diode trio with a high reading in one direction and a
low reading in the other direction is good. A diode trio
with the same reading in both directions is defective

T5916AH
and should be replaced.

Test Diodes

RG,RG34710,2087 –19–15MAR97–11/20

15. To separate the diode plate from the alternator half,

remove the nut and insulator on the stator terminal
(A) and the nut on the ground terminal (B).

A—Stator Terminal
B—Ground Terminal
–UN–14FEB90
T91378

Stator and Ground Terminals

Continued on next page RG,RG34710,2087 –19–15MAR97–12/20

CTM77 (30OCT00) 15-30-9 Alternators and Starter Motors

103000
PN=157
 Motorola TA-Series Alternator Repair

16. Remove diodes if defective. Use a standard punch.

IMPORTANT: Support underside of casting to prevent

damage when removing diodes.

The rectifying diode in TA-Series

–UN–14FEB90
alternators have their leads welded, not
soldered, to the stems. Do not attempt
to substitute diode and solder the lead
to the diode stem.

T91379
15
30
10 Remove Defective Diodes

RG,RG34710,2087 –19–15MAR97–13/20

17. To replace the diodes, use a piece of pipe to press

diodes into diode plate.

IMPORTANT: Before installing diode plate, make

certain that it is properly insulated from
housing. (See ASSEMBLE MOTOROLA

–UN–14FEB90
TA-SERIES ALTERNATOR in this
group.)

T91380
Replacing Diodes

Continued on next page RG,RG34710,2087 –19–15MAR97–14/20

CTM77 (30OCT00) 15-30-10 Alternators and Starter Motors

103000
PN=158
 Motorola TA-Series Alternator Repair

18. Remove the front housing from the stator.

–UN–14FEB90
T91381
15
30
Remove Front Housing 11

RG,RG34710,2087 –19–15MAR97–15/20

19. Remove nut and lock washer. Remove the pulley with
a gear puller from D01047AA 17-1/2 Ton Puller Set.

–UN–14FEB90
T91382
Remove Pulley

Continued on next page RG,RG34710,2087 –19–15MAR97–16/20

CTM77 (30OCT00) 15-30-11 Alternators and Starter Motors

103000
PN=159
 Motorola TA-Series Alternator Repair

20. To remove rotor, remove the key from the shaft and
tap on the shaft with a plastic hammer.

–UN–14FEB90
T91383
15
30
12 Remove Rotor

RG,RG34710,2087 –19–15MAR97–17/20

21. Remove three screws and lock washers to remove

bearing retainer.

–UN–14FEB90
T91384
Remove Bearing Retainer

Continued on next page RG,RG34710,2087 –19–15MAR97–18/20

CTM77 (30OCT00) 15-30-12 Alternators and Starter Motors

103000
PN=160
 Motorola TA-Series Alternator Repair

22. Remove the front seal and bearing using a 3/32 in.
punch.

–UN–14FEB90
T91385
15
30
Remove Front Seal and Bearing 13

RG,RG34710,2087 –19–15MAR97–19/20

23. Remove the rear bearing if bearing replacement is

necessary.

–UN–14FEB90
T91386
Remove Rear Bearing if Necessary

RG,RG34710,2087 –19–15MAR97–20/20

CTM77 (30OCT00) 15-30-13 Alternators and Starter Motors

103000
PN=161
 Motorola TA-Series Alternator Repair

Assemble Motorola TA-Series Alternator

1. Install seal open face to driver from the D01045AA

Bushing, Bearing and Seal Driver Set. Install seal in
housing bore.

–UN–14FEB90
T91387
15
30
14 Install Seal in Housing Bore

RG,RG34710,2088 –19–15MAR97–1/15

2. Install bearing using a driver that contacts the outer

race.

–UN–14FEB90
T91388
Install Bearing

Continued on next page RG,RG34710,2088 –19–15MAR97–2/15

CTM77 (30OCT00) 15-30-14 Alternators and Starter Motors

103000
PN=162
 Motorola TA-Series Alternator Repair

3. Install bearing retainer using three screws and

washers.

–UN–14FEB90
T91389
15
30
Install Bearing Retainer 15

RG,RG34710,2088 –19–15MAR97–3/15

4. Install seals (B) and bearing (A).

A—Bearing
B—Seals

–UN–12APR90
T5916AI
Install Seals and Bearing

Continued on next page RG,RG34710,2088 –19–15MAR97–4/15

CTM77 (30OCT00) 15-30-15 Alternators and Starter Motors

103000
PN=163
 Motorola TA-Series Alternator Repair

5. Install rotor to housing. Install the spacer and shaft

key. Install the pulley, lock washer and hex nut.
Tighten hex nut to specifications.

Specification
Alternator Pulley Retaining Nut—
Torque .............................................................. 47—68 N•m (35—50 lb-ft)

–UN–14FEB90
IMPORTANT: Clamp pulley in a soft-jawed vise or use
an old oversize belt to prevent damage
to pulley.

T91390
15
30
16 Install Rotor to Housing

RG,RG34710,2088 –19–15MAR97–5/15

6. Install O-ring (A). Lubricate the exposed area of the

O-ring with hydraulic brake fluid only. Do not use oil.

A—O-Ring

–UN–14FEB90
T91391
Install O-ring

Continued on next page RG,RG34710,2088 –19–15MAR97–6/15

CTM77 (30OCT00) 15-30-16 Alternators and Starter Motors

103000
PN=164
 Motorola TA-Series Alternator Repair

7. Install diode plate mounting terminals, diode trio, and

insulators (A—H) on diode plate.

A—Insulator
B—Insulator, Square (2 Used)
C—Insulator
D—Insulator
E—Diode Trio
F—Nut (3 Used)
G—Insulator (3 Used)
H—Bolt
15
30
17

–UN–16APR90
T5919AD
Install Diode Plate Mounting Terminals

RG,RG34710,2088 –19–15MAR97–7/15

8. Install diode plate into rear housing. Install insulators,

washers, and nuts (A—J).

A—Insulator Sleeve
B—Insulator
C—Washer
–UN–02APR90

D—Nut
E—Insulator
F—Flat Washer
G—Lock Washer
H—Nut
T6106AG

I—Insulator
J—Nut
Install Diode Plate

Continued on next page RG,RG34710,2088 –19–15MAR97–8/15

CTM77 (30OCT00) 15-30-17 Alternators and Starter Motors

103000
PN=165
 Motorola TA-Series Alternator Repair

9. Install stator into front housing. Install gasket.

–UN–14FEB90
T91381
15
30
18 Install Stator and Gasket

RG,RG34710,2088 –19–15MAR97–9/15

10. Connect each diode lead to the terminal (B) adjacent

to it. Also connect stator leads (A) leads to terminals
(B). Fasten with nuts and lock washers.

A—Stator Leads
B—Terminals

–UN–12APR90
T5916AJ
Connect Leads

Continued on next page RG,RG34710,2088 –19–15MAR97–10/15

CTM77 (30OCT00) 15-30-18 Alternators and Starter Motors

103000
PN=166
 Motorola TA-Series Alternator Repair

11. After stator leads are fastened to diode terminals,

fasten the stator leads together using a tie band along
the rear housing shell. Place stator leads as far as
possible from rotor.

–UN–12FEB90
T92062
15
30
Attach Leads 19

RG,RG34710,2088 –19–15MAR97–11/15

12. Install rear housing and stator into the front housing.
Make sure grooves in stator line up with cap screw
holes. Install four screws (A) and tighten to
specifications. Horseshoe clip (B) must be installed on
lower screw.

Specification

–UN–14FEB90
Front-to-Rear Alternator Housing
Cap Screws—Torque ................................... 2.8—3.4 N•m (20—30 lb-in.)

After assembly, rotate the alternator pulley. The pulley

T91366
must rotate without any rough spots. Rough spots could
be caused by the stator leads rubbing the rotor or a rough Screws and Horseshoe Clip
bearing. If rough spots are felt, disassemble rear housing
and correct the problem. A—Cap Screws (4 Used)
B—Horseshoe Clip

Continued on next page RG,RG34710,2088 –19–15MAR97–12/15

CTM77 (30OCT00) 15-30-19 Alternators and Starter Motors

103000
PN=167
 Motorola TA-Series Alternator Repair

13. Install the brush assembly (B). Isolator (A) must be

installed with tab over the brush leads to prevent
brush leads from touching housing. Tighten brush
holder retaining cap screws to specifications.

Specification
Brush Holder Retaining Screws—

–UN–14FEB90
Torque .......................................................... 2.8—3.4 N•m (20—30 lb-in.)

A—Isolator
B—Brush Assembly

T91364
15
30
20 Install Brush Assembly and Isolator

RG,RG34710,2088 –19–15MAR97–13/15

14. Install brush holder cover (A) and dust shield.

A—Brush Holder Cover and Dust Shield

–UN–12APR90
T5916AG
Brush Holder Cover and Shield

Continued on next page RG,RG34710,2088 –19–15MAR97–14/15

CTM77 (30OCT00) 15-30-20 Alternators and Starter Motors

103000
PN=168
 Motorola TA-Series Alternator Repair

15. Install voltage regulator (A) and wiring leads.

16. Refer to your machine technical manual for

installation of alternator.

A—Voltage Regulator

–UN–02APR90
T6106AF
15
30
Voltage Regulator 21

RG,RG34710,2088 –19–15MAR97–15/15

CTM77 (30OCT00) 15-30-21 Alternators and Starter Motors

103000
PN=169
 Motorola TA-Series Alternator Repair

15
30
22

CTM77 (30OCT00) 15-30-22 Alternators and Starter Motors

103000
PN=170
 Section 20
Niehoff Alternators
Contents

Page

Group 05—Niehoff Alternator Theory of Operation

Starting the Niehoff Alternator . . . . . . . . . . . . . .20-05-1
Niehoff Alternator Operation . . . . . . . . . . . . . . .20-05-1
Niehoff Alternator Load Dump Circuit . . . . . . . .20-05-4

Group 10—Niehoff 12-Volt, 110-Amp Alternator

Repair
20
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-3
Niehoff 12-Volt Charging Circuit Repair
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .20-10-3
Niehoff 12-Volt Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .20-10-4
Disassemble Niehoff 12-Volt, 110-Amp
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-4
Test Niehoff 12-Volt, 110-Amp Alternator
Components . . . . . . . . . . . . . . . . . . . . . . . .20-10-17
Assemble Niehoff 12-Volt, 110-Amp
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-22
Establish Magnetic Field . . . . . . . . . . . . . . . . .20-10-27

Group 15—Niehoff 24-Volt, 50-Amp Alternator

Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .20-15-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .20-15-2
Niehoff 24-Volt Charging Circuit Repair
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .20-15-3
Niehoff 24-Volt Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .20-15-3
Disassemble Niehoff 24-Volt, 50-Amp
Alternator and Test Components . . . . . . . . . .20-15-4
Assemble Niehoff 24-Volt, 50-Amp
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .20-15-11
Re-Establish Magnetic Field . . . . . . . . . . . . . .20-15-17

CTM77 (30OCT00) 20-1 Alternators and Starter Motors

103000
PN=1
 Contents

20

CTM77 (30OCT00) 20-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Niehoff Alternator Theory of Operation
Starting the Niehoff Alternator

As the engine is cranking to start, the alternator rotor will

turn. The residual magnetism in the rotor and stationary
forging creates a magnetic field. The turning rotor causes
the magnetic field to alternately increase and decrease in
strength. This induces current into the stator (A). This
current is sufficient to turn on the power transistor (B).
The alternator and regulator are now operating.

A—Stator
B—Power Transistor

20
05

–UN–06APR89
1

RW5112
Starting Niehoff Alternator

RG,RG34710,2089 –19–15MAR97–1/1

Niehoff Alternator Operation

With the power transistor (A) on, field current is permitted

to flow through the alternator field winding (B) from the
battery (C). The field coil current will produce a magnetic
field.

A—Power Transistor
B—Alternator Field Winding
C—Battery

–UN–06APR89
RW5113

Niehoff Alternator Operation

Continued on next page RG,RG34710,2090 –19–15MAR97–1/3

CTM77 (30OCT00) 20-05-1 Alternators and Starter Motors

103000
PN=173
 Niehoff Alternator Theory of Operation

This magnetic field flows through a small air gap to the

rotor and to the stator windings. As the rotor turns, the
magnetic field is alternately increased and decreased in
strength. This induces an alternating three-phase voltage
and current in the stator coil windings (A). The alternating
current output from the stator is applied to a three-phase
full wave bridge rectifier (B), which provides direct current
to the battery (C).

The compound winding produces a magnetic field which

adds to the magnetic field created by the field coil. This
helps the alternator produce output at the high end of the
output range.

A—Stator Coil Windings

20 B—Bridge Rectifier
05 C—Battery
D—Rotor Winding

–UN–06APR89
2
E—Field Winding

RW5114
Magnetic Field

Continued on next page RG,RG34710,2090 –19–15MAR97–2/3

CTM77 (30OCT00) 20-05-2 Alternators and Starter Motors

103000
PN=174
 Niehoff Alternator Theory of Operation

The voltage regulator senses the voltage of the charging

system through the diode trio (A). If the alternator loading
demand is high, the power transistor (B) becomes
conductive for longer periods of time and supplies a
greater amount of current to the field winding (C). An
increase in current flow through the field winding causes
an increase in alternator output voltage.

As the charging system builds up to the predetermined

setting of the regulator, the Zener diode (D) in the
regulator causes the power transistor (B) to turn off. With
the power transistor (B) turned off, little or no current is
applied to the field winding, thereby decreasing the
alternator output voltage.

This on/off field switching action is repeated as often as

20
necessary so that the average voltage output of the 05
alternator is maintained at the regulator setting.

–UN–06APR89
3

A—Diode Trio
B—Power Transistor

RW5115
C—Field Winding
D—Zener Diode

Voltage Regulator

RG,RG34710,2090 –19–15MAR97–3/3

CTM77 (30OCT00) 20-05-3 Alternators and Starter Motors

103000
PN=175
 Niehoff Alternator Theory of Operation

Niehoff Alternator Load Dump Circuit

The load dump circuit protects the alternator and the

vehicle’s electrical system when the battery connection is
broken.

When the battery connection is broken, a high voltage

appears at the alternator output (A). This high voltage
causes the Zener diode (B) and the transistor (C) to
conduct. This will turn on three SCR’s (D)

A—Alternator Output
B—Zener Diode
C—Transistor
D—SCR’s (3 Used)

20
05
4

–UN–24MAY89
RW5164
Load Dump Circuit

RG,RG34710,2091 –19–15MAR97–1/2

All the alternator output will flow through the three SCR’s
(A) to ground (B).

After a short time, the high voltage is gone and the

regulator will take control of the alternator. The alternator
output will remain at a level necessary to operate the
vehicle’s electrical system.

Repeated operation of the load dump circuit will result in

regulator failure.

A—SCR’s (3 Used)
B—Ground
–UN–04MAY89
RW5165

SCR to Ground

RG,RG34710,2091 –19–15MAR97–2/2

CTM77 (30OCT00) 20-05-4 Alternators and Starter Motors

103000
PN=176
 Group 10
Niehoff 12-Volt, 110-Amp Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B6C –19–21SEP00–1/5

Stator Support . . . . . . . . . . . . . . . . . . . . . . . JDG255

20
Support shell while pressing out stator. 10
1

–UN–10NOV89
RW10306
JDG255

OUO1004,0000B6C –19–21SEP00–2/5

Blind Hole Puller Set . . . . . . . . . . . . . . . . . D01061AA

Remove bearings from front housing assembly.

–UN–21SEP00
RG11161

D01061AA

Continued on next page OUO1004,0000B6C –19–21SEP00–3/5

CTM77 (30OCT00) 20-10-1 Alternators and Starter Motors

103000
PN=177
 Niehoff 12-Volt, 110-Amp Alternator Repair

Bushing, Bearing and Seal Driver Set . . . . . . D01045AA

Install bearings in front housing assembly.

–UN–21SEP00
RG11162
D01045AA

20
10
2

OUO1004,0000B6C –19–21SEP00–4/5

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B6C –19–21SEP00–5/5

CTM77 (30OCT00) 20-10-2 Alternators and Starter Motors

103000
PN=178
 Niehoff 12-Volt, 110-Amp Alternator Repair

Other Material

Number Name Use

TY16285 (U.S.) Thread Lock and Sealer (Low Apply to all cap screws and nuts
CXTY24311 (Canadian) Strength) when assembling alternator.
222 (LOCTITE)

(U.S.) High Temperature, Silicone Base Fill front and rear grease reservoir in
Grease alternator housing.

(U.S.) Silicone Rubber Compound Apply to all internal wiring lead cap
screws.

20
10
3

LOCTITE is a registered trademark of Loctite Corp. OUO1004,0000B6E –19–21SEP00–1/1

Niehoff 12-Volt Charging Circuit Repair

Specifications

Item Measurement Specification

Fan Pulley Lock Nut Torque 95 N•m (70 lb-ft)

Front Housing-to-Stator Shell Nuts Torque 3.4 N•m (30 lb-in.)

Rotor Nut Torque 68 N•m (50 lb-ft)

Regulator Field Lead-to-Standoff Torque 0.9—1.1 N•m (8—10 lb-in.)

Screw and Y-Lead-to-Load Dump
Screw

Output and Relay Leads-to-Standoff Torque 2.3 N•m (20 lb-in.)

Screw

Ground Lead-to-Load Dump Screw Torque 1.1—1.7 N•m (10—15 lb-in.)

Flanged Nuts Torque 5.1 N•m (45 lb-in.)

OUO1004,0000B6F –19–21SEP00–1/1

CTM77 (30OCT00) 20-10-3 Alternators and Starter Motors

103000
PN=179
 Niehoff 12-Volt, 110-Amp Alternator Repair

Niehoff 12-Volt Charging Circuit Test

Specifications
John Deere Niehoff Model No. Ground Voltage Rated Output Winding
Part No. (Amps) Resistance @
21—27°C (70—
80°F) (Ohms)
AR94100 N1114-1 N 12 110 2.9—3.1

RG,RG34710,2094 –19–08SEP00–1/1

Disassemble Niehoff 12-Volt, 110-Amp Alternator

20
10
4

–UN–02MAR90
RW3289
Niehoff 12-Volt, 110-Amp Alternator

A—Screw (3 Used) I—Screw (4 Used) Q—Insulator (6 Used) Y—Front Housing Assembly

B—Dust Cover J—Washer (4 Used) R—Nut (6 Used) Z—Shaft
C—Ground Bolt with Washer K—Screw (7 Used) S—Spacer (6 Used) AA—Woodruff Key
D—Battery Stud with Washers L—Regulator Assembly T—Stator Assembly BB—Bearing Cover
E—Lock Nut M—Insulator U—Lock Nut CC—Fan
F—Insulator N—Nut (6 Used) V—Washer DD—Pulley
G—Nut (6 Used) O—Insulator (6 Used) W—Rotor EE—Washer
H—Rear Housing P—Rectifier Assembly X—Washer FF—Nut

Refer to your machine technical manual for removal of

alternator.

Continued on next page RG,RG34710,2096 –19–15MAR97–1/26

CTM77 (30OCT00) 20-10-4 Alternators and Starter Motors

103000
PN=180
 Niehoff 12-Volt, 110-Amp Alternator Repair

IMPORTANT: Never immerse alternator in cleaning

solution. Remove dirt and grease by
scraping and using a stiff brush with
solvent. Dry with compressed air.

NOTE: Because of the manufacturer’s design of the rotor

–UN–02MAR90
and the field flux noise, this alternator is noisier
than others.

Unnecessary disassembly may be prevented by

RW3274
first checking alternator output, shell temperature
and pulley nut tension before the decision to
disassemble is made. (Refer to your machine Remove Dust Cover
Operation and Test manual for complete charging
circuit diagnosis. A—Dust Cover

20
1. Remove dust cover (A). 10
5
NOTE: If alternator is being disassembled for testing,
follow Steps 1 through 8 only. Refer to TEST
NIEHOFF 12-VOLT, 110-AMP ALTERNATOR
COMPONENTS, later in this group.

RG,RG34710,2096 –19–15MAR97–2/26

2. Remove battery positive bolt (A), negative bolt (B), and

lock nut and insulator from terminal (C).

A—Battery Positive Bolt

B—Negative Bolt
C—Terminal

–UN–02MAR90
RW3275
Remove Bolts from Terminal

Continued on next page RG,RG34710,2096 –19–15MAR97–3/26

CTM77 (30OCT00) 20-10-5 Alternators and Starter Motors

103000
PN=181
 Niehoff 12-Volt, 110-Amp Alternator Repair

3. Remove six lock nuts (A) from studs and pry with
screwdriver in detent (B) to lift off rear housing (C).

A—Lock Nuts (6 Used)

B—Detent
C—Rear Housing

–UN–02MAR90
RW3276
Lift Off Rear Housing

20
10
6

RG,RG34710,2096 –19–15MAR97–4/26

4. Remove two screws (A) to detach compound winding

leads.

A—Screws (2 Used)

–UN–02MAR90
RW3277
Detach Compound Winding Leads

Continued on next page RG,RG34710,2096 –19–15MAR97–5/26

CTM77 (30OCT00) 20-10-6 Alternators and Starter Motors

103000
PN=182
 Niehoff 12-Volt, 110-Amp Alternator Repair

5. Remove two screws (A) to detach field leads.

A—Screws (2 Used)

–UN–02MAR90
RW3278
Detach Field Leads

20
10
7

RG,RG34710,2096 –19–15MAR97–6/26

6. Remove three screws (A) with washers at stand-offs.

A—Screws (3 Used)

–UN–02MAR90
RW3279
Remove Screws at Stand-Offs

Continued on next page RG,RG34710,2096 –19–15MAR97–7/26

CTM77 (30OCT00) 20-10-7 Alternators and Starter Motors

103000
PN=183
 Niehoff 12-Volt, 110-Amp Alternator Repair

7. Remove three screws with washers (A) to detach

regulator (B).

A—Screws with Washers

B—Regulator

–UN–02MAR90
RW3280
Remove Screws to Detach Regulator

20
10
8

RG,RG34710,2096 –19–15MAR97–8/26

8. Loosen three terminal locks (A) and detach stator

leads (B).

NOTE: The alternator has now been disassembled for

testing. Refer to TEST NIEHOFF 12-VOLT,
110-AMP ALTERNATOR COMPONENTS, later in

–UN–02MAR90
this group.

A—Terminal Locks (3 Used)

B—Stator Leads

RW3281
Detach Stator Leads

Continued on next page RG,RG34710,2096 –19–15MAR97–9/26

CTM77 (30OCT00) 20-10-8 Alternators and Starter Motors

103000
PN=184
 Niehoff 12-Volt, 110-Amp Alternator Repair

9. Remove six nuts (A) and six insulators (B) to detach

rectifier assembly.

A—Nuts (6 Used)
B—Insulators (6 Used)

–UN–02MAR90
RW3290
Detach Rectifier Assembly

20
10
9

RG,RG34710,2096 –19–15MAR97–10/26

IMPORTANT: Use soft-jawed vise when clamping

pulley.

10. Remove lock nut (A) and hardened washer (B).

A—Lock Nut

–UN–02MAR90
B—Hardened Washer

RW3291
Remove Lock Nut and Washer

Continued on next page RG,RG34710,2096 –19–15MAR97–11/26

CTM77 (30OCT00) 20-10-9 Alternators and Starter Motors

103000
PN=185
 Niehoff 12-Volt, 110-Amp Alternator Repair

11. Lift rotor (A) from shaft (B).

A—Rotor
B—Shaft

–UN–02MAR90
RW3292
Lift Rotor from Shaft

20
10
10

RG,RG34710,2096 –19–15MAR97–12/26

12. Remove six insulators (A), six washer nuts (B), and
six spacers (C) from studs (D).

A—Insulator
B—Washer Nut
C—Spacer

–UN–02MAR90
D—Stud

RW3293
Remove Insulators, Nuts and Spacers

Continued on next page RG,RG34710,2096 –19–15MAR97–13/26

CTM77 (30OCT00) 20-10-10 Alternators and Starter Motors

103000
PN=186
 Niehoff 12-Volt, 110-Amp Alternator Repair

13. Identify wires for reassembly.

IMPORTANT: Note and mark position of compound

winding leads (A) and field winding
leads (B) to stator (C). All must be in
original position for correct assembly.

–UN–02MAR90
A—Compound Winding Leads
B—Field Winding Leads (White)
C—Stator

RW3294
Leads and Stator

20
10
11

RG,RG34710,2096 –19–15MAR97–14/26

14. Tap shell (A) lightly with soft hammer to loosen it from
front housing assembly (B).

A—Shell
B—Housing Assembly

–UN–02MAR90
RW3295
Front Housing Assembly

Continued on next page RG,RG34710,2096 –19–15MAR97–15/26

CTM77 (30OCT00) 20-10-11 Alternators and Starter Motors

103000
PN=187
 Niehoff 12-Volt, 110-Amp Alternator Repair

15. Pry shell (A) from front housing assembly (B).

A—Shell
B—Housing Assembly

–UN–02MAR90
RW3296
Front Housing Assembly

20
10
12

RG,RG34710,2096 –19–15MAR97–16/26

IMPORTANT: Note and mark the relationship of

stator-to-shell before disassembly.

16. Press stator from shell. Use JDG255 Stator Support

(A) to support shell (B). Using a punch, tap stator out
evenly.

–UN–10NOV89
A—JDG255 Stator Support Tool
B—Alternator Shell

RW10426
Tap Stator Out

Continued on next page RG,RG34710,2096 –19–15MAR97–17/26

CTM77 (30OCT00) 20-10-12 Alternators and Starter Motors

103000
PN=188
 Niehoff 12-Volt, 110-Amp Alternator Repair

17. Remove nut and washer to detach pulley (A) and fan
(B) from shaft (C).

A—Pulley
B—Fan
C—Shaft

–UN–02MAR90
RW3297
Detach Pulley and Fan

20
10
13

RG,RG34710,2096 –19–15MAR97–18/26

18. Remove Woodruff key (A) to detach bearing seal

cover (B) from shaft (C).

A—Woodruff Key
B—Bearing Seal Cover
C—Shaft

–UN–02MAR90
RW3298
Remove Woodruff Key

Continued on next page RG,RG34710,2096 –19–15MAR97–19/26

CTM77 (30OCT00) 20-10-13 Alternators and Starter Motors

103000
PN=189
 Niehoff 12-Volt, 110-Amp Alternator Repair

NOTE: Remove bearings for replacement only, and

replace both ball and roller bearings. Bearings are
prelubricated by supplier. Use D01061AA Blind
Hole Puller Set and ensure full ID contact when
removing bearings.

19. Remove snap ring (A).

–UN–23FEB90
A—Snap Ring
B—Bearing
C—Shaft

RW5120
Remove Snap Ring

20
10
14

RG,RG34710,2096 –19–15MAR97–20/26

20. Remove ball bearing (A). Use 16 mm (5/8 in.) collet

(No. 33860).1

A—Ball Bearing

–UN–02MAR90
RW3283
Remove Ball Bearing

1
From the D01061AA Blind Hole Puller Set.
Continued on next page RG,RG34710,2096 –19–15MAR97–21/26

CTM77 (30OCT00) 20-10-14 Alternators and Starter Motors

103000
PN=190
 Niehoff 12-Volt, 110-Amp Alternator Repair

21. Remove roller bearing and seal (A). Use 26—32 mm

(1—1-1/4 in.) collet (No. 33863).1

A—Roller Bearing and Seal

–UN–02MAR90
RW3284
Remove Roller Bearing and Seal

20
10
15
1
From the D01061AA Blind Hole Puller Set.
RG,RG34710,2096 –19–15MAR97–22/26

To install new alternator bearings:

22. Press roller bearing (A) into front housing assembly.

Use 27 mm (1-1/16 in.) pilot disk (B) and 46 mm
(1-13/16 in.) driver disk (C) (No. 27500 and 27512.)1

–UN–02MAR90
A—Roller Bearing
B—27 mm (1-1/16 in.) Pilot Disk
C—46 mm (1-13/16 in.) Driver Disk (No. 24500 and
27512.) *

RW3286
New Alternator Bearings

1
From the D01045AA Bushing, Bearing and Seal Driver Set.
Continued on next page RG,RG34710,2096 –19–15MAR97–23/26

CTM77 (30OCT00) 20-10-15 Alternators and Starter Motors

103000
PN=191
 Niehoff 12-Volt, 110-Amp Alternator Repair

IMPORTANT: Seal spring and lip must be visible

when seal is properly installed for
maximum protection against dust
penetration into bearing.

23. Press roller bearing seal (A) into front housing

–UN–02MAR90
assembly (B) using 54 mm (2-1/8 in.) driver disk (C),
(No. 27517).1

A—Roller Bearing Seal

RW3287
B—Front Housing Assembly
C—Driver Disk
Roller Bearing Seal

20
10
16
1
From the D01045AA Bushing, Bearing and Seal Driver Set.
RG,RG34710,2096 –19–15MAR97–24/26

24. Press ball bearing (A) into front housing using 16 mm

(5/8 in.) disk (B) and 40 mm (1-9/16 in.) driver disk
(C) (No. 27493 and 27508).1

A—Ball Bearing
B—16 mm (5/8 in.) Disk

–UN–02MAR90
C—40 mm (1-9/16 in.) Driver Disk (No. 27493 and
27508)

RW3285
Ball Bearing

1
From the D01045AA Bushing, Bearing and Seal Driver Set.
Continued on next page RG,RG34710,2096 –19–15MAR97–25/26

CTM77 (30OCT00) 20-10-16 Alternators and Starter Motors

103000
PN=192
 Niehoff 12-Volt, 110-Amp Alternator Repair

NOTE: Snap ring (A) must be seated completely with flat

side against the bearing (B) (bevel is away from
bearing).

25. Assemble snap ring (A) to front housing assembly

(C).

–UN–12MAY89
A—Snap Ring
B—Bearing
C—Front Housing Assembly

RW3282
Assemble Snap Ring

20
10
17

RG,RG34710,2096 –19–15MAR97–26/26

Test Niehoff 12-Volt, 110-Amp Alternator

Components

1. Test stator windings by measuring resistance in each

successive pair of stator phase leads (A) (three pair).
Use JT05791 Digital Multimeter to measure resistance.

–UN–02MAR90
Less than 0.5 ohm of resistance should be indicated in
each pair.

RW3265
A—Stator Phase Leads

Stator Phase Leads

Continued on next page RG,RG34710,2097 –19–15MAR97–1/9

CTM77 (30OCT00) 20-10-17 Alternators and Starter Motors

103000
PN=193
 Niehoff 12-Volt, 110-Amp Alternator Repair

2. Test for shorted stator windings by measuring

resistance between each stator lead (A) and stator
frame (B).

Infinite resistance or “open” should be indicated.

–UN–02MAR90
A—Stator Lead
B—Stator Frame

RW3266
Measure Resistance

20
10
18

RG,RG34710,2097 –19–15MAR97–2/9

NOTE: A resistance reading above or below specification

indicates a defective field winding. Front housing
and field coil assembly should be replaced.

3. Test field windings (A) for a resistance of 2.9—

3.1 ohms and compound windings (B) for less than 0.5

–UN–17APR90
ohms.

A—Field Windings
B—Compound Windings

RW11292
Test Field Windings

Continued on next page RG,RG34710,2097 –19–15MAR97–3/9

CTM77 (30OCT00) 20-10-18 Alternators and Starter Motors

103000
PN=194
 Niehoff 12-Volt, 110-Amp Alternator Repair

4. Test for shorted field windings to compound windings

by measuring resistance between field leads (A) and
compound winding leads (B).

Infinite resistance or “open” should be indicated. If a

short is indicated, the front housing assembly must be

–UN–02MAR90
replaced.

A—Field Leads
B—Compound Winding Leads

RW3268
Measure Resistance

20
10
19

RG,RG34710,2097 –19–15MAR97–4/9

5. Test for shorted field windings to front housing

assembly by checking resistance between field leads
(A) and front housing/shell assembly (B).

Infinite resistance or “open” should be indicated. If a

short is indicated, the front housing assembly must be

–UN–02MAR90
replaced.

A—Field Leads
B—Front Housing/Shell Assembly

RW3269
Field Leads and Housing/Shell Assembly

Continued on next page RG,RG34710,2097 –19–15MAR97–5/9

CTM77 (30OCT00) 20-10-19 Alternators and Starter Motors

103000
PN=195
 Niehoff 12-Volt, 110-Amp Alternator Repair

NOTE: Evidence of defective diodes require replacement

of rectifier diode and rectifier assembly. When
checking diodes with a digital meter, use the
diode position.

6. Test top plate (A) diodes of rectifier assembly by

–UN–02MAR90
checking resistance between output terminal (B) and
each stator phase terminal (C).

All readings should be of low resistance or infinite

RW3270
resistance, depending on direction of current flow
through the diodes.
Test Top Plate Diodes

A—Top Plate
B—Output Terminal
20 C—Stator Phase Terminal
10
20

RG,RG34710,2097 –19–15MAR97–6/9

7. Test top plate (A) diodes for reverse current flow by

reversing test probes at output terminal. Measure
resistance between output terminal (B) and stator
phase terminals (C).

All readings should be the reverse of those in the

–UN–02MAR90
preceeding step.

A—Top Plate
B—Output Terminal

RW3271
C—Stator Phase Terminal

Test Top Plate Diodes

Continued on next page RG,RG34710,2097 –19–15MAR97–7/9

CTM77 (30OCT00) 20-10-20 Alternators and Starter Motors

103000
PN=196
 Niehoff 12-Volt, 110-Amp Alternator Repair

8. Test the lower plate (A) diodes of the rectifier assembly

by checking the resistance between output terminal (B)
and stator phase terminals (C).

All readings should be infinite or low depending on

direction of current flow through the diodes.

–UN–02MAR90
A—Lower Plate
B—Output Terminal
C—Stator Phase Terminals

RW3272
Test Lower Plates Diodes

20
10
21

RG,RG34710,2097 –19–15MAR97–8/9

9. Test lower plate (A) diodes for reverse current flow by

reversing probes at output terminal (B) and stator
phase terminals (C).

All readings should be the reverse of those in the

preceeding step.

–UN–02MAR90
Example: An infinite reading in this step should have
been a low resistance reading in step 8. If the same
reading is indicated in steps 6 and 7 or 8 and 9,

RW3273
defective diodes are evident and the rectifier assembly
must be replaced.
Test Lower Plate Diodes

A—Lower Plate
B—Output Terminal
C—Stator Phase Terminal

RG,RG34710,2097 –19–15MAR97–9/9

CTM77 (30OCT00) 20-10-21 Alternators and Starter Motors

103000
PN=197
 Niehoff 12-Volt, 110-Amp Alternator Repair

Assemble Niehoff 12-Volt, 110-Amp

Alternator

NOTE: Apply LOCTITE 222 Thread Lock and Sealer

(low strength) on all cap screws and nuts when
assembling alternator.

–UN–02MAR90
1. Assemble roller bearing cover (B) to shaft (C) and
insert Woodruff key (A) in slot.

RW3298
A—Woodruff Key
B—Roller Bearing Cover
Assemble Roller Bearing Cover
C—Shaft

20
10
22

LOCTITE is a registered trademark of Loctite Corp. RG,RG34710,2098 –19–15MAR97–1/10

2. Assemble fan (B) and pulley (A) to shaft (C). Tighten

lock nut to specifications.

Specification
Fan Pulley Lock Nut—Torque ......................................... 95 N•m (70 lb-ft)

–UN–02MAR90
A—Pulley
B—Fan
C—Shaft

RW3297
Assembly Fan and Pulley

Continued on next page RG,RG34710,2098 –19–15MAR97–2/10

CTM77 (30OCT00) 20-10-22 Alternators and Starter Motors

103000
PN=198
 Niehoff 12-Volt, 110-Amp Alternator Repair

IMPORTANT: Note your marked position of shell to

stator as in disassembly.

3. Assemble stator (A) to shell (B), by tapping evenly

around outside edge.

–UN–10NOV89
A—Stator
B—Shell

RW10427
Assemble Stator to Shell

20
10
23

RG,RG34710,2098 –19–15MAR97–3/10

IMPORTANT: Note your marked position of shell (A)

to front housing (B) as in disassembly.
Also note the way compound winding
leads (C) and field winding leads (D) are
threaded through stator (E). All must be
in the original position before shell is

–UN–02MAR90
seated onto front housing assembly.

4. Fill front and rear grease reservoir two-thirds full of

high temperature, silicone-base grease.

RW3301
Assemble shell (A) to front housing (B).
Assemble Shell
A—Shell
B—Front Housing
C—Compound Winding Lead
D—Field Winding Lead
E—Stator

Continued on next page RG,RG34710,2098 –19–15MAR97–4/10

CTM77 (30OCT00) 20-10-23 Alternators and Starter Motors

103000
PN=199
 Niehoff 12-Volt, 110-Amp Alternator Repair

IMPORTANT: Be sure to assemble spacer, nuts,

insulators and rectifier assembly to
alternator, in the order shown.

–UN–12MAY89
A—Spacer
B—Nut
C—Insulator
D—Rectifier Assembly
E—Insulator

RW3299
F—Nut
G—Stud
Assemble Hardware

20
10
24

RG,RG34710,2098 –19–15MAR97–5/10

5. Assemble six spacers and six washer nuts. Tighten

washer nuts (A) to specifications.

Specification
Front Housing-to-Stator Shell
Nuts—Torque ................................................................ 3.4 N•m (30 lb-in.)

–UN–02MAR90
A—Washer Nuts (6 Used)

RW3303
Tighten Washer Nuts

Continued on next page RG,RG34710,2098 –19–15MAR97–6/10

CTM77 (30OCT00) 20-10-24 Alternators and Starter Motors

103000
PN=200
 Niehoff 12-Volt, 110-Amp Alternator Repair

6. Assemble six insulators (A) to studs (D).

A—Insulators
B—Washer Nuts
C—Spacer
D—Studs

–UN–02MAR90
RW3293
Assemble Insulators

20
10
25

RG,RG34710,2098 –19–15MAR97–7/10

7. Assemble rotor (A) and washer (B) to shaft (C).

A—Rotor
B—Washer
C—Shaft

–UN–02MAR90
RW3288
Assemble Rotor and Washer to Shaft

Continued on next page RG,RG34710,2098 –19–15MAR97–8/10

CTM77 (30OCT00) 20-10-25 Alternators and Starter Motors

103000
PN=201
 Niehoff 12-Volt, 110-Amp Alternator Repair

8. Assemble hardened washer (B) and nut (A). Tighten to

specifications.

Specification
Rotor Nut—Torque .......................................................... 68 N•m (50 lb-ft)

–UN–02MAR90
A—Nut
B—Hardened Washer

RW3291
Hardened Washer and Nut

20
10
26

RG,RG34710,2098 –19–15MAR97–9/10

IMPORTANT: Coat all screw heads on regulator and

rectifier assembly with silicone rubber
compound.

9. Assemble remaining alternator parts in reverse order of

disassembly, starting with step 9 back to step 1.

–UN–02MAR90
Specification
Regulator Field Lead-to-Standoff
Screw and Y-Lead-to-Load Dump
Screw—Torque ............................................... 0.9—1.1 N•m (8—10 lb-in.)

RW3290
Output and Relay
Leads-to-Standoff Screw—Torque ................................ 2.3 N•m (20 lb-in.)
Ground Lead-to-Load Dump Assemble Remaining Parts
Screw—Torque ............................................. 1.1—1.7 N•m (10—15 lb-in.)
Flanged Nuts—Torque .................................................. 5.1 N•m (45 lb-in.) A—Nuts (6 Used)
B—Insulators (6 Used)
10. Refer to your machine technical manual for alternator
installation.

RG,RG34710,2098 –19–15MAR97–10/10

CTM77 (30OCT00) 20-10-26 Alternators and Starter Motors

103000
PN=202
 Niehoff 12-Volt, 110-Amp Alternator Repair

Establish Magnetic Field

NOTE: This action will take only a few seconds.

Connect alternator ground stud (A) to field coil through

inspection hole (B) while alternator output is connected to
battery positive post and alternator ground is connected to

–UN–12MAY89
battery negative post.

A—Alternator Ground Stud

RW3305
B—Inspection Hole

Establish Magnetic Field

20
10
27

RG,RG34710,2099 –19–15MAR97–1/1

CTM77 (30OCT00) 20-10-27 Alternators and Starter Motors

103000
PN=203
 Niehoff 12-Volt, 110-Amp Alternator Repair

20
10
28

CTM77 (30OCT00) 20-10-28 Alternators and Starter Motors

103000
PN=204
 Group 15
Niehoff 24-Volt, 50-Amp Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B70 –19–21SEP00–1/4

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

20
Test electrical components for voltage, resistance, or 15
current flow. It is especially good for measuring low 1
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B70 –19–21SEP00–2/4

Blind Hole Puller Set . . . . . . . . . . . . . . . . . D01061AA

Remove bearings from front housing assembly.

–UN–21SEP00
RG11161

D01061AA

Continued on next page OUO1004,0000B70 –19–21SEP00–3/4

CTM77 (30OCT00) 20-15-1 Alternators and Starter Motors

103000
PN=205
 Niehoff 24-Volt, 50-Amp Alternator Repair

Bushing, Bearing and Seal Driver Set . . . . . . D01045AA

Install bearings in front housing assembly.

–UN–21SEP00
RG11162
D01045AA

20
15
2

OUO1004,0000B70 –19–21SEP00–4/4

Other Material

Number Name Use

TY16285 (U.S.) Thread Lock and Sealer (Low Apply to all cap screws and nuts
CXTY24311 (Canadian) Strength) when assembling alternator.
222 (LOCTITE)

(U.S.) High Temperature, Silicone Base Fill front and rear grease reservoir in
Grease alternator housing.

(U.S.) Silicone Rubber Compound Apply to all internal wiring lead cap
screws.

LOCTITE is a registered trademark of Loctite Corp. OUO1004,0000B72 –19–21SEP00–1/1

CTM77 (30OCT00) 20-15-2 Alternators and Starter Motors

103000
PN=206
 Niehoff 24-Volt, 50-Amp Alternator Repair

Niehoff 24-Volt Charging Circuit Repair

Specifications

Item Measurement Specification

Pulley Nut Torque 95 N•m (70 lb-ft)

Rotor Nut Torque 75 N•m (55 lb-ft)

Front Housing-to-Stator Nuts Torque 3.4 N•m (30 lb-in.)

Rotor-to-Stator Poles Minimum Air Gap 0.13 mm (0.005 in.)

Rotor Housing Stud Ground Lead Torque 2.8—3.4 N•m (25—30 lb-in.)
Nut
20
Field Lead-to-Regulator Stand-Off Torque 0.91—1.1 N•m (8—10 lb-in.) 15
Cap Screw 3

Output and Relay Lead Cap Screws Torque 2.3 N•m (20 lb-in.)

Ground Lead-to-Load Dump Screw Torque 1.1—1.7 N•m (10—15 lb-in.)

Y-Lead-to-Load Dump Screw Torque 0.9—1.1 N•m (8—10 lb-in.)

Load Dump Assembly Mounting Cap Torque 0.9—1.1 N•m (8—10 lb-in.)
Screws

Rear Housing Flange Nuts Torque 5.1 N•m (45 lb-in.)

OUO1004,0000B73 –19–21SEP00–1/1

Niehoff 24-Volt Charging Circuit Test

Specifications
John Deere Niehoff Model No. Ground Voltage Rated Output Winding Resistance @
Part No. (Amps) 21—27°C (70—80°F)
(Ohms)
AT56873 N-1031 N 24 50 9.0—11.0
a
AT53676 N-1108 N 24 70—80 11.0—13.0
a
Alternator output is adjustable on this model.

RG,RG34710,2102 –19–08SEP00–1/1

CTM77 (30OCT00) 20-15-3 Alternators and Starter Motors

103000
PN=207
 Niehoff 24-Volt, 50-Amp Alternator Repair

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

20
15
4

–UN–25MAY89
T6090AX
Niehoff 24-Volt, 50-Amp Alternator

1—Pulley Nut 14—Shorter Stud 28—Regulator Assembly 38—No. 6 Cap Screw

2—Hardened Washer 15—Longer Stud (2 Used) 29—Spring Washer (4 Used) 39—Gasket
3—Pulley 16—Rear Bearing 30—Double Chamfered Hex 40—Voltage Adjust Cover
4—Fan 17—Retaining Ring Nut (3 Used) 41—Red Insulator
5—Shaft Key 18—Flat Washer (2 Used) 31—No. 6 Cap Screw (2 Used) 42—Output Stud
6—Shaft 19—Lock Nut 32—No. 10 Cap Screw (2 43—Rear Housing
7—Shaft Seal 20—Flanged Hex Nut (3 Used) Used) 44—No. 6 Cap Screw
8—Front Bearing 21—Spacer (3 Used) 33—No. 8 Cap Screw 45—Nameplate Cover
9—Cap Screw (4 Used) 22—Hardened Washer 34—Spring Washer (8 Used) 46—White Insulator
10—Terminal Lock (7 Used) 23—Stator and Shell Assembly 35—No. 6 Cap Screw (3 Used) 47—Flat Washer
11—Cap Screw (7 Used) 24—Rotor 36—Insulator 48—Lock Nut
12—Heat Sink Assembly 25—Hardened Washer 37—Single Flanged Hex Nut (3 49—Rubber Relay Terminal
13—Front Housing and Field 26—Ground Lead Used) Cap
Winding Assembly 27—Lock Nut

Continued on next page RG,RG34710,2103 –19–15MAR97–1/13

CTM77 (30OCT00) 20-15-4 Alternators and Starter Motors

103000
PN=208
 Niehoff 24-Volt, 50-Amp Alternator Repair

NOTE: The alternator does not have to be completely

disassembled to test components.

1. Remove parts (1—7) to remove cover.

1—Cover
2—Lock Nut (3 Used)
3—Voltage Adjusting Screw
4—Output Terminal
5—Name Plate Cover Cap Screw
6—Regulator Support Screw
7—Relay Terminal

20
15
5

–UN–29MAR90
T6090AP
Remove Alternator Parts

RG,RG34710,2103 –19–15MAR97–2/13

2. Remove insulation from screw heads.

3. Remove screws (1) and spring washers.

4. Turn load dump (2) over and remove insulation from

wire connections.
–UN–29MAR90

1—Screws (3 Used)
2—Load Dump
T6090AT

Load Dump

Continued on next page RG,RG34710,2103 –19–15MAR97–3/13

CTM77 (30OCT00) 20-15-5 Alternators and Starter Motors

103000
PN=209
 Niehoff 24-Volt, 50-Amp Alternator Repair

5. Disconnect wiring leads (4 and 6) to remove load

dump (5).

6. Disconnect wiring leads (1, 2, and 3).

–UN–29MAR90
1—Relay Lead (Brown)
2—Field Lead (White)
3—Output Lead (Red)
4—Ground Lead (White)
5—Load Dump

T6090AO2
6—Y-Lead (Brown)

Remove Load Dump

20
15
6

RG,RG34710,2103 –19–15MAR97–4/13

7. Put alternator pulley in a vise. Use an oversize belt on

pulley for protection or use a soft-jawed vise.

8. Remove parts (1—4).

1—Nut

–UN–25MAY89
2—Hardened Washer
3—Pulley
4—Fan

T6104AB
Remove Parts

Continued on next page RG,RG34710,2103 –19–15MAR97–5/13

CTM77 (30OCT00) 20-15-6 Alternators and Starter Motors

103000
PN=210
 Niehoff 24-Volt, 50-Amp Alternator Repair

9. Disconnect wire leads (1—3).

10. Adjust ohmmeter to zero and check for continuity

between each of the black phase leads (1). If there is
no continuity, the stator is open and must be
replaced.

–UN–02APR90
11. Check for continuity between each phase lead (1—3)
and alternator housing. If there is continuity, the stator
is grounded and must be replaced.

T6103AH
1—Black Phase Leads
Check for Continuity
2—Phase Lead
3—Phase Lead

20
15
7

RG,RG34710,2103 –19–15MAR97–6/13

12. Adjust ohmmeter to zero. Check for 9—13 ohms

resistance between white field lead (1) and thinner
red field lead (2). If resistance is not within
specification, the coil or assembly must be replaced.

13. Check for continuity between either field lead and

–UN–02APR90
alternator housing. If there is continuity, replace the
forging and coil assembly and field coil.

T6103BK
1—White Field Lead
2—Red Field Lead

Field Leads

Continued on next page RG,RG34710,2103 –19–15MAR97–7/13

CTM77 (30OCT00) 20-15-7 Alternators and Starter Motors

103000
PN=211
 Niehoff 24-Volt, 50-Amp Alternator Repair

14. Make sure all leads are disconnected from, and are
not touching, the heat sink assembly.

15. Check continuity between output terminal (1) and

each phase lead terminal (2). All readings should be
the same.

–UN–02APR90
16. Reverse leads and repeat step 15. All readings must
be opposite of those recorded in step 15. If any
reading is the same as in step 15, one or more

T6103BJ
diodes are defective and heat sink must be replaced.

Check Continuity
1—Output Terminal
2—Phase Lead Terminal

20
15
8

RG,RG34710,2103 –19–15MAR97–8/13

17. Check continuity between phase terminals (1) and

alternator housing. All readings must be the same.

18. Reverse probes and repeat step 17. If any reading is

the same as in step 17, a diode is defective and the
heat sink must be replaced.

–UN–02APR90
19. Remove heat sink (2).

T6103BH
1—Phase Terminals
2—Heat Sink

Check Continuity

Continued on next page RG,RG34710,2103 –19–15MAR97–9/13

CTM77 (30OCT00) 20-15-8 Alternators and Starter Motors

103000
PN=212
 Niehoff 24-Volt, 50-Amp Alternator Repair

20. Remove nuts (1) to remove regulator (2).

1—Nuts
2—Regulator

–UN–29MAR90
T6090AO1
Remove Nuts to Remove Regulator

20
15
9

RG,RG34710,2103 –19–15MAR97–10/13

21. Remove parts (1—5).

1—Nut
2—Special Washer (2 Used)
3—Rotor
4—Alternator

–UN–29MAR90
5—Shaft Assembly

T6090AU
Remove Parts

Continued on next page RG,RG34710,2103 –19–15MAR97–11/13

CTM77 (30OCT00) 20-15-9 Alternators and Starter Motors

103000
PN=213
 Niehoff 24-Volt, 50-Amp Alternator Repair

NOTE: Remove bearings and seal only for replacement.

22. Remove shaft seal (1) and front bearing (2) using a
D01061AA Blind Hole Puller Set.

23. Remove snap ring (4) and rear bearing (3).

–UN–25MAY89
1—Shaft Seal
2—Front Bearing
3—Rear Bearing

T6090AY
4—Snap Ring

Remove Bearings

20
15
10

RG,RG34710,2103 –19–15MAR97–12/13

24. Remove nuts from studs (3).

25. Hold front housing (1) upward and lightly tap housing
using a soft-faced hammer to remove shell (2).

NOTE: DO NOT soak front housing in solvent; wipe with

–UN–29MAR90
clean cloth.

26. Clean and inspect all parts for damage. Replace parts
as necessary.

T6090AL1
1—Front Housing
Clean and Inspect Parts
2—Shell
3—Studs

RG,RG34710,2103 –19–15MAR97–13/13

CTM77 (30OCT00) 20-15-10 Alternators and Starter Motors

103000
PN=214
 Niehoff 24-Volt, 50-Amp Alternator Repair

Assemble Niehoff 24-Volt, 50-Amp Alternator

NOTE: Apply LOCTITE 222 Thread Lock and Sealer

(low strength) on all cap screws and nuts when
assembling alternator.

–UN–29MAR90
1. Install short threaded end of studs (1 and 2) into
housing (3). Install shorter stud (1) in hole below
mounting ear.

T6099AP
1—Shorter Stud
2—Longer Stud
3—Housing Assemble Alternator

20
15
11

LOCTITE is a registered trademark of Loctite Corp. RG,RG34710,2104 –19–15MAR97–1/9

2. Align ground terminal (4) with shorter stud (2) and

phase and output leads (3) toward front housing (1).

3. Put shell assembly on stud.

4. Put phase and output leads (3) through opening in

–UN–25MAY89
front housing (1).

5. Push shell assembly against housing.

T6099AQ
6. Tap shell with a soft-faced hammer until shell seats in
front housing.
Shell Assembly
IMPORTANT: If the thicker stud nuts are not used, the
1—Front Housing and Field Winding Assembly
regulator support screw and threads 2—Shorter Stud
will engage when installing cover. 3—Phase and Output Leads
4—Ground Terminal
7. Loosely install three thicker flange head nuts. 5—Longer Stud (2 Used)

Continued on next page RG,RG34710,2104 –19–15MAR97–2/9

CTM77 (30OCT00) 20-15-11 Alternators and Starter Motors

103000
PN=215
 Niehoff 24-Volt, 50-Amp Alternator Repair

8.

Fill front and rear grease reservoir two-thirds full of

high-temperature, silicone-base grease.

9. Press front bearing (3) into housing (4) using a 44 mm

–UN–29MAR90
disk (1) (from D01045AA Bushing, Bearing and Seal
Driver Set) and press.

10. Put high-temperature, silicone-base grease on seal lip

T6093AG
and fill space between front bearing and seal.

11. Position seal (2) with open side toward front bearing Press Seal into Housing
and press seal into housing using a 44 mm disk (1).

12. Position rear bearing (5) with open side toward

20
15 housing.
12
13. Press rear bearing into alternator using a 38 mm disk
and press.

–UN–25MAY89
1—44 mm Disk
2—Seal

T6093AH
3—Front Bearing
4—Alternator Housing
5—Rear Bearing
Position Rear Bearing

RG,RG34710,2104 –19–15MAR97–3/9

14. Install snap ring (2) with flat side against bearing (1)
in housing core (3).

1—Bearing
2—Snap Ring
3—Housing Core
–UN–25MAY89
T6090AV

Install Snap Ring

Continued on next page RG,RG34710,2104 –19–15MAR97–4/9

CTM77 (30OCT00) 20-15-12 Alternators and Starter Motors

103000
PN=216
 Niehoff 24-Volt, 50-Amp Alternator Repair

15. Install key (5) in shaft (6).

16. Assemble parts (1—6) and tighten nut (1) to

specifications.

Specification

–UN–25MAY89
Pulley Nut—Torque ......................................................... 95 N•m (70 lb-ft)

17. Put high-temperature, silicone-base grease on shaft

large area.

T6099AO
1—Pulley Nut
2—Special Washer Assemble Parts
3—Pulley
4—Fan
5—Shaft Key
6—Shaft 20
15
13

RG,RG34710,2104 –19–15MAR97–5/9

18. Carefully put shaft assembly (5) in front housing (4).

19. Assemble parts (1—3) and tighten rotor nut to

specifications.

Specification

–UN–29MAR90
Rotor Nut—Torque .......................................................... 75 N•m (55 lb-ft)

IMPORTANT: Correct rotor-to-stator clearance is

essential to operation of alternator.

T6090AU
20. Put a 25 x 76 mm (1 x 3 in.) piece of 0.2 mm
(0.008 in.) shim stock between each pole of the rotor Assemble Parts
and adjacent poles of stator.
1—Rotor Nut
2—Special Washer (2 Used)
IMPORTANT: Shims must not overlap.
3—Rotor
4—Front Housing and Field Winding Assembly
21. Move stator in shell for best free movement of shims. 5—Shaft Assembly

Continued on next page RG,RG34710,2104 –19–15MAR97–6/9

CTM77 (30OCT00) 20-15-13 Alternators and Starter Motors

103000
PN=217
 Niehoff 24-Volt, 50-Amp Alternator Repair

22. Tighten the three thicker flange hex nuts (2) to

specifications.

Specification
Front Housing-to-Stator Nuts—
Torque ........................................................................... 3.4 N•m (30 lb-in.)

23. Remove shims and check air gap between rotor and
stator poles.

Specification
Rotor-to-Stator Poles—Minimum
Air Gap ....................................................................... 0.13 mm (0.005 in.)

24. Install spacers (3).

25. Put white ground lead (4) on longer stud on alternator

20
15 right side.
14
26. Install regulator assembly (5) on studs with the four
voltage adjustment stand-offs toward ground terminal.

–UN–25MAY89
27. Install spring washers (6) and nuts (7). Tighten to
specifications.

T6090AW
Specification
Rotor Housing Stud Ground Lead
Nut—Torque ................................................. 2.8—3.4 N•m (25—30 lb-in.)
Assemble Parts

1—Stud
2—Flange Hex Nut (3 Used)
3—Spacer (3 Used)
4—Ground Lead (White)
5—Regulator
6—Spring Washer (3 Used)
7—Double Chamfered Nut (3 Used)

Continued on next page RG,RG34710,2104 –19–15MAR97–7/9

CTM77 (30OCT00) 20-15-14 Alternators and Starter Motors

103000
PN=218
 Niehoff 24-Volt, 50-Amp Alternator Repair

28. Attach field lead (2) to regulator stand-off. Tighten

screws to specifications.

Specification
Field Lead-to-Regulator Stand-Off
Cap Screw—Torque ..................................... 0.91—1.1 N•m (8—10 lb-in.)

–UN–29MAR90
29. Install output leads (3), relay lead (1), spring washers,
and screws. Tighten screws to specifications.

T6090AO
Specification
Output and Relay Lead Cap
Screws—Torque ............................................................ 2.3 N•m (20 lb-in.)
Leads
30. Install ground lead (4), spring washer, and screw.
1—Relay Lead (Brown)
Tighten screw to specifications. 2—Field Lead (White)
3—Output Lead (Red)
20
Specification 4—Ground Lead (White)
15
Ground Lead-to-Load Dump 5—Load Dump Assembly
15
Screw—Torque ............................................. 1.1—1.7 N•m (10—15 lb-in.) 6—Y- Lead (Brown)
7—Regulator
31. Install Y-lead (6), spring washer, and screw. Tighten 8—Nut (3 Used)
screw to specifications.

Specification
Y-Lead-to-Load Dump Screw—
Torque ............................................................ 0.9—1.1 N•m (8—10 lb-in.)

32. Put silicone rubber compound on all connections.

33. Install load dump, spring washers, and screws.

Tighten screws to specifications.

Specification
Load Dump Assembly Mounting
Cap Screws—Torque ..................................... 0.9—1.1 N•m (8—10 lb-in.)

34. Put silicone rubber compound on load dump screws.

Continued on next page RG,RG34710,2104 –19–15MAR97–8/9

CTM77 (30OCT00) 20-15-15 Alternators and Starter Motors

103000
PN=219
 Niehoff 24-Volt, 50-Amp Alternator Repair

35. Install housing and tighten nuts (2) to specifications.

Specification
Rear Housing Flange Nuts—
Torque ........................................................................... 5.1 N•m (45 lb-in.)

36. Install voltage adjusting screw (3), spring washer, and

cover (1).

37. Install regulator support screw (6) and spring washer.

38. Install plate cover and screws (5).

39. Install flat washer, nut and cover on relay terminal (7).

40. Install output stud (4).

20
15 41. If rotor and stator were removed from alternator
16
during repair, the magnetic field must be
re-established. (See REESTABLISHING MAGNETIC
FIELD, later in this group.)

–UN–29MAR90
42. Install alternator. (See your machine technical
manual.)

T6090AP
1—Cover
2—Lock Nut (3 Used)
3—Voltage Adjusting Screw
Components
4—Output Terminal
5—Name Plate Cover Cap Screw
6—Regulator Support Screw
7—Relay Terminal

RG,RG34710,2104 –19–15MAR97–9/9

CTM77 (30OCT00) 20-15-16 Alternators and Starter Motors

103000
PN=220
 Niehoff 24-Volt, 50-Amp Alternator Repair

Re-Establish Magnetic Field

1. Remove voltage adjustment cover.

2. Connect battery positive terminal to alternator output

and battery negative terminal to alternator ground.

–UN–25MAY89
3. Make a jumper wire (1) with an alligator clamp.
Remove 1.5 mm (1/16 in.) of insulation (2) from end of
wiring lead.

T6100AV
4. Connect clamp to ground stud (3) and put the other
end of wiring lead momentarily into hole (4) in end of Jumper Wire and Insulation
housing.

5. Remove jumper wire. Disconnect cables and install

20
cover. 15
17
6. After alternator is installed, check that magnetic field
has been established. Turn key switch on, then check

–UN–29MAR90
voltage reading (battery voltage) on voltmeter.

Start engine, then check voltage reading (charging

voltage) on the voltmeter. Charging voltage must be

T6100AU
higher than battery voltage to indicate magnetic field
has been established.
Ground Stud

1—Jumper Wire
2—1.5 mm (1/16 in.)
3—Ground Stud
4—Hole In Housing

RG,RG34710,2105 –19–15MAR97–1/1

CTM77 (30OCT00) 20-15-17 Alternators and Starter Motors

103000
PN=221
 Niehoff 24-Volt, 50-Amp Alternator Repair

20
15
18

CTM77 (30OCT00) 20-15-18 Alternators and Starter Motors

103000
PN=222
 Section 25
Denso Alternators
Contents

Page Page

Group 05—Denso Alternator Theory of Operation Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .25-15-2

Denso Alternator Operation . . . . . . . . . . . . . . . .25-05-1 Denso Charging Circuit Repair
Denso Regulator Operation . . . . . . . . . . . . . . . .25-05-2 Specifications (Alternators with Built-In
Group 10—Denso Alternator with Add-On Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . .25-15-3
Regulator Repair Denso Charging Circuit Test
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .25-10-1 Specifications (Alternators with Built-In
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .25-10-2 Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . .25-15-4
Denso Charging Circuit Repair Disassemble and Test Denso Alternator with
Specifications (Alternators with Add-On Built-In Regulator . . . . . . . . . . . . . . . . . . . . . .25-15-5
Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . .25-10-2 Disassemble Alternator . . . . . . . . . . . . . . . . . . .25-15-6
Denso Charging Circuit Test Assemble Denso Alternator . . . . . . . . . . . . . . .25-15-12
Specifications (Alternators with Add-On 25
Regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . .25-10-2
Disassemble Denso Alternator with
Add-On Regulator and Test Components . . .25-10-3
Separate Housing . . . . . . . . . . . . . . . . . . . . . . .25-10-4
Separate Housing and Remove Rear
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-10-5
Inspect Rear Bearing . . . . . . . . . . . . . . . . . . . .25-10-8
Install Rear Bearing. . . . . . . . . . . . . . . . . . . . . .25-10-8
Remove Stator, Rectifier Bridge and Brush
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-10-8
Test Brush Assembly . . . . . . . . . . . . . . . . . . . .25-10-9
Install New Brushes . . . . . . . . . . . . . . . . . . . .25-10-11
Inspect Stator . . . . . . . . . . . . . . . . . . . . . . . . .25-10-11
Test Stator for Grounds. . . . . . . . . . . . . . . . . .25-10-12
Test Stator for Open or Short . . . . . . . . . . . . .25-10-12
Test Diodes in Rectifier Bridge . . . . . . . . . . . .25-10-13
Test Diodes for Open or Short Circuit . . . . . . .25-10-13
Test Diode/Resistor Trio . . . . . . . . . . . . . . . . .25-10-14
Connect Stator Windings. . . . . . . . . . . . . . . . .25-10-15
Test Regulator . . . . . . . . . . . . . . . . . . . . . . . .25-10-15
Assemble Rear Frame . . . . . . . . . . . . . . . . . .25-10-16
Remove Pulley Nut . . . . . . . . . . . . . . . . . . . . .25-10-17
Remove and Inspect Front Bearing . . . . . . . . .25-10-17
Install Front Bearing Assembly . . . . . . . . . . . .25-10-18
Test Rotor for Grounds . . . . . . . . . . . . . . . . . .25-10-18
Test Rotor for Open or Shorted Circuits . . . . .25-10-19
Recondition Slip Rings . . . . . . . . . . . . . . . . . .25-10-19
Install Rotor and Front Housing. . . . . . . . . . . .25-10-20
Install Pulley Assembly . . . . . . . . . . . . . . . . . .25-10-21
Install Regulator . . . . . . . . . . . . . . . . . . . . . . .25-10-21

Group 15—Denso Alternator with Built-In Regulator

Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .25-15-1

CTM77 (30OCT00) 25-1 Alternators and Starter Motors

103000
PN=1
 Contents

25

CTM77 (30OCT00) 25-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Denso Alternator Theory of Operation
Denso Alternator Operation

The drawing at right shows alternator circuitry. Schematic

of regulator (E) has been simplified.

An alternator (unlike generator) uses a rotating magnetic

field with stationary windings. The magnetic field is
externally excited. This means that it requires an outside
current source. The rotor (F) consists of two interlocking
soft iron sections and a wire coil wrapped around an iron
core. When current is passed through the wire coil, the
rotor becomes an electromagnet.

The rotating magnetic field induces an alternating current

in the stator windings (G). This is converted to direct
current by six diodes in the rectifier bridge (H).

A capacitor inside rear housing protects rectifier bridge

and diode trio (D) from voltage surges. It also suppresses

–UN–29NOV89
radio interference.

This alternator uses an “A” field circuit with regulator 25

located after field. Full output is obtained by grounding 05

RW10118L
1
field.

A—Diode Denso Alternator Operation

B—Switch
C—Battery
D—Diode Trio
E—Regulator
F—Rotor (Field)
G—Stator
H—Rectifier Bridge

RG,RG34710,2106 –19–15MAR97–1/1

CTM77 (30OCT00) 25-05-1 Alternators and Starter Motors

103000
PN=225
 Denso Alternator Theory of Operation

Denso Regulator Operation

The solid-state regulator is mounted inside the alternator.

It controls output by controlling the current through the
field. In operation, the regulator has the following three
phases.

Phase I—Alternator Stopped

(Phase I also applies when alternator is running but only if

not running fast enough for output to exceed battery
voltage.)

1. Current flows from battery through key switch and

diode to terminal IG.

2. From there, current flows through resistor R1 to

transistor TR1 and turns it on.

–UN–29NOV89
3. Transistor TR1 then provides a path to ground so
current can flow through field, enabling alternator to
25 generate electricity.
05

RW10119L
2
4. Zener diode Z prevents flow of current from terminal IG
to transistor TR2. A Zener diode is a special type of
diode which will not permit current to pass until voltage Phase I—Alternator Stopped
reaches a certain preset level. If voltage exceeds that
level, current can pass through the Zener diode.

Continued on next page RG,RG34710,2107 –19–18OCT00–1/3

CTM77 (30OCT00) 25-05-2 Alternators and Starter Motors

103000
PN=226
 Denso Alternator Theory of Operation

Phase II—Generating Electricity

1. The diode trio, key switch, rectifier bridge, and terminal

1 all have equal voltage. Therefore, no current flows
through diodes.

2. Current, now coming from diode/resistor trio, still flows

through resistor R1 to turn on transistor TR1.

3. Transistor TR1 still provides a path to ground so

current can flow through field, enabling alternator to
generate electricity.

4. Since the field is rotating, it does generate electricity.

Alternating current is induced in the stator windings.
The rectifier bridge converts it to direction current,
providing current to run electrical accessories and
charge batteries.

–UN–29NOV89
5. Output voltage still has not reached critical voltage of
Zener diode Z, so no current can flow from terminal 2
to transistor TR2. 25
05

RW10120L
3

Phase II—Generating Electricity

RG,RG34710,2107 –19–18OCT00–2/3

Phase III—Shut-Off

1. Output voltage reaches critical voltage of Zener diode

Z.

2. Current can now pass through Zener diode Z to turn

on transistor TR2.

3. Transistor TR2 now provides a direct path to ground

for any current coming through resistor R1.

4. This cuts off the current to transistor TR1, turning it off.

There is now no path to ground for current through
field.

5. Current through field is shut off instantly, and alternator

stops generating electricity.

6. Phases II and III are repeated many times per second

–19–28NOV89

to maintain voltage at proper level.

RW10121L

Phase III—Shut-Off
RG,RG34710,2107 –19–18OCT00–3/3

CTM77 (30OCT00) 25-05-3 Alternators and Starter Motors

103000
PN=227
 Denso Alternator Theory of Operation

25
05
4

CTM77 (30OCT00) 25-05-4 Alternators and Starter Motors

103000
PN=228
 Group 10
Denso Alternator with Add-On Regulator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B74 –19–21SEP00–1/3

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
25
10
1

RW11274
JT05791

OUO1004,0000B74 –19–21SEP00–2/3

Alternator Pulley Tool Set . . . . . . . . . . . . . . . . JD306A

Remove and install alternator pulley retaining nut.

–UN–31JAN89
R26528

JD306A

OUO1004,0000B74 –19–21SEP00–3/3

CTM77 (30OCT00) 25-10-1 Alternators and Starter Motors

103000
PN=229
 Denso Alternator with Add-On Regulator Repair

Other Material

Number Name Use

(U.S.) Chevron SR1-2 Grease Lubricate alternator bearings.

(U.S.) 400-Grit Silicon Carbide Paper or 00 Polish slip rings.

Sandpaper

OUO1004,0000B76 –19–21SEP00–1/1

Denso Charging Circuit Repair Specifications

(Alternators with Add-On Regulator)

Item Measurement Specification

Used Brushes Minimum Exposed Length 6 mm (0.25 in.)

25
10 New Brushes Exposed Length 16 mm (0.625 in.)
2
Pulley Nut Torque 66—87 N•m (50—65 lb-ft)

OUO1004,0000B77 –19–21SEP00–1/1

Denso Charging Circuit Test Specifications

(Alternators with Add-On Regulator)
John Deere Denso Voltage Rated Output
Part No. Part No. (Amps)
AN193461 100211—5800 12 90
AR87205 100211—0081 12 90
AR93448 100211—0290, 100211—0291 12 90
AT103789 100211—0292 12 90

Item Specification
Regulator Output Voltage 13.8—14.8 volts

NOTE: Earlier Denso alternators may have the original

Nippondenso label.

RG,RG34710,2110 –19–08SEP00–1/1

CTM77 (30OCT00) 25-10-2 Alternators and Starter Motors

103000
PN=230
 Denso Alternator with Add-On Regulator Repair

Disassemble Denso Alternator with Add-On Regulator and Test Components

–UN–13APR89
R31563
25
10
Denso Alternator 3

A—Fan G—Bearing Retainer M—Regulator Cover S—Insulator

B—Front Housing H—Condenser N—Through Bolt (4 Used) T—Brush (2 Used)
C—Felt Washer (2 Used) I—Insulating Bushing O—Rear Housing U—Stator
D—Collar (2 Used) J—Insulating Bushing P—Felt Washer V—Rear Bearing
E—Front Bearing K—Rear Cover Q—Insulating Bushings W—Felt Washer
F—O-Ring L—Voltage Regulator R—Rectifier Bridge X—Rotor

Disassemble alternator only after making an external IMPORTANT: Never immerse alternator in cleaning
examination and performing alternator tests outlined in solvent. Remove dirt and grease by
your machine technical manual. scraping and using a stiff brush with
solvent. Dry with compressed air.
Refer to your machine technical manual for removal of
alternator from engine.

RG,RG34710,2111 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-3 Alternators and Starter Motors

103000
PN=231
 Denso Alternator with Add-On Regulator Repair

Separate Housing

1. Remove four through bolts (A).

NOTE: Pulley need not be removed at this time. See

REMOVE PULLEY NUT in this group if only

–UN–10NOV88
pulley service is required.

IMPORTANT: Inserting screwdriver blade farther than

1.6 mm (1/16 in.) may damage stator

RW6037
windings.

2. Separate front and rear housings. Carefully pry Remove Through Bolts
between the two end frames with a screwdriver on A—Through Bolts (4 Used)
each side.

3. If housings separate, set alternator on rear housing

and slide off from housing; go to INSPECT REAR
BEARING, later in this group.

4. In some cases, removing the rotor and rear bearing

25 may be difficult. A vacuum may be created in the
10 bearing cavity as the bearing and rotor are removed. If
4
this happens, see SEPARATE HOUSING AND
REMOVE REAR BEARING, later in this group.

RG,RG34710,2112 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-4 Alternators and Starter Motors

103000
PN=232
 Denso Alternator with Add-On Regulator Repair

Separate Housing and Remove Rear Bearing

IMPORTANT: Mark must be centered to prevent

off-center drilling of rotor shaft if
tapping is later required. (See step 3
below.)

1. Carefully center punch and drill a 2 mm (1/16 in.) hole

(A) in the center of the rear housing. This will allow air
into the bearing bore as bearing is removed.

A—Center Punch On Center

B—19 mm (0.741 in.)
C—28 mm (1.092 in.)

–UN–10NOV88
25
10
5

RW12623
Center Punch

Continued on next page RG,RG34710,2113 –19–15MAR97–1/4

CTM77 (30OCT00) 25-10-5 Alternators and Starter Motors

103000
PN=233
 Denso Alternator with Add-On Regulator Repair

Again try to remove rotor and bearing. If rotor and

bearing still cannot be removed, go to step 2. If
bearing remains in end frame, do the following;

a. Install a pin (A) to hold brushes fully retracted.

b. Fill cavity behind bearing with grease through

–UN–10NOV88
bearing bore. Place end frame on a hard, flat
surface. Place a 12 mm (0.47 in.) screw or rod into
bearing bore.

RW6054
c. Strike end of screw or rod sharply with a hammer to
hydraulically remove the bearing. Filling the cavity Remove Rotor and Bearing
four to six times may be required to completely
remove the bearing. Continue repairing alternator as A—Pin
detailed under INSPECT REAR BEARING later in B—Alternator
this group.

2. Enlarge drilled hole with a 1/4 in. drill, 13 mm (1/2 in.)

deep.

25 3. Measure length of a 1/16-27 NPT tap (JDG417, or

10 equivalent) . Turn tap in hole until exposed end is 10—
6
11 mm (0.390—0.430 in.) less than total length of tap.

Continued on next page RG,RG34710,2113 –19–15MAR97–2/4

CTM77 (30OCT00) 25-10-6 Alternators and Starter Motors

103000
PN=234
 Denso Alternator with Add-On Regulator Repair

4. Install a 1/16-27 NPT grease zerk (A) firmly in tapped

hole.

5. Attach a grease gun to zerk and fill bearing cavity with

grease. Extend handle of grease gun and apply
several quick, pumping strokes until alternator frame

–UN–18APR90
and stator separate approximately 3—6 mm (1/8—1/4
in.)

IMPORTANT: Inserting screwdriver blade farther than

RW12628
1.6 mm (1/16 in.) may damage stator
windings.
1/16-27 NPT Grease Zerk
6. Using two screwdrivers, complete alternator separation
A—Grease Zerk
by prying between stator and front end frame.

7. Set alternator on rear housing and lift front housing.

25
10
7

RG,RG34710,2113 –19–15MAR97–3/4

8. Remove grease zerk and install a 15H560 Allen plug

(A) in drilled hole. If plug extends into bearing cavity
more than 2 mm (1/6 in.), grind a tapper on end of
plug and reinstall. Continue repairing alternator at
INSPECT REAR BEARING, later in this group.

–UN–18APR90
A—15H560 Allen Plug

RW12627
15H560 Allen Plug

RG,RG34710,2113 –19–15MAR97–4/4

CTM77 (30OCT00) 25-10-7 Alternators and Starter Motors

103000
PN=235
 Denso Alternator with Add-On Regulator Repair

Inspect Rear Bearing

1. Check bearing ID and OD for damage.

2. Make sure bearing turns freely.

Replace bearing as required.

RG,RG34710,2114 –19–15MAR97–1/1

Install Rear Bearing

IMPORTANT: Do not clean bearing in solvent.

1. Install a pin to hold brushes fully retracted. Clean

grease and chips from bearing cavity.

–UN–10NOV88
25
2. Wipe bearing (A), bearing cavity and felt washers (B)
10
8 with a clean cloth.

RW12629
3. Coat bearing with a thin coat of grease to aid in
installation of bearing in rear housing.
Install Rear Bearing
4. If a small hole 2 mm (1/16 in.) was drilled during
A—Bearing
disassembly, seal with a silicone sealer to prevent B—Felt Washers
contaminant entry.

RG,RG34710,2115 –19–15MAR97–1/1

Remove Stator, Rectifier Bridge and Brush

Assembly

1. Remove screws (A), regulator cover (B) and regulator

(C).
–UN–10NOV88

2. Disconnect condenser wire (D) and remove condenser.

A—Screws
RW10654

B—Regulator Cover
C—Regulator
D—Condenser Wire
Regulator Components

Continued on next page RG,RG34710,2116 –19–15MAR97–1/2

CTM77 (30OCT00) 25-10-8 Alternators and Starter Motors

103000
PN=236
 Denso Alternator with Add-On Regulator Repair

3. Remove four nuts (A), insulators (B), condenser (C)

and rear cover (D).

4. Lift out stator, rectifier bridge and brush assembly.

A—Nuts

–UN–10NOV88
B—Insulators
C—Condenser
D—Rear Cover

RW6043
Lift Out Parts

RG,RG34710,2116 –19–15MAR97–2/2

25
Test Brush Assembly 10
9
1. Inspect assembly for damage. Be sure brushes slide
freely. Be sure springs hold brushes firmly against slip
rings.

–UN–31JAN89
R78111K1
Inspect Brush Assembly

Continued on next page RG,RG34710,2117 –19–15MAR97–1/3

CTM77 (30OCT00) 25-10-9 Alternators and Starter Motors

103000
PN=237
 Denso Alternator with Add-On Regulator Repair

2. Measure brushes for wear. If exposed length is not

within specification, replace brushes.

Specification
Used Brushes—Minimum
Exposed Length................................................................. 6 mm (0.25 in.)

–UN–31JAN89
R78111L1
Measure Brushes for Wear

RG,RG34710,2117 –19–15MAR97–2/3

25
10 3. Connect ohmmeter (or test light) to check continuity
10 between the two brushes and between each brush and
ground. There should be no continuity.

If brush holder is defective, rectifier bridge must be

replaced.

–UN–31JAN89
R31565
Check Continuity

RG,RG34710,2117 –19–15MAR97–3/3

CTM77 (30OCT00) 25-10-10 Alternators and Starter Motors

103000
PN=238
 Denso Alternator with Add-On Regulator Repair

Install New Brushes

1. Install new brushes, blocking them in position so that

exposed length (A) is within specification.

Specification

–UN–10NOV88
New Brushes—Exposed Length ................................... 16 mm (0.625 in.)

2. Solder brush leads firmly in this position. Cut off

excess length of leads.

RW12624
A—Brush Exposed Length 16 mm (5/8 in.)
Exposed Brush Length

RG,RG34710,2118 –19–15MAR97–1/1

25
Inspect Stator 10
11
1. Inspect stator (A) for defective insulation.

2. Check for discoloration or a burned odor indicating a

short circuit.

–UN–10NOV88
3. Replace stator if you find any defect.

RW6020
A—Stator

Inspect Stator

RG,RG34710,2119 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-11 Alternators and Starter Motors

103000
PN=239
 Denso Alternator with Add-On Regulator Repair

Test Stator for Grounds

1. Connect ohmmeter (A) (or test lamp) to stator lead (B)

and stator frame (C).

2. Repeat test for each stator lead.

–UN–10NOV88
3. If test shows continuity, replace stator.

A—Ohmmeter

RW6045
B—Stator Lead
C—Stator Frame
Test Stator for Grounds

RG,RG34710,2120 –19–15MAR97–1/1

25
10
Test Stator for Open or Short
12
NOTE: Stator cannot be tested for open circuit unless
windings are disconnected.

A stator will occasionally exhibit an open or short circuit

only when hot, making the defect even more difficult to
diagnose.

If a defective stator is suspected, but cannot be

confirmed, recheck all other electrical components. If a
problem is not found elsewhere, replace stator.

RG,RG34710,2121 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-12 Alternators and Starter Motors

103000
PN=240
 Denso Alternator with Add-On Regulator Repair

Test Diodes in Rectifier Bridge

NOTE: Stator must be disconnected from rectifier bridge

to test diodes. Test diodes only if diagnostic tests
indicate defective diodes.

–UN–10NOV88
1. Use a soldering iron (A) of at least 120-watt capacity.

2. Grasp diode connector (B) with needle-nose pliers to

serve as heat sink and to protect diode from

RW6046
overheating.
Test Diodes in Rectifier Bridge
3. Work quickly to disconnect.
A—Soldering Iron
B—Diode Connector

RG,RG34710,2122 –19–15MAR97–1/1

25
Test Diodes for Open or Short Circuit 10
13
1. Connect one ohmmeter probe (A) to metal base.

2. With other ohmmeter probe (B), touch each of three

diodes (C). Note ohmmeter readings.

–UN–10NOV88
A—Ohmmeter Probe
B—Ohmmeter Probe
C—Diodes

RW6047
Test Diodes for Open or Short Circuit

Continued on next page RG,RG34710,2123 –19–15MAR97–1/2

CTM77 (30OCT00) 25-10-13 Alternators and Starter Motors

103000
PN=241
 Denso Alternator with Add-On Regulator Repair

3. Reverse ohmmeter probes (A and B) and make the

same checks. Note ohmmeter readings.

4. Perform steps 1 through 3 on diodes (C) on the

opposite side of rectifier bridge.

–UN–10NOV88
Ohmmeter readings should indicate that each diode
has continuity in only one direction. A shorted diode
would have continuity in both directions. An open diode
would not have continuity in either direction.

RW6048
A—Ohmmeter Probe Reverse Check
B—Ohmmeter Probe
C—Diodes

RG,RG34710,2123 –19–15MAR97–2/2

25
10
Test Diode/Resistor Trio
14
1. Touch one ohmmeter probe (A) against terminal “G”.
Touch other ohmmeter probe (B) to the NEARER
terminal (C) (the terminal that would be connected to
stator windings) of each of the two diodes (D). Note

–UN–10NOV88
ohmmeter readings.

2. Reverse ohmmeter probe.

RW6049
Each diode should have continuity in only one
direction. If either diode is defective, rectifier bridge
must be replaced. Test Diode/Resistor Trio

A—Ohmmeter Probe
B—Ohmmeter Probe
C—Stator Winding Terminal
D—Diodes

Continued on next page RG,RG34710,2124 –19–15MAR97–1/2

CTM77 (30OCT00) 25-10-14 Alternators and Starter Motors

103000
PN=242
 Denso Alternator with Add-On Regulator Repair

3. Place one ohmmeter probe (A) against terminal “G”.

Touch probe (B) to NEARER terminal of resistor (C).

4. Resistance should be about 100 ohms. If resistor is

defective, replace rectifier bridge.

–UN–10NOV88
A—Ohmmeter Probe
B—Ohmmeter Probe
C—Resistor Terminal

RW6050
Check Resistor

RG,RG34710,2124 –19–15MAR97–2/2

25
Connect Stator Windings 10
15
1. Use a soldering iron (A) with 120-watt capacity.

2. Grasp diode connector (B) with needle-nose pliers to

act as heat sink.

–UN–10NOV88
3. Connect triple leads of stator winding to side of rectifier
bridge. Connect each triple lead to both a rectifier
diode and the diode/resistor trio.

RW6046
4. Solder all nine connections quickly to prevent
Connect Stator Windings
overheating. Use rosin-core solder only.
A—Soldering Iron
B—Diode Connector

RG,RG34710,2125 –19–15MAR97–1/1

Test Regulator

The only suitable way to test a regulator is to install it on

an alternator known to be good and measure regulator
output voltage. Normal regulator voltage is 13.8—14.8
volts. Replace regulator if voltage is too high or too low.

RG,RG34710,2126 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-15 Alternators and Starter Motors

103000
PN=243
 Denso Alternator with Add-On Regulator Repair

Assemble Rear Frame

1. Place insulating bushings (A) on two screws on output

side of rectifier bridge.

–UN–10NOV88
A—Insulating Bushings

RW6051
Insulating Bushings

RG,RG34710,2127 –19–15MAR97–1/2

25
10 2. Install rectifier bridge/stator in rear housing.
16
3. Install rear cover (A).

4. Install insulator bushings (B).

–UN–10NOV88
5. Install condenser (C) and attach condenser wire (D).

A—Rear Cover
B—Insulator Bushings

RW6052
C—Condenser
D—Condenser Wire
Install Parts

RG,RG34710,2127 –19–15MAR97–2/2

CTM77 (30OCT00) 25-10-16 Alternators and Starter Motors

103000
PN=244
 Denso Alternator with Add-On Regulator Repair

Remove Pulley Nut

NOTE: Pulley nut need not be removed if you are certain

that front bearing is in good condition. Separate
housing as described earlier in this group and
leave rotor in front housing.

–UN–15DEC88
1. Install a 22 mm socket (A) on JD306A-1 Tool (B) (from
JD306A Alternator Pulley Nut Tool Set) to hold nut.

RW6036
2. Install JD306A-2 (C) on hex shaft of JD306A-1 to hold
rotor shaft.
Remove Pulley Nut
3. Hold rotor and remove nut, pulley and fan. A—22 mm Socket
B—JD306A-1 Tool
C—JD306A-2 Tool

RG,RG34710,2128 –19–15MAR97–1/1

25
Remove and Inspect Front Bearing 10
17
1. Remove three screws (A) holding bearing retainer to
front housing.

A—Screws (3 Used)

–UN–10NOV88
RW6038
Remove Screws

Continued on next page RG,RG34710,2129 –19–15MAR97–1/2

CTM77 (30OCT00) 25-10-17 Alternators and Starter Motors

103000
PN=245
 Denso Alternator with Add-On Regulator Repair

2. Remove bearing retainer (A), collars (B) and bearing

(C).

3. Inspect bearing and bearing bore (D) for damage.

Bearing may be reused, if not damaged.

–UN–10NOV88
4. Inspect collars (B) and felt washers on collars. Also
inspect O-ring on bearing retainer.

A—Bearing Retainer

RW6039
B—Collars
C—Bearing
D—Bearing Bore Inspect Parts for Damage

RG,RG34710,2129 –19–15MAR97–2/2

25
10
Install Front Bearing Assembly
18
1. Wipe bearing, bearing cavity, collars and felt washers
with a clean cloth.

2. Coat bearing with a thin film of grease to aid

installation of bearing in housing.

3. Install bearing assembly.

RG,RG34710,2130 –19–15MAR97–1/1

Test Rotor for Grounds

1. Use an ohmmeter (A) or test lamp to test for continuity.

2. Attach ohmmeter to rotor shaft (B) and each slip ring

(C).
–UN–10NOV88

3. Replace rotor if test shows continuity.

A—Ohmmeter
RW6017

B—Rotor Shaft
C—Slip Rings
Test Rotor for Grounds

RG,RG34710,2131 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-18 Alternators and Starter Motors

103000
PN=246
 Denso Alternator with Add-On Regulator Repair

Test Rotor for Open or Shorted Circuits

1. Connect ohmmeter (A) to each slip ring (B and C) to

measure resistance.

2. Resistance should be 3—5 ohms. Replace rotor if

–UN–10NOV88
resistance is too high or too low.

A—Ohmmeter
B—Slip Ring

RW6018
C—Slip Ring

Measure Resistance

RG,RG34710,2132 –19–15MAR97–1/1

25
Recondition Slip Rings 10
19
NOTE: Rough or out-of-round slip rings can cause short
brush life.

1. Mount rotor assembly on lathe.

2. If slip rings are rough or scored, turn them just enough

to eliminate roughness. If slip rings are out-of-round,
turn them to within 0.05 mm (0.002 in.) of total
indicator reading.

3. Polish slip rings sparingly with No. 00 sandpaper or

400-grit silicon carbide paper.

IMPORTANT: Clean rotor and stator with compressed

air only. Cleaning solvent will damage
insulation.

RG,RG34710,2133 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-19 Alternators and Starter Motors

103000
PN=247
 Denso Alternator with Add-On Regulator Repair

Install Rotor and Front Housing

1. Push back brushes to clear rear bearing.

2. Insert pin (A) through hole in rear housing to hold

brushes fully retracted.

–UN–10NOV88
3. Place felt washer on rear bearing end of rotor shaft,
install rotor in rear housing (B) and remove wire. Be
sure brushes have good contact with rotor slip rings.

RW6054
A—Pin
B—Rear Housing Install Rotor and Front Housing

RG,RG34710,2134 –19–15MAR97–1/2

25
10 4. Slide front housing (A) onto rotor shaft and secure with
20 four through bolts (B). Rotate rotor to ensure that it is
free from any interferences.

A—Front Housing

–UN–10NOV88
B—Through Bolts (4 Used)

RW6055
Secure Front Housing

RG,RG34710,2134 –19–15MAR97–2/2

CTM77 (30OCT00) 25-10-20 Alternators and Starter Motors

103000
PN=248
 Denso Alternator with Add-On Regulator Repair

Install Pulley Assembly

Install fan, pulley, washer and pulley nut. Tighten pulley

nut to specifications using JD306A Alternator Pulley Nut
Tool.

–UN–15DEC88
Specification
Pulley Nut—Torque .......................................... 66—87 N•m (50—65 lb-ft)

1. Install a 22 mm socket (A) on JD306A-1 (B) to hold

RW6036
nut.

2. Install JD306A-2 (C) on hex shaft of JD306A-1 to hold Install Pulley Assembly
rotor shaft.
A—22 mm Socket
B—JD306A-1 Tool
3. Hold rotor shaft and tighten nut to torque above. C—JD306A-2 Tool

RG,RG34710,2135 –19–15MAR97–1/1

25
Install Regulator 10
21
1. Slip insulator (A) over regulator terminals. Slip it back
into notches at base of terminals.

2. Attach regulator (B) and cover (C).

–UN–10NOV88
Refer to your machine technical manual for alternator
installation and correct V-belt adjustments.

RW6053
A—Insulator
B—Regulator
C—Cover Install Regulator

RG,RG34710,2136 –19–15MAR97–1/1

CTM77 (30OCT00) 25-10-21 Alternators and Starter Motors

103000
PN=249
 Denso Alternator with Add-On Regulator Repair

25
10
22

CTM77 (30OCT00) 25-10-22 Alternators and Starter Motors

103000
PN=250
 Group 15
Denso Alternator with Built-In Regulator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B78 –19–21SEP00–1/4

Alternator Pulley Tool Set . . . . . . . . . . . . . . . . JD306A

Remove and install alternator pulley retaining nut.

–UN–31JAN89
25
15
1

R26528
JD306A

OUO1004,0000B78 –19–21SEP00–2/4

Alternator Pulley Tool Set . . . . . . . . . . . . . . . . JDG672

Remove and install alternator pulley retaining nut on

12-volt, 120-amp Denso alternator.
–UN–09JAN90
RG5495

JDG672

Continued on next page OUO1004,0000B78 –19–21SEP00–3/4

CTM77 (30OCT00) 25-15-1 Alternators and Starter Motors

103000
PN=251
 Denso Alternator with Built-In Regulator Repair

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B78 –19–21SEP00–4/4

25
15
Other Material
2
Number Name Use

(U.S.) 400-Grit Silicon Carbide Paper or 00 Polish slip rings.

Sandpaper

(U.S.) Chevron SR1-2 Grease Lubricate alternator bearing

OUO1004,0000B7A –19–21SEP00–1/1

CTM77 (30OCT00) 25-15-2 Alternators and Starter Motors

103000
PN=252
 Denso Alternator with Built-In Regulator Repair

Denso Charging Circuit Repair Specifications

(Alternators with Built-In Regulator)

Item Measurement Specification

New Brush Exposed Length 10.5 mm (0.40 in.)

Used Brush Minimum Exposed Length 4.5 mm (0.18 in.)

Rotor Slip Ring OD 14.0—14.4 mm (0.55—0.57 in.)

Rear End Cover Torque 4.5 N•m (40 lb-in.)

Drive End-to-Rear End Frame Torque 4.5 N•m (40 lb-in.)

IC Regulator Torque 2.0 N•m (18 lb-in.)

Brush Assembly Torque 2.0 N•m (18 lb-in.)

Rectifier Terminal Torque 6.5 N•m (57 lb-in.)

Pulley Nut Torque 94—127 N•m (70—95 lb-ft) 25

15
3

OUO1004,0000BB3 –19–28SEP00–1/1

CTM77 (30OCT00) 25-15-3 Alternators and Starter Motors

103000
PN=253
 Denso Alternator with Built-In Regulator Repair

Denso Charging Circuit Test Specifications

(Alternators with Built-In Regulator)
John Deere Denso Voltage Rated Output
Part No. Part No. (Amps)
CH10493 021000—7281 12 25
RE34888 100211—5030 12 90
RE34890 100211—7130 12 120
RE37201 100211—6031 12 120
RE42123 100211—6030 12 120
RE42778 100211—4200 12 40
RE44140 100311—6050 12 120
RE46043 100211—2470 12 60
RE46608 100211—6420 12 140
RE500226 101211—7780 12 140
RE500227 102211—1180 12 90
RE51921 101211—6050 12 120
RE51922 100211—6040 12 120
RE60745 101211—7130 12 120
25
RE65414 102211—0040 24 60
15
4 RE70268 101211—133 12 40
RE71763 5—101211—148 12 65
RE72917 101211—2471 12 60
RE72918 102211—5121 12 65

Item Specification
Regulator Output Voltage 13.9—15.1 volts

NOTE: Earlier Denso alternators may have the original

Nippondenso label.

RG,RG34710,2139 –19–08SEP00–1/1

CTM77 (30OCT00) 25-15-4 Alternators and Starter Motors

103000
PN=254
 Denso Alternator with Built-In Regulator Repair

Disassemble and Test Denso Alternator with Built-In Regulator

25
15
5

–UN–02FEB89
RG5480

Test Denso Alternator with Regulator

A—V-Ribbed Pulley F—Bearing (2 Used) K—“S” Terminal Insulator O—Brush Holder

B—Spacer Collar G—Bushing L—Rectifier P—Spring
C—Drive End Frame H—Retainer Plate M—IC Regulator Q—Brush
D—Stator I—Rotor N—Bearing Cover R—Rear End Cover
E—Stud Bolt J—Rear End Frame

RG,RG34710,2140 –19–15MAR97–1/1

CTM77 (30OCT00) 25-15-5 Alternators and Starter Motors

103000
PN=255
 Denso Alternator with Built-In Regulator Repair

Disassemble Alternator

NOTE: Pulley nut need not be removed if you are sure

that front bearing is in good condition. Separate
housing as described and leave rotor in front
housing.

–UN–09JAN90
Remove alternator pulley using JD306A Alternator Pulley
Tool Set.

RG5481
For 12-volt, 120-amp alternator, use JDG672 Alternator
Pulley Tool Set as follows:
Install Sockets
1. Install JDG672 Socket (A) on shaft nut. Hold socket
A—JDG672 Socket
using a 24 mm wrench as shown. B—Snap-On SIMM100, 10 mm Impact Socket

2. Install Snap-On SIMM100, 10 mm Impact Socket (B)

onto rotor shaft hex.

3. Hold rotor shaft and remove nut and pulley.

25
15
6

RG,RG34710,2141 –19–15MAR97–1/13

4. Remove nut and insulator from rectifier terminal (A).

5. Remove three nuts holding rear end cover to alternator

assembly and remove cover.

A—Rectifier Terminal

–UN–09JAN90
RG5482

Remove Nut from Rectifier Terminal

Continued on next page RG,RG34710,2141 –19–15MAR97–2/13

CTM77 (30OCT00) 25-15-6 Alternators and Starter Motors

103000
PN=256
 Denso Alternator with Built-In Regulator Repair

6. Remove rubber boot (A) from brush assembly.

7. Remove two screws securing brush holder assembly to

rectifier and remove brush holder assembly. Remove
gasket from below brushes.

–UN–09JAN90
A—Rubber Boot

RG5483
Remove Rubber Boot

RG,RG34710,2141 –19–15MAR97–3/13

25
8. Measure length of brush protruding from the brush 15
holder. 7

Replace brush assembly if length is not within

minimum serviceable length.

–UN–02MAR89
Specification
New Brush—Exposed Length ...................................... 10.5 mm (0.40 in.)
Used Brush—Minimum Exposed
Length ............................................................................. 4.5 mm (0.18 in.)

RG5484
Measure Length of Brush

Continued on next page RG,RG34710,2141 –19–15MAR97–4/13

CTM77 (30OCT00) 25-15-7 Alternators and Starter Motors

103000
PN=257
 Denso Alternator with Built-In Regulator Repair

9. Remove three screws securing IC regulator (A) to end

frame and remove regulator.

A—IC Regulator

–UN–09JAN90
RG5485
Remove IC Regulator Screws

RG,RG34710,2141 –19–15MAR97–5/13

25
15 10. Disconnect four stator lead wires. Remove rectifier
8 from alternator end frame.

11. Connect red lead of multimeter to output terminal (A)

of rectifier. Connect stator attaching points (B) with
the black lead of meter.

There should not be continuity.

12. Reverse polarity of multimeter leads and repeat test

outlined in step 11.

–UN–02MAR89
There should be continuity.

If there is continuity in both directions, diode is

shorted. If no continuity in either direction, diode is

RG5487
open.
Check Continuity
If either diode is defective, rectifier bridge must be
replaced. A—Rectifier Output Terminal
B—Stator Attaching Points

Continued on next page RG,RG34710,2141 –19–15MAR97–6/13

CTM77 (30OCT00) 25-15-8 Alternators and Starter Motors

103000
PN=258
 Denso Alternator with Built-In Regulator Repair

13. Remove four rubber bushings (A) from stator leads.

Do not stretch stator leads.

14. Remove four nuts (B) from stud bolts that hold drive
and rear end frames together.

A—Rubber Bushings (4 Used)

B—Nuts (4 Used)

–UN–09JAN90
RG5488
Remove Nuts and Bushings

RG,RG34710,2141 –19–15MAR97–7/13

25
15. Carefully insert two flat screwdrivers in opposite 15
openings between front and rear end housing. 9

IMPORTANT: DO NOT insert screwdriver blade more

than 1.6 mm (1/16 in.). Damage to stator
windings may result.

16. Apply prying pressure at several points to separate

housings.

–UN–09JAN90
NOTE: If housings are difficult to separate, use a jaw-type
puller to bear on rotor shaft and pull on rear end
frame.

RG5489
RG,RG34710,2141 –19–15MAR97–8/13

17. Remove rotor from housing by lightly tapping shaft

(as shown) with a soft-faced hammer. Be careful not
to drop rotor.
–UN–09JAN90
RG5490

Continued on next page RG,RG34710,2141 –19–15MAR97–9/13

CTM77 (30OCT00) 25-15-9 Alternators and Starter Motors

103000
PN=259
 Denso Alternator with Built-In Regulator Repair

18. Remove screws holding bearing retainer plate and

remove plate. Drive bearing from housing. Remove
bearing cover.

19. Install new bearing and bearing cover in housing

bore. Install bearing retainer plate and tighten screws

–UN–09JAN90
securely.

RG5491
RG,RG34710,2141 –19–15MAR97–10/13

20. Connect ohmmeter leads to each slip ring (as shown)

to measure resistance.

Resistance should be 2.0—4.0 ohms. Replace rotor if

resistance is not within specification.

–UN–09JAN90
21. Connect black (—) lead of ohmmeter to end of shaft
25
and the red (+) lead to each slip ring.
15
10
There should be no continuity (0.1 ohm or less).

RG5492
Replace rotor if test shows continuity.

RG,RG34710,2141 –19–15MAR97–11/13

22. Measure slip ring OD. Replace rotor if slip ring OD is

below the acceptable limit.

Specification
Rotor Slip Ring—OD ............................... 14.0—14.4 mm (0.55—0.57 in.)

23. If slip rings are rough or scored, turn them just

–UN–09JAN90

enough to eliminate roughness. Polish sparingly with

No. 00 sandpaper or 400-grit silicon carbide paper.
RG5493

Continued on next page RG,RG34710,2141 –19–15MAR97–12/13

CTM77 (30OCT00) 25-15-10 Alternators and Starter Motors

103000
PN=260
 Denso Alternator with Built-In Regulator Repair

IMPORTANT: Clean rotor and stator with compressed

air only. Cleaning solvent will damage
insulation.

NOTE: Remove bearing only if replacement is necessary.

–UN–09JAN90
24. If necessary, remove bearing from rotor shaft using a
puller as shown. If desired, rotor may be clamped in a
soft-jawed vise.

RG5494
RG,RG34710,2141 –19–15MAR97–13/13

25
15
11

CTM77 (30OCT00) 25-15-11 Alternators and Starter Motors

103000
PN=261
 Denso Alternator with Built-In Regulator Repair

Assemble Denso Alternator

25
15

–UN–02FEB89
12

RG5479
Assemble Denso Alternator

A—Driver End Frame E—Connector I—Slip Ring L—Rotor

B—Rear End Frame F—IC Regulator J—Rectifier M—Bearing (2 Used)
C—Stator Windings G—Spring K—Rear End Cover N—Pulley
D—“S” Terminal H—Brush

Assemble alternator in the reverse sequence of 4. Torque all hardware to specifications.

disassembly procedure while paying close attention to
the following details: Specification
Rear End Cover—Torque ....................................... 4.5 N•m (40 lb-in.)
Drive End-to-Rear End
1. If one bearing needs replacing, replace both Frame—Torque ....................................................... 4.5 N•m (40 lb-in.)
bearings as a set. Lubricate bearings with grease. IC Regulator—Torque............................................. 2.0 N•m (18 lb-in.)
Brush Assembly—Torque ....................................... 2.0 N•m (18 lb-in.)
2. Be sure screws securing IC regulator are in the Rectifier Terminal—Torque..................................... 6.5 N•m (57 lb-in.)
correct position, so that too long of a screw will not Pulley Nut—Torque ................................. 94—127 N•m (70—95 lb-ft)
touch rear end frame and cause battery
overcharging.

3. Compress brush springs during assembly for

clearance past slip rings.

RG,RG34710,2142 –19–15MAR97–1/1

CTM77 (30OCT00) 25-15-12 Alternators and Starter Motors

103000
PN=262
 Section 30
Robert Bosch Alternators
Contents

Page

Group 05—Robert Bosch Alternator Theory of

Operation
Function of Alternator . . . . . . . . . . . . . . . . . . . .30-05-1

Group 10—Robert Bosch Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
Robert Bosch Charging Circuit Repair
Specifications . . . . . . . . . . . . . . . . . . . . . . . .30-10-2
Robert Bosch Charging Circuit Test
Specifications . . . . . . . . . . . . . . . . . . . . . . . .30-10-3
Alternator, Section View . . . . . . . . . . . . . . . . . .30-10-4
Alternator Removal . . . . . . . . . . . . . . . . . . . . .30-10-5
Removing Brush Holder with Regulator. . . . . . .30-10-5
Alternator Disassembly . . . . . . . . . . . . . . . . . . .30-10-6
Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . .30-10-6
Diode Plate Removal . . . . . . . . . . . . . . . . . . . .30-10-7
Alternator Exploded View . . . . . . . . . . . . . . . . .30-10-8
30
Testing Rotor for Short Circuit . . . . . . . . . . . . . .30-10-9
Testing Rotor for Ground. . . . . . . . . . . . . . . . . .30-10-9
Testing Slip Rings and Rotor Shaft for Radial
Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-10
Turning Down Slip Rings. . . . . . . . . . . . . . . . .30-10-10
Testing Stator Coil for Short Circuit . . . . . . . . .30-10-11
Testing Stator Coil for Grounds . . . . . . . . . . . .30-10-11
Replacing Carbon Brushes . . . . . . . . . . . . . . .30-10-12
Replacing Ball Bearings . . . . . . . . . . . . . . . . .30-10-12
Checking Positive Diodes . . . . . . . . . . . . . . . .30-10-13
Checking Negative Diodes . . . . . . . . . . . . . . .30-10-14
Testing Exciting Diodes. . . . . . . . . . . . . . . . . .30-10-15
Diode Plate Installation . . . . . . . . . . . . . . . . . .30-10-16
Soldering Stator Coils . . . . . . . . . . . . . . . . . . .30-10-16
Pressing Ball Bearing onto Rotor Shaft . . . . . .30-10-17
Pressing Rotor into Drive End Frame . . . . . . .30-10-17
Assemble Alternator . . . . . . . . . . . . . . . . . . . .30-10-18
Installing Brush Holder with Regulator. . . . . . .30-10-18
Fan and Belt Pulley Installation . . . . . . . . . . . .30-10-19

CTM77 (30OCT00) 30-1 Alternators and Starter Motors

103000
PN=1
 Contents

30

CTM77 (30OCT00) 30-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Robert Bosch Alternator Theory of Operation
Function of Alternator

–UN–01FEB89
L110749
30
05
Bosch 14-Volt Alternator 1

A—Alternator C—Exciting Coil (Rotor) E—Battery G—Starter Motor Switch

B—Current Coil (Stator) D—Regulator F—Alternator Indicator Light

The Bosch 14-volt alternator is a 12-pole, self-induced diode and terminal B+ directly to the positive pole of
synchronous generator. The current coil is located in the battery.
the stator, and the exciting coil in the rotor. The
exciting current is supplied by the rectifier (terminal Alternator current is generated in each stator coil (B) of
D+) through the regulator, two carbon brushes and slip the alternator. During one revolution of the rotor (C),
rings to the exciting coil in the rotor. the voltage in the stator coil rises from 0 to the positive
maximum, drops to 0, rises to the negative maximum
The alternator is normally driven by a fan belt from the and again drops to 0. Then the process is repeated.
engine crankshaft. The rotor is supported by two
permanently lubricated bearings. As the stator coils are Y-connected, a three-phase or
alternating current is generated. The individual phases
The alternator generates alternating current which is are shifted 120°.
then transformed into direct current by the rectifier
diodes. A sealed electronic regulator is used to regulate the
alternator voltage. This regulator, which cannot be
The alternator windings are Y-connected. The coil adjusted, limits the alternator voltage to approximately
ends U, V and W (see illustration) are connected to 14 volts.
the rectifier diodes. The current flows through the

RG,RG34710,2143 –19–15MAR97–1/1

CTM77 (30OCT00) 30-05-1 Alternators and Starter Motors

103000
PN=265
 Robert Bosch Alternator Theory of Operation

30
05
2

CTM77 (30OCT00) 30-05-2 Alternators and Starter Motors

103000
PN=266
 Group 10
Robert Bosch Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B7C –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791
30
10
1

OUO1004,0000B7C –19–21SEP00–2/2

Other Material

Number Name Use

194891 (U.S.) Delco-Remy High Temperature Apply to end frame bearing seat.
Bearing Grease

OUO1004,0000BBF –19–19OCT00–1/1

CTM77 (30OCT00) 30-10-1 Alternators and Starter Motors

103000
PN=267
 Robert Bosch Alternator Repair

Robert Bosch Charging Circuit Repair

Specifications

Item Measurement Specification

Slip Rings Maximum Radial Runout 0.03 mm (0.0012 in.)

Rotor Shaft Maximum Radial Runout 0.05 mm (0.002 in.)

Slip Rings Minimum Length 20 mm (0.79 in.)

Slip Rings Minimum OD 26.8 mm (1.055 in.)

Used Brushes Minimum Exposed Length 5 mm (0.2 in.)

New Brushes Exposed Length 10 mm (0.4 in.)

Alternator Housing Cap Screws Torque 4.0—5.5 N•m (33—48 lb-in.)

Armature End Play 0.1—0.3 mm (0.004—0.012 in.)

Alternator Pulley Nut Torque 35—45 N•m (25—32 lb-ft)

OUO1004,0000B7F –19–21SEP00–1/1
30
10
2

CTM77 (30OCT00) 30-10-2 Alternators and Starter Motors

103000
PN=268
 Robert Bosch Alternator Repair

Robert Bosch Charging Circuit Test

Specifications
Rating
John Deere Robert Bosch Model/Series Volts Amps
Part No. Part No.
AE52707 F120 061 422 — 12 120
AE53101 9 120 060 042, 0 120 K1 12 (14) 120
484 017, 0 120 484 019
AH137883 0 120 484 011 K1 12 (14) 95
AL32141 0 120 339 512 — 12 (14) 33
AL35998 0 120 488 218 — 12 55
AL67175 0 120 402 318 — 12 55
AL78689 0 120 488 267 K1 12 (14) 55
AL78690 0 120 484 016 K1 12 (14) 85
AL78692 0 120 484 017 K1 12 (14) 120
AL81436 0 120 488 290 K1 12 (14) 55
AL81437 0 120 484 020 K1 12 (14) 85
AL81438 0 120 488 019 K1 12 (14) 120
AT161324 0 120 488 206 K1 24 (28) 45
AT168711 0 120 468 136 N1 24 (28) 80
AT173624 0 120 488 205, 0 120 K1 12 (14) 65
060 040
AT175194 9 120 060 041 K1 12 (14) 95
AT175195 9 120 060 039 K1 24 (28) 45 30
10
AT175839 0 120 468 055 N1R 12 (14) 135
3
AT185696 F 005 0022 — 24 45
AT208541 0 120 500 078 — 24 80
AT220393 F 005 A0 0023 — 12 65
AT220394 F 005 A0 0024 — 12 95
AT85458 0 122 469 004 N1 24 (28) 50
AT185951 F 005 A0 0025 — 12 120
AZ23575 0 120 339 549 — 12 (14) 35
AZ38462 0 120 484 012, 0 120 K1 12 (14) 95
402 566
RE36267 0 120 484 011 K1 12 (14) 90
RE36268 0 120 468 055 N1 12 (14) 135

Item Specification
Stator winding resistance 0.40—0.44 ohms
Rotor winding resistance 4.0—4.40 ohms

RG,RG34710,2145 –19–08SEP00–1/1

CTM77 (30OCT00) 30-10-3 Alternators and Starter Motors

103000
PN=269
 Robert Bosch Alternator Repair

Alternator, Section View

30
10
4

–UN–06APR89
L106767A

Alternator, Section View

A—Stator Assembly D—Bearing and End Frame G—Regulator I—Rotor

B—Stator Winding E—Slip Ring H—Bearing and Drive End
C—Heat Sink F—Carbon Brush Frame
RG,RG34710,2146 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-4 Alternators and Starter Motors

103000
PN=270
 Robert Bosch Alternator Repair

Alternator Removal

Disconnect ground straps of battery.

Disconnect cables from alternator.

–UN–11JUL89
Remove alternator per instructions in machine technical
manual.

L106768
Alternator Removal

RG,RG34710,2147 –19–15MAR97–1/1

Removing Brush Holder with Regulator

NOTE: Before dismantling alternator, first remove brush

holder with regulator so carbon brushes will not
break during disassembly.
30

–UN–11JUL89
10
5

L106769
Remove Brush Holder with Regulator

RG,RG34710,2148 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-5 Alternators and Starter Motors

103000
PN=271
 Robert Bosch Alternator Repair

Alternator Disassembly

Mark position of both bearing end frames and stator for

later assembly (A).

Press rotor out of drive end frame.

–UN–11JUL89
A—Position Marks

L106770
Mark End Frames and Stator

RG,RG34710,2149 –19–15MAR97–1/1

Stator Removal

Unsolder stator windings from diode leads of diode plate.

30

–UN–11JUL89
10
6

L106771
Unsolder Stator Windings

RG,RG34710,2150 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-6 Alternators and Starter Motors

103000
PN=272
 Robert Bosch Alternator Repair

Diode Plate Removal

Remove screws from connections “D+” and “B+”.

Lift out diode plate.

–UN–11JUL89
L106772
Diode Plate Removal

RG,RG34710,2151 –19–15MAR97–1/1

30
10
7

CTM77 (30OCT00) 30-10-7 Alternators and Starter Motors

103000
PN=273
 Robert Bosch Alternator Repair

Alternator Exploded View

30
10
8

–UN–06APR89
L106773
Alterator—Exploded View

1—Retaining Plate 8—Fan 15—Carbon Brush (2 Used) 24—Ball Bearing

2—Ball Bearing 9—Belt Pulley Repair Set 16—Gasket 25—Slip Ring
3—Washer 10—Snap Ring1 17—Suppression Capacitor 26—Rotor
4—Stator Coil 11—Hex Nut1 18—Cylinder Screw 27—Woodruff Key1
5—Drive End Frame 12—Screw with Spring Washer 19—Gasket 28—Screw with Spring Washer
6—Cylinder Screw (4 Used) (2 Used) 20—End Frame (3 Used)
7—Countersunk Screw (4 13—Regulator with Brush 21—Diode Plate 29—Protective Cap
Used)1 Holder 22—Spring Washer1 30—Repair Kit for Terminals
14—Compression Spring (2 23—O-Ring W, D+ and B+
Used)

1
Rotor Repair Kit.
RG,RG34710,2152 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-8 Alternators and Starter Motors

103000
PN=274
 Robert Bosch Alternator Repair

Testing Rotor for Short Circuit

With a test lamp:

Test lamp must light brightly.

–UN–11JUL89
With an ohmmeter:

Ohmmeter indication must be between 4.0 and 4.4 ohms.

L106774
If test fails, replace rotor.

Test Rotor for Short Circuit

RG,RG34710,2153 –19–15MAR97–1/1

Testing Rotor for Ground

Use an ohmmeter to test for continuity.

Attach ohmmeter to rotor and each slip ring.

30

–UN–11JUL89
Replace rotor if test shows continuity. 10
9

L106775
Test Rotor for Ground

RG,RG34710,2154 –19–21SEP00–1/1

CTM77 (30OCT00) 30-10-9 Alternators and Starter Motors

103000
PN=275
 Robert Bosch Alternator Repair

Testing Slip Rings and Rotor Shaft for Radial

Runout

Check maximum radial runout of slip rings and rotor

shaft.

–UN–11JUL89
Specification
Slip Rings—Maximum Radial
Runout ...................................................................... 0.03 mm (0.0012 in.)
Rotor Shaft—Maximum Radial
Runout ........................................................................ 0.05 mm (0.002 in.)

L106777
A—Rotor Shaft Test Point Rotor Shaft Test Point

RG,RG34710,2155 –19–15MAR97–1/1

Turning Down Slip Rings

Turn down slip rings to length of only (A).

Specification
30 Slip Rings—Minimum Length .......................................... 20 mm (0.79 in.)

–UN–11JUL89
10
10 Check diameter of slip rings.

Specification
Slip Rings—Minimum OD........................................... 26.8 mm (1.055 in.)

L106776
A—Slip Ring Length Turning Down Slip Rings

RG,RG34710,2156 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-10 Alternators and Starter Motors

103000
PN=276
 Robert Bosch Alternator Repair

Testing Stator Coil for Short Circuit

Test phase outlets with respect to each other as follows:

A and B; B and C; A and C.

With test lamp:

–UN–11JUL89
Test lamp must light up brightly

With ohmmeter:

L106778
Indications between 0.40 and 0.44 ohms.
Test Phase Outlets
If test fails, replace stator coil.
A—Phase Outlet
B—Phase Outlet
C—Phase Outlet

RG,RG34710,2157 –19–15MAR97–1/1

Testing Stator Coil for Grounds

Connect ohmmeter (or test lamp) to stator lead and stator

frame.

Repeat test for each stator lead. 30

–UN–11JUL89
10
11
If test shows continuity, replace stator.

L106779
Test Stator Coil for Grounds

RG,RG34710,2158 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-11 Alternators and Starter Motors

103000
PN=277
 Robert Bosch Alternator Repair

Replacing Carbon Brushes

Replace carbon brushes if dimension (A) is less than

specified.

Specification
Used Brushes—Minimum

–UN–11JUL89
Exposed Length................................................................... 5 mm (0.2 in.)

NOTE: When soldering copper lead, make sure solder

(rosin-core solder only) does not seep into the

L106780
copper leads.
Dimension
Solder new carbon brushes in such a way that dimension
(A) does not exceed specifications. A—Carbon Brush Dimension

Specification
New Brushes—Exposed Length ....................................... 10 mm (0.4 in.)

IMPORTANT: The service life of carbon brushes and

ball bearings are matched to each
other. Therefore, always replace ball
bearings when renewing carbon
brushes. Before installing new carbon
brushes, slip rings must be checked
and turned down if necessary.

30
10
12

RG,RG34710,2159 –19–19OCT00–1/1

Replacing Ball Bearings

Remove attaching screws (A) of drive end frame retaining

plate and force rotor out of drive end frame.

Pull off rotor ball bearing.

–UN–11JUL89

Removed ball bearings must be replaced.

A—Screws (4 Used)
L106781

Remove Attaching Screws

RG,RG34710,2160 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-12 Alternators and Starter Motors

103000
PN=278
 Robert Bosch Alternator Repair

Checking Positive Diodes

Consecutively place positive test probe of ohmmeter to

positive heat sink (A) and negative test probe to leads (B)
of diodes.

–UN–11JUL89
Meter must not show continuity.

A—Positive Heat Sink

B—Diode Leads

L106782
Check Positive Diodes

RG,RG34710,2161 –19–15MAR97–1/2

If no fault is found in the above described test, carry out

this test with reversed polarity (see illustration).

Meter must show continuity.

NOTE: Test voltage 6—12 volts DC. 30

–UN–11JUL89
10
13

L106783
Reversed Polarity

RG,RG34710,2161 –19–15MAR97–2/2

CTM77 (30OCT00) 30-10-13 Alternators and Starter Motors

103000
PN=279
 Robert Bosch Alternator Repair

Checking Negative Diodes

Consecutively place positive test probe of ohmmeter to

positive heat sink (B) and negative test probe to leads (A)
of diodes.

–UN–11JUL89
Meter must not show continuity.

A—Diode Leads
B—Positive Heat Sink

L106784
Check Negative Diodes

RG,RG34710,2162 –19–15MAR97–1/2

If no fault is found in the above described test, carry out

this test with reversed polarity (see illustration).

Meter must show continuity.

30 NOTE: Test voltage 6—12 volts DC.

–UN–11JUL89
10
14
A—Diode Leads
B—Positive Heat Sink

L106785
Reverse Polarity

RG,RG34710,2162 –19–15MAR97–2/2

CTM77 (30OCT00) 30-10-14 Alternators and Starter Motors

103000
PN=280
 Robert Bosch Alternator Repair

Testing Exciting Diodes

Place positive test probe of an ohmmeter on connection

“D+” (B) and negative probe onto diode lead (A).

Meter must not show continuity.

–UN–11JUL89
A—Diode Leads
B—“D+” Connection

L106786
Test Exciting Diodes

RG,RG34710,2163 –19–15MAR97–1/2

If no fault is found in the above described test, carry out

this test with reversed polarity (see illustration).

Meter must show continuity.

NOTE: Test voltage 6—12 volts DC. 30

–UN–11JUL89
10
15
A—Diode Leads
B—“D+” Connection

L106787
Reverse Polarity

RG,RG34710,2163 –19–15MAR97–2/2

CTM77 (30OCT00) 30-10-15 Alternators and Starter Motors

103000
PN=281
 Robert Bosch Alternator Repair

Diode Plate Installation

Pay attention to perfect insulation connections “B+”, “D+”

and the positive diode heat sink in respect to end frame.

Install diode plate as shown and tighten screws.

–UN–11JUL89
L106772
Install Diode Plate

RG,RG34710,2164 –19–15MAR97–1/1

Soldering Stator Coils

IMPORTANT: Use only rosin-core solder.

Make sure that no solder seeps inside diode plate.

30

–UN–11JUL89
10 Avoid overheating diodes.
16

L106771
Solder Stator Coils

RG,RG34710,2165 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-16 Alternators and Starter Motors

103000
PN=282
 Robert Bosch Alternator Repair

Pressing Ball Bearing onto Rotor Shaft

For pressing on, use a sleeve which presses against the

ball bearing inner race.

IMPORTANT: Never press onto drive end frame;

–UN–11JUL89
damage may result.

L106788
Pressing Ball Bearing Onto Rotor Shaft

RG,RG34710,2166 –19–15MAR97–1/1

Pressing Rotor into Drive End Frame

Use a new retaining plate (A) when installing new ball

bearing.

30
A—Retaining Plate

–UN–11JUL89
10
17

L106789
Retaining Plate

RG,RG34710,2167 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-17 Alternators and Starter Motors

103000
PN=283
 Robert Bosch Alternator Repair

Assemble Alternator

Apply high temperature bearing grease such as Bosch

FT70V1 or Delco Remy No. 194891 to end frame bearing
seat. Place spring washer end in frame and carefully join
both alternator halves, paying attention to markings.

–UN–11JUL89
Tighten screws (A) to specifications.

Specification

L106790
Alternator Housing Cap Screws—
Torque .......................................................... 4.0—5.5 N•m (33—48 lb-in.)
Alternator Assembly
Check armature end play.
A—Screws (4 Used)
Specification
Armature—End Play ................................ 0.1—0.3 mm (0.004—0.012 in.)

RG,RG34710,2168 –19–21SEP00–1/1

Installing Brush Holder with Regulator

Carefully insert brush holder with regulator. Make sure

that gasket (A) fits correctly. Tighten screws securely.

30
A—Gasket

–UN–11JUL89
10
18

L106791
Install Brush Holder with Regulator

RG,RG34710,2169 –19–15MAR97–1/1

CTM77 (30OCT00) 30-10-18 Alternators and Starter Motors

103000
PN=284
 Robert Bosch Alternator Repair

Fan and Belt Pulley Installation

Tighten securing nut to specifications.

Specification
Alternator Pulley Nut—Torque ......................... 35—45 N•m (25—32 lb-ft)

–UN–11JUL89
NOTE: To install alternator and adjust belt tension, refer
to machine technical manual.

L106792
Tighten Securing Nut

RG,RG34710,2170 –19–15MAR97–1/1

30
10
19

CTM77 (30OCT00) 30-10-19 Alternators and Starter Motors

103000
PN=285
 Robert Bosch Alternator Repair

30
10
20

CTM77 (30OCT00) 30-10-20 Alternators and Starter Motors

103000
PN=286
 Section 35
Valeo Alternators
Contents

Page

Group 05—Valeo Alternator Theory of Operation

Valeo Alternator Operation . . . . . . . . . . . . . . . .35-05-1
Valeo Regulator Operation . . . . . . . . . . . . . . . .35-05-2

Group 10—Valeo Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .35-10-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .35-10-1
Valeo Charging Circuit Repair Specifications. . .35-10-2
Valeo Charging Circuit Test Specifications . . . .35-10-2
Disassemble Alternator and Test
Components . . . . . . . . . . . . . . . . . . . . . . . . .35-10-3
Assemble Alternator . . . . . . . . . . . . . . . . . . . . .35-10-8

Group 15—Valeo A13N-Series Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .35-15-1
Valeo A13N-Series Repair Specifications . . . . .35-15-1
Valeo A13N-Series Test Specifications . . . . . . .35-15-2
Disassemble and Test Valeo A13N-Series
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .35-15-2
Assemble Valeo A13N-Series Alternator . . . . . .35-15-9

35

CTM77 (30OCT00) 35-1 Alternators and Starter Motors

103000
PN=1
 Contents

35

CTM77 (30OCT00) 35-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Valeo Alternator Theory of Operation
Valeo Alternator Operation

In an alternator, the magnetic field of the rotor is moved

across stationary conductors in the stator. This permits a
permanent connection between the stator windings and
the output terminal. Slip rings are used to transmit the
field current to the rotor field winding.

–UN–31MAY89
The alternator produces power in the form of a
three-phase alternating current and voltage. The
alternating current is rectified to direct current by a
three-phase full-wave rectifier circuit using six silicon

T52184
rectifier diodes. Since the diode will pass current in only
one direction (from alternator to battery or load), the Valeo Alternator Operation
alternator does not require the use of a cutout relay.
1—Stator
The entire DC output of the system passes through the 2—Rotor Winding (Field)
isolation diode. This provides the system with several 3—Rotor Slip Ring
4—Brushes
distinct advantages. It prevents the battery from 5—Regulator Terminal
discharging through the regulator and alternator field 6—Output Terminal
without the use of relays or switches. Electrically, the 7—Isolation Diode
indicator lamp is connected across the isolation diode. 8—Regulator
When the system is operating properly, the alternator
output voltage is very nearly the same as the battery
voltage. This means that the voltage potential across the
isolation diode is low and the indicator lamp shows that
the alternator is charging.

The alternator output current is controlled by the current

flow through the field coil (rotor). The amount of current
required is determined and controlled by the regulator.
Since there is very little residual magnetism in the
alternator, it is necessary to supply a small amount of 35
excitation current to the field (rotor) to start the process of 05
1
current generation. The excitation resistor supplies this
starting current when the key switch is turned on. This
resistor is enclosed in the sealed regulator case. Once the
alternator is excited, a voltage is developed at the
regulator terminal and the voltage regulator takes over
control of the system voltage.

RG,RG34710,2171 –19–15MAR97–1/1

CTM77 (30OCT00) 35-05-1 Alternators and Starter Motors

103000
PN=289
 Valeo Alternator Theory of Operation

Valeo Regulator Operation

The transistor regulator is an electronic switching device

composed principally of transistors, resistor, and diodes to
form a completely static unit containing no moving parts.

The transistors are used to switch the alternator field

current on and off and are controlled by the resistors and
the Zener diode.

–UN–02JUN89
A Zener diode is a special diode that will break down and
permit a reverse flow of current when the voltage reaches
a certain value, without damaging the semiconductor

T51537
material. This diode is the trigger which senses the
maximum desired voltage and turns the transistor on or
off to limit charging system voltage. Valeo Regulator Operation

1—Thermistor (RT)
The field discharge diode provides an alternator current 2—Field Discharge Diode
path to protect the transistors from induced high voltage 3—Transistor (T-2)
from the alternator field windings. The sudden stopping of 4—Transistor (T-1)
field current by the transistor and subsequent collapsing of 5—Zener Diode
the magnetic field cause an induced voltage in the rotor 6—Excitation Resistor
7—To Alternator Indicator Light
windings.

The thermistor (RT) is a temperature compensating

resistor. Its resistance varies with temperature and
controls the operating point of the Zener diode so that a
high system voltage is produced in cold weather when
needed, and a lower system voltage in warm weather.

When the voltage appearing at the output terminal of the

alternator rises to a predetermined value (1.44 volts), the
35 voltage which appears across the Zener diode permits
05 current to flow in the base of transistor T-1. This causes
2
transistor T-1 to turn on and reverse bias transistor T-2,
thus turning off the current applied to the alternator field.

When the system voltage drops below the predetermined

value, the Zener diode stops conducting, T-1 turns off and
T-2 turns on. When transistor T-2 is switched on, field
current again is supplied to the alternator.

The operation of transistor T-2 is in effect like a switch,

turning the alternator field current on and off as the
electrical supply varies due to the varying electrical load.
This action occurs many times a second, so fast it cannot
be detected in the alternator output.

Continued on next page RG,RG34710,2172 –19–15MAR97–1/5

CTM77 (30OCT00) 35-05-2 Alternators and Starter Motors

103000
PN=290
 Valeo Alternator Theory of Operation

The solid-state regulator is either mounted on rear of

alternator or mounted internally. It controls output by
controlling current through the field. In operation, the
regulator has the following three phases.
RG,RG34710,2172 –19–15MAR97–2/5

Phase I—Alternator Stopped

(Phase I also applies when alternator is running but only if

not running fast enough for output to exceed battery
voltage.)

1. Current flows from battery (B) through key switch (C)

to regulator (A).

2. From there, current flows through resistors R8, R7, and

R1 to transistor Q2, turning it on.

3. Transistor Q2 then provides a path so current can flow

through field (E) to ground, enabling alternator to
generate electricity.

4. Zener diode D1 prevents flow of current to transistor

Q1. A Zener diode is a special type of diode which will
not permit current to pass until voltage reaches a
certain preset level. If voltage exceeds that level,
current can pass through the Zener diode.

A—Regulator
B—Battery
C—Key Switch
D—Rotor 35
E—Field Windings 05
F—Delta Stator 3
G—Rectifier Diodes
H—Diode Trio
I—Suppression Capacitor

–UN–02MAY89
N37761

Phase I—Alternator Stopped

Continued on next page RG,RG34710,2172 –19–15MAR97–3/5

CTM77 (30OCT00) 35-05-3 Alternators and Starter Motors

103000
PN=291
 Valeo Alternator Theory of Operation

Phase II—Generating Electricity

1. The key switch (C) and rectifier bridge diodes (G) all
have equal voltage. Therefore, no current flows from
key switch to regulator.

2. Current, now coming from rectifier bridge diodes, flows

through resistors R7 and R1 to turn on transistor Q2.

3. Transistor Q2 still provides a path to ground through

field (E), enabling alternator to generate electricity.

4. Since the field is rotating, it does generate electricity.

Alternating current is induced in the stator windings (F).
The rectifier bridge converts it to direct current,
providing current to run electrical accessories and
charge the battery.

5. Output voltage still has not reached critical voltage of

the Zener diode D1.

A—Regulator
B—Battery
C—Key Switch
D—Rotor
E—Field Windings
F—Delta Stator
G—Rectifier Diodes
H—Diode Trio
I—Suppression Capacitor

35
05
4

–UN–02MAY89
N37762

Phase II—Generating Electricity

Continued on next page RG,RG34710,2172 –19–15MAR97–4/5

CTM77 (30OCT00) 35-05-4 Alternators and Starter Motors

103000
PN=292
 Valeo Alternator Theory of Operation

Phase III—Shut-Off

1. Output voltage reaches critical voltage of Zener diode

D1.

2. Current cannot pass through Zener diode D1 to turn on

control transistor Q1.

3. Current from transistor Q1 cuts off voltage to transistor

Q2, turning it off. There is now no path to ground for
current through field (E).

4. Current through field is shut off instantly, and alternator

stops generating electricity.

5. With transistor Q2 off, system voltage starts to drop in

unrestricted fashion until it falls below the Zener diode
D1 critical voltage. When this occurs, Zener diode D1
and transistor Q1 switch off and Q2 turns on again.

6. Phases II and III are repeated many times per second

to maintain voltage at proper level.

A—Regulator
B—Battery
C—Key Switch
D—Rotor
E—Field Windings
F—Delta Stator
G—Rectifier Diodes
H—Diode Trio
I—Suppression Capacitor

35
05
5

–UN–02MAY89
N37763
Phase III—Shut-Off

RG,RG34710,2172 –19–15MAR97–5/5

CTM77 (30OCT00) 35-05-5 Alternators and Starter Motors

103000
PN=293
 Valeo Alternator Theory of Operation

35
05
6

CTM77 (30OCT00) 35-05-6 Alternators and Starter Motors

103000
PN=294
 Group 10
Valeo Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B80 –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

35
10
OUO1004,0000B80 –19–21SEP00–2/2
1

Other Material

Number Name Use

TY16285 (U.S.) Thread Lock and Sealer (Low Apply to front bearing plate and
CXTY24311 (Canadian) Strength) housing through bolts.
222 (LOCTITE)

LOCTITE is a registered trademark of Loctite Corp. OUO1004,0000B82 –19–21SEP00–1/1

CTM77 (30OCT00) 35-10-1 Alternators and Starter Motors

103000
PN=295
 Valeo Alternator Repair

Valeo Charging Circuit Repair Specifications

Item Measurement Specification

Alternator Housing Through Bolts Torque 5 N•m (44 lb-in.)

Pulley Nut Torque 61 N•m (45 lb-ft)

Ground (—) Terminal Nut Torque 4 N•m (35 lb-in.)

Optional Terminal Nut Torque 4 N•m (35 lb-in.)

Battery Positive (+) Terminal Nut Torque 5 N•m (44 lb-in.)

OUO1004,0000B83 –19–21SEP00–1/1

Valeo Charging Circuit Test Specifications

NOTE: Formerly Motorola alternators made in France.

Min. Output @ 25°C (77°F)

John Deere Part Field Current
Valeo Part No. Pulley Grooves Rated Amps Amps RPM
No. (Volts)
RE20600 2940090a W/O 35 14 26—30 3000—4000
RE30838 2518033b Dual 35 14 26—30 3000—4000
b
RE40575 2518032 Single 35 14 26—30 3000—4000
35 RE40576 2518073b Single 80 14 68—78 3000—4000
10 a
With additional resistor.
2
b
With included regulator (Packard connector).

Item Specification
Maximum Continuous Speed 12000 rpm
Maximum Intermittent Speed 16000 rpm
Maximum Recommended Working Temperature 80°C (176°F)

RG,RG34710,2174 –19–08SEP00–1/1

CTM77 (30OCT00) 35-10-2 Alternators and Starter Motors

103000
PN=296
 Valeo Alternator Repair

Disassemble Alternator and Test

Components

1. Remove regulator after having identified the color

coding of the wires.

–UN–26JUL89
2. Unscrew the three cover attaching screws (1) and
remove cover.

CD5712
1—Screws (3 Used)

Unscrew Cover Attaching Screws

RG,RG34710,2175 –19–15MAR97–1/19

3. Remove the brush assembly with caution and turn it

toward the outside in order to protect the brushes.

4. Inspect brushes. If either one is worn, cracked or oil

soaked, replace the brush assembly.

–UN–26JUL89
CD5713
35
Remove Brush Assembly 10
RG,RG34710,2175 –19–15MAR97–2/19
3

5. Touch each brush with test leads using JT05791

Digital Multimeter. No continuity should be found, even
if either brush has slid up or down in its channel. If
there is continuity, replace the brush assembly. –UN–26JUL89
CD5714

JT05791 Digital Multimeter

Continued on next page RG,RG34710,2175 –19–15MAR97–3/19

CTM77 (30OCT00) 35-10-3 Alternators and Starter Motors

103000
PN=297
 Valeo Alternator Repair

6. Connect the test leads of JT05791 Digital Multimeter

on the field terminal and on its corresponding brush.
Continuity should be found even when moving
brushes. If there is no continuity, replace the brush
assembly.

–UN–26JUL89
CD5715
Connect Test Leads
RG,RG34710,2175 –19–15MAR97–4/19

7. Connect the test leads of JT05791 Digital Multimeter

on the second terminal and on its corresponding brush.
Continuity should be found even when moving
brushes. If there is no continuity, replace the brush
assembly.

–UN–26JUL89
CD5716
Test for Continuity
RG,RG34710,2175 –19–15MAR97–5/19

8. Connect the test leads to each slip ring. The resistance

must be between 3.8 and 5.2 ohms.

35 9. Connect an ohmmeter between a slip ring and the

10 alternator housing. The resistance should be infinity.
4

–UN–26JUL89
CD5717

Test Resistance
RG,RG34710,2175 –19–15MAR97–6/19

10. Check if the winding has been damaged by

overheating.

11. Check the stator insulation by connecting an

ohmmeter between the alternator housing and in
succession with each stator phase winding. The
–UN–26JUL89

resistance should be infinity.

CD5718

Check the Stator Insulation

Continued on next page RG,RG34710,2175 –19–15MAR97–7/19

CTM77 (30OCT00) 35-10-4 Alternators and Starter Motors

103000
PN=298
 Valeo Alternator Repair

12. Unsolder the leads of phase winding (1), and D+

terminal (2).

13. Take out link diode bridge after removing the screws
(3).

–UN–26JUL89
1—Phase Winding
2—D+ Terminal
3—Screws

CD5719
Remove Link Diode Bridge
RG,RG34710,2175 –19–15MAR97–8/19

14. Using a power supply not exceeding 12 volts and an

indicator lamp in series, check the current flow
through each diode.

15. Test positive diodes by connecting the indicator lamp

between each phase terminal and the B+ terminal.

–UN–26JUL89
Just touch the lamp probes briefly.

If the indicator lamp lights only in one direction, the

diode is good. Continue testing diode as outlined in

CD5720
step 16.
Test Diode
If the indicator lamp lights in both directions, the diode
is shorted. Replace diode.

If the indicator lamp does not light in either direction,

the diode circuit is open. Replace diode.
35
10
5

Continued on next page RG,RG34710,2175 –19–15MAR97–9/19

CTM77 (30OCT00) 35-10-5 Alternators and Starter Motors

103000
PN=299
 Valeo Alternator Repair

16. Test negative diodes by connecting the lamp between

each phase terminal and the heat sink.

If the indicator lamp lights only in one direction, the

diode is good. Continue with step 17.

–UN–26JUL89
If the indicator lamp lights in both directions, the diode
is shorted. Replace diode.

If the indicator lamp does not light in either direction,

CD5721
the diode is open circuit. Replace diode.
Test Diodes
17. Test the trio by connecting the test leads on the D+
terminal and on each phase terminal in sequence.
Then reverse the polarity.

RG,RG34710,2175 –19–15MAR97–10/19

18. Note the orientation of the housing and take out the
four through bolts.

–UN–26JUL89
CD5722
35
Remove Through Bolts
10
RG,RG34710,2175 –19–15MAR97–11/19
6

19. Remove the rear housing. If it is glued to the stator,

take care not to damage the winding.
–UN–26JUL89
CD5723

Remove Rear Housing

Continued on next page RG,RG34710,2175 –19–15MAR97–12/19

CTM77 (30OCT00) 35-10-6 Alternators and Starter Motors

103000
PN=300
 Valeo Alternator Repair

20. Remove O-ring from rear bearing bore.

–UN–26JUL89
CD5724
Remove O-Ring
RG,RG34710,2175 –19–15MAR97–13/19

21. Remove stator from front housing.

–UN–26JUL89
CD5725
Remove Stator
RG,RG34710,2175 –19–15MAR97–14/19

22. Remove pulley nut and lock washer.

23. Pull alternator from pulley. Remove fan.

35
10
7

–UN–26JUL89
CD5726
Remove Pulley Nut and Lock Washer
RG,RG34710,2175 –19–15MAR97–15/19

24. Press rotor out of front housing.

–UN–26JUL89
CD5727

Press Rotor Out

Continued on next page RG,RG34710,2175 –19–15MAR97–16/19

CTM77 (30OCT00) 35-10-7 Alternators and Starter Motors

103000
PN=301
 Valeo Alternator Repair

25. Remove rear bearing using a suitable puller.

–UN–26JUL89
CD5728
Remove Rear Bearing
RG,RG34710,2175 –19–15MAR97–17/19

26. Unscrew the three screws securing the bearing plate.

–UN–26JUL89
CD5729
Unscrew Screws
RG,RG34710,2175 –19–15MAR97–18/19

27. Extract the front bearing.

35
10
8

–UN–26JUL89
CD5730

Extract the Front Bearing

RG,RG34710,2175 –19–15MAR97–19/19

Assemble Alternator

1. Fit the front bearing to its housing by pressing on the

outer ring as shown.

2. Install the bearing plate. Apply LOCTITE 222 Thread

–UN–26JUL89

Lock and Sealer (low strength) on the threads of the

three screws and tighten.
CD5731

Assemble Alternator
LOCTITE is a registered trademark of Loctite Corp. Continued on next page RG,RG34710,2176 –19–15MAR97–1/11

CTM77 (30OCT00) 35-10-8 Alternators and Starter Motors

103000
PN=302
 Valeo Alternator Repair

3. Press rear bearing onto rotor using a suitable driver.

–UN–26JUL89
CD5732
Press Rear Bearing onto Rotor
RG,RG34710,2176 –19–15MAR97–2/11

4. Install rotor into front housing.

–UN–26JUL89
CD5733
Install Rotor
RG,RG34710,2176 –19–15MAR97–3/11

5. Install stator.

35
10
9

–UN–26JUL89
CD5725
Install Stator
RG,RG34710,2176 –19–15MAR97–4/11

6. Install rear housing, taking care that marks made when

disassembling are in line. Use a new O-ring in rear
bearing bore.
–UN–26JUL89
CD5734

Install Rear Housing

Continued on next page RG,RG34710,2176 –19–15MAR97–5/11

CTM77 (30OCT00) 35-10-9 Alternators and Starter Motors

103000
PN=303
 Valeo Alternator Repair

7. Install the four through bolts. Apply LOCTITE 222

Thread Lock and Sealer (low strength) on the threads
of the through bolts and tighten to specifications.

Specification
Alternator Housing Through

–UN–26JUL89
Bolts—Torque ................................................................... 5 N•m (44 lb-in.)

CD5722
Install Through Bolts
LOCTITE is a registered trademark of Loctite Corp. RG,RG34710,2176 –19–15MAR97–6/11

8. Install fan.

–UN–26JUL89
CD5735
Install Fan
RG,RG34710,2176 –19–15MAR97–7/11

9. Install pulley, nut and lock washer. Tighten the pulley

nut to specifications.

Specification
35
Pulley Nut—Torque ......................................................... 61 N•m (45 lb-ft)
10
10

–UN–26JUL89
CD5726

Tighten Pulley Nut

RG,RG34710,2176 –19–15MAR97–8/11

10. Install the diode bridge and tighten screws (3).

11. Solder the leads of phase winding (1) and D+ terminal

(2). DO NOT use acid-core solder.
–UN–26JUL89

1—Phase Winding
2—D+ Terminal
3—Screws
CD5719

Install Diode Bridge

Continued on next page RG,RG34710,2176 –19–15MAR97–9/11

CTM77 (30OCT00) 35-10-10 Alternators and Starter Motors

103000
PN=304
 Valeo Alternator Repair

12. Install the brush assembly.

–UN–26JUL89
CD5713
Install Brush Assembly
RG,RG34710,2176 –19–15MAR97–10/11

13. Install the rear cover. Tighten the three screws (1).

14. Install regulator. It is essential that connections be

made correctly; reversals will cause damage.

15. Refer to your machine technical manual for alternator

–UN–26JUL89
installation and proper V-belt adjustments.

16. Tighten terminal nuts to specifications.

CD5712
Specification
Ground (—) Terminal Nut— Installation and Adjustments
Torque .............................................................................. 4 N•m (35 lb-in.)
Optional Terminal Nut—Torque ....................................... 4 N•m (35 lb-in.) 1—Screws (3 Used)
Battery Positive (+) Terminal
Nut—Torque ..................................................................... 5 N•m (44 lb-in.)

35
10
RG,RG34710,2176 –19–15MAR97–11/11
11

CTM77 (30OCT00) 35-10-11 Alternators and Starter Motors

103000
PN=305
 Valeo Alternator Repair

35
10
12

CTM77 (30OCT00) 35-10-12 Alternators and Starter Motors

103000
PN=306
 Group 15
Valeo A13N-Series Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B84 –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

35
15
OUO1004,0000B84 –19–21SEP00–2/2
1

Valeo A13N-Series Repair Specifications

Item Measurement Specification

Ground (B—) Terminal Nut Torque 4 N•m (35 lb-in.)

Output (B+) Terminal Nut Torque 5 N•m (44 lb-in.)

Front-to-Rear Housing Through Bolts Torque 5 N•m (44 lb-in.)

Pulley-to-Shaft Nut Torque 55 N•m (41 lb-ft)

OUO1004,0000B87 –19–21SEP00–1/1

CTM77 (30OCT00) 35-15-1 Alternators and Starter Motors

103000
PN=307
 Valeo A13N-Series Alternator Repair

Valeo A13N-Series Test Specifications

Min. Output
@ 25°C (77°F)
John Deere Valeo Model Pulley Ground Rated Amps Alt. RPM
Part No. Grooves (Amps)
RE53906 2541673 Single N 50 39—43 3000—4000

Item Specification
Rotor winding resistance 3.6 ohms
Stator resistance 0.000 ohms
Alternator output voltage 13.7—14.7 volts
Maximum recommended working temperature 80°C (176°F)
Maximum continuous alternator speed 9000 rpm

RG,RG34710,2177 –19–15MAR97–1/1

Disassemble and Test Valeo A13N-Series Alternator

35
15
2

–UN–14APR94
CD30363

Valeo A13N-Series Alternator

1—Nut 6—Fan Spacer 11—Rotor 16—Regulator and Brush

2—Washer 7—Front Housing 12—Rear Ball Bearing Assembly
3—Pulley 8—Through-Bolt (4 Used) 13—Plastic Ball Bearing Cage 17—Rear Cover
4—Spacer 9—Front Ball Bearing 14—Rear Housing
5—Fan 10—Stator 15—Rectifier Diode Bridge and
Diode-Trio Assembly

Continued on next page DPSG,RG34710,102 –19–13SEP99–1/15

CTM77 (30OCT00) 35-15-2 Alternators and Starter Motors

103000
PN=308
 Valeo A13N-Series Alternator Repair

1. Pull out the rear cover (A).

2. Remove regulator/brush assembly (B).

A—Rear Cover
B—Regulator/Brush Assembly

–UN–14APR94
CD30364
Remove Regulator/Brush Assembly

DPSG,RG34710,102 –19–13SEP99–2/15

3. Inspect brushes. If either one is worn, cracked or oil

soaked, replace the regulator/brushes assembly.

4. Touch each brush with test leads. No continuity should

be found even if either brush has slid up or down in its
channel. If there is continuity, replace the brush

–UN–14APR94
assembly.

CD30365
35
15
Inspect Brushes
3

Continued on next page DPSG,RG34710,102 –19–13SEP99–3/15

CTM77 (30OCT00) 35-15-3 Alternators and Starter Motors

103000
PN=309
 Valeo A13N-Series Alternator Repair

5. Check for continuity between terminal (A) and brush

(B) and between metallic box of regulator (C) and
brush (D). If there is no continuity at either brush,
replace the brush assembly.

A—Terminal

–UN–14APR94
B—Brush
C—Metallic Regulator Box
D—Brush

CD30366
Check for Continuity

DPSG,RG34710,102 –19–13SEP99–4/15

6. Connect the test leads to each slip ring of the rotor.

The ohmmeter should read a resistance of 3.60 ohms.

7. Connect the ohmmeter between a slip ring and the

alternator housing. The resistance should be infinity.

–UN–14APR94
CD30367
35
15
Check Resistance
4

Continued on next page DPSG,RG34710,102 –19–13SEP99–5/15

CTM77 (30OCT00) 35-15-4 Alternators and Starter Motors

103000
PN=310
 Valeo A13N-Series Alternator Repair

8. Check if the winding has been damaged by

overheating.

9. Check the stator insulation by connecting an ohmmeter

between the alternator housing and in succession with
each stator phase winding. The resistance should be

–UN–14APR94
infinity.

CD30368
Check Winding for Damage

DPSG,RG34710,102 –19–13SEP99–6/15

10. Unsolder the leads of phase winding (A).

11. Take out the rectifier diode bridge/diode trio assembly

after removing the screw and nuts (B).

A—Phase Winding

–UN–14APR94
B—Screw and Nuts

CD30369
35
15
Remove Rectifier Diode Bridge/Diode Trio
5

Continued on next page DPSG,RG34710,102 –19–13SEP99–7/15

CTM77 (30OCT00) 35-15-5 Alternators and Starter Motors

103000
PN=311
 Valeo A13N-Series Alternator Repair

12. Test positive diodes. Test for continuity between the

positive plate (A) and each of three terminals (B).
Continuity should be observed in one direction only.

Replace entire rectifier diode bridge if any diode fails

test.

–UN–14APR94
A—Positive Plate
B—Three Terminals

CD30370
Test Positive Diodes

DPSG,RG34710,102 –19–13SEP99–8/15

13. Test negative diodes. Test for continuity between the

negative plate (A) and each of three phases (B).

14. Test the diode trio by connecting the test leads on

each phase (B) with the corresponding diode trio
terminal (C).

–UN–14APR94
Continuity should be observed in one direction only.
Replace entire rectifier diode bridge if any diode fails
test.

CD30371
35
15 A—Negative Plate
Test Negative Diodes
6 B—Three Phases
C—Diode Trio Terminal

Continued on next page DPSG,RG34710,102 –19–13SEP99–9/15

CTM77 (30OCT00) 35-15-6 Alternators and Starter Motors

103000
PN=312
 Valeo A13N-Series Alternator Repair

15. Note the orientation of the housing and take out the
four through bolts.

–UN–14APR94
CD30372
Remove Through Bolts

DPSG,RG34710,102 –19–13SEP99–10/15

16. Remove the rear housing. If it is glued to the stator,

take care not to damage the winding.

–UN–14APR94
CD30373
35
15
Remove Rear Housing
7

DPSG,RG34710,102 –19–13SEP99–11/15

17. Remove stator from housing.

–UN–26JUL89
CD5725

Remove Stator
Continued on next page DPSG,RG34710,102 –19–13SEP99–12/15

CTM77 (30OCT00) 35-15-7 Alternators and Starter Motors

103000
PN=313
 Valeo A13N-Series Alternator Repair

18. Remove pulley and fan. Note the order of washers

and spacers to ensure a proper reinstallation.

–UN–14APR94
CD30374
Remove Pulley and Fan

DPSG,RG34710,102 –19–13SEP99–13/15

19. Press rotor out of front housing.

–UN–26JUL89
CD5727
35
15 Press Rotor Out of Front Housing
DPSG,RG34710,102 –19–13SEP99–14/15
8

20. Remove rear ball bearing using a suitable puller.

NOTE: Since the front ball bearing is set in front housing,

it cannot be removed. If required, replace the front
housing/ball bearing assembly.
–UN–26JUL89
CD5728

Remove Rear Ball Bearing

DPSG,RG34710,102 –19–13SEP99–15/15

CTM77 (30OCT00) 35-15-8 Alternators and Starter Motors

103000
PN=314
 Valeo A13N-Series Alternator Repair

Assemble Valeo A13N-Series Alternator

–UN–08DEC94
CD30375
Valeo A13N-Series Alternator

1—Through Bolt (4 Used) 2—Pulley Nut

Assemble alternator in the reverse sequence of

disassembly procedure using the following torque
specifications.

Item Measurement Specification

Ground (B—) Terminal Nut Torque 4 N•m (35 lb-in.)

35
15
Output (B+) Terminal Nut Torque 5 N•m (44 lb-in.) 9

Front-to-Rear Housing Through Bolts Torque 5 N•m (44 lb-in.)

Pulley-to-Shaft Nut Torque 55 N•m (41 lb-ft)

RG,RG34710,2178 –19–15MAR97–1/1

CTM77 (30OCT00) 35-15-9 Alternators and Starter Motors

103000
PN=315
 Valeo A13N-Series Alternator Repair

35
15
10

CTM77 (30OCT00) 35-15-10 Alternators and Starter Motors

103000
PN=316
 Section 40
Magneton Alternators
Contents

Page

Group 05—Magneton Alternator Theory of

Operation
Operation of Alternator . . . . . . . . . . . . . . . . . . .40-05-1

Group 10—Magneton Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1
Magneton Charging Circuit Repair
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .40-10-2
Magneton Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .40-10-3
Exploded View of Alternator . . . . . . . . . . . . . . .40-10-4
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-5
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .40-10-6
Disassembly of Alternator . . . . . . . . . . . . . . . . .40-10-7
Testing Brush/Regulator Assembly . . . . . . . . . .40-10-9
Testing Rotor . . . . . . . . . . . . . . . . . . . . . . . . .40-10-10
Testing Stator/Rectifier Bridge Assembly. . . . .40-10-11
Rectifier Bridge Replacement . . . . . . . . . . . . .40-10-12
Reassembly of Alternator . . . . . . . . . . . . . . . .40-10-12
Installation of Alternator. . . . . . . . . . . . . . . . . .40-10-14

40

CTM77 (30OCT00) 40-1 Alternators and Starter Motors

103000
PN=1
 Contents

40

CTM77 (30OCT00) 40-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Magneton Alternator Theory of Operation
Operation of Alternator

–UN–07JAN97
CD30489
Magnetron Alternator

A—Alternator D—Regulator G—Ignition J—Diode Trio

B—Current Coil (Stator) E—Battery H—Protection Device K—Rectifier Diode Bridge
C—Exiting Coil (Rotor) F—Indicator Light

The Magneton alternator is a synchronous three-phase as shown. Alternating current is generated in each
generator. The current coil is located in the stator, and stator coil (B) of the alternator. During one revolution
the exiting current is supplied by the diode trio (J) of the rotor (C), the voltage in the stator coil rises from
through the regulator (D+ circuit), two carbon brushes 0 to the positive maximum, drops to 0, rises to the
and slip rings to the exiting coil in the rotor. negative maximum and again drops to 0. The current
then flows through the diode and terminal B+ directly
The alternator is normally driven by the fan belt from to the positive pole of the battery.
the engine crankshaft. The rotor is supported by two
permanently lubricated bearings. A sealed electronic regulator is used to regulate
alternator voltage. This regulator, which cannot be
The alternator generates alternating current which is adjusted, limits the alternator voltage to approximately 40
then transformed into direct current by the rectifier 14 volts. 05
diode bridge (K). 1
A protection device (H), including a Zener diode and a
The alternating windings are delta-connected. The coil capacitor, protects diode from voltage surges and
ends X, Y, and Z are connected to the rectifier diode suppresses radio interference.

RG,RG34710,2179 –19–15MAR97–1/1

CTM77 (30OCT00) 40-05-1 Alternators and Starter Motors

103000
PN=319
 Magneton Alternator Theory of Operation

40
05
2

CTM77 (30OCT00) 40-05-2 Alternators and Starter Motors

103000
PN=320
 Group 10
Magneton Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B88 –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B88 –19–21SEP00–2/2

40
10
1

CTM77 (30OCT00) 40-10-1 Alternators and Starter Motors

103000
PN=321
 Magneton Alternator Repair

Magneton Charging Circuit Repair

Specifications

Item Measurement Specification

Brush Minimum Exposed Length 7 mm (0.27 in.)

Rectifier Bridge-to-Rear Housing Torque 3 N•m (27 lb-in.)

Nuts

Capacitor Mounting Nut Torque 3 N•m (27 lb-in.)

B+ Terminal Nut Torque 4 N•m (35 lb-in.)

“W” Terminal Nut Torque 3 N•m (27 lb-in.)

Front-to-Rear Housing Bolts Torque 3 N•m (27 lb-in.)

Alternator Pulley Nut Torque 40 N•m (29 lb-ft)

OUO1004,0000B8B –19–21SEP00–1/1

40
10
2

CTM77 (30OCT00) 40-10-2 Alternators and Starter Motors

103000
PN=322
 Magneton Alternator Repair

Magneton Charging Circuit Test

Specifications
John Deere Magneton Rated Nominal Nominal Pulley
Part No. Model No.a Amps Voltage Alternator rpm Grooves
RE501634 443 113 516 241 55 12 6000 Poly-Vee
RE503543 443 113 516 971 40 24 6000 Poly-Vee
RE506196 9515-241 55 14 6000 Poly-Vee
RE57960 443 113 516 765 55 14 6000 Single
b
RE57961 443 113 516 762 55 14 6000 Dual
RE70779 443 113 516 875 40 24 6000 Single
RE70780 443 113 516 872 40 24 6000 Dual
a
Magneton Alternators are now manufactured by Pal-Mag Company (since 1988).
b
Not a service part. Order RE57960.

Item Specification
Rotor winding resistance 2.95 ohms
Stator resistance 0.00 ohms
Alternator output voltage 13.5—14.2 volts
Working temperature range -40°C—+90°C
Maximum D+ terminal current load 0.5 amp
Maximum continuous alternator speed 13000 rpm

RG,RG34710,2181 –19–08SEP00–1/1

40
10
3

CTM77 (30OCT00) 40-10-3 Alternators and Starter Motors

103000
PN=323
 Magneton Alternator Repair

Exploded View of Alternator

–UN–13DEC96

40
10
4
CD30488

Alternator—Exploded View

1—Pulley Nut, M14 x 1.5 5—Rotor 9—Front Bearing 12—Rectifier Bridge Assembly1
2—Lock Washer 6—Rear Bearing 10—Front Housing 13—Capacitor1
3—Pulley1 7—Spring Collar 11—Regulator and Brush 14—Rear Housing
4—Fan 8—Stator Assembly1

1
Available as service parts.
RG,RG34710,2182 –19–15MAR97–1/1

CTM77 (30OCT00) 40-10-4 Alternators and Starter Motors

103000
PN=324
 Magneton Alternator Repair

Identification

The information for parts identification is stamped on the

body of the alternator.

–UN–13DEC96
CD30470
Parts Identification

RG,RG34710,2183 –19–15MAR97–1/1

40
10
5

CTM77 (30OCT00) 40-10-5 Alternators and Starter Motors

103000
PN=325
 Magneton Alternator Repair

Troubleshooting

Symptom Problem Solution

Alternator indicator light stays Loose connection Check

off with ignition on and engine
not running.

Regulator failure Replace brush/regulator assembly

Stator failure (short-circuit) Replace complete alternator.

Alternator indicator light stays Drive belt loose or broken Adjust tension or replace
on with engine running
(alternator is not charging) at any
speed.

Loose connection Check

Brush/regulator or capacitor failure Replace

Diode failure Replace complete rectifier bridge

Stator failure Replace complete alternator

Rotor failure Replace complete alternator

Alternator indicator light stays Alternator speed too low Use smaller alternator pulley
on with engine running
(alternator is not charging) at low
speed.

Battery overcharging. Low electrical consumption Use regulator with narrower

regulation range (RE69380)

Regulator failure Replace

40
10
6

RG,RG34710,2184 –19–19OCT00–1/1

CTM77 (30OCT00) 40-10-6 Alternators and Starter Motors

103000
PN=326
 Magneton Alternator Repair

Disassembly of Alternator

1. Remove pulley nut (A), lock washer, pulley and fan

from shaft.

A—Pulley Nut

–UN–01FEB94
ZT0613
Remove Pulley Nut

RG,RG34710,2185 –19–15MAR97–1/7

2. Remove shaft key (B) and spacer (C) from shaft.

B—Shaft Key
C—Spacer

–UN–01FEB94
ZT0614
Remove Shaft Key and Spacer

40
10
7

Continued on next page RG,RG34710,2185 –19–15MAR97–2/7

CTM77 (30OCT00) 40-10-7 Alternators and Starter Motors

103000
PN=327
 Magneton Alternator Repair

3. Disconnect wire (D) from terminal. Remove screws and

washers (E). Remove brush/regulator assembly by
tilting top of regulator up and away from alternator.

D—Wire

–UN–13DEC96
E—Screws and Washers

CD30471
Remove Brush/Regulator Assembly

RG,RG34710,2185 –19–15MAR97–3/7

4. Remove the three bolts (A) from front housing side.

A—Bolts (3 Used)

–UN–01FEB94
ZT0616
Remove Bolts

40
10
8

RG,RG34710,2185 –19–15MAR97–4/7

5. Place alignment marks along the alternator to note the

orientation of housings. Split alternator by carefully
prying at slot (B) using a screwdriver against housing.

B—Slot
–UN–13DEC96
CD30472

Split Alternator
Continued on next page RG,RG34710,2185 –19–15MAR97–5/7

CTM77 (30OCT00) 40-10-8 Alternators and Starter Motors

103000
PN=328
 Magneton Alternator Repair

6. Remove rotor/front housing assembly (C) from

stator/rear housing assembly (D).

C—Rotor/Front Housing Assembly

D—Stator/Rear Housing Assembly

–UN–13DEC96
CD30473
Housing Assemblies
RG,RG34710,2185 –19–15MAR97–6/7

7. Remove capacitor (E). Remove nuts and washers (F)

from rear housing. Remove “B+” terminal nut and
washers (G). Remove “W” terminal nut and washers
(H). Remove stator/rectifer bridge assembly (J) from
rear housing.

–UN–13DEC96
E—Capacitor
F—Nuts and Washers (2 Used)
G—“B+” Terminal Nut and Washers
H—“W” Terminal Nut and Washers

CD30474
J—Stator/Rectifer Bridge Assembly

Remove Capacitor

RG,RG34710,2185 –19–15MAR97–7/7

Testing Brush/Regulator Assembly

40
1. Check brushes (A) for free movement against spring
10
tension. If either brush is worn beyond specification, 9
replace the brush/regulator assembly. Also replace if
–UN–13DEC96

the brushes are cracked or oil-soaked.

Specification
Brush—Minimum Exposed Length .................................... 7 mm (0.27 in.)
CD30475

2. Touch each brush with meter test leads. No continuity

should be found, even if either brush can slip up or
Check Brushes
down in its channel. If there is continuity, replace the
brush/regulator assembly. A—Brushes

Continued on next page RG,RG34710,2186 –19–15MAR97–1/2

CTM77 (30OCT00) 40-10-9 Alternators and Starter Motors

103000
PN=329
 Magneton Alternator Repair

3. Check for continuity between brush (B) and wire (C).

4. Connect regulator to an electrical source corresponding

to the nominal voltage, the “+” at the wire (C) and the
“—” (ground) on the body (E). Continuity between

–UN–13DEC96
brush (D) and body should be observed in one
direction only.

If defective, replace the brush/regulator assembly.

CD30476
B—Brush
C—Wire Check for Continuity
D—Brush
E—“—” Body Ground

RG,RG34710,2186 –19–15MAR97–2/2

Testing Rotor

1. Inspect slip rings (A) of rotor for scoring or rough

surface. Polish slip rings sparingly with No. 00
sandpaper.

–UN–13DEC96
A—Slip Rings

CD30477
Inspect Slip Rings
RG,RG34710,2187 –19–15MAR97–1/2

2. Connect ohmmeter between both slip rings of the rotor.

Resistance should be 2.95 ohms.
40
10
10 3. Check the rotor for insulation by connecting an
ohmmeter between each slip ring and shaft (B).
–UN–13DEC96

Resistance should be infinity.

If insulation, resistance or slip ring are defective,

replace complete alternator.
CD30478

B—Shaft
Slip Ring and Shaft

RG,RG34710,2187 –19–15MAR97–2/2

CTM77 (30OCT00) 40-10-10 Alternators and Starter Motors

103000
PN=330
 Magneton Alternator Repair

Testing Stator/Rectifier Bridge Assembly

1. Inspect stator winding (A) for discoloration or a burned

odor indicating a short circuit.

–UN–13DEC96
2. Check stator for grounds by connecting an ohmmeter
between each stator lead (B) and stator frame (C).
Resistance should be infinity.

CD30479
Replace complete alternator if any defect is noted.

Test Stator/Rectifier Bridge Assembly

A—Stator Winding
B—Stator Lead
C—Stator Frame

RG,RG34710,2188 –19–15MAR97–1/2

3. Check positive diodes by connecting an ohmmeter

between each phase terminal (D) and the “B+” plate
(E), then reverse the polarity.

4. Check negative diodes by connecting an ohmmeter

–UN–13DEC96
between each phase terminal (D) and the “B—” plate
(F) or ground, then reverse the polarity.

5. Check the diode trio by connecting an ohmmeter

CD30480
between each phase terminal (D) and the “D+” terminal
(G), then reverse the polarity.
Check Positive Diodes
A diode with a high reading in one direction and a low
D—Phase Terminal
reading in the other direction is good. A diode with the
E—“B+” Plate
same reading in both directions is bad. If any diode F—“B—” Plate
fails the test, replace the entire rectifier bridge. G—“D+” Terminal
40
10
11

RG,RG34710,2188 –19–15MAR97–2/2

CTM77 (30OCT00) 40-10-11 Alternators and Starter Motors

103000
PN=331
 Magneton Alternator Repair

Rectifier Bridge Replacement

1. To replace the rectifier bridge, unsolder the leads of

phase winding (A) and “W” terminal (B) using a
soldering iron.

–UN–13DEC96
2. Position the replacement rectifier bridge and solder
phase winding leads. Solder “W” terminal at the proper
location.

CD30481
A—Phase Winding
B—“W” Terminal Rectifier Bridge Replacement

RG,RG34710,2189 –19–15MAR97–1/1

Reassembly of Alternator

NOTE: Refer to exploded view earlier in this group.

1. Install stator and rectifier bridge into rear housing using

–UN–13DEC96
alignment mark.

CD30482
Reassembly of Alternator
Continued on next page RG,RG34710,2190 –19–15MAR97–1/6

40
10
12

CTM77 (30OCT00) 40-10-12 Alternators and Starter Motors

103000
PN=332
 Magneton Alternator Repair

2. Secure rectifier bridge to rear housing by the two nuts

and washers (A). Install capacitor (B) with nut and
washer (C). Tighten nuts (A) and (C) to specifications.

Specification

–UN–13DEC96
Rectifier Bridge-to-Rear Housing
Nuts—Torque ................................................................... 3 N•m (27 lb-in.)
Capacitor Mounting Nut—Torque .................................... 3 N•m (27 lb-in.)

CD30483
3. Install insulated washer, flat washer, capacitor wire,
lock washer and nut on “B+” terminal (D). Tighten to
specification. Install Parts

Specification A—Nuts and Washers (2 Used)

B+ Terminal Nut—Torque ................................................ 4 N•m (35 lb-in.) B—Capacitor
C—Nut and Washer
4. Install insulated washer, flat washer, spade terminal, D—“B+” Terminal
lock washer and nut on “W” terminal (E). Tighten to E—“W” Terminal

specifications.

Specification
“W” Terminal Nut—Torque ............................................... 3 N•m (27 lb-in.)

RG,RG34710,2190 –19–15MAR97–2/6

5. Place rotor/front housing assembly into rear housing

using alignment marks. Press by hand for final
installation.

6. Install the three mounting bolts (F) with washers.

–UN–13DEC96
Tighten to specifications.

Specification
Front-to-Rear Housing Bolts—

CD30484
Torque .............................................................................. 3 N•m (27 lb-in.) 40
10
Install Mounting Bolts 13
F—Mounting Bolts (3 Used)

Continued on next page RG,RG34710,2190 –19–15MAR97–3/6

CTM77 (30OCT00) 40-10-13 Alternators and Starter Motors

103000
PN=333
 Magneton Alternator Repair

7. Install brush/regulator assembly with caution. Tilt it so

that the brushes contact the rotor slip rings. Secure
brush/regulator with the two screws and washers (G).
Attach wire to terminal (H).

–UN–13DEC96
G—Screws and Washers (2 Used)
H—Terminal

CD30485
Install Brush/Regulator Assembly
RG,RG34710,2190 –19–15MAR97–4/6

8. Install shaft key (J), spacer (K) and fan (L).

J—Shaft Key
K—Spacer
L—Fan

–UN–13DEC96
CD30486
Install Shaft Key, Spacer, and Fan
RG,RG34710,2190 –19–15MAR97–5/6

9. Install pulley (M) with lock washer and nut (N). Tighten
to specifications.

Specification
Alternator Pulley Nut—Torque ........................................ 40 N•m (29 lb-ft)

–UN–16DEC96
M—Pulley
N—Lock Washer and Nut

40
10 CD30487
14

Install Pulley

RG,RG34710,2190 –19–15MAR97–6/6

Installation of Alternator

Refer to machine technical manual to install alternator and

to adjust belt tension.

RG,RG34710,2191 –19–15MAR97–1/1

CTM77 (30OCT00) 40-10-14 Alternators and Starter Motors

103000
PN=334
 Section 45
Leece-Neville Alternators
Contents

Page

Group 05—Leece-Neville Alternator Theory of

Operation
Alternator Operation . . . . . . . . . . . . . . . . . . . . .45-05-1

Group 10—Leece-Neville Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .45-10-1
Leece-Neville Repair Specifications. . . . . . . . . .45-10-1
Leece-Neville Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .45-10-1
Repair Alternator . . . . . . . . . . . . . . . . . . . . . . . .45-10-2
Charging System Failure . . . . . . . . . . . . . . . . . .45-10-2
Alternator Troubleshooting . . . . . . . . . . . . . . . .45-10-2
Alternator Output Test . . . . . . . . . . . . . . . . . . . .45-10-3
Diode Trio Test . . . . . . . . . . . . . . . . . . . . . . . . .45-10-3
Full Field Test . . . . . . . . . . . . . . . . . . . . . . . . . .45-10-4
Adjust Regulator . . . . . . . . . . . . . . . . . . . . . . . .45-10-5

45

CTM77 (30OCT00) 45-1 Alternators and Starter Motors

103000
PN=1
 Contents

45

CTM77 (30OCT00) 45-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Leece-Neville Alternator Theory of Operation
Alternator Operation

Vehicle battery power is applied to the ignition terminal

(A), to supply excitation to the field coil (rotor coil) through
the regulator and brushes. This creates a magnetic field
around the rotor and through the stator.

–UN–12SEP00
When the rotor is set in motion, the moving magnetic field
induces an alternating current (AC) in the stator windings.
This output current increases with the speed of the rotor.

RG11155
The AC produced in the stator is converted to direct
Alternator Operation
current (DC) by the positive and negative rectifier
assemblies. The rectifier assemblies are connected to the A—Ignition Terminal
alternator output terminals to provide DC output for B—Battery
charging the batteries and to satisfy the vehicle electrical
loads.

The adjustable regulator monitors the output voltage

through sensing leads which are connected to the positive
and negative rectifier assemblies. When the output
voltage deviates from the set voltage, the regulator takes
corrective action to maintain the output voltage at the
proper level.

OUO1004,0000B34 –19–11SEP00–1/1

45
05
1

CTM77 (30OCT00) 45-05-1 Alternators and Starter Motors

103000
PN=337
 Leece-Neville Alternator Theory of Operation

45
05
2

CTM77 (30OCT00) 45-05-2 Alternators and Starter Motors

103000
PN=338
 Group 10
Leece-Neville Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B8C –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
OUO1004,0000B8C –19–21SEP00–2/2

Leece-Neville Repair Specifications

Item Measurement Specification

Alternator Pulley Nut Torque 95—108 N•m (70—80 lb-ft)

OUO1004,0000B3B –19–13SEP00–1/1

Leece-Neville Charging Circuit Test 45

Specifications 10
1

John Deere Part No. Leece-Neville Part No. Volts Rated Amps
RE500920 A0014860JB 12 200

OUO1022,0000002 –19–14SEP00–1/1

CTM77 (30OCT00) 45-10-1 Alternators and Starter Motors

103000
PN=339
 Leece-Neville Alternator Repair

Repair Alternator

There are no serviceable parts for the alternator available

from John Deere. Replace alternator as required. (Refer
to machine technical manual for removal and installation.)
If alternator pulley is removed, reinstall and torque pulley
nut to specifications.

Specification
Alternator Pulley Nut—Torque ....................... 95—108 N•m (70—80 lb-ft)

OUO1004,0000B35 –19–11SEP00–1/1

Charging System Failure

Causes of Charging System Failure: – Damaged or worn slip rings.

– Poor connection between slip ring assembly and
• Charging system malfunction is identified by battery field coil leads.
condition. – Rotor coil shorted, open, or grounded.
• Alternator generating section malfunction caused by
Undercharged batteries caused by one or a one or a combination of the following:
combination of the following: – Stator phase(s) shorted, open, or grounded.
– Rectifier assembly grounded.
• Loose belts; corroded, broken, loose, or dirty – Rectifier(s) shorted or open.
terminals; broken wiring; undersize wiring; defective Overcharged batteries caused by one or a
batteries. combination of the following:
• Alternator field circuit malfunction caused by one or
a combination of the following: • Defective battery.
– Poor contacts between regulator and brushes. • Defective diode trio.
– Defective diode trio. • Defective or improperly adjusted regulator.
– No residual magnetism in rotor. • Poor sensing lead contact to regulator or rectifier
– Defective or improperly adjusted regulator. assembly.
– Damaged or worn brushes.

OUO1004,0000B3D –19–13SEP00–1/1

45 Alternator Troubleshooting
10
2
NOTE: For fast and accurate troubleshooting, ensure that
belts are properly tensioned, and that wiring and
terminals are in good working condition. Check
batteries per manufacturer’s specifications to
establish if they are defective. Ensure that
batteries are 95—100% charged.

OUO1004,0000B3E –19–13SEP00–1/1

CTM77 (30OCT00) 45-10-2 Alternators and Starter Motors

103000
PN=340
 Leece-Neville Alternator Repair

Alternator Output Test

1. Shut off all electrical accessories and run engine at If either condition is observed, perform DIODE TRIO
approximately 1000—1200 rpm. TEST in this group.

IMPORTANT: Use an accurate voltmeter to NOTE: The following tests are designed to identify the
measure output voltage. DO NOT source of alternator failure. Refer to the
rely on dashboard gauges. manufacturer’s service manual for detailed
descriptions on how to disassemble, test, and
2. Connect a DC voltmeter to the battery terminals properly assemble the alternator. No repair
and measure voltage. Make a note of the readings, parts are available from John Deere. Only
Compare to the values specified by the vehicle replacement alternators are available.
manufacturer. If reading is above specified voltage,
an OVERCHARGE condition is present.

3. If the reading is below specified voltage, an

UNDERCHARGE condition is present.

OUO1004,0000B3F –19–13SEP00–1/1

Diode Trio Test

1. Remove the diode trio from the alternator. NOTE: The diode trio is OK when a LOW resistance
reading is observed in one direction and a
2. Connect the negative (—) ohmmeter test lead to HIGH resistance is observed in the other
the diode trio lead terminal. Connect the positive (+) direction. Occasionally the diode trio
test lead to each of the three copper contact pads, malfunctions under operating conditions only.
one at a time. Observe the resistance at each
contact pad and write down the resistance for each 4. If the diode trio is malfunctioning, replace alternator.
contact for later reference. Otherwise, reinstall the diode trio on the alternator.

3. Reverse the leads so the positive (+) lead is NOTE: There are no serviceable parts available from
connected to the diode trio lead terminal and the John Deere. Replacement of entire alternator
negative (—) test lead connects to the contact is necessary if failure is detected.
pads. Again observe the resistance at each of the 45
contact pads and record the results for each 10
contact. 3

OUO1004,0000B40 –19–13SEP00–1/1

CTM77 (30OCT00) 45-10-3 Alternators and Starter Motors

103000
PN=341
 Leece-Neville Alternator Repair

Full Field Test

1. Run engine at approximately 1000 rpm with all

electrical accessories OFF. Measure the output voltage
across the alternator terminals (C and D) and write it
down for later reference.

–UN–13SEP00
NOTE: Use a digital voltmeter with 0.01-volt reading
capabilities.

RG11157A
2. Attach a short jumper to a 51 mm (2 in.) piece of stiff
wire (a paper clip is suitable).
Test Alternator
3. Connect the other end of the jumper to the negative
A—Ignition Terminal
(—) alternator output terminal (D) and insert the wire in B—Full Field Access Hole
the full field access hole (B). Hold the wire firmly C—Positive Battery Terminal
against the brush terminal inside the housing. D—Negative Output Terminal
E—Terminal 3
F—Terminal 2
4. With the jumper in place, connect a voltmeter across
G—Terminal 1
the alternator terminals (C and D) and run the engine
at approximately 1000 rpm. Compare this voltage
reading with the voltage reading obtained in Step 1.

5. With the jumper still hooked up and the wire in the

FULL FIELD ACCESS HOLE, connect an AC voltmeter
across terminals 1 and 2 (G and F), 1 and 3 (G and
E), and 2 and 3 (F and E), and note the voltages. If all
of the voltages are approximately the same, they are
considered “balanced.”

6. Remove the jumper and wire from the alternator. If the

voltage in step 4 is higher than the voltage in step 1,
and the voltages measured in step 5 are balanced, the
stator and alternator are OK.

If the voltage in step 4 is higher than the voltage in

step 1, and the voltages measured in step 5 are not
balanced, the alternator stator or rectifier(s) are
defective. Replace alternator.

If the voltage in step 4 is lower or equal to the voltage

in step 1, and the voltages measured in step 5 are
balanced, the alternator is defective. Replace
45 alternator.
10
4

Continued on next page OUO1004,0000B38 –19–12SEP00–1/2

CTM77 (30OCT00) 45-10-4 Alternators and Starter Motors

103000
PN=342
 Leece-Neville Alternator Repair

If the voltage in step 4 is lower or equal to the voltage

in step 1, and the voltages measured in step 5 are not
balanced, alternator stator or rectifier(s) are defective.
Replace alternator.
OUO1004,0000B38 –19–12SEP00–2/2

Adjust Regulator

NOTE: Battery must be at least 95% charged prior to

performing this procedure. Also, make sure wire
connections and belt tension are OK.

–UN–13SEP00
1. Shut off all electrical accessories and run the engine at
approximately 1000 rpm.

2. Connect a voltmeter across alternator terminals.

RG11156A
3. Remove plastic screw (A) from regulator and insert a
small screwdriver through hole to engage in slotted Adjust Regulator
adjustment screw inside regulator.
A—Plastic Screw

IMPORTANT: The adjustment potentiometer screw

has high and low stops. DO NOT exert
excessive pressure and force the
screwdriver past the stops.

4. Turn the adjustment screw clockwise to raise the

voltage or counterclockwise to lower the voltage. Set
alternator voltage to vehicle specifications.

5. Reinstall plastic screw (A) in regulator.

OUO1004,0000B37 –19–11SEP00–1/1

45
10
5

CTM77 (30OCT00) 45-10-5 Alternators and Starter Motors

103000
PN=343
 Leece-Neville Alternator Repair

45
10
6

CTM77 (30OCT00) 45-10-6 Alternators and Starter Motors

103000
PN=344
 Section 50
Prestolite Alternators
Contents

Page

Group 05—Prestolite Alternator Theory of

Operation
Alternator Operation . . . . . . . . . . . . . . . . . . . . .50-05-1

Group 10—Prestolite Alternator Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
Prestolite Charging Circuit Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
Repair Alternator . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
Charging System Failure . . . . . . . . . . . . . . . . . .50-10-2
Alternator Troubleshooting . . . . . . . . . . . . . . . .50-10-2
Test Alternator . . . . . . . . . . . . . . . . . . . . . . . . .50-10-3

50

CTM77 (30OCT00) 50-1 Alternators and Starter Motors

103000
PN=1
 Contents

50

CTM77 (30OCT00) 50-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Prestolite Alternator Theory of Operation
Alternator Operation

The alternator converts mechanical and magnetic energy

to AC current and voltage by the rotation of an
electromagnetic field/rotor (C) inside a three-phase stator
assembly (B). The AC current and voltage are changed to

–UN–18SEP00
DC by a three-phase, full-wave rectifier assembly using
negative and positive diodes (A and H).

Since diodes pass current in only one direction, their

RG11160
arrangement in the alternator eliminates the need for a
cut-out relay in the voltage regulator. The individual
rectifier diodes, three positive (H) and three negative (A), Alternator Operation
are assembled in two temperature dissipating heat sinks.
A—Negative Diode Assembly
The heat sinks are placed in the alternator with threaded B—Stator
studs that also serve as circuit terminals. C—Rotor
D—Negative Output
Maximum charging current is limited by the design and E—Diode Trio
connections in the stator assembly, eliminating the need F—Regulator Terminal
G—Positive Output
for a current regulating relay in the voltage regulator. H—Positive Diode Assembly

The diode trio (E) is a low-current version of the rectifier

assembly and must be of the same polarity. The diode trio
allows for the use of a charging lamp and prevents battery
drain when the charging system is not in operation.

The voltage regulator is an electronic switching device

which senses the system voltage level at regulator
terminal (F) and switches the voltage applied to the field
in order to maintain proper system voltage.

OUO1004,0000B43 –19–14SEP00–1/1

50
05
1

CTM77 (30OCT00) 50-05-1 Alternators and Starter Motors

103000
PN=347
 Prestolite Alternator Theory of Operation

50
05
2

CTM77 (30OCT00) 50-05-2 Alternators and Starter Motors

103000
PN=348
 Group 10
Prestolite Alternator Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B8D –19–21SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
OUO1004,0000B8D –19–21SEP00–2/2

Prestolite Charging Circuit Test

Specifications
John Deere Part No. Prestolite Part No. Volts Rated Amps
AH148633 8SC2020Z 12 185
AT178902 8MR2084KS 12 51
RE50811 8MR2069T, 70D43841T, 12 90
70D43841T02
RE20486 70D43198S, 85AZ2035V 12 130

OUO1022,0000001 –19–14SEP00–1/1
50
10
Repair Alternator 1

There are no serviceable parts from John Deere available

for this alternator. Replace alternator as required.

OUO1004,0000B42 –19–14SEP00–1/1

CTM77 (30OCT00) 50-10-1 Alternators and Starter Motors

103000
PN=349
 Prestolite Alternator Repair

Charging System Failure

Causes of Charging System Failure: – Damaged or worn slip rings.

– Poor connection between slip ring assembly and
• Charging system malfunction is identified by battery field coil leads.
condition. – Rotor coil shorted, open, or grounded.
• Alternator generating section malfunction caused by
Undercharged batteries caused by one or a one or a combination of the following:
combination of the following: – Stator phase(s) shorted, open, or grounded.
– Rectifier assembly grounded.
• Loose belts; corroded, broken, loose, or dirty – Rectifier(s) shorted or open.
terminals; broken wiring; undersize wiring; defective Overcharged batteries caused by one or a
batteries. combination of the following:
• Alternator field circuit malfunction caused by one or
a combination of the following: • Defective battery.
– Poor contacts between regulator and brushes. • Defective diode trio.
– Defective diode trio. • Defective or improperly adjusted regulator.
– No residual magnetism in rotor. • Poor sensing lead contact to regulator or rectifier
– Defective or improperly adjusted regulator. assembly.
– Damaged or worn brushes.

OUO1004,0000B3D –19–13SEP00–1/1

Alternator Troubleshooting

NOTE: For fast and accurate troubleshooting, ensure that

belts are properly tensioned, and that wiring and
terminals are in good working condition. Check
batteries per manufacturer’s specifications to
establish if they are defective. Ensure that
batteries are 95—100% charged.

OUO1004,0000B3E –19–13SEP00–1/1

50
10
2

CTM77 (30OCT00) 50-10-2 Alternators and Starter Motors

103000
PN=350
 Prestolite Alternator Repair

Test Alternator

Alternator Output Test

NOTE: Ensure that belts are properly tensioned, and that

wiring and terminals are in good working

–UN–15SEP00
condition. Check batteries per manufacturer’s
specifications to establish if they are defective.
Ensure that batteries are 95—100% charged.

RG11158
IMPORTANT: Use an accurate voltmeter to measure
output voltage. DO NOT rely on
dashboard gauges. Typical Alternator Configuration

A—Ignition Switch
1. Start and run engine at approximately 1000 rpm. Turn B—Charging Lamp
on vehicle headlights and blower fan (low speed). C—Regulator Terminal
Check system voltage by connecting voltmeter to D—Negative Terminals
output terminal (G) and negative battery post. Compare E—Ground
reading to the values specified by the vehicle F—Battery
G—Positive Output Terminal
manufacturer. H—Jumper Wire (Use Only for Diode Trio Test)

2. If alternator voltage does not fall within the specified

range, replace alternator.

Diode Trio Test (MR Series Alternator)

1. Check for battery voltage at output terminal (G) and for

1.5—3 volts at regulator terminal (C).

2. Install jumper wire (H) between terminals (C and G).

3. Operate engine at low idle with all electrical

accessories OFF.

4. If charging lamp (B) is off and charging voltage is

present at output terminal (G), the diode trio is
probably open (defective). Replace alternator.

Field Diode Test (SC Series Alternators)

1. Check for battery voltage at output terminal.

2. Install jumper wire between alternator positive output

tereminal and indicator lamp terminal.

3. Operate engine at low idle with all electrical

accessories OFF.

50
10
3

Continued on next page OUO1004,0000B46 –19–14SEP00–1/2

CTM77 (30OCT00) 50-10-3 Alternators and Starter Motors

103000
PN=351
 Prestolite Alternator Repair

4. Connect voltmeter to positive and negative output

terminals on alternator.

5. If alternator output is 13.5—14.1 volts, the field diode

assembly is defective. Replace alternator.

OUO1004,0000B46 –19–14SEP00–2/2

50
10
4

CTM77 (30OCT00) 50-10-4 Alternators and Starter Motors

103000
PN=352
 Section 60
Delco-Remy Starter Motors 60

Contents

Page Page

Group 05—Starting Circuit Theory of Operation Check Pinion Clearance . . . . . . . . . . . . . . . . .60-10-23

General Information. . . . . . . . . . . . . . . . . . . . . .60-05-1 Make Solenoid No-Load Test . . . . . . . . . . . . .60-10-24
Typical Starting Circuit Operation . . . . . . . . . . .60-05-1
Typical Starter Motor Operation. . . . . . . . . . . . .60-05-2 Group 15—Delco-Remy 30MT, 35MT, 37MT Starter
Motor Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .60-15-1
Group 10—Delco-Remy 10/20/22/25/27/28MT Starter Service Equipment and Tools . . . . . . . . . . . . . .60-15-1
Motor Repair Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .60-15-2
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1 Delco-Remy 30MT, 35MT, and 37MT
Service Equipment and Tools . . . . . . . . . . . . . .60-10-1 Starter Motor Repair Specifications . . . . . . . .60-15-3
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-2 Delco-Remy 30MT, 35MT, and 37MT
Delco-Remy 10MT, 20MT, 22MT, 25MT, Starter Motor Test Specifications . . . . . . . . . .60-15-4
27MT, 28MT Starter Motor Repair Diagnosing Starter Motor Malfunctions . . . . . . .60-15-5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .60-10-3 Delco-Remy Starter Motor Cutaway
Delco-Remy 10MT, 20MT, 22MT, 25MT, View—Series 30MT, 35MT, and 37MT . . . . .60-15-6
27MT, 28MT Starter Motor Test Test Starter Motor Before Disassembly . . . . . . .60-15-7
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .60-10-4 Make No-Load Test for Solenoid. . . . . . . . . . . .60-15-9
Diagnosing Starter Motor Malfunctions . . . . . . .60-10-5 Disassemble Delco-Remy Starter Motor
Delco-Remy Starter Motor Cutaway (Series 35MT Illustrated) . . . . . . . . . . . . . . .60-15-10
View—Series 10MT, 20MT, 22MT, 25MT, 27MT, Install New Bushings During Disassembly. . . .60-15-15
28MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-6 Clean Starter Motor Components . . . . . . . . . .60-15-16
Inspect Armature. . . . . . . . . . . . . . . . . . . . . . .60-15-17
Check Operation of Motor Drive . . . . . . . . . . . .60-10-6
Make Short Circuit Test. . . . . . . . . . . . . . . . . .60-15-17
Make Solenoid Pull-In Test . . . . . . . . . . . . . . . .60-10-7
Make Armature Ground Test . . . . . . . . . . . . . .60-15-18
Make Solenoid Hold-In Test . . . . . . . . . . . . . . .60-10-8
Make Open Circuit Test . . . . . . . . . . . . . . . . .60-15-18
Make Solenoid No-Load Test . . . . . . . . . . . . . .60-10-8
Make Ground Circuit Test for Field
Disassemble Starter Motor and Test Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .60-15-19
Components . . . . . . . . . . . . . . . . . . . . . . . . .60-10-9 Make Open Circuit Test for Shunt
Clean Starter Motor Components . . . . . . . . . .60-10-12 Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .60-15-19
Inspect Armature. . . . . . . . . . . . . . . . . . . . . . .60-10-13 Make Open Circuit Test for Field Windings . . .60-15-20
Make Short Circuit Test. . . . . . . . . . . . . . . . . .60-10-13 Remove Field Windings . . . . . . . . . . . . . . . . .60-15-20
Make Armature Ground Test . . . . . . . . . . . . . .60-10-14 Inspect Brushes . . . . . . . . . . . . . . . . . . . . . . .60-15-21
Make Open Circuit Test . . . . . . . . . . . . . . . . .60-10-14 Test Brush Holder for Ground . . . . . . . . . . . . .60-15-21
Make Ground Circuit Test for Field Inspect Brush Springs . . . . . . . . . . . . . . . . . . .60-15-22
Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-14 Inspect and Clean Solenoid . . . . . . . . . . . . . .60-15-22
Make Open Circuit Test for Field Windings . . .60-10-15 Assemble Solenoid . . . . . . . . . . . . . . . . . . . . .60-15-22
Remove Field Coils (If Necessary) . . . . . . . . .60-10-15 Inspect Plunger, Shift Lever, and Overrunning
Install Field Windings . . . . . . . . . . . . . . . . . . .60-10-16 Clutch Assembly . . . . . . . . . . . . . . . . . . . . .60-15-23
Disassemble Solenoid . . . . . . . . . . . . . . . . . . .60-10-16 Assemble Starter Motor. . . . . . . . . . . . . . . . . .60-15-23
Inspect and Clean Solenoid Parts . . . . . . . . . .60-10-17 Check Armature End Play . . . . . . . . . . . . . . . .60-15-26
Check for Proper Pinion Clearance . . . . . . . . .60-15-27
Assemble Solenoid . . . . . . . . . . . . . . . . . . . . .60-10-18
Make No-Load Test (After Assembly) . . . . . . .60-15-28
Remove Drive End Bushing and Wick. . . . . . .60-10-18
Install Drive End Bushing and Wick. . . . . . . . .60-10-19 Group 20—Delco-Remy 40MT, 41MT, 42MT, 50MT
Inspect Drive Motor ID . . . . . . . . . . . . . . . . . .60-10-19 Starter Motor Repair
Inspect Center Bushing ID . . . . . . . . . . . . . . .60-10-20 Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1
Inspect Commutator End Frame Bushing . . . .60-10-20
Assemble Starter Motor. . . . . . . . . . . . . . . . . .60-10-21 Continued on next page

CTM77 (30OCT00) 60-1 Alternators and Starter Motors

103000
PN=1
 Contents

Page

60
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-2
Delco-Remy 40MT, 41MT, 42MT, and
50MT Starter Motor Repair Specifications . . .60-20-3
Delco-Remy 40MT, 41MT, 42MT, and
50MT Starter Motor Test Specifications . . . . .60-20-4
Diagnosing Starter Motor Malfunctions . . . . . . .60-20-5
Delco-Remy Starter Motor Cutaway
View—Series 40MT, 41MT, 42MT, and
50MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-6
Test Starter Motor Before Disassembly . . . . . . .60-20-6
Test Pull-In and Hold-In Windings . . . . . . . . . . .60-20-9
Make No-Load Test. . . . . . . . . . . . . . . . . . . . .60-20-10
Disassemble Delco-Remy Starter Motor (
Series 50MT Illustrated). . . . . . . . . . . . . . . .60-20-12
Make Ground Circuit Test for Field
Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-17
Make Open Circuit Test for Shunt
Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-17
Make Open Circuit Test for Field Windings . . .60-20-18
Remove Field Windings . . . . . . . . . . . . . . . . .60-20-18
Inspect Brushes . . . . . . . . . . . . . . . . . . . . . . .60-20-19
Test Brush Holder for Ground . . . . . . . . . . . . .60-20-20
Inspect Brush Springs . . . . . . . . . . . . . . . . . . .60-20-20
Install New Bushings—40MT, 41MT, and
42MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-21
Install New Bushings—50MT. . . . . . . . . . . . . .60-20-23
Clean Starter Motor Components . . . . . . . . . .60-20-24
Inspect Armature. . . . . . . . . . . . . . . . . . . . . . .60-20-25
Make Short Circuit Test. . . . . . . . . . . . . . . . . .60-20-25
Make Armature Ground Test . . . . . . . . . . . . . .60-20-26
Make Open Circuit Test . . . . . . . . . . . . . . . . .60-20-26
Inspect Solenoid Plunger and Shift Lever
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-27
Inspect Overrunning Clutch and Pinion . . . . . .60-20-27
Inspect and Clean Solenoid . . . . . . . . . . . . . .60-20-28
Assemble Solenoid . . . . . . . . . . . . . . . . . . . . .60-20-28
Assemble Starter Motor. . . . . . . . . . . . . . . . . .60-20-29
Check for Proper Pinion Clearance . . . . . . . . .60-20-32

CTM77 (30OCT00) 60-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Starting Circuit Theory of Operation
General Information

IMPORTANT: Never operate starter motor longer than 60

05
30 seconds. Allow at least 2 minutes for 1
cooling and battery recovery before
operating again. Overheating caused by
excessive operation will seriously
damage starter motor.

RG,RG34710,2192 –19–15MAR97–1/1

Typical Starting Circuit Operation

When wire from relay (A) is energized, current flows

through both pull-in winding (C) and hold-in winding (D) to
ground.

Current through windings engages solenoid plunger (E),

which closes main contacts (F). When main contacts

–UN–20APR89
close, current through pull-in windings stops. Current
continues through hold-in winding, keeping solenoid
engaged and main contacts closed.

RG1313
With main contacts closed, current flows from battery
cable (B) to starter motor at a very high rate. Four heavy Typical Starting Circuit Operation
field windings (G) carry current to commutator brushes
(H). A—Wire from Relay
B—Cable from Battery
C—Pull-In Winding
Light shunt windings (J) are wrapped together with two of D—Hold-In Winding
the heavy field windings. Shunt windings are connected to E—Solenoid Plunger
solenoid switch terminal and directly to ground. They F—Main Contacts
provide additional low speed torque to assist engine G—Field Windings
rotation and prevent overheating of motor. H—Commutator Brushes
I—Armature
J—Shunt Windings
From field windings, current flows through armature
windings (I) to ground, making contact through
commutator brushes (H).

Strong magnetic fields are set up by current flow through

field windings and armature windings. Windings are
arranged so that magnetic fields constantly repel each
other, rotating armature.

RG,RG34710,2193 –19–09OCT00–1/1

CTM77 (30OCT00) 60-05-1 Alternators and Starter Motors

103000
PN=355
 Starting Circuit Theory of Operation

Typical Starter Motor Operation

60
05
2

–UN–14NOV88
R25228
Typical Starter Motor Operation

1—Snap Ring 7—Field Connector 13—Field Windings 19—Brake Washer

2—Drive End Housing 8—End Frame Cover 14—Armature 20—Wear Pads
3—Shift Lever 9—Brush 15—Pole Shoe 21—Overrunning Clutch
4—Plunger 10—Bushing 16—Oil Seal 22—Pinion Stop
5—Shunt Field Terminal 11—Thrust Washers 17—Bushing 23—Bushing
6—Solenoid Assembly 12—Commutator 18—Felt

When solenoid (6) engages, it pulls shift lever (3). Shift but direction of current is reversed in pull-in winding.
lever pushes overrunning clutch drive (21) to engage The two windings cancel each other, and solenoid is
pinion in starter gear on flywheel. As armature (14) released.
turns, it cranks engine.
A spring pushes solenoid back to disengaged position.
When engine starts, overrunning clutch spins freely on This opens main contacts and shuts off current to field
shaft. This prevents overspeeding of armature by windings and armature.
flywheel.
Shift lever retracts overrunning clutch drive,
When key switch is released, current to solenoid disengaging pinion from flywheel. Brake washer (19)
hold-in winding is shut off. Current can feed through slows armature to a stop.
both pull-in and hold-in windings from main contacts,

RG,RG34710,2194 –19–15MAR97–1/1

CTM77 (30OCT00) 60-05-2 Alternators and Starter Motors

103000
PN=356
 Group 10
Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the 60

10
U.S. SERVICEGARD Catalog or from the 1
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B8F –19–25SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B8F –19–25SEP00–2/2

Service Equipment and Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B90 –19–25SEP00–1/2

Bushing, Bearing, and Seal Driver Set. . . . . . D01045AA

Remove and install all commutator, drive end, and center

bushings and/or bearings.

OUO1004,0000B90 –19–25SEP00–2/2

CTM77 (30OCT00) 60-10-1 Alternators and Starter Motors

103000
PN=357
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Other Material
60 Number Name Use
10
2
(U.S.) Mineral Spirits Clean armature, solenoid and
brushes.

(U.S.) 00 Sandpaper Clean commutator.

OUO1004,0000B91 –19–25SEP00–1/1

CTM77 (30OCT00) 60-10-2 Alternators and Starter Motors

103000
PN=358
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Delco-Remy 10MT, 20MT, 22MT, 25MT, 27MT,

28MT Starter Motor Repair Specifications
60
10
Item Measurement Specification 3

Brush Spring Minimum Tension 990 gram force(35 ounce-force)

Brushes Minimum Length Beyond Holder 7.9 mm (0.31 in.)

Field Pole Shoe Screws Torque 41 N•m (30 lb-ft)

Solenoid “R” Terminal Contact Height 1.59—2.38 mm (0.062—0.093 in.)

New Drive End Housing Bushing ID 11.709—11.811 mm (0.4610—

0.4650 in.)
Wear Limit 12.065 mm (0.475 in.)
Oil Clearance 0.051—0.127 mm (0.0020—0.0050
in.)
Wear Limit 0.432 mm (0.0170 in.)

Motor Drive ID 14.275—14.300 mm (0.5620—

0.5630 in.)
Wear Limit 14.579 mm (0.5740 in.)

New Center Bearing Plate Bushing ID 19.304—19.354 mm (0.7600—

0.7620 in.)
Wear Limit 19.608 mm (0.7720 in.)
Oil Clearance 0.254—0.381 mm (0.0100—0.0150
in.)
Wear Limit 0.635 mm (0.0250 in.)

New Commutator End Frame ID 14.313—14.338 mm (0.5635—

Bushing 0.5645 in.)
Wear Limit 14.554 mm (0.5730 in.)
Oil Clearance 0.051—0.127 mm (0.0020—0.0050
in.)
Wear Limit 0.406 mm (0.0160 in.)

Housing Attaching Cap Screws Torque 18—23 N•m (159—204 lb-in.)

Commutator End Frame Cap Screws Torque 18—23 N•m (159—204 lb-in.)

Pinion-to-Pinion Stop Clearance 0.25—3.56 mm (0.010—0.140 in.)

OUO1004,0000B92 –19–25SEP00–1/1

CTM77 (30OCT00) 60-10-3 Alternators and Starter Motors

103000
PN=359
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Delco-Remy 10MT, 20MT, 22MT, 25MT, 27MT,

28MT Starter Motor Test Specifications
60
10
No Load Test (Includes Solenoid Current)
4
John Deere Delco-Remy System Motor Current Draw (Amps) Armature RPM
Part No. Model No. -Series Voltage Voltage
AH76330 1108360-10MT 12 9 — 3500—6000
AR11160 1109434 12 10 65—110 6500—10700
AR11161 1107547 24 23.5 60—130 4900—8500
AR60085 1109147-20MT 12 9 50—80 5500—9000
AR69750 1998364-22MT 12 10 75—175 6900—14900
AR91813 1109576-SD300 12 10 65—110 6500—10700
AT10806 1107736 12 9 50 3500—6000
AT10958 1113104 12 9 50—75 3500—5500
AT11324 1107175 6 5.6 70 5500
AT12283 1107879 12 9 55—80 3500—6000
AT12458 1108672 12 11.8 55—85 6300—8700
AT15335 1107547 24 23.5 60—130 4900—8500
AT16883 1107176 6 5.6 70 5500
AT17411 1108672 12 11.8 55—85 6300—8700
AT18025 1109421-SD300 12 10 60—90 6500—10500
AT18150 1107577-20MT 12 9 40—140 8000—13000
AT18150 1107599-20MT 12 9 40—140 8000—13000
AT18150 1107863-20MT 12 9 40—140 8000—13000
AT18150 1107871-20MT 12 9 40—140 8000—13000
AT19196 1998364-20MT 12 10 75—175 6900—14900
AT25619 1107863-20MT 12 9 40—140 8000—13000
AT25619 1107871-20MT 12 10 75—175 8000—13000
AT418T 1107685 12 9 50—75 3500—6000
AT452T 1107713 12 9 50—75 3500—6000
RE19187 1998367-20MT 12 9 40—140 6900—14900
RE19737 1998519-20MT 24 20 40—80 8000—13700
RE50095 1113271-28MT 12 10 125—190 3000—5600
RE51723 1113283-28 MT 12 10 125—190 3000—5600
RE51725 1113272-28MT 24 20 75—100 3600—6300
RE52119 1113272-28MT 24 20 75—100 3600—6300
RE60654 10479628-28MT 12 10.6 135—190 3600—5600
RE62916 1113271-28MT 12 10 125—190 3000—5600
RE64647 10479630-28MT 12 10.6 135—190 3600—5600

RG,RG34710,2198 –19–08SEP00–1/1

CTM77 (30OCT00) 60-10-4 Alternators and Starter Motors

103000
PN=360
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Diagnosing Starter Motor Malfunctions

Fails to Operate, No Current Draw Low Speed, High Current Draw 60

10
5
Open field circuit (all field windings) Excessive friction

Open armature windings Shorted armature

Defective brush contact with commutator Grounded armature or field windings

Open solenoid windings High Speed, High Current Draw

Defective solenoid contacts Shorted field windings

Fails to Operate, High Current Draw NOTE: This test will not detect individual
open-circuited field coils—the stator would
Grounded field windings or armature windings have a slow cranking speed but would pass
this test.
Seized bearings

Low Speed, Low Current Draw

High internal resistance

Defective brush contact with commutator

RG,RG34710,2199 –19–15MAR97–1/1

CTM77 (30OCT00) 60-10-5 Alternators and Starter Motors

103000
PN=361
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Delco-Remy Starter Motor Cutaway View—

Series 10MT, 20MT, 22MT, 25MT, 27MT, 28MT
60
10
6 IMPORTANT: Never operate starter motor more than
30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating, caused
by excessive operation, will seriously
damage starter motor.

A—Grommet
B—Field Connectors

–UN–22SEP88
C—Plunger
D—Solenoid
E—Return Spring
F—Shift Lever
G—Brake Washer

N27622
H—Bushing
I—Pinion Stop
J—Overheating Clutch Series 20MT Shown
K—Spiral Splines
L—Center Bearing
M—Field Coil
N—Armature
O—Bushing

RG,RG34710,2200 –19–15MAR97–1/1

Check Operation of Motor Drive

1. Turn overrunning clutch pinion by hand. Clutch pinion

should turn freely on shaft in overrunning direction
only.
–UN–01NOV88
T81530

Turn Overrunning Clutch Pinion

Continued on next page RG,RG34710,2201 –19–15MAR97–1/2

CTM77 (30OCT00) 60-10-6 Alternators and Starter Motors

103000
PN=362
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

2. Turn armature by prying against pinion with

screwdriver. Check for dragging armature, seized
bushings or bent shaft. 60
10
7
If there is any interference, disassemble and repair
starter motor.

–UN–01NOV88
NOTE: DO NOT conduct the no-load test unless armature
turns freely.

T81531
Turn Armature

RG,RG34710,2201 –19–15MAR97–2/2

Make Solenoid Pull-In Test

1. To prevent damage, solenoid must be on starter motor

when testing the windings.

2. Disconnect field connector from solenoid “M” terminal

–UN–01NOV88
as shown.

T81532
Disconnect Field Connector
RG,RG34710,2202 –19–15MAR97–1/2

3. Make connections as shown. Quickly adjust the carbon

pile resistor to obtain 5 volts. The ammeter reading
must be 13—15.5 amps.

1—Voltmeter
2—Carbon Pile Resistor
–UN–25MAY89

3—Battery
4—Ammeter
T81519

Make Connections

RG,RG34710,2202 –19–15MAR97–2/2

CTM77 (30OCT00) 60-10-7 Alternators and Starter Motors

103000
PN=363
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Make Solenoid Hold-In Test

60 Make connections as shown. Adjust the carbon pile
10
8
resistor to obtain 10 volts. The ammeter reading should
be 14.5—16.5 amps.

–UN–25MAY89
A high ammeter reading indicates windings are grounded
or short circuited.

A low ammeter reading indicates excessive resistance

T81520
(usually in a connection).

No ammeter reading indicates windings are open Make Solenoid Hold-In Test
circuited.
1—Voltmeter
2—Carbon Pile Resistor
To prevent overheating, do not energize the pull-in 3—Battery
winding longer than 15 seconds. Current draw will 4—Ammeter
decrease as the winding temperature increases.

If the fault cannot be repaired and the solenoid

performance is questionable, replace the windings.

RG,RG34710,2203 –19–15MAR97–1/1

Make Solenoid No-Load Test

1. Clamp starter motor drive housing in vise.

2. Make connections as shown.

–UN–25MAY89
3. Close switch to operate starter motor and adjust
carbon pile resistor to obtain 9.0 volts.

Current draw must be to specifications given at

T81521
beginning of this group.

Make Solenoid No-Load Test

1—Carbon Pile Resistor
2—Battery
3—Ammeter
4—Voltmeter
5—Jumper Lead with Switch
6—Tachometer

DPSG,OUOE003,27 –19–17DEC98–1/1

CTM77 (30OCT00) 60-10-8 Alternators and Starter Motors

103000
PN=364
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Disassemble Starter Motor and Test Components

60
10
9

–UN–20APR89
N38155
Delco-Remy No. 1998367 Shown

1—Bushing 13—Armature 23—Snap Ring 33—Brush Pivot Pin (2 Used)

2—Lubricating Wick 14—Thrust Washer 24—Thrust Collar 34—Brush Holder Kit
3—Plug 15—Center Bearing Assembly 25—Dowel Pin 35—Bushing
4—Drive End Housing 16—Brake Washer 26—Field Frame 36—Lubricating Wick
5—Shifter Pivot Screw 17—Lock Wire 27—Insulating Bushing 37—Commutator End Frame
6—Spring Pin 18—Collar 28—Field Winding Coil 38—Bolt (2 Used)
7—Shifter 19—Overrunning Clutch 29—Brush Spring (2 Used) 39—Brush Ground Lead (2
8—Solenoid Plunger Spring 30—Grounded Brush Holder (2 Used)
9—Solenoid Return Spring 20—Bushing Used) 40—Brush (4 Used)
10—Gasket 21—Overrunning Clutch 31—Insulated Brush Holder (2 41—Field Pole Shoe
11—Solenoid Assembly Assembly Used) 42—Pole Shoe Screw (8 Used)
12—Field Coil Connector 22—Pinion Stop 32—Brush Mounting Screws (4
Used)

RG,RG34710,2204 –19–15MAR97–1/11

1. Remove commutator end frame cap screws and

commutator end frame.
–UN–22MAR90
T81535

Remove Commutator End Frame

Continued on next page RG,RG34710,2204 –19–15MAR97–2/11

CTM77 (30OCT00) 60-10-9 Alternators and Starter Motors

103000
PN=365
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

2. Disconnect field coil connector and remove field frame.

60
10
10

–UN–22MAR90
T81536
Remove Field Frame
RG,RG34710,2204 –19–15MAR97–3/11

3. Make sure brushes are not binding holders. The full

brush surface must ride on commutator.

4. Check by hand to make certain brush springs are

giving firm contact between brushes and commutator.
If springs are distorted or discolored, replace them.

–UN–12APR90
T5983AV
Check Brushes and Brush Springs

RG,RG34710,2204 –19–15MAR97–4/11

5. Remove brush pins, brush holders and brush springs.

Check brush spring tension.

Specification
Brush Spring—Minimum Tension........... 990 gram force (35 ounce-force)
–UN–22MAR90
T81537

Remove Pins, Holders, and Springs

Continued on next page RG,RG34710,2204 –19–15MAR97–5/11

CTM77 (30OCT00) 60-10-10 Alternators and Starter Motors

103000
PN=366
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

6. Check brushes for being oil soaked or worn beyond

specifications.
60
Specification 10
Brushes—Minimum Length 11
Beyond Holder ................................................................ 7.9 mm (0.31 in.)

–UN–22MAR90
T81523
Measure Brushes
RG,RG34710,2204 –19–15MAR97–6/11

7. Tighten screws securely when installing new brushes.

–UN–22MAR90
T81538
Tighten Screws Securely
RG,RG34710,2204 –19–15MAR97–7/11

8. Remove screws, solenoid switch assembly, solenoid

gasket and plunger return spring.

Remove Parts –UN–22MAR90

T81539
RG,RG34710,2204 –19–15MAR97–8/11

9. Remove the shift lever cap screw and center bearing

screws (A).

10. Remove armature.

–UN–21FEB90

A—Bearing Screws
T88855

Remove Armature

Continued on next page RG,RG34710,2204 –19–15MAR97–9/11

CTM77 (30OCT00) 60-10-11 Alternators and Starter Motors

103000
PN=367
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

11. Use a 1/2-in. pipe nipple or other suitable metal

cylinder to drive pinion stop toward pinion.
60
10
12

–UN–22MAR90
T81541
Drive Pinion Stop
RG,RG34710,2204 –19–15MAR97–10/11

12. Remove retaining ring (A), pinion stop, and

overrunning clutch drive.

13. Remove brake washer and center bearing plate (B).

–UN–21FEB90
A—Retaining Ring
B—Bearing Plate

T88856
Center Bearing Plate
RG,RG34710,2204 –19–15MAR97–11/11

Clean Starter Motor Components

IMPORTANT: Never clean armature, field windings, or

overrunning clutch drive in solvent. All
parts except overrunning clutch drive
may be cleaned with mineral spirits and
a brush.

1. Clean components using mineral spirits and a brush.

2. Dry with compressed air or a clean cloth.

DPSG,OUOE003,28 –19–17DEC98–1/1

CTM77 (30OCT00) 60-10-12 Alternators and Starter Motors

103000
PN=368
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Inspect Armature

–UN–25JAN89
1. Place armature in V-blocks and check for a bent shaft. 60
10
Replace armature if shaft is bent. 13

2. Inspect armature for signs of dragging against pole

X1451
shoes or scoring under bushings.
Inspect Armature
3. Carefully check commutator for roughness, burned
commutator bars or any material that might cause
short circuits between bars.

4. Clean and touch up commutator, if necessary, with 00

sandpaper. NEVER use emery cloth.

NOTE: If commutator is out of round, badly burned or

rough, it can be turned down slightly on a lathe.
Remove only enough metal to eliminate problem.
Do not undercut commutator after turning, as this
will cause shorts between commutator bars.

RG,RG34710,2205 –19–15MAR97–1/1

Make Short Circuit Test

Place armature in a growler and hold hacksaw blade

above each slot while slowly rotating the armature.

If coil is shorted, the blade will be attracted to and

repelled from the slot.

–UN–07DEC88
Short circuit most often occurs because of copper dust or
filings between two commutator segments. Clean

T81543
commutator segments to correct this short.

Make Short Circuit Test

RG,RG34710,2206 –19–15MAR97–1/1

CTM77 (30OCT00) 60-10-13 Alternators and Starter Motors

103000
PN=369
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Make Armature Ground Test

60 1. Set ohmmeter to read on highest scale.
10
14
2. Place one test lead on the armature core or shaft.
Place other lead on commutator.

–UN–20NOV89
If the test meter indicator swings toward zero, the
armature is grounded. Replace armature.

T90253
Make Armature Ground Test

RG,RG34710,2207 –19–15MAR97–1/1

Make Open Circuit Test

1. Set ohmmeter to read on lowest scale.

2. Place one test lead on ohmmeter segment. Place other

test lead on an adjacent segment.

–UN–19OCT88
3. Repeat this operation for all segments by moving one
lead at a time.

T90254
If the test meter indicator does not swing to zero and
remain stationary, the armature coil between these two
segment is open. Replace armature. Make Open Circuit Test

RG,RG34710,2208 –19–15MAR97–1/1

Make Ground Circuit Test for Field Windings

1. Set ohmmeter to read on highest scale.

2. Connect one test lead to the field frame and the other
test lead to the field connector.
–UN–22MAR90

If the test meter indicator swings toward zero, the field

coils are grounded. Replace the field windings.
T81546

Make Ground Circuit Test

RG,RG34710,2209 –19–15MAR97–1/1

CTM77 (30OCT00) 60-10-14 Alternators and Starter Motors

103000
PN=370
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Make Open Circuit Test for Field Windings

1. Set ohmmeter on its lowest scale. 60

10
15
2. Connect one test lead to a field coil lead. Connect the

–UN–22MAR90
other test lead to the field connector.

If the test meter indicator does not swing to zero and

remains stationary, the field coils have an open circuit.

T81547
Replace field coils.

Make Open Circuit Test

RG,RG34710,2210 –19–15MAR97–1/1

Remove Field Coils (If Necessary)

1. The field connector must be removed before the field

coils can be removed from frame.

–UN–22MAR90
T81548
Remove Field Connector
RG,RG34710,2211 –19–15MAR97–1/2

2. Place field frame in a soft-jawed vise.

IMPORTANT: Do not squeeze sides of field frame in

vise or strike with a hammer. If an
impact screwdriver is used to remove
pole shoe screws, support each pole

–UN–22MAR90
shoe individually using a pole shoe
spreader or nose of anvil.

3. Make a scribe mark on pole shoe and field frame for

T81549
proper assembly.
Remove Field Windings
4. Use a large screwdriver bit and socket wrench to
remove pole shoe screws.

5. Remove pole shoes. Then carefully remove field

windings as an assembly.

IMPORTANT: Handle windings very carefully.

Windings are easily damaged, causing
shorts, opens, or grounds.

RG,RG34710,2211 –19–15MAR97–2/2

CTM77 (30OCT00) 60-10-15 Alternators and Starter Motors

103000
PN=371
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Install Field Windings

60 1. Carefully insert field windings.
10
16
2. Align scribe marks on pole shoes and field frame.
Assemble shoe so the long lip points in direction of
armature rotation.

3. Tighten pole shoe screws to specifications. Use a

center punch to lightly stake one edge of each screw.

Specification
Field Pole Shoe Screws—Torque ................................... 41 N•m (30 lb-ft)

RG,RG34710,2212 –19–15MAR97–1/1

Disassemble Solenoid

1. Remove hex nuts from “M” and “S” terminals (A) and
(B).

2. Remove the two screws (C) and cover.

–UN–02APR90
A—“M” Terminal
B—“S” Terminal
C—Cover Screws

T5966AB
Disassemble Solenoid

RG,RG34710,2213 –19–15MAR97–1/1

CTM77 (30OCT00) 60-10-16 Alternators and Starter Motors

103000
PN=372
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Inspect and Clean Solenoid Parts

Inspect all solenoid parts for wear, dirt, and corrosion. 60

10
17
Wipe all parts and connections with mineral spirits and a
clean cloth or brush. Dry with a clean cloth.

–UN–11APR90
Firm pressure should be felt on the plunger when fully
depressed. If plunger is weak, replace solenoid winding
and plunger assembly.

T5966AA
Inspect and Clean Solenoid Parts

RG,RG34710,2214 –19–15MAR97–1/3

The “R” terminal contact finger (B) height above the

surface of the main contact (A) must be 1.59—2.38 mm
(1/16—3/32 in.). Bend contact finger if adjustment is
necessary.

–UN–21FEB90
Specification
Solenoid “R” Terminal Contact—
Height .................................................. 1.59—2.38 mm (0.062—0.093 in.)

T88858
A—Main Contact
B—“R” Terminal Contact Finger
“R” Terminal Contact Finger

RG,RG34710,2214 –19–15MAR97–2/3

Replacement “S” terminal and “M” terminal stud clips must

be crimped to winding leads.
–UN–22MAR90
T81553

Replacement Stud Clips

RG,RG34710,2214 –19–15MAR97–3/3

CTM77 (30OCT00) 60-10-17 Alternators and Starter Motors

103000
PN=373
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Assemble Solenoid
60 1. Place gasket on winding terminal.
10
18
2. Align main contact vertically.

3. Place packing on switch cover.

4. Tighten switch cover screws to solenoid winding and

plunger assembly securely.

NOTE: Solenoid contacts and plunger will be damaged if

current is applied to solenoid when removed from
starter motor.

RG,RG34710,2215 –19–15MAR97–1/1

Remove Drive End Bushing and Wick

1. Measure drive end bushing.

Specification
New Drive End Housing

–UN–22MAR90
Bushing—ID............................................................... 11.709—11.811 mm
(0.4610—0.4650 in.)
Wear Limit .............................................................. 12.065 mm (0.475 in.)
Oil Clearance ................................................................. 0.051—0.127 mm
(0.0020—0.0050 in.)

T81524
Wear Limit .............................................................. 0.432 mm (0.0170 in.)

Measure Drive End Bushing

RG,RG34710,2216 –19–15MAR97–1/3

2. Remove plug and drive end wick.

–UN–22MAR90
T81556

Remove Plug and Drive End Wick

Continued on next page RG,RG34710,2216 –19–15MAR97–2/3

CTM77 (30OCT00) 60-10-18 Alternators and Starter Motors

103000
PN=374
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

3. Use 27493 Disk (1) and 27491 Disk (2) from

D01045AA Bushing, Bearing and Seal Driver Set to
remove the drive end bushing. 60
10
19
1—27493 Disk

–UN–22MAR90
2—27491 Disk

T81557
27493 Disk and 27491 Disk
RG,RG34710,2216 –19–15MAR97–3/3

Install Drive End Bushing and Wick

1. Install drive end bushing by pressing it from the outside

in. Press it even with the end of the drive housing.

–UN–22MAR90
T81558
Drive End Bushing and Wick
RG,RG34710,2217 –19–15MAR97–1/2

2. Drill bushing through oil wick hole using same size drill
as oil wick hole.

3. After drilling, ream bushing to maintain proper oil

clearance between shaft and bushing.

–UN–22MAR90
4. Soak new wicks in SAE 10 engine oil. Install drive end
wick and pipe plug.

Drive End Wick and Pipe Plug T81559

RG,RG34710,2217 –19–15MAR97–2/2

Inspect Drive Motor ID

Measure the motor drive ID.

Specification
Motor Drive—ID ......................................................... 14.275—14.300 mm
–UN–22MAR90

(0.5620—0.5630 in.)
Wear Limit ............................................................ 14.579 mm (0.5740 in.)

The motor drive cannot be repaired and must be replaced

T81525

if defective.

Inspect Drive Motor ID

RG,RG34710,2218 –19–15MAR97–1/1

CTM77 (30OCT00) 60-10-19 Alternators and Starter Motors

103000
PN=375
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Inspect Center Bushing ID

60 Measure the center bushing ID and oil clearance.
10
20
Specification
New Center Bearing Plate

–UN–22MAR90
Bushing—ID............................................................... 19.304—19.354 mm
(0.7600—0.7620 in.)
Wear Limit ............................................................ 19.608 mm (0.7720 in.)
Oil Clearance ................................................................. 0.254—0.381 mm
(0.0100—0.0150 in.)

T81526
Wear Limit .............................................................. 0.635 mm (0.0250 in.)

Inspect Center Bushing ID

Burnish bushing to size if necessary.

RG,RG34710,2219 –19–15MAR97–1/1

Inspect Commutator End Frame Bushing

Measure commutator end frame bushing ID and oil

clearance.

Specification

–UN–22MAR90
New Commutator End Frame
Bushing—ID............................................................... 14.313—14.338 mm
(0.5635—0.5645 in.)
Wear Limit ............................................................ 14.554 mm (0.5730 in.)
Oil Clearance ................................................................. 0.051—0.127 mm

T81527
(0.0020—0.0050 in.)
Wear Limit .............................................................. 0.406 mm (0.0160 in.)
Inspect Commutator End Frame Bushing

Burnish bushing to size if necessary.

RG,RG34710,2220 –19–18OCT00–1/1

CTM77 (30OCT00) 60-10-20 Alternators and Starter Motors

103000
PN=376
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

Assemble Starter Motor

1. Lubricate splines and drive end of armature shaft with 60

10
SAE 10 engine oil. 21

2. Install center bearing plate and brake washer.

–UN–22MAR90
T81560
Lubricate Splines and Armature Shaft

RG,RG34710,2221 –19–15MAR97–1/7

3. With motor drive in place on armature shaft, install

pinion stop (A) with cupped side toward drive end of
armature shaft.

4. Use the drive end thrust collar (B) and a 1/2-in. pipe

–UN–21FEB90
nipple, or other suitable metal cylinder, to drive the
retaining ring (C) into its groove on the armature shaft.

T88860
A—Pinion Stop
B—Drive End Thrust Collar
C—Retaining Ring Armature Shaft

RG,RG34710,2221 –19–15MAR97–2/7

5. Use pliers and the drive end thrust collar (A) to force
the pinion stop into place over the retaining ring.

6. Hold thrust collar (A) in place while installing armature.

–UN–21FEB90

A—Drive End Thrust Collar

T88861

Hold Thrust Collar

Continued on next page RG,RG34710,2221 –19–15MAR97–3/7

CTM77 (30OCT00) 60-10-21 Alternators and Starter Motors

103000
PN=377
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

7. With shift lever fork in motor drive collar, install

armature, shift lever and solenoid switch plunger in
60 drive housing.
10
22
8. Install the shift lever cap screw and the center bearing

–UN–21FEB90
plate screws (A).

A—Center Bearing Plate Screws

T88855
Center Bearing Plate Screws

RG,RG34710,2221 –19–15MAR97–4/7

9. Install solenoid gasket and plunger return spring.

–UN–22MAR90
T81563
Solenoid Gasket/Plunger Return Spring
RG,RG34710,2221 –19–15MAR97–5/7

10. Install solenoid switch assembly and screws.

11. Install commutator end spacer washer (A).

–UN–21FEB90
A—Commutator End Spacer Washer

Commutator End Spacer Washer T88862

Continued on next page RG,RG34710,2221 –19–15MAR97–6/7

CTM77 (30OCT00) 60-10-22 Alternators and Starter Motors

103000
PN=378
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

12. Install frame, with field coil assembly and brushes,

onto rotor.
60
Specification 10
Housing Attaching Cap Screws— 23
Torque ........................................................ 18—23 N•m (159—204 lb-in.)

–UN–22MAR90
13. Attach field connector to the solenoid switch “M”
terminal.

T81535
14. Install commutator end frame and cap screws and
tighten to specifications.
Install Commutator End Frame
Specification
Commutator End Frame Cap
Screws—Torque ......................................... 18—23 N•m (159—204 lb-in.)

RG,RG34710,2221 –19–15MAR97–7/7

Check Pinion Clearance

Pinion clearance cannot be adjusted, but must be

checked after reassembly of the starter motor. Improper
clearance is an indication of worn parts.

1. Disconnect motor field coil connector from the solenoid

motor terminal and insulate it carefully.

2. Make connections as shown using a 12-volt battery.

A—Battery
B—Solenoid
C—Starter Motor
D—Jumper Wire

–UN–25MAY89
T88952

Check Pinion Clearance

Continued on next page RG,RG34710,2222 –19–15MAR97–1/2

CTM77 (30OCT00) 60-10-23 Alternators and Starter Motors

103000
PN=379
 Delco-Remy 10/20/22/25/27/28MT Starter Motor Repair

3. Momentarily touch a jumper lead from the solenoid

motor terminal to solenoid frame. The pinion will shift
60 into cranking position and remain until the battery is
10
24
disconnected.

4. Push pinion toward armature.

–UN–22MAR90
5. Measure the distance between pinion and pinion stop.

Specification

T81528
Pinion-to-Pinion Stop—Clearance ....... 0.25—3.56 mm (0.010—0.140 in.)

Push Pinion Toward Armature

RG,RG34710,2222 –19–15MAR97–2/2

Make Solenoid No-Load Test

1. Clamp starter motor drive housing in vise.

2. Make connections as shown.

–UN–25MAY89
3. Close switch to operate starter motor and adjust
carbon pile resistor to obtain 9.0 volts.

Current draw must be to specifications given at

T81521
beginning of this group.

Make Solenoid No-Load Test

1—Carbon Pile Resistor
2—Battery
3—Ammeter
4—Voltmeter
5—Jumper Lead with Switch
6—Tachometer

RG,RG34710,2223 –19–15MAR97–1/1

CTM77 (30OCT00) 60-10-24 Alternators and Starter Motors

103000
PN=380
 Group 15
Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the 60

15
U.S. SERVICEGARD Catalog or from the 1
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B93 –19–25SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B93 –19–25SEP00–2/2

Service Equipment and Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B94 –19–25SEP00–1/2

Bushing, Bearing, and Seal Driver Set. . . . . . D01045AA

Remove and install all commutator, drive end, and center

bushings and/or bearings.

OUO1004,0000B94 –19–25SEP00–2/2

CTM77 (30OCT00) 60-15-1 Alternators and Starter Motors

103000
PN=381
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Other Material
60 Number Name Use
15
2
(U.S.) Mineral Spirits Clean armature, solenoid and
brushes.

(U.S.) 00 Sandpaper Clean commutator.

(U.S.) ESSO Beacon 325 or Delco-Remy Lubricate various stator components.

No. 1960954 Lubricant

OUO1004,0000B95 –19–25SEP00–1/1

CTM77 (30OCT00) 60-15-2 Alternators and Starter Motors

103000
PN=382
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Delco-Remy 30MT, 35MT, and 37MT Starter

Motor Repair Specifications
60
15
Item Measurement Specification 3

Drive Housing Bushing ID 14.28—14.33 mm (0.562—0.564 in.)

Wear Tolerance 14.58 mm (0.574 in.)
Oil Clearance 0.05—0.13 mm (0.002—0.005 in.)
Wear Tolerance 0.43 mm (0.017 in.)

Lever Housing Bushing ID 19.23—19.25 mm (0.757—0.758 in.)

Wear Tolerance 19.61 mm (0.772 in.)
Oil Clearance 0.25—0.33 mm (0.010—0.013 in.)
Wear Tolerance 0.69 mm (0.027 in.)

Commutator End Frame Bushing ID 14.28—14.33 mm (0.562—0.564 in.)

Wear Tolerance 14.55 mm (0.573 in.)
Oil Clearance 0.05—0.13 mm (0.002—0.005 in.)
Wear Tolerance 0.41 mm (0.016 in.)

Brush Minimum Length 12 mm (0.50 in.)

Brush Minimum Tension 22 N (80 ounce-force)

Shift Lever Housing-to-Field Housing Torque 18—23 N•m (159—204 lb-in.)

Cap Screws

Drive Housing-to-Shift Lever Housing Torque 18—23 N•m (159—204 lb-in.)

Cap Screws

Commutator End-to-Field Frame Cap Torque 18—23 N•m (159—204 lb-in.)

Screws

Armature End Play 0.13—1.27 mm (0.005—0.050 in.)

Wear Limit 1.52 mm (0.060 in.)

Pinion-to-Pinion Stop Clearance 0.25—3.56 mm (0.010—0.140 in.)

OUO1004,0000B96 –19–25SEP00–1/1

CTM77 (30OCT00) 60-15-3 Alternators and Starter Motors

103000
PN=383
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Delco-Remy 30MT, 35MT, and 37MT Starter

Motor Test Specifications
60
15
No Load Test (Includes Solenoid Current)
4
John Deere Delco-Remy System Motor Current Draw (Amps) Armature RPM
Part No. Model No. -Series Voltage Voltage
AB4094R 1107193 6 5 30—60 2900—5300
AM3397T 1107165 6 5.6 70 5500
AR11010 1107725 12 9 50—75 4500—6400
AR11138 1107555 24 20 52—90 7000—13000
AR11141 1113135 24 20 50—70 7000—9500
AR11152 1108180 12 9 50—75 3500—6000
AR11300 1107785 12 9 55—80 3500—6000
AR28053 1113148 24 20 50—70 7000—9500
AR34406 1113656-35MT 12 9 75—105 5000—7000
AR41627 1113402-35MT 12 9 124—185 4700—7600
AR55638 1113672-35MT 12 9 124—185 4700—7600
AR62267 1113402-35MT 12 9 124—185 4700—7600
AR72308 1113093-35MT 12 9 50—70 3500—5500
AR77254 1113391-35MT 12 9 124—185 4700—7600
AR78538 1113391-35MT 12 9 124—185 4700—7600
AR91813 1109576-SD300 12 10 65—110 6500—10700
AT10224 1108072 6 5.7 53—91 3650—6350
AT15334 1107523 12 9 50—80 5500—9000
AT16209 1107556 12 9 40—140 8000—13000
AT16880 1108099 6 5 90—125 2900—5300
AT16881 1107200 6 5.7 90—125 4500—6400
AT91813 1109421-SD300 12 10 60—90 6500—10500
RE27462 1993799-37MT 12 10 140—175 6600—8200
RE29400 1993829-37MT 24 20 115—175 3000—4800
RE36646 1993930-37MT 24 20 50—75 3300—4400
RE37961 1993894-37MT 12 10 120—160 6000—8700
RE38632 1993917-37MT 24 20 50—75 3300—4400
RE41755 1993894-37MT 12 10 120—160 6000—8700
RE43300 1993917-37MT 24 20 50—75 3300—4400
RE48077 10478819-37MT 24 20 50—75 3300—4400
RE48134 1993917-37MT 24 20 50—75 3300—4400
RE52955 10478957-37MT 12 10 120—160 6000—8700
RE53217 10478957-37MT 12 11 130—175 6100—8700
RE53404 10478814-37MT 24 20 50—75 3300—4400
RE53575 10478814-37MT 24 20 — 3300—4400
RE59586 10478819-37MT 24 20 50—75 3300—4400

Continued on next page RG,RG34710,2227 –19–08SEP00–1/2

CTM77 (30OCT00) 60-15-4 Alternators and Starter Motors

103000
PN=384
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

No Load Test (Includes Solenoid Current)

John Deere Delco-Remy System Motor Current Draw (Amps) Armature RPM
Part No. Model No. -Series Voltage Voltage 60
15
RE59593 10478957-37MT 12 11 130—175 6100—8700
5
RE59594 10478814-37MT, 24 20 50—75 3300—4400
10479181
RE65189 10478814-37MT 24 20 50—75 3300—4400

RG,RG34710,2227 –19–08SEP00–2/2

Diagnosing Starter Motor Malfunctions

Fails to Operate, No Current Draw Low Speed, High Current Draw

Open field circuit (all field windings) Excessive friction

Open armature windings Shorted armature

Defective brush contact with commutator Grounded armature or field windings

Open solenoid windings High Speed, High Current Draw

Defective solenoid contacts Shorted field windings

Fails to Operate, High Current Draw NOTE: This test will not detect individual
open-circuited field coils—the stator would
Grounded field windings or armature windings have a slow cranking speed but would pass
this test.
Seized bearings

Low Speed, Low Current Draw

High internal resistance

Defective brush contact with commutator

RG,RG34710,2228 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-5 Alternators and Starter Motors

103000
PN=385
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Delco-Remy Starter Motor Cutaway View—

Series 30MT, 35MT, and 37MT
60
15
6 IMPORTANT: Never operate starter motor more than
30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating, caused
by excessive operation, will seriously
damage starter motor.

–UN–19JAN90
NOTE: Series 37MT starter motors use TORX screws
for all external fasteners. Two different size
TORX drivers are required to service the 37MT
motor—T40 and E8. These drives can be

RG4993
procured from a local tool source.
Series 37MT Shown
A—Grommet
B—Field Connectors
C—Gaskets
D—Plunger
E—Solenoid
F—O-Ring
G—Oil Wick
H—Boot
I—Shift Lever
J—Bushing
K—Overrunning Clutch
L—Seal
M—Field Coil
N—Armature
O—Brushes
P—End Cap

TORX is a registered trademark of Camcar/Textron. RG,RG34710,2229 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-6 Alternators and Starter Motors

103000
PN=386
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Test Starter Motor Before Disassembly

1. Turn overrunning clutch pinion by hand. Clutch pinion 60

15
should turn freely on shaft in overrunning direction 7
only.

–UN–16SEP99
R26549N
Turn Overrunning Clutch Pinion

RG,RG34710,2230 –19–15MAR97–1/4

2. Turn armature by prying against pinion with

screwdriver. Check for dragging armature, seized
bushings or bent shaft.

If you discover any interference, disassemble and

repair starter motor. Do not conduct no-load test unless

–UN–09FEB90
armature turns freely.

R26550
Turn Armature

Continued on next page RG,RG34710,2230 –19–15MAR97–2/4

CTM77 (30OCT00) 60-15-7 Alternators and Starter Motors

103000
PN=387
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

3. Connect a 12-volt battery to solenoid (A) with

heavy-duty jumper cables. Connect battery terminal (B)
60 on solenoid to positive battery terminal and motor
15
8
terminal (C) to negative battery terminal.

IMPORTANT: Do not engage solenoid longer than one

–UN–06APR89
to two seconds, because closing
solenoid switch provides a dead short
across battery.

RG4666
4. Use a screwdriver blade to short across from battery
terminal to switch terminal (D). Solenoid should
engage, pushing overrunning clutch drive to engage Terminals
position.
A—Solenoid
B—Battery Terminal
When screwdriver is removed, solenoid should return C—Motor Terminal
sharply to the disengage position. If solenoid engages D—Switch Terminal
but then chatters instead of staying firmly engaged,
hold-in winding is defective and solenoid must be
replaced. Be sure solenoid is connected securely to
start frame. If shift lever or overrunning clutch drive
appears to bind, disassemble and repair starter.

RG,RG34710,2230 –19–15MAR97–3/4

5. If solenoid does not engage, remove solenoid and

manually move shift lever back and forth. If lever
moves smoothly, pull-in winding is defective and
solenoid must be replaced. If there is pressure felt
when moving the shift lever, but solenoid does not
engage when tested, disassemble and repair starter.

–UN–23JAN90
R78220P1

Check for Defects

RG,RG34710,2230 –19–15MAR97–4/4

CTM77 (30OCT00) 60-15-8 Alternators and Starter Motors

103000
PN=388
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Make No-Load Test for Solenoid

1. If armature turns freely, make connections as shown. 60

15
Use an ammeter capable of measuring several 9
hundred amps. Make sure the battery is fully charged.

–UN–06APR89
2. Close switch to operate starter motor and adjust
carbon pile resistor to obtain specified voltage.
Compare rpm and current draw with values given in
specifications at the beginning of this group.

RG4660
3. If speed and current draw are slightly low, connect a
voltmeter between motor terminal and field frame. Make No-Load Test for Solenoid
Voltage during test may be reduced because of high
A—Battery
current draw on battery. B—Ammeter
C—Shunt
4. If speed or current draw is significantly different than D—Switch
specified, use the diagnostic list earlier in this group. E—Voltmeter
F—Starter Motor
G—Tachometer
H—Carbon Pile Resistor

RG,RG34710,2231 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-9 Alternators and Starter Motors

103000
PN=389
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

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

60
15
10

–UN–06JAN94
RG4661

Series 35MT

Continued on next page RG,RG34710,2232 –19–15MAR97–1/8

CTM77 (30OCT00) 60-15-10 Alternators and Starter Motors

103000
PN=390
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

1—Solenoid Case and Coil 17—Shift Lever 34—Washer 50—Field Winding Connector
2—Switch Terminal Stud (2 18—O-RIng 35—Armature 51—Brush Support (2 Used)
Used) 19—Plug 36—Spacer 52—Brush Holder Support Pin 60
3—Motor Terminal Stud 20—Brake Washer 37—Oil Seal (2 Used) 15
4—Contact Disk and Push Rod 21—Gasket 38—O-Ring 53—Brush Holder Pin (2 Used) 11
5—Return 22—O-Ring 39—Center Bushing 54—Brush Spring (2 Used)
6—Battery Terminal Stud 23—Shift Lever Shaft 40—Pipe Plug 55—Brush Spring Lead (2
7—Cover Gasket 24—O-Ring 41—Wick Used)
8—Cover 25—Shift Lever Housing 42—Retaining Ring 56—Brush Holder (2 Used)
9—Sealing Washer 26—Special Nut 43—Field Winding Assembly 57—Brush Holder (2 Used)
10—Rear Bushing 27—Retaining Ring 44—Pole Shoe (4 Used) 58—Brush (4 Used)
11—Drive Housing 28—Spring Retainer 45—Insulator (2 Used) 59—Tapping Screw (4 Used)
12—Wick 29—Shift Lever Spring 46—Field Terminal Stud 60—Front Bushing
13—Pipe Plug 30—Spring Retainer 47—Insulator Bushing 61—Commutator End Frame
14—Retaining Ring 31—Boot 48—Main Frame 62—Pipe Plug
15—Pinion Stop 32—Washer 49—Machine Screw (8 Used) 63—Wick
16—Overrunning Clutch Drive 33—Plunger

RG,RG34710,2232 –19–15MAR97–2/8

1. Clean exterior of starter motor with compressed air

before disassembling.

2. Remove field winding connector (A).

3. Remove solenoid mounting cap screws (B).

–UN–06APR89
4. Remove nuts and sealing washers (9) from solenoid
motor and “S” terminals. (See exploded view.)

RG4662
5. Remove switch cover (8) and cover gasket (7).

Field Winding Connector and Cap Screws

A—Field Winding Connector
B—Solenoid Mounting Cap Screws

Continued on next page RG,RG34710,2232 –19–15MAR97–3/8

CTM77 (30OCT00) 60-15-11 Alternators and Starter Motors

103000
PN=391
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

6. Push boot (1) back, and slide solenoid away (shown

removed) from boot and plunger (2).
60
15
12 1—Boot
2—Plunger

–UN–17JUL89
RG2989
Solenoid Removed

RG,RG34710,2232 –19–15MAR97–4/8

7. IF NECESSARY, remove cover plug and disconnect

solenoid plunger from shift lever. Grasp plunger and
remove self-locking nut.

NOTE: Pinion clearance is controlled by self-locking nut.

Do not change adjustment unless complete
disassembly is required. Check pinion clearance,
covered later in this group.

–UN–23JAN90
8. Scribe a mark across main frame (48) and end frame
(61) as reassembly reference. (See exploded view.)

9. Remove four cap screws attaching commutator end

R78220T1
frame to main frame.

10. Remove commutator end frame. Remove Commutator End Frame

Continued on next page RG,RG34710,2232 –19–15MAR97–5/8

CTM77 (30OCT00) 60-15-12 Alternators and Starter Motors

103000
PN=392
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

11. Slide brush holder pin (F) out of support (E) to

remove brushes (A). Remove tapping screws (D)
which attach brushes to grounded brush holders (B) 60
15
and insulated brush holders (C). 13

12. Scribe a mark across drive housing and shift lever

housing for proper assembly.

13. Remove drive end housing cap screws and remove

–UN–19JAN90
drive housing.

A—Brushes
B—Grounded Brush Holders

RG4663
C—Insulated Brush Holders
D—Tapping Screws
E—Support Remove Drive Housing
F—Pin

RG,RG34710,2232 –19–15MAR97–6/8

14. Remove pinion stop (B). Use a pipe coupling (A) or

other metal cylinder to drive pinion stop toward pinion
as shown. Remove retaining ring and slide pinion
stop off shaft.

15. Slide shift lever housing and overrunning clutch drive

off shaft.

A—Pipe Coupling

–UN–09FEB90
B—Pinion Stop

R26558

Pinion Stop and Pipe Coupling

Continued on next page RG,RG34710,2232 –19–15MAR97–7/8

CTM77 (30OCT00) 60-15-13 Alternators and Starter Motors

103000
PN=393
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

16. Carefully slide armature (1) out of field frame. If

spacer washer remains in housing, pull it out and
60 install on shaft.
15
14
1—Armature

–UN–17JUL89
RG2992
Slide Armature
RG,RG34710,2232 –19–15MAR97–8/8

CTM77 (30OCT00) 60-15-14 Alternators and Starter Motors

103000
PN=394
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Install New Bushings During Disassembly

NOTE: Refer to exploded view earlier in this group. 60

15
15
1. Remove plugs (13 and 62) and lubricating wicks (12
and 63).

2. Replace bushings (10, 39, and 60) if worn longer than

wear tolerances given.

Specification
Drive Housing Bushing—ID................... 14.28—14.33 mm (0.562—0.564
in.)
Wear Tolerance ........................................................ 14.58 mm (0.574 in.)
Oil Clearance ....................................... 0.05—0.13 mm (0.002—0.005 in.)
Wear Tolerance .......................................................... 0.43 mm (0.017 in.)

Specification
Lever Housing Bushing—ID .................. 19.23—19.25 mm (0.757—0.758
in.)
Wear Tolerance ........................................................ 19.61 mm (0.772 in.)
Oil Clearance ....................................... 0.25—0.33 mm (0.010—0.013 in.)
Wear Tolerance .......................................................... 0.69 mm (0.027 in.)

Specification
Commutator End Frame
Bushing—ID........................................... 14.28—14.33 mm (0.562—0.564
in.)
Wear Tolerance ........................................................ 14.55 mm (0.573 in.)
Oil Clearance ....................................... 0.05—0.13 mm (0.002—0.005 in.)
Wear Tolerance .......................................................... 0.41 mm (0.016 in.)

3. Remove the commutator end frame housing (61) using

a blind hole puller. Remove other bushings using
drivers from tool set listed below.

Use the following disks from D01045AA Bushing,

Bearing and Seal Driver Set when replacing bushing.

Bushing Pilot Disk Drive Disk

Drive Housing Bushing 27491 27495
Commutator Bushing 27491 27494
Lever Housing Bushing 27494 27497

4. Drive new bushings into end frame to same depth as

old bushing.

Continued on next page RG,RG34710,2233 –19–15MAR97–1/2

CTM77 (30OCT00) 60-15-15 Alternators and Starter Motors

103000
PN=395
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

5. Use a drill the same size as the oil wick hole and drill
bushing (1).

–UN–31MAY89
60
15
16
Only if necessary, carefully ream bushing to size.

6. Saturate new wicks (3) with SAE 10W clean engine oil

T33142N
and install.

7. Install plug (2) and tighten securely. Install Plug

1—Drill Bushing
2—Plug
3—Oil Wick

RG,RG34710,2233 –19–15MAR97–2/2

Clean Starter Motor Components

IMPORTANT: Never clean armature, field windings, or

overrunning clutch drive in solvent. All
parts except overrunning clutch drive
may be cleaned with mineral spirits and
a brush.

1. Clean components using mineral spirits and a brush.

2. Dry with compressed air or a clean cloth.

RG,RG34710,2234 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-16 Alternators and Starter Motors

103000
PN=396
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Inspect Armature

–UN–25JAN89
1. Place armature in V-blocks and check for a bent shaft. 60
15
Replace armature if shaft is bent. 17

2. Inspect armature for signs of dragging against pole

X1451
shoes or scoring under bushings.
Inspect Armature
3. Carefully check commutator for roughness, burned
commutator bars or any material that might cause
short circuits between bars.

4. Clean and touch up commutator, if necessary, with 00

sandpaper. NEVER use emery cloth.

NOTE: If commutator is out of round, badly burned or

rough, it can be turned down slightly on a lathe.
Remove only enough metal to eliminate problem.
Do not undercut commutator after turning, as this
will cause shorts between commutator bars.

RG,RG34710,2235 –19–15MAR97–1/1

Make Short Circuit Test

Place armature in a growler and hold hacksaw blade

above each slot while slowly rotating the armature.

If coil is shorted, the blade will be attracted to and

repelled from the slot.

–UN–09JAN90
Short circuit most often occurs because of copper dust or
filings between segments. Clean commutator segments to
correct this short.
RG78074C1

Make Short Circuit Test

RG,RG34710,2236 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-17 Alternators and Starter Motors

103000
PN=397
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Make Armature Ground Test

60 1. Set ohmmeter to read on highest scale.
15
18
2. Place one test lead on the armature core or shaft.
Place other lead on commutator.

–UN–20NOV89
If the test meter indicator swings toward zero, the
armature is grounded. Replace armature.

T90253
Make Armature Ground Test

RG,RG34710,2237 –19–15MAR97–1/1

Make Open Circuit Test

1. Set ohmmeter to read on lowest scale.

2. Place one test lead on ohmmeter segment. Place other

test lead on an adjacent segment.

3. Repeat this operation for all segments by moving one

lead at a time.

If the test meter indicator does not swing to zero and

remains stationary, the armature coil between these

–UN–27JUL89
two segments is open. Replace armature.

T31426
Make Open Circuit Test

RG,RG34710,2238 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-18 Alternators and Starter Motors

103000
PN=398
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Make Ground Circuit Test for Field Windings

1. Set the D09001TT Volt-Ohm-Amp Meter to read on 60

15
highest scale. 19

2. Place one test lead on a clean stop on field frame.

Place other lead on the copper terminal bolt.

–UN–09JAN90
If the ohmmeter indicator swings toward zero, a
grounded circuit is indicated. Replace the field
windings.

RG78076Q1
Make Ground Circuit Test

RG,RG34710,2239 –19–15MAR97–1/1

Make Open Circuit Test for Shunt Windings

1. Set ohmmeter on its lowest scale.

2. Place one test lead on the eyelet terminal. Place other

lead on the terminal bolt.

If the ohmmeter does not swing to zero, it is open

circuited. Replace the field winding assembly.

RG,RG34710,2240 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-19 Alternators and Starter Motors

103000
PN=399
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Make Open Circuit Test for Field Windings

60 All four windings are connected in parallel. Test each
15
20
winding for an open circuit.

1. Connect a test battery (B) to field terminal (C) and

–UN–11APR89
either insulated brush lead (D) using a resistor (A) to
limit current draw.

2. Use a hacksaw blade (E) to test windings for

R26554N
magnetism. If any winding is not magnetic, the winding
is open circuited. Repair or replace windings.
Make Open Circuit Test
NOTE: Because 1/4 ohm resistors capable of carrying
several hundred watts are not widely available, a A—1/4-Ohm Resistor
B—12-Volt Battery
suggested alternative is to connect four 1-ohm C—Field Terminal
resistors in parallel. Each resistor should be rated D—Insulated Brush Lead
for at least 150 watts. A carbon pile resistor can E—Hacksaw Blade
also be used. Limit current to 40—70 amps.

There is no suitable way to check field windings for

short circuits. Winding resistance is too low to permit
detection of a short circuit.

RG,RG34710,2241 –19–09OCT00–1/1

Remove Field Windings

1. If field windings are suspected of being damaged,

place field frame in a soft-jawed vise.

NOTE: Do not squeeze sides of field frame in vise or

–UN–23JAN90
strike with a hammer. If an impact screwdriver is
used to remove pole shoe screws, support each
pole shoe individually using a pole shoe spreader
or the nose of an anvil.
R78221I1

2. Use a large screwdriver or bit and socket wrench on

pole shoe screws. Remove Field Windings

Continued on next page RG,RG34710,2242 –19–15MAR97–1/2

CTM77 (30OCT00) 60-15-20 Alternators and Starter Motors

103000
PN=400
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

3. Remove pole shoes (2). Then carefully remove field

windings as an assembly.
60
15
IMPORTANT: Handle windings very carefully. 21
Windings are easily damaged, causing
shorts, opens, or grounds.

–UN–17JUL89
4. Install new field windings and tighten pole shoe screws
as tight as possible. Use a center punch to lightly stake
one edge of each screw.

RG2995
IMPORTANT: Make sure the notched end (3) on pole
shoe is facing the brush end of the field New Field Windings
frame starter (1). 1—Starter Field Frame
2—Pole Shoe
3—Notched End

RG,RG34710,2242 –19–15MAR97–2/2

Inspect Brushes

1. Inspect brushes (58) closely. (See exploded view this

group.) Make sure brush holders (56 and 57) are clean
and are not binding. Full width of brush should contact
commutator.

2. Replace brushes if they are oil soaked or are worn

beyond specifications.

Specification
Brush—Minimum Length ................................................. 12 mm (0.50 in.)

RG,RG34710,2243 –19–09OCT00–1/1

Test Brush Holder for Ground

1. Set ohmmeter on its highest scale.

2. Place one test lead on commutator end frame. Place

other lead on brush holder.

If dial indicator swings toward zero, the positive brush

holder is grounded and should be replaced.

RG,RG34710,2244 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-21 Alternators and Starter Motors

103000
PN=401
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Inspect Brush Springs

60 1. Inspect and replace brush springs if they are distorted
15
22
or discolored.

2. Measure brush spring tension with a spring scale.

Specification
Brush—Minimum Tension ....................................... 22 N (80 ounce-force)

RG,RG34710,2245 –19–15MAR97–1/1

Inspect and Clean Solenoid

1. Replace contact disk (4, see exploded view in this

group), if it is badly corroded.

2. Be sure all connections are clean and tight. Wipe parts

with mineral spirits and brush. Dry clean with a cloth.

IMPORTANT: Solenoid contacts and plunger will be

damaged if current is applied to
solenoid when removed from starter
motor.

RG,RG34710,2246 –19–15MAR97–1/1

Assemble Solenoid

NOTE: Replacement “S” terminal clips and motor terminal

studs are soldered to wiring leads.

1. Assemble solenoid parts using a new gasket (7, see

exploded view in this group) and sealing washers (9).

2. Tighten cover (8) screws securely.

RG,RG34710,2247 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-22 Alternators and Starter Motors

103000
PN=402
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Inspect Plunger, Shift Lever, and

Overrunning Clutch Assembly
60
15
1. Remove plug (19, see exploded view in this group) and 23
inspect shift lever spring (33) and shift lever assembly
for wear or damage.

2. Press plunger inward and check tension on plunger

spring (29). Spring should not compress easily.
Replace plunger assembly if spring is weak.

3. Inspect overrunning clutch drive (16) for wear or

damage. Rotate the pinion. Pinion gear should rotate
smoothly (but not easily) in one direction. The pinion
gear should not rotate in the opposite direction.

4. If pinion gear does not rotate smoothly or if it is worn,

chipped, or burred, replace clutch drive assembly.

IMPORTANT: Do not clean overrunning clutch drive

with solvent. Solvent would dissolve
lubricant in clutch mechanism. Clean
only by wiping with a clean cloth. Do
not lubricate drive.

RG,RG34710,2248 –19–09OCT00–1/1

Assemble Starter Motor

1. Carefully install armature (1) into field frame. Be sure

spacer is installed on end of armature shaft before
installing into main frame. –UN–17JUL89

IMPORTANT: To avoid possible damage to brush

holders, it is best to install brush
assembly dismantled.
RG2992

1—Armature
Install Armature

Continued on next page RG,RG34710,2249 –19–15MAR97–1/4

CTM77 (30OCT00) 60-15-23 Alternators and Starter Motors

103000
PN=403
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

NOTE: Always use new O-rings, packing, and gaskets

when assembling starter motor.
60
15
24
2. Lubricate bearing surface with Delco-Remy No.
1960954 Lubricant or its equivalent.

3. Install seal plug (3), gasket (1) and brake washer (5)
into shift lever housing.

–UN–27JUL89
4. Place overrunning clutch drive in shift lever housing,
making certain that shift lever is engaged in slot.

T33145NY
5. Slide shift lever housing and overrunning clutch drive
into armature shaft.
Shift Lever Housing
1—Gasket
2—Shift Lever
3—Seal Plug
4—Shift Lever Shaft
5—Brake Washer

Continued on next page RG,RG34710,2249 –19–15MAR97–2/4

CTM77 (30OCT00) 60-15-24 Alternators and Starter Motors

103000
PN=404
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

6. Slide pinion stop (A) onto shaft, with open side toward
end of shaft. Install retaining ring (B) in groove. Force
pinion stop over ring, using a washer (C) and two pairs 60
15
of pliers as shown. Remove washer. 25

NOTE: Series 37MT starter motors have TORX screws

–UN–09FEB90
for all external fasteners. Tighten screws to same
torque values as given for conventional screws.

7. Install shift lever housing on field using five cap screws

R26560N
and lock washers. Tighten screws to specifications.

Specification Pinion Stop

Shift Lever Housing-to-Field
Housing Cap Screws—Torque ................... 18—23 N•m (159—204 lb-in.) A—Pinion Stop
B—Retaining Ring
C—Washer
8. Align scribe marks on drive housing and shift lever
housing (made during disassembly). Install the six
special screws in drive housing.Tighten screws to
specifications.

Specification
Drive Housing-to-Shift Lever
Housing Cap Screws—Torque ................... 18—23 N•m (159—204 lb-in.)

9. If pinion clearance has not been changed, install hole

plug (19, see exploded view in this group) in shift lever
housing. Otherwise, it should be left out until clearance
is adjusted at conclusion of assembly.

TORX is a registered trademark of Camcar/Textron. Continued on next page RG,RG34710,2249 –19–15MAR97–3/4

CTM77 (30OCT00) 60-15-25 Alternators and Starter Motors

103000
PN=405
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

10. Install brush holders (B and C), brushes (A) and

springs (D). When installing brushes, turn longer side
60 toward armature windings. Make sure full width of
15
26
each brush contacts commutator and brush holders
are not binding.

11. Install commutator end frame on field frame (position

so scribe marks made during disassembly are
aligned). Tighten cap screws securely and evenly to

–UN–19JAN90
specifications.

Specification
Commutator End-to-Field Frame
Cap Screws—Torque ................................. 18—23 N•m (159—204 lb-in.)

RG4664
12. Install solenoid on field frame. Be sure that plunger Brushes, Holders, and Springs
(33, see exploded view) and boot (31) are installed
correctly. Tighten solenoid-to-field frame cap screws A—Brushes
securely. B—Grounded Brush Holders
C—Installed Brush Holders
D—Brush Springs
NOTE: Do not install field winding connector (50) until
pinion clearance has been checked.

13. Check armature end play and pinion clearance before

installing starter motor.

RG,RG34710,2249 –19–15MAR97–4/4

Check Armature End Play

1. Attach a dial indicator on drive housing and position

indicator plunger on end of armature shaft to measure
end play.

Specification
Armature—End Play ............................ 0.13—1.27 mm (0.005—0.050 in.)
Wear Limit .................................................................. 1.52 mm (0.060 in.)

2. If end play is not within specifications, recheck

installation to determine cause.

RG,RG34710,2250 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-26 Alternators and Starter Motors

103000
PN=406
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Check for Proper Pinion Clearance

1. Connect a 12-volt battery to the solenoid frame and “S” 60

15
terminal. 27

2. Momentarily connect a jumper wire between solenoid

–UN–09FEB90
frame and motor terminal to pull solenoid plunger in.

3. Press overrunning clutch (D) toward commutator and

measure pinion clearance (E) with a feeler gauge (C).

R25224
4. Clearance between pinion (A) and pinion stop (B)
should be as follows: Check for Proper Pinion Clearance

A—Pinion
Specification
B—Pinion Stop
Pinion-to-Pinion Stop—Clearance ....... 0.25—3.56 mm (0.010—0.140 in.)
C—Feeler Gauge
D—Press on Clutch to Take Up Movement
5. If pinion clearance is not within specifications, turn E—0.25—3.56 mm (0.010—0.140 in.) Clearance
self-locking nut (26, see exploced view in this group) to
adjust clearance.

6. After adjusting to correct pinion clearance, install

adjusting hole plug (19) and tighten securely.

7. Install field winding connector (50). Tighten nuts

securely.

RG,RG34710,2251 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-27 Alternators and Starter Motors

103000
PN=407
 Delco-Remy 30MT, 35MT, 37MT Starter Motor Repair

Make No-Load Test (After Assembly)

60 1. Clamp starter in vise.
15
28
2. Connect a fully charged 12-volt battery (A), ammeter
(B), shunt (C), control switch (D), voltmeter (E) carbon

–UN–06APR89
pile resistor (H), and tachometer (G) to starter motor
(F).

3. Close switch to operate starter motor and adjust

RG4660
carbon pile resistor to obtain specified voltage.

4. Starter motor should rotate smoothly at the specified Make No-Load Test
speed, voltage, and current draw given at the
A—Battery
beginning of this group. B—Ammeter
C—Shunt
D—Switch
E—Voltmeter
F—Starter Motor
G—Tachometer
H—Carbon Pile Resistor

RG,RG34710,2252 –19–15MAR97–1/1

CTM77 (30OCT00) 60-15-28 Alternators and Starter Motors

103000
PN=408
 Group 20
Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the 60

20
U.S. SERVICEGARD Catalog or from the 1
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B97 –19–25SEP00–1/4

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B97 –19–25SEP00–2/4

Bushing, Bearing and Seal Driver Set . . . . . . D01045AA

Install commutator end frame bushing.

–UN–21SEP00
RG11162

D01045AA

Continued on next page OUO1004,0000B97 –19–25SEP00–3/4

CTM77 (30OCT00) 60-20-1 Alternators and Starter Motors

103000
PN=409
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Blind Hole Puller Set . . . . . . . . . . . . . . . . . D01061AA

60 Remove commutator end frame bushing.

20
2

–UN–21SEP00
RG11161
D01061AA

OUO1004,0000B97 –19–25SEP00–4/4

Other Material

Number Name Use

(U.S.) Mineral Spirits Clean armature, solenoid and

brushes.

(U.S.) 00 Sandpaper Clean commutator.

(U.S.) ESSO Beacon 325 or Delco-Remy Lubricate various stator components.

No. 1960954 Lubricant

OUO1004,0000B99 –19–25SEP00–1/1

CTM77 (30OCT00) 60-20-2 Alternators and Starter Motors

103000
PN=410
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Delco-Remy 40MT, 41MT, 42MT, and 50MT

Starter Motor Repair Specifications
60
20
Item Measurement Specification 3

Field Pole Shoe Cap Screws Torque 41 N•m (30 lb-ft)

New Brush Length 19 mm (0.75 in.)

Used Brush Minimum Length 16 mm (0.63 in.)

Brush Spring Minimum Tension 22 N (80 ounce-force)

Starter Motor Drive Housing Bushing ID 15.88—15.93 mm (0.625—0.627 in.)

(40MT, 41MT, 42MT) Maximum Serviceable ID 16.18 mm (0.637 in.)

Starter Motor Lever Housing Bushing ID 24.46—24.51 mm (0.963—0.965 in.)

(40MT, 41MT, 42MT) Maximum Serviceable ID 24.69 mm (0.972 in.)

Starter Motor Commutator End ID 16.87—16.97 mm (0.664—0.668 in.)

Frame Bushing (40MT, 41MT, 42MT) Maximum Serviceable ID 17.22 mm (0.678 in.)

Starter Motor Drive Housing Bushing ID 15.88—15.90 mm (0.6250—0.6260

(50MT) in.)
Wear Tolerance 16.15 mm (0.636 in.)
Oil Clearance 0.05—0.10 mm (0.0020—0.0040 in.)
Wear Tolerance 0.38 mm (0.0150 in.)

Starter Motor Lever Housing Bushing ID 21.41—21.44 mm (0.8430—0.8440

(50MT) in.)
Wear Tolerance 21.59 mm (0.850 in.)
Oil Clearance 0.48—0.53 mm (0.0190—0.0210 in.)
Wear Tolerance 0.69 mm (0.0270 in.)

Starter Motor Commutator End ID 14.27—14.30 mm (0.5620—0.5630

Frame Bushing (50MT) in.)
Wear Tolerance 14.55 mm (0.5730 in.)
Oil Clearance 0.05—0.10mm (0.0020—0.0040 in.)
Wear Tolerance 0.38 mm (0.0150 in.)

Shift Lever Housing Cap Screws Torque 18—23 N•m (159—204 lb-in.)

Drive End Housing Cap Screws Torque 18—23 N•m (159—204 lb-in.)

Commutator End Frame Cap Screws Torque 18—23 N•m (159—204 lb-in.)

Pinion-to-Drive Housing Clearance 8.33—9.92 mm (0.328—0.391 in.)

OUO1004,0000B9A –19–25SEP00–1/1

CTM77 (30OCT00) 60-20-3 Alternators and Starter Motors

103000
PN=411
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Delco-Remy 40MT, 41MT, 42MT, and 50MT

Starter Motor Test Specifications
60
20
No Load Test (Includes Solenoid Current)
4
John Deere Delco-Remy System Motor Current Draw (Amps) Armature RPM
Part No. Model No. -Series Voltage Voltage
AM3397T 1107165 6 5.6 70 5500
AR102188 1114831-40MT 12 10 140—215 4000—7000
AR102190 1109841-50MT 24 20 80—125 5500—8500
AR102770 1114869-40MT 24 20 95—120 5500—7500
AR102771 1114843-40MT 24 20 70—110 5500—9000
AR46886 1114191-40MT 12 9 140—215 4000—7000
AR55313 1114735-40MT 24 20 70—110 5500—9000
AR55314 1113827-40MT 24 20 75—95 5500—7500
AR62153 1114166-40MT 12 11 160—230 4900—8300
AR72308 1113093 12 9 50—70 3500—5500
AR78235 1109978-50MT 24 20 95—120 5500—7500
AT16311 1107326 12 9 55—80 3500—6000
AT16882 1108093 6 5.7 90—125 4500—6400
AT409T 1107166 12 10 115—170 6600—9000
RE10321 1114819-40MT 12 10 140—215 4000—7000
RE10464 1990269-50MT 24 20 95—120 5500—7500
RE12101 1990270-50MT 24 20 95—120 5500—7500
RE13942 1990325-40MT 12 10 140—215 4000—7000
RE24305 1990354-42MT 12 10 115—170 6600—9000
RE28781 1990356-42MT 12 10 100—170 5500—7800
RE28782 1990357-42MT 24 20 60—75 6500—7700
RE28783 1990358-42MT 12 10 100—170 5500—7800
RE38633 1993935-42MT 12 10 115—170 6600—9000
RE38634 1993936-42MT 24 20 50—90 6300—8400
RE41756 1190325-42MT 12 10 140—215 4000—8300
RE51792 1993934-42MT 12 10 115—170 6600—9000
RE61547 10479052-42MT 12 11 100—170 5500—7800
RE62911 1049071-41MT 12 11 130—175 6100—8700
RE63094 10479053-42MT 24 23 60—75 6300—8400
RE64474 10479071-41MT 12 11 130—175 6100—8700
RE65103 10479628 12 10.6 135—190 3600—5600
RE67432 10479098-41MT 12 11 130—175 6100—8700
RE69590 1193935-42MT 12 10 115—170 6600—9000

RG,RG34710,2256 –19–08SEP00–1/1

CTM77 (30OCT00) 60-20-4 Alternators and Starter Motors

103000
PN=412
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Diagnosing Starter Motor Malfunctions

Fails to Operate, No Current Draw Low Speed, High Current Draw 60

20
5
Open field circuit (all field windings) Excessive friction

Open armature windings Shorted armature

Defective brush contact with commutator Grounded armature or field windings

Open solenoid windings High Speed, High Current Draw

Defective solenoid contacts Shorted field windings

Fails to Operate, High Current Draw NOTE: This test will not detect individual
open-circuited field coils—the stator would
Grounded field windings or armature windings have a slow cranking speed but would pass
this test.
Seized bearings

Low Speed, Low Current Draw

High internal resistance

Defective brush contact with commutator

RG,RG34710,2258 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-5 Alternators and Starter Motors

103000
PN=413
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Delco-Remy Starter Motor Cutaway View—

Series 40MT, 41MT, 42MT, and 50MT
60
20
6 IMPORTANT: Never operate starter motor more than
30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating, caused

–UN–19JAN90
by excessive operation, will seriously
damage starter motor.

NOTE: Series 42MT starter motors use TORX screws

RG4994
for all external fasteners. Two different size
TORX drivers are required to service the motor—
T40 and E8. These drivers can be procured from Series 42MT Shown
a local tool source.
A—Field Connectors
B—Gasket
C—Bushing
D—Solenoid
E—O-Ring
F—Boot
G—Shift Lever
H—Bushing
I—Overrunning Cutch
J—Seal
K—Field Coil
L—Armature
M—Brushes
N—End Cap
O—Oil Wick

TORX is a registered trademark of Camcar/Textron. RG,RG34710,2259 –19–15MAR97–1/1

Test Starter Motor Before Disassembly

1. Turn overrunning clutch pinion by hand. Clutch pinion

should turn freely on shaft in overrunning direction
only.
–UN–23JAN90
R78220Q1

Turn Overrunning Clutch Pinion

Continued on next page RG,RG34710,2260 –19–15MAR97–1/5

CTM77 (30OCT00) 60-20-6 Alternators and Starter Motors

103000
PN=414
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

2. Turn armature by prying against pinion with

screwdriver. Check for dragging armature, seized
bushings or bent shaft. 60
20
7
If you discover any interference, disassemble and
repair starter motor.

–UN–23JAN90
NOTE: Do not conduct the no-load test unless armature
turns freely.

R78220R1
Turn Armature

RG,RG34710,2260 –19–15MAR97–2/5

3. Be sure solenoid ground wire (A) is connected securely

to starter end frame.

A—Solenoid Ground Wire

–UN–25SEP89
RG3422
Solenoid Ground Wire
RG,RG34710,2260 –19–15MAR97–3/5

4. Connect a 12-volt battery to solenoid with heavy-duty

jumper cables. Connect battery terminal on solenoid to
positive (+) battery terminal. Connect motor terminal to
negative (-) battery terminal.
–UN–31JUL89
RG3423

Connect 12-Volt Battery

Continued on next page RG,RG34710,2260 –19–15MAR97–4/5

CTM77 (30OCT00) 60-20-7 Alternators and Starter Motors

103000
PN=415
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

IMPORTANT: DO NOT engage solenoid longer than

one or two seconds, because closing
60 solenoid switch provides a dead short
20
8
across battery.

5. Use a screwdriver to short across from battery terminal

–UN–31JUL89
to switch terminal. Solenoid should engage, pushing
overrunning clutch drive to engaged position.

When screwdriver is removed, solenoid should return

RG3424
sharply to the disengaged position. If solenoid
engages, but then chatters instead of staying firmly Use Screwdriver
engaged, hold-in winding is defective and solenoid
must be replaced. Be sure solenoid and ground wire
are connected securely to starter frame. If shift lever or
overrunning clutch drive appears to bind, disassemble
and repair starter.

RG,RG34710,2260 –19–15MAR97–5/5

CTM77 (30OCT00) 60-20-8 Alternators and Starter Motors

103000
PN=416
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Test Pull-In and Hold-In Windings

60
20
9

–UN–06APR89
RG3418
Exploded View

A—Ground Terminal C—Battery Terminal E—Ammeter G—24-Volt Battery

B—Motor Terminal D—Switch Terminal F—Switch

1. (See exploded view in this group.) Remove field coil 6. Interpret test results as follows:
connector (42) and return wire (31).
High Ammeter Reading
2. Make connections shown by dashed lines for
testing pull-in windings. Windings are grounded or short circuited.

IMPORTANT: DO NOT energize pull-in windings Low Ammeter Reading

longer than 15 seconds. Current
draw will decrease as winding Excessive resistance is present (usually in a
temperature increases, which could connection).
damage windings.
No Ammeter Reading
3. Close switch (F) and observe ammeter (E).
Ammeter should read 24—28 amps for 24-volt Windings are open circuited.
motors and 55—63 amps for 12-volt motors.
NOTE: If the fault cannot be repaired and the solenoid
4. Make connections shown by solid lines for testing performance is questionable, replace the
hold-in windings. windings.

5. Close switch and observe ammeter. Ammeter

should read 4.1 amps maximum for 24-volt motors
and 6—9 amps for 12-volt motors.

RG,RG34710,2261 –19–09OCT00–1/1

CTM77 (30OCT00) 60-20-9 Alternators and Starter Motors

103000
PN=417
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Make No-Load Test

60 1. Install field connector and connect solenoid return lead.
20
10
2. Make connections as shown. Use an ammeter capable
of measuring at least 300 amps.

3. Close switch to operate starter. Compare rpm and

current draw with specifications given at beginning of
this group.

Battery voltage will drop due to high current draw. If

speed and current draw are slightly low, repeat test,
observing voltmeter. Voltage may be reduced due to
high current draw.

Interpret test results as follows:

–UN–06APR89
Fails to Operate, No Current Draw

Open field circuit (all field windings)

RG3419
Open armature windings
Make No-Load Test
Defective brush contact with commutator
A—Batteries
Fails to Operate, High Current Draw B—Tachometer
C—Switch
D—Ammeter
Grounded terminal or field windings E—Voltmeter
F—To Voltmeter
Seized bearings G—To Ammeter
H—To Switch
Low Speed, Low Current Draw

High internal resistance

Defective brush contact with commutator

Low Speed, High Current Draw

Excessive friction

Shorted armature

Grounded armature or field windings

High Speed, High Current Draw

Shorted field windings

RG,RG34710,2262 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-10 Alternators and Starter Motors

103000
PN=418
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

60
20
11

CTM77 (30OCT00) 60-20-11 Alternators and Starter Motors

103000
PN=419
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

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

60
20
12

–UN–03SEP91
RG4278

Delco-Remy Starter Motor (50MT)

Continued on next page RG,RG34710,2263 –19–15MAR97–1/9

CTM77 (30OCT00) 60-20-12 Alternators and Starter Motors

103000
PN=420
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

1—Terminal Plate Gasket 27—Wiring Lead 48—Insulator Bushing 72—Small O-Ring

2—Terminal Stud (2 Used) 28—Bushing 49—O-Ring (2 Used) 73—Shift Lever Housing
3—Machine Screw (2 Used) 29—Disk 50—Commutator End Frame 74—Lever Housing Bushing 60
4—Solenoid Winding Terminal 30—Spring Bushing 75—Oil Seal 20
5—Strip Insulator 31—Solenoid Return Wire 51—Commutator End Frame 76—Spacer Washer 13
6—Insulator 32—Field Frame 52—Lubrication Wick (3 Used) 77—Armature
7—Screw (4 Used) 33—Brush Plug Gasket (2 53—Plug (3 Used) 78—Thrust Washer
8—Terminal Used) 54—Lock Washer (9 Used) 79—Drive End Housing
9—Plate 34—Plug (3 Used) 55—Special Hex Screw (9 Bushing
9A—Solenoid Cover 35—Field Lead Insulator (2 Used) 80—Special Screw 38 mm
10—Nut (4 Used) Used) 56—Insulator (1-1/2 in.) Long (5 Used)
11—Washer (2 Used) 36—Field Coil and Brush Lead 57—Brushes (4 Used) 81—Special Screw 22 mm (7/8
12—Lock Washer Insulator (2 Insulator 58—Machine Screw (4 Used) in.) Long (2 Used)
Used) 37—Field Terminal Stud 59—Spring (4 Used) 82—Drive End Housing
13—Washer (2 Used) 38—Insulator 60—Plain Washer (3 Used) 83—Split Washer (2 Used)
14—Lock Washer (2 Used) 39—Special Packing 61—Lock Washers (3 Used) 84—Pinion Stop Cup
15—Nut (2 Used) 40—Insulating Washers 25 mm 62—Machine Screw (3 Used) 85—Pinion
16—Nut (2 Used) (1 in.) OD (2 Used) 63—Field Pole Shoe (4 Used) 86—Small Washer
17—Lock Nut 41—Solenoid Mounting (4 64—Field Coil Assembly 87—Spring
18—Snap Ring Used) 65—Gasket 88—Spring Cup
19—Retainer 42—Field Coil Connector 66—Brake Washer 89—Large Washer
20—Spring 43—Jam Nut (3 Used) 67—Adjusting Hole Plug 90—Spacer
21—Retainer 44—Washer (2 Used) Gasket 91—Overrunning Clutch
22—Boot 45—Brush Holder Assembly 68—Seal Plug Bushing
23—Washer 46—Insulating Washers 2mm 69—Pole Shoe Screw (8 Used) 92—Overrunning Clutch
24—Plunger (7/8 in.) OD (2 Used) 70—Shift Lever Shaft 93—Shift Lever
25—Screw (4 Used) 47—Packing 71—O-Ring
26—Solenoid Winding and
Case Assembly

RG,RG34710,2263 –19–15MAR97–2/9

1. Disconnect solenoid ground wire (A).

2. Remove field winding connector (B).

3. Remove solenoid mounting cap screws (C). –UN–31JUL89

A—Solenoid Ground Wire

B—Field Winding Connector
C—Solenoid Mounting Cap Screws
RG3427

Disassemble Starter Motor

Continued on next page RG,RG34710,2263 –19–15MAR97–3/9

CTM77 (30OCT00) 60-20-13 Alternators and Starter Motors

103000
PN=421
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

4. Push boot (A) back, and slide solenoid away (shown

removed) from boot and plunger (B).
60
20
14 A—Boot
B—Plunger

–UN–31JUL89
RG3428
Push Boot Back

RG,RG34710,2263 –19–15MAR97–4/9

5. IF NECESSARY, remove cover plug and disconnect

solenoid plunger from shift lever. Grasp plunger and
remove self-locking nut as shown.

NOTE: Pinion clearance is controlled by self-locking nut.

Do not change adjustment unless complete
disassembly is required. Check pinion clearance
as covered later in this group.

–UN–23JAN90
R78220T1
Remove Self-Locking Nut

Continued on next page RG,RG34710,2263 –19–15MAR97–5/9

CTM77 (30OCT00) 60-20-14 Alternators and Starter Motors

103000
PN=422
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

6. Remove field brush cover plugs (shown removed) and

O-rings (A). Remove screws (B) from field winding
leads. 60
20
15
NOTE: Scribe reference marks (C) across end frame and
field frame for reassembly.

–UN–31JUL89
7. Remove end frame cap screws (D).

A—O-Ring (2 Used)

RG3429
B—Cap Screw (2 Used)
C—Reference Marks
D—Cap Screw (4 Used) Brush Cover Plugs Shown Removed

RG,RG34710,2263 –19–15MAR97–6/9

8. Carefully slide brush holder assembly away from

armature. Remove brush strap machine screws (A).
Inspect brush leads (B) for fraying or discoloration.

NOTE: If only brushes are going to be installed, it is not

necessary to remove brush holder assembly.

–UN–31JUL89
A—Brush Strap Machine Screws
B—Brush Leads

RG3420
Slide Brush Holder Assembly

Continued on next page RG,RG34710,2263 –19–15MAR97–7/9

CTM77 (30OCT00) 60-20-15 Alternators and Starter Motors

103000
PN=423
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

9. Scribe a reference mark (A) across drive housing (B)

and shift lever housing (C) for proper assembly.
60
20
16
10. Remove drive end housing cap screws and remove
drive housing.

11. Remove shift lever housing with overrunning clutch

–UN–31JUL89
(D).

A—Reference Mark

RG3431
B—Drive End Housing
C—Shift Lever Housing
D—Overrunning Clutch Remove Shift Lever Housing

RG,RG34710,2263 –19–15MAR97–8/9

12. Carefully slide armature (A) out. If spacer washer

remains in housing, pull it out and install on shaft.

A—Armature

–UN–31JUL89
RG3432
Armature

RG,RG34710,2263 –19–15MAR97–9/9

CTM77 (30OCT00) 60-20-16 Alternators and Starter Motors

103000
PN=424
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Make Ground Circuit Test for Field Windings

1. Set the D09001TT Volt-Ohm-Amp Meter to read on 60

20
highest scale. 17

2. Place one test lead on a clean spot on field frame.

Place other lead on the copper terminal bolt.

–UN–09JAN90
If the ohmmeter indicator swings toward zero, a
grounded circuit is indicated. Replace the field
windings.

RG78076Q1
Volt-Ohm-Amp Meter

RG,RG34710,2264 –19–15MAR97–1/1

Make Open Circuit Test for Shunt Windings

1. Set ohmmeter on its lowest scale.

2. Place one test lead on the eyelet terminal. Place other

lead on the terminal bolt.

3. If the ohmmeter does not swing to zero, it is open

circuited. Replace the field winding assembly.

RG,RG34710,2265 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-17 Alternators and Starter Motors

103000
PN=425
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Make Open Circuit Test for Field Windings

60 All four field windings are connected in parallel. Test each
20
18
winding for an open circuit.

1. Connect a test battery (B) to field terminal (C) and to

–UN–11APR89
either insulated brush lead (D) using a resistor (A) to
limit current draw.

2. Use a hacksaw blade (E) to test windings for

R26554N
magnetism. If any winding is not magnetic, the winding
is open circuited. Repair or replace windings.
Make Open Circuit Test
NOTE: Because 1/4 ohm resistors capable of carrying
several hundred watts are not widely available, a A—1/4-Ohm Resistor
B—12-Volt Battery
suggested alternative is to connect four 1-ohm C—Field Terminal
resistors in parallel. Each resistor should be rated D—Insulated Brush Lead
for at least 150 watts. A carbon pile resistor can E—Hacksaw Blade
also be used. Limit current to 40—70 amps.

There is no suitable way to check field windings for

short circuits. Winding resistance is too low to permit
detection of a short circuit.

RG,RG34710,2266 –19–09OCT00–1/1

Remove Field Windings

1. If field windings are suspected of being damaged,

place field frame in a soft-jawed vise.

NOTE: Do not squeeze sides of field frame in vise or

–UN–23JAN90
strike with a hammer. If an impact screwdriver is
used to remove pole shoe screws, support each
pole shoe individually using a pole shoe spreader
or the nose of an anvil.
R78221I1

2. Use a large screwdriver or bit and socket wrench on

pole shoe screws. Field Frame in Vise

Continued on next page RG,RG34710,2267 –19–15MAR97–1/2

CTM77 (30OCT00) 60-20-18 Alternators and Starter Motors

103000
PN=426
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

3. Remove pole shoes. Then carefully remove field

windings as an assembly.
60
20
IMPORTANT: Handle windings very carefully. 19
Windings are easily damaged, causing
shorts, opens, or grounds.

–UN–23JAN90
4. Install new field windings and tighten pole shoe screws
to specifications. Use a center punch to lightly stake
one edge of each screw.

R78221H1
Specification
Field Pole Shoe Cap Screws— Notched End Facing Brush End
Torque ............................................................................. 41 N•m (30 lb-ft)
A—Field Frame
IMPORTANT: Make sure the notched end (B) on pole B—Notched End on Pole Shoes
shoe is facing the brush end of the field
frame (A).

RG,RG34710,2267 –19–15MAR97–2/2

Inspect Brushes

1. Remove brushes (B) by lifting brush up and away from

brush spring (A).

2. Replace brushes if they are oil soaked, worn, pitted, or

damaged. If brushes are worn beyond specification,
replace them.

–UN–31JUL89
Specification
New Brush—Length ........................................................ 19 mm (0.75 in.)
Used Brush—Minimum Length ....................................... 16 mm (0.63 in.)

3. Make sure brush holders (C) are clean and brushes

RG3421

are not binding in holders. The full brush surface

should ride on the commutator. Inspect Brushes

A—Brush Spring
B—Brushes
C—Brush Holders

RG,RG34710,2268 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-19 Alternators and Starter Motors

103000
PN=427
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Test Brush Holder for Ground

60 1. Set ohmmeter on its highest scale.
20
20
2. Place one test lead on commutator end frame. Place
other lead on brush holder.

If dial indicator swings toward zero, the positive brush

holder is grounded and should be replaced.

RG,RG34710,2269 –19–15MAR97–1/1

Inspect Brush Springs

1. Inspect and replace brush springs if they are distorted

or discolored.

2. Measure brush spring tension with a spring scale.

Specification
Brush Spring—Minimum Tension............................ 22 N (80 ounce-force)

RG,RG34710,2270 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-20 Alternators and Starter Motors

103000
PN=428
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Install New Bushings—40MT, 41MT, and

42MT
60
20
NOTE: See exploded view earlier in this group. 21

1. Remove all plugs (53) and lubricating wick (52).

2. Replace bushings if worn beyond specification.

Specification
Starter Motor Drive Housing
Bushing (40MT, 41MT, 42MT)—
ID ........................................................... 15.88—15.93 mm (0.625—0.627
in.)
Maximum Serviceable ID ......................................... 16.18 mm (0.637 in.)
Starter Motor Lever Housing
Bushing (40MT, 41MT, 42MT)—
ID ........................................................... 24.46—24.51 mm (0.963—0.965
in.)
Maximum Serviceable ID ......................................... 24.69 mm (0.972 in.)
Starter Motor Commutator End
Frame Bushing (40MT, 41MT,
42MT)—ID ............................................. 16.87—16.97 mm (0.664—0.668
in.)
Maximum Serviceable ID ......................................... 17.22 mm (0.678 in.)

NOTE: The overrunning clutch drive bushing (91) is not

replaceable. Entire drive must be replaced if
bushing is worn.

NOTE: When replacing lever housing bushing, seal plug

(68, refer to exploded view) must be removed.
Install new seal plug after replacing bushing.

3. Remove commutator end frame bushing using the

D01061AA Blind Hole Puller Set.

4. Drive old bushing out and drive new bushing in to

same depth as old bushing. Use the following disks
from D01045AA Bushing, Bearing and Seal Driver Set.

Bushing Location Pilot Disk Disk Driver

Drive Housing 27492 27494
Lever Housing 27496 27498
Commutator 27491 27495

Continued on next page RG,RG34710,2271 –19–09OCT00–1/2

CTM77 (30OCT00) 60-20-21 Alternators and Starter Motors

103000
PN=429
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

5. Use a drill the same size as the oil wick hole and drill
bushing (A).
60
20
22
Only if necessary, carefully ream bushing to size.

–UN–17APR89
6. Saturate new wicks (C) with SAE 10W clean engine oil
and install.

7. Install plug (B) and tighten securely.

R25221
A—Drill Bushing Install Plug
B—Plug
C—Oil Wick

RG,RG34710,2271 –19–09OCT00–2/2

CTM77 (30OCT00) 60-20-22 Alternators and Starter Motors

103000
PN=430
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Install New Bushings—50MT

NOTE: See exploded view earlier in this group. 60

20
23
1. Remove plugs (53) and lubricating wicks (52).

2. Replace bushings if worn more than wear tolerance

given.

Specification
Starter Motor Drive Housing
Bushing (50MT)—ID ...................................................... 15.88—15.90 mm
(0.6250—0.6260 in.)
Wear Tolerance ........................................................ 16.15 mm (0.636 in.)
Oil Clearance ......................................... 0.05—0.10 mm (0.0020—0.0040
in.)
Wear Tolerance ........................................................ 0.38 mm (0.0150 in.)
Starter Motor Lever Housing
Bushing (50MT)—ID ...................................................... 21.41—21.44 mm
(0.8430—0.8440 in.)
Wear Tolerance ........................................................ 21.59 mm (0.850 in.)
Oil Clearance ......................................... 0.48—0.53 mm (0.0190—0.0210
in.)
Wear Tolerance ........................................................ 0.69 mm (0.0270 in.)
Starter Motor Commutator End
Frame Bushing (50MT)—ID .......................................... 14.27—14.30 mm
(0.5620—0.5630 in.)
Wear Tolerance ...................................................... 14.55 mm (0.5730 in.)
Oil Clearance ........................................... 0.05—0.10mm (0.0020—0.0040
in.)
Wear Tolerance ........................................................ 0.38 mm (0.0150 in.)

NOTE: The overrunning clutch drive bushing (91) is not

replaceable. Entire drive must be replaced if
bushing is worn.

NOTE: When replacing lever housing bushing, seal plug

(68, refer to exploded view) must be removed.
Install new seal plug after replacing bushing.

3. Remove commutator end frame bushing using the

D01061AA Blind Hole Puller Set.

4. Drive old bushing out and drive new bushing in to

same depth as old bushing. Use the following disks
from D01045AA Bushing, Bearing and Seal Driver Set.

Continued on next page RG,RG34710,2272 –19–09OCT00–1/3

CTM77 (30OCT00) 60-20-23 Alternators and Starter Motors

103000
PN=431
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Bushing Location Pilot Disk Disk Driver

Drive Housing 27492 27494
60
Lever Housing 27496 27498
20
24 Commutator 27491 27495

RG,RG34710,2272 –19–09OCT00–2/3

5. Use a drill the same size as the oil wick hole and drill
bushing (A).

Only if necessary, carefully ream bushing to size.

–UN–17APR89
6. Saturate new wicks (C) with SAE 10W clean engine oil
and install.

7. Install plug (B) and tighten securely.

R25221
A—Drill Bushing Install Plug
B—Plug
C—Oil Wick

RG,RG34710,2272 –19–09OCT00–3/3

Clean Starter Motor Components

IMPORTANT: Never clean armature, field windings, or

overrunning clutch drive in solvent. All
parts except overrunning clutch drive
may be cleaned with mineral spirits and
a brush.

1. Clean components using mineral spirits and a brush.

2. Dry with compressed air or a clean cloth.

RG,RG34710,2273 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-24 Alternators and Starter Motors

103000
PN=432
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Inspect Armature

–UN–25JAN89
1. Place armature in V-blocks and check for a bent shaft. 60
20
Replace armature if shaft is bent. 25

2. Inspect armature for signs of dragging against pole

X1451
shoes or scoring under bushings.

3. Carefully check commutator for roughness, burned

commutator bars or any material that might cause
short circuits between bars.

4. Clean and touch up commutator, if necessary, with 00

sandpaper. NEVER use emery cloth.

NOTE: If commutator is out of round, badly burned or

rough, it can be turned down slightly on a lathe.
Remove only enough metal to eliminate problem.
Do not undercut commutator after turning, as this
will cause shorts between commutator bars.

RG,RG34710,2274 –19–15MAR97–1/1

Make Short Circuit Test

Place armature in a growler and hold hacksaw blade

above each slot while slowly rotating the armature.

If coil is shorted, the blade will be attracted to and

repelled from the slot.

–UN–09JAN90
A short circuit most often occurs because of copper dust
or filings between segments. Clean commutator segments
to correct this short.
RG78074C1

Make Short Circuit Test

RG,RG34710,2275 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-25 Alternators and Starter Motors

103000
PN=433
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Make Armature Ground Test

60 1. Set ohmmeter to read on highest scale.
20
26
2. Place one test lead on the armature core or shaft.
Place other lead on commutator.

–UN–20NOV89
If the test meter indicator swings toward zero, the
armature is grounded. Replace armature.

T90253
Make Armature Ground Test

RG,RG34710,2276 –19–15MAR97–1/1

Make Open Circuit Test

1. Set ohmmeter to read on lowest scale.

2. Place one test lead on ohmmeter segment. Place other

test lead on an adjacent segment.

3. Repeat this operation for all segments by moving one

lead at a time.

If the test meter indicator does not swing to zero and

remains stationary, the armature coil between these

–UN–27JUL89
two segments is open. Replace armature.

T31426
Make Open Circuit Test

RG,RG34710,2277 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-26 Alternators and Starter Motors

103000
PN=434
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Inspect Solenoid Plunger and Shift Lever

Assembly
60
20
1. Remove plug (A) and inspect plunger and shift lever 27
assembly for wear or damage.

2. Press plunger (B) inward and check tension on plunger

spring. Spring should not compress easily. Replace
plunger assembly if spring is weak.

3. Inspect shift lever wear pads (C) for wear or damage.

If damaged, replace both wear pads.

–UN–31JUL89
4. Inspect overrunning clutch (D) for wear or damage.
Replace as necessary.

RG3435
A—Plug
B—Plunger
C—Wear Pads Solenoid Plunger/Shift Lever Assembly
D—Overrunning Clutch

RG,RG34710,2278 –19–15MAR97–1/1

Inspect Overrunning Clutch and Pinion

Rotate the pinion. Pinion gear should rotate smoothly (but

not easily) in one direction. The pinion gear should not
rotate in the opposite direction.

If pinion gear does not rotate smoothly or if it is worn,

chipped, or burred, it should be replaced.

RG,RG34710,2279 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-27 Alternators and Starter Motors

103000
PN=435
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Inspect and Clean Solenoid

60 1. Remove terminal plate (A) and inspect all parts.
20
28
Replace contact disk (B) and terminal studs (C), if they
are badly corroded.

Be sure all connections are clean and tight.

–UN–31JUL89
2. Replace gasket (D), if corroded or damaged.

RG3436
3. Wipe parts with mineral spirits and brush. Dry with a
clean cloth.
Inspect and Clean Solenoid
IMPORTANT: Solenoid contacts and plunger will be
damaged if current is applied to A—Terminal Plate
B—Contact Disk
solenoid when removed from starter
C—Terminal Studs
motor. D—Gasket

RG,RG34710,2280 –19–15MAR97–1/1

Assemble Solenoid

1. Place new gasket (D) on solenoid housing.

2. Align terminal studs (C) and contact disk (B).

3. Tighten terminal plate (A) cap screws securely.

–UN–31JUL89
A—Terminal Plate
B—Contact Disk

RG3436
C—Terminal Studs
D—Gasket
Assemble Solenoid

RG,RG34710,2281 –19–15MAR97–1/1

CTM77 (30OCT00) 60-20-28 Alternators and Starter Motors

103000
PN=436
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

Assemble Starter Motor

NOTE: Always use new O-rings, packing, and gaskets 60

20
when assembling starter motor. 29

1. Lubricate bearing surfaces with Delco-Remy No.

1960954 Lubricant or its equivalent.

2. Install seal plug (C), gasket (A), and brake washer (E)

–UN–31JUL89
into shift lever housing.

A—Gasket
B—Shift Lever

RG3437
C—Seal plug
D—Shift Lever Shaft
E—Brake Washer Shift Lever Housing

RG,RG34710,2282 –19–15MAR97–1/8

3. Install wear pads (C) and overrunning clutch (D).

4. Make sure plunger (B) moves shift lever back and forth
easily.

NOTE: Do not install adjusting hole plug (A) until pinion

clearance has been checked.

A—Adjusting Hole Plug

B—Plunger
C—Wear Pads
D—Overrunning Clutch

–UN–31JUL89
RG3435
Shift Lever
Continued on next page RG,RG34710,2282 –19–15MAR97–2/8

CTM77 (30OCT00) 60-20-29 Alternators and Starter Motors

103000
PN=437
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

5. Carefully install armature (A) into field frame. Be sure

spacer is installed on end of armature shaft before
60 installing into main frame.
20
30
A—Armature

–UN–31JUL89
RG3432
Install Armature

RG,RG34710,2282 –19–15MAR97–3/8

NOTE: Series 42MT starter motors have TORX screws

for all external fasteners. Tighten screws to same
torque values as given for conventional screws.

6. Install shift lever housing (C), making sure armature

shaft goes through overrunning clutch (D). Tighten cap
screws to specifications.

–UN–31JUL89
Specification
Shift Lever Housing Cap
Screws—Torque ......................................... 18—23 N•m (159—204 lb-in.)

RG3431
7. Align reference marks (A) (made prior to disassembly)
Install Shift Lever Housing
and install drive end housing (B). Make sure armature
shaft fits through drive housing bushing.Tighten special A—Reference Mark
screws to specifications. B—Drive End Housing
C—Shift Lever Housing
Specification D—Overrunning Clutch
Drive End Housing Cap Screws—
Torque ........................................................ 18—23 N•m (159—204 lb-in.)

TORX is a registered trademark of Camcar/Textron. Continued on next page RG,RG34710,2282 –19–15MAR97–4/8

CTM77 (30OCT00) 60-20-30 Alternators and Starter Motors

103000
PN=438
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

8. Pull brushes (B) up against brush holder (C) and

spring (A). Pull brushes up far enough to allow
installation of the commutator. 60
20
31
A—Spring
B—Brushes
C—Brush Holder

–UN–31JUL89
RG3421
Pull Brushes

RG,RG34710,2282 –19–15MAR97–5/8

9. Install bush assembly onto commutator. Press brushes

down until spring clips over brush.

10. Press brush leads (B) down onto brush holder. Be

sure that the leads DO NOT touch each other.

–UN–31JUL89
11. Install brush strap machine screws (A), and tighten
brush strap securely to brush holder.

A—Brush Strap Machine Screws

RG3420
B—Brush Leads

Install Bush Assembly

Continued on next page RG,RG34710,2282 –19–15MAR97–6/8

CTM77 (30OCT00) 60-20-31 Alternators and Starter Motors

103000
PN=439
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

12. Carefully press brush assembly and end frame into

main frame and align reference mark (C) (made prior
60 to disassembly).
20
32
13. Install O-ring (A) and install field winding
lead-to-brush holder machine screws (B). Tighten cap
screws securely. Install field brush cover plugs

–UN–31JUL89
(shown removed).

14. Install commutator end frame cap screws and tighten

RG3429
to specifications.

Specification Bush Assembly and End Frame

Commutator End Frame Cap
Screws—Torque ......................................... 18—23 N•m (159—204 lb-in.) A—O-Ring (2 Used)
B—Machine Screw (2 Used)
C—Reference Marks
D—Cap Screw (4 Used)

RG,RG34710,2282 –19–15MAR97–7/8

15. Install solenoid. Be sure plunger and boot are

installed correctly. Tighten solenoid-to-field frame cap
screws (C) securely.

16. Install solenoid ground wire (A) and field winding

connector (B). Tighten all connections securely.

–UN–31JUL89
A—Solenoid Ground Wire
B—Field Winding Connector
C—Solenoid-to-Field Frame Cap Screws

RG3427
Install Solenoid

RG,RG34710,2282 –19–15MAR97–8/8

Check for Proper Pinion Clearance

1. Disconnect solenoid ground wire and connect a 12-volt

battery to solenoid “SW” and ground terminals.

2. Briefly touch a screwdriver blade across motor and

–UN–31JUL89

ground terminals to pull solenoid plunger in.

RG3424

Screwdriver Blade
Continued on next page RG,RG34710,2283 –19–15MAR97–1/2

CTM77 (30OCT00) 60-20-32 Alternators and Starter Motors

103000
PN=440
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

3. Push pinion back toward armature (arrow).

4. Measure distance between pinion (C) and drive 60

20
housing. 33

Correct pinion clearance (E) is as follows:

Specification
Pinion-to-Drive Housing—
Clearance ............................................ 8.33—9.92 mm (0.328—0.391 in.)

5. If pinion clearance is not within specifications, turn

self-locking nut (B) to adjust clearance.

6. After adjusting to correct pinion clearance, install

–UN–09JAN90
adjusting hole plug and tighten securely.

A—Plug Removed
B—Self-Locking Nut (Turn to Adjust Clearance)

R32571
C—Pinion
D—Press on Clutch to Take Up Movement
E—8.33 to 9.92 mm (0.328—0.391 in.) Clearance Pinion Clearance

RG,RG34710,2283 –19–15MAR97–2/2

CTM77 (30OCT00) 60-20-33 Alternators and Starter Motors

103000
PN=441
 Delco-Remy 40MT, 41MT, 42MT, 50MT Starter Motor Repair

60
20
34

CTM77 (30OCT00) 60-20-34 Alternators and Starter Motors

103000
PN=442
 Section 65
John Deere/Denso Starter Motors
Contents

Page Page 65

Group 05—Starting Circuit Theory of Operation Install Solenoid . . . . . . . . . . . . . . . . . . . . . . . .65-10-27

General Information . . . . . . . . . . . . . . . . . . . . .65-05-1 Make No-Load Test. . . . . . . . . . . . . . . . . . . . .65-10-29
Typical Starting Circuit Operation . . . . . . . . . . .65-05-1
Starter Motor Operation (Conventional Group 15—John Deere/Denso Gear Reduction
Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-05-2 Starter Motor Repair
Starter Motor Operation (Gear Reduction Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .65-15-1
Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-05-3 Service Equipment and Tools . . . . . . . . . . . . . .65-15-1
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .65-15-2
Group 10—John Deere/Denso Conventional Starter John Deere/Denso Gear Reduction Starter
Motor Repair Motor Repair Specifications . . . . . . . . . . . . .65-15-2
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .65-10-1 John Deere/Denso Gear Reduction Starter
Service Equipment and Tools . . . . . . . . . . . . . .65-10-1 Motor Test Specifications . . . . . . . . . . . . . . .65-15-3
Dealer Fabricated Tools . . . . . . . . . . . . . . . . . .65-10-2 Bench Test Starter Motor . . . . . . . . . . . . . . . . .65-15-4
Other Material . . . . . . . . . . . . . . . . . . . . . . . . . .65-10-3 No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . .65-15-5
John Deere/Denso Conventional Starter Exploded View of Gear Reduction Starter
Motor Repair Specifications . . . . . . . . . . . . .65-10-4 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-15-6
John Deere/Denso Conventional Starter Disassemble Field Frame, Armature, and
Motor Test Specifications . . . . . . . . . . . . . . .65-10-5 Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . .65-15-6
Test Starter Motor Before Disassembly . . . . . .65-10-7 Inspect and Repair Armature. . . . . . . . . . . . . . .65-15-8
Make Solenoid Pull-In Test . . . . . . . . . . . . . . . .65-10-7 Inspect Brushes and Brush Holder . . . . . . . . .65-15-12
Make Solenoid Return Test . . . . . . . . . . . . . . . .65-10-9 Inspect Field Coils. . . . . . . . . . . . . . . . . . . . . .65-15-14
Make No-Load Test. . . . . . . . . . . . . . . . . . . . . .65-10-9 Assemble Field Frame, Armature, and
Diagnose No-Load Test . . . . . . . . . . . . . . . . .65-10-10 Brush Holder . . . . . . . . . . . . . . . . . . . . . . . .65-15-15
Disassemble Starter Motor . . . . . . . . . . . . . . .65-10-10 Disassemble Gear Train and Overrunning
John Deere/Denso Conventional Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-15-18
Motor Exploded View . . . . . . . . . . . . . . . . .65-10-14 Assemble Gear Train and Overrunning
Install New Bushings/Needle Bearings . . . . . .65-10-15 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-15-21
Clean Starter Motor Components . . . . . . . . . .65-10-15 Disassemble, Inspect, and Repair Starter
Inspect Armature. . . . . . . . . . . . . . . . . . . . . . .65-10-16 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .65-15-24
Make Short Circuit Test. . . . . . . . . . . . . . . . . .65-10-16 Assemble Solenoid Assembly . . . . . . . . . . . . .65-15-26
Make Armature Ground Test . . . . . . . . . . . . . .65-10-17
Make Open Circuit Test . . . . . . . . . . . . . . . . .65-10-17
Repair Armature . . . . . . . . . . . . . . . . . . . . . . .65-10-18
Inspect Overrunning Clutch and Pinion . . . . . .65-10-18
Make Grounded Circuit Test for Field
Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .65-10-19
Make Open Circuit Test for Shunt
Windings . . . . . . . . . . . . . . . . . . . . . . . . . . .65-10-19
Make Open Circuit Test for Field Windings . . .65-10-20
Remove Field Windings (If Necessary) . . . . . .65-10-20
Install Field Windings . . . . . . . . . . . . . . . . . . .65-10-21
Inspect and Repair Brushes . . . . . . . . . . . . . .65-10-21
Test Brush Holder for Grounds . . . . . . . . . . . .65-10-22
Measure Brush Spring Tension . . . . . . . . . . . .65-10-22
Disassemble Solenoid . . . . . . . . . . . . . . . . . . .65-10-23
Assemble Starter Motor. . . . . . . . . . . . . . . . . .65-10-24

CTM77 (30OCT00) 65-1 Alternators and Starter Motors

103000
PN=1
 Contents

65

CTM77 (30OCT00) 65-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Starting Circuit Theory of Operation
General Information

IMPORTANT: Never operate starter motor longer than

30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating caused by
excessive operation will seriously
damage starter motor. 65
05
1

RG,RG34710,2284 –19–15MAR97–1/1

Typical Starting Circuit Operation

When wire from relay (A) is energized, current flows

through both pull-in winding (C) and hold-in winding (D) of
starter motor to ground.

Current through windings engages solenoid plunger (E),

which closes main contacts (F). When main contacts

–UN–20APR89
close, current through pull-in windings stops. Current
continues through hold-in winding, keeping solenoid
engaged and main contacts closed.

RG1313
With main contacts closed, current flows from battery
cable (B) to starter motor at a very high rate. Four heavy Starting Circuit Operation
field windings (G) carry current to commutator brushes
(H). A—Wire from Relay
B—Cable from Battery
C—Pull-In Winding
Light shunt windings (J) are wrapped together with two of D—Hold-In Winding
the heavy field windings. Shunt windings are connected to E—Solenoid Plunger
solenoid switch terminal and directly to ground. They F—Main Contacts
provide additional low speed torque to assist engine G—Field Windings
rotation and prevent overspeeding of motor. H—Commutator Brushes
I—Armature
J—Shunt Windings
From field windings, current flows through armature
windings (I) to ground, making contact through
commutator brushes (H).

Strong magnetic fields are set up by current flow through

field windings and armature windings. Windings are
arranged so that magnetic fields constantly repel each
other, rotating armature.

RG,RG34710,2285 –19–15MAR97–1/1

CTM77 (30OCT00) 65-05-1 Alternators and Starter Motors

103000
PN=445
 Starting Circuit Theory of Operation

Starter Motor Operation (Conventional Type)

65
05
2

–UN–14NOV88
R25228
Starter Motor (Conventional Type)

1—Snap Ring 7—Field Connector 13—Field Windings 19—Brake Washer

2—Drive End Housing 8—End Frame Cover 14—Armature 20—Wear Pads
3—Shift Lever 9—Brush 15—Pole Shoe 21—Overrunning Clutch
4—Plunger 10—Bushing 16—Oil Seal 22—Pinion Stop
5—Shunt Field Terminal 11—Thrust Washer 17—Bushing 23—Bushing
6—Solenoid Assembly 12—Commutator 18—Felt

When solenoid (6) engages, it pulls shift lever (3). Shift The two windings cancel each other, and solenoid is
lever pushes overrunning clutch drive (21) to engage released.
pinion in starter gear on flywheel. As armature (14)
turns, it cranks engine. A spring pushes solenoid back to disengaged position.
This opens main contacts and shuts off current to field
When engine starts, overrunning clutch spins freely on windings and armature.
shaft. This prevents overspeeding of armature by
flywheel. Shift lever retracts overrunning clutch drive,
disengaging pinion from flywheel. Brake washer (19)
When key switch is released, current to solenoid slows armature to a stop.
hold-in winding is shut off. Current can feed through
both pull-in and hold-in windings from main contacts,
but direction of current is reversed in pull-in winding.

RG,RG34710,2286 –19–15MAR97–1/1

CTM77 (30OCT00) 65-05-2 Alternators and Starter Motors

103000
PN=446
 Starting Circuit Theory of Operation

Starter Motor Operation (Gear Reduction Type)

65
05
3

–UN–03DEC97
RG8614
Starter Motor (Gear Reduction Type)

1—Pinion Gear 4—Brush 7—Field Windings 10—Solenoid Assembly

2—Idle (Reducing) Gear 5—Brush Spring 8—Armature 11—Overrunning Clutch
3—Drive Gear 6—Field Frame 9—Solenoid Plunger

The reduction or “R” type starter motor is a positive When solenoid (10) engages, it pushes overrunning
shift type and consists of the motor, reduction gear, clutch drive (11) to engage pinion gear (1) in starter
overrunning clutch, and solenoid switch. The solenoid gear on flywheel. As armature (8) turns, it cranks
switch and overrunning clutch mechanism are on the engine.
same axis as shown.
When engine starts, overrunning clutch (11) spins
In a conventional starter motor the armature and freely on shaft. This prevents overspeeding of
overrunning pinion rotate at the same speed. In a armature by flywheel.
reduction-type starter motor, the armature rotation is
reduced by one-fourth to one-third by the reduction When key switch is released, current to solenoid
gears, and is transmitted to the pinion through the hold-in winding is shut off. Current can feed through
clutch mechanism. both pull-in and hold-in windings from main contacts,
but direction of current is reversed in pull-in winding.
Operation is as follows:

Continued on next page RG,RG34710,2287 –19–09OCT00–1/2

CTM77 (30OCT00) 65-05-3 Alternators and Starter Motors

103000
PN=447
 Starting Circuit Theory of Operation

The two windings cancel each other, and solenoid is Overrunning clutch (11) retracts, disengaging pinion
released. gear (1) from flywheel.

A spring pushes solenoid back to disengaged position.

This opens main contacts and shuts off current to field
windings (7) and armature (8).

65
05
4

RG,RG34710,2287 –19–09OCT00–2/2

CTM77 (30OCT00) 65-05-4 Alternators and Starter Motors

103000
PN=448
 Group 10
John Deere/Denso Conventional Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

65
10
1

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B9B –19–25SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B9B –19–25SEP00–2/2

Service Equipment and Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B9C –19–25SEP00–1/2

Bushing, Bearing, and Seal Driver Set. . . . . . D01045AA

Remove and install all commutator, drive end, and center

bushings and/or bearings.

OUO1004,0000B9C –19–25SEP00–2/2

CTM77 (30OCT00) 65-10-1 Alternators and Starter Motors

103000
PN=449
 John Deere/Denso Conventional Starter Motor Repair

Dealer Fabricated Tools

Starter Motor Commutator, Center Bearing and Drive End

Bushing Tool

Commutator and Drive End Bushing Tool

–UN–11APR89
Dimension Removal Installation
65 A 25.4 mm (1 in.) 25.4 mm (1 in.)
10
2
B 18.6—18.7 mm 18.6—18.7 mm (0.731—

R18972
(0.731—0.736 in.) 0.736 in.)

Dealer Fabricated Tools

C 16.8—16.9 mm 16.8—16.9 mm (0.661—
(0.661—0.665 in.) 0.665 in.)

D 50.8 mm (2 in.) 100.08 mm (3.94 in.)

E 22.9—23.1 mm 0.46—0.56 mm (0.018—

(0.901—0.909 in.) 0.022 in.)

F 19.9—20.1 mm 19.9—20.1 mm (0.783—

(0.783—0.791 in.) 0.791 in.)

Center Bearing Bushing Tool

Dimension Removal Installation
A 39.9 mm (1.57 in.) 39.9 mm (1.57 in.)

B 34.5—34.8 mm 34.5—34.8 mm (1.36—

(1.36—1.37 in.) 1.37 in.)

C 29.7—30.0 mm 29.7—30.0 mm (1.17—

(1.17—1.18 in.) 1.18 in.)

D 50.8 mm (2 in.) 50.8 mm (2 in.)

E 24.1—25.9 mm 0.46—0.51 mm (0.018—

(0.95—1.02 in.) 0.02 in.)

F 22.0—24.0 mm 25.3—25.4 mm (0.996—

(0.866—0.945 in.) 1.000 in.)

RG,RG34710,2290 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-2 Alternators and Starter Motors

103000
PN=450
 John Deere/Denso Conventional Starter Motor Repair

Other Material

Number Name Use

(U.S.) Mineral Spirits Clean armature, solenoid and

brushes.

(U.S.) 00 Sandpaper Clean commutator. 65

10
(U.S.) ESSO Beacon 325 or Delco-Remy Lubricate various stator components. 3
No. 1960954 Lubricant

OUO1004,0000B9D –19–25SEP00–1/1

CTM77 (30OCT00) 65-10-3 Alternators and Starter Motors

103000
PN=451
 John Deere/Denso Conventional Starter Motor Repair

John Deere/Denso Conventional Starter

Motor Repair Specifications

Item Measurement Specification

Commutator and Drive End Bushing ID 17.000—17.028 mm (0.6693—

0.6704 in.)
65 Wear Limit 17.120 mm (0.674 in.)
10 Oil Clearance 0.091—0.178 mm (0.0036—0.0070
4 in.)
Wear Limit 0.41 mm (0.016 in.)
Bushing Depth 0.20—0.56 mm (0.008—0.022 in.)

Center Housing Bushing ID 30.023—30.074 mm (1.182—1.84

in.)
Maximum Oil Clearance 0.599 mm (0.0236 in.)
Bushing Depth 0.43—0.81 mm (0.017—0.032 in.)

Standard Commutator Runout 0.05 mm (0.002 in.)

Wear Limit 0.38 mm (0.016 in.)

Armature Undercut Depth 0.79 mm (0.0312 in.)

Wear Limit 0.20 mm (0.008 in.)

Commutator OD 48 mm (1.89 in.)

Minimum OD 46 mm (1.81 in.)

Armature End Play 0.05—0.50 mm (0.002—0.020 in.)

Pole Shoe Cap Screws Torque 41 N•m (30 lb-ft)

New Brush Length 26 mm (1.02 in.)

Used Brush Minimum Length 16 mm (0.68 in.)

Brush Spring Minimum Tension 11 N (40 ounce-force)

Shift Lever Pivot Cap Screw Torque 41 N•m (30 lb-ft)

Center Housing-to-Field Frame Cap Torque 8 N•m (71 lb-in.)

Screw

Armature End Play Torque 0.05—0.50 mm (0.002—0.020 in.)

Drive End Housing-to-Center Torque 14 N•m (124 lb-in.)

Housing Cap Screws

Commutator End Frame Cap Screws Torque 14 N•m (124 lb-in.)

OUO1004,0000BB0 –19–26SEP00–1/1

CTM77 (30OCT00) 65-10-4 Alternators and Starter Motors

103000
PN=452
 John Deere/Denso Conventional Starter Motor Repair

John Deere/Denso Conventional Starter

Motor Test Specifications
John Deere Part Denso Part No. System Rating kW Motor No Load Test RPM
No. Voltage Type Voltage Current Draw (Min.)
Amps (Max.)
AR41627 028000-3290 12 F 4.0 11.7 130 3100
AR46886 028000-3811 12 F 5.0 11.7 130 3100 65
AR55639 028000-3290 12 F 4.0 11.7 130 3100 10
5
AR62154 028000-3810, 028000-3811 12 F 5.0 11.7 130 3100
AR63341 028000-3970 12 F 4.0 11.7 130 3100
AR63341 028000-3971 12 F 4.0 11.7 130 3100
AR77254 028000-3291 12 F 4.0 11.7 130 3100
AR77254 028000-3291 12 F 4.0 11.7 130 3100
AR84333 028000-5250 24 F 7.5 23.5 75 4200
CH12084 028000-7640 12 R 1.0 11.5 90 3000
CH12096 028000-5660 12 R 2.5 11.0 180 3500
CH15586 028000-7640 12 R 1.0 11.5 90 3000
CH19282 128000-0740 12 R 1.0 11.5 90 3000
CH19284 128000-0710 12 R 1.4 11.5 90 3500
CH19285 128000-0790 12 R 2.5 11.0 180 3500
RE13722 028000-3292 12 F 4.0 11.7 130 3100
RE15663 028000-5251 24 F 7.5 23.5 75 4200
RE15718 128000-0480 24 F 7.5 23.5 75 4800
RE23900 128000-3690 12 F 4.0 11.7 130 3100
RE38336 128000-5970, 128000-5971 12 IIF 4.0 11.7 130 3300
RE38369 128000-7170 24 IIF 7.5 23.5 80 3500
RE39832 128000-7230 12 IIF 4.0 11.7 130 3300
RE39833 128000-7240 24 IIF 7.5 23.5 80 3500
RE40595 128000-8303 24 R 4.5 23.0 90 3500
RE41799 028000-8400 12 R 2.5 11.0 180 3500
RE42670 128000-7250 12 IIF 4.0 11.7 130 3300
RE43266 128000-5972, 228000-2360 12 IIF 4.0 11.7 130 3300
RE43421 128000-7230 12 IIF 4.0 11.7 130 3300
RE43422 128000-0480 24 F 7.5 23.5 75 4800
RE44151 128000-7172 24 IIF 7.5 23.5 80 3500
RE44511 228000-2390 24 IIF 7.5 23.5 80 3500
RE44515 128000-7172 24 IIF 7.5 23.5 80 3500
RE45328 128000-7172, 228000-2390 24 IIF 7.5 23.5 80 3500
RE48827 128000-8301 24 R 4.5 23.0 90 3500
RE500199 228000-7011 24 R 7.8 23 120 3800
RE500345 228000-6570 24 R 7.5 23 120 3800

Continued on next page RG,RG34710,2292 –19–08SEP00–1/2

CTM77 (30OCT00) 65-10-5 Alternators and Starter Motors

103000
PN=453
 John Deere/Denso Conventional Starter Motor Repair

John Deere Part Denso Part No. System Rating kW Motor No Load Test RPM
No. Voltage Type Voltage Current Draw (Min.)
Amps (Max.)
RE501060 228000-7411 24 R 7.8 23 120 3800
RE501150 228000-7410 24 R 7.8 23 120 3800
RE501294 228000-7871 12 R 4.8 11 220 4200
RE502811 228000-8470 12 R 4.8 11 220 4200
65 RE504244 228000-9140 12 R 4.8 11 220 4200
10
RE504245 228000-9150 24 R 7.8 23 120 3800
6
RE505465 228000-9630 24 R 7.8 23 120 3800
RE54416 128000-5973, 228000-2360 12 IIF 4.0 11.7 130 3300
RE54874 228000-2370 12 IIF 4.0 11.7 130 3300
RE54909 228002-2380 12 IIF 4.0 11.7 130 3300
RE55378 228000-2370 12 IIF 4.0 11.7 130 3300
RE55641 228000-2390 24 IIF 7.5 23.5 80 3500
RE57078 228000-2390 24 IIF 7.5 23.5 80 3500
RE59583 228000-4690 12 IIF 4.0 11.7 130 3300
RE59584 228000-4730 24 IIF 7.5 23.5 80 3500
RE59585 228000-4611 24 IIF 7.5 23.5 80 3500
RE59596 228000-4700 12 IIF 4.0 11.7 130 3300
RE59589 228000-4601 12 IIF 4.0 11.7 130 3300
RE61517 228000-4610 24 IIF 7.5 23.5 80 3500
RE65100 228000-4630 12 IIF 4.0 11.7 130 3300
RE65173 228000-4730 24 IIF 7.5 23.5 80 3500
RE65174 228000-4611 24 IIF 7.5 23.5 80 3500
RE65176 228000-4601 12 IIF 4.0 11.7 130 3300
RE65191 228000-4700 12 IIF 4.0 11.7 130 3300
RE70958 228000-6560 24 R 7.8 23 120 3800
RE70961 228000-7010 24 R 7.8 23 120 3800
RE79474 228000-6550 12 R 4.8 11 220 4200

NOTE: Earlier Denso starter motors may have the original

Nippondenso label.

RG,RG34710,2292 –19–08SEP00–2/2

CTM77 (30OCT00) 65-10-6 Alternators and Starter Motors

103000
PN=454
 John Deere/Denso Conventional Starter Motor Repair

Test Starter Motor Before Disassembly

IMPORTANT: Never operate starter motor more than

30 seconds. Allow at least 2 minutes for
cooling and battery recovery before

–UN–09FEB90
operating again. Overheating, caused
by excessive operation, will seriously
damage starter motor. 65
10

R26569N
1. Turn overrunning clutch drive by hand. Clutch drive 7
should turn freely on shaft in overrunning direction
only. Turn Overrunning Clutch Drive

RG,RG34710,2294 –19–15MAR97–1/2

2. Turn armature by prying against pinion with

screwdriver. Check for dragging armature, seized
bushings, or bent shaft.

If you discover any interference, disassemble and

repair starter motor.

–UN–09FEB90
IMPORTANT: Do not conduct the no-load test unless
armature turns freely. Damage to the

R26570N
starter motor may result.

Turn Armature
RG,RG34710,2294 –19–15MAR97–2/2

Make Solenoid Pull-In Test

1. To prevent damage, solenoid must be on starter motor

when testing the windings.

2. Remove shunt field winding lead (A) from terminal on

–UN–09NOV89

field frame.

3. Remove terminal cover (B).

RG3892

A—Shunt Field Winding Lead

B—Terminal Cover Shunt Field Winding Lead and Cover

Continued on next page RG,RG34710,2295 –19–15MAR97–1/4

CTM77 (30OCT00) 65-10-7 Alternators and Starter Motors

103000
PN=455
 John Deere/Denso Conventional Starter Motor Repair

4. Remove field coil connector (A).

A—Field Coil Connector

–UN–09NOV89
65

RG3893
10
8
Remove Field Coil Connector

RG,RG34710,2295 –19–15MAR97–2/4

5. Make connections as shown.

With 8 volts applied, the solenoid should push the

pinion out to the pinion stop when the jumper wire (D)
is connected. The drive gear should remain out at the
pinion stop. Current through jumper wire will be
approximately 90 amps. Use a heavy jumper wire and
remove as soon as the pinion is at stop.

–UN–06APR89
A—12-Volt Battery
B—Voltmeter
C—Carbon Pile Resistor

RG4636
D—Jumper Wire

Make Connections

RG,RG34710,2295 –19–15MAR97–3/4

If solenoid does not engage, remove solenoid and

manually move shift lever (A) back and forth. If lever
moves smoothly, pull-in winding is defective and
solenoid must be replaced. If not, disassemble and
repair starter.

If solenoid engages but then chatters instead of staying

–UN–09NOV89

firmly engaged, the hold-in winding is defective and

solenoid must be replaced. Be sure solenoid ground
wire is connected to starter frame.
RG3895

A—Shift Lever
Move Shift Lever

RG,RG34710,2295 –19–15MAR97–4/4

CTM77 (30OCT00) 65-10-8 Alternators and Starter Motors

103000
PN=456
 John Deere/Denso Conventional Starter Motor Repair

Make Solenoid Return Test

1. Make connections as shown.

2. Close the switch (A).

3. Pull the drive out until the pinion contacts the pinion
stop. When released, the drive should return without 65
hesitation. 10
9

–UN–05DEC97
A—Switch

RG3896
Make Solenoid Return Test

RG,RG34710,2296 –19–15MAR97–1/1

Make No-Load Test

1. Make connections as shown, and use an ammeter (A)

capable of measuring several hundred amps.

2. Measure current draw and compare with specifications

–UN–28SEP00
given earlier in this group.

3. If speed and current draw are slightly low, connect a

voltmeter between motor terminal and frame. Observe

RG11163
voltage during test. Voltage may be reduced because
of high current draw on battery.
Make Connections
4. If speed or current draw is significantly different than
A—Ammeter
specified, diagnose problem as follows: B—Battery
C—Starter Frame
D—Tachometer
E—Battery Terminal
F—Switch
G—Field Coil Connector

RG,RG34710,2297 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-9 Alternators and Starter Motors

103000
PN=457
 John Deere/Denso Conventional Starter Motor Repair

Diagnose No-Load Test

Fails to Operate-Low Current Draw (Approx. 25 Low Speed-High Current Draw

Amps)
Excessive friction
Open series field circuit.
Shorted armature
65 Open armature coils.
10 Grounded armature or fields.
10 Defective brush contact with commutator.
High Speed-Low Current Draw
Fails to Operate-High Current Draw
Open shunt field circuit.
Grounded terminal or fields.
High Speed-High Current Draw
Seized bearings.
Shorted series field coils.
Low Speed-Low Current Draw

High internal resistance

Defective brush contact with commutator

RG,RG34710,2298 –19–15MAR97–1/1

Disassemble Starter Motor

NOTE: Starter motor has metric bolts and nuts except for
those on switch cover.

1. Remove solenoid cap screws (A) and lock washers.

–UN–09NOV89
IMPORTANT: Whenever starter motor is
disassembled, for any reason, lubricate

RG3898
as follows: Apply a coat of ESSO
Beacon 325 or Delco-Remy Lubricant
No. 1960954 to both end bearings. Solenoid Cap Screws
Grease reservoirs for both end
bearings, armature shaft except center A—Solenoid Cap Screws
bearing area, brake washer, solenoid
plunger, both ends of shaft lever, wear
pads, and shaft lever pivot shaft.

Continued on next page RG,RG34710,2299 –19–15MAR97–1/10

CTM77 (30OCT00) 65-10-10 Alternators and Starter Motors

103000
PN=458
 John Deere/Denso Conventional Starter Motor Repair

2. Remove solenoid from center bearing housing by lifting

plunger shaft (A) up and away from shift lever.

A—Plunger Shaft

–UN–09NOV89
65
10

RG3899
11

Lift Plunger Shaft

RG,RG34710,2299 –19–15MAR97–2/10

3. Remove end frame cover and gasket.

–UN–17JUL89
RG2705
Remove End Frame Cover and Gasket
RG,RG34710,2299 –19–15MAR97–3/10

4. Inspect brush leads (A) for fraying or corrosion.

NOTE: If only new brushes are going to be installed, it

isn’t necessary to remove the commutator end
frame.

–UN–09NOV89
5. Remove commutator end frame cap screws (B) with
washers. Inspect O-ring (C) for wear.

RG3900
A—Brush Leads
B—Commutator End Frame Cap Screws
C—O-Ring Inpect Brush Leads and O-Ring

Continued on next page RG,RG34710,2299 –19–15MAR97–4/10

CTM77 (30OCT00) 65-10-11 Alternators and Starter Motors

103000
PN=459
 John Deere/Denso Conventional Starter Motor Repair

6. Remove brush lead cap screws (A).

7. Remove brush ground straps (B).

A—Brush Lead Cap Screws

–UN–09NOV89
B—Brush Ground Straps

65
10

RG3901
12

Remove Cap Screws and Ground Straps

RG,RG34710,2299 –19–15MAR97–5/10

8. Use an O-ring pick (A) or other suitable tool to pull

brush spring (B) back and remove brush (C).

A—O-Ring Pick
B—Brush Spring

–UN–09NOV89
C—Brush

RG3902
Remove Brush
RG,RG34710,2299 –19–15MAR97–6/10

9. Remove shift lever pivot (A).

NOTE: Before removal of drive end housing, place

alignment marks on drive end housing and center
bearing housing for aid in reassembly.

–UN–09NOV89
10. Remove drive end housing Allen screws (B) and
center bearing housing cap screws (D).

11. Remove drive end housing (C).

RG3903

A—Shift Lever Pivot

B—Allen Screw (6 used) Remove Drive End Housing
C—Drive End Housing
D—Cap Screw (2 Used)

Continued on next page RG,RG34710,2299 –19–15MAR97–7/10

CTM77 (30OCT00) 65-10-12 Alternators and Starter Motors

103000
PN=460
 John Deere/Denso Conventional Starter Motor Repair

12. Use a pipe coupling (A) or other metal cylinder to

drive pinion stop (B) toward pinion.

13. Remove retaining ring and slide pinion stop off shaft.

A—Pipe Coupling
B—Pinion Stop
65
10
13

–UN–09FEB90
R26558
Slide Pinion Stop

RG,RG34710,2299 –19–15MAR97–8/10

14. Carefully remove overrunning clutch (A), brake

washer (B), shift lever (C), and wear pads (D) from
center bearing housing and armature shaft. Inspect
wear pads for excessive wear or damage. Replace
wear pads if necessary.

–UN–09NOV89
A—Overrunning Clutch
B—Brake Washer
C—Shift Lever

RG3904
D—Wear Pads

Inspect for Damage

RG,RG34710,2299 –19–15MAR97–9/10

15. Remove center bearing housing (C).

16. Carefully remove armature (B) from field frame (A).

A—Field Frame –UN–09NOV89

B—Armature
C—Center Bearing Housing
RG3905

Remove Armature
RG,RG34710,2299 –19–15MAR97–10/10

CTM77 (30OCT00) 65-10-13 Alternators and Starter Motors

103000
PN=461
 John Deere/Denso Conventional Starter Motor Repair

John Deere/Denso Conventional Starter Motor Exploded View

65
10
14

–UN–15DEC88
RG4541
Starter Motor Components

1—Drive End Bushing 11—Shunt Winding Lead 21—Field Winding 31—Gasket

2—Drive End Housing 12—Armature 22—Pole Shoe (4 Used) 32—Commutator End Frame
3—O-Ring 13—Bakelite Washer 23—Square Washer Bushing
4—Overrunning Clutch 14—Oil Seal 24—Insulating Bushing 33—Brush (4 Used)
5—Shift Lever Pivot 15—Center Bearing Bushing 25—Square Insulator 34—Brush Spring (4 Used)
6—O-Ring 16—Oil Felt 26—Special Bolt 35—Commutator End Frame
7—Shift Lever 17—Brake Washer 27—Field Coil Connector Bushing
8—Center Bearing Housing 18—Pinion Stop 28—Terminal Cover 36—Field Frame
9—Solenoid Winding 19—Snap Ring 29—Brush Ground Strap 37—Shims (as required)
10—Solenoid Switch Cover 20—Shunt Winding Ground 30—End Frame Cover
Screw

OUO1004,0000B48 –19–15SEP00–1/1

CTM77 (30OCT00) 65-10-14 Alternators and Starter Motors

103000
PN=462
 John Deere/Denso Conventional Starter Motor Repair

Install New Bushings/Needle Bearings

NOTE: Refer to exploded view on previous page. Specification

Commutator and Drive End
Bushing—ID ........................................................ 17.000—17.028 mm
1. If needed, install new bushings (1, 15, and 32). (0.6693—0.6704 in.)
Wear Limit........................................................ 17.120 mm (0.674 in.)
2. Install a new oil seal (14) and oil felt (16) saturated Oil Clearance .......................................................... 0.091—0.178 mm
with clean engine oil. (0.0036—0.0070 in.)
65
Wear Limit............................................................ 0.41 mm (0.016 in.)
10
Bushing Depth .................................... 0.20—0.56 mm (0.008—0.022
3. Make a bushing tool as shown earlier in Dealer 15
in.)
Fabricated Tools or use the following components
from the D01045AA Bushing, Bearing, and Seal 6. Install center bushing and oil seal using tools and
Driver Set. specifications listed below.
Commutator and Drive End Bushing Tools Center Bushing Tools
Bushing Bushing Component Bushing Oil Seal
Component Removal Installation
Handle 27487 27487
Handle 27487 27487
Disk 27505 27512
Disk (Spacers) 27491 27492
Disk (pilot) 27501 27501
Disk (Pilot) 27493 27493
Disk 27494 27495 Specification
Center Housing Bushing—ID ............................. 30.023—30.074 mm
4. Install commutator and drive end bushing and (1.182—1.84 in.)
Maximum Oil Clearance .................................. 0.599 mm (0.0236 in.)
determine depth. Compare to specification below.
Bushing Depth .................................... 0.43—0.81 mm (0.017—0.032
in.)
5. Ream bushing, if necessary, so following
specifications are maintained.

RG,RG34710,2300 –19–09OCT00–1/1

Clean Starter Motor Components

IMPORTANT: Do not immerse the solenoid, field 3. Clean the drive end housing, overrunning clutch,
windings, or armature in cleaning center bearing housing, and commutator end frame
solvent because it may damage the the same way.
insulation.
All other parts which are not made of rubber or
1. Clean parts by wiping with a cloth or brush, mentioned previously, can be dipped in cleaning
moistened with mineral spirits. solvent to remove all oil and dirt.

2. Dry with compressed air.

RG,RG34710,2301 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-15 Alternators and Starter Motors

103000
PN=463
 John Deere/Denso Conventional Starter Motor Repair

Inspect Armature

–UN–25JAN89
1. Place armature in V-blocks and check for bent shaft. If
shaft is bent, replace armature.

Inspect armature using the following specifications:

X1451
Specification
65 Inspect Armature
Standard Commutator—Runout ................................. 0.05 mm (0.002 in.)
10
Wear Limit .................................................................. 0.38 mm (0.016 in.)
16
Armature—Undercut Depth ...................................... 0.79 mm (0.0312 in.)
Wear Limit .................................................................. 0.20 mm (0.008 in.)
Commutator—OD ............................................................ 48 mm (1.89 in.)
Minimum OD.................................................................... 46 mm (1.81 in.)
Armature—End Play ............................ 0.05—0.50 mm (0.002—0.020 in.)

2. Check armature for opens, shorts and grounds. Burned

edge of commutator bar indicates an open circuit.

RG,RG34710,2302 –19–15MAR97–1/1

Make Short Circuit Test

1. Place armature in a growler and hold hacksaw blade

above each slot while slowly rotating the armature.

2. If coil is shorted, the blade will be attracted to and

repelled from the slot.

–UN–09JAN90
A short circuit most often occurs because of copper
dust or filings between two commutator segments.
Clean commutator segments to correct this short.

RG78074C1
Place Armature in Growler

DPSG,OUOE003,29 –19–18DEC98–1/1

CTM77 (30OCT00) 65-10-16 Alternators and Starter Motors

103000
PN=464
 John Deere/Denso Conventional Starter Motor Repair

Make Armature Ground Test

1. Set ohmmeter to read on highest scale.

2. Place one test lead on the armature core or shaft.

Place other lead on commutator.

–UN–20NOV89
If the test meter indicator swings toward zero, the 65
armature is grounded. Replace armature. 10
17

T90253
Make Armature Ground Test

RG,RG34710,2303 –19–15MAR97–1/1

Make Open Circuit Test

1. Set ohmmeter to read on lowest scale.

2. Place one test lead on ohmmeter segment. Place other

test lead on an adjacent segment.

3. Repeat this operation for all segments by moving one

lead at a time.

If the test meter indicator does not swing to zero and

remains stationary, the armature coil between these

–UN–27JUL89
two segment is open. Replace armature.

T31426NY
Make Open Circuit Test

RG,RG34710,2304 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-17 Alternators and Starter Motors

103000
PN=465
 John Deere/Denso Conventional Starter Motor Repair

Repair Armature

1. If commutator bars are rough or burned, clean with 00

sandpaper. Never use emery cloth.

2. Clean all dust from armature.

65 IMPORTANT: Do not clean armature with solvent.

10 Solvent could damage insulation on
18 windings. Use only mineral spirits and a
clean cloth or brush. Wipe dry with a
clean cloth.

RG,RG34710,2305 –19–15MAR97–1/1

Inspect Overrunning Clutch and Pinion

1. Rotate the pinion. Pinion gear should rotate smoothly

(but not easily) in one direction. The pinion gear should
not rotate in the opposite direction.

If pinion gear does not rotate smoothly or if it is worn,

chipped, or burred, it should be replaced.

RG,RG34710,2306 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-18 Alternators and Starter Motors

103000
PN=466
 John Deere/Denso Conventional Starter Motor Repair

Make Grounded Circuit Test for Field

Windings

1. Remove screw and hang eyelet terminal in the air.

2. Set ohmmeter to read on highest scale.

3. Place one test lead on a clean spot on the field frame. 65

Place other leads on the copper terminal bolt as 10
shown. 19

If the ohmmeter indicator swings toward zero, a

grounded circuit is indicated. Replace the field
windings.

–UN–28JUL89
T35198
Make Grounded Circuit Test

RG,RG34710,2307 –19–15MAR97–1/1

Make Open Circuit Test for Shunt Windings

1. Set the ohmmeter on its lowest scale.

2. Place one test lead on the eyelet terminal. Place other

lead on the terminal bolt.

If the ohmmeter does not swing to zero, it is open

circuited. Replace the field winding assembly.

–UN–27JUL89
T31428NY

Make Open Circuit Test for Shunt Windings

RG,RG34710,2308 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-19 Alternators and Starter Motors

103000
PN=467
 John Deere/Denso Conventional Starter Motor Repair

Make Open Circuit Test for Field Windings

1. Set ohmmeter on its lowest scale.

2. Place one test lead on the naked field end. Place other
lead on the copper terminal bolt.

65 If ohmmeter dial indicator does not swing to zero, the

10 field windings are open circuited. Replace field
20 windings.

–UN–27JUL89
T31429NY
Make Open Circuit Test for Field Windings

RG,RG34710,2309 –19–15MAR97–1/1

Remove Field Windings (If Necessary)

1. Use a large screwdriver bit and socket wrench on pole

shoe cap screws.

2. Scribe mark on pole shoe and field frame for proper

–UN–09FEB90
assembly.

IMPORTANT: Do not tightly squeeze side of main

frame in a vise or strike with a hammer. R26555N
Damage may result.
Remove Field Windings
If an impact screwdriver is used to loosen screws,
support each pole shoe individually using a pole shoe
spreader or the nose of an anvil.

Remove windings very carefully. Windings are easily

damaged, causing shorts, opens, or grounds.

RG,RG34710,2310 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-20 Alternators and Starter Motors

103000
PN=468
 John Deere/Denso Conventional Starter Motor Repair

Install Field Windings

NOTE: Two different field winding assemblies are

available. Starter motors with date code 9U0001
and lower have shunt wire lead (A), while those
with date code 10U001 and higher have shunt
wire lead (B). Shunt wire lead (A) will be too short
for the later starter motors. 65
10
1. Carefully insert field windings. 21

2. Align scribe marks on pole shoes and field frame.

3. Tighten pole shoe screws to specifications.

–UN–06APR89
Specification
Pole Shoe Cap Screws—Torque .................................... 41 N•m (30 lb-ft)

RG4958
A—Earlier Field Winding Shunt Lead
B—Later Field Winding Shunt Lead
Install Field Windings

RG,RG34710,2311 –19–15MAR97–1/1

Inspect and Repair Brushes

Replace brushes if they are oil soaked, worn, damaged,

or worn beyond specification.

Specification
New Brush—Length ........................................................ 26 mm (1.02 in.)
Used Brush—Minimum Length ....................................... 16 mm (0.68 in.)

If brushes are burned or rough, use 00 sandpaper to

clean commutator contact area of brushes. Never use
emery cloth. Clean all dust from brush before reassembly.

RG,RG34710,2312 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-21 Alternators and Starter Motors

103000
PN=469
 John Deere/Denso Conventional Starter Motor Repair

Test Brush Holder for Grounds

1. Set ohmmeter on its highest scale.

2. Place one test lead on commutator end frame. Place

other lead on brush holder.

65 If needle swings toward zero, the positive brush holder

–UN–27JUL89
10 is grounded and should be replaced.
22

T31430NY
Test Brush Holder for Grounds

RG,RG34710,2313 –19–15MAR97–1/1

Measure Brush Spring Tension

Measure spring tension with a spring scale.

Brush spring tension should be as specified, just as the

spring leaves the brush holder.

Specification
Brush Spring—Minimum Tension............................ 11 N (40 ounce-force)

When measuring tension, scale should be parallel with

edge of brush holder.

–UN–27JUL89
T31431NY
Measure Brush Spring Tension
RG,RG34710,2314 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-22 Alternators and Starter Motors

103000
PN=470
 John Deere/Denso Conventional Starter Motor Repair

Disassemble Solenoid

1. Remove nut, washer and gasket from solenoid “S”

terminal (C).

2. Remove nut, washer and gasket from pull-in terminal

–UN–09NOV89
(F).
65
3. Remove switch cover (A). 10
23

RG3906
4. Inspect all solenoid parts for wear, dirt, and corrosion.

5. Wipe all parts and connections with mineral spirits and Disassemble Solenoid
a clean cloth or brush. Dry with a clean cloth. A—Switch Cover
B—Shunt Winding Lead
Firm pressure should be felt on the plunger when fully C—“S” Terminal
depressed. If plunger is weak, replace solenoid winding D—Solenoid Winding and Plunger Assembly
and plunger assembly. E—Plunger Cover
F—Pull-In Winding Terminal
G—Gaskets
6. Place gaskets on pull-in terminal and “S” terminal. H—Packing

7. Align main contact vertically.

8. Place packing on switch cover.

9. Tighten switch cover screws to solenoid winding and

plunger assembly securely.

IMPORTANT: Solenoid contacts and plunger will be

damaged if current is applied to
solenoid when removed from starter
motor.

RG,RG34710,2315 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-23 Alternators and Starter Motors

103000
PN=471
 John Deere/Denso Conventional Starter Motor Repair

Assemble Starter Motor

1. Lubricate both ends of shift lever (C) and wear pads

(D) on overrunning clutch (A), with a multi-purpose
lubricant.

–UN–09NOV89
2. Lubricate brake washer (B) and place on end of
65 overrunning clutch.
10

RG3904
24 NOTE: Avoid excessive lubrication.

A—Overrunning Clutch Assemble Starter Motor

B—Brake Washer
C—Shift Lever
D—Wear Pads

RG,RG34710,2316 –19–15MAR97–1/9

3. Place shift lever and overrunning clutch (A) up into

center bearing housing (B).

4. Install shift lever pivot (C) through shift lever and

tighten to specifications.

–UN–09NOV89
Specification
Shift Lever Pivot Cap Screw—
Torque ............................................................................. 41 N•m (30 lb-ft)

RG3907
5. Bend washered edge of shift lever pivot down to
prevent loosening.
Install and Inspect
6. Lubricate bearing in center bearing housing
A—Overrunning Clutch
generously, but not excessively with either Esso
B—Center Bearing Housing
Beacon 325 or Delco-Remy Lubricant No. 1960954. C—Shift Lever Pivot
D—O-Ring
7. Inspect O-ring (D) for wear and damage. Replace if
necessary.

Continued on next page RG,RG34710,2316 –19–15MAR97–2/9

CTM77 (30OCT00) 65-10-24 Alternators and Starter Motors

103000
PN=472
 John Deere/Denso Conventional Starter Motor Repair

8. Carefully install armature into field frame (A).

9. Place center bearing housing with overrunning clutch

assembly (B) onto armature shaft (C) and against field
frame.

Make sure O-ring in center bearing housing is not

–UN–09NOV89
twisted or crimped when placed against field frame. 65
10
10. Slide pinion stop over ring using a washer (F) and 25

RG3908
two pair of pliers.

11. Remove washer. Install Center Bearing Housing

12. Tighten all center bearing housing cap screws (G) in A—Field Frame
B—Overrunning Clutch Assembly
field frame to specifications. C—Armature Shaft
D—Pinion Stop
Specification E—Retaining Ring
Center Housing-to-Field Frame F—Washer (remove after using)
Cap Screw—Torque ......................................................... 8 N•m (71 lb-in.) G—Cap Screws

NOTE: Before installing drive end housing, check

armature end play. Using a dial indicator, place a
tip against end of armature shaft on drive end. If
end play is not within specifications, add or
remove shims (37, see exploded view) to obtain
correct end play.

Specification
Armature End Play—Torque ............... 0.05—0.50 mm (0.002—0.020 in.)

RG,RG34710,2316 –19–15MAR97–3/9

13. Install drive end housing (A) against center bearing

housing. Armature shaft must come through drive end
bushing (B).

14. Tighten drive end Allen-head bolts (C) to –UN–08SEP89

specifications.

Specification
Drive End Housing-to-Center
Housing Cap Screws—Torque ..................................... 14 N•m (124 lb-in.)
RG4205

A—Drive End Housing Install Drive End Housing

B—Drive End Bushing
C—Drive End Allen-Head Bolts

Continued on next page RG,RG34710,2316 –19–15MAR97–4/9

CTM77 (30OCT00) 65-10-25 Alternators and Starter Motors

103000
PN=473
 John Deere/Denso Conventional Starter Motor Repair

15. Place commutator end frame over armature.

NOTE: Be sure commutator end frame notches fit

correctly in field frame.

–UN–09NOV89
16. Using O-ring pick (A) or other suitable tool, raise
brush springs (B) and install brushes (C).
65
10 A—O-Ring Pick

RG3902
26 B—Brush Springs
C—Brushes
Install Brushes

RG,RG34710,2316 –19–15MAR97–5/9

17. Twist brush leads (B) 180 degrees.

18. Press leads of insulated brush (A) down against

brush. Make sure spring (C) is fully seated on top of
brush.

–UN–09NOV89
A—Insulated Brush
B—Brush Leads
C—Spring

RG3909
Twist Brush Leads
RG,RG34710,2316 –19–15MAR97–6/9

19. Install brush ground straps (B).

20. Screw brush cap screws (A) down securely.

NOTE: Make sure field winding lead and shunt winding

–UN–09NOV89

leads are tightened down with the brush cap

screws.

A—Brush Cap Screws

RG3901

B—Brush Ground Straps

Install Brush Ground Straps

Continued on next page RG,RG34710,2316 –19–15MAR97–7/9

CTM77 (30OCT00) 65-10-26 Alternators and Starter Motors

103000
PN=474
 John Deere/Denso Conventional Starter Motor Repair

21. Install washers and cap screws (B) through

commutator end frame.

22. Tighten screws to specifications.

–UN–09NOV89
Specification
Commutator End Frame Cap
Screws—Torque ........................................................... 14 N•m (124 lb-in.)
65
10
Make sure brush leads (A) are properly positioned.

RG3900
27

NOTE: Replace O-ring (C) if cracked or worn. Position Brush Leads

A—Brush Leads
B—Washers and Cap Screws
C—O-Ring

RG,RG34710,2316 –19–15MAR97–8/9

23. Place end frame cover onto field frame.

24. Install end frame cover washers, lock washers and

cap screws. Tighten securely.

–UN–17JUL89
RG2705
End Frame Cover
RG,RG34710,2316 –19–15MAR97–9/9

Install Solenoid

1. Install solenoid plunger shaft (A) up onto shift lever.

A—Solenoid Plunger Shaft –UN–09NOV89

RG3899

Solenoid Plunger Shaft

Continued on next page RG,RG34710,2317 –19–15MAR97–1/4

CTM77 (30OCT00) 65-10-27 Alternators and Starter Motors

103000
PN=475
 John Deere/Denso Conventional Starter Motor Repair

2. Push solenoid assembly forward up against center

bearing housing.

3. Screw solenoid cap screws with lock washers (A) into

solenoid and tighten securely.

–UN–09NOV89
A—Solenoid Cap Screws and Lock Washers
65
10

RG3898
28

Lock Washers
RG,RG34710,2317 –19–15MAR97–2/4

4. Install field coil connector (A), washers and nuts.

Tighten nuts securely.

A—Field Coil Connector

–UN–09NOV89
RG3893
Install Field Coil Connector

RG,RG34710,2317 –19–15MAR97–3/4

5. Install shunt lead wire (A), lock washer, and nut.

Tighten nut securely.

6. Install terminal cover (B) on solenoid securely.

–UN–09NOV89
A—Shunt Lead Wire
B—Terminal Cover

RG3892

Install Terminal Cover

RG,RG34710,2317 –19–15MAR97–4/4

CTM77 (30OCT00) 65-10-28 Alternators and Starter Motors

103000
PN=476
 John Deere/Denso Conventional Starter Motor Repair

Make No-Load Test

1. Make connections as shown, and use an ammeter (A)

capable of measuring several hundred amps.

2. Measure current draw and compare with specifications

–UN–28SEP00
given earlier in this group.
65
3. If speed and current draw are slightly low, connect a 10
voltmeter between motor terminal and frame. Observe 29

RG11163
voltage during test. Voltage may be reduced because
of high current draw on battery.
Make No-Load Test
4. If speed or current draw is significantly different than
A—Ammeter
specified, diagnose problem by referring to Diagnose B—Battery
No-Load Test chart earlier in this group. C—Start Frame
D—Tachometer
E—Battery Terminal
F—Switch
G—Field Coil Connector

RG,RG34710,2318 –19–15MAR97–1/1

CTM77 (30OCT00) 65-10-29 Alternators and Starter Motors

103000
PN=477
 John Deere/Denso Conventional Starter Motor Repair

65
10
30

CTM77 (30OCT00) 65-10-30 Alternators and Starter Motors

103000
PN=478
 Group 15
John Deere/Denso Gear Reduction Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

65
15
1

SERVICEGARD is a trademark of Deere & Company OUO1004,0000B9F –19–25SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000B9F –19–25SEP00–2/2

Service Equipment and Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC). Some
tools may be available from a local supplier.

SERVICEGARD is a trademark of Deere & Company OUO1004,0000BA0 –19–25SEP00–1/5

Armature Growler

Test windings for shorts.

Continued on next page OUO1004,0000BA0 –19–25SEP00–2/5

CTM77 (30OCT00) 65-15-1 Alternators and Starter Motors

103000
PN=479
 John Deere/Denso Gear Reduction Starter Motor Repair

Bearing Puller. . . . . . . . . . . . . . . . . . . . . . D01203AA

Remove bearings.

OUO1004,0000BA0 –19–25SEP00–3/5

65 Bearing Puller. . . . . . . . . . . . . . . . . . . . . . D01217AA

15
2 Remove bearings.

OUO1004,0000BA0 –19–25SEP00–4/5

Bushing, Bearing and Seal Drive Set. . . . . . . D01045AA

Remove and install all commutator, drive end, and center

bushings.
OUO1004,0000BA0 –19–25SEP00–5/5

Other Material

Number Name Use

(U.S.) Mineral Spirits Clean armature, solenoid and

brushes.

(U.S.) 00 Sandpaper Clean commutator.

(U.S.) ESSO Beacon 325 or Delco-Remy Lubricate various stator components.

No. 1960954 Lubricant

OUO1004,0000BA1 –19–25SEP00–1/1

John Deere/Denso Gear Reduction Starter

Motor Repair Specifications

Item Measurement Specification

Armature Undercut Depth 0.08 mm (0.031 in.)

Service Minimum 0.20 mm (0.008 in.)

Commutator OD (New Part) 36 mm (1.41 in.)

Wear Limit 35 mm (1.38 in.)

Commutator Runout (New Part) 0.02 mm (0.0008 in.)

Wear Limit 0.05 mm (0.002 in.)

Negative Brushes Minimum Length 9.0 mm (0.35 in.)

Field Coil Brushes Minimum Length 12.7 mm (0.500 in.)

OUO1004,0000BA2 –19–25SEP00–1/1

CTM77 (30OCT00) 65-15-2 Alternators and Starter Motors

103000
PN=480
 John Deere/Denso Gear Reduction Starter Motor Repair

John Deere/Denso Gear Reduction Starter

Motor Test Specifications
John Deere Denso System Rating kW Motor No Load Test RPM (Min.)
Part No. Part No. Voltage Type Voltage Current Draw
Amps (Max.)
RE19275 028000-8400 12 R 2.5 11 180 3500
RE40092 028000-8290 12 R 2.5 11 200 3000 65
RE50165 228000-0840 12 R 2.5 11 200 3000 15
3
RE51447 028000-8401 12 R 2.5 11 200 3000
RE54090 128000-8291 12 R 2.5 11 200 3000
RE54091 228000-0841 12 R 2.5 11 200 3000
RE54092 028000-8402 12 R 2.5 11 200 3000
RE59588 228000-0844 12 R 2.5 11 200 3000
RE59595 128000-8294 12 R 2.5 11 200 3000
RE68470 228000-6471 12 R 2.7 11 200 3000
RE69704 228000-6530, 12 R 4.0 11 220 4200
228000-6531
RE69705 228000-6560 24 R 7.5 23 120 3800
RE70473 228000-6540 12 R 4.8 11 220 4200
RE70474 228000-6550, 12 R 4.8 11 220 4200
228000-6551
RE70475 228000-6570 24 R 7.5 23 120 3800
RE70959 228000-6540 12 R 4.8 11 220 4200
RE70960 228000-6550 12 R 4.8 11 220 4200

NOTE: Earlier Denso starter motors may have the original

Nippondenso label.

RG,RG34710,2322 –19–08SEP00–1/1

CTM77 (30OCT00) 65-15-3 Alternators and Starter Motors

103000
PN=481
 John Deere/Denso Gear Reduction Starter Motor Repair

Bench Test Starter Motor

IMPORTANT: Never operate starter motor more than

30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating, caused
by excessive operation, will seriously
65 damage starter motor.
15
4 NOTE: Perform bench tests before disassembling the
starter motor to determine the cause of the
problem.

1. Turn overrunning clutch drive clockwise by hand.

Pinion should turn freely.

2. Turn pinion counterclockwise. A definite resistance

should be felt. If clutch assembly is defective,

–UN–06MAR90
disassemble the starter clutch.

3. If armature turns freely and the clutch is not defective,

test starter under no-load conditions as follows.

RW2158
NOTE: Starter motors illustrated in this group are
equipped with a four-hole mounting flange instead Turn Overrunning Clutch
of one that has two holes. In addition, later R 4.0
kW and R 7.5 kW starter motors have the brush
assemblies at the opposite end of the armature.
Service procedures are not affected.

RG,RG34710,2323 –19–15MAR97–1/1

CTM77 (30OCT00) 65-15-4 Alternators and Starter Motors

103000
PN=482
 John Deere/Denso Gear Reduction Starter Motor Repair

No-Load Test

NOTE: Do not conduct the no-load test unless the

armature turns freely.

1. Connect a 12-volt battery (A) to starter battery terminal

(B) and starter frame (C) as shown. Use heavy-duty
cables. 65
15
2. Connect a remote start switch (D) between switch 5
terminal (E) and battery terminal (B).

3. When switch is activated, starter should engage and

run.

4. If solenoid only chatters, hold-in winding is

open-circuited. If nothing happens, either the pull-in

–UN–01DEC88
winding is open-circuited or mechanical parts are
sticking. To check for sticking, remove solenoid end
cover and push plunger by hand.

RW2159
5. If solenoid engages properly, but motor does not run,
check main contact points, bearings, brushes,
reduction gears, armature, and field windings. No-Load Test

NOTE: The solenoid cannot be repaired, although A—12-Volt Battery

B—Battery Terminal
mechanical parts may be replaced. Disassemble C—Starter Frame
solenoid to determine cause of problem. D—Remote Start Switch
E—Switch Terminal

RG,RG34710,2324 –19–15MAR97–1/1

CTM77 (30OCT00) 65-15-5 Alternators and Starter Motors

103000
PN=483
 John Deere/Denso Gear Reduction Starter Motor Repair

Exploded View of Gear Reduction Starter Motor

65
15
6

–UN–16SEP99
RG8615
Gear-Reduction Starter Motor

1—End Frame 6—Armature 11—Idler Gear 15—Return Spring

2—O-Ring 7—Front Bearing 12—Retainer 16—Steel Ball
3—Field Frame 8—Brush (4 Used) 13—Roller (5 Used) 17—Overrunning Clutch
4—O-Ring 9—Brush Holder 14—Solenoid Assembly 18—Motor Frame
5—Rear Bearing 10—Drive Gear

RG,RG34710,2334 –19–15MAR97–1/1

Disassemble Field Frame, Armature, and

Brush Holder

NOTE: Bench test the starter motor before disassembly.

1. Disconnect field lead (A) from solenoid.

–UN–10NOV89

2. Remove two through bolts (B) and separate field frame

assembly from motor frame.
RW10058

A—Field Lead
B—Through Bolts (2 Used)
Disconnect Field Lead

Continued on next page RG,RG34710,2325 –19–15MAR97–1/4

CTM77 (30OCT00) 65-15-6 Alternators and Starter Motors

103000
PN=484
 John Deere/Denso Gear Reduction Starter Motor Repair

3. Remove two screws from brush end cap and remove

cap from frame assembly.

–UN–10NOV89
65
15
7

RW10059
Remove Cap from Frame Assembly

RG,RG34710,2325 –19–15MAR97–2/4

4. Lift two field coil brush springs away and pull field coil
brushes (A) away from brush holder assembly.

A—Field Coil Brushes

–UN–10NOV89
RW10067
Field Coil Brushes

Continued on next page RG,RG34710,2325 –19–15MAR97–3/4

CTM77 (30OCT00) 65-15-7 Alternators and Starter Motors

103000
PN=485
 John Deere/Denso Gear Reduction Starter Motor Repair

5. Lift two negative brush springs away and pull brushes

back about 6 mm (0.250 in.). Release springs to hold
brushes in place in brush holder (A).

6. Remove brush holder from frame assembly and

armature.

–UN–10NOV89
65 7. Remove armature from frame assembly.
15
8

RW10068
A—Brush Holder

Brush Holder

RG,RG34710,2325 –19–15MAR97–4/4

Inspect and Repair Armature

1. Remove armature from field frame assembly. See

Disassemble Field Frame, Armature and Brush Holder
earlier in this group.

–UN–06MAR90
IMPORTANT: Do not clean armature with solvent.
Solvent could damage insulation on
windings. Use only mineral spirits and a
brush.

RW2166
2. Visually inspect armature. Look for signs of dragging Inspect and Repair Armature
against pole shoes.

Specification
Armature—Undercut Depth ........................................ 0.08 mm (0.031 in.)
Service Minimum ........................................................ 0.20 mm (0.008 in.)

Continued on next page RG,RG34710,2326 –19–15MAR97–1/8

CTM77 (30OCT00) 65-15-8 Alternators and Starter Motors

103000
PN=486
 John Deere/Denso Gear Reduction Starter Motor Repair

3. Check for grounded windings using an ohmmeter as

shown, or a test lamp. Place ohmmeter probes on
commutator bar and armature shaft. If test shows
continuity (needle movement) a winding is grounded
and the armature must be replaced.

–UN–26FEB93
NOTE: Operating symptoms of grounded windings would
be that the starter motor cranks engine slowly or 65
not at all. On no-load test, the starter motor would 15
have low armature speed and high current draw, 9

RW2167
or fail to operate and have high current draw.

Ohmmeter

RG,RG34710,2326 –19–15MAR97–2/8

NOTE: Operating symptoms of short-circuited windings

would be that the starter motor cranks engine
slowly. On no-load test, motor has low armature
speed and high current draw.

4. Check for short-circuited windings using a growler such

as shown.

5. Place armature in growler and hold a hacksaw blade

above each slot while slowly rotating the armature. The
blade will be attracted to and repelled (vibrating
motion) from the slot.

NOTE: A short circuit most often occurs because of

copper dust or fillings between two commutator
segments.

6. If test indicates short-circuited windings, clean the

–UN–01DEC88
commutator of dust and filings and recheck the
armature. If test still indicates a short circuit, replace
the armature.
RW2168

Growler

Continued on next page RG,RG34710,2326 –19–15MAR97–3/8

CTM77 (30OCT00) 65-15-9 Alternators and Starter Motors

103000
PN=487
 John Deere/Denso Gear Reduction Starter Motor Repair

7. Check for open-circuited windings using an ohmmeter

as shown, or a test lamp. Place ohmmeter probes on
two different commutator bars. If test shows no
continuity (no needle movement), there is an open
circuit and the armature must be replaced.

–UN–10NOV89
NOTE: Operating symptoms of open-circuited windings
65 would be that the starter motor cranks engine
15 slowly. On no-load test, motor has low armature
10 speed and high current draw.

RW10060
Ohmmeter Probes

RG,RG34710,2326 –19–15MAR97–4/8

8. Check commutator (A), looking for roughness or

burned commutator bars.

9. If necessary, clean and touch up with 00 sandpaper.

NEVER use emery cloth. Clean all dust from armature
when finished.

–UN–10NOV89
10. Turn down slightly on a lathe if commutator is out of
round, badly burned, or rough. Remove only enough
metal to eliminate the problem. After turning down,

RW10061
undercut the insulation between bars to 0.5—0.8 mm
(0.019—0.031 in.) deep. Touch up commutator with
sandpaper and clean metal chips and dust from Check Commutator
armature when finished.
A—Commutator

Specification
Commutator—OD (New Part) ......................................... 36 mm (1.41 in.)
Wear Limit ....................................................................... 35 mm (1.38 in.)
Commutator—Runout (New Part) ............................ 0.02 mm (0.0008 in.)
Wear Limit .................................................................. 0.05 mm (0.002 in.)

Continued on next page RG,RG34710,2326 –19–15MAR97–5/8

CTM77 (30OCT00) 65-15-10 Alternators and Starter Motors

103000
PN=488
 John Deere/Denso Gear Reduction Starter Motor Repair

11. Inspect front and rear armature bearings for smooth,

quiet operation. Replace as necessary.

12. Remove bearings by using D01217AA Bearing Puller

and D01203AA Bearing Puller as shown.

–UN–10NOV89
65
15
11

RW10069
Front and Rear Armature Bearings

RG,RG34710,2326 –19–15MAR97–6/8

IMPORTANT: Install both bearings with the sealed

side toward the middle of the armature.

13. Install new bearing on the rear of armature using a

piece of 15.88 mm (0.625 in.) ID pipe (A) drilled out
to 17.45 mm (0.687 in.) ID. Be sure to drive only on

–UN–10NOV89
the inner race. Make sure bearing is tight against
shoulder of shaft.

NOTE: Pipe must be drilled out to the larger size to allow

RW10070
it to pass over the splined end of the armature.

15.88 mm (0.625 in.) ID Pipe

A—15.88 mm (0.625 in.) ID Pipe

Continued on next page RG,RG34710,2326 –19–15MAR97–7/8

CTM77 (30OCT00) 65-15-11 Alternators and Starter Motors

103000
PN=489
 John Deere/Denso Gear Reduction Starter Motor Repair

14. Install bearing (A) with sealed side of bearing toward

middle of armature on commutator end of armature
using 27491 1/2 in. driver disk from D01045AA
Bushing, Bearing and Seal Drive Set. Drive only on
the inner race. Install bearing until tight against
shoulder of shaft.

–UN–10NOV89
65 A—Bearing
15
12

RW10071
Install Bearing

RG,RG34710,2326 –19–15MAR97–8/8

Inspect Brushes and Brush Holder

1. Measure negative brushes mounted on brush holder. If

worn below specification, replace the brush holder
assembly.

–UN–10NOV89
Specification
Negative Brushes—Minimum
Length ............................................................................. 9.0 mm (0.35 in.)

RW10072
Measure Negative Brushes

Continued on next page RG,RG34710,2327 –19–15MAR97–1/4

CTM77 (30OCT00) 65-15-12 Alternators and Starter Motors

103000
PN=490
 John Deere/Denso Gear Reduction Starter Motor Repair

2. Measure the field coil brushes attached to the field

frame assembly. If worn below specified length,
replace the entire field frame assembly.

Specification
Field Coil Brushes—Minimum

–UN–10NOV89
Length ......................................................................... 12.7 mm (0.500 in.)

65
15
13

RW10073
Measure Field Coil Brushes

RG,RG34710,2327 –19–15MAR97–2/4

3. Test the brush holder using an ohmmeter as shown, or

a test light. Place one lead of tester to the negative
brush holder and the other lead to field brush holder. If
there is continuity (needle movement), replace the
brush holder.

–UN–10NOV89
RW10074
Test Brush Holder with Ohmmeter

Continued on next page RG,RG34710,2327 –19–15MAR97–3/4

CTM77 (30OCT00) 65-15-13 Alternators and Starter Motors

103000
PN=491
 John Deere/Denso Gear Reduction Starter Motor Repair

4. Check the brush springs to be sure they are not weak

or distorted. Replace as necessary.

5. Remove spring using a pair of needle nose pliers.

Raise brush end of spring from holder and pry spring
upward from lug on holder with a screwdriver.

–UN–10NOV89
65 6. To install, start spring on lug and wind spring so brush
15 end of spring fits in brush holder, while at the same
14 time pushing the spring on the lug.

RW10075
Check Brush Springs

RG,RG34710,2327 –19–15MAR97–4/4

Inspect Field Coils

1. Check for grounded field winding using an ohmmeter

as shown, or a test light. Touch one lead to a field coil
brush and the other lead to the field frame. Be sure the
brush lead is not touching the frame. If there is

–UN–10NOV89
continuity (needle movement), the coil is grounded and
the field frame assembly must be replaced.

RW10076
Check for Gounded Field Winding

Continued on next page RG,RG34710,2328 –19–15MAR97–1/2

CTM77 (30OCT00) 65-15-14 Alternators and Starter Motors

103000
PN=492
 John Deere/Denso Gear Reduction Starter Motor Repair

2. Check for open field coil using an ohmmeter as shown,

or a test light. Touch a lead to each field coil brush. If
there is no continuity (no needle movement), the field
coil is open and the field frame assembly must be
replaced.

–UN–10NOV89
65
15
15

RW10077
Check for Open Field Coil

RG,RG34710,2328 –19–15MAR97–2/2

Assemble Field Frame, Armature, and Brush

Holder

1. Place armature in field frame assembly and place in

vise.

–UN–10NOV89
2. Lift the two negative brush springs away and pull
brushes back about 6 mm (0.250 in.). Release the
spring to lock the brushes in the outward position.

RW10095
3. Place brush holder on armature and frame assembly.
Field Frame, Armature and Brush Holder

Continued on next page RG,RG34710,2329 –19–15MAR97–1/5

CTM77 (30OCT00) 65-15-15 Alternators and Starter Motors

103000
PN=493
 John Deere/Denso Gear Reduction Starter Motor Repair

4. Lift two field coil brush springs away from holder and
place brushes (A) in holders. Allow springs to hold
brushes against commutator.

5. Push negative brushes inward to allow springs to hold

brushes against commutator.

–UN–10NOV89
65 A—Brushes
15
16

RW10067
Place Brushes in Holders

RG,RG34710,2329 –19–15MAR97–2/5

6. Apply a small amount of Delco-Remy Lubricant No.

1960954, or equivalent, to the open side of the brush
end bearing.

7. Install brush end cap in place and install and tighten

two screws from brush end cap to field frame

–UN–10NOV89
assembly.

RW10059
Install Brush End Cap

Continued on next page RG,RG34710,2329 –19–15MAR97–3/5

CTM77 (30OCT00) 65-15-16 Alternators and Starter Motors

103000
PN=494
 John Deere/Denso Gear Reduction Starter Motor Repair

8. Apply a small amount of Delco-Remy Lubricant No.

1960954, or equivalent, to the open side of the drive
end bearing.

9. Install felt washer (A) in place on armature shaft.

–UN–10NOV89
10. Align indexing slot in solenoid frame (B) with flange
on lip of field frame assembly (C). 65
15
NOTE: Some starter motors may have a small-square 17

RW10078
shaped locking key which fits into the cast slot (B)
in solenoid frame.
Install Felt Washer

A—Felt Washer
B—Indexing Slot
C—Field Frame Assembly

RG,RG34710,2329 –19–15MAR97–4/5

11. Install field frame assembly to motor frame.

12. Install and tighten two through bolts (B).

13. Connect field lead (A) to solenoid.

–UN–10NOV89
14. Bench test the repaired starter motor as instructed
earlier in this group.

15. If bench tests indicate that the starter motor is

RW10058
working, install starter motor on engine as instructed
in machine technical manual.
Connect Field Lead to Solenoid

A—Field Lead
B—Through Bolts (2 Used)

RG,RG34710,2329 –19–15MAR97–5/5

CTM77 (30OCT00) 65-15-17 Alternators and Starter Motors

103000
PN=495
 John Deere/Denso Gear Reduction Starter Motor Repair

Disassemble Gear Train and Overrunning

Clutch

1. Disassemble the field frame assembly from the

housing as previously instructed in this group.

–UN–10NOV89
2. Remove three screws (A) and separate gear train
65 assembly from motor frame.
15
18

RW10062
A—Screws (3 Used)

Remove Screws

RG,RG34710,2330 –19–15MAR97–1/6

3. Place gear assembly in a soft-jaw vise as shown. Be

sure rear vise jaw is against shaft and front jaw is
against pinion.

4. Slowly tighten vise until pinion compresses.

–UN–12FEB90
R30383
Compress Pinion

Continued on next page RG,RG34710,2330 –19–15MAR97–2/6

CTM77 (30OCT00) 65-15-18 Alternators and Starter Motors

103000
PN=496
 John Deere/Denso Gear Reduction Starter Motor Repair

5. Drive back retainer (B) until snap ring is exposed,

using a short length of 5/8 in. ID pipe (A).

6. Remove snap ring and retainer from pinion shaft.

CAUTION: Shaft could be propelled from clutch

–UN–12FEB90
unit with considerable force, if spring is not
allowed to extend fully while in vise. 65
15
19

R30384
7. Slowly open vise until all spring tension is relieved and
remove gear assembly from vise.
Remove Snap Ring and Retainer

A—5/8 in. ID Pipe

B—Retainer

RG,RG34710,2330 –19–15MAR97–3/6

8. Remove drive pinion from shaft.

9. Remove shaft with springs (A) and clutch unit (B) from
housing.

–UN–10NOV89
A—Shaft with Springs
B—Clutch Unit

RW10080
Remove Shaft

Continued on next page RG,RG34710,2330 –19–15MAR97–4/6

CTM77 (30OCT00) 65-15-19 Alternators and Starter Motors

103000
PN=497
 John Deere/Denso Gear Reduction Starter Motor Repair

10. Inspect all parts for wear or damage. Replace as

necessary.

11. If clutch unit (E) is defective, the entire unit must be

replaced.

–UN–10NOV89
A—Shaft
65 B—Spring
15 C—Spring
20 D—Retainer

RW10081
E—Clutch Unit

Inspect Parts for Wear or Damage

RG,RG34710,2330 –19–15MAR97–5/6

12. Remove the starter pinion (B), needle roller retainer

(D) with six needle rollers (C), and thrust washer (A)
from housing.

13. Remove the spring (E) from the solenoid plunger.

–UN–10NOV89
14. Inspect all parts for wear or damage. Replace as
necessary.

RW10082
A—Thrust Washer
B—Pinion
C—Needle Rollers (6 used)
D—Needle Roller Retainer Inspect Parts
E—Solenoid Plunger Spring
F—Solenoid Housing

RG,RG34710,2330 –19–15MAR97–6/6

CTM77 (30OCT00) 65-15-20 Alternators and Starter Motors

103000
PN=498
 John Deere/Denso Gear Reduction Starter Motor Repair

Assemble Gear Train and Overrunning

Clutch

NOTE: Use Delco-Remy No. 1960954 Lubricant or a

similar lubricant when assembling starter motor.

–UN–10NOV89
1. Make sure the solenoid plunger ball (A) is in place in
the shaft bore (B). Apply a light coat of grease to the 65
ball to hold in place. 15
21

RW10079
A—Solenoid Plunger Ball
B—Shaft Bore
Solenoid Plunger Ball in Shaft Bore

RG,RG34710,2331 –19–15MAR97–1/7

NOTE: Lubricate the shaft lightly with lubricant before

installing springs.

2. First place the long spring (B) on the pinion shaft, then
the short spring (C), and spring retainer (D).

–UN–10NOV89
3. Install pinion shaft assembly into clutch unit (E), as
shown.

RW10081
A—Pinion Shaft
B—Spring
C—Spring
D—Spring Retainer Install Pinion Shaft Assembly into Clutch Unit
E—Clutch Unit

Continued on next page RG,RG34710,2331 –19–15MAR97–2/7

CTM77 (30OCT00) 65-15-21 Alternators and Starter Motors

103000
PN=499
 John Deere/Denso Gear Reduction Starter Motor Repair

4. Install clutch unit (B) with pinion shaft assembly (A)

into housing.

A—Pinion Shaft Assembly

B—Clutch Unit

–UN–10NOV89
65
15
22

RW10080
Clutch Unit with Pinion Shaft Assembly

RG,RG34710,2331 –19–15MAR97–3/7

5. Make sure retaining ring (A) is in drive pinion and is

not worn or damaged.

A—Retaining Ring

–UN–10NOV89
RW10083
Retaining Ring

Continued on next page RG,RG34710,2331 –19–15MAR97–4/7

CTM77 (30OCT00) 65-15-22 Alternators and Starter Motors

103000
PN=500
 John Deere/Denso Gear Reduction Starter Motor Repair

6. Lightly lubricate the pinon shaft and install drive pinion

(A) onto pinion shaft, as shown, with large flange to the
outside of clutch.

7. Place gear assembly in a soft jaw vise, as shown. Be

sure rear vise jaw is against shaft and front jaw is

–UN–10NOV89
against pinion.
65
8. Slowly tighten vise until pinion compresses enough to 15
allow installation of retainer and retaining ring. 23

RW10084
9. Install retainer (B) and snap ring (C) and remove from
vise. Make sure snap ring is seated in retainer. Install Retainer and Snap Ring

A—Drive Pinion
B—Retainer
C—Snap Ring

RG,RG34710,2331 –19–15MAR97–5/7

10. Apply a thin coating of lubricant to the thrust washer

(A) and install on shaft.

11. Apply a thin coating of lubricant to the needle rollers

(C) and install them into retainer (D).

–UN–10NOV89
12. Install the needle roller retainer with needle rollers
into the starter pinion (B).

13. Place the pinion assembly onto the shaft with the

RW10082
open side of the retainer facing the thrust washer.

14. Install spring (E) on solenoid plunger. Components

A—Thrust Washer
B—Pinion
C—Needle Rollers (6 used)
D—Needle Roller Retainer
E—Solenoid Plunger Spring
F—Solenoid Housing

Continued on next page RG,RG34710,2331 –19–15MAR97–6/7

CTM77 (30OCT00) 65-15-23 Alternators and Starter Motors

103000
PN=501
 John Deere/Denso Gear Reduction Starter Motor Repair

15. Assemble gear train assembly to frame and install

and tighten three screws (A).

16. Assemble field frame assembly to housing and bench

test the starter as previously instructed in this group.

–UN–10NOV89
A—Screws (3 Used)
65
15
24

RW10062
Screws

RG,RG34710,2331 –19–15MAR97–7/7

Disassemble, Inspect, and Repair Starter

Solenoid

1. Remove starter motor from engine.

2. Disconnect field frame lead (A).

–UN–10NOV89
3. Remove three screws (B) and remove solenoid cover
and gasket.

RW10086
A—Field Frame Lead
B—Screws (3 Used)
Remove Solenoid Cover and Gasket

Continued on next page RG,RG34710,2332 –19–15MAR97–1/3

CTM77 (30OCT00) 65-15-24 Alternators and Starter Motors

103000
PN=502
 John Deere/Denso Gear Reduction Starter Motor Repair

4. Remove plunger (A).

A—Plunger

–UN–10NOV89
65
15
25

RW10087
Remove Plunger

RG,RG34710,2332 –19–15MAR97–2/3

5. Remove plunger spring (A).

A—Plunger Spring

–UN–10NOV89
RW10088
Remove Plunger Spring

RG,RG34710,2332 –19–15MAR97–3/3

CTM77 (30OCT00) 65-15-25 Alternators and Starter Motors

103000
PN=503
 John Deere/Denso Gear Reduction Starter Motor Repair

Assemble Solenoid Assembly

65
15
26

–UN–29NOV89
RW10085L
Exploded View of Solenoid Assembly

A—Screw (3 Used) E—Bolt H—Nut (2 Used) K—Solenoid Housing

B—Solenoid Cover F—Plate (2 Used) I—Special Washer (2 Used) L—Bolt
C—Gasket G—Bushing (2 Used) J—Bushing M—Plunger Spring
D—Plunger

1. Inspect all solenoid components shown and replace

as necessary if broken or worn.

2. The complete solenoid housing must be replaced if

there is a solenoid problem other than the loose
parts shown.

Continued on next page RG,RG34710,2333 –19–15MAR97–1/4

CTM77 (30OCT00) 65-15-26 Alternators and Starter Motors

103000
PN=504
 John Deere/Denso Gear Reduction Starter Motor Repair

3. Place plunger spring (A) in housing.

A—Plunger Spring

–UN–10NOV89
65
15
27

RW10088
Plunger Spring

RG,RG34710,2333 –19–15MAR97–2/4

4. Place solenoid plunger (A) into spring in housing.

A—Plunger

–UN–10NOV89
RW10087
Solenoid Plunger

Continued on next page RG,RG34710,2333 –19–15MAR97–3/4

CTM77 (30OCT00) 65-15-27 Alternators and Starter Motors

103000
PN=505
 John Deere/Denso Gear Reduction Starter Motor Repair

5. Carefully inspect gasket and replace if hard and brittle

or torn.

6. Install solenoid cover and gasket onto solenoid housing

and install and tighten three screws (B).

–UN–10NOV89
7. Connect field frame lead (A).
65
15 A—Field Frame Lead
28 B—Screws (3 Used)

RW10086
Connect Field Frame Lead

RG,RG34710,2333 –19–15MAR97–4/4

CTM77 (30OCT00) 65-15-28 Alternators and Starter Motors

103000
PN=506
 Section 70
Robert Bosch Starter Motors
Contents

Page

Group 05—Starting Circuit Theory of Operation

General Information . . . . . . . . . . . . . . . . . . . . .70-05-1
Typical Starting Circuit Operation . . . . . . . . . . .70-05-1
Typical Starter Motor Operation . . . . . . . . . . . .70-05-2
70
Group 10—Robert Bosch Starter Motor Repair
Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
Robert Bosch Starter Motor Repair
Specifications . . . . . . . . . . . . . . . . . . . . . . . .70-10-2
Robert Bosch Starter Motor Test
Specifications . . . . . . . . . . . . . . . . . . . . . . . .70-10-3
Make No-Load Test . . . . . . . . . . . . . . . . . . . . .70-10-4
Diagnosing Starter Motor Malfunctions . . . . . . .70-10-5
Robert Bosch Starter Motor Cutaway View . . .70-10-6
Robert Bosch Starter Motor Exploded View . . .70-10-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-8
Solenoid Switch—Removal . . . . . . . . . . . . . . . .70-10-8
Carbon Brush Plate—Removal . . . . . . . . . . . . .70-10-9
Armature—Removal . . . . . . . . . . . . . . . . . . . . .70-10-9
Snap Ring—Removal . . . . . . . . . . . . . . . . . . .70-10-10
Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . .70-10-10
Testing Armature for Grounds . . . . . . . . . . . . .70-10-10
Testing Armature for Short Circuit . . . . . . . . . .70-10-11
Testing Armature for Open Circuit . . . . . . . . . .70-10-11
Turning Commutator Down . . . . . . . . . . . . . . .70-10-12
Testing Commutator for Out-of-Roundness . . .70-10-12
Testing Field Winding for Grounded Circuit . . .70-10-13
Field Winding—Removal . . . . . . . . . . . . . . . . .70-10-13
Make Open Circuit Test for Field Windings . . .70-10-14
Lubrication of Starter Motor (Before and
During Assembly) . . . . . . . . . . . . . . . . . . . .70-10-14
Field Winding—Installation . . . . . . . . . . . . . . .70-10-15
Checking Carbon Brush Plate for Grounds . . .70-10-15
Testing Carbon Brushes . . . . . . . . . . . . . . . . .70-10-16
Replace Carbon Brushes . . . . . . . . . . . . . . . .70-10-16
Engaging Lever—Installation . . . . . . . . . . . . . .70-10-17
Checking Armature End Play and Torque . . . .70-10-17
Installing Starter Motor . . . . . . . . . . . . . . . . . .70-10-17

CTM77 (30OCT00) 70-1 Alternators and Starter Motors

103000
PN=1
 Contents

70

CTM77 (30OCT00) 70-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Starting Circuit Theory of Operation
General Information

IMPORTANT: Never operate starter motor longer than

30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating caused by
excessive operation will seriously
damage starter motor.

RG,RG34710,2335 –19–15MAR97–1/1
70
05
Typical Starting Circuit Operation 1

When wire from relay (A) is energized, current flows

through both pull-in winding (C) and hold-in winding (D) to
ground.

Current through windings engages solenoid plunger (E),

which closes main contacts (F). When main contacts

–UN–20APR89
close, current through pull-in windings stops. Current
continues through hold-in winding, keeping solenoid
engaged and main contacts closed.

RG1313
With main contacts closed, current flows from battery
cable (B) to starter motor at a very high rate. Four heavy Typical Starting Circuit
field windings (G) carry current to commutator brushes
(H). A—Wire From Relay
B—Cable from Battery
C—Pull-In Winding
Light shunt windings (J) are wrapped together with two of D—Hold-In Winding
the heavy field windings. Shunt windings are connected to E—Solenoid Plunger
solenoid switch terminal and directly to ground. They F—Main Contacts
provide additional low-speed torque to assist engine G—Field Windings
rotation and prevent overspeeding of motor. H—Commutator Brushes
I—Armature
J—Shunt Windings
From field windings, current flows through armature
windings (I) to ground, making contact through
commutator brushes (H).

Strong magnetic fields are set up by current flow through

field windings and armature windings. Windings are
arranged so that magnetic fields constantly repel each
other, rotating armature.

RG,RG34710,2336 –19–15MAR97–1/1

CTM77 (30OCT00) 70-05-1 Alternators and Starter Motors

103000
PN=509
 Starting Circuit Theory of Operation

Typical Starter Motor Operation

70
05
2

–UN–14NOV88
R25228
Typical Starter Motor Operation

1—Snap Ring 7—Field Connector 13—Field Windings 19—Brake Washer

2—Drive End Housing 8—End Frame Cover 14—Armature 20—Wear Pads
3—Shift Lever 9—Brush 15—Pole Shoe 21—Overrunning Clutch
4—Plunger 10—Bushing 16—Oil Seal 22—Pinion Stop
5—Shunt Field Terminal 11—Thrust Washer 17—Bushing 23—Bushing
6—Solenoid Assembly 12—Commutator 18—Felt

When solenoid (6) engages, it pulls shift lever (3). Shift The two windings cancel each other, and solenoid is
lever pushes overrunning clutch drive (21) to engage released.
pinion in starter gear on flywheel. As armature (14)
turns, it cranks engine. A spring pushes solenoid back to disengaged position.
This opens main contacts and shuts off current to field
When engine starts, overrunning clutch spins freely on windings and armature.
shaft. This prevents overspeeding of armature by
flywheel. Shift lever retracts overrunning clutch drive,
disengaging pinion from flywheel. Brake washer (19)
When key switch is released, current to solenoid slows armature to a stop.
hold-in winding is shut off. Current can feed through
both pull-in and hold-in windings from main contacts,
but direction of current is reversed in pull-in winding.

RG,RG34710,2337 –19–15MAR97–1/1

CTM77 (30OCT00) 70-05-2 Alternators and Starter Motors

103000
PN=510
 Group 10
Robert Bosch Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000BA3 –19–25SEP00–1/2

70
10
Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791 1

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
JT05791

OUO1004,0000BA3 –19–25SEP00–2/2

CTM77 (30OCT00) 70-10-1 Alternators and Starter Motors

103000
PN=511
 Robert Bosch Starter Motor Repair

Robert Bosch Starter Motor Repair

Specifications

Item Measurement Specification

Commutator (3.0 and 3.1 kW) Minimum OD 42.5 mm (1.67 in.)

Commutator (2.7 kW) Minimum OD 39.5 mm (1.555 in.)

Commutator Insulation Undercut after Turning 0.5—0.8 mm (0.02—0.03 in.)

Down

Commutator Maximum Out-of-Round 0.03 mm (0.0012 in.)

70
10
2 Armature Plate Stacks Maximum Out-of-Round 0.05 mm (0.002 in.)

Brushes Minimum Length 7.5 mm (0.30 in.)

Armature End Play 0.1—0.3 mm (0.004—0.012 in.)

Armature (2.7 kW) Braking Torque 0.45—0.75 N•m (4.0—6.6 lb-in.)

Overrunning Torque 0.40—0.55 N•m (3.5—4.8 lb-in.)

Armature (3.0 and 3.1 kW) Braking Torque 0.5—1.2 N•m (4.42—10.62 lb-in.)
Overrunning Torque 0.35—0.65 N•m (3.10—5.75 lb-in.)

OUO1004,0000BA6 –19–25SEP00–1/1

CTM77 (30OCT00) 70-10-2 Alternators and Starter Motors

103000
PN=512
 Robert Bosch Starter Motor Repair

Robert Bosch Starter Motor Test

Specifications
No Load Test
John Deere Bosch System Rating Motor Voltage Amps RPM
Part No. Model No. Voltage kW (Max.)
AL110503 0 001 367 078 12 3.0 11.5 130 7000
AL110504 0 001 369 022 12 3.1 11.5 170 8000
AL41247 0 001 362 312 12 2.7 11.5 125 7000
AL62690 0 001 362 316 12 2.7 11.5 125 7000
AL62772 0 001 369 005 12 3.1 11.5 170 8000
AL78760 0 001 367 075 12 3.0 11.5 130 7000
70
AL81154 0 001 367 077 12 3.0 11.5 130 7000
10
RE30493 0 001 362 324 12 2.7 11.5 125 7000 3
RE65169 0 001 369 021 12 3.1 11.5 170 8000

Item Specification
Minimum voltage of solenoid 8 volts
Testing armature for grounded circuit, voltage 40 volts AC
Testing field coils for grounded circuit, voltage 40 volts AC
Testing field coils for open windings, voltage 6—12 volts DC
Testing brush holder insulation for grounded circuit, voltage 40 volts AC

RG,RG34710,2339 –19–08SEP00–1/1

CTM77 (30OCT00) 70-10-3 Alternators and Starter Motors

103000
PN=513
 Robert Bosch Starter Motor Repair

Make No-Load Test

1. Make connections as shown, and use an ammeter (A)

capable of measuring several hundred amps.

2. Measure current draw in amps and compare with

–UN–28SEP00
specifications given earlier in this group.

3. If speed and current draw are slightly low, connect a

voltmeter between motor terminal and frame. Observe

RG11163
voltage during test. Voltage may be reduced because
of high current draw on battery.
Make Connections
70 4. If speed or current draw is significantly different than
10 A—Ammeter
4
specified, diagnose problem per chart which follows. B—Battery
C—Starter Frame
D—Tachometer
E—Battery Terminal
F—Switch
G—Field Coil Connector

RG,RG34710,2340 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-4 Alternators and Starter Motors

103000
PN=514
 Robert Bosch Starter Motor Repair

Diagnosing Starter Motor Malfunctions

Fails to Operate, No Current Draw Low Speed, High Current Draw

Open field circuit (all field windings) Excessive friction

Open armature windings Shorted armature

Defective brush contact with commutator Grounded armature or field windings

Open solenoid windings High Speed, High Current Draw

Defective solenoid contacts Shorted field windings

70
10
Fails to Operate, High Current Draw NOTE: This test will not detect individual 5
open-circuited field coils—the stator would
Grounded field windings or armature windings have a slow cranking speed but would pass
this test.
Seized bearings

Low Speed, Low Current Draw

High internal resistance

Defective brush contact with commutator

RG,RG34710,2341 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-5 Alternators and Starter Motors

103000
PN=515
 Robert Bosch Starter Motor Repair

Robert Bosch Starter Motor Cutaway View

70
10
6

–UN–06APR89
L107007
Robert Bosch Starter Motor

A—Solenoid Switch E—Commutator I—Overrunning Clutch K—Drive Hub

B—Commutator End Frame F—Field Winding (Roller-Type) L—Engaging Spring
C—Compression Spring G—Field Frame J—Pinion M—Engaging Lever
D—Carbon Brush H—Guide Ring

RG,RG34710,2342 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-6 Alternators and Starter Motors

103000
PN=516
 Robert Bosch Starter Motor Repair

Robert Bosch Starter Motor Exploded View

70
10
7

–UN–02FEB89
L117559
Starter Motor—Exploded View

1—Starter Motor Assembly 11—Pivot Screw 19—Center Bearing 28—Commutator End Frame
2—Hex Nut 12—Countersunk Screw (3 20—Bushing 29—Bushing
3—Stud Used) 21—Washer (2 Used) 30—Carbon Brushes (Kit)
4—Cap Screw 13—Drive End Frame 22—Hex Nut (2 Used) 31—Compression Spring (4
5—Solenoid Switch Assembly 23—Cylinder Head Screw (2 Used)
6—Securing Clip 14—Bushing Used) 32—Carbon Brush Plate
7—Cylinder Head Screw 15—Snap Ring 24—Cover Cap 33—Winding
8—Hex Nuts (4 Used) 16—Stop Ring 25—Rubber Ring 34—Armature
9—Hex Nut 17—Bushing 26—Fixing Washer 35—Stud (2 Used)
10—Engaging Lever 18—Drive with Pinion 27—Shims 36—Field Frame

RG,RG34710,2343 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-7 Alternators and Starter Motors

103000
PN=517
 Robert Bosch Starter Motor Repair

Disassembly

Unscrew cover cap (A) and remove fixing washer and

shims. Be careful with rubber ring.

Remove hex nuts (B).

–UN–17JUL89
A—Cover Cap
B—Hex Nuts (2 Used)

L107008
Unscrew Cover Cap and Remove Hex Nuts
70
10
8

RG,RG34710,2344 –19–15MAR97–1/1

Solenoid Switch—Removal

Disconnect wiring connection from solenoid switch.

Remove attaching screws (A) and pull out solenoid switch

with pinion head.

–UN–17JUL89
A—Screws (3 Used)

L107009
Remove Attaching Screws

RG,RG34710,2345 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-8 Alternators and Starter Motors

103000
PN=518
 Robert Bosch Starter Motor Repair

Carbon Brush Plate—Removal

Carefully remove commutator end frame as shown.

NOTE: When removing commutator end frame, the brush

compression springs may spring out of the brush

–UN–17JUL89
holders.

Pull carbon brushes out of carbon brush plate and remove

carbon brush plate from armature shaft.

L107010
Remove Commutator End Frame
70
10
9

RG,RG34710,2346 –19–15MAR97–1/1

Armature—Removal

Carefully pull armature with drive end frame assembly

from field frame (do not damage windings).

Remove engaging lever and armature jointly out of drive

–UN–17JUL89
end frame assembly.

L107011
Armature Removal

RG,RG34710,2347 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-9 Alternators and Starter Motors

103000
PN=519
 Robert Bosch Starter Motor Repair

Snap Ring—Removal

Drive back stop ring (A) and bend open snap ring (B).

Remove drive with pinion and center bearing from

armature shaft.

–UN–17JUL89
A—Stop Ring
B—Snap Ring

L107013
Snap Ring Removal
70
10
10

RG,RG34710,2348 –19–15MAR97–1/1

Cleaning Parts

Wash parts in solvent and dry with compressed air.

NOTE: Armature, windings and drive with pinion must not

be placed in cleaning fluid.

Inspect all parts for wear and mechanical damage.

RG,RG34710,2349 –19–15MAR97–1/1

Testing Armature for Grounds

Set ohmmeter to read on highest scale.

Place one test lead on the armature core or shaft. Place

other lead on commutator.
–UN–17JUL89

If the test meter indicator swings toward zero, the

armature is grounded. Replace armature.
L107014

Test Armature for Grounds

RG,RG34710,2350 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-10 Alternators and Starter Motors

103000
PN=520
 Robert Bosch Starter Motor Repair

Testing Armature for Short Circuit

Place armature in a growler and hold hacksaw blade

above each slot while slowly rotating the armature.

If coil is shorted, the blade will be attracted to and

repelled from the slot.

–UN–09JAN90
Short circuit most often occurs because of copper dust or
filings between two commutator segments. Clean
commutator segments to correct this short.

RG78074C1
70
10
Test Armature for Short Circuit 11

RG,RG34710,2351 –19–15MAR97–1/1

Testing Armature for Open Circuit

Set ohmmeter to read on lowest scale.

Place one test lead on commutator segment. Place other

test lead on an adjacent segment. Repeat this operation
for all segments by moving one lead at a time.

If the test meter indicator does not swing to zero and

remains stationary, the armature coil between these two
segments is open. Replace armature.

RG,RG34710,2352 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-11 Alternators and Starter Motors

103000
PN=521
 Robert Bosch Starter Motor Repair

Turning Commutator Down

Check commutator OD and compare to specifications.

After turning the commutator down, undercut its insulation

to specification with a commutator saw and then
finish-turn.

Specification

–UN–06APR89
Commutator (3.0 and 3.1 kW)—
Minimum OD................................................................. 42.5 mm (1.67 in.)
Commutator (2.7 kW)—Minimum
OD .............................................................................. 39.5 mm (1.555 in.)
Commutator—Insulation Undercut

L107016
70 after Turning Down ...................................... 0.5—0.8 mm (0.02—0.03 in.)
10
12 Turning Commutator Down
A—Solenoid Lug
B—Claw
C—Turn Down Only to Here

RG,RG34710,2353 –19–15MAR97–1/1

Testing Commutator for Out-of-Roundness

Check commutator out-of-round.

Specification
Commutator—Maximum
Out-of-Round ............................................................ 0.03 mm (0.0012 in.)

–UN–17JUL89
Armature Plate Stacks—
Maximum Out-of-Round ............................................. 0.05 mm (0.002 in.)

Check armature once again for grounds and short circuits.

L107017

Test Commutator for Out-of-Roundness

RG,RG34710,2354 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-12 Alternators and Starter Motors

103000
PN=522
 Robert Bosch Starter Motor Repair

Testing Field Winding for Grounded Circuit

Set ohmmeter to read on highest scale.

Place one test lead on a clean spot on field frame. Place

other lead on brush lead.

–UN–17JUL89
If the ohmmeter indicator swings toward zero, a grounded
circuit is indicated. Replace the field windings.

L107018
Test Field Winding for Grounded Circuits
70
10
13

RG,RG34710,2355 –19–15MAR97–1/1

Field Winding—Removal

Mark position of pole shoes and winding ends and

unscrew pole shoe screws (A).

A—Pole Shoe Screws

–UN–17JUL89
L107019
Unscrew Pole Shoe Screws

RG,RG34710,2356 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-13 Alternators and Starter Motors

103000
PN=523
 Robert Bosch Starter Motor Repair

Make Open Circuit Test for Field Windings

All four field windings are connected in parallel. Test each

winding for an open circuit.

Connect a test battery (B) to field terminal (C) and either

–UN–02FEB89
insulated brush lead (D), using a resistor (A) to limit
current draw.

Use a hacksaw blade (E) to test winding for magnetism. If

L113431
any winding is not magnetic, the winding is open circuited.
Repair or replace windings.
Make Open Circuit Test for Field Windings
70 NOTE: Because 1/4-ohm resistors capable of carrying
10 A—1/4-Ohm Resistor
14
several hundred watts are not widely available, a B—12-Volt Battery
suggested alternative is to connect four 1-ohm C—Field Terminal
resistors in parallel. Each resistor should be rated D—Insulated Brush Lead
for at least 150 watts. A carbon pile resistor can E—Hacksaw Blade
also be used. Limit current to 40—70 amps.

There is no suitable way to check field windings for short

circuits. Winding resistance is too low to permit detection
of a short circuit.

RG,RG34710,2357 –19–15MAR97–1/1

Lubrication of Starter Motor (Before and

During Assembly)
Lubrication Point Lubrication Instructions
Bushings Soak new bushings for at least 1/2 hour before installation.
Armature shaft Coat drive and commutator end journals of shaft, splines and bearing surfaces of
clutch drive with a light film of grease.
Shift Lever Lubricate bearing surfaces and pivot bolts liberally with grease.
Solenoid switch Coat inside of yoke and bolt threads with a light film of grease.

NOTE: Keep contacts free from grease.

RG,RG34710,2358 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-14 Alternators and Starter Motors

103000
PN=524
 Robert Bosch Starter Motor Repair

Field Winding—Installation

Slightly warm windings and insert together with pole

shoes into field frame. Insert pole shoe screws.

Press suitable mandrel (see illustration) between pole

–UN–09MAY89
shoes.

Firmly tighten pole shoe screws and press out mandrel.

L55571A
Check installed windings for shorted or open circuits.

a—85 mm (3.35 in.) Field Winding Installation

70
b—5° Chamfer
10
c—12—14 mm (0.47—0.55 in.)
15
d—75.80—75.85 mm (2.984—2.986 in.)
e—Wall Thickness 12—15 mm (0.47—0.59 in.)

RG,RG34710,2359 –19–15MAR97–1/1

Checking Carbon Brush Plate for Grounds

Set ohmmeter on its highest scale.

Place one test lead on commutator end frame. Place

other lead on brush holder.

–UN–17JUL89
If needle swings toward zero, the positive brush holder is
grounded and should be replaced.

L107020
Check Carbon Brush Plate for Grounds

RG,RG34710,2360 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-15 Alternators and Starter Motors

103000
PN=525
 Robert Bosch Starter Motor Repair

Testing Carbon Brushes

The carbon brushes must move freely in their guides.

Check brush length and compare to specifications.

–UN–17JUL89
Specification
Brushes—Minimum Length ............................................ 7.5 mm (0.30 in.)

a—Brush Length

L107021
Test Carbon Brushes
70
10
16

RG,RG34710,2361 –19–15MAR97–1/1

Replace Carbon Brushes

Cut off old brushes at end of brush strands.

Secure new brushes in bores (A).

–UN–17JUL89
Check for easy movement of carbon brushes in brush
holders.

NOTE: Screws and hex nuts are included in the repair kit.

L117234
A—Brush Bores
Secure Brushes in Bores

RG,RG34710,2362 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-16 Alternators and Starter Motors

103000
PN=526
 Robert Bosch Starter Motor Repair

Engaging Lever—Installation

Driving hub pins (B) of engaging lever (A) must engage in

guide (C) of drive pinion.

Screw in studs and slide field frame over armature.

–UN–17JUL89
A—Engaging Lever
B—Pins
C—Guide

L107023
Engaging Lever Installation
70
10
17

RG,RG34710,2363 –19–15MAR97–1/1

Checking Armature End Play and Torque

Check end play of armature using a dial indicator.

Specification
Armature—End Play ................................ 0.1—0.3 mm (0.004—0.012 in.)

–UN–17JUL89
Check armature torque.

Specification
Armature (2.7 kW)—Braking

L107024
Torque .................................................... 0.45—0.75 N•m (4.0—6.6 lb-in.)
Overrunning Torque ............................... 0.40—0.55 N•m (3.5—4.8 lb-in.)
Armature (3.0 and 3.1 kW)— Test Armature End Play
Braking Torque ..................................... 0.5—1.2 N•m (4.42—10.62 lb-in.)
Overrunning Torque ...................................... 0.35—0.65 N•m (3.10—5.75
lb-in.)

RG,RG34710,2364 –19–25SEP00–1/1

Installing Starter Motor

Refer to machine technical manual for installing starter

motor and adjusting belt tension.
RG,RG34710,2365 –19–15MAR97–1/1

CTM77 (30OCT00) 70-10-17 Alternators and Starter Motors

103000
PN=527
 Robert Bosch Starter Motor Repair

70
10
18

CTM77 (30OCT00) 70-10-18 Alternators and Starter Motors

103000
PN=528
 Section 75
Iskra Starter Motors
Contents

Page

Group 05—Starting Circuit Theory of Operation

General Information. . . . . . . . . . . . . . . . . . . . . .75-05-1
Typical Starting Circuit Operation . . . . . . . . . . .75-05-1
Typical Starter Motor Operation. . . . . . . . . . . . .75-05-2

Group 10—Iskra Starter Motor Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .75-10-1
Dealer Fabricated Tools . . . . . . . . . . . . . . . . . .75-10-1
Iskra AZJ-Series Starter Motor Repair
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .75-10-3 75
Iskra AZJ-Series Starter Motor Test
Specifications. . . . . . . . . . . . . . . . . . . . . . . . .75-10-4
Exploded View of Iskra Starter Motor
(AZJ-Series) . . . . . . . . . . . . . . . . . . . . . . . . .75-10-5
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .75-10-6
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .75-10-7
Disassembly of Starter Motor . . . . . . . . . . . . . .75-10-7
Testing Solenoid Switch . . . . . . . . . . . . . . . . .75-10-11
Testing Brushes . . . . . . . . . . . . . . . . . . . . . . .75-10-11
Brush Replacement. . . . . . . . . . . . . . . . . . . . .75-10-12
Testing Armature. . . . . . . . . . . . . . . . . . . . . . .75-10-12
Testing Field Windings . . . . . . . . . . . . . . . . . .75-10-13
Checking Engaging Lever . . . . . . . . . . . . . . . .75-10-13
Checking Overrunning Clutch Pinion . . . . . . . .75-10-14
Reassembly of Starter Motor. . . . . . . . . . . . . .75-10-14

CTM77 (30OCT00) 75-1 Alternators and Starter Motors

103000
PN=1
 Contents

75

CTM77 (30OCT00) 75-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Starting Circuit Theory of Operation
General Information

IMPORTANT: Never operate starter motor longer than

30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating caused by
excessive operation will seriously
damage starter motor.

RG,RG34710,2366 –19–15MAR97–1/1

Typical Starting Circuit Operation

When wire from relay (A) is energized, current flows

through both pull-in winding (C) and hold-in winding (D) to
ground. 75
05
1
Current through windings engages solenoid plunger (E),
which closes main contacts (F). When main contacts

–UN–20APR89
close, current through pull-in windings stops. Current
continues through hold-in winding, keeping solenoid
engaged and main contacts closed.

RG1313
With main contacts closed, current flows from battery
cable (B) to starter motor at a very high rate. Four heavy Typical Starting Circuit Operation
field windings (G) carry current to commutator brushes
(H). A—Wire from Relay
B—Cable from Battery
C—Pull-In Winding
Light shunt windings (J) are wrapped together with two of D—Hold-Iin Winding
the heavy field windings. Shunt windings are connected to E—Solenoid Plunger
solenoid switch terminal and directly to ground. They F—Main Contacts
provide additional low speed torque to assist engine G—Field Windings
rotation and prevent overheating of motor. H—Commutator Brushes
I—Armature
J—Shunt Windings
From field windings, current flows through armature
windings (I) to ground, making contact through
commutator brushes (H).

Strong magnetic fields are set up by current flow through

field windings and armature windings. Windings are
arranged so that magnetic fields constantly repel each
other, rotating armature.

RG,RG34710,2367 –19–15MAR97–1/1

CTM77 (30OCT00) 75-05-1 Alternators and Starter Motors

103000
PN=531
 Starting Circuit Theory of Operation

Typical Starter Motor Operation

–UN–14NOV88
75
05
2

R25228
Typical Starter Motor Operation

1—Snap Ring 7—Field Connector 13—Field Windings 19—Brake Washer

2—Drive End Housing 8—End Frame Cover 14—Armature 20—Wear Pads
3—Shift Lever 9—Brush 15—Pole SHoe 21—Overrunning Clutch
4—Plunger 10—Bushing 16—Oil Seal 22—Pinion Stop
5—Shunt Field Terminal 11—Thrust Washers 17—Bushing 23—Bushing
6—Solenoid Assembly 12—Commutator 18—Felt

When solenoid (6) engages, it pulls shift lever (3). Shift but direction of current is reversed in pull-in winding.
lever pushes overrunning clutch drive (21) to engage The two windings cancel each other, and solenoid is
pinion in starter gear on flywheel. As armature (14) released.
turns, it cranks engine.
A spring pushes solenoid back to disengaged position.
When engine starts, overrunning clutch spins freely on This opens main contacts and shuts off current to field
shaft. This prevents overspeeding of armature by windings and armature.
flywheel.
Shift lever retracts overrunning clutch drive,
When key switch is released, current to solenoid disengaging pinion from flywheel. Brake washer (19)
hold-in winding is shut off. Current can feed through slows armature to a stop.
both pull-in and hold-in windings from main contacts,

RG,RG34710,2368 –19–15MAR97–1/1

CTM77 (30OCT00) 75-05-2 Alternators and Starter Motors

103000
PN=532
 Group 10
Iskra Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000BA7 –19–25SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits. 75
10

–UN–12DEC88
1

RW11274
JT05791

OUO1004,0000BA7 –19–25SEP00–2/2

Dealer Fabricated Tools

Pilot for Retaining Ring Installation

a—Dia. 15.4—15.5 mm (0.606—0.610 in.)

b—Dia. 14.4—14.5 mm (0.567—0.571 in.)
–UN–31JAN97

c—50 mm (1.97 in.)

d—25 mm (0.98 in.)
e—5 mm (0.20 in.)
f—30°
g—R10 mm (0.39 in.)
CD30492

Pilot for Retaining Ring

Continued on next page RG,RG34710,2370 –19–15MAR97–1/3

CTM77 (30OCT00) 75-10-1 Alternators and Starter Motors

103000
PN=533
 Iskra Starter Motor Repair

Driver for Retaining Ring Installation and for Pinion

Stop Removal

a—Dia. 25 mm (0.98 in.)

b—Dia. 15.5—15.6 mm (0.610—0.614 in.)
c—75 mm (2.95 in.)

–UN–03FEB97
d—60 mm (2.36 in.)
e—Chamfer 45° x 2 mm (0.08 in.)
f—Chamfer 45° x 0.5 mm (0.02 in.)

CD30493
Driver for Retaining Ring and Pinion Stop

75
10 RG,RG34710,2370 –19–15MAR97–2/3
2

Dummy Commutator for Brush Holder Removal and

Installation

Material: Plastic

a—Dia. 44.9—45.1 mm (1.768—1.775 in.)

–UN–31JAN97
b—Dia. 20 mm (0.79 in.)
c—Dia. 50 mm (1.97 in.)
d—35 mm (1.38 in.)
e—2.5 mm (0.10 in.)

CD30494
f—Chamfer 15°
g—2.5 mm (0.10 in.)

Dummy Commutator for Brush Holder

RG,RG34710,2370 –19–15MAR97–3/3

CTM77 (30OCT00) 75-10-2 Alternators and Starter Motors

103000
PN=534
 Iskra Starter Motor Repair

Iskra AZJ-Series Starter Motor Repair

Specifications

Item Measurement Specification

New Brush Length 23 mm (0.91 in.)

Used Brush Minimum Length 13 mm (0.51 in.)

Engaging Lever Pivot Pin Torque 12 N•m (106 lb-in.)

Commutator End Frame Nuts Torque 6 N•m (53 lb-in.)

Field Winding Terminal Nut Torque 13 N•m (115 lb-in.)

75
OUO1004,0000BAA –19–25SEP00–1/1 10
3

CTM77 (30OCT00) 75-10-3 Alternators and Starter Motors

103000
PN=535
 Iskra Starter Motor Repair

Iskra AZJ-Series Starter Motor Test

Specifications
Solenoid Current Pinion
Pull-In Hold-In
John Deere Iskra Motor System Rating Winding Winding No. of
Part Number Part Number Model Voltage (kW) (Amps) (Amps) Teeth Model
RE500733 11.130.819 AZJ3283 12 3.1 62 14 10 2.54
RE501002a 11.130.762 AZJ3274 12 3.1 62 14 10 2.54
a
RE501766 11.130.679 AZJ3326 12 3.1 62 14 10 3.175
RE501769a 11.130.745 AZJ3265 24 4.0 30 6 10 3.175
RE503093 11.130.796 AZJ3325 12 3.0 62 12 10 3.175
RE503118 11.130.797 AZJ3326 24 4.0 30 6 10 2.54
RE503119 11.130.798 AZJ3327 24 4.0 30 6 10 3.175
RE503120 11.130.799 AZJ3328 12 3.1 62 14 10 3.175
RE503632 11.130.936 AZJ3338 24 4.0 30 6 10 3.175
RE504009 11.130.940 AZJ3342 12 3.0 62 12 10 3.175
75
RE504915 11.130.977 AZJ3350 24 4.0 30 6 10 3.175
10
4 RE505744 11.130.794 AZJ4522 12 4.2 62 14 10 3.175
RE505745 11.130.793 AZF4521 12 4.2 62 14 10 2.54
RE59010 11.130.605 AZJ3190 12 3.0 62 14 10 3.17
RE60239a 11.130.679 AZJ3226 12 3.1 62 14 10 3.175
RE60384 11.130.569 AZJ3181 12 3.1 62 14 10 2.54
RE67086 11.130.662 AZJ3214 24 4.0 30 6 10 2.54
RE67087 11.130.678 AZJ3225 24 4.0 30 6 10 3.175
RE68783 11.130.703 AZJ3241 12 3.1 62 14 10 3.175
a
RE71007 111.307.45 AZJ3265 24 4.0 30 6 10 3.175
a
Not a service part. For service, consult parts catalog.

RG,RG34710,2371 –19–08SEP00–1/1

CTM77 (30OCT00) 75-10-4 Alternators and Starter Motors

103000
PN=536
 Iskra Starter Motor Repair

Exploded View of Iskra Starter Motor (AZJ-Series)

75
10
5

–UN–03FEB97
CD30491

Iskra Starter Motor (AZJ-Series)

A—Drive End Housing D—Bushing H—Commutator End Frame L—Overrunning Clutch Pinion1
B—Solenoid1 E—Field Winding J—Bushing M—Center Bearing
C—Engaging Lever1 F—Brush Holder K—Armature N—Service Parts Kit1
G—Brushes1 (4 Used)

1
Available as service parts.
RG,RG34710,2372 –19–15MAR97–1/1

CTM77 (30OCT00) 75-10-5 Alternators and Starter Motors

103000
PN=537
 Iskra Starter Motor Repair

Troubleshooting

Symptom Problem Solution

Fails to operate, no current draw Open field circuit Replace starter motor

Open armature windings Replace starter motor

Defective brush contact with Clean brush holder or replace

commutator brushes

Open solenoid windings Replace solenoid

Defective solenoid contact Replace solenoid

Fails to operate, high current Grounded field windings or armature Replace starter motor
draw windings

75 Seized bearings Replace starter motor

10
6 Low speed, low current draw High internal resistance Replace starter motor

Defective brush contact with Clean brush holder or replace

commutator brushes

Low speed, high current draw Shorted armature Replace starter motor

Grounded armature or field windings Replace starter motor

High speed, high current draw Shorted field windings Replace starter motor

Solenoid switch operates but Worn or broken brushes Clean brush holder and commutator
armature does not rotate and replace brushes

Shorted field windings Replace starter motor

Solenoid quickly engages and Shorted hold-in windings Replace solenoid

disengages

Starter motor spins, but does not Overrunning clutch slipping Replace overrunning clutch
crank the engine

Pinion does not move into mesh with Replace engaging lever or clutch
the gear ring

RG,RG34710,2373 –19–15MAR97–1/1

CTM77 (30OCT00) 75-10-6 Alternators and Starter Motors

103000
PN=538
 Iskra Starter Motor Repair

Identification

The information for parts identification is stamped on the

body of the starter motor as shown.

–UN–03FEB97
CD30490
Parts Identification

75
RG,RG34710,2374 –19–15MAR97–1/1 10
7

Disassembly of Starter Motor

NOTE: Before separating, mark parts so that they can be

reinstalled in their original positions.

1. Disconnect field winding cable (A).

–UN–03FEB97
2. Remove the three screws holding the solenoid switch
(B).

CD30495
A—Field Winding Cable
B—Solenoid switch
Field Winding Cable and Solenoid Switch

Continued on next page RG,RG34710,2375 –19–15MAR97–1/7

CTM77 (30OCT00) 75-10-7 Alternators and Starter Motors

103000
PN=539
 Iskra Starter Motor Repair

3. Remove solenoid switch.

4. Extract spring (C) and plunger (D).

C—Spring
D—Plunger

–UN–03FEB97
CD30496
Remove Solenoid Switch

75
10 RG,RG34710,2375 –19–15MAR97–2/7
8

5. Remove cover (E).

6. Remove clip and washers (F).

7. Remove screws (G) fixing the brush holder.

–UN–03FEB97
8. Unscrew nuts (H) and remove commutator end frame
(J).

CD30497
E—Cover
F—Clip and Washer
G—Brush Holder Fixing Screws
H—Nuts Remove Components
J—Commutator End Frame

Continued on next page RG,RG34710,2375 –19–15MAR97–3/7

CTM77 (30OCT00) 75-10-8 Alternators and Starter Motors

103000
PN=540
 Iskra Starter Motor Repair

9. Remove insulation washer (K).

10. Extract positive brushes (L).

11. Install a dummy commutator as shown in Dealer

Fabricated Tools earlier in this group, then remove

–UN–03FEB97
the brush holder.

K—Insulation Washer
L—Brushes

CD30498
Remove Brush Holder

75
RG,RG34710,2375 –19–15MAR97–4/7 10
9

12. Remove pivot pin (M) from engaging lever.

13. Separate field winding frame (N) from armature/drive

end housing assembly (P).

M—Pivot Pin

–UN–03FEB97
N—Field Winding Frame
P—Armature/Drive End Housing Assembly

CD30499
Separate Field Winding Frame

Continued on next page RG,RG34710,2375 –19–15MAR97–5/7

CTM77 (30OCT00) 75-10-9 Alternators and Starter Motors

103000
PN=541
 Iskra Starter Motor Repair

14. Remove studs.

15. Extract armature with clutch and engaging lever from

drive end housing (Q).

Q—Drive End Housing

–UN–03FEB97
CD30500
Drive End Housing

75
10 RG,RG34710,2375 –19–15MAR97–6/7
10

16. Using appropriate tool or self-made driver, as shown

in Dealer Fabricated Tools earlier in this group, push
in pinion stop (R) to have access to retaining ring (S).

17. Remove retaining ring and slide out of armature shaft

the overrunning clutch (T), the center bearing (U) and,

–UN–03FEB97
if equipped, the armature brake component.

R—Pinion Stop
S—Retaining Ring

CD30501
T—Overrunning Clutch
U—Center Bearing
Remove Components

RG,RG34710,2375 –19–15MAR97–7/7

CTM77 (30OCT00) 75-10-10 Alternators and Starter Motors

103000
PN=542
 Iskra Starter Motor Repair

Testing Solenoid Switch

1. Check for continuity between terminals (A) and (B). If

there is no continuity, replace the solenoid switch.

2. Check for continuity between terminals (A) and (C). If

–UN–03FEB97
there is continuity, replace the solenoid switch.

3. Perform this test with the plunger removed from the

solenoid body: Apply appropriate voltage (12 volts or

CD30502
24 volts) between terminal (A) and ground. Connect
the ohmmeter between terminals (B) and (C). Replace
the solenoid switch if the resistance is not infinity. Check for Continuity

A—Terminal
B—Terminal
C—Terminal

75
RG,RG34710,2376 –19–15MAR97–1/1 10
11

Testing Brushes

1. Check positive brush holder (A) by connecting an

ohmmeter between brushes and plate. If the resistance
is not infinity, replace starter motor.

–UN–03FEB97
2. Inspect brushes. Brushes must move freely in their
guides. Check brush overall length. Replace brushes if
frozen or too worn.

CD30503
Specification
New Brush—Length ........................................................ 23 mm (0.91 in.)
Used Brush—Minimum Length ....................................... 13 mm (0.51 in.) Test Brushes

A—Brush Holder

RG,RG34710,2377 –19–15MAR97–1/1

CTM77 (30OCT00) 75-10-11 Alternators and Starter Motors

103000
PN=543
 Iskra Starter Motor Repair

Brush Replacement

1. Cut off old brush at end of brush strand (A).

2. Solder new brush using a 40—60% tin-lead mix. Heat

to 230°C (446°F).

–UN–03FEB97
NOTE: This operation needs a specialized tooling.
Eventually, have the brushes replaced by a local
electrical repair station.

CD30504
A—Brush Strand Cut off Brush at End of Strand

75
10 DPSG,OUOE003,30 –19–18DEC98–1/1
12

Testing Armature

1. Check the armature insulation by connecting an

ohmmeter between the commutator (A) and the shaft
(B). If test shows continuity (needle movement), the
armature is grounded.

–UN–03FEB97
2. Check for armature condition. Space between bars
must be clean and regular. Small defects can be
eliminated using sandpaper and lathe.

CD30505
3. If insulation is defective or armature is quite worn,
replace the complete starter motor. Test Armature

A—Commutator
B—Shaft

RG,RG34710,2378 –19–15MAR97–1/1

CTM77 (30OCT00) 75-10-12 Alternators and Starter Motors

103000
PN=544
 Iskra Starter Motor Repair

Testing Field Windings

Check insulation by connecting an ohmmeter between

brush (A) and field frame (B). If ohmmeter swings toward
zero, a grounded circuit is indicated. If defective, replace
the complete starter motor.

–UN–03FEB97
A—Brush
B—Field Frame

CD30506
Test Field Windings

75
RG,RG34710,2379 –19–15MAR97–1/1 10
13

Checking Engaging Lever

Inspect wear pads (A) for excessive wear or damage.

Replace engaging lever if necessary.

A—Wear Pads

–UN–03FEB97
CD30507
Inspect Wear Pads

RG,RG34710,2380 –19–15MAR97–1/1

CTM77 (30OCT00) 75-10-13 Alternators and Starter Motors

103000
PN=545
 Iskra Starter Motor Repair

Checking Overrunning Clutch Pinion

1. Check for pinion tooth condition. Slight damage to

teeth can be eliminated by grinding.

NOTE: Damage to teeth can be caused by a malfunction

–UN–03FEB97
of electrical system. Also check electrical circuit
for proper operation (switch, relay etc.).

2. Turn overrunning clutch pinion by hand. Clutch pinion

CD30508
should turn freely on shaft in overrunning direction
only.
Check Overrunning Clutch Pinion
3. If defective, replace overrunning clutch pinion.

75
10 RG,RG34710,2381 –19–15MAR97–1/1
14

Reassembly of Starter Motor

NOTE: Use petrolatum-base grease to lubricate

mechanical parts such as shaft in nose bushing,
overrunning clutch pinion on shaft, and shaft in
rear bearing.

–UN–03FEB97
Use service parts kit when reassembling the
starter motor. (See (N) in exploded view earlier in
this group.)

CD30509
1. Install pinion stop (A) with cupped side toward shaft
end. Reassemble Starter Motor

A—Pinion Stop
2. Install retaining ring (B) using suitable tools or B—Retaining Ring
self-made tools as shown in Dealer Fabricated Tools
earlier in this group.

3. Force pinion stop over retaining ring.

Continued on next page RG,RG34710,2382 –19–15MAR97–1/8

CTM77 (30OCT00) 75-10-14 Alternators and Starter Motors

103000
PN=546
 Iskra Starter Motor Repair

4. Install armature and engaging lever into drive end

housing. Engaging lever pads (C) must engage in
groove (D) of drive pinion.

C—Engaging Lever Pads

D—Drive Pinion Groove

–UN–03FEB97
CD30510
Armature and Engaging Lever

75
RG,RG34710,2382 –19–15MAR97–2/8 10
15

5. Install pivot pin (E). Tighten to specifications.

Specification
Engaging Lever Pivot Pin—
Torque .......................................................................... 12 N•m (106 lb-in.)

–UN–03FEB97
6. Screw in studs (F) with insulation sleeve.

7. Slide field winding frame (G) over armature.

CD30511
E—Pivot Pin
F—Studs
G—Field Winding Frame Field Winding Frame

Continued on next page RG,RG34710,2382 –19–15MAR97–3/8

CTM77 (30OCT00) 75-10-15 Alternators and Starter Motors

103000
PN=547
 Iskra Starter Motor Repair

8. Slide brush holder (H) onto commutator. Remove the

dummy commutator.

9. Install positive brushes (J).

10. Install insulation washer (K).

–UN–03FEB97
H—Brush Holder
J—Brushes
K—Insulation Washer

CD30512
Install Parts

75
10 RG,RG34710,2382 –19–15MAR97–4/8
16

11. Install commutator end frame.

12. Screw in screws (L) for the brush holder and secure.

13. Install washers and nuts (M). Tighten to

specifications.

–UN–03FEB97
Specification
Commutator End Frame Nuts—
Torque .............................................................................. 6 N•m (53 lb-in.)

CD30513
14. Install thrust washers and clip (N).
Install Commutator End Frame
L—Screws
M—Washers and Nuts
N—Thrust Washers and Clip

Continued on next page RG,RG34710,2382 –19–15MAR97–5/8

CTM77 (30OCT00) 75-10-16 Alternators and Starter Motors

103000
PN=548
 Iskra Starter Motor Repair

15. Install O-ring into groove (P).

16. Put grease into cover (Q) and install cover. Tighten
screws (R).

–UN–03FEB97
P—Groove
Q—Cover
R—Screws (2 Used)

CD30514
Install Cover

75
RG,RG34710,2382 –19–15MAR97–6/8 10
17

17. Install plunger end (S) onto engaging lever.

18. Slide spring (T) into solenoid body.

19. Install O-ring (U) into groove of body pilot (V).

–UN–03FEB97
S—Plunger
T—Spring
U—O-Ring
V—Solenoid Body Pilot Groove

CD30515
Assemble Parts

Continued on next page RG,RG34710,2382 –19–15MAR97–7/8

CTM77 (30OCT00) 75-10-17 Alternators and Starter Motors

103000
PN=549
 Iskra Starter Motor Repair

20. Install solenoid body onto starter motor. Tighten

screws (W).

21. Connect field winding cable. Tighten nut (X) to

specifications.

–UN–03FEB97
Specification
Field Winding Terminal Nut—
Torque .......................................................................... 13 N•m (115 lb-in.)

CD30516
W—Solenoid Body Screws
X—Field Winding Cable Nut
Tighten Screw and Nut

75
10 RG,RG34710,2382 –19–15MAR97–8/8
18

CTM77 (30OCT00) 75-10-18 Alternators and Starter Motors

103000
PN=550
 Section 80
Valeo Starter Motors
Contents

Page

Group 05—Starting Circuit Theory of Operation

General Information. . . . . . . . . . . . . . . . . . . . . .80-05-1
Typical Starting Circuit Operation . . . . . . . . . . .80-05-1
Typical Starter Motor Operation. . . . . . . . . . . . .80-05-2

Group 10—Valeo Starter Motor Repair

Essential Tools . . . . . . . . . . . . . . . . . . . . . . . . .80-10-1
Valeo Starter Motor Repair Specifications . . . . .80-10-1
Valeo Starter Motor Test Specifications. . . . . . .80-10-2
Exploded View of Starter Motor. . . . . . . . . . . . .80-10-3
Disassembly of Starter Motor . . . . . . . . . . . . . .80-10-4
Testing Solenoid Switch . . . . . . . . . . . . . . . . . .80-10-9
Testing Brushes . . . . . . . . . . . . . . . . . . . . . . .80-10-10
Positive Brush Replacement . . . . . . . . . . . . . .80-10-10
Testing Armature. . . . . . . . . . . . . . . . . . . . . . .80-10-11
Testing Field Winding . . . . . . . . . . . . . . . . . . .80-10-11 80
Checking Overrunning Clutch Pinion . . . . . . . .80-10-12
Reassembly of Starter Motor. . . . . . . . . . . . . .80-10-13

CTM77 (30OCT00) 80-1 Alternators and Starter Motors

103000
PN=1
 Contents

80

CTM77 (30OCT00) 80-2 Alternators and Starter Motors

103000
PN=2
 Group 05
Starting Circuit Theory of Operation
General Information

IMPORTANT: Never operate starter motor longer than

30 seconds. Allow at least 2 minutes for
cooling and battery recovery before
operating again. Overheating caused by
excessive operation will seriously
damage starter motor.

RG,RG34710,2383 –19–15MAR97–1/1

Typical Starting Circuit Operation

When wire from relay (A) is energized, current flows

through both pull-in winding (C) and hold-in winding (D) to
ground.

Current through windings engages solenoid plunger (E),

which closes main contacts (F). When main contacts

–UN–20APR89
close, current through pull-in windings stops. Current
continues through hold-in winding, keeping solenoid 80
engaged and main contacts closed. 05

RG1313
1
With main contacts closed, current flows from battery
cable (B) to starter motor at a very high rate. Four heavy Typical Starting Circuit Operation
field windings (G) carry current to commutator brushes
(H). A—Wire From Relay
B—Cable from Battery
C—Pull-In Winding
Light shunt windings (J) are wrapped together with two of D—Hold-In Winding
the heavy field windings. Shunt windings are connected to E—Solenoid Plunger
solenoid switch terminal and directly to ground. They F—Main Contacts
provide additional low speed torque to assist engine G—Field Windings
rotation and prevent overspeeding of motor. H—Commutator Brushes
I—Armature
J—Shunt Windings
From field windings, current flows through armature
windings (I) to ground, making contact through
commutator brushes (H).

Strong magnetic fields are set up by current flow through

field windings and armature windings. Windings are
arranged so that magnetic fields constantly repel each
other, rotating armature.

RG,RG34710,2384 –19–15MAR97–1/1

CTM77 (30OCT00) 80-05-1 Alternators and Starter Motors

103000
PN=553
 Starting Circuit Theory of Operation

Typical Starter Motor Operation

80

–UN–17JUL96
05
2

CD30450
Typical Starter Motor Operation

A—Solenoid Switch D—Brush F—Gear Reduction Assembly H—Pinion

B—Field Winding E—Commutator G—Overrunning Clutch J—Engaging Lever
C—Rear Bearing

When solenoid (A) engages, it pulls engaging lever (J). The two windings cancel each other, and solenoid is
Lever pushes overrunning clutch drive (G) to engage released.
pinion in starter gear on flywheel. As armature turns, it
cranks engine. A spring pushes solenoid back to disengaged position.
This opens main contacts and shuts off current to field
When engine starts, overrunning clutch spins freely on windings and armature.
shaft. This prevents overspeeding of armature by
flywheel. Shift lever retracts overrunning clutch drive,
disengaging pinion from flywheel.
When key switch is released, current to solenoid
hold-in winding is shut off. Current can feed through In this reduction-type starter, the speed of armature
both pull-in and hold-in windings from main contacts, rotation is reduced by the gear reduction assembly (F).
but direction of current is reversed in pull-in winding.

RG,RG34710,2385 –19–15MAR97–1/1

CTM77 (30OCT00) 80-05-2 Alternators and Starter Motors

103000
PN=554
 Group 10
Valeo Starter Motor Repair
Essential Tools

NOTE: Order tools according to information given in the

U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).

SERVICEGARD is a trademark of Deere & Company OUO1004,0000BAB –19–25SEP00–1/2

Digital Multimeter . . . . . . . . . . . . . . . . . . . . . JT05791

Test electrical components for voltage, resistance, or

current flow. It is especially good for measuring low
voltage or high resistance circuits.

–UN–12DEC88
RW11274
80
10
1
JT05791

OUO1004,0000BAB –19–25SEP00–2/2

Valeo Starter Motor Repair Specifications

Item Measurement Specification

New Brush Length 14 mm (0.55 in.)

Used Brush Minimum Length 8.5 mm (0.22 in.)

Starter Solenoid Mounting Cap Torque 3 N•m (27 lb-in.)

Screws

Housing Through Bolts Torque 7 N•m (62 lb-in.)

Field Winding Terminal Screw Torque 10 N•m (88 lb-in.)

OUO1004,0000BAE –19–25SEP00–1/1

CTM77 (30OCT00) 80-10-1 Alternators and Starter Motors

103000
PN=555
 Valeo Starter Motor Repair

Valeo Starter Motor Test Specifications

John Deere Valeo Valeo Model System Rating Solenoid Current

Part No. Part No. Voltage (kW) Hold-In Windings
(Amps)
RE60641a 187031 D7R14 12 2.5 32
RE501680 187031 D7R14 12 2.5 32
RE502156 187031 D7R14 12 2.5 32
a
Not a service part. For service, consult parts catalog.

RG,RG34710,2387 –19–08SEP00–1/1

80
10
2

CTM77 (30OCT00) 80-10-2 Alternators and Starter Motors

103000
PN=556
 Valeo Starter Motor Repair

Exploded View of Starter Motor

80
10
3

–UN–17JUL96
CD30451
Starter Motor

1—Pivot Pin1 7—Overrunning Clutch Pinion1 14—Shim1 21—Clip1

2—Engaging Lever/Plunger 8—Pinion Stop1 15—Rear Bearing 22—Field Winding
Assembly 9—Retaining Ring1 16—Clip1 23—Pole Shoe Screw
3—Solenoid Spring 10—Bushing1 17—Plastic Cap1 24—Field Winding Terminal
4—Gear Reduction Assembly 11—Armature 18—Through Bolt1 (2 used) Nut
5—Solenoid Body1 12—Field Frame 19—Brush1 (4 used) 25—Solenoid Attaching Screw
6—Cover 13—Brush Plate1 20—Brush Spring1 (3 Used)

1
Available as service parts.
RG,RG34710,2395 –19–15MAR97–1/1

CTM77 (30OCT00) 80-10-3 Alternators and Starter Motors

103000
PN=557
 Valeo Starter Motor Repair

Disassembly of Starter Motor

1. Disconnect field winding cable (A).

2. Unscrew the two through bolts (B).

–UN–22JUL96
A—Field Winding Cable
B—Through Bolts (2 Used)

CD30452
Starter Motor Disassembly

RG,RG34710,2388 –19–15MAR97–1/11

3. Separate electric motor (A) from complete front

assembly (B).
80
10 4. Unscrew the screw (C) holding the contactor using a
4 TORX screwdriver.

–UN–22JUL96
NOTE: Do not unscrew the pole shoe screws (D) as it is
difficult to perform the tighening procedure.

CD30453
A—Electric Motor
B—Front Assembly
C—Contactor Screw
D—Pole Shoe Screws Separate Electric Motor

TORX is a registered trademark of Camcar/Textron. Continued on next page RG,RG34710,2388 –19–15MAR97–2/11

CTM77 (30OCT00) 80-10-4 Alternators and Starter Motors

103000
PN=558
 Valeo Starter Motor Repair

5. Separate gear reduction/solenoid/overrunning clutch

assembly (A) from drive end housing (B).

6. Push pinion stop (C) toward pinion to have access to

the retaining ring (D).

–UN–22JUL96
7. Remove retaining ring and slide pinion stop off shaft.

A—Gear Reduction/Solenoid/Overrunning Clutch

Assembly

CD30454
B—Drive End Housing
C—Pinion Stop
D—Retaining Ring Slide Pinion Stop Off Shaft

RG,RG34710,2388 –19–15MAR97–3/11

8. Remove pivot pin (A).

A—Pivot Pin 80
10
5

–UN–22JUL96
CD30455
Remove Pivot Pin

Continued on next page RG,RG34710,2388 –19–15MAR97–4/11

CTM77 (30OCT00) 80-10-5 Alternators and Starter Motors

103000
PN=559
 Valeo Starter Motor Repair

9. Separate overruning clutch/engaging lever/mobile core

assembly (A) from gear reduction/solenoid body
assembly (B).

A—Overruning Clutch/Engaging Lever/Mobile Core

Assembly

–UN–22JUL96
B—Gear Reduction/Solenoid Body Assembly

CD30456
Separate Assemblies

RG,RG34710,2388 –19–15MAR97–5/11

10. Unscrew the two screws holding the contactor (A)

using TORX screwdriver.
80
10 A—Screws (2 used)
6

–UN–22JUL96
CD30457
Contactor

TORX is a registered trademark of Camcar/Textron. Continued on next page RG,RG34710,2388 –19–15MAR97–6/11

CTM77 (30OCT00) 80-10-6 Alternators and Starter Motors

103000
PN=560
 Valeo Starter Motor Repair

11. Before disassembly, mark both the rear bearing (A)

and the field frame (B).

12. Remove rear plastic cap (C) and clip (D).

–UN–22JUL96
A—Rear Bearing
B—Field Frame
C—Rear Plastic Cap
D—Clip

CD30458
Cap and Clip

RG,RG34710,2388 –19–15MAR97–7/11

13. Remove the rear bearing (A).

NOTE: Two shims (B) are located on each side of rear 80

bearing. 10
7

–UN–22JUL96
A—Rear Bearing
B—Shims (4 Used)

CD30459
Remove Rear Bearing

Continued on next page RG,RG34710,2388 –19–15MAR97–8/11

CTM77 (30OCT00) 80-10-7 Alternators and Starter Motors

103000
PN=561
 Valeo Starter Motor Repair

14. Position and push the disassembly sleeve (A) on the

shaft to hold brushes in their housing and remove the
armature.

NOTE: The disassembly sleeve (A) is provided with the

brush repair kit available through John Deere.

–UN–22JUL96
A—Disassenbly Sleeve

CD30460
Disassembly Sleeve

RG,RG34710,2388 –19–15MAR97–9/11

15. Slide carbon brush plate away from the field frame.

80 16. Loosen and remove the four brush clips from the
10 plate. Take care to avoid losing the four springs.
8
17. Remove the disassembly sleeve.

–UN–22JUL96
CD30461
Remove the Disassembly Sleeve

Continued on next page RG,RG34710,2388 –19–15MAR97–10/11

CTM77 (30OCT00) 80-10-8 Alternators and Starter Motors

103000
PN=562
 Valeo Starter Motor Repair

18. Push the two positive brushes inwards and remove

the brush plate from the field frame.

–UN–22JUL96
CD30462
Remove Brush Plate

RG,RG34710,2388 –19–15MAR97–11/11

Testing Solenoid Switch

1. Check for continuity between terminals (A) and (B). If 80

there is no continuity, replace the solenoid switch. 10
9
2. Check for continuity between terminals (A) and (C). If

–UN–22JUL96
there is continuity, replace the solenoid switch.

3. Apply appropriate voltage (12 volts or 24 volts)

between terminal (A) and ground. Connect the

CD30463
ohmmeter between terminals (B) and (C). Replace the
solenoid switch if the resistance is not infinity.
Test Solenoid Switch

NOTE: Solenoid switch is available as a John Deere A—Terminal

service part. B—Terminal
C—Terminal

RG,RG34710,2389 –19–15MAR97–1/1

CTM77 (30OCT00) 80-10-9 Alternators and Starter Motors

103000
PN=563
 Valeo Starter Motor Repair

Testing Brushes

1. Check positive brushes (A) by connecting an

ohmmeter between brushes and plate. The resistance
should be infinity.

–UN–22JUL96
2. Inspect brushes. Brushes must move freely in their
guides. Check brush overall length.

Specification

CD30464
New Brush—Length ........................................................ 14 mm (0.55 in.)
Used Brush—Minimum Length ...................................... 8.5 mm (0.22 in.)
Test Brushes
3. If defective, replace the brush plate assembly.
A—Brushes

NOTE: Brush plate assembly is available as a John

Deere Service part.

RG,RG34710,2390 –19–15MAR97–1/1

Positive Brush Replacement

80 1. Cut off old brush at end of brush strand (A).

10
10 2. Solder new brush using a 40—60% tin-lead mix. Heat
to 230°C (446°F).

–UN–22JUL96
NOTE: This operation requires specialized soldering
tools. If not available, have the brushes replaced
by a local electrical repair station.

CD30465
A—Brush Strand Positive Brush Replacement

RG,RG34710,2391 –19–15MAR97–1/1

CTM77 (30OCT00) 80-10-10 Alternators and Starter Motors

103000
PN=564
 Valeo Starter Motor Repair

Testing Armature

1. Check the armature insulation by connecting an

ohmmeter between the commutator (A) and the shaft
(B). If test shows continuity (needle movement), the
armature is grounded.

–UN–22JUL96
2. Check for armature condition. Space between bars
must be clean and of even depth. Small defects can be

CD30466
eliminated using sandpaper and a lathe.

3. If insulation is defective or armature is quite worn, Test Armature

replace the complete starter motor.
A—Commutator
B—Shaft

RG,RG34710,2392 –19–15MAR97–1/1

Testing Field Winding

1. Check insulation by connecting an ohmmeter between 80

brush (A) and field frame (B). If ohmmeter indicator 10
swings toward zero, a grounded circuit is indicated. 11

–UN–22JUL96
2. Connect ohmmeter between brush (A) and terminal
(C). Resistance should be below 1 ohm.

CD30467
3. If defective, replace the complete starter motor.

A—Brush Test Field Winding

B—Field Frame
C—Field Frame Terminal

RG,RG34710,2393 –19–15MAR97–1/1

CTM77 (30OCT00) 80-10-11 Alternators and Starter Motors

103000
PN=565
 Valeo Starter Motor Repair

Checking Overrunning Clutch Pinion

1. Check for pinion tooth condition. Slight damage on

teeth can be eliminated by grinding.

NOTE: Damage on teeth can be caused by a malfunction

–UN–22JUL96
of electrical system. Also check electrical circuit
for proper operation (switch, relay etc.).

CD30468
2. Turn overrunning clutch pinion by hand. Clutch pinion
should turn freely on shaft in overrunning direction
only. Check Overrunning Clutch Pinion

3. If defective, replace overrunning clutch pinion.

NOTE: Overrunning clutch pinion is avilable as a John

Deere service part.

RG,RG34710,2394 –19–15MAR97–1/1

80
10
12

CTM77 (30OCT00) 80-10-12 Alternators and Starter Motors

103000
PN=566
 Valeo Starter Motor Repair

Reassembly of Starter Motor

80
10

–UN–17JUL96
13

CD30469
Reassemble Starter Motor

Reassemble starter motor in the reverse sequence of reduction train, overrunning clutch pinion on shaft, and
disassembly procedure. shaft rear bearing.

Use petroleum-base grease to lightly coat mechanical Refer to machine technical manual to install starter
part assemblies such as shaft in nose bushing, gear motor and adjust belt tension.

Item Measurement Specification

Starter Solenoid Mounting Cap Torque 3 N•m (27 lb-in.)

Screws

Housing Through Bolts Torque 7 N•m (62 lb-in.)

Field Winding Terminal Screw Torque 10 N•m (88 lb-in.)

RG,RG34710,2396 –19–15MAR97–1/1

CTM77 (30OCT00) 80-10-13 Alternators and Starter Motors

103000
PN=567
 Valeo Starter Motor Repair

80
10
14

CTM77 (30OCT00) 80-10-14 Alternators and Starter Motors

103000
PN=568
 Index
Page Page

B Specifications, repair. . . . . . . . . . .10-10-2, 10-15-2

Specifications, test . . . . . . . . . . . .10-10-3, 10-15-3
Bosch alternator Denso alternator
Alternator operation. . . . . . . . . . . . . . . . . . .30-05-1 Alternator operation. . . . . . . . . . . . . . . . . . .25-05-1
Exploded view. . . . . . . . . . . . . . . . . . . . . . .30-10-8 Regulator operation. . . . . . . . . . . . . . . . . . .25-05-2
Repair and test . . . . . . . . . . . . . . . . . . . . . .30-10-5 Denso alternator (with add-on regulator)
Sectional view. . . . . . . . . . . . . . . . . . . . . . .30-10-4 Repair and test . . . . . . . . . . . . . . . . . . . . . .25-10-3
Specifications, repair. . . . . . . . . . . . . . . . . .30-10-2 Specifications, repair. . . . . . . . . . . . . . . . . .25-10-2
Specifications, test . . . . . . . . . . . . . . . . . . .30-10-3 Specifications, test . . . . . . . . . . . . . . . . . . .25-10-2
Bosch starter motor Denso alternator (with built-in regulator)
Cutaway view . . . . . . . . . . . . . . . . . . . . . . .70-10-6 Repair and test . . . . . . . . . . . . . . . . . . . . . .25-15-5
Exploded view. . . . . . . . . . . . . . . . . . . . . . .70-10-7 Specifications, repair. . . . . . . . . . . . . . . . . .25-15-3
General information. . . . . . . . . . . . . . . . . . .70-05-1 Specifications, test . . . . . . . . . . . . . . . . . . .25-15-4
Repair and test . . . . . . . . . . . . . . . . . . . . . .70-10-4 Denso/John Deere starter motor
Specifications, repair. . . . . . . . . . . . . . . . . .70-10-2 General information. . . . . . . . . . . . . . . . . . .65-05-1
Specifications, test . . . . . . . . . . . . . . . . . . .70-10-3 Starting circuit operation . . . . . . . . . . . . . . .65-05-1
Starter motor operation . . . . . . . . . . . . . . . .70-05-2 Denso/John Deere starter motor (conventional type)
Starting circuit operation . . . . . . . . . . . . . . .70-05-1 Exploded view. . . . . . . . . . . . . . . . . . . . . .65-10-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . .70-10-5 Repair and test . . . . . . . . . . . . . . . . . . . . . .65-10-7
Specifications, repair. . . . . . . . . . . . . . . . . .65-10-4
Specifications, test . . . . . . . . . . . . . . . . . . .65-10-5
Starter operation . . . . . . . . . . . . . . . . . . . . .65-05-2
D Denso/John Deere starter motor (gear recuction
type)
Delco-Remy alternator Exploded view. . . . . . . . . . . . . . . . . . . . . . .65-15-6
Alternator operation. . . . . . . . . . . . . . . . . . .10-05-1 Repair and test . . . . . . . . . . . . . . . . . . . . . .65-15-4
Regulator operation. . . . . . . . . . . . . . . . . . .10-05-1 Specifications, repair. . . . . . . . . . . . . . . . . .65-15-2
Delco-Remy starter motor Specifications, test . . . . . . . . . . . . . . . . . . .65-15-3
General information. . . . . . . . . . . . . . . . . . .60-05-1 Starter operation . . . . . . . . . . . . . . . . . . . . .65-05-3 Indx
Starter motor operation . . . . . . . . . . . . . . . .60-05-2 1
Starting circuit operation . . . . . . . . . . . . . . .60-05-1
Delco-Remy starter motor (10MT, 20MT, 22MT,
E
25MT, 27MT, 28MT)
Cutaway view . . . . . . . . . . . . . . . . . . . . . . .60-10-6
Electrical system
Repair and test . . . . . . . . . . . . . . . . . . . . . .60-10-6
Circuit malfunctions. . . . . . . . . . . . . . . . . . .05-15-1
Specifications, repair. . . . . . . . . . . . . . . . . .60-10-3
Grounded circuit . . . . . . . . . . . . . . . . . . . . .05-15-5
Specifications, test . . . . . . . . . . . . . . . . . . .60-10-4
High resistance circuit . . . . . . . . . . . . . . . . .05-15-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . .60-10-5
Open circuit . . . . . . . . . . . . . . . . . . . . . . . .05-15-3
Delco-Remy starter motor (30MT, 35MT, 37MT)
Seven step test procedure . . . . . . . . . . . . .05-15-8
Cutaway view . . . . . . . . . . . . . . . . . . . . . . .60-15-6
Shorted circuit. . . . . . . . . . . . . . . . . . . . . . .05-15-7
Repair and test . . . . . . . . . . . . . . . . . . . . . .60-15-7
Test equipment . . . . . . . . . . . . . . . . . . . . .05-15-10
Specifications, repair. . . . . . . . . . . . . . . . . .60-15-3
Specifications, test . . . . . . . . . . . . . . . . . . .60-15-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . .60-15-5
Delco-Remy starter motor (40MT, 41MT, 42MT, I
50MT)
Cutaway view . . . . . . . . . . . . . . . . . . . . . . .60-20-6 Inch torque values . . . . . . . . . . . . . . . . . . . . .05-10-1
Repair and test . . . . . . . . . . . . . . . . . . . . . .60-20-6 Iskra starter motor
Specifications, repair. . . . . . . . . . . . . . . . . .60-20-3 Exploded view. . . . . . . . . . . . . . . . . . . . . . .75-10-5
Specifications, test . . . . . . . . . . . . . . . . . . .60-20-4 General information. . . . . . . . . . . . . . . . . . .75-05-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . .60-20-5 Identification . . . . . . . . . . . . . . . . . . . . . . . .75-10-7
Delco-Remy 10SI, 12SI, and 15SI alternator Repair and test . . . . . . . . . . . . . . . . . . . . . .75-10-7
Repair and test . . . . . . . . . . . . . . .10-10-4, 10-15-4 Specifications, repair. . . . . . . . . . . . . . . . . .75-10-3

CTM77 (30OCT00) Index-1 Alternators and Starter Motors

103000
PN=1
 Index

Page Page

Specifications, test . . . . . . . . . . . . . . . . . . .75-10-4 Motorola alternator

Starter motor operation . . . . . . . . . . . . . . . .75-05-2 Alternator operation. . . . . . . . . . . . . . . . . . .15-05-1
Starting circuit operation . . . . . . . . . . . . . . .75-05-1 Regulator operation. . . . . . . . . . . . . . . . . . .15-05-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . .75-10-6 Motorola HC-, MA-, MR-Series alternator
Repair and test . . . . . . . . . . . . . . . . . . . . . .15-15-4
Specifications, repair. . . . . . . . . . . . . . . . . .15-15-2
Specifications, test . . . . . . . . . . . . . . . . . . .15-15-3
J Motorola SA-Series alternator
Repair and test . . . . . . . . . . . . . . . . . . . . . .15-25-3
John Deere/Denso starter motor Specifications, repair. . . . . . . . . . . . . . . . . .15-25-2
General information. . . . . . . . . . . . . . . . . . .65-05-1 Specifications, test . . . . . . . . . . . . . . . . . . .15-25-2
Starting circuit operation . . . . . . . . . . . . . . .65-05-1 Motorola TA-Series alternator
John Deere/Denso starter motor (conventional type) Repair and test . . . . . . . . . . . . . . . . . . . . . .15-30-3
Exploded view. . . . . . . . . . . . . . . . . . . . . .65-10-14 Specifications, repair. . . . . . . . . . . . . . . . . .15-30-2
Repair and test . . . . . . . . . . . . . . . . . . . . . .65-10-7 Specifications, test . . . . . . . . . . . . . . . . . . .15-30-3
Specifications, repair. . . . . . . . . . . . . . . . . .65-10-4 Motorola 8E-Series alternator
Specifications, test . . . . . . . . . . . . . . . . . . .65-10-5 General information. . . . . . . . . . . . . . . . . . .15-10-3
Starter operation . . . . . . . . . . . . . . . . . . . . .65-05-2 Repair and test . . . . . . . . . . . . . . . . . . . . . .15-10-3
John Deere/Denso starter motor (gear reduction Specifications, repair. . . . . . . . . . . . . . . . . .15-10-2
type) Specifications, test . . . . . . . . . . . . . . . . . . .15-10-2
Exploded view. . . . . . . . . . . . . . . . . . . . . . .65-15-6
Repair and test . . . . . . . . . . . . . . . . . . . . . .65-15-4
Specifications, repair. . . . . . . . . . . . . . . . . .65-15-2
Specifications, test . . . . . . . . . . . . . . . . . . .65-15-3 N
Starter operation . . . . . . . . . . . . . . . . . . . . .65-05-3
Niehoff alternator
Alternator operation. . . . . . . . . . . . . . . . . . .20-05-1
Load dump circuit . . . . . . . . . . . . . . . . . . . .20-05-4
Indx L Starting alternator . . . . . . . . . . . . . . . . . . . .20-05-1
2 Niehoff 12-volt, 110-amp alternator
Leece-Neville alternator Repair and test . . . . . . . . . . . . . . . . . . . . . .20-10-4
Alternator operation. . . . . . . . . . . . . . . . . . .45-05-1 Specifications, repair. . . . . . . . . . . . . . . . . .20-10-3
Repair and test . . . . . . . . . . . . . . . . . . . . . .45-10-2 Specifications, test . . . . . . . . . . . . . . . . . . .20-10-4
Specifications, repair. . . . . . . . . . . . . . . . . .45-10-1 Niehoff 24-volt, 50-amp alternator
Specifications, test . . . . . . . . . . . . . . . . . . .45-10-1 Repair and test . . . . . . . . . . . . . . . . . . . . . .20-15-4
Specifications, repair. . . . . . . . . . . . . . . . . .20-15-3
Specifications, test . . . . . . . . . . . . . . . . . . .20-15-3

M
P
Magneton alternator
Alternator operation. . . . . . . . . . . . . . . . . . .40-05-1 Prestolite alternator
Exploded view. . . . . . . . . . . . . . . . . . . . . . .40-10-4 Alternator operation. . . . . . . . . . . . . . . . . . .50-05-1
Identification . . . . . . . . . . . . . . . . . . . . . . . .40-10-5 Repair and test . . . . . . . . . . . . . . . . . . . . . .50-10-1
Repair and test . . . . . . . . . . . . . . . . . . . . . .40-10-7 Specifications, test . . . . . . . . . . . . . . . . . . .50-10-1
Specifications, repair. . . . . . . . . . . . . . . . . .40-10-2
Specifications, test . . . . . . . . . . . . . . . . . . .40-10-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . .40-10-6
Metric torque values . . . . . . . . . . . . . . . . . . . .05-10-2 R
Motorola A-, RA-, 8AR-Series alternator
Repair and test . . . . . . . . . . . . . . . . . . . . . .15-20-3 Robert Bosch alternator
Specifications, repair. . . . . . . . . . . . . . . . . .15-20-1 Alternator operation. . . . . . . . . . . . . . . . . . .30-05-1
Specifications, test . . . . . . . . . . . . . . . . . . .15-20-2 Exploded view. . . . . . . . . . . . . . . . . . . . . . .30-10-8

CTM77 (30OCT00) Index-2 Alternators and Starter Motors

103000
PN=2
 Index

Page

Repair and test . . . . . . . . . . . . . . . . . . . . . .30-10-5

Sectional view. . . . . . . . . . . . . . . . . . . . . . .30-10-4
Specifications, repair. . . . . . . . . . . . . . . . . .30-10-2
Specifications, test . . . . . . . . . . . . . . . . . . .30-10-3
Robert Bosch starter motor
Cut away view . . . . . . . . . . . . . . . . . . . . . .70-10-6
Exploded view. . . . . . . . . . . . . . . . . . . . . . .70-10-7
General information. . . . . . . . . . . . . . . . . . .70-05-1
Repair and test . . . . . . . . . . . . . . . . . . . . . .70-10-4
Specifications, repair. . . . . . . . . . . . . . . . . .70-10-2
Specifications, test . . . . . . . . . . . . . . . . . . .70-10-3
Starter motor operation . . . . . . . . . . . . . . . .70-05-2
Starting circuit operation . . . . . . . . . . . . . . .70-05-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . .70-10-5

Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-10-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-10-2

Valeo alternator
Alternator operation. . . . . . . . . . . . . . . . . . .35-05-1
Regulator operation. . . . . . . . . . . . . . . . . . .35-05-2 Indx
3
Repair and test . . . . . . . . . . . . . . . . . . . . . .35-10-3
Specifications, repair. . . . . . . . . . . . . . . . . .35-10-2
Specifications, test . . . . . . . . . . . . . . . . . . .35-10-2
Valeo A13N-Series alternator
Repair and test . . . . . . . . . . . . . . . . . . . . . .35-15-2
Specifications, repair. . . . . . . . . . . . . . . . . .35-15-1
Specifications, test . . . . . . . . . . . . . . . . . . .35-15-2
Valeo starter motor
Exploded view. . . . . . . . . . . . . . . . . . . . . . .80-10-3
General information. . . . . . . . . . . . . . . . . . .80-05-1
Repair and test . . . . . . . . . . . . . . . . . . . . . .80-10-4
Specifications, repair. . . . . . . . . . . . . . . . . .80-10-1
Specifications, test . . . . . . . . . . . . . . . . . . .80-10-2
Starter motor operation . . . . . . . . . . . . . . . .80-05-2
Starting circuit operation . . . . . . . . . . . . . . .80-05-1

CTM77 (30OCT00) Index-3 Alternators and Starter Motors

103000
PN=3
 Index

Indx
4

CTM77 (30OCT00) Index-4 Alternators and Starter Motors

103000
PN=4
SPINE2