Electric Divice

1452-01/1462-01/2610-01/1440-01
GENERAL
1. DIAGNOSTIC INFORMATION AND

PROCEDURE......................................... 3
OVERVIEW AND OPERATION

PROCESS
1. DESCRIPTION AND OPERATION.......... 5
REMOVAL AND INSTALLATION
1452-01 GENERATOR REPAIR

INSTRUCTIONS........................... 11
1462-01 STARTER REPAIR
INSTRUCTIONS........................... 12
2610-01 BATTERY REPAIR
INSTRUCTIONS........................... 13
1440-01 SPARK PLUG AND IGNITION
COIL REPAIR INSTRUCTIONS.... 14
05-2
1452-01 05-3
1. DIAGNOSTIC INFORMATION AND PROCEDURE

1) Ignition System
05-4
2) Ignition System (Cont'd)

1452-01 05-5
1. DESCRIPTION AND OPERATION

1) Battey
The sealed battery is standard on all cars. There are no vent plugs in the cover.
The battery is completely sealed, except for two small vent holes in the sides.
These vent holes allow the small amount of gas produced in the battery to escape.
The battery has the following advantages over conventional batteries:
· No water addition for the life of the battery.
· Overcharge protection. If too much voltage is applied to the battery, it will not accept as much
current as a conventional battery.
In a conventional battery, the excess voltage will still try to charge the battery, leading
to gassing, which causes liquid loss.
· Not as liable to self-discharge as a conventional battery. This is particularly important when a
battery is left standing for long periods of time.
· More power available in a lighter, smaller case.
The battery has three major functions in the electrical system.

First, the battery provides a source of energy for cranking the engine.
Second, the battery acts as a voltage stabilizer for the electrical system. Finally, the battery
can, for a limited time, provide energy when the electrical demand exceeds the output of the
generator.
2) Ratings
▶ A battery has two ratings: (1) a reserve capacity rating designated at 27°C(80°F), which is the
time a fully charged battery will provide 25 amperes of current flow at or above 10.5 volts (2) a
cold cranking amp rating determined under testing at -18°C(0°F), which indicates the cranking
load capacity.
(1)Reserve Capacity
The reserve capacity (RC) is the maximum length of time it is possible to travel at night with the
minimum electrical load and no generator output. Expressed in minutes, the RC rating is the time
required for a fully charged battery, at a temperature of 27°C(80°F) and being discharged at a
current of 25 amperes, to reach a terminal voltage of 10.5 volts.
05-6
(2) Cold Cranking Amperage

The cold cranking amperage test is expressed at a battery temperature of -18°C(0°F).
The current rating is the minimum amperage, which must be maintained by the battery for 30
seconds at the specified temperature, while meeting a minimum voltage requirement of 7.2 volts.
This rating is a measure of cold cranking capacity.
The battery is not designed to last indefinitely. However, with proper care, the battery will provide
many years of service. If the battery tests well, but fails to perform satisfactorily in service for no
apparent reason, the following factors may point to the cause of the trouble:
· Vehicle accessories are left on overnight.

· Slow average driving speeds are used for short periods.
· The vehicle's electrical load is more than the generator output, particularly with the addition of
aftermarket equipment.
· Defects in the charging system, such as electrical shorts, a slipping generator belt, a faulty
generator, or a faulty voltage regulator.
· Battery abuse, including failure to keep the battery cable terminals clean and tight or a loose
battery hold-down clamp.
· Mechanical problems in the electrical system, such as shorted or pinched wires.
3) Charging Time Required

The time required to charge a battery will vary depending upon the following factors:
▶ Size of Battery - A Completely discharged large heavy-duty battery required more than twice
the recharging time as a completely discharged small passenger car battery.
▶ Temperature - A longer time will be needed to charge any battery at -18°C(0°F) than at
27°C(80°F).
When a fast charger is connected to a cold battery, the current accepted by the battery will be
very low at first.
The battery will accept a higher current rate as the battery warms.
▶ Charger Capacity - A charger which can supply only 5 amperes will require a much longer
charging period than a charger that can supply 30 amperes or more.
▶ State-of-Charge - A completely discharged battery requires more than twice as much charge
as a onehalf charged battery.
Because the electrolyte is nearly pure water and a poor conductor in a completely discharged
battery, the current accepted by the battery is very low at first. Later, as the charging current
causes the electrolyte acid content to increase, the charging current will likewise increase.
1452-01 05-7
4) Charging a Completely Discharged Battery (Off the Vehicle)

Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced.
The following procedure should be used to recharge a completely discharged battery:
1. Measure the voltage at the battery terminals with an accurate voltmeter.

If the reading is below 10 volts, the charge current will be very low, and it could take some
time before the battery accepts the current in excess of a few milliamperes.
Refer to "Charging Time Required" in this section, which focuses on the factors affecting
both the charging time required. Such low current may not be detectable on ammeters
available in the field.
2. Set the battery charger on the high setting.
3. Continue to charge the battery until the charge current is measurable. Battery chargers vary
in the amount of voltage and current provided. The time required for the battery to accept a
measurable charger current at various voltages may be as follows:
· If the charge current is not measurable at the end of the above charging times, the battery
should be replaced.
· If the charge current is measurable during the charging time, the battery is good, and
charging should be completed in the normal manner.
It is important to remember that a completely discharged battery must be recharged for a

sufficient number of ampere hours (AH) to restore the battery to a usable state.
· If the charge current is still not measurable after using the charging time calculated by the
above method, the battery should be replaced.
05-8
5) Jump Starting Procedure

1. Position the vehicle with the charged battery so that the jumper cables will reach from the
charged battery to the battery that requires charging.
2. Turn off the ignition, all the lights, and all the electrical loads in both vehicles.
3. Leave the hazard flasher on if jump starting where there may be other traffic and any other
lights needed for the work area.
4. Apply the parking brake firmly in both vehicles.
In order to avoid damaging the vehicle make sure the cables are not on or near pulleys, fans,
or other parts that will move when the engine starts.
5. Shift an automatic transmission to PARK.
In order to avoid injury, do not use cables that have loose or missing insulation.
6. Clamp one end of the first jumper cable to the positive terminal on the booster battery. Make
sure it does not touch any other metal parts.
7. Clamp the other end of the same cable to the positive terminal on the discharged battery.
Never connect the other end to the negative terminal of the discharged battery.
8. Clamp one end of the second cable to the negative terminal of the booster battery.
9. Make the final connection to a solid engine ground, such as the engine lift bracket at least 450
millimeters (18 inches) from the discharged battery.
10.Start the engine of the vehicle with the good battery.
Run the engine at a moderate speed for several minutes.
11.Then start the engine of the vehicle with the discharged battery.
12.Remove the jumper cables by reversing the above sequence exactly, removing the negative
cable from the vehicle with the discharged battery first.
While removing each clamp, take care that it does not touch any other metal while the other
end remains attached.
1452-01 05-9
6) Alternator
Alternators are equipped with internal regulators.
Unlike three-wire generators, the alternator may be used with only two connections: battery
positive and an "D+" terminal to the charge indicator lamp.
As with other charging systems, the charge indicator lamp lights when the ignition switch is turned
to RUN, and goes out when the engine is running.
If the charge idicator is on with the engine running, a charging system defect is indicated. This
indicator light will glow at full brilliance for several kinds of defects as well as when the system
voltage is too high or too low.
The regulator voltage setting varies with temperature and limits the system voltage by controlling
rotor field current.
Achieve correct average field current for proper system voltage control by varying the on-off time.
At high speeds, the on-time may be 10 percent and the off-time 90 percent.
At low speeds, with high electrical loads, the on-time may be 90 percent and the off-time 10
percent.
7) Charging System
Generators use a new type of regulator that incorporates a diode trio.
A Delta stator, a rectifier bridge, and a rotor with slip rings and brushes are electrically similar
to earlier generators.
A conventional pulley and fan are used.
There is no test hole.
8) Starter
Wound field starter motors have pole pieces, arranged around the armature, which are energized
by wound field coils.
Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger
enclosed in the drive housing, protecting them from exposure to dirt, icy conditions, and
splashes.
In the basic circuit, solenoid windings are energized when the switch is closed.
The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel
ring gear.
The solenoid main contacts close. Cranking then takes place.
When the engine starts, pinion overrun protects the armature from excessive speed until the
switch is opened, at which time the return spring causes the pinion to disengage.
To prevent excessive overrun, the switch should be released immediately after the engine starts.
05-10
9) Starting System
The engine electrical system includes the battery, the ignition, the starter, the generator, and all
the related wiring.
Diagnostic tables will aid in troubleshooting system faults. When a fault is traced to a particular
component, refer to that component section of the service manual.
The starting system circuit consists of the battery, the starter motor, the ignition switch, and all the
related electrical wiring.
All of these components are connected electrically.

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1452-01/1462-01/2610-01/1440-01

1. DIAGNOSTIC INFORMATION AND

OVERVIEW AND OPERATION

REMOVAL AND INSTALLATION

1452-01 GENERATOR REPAIR

1. DIAGNOSTIC INFORMATION AND PROCEDURE

2) Ignition System (Cont'd)

1. DESCRIPTION AND OPERATION

The battery has three major functions in the electrical system.

(2) Cold Cranking Amperage

· Vehicle accessories are left on overnight.

3) Charging Time Required

4) Charging a Completely Discharged Battery (Off the Vehicle)

1. Measure the voltage at the battery terminals with an accurate voltmeter.

It is important to remember that a completely discharged battery must be recharged for a

5) Jump Starting Procedure

5. Shift an automatic transmission to PARK.

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