Technical Pages - Motor-Talk

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Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Technical Pages
Alternator
JAS Alternator
Part No.
Internal Regulator
Internal Fan
GQ: Genuine Quality
Remanufactured Equivalent
L
Refer to Plug Table
S
Plug Diagram
* Red:
GQ
Green: Remanufactured
Orange: New Aftermarket
Adj Hole
No of Grooves
Pulley Dia
Adj Hole
to
Piv Hole
Piv
Length
Inside
Ft to Ft
Piv Hole
Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Technical Pages
Starter Motor
JAS Starter
Part No.
Permanent Magnet
Gear Reduction
R: Remanufactured
New Equivalent
Pinion Dia
* Red:
GQ
Green: Remanufactured
Orange: New Aftermarket
Pinion at Rest
Mounting Holes
Cnt to Cnt
Field Hsg. Dia
Flange
Dia
Nose Cone Length
Overall Length
Mounting Hole
Dia
Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Technical Pages
Universal Starters
To Suit Denso
12V 2.5KW Suits Denso with Indexable Housing
Suits Universal, Perkins / Left & Right Hand Mountings
Teeth Teeth Dia
Rot
Wet / Dry Clutch
JAS
9
35
CW
Wet & Dry Clutch
SNJ051
9
35
CCW
Wet & Dry Clutch
SNJ042
10
32
CW
Wet & Dry Clutch
SNJ043
10
40
CW
Wet & Dry Clutch
SNJ026
10
40
CCW
Wet & Dry Clutch
SNJ040
11
40
CW
Wet & Dry Clutch
SNJ202
11
40
CCW
Wet & Dry Clutch
SNJ232
12
46
CW
Wet & Dry Clutch
SNJ246
12
46
CCW
Wet & Dry Clutch
SNJ206
48
290
90
10
13
46
CW
Wet & Dry Clutch
SNJ039
90
24V 4.5KW Suits Denso with Indexable Housing
Suits Universal, Perkins / Left & Right Hand Mountings
Teeth Teeth Dia
Rot
Wet / Dry Clutch
JAS
9
35
CW
Wet & Dry Clutch
SNJ044
10
32
CW
Wet & Dry Clutch
SNJ045
10
40
CW
Wet & Dry Clutch
SNJ025
10
40
CCW
Wet & Dry Clutch
SNJ041
11
40
CW
Wet & Dry Clutch
SNJ201
12
46
CW
Wet & Dry Clutch
SNJ233
127
89
E46-1800
18mm Spacer reduces
Pinion at Rest from 48mm - 30mm
10
Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Technical Pages
Instalation Notice
Correct Use of Shims on GM Starters
GM Starters require the use of shims or a shim, to ensure that the starter drive engages
correctly with the flywheel.
When replacing a GM Starter, remove the old unit; remove the old shim(s).
NOTE: Sometimes Shim(s) are required even if none were present
in the original installation.
• A high pitched whining sound as the starter disengages indicates that an increase in clearance is required.
• A clanging sound when the starter is engaged indicates that a decrease in clearance
is required.
TO INCREASE CLEARANCE:
• Shim(s) may be placed at both the mounting holes for gradual clearance (See Figure 1).
• For greater clearance, insert Shim(s) only at the inboard mounting hole (See Figure 2).
Figure 1
TO DECREASE CLEARANCE:
• Place Shim(s) only at the outboard mounting hole (See Figure 3).
Figure 2
E46-1001
E46-1000
Figure 3
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11
Technical Pages
BEFORE INSTALLING
Starter Motor
62% of all Starter Failure is due to a faulty or weak battery (Batteries should be
replaced every 3 years with the required cold cranking amps rating).
19% of all Starter Failure is due to poor electrical connections, fusible links,
bad battery cables and weak grounds. (Cable can be tested by verifying
that the voltage drop doesn’t exceed ½ volt from end to end).
8% of all Starter Failure is due to incorrectly shimmed General Motor Starters.
7% of all Starter Failure is due to improper engine timing and overheating.
NOTE: Before Installing Starter you must be certain of fully charged battery.
BEFORE INSTALLING
Alternator
67% of all Alternator Failure is due to a faulty or weak battery (Batteries should be
replaced every 3 years with the required cold cranking amps rating).
14% of all Alternator Failure is due to poor electrical connections, fusible links,
bad battery cables and bad grounds. (Cable can be tested by verifying that
the voltage drop doesn’t exceed ½ volt from end to end).
9% of all Alternator Failure is due to belt wear or improper adjustment
(Check for cracks, polished wear on belts and proper tension on belts).
6% of all Alternator Failure is due to jump starting another car incorrectly.
(Failure to disconnect connection on alternator may cause voltage spikes).
NOTE:Before Installing Alternator you must be certain of fully charged battery.
Never remove battery cable from battery to check charging system.
This will cause damage to the alternator and computer system.
Voltage Meter
12.6
Battery Condition
12.6
12.4
12.2
12.0
11.8
12
Volts
Volts
Volts
Volts
Volts
100%
75%
50%
25%
0%
+
Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Technical Pages
Failures with Ford Transit
Starter Motors
Model: Ford 2.4 TDCi
JAS Oceania reports on a recurring problem with the PAD MOUNT starter
for the FORD Transit (2000 onwards). (JAS Part Number SNA008, SNA013)
The unit is failing due to significantly high levels of metal
dust particles contaminating the pinion housing.
On inspection, the units do not exhibit any
manufacturing defects. The premature failure
of the unit is due to;
* Contamination of the pinion/drive area from
metal dust particles produced within the
Dual-mass Flywheel, when the clutch wears
or becomes overheated. During scheduled
servicing, it is recommended that the clutch is
checked and if found to be showing signs of wear
should be replaced.
Replacing a starter motor that is found to be
contaminated with high levels of metal dust particles in the pinion area
and the transmission bell housing, which has not been thoroughly cleaned
out before installing the replacement unit. This will lead to the Starter failing in
a short period of time.
NOTE: JAS Oceania cannot accept under warranty any units that have failed due to
this contamination fault, as this is not a manufacturing defect of the starter motor.
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13
Technical Pages
Oil contamination &
Warning Light Failure
Ford Falcon AU-BA
JAS Oceania reports on 2 problems with ANJ087 Alternators fitted to late model
Ford Falcon AU-BA
On inspection, the units do not exhibit any manufacturing defects. The premature
failures of the unit are due to;
* Inadvertently connecting battery supply to the warning light terminal of the regulator
plug. There are many wiring diagrams in circulation relating to this unit and there may be
incorrect versions in the market leading to the technician unknowingly incorrectly
connecting wiring when replacing the plug.
Please refer to Diagram below.
* Power steering fluid leaking into the unit from the power steering pump and
destroying the brush gear and slip rings.
These JAS supplied units are individually tested before being packaged and are
supplied with a test data sheet, therefore any damage to the warning light circuit or oil
contamination will be treated as damage after supply.
Please ensure correct connection as per diagram attached and any leaks from the power
steering system are repaired.
NOTE: JAS Oceania cannot accept under warranty any units that are returned that charge but have no warning light circuit or are contaminated by oil, as this is not a manufacturing defect of the alternator.
L
S
14
Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Technical Pages
Overrunning
Alternator Pulley
The function of the overrunning alternator pulley is to decouple the alternator
from the rotational irregularities of the crankshaft, since the alternator has the highest
mass moment of inertia in the accessory belt drive. In this way, the alternator is driven
using only the acceleration components of the rotational irregularity of the crankshaft.
ADVANTAGES
The positive influences on the accessory belt drive result in:
• The damping of belt vibrations
• A reduced load in the belt drive
• Reduced tensioner movement
• Increased belt life
• Improved noise behaviour of the belt drive
• Increased alternator speed in the idling speed range
• Reduced belt slip and noise on the alternator drive wheel
during gear changes
DECOUPLING FUNCTION
The overrunning alternator pulley decouples the alternator from
the rotational irregularities of the crankshaft up to an engine speed of approx. 2000
min-1. The decoupling function of the overrunning pulley unit is dependent on
the load condition of the engine, the inertia and the load condition of the alternator.
Furthermore the overrunning pulley decouples the alternator inertia
during significant decreases in engine speed (gear change).
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15
Technical Pages
Alternators with P-D
Field Control Unit
These types of Alternator do not have a traditional Regulators but instead have a field control Unit.
Mitsubishi & Hitachi Alternators with P-D Regulators require special testing, the voltage control &
warning lamp functions are in the vehicle PCM (Computer).
* P Terminal is Stator Phase & is a direct connection to stator AC Volts.
This allows the PCM to Monitor Alternator Field.
* D Terminal is Driver connected to Vehicle PCM (Computer), and is used to control the output of
the field control unit by varying base current on a transistor which in turn varies field current thereby
controlling Alternator output and voltage. These Alternators cannot be tested in the traditional manner
without dedicated testing equipment. Connecting battery voltage to the “D” terminal will destroy the unit.
JAS provides this information to assist the technician and is not designed to take the place of the Vehicle
Manufacturers Technical Advice or Instructions so please verify wherever possible from Manufacturers
technical publications.
ALTERNATORS WITH P-D FUNCTIONS ARE:
HITACHI
LR170-758
LR165-712
JAS NO.
ANJ057
ARJ031
ANJ057
ARJ031
MITSUBISHI
A2TB0091
A2TB2391
A2TB6191
A2TB6192
A2TB0191
A2TB7791
A3TG0081
A3TG0091
A3TG1391A
A3TG1081A
JAS NO.
ANJ057
ARJ031
ANJ057
ARJ031
ANJ057
ARJ031
ANJ057
ARJ031
ARJ099
ARJ099
ANJ512GQ
ANJ512GQ
ANJ513GQ
ANJ520
Phase
P
D
Driver
16
Copyright©2009. JAS Oceania Pty Ltd. All Rights Reserved
Field Control Unit
Technical Pages
Ford 6G,
Magneti Marelli / Denso Alternators
Ford Regulators fitted to 6G & Magneti Marelli Alternators have unique characteristics compared
to earlier versions. Both Alternators are controlled by the Vehicle Powertrain Control Module (PCM).
There is no direct control over the Vehicle indicator warning lamp by the Alternator. The RC is an input
terminal to the Alternator that receives a Pulse Width Modulation (PWM) signal from the vehicle PCM
that is used to control Alternator Voltage and output. The LI or Load Indicator in turn provides the PCM
with a PWM signal as a reference to tell the PVM how hard the Alternator is working to allow it to make
adjustments to the Alternator output based on vehicle requirements i.e. Electrical and Transmission load.
These Alternators can be traditionally tested in a very basic fashion to verify that the Alternator does or
does not charge by running the Alternator with the battery output lead only connected and allowing the
Alternator to self excite and charge at a basic set voltage level. This DOES NOT indicate that
the complete charging function of the Alternator is correct and fully functional however as there is
obviously no interaction between Vehicle and Alternator.
LI
RC
S
Feedback (FR)
Signal (SIG)
B+ or Sense (S As)
Load Indicator
Regulator Control
External Voltage Sense
JAS provides this information to assist the technician and is not designed to take the place
of the Vehicle Manufacturers Technical Advice or Instructions so please verify wherever possible from
Manufacturers technical publications.
Signal
Sense
Load
Indicator
A SIG FR
Signal
Sense
Load
Indicator
A SIG FR
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17