led YET Ta Le aoa Training Manual Diagnostic ProceduresTABLE OF CONTENT: SECTION 1: INTRODUCTION Ll Leece-Neville’s Training Manual for Preventive Maintenance and Diagnostic Procedures on Heavy-Duty Vehicles......3 1.2. The Heavy-Duty Vehicle's Electrical System, 3 13 The Importance of Using Proper Preventive Maintenance Procedures. 4 14 The Importance of Using Proper Diagnostic Procedures. 4 LS The Importance of Selecting the Proper Electrical Components. 4 16 The Importance of Following Safety Precautions. SECTION 2: THE BATTERY SYSTEM 21 An Overview of the Battery System. 6 22 The Primary Causes of Battery System Malfunction. . 67 23 Preventive Maintenance ProcedureS.sumoun7 24 Diagnostic / Troubleshooting Procedures... . 79 25 Battery Charging... 9 2.6 Battery Replacement. a) SECTION 3: THE CHARGING SYSTEM 3.1 An Overview of the Charging System....10 3.2. The Primary Causes of Charging System Malfunetion..senrsnn 10 3.3. Preventive Maintenance Procedures....10-I1 34 Diagnostic / Troubleshoot Provedutesenneussinenn 1-12 3.9 Alternator Replacement, 2 SECTION 4: THE STARTING SYSTEM 4A An Overview of the Starting System .wnnminl3 4.2 The Primary Causes of Starting System Malfunction. . en) 43 Preventive Maintenance Procedures.nnnool4 44 Diagnostie/Troubleshooting Procedures. 4.9 Starter Replacement SECTION 5: CONCLUSION 5.1 The Benefits of U ig Proper Preventive Maintenance and Diagnostic Procedures....17 5.2 The Benefits of Selecting Proper Electrical Components. 17 APPENDIX Appendix A Altemator Sizing Worksheet. Is Appendix B_ Charging System Trouble Shooting Flowchart. 19 Appendix C _Altemator Test Procedure Flowehatt. 20AA Lecee-Neville’s Training Manual for Preventive Maintenance and Diagnostic Procedures on Heavy-Duty ‘The objective of this training manual isto provide the customer with a step by step, easy to understand outline Of the procedures for maintaining and diagnosing 2 heavy-duty vehicle's eletrical system, Asasservice technician, you should consider yourself as the “docior” who cares for your company's heavy-duty vehicles. It's your responsibility to make sure the vehi cles are well-maintained. And it’s your job to accurately diagnose and repair equipment problems if they occur, Unfortunately, problems with the vehicle's electrical sys- tem are ofiea misdiagnosed. What happens as a result? ‘Well, most industry studies indieate that approximately 155% of altemators and starters retumed under warranty {to manufacturers, and noted as “defective”, are later discovered to be in fine working order Now it’s certainly true that electrical components can become damaged due to excessive heat and vibration, voltage spikes, careless handling and misapplication, ‘Components can also become damaged by excessive heat, whenever they are foreed to operate at continu ‘ously high levels of electrical output. (For instance, the addition of even a few accessories ~ suchas mobile telephones, CB radios, portable CD players, coolers, mi- crowaves, satelite tracking, bunk heaters, inverters, etc. can overburden the amperage capacity ofthe originally installed alternator.) Generally speaking, however, electrical components - Itemators and starters - are designed to perform ‘ouble- free for many thousands of miles. So with knowledge and training, you'll be able to prop- erly maintain your company's vehicles. And if problems ‘occur in the electrical system, you'll be able to accu rately diagnose and correct them, instead of immediately assuming that an electrical component itself is faulty ‘That indeed is the goal ofthis training manual 1.2 The Heavy-Duty Vehicle's Flect sal System Ifa technician does not have a clear understanding of how a vehicle’ electrical system works, i's neatly impossible to accurately diagnose « problem, A vehicle's electrical system is comprised of three ele- ‘ments: the battery system, the charging system, and the starting system, Ali three systems work together as a veam, Figare 1: Vohiclclcrical ayer As with any team, each member has a specific and im portant job to perform. When diagnosing an electrical problema, it's necessary to consider each team member as Potentially contributing to the problem, ‘That's why we've organized this training manual to cover the battery system first, followed by the charging system and finally the starting system, ‘You'll find that each of these three sections starts with an overview of how the system works, then moves on (0 cover various preventive maintenance and diagnostic (Le troubleshooting) procedures.1.3 The Importance of Using Proper Preventive ‘Maintenance Procedures Throughout this manual, we'll underscore the importance of preventive maintenance, and show you the stops to be- come very proficient at it. Equally important, we'll show you how to perform preventive maintenance safely. The advantages of performing preventive maintenance can be summarized in two ways. Firs, it enhances the lifespan of electrical components; and second, it improves the likelihood of trouble-free operation, thereby mini- mizing vehicle downtime, 1.4 The Importance of Using Proper Diagnostic Proce- dures There's absolutely no question that diagnosing « problem ima vehicle's electrical system can be tedious and time consuming, However, spending the upfioat time requis is much more efficien’ than having the vehicle's driver come back to you with an uncorrected problem. Simply put, its important to take enough time to properly disy- nose and correct the real problem, ed To accurately diagnose an electrical problem, you need to quip yourself with two things: the proper tools and the proper techniques, ire Diagnostic esting eminent We'll provide diagrams to show how to connect the test- ing devices to the vehicle's electrical components. We'll provide charts to reveal what are acceptable readings ‘on the various devices, And as in the preventive main- tenance section, we'll show you how to safely perform diagnostic procedures. 15 The Importance of Selecting the Proper Electrical Components In the event that your diagnostic procedures point to a faulty electrical component, you'll need to carefully soleet the correct replacement component, I's not enough to simply replace an alternator or starter, for example, with an identical version of the faulty part heing replaced. There are two primary reasons why this is so, First, there's a chance the faulty part’s specifications never actually met the vehicle's amperage demands. Second, the vehicle's amperage needs might have inereased over time. Tn any case, a new component needs to support the vehicle's electrical load requirements, This is especially true with newer vehicles’ highly sophisticated computer systems, which need to be closely integrated with elec- trical systems components, Caron pile tster1.6 The Importance of Following Safety Precautions ‘We want your vehicle to operate trouble-free, But we also want you to follow safety precautions when pei forming preventive maintenance and diagnostic proce- dures. ‘Whether you're working on the battery system, charg- ing system, or starting system, make sure the vehi wheels are securely chocked and the vehicle is out of gear. When working on any of these three systems, al- ‘ways wear safety goggles ora face shield, never smoke, and do not wear jewelry of loose fiting clothing. In the battery system section, we've listed several pre- cautions to follow when recharging batteries. Here are some addtional precautions to adhere to A. Always follow the battery manuftcturer’s instructions ‘when equipment such as a battery charger or tester is used, B. Never Iean over a battery during charging, testing, or “jump starting” operations C. Don’t break “live” circuits atthe battery’s terminals, because a spark invariably occurs where a “live” circuit is broken, D. Keep batteries protected from sparks and open flames; never smoke near a battery. Batteries emit col- orless hydrogen gas, which is extremely flammable; they ccan explode if they come in contact with sparks, flames, or ashes. E. Be certain that battery charger eable clamps or boost- cr leads are clean and making good connections. A poor connection can cause an electrical are, which in tum ean ignite the battery's gases and cause an explosion. Sparks ccan occur as 2 result of loose cable connections, metal tools making contact between the battery terminals, and ‘metal tools making contact between the ungrounded bat- tery terminal and adjacent metal parts that are grounded, Don’ use the top of the battery as a tool rest. F. Do not charge a battery unless you are thoroughly familiar with the step-by-step procedure for using the battery charger. G. The room in which you're charging a battery must be well-ventilated H. Loose clothing shouldn’t be worn around moving, parts, I. Keep in mind radiator eooling fans can be thermostati- cally controlled and could turn on at any time,a the topic of the battery system, we've provided ‘you with some basic information on how the battery system functions. Each cell of a battery consists of positive plates, nega tive plates, and an elecuolyte solution. Batteries produce electricity because of a chemical reaction between these three elements, ign 3: ary components od battery, the positive plate consists of lead peroxide (the symbol PbO.), which is also called lead dioxide. Each molecule of PbO, consists of one lead atom and two oxygen atoms. The negative plate is sponge lead (the symbol Pb), which may be composed of an alloy of antimony or calcium. The electrolyte solution is sulfurie acid (the symbol H,SO, ) diluted with wat (H,0), Pep Sponge tens ey 0 8 280 ° Fipae 4: Fully charged hasty When an clctrial load is placed on battery, a chen ical waction tes place. The sulfate molecules inthe elecrlyte break of and atch themselves to the nee- ive end positive plites. AL the sete, the oxygen atoms fom the lead peroxide positive plates go ino the elecrlyte solution to join wit the hydrogen atoms, foning H,0 or water, The sulfate molecules moving to the plats and the oxygen atoms moving to the alt= ton release energy. This i called te discharge cy Figure: Fully duchanged batery When the battery is fully discharged, both plate are lead sulfate (he symbol PoSO, ), and the solution is wa: ter. In the charging cycle, the Sulfate molecules retura to the solution, and the oxygen molecules in the water return to the positive plates. Fully charged and fully discharged states are the extremes, Normally, a batery is partially ebar partially discharged. For example, a batte 25% discharged, meaning that 25% of the chemical reaction has taken place and 75% of the battery isin its ‘original chemieal condi 22 The Primary Causes of Battery System Malfunction Before dealing with preventive maintenance and diag nostic procedures for the battery system, we're going to cover certain environmental and usage handling factors that can cause the system to malfunction, Excessive heat. When batteries are subjected to high temperatures, positive plates corrode quickly and bat tery cells dry outCold weather. Because engine oil thickens in cold tem- peratures, it makes engines harder to crank. This places ‘heavier and longer-lasting drain on the battery. ‘Vibration, 1a batery is not securely fastened t0 the vehicle's frame, the resulting vibration can shed the ac- tive material from the battery's plate grids. Fast charging, Using a high charging rate to quickly charge batteries ean be damaging, if the battery be- comes overheated and begins gassing, Deep eycling. Repeated deep cycling will eventually cause a battery o lose its ability to accept a charge. If battery cycling occurs use high eycle batteries. 23. Preventive Maintenance Procedure ‘There are six preventive maintenance procechres that ‘can help preserve battery life. These six procedures are also the first steps you should take when diagnosing (i.e ‘oubleshooting) a problem in the vehicle's electrical system, The six preventive maintenance procedures are a8 follows: A. Check eleanliness. Ifthe battery rack is dirty, remove the battery cables first, then remove the battery from the vehicle. Wash the battery rack with a water and baking soda solution, Flush the ease with water, and dry with a towel. If necessary, clean the battery post and cable terminal with a wire brush or a special terminal cleaning tool. Wash batteries with baking soda and water Figure 6: Bauer hold dow backer. 2. Check held-down brackets. Make sure the brackets the battery to the yehicle’s frame are secure. If ighten to manufacturer speci Figne 7: Rater terminal locations 3. Check battery cables. Battery cable connections to terminal should be checked for corrosion and proper tightness, and cleaned and /or tightened as necessary. The cables themselves should be checked for swelling, cracking, or brittleness, cables should be replaced as necessary. 4. Check battery ground cables. The batiery ground cables must be securely fastened to the alternator ‘ground. Also be sure that the points where the cables ‘are connected to the vehicle's frame or engine block are clean and secure. 5. Check battery case. The condition ofthe battery cease often indiates whether intemal component damage or loss has occurred, Telltale signs are swelling and cracking ofthe ease. 6, Check fluid tevels (only on non-maintenance-fiee types of batteries), If liquid in the battery is tow, add clean soft water or distilled water only. Adding a pre- ‘mixed electrolyte solution will make the sulfuric acid too strong and cause the plates, separators, and case to deteriorate prematurely: 24 Diagnostic / Troubleshooting Procedures ‘When trying to find the cause of a problem ina vehicle's electrical system, you should always begin with the bat~ \ery. In performing any diagnostic procedure, refer to the safety information section in the Introduction section L6. ws critically important for each individual baitery to be properly tested and fully changed, It’s only then that you ‘can move on to diagnosing problems with the cherging or starting systems, \ battery not fully charged will eause all other electrical systems tests to be inaccurate.Remember to always diseonnect all hattery ground cables, at the batteries, before replacing or servicing any clectrical equipment. After removing battery ground cables verify no voltage is present at alternator output ‘erminals, Beyond the visual inspection procedures mentioned earlier, there are three simple steps to testing a bartery: removal of the surface charge, determination of the state of charge, and load testing Remove the battery's surface charge. Electrical charges on the surface of the battery's positive plates cause a falsely high voltmeter reading. Removal of this so-called “surface charge” is required on batteries that have been charged by an altemator or a battery charger within 48 hours. Batteries on trucks that have not been rn or charged on a charger within 48 hours will not have significant surface charge. To remove the surface charge, you'll need to slightly discharge the batteries, This ean be done by using carbon pile load tester to load each battery to one-quar- ter of its cold cranking amps rating for 15 seconds, so Figure 8. Fifteen seconds is long enough to dissipate the surface charge from the plates. The surface charge ean be removed by simply tuming on the vehicle's lights - without starting the engine - for ‘svo to three minutes per battery. Figure: Carbon ple land teste ‘Test the battery's state of charge. The second step in battery testing involves testing each individual battery's sare of charge. Connect a voltzacter across cach battery and record the readings. Compare the readings to the Figure 9 chart to determine the percentage of charge, If the battery is at 75% or higher, you can proceed to the third step - the load test. Ifthe battery is below 75%, recharge it, (See charging instructions at the end cof this section), Remove the surface cha iarged, the battery may require further ch tive, 12.30V 50% 12.15 V 25% Figures Carbon pile load testing. The third step in batiory test- ing isto load test the battery. Follow the carbon pile- load tester manufacturer's instructions when connecting, the tester and ammeter across the battery. Determine the battery's cold cranking amp rating, or CCA. Divide the CCA rating by two to determine the load. Load the battory for 15 seconds, adjusting the carbon pille to ‘maintain the proper load. Do not load the battery any longer than 15 seconds, as this may cause damage to the carbon pile. At the ond of the 15-second load, road the voltmeter and tum off the carbon pile,‘The table in Figure 10 below is used as a guideline for the minimum acceptable load test results. Notice that as the electrolyte temperature declines, so does the mini- ‘mum voltage. This is due to the effect of temperature ‘on most chemical reactions. The battery reaction is slower as the electrolyte becomes colder. Electrolyte Temp (F ) Voltage 70° or above 9.6 60" 95 30" 9A 40° 93 30° OL 20" 89 10° 8.7 0° 8.5 Figure 10 Batteries that pass the load test may be put back into service. Fully charged batteries that fail the load test have lost capacity or the ability to provide electrical cur- rent for cranking, wg batteries, pl safety precautions; follow these important 1) Leave the battery charger unplugged until its cables are connected to the battery 2) Charge each battery separately. 3) Use the proper charg 4) Charge batteries in a well ventilated area. '5) Never smoke while charging batteries. 6) Use protective ey 7) Do not wear watches or other jewelry 2.6 Battery Replacement Ifyou perform regular preventive maintenance teries, and always properly charge and test batteries, you can avoid or reduce the need for costly replacements. However, if your diagnostic procedures point to a faulty battery, you'll ned to carefully select a new batery. The new battery’s “cold cranking amp” rating must sup- port the vehicle's intended application, or load and duty eycle. 9ECTION 3 Ueto OletV erm 3.1 An Overview of the Charging System The Charging system is an important part ofthe electri cal system. It provides electrical current for the lights, the radio, the heater, the engine's electrical systerns, and other electrical accessories. It also maintains the bate ies ina charged state recharging them as necessary. In order to properly service the charging system, you. ced 1 undersiand how it operates. The chargi system has three main components: the alternator, the voltage regulator, and the batteries, ‘The alternator generates electrical power to run ae cessories and to recharge the batteries. Itis normally driven by a belt located off the erankshait. Mecha cal energy from the crankshaft is converted by the altemator into electrical energy for the batteries and accessories The voltage regulstor acts as an electrical “traffic cop” tocomtro] alternator output. It seases when the batteries ced recharging, or when the vehicle's electrical needs increase, an adjusts the alterator's output accordingly. ‘The batteries are a reservoir of chemical elestrical power. Their primary purpose is to crank the engine. They also supply power to vehicle accessories when the electrical load is too great for the alternator alone. ALTERNATOR VOLTAGE REGULATOR BATTERIES Figee 1: Witing diagram 32 The Primary Causes of Charging System Mal funetion Before discussing the preventive maintenance and diagnostic procedure: for the charging system, we're ‘going 10 cover certain environmental and product ap- plication factors that can cause the charging system 10 ‘malfunction, Excessive heat. An altemator can become damaged if) it operates too long at excessive temperatures. Dam ing beat levels are generated in two ways: when the alternator becomes ditty either extemally or internally restricting its ability to dissipate heat from its external surface or not allowing air to passthrough the unit, and ‘when air ducts and heat shields are not replaced after the alternator has been serviced, Dirtand dust. Charging system components oper atc less efficiently when buildup of dirt particles form around wire and cable connection points. Dirty con- nection points impair the flow of electrical Vibration. If charging system components are poorly cr loosely mounted to the vehicle's frame, the resulting Vibration ean damage sensitive internal components, A loosely mounted component will also diminish the performance of the important belt drives. This is very important on high powered engines. 33. Preventive Maintenance Procedures ‘The object of preventive maintenance is w identify and correct the potential problems before they occur. ‘There are three preventive maintenance procedures that can greatly enhance the efficiency of the charging sys- tem’s functions. These three procedu the initial steps you should take when fully di (troubleshooting) a problem in the vel system, The three preventive maintenance procedures areas follows also represe (Clean alternator and connection points. Insure that termator surfaces are clean to Uie point that they do not have a buildup of dirt, grease or dust. Air flow passages ‘must also be clear so that air can easily pass through the ‘unit, All connection points must be clean and free fiom,Component mounting brackets. As mentioned previ- ‘ously, you need to make sure thatthe charging system, ‘components are securely mounted to their applicable brackets; the brackets, in tum, need to be bolted secure- ly tothe engine. Again, if charging system components are poorly or loosely mounted, damaging vibration and diminished belt drive performance are the result. ‘Tension and condition of belts. You need to also check the belt far proper tension. Caution: be sure the engine is turned off. A loose belt will slip on the pul- ley and fail to turn the aliernator’s rotor. Check belt ten- sion with cricket belt tension gauge. Refer to vehicle ‘manufacture’s specifications for proper belt tension, Before you adjust it, however, tilt the belt and inspect it for glaving, cracks, or dryness. A wom or damaged belt should be replaced, [the belt is in satisfactory condition, use a bell tension ‘gauge and check the results, see Figure 12. Different belt systems use diferent gauges, Use proper lensi ‘ng gauge for your application, adjust the tension 2 cording ro the manufacturer's specifications. 1f engine is equipped with an automatic belt tensioner and the leading edge of the bel is damaged or fraying, inspect the tensioner. Itcould be worn or damaged and has contributed to belt damage. Figure 12: el nso gauge Ifyou replace a wom or damaged belt, the new belt should be checked for proper tension as well. A new belt loses 60% of its tension in the first few hours of opera tion, So it needs io be tested under heavy load, and then retensioned. After a new belt is installed, run the engine = with every azcessory turned on - for 15 minutes (this puts aeavy load on the bell). Then check the belt ten sioa again and adjust itif needed. Please note that bel ‘on high amperage output alternators may need rete ing twice after installation. Further note that ifthe ve- hiicle has a multi belt drive, the belts need to be matched, Finally, in most eases and on most vehicles, belt tension should be tested every 10,000 mil 34. Diagnostic / Troubleshooting Procedures ‘Timely preventive maintenance of the charging system should keep it running smoothly. However, when a prob- lem does occur, effective diagnostic (i.e. troubleshooting) procedures will help you locate and correct the problem quickly and economically. In performing any diagnos: tic procedure, refer to the safety information section in the Introduction section 1.6. Any discussion about the electrical system must begin. with the batteries, Before you begin analyzing the charg- ing system, you must be sure the batteries have been properly tested and are at least 75% charged. Otherwise, any electrical tests you conduct on the charging system will be inaccurate, (Please refer to Section Two of this manual for procedures on testing and charging batteries) |We're now going to show you how to perform four dif ferent tess specifically related to the charging system. Alternator Performance Test. Connect voltmeter to aakernator terminals and ammeter to altemator’s positive ‘output cable, per Figure 13. Make sure ammeter is at least 6 inches (15 em) away from altemator to eliminate the possibility of faulty readings. Make sure voltage is present at alemmtor’s ouput terminals, Start engine and run it at 1500 rpm (operating rpm), Cheek that all vehicle loads are tured off and reading on ammeter is less than 20 amps. Ifammeter reading is greater than 20 amps double check that all vehicle loads are turned off and that hatteries are fully charged. Record voltage on voltmeter, Reading should be between 13.8 & 14.4 v for a 12 volt syatem, 27.8 & 28.4 v for 24 volt systems, Ifthe voltage is not within these ranges then try adust- ing the regulator ifavailable, Ifthe regulator can not be adjusted, alternator is defeetive. Figie 15: Atemator perfomance tstunder loadAlternator Performance Test Under Load. Keep engine running at 1500 RPM (operating RPM) and meters are connecied per Figure 13. Tum on vehicle londs until 75% of the alternator’ rated output is achieved on ammeter display. Record voltage on volimeier. Compare reading to that iaking during the Alternator Performance Test. If aliemator voltage {drops more than.$ volts for a 12 V system and , 7 volts for a 24 V system then altemator is defective. An alternative method of putting load on an alterna ‘or is with & carbon pile tester. Connect carbon pile tester across batteries, Adjust carbon pile umil desired sd on ammeter. Record voltage on voltmeter and shut off vehicle. Alternator Cable Test. To test the positive cable connect the ammeter to the positive cable trom the altemator. Make sure the ammeter is atleast 6 inches (15 .em) away from the altematar to eliminate the Dossibility of faulty readings. Connect the voltmeter's negative lead to the positive terminal of the alternator and the positive lead tothe positive terminal on the battery, see Figure 14, Start engine and set engine RPM to 1500 RPMs (operating speed). Tum on vehicle loads until 75% of altemator's rated output ‘sachieved on ammeter display. If necessary use a carbon pile tester to apply load on altemator, Record voltage on voltmeter. If reading is greater than 25 Volts ina 12 volt circuit or 50 volts in a 24 volt cir- cuit check all wire connections and cable conditions. Freading is less than 25 volts in 12 volt circuit and .50 volts in a 24 vol circuit cables are good. Tum off Vehicle loads and shut off engine. To test the negative cable move voltmeter’s negative lead to the nega tive terminal ofthe battery and the postive lead 10 the negative terminel ofthe alternator, see Figure 15. Run test again. Use Figure 16 for recommended wire sizes for any cable repairs, CO Lo ap Figure M4: Positive eb tet Figure 15: Negativecabetest Maximum Total Cireuit Recommended Available Length Wire Size Current 60-75 amps 15 feet or less +6 16-25 Feet ” 26-40 feet 2 80-125 amps 15 foet or less rt 16-28 Feet 2 26-40 feet 0 130-250 amps 15 feet oF less #0 16-25 feet 0 26-40 feet 00 250-325 amps 00 #0000 Figure 16 Recommended wie sac chat 3S Alternator Replacement In the event that all ofthe diagnostic / troubleshooting. procedures point to a faulty alternator, you'll need 10 select a new altemator. Its “amperage copacity” rating ‘must support the vehicle's intended application, or load. and duty eycle. Ifthe vehicle has had a history of charging problems and ‘you've eliminated failure in the system, you may want to,reevaluate the capacity of the altsmater. ‘When installing a new alternator and retensioning belts, be sure to carefully follow the instructions noted earlier in this section under “preventive maintenance”. See Appendix A, B, and C at the end of this manual for the Aerator Sizing Worksheet, Trouble Shooting Flowchar, and Altemator Test Procedure Flowchart4.1_An Overview of the Starting System The starting system converts electrical enesgy from the baiteries into mechanical energy to turn the engine over. ‘A malfunction within the starting sysiem will make it difficult to got the engine started. In order to properly servies the start tounderstand how it operates. The starting system has five main components: the ignition switch or start bution, ‘a neutral safety switch (an option on some vehicles), the starter solenoid, the starter motor, and the batteries. system, you need gyn Scher (or clutch Switch) Figate 17 Sang yes ‘When the key is tumed in the ignition switeh to the start, position, or the stare button is pusked, electricity flows, from the batteries to the starter solenoic, Some vehicles are equipped with « neutral safety switeh and/ora clutch switch. If the vehicle isin gear when the key is cumed, the neutral safety switch blocks the signal to the batteries, so the engine doesn't start eran Otherwise, when the Key is turned, ‘The starter solenoid is an electromagnetic switch mount ced on the starter motor, When coils inside the sotenoid are energized by electricity, they ereate a magnetic field which attracts and pulls a plunger. Attached to one end. Of this plunger isa shifi eves. The lever is connected to the drive pinion and cluteh assembly of the starter motor. ‘The starter motor isa small but powerful electric motor that delivers a high degree of power for a short period of time. When the starter motor is energized it engages the flywheel ring gear and produces torque, which turns the flywheel and eranks the engine When the driver releases the ignition switch from the start position to the run position, the solenoid is dee. tivated. Its intemal retum springs cause the drive pinion to be pulled out of mesh with the flywheel, and the starter motor stops 4.2 The Primary Causes of Starting System Malfunetion Bofore discussing the preventive maintenance and ding nostic procedures for the starting system, we're going to cover certain environmental and product application factors that can cause the starting system to malfunction. 1. Battery charge. A battery having 2 low / poor state of charge will place abnormal stresses on the starting system, When measuring battery voltage, make sure voltage is 12.4 V or greater 2. Excessive heat. A starter motor can become damaged if it operates too long at high temperatures. Excessive heat is generally due to continuous engagement of the starter, Damage to starting system components can ¢e- ‘cur when the starter motor is eranked for long periods (often due to cold weather starts). Siarter should operate for 30 seconds maximum then let to cool down for 2 minutes. Excessive vibration, If starting system compor are poerly or loosely mounted fo the vehicle’s engine, the resulting vibration can damage sensitive internal ‘components, 1. Corrosion, dirt, and dust. Starting system compo= nents operate less efficiently when corrosion forms or dirt particles build up around wire and cable connection, points. Corroded and dirty connection points impair the flow of electrical current. 5. Defective solenoid. Ifthe starter fails to engage or fails o stay the pulkin or holdin coil may be ng to the solenoid is bad. You need to check the wiring to the solenoid. If the wiring is ok then the coil is defective and you will have to replace the solenoid,43° Prevent Maintenance Procedures ‘The object of preventive maintenance is to identify and correct potential problems before they ovcur. ‘There are two preventive mainterance procedures that can greatly enhance the efficiency of the starting system's functions. These two procedures also represent the initial steps you should take when fully diagnosing (.. troubleshooting) « problem in the vehicle's starting system. Engine operating condition. Keeping the engine in good running condition is essential to ensure efficient ‘operation of the starting system. Simply put, an engine in poor condition is harder to start, and this shortens the life of the starter motor. An engine that starts easily results in fewer tums of the starter motor, and therefore, a longer life for the starter Wires and cables. For any type of vehicle electrical system, it's important to keep all connection poin's clean. Road dirt and grease create resistance that in- terferes with electra current ow. In order to get the necessary power from a unit the size of a starter motor, there must be litte or no resistance between the batter- ies and the starter motor. In the same vein, you need to ‘make sure that wires and eables are clean, properly tight- ened, and of the proper size, Any loss of current duc to poor connections will reduce power of the starter motor Clean all connections on 9 periodic basis. Employing the preventive maintenance steps we've ‘outlined will be extremely beneficial to the starting sys. tem. There's also another way to save yourself alot of time and wrench work: visually inspecting the starting system's components for signs of damage 44 Diagnostic /‘Troubleshooting Procedures Timely preventive mainteance of the siarting system should keep it running smoothly. However, ithe siarter motor is cranking slowly, or not atl, it’s time (o diag- nose (i.e. troubleshooting) the starting system. In per~ forming any diagnostic procedure, refer to the safety information section in the Introduction section 1.6, Any discussion about the electrical system must begin with the batteries. Before you begin analyzing the star ing system, you must be sure the batteries have been properly tested and are at least 75% changed, Otherwise, any electrical tests you conduct on the starting system will be inaccurate, (Please refer to Section Two of this manual for procedures on testing and charging batteries.) You must also be aware thet if the batteries aren't be- ing recharged, there may be a problem in the charging, system, which will lead to starting system problems. (that’s the case, please refer to Section Three of this ‘manual for procedures on testing and troubleshooting the charging system). Ones you have verified that the batteries and charging system are working, you can begin testing the siarting system, When troubleshooting, you slways want to strive for ‘the most easily obtainable solution and progress toward the most difficult problems to address, And remember, ‘hen replacing electrical equipment, always discon rect all battery ground cables at the batteries, Ignition / run switch test. You should begin by det mining whether the problem is in the ignition switeh, button, mag switeh and associated wiring or if i's in the solenoid and starter motor. We'll bogin with the ignition switeh circuit, Connoet a volimeter between the ignition switeh terminal of the starter solenoid and ground see Figure 18. Have some- ‘one attempt to erank the engine and record the voliage. You'll get either no voltage, low voltage, or normal volt- age, with slow cranking or no cranking at all, First, troubleshoot the switch circuit. You ean test it by connecting 2 remote start switch between the battery positive and the switch terminal on the starter solenoid. ‘When you close the switch, the starter should engage and start the engine. Again, record the voltage while erank- ing and compare it io your first reading. A difference of | less than one volt is ot enough fo indicate a problem. If there is 2 difference of more than one vol, however, then there is « problem in the switch circuit Figure 1 lgiion rum ete totUse the voltmeter to check each connection, moving backward through the switch eicuit, If your first test of the ignition switch had shown low voltage, that may indicate a shorted starter movor, which would have to repaired or replaced. Ifthe voltage in your first test was normal, but there was slow cranking or no cranking at all, that would indicate ‘problem related to the batteries, battery cables, or a damaged starter Solenoid test. Although the reasons for low voliage (or normal voltage with slow cranking are different, the procedures for locating the problem area are the samme, If the solenoid clicks but the motor won’t tur, it means, ‘current is flowing throuigh the solenoid coils but not ‘throug the main contacts, Connect the voltmeter to the motor terminal of the sole= noid pet Figure 19. If there's no voltage from the motor terminal to ground (when the soleacid is activated), that indicates the disc isn't making contset with the termi tals, or there is problem with the cable between the battery positive terminsl and the solenoid. The solution is to repair or replace the solenoid or cable. Figure 19: Solenoid test, Starter motor test. If voltage is present atthe sotenoid ‘motor terminal, then the problem is the starcr motor or its cabling. If your original test ofthe ignition (or run) ‘switch indicated normal voltage, but slow or no crank ing, your next step is to check the motor system and its If the drive pinion keeps shifiing out of mesh with the flywheel, then check for s broken or a loose external ground wire on the solenoid. Replace a broken wite or reattach a loose one, Measure the arp craw with ammeter in ether the positive, see Figure 20, or ground cable, see Fig ture 21, of the starter motor while pressing the start switch, Ifthe amp draw is excessive, according to the manufactures specifications, then the starter ‘motors faulty, Slow cranking or high eurrent draw ean also indicate that bushings are worn because of an off-center armature. Worn bushings and / or and off-center armature cause poling and throw off the aligarnent of the magnetic fields. Bul, before you. replace the starter, check the condition of the engine to make sire itturns freely. An engine in poor condi tion could cause the starter to work harder or longer. In oer words, the starter may not be the problem. It ‘may be damaged by the engine's poor cons Figee 21: Starter motor test, ground (negative) able Voltage drop test. Slugaish cranking may be caused by. very small amount of extra resistance in the circuit. This may come from dirty connections or bad. ‘or broken cables, With the voltage drop test, you fist ‘must check the starter’s positive terminals, then the negative terminals, 1sPositive cable test. Connect voltmeter, ammeter, and carbon pile tester per Figure 22. Adjust a carbon pile load tester until ammeter reads 500 amps throagh to the meter. Note the voltage reading. On 12-volt system, voltage drop should not exceed 4 volts. On a 24 volt system, voltage drop should no: exceed | volt, Turn off carbon pile tester when test is complete iO} Fire 22: Poste cable est Negative cable test, Connect voltmeter, ammeter, and carton pile load tester per Figure 23. Adjust carbon pile load tester until ammeter reads $00 amps. Note the voltage reading. On 12-vokt system, vaktage drop should not exceed .4 volts. Ona 24 volt system, voli- age drop should not exesed I volt. Tur off carbon pile tester when testis complete. Figue 23: Negative cable test, Solenoid voltage drop test. ‘The final check takes place atthe Solenoid terminal, And for this test, you must crank the engine, Disconnect the earbon pile load tester, voltmeter (ifapplicable), and ammeter so that none ofthe testing equipment will be damaged by the test procedure. An auiocanging digital voltmeter is useful inthis ease, os full battery voltage appears across the solenoid terminals before they close, Connect voltmeter per Figure 24, rank the engine and note the voltage reading. No more than two-tenths voltage drop should exist between the solenoid contacts ‘The voltage readings from the three tests (Positive and ‘Negative cable tests and Solenoid voltage drop test) must not add up to more than one volt for a 12 volt system or 2.5 volts maximum for a 24 volt system. Figite 24: Solenoid volinge drop tert I the voltage drop is more than allowable, check the cables and connections. One final note; ‘There are many variations of grounding the starter cireuit. Some vehicles have a ground cable forthe battery and another ground cable for the starter moter, Both atch to the frame, When doinga voltage crop test, you must check all cables regardless of the circuit, 4S Starter Replacement In the event that all of the diagnostic / troubleshoot- ing procedures point to a faulty starter, you'll need to replace your unit with a new starter.5.1 The Benefits of Using Proper Preventive Main- tenance and Diagnostic Procedures ‘After having read this manual, we think you'll agree that service technicians who approach their eraft as “diagnostic experts” exhibit a higher degree of profes- sionalisin than mere “parts changers”. ‘The use of proper preventive maintenance and diag. ‘nostic procedures has many advantages. Electronic ‘components inevitably last longer and vehicle dow is greatly minimized. You will be able to take prid job well done. And your company will be pleased with the cost savings resulting from trouble free vehicle operation, 5.2 The Benefits of Selecting Proper Electrical Components, ‘As we've also noted throughout this manual, careful selection and replacement of electrical components assures that your heavy-duty vehicle’s entire electrical system will operate to it’s utmost efficiency. We at Leece-Neville trust that you've found this manual to be helpful. Continue to use it as a reference guide, and refer to itas necessary. Always feel free to contact ‘us with your comments or questions, Leece-Neville is commited to providing you with reli- able, durable, quality built electrical components. And. ‘we're committed to equipping you with the knowledge to perform your important job in the most professional ‘manner possible, Figure 26: Quality Lecce Nevill AeratorsAppendix A: Alternator Sizing Worksheet Typical ay Totat “Toleal ay Total current /Amp ‘current /Amp ‘Current Amp Current Amp Rating Rating cAB LIGHTS ON TRACTOR Heater (Select only ONE) Headlights (Select only ONE) HeateriAC Blowor Motor 4 (high) 2800 x 4-HiBeam 40x . Heater/AC Blower Motor-3 00x 2-HiBoam t00 x. = HoateriAC Blower Motor -2 4800 x = HeateriAC Blower Motor-1 (low) 1200 x Daytime Running Lights sox : LIGHTS ON TRACTOR LIGHTS ON TRAILER. RepOoANLRRSRIC NNN) Ta! 1 = tien tanner ine csrgeen Gath ioe TeDuvweettiowts) one x = ‘wor ge 2 inanvertun@rarsuLss) 030 x ‘tro Heome S js varariat onis) io 1: — Seis vena Won fo) es ft: —eiveiiem we s_= __ foncecetigapotinone) ar rout Tenis ‘SLEEPER LED Light (# of LIGHTS) 075 a surcro kt Om) poaniiht awe ere a io me ‘0 tistom im Footing tanos wo xs i am = Sea ae Tataree ia fs burt Hear 20 x ton to fe ret Tail UGHTS ON TRAILER aac aorta anos CeDUgm@oruioms) 08 xs eaniog so ee hrandenariLnt WeIBULES) 030 x om: oe ‘™* ‘Brake Lights TEDLgn@eottionrs) ogo x Baal Incandensent Light (# of LIGHTS) 2.20 x . pccasons susie fone OR oNaTrona MNT RE cy ote x = Blectric Blanket 3.00 x __ Incandensent Light (# of LIGHTS) 2.20 x = aan to = Famert (Cote Si) pon resin am no x Tomson VER to once 22 5 Taam ‘ Total is a Tt oxrrarecs Battery @ 8 amps each 8.00 x — = —_ ToTALs. oe : Total ____ Si gepeR = foes Recesones 4 Grand Total “Note - amps are all estimated values and should be used as @ guideline only Total Electrical Load values may vary depending on vehicle Total Amperage @ Idle (80% of total elec load) = 18Appendix B- Charging System Troubleshooting Flowchart (12 Volt System) Before you begin analyzing the charging system, you must be se the batteries have been propel tested and ate atleast 75% charged. Otherwise, any electical ests you conduct on the charging system vil be inaccurate, You need to aso check the bal for proper tension. Caution: Be sure the engine is tuned off. Dooce bat wil tip ‘on the pulley and fallto tun the alternator’ rotor Refer to manufacturers specifications for proper bet tension Before you adjust it however, tt the belt and inspect it or lazing. cracks, oF frye. A worn oF damaged belt should be replaced ‘Cheek vatage at Alternator"Engine Off" Sart engine Paste 3800 RPM, Record "Wo Loa Vohnge ‘shouldbe 13800142 ‘Check Alternator Label for Output Rating Tears Rrra "eitage and Compare te ‘No aa Test “Aerator OK, with Tad ‘on Alt check Voltage from’ Ait to Battery ‘Check Voltage at [Alternator “Engle Of” se TART ETAT stage hen 12 Volt Charging System Troubleshooting Flowchart ‘heck cables and connections. Replace corroded eables cle tighten connections. veliage drop stl exceeds «5 volts increase cable sie, ‘Check cables and connector Replace corroded cables, clean and tighten connections. If voltage drop still. Exceeds 5 volts increase cable sie. Replace AlternatorAppendix C. Alternator ‘Test Procedure Flowchart (12 Volt System) + Make electrical connections to aternator “Inspect for ignition! IGN" & DUVACY *3" terminals It present each terminal must de connected to B+ source of test stand” See Procedure + ‘Siar alternator Drive Motor Forward postion” if voltage =13.8 10 14.2 volts (Very with volt mater at lakernator output stude)* Chock for voltage adjust ‘ment adjustable regulator is present agjust volage to14.0 volts Gaara 1 FB SOG EST DS PSS BSS TS [_vessrepesion [>| hwarany save dashleteve oe warty Tea Tren | policy’ (TSE 1 Visual Inspection procedures.) tte eects oh At gears cxmecn sore ares Gongs Hoag a rin, done —— Mount Anernator ‘Make certain that drive bek is placed conto Test Star. ‘onto largest pulley closast to drive. Tie oe ws sByBKE tT Ther Test Stand Ena vot rar ttt san nd i Tur ponorsnitch ot |_| cates batery voltage i 1240 vole or Troubleshecting, eS Lp etter os cnt os ruse tony Flowchart ws Sram Submit for waranty Package partso that damege does not ‘occur in shipping ea It voltage drops >| more tnan so V ‘Select prope: load switch and apply load tae Tees eT Se partis defective for 10 seconds. (Load should not exceed Teena [ora Dewees | aang ‘Submit for war 75% of total rated output rating of aterra- SS renty appieabio" ton vpn scnre | cee \otage drop less sree [| m0 than 0 V renotal oie ‘On ruck “Part — waa | eons sal Note: Poor alligator clamp connections can eause voltage drop to be Use external voltmeter on output terminals to correct this, 20Notes:Notes:Notes:sE-NEVILLE SYSTEMS if AFTERMARKET SALES LEECE-NEVILLE {Steen 03000 Certified sees a a woww.prestolite.com Florence, KY 41082 Site see a ets bres fn ‘Fax (00) 987-6202 rs a ren, 406