Technical Pages. Copyright JAS Oceania Pty Ltd. All Rights Reserved

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1 Technical Pages 7

2 Alternator JAS Alternator Part No. GQ: Genuine Quality Internal Regulator Internal Fan Remanufactured Equivalent L S Refer to Plug Table Plug Diagram * Red: GQ Green: Remanufactured Orange: New Aftermarket No of Grooves Adj Hole Pulley Dia Adj Hole to Piv Hole Piv Length Inside Ft to Ft Piv Hole 8

3 Starter Motor JAS Starter Part No. R: Remanufactured Technical Pages Permanent Magnet Gear Reduction 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 9

4 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 SNJ CCW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ CCW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ CCW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ CCW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ V 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 E CW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ CCW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ CW Wet & Dry Clutch SNJ mm Spacer reduces Pinion at Rest from 48mm - 30mm

5 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). E Figure 2 E Figure 3 11

6 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 Volts 100% 12.4 Volts 75% 12.2 Volts 50% 12.0 Volts 25% 11.8 Volts 0%

7 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. 13

8 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

9 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 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). 15

10 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 JAS NO. MITSUBISHI JAS NO. LR A2TB0091 LR A2TB2391 A2TB6191 A2TB6192 A2TB0191 ARJ099 A2TB7791 ARJ099 A3TG0081 ANJ512GQ A3TG0091 ANJ512GQ A3TG1391A ANJ513GQ A3TG1081A ANJ520 Phase P D 16 Driver Field Control Unit

11 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 Feedback (FR) Load Indicator RC Signal (SIG) Regulator Control S B+ or Sense (S As) 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. Sense Signal Load Indicator A SIG FR Sense Signal Load Indicator A SIG FR 17