ELECTRICAL SYSTEM PRESTOLITE AND MANDO ALTERNATORS

Transcription

1 ELECTRICAL SYSTEM C PRESTOLITE AND MANDO ALTERNATORS

2 Tl of Contnts Pg Spifitions for Prstolit 65 Amp Altrntor C- Tools/Slnts C- Torqu Spifitions C- Explo Viw of Prstolit Altrntor.... 4C- Prutions C- Systm Componnts C- Bttry Isoltor C-4 Tsting Altrntor C-5 Ciruitry Tst C-5 Spifitions for Mno 55 Amp Altrntor. 4C-9 Tools/Slnts C-9 Torqu Spifitions C-9 Explo Viw of Mno Altrntor C-0 Bttry Isoltor C- Tsting Altrntor C- Ciruitry Tst C- Currnt Output Tst C- Voltg Output Tst C-4 4C-0 - ELECTRICAL SYSTEMS

3 Spifitions for Prstolit 65 Amp Altrntor Exittion Wir - Purpl - Snsing Wir - R/Purpl - Prstolit Prt Numr Dsription Exittion Ciruit Currnt Output Voltg Output Connsr Cpity Minimum Brush Lngth TOOLS/SEALANTS Spifition.5-.0 Volts 5 Ampr Min Volts.5 MFD.87In.(5mm) Mgnto Anlyzr 9-74 Univrsl Pullr Plt Multi-Mtr/DVA Tstr Quiksilvr Liqui Noprn Otin Lolly TORQUE SPECIFICATIONS Ammtr (0-50 Volts) Fstnr Lotion l. ft (N m) l. in. (N m) Housing Srws 55(5.6) Pully Nut 4(58) Front Bring Srws 0(.8) Altrntor Mount 5(48) Ajustmnt Bolt 6(8) V-Blt Tnsion / In. () Dprss lt with thum t miwy point twn irulting pump n ltrntor ELECTIRCAL SYSTEMS - 4C-

4 Explo Viw of Prstolit Altrntor GREEN PURPLE RED 0 BLACK 4 BROWN Rgultor n Ls - Srws (4) - Insultor Cp 4 - Nuts (6) 5 - Wshrs () 6 - Connsr 7 - Insulting Wshr 8 - Nuts () 9 - Insulting Wshrs () 0-Flt Gskt - Srws () -Brush Assmly -Srws (4) 4-Rr En Frm 5-Str Wshrs () 6-Insultor 7-Insulting Wshrs () 8-Nut 9-Wshr 0-Insulting Wshr -Insultor -Ngtiv Rtifir -Positiv Rtifir/Dio-Trio 4-Sttor 5-Rotor n Slip Rings 6-Snp Ring 7-Bring 8-Front En Frm 9-Fn Bushing 0-Wooruff Ky -Fn -Pully -Lokwshr 4-Nut 4C- - ELECTRICAL SYSTEMS

5 Prutions Th following prutions MUST BE osrv whn working on th ltrntor systm. Filur to osrv ths prutions my rsult in srious mg to th ltrntor or ltrntor systm.. DO NOT ttmpt to polriz th ltrntor.. DO NOT short ross or groun ny of th trminls on th ltrntor, xpt s spifilly instrut in th Troulshooting Tsts.. NEVER isonnt th ltrntor output l or ttry ls whn th ltrntor is ing rivn y th ngin. 4. NEVER isonnt rgultor l from ltrntor rgultor trminl whn th ltrntor is ing rivn y th ngin. 5. ALWAYS rmov ngtiv ( ) ttry l from ttry for working on ltrntor systm. 6. Whn instlling ttry, BE SURE to onnt th positiv (+) ttry l to th positiv (+) ttry trminl n th ngtiv ( ) (groun) ttry l to ngtiv ( ) ttry trminl. 7. If hrgr or oostr ttry is to us, BE SURE to onnt it in prlll with xisting ttry (positiv to positiv; ngtiv to ngtiv). Systm Componnts Th ltrntor systm onsists of th ltrntor, ttry, th ignition swith n th wiring whih onnts ths omponnts Bttry Mtr - Ignition Swith - Hrnss Plug 4 - Altrntor 5 - Ciruit Brkr 6 - Strtr Motor 7 - Groun Stu 8 - Bttry ELECTIRCAL SYSTEMS - 4C-

6 Bttry Isoltor A B C Altrntor with Voltmtr Ciruit (Typil Wiring Shown) Not : Disonnt orng wir from ltrntor Btt trminl. Spli suffiint lngth of propr gug wir n onnt s shown. A - Wiring Digrm - Ciruit Brkr - Wiring Hrnss - Altrntor 4 - Strtr 5 - Crnking Bttry B - Originl Wiring - Altrntor C - Wiring Conntions With Isoltor - Isoltor - Us 8 Gug Wir Minimum - Auxiliry Bttry 4C-4 - ELECTRICAL SYSTEMS

7 Tsting Altrntor Bfor proing with th tsts, howvr, prform th following hks to limint possil prolm rs. Also osrv Prutions, on pg, to prvnt mg to ltrntor systm.. If th prolm is n unrhrg ttry, hk to nsur tht unrhrg onition hs not n us y xssiv ssory urrnt rw or y ssoris whih hv intlly n lft in th ON position. Also, hk tht unrhrg onition hs not n us y running ngin t too low sp for xtn prios of tim.. Chk physil onition n stt of hrg of ttry. Bttry MUST BE t lst 75% (.0 spifi grvity) of fully hrg to otin vli rsults in th following tsts. If not, hrg ttry for tsting systm.. Inspt ntir ltrntor systm wiring for fts. Chk ll onntions for tightnss n lnlinss, prtiulrly ttry l lmps n ttry trminls. 4. Chk ltrntor riv lt for xssiv wr, rks, frying n glz surfs n rpl if nssry. Also, hk riv lt tnsion n just if nssry. Ciruitry Tst. If voltg output os not fll within spifitions, ltrntor shoul tst for prol us n isssml for rpir. - Output Wir - Orng - Exittion Wir - Purpl - Snsing Wir - R/Purpl - Voltmtr (0-0 Volts) - Groun HARNESS VOLTAGE TEST 708 With ignition off, unplug r/purpl wir n hk for ttry voltg t hrnss wir. No voltg t hrnss wir inits wiring hrnss is opn n shoul rpir or rpl. Prform th following tsts, using 0-0 volt DC voltmtr, to hk tht ll of th iruits twn th ltrntor n th othr omponnts within th ltrntor systm r in goo onition.! WARNING B sur tht ngin omprtmnt is wll-vntilt n tht thr r no gsolin vpors prsnt (uring th tst) to prvnt th possiility of n xplosion n/or fir, shoul sprk our. ALTERNATOR OUTPUT TEST. Connt positiv (+) voltmtr l to ltrntor output trminl (orng wir) n ngtiv ( ) l to groun trminl on ltrntor. With ngin running out 500 RPM n ll ssoris turn on, voltg shoul twn Exittion Wir - Purpl - Snsing Wir - R/Purpl - Voltmtr (0-0 Volts) - Groun ELECTIRCAL SYSTEMS - 4C-5

8 OPEN DIODE-TRIO TEST. With ignition on n ngin not running, hk for ttry voltg t ltrntor output trminl (Tst ) n.5 to.0 volts t rgultor trminl (Tst ). OPEN DIODE-TRIO TEST. With ignition on n ngin not running, hk for ttry voltg t ltrntor output trminl (Tst ) n.5 to.0 volts t rgultor trminl (Tst ). TEST TEST Rgultor Trminl - Output Trminl - Groun - Voltmtr (0-0 Volts) TEST - Rgultor Trminl - Output Trminl - Groun - Voltmtr (0-0 Volts) TEST. Connt jumpr wir twn rgultor n output trminl. Strt ngin n run t il. If hrging voltg ( volts) is prsnt t output trminl, th io-trio is proly ftiv n ltrntor shoul rmov for rpir.. Connt jumpr wir twn rgultor n output trminl. Strt ngin n run t il. If hrging voltg ( volts) is prsnt t output trminl, th io-trio is proly ftiv n ltrntor shoul rmov for rpir Rgultor Trminl - Output Trminl - Jumpr L - Groun - Voltmtr (0-0 Volts) - Rgultor Trminl - Output Trminl - Jumpr L - Groun - Voltmtr (0-0 Volts) 4C-6 - ELECTRICAL SYSTEMS

9 CURRENT OUTPUT TEST Prform this tst to hk if ltrntor is pl of prouing rt urrnt output, using 0-50 mp DC mmtr.! WARNING B sur tht ngin omprtmnt is wll-vntilt n tht thr r no gsolin vpors prsnt (uring th tst) to prvnt th possiility of n xplosion n/or fir, shoul sprk our.. Disonnt ngtiv ( ) ttry l from ttry.. Disonnt orng l from ltrntor output trminl n onnt mmtr in sris twn l n output trminl. Connt positiv (+) si of mmtr towr output trminl.. Ronnt ngtiv ttry l. 4. Rmov oil high-tnsion l from istriutor p towr n groun it to lok. Turn on ll ssoris n rnk ngin ovr with strtr motor for 5-0 sons. 5. Turn off ssoris n rinstll oil hi-tnsion l. Strt ngin n just ngin sp to RPM. Quikly osrv mmtr. Ring shoul t lst 0 mps. 6. If ring is low, stop ngin n onnt jumpr wir twn ltrntor output trminl n rgultor trminl. Rpt Stps 4 n If ring is now within spifitions, ios r fulty. Disssml ltrntor n rpl rtifir s xplin unr Altrntor Rpir, following, to trmin if fult is in rgultor or ltrntor. 8. If ring is still low with jumpr wir onnt, prform Voltg Output Tst, following, to trmin if fult is in rgultor or ltrntor. - Output Wir - Orng - Output Trminl - Ammtr (0-50 Amps) - Jumpr L - Rgultor Trminl f - Groun f ELECTIRCAL SYSTEMS - 4C-7

10 OPEN REGULATOR TEST IMPORTANT: This tst rquirs rmovl of rgultor.! CAUTION To prvnt ltril systm mg n/or sprks, isonnt ttry ls t ttry.. Rmov insultor p from rgultor trminl.. With ignition swith on n ngin not running, hk for ttry voltg t ltrntor output trminl (Tst ) n rgultor trminl (Tst ). 4. Connt jumpr wir twn fil trminl (grn wir) n groun/ If.5 to.0 volts r prsnt t rgultor trminl, rgultor is ftiv. If voltg is not prsnt t rgultor trminl, thr is n opn fil iruit (rushs slip rings, t.). Rmov ltrntor for rpir. TEST Fil Trminl (Grn Wir) - Rgultor Trminl - Groun - Voltmtr (0-0 Volts) NOTE: Flt gskt is shown rmov for visul lrity Rgultor Trminl - Output Trminl - Groun - Voltmtr (0-0 Volts) TEST. Rmov th four srws whih sur th rgultor to th ltrntor. 4C-8 - ELECTRICAL SYSTEMS

11 Spifitions for Mno 55 Amp Altrntor - Exittion Wir - Purpl - Snsing Wir - R/Purpl - Mno Prt Numr (Hin in This Viw) 7078 Dsription Exittion Ciruit Currnt Output Voltg Output Connsr Cpity Tools/Slnts Spifition.-.5 Volts 50 Ampr Min Volts.5 MFD Mgnto Anlyzr 9-9A5 Bring Rmovl n Instlltion Kit 9-74 Univrsl Pullr Plt Multi-Mtr/DVA Tstr 9-57 Quiksilvr Liqui Noprn Otin Lolly Ammtr (0-50 Volts) Torqu Spifitions Fstnr Lotion l. ft (N m) l. in. (N m) En Frm Srws 55(5.6) Brush Stsrws 8(.5) Rgultor Mounting Srws 4(4.5) Groun Trminl Nuts 5(.5) Rgultor Ls 5(.5) Pully Nut (58) V-Blt Tnsion / In. () Dprss lt with thum t miwy point twn irulting pump n ltrntor ELECTIRCAL SYSTEMS - 4C-9

12 Explo Viw of Mno Altrntor Srw () - Nut (9) - Flt Wshr (4) 4 - Snsing Wir (R/Purpl) 5 - Exittion Wir (Purpl) 6 - Covr 7 - Ti Strp 8 - Rur Gskt 9 - Connsr 0- Insultor () - Bolt (4) - En Frm (Rr) - Cp () 4- Brush/Rgultor Assmly 5- Rtifir Assmly 6- Flt Wshr 7- Srw 8- Sttor 9- Rotor n Slip Rings 0- Rtining Plt - Front Bring - En Frm (Front) - Srw () 4- Fn Spr 5- Fn 6- Pully Spr 7- Pully 8- Lokwshr 9- Nut 4C-0 - ELECTRICAL SYSTEMS

13 Bttry Isoltor A B C Altrntor with Voltmtr Ciruit (Typil Wiring Shown) Not : Disonnt orng wir from ltrntor Btt trminl. Spli suffiint lngth of propr gug wir n onnt s shown. A - Wiring Digrm - Ciruit Brkr - Wiring Hrnss - Altrntor 4 - Strtr 5 - Crnking Bttry B - Originl Wiring - Altrntor C - Wiring Conntions With Isoltor - Isoltor - Us 8 Gug Wir Minimum - Auxiliry Bttry ELECTIRCAL SYSTEMS - 4C-

14 Tsting Altrntor Bfor proing with th tsts, howvr, prform th following hks to limint possil prolm rs. Also osrv Prutions, pring, to prvnt mg to ltrntor systm.. If prolm is n unrhrg ttry, hk to nsur tht unrhrg onition hs not n us y xssiv ssory urrnt rw or y ssoris whih hv intlly n lft on. Also, hk tht unrhrg onition hs not n us y running ngin t too low sp for xtn prios of tim.. Chk physil onition n stt of hrg of ttry. MUST BE t lst 75% (.0 spifi grvity) of fully hrg to otin vli rsults in th following tsts. If not, hrg ttry for tsting systm.. Inspt ntir ltrntor systm wiring for fts. Chk ll onntions for tightnss n lnlinss, prtiulrly ttry l lmps n ttry trminls. 4. Chk ltrntor riv lt for xssiv wr, rks, frying n glz surfs n rpl if nssry. Also, hk riv lt tnsion n just if nssry. Ciruitry Tst Prform th following tsts, using 0-0 volt DC voltmtr, to hk tht ll of th iruits twn th ltrntor n th othr omponnts within th ltrntor systm r in goo onition. OUTPUT CIRCUIT. Connt positiv (+) voltmtr l to ltrntor output trminl n ngtiv ( ) l to groun trminl on ltrntor.. Wiggl ngin wiring hrnss whil osrving voltmtr. Mtr shoul init pproximt ttry voltg n shoul not vry. If no ring is otin, or if ring vris, hk ltrntor output iruit for loos or irty onntions or mg wiring. - Output Wir - Orng - Exittion Wir - Purpl - Snsing Wir - R/Purpl - Voltmtr (0-0 Volts) - Groun EXCITATION CIRCUIT Connt positiv (+) voltmtr l to ti strp trminl on ltrntor n ngtiv ( ) l to groun trminl on ltrntor (Tst ).. Turn ignition swith to ON position n not voltmtr ring. Ring shoul. to.5 volts.. If no ring is otin, n opning xists in ltrntor xittion l or in xittion iruit of rgultor. Unplug purpl l from rgultor. Connt positiv voltmtr l to purpl l n ngtiv voltmtr ls to groun (Tst ). If voltmtr now inits pproximt ttry voltg, voltg rgultor is ftiv n must rpl. If no voltg is init, hk xittion iruit for loos or irty onntions or mg wiring. 4. If ring is twn.75 n. volts, rotor fil iruit proly is short or groun. Disssml ltrntor n tst rotor s outlin unr Altrntor Rpir, following. 4C- - ELECTRICAL SYSTEMS

15 5. If ring is twn 6.0 n 7.0 volts, rotor fil iruit proly is opn. Rmov rgultor n inspt for worn rushs or irty slip rings. Rpl rushs if lss thn /4 in. (6 mm) long. If rushs n slip rings r in goo onition, isssml n prform rotor tst s outlin unr Componnt Tsting - Rotor following. TEST TEST. Connt positiv (+) voltmtr l to r/purpl l n ngtiv ( ) voltmtr l to groun trminl.. Voltmtr shoul init ttry voltg. If ttry voltg is not prsnt, hk snsing iruit (r/purpl l) for loos or irty onntion or mg wiring. - Exittion Wir - Purpl - Snsing Wir - R/Purpl - Ti Br - Voltmtr (0-0 Volts) - Groun SENSING CIRCUIT Unplug r/purpl l from voltg rgultor. - Output Wir - Orng - Exittion Wir - Purpl - Snsing Wir - R/Purpl - Voltmtr (0-0 Volts) - Groun Currnt Output Tst 7786 Prform this tst to hk if ltrntor is pl of prouing rt urrnt output, using 0-50 mp DC mmtr.! WARNING B sur tht ngin omprtmnt is wll-vntilt n tht thr r no gsolin vpors prsnt (uring th tst) to prvnt th possiility of n xplosion n/or fir, shoul sprk our.. Disonnt ngtiv ( ) ttry l from ttry.. Disonnt orng l from ltrntor output trminl n onnt mmtr in sris twn l n output trminl. Connt positiv (+) si of mmtr towr output trminl.. Ronnt ngtiv ttry l ELECTIRCAL SYSTEMS - 4C-

16 4. Rmov oil high-tnsion l from istriutor p towr n groun it to lok. Turn on ll ssoris n rnk ngin ovr with strtr motor for 5-0 sons. 5. Turn off ssoris n rinstll oil hi-tnsion l. Strt ngin n just ngin sp to RPM. Quikly osrv mmtr. Ring shoul t lst 0 mps. 6. If ring is low, stop ngin n onnt jumpr wir twn ltrntor output trminl n rgultor trminl. Rpt Stps 4 n If ring is now within spifitions, ios r fulty. Disssml ltrntor n rpl rtifir s xplin unr Altrntor Rpir, following, to trmin if fult is in rgultor or ltrntor. 8. If ring is still low with jumpr wir onnt, prform Voltg Output Tst, following, to trmin if fult is in rgultor or ltrntor.. Strt ngin n run t fst il until ngin rhs norml oprting tmprtur. Ajust ngin sp to RPM n osrv voltmtr for highst ring. Ring shoul twn.9 n 4.7 volts.. If ring is high, hk for loos or irty rgultor groun l onntion. If onntion is goo (n snsing iruit hk out goo in Ciruitry Tst ), voltg rgultor is fulty n must rpl. B sur to isonnt ttry ls for ttmpting to rmov rgultor f - Output Wir - Orng - Exittion Wir - Purpl - Snsing Wir - R/Purpl - Voltmtr (0-0 Volts) - Groun - Output Wir - Orng - Output Trminl - Ammtr (0-50 Amps) - Jumpr L - Rgultor Trminl f - Groun 7787 Voltg Output Tst Prform this tst to trmin if voltg rgultor is oprting orrtly, using 0-0 volt DC voltmtr. IMPORTANT: Bttry MUST BE fully hrg (.60 or ov spifi grvity) to otin propr voltg ring in this tst. If nssry, hrg ttry with ttry hrgr or llow ngin to run suffiint lngth of tim to fully hrg ttry for tking ring.. Connt positiv (+) voltmtr l to positiv ttry trminl n ngtiv ( ) voltmtr l to ngtiv trminl. 4C-4 - ELECTRICAL SYSTEMS