Installation manual
ALTERNATORS
TESTING/TROUBLESHOOTING
'10
ORANGE
B
TO
STARTER
SOLENOID
#16
VIOLETR
TO
K-3
RELAY
.
'16
RED
TO
ACTUATOR
DESCRIPTION
60
AMP
ALTERNATOR
EXCITER
TERMINAL
R
REFER
TO
THE
WIRING
DIAGRAM
IN
THIS
MANUAL
FOR
ALL
WIRING
CONNECTIONS
The following iofonnation applies
to
Ibe
standard
alternato~
Ibat
are
supplied
wilb
WES1ERBEKE'S Engines
and
Generators.
ELECTRICAL
CHARGING
CIRCUIT
The charging system consists of
an
alternator
wilb
a
voltage
regulator,
an
engine DC wiring hamess, a mounted
DC
circuit breaker
and
a battery
wilb
connecting
cables.
Because
of
Ibe
ose of integrated circuits (IC's),
Ibe
electronic voltage
regulator
is
very compact
and
is
mounted
internally or
on
the
back
of
the
alternator.
It
is desirable to
test
Ibe
charging system (alternator and
voltage regulator) using the
wiring
hamess and electrical
loads
that
are
a pennanent part of
Ibe
system
and
williben
provide
the
technician
with
an
operational test of the
charging system
as
well
as
the
major components of
Ibe
electrical
system.
ALTERNATOR
OESCRIPTION
The stator
is
connected
to
a three-phase, full-wave bridge
rectifier package
which
contains
six
diodes.
The
bridge
converts
the
AC
generated
in
the
stator
to
a
DC
output
for
battery charging
and
accessories,
Power
to
the
regulator
and
Ibe
field
of
the
integral regulator
alternator
is
provided
by
the
field
diode (or diode
trio)
package contained
in
the
alternator.
These alternators produce a rated output
of
60
amps.
Rated
output
is
achieved
at
approximately 6000 alternator
rpm
at
an
ambient temperature of 75°P
(23.8°<::).
The
alternators
are
designed
to
operate
in
an
ambient temperature range
of
-40°
to
212°P
(-40°
to
!OO°C).
VOLTAGE
REGULATOR
The
integral voltage regulator
is
an
electronic switching
device
which
senses
the
system voltage
level
and
switches
Ibe
voltage
applied
to
Ibe
field
in
order to maintain a proper
system
voltage.
The
regulator design utilizes all-silicon semi conductors
and
thick-film
assembly techniques. After
Ibe
voltage
has
been
adjusted
to
the
proper regulating valve,
Ibe
entire circuit
is
encapsulated
to
protect
Ibe
circuit
and
the
components
from
possible damage
due
to
handling or vibration.
ALTERNATOR
TROUBLESHOOTING
Use
this
troubleshooting section
to
deterntine
if
a
problem
exists
wilb
Ibe
charging circuit or
with
the
alternator.
If
it
is
deterntined that
the
alternator or voltage regulator
is
faulty,
have
a qualified technician check
it.
A
WARNING:
A
working
alternator
runs
hot.
A
failed
alternator
can
become
very
hot.
Do
not
touch
the
alternator
until
if
has
cooled.
LOW
BATTERY/FAULTY
CIRCUIT
If
Ibe
starter only
moans
or
makes
a clicking sound instead
of spinning
Ibe
engine
to
life
it
is
likely a
low
battery
or
a
faulty
connection in
Ibe
starting circuit
and
not
an
alternator
problem.
PRELIMINARY
INSPECTION
Before starting
the
actual
alternator
and
voltage
regulator,
testing
the
following checks are recommended.
1. Make certain your alternator
is
securely
mounted.
2.
Check
Ibe
drive
belts
for proper tension.
Replace
Ibe
belt
if
it
is
worn
or
glazed.
3.
Check that all tenninals, connectors and
plugs
are
clean
and
tight.
Loose
or
corroded connections cause
high
resistance
and
this
could cause overcharging,
undercharging or damage
to
the
charging
system.
Badly
corroded battery
cables
could prevent the
battery
from
reaching a
fully
charged condition.
4.
Check
Ibe
condition of
Ibe
battery
and
charge if
necessary.
A
low
or discharged battery
may
cause false or
misleading
readings
in
Ibe
tests.
NOTE:
An
isolator with a diode, a solenoid,
or
a battery
selector switch is usually mounted
in
the circuit to isolate
the batteries so the starting battery is not discharged along
with the house batteries.
If
the isolator is charging the
starting battery but not the house battery, the alternator is
OK
and
the problem is in the battery charging circuit.
Engines & Generators
24