ELECTRICAL SYSTEM 4 C 72078 CHARGING SYSTEM
Tle of Contents Pge Ientifition............................. 4C-1 Replement Prts Wrning............... 4C-1 Mno 55 n 65 Amp Alterntor.......... 4C-1 Speifitions............................ 4C-1 Tools/Selnts........................... 4C-1 Torque Speifitions..................... 4C-2 Desription.............................. 4C-2 Preutions............................. 4C-2 System Components..................... 4C-3 Perioi Mintenne..................... 4C-3 Drive Belt Tension Ajustment............. 4C-4 Alterntor............................. 4C-4 Trouleshooting Tests (Alterntor on Engine).................... 4C-4 Ciruitry Test.......................... 4C-4 Current Output Test.................... 4C-6 Voltge Output Test.................... 4C-6 Alterntor Repir......................... 4C-7 Removl............................. 4C-7 Exploe View........................ 4C-8 Disssemly.......................... 4C-9 Clening n Inspetion............... 4C-12 Component Testing................... 4C-13 Ressemly......................... 4C-16 Instlltion............................. 4C-18 Prestolite 65 Amp Alterntor.............. 4C-19 Replement Prts Wrning.............. 4C-19 Speifitions........................... 4C-19 Tools/Selnts.......................... 4C-19 Torque Speifitions.................... 4C-19 Desription............................. 4C-19 Pge Preutions............................ 4C-20 System Components.................... 4C-20 Perioi Mintenne.................... 4C-21 Drive Belt Tension Ajustment............ 4C-21 V-Belt............................... 4C-21 Trouleshooting Tests (Alterntor on Engine)................... 4C-22 Ciruitry Test......................... 4C-22 Alterntor Repir........................ 4C-25 Removl............................ 4C-25 Exploe View....................... 4C-26 Disssemly......................... 4C-27 Clening n Inspetion............... 4C-29 Front Bering........................... 4C-29 Removl............................ 4C-29 Instlltion........................... 4C-29 Slip Rings/Rer Bering.................. 4C-30 Removl............................ 4C-30 Instlltion........................... 4C-30 Component Testing...................... 4C-31 Rotor............................... 4C-31 Sttor............................... 4C-32 Positive/Negtive Retifier n Dioe-Trio Assemly................. 4C-33 Conenser........................... 4C-34 Ressemly............................ 4C-34 Instlltion............................. 4C-36 Bttery Isoltors......................... 4C-37 Dul Bttery Chrging Systems Using Bttery Isoltor..................... 4C-37 Bttery Isoltor.......................... 4C-38 4C-0 - CHARGING - SYSTEM 90-823224--2 796
Ientifition Replement Prts Wrning! WARNING Eletril, ignition n fuel system omponents on your MerCruiser re esigne n mnufture to omply with U.S. Cost Gur Rules n Regultions to minimize risks of fire n explosion. Use of replement eletril, ignition or fuel system omponents, whih o not omply with these rules n regultions, oul result in fire or explosion hzr n shoul e voie. 72078 Mno 55 n 65 Amp Alterntor Mno 55 n 65 Amp Alterntor - Exittion Wire - PURPLE - Sensing Wire - RED/PURPLE - Mno Prt Numer (Hien In This View) Speifitions Desription Speifition Exittion Ciruit 1.3 to 2.5 Volts Current Output 55 Amp. 50 Amp. Min. 65 Amp. 60 Amp. Min. Voltge Output 13.9 to 14.7 Volts Min. Brush Length 1/4 in. (6 mm) 73078 Tools/Selnts Prestolite 65 Amp Alterntor - Exittion Wire - PURPLE e - Sensing Wire - RED/PURPLE f - Prestolite Prt Numer (Hien In This View) Desription Prt Numer Bering Removl n Instlltion Kit 91-31229A5 Mgneto Anlyzer 91-76032 Universl Puller Plte 91-37241 Multi-Meter/DVA Tester 91-99750 Quiksilver Liqui Neoprene 92-27511-2 Ammeter (0-50 mm) Otin Lolly 90-823224--2 796 CHARGING SYSTEM - 4C-1
Torque Speifitions Fstener Lotion in. l. ft. l. N m En Frme Srews 55 5.5 Brush Setsrews 18 1.5 Regultor Mounting Srews 42 4.2 Regultor Les 25 2.5 Groun Terminl Nut 25 2.5 Pulley Nut 42 4.2 Alterntor Bre to Alterntor 20 27 Alterntor Bre to Blok 30 41 Alterntor to Mounting Brket 35 48 Alterntor Mounting Brket 30 41 V-Belt Tension (Note) Depress 1/4 in. Desription The lterntor hs rotor, whih is supporte in two en frmes y ll erings, n is riven y pulley t pproximtely twie engine spee. The rotor ontins fiel wining tht is enlose etween two multiple-finger pole piees. The ens of the fiel wining re onnete to two rushes (mounte in the rer en frme) whih mke ontinuous sliing (or slipping) ontt with the slip rings. The urrent (flowing through the fiel wining) retes mgneti fiel tht uses the jent fingers of the pole piees to eome lternte north n south mgneti poles. A 3-phse sttor is mounte iretly over the rotor pole piees n etween two en frmes. It onsists of three winings woun 120 egrees eletrilly out-of-phse on the insie of lminte ore. The winings re ll onnete together on one en, while the other ens re onnete to full-wve retifier rige. The retifier rige ontins six ioes whih re rrnge so tht urrent flows from groun, through the sttor n to the output terminl, ut not in the opposite iretion. When urrent is supplie to the rotor fiel wining, n the rotor is turne, the movement of the mgneti fiels rete inues n lternting urrent into the sttor winings. The retifier rige then hnges this lternting urrent to iret urrent whih ppers t the output terminl. A ioe trio lso is onnete to the sttor winings to supply urrent to the regultor n the rotor fiel uring opertion. Voltge output of the lterntor is ontrolle y regulting the urrent supplie to the rotor fiel. This is omplishe y trnsistorize voltge regultor tht senses the voltge t the ttery n regultes the fiel urrent to mintin lterntor voltge within presrie limits for properly hrging the ttery. Current output of the lterntor oes not require regultion, s mximum urrent output is self-limite y the esign of the lterntor. As long s the voltge is regulte within the presrie limits, the lterntor nnot proue exessive urrent. A ut-out rely in the voltge regultor lso is not require, s the retifier ioes (whih llow urrent to flow in one iretion only) prevent the ttery from ishrging k through the sttor. Due to the lk of resiul mgnetism in the rotor pole piees, smll mount of urrent must e supplie to the rotor fiel to initilly strt the lterntor hrging. This is omplishe y mens of n exittion iruit in the regultor whih is onnete to the ignition swith. One the lterntor egins to proue output, fiel urrent is supplie solely y the ioe trio, s expline, preeing. The lterntor lso is equippe with fn (mounte on the rotor shft) whih inues ir flow through the lterntor to remove the het rete y the retifiers n sttor. A pitor protets the retifier system from high voltges n suppresses rio noise. Preutions The following preutions MUST BE oserve when working on the lterntor system. Filure to oserve these preutions my result in serious mge to the lterntor or lterntor system. 1. DO NOT ttempt to polrize the lterntor. 2. DO NOT short ross or groun ny of the terminls on the lterntor, exept s speifilly instrute in the Trouleshooting Tests. 3. NEVER isonnet the lterntor output le or ttery les when the lterntor is eing riven y the engine. 4C-2 - CHARGING SYSTEM 90-823224--2 796
4. NEVER isonnet regultor le from lterntor regultor terminl when the lterntor is eing riven y the engine. 5. ALWAYS remove negtive ( ) ttery le from ttery efore working on lterntor system. 6. When instlling ttery, BE SURE to onnet the positive (+) ttery le to the positive (+) ttery terminl n the negtive ( ) (groune) ttery le to negtive ( ) ttery terminl. 7. If hrger or ooster ttery is to e use, BE SURE to onnet it in prllel with existing ttery (positive to positive; negtive to negtive). System Components The lterntor system onsists of the lterntor, ttery, the ignition swith n the wiring whih onnets these omponents. h g Perioi Mintenne The following mintenne hek shoul e performe every 50 hours or 60 ys (whihever omes first) in fresh wter res or every 25 hours or 30 ys in slt wter res.! CAUTION Remove ll ttery les from ttery (efore onuting the following hek) to prevent ientlly shorting out eletril system. 1. Inspet entire lterntor system for orroe or loose onnetors. 2. Chek wiring for frye or worn insultion. 3. Chek lterntor rive elt for exessive wer, rks, frying n glze surfes. Also, hek rive elt tension n just, if neessry, s expline uner Drive Belt Tension Ajustment. 4. Chek lterntor mounting olts for equte tightness. 5. Inspet slip ring en frme flme rrestor sreen for eris n len, if neessry, using ompresse ir or loth. Sreen MUST BE len, or lterntor my overhet. f - Ignition Swith - Alterntor - Strter Motor - Groun Stu e - Bttery f - Ciruit Breker g - Hrness Plug h - Bttery Meter e 72933 90-823224--2 796 CHARGING SYSTEM - 4C-3
Drive Belt Tension Ajustment Alterntor 1. Instll rive elt on pulleys n just tension s follows:. Pivot lterntor wy from engine, s require, until orret tension is otine s shown. Belt shoul epress 1/4 in. (6 mm). - Chek Point 72669. After otining orret tension, seurely retighten lterntor re tthing olts n lterntor mounting olts. 2. If new rive elt hs een instlle, rehek elt tension fter running for five minutes. Trouleshooting Tests (Alterntor on Engine) Use the following tests in onjuntion with the Trouleshooting in Setion 1. Before proeeing with the tests, however, perform the following heks to eliminte possile prolem res. Also oserve Preutions, preeing, to prevent mge to lterntor system. 1. If prolem is n unerhrge ttery, hek to ensure tht unerhrge onition hs not een use y exessive essory urrent rw or y essories whih hve ientlly een left on. Also, hek tht unerhrge onition hs not een use y running engine t too low spee for extene perios of time. 2. Chek physil onition n stte of hrge of ttery, s outline in Bttery - Storge in Setion 4A. Bttery MUST BE t lest 75% (1.230 speifi grvity) of fully hrge to otin vli results in the following tests. If not, hrge ttery efore testing system. 3. Inspet entire lterntor system wiring for efets. Chek ll onnetions for tightness n lenliness, prtiulrly ttery le lmps n ttery terminls. 4. Chek lterntor rive elt for exessive wer, rks, frying n glze surfes n reple if neessry. Also, hek rive elt tension n just if neessry, s outline uner Drive Belt Tension Ajustment. Ciruitry Test Perform the following tests, using 0-20 volt DC voltmeter, to hek tht ll of the iruits etween the lterntor n the other omponents within the lterntor system re in goo onition. OUTPUT CIRCUIT 1. Connet positive (+) voltmeter le to lterntor output terminl n negtive ( ) le to groun terminl on lterntor. 4C-4 - CHARGING SYSTEM 90-823224--2 796
2. Wiggle engine wiring hrness while oserving voltmeter. Meter shoul inite pproximte ttery voltge n shoul not vry. If no reing is otine, or if reing vries, hek lterntor output iruit for loose or irty onnetions or mge wiring. e If voltmeter now inites pproximte ttery voltge, voltge regultor is efetive n must e reple. If no voltge is inite, hek exittion iruit for loose or irty onnetions or mge wiring. 4. If reing is etween.75 n 1.1 volts, rotor fiel iruit proly is shorte or groune. Disssemle lterntor n test rotor s outline uner Alterntor Repir, following. 5. If reing is etween 6.0 n 7.0 volts, rotor fiel iruit proly is open. Remove regultor n inspet for worn rushes or irty slip rings. Reple rushes if less thn 1/4 in. (6 mm) long. If rushes n slip rings re in goo onition, isssemle n perform rotor test s outline uner Component Testing - Rotor following. TEST 1 TEST 2 - Output Wire - ORANGE - Exittion Wire - PURPLE - Sensing Wire - RED/PURPLE - Voltmeter (0-20 Volts) e - Groun 72784 e EXCITATION CIRCUIT 1. Connet positive (+) voltmeter le to tie strp terminl on lterntor n negtive ( ) le to groun terminl on lterntor (Test 1). 2. Turn ignition swith to ON position n note voltmeter reing. Reing shoul e 1.3 to 2.5 volts. 3. If no reing is otine, n opening exists in lterntor exittion le or in exittion iruit of regultor. Unplug PURPLE le from regultor. Connet positive voltmeter le to PURPLE le n negtive voltmeter les to groun (Test 2). - Exittion Wire - PURPLE - Sensing Wire - RED/PURPLE - Tie Br - Voltmeter (0-20 Volts) e - Groun SENSING CIRCUIT 72785 1. Unplug RED/PURPLE le from voltge regultor. 90-823224--2 796 CHARGING SYSTEM - 4C-5
2. Connet positive (+) voltmeter le to re/purple le n negtive ( ) voltmeter le to groun terminl. 3. Voltmeter shoul inite ttery voltge. If ttery voltge is not present, hek sensing iruit (re/purple le) for loose or irty onnetion or mge wiring. e 4. Remove oil wire from istriutor p tower n groun it to lok. Turn on ll essories n rnk engine over with strter motor for 15-20 seons. 5. Turn off essories n reinstll oil wire. Strt engine n just engine spee to 1500-2000 RPM. Quikly oserve mmeter. Reing shoul e t lest 30 mps. 6. If reing is low, stop engine n onnet jumper wire etween lterntor output terminl n regultor terminl. Repet Steps 4 n 5. 7. If reing is now within speifitions, ioes re fulty. Disssemle lterntor n reple retifier s expline uner Alterntor Repir, following, to etermine if fult is in regultor or lterntor. 8. If reing is still low with jumper wire onnete, perform Voltge Output Test, following, to etermine if fult is in regultor or lterntor. 72786 - Output Wire - ORANGE - Exittion Wire - PURPLE - Sensing Wire - RED/PURPLE - Voltmeter (0-20 Volts) e - Groun e Current Output Test Perform this test to hek if lterntor is ple of prouing rte urrent output, using 0-50 mp DC mmeter.! WARNING Be sure tht engine omprtment is well-ventilte n tht there re no gsoline vpors present (uring the test) to prevent the possiility of n explosion n/or fire, shoul sprk our. 1. Disonnet negtive ( ) ttery le from ttery. 2. Disonnet ornge le from lterntor output terminl n onnet mmeter in series etween le n output terminl. Connet positive (+) sie of mmeter towr output terminl. 3. Reonnet negtive ttery le. - Output Wire - ORANGE - Ammeter (0-50 Amps) - Jumper Le - Regultor Le e - Groun Voltge Output Test 72787 Perform this test to etermine if voltge regultor is operting orretly, using 0-20 volt DC voltmeter. IMPORTANT: Bttery MUST BE fully hrge (1.260 or ove speifi grvity) to otin proper voltge reing in this test. If neessry, hrge ttery with ttery hrger or llow engine to run suffiient length of time to fully hrge ttery efore tking reing. 4C-6 - CHARGING SYSTEM 90-823224--2 796
1. Connet positive (+) voltmeter le to positive ttery terminl n negtive ( ) voltmeter le to negtive terminl. 2. Strt engine n run t fst ile until engine rehes norml operting temperture. Ajust engine spee to 1500-2000 RPM n oserve voltmeter for highest reing. Reing shoul e etween 13.9 n 14.7 volts. 3. If reing is high, hek for loose or irty regultor groun le onnetion. If onnetion is goo (n sensing iruit heke out goo in Ciruitry Test ), voltge regultor is fulty n must e reple. Be sure to isonnet ttery les efore ttempting to remove regultor. e 4. Remove four nuts holing exittion n sensing wires n Phillips srew. Remove regultor over n instll wires n nuts for testing. Connet jumper wire from the groun stu to the rush terminl on the lower right- hn sie of the rush ssemly. Restrt engine n grully inrese engine spee to 1500 RPM while oserving voltmeter. DO NOT llow voltge to exee 16 volts. 5. If voltmeter reing of 14.5 volts or ove is now otine, voltge regultor is fulty n must e reple. If voltmeter reing is elow 14.5 volts, inspet rushes n slip rings for wer, irt or mge. If rushes n slip rings re goo, lterntor is fulty internlly. Disssemle lterntor n test omponents, s outline uner Alterntor Repir, following. - Output Wire - ORANGE - Exittion Wire - PURPLE - Sensing Wire - RED/PURPLE - Voltmeter (0-20 Volts) e - Groun! WARNING 72788 Be sure tht engine omprtment is well-ventilte n tht there re no gsoline vpors present (uring the next steps) to prevent the possiility of n explosion n/or fire, shoul sprk our.! CAUTION DO NOT llow tie jumper wire to ontt lterntor en frme (in next step), s retifier n ioe ssemly my e mge. - Groun - Brush / Regultor Assemly - Brush Terminl - Jumper Wire (Soler Connetion Groun) Alterntor Repir Removl 72971 1. Disonnet negtive ( ) ttery le from ttery. 2. Disonnet wiring hrness from lterntor. 3. Remove lterntor re-to-lterntor tthing olt, wsher(s) n sper (if use). 4. Loosen lterntor re-to-engine tthing olt n lterntor mounting olt, then pivot lterntor inwr n remove lterntor rive elt. 5. Remove lterntor mounting olt, wshers (if use), sper n nut, n remove lterntor. 90-823224--2 796 CHARGING SYSTEM - 4C-7
Exploe View 22 21 20 19 25 24 29 28 27 26 23 2 6 3 1 2 4 12 10 10 2 13 9 3 8 2 5 18 17 16 15 14 3 1 10 7 2 13 11 72276 4C-8 - CHARGING SYSTEM 90-823224--2 796
1 - Srews (3) 2 - Nut (9) 3 - Flt Wsher (4) 4 - Sensing Wire (RED / PURPLE) 5 - Exittion Wire (PURPLE) 6 - Cover 7 - Tie Strp 8 - Ruer Gsket 9 - Conenser 10- Insultor 11- Bolt (4) 12 -En Frme (Rer) 13 -Cp (2) 14- Brush / Regultor Assemly 15- Retifier Assemly 16- Flt Wsher 17- Srew 18- Sttor 19- Rotor An Slip Ring 20- Retining Plte 21- Front Bering 22- En Frme (Front) 23- Srew (3) 24- Fn Sper 25- Fn 26- Pulley Sper 27- Pulley 28- Lokwsher 29- Nut Disssemly IMPORTANT: The following instrutions re for omplete isssemly n overhul of the lterntor. In mny ses, however, omplete isssemly of lterntor is not require n, in those ses, it is neessry only to perform the opertions require to repir or reple the fulty prt. 1. Mount lterntor in vise so tht rer en frme is fing you. 2. Disonnet regultor les from terminls on rer en frme. Remove four nuts, Phillips he srew n two regultor les. Then pull regultor over wy from rer en frme. 72963 - Regultor Les - Nuts (4) - Phillips He Srew - Regultor Cover 3. Remove stu over insultor, two nuts n tie strp from rush/regultor ssemly. 90-823224--2 796 CHARGING SYSTEM - 4C-9
4. Remove two rush/regultor tthing srews n remove rush/regultor ssemly. 7. Seprte rer en frme n sttor ssemly from front en frme n rotor ssemly using two thin le srewrivers (positione 180 egrees prt from one nother) t the lotions shown. Use the two slots shown to initilly seprte units. e 72823 - Srews - Brush / Regultor Assemly - Stu Cover Insultor - Tie Strp 5. Srie mrk on rer en frme, sttor n front en frme to ensure proper ressemly lter. 6. Remove four srews whih seure en frmes n sttor together. IMPORTANT: DO NOT insert srewriver les more thn 1/16 in. (1.5 mm) into openings (in next step), s sttor winings my e mge. - DO NOT Insert Srewriver Bles More Thn 1/16 In. (1.5 mm) Into Slots. - Rer En Frme - Sttor - Front En Frme e - Srie Mrks 72824 8. Ple rer en frme n sttor ssemly on the enh with sttor ownwr. Be sure tht enh is len n free of metl hips. Remove nuts, wshers, insultors n onenser from output n groun stus. 4C-10 - CHARGING SYSTEM 90-823224--2 796
9. Turn en frme over (sttor upwr) n remove one Phillips he srew whih seures retifiers to en frme. IMPORTANT: With lterntor isssemle to this point, sttor, retifier, ioes, n rotor my e teste, s expline uner Component Testing, following. IMPORTANT: DO NOT lmp vise on rotor pole piees when removing pulley nut (in next step), s pole piees my e istorte. 12. Remove pulley retining nut y lmping pulley in vise (using n oversize V-elt or protetive jws to protet pulley) n turning nut ounterlokwise with wrenh. Remove lokwsher n slie pulley n fn from shft. If pulley is iffiult to remove, it my e neessry to use universl puller. 72826 - Retifier Assemly - Phillips He Srew 10. Seprte sttor n retifier ssemly from rer en frme using srewriver slots. 11. Unsoler the three sttor les from the retifier het sink. Ple neele nose pliers on ioe terminl etween soler joint n ioe oy to help prevent het mge to ioes. Unsoler joints s quikly s possile n llow ioe terminl to ool efore removing pliers. - Wrenh - Over-Size Belt To Protet Pulley 72828 - Het Sink - Sttor Les (3) 72827 90-823224--2 796 CHARGING SYSTEM - 4C-11
13. Remove the three phillips he srews n lokwshers whih seure the front ering retining plte. - Phillips He Srews n Lokwshers - Front Bering Retining Plte 72829 14. Remove front ering from front en frme using n ror press n suitle size mnrel. (Disr ering.) Removing Front Bering from Front En Frme 72830 15. If rotor slip rings or rer ering requires replement, entire rotor must e reple. Prts nnot e purhse seprtely. Clening n Inspetion 1. Clen ll prts with len, soft loth. DO NOT use solvent, or eletril omponents my e mge. 2. Inspet the following prts for wer n mge:. Brush/regultor ssemly - inspet for rke sing, mge rush les, poor rush le soler onnetions, wek or roken rush springs or worn rushes. Reple rush set if rushes re less thn 1/4 in. (6 mm) long.. Rotor - inspet for strippe thres, suffe pole piee fingers or mge ering surfes (euse of ering turning on shft).. Rotor-slip rings - len slip rings with 400 grin (or finer) polishing loth while spinning rotor in lthe. Blow off ust with ompresse ir. Inspet slip rings for grooves, pits, flt spots or out-of-roun [.002 in. (0.051 mm) mximum] n reple rotor, if present.. Rotor shft n front en erings - inspet for mge sels, lk of lurition, isolortion (from overheting) n exessive sie or en ply. Bering shoul turn freely without ining or eviene of rough spots. e. Sttor - inspet for mge insultion or wires; lso inspet insulting enmel for het isolortion, s this is usully sign of shorte or groune wining or shorte ioe. f. Front n rer en frmes - inspet for rks, istortion, strippe thres or wer in ering ore (from ering outer re spinning in ore). En frme(s) MUST BE reple, if ering hs spun. Also, inspet ering retiner reess in front en frme for mge. g. Fn - inspet for rke or ent fins, roken wels (i-rottionl fn only) or worn mounting hole (from fn spinning on shft). h. Pulley - inspet pulley mounting ore en for wer. Inspet rive surfe of pulley sheves for trueness, exessive wer, grooves, pits, niks n orrosion. Repir mge surfes, if possile, with fine file n wire rush or reple pulley, if eyon repir. Drive surfes MUST BE perfetly true n smooth or rive elt wer will e gretly elerte. 4C-12 - CHARGING SYSTEM 90-823224--2 796
Component Testing ROTOR 1. Test rotor fiel iruit for opens, shorts or high resistne (Test 1), using n ohmmeter (set on R x1 sle), s follows: TEST 1 TEST 2. If reing is low, short exists in the fiel iruit. Inspet slip rings to e sure tht they re not ent n touhing outer slip ring. Also, e sure tht exess soler is not shorting terminls to ft slip ring. If use for short nnot e foun, unsoler fiel wining les from slip ring terminls n onnet ohmmeter iretly to les. If orret reing is now otine, or if reing is still low, slip rings n rotor fiel winings re shorte, n omplete rotor ssemly must e reple. Testing Rotor Fiel Ciruit 72831. Connet one ohmmeter le to eh slip ring.. Ohmmeter reing shoul e 4.2 to 5.5 ohms with rotor t room temperture 70-80 F (21-26 C).. If reing is high or infinite (no meter movement), high resistne or n open exists in the fiel iruit. Chek for poor onnetions etween fiel wining les n slip ring terminls. If use for open or high resistne nnot e foun, onnet ohmmeter iretly to slip ring terminls. If orret reing is now otine, or if reing is still high or infinite, reple omplete rotor ssemly. - Fiel Wining Les - Slip Rings - Rotor Shft - Pole Piees 73112 2. Test rotor fiel iruit for grouns (Test 2), using n ohmmeter (set on R x1 sle) s follows:. Connet one le of ohmmeter to either slip ring n the other le to rotor shft or pole piees.. Meter shoul inite no ontinuity (meter shoul not move).. If ontinuity oes exist, omplete rotor ssemly must e reple. IMPORTANT: If lterntor hs output t low spees, ut no output t high spees, rotor fiel wining my e shorting or grouning out, ue to entrifugl fore. Reple rotor if ll other eletril omponents test goo. 90-823224--2 796 CHARGING SYSTEM - 4C-13
STATOR IMPORTANT: Sttor les MUST BE isonnete from retifier for this test. 1. Test sttor for grouns (Test 1), using n ohmmeter (set on R x1 sle) s follows:. Connet one le of ohmmeter to one of the sttor les n the other le to sttor frme. Be sure tht le mkes goo ontt with frme.. Meter shoul inite no ontinuity (meter shoul not move). If ontinuity oes exist, sttor is groune n must e reple. 2. Test for opens in sttor (Test 2), using n ohmmeter (set on R x1 sle) s follows:. Connet ohmmeter etween eh pir of sttor winings (three ifferent wys).. Continuity shoul e present in ll three ses (meter shoul move). If it oes not, one or more of the winings re open n sttor must e reple. TEST 1 TEST 2 TEST 2 TEST 2 RECTIFIER AND DIODE ASSEMBLY NOTE: Filure of ny omponent in tests following will require replement of entire retifier ssemly. NEGATIVE ( ) RECTIFIER IMPORTANT: Retifier MUST BE isonnete from sttor for this test.! CAUTION DO NOT use test instrument with more thn 12 volt soure (in the following test), s retifier my e mge. 1. Connet one le of n ohmmeter (set on R x1 sle) to negtive ( ) retifier het sink n the other le to one of the retifier terminls. Note the reing. 2. Reverse les n gin note reing. 3. Meter shoul inite high or infinite resistne (no meter movement) when onnete one wy n low reing when onnete the other. If oth reings re high or infinite, retifier is open. If oth reings re low, retifier is shorte. 4. Repet Steps 1 through 3 for two other retifiers in het sink. 5. Reple ssemly if ny of the retifiers is shorte or open. Testing Sttor 72833 3. A short in the sttor is iffiult to etet without speil equipment, euse of the low winings resistne. If ll other eletril omponents test out goo, n lterntor fils to proue rte output, sttor proly is shorte n shoul e reple. Also, exmine sttor for het isolortion, s this usully is sure sign of short. - Het Sink - Retifier Terminl - Test These Two Retifiers In The Sme Mnner 72147 4C-14 - CHARGING SYSTEM 90-823224--2 796
POSITIVE (+) RECTIFIER AND DIODES! CAUTION DO NOT use test instrument with more thn 12 volt soure (in the following test), s retifier my e mge. 1. Connet one le of n ohmmeter (set on R x1 sle) to 1/4 in. stu on positive (+) retifier het sink n the other le to one of the retifier terminls. Note the meter reing. 2. Reverse les n gin note reing. 3. Meter shoul inite high or infinite resistne (no meter movement) when onnete one wy n low reing when onnete the other. If oth reings re high or infinite, retifier is open. If oth reings re low, retifier is shorte. 4. Repet Steps 1 through 3 for two other retifiers in het sink. 6. Connet one le of n ohmmeter (set on R x1) to the ommon sie of the ioe n the other le to the other sie, of one of the three ioes. - Common Sie Of Dioe Ciruit Bor - Repet Test For Two Dioes 72148 - Stu - Retifier Terminl - Repet Test Between These Terminls An Stu 72834 5. Reple ssemly if ny one of the retifiers is shorte or open. 7. Reverse les n gin note reing. 8. Meter shoul inite high or infinite resistne (no meter movement) when onnete one wy n low reing when onnete the other. If oth reings re high or infinite, ioe is open. If oth reings re low, ioe is shorte. 9. Repet Steps 6 through 8 for the other two ioes. 10. Reple retifier ssemly if ny one of the ioes is shorte or open. CONDENSER 1. Using mgneto nlyzer n ompnying instrutions, perform the following onenser tests:. Conenser Cpity Test (must e.5 mf).. Conenser Short or Lekge Test.. Conenser Series Resistne Test. 2. Reple onenser if test results re not within speifitions. 90-823224--2 796 CHARGING SYSTEM - 4C-15
Ressemly 1. Instll new front ering into front en frme ering ore using n ror press. If neessry, use ering river tht ontts outer re only. 3. Slie front en frme over rotor. IMPORTANT: DO NOT lmp vise on rotor pole piees when tightening pulley nut (in next step), or pole piees my e istorte. 4. Slie fn sper onto rotor shft. Instll fn, pulley, lokwsher n nut on shft. Clmp pulley in vise, using protetive jws or n ol oversize V-elt to protet pulley, n torque nut to speifitions. Tighten vise only enough to llow tightening of nut, s exessive tightening my istort pulley. 5. Assemle sttor to retifier y solering the three les to the three retifier terminls. 72835 Instlling Front Bering into Front En Frme 2. Instll front ering retining plte using three Phillips he srews n lokwshers. 72826 - Sttor Le Connetions - Philips He Srews An Lokwshers - Front Bering Retining Plte 72829 NOTE: Be sure to onnet les to their originl positions. 6. Instll ssemle sttor n retifier ssemly into rer en frme, ligning srie mrks on eh (srie uring isssemly), n instll Phillips he srew n wsher to retin. IMPORTANT: The insulting wshers MUST BE instlle s shown or mge to the lterntor will result. 4C-16 - CHARGING SYSTEM 90-823224--2 796
7. Position sttor own with rer en frme up n reinstll insultors, nuts n onenser. 9. Depress rushes flush with top of rush holer n insert #54,.050 in. rill it or smller into hole in rush holer to hol rushes ompresse uring ressemly. 72561 - Insultors (3) - Nuts (5) - ONE REMOVED - Conenser 72836 8. Position rer en frme n sttor ssemly over front en frme n rotor ssemly n lign srie mrks on eh (srie uring isssemly). Hn-press en frmes together, then instll four srews. Tighten srews seurely. - Drill Bit NOTE: Ruer gsket shown remove for lrity. 10. Instll rush/regultor ssemly in rer en frme vity n seure with two mounting srews, s shown. Tighten srews seurely. Remove rill it to relese rushes ginst slip rings. e 72561 - Rer En Frme - Sttor - Front En Frme - Srie Mrks e - Insert Srews (4) (Two Hien) 72837 - Brush / Regultor Assemly - Mounting Srews 90-823224--2 796 CHARGING SYSTEM - 4C-17
11. Instll tie strp to retifier stu n stu on rush/ retifier ssemly. Tighten nuts seurely. 13. Instll insultor ps. 72078 - Stus - Tie Strps 72823 12. Instll over with one phillips he srew n two nuts. Instll two les with nuts. - Insultor Cps Instlltion 1. Position lterntor in mounting rket n instll mounting olt, wshers (if use), sper n nut. Ple wshers (if use), on eh sie of sper. DO NOT tighten seurely t this time. 2. Fsten lterntor re to lterntor with olt, wshers n sper (if use). DO NOT tighten olt t this time. 3. Position lterntor rive elt on pulleys n just tension s expline uner Drive Belt Tension Ajustment. 4. Reonnet wiring hrness to lterntor n negtive ttery le to ttery. 72963 - Phillips He Srew - Nuts (4) - Les 72838 - Exittion Le -(PURPLE) - Sensing Le - (RED / PURLPE) - Groun Le - (BLACK) - Output Le - (ORANGE) 4C-18 - CHARGING SYSTEM 90-823224--2 796
Prestolite 65 Amp Alterntor Replement Prts Wrning! WARNING Eletril, ignition n fuel system omponents on your MerCruiser re esigne n mnufture to omply with U.S. Cost Gur Rules n Regultions to minimize risks of fire n explosion. Use of replement eletril, ignition or fuel system omponents, whih o not omply with these rules n regultions, oul result in fire or explosion hzr n shoul e voie. Speifitions Desription Exittion Ciruit Current Output Voltge Output Conenser Cpity Minimum Brush Length Tools/Selnts Speifition 1.5 to 3.0 Volts 51 Amp. Min. 13.8 to 14.8 Volts.5 MFD 3/16 in. (5 mm) Desription Prt Numer Mgneto Anlyzer 91-76032 Universl Puller Plte 91-37241 Multi-Meter / DVA Tester 91-99750 Quiksilver Liqui Neoprene 92-27511--2 Ammeter (0-50 Amp.) Otin Lolly Torque Speifitions Fstener Lotion In. L. Ft. L. N m Housinhg Srews 55 5.6 Pulley Nut 35-50 48-68 Front Bering Srews 30 2.8 Alterntor Mount 35 48 Ajustment Bolt 16 28 V-Belt Tension (Note) Depress 1/4 in. (13mm) Desription The lterntor hs rotor, whih is supporte in two en frmes y ll erings, n is riven y pulley t pproximtely twie engine spee. The rotor ontins fiel wining tht is enlose etween two multiple-finger pole piees. The ens of the fiel wining re onnete to two rushes (mounte in the rer en frme) whih mke ontinuous sliing (or slipping) ontt with the slip rings. The urrent (flowing through the fiel wining) retes mgneti fiel tht uses the jent fingers of the pole piees to eome lternte north n south mgneti poles. A 3-phse sttor is mounte iretly over the rotor pole piees n etween two en frmes. It onsists of three winings woun 120 egrees eletrilly out-of-phse on the insie of lminte ore. The winings re ll onnete together on one en, while the other ens re onnete to full-wve retifier rige. The retifier rige ontins six retifiers whih re rrnge so tht urrent flows from groun, through the sttor n to the output terminl, ut not in the opposite iretion. When urrent is supplie to the rotor fiel wining, n the rotor is turne, the movement of the mgneti fiels rete inues n lternting urrent into the sttor winings. The retifier rige then hnges this lternting urrent to iret urrent whih ppers t the output terminl. A ioe trio lso is onnete to the sttor winings to supply urrent to the regultor n the rotor fiel uring opertion. Voltge output of the lterntor is ontrolle y regulting the urrent supplie to the rotor fiel. This is omplishe y trnsistorize voltge regultor tht senses the voltge t the ttery n regultes the fiel urrent to mintin lterntor voltge within presrie limits for properly hrging the ttery. Cur- 90-823224--2 796 CHARGING SYSTEM - 4C-19
rent output of the lterntor oes not require regultion, s mximum urrent output is self-limite y the esign of the lterntor. As long s the voltge is regulte within the presrie limits, the lterntor nnot proue exessive urrent. A ut-out rely in the voltge regultor lso is not require, s the retifier ioes (whih llow urrent to flow in one iretion only) prevent the ttery from ishrging k through the sttor. Due to the lk of resiul mgnetism in the rotor pole piees, smll mount of urrent must e supplie to the rotor fiel to initilly strt the lterntor hrging. This is omplishe y mens of n exittion iruit in the regultor whih is onnete to the ignition swith. One the lterntor egins to proue output, fiel urrent is supplie solely y the ioe trio, s expline, preeing. The lterntor lso is equippe with fn (mounte on the rotor shft) whih inues ir flow through the lterntor to remove the het rete y the retifiers n sttor. A pitor protets the retifier system from high voltges n suppresses rio noise. Preutions The following preutions MUST BE oserve when working on the lterntor system. Filure to oserve these preutions my result in serious mge to the lterntor or lterntor system. 1. DO NOT ttempt to polrize the lterntor. 2. DO NOT short ross or groun ny of the terminls on the lterntor, exept s speifilly instrute in the Trouleshooting Tests. 3. NEVER isonnet the lterntor output le or ttery les when the lterntor is eing riven y the engine. 4. NEVER isonnet regultor le from lterntor regultor terminl when the lterntor is eing riven y the engine. 5. ALWAYS remove negtive ( ) ttery le from ttery efore working on lterntor system. 6. When instlling ttery, BE SURE to onnet the positive (+) ttery le to the positive (+) ttery terminl n the negtive ( ) (groune) ttery le to negtive ( ) ttery terminl. 7. If hrger or ooster ttery is to e use, BE SURE to onnet it in prllel with existing ttery (positive to positive; negtive to negtive). System Components The lterntor system onsists of the lterntor, ttery, the ignition swith n the wiring whih onnets these omponents. - Ingition Swith - Alterntor - Strter Motor - Groun Stu e - Bttery f - Ciruit Breker g - Hrness Plug h - Bttery Meter e h g f 73079 4C-20 - CHARGING SYSTEM 90-823224--2 796
Perioi Mintenne The following mintenne hek shoul e performe every 50 hours or 60 ys (whihever omes first) in fresh wter res or every 25 hours or 30 ys in slt wter res.! CAUTION Remove ll ttery les from ttery (efore onuting the following hek) to prevent ientlly shorting out eletril system. 1. Inspet entire lterntor system for orroe or loose onnetors. 2. Chek wiring for frye or worn insultion. 3. Chek lterntor rive elt for exessive wer, rks, frying n glze surfes. Also, hek rive elt tension n just, if neessry, s expline uner Drive Belt Tension Ajustment. 4. Chek lterntor mounting olts for equte tightness. 5. Inspet slip ring en frme flme rrestor sreen for eris n len, if neessry, using ompresse ir or loth. Sreen MUST BE len, or lterntor my overhet. Drive Belt Tension Ajustment V-Belt 1. Instll rive elt on pulleys n just tension s follows:. Pivot lterntor wy from engine, s require, until orret tension is otine s shown. Belt shoul epress 1/4 in. (6 mm). 72669 - Chek Point. After otining orret tension, seurely retighten lterntor re tthing olts n lterntor mounting olts. 90-823224--2 796 CHARGING SYSTEM - 4C-21
Trouleshooting Tests (Alterntor on Engine) Use the following tests in onjuntion with the Trouleshooting in Setion 1. Before proeeing with the tests, however, perform the following heks to eliminte possile prolem res. Also oserve Preutions, preeing, to prevent mge to lterntor system. 1. If prolem is n unerhrge ttery, hek to ensure tht unerhrge onition hs not een use y exessive essory urrent rw or y essories whih hve ientlly een left on. Also, hek tht unerhrge onition hs not een use y running engine t too low spee for extene perios of time. 2. Chek physil onition n stte of hrge of ttery, s outline in Bttery - Storge in Setion 4A. Bttery MUST BE t lest 75% (1.230 speifi grvity) of fully hrge to otin vli results in the following tests. If not, hrge ttery efore testing system. 3. Inspet entire lterntor system wiring for efets. Chek ll onnetions for tightness n lenliness, prtiulrly ttery le lmps n ttery terminls. 4. Chek lterntor rive elt for exessive wer, rks, frying n glze surfes n reple if neessry. Also, hek rive elt tension n just if neessry, s outline uner Drive Belt Tension Ajustment.! WARNING Be sure tht engine omprtment is well-ventilte n tht there re no gsoline vpors present (uring the test) to prevent the possiility of n explosion n/or fire, shoul sprk our. ALTERNATOR OUTPUT TEST 1. Connet positive (+) voltmeter le to lterntor output terminl (ornge wire) n negtive ( ) le to groun terminl on lterntor. With engine running out 1500 RPM n ll essories turne on, voltge shoul e etween 13.8-14.8. 2. If voltge output oes not fll within speifitions, lterntor shoul e teste for prole use n isssemle for repir. e Ciruitry Test Perform the following tests, using 0-20 volt DC voltmeter, to hek tht ll of the iruits etween the lterntor n the other omponents within the lterntor system re in goo onition. - Output Wire (ORANGE) - Exittion Wire (PURPLE) - Sensing Wire (RED / PURPLE) - Voltmeter e - Groun 73081 4C-22 - CHARGING SYSTEM 90-823224--2 796
HARNESS VOLTAGE TEST With ignition off, unplug re/purple wire n hek for ttery voltge t hrness wire. No voltge t hrness wire inites wiring hrness is open n shoul e repire or reple. 2. Connet jumper wire etween regultor n output terminl. Strt engine n run t ile. If hrging voltge (13.8-14.8 volts) is present t output terminl, the ioe-trio is proly efetive n lterntor shoul e remove for repir. e 73084 73082 - Output Wire (ORANGE) - Sensing Wire (RED / PURPLE) - Voltmeter (0-20 Volts) - Groun OPEN DIODE-TRIO TEST 1. With ignition on n engine not running, hek for ttery voltge t lterntor output terminl (Test 1) n 1.5 to 3.0 volts t regultor terminl (Test 2). - Regultor Terminl - Output Terminl - Groun - Jumper Le e - Voltmeter (0-20 Volts) CURRENT OUTPUT TEST Perform this test to hek if lterntor is ple of prouing rte urrent output, using 0-50 mp DC mmeter.! WARNING Be sure tht engine omprtment is well-ventilte n tht there re no gsoline vpors present (uring the test) to prevent the possiility of n explosion n/or fire, shoul sprk our. 1. Disonnet negtive ( ) ttery le from ttery. 2. Disonnet ornge le from lterntor output terminl n onnet mmeter in series etween le n output terminl. Connet positive (+) sie of mmeter towr output terminl. 3. Reonnet negtive ttery le. - Regultor Terminl - Output Terminl - Groun - Voltmeter (0-20 Volts) 73083 4. Remove oil high-tension le from istriutor p tower n groun it to lok. Turn on ll essories n rnk engine over with strter motor for 15-20 seons. 90-823224--2 796 CHARGING SYSTEM - 4C-23
5. Turn off essories n reinstll oil hi-tension le. Strt engine n just engine spee to 1500-2000 RPM. Quikly oserve mmeter. Reing shoul e t lest 30 mps. 6. If reing is low, stop engine n onnet jumper wire etween lterntor output terminl n regultor terminl. Repet Steps 4 n 5. 7. If reing is now within speifitions, ioes re fulty. Disssemle lterntor n reple retifier s expline uner Alterntor Repir, following, to etermine if fult is in regultor or lterntor. 8. If reing is still low with jumper wire onnete, perform Voltge Output Test, following, to etermine if fult is in regultor or lterntor. OPEN REGULATOR TEST IMPORTANT: This test requires removl of regultor.! CAUTION To prevent eletril system mge n/or sprks, isonnet ttery les t ttery. 1. Remove insultor p from regultor terminl. 2. With ignition swith on n engine not running, hek for ttery voltge t lterntor output terminl (Test 1) n regultor terminl (Test 2). e 73109 - Output Wire (ORANGE) - Ammeter (0-50 Amps.) - Jumper Le - Regultor Terminl e - Groun - Regultor Terminl - Output Terminl - Groun - Voltmeter (0-20 Volts) 73083 3. Remove the four srews whih seure the regultor to the lterntor. 4C-24 - CHARGING SYSTEM 90-823224--2 796
4. Connet jumper wire etween fiel terminl (green wire) n groun. If 1.5 to 3.0 volts re present t regultor terminl, regultor is efetive. If voltge is not present t regultor terminl, there is n open fiel iruit (rushes slip rings, et.). Remove lterntor for repir. Alterntor Repir! WARNING Be sure tht engine omprtment is well-ventilte n tht there re no gsoline vpors present to prevent the possiility of n explosion n/ or fire, shoul sprk our. Removl - Fiel Terminl (GREEN Wire) - Regultor Terminl - Groun - Voltmeter (0-20 Volts) 73086! CAUTION To prevent eletril system mge n/or sprks, isonnet ttery les t ttery. 1. Disonnet ttery les from ttery. 2. Disonnet wiring hrness from lterntor. 3. Remove lterntor elt. 4. Remove lterntor. NOTE: Felt gsket is shown remove for visul lrity. 90-823224--2 796 CHARGING SYSTEM - 4C-25
Exploe View 25 28 27 26 31 30 29 32 34 33 RED PURPLE 1 2 13 10 BLACK 4 GREEN 12 11 5 14 5 BROWN 7 4 4 3 22 15 17 5 24 16 6 9 8 9 8 19 18 20 21 23 73106 4C-26 - CHARGING SYSTEM 90-823224--2 796
1 - Regultor An Les 2 - Srews (4) 3 - Insultor Cp 4 - Nuts (6) 5 - Wshers (3) 6 - Conenser 7 - Insultor Wsher (2) 8 - Nuts (2) 9 - Isulting Wsher (2) 10- Felt Gsket 11 - Srews (2) 12- Brush Assemly 13- Srews (4) 14- Rer En Frme 15- Str Wshers (2) 16- Insultor 17- Insulting Wsher (2) 18- Nut 19- Wsher 20- Insulting Wsher 21- Insultor 22- Negtive Retifier 23- Positive Retifier / Dioe Trio 24- Sttor 25- Rotor n Slip Rings 26- Snp Ring 27- Bering 28- Front En Frme 29- Fn Bushing 30- Wooruff key 31- Fn 32- Pulley 33- Lokwsher 34- Nut Disssemly 1. Using n oversize V-elt to protet the pulley, lmp lterntor in vise s shown. Remove pulley nut n lokwsher. - Wrenh - Oversize V-Belt To Protet Pulley 72828 2. Remove pulley, fn, wooruff key n sper. e f g - Nut - Lokwsher - Pulley - Wooruff Key e - Fn f - Sper g - Alterntor 73087 90-823224--2 796 CHARGING SYSTEM - 4C-27
3. Disonnet regultor les from terminls on rer en frme. Remove four regultor tthing srews, then pull regultor wy from rer en frme n isonnet fiel le. 6. Srie mrk on rer en frme, sttor n front en frme to ensure proper ressemly lter. 7. Remove the four srews whih seure en frmes n sttor together.! CAUTION Do not insert srewriver les eeper thn 1/16 in. (1.58 mm) to voi mging sttor winings. 8. Using suitle holing fixture, seprte front en frme n sttor ssemly from rer en frme using two thin le srewrivers (positione 180 egrees prt from eh other) t the lotions shown. 73088 - Regultor Les (2) - Srews (4) - Regultor 4. Remove rush holer. 73091 - Front En Frme - Sttor - Rer En Frme - Srie Mrks 9. While supporting front housing, use n ror press to remove rotor from front en frme. 73090 - Atthing Srews - Brush Holer 5. Note lotion of remining insulting wshers n nuts n remove. - Front Housing - Rotor Shft - Bering Driver 73092 4C-28 - CHARGING SYSTEM 90-823224--2 796
Clening n Inspetion 1. Clen ll prts with len, soft loth. Do not use solvent, or eletril omponents my e mge. 2. Inspet the following:. Brush Set - Inspet for rke porelin sing, mge rush les, poor rush springs or worn rushes. Reple rush set if rushes re less thn 3/16 in (5 mm) long.. Rotor - Inspet for strippe thres, suffe pole piee fingers or mge ering surfes (euse of ering turning on shft).. Rotor Slip Rings - Clen slip rings with 400 grin (or finer) polishing loth. Blow off ust with ompresse ir. Inspet slip rings for grooves, pits, flt spots or out-of-roun [.002 in. (.05 mm) mximum]. Reple if efetive.. Rotor Shft Berings - Inspet for mge sels, lk of lurition, isolortion (from overheting) or exessive sie or en ply. Hol inner re of erings while turning outer re. Bering shoul turn freely without ining or eviene of rough spots. e. Sttor - Inspet for mge insultion or wires; lso inspet insulting enmel for het isolortion, s this is usully sign of shorte or groune wining or shorte ioe. f. Regultor - Inspet les for mge insultion. g. Front n Rer Housings - Inspet for rks, istortion, strippe thres or wer in ering ore (from ering outer re spinning in ore). Reple if efetive. h. Fn - Inspet for rke or ent fins, roken wels or worn mounting hole (from fn spinning on shft). i. Pulley - Inspet pulley mounting ore n for wer. Inspet rive surfe of pulley sheves for trueness, exessive wer, or orrosion. Repir mge surfes, if possile, with fine file n wire rush, or reple pulley. Drive surfes must e true n smooth, or rive elt wer will e gretly elerte. j. Alterntor - If lterntor hs output t low spees, ut no output t high spees, rotor fiel wining my e shorting or grouning out euse of entrifugl fore. Reple rotor, if ll other eletril omponents test goo. Front Bering Removl 1. Remove snp ring. 2. Use n ror press to remove ering from housing. - Front Housing - Bering Driver - Bering Instlltion 73093 1. Using n ror press, press on outer re of new ering until fully sete in housing. 2. Instll snp ring to retin ering. 73094 90-823224--2 796 CHARGING SYSTEM - 4C-29
Slip Rings/Rer Bering Removl 1. Unsoler wires n refully unwin them from slip ring terminls. IMPORTANT: Do not mge rotor wires when removing slip rings or ering. 2. Instll universl puller plte etween ering n slip rings. Insert 10 x 1 in. psrew into opening of slip ring ssemly. Instlltion 1. Press new rer ering ll the wy onto rotor shft (until inner re ontts shouler) with n ror press n ering river tht ontts inner ering re only, s shown. Use extreme re to prevent mge to fiel wining les. IMPORTANT: Be sure to support rotor on en of shft n not on pole piees, s pole piees re only press-fit onto shft. 73096 - Univerl Plte Puller - Cpsrew - Slip Rings 73095 - Aror Press - Bering Driver - Bering - Rotor 2. Insert wires through hole in slip rings s shown. 3. Using n ror press, push ginst psrew to remove slip rings. 4. Instll universl puller plte uner ering. 5. Using n ror press, remove ering. 73097 4C-30 - CHARGING SYSTEM 90-823224--2 796
IMPORTANT: Press on the enter of slip rings only. Do not en terminls or pinh wires. 3. Using n ror press, instll slip rings. Press on enter of slip rings until they ontt shouler of rotor. 4. Crefully wrp white wire roun outer slip ring terminl, n lue wire roun inner slip ring terminl. Soler wires in ple.. If ontinuity oes exist, rotor fiel iruit is groune. Inspet slip ring terminls to e sure tht they re not ent n touhing rotor shft. Also e sure tht exess soler is not grouning terminls to rotor shft. If use for groun nnot e foun, unsoler fiel wining les from slip ring terminls n onnet ohmmeter etween one of the les n rotor shft or pole piees. If ontinuity still exists, reple rotor ssemly. If ontinuity is eliminte, reple slip rings. - WHITE Wire - BLUE Wire Component Testing 73098 Rotor 1. Test rotor fiel iruit for grouns, using n ohmmeter (set on Rx1 sle) s follows:. Connet one le of ohmmeter to either slip ring n the other le to rotor shft or pole piees.. Meter shoul inite no ontinuity (meter shoul not move). - Slip Rings - Ohmmeter With Les - Pole Piees 73099 2. Test rotor fiel iruit for opens, shorts or high resistne, using n ohmmeter (set on Rx1 sle) s follows:. Connet one ohmmeter le to eh slip ring.. Ohmmeter reing shoul e 4.1 to 4.7 ohms with rotor t room temperture [70-80 F (21-26 C)]. 90-823224--2 796 CHARGING SYSTEM - 4C-31
. If reing is high or infinite (no meter movement), high resistne or n open exists in the fiel iruit. Chek for poor onnetions etween fiel wining les n slip ring terminls. If use for open or high resistne nnot e foun, onnet ohmmeter iretly to slip ring terminls. If orret reing is now otine, reple slip rings. If reing is still high or infinite, reple omplete rotor ssemly.. If reing is low, short exists in the fiel iruit. Inspet slip rings to e sure tht they re not ent n touhing outer slip ring. Also e sure tht exess soler is not shorting terminls to ft slip ring. If use for short nnot e foun, unsoler fiel wining les from slip ring terminls n onnet ohmmeter iretly to les. If orret reing is now otine, slip rings re shorte n must e reple. If reing is still low, rotor fiel winings re shorte, n omplete rotor ssemly must e reple. Sttor IMPORTANT: Sttor les MUST BE isonnete from retifiers n ioe-trio for this test.! CAUTION Exessive het from e-solering my use mge to retifiers or ioe-trio ssemly when isonneting les. 1. Test sttor for grouns, using n ohmmeter (set on Rx1 sle) s follows:. Connet one le of ohmmeter or test lmp to one of the sttor les n the other le to sttor frme. Be sure tht le mkes goo ontt with frme.. Meter shoul inite no ontinuity (meter shoul not move). If ontinuity oes exist, sttor is groune n must e reple. 73101 73112 - Fiel Wining Les - Slip Rings - Rotor Shft - Pole Piees NOTE: It is neessry to test only three of the six les on EITHER sie of the sttor s the les re interonnete in the winings. 2. Test for opens in sttor, using n ohmmeter (set on Rx1 sle) s follows:. Connet ohmmeter or test lmp etween eh pir of sttor winings (3 ifferent wys).. Continuity shoul e present in ll three ses (meter shoul move). If it oes not, one or more of the winings re open n sttor must e reple. 4C-32 - CHARGING SYSTEM 90-823224--2 796