IDENTIFICATION S Six different alternator assemblies will be found on, Testing procedures of all alternators are the same. the electric start Lawn-Boy mower since 1975. The Output specifications will vary between early and first was introduced on the 8233AE models with the later models. D-600 series engines. PART 681362 NO. PART 681563 NO. PART 682529 NO. D-600 SERIES F-100 SERIES F-100 SERIES EARLY MODEL LATER MODEL RUBBER CONNECTOR PLUG PLASTIC CONNECTOR 1982 AND LATER 1975-76-77 PLUG 1978-79-80-81 PART NO. PART 683095 NO. PART 682719 NO. 683092 F-100 SERIES COMPLIANCE 1983 MODELS GRAY 1984 COLORED DELS) (LATE SUPERCEDES 682719 ITH 682529 SUPERCEDES CONNECTOR BLACK WHITE WITH 1981-82 NOTE See page 13-21 for information and specifications on alternators used on 1983 and later models. SERVICE REFERENCE MANUAL..13-19
TESTING TESTING PROCEDURES NOTE To check output of all alternators, a milliameter with a capacity of 500 M.A. (milliamps) is required for testing. 1. Before testing output of the alternators, check the air gap and readjust to.010 if necessary. SEE PAGE 13-21 FOR SPECIFICATIONS OF EACH. 2. To check output of the alternator accurately, it is necessary to run the enginebetween 3100 and 3300 R.P.M. Readjust the governor if necessary. 4. With the engine running disconnect the plug from the battery. Reverse the plugs and reconnect as shown. Attach meter leads. Be sure polarity is correct. 3. Before attaching milliameter leads start the engine. Run at high speed 3100-3300 R.P.M. NOTE With meter leads attached DO NOT STOP AND THEN RE-START ENGINE ELECTRICALLY. If the starter is activated irreparable damage to meter will occur. 4 BLACK WIRES TO MOWER To Battery \ MILLIAMETER 13-20..SERVICE REFERENCE MANUAL
5. Milliampere (M.A.) output specifications for each alternator is: TESTING D-600 Series Part No. 681362 F-100 Series (Early Models), Part No. 681653 F-100 Series (Late Models) Part No. 682529 Millimeter readings should be between: 70-120 M.A. 70-120 M.A. 200-450 M.A. Volt meter readings should be between: 1.2-1.5 volts 1.2-1.5 volts 140-160 volts F-100 Series 1983 Compliance Models 1984 Gray Colored (Late Models) Part No. 682719 Part No. 683092 Part No. 683095 Supercedes 682719 (Supercedes 682529) Connector Black With With White Connector Millimeter readings should be between: 200-450 M.A. 200-450 M.A. 200-450 M.A. Volt meter readings should be between: 18-32 volts 140-160 volts 18-32 volts 4 BLACK WURES 6. To voltage check output for the alternator proceed as follows. Start and run engine at 3200 RPM. TO MOWER 7. With engine running, disconnect wiring harness plug from battery. Connect leads from volt meter to plug connector as Be shown. sure METER polarity is correct. Refer to the voltage requirements listed above for each alternator. SERVICE REFERENCE MANUAL TO BATTERY CASE
TROUBLE SHOOTING THE PART NO. 681 362 CHARGING SYSTEM MODEL 8233AE, 8234AE & 8235AE D-600 SERIES DOES NOT TURN ENGINE: BATTERY DOWN RUN BATTERY VOLTAGE BELOW 10 VOLTS Alternator Not Charging Battery run down. The resistance on the pins of plug H should read LOW with V.O.M. leads in one direction and HIGH with leads reversed. (Meter on RX 1). This checks for bad diodes. A low resistance or high resistance in both directions indicates defective diodes. The output voltage of plug E with the engine running on: Normal (high) speed 1.2 to 1.5 Volts (Using a 20,000 ohms per volt meter) Ground Wire M Open or Loose Key Switch Defective Check resistance at plug E. With the self-propelled handle in neutral, and the key switch in the START position, and plugs G & H disconnected, the circuit reads: A GOOD CIRCUIT READS SHORTED A BADCIRCUITREADSHIGH RESISTANCE (METER ON RX 1) Key switch in the START position. A good switch reads SHORTED on terminals 2 & 3. A bad switch will read 1 or more ohms. (Meter on RX 1) Starter Motor Defective Check voltage at starter plug A when key switch is in START position. Voltage is to be above 10 volts. The resistance between the terminals on plug B should read approximately.3 ohms resistance for a good motor. (Meter on RX 1) Turn motor for lowest reading. Self-propelled Interlock When the self-propelled handle is in neutral, the interlock switch should be Switch Open closed. A good switch reads SHORTED on the pins of plug D. (Meter on RX 1) Short Circuit Battery run down. The resistance on pins of plug E (with all other plugs connected, self-propelled in neutral, and, key switch in off position) should read as follows: With volt-ohmeter on RX 1 the low reading will be between 15 ohms and 20 ohms. With the volt-ohmeter on its highest setting, the high reading will be MEG ohms. -- - Alternator Diodes Battery run down. Disconnect plugs A, C and J. Connect a 20,000 Leaking ohms per volt volt meter as follows: Use 15 volt D.C. scale (Min.). Disconnect plug E. Reconnect plug E so that the male pin of plug E and the female of plug F are not connected. Connect the positive lead of the volt meter to the male pin of plug E. Connect the negative lead of the volt meter to the female of plug F. The meter should read zero. A reading of more than one volt indicates excessive leakage which could run the. battery down during storage. ENGINESTOPSWHEN IS IN RUN POSITION: Key Switch Defective Key in RUN position, the resistance between terminals 1 & 2 on plug K reads less than 1 MEG ohm. ENGINE DOES NOT STOP IN KEY IN OFF POSITION: Key Switch Defective Key on OFF position, the resistance between terminals 1 & 2 on plug K reads INFINITE resistance. (Meter on RX 100) Ground Lead M Open Check terminal 2 on plug J to engine. If the resistance reads INFINITE at Ground ground the is bad. (Meter on RX 100) Connection at L Open Lead disconnected. 13.22..SERVICE REFERENCE MANUAL
ELECTRIC START SERVICING D-600 SERIES WIRING DIAGRAM NICKEL CADMIUM BATTERY FIGURE KEY IN OFF POSITION FIGURE 2 KEY IN START POSITION ST IGNITION A SERVICE REFERENCE FIGURE 3 KEY IN "RUN" POSITION MANUAL 13-23
-I-- TROUBLE SHOOTING THE EARLY MODEL F-lo0 SERIES CHARGING SYSTEM PART NO. 681653 DOESNOTTURNENGINE: BATTERY RUN DOWN Alternator or Charger Not Charging Ground Wire M Open or Loose Key Switch Defective Starter Motor Defective Self-propelled Interlock Switch Open Short Circuit Alternator Diodes Leaking REFER TO BATTERY TEST PROCEDURES Battery run down. The resistance on the pins of plug H should read LOW with V.O.M. leads in one direction and HIGH with leads reversed. (Meter on RX 1). This checks for bad diodes. A low resistance or high resistance in both directions indicates defective diodes. The output voltage of plug E with the engine running on: High speed 1.2 to 1.5 Volts (Using a 20,000 ohms per volt meter) Check resistance at plug E. With the self-propelled handle in neutral, and the key switch in the START position, and plugs G & H disconnected, the circuit reads: A GOODCIRCUITREADSSHORTED A BAD CIRCUITREADSHIGH RESISTANCE (METER ON RX 1) Key switch in the START position. A good switch reads SHORTED on terminals 2 & 3. A bad switch will read 1 or more ohms. (Meter on RX 1) Check voltage at starter plug A when key switch is in START position. Voltage is to be above 10 volts. The resistance between the terminals on plug B should read approximately.3 ohms resistance for a good motor. (Meter on RX motor 1) Turn for lowest reading. When the self-propelled handle is in neutral, the interlock switch should be closed. A good switch reads SHORTED on the pins of plug D. (Meter on RX 1) - - Battery run down. The resistance on pins of plug E (with all other plugs connected, self-propelled in neutral, and key switch in off position) should read as follows: With volt-ohmeter on RX 1 the low reading will be between 15 ohms and 20 ohms. With the volt-ohmeter on its highest setting, the high reading will be MEG ohms. Battery run down. Disconnect plugs A, C and J. Connect a 20,000 ohms per voltvolt meter as follows: Use 15 volt D.C. scale (Min.). Disconnect plug E. Reconnect plug E so that the male pin of plug E and the female of plug F are not connected. Connect the positive lead of the volt meter to the male pin of plug E. Connect the negative lead of the volt meter to the female (-) of plug F. The meter should read zero. A reading of more than one volt indicates excessive leakage which could run the. battery down during storage. ENGINESTOPSWHENKEYISIN RUN POSITION: Key Switch Defective Key in RUN position, the resistance between terminals 1 & 2 on plug K reads less than 1 MEG ohm. ENGINE DOES NOT STOP WITH KEY IN OFF POSITION: Key Switch Defective Ground Lead M Open at Ground Connection at L Open Check terminal 2 on plug J to engine. If the resistance reads the ground is bad. (Meter on RX 100) Lead disconnected. _I. Key in OFF position, the resistance between terminals 1 & 2 on plug K reads less than 1 MEG ohm. INFINITE 13-24 ;SERVICE REFERENCE MANUAL
WIRING DIAGRAM F-100 SERIES (EARLY MODELS) (USING 681653 ) (LOW OUTPUT) IGNITION FIGURE 1 KEY IN "OFF" POSITION FIGURE 2 KEY IN "STAR'T" POSITION RED-ELK FIGURE 3 KEY IN "RUN" POSITION SERVICE REFERENCE MANUAL 13-25
TROUBLE SHOOTING THE LATER MODEL F-100 SERIES HIGH OUTPUT CHARGING SYSTEM PART NO. 682529 DOES NOTTURN ENGINE: BATTERY RUN DOWN Alternator or Charger Not Charging REFER TO BATTERY TEST PROCEDURES Battery run down. The resistance on the pins of plug H should read LOW with V.O.M. leads in one direction and HIGH with leads reversed. (Meter on RX 1). This checks for bad diodes. A low resistance or high resistance in both directions indicates defective diodes. The output voltage of plug E with the engine running on: High speed 140 Volts 160 Volts (Using a 20,000 ohms per volt meter) Ground Wire M Open Check resistance at plug E. With the self-propelled handle in neutral, and or Loose the key switch in the START position, and plugs G & H disconnected, the circuit reads: A GOOD CIRCUIT READS SHORTED A BADCIRCUITREADSHIGH RESISTANCE (METER ON RX 1) Key Switch Defective Key switch in the START position. A good switch reads SHORTED on terminals 2 & 3. A bad switch will read 1 or more ohms. (Meter on RX 1) Starter Motor Defective Check voltage at starter plug A when key switch is in START position. Voltage is to be above 10 volts. The resistance between the terminals on plug B should read approximately.3 ohms resistance for a good motor. (Meter on RX 1) Turn motor for lowest reading. Self-propelled Interlock When the self-propelled handle is in neutral, the interlock switch should be Switch Open closed. A good switch reads SHORTED on the pins of plug D. (Meter on RX 1) Short Circuit Battery run down. The resistance on pins of plug E (with all other plugs connected, self-propelled in neutral, and key switch in off position) should read as follows: With volt-ohmeter on RX 1 the low reading will be between 15 ohms and 20 ohms. With the volt-ohmeter on its highest setting, the high reading will be MEG ohms. Alternator Diodes Battery run down. Disconnect plugs A, C and J Connect a 20,000 Leaking ohms per volt volt meter as follows: Use 15 volt D.C. scale (Min.). Disconnect plug E. Reconnect plug E so that the male pin of plug E and the female of plug F are not connected. Connect the positive lead of the volt meter to the male pin of plug E. Connect the negative lead of the volt meter to the female (-) of plug F. The meter should read zero. A reading of more than one volt indicates excessive leakage which could run the. battery down during storage. ENGINE STOPS WHEN IS IN RUN POSITION: Key Switch Defective Key in RUN position, the resistance between terminals 1 & 2 on plug K I reads less than 1 MEG ohm. ENGINE DOES NOT STOP WITH KEY IN OFF POSITION: terminals 1 & 2 on plug K resistance reads INFINITE 13-26 SERVICE REFERENCE MANUAL
WIRING DIAGRAM F-100 SERIES (LATER MODELS THRU (USING 682529 S) (HIGH 1982) OUTPUT), SELF PROPELLED. FIG FIGURE 1 KEY IN "OFF." POSITION SELF FIGURE 2 KEY IN "START" POSITION SELF PROPELLED FIGURE 3 KEY IN -RUN- POSITION
TROUBLE SHOOTING-THE MODEL F-100 SERIES CHARGING SYSTEM PART NO. 683095 CONNECTOR WHITE WITH DOESNOTTURNENGINE: BATTERY RUN DOWN Alternator or Charger Not Charging REFER TO BATTERY TEST PROCEDURES Battery run down. The resistance on the pins of plug H should read LOW with V.O.M. leads in one direction and HIGH with leads reversed. (Meter on RX 1). This checks for bad diodes. A low resistance or high resistance in both directions indicates defective diodes. Ground Wire M Open or Loose Key Switch Defective Starter Motor Defective Self-propelled Interlock Switch Open Short Circuit Alternator Diodes Leaking (Using a 20,000 ohms per volt meter) Check resistance at plug E. With the self-propelled handle in neutral, and the key switch in the START position, and plugs G & H disconnected, the circuit reads: A GOODCIRCUITREADSSHORTED A BAD CIRCUIT READS HIGH RESISTANCE (METER ONRX 1) Key switch in the START position. A good switch reads SHORTED on terminals 2 & 3. A bad switch will read 1 or more ohms. (Meter on RX 1) Check voltage at starter plug A when key switch is in START position. Voltage is to be above 10 volts. The resistance between the terminals on plug B should read approximately.3 ohms resistance for a good motor. (Meter on RX 1) Turn motor for lowest reading. When the self-propelled handle is in neutral, the interlock switch should be closed. A good switch reads SHORTED on the pins of plug D. (Meter on RX 1) Battery run down. The resistance on pins of plug E (with all other plugs connected, self-propelled in neutral, and key switch in off position) should read as follows: With volt-ohmeter on RX 1 the low reading will be between 15 ohms and 20 ohms. With the volt-ohmeter on its highest setting, the high reading will be MEG ohms. Battery run down. Disconnect plugs A, C and J. Connect a 20,000 ohms per volt volt meter as follows: Use 15 volt D.C. scale (Min.). Disconnect plug E. Reconnect plug E so that the male pin of plug E and the female of plug F are not connected. Connect the positive lead of the volt meter to the male pin of plug E. Connect the negative lead of the volt meter to the female (-) of plug F. The meter should read zero. A reading of more than one volt indicates excessive leakage which could run the. battery down during storage. ENGINESTOPSWHENKEY IS IN RUN POSITION:. Key Switch Defective Key in RUN position, the resistance between terminals 1 & 2 on plug K reads less than 1 MEG ohm. ENGINE DOES NOT STOP WITH KEY IN OFF POSITION: 1 & 2 on plug K resistance reads INFINITE 13-28 SERVICE REFERENCE MANUAL
WIRING DIAGRAM F-100 SERIES WITH PART NO. 683095 WITH WHITE CONNECTOR. FIGURE 1 KEY IN "OFF' POSITION IGNITION figure 2 KEY IN "START" POSITION SERVICE REFERENCE MANUAL 13-29
TROUBLE SHOOTING THE MODEL F-100 SERIES CHARGING SYSTEM PART NO. 6,83092 CONNECTOR BLACK WITH DOESNOTTURNENGINE: BATTERY RUN DOWN Alternator or Charger Not Charging REFER TO BATTERY TEST PROCEDURES Battery run down. The resistance on the pins of plug H should read LOW with V.O.M. leads in one direction and HIGH with leads reversed. (Meter on RX 1). This checks for bad diodes. A low resistance or high resistance in both directions indicates defective diodes. The output voltage of plug E with the engine running on: High speed 18 Volts 32 Volts (Using a 20,000 ohms per volt meter) Ground Wire M Open or Loose Key Switch Defective Starter Motor Defective reading. lowest Self-propelled Interlock Switch Open Short Circuit Alternator Diodes Leaking Check resistance at plug E. With the self-propelled handle in neutral, and the key switch in the START position, and plugs G & H disconnected, the circuit reads: A GOODCIRCUITREADSSHORTED A BADCIRCUITREADSHIGH RESISTANCE (METERONRX 1) Key switch in the START position. A good switch reads SHORTED on terminals 2 & 3. A badswitchwill read 1 or more ohms. (Meter on RX 1) Check voltage at starter plug A when key switch is in START position. Voltage is to be above 10 volts. The resistance between the terminals on plug B should read approximately.3 ohms resistance for a good motor. (Meter for on RX motor 1) Turn When the self-propelled handle is in neutral, the interlock switch should be closed. A good switch reads SHORTED on the pins of plug D. (Meter on RX 1) Battery run down. The resistance on pins of plug E (with all other plugs connected, self-propelled in neutral, and key switch in off position) should read as follows: With volt-ohmeter on RX 1 the low reading will be between 15 ohms and 20 ohms. With the volt-ohmeter on its highest setting, the high reading will be MEG ohms. Batteryrundown.Disconnectplugs A, C and J. Connecta 20,000 ohms per volt volt meter as follows: Use 15 volt D.C. scale (Min.). Disconnect plug E. Reconnect plug E so that the male pin of plug E and the female of plug F are not connected. Connect the positive lead of the volt meter to the male pin of plug E. Connect the negative lead of the volt meter to the female (-) of plug F. The meter should read zero. A reading of more than one volt indicates excessive leakage which could run the. battery down during storage. ENGINESTOPSWHEN IS IN RUN POSITION: Key Switch Defective Key in RUN position, the resistance between terminals 1 & 2 on plug K I reads less than 1 MEGohm. ENGINE DOES NOT STOP WITH KEY IN OFF POSITION: 1 & 2 on plug K at Ground resistance reads INFINITE 13-30 SERVICE REFERENCE MANUAL
WIRING DIAGRAM F-100 SERIES WITH, PART NO. 683092 WITH BLACK CONNECTOR SELF FIGURE 1 - KEY IN "OFF",POSITION I BROWN BLK FIGURE 2 KEY IN START POSITION FIGURE 3 KEY IN "RUN" POSITION SERVICE REFERENCE MANUAL 13-31