Mercury 2B Manual

Battery charging system and starting system

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ELECTRICAL
2
B
51806
BATTERY CHARGING SYSTEM
AND STARTING SYSTEM

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Summary of Contents for Mercury 2B

  • Page 1 ELECTRICAL 51806 BATTERY CHARGING SYSTEM AND STARTING SYSTEM...
  • Page 2: Table Of Contents

    Removal of Voltage Regulator ..2B-7 Installation of Voltage Regulator/Rectifier ....2B-7 2B-0 - ELECTRICAL 90-852396 MAY 1996...
  • Page 3: Specifications

    Starter Draw (Under 175 Amperes Load) Battery Rating 670 Marine Carnking Amps (MCA) or 520 Cold Cranking Amps (CCA) Alternator Output 12 Amperes @ 3000 Description Part Number Hydrometer Obtain Locally Ammeter Obtain Locally 90-852396 MAY 1996 ELECTRICAL - 2B-1...
  • Page 4: Battery

    1.272 at 0 F (-18 C) would be 1.240 corrected to 80 least 15 minutes at a rate high enough to cause F, indicating a partially charged battery. vigorous gassing. 2B-2 - ELECTRICAL 90-852396 MAY 1996...
  • Page 5: Specific Gravity Cell Comparison Test

    POSITIVE (+) battery terminal and BLACK (-) lead of tester on NEGATIVE (-) battery terminal. If the voltage drops below 9-1/2 volts while cranking, the battery is weak and should be recharged or replaced. 90-852396 MAY 1996 ELECTRICAL - 2B-3...
  • Page 6: Winter Storage Of Batteries

    Sulfuric acid in battery can cause serious burns, if spilled on skin or in eyes. Flush or wash away immediately with clear water. 2B-4 - ELECTRICAL 90-852396 MAY 1996...
  • Page 7: Battery Charging System Troubleshooting

    IMPORTANT: The charging system may be con- nected to one or more batteries during these tests. However, these batteries MUST BE fully charged. These batteries MUST NOT BE con- nected to any other charging source. 90-852396 MAY 1996 ELECTRICAL - 2B-5...
  • Page 8: Determining Cause Of Problem

    Run engine at 1000-2000 RPM. Any out- possibility of erroneous readings from ignition noise. put current indicates stator is shorted to ground. Replace stator. 4. If there is no output with YELLOW lead discon- nected, the regulator is defective. 2B-6 - ELECTRICAL 90-852396 MAY 1996...
  • Page 9: Voltage Regulator Test (Using Ohm Meter)

    2. Connect YELLOW, RED and GRAY (as required) ground. leads to their respective bullet connectors. Tachometer Circuit Check: Connect NEGATIVE (–) ohm lead to case ground. 10K to 30K R x 1K Connect POSITIVE (+) ohm lead to GRAY lead. 90-852396 MAY 1996 ELECTRICAL - 2B-7...
  • Page 10: Starter System

    - Starter Solenoid b - Starter c - Neutral Start Switch d - Ignition Switch e - 20 Ampere Fuse f - Starter Solenoid g - Battery 2B-8 - ELECTRICAL 90-852396 MAY 1996...
  • Page 11: Flywheel/Starter Assembly

    COLLAR-Starter Cap DECAL-Start In Gear DECAL-High Voltage WIRE ASSEMBLY (12.500 in.) (BLACK) NUT (.250-20) LOCKWASHER (.250) STARTER ASSEMBLY BOOT (Red)-Starter Lead SCREW W/ LOCKWASHER (.250-20 x .625) WIRE ASSEMBLY (6.00 in.) (BLACK) STOP (Rubber) 90-852396 MAY 1996 ELECTRICAL - 2B-9...
  • Page 12: Starter Assembly

    N·m STARTER ASSEMBLY DRIVE KIT-Pinion PINION ASSEMBLY-Drive CAP ASSEMBLY-Drive End THRU BOLT O RING-Thru Bolt ARMATURE O RING-Starter Frame BRUSH/SPRING KIT SCREW-Brush Holder HOLDER-Brush CAP-Comm End WASHER-Insulator-Brush Post NUT-Brush Post 2B-10 - ELECTRICAL 90-852396 MAY 1996...
  • Page 13: Starter Circuit Troubleshooting Flow Chart

    Check RED wire between battery (+) Check fuse in RED wire between Test Points POSITIVE terminal and Test Point 6. 5 and 6. Check for open RED wire between Test Points 5 and 6. Battery Voltage 90-852396 MAY 1996 ELECTRICAL - 2B-11...
  • Page 14: Starter Removal And Installation

    Disconnect battery leads from battery before re- moving starter. 1. Disconnect BLACK ground cable from starter. 2. Disconnect BLACK (with YELLOW sleeve) cable from starter. a - BLACK (with YELLOW sleeve) POSITIVE (+) 12- b - BLACK Ground Cable 2B-12 - ELECTRICAL 90-852396 MAY 1996...
  • Page 15: Installation

    4. Brush replacement is recommended if brushes are pitted, chipped or worn to less than 0.25 in. (6.4 mm). If necessary, remove brushes as fol- lows: a - Hold Armature Shaft with Wrench on Hex Portion of Drive Assembly 90-852396 MAY 1996 ELECTRICAL - 2B-13...
  • Page 16: Starter Cleaning, Inspection And Testing

    Resurface the commutator and undercut the insulation between the commutator bars 1/32 in. (0.8mm) to the full width of the insulation 11669 and so that the undercut is flat. b. Clean the commutator slots after undercut- ting. 2B-14 - ELECTRICAL 90-852396 MAY 1996...
  • Page 17 If resistance is indi- cated, inspect lead to brush and lead to POSITIVE terminal solder connection. If connection cannot be repaired, brushes must be replaced. 11673 a - POSITIVE (+) Brushes 90-852396 MAY 1996 ELECTRICAL - 2B-15...
  • Page 18: Starter Reassembly

    - Armature Shaft g - Washer 3. Lubricate helix threads on armature shaft with a drop of SAE 10W oil. 4. Lubricate bushing in drive end plate with a drop of SAE 10W oil. 2B-16 - ELECTRICAL 90-852396 MAY 1996...
  • Page 19 = 12.7mm b - Alignment Marks c - Bolts [Torque to 70 lb. in. (8.0 N·m)] 7. Lubricate bushing (located in commutator end cap) with one drop of SAE 10W oil. DO NOT over lubricate. 90-852396 MAY 1996 ELECTRICAL - 2B-17...
  • Page 20: Starter Solenoid Test

    3 and 4. Solenoid should click and meter should read 0 ohms (full continuity). 4. If meter does not read 0 ohms (full continuity), re- place solenoid. 51809 a - 12-VOLT Supply b - VOA Leads 2B-18 - ELECTRICAL 90-852396 MAY 1996...

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