Troubleshooting; Flywheel Alternator Service Procedure; Wiring Circuit - Wisconsin VH4D Repair Manual

WIRING CIRCUIT, Flg. 42, Flg. 43
The fool-proof type connectors used to prevent incor-
rect wiring from the stator to the rectifier and regulator
modules. To disconnect plugs, squeeze outer ends of
receptical and pull apart.
The rectifier is insulated from ground, but the stator
and regulator module are grounded to the engine
through their mounting surface. The regulator module
therefore should not be removed and mounted at some
remote location. This is a negative ground circuit. Connect
grotmd strap from negative post of battery to starting motor
flange, or good clean grounding surface on engine.
FLYWHEEL ALTERNATOR
SERVICE PROCEDURE:
PRELINIMARY TESTS
Wsual Inspection should be made to eliminate
conditions that may be interpreted as a defected
alternator. Examine leads for broken or loose
connections, and make sure modules are securely
mounted. The regulator module must be mounted
to a metal surface for grounding purposes, (Test
5.0) while the rectitier module, although insulated
from ground, should be securely mounted for heat
dissipation. The mounting surfaces must be clean
and free of contaminants, oil, grease, etc.
Check Battery. Use a Automotive battery in good
condition, fully charged and with clean, tight ter-
minal connections.
Check Ammeter. Be certain
the ammeter is func-
tioning correctly. Amperage output is regulated
by engine speed. The maximum amperage output
for Model VH4D is:
Maximum RPM IOAMP System 25 AMP Syetem
2800
9 amps 20 amps
When assured that the problem is with the alternator,
follow the tests outlined in 'Trouble Shooting'.
TROUBLE SHOOTING
FLYWHEEL ALTERNATOR
12 VOLT - 10 AMP and 25 AMP Systems
Trouble Shooting Procedure is a guide showing
methods of testing the charging components. The
following chart of Tests 1.0 to 4.1 are with the engine
running, and substituting known good components in
place of suspected faulty components. $totic Tests
5.0 thru 7.2, following the running tests, are more
conclusive but some test require special Wisconsin
Test Lights.
Problem: Battery Overcharge
Possible Cuase & Remedy
Test 1.0 Engine not running
check battery with
DC Voltmeter.
I. 1 If voltage is great-
er than 13.5 volts
1.2 With engine running
at full RPM, check
battery voltage
with DC Voltmeter.
I. 3 [[ the charge in-
creases beyond
13.5 volts.
1.4 If the charge re-
mains under 13.5
volts.
1.1 Place 12 volt light
bulb or carbon pile
across battery to re-
duce voltabe to below
13.5 volts.
1.3 Faulty regulator, l~e-
place, -- static check
regulator per "rest
No. 5.1.
1.4 Alternator functioning
properly. Check bat-
tery condition.
Fig. 43, WIRING DIAGRAM
ELECTRICAL SYSTEM
WITH
10 AMP or 25 AMP
FLYWH EEL ALTERNATOR
SOLENOIDSWITCH_
SPARK PLUGS
12 VOLT
MOTOR
3
1
7
BATTERY
I
~"'~L-~--411 ~ '
I~---
~--~ R at'o
RECTIFIER REGULATOR ~ I "~ ~ Ot , n
cHoK
I
~
STARTER
/ II
HI-TEIP
(~ST ATOR
term. ~. ~
~ ~
(optional)
Make connections; for lights at charge
SWITCH
COIL
side of ammeter (negative terminal).
29