TECHNICAL SERvICE MANUAL SERvICE MANUAL FOR THE 12
Contents
1. Voltage readings for a good unit 0 4V 0 5V If voltage does not fall into these parameters then the rectifier is defective Step 5 Reverse test leads Connect positive test lead to rectifier heatsink and negative test lead to diode post TP 1 Move the Negative test lead to TP 2 TP 3 TP 4 TP 5 and TP 6 Record readings at all six TP locations oee Fig 4 Voltage readings for a good unit or OL If voltage does not fall into these parameters then the rectifier is defective Note Due to the wiring configuration of the rectifier the tests above will not identify an open diode 8 www prestolite com Negative Rectifier Test Note You will need a multimeter to perform the fol lowing tests Test for complete alternator otep 1 Set multimeter to diode check mode Step 2 Connect positive test lead to alternator negative post and negative test lead to alternator AC post TP 1 Move the negative test lead to TP 2 and TP 3 Record readings at all three TP locations oee Fig 1 Fig 1 Voltage readings for a good unit 0 4 V 0 5V If voltage does not fall into these parameters then their is a possibility that the rectifier is faulty Continue to step 3 Step 3 Reverse test leads Connect positive test lead to alternator AC post TP 1 and negative test lead to alternator negative post Move the positive test lead to TP 2 a2. contacts the entire diameter of the bearing outer race is recommended otep 2 Place bearing spacer into front housing See Fig 2 Note On some models a wider front bearing will be utilized If your alternator uses this wider bearing then the front bear ing spacer used in step 2 will not be needed otep 3 Place bearing retainer on front housing and tighten mounting screws to 33 39 in Ibs See Fig 3 Note Apply Blue 242 Locktite to mounting screws before assembly Rotor installation otep 1 Slide spacer onto rotor shaft See Fig 4 Note On some models a wider front bearing will be utilized If your alternator uses this wider bearing then the spacer shown in Fig 4 will not be needed otep 2 Press rotor into front bearing See Fig 5 Note To prevent damage to the front bearing press on the bearing s inner race Note Use of a brass or copper block between the press and the rotor shaft will prevent damage to the end of the rotor shaft oee Fig 5 14 www prestolite com Rear bearing installation Step 1 Determine the length of bearing you are installing oee Fig 1 1a otep 2 Place bearing into rear housing and press into place See Fig 2 y Note Use figure 3 and 3 a to determine correct depth to Fig 1 press bearing Long Bearing Short Bearing Note To prevent damage to the front bearing press on the bearing s outer diameter Use of an appropriate bearing press adaptor socket or pipe that cont
3. nuts holding stator to rear housing and remove stator oee Fig and 8 Fig 7 Negative Rectifier Ring Removal otep 1 Remove two bolts holding negative cover plate otep 2 Remove negative plate oee Fig 1 otep 3 Remove three 1 4 AC tap X nuts See Fig 2 Fig 1 Step 4 Remove two 1 4 bolts See Fig 2 Step 5 Remove two screws See Fig 2 Step 6 Remove negative rectifier ring from alternator See Fig 3 Remove two 1 4 bolts Fig 2 Fig 3 Positive Rectifier Ring Removal otep 1 Remove hardware oee Fig 1 otep 2 Flip alternator housing and remove hardware Remove output studs See Fig 2 Step 3 Remove positive rectifiers from rear housing See Fig 3 Note Brush box will come out of rear housing when rectifier is removed Remove hardware and push output bolts from rear housing Rotor Removal Step 1 Place front housing rotor assembly on a press Step 2 Press rotor from front housing See Fig 1 for steps 1 and 2 Front Bearing Removal Step 1 Remove screws that attach the bearing retainer to the front housing See Fig 1 Step 2 Press bearing from front housing See Fig 2 Loosen and remove screws 6 www prestolite com Rear Bearing Removal otep 1 Place rear housing on a press oee Fig 1 otep 2 Press rear bearing seal from rear housing oee Fig 2 Alternator Diagnostic Component Testing All tests are designed to be performed off the
4. to step 2 If a low resistance reading Short is recorded then the stator will need to be replaced Note It is recommended that a High Pot test be performed on a stator for grounds by a qualified electrical shop Note To perform the test below a digital ohmmeter with 1 1000th of a ohm m Q display capability must be used otep 2 Connect test leads to stator terminals TP 1 amp TP 2 TP 2 amp TP 3 and TP 1 amp TP 3 Record measurements at all three locations Wheatstone Bridge or Ohmmeter with 1 1000 scale Fig 2 Refer to chart for correct readings If readings are not within specifications then stator is defective Voltage Current Phase to Phase Resistance Ohms 185 amps 0 020 0 023 200 amps 0 012 0 016 220 270 amps 0 008 0 010 320 amps 0 007 0 009 200 amps 0 022 0 026 12 www prestolite com Regulator Test The tests below will help determine if any faults are in the regulator Diode Check Note It may be necessary to have the regulator tested on a Transpo regulator tester by a qualified electrical shop The tests below will diagnose about 80 of regulator failures Set multimeter to diode check mode Step 1 Connect one test lead to a bare metal surface on the regulator housing and the other test lead to TP 1 Move test lead to TP 2 TP 3 TP 4 TP 5 and TP 6 If a terminal is not shown in Fig 1 make sure all terminals are tested Record readings at all T
5. P locations If a high reading OL is recorded then the regulator is good Continue to step 2 Diode Check If a low reading OV is recorded then the regulator is defective and needs to be replaced Step 2 Connect negative test lead to regulator positive terminal Connect positive test lead to TP 1 Record measurement See Fig 2 If a low reading OV is recorded then the regulator is good Continue on with Step 2 If a high voltage reading OL is recorded then the regulator is defective and needs to be replaced otep 2 Cont Move positive test lead to TP 2 Record measurement See Fig 2 If a voltage reading of 0 4V to 0 5V is recorded then the regulator is good Continue to Step 3 If the measurements are not within these values then the regulator is defective and needs to be replaced Step 3 Connect test leads per Fig 3 and record the reading If a voltage reading of 0 4V to 0 5V is recorded then the regulator is good If the measurements are not within these values then the regulator is defective and needs to be replaced 13 Alternator Assembly instructions Press bearing on outer race to prevent damage ress bearing on outer race to prevent damage otep 1 Place bearing into front housing and press into place CX TE See Fig 1 Note To prevent damage to the front bearing press on the bearing s outer race Use of an appropriate bearing press adaptor socket or pipe that
6. TECHNICAL SERVICE MANUAL SERVICE MANUAL FOR THE 12 DIODE 4000 SERIES ALTERNATOR TROUBLESHOOTING DIAGNOSTICS AND REPAIR A A Prestolite Leece Neville electric HEAVY DUTY SYSTEMS 7585 Empire Drive Florence KY 41042 800 354 0560 www prestolite com Table of Contents PostiveRectifier Ring Removal 6 Front Bearing Removal 6 Negative Rectifier Test 9 www prestolite com Description The 4000 series alternators are air cooled belt driven units designed for heavy duty diesel engine applications These units feature an integral external voltage regulators fully enclosed brushes built in rectifier assemblies with solid lead frame and extra large heat sinks a dynamically balanced rotor and heavy duty stator and bearings The 4000 series comes in a vast array of features which includes remote sense self excite ignition excite lamp and Multip ower Technology Mode of operation The vehicle battery supplies excitation to the field coil rotor coil through the regulator and brushes to create a magnetic field around the rotor and through the stator When the rotor is set in motion the moving magnetic field induces an alternating current AC in the sta tor windings This output current increases with the speed of the rotor The AC produced in the stator is converted to direct current DC by the positive and nega
7. acts the entire diam eter of the bearing outer race is recommended Use caution not to get debris inside bearing during assembly 22 19 Fig 3a Long Bearing Short Bearing Rear bearing seal installation Step 1 Place rear bearing seal into rear housing See Fig 4 Note correct orientation of seal before pressing into place Step 2 Press seal into place Note To prevent damage to the rear bearing seal press on the seal outer diameter Use of an appropriate press adaptor socket or pipe that contacts the entire diameter of the seal outer diameter is recommended Use caution not to get debris inside bearing during assembly After assembly coat lip of seal with a high quality synthetic bearing grease 15 Regulator brushbox assembly instructions otep 1 Attach regulator wires to regulator and brush box oee Fig 1 If your model has a rubber grommet or any additional wires attach them at this time Torque value 10 32 nuts 17 23 in Ibs Note Many different regulator models exist with different wiring configerations to the brush box Please refer to TSB 1134 that will aid in identifying these wires otep 2 Place regulator onto brush box See Fig 2 Note Make sure regulator red and black leads are properly seated into notches before securing regulator otep 3 Insert four regulator screws and tighten Torque screws to 11 13 in lbs See Fig 3 otep 4 T
8. l it stops about 1 4 Do not Force Hold firmly in place to ensure appropriate contact See Fig 1 Step 2 Connect voltmeter where one test lead connects to the wire or drill bit inserted into the full field access hole and the other test lead connects to the alternator B terminal Observe reading on multimeter Note While performing this test you may need to rotate the rotor to make sure the brushes are making contact to the slip rings If a low voltage reading OV is observed on the multim eter then the field circuit is good If a high voltage reading 9 or OL on the multimeter then the field circuit is open 10 www prestolite com Possible causes for an open field circuit 1 Poor contact between regulator and brushes 2 Poor contact between brushes and slip rings 2 Damaged or worn brushes 3 Rotor coil open 4 Positive regulator sense lead damaged or a loose connection 5 Defective regulator 6 Worn or damaged slip rings Rotor Test RX1 Scale The tests below will help determine if the rotor is within specifications oet multimeter to check resistance R X 1 scale otep 1 Connect multimeter test leads per Fig 1 Move test lead to TP 2 Record readings at both TP locations If a high resistance reading is observed then the rotor is good Continue to step 2 If a low resistance Short is observed then the rotor is sena defective Rotor will need to be replaced otep 2 Con
9. ll not be present Step 8 Turn rear housing over and install hardware to output post and torque to 80 100 in lbs See Fig 7 EN Install bolts 17 Negative rectifier installation otep 1 Place negative rectifier ring onto rear housing and install hardware Torque hardware per Fig 1 Step 2 Install hardware to alternator AC terminals See Fig 1 Note If model applies connect regulator AC terminals to alternators AC posts Note Use Fig 2 for proper orientation of hardware that attaches rectifier rings to rear housing Stator Installation otep 1 Place stator on rear housing and attach stator terminals to alternator AC studs Attach nuts and torque to 17 23 in lbs See Fig 3 Note On 4800 J 180 models it is important to line up the stator through bolt holes with the rear housing holes in order to insert the through bolts See Fig 4 18 www prestolite com ad cas Fig 2 m m i yu m vo s o re E InstallAC nuts Bess Torque 50 60 in lbs f St rough bolt holes must line up Alternator final assembly otep 1 Insert front housing rotor assembly into rear housing stator assembly Step 2 On pad mount alternators place the alternator on a flat surface so the front and rear pads are in line No rocking should be present between the front and rear pads See Fig 1 otep 3 Insert through bolts and torque in a cross pattern to 90 110 in Ibs See Fig 2 ote
10. n between slip ring assembly and field coil leads g Rotor coil shorted open or grounded C Alternator generating section malfunction caused by one of the following a Stator phase s shorted open or grounded b Rectifier assembly grounded c Rectifier s shorted or open On Vehicle or Test Stand Troubleshooting Detailed information can be found on our web site at www prestolite com When on our web site look up the alternator model you have questions on and you will find hyperlinks that will take you to information pertaining to that model You can also contact our technical support hot line at 1 866 288 9853 Good information to reference would be our training Alternator Disassembly Step 1 Remove fan and 4 screws that attach the regulator to alternator oee Fig 1 Step 2 Lift regulator from alternator and remove all hardware that attaches regulator to alternator oee Fig 2 otep 3 Remove brushes and regulator from brushbox E i R V otep 4 Remove through bolts from alternator See Fig 3 Pad mount alternators see Fig 4 J 180 mount alternators WN Tap front housing with soft face mallet Step 5 Tap front housing with a soft face mallet to separate the front housing rotor assembly from the rear housing stator assembly See Fig 5 Step 6 Pull front housing rotor assembly from rear housing stator assembly See Fig 6 4 www prestolite com otep 7 Remove three stator
11. nd TP 3 Record PAM readings at all three TP locations See Fig 2 ET IN Voltage readings for a good unit 1V 2V If voltage does not fall into these parameters then their is a possibility that the rectifier is faulty Continue to steps 4 and 5 Fig 2 TP 1 TP 2 TP 3 Test for rectifier ring only Step 4 Connect positive test lead to rectifier heatsink and negative test lead to diode post TP 1 Move the negative test lead to TP 2 TP 3 TP 4 TP 5 and TP 6 Record readings at all six TP locations oee Fig 3 Voltage readings for a good unit 0 4 V 0 5V If voltage does not fall into these parameters then the rectifier is defective otep 5 Reverse test leads Connect positive test lead to diode post TP 1 and negative test lead to rectifier heatsink Move the positive test lead to TP 2 TP 3 TP 4 TP 5 and TP 6 Record readings at all six TP locations oee Fig 4 Voltage readings for a good unit or OL If voltage does not fall into these parameters then the rectifier is defective Note Due to the wiring configuration of the rectifier the tests above will not identify an open diode Alternator Field Test The test below will help determine if the alternator field is working properly Set multimeter to diode check mode Step 1 Insert 1 16 drill bit or mechanics wire into alternators full field access hole Insert straight into hole unti
12. nect multimeter test leads per Fig 2 and record resistance reading Note It may be necessary to clean the carbon coating off the slip rings with a strip of emery cloth Determine the voltage and amperage rating of the Fig 2 alternator you are testing and compare your reading to the chart below 5 1 057 6688 16 987mm 26 847mm If the resistance reading measured does not compare Fig 3 then the rotor is defective and will need to be replaced Step 3 Check shaft diameter for wear where it contacts the rear bearing If the diameter is less than 6688 16 987 mm then rotor will need to be replaced otep 4 Check slip ring diameter for wear If the diameter is less than 1 057 26 84 7mm then the rotor will need to be replaced 11 Brush Inspection If brushes appear burned cracked broken or if they are worn to a length of 3 16 or less brushes must be replaced Check shunt lead within the brush spring If the shunt lead is broken frayed or damaged install new brushes lt ie Stator Test Tests below will help determine if stator is within Minimum brush length specifications oet multimeter to check resistance R X 1 scale otep 1 Connect one test lead to a bare metal surface on the stator lamination and the other test lead to TP 1 Move test lead to TP 2 and TP 3 Record reading at all three TP locations See Fig 1 If a high resistance reading is recorded then the stator is good Continue
13. p 4 On J 180 mount alternators insert a 1 2 rod through the two mounting holes This will aid in lining up the through bolts holes See Fig 3 Step 5 Insert through bolts and torque nuts to 45 50 in lbs oee Fig 4 otep 6 Pull brush retaining pin See Fig 5 Step 7 Install negative cover plate and tighten mounting bolts See Fig 6 19 www prestolite com 20 Manufacturing OE Sales 400 Main Street Arcade NY USA 14009 Phone 585 492 1700 Fax b85 492 1660 C Prestolite PICCITIC Distribution Aftermarket Sales 7585 Empire Drive Florence KY USA 41042 Phone 859 525 8801 800 354 0560 Fax 800 997 6202 CA Leece Nevie HEAVY DUTY SYSTEMS
14. tive recti fier assemblies The rectifier assemblies are con nected to the alternator output terminals to provide DC output for charging the batteries and to satisfy the vehicle electrical loads The regulator monitors the output voltage through sensing leads which are connected to the positive and negative rectifier assemblies or on some mod els this is done externally through a remote sense S terminal When the output voltage deviates from the set voltage the regulator takes corrective action to maintain the output voltage at the proper level For more detailed information on how an alternator works please see our training CD PP 1216 Causes of Charging System Failure Charging system malfunction is identified by the bat tery 1 OVERCHARGED BATTERIES caused by one or a combination of the following A Defective Battery B Defective regulator C Poor sensing lead contact to regulator or rectifier assembly 2 UNDERCHARGED BATTERIES caused by one or a combination of the following A Loose belts corroded broken loose or dirty terminals broken wiring undersize wiring defective batteries B Alternator field circuit malfunction caused by one or a combination of the following a Poor contacts between regulator and brushes b No residual magnetism in rotor Refer to TSB 1034 to restore residual magnetism c Defective regulator d Damaged or worn brushes e Damaged or worn slip rings f Poor connectio
15. urn over assembly and place brushes into brush box see Fig 4 Step 5 With brush placed into holder compress entire brush into holder and retain brush into opening with a safety pin Install second brush following the same procedure slipping retaining pin forward through front opening of brush box to secure both brushes oee Fig 5 Tighten screws to 11 13 in Ibs Fig 3 16 www prestolite com Attach regulator wires Positive rectifier installation otep 1 Place insulators into rear housing See Fig 1 rear housing Step 2 Install positive rectifier ring into rear housing Make sure insulators are properly seated Install two bottom bolts do not tighten See Fig 2 Step 3 For proper orientation of hardware and insulators refer to Fig 3 Step 4 Install brush box assembly into rear housing l See Fig 4 7 a Step 5 Insert positive bolt and shorter 5 16 carrage bolt into rectifier ring Slight downward pressure on the brush box assembly may be needed in order to pass the bolts through the brush box See Fig 5 Note Location of bolts are dependant on application Review possible clearance issues on application and determine best location for the positive stud Step 6 Tighten two lower rectifier mounting bolts and torque to 20 25 in lbs See Fig 6 Step 7 Route regulator sense leads per Fig 6 and attach mounting screws Torque to 17 25 in Ibs Note On remote regulated models regulator sense leads wi
16. vehicle Positive Rectifier Test Note You will need a multimeter to perform the fol lowing tests BN Test for complete alternator OO 1 Step 1 Set multimeter to diode check mode otep 2 Connect positive test lead to alternator AC post TP 1 and negative test lead to alternator B post Move the positive test lead to TP 2 and TP 3 Record readings at all three TP locations oee Fig 1 Fig 1 Voltage readings for a good unit 0 4 V 0 5V If voltage does not fall into these parameters then their is a possibility that the rectifier is faulty Continue to step 3 otep 3 Reverse test leads Connect positive test lead to alternator B post and negative test lead to alternator AC post TP 1 Move the Negative test lead to TP 2 and TP 3 Record readings at all three TP locations See Fig 2 ONES JS n C lt Voltage readings for a good unit 1V 2V If voltage does not fall into these parameters then their is a possibility that the rectifier is faulty Continue to steps 4 and 5 Fig 2 Note You will need a multimeter to perform the fol lowing tests ERE Test for rectifier ring only Step 4 Connect positive test lead to diode post TP 1 and negative test lead to rectifier heatsink Move the positive test lead to TP 2 TP 3 TP 4 TP 5 and TP 6 Record readings at all six TP locations See Fig 3
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