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Alternator and Starter Motor Testing

This document provides testing procedures for alternators and starter motors. It describes how to check connections, mountings, wiring, and voltages for alternators. The testing procedure for starter motors involves checking connections and using a battery, cables, and switch to engage the solenoid and test for abnormal noises or performance issues. Diagrams show wiring configurations and component locations for different alternator and starter motor types.

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M. Shaat
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
1K views

Alternator and Starter Motor Testing

This document provides testing procedures for alternators and starter motors. It describes how to check connections, mountings, wiring, and voltages for alternators. The testing procedure for starter motors involves checking connections and using a battery, cables, and switch to engage the solenoid and test for abnormal noises or performance issues. Diagrams show wiring configurations and component locations for different alternator and starter motor types.

Uploaded by

M. Shaat
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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-;HA?

DI

Service Bulletin
General 176 Issue 1
Alternator and starter motor testing May 2003

Alternator testing
To avoid the return of parts that are not faulty, follow this procedure for all suspected failures. This will isolate
the problem between either the alternator or the main electrical system.
Check all connections to the alternator are secure and free from contamination. If the alternator is earthed
using the engine block check that there is a good connection between the alternator, earth connection and the
engine block. If the alternator mounting bracket is of the black painted type, the bracket should be removed
from the engine block and the paint removed from the mounting surfaces between the alternator, the mounting
bracket and the engine block.
If the machine tachometer is not operating, check the security of the ‘W’ terminal.
If the alternator is excessively contaminated by dust or dirt, use an airline and compressed air applied to the
vent holes on the alternator.
If the ignition warning lamp is illuminated, check the phase wiring.
Check the alternator charging voltage with a volt meter between the alternator +Ve and the alternator earth
terminal when the engine is operating at idle, with the minimal electrical load. The voltage should be between
13.6 and 14.7 volts, if it is outside this range then the alternator is faulty.

External fan type


Phase wiring

‘W’ terminal

Alternator +Ve terminals

Alternator earth terminals


Note: Not used on some applications.

1
Service Bulletin - General 176 Issue 1 May 2003

Internal fan type


‘W’ terminal
Phase wiring

Alternator +Ve terminals

2
Service Bulletin - General 176 Issue 1 May 2003

Starter motor testing


Before removing a suspect faulty starter motor, check the security of all of the electrical connections on the
starter motor.
To test the starter motor use:
l 12 volt fully charged battery.
l Two heavy duty cables with suitable clips.
l One small lead with an in-line switch capacity of 5 amperes minimum. The switch should be of the push to
make type.
Secure the starter motor in a vice.
Connect the leads as shown in the diagram, there should be no operation of the starter motor. If there is any
smoke, buzzing or sparking from the starter motor, it is faulty.
Operate the switch and the solenoid should operate, moving the pinion forward to engage the starter. The
starter motor pinion will then rotate. Releasing the switch will allow the pinion to retract and stop rotating.
If there is any abnormal noise, such as knocking, electrical buzzing, smoke, the starter does not operate, or
the pinion does not move forward or backward, or the pinion rotates at less than 5000 rev/min, the starter motor
is faulty.
If the starter motor operates correctly then the machine electrical system is faulty.

1000 Series Starter motor

Lead with push button switch


12 volt battery

Solenoid
Connection
5.6-6.2Nm

Lucar connector for


Ignition Switch

Starter Earth
Connection
8.0-8.5Nm
The starter Earth
should be connected
directly to B- OR
via another Earth.
This SHOULD NOT
be used as the main
engine earth.

3
Service Bulletin - General 176 Issue 1 May 2003

1100 Series P95 starter motor

Lead with push button switch


12 volt battery
Terminal Torque (Nm)
Earth 8.25
Solenoid B+ (copper) 8
Ignition switch (starter) 5.4

Caution: Do not apply 12v directly across


these terminals. The starter motor may be
damaged.

End

Issued by Perkins Engines Company Ltd, Peterborough PE1 5NA, England.  Proprietary information of Perkins Engines Company Ltd
2003, all rights reserved. The information is correct at the time of print. This bulletin is for technical information only and cannot be used
as a basis for any claim including but not limited to warranty.

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