alternator identification · pdf filealternator identification alternators six different...

ALTERNATOR IDENTIFICATION

ALTERNATORS

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 NO. 681362 PART NO. 681563 PART NO. 682529

ALTERNATOR EARLY MODEL LATER MODEL RUBBER CONNECTOR ALTERNATOR ALTERNATOR

PLUG PLASTIC CONNECTOR 1982 AND LATER

D-600 SERIES F-100 SERIES F-100 SERIES

1975-76-77 PLUG 1978-79-80-81

PART NO. 683095 PART NO. 682719 PART NO. 683092

(LATE MODELS) SUPERCEDES 682719 SUPERCEDES 682529 WITH BLACK CONNECTOR

F-100 SERIES 1983 COMPLIANCE MODELS 1984 GRAY COLORED

WITH WHITE CONNECTOR GRAY COLORED 1981-82

NOTE

See page 13-21 for information and specifications on alternators used on 1983 and later models. SERVICE REFERENCE MANUAL. .13-19

REVISED 1983

ALTERNATOR TESTING

ALTERNATOR TESTING PROCEDURES

NOTE

To check output of all alternators, a milliameter with a capacity of 500 M.A. (mil- liamps) 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 ALTERNATOR.

2.

3.

To check output of the alternator accurately, it is necessary to run the engine between 3100 and 3300 R.P.M. Readjust the governor if necessary.

Before attaching milliameter leads start the engine. Run at high speed R.P.M. 3100-3300

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.

NOTE

With meter leads attached DO NOT

ENGINE ELECTRICALLY. If the starter is activated irreparable damage to meter will occur.

STOP AND THEN RE-START

4 BLACK WIRES

TO MOWER To Battery

\ MILLIAMETER

13-20. .SERVICE REFERENCE MANUAL REVISED 1983

ALTERNATOR TESTING 5. Milliampere (M.A.) output specifications for

each alternator is:

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) With Black Connector

With White Connector Millimeter readings should be between:

Volt meter readings should be between: 200-450 M.A. 200-450 M.A. 200-450 M.A.

18-32 volts 140-160 volts 18-32 volts 4 BLACK WURES

6. To check voltage output for the alternator pro- ceed as follows. Start and run engine at 3200 TO MOWER RPM. TO BATTERY CASE

7. With engine running, disconnect wiring harness plug from battery. Connect leads from volt meter to connector plug as shown. Be sure METER

polarity is correct. Refer to the voltage require- ments listed above for each alternator.

SERVICE REFERENCE MANUAL REVISED 1983

TROUBLE SHOOTING THE ALTERNATOR PART NO. 681 362 CHARGING SYSTEM

MODEL 8233AE, 8234AE & 8235AE D-600 SERIES

STARTER DOES NOT TURN ENGINE: BATTERY RUN DOWN 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 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 BAD CIRCUIT READS HIGH 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 KEY SWITCH 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 the ground is bad. (Meter on RX 100) Connection at “L” Open Lead disconnected.

13.22. .SERVICE REFERENCE MANUAL REVISED 1983

ELECTRIC START SERVICING D-600 SERIES WIRING DIAGRAM NICKEL CADMIUM BATTERY

LOCKOUT SWITCH STARTER

KEY SWITCH

FIGURE KEY IN “OFF” POSITION


C.D.

FIGURE

LOCKOUT SWITCH

2 KEY IN ‘START’ POSITION

ST C.D.

IGNITION A

SERVICE REFERENCE FIGURE 3 KEY IN "RUN" POSITION

MANUAL 13-23 REVISED 1983

TROUBLE SHOOTING THE EARLY MODEL F - l o 0 SERIES ALTERNATOR CHARGING SYSTEM PART NO. 681653

STARTER DOES NOT TURN ENGINE:

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 GOOD CIRCUIT READS SHORTED A BAD CIRCUIT READS HIGH 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 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:


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.

-___-

_I.__

ENGINE STOPS WHEN KEY SWITCH 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: Key Switch Defective

Lead disconnected. Connection at “L” Open the ground is bad. (Meter on RX 100) at Ground Check terminal 2 on plug “J” to engine. If the resistance reads INFINITE Ground Lead “M” Open

Key in ‘OFF’ position, the resistance between terminals 1 & 2 on plug “K” reads less than 1 MEG ohm.

-I--

13-24 ;SERVICE REFERENCE MANUAL REVISED 1983

STARTER WIRING DIAGRAM

(USING 681653 ALTERNATOR) (LOW OUTPUT) F-100 SERIES (EARLY MODELS)


C.D. IGNITION

WHT-BRN

FIGURE 1 KEY IN "OFF" POSITION

LOCKOUT SWITCH STARTER C.D.

ONLY

ALTERNATOR

FIGURE 2 KEY IN "STAR'T" POSITION

RED-BLK KEY SWITCH

WHT-BRN

RED-BLK

KEY SWITCH


ONLY

ALTERNATOR RED-ELK

KEY SWITCH

FIGURE 3 KEY IN "RUN" POSITION

SERVICE REFERENCE MANUAL 13-25 REVISED 1983

TROUBLE SHOOTING THE LATER MODEL F-100 SERIES

PART NO. 682529 HIGH OUTPUT ALTERNATOR CHARGING SYSTEM

STARTER DOES NOT TURN ENGINE:

BATTERY RUN DOWN


Ground Wire “M” Open or Loose




Short Circuit



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)




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:


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.

ENGINE STOPS WHEN KEY SWITCH 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. I ENGINE DOES NOT STOP WITH KEY IN ‘OFF‘ POSITION:

terminals 1 & 2 on plug “K”

resistance reads INFINITE

13-26 SERVICE REFERENCE MANUAL REVISED 1983


F-100 SERIES (LATER MODELS THRU (USING 682529 ALTERNATORS) (HIGH

LOCKOUT,

1982) OUTPUT)

SWITCH STARTER C.D.

SELF PROPELLED. ONLY

ALTERNATOR

FIG FIGURE 1 KEY IN "OFF." POSITION


SELF

ALTERNATOR

FIGURE 2 KEY IN "START" POSITION


SELF PROPELLED ONLY

ALTERNATOR

FIGURE 3 KEY IN -RUN- POSITION

WHT-BRN

RED-BLK

KEY SWITCH

WHT-BRN

RED-BLK

KEY SWITCH

WHT-BRN

RED-BLK

KEY SWITCH

TROUBLE SHOOTING-THE MODEL F-100 SERIES ALTERNATOR CHARGING SYSTEM PART NO. 683095

WITH WHITE CONNECTOR STARTER DOES NOT TURN ENGINE:

BATTERY RUN DOWN






Short Circuit



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.

(Using a 20,000 ohms per volt meter)


A GOOD CIRCUIT READS SHORTED

RESISTANCE (METER ON RX 1) A BAD CIRCUIT READS HIGH


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)


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:


ENGINE STOPS WHEN KEY SWITCH 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



F-100 SERIES WITH ALTERNATOR PART NO. 683095 WITH WHITE CONNECTOR

.LOCKOUT SWITCH

ALTERNATOR

KEY SWITCH

FIGURE 1 KEY IN "OFF'” POSITION


IGNITION

ONLY

ALTERNATOR

fIGURE 2 KEY IN "START" POSITION

ALTERNATOR


ONLY

WHT-BRN

RED-BLK KEY SWITCH

WHT-BRN

RED-BLK

KEY SWITCH


TROUBLE SHOOTING THE MODEL F-100 SERIES ALTERNATOR CHARGING SYSTEM PART NO. 6,83092

WITH BLACK CONNECTOR STARTER DOES NOT TURN ENGINE:

BATTERY RUN DOWN Alternator or Charger Not Charging





Short Circuit


ENGINE STOPS WHEN


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)



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. Disconnect plugs “A”, “C” and “J”. Connect a 20,000 ohms per volt volt meter as follows:


KEY SWITCH 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. I ENGINE DOES NOT STOP WITH KEY IN ‘OFF’ POSITION:

1 & 2 on plug “K”

resistance reads INFINITE at Ground



WITH BLACK CONNECTOR F-100 SERIES WITH ALTERNATOR, PART NO. 683092

ALTERNATOR


C.D.

SELF

ALTERNATOR

FIGURE 1 - KEY IN "OFF" ,POSITION


ONLY

I BROWN

ALTERNATOR BLK

FIGURE 2 KEY IN “START” POSITION


WHT-BRN

RED-BLK

KEY SWITCH

WHT-BRN

RED-BLK KEY SWITCH

C.D.

WHT-BRN

ALTERNATOR RED-BLK

KEY SWITCH

FIGURE 3 KEY IN "RUN" POSITION


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