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TESTPROCEDUR T Y L I B E L E C T R O N I CI G I I I T I I J i I S Y S i I M
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DESCfilPTIOi' :
ThcPrcstolite E l e c t r o m a qC . D .l q n i t i o nS y s t e mi s a tronreg 9,,'r;tcms'lh :: c.,t; i1,. pi':.,t1
ucticrnr);1,1 ._l i _>.r,"s
c o r r b i n a t i o n p e r m a n e n t r n e g r r i : tl l v v l h c e l a l t e r - covcred in tf rei i', .C i :,i:;1rf rrrar.iwt iirt i,ir ,: .:irrlii
nator tlncJsolid stato brcal<erlsil.;s canaciior cJis- 5-31,73.
c h a r { J l i g n i t i o n s y : ; t r : m l.- h a E k r c t r L ) n i a qis de- ty ar:tl i .,ie 1.. I :r:ir O::tt bc Oetci ;-,ii;.od b, i'tu
f ;.27 ; c;Cl.lr:
s i g r r c dt o s u p p l yt h r : h i g h v o l t a g ef o r t i r e r g n i t i o n
t i l p e t : l i j O i ' , t l ( : ' (- t ) f : : i : I : : J , : l ' . , t i i : t h : l i : y r , : i ; . , 1 ' r[ .- . p l i r
s y s t e ma s w e l l a sg c n e i r a t teh e c ; u r r r r nr te q u i r e df o r . i ; l C t l r ; : ; , i 1 1 ; . . 1 ;1] s i
b a t t e r yc t - r a r g i nagn d / o rf r : r l i g h t i n gs y i t i c m s n y S . ' . . f i t Si t a l ' . t p i , ; i l
F r ' ' ( , , d i t O ' r i 'S
t l r t r e l t : c t r , i t i i . . sm i . ' i i lt l . : r, v i t i i t i , r ; . l c ' { } r ; . r i j r , , . i . . i
Thiswrite,'-up soversthe laterproductionFr\CElec. r i Y S l t j l l - rfsi a y i : f h e p t t , q l : t . O f l i - i e' ' 1 . , ' r n 5 j r i l i l q ; r ; 1 , r ,,
as iilusll',i ied br,li-r',,1.

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I c l r i ti r c r n ' i -i i n i r ,c l l i , . . { t : ,
3. Altern:toi irtaiJl
4 . l g n i t i c r n ' f i r n ; r i qi - i i : r . 1
,i
E l e c i r o n i e s 1 , 1 6 1f l' : i , :
6 . l g n i l i r :t r T r A t - l sl c )I : . r 1:.' ,3 , : , j r l s l
0 r r r f : : c e$ a J : S p a r k ; r i i
B, Tnggoring $iot

OPEFIATION
I n o p e r a i i o no n a v e h i c l e ,t h e f l v w h e e lr o t o r ( 1 ) , T h e e l e c t r o n i cm o c j r i l e( 5 ) i n c o r p o r a l e st h r i g r r r t i u r :
w h i c h i n c o r p o r a t e as s p c c i a lf l e x i b i , -nrr a-er envectal nv d es c o n d e n s e r s a n d t h e n o c e s s a r ys o i r d - s l i r t e' - ' r , .r i , r . , , ,
i s m o u n t r : do n t h o e n r ; i n e c r a n k s h i t t . f o r c h a r g i t t 6 ;a n d d i s c i r e i q i n q l h c r n J i r ' . .l ; i : ' ,r ' , : J
a r o u n dl t r oa l t e r n a i t osrt i t t o r( 3 ) w l r i c l irs f i x e r cl oi t h e r o t c r ( 2 ) r o v o l v i n ew i t t t r nt h u t i m i n g n n g { 4 )i : r , 1. . . r ' ' ;
o n g i n c .C u r r e r i its g e n o r a i . ei dn t h ew i r r d i n e sc . rtnh e l l t c d i s c l r i l r g e o f t i t a s e c o t t d a n s { r r ' tl l : r t r r i g ; 11 ; 1 . '
t w e l v ep o l e so f t h e s t a l o i p l a t a ,r r r n e, r f w l r i c l ts u p - - r ,,
electrqrniom s o d u l r : t o t h e i g r t t t t o r it r r n . . j i t r i. i,
p l y p o l o r f o r t l r e r y e h i c l elsi g h t sa n d i o rf o r c h a r g - whictt "::tep up" tho r . ' o i t a O c
t o a l L . v c ln , ' : " , i i i ' 1 ,| ' y
i n g t h e b a t t e r y ,a n d t h r e e o f v y h i c hs u p p t yp o w e r i n s u r e s ( J c c r r s sLf l l f i l i n r l o f l l t r J s u r t a c i r i : . i , , i: .D i i r i l
for ignition. p l u g s ( 7 ) w t i i c h a r e r o q u i r o df o r m o s t r n o i l , . irr l r i l l i
'.€dcrnr;rncr: enginos.The specialconfigurationof in connector, arid repeating tfto check for sperk
; r o t i i ' : r r , r r ' ! nsal o t ( B ) i n t h e t i m i n g r o t o r c o n t r o l s discttarges.
ihe aldcironic timing advanco. l l a l l c h e c k st o t h i s p c i n t i n t l t ' - ' a ia, ; f : - l u l t yi g n i f i c r t
'l s y s t e . md , i r e c t c o r n p o n c ;i e r r l , , - ' i i ' u l i ocn. : . r t i e
hc;trigaeringslot genoralosvoltagein the trigger
coiis.Tho rleep slotted portion generatesa higher u s e d t o l o c a t et h e f a u l t y c o { i , i ) ( ) n c r l t .
vulliag,n ihan tho shallowslottedportion. In opera- W/{t?}ltt'iCl: it is nc:-r',iltic to iui''t;i ne\{ eiorltrr.r,r;63
tion (SeeFigure2) the sh;.illowpodion of tha trig- m o d u l ei f t h , rf a l ; l tc ; ' " itis i n t f i ' rt i i n i n gi l n q . i i t : r1 i ' i : r t
ieerson,Do l'-.:: t l;t tt:rr;i utr-'lilr+a i rct rrrr',i r:s,r'lot:i ti,t
TRIGGENP I C K U PC O I L
IN TRIGGEN HOUSIITG
until the liminq i'iI1.l',1s brten'rlb::iitt-tti:d .rt'le';i i:.::
as outlined iit tire orttrti'nr,'llr test proc;;ili;;e.
TATIOHARY t:); i I,i ;'i i:i'i.: !:i Tfr i:iT
i; i;i1.rl.)i;DURH
fu!akeei:rtaintlie ohrrrnretr:r i..ciriilu':ei1is ilccurate.
T R } G G E RR O T O R and the baiieries 1t.4{;i.si't.Perir;ritc;,rlly .zerothe
r n e t e rd u r i n g t a s t i n r t .
S ? c p 1 U n o i : < tj l i e ' , " 1i r; t of ) i a n c r ' sr : : r ) n , ' r - ' ctttcci.'i r r
LOW RPM HIGH RPM t l i e l l r l C t f r i ; i i C S r r . l O r j i t l Cir\.r lt l ( i : i . t i l r ' , i - r 1 y 1 ; : r ,f . t. (i , : . l i i i f l
TTiIGGERING TRIGGERING
t i r e r t i r i n q ; l t ; _ i r ' , t C SC$r ; i i l r ' : . (i r ' , r l C i . , 1l l r l i t i l t i : ; S t i t i O r ,

t
t Figure2 tiirt iiro rilirl i'rri ,)v,,itcf Iri:;i:,1
-:
i:'.,
' 3 n 1 : : i , ry - r 1 1 ; i l i rie- ) f

I t l - t r :c o n t t c r : i r - . i t l t r ; i i l . t ' , r : t r ; r , - , . , , i 5. i . i i r l i : r ; n t ; t , . l l s .
I
.{ gerinli slot pa.ss,ac
J : i r l u i ' c . i3s a ' l i r . , I i : a : . i ; r r i t r ' i , ' :t l ; i . : ' l r n i l . l t r ; , i i r ) r ''i) J
tho triggor coils first. However,
t i l , . r i : O i t ft C r ' i ' t V , ; i l r ;t i ' ; ; i l 1 , : :i r ' , : ; t r i f l ; , il l i c : : : i i l : r l S
ari lnr,.,r FlPl-iiiire voltage gonerated by the shallow
a a n d l e a C c o , r : r ' s i n a r ! ' : 'i C .
r l r j i o n c , i t h e : , l o t i s r i o t s u f f i c i e n tt o t r i g g e rt h e
:l
e l i , : : ' . r D n i cms o d u i n . t i r e r e f u r . )i,i r e l ; i g g c i ' i n gi s iir_uc
ercr:omplisheC at lhe deep slotted portion. As en- \ tst.'"-:x i
oinri spor:11 increait,)stho voltag;e eneratedby the
' s h i : i i o i ;p o r t i o no f t h o t r i g g e r i n g nt:'ir'*-fl
| ,|-r r;;--a c::.r
s l o t b e c o m e ss u f - I

i i c i : n t ? o t r i o f l e rt h o o l c c t r o n i c sm o d u l e t h e r e b y [ .r.., ;.rt ..--1 .l


electronicarla l yd v , : n c i n gt h c i g n i t i o n t i m l n g a p - "'"r,J:*l";.-. :.li;
l r o x i r n : r t e i yi 5 d e g r e r s .T h i s e l e c t r o n i ca c j v a n c e / cri[Eil \
u l l o w s t h c i g n i t i o nt i m i n g t o b o s e t i n a r e t a r d e d VIH E YgLLQf/
p o s i i i o nf o r e a s i o rs t a r t i n g .
F i g u r o3
PRHLl F$I iJd\nY C HtiC t{S
$l,ap 2 Connt'ct onc olrrrrrnetlrlcl.j ;o ii) goctl
CAU?Iel.!:
Do nct operatetha $tarterwith tho g r o u n Cc o r t n e c t i o nr : f l t l t c r _ . , i t f , i:f:ij c{ : . ;i . L l r i i r r i e $ t
plr.rg-in connectorLrnpiugged as danragecan ro- the OtltorolirnrntrleflaacitC.6;:t'::h tl:ii;,:rt.tlrn the
suli t'c the statorassembly.
S'J/ITf.IJ il'r'/lICt{
Checkthe plug-inconnectorto makecertaintho ON OFF
c o n n e c t i o ni s c l e a na n d t i g ; h tC
. h o c kf o r b r o k e n
loac!sand leadsvrithdamagedirrsulation. f-0 I
Checkfor cleanand tight groundconnections.
L:r:lCl-
Dis:onnecta spark plug wire from one cylinder
anclconnectit to a testplug.Turntheswilchto the o"-Iiq
IRCLIIT
on position,pull the startsr,and checkfor spark
dischargesat tho ieit plug.Testboth cylindersin
thes;ii'no manner.lf sparkdischargos areobserved
for irotlt cylinders,ths problemliesolsewherein
thoengino
ll sparkdischargasaro not observodat the test
pluq,makocertainthe problemis not a defective
srvitcir.Thiscanbo accomplished by removingthe
hlackleaci, eitherfromtheswitchor f romthe plug-
')

.rk
connoctor.Tho ohmmetsr should indicatclas fol- gEfV0 l."CCt'iltd0
TAn nt:dfli
l o r v s( $ a o f i g t , r e4 ) . T0 pe t*ovE T:QtitliFj-

A. Tarminali:1 (,rqrl]l - open ciruurl,infinityohrns.


B, Terntinall:;l (hlack)- switctron-op€n circuit,
i n f i n i t yo h r n s .
C . T c r r n i n a;l i 2 ( b l a c i < ) - -s w i t c ho f f - c o m p l e t oc i r -
c u i t ,0 o h r n s .
. ir)
,l
D. T o r m i n e l/ ' 3 ( b l u e )- - 3 0 t , : 1 0 0 o h m s . i:igura6
E , Teirrrinal ;#4 (r.;hitr:)- olie:'r circuit, irrfirtity
ohms.
F . T a r m i n a l l ; r 5 ( g r e o n )- o p e n c i r c u l t , i i r f i n i i y
ohms. S t c r p 3 [ - ] e l n c t ' e i i i t : t : r - r rci lr - : \ r e ri.l r ; t ; q r.r it t ) ' r ; , . i . r , : , ,
G , Terminal #lj (y::ltrw) - ?Ql',C tt.r3l'J00ohrr'rs. t l t e i g n i t i o n c c i l s . t l i i r , r : ka a < : hc o i { : ; r : i , : ; a ' l i : i ! ,; j. r ,
l-t, Fl*move; tirs,o:":'nneferloarjlrorr qrounrj.Cc;rr- m o v e l h e p r i r i r ; i r v l r : a < i' , r t r n t . n e r t , \ ' . ( ' ' , . ' . . ;' , . , ' : ,
nect the ohmr,.l{.ler icaCsto !r:rminalsri'1 (reC) l e a d ) . C o n n e c t c i ' l r ' l. - . t ' r n i f n r : l f l 't: : ;j l c i r ' , . l ' i - . . . - -
;#5 (grc:n), "i'fio
and chmmeter shcul<1in'iicate i ,rj i] ; ; 1 ; r ' : : :
t e r r n i n a l s l u r - jc r ; l n c i r : i l . ( l . L l r n , ' ; r : l ' ; f 1
20 to 40 ohrns. n t t . t o r l e r a dt r . ri l ' ! . J( r i ) r J n r Jo { J i 1 n { r L ( i / ) i,^. t ' l, i r . , , ' '
J . C o n n r : c t h ( i o h n t r n 2 l e rl e , - r dtso i e r m i n a l s# 4 S e e F i ' - q u r e7 . T l r e o r ' t m r f l ( : l o r$ i r : i l l c r j i r d i i , ; : ' , n ' . . , ;i ,
( w h i t e )a n d i ' 5 ( p r e t r r r )T.l " r ao i i m r n e t e rs i r c u i d
' i n d i c a t e2 0 l c ) 4 3
c r l i n s .( $ . e F i i l u r eS . )

..{

ffiff-i
Fi,;uroS
l f a l l o h r n m e t e rt e s t s t o t h i s p o i n t a r o a s l i s t e d ,
procaecjto coil ters11pq. -/t
rcd f f a l i o i r r n m e t etrc s t : :t o t i r i sp o i n t a r r :n o t a s l i r t e d ,
-'OCt i
'rne replace the componenl.as icllr_rvrs. /----..._--.\ |
FailedTest A, E, F, H, or J, icplace the ti,.nirrg
/,qc rc loo'r t
tl

ring assembiy. j|i*i-r'


F a i l e dT e s tD o r G , r e o l l c e t h s :s t a t o ra s s e m b l y .
FailedTestB or C, repiacetlrr,r sv;ftc.tr assernbly. Figure .-/ "
W h e n r e p l a c i n ot h e s t a t c ro r t i n r i n or i n r l i l w i l l b e
necessaryto rerrrovethe leacitenninals frorr the
p l u g - i nc o n n e c t o r . . 0 6 o h r n s .T h g e > r i r a r n e tl cv w n r i n , a r yr c s i s i a r r l er : i
practlcailyirnporsrclc lo reiiC oll .r or;r';.rr',,tllcri.''.
T h i s i s e a s i l ya c c o m p l i s l r e cbiy u s i n q n e o d l cn c s o Ohmmeter.!f tha lh.rntetfir iranCntr)Vtc+q1il 1:r'--ii,':
pliors or a small s,;revydriver lo l;enrj the tprnrirral t O 0 C , h r n S ,t h r . C t : i l a r i m a r y C 3 r - tl - , o ; 3 r i ' ' 1 . i , . r , : ' 1 ;
l o c k i n gt a n g o o w n , l s r - h o v y n i n f i q t r r e6 , a n r i r . i u l - g o o c . li.i e t r ' o v e trl - i , o: h m r r r e l r r l e i t t i t r o t ' t l h p e ! - ' ' 1 r ' r ( i
l i n g t h e t e r n r i n ao l ut of the conne.rcior. c o n n e c t i o n a n d c o n n c c t i l t o t h e l i , r t i ' k r fr l , : r . . ' i l c '
M a l t oc e r t a i nl h a i t r r wc o t n O o l r t : n!le a c lt e r m i n : r i S d l i , i . : li s ! C i -flr ' . i - l i i
t e r r n i n a l . J h e o h , " n l r ; r , t esr : l - , o ' - t il n
a r e i n s t a l l a di n ' h e r i r : o r r e c lto c r i t i r r ri n t n e tp l u q - i r r O l t m S .l f t h e a b r l l O r O j d i r , i ; . (aj r + n , . r t6 [ l ; r j r ' . r ; Jf i . r ,
c o n n o c l o r .R e f e rt o f i g u r e3 f o r l c c ; r i i c n; l n d c o l c r c r i l i s r i e f e c t i v o i l : r ( i r r t ( r i . t L ) r ! r e D i i i ' : r .1 \ : 7 , t , i ; ' , , '
codo. s a r l - l ep r o a e d u r o t c i r : s : :i h e o l h t - : r l r : r l .
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C O I LT E S T TROUBLESHISOTING
SPECIFICATIONS TFiE ALTENhJATOR
Graham Coil Tester
M o d e l5 1
In order to test tiie alternator
l o 4 a x i m u nSrr : c o n d a r y ...........5o 0h 0ms. i t t / ' il l b'eo unt e cessar'/ to discon-
l v l a x r r n r mP r i m a r y 0.5ohms. P ut I c.ids from the
.loil nect the
lntlex . . . . . . . . . . . . . . . . . . . . . . . . 6s0y s t e n t w i r i n g a n d l h e g r o t l n d
. ) o i lT e s t . . . . . . . . . . . . . . . .m. .i3n9. 'l
eads fastcned to t-he bottonl
( a m p l i f i o dw
) i t h s e c c n d a r yo p € n
Gapindex. . . . . . . . . . . . . .m
. 6a0x .
mount bol t of CDI box.
(coilmust firegap at thisselting)
l\ check of the alternator can be matji: with an
Msrc-O-T ronic o h m r n e t e rt o d e t e r m t n ei f t h e l e a d so r s t a t c r a r e
. Model6&98 o p e n c r g r c r r t n d e dT. n e r e : ; i s i a n c er r f t h e s t a t o r
Q.[J.frrJ3f-rtor Model55-980 assomLrly sh,ruldbc 0.1 to 0.rjohn').t'vhencltecked
O p ; r ' ; : t i nAgm p e r a g e .....1.4 beiweo'n t h e o u i p t - rl te a d sa s s l t o l n i n F i 3 u r uB . ' T h e
:-3 Prir:'rary iiesistanco 0.1or less ohmrnetorsltcLrld re;:dinfliti,yvrh'inr:hocl<ittg; lre-
5 ' : i ; o n d a rCyo n t i n u i t y ...............o
. .r. . . . 5 i w ec n e i t h r r lre i i dt t n dt l t pe l i i j n el l t ' . u i i n or ' l : ;r r : a l -
,li '
10S'300 ohms. ing i,icro::;tite two leitclswr-,uicj inCicaica,1opcrl
*i
c i r c u i t a r i d a r e a d i r r gf r o i t ' r J i t h e lre a r li c r 5 ; r c u l t d
!j w o u l c li n . i i c a t t a: r l r o ' r n r 1 . rcrij: . c u i ti.f a i : r o l l l e t i irs
f a . ' l J l f a l l t e s t st o t h i sp ; i n th a v eb e e nw i i h i nl h e indica:eC,cllftrtkifre l,:lr'.J','vlrr::' fi:irYv(lrrt ci l:rokert
i i ; t r r cs'l ; e c i i i c a t i o ni hs;,.t r c r : b l ep r es u m a b llyi e si n i n s u l a i i o no r a b r o k e r i e a a .i f t ; a d . 9a r a O i ( r e p l a c o
':r!.-ii::.,uli1)iiics nrodr.rls. Ee.causqof the nianyvari- t h e s i a t o ra s s e m b l y .
i l r i , , i i n v o l v o dw h u n t s s t i n r sl o l i ds t a t eo o m p o n e n -
t r , , , ' . , i l l lrn o h f f l r r t . r t ; i',' v es u E g 3 s t4 [ g r ; k r n qt l t e
.iit;'.i'.;criics module by replacer-nent only.
'l-r:lrtr:clrLinrnerrt
and tr,'stprococlures{or the igni-
tion t;o;ti'rn of tho FAC Electromag Svstemsare
a v a i i : b l at h r o u g h v a r i o u st e s t o q u r p r n e r rmt a n -
ui;-rciurers. Trvo of these manufacturersare listed
br+l'lvl.
(l r ::ltnn'l-Lt-.o Eloctronics, I nc.
-i22i Cr;rttralAvenue f.Jorlheast
fr4inr;eirpoIis,it,4innesotat 55421
ft4r:rc-O-TroniclnstrumentsCorp,
2 1 5 B r a n c hS t r o e t
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