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1. Programming Modes

B. Alternator testing

Test A - The alternator and regulator can be tested for function by determining if a magnetic field exists at the

alternator's pulley shaft or rear bearing. To test:

With the ignition in the OFF position, place the tip of a steel screwdriver near the nut on the pulley shaft or near the

rear bearing of the alternator. There should be no evidence of a magnetic field pulling the screwdriver toward the

alternator. (A slight amount of magnetism may be present, due to residual voltage in the alternator.

Engage the ignition, without starting the engine, to activate the voltage regulator. If an oil pressure switch is used, a

jumper between the RED and BROWN wires in the Ford-style plug will activate the regulator.

After allowing time for the regulator's start-up delay, place the head of a steel screwdriver near the nut on the pulley

shaft or near the rear bearing of the alternator. There should be substantial magnetic pull. If a magnetic field is pres-

ent, the voltage regulator, alternator brushes and rotor are likely to be working

properly.

Test B - If there is little or no magnetic pull at the pulley shaft or at the rear bear-

ing, initiate the following test:

With the key off and the engine off, remove the large harness plug from the regula-

tor.

Insert the end of a short length of electrical wire to the RED connector slot of the

regulator harness and the other end of the wire to the BLUE connector slot. (See

Figure 24.) This bypasses the regulator and tests the alternator and the harness.

Using your steel screwdriver, inspect for a magnetic field as described above.

With your voltmeter, check for voltage on the blue wire at the alternator. If voltage

does not exist, the harness may be at fault. If voltage does exist at the harness, but

no magnetism is present, the alternator is likely to be malfunctioning.

If a magnetic field is present. Both harness and alternator brushes and rotor appear to be working properly. If

no magnetic field is present, proceed with the next test.

Test C - Testing the actual output of the alternator is known as "Full Field Testing". This can be accomplished

by jumping a positive 12VDC current to the field terminal at the rear of the alternator. This test eliminates both

the regulator and the harness, making it easier to isolate your investigation to the alternator. CAUTION: Ensure

that all voltage sensitive equipment is turned off prior to starting the engine. Voltage is unregulated during this

test and could damage sensitive electronics. DO NOT let the engine run any longer than necessary to detect

charging. If the system is not charging, remove the alternator and have it inspected by a qualified alternator

shop, or call Balmar for warranty evaluation.

To test the alternator:

Clip a jumper wire to the positive post of the alternator, or on the battery side of the isolator (if an isolator is in use).

Use a SHIELDED alligator clip for post attachment. Unintentional contact between the alligator clip and the alter-

nator case could result in damage to your electrical system.

Disconnect the field/stator plug from the rear of the alternator and attach the other end of the jumper wire to the alter-

nator's Field terminal (F). Attach a female spade connector to the field end of the wire for a solid connection. CAU-

TION: Do not allow the wire to contact the case while it is attached to the positive post. The case is grounded and

severe damage could occur.

The regulator is now bypassed. When the ignition is engaged and the motor is started, the voltage should rise and

charging current should be present.

The motor should be run long enough to determine that charging voltage is present. Unregulated voltage can rise

quickly. Do not allow extended unregulated charging to occur without carefully monitoring voltage levels.

If the alternator fails to generate voltage during field testing, a malfunction of the alternator is likely. Contact

your local alternator repair shop or Balmar's technical service staff for recommendations.

C. Conclusion

If your readings differ substantially from the "Expected Readings" listed in the troubleshooting charts, the reg-

ulator may be malfunctioning, or there may be a continuity problem. Contact our technical support staff at (360)

435-6100. If you determine that repair service is necessary for either your alternator or regulator, please gath-

er the following information before contacting our service technicians: Make and model of alternator. Model of

voltage regulator and date of mfg. (date punched on rear side label of regulator). Voltage readings on red, brown

and blue wire at regulator with engine off, key on. Voltage readings on red, brown and blue wire at regulator

with engine running at a fast ideal 1400 rpm.

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F F i i g g u u r r e e 2 2 4 4 - Jumping power wire

to field.