ELECTRICAL EQUIPMENT - Q.3Batteries overcharging and Ammeter indicates highor full output all the time.Check regulator positive sensing lead and itsconnection at regulator.If no fault, regulator is faulty.5.Fault Finding on 11 ACIf the alternator does not produce its rated output of43 amps for 12 volt and 23 amps for 24 volt circuit, thefailure may be due to any unit or the associated wiring,and the following procedure should be followed.TEST 1.Check the Field Isolating RelayDisconnect the earthed battery terminal and thecable from the alternator main output terminal.Connect a 0-60 DC ammeter between the terminaland disconnected cable. Link terminals 'C1' and 'C2'on the field relay. Reconnect the battery cable.Close the master switch and start engine and run atcharging speed. If ammeter shows a charge therelay is faulty. or its wiring and connections.If ammeter shows no charge, carry on with Test 2.TEST 2Check the Alternator and Control BoxLeave the test ammeter connected, and disconnectcables 'F' and '-' from control unit and join themtogether. Remove link from field relay terminals andensure they are connected to 'C1' and 'C2'. Startengine and run at charging speed.Ammeter should indicate current values of 35 ampsor more for 12 volt circuit or 22 amps or more for 24volt circuit. A zero or low reading indicates a faultyalternator.If satisfactory output is recorded, a faulty control unitis indicated.TEST 3Checking or Adjusting the Voltage SettingThe regulator of the 4 TR control unit must be set onCLOSED CIRCUIT, when the alternator is underload. Also, the system must be stabilized beforechecking or resetting is carried out, and the batterymust be in a well charged condition. Check thebattery to control unit wiring, to ensure that theresistance of the complete circuit does not exceed0.1 ohm. Any high resistance must be traced andremedied. Connect a test DC voltmeter (suppressedzero type) scale 12-15 volts for 12 volt installationsor 24-30 volts for 24 volt installations, between thebattery terminals, and note the reading with noelectrical load. Disconnect battery earth cable andconnect test ammeter between alternator mainterminal and disconnected cable. Reconnect batteryearth cable, and switch on an electrical load ofapproximately two amps. Start engine and run atabout 2000 rev/min, for at least eight minutes. If thecharging current is still greater than ten amps,continue to run engine until this figure is reached.Then compare the volt meter reading with theappropriate setting limits, as specified for theparticular control unit as follows.12 V (37423)/(37449)13.914.3 volts24 V (37444)'(37502)27 928.3 volts12 V 3742913.714.1 volts(Part no. marked on upper edge of the mouldedcover of Control Unit).If reading obtained is stable hut outside theappropriate limits the unit can be adjusted asfollows.ADJUSTMENT OF VOLTAGE SETTINGStop the engine and remove the control unit from itsmounting.. At the back of the unit is a sealedpotentiometer adjuster. Carefully scrape away thesealing compound. Then start the engine, and whilerunning the alternator at charging speed, turn theadjuster slot — CLOCKWISE to INCREASE thesetting or ANTI-CLOCKWISE to DECREASE it —until the required setting is obtained.Recheck the setting by stopping the engine, thenstart again and slowly "run-up" to charging speed. Ifsetting is now correct, remount the control unit,disconnect test meters and restore original wiringconnections. If, after adjustment, the voltmeterreading remains unchanged, or increases in anuncontrolled manner, then the control unit is faultyand a replacement must be fitted.
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