G-25
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Electrical System
6. ALTERNATOR DO’S AND DONT’S
DO’s DONT’s
Do ensure that all electrical connections are Do not dis-assemble the Alternator without
clean and secure. removing the brush box assembly.
Do ensure that no electrical connection in the Do not run the Alternator with the battery
circuit including the battery is open. disconnected.
Do observe correct polarity, i.e. connect Do not disconnect any lead of Alternator /
negative to negative and positive to positive. Regulator with the engine in running condition.
Otherwise, Alternator will be damaged.
Disconnect all Alternator terminals, while Do not disconnect battery cables while the engine
carrying out welding jobs on the vehicle. is running.
Disconnect the battery earth cable before
removing the Alternator.
7. Increase the speed to 3000 rpm. The warning
lamp should not glow and ammeter should
shown charging current. Oil pressure should be
1.0 to 3 kgs/cm
2
.
8. Run the Alternator at 5000 rpm. Adjust the load
so that Terminal voltage is between 13.0 to 13.5
Volts. The Ammeter should read the rated output.
9. Run the Alternator at 6003 rpm, and adjust the
loads to 18 Amps. The volt meter should read
14.1 – 14.6 Volts.
10. Disconnect the Air pipe at the Vacuum pump,
install Vacuum gauge. Run Alternator at
5,000 RPM speed. After 35 seconds the Vacuum
reading should read 500 mm/Hg.
11. Close the solenoid valve, the Vacuum pump gauge
should read the rated Vacuum in 3 minutes at
5,000 RPM.
12. Check for Vacuum leak : Stop the drive (both main
drive and oil pump). There should not be any drop
in vacuum for 15 seconds.
5. ROUTINE MAINTENANCE
• Keep the alternator clean.
• Ensure that the ventilation slots are clear.
• Check and ensure that mounting bolts are
tightened properly.
• Ensure that the belt on the alternator is in good
condition.
• Check the belt tension and ensure that it is neither
too slack nor too tight.
• Adjust the belt deflection to be 10-15 mm at the
longest point when pressed at midway between
pulleys.
• Check the brush length after every 60,000 km.
• Ensure correct level of electrolyte in the battery.
• Check the general condition of the battery.
• Grease battery terminals with petroleum jelly.
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