G-26
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Electrical System
7. TROUBLE SHOOTING FLOW CHART FOR ALTERNATORS
SERVICE RECOMMENDATIONS :
Before dismantling Alternator from engine, make sure that Alternator is faulty. Below flow chart will
help on diagnosing the fault. It is recommended to replace complete Alternator for any internal failure
of Alternator. Not to disassemble the Alternator for repairing inside components.
SWITCH ON THE IGNITION
DOES WARNING
LAMP GLOW ?
NO
RAISE THE ENGINE SPEED
TO 1000 RPM (APPROX)
CHECK WARNING LAMP FOR ANY
DEFECT. CHECK “WL” TERMINAL IN
ALTERNATOR FOR PROPER
CONNECTION.
DOES WARNING
LAMP GO OFF ?
YES
NO
CHECK THE BELT TENSION. IF FOUND
SLACK ADJUST THE BELT DEFLECTION TO
BE 10-15MM WHEN PRESSED MIDWAY
AT THE LONGEST POINT BETWEEN
PULLEYS (REFER FIGURE BELOW) AND
CHECK FOR CHARGING. IF THE UNIT IS
STILL NOT CHARGING REMOVE THE
ALTERNATOR AND CHECK.
CONNECT DC AMMETER IN SERIES WITH ALTERNATOR
& BATTERY POSITIVE TERMINAL. ENSURE THAT THE
AMMETER READING FALLS BETWEEN 7 TO 10 AMPS.
IN CASE THE BATTERY IS FULLY CHARGED THE
AMMETER INDICATION MAY VARY. ALSO CONNECT
THE VOLTMETER ACROSS THE ALTERNATOR MAIN
TERMINALS. CHECK THE VOLTMETER READING.
DOES
THE VOLTMETER READ
BETWEEN 14.2 TO 15.0
VOLTS ?
YES
NO
REMOVE THE ALTERNATOR
AND CHECK REGULATOR
SWITCH “ON” THE HEAD LAMP
PARKING LAMP, TAIL LAMP AND OTHER
ELECTRICAL LOADS EXCEPT HEATER.
IS RATED
CURRENT OUTPUT
REACHED WITHOUT VOLTAGE
DROPPING BELOW
13.5 VOLTS ?
YES
NO
REMOVE THE ALTERNATOR AND CHECK
YES
ALTERNATOR FOUND ACCEPTABLE
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