Alternators Mitsubishi Mazda 1971-73

• Colt (1971-73)
• Mazda (1971-73)

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION, BATTERY CHARGING, OR USING A BOOSTER BATTERY FOR ENGINE START - Reverse polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage:

Battery Installation - Negative battery terminal must be connect to ground (negative ground system) and positive battery terminal must be connected to starter. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from the battery. DO NOT use a  Quick Charger to provide starting voltage.

Circuit Interruption - Battery must NEVER be disconnected when alternator is running.

High Voltage - DO NOT use a high voltage source to test diodes.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to negative battery terminal and positive lead to positive battery terminal. DO NOT reverse battery leads.

MITSUBISHI ALTERNATOR ASSEMBLY

DESCRIPTION

Mitsubishi alternators are conventional three-phase, self rectifying type units containing six diodes (three positive and three negative) which are used to rectify current. 

                             APPLICATION

Model                                                 Part No.

Dodge Colt

   1971-72 ....................................... AC2040K

   1973 ............................................. AG2040K

Mazda

   1971

      616 ...................................... 0290 18 300A

      1200 ....................................... 0324 18 300

      R-100, RX-2 .......................... 0839 18 300

   1972

      1200

         Standard ............................... 0324 18 300

         Optional ..............................0327 18 300A

      618

         Prior to 1/72 ...................... 0290 18 300A

         From 1/72 ......................... 0552 18 300A

         Optional from 1/72 ............. 0824 18 300A

      808 

         Prior to 1/72 ...................... 0290 18 300A

         From 1/72 ......................... 0552 18 300A

      B1600 .................................. 0605 18 300A

      RX-2, RX-3 ........................... 0866 18 300

   1973

      808

         Prior to 6/73 ........................ 0552 18 300

         From 6/73 ........................... 0453 18 300

      B1600 .................................. 0605 18 300A

      RX-2, RX-3 ........................... 0866 18 300

                                 SPECIFICATIONS

                      Nominal Output @ 2500 RPM

Application                       Amps                       *Volts

AC2040K .......................... 40 ........................... 14

AG2040K ...................... **33 ........................... 14

0290 18 300A .................... 32 ........................... 14

0324 19 300 ....................... 20 ........................... 14

0453 18 300 ....................... 50 ........................... 14

0552 18 300 ....................... 40 ........................... 14

0552 18 300A .................... 45 ........................... 14

0605 18 300A .............. ***28 ........................... 14

0824 18 300A .................... 60 ........................... 14

0839 18 300A .................... 32 ........................... 14

0866 18 300 .............. **** 32 ........................... 14

2329 18 300A .................... 32 ........................... 14

* - Rated output is 12 olts.

** - At normal temperature, 30 amps. at hight temperature.

*** - For 1972, 35 amps. for 1973.

**** - For 1972, 50 amps. for 1973.

                               Coil Resistance (Ohms)

Application                           Rotor                        Stator

All Colt .................................. 4.7 ............................. *

All Mazda .......................... **5-6 ............................. *

* - Test must show current continuity, no given alue.

** - Rotor resistance for 0866 18 300 in 1971-72 is 4-6 ohms.

Brush Wear Limit - To wear limit line (one third of original length).

Brush Spring Pressure - Standard value for 1973 is .79  lbs. with minimum of .46 lbs. For 1971-72, spring pressure is .6-.9 lbs.

TESTING

NOTE - Some testing is done as part of Overhaul procedure.

ON CAR TEST

Whenever battery is discharged and charging rate is low, following test should be made to determine whether fault lies in alternator or regulator. First, place ammeter between "A" terminal of regulator and battery. Disconnect wire at "F" terminal of regulator and touch lead "A" terminal of regulator. If charging rate remains constant, alternator is defective. If current increases greatly, then regulator is faulty.

OVERHAUL

DISASSEMBLY

1) Remove brush cover and through bolts. Separate diode end housing from drie housing by tapping front

CHECKING DIODES

bracket lightly with a soft mallet.

2) Place rotor shaft in padded vise using caution. Remove pulley nut, pulley, fan and spacer. Remove rotor drive end housing by lightly tapping end housing with a soft mallet.

3) To separate stator from diode end housing, unsolder three negative diode leads and connections between diodes. CAUTION - If excessive temperature is allowed, diode will become inoperatie.

TESTING

Diode Assemblies - Disconnect heat sink and check each diode with tester on continuity in forward or reverse direction. If the diode shows large resistance in one direction and small resistance in other direction, diode is normal. If it shows small resistance in both directions it is shorted. If large resistance is shown in both directions, diode is open.

Field Continuity - Check continuity between field coil and slip ring. No continuity indicates broken wire; field coil must be replaced.

Field Coil Ground - Check continuity between slip ring and shaft (core). If there is continuity, coil or slip ring is grounded and must be replaced.

Stator Coil Continuity - Check continuity between leads of stator coil. If there is not continuity, coil has broken wire and must be replaced.

PARTS REPLACEMENT

Diodes - To remove diode, use a suitable tool to support heat sink and remove diode by use of a suitable

INSTALLING DIODE

press. Press out carefully to avoid damaging mounting bore of heat sink. CAUTION - Do not strike diode as shock may damage other diodes. To install diode, support heat sink as in removal, select correct type diode (positive diodes have red markings; negative diodes have black marking), and press diode into heat sink.

Drive End Bearing - Remove bearing retainer by unscrewing set screws and press out bearing, using a suitable press.

Rear Bearing - Remove rear bearing from housing assembly, using a suitable press or bearing puller.

REASSEMBLY

Reassemble by reversing disassembly procedures, making sure polarity of diodes is correct.

Lucas Alternators 1968-73 Models

Car Models With Lucas Alternators:

• Austin (1968-73)
• Capri (1970-73)
• Cortina (1970)
• Cricket (1971-72)
• Jaguar (1969-73)
• MG (1968-73)
• Rover (1967-73)
• Sunbeam (1968-70)
• Triumph (1968-73)

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION & OTHER ELECTRICAL SYSTEM REPAIR CAUTIONS - Reverse polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage.

Battery Installation - Negative battery terminal must be connected to ground (if negative ground system) and positive terminal to starter. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from the battery. DO NOT use a Quick Charger to provide starting voltage.

Circuit Interruption - Battery must NEVER be disconnected while alternator is running.

Alternator Removal - Always disconnect battery ground before replacement of alternator.

High Voltage - DO NOT use a high voltage source to test diodes.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to negative terminal of battery and positive lead to positive terminal of battery. DO NOT reverse battery leads.

LUCAS 12-POLE "AC" TYPE ALTERNATOR

DESCRIPTION

Construction of the Lucas "AC" type alternators is similar to "ACR" type, except that a voltage regulator of micro-circuit construction is incorporated as  integral part of the "ACR" alternator. "AC" type alternators use an external regulator. Both type alternators have stators consisting of thee-phase, star-connected windings on a ring end cover and drive end bracket. The rotor is of eight or 12-pole construction (depending on model) and carries a field winding connected to two face-type slip rings. It is supported by a ball bearing in the drive end bracket and a needle roller bearing in the slip ring end cover. Two carbon brushes, one positive and one negative, bear against a pair of concentric brass slip rings. Slip ring end cover also carries sis silicone diodes, connected in a thee-phase bridge circuit to provide rectification of the generated alternating current output. On some models, field windings are isolated by means of a relay incorporated in the ignition switch circuit.

                                  APPLICATION

Model                                         Lucas Model No. (Part No.)

Austin America (1968-71) .................................. 16ACR (...)

Austin Marina (1973) .......................................... 17ACR (...)

Capri (1970-73)

   1600cc (1970-72)

      28 Amp ............................................. 15ACR (23593-B)

      35 Amp ............................................. 17ACR (23647-A)

   2000cc (1971-73) ........................................... 15ACR (...)

Cortina (1970) .................................................... 15ACR (...)

Cricket (1971-72 ................................................ 16ACR (...)

Jaguar (1969-73)

   6 Cylinder

      1969 Early ............................................... 11AC (23579)

      1969 Late ................................................ 11AC (23580)

      1970

          XJ6 .................................................. 11AC (23579-A)

          XKE ................................................. 11AC (23580-B)

      1971 .................................................... 11AC (23579-A)

      1972-73

         W/O AC .................................................... 18ACR (...)

         W/ AC ....................................................... 20ACR (...)

      12 Cylinder

         1971 XKE W/O AC ..................................... 11AC (...)

         1973 XJ12 .................................................... 11AC (...)

MG (1968-73)

   MGB & MGB GT

      1968-71 ............................................. 16ACR (23566-A)

      1972-73 ........................................................ 16ACR (...)

Rover (1967-73)

   2000 TC & SC

      1967-68 ......................................................... (54021162)

      1969 ..................................................................... (23549)

      1970 ................................................................. (23541-F)

   3500S (1970-71) ...................................... 11AC (23545-D)

   Land Rover 

      1971 ...................................................... 11AC (23549-D)

      1972 .....................................................  *16ACR (23685)

      1973 ............................................................  *16ACR (...)

Sunbeam (1968-70)

   1968-69 .................................................................. (23548)

   1970 ........................................................................ (23606)

Triumph (1968-73)

   Stag (1971-73) .................................................... 11AC (...)

   Spitfire Mk IV

      1971-72 .............................................. 15ACR (23634-A)

      1973 ...................................................... 16ACR (219267)

   GT6+ (1969-70) .................................... 15ACR (23562-A)

   GT6 Mk III (1971-73) ................................ 15ACR (23636)

   TR250 (1968-69) .......................................... 15AC (23544)

   TR6

      1970 ........................................................ 15ACR (23636)

      1971-73 .................................................. 17ACR (23635)

* - Standard, optional type number is 18ACR

                                   SPECIFICATIONS

                                    Nominal Output

Alternator                      Amps @ RPM                    *Volts

11AC ............................... 43 @ 6000 .......................... 12

15ACR ............................. 28 @ 6000 ......................... 12

16ACR ............................. 34 @ 6000 ......................... 12

17ACR ............................. 36 @ 6000 ......................... 12

18ACR ............................. 45 @ 6000 ......................... 12

20ACR ............................. 66 @ 6000 ......................... 12

* - Charging Voltage; 14.

                             Resistance Values (Ohms)

Alternator                        Stator Coil                 Rotor Coil

11AC ............................... 0.127 .............................. 3.8

15ACR ............................. 0.198 ................,,,......... *4.3

16ACR ............................. 0.138 ..................,,,....... *4.3

17ACR ............................. 0.133 ...............,,,,.......... 4.2

18ACR ....................... 0.087-0.097 ...........,............. 3.2

20ACR ....................... 0.180-0.200 ......................... 3.6

* - With pink windings. Purple windings are 3.3 ohms.

TESTING

ON CAR TESTING ("ACR" TYPE)

"ACR" ALTERNATOR
OUTPUT TEST CIRCTUIT

Testing Alternator Output With Regulator Inoperative 

1) Disconnect alternator harness connector. Unscrew molded cover from rear of alternator. Link together regulator negative terminal and "F" terminal. Connect an external test circuit as shown in lower half of illustration. CAUTION - Be aware of proper connections to avoid reversed polarity.

2) NOTE - Variable resistor across battery terminals must not be left connected any longer than necessary to complete the test. Start engine and run 800 RPM (1500 alternator RPM). The test circuit bulb should now be out.

3) Increase engine speed to 3200 RPM (6000 alternator RPM) and adjust variable resistance until voltmeter reads 14 volts. Ammeter reading should then be approximately specified rated output. If obvious variance from specifications is encountered, alternator necessitates removal and overhaul or replacement.

Regulator Test - NOTE - The following test assumes alternator is satisfactory. - 1) Disconnect variable resistor and remove link bridging regulator negative and "F" terminals. With remainder of test circuit still connected, start engine and run up to 3200 RPM (6000 alternator RPM), until ammeter registers output current of less than 10 amps. Voltmeter should then read 13.6-14.4 volts. Any variation necessitates regulator replacement.

2) If regulator is still shown to be satisfactory, disconnect entire external test circuit and reconnect alternator harness connector. Attach a low-range voltmeter between either positive alternator terminal and positive battery terminal.

3) Turn on headlights, start engine and increase engine speed to 3200 RPM. Record voltmeter reading. Transfer voltmeter connection to alternator frame and negative battery terminal. Record reading. If reading exceeds 0.5 volts on positive side or 0.25 volt on negative side, there is a high resistance in charging circuit which must be traced and corrected. See further testing on Overhaul procedure.

ON CAR TESTING (11AC)

1) Check alternator belt and adjust tension. Disconnect battery negative terminal lead. Disconnect the 35-amp output lead from alternator and connect on ammeter between output terminal and output lead. Disconnect leads from alternator field terminals and connect them to battery terminals. Then reconnect battery negative terminal.

2) Start engine and run up to 4000 alternator RPM. Ammeter should register 40 amps, indicating a good alternator and output lead. If zero or low reading is obtained, check output circuit and wiring by connecting a voltmeter between alternator output terminal and battery positive terminal. Note reading, then transfer voltmeter to alternator frame and battery negative terminal note this reading. If either reading exceeds 0.5 volt, there is a high resistance is circuit which must be traced and corrected.

3) If a high resistance is not found, but alternator output is low, remove and examine alternator brush assembly. Retest and if low output remains, replace or overhaul alternator.

4) If alternator output is satisfactory, disconnect battery terminal, remove ammeter, and connect alternator output cable to its terminal. Connect battery negative terminal. Switch on ignition and check for proper battery voltage at cable ends by connecting a voltmeter across them. A suitable battery voltage reading indicates field isolating relay circuit and wiring is satisfactory. A low or zero reading indicates a fault in field isolating relay or isolating contacts in ignition switch. See further testing in Overhaul procedure.

LUCAS INTEGRAL REGULATOR ALTERNATOR ("ACR" TYPE)

OVERHAUL

DISASSEMBLY

"AC" & "ACR" - 1) Except for regulator removal, both alternators can be disassembled as follows: Unscrew cover retaining screws and remove cover. Unsolder three stator connections from rectifier pack, noting positions. Remove two brush molding securing screws. Loosen rectifier pack retaining nuts and withdraw brush molding and rectifier pack.

2) Remove thee through bolts. Remove bearing, by slipping a tube over slip ring molding until it is even with outer track of slip ring end bearing, then drive bearing from its housing. Remove shaft nut, pulley and hsaft key. Press rotor from drive end bracket. Remove circlip retaining the drive end bearing and remove bearing. Unsolder field connections from slip ring assembly and withdraw assembly from rotor shaft. Remove slip ring end bearing.

Regulator Removal "ACR" - Disconnect colored tag  lead connectors from brush screw or brush box retaining screw. Remove other retaining screw and withdraw regulator.

TESTING

Rotor - Connect an ohmmeter and read resistance of field coil (across slip rings). Using a 110-volt A.C. supply and 15 watt test lamp, check for insulation between one of the slip rings and any rotor pole. If lamp lights, rotor is shorted.

Stator - Connect 12-volt battery and 36-watt test lamp to two of the stator connections. Then repeat test using any other combination of two of the three connections. If lamp fails to light in either test, stator has an open coil. Using a 110-volt A.C. supply and a 15-watt test lamp, check for insulation between any one of the three stator connections and stator laminations. If lamp lights, stator should be replaced.

Diodes - Connect a 12-volt battery and a 1.5 watt test lamp in turn to each of the nine diode pins and its corresponding heat sink on the rectifier pack, then reverse the connections. Lamp should light (with current flow) in one direction only. If lamp lights in both directions or fails in either, rectifier pack must be renewed.

PARTS REPLACEMENT

Diodes - If a defective diode is detected, the rectifier pack must be replaced as a unit.
Brushes - If length of brush protruding beyond brush box molding is .2" (5 mm) or less, the brush must be replaced. Check brush spring pressure, using a push type spring gauge. Gauge should register 7-10 oz. (when brush is pushed back flush with housing). If gauge is outside limits, renew brush assembly.

REASSEMBLY

Reverse disassembly procedure, noting the following: When installing slip ring end bearing, ensure it is fitted with open side facing rotor and that is seated fully. When replacing rotor to drie end bracket, support inner track of bearing with suitable piece of tubing. DO NOT use drive end bracket as the only support for bearing when fitting rotor.

Hitachi Honda Civic 1973 Alternator

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION & OTHER ELECTRICAL SYSTEM REPAIR CAUTIONS - Reversed polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage.

Battery Installation - Negative battery terminal must be connected to ground (negative ground systems) and positive terminal must be connected to starter. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery, cables must be disconnected from battery. DO NOT use a Quick Charger to provide starting voltage.

Alternator Removal - Always disconnect battery ground before replacement of alternator.

High Voltage - DO NOT use a high voltage source to test diodes.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to negative terminal of battery and positive lead to positive battery terminal. DO NOT reverse battery leads.

DESCRIPTION

Honda alternators are conventional three-phase, self rectifying type alternators. Six diodes (three positive and three negative), are used to rectify current.

                           APPLICATION & SPECIFICATIONS

Application                             Amps (RPM)                        Volts

Prior to Frame

   #1011758 ............................... 35 (2000) ........................... 12

From Frame

   #1011759 ............................... 40 (2000) ........................... 12

Minimum Brush Length - .2165" (5.5 mm).

TESTING

ON CAR TEST

1) Remove coolant reserve tank, start engine and allow to idle. Remove negative battery cable at battery.NOTE - If engine stops during test, reconnect negative cable before restarting engine.

ON CAR TEST CONNECTIONS

2) Connect a jumper wire from negative cable to positive side of ammeter. Connect a second jumper from minus side of ammeter to negative battery post.

3) Attach one end of a third jumper wire to positive battery post. Disconnect voltage regulator plug and touch other end of jumper to white/red wire terminal on male side of regulator plug. CAUTION - Do not leave this wire connected for more than 15 seconds.

4) Read ammeter and increase engine speed until ammeter reads maximum value. If value is below specifications, alternator must be repaired or replace.

OVERHAUL

DISASSEMBLY

1) Remove alternator pulley by using an allen wrench and box wrench. Mark alternator housing and stator frame for correct reassembly. Remove three alternator case screws and remove front housing, tapping lightly with a rubber mallet if necessary.

2) Remove rear housing with stator by holding rotor shaft and tapping screw bosses with rubber mallet. Remove nuts and washers from rear housing, noting location of all spacers, washers, insulators and nuts for reassembly. Separate stator and rectifiers from housing.

3) Unsolder brush holder lead and remove holder from stator. Unsolder stator coil leads from rectifier terminals using care not to overheat diodes.

TESTING

Rotor & Stator - Check rotor and stator for open, shorted or grounded circuits using a ohmmeter.

Diode Test - With diodes disconnected from stator, connect one ohmmeter lead to a diode and the other lead to diode plate. Note reading with ohmmeter on X1 scale. Reverse leads and again observe ohmmeter. If diode indicates either a high or low resistance in both directions, diode is defective. Repeat test on remaining diodes. If a diode is defective, entire diode palte, must be replaced as diodes are not replaceable individually.

Brushes - Measure length of each brush. If length is shorter than specifications, brush must be replaced.

HONDA ALTERNATOR

REASSEMBLY

Reassemble alternator by reversing disassembly procedure noting the following points:

1) When soldering diode terminals use care not to overheat diodes.

2) When installing rotor to rear housing, push up each of the brushes into the holder and insert a pin in brush lifting hole in rear housing. After installing rotor, pull out pin to permit brushes to seat on slip rings.

3) Tighten pulley locknut to 36-51 ft. lbs. (5-6.5 mkg) torque.

4) After assembly, rotate pulley and check that rotor is free of any interference.

Hitachi Honda Alternators 1963-74

Honda 1971-72

Application                                  Hitachi Part No.

AN600 Sedan ............................ LD 130-03 (USA)

AN600B Sedan ......................... LD 130-03 (USA)

AZ600 Coupe ............................ LD 130-03 (USA)

CHANGES, CAUTIONS & CORRECTIONS

BATTERY INSTALLATION, BATTERY CHARGING, OR USING A BOOSTER BATTERY TO START ENGINE CAUTION - Reversed polarity or excessive voltage will result in excessive damage to alternator system. NOTE the following to prevent damage:

Battery Installation - Negative battery terminal must be connected to ground. Positive terminal must be connected to starter lead. Do not reverse battery leads.

Battery Charging - If a "Fast Charger" is used, both of the car's battery cables must be disconnected from battery. Do not use "Fast Charger" to provide starting voltage.

Booster Battery (Used to Start Engine) - Booster Battery must be connected with negative lead to negative terminal of battery and positive lead to positive terminal of battery. Do not reverse battery leads.

DESCRIPTION

RECTIFIER LOCATION

The alternator is installed on the right side of the engine. The alternator rotor unit is a part of the flywheel and ring gear assembly which is mounted on the right end of the crankshaft. The alternator stator is installed in the flywheel housing. A separate rectifier, using silicone diodes, is installed at the right front bumper support and connected to alternator with lead wire.

SPECIFICATIONS

Alternator

Type ................................................ LD 130-03 (USA)

Operating Speed ............................. 1,200-7,500 RPM

Rated Speed .............................................. 5,000 RPM

14V Speed (Normal Temp) .......... 1,200 RPM (or less)

Output Speed ............................................. 5,000 RPM

Output Voltage ...................................................... 14V

Output Current ...................................... 35A (or More)

Rectifier 

Type ................................................. 5B 68-8A (USA)

Output ......................................................... 12V, 40A

Connection .......................................... 3-Phase, Bridge

Stator Coil Resistance ........................... 0.115 Ohms

Rotor Coil Resistance ............................. 4.05 Ohms

Minimum Brush Length ...................... 276" (7.0 mm)

Brush Spring Tension .... .56 lb. (0.255 mm) minimum.

                                         .76 lb. (0.345 mm) maximum

HITACHI (HONDA) ALTERNATOR (TYPICAL)

REMOVAL

REMOVING BRUSH HOLDER

1) Disconnect battery ground cable. Identify (for reassembly) and disconnect white lead wire from rectifier, then disconnect the white with red stripe lead from black lead. Remove starter assembly. Remove fan belt from crankshaft pulley, then remove pulley.

2) Remove brush holder assembly. Remove flywheel housing cover bolts, then remove cover. To remove rotor, install a rotor holder (special tool) to keep rotor from turning. Then fully thread in a rotor remover (special tool), and tap rotor out, while lightly hammering head of rotor remover. NOTE - Rotor is a taper fit to crankshaft.

3) Stator is installed in flywheel housing. To remove, separate flywheel housing from engine after removing four bolts. Stator then may be lifted out after removing the three bolts and nuts holding it in place.

REMOVING ROTOR

INSPECTION

1) Check rotor coil for disconnection and condition of insulation. Inspect continuity between the two slip rings using a suitable tester. No continuity indicates rotor coil is disconnected, and should be replaced. If continuity exists between slip rings and shaft, or core, the coil or slip rings are grounded, and should be replaced as required.

2) Alternator brush wear is normally minimal, however. If wear has reduced brush to minimum length specified, replace brush.

3) Using a suitable tester, check stator coil for insulation and disconnection. If no continuity exists between terminals, coil is disconnected and should be replaced. If there is continuity between stator coil terminals and

STATOR ASSEMBLY

flywheel housing or core, coil is grounded and should be replaced.

4) Inspect condition of brush and brush spring, and check also to see that brush slides smoothly in holder. To measure tension of brush spring, push in brush to depth corresponding to amount of brush wear plus .08" (2 mm). Check brush spring tension with suitable scale and compare reading with specification. NOTE - Length of new brush is .57" (14.5 mm).

5) Inspect rotor slip ring surface. If surface is stained or rough, refinish slip ring.

INSTALLATION 

Reinstall in reverse order of removal and note the following: When installing the flywheel housing cover, make sure that the two hollow pins (dowel pins) are installed in the housing. When installing the pulley, align puley

DOWEL PIN LOCATION

shaft pawl with the end notch of the crankshaft.

ALTERNATOR CIRCUIT (TYPICAL)

Hitachi Alternators Datsun & Subaru 1963-67

Models with hitachi alternators:

• Datsun 510
• Datsun 521 Pickup
• Datsun 520 Pickup
• Datsun 240Z Sports
• Subaru 1100
• Subaru 1300

CHANGES, CAUTIONS & CORRECTIONS

BATTERY INSTALLATION, BATTERY CHARGING, OR USING A BOOSTER BATTERY TO START ENGINE CAUTION - Reversed polarity or excessive voltage will result in extensive damage to alternator system. NOTE - the following to prevent damage.

Battery Installation - Negative battery terminal must be connected to ground. Positive terminal must be disconnected from battery. Do not use "Fast Charger" to provide starting voltage.

Booster Battery (Used To Start Engine) - Booster battery must be connected with negative lead to negative terminal of battery and positive lead to positive terminal of battery. Do not reverse battery leads.

DESCRIPTION

Hitachi alternators are conventional thee-phase, self-rectifying type alternators. Six diodes (three positive and three negative) are used to rectify current.

Application                                            Hitachi Part No.

Datsun

   520 (1966-67)...........................................LT119-07

   510 (1968-71)...........................................LT130-41

   521 (1969-71)...........................................LT130-41

   240Z (1970-71).........................................LT145-35

Subaru

   1100 (1971)..............................................LT170-75

   1300 (1971)..............................................LT130-59

                          SPECIFICATIONS

                    At 2500 Alternator RPM

Alternator                      Amps                      Volts

LT119-07.........................19.5.........................14

LT130-41...........................22..........................14

LT135-05...........................33..........................14

LT145-35...........................34..........................14

LT170-75 & 130-59............27..........................14

                               Nominal Output

Alternator                      Volt                      Amps

LT119-07..........................12..........................25

LT130-41..........................12..........................30

LT133-05..........................12..........................33

LT145-35..........................12..........................45

LT170-75 & 130-59...........12..........................30

Rotation - Clockwise at drive end.

Field Coil Resistance - 4.47 Ohms measured at slip rings at normal ambient temperature.

Alternator                                      Min. Brush Length

LT130-41.......................................... .256" (6.5 mm)

LT133-05.......................................... .275" (7.0 mm)

LT145-35.......................................... .295" (7.5 mm)

LT170-75 & 130 -59........................... .470" (12 mm)

Brush Spring Tension - Nominal........ .77 lb (.35 kg.)

                                    Minimum.......... .44 lb (.2 kg)

TESTING

ON CAR TEST

Whenever battery is discharged and charging rate is low, following test should be performed to determine

CIRCUIT FOR ALTERNATOR OUTPUT TEST

whether fault lies in alternator or regulator. First, place ammeter between "A" terminal of regulator and battery. Disconnect wire at "F" terminal of regulator and touch lead to "A" terminal of regulator. If charging current remains constant, alternator is defective. But if current increases greatly, then regulator is faulty.

ALTERNATOR OUTPUT

NOTE - Battery used for this test should be fully harged.

For output test, remove alternator from vehicle and connect wiring as shown in illustration. Drive alternator with a motor. Run alternator up to a speed where there is no reverse current flow to field coil. At this point alternator speed should be approximately 1000 RPM. Next, increase alternator RPM while at the same time, increasing load resistance to prevent voltage output from becoming too high. If alternator is functioning correctly, output current should be close to specified value at specified RPM and voltage, see specifications.

CHECKING DIODES

Drive End Bearing - Remove bearing retainer by unscrewing screws and press out bearing using a suitable press.

Rear Bearing - Remove rear bearing from housing using a suitable press or bearing puller.

REASSEMBLY

Reassemble alternator by reversing disassembly procedure. During assembly, always make sure polarity of diodes is correct.

OVERHAUL

DISASSEMBLY

1) Unscrew and remove through bolts. Separate diode end housing from drive end housing assembly by hitting front bracket lightly with a soft mallet.

INSTALLING DIODES

2) Place rear shaft carefully into vice so as not to damage rear shaft. Remove pulley nut, pulley fan and spacer. Now, remove rotor from drive end housing assembly by lightly hitting drive end housing with a soft mallet.

3) To separate stator from diode end housing assembly, melt solder from three negatie diode leads and from each wire between diodes and disconnect leads. CAUTION - If internal temperature of a diode rises over 300 degrees Fahrenheit (150 degrees Celcius), diode will be destroyed. Therefore, use a electric solder iron of 100-200 watt capacity for approximately two seconds to safely unsolder connections. Remove brush cover by unscrewing setscrews. Unsolder "N" terminal (yellow color) lead wire, then separate diode end housing and stator.

4) Remove heat sink and brush holder from rear cover by removing setscrews. Disassemble brush holder. Unsolder lead wire "F" (black/white), lead wire "E" (black color) and brush holder wires (negative and positive).

HITACHI ALTERNATOR ASSEMBLY

TESTING

Rotor - To test for open circuit, connect an ohmmeter between rotor slip rings. If ohmmeter reading is high, windings are open. A good rotor should have a resistance of approximately 4.46 ohms at normal ambient temperature. To test for grounded coils, connect an ohmmeter between either slip ring and rotor core or shaft. If ohmmeter reading is low, field windings are grounded. Check eccentricity of rotor, using a dial indicator. If eccentricity of rotor exceeds .0039 in. (.10 mm). it must be either repaired or replaced.

Stator - To test for open circuit, connect an ohmmeter successively between neutral lead wire (yellow color) and three stator leads. If ohmmeter reading is high, stator windings are open. To test for grounded coil, connect an ohmmeter from any stator lead to stator frame. If ohmmeter reading is low, windings are grounded. Repair or replace stator as necessry.

Diodes - With diodes disconnected from stator leads, check each diode with ohmmeter as follows.
Connect one ohmmeter lead to diode lead and connect other ohmmeter lead to heat sink and note reading. Reverse ohmmeter leads, and note reading. If both readings are very low or very high, diode is defective and must be replaced. A good  will give you one low and and one high reading.