Associated 8600 User Manual
ALTERNATOR - STARTER TESTER
Model 8600 1/2 HP
8601 1 HP
ASSOCIATED
OPERATION AND MAINTENANCE MANUAL
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions for the
alternator/starter tester you have purchased. You may need to refer to these instructions at a later date.
CAUTION: THE WEIGHT OF THE INDIVIDUAL COMPONENTS AND/OR THE ASSEMBLED UNIT MAY EXCEED
THE SAFE LIMIT THAT MAY BE LIFTED BY ONE INDIVIDUAL. EXTREME CARE SHOULD BE
EXERCISED WHEN HANDLING THIS MACHINE !
a) Always wear safety glasses while conducting tests. Foreign matter in the device being tested may fly out at high
speed and cause personal injury.
b) Keep fingers, loose clothing, ties, etc. away from the “V” belt drive components, rotating pulleys, fans, and starter drive
mechanisms.
c) Make sure the device under test is mechanically secure prior to the start of testing.
d) Keep one hand on the vise knob to stabilize the unit under test and the other hand on the test switch.
e) Use only a properly grounded, 20 AMP., 120 VAC, 60 Hz. dedicated receptacle. Wire supplying power to this
receptacle should be no smaller than 12AWG.
you are defeating a safety feature. Removing the ground prong could cause a harmful shock.
f) Use of an extension cord is not recommended. Tester performance may be degraded and it may also cause serious
internal heating in the machine.
g) Do not use outdoors, near flammable materials, or with extension cords. Use good judgement whenever operating
any electrical appliance.
h) Replace frayed or worn power cords and operate only in dry areas.
I) Keep away from children.
j) It is of the utmost importance that this test equipment be used only by a qualified, trained operator.
CAUTION - Do not remove the ground prong from the line cord as
INTRODUCTION
Your test bench is designed and manufactured to provide you with a state of the art, quality, accurate, sturdy piece of
equipment, and is intended to quickly and easily determine the condition of Starters and both internal and external
regulated Alternators.
The test bench is completely self contained and does not require the use of external automotive type batteries. This
feature alone results in customer convenience, safety, and overall reduced operating cost. The only requirement is that
the test bench be plugged into a dedicated 120 VAC, 60 Hz. receptacle. It is suggested that the wire to the receptacle be
no smaller than #12 AWG.
Some older buildings may require new wiring to be installed for your tester; consult a licensed electrician if you are unsure
of your wiring. It is also suggested that the tester be protected with a 20 amp. breaker or fuse. If your service is fused, it
should be of the slow blow type.
To prevent the possible ignition of fuel fumes found in some shops, and to aid in operator convenience and safety, the
tester must be operated at a minimum of 18 inches above the shop floor. The test bench can be conveniently operated on
a counter to demonstrate to the customer the conditions of his electrical device.
1
SPECIFICATIONS
Cabinet Dimensions:
Height: 17 inches Width: 14 inches Depth: 28 inches
Shipping Weight ........................ 108 Lbs..
Line Under voltage Alarm Point ............. 90 VAC
Starter Current Available ................350 Amps.
Alternator Load .......................... 8 Amps
Motor HP ..... ½ HP (1 HP Optional) Continuous Duty
Motor Protection ......Automatic Reset Circuit Breaker
Power Requirements ...... 120 VAC, 60 Hz., 20 Amps
Control Function Descriptions
Additional Features:
a) A sturdy, oversized “V” block with an easily
adjustable cast aluminum vise holds both
Alternators and Starters firmly and safely in
place during testing.
b) Slim-line design, heavy gauge steel cabinet and
base. Only 14 inches wide to maximize usable
bench top work space. Modular construction.
c) Constant voltage, current regulated solid-state
power supply with overload protection. A solidstate voltage regulator correctly simulates actual
vehicle voltage conditions. No contacts to burn
or to wear out.
d) A ½ HP (1 HP Optional) continuous duty
industrial motor - clockwise or counter clockwise
rotation, automatic reset circuit breaker
protected.
Starter Test Switch - Used to energize Starters.
Power - On/Off Switch - Main power switch. Used to
turn on the unit; allows all tests to be performed.
Drive Motor Switch - Activates drive motor - Press
switch up for clockwise (CW) rotation units, down for
counter-clockwise (CCW) rotation units. Note:
Alternators will operate correctly in either direction.
Volt-Amp. Meter - In VOLTS mode indicates the
charging voltage (under load) of the Alternator or the
Generator (if so equipped with optional Generator Test
Lead Module). The VOLTS mode indicates alternator
DC output voltage; the AMPS mode shows starter free
running amperage draw. Unit automatically selects the
mode needed (VOLTS/AMPS).
Stator-Relay LED - Indicates proper operation of stator
or relay output terminal (if Alternator is so equipped).
LED brilliance may vary from alternator to alternator.
Alternator LED - Functions the same as the Alternator
lamp in the vehicle.
Trio LED - This LED is used primarily with the Delco 1-2
plug and other Alternators with internal regulators disregard it on all other types of Alternators.
Diode LED - When the LED is on, reject the Alternator.
Illumination is caused by excess ripple (AC).
Most
Fuse - This fuse is for the DC Alternator current supply.
Replace only with a 15 Amp. fuse (AGC-15). Failure to
replace it with the correct fuse may cause damage to the
tester and will void factory warranty.
Voltage Switch - Switch up for Alternators being tested
at 12 volts. Switch down for Alternators being tested at
24 volts. (This switch applies to Alternator/Generator
voltages only.)
Generator testing is done in the same manner if
equipped with an optional Generator Test Lead Module.
6 Volt Generators are tested in the 12 Volt mode by
dividing the voltage reading in half to give the operator a
correct reading.
Short/Low Voltage LED - If the LED turns on and an
audible alarm sounds the Alternator is either shorted or
the hook up is incorrect, thus causing a short circuit in
the battery or the field circuit. If the LED turns on and an
audible alarm sounds when testing Starters, the starter
is either shorted or the power line voltage to the test
bench is too low to perform a valid test
Ignition LED - Indicates proper operation of the auto
ignition system while starting. (Applicable on solenoids
having this terminal connection.)
A-B Switch - Switch up for “A” circuit - Switch down for
“B” circuit. Consult the operating instructions for proper
position.
Safety Interlock Switch - This safety switch is
controlled by the belt guard position. When the belt
guard is up, the Drive Motor Switch is inoperative.
DO NOT, UNDER ANY CIRCUMSTANCES, ATTEMPT
TO BYPASS THE OPERATION OF THIS INTERLOCK
!!
Lead Socket - Socket for the Universal Lead Set of
Alternator test wires (For the Generator Test Lead
Module as well, if so equipped.)
2
ASSEMBLY INSTRUCTIONS
CAUTION: THE WEIGHT OF THE INDIVIDUAL COMPONENTS AND/OR THE ASSEMBLED UNIT MAY EXCEED
THE SAFE LIMIT THAT MAY BE LIFTED BY ONE INDIVIDUAL. EXTREME CARE SHOULD BE
EXERCISED WHEN HANDLING THIS MACHINE !
a) Attach the plastic handle to the outside of the upper belt guard with the self tapping screw.
b) Thread the vise handle onto the vise.
c) The upper guard interlock trip rod may need to be adjusted. Loosen the two (2) jam nuts on the interlock trip rod and
adjust the rod so that it trips the interlock switch just prior to the guard being in the DOWN position. Once the
adjustment is made, tighten the jam nuts to secure the trip rod in place. To test the operation of the interlock, listen
carefully as the guard is lowered. A faint "click" should be heard just before the guard is in the DOWN position,
indicating that the trip rod has tripped the switch.
d) Plug the Universal Test Lead Set into the front panel. Read this manual completely before attempting to operate this
machine. This will insure years of trouble free operation and insure operator safety.
e) In the event of hidden shipping damage, contact the carrier immediately. Do not discard the packaging materials -
save them for the carrier’s inspection.
INSTALLATION
a) Once you have the tester assembled, it is very important to install your machine in the following manner:
b) The tester must be placed on a sturdy work bench or counter that is larger than the base of the tester.
c) The tester must be plugged into a dedicated 120 VAC, 60 Hz., GROUNDED wall receptacle. It is suggested that the
supply wire to the outlet be no smaller than #12 AWG and be as close to the circuit breaker panel or fuse box as
possible. It is also suggested that if fuses are used, that the fuse be of a 20 Amp. slow blow type.
Use of an extension cord may degrade the performance of the tester and is not recommended. It may also cause
serious internal heating in the machine.
d) For safety reasons and ease of operation, the tester should be placed on a sturdy work bench or counter top.
WARNING: This equipment, or the equipment that it is testing, may produce arcing or emit
sparks. Locate this device a minimum of 18 inches above the floor.
Do not use outdoors or near flammable material.
This device employs rotating machinery. Do not operate it while wearing loose clothing or
apparel that may become entangled, such as neckties.
OPERATION
WARNING: Attempting to test a generator without using the optional generator test module may cause damage
to the internal electronics of this tester.
NOTE: The A/B switch must be properly positioned for alternators and generators. Normally alternators should
be tested with the switch in the "B" circuit.
Operating Procedures - Alternators:
a) Mount the Alternator in the vise using the bar to secure the lower end to the vise. Secure the top portion of the
alternator with the hold down arm attached to the vise handle.
b) Line up the motor and the Alternator pulleys by moving the vise to the left or to the right. Tighten the vise to the base
with the hold-down screws.
c) Push the vise handle forward; attach the V-Belt and release the vise slowly.
d) For Negative ground units, connect the large Black clamp (Ground) to the ground (GRD) terminal, or to the frame of
the Alternator being tested.
e) For Negative ground units connect the small Red lead wire (Batt) to the terminal of the Alternator marked “BATT” or
“Output”.
NOTE: On Positive ground units, the small Red lead and the large Black clamp are reversed.
3
Loading...