Craftsman 161.210400 User Manual

IIIIIIIII I

2-170701

I [11 II ........

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Sears

k ............. . ......

owners

manual

MODEL NO.

161.210400

.;_(/ )-

CRRFTSHRN

Caution:

Read Rules For Safe Operation

and Complete Operating Test

Procedures

Carefully

ENGINE ANALYZER

FOR 12& 24 VOLT SYSTEMS

. OPERATING INSTRUCTIONS

• SAFETY RULES

•TUNE- UP PROCEDURES

• REPAIR PARTS

............ •........ . .....

PRINTED iN U.S.A.

,, ,,,, , ,, ,,,,,, , ,I .......... ' I I II Illl 11 IIIIIII IIII 11

SEARS, ROEBUCK AND CO. U.S.A.

CHICAGO, ILLINOIS 6068.4 ......

2-17070_

TOT Numld

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IMPORTANT

The information in thls manual will serve as a generaJ gulde for engine

tune-up and charging systemtests and adlustments.

CONSULT THE VEHICLE SERVICE MANUAL FOR SPECIFIC TUNE..UP

INFORMATION AND TEST PROCEDURES. ALWAYS FOLLOW THE

MANUFACTURER°S SPECIFICATIONS AND TEST PROCEDURES FOR ADJUSTING DWELL ANGLEe IDLE SPEED AND CHARGING SYSTEM

OUTPUT, ESPECIALLY VEHICLES WITH MODERN ELECTRONIC

IGNITION AND EMISSION CONTROLS. DO NOT ATTEMPT TO

SERVICE VEHICLE WITHOUT MANUFACTURER'S INSTRUCTIONS.

The following Is a list of publishers who have service manuals available for your

specific vehicle at a nominal cost. Write to them for availability and prices, specifying the make, style, and model year of your vehicle.

A. E. A. Tune-Up Charts

Automotive Electric Assn.

130i W. 22nd St., Suite 202

Executive Plaza Building Oak Brook, Illinois 6052%

Chilton_s Auto Repair Manual

Chllton Company

56th and Chestnut Streets Philadelphia, Pennsylvania 19139

GM Diagnosis and Repair Manual GM DR Manual Headquarters

P. O. Box 1185 Southfield, Michigan 48075

Motor's Auto Repair Manual

250 W. 55th Street

New York, N. Y. 10019

National Service Data Book National Automotive Service, Inc.

Div. Glenn Mitchell Manuals, Inc. Box 10465

San Diego, Ca]ifornia 92110

Chrysler Corporation Service Publications Dept.

26001 Lawrence Ave. Center Line, Michigan 48015

Helm Incorporated

P. O. Box 07150 Detroit, Michigan 48207

FULL 1 YEAR WARRANTY

IF, WITHIN 1 YEAR FROM THE DATE OF PURCHASE, THIS AUTOMOTIVE TEST INSTRUMENT FALLS DUE TO A DEFECT iN MATERIAL OR WORKMANSHIP,

RETURN tT TO THE NEAREST SEARS STORE THROUGHOUT THE UNITED STATES÷ AND SEARS WILL REPAIR OR REPLACE iT, FREE OF CHARGE.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO

HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

SEARS, ROEBUCK AND CO, DEPARTMENT 898/731A

SEARS TOWER CHICAGO, IL 60684

Wage

RULESFOR SAFE AUTOMOTIVE TESTING

READ CAREFULLY

Read this Owner's Manual and these

Rules for Safe Automotive Testing core- fully. Fa_iure to Follow instructions

and safety _ies could result tn serious

bodily _nlury and/or damage to the

Instrument.

Beforestarting the englne_ set the park.,

Ing brake and place gear selector In

NEUTRAL an standard transmissionsor

PARKon automatic transmission.

The carbon monoxide in exhaust gas is

highly toxic. To avoid asphyxiation, alway_ operate vehlcle In a well..

ventilated area. if vehicle Is In an en- closed arean exhaust should be routed

dtrectly to the outside via leakproof ex-

haust hose.

Whenoperating any test instrument from

on auxiliary battery+ connect a jumper

wlre between the negative terminal of the aux_llary battery and chards ground

on the vehicle under testfor negative groundsysten_h Forpositive ground systems+connect the jumperwire to the positive terminal of the auxll _ary battery

and chosdsground an the vehicle.

Whenworking in a garage or other en-

closedarea, auxii la_ battery should be

located at least 18 Inches above the floor to minimize the potsibllity of spork_

;gniHng gasolinevaporsand causlng an

explosion.

comportment€ontaining charging bat.. terles shouldbe well ventilated to

prevent accumulaHon of explosive gases. To avoid spark_, do ru_tdisturb the battery charger connectlonswhile battery is charglngs and always turn

charger off before dlsconnecti_'gthe battery clips. When removing or re-

connecting battery cables, make sure

Ignition switch and all acce.orles are

turned off.

Never add acid to a battery once the

battery has beenplaced In service.

Doing so m_y result in dangerous spatteringof electrolyte o

Keep hanch, halr_ necktie, loose clothing and test leadswell away from fan blade, fan belt_ power steering

belt, air conditioner belt and other

movingengine parts_as serious injury

could result from entanglement.

10.

Do not touch hot exhaust manifold, radiator or hlgh-voitage spark plug

and coil ter_nlnals. Spark voltages ore nat normal ll) lethal but an tnvotuntmy

lerk of the handsor armscaused by

electrical shockm_ result in Injury,

II.

Never took dlre:tly Into carburetor

throat while engine iscranking or

running. A sudden backfire can cause serious burns.

An automobile battery Is €apable or pm- duc|ng very hlgh currents. Therefore,

exercise reasonable care when working

near the battery to avoid electrical con- nectionsthroughtools, wristwatch, etc.

Avoid contact with battery electrolyte.

It can eat holes In clathlng, burn skin

and cause permanent damage to eyes. Always wear q_iash proof safety goggles when working around the battery, if

battery electrolyte is splashed in the eyes or on skln, immediately flush the affected area for 15 minutes with large

quantities of clean water. In case of eye €ontact0 seek medical a_d,

The gasesgeneratedby a chargtng bat-.

tory are highly explosive. Do not

smokeor permit flame or spark to occur near o battery at any tlme+ particular-

ly when it Is charglng. Any roomor

i2.

To avoid the possibility of a flash fire,

do not smoke or permit flame or spark

to occur rear carburetor_ fuel line+

fuel filter, fuel pumpor other poten-

tial sourcesof spilled gasoline or

go$ol|ne vapors.

13.

Never remove radiator cop while the

engine is hot. Hot €oolant escaplng

under pressure can cause serious burnt.

14.

The jack suppliedwith the vehicle

shou|dbe usedon|y for changing wheels.

Never crawl under car or run engine while vehicle lson iack.

15.

When making electrical test connec-

tions to the vehicle, do not usethe

carburetor or other fuel systemcompo-

nentsas a groundconnectlon_ as a spark could lgnffe the gasoline vapors and cause a fire or an explosion.

DESCRIPTION

_ge J

I •

METER. Provides following scales- Low Ohms X 1, 0 to 1,000 Ohms (10

Ohms center scale), HI Ohms X

1,000, (10,000 Ohms center scale)t

RPM Hi 0-6000, Lo 0-1200 RPM, Volts 0-i6 Lo, 0-32 Hi. Dwell 8

cyl. _)-45 a , 4 cy!. 0-90 °, 6 cyl.

0-60 , Amps, Parers 0-3.2 Volts1

AIte rnator-good/defective zones.

ZERO ADJUSTER. Meter painter

adjustment, if pointer is not on zero, slowly rotate this plastic slotted screw

right or left to set pointer on zero

line. Check before testing.

RED AMPS SOCKET. Insert RED plug on Amps lead.

FRONT PANEL AND CONTROLS

FIGURE I

6. BLACK - OTHER TESTSSOCKET. In- sert BLACK plug on test lead.

OTHER TESTS SELECTOR SWITCH.

•

Always place switch In CENTER posi-

tion for all tests, indlcoted by functlon switch (No.B) above. Use left hand posl-

tlon for charging Amps and right hand positton for starting Amps. ALWAYS return switch to center posltlon when Amp$ test is completed.

. FUNCTION SELECTOR SWITCH. Used

to select meter range for each test. A description of each test function is described on page 4.

WHITE OHMS SOCKET. Insert WHITE

plug on Ohms lead.

BLUE RPM PICK UP SOCKET. Insert

Blue plug on inductive pickup lead.

. RANGE SELECTOR SWITCH. Select

for HIGH or LOW scale range for VOLTS,

RPM, or OHMS depending on the test being performed.

Function Selector

Alternator RPM InducttveTach

m m D

Volts__, well

Points m _ Ohms

FUNCTION SELECTOR SWITCH POSITIONS

FIGURE 2

POINTS. 3.2 Volt Lo scale-provldes

point condition on scale. Also used

for locating voltage drops in elect.. rlcal starting and charging system.

VOLTS. Used to Indicate battery charging and starting cor_ditlons. Use 16volt Lo scale for t2 volt systems_

and 32 volt (HI) r_ale for 24 volt systems•

. ALTERNATOR. Indlcates alternator

condition on GOOD or DEFECTIVE sca'te wlth englne running. It w(ll

detect open or shorted diodes or windings.

.................................................. i i i iiillll illrlll[ i iii ii ...................................................

IMPORTANT: The above function tests will

4. RPM. Provides i200 or 6000 RPM engine speed reading. See item #9

Page 3. Use Lo-i200 RPM range fat

all Lo speed carburetor idle tests

and Hi- 6000 RPM range for high speed tests.

5. DWELL. Used to check point dwell

on breaker polnt ignitton systems.

Read 45 ° scale fo[ 8 cvi.o 60 ° scale for 6 cyl, and 90" scale for 4 cyt.

engines.

OHMS. HI & Lo - used to measure

electrical resistance in Ohms, on

ignition cables, ballast resistOrSeor ignition coil windings. Select HI or Lo position. See Item 19 Page 3.

NOT WORK on meter unless other

tests selector sw(tch4, ITEM Nc. 7 Page No. 3) Is in CENTER

POSITION for OTHER TESTS.

NOTE: The Ohms test operates from an

internal 9 volt battery and ;ncorperates

automatic Internal zero calibration.

No external zero adjustment ;s required.

IGNITION J

KIT

ACCESSORIES

FIGURE 3

BATTERY POST ADAPTER. Used in

electrical systems tests with i00 Amp

4t FOREIGN SPARK PLUG ADAPTER.

Used to make ignition cable tests.

and 400 Amp shunts.

G.M. DIAGNOSTIC CONNECTOR.

SIDE MOUNT ADAPTER. Used with

Battery Post Adapter on batteries with

side terminals.

JUMPER LEAD. Used in electrical sys- tems tests.

ALTERNATER FIELD PLUG CONNECT-

ADAPTER. Used to make tests on G.M. cars equipped with the diag-

nostic connector.

PRIMA!RY COIL ADAPTER. Used to

provide easy hook-up on ignLtion sys-

tems with insulated call primary con-

necHons.

OR. Used in "A" & "B" circuit alter-.

nator output tests.

H.E.i. ADPTER. Used to provide

DOMESTIC SPARK PLUG ADAPTER. Used to make ignition cable tests.

................................................ ' .......................... _'_ ..................... Itrtrnlnrlrllllllrlrlll .................................................................................................

Dwell connection on G.M.H.E.I.

systems.

TEST LEADS

FIGURE 4

The plugs and socketsare pol-

arized to insure correct attach-

ment. The socket has a groove on each top corner. The plug

has a mating ridge on the inside of the top corners.

BLACK

RED

POINTS, VOLTS, j _m,._

AND DWELL ..................._.,_,,_ _,_

AMPS ....

r* _"b'_WITH '-'_':::':'100/400.......AMP"' _'SHUNT'" _-- I_€;

LEAD _ PANEL PLUG k_ SOCKET

BLUE

_m,.. OHMS

WHITE

RPM

v_,a_,.,/l_ll_lr'1_,. I IUI_I_'.'_ run r-t_l_C.lll_iL I r..,.._ t O

BREAKER POINT CONVENTIONAL IGNITION SYSTEMS

I,, METER ZERO ADJUSTER. Before con-

necting any test leads, always check meter po_nter zero position, if not on zero, slowly rotate adjuster with pro- per size flat screwdriver and set point-

er on zero line.

2. LEADS. insert all three test leads

into matching color sockets on panel. Connect leads as illustrated below.

3. Install battery post adapter on the negative ground battery terminal as

shown.

4, Connect RED clip to battery positive

(+) termlnal,

5. Connect BLACK clip to battery neg-

atlve (-) GRD terminal,

JAWS MUSTCLOSE SO UPPERAND LOWER yPLUG

PoLEP,ECESTOUt. ACH'o'r.ER®

10.

Connect the GREEN clip to the dis,. tr_butor termlnai on call primary.

Attach RPM induction pickup to a spark plug cable as close to dlstrtbu-

tar cap as possible. ,Jaws must be fuliy closed.

DO NOT cc_nect OHMS clip. Engine must be at operating tempera-

ture before testing, Proceed with tests

as outt_ed in this manual. Starter Amp shunt must remain closed

at all times except for charging sys-

tem test as indicated. Damage to Battery Adaptor can occur if the

above instruction is not followed,

WIRE TO E

THIS GAP

CLOSE STARTER SHUNT FOR

STARTERAMPS

OPEN FOR CHARGING

AMPS

RED

TACH PICK-UP MUST BE AS CLOSE TO DISTRIBUTOR CAP

AS POSSIBLE

tEEN

FIGURE

TO GROUND

ON ENGINE

iSE NUTS MUST

_-_ BETIGHTENED WITH

A WRENCH.

TI EN

THIS SCREW

I'O STARTER AND ALTERNATOR

SCREW POST INTO BATTERY

TERMINAL BEFORE INSTALLI

BATTERY POST ADAPTER,

RED

CONNECTIONS FOR ENGINE TESTS

ELECTRONIC IGNITION SYSTEMS

Connect test leads as instructed on previous page for BREAKER POINT

systemsand as illustrated below with

the following exception; See Test Number

15 far proper connection of the GREEN

clip.

Engine must be at operating temperature

before testing.

SEE PAGE No. 6 FOR NUMBER IDENT- IFICATION.

BLUE

Proceed with tests as outlined in this manual--Oral fling those tests which

apply only to BREAKERPOINT SYSTEMS

Always close starter shunt b6fore

starting engine.

_PLUG WIRE TO BE

JAWS MUST CLOSE SO UPPERAND LOWER POLE PIECES TOUCH EACH OTHER

RED

CLOSESTARTE_SHUNT

FORSTARTERAMPS OPENFORCHARGING

AMPS_.__

_LACK

See Test

Numbe r 1.5for

connection

CLAMP TACH PICK-UP MUST BE

CLOSE TO DISTRIBUTOR CAP AS

POSSIBLE

IEEN

DISTRIBUTOR

STRIBUTOR MAGNETIC

_ICK-UP CONNECTOR.

)BLACK

GROUND

ON ENGINE

NUTS MUST

BETIGHTENED WITH

EN A WRENCH.

THIS SCREW

STARTER AND ALTERNATOR

Test Number 1--Startin_ and Crank ing_Vg.!tage,

I. Place function switch in the VOLTS position. Engine must be disabled

to prevent Starting for this test. On ELECTRONIC IGNITION, disconnect battery cable at coil or unplug pickup coil connector at distributor

or ground HT secondary lead on any external coil system. ,

2. Close starter amp shunt (See page 6, Figure 6) before operating starter.

3. Have an assistant turn the ignition switch to the START position and operate starter for 15 seconds. Observe battery voltage reading

with engine cranking, (Figure 8).

4. A battery in good, fully charged condition should read a steady 9 volts

or more.

5. If the battery voltage reads below g volts, recharge battery to full

charge condition.

6. Excessive fluctuating voltage reading (over i volt) can be caused

by a starter in poor condition due to worn bearings, dirty commutator, a defective battery or corroded starter cables, Clean, tight connec-

tions are a must throughout the starter system.

STARTING AND CRANKING

BA TTERY V OLTS

RED

BLACK

CLIP

GR BATTERY STARTERMOTOR ENGI NE

Test Number_2-,Starter Current Draw

VOLTAGE TEST CONNECTIONS

FIGURE B

SOLENOID

TERMINAL"S"

)UND

I. Place center slide switch to the right hand starter amps position.

Operate starter and note starter current on the 400 Amp scale, (Figure 10), Compare to specifications. IMPORTANT--Always return switch to center

position for other tests when amps reading is compieted{AZ_o _¢e F_gu_e 15J.

2. If battery-starter test is normal (a steady reading over 9 volts),

proceed to Test Number 4_Cha_gingS_stemVg]tage and Current.

CLOSE STARTER SHUNT FOR

STARTER AMPS OPEN FOR

CHARGING

AMPS

BLACK

Page 9

RED

BETIGHTENED WITH

A WRENCH.

TIGH!

v THIS SCREW

STARTERAND ALTERNATOR

Conn_c_on_ For S_J_uzt_.ng il C,ho_rg_ng

CuArent Measurements

FIGURE g

Test Number 3--Starter Circuit Voltage_..Loss

I. Disconnect all tester leads. Use only the BLACK PLUG battery-dwell

lead for this test. Use the BLACK and GREEN test clip for voltage loss tests.

2. Place function switch in POINTS position and read 3 volt points scale. Each division is .I volt.

3. Disable engine to prevent starting by grounding HV iead of the coil as shown below. On HEI or electronic systems disconnect battery

lead at coil or unplug distributor pickup coil connector.

4. Refer to starter system illustrated below. Connect GREEN and BLACK clips across each section of circuit shown by numbers (i-2-3-4 etc.).

5. All readings must read .2 volts (2 div) or less for normal conditions. Reverse test leads if meter reads backwards.

6. High readings will be caused by corroded or loose connections at battery terminals, cables or a worn solenoid.

TO GROUND

ON ENGINE

NUTS MUST

STARTERAMPS

S_t_ C_r{nt .,c_it_h Po_Z_Zon

FIGURE 10

Connect_Lon,s For Vo.&_ge

Lo_S M_asu_r_ments

FIGURE 11

STARTER

va_ iu

7, Remove and clean battery terminals and cable terminals in a warm

water solution with baking soda to dissolve corrosion, Tighten nuts

on starter solenoid terminals. Readings below B volts at the starter usually indicate a defective starter cable or burned solenoid con-

tacts. Replace defective parts as required for good starter per- formance.

8. Replace worn or corroded cables as required to correct condition. g. Do not crank for mor_ than 15 seconds at a time, Allow starter

motor to cool off for 30 seconds between tests,

10. When tests are completed, reconnect coil for normal starting.

The function of the charging system is to keep the battery In an optimum

state of charge, to provide the necessary current to start the engine,

and operate the electrical systems when the engine is running. The

battery is charged by an alternator that is driven bye belt connected to a pulley on the engine crankshaft. The alternator generates an alter-

nating current (A, C. ) that is converted by internal diodes Into direct current (D. C,) to charge the battery, A regulator is needed in the

charging system because the alternator output voltage increases as the

engine speed increases, The regulator keeps the alternator output voltage

at a safe upper limit so the battery will not be overcharged and the headlights and accessories will not be damaged by excessive voltage.

I. Place function switch in the VOLTS position. The Center Slide Switch

must be in the OTHER TESTS position.

2. Slide the RANGE SELECTOR switch to the LOW range(O-16 volts) for

12 volt systems or to the HIGH range (0-32 volts) for 24 volt sy- stems. Read test results on the appropriate VOL_S scale.

3. Be sure the shunts are in position on the Battery Amps Adapter as shown in Key No.I Page 5, before starting the vehicle.

CAUTION: TIGHTEN ALL NUTS ON THE BATTERY ADAPTOR FIRMLY WITH A WRENCH TO AVOID EXCESSIVE HEAT AND POSSIBLE SHUNT DAMAGE.

4. Before performing Step 5, start the engine and allow it to run for

10 to 15 minutes or until the engine compartment is warm, then shut it off. In order to obtain proper results from this test, the battery must be partially discharged. To accomplish this, switch

on the headlights and put the blower on HIGH for a minimum of one minute, or remove the distributor wire to prevent the car from

starting and crank the engine for about 30 seconds, then follow step 5,

5, Start the engine. Operate at a fast idle (approximately 1500 RPM).

Open the starter amps shunt. Note the battery charging voltage. The

meter should read over 12 volts and slowly rise to regulated voltage

in a few minutes (15 I/2 volts maximum).(Figure 12)

6. Move the Center Slide Switch to the CHARGING AMPS position and note the alternator charging rate compared to vehicle specifications.(Figure 12)

Shortly after starting, an alternator in good condition should charge from 50 to 80% of its rated capacity, and slowly decrease as the

battery regains its charge. The charging voltage will slowly rise as the ampere rate decreases and maximum regulated voltage Is obtained.

7. Move the Center Slide Switch tO the OTHER TESTS position again for

voltage reading and operate the engine at fast idle until the charging voltage stops increasing. Note the maximum voltage and compare

to vehicle specifications.

8. If the charging voltage exceeds IB I/2 volts or as specified, replace

or adjust the voltage regulator. If the voltage reading is too high,

the defect could be:

Page 11

DEFECT

A. High resistance in the ground

circuit

B. Regulator set too high

Clean and tighten all ground

connections

Adjust to the proper setting

ACTION

(If adjustment is possible)

Most late model vehicles use a regulator which is of solid

state design and cannot be adjusted. These must be re-

placed when they are defective,

C. Defective regulator

Replace Regulator

if the voltage reading is too low, the problem is either in the alternator, regulator, or the battery.

9. If charging voltage DOES NOT slowly INCREASE, this may indicate a defective alternator. Rotate the Function Switch to the alternator

position, turn lights on and operate the engine at approximately 1200 RPM. Read the aiternator scale. A reading in the gray defective zone indicates defective diodes or windings in which case the alternator

diodes and windings are functloningproperly.(Figure 12).

10. If a low or no charging rate is indlcated, check alternator output under full field conditions by removing voltage regulator control action. (See pages12& 13 for connections.) To apply full field voltage for maximum output, refer to vehicle specifications to determine whether type "A" or "B" system is used for proper field bypass

connections.

CHARGING

AMPS

CHARGING

V OLTS

ALTERNA TOR

om,w_,m CONDITION

RED CLIP

BLACK

VEHICLE TO REGULATOR

ENGINE GROUND

12 VOLT BATTERY FIGURE 12

"J_'/ CHARGING AMPS & VOLTS

ALTERNATOR

WIRES

Page12

IIATTERY _ft AOAPTI[R CONN- tCtlONS ItOlt ALTERNATOR Tilt

CHARGING ot_,r_

AM ,s gill

FIGURE 13

NOTE: If the AMPS indicates below

zero (left) during CHARGING or STARTING, reverse the leads as

shown,

Caution: DO NOT pull on the wires, if

necessary_ grasp the terminal with pliers

tO remove it,

FIGURE 15

FIGURE 14

FIGURE 16

"A" CIRCUIT

(Electronic Voltage

Regulator)

Remove field lead (green wire) from the alternator field terminal. Connect

iumper wire from the alternator field terminal to ground.

Battery

Output

Remove

Field Lead

(Green

Wire)

Field Terminal

(Horizonhal)

CHRYSLER to ground

JJL ...... _.....................

Remove cap from the field Stator terminal. Connect jumper Terminal

wlre to field terminal and !

ground. Ground Terminal

Terminal

Plug

Jumper

Connect Jumper

FIGURE i7 A

Field Terminal

(Vertical) (Blue Wire)

FIGURE 17 C

Field Term;hal

Regulat_

Terminal

Insert screwdriver not more than I inch in end frame hole, ground tab

to frame with screwdr;ver. No

additional adapter is needed.

FIGURE 17 B

Hole

DELCO

Tab

End Frame

Remove Cap

INTEGRAL DESIGN

FORD Regulator Exclte' Terminal

(to Ignition Switch)

Ground with

Jumper Wire

"B" CIRCUIT ( External Voltage Regulator)

i'_e 13

.................................................... II II]llllllnll I IIIIIIIIII II ................. r

Battery Jumper Term _nol

Plug

CHRYSLER

bisconnect

F_eld Lead

FIGURE 18

On some vehicles if may be inc_onvenlent to

connect the iumper wlre at the alternator.

Imsuch a iftuaHon remove the regulator con-

nector from the voltage regulator and €onnect

a iumper wire as illustrated.

ignition

Te _1

DELCO

Stator _"_\ /

Di,conoe=t/ __./7,_

Remove field lead from field terminal. Connect iumper w_re from positive

terminal of battery to the field lead.

Jumper

Battery,

Ignition Switch

F;et

Gr°umd__B_attery

FORD Term;hal

........................................................................ 1111111111111111111111111111111111"

Jumper

Batter

Regulator

Commector

Field

Field Stator

ru_E _

I. Be sure the shunts are tightly secured to the Battery Amps Adaptor

as shown in Key No. I Page 5 , and the Function Selector Switch is placed in the Alternator position.

CAUTION: TIGHTEN ALL NUTS ON THE BATTERY ADAPTOR WITH A WRENCH TO

AVOID EXCESSIVE HEAT AND POSSIBLE SHUNT DAMAGE. IF YOU ATTEMPT TO

START THE ENGINE WITH THE SHUNT DISCONNECTED, THE 1/40HM RESISTOR

MOUNTED ON THE BATTERY ADAPTOR MAY BLOW OUT.

2. Start the engine, then carefully disconnect the slotted ends

of the shunts as shown in the figure below. Turn the headlights on and operate the engine at approximately 1200 RPM and observe the

alternator condition scale.

3. A reading in the RED GOOD ZONE on the meter indicates that the alternator windings and diodes are satisfactory.

4. A reading in the GRAY DEFECTIVE ZONE indicates that one or more diodes are open or shorted or that the stator winding is open or

shorted to ground or has shorted turns. Refer to Tests 9 and 10

Alternator Diode, Statorand Rotor Tests for further testing.

IMPORTANT: Refer to vehicle specifications to determine whether type "A" or type "B"system is on the vehicle, Also check the rated output of

alternator on the nameplate or specifications listing,

1. To perform this test, it is necessary to ground the field in the type A Circuit or remove the regulator from the charging system and

energize the field in the Type B Circuit. This provides full field

operation and the alternator will charge at its maximum rated capacity,

2. Place the FUNCTION SELECTOR Switch in the VOLTS position and slide

the Center Slide Switch to the AMPS CHARGING position.

3, On the Type A Circuit, ground the field as shown on page 12, proceed

with Step 5 below.

4. On the Type B Circuit, disconnect the wiring harness plug from the

regulator and energize the field as shown on page 13.

5. Before starting the vehicle, be sure the shunts are connected to the Battery Amps Adapter as shown in Key No. I on page 5 • Turn

on the headlights and set blower speed to high. The meter should read to the left of zero or "backwards". If it reads up scale, re-

verse the shunt connections as shown in Figure 1 5.

Turn all lights and accessories "OFF". Start the engine and operate

it at the speed recommended by the manufacturer for alternator

output test. Unless otherwise specified, adjust engine speed as follows:

Chrysler 1250 RPM

GM-Delco-Remy 2500 RPM Ford 2900 RPM

With the engine running, carefully open the starter shunt as shown in Key 10 on page 6 . Observe the current (amps) reading on the 0-100 Amps scale, reduce engine speed to curb idle and compare meter reading with the manufacturer's specifications.

ALTERNATOR FULL FIELD

NOTE: To determine the actual output current, add 5 amperes to the meter reading obtained during the output test. This is the approximate current

used by the ignition system, dash instruments and alternator field toll combined which does not reach the battery to be measured during

this test. If the meter reading is at or higher than specified, the alternator output is satisfactory. If the meter reading Is less than

specified, a loose or worn alternator drive belt, a faulty field or

battery wire to the alternator, or a poorly grounded or defective alternator is indicated. If the meter reading is to the left of zero, a broken

field wire or a defective alternator is indicated. (Meter reading is the

battery discharge current used by the ignition system and dash instruments.)

Page 15

6. When test is completed, shut off the engine, disconnect jumper lead, remove the shunt, and reconnect wiring harness plug, connector or field wire to the regulator for normal operation,

Repeat Test Number 4:±Charging System Vp]tage and Current

If the voltage reading is within the range as specified by the vehicle service manual, (typically between i3.8 and 15.2 volts on 12 volt systems,

and 27.6 and 30.4 on 24 volt systems) the regulator is satisfactory.

If the voltage reading is out of specifications but satisfactory operation was obtained on the CHARGING SYSTEM VOLTAGE AND CURRENT and ALTERNATOR CONDITION tests, the voltage regulator should be adjusted

(if possible) or replaced.

Test Number B--Battery

Repeat Test Number4-,ChargingSystemvo]tage and Current

After the VOLTAGE REGULATOR--TEST 7 is completed, the regulator should

be functioning satisfactorily, leaving the battery as the only untested component remaining in the CHARGING SYSTEM. To test battery condition,

attach the shunt to the BATTERY POST ADAPTER (Key I Page 5 ), start the engine, and operate it at approximately 1200 RPM. If the voltage

reading is less than 13.8 volts, check the water level in the battery and fill to the proper level, if necessary. Charge the battery and repeat

this test. if the voltage reading is still low, the battery is defective

and should be replaced.

Page 16

Test Number 9--Ohms Test

1. The ohmmeter test is powered by an internal 9 volt battery. No zero calibration is required by the operator. Place Function Selector Switch in the Ohms position and select either the Hi

or Lo range to match the component under test. (X i or X lOOd)

2. CONNECTIONS: Insert the white Plug Ohms Lead into the corresponding tester socket as illustrated below.

3. OPERATION: The meter will read full scale at INF. with cllps,open, and when the clips are connected together will read zero on the

left. (See Paragraph #6.) To measure resistance, connect the clips to the component to be tested and read the prope_ Ohms scale. (X 1 or

x 1ooo)

4. IMPORTANT CAUTION: ALWAYS disconnect ALL L£ADS from any electrical part to be tested on the vehicle. Failure to observe this caution may result in damage to the tester.

5. Refer to manufacturer's specifications for normalresistance value

of any part being tested, ignition cables, ballast resistor, coil windings, etc.

WHITE PLUG

FIGURE 19

I i

SECONDARY

OHMS

OHMMETER BATTERY

The 9 volt battery ts located in the rear com-

partment,

Observe correctt polarity when installing

battery.

IMPORTANT: 9 VOLT BATTERY ( SEARS#

64i7) IS NOT SUPPLIED WiTH THIS ANA-

LYZER.--OHMS CIRCUIT WILL NOT WORK

WITHOUT BATTERY.

OHMS TESTS ON VARIOL

VEHICLE COMPONENTS

PRIMARY

OHMS

FUSE

OHMMETERCONNECTIONS

RED

BLACK

BA LLAST RESISTOR

COIL

6. BATTERY REPLACEMENT. When the g volt battery is low, the meter will

not read full scale with the clips open. Replace the battery to obtain accurate OHMS measurement.

7. IMPORTANT: When the tester is not in use or when Ohms tests are completed ALWAYS turn the Function Selector Switch OUT of the

Ohms position to prevent battery discharge.

DIODE TESTS ON OHMS X 1000 POSITION

Alternator diodes in a disassembled alternator can be tested for "shorts" or "opens" with the stator leads disconnected as illustrated. To

facilitate checking the diodes in the end frame and heat sink, place a short length of wire or nail in the jaws of the RED and BLACK test clips as shown

in the illustration. Touch the RED lead to the diode case and the BLACK lead to the diode lead as illustrated in Step A and note the meter reading, Reverse the lead connections on the same diode and again note the reading

as in Step B. A good diode will have one low and one high reading, if

both readings are very low, or if both readings are very high, the diode is defective and should be replaced.

Page 17

WHITE PLUG

Initial Connection

FIGURE 20

ALTERNATOR DIODE TESTS

LACK

RED

STEP

See steps 1-7 TestNumberg--OhmsTest for Ohmmeter use

ROTOR AND STATOR TESTS ON OHMS X 1000 POSITION

Rotor-- The alternator rotor may be tested for open or grounded field coils. To

check for opens, touch the test leads to each slip rJng. If the meter reading is near zero, (left end) the winding is not open. If the meter shows high reading (extreme right end of the scale), the winding is open

and the alternator should be repaired or replaced. To check for grounds, touch the test leads from either sllp ring to the rotor shaft or to the rotor poles. If the meter shows only a slight reading or none at all, the field winding is not grounded. If the meter reading is near zero

(left end), the winding is grounded and the alternator should be re-

paired or replaced.

Stator-- The alternator stator windings may be checked for grounds or opens. Dis-

connect the three stator leads from the diodes before any test. To check for opens, successively connect the tester leads between each pair of stator leads. In each case, if the meter reading is near zero (left end), the windings are not open. If the meter shows a high reading, the winding is open and the alternator should be repaired or replaced. To check for

grounds, connect the tester leads to each stator lea_ and to the frame.

If the meter shows a full scale reading, the stator is not grounded, if

the meter is near zero (left end), the stator winding is grounded to the frame and the alternator should be repaired or replaced.

The purpose of this test is to confirm the presence of supply voltage to

the positive (+) or Battery (Bat) terminal of the Ignition Coil. NO

VOLTAGE AT THIS POINT RESULTS IN A "NO START" CONDITION,

Perform this test as follows:

Place the Function Selector Switch of your Craftsman Analyzer in the

VOLTS position. Place the RANGE SELECTOR in the 0-16 volts position.

Insert the BLACK OTHER TESTS lead in its corresponding socket on the

Analyzer. Connect the BLACK clip to a good vehicle ground such as

the engine block or negative (-) battery post. Connect the RED clip to the to the positive (+) or battery_at) terminal of the i__R-

nition coil. In the case of the General Motors HEI Syste_,,disconnect

_-e_Tn_ttery (Bat) lead at the Distributor (on Integrai Coil

Systems) or at the coll (on External Coil Systems). Insert the GM Diagnostic Connector, Page 5 , Key No, 7 into the socket of this disconnected wire and connect the RED clip to the adaptor.

IMPORTANT: DO NOT ALLOW THIS CONNECTION TO TOUCH GROUNDI THE GREEN CLIP IS NOT USED.

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