306 - Powermaster
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1. the battery be in good condition and fully charged when replacing the alternator Do use an alternator to charge a dead battery service manual for more details INSTALL THE NEW ALTERNATOR Mount the alternator and check for interference with the brackets or other engine components Start the bolts but do not tighten them at this time FIGURE 1 Check for proper belt alignment Proper alignment is critical Adjust belt tension and tighten belt tension bolt as illustrated in Figure 1 Do not use heavy toc to pry on alternator case hand pressure is adequate When an automatic tensioner system 1s installed as is common with V belts tension the belt to the engine manufacture s specifica This is typically half an inch of deflection Tighten all other bolts Run anew IOAWG stranded wire suitable for automotive use from the alternator to the po post of the battery or the battery side of the starter relay Be sure this wire is secured in the eng compartment and out of the way of moving parts Your speed shop has Powermaster charge wi for this purpose The 140A Powermaster alternators come with an upgraded battery output cable and this should be used in place of the OE If the vehicle has an external voltage regulator this L should be unplugged Note that this Powermaster alternator is a one wire alternator This means that it only requires the battery cable to operate Additional wires connected to the al2. INSTRUCTION SHEET Ford Upgrade One Wire Alternators 8 37101 8 37141 8 47101 8 47106 8 47141 8 47146 8 57101 8 57141 8 67101 8 67141 We want to help If you have any comments or difficulty with this product please contact technical support at POWERMASTER 1833 Downs Drive West Chicago IL 60185 800 862 7223 e mail tech powermastermotorsports com The box contains 1 alternator 1 adjusting bolt 140A alternators also contain 1 upgrade charge wire PLEASE KEEP IN MIND e ALWAYS wear eye protection when working around batteries e ALWAYS disconnect battery ground terminal and cable assembly before INSTALLATION replacing electrical components NEVER disconnect a battery cable or alternator cable and wires when These instructions are provided as supplementary engine is running Transient voltages spikes are produced when this information to the factory service manual instructions for occurs and some of these voltages exceed 200 volts This can cause alter alternator replacement nator voltage regulator or engine computer failure AVOID short circuits When working with live circuits never jumper DISCONNECT THE BATTERY between terminals or from terminals to ground nor try to trouble shoot by sparking terminals Always use a quality voltmeter to check the operation REMOVE THE OLD ALTERNATOR See the factory of live circuits CHECK the battery Alternators and batteries work together It is important that
3. at slow the alternator relative to the engine 1 e power pulleys can greatly magnify this problem Why does my voltage test good at the alternator but low at the battery and fuse box Any resistance in the electrical path will decrease voltage This includes all positive and negative conductors and connections between the alternator and the second test point All connections must be secure and free of corrosion All ground points must be free of paint and rust Charging wires must be of adequate size for the amperage capabilities of your alternator Improving any weak points in the electrical paths should bring voltage readings to within 0 5 volts of each other So what is the difference between a one wire and a three wire hookup The difference is the way the alternator is switched on With one wire operation the alternator internally senses its rotation and switches its self on With three wire operation an external exciter wire switches on the alternator Three wire operation is as your vehicle s original manufacture intended and assures that the alternator is switched on anytime the engine is running Three wire is an industry term that describes a situation that in most cases can be accomplished using only two wires the exciter wire and the charge wire
4. ndicator Lights Some Fords came OE with an indicator light on the dash to signal the alternator s state during operation Under normal operation the light should come on any time the ignition switch is on and the engine is stopped When the alternator is not functioning and the engine is running the light will come on to warn the driver of this condition OE alternators require that this circuit function for proper alternator function whereas Powermaster alternators do not require this The light will simply be off at all times Optionally this indicator light function can be used on a Powermasier alternator in vehicles with a factory voltmeter by removing the black rubber cover on the side of the alternator and connecting the indicator light circuit to the 1 terminal of the Powermaster alternator Vehicles with a factory ammeter cannot use this function 1966 1985 WITH EXTERNAL REGULATOR 1986 1993 with INTERNAL REGULATOR AND FACTORY VOLTMETER AND FACTORY VOLTMETER Connect to green wire w red stripe Why is my voltage low when I m cruising around at a show or sitting at a traffic light All alternators have an output curve that increases with RPM In other words your alternator cannot provide as many amps at idle as it can at higher speeds If you car demands more amperage than the alternator can supply at idle the remaining amps must come from the battery thus a decrease in voltage results Any after market pulleys th
5. ternator provide optional features such as charging system indicator light function but are not required INS306 Revised 8 16 10 CONNECT THE BATTERY FIGURE 2 SYSTEM CHECK Apply a moderate load to the charging system 1 e high beam headlights and A C for example and bring the engine to 1 500rpm Using a digital voltmeter measure the DC voltage from a metal point on the case of the alternator to the negative battery terminal Readings higher than 0 10VDC indi cate a poor ground connection Check the ground path including any paint or anodizing on the brackets the engine ground strap and the ground cable from the frame to the battery See figure 2 With battery fully charged and engine running at 1 500rpm measure the voltage at battery positive post and the ground post Voltage FIGURE 3 should be 13 8 14 5VDC Readings above 15 5VDC indicate a defec tive alternator and readings below 12 7VDC indicate that the alternator is not functioning or cannot supply the present amperage needs of the vehicle at this engine speed Using the voltmeter measure the voltage drop between the batty positive post and the alternator output post See figure 3 Voltage should be less that 0 40VDC If voltage is higher that 0 40VDC check for poor connections between the alternator and the battery Possible causes are under sized battery cables loose or improperly crimped terminals and corroded connections A Word About I
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