ALTERNATOR - STARTER TESTER Model 8600 1/2 HP 8601 1 HP
Contents
1. Place the A B switch in the B position Touch the GREEN clip to the GROUND clamp The SHORT LED should illuminate Motor will not run Motor rotates in one direction only Defective motor switch POWER switch is in the ON position POWER lamp is illuminated If motor does not rotate in either direction Defective motor switch check to make sure that belt guard safety Defective belt guard safety switch switch is being depressed by its actuator Defective motor disconnect plug NOTE The above tests are presented as a aid in operator diagnosis The tester contains complex electronic circuits and requires a trained service technician or the aid of factory Technical Service personnel prior to proceeding any further Before calling the factory for technical assistance please review the above tests This will be very helpful in assisting you in repairs DO NOT return any portion of the tester to the factory without return authorization Return authorization will result in quicker repair and allow the factory to keep track of your equipment For a qualified electronics technician additional technical information is available from the factory See the Limited Warranty section of this manual for the phone number of the factory Technical Service Department REPLACEMENT PARTS Key Description Part C Power Off On Switch 610423 A Univ Test Lead Set 610421 D Motor Switch 000 610424 B Starte2. c Connect the large Red Positive Pos battery clamp to the battery post of the solenoid or starter under test d On Solenoid equipped Starters connect the short lead from the large Red battery clamp to the Solenoid Switch Terminal SW If this lead is not used be sure it is not contacting ground e On ignition terminal R equipped solenoids connect the ignition clip small Blue wire to the terminal The Ignition LED should come on when this type of starter is being tested f Hold the Starter Test Switch the Starter should engage and spin up Observe the meter reading Check the no load current draw against the published starter specifications Do not over rev the Starter Limit the test to 2 seconds to allow time for the meter to stabilize and indicate the condition of the Starter The meter should initially read low and then ramp up to the current indicated in the specifications g If the LOW VOLTAGE LED turns on and an audible alarm is detected the starter is either shorted or the power line voltage to the test bench is too low to perform a valid test Should you suspect low supply voltage have it checked by a qualified electrician Use of an extension cord may also cause the supply voltage to the test bench to be too low TYPICAL TEST SPECIFICATIONS ALTERNATORS Output Voltage 12 Volt Alternators 13 8 to 15 5 Volts STARTERS Delco Passenger with Solenoid 5MT 70 to 100 Amps 24 Volt Alternators 26 5 to 30 0 Volts 10 MT 1
3. NOT in Warranty The part s will be sent the next business day via a carrier of your choice Parts and shipping charges will be billed net thirty 30 days to qualified wholesalers THIS IS THE ONLY EXPRESS LIMITED WARRANTY ASSOCIATED WITH THE PRODUCT AND THE COMPANY NEITHER ASSUMES NOR AUTHORIZES ANYONE TO ASSUME OR MAKE ANY OTHER EXPRESS WARRANTY WITH RESPECT TO THE PRODUCT OTHER THAN THIS EXPRESS LIMITED WARRANTY ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THIS PRODUCT IS LIMITED TO A PERIOD OF NINETY 90 DAYS FROM THE DATE OF THE PRODUCT S PURCHASE AT RETAIL BY THE PURCHASER SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU The Company is not and shall not be responsible or otherwise liable for any loss claim injury or damage to any person or property or lost profits or other similar loss damage which may arise directly or indirectly result or be claimed to have resulted from a defect in the workmanship or material of the Product or any part thereof Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Associated Equipment does not recognize nor will it reimburse the user for any third party labor or material charges required to repai
4. 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 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 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 solid state voltage regulator correctly simulates actual vehicle voltage conditions No contacts to burn or to wear out d A HP 1 HP Optional continuous duty industrial motor clockwise or counter clockwise rotation automatic reset circuit breaker protected 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 c
5. 00 to 125 Amps TesterLEDs DIODE Off TRIO Off ALT OFF or on low STATOR May Be ON Delco Passenger w o Solenoid 7 to 100 Amps Ford With Solenoid 100 to 125 Amps Ford Without Solenoid 60 to 90 Amps Only if Yellow Clip or DN Plug Connected Chrysler Gear Reduction 70 to 125 Amps Note For some alternators the TRIO or the ALT LED may light when the alternator is connected but not rotating Solenoids With Ignition Terminal R Ignition LED should be on Other Starter Specifications For other starter specifications refer to the OEM or rebuilder s published specifications OTHER ALTERNATOR SPECIFICATIONS For other Alternator specifications refer to the OEM or rebuilder s published specifications MAINTENANCE CAUTION DO NOT ATTEMPT ANY MAINTENANCE BEFORE UNPLUGGING THE LINE PLUG FROM THE POWER RECEPTACLE a Extreme care should be taken not break any components or wire leads when doing any maintenance to the unit b Test leads can be cleaned and kept in a like new condition by cleaning them with petroleum jelly c The Test Bench has been designed for a long life of trouble free service and requires only the minimum amount of maintenance to assure many years of dependable service Good housekeeping techniques will insure dependability The meter lens can be cleaned with a damp clean rag utilizing a mild dish washing detergent water solution The case can be cleaned with a furniture grade spray wax d The motor sho
6. 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 CAUTION Do not remove the ground prong from the line cord as 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
7. RCISED 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 Inthe 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 clos
8. ause 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 Lead Socket Socket for the Universal Lead Set of Alternator test wires For the Generator Test Lead Module as well if so equipped 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 EXE
9. bove the shop floor The test bench can be conveniently operated on a counter to demonstrate to the customer the conditions of his electrical device SPECIFICATIONS Cabinet Dimensions Height 17 inches Width 14 inches Depth 28 inches Shipping Weight 0000 108 Lbs Line Under voltage Alarm Point 90 VAC Starter Current Available 350 Amps Alternator Load aaan aaar 8 Amps Motor HP 2 HP 1 HP Optional Continuous Duty Motor Protection Automatic Reset Circuit Breaker Power Requirements 120 VAC 60 Hz 20 Amps Control Function Descriptions 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 Most 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
10. d be rejected Test 3 Observe the Volt Meter 12 Volt Alternators will indicate an operating voltage between 13 8 to 15 5 volts 24 volt Alternators will indicate an operating voltage between 26 5 to 30 0 volts Test 4 Observe the Diode LED This LED should not be lit If the LED is on the Alternator is defective Test 5 Observe the Stator Relay LED the LED should be on with Alternators having this feature and the Stator Relay lead connected Delcotrons and other internally regulated alternators using the 1 2 plug The Diode Trio LED should be on when the alternator is electrically connected to the 1 2 plug but is not rotating Once the unit is under test and rotating should the LED remain on reject the alternator On all other Alternators this LED will be off Chrysler Isolated Field Alternator This type of Alternator has 2 insulated field terminals To test this type of Alternator ground one of the field terminals and connect the small Green FLD field lead FLD to the other terminal Then proceed to test as a regular Alternator GENERATORS WARNING Attempting to test a generator without using the optional Generator Test Module may cause damage to the internal electronics of this tester OPERATING PROCEDURES STARTERS a Mount the Starter in the vise and secure it with the hold down clamp b Connect the large Black Negative Neg battery clamp to a good ground connection on the Starter
11. dle 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 f Connect the small Green lead FIELD to the terminal marked F FLD or FIELD on alternators so equipped g Connect the small Yellow lead wire Stator Relay to the terminal marked STA or R on Alternators so equipped h Set the program switches for 12 volt or 24 volt depending upon the output voltage of the device under test I Grasp the vice handle with one hand to steady the alternator and apply additional tension to the drive belt ALTERNATOR TEST SEQUENCE Test 1 If the SHORT LOW VOLTAGE 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 Check the hook up If it is correct reject the alternator Test 2 Turn on the motor switch for the desired rotation direction At this point the unit is rotating with a load applied It should start up quickly If the motor stalls or a bearing noise is noticed do not proceed The Alternator under test has mechanical problems and shoul
12. e 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 han
13. 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 Itis of the utmost importance that this test equipment be used only by a qualified trained operator 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 a
14. r Test Switch 610422 E Solenoid Xd aaa Laan EA 610440 Power Semiconductor Assy 610442 Safety Interlock Switch 610427 Front Panel Assy 610786 V Belt 30 1 2HP 610455 V Belt 34 1HP 610429 Fuse Holder 2 2 22 2000s cece 610430 Ng A Universal Test Lead Set Description Part V Pulley 2 5 2 HP 610454 V Pulley 5 1HP 610438 Vise Assembly aan 610436 Motor ZHP aaa 610435 Motor THP icine PAGA NANG LAng 610453 Swivel Pad w Rod 610441 Alternator Bracket 610439 AG CO abangan pond tetie vate nes 605205 Power Light 0 0 0 3 aaa ERARE 610600 Front Panel Harness 610778 Output Cables 610791 Transformer ASSY 610941 plugs into this receptacle LIMITED WARRANTY Associated Equipment Corporation 5043 Farlin St Louis Missouri 63115 makes this limited warranty to the original and user purchaser of all Associated products The Company hereby warrants the Purchaser that if the Product or any parts thereof shall prove to be defective due to improper workmanship or materials at any time up to and including NINETY 90 DAYS from the date of the Product s purchase at retail then the Company shall repair or replace the Product or any part thereof as the case may be at
15. r reading No short LED when the small RED and 1 Defective PC board Motor switch ON GROUND clamp are touched together 2 Power semi conductor assembly Motor runs with guard closed 3 Power fuse may need replacement Short LED turns on when the small RED and 1 Defective PC board GROUND clamp are touched together Voltage remains on starter clamps 1 Defective solenoid No TRIO LED TRIO LED should turn on if the 1 terminal of 1 Defect in test lead assembly the 1 2 plug is touching the GROUND clamp 2 Defective PC board Delco alternator will not test The SHORT LED should turn on if the 2 1 Defect in test lead assembly terminal of the 1 2 plug is touching the 2 Defective PC board GROUND clamp The TRIO LED should turn on if the 1 terminal of the 1 2 plug is touching the GROUND clamp No ALT LED The ALT LED should turn on if the WHITE clip 1 Defect in test lead assembly is touching the GROUND clamp 2 Defective PC board No STATOR LED The STATOR LED should turn on if the RED 1 Defect in test lead assembly and YELLOW clips are touching 2 Defective PC board Externally regulated alternators will not A Circuit 1 10 Amp fuse open in test lead set function The implication is that the external Place the A B switch in the A position 2 Defective test lead set field circuit is not functioning Touch the GREEN clip to the small RED clip 3 Defective PC board The SHORT LED should illuminate B Circuit
16. r this piece of equipment unless the user obtains written permission prior to having the work performed Should the user elect to return this device for repair without first contacting the factory and obtaining permission the factory reserves the right to refuse delivery If you feel that you can service this unit yourself you may elect to 1 Remove the cover from the unit Inspect for obvious damage i e broken wires burned or loose connections etc 2 Have the unit near you when you call 3 Call 1 800 654 0853 In Missouri call 1 314 385 6541 A qualified service technician will ask you several questions and have you perform several tests to determine the problem FAX number 1 314 385 3254 WARRANTY REGISTRATION 1 Check the Model Serial Number printed on the back of this unit 2 Record the information below and keep this document for your permanent record MODEL SERIAL PURCHASE DATE JOBBERS NAME W2106 Rev 06 01 027 0609
17. the Company s option without charge to the Purchaser for parts and labor provided that the Purchaser follows the procedures set forth herein This warranty does not and shall not apply 1 to any Product parts subject to normal wear and tear including but not limited to clamps test lead sets belts and cables 2 if the Product or any part thereof is subject to accident misuse abuse or operated contrary to the company s instructions pertaining to the Product or 3 to the Product or any part thereof damaged by alteration or by improper repair or service not rendered by the Company TO OBTAIN WARRANTY REPAIR SERVICE 1 Contact the Technical Service Department at the factory by either of the phone numbers listed below or send in a request for service via FAX 2 DO NOT SHIP THE UNIT OR ANY OF ITS COMPONENT PARTS BACK WITHOUT PRIOR AUTHORIZATION 3 Be prepared to answer specific questions concerning what is or is not operating Please have your instruction manual in front of you please also have the serial number and date of manufacture available found on the rear of the cabinet 4 A determination will then be made concerning repair If the Unit is in Warranty The part s will be invoiced and sent the next business day by ground service The defective part s must be returned within thirty 30 days along with proof of warranty so that a credit will be issued offsetting the invoice for part and shipping charges If the Unit is
18. uld be lubricated once a year with a few drops of light oil Some testers may be supplied with sealed Oilite bushings and in this case no lubrication is required TROUBLESHOOTING GUIDE BEFORE YOU CALL FOR SERVICE PROCEED WITH THE FOLLOWING TESTS This tester is designed so that many functional tests may be made without the need for additional test equipment If a portion of the tester appears to malfunction proceed according to the following chart For purposes of this guide the Bench Tester may be divided into two sections POWER PANEL SECTION The left hand portion above the belt guard containing the On Off Switches etc METER PANEL SECTION The larger right hand portion containing the meter A B switch etc WARNING UNDER NO CIRCUMSTANCES SHOULD THE UNIT BE DISASSEMBLED WITH THE UNIT PLUG TO THE WALL RECEPTACLE PROBLEM TEST POSSIBLE CAUSE Power Lamp is inoperative Motor switch is ON 1 Unit is un plugged or circuit is not energized No meter reading Belt guard is down Check the power source circuit breaker or fuse Motor won t run 2 Outlet is defective 3 Power cord is defective 4 On Off switch is defective Power light on Audible click from Safety Interlock Switch as 1 Thermal switch may be open due to motor Motor won t run or Motor starts and stops Belt Guard closes overload Wait several minutes for the switch to reset 2 Check Safety Interlock Switch for correct operation Switch may be defective No mete
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