Alternator connections

[Ron Kwas]

arcturus;

I guess I cannot argue with success...if Charging Indicator is OFF after starting is certainly a good sign, but I still recommend checking system voltage at Battery, at idle when Alt output is minimal and then elevated RPMs to verify Alt output is pulling voltage up and charging Bat. That would be the desirable condition!

In looking at the picture, I can't get by where I still have some questions...


1. I see B+ cast into casing at both places marked in Yellow...the left one is an insulated post, so it must not be used in this configuration of the ALt, but I get the feeling the one at right refers to the terminal which has the small Red wire at this time. Maybe someone familiar with this Alt can clarify. Also, where does other end of small Red wire go?

2. Is Blue terminal connected to Alt case? If it is, I would not expect heavy Red wire to connect there...again, I would expect heavy Red wire to connect to where smaller Red wire is presently (which sure looks like its the Alt output B+ term)....and that also explains overheated heavy Red and fused Black wires from before...Battery, connected to other end of heavy Red wire, was shorted to this chassis terminal through the Pi Filter.

3. What is cast into housing at Orange?

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Comments to Starter Picture:
"Wire from B+ goes to solenoid and from there to battery. Also on same terminal lead from ign' switch. " This is as expected!
"The connection at solenoid looks dodgy. seems to connect directly against solenoid body which would cause a short. " Much of the (brittle Bakelite) insulating walls are broken away, but nothing looks worse than that.
Reference Solenoid Pix: http://www.sw-em.com/starter.htm#bosch_starter_solenoid

Cheers

[Ron Kwas]

...at No.2, I asked about blue terminal...I meant at Blue arrow! Is this a connection to Alt Housing? If it is, that would be a problem!

[arcturus]

I think that the red goes to the charge light and the green to external regulator. It could be the other way round,i will need to check again in garage.

[Underdrive]

The terminal that the green wire is connected to seems not to be insulated as it passes through the cover plate (which is presumably earthed) and looks like they could easily touch.

[arcturus]

Thanks, will check that. maybe needs to be pushed in a bit more.

[arcturus]

Originally Posted by Underdrive

The terminal that the green wire is connected to seems not to be insulated as it passes through the cover plate (which is presumably earthed) and looks like they could easily touch.

Well spotted! have changed the connector to an insulated one.

[simonvolvo]

That suppressor isn’t a “Pi-filter”. It is a plain condenser - Bosch part 1 297 330 070. Electrically, those two terminal screws are at one and the same point. (Connecting the thick red wire to one of those terminals and the other terminal to earth would therefore create a dead short.)

You wouldn’t have caused any damage to the suppressor I think, so you could, if you want to, re-connect it in circuit. Whilst I’m not familiar with your alternator, I think the connection should be (as in your very first pic): thick red wire to one terminal screw of the suppressor (doesn’t matter which one), and the other terminal screw of the suppressor via a short wire to B+. Terminal B+ (indicated by Ron’s blue arrow) seems to be the output terminal (diode bridge) of the alternator.

Regarding the connection of the green wire (field terminal): I think you will find that that “cover plate” is actually of Bakelite or some other insulating material, so it wouldn’t really matter if the spade connector touches.