This chart lists and translates voltage regulator terminal codes for most all manufacturers voltage regulators.(54K PDF)

By Scott Fureman - Purfex Electrical Distributors

This handy charts displays the proper time/amps to bring a discharged battery to a full charge. It's great to hand out to customers.(5K PDF)

Courtesy Mike Schroeder

This article describes the Delphi liquid cooled alternators used by Cadillac (Lester 8236 and 8294). Wiring diagrams are included.(1,170K PDF)

Created by Wes Grueninger Sr.

Chrysler has changed from "A" circuit to "B" circuit charging systems. This one-page guide explains current flow through both systems.(324K PDF)

Created by Wes Grueninger Sr.

This two page article discusses the function of the alternator "C" terminal used on 2005 and up Nissan and Infiniti vehicles. The "C" terminal no longer functions as it has in the past. Testing procedures and a wiring diagram are included (89K PDF)

Created by Rich Herrington (AmFor Electronics)

Direct from the OE Manufacturer, this sheet provides proper testing procedures and methodology to prevent damaging the new ASVR (All Silicon Voltage Regulator) regulators being used in GM's CS-series alternators.(28K PDF)

Courtesy Taditel

This guide provides specifications and cross reference information for regulators used in CS-series and AD-series alternators.(57K PDF)

Courtesy Regitar

From 1977 this six-page guide gives torque specifications for 20DN, 30DN, 50DN, 25SI, 30SI and 40SI alternators. It also includes thread and screw measuring tips.

Courtesy AC-Delco

This guide shows how to convert a 10SI alternator to postive ground and how to use a relay to control alternator turn-on.(401K PDF)

Created by Wes Grueninger Sr.

This article was created using slides from Joe Davis' 2005 seminar series. It shows a simple and reliable way to remove broken screws from aluminum housings - without drilling!(448K PDF)

Courtesy Joe Davis and Joe Bradish

Use this guide to find information about Delco-Remy alternators from the OE number.
Information includes:

• Series
• Type
• Ground
• Service Bulletins
• Rotation
• Spec. No.
• Field Current Amps and Volts
• Cold Output
• Hot Output

Created by Wes Grueninger Sr.

This chart contains all known regulators used in Denso internal-fan alternators (as of 05/2004). List is broken down by OE regulator number and lists pinouts, voltage set point, L terminal functions, load response control, and more.(46K PDF)

By Alan Melton - Northwest Regulator Supply

Alternator air gap is a subject with which few small rebuilders concern themselves, but most have been bitten by it, whether they know it or not. By air gap, we are referring to the clearance between the outside diameter of the rotor poles and the inside diameter of the stator laminations. This three-page artice discusses the effects of a large air gap - low output and decreased regulator life. It includes test data from two different controlled experiments.

Created by Wes Grueninger Sr. and Bob Thomas

This one-page guide explains how to tell the difference between the two styles of Ford 4G rectifiers. It includes photos and wiring diagrams.(1418K PDF)

Created by Wes Grueninger Sr.

The most common cause of 6G alternator failure appears to be worn out brushes. In most cases, slip rings wear out as well. This 6-page, fully illustrated article explains methods that have been used to reclaim good regulators by replacing the brushes. It also explains the best way to salvage good rotors by replacing the slip rings. Stator and SRE bearing removal are also discussed.(3.6MB PDF)

Created by Wes Grueninger Sr. and Bob Thomas

Choosing the correct rectifier has never been as important as it is with the Ford 6G series alternators. This 5-page guide explains the characteristics that separate the different part numbers.(1117K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

This one page article explains how corrosion at the B+ stud-to-rectifier connection can cause charging problems for 6G alternators.

Created by Wes Grueninger Sr. and Larry Hagemeister

This six-page guide explains how Ford 6G voltage regulators operate. It includes wiring diagrams of typical 6G charging systems and explains how the voltage regulator functions in each type of system. Color codes and OE numbers are included for all know North American applications as of January, 2008.(719K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

Fluctuating or pulsing voltage on Ford vehicles using 2G, 3G or 4G alternators is a relatively common problem with a simple cure. Most technicians will immediately place the blame on the voltage regulator when this condition exists. But in nearly every case, the real cause is low voltage at the regulator's "A" or sense terminal. This two-page guide will show you how to identify and repair the problem, whether it exists on a vehicle or on your test bench.

Created by Wes Grueninger Sr. and Bob Thomas

General Motors introduced their Regulated Voltage Control charging system on 2004 Cadillac CTS and SRX models. It is now being used on most of their current applications. RVC has taken voltage control to a new level. This seven-page article discusses the purpose and reasoning behind RVC and the two styles of RVC systems (integrated and stand-alone). It includes descriptions of RVC system components and how they interact. You will learn to recognize the six different RVC system operating modes. Test procedures on the vehicle, as well as on the test bench, are covered. Wiring diagrams of typical integrated and stand-alone versions are included.

Created by Wes Grueninger Sr. and Bob Thomas

This two-page guide explains how to adapt a hardware-store pulley for testing these alternators. It includes motorcycle wiring diagrams and test bench hookup instuctions(495K PDF). For more information about Honda Goldwing alternators and starters see the repair manual listed below.

Created by Wes Grueninger Sr. and Bob Thomas

This 76-page excerpt from the factory service manual covers all aspects of the charging and starting systems. This is a large download!(10.5mb PDF)

Courtesy Honda Motor Company

The NPR charging system has several unique features that make it difficult to test and diagnose. This guide will show you how to successfully test and rebuild the alternator and how to identify problems in the vehicle's electrical system. It specifically deals with LR170-410B and LR170-418B alternators. (3.28MB PDF)

Created by Wes Grueninger Sr.

If the charge indication lamp flashes every 8 seconds on John Deere small farm/utility tractors or John Deere Gator utility vehicles, this one-page guide will explain how to fix the problem.

Four Lester numbers are affected: 12080, 12081, 12353 and 12354.

Created by Wes Grueninger Sr. and Bob Thomas

This four page reference guide crosses the "9801-" Lester Plug Codes to JIMCO Test Leads/Test Boxes

Courtesy JIMCO Inc.

This two page article discusses the John Deere 2500E Hybrid Greens Mower. It includes a description of the 48-volt alternator and how it powers the electric reel motors. Testing procedures as well as a system wiring diagram are included. (675K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

That small relay you'll find attached to many Nikko industrial starters is more than just your ordinary starter relay. Nikko calls it a solenoid control relay. As the name implies, it controls the operation of the starter solenoid. Nikko utilizes the output from the alternator R terminal, in conjunction with this relay, to prevent accidental engagement of the starter once the engine is running. This document will explain how the system works and how to test the relay to ensure it is working properly.

Created by Wes Grueninger Sr. and Bob Thomas

This step by step guide shows how to test Niehoff alernators on or off the vehicle. Covers A1-100 through A1-162.(500K PDF)

Courtesy Jim Morton - Peoria Electric, Albany, OR

Test it right - use the correct test lead. This 28-page guide references Lester alternator numbers and lists the correct test lead to use. It includes plug diagrams with each terminal clearly labeled. Print up a copy to keep by your test bench!
Updated 01-2011

Courtesy of Alan Melton, Northwest Regulator Supply

• Common Trouble Spots For Charging Systems
• How To Disassemble A PennTex Alternator
• How To Full-Field A PennTex Alternator
• How To Identify A PennTex Voltage Regulator
• Critical Voltage Points - "The Golden Triangle"

Courtesy PennTex Industries, Inc.

Most rebuilders will test rotors with quick checks for shorts-to-ground and amperage draw. If the rotor looks good and passes both tests, it's reclaimed. If it fails either test, it's replaced. When a rotor does fail, it pays to take an extra minute to figure out why. In many cases, the bad rotor can be repaired and reused. This four-page guide will suggest a number of things you can check that might help you save an original OEM rotor. (976K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

This eight page guide contains test procedures, wiring diagrams and repair procedues for an 80A Sawafuji alternator on a 2000 UD Truck Model 2300-DH

Courtesy Ken Plourde

This two page article discusses why the OEMs attach each slip ring to a specific coil wire. Testing instructions about how to identify which lead goes to which slip ring are included. (204K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

The Tech Basics series covers eight of the most popular charging systems. Each guide describes how system components work and interact. Wiring diagrams are included.
Tech Basics are available for:

• Ford (1G, 2G, 3G)
• Delco 10DN
• Chrysler External Regulator 1961-1987
• Lucas ACR
• AMC Motorola
• Honda/Toyota

By Wes Grueninger Sr. - ERA Web Site Director

This three page article discusses the differences and similarities between trio-activated and stator-activated voltage regulators. Learn how to identify the two different systems and avoid the problems caused by mis-matching components.

Created by Wes Grueninger Sr. and Bob Thomas

This is a great reference guide—12 pages showing 443 Transpo voltage regulators and their terminal identification.

Courtesy WAIglobal

From 1956, this military manual describes the then new 100 amp alternator charging system and also troubleshoots the entire system. This charging system features an external selenium rectifier and an alternator that could be submerged under water without damage! It's an interesting read even if you may never work on one of these.

Courtesy Vonnie Coke

Confused by the 12/24 volt charging system on these vehicles? No more. This article offers a short history of the vehicles as well as detailed wiring diagrams. For more CUCV information, download the complete U.S. military manual listed below. (2,232K PDF)

Created by Wes Grueninger Sr.

This guide describes how to convert the 24 volt portions of the CUCV electrical system to 12 volts. It offer two different types of conversions:

• Convert to a 12-volt system utilizing two batteries for starting power and one alternator for charging
• Convert to two 12-volt isolated systems. One system utilizing the two existing batteries and one alternator. The second system utilizing the other alternator and an additional battery.
• (1,660K PDF)

Courtesy of the National Association of State Foresters and the Michigan Department of Natural Resources

This is all you've ever wanted to know, and more, about the Commercial Utility Cargo Vehicle (CUCV pronounced "cuck-vee"). A CUCV is a modified Chevy Blazer or GMC pickup produced from 1983 to 1986 for the U.S. military. This is the entire U.S. Military UNIT MAINTENANCE MANUAL (Warning - huge download - 940 pages! 14,962K PDF)

Courtesy U.S. Taxpayers

From 1941. This Auto-Lite training manual has 62 pages full of rebuilding information for most all Auto-Lite generators and starters built before 1941. It includes specifications by unit number, as well as detailed rebuilding and testing information. (3.74mb PDF)

This 19 page manual is the official Delco publication for repair of the 1914 Junior Delco Starter-Generator system. This system was used on: 1914 Buick Models B-24-25, B-36-37—Cartercar Model 7—Hudson Model 6-40—Keeton Model 4-35—Oakland Model 36—Oldsmobile Model 42—Paterson Models 32-33—Westcott Model 0-4 (1.15mb PDF)

courtesy Dan Poremba

This 22 page manual is the official Delco publication for repair of the 1914-1915 Delco Starter-Generator system. This system was used on: 1914 Buick B-55—1914 Cole Series 9—1915 Coles Series 10—1914 Moon 42, 6-50—1914 Oakland 43, 6-48, 6-60—1914 Oldsmobile 54 and 1915 Oldsmobile 55 (1.15mb PDF)

Courtesy John L. Prinvale - John's Automotive Electrical, Quincy, CA

From 1958. This 36-page full-color manual covers everything you ever wanted to know about how generators operate...and more! This is a long download - recommended for those with broadband.(2960K PDF)

Courtesy Henry Henke - United Starter and Alternator, Lowell, IN

From 1935. At first glance, you might think, "Why is this in the Technical Library," but don't let that keep you from reading this fascinating guide. It covers 2 brush and 3 brush generators and how they are regulated. The voltage regulator section explains how the current regulator and voltage regulator operate. Highly recommended to anyone seeking a better knowledge of how generators operate.(549K PDF)

Courtesy John L. Prinvale - John's Automotive Electrical, Quincy, CA

From 1963. This 8-page full-color manual covers testing and rebuilding motor-generators. Included are sections about the voltage regulator and wiring diagrams (1912K PDF)

Use this chart to determine if a generator your are working on is positive or negative ground, six or twelve volt, and what regulator should be matched to the generator for proper output.(6191K PDF)

This 6 page guide shows internal generator diagrams and testing data for 6V Harley-Davidson generators. Includes information for models: 32E, 32E2R, 48 (2 brush), 48 (3 brush), 51, 52, 52K and 52KH. (1.2mb PDF)

Information provided by Vensel Enterprises

This 5 page article covers the most popular Hitachi/Mando golf-cart motor-generators. Circuit diagrams and current-flow explainations are included, along with bench testing instructions. Updated to Version 2.0, December 2010 (1.8mb PDF)

Created by Wes Grueninger Sr. and Bob Thomas

A wiring diagram for an EZ-GO G2A Golf Cart (with Hitachi motor-generator) is available to supplement this article.

Dodge Brothers vehicles used a chain-driven starter/generator in the 1920's. This vintage guide shows how to rebuild the unit, install and adjust the chain and test the entire charging system.(2549K PDF)

Courtesy Wes Grueninger Sr.

This 3 page article, the first in a series on generator rebuilding, describes generator components and their basic operation. Included are diagrams and descriptions of "A" and "B" circuit generators. (1mb PDF)

• Components And Operation
• The Field Circuit
• Are The Fields “A” or “B” Circuit
• Generators Are Self Exciting
• System Polarity - Positive or Negative Ground

Created by Wes Grueninger Sr. and Bob Thomas

This 5 page article, the second in a series on generator rebuilding, describes generator cutout relays and their operation. Included are diagrams and descriptions along with instructions on testing and adjusting. (1mb PDF)

• How A Cutout Relay Works
• Testing Cutout Relays
• Adjusting Cutout Relays
• Electronic Cutout Relays
• Using A Diode To Repair A Conventional Cutout Relay
• Importance of Polarizing The Generator

Created by Wes Grueninger Sr. and Bob Thomas

This 5 page article, the third in a series on generator rebuilding, describes field coils. How to test and rewrap coils is covered in depth. Included are diagrams illustrating "A" circuit and "B" circuit systems. (1.2mb PDF)

• Testing Field Coils
• Repairing and Salvaging Cloth- Or Paper-Wrapped Coils
• Shunt-Wound Field Coils

Created by Wes Grueninger Sr. and Bob Thomas

This 10 page article, the fourth in a series on generator rebuilding, describes armatures. Armature design, theory of operation, testing, soldering, repairing and undercutting are covered in depth. Included are diagrams illustrating wave-wound and lap-wound circuits. (1.6mb PDF)

• Armature Components
• Lap-Wound Armatures
• Wave-Wound Armatures
• Armature ID Summary
• Visual Inspection
• Testing For Grounds And Shorts
• Testing For Weak And Open Connections
• Re-soldering Weak Or Open Connections
• Turning and Undercutting

Created by Wes Grueninger Sr. and Bob Thomas

This 9 page article, the fifth in a series on generator rebuilding, describes how generator output was controlled before electromechanical voltage regulators, as we know them now, were used. Many different methods of limiting field current are shown. Third-brush generator magnetic theory, operation and adjustments are covered in detail. Included are diagrams illustrating field circuits and magnetic flux. (2.2mb PDF)

• Manual Mechanical Regulation
• Automatic Mechanical Speed Controls (Governors)
• Inherent Method Of Regulation
• Third Brush (Field-Brush) Regulation
• Field Fuses and Circuit Breakers
• Testing Notes

Created by Wes Grueninger Sr. and Bob Thomas

This 15 page article, the sixth in a series on generator rebuilding, describes the history and operation of generator voltage regulators.(3.7mb PDF)

• Carbon-Pile Regulators
• Mercury-Tube Regulators
• Two-Unit Regulators
• Two-Unit Regulators with Combined Current-Voltage Relay
• Three-Unit Regulators
• Double Contact Regulators
• Electronic Regulators
• Polarizing
• How the Battery Affects Voltage
• Eight Volt Batteries
• Indicator Light
• Cleaning Relay Contacts

Created by Wes Grueninger Sr. and Bob Thomas

This 8 page article, the seventh in a series on generator rebuilding, describes the “small, but important” components of a generator.(1.6mb PDF)

• Generator Brushes
• Brush Holders and Brush Springs
• Pulleys and Means of Attaching
• Bearings and Bushings
• End Frames
• The Effects of Corosion

Created by Wes Grueninger Sr. and Bob Thomas

Some of the Asian made Briggs & Stratton replacement motors have a serious flaw. The negative brushes are not making good contact to ground. This article will tell you how to identify the problem. (21K PDF)

By Mike Schroeder - Central Auto Electric, Union, MO

When conversion coils aren't available, this 5-page article shows how to convert parallel 6-volt field coils to safely work with 12 volts. Performing this conversion helps to prevent damaged and jammed drives as well as cracked drive-end housings.

By Bob Thomas and Wes Grueninger Sr.

This 5-page guide from Accumax discusses 35MT starter solenoids and shifter forks. It points out the problems that can be caused by using a too short aftermarket shifter fork with an OE-style solenoid. Solutions and adjustment procedures are included.

courtesy Robbie Sullivan - Accumax

This 1-page guide from Accumax discusses how aftermarket solenoid plunger springs with too many coils can cause chattering. Illustrations show how to tell good springs from bad springs.

courtesy Robbie Sullivan - Accumax

This chart lists the current Delco 37, 41 and 42MT switches and the Delco Semi-Solid link equivalents.(66K PDF)

By Scott Fureman - Purfex Electrical Distributors

The first time most rebuilders are confronted with a 41MT series Delco Remy starter, they probably think they've got a 37MT starter. From the outside, the two look exactly the same at first glance. While they are very similar and share some applications, they are not the same, nor are the internal parts universally interchangeable. Some of the differences are obvious after you take the starters apart. Others are not. This four-page, fully illustrated document explains the differences between the two starters.

Created by Wes Grueninger Sr. and Bob Thomas

From 1957. This excellent 24-page full-color manual covers all aspects of starter operation - circuits, drives, solenoids, maintenance and testing. Includes a section on how series-parallel switches work.(2232K PDF)

Courtesy Jim Morton - Peoria Electric, Corvallis, OR

Minimum and maximin “free speed” specifications for 28MT, 29MT, 37MT, 38MT, 39MT HD, 42MT and 50MT starters.

courtesy Bob Jefferies - Delco Remy Of America

This four-page article explains how to replace the tracking gear and rebuild the starter drive on this unique starter. Instructions are included that explain how to make a tool to open the starter drive cap.(880K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

This article contains spec sheets from AC-Delco about many heavy-duty MT series starters.(923K PDF)

Courtesy Dick Vensel - Vensel Enterprises

This chart lists Ford Starter interchange from Direct Drive through the latest PMGR styles.(40K PDF)

By Scott Fureman - Purfex Electrical Distributors

This article provides illustrated, step-by-step instructions how to replace a Ford direct-drive starter with a Ford PMGR starter. It's meant to printed on both sides of letter-sized paper and then folded to create a pamphlet. Great to hand to customers or include in a box with the unit. For a complete listing of PMGR replacement units see the tech article Ford Starter Interchange Guide listed below.(329K PDF)

Courtesy Wes Grueninger Sr.

This article discusses early and late style shifter forks used in Ford PMGR starters and how to install and interchange them.

Created by Bob Thomas and Wes Grueninger Sr.

This one-page bulletin describes how starter kick-back occurs on the 3.0L GM and 2.0L Mazda engines. It also details how a delay timer will fix the problem. (39K PDF)

Courtesy of Hyster

This one-page bulletin describes the mounting procedure for Mitsubishi starters with elongated mounting holes. It's great to hand out to any of your customers that repair lift trucks.

Created by Wes Grueninger

This one-page drawing shows the correct installed position of the shift lever on Lucas M127 Starters. It's great to print and hang on the wall by your starter assemby station!

Created by Wes Grueninger Sr.

This eight-page article explains in detail exactly how Lucas M50 starters implement "soft-start" to prevent drive milling. Complete with many wiring diagrams and pictures, this article will help you to understand, and to successfully rebuild, these starters.

Created by Nathan Unger and Wes Grueninger Sr.

The Lucas M50 factory manual from 1972 is available to supplement this article.

This five-page article explains how a starting circuit can be damaged when solenoid contacts wear out. It also explains how the pull-in and hold-in coils of a solenoid work. Instructions on performing a voltage-drop test of the starter "S" circuit are included.(691K PDF)

Created by Wes Grueninger Sr. and Bob Thomas

A shunt coil is simply a field coil connected directly to the battery in parallel with the armature, as opposed to being connected in series with the armature, as most starter field coils are.

Shunts have been used in many different starters in combination series field coils and sometimes cause confusion or misunderstanding for rebuilders.

Why is the shunt coil there, what does it really do and how does it work? This 4 page article will explain it all.

Created by Wes Grueninger Sr.

This style starter drive has many parts that have to be assembled on the armature shaft, one piece at a time. Replacement drives were sold on a wooden dowel (the "stick"). The stick held all of the pieces in the correct order of assembly.

Once the stick is removed, it is all too easy to forget how the parts stack up. This guide will help you reassemble the parts in the correct order.

Created by Wes Grueninger Sr.

This 4 page installation guide, by Sure Power Industries, offers detailed instructions on wiring up battery isolators. It includes detailed wiring diagrams for most domestic and import vehicles, including:

• Ford (1985 and later 2G)
• Ford (1998 and later 3G )
• General Motors CS and CS130D
• Toyota
• Honda
• Bosch Systems

Courtesy of Sure Power Industries, Inc..

One-page guide shows how to create diamond-tipped or Carboloy cutting tools and how to properly position them for the best armature cutting. Even if you are not creating your own cutting tools, using the angles shown in this guide when resharpening existing bits will result in improved cutting. (282Kb PDF)

Created by Wes Grueninger Sr.

Perhaps the most important tool you'll use in troubleshooting auto electrical systems is the multimeter. This interactive slide show teaches how to use a multimeter. Topics include:

• Batteries
• Alternators, Alternator AC Leakage
• Starter Current, Circuit Resistance
• Ohm's Law, Voltage Drop
• Ford BP/MAP Sensor, Feedback Carburetor, Fuel Pressure
• Throttle Position Sensor, Ignition Coils
• Condensers, Hall-Effect Position Sensors
• Magnetic Position Sensors, RPM
• Rear Window Grid Defogger
• Duty Cycle, Temperature Measurement
• Locating Current Drains, Bad Grounds
• Spark Plug Wires

Material Courtesy Fluke Corp. - Slideshow created by Wes Grueninger Sr.

The inside cover describes this manual as follows:

"The International Products and Manufacturing Company's No. 36-37FO1 Preformed Armature Coil Winding Information Manual is the most comprehensive and complete passenger car, light and heavy truck, tractor, off the road equipment, foreign car, outboard marine, motorcycle, light and heavy alternator stator winding data ever compiled for the armature rewinders.

Over thirty-five years of painstaking research and records by the Experimental and Research Department of International Products & Manufacturing Co., of their armature winding data and compilation are incorporated into this valuable manual. In fact, invaluable and no rewinding shop is complete without it.

Pertinent winding information, data and armature component part numbers of Delco-Remy, Autolite, Chrysler, Ford, Prestolite, Leece-Neville, Ducellier, Fiat, Simca, Renault Dauphine, German Bosch Volkswagen, Delco-Remy and Autolite Outboard Marine Armatures are listed. Also, Delco-Remy and Chrysler passenger car and heavy duty alternator stator winding and hook-ups."

Information provided by Richard Vensel, Vensel Enterprises

First Published October, 1993. All charts are ready to print on letter-sized paper (8.5" x 11"). They are a great learning tool for new employees. Use them for parts reference - write on your own part numbers and display on wall. They can help to organize inventory.

Provided courtesy of NRG Auto Systems/IPM, Cicero, IN

The 24-volt split-ground electrical system used on John Deere 730, 820, 830, 3020, 4010 and 4020 tractors with diesel engines and electric start from 1958 to 1968 is probably the least understood and most confusing system ever created. This 5-page guide discusses every aspect of the charging, starting and lighting systems. Wiring diagrams of the starting/charging and the lighting system are included.

Created by Wes Grueninger Sr. and Bob Thomas

In the 1930s the LeJay Manufacturing Company started publishing a series of articles about converting then common automotive generators into all kinds of useful items. These items were primarily meant to be used by rural dwellers where electricity was not available. This manual, from 1945, contains 50 plans.

This manual is not only a testament to how clever the designers were, but it is an education in how generators are constructed. Learn how to hand rewire an armature and how to wind your own field coils!

• 110V A.C. Light Plant made from Ford Model "T" Generator
• 75 to 110 Ampere Arc Welder Made From Dodge 'G' or 'GA' Generator
• An Electric Outboard Motor from Old Ford 'T' Generator
• An Armature Growler from a Ford Model 'T' Generator
• A Drill Press from a 'T' Generator
• A Battery Spot Welder
• A Direct Drive 32 Volt Wind Plant - All Metal Construction
• An Electric Scooter using a Ford Model 'T' Generator
• An A.C. Welding Transformer Using Dodge Generator Coils

This 9-page instruction guide describes how the entire Low Voltage Thermal Switch system works. Includes a wiring diagram and manual override instructions

Courtesy MAXON Lift Corporation

The guide was produced by Mitsubishi Electric Automotive America, Inc. While it specifically deals with Mitsubishi HD alternators and starters, it also offers good training on electrical basics. There is a very good explanation of what voltage drop is and how to perform voltage drop tests.(1,009K PDF)

Courtesy Mitsubishi Electric Automotive America, Inc.

The 24-page manual from Prestolite Electric contains:

• Characteristics of HD electrical systems
• The Battery system and testing
• The Charging system and testing
• The Starting system and testing
• Alternator sizing worksheet

Courtesy Prestolite Electric

This one-page guide provides an explanation of how to use the PIC numbering system.(19K PDF)

Courtesy Dennis Jacinto - Lester Catalog Company

One-page guide shows how to use a tap to remove blind-end bushings from housings. (186Kb PDF)

Created by Bob Thomas

This seven-page guide details four problem solving uses for small relays, commonly referred to as "Bosch Relays". It starts with a close-up look at the inside and the pinouts of the relays, and goes on to explain, along with detailed wiring diagrams, how to:

• Repair Low Voltage at Starter S Terminal
• Create a Starter Lock-Out
• Control Charge Light in a Positive-Ground 10SI System
• Limit Voltage Drop to Accessories

Created by Wes Grueninger Sr. and Bob Thomas

This two page guide is designed as a quick course in voltage-drop testing. It's perfect to give to a customer that you suspect may have voltage-drop problems. You can build goodwill and save time! It's also a good introduction to voltage-drop testing for new employees.

Page One gives a concise explanation of how voltage-drop testing works.
Page Two includes a wiring diagram of a generic charging and starting system with voltage-drop test points clearly labeled.
Page Two also includes a series of 10 tests, that if followed in sequence, will find the voltage drops in the high-current circuits.

Created by Wes Grueninger Sr. and Bob Thomas

WAI has made their entire collection of Technical Updates available online. Lots of good information available on everything from rebuilding basics to the latest units.

Click here to go to the WAI Technical Update section

Courtesy WAI

This 7-page guide discusses how direction reversing of DC-motors is accomplished. It includes generic wiring diagrams for popular winch motor circuits and detailed diagrams of two popular Warn winch solenoid packs.(2.3MB PDF)

Created by Wes Grueninger Sr.

This one-page guide will help you figure out what gauge wire to use for a given amperage load and wire length.

Courtesy Bob Thomas - B&H Electric