Mercury 2B, Manual

Page 1: ...B 2 51806 ELECTRICAL BATTERY CHARGING SYSTEM AND STARTING SYSTEM ...

Page 2: ...ystem 2B 5 Determining Cause Of Problem 2B 6 Problem Constant High Output 2B 6 Problem No Output 2B 6 Regulation Voltage Check 2B 6 Voltage Regulator Test Using Ohm Meter 2B 7 Removal of Voltage Regulator 2B 7 Installation of Voltage Regulator Rectifier 2B 7 Starter System 2B 8 Starter System Components 2B 8 Description 2B 8 Troubleshooting The Starter Circuit 2B 8 Flywheel Starter Assembly 2B 9 S...

Page 3: ...Amperes Starter Draw Under Load 175 Amperes Battery Rating 670 Marine Carnking Amps MCA or 520 Cold Cranking Amps CCA Alternator Output 12 Amperes 3000 RPM Special Tools Multi Meter DVA Tester 91 99750A1 Description Part Number Hydrometer Obtain Locally Ammeter Obtain Locally ...

Page 4: ... Never take hydrometer readings immediately af ter water has been added Water must be thor oughly mixed with electrolyte by charging for at least 15 minutes at a rate high enough to cause vigorous gassing 3 If hydrometer has built in thermometer draw liq uid in several times to ensure correct tempera ture before taking reading 4 Hold hydrometer vertically and draw in just enough liquid from batter...

Page 5: ...charged at any rate in am peres or as long as spewing of electrolyte from violent gassing does not occur and for as long as electrolyte temperature does not exceed 125 F 52 C If spewing of electrolyte occurs or if elec trolyte temperature exceeds 125 F charging rate in amperes must be reduced or temporarily halted to avoid damage to the battery 2 Battery is fully charged when over a 2 hour peri od...

Page 6: ...eceding charging procedure every 30 45 days as long as battery is in storage for best possible maintenance during inactive peri ods to ensure a good serviceable battery in spring When ready to place battery back in ser vice remove excess grease from terminals a small amount is desirable on terminals at all times recharge again as necessary and reinstall battery WARNING Hydrogen and oxygen gases ar...

Page 7: ... tested without removing from engine 1 Disconnect 2 YELLOW stator leads from bullet connectors to voltage regulator rectifier 2 Use an ohmmeter and perform the following test Test Leads To Resistance Ohms Scale Reading Connect test leads between 2 YELLOW stator leads 25 45 R x 1 RED test lead to 1 YELLOW stator lead and BLACK test lead to engine ground if stator is mounted or to steel frame of sta...

Page 8: ...engine at 1000 2000 RPM Any out put current indicates stator is shorted to ground Replace stator 4 If there is no output with YELLOW lead discon nected the regulator is defective PROBLEM NO OUTPUT IMPORTANT Regulator MUST have a good ground Verify a clean contact surface exists be tween regulator case powerhead and attaching hardware 1 Check voltage on either RED wire to regulator bullet connector...

Page 9: ...TIVE test lead to thick RED lead 100 400 R x 10 Diode Check Con nect NEGATIVE ohm lead to thick RED lead Connect POSITIVE ohm lead to either YEL LOW lead 40K to R x 1K SCR Checks Con nect NEGATIVE ohm lead to either YELLOW lead Con nect POSITIVE ohm lead to case ground 10K to R x 1K Tachometer Circuit Check Connect NEGATIVE ohm lead to case ground Connect POSITIVE ohm lead to GRAY lead 10K to 30K ...

Page 10: ...ental starting when the engine is in gear CAUTION The starter motor may be damaged if operated continuously DO NOT operate continuously for more than 30 seconds Allow a 2 minute cooling period between starting attempts TROUBLESHOOTING THE STARTER CIRCUIT Before beginning the troubleshooting flow chart verify the following conditions 1 Confirm that battery is fully charged 2 Check that control leve...

Page 11: ... 32 x 380 6 1 MARKER Timing 7 1 PLUG 8 1 NUT 625 18 120 163 9 1 WASHER 10 1 FLYWHEEL ASSEMBLY 11 4 SCREW 10 32 x 1 00 12 4 LOCKWASHER 10 13 1 STATOR ASSEMBLY 14 1 TRIGGER PLATE ASSEMBLY 15 2 COLLAR Starter Cap 16 1 DECAL Start In Gear 17 1 DECAL High Voltage 18 1 WIRE ASSEMBLY 12 500 in BLACK 19 1 NUT 250 20 20 1 LOCKWASHER 250 21 1 STARTER ASSEMBLY 22 1 BOOT Red Starter Lead 23 1 SCREW W LOCKWASH...

Page 12: ...TION lb in lb ft N m 1 1 STARTER ASSEMBLY 2 1 DRIVE KIT Pinion 3 1 PINION ASSEMBLY Drive 4 1 CAP ASSEMBLY Drive End 5 2 THRU BOLT 6 2 O RING Thru Bolt 7 1 ARMATURE 8 2 O RING Starter Frame 9 1 BRUSH SPRING KIT 10 2 SCREW Brush Holder 11 1 HOLDER Brush 12 1 CAP Comm End 13 1 WASHER Insulator Brush Post 14 1 NUT Brush Post ...

Page 13: ...est Point 3 c Turn ignition key to Start position 12 Volt Reading Check BLACK ground wire for poor connection or open circuit Reconnect ground wire to starter solenoid Proceed to TEST 7 No voltage reading Proceed to TEST 4 12 Volt Reading Defective starter solenoid TEST 4 a Connect voltmeter between common engine ground and Test Point 4 b Turn ignition key to Start position No voltage reading Proc...

Page 14: ...o Start position No voltage reading Check BLACK cable with YELLOW sleeve for poor connection or open circuit 12 Volt Reading If starter motor does not turn check starter motor Battery Voltage 2B 12 ELECTRICAL 90 852396 MAY 1996 Starter Removal and Installation REMOVAL CAUTION Disconnect battery leads from battery before re moving starter 1 Disconnect BLACK ground cable from starter 2 Disconnect BL...

Page 15: ...from starter 11646 a b a Through Bolts b Commutator End Cap 3 Tap commutator end cap to loosen and remove from frame Do not lose brush springs 4 Brush replacement is recommended if brushes are pitted chipped or worn to less than 0 25 in 6 4 mm If necessary remove brushes as fol lows a Remove hex nut and washers from POSI TIVE terminal and remove POSITIVE brushes and terminal as an assembly b Remov...

Page 16: ...rcut is flat b Clean the commutator slots after undercut ting c Sand the commutator lightly with No 00 sandpaper to remove burrs then clean the commutator d Recheck the armature on a growler for shorts as specified in the following procedure Test ing 8 Open circuited armatures often can be repaired The most likely place for an open circuit is at the commutator bars as a result of long cranking pe ...

Page 17: ...rushes Meter must indicate full continuity or zero resistance If resistance is indi cated inspect lead to brush and lead to POSITIVE terminal solder connection If connection cannot be repaired brushes must be replaced a 11673 a POSITIVE Brushes Testing Negative Brushes for Ground Set ohmmeter to R x1 scale Place one lead of the ohmmeter on the NEGATIVE brush and the other lead on the end cap bare ...

Page 18: ...Push Lead into Slot b Install NEGATIVE brushes along with brush holder 11656 a c b d a b d a POSITIVE Brushes b NEGATIVE Brushes c Brush Holder d Bolts Fasten NEGATIVE Brushes and Holder 2 If removed reinstall parts on armature shaft Use a new locknut and tighten securely on end of shaft 11658 e f g a b c d a Locknut b Spacer c Spring d Drive Assembly e Drive End Cap f Armature Shaft g Washer 3 Lu...

Page 19: ...ing located in commutator end cap with one drop of SAE 10W oil DO NOT over lubricate 8 Place springs and brushes into brush holder and hold in place with brush retainer tool 11661 b a a Brush Retainer Tool b Bushing DO NOT over lubricate 9 Install armature into starter frame and align match marks a Install commutator end cap onto starter frame and align match marks b Re move brush retainer tool In...

Page 20: ... scale and connect me ter leads between solenoid terminals 1 and 2 3 Connect a 12 volt power supply between sole noid terminals 3 and 4 Solenoid should click and meter should read 0 ohms full continuity 4 If meter does not read 0 ohms full continuity re place solenoid 51809 b a b a 3 1 4 2 a 12 VOLT Supply b VOA Leads ...