3R0-07422-0 Tohatsu O-RING, 3.1 - 24.4

Table 1
Tools Needed     Quantity    
4C-4911 Battery Load Tester     1    
6V-7070 Digital Multimeter     1    
8T-0900 Ammeter     1    Most of the tests of the electrical system can be done on the engine. The wiring insulation must be in good condition. The wire and cable connections must be clean and tight. The battery must be fully charged. If the on-engine test shows a defect in a component, remove the component for more testing.The service manual Testing And Adjusting Electrical Components, REG00636 has complete specifications and procedures for the components of the starting circuit and the charging circuit.The 8T-0900 Ammeter is completely portable. This ammeter is a self-contained instrument that measures electrical currents without breaking the circuit and without disturbing the conductor's insulation.
Illustration 1 g00296441
8T-0900 Ammeter The ammeter contains a digital display that is used to monitor current directly within a range between 1 ampere and 1200 amperes. If an optional 6V-6014 Cable is connected between this ammeter and a digital multimeter, current readings can be viewed directly from the display of the multimeter. This can be accomplished under only one condition:
The readings are less than 1 ammeter.A lever opens the ammeter's jaws over a conductor. The conductor's diameter can not be larger than 19 mm (0.75 inch).The spring loaded jaws close around the conductor. A trigger switch controls the ammeter. The trigger switch can be locked into the ON position or into the OFF position.After the trigger has been turned to the OFF position, the reading will remain on the digital display for five seconds. This accurately measures currents in areas with limited access. For example, these areas include areas that are beyond the operator's sight. An ammeter for DC operation contains a zero control. This ammeter has batteries that supply the power for operation. The batteries are located in the handle of the ammeter.Note: Refer to Special Instruction, SEHS8420 for more information about using the 8T-0900 Ammeter.
Illustration 2 g00283566
6V-7070 Digital Multimeter The 6V-7070 Digital Multimeter is a portable, hand-held service tool with a digital display. This multimeter is built with extra protection against damage that may occur in field applications. The multimeter is equipped with 7 functions and 29 ranges. The 6V-7070 Digital Multimeter has an instant ohms indicator. This indicator permits checking continuity for a fast inspection of the circuits. The multimeter can also be used for troubleshooting capacitors with small values.Note: Refer to Special Instruction, SEHS7734.Battery
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the battery.
The charging unit will be damaged if the connections between the battery and the charging unit are broken while in operation. Damage occurs because the load from the battery is lost and because there is an increase in charging voltage. High voltage will damage the charging unit, the regulator, and other electrical components.
Use the 4C-4911 Battery Load Tester in order to test a battery that does not maintain a charge when the battery is active. Refer to Operating Manual, SEHS9249 for detailed instruction on the use of the 4C-4911 Battery Load Tester. See Special Instruction, SEHS7633 for the correct procedure and for the specifications to use when you test the batteries.Charging System
The condition of charge in the battery at each regular inspection will show if the charging system operates correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or when a large amount of water is needed. A large amount of water would be more than one ounce of water per cell per week or per every 50 service hours.When it is possible, make a test of the charging unit and voltage regulator. Use wiring and components that are a permanent part of the system. Off-engine testing or bench testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, perform a test in order to prove that the units have been repaired to the original condition of operation.Before the start of on-engine testing, the charging system and the battery must be checked according to the following steps.
The battery must be at least 75 percent (1.225 Sp Gr) of the full charge. The battery must be held tightly in place. The battery holder must not put too much stress on the battery.
Cables between the battery, the starter, and the engine ground must be the correct size. Wires and cables must be free of corrosion. Wires and cables must have cable support clamps in order to prevent stress on battery connections (terminals).
Leads, junctions, switches, and panel instruments that have direct relation to the charging circuit must give correct circuit control.
Inspect the drive components for the charging unit in order to be sure that the components are free of grease and oil. Be sure that the drive components have the ability to operate the charging unit.Alternator Regulator Adjustment
(Delco-Remy)
The charging rate of the alternator should be checked when an alternator is charging the battery too much. The charging rate of the alternator should be checked when an alternator is not charging the battery enough. Make reference to the Specifications module in order to find all testing specifications for the alternators and regulators.To adjust the voltage setting, use the following procedure: 3T-6352 Alternator And 6N-9294 Alternator
No adjustment can be made in order to change the rate of charge on the alternator regulators. If the rate of charge is not correct, a replacement of the regulator is necessary.
Illustration 3 g00346692
6N-9294 Alternator (1) Output terminal. (2) Relay termin