Dear all in Hyderabad / Bangalore - in the last 2 pages, I have read about starting issues due to battery issues. Please do as indicated, your cars will work properly. If you don't do as indicated, your cars will not work properly. This is for upgrading the charging system.
Use Lucas TVS SA15 brand new alternator. These were supplied as OE to brand new carburettor driven Maruti 800 cars and are freely available across the country. Go to an authorized Lucas TVS dealer and purchase. Some guys will try to sell you the same alternator but with the packing box indicating as being for tractor use. You can buy this alternator also, it is exactly same but tax is less due to "agricultural use" (approximately rupees 2200 to 2500). Then please see if you can lay your hands on an S1 alternator mounting bracket and brace. The bracket is made of cast iron and then machined. The brace has 2 bends in 2 planes. I will post photographs shortly when I am in Mumbai (I am in Nasik just now). I have around 10 sets lying at home. Use only good quality TVS make 8.8 grade bolts to mount the alternator. I pick up alternator mounting brackets whenever I get them. Please wire the new alternator as follows:
If the car had a dynamo, it would also have a voltage regulator ("cut out" in garage jargon). Remove this regulator and throw it out. It will have a thick brown wire going to a point marked "D" (dynamo). There will also be another thin wire attached to this thick wire with a common terminal. Cut the common terminal and throw it out. Splay the ends of both the wires with a good 6" Taparia make plier. There is a thin black wire going to a point marked "F" (field coil) with an open ended terminal. Cut this terminal and throw it out. Splay this wire and connect it to the thin wire which came fromthe "D" terminal. Tape the connection with a good insulation tape properly. There is a thick pink wire going to a terminal marked "B" (battery), equipped with a round terminal. Cut the terminal and throw it out. Splay this wire. Connect it to the thick brown wire which came from the "D" terminal. Tape the joint securely. Now tape all the joints thus formed securely using the wiring harness quality black tape. This tape is freely available. The name of the manufacturer is "Notre". Bring the dynamo ends of the thick pink and the thin red wires up, clean them and tape them properly. Buy one Maruti 800 2 point connector having a composite base having 2 connectors at 90 degree orientation. Press this connector in the alternator slot marked "L" and "IG". Do not connect the "IG" wire anywhere, just hide it inside the tape to prevent it from touching anywhere. Connect the thin black wire of the wiring harness formed after discarding the dynamo voltage regulator to the "L" terminal of the connector coming out of the alternator. Tape this joint properly. Connect the round connector of the thick pink wire of the harness to the main output point of the alternator and tighten this M6*1.0 threaded nut by using a size 10 spanner. Use a slightly longer fan belt to drive the alternator. Ask for an old Matador size belt. They are freely available. Start the engine and check the headlights for brightness etc. If your old dynamo was an almost dud, you will be amazed at the transformation of the electrical system.
All above was normal work which I expect any self respecting electrician to know and do properly (easier said than done though!). IF you want still better performance as I do because all my cars have 140/110 watts headlights with GE bulbs (daylight in front of me!), you will need to shunt the alternator. For this, it is necessary to purchase only "FINOLEX 84" size wire in suitable length (25 mts costs around 1500 rupees at current rate), solder correct sizes of terminals at both ends and CONNECT THE MAIN OUTPUT OF THE ALTERNATOR DIRECTLY TO EITHER THE BATTERY POSITIVE TERMINAL OR TO THE POSITIVE TERMINAL OF THE SOLENOID SWITCH. I prefer the direct shunt to the battery but you must be very careful to locate the shunt, route it and tape it properly. Also please read the thread in the "Technical Information on Premier Padmini" thread for further details. Also read my comments on page 60 of the hadlights thread elsewhere on the forum.
If in doubt, please ask.
Best regards,
Behram Dhabhar |