WAGINER PRODU~C'TS,

MO~DEL DC-6~0

lnstallatiion

l lnstr'ucti~ons

llllftl.lll II'IIO:IJUCFS COMMII'I

I. FOREWORD

This system is designed to fit on 470* Series Mercruiser Sterndrives Serial numbers 4625580 and above. Older engines require additional parts.

The alternator provided has been carefully assembled and tested before leaving our factory to insure a charging output between 13.8 and 14.2 volts, and in excess of 60 amperes current capacity.

This alternator has been shipped as a sealed unit. Attempting to service this unit will void the warranty. However, units out of warranty may be easily repaired using standard Delco replacement parts. Be sure to follow the installation instructions carefully and contact the factory if problems are encountered.

Kit contains the parts pictured below.

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FIGURE 1: ILLUSTRATED PARTS BREAKDOWN .. 3.7 Liter/224 CID 4 cylinder aluminum block engines.

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Drawing Wagner Reference Products Quality

Number Part No. Part Descnption Used

1 HN-2 #12-24 Hex Nut 1 2 LW-4 #12 Lock Washer 1 3 ST-1 Heat Shrink Tubing 1 4 WL-1 Wire Lead Assembly 1 5 CT-1 Split Convolute Tubing 1 6 TW-1 Wire Ty-Wraps 6 7 MB-1 Altemator Mounting Bracket 1 8 TA-1 Tensioning Arm 1 9 OP-1 Balanced Drive Pulley 1 10 RP-1 3/16" Roll Pins 2 11 FW-2 3/8" Stainless Flat Washer 3 12 LW-2 3/8" Stainless Lock Washer 4 13 HB-2 3/8 x 1" Sta1nless Hex Bolt 3 14 LW-1 5/16" Stainless Lock Washer 2 15 HB-1 5/16 x 1" Stainless Hex Bolt 2 16 DB-1 Alternator Drive Belt 1 17 LW-3 7/16" Stamless Lock Washer 2 16 HB-5 7/16 x 1-1/2" Grade 8 Hex Bolt 1 19 HB-4 7/16 x 1-1/4" Grade 8 Hex Bolt 1 20 HB-3 3/8 x 3·1/2" Grade 8 Hex Boa 1 21 FW-1 5/16" Stainless Flat Washer 1 22 SE-63 Alternator (68 Amp. new) 1

II. REMOVAL OF ORIGINAL EQUIPMENT

A. Remove the motor cover or engine hatch as required to provide access to the front, right, and left sides of the engine.

B. Disconnect the battery ground cable(s) to insure that all power is off.

C. Remove the engine balancer using approved Mercury pulling tool or equivalent, taking care not to damage the front crankshaft seaL

D. Remove the stator windings and discard.

E. Inspect the front crankshaft seal and replace if worn.

F. Reinstall the engine balancer and tighten bolt to factory specifications. (See Installation Tip on page 8)

NOTE: On some installations the coolant recovery tank must be relocated to the front of the cylinder head or a remote location.

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7/16 X 11/2 HEX BOLT

7/16 X 11/4 HEX B07T /7 7/16 LOCK WASHER

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Ill. INSTALLING NEW EQUIPMENT

A. Remove the alternator from the mounting bracket and install the bracket using the hardware provided. (See fig 2). Be sure to use locktite part no. 290 thread locking compound and torque bolts securely. (55-60 ft./lb. min.)

B. Installing the drive pulley. Experience has shown that the holes in 470 Series Mercruiser engine balancers vary and may not be centered. To compensate for this fact, this pulley has been shipped with oversize mount­ing holes. In addition there are two different styles of balancers which require different mounting procedures. Please read the following instructions carefully to insure a trouble free installation.

NOTE: On engines with serial numbers 4625579 and below a different engine mount and balancer are used which are not compatible with this charging system. The new style balancer, (Mercruiser part no. B-93009-A5), supersedes the old style, (part no. B-77180-A1). Therefore, some engines with lower serial numbers may be equipped with the new style balancer in the event that the balancer was replaced.

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OLD STYLE NEW STYLE Engine Serial Numbers: Engine Serial Numbers: 4625580 Through 5520114. 5520115 and up.

FIGURE 3: IDENTIFICATION OF BALANCER; IDENTIFY THE BALANCER AND PROCEED TO THE NEW OR OLD STYLE SECTION ON PULLEY INSTALLATION.

OLD STYLE BALANCER, PULLEY INSTALLATION PROCEDURE:

STEP 1: Center the pulley on the balancer using the machined in shoulder on the rear of the pulley, see figure 4.

~~~:=ti 0 0 0 0 0 0 0 0 ;LAPPROX. 1/8 INCH GAP,

ALL AROUND BETWEEN MACHINED SHOULDER AND FACE OF BALANCER.

FIGURE 4: CORRECT PULLEY & BALANCER ALIGNMENT.

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STEP 2: After aligning the pulley and balancer, check the align­ment of the 3 mounting bolts. If all three holes do not align, mark the pulley and enlarge the mounting holes as required.

NOTE: For convenience, the pulley may be mounted on the bal­ancer while off of the engine in applications where sufficient front clearance is available to install the pulley and balancer as a unit.

STEP 3: Mount the pulley using the 3/8 hardware provided and thread locking compound, see figure 5.

STEP 4: nghten the bolts with a torque wrench to 25-30 foot pounds. Start engine, or rotate by hand to check for runout in the drive pulley.

STEP 5: Install the roll pins provided to insure proper re-align­ment of the pulley after removal. Follow steps 7 and 8 under new style installation procedure. Note the roll pins are optional on the old style balancer as the machined in groove will center the pulley. However, it is a good idea to install them in order to prevent future misalignment in the event that care is not used when removing and reinstalling the pulley.

~~~ Experience has shown that Mercruiser has : CAUTli~ shipped some old style balancers with non­machined front surfaces. If pulley does not align exactly as shown in Figure 4, you must follow new style installation instructions to remove all run-out.

FIGURE 5: DRIVE PULLEY & MOUNTING HARDWARE.

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PULLEY INSTALLATION IS NOW COMPLETE, CONTINUE TO SECTION C, ON PAGE 10, REINSTALLING THE ALTERNATOR.

NEW STYLE BALANCER, PULLEY INSTALLATION PROCEDURE:

STEP 1: Loosely mount the pulley using the 3/8 hardware provid­ed, tightening the bolts only until the washers contact. See figure 5, under old style installation procedure.

FIGURE 6: ROTATING ENGINE WITH DIAL INDICATOR.

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STEP 2: Mount a dial indicator on the engine front mount, or other convenient surface, and rotate the engine by hand using a 3/4 socket and ratchet wrench as shown in figure 6, (note, remov­ing the spark plugs will make engine rotation much easier.)

STEP 3: Mark the high spot on the pulley with a wipe off marker or grease pencil, (see figure 7).

STEP 4: Rotate the pulley to the side, and use a plastic hammer to tap the high spot towards the center of the crankshaft, (see figure 8).

STEP 5: Recheck the high spot using the dial indica­tor and note the difference in runout. Check the entire pulley and if neces­sary, wipe off the first mark and remark the high spot. Repeat steps 3 and 4 until the pulley indicates .010: off center or less, ( .020" total indicated readout).

FIGURE 7: MARKING THE DRIVE PULLEY HIGH SPOT.

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STEP 6: Tighten the mounting bolts securely and re-check the runout. If in tolerance, remove one bolt at a time, apply thread locking compound and reinstall tightening to 25-30 foot pounds of torque.

FIGURE 8: TAPPING THE HIGH SPOT TOWARDS THE CENTER OF THE CRANKSHAFT.

INSTALLATION TIP: If a machine lathe is available, centering of the drive pulley may be simplified by following these proceedures while the balancer is off of the engine.

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STEP 7: Drill two locator-pin holes into the balancer 1/4 to 3/8" deep using a power drill, 3/16" drill bit and the pilot holes provided in the pulley, (see figure 9).

STEP 8: Install the two 3116" roll pins provided by driving in place with a drift pin punch and ham­mer. Note, the pins should be bottomed out in the balancer and will remain in the balancer in the event that the pulley should have to be removed.

FIGURE 9: DRILLING THE LOCATOR PIN HOLES.

PULLEY INSTALLATION IS NOW COMPLETE, CONTINUE TO SECTION C, ON PAGE 10, REINSTALLING THE ALTERNATOR.

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c.

/- 3/8 LOCK WASHER

''tff( ~318 X 3 112 HEX BOLT

LTER~ATOR WITH PULLEY ',@, '(j 'E{) 5/16 FLAT WASHER~/ '

5/16 LOCK WASHER / /

5/16 X 1 HEX BOLT_____.,./

FIGURE 10 D. Tension "V'' belt and tighten adjusting screws

(See figure 11 ).

~-=~~ ~t~e~~~~:~~i~~;~e~~:~ as belt failure or

PRYBAR~~

ADJUSTING SCREW

PIVOT BOLT

FIGURE 11

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IV. WIRING

A. Attach the feed wire to the battery stud on the rear of the alternator using the hardware provided. (See figure 12).

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RUN WIRE DOWN AND UNDER ENGINE:

WIRE CONTINUES ON FIGURE NO. 14

(SEE CAUTION NOTE)

FIGURE 12

B. Cut wires on factory harness, remove loose ends, and strip wires. (See figure 13).

CUT WIRES I-MAE

~BATTERY CABLE

FIGURE 13

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\_STARTER

C. Run wire under engine to the position of the original voltage regulator. (See figures 12, 14 and caution note).

This is suggested wire routing only, differing models may require different routing. It is the installer's responsibility to insure that the wire is kept away from all moving parts and/or hot areas that may cause damage.

D. Slip heat shrink tubing provided over factory wires. (See figure 14).

E. Insert wires into feed wire splice. (See figure 14).

F. Crimp splice to hold wires in place, then solder.

1/2 INCH

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\_STARTER

WIRE CONTINUED FROM ____-FIGURE NO. 12 __..- ~BATTERY CABLE

FIGURE 14

G. Center heat shrink tubing over splice and shrink in place. (See figure 15).

H. Install plastic tubing over teed wire, splice, and factory harness. (See figure 15).

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b-- ~'9 CENTE'l TUBING OVER SPLICE / :

FIGURE 15

I. Use tie-wraps provided to secure plastic tubing. (See figure 16).

J. Reconnect battery cables. - Installation is now complete-

FIGURE 16

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NOTE: At the installer's option, the original voltage regulator may be removed, and the cooling hoses replaced with a continuous length of hose.

V. TESTING

Follow normal engine starting safety procedures, and start engine.

Alternator should begin charging within 20 to 30 seconds.

NOTE: This is a normal condition as this alternator must "build" a charge. It unit tails to charge see trouble­shooting section.

VI. TROUBLESHOOTING

A. Pertorm the following tests with a volt/ohm meter.

1. With key off and meter in lowest in lowest ohm position, check alternator case to battery ground (Resistance should be zero).

2. With key on and meter in D.C. volts position, check voltage on battery stud on rear of alterna­tor. (Battery voltage should be found).

8. It these two tests are pertormed and unit will still not charge, contact the factory tor assistance.

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