@@ Line 11: / Line 11: @@
 ==Wiring==
+[[File:Wire gaguecompro.jpg|frame|Relative cable sizes]]
 ===Charging wire size===
-<table bgcolor="#FFF8DC" border="1" cellpadding="2" cellspacing="0"><tr>
+The charging wire is the wire from the back of the alternator to the battery, not the positive battery cable from the battery to the starter or solenoid.
-             <td bgcolor="#CCCCFF" colspan="9">
-               <div align="center"><span style="font-size:10.0pt;
+<table valign="MIDDLE" align="center" border="1" cellpadding="2" cellspacing="0"><tr>
-     font-family:&quot;Arial&quot;,&quot;sans-serif&quot;"><font face="Arial, Helvetica, sans-serif" size="3"><b>Recommended Charging Cable Gauge Size</b></font></span></div>
+             <td bgcolor="#eeeeee" colspan="9">
-            </td>
+               <div align="center"><span style="font-size:medium;
-          </tr>
+     font-family:&quot;Arial&quot;,&quot;sans-serif&quot;"><font face="Arial, Helvetica, sans-serif" size="3"><b>Recommended Charging Cable Gauge Size</b></font></span>  </div></td></tr>
-          <tr>
+<tr><td bgcolor="#CCCCFF"  align="center" width="88"> <font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:5">Amps</span></b></font></td>
-            <td align="center" width="88"> <font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">AMPS</span></b></font></td>
+             <td tr bgcolor="#FFF8DC" width="74"> <font face="Arial, Helvetica, sans-serif" size="medium"><b></= 4 ft.</b></font></td>
-             <td width="74"> <font face="Arial, Helvetica, sans-serif" size="2"><b></= 4 ft.</b></font></td>
+             <td tr bgcolor="#FFF8DC" align="center" valign="middle" width="60"> <font face="Arial, Helvetica, sans-serif" size="medium"><b>4-7 ft.</b></font></td>
-             <td align="center" valign="middle" width="60"> <font face="Arial, Helvetica, sans-serif" size="2"><b>4-7 ft.</b></font></td>
+             <td bgcolor="#FFF8DC" align="center" valign="middle" width="70"> <font face="Arial, Helvetica, sans-serif" size="2"><b>7-10 ft.</b></font></td>
-             <td align="center" valign="middle" width="70"> <font face="Arial, Helvetica, sans-serif" size="2"><b>7-10 ft.</b></font></td>
+             <td bgcolor="#FFF8DC" align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>10-13 ft.</b></font></td>
-             <td align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>10-13 ft.</b></font></td>
+             <td bgcolor="#FFF8DC" align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>13-16 ft.</b></font></td>
-             <td align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>13-16 ft.</b></font></td>
+             <td bgcolor="#FFF8DC" align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>16-19 ft.</b></font></td>
-             <td align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>16-19 ft.</b></font></td>
+             <td bgcolor="#FFF8DC" align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>19-22 ft.</b></font></td>
-             <td align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>19-22 ft.</b></font></td>
+             <td bgcolor="#FFF8DC" align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>22-28 ft.</b></font></td>
-             <td align="center" valign="middle" width="80"> <font face="Arial, Helvetica, sans-serif" size="2"><b>22-28 ft.</b></font></td>
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">35
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10.0pt">35-50</span></b></font></p>
-                - 50</span></b></font></p>
              </td>
              <td width="64">
@@ Line 61: / Line 60: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">50
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">50-65</span></b></font></p>
-                - 65</span></b></font></p>
              </td>
              <td width="64">
@@ Line 92: / Line 90: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">65
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">65-85</span></b></font></p>
-                - 85</span></b></font></p>
              </td>
              <td width="64">
@@ Line 122: / Line 119: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">85
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">85-105</span></b></font></p>
-                - 105</span></b></font></p>
              </td>
              <td width="64">
@@ Line 153: / Line 149: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">105
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">105-125</span></b></font></p>
-                - 125</span></b></font></p>
              </td>
              <td width="64">
@@ Line 183: / Line 178: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">125
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">125-150</span></b></font></p>
-                - 150</span></b></font></p>
              </td>
              <td width="64">
@@ Line 214: / Line 208: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">150
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">150-175</span></b></font></p>
-                - 175</span></b></font></p>
              </td>
              <td width="64">
@@ Line 244: / Line 237: @@
            </tr>
            <tr>
-             <td align="center" width="68">
+             <td bgcolor="#FFF8DC" align="center" width="68">
-               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:8.5pt">175
+               <p><font face="Arial, Helvetica, sans-serif" size="2"><b><span style="font-size:10pt">175-200</span></b></font></p>
-                - 200</span></b></font></p>
              </td>
              <td width="64">
@@ Line 274: / Line 266: @@
 </td></tr></table><br>
+==Pulley ratio==
+The pulley ratio is the diameter of the crankshaft pulley divided by the diameter of the alternator pulley.
+*a 6" crankshaft pulley and a 2" alternator pulley equals a pulley ratio of '''3:1'''
+*Multiply the pulley ratio by the engine RPM to get the alternator RPM.
+;For example,
+:1 ratio and an idle speed of 900 RPM gives an alternator speed of (3 x 900) 2700 RPM
+The general rule of thumb is the alternator ratio should be about 3:1 for the best all around performance. However, in cases where the engine will see high RPM, the alternator (as well as other belt/engine driven accessories) might need to be driven at a reduced ratio by using a larger diameter accessory pulley (or a smaller diameter crankshaft pulley) to lower the peak RPM. This ratio reduction needs to be balanced between low and high engine rpm operation if the vehicle will be used on the street.
+[[File:Deep groove alt pulley.jpg|border|right]]
+If using a V-belt to drive the alternator, the belt depth can be increased to help prevent the belt from being thrown off at high RPM. One such pulley combines a larger diameter with a deeper groove (right).
+<br style="clear:both"/>
+===Pulley ratio chart===
+<table valign="MIDDLE" align="center" border="1" cellpadding="2" cellspacing="0" ><tr height="33">
+<td  bgcolor="#CCCCFF" style="TEXT-ALIGN: center" rowspan="2" height="66" width="71"><strong><span style="font-size:medium;">Alternator Pulley Diameter</span></strong></td>
+<td  bgcolor="#FFF8DC" style="TEXT-ALIGN: center" colspan="11"><span style="font-size: medium;"><strong><span style="font-size:medium;">'''Crankshaft Pulley Diameter'''</span></strong></span></td>
+</tr>
+<tr bgcolor="#eeeeee" height="33">
+<td style="TEXT-ALIGN: center" height="33"><strong><span style="font-size:medium;">5.0"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size:medium;">5.25"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">5.5"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">5.75"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">6.0"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">6.25"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">6.5"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">6.75"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">7.0"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">7.5"</span></strong></td>
+<td style="TEXT-ALIGN: center"><strong><span style="font-size: medium;">8.0"</span></strong></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">1.9"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.63</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.76</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.89</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.03</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.16</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.29</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.42</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.55</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.68</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.95</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">4.21</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">2.0"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.63</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.75</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.88</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.13</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.25</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.38</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.75</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">4.00</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">2.2"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.27</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.39</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.61</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.73</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.84</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.95</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.07</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.18</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.41</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.64</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">2.4"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.08</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.19</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.29</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.40</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.60</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.71</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.81</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.92</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.13</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.33</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">2.5"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.10</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.20</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.30</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.40</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.60</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.70</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.80</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">3.20</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">2.75"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.82</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.91</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.09</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.18</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.27</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.36</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.45</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.55</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.73</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.91</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">3.0"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.67</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.75</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.83</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.92</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.08</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.17</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.25</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.33</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.67</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">3.25"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.54</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.62</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.69</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.77</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.85</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.92</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.08</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.15</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.31</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.46</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size: medium;">3.5"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.43</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.57</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.64</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.71</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.79</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.86</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.93</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.00</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.14</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.29</span></td>
+</tr>
+<tr height="33">
+<td bgcolor="#eeeeee" style="TEXT-ALIGN: center" height="33"><strong><span style="font-size:medium;">4.0"</span></strong></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.25</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.31</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.38</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.44</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.50</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.56</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.63</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.69</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.75</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">1.88</span></td>
+<td style="TEXT-ALIGN: center"><span style="font-size: small;">2.00</span></td>
+</tr></table>
+Beyond here the text is normal font and size.
 ==Resources==
 *[http://www.madelectrical.com  Mad Electrical], a good source of information on the topic of alternators and automotive electrical systems.

Troubleshooting alternators

Revision as of 09:22, 4 February 2013

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