Alternator Replacement Wiring Instructions w/ Selector Switch for QAS/CPG 70, 90, 120

This picture shows what the wiring of a new alternator looks like This picture shows what the wiring of a new alternator looks like. After swapping out the old alternator for the new, begin by removing the 8 sets of nuts and washers from the studs and set aside. Throw away the buss bar. Cut the wire bundle zip ties Remove the 6-6, 7-7, and 8-8 small wires from the terminals. Remove U5 wire from U2 terminal Remove V5 wire from V2 terminal Move W5 wire from W2 to N2 Remove V6 wire from N terminal BUSS BAR N2 N1 W2 W1 V2 V1 U2 U1

Install old switch panel onto the new alternator Install old switch panel onto the new alternator. There should be three rubber isolators on the panel. The leads on the switch are labeled. Attach 6-6 small wire to V2 lug on the alternator. See next page for isolator wiring. I-1 I-3 I-2 RUBBER ISOLATORS

U5 wires from alternator and switch plus 8-8 small wire from alternator on I-1 On I-1, attach U5 from alternator, 8-8 from alternator, and U5 from switch. On I-2, attach V5 from alternator, 7-7 from alternator, and V5 from switch. On I-3, attach V6 from alternator and V6 from switch. Do not allow wires on an isolator touch wires on a nearby isolator. V5 wires from alternator and switch Plus 7-7 small wire from alternator on I-2 V6 wires from alternator and switch on I-3 W5 wire on N2 lug from W2 lug

W5 wire from switch attaches to N2 lug on the alternator. U6 W6 wire from switch attaches to N1 lug on the alternator. Attach the 6 remaining wires from the switch to the alternator. Follow the labels. U1 wires attaches to U1 lug, V1 wire attaches to V1 lug, etc etc. Attach the cubicle cables to the alternator as labeled with blue shielded cable on the N1 lug. Secure cables with the lockwashers and nuts removed earlier. U6 W6 Switch Wire W5 wire from alternator and W5 wire from switch

Attach ground cable from cubicle to the front bolt on the alternator case. Remove AVR cover. Route the blue and red sheaved wire into the AVR Board and attach as shown. Red wire on left and blue wire on right. The two remaining wires from the cubicle attach to the switch Attach the #105 wire to the #2 terminal on the switch. Attach the #109 wire to the #3 terminal on the switch. Zip tie wires where necessary and finish assembly of the generator. Run AVR wires through grommet and attach on the other side Ground cable attachment Red on left and blue on right