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Describe how a generator works. Discuss the various generator test procedures. Explain how to disassemble a generator and test its component parts. Discuss how to check the wiring from the generator to the battery. OBJECTIVES: After studying Chapter 41, the reader should be able to:
AC voltage • brushes charging voltage delta-connected stator • delta winding • diodes • diode check • diode trio • drive-end (DE) housing • duty cycle Electrical power management (EPM) fusible link generator output test KEY TERMS: Continued
overrunning alternator dampener (OAD) • overrunning alternator pulley (OAP)  poles rectifier bridge • rotors sine wave • slip ring end (SRE) • stators • stator tap temperature compensation • thermistor wye-connected stator KEY TERMS:
All vehicles operate electrical components by taking current from the battery. It is the purpose and function of the charging system to keep the battery fully charged. The Society of Automotive Engineers (SAE) term for the unit that generates electricity is the generator. The term alternator is also commonly used, especially in service manuals before 1993 when the SAE term was adopted by most vehicle manufacturers.
PRINCIPLES OF GENERATOR OPERATION All electrical generators use the principle of electromagnetic induction to convert mechanical energy into electrical energy. Electromagnetic induction involves the generation of an electrical current in a conductor when the conductor is moved through a magnetic field. The amount of current generated can be increased by the following factors: Increasing the  speed  of the conductor through the magnetic field Increasing the  number  of conductors passing through the magnetic field Increasing the  strength  of the magnetic field
An AC generator generates an alternating current when the current changes polarity during the generator’s rotation. A battery cannot “store” alternating current; therefore, this alternating current is changed to direct current (DC) by diodes inside the generator. Diodes are one-way electrical check valves that permit current to flow in only one direction. Most manufacturers call an AC generator an alternator. ALTERNATING CURRENT GENERATORS (ALTERNATORS) Continued
GENERATOR CONSTRUCTION A generator is constructed of a two-piece cast-aluminum housing. Aluminum is used because of its lightweight, nonmagnetic properties and heat transfer properties needed to help keep the generator cool. A front ball bearing is pressed into the front housing (called the  drive-end  [ DE ]  housing ) to provide the support and friction reduction necessary for the belt-driven rotor assembly. The rear housing, or the  slip ring end  ( SRE ), usually contains a roller-bearing support for the rotor and mounting for the brushes, diodes, and internal voltage regulator (if the generator is so equipped). See Figures 41–1 and 41–2. Continued
Figure 41–1  A typical generator (alternator) on a Chevrolet V-8 engine. Figure 41–2 The end frame toward the drive belt is called the drive-end housing and the rear section is called the slip-ring-end housing. Continued
Many technicians are asked how much power certain accessories require. A 100-ampere generator requires about 2 horsepower from the engine. One horsepower is equal to 746 watts. Watts are calculated by multiplying amperes times volts: Generator Horsepower and Engine Operation - Part 1 Power in watts 100A x 14.5V = 1450  1hp = 746 W 1450 watts is about 2 horsepower and the generator uses about 2 hp to generate 100 A. Allowing about 20% for mechanical and electrical losses adds another 0.4 horsepower. When someone asks how much power it takes to produce 100 amperes from a generator, the answer is 2.4 hp.
Generator Horsepower and Engine Operation - Part 2 Many generators delay output to prevent the engine from stumbling when a heavy electrical load is applied. The voltage regulator or vehicle computer is capable of gradually increasing the generator output over a period of up to several minutes.  Power in watts 100A x 14.5V = 1450  1hp = 746 W Though it does not sound like much, a sudden demand for 2 horsepower from an idling engine can cause the engine to run rough or stall. The difference in part numbers of various generators is often an indication of the time interval over which the load is applied. Therefore, the use of the wrong replacement generator could cause the engine to stall!
ALTERNATOR OVERUNNING PULLEY Purpose and Function   Many generators are equipped with an  overrunning alternator pulley  ( OAP ), called a  clutch pulley . This eliminates noise and vibration in the accessory drive belt system, especially when at idle, when engine impulses are transmitted to the alternator through the accessory drive belt. The mass of the rotor of the alternator tends to want to keep spinning, but the engine crankshaft speeds up and slows down slightly due to the power impulses. Using a one-way clutch in the alternator pulley allows the belt to apply power to the alternator in only one direction thereby reducing the fluctuations in the belt. See Figure 41–3. Continued
Figure 41–3  An OAP on a generator on a Chevrolet Corvette.
A conventional drive pulley attaches to the alternator (rotor) shaft with a nut and lock washer. In the overrunning clutch pulley, the inner race of the clutch acts as the nut and screws onto the shaft. Special tools are required to remove and install this type of pulley. Another type of alternator pulley uses a dampener spring inside plus a one-way clutch. This unit is called an  overrunning alternator dampener  ( OAD ). An OAD is larger than an OAP and is used on the Pontiac G8 and other vehicles. See Figure 41–4. Continued
Figure 41–4  An overrunning alternator dampener (OAD) disassembled, showing all of its internal parts.
Diagnosis and Service   Overrunning alternator pulleys and alternator dampeners can fail, with the most common factor the one-way clutch. If it fails, it can freewheel and not power the alternator or it can lock up and not provide dampening as designed. If the charging system is not working, the OAP or OAD could be the cause rather than a fault in the alternator itself. In most cases, the entire alternator assembly will be replaced because each OAP or OAD is unique for each application and they require special tools to remove and replace.
No. An alternator needs to be equipped with the proper shaft to allow the installation of an OAP or OAD. This also means a conventional pulley cannot be used to replace a defective overrunning alternator pulley or dampener. Can I Install an OAP or OAD to My Alternator?
ROTORS The  rotor  creates the magnetic field of the generator and produces a current by electromagnetic induction in the stationary stator windings. The generator rotor is constructed of many turns of copper wire coated with a varnish insulation wound over an iron core. The iron core is attached to the rotor shaft. At both ends of the rotor windings are heavy-gauge metal plates bent over the windings with triangular fingers called  poles . These pole fingers do not touch, but rather they alternate or interlace as shown in Figure 41–5.  Continued
Figure 41–5  A cutaway of a General Motors CS-130D generator showing the rotor and cooling fans that are used to force air through the unit to remove the heat created when it is charging the battery and supplying electrical power for the vehicle. Continued
If current flows through the rotor windings, the metal pole pieces at each end of the rotor become electromagnets. Whether a north or a south pole magnet is created depends on the  direction  in which the wire coil is wound. Because the pole pieces are attached to each end of the rotor, one pole piece will be a north pole magnet. The other pole piece is on the opposite end of the rotor and therefore is viewed as being wound in the opposite direction, creating a south pole. The rotor fingers are alternating north and south magnetic poles. The magnetic fields are created between the alternating pole piece fingers. These individual magnetic fields produce a current by electromagnetic induction in the stationary stator windings. See Figure 41–6. Continued
Figure 41–6  Rotor assembly of a typical alternator (AC generator). Current through the slip rings causes the “fingers” of the rotor to become alternating north and south magnetic poles. As the rotor revolves, these magnetic lines of force induce a current in the stator windings. The current necessary for the field (rotor) windings is conducted through carbon brushes to the slip rings. Maximum-rated generator output in amperes is largely dependent on the number and gauge of the windings of the rotor.  Substituting rotors from one generator into another can greatly affect maximum output either positive or negative.
GENERATOR BRUSHES The current for the field is controlled by the voltage regulator and is conducted to the slip rings through carbon  brushes . The brushes conduct only the field current (approximately 2 to 5 amps), and therefore tend to last longer than the brushes used on a DC generator, where all the current generated in the generator must flow through the brushes.
STATORS Supported between the two halves of the generator housing are three copper wire windings wound on a laminated metal core. See Figure 41–7. As the rotor revolves, its moving magnetic field induces a current in the windings of the  stator . See Figure 41–8. Continued
Figure 41–7  A cutaway view of a typical AC generator (alternator) Continued
Figure 41–8  An exploded view of a typical generator (alternator) showing all of its internal parts.
Whenever checking for the root cause of a generator failure, one of the first things that a technician should do is to sniff (smell) the generator! If the generator smells like a dead rat (rancid), the stator windings have been overheated by trying to charge a discharged or defective battery. If the battery voltage is continuously low, the voltage regulator will continue supplying full field current to the generator. The voltage regulator is designed to cycle on and off to maintain a narrow charging system voltage range. If battery voltage is continually below the cutoff point of the voltage regulator, the generator is continually producing current in the stator windings. This constant charging can often overheat the stator and burn the insulating varnish covering the stator windings. If the generator fails the sniff test, the tech should replace the stator and other generator components found to be defective and replace or recharge and test the battery. The Sniff Test
DIODES Diodes  are constructed of a semiconductor material (usually silicon) and operate as a one-way electrical check valve that permits the current to flow in only one direction. AC generators use six diodes (one positive and one negative diode for each of the three stator windings) to convert alternating current to direct current. The symbol for a diode is shown here. Figure 41–9 A diode symbol.
HOW A GENERATOR WORKS A rotor inside a generator is turned by a belt and drive pulley turned by the engine. The magnetic field of the rotor generates a current in the windings of the stator by electromagnetic induction.  Continued Figure 41–10  Magnetic lines of force cutting across a conductor induce a voltage and current in the conductor. Field current flowing through the slip rings to the rotor creates alternating north & south poles on the rotor, with a magnetic field between each finger of the rotor.
The induced current in the stator windings is an alternating current because of the alternating magnetic field of the rotor. The induced current starts to increase as the magnetic field starts to induce current in each winding of the stator. The current then peaks when the magnetic field is the strongest and starts to decrease as the magnetic field moves away from the stator winding. The current generated is described as being of a  sine wave  pattern  See Figure 41–11.  Continued
Figure 41–11  Since wave voltage curve created by one revolution of a winding rotating in a magnetic field. As the rotor continues to rotate, this sine wave current is induced in each of the three windings of the stator. Continued
Figure 41–12  When three windings (A, B, and C) are present in a stator, the resulting current generation is represented by the three sine waves. The voltages are 120° out of phase. The connection of the individual phases produces a three-phase alternating voltage. Because each of the three windings generates a sine wave current, the resulting currents combine to form a three-phase voltage output. AC generators contain six diodes, one pair of positive and a negative for each of the three stator windings.
WYE-CONNECTED STATORS The  Y  (pronounced “wye” and generally so written) type or star pattern is the most commonly used generator stator winding connection. Continued Figure 41–13  Wye-connected stator winding.
The output current with a  wye - type stator connection  is constant over a broad generator speed range. Current is induced in each winding by electromagnetic induction from the rotating magnetic fields of the rotor. In a wye-type stator connection, the currents must combine because two windings are always connected in series. See Figure 41–14. The current produced in each winding is added to the other’s current and flows through the diodes to the generator output terminal. One-half of the current produced is available at the neutral junction (usually labeled “STA” for stator). Voltage at this center point is used by some generator manufacturers (especially Ford) to control the charge indicator light or is used by the voltage regulator to control the rotor field current. Continued
Figure 41–14  As the magnetic field, created in the rotor, cuts across the windings of the stator, a current is induced. Notice that the current path includes passing through one positive () diode on the way to the battery and one negative () diode as a complete circuit is completed through the rectifier and stator.
Figure 41–15  Delta-connected stator winding. The  delta winding  is connected in a triangular shape, as shown in here. (Delta is a Greek letter shaped like a triangle.) Continued DELTA-CONNECTED STATORS
Current induced in each winding flows to the diodes in a parallel circuit. More current can flow through two parallel circuits than can flow through a series circuit (as in a wye-type stator connection). Delta-connected stators  are used on generators where high output at high-generator rpm is required. The delta-connected generator can produce 73% more current than the same generator with wye-type stator connections.  If a generator with a wye-connected stator can produce 55 A, the  same  generator with delta-connected stator windings can produce 73% more current, or 95 A (55    1.73 = 95). The delta-connected generator, however, produces lower current at low speed and must be operated at high speed to produce its maximum output.  Continued
GENERATOR OUTPUT FACTORS Output voltage and current of a generator depend on:  Continued The  Speed of rotation  Generator output is increased with generator rotational speed up to the generator’s maximum possible ampere output. Generators normally rotate at a speed two to three times faster than engine speed, depending on relative pulley sizes used for the belt drive.  The  Number of conductors.  A high-output generator contains more turns of wire in the stator windings. Stator winding connections (whether wye or delta) also affect the maximum generator output. See 41-16.
Figure 41–16  A stator assembly with six, rather than the normal three, windings. Here is an example of a stator that has six rather than three windings, which greatly increases the amperage output of the generator (alternator). Continued
The  Strength of the magnetic field.  If the magnetic field is strong, a high output is possible because the current generated by electromagnetic induction is dependent on the number of magnetic lines of force that are cut. The strength of the magnetic field can be increased by increasing the number of turns of conductor wire wound on the rotor. A higher-output generator has more turns of wire than a generator with a low-rated output. The strength of the magnetic field also depends on the current through the field coil (rotor). Because magnetic field strength is measured in ampere-turns, the greater theamperage or the number of turns, or both, the greater the generator output.
GENERATOR VOLTAGE REGULATION An automotive generator must be able to produce electrical pressure (voltage) higher than battery voltage to charge the battery. Excessive high voltage can damage battery, electrical components, and the lights of a vehicle. If no current (zero amperes) was flowing in the field coil of the generator (rotor), generator output would be zero because without field current a magnetic field does not exist.  Continued The field current required by most automotive generators is less than 3 amps. It is the  control  of the  field  current that controls the output of the generator.  See Figure 41–17.
Figure 41–17  Typical voltage regulator voltage range. Current for the rotor flows from the battery through the brushes to the slip rings. After generator output begins, the voltage regulator controls the current flow through the rotor.
CHARGING VOLTAGE CONTROL If an automotive battery is discharged, its voltage will be lower than the voltage of a fully charged battery. The generator will supply charging current, but it may not reach maximum  charging voltage . A good but discharged battery should be able to convert into chemical energy all the current the generator can produce. As long as generator voltage is higher than battery voltage, current will flow from the generator (high pressure, high voltage) to the battery (lower pressure, lower voltage). The condition and voltage of the battery  do  determine the charging rate of the generator.  If a discharged battery is used during charging system testing, tests could mistakenly indicate a defective generator and/or voltage regulator. Continued
Temperature Compensation   All voltage regulators (mechanical or electronic) provide a method for increasing the charging voltage slightly at low temperatures and for lowering the charging voltage at high temperatures. A battery requires a higher charging voltage at low temperatures because of the resistance to chemical reaction changes. However, the battery would be overcharged if the charging voltage were not reduced during warm weather. Electronic voltage regulators use a temperature-sensitive resistor, called a  thermistor  in the regulator circuit, and it provides lower resistance as temperature increases. A thermistor is used to control charging voltage over a wide range of under-the-hood temperatures. See Figure 41–18.  Continued
Figure 41–18  A typical electronic voltage regulator showing the connections and the circuits involved. NOTE :   Voltmeter test results may vary according to temperature. Charging voltage tested at 32°F (0°C) will be higher than for the same vehicle tested at 80°F (27°C) because of the  temperature - compensation  factors built into voltage regulators.
DIODE TRIO GENERATORS Some generators (alternators) use a diode trio to provide current to the rotor (field) and turn off the charge indicator light on the dash. A diode trio is three diodes connected in parallel with the anode ends connected to the three stator winding connectors at the rectifier bridge. The single output terminal of the diode trio is applied to the ignition feed terminal. NOTE:   If one of the three diodes is open, only 8 volts will be applied against the 12 volts from the ignition. The result is a dim generator charge indicator light. While this light may be a customer concern, the generator will produce normal output.
When the ignition is on, 12 volts is applied through the charge light bulb and is grounded through the rotor winding. This current is blocked from flowing through the diode trio because the diodes are reversed biased. When the stator and the generator start to generate voltage, the 12-volt output of the diode trio opposes the 12 volts from the ignition through the charge light causing the charge light to go out.
ELECTRONIC VOLTAGE REGULATORS The electronic circuit of the voltage regulator cycles between 10 and 7,000 times per  second  as needed to accurately control the field current through the rotor, and therefore control the generator output. The control of the field current is accomplished by opening and closing the  ground  side of the field circuit through the rotor of the generator. Electronic voltage regulators also use many resistors to help reduce the current through the regulator, and the resulting heat must be dissipated into the air to prevent damage to the diodes and transistors. Whether mounted inside the generator or externally under the hood, electronic voltage regulators are mounted where normal airflow can keep the electronic components cool.  Continued
The zener diode is a major electronic component that makes voltage regulation possible.  Generator voltage from the stator and diodes is first sent through a thermistor, which changes resistance with temperature, and then to a zener diode. Whenever the upper-limit voltage is reached, the zener diode conducts current to a transistor, which then opens the field (rotor) circuit. All the current stops flowing through the generator’s brushes, slip rings, and rotor, and no magnetic field is formed.  Without a magnetic field, a generator does not produce current in the stator windings.  Continued
When no voltage is applied to the zener diode, current flow stops and the base of the transistor is turned off, closing the field circuit. The magnetic field is thus restored in the rotor. The rotating magnetic fields of the rotor induce a current in the stator, which is again controlled if the output voltage exceeds the designed limit as determined by the zener diode breakdown voltage. Depending on the generator rpm, vehicle electrical load, and state of charge of the battery, this controlled switching on and off can occur between 10 and 7,000 times per second. See Figure 41–19.  Continued
Figure 41–19  Typical General Motors SI-style AC generator. Full Caption next slide.
Figure 41–19  Typical General Motors SI-style AC generator with an integral voltage regulator. Voltage present at terminal 2 is used to reverse bias the zener diode (D2) that controls TR2. The hot brush is fed by the ignition current (terminal I) plus current from the diode trio. See the entire schematic on Page 442 of your textbook.
Computer-Controlled Generators   Computers can interface with the charging system in three ways: Continued The computer can  activate  the charging system by turning on and off the field. The computer can  monitor  the operation of the generator and therefore can increase idle speed to compensate for the additional load if the generator is producing at maximum output. The computer can  control  the generator by not only turning the field on and off but can also delay or limit the output of the generator, depending on other loads on the engine, such as power steering or an air-conditioning compressor.
The engine control module (ECM) controls the alternator by changing the on-time of the current through the rotor. The on-time, or  duty cycle , is varied from 5% to 95%. See the following chart:  Continued See the chart on Page 443 of your textbook.
Figure 41–20  A Hall-effect current sensor attached to the negative battery cable is used as part of the EPM system. A system used on some GM vehicles is called  Electrical power management  ( EPM ) and uses a Hall-effect sensor attached to the negative battery cable to measure the current leaving and entering the battery.  Continued This system has six modes of operation including:
The  Fuel economy mode . This mode reduces the load on the engine from the generator (alternator) for maximum fuel economy. Activated when the following conditions are met: Continued The  Charge mode . The charge mode is activated whenever any of the following occurs: Electric cooling fans are on high speed Rear window defogger is on Battery state of charge (SOC) is less than 80% Outside (ambient) temperature is less than 32°F (0°C) Ambient temperature is above 32°F (0°C) The state of charge of the battery is 80% or higher The cooling fans and rear defogger are off The target voltage is 13 volts and will return to the charge mode, if needed.
The  Voltage reduction mode . This mode is commanded to reduce the stress on the battery during low-load conditions. This mode is activated whenever the following conditions are met Continued Ambient temperature is above 32°F (0°C) Low battery discharge rate (less than 7 amperes) Rear defogger is off Cooling fans are on low or off  The  Start-up mode . This mode is selected after engine start and commands a charging voltage of 14.5 volts for 30 seconds. After 30 seconds, the mode is changed depending on conditions.
The  Battery sulfation mode . This mode is commanded if the output voltage is less than 13.2 volts for 45 minutes, which can indicate that sulfated plates could be the cause. The target voltage is 13.9 to 15.5 volts for 3 minutes. After 3 minutes, the system returns to another mode based on conditions.  The  Headlight mode . This mode is selected whenever the headlights are on and the target voltage is 14.5 volts.  A customer may complain that the voltmeter reading on the dash fluctuates up and down. This may be normal as the computer-controlled charging system commands various modes of operation based on the operating conditions. Follow the vehicle manufacturer’s recommended procedures to verify proper operation. The Voltage Display Can Be a Customer Concern
Beginning in the mid-1980s, GM introduced a smaller, high-output series of generators called the CS (charging system) series. See Figures 41–21 and 41–22. Following  CS  are numbers indicating the  outside diameter  in millimeters of the stator laminations. Typical sizes, designations, and outputs include the following:  CS - 121, 5 - SI 74 A   CS - 130, 9 - SI 105 A   CS - 144, 17 - SI 120 A   These generators feature two cooling fans (one internal) and terminals designed to permit connections to an onboard body computer through terminals  L  and  F . Continued
Figure 41–21  General Motors CS generator. Notice the use of zener diodes in the rectifier to help control any high-voltage surges that could affect delicate computer circuits. If a high-voltage surge does occur, the zener diode(s) will be reversed biased and the potentially harmful voltage will be safely conducted to ground. Voltage must be preset at the L terminal to allow the generator to start producing current. Continued
Figure 41–22  The components inside a GM CS generator. The voltage regulator switches field voltage on and off at a fixed frequency of about 400 times per second.  The reduced-size generators also feature ball bearings in the front and rear and totally soldered internal electrical connections. The voltage is controlled either by the body computer (if so equipped) or by the built-in voltage regulator. Voltage is controlled by varying the on time and off time of the field current.
CHARGING SYSTEM TESTING AND SERVICE The charging system can be tested as part of routine inspection or to determine reason for a no- or reduced-charging circuit performance. Charging Voltage Test   First and easiest test to perform to check if the generator is working correctly is to check the charging system voltage at the battery. Use a digital multimeter to check using the following steps:  Continued Step #1   Select DC volts.  Step #2  Connect the red meter lead to the positive (+) terminal of the battery and the black meter lead to the negative (  ) terminal. Step #3  Start the engine and increase the engine speed to about 2000 rpm (fast idle) and record the charging voltage.
Charging voltage =  13.5  to  15.0 V   (GM =  14.2  to  15.2 V ). If the voltage is too high, check that the charging system components such as the generator and voltage regulator (if separate) are properly grounded. If the battery voltage is still higher than specified, then there is likely a fault with the electrical connections at the voltage regulator or generator. If the voltage is lower than specifications, there is a fault with the wiring, generator, or regulator (if external). Additional testing is required to help pinpoint the root cause.  NOTE:   Polarity of meter leads is not  important when using a digital multimeter. If meter leads are connected backward on the battery, the  readout will have a negative (-) sign in front of  the voltage reading. Continued
Figure 41–23  The digital multimeter should be set to read DC volts, with the red lead connected to the positive (+)   battery terminal and the black meter lead connected to the negative (-) battery terminal. Figure 41–24  A scan tool can be used to diagnose charging system problems.
Lower-than-normal generator output could be the result of a loose or slipping drive belt. A common trick used to determine if the noise is belt related is to use grit type hand cleaner or scouring powder. With the engine off, sprinkle some powder onto the pulley side of the belt. Start the engine. The excess powder will fly into the air, so get away from under the hood when the engine starts. If the belts are now quieter, you know that it was the glazed belt that made the noise. Often, the grit from the hand cleaner will remove the glaze from the belt and the noise will not return. However, if the belt is worn or loose, the noise will return and the belt should be replaced. A fast alternative method to see if the noise is from the belt is to spray water from a squirt bottle at the belt with the engine running. If the noise stops, the belt is the cause of the noise. The water quickly evaporates, and therefore, unlike the gritty hand cleaner, water simply finds the problem—it does not provide a short-term fix.  The Hand Cleaner Trick
Figure 41–25  If the rear bearing is magnetized, the voltage regulator, generator brushes, and rotor are functioning. Magnetized Rear Bearing Test   All 12-volt automotive generator systems use the voltage regulator to control the current through the rotor of the generator. The rotor creates a magnetic field when there is a complete circuit through the brushes and slip rings of the rotor.  No current through the rotor means no generator output.  When the rotor is energized, the entire rotor shaft and the generator bearings become magnetized.  Continued
If the rear bearing  is  magnetized, the following facts are known:  The voltage regulator is working.  The generator brushes are working.  The rotor in the generator is producing a magnetic field.  If the rear bearing is  not  magnetized, then one or more of the following problems exist:  The voltage regulator is not working.  The generator brushes are worn or stuck, and they are not making good electrical contact with the rotor slip rings. The generator rotor could be defective.  NOTE:   The front bearing is also magnetized, but testing for magnetism of the front bearing with the engine running can be dangerous. Continued
If the rotor is not producing a magnetic field, no automotive generator can produce charging current. It is this rotating magnetic field created in the rotor that induces current in the stator windings. By checking for a magnetized rear bearing, the technician can better determine where the charging system problem is located.  If the rear bearing is magnetized, yet the “charge” (“GEN”) light is on and the generator is not charging, the problem has to be inside the generator (diodes, stator, etc.).
Battery voltage measurements can be read through the lighter socket. Construct a test tool using a lighter plug at one end of a length of two-conductor wire and the other end connected to a double banana plug. The double banana plug will fit most meters in the common (COM) terminal and the volt terminal of the meter. The Lighter Plug Trick Figure 41–26 Charging system voltage can be easily checked at the lighter plug by connecting a lighter plug to the voltmeter through a double banana plug.
Use a Test Light to Check for a Defective Fusible Link Most AC generators (alternators) use a  fusible link  between the output terminal located on the slip-ring-end frame and the positive (+) terminal of the battery. If this link is defective (blown), then the charging system will not operate. Many AC generators have been replaced repeatedly because of a blown fusible link, not discovered until later. A quick and easy test of the fusible link is to touch a test light to the output terminal.  Figure 41–27 Before replacing a generator (alternator), the wise tech checks that battery voltage is present at the output and battery voltage sense terminals. With the other end of the test light attached to a good ground, the fusible link is OK if the light lights. This confirms the circuit between the AC generator and the battery has continuity.
AC Voltage Check   A generator should produce very little  AC voltage .   It is the purpose of the diodes in the generator to rectify AC voltage into DC voltage. The procedure to check for AC voltage includes the following steps:  Continued The results should be interpreted as follows: If the diodes are good, the voltmeter should read  less  than 0.4 volt AC. If the reading is over 0.5 volt AC, the rectifier diodes are defective.  Step #1   Set the digital meter to read AC volts.  Step #2   Start the engine and operate it at 2000 rpm (fast idle).  Step #3   Connect the voltmeter leads to the positive and negative battery terminals.  Step #4   Turn on the headlights to provide an electrical load on the generator.
This test will  not   test for a defective diode trio.  NOTE:   A higher, more accurate reading can be obtained by touching the meter lead to the out- put terminal of the generator. Figure 41–28 AC ripple at the output terminal of the generator is more accurate than testing at the battery due to the resistance of the wiring between the generator and the battery. The reading shown on the meter is only 78 mV (0.078 V ), far below what the reading would be if a diode were defective. (Courtesy of Fluke Corporation)
Generator output can be easily measured using a digital mini clamp-on-type digital multimeter. A typical clamp-on meter is capable of reading as low as 10 mA (0.01 A) to 200 A or more. To set up for the test, clamp the meter around the generator output wire and select DC amperes and the correct scale. Start the engine and turn on all lights and accessories and then observe the meter display. The results should be within 10% of the specified generator rating. An AC/DC current clamp adapter can also be used along with a conventional digital multimeter set on the DC millivolt scale. To check for AC current ripple, switch the meter to read AC amperes and record the reading. A reading of greater than 10 amperes AC indicates defective generator diodes. The Mini Clamp-On DMM Test
Figure 41–29  A mini clamp-on digital multimeter can be used to measure generator output. This meter was set on the 200-A DC scale. With the engine running and all lights and accessories on, the generator was able to produce almost exactly its specified rating of 105 A. Continued
Charging System Voltage-Drop Testing   For the proper operation of any charging system, there must be good electrical connections between the battery positive terminal and the generator output terminal. The generator must also be properly grounded to the engine block.  Many vehicle manufacturers run the lead from the output terminal of the generator to other connectors or junction blocks that are electrically connected to the positive terminal of the battery. If there is high resistance (a high voltage drop) in these connections or in the wiring itself, the battery will not be properly charged.  Continued
Whenever there is a suspected charging system problem (with or without a charge indicator light on), follow these steps to measure voltage drop of the insulated (power side) charging circuit:  Continued Step #1   Start the engine and run it at a fast idle (about 2000 engine rpm).  Step #2   Turn on the headlights to ensure an electrical load on the charging system.  Step #3   Using any voltmeter, connect the positive test lead (usually red) to the output terminal of the generator. Attach the negative test lead (usually black) to the positive post.
If there is less than a 0.4-volt reading, then all wiring and connections are satisfactory.  If the voltmeter reads higher than 0.4 volt, there is excessive resistance (voltage drop) between the generator output terminal and the positive terminal of the battery.  If the voltmeter reads battery voltage (or close to battery voltage), there is an open circuit between the battery and the generator output terminal.  Continued The results should be interpreted as follows:
To determine whether the generator is correctly grounded, maintain the engine speed at 2000 rpm with the headlights on.  Figure 41–30  Voltmeter hookup to test the voltage drop of the charging circuit. Connect the positive voltmeter lead to the case of the generator and the negative lead to the negative terminal of the battery.  The voltmeter should read less than 0.2 volt if the generator is properly grounded.
Continued If the reading is over 0.2 volt, connect one end of an auxiliary ground wire to the case of the generator and the other end to a good engine ground.  Most voltage-drop specifications range between 0.2 and 0.4 volt. Generally, if the voltage loss (voltage drop) in a circuit exceeds 0.5 volt (1/2 volt), the wiring in that circuit should be repaired or replaced. During automotive testing, it is sometimes difficult to remember the exact specification for each test; therefore, the technician can simply remember “2 to 4” and that any voltage drop over this amount indicates a problem. “ 2 to 4”
Whenever diagnosing a generator charging problem, try using jumper cables to connect the positive and negative terminals of the generator directly to the positive and negative terminals of the battery. If a definite improvement is noticed, the problem is in the wiring of the vehicle. High resistance, due to corroded connections or loose grounds, can cause low generator output, repeated regulator failures, slow cranking, and discharged batteries. A voltage-drop test of the charging system also can be used to locate excessive resistance (high-voltage drop) in the charging circuit, but using jumper wires (cables) is often faster and easier. Use Jumper Cables as a Diagnostic Tool
GENERAL MOTORS SI TEST LIGHT TEST All General Motors SI (System Integration [internal voltage regulator]) series Delcotron generators (alternators) can be easily tested using a standard 6- to 12-volt test light.  Continued Figure 41–31  Typical GM SI generator. Note the location and wire color used for terminal #1 and #2.
Problems and Possible Causes   If the test light is not on at all on terminal #1 (brown or tan wire), the problem is an open circuit in the wiring between the dash and the generator. If the test light is bright on terminal #1 with the key turned to on and the engine off, the most likely cause is a defective (open) voltage regulator. If the test light does not light on either the BAT terminal or #2 terminal, an open circuit exists between the positive post of the battery and the generator. Check the condition of all fusible links.  NOTE:   Terminal #2 is the battery-sensing terminal. On many GM applications, a jumper wire simply connects the BAT terminal to terminal #2. The test light should be dim when touched to terminal #1. Terminal #1 is the wire from the dashboard warning light. The test light should be dim because of the voltage drop across the dashboard light bulb.
A General Motors CS series generator requires only two wires to operate—the battery (BAT) feed and the wire to the L terminal. The CS series generators are designed to operate as a stand-alone generator or be controlled by a vehicle computer system. See Figure 41–32 for terminal identification. GENERAL MOTORS CS SERIES AC GENERATORS Continued
Figure 41–32 Typical GM CS generator wiring plug identification. Note that terminal F is sometimes terminal I on some generators. The  P  terminal, sometimes called the  stator tap,  is connected directly to the stator that produces about one-half of the system alternating current and is used as a tachometer signal.  P  is used because it is an abbreviation for  pseudo,  meaning “alternating (not straight) output.” Terminal  S  is the sensing terminal for true battery voltage. Terminal  F  is the computer-sensing terminal. The computer monitors this terminal and sets trouble codes and alerts the driver if there is a charging system malfunction. The letter  I  is sometimes used instead of  F  and this terminal is used as a backup voltage source to the voltage regulator if the  L  terminal circuit is lost.  Continued
The battery and generator (alternator) had been replaced by another shop, yet the battery would be totally discharged after three days. A check of the charging system showed that the generator was not charging.  The Chevrolet Van Story - Part 1 Before another generator was installed, the tech checked for voltage at both the output terminal of the generator ( B  terminal) and the  L  terminal with the ignition switch in the on (run) position. There was no voltage at the  L  terminal indicating the problem was in the wiring to the  L  terminal, because without voltage at this terminal, the CS130 will charge.  Checking the schematic in the service information showed that the power to the  L  terminal came from the gauges fuse and then through the charge warning lamp. See Figure 41–33 following.  What could have caused the fuse to blow? Further checking of the circuit showed that the gauges fuse also fed the automatic transmission torque converter clutch circuit. A visual inspection discovered a damaged wire under the van most likely due to road debris. Repairing the wire and installing a new fuse solved the charging system problem.
The Chevrolet Van Story - Part 2
Figure 41–33 A schematic showing a typical wiring for a General Motors CS generator, showing that the L terminal is fed from the gauges fuse. If the fuse was blown, the charger light would never light and the generator (alternator) will not charge. The Chevrolet Van Story - Part 3
If the charge indicator light is on in the dash, unplug the connector (which can have up to four wires). Start the engine and observe the dash charge light. If the light is still on, there is a short-to-ground in the  L  wire circuit between the generator and the dash. If the charge light is out, check for voltage at the  L  terminal. If there is voltage available at the  L  terminal (remember, the connector is still unplugged from the generator), the problem is in the generator, if charging is not occurring. If there is  no  voltage available at the  L  terminal, apply a voltage through a standard test light to the  L  terminal of the generator. This supplies the power for the regulator.  DIAGNOSING PROBLEMS WITH THE GENERAL MOTORS CS SERIES Continued
If the generator output is now normal, the problem is in the wiring to the  L  terminal of the generator. Check all fuses, all fusible links, and the charge light indicator bulb.  Continued Generator Output Test  A charging circuit may be able to produce correct charging circuit voltage but not produce adequate amperage. If in doubt about charging system output, first check the condition of the generator drive belt. See Figure 41–34. With the engine off, attempt to rotate the fan of the generator by hand. Replace or tighten the drive belt if the generator fan can be rotated this way. See Figure 41–35 for typical test equipment hookup.
Figure 41–34  This accessory drive belt should be replaced because it has so many cracks. The usual specification for when a serpentine belt requires replacement is when there are three or more cracks in any one rib in any 3-inch length. Figure 41–35 Typical hookup of a starting and charging tester.
The testing procedure for  generator output  is as follows:  Step #1   Connect starting and charging test leads according to the test equipment manufacturer’s instructions.  Step #2   Turn ignition switch on (engine off); observe the ammeter. The ignition circuit current should be about 2 to 8 amperes. Step #3   Start the engine and operate it at 2000 rpm (fast idle). Turn the load increase control slowly to obtain the highest reading on the ammeter scale. Note the ampere reading. Step #4   Total the amperes from step 2 and step 3. Results should be within 10% (or 15 amperes) of the rated output. Rated ­output may be printed on the generator as shown in Figure 41–37.  Continued
HINT:   Step #2 can be skipped if the ammeter current clamp can be connected around the generator output wire instead of the battery cable(s). Figure 41–36  The best place to install a charging system tester amp probe is around the generator output terminal wire as shown.
Figure 41–37  The output on this generator is printed on a label.
How to Determine Minimum Required Generator Output All charging systems must be able to supply the electrical demands of the electrical system. If lights and accessories are used constantly and the generator cannot supply necessary ampere output, the battery will be drained. To determine minimum electrical load requirements, connect an ammeter in series with either battery cable.  NOTE:   When applying a load to the battery with a carbon pile tester during a generator output test, do not permit the battery voltage to drop below 12 volts. Most generators will produce their maximum output (in amperes) above 13 volts. Continued
NOTE:   If using an inductive-pickup ammeter, ensure the pickup is over all  the wires leaving the battery terminal. Failure to include the small body ground wire from the negative terminal to the body or the positive wire (if testing from the positive side) will  greatly decrease  current flow readings. Figure 41–38 A diagram showing the location of the charging system wiring of a typical vehicle. The best location to use to check for the generator (alternator) output is at the output wire from the B+ (BAT) terminal. Notice that the generator supplies all electrical needs of the vehicle first, then charges the battery if needed.
After connecting an ammeter correctly in the battery circuit, continue as follows:  Start the engine and operate to about 2000 rpm (fast idle).  Turn the heat selector to air conditioning (if so equipped).  Turn the blower motor to high speed.  Turn the headlights on bright.  Turn on the radio.  Turn on the windshield wipers.  Turn on other accessories used continuously (do not operate  horn, door locks, or units not used more than a few seconds).  Observe the ammeter. Current indicated is the electrical load the generator is able to exceed to keep the battery fully charged. The minimum acceptable generator output is 5 amps greater than the accessory load. A negative (discharge) reading indicates that the generator is not capable of supplying current needed.
Many technicians are asked to install a higher-output generator to allow the use of emergency equipment or other high-amperage equipment such as a high-wattage sound system. Although many higher-output units can be physically installed, it is important not to forget to upgrade the wiring and the fusible link(s) in the generator circuit. Failure to upgrade the wiring could lead to overheating. The usual failure locations are at junctions or electrical connectors. Bigger is Not Always Better
GENERATOR DISASSEMBLY If testing has confirmed that there are generator problems, remove the generator from the vehicle  after  disconnecting the  negative  battery cable. This will prevent the occurrence of damaging short circuits. Mark the case with a scratch or with chalk to ensure proper reassembly. Continued Figure 41–39  Always mark the case of the generator before disassembly to be assured of correct reassembly.
Figure 41–40  Explanation of clock positions. Because the four through-bolts are equally spaced, it is possible for a generator to be installed in one of four different clock positions. The connector position is determined by viewing the generator from the diode end with the threaded adjusting lug in the up or 12 o’clock position. Select the 3 o’clock, 6 o’clock, 9 o’clock, or 12 o’clock position to match the unit being replaced. The four through bolts that hold the two halves together are equally spaced; the rear generator housing  can  be installed in one of four clock positions to match needs of various models. NOTE:   Most generators of a particular manufacturer can be used on a variety of vehicles, which may require wiring connections placed in various locations. A Chevrolet and Oldsmobile generator may be identical except for position of the rear section containing electrical connections.
Testing the Rotor   Slip rings on the rotor should be smooth and round (within 0.002 inch of perfectly round). If grooved, the slip rings can be machined to provide a suitable surface for the brushes. If the slip rings are discolored or dirty, they can be cleaned with 400-grit or fine emery (polishing) cloth. The rotor must be turned while being cleaned to prevent flat spots on the slip rings.  The field coil continuity in the rotor can be checked by touching one test lead of a 110-volt (15-watt bulb) tester on each slip ring. The test light should light. A more accurate method is to measure the resistance between the slip rings using an ohmmeter.  Continued
Figure 41–41 Testing a generator rotor using an ohmmeter. If the resistance is below spec, the rotor is shorted.  Continued Typical resistance values:  GM :   2.2 to 3.5 ohms Ford :   3.0 to 5.5 ohms Chrysler :   3.0 to 6.0 ohms  Exact specs for the generator tested should be consulted before condemning a rotor.  If the resistance is above spec, the rotor connections are corroded or open.
Testing the Stator   The stator must be disconnected from the diodes (rectifiers) before testing. Because all three windings of the stator are electrically connected (either wye or delta), a powered (110- or 12-volt) test light or an ohmmeter can be used to check a stator. There should be low resistance at all three stator leads (continuity), and the test light  should  light. There should  not  be continuity (infinity ohms, or test light should  not  light) when the stator is tested between any stator lead and the metal stator core. If there is continuity, the stator is  grounded  (short to ground) and must be repaired or replaced. See Figure 41–42.  Continued
Figure 41–42  If the ohmmeter reads infinity between any two of the three stator windings, the stator is open and, therefore, defective. The ohmmeter should read infinity between any stator lead and the steel laminations. If the reading is less than infinity, the stator is grounded. Stator windings can be tested if shorted because the normal resistance is very low. Continued
Because the resistance is very low for a normal stator, it is generally  not  possible to test for a  shorted  (copper to copper) stator. A shorted stator will, however, greatly reduce generator output. If all generator components test OK and output is still low, substitute a known good stator and retest. If the stator is black or smells burned, check vehicle for a discharged or defective battery. If battery voltage never reaches the voltage regulator cutoff point, the generator will be continuously producing current in the stator windings. This continuous charging often overheats the stator.  Continued NOTE:   The cost of a replacement rotor may exceed the cost of an entire rebuilt generator. Be certain, however, that the rebuilt generator is rated at the same output as the original or higher.
Figure 41–43  An open in a delta- wound stator cannot be detected using an ohmmeter. An ohmmeter cannot detect an open stator if the stator is delta wound.  The ohmmeter will still indicate low resistance because all three windings are electrically connected.  Continued
Testing the Diode Trio   Many generators are equipped with a diode trio. A diode is an electrical one-way check valve permitting current to flow in only one direction.  Figure 41–44  Typical diode trio. If one leg of a diode trio is open, the generator may produce close to normal output, but the charge indicator light on the dash will be on dimly. The plus signs indicate the anodes, and the minus sign indicates the cathode terminal of the diodes. Continued The diode trio is connected to all three stator windings.  Current generated in the stator flows through the diode trio to the internal voltage regulator.  If one of the diodes in the trio is defective (usually open), the generator may produce close-to-normal output; however, the charge indicator light will be on dimly.
Testing the Rectifier Bridge (Diodes)   Generators are equipped with six diodes to convert the alternating current (AC) generated in the stator windings into direct current (DC) for use by the vehicle’s battery and electrical components. The six diodes include three positive diodes and three negative diodes (one positive and one negative for each winding of the stator). These diodes can be individual diodes or grouped into a positive and a negative rectifier that each contain three diodes. All six diodes can be combined into one replaceable unit called a  rectifier bridge . The rectifier(s) (diodes) should be tested using a multimeter that is set to “ diode check ” or “ohms.”  Continued
Because a diode (rectifier) should allow current to flow in only one direction, each diode should be tested to determine if the diode allows current flow in one direction and blocks current flow in the opposite direction. To test many generator diodes, it may be necessary to unsolder the stator connections. Accurate testing is not possible unless the diodes are separated electrically from other generator components.  Figure 41–45  A GM rectifier bridge that has been disassembled to show the individual diodes. Continued
Connect the leads to the leads of the diode (pigtail and housing of the rectifier bridge). Read the meter. Reverse the test leads. A good diode should have high resistance (OL) one way (reverse bias) and low-voltage drop (0.5 to 0.7 volt) the other way (forward bias). An ohmmeter also can be used. If the ohmmeter reads low ohms (low-voltage drop) in both directions, the diode is shorted. If the meter reads high ohms (OL) in both directions, the diode is open. Open or shorted diodes must be replaced. Most generators group or combine all positive and all negative diodes in the one replaceable rectifier component. General Motors Delcotron generators use a replaceable rectifier bridge containing all six diodes in one unit combined with a finned heat sink.  Continued
Brush Holder Replacement   Generator carbon brushes often last for many years and require no scheduled maintenance. The life of the generator brushes is extended because they conduct only the field (rotor) current, which is normally only 2 to 5 amperes. The generator brushes should be inspected whenever the generator is disassembled and should be replaced when worn to less than 1/2 inch in length. Generator brushes are spring loaded, and if the springs are corroded or damaged, the brushes will not be able to keep constant contact with the slip rings of the rotor. If the brushes do not contact the slip rings, field current cannot create the magnetic field in the rotor that is necessary for current generation.  Continued
Brushes are commonly purchased assembled together in a brush holder. After the brushes are installed (usually retained by two or three screws) and the rotor is installed in the generator housing, a brush retainer pin can be pulled out through an access hole in the rear of the generator, allowing the brushes to be pressed against the slip rings by the brush springs Figure 41–46  A brush holder assembly shown assembled in the generator. The brush retainer is actually a straightened -out paper clip. Continued
Bearing Service and Replacement   The bearing of a generator must be able to support the rotor and reduce friction. A generator must be able to rotate at up to 15,000 rpm and withstand the forces created by the drive belt. The front bearing usually is a ball bearing type and the rear is a smaller roller bearing. The front bearing is located under a retainer and pressed into the front generator case. The pulley must be removed before the rotor can be separated from the case. Some generator press-fit pulleys must be removed using a puller, whereas Ford and GM generators use a nut to hold the drive pulley to the rotor. The front pulley can be removed from most GM generators by using a 15/16-inch wrench while holding the rotor shaft to keep it from rotating using a 5/16-inch hex (Allen) wrench.  Continued
The old or defective bearing sometimes can be pushed out of the front housing and the replacement pushed in by applying pressure with a socket or pipe against the outer edge of the bearing (outer race). Replacement bearings are usually prelubricated and sealed. Adding additional grease could cause overheating of the bearing by reducing heat transfer from the bearing surfaces to the generator housing. Many generator front bearings must be removed from the rotor using a special puller.
GENERATOR ASSEMBLY After testing or servicing, the generator rectifier(s), regulator, stator, and brush holder must be reassembled. If the brushes are internally mounted, insert a wire through the holes in the brush holder and in the generator rear frame to retain the brushes for reassembly. Install the rotor and front-end frame in proper alignment with the mark made on the outside of the generator housing. Install the through bolts. Before removing the wire pin holding the brushes, spin the generator pulley. If the generator is noisy or not rotating freely, the generator can  be disassembled again to check the cause. After making certain the generator is free to rotate, remove the brush holder pin and spin the generator again by hand.  Continued
The noise level may be slightly higher with the brushes released onto the slip rings. Generators should be tested on a bench tester, if available, before they are reinstalled on a vehicle. When installing the generator on the vehicle, be certain that all mounting bolts and nuts are tight. The battery terminal should be covered with a plastic or rubber protective cap to help prevent accidental shorting to ground, which could seriously damage the generator.
REMANUFACTURED GENERATORS Remanufactured or rebuilt generators are totally disassembled and rebuilt. Even though there are many smaller rebuilders who may not replace all worn parts, the major national remanufacturers  totally  remanufacture the generator. Old generators (cores) are totally disassembled and cleaned. Both bearings are replaced and all components tested. Rotors are rewound to original specifications if required. The rotor windings are rewound on the rotor “spool,” using the correct-gauge copper wire, to the  weight  specified by the original manufacturer. New slip rings are replaced as required and soldered to the rotor spool windings and machined. Rotors are  balanced and measured to ensure outside diameter meets specifications.  Continued
Figure 41–47  (a) A generator for a GEO Prism looks like a typical General Motors CS-130 except for this adapter that converted the Toyota wiring harness to the GM generator: (b) After removing the adapter, the original generator connection is visible. Every generator is assembled and tested for proper output, boxed, and shipped to a warehouse. (a) (b) Individual  diodes (within the rectifiers) are replaced if required.
The Cold Weather Charge Lamp Problem A customer brought his vehicle (Ford) to an independent service facility complaining that occasionally, whenever the temperatures dropped below 10°F (-12°C), his charge indicator lamp stayed on until he had driven for several minutes. The customer left the vehicle overnight and the technician observed that, indeed, the charge lamp was on after starting the vehicle the next morning. The tech immediately got out of the vehicle, opened the hood, and checked to see if the rear bearing was magnetized—it was not.  After a few minutes of operation, the charge lamp went out and the rear generator bearing was magnetized. The technician then knew that the problem was sticking generator brushes. The brushes had worn to less than one-half length, and the springs were not strong enough, when cold, to exert sufficient pressure on the rotor slip rings to conduct the current for the field (rotor). After the technician replaced the brushes and cleaned and checked all other generator components, the problem did not recur.
An 80-ampere generator was tested at 2000 engine RPM and found to be producing only 69 amperes. The recommended spec for a generator is the output should be within 10% of the rated output. Ten percent of 80 amps is 8 amps; therefore, the minimum recommended output is 72 amp (80 - 8 = 72). Because 69 amps is less than 72 amps, the generator should be serviced (repaired or replaced).  The Weak But Good Generator However, because the test result was so close to specs, it was decided a charging system requirement test should be performed. This determines the electrical load of that may be required on a continuous basis.  The procedure: Turn on everything electrical, except horn or other short-term accessories. Add 5 amps to the reading and the result is the minimum current required of the generator. The electrical demand test indicated that only 49 amps was needed. Add 5 amps (49 + 5 = 54) and you see that a 54-amp generator is all that is needed. Because the original generator is capable of 69 amps, it is more than adequate for the vehicle.
The Two-Minute Generator Repair A Chevrolet pickup truck was brought to a dealer for routine service. The owner stated the battery required a jump-start after a weekend of sitting. The tech tested the battery and charging system voltage using a small hand-held digital multimeter. The battery voltage was 12.4 volts (about 75% charged), but the charging voltage was also 12.4 volts at 2000 RPM. Because normal charging voltage should be 13.5 to 15.0 volts, it was obvious that the charging system was not operating correctly.  The tech checked the dash and found the “charge” light was not on, even though the rear bearing was not magnetized, indicating the voltage regulator was not working. Before removing the generator for service, the tech checked the wiring connection on the generator. When the two-lead regulator connector was removed, the connector was discovered to be rusty. After the contacts were cleaned, the charging system was restored to normal operation. The tech had learned that simple things should always be checked first before tearing into a big (or expensive) repair.
A technician wanted help in determining what the generator output should be on a Toyota truck. If the generator is protected by a fuse, check the fuse rating. In this case, the fuse was listed as being 80 amperes. The 80% rule states that the maximum current in a circuit should not exceed 80% of the fuse rating. Eighty percent of 80 amps is 65 amps. The generator output was measured to be 62 amps, well within the normal range of within 10% of specifications (10% of 64 is 6.4 amps). Help!
PHOTO SEQUENCE  Generator (Alternator) Overhaul Continued
PHOTO SEQUENCE  Generator Overhaul ( cont. ) Continued
PHOTO SEQUENCE  Generator Overhaul ( cont. ) Continued
PHOTO SEQUENCE  Generator Overhaul ( cont. ) Continued
PHOTO SEQUENCE  Generator Overhaul ( cont. ) Continued
PHOTO SEQUENCE  Generator Overhaul ( cont. )
SUMMARY Charging system testing requires the battery be at least 75% charged to be assured of accurate test results. The charge indicator light should be on with the ignition switch on but should go out whenever the engine is running. Normal charging voltage (at 2000 engine RPM) is 13.5 to 15.0 volts. If the system is not charging properly, the rear bearing of the generator should be checked for magnetism. If it is magnetized, voltage regulator, brushes, and generator rotor are functioning correctly. If the rear bearing is not magnetized, the voltage regulator, generator brushes, or rotor is not functioning. Bypass the voltage regulator by supplying battery voltage to the field. If the rear bearing is now magnetized and the charging system output is normal; the voltage regulator is at fault. Continued
SUMMARY To check for excessive resistance in the wiring between generator and battery, a voltage-drop test should be performed. Generators do not produce their maximum-rated output unless required by circuit demands. Therefore, to test for maximum generator output, the battery must be loaded to force the generator to produce its maximum output. Continued ( cont. )
SUMMARY Each generator should be marked across its case before disassembly to ensure proper clock position during reassembly. After disassembly, all generator internal components should be tested using a continuity light or an ohmmeter. The following components should be tested: Continued ( cont. ) Stator Rotor Diodes Diode trio (if the generator is so equipped) Bearings Brushes (should be more than 1/2 inch in length)
SUMMARY Electronic voltage regulators can be tested either off the vehicle using a special tester or on the vehicle using the full-field bypass procedure. ( cont. )
end

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Chapter 41

  • 2. Describe how a generator works. Discuss the various generator test procedures. Explain how to disassemble a generator and test its component parts. Discuss how to check the wiring from the generator to the battery. OBJECTIVES: After studying Chapter 41, the reader should be able to:
  • 3. AC voltage • brushes charging voltage delta-connected stator • delta winding • diodes • diode check • diode trio • drive-end (DE) housing • duty cycle Electrical power management (EPM) fusible link generator output test KEY TERMS: Continued
  • 4. overrunning alternator dampener (OAD) • overrunning alternator pulley (OAP) poles rectifier bridge • rotors sine wave • slip ring end (SRE) • stators • stator tap temperature compensation • thermistor wye-connected stator KEY TERMS:
  • 5. All vehicles operate electrical components by taking current from the battery. It is the purpose and function of the charging system to keep the battery fully charged. The Society of Automotive Engineers (SAE) term for the unit that generates electricity is the generator. The term alternator is also commonly used, especially in service manuals before 1993 when the SAE term was adopted by most vehicle manufacturers.
  • 6. PRINCIPLES OF GENERATOR OPERATION All electrical generators use the principle of electromagnetic induction to convert mechanical energy into electrical energy. Electromagnetic induction involves the generation of an electrical current in a conductor when the conductor is moved through a magnetic field. The amount of current generated can be increased by the following factors: Increasing the speed of the conductor through the magnetic field Increasing the number of conductors passing through the magnetic field Increasing the strength of the magnetic field
  • 7. An AC generator generates an alternating current when the current changes polarity during the generator’s rotation. A battery cannot “store” alternating current; therefore, this alternating current is changed to direct current (DC) by diodes inside the generator. Diodes are one-way electrical check valves that permit current to flow in only one direction. Most manufacturers call an AC generator an alternator. ALTERNATING CURRENT GENERATORS (ALTERNATORS) Continued
  • 8. GENERATOR CONSTRUCTION A generator is constructed of a two-piece cast-aluminum housing. Aluminum is used because of its lightweight, nonmagnetic properties and heat transfer properties needed to help keep the generator cool. A front ball bearing is pressed into the front housing (called the drive-end [ DE ] housing ) to provide the support and friction reduction necessary for the belt-driven rotor assembly. The rear housing, or the slip ring end ( SRE ), usually contains a roller-bearing support for the rotor and mounting for the brushes, diodes, and internal voltage regulator (if the generator is so equipped). See Figures 41–1 and 41–2. Continued
  • 9. Figure 41–1 A typical generator (alternator) on a Chevrolet V-8 engine. Figure 41–2 The end frame toward the drive belt is called the drive-end housing and the rear section is called the slip-ring-end housing. Continued
  • 10. Many technicians are asked how much power certain accessories require. A 100-ampere generator requires about 2 horsepower from the engine. One horsepower is equal to 746 watts. Watts are calculated by multiplying amperes times volts: Generator Horsepower and Engine Operation - Part 1 Power in watts 100A x 14.5V = 1450 1hp = 746 W 1450 watts is about 2 horsepower and the generator uses about 2 hp to generate 100 A. Allowing about 20% for mechanical and electrical losses adds another 0.4 horsepower. When someone asks how much power it takes to produce 100 amperes from a generator, the answer is 2.4 hp.
  • 11. Generator Horsepower and Engine Operation - Part 2 Many generators delay output to prevent the engine from stumbling when a heavy electrical load is applied. The voltage regulator or vehicle computer is capable of gradually increasing the generator output over a period of up to several minutes. Power in watts 100A x 14.5V = 1450 1hp = 746 W Though it does not sound like much, a sudden demand for 2 horsepower from an idling engine can cause the engine to run rough or stall. The difference in part numbers of various generators is often an indication of the time interval over which the load is applied. Therefore, the use of the wrong replacement generator could cause the engine to stall!
  • 12. ALTERNATOR OVERUNNING PULLEY Purpose and Function Many generators are equipped with an overrunning alternator pulley ( OAP ), called a clutch pulley . This eliminates noise and vibration in the accessory drive belt system, especially when at idle, when engine impulses are transmitted to the alternator through the accessory drive belt. The mass of the rotor of the alternator tends to want to keep spinning, but the engine crankshaft speeds up and slows down slightly due to the power impulses. Using a one-way clutch in the alternator pulley allows the belt to apply power to the alternator in only one direction thereby reducing the fluctuations in the belt. See Figure 41–3. Continued
  • 13. Figure 41–3 An OAP on a generator on a Chevrolet Corvette.
  • 14. A conventional drive pulley attaches to the alternator (rotor) shaft with a nut and lock washer. In the overrunning clutch pulley, the inner race of the clutch acts as the nut and screws onto the shaft. Special tools are required to remove and install this type of pulley. Another type of alternator pulley uses a dampener spring inside plus a one-way clutch. This unit is called an overrunning alternator dampener ( OAD ). An OAD is larger than an OAP and is used on the Pontiac G8 and other vehicles. See Figure 41–4. Continued
  • 15. Figure 41–4 An overrunning alternator dampener (OAD) disassembled, showing all of its internal parts.
  • 16. Diagnosis and Service Overrunning alternator pulleys and alternator dampeners can fail, with the most common factor the one-way clutch. If it fails, it can freewheel and not power the alternator or it can lock up and not provide dampening as designed. If the charging system is not working, the OAP or OAD could be the cause rather than a fault in the alternator itself. In most cases, the entire alternator assembly will be replaced because each OAP or OAD is unique for each application and they require special tools to remove and replace.
  • 17. No. An alternator needs to be equipped with the proper shaft to allow the installation of an OAP or OAD. This also means a conventional pulley cannot be used to replace a defective overrunning alternator pulley or dampener. Can I Install an OAP or OAD to My Alternator?
  • 18. ROTORS The rotor creates the magnetic field of the generator and produces a current by electromagnetic induction in the stationary stator windings. The generator rotor is constructed of many turns of copper wire coated with a varnish insulation wound over an iron core. The iron core is attached to the rotor shaft. At both ends of the rotor windings are heavy-gauge metal plates bent over the windings with triangular fingers called poles . These pole fingers do not touch, but rather they alternate or interlace as shown in Figure 41–5. Continued
  • 19. Figure 41–5 A cutaway of a General Motors CS-130D generator showing the rotor and cooling fans that are used to force air through the unit to remove the heat created when it is charging the battery and supplying electrical power for the vehicle. Continued
  • 20. If current flows through the rotor windings, the metal pole pieces at each end of the rotor become electromagnets. Whether a north or a south pole magnet is created depends on the direction in which the wire coil is wound. Because the pole pieces are attached to each end of the rotor, one pole piece will be a north pole magnet. The other pole piece is on the opposite end of the rotor and therefore is viewed as being wound in the opposite direction, creating a south pole. The rotor fingers are alternating north and south magnetic poles. The magnetic fields are created between the alternating pole piece fingers. These individual magnetic fields produce a current by electromagnetic induction in the stationary stator windings. See Figure 41–6. Continued
  • 21. Figure 41–6 Rotor assembly of a typical alternator (AC generator). Current through the slip rings causes the “fingers” of the rotor to become alternating north and south magnetic poles. As the rotor revolves, these magnetic lines of force induce a current in the stator windings. The current necessary for the field (rotor) windings is conducted through carbon brushes to the slip rings. Maximum-rated generator output in amperes is largely dependent on the number and gauge of the windings of the rotor. Substituting rotors from one generator into another can greatly affect maximum output either positive or negative.
  • 22. GENERATOR BRUSHES The current for the field is controlled by the voltage regulator and is conducted to the slip rings through carbon brushes . The brushes conduct only the field current (approximately 2 to 5 amps), and therefore tend to last longer than the brushes used on a DC generator, where all the current generated in the generator must flow through the brushes.
  • 23. STATORS Supported between the two halves of the generator housing are three copper wire windings wound on a laminated metal core. See Figure 41–7. As the rotor revolves, its moving magnetic field induces a current in the windings of the stator . See Figure 41–8. Continued
  • 24. Figure 41–7 A cutaway view of a typical AC generator (alternator) Continued
  • 25. Figure 41–8 An exploded view of a typical generator (alternator) showing all of its internal parts.
  • 26. Whenever checking for the root cause of a generator failure, one of the first things that a technician should do is to sniff (smell) the generator! If the generator smells like a dead rat (rancid), the stator windings have been overheated by trying to charge a discharged or defective battery. If the battery voltage is continuously low, the voltage regulator will continue supplying full field current to the generator. The voltage regulator is designed to cycle on and off to maintain a narrow charging system voltage range. If battery voltage is continually below the cutoff point of the voltage regulator, the generator is continually producing current in the stator windings. This constant charging can often overheat the stator and burn the insulating varnish covering the stator windings. If the generator fails the sniff test, the tech should replace the stator and other generator components found to be defective and replace or recharge and test the battery. The Sniff Test
  • 27. DIODES Diodes are constructed of a semiconductor material (usually silicon) and operate as a one-way electrical check valve that permits the current to flow in only one direction. AC generators use six diodes (one positive and one negative diode for each of the three stator windings) to convert alternating current to direct current. The symbol for a diode is shown here. Figure 41–9 A diode symbol.
  • 28. HOW A GENERATOR WORKS A rotor inside a generator is turned by a belt and drive pulley turned by the engine. The magnetic field of the rotor generates a current in the windings of the stator by electromagnetic induction. Continued Figure 41–10 Magnetic lines of force cutting across a conductor induce a voltage and current in the conductor. Field current flowing through the slip rings to the rotor creates alternating north & south poles on the rotor, with a magnetic field between each finger of the rotor.
  • 29. The induced current in the stator windings is an alternating current because of the alternating magnetic field of the rotor. The induced current starts to increase as the magnetic field starts to induce current in each winding of the stator. The current then peaks when the magnetic field is the strongest and starts to decrease as the magnetic field moves away from the stator winding. The current generated is described as being of a sine wave pattern See Figure 41–11. Continued
  • 30. Figure 41–11 Since wave voltage curve created by one revolution of a winding rotating in a magnetic field. As the rotor continues to rotate, this sine wave current is induced in each of the three windings of the stator. Continued
  • 31. Figure 41–12 When three windings (A, B, and C) are present in a stator, the resulting current generation is represented by the three sine waves. The voltages are 120° out of phase. The connection of the individual phases produces a three-phase alternating voltage. Because each of the three windings generates a sine wave current, the resulting currents combine to form a three-phase voltage output. AC generators contain six diodes, one pair of positive and a negative for each of the three stator windings.
  • 32. WYE-CONNECTED STATORS The Y (pronounced “wye” and generally so written) type or star pattern is the most commonly used generator stator winding connection. Continued Figure 41–13 Wye-connected stator winding.
  • 33. The output current with a wye - type stator connection is constant over a broad generator speed range. Current is induced in each winding by electromagnetic induction from the rotating magnetic fields of the rotor. In a wye-type stator connection, the currents must combine because two windings are always connected in series. See Figure 41–14. The current produced in each winding is added to the other’s current and flows through the diodes to the generator output terminal. One-half of the current produced is available at the neutral junction (usually labeled “STA” for stator). Voltage at this center point is used by some generator manufacturers (especially Ford) to control the charge indicator light or is used by the voltage regulator to control the rotor field current. Continued
  • 34. Figure 41–14 As the magnetic field, created in the rotor, cuts across the windings of the stator, a current is induced. Notice that the current path includes passing through one positive () diode on the way to the battery and one negative () diode as a complete circuit is completed through the rectifier and stator.
  • 35. Figure 41–15 Delta-connected stator winding. The delta winding is connected in a triangular shape, as shown in here. (Delta is a Greek letter shaped like a triangle.) Continued DELTA-CONNECTED STATORS
  • 36. Current induced in each winding flows to the diodes in a parallel circuit. More current can flow through two parallel circuits than can flow through a series circuit (as in a wye-type stator connection). Delta-connected stators are used on generators where high output at high-generator rpm is required. The delta-connected generator can produce 73% more current than the same generator with wye-type stator connections. If a generator with a wye-connected stator can produce 55 A, the same generator with delta-connected stator windings can produce 73% more current, or 95 A (55  1.73 = 95). The delta-connected generator, however, produces lower current at low speed and must be operated at high speed to produce its maximum output. Continued
  • 37. GENERATOR OUTPUT FACTORS Output voltage and current of a generator depend on: Continued The Speed of rotation Generator output is increased with generator rotational speed up to the generator’s maximum possible ampere output. Generators normally rotate at a speed two to three times faster than engine speed, depending on relative pulley sizes used for the belt drive. The Number of conductors. A high-output generator contains more turns of wire in the stator windings. Stator winding connections (whether wye or delta) also affect the maximum generator output. See 41-16.
  • 38. Figure 41–16 A stator assembly with six, rather than the normal three, windings. Here is an example of a stator that has six rather than three windings, which greatly increases the amperage output of the generator (alternator). Continued
  • 39. The Strength of the magnetic field. If the magnetic field is strong, a high output is possible because the current generated by electromagnetic induction is dependent on the number of magnetic lines of force that are cut. The strength of the magnetic field can be increased by increasing the number of turns of conductor wire wound on the rotor. A higher-output generator has more turns of wire than a generator with a low-rated output. The strength of the magnetic field also depends on the current through the field coil (rotor). Because magnetic field strength is measured in ampere-turns, the greater theamperage or the number of turns, or both, the greater the generator output.
  • 40. GENERATOR VOLTAGE REGULATION An automotive generator must be able to produce electrical pressure (voltage) higher than battery voltage to charge the battery. Excessive high voltage can damage battery, electrical components, and the lights of a vehicle. If no current (zero amperes) was flowing in the field coil of the generator (rotor), generator output would be zero because without field current a magnetic field does not exist. Continued The field current required by most automotive generators is less than 3 amps. It is the control of the field current that controls the output of the generator. See Figure 41–17.
  • 41. Figure 41–17 Typical voltage regulator voltage range. Current for the rotor flows from the battery through the brushes to the slip rings. After generator output begins, the voltage regulator controls the current flow through the rotor.
  • 42. CHARGING VOLTAGE CONTROL If an automotive battery is discharged, its voltage will be lower than the voltage of a fully charged battery. The generator will supply charging current, but it may not reach maximum charging voltage . A good but discharged battery should be able to convert into chemical energy all the current the generator can produce. As long as generator voltage is higher than battery voltage, current will flow from the generator (high pressure, high voltage) to the battery (lower pressure, lower voltage). The condition and voltage of the battery do determine the charging rate of the generator. If a discharged battery is used during charging system testing, tests could mistakenly indicate a defective generator and/or voltage regulator. Continued
  • 43. Temperature Compensation All voltage regulators (mechanical or electronic) provide a method for increasing the charging voltage slightly at low temperatures and for lowering the charging voltage at high temperatures. A battery requires a higher charging voltage at low temperatures because of the resistance to chemical reaction changes. However, the battery would be overcharged if the charging voltage were not reduced during warm weather. Electronic voltage regulators use a temperature-sensitive resistor, called a thermistor in the regulator circuit, and it provides lower resistance as temperature increases. A thermistor is used to control charging voltage over a wide range of under-the-hood temperatures. See Figure 41–18. Continued
  • 44. Figure 41–18 A typical electronic voltage regulator showing the connections and the circuits involved. NOTE : Voltmeter test results may vary according to temperature. Charging voltage tested at 32°F (0°C) will be higher than for the same vehicle tested at 80°F (27°C) because of the temperature - compensation factors built into voltage regulators.
  • 45. DIODE TRIO GENERATORS Some generators (alternators) use a diode trio to provide current to the rotor (field) and turn off the charge indicator light on the dash. A diode trio is three diodes connected in parallel with the anode ends connected to the three stator winding connectors at the rectifier bridge. The single output terminal of the diode trio is applied to the ignition feed terminal. NOTE: If one of the three diodes is open, only 8 volts will be applied against the 12 volts from the ignition. The result is a dim generator charge indicator light. While this light may be a customer concern, the generator will produce normal output.
  • 46. When the ignition is on, 12 volts is applied through the charge light bulb and is grounded through the rotor winding. This current is blocked from flowing through the diode trio because the diodes are reversed biased. When the stator and the generator start to generate voltage, the 12-volt output of the diode trio opposes the 12 volts from the ignition through the charge light causing the charge light to go out.
  • 47. ELECTRONIC VOLTAGE REGULATORS The electronic circuit of the voltage regulator cycles between 10 and 7,000 times per second as needed to accurately control the field current through the rotor, and therefore control the generator output. The control of the field current is accomplished by opening and closing the ground side of the field circuit through the rotor of the generator. Electronic voltage regulators also use many resistors to help reduce the current through the regulator, and the resulting heat must be dissipated into the air to prevent damage to the diodes and transistors. Whether mounted inside the generator or externally under the hood, electronic voltage regulators are mounted where normal airflow can keep the electronic components cool. Continued
  • 48. The zener diode is a major electronic component that makes voltage regulation possible. Generator voltage from the stator and diodes is first sent through a thermistor, which changes resistance with temperature, and then to a zener diode. Whenever the upper-limit voltage is reached, the zener diode conducts current to a transistor, which then opens the field (rotor) circuit. All the current stops flowing through the generator’s brushes, slip rings, and rotor, and no magnetic field is formed. Without a magnetic field, a generator does not produce current in the stator windings. Continued
  • 49. When no voltage is applied to the zener diode, current flow stops and the base of the transistor is turned off, closing the field circuit. The magnetic field is thus restored in the rotor. The rotating magnetic fields of the rotor induce a current in the stator, which is again controlled if the output voltage exceeds the designed limit as determined by the zener diode breakdown voltage. Depending on the generator rpm, vehicle electrical load, and state of charge of the battery, this controlled switching on and off can occur between 10 and 7,000 times per second. See Figure 41–19. Continued
  • 50. Figure 41–19 Typical General Motors SI-style AC generator. Full Caption next slide.
  • 51. Figure 41–19 Typical General Motors SI-style AC generator with an integral voltage regulator. Voltage present at terminal 2 is used to reverse bias the zener diode (D2) that controls TR2. The hot brush is fed by the ignition current (terminal I) plus current from the diode trio. See the entire schematic on Page 442 of your textbook.
  • 52. Computer-Controlled Generators Computers can interface with the charging system in three ways: Continued The computer can activate the charging system by turning on and off the field. The computer can monitor the operation of the generator and therefore can increase idle speed to compensate for the additional load if the generator is producing at maximum output. The computer can control the generator by not only turning the field on and off but can also delay or limit the output of the generator, depending on other loads on the engine, such as power steering or an air-conditioning compressor.
  • 53. The engine control module (ECM) controls the alternator by changing the on-time of the current through the rotor. The on-time, or duty cycle , is varied from 5% to 95%. See the following chart: Continued See the chart on Page 443 of your textbook.
  • 54. Figure 41–20 A Hall-effect current sensor attached to the negative battery cable is used as part of the EPM system. A system used on some GM vehicles is called Electrical power management ( EPM ) and uses a Hall-effect sensor attached to the negative battery cable to measure the current leaving and entering the battery. Continued This system has six modes of operation including:
  • 55. The Fuel economy mode . This mode reduces the load on the engine from the generator (alternator) for maximum fuel economy. Activated when the following conditions are met: Continued The Charge mode . The charge mode is activated whenever any of the following occurs: Electric cooling fans are on high speed Rear window defogger is on Battery state of charge (SOC) is less than 80% Outside (ambient) temperature is less than 32°F (0°C) Ambient temperature is above 32°F (0°C) The state of charge of the battery is 80% or higher The cooling fans and rear defogger are off The target voltage is 13 volts and will return to the charge mode, if needed.
  • 56. The Voltage reduction mode . This mode is commanded to reduce the stress on the battery during low-load conditions. This mode is activated whenever the following conditions are met Continued Ambient temperature is above 32°F (0°C) Low battery discharge rate (less than 7 amperes) Rear defogger is off Cooling fans are on low or off The Start-up mode . This mode is selected after engine start and commands a charging voltage of 14.5 volts for 30 seconds. After 30 seconds, the mode is changed depending on conditions.
  • 57. The Battery sulfation mode . This mode is commanded if the output voltage is less than 13.2 volts for 45 minutes, which can indicate that sulfated plates could be the cause. The target voltage is 13.9 to 15.5 volts for 3 minutes. After 3 minutes, the system returns to another mode based on conditions. The Headlight mode . This mode is selected whenever the headlights are on and the target voltage is 14.5 volts. A customer may complain that the voltmeter reading on the dash fluctuates up and down. This may be normal as the computer-controlled charging system commands various modes of operation based on the operating conditions. Follow the vehicle manufacturer’s recommended procedures to verify proper operation. The Voltage Display Can Be a Customer Concern
  • 58. Beginning in the mid-1980s, GM introduced a smaller, high-output series of generators called the CS (charging system) series. See Figures 41–21 and 41–22. Following CS are numbers indicating the outside diameter in millimeters of the stator laminations. Typical sizes, designations, and outputs include the following: CS - 121, 5 - SI 74 A CS - 130, 9 - SI 105 A CS - 144, 17 - SI 120 A These generators feature two cooling fans (one internal) and terminals designed to permit connections to an onboard body computer through terminals L and F . Continued
  • 59. Figure 41–21 General Motors CS generator. Notice the use of zener diodes in the rectifier to help control any high-voltage surges that could affect delicate computer circuits. If a high-voltage surge does occur, the zener diode(s) will be reversed biased and the potentially harmful voltage will be safely conducted to ground. Voltage must be preset at the L terminal to allow the generator to start producing current. Continued
  • 60. Figure 41–22 The components inside a GM CS generator. The voltage regulator switches field voltage on and off at a fixed frequency of about 400 times per second. The reduced-size generators also feature ball bearings in the front and rear and totally soldered internal electrical connections. The voltage is controlled either by the body computer (if so equipped) or by the built-in voltage regulator. Voltage is controlled by varying the on time and off time of the field current.
  • 61. CHARGING SYSTEM TESTING AND SERVICE The charging system can be tested as part of routine inspection or to determine reason for a no- or reduced-charging circuit performance. Charging Voltage Test First and easiest test to perform to check if the generator is working correctly is to check the charging system voltage at the battery. Use a digital multimeter to check using the following steps: Continued Step #1 Select DC volts. Step #2 Connect the red meter lead to the positive (+) terminal of the battery and the black meter lead to the negative (  ) terminal. Step #3 Start the engine and increase the engine speed to about 2000 rpm (fast idle) and record the charging voltage.
  • 62. Charging voltage = 13.5 to 15.0 V (GM = 14.2 to 15.2 V ). If the voltage is too high, check that the charging system components such as the generator and voltage regulator (if separate) are properly grounded. If the battery voltage is still higher than specified, then there is likely a fault with the electrical connections at the voltage regulator or generator. If the voltage is lower than specifications, there is a fault with the wiring, generator, or regulator (if external). Additional testing is required to help pinpoint the root cause. NOTE: Polarity of meter leads is not important when using a digital multimeter. If meter leads are connected backward on the battery, the readout will have a negative (-) sign in front of the voltage reading. Continued
  • 63. Figure 41–23 The digital multimeter should be set to read DC volts, with the red lead connected to the positive (+) battery terminal and the black meter lead connected to the negative (-) battery terminal. Figure 41–24 A scan tool can be used to diagnose charging system problems.
  • 64. Lower-than-normal generator output could be the result of a loose or slipping drive belt. A common trick used to determine if the noise is belt related is to use grit type hand cleaner or scouring powder. With the engine off, sprinkle some powder onto the pulley side of the belt. Start the engine. The excess powder will fly into the air, so get away from under the hood when the engine starts. If the belts are now quieter, you know that it was the glazed belt that made the noise. Often, the grit from the hand cleaner will remove the glaze from the belt and the noise will not return. However, if the belt is worn or loose, the noise will return and the belt should be replaced. A fast alternative method to see if the noise is from the belt is to spray water from a squirt bottle at the belt with the engine running. If the noise stops, the belt is the cause of the noise. The water quickly evaporates, and therefore, unlike the gritty hand cleaner, water simply finds the problem—it does not provide a short-term fix. The Hand Cleaner Trick
  • 65. Figure 41–25 If the rear bearing is magnetized, the voltage regulator, generator brushes, and rotor are functioning. Magnetized Rear Bearing Test All 12-volt automotive generator systems use the voltage regulator to control the current through the rotor of the generator. The rotor creates a magnetic field when there is a complete circuit through the brushes and slip rings of the rotor. No current through the rotor means no generator output. When the rotor is energized, the entire rotor shaft and the generator bearings become magnetized. Continued
  • 66. If the rear bearing is magnetized, the following facts are known: The voltage regulator is working. The generator brushes are working. The rotor in the generator is producing a magnetic field. If the rear bearing is not magnetized, then one or more of the following problems exist: The voltage regulator is not working. The generator brushes are worn or stuck, and they are not making good electrical contact with the rotor slip rings. The generator rotor could be defective. NOTE: The front bearing is also magnetized, but testing for magnetism of the front bearing with the engine running can be dangerous. Continued
  • 67. If the rotor is not producing a magnetic field, no automotive generator can produce charging current. It is this rotating magnetic field created in the rotor that induces current in the stator windings. By checking for a magnetized rear bearing, the technician can better determine where the charging system problem is located. If the rear bearing is magnetized, yet the “charge” (“GEN”) light is on and the generator is not charging, the problem has to be inside the generator (diodes, stator, etc.).
  • 68. Battery voltage measurements can be read through the lighter socket. Construct a test tool using a lighter plug at one end of a length of two-conductor wire and the other end connected to a double banana plug. The double banana plug will fit most meters in the common (COM) terminal and the volt terminal of the meter. The Lighter Plug Trick Figure 41–26 Charging system voltage can be easily checked at the lighter plug by connecting a lighter plug to the voltmeter through a double banana plug.
  • 69. Use a Test Light to Check for a Defective Fusible Link Most AC generators (alternators) use a fusible link between the output terminal located on the slip-ring-end frame and the positive (+) terminal of the battery. If this link is defective (blown), then the charging system will not operate. Many AC generators have been replaced repeatedly because of a blown fusible link, not discovered until later. A quick and easy test of the fusible link is to touch a test light to the output terminal. Figure 41–27 Before replacing a generator (alternator), the wise tech checks that battery voltage is present at the output and battery voltage sense terminals. With the other end of the test light attached to a good ground, the fusible link is OK if the light lights. This confirms the circuit between the AC generator and the battery has continuity.
  • 70. AC Voltage Check A generator should produce very little AC voltage . It is the purpose of the diodes in the generator to rectify AC voltage into DC voltage. The procedure to check for AC voltage includes the following steps: Continued The results should be interpreted as follows: If the diodes are good, the voltmeter should read less than 0.4 volt AC. If the reading is over 0.5 volt AC, the rectifier diodes are defective. Step #1 Set the digital meter to read AC volts. Step #2 Start the engine and operate it at 2000 rpm (fast idle). Step #3 Connect the voltmeter leads to the positive and negative battery terminals. Step #4 Turn on the headlights to provide an electrical load on the generator.
  • 71. This test will not test for a defective diode trio. NOTE: A higher, more accurate reading can be obtained by touching the meter lead to the out- put terminal of the generator. Figure 41–28 AC ripple at the output terminal of the generator is more accurate than testing at the battery due to the resistance of the wiring between the generator and the battery. The reading shown on the meter is only 78 mV (0.078 V ), far below what the reading would be if a diode were defective. (Courtesy of Fluke Corporation)
  • 72. Generator output can be easily measured using a digital mini clamp-on-type digital multimeter. A typical clamp-on meter is capable of reading as low as 10 mA (0.01 A) to 200 A or more. To set up for the test, clamp the meter around the generator output wire and select DC amperes and the correct scale. Start the engine and turn on all lights and accessories and then observe the meter display. The results should be within 10% of the specified generator rating. An AC/DC current clamp adapter can also be used along with a conventional digital multimeter set on the DC millivolt scale. To check for AC current ripple, switch the meter to read AC amperes and record the reading. A reading of greater than 10 amperes AC indicates defective generator diodes. The Mini Clamp-On DMM Test
  • 73. Figure 41–29 A mini clamp-on digital multimeter can be used to measure generator output. This meter was set on the 200-A DC scale. With the engine running and all lights and accessories on, the generator was able to produce almost exactly its specified rating of 105 A. Continued
  • 74. Charging System Voltage-Drop Testing For the proper operation of any charging system, there must be good electrical connections between the battery positive terminal and the generator output terminal. The generator must also be properly grounded to the engine block. Many vehicle manufacturers run the lead from the output terminal of the generator to other connectors or junction blocks that are electrically connected to the positive terminal of the battery. If there is high resistance (a high voltage drop) in these connections or in the wiring itself, the battery will not be properly charged. Continued
  • 75. Whenever there is a suspected charging system problem (with or without a charge indicator light on), follow these steps to measure voltage drop of the insulated (power side) charging circuit: Continued Step #1 Start the engine and run it at a fast idle (about 2000 engine rpm). Step #2 Turn on the headlights to ensure an electrical load on the charging system. Step #3 Using any voltmeter, connect the positive test lead (usually red) to the output terminal of the generator. Attach the negative test lead (usually black) to the positive post.
  • 76. If there is less than a 0.4-volt reading, then all wiring and connections are satisfactory. If the voltmeter reads higher than 0.4 volt, there is excessive resistance (voltage drop) between the generator output terminal and the positive terminal of the battery. If the voltmeter reads battery voltage (or close to battery voltage), there is an open circuit between the battery and the generator output terminal. Continued The results should be interpreted as follows:
  • 77. To determine whether the generator is correctly grounded, maintain the engine speed at 2000 rpm with the headlights on. Figure 41–30 Voltmeter hookup to test the voltage drop of the charging circuit. Connect the positive voltmeter lead to the case of the generator and the negative lead to the negative terminal of the battery. The voltmeter should read less than 0.2 volt if the generator is properly grounded.
  • 78. Continued If the reading is over 0.2 volt, connect one end of an auxiliary ground wire to the case of the generator and the other end to a good engine ground. Most voltage-drop specifications range between 0.2 and 0.4 volt. Generally, if the voltage loss (voltage drop) in a circuit exceeds 0.5 volt (1/2 volt), the wiring in that circuit should be repaired or replaced. During automotive testing, it is sometimes difficult to remember the exact specification for each test; therefore, the technician can simply remember “2 to 4” and that any voltage drop over this amount indicates a problem. “ 2 to 4”
  • 79. Whenever diagnosing a generator charging problem, try using jumper cables to connect the positive and negative terminals of the generator directly to the positive and negative terminals of the battery. If a definite improvement is noticed, the problem is in the wiring of the vehicle. High resistance, due to corroded connections or loose grounds, can cause low generator output, repeated regulator failures, slow cranking, and discharged batteries. A voltage-drop test of the charging system also can be used to locate excessive resistance (high-voltage drop) in the charging circuit, but using jumper wires (cables) is often faster and easier. Use Jumper Cables as a Diagnostic Tool
  • 80. GENERAL MOTORS SI TEST LIGHT TEST All General Motors SI (System Integration [internal voltage regulator]) series Delcotron generators (alternators) can be easily tested using a standard 6- to 12-volt test light. Continued Figure 41–31 Typical GM SI generator. Note the location and wire color used for terminal #1 and #2.
  • 81. Problems and Possible Causes If the test light is not on at all on terminal #1 (brown or tan wire), the problem is an open circuit in the wiring between the dash and the generator. If the test light is bright on terminal #1 with the key turned to on and the engine off, the most likely cause is a defective (open) voltage regulator. If the test light does not light on either the BAT terminal or #2 terminal, an open circuit exists between the positive post of the battery and the generator. Check the condition of all fusible links. NOTE: Terminal #2 is the battery-sensing terminal. On many GM applications, a jumper wire simply connects the BAT terminal to terminal #2. The test light should be dim when touched to terminal #1. Terminal #1 is the wire from the dashboard warning light. The test light should be dim because of the voltage drop across the dashboard light bulb.
  • 82. A General Motors CS series generator requires only two wires to operate—the battery (BAT) feed and the wire to the L terminal. The CS series generators are designed to operate as a stand-alone generator or be controlled by a vehicle computer system. See Figure 41–32 for terminal identification. GENERAL MOTORS CS SERIES AC GENERATORS Continued
  • 83. Figure 41–32 Typical GM CS generator wiring plug identification. Note that terminal F is sometimes terminal I on some generators. The P terminal, sometimes called the stator tap, is connected directly to the stator that produces about one-half of the system alternating current and is used as a tachometer signal. P is used because it is an abbreviation for pseudo, meaning “alternating (not straight) output.” Terminal S is the sensing terminal for true battery voltage. Terminal F is the computer-sensing terminal. The computer monitors this terminal and sets trouble codes and alerts the driver if there is a charging system malfunction. The letter I is sometimes used instead of F and this terminal is used as a backup voltage source to the voltage regulator if the L terminal circuit is lost. Continued
  • 84. The battery and generator (alternator) had been replaced by another shop, yet the battery would be totally discharged after three days. A check of the charging system showed that the generator was not charging. The Chevrolet Van Story - Part 1 Before another generator was installed, the tech checked for voltage at both the output terminal of the generator ( B terminal) and the L terminal with the ignition switch in the on (run) position. There was no voltage at the L terminal indicating the problem was in the wiring to the L terminal, because without voltage at this terminal, the CS130 will charge. Checking the schematic in the service information showed that the power to the L terminal came from the gauges fuse and then through the charge warning lamp. See Figure 41–33 following. What could have caused the fuse to blow? Further checking of the circuit showed that the gauges fuse also fed the automatic transmission torque converter clutch circuit. A visual inspection discovered a damaged wire under the van most likely due to road debris. Repairing the wire and installing a new fuse solved the charging system problem.
  • 85. The Chevrolet Van Story - Part 2
  • 86. Figure 41–33 A schematic showing a typical wiring for a General Motors CS generator, showing that the L terminal is fed from the gauges fuse. If the fuse was blown, the charger light would never light and the generator (alternator) will not charge. The Chevrolet Van Story - Part 3
  • 87. If the charge indicator light is on in the dash, unplug the connector (which can have up to four wires). Start the engine and observe the dash charge light. If the light is still on, there is a short-to-ground in the L wire circuit between the generator and the dash. If the charge light is out, check for voltage at the L terminal. If there is voltage available at the L terminal (remember, the connector is still unplugged from the generator), the problem is in the generator, if charging is not occurring. If there is no voltage available at the L terminal, apply a voltage through a standard test light to the L terminal of the generator. This supplies the power for the regulator. DIAGNOSING PROBLEMS WITH THE GENERAL MOTORS CS SERIES Continued
  • 88. If the generator output is now normal, the problem is in the wiring to the L terminal of the generator. Check all fuses, all fusible links, and the charge light indicator bulb. Continued Generator Output Test A charging circuit may be able to produce correct charging circuit voltage but not produce adequate amperage. If in doubt about charging system output, first check the condition of the generator drive belt. See Figure 41–34. With the engine off, attempt to rotate the fan of the generator by hand. Replace or tighten the drive belt if the generator fan can be rotated this way. See Figure 41–35 for typical test equipment hookup.
  • 89. Figure 41–34 This accessory drive belt should be replaced because it has so many cracks. The usual specification for when a serpentine belt requires replacement is when there are three or more cracks in any one rib in any 3-inch length. Figure 41–35 Typical hookup of a starting and charging tester.
  • 90. The testing procedure for generator output is as follows: Step #1 Connect starting and charging test leads according to the test equipment manufacturer’s instructions. Step #2 Turn ignition switch on (engine off); observe the ammeter. The ignition circuit current should be about 2 to 8 amperes. Step #3 Start the engine and operate it at 2000 rpm (fast idle). Turn the load increase control slowly to obtain the highest reading on the ammeter scale. Note the ampere reading. Step #4 Total the amperes from step 2 and step 3. Results should be within 10% (or 15 amperes) of the rated output. Rated ­output may be printed on the generator as shown in Figure 41–37. Continued
  • 91. HINT: Step #2 can be skipped if the ammeter current clamp can be connected around the generator output wire instead of the battery cable(s). Figure 41–36 The best place to install a charging system tester amp probe is around the generator output terminal wire as shown.
  • 92. Figure 41–37 The output on this generator is printed on a label.
  • 93. How to Determine Minimum Required Generator Output All charging systems must be able to supply the electrical demands of the electrical system. If lights and accessories are used constantly and the generator cannot supply necessary ampere output, the battery will be drained. To determine minimum electrical load requirements, connect an ammeter in series with either battery cable. NOTE: When applying a load to the battery with a carbon pile tester during a generator output test, do not permit the battery voltage to drop below 12 volts. Most generators will produce their maximum output (in amperes) above 13 volts. Continued
  • 94. NOTE: If using an inductive-pickup ammeter, ensure the pickup is over all the wires leaving the battery terminal. Failure to include the small body ground wire from the negative terminal to the body or the positive wire (if testing from the positive side) will greatly decrease current flow readings. Figure 41–38 A diagram showing the location of the charging system wiring of a typical vehicle. The best location to use to check for the generator (alternator) output is at the output wire from the B+ (BAT) terminal. Notice that the generator supplies all electrical needs of the vehicle first, then charges the battery if needed.
  • 95. After connecting an ammeter correctly in the battery circuit, continue as follows: Start the engine and operate to about 2000 rpm (fast idle). Turn the heat selector to air conditioning (if so equipped). Turn the blower motor to high speed. Turn the headlights on bright. Turn on the radio. Turn on the windshield wipers. Turn on other accessories used continuously (do not operate horn, door locks, or units not used more than a few seconds). Observe the ammeter. Current indicated is the electrical load the generator is able to exceed to keep the battery fully charged. The minimum acceptable generator output is 5 amps greater than the accessory load. A negative (discharge) reading indicates that the generator is not capable of supplying current needed.
  • 96. Many technicians are asked to install a higher-output generator to allow the use of emergency equipment or other high-amperage equipment such as a high-wattage sound system. Although many higher-output units can be physically installed, it is important not to forget to upgrade the wiring and the fusible link(s) in the generator circuit. Failure to upgrade the wiring could lead to overheating. The usual failure locations are at junctions or electrical connectors. Bigger is Not Always Better
  • 97. GENERATOR DISASSEMBLY If testing has confirmed that there are generator problems, remove the generator from the vehicle after disconnecting the negative battery cable. This will prevent the occurrence of damaging short circuits. Mark the case with a scratch or with chalk to ensure proper reassembly. Continued Figure 41–39 Always mark the case of the generator before disassembly to be assured of correct reassembly.
  • 98. Figure 41–40 Explanation of clock positions. Because the four through-bolts are equally spaced, it is possible for a generator to be installed in one of four different clock positions. The connector position is determined by viewing the generator from the diode end with the threaded adjusting lug in the up or 12 o’clock position. Select the 3 o’clock, 6 o’clock, 9 o’clock, or 12 o’clock position to match the unit being replaced. The four through bolts that hold the two halves together are equally spaced; the rear generator housing can be installed in one of four clock positions to match needs of various models. NOTE: Most generators of a particular manufacturer can be used on a variety of vehicles, which may require wiring connections placed in various locations. A Chevrolet and Oldsmobile generator may be identical except for position of the rear section containing electrical connections.
  • 99. Testing the Rotor Slip rings on the rotor should be smooth and round (within 0.002 inch of perfectly round). If grooved, the slip rings can be machined to provide a suitable surface for the brushes. If the slip rings are discolored or dirty, they can be cleaned with 400-grit or fine emery (polishing) cloth. The rotor must be turned while being cleaned to prevent flat spots on the slip rings. The field coil continuity in the rotor can be checked by touching one test lead of a 110-volt (15-watt bulb) tester on each slip ring. The test light should light. A more accurate method is to measure the resistance between the slip rings using an ohmmeter. Continued
  • 100. Figure 41–41 Testing a generator rotor using an ohmmeter. If the resistance is below spec, the rotor is shorted. Continued Typical resistance values: GM : 2.2 to 3.5 ohms Ford : 3.0 to 5.5 ohms Chrysler : 3.0 to 6.0 ohms Exact specs for the generator tested should be consulted before condemning a rotor. If the resistance is above spec, the rotor connections are corroded or open.
  • 101. Testing the Stator The stator must be disconnected from the diodes (rectifiers) before testing. Because all three windings of the stator are electrically connected (either wye or delta), a powered (110- or 12-volt) test light or an ohmmeter can be used to check a stator. There should be low resistance at all three stator leads (continuity), and the test light should light. There should not be continuity (infinity ohms, or test light should not light) when the stator is tested between any stator lead and the metal stator core. If there is continuity, the stator is grounded (short to ground) and must be repaired or replaced. See Figure 41–42. Continued
  • 102. Figure 41–42 If the ohmmeter reads infinity between any two of the three stator windings, the stator is open and, therefore, defective. The ohmmeter should read infinity between any stator lead and the steel laminations. If the reading is less than infinity, the stator is grounded. Stator windings can be tested if shorted because the normal resistance is very low. Continued
  • 103. Because the resistance is very low for a normal stator, it is generally not possible to test for a shorted (copper to copper) stator. A shorted stator will, however, greatly reduce generator output. If all generator components test OK and output is still low, substitute a known good stator and retest. If the stator is black or smells burned, check vehicle for a discharged or defective battery. If battery voltage never reaches the voltage regulator cutoff point, the generator will be continuously producing current in the stator windings. This continuous charging often overheats the stator. Continued NOTE: The cost of a replacement rotor may exceed the cost of an entire rebuilt generator. Be certain, however, that the rebuilt generator is rated at the same output as the original or higher.
  • 104. Figure 41–43 An open in a delta- wound stator cannot be detected using an ohmmeter. An ohmmeter cannot detect an open stator if the stator is delta wound. The ohmmeter will still indicate low resistance because all three windings are electrically connected. Continued
  • 105. Testing the Diode Trio Many generators are equipped with a diode trio. A diode is an electrical one-way check valve permitting current to flow in only one direction. Figure 41–44 Typical diode trio. If one leg of a diode trio is open, the generator may produce close to normal output, but the charge indicator light on the dash will be on dimly. The plus signs indicate the anodes, and the minus sign indicates the cathode terminal of the diodes. Continued The diode trio is connected to all three stator windings. Current generated in the stator flows through the diode trio to the internal voltage regulator. If one of the diodes in the trio is defective (usually open), the generator may produce close-to-normal output; however, the charge indicator light will be on dimly.
  • 106. Testing the Rectifier Bridge (Diodes) Generators are equipped with six diodes to convert the alternating current (AC) generated in the stator windings into direct current (DC) for use by the vehicle’s battery and electrical components. The six diodes include three positive diodes and three negative diodes (one positive and one negative for each winding of the stator). These diodes can be individual diodes or grouped into a positive and a negative rectifier that each contain three diodes. All six diodes can be combined into one replaceable unit called a rectifier bridge . The rectifier(s) (diodes) should be tested using a multimeter that is set to “ diode check ” or “ohms.” Continued
  • 107. Because a diode (rectifier) should allow current to flow in only one direction, each diode should be tested to determine if the diode allows current flow in one direction and blocks current flow in the opposite direction. To test many generator diodes, it may be necessary to unsolder the stator connections. Accurate testing is not possible unless the diodes are separated electrically from other generator components. Figure 41–45 A GM rectifier bridge that has been disassembled to show the individual diodes. Continued
  • 108. Connect the leads to the leads of the diode (pigtail and housing of the rectifier bridge). Read the meter. Reverse the test leads. A good diode should have high resistance (OL) one way (reverse bias) and low-voltage drop (0.5 to 0.7 volt) the other way (forward bias). An ohmmeter also can be used. If the ohmmeter reads low ohms (low-voltage drop) in both directions, the diode is shorted. If the meter reads high ohms (OL) in both directions, the diode is open. Open or shorted diodes must be replaced. Most generators group or combine all positive and all negative diodes in the one replaceable rectifier component. General Motors Delcotron generators use a replaceable rectifier bridge containing all six diodes in one unit combined with a finned heat sink. Continued
  • 109. Brush Holder Replacement Generator carbon brushes often last for many years and require no scheduled maintenance. The life of the generator brushes is extended because they conduct only the field (rotor) current, which is normally only 2 to 5 amperes. The generator brushes should be inspected whenever the generator is disassembled and should be replaced when worn to less than 1/2 inch in length. Generator brushes are spring loaded, and if the springs are corroded or damaged, the brushes will not be able to keep constant contact with the slip rings of the rotor. If the brushes do not contact the slip rings, field current cannot create the magnetic field in the rotor that is necessary for current generation. Continued
  • 110. Brushes are commonly purchased assembled together in a brush holder. After the brushes are installed (usually retained by two or three screws) and the rotor is installed in the generator housing, a brush retainer pin can be pulled out through an access hole in the rear of the generator, allowing the brushes to be pressed against the slip rings by the brush springs Figure 41–46 A brush holder assembly shown assembled in the generator. The brush retainer is actually a straightened -out paper clip. Continued
  • 111. Bearing Service and Replacement The bearing of a generator must be able to support the rotor and reduce friction. A generator must be able to rotate at up to 15,000 rpm and withstand the forces created by the drive belt. The front bearing usually is a ball bearing type and the rear is a smaller roller bearing. The front bearing is located under a retainer and pressed into the front generator case. The pulley must be removed before the rotor can be separated from the case. Some generator press-fit pulleys must be removed using a puller, whereas Ford and GM generators use a nut to hold the drive pulley to the rotor. The front pulley can be removed from most GM generators by using a 15/16-inch wrench while holding the rotor shaft to keep it from rotating using a 5/16-inch hex (Allen) wrench. Continued
  • 112. The old or defective bearing sometimes can be pushed out of the front housing and the replacement pushed in by applying pressure with a socket or pipe against the outer edge of the bearing (outer race). Replacement bearings are usually prelubricated and sealed. Adding additional grease could cause overheating of the bearing by reducing heat transfer from the bearing surfaces to the generator housing. Many generator front bearings must be removed from the rotor using a special puller.
  • 113. GENERATOR ASSEMBLY After testing or servicing, the generator rectifier(s), regulator, stator, and brush holder must be reassembled. If the brushes are internally mounted, insert a wire through the holes in the brush holder and in the generator rear frame to retain the brushes for reassembly. Install the rotor and front-end frame in proper alignment with the mark made on the outside of the generator housing. Install the through bolts. Before removing the wire pin holding the brushes, spin the generator pulley. If the generator is noisy or not rotating freely, the generator can be disassembled again to check the cause. After making certain the generator is free to rotate, remove the brush holder pin and spin the generator again by hand. Continued
  • 114. The noise level may be slightly higher with the brushes released onto the slip rings. Generators should be tested on a bench tester, if available, before they are reinstalled on a vehicle. When installing the generator on the vehicle, be certain that all mounting bolts and nuts are tight. The battery terminal should be covered with a plastic or rubber protective cap to help prevent accidental shorting to ground, which could seriously damage the generator.
  • 115. REMANUFACTURED GENERATORS Remanufactured or rebuilt generators are totally disassembled and rebuilt. Even though there are many smaller rebuilders who may not replace all worn parts, the major national remanufacturers totally remanufacture the generator. Old generators (cores) are totally disassembled and cleaned. Both bearings are replaced and all components tested. Rotors are rewound to original specifications if required. The rotor windings are rewound on the rotor “spool,” using the correct-gauge copper wire, to the weight specified by the original manufacturer. New slip rings are replaced as required and soldered to the rotor spool windings and machined. Rotors are balanced and measured to ensure outside diameter meets specifications. Continued
  • 116. Figure 41–47 (a) A generator for a GEO Prism looks like a typical General Motors CS-130 except for this adapter that converted the Toyota wiring harness to the GM generator: (b) After removing the adapter, the original generator connection is visible. Every generator is assembled and tested for proper output, boxed, and shipped to a warehouse. (a) (b) Individual diodes (within the rectifiers) are replaced if required.
  • 117. The Cold Weather Charge Lamp Problem A customer brought his vehicle (Ford) to an independent service facility complaining that occasionally, whenever the temperatures dropped below 10°F (-12°C), his charge indicator lamp stayed on until he had driven for several minutes. The customer left the vehicle overnight and the technician observed that, indeed, the charge lamp was on after starting the vehicle the next morning. The tech immediately got out of the vehicle, opened the hood, and checked to see if the rear bearing was magnetized—it was not. After a few minutes of operation, the charge lamp went out and the rear generator bearing was magnetized. The technician then knew that the problem was sticking generator brushes. The brushes had worn to less than one-half length, and the springs were not strong enough, when cold, to exert sufficient pressure on the rotor slip rings to conduct the current for the field (rotor). After the technician replaced the brushes and cleaned and checked all other generator components, the problem did not recur.
  • 118. An 80-ampere generator was tested at 2000 engine RPM and found to be producing only 69 amperes. The recommended spec for a generator is the output should be within 10% of the rated output. Ten percent of 80 amps is 8 amps; therefore, the minimum recommended output is 72 amp (80 - 8 = 72). Because 69 amps is less than 72 amps, the generator should be serviced (repaired or replaced). The Weak But Good Generator However, because the test result was so close to specs, it was decided a charging system requirement test should be performed. This determines the electrical load of that may be required on a continuous basis. The procedure: Turn on everything electrical, except horn or other short-term accessories. Add 5 amps to the reading and the result is the minimum current required of the generator. The electrical demand test indicated that only 49 amps was needed. Add 5 amps (49 + 5 = 54) and you see that a 54-amp generator is all that is needed. Because the original generator is capable of 69 amps, it is more than adequate for the vehicle.
  • 119. The Two-Minute Generator Repair A Chevrolet pickup truck was brought to a dealer for routine service. The owner stated the battery required a jump-start after a weekend of sitting. The tech tested the battery and charging system voltage using a small hand-held digital multimeter. The battery voltage was 12.4 volts (about 75% charged), but the charging voltage was also 12.4 volts at 2000 RPM. Because normal charging voltage should be 13.5 to 15.0 volts, it was obvious that the charging system was not operating correctly. The tech checked the dash and found the “charge” light was not on, even though the rear bearing was not magnetized, indicating the voltage regulator was not working. Before removing the generator for service, the tech checked the wiring connection on the generator. When the two-lead regulator connector was removed, the connector was discovered to be rusty. After the contacts were cleaned, the charging system was restored to normal operation. The tech had learned that simple things should always be checked first before tearing into a big (or expensive) repair.
  • 120. A technician wanted help in determining what the generator output should be on a Toyota truck. If the generator is protected by a fuse, check the fuse rating. In this case, the fuse was listed as being 80 amperes. The 80% rule states that the maximum current in a circuit should not exceed 80% of the fuse rating. Eighty percent of 80 amps is 65 amps. The generator output was measured to be 62 amps, well within the normal range of within 10% of specifications (10% of 64 is 6.4 amps). Help!
  • 121. PHOTO SEQUENCE Generator (Alternator) Overhaul Continued
  • 122. PHOTO SEQUENCE Generator Overhaul ( cont. ) Continued
  • 123. PHOTO SEQUENCE Generator Overhaul ( cont. ) Continued
  • 124. PHOTO SEQUENCE Generator Overhaul ( cont. ) Continued
  • 125. PHOTO SEQUENCE Generator Overhaul ( cont. ) Continued
  • 126. PHOTO SEQUENCE Generator Overhaul ( cont. )
  • 127. SUMMARY Charging system testing requires the battery be at least 75% charged to be assured of accurate test results. The charge indicator light should be on with the ignition switch on but should go out whenever the engine is running. Normal charging voltage (at 2000 engine RPM) is 13.5 to 15.0 volts. If the system is not charging properly, the rear bearing of the generator should be checked for magnetism. If it is magnetized, voltage regulator, brushes, and generator rotor are functioning correctly. If the rear bearing is not magnetized, the voltage regulator, generator brushes, or rotor is not functioning. Bypass the voltage regulator by supplying battery voltage to the field. If the rear bearing is now magnetized and the charging system output is normal; the voltage regulator is at fault. Continued
  • 128. SUMMARY To check for excessive resistance in the wiring between generator and battery, a voltage-drop test should be performed. Generators do not produce their maximum-rated output unless required by circuit demands. Therefore, to test for maximum generator output, the battery must be loaded to force the generator to produce its maximum output. Continued ( cont. )
  • 129. SUMMARY Each generator should be marked across its case before disassembly to ensure proper clock position during reassembly. After disassembly, all generator internal components should be tested using a continuity light or an ohmmeter. The following components should be tested: Continued ( cont. ) Stator Rotor Diodes Diode trio (if the generator is so equipped) Bearings Brushes (should be more than 1/2 inch in length)
  • 130. SUMMARY Electronic voltage regulators can be tested either off the vehicle using a special tester or on the vehicle using the full-field bypass procedure. ( cont. )
  • 131. end