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OBJECTIVES:
After studying Chapter 41, the reader should
be able to:
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KEY TERMS:
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
Continued
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KEY TERMS:
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
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1. Increasingthespeedoftheconductorthroughthe
magneticfield
2. Increasingthenumberofconductorspassingthrough
themagneticfield
3. Increasingthestrengthofthemagneticfield
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Continued
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GENERATOR CONSTRUCTION
Ageneratorisconstructedofatwopiececastaluminumhousing.
Aluminumisusedbecauseofitslightweight,nonmagnetic
propertiesandheattransferpropertiesneededtohelpkeepthe
generatorcool.
Afrontballbearingispressedintothefronthousing(calledthe
driveend[DE]housing)toprovidethesupportandfriction
reductionnecessaryforthebeltdrivenrotorassembly.
Therearhousing,ortheslipringend(SRE),usuallycontainsa
rollerbearingsupportfortherotorandmountingforthebrushes,
diodes,andinternalvoltageregulator(ifthegeneratorisso
equipped).SeeFigures411and412.
Continued
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Figure 412
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
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Aconventionaldrivepulleyattachestothealternator(rotor)shaft
withanutandlockwasher.
Intheoverrunningclutchpulley,theinnerraceoftheclutchactsas
thenutandscrewsontotheshaft.Specialtoolsarerequiredto
removeandinstallthistypeofpulley.
Anothertypeofalternatorpulleyusesadampenerspringinsideplus
aonewayclutch.Thisunitiscalledanoverrunningalternator
dampener(OAD).
AnOADislargerthananOAPandisusedonthePontiacG8and
othervehicles.
SeeFigure414.
Continued
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Figure 414 An overrunning alternator dampener (OAD) disassembled, showing all of its
internal parts.
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DiagnosisandServiceOverrunningalternatorpulleysand
alternatordampenerscanfail,withthemostcommonfactorthe
onewayclutch.
Ifitfails,itcanfreewheelandnotpowerthealternatororitcanlock
upandnotprovidedampeningasdesigned.Ifthechargingsystem
isnotworking,theOAPorOADcouldbethecauseratherthana
faultinthealternatoritself.
Inmostcases,theentirealternatorassemblywillbereplaced
becauseeachOAPorOADisuniqueforeachapplicationandthey
requirespecialtoolstoremoveandreplace.
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ROTORS
Therotorcreatesthemagneticfieldofthegeneratorandproduces
acurrentbyelectromagneticinductioninthestationarystator
windings.
Thegeneratorrotorisconstructedofmanyturnsofcopperwire
coatedwithavarnishinsulationwoundoveranironcore.Theiron
coreisattachedtotherotorshaft.Atbothendsoftherotor
windingsareheavygaugemetalplatesbentoverthewindings
withtriangularfingerscalledpoles.
Thesepolefingersdonottouch,butrathertheyalternateor
interlaceasshowninFigure415.
Continued
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Figure 415 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
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Ifcurrentflowsthroughtherotorwindings,themetalpolepiecesateachendoftherotorbecome
electromagnets.Whetheranorthorasouthpolemagnetiscreateddependsonthedirectioninwhichthe
wirecoiliswound.
Becausethepolepiecesareattachedtoeachendoftherotor,onepolepiecewillbeanorthpolemagnet.
Theotherpolepieceisontheoppositeendoftherotorandthereforeisviewedasbeingwoundinthe
oppositedirection,creatingasouthpole.Therotorfingersarealternatingnorthandsouthmagneticpoles.
Themagneticfieldsarecreatedbetweenthealternatingpolepiecefingers.Theseindividualmagnetic
fieldsproduceacurrentbyelectromagneticinductioninthestationarystatorwindings.
SeeFigure416.
Continued
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Thecurrentnecessaryforthe
field(rotor)windingsis
conductedthroughcarbon
brushestothesliprings.
Maximumratedgenerator
outputinamperesislargely
dependentonthenumber
andgaugeofthewindings
oftherotor.
Substitutingrotorsfromone
generatorintoanothercan
greatlyaffectmaximumoutput
eitherpositiveornegative.
Figure 416 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.
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GENERATOR BRUSHES
Thecurrentforthefieldiscontrolledbythevoltageregulatorand
isconductedtotheslipringsthroughcarbonbrushes.
Thebrushesconductonlythefieldcurrent(approximately2to5
amps),andthereforetendtolastlongerthanthebrushesusedona
DCgenerator,whereallthecurrentgeneratedinthegeneratormust
flowthroughthebrushes.
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STATORS
Supportedbetweenthetwohalvesofthegeneratorhousingare
threecopperwirewindingswoundonalaminatedmetalcore.
SeeFigure417.
Astherotorrevolves,itsmovingmagneticfieldinducesacurrent
inthewindingsofthestator.
SeeFigure418.
Continued
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Continued
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Figure 418 An exploded view of a typical generator (alternator) showing all of its internal
parts.
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DIODES
Diodesareconstructedofasemiconductormaterial(usually
silicon)andoperateasaonewayelectricalcheckvalvethat
permitsthecurrenttoflowinonlyonedirection.
ACgeneratorsusesixdiodes(onepositiveandonenegativediode
foreachofthethreestatorwindings)toconvertalternatingcurrent
todirectcurrent.Thesymbolforadiodeisshownhere.
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Theinducedcurrentinthestatorwindingsisanalternatingcurrent
becauseofthealternatingmagneticfieldoftherotor.
Theinducedcurrentstartstoincreaseasthemagneticfieldstartsto
inducecurrentineachwindingofthestator.
Thecurrentthenpeakswhenthemagneticfieldisthestrongestand
startstodecreaseasthemagneticfieldmovesawayfromthestator
winding.
Thecurrentgeneratedisdescribedasbeingofasinewavepattern
SeeFigure4111.
Continued
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Figure 4111 Since wave voltage curve created by one revolution of a winding rotating in a
magnetic field.
Astherotorcontinuestorotate,thissinewavecurrentisinducedin
eachofthethreewindingsofthestator.
Continued
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Becauseeachofthethreewindingsgeneratesasinewavecurrent,the
resultingcurrentscombinetoformathreephasevoltageoutput.
Figure 4112 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.
ACgeneratorscontainsixdiodes,onepairofpositiveanda
negativeforeachofthethreestatorwindings.
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WYE-CONNECTED STATORS
TheY(pronouncedwyeandgenerallysowritten)typeorstar
patternisthemostcommonlyusedgeneratorstatorwinding
connection.
Continued
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Theoutputcurrentwithawyetypestatorconnectionisconstant
overabroadgeneratorspeedrange.
Currentisinducedineachwindingbyelectromagneticinduction
fromtherotatingmagneticfieldsoftherotor.Inawyetypestator
connection,thecurrentsmustcombinebecausetwowindingsare
alwaysconnectedinseries.SeeFigure4114.
Thecurrentproducedineachwindingisaddedtotheotherscurrent
andflowsthroughthediodestothegeneratoroutputterminal.One
halfofthecurrentproducedisavailableattheneutraljunction
(usuallylabeledSTAforstator).
Voltageatthiscenterpointisusedbysomegeneratormanufacturers
(especiallyFord)tocontrolthechargeindicatorlightorisusedbythe
voltageregulatortocontroltherotorfieldcurrent.
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Figure 4114 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.
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DELTA-CONNECTED STATORS
Thedeltawindingisconnectedinatriangularshape,asshownin
here.(DeltaisaGreeklettershapedlikeatriangle.)
Continued
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Currentinducedineachwindingflowstothediodesinaparallel
circuit.Morecurrentcanflowthroughtwoparallelcircuitsthancan
flowthroughaseriescircuit(asinawyetypestatorconnection).
Deltaconnectedstatorsareusedongeneratorswherehighoutputat
highgeneratorrpmisrequired.Thedeltaconnectedgeneratorcan
produce73%morecurrentthanthesamegeneratorwithwyetype
statorconnections.
Ifageneratorwithawyeconnectedstatorcanproduce55A,the
samegeneratorwithdeltaconnectedstatorwindingscanproduce
73%morecurrent,or95A(551.73=95).
Thedeltaconnectedgenerator,however,produceslowercurrent
atlowspeedandmustbeoperatedathighspeedtoproduceits
maximumoutput.
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Hereisanexampleofastatorthathassixratherthanthree
windings,whichgreatlyincreasestheamperageoutputofthe
generator(alternator).
Figure 4116 A stator assembly with six, rather than the normal three, windings.
Continued
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3.
TheStrengthofthemagneticfield.Ifthemagneticfieldis
strong,ahighoutputispossiblebecausethecurrentgenerated
byelectromagneticinductionisdependentonthenumberof
magneticlinesofforcethatarecut.
a. Thestrengthofthemagneticfieldcanbeincreasedby
increasingthenumberofturnsofconductorwire
woundontherotor.Ahigheroutputgeneratorhasmore
turnsofwirethanageneratorwithalowratedoutput.
b. Thestrengthofthemagneticfieldalsodependsonthe
currentthroughthefieldcoil(rotor).Becausemagnetic
fieldstrengthismeasuredinampereturns,thegreater
theamperageorthenumberofturns,orboth,thegreater
thegeneratoroutput.
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Currentfortherotorflowsfromthebatterythroughthebrushesto
thesliprings.Aftergeneratoroutputbegins,thevoltageregulator
controlsthecurrentflowthroughtherotor.
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TemperatureCompensationAllvoltageregulators(mechanicalor
electronic)provideamethodforincreasingthechargingvoltage
slightlyatlowtemperaturesandforloweringthechargingvoltageat
hightemperatures.
Abatteryrequiresahigherchargingvoltageatlowtemperatures
becauseoftheresistancetochemicalreactionchanges.However,the
batterywouldbeoverchargedifthechargingvoltagewerenot
reducedduringwarmweather.
Electronicvoltageregulatorsuseatemperaturesensitiveresistor,
calledathermistorintheregulatorcircuit,anditprovideslower
resistanceastemperatureincreases.
Athermistorisusedtocontrolchargingvoltageoverawiderangeof
underthehoodtemperatures.SeeFigure4118.
Continued
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NOTE: Voltmetertestresultsmayvaryaccordingtotemperature.
Chargingvoltagetestedat32F(0C)willbehigherthanforthesame
vehicletestedat80F(27C)becauseofthetemperaturecompensation
factorsbuiltintovoltageregulators.
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againstthe12voltsfromtheignition.Theresultisadimgeneratorcharge
indicatorlight.Whilethislightmaybeacustomerconcern,thegenerator
willproducenormaloutput.
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Whentheignitionison,12voltsisappliedthroughthechargelight
bulbandisgroundedthroughtherotorwinding.
Thiscurrentisblockedfromflowingthroughthediodetriobecause
thediodesarereversedbiased.Whenthestatorandthegenerator
starttogeneratevoltage,the12voltoutputofthediodetrioopposes
the12voltsfromtheignitionthroughthechargelightcausingthe
chargelighttogoout.
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Thezenerdiodeisamajorelectroniccomponentthatmakesvoltage
regulationpossible.Generatorvoltagefromthestatoranddiodesis
firstsentthroughathermistor,whichchangesresistancewith
temperature,andthentoazenerdiode.
Whenevertheupperlimitvoltageisreached,thezenerdiode
conductscurrenttoatransistor,whichthenopensthefield(rotor)
circuit.Allthecurrentstopsflowingthroughthegenerators
brushes,sliprings,androtor,andnomagneticfieldisformed.
Withoutamagneticfield,ageneratordoesnotproducecurrentin
thestatorwindings.
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Whennovoltageisappliedtothezenerdiode,currentflowstops
andthebaseofthetransistoristurnedoff,closingthefieldcircuit.
Themagneticfieldisthusrestoredintherotor.
Therotatingmagneticfieldsoftherotorinduceacurrentinthe
stator,whichisagaincontrollediftheoutputvoltageexceedsthe
designedlimitasdeterminedbythezenerdiodebreakdownvoltage.
Dependingonthegeneratorrpm,vehicleelectricalload,andstateof
chargeofthebattery,thiscontrolledswitchingonandoffcanoccur
between10and7,000timespersecond.
SeeFigure4119.
Continued
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Figure 4119 Typical General Motors SI-style AC generator. Full Caption next slide.
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Figure 4119 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.
SeetheentireschematiconPage442ofyourtextbook.
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ComputerControlledGeneratorsComputerscaninterfacewith
thechargingsysteminthreeways:
1. Thecomputercanactivatethechargingsystembyturning
onandoffthefield.
2. Thecomputercanmonitortheoperationofthegenerator
andthereforecanincreaseidlespeedtocompensatefor
theadditionalloadifthegeneratorisproducingat
maximumoutput.
3. Thecomputercancontrolthegeneratorbynotonlyturning
thefieldonandoffbutcanalsodelayorlimittheoutputof
thegenerator,dependingonotherloadsontheengine,suchas
powersteeringoranairconditioningcompressor.
Continued
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Theenginecontrolmodule(ECM)controlsthealternatorby
changingtheontimeofthecurrentthroughtherotor.Theontime,
ordutycycle,isvariedfrom5%to95%.Seethefollowingchart:
Seethechart
onPage443
ofyourtextbook.
Continued
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AsystemusedonsomeGMvehiclesiscalledElectricalpower
management(EPM)andusesaHalleffectsensorattachedtothe
negativebatterycabletomeasurethecurrentleavingandentering
thebattery.
Thissystemhassix
modesofoperation
including:
Continued
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1. TheChargemode.Thechargemodeisactivatedwheneverany
ofthefollowingoccurs:
Electriccoolingfansareonhighspeed
Rearwindowdefoggerison
Batterystateofcharge(SOC)islessthan80%
Outside(ambient)temperatureislessthan32F(0C)
2. TheFueleconomymode.Thismodereducestheloadonthe
enginefromthegenerator(alternator)formaximumfuel
economy.Activatedwhenthefollowingconditionsaremet:
Ambienttemperatureisabove32F(0C)
Thestateofchargeofthebatteryis80%orhigher
Thecoolingfansandreardefoggerareoff
Thetargetvoltageis13voltsandwillreturntothe
chargemode,ifneeded.
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3. TheVoltagereductionmode.Thismodeiscommandedto
reducethestressonthebatteryduringlowloadconditions.This
modeisactivatedwheneverthefollowingconditionsaremet
Ambienttemperatureisabove32F(0C)
Lowbatterydischargerate(lessthan7amperes)
Reardefoggerisoff
Coolingfansareonloworoff
4. TheStartupmode.Thismodeisselectedafterenginestartand
commandsachargingvoltageof14.5voltsfor30seconds.After
30seconds,themodeischangeddependingonconditions.
Continued
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5. TheBatterysulfationmode.Thismodeiscommandedifthe
outputvoltageislessthan13.2voltsfor45minutes,whichcan
indicatethatsulfatedplatescouldbethecause.Thetarget
voltageis13.9to15.5voltsfor3minutes.After3minutes,the
systemreturnstoanothermodebasedonconditions.
6. TheHeadlightmode.Thismodeisselectedwheneverthe
headlightsareonandthetargetvoltageis14.5volts.
The Voltage Display Can Be a Customer
Concern
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 manufacturers recommended procedures to
verify proper operation.
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Beginninginthemid1980s,GMintroducedasmaller,highoutputseriesofgeneratorscalledtheCS
(chargingsystem)series.SeeFigures4121and4122.
FollowingCSarenumbersindicatingtheoutsidediameterinmillimetersofthestatorlaminations.
Typicalsizes,designations,andoutputsincludethefollowing:
CS121,5SI74A
CS130,9SI105A
CS144,17SI120A
Thesegeneratorsfeaturetwocoolingfans(oneinternal)andterminalsdesignedtopermitconnections
toanonboardbodycomputerthroughterminalsLandF.
Continued
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Figure 4121 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 highvoltage 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.
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Thereducedsizegeneratorsalsofeatureballbearingsinthefront
andrearandtotallysolderedinternalelectricalconnections.The
voltageiscontrolledeitherbythebodycomputer(ifsoequipped)or
bythebuiltinvoltageregulator.
Thevoltageregulator
switchesfieldvoltage
onandoffatafixed
frequencyofabout400
timespersecond.
Voltageiscontrolled
byvaryingtheontime
andofftimeofthe
fieldcurrent.
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Chargingvoltage=13.5to15.0V (GM=14.2to15.2V).
Ifthevoltageistoohigh,checkthatthecharging
systemcomponentssuchasthegeneratorandvoltage
regulator(ifseparate)areproperlygrounded.Ifthe
batteryvoltageisstillhigherthanspecified,thenthere
islikelyafaultwiththeelectricalconnectionsatthe
voltageregulatororgenerator.
Ifthevoltageislowerthanspecifications,thereisa
faultwiththewiring,generator,orregulator(if
external).Additionaltestingisrequiredtohelppinpoint
therootcause.
NOTE: Polarityofmeterleadsisnotimportantwhenusingadigital
multimeter.Ifmeterleadsareconnectedbackwardonthebattery,the
readoutwillhaveanegative()signinfrontofthevoltagereading.
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Figure 4123 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.
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MagnetizedRearBearingTestAll12voltautomotivegenerator
systemsusethevoltageregulatortocontrolthecurrentthroughthe
rotorofthegenerator.
Therotorcreatesamagnetic
fieldwhenthereisacomplete
circuitthroughthebrushesand
slipringsoftherotor.
Nocurrentthroughtherotor
meansnogeneratoroutput.
Whentherotorisenergized,
theentirerotorshaftandthe
generatorbearingsbecome
magnetized.
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NOTE: Thefrontbearingisalsomagnetized,buttestingformagnetism
ofthefrontbearingwiththeenginerunningcanbedangerous.
Iftherearbearingismagnetized,thefollowingfactsareknown:
1. Thevoltageregulatorisworking.
2. Thegeneratorbrushesareworking.
3. Therotorinthegeneratorisproducingamagneticfield.
If the rear bearing is not magnetized, then one or more of the
followingproblemsexist:
1. Thevoltageregulatorisnotworking.
2. Thegeneratorbrushesarewornorstuck,andtheyarenot
makinggoodelectricalcontactwiththerotorsliprings.
3. Thegeneratorrotorcouldbedefective.
Continued
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Iftherotorisnotproducingamagneticfield,noautomotive
generatorcanproducechargingcurrent.Itisthisrotatingmagnetic
fieldcreatedintherotorthatinducescurrentinthestatorwindings.
Bycheckingforamagnetizedrearbearing,thetechniciancanbetter
determinewherethechargingsystemproblemislocated.
Iftherearbearingismagnetized,yetthecharge(GEN)lightis
onandthegeneratorisnotcharging,theproblemhastobeinside
thegenerator(diodes,stator,etc.).
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Figure 4126
Charging system voltage can be
easily checked at the lighter plug
by connecting a lighter plug to
the voltmeter through a double
banana plug.
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ACVoltageCheckAgeneratorshouldproduceverylittleAC
voltage.Itisthepurposeofthediodesinthegeneratortorectify
ACvoltageintoDCvoltage.TheproceduretocheckforACvoltage
includesthefollowingsteps:
Step#1SetthedigitalmetertoreadACvolts.
Step#2Starttheengineandoperateitat2000rpm(fastidle).
Step#3Connectthevoltmeterleadstothepositiveandnegative
batteryterminals.
Step#4Turnontheheadlightstoprovideanelectricalloadonthe
generator.
Theresultsshouldbeinterpretedasfollows:Ifthediodesaregood,
thevoltmetershouldreadlessthan0.4voltAC.Ifthereadingis
over0.5voltAC,therectifierdiodesaredefective.
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NOTE: Ahigher,moreaccuratereadingcanbe
obtainedbytouchingthemeterleadtotheout
putterminalofthegenerator.
Thistestwillnottestforadefectivediodetrio.
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Figure 4129 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
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ChargingSystemVoltageDropTestingFortheproperoperation
ofanychargingsystem,theremustbegoodelectricalconnections
betweenthebatterypositiveterminalandthegeneratoroutput
terminal.Thegeneratormustalsobeproperlygroundedtothe
engineblock.
Manyvehiclemanufacturersruntheleadfromtheoutputterminal
ofthegeneratortootherconnectorsorjunctionblocksthatare
electricallyconnectedtothepositiveterminalofthebattery.
Ifthereishighresistance(ahighvoltagedrop)intheseconnections
orinthewiringitself,thebatterywillnotbeproperlycharged.
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Wheneverthereisasuspectedchargingsystemproblem(withor
withoutachargeindicatorlighton),followthesestepstomeasure
voltagedropoftheinsulated(powerside)chargingcircuit:
Step #1 Start the engine and run it at a fast idle (about 2000
enginerpm).
Step#2Turnontheheadlightstoensureanelectricalloadonthe
chargingsystem.
Step #3 Using any voltmeter, connect the positive test lead
(usually red) to the output terminal of the generator. Attach the
negativetestlead(usuallyblack)tothepositivepost.
Continued
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Theresultsshouldbeinterpretedasfollows:
1. Ifthereislessthana0.4voltreading,thenallwiringand
connectionsaresatisfactory.
2. Ifthevoltmeterreadshigherthan0.4volt,thereisexcessive
resistance(voltagedrop)betweenthegeneratoroutput
terminalandthepositiveterminalofthebattery.
3. Ifthevoltmeterreadsbatteryvoltage(orclosetobattery
voltage),thereisanopencircuitbetweenthebatteryandthe
generatoroutputterminal.
Continued
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Todeterminewhetherthegeneratoriscorrectlygrounded,maintain
theenginespeedat2000rpmwiththeheadlightson.
Connectthepositive
voltmeterleadtothe
caseofthegenerator
andthenegativelead
tothenegative
terminalofthebattery.
Figure 4130 Voltmeter hookup to
test the voltage drop of the charging
circuit.
Thevoltmetershould
readlessthan0.2volt
ifthegeneratoris
properlygrounded.
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Ifthereadingisover0.2volt,connectoneendofanauxiliary
groundwiretothecaseofthegeneratorandtheotherendtoagood
engineground.
2 to 4
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.
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NOTE: Terminal#2isthebatterysensingterminal.OnmanyGM
applications,ajumperwiresimplyconnectstheBATterminaltoterminal
#2.Thetestlightshouldbedimwhentouchedtoterminal#1.Terminal#1
isthewirefromthedashboardwarninglight.Thetestlightshouldbedim
becauseofthevoltagedropacrossthedashboardlightbulb.
ProblemsandPossibleCausesIfthetestlightisnotonatallon
terminal#1(brownortanwire),theproblemisanopencircuitin
thewiringbetweenthedashandthegenerator.
Ifthetestlightisbrightonterminal#1withthekeyturnedtoon
andtheengineoff,themostlikelycauseisadefective(open)
voltageregulator.
IfthetestlightdoesnotlightoneithertheBATterminalor#2
terminal,anopencircuitexistsbetweenthepositivepostofthe
batteryandthegenerator.Checktheconditionofallfusiblelinks.
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Figure 4132
Typical GM CS generator wiring plug
identification. Note that terminal F is
sometimes terminal I on some generators.
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Figure 4133 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.
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Ifthegeneratoroutputisnownormal,theproblemisinthewiringto
theLterminalofthegenerator.Checkallfuses,allfusiblelinks,and
thechargelightindicatorbulb.
GeneratorOutputTestAchargingcircuitmaybeabletoproduce
correctchargingcircuitvoltagebutnotproduceadequateamperage.
Ifindoubtaboutchargingsystemoutput,firstcheckthecondition
ofthegeneratordrivebelt.SeeFigure4134.
Withtheengineoff,attempttorotatethefanofthegeneratorby
hand.Replaceortightenthedrivebeltifthegeneratorfancanbe
rotatedthisway.
SeeFigure4135fortypicaltestequipmenthookup.
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Figure 4134 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 4135
Typical hookup of a starting
and charging tester.
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Thetestingprocedureforgeneratoroutputisasfollows:
Step#1Connectstartingandchargingtestleadsaccordingtothe
testequipmentmanufacturersinstructions.
Step#2Turnignitionswitchon(engineoff);observetheammeter.
Theignitioncircuitcurrentshouldbeabout2to8amperes.
Step#3Starttheengineandoperateitat2000rpm(fastidle).Turn
theloadincreasecontrolslowlytoobtainthehighestreadingonthe
ammeterscale.Notetheamperereading.
Step#4Totaltheamperesfromstep2andstep3.Resultsshould
bewithin10%(or15amperes)oftheratedoutput.Ratedoutput
maybeprintedonthegeneratorasshowninFigure4137.
Continued
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HINT: Step#2canbeskippediftheammetercurrentclampcanbe
connectedaroundthegeneratoroutputwireinsteadofthebatterycable(s).
Figure 4136 The best place to install a charging system tester amp probe is around the generator
output terminal wire as shown.
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NOTE: Whenapplyingaloadtothebatterywithacarbonpiletester
duringageneratoroutputtest,donotpermitthebatteryvoltagetodrop
below12volts.Mostgeneratorswillproducetheirmaximumoutput(in
amperes)above13volts.
HowtoDetermineMinimumRequiredGeneratorOutput
Allchargingsystemsmustbeabletosupplytheelectricaldemands
oftheelectricalsystem.
Iflightsandaccessoriesareusedconstantlyandthegeneratorcannot
supplynecessaryampereoutput,thebatterywillbedrained.
Todetermineminimumelectricalloadrequirements,connectan
ammeterinserieswitheitherbatterycable.
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NOTE: Ifusinganinductivepickupammeter,ensurethepickupisover
allthewiresleavingthebatteryterminal.Failuretoincludethesmallbody
groundwirefromthenegativeterminaltothebodyorthepositivewire(if
testingfromthepositiveside)willgreatlydecreasecurrentflowreadings.
Figure 4138 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.
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Afterconnectinganammetercorrectlyinthebatterycircuit,
continueasfollows:
1.
2.
3.
4.
5.
6.
7.
Starttheengineandoperatetoabout2000rpm(fastidle).
Turntheheatselectortoairconditioning(ifsoequipped).
Turntheblowermotortohighspeed.
Turntheheadlightsonbright.
Turnontheradio.
Turnonthewindshieldwipers.
Turnonotheraccessoriesusedcontinuously(donotoperate
horn,doorlocks,orunitsnotusedmorethanafewseconds).
Observetheammeter.Currentindicatedistheelectricalloadthe
generatorisabletoexceedtokeepthebatteryfullycharged.The
minimumacceptablegeneratoroutputis5ampsgreaterthanthe
accessoryload.Anegative(discharge)readingindicatesthatthe
generatorisnotcapableofsupplyingcurrentneeded.
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GENERATOR DISASSEMBLY
Iftestinghasconfirmedthattherearegeneratorproblems,remove
thegeneratorfromthevehicleafterdisconnectingthenegative
batterycable.Thiswillpreventtheoccurrenceofdamagingshort
circuits.Markthecasewithascratchorwithchalktoensureproper
reassembly.
Continued
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NOTE: Mostgeneratorsofaparticularmanufacturercanbeusedona
varietyofvehicles,whichmayrequirewiringconnectionsplacedin
variouslocations.AChevroletandOldsmobilegeneratormaybeidentical
exceptforpositionoftherearsectioncontainingelectricalconnections.
Thefourthroughboltsthatholdthe
twohalvestogetherareequally
spaced;thereargeneratorhousing
canbeinstalledinoneoffourclock
positionstomatchneedsofvarious
models.
Figure 4140 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 oclock position. Select the 3
oclock, 6 oclock, 9 oclock, or 12 oclock
position to match the unit being replaced.
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TestingtheRotorSlipringsontherotorshouldbesmoothand
round(within0.002inchofperfectlyround).Ifgrooved,theslip
ringscanbemachinedtoprovideasuitablesurfaceforthebrushes.
Iftheslipringsarediscoloredordirty,theycanbecleanedwith400
gritorfineemery(polishing)cloth.Therotormustbeturnedwhile
beingcleanedtopreventflatspotsonthesliprings.
Thefieldcoilcontinuityintherotorcanbecheckedbytouchingone
testleadofa110volt(15wattbulb)testeroneachslipring.Thetest
lightshouldlight.
Amoreaccuratemethodistomeasuretheresistancebetweentheslip
ringsusinganohmmeter.
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Exactspecsforthegenerator
testedshouldbeconsulted
beforecondemningarotor.
Typicalresistancevalues:
GM:2.2to3.5ohms
Ford:3.0to5.5ohms
Chrysler:3.0to6.0ohms
Iftheresistanceisbelowspec,
therotorisshorted.
Iftheresistanceisabovespec,
therotorconnectionsare
corrodedoropen.
Figure 4141
Testing a generator rotor using an ohmmeter.
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TestingtheStatorThestatormustbedisconnectedfromthe
diodes(rectifiers)beforetesting.Becauseallthreewindingsofthe
statorareelectricallyconnected(eitherwyeordelta),apowered
(110or12volt)testlightoranohmmetercanbeusedtochecka
stator.
Thereshouldbelowresistanceatallthreestatorleads(continuity),
andthetestlightshouldlight.Thereshouldnotbecontinuity
(infinityohms,ortestlightshouldnotlight)whenthestatoris
testedbetweenanystatorleadandthemetalstatorcore.
Ifthereiscontinuity,thestatorisgrounded(shorttoground)and
mustberepairedorreplaced.
SeeFigure4142.
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Figure 4142 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.
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Becausetheresistanceisverylowforanormalstator,itisgenerally
notpossibletotestforashorted(coppertocopper)stator.Ashorted
statorwill,however,greatlyreducegeneratoroutput.
IfallgeneratorcomponentstestOKandoutputisstilllow,
substituteaknowngoodstatorandretest.Ifthestatorisblackor
smellsburned,checkvehicleforadischargedordefectivebattery.
Ifbatteryvoltageneverreachesthevoltageregulatorcutoffpoint,
thegeneratorwillbecontinuouslyproducingcurrentinthestator
windings.Thiscontinuouschargingoftenoverheatsthestator.
NOTE: Thecostofareplacementrotormayexceedthecostofanentire
rebuiltgenerator.Becertain,however,thattherebuiltgeneratorisratedat
thesameoutputastheoriginalorhigher.
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Figure 4143 An open in a delta- wound stator cannot be detected using an ohmmeter.
Anohmmetercannotdetectanopen
statorifthestatorisdeltawound.
Theohmmeterwillstillindicate
lowresistancebecauseallthree
windingsareelectrically
connected.
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TestingtheDiodeTrioManygeneratorsareequippedwithadiode
trio.Adiodeisanelectricalonewaycheckvalvepermittingcurrent
toflowinonlyonedirection.
Thediodetrioisconnectedto
allthreestatorwindings.
Currentgeneratedinthestator
flowsthroughthediodetrioto
theinternalvoltageregulator.
Ifoneofthediodesinthetrio
isdefective(usuallyopen),the
generatormayproduceclose
tonormaloutput;however,the
chargeindicatorlightwillbe
ondimly.
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TestingtheRectifierBridge(Diodes)Generatorsareequipped
withsixdiodestoconvertthealternatingcurrent(AC)generatedin
thestatorwindingsintodirectcurrent(DC)forusebythevehicles
batteryandelectricalcomponents.
Thesixdiodesincludethreepositivediodesandthreenegative
diodes(onepositiveandonenegativeforeachwindingofthe
stator).Thesediodescanbeindividualdiodesorgroupedintoa
positiveandanegativerectifierthateachcontainthreediodes.
Allsixdiodescanbecombinedintoonereplaceableunitcalleda
rectifierbridge.
Therectifier(s)(diodes)shouldbetestedusingamultimeterthatis
settodiodecheckorohms.
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Becauseadiode(rectifier)shouldallowcurrenttoflowinonlyone
direction,eachdiodeshouldbetestedtodetermineifthediode
allowscurrentflowinonedirectionandblockscurrentflowinthe
oppositedirection.
Totestmanygeneratordiodes,itmaybenecessarytounsolderthe
statorconnections.Accuratetestingisnotpossibleunlessthediodes
areseparatedelectricallyfromothergeneratorcomponents.
Figure 4145 A GM
rectifier bridge that has
been disassembled to
show the individual
diodes.
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Connecttheleadstotheleadsofthediode(pigtailandhousingofthe
rectifierbridge).Readthemeter.Reversethetestleads.Agooddiode
shouldhavehighresistance(OL)oneway(reversebias)andlow
voltagedrop(0.5to0.7volt)theotherway(forwardbias).
Anohmmeteralsocanbeused.Iftheohmmeterreadslowohms
(lowvoltagedrop)inbothdirections,thediodeisshorted.Ifthe
meterreadshighohms(OL)inbothdirections,thediodeisopen.
Openorshorteddiodesmustbereplaced.Mostgeneratorsgroupor
combineallpositiveandallnegativediodesintheonereplaceable
rectifiercomponent.
GeneralMotorsDelcotrongeneratorsuseareplaceablerectifier
bridgecontainingallsixdiodesinoneunitcombinedwithafinned
heatsink.
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BrushHolderReplacementGeneratorcarbonbrushesoftenlast
formanyyearsandrequirenoscheduledmaintenance.Thelifeof
thegeneratorbrushesisextendedbecausetheyconductonlythe
field(rotor)current,whichisnormallyonly2to5amperes.
Thegeneratorbrushesshouldbeinspectedwheneverthegeneratoris
disassembledandshouldbereplacedwhenworntolessthan1/2
inchinlength.
Generatorbrushesarespringloaded,andifthespringsarecorroded
ordamaged,thebrusheswillnotbeabletokeepconstantcontact
withtheslipringsoftherotor.
Ifthebrushesdonotcontactthesliprings,fieldcurrentcannot
createthemagneticfieldintherotorthatisnecessaryforcurrent
generation.
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Brushesarecommonlypurchasedassembledtogetherinabrush
holder.Afterthebrushesareinstalled(usuallyretainedbytwoor
threescrews)andtherotorisinstalledinthegeneratorhousing,a
brushretainerpincanbepulledoutthroughanaccessholeinthe
rearofthegenerator,allowingthebrushestobepressedagainstthe
slipringsbythebrushsprings
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BearingServiceandReplacementThebearingofagenerator
mustbeabletosupporttherotorandreducefriction.Agenerator
mustbeabletorotateatupto15,000rpmandwithstandtheforces
createdbythedrivebelt.
Thefrontbearingusuallyisaballbearingtypeandtherearisa
smallerrollerbearing.Thefrontbearingislocatedunderaretainer
andpressedintothefrontgeneratorcase.Thepulleymustbe
removedbeforetherotorcanbeseparatedfromthecase.
Somegeneratorpressfitpulleysmustberemovedusingapuller,
whereasFordandGMgeneratorsuseanuttoholdthedrivepulley
totherotor.ThefrontpulleycanberemovedfrommostGM
generatorsbyusinga15/16inchwrenchwhileholdingtherotor
shafttokeepitfromrotatingusinga5/16inchhex(Allen)wrench.
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GENERATOR ASSEMBLY
Aftertestingorservicing,thegeneratorrectifier(s),regulator,stator,
andbrushholdermustbereassembled.Ifthebrushesareinternally
mounted,insertawirethroughtheholesinthebrushholderandin
thegeneratorrearframetoretainthebrushesforreassembly.
Installtherotorandfrontendframeinproperalignmentwiththe
markmadeontheoutsideofthegeneratorhousing.Installthe
throughbolts.Beforeremovingthewirepinholdingthebrushes,
spinthegeneratorpulley.Ifthegeneratorisnoisyornotrotating
freely,thegeneratorcanbedisassembledagaintocheckthecause.
Aftermakingcertainthegeneratorisfreetorotate,removethe
brushholderpinandspinthegeneratoragainbyhand.
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Thenoiselevelmaybeslightlyhigherwiththebrushesreleased
ontothesliprings.
Generatorsshouldbetestedonabenchtester,ifavailable,before
theyarereinstalledonavehicle.Wheninstallingthegeneratoron
thevehicle,becertainthatallmountingboltsandnutsaretight.
Thebatteryterminalshouldbecoveredwithaplasticorrubber
protectivecaptohelppreventaccidentalshortingtoground,which
couldseriouslydamagethegenerator.
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REMANUFACTURED GENERATORS
Remanufacturedorrebuiltgeneratorsaretotallydisassembledand
rebuilt.Eventhoughtherearemanysmallerrebuilderswhomaynot
replaceallwornparts,themajornationalremanufacturerstotally
remanufacturethegenerator.
Oldgenerators(cores)aretotallydisassembledandcleaned.Both
bearingsarereplacedandallcomponentstested.Rotorsare
rewoundtooriginalspecificationsifrequired.Therotorwindings
arerewoundontherotorspool,usingthecorrectgaugecopper
wire,totheweightspecifiedbytheoriginalmanufacturer.
Newslipringsarereplacedasrequiredandsolderedtotherotor
spoolwindingsandmachined.Rotorsarebalancedandmeasured
toensureoutsidediametermeetsspecifications.
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Figure 4147 (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.
(a)
Everygeneratorisassembled
andtestedforproperoutput,
boxed,andshippedtoa
warehouse.
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Individualdiodes(withinthe
rectifiers)arereplacedif
required.
(b)
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Help!
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).
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(cont.)
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(cont.)
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(cont.)
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(cont.)
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SUMMARY
1. Chargingsystemtestingrequiresthebatterybeatleast75%
chargedtobeassuredofaccuratetestresults.Thecharge
indicatorlightshouldbeonwiththeignitionswitchonbut
shouldgooutwhenevertheengineisrunning.Normal
chargingvoltage(at2000engineRPM)is13.5to15.0volts.
2. Ifthesystemisnotchargingproperly,therearbearingofthe
generatorshouldbecheckedformagnetism.Ifitismagnetized,
voltageregulator,brushes,andgeneratorrotorarefunctioning
correctly.Iftherearbearingisnotmagnetized,thevoltage
regulator,generatorbrushes,orrotorisnotfunctioning.Bypass
thevoltageregulatorbysupplyingbatteryvoltagetothefield.
Iftherearbearingisnowmagnetizedandthechargingsystem
outputisnormal;thevoltageregulatorisatfault.
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SUMMARY
(cont.)
3. Tocheckforexcessiveresistanceinthewiringbetween
generatorandbattery,avoltagedroptestshouldbeperformed.
4. Generatorsdonotproducetheirmaximumratedoutputunless
requiredbycircuitdemands.Therefore,totestformaximum
generatoroutput,thebatterymustbeloadedtoforcethe
generatortoproduceitsmaximumoutput.
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SUMMARY
(cont.)
5. Eachgeneratorshouldbemarkedacrossitscasebeforedisassemblyto
ensureproperclockpositionduringreassembly.Afterdisassembly,all
generatorinternalcomponentsshouldbetestedusingacontinuitylight
oranohmmeter.Thefollowingcomponentsshouldbetested:
a.
b.
c.
d.
e.
f.
Stator
Rotor
Diodes
Diodetrio(ifthegeneratorissoequipped)
Bearings
Brushes(shouldbemorethan1/2inchinlength)
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SUMMARY
6.
(cont.)
Electronicvoltageregulatorscanbetestedeitheroffthe
vehicleusingaspecialtesteroronthevehicleusingthefull
fieldbypassprocedure.
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end
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