Generator Motorcraft

1997 Ford Pickup F150
GENERATOR - MOTORCRAFT 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Motorcraft
GENERATOR - MOTORCRAFT
1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Motorcraft
DESCRIPTION
Major components of the Motorcraft integral generator-regulator system with internal fan are: end frames, rotor,
stator, rectifier assembly and electronic voltage regulator mounted on the rear of the generator. These generators
are rated at 75, 95 or 130 amps, depending on application. See Fig. 1 .
NOTE: The terms generator and alternator are interchangeable. Either may be found
within illustrations.
ADJUSTMENTS
BELT TENSION
Inspect condition and tension of generator drive belt prior to performing any on-vehicle charging system tests.
Replace belt and/or repair tensioner mechanism if necessary. Belt tension is okay if belt length indicator is
within limit marks on tensioner. Replace belt and/or tensioner mechanism if necessary.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

INFORMATION.
ON-VEHICLE TESTING
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.
GENERAL INSPECTION
Ensure battery posts and cables are clean and tight. Check drive belt tension. Ensure connections at generator,
regulator and engine ground are clean and tight. Check fuses and fusible links, replace as necessary.
Check condition of battery to see if battery has the ability to accept and hold a charge. If battery capacity meets
requirements, charge battery before proceeding with testing to ensure battery is fully charged.
NO-LOAD TEST
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1. Connect voltmeter positive lead to B+ terminal on generator and negative lead to ground. Start and run
engine at 1500 RPM with no electrical load (foot off brake and doors closed). Read voltmeter when
voltage stabilizes. This may require waiting a few minutes. Voltage should be 13-15 volts.
2. If voltage increases to proper level, proceed to LOAD TEST . If voltage increases beyond proper level,
proceed to OVERCHARGE CONDITION . If there is no voltage increase, proceed to LOW OR NO
CHARGE CONDITION .
Fig. 1: Identifying Generator-Regulator Terminals

Courtesy of FORD MOTOR COMPANY
LOAD TEST
1. Ensure drive belt is in good condition and properly tightened. Connect charging system load tester in
accordance with manufacturer's instructions. Start and run engine at 2000 RPM and apply load until
generator output amperage levels off.
2. Record maximum generator amperage output. See GENERATOR OUTPUT SPECIFICATIONS TABLE
for output values. If generator output is within 20 percent of rated output amperage and voltage remains
12.5-14.5 volts, generator output is okay. If generator does not produce rated output, proceed with
appropriate testing.
GENERATOR OUTPUT SPECIFICATIONS
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Monday, May 11, 2009 6:31:03 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Application Amps Rating

Standard 95
Optional 130
OVERCHARGE CONDITION
1. If voltmeter indicates high voltage (more than 15.4 volts), turn ignition switch to ON position. Connect
negative voltmeter lead to ground. Connect positive voltmeter lead to generator output connection at
starter solenoid. Record voltage.
2. Connect positive voltmeter lead to regulator "A" terminal screw on rear of generator. See Fig. 1 and Fig.
3 . If voltage difference between both locations exceeds 0.25 volt, repair high resistance condition in "A"
circuit wiring.
3. If excessive voltage still exists, check ground connections for both generator and regulator. Tighten
regulator ground screws to 16-24 INCH lbs. (1.8-2.7 N.m.), and recheck output voltage.
4. If excessive voltage still exists, connect voltmeter negative lead to ground. Connect positive voltmeter
lead first to regulator "A" terminal screw, then to "F" terminal screw. Record readings. Different voltages
at each screw head indicates a short in field circuit or a grounded rotor coil. To correct either condition,
replace generator.
5. If same voltage appears at both screw heads, no internal short to ground is indicated. Replace voltage
regulator.
LOW OR NO CHARGE CONDITION
1. Unplug harness connector from regulator at rear of generator. Connect ohmmeter between regulator "A"
and "F" terminal screws. See Fig. 1 and Fig. 3 . If resistance is not greater than 2.4 ohms, a short in field
circuit or a grounded rotor coil is indicated. Replace generator. If resistance is greater than 2.4 ohms, go
to next step.
2. Reconnect regulator wiring plug. Connect negative voltmeter lead to ground. Contact positive voltmeter
lead to regulator "A" terminal screw. If voltmeter does not indicate battery voltage, repair open or high
resistance in "A" circuit wiring. Perform load test after repairs.
3. If battery voltage is indicated at "A" terminal screw, ensure ignition switch is in OFF position. Connect
positive voltmeter lead to regulator "F" terminal screw. If battery voltage is present, go to step 4). If
battery voltage is not present, replace generator.
4. Turn ignition switch to ON position (engine off). With voltmeter negative lead to ground, contact positive
lead of voltmeter to regulator "F" terminal screw. If voltmeter indicates 2 volts or less, go to next step. If
voltage is greater than 2 volts, check circuit between "I" terminal and ignition switch. Repair if necessary.
See "S" & "I" CIRCUIT TEST . If "I" circuit is okay, replace regulator. Perform LOAD TEST after
repair.
5. Start engine and run at 2000 RPM with headlights on. Measure voltage at "B+" terminal of generator and
at generator feed wire at starter relay. If voltage readings differ by more than 0.5 volt, repair high
resistance or open in wire between "B+" terminal and junction near starter relay.
6. If generator still does not charge sufficiently, connect a jumper wire to regulator "F" terminal screw and
ground it to rear housing. If output voltage increases to 13-15 volts, replace regulator. If output voltage
does not increase to at least 13 volts, replace generator.
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"S" & "I" CIRCUIT TEST
1. Unplug regulator 3-wire harness connector. Connect jumper wire from harness "A" terminal to regulator
"A" terminal. See Fig. 1 and Fig. 2 . Connect another jumper wire from regulator "F" terminal screw to
generator housing.
2. With engine idling, connect voltmeter negative lead to battery ground terminal. Connect voltmeter
positive lead first to "S" terminal and then to "I" terminal of regulator harness connector. See Fig. 2 .
Voltage at "S" terminal should be about 7 volts and about 14 vo lts at "I" terminal. If "S" terminal and "I"
voltages are okay, replace voltage regulator. Repeat LOAD TEST. If "S" and "I" circuit voltages are not
as specified, go to next step.
3. If voltage is present at "S" terminal, but not 6-8 volts, replace generator. If no voltage is present at "S"
terminal, disconnect one-wire connector ("S" terminal) on back of generator. See Fig. 1 . Check voltage
at single "S" terminal. If about 7 volts are present repair "S" circuit wiring. If no voltage is present at
single "S" terminal, replace generator.
4. If no voltage is present at "I" terminal, repair indicator light wiring circuit. Restore wiring connections
and repeat LOAD TEST.
Fig. 2: Identifying Regulator Harness Connector Terminals

Courtesy of FORD MOTOR CO.
REMOVAL & INSTALLATION
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.
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GENERATOR
Removal & Installation
Disconnect negative battery cable. Disengage drive belt from pulley. Disconnect wiring from generator.
Remove generator mounting bolts (and mounting bracket if necessary). Remove generator. To install, reverse
removal procedure.
REGULATOR & BRUSH HOLDER
Removal & Installation
1. Remove generator. Remove 4 Torx screws from regulator and separate regulator and brush holder from
generator.
2. Holding regulator in one hand, pry off the cap covering "A" terminal screw head with a screwdriver.
Remove 2 screws attaching regulator to brush holder ("A" and "F" terminal screws). See Fig. 3 . Separate
regulator from brush holder. To install, reverse removal procedure. Tighten screws to 25-35 INCH lbs.
(2.8-4.0 N.m).
Fig. 3: Exploded View Of Voltage Regulator & Brush Holder

Courtesy of FORD MOTOR CO.
OVERHAUL
Overhaul information is not supplied by manufacturer. The only serviceable parts are the integral voltage
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regulator and brush holder. See Fig. 3 .
WIRING DIAGRAMS
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Fig. 4: Charging System Wiring Diagram (F150 & F250 Light Duty)
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Fig. 5: Charging System Wiring Diagram (F250 Heavy-Duty & F350 - Diesel)
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Fig. 6: Charging System Wiring Diagram (F250 Heavy-Duty & F350 - Gasoline)
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Generator Motorcraft

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1997 Ford Pickup F150

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

CAUTION: When battery is disconnected, vehicle computer and memory systems

Fig. 1: Identifying Generator-Regulator Terminals

GENERATOR OUTPUT SPECIFICATIONS

Application Amps Rating

LOW OR NO CHARGE CONDITION

"S" & "I" CIRCUIT TEST

Fig. 2: Identifying Regulator Harness Connector Terminals

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

Removal & Installation

REGULATOR & BRUSH HOLDER

Removal & Installation

Fig. 3: Exploded View Of Voltage Regulator & Brush Holder

regulator and brush holder. See Fig. 3 .

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