ELECTRICAL Charging - Service Information - Ram Pickup

2014 RAM 3500 HD Laramie
2014 ELECTRICAL Charging - Service Information - Ram Pickup
2014 ELECTRICAL
Charging - Service Information - Ram Pickup
DESCRIPTION
DESCRIPTION
The charging system consists of:
Generator
Electronic Voltage Regulator (EVR) circuitry within the Powertrain Control Module (PCM).
Ignition switch
Battery (refer to BATTERY SYSTEM - SERVICE INFORMATION - 2500 HD & 3500 HD for
information)
Battery temperature sensor
Check Gauges Lamp (if equipped)
Voltmeter (refer to INSTRUMENT PANEL for information)
Wiring harness and connections (refer to SYSTEM WIRING DIAGRAMS for information)
OPERATION
OPERATION
Fig. 1: Charging System

Courtesy of CHRYSLER GROUP, LLC
1 - PCM
2 - PDC
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18:59:20 Page 1
3 - Battery
4 - Generator
5 - Feed Back Circuit B+
6 - Control Circuit
7 - Battery Sense
The charging system is turned on and off with the Powertrain Control Module (PCM) and ignition switch with
engine running. The field circuit will not be energized until engine is running and ignition switch on. This
voltage is connected through the PCM and supplied to one of the generator field terminals (Gen. Source B+) at
the back of the generator. The generator is internally grounded. The generator regulates the field using pin-1 of
the field connector (high side driver).
The generator is driven by the engine through a serpentine belt and pulley, or a decoupler pulley arrangement.
The PCM receives a voltage input from the generator (5) and also a battery voltage input (7) from the Power
Distribution Center (PDC), it then compares the voltages to the desired voltage programed in the Electronic
Voltage Regulator (EVR) software, and, if there is a difference it sends a signal to the generator EVR circuit to
increase or decrease output. It uses a Pulse Width Modulation (PWM) to send signals to the generator circuitry
to control the amount of output from the generator. The amount of DC current produced by the generator is
controlled by the EVR circuitry contained within the PCM (1).
All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including EVR
circuitry, are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The
PCM will store a DTC in electronic memory for certain failures it detects.
The Check Gauges Lamp (if equipped) monitors: charging system voltage, engine coolant temperature and
engine oil pressure. If an extreme condition is indicated, the lamp will be illuminated. This is done as reminder
to check the three gauges. The lamp is located on the instrument panel.
Voltage is monitored at the B+ terminal stud to insure it is connected. If the B+ cable is loose, the PCM will
shut down generator field. Because of this new feature, pin-2 of the field connector is internally connected to
the B+ terminal.
DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - CHARGING SYSTEM
The following procedures may be used to diagnose the charging system if:
the check gauges lamp (if equipped) is illuminated with the engine running
the voltmeter (if equipped) does not register properly
an undercharged or overcharged battery condition occurs.
Remember that an undercharged battery is often caused by:
Thursday, November 16, 2017 18:59:20 Page 2

accessories being left on with the engine not running

a faulty or improperly adjusted switch that allows a lamp to stay on for Ignition-Off Draw Test. Refer to
BATTERY, STANDARD PROCEDURE .
INSPECTION
The PCM (Powertrain Control Module) monitors the critical input and output circuits of the charging system,
making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output circuit
monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are checked
continuously, and some are checked only under certain conditions.
Refer to DTC INDEX - 2500 HD & 3500 HD in; Powertrain Control Module for more DTC information.
To perform a complete test of the charging system, use a diagnostic scan tool. Perform the following
inspections before attaching the scan tool.
1. Inspect the battery condition. Refer to INSPECTION .

2. Inspect the condition of battery cable terminals, battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight. Repair as required.
3. Inspect all fuses in both the fuseblock and the Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and tight. Repair or replace as required.
4. Inspect the generator mounting bolts for tightness. Replace or tighten the bolts if required for torque
specifications. Refer to SPECIFICATIONS.
5. Inspect the generator drive belt condition and tension. Tighten or replace the belt as required. Refer to
ACCESSORY DRIVE .
6. Inspect the automatic belt tensioner (if equipped).
7. Inspect the generator electrical connections at generator field, battery output, and ground terminal (if
equipped). Also check the generator ground wire connection at the engine (if equipped). They should all
be clean and tight. Repair as required.
SPECIFICATIONS
GENERATOR RATINGS
TYPE RATED SAE AMPS ENGINES

DENSO 160 3.7L / 4.7L / 5.7L
DENSO 160 6.7L Diesel
DENSO 180 6.7L Diesel
TORQUE - GENERATOR / CHARGING SYSTEM
DESCRIPTION N.m Ft. Lbs. In. Lbs.

Generator Mounting Bolts 50 36 -

Generator B+ Output Cable 12 9 125

Terminal Nut
Generator B+ Cable Nut 6.7L
15 - 133
Diesel Engine
Generator Bolts 6.7L Diesel
48 35 -
Engine
GENERATOR
DESCRIPTION
DESCRIPTION
The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete
assembly. If the generator fails for any reason, the entire assembly must be replaced.
OPERATION
OPERATION
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into
the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the
current needed to energize the rotor.
The stator winding connections deliver the induced alternating current to 3 or 6 positive and 3 or 6 negative
diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system
through the generator battery terminal.
Although the generators appear the same externally, different generators with different output ratings are used
on this vehicle. Be certain that the replacement generator has the same output rating and part number as the
original unit. Refer to GENERATOR for amperage ratings and part numbers.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective
drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive
pulley or a defective stator or diode.
REMOVAL
5.7L

Fig. 2: Remove/Install Generator

WARNING: Disconnect the negative cable from the battery before removing the
battery output wire (B+ wire) from the generator. Failure to do so can
result in injury or damage to the electrical system.
1. Disconnect the negative battery cable.

2. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
3. Unsnap the plastic insulator cap from the B+ output terminal.
4. Remove the B+ terminal mounting nut at the rear of the generator (1). Disconnect the terminal from the
generator.
5. Disconnect the field wire connector at the rear of generator by pushing on the connector tab.
6. Remove the two generator mounting bolts (2).
7. Remove the generator from the vehicle.
6.4L

Fig. 3: Generator - 6.4L

1. Disconnect and isolate the negative battery cable.

2. Remove the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL .
3. Unsnap the plastic insulator cap (5) from the B+ output terminal.
4. Remove the B+ terminal mounting nut (2) at the rear of the generator. Disconnect the terminal from the
generator.
5. Disconnect the field wire connector (6) at the rear of the generator by pushing on the connector tab.

Fig. 4: Generator, Bolts & Connector

6. Remove the mounting bolts (3).

7. Remove the generator (1) from vehicle.
6.4L - DUAL
Fig. 5: Removing/Installing Belt

1. Disconnect and isolate the negative battery cable.

2. Remove the secondary accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .


3. If required, remove the secondary generator wiring harness (3) from the intake manifold.
4. Partially raise the vehicle.
5. Remove the right front wheel.
6. Remove the inner splash shield.
Fig. 7: Generator, Insulator Cap, B+ Output Terminal & Connector

7. Unsnap the plastic insulator cap (4) from the B+ output terminal (2).
8. Remove the B+ terminal mounting nut (3) at the rear of the generator. Disconnect the terminal from the
generator.
9. Disconnect the field wire connector (1) at the rear of the generator by pushing on the connector tab.


10. Remove the front mounting bolts (2).

11. Remove the side mount bolt (4).
Fig. 9: Generator & Heater Hose

12. Using care, remove the generator (1) past the heater hose (2).
13. Remove the generator (3) from vehicle.
6.7L DIESEL

Fig. 10: Installing Field Wire Connector

WARNING: Disconnect both negative cables from both batteries before removing
battery output wire (B+ wire) from generator. Failure to do so can result in
injury or damage to electrical system.
1. Disconnect both negative battery cables.

2. Remove the serpentine drive belt. Refer to BELT, SERPENTINE, REMOVAL .
3. Disconnect field wire connector (3) from the generator.

Fig. 11: Removing Generator B+ Cable & Nut

4. Unsnap plastic insulator cap (1) from B+ output terminal.

5. Remove nut (2) and the B+ cable (1) from generator.
Fig. 12: Removing Generator & Bolts

6. Remove bolts (2) and the generator (1) from engine.
6.7L DIESEL-DUAL
WARNING: Disconnect both negative cables from both batteries before removing
battery output wire (B+ wire) from generator. Failure to do so can result in
injury or damage to electrical system.
1. Disconnect both negative battery cables.

2. Remove engine oil dipstick.
3. Remove fasteners and the engine cover.
4. Remove the serpentine drive belt. Refer to BELT, SERPENTINE, REMOVAL .
5. Partially drain the cooling system. Refer to STANDARD PROCEDURE .
6. Disconnect the upper radiator hose at the radiator.
7. Remove bolt and the upper radiator hose support bracket.
8. Disconnect field wire connector (3) from the generator.
9. Unsnap plastic insulator cap (1) from B+ output terminal.
10. Remove nut (2) and the B+ cable (1) from generator.
Fig. 13: Removing Generator & Bolt

11. Remove bolts (2) and the generator (1) from engine.

Fig. 14: Removing Lower Generator Mounting Bracket Bolts

12. If necessary, remove the lower generator mounting bracket bolts (1).
Fig. 15: Removing Generator Mounting Bracket & Bolt


13. If necessary, remove bolts (1) and the generator mounting bracket (2).
INSTALLATION
5.7L
Fig. 16: Remove/Install Generator

1. Position the generator (2) to the engine and install the two mounting bolts (2). Tighten to 50 N.m (36 ft.
lbs.).
2. Snap the field wire connector into the rear of the generator.
3. Install the B+ terminal eyelet to the generator output stud. Tighten mounting nut to 12 N.m (8.8 ft. lbs.).
CAUTION: Never force a belt over a pulley rim using a screwdriver. The
synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt must be
routed correctly. The water pump may be rotating in the wrong
direction if the belt is installed incorrectly, causing the engine to
overheat. Refer to belt routing label in engine compartment, or refer
to ACCESSORY DRIVE .
4. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .

5. Connect the negative battery cable.
6.4L

Fig. 17: Generator, Bolts & Connector

1. Position the generator (1) to the engine.

2. Install the mounting bolts (3). Torque the bolts to 50 N.m (37 ft. lbs.).

3. Snap the field wire connector (6) into the rear of the generator.
4. Install the B+ terminal eyelet (1) to the generator output stud.
Tighten the mounting nut (2) to 12 N.m (106 in. lbs.).

5. Install the serpentine belt. Refer to BELT, SERPENTINE, INSTALLATION .

6. Install the negative battery cable.
6.4L - DUAL

1. Position the generator (3) to the engine.

2. Hand start the upper side bolt (4).
3. Install the mounting bolts (3). Torque the bolts to 50 N.m (37 ft. lbs.).
4. Torque the upper side bolt to 50 N.m (37 ft. lbs.).


5. Snap the field wire connector (1) into the rear of the generator.
6. Install the B+ terminal eyelet (2) to the generator output stud.
Tighten the mounting nut (3) to 12 N.m (106 in. lbs.).
Fig. 21: Removing/Installing Belt

7. Install the secondary generator accessory drive belt (3). Refer to BELT, SERPENTINE,
INSTALLATION .
8. Install the inner splash shield.
9. Install the right front wheel.

10. Lower the vehicle.

11. If removed, install the secondary generator wiring harness (3) to the intake manifold.
12. Install the negative battery cable.
6.7L DIESEL

Fig. 23: Removing Generator & Bolts

1. Install the generator (1). Tighten bolts (2) to 48 N.m (35 ft. lbs.).
Fig. 24: Removing Generator B+ Cable & Nut


2. Install B+ terminal eyelet to generator output stud. Tighten nut to 15 N.m (133 in. lbs.).
3. Snap the plastic insulator cap (1) onto B+ output terminal.
Fig. 25: Installing Field Wire Connector

4. Connect the field wire connector (1) into the generator.

5. Install the serpentine drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
Install both negative battery cables.
6.7L DIESEL-DUAL

Fig. 26: Removing Generator Mounting Bracket & Bolt

1. If removed, install the generator mounting bracket (2). Tighten bolts (1) 60 N.m (44 ft. lbs.).
Fig. 27: Removing Lower Generator Mounting Bracket Bolts


2. If removed, install the lower generator mounting bracket bolts (1) and tighten to 33 N.m (24 ft. lbs.).
Fig. 28: Removing Generator & Bolt

3. Install the generator (1). Tighten bolts (2) to 65 N.m (48 ft. lbs.).
4. Install B+ terminal eyelet to generator output stud. Tighten nut to 15 N.m (133 in. lbs.).
5. Snap the plastic insulator cap (1) onto B+ output terminal.
6. Connect the field wire connector (1) into the generator.
7. Install the upper radiator hose support bracket. Tighten bolt to 15 N.m (133 in. lbs.).
8. Connect the upper radiator hose at the radiator.
9. Fill the cooling system. Refer to STANDARD PROCEDURE .
10. Install the serpentine drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
11. Install the engine cover and fasteners.

12. Install the engine oil dipstick.

13. Install both negative battery cables.
REGULATOR, VOLTAGE
DESCRIPTION
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit
located within the PCM (Powertrain Control Module). The EVR is not serviced separately. If replacement is
necessary, the PCM must be replaced.
OPERATION
OPERATION
The amount of direct current produced by the generator is controlled by EVR circuitry contained within the
PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground.
Voltage is regulated by cycling the battery positive path to control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and battery temperature (refer to SENSOR, INTELLIGENT
BATTERY (IBS) for more information). It then determines a target charging voltage. If sensed battery voltage
is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is
0.5 volts above target voltage. A circuit in the PCM cycles the battery positive (high side) of the generator field
up to 400 times per second (400Hz), but has the capability to ground the field control wire 100% of the time
(full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25%
is used by the PCM in order to have some generator output for additional information. Refer to OPERATION.

ELECTRICAL Charging - Service Information - Ram Pickup

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2014 RAM 3500 HD Laramie

2014 ELECTRICAL Charging - Service Information - Ram Pickup

Charging - Service Information - Ram Pickup

The charging system consists of:

Fig. 1: Charging System

Thursday, November 16, 2017 18:59:23

DIAGNOSIS AND TESTING

Remember that an undercharged battery is often caused by:

Thursday, November 16, 2017 18:59:20 Page 2

accessories being left on with the engine not running

1. Inspect the battery condition. Refer to INSPECTION .

TYPE RATED SAE AMPS ENGINES

TORQUE - GENERATOR / CHARGING SYSTEM

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Thursday, November 16, 2017 18:59:20 Page 3

Generator B+ Output Cable 12 9 125

Thursday, November 16, 2017 18:59:20 Page 4

Fig. 2: Remove/Install Generator

1. Disconnect the negative battery cable.

Thursday, November 16, 2017 18:59:20 Page 5

Fig. 3: Generator - 6.4L

1. Disconnect and isolate the negative battery cable.

Thursday, November 16, 2017 18:59:20 Page 6

Fig. 4: Generator, Bolts & Connector

6. Remove the mounting bolts (3).

Fig. 5: Removing/Installing Belt

1. Disconnect and isolate the negative battery cable.

Thursday, November 16, 2017 18:59:20 Page 7

Fig. 6: Generator - 6.4L

Fig. 7: Generator, Insulator Cap, B+ Output Terminal & Connector

Thursday, November 16, 2017 18:59:20 Page 8

Fig. 8: Generator, Insulator Cap, B+ Output Terminal & Connector

10. Remove the front mounting bolts (2).

Fig. 9: Generator & Heater Hose

Thursday, November 16, 2017 18:59:20 Page 9

Fig. 10: Installing Field Wire Connector

1. Disconnect both negative battery cables.

Thursday, November 16, 2017 18:59:20 Page 10

Fig. 11: Removing Generator B+ Cable & Nut

4. Unsnap plastic insulator cap (1) from B+ output terminal.

Fig. 12: Removing Generator & Bolts

Thursday, November 16, 2017 18:59:20 Page 11

Courtesy of CHRYSLER GROUP, LLC

6. Remove bolts (2) and the generator (1) from engine.

1. Disconnect both negative battery cables.

Fig. 13: Removing Generator & Bolt

Thursday, November 16, 2017 18:59:20 Page 12

Fig. 14: Removing Lower Generator Mounting Bracket Bolts

Fig. 15: Removing Generator Mounting Bracket & Bolt

Thursday, November 16, 2017 18:59:20 Page 13

Fig. 16: Remove/Install Generator

4. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .

Thursday, November 16, 2017 18:59:20 Page 14

Fig. 17: Generator, Bolts & Connector

1. Position the generator (1) to the engine.

Fig. 18: Generator - 6.4L

Tighten the mounting nut (2) to 12 N.m (106 in. lbs.).

Thursday, November 16, 2017 18:59:20 Page 15

synthetic fiber of the belt can be damaged.

5. Install the serpentine belt. Refer to BELT, SERPENTINE, INSTALLATION .

Fig. 19: Generator, Insulator Cap, B+ Output Terminal & Connector

1. Position the generator (3) to the engine.

Thursday, November 16, 2017 18:59:20 Page 16

Fig. 20: Generator, Insulator Cap, B+ Output Terminal & Connector