Starting elite Milles iit: im System DiagnosisIMPORTANT SAFETY NOTICE Appropriate service mathods and proper repair procedures are essential for the safe, raiabie operation of al motor vehicles, is well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing Service and repair work with tested, effective techniques, Fsowing them wal help assure reliability There are numerous variations in procedures, techniques, foals and parts for servicing vehicles, as well as in the ski ofthe individual doing the work. This manual cannot possibly anticipate all such variahons and provide advice or cautions aso each, ‘Accordingly, anyone who departs fram instructions provided in ths manual must fist establish that he compromises neither bes personal salety nor the vehicle integrty by his choice of mathods, tools or parts ‘As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a ‘specie purpose. NOTES give you added information that wil help you to compiste a paricular procedure, CAUTIONS are ‘gon {9 prevent you fram making an error that could damage the vehicle. WARNINGS remind you to bs ly careful ‘hose areas where carelessness can cause personal injury, The following Est contans some general WARNINGS that you -should follaw when you work on a vehicie * Aways wear salety glasses for eye protection, * To prevent serious bums, avoid contact with hot metal Bing ceay esi viemnet omer eae ri on See en mn TO + Be eure that te ignition swich is aways in the OFF * OONatsmoke while working on the vehicle, ppesition, unless othenvise required by the procedure * Sethe parking brake when working on the vehicle. II you have an automatic transmission, set it in PARK unioss instructed atherwise fora specific service operation. i you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON} unlessinsiructed otherwise far a spetitic service operation * Operate the engine only in a wel-venilated area to avoid * To avakd injury, always remove rings, watches, loose hanging jewoiry, and loose clothing Belore beginning to work on a vehicle. Tie long hair securely behind your head, Keep hands and other objects clear of the radiator fan blades. Electric caging tans can start to operate at any time by an incraase in underhood termperalures, ave though theignition ie in the OFF position. Tharefors, care should be taken to ensure tat the electric cooling ian is ‘completely disconnected when warking under the hood the danger of carbon monoxide. * Koop yoursel! and your clathing away from moving parts when the engine is running, especially the fan and bells, The recommendations and suggestians contained in this manual are made to assist the dealer in improving his dealership parts and ‘or service department operations, These recommendations and suggestions do not supersede or overnde the provisions of the ‘Warranty and Policy Manual or the Service Manual and in any cases where there may be a confi, the provisions of the Warranty and Policy Manual or the Service Manual shall govern, The desripions,hesing procedures, andepecicaionsin his hancock were natect atthe ime ha handhook wasapproved | for printing, Ford Motor Company reserves the night to discontinue models at any time. or change specications, design, or tasting procedures witout notice and without incurring obligation. Any relerence to brand names in this manual is intended ‘merely a an example of the types of tools, lubricants, matenals, etc. recommended for uss. Equivalents il avaiable, may be Used. The righ! 6 reserved to make changes at any time without notice. |WARINING: Many brake linings contain asbestos fibers. When working an brake components, avoid breathing the dust, Breathing the asbestos dus! can cause asbestosis and cancer. Breathing asbestos dust is harm ta your health [Dust and gin present on cat wheel brake and clutch assemblies may contain asbestos srs that are hazardous io yout health when made airbome by cleaning with eompressed air or by dry brushing, "Whoe! brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with ashestas bers. Dust and dint should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHA instructions and the trash haule* notified a5 to the contents af the bag, if a vacuum bag sutable for asbestos is not available, cleaning should be done wet. Iidust generation & stil possible, technicians ‘should wear government approved oxic dust purifying respirators, OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians ‘concerned with paetorming brake or clutch service should be prasent in the area. Produced and Coordinated by ‘William R. Jacoby ‘Technical Training Ford Parts and Service Division Copynght © 1992 Ford Motor Companyee ee Se INTRODUCTION......... SAE J1930 Terminology . Technician’s Objective: LESSON 1: CHARGING SYSTEM DESCRIPTION System Description... System Components Review Questions... LESSON 2: BATTERY DESCRIPTION Introduction... Battery Design z Low Maintenance and Maintenance-Free Batteries . Battery Ratings Safety Precautions . Review Questions... LESSON 3; BATTERY DIAGNOSIS AND TESTING .. Preliminary Inspection Tasting Procedures Battery Charging Review Questions LESSON 4: GENERATOR SAE J1930 Terminology . Generator Operation . Generator Components Generator Circuit Descripti Generator Circuit Operation Review Questions ....... LESSON 5: CHARGING SYSTEM DIAGNOSIS AND TESTING. eat Cree on reliminary Inspection Charging System Chock Generator/Reguiator Tests - Charging Systam Summary Review Questions....... LESSON 6: STARTING SYSTEM Starting System Components , Starter Design Starter Operation .. Starter Drive Engagement Solencid-Actuated Starter Permanent Magnet Starters Review Questions LESSON 7: STARTER DIAGNOSIS AND TESTING .. Preliminary Inspection .. Starter Testing . Review Question: GLOSSARY ..INTRODUCTION “This self-study Comprehensive Training Program (CTP) is designed to give you a basic and thor ‘ough understanding of charging and starting systems in use today. This reference book com- ‘bines component identification, system operation and testing procedures for both charging and starting systems. Review questions at the conclu- sion of each lesson will determine your under- standing of the material, SAE J1930 TERMINOLOGY For the 1993 model year, Ford has extensively revised the list of names for the various terms and components used in automobiles. These changes have been mandated by the Society of Automotive Engineers’ (SAE) list of terms entitled J1930. The terminology used in this list must soon be stan: dardized among all vehicle manufacturers. As a result, the language used to convey automotive Service information will be standardized and less confusing. ‘One change to note in reading this book includes the term GENERATOR in place of ALTERNATOR. This change has been mandated by SAE J1930 and is used consistently thraughout this book Introduction TECHNICIAN'S OBJECTIVES Upon completion of this program, you will be able to: @ Locate and describe the function and opera- tion of charging system components Il Identity the design and construction of typical lead acid battenes. Il List the safe and correct battery testing and charging procedures lm Identify correct diagnosis and testing proce- dures for charging system components @ Locate and describe starting system components 1 identity correct diagnosis and testing prace- ‘dures for starting system components Intro-1LESSON OBJECTIVES LESSON 1: CHARGING SYSTEM DESCRIPTION TECHNICIANS OBJECTIVES Locate and describe the functian and opera- 1 Charging system description tion of charging system components im Charging system component cation and descriptionEER AME melas a SYSTEM DESCRIPTION ‘The two basic {unctians of the charging system are to: § Generate power to operate all the electrical components in the vehicle when the engine is running i Charge the battery Several mechanical and electrical components comprise the charging system. They work together to provide sufficient electricity to the vehicte's electrical system (Figure 1-1), The major charging system components are: lm Battery § Cables and wiring hamess Fuse link I Ignition switch \m Clutch Pedal Position switch 'm Park/Neutral Position switch im Power distribution box (some applications) @ Generator I Drive belt @ Voltage regulator If Indicator lamp (or voltmeter) ‘Some applications also require a starter relay. SYSTEM COMPONENTS Generator ‘The generator produces electricity for the charging system and, as necessary, recharges the battery. Bult into the generator is a rectifier which conwerts the generated current from AC to DC for vehicle use. BATTERY Figure 1-1 Charging System Components Lesson 1CHARGING SYSTEM DESCRIPTION Drive Belt. Driven by the crankshaft, the drive belt tums the rotor shaft in the generator when the engine is. running. To assure proper operation of the genera- tor and charging system, drive belt tension should be checked at regular maintenance intervals, A belt that Is too loose can prevent proper charging. ‘An overtightened belt can result in early compo- nent bearing failure, Voltage Regulator Generator output voltage is controlled by the voltage regulator to prevent overcharging the battery and damage to other electrical compo- nents. The regulator also ensures that the genera- ‘tor will provide sufficient current for the charging system load. ‘Starter Relay (or Power Distribution Box) Starter relays are present in vehicles equipped with field wound starters. Vehicles equipped with permanent magnet starters do not require a starter relay. The starter relay or power distribution box is the point at which power is distributed to tha vehicle's electrical systems. Indicator Lamp (or Voltmeter) Wired between the ignition switch and the voltage regulator is the indicator lamp. er warning lamp (Figure 1-2). With the ignition in the RUN position and befare the engine starts, the lamp wll illumi- nate through lamp proveout (turn on). This indi: cates that the bulb and circuit are operating properly. When the vehicle is started, the lamp automatically goes out Lesson 1 Figure 1-2 Indicator Lamp When a generator malfunction prevents the generator from charging, the indicator lamp illuminates 10 indicate a problem. On vehicles. equipped with the Integral Altemator Regulator (JAR) type generator, unusually high voltage will also trigger the lamp. Some vehicles utilize a volmater with or without an indicator lamp to indicate system charging, ition Sw The ignition switch closes the circuit which sup- plies power to the indicator lamp and excites the generator field. It is generally located in the sieer- ing column Battery The battery supplies pawer to the electrical system when the engine is not running, It also provides power under heavy-load conditions that the generator cannot support alone.eM DAMA) ata ee 8 Fuse Link Charging systems on some vehicles include a fuse link. The fuse link prevents damage to the generator and wiring harness if: lm the wiring hamess should became grounded l@ 2 booster battery is connected to the charging system with the wrang polarity The fuse link is a shor segment of insulated wire within the engine compartment wiring hamess. It burns out to protect the rest of the wiring when an excessively heavy current is fed into the circuit. NOTE: Some vehicles use fuses in place of fuse links. i Cables and Wiring Harness The cables and wiring harness serve to connect all the system components and conduct electricity throughout the vehicle More detailed explanations of charging system ‘components, their functions, operation and testing procedures will appear later in this publication, Lesson feas hom hea M lial Le) REVIEW QUESTIONS 1. What is the function of the rectifier? 2. Which of the following best describes a fuse link? a) A component which connects all vehicle fuses together. bb} A short segment of insulated wire within the engine compartment wiring hamess that bums aut ‘with excessive current to protect the circuit. ¢) Another term for “fuse.” d) A short segment of insulated wire that burns out in the event of low current, 3. List the missing major charging system components. — } Drive belt co) a 8) Ignition switch i 9) Fuse link —————EEE——————Eee ‘What can happen if the generator belt is too tight? Too loose? = ” Which component prevents overcharging the battery and causing damage to other electrical: components? a) Batery ) Fuse link €) Voltage regulator 4) Rectifiera elaedl pea Sree REVIEW ANSWERS 1, The generator produces alternating currant (AC). However, the vehicle electrical systems use direct ‘current (DG), The rectifier converts the AC current produced by the generator to DC for use by the vehicle's electrical system. 6 'b) A fuse link is a short segment of insulated wire within the engine compartment wiring harness that bums out with excessive current. It protects the rest af the circuit, e Fill in the missing major charging system components. a) Generator b) Drive belt ¢) Voltage regulator @) Indicator lamp e) Ignition switch ) Battery —eE @) Fuse link h) Cables and wiring hamess the belt is too tight it can cause premature bearing failure. If the belt is too loose, the battery will lose charge. 5. ¢) The voltage regulator controls generator output voltage to prevent overcharging the battery. a 16 Lesson 1ae) he = 8 eS) LESSON 2: BATTERY DESCRIPTION identify the design and construction of typical ‘ill Battery design description lead acid batteries Safety precautions Lesson 2 Bthe) Ose INTRODUCTION ‘The vehicle's main power source is the battery. ‘The battery supplies electrical eneray during vehicle startup and when accessories are operat- ing with the engine off or idling. It alse compen- sates for generator power shortages when the electrical load is unusually heavy. Whenever servicing a vehicle for an electrical malfunction, the battery should always be checked first ‘The battery is an electrachemical device that converts electrical energy into chemical eneray. This chemical energy is then stored until itis needed. The chemical reaction occurs between two dissimilar conductors (or plates) immersed in an electrolyte ta produce electrical energy. The amount of electrical energy a battery can produce is datermined by the following factors: m the size, weight and active area of the material in the plates @ the quantity of sulturie acid in the electrolyte ‘The battery is said to be in the “discharged” state when all the active materials on the plates have reacted with the electrolyte. The remainder of this section will discuss the design and operation of the battery as well as the related testing, charging and diagnostic proce- dures BATTERY DESIGN The conventional lead-acid storage battery is made up af the following components: Positive plates i Negative plates m Separators Electrolyte mi Container (or case) and cover 1 Intercell connectors Terminals 22 Positive and Megative Plates Providing the foundation for battery plates is the grid, made primarily of lead for low electrical resistance and high canductivity. The function of this structure is to conduct electric current to and from active materials on the positive and negative plates. A conventional battery grid is composed of a lead-antimony alloy. ‘The grid becomes either a negative or pasitive plate when the grid is “pasted” with active maten- als. To form a positive plate, a lead oxide paste is applied to the grid. A negative plate is formed when the grid is pasted and formed into sponge lead. Separators positive and negative plates come into contact with one another, they will quickly short out and lose their potential energy. Thin sheets of nan- conducting, microporous material, or separators, are placed between each plate to prevent this ‘contact (Figure 2-1) PLATE STRAP: PLATE GRID Figure 2-1 Element Construction Lesson 2ES hae The structure obtained by cambining one positive plate group and one negative plate group with separators is called an element (Figure 2-2). plate strap connects the lugs at the top of the positive plates and a second plate connects the negative plates. ‘SEPARATORS ASSEMBLED ELEMENT Figure 2-2 Cell Elements Lesson 2 Battery Case The plate and separator assemblies (or cell elements) and the electrolyte are enclosed in the ‘battery case (Figure 2-3). It is composed of polypropylene, hard rubber or other plastic-like material, Figure 2-3 Battery Case The design of the battery case enables it 10: @ Withstand hot and cold temperature extremes. @ Resist acid absorption @ Rasist vibration caused by mechanical shock Partitions within the battery case separate the individual coll elements, Each cell produces just ‘over twa volts. Thus, six cells make up a twelve- volt battery; a six-volt battery requires three calls. 23SS Intercell Connectors Individual cell elements of the battery are serially linked together by intercell connectors; i.e., the positive strap of ane cell is connected tothe negative strap of the adjacent cell ‘There are three types of intercell connectors: 8 Through-the-partiion connections provide the shortest path between cells and, therefore, the lowest electrical resistance. if Over-the-partitian connectors after slightly increased resistance because they are slightly longer. @ Extemal connecters are the longest and Provide the greatest resistance. Se Figure 2-4 Intercell Connectors ‘These connections are made betore the cover is placed on the battery, providing an acid-tight seal between the cells and assuring minimum voltage loss. Electrolyte ‘The one essential ingredient needed to complete ‘the battery, the electrolyte, consists of a sulfuric acid-water solution. By weight, the ratio is about 35% acid to 65% water. Electricity is produced ‘when an electrical load is connected to the a4 terminals of a charged battery and the acid in the electrolyte reacts with the active materials on the plates. Battery Cover The battery cover is permanently bonded to the case. One piece cavers are used with both through-the-partition and over-the-partition cell connectors. Battery Terminals Battery terminals are the points trom which power is distributed from the battery. The positive termi- nal (+) connects to the red lead, and the negative terminal (-) connects ta the black lead. The three most common types of automotive battery terminals are: Top post terminals, used on most car and truck batteries. i Side terminals, which are positioned in the sidewall of the container near the top edge. ‘These terminals are threaded and require a special bolt to attach the cables. ®@ L-terminals, widely used on specialty batteries and on some import car batteries. Figure 2-5 Common Terminals in addition to post terminals, stud terminals are often used in heavy-duty commercial applications. Lesson 2LOW MAINTENANCE AND MAINTENANCE-FREE BATTERIES ‘Structurally, low maintenance and maintenance- free battenes are similar to most other batteries. They do, however, differ in ways that significantly atfect their performance. @ Maintenance-tree batteries sharply reduce the "gassing" effect found in conventional batter ies. Gassing, the breakdewn of water into hydrogen and oxygen, contributes to water loss. Maintenance-free batteries have a high resistance to avercharge. Maintenance-free and low maintenance battery grids are shawn in Figure 2-6. LOW MAINTENANCE Figure 2-6 Low Maintenance and Mainienance-Free Batiery Grids NA microporous plastic plate separator enve- lope wraps each plate in a maintenance-free battery, cushioning against tha effects ot eyciing and vioration (Figure 2-7). insulation and resistance to shedding of active materials is also provided by this envelope design. @ Maintenance-free batteries are sealed in a ane-piece battery caver because there is no need to add water, Low maintenance and older conventional batteries have cell open- ings to allow for the addition of water. MAINTENANCE-FREE ONE-PIECE BATTERY COVER ELEMENT SEPARATOR ENVELOPES Figure 2-7 Maintanance-Free Battery Assembly Lesson 2 25BATTERY DESCRIPTIO BATTERY RATINGS Several methods are used to refer to the capacity of a battery, or its ability to deliver current. This value is specified on the battery label. Reserve Capacity The battery reserve capacity indicates how long the battery can power the electrical load if the generator fails. Usually capacity is measured in the length of time in minutes that a fully charged battery at 80°F (26.7°C) can deliver 25 amps. Ampere-Hour Capacity Ampere-hour capacity is the amount of current the battery can deliver for 20 hours without the cell voltage dropping below 1.75 volts at 80°F (26.7°C). Cold-Cranking Rate The cold-cranking rate indicates the ability of the battery to crank the engine at low temperatures. Batteries are cold-crank rated in two ways: 1 The number of amperes a battery can deliver for 30 seconds at 0°F (-17.8°C) without cell voltage falling below 1.2 volts, The number of amperes a battery can deliver for 30 seconds at -20°F (-28.9°C). The final voltage is allowed to drop one volt per cell SAFETY PRECAUTIONS When handling and servicing automotive batteries, itis extremely important that you abserve all safety precautions. ‘Sulfuric acid, the active ingredient in electrolyte, is ‘a very powerful acid capable of destroying paint finishes and corroding common metals. 26 Electrolyte is shipped in containers specifically designed to handle acid. Always store electrolyte in thase containers. Use the special non-metallic filer containers when filling batteries. Always wear Ford approved splash-proat goagles when servicing batteries or handling electrolyte. ‘Should electrolyte be spilled on the body, IMMEDI. ATELY take the following appropriate action(s): '@ External contact: Flush with large quantities of water. I Internal contact: Drink large quantities of water oF milk, followed with mitk of magnesia, beaten egg or vegetable oil. Eyes: Flush with water for 15 minutes and ‘seek immediate medical attention. Call a physician IMMEDIATELY. During battery charging, highly explosive hydrogen gas is emitted. When charging batteries, observe the following precautions; 1 Protect eyes from batteries at all times by wearing Ford-approved safety goggles. 1 Work only in a well-ventilated area. 1 Do not expase the battery to sparks, flames or lighted cigarettes. § Never remove vent caps (il present) while charging IB Make sure that charging equipment is tuned off before connecting or disconnecting cable clamps. These precautions should also be observed when jump-starting a vehicle. Lesson 2Lesson 2 az=a) el REVIEW QUESTIONS 1 2E The electrolyte in a car or truck battery consists primanily of: a) Sulfuric acid and water b) Hydrochioric acid and water ¢) Calcium particles suspended in an alkaline solution . Define the term gassing. . True or False Maintenance-(ree batterias have cell openings to allow for the addition of water. . Which method is not used to refer to a battery's capacity? a) Ampere-hour b) Watt-hour ¢) Cald-cranking rate d) Capacity . Label the battery element assembly components below. Lesson 2yah Meet 6. Abatiery with less cold-cranking amps will most likely: 2) Output less voltage than required b) Overcharge all af the time c) Run down with extended cold-cranking Which af the following is nat a safaty precaution necessary when charging the battery? a) Wear protective safety goggles b) Work in enclosed, unventilated areas c) Never remove vent caps when charging ) Tum off charging equipment prior te connecting or disconnecting equipment 2) Work in ventilated areas ~FN Sy) eel ade REVIEW ANSWERS: . a) The electrolyte in automotive batteries consists primarily of sulfuric acid and water. 2. Battery gassing is the breakdown of a battery's water inta its component elements: hydrogen and oxygen. 3. False. Only conventional and some low maintenance batteries have cell openings. Maintenance-iree batteries are sealed. |. b) Battery capacity is nat referenced in watt-hours. = ©sePanators 6. c) With reduced cold-cranking amps, the battery will most likely run down with extended cold- cranking. 7. b) When charging a battery, never work in an enclosed, unventitated area. 210 Lesson 2LESSON OBJECTIVES LESSON 3: BATTERY DIAGNOSIS AND TESTING List the safe and correct battery testing and Preliminary inspection ‘charging procedures im Battery testing procedures Wm Battery charging procedures Lesson 3 a1=} eee Oks teme th ML Be) ideally, the battery should be inspected and tested whenever a vehicle undergoes routine mainte- nance. There is, however, no recommended schedule for battery service. This section provides an overview of diagnostic and testing procedures. Detailed procedures can be found in the appropri- ate vehicle Service Manual. PRELIMINARY INSPECTION To save lime, energy and needless cost, prelimi nary checks should be made betore battery testing. Otten a malfunction can be determined by ‘observing the physical condition of the battery. ‘The following visual inspections should be made before testing: im Check the battery date code to ensure that the battery has nat exceeded its service life IM Inspect the battery case and cover (Figure 3-1) for cracks or buckling. These conditions: could result from hold-down attachments that are either too tight or too loose, exposure to extreme heat in the engine compartment or freezing of the electrolyte. Acid deposits on the battery cover may indicate leakage, spill-over of gassing due to a high charging rate, 1§ Inspect the cable clamps far excessive coro: sion deposits, acid erosion or loase battery post connections. Any of these conditions could result in voltage loss through the cables. i Check for secure ground connections at the engine and body, Also check for proper con- nections at the genarator and voltage regula- tor, a2 FRAYEO CABLE Loose Figure 3-1 Battery Case I Make sure that the battery terminals are not broken or loose. These connections should also be clean and tree of deposits. In addition, check the external surface and the battery posts for signs of abuse such as hammer- ing or improper cable removal. These can often provide clues to battery malfunctions. If the discharged battery is relatively new, test for current drain, The follawing are some of the most ‘commen current drain problems. — Glove compartment lamp stays on indeti- nitely after door closed. — Hood lamp stays an constantly — License piate lamp of interior lamp stays an constantly. LessonTESTING PROCEDURES: Battery tests determine the battery's state of charge and its capacity to crank an engine. The purpase of these tests is ta show whether the: battery is good, needs recharging or must be replaced, The cause af a battery malfunction is not always obvious. The testing procedures that follow will help you to pinpoint the source af the concem. Refer to the appropriate vehicle Service Manual for more detailed procedures. Testing Instruments Several devices are used to test and diagnose automotive batteries. They include the valt- ohmmeter Rotunda Tool Number 105-00051, test lamp and Rotunda Starting and Charging Tester (VAT-40), Rotunda Too! Number 078-00005. The volt-ohmmeter (Figure 3-2} has several applications, including: Determining battery condition and state of charge DIGITAL VOLT-OHMMETER '105-00081 Figure 3-2 Digital Volt-Chmmeter Lesson 3 1 Testing battery cables Testing electrical systems for shorts and drains The volt-ohmmeter can be used to check the state of charge for conventional, low maintenance and maintenance-free batteries. The test values cited in this text are referenced to Ford Rotunda volt- ‘ohmmeters. Use of a different tester may result in different values. Figure 3-3 Test Lamp A test lamp (Figure 3-3) is used to detect currant Grain from the battery. consists of a small lamp connected between twa leads, Current flowing between the connections will cause the lamp to light. aSeee ela eR The Starting and Charging Tester (VAT-40) the tests described in this text, we will use the (Figure 3-4) is a multi-purpose lester used totest ‘Rotunda Starting and Charging tester (VAT-40), the battery's capacity to start the engine. For Rotunda Tool Number 078-0005. Figure 3-4 Rotunda Starting and Charging Tester (VAT-40) ad Lesson3ees eA ed ee ee NOTE: Ifthe reading on your volt-ohmmeter is The open circuit voltage test is used to indicate the a negative (-) sign, the battery has reversed battery's state of charge. polarity and must be replaced, or you have: 1. ifthe battery has just been recharged or has Connected the meter incorrectly. been in service, the present surface charge must be removed betore accurate voltage Go ete pt tu ae measurements can be made, If in service, ae . turn on the high beams for ten seconds, turn 4. To determine the battery's specific gravity or the headlights off, Then let the vehicle stand siale of charge, use the battery state of fortwo minutes, charge chant (Figure 2-6). 2, With the engine and all accessories off, dis- connect the negative battery cable. Touch the volt-ohmmeter's fixed probe to the nega- tive (-) terminal and the volt-ohmmeter's red lead to the positive battery (+) terminal, Then read the woltage (Figure 3-5). Figure 2-6 Battery State of Charge Chart Follow the voltage up the linear curve to determine the state of charge or specific gravity. 5. Ifthe volt-ohmmeter gives no reading at all, make sure you have connected it properly. Figure 3-5 Open Circuit Voltage (OCV) Test Check the meter and leads on a good bat- tery. If the connections are proper and you still have no reading, charge the battery to an OGV greater than 12.5 volts before cantinu- ing to test the battery. Lesson 3 35Ye aaa meee] 8 hs] ees OL == Battery Drain Test With Clamp-On DOC Ammeter Battery drain testing can determine if there is a ‘drain on the battery that may cause it to discharge. This type of test can be done using a clamp-cn DG ammeter or a volt-ohmmeter, INOTE: OCV must be greater than 11.5 volts to pertorm the following tests. 4. Turn the ignition to the OFF position and make sure there are no electrical loads. After determining that the underhood lamp is tuming aff properly when the hood is closed, disconnect the bulb. Clamp the meter clip securely around the positive or ground battery cable (all cables if two or more lead to post). NOTE: Do not start the vehicle with the clip on. the cable, = p The current reading (current drain) should be less than 0.05 amp. If it exceeds 0.05, it indicates a constant current drain which could cause a dis- charged battery. Possible sources of current drain a6 problems are vehicle lamps (underhood, glove compartment, luggage compartment, etc.) that do not shut off properly. If the drain is not caused by a vehicle lamp, remove the fuses, one at a time, until the cause of the drain is located. Battery Drain Test With Volt-Ohmmeter Using a volt-ohmmeter for the battery drain test will render specific values, By establishing a. number of different drain values, it may be easier to determine the cause of the drain. This test requires a volt-ohmmeter with an appro- priate low-voltage scale. The meter must read within .01 millivolts. You will also need a shunt assembly. Lon aie very small normal caused by “always-on” electronic systems such as anti-theft, llumi- nated entry, etc. These drains are so small they cause no problem when functioning normally. Lesson 3EPA ee The steps for this test are outlined below: - Tum the ignition to OFF and make sure there are no electrical loads, After determining that the underhood lamp is shutting off property when the hood is closed, disconnect the bulb, Check the battery voltage. If voltage is under 11.5 volts, charge the battery to above 11.5 volts. Disconnect the negative battery cable, Connect the shunt assembly as shown in Figure 3-7. p Pe CAUTION: Do not crank the engine. It could destroy the shunt. Also do not use the shunt to measure starting currents. 5. Set the volt-ohmmeter to 200 or 300 millivolt (my) scale for an accurate reading. It must be within 0.01 millivolts. 6, Connect the meter leads to the shunt, With this size shunt (50 my = 50 amps) and meter, a direct current drain measurement can be made, ‘The current reading should be less than 0.05 amp. It the reading is between 0.2 and 0.6, a possible source is a vehicle lamp (glove compartment, underhood, luggage compartment, etc.) that does ‘not tur off, If the problem is not a lamp, remove the fuses from the fuse panel, one at a time, until the cause of the drain is located NEGATIVE BATTERY TERMINAL ja. GAUGE Wine (anu SHUNT ASSEMBLY (Sa My = 50 AMP) VOLTAGE ppp (AMP DRAIN} ‘TEST POINTS. Figure 3-7 Battery Drain Test With Voltmeter and Shunt Lesson 3 a7BATTERY DIAGNOSIS AND TESTING To Test Vehicles With Major Key-Off Loads Such as Air Suspension or Load Leveling Vehicles equipped with these features will have temporary current drains that may last up to 70 ‘minutes after the ignition is switched OFF. These drains can range from 0.1 to 20 amps if the cam- pressor is cycling. This action can offen mask a problem and must be considered when evaluating test results. To test for this kind of drain 1. Follow Steps 1 through 5 of the Battery Drain Test With Volt-Ohmmeter. 2. Turn the ignition to RUN fora moment and then OFF again. 3. Disconnect the major key-off circuits. 4. Make sure illuminated entry is off, if appli- cable: The drain should be less than 0.05 amp. If itis higher, disconnect the fuses as in the previous test to locate the problem circuit If the drain is less than 0.05 amp, reconnect the major key-otf load circufts, turn ignition ON and then OFF, and wait 70 minutes to make sure they shut off properly. If current drain is stil greater than 0.05 amp after 70 minutes, disconnect each of the components, one at a time, until the source of the drain is located. To Check for Electronic Drains Which ‘Shut Off When the Battery Cable is Disconnected 1. Follow Steps 1 through 5 of the Battery Drain Test With Volt-Ohmmeter. 2, Without starting the engine, turn the ignition ‘switch to RUN for a moment and then OFF. If applicable, wait one minute for the illuminated entry lights to shut off 3. Connect the volt-chmmeter and read the voltage, 38 The current reading (current drain) should be less than 0.05 amp. If it exceeds 0.05 after a few minutes, and if this drain did not show in previous tasts, the drain is most likely caused by a malfunc- tioning electronic component. As in previous tests, remove fuses one at a time, to locate the problem circuit. Hydrometer Test The hydrometer measures the specific gravity at the battery. The hydrometer, Rotunda Tool Number 0271-00046, is a bulb-lype syringe which, when squeezed and released, draws electrolyte from a battery cell. A float with a graduated specific gravity scale is housed inside the barrel of the hydrometer, ‘The float covers an approximate specific gravity range from 1.100 to 1.300. (This rating is based an ‘the relative weight of equal volumes of water and ‘electrolyte. Pure water has a rating of 1.000.) ‘Specific gravity varies bath with chemical compo- sition and with temperature, As temperature rises, specific gravity decreases and vice versa. There- fore, most hydrometers combine the basic hy- drometer and a thermometer to provide a tem- perature corrected reading. Lesson 3EVES ey ME Oi eB To perform the hydrometer test: 7. Read the specific gravity directly on the float scale where it intersects the lower surface of 1. Raise the hood and put a fender cover in the loctnotyte in tha leyckomerer beara 8. Record the specific gravity reading, Read the eee correction at the side of the thermometer . Make sure the electrolyte level is high column and add this value to, or subtract it enough to withdraw the proper amaunt of from, the indicated float reading to obtain a acid into the hydrometer barrel. Take no temperature-corrected reading. Reefer to the readings immediately after adding water, table in Figure 3-9 for the state of charge Water must be thoroughly mixed with the indicated by the hydrometer reading. underlying electrolyte, by charging, betore hydrometer readings are reliable. 4. Insert the hydrameter pick-up tube into a cell with the bulb squeezed tightly by thumb pressure (Figure 3-8), HYDROMETER Figura 3-8 Specific Gravity and State of Charge 8, Repeat Steps 3 through 8 for each cell in the batlery. Hf the gravity readings for the individual cells are 1.235 or higher, the state of charge is OK. Perform a Load Test. Hone ar more cells have a gravity reading below Figure 3-8 Testing Specitic Gravity With a Hydrometer 4,235, but with less than 50 points dilerence between the cells, charge the battery for 20 5. Slowly release thumb pressure until the bulb minutes at 95 amperes; then conduct a Load Test is fully expanded and the float is suspended if there is a 50-point variation between any cells, freely in the barrel. Always hold the barrel replace the battery. (An example of a 50-point vertically to prevent the float from binding or Tistion would be il the highest reading i 1,200 Sticking fo the sides. and the lowest is 1.150. 1.200-1.150 = 50 points.) = With the hydrometer at eye level, read the float scale at the electrolyte level, (Hydro- meter floats are calibrated at 80°F.)BATTERY DIAGNOSIS AND TESTING (Capacity Test (Load Test) ‘The capacity test determines if the battery is capable of meeting the demands required to start ‘the engine, The steps for this test are outlined below: ‘To complete this test, use the Starting and Charg- ing Tester (VAT-40). 1. Be sure the oad control knob on the \VAT-40 is in the OFF position. 2, Attach the tester's positive lead to the positive (+) battery terminal and negative lead to the negative (-) battery terminal (Figure 3-10) STARTING AND CHARGING TESTER (VAT-40) Figure 3-10 Load Test 3, Turn the load contro! knob clockwise until the amperage reading is one-half of the “cold- cranking amps.” This value is specified on the battery label 310 H cold-cranking amperage data is not avail able, the general rule is: tester load may be: added until an amperage reading equal to three times that of the ampere:hour rating af the battery is reached, See chart in Figure 3-11 Figure 3-11 Ampere-Hours/Ampere Readings 4. Maintain the specified load for 15 seconds. The voltage reading should be above 9.6 volts. The reading may be somewhat lower if the ambient temperature is less than 21°C (70°F). Thus, a battery with an adequate ‘capacity to crank and start an engine may have voltage readings as listed in the chart in Figure 3:12. 2.06 (TOF) 15.5°C (60°F) 10.0°G (60°F) 3.0°G (40°F) -1.0°C (30°F) -6.6°C (20°F) “12.0°C (10°F) A7.8°C (OF) Figure 3-12 Temperature/ VolagerCranking Capacity If the battery does nat reach the minimum pre- scribed voltage, charge it for 25 minutes at 35 amperes. Then, repeat the test. If it still does not come up to minimum voltage specifications, replace the battery, Lesson 3Sa AOE eral me Be tea Le) For batteries with removable vents: If the voltage reading is less than the voltage listed in the chart, replace the battery. It the voltage reading equals or exceeds the voltage listed in the chan in Figure 3-12, charge the battery, if necessary, and retum it to service, BATTERY CHARGING ‘When the battery state of charge has been largely ‘exhausted by discharging the battery, the battery may be recharged. This is done by passing an electric current through the battery from positive to negative instead of from negative to positive as in discharging. The charging process reverses the chemical action and restores the electrolyte to its state before discharge. Charging methods and types of chargers vary widely, Whichever method and equipment is used, charging must be done carefully to achieve proper results and avoid damage to batteries and pos- sible personal injury. Before recharging a discharged battery, inspect and service the following conditions, if they exist @ Loose generator belt | Pinched or grounded ganeratorivoltage regu- lator wiring harness i Loose harness connections at the generator andior voltage regulator @ Loose or corraded connections at battery, starter relay andior engine ground Excessive battery drain ‘The three basic battery charging concepts are: 1 Slow charging @ Fast charging Constant potential charging Lesson 3 in simplest terms, slow charging involves a low ‘current applied over a long period of time. Fast charging is the oppasite — high current over a relatively short period of time, If a fast charge is prolonged — longer than 2 hours or so — serious damage to the battery may result. The amount of charge a battery requires depends on the battery size and its initial state of charge. For example, a battery with a reserve capacity of 120 minutes will require twice the amount af charge as one with 60 minutes reserve capacity; and a completely discharged battery will require twice the amount of charge as one which is half charged. A cold battery (below 40°F) will not readily accept a charge, When a fast charger is connected to a cold battery, the charging rate will be low at fiest, ‘and then increase as the battery temperature increases. Do not attempt to charge a frozen battery. Allow it to warm to approximately 60°F betare starting the charge. ‘A battery which is in a highly discharged state (OCY below 12.5) may be slow to accept a charge at first and in some cases may not accept a charge at the normal charger setting. Batteries in this condition can be charged with the use of the ead battery switch on chargers so equipped. Batteries may be charged by any af the following methods: Slow Charging The slow charge method offers two important advantages: i Its the preferred method to restare a battery to full charge. Since the charging current is relatively low, the chances of overcharge damage are minimized. Slow charging should be dane at a rate equal to ane percent of the cald-crank rating of the battery being charged (about 3 1 5 amperes, depending on battery size). Charging should not stop until the battery is fully charged. The average charging time is 12 to 16 hours, but could be as much as 24 hours or more.EF V SSN NE Oral BY Fast Charging Fast charging is designed to bring a battery's state of charge, within a short period of tima, up to a level that will enable the battery to perform its critical function: cranking the engine, Fast charg- ing, however, cannot bring a battery up to full charge, so it must be followed by a period af slow charge. This latter requirement is normally met by the vehicle's charging system, Since excessive fast-rate charging can damage a battery, charging time must be carefully controlled. Fast charging equipment can vary wadely in design and operation. Thus, it is important to strictly follow: the charger manufacturer's operating instructions. Generally speaking, a “boast” charge at 30 amps fora 12 volt battery (or 60 amps for a 6 volt bat- tery) for up to 30 minutes is most common. If the battery was deeply discharged to begin with and further fast charaing is required, the rate should be reduced to 20 amps for a 12 volt battery (40 amps for a 6 volt battery) and continued for up to one and one half hours more. Fast charging beyond two hours sharply increases the risk of battery damage, so transferring to a slow-rate charger is recommended, ‘The recommended method of fast charging is to use the “Automatic” setting on chargers so equipped. This setting maintains the charging rate ‘within safe limits by automatically adjusting the ‘voltage and current which prevents excessive gassing and spewing of electrolyte. Another advantage of this method is that it is not necessary to know the electrical size af the battery nor its state of charge since the battery will accept only the amount of charge required. The charging time ‘will depend on the battery size and state of charge. Completely discharged automotive size batteries will require approximately 2 to 4 hours to recharge to a serviceable state. Constant Potential Charging ‘Constant potential chargers start the charge off at a high rate, As the battery voltage builds up, the charge rate tapers off to a lower value, depending ‘on the design of the charger and on the condition, age and temperature of the battery: A battery in ‘900d condition is not harmed by this type of charging. A badly sulfated battery, however, may not come up fo full charge in a normal way on this ‘type of charger. ‘Reserve Capacity Rating ‘80 orLess | 81-125 | 126-180 | 181 Above 250 Charging Rate (Amperes) 510 2 | 510 20| 510 20| 5.10 20| 5 10 20 Open Circuit Charging Time in Hours. Voltage" 12.25 = 12.40 1,200 ~ 1.225 a2 6314/8 42/10 5 24/14 7 3 12.05 - 12.24 1.170 - 1.200 631%/842 263/16 8 4 2 & 11.90 = 12.04 1.145 =1.170 B42 |12 63 16 8 4/2211 Se) 15 7 ‘Less than 11.90 Less than 1.145 10 5 24|14 7 34/2010 5 | 2814 7 319 8 Figure 3-13 Charging Alte and Time Table B12 Lesson 3Sse) The table in Figure 3-13 shaws the approximate charging times and rates required to recharge batteries in various states of charge to a service- able state. Higher charging rates than those shown can be used as lang as electrolyte spewing ‘does not occur or the battery does not feel exces- sively hot (aver 125°F). if spewing occurs or the battery feels excessively hot. the charge rate must bbe reduced to a level at which the spewing will ‘stop. This is particularly tue for maintenance-free batteries where excessive gassing will result in non-replaceable loss of electrolyte and thus shorten battary life. in general, the higher the charge rate, the more closely the battery must be ‘watched while being charged. The rates and times shown in the table will not fully charge the battery ut will recharge it to a state of charge at which point a properly operating vehicle charging system ‘will charge the battery up to the normal operating level. peried of time (aver ane month). Under these ‘conditions the battery may show no indication of accepting a charge aven with the use of a dead battery switch. The initial charging rate accepted by batteries in this condition may be s0 low that the ammeter on certain chargers ‘will nat show any indication of charge for five joten minutes. A method of determining whether a battery is accepting a charge is as follows: Follow the charger manutacturer's instructions. ‘or use of the dead battery switch if necessary. If the dead battery switch is the spring loaded ‘type, It should be held in the ON position for up to three minutes. After releasing the dead ‘battery switch and with the charger still on, ‘measure the batiery voltage. If it shows 12 ‘volts or higher, the battery is accapting a charge and is capable of being recharged. ‘However, it may require up io 30 minutes, particularly with cold batteries (below 40°F), before the charge rate is high anough to show ‘on the charger ammeter. Lasson 3 Charging a Single Battery NOTE: Aconventional or low maintenance battery must first be filled with electrolyte before charging. Figure 3-14 Battery Charging To charge the battary, follow these procedures: 1, Measure the battery's state of charge. 2, Connect the battery to the charger — positive to positive and negative to negative. Be careful not to reverse the polarity. , Plug the charger into the power source. ‘Adjust the charger for the desired rate. If the charger is not the constant potential type, see the Charging Flate and Time Table for the proper charging duration. 5, Check periodically for spewing, excessive gassing and high temperature (over 125°F). If any of these conditions are present, reduce the rate or stop the charging temporarily. 6, Unplug the charger and disconnect the leads when the charging operation is complete, aeMultiple Battery Charging In addition to charging batteries individually, it is ‘common practice to charge more than one battery ‘on the same charger. Depending on the type ot charger used, either a series or parallel connection ‘will work for muttiple charging. A series connection (Figure 3-15) is made when the positive terminal of one battery is connected to the negative terminal of the next battery in the total charging hook-up. With this type of connection, each battery receives the full current output of the charger. The quantity of batteries which can be charged in series depends upon the voltage rating of the charger. Batteries with various capacity ratings may be charged simultaneously in a series, ‘connection, but the charging and the rate of charge must not exceed that specified for the unit with the lowest capacity. Figure 3-15 Series Connections for Multiple Charging Batteries charged in parallel connection will have all the positive terminals connected to each other in sequence (Figure 3-16). Similarly, the negative terminals will be connected to each other in sequence. a4 Figure 3-16 Parallel Connections for Multiple Charging With a parallel connection, there are two things in particular to remember: All batteries in the charging circuit must be of the same capacity (i.¢., all 12 volt or all 6 volt). IB The output of the charger will be divided among all batteries in the eircult, In theory, this division would mean that charge is distributed equally to each battery. Actually, factors such as each battery's rating and its state of charge when it is introduced into the circuit will govern the distribution of the charge. As with series connections, the charger voltage rating determines the number af batteries that can be handled in a parallel connection. LessonTNE a Oe elim Oa MM REVIEW QUESTIONS 1. Can a vol-ohmmeter be used to test battery output amperage? 2. Ahydrometer is used 10 test the electrolyte’s specific gravity. On what type of battery is this test not applicable? 3. What is the advantage of slow charging as opposed to fast charging? 4. Which of the following illustrates. parallel connections for battery charging? BATTERY. Lesson 3 FEBATTERY DIAGNOSIS AND TESTING 5. When performing a battery drain test with a volt-ohmmeter, which battery cable must be disconnected? 6. Which of the following pieces of equipment is required to perform a capacity test (Load Test)? a) Volt-ohmmeter b) Test lamp ) VAT-40 d) Inductive tachidwell meterLesson 3 a7SPV eS Sh Mee) else) STING REVIEW ANSWERS 1 a 3. No. An ammeter must be used to test amperage. Electrolyte specific gravity testing using a hydrometer is not possible on maintenance-free batteries, Maintenance-free batteries are completely sealed and allow no access to the electrolyte. Slow charging minimizes the chance of overcharging because the charging current is retatively low. a) When parallel charging, all positive terminals are connected in sequence. All negative terminals, are also connected in sequence 5. When performing a battery drain test with a volt-ohmmeter, disconnect the negative battery cable. 6. c) Topertarm a capacily test (Load Test), be sure to use the VAT-40. a8 Lesson 3ee) he =e eal LESSON 4: GENERATOR TECHNICIAN'S OBJECTIV eS LE . Locate and describe the function and opera- § Generator operation description tion of generator components § Generator component location and operation description Lessan 4 44er Sel SAE J1930 TERMINOLOGY For the 1993 model year, Ford has extensively revised the list of names for the various terms and components used in automobiles. These changes have been mandated by the Society of Automotive Engineers’ (SAE) list of terms entitled J1930, The terminalogy used In this list must saon be stan- dardized among all vehicle manufacturers. As a result, the language used to convey automotive service information will be standardized and less confusing. ‘One change to nate in reading this book includes the term GENERATOR in place of ALTERNATOR. This change has been mandated by SAE J1930 and is used consistently throughout this book. GENERATOR OPERATION ‘The generator converts mechanical energy trom the engine into electrical energy. It is the vehicle's source of electricity when the engine is running and it maintains the battery's proper state of charge. All generators operate on the principle that a magnetic field moving past a conductor will cause the conductor to generate electricity 42 ‘The generator is belt-driven fram the engine. It ‘supplies field current to the rotating field through ‘the brushes and slip rings, The rotating magnetic field cuts across the conductor windings (the stator) and generates current. When the engine is started, the generator pro- duces power in the form af alternating current. This current is then rectified to direct current by built-in diodes in the recttier. Field current is automatically adjusted by the voltage regulator to maintain generator output voltage within specified limits. ‘There are three different types of generators: I Intagral Alternator Regulator (IAR) — External Fan Type integral Altemator Regulator (IAR) — Inemal Fan Type W Integral Altemator Regulator (IAR) — Internal Fan and Regulator Type ‘A fuse link is included in the charging system wiring on most vehicles. The fuse link is used to prevent damage to the wiring hamess and genera- tor ifthe wiring hamess should became grounded, or if a booster battery with the wrong polarity is connectad to the charging system. Lesson 4FAN BATTERY TERMINAL REGULATOR TERMINAL BATTERY TERMINAL IAR - EXTERNAL FAN JAR — INTERNAL FAN BATTERY TERMINAL IAR INTERNAL FAN AND REGULATOR Figure 4-1 Generator Types Lesson 4 4ea eel GENERATOR COMPONENTS ‘The construction of the rotor creates the magnetic “The ftiain ‘corrcionente ot the pengialarare the lines of force which surround it. Two si-fingered rotor, stator, recttien brushes, volage regulator —-—_«éle Pieces (Figure 42) fi around a fla winding and housing. and provide alternating north and sauth poles, Current alternates as the pole fields pass across Rotor the conductors in the stator windings, Two slip “The magnetic flek! that rotates within the stator rings, pressed onto the end of the ratar shaft, winding is called the rotor. To maximize the folate and rub against the carbon brushes. to magnetic force, a very small clearance (approxi- conduct current to the rotor. mately 0.005 inch) is required between the rotar and the stator. Voltage is produced as the rotor spins and the magnetic lines of force around it cut the stator windings. sup RINGS: Aeietewy ROTOR COIL SSSEMBLY F ‘SHAFT NonTH SAINGERS" ROTOR HALVES WITH MAGNETIC POLES. UT Figure 4-2 Fiotor Assembly ad Lesson 4GENERATOR ‘Stator Current is produced in the stator windings as the magnetic field (rotor) tums inside the stator (Figure 4-3), The stator is made of three phases of conductor windings wound in slots around a core. ‘The voltage generated in each winding is determined by: Im Field current in the rotor windings '@ Rotational speed of the rotor inside the stator 1 Wire in the stator windings — both the wire gauge and the number of tums per sla! Figure 4-4 Rectifier Assembly Brush Assembly ‘Two carbon brushes in the generator rub against the copper slip rings at the end of rator to conduct electric current to the rotor, It is imperative to maintain constant contact between the brush and sip ring. This is accomplished by spring pressure against the brushes. See Figure 4-5. Figure 4-3 Stator Rectifier ‘The generator has a built-in rectifier. Diades in the Tectiier convert altemating current inta direct current. Haif of the diodes are negative, the other half positive. The diode acts as an electronic “check valve,” Figure 4-5 Brush Assembly allowing the alternating current of the stator ta flow only in one direction. Thus, the current is “rectified” to direct current to power the vehicle's electrical systems, Lesson 4 45GENERATOR Generator Housing The two end housing portions of the generator Support the rotor shaft with mounted front and rear bearings. Voltage Regulator A voltage regulator (Figure 4-6) controls the generator's output voltage by maditying the generator field voltage to meet system demands The regulator increases generator current output to recharge the battery when battery voltage is low and electrical accessory load is high. This means that the regulator wil permit accessory operation under a heavy electrical load with lttie drain on the battery, In this case, most of the current will come cirectly from the generator. Generator current output is reduced when the battery is fully charged and the acoessary load is low. ACTERMINAL ‘SCREW (UNDER, INSULATOR) Figure 4-6 Integral Vattage Regulator ‘The Integral Akemnator/Regulators (IARs) are mounted at the rear of the generator hausing. is position makes It easier to test and replace on most vehicles, ee oe canoe, generator, but are designed into the generator 46 GENERATOR CIRCUIT DESCRIPTION The following is a description of the circuits and ‘connections designed for IAR-type generators. (8+ Output ‘The B+ output connection supplies the generator ‘output to the battery and the electrical system. Circuit The [-circuit (ignition circuit) is used to turn on the voltage regulator. This circuit is powered when the ignition ig turned to the RUN pasitian. This circuit is also used to turn the charging indicator lamp on if there is a fault in the system or wiring circuit A-circuit ‘The A-circuit (battery sense circuit) is used to sense battery voltage. The regulator uses this voltage to determine the generator output, This circuit also supplies power to the generator field coll, The circuit is connected back to the load distribution point and is a protected circuit, SCircuit: NOTE: The S-circuit is internal and nat ser- \iceable on IAF-type generators with internal fan and regulators. The S-circuit (stator circuit) is used to feed a voltage signal from the generator to the regulator. This voltage, typically ‘/e battery voltage, is used by the regulator to turn off the charging indicator lamp. (Figure 4-7) NOTE: On some applications with 2-pin gre akin ei L-circuit corresponds to the |-circuit on the ae Lesson 4INTEGRAL REGULATOR IAR TYPE GENERATOR — INTERNAL FAM AND ‘REGULATOR (2-PIN) TYPICAL Figure 4-7 Terminal Designations — Typical GENERATOR CIRCUIT OPERATION With the ignition key in the RUN position, voltage is applied through the charge indicator lamp. |-circuit to the voltage regulator. This turns the voltage regulator on, allowing current to flow from the battery sense A-circuit to the generator field coil. When the engine starts the generator pro- duces allerating (AC) current. This current is then converted to direct (DC) current by the rectifier assembly inside the generator. This current then powers the vehiicie’s electrical system through the output connector B+ located on the rear of the generator. Once the generator begins producing current, a voltage signal from the stator feeds back to the voltage regulator S-circuit, tuming off the charge indicator lamp. Lesson 4 With the system functioning normally, the genera- tor output current is determined by the voltage of the A-circuit (battery sense voltage). The regulator then compares the A-circuit voltage to its internal set voltage. It then controls the generator field ‘current to maintain proper generator output. The set voltage will vary with temperature and is. typically higher in the winter than in the summer, This allows for better battery recharge in the winter and reduces the chanoe of avercharging in the summer.48 Lesson 4el Sa IR REVIEW QUESTIONS 1. What Is the function of the carbon brushes in a generator? 2. What is meant by the term “IAR-type generator?” 3. List the three factors that determine tha voltage generatad in the stator winding, 4. Label the rotor assembly components on the illustration, se Lesson 4 49eS Se REVIEW ANSWERS 1. The carbon brushes conduct electric current to the rotor through the two copper slip rings tocated at each end of the rotor. 2. Integral Alternator Rlagulator type generator, This simply means that the voltage regulator is mounted to the generator housing, Previous generator designs used extemal voltage regulators. 3. The three factors that determine voltage generated in each stator winding are: — Field current in the rotor windings — Rotational speed of the rotor inside the stator — Wire in the stator windings (gauge and number of turns) ® SUP RINGS: 410 Lesson 4ete een ert LESSON 5: CHARGING SYSTEM DIAGNOSIS AND TESTING Ba ee eam el Se) CONTENT: 1H identify correct diagnosis and testing proce- § Safety precautions for diagnosis and testing dures for charging system components § Preliminary inspections @ Charging system checks § Generator/Regulaior tests Lesson 5 54eRe ema M ame O ral ewe Ota Ay The first component to check when the vehicle's if the battery has been tested and found ta have a electrical system is not working properly is the full charge, check tha wiring (Figure 5-1) and battery. I a relatively new battery is dead or low in connections in the charging system. If these charge, check first for an excessive drain caused conditions are satistactory, check the voltage by a light that was not tumed off or some other regulator and then the generator. electronic component or wiring problem. These common conditions can cause the battery to discharge continuously. Figure 5-1 Wiring Diagram IAR— Internal Fan-Type Generator 52 Lesson §