Alternators & Regulators MOTORCRAFT ALTERNATORS Fiesta DESCRIPTION Alternotor is belt driven from engine, An external regulator controls charging rate by switching rotor field current in. ond ‘out os required through brushes contacting slip rings. Alter nating current is produced and converted to direct current by the diode rectifier casembly, IDENTIFICATION & SPECIFICATIONS Alternator is stomped with "Motorcraft" trademerk in either orange oF green APPLICATION Color Rating Orange Green 40 Amps.@15V 60 Ampsa15V TESTING FUSE LINK Fuse links ore provided in the charging system to prevent domage to the harness and alternator in cose the harness becomes grounded or a booster battery is connected with reverse polarity, Insulation which is rippled or bubbled i dicotes that the link is blown ond must be eeplaced. In case of vehicles with two fuse links, check the accessories link by turn ing headlomps or an accessory an, If fuses are not blown and they sil foil to function, the link is prabably blown and must be replaced. INDICATOR UGHT Wersing light should come an when starting engine and go off atter engine is idling. If no light, check bulb ond replace it burned our. Irbulb is not burned out check for open circuit bet ween switch ond regulator. If light does not go out until engine reaches high RPM, check 15 ohm resistor connected in parallel ‘with light VOLTAGE OUTPUT TEST 1) Attach voltmeter to battery ond record voltage. Stort fengine and increase engine speed to 1500 RPM when normal ‘operating temperature is reached, With NO electrical load on system, voltage should increase to at least} volt but not more than 2 volts above original reading 2) Turn on heater blower motor to high speed and headlights to high beam. Increase engine speed to 2000 RPM ond note bottery voltage ot least 0.5 volt above original reading with engine off 3) If noload voltage in step 1) exceeds 2 volts, ossure that ‘ground connections between regulator, alternator and engine fre fight. Disconnect wiring plug from egulator and recheck novload voltage. If voltmeter now indicotes battery voltage throughout the fest, replace voltage regulotor and recheck 4) tf voltage increase is excessive with regulatar disconnected, repoir shorted wiring horness between allernator ond regulator. = It harness is shorted, regulator will hove been damaged ond must be replaced. 5) I lood voltage in step 2) did not increase or increase was less than 0.5 volt, check battery voltage at alternator “BAT” terminal. Disconnect regulator plug ond check battery voltage of "A" terminal. IF no voltage present at these terminals, repair wicing ond repeat output tes. 6) Il bottery voltage is present at both "BAT" ond "A" ter- minals, connect jumper across "A" ond "F" terminals of Fegulator plug. I field circuit is grounded, jumper will spark fond heot, Check field cirevit for ground ‘end regulator for open belore continuing 7) To check field circuit, measure resistance between °F” ter: ‘minal on regulator plug ond negative battery cable clamp. COhmmeter should read between 4 ohms ond 250 ohms. NO resistance indicotes that the field circut is grounded and re. quires alternator removal and repair 8) Check resistance between "I" and "F” terminals with plug removed. Ohmmeter should indicate zero resistance, A reading ‘of 10 or more ohms indicotes an open connection in the Fegulator. Replace requlator and repair alternatar field circuit 9) It load voltage is sill less thon specified, remove jumper from regulator wiring plug and installa jumper between olter notor "BAT" ond "FLD" terminals. Repeat output tet. IF results are sotistactory, witing harness is at foult_ ond must be repaired or replaced, If load voltage increase is fll ess thon 0.5 volt, alternator must be removed from vehicle for bench testing Jumper Wire Connected to Jalternotor "BAT" ond "FLD" Terminels oQ Regulator with Connector Plug Removed Fig. 1 Alternator with Jumper for Testing ‘ipo 200 Rapa ema CampaAlternators & Regulators 3 19 MOTORCRAFT ALTERNATORS (Cont. OVERHAUL DISASSEMBLY 1) Scribe mark across front and rear housings and stator for clignment during reassembly. Remove through bolls and ‘separate front housing ond rotor from rear housing and stator. 2) Remove terminal nuts and insulators from rear housing ond separate stotor/rectitier assembly from havsing, Remove brushes and brush holder. 3) To remove stacked type rectifier, remove stator terminal ‘crew ond grounded screw by turning them "4 turn to unlock from rectiier. Unsolder leads fram rectifier using caution not 10 overheat rectifier aseembly. To remove flat type rectifier, remove stator terminal screw by pressing straight out of rec fife. Do NOT turn screw or remove grounded screws. Un solder leads from rectifier. 4) Remove front pulley and fon, then separate rotor from housing and bearing, Bearing may be reploced by removing retainer screws ond retainer TESTING 1) Using 12 volt test lamp, check rotor continuity ot slip rings cond absence of ground between slip ring and rotor shaft. With ohmmeter, check for resistance of 4.0 10 4.4 ohms between slip, rings 2) Check resistance of 14 to .16 ohms between stator wires ‘ath chmmeter. Check that windings ore not grounded ond have winding continuity with 12 volt test lamp. 3) Check diodes for continuity (approximately 60 ohms) in one direction only, It na continuity is observed in either direction, diode is open. I continuity is observed in both directions, diode is shorted. Rectifier assembly must be replaced if open or shor ted diodes are found, REASSEMBLY 1) Install bearing and retainer in front housing. Install rotor in housing to stop-ring, then install spacer, fan, pulley and nut with Tock washer. 2) Assemble brush holder with brushes and springs, holding brushes in retracted position by inserting length af wire (paper clip} in holder. Solder leads from stator to rectifier pack and everse disossembly procedure noting thot scribe marks ore cligned. 3) Remove brush retracting wire (paper clip) and seal hole ‘with waterproof cement, Install and test alternator. Rear Bearing Rear Housing Rectitior Assembly Springs Bearing ue Spacer Terminal fea Insulators Radio Suppression Copacitor Stotor Assembly Front Housing Rotor Assembly Front Bearing ah? Front Bearing Fan Spacer Retainer . Fig. 2 Exploded View of Motorcraft Alternator ‘ipo 200 Rapa ema Campa -PO-240Mmem