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AT 121 Chapter 13a – Charging Systems Name: _________________________________ Group: _________________________ Date: __________________________________ Symptom Chart Condition Charging system malfunction (high or low system voltage) Dead battery or battery will not stay charged Charging system warning indicator malfunctioning (light on with engine running, light off with key on engine off, light on with key off) Generator is noisy Radio interference Possible Sources A circuit fuse link. B+ circuit fuse links. Generator. PCM/Regulator Loose/Damaged Drive Belt Defective Generator. Defective Battery. B+ Circuit. High key-off load. (Parasitic Drain) Loose, corroded terminal(s). Charging system warning indicator bulb. Instrument cluster. Generator. PCM/Regulator Loose bolts/brackets. Drive belt. Generator Bearings Generator. Wiring/routing - poor grounds In-vehicle entertainment system. Tools you will need: Given Vehicle ARBST Tester Amp Probe SECTION 1 Inspect Accessory Drive Belt Condition and Tension. Incorrect belt tension will cause undercharging. A loose belt will slip and squeal. An over tightened belt will cause will cause bearing damage. An oily belt will slip, but be quiet. Misaligned drive belts will cause fraying and constantly be “thrown off”. Is there oil on the belt? _________________________ (Yes/No) Drive the belt show signs of chunking? ________________ (Yes/No) Are the pulleys in alignment? ______________________ (Yes/No) Is the accessory drive belt OK? __________________ (Yes/No) SECTION 2 Check Generator Connections Poor generator connections will cause high resistance in the B+ circuit. This will cause a voltage drop. Are the generator connections (B+, Ground, and Regulator Connections) clean and tight? __________________ (Yes/No) Be sure to properly torque all fittings on the alternator! A loose fitting will arc, causing high heat and possible fire! NEVER run a vehicle with a poorly grounded alternator. Severe voltage spikes may occur and damage electronic components. 1 SECTION 3 Charging System Voltage With the engine running, monitor the voltage at the battery. Is the battery voltage between 13 and 15 volts? __________ (Yes/No) What is the battery voltage? ____________________ When finished have the instructor sign off on your work. _____________________________________ SECTION 4 Voltage Drop Tests Output Circuit – Insulated (Power) Side Place one end of the meter at the B+ terminal of the alternator. Place the other end of the meter at the (+) terminal of the battery. Run the vehicle with no loads at 2000 rpm The voltage drop should be less than 0.5 volts. The voltage drop is _______________________ If the voltage drop were greater than 0.5 volts this would indicate high resistance in the B+ circuit of the alternator. A corroded wire or terminal end could be the cause. Output Circuit – Ground Side Place one end of the meter at the case of the alternator. Place the other end of the meter at the (-) terminal of the battery. Run the vehicle with no loads at 2000 rpm The voltage drop should be less than 0.2 volts. The voltage drop is _______________________ If the voltage drop were greater than 0.2 volts this would indicate high resistance in the ground circuit of the alternator. A corroded wire or terminal end could be the cause as well as a poor engine ground or loose alternator mount. SECTION 5 Checking for Diode Ripple (AC voltage) (no, not THAT Ripple!) Checking Ripple Voltage Ripple voltage or (AC voltage) can be measured by switching the DVOM to AC and connecting the black lead to a good ground and the red lead to the B+ on the back of the alternator. A good alternator should measure less than .5 VAC with the engine running. A higher reading indicates damaged alternator diodes. Voltage A/C __________________ Pass/Fail? _________________________ 2 Q At what RPM should the voltage drop tests be done at? __________________________ A voltage drop of more than ____________________ indicates high resistance in the B+ circuit. A voltage drop of more than ____________________ indicates high resistance in the ground circuit. When checking for AC diode ripple, if the AC voltage is more than _______________ volts ___________ the diodes in the alternator may have failed. What will be the end result of an over tightened belt? _______________________________________ What would cause the belt to slip, even if it were tight? _______________________________________ When would one hear a loose alternator belt? _____________________________________________ Name 5 things that would cause a generator to undercharge: ___________________________________________________________________________________________________ ___________________________________________________________________________________________________ When finished have the instructor sign off on your work. _____________________________________ SECTION 6 Alternator Load Testing Tools you will need: 2001 Honda Accord (70 amp Alternator) ARBST Tester Amp Probe Following the procedure demonstrated to you by the instructor test the alternator using the ARBST tester. ARBST Tester Results; Volts _____________________ Amps ______________________ Diodes ___________________ Leaving the ARBST tester hooked up. With the engine running, turn the A/C on, the blower motor on high speed, rear defroster on, and the headlamps on high beam. Increase the engine speed to approximately 2,000-rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. The total amps should be close to the maximum of the alternator total output. Fact is this test can be done with any inductive amp meter. Volts _____________________ Amps ______________________ If voltage were low – the next step would be to full field the alternator. Full Fielding the Alternator WARNING! DO NOT FULL FIELD ALTERNATOR FOR MORE THAN 10 SECONDS AT A TIME! Ground the “F” terminal Results - Volts _____________________ This test bypasses the regulator and sends full field voltage and current to the rotor assembly. Voltage should be about 17-18 volts. If not a damaged rotor or stator is possible. If voltage DOES go up, but falls back to a voltage lower than 13 volts – the regulator is bad. 3 SECTION 7 Generator Removal and Installation Alternator Removal: Jetta 2.0 BBW Gasoline Engine 1 - Tensioner 2 - Bracket 3 - Hex socket bolts M10 x 45mm - 45 Nm 4 - Screws 5 – D Terminal - Nut M8 – 3Nm 6 – B+ Terminal - Nut M8 – 3Nm 7 - Screw 8 - Voltage Regulator (VR) Removing and installing. Refer to Voltage Regulator (VR), removing and installing Checking carbon brushes. Refer to Generator (GEN) carbon brushes, checking 9 - Protective cap 10 - Generator (GEN) 11 - Ribbed belt 12 - Hex bolts M8 x 85mm - 25 Nm 13 - Hex bolts M8 x 45mm - 25 Nm Ribbed belt routing 1 - Tensioning roller 2 - Pulley - generator (GEN) 3 - Pulley - a/c compressor 4 - Ribbed belt - generator, a/c compressor, power steering pump and crankshaft/vibration damper 5 - Pulley - power steering pump 6 - Pulley - crankshaft/vibration damper CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction. Check ribbed belt. Always replace ribbed belt if found to be damaged. This will avoid related failures or operating problems. Mark direction of rotation of ribbed belt if it is to be reused. 1 - Loosen ribbed belt by turning tensioner in direction of -arrow-. 2 - Block Tensioner With Pin, Lock, or Punch 3 - Remove ribbed belt. 4 - Remove Alternator. 4 Once the alternator has been reinstalled on the vehicle. Verify its operation using the Midtronics tester: Install the Midtronics tester to the battery. Select Automotive Charging System Test. Once the test is started, follow the prompts: 1. Rev the engine. 2. Turn on high beams headlights and the blower fan. 3. Rev engine with loads on. 4. Idle engine and turn off loads. 5. The Charging System decision is displayed at the end of the procedure. Test Results? _________________________________________________________ Using the following diagram, indicate where and how you would test for a B+ voltage drop test, and a groundside voltage drop test SECTION 8 Testing for radio interference Tune the radio to a station where the interference is present (640 AM) Is the interference present with the generator regulator (D wire) disconnected? ________________ (Yes/No) If the noise goes away a new generator is needed due to a bad diode assembly or damaged stator or rotor. If the noise is still present it may be an ignition system malfunction or a poor ground on the audio system 5 Proper Charging Voltage would be; A. B. C. D. 12.5 – 13.6 V 13.5 – 15.5 V 14.5 – 16 V 15.5 – 17.2 V The drive belt must be; A. B. C. D. The Stationary Component is the; A. B. C. D. Slip Rings Rotor Fan Stator The Moving Component is the; A. B. C. D. Regulator Rotor Brushes Stator Current is sent into the _____________ from the regulator; this can increase or decrease the output of the _______________ A. B. C. D. Bearings, Case Stator, Brushes Rotor, Stator Stator, Rotor The _________ allows contact between the rotor and the regular and battery; A. B. C. D. Bearings Case Mount Brushes Stator The pulley must: A. B. C. D. Have the correct number of grooves Be loose Be not aligned with the other accessory drive units Be press fit Have the correct number of grooves Very tight so it does not slip Very loose so as not to damage the bearings in the alternator Oily so it slides nicely over the pulley grooves Diodes A. B. C. D. Convert DC into AC Convert AC into DC Do not get hot Do not exist in the alternator The ___________ monitors battery voltage A. B. C. D. Rotor Stator Regulator Brushes Voltage regulators can be controlled by; A. B. C. D. The PCM A transistor A relay All of the above A screeching sound is heard right after startup; A. B. C. D. The alternator belt is too tight The alternator belt has oil on it The alternator belt is too loose The alternator bearings are bad The charge lamp A. B. C. D. Will be on when the vehicle is at KOEO Will be on when the vehicle is at KOER Will be on when the vehicle is overcharging Will be on when the vehicle is off The charge lamp does not operate, what is the most likely cause? A. B. C. D. Grounded bulb circuit in regulator Loose belt Burned out bulb Over charged battery 6