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Practice Assignment on Charging Systems | AT 121, Lab Reports of Automobile Engineering

Community College of PhiladelphiaAutomobile Engineering
Prof. Daniel J. Reed

Material Type: Lab; Professor: Reed; Class: Auto Elec & Elec Sys; Subject: Automotive Technology; University: Community College of Philadelphia; Term: Unknown 1989;

Typology: Lab Reports

Pre 2010

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AT 121 Chapter 13a – Charging Systems
Name: _________________________________ Group: _________________________
Date: __________________________________
Symptom Chart
Condition Possible Sources
Charging system malfunction (high or low
system voltage)
A circuit fuse link.
B+ circuit fuse links.
Generator.
PCM/Regulator
Loose/Damaged Drive Belt
Dead battery or battery will not stay charged
Defective Generator.
Defective Battery.
B+ Circuit.
High key-off load. (Parasitic Drain)
Loose, corroded terminal(s).
Charging system warning indicator
malfunctioning (light on with engine running,
light off with key on engine off, light on with key
off)
Charging system warning indicator bulb.
Instrument cluster.
Generator.
PCM/Regulator
Generator is noisy
Loose bolts/brackets.
Drive belt.
Generator Bearings
Radio interference
Generator.
Wiring/routing - poor grounds
In-vehicle entertainment system.
Tools you will need:
2001 Honda Accord or 1997 Acura 2.2 CL - Alternator Specifications – 80 Amps at 2000 RPM – 70 Deg F.
Factory Shop Manual
Straight Edge
DVOM
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”.
Tension Spec? _____________________________
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)
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Partial preview of the text

Download Practice Assignment on Charging Systems | AT 121 and more Lab Reports Automobile Engineering in PDF only on Docsity!

AT 121 Chapter 13a – Charging Systems Name: _________________________________ Group: _________________________ Date: __________________________________

 Symptom Chart

Condition Possible Sources Charging system malfunction (high or low system voltage)  A circuit fuse link.  B+ circuit fuse links.  Generator.  PCM/Regulator  Loose/Damaged Drive Belt Dead battery or battery will not stay charged  Defective Generator.  Defective Battery.  B+ Circuit.  High key-off load. (Parasitic Drain)  Loose, corroded terminal(s). Charging system warning indicator malfunctioning (light on with engine running, light off with key on engine off, light on with key off)  Charging system warning indicator bulb.  Instrument cluster.  Generator.  PCM/Regulator Generator is noisy  Loose bolts/brackets.  Drive belt.  Generator Bearings Radio interference  Generator.  Wiring/routing - poor grounds  In-vehicle entertainment system. Tools you will need: 2001 Honda Accord or 1997 Acura 2.2 CL - Alternator Specifications – 80 Amps at 2000 RPM – 70 Deg F. Factory Shop Manual Straight Edge DVOM 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”.  Tension Spec? _____________________________  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)

 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? _________________________

Tools you will need: Tool Board 1996 Ford Thunderbird or 1991 Lincoln Towncar Snap-On Alternator Tester Removal  Disconnect battery ground cable.  Remove engine appearance cover.  Remove generator bracket bolts.  Disconnect voltage regulator wiring and output cable from generator.  Remove serpentine belt from generator pulley.  Remove remaining bolts from generator and remove generator. Item Description 1 Generator Mounting Bracket Bolt (4 Req'd) 2 Generator Mounting Bracket 3 Generator Mounting Bolt (2 Req'd) 4 Generator A Tighten to 10Nm (89 Lb-In) B Tighten to 25Nm (18 Lb-Ft) Installation  Install generator. Tighten front generator bolts to 25Nm (18 lb-ft).  Install serpentine belt.  Connect voltage regulator wiring and output cable. Tighten cable nut to 8Nm (71 lb-in).  Install generator bracket bolts and tighten them to 10Nm (89 lb-in).  Install engine appearance cover and securely tighten the nut.  Connect battery ground cable.

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.  Test the alternator on this vehicle using the older style analog tester.  Set it to the 100 A scale, remember to ZERO the meter! Run all vehicle accessories and raise the RPM to 2000 for 20 seconds. ALTERNATOR SPEC - 100 AMPS FULL LOAD Voltage______________________ Amps__________________

 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 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. Describe how to “load test” the alternator - using only an ammeter - and no other tools.

 When finished have the instructor sign off on your work. _____________________________________

NATEF TASKS - VI. ELECTRICAL/ELECTRONIC SYSTEMS D1. Perform charging system output test; determine necessary action. P-

D3. Inspect, adjust, or replace generator (alternator) drive belts, pulleys, and tensioners; check pulley and belt alignment.

  • D2. Diagnose charging system for the cause of undercharge, no-charge, and overcharge conditions. P-
    • P-
  • D4. Remove, inspect, and install generator (alternator). P-
  • D5. Perform charging circuit voltage drop tests; determine necessary action. P-