CHARGING SYSTEM. SECTION Battery and Charging System-Service GROUP BATTERY AND VEHICLE APPLICATION DESCRIPTION AND OPERATION

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1 GROUP BATTERY AND 14 CHARGNG SYSTEM SECTON TTLE PAGE SECTON TTLE PAGE GENERATOR, REGULATOR-NTERNAL FAN AND BATTERY AND CHARGNG REGULATOR TYPE SYSTEM-SERVCE... BATTERY SECTON Battery and Charging System-Service SUBJECT PAGE SUBJECT PAGE DESCRPTON AND OPERATON SPECAL SERVCE TOOLS... DAGNOSS AND TESTNG SPECFCATONS... On-Bench Testing VEHCLE APPLCATON... On-Vehicle Charging System Tests VEHCLE APPLCATON Capri. DESCRPTON AND OPERATON The generator charging system is a negative ground system consisting of a generator with an integral regulator, a charge indicator lamp, a storage attery, and associated wiring. The integral regulator is solid-state. t is mounted onto the rear of the generator and contains the generator rushes. DAGNOSS AND TESTNG Battery and charging system troule is frequently due 1. Make sure attery terminals and cale to physical rather than electrical factors including connections are clean and tight. Refer to Section loose or corroded wiring connections, damaged wiring, slipping drive elts, dirty attery surfaces and 2. nspect attery cale connections to starter and terminals, or poor maintenance. engine ground for surface dirt or foreign matter. Thoroughly inspect the system Capri July. 1992

14-00-2 Battery and Charging System-Service 14-00-2 DAGNOSS AND TESTNG (Continued) 3. Check generator drive elt for glazing or cracking which may have een caused y elt slippage.

2 Battery and Charging System-Service DAGNOSS AND TESTNG (Continued) 3. Check generator drive elt for glazing or cracking which may have een caused y elt slippage. f sides of elt are shiny or feel slick, replace them. Check elt tension. Refer to Section for elt replacement or tension adjustment. 4. Make sure that top surface of attery is clean and free of moisture or foreign matter. Charging system troules such as low generator output, no generator output (indicated y the indicator lamp eing on while the engine is running), or generator output voltage too high, require testing of oth the generator and the voltage regulator. Voltage regulator failures are usually not recognized except y the direct affect on the generator output, and eventual attery discharge. The voltage regulator is the control valve for the generator. t protects the attery y preventing excessive voltage output. Discharge of the attery to ground through the generator is prevented y the diodes of the generator which permit current flow in one direction (to the attery) only. A discharged attery is not always due to a prolem in the charging system. Excessive use of lamps and accessories while the engine is either off or running at low idle, corroded attery cales and connectors, low acid level in the attery, or prolonged disuse of the attery, which would permit self-discharge are all possile reasons which should e considered when a attery is run down or low in charge. NOTE: Always determine the cause of failure as well as servicing the concern. Polarity and Connections: The generator is for use on negative ground electrical systems only. Polarity cannot e reversed and any attempt to do so will damage the generator. nstalling Vehicle Battery: Reversed attery connections will damage the generator rectifiers. When installing, first connect the positive connector to the attery positive terminal and then connect the negative connector to the negative attery terminal. Battery Charging: Disconnect the attery negative cale to isolate the generator from the attery and external charging equipment. Battery Connections: Never disconnect the attery while the engine is running. Damage to the rectifier and/or other electrical components may occur. Using a slave attery to start the engine and then reconnecting the original attery while the engine is running must not e attempted. Do not reak or make any other connections in the generator circuit while the engine is running. Generator Main Output Cale: The cale connecting the generator and the attery has constant attery voltage even when the engine is not running. Care must e taken not to ground this cale if it should ever e removed, or damage to the cale will occur. Never run the generator with the main output cale disconnected either at the generator or attery end while the field remains energized or the rectifiers may e damaged. Arc Welding: solate the control ox and generator y disconnecting their wiring connectors prior to performing any arc welding on the vehicle. Lamps and Fuses Fail Prematurely, Short Battery Life: Other systems covered under this heading are: attery uses excessive amount of water; high attery charging rate. Check all charging system wiring connections including the voltage regulator ground and attery sensing wire. Tighten or service as required. Check the generator voltage limiter setting. Replace if not to specification. Generator Noisy: When diagnosing the complaint of generator noise, isolate the noise area and make sure that the generator is at fault rather than the generator elt, water pump, or another part of the vehicle. Start the engine and use a stethoscope or similar tool to isolate the noise. A generator earing, water pump earing or elt noise is usually evident y a squealing sound. A generator with a shorted diode will normally whine (magnetic noise) and will e most noticeale at idle speeds. Perform the generator output tests. f the output is approximately 10 amperes less than that specified, a shorted diode is usually indicated. To eliminate the elt(s) as the cause of noise, check the elt(s) for umps, apply a light spray of water to the elt(s). f the generator elt is at fault, adjust the elt to specification, or replace the elt if necessary. f the elt(s) is satisfactory and the noise is elieved to e in the generator or water pump, remove the generator elt. Start the engine and listen for the noise to e sure that the noise is not caused y another component. Use this test and the sound detector test to isolate the noisy component. f the noise is traced to the generator, remove it and check earings for play or roughness. 9. Charge Warning ndicator Lamp Flickers: This condition may e caused y loose or damaged connections in the charging system wiring harness, worn rushes, or improper rush tension. On-Vehicle Charging System Tests Generator Load Test 1. Start the engine and verify that the charge warning indicator lamp goes out. f the indicator goes, out, refer to Step 6. F the indicator does not go out, refer to Step 2. CAUTON: Do not ground the B- terminal.

3 Batterv and Charaina Svstem-Service DAGNOSS AND TESTNG (Continued) 2. With the ignition switch in the ON position and the engine not running, verify that the voltage at the generator wiring connector terminals are as follows: 0 6-terminal = Battery Voltage 0 L-terminal = Approximately 1 volt 0 S-terminal = Battery Voltage 3. Start engine. 4. With the engine running and at normal cur idle, verify that the voltage at the generator wiring connector terminals are as follows: 0 6-terminal = L-terminal = S-terminal = f the voltages are as specified, check the wiring harness etween the attery and 6-terminal. f the voltages are elow specification, check the wiring harness. f wiring harness is in good condition, service or replace the generator. 6. Using Rotunda StartingCharging Tester (VAT-40) or equivalent, connect the positive lead to the generator 6-terminal connector and the negative lead to the 6-terminal wiring connector. POSTVE LEAD \/LEAD NEGATVE Generator lgnltlon ON/ Engine at Terminal Engine OFF dle B Approximately L Approximately S Approximately B-TERMNAL WRNG CONNECTOR GENERATOR CONDTON CHART-CHARGNG SYSTEM 7. Switch the tester to the ammeter function. 8. Connect Rotunda nductive Dwell-Tach-Volts Ohms Tester or equivalent. 9. With the engine running, turn on all lamps, lights, accessories and press the rake pedal. 10. With an engine speed of rpm check that the generator output current is 70 amps or more. f output current is as specified, the charging system is functioning properly. f the output current is elow specification, check the accessorv elt. Refer to Section f the elt tension isat specification, service or replace the generator. CONDTON POSSBLE SOURCE ACTON Battery Does Not Stay Battery. Test attery, replace if necessary. Charged-Engine Starts OK Refer to Section Loose or worn generator elt. Adjust or replace elt. Refer to Section Wiring or cales. Service as required. Refer to Section Test and/or replace components as required. Refer to Section Other vehicle electrical systems. Check other systems for current draw. Service as required.

4 Battery and Charninn System-Service DAGNOSS AND TESTNG (Continued) CONDTON Generator Noisy Lamps and/or Fuses Burn Out Frequently Flickers After Engine Starts or Comes On While Vehicle is Being Driven Flickers While Vehicle is Being Driven Voltmeter Pointer Reads in the Red Area (High or Low) CONDTON CHART-CHARGNG SYSTEM (Continued) POSSBLE SOURCE Loose or worn generator elt. Bent pulley flanges. a Wiring. Battery. Loose or worn generator elt. a Field circuit ground. a Lamp circuit wiring and connector. Loose or worn generator elt. Loose or improper wiring connections. Loose or worn generator elt. Damaged or worn wiring (attery to generator for ground or open). Field circuit ground. Voltmeter indicator gauge wiring and connections. Damaged or worn gauge. Other vehicle electrical system malfunction. ACTON Adjust tension or replace elt. Referto Section Replace pulley. Refer to Section a Service or replace generator. Refer to Section Service as required. Test, service, replace if necessary. a Test, replace if necessary. Refer to Section Adjust tension or replace. Refer to Section Service or replace. Refer to Section Service or replace worn or damaged wiring. Service as required. a Adjust tension or replace elt. Refer to Section Service as required. a Service or replace. Refer to Section Adjust tension or replace. Refer to Section Service or replace wiring. Service or replace wiring. Service or replace. Refer to Section Service as required. Replace gauge. a Service as required. The following pinpoint tests have een arranged in a series to isolate the component or cause of a charging system complaint. Start at the eginning and continue through the test steps even after the cause of the complaint is found. This will rule out the possiility that the original condition was not caused y more than one charging system condition. TEST STEP A1 1 CHECK CHARGE LAMP FUNCTON -- a Without starting engine, turn ignition switch to RUN position. Charge warning indicator lamp should come on. Key OFF. Disconnect the generator connector. KeyON. a Ground L terminal of generator connector. Charge warning indicator lamp should come on. PNPONT TEST A-CHARGNG SYSTEM DAGNOSS NOTE: Testing to e performed on wiring harness side. RESULT Lamp functions properly Lamp does not come on Lamp does not go off Lamp comes on only with L-terminal grounded ACTON TO TAKE GO toa2. REPLACE meter fuse or lamp ul or SERVCE open in lamp feed circuit. SERVCE short to ground in lamp feed circuit. CHECK rotor, rushes, or voltage regulator. Refer to ench tests. Section

5 Batterv and Charaincl Svstem-Service DAGNOSS AND TESTNG (Continued) A2 A3 PNPONT TEST A-CHARGNG TEST STEP CHECK BATTERY CONDTON Perform sealed attery voltage1 load test. Refer to Section Does attery pass load test? CHECK B+ WRNG With ignition switch in OFF position, use a voltmeter, such as Rotunda Digital Volt-Ohmmeter or equivalent to test for attery voltage at generator B+ terminal. 0 s voltage within 0.2 ot attery voltage? NOTE: Test step must e performed with generator installed and all wiring connected. SYSTEM DAGNOSS (Continued) Yes No Yes No RESULT ACTON TO TAKE GO to A3. REPLACE attery. GO to A4. SERVCE loose, corrodec or damaged B+ wire. A4 A5 CHECK BATTERY GROUND Use a voltmeter to check voltage drop from attery negative post to ground. 0 Voltage drop should e less than 0.2. CHECK GENERATOR GROUND 0 Use a voltmeter to check voltage drop from generator frame to engine ground. Voltage drop should not exceed 0.2. A6 PERFORM BATTERY DRAN TEST-KEY OFF Turn ignition switch to OFF position. Disconnect attery positive cale. Connect an ammeter or test lamp etween attery positive terminal and positive cale. 0 Current draw should e no more than.05 amps (clock draw). Test lamp should not light. Does test lamp illuminate? Within 0.2 Greater than 0.2 Within 0.2 Greater than 0.2 Yes D GO to A5. SERVCE loose or corroded connections or damaged ground cale. SERVCE excessive resistance in generator mounting. CHECK vehicle circuits for drain y pulling fuses from fuse panel one at a time until affected circuit is found. SERVCE as necessary. A7 PERFORM BASE VOLTAGE AND NO-LOAD TEST Connect a voltmeter across attery terminals. Read and record voltage (this is ase reading). Start engine, run at 1500 rpm with no electrical load. Voltage should increase from ase reading, ut not moe than 2.5. NOTE: Test step must e performed with generator installed. Engine should e running at approximately 1500 rpm. Voltage increase ut less than 2.5 No voltage increase or increase greater than 2.5. SERVCE or REPLACE generator. REFER to this Section. A8 1 PERFORM LOAD TEST ncrease engine speed to 2000 rpm. 0 Turn A1 C, lower and headlamps on HGH. 0 The voltage should read a minimum of 0.5 volt over the ase voltage. ncreases 0.5 volt or more ncreases less than 0.5 volt The concern is not in the charging system. CHECK other vehicle systems for a constant or intermittent current overdraw y repeating the attery drain test with various auxiliary circuits on. REPLACE or SERVCE generator for shorted or open stator and field windings or diodes reaking down under load. REFER to Bench Tests as outlined.

6 Battery and Charging System-Service DAGNOSS AND TESTNG (Continued) Whenever the generator assemly is removed from the vehicle and disassemled, a thorough inspection of the components should e performed as outlined in the Component Visual nspection chart. NOTE: Clean all parts thoroughly efore inspecting. Do not wash the rotor, stator, voltage regulator, rectifier or earings in cleaning solvent. GENERATOR COMPONENT VSUAL NSPECTON CHART COMPONENT CHECK FOR ROTOR STATOR HOUSNGS DRVE PULLEY (Continued) Thread stripped or damaged at pulley end. Scored earing surfaces indicating the earing has spun on the shan. Scuff marks on the pole fingers indicating a ent shaft which allows the rotor to ru against the stator frame. Dirty or contaminated slip rings. Slip rings can e cleaned using a No. 400 silicon caride paper and finish polished using crocus cloth (DO NOT USE EMERY PAPER). The est cleaning method is to spin the rotor in a lathe or drill press to prevent flat spots. Burned or discolored windings indicating insulation reakdown from excessive heat. Scuff marks on the inside of stator frame indicating a ent rotor shaft. Damage to the stator frame. Cracked or damaged mountings. Scoring in the earing ores indicating the earings have spun in the housing. Luricant in the earing ores indicating damaged earings. Bent, roken or cracked pulley groove. Wear or damage to the pulley ore which could prevent a tight fit on the shan. GENERATOR COMPONENT VSUAL NSPECTON CHART (Cont'd) COMPONENT BRUSHES BEARNGS CHECK FOR Burn spots or discoloration indicating arcing. Dirt or contamination. Wear f rush length is less than 5mm (318 inch), replace the rushes. Roughness or flat spots: To determine this condition, slowly rotate the earing on the shan or etween fingers. A flat spot will appear as a sudden tightening and then loosening of the outer race. Roughness will have a general uneven feel as the earing is rotated. Leakage of luricant past the earing seals. Scoring on the inner or outer races, indicating the earing has spun on the shaft or in the housing. L Generator and voltage regulator testing is roken down into on-vehicle testing and ench testing. Refer to On-Vehicle Charging System Tests efore proceeding to On-Bench testing. On-Bench Testing n order to perform the component testing in the following charts, it will e necessary to partially or completely disassemle the generator as outlined. Use Rotunda nductive Dwell-Tach-Volts-Ohms Tester for on-ench testing procedures.

7 Battery and Charging System-Service DAGNOSS AND TESTNG (Continued) B 1 CHECK ROTOR COlL RESSTANCE PNPONT TEST B-GENERATOR COMPONENT DAGNOSS AND TESTNG TEST STEP RESULT ACTON TO TAKE Set ohmmeter on X scale. Connect meter leads across rotor slip rings. Resistance should e 2-6 ohms. Rotor coil resistance 2-6 ohms Rotor coil outside specified tolerance Rotor coil OK. GO to 82. REPLACE rotor CHECK ROTOR COlL GROUND Set ohmmeter on X scale. Place one meter test lead on rotor slip ring, and the other meter lead on a rotor pole. Repeat for other rotor slip ring. Ohmmeter reading should e infinite. ROTOR CORE OHMMETER Resistance infinite Continuity etween slip ring and rotor pole Rotor coil OK. GO to 83. REPLACE rotor assemly.

8 Batterv and Charaina Svstem-Service DAGNOSS AND TESTNG (Continued) PNPONT TEST B-GENERATOR TEST STEP 83 1 CHECK STATOR WNDNG GROUND Set ohmmeter on X scale. Clip one meter lead to a stator lead. Place other meter lead on stator frame. Resistance should e infinite. COMPONENT DAGNOSS AND TESTNG (Continued) RESULT ACTON TO TAKE Resistance infinite Stator coil OK. GO to 84. Continuity REPLACE stator. etween frame and stator lead: windings grounded 84 1 CHECK OPEN STATOR WNDNGS Set ohmmeter on X scale. Clip one meter lead to a stator lead. Place other meter lead on each of remaining three stator leads. There should e continuity in all three positions. NOTE: SHORTED STATOR WNDNGS. An internal short etween adjacent windings is difficult to locate without laoratory equipment. f all other test results are normal and generator fails to supply rated output, shorted stator windings are proale. Continuity in all Stator windings OK. GO three positions to 85. nfinite resistance REPLACE stator. n any of three positions: shorted stator windings. Shorted stator REPLACE stator. windings

9 Batterv and Charaina Svstem-Service DAGNOSS AND TESTNG (Continued) PNPONT TEST 6-GENERATOR TEST STEP 65 CHECK BRUSH CRCUT CONTNUTY Set ohmmeter on X scale. Touch one meter lead to rush. Touch other meter lead to rush terminal. Check inner and outer terminals using this method. There should e continuity in oth positions. COMPONENT DAGNOSS AND TESTNG (Continued) RESULT Continuity in oth positions nfinite resistance in either position: rush circuit open ACTON TO TAKE Brush circuits OK. GO to 66. REPLACE rush and voltage regulator as an assemly. 66 CHECK NEGATVE RECTFERS Set ohmmeter on X scale. Clip one meter lead to negative diode heat sink. Touch other meter lead to each negative rectifier pin. Reverse ohmmeter leads and repeat test. Rectifier should show continuity in one direction only CHECK POSTVE RECTFERS Set ohmmeter on X scale. Clip one meter lead to positive diode heat sink. Touch other meter lead to each positive rectifier pin. Reverse ohmmeter leads and repeat test. Rectifier should show continuity in one direction only. Continuity in one direction only Continuity in oth directions on any one rectifier: rectifier shorted No continuity in either direction on any one rectifier:rectifier open Continuity in one direction only Continuity in oth directions on any one rectifier: rectifier shorted No continuity in either direction on any one rectifier:rectifier open Negative diodes OK. GO to 67. REPLACE rectifier assemly. REPLACE rectifier assemly Positive diodes OK. REPLACE rectifier assemly. REPLACE rectifier assemly.

10 Battery and Charging System-Service SPECFCATONS Electrical Specifications SPECAL SERVCE TOOLS ROTUNDA EQUPMENT Digital Volt-Ohmmeter Description Ground Polarity Nominal Voltage Nominal DC Output Stator Phases Stator Winding Connection Numer of Poles Resistance of Rotor Windings Resistance of Stator Windings Brush Length (Protrusion) New Minimum Minimum Diameter of Slip Rings Specification Negative 14 Volts 85 amps ohms,037 + lqo/o ohms 9.8mm (0.39 inch) 3.8mm (0.15 inch) 26.7mm (1.05 inch) CJ3485-A

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