Automotive Parts. Charging & Starting Systems
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1 Automotive Parts Charging & Starting Systems
2 Charging Systems Output voltage kept to about 2 volts higher than battery voltage Controlled by varying current into rotor field winding (voltage regulator or PCM) No permanent magnets inside of the alternator Battery Testing with Midtronics Charging Output & Full Field Testing Carbon Pile Rheostat Identify Maximum Output on the Alternator Case
3
4 Alternator
5 Rotor with Field Coil Check rotor for opens, short coils, & shorts to the shaft Copper Slip Rings Rotor rotating magnetic field Check stator for opens, short coils, & shorts to the soft iron armature Stator stationary coils of wire Wye wound has 4 connections Delta wound has 3 connections
6 Diode Trio.4 to.7 VD in one direction OL in the other direction OL both ways = open 0.0 both ways = shorted
7 Full Fielding Tab Carbon Brush Brush Holders Internal Voltage Regulators
8 Rectifier Bridges change AC to DC before it leaves the alternator
9 B + Output side Ground side Test 6 diodes from copper tab to heat sink, Reverse leads to verify diode integrity
10 Charging System External Voltage Regulator Apply 12 volts to Field Terminal to full field the alternator
11 Starting (Cranking) Systems Cranks engine with a 10:1 to 15:1 reduction between starter drive pinion & ring gear Typical current draw is about 200 amps No click = no solenoid operation (check pull in coil) Click, but no crank = motor issue open windings Voltage Drop Test both B + and B cables (.2 maximum)
12
13 Starter Motor with solenoid mounted on it
14 Movable Pole Shoe Starter Motor (solenoid mounted remotely)
15
16
17 Pinion Gear Starter Drive Fork Starter Drive with Overrunning Clutch Hold in & Pull in Windings Starter Mounted Solenoid
18 Pinion Gear Fork goes here Starter Drive Starter Shim gets placed between drive end housing & engine block
19 Remotely Mounted Starter Solenoids Used with movable pole shoe starter drives B B+ Apply 12 volts here to by pass the ignition switch
20 Solenoids Plungers
21 Automotive Parts Electrical & Accessory Systems
22 Electrical & Accessory Arguably one of the most intricate vehicle systems to trouble shoot Electrical Understanding is a Necessity! Even the dome light circuit is challenging now
23 Turn Signal &/or Hazard Flashers
24 Fusible Links with heat resistant Hypalon coating
25 Weather pack connector Fusible Links are 2 to 4 gauge sizes smaller than the regular circuit wiring
26 Ignition Switch. Located low on the steering column Operated by twisting the key Ignition Key & Lock Cylinder
27 Headlight Switch with dash light dimmer rheostat Has a push button to release the knob Ignition Switch Mechanism Located on Lower Steering Column
28 Brake Switch & Cruise Cancel Switch BPP or BOO Located on Brake Pedal Bracket
29 Air Temperature Sensors Ambient Evaporator Intake Air In evaporator housing In front of radiator Inlet air stream Cabin Air Temperature sensors found in automatic climate control HVAC
30 Low Brake Fluid Sensors Located on Master Cylinder
31 Blower Motor Resistors: drop the voltage to the blower motor to get a variety of speeds can be open on just one speed Solid State Solid State Coil Types
32 Battery Temperature Sensor Chrysler Located in the Bottom of the Battery Tray
33 Solid State Flashers NOTE: Closely Resemble a Relay, but the number and the arrangement of the prongs differs Regular Flasher Turn Signal, Hazard, or Combo Blinks Faster with a Burnt Out Bulb
34 Brake Pedal Position Sensors Also used for brake light switch & cruise control cancel switch 1 Time Use BPP & BOO
35 Low Coolant Sensor Low Brake Fluid Sensor Float type Reed Switch type is also in use
36 Electronic Flasher built right on to the Hazard Switch Note: found on some versions of S.E.T. boards Regular Flashers Look very different than a round, European relay
37 Electric Seat Heater Switch & Harness Almost any switch is a good component to bug on a vehicle
38 Door Buzzer or Chime Many door ajar and dome light switches are now a part of the door latch mechanisms Door Jamb Switches
39 Wiring Harnesses can be tricky to trouble shoot Fuse hidden in the harness SIR/SRS wiring has yellow connectors High Voltage DC Hybrid power systems wiring is in a bright orange loom
40 Test Voltage Available to me I am a Wiring Harness. How can I fail thee? Let me count the ways: I Can be open (inoperative) I Can be shorted to ground (fuse blow) I Can be shorted to power (always on) I Can have high resistance (voltage drop) I might also be diode equipped (.4 to.7 VD)
41 Diagnostic Link Connectors (DLC) OBD I & OBD II GM Chrysler Ford Toyota Global OBD II 1996 to present
42 Windshield Wiper Motor Windshield Washer Pump Motors
43 Anti theft hood switch Key Fob Immobilizer Module with wrong key will cause a no start or a starts & stops Door Lock or Deck Lid Actuator or Motor
44 Relays
45 Relay coil typically has ohms OL = inoperative (no click) Insulated Contacts = click, but no conduct Jammed Contacts = good coil, but no click
46 Fuses of All Types Maxi Pal ATO Cartridge Fusible Links Glass Fuse Puller Missing Fuse Puller = Demerit
47 Circuit Breakers a forced open cb may read a few heater ohms
48 Diodes! Some resemble fuses, but note the prong positions Alternator Button Diode Often used as clamping diodes in large coil circuits
49 Windshield Washer Pump Motor
50 Weather Pack Connector Rocker Switch for a Window Know how to release wires from harness connectors
51 Hood &/or Deck Lid Light Switches Similar to those used in Glove Boxes Contain a mercury filled capsule that conducts only when the angle is correct
52 Multi Function Switch Snaps or screws into the steering column Lights Signals Wipers Cruise Popular competition bug: Wiring to and from Connectors at the MF Switch One tab that controls one small aspect of the switch
53 Bulbs & Sockets Cheap & easy open or short circuits! Headlamp Fog Lamp
54 Floor mounted Dimmer Switch Door Jamb Switch Very Old For Dome Light Operation
55 Windshield Washer Pump Motors Some vehicles have both a front & a rear washer pump motor
56 Hood & Deck Lid Light Switches
57 Horn Pad Switch grounds the relay coil to energize the horns
58 Seat Belt Switch Causes SIR codes, and keeps the warning chime on
59 SPOUT (Spark Output) Connectors Remove to put a Distributor Ignition Ford into base timing mode
60 Multi Function Switch Easily accessible through the steering column cover
61 Insulated ground = inoperative B B + Horn always relayed & fused
62
63
64 85 to 85 = coil 30 = B+ 87a = NC (obedience check) 87 = switched output D to F = coil E = B+ C = NC (obedience check) A = switched output
65 Door Latch & Trunk Latch
66 Electric Antenna Motor
67 Power Antenna Motor
68 Electric Window Cable Motor
69 Electric Window Regulator Motor
70 Electric Window Regulator Motor
71 Pulse Width Modulated Blower Motor
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