Generator Output Voltage Drop Test
This check is necessary to evaluate the status of the wiring from the output "IN" alternator to positive battery terminal (including fusible link).
Preparing for the test
1. Move the ignition key to position 8 "OFF".
Note: In order to pinpoint a fault at the connections, make sure that both outputs or their connections are not disturbed during the test.
2. Connect a digital voltmeter to the terminal "IN" alternator and positive battery terminal. Connect wire "pluses" voltmeter to output "IN" generator, and the wire "minus" voltmeter to the positive battery terminal.
Engines 2.0 l / 2.4 l. | Engines 2.7 liters. |
Conditions for the verification
1. Start the engine.
2. Read the voltmeter reading with the engine idling and the generator loaded (headlights, heater fan, etc.).
Analysis of results
1. The voltmeter should show voltage drops corresponding to the nominal value.
- Rated value: 0.2 V maximum
2. If the voltage drop is greater than the rated value (more than 0.2 V), then the cause is most likely a wiring fault. In this case, check the wiring between the terminal "IN" alternator and positive battery terminal (including fusible link). Check if there is a problem (bad contact) in connectors and connections, changes in the color of wire insulation (due to overheating) etc. Correct the problem and recheck.
3. After completing the check, let the engine idle. Turn off the headlights, heater fan and other loads, then turn the ignition key to the "OFF" (OFF).
Checking the output current of the generator
Engines 2.0 l / 2.4 l. | Engines 2.7 liters. |
This test determines if the generator output current is within the nominal value.
Preparing for the test
1. Before starting the test, perform the following checks and repair as necessary:
- A) Check the condition of the battery installed in the vehicle.
Note: The battery used in this test should be slightly discharged. A fully charged battery is not suitable for this test to be accurate, as the load generated will not be sufficient.
- b) Check alternator drive belt tension.
2. Turn the ignition key to the position "OFF".
3. Disconnect a wire from the negative plug of the storage battery.
4. Disconnect the standard wire from the output "IN" generator.
5. Connect ammeter (DC, with a range of 0-100 A) in series between output "IN" generator and its standard wire. Make sure the wire "minus" ammeter is connected to a standard wire disconnected from the generator.
Note: Be sure to fasten each connection securely and tightly as the terminals will carry a lot of current. Do not use clamps (type "crocodile") when connected to an electrical circuit.
6. Connect a voltmeter (with scale 0-20 V) between output "IN" generator and "weight". Connect wire "pluses" voltmeter to output "IN" generator and then wire "minus" voltmeter to a suitable "mass" (to the body).
7. Connect a control tachometer according to the manufacturer's instructions. Connect the wire to the negative battery terminal.
Verification procedure
1. Make sure the voltmeter shows battery voltage. If the voltmeter shows 0 V, then there is an open circuit between the output "IN" alternator and negative battery terminal. Check for a blown fuse link or poor connection to "weight".
2. Start the engine and turn on the headlights.
3. Turn on the high beam headlights and set the heater fan switch to the position "HIGH", then sharply increase the engine speed to 2500 rpm and read the maximum value of the generator output current (indicated by an ammeter).
Note: After starting the engine, the charging current drops rapidly. Carry out the test as soon as possible in order to have time to measure the maximum value of the generator output current.
Analysis of results
1. The reading of the ammeter must be above the limit value. If the ammeter reading is below the limit value, and the output circuit "IN" generator is serviceable, then remove the generator from the car and check it on the stand.
- Limit value: 63.0 A minimum
Note:
- The rated recoil force of the generator is stamped on a plate affixed to the generator housing.
- The value of the recoil current varies depending on the load on the generator and the temperature of the generator case. Therefore, the rated recoil force may not be achieved. In such cases, to increase the electrical load (in order to discharge the battery) turn on the high beam headlights for a while or connect the exterior lighting system of another car.
- The rated value of the generator output current may also not be obtained as a result of overheating of the generator housing or too high ambient temperature. In such cases, let the generator cool down and retest.
2. After checking the generator output current, gradually reduce the engine speed to idle, then turn off the ignition.
3. Disconnect a wire from the negative plug of the storage battery.
4. Remove the ammeter, voltmeter and control tachometer.
5. Connect the standard wire to the terminal "IN" generator.
6. Connect a wire to the negative plug of the storage battery.
Checking the regulated voltage (voltage regulator test)
This test determines if the generator voltage regulator is properly controlling the generator output voltage.
Preparing for the test
1. Before starting the test, perform the following checks and repair as necessary:
- A) Check that the battery installed in the vehicle is fully charged.
Note: The procedure for checking the battery is given in the section "Accumulator battery".
- b) Check alternator drive belt tension.
2. Turn the ignition key to position "OFF".
3. Disconnect a wire from the negative plug of the storage battery.
4. Connect a digital voltmeter between the terminal "S (L) " generator and "weight". Connect the wire first "pluses" voltmeter to output "S (L) " generator, then wire "minus" to a suitable "mass" (to body or negative battery terminal).
5. Disconnect the standard wire from the output "IN" generator.
6. Connect ammeter (DC, with a range of 0-100 A) in series between output "IN" generator and disconnected regular wire. Connect wire "minus" ammeter to the disconnected standard wire.
7. Connect a control tachometer according to the manufacturer's instructions. Connect the wire to the negative battery terminal.
Engines 2.0 l / 2.4 l. | Engines 2.7 liters. |
Verification procedure
1. Turn on the ignition and check that the voltmeter shows the specified voltage value. If the voltmeter shows 0 V, then either an open circuit has occurred between the output "S (L) " alternator and the positive battery terminal, or the fuse has blown.
- Rated value: battery voltage
2. Turn off all lights and additional electrical equipment. Start the engine.
3. Set the engine speed to 2500 rpm. Read the voltmeter reading when the generator output current is 10A or less.
Analysis of results
1. If the voltmeter readings correspond to the nominal values \u200b\u200bof the regulated voltage given in the table, then the voltage regulator is working. If the voltmeter readings do not correspond to the range of nominal values, then either the voltage regulator or the generator is faulty.
Table. Rated values of regulated voltage.
2. After completing the check, gradually reduce the engine speed to idle, then turn off the ignition.
3. Disconnect a wire from the negative plug of the storage battery.
4. Disconnect the ammeter, voltmeter and control tachometer.
5. Connect the standard wire to the terminal "IN" generator.
6. Connect a wire to the negative plug of the storage battery.