Page 1
TG0060A
Table of Contents
Section A: Wiring ...............................................................2
Section B: Basic Troubleshooting ......................................3
Section C: Advanced Troubleshooting ......................... 4 – 5
Battery Conditions
Until temperatures of electrical
system components stabilize, these
conditions may be observed during
cold start voltage tests.
• Maintenance or low maintenance battery:
— Immediately after engine starts, system volts are
lower than regulator setpoint with medium amps.
— 3-5 Minutes into charge cycle, system volts are
higher and amps are dropping.
— 5-10 Minutes into charge cycle, system volts are
at, or nearly at, regulator setpoint and amps are
reduced to a minimum.
— Low maintenance battery has same characteris-
tics with slightly longer recharge times.
• Maintenance-free
battery:
— Immediately after engine start, system volts are
lower than regulator setpoint with low charging
amps.
— 15-30 minutes into charge cycle, volts and amps
are still low.
— 15-30 minutes into charge cycle, volts increase
several tenths. Amps increase gradually, then
quickly, to medium to high amps.
— 20-35 minutes into charge cycle, volts increase
to setpoint and amps decrease.
• High-cycle maintenance-free battery:
— These batteries respond better than standard
maintenance-free. Charge acceptance of these
batteries may display characteristics similar to
maintenance
batteries.
NOTICE
Hazard De
fi
nitions
These terms are used to bring attention to presence of hazards
of various risk levels or to important information concerning
product life.
NOTICE
C524 Alternator
Troubleshooting Guide
Charge Volt and Amp Values
The volt and amp levels are a function of the battery state of
charge. If batteries are in a state of discharge, as after ex-
tended cranking time to start the engine, the system volts,
when measured after the engine is started will be lower
than the regulator setpoint and the system amps will be
high. This is a normal condition for the charging system.
The measured values of system volts and amps will depend
on the level of battery discharge. In other words, the greater
the battery discharge level, the lower the system volts and
higher the system amps will be. The volt and amp readings
will change, system volts reading will increase up to regula-
tor setpoint and the system amps will decrease to low level
(depending on other loads) as the batteries recover and
become fully charged.
•
Low Amps:
A minimum or lowest charging system amp
value required to maintain battery state of charge,
obtained when testing the charging system with a fully
charged battery and no other loads applied. This value
will vary with battery type.
•
Medium Amps:
A system amps value which can cause
the battery temperature to rise above the adequate
charging temperature within 4-8 hours of charge time.
To prevent battery damage, the charge amps should be
reduced when battery temperature rises. Check battery
manufacturer’s recommendations for proper rates of
charge amps.
•
High Amps:
A system amps value which can cause the
battery temperature to rise above adequate charging
temperature within 2-3 hours. To prevent battery dam-
age, the charge amps should be reduced when the
battery temperature rises. Check battery manufactur-
er’s recommendations for proper rates
of charge amps.
•
Battery Voltage:
Steady-state voltage value as
measured with battery in open circuit with no battery
load. This value relates to battery state of charge.
•
Charge Voltage:
A voltage value obtained when the
charging system is operating. This value will be higher
than battery voltage and must never exceed the regula-
tor voltage setpoint.
•
B+ Voltage:
A voltage value obtained when measuring
voltage at battery positive terminal or alternator B+
terminal.
•
Surface Charge:
A higher than normal battery voltage
occurring when the battery is removed from a battery
charger. The surface charge must be removed to deter-
mine true battery voltage and state of charge.
•
Significant Magnetism:
A change in the strength or
intensity of a magnetic field present in the alternator
rotor shaft when the field coil is energized. The mag-
netic field strength when the field coil is energized
should feel stronger than when the field is not ener-
gized.
•
Voltage Droop or Sag:
A normal condition which
occurs when the load demand on the alternator is
greater than rated alternator output at given rotor
shaft RPM.
Indicates presence of hazards that
will or can cause minor personal
injury or property damage if
ignored.
Indicates special instructions on
installation, operation or mainte-
nance that are important but not
related to personal injury hazards.
CAUTION
