ADAMA SCIENCE AND TECHNOLOGY

UNIVERSITY
School of Mechanical, Chemical and Material Engineering
AUTOMOTIVE MAINTENANCE GROUP ASIGNMENT

GROUP MEMBERS ID

1. OLANA BIRHANU UGR/19799/12

2. MISGANAW FEREJA UGR/19690/12
3. FANUEL MESKELE UGR/20062/12
4. ABDI GASHAHUN UGR/20105/12
5. ROBEL WASSIE UGR/19536/12
6. GIRUMNEH KASSAYE UGR/19880/12
7. YARED ANETSE UGR/20086/12
8. ASTER AYANA UGR/19527/12
9. ABEL KIFLE UGR/19697/12
10. YOHANAN SOLOMON UGR/20685/12

SUBMITTED TO; Mr. TESGAYE TEFARI

DATE; 2 Feb, 2024
 CHARGING SYSTEM

The primary purpose of a charging system is to recharge the battery. The charging system
recharges the battery by supplying a constant and relatively low charge to the battery. Charging
systems work on the principles of magnetism to change mechanical energy into electrical energy.
This is done by inducing voltage. Voltage is induced in a wire when it moves through a magnetic
field. The wire or conductor becomes a source of electricity and has a polarity or distinct positive
and negative ends. However, this polarity can be switched depending on the relative direction of
movement between the wire and magnetic field.
.

Fig. charging system

Working principle
In AC generator a spinning magnetic field(rotor)rotates inside an assembly of stationary
conductors(stator) They induce a voltage that first flows in one direction and then in the opposite
direction (AC voltage). Because automobiles use DC voltage, the AC must be changed or
rectified into DC. As the spinning north and south poles of the magnetic field pass the
conductors, they induce a voltage that first flows in one direction and then in the opposite
direction (AC voltage). Because automobiles use DC voltage, the AC must be changed
or rectified into DC. This is done through an arrangement of diodes that are placed between the
output ofthe windings and the output of the AC generator.

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AC Generator Construction
Rotor:The rotor assembly consists of a drive shaft coil, and two pole pieces.

Slip Rings and Brushes:Current to create the magnetic field is supplied to the coil from one of
two sources: the battery or the AC generator itself.

Slip rings:and brushesconduct current to the spinning rotor. Most AC generators

have two slip rings mounted directly on the rotor shaft.

Stator: The statoris the stationary member of the generator. It is made up of a number of
conductors,or wires, into which the voltage is induced. Most AC generators use three windings
to generate the required amperage output.

End Frame Assembly:The end frame assembly, or housing, contains the bearings for the rotor
shaft. Each end frame also has built-in ducts so the air from the rotor shaft fan can pass through
the AC generator.

Cooling Fans:Behind the drive pulley on most AC generators is a cooling fan that rotates with
the rotor. This cooling fan draws air into the housing through the openings at the rear of the
housing. The air leaves through openings behind the cooling fan

Fig.AC generator construction

CHARGING SYSTEM TESTING AND SERVICE

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BATTERY STATE OF CHARGE
The charging system can be tested as part of a routine vehicle inspection or to determine the
reason for a no-charge or reduced charging circuit performance. The battery must be at least 75%
charged before testing the alternator and the charging system. A weak or defective battery wills
cause inaccurate test results. If in doubt, replace the battery with a known good shop battery for
testing.
CHARGING VOLTAGE TEST
The easiest way to check the charging system voltage at the battery. Specifications for charging
voltage 13.5 to 15 V.

STEP 1: Select DC volts.

STEP 2:Connect the red meter lead to the positive terminal of the battery and the black meter
lead to the negative terminal of the battery..
STEP 3:Start the engine and increase the engine speed to about2000 RPM (fast idle) and record
the charging voltage

Fig. voltage test

 If the voltage is too high, check that the alternator is properly

grounded.
 If the voltage is lower than specifications, then there is a fault
with the wiring or the alternator.
 If the voltage is too high, check that the alternator is properly
grounded. Otherwise there is a faultwith the wiring or the alternator.

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 SCAN TESTING THE CHARGING CIRCUIT
Most vehicles that use a computer-controlled charging system can be diagnosed using a
scan tool.
DRIVE BELT INSPECTION AND ADJUSTMENT
It is generally recommended that all belts be inspected regularly and replaced as needed.
Replace any serpentine belt that has more than three cracks in any one rib that appears in
a 3 in. span. Check service information for the specified procedure and recommended
replacement interval.
 It is generally recommended that null belts be inspected regularly and replaced as needed
 If the vehicle does not use a belt tensioner, then a belt tension gauge is needed to achieve
the specified belt tension.
 Install the belt and operate the engine with all of the accessories turned on to “run-in” the
belt for at least five minutes.
 Adjust the tension of the accessory drive belt to factoryspecifications
Belt tension gauge:A belt tension gauge is needed to determine if it is at the specified
belt tension. Install the belt and operate the engine with all of the accessories turned on to
“run-in” the belt for at least five minutes. Adjust the tension
Marks on a tensioner: Many tensioners have marks that indicate the normal operating
tension range for the accessory drive belt. Check service information for the preferred
location of the tensioner mark.

ALTERNATOR REMOVAL
 Use a test light or a voltmeter and check for battery voltage at the output terminal
of the alternator.
 Disconnect the negative terminal from the battery
 Remove the accessory drive belt that drives the alternator.
 Remove electrical wiring, fasteners, spacers, and brackets, as necessary, and
remove the alternator from the vehicle.

ALTERNATOR OUTPUT TEST

The testing procedure for alternator output is as follows:
STEP 1:Connect the starting and charging test leads according to the manufacturer’s
instructions, which usually include installingthe amp clamp around the output wire
near the alternator.
STEP 2:Turn off all electrical accessories to be sure that the tester
is measuring the true output of the alternator.
STEP 3:Start the engine and operate it at 2000 RPM (fast idle). Turn the load
increase control slowly to obtain the highest reading on the ammeter scale. Do not
allow the voltage to drop below 12.6 volts. Note the ampere reading.

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 STEP 4: Add 5 to 7 amperes to the reading because this amount of current is used by
the ignition system to operate the engine.

ALTERNATOR OUTPUT TEST

 An alternator output test measures the current (amperes) of the alternator.
 Check the condition of the alternator drive belt.
 With the engine off, attempt to rotate the fan of the alternator by hand.
 Replace or tighten the drive belt if the alternator fan can be rotated this way.

ALTERNATORDISASSEMBLY
STEP 1:Mark the case with a scratch or with chalk to ensure proper
reassembly of the alternator case.
STEP 2:After the through bolts have been removed, carefully separate the two
halves. The stator windings must stay with the rear case. When this happens, the
brushes and springs will all out.
STEP 3: Remove the rectifier assembly and voltage regulator.

ROTOR TESTING
 The slip rings on the rotor should be smoothand round (within 0.002 in. of being
perfectly round).
 If grooved, the slip rings can be machined to provide suitable surface for the brushes. Do
not machine beyond the minimum slip-ring dimension as specified by the
manufacturer.
 If the slip rings are discolored or dirty, they can be cleaned with 400-grit or fine emery
(polishing) cloth. The rotor must be turned while being cleaned to prevent flat spots on
the slip rings.

Measure the resistance between the slip rings using an

ohmmeter. Typical resistance values and results include the
following:
1. The resistance measured between either slip ring and the steel rotor shaft should be infinity
(OL). If there is continuity, then the rotor is shorted to ground.
2. Rotor resistance range is normally between 2.4 and 6 ohms.
3. If the resistance is below specification, the rotor is shorted.
4. If the resistance is above specification, the rotor connections are corroded or open.TESTA

If the rotor is found to be bad, it must be replaced or repaired at a specialized shop.

VESTALTERNATOR OUTPUT TESTHARGINGALTERNATOR OUTPUT

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TESS FIFIFIFFYSTEM

VOLTAFFFFGE DROPFig. Rotor test

STATOR TESTING
The stator must be disconnected from the diodes (rectifiers) before testing. Because all three
windings of the stator are electrically connected (either wye or delta), an ohmmeter
can be used to check a stator.

 There should be low resistance at all three stator leads (continuity).

 There should not be continuity (in other words, there should be a meter reading of infinity
ohms) when the stator is tested between any stator lead and the metal stator core.
 If there is continuity, the stator is shorted-to-ground and must
be repaired or replaced.

 Because the resistance is very low for a normal stator, it is generally not possible
to test for a shorted (coppertop-copper) stator. A shorted stator will, however,
greatly reduce alternator output. An ohmmeter cannot detect an open stator if the
stator is delta wound. The ohmmeter will still indicate low resistance because all
three windings are electrically connected.

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 Fig. stator test

TESTING THE DIODE TRIO

Many alternators are equipped with a diode trio. A diode is an electrical one-way check valve
that permits current to flow in only one direction. Because trio means “three,” a diode trio is
three diodes connected together.

The diode trio is connected to all windings. The current generated in the stator flows through the
diode trio to the internal voltage regulator. The diode trio is designed to supply current for the
field (rotor) and turns off the charge indicator light when the alternator voltage equals or exceeds
the battery voltage.

If one of the three diodes in the diode trio is defective (usually open), the alternator may produce
close-to-normal output; however, the charge indicator light will be on dimly.

 A diode trio should be tested with a digital multimeter. The meter should be set to the
diode-check position. The multi meter should indicate 0.5 to 0.7 V (500 to 700 mV) one
way and OL (over limit) after reversing the test leads and touching all three connectors of
the diode trio.

Testing procedures:
 Connect the leads to the leads of the diode (pigtail and housing of the rectifier
bridge).
 Read the meter.
 Reverse the test leads.
 A good diode should have high resistance (OL) one way (reverse bias) and low voltage
drop of 0.5 to 0.7 V (500 to 700 mV) the other way (forward bias).

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RESULTS: Open or shorted diodes must be replaced. Most alternators group or combine all
positive and all negative diodes in the
one replaceable rectifier component.

Fi .Diode trio

Diode (rectifier) should allow current to flow in only one direction, each diode should be
tested to determine if the diode allows current flow in one direction and blocks current
flow in the opposite direction.

Accurate testing is not possible unless the diodes are separated electrically from other
alternator components

REASSEMBLING THE ALTERNATOR

BRUSH HOLDER REPLACEMENT

 Alternator carbon brushes often last for many years and require no scheduled
maintenance. The life of the alternator brushes is extended because they conduct
only the field (rotor) current, which is normally only 2 to 5 amperes.
 The alternator brushes should be inspected when the alternator is disassembled and
should be replaced when worn to less than1/2 in. long. Brushes are commonly purchased
assembled together in a brush holder.

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  After the brushes are installed (usually retained by two or three screws) and the rotor is
installed in the alternator housing, a brush retainer pin can be pulled out through an
access hole in the rear of the alternator, allowing thebrushes to be pressed against the slip
rings by the brush springs.

BEARING SERVICE AND REPLACEMENT

 The bearings of an alternator must be able to support the rotor and reduce friction. An
alternator must be able to rotate at up to 15,000 RPM and withstand the forces created by
the drive belt. The front bearing is usually a ball bearing type and the rear can be either a
smaller roller or ball bearing.
 The old or defective bearing can sometimes be pushed out of
the front housing and the replacement pushed in by applying pressure with a socket or
pipe against the outer edge of the bearing(outer race). Replacement bearings are usually
pre lubricated and seated. Many alternator front bearings must be removed from the
rotor using a special puller.

ALTERNATOR ASSEMBLY
After testing or servicing, the alternator rectifier(s), regulator, stator, and brush holder must be
reassembled using the following steps.

STEP 1:If the brushes are internally mounted, insert a wire through the holes in the brush holder
to hold the brushes against the springs.

STEP 2:Install the rotor and front-end frame in proper alignment with the mark made on the
outside of the alternator housing. Install the through bolts. Before removing the wire pin holding
the brushes, spin the alternator pulley. If the alternator is noisy or not rotating freely, the
alternator can easily be disassembled again to check for the cause. After making certain the
alternator is free to rotate, remove the brush holder pin and spin the alternator again by hand.

The noise level may be slightly higher with the brushes released onto the slip rings.

STEP 3:Alternators should be tested on a bench tester, if available, before they are reinstalled on
a vehicle. When installing the alternator on the vehicle, be certain that all mounting bolts and
nuts are tight. The battery terminal should be covered with a plastic or rubber protective cap to
help prevent accidental shorting to ground, which could seriously damage the alternator

ALTERNATOR INSTALLATION

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 Before installing a replacement alternator, check service information for the exact
procedure to follow for the vehicle being serviced. A typical installation procedure
includes the following steps.

STEP 1:Verify that the replacement alternator is the correct unit for the vehicle.
STEP 2:Install the alternator wiring on the alternator and install the alternator.
STEP 3: Check the condition of the drive belt and replace, if necessary. Install the drive
belt over the drive pulley.
STEP 4: Properly tension the drive belt.
STEP 5: Tighten all fasteners to factory specifications.
STEP 6:Double-check that all fasteners are correctly tightened and remove all tools from
the engine compartment area.
STEP 7: Reconnect the negative battery cable.
STEP 8:Start the engine and verify proper charging circuit op

Fig: AC assembly and installation

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