The easiest way to test it is by using a voltmeter. Testing an alternator and checking output how a car works. This test procedure covers the tests required for the insuation integrity of a high power, high voltage, short liletime alternating, current generator for use in or in conjuction with airborne equipment. This manual contains important safety and operating instructions for the alternatorstarter tester 8600ksa8503a. Dc alternator test voltage battery electricity scribd. The ir test involves an instrument commonly called a megger. Alternators basic principle stationary armature rotor armature windings wye and delta connections distribution or breadth factor or winding factor or spread factor equation of induced e. Open circuit test and short circuit test of synchronous. Other members of the family are the directcurrent dc motor or generator, the induction motor or generator, and a number. Immediately after engine starts, system volts are lower. The older sm20205 alternator was used on the 7000pt and sm916 units and can be replaced by the new alter. N is known as synchronous speed, because it is the speed at which an alternator must run, in order to generate an e. The following is offered as an explanation of the policy and procedures followed by cummins generator technologies to provide traceable and quality management system supported technical documentation regarding the performance details of. One of the easiest ways to test the integrity of your alternator is by using a very simple device called a voltmeter.
We are a team of ase certified mechanics that have created this guide for you so you can save money or at least see what you are paying for when taking your car in for repairs. A new design for automotive alternators semantic scholar. Fault finding manual for self excited and separately excited. Understanding the alternator four wires connect the alternator to the rest of the charging system. Perreault vahe caliskan massachusetts institute of technology abstract this paper introduces a new design for alternator systems that provides dramatic increases in peak and average power output from a conventional lundell alternator, along with substantial improvements in efficiency. Inspection and test procedures for rotating machinery, mynchronous motors and generators consist of visual and mechanical inspection, electrical tests. The following test procedures will assist you in fault finding on the alternator. This alternator works together with the battery to supply power when the vehicle is running.
The basic charging system consists of a battery, alternator, voltage regulator, ignition switch, and. Explain the constructional details of alternator in. Regulator control voltage test 1 connect voltmeter to battery. Battery cable test with single battery location 32 310. This manual has several features which make it easy to use online. Digital volt ohm meter dvom, ammeters, test lamp, alternator testing equipment such as load banks, oscilloscope, wire, cable connectors. The purpose of this test is to check the command, feedback, and output voltage signals from a fordtype smart charging alternator. Alternator performance depends on good electrical insulation of the windings. Onewire refers to the minimum number of lead wire connections necessary at the alternator for operation and requires only that the alternator output terminal be connected to the battery insulated positive for a negativeground system terminal. Go no go control basis, with this system not issuing a test certificate.
The manual contains a functional description of the miles zx40st system followed by notes on schematics, test procedures and most importantly, safety procedures. Be sure to check all safety warnings in your equipments operating manual before performing any work on. For producing a frequency of 50hz, the alternator will have to run at the following speeds. N1506 series troubleshooting guide for n15061 alternators. It applies to any unit that uses the sm22900 or sm20205 not available from core alternator. Still, using a few simple tests at home that show you how to test an alternator, how to inspect a battery, if necessary, and check a drive belt will help you pinpoint the cause of the problem. The full test procedure is detailed in the installation, service and. This rep3rt contains the highvoltage tests and test procedures required to evaluate the generator insulation integrity. Output current and voltage should meet the specifications of the alternator.
This simple guide shows you how easy testing an alternator is. If no voltage, remove the blue tach wire from the alternator, while staircase is. Technical information from cummins generator technologies. Page 19 alternator tests black 12 volt system test using two 6 volt batteries in series 6 volts 6 volts 6 volts using the hookup above follow test procedures on page 12. Figure 3typical scale on the megger insulation tester. Active grill shutter test, alternator field control state, alternator. Reconnect the earth terminal on the battery, and switch on the ignition. The output of an alternator is direct current, however ac voltage is actually created and then converted to dc as voltage leaves the alternator on its way to the battery and the electrical loads. Chapter 8 automotive electrical circuits and wiring navy bmr. Lincoln mark vii basic alternator repair lincoln mark vii basic alternator repair 20070630ab 90% of the time, when our alternator needs replacement it is because of bearing noise, worn brushes or a broken brush holder. Tyler borysiak, myles moore, alex sklar, joshua lamb, stephen.
If a customer order includes a request for factory test certificate, this will be produced at final point of documentation control for the alternator, prior to despatch. This means that if your battery is too low, you will be unable to start the vehicle and thus you will also be unable to test the alternator, rendering any additional voltmetertesting totally useless. Tyler borysiak, myles moore, alex sklar, joshua lamb. For penntex systems with other than a px7000 voltage regulator, contact us or refer to our web site at. This alternator is uniquely engineered to provide the finest performance and durability for your vessel. Range cost of parts required, availability of replacement parts, cost of. The alternator shall be capable of delivering rated output kva at rated frequency and power factor, at any voltage up to 5 percent above or below rated voltage. The ball in the main stator must rotate in the opposite direction to that of the exciter stator.
If the test bench results show the alternator s output performance to be out of specification, replace the alternator. Connect the test leads of a volt meter to the alternator output terminals. Ig is the ignition input that turns on the alternator regulator assembly. All the regulator does is connect the brushes to the supply until some voltage between and 14 volts is reached. Cooling the integral fan provides effective through cooling of the alternator. If voltage does not fall into these parameters then their is a possibility that the rectifier is faulty. Reverse side of card at right is used to record the test data.
If rotation is the same for both stators, reverse tag using the procedures below, and reconnect before preceding with installing. Troubleshooting guide for n12251n12371n15051 alternators. For the battery testing procedure, see our blog post on battery testing. If you still dont find it, try getting the test done with the alternator in the car and not on the bench, the chain part stores have a real nice handheld machine to test the. The electrical frequency of synchronous generators is synchronized locked in with the mechanical rate of rotation. Do not install your highoutput alternator without ensuring that the system wiring is. The very first thing you need is to measure the voltage output of your car s battery. Curve b shows same values corrected to 20c see page 22, giving a definite downward trend toward an unsafe condition. Alternator output test the alternator output test checks the ability of the alternator to deliver its rated output of voltage and current. Battery cable test with dualbattery locations 33 3. It is essential that all test instruments be regularly checked for safety, and any connection leads, probes or clips checked to. How to test an alternator testing the voltage regulator, diode rectifier and stator. S is used by the regulator to monitor charging voltage at the battery.
Capitulo 2 automotive electrical circuits and wiring. All the regulator does is connect the brushes to the supply. This enables you to do a safe and thorough alternator test while bypassing the vehicle wiring and ecm. Testing an alternator and checking output alternator electrical. The alternator generates a stronger voltage that builds up after buildup the field is supplied by rectified voltage from stator with brushes. The very first thing you need is to measure the voltage output of your cars battery. Use proper personnel protective equipment when handling hazardous materials, fuels, and lubricants. Various design solutions are available depending upon the application. The current necessary to magnetize the alternator field during operation is obtained from the exciter.
Diagnosing computercontrolled charging systems motor. An alternator or ac generator is an electrical machine which converts mechanical energy into alternating electric energy. Ig is the ignition input that turns on the alternatorregulator assembly. The alternator generates a stronger voltage that builds up after buildup the field is supplied by rectified voltage from stator with brushes direct connected dc generator smaller generator to excite the field coils brushes to excite the rotor variation. Chapter 1 principles of operation of synchronous machines the synchronous electrical generator also called alternator belongs to the family of electric rotating machines. Brake specialists who diagnose, overhaul, repair or replace and test the parts of disc, drum or. Dc vs ac dcac field theory electromagnetic induction. Alternator test to charge a battery, the alternator must produce a voltage higher than the battery voltage to cause current to flow into it. The rheostat r 3 is brought to its initial position cutin and tpst s 2 is closed.
Most leece neville alternators have isolated ground rectification. This test should be performed whenever an overcharging or undercharging problem is suspected. Test the alternator leads by connecting each in turn with the voltmeter to an earth. After a stator rewind, run a ball test on both stators once they are installed in the frame and interconnected. Use manufacturers data to identify the alternator command, feedback, and output circuits. Alternator testing all stepmills this document details the procedure for troubleshooting and testing a suspected bad alternator. Inspection and test procedures of rotating machinery, synchronous motors and generators on photo. Alternator problems manifest themselves in various ways, depending upon the particular failure. Follow the vehicle manufacturers recommended procedures to inspect the remainder of the charging circuit and other electrical circuits that may affect charging circuit performance. The battery is needed to start the vehicle, which, in turn spins the alternator at sufficient speed to keep the battery charged. By gradually cutting out the rheostat r 3, reading of the ammeter a 2,01020a is adjusted to the rated current of the alternator and the corresponding field current a 1, 012a is noted down.
The working principle of an alternator or ac generator is similar to the basic working principle of a dc generator. A safe test can be made with an induction ammeter held parallel to the output cable, but it is less reliable. Tp6353 312 safety precautions and instructions 7 fuel system explosive fuel vapors. These are followed by complete information about the 35 pin connector at the curtis controller and subsystem schematics with troubleshooting charts that will guide you through diagnosis. Automotive specialist tradespersons carry out diagnostic procedures and test, service and repair vehicle components. The alternator is a threephase, 12pole synchronous selfexcited generator with builtin rectifier and regulator and cooled by an external fan. When less than 8 amps are entering the battery voltage should be more than. The synchronous electrical generator also called alternator belongs to the family of electric rotating machines. You may need to refer to these instructions at a later date.
Identify the basic types of automotive wiring, types of terminals, and wiring diagrams. Figure 4typical record of insulation resistance of a mill motor. Load test the battery to know if it is reliable if the battery is not fully charged. Perform tach test by entering diagnostics on the console. Where necessary, the adapter harness for a specific application includes features such as a lowcurrent excitation light bulb and a test point. An alternator has 3,phase winding on the stator and a d. Initially, upon starting the unit, voltage is induced into the main stator. The full test procedure is detailed in the installation, service and maintenance manuals also known as the owners manual issued with every alternator and can also be found on the website.
Explain the constructional details of alternator in detail with neat sketches. Inspection and test procedures for rotating machinery. Black red 6 or 12 volt system tests using single or multiple batteries connected in parallel use the scale appropriate for the system test. List the inspection and test procedures for panelmounted voltmeters andor indicator lamps. Stator it is the stationary part of the machine and is built up of silicon steel laminations having slots on its inner periphery. The testing procedures, instruments and records should be submitted by the ge contractor for approval of pbsepeme. Factors affecting alternator size alternator on load synchronous reactance vector diagrams of loaded alternator. This manual contains important safety and operating instructions for the alternator starter tester 8600ksa8503a. View and download auto meter sb5 instruction manual online. Explain the constructional details of alternator in detail. Ensure that the engine has cooled sufficiently before beginning installation. It will prevent you from ensuring the alternator is not overcharging the battery battery must get to full charge before it can overcharge. The rotor consists of a smooth solid forged steel cylinder, having a number of slots milled out at intervals along the outer periphery and parallel to the shaft for accommodating field.
Therefore, the voltage must rise to the ok test zone of the alt. B is the alternator output wire that supplies current to the battery. Page 8 tg0018a if you have questions about your alternator or any of these test procedures, or if you need to locate a factory authorized. Other members of the family are the directcurrent dc motor or generator, the induction motor or generator, and a number of derivatives of all these three. The rate of rotation of the magnetic fields mechanical speed is related to the stator electrical frequency by. Excitation and automatic voltage regulator system excitation and automatic voltage regulator system note. Performing an alternator test on briggs and stratton engine.
By the time you need to use the toothpick, youll have just finished the martini procedure now that you have an understanding of the operation of the alternator, and know the component parts and their typical failures, youre ready to start your alternator. Throttle position switch notes the position of the throttle. The following describes two methods for performing an alternator test on a briggs and stratton engine. The complete guide to electrical insulation testing. Generator coils and coil segments were tested as part of the test evaluation reported in volume i of this. To conduct this test procedure you will need a meter that is sensitive. Testing the charging system be sure to follow safety precautions to protect the vehicle and yourself exhaust hoses and fender covers are often neglected. Electromagnetic interferencecompatibility emiemc control.
Alternator shall be provided with protection to prevent damage due to any external fault or overload condition, including short circuit, ground fault, or overload. Hook around all positive, or all negative battery cables 3. Open circuit test and short circuit test are performed on a synchronous machine to find out the synchronous impedance for large machine to determine the voltage regulation open circuit test the alternator is run at rated synchronous speed and the load terminals are kept open. An onsite tour of the facility is highly recommended for familiarization and to provide an opportunity for an exchange of technical information. Electrical, mechanical and thermal stresses, along with the environmental contaminations, cause the insulation system to degrade. Its hard to tell whether or not an alternator works if you dont know what to look for. Alternator starter tester associated model 8600ksa8503a. However, some of the procedures require you to take certain pre. This section will enable the main generator windings to be tested while running the generator at normal speed without load. Always connect tester volt meter directly to the negative output terminal of alternator or your test will be inaccurate. Tyler borysiak, myles moore, alex sklar, joshua lamb, stephen dunn.
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