SECTION 6D3-1 - CHARGING SYSTEM -

GEN III V8 ENGINE

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver’s air bag, seat belt pre-tensioners and driver’s and front

passenger’s air bags or seat belt pre-tensioners, driver’s and front passenger’s air bags and left and

right-hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M Supplemental Restraint System

of the VT Series I Service Information before performing any service operation on, or around any SRS

components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could

result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.

1. GENERAL INFORMATION

A Mitsubishi 140 amp generator is fitted to all VT Series II models with GEN III V8 engines. The generator is

mounted on the left-hand side of the engine below the power steering pum p. The generator can be identif ied by its

external appearance in that it has neither an external cooling fan nor an externally mounted regulator.

The generator is a three-phase type, incorporating a rotor having six pole pairs fitted with two cooling fans, one on

the drive end and the other on the slip-ring end. Rotor cur rent is c onveyed to the rotor winding by a pair of slip-r ings

and carbon brushes via the voltage regulator. T he rotor is supported by ball bearings in both the drive and s lip-ring

end housings. Surrounding the rotor is a field coil, which is of a three-phase star connected output winding

construction on a ring shaped lamination pack.

The output of the field coil winding is rectified by eight diodes which are contained within the slip-ring end housing.

Excitation current is supplied to the rotor field coil via the voltage regulator, brushes and slip-rings. The electronic

voltage regulator requires no adjustment in service.

The generator has three external connections; the B+ lead to the battery positive terminal, the L lead to the

generator warning lamp (max. 2 watts), the S lead for battery voltage sensing, refer to Fig. 6D3-1-1.

Fig. 6D3-1-2 shows an exploded view of the 140 amp generator.

T26D3101

Figure 6D3-1-1

1. Battery B+ Terminal

2. Wiring Lamp (L Terminal)

3. Battery Sensing (S Terminal)

4. Bearing

5. Pulley

6. Front Bracket

7. Rotor

8. IC Regulator

9. B+ Terminal Bolt

10. Rectifier

11. Brushes

12. Bearing

13. Rear Bracket

14. Field Coil

T26D3102

12 13 14

15 16

Figure 6D3-1-2

1. Through Bolt (4 off) 7. Bearing Retaining Plate 15. Thrust Washer

2. Bearing Retaining Plate Screw 8. Rotor 16. Rectifier Assembly

(4 off) 9. Slip-ring End Bearing 17. Rear Bracket Assembly (Includes

3. Nut 10. Field Coil Items 11 to 19)

4. Drive Pulley 11. Regulator and Brush Screws 18. Terminal Cover Bush

5. Front Bracket Assembly (Includes 12. Brush Retaining Plate 19. Nut

Items 2, 5, 6 and 7) 13. Regulator

6. Front Bearing 14. Brush

1.1 OPERATION

With the ignition switch turned to the on position,

current is supplied via the warning lamp to the

L terminal of the regulator. Current then flows from

the B+ terminal through the rotor winding via the

regulator brushes and the collector emitter junction

of the regulator switching transistor to earth,

completing the circuit.

The current in the rotor causes a magnetic field

between adjacent poles to be created, this field is

rotated and cuts the windings of the field coil at

right angles inducing a voltage into them. As the

speed is increased, this induced voltage increases

and results in current being rectified in the 3 phase

diode bridge and supplied as DC to the B+ output

and hence to the battery. When the voltage at the

B+ terminal to the battery reaches approximately

14.2 volts, the S terminal which is monitoring this

voltage, turns the regulator transistor base current

off, removing rotor current. This results in a

decrease in output voltage to below the regulating

voltage, turning the regulator transistor base

current back on and the whole cycle is repeated

very rapidly. An internal diode protects the

transistor and the regulator the against back

voltage developed across the rotor winding when

the regulator transistor turns off.

T26D3103

B+

0.5 F

IC REGULATOR

12V BATTERY

BATTERY SENSE

IGNITION

SWITCH

SWARNING LAMP

12 WATT

Figure 6D3-1-3

Should a situation arise where the main B+ cable

or battery sense wire (S terminal) become

disconnected or have a high resistance, the

regulator will limit the output voltage to a safe level

(backup mode), approximately 1 to 3 volts above

the regulators normal setting.

When the ignition switch is turned on and the

engine is not running, the current to the rotor is

reduced by switching it on and off at a 50% duty

cycle (active standby mode), the frequency is

approximately 4 kHz and may be audible at times

(this is norm al). Once the engine is s tarted, normal

regulation commences.

Should the warning lamp f ail, the generator will self

excite by deriving a small current from the phase

connection allowing the voltage to build up to

regulating level.

IMPORTANT: No rotor winding current will flow

when the engine is cranking.

The regulator incorporates internal diagnostics

which will illuminate the warning lam p as a result of

fault conditions in the generator and/or external

circuitry.

These conditions include:

1. Overcharging of the battery.

2. Regulator output stage short circuit.

3. Open circuit in the rotor winding.

4. Diode short circuit.

The regulator compares the voltage at the

B+ terminal with the voltage sensed at the

S terminal connected to the battery positive. If the

voltage differential exceeds a predetermined

threshold, the regulator will operate in backup

mode to limit the output voltage to a s af e level. T he

warning lam p will remain illum inated as long as the

fault conditions prevail.

Sources of high resistance which will trigger the

warning lamp are:

1. Poor contact in the wiring harness connectors.

2. Poor contact between the rectifier and the

regulator.

3. High resistance in the fusible link assem bly or

battery terminals and cables.

2. MI NOR SERVICE OPERATIONS

2.1 SAFETY PRECAUTIONS

Since the generator and voltage regulator are designed for use only on a negative earth system, the following

precautions must be observed. Failure to observe these precautions will result in serious damage to the generator.

1. When installing a battery, first f it positive (+) c able to battery positive (+) term inal and then f it negative (–) c able

to battery negative (–) terminal.

2. When a slave battery is utilised for starting purposes, ensure both batteries are connected in parallel, ie.

positive terminals together and negative terminals together.

3. When charging battery, disconnect both battery cables, thus isolating generator from battery and external

charging equipment.

4. The generator must not be oper ated on an open c irc uit (this is without the battery in the circuit), and the battery

must not be disconnected while the generator is running.

5. Do not attempt to polarise the generator.

6. Always ensure that generator warning lamp glows when ignition switch is turned to the ON position.

IMPORTANT: As this circuit is related to and assists in the exc itation of the r otor f ield windings, do not proc eed until

any faults in the generator warning lam p c ircuit have been rec tified. Ens ure that the warning lam p wattage does not

exceed 2 watts.

7. The L terminal of generator should never be connected to battery or ignition circuit (12 volts), as this will

damage generator warning lamp circuit.

8. Some battery powered timing lights can produce high transient voltages when connected or disconnected. Only

disconnect or connect timing lights when the engine is switched off.

2.2 MAINTENANCE AND ON - VEHICLE TESTING

At regular intervals, inspect the terminals of the generator for corrosion, check wiring for loose connectors or

damaged insulation. Check the mounting bolts for tightness, check the drive belt for alignment and wear and the

drive pulley for damage. The drive belt adjustment for the engine ancillaries, such as the generator and water pump,

is provided by a spring loaded tensioner. The drive belt therefore, does not require any regular adjustment.

LUBRICATION

The ball bearings supporting the rotor shaft are pre- lubr icated and s ealed, ther ef ore no lubr ic ation is poss ible during

service.

The bearings used in this generator are high tolerance type. If the bearings are removed during the generator

disassembly, new bearings must be installed to restore the generator to original specification.

TESTING THE GENERATOR OUTPUT AND VOLTAGE REGULATOR

Testing Prerequisites

Before testing the generator output, m ake certain that the generator circuit is thoroughly check ed for loose or dirty

connections. The generator must always be connected to the battery during testing, otherwise damage to the

diodes could result.

The battery should be fully charged. Test the specific gravity of the individual cells. The readings should be within

10 points of each other. It is recommended that the average specific gravity should be 1.260 or higher.

A load test should be carried out to determ ine the ability of the battery to supply and accept current. T his is a good

indicator as to the general condition of the battery. Refer to Section 12A BAT T ERY AND CABLES of the VT Ser ies

I Service Information for details of battery testing.

The generator warning light, in addition to indic ating that the generator is charging, is also necessary for initial f ield

excitation.

Inspect the drive belt and belt tens ioner markings to deter mine if the drive belt is within operating limits. Replac e the

belt if excessive wear is evident or outside the belt tensioner’s operating range, refer to Section 6A3 ENGINE

MECHANICAL — GEN III V8 ENGINE of the VT Series II Service Information for details.

TESTING GENERATOR OUTPUT

Regulating Voltage Test on the Vehicle

1. Ensure that all the electrical equipment is

turned off, and the ignition switch is in the OFF

position.

2. Disconnect battery earth cable at battery.

3. Disconnect the generator positive lead (Red

wire) from the generator B+ terminal.

4. Connect the positive lead of an ammeter (1)

with a 0 - 100 am p scale to B+ term inal on the

generator (3), and the ammeter negative lead

to the disconnected generator positive lead

(Red wire).

5. Connect positive lead of a voltm eter (2) with a

minimum voltage scale of 0 - 20 volt to the

generator B+ terminal, and voltmeter negative

lead to a good earth connection on the

generator housing.

IMPORTANT: Insulate the generator positive lead

(red wire) terminal to prevent contact with any

metal part of the vehicle. If the terminal is earthed,

damage to the charging circuit will result when the

battery is reconnected.

6. Connect the earth cable to the battery (5). Fit a

loading device (4) across battery terminals, ie.

an adjustable carbon pile.

IMPORTANT: Loading device must have a

minimum power consumption of 1000 watts.

7. Record the voltmeter reading before starting

the engine. This reading s hould inc reas e when

the engine is running, indicating generator

output.

8. Start engine, raise engine speed and adjust

load (ammeter reading) to that nominated in

the following chart. Check generator output

(voltmeter reading) against specification.

T26D3104

B+

0+200-200

020

Figure 6D3-1-4

Load Regulation Test

With the voltmeter, ammeter and carbon pile

connected as in previous test, increase engine

speed to 2350 rpm (approximately 5000 generator

rpm ) and increas e load to approximately 126 am ps

(90% of full output). A decrease in the regulating

voltage should not exceed 0.5 volt of the readings

obtained in the previous test.

If the decrease in the regulating voltage is greater

than 0.5 volt, the regulator is defec tive and mus t be

replaced.

Generator Output Test at Full Load

With the voltmeter, ammeter and carbon pile

connected as in previous tests, increase engine

speed to 2350 rpm (approximately 5000 generator

rpm) and increase load until the generator output

voltage drops to 13.5 volts and note ammeter

reading.

ENGINE RPM

LOAD

VOLTMETER READING

1300

5 Amps

14.4 ±0.3 Volts

Full output (140 amps) should be obtained under

these conditions. It m ay be nec essary to adjust the

throttle so as to maintain the desired engine speed.

IMPORTANT: Keep the time for this test to a

minimum so as to avoid undue heating and high

engine speeds.

If the generator does not provide rated output, it

should be removed for repair, refer to

3.1 GENERATOR in this Section.

NOTE: On completion of the generator output

testing, to prevent excessive battery discharge

occurring, the engine should be returned to idle

speed and the loading device disconnected from

battery terminals.

9. Disconnect the battery earth cable at battery.

Remove the voltmeter and ammeter, then

reconnect the generator positive lead (Red

wire) to the generator B+ terminal. Reconnect

the battery earth cable to the battery.

CHARGING CIRCUIT VOLTAGE DROP TEST

With normal connections made at generator,

charging circuit can be checked for voltage

drop as follows:

1. Connect a low range voltmeter between

generator positive terminal and battery

positive post.

2. Switch on headlamps, start engine and

increase engine speed to approximately

2500 rpm and note voltmeter reading.

3. Reduce engine speed and transfer voltmeter

connections, negative to generator housing

and positive to battery negative post. Increas e

engine speed to approximately 2500 rpm and

again note voltmeter reading.

4. If readings exceed 0.5 volt on positive side

and 0.25 volt on negative side, there is a high

resistance in the charging circuit which must

be traced and corrected.

3. MAJOR SERVICE OPERATIONS

3.1 GENERATOR

REMOVE

CAUTION: Generator is in close proximity to

left-hand exhaust manifold. Allow engine to

cool before removing generator.

1. Disconnect battery earth lead.

2. Remove four dome nuts (2) securing engine

dress cover assembly (1) to intake manifold

studs, then lift off and remove cover assembly.

T26D3105

Figure 6D3-1-5

3. Loosen clamps (1 ) s ec uring air intake hos e (2)

to throttle body and to air filter. Disconnect

wiring harness connector from mass airflow

meter and remove air intake hose and airflow

meter assembly.

T26D3106

Figure 6D3-1-6

4. Lift and remove PCM heat shield (1) from

left-hand side of engine compartment.

5. Remove air filter housing assembly, refer to

Section 6C3-3 SERVICE OPERATIONS —

GEN III V8 ENGINE of the VT Series II

Service Information for details.

T26D3107

Figure 6D3-1-7

6. Using a 15 mm ring spanner on drive belt

tensioner pulley pivot bolt, rotate tensioner

pulley assembly clockwise and remove drive

belt from power steering pump and generator

drive pulleys. Release drive belt tensioner.

T26D3108

Figure 6D3-1-8

7. Remove power steering pump and reservoir,

refer to Section 9A STEERING of the VT

Series II Service Information for details.

8. Pull battery harness cap fr om B+ terminal, and

remove nut (1) and positive lead (2).

9. Press loc k tab on generator connec tor (3) and

remove generator connector (3) from

generator.

T26D3109

Figure 6D3-1-9

10. Remove bolt (1) securing rear of generator to

mounting bracket.

T26D3110

Figure 6D3-1-10

11. Remove two bolts (1) securing generator and

mounting br acket to the engine, then separate

generator from mounting bracket and lower

generator down onto stabiliser bar.

12. Remove bolt (2) securing generator and idler

pulley m ounting brack et to engine and r emove

mounting bracket and idler pulley assembly.

13. Lift generator up and out between engine and

radiator.

T26D3111

Figure 6D3-1-11

REINSTALL

1. Installation of generator is reverse of removal

procedure. Ensure that the mounting bracket

and generator retaining bolts are torqued to

specification.

2. Ensure that the nut retaining battery harness

positive lead to B+ terminal is torqued to

specification. Install cap over B+ terminal.

3. Install power steering pump, refer to Section

9A STEERING of the VT Series II Service

Information for details.

4. Using a 15 mm ring spanner on drive belt

tensioner pulley pivot bolt, rotate tensioner

pulley clockwise and install drive belt onto

power steering pump, generator and idler

pulleys.

Ensure that the drive belt is correctly routed

and that drive belt ribs are correctly installed

into all accessory drive belt pulleys and

crankshaft balancer drive belt grooves.

5. Install engine dress cover ensuring that stud

grommets in the dress cover remain in place.

Install dome nuts and tighten to correct torque

specification.

6. Reconnect battery earth lead.

7. Start engine and check generator warning lamp

operation, drive belt alignment, generator

output and voltage regulator operation.

ENGINE DRESS COVER TO

INTAKE MANIFOLD DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

GENERATOR

RETAINING BOLTS

TORQUE SPECIFICATION 40 – 60 Nm

B+ TERMINAL NUT

TORQUE SPECIFICATION 5-12 Nm

T26D3112

Figure 6D3-1-12

1. Tensioner

2. Water Pump

3. Drive Belt

4. Power Steering Pump

5. Generator

6. Idler

7. Crankshaft

8. Drive Belt (Air Conditioner Pump)

9. Tensioner (Air Conditioner Pump Drive Belt)

10. Air Conditioner Pump

11. Idler (Air Conditioner Pump Drive Belt)

DISASSEMBLE

The following precautions must be noted before

attempting to disassemble the generator to check

for faulty components.

• When testing the rectifier diodes with an AC

type tester, the RMS output must not exceed

12 volts. It is recommended that the field coil

should be disconnected before testing the

diodes.

• Insulation tests on the rotor and field coil should

use a voltage not exceeding 110 volts for a

series test lamp. The rectifier must be

disconnected from the field coil prior to testing.

• Due to the very low resistance value of the field

coil winding, it may not be possible to obtain

accurate readings using a conventional

ohmmeter.

1. Using a permanent marking pen align mark (4)

relative positions of front bracket (1), field coil

frame (2) and rear bracket (3).

T26D3113

Figure 6D3-1-13

2. Remove four through bolts.

3. Using a screwdriver, carefully prise between

the field coil and the front bracket, ensuring

that the screwdriver is not inserted too far or

the field coil will be damaged. Separate the

front bracket, pulley and rotor assembly away

from the field coil and rear bracket assembly.

T26D3114

Figure 6D3-1-14

4. Clamp rotor in a vice, ensuring that the rotor

poles are not distorted, and remove drive

pulley attaching nut (1), drive pulley (2) and

front bracket (3).

T26D3115

Figure 6D3-1-15

5. Remove four screws (1) securing the bearing

retaining plate to front bracket.

6. Press the bearing from the f ront br ack et with a

suitable socket.

NOTE: The bearing MUST be replaced with a new

bearing on assembly.

T26D3116

Figure 6D3-1-16

7. Using a bearing puller (1), remove slip-ring

end bearing (2) from rotor shaft (3), taking

care not to damage the plastic side of the

slip-ring or distort the rear fan during the

process.

NOTE: The bearing MUST be replaced with a new

bearing on assembly.

T26D3117

Figure 6D3-1-17

8. Remove nut, wave washer, flat washer and

insulating washer from the B+ terminal bolt.

9. Remove the rectifier retaining screw and two

brush holder retaining screws. Separate the

field coil and rectifier assemblies as a unit

from the rear bracket.

10. Unsolder and remove each brush and spring

assembly.

11. Separate field coil from rectifier assembly by

unsoldering the four field coil windings to

rectifier connections (arrowed in Fig. 6D3-1-

18).

NOTE: Use only as much heat as required to melt

the solder. Excessive heat may damage the

diodes.

IMPORTANT: T he rec tifier assemb ly is serviced as

an assembly only. Individual replacement parts are

not available.

T26D3118

Figure 6D3-1-18

12. Unsolder the two joints connecting the brush

holder and regulator assembly to the rectifier,

and remove the assembly from the rectifier.

CLEANING AND INSPECTION

With generator completely disassembled,

components should be cleaned and inspected.

Wash all components except field coil, rotor,

rectifier and regulator in a suitable cleaning solvent.

Carefully clean rotor and f ield coil with comp ressed

air.

NOTE: Do not clean field coils or rotor windings

with the cleaning solvent or damage to the

insulation could result.

NOTE: Clean all parts other than those previously

nominated using a non volatile or low inflammable

agent in a well ventilated area.

It is important that all parts are thoroughly dried

before assembly, taking care not to breath in any

vapours.

Observe the safety regulations and precautions

issued by the manuf actur er of the c leaning agent in

use.

COMPONENT CHECKING

Brush Gear

Check the length of the brushes protruding from

the brush holder. Replace the brush and spring

assembly if the brush is worn down to the wear

limit. Also replace if abnormal wear or cracks are

noticed.

MINIMUM BRUSH

LENGTH 5.0 mm

Clean the brushes and brush holder, removing

particles by wiping with a clean cloth. Ensure that

the brush moves smoothly in the brush holder.

Replace if necessary.

Check the brush spring function. Push the brush

into the brush holder until the wear limit line of the

brush protrudes 1 mm from the brush holder

moulding and check the spring is functioning

correctly. Replace if necessary.

Check that brushes move smoothly in and out of

holder by pushing on end of brushes, and then

releasing. Replace if necessary.

T26D3119

Figure 6D3-1-19

Diodes

IMPORTANT: The rectifier assembly is not

repairable and should be replaced if any diodes

prove to be faulty.

The following commercially available test

equipment is essential for correctly testing the

diodes within the rectifier assembly.

A diode tester or multimeter with a diode test

feature where the DC output at the test pr obes

does not exceed 14 volts, or in the case of AC

testers, 12 volts RMS.

This is necessary so as to ensure that when

testing the diodes, the forward and reverse

voltage checks are completed and are not

masked by the diode turning on due to Zener

breakdown voltage.

IMPORTANT: In Steps 1 and 2, ensure that the

reverse voltage applied is less than 14 volts DC, or

12 volts RMS when using an AC tester.

1. Attach negative test probe of diode tester or

multimeter with diode test function to the

positive heatsink (1) of the rectifier assembly

and the positive probe alternatively to positive

diode connections (2).

A low resistance reading, or the forward

voltage drop across the diode should be

obtained.

Reverse probe connections and repeat test to

check that current is passed in one direction

only (high res istance r eading or higher r everse

voltage should be obtained).

If necessary, replace the rectifier assembly.

T26D3120

Figure 6D3-1-20

2. Repeat procedure on negative heatsink (3) by

attaching positive test probe to the negative

heatsink and the negative probe alternatively

to negative diode connections.

A low resistance reading, or the forward

voltage drop across the diode should be

obtained.

Reverse probe connections and repeat test to

check that current is passed in one direction

only (high res istance r eading or higher r everse

voltage should be obtained).

If necessary, replace the rectifier assembly.

Rotor

Clean any dirt or particles from the rotor with

compressed air or a clean cloth.

Insulation Test

Using an insulation tester, or a series test lamp (up

to 110 volts), check insulation between slip-rings

and rotor core or shaft. Test light should not glow or

insulation tester should indicate an open circuit

(greater than 1 Mohm). If an open circuit does not

exist replace rotor.

T26D3121

Figure 6D3-1-21

Open Circuit Test

Connect ohmmeter probes across slip-rings and

measure resistance of rotor windings.

If the rotor winding is open circuit, replace the rotor.

IMPORTANT:T he ac tual rotor winding resis tanc e is

too small to measure on a conventional multimeter.

T26D3122

Figure 6D3-1-22

Slip-rings

Check slip-rings for wear or damage. If the

slip-rings are worn, damaged or out-of-round, the

rotor must be replaced.

SLIP-RING

OUTER DIAMETER 22.7 mm

SLIP-RING

SERVICE LIMIT 22.1 mm

Bearings

The bearings used in this generator are a high

tolerance type. Only genuine replacem ent bearings

are to be used. It is recommended that the

bearings be replaced during the reconditioning

process to restore the generator to original

specification.

Field Coil

Inspect the f ield coil for damage, loose c onnec tions

or discoloured windings. Replace if necessary.

Insulation Test

Connect a powered test lam p (up to 40 volts) or an

ohmm eter between any field coil lead and field coil

frame. If test lamp glows or ohmmeter reading is

low indicating that an open circuit does not exist,

replace field coil.

T26D3123

Figure 6D3-1-23

Open Circuit Test

1. Connect ohmmeter to any two field coil leads.

Ohmmeter should not register any significant

resistance.

2. Repeat test on remaining field coil leads. If

resistances are high, replace the field coil.

T26D3124

Figure 6D3-1-24

REASSEMBLE

Reassembly of the alternator is the reverse of the

disassembly procedure, noting the following:

1. Do not lubricate the bearings as they are pre-

lubricated.

2. For rotor bearings with resin bands, grease

should not be applied. Remove oil completely

if found on the bearing box to prevent bearing

creep.

3. Use high temperature solder (melting point

230°C) and a 180 – 270 watts soldering iron.

Do not used exces sive heat as dam age to the

rectifier may result.

4. As the rotor bearing and rear bracket fitting is

tight, heat the area around the rear bracket

bearing box to 50 – 60°C before installing the

rotor into the rear bracket.

FIELD COIL RESISTANCE

@ 20°C 1.7 – 2.1

ohms

5. Position brushes (1) in the brush holder (2) in

relation to rotor rotating direction as indicated

by arrow in Fig. 6D3-1-25.

T26D3125

Figure 6D3-1-25

6. Before installing the rotor, push brushes (1)

into the brush holder and insert a wire (2) to

hold them in the raised position. Install the

rotor and remove the wire (2).

T26D3126

Figure 6D3-1-26

7. Do not over tighten the B+ terminal nut as

damage to the insulating washer will result.

8. After assembly, rotate the pulley slowly by

hand to verify that the rotor turns smoothly.

The following tightening torques apply.

DRIVE PULLEY ATTACHING

NUT TIGHTENING TORQUE 99 – 137 Nm

THROUGH BOLTS

TIGHTENING TORQUE 3.5 – 5.3 Nm

BEARING RETAINER SCREWS

TIGHTENING TORQUE 2.0 – 5.3 Nm

BRUSH HOLDER

RETAINING SCREWS

TIGHTENING TORQUE 2.0 – 5.3 Nm

RECTIFIER

RETAINING SCREWS

TIGHTENING TORQUE

2.0 – 5.3 Nm

B+ TERMINAL NUT

TIGHTENING TORQUE 12.8 – 18.6 Nm

4. DIAGNOSIS

1. UNDERCHARGED BATTERY

a. Defective battery.

b. Loose connection in charging system.

c. Corroded connections in charging circuit.

d. Defective wiring.

e. Faulty generator.

f. Faulty voltage regulator.

2. OVERCHARGED BATTERY

a. Shorted battery cell.

b. Faulty voltage regulator.

c. Short circuit in rotor winding.

d. Voltage drop in sense wire.

3. FAULTY INDICATOR LIGHT OPERATION

(LIGHT DOES NOT GLOW)

a. Burnt out bulb.

b. Defective bulb socket.

c. Defective wiring.

d. Defective rectifier.

e. Defective regulator.

4. FAULTY INDICATOR LIGHT OPERATION

(LIGHT REMAINS ON)

a. Negative diode failure.

b. Defective voltage regulator.

c. Faulty generator.

d. ‘B+’ cable off or broken.

e. ‘S’ cable off or broken.

f. Battery overcharged.

g. Open circuit in rotor winding.

5. NOISY GENERATOR OPERATION

a. Normal magnetic hum.

b. Badly discharged battery.

c. Generator mounting brackets loose or bolts loose.

d. Worn or frayed drive belt.

e. Worn bearings.

f. Loose drive pulley attaching nut.

g. Open or shorted diodes.

h. Open or shorted field coil winding.

5. SPECIFICATIONS

Earth Polarity......................................................................... Negative

Nominal Voltage.................................................................... 12 V

Nominal Output..................................................................... 140 Amps

Voltage Regulator Setting..................................................... 14.4 ±0.3 V

Field Coil Resistance @ 20°C............................................... 1.7 – 2.1 ohms

Rotor Resistance @ 20°C..................................................... Too small to measure

Slip-ring Outer Diameter....................................................... 22.7 mm

Slip-ring Service Limit........................................................... 22.1 mm

Brush Length New ................................................................ 18.5 mm

Brush Length Service Limit................................................... 5.0 mm

Direction of Rotation (viewed from pulley)............................ Clockwise

6. TORQUE WRENCH SPECIFI CATIONS

Engine Dress Cover to Intake Manifold Dome Nut............... 4 – 6

Through Bolts........................................................................ 3.5 – 5.3

Drive Pulley Attaching Nut .................................................... 99 – 137

B+ Terminal Nut.................................................................... 12.8 – 18.6

Battery Harness Terminal to B+ Terminal Nut...................... 5 – 12

Generator to Drive Belt Tensioner Attaching Bolts............... 40 – 50

Generator Support Brace Mounting Bolts............................. 20 – 30

Generator to Drive Belt Tensioner

Bracket Mounting Bolt........................................................... 20 – 34

Bearing Retainer Screws...................................................... 2.0 – 5.3

Brush Holder Retaining Screws............................................ 2.0 – 5.3

Rectifier Retaining Screws.................................................... 2.0 – 5.3