Section 4006 Charging System
Section 4006 Charging System
Section 4006 Charging System
SECTION 4006
CHARGING SYSTEM
CONTENT
Description Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal, Installation and Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
Alternator Type
A127–120
Polarity Negative Ground
Nominal Voltage 12.0 v
Maximum Rev/Min. 18,000
Maximum Output 120 Amps
Regulator Controlled Voltage 13.6 – 14.4 v
Rotor Field Winding Resistance 2.6 Ω
Stator Field Winding Resistance 0.075 Ω
New Brush Length 20.0 mm
Minimum Brush Length 5.0 mm
Brush Spring Pressure 1.3 – 2.7 N (4.7 – 9.8 oz)
TORQUE SPECIFICATIONS
lbf.ft Nm
Alternator Through Bolts 4.0 5.5
Pulley Retaining Nut 52.0 70.0
Rectifier Attaching Screws 3.0 4.0
Regulator and Brushbox Screws 2.0 2.7
Terminal Nuts 2.0 2.7
Mounting Bolt 16.0 23.0
Adjusting Bolt 8.0 12.0
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2
Alternator Charging Circuit
G1 To Starter Motor S1 Ignition Switch
G2 Alternator MF1 Maxi–Fuse 1
M1 Starter Motor MF2 Maxi–Fuse 2
K1 Ignition Relay FL1 & FL2 Fuse Links
K2 Start Relay F9 Fuse 9–10A
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8
1
7
4 3
TA6010093A TA6010093B
3
Fan Belt Tensioner
A. Fan Belt Less Air Conditioning B. Fan Belt With Air Conditioning
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3. Brushes–and–Springs and Rotor Slip Rings
1. Remove the regulator and brushbox assembly
as described in this Chapter.
2. Ensure the brushes and slip rings are clean and
check for freedom of movement of the brushes
in the brushbox moulding.
3. Check the brush spring pressure with a push
type spring gauge and record the spring
pressure when the brush end face is flush with
the moulding. Install a new regulator and
brushbox assembly if the pressure is less than
specified.
If the visible length of the brushes(1) in the free
position is less than 0.25 in. (5mm) this is a probable 11
cause of open circuit in the field circuit and the
regulator and brushbox assembly should be
renewed, Figure 11.
NOTE: The brushes are an integral part of the
regulator and brushbox assembly and cannot be
replaced as individual items.
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13
Alternator Components
1. Shield 6. Bearing retainer Plate
2. Pulley Retaining Nut 7. Rotor Assembly
3. Pulley 8. End Cover
4. Stator and Housing Assembly 9. Regulator and Brushbox Assembly
5. Bearing 10. Rectifier and Housing Assembly
Disassembly – 120 Amp Alternator 4. Remove the three nuts securing the two halves
With reference to Figure 13 of the outer casing. Mark each half of the casing
to aid reassembly and carefully pull the casing
1. Remove the three nuts securing the plastic end
apart, it may be necessary to gently tap the
cover.
casing on the mounting lugs.
2. Remove the nut securing the blue wire to the
5. Remove the nut securing the pulley to the rotor
warning lamp terminal and disconnect the wire.
shaft and withdraw the rotor from the casing.
Remove the two bolts and two nuts securing the
regulator and brushbox assembly, withdraw the 6. It is not necessary to remove the rectifier from the
assembly from the alternator. casing as these are serviced as one unit.
3. Using a suitable soldering iron, unsolder the six
wires from the stator to rectifier.
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COMPONENT TEST
Rectifier Assembly – Diode Testing
With reference to Figure 14.
1. Test each of the nine diodes separately, using a
multimeter with a diode check facility or a
multimeter set on the resistance scale.
2. Connect one test lead onto the lower plate(3) and
the other to the diode pin(1).
On a multimeter(2) with the diode check facility,
note if a reading of 0.49 (volts) is shown. Reverse
the test lead connections. The meter should
indicate 0.49 (volts) during one half of the test
and 0 volts with the leads reversed. Repeat this
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test on all nine diodes. If any one diode fails this
test it will be necessary to replace the rectifier
and housing assembly.
3. Where only an ohmmeter is available repeat the
above test observing the following results, 0
ohms with leads in one direction and when the
test leads are reversed a reading of between
900–1000KΩ, again if any one diode fails this
test it will be necessary to replace the rectifier
and housing assembly.
Rectifier Insulation
With reference to Figure 15.
1. Check the insulation of the rectifier to the casing.
With an ohmmeter (2), connect the test leads
between the alternator casing(3) and the positive
plate of the diodes(1). An infinity reading should
be displayed, therefore indicating an open
circuit. If a resistance of any kind is indicated, i.e,
a short circuit, the rectifier and housing assembly
should be replaced.
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Stator Test – Winding Continuity
With reference to Figure 16.
1. Connect the ohmmeter (2) test leads between
the pairs of wires, A, B and C. There should be
a small resistance of 0.1Ω, between each pair of
wires. If a resistance higher than this is
registered it will indicate a possible break within
the winding, i.e, an open circuit. A lower reading,
for example 0.0Ω will indicate a short circuit
within the winding. If any one of the three pairs of
wires fail the test a new stator(1) and housing
assembly will be required.
16
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Rotor Test
Prior to performing component tests on the rotor the
following slip ring inspection should be carried out.
1. Ensure the slip rings are clean and smooth. If
necessary the slip rings may be cleaned with a
petrol moistened cloth. If the slip rings are burnt
and require re–finishing use very fine glass paper
(not emery cloth) and wipe clean.
NOTE: Ensure the re–finishing glass paper is
sufficiently fine to produce a highly polished slip ring
surface otherwise excessive brush wear will occur.
2. If the slip rings are excessively worn a new rotor
must be installed.
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Rotor Field Winding Insulation
With reference to Figure 19.
1. Using an ohmmeter(3) test between each of the
slip rings(2) and the rotor poles(1). An infinity
reading should be indicated in each case. If any
resistance reading is indicated the rotor
assembly must be replaced.
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RE–ASSEMBLY
1. Re–assembly of the alternator follows the
disassembly procedure in reverse.
INSTALLATION
1. Installation of the alternator is the removal
procedure in reverse.
On installation observe the following:
• Ensure the battery ground (negative) cable is
disconnected from the battery when installing the
alternator.
• Adjust the alternator drive belt as previously
described in this Chapter.
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