Ford Falcon. Manual — part 352

414-02-1

Alternator and Regulator

414-02-1

SECTION : 414-02 Alternator and Regulator

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414-02-2

DESCRIPTION AND OPERATION

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..414-02-3

Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...414-02-3

Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414-02-3

DIAGNOSIS AND TESTING

Alternator and Regulator . . . . . . . . . . . . . . . . . . . . . . . . . ...414-02-5

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...414-02-5

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414-02-5

Component

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .414-02-6

Pinpoint

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..414-02-7

REMOVAL AND INSTALLATION

Alternator Installation — 6 Cylinder . . . . . . . . . . . . . . . . . . . . . 414-02-14

Alternator Installation — 8 Cylinder . . . . . . . . . . . . . . . . . . . . . 414-02-14

414-02-2

Alternator and Regulator

414-02-2

SPECIFICATIONS

General Specifications

Description

Nm

Description

Specification

Pulley Securing Torque

98 - 137 Nm

Mitsubishi LC30 6 Cylinder

Rectifier

Riveted

Current Output

110 Amps @ Ambient

B+ Nut

8 +/- 1.2

Temp

Set Voltage

14.5 Volts @ 20

°C

Alternator Speed (RPM)

1300/32

/ Output Current (Amps)

2500/81

in Hot

5000/102

Earth Polarity

Negative

Mass

6.3 kg

Regulator Performance - 14.5 +/- 0.3 V

Set voltage
Regulator Performance - -5 mV/

°C

Temp Compensation
Synthetic Resistance: L

10 - 100 W / 12 V

terminal to Battery
Speed In Use

1000 - 19000 r / min

Rotor Inertia

3.4 x 10-3 kg m2

Pulley Pitch Diameter

51.25 mm +/- 0.5

Rear Fan Diameter

96.5 mm

Visteon 8 Cylinder
Current Output

130 Amps @ Ambient

Temp

Set Voltage

14.45 Volts @ 25

°C

Alternator Speed (RPM)

1300/32

/ Output Current (Amps)

2500/81

in Hot

5000/102

Earth Polarity

Negative

Mass

6.3 kg

Regulator Performance - 14.45 +/- 10.3 mV/

°C

Set voltage
Regulator Performance - 14.45 +/- 10.3 mV/

°C

Temp Compensation
Output Ramp Up Time

7 s

Max Speed In Use

19600 r / min

Max Ambient Temp

115

°C

Torque Specifications

Description

Nm

Mitsubishi LC30 6 Cylinder
Retaining Bracket Bolts

25 Nm

Bearing Retainer Plate

7.7 +/- .8 Nm

Through Bolts

8.8 +/- .8 Nm

Pulley Securing Torque

98 - 137 Nm

Rectifier

Riveted

B+ Nut

8 +/- 1.2

Mitsubishi LC30 8 Cylinder
Retaining Bracket Bolts

25 Nm

Bearing Retainer Plate

7.7 +/- .8 Nm

Through Bolts

8.8 +/- .8 Nm

G86726 en

414-02-3

Alternator and Regulator

414-02-3

DESCRIPTION AND OPERATION

field coil. This circuit is connected back to the load

Alternator

distribution point and is a protected circuit.

Description

CAUTION: DO NOT reverse battery sense and

Both the Mitsubishi (6 Cyl.) and Visteon (8 Cyl.)

warning lamp connections as this will destroy the

alternators are three phase alternating current (AC)

warning lamp circuitry. If replacing the alternator

generators with integrally mounted diodes that convert

warning lamp bulb, use of a bulb over 2 Watts

the AC into direct current (DC) suitable for charging

capacity may cause voltage regulator failure.

the battery.

Operation

The alternator is inherently self current limiting and

the diodes (shown in the circuit diagrams in Fig 2 & 4)

With the ignition switch turned on and the engine

prevent reverse current flow from the battery. The

running, the flow of current through the rotor field coil

alternator consists of the following major parts:

energises the twelve pole rotating electromagnet. The

The Stator: a laminated frame which carries the three rotation of the energised rotor unit induces an A.C.

phase star connected output winding in slots.

voltage in the three phase stator winding. This is

converted into D.C. by the diode rectifiers and

The Rotor: comprising the slip rings and field (exciter)

conducted to the B+ terminal.

windings. It is constructed of interfaced poles or

fingers which form alternate north and south poles.

The electronic regulator operation is similar to that of

The field winding is wound concentric with the shaft

the conventional electro-mechanical regulator in that

inside the claw and has its ends connected to the slip the field current is varied to maintain the output

rings.

voltage within close limits. However, switching is

performed by a transistor instead of vibrating

The rectifier pack contains eight output diodes on the

contacts.

six cylinder alternator (as shown in Fig 2), and six

output diodes on the eight cylinder alternator (as

The rectifiers, which only conduct current flow in the

shown in Fig 4). The diodes are arranged in a three

one direction through the alternator output diodes,

phase bridge connection having three diodes of

prevent the battery (which is directly and permanently

positive polarity and three diodes of negative polarity. connected to the alternator output terminal) from

discharging through the alternator. This characteristic

The two end heads carry the ball races. The drive

of the rectifiers eliminates the need for a cut-out relay,

end head incorporates the mounting lug, while the slip

(However, the battery must always be connected with

ring end head contains the brush gear, regulator and

the negative terminal to ground. Failure to connect a

rectifier pack.

battery with the correct polarity will damage the

The electronic regulator is integrated with the

alternator and regulator. Disconnect the negative

alternator assembly. The regulator consists of a static

battery lead when using a battery charger.)

compact assembly, consisting of a Hybrid circuit,

As the speed of the rotor increases, the induced

transistor and diode, soldered to a printed circuit

voltage in the stator winding increases, causing more

board.

current to flow to satisfy the load requirements.

The electronic voltage regulator and the brush

However, the inductive reactance of the stator winding

gear are an integral assembly mounted on the slip

provides an automatic self-regulating upper limit on

ring end head. The regulator is not adjustable and

the current output of the alternator.

if tested and found defective it must be replaced.

The regulator senses the battery voltage via the

B+ Battery Connection

battery sense wire and controls this voltage by

switching the alternator excitation field current on and

The B connection is used to connect the alternator to

off. If battery voltage is below regulated voltage, the

the Power Distribution Box (PDB) located in the front

power transistor is switched on. When the battery

right hand side of the engine bay.

voltage exceeds the specified limit, the transistor is

’I’ Warning light

switched off, causing output voltage to drop. A diode

protects the transistor and regulator circuitry from

The ’I’ circuit (or ignition circuit), is used to turn on the

voltage transients when the field is switched off by the

voltage regulator. This circuit is powered up with the

transistor. Switching the regulator on and off ensures

ignition key in the ON position. This circuit is also

the output voltage is maintained constant at the

used to turn the indicator lamp on, if there is a fault in

required regulated level.

the charging system operation or associated wiring

circuits.

’A’ Battery sense (V8 only)
The ’A’ circuit (or battery sense circuit) is used to

sense the battery voltage. This voltage is used by the

regulator to determine the alternator output. This

circuit is also used to supply power to the alternator

G86727 en

414-02-4

Alternator and Regulator

414-02-4

DESCRIPTION AND OPERATION (Continued)

8 Cylinder Visteon Alternator

6 Cylinder Mitsubishi Alternator Regulator Circuit

Diagram

8 Cylinder Visteon Alternator Regulator Circuit

Diagram

6 Cylinder Mitsubishi Alternator

G86727 en