Academy of Clermont-Ferrand ....... B.E.P.

Automotive Vehicle Maintenance

The alternator

Operational Educational Objective:

Remove, replace an alternator.

Adjust the belt tension.
Check the voltage and the current output by the alternator.

Student's name
Class
Date of completion
.../.../...
of the TP

Duration of the lab 4 hours TP B6

Update date: 28/03/01 TPB6.doc
Clermont-Ferrand Academy B.E.P. Automobile Vehicle Maintenance

The alternator B6
Mechanical actigram Charging circuit flowchart:
Driver's action (Information) Electricity consumers' demand (Information)
 Visual information
key switch
Minutes

MECHANICALENERGY

TRANSFORMER ELECTRICENERGY
Continue
Regulator

The alternator Engine Alternator

Reference B.O. of October 25, 1990

EQUIPMENT
EXPECTED FINAL COMPETENCIES SUPPORTS ET
DOCUMENTS

S1 Localize the system by its external borders .

S2 List the main functional characteristics of the system.
S3 State the reason for being of the system Book of
S4 Identify the constituent elements and their functions technology
S5.1 State the operational phases
S5.2 Represent the operating phases
S6.1 Cite the settings that depend on proper functioning.
S6.2 Cite the influence of the variation of the characteristics of the environment.
surrounding the operation
S7 State the regulations related to interventions
S8 State the relationship between input and output variables.
S9 Decode the functional graph of a system
S10 State the principles and physical laws of operation
S11 Identify new technological solutions

C1 COMMUNICATE Manual of
C11 Use the self-service spare parts store repair
C12 Working in a group on a total quality problem A vehicle with
C13 Sell a service alternator Voltmeter
C14 Sell a product or equipment easily Ammeter
removable and Controller of
C15 Acquire, process, transmit information
belt tension of
C2 TREAT DECIDE
multipistes belt
C21 Organizers will have a workstation
C22 Order the necessary parts for an intervention
C23 Decide to request additional information Tachometer
C24 Inventory the possible anomalies
C25 Design a diagnostic process
C26 Carry out the diagnosis
C3 ACHIEVER
C31 Maintain and restore your workstation
C32 Perform routine maintenance operations
C33 Settle subsets
C34 Pose an equipment or an accessory
C35 Assemble, disassemble, and reassemble subassemblies
C36 Manufacture, modify, adapt
C4 EVALUATE
C41 Working evaluation
C42 Evaluate the state of a subset
Clermont-Ferrand Academy B.E.P. Automotive Vehicle Maintenance

WORK REQUEST

Preliminary work:

Individually answer the questions in document B6-3 before executing the practical work.

Upon arrival at the workshop, have the 'PRELIMINARY WORK CONTROL' form filled out.
(doc. B6-4) by the professor.

Work to be done in the workshop:

1- Remove, then reinstall the alternator following the procedure guide and the manual.
builder. Fill in the sheet B6-5.

2- Adjust the tension of the alternator belt. Fill out form B6-5.

3- Check the voltage and current output from the alternator according to the specification sheet.
intervention procedure for alternator control. Fill out form B6-5.

B6-2
 PRELIMINARY WORK

Question 1 Indicate the meaning of the following terms marked on a battery.

Term Meaning Unit (in full letters)

12V

48Ah

350A

Question 2 List the name and function of the components that are part of the charging circuit.

FUNCTION NAME

Question 3 Explain why the charge circuit indicator light turns on, engine off, ignition.
what?

B6-3
Clermont-Ferrand Academy B.E.P. Automobile Vehicle Maintenance

CONTROL OF PRELIMINARY WORK

Observation grid:
 Document to
Associated Knowledge Work to be done Criteria and evaluation indicators
complete
S2 List the The
characteristics meanings and Not 1 morethan1
functional
Questions 1
the units are of error error error
main principles of the system
exact
S4 Identify them B6-3 The names and
constituent elements and Step 1 2 morethan2
Questions 2 functions are
their functions error error errors errors
exacts
S5.1 State the
phases of The explanation step 1 morethan1
Question 3
operation is coherent of error error error

A B C D

Circle in red the corresponding letter.

The student must have at least a B to complete the lab. A B C D

B6-4
 WORK REQUEST

1 Remove the alternator according to the procedure sheet (B6-6) and the manufacturer's manual.

Indicate the references for the alternator.

Indicate the torque values.

2- Adjust the alternator belt tension by following the procedure sheet (B6-6) and the
constructor notice.

Manufacturer value: .................................. Valuefound:.....................................

3- Check the voltage and current output by the alternator and fill in the following table using
from the intervention procedure sheet for the alternator control (B6-7).
No. Operation Medium Value of Value conclusion
reference found

Battery voltage control

Regulated voltage control

2
without consumer
Controlled regulated voltage
with several consumers

Control of the intensity delivered

4
by the alternator

B6-5
 PROCEDURE SHEET FOR REMOVAL/REINSTALLATION
: OF AN ALTERNATOR

Phases Operations Tools Schemes

100 Post preparation

101 Protect the vehicle for the intervention. Covers
102 Disconnect the battery. Common tools
Draw on a sheet the alternator with its terminals Paper,
and pencil
note their name, the color and thickness of the thread, the color of
the pod.

200 Removal of the alternator

201 Disconnect each of the wires and put the nuts back on
place.
202 Loosen without completely unscrewing the shaft of
pivoting.
Loosen without completely unscrewing the screw or the
tensioner bolt.
204 Relax the belt and remove it
205 Remove the screw or the bolt from the tensioner. Common tools

206 Remove the pivot axis of the alternator.

207 Remove the alternator.

300 Rest of the alternator

301 Check the visual condition of the alternator as well as its
compliance.
302 Set up the alternator.
303 Raise without fully tightening the axle of
Common tools
pivoting.
304 Raise without fully tightening the screw or bolt
the tensioner.

305 Reconnect the alternator wires to their Tracking sheet

respective locations (see wire marking).
306 Replace the belt after checking it and replacing it if necessary.
necessary.

400 Belt tension

401 Set up the SEEM voltage controller on the Controller of
good belt strand (see manufacturer's doc). tension SEEM
402 Pivot the alternator to tension the belt and obtain the
SEEM voltage value indicated by the manufacturer.
Common tools
403 Tighten the screw or bolt of the tensioner to the Key
couple.
dynamometric
404 Tighten the alternator pivot axis to the coupling
405 Remove the voltage regulator.
406 Run the engine for two laps to distribute the
belt tension.

407 Replace the voltage controller and check the value.

408 Adjust the belt tension if necessary.
 INTERVENTION PROCEDURE SHEET FOR CONTROL PURPOSES
OF THE ALTERNATOR

Phases Operations Tooling Schemas

100 Preparation of the workstation

101 Protect the vehicle for the intervention. Covers

 102 Gather on the post, a voltmeter, a clamp Voltmeter, clamp
amperometric (0 to 150A min), tachometer. amperometric
tachometer

200 Battery voltage control

201 Place a voltmeter across the battery terminals. Voltmeter
202 Raise the tension, engine stopped.
203 Compare the found value to the reference value. Doc. B6-5

300 Regulated voltage control without load

301 Place a voltmeter across the terminals of the battery.Voltmeter
Gas aspirator
302 Start the engine without a load.
exhaust
303 Gradually accelerate and raise the tension when it
is stabilizing.
Doc. B6-5
304 Compare the found value to the reference value.
400 Control of regulated tension with several
consumers
Voltmeter
401 Place a voltmeter across the terminals of the battery.
Gas vacuum cleaner
402 Start the engine with several exhaust
consumers (headlights, rear defrost, ventilation,
windshield wiper...)
403 Gradually accelerate and increase the tension when it
is stabilizing. Doc.B6-5
404 Compare the found value to the reference value.

500 Control of the intensity delivered by the alternator

Clamp
501 Place the ammeter clamp on the + wire connecting
amperometric
the alternator to the battery
Gas vacuum cleaner
502 Start the engine with several exhaust
consumers (headlights, rear defrost, ventilation,
windshield wiper...)
503 Accelerate to 2000 RPM and increase the intensity
Tachometer
504 Compare the found value to the reference value. Doc.B6-5

B6-7
Clermont-Ferrand Academy B.E.P. Automotive Vehicle Maintenance

FORMATIVE EVALUATION
 Document to
Skills Work to be done complete Criteria and evaluation indicators
The vehicle is
Without 1
correctly
error error
protégé
The procedure of
Without 1
Removal of the alternator disassembly is
error error
C35 Place, deposit, respected
subsets The pieces are
Without 1
rows
error error
rationally
The procedure of
Without 0 1
Alternator rest assembly is
error error error
respected
The value
Without
builder is
error
found
C33Adjustthe under- Belt tension B6-5 The tension of
ensembles the belt is Without 1 more than 1

correctly error error error

made
The devices
Without 1 more than 1
are connected
error error error
without error
C2.6.1. Lead a The process of
Control of the tension and Without 1 2 >2
measurement process
B6-5 control is
the intensity of the alternator error error errors errors
respected
The painting is
Without 1
correctly
error error
filled
A B C D

B6-8
 RESOURCE FILE

I A] Battery limit:

The battery is a source of electrical energy whose capacity (Ah) is limited.

The battery alone is not capable of powering the electrical devices.

vehicle continuously. When it is discharged, it is no longer able to
provide electrical energy.

II Function of the alternator:

The alternator is an energy transformer.

The function of the alternator is to transform a part of the mechanical energy of

motor in electrical energy.

The alternator can therefore provide electrical energy only if it is

mechanically connected to the engine (belt) and if it is functioning.

The electrical energy provided by the alternator is used for:

Power the electrical devices of the vehicle.
Charge the battery when it is discharged.

C) The charge witness:

Its function is to indicate a failure in the charging circuit to the driver.

Current vehicles are equipped with an alternator with an integrated regulator.

seeing the dashboard whose operation is as follows:
When the ignition is turned on, the warning light comes on because there is no
of mechanical energy supplied to the alternator. This phase allows for
check the proper operation of the light.
When the engine starts, the indicator goes out.
If the indicator light comes on while the engine is running, it
indicates a charging defect.

B6-9
 D] The charging circuit:

1ermontage :

2thmontage

B6-10