Phase
                             2
        Trade of Motor Mechanic
                 Module 2
                  Unit 4
         AlternAtor/CirCuit
                      Produced by
                     In cooperation with:
                    Subject Matter Experts
                    Martin McMahon
                        &
                      CDX Global
                  Curriculum Revision 2.2 16-01-07
                     © SOLAS 2013
                         Module 2 - Unit 4                                                                                                Alternator/Circuit
                                                                                          Table of Contents
                                                           Introduction ........................................................................................................ 1
                                                           Unit Objective ..................................................................................................... 2
                                                           1.0     Hazards when Working Charging Systems .............................................3
                                                                   1.1      Hazards when Working Charging Systems ..................................3
                                                           2.0     Electrical Loads ....................................................................................... 4
                                                                   2.1      Alternator Loads ........................................................................... 4
                                                           3.0     Current Load Manufacturers Data .......................................................... 6
                                                           4.0     Diagram of the Charging System............................................................ 6
                                                                   4.1      Schematic Block Diagrams .......................................................... 6
                                                           5.0     Function of the Alternator ....................................................................... 8
                                                                   5.1      Charging System ........................................................................... 8
                                                                   5.2      Alternator Principles ..................................................................... 9
                                                           6.0     Faraday's Conclusion on Electromagnetic Induction ...........................11
                                                                   6.1      Faraday’s Laws and Fleming’s Right Hand Rule........................11
                                                           7.0     Testing a Battery Using a Voltmeter ......................................................13
                                                                   7.1      Checking a Charging System.......................................................13
                                                                   7.2      Using a DVOM to Measure Voltages ..........................................15
                                                           8.0     Circuit Continuity Testing on the Alternator Wiring .............................17
                                                           9.0     Voltage Drop Testing on the Alternator Output Lead ...........................17
                                                                   9.1      Voltage Drop Test ........................................................................17
                                                           10.0    Alternator Brush and Voltage Regulator Examination ..........................18
                                                           11.0    Servicing an Alternator Drive Belt ..........................................................18
                                                                   11.1     Inspecting & Adjusting an Engine Drive Belt ............................18
                                                                   11.2     Replacing an Engine Drive Belt ................................................. 23
                                                           Self Assessment ................................................................................................ 27
                                                           Task Sheets ....................................................................................................... 30
                                                                   Checking a Charging System ................................................................ 30
                                                                   Removing & Replacing an Alternator ................................................... 32
                                                                   Inspecting & Adjusting an Engine Drive Belt ...................................... 35
                                                                   Replacing an Engine Drive Belt ............................................................ 40
                                                           Suggested Further Reading .............................................................................. 44
                         Trade of Motor Mechanic - Phase 2 Course Notes                                                        Revision 3.0 November 2013