Automotive Technologies

Student Workbook

AURETR129 – Diagnose and repair charging

systems
© TAFE - 2018

Version 2.0 02/2021

Acknowledgements

This Unit Guide has been prepared by TAFE Lecturers.

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Charging Systems

Automotive Electrical Technology

Name:

Student Workbook

AURETR129
Diagnose and repair charging
systems

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Blank page

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Student Workbook Index

Description Page
Student Instructions 4
Assessment Information 5
Theory Questions
Theory Questions 7
Practical Tasks
Volt Drop Testing 1 18
Volt Drop Testing 2 20
Wiring Diagram Exercise 1 22
Wiring Diagram Exercise 2 24
Wiring Diagram Exercise 3 25
Scan Tool Exercise 1 26
Plug Identification Exercise 27
Component Testing 29

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Student Instructions
This Student Workbook contains all of the specific information, theory questions and
practical task instructions to prepare for the assessments in these units.

Refer to your lecturer for assessment dates and times.

The information required to complete the theory questions in this book can be found
from the following recommended sources:

• Automotive Electrical Resource Book (Textbook or eBook)

Charging Systems

• Lecturer delivery
(Presentations, videos, handouts, demonstrations, class discussions)

• Further research
(Workshop manuals, textbooks, magazines, PC programs, websites, Apps,
Industry experience and contacts)

Refer to the recommended information source at the beginning of each theory question
section.

If you have any questions regarding the theory questions please ask.

The information required to complete the practical tasks in this book will be from a
combination of theory knowledge, experience, research and lecturer demonstration.

Practical tasks are covered at the rear of this workbook.

Student eLinks

SM TAFE My Campus May Simpson Connect

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Assessment Information

Student Learning Resources

Provided by South Metro TAFE
South Metro TAFE Student Workbook.
Computer access, internet access and student account with data storage.
Workshop manuals (hardcopy and electronic), applicable tools and equipment.
Required by student
Textbook or eBook - May and Simpson, Automotive Mechanics 9 th Edition.
Appropriate stationery and study equipment.
Appropriate work wear and PPE – trousers, work shirt, steel cap boots, safety glasses.
Electronic pdf reader is recommended. Eg. Your own laptop, tablet or e-Reader.

Assessment guidelines
Method Requirement
Assessment guidelines
Method Requirement

Written or verbal exam questions to assess aspects of competency that

cannot be demonstrated during either practical task. Must answer all
correctly.
Theory Overhaul charging system alternators
15 Questions with 2 Attempts
1st Attempt multiple choice, 2nd Attempt may require written responses

AURETR029 Diagnose and repair charging systems

Practical
You will be required to conduct a volt drop test on a charging system
Task 1

Practical
You will be required to test a machinery charging system circuit
Task 2

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Notes

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Theory Questions

1. What hazards exist when wearing jewellery around high current devices?

2. What precautions need to be considered when working on high voltage

ignition systems?

3. Name the parts of a charging system.

4. What is the purpose of the alternator?

5. What is a diagnostic flow chart?

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6. Name the external parts of an alternator.

7. Give a simple explanation of how EMF (Voltage) is induced in a conductor.

8. Why is it important to have tight electrical connections?

9. The alternators reserve capacity is approximately how much above the

average electrical requirements of the vehicle.

10. Explain how a simple alternator works.

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11. State the difference between AC and DC.

12. What types of alternator charging systems are there?

13. What is the purpose of the generator field windings?

14. Why is AC changed to DC?

15. How is AC changed to DC?

16. What is the purpose of a voltage and current regulator on a generator?

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17. Using figure below, describe the action of a simple alternator.

18. Name the internal parts of an alternator.

19. Why is it important to check for electrical connector mating?

20. What is the purpose of the rotor?

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21. What is the purpose of the voltage regulator on an alternator?

22. Describe how you would replace a faulty or damaged cable.

23. What are the characteristics of an alternator charging system?

24. Draw a diode symbol and indicate the direction in which current would flow.

25. What is meant by three phase?

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26. Trace out the current flow from the stator windings under all likely conditions.
Red – Positive Blue – Negative Black - Neutral

27. Explain briefly how the voltage of an alternator is regulated.

28. Explain how you would remove and replace a faulty component (Alternator).

29. Draw a half-wave sinusoidal waveform.

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30. Draw a full-wave sinusoidal waveform.

31. Why is it important to check DTC’s on newer vehicles?

32. How do you clear DTC’s?

33. What is the purpose of the field exciter diodes?

34. What is a heat sink?

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35. What is the most appropriate method of cleaning an alternator or

components?

36. Neatly draw a star and delta connected stator.

37. In some systems, a faulty indicator warning lamp will prevent the alternator
from charging. Briefly explain why.

38. How would you know if a bearing housing is worn and needs repair?

39. What is an electronic voltage regulator?

40. Explain how a simple electronic-voltage regulator works.

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41. What is the purpose of a Zener diode in an electronic voltage regulator?

42. What is a Zener diode?

43. What is a vibrating-contact regulator?

44. State the precautions that are needed when working on a charging system.

45. State the basic checks that can be made on a charging system.

46. Why is it important to check for electrical connector mating?

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47. Replacing a slip ring on a rotor, how do you make sure that brush to slip ring
alignment is correct?

48. How can an alternator be checked to see if it is charging?

49. If a voltmeter is connected across the battery, what reading is likely to be

shown:

• With the engine stopped?_________________________________________

• With the engine running?__________________________________________

50. List a piece of specialty test equipment for repairing alternators and explain
how to use it.

51. If a How is the alternator driven?

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52. How does a solar panel generate current flow?

Notes

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Practical Tasks

Using a shop engine measure the voltage drop on the charging system.

V1
V2
V1 – V2 =
V3
V4
V3 + V4 =

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1. Does the shop engine have voltage drop in the charging circuit?

__________________________________________________________________________

2. What is the permissible voltage drop in a charging circuit?

__________________________________________________________________________

3. What is the charging voltage of a 12 volt system?

__________________________________________________________________________

4. Is the alternator working correctly?

__________________________________________________________________________

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Using a workshop vehicle measure the voltage drop on the charging system.

V1
V2
V1 – V2 =
V3
V4
V3 + V4 =

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1. Does the shop engine have voltage drop in the charging circuit?

__________________________________________________________________________

2. What is the permissible voltage drop in a charging circuit?

__________________________________________________________________________

3. Is the alternator working correctly?

__________________________________________________________________________

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1. In the diagram above trace through the alternator circuit.

2. What colour is the main battery wire?

_______________________________________________________________________________

3. What colour is the warning light wire?

_______________________________________________________________________________

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1. In the above diagram what fuse provides ignition to the battery warning light?

____________________________________________________________________________

2. What colour is the warning light wire?

____________________________________________________________________________

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1. In the above diagram what size fuse provides main battery to the alternator?

____________________________________________________________________________

2. What size fuse is in the charge warning light circuit?

____________________________________________________________________________

3. What size fuse is in the sensing wire?

____________________________________________________________________________

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Scan Tool Exercise 1

Using a scan tool, correctly connect it to a workshop vehicle and draw a flow diagram of how you
retrieved the fault codes related to the charging system from the vehicle.

Make and type of vehicle? _______________________________________________________

What connector did you use? _____________________________________________________

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Plug Identification
What do the following terminals mean?

S
D
IG
L

C
IG
L

R
L

A
ST
I

FR
L
S
G

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Universal terminal identification for internal regulators

B Alternator +

C Control – Computer

E D- Earth

F DF Field

FR Control (Feedback voltage to ECU)

IG R Ignition

G L I W/L EXC Charge Warning Lamp

P W Stator (Tachometer)

S A Battery + (Sensing Wire)

T Diode Trio

ST Stator

D Dummy

N Neutral Point

Field Control Units

P Phase

D Driver

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Component Testing
Rotor Circuit

Using an ohmmeter check the resistance between the slip rings or a rotor.

________________________________________________________________________

Using Ohms Law, what is the current draw of the above rotor circuit with an applied voltage
of 12 Volts?

________________________________________________________________________

What are the specifications for a 12V rotor?

________________________________________________________________________

Is the above rotor drawing an acceptable amount of current?

________________________________________________________________________________

Stator Circuit

Using an ammeter check the current draw between each phase of the stator.

________________________________________________________________________

Is the current draw of the stator within 10% of the rated output?

________________________________________________________________________

Why is the stator tested on 6 Volts?

________________________________________________________________________

Is the stator shorted to ground?

________________________________________________________________________________

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Voltage Regulator

Using the regulator test a Bosch 005 style voltage regulator.

What is the regulating voltage of the regulator? _______________________________

What circuit type is the regulator? __________________________________________

Is the regulator working correctly? __________________________________________

Using the regulator test a Bosch RE60 style voltage regulator.

What is the regulating voltage of the regulator? _______________________________

What circuit type is the regulator? __________________________________________

Additional tests? _______________________________________________________

Is the regulator working correctly? _________________________________________

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