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electrical charging and cranking > Charging testing service > Flashcards

Charging testing service Flashcards

1
Q

alternator drive belt in poor condition and not tensioned properly can

A

result in an undercharged battery

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2
Q

all belts are considered used when

A

they have been operating for more then 15 min

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3
Q

drive belt glazing is caused by

A

heat friction when a loose belt slips or oil/grease on the belt and pulley

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4
Q

separating layers

A

oil grease or belt design can cause the belt to fall apart in layers

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5
Q

Jagged or streaked side walls

A

can be the result of a foreign object embedded in the pulley drive surface

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6
Q

tensile breaks

A

are breaks in the belts cord body can be caused by prying or forcing belt over pulleys during installation

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7
Q

multi ribbed belts must be check for

A

uneven ribs in the belt

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8
Q

cracks in the belt

A

signs of an old belt

if the belt has evenly spaced deep bottom cracks means the idler diameter is to small and the belt is being over flexed

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9
Q

duel belts or matched belts

A

must be replaced together at the same time

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10
Q

when inspecting pulleys

A

hold a small straight edge against the side walls and check for worn groves and oil and grease build up if it cannot be cleaned it must be replaced

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11
Q

when checking belt tension

A

use a belt tension gauge

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12
Q

when working on drive belts you should always make sure

A

the batteries are disconnected to ensure the unit will not start

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13
Q

is a multi ribbed belt is slipping

A

check the belt tensioner is operating in the right range

if it is it may have to be replaced

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14
Q

alternator alignment

A

use a straight edge

pulleys must not be offset more than 1mm for every 20 cm of distance between the pulley centers

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15
Q

when should you check belt alignment

A

every time belt maintenance is preformed or alternators are being replaced

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16
Q

when mounting an alternator

A

use a minimum of grade 5 bolts with hardened washers no less than 3mm thick and flanged locknuts

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17
Q

when checking insulated and ground circuits

A

check for unwanted high resistances resulting in excessive voltage drops

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18
Q

if the alternator senses a false voltage created by unwanted high resistances

A

the units batteries will be under charged

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19
Q

when checking alternator and batteries circuits make sure to

A

not exceed the rated output of the alternator

if you do damage to the systems electrical components could be caused

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20
Q

why must you move quickly when using a carbon pile and a volt meter testing for voltage drops in a circuit

A

because the carbon pile will over heat quickly

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21
Q

if the the sum of the voltage drops is greater than _ in a 12 volt system it will not charge batteries correctly

A

.5 volt

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22
Q

if the sum of the voltage drops in a 24 volt system is greater than _ it will not charge the batteries correctly

A

1 volt

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23
Q

when preforming on unit electrical checks the components must be

A

at normal shop temperatures 16 to 23 degrees

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24
Q

symptoms of not completely charged batteries

A

slow or no engine cranking
low voltmeter reading
dim work lights
slow cycling of equipment warning lights

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25
Q

symptoms of over charged batteries

A

voltmeter readings are high
lights burn very bright or burn out rapidly
batteries emits bad smelling fumes
batteries spews out acid or swells or distorts

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26
Q

batteries can become sulfated if

A

they are undercharged due to unbalanced internal resistance

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27
Q

if batteries have become sulfated

A

will have less capacity to convert chemical energy into electrical energy

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28
Q

if batteries have an unbalanced internal resistance

A

they will be unable to crank engine during start up

29
Q

before preforming any charging system diagnostics

A

check the battery group for proper charging and condition

30
Q

when testing batteries for proper operation

A

must be properly charger as to not interfere with voltage and current readings

31
Q

OCV of a battery group system is 12.8 or 25.6

A

batteries have a surface charge on there plates and it must be removed
leaving the lights on for 3 min will remove surface charge

32
Q

OCV of a battery group system is under 12.6 or 25.2

A

the batteries are undercharged and must be charged and re tested
important to disconnect batteries from system to avoid component damage

33
Q

when testing alternator regulator voltage under a no load condition

A

all electrical loads must be turned off
set engine speed to provide maximum alternator output
after 2 min record voltage reading

34
Q

alternator regulator test results

  1. 8-14.8 volts for a 12 volt system
  2. 6-29.6 volts for a 24 volt system
A

regulator is set correctly

35
Q

Alternator regulator test results
less than 13.8-27.6 volts or
more than 14.8-29.6 volts

A

regulator needs to be adjusted

36
Q

the regulator must not be

A

30% more than the rated output

37
Q

if the alternator is not within _ of the rated out put it must be replaced or repaired

A

10%

38
Q

most common internal alternator faults

A 
open field (brushes worn ) 
shorted stator 
open stator 
shorted diode 
open diode
39
Q

effects of an open stator winding

A

amperage output will be greatly reduced

40
Q

effects of a shorted diode

A

allows current to flow in both directions causing a large drop in alternator current output
output may be reduced as much as 60 to 70 %
could easily over heat

41
Q

effects of an open diode

A

an open rectifier diode will produce a whining sound

current will be reduced by 33 %

42
Q

when disassembling alternators

A

you may need to use special disassembly tools

43
Q

when disassembling alternator housings never

A

use a hammer and a chisel to index the housing for orientation this will cause electrical insulation breakdown and distortion of the case

44
Q

when removing the shaft nut on the alternator

A

hold the alternator with a strap wrench

do not hold the fan blades they can be easily damaged or warped becoming unbalanced and useless

45
Q

if bolts in the housing are seized

A

you can carefully warm a localized spot on the case

jarring the bolts and applying penetrating oil will also help

46
Q

if the drive end housing binds to the stator when removing

A

tap the aluminium case gently with a plastic or rawhide mallet

47
Q

when checking the diode trio

A

use the DDM in diode check mode and check for a millivolt reading in forward bias
meter should read OL in reverse bias

48
Q

if any of the three diodes in the diode trio exhibit a short or open condition

A

the whole diode trio must be replaced

49
Q

if a diode in the rectifier bridge exhibits a shorted or open condition

A

you can replace the individual diode

50
Q

when visually inspecting the stator windings

A

look for signs of overheating or bare wires

51
Q

when conducting a stator ground fault test and your multi meter reads (infinite ohms)

A

this indicates that the stator is not grounded

52
Q

when checking for opens in the rotor windings connect each lead of your meter to the slip rings if your meter reads (OL)

A

there is an open in the windings and the rotor must be replaced

53
Q

when checking for ground faults on the rotor your meter is connected to the slip ring and the metal components and your meter reads less than (OL)

A

the rotor has a ground fault and must be replaced

54
Q

how do you check for shorts or excessive resistance in rotor windings

A

by connecting a battery and a ammeter in series with the surface of the two slip rings
should also connect the volte meter in parallel to check for proper volt reading

55
Q

if the rotor slip rings at dirty you can clean them with

A

400 or more grit sandpaper

56
Q

why should you not use emery cloth to clean slip rings

A

because the metal particles can adhere to the rotor and cause premature brush wear

57
Q

slip rings that are rough or out of round can be refinished

always make sure to be within _ of the total allowable runout

A

0.05 mm

58
Q

if the rotor must be removed from the drive end housing

A

it must be pressed out

can be easily cracked because they are not designed to absorb axial load

59
Q

when inspecting the brushes you should replace them when

A

they are worn over half or show signs of burning or cracked

60
Q

if brushes are to be reused you must

A

rematch the wear pattern on the brush to the slip ring it was on

61
Q

capacitors are tested for

A

capacity
leakage
series resistance

62
Q

when testing a capacitor for leakage or series resistance you must use

A

a capacitor tester

63
Q

why should you never soak the stator windings in petroleum based solvents

A

because this can dissolve the components insulation layer causing ground faults or electrical shorts

64
Q

when using electrical contact cleaner it must not contain

A

silicone because it will attack the brush material causing short brush life

65
Q

after reassembling an alternator you should

A

bench test it for proper operation

66
Q

two types of sound to listen for when troubleshooting

A

electrical and mechanical

67
Q

electrically generated sounds

A

will produce a whining noise that varies in intensity as the electrical load changes

68
Q

mechanical sounds

A

do not change when extra load is placed on alternator

69
Q

when changing voltage regulator settings

A

should be changed in steps of 1/10 of a volt and allow time for system to re-evaluate before changing again

electrical charging and cranking (5 decks)

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