Alternator & Regulator Chevrolet Cab & Chassis K3500

DESCRIPTION

The CS130 and CS144 (Charging System) alternators have a high amperage output. The 130 or 144 designation is the outside diameter of the stator laminations, measured in millimeters. This alternator series also has an integral regulator but does not have a diode trio. (Scheme 1) The delta wound stator, rectifier bridge, rotor with slip rings, and brushes are similar to other alternators. A conventional fan and pulley are used. An internal fan cools the slip rings, end frame, rectifier bridge and regulator.

The CS130 alternator should not be disassembled for any reason. The alternator requires no periodic maintenance or adjustment and can not be serviced. The CS144, is serviceable. For model application, see ALTERNATOR IDENTIFICATION & OUTPUT .

Scheme 1

OPERATION

Regulator voltage varies to compensate for temperature. Voltage is regulated by controlling rotor field current. The regulator switches rotor field current on and off at a fixed frequency of about 400 cycles per second.

The regulator has 4 terminals: "P", "L", "I" and "S". (Scheme 2) The "L" terminal and/or the "I" terminal is used to turn on regulator and allows field current to flow when ignition switch is turned to START or RUN position. The "L" terminal is connected through a charging indicator light or resistor. The "I" terminal is connected to positive battery terminal either directly or through a resistor. These terminals are often used in parallel and are connected to 2 different vehicle circuits.

The "P" terminal is connected internally to the stator and may be wired to a tachometer or other device. The "S" terminal may be used to sense voltage at another vehicle location for voltage control. If "S" terminal is not used, alternator uses an internal sensor for voltage control.

Scheme 2

BELT TENSION

On 2.2L, 3.1L, 3.8L, 4.3L, 5.0L, 5.7L, 6.5L Diesel & 7.4L engines, serpentine single belt tension is maintained automatically by a spring tension idler pulley. No adjustment is necessary.

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL TROUBLE SHOOTING section.

ON-VEHICLE TESTING

Note. Before making electrical checks, visually inspect all terminals for clean, tight connections. Check alternator mounting bolts and drive belt tension. Ensure battery is in good condition prior to testing charging system.

OVERCHARGED OR UNDERCHARGED BATTERY

1. If an overcharging condition is suspected, run engine at moderate speed. Connect voltmeter across battery terminals. If voltmeter indicates more than 16 volts, replace alternator.
2. If an undercharging condition is suspected, disconnect 4-wire connector from alternator. Turn ignition on with engine off. Connect a voltmeter between terminal "L" in wiring harness and ground. (Scheme 2) Record reading.
3. If terminal "I" is used, connect voltmeter between terminal "I" and ground. Record reading. If voltmeter reads battery voltage, circuits are okay. If voltmeter reads zero, this indicates an open circuit between terminal checked and battery. Repair as necessary.

ALTERNATOR OUTPUT TEST

1. Connect an ammeter in series with wire connected to BAT terminal of alternator. (Scheme 2) Turn on all available accessories. Connect a carbon pile across battery. Operate engine at 2000 RPM. Adjust carbon pile (as required) to obtain maximum current output while maintaining 13 volts or more.
2. Ampere output must be within 15 amps of rated output. If output is not within 15 amps of rated output, replace alternator. See «ALTERNATOR IDENTIFICATION & OUTPUT»(/chevrolet/cab-chassis-k3500/1989-2000/remont/charging-system/#alternator-regulator).

BENCH TESTING (CS144)

Note. Internal components of CS130 alternator are not serviceable. Alternator replacement is required.

Scheme 3

1. To check for ground, attach one ohmmeter lead to shaft and other lead to either slip ring. (Scheme 3) If reading is not infinity, replace rotor.
2. To test for open, attach one ohmmeter lead to each slip ring. (Scheme 3) Resistance should be low. If reading is high (infinity), replace rotor.
3. To test for short, connect 12-volt battery and ammeter in series with edge of two slip rings. Reading should be 5.0-5.7 amps. If reading is greater than 5.7 amps, winding is shorted, replace rotor.
4. To test for excessive resistance, connect ohmmeter across 2 slip rings. Reading should be 2.1-2.4 ohms at 80°F (27°C). If reading is greater than 2.4 ohms, excessive resistance is present. If reading is less than 2.1 ohms, winding is shorted, replace rotor.
5. Resistance and ammeter readings will vary slightly with winding temperature changes. If alternator does not supply rated output, and rotor is okay, rectifier bridge, stator or regulator is faulty.

STATOR TEST

1. To check for ground, connect one ohmmeter lead to any stator lead. Connect remaining ohmmeter lead to stator frame. Ohmmeter reading should be infinity. (Scheme 4)
2. Delco CS series alternators have delta stator windings and cannot be tested for short or open circuits with ohmmeter. A noticeable discoloration anywhere on the stator usually indicates stator failure.

Scheme 4

Note. Some digital ohmmeters cannot be used to check diodes in rectifier bridge. Consult ohmmeter manufacturer to determine ohmmeter capabilities.

Scheme 5

1. Position ohmmeter with one lead touching grounded heat sink and other lead pressed firmly against flat metal clip on one of 3 terminals. Observe reading, and reverse test lead connections. (Scheme 5)
2. If readings are same, replace rectifier bridge. A good bridge will give a high and low reading. Repeat tests for remaining terminals. There should be 6 tests altogether (2 tests at each terminal).
3. Connect test leads to insulated heat sink and one of the 3 terminals. (Scheme 5) Observe reading and reverse connections. Repeat tests for remaining terminals. There should be a total of 6 tests (2 at each terminal).
4. Testing is complete when all 12 tests have been made. If any terminals have same readings for both connections (leads reversed), replace rectifier bridge.

REGULATOR TEST

Regulator cannot be tested for short, open or grounded circuits. If rotor, stator and rectifier bridge are okay and alternator continues to produce greater than 16 volts or does not produce within 15 amps of rated output during alternator output test, replace regulator. See ALTERNATOR IDENTIFICATION & OUTPUT table.

REMOVAL & INSTALLATION

Disconnect negative battery cable. Remove drive belt. Remove nut retaining positive battery terminal. Disconnect alternator electrical connector. Remove mounting bolts, nuts, braces and brackets. Remove other components as necessary. Remove alternator. To install, reverse removal procedure.

OVERHAUL

Note. CS130 is not serviceable. Replacement is required.

SPECIFICATIONS

ALTERNATOR IDENTIFICATION & OUTPUT

Charging System Wiring Diagram. Scheme 6

See also:
• ALTERNATOR IDENTIFICATION & OUTPUT