Generators & Regulators: Diagnosis Hyundai Accent II рестайлинг

Drive Belt Inspection

1. Check that the belts are not damaged and are properly fit for the pulley grooves.
2. Apply 22 lbs. (10 kg) of force to the back and midway portion of the longest belt run. (Scheme 3) Measure the amount of deflection or tension and compare to specification. See «GENERATOR BELT ADJUSTMENT SPECIFICATIONS»(ref-167604-S32449103742004101800000) table.
3. Adjust generator drive belt as necessary. See «GENERATOR DRIVE BELT ADJUSTMENT»(ref-167604-S25699455012004101800000). If unable to adjust generator drive belt to specification, install a NEW drive belt.

GENERATOR BELT ADJUSTMENT SPECIFICATIONS

Scheme 3

ON-VEHICLE TESTING

Note. Before beginning ON-VEHICLE TESTING, ensure generator is installed properly and drive belt tension and fusible link are okay. Check for abnormal generator noise while engine is operating.

BATTERY CONDITION TEST

1. Perform visual inspection. See «VISUAL INSPECTION»(ref-167604-S12562266672004101800000) . If battery fails visual inspection, replace battery. If okay, go to next step.
2. Measure the battery voltage. Is battery voltage below 11.0 volts? If yes, replace battery and retest system for normal operation. If no, go to next step.
3. Ensure battery has been properly charged. Perform battery load test. See «LOAD TEST»(ref-167604-S13639095222004101900000) . Did battery pass the load test? If yes, battery is okay. If no, replace battery and retest system for normal operation.

Visual Inspection

1. Make sure ignition switch is in the OFF position and all accessories are OFF.
2. Disconnect the battery cables, negative cable first.
3. Remove the battery from the vehicle.
4. Inspect the battery carrier for damage caused by the loss of acid from the battery. If acid damage is present, it will be necessary to clean the area with a solution of clean, warm water and baking soda. Scrub the area with a stiff brush and wipe off with a cloth moistened with baking soda and water. Clean the top of the battery with the same solution.
5. Inspect the battery case, and cover, for cracks. If cracks are present, the battery must be replaced.
6. Clean the battery posts with a suitable battery post cleaner.
7. Clean the inside surface of the terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or frayed cables and broken terminal clamps.
8. Install the battery in the vehicle.
9. Connect the cable terminals to the battery post, making sure the top of the terminals are flush with the top of the post.
10. Tighten the terminal nut securely.
11. Coat all connections with light mineral grease after tightening.

Battery Voltage Test

1. Within 20 minutes after having driven vehicle and turning the engine OFF, turn ignition ON. Turn on electrical systems (head lights, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge.
2. Turn ignition and electrical systems OFF.
3. Measure battery voltage between negative and positive battery terminals.
4. If battery voltage is less than 12.5-12.9 volts at 68°F (20°C), charge the battery.

Load Test

Note. If the battery has been on a charge, remove surface charge by connecting a 300 ampere load for 15 seconds. If necessary, refer to battery load tester manual for additional instructions.

1. Connect the load tester clamps to the battery terminals.
2. Connect voltmeter and apply specified load.
3. Read voltage after load has been applied for 15 seconds.
4. Disconnect the load.
5. Compare voltage reading with minimum specification and replace battery if battery test voltage is below that shown in the voltage table. See «BATTERY LOAD TEST SPECIFICATIONS»(ref-167604-S09574652452004101900000) table.

BATTERY LOAD TEST SPECIFICATIONS (1)

MICRO 570 ANALYZER BATTERY, STARTER & CHARGING TEST

Note. The Micro 570 Analyzer provides the ability to test the charging and starting systems, including battery, starter and generator.

Note. Cold Cranking Amps (CCA), is an Society of Automotive Engineers (SAE) specification for cranking batteries at 0°F (-18°C). A CCP rating is an SAE specification for Korean manufacturer's for cranking batteries at 0°F (-18°C).

For Micro 570 key pad functions (Scheme 4)

1. Connect Micro 570 analyzer to battery. Red lead to battery positive and black lead to battery negative.
2. The tester will ask if the battery is connected IN A VEHICLE or OUT OF A VEHICLE. (Scheme 5) Make selection by pressing arrow buttons. Then press ENTER.
3. Using the UP and DOWN buttons, choose CCA or CCP. (Scheme 6) Press ENTER.
4. Using the UP and DOWN buttons, set the CCA value displayed on the screen to the CCA value marked on the battery label. (Scheme 7). Press ENTER.
5. The Micro 570 displays battery test results including voltage and battery ratings. A relevant action must be given according to the test results. See «MICRO 570 BATTERY TEST RESULTS/SERVICE REQUIRED»(ref-167604-S21280751602004082600000) table. MICRO 570 BATTERY TEST RESULTS/SERVICE REQUIRED Test Results Service Required GOOD BATTERY Return To Service GOOD - RE-CHARGE Fully Charge Battery & Return To Service CHARGE & RE-TEST (1) Fully Charge Battery & Retest REPLACE BATTERY (2) Replace Battery & Retest BAD CELL - REPLACE (3) Disconnect Battery From Vehicle & Retest (1) Failure to fully charge battery may result in incorrect measurement values. (2) Improper connections between battery and vehicle cables may cause a REPLACE BATTERY result. Prior to replacing the battery, retest battery after removing cables and connecting tester directly to battery terminals. (3) Charge and retest the battery. Test results may cause REPLACE BATTERY result. Replace battery and recheck the charging system.
6. Press ENTER to continue to starter and charging test procedures. Start the engine. Cranking voltage and starter test results will be displayed on the screen. (Scheme 8) A relevant action must be given according to the test results. See «MICRO 570 STARTER TEST RESULTS/SERVICE REQUIRED»(ref-167604-S05811061232004102000000) table. MICRO 570 STARTER TEST RESULTS/SERVICE REQUIRED Test Results Service Required CRANKING VOLTAGE NORMAL System Shows Normal Starter Draw CRANK VOLTAGE LOW Check Starter CHARGE BATTERY Charge Battery & Retest REPLACE BATTERY (1) Replace Battery (1) If the vehicle is not started and battery condition of GOOD & FULLY CHARGED is displayed, check wiring for an open circuit, battery cable connections and starter. Repair as necessary. If engine cranks but does not start, check fuel system.
7. Press ENTER to continue to charging test procedures. (Scheme 9)
8. Tester displays actual voltage of generator. Press ENTER to continue with charging system test.
9. Turn OFF all electrical load, rev engine for 5 seconds by pressing accelerator pedal. (Scheme 10) Then press ENTER to continue.
10. The Micro 570 will compare charging system output at idle to other readings. (Scheme 11)
11. The Micro 570 will display the charging system test results. (Scheme 12) A relevant action must be given according to the test results after shutting OFF engine and disconnecting tester clamps from battery. See «MICRO 570 CHARGING SYSTEM TEST RESULTS/SERVICE REQUIRED»(ref-167604-S31293811742004102000000) table. MICRO 570 CHARGING SYSTEM TEST RESULTS/SERVICE REQUIRED Test Results Service Required CHARING SYSTEM NORMAL/DIODE RIPPLE NORMAL Charging System Okay NO CHARGING VOLTAGE (1) Charging Current Not Supplied To Battery LOW CHARGING VOLTAGE (2) Insufficient Charging Current Supplied To Battery HIGH CHARGING VOLAGE (3) Voltage To Battery Higher Than Normal During Voltage Regulation EXCESS RIPPLE DETECTED (4) One Or More Diodes In Generator Not Functioning Properly (1) Check belts and connections between generator and battery. Replace belts, cables or generator as necessary. (2) Check belts and generator. Replace as necessary. (3) Check connections and grounds; replace regulator as necessary. Check electrolyte level in the battery. (4) Check alternator mounting and belts; replace as necessary.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

CHARGING SYSTEM VISUAL INSPECTIONS

1. Check that battery terminals are not loose or corroded. Check fusible links and fuses for continuity.
2. Visually check drive belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt.
3. Check that wiring is in good condition. Check that there is no abnormal noise from generator while engine is running.
4. Warm engine and then turn it OFF. Turn off all accessories. Turn ignition ON. Check that charge warning light is ON. Start engine. Check that the light goes OFF. If charge warning light does not go OFF, see «CHECKING STATOR POWER SOURCE CIRCUIT»(ref-167604-S16283353282004101800000) .

Test Procedure

1. Turn ignition on, with engine off. Ensure that the charge indicator light is illuminated.
2. Disconnect pre-excitation resistor 4-pin connector, located in engine compartment fuse box. Connect the positive lead of the DVOM to terminal No. 4 and the negative lead to terminal No. 1 of the pre-excitation resistor. (Scheme 13)

Scheme 13

Test Results

Note. The power source to the field coil circuit consists of a pre-excitation resistor in parallel with the charge indicator light. If continuity is absent through either leg of the parallel circuit, the charging system will still function normally. However, the failed leg of the parallel circuit should be repaired for more reliable system operation.

1. If charge indicator light is illuminated and there is continuity though the pre-excitation resistor, the charge indicator light circuit and pre-excitation resistor are okay.
2. If the charge indicator light is not illuminated and there is no continuity though the pre-excitation resistor, the charge indicator light circuit and pre-excitation resistor are at fault, not the battery. Repair the circuit and replace the pre-excitation resistor as necessary.
3. If the charge indicator light is not illuminated but there is continuity through the pre-excitation resistor circuit, repair the charge indicator light circuit as necessary.
4. If the charge indicator light is illuminated but there is not continuity through the pre-excitation resistor, replace the pre-excitation resistor.

Note. To identify connection problems, be sure not to disturb either of the 2 terminals or their connections during this test.

Turn the engine off. Connect a Digital Volt Ohmmeter (DVOM) positive lead to the generator "B" terminal and negative lead to the battery positive terminal. (Scheme 14)

Scheme 14

Conditions For Testing

With the engine running and head lights, blower motor etc. ON, check the reading on the voltmeter.

1. The DVOM should read 0.2-0.3 volt.
2. If the reading is above 0.2-0.3 volt, poor wiring should be suspected. Check wiring from generator "B" terminal through the fusible link to the battery positive terminal. Check for loose wiring or color change from an overheated harness. Correct as necessary and check again.
3. On completion of the test, set the engine at idle. Then turn off the head lights, blower motor etc. Turn off the ignition.

Test Preparation

Note. The battery that is used to test the output current should be partially discharged. With a fully charged battery, the test may not be conducted correctly due to an insufficient load.

Prior to the test, check the following

1. Battery installed in the vehicle is in good condition. See «BATTERY CONDITION TEST»(ref-167604-S11512690502004101900000). Check generator drive belt tension. See «DRIVE BELTS»(ref-167604-S39524377352004101800000) under ADJUSTMENTS.
2. Turn the ignition switch to OFF position.
3. Disconnect the battery ground cable.
4. Disconnect the generator output wire from the generator terminal "B".
5. Connect a DC ammeter (0 to 100A) in series between the terminal "B" and the disconnected output wire. Be sure to connect the negative lead of the ammeter to generator terminal "B" harness connector. (Scheme 15)
6. Connect Digital Volt Ohmmeter (DVOM) between generator terminal "B" and ground. Connect the positive lead to the generator terminal "B" and negative lead of the DVOM to ground. (Scheme 15)
7. Attach an engine tachometer and connect battery ground cable.
8. Leave the engine hood open.

Scheme 15

Note. After the engine starts up, the charging current quickly drops. Therefore, this test must be done quickly to read the maximum current value correctly.

1. Ensure voltmeter reads the same value as the battery voltage. If the voltmeter reads 0 volt, repair open circuit between the generator harness connector terminal "B" and battery, replace blown fusible link or repair poor ground as necessary.
2. Start the engine and turn on the head lights.
3. Set the head lights to high beam and the heater blower switch to HIGH position, quickly increase the engine speed to 2500 RPM and read the maximum output current value indicated on the ammeter.

1. The ammeter reading must be higher than the limit value. See «GENERATOR OUTPUT CURRENT SPECIFICATIONS»(ref-167604-S21201362102004101800000) table. If reading is lower but the generator output wire is in good condition, remove the generator from the vehicle for testing.
2. Upon completion of the output current test, lower the engine speed to idle and turn ignition switch to OFF position.
3. Disconnect battery ground cable.
4. Remove the ammeter, DVOM and the engine tachometer.
5. Connect generator harness connector terminal "B" to generator.
6. Connect battery ground cable.

GENERATOR OUTPUT CURRENT SPECIFICATIONS (1)

1. Prior to the test, check the following items and correct if necessary: Check that the battery installed in the vehicle is fully charged. See «BATTERY CONDITION TEST»(ref-167604-S11512690502004101900000). Check the generator drive belt tension. See «DRIVE BELTS»(ref-167604-S39524377352004101800000) under ADJUSTMENTS.
2. Turn ignition to OFF position.
3. Disconnect battery ground cable.
4. Connect the positive lead of the Digital Volt Ohmmeter (DVOM) to the generator "S" terminal and the negative lead of the DVOM to ground. (Scheme 16)
5. Disconnect generator output wire from generator "B" terminal.
6. Connect a DC ammeter (0 to 100A) in series between the "B" terminal and the disconnected output wire. Be sure to connect the negative lead of the ammeter to generator terminal "B" harness connector. (Scheme 16)
7. Attach an engine tachometer and connect battery ground cable.

Scheme 16

1. Turn ignition to ON position and check to see that the DVOM indicates battery voltage. If the DVOM reads 0 volts, there is an open circuit between the generator harness connector terminal "S" and battery positive terminal, or the fusible link is blown.
2. Start engine. Keep all lights and accessories off.
3. Run engine at a speed of approximately 2500 RPM and read the voltmeter when the generator output current drops to 10A or less.

1. If the DVOM reading are within specification, the voltage regulator is functioning correctly. See «REGULATOR VOLTAGE SPECIFICATIONS»(ref-167604-S22528246662004101800000) table. If the reading is not within specification, the voltage regulator or the generator is faulty.
2. Upon completion of the test, reduce engine speed to idle and turn ignition to OFF position.
3. Disconnect battery ground cable.
4. Remove the DVOM, ammeter, and engine tachometer.
5. Connect the generator output wire to the generator "B" terminal.
6. Reconnect battery ground cable.

REGULATOR VOLTAGE SPECIFICATIONS

RECTIFIER ASSEMBLY TEST

Note. Information not available from manufacturer.