Rectifying Alternator Current

Rectification is the process of changing the alternating current (AC) to direct current (DC). This
signifies that the current induced by the rotor in the loop of stator, which is constantly changing its
direction must be directed so that it always flows the same way. Thus, obtaining the desired current to
run the engine and operate most automotive electrical equipments.

In rectifying AC, it needs an electronic device called diode to do the job of redirecting AC
voltage to DC voltage. In automotive alternator, a six to eight diodes are used to rectify AC to DC
hence a single diode will only block half the AC voltage. Below is an illustration showing the process
of rectifying its AC voltage to DC voltage in an IC type alternator.

The aforementioned diagram elucidates that the diodes uses full-wave rectification, hence it
redirects both the positive and negative polarity signals of the AC voltage to produce DC voltage. Left
diagram illustrates that the B+ current as indicated in the solid heavy line pass through the rectifier as it
goes to the battery. The lighter line indicates the current return path.

In addition, right diagram depicts that the B+ current as still indicated in the solid heavy line
pass through the rectifier as it goes to the battery but this time in an opposite direction. The lighter line
illustrates the current new path.

Note:

Even though the B+ current enters the rectifier at a different location, still it
goes to the battery in the same direction.

Servicing the Charging System

In any automotive servicing, safety precautions should be taking into consideration to avoid
committing an injury or accident. Likewise, it should also protect oneself in committing serious
damage to the vehicle entrusted for servicing.

In the case of charging system service, necessary safety measures should always be observed,
hence short circuits, open circuits, incorrect polarity of the battery, or any irregular connection to the
system could overload or damage the important component parts like alternator or the semiconductor
devices in the voltage regulator.

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 158

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
Precautions in Charging System Service

The following safety precautions should be observed in charging system servicing, to wit:

 Remove the battery terminal before working on any part of the charging system.
When refitting the terminals, the positive ( + ) terminal should be first to be
connected, then it follows the negative ( - ) terminal.

 The battery must be installed with the correct polarity, An incorrectly connected
battery can damage the diodes even before the engine is started.

 If the battery is to be charged with a battery charger while it is installed in the

vehicle, the terminals should be disconnected. A battery charger connected with
incorrect polarity, or producing a high voltage, it can damage the diodes and other
semiconductor components.

 Earthing the alternator output terminal or cable will damage the alternator or
regulator. This can apply whether the engine is running or not.

 The alternator should not be run on open circuit at any time. Circuit connections
should not be broken when the alternator is operating.

Charging System Checks

If the charging system seems to have a problem, the following should be checked:

 The drive belt should be in good condition and at the correct tension to prevent slip
at high speeds.

 The alternator indicator lamp (on some alternators) must be functioning to give
initial excitation of the field. It should also be of the correct wattage.

 The battery should be in sound condition. Check the state of charge, cleanliness of
the terminals.

 All circuit connections should checked but care should be taken that the circuit is
not accidentally earthed, or damage to the alternator or regulator will result.

 The system can be given a quick check by connecting a voltmeter between the
output terminal and earth, or across the battery terminals.

Note:

With the alternator operating at idle speed, the voltmeter should

indicate an above-normal battery voltage and should show approximately
14 volts.

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 159

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
Common Problems

There are common problems of the charging system, to wit:

 If a warning light remains on after the engine is started, then the alternator is not
charging;

 A battery that remains flat could be due to the condition of the battery, or the
alternator output could be too low; and

 A battery that needs frequent topping-up indicates excessive alternator output.

Alternator Checks

The alternator can be given a quick check as previously described. If any doubt exists, then a
more detailed checked could be made with the alternator under no-load and load as follows:

 With the engine stopped, connect a voltmeter between the output terminal of the
alternator and earth, or across the battery terminals. A reading of approximately
12.5 volts be obtained.

 Start the engine. The alternator should commence to operate, and the voltage
reading on the meter should increase as the engine speed is increased. If this does
not occur, the alternator has no output. A fault could exist either the alternator or the
regulator, or in the circuit connection.

 Increase the engine speed gradually. At a moderate engine speed, the voltmeter
needle should flicker slightly and then remain stationary at around 14 volts.

 Switch ON the headlamps of the vehicle and observe the effect on the voltmeter.
The voltage reading may drop slightly, but still remain stable.

 Stop the engine, it will be noticed that the voltmeter reading will remain higher than
the original battery voltage. The battery plates have a surface charge, and this can
be reduced by switching the headlamps ON until the battery voltage drops to about
normal.

 Restart the engine and recheck the voltage setting as before.

Note:

If a voltage higher than battery voltage cannot be obtained, either

the alternator or the regulator could be at fault. All circuit connections
should first be checked including earth connections.

For a system with an electronic regulator, the indicator should be

checked, or the resistor in the wiring, if fitted. If the bulb is blown or the
resistor is open-circuited, there will be no initial excitation of the rotor field,
and the alternator will not start to charge.

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 160

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
 The regulator points of a vibrating-contact regulator should be
checked and carefully cleaned.

If the alternator output is still not obtained, consideration will have

to be given – removing the alternator for dismantling and testing.

Alternator Service

The first step in doing alternator service is to conduct a bench test in order to arrive for
accurate conclusions and recommendations to solve the problem at hand. Thus, one of the activities in
bench testing is checking the resistance of an alternator circuit including the circuit of the external
voltage regulator. Below are the procedures to be followed, to wit:

1. Unplug the voltage regulator wire

connector, and measure the resistance
between IG and F terminals respectively
with a circuit tester.

Standard Resistance ---------- 0

In case the resistance indicated between

IG and F is more than 0, then

Excessive contact resistance at

low speed points.
Resistance Test between Regulator IG – F
Terminals

2. Measure the resistance between F and E (rotor

coil at alternator body.

Reference Value -------- 4.1 to 4.9

In case the resistance indicated between F and E

is small and near to 0, then

Short circuit in rotor coil or wiring

Resistance Test between Alternator F - E
Terminals

3. In case the resistance indicated between F

and E exceeds 9

3.1 - Open-circuit in rotor coil; and

3.2 - Brush or slip ring burnt out or
contacting improperly

Excessive Resistance between Alternator

F - E Terminals

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 161

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
 In case the findings of the test do not comply with manufacturer’s specifications, conclusion
should be – to dismantle the alternator. In dis-assembling the alternator, make sure that all parts are
properly identified including its functions and exact location to avoid errors in re-assembling of its
parts.

Below are the disassembled parts of a conventional alternator.

01 Alternator Pulley 13 Alternator Stator

02 Alternator Fan 14 Rectifier Positive Holder
03 Space Collar 15 Rectifier Negative Holder
04 Drive end Frame 16 Insulator
05 Felt 17 Rear End Frame
06 Felt Cover 18 Rear End Cover
07 Bearing 19 B Terminal Insulator
08 Bearing Retainer Plate 20 Insulator
09 Space Ring 21 Brush Holder
10 Snap Ring 22 Brush Spring
11 Alternator Rotor 23 Brush
12 Bearing

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 162

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
Inspection and Repair

Rotor

 Check the rotor coil for open circuit.

Connect a circuit tester from the slip ring
to the other slip ring, and check the
conductance between the rings. If there is
no conductance, the coil is opened. There
fore, replace the rotor.

Standard Resistance -------- 4.2 

Checking Coil for Open Circuit

 Connect the tester from the slip ring to the

rotor shaft, and check the insulation. If the
tester needle moves, the slip ring to rotor
coil is grounded. Therefore the rotor
assembly must be replaced.

 Check the bearing, and if defective,

replace the bearing.

 Check the slip rings for roughness and

scores, and if defective, replace the rotor. Testing Rotor Coil for Ground

Stator

 Check the stator coil for insulation.

Connect the tester between the stator coil
lead and the stator core. If the tester needle
moves, the coil is grounded. Therefore,
repair or replace the stator assembly.

Testing Stator Coil for Ground

 Check the four leads of the stator coil for

conductance between them. If the tester
needle does not move, the stator coil is
opened, and must be replaced. The
resistance should be zero.

Testing Stator Coil for Open Circuit

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 163

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
 Brush and Brush Holder

 Check the brush protrusion length, and if the

length is less than the limit, replace the brush.

Brush Protrusion Limit ------ 5.5 mm

(0.217 in)

If the replacing the brush, install the new

brush and the brush spring into the brush Brush Protrusion
holder, then solder the brush lead wire
keeping the protruded brush.

After soldering the brush lead, cut off the

surplus wire.

Standard Protrusion --------- 12.5 mm

(0.492 in)

 Check the brush for smooth movement in the

brush holder. Also test for insulation between
the brush holder and brush. If defective,
replace the brush holder. Replacing Brush into Brush Holder

Rectifiers

 Rectifier Holder Positive Side.

Connect the tester ( + ) lead onto the rectifier

holder, and the ( - ) lead of the tester onto the
rectifier lead. In this case, the tester should
indicate near zero ohm. If it indicates infinity,
that rectifier is open circuit.

Positive Rectifier Open Test

Next, change the polarity of the tester, and

check again. The tester should indicate
infinity. If it indicates near zero ohm, the
rectifier is shorted. Even if one rectifier is
defective, replace with the positive holder
assembly.

Positive Rectifier Short Test

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 164

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte
Rectifier Holder Negative Side

Connect the tester ( + ) lead onto the rectifier

lead, and the tester ( - ) lead to the holder. At
this time, the tester should indicate near zero
ohm. If it indicates infinity, the rectifier is
open circuit.

Negative Rectifier Open Test

Next, turn the polarity of the tester, and check

again. In this case, the tester should indicate
infinity. If it indicates near zero ohm, the
rectifier is shorted. Even if one rectifier is
defective, replace with the negative holder
assembly.

Negative Rectifier Short Test

Developed by: NEIL A. DIVINAGRACIA, Ph.D. 165

Automotive Expert / Industry Based Focal
TESDA – Surigao del Norte