The battery is the heart of your electrical system. But you need something to keep the battery charged or it will lose its charge and die. This is the job of the alternator. The alternator produces electricity and delivers this electricity to the battery and maintains a full charge at all times. If the voltage produced by the alternator goes above 13.5 – 14.5 volts, the battery will be ruined very quickly. It’s the job of the voltage regulator to keep the output voltage between the 13.5 – 14.5-volt range.
An alternator is a device used to produce the electricity the car needs to run and to keep the battery charged. The alternator uses the principle of electromagnetic induction to produce voltage and current.
The four main parts of the alternator are the Rotor, Stator, Diode Pack, Voltage Regulator, and an Ammeter or Indicator Light to inform the driver of any problems. All of these parts must be in good working order for the alternator to do its job. Let’s take a look at each of these parts and what they do.
The rotor is basically a magnet that rotates inside thousands of loops of copper wire wound around a core of iron. This wire wrapped iron core is the stator. As the rotor spins inside the stator the magnetic lines of force cut through the copper wire inducing a voltage. This is the voltage that will go to the battery.
The only problem is this produces AC current and your car runs on DC current. So we need something that will convert the AC current to DC current. This is the job of the diode pack. A diode is an electrical one-way check valve that will let current flow in only one direction. The typical diode pack uses four diodes to accomplish this. AC current is feed in on one side of the diode pack and DC current comes out the other side. The diode pack also works the dash ammeter or indicator light.
Okay, now that we have a DC current that the car can use, we need a way to control that current. That is the job of the voltage regulator. As the name implies, it regulates the voltage going to the battery. It does this by turning current to the field (stator) terminal of the alternator on and off. If the battery voltage goes below 13.5 volts, the voltage regulator sends current to the field terminal and allows the alternator to start charging. The current will then flow into the battery and bring it up to full charge. If the voltage goes above 14.5 volts, the voltage regulator shuts off the current to the field terminal and keeps the battery from overcharging and cooking itself. This is how the voltage regulator controls the alternator output.
When you first start your car, the alternator needs some current to start working. The voltage regulator supplies this current to the field (stator) terminal of the alternator to get it started.
So far, all we have talked about is the voltage. Now we’ll discuss the amperage output of the alternator. The state of charge of the battery controls amperage output. When the battery has a full charge, the electro-motive force of the voltage lowers the amperage to almost zero. As the battery charge wears down, the electromotive force is not enough to stop the amperage, so it flows into the battery and charges it again.
As you use more electrical accessories, such as lights, heater, etc., the electro-motive force decreases and more amperage flows into the battery to compensate for the added load. It is extremely important that when alternator efficiency is checked, both voltage and amperage outputs are checked. Each alternator has a rated amperage output depending on the electrical requirements of the vehicle.
In modern alternators, the voltage regulator and diode pack are inside the alternator and are not serviceable by most DIYs and mechanics.
If anyone of these parts goes bad, the whole alternator assembly needs to be replaced.
Testing the alternator is simple and basic. You need to check the voltage and amperage output. The voltage is easy enough to check with a voltmeter. If the voltage is between 13.5 and 14.5, it’s a good bet the alternator is good. To check the amperage output, you’ll need some special equipment. You’ll need an ammeter and a load tester to check the amperage.
When the alternator is load tested, a simulated load, usually ½ the Cold Cranking Amperage rating of the battery is applied to the charging system. Then the engine is run at 2200 to 2500 rpm and the amperage is read on the ammeter. The reading should be close to or at the rated amperage of the alternator. If it is, then it’s good. If it’s substantially lower, then it is weak and should be replaced.
There are some signs you can look for that will indicate a problem with the charging system. If the headlights brighten or the blower motor picks up speed when you rev the engine, you may have a weak battery. This indicates the battery may not be holding enough current to run the car and is working off the alternator. If the charge light is dimly at idle, this could indicate a weak alternator. If all the warning lights come on while driving, this could indicate a bad diode pack in the alternator. It may or may not still be charging, but you don’t know unless you have it checked. At any rate, it will need to be replaced.
If you notice a strong sulfur smell, it could indicate a bad voltage regulator. The battery acid boiling inside the battery is causing the smell. This could lead to a battery explosion so be very careful when checking it.
Today’s charging systems have come a long way and are very reliable. A new alternator can last seven to ten years and a rebuilt alternator can last five or more years. It’s a good idea to have the system checked when you have the car serviced at every 30,000 miles to make sure it is in good shape and it will greatly reduce your chances of getting stuck with a dead battery.