Generator Regulator Page 1

Electrical
2001 STARTING & CHARGING SYSTEMS
Generator & Regulators - Excursion & F250/350 Pickups - Diesel With Single Generator
DESCRIPTION
System consists of 110-amp generator with internal voltage regulator, battery, charge warning indicator, related
fuses and wiring. Internal regulator provides temperature compensation circuitry for optimum charging rates in
different conditions. Some vehicles were produced with extra circuitry to allow for future addition of a second
generator.
Charge warning indicator should illuminate with ignition on, engine off. Charge warning indicator should not
illuminate with ignition off, or with engine running.
ADJUSTMENTS
BELT TENSION
Vehicles are equipped with automatic drive belt tensioner. Drive belt does not require adjustment. Inspect
condition and tension of generator drive belt prior to performing any on-vehicle charging system tests. Replace
belt and/or tensioner mechanism if necessary.
TROUBLE SHOOTING
Verify customer's complaint. Verify battery condition. Inspect accessory drive belt and tensioner. Inspect
fusible links. Inspect battery junction box fuse No. 6 (10-amp) and No. 7 (5-amp). Inspect central junction box
fuse No. 29 (5-amp). Check all connections for looseness or corrosion. If problem is found, repair as necessary.
If problem is not found, repair by symptom. See SYMPTOM INDEX
table under SYSTEM TESTS.
ON-VEHICLE TESTING
NOTE: References to F250/F350 Pickups include Cab & Chassis.
NOTE: Generator and regulator cannot be serviced separately, and must be replaced
as an assembly.
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
NOTE: Battery junction box fuse No. 7 (5-amp) is only used for charging system on
vehicle that are wired for installation of dual generators from the factory.
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Generator & Regulators - Excursion & F250/350 Pickups - Diesel With
Single Generator
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Generator & Regulators - Excursion & F250/350 Pickups - Diesel With
Single Generator
Helpmelearn
November-29-07 6:24:28 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Helpmelearn
November-29-07 6:24:30 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Contents Summary of Generator Regulator

  • Page 12001 STARTING & CHARGING SYSTEMS Generator & Regulators - Excursion & F250/350 Pickups - Diesel With Single Generator DESCRIPTION NOTE: References to F250/F350 Pickups include Cab & Chassis. System consists of 110-amp generator with internal voltage regulator, battery, charge warning indicator, rela
  • Page 2PROCEDURES article in GENERAL INFORMATION before disconnecting battery. BATTERY DRAIN TEST 1. Ensure junction box/fuse panels are accessible without turning on interior and hood lights. Drive vehicle over 30 MPH for at least 5 minutes. Park vehicle and allow to sit with ignition off for at least 40
  • Page 3load tester in accordance with manufacturer's instructions. Start and run engine at 2000 RPM, and apply load until generator output levels off. Generator amperage should be at least 87 amps with engine at 2000 RPM. Go to next step. 2. Turn A/C system on. Turn blower speed to high. Turn headlights on
  • Page 4battery and generator. See WIRING DIAGRAMS . 2. Turn ignition switch to LOCK position. Disconnect generator 3-pin harness connector. Measure voltage between ground and generator harness connector terminal "A" (Orange/Light Blue wire). If battery voltage is present, go to next step. If battery voltag
  • Page 53. Turn ignition switch to LOCK position. Using a jumper (15-amp) wire connected to positive battery terminal, backprobe generator 3-pin harness connector terminal "A" (Orange/Light Blue wire). Start engine and let idle. Observe warning indicator. If warning indicator flickers, replace generator. If
  • Page 6Application Ft. Lbs. (N.m) Generator Mounting Bolts 35 (47) INCH Lbs. (N.m) Generator B+ Terminal Nut 71 (8) WIRING DIAGRAMS
  • Page 7
  • Page 8Fig. 1: Charging System Wiring Diagram (Excursion & F250/F350 Super Duty Pickups - Diesel With Single Generator)
  • Page 92001 STARTING & CHARGING SYSTEMS Generators & Regulators - Excursion & F250/F350 Super Duty Pickups - Gasoline & Bi-Fuel DESCRIPTION System consists of generator, integral voltage regulator, storage battery, warning indicator light, fusible links, instrument cluster fuse and associated wiring. Gener
  • Page 10connecting ammeter. If continuity is broken, go to step 1 . 3. Ensure ammeter is set to read milliamps with at least a 10 amp capability. Connect ammeter between negative battery cable and negative battery post. Remove fused jumper wire. Go to next step. 4. If excessive current draw is present, pull
  • Page 11SYMPTOM INDEX Symptom Perform Test Battery Is Discharged or Voltage Is Low A Warning Indicator Is On With Engine Running (System Voltage Does Not Increase) B System Overcharges (Battery Voltage Is Greater Than 15 Volts) C Warning Indicator Is On With Engine Running and System Voltage Increases D War
  • Page 12terminal screw on back of generator and generator 3-pin connector terminal "A" (component side). See Fig. 1 and Fig. 3 . If resistance is 5 ohms or less, replace generator. If resistance is 5 ohms or more, replace voltage regulator. Fig. 1: Identifying Generator Terminals Courtesy of FORD MOTOR CO.
  • Page 13Fig. 2: Identifying Generator 3-Pin Harness Connector Terminals Courtesy of FORD MOTOR CO, Fig. 3: Exploded View Of Voltage Regulator & Brush Holder Courtesy of FORD MOTOR CO.
  • Page 14TEST C: SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN 15 VOLTS) 1. Disconnect generator 3-pin harness connector. Turn ignition on. Measure voltage between generator harness connector terminal "A" (Orange/Light Blue wire) and positive battery terminal. See Fig. 2 . If voltage is less than .5 vo
  • Page 15DIAGRAMS . 4. Turn ignition off. Check generator 1-pin harness connector for damage, corrosion and looseness (White/Black wire). If problem does not exist, go to next step. If problem exists, repair as necessary. 5. Remove generator from vehicle. Measure resistance between voltage regulator "F" term
  • Page 16defogger on. Turn blower motor to high speed. If noise still exists, go to next step. If noise does not still exist, replace generator. 4. Turn ignition off. Connect generator harness connector. Start engine and let idle. Turn all accessories off. Using a stethoscope, check generator for unusual mec
  • Page 171. Remove generator. See GENERATOR . Remove 4 screws and remove voltage regulator from generator. Remove 2 screws and separate regulator from brush holder. See Fig. 3 . 2. To install, attach brush holder to regulator. Manually depress brushes, and install wire in hole to retain brushes during instal
  • Page 18
  • Page 19Fig. 5: Charging System Wiring Diagram (Excursion
  • Page 20
  • Page 21Fig. 6: Charging System Wiring Diagram (F250/F350 Super Duty Pickups
  • Page 222001 STARTING & CHARGING SYSTEMS Generators & Regulators - F250/F350 Super Duty Pickups - Diesel With Dual Generators DESCRIPTION System consists of a pair of 110-amp generators with internal voltage regulators, 2 batteries, Powertrain Control Module (PCM), warning indicator and wiring. Generators o
  • Page 231. Ensure junction box/fuse panels are accessible without turning on interior and hood lights. Drive vehicle over 30 MPH for at least 5 minutes. Park vehicle and allow to sit with ignition off for at least one hour to allow electronic modules to power down. Go to next step. 2. Connect a fused jumper
  • Page 24Connect a voltmeter positive lead to B+ terminal on generator and negative lead to ground. Start and run engine at 2000 RPM, with all accessories off. Read voltmeter when voltage stabilizes. Voltage should be 13-15 volts. If voltage is not as specified, repair by symptom. See SYMPTOM INDEX table und
  • Page 25Warning Indicator Is ON With Engine Running, System Is Not Charging A Warning Indicator Is OFF With Ignition On B Warning Indicator Is ON With Engine Running, System Is Charging C Warning Indicator Operates Properly, System Is Not Charging D Batteries Are Dead Or Will Not Stay Charged E Warning Indi
  • Page 267. Turn ignition switch to LOCK position. Disconnect PCM harness connector. Inspect PCM harness connector for corrosion and pushed out pins. Connect PCM harness connector, ensuring it is connected properly. Connect all disconnected connectors. Operate system. If fault is still present, replace PCM.
  • Page 27ignition switch to RUN position. Measure voltage between ground and generator harness connector terminal "A" (Orange/Light Blue wire). If battery voltage is present, go to next step. If battery voltage is not present, repair circuit between upper generator and battery junction box. See WIRING DIAGRA
  • Page 287. Connect lower generator harness connector. Disconnect upper generator 3-pin harness connector. Perform load and no-load tests on lower generator. See LOAD TEST and NO-LOAD TEST under ON- VEHICLE TESTING. If lower generator is okay, system is operating properly at this time. If lower generator is
  • Page 29at male side of in-line harness connector C130. If warning indicator illuminates, go to next step. If warning indicator does not illuminate, check for open in Light Green/Red wire between PCM and instrument cluster, or check for a defective indicator bulb. See WIRING DIAGRAMS . 6. Turn ignition swit
  • Page 301. Check for acid damage to both battery harnesses and cables. If damage does not exist, go to next step. If damage exists, repair as necessary. 2. Start engine and let idle. Turn all accessories off. Increase engine speed to 2000 RPM. Measure voltage between primary battery terminals. If voltage is
  • Page 311. Start engine and let idle. Tune radio to station where interference is present. Turn ignition switch to LOCK position. Disconnect upper generator 3-pin harness connector. Start engine and let idle. If interference is not still present, go to next step. If interference is still present, go to step
  • Page 321. Turn ignition switch to LOCK position. Disconnect lower generator 3-pin harness connector. Disconnect generator Black 8-pin in-line harness connector C130. In-line harness connector C130 is located in right front corner of engine compartment, near battery. Inspect connectors for damage or loose c
  • Page 33voltage. See WIRING DIAGRAMS . 4. Disconnect PCM harness connector. Inspect PCM harness connector for corrosion and pushed out pins. Connect PCM harness connector, ensuring it is connected properly. Connect all disconnected connectors. Operate system. If fault is still present, replace PCM. If fault
  • Page 34TORQUE SPECIFICATIONS TORQUE SPECIFICATION Application Ft. Lbs. (N.m) Generator Mounting Bolts 35 (47) Generator Pulley Nut 80 (108) INCH Lbs. (N.m) Generator B+ Terminal Nut 71 (8) WIRING DIAGRAMS
  • Page 35
  • Page 36Fig. 2: Charging System Wiring Diagram (F250/350 Super Duty Pickups - Diesel With Dual Generators