Generator Regulatorr Page 1

Electrical
2001 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. Generators integral electronic voltage regulator is fastened to rear
of generator with brush holder assembly. Voltage regulator incorporates temperature compensation circuitry, so
battery charging voltage is maintained at the optimum level in all climates. Charging system voltage is
maintained within an operating range of 13-15 volts.
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 repair tensioner mechanism if necessary.
TROUBLE SHOOTING
Verify customer's complaint. Ensure battery posts and cables are clean and tight. Inspect drive belt. Ensure
connections at generator, regulator and engine ground are clean and tight. Inspect central junction box fuse No.
29 (5-amp). Check fusible links. 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
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 minutes
to allow electronic modules to power down. Go to next step.
2. Connect a fused jumper wire between negative battery cable and negative battery post. Disconnect
negative battery cable from negative battery post, without breaking the jumper wire connection to prevent
modules from resetting. Go to next step.
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
NOTE: It is very important that continuity is not broken between negative battery
post and negative battery cable when disconnecting battery cable or
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Generators & Regulators - Excursion & F250/F350 Super Duty Pickups -
Gasoline & Bi-Fuel
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Generators & Regulators - Excursion & F250/F350 Super Duty Pickups -
Gasoline & Bi-Fuel
Helpmelearn
November-29-07 6:25:05 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Helpmelearn
November-29-07 6:25:08 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Contents Summary of Generator Regulatorr

  • Page 12001 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 2connecting 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 3SYMPTOM 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 4terminal 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 5Fig. 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 6TEST 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 7DIAGRAMS . 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 8defogger 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 91. 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 10
  • Page 11Fig. 5: Charging System Wiring Diagram (Excursion
  • Page 12
  • Page 13Fig. 6: Charging System Wiring Diagram (F250/F350 Super Duty Pickups