Generator Regulatorrr Page 1

Electrical
2001 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 operate independently through internal voltage
regulation. PCM monitors both generators, and is able to set diagnostic trouble codes and control charge
warning indicator operation. PCM generator control is limited to disabling lower generator during glow plug
operation to avoid over-voltage damage to glow plug circuit. Generators have different size pulleys, and are not
interchangeable.
Charge warning indicator should illuminate with ignition on, engine off. Charge warning indicator should not
illuminate with ignition off, or with engine running. Generator and regulator cannot be serviced separately, and
must be replaced as an assembly.
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. Check for bent and/or misaligned pulleys. Inspect
accessory drive belt and tensioner. Inspect all fusible links. Inspect battery junction box fuses No. 6 (10-amp).
N
o. 5 (5-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, perform self-
diagnostics. See SELF-DIAGNOSTIC SYSTEM .
ON-VEHICLE TESTING
BATTERY DRAIN TEST
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
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
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Generators & Regulators - F250/F350 Super Duty Pickups - Diesel With
Dual Generators
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Generators & Regulators - F250/F350 Super Duty Pickups - Diesel With
Dual Generators
Helpmelearn
November-29-07 6:25:53 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Helpmelearn
November-29-07 6:25:56 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Contents Summary of Generator Regulatorrr

  • Page 12001 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 21. 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 3Connect 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 4Warning 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 57. 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 6ignition 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 77. 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 8at 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 91. 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 101. 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 111. 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 12voltage. 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 13TORQUE 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 14
  • Page 15Fig. 2: Charging System Wiring Diagram (F250/350 Super Duty Pickups - Diesel With Dual Generators