Advanced Automotive Fault Diagnosis



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Advanced Automotive Fault Diagnosis
LÔØI NOÙI ÑAÀU, ledklok
Facilities/resources
A ‘Kryptontest bench model R2D2 was used to
drive the alternator. The test bench revcounter
was used and a ‘Flake’ digital meter fitted with a
200 A shunt was used to measure the output. A
variable resistance load was employed.
Test procedures
The alternator was run for 10 minutes at
3000 rev/min and the load adjusted to cause an
output of 30 A. This was to ensure that it was at a
nominal operating temperature. The normal fan
was kept in place during the test.
Speed was then increased to 6000 rev/min 
and the load adjusted to achieve the maximum
possible output. The load was further adjusted as
required to keep the maximum possible output in
case the load resistance changed due to tempera-
ture. Measurements were taken every 30 seconds
for a period of 10 minutes.
Measured results
Speed held constant at 6000 (⫾200) rev/min.
Room temperature (18°C).
Time (⫾1 s)
0
30 60 90 120 150 180 210 240 270
Output
101 100 99 99
98
98
98
98
98
98
(⫾0.2 A)
Time 
300 330 360 390 420 450 480 510 540 570 600
(⫾1 s)
Output 
97
97
96
96
96
96
96
96
96
96
96
(⫾0.2 A)
To ensure that the alternator output had stabilised
it was kept running for a further 20 minutes at
full output. It continued to hold at 96 A.
Analysis of results
Figure 1.2 shows the results in graphical format.
Conclusions
The manufacturer’s claims were validated. The
device exceeded the rated output by 6% at the start
4
Advanced automotive fault diagnosis
Figure 1.2 Results presented in graphical format


of the test and under continuous operation at full
load, continued to exceed the rated output by 1%.
The maximum duration of this test was 20 min-
utes. It is possible, however, that the device would
increase in temperature and the output may fall
further after prolonged operation. Further tests are
necessary to check this. Overall the device per-
formed in excess of its rated output.
(Sign and date the report)
Tom Denton, Wednesday, 25th Jan. 2006
Introduction
5
Knowledge check questions
To use these questions, you should first try to answer them without help but if necessary, refer back to
the content of the chapter. Use notes, lists and sketches as appropriate to answer them. It is not neces-
sary to write pages and pages of text!
1. State the meaning of the terms ‘fault’ and ‘symptom’.
2. Explain how to reduce the risk of a short circuit when testing electrical systems.
3. List the main headings that could be used for a standard report.
4. State the two main pieces of knowledge necessary to diagnose faults.
5. Describe the potential dangers of running an engine in an enclosed space without exhaust extraction.



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