ALTERNATOROVERHAUL

Teknik Kendaraan RinganSemester 3th Class XI

Kompetensi Kejuruan (KK)SK-KD 18

DIAGRAM ALUR PENCAPAIAN KOMPETENSI

BEFORE YOU REMOVE ALTERNATOR

Pay attention to how wires are connected

Pay attention to Alternator oreintation

Disconnect Battery!!

Check Belt tension and condition

Check wiring condition

DISASSEMBLY

Mark frames for correct reassembly Note spacers placement Identify Alternator by Part Number Note Terminal Condition & orientation

INSPECTION OF “COM” END HOUSING

Bearing condition

Stator windings Pulley condition Brush wear Internal Wiring

Connections Component

external damage

INSPECTION OF DRIVE END HOUSING (FRAME)

Bearing race housings

Frame Condition Cracks Wear Stripped threads

Mounting boss condition

ROTOR VISUAL INSPECTION

Rotor slip ring condition

Rotor Windings external condition

Shaft condition

Cooling Fan condition

TESTING ROTOR FIELD COIL

Rotor resistance GM 2.4 to 3.5 ohms Ford 3.0 to 5.5 ohms Chrysler 3.0 to 6.0 ohms

Some shop manuals give rotor specifications in amps.

ROTOR TESTING FOR GROUNDED SLIP RINGS

Inspect rotor lead soldering area

Test rotor for Grounds to shaft

Can use ohmmeter

Can use 110 Volt continuity tester

ROTOR TESTING FOR GROUND TO ROTOR ROTOR TESTING FOR GROUND TO ROTOR FRAMEFRAME

Test rotor for grounds to rotor frame (open circuit cats claw)

Should be Inspect cats

claw for signs of rubbing on stator

DIODE TESTING Check Positive

diodes for one way operation by switching leads.

Can test with diode check function of DVOM

Can check with 110V diode tester tool.

Check Negative Diodes also

Must only get continuity one way!!!

Note: Diodes can be checked on car with Sun VAT 40

TEST STATOR FOR CONTINUITY

Check Stator for Continuity between phases of windings

Usually check resistance of windings

Must be same resistance

TEST STATOR FOR GROUNDS

Make sure Stator windings are not grounded to frame!

Inspect windings for worn spots on windings.

Check looseness

DELCO REMY 25SI AND 30SI ALTERNATORS

ADVANTAGES OF HEAVY DUTY 25-SI ALTERNATOR

BRUSHLESS - ROTOR WORKS ON PERMANENT MAGNETISM

BELT OR GEAR DRIVEN12V, 24V, 32V85 AMP TO 300 AMP CAPABILITYELECTRONIC REGULATOR12V - 24V COMBINATION OUTPUTSOME ARE OIL COOLED

LOTS OF WIRE CONNECTIONS!!!

25SI ROTOR Rotor doesn’t spin

in this alternator Stator is

stationary also Inspect Rotor and

stator for interference

Check stator and rotor as any other alternator

25SI ROTOR HOUSING Inspect for

interference Inspect bearing races Remove bearing race

with bearing splitter Inspect D.E. Bearing Inspect C.E. Bearing Inspect Housing

threads and condition

REPAIR

Clean components OK to clean in solvent but make sure dry

Replace Bearings Don’t spin bearings Inspect races closely Use proper procedures to replace and

remove bearings.Replace Brushes and SpringsReplace other faulty components

REASSEMBLY

Proper TorquePaint Housing if necessaryUse Lock Tight on H.D. AlternatorsMake sure there is no tension on

wiringMake sure connections are tight!!Always retest output after Overhaul.

CONVENTIONAL REGULATOR CHECKING

IG and F terminalResistanceFree : 0Pulled : in about 11

L and E terminalVoltage regulator resistanceFree : 0Pulled : in about 100

CONVENTIONAL REGULATOR CHECKING

B and E terminalFree : unlimitedPulled : in about 100

B and L terminalFree : unlimitedPulled : 0

N and E terminal23

Final Bench TestingCheck amperage output

Look up specifications In book Listen for abnormal noises

Check internal regulator operation Make sure cutoff voltage is correct.

Test Light/Indicator circuits also.Reinstall on Vehicle

BIBLIOGRAPHY:

Manual BookToyota Kijang 5 K, Toyota Astra Motor

www. Autoshop101.com

www.carrersnet.com

SMKN 1 MAGELANG