ALTERNATOR

OVERHAUL

Teknik Kendaraan Ringan

Semester 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
FRAME

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
Note: Diodes can be checked on  Must only get
car with Sun VAT 40 continuity one
way!!!
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 DRIVEN
12V, 24V, 32V
85 AMP TO 300 AMP CAPABILITY
ELECTRONIC REGULATOR
12V - 24V COMBINATION OUTPUT
SOME 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 Springs
Replace other faulty components
REASSEMBLY
Proper Torque
Paint Housing if necessary
Use Lock Tight on H.D. Alternators
Make sure there is no tension on
wiring
Make sure connections are tight!!
Always retest output after Overhaul.
CONVENTIONAL REGULATOR
CHECKING

IG and F terminal L and E terminal

Resistance Voltage regulator resistance
Free : 0 Free : 0
Pulled : in about 11 Pulled : in about 100
CONVENTIONAL REGULATOR
CHECKING

B and E terminal N and E terminal B and L terminal

Free : unlimited 23  Free : unlimited
Pulled : in about Pulled : 0 
100
Final Bench Testing
Check 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