1. ALTERNATOR OVERHAUL Teknik Kendaraan Ringan Semester 3th Class XI Kompetensi Kejuruan (KK) SK-KD 18

2. DIAGRAM ALUR PENCAPAIAN KOMPETENSI

3. 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

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

5. INSPECTION OF “COM” END HOUSING  Bearing condition  Stator windings  Pulley condition  Brush wear  Internal Wiring Connections  Component external damage

6. INSPECTION OF DRIVE END HOUSING (FRAME)  Bearing race housings  Frame Condition  Cracks  Wear  Stripped threads  Mounting boss condition

7. ROTOR VISUAL INSPECTION  Rotor slip ring condition  Rotor Windings external condition  Shaft condition  Cooling Fan condition

8. 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.

9. 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

10. 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

11. 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

12. TEST STATOR FOR CONTINUITY  Check Stator for Continuity between phases of windings  Usually check resistance of windings  Must be same resistance

13. TEST STATOR FOR GROUNDS  Make sure Stator windings are not grounded to frame!  Inspect windings for worn spots on windings.  Check looseness

14. DELCO REMY 25SI AND 30SI ALTERNATORS

15. 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

16. LOTS OF WIRE CONNECTIONS!!!

17. 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

18. 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

19. 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

20. 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.

21. CONVENTIONAL REGULATOR CHECKING IG and F terminal Resistance Free: 0  Pulled: in about 11  L and E terminal Voltage regulator resistance Free: 0  Pulled: in about 100 

22. CONVENTIONAL REGULATOR CHECKING B and E terminal Free: unlimited Pulled: in about 100  B and L terminal Free: unlimited Pulled: 0  N and E terminal 23 

23. 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

24. BIBLIOGRAPHY: Manual BookToyota Kijang 5 K, Toyota Astra Motor www. Autoshop101.com www.carrersnet.com

25. SMKN 1 MAGELANG