Alternator: Testing and Inspection

1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance:
At 20° C (68° F): 2.7 - 3.1 ohm
If there is no continuity, replace the rotor.




2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
If there is continuity, replace the rotor.




3. INSPECT SLIP RINGS
a Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
b Using a vernier caliper, measure the slip ring diameter.
Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.




4. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the coil leads.
If there is no continuity, replace the drive end frame assembly.




5. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.




6. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes (M/T) or brush holder assembly (A/T).

7. M/T:

IF NECESSARY, REPLACE BRUSHES




a. Unsolder and remove the brush and spring.
b. Run the wire of a new brush through the hole in the brush holder, and insert the spring and brush into the brush holder.




c Solder the brush wire to the brush holder at specified exposed length.
Exposed length: 10.5 mm (0.413 in.)
d Check that the brush moves smoothly in the brush holder.
e Cut off the excess wire.
f Apply insulation paint to the soldered area.




8. INSPECT POSITIVE RECTIFIER
a Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
b Reverse the polarity of the tester probes and repeat step (a).
c Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.




9. INSPECT NEGATIVE RECTIFIER
a Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
b Reverse the polarity of the tester probes and repeat step (a).
c Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.

10. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.

11. IF NECESSARY, REPLACE FRONT BEARING




a Remove the 4 screws, bearing retainer and bearing.




b Using a socket wrench and press, press out the bearing.




c Using SST and a press, press in a new bearing.
SST 09950-60010 (099510460)

d Install the bearing retainer with the 4 screws.
Torque:
M/T: 2.6 Nm (27 kgf.cm, 23 in.lbf)
A/T: 3.0 Nm (31 kgf.cm, 27 in.lbf)

12. INSPECT REAR BEARING
Check that the bearing is not rough or worn.

13. IF NECESSARY, REPLACE REAR BEARING




a. Using SST; remove the bearing cover (outside) and bearing.
SST 0982O-O0021

NOTE: Be careful not to damage the fan.

b. Remove the bearing cover (inside).




c. Place the bearing cover (inside) on the rotor.




d. Using SST and a press, press in a new bearing.
SST 09820-00030




e. Using SST push in the bearing cover (outside).
SST 09285-76010