Alternator: Testing and Inspection

1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance: 2.1-2.5 Ohms at 20°C (68°F)
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 a vernier caliper, 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 and brush holder assembly.




7. 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.




8. 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.




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




10. 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 (09951-00500)
d. Install the bearing retainer with the 4 screws.
Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf)




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




12. IF NECESSARY, REPLACE REAR BEARING
a. Using SST, remove the bearing cover (outside) and bearing.
SST 09820-00021

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