Page 186 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

EXERCISE 10.2: Overhaul and test alternator

Objectives

At the end of this exercise you shall be able to
• remove the alternator
• dismantle the alternator
• check the stator
• check the rotor
• check the diodes
• check the condition of the brushes
• check the slip-rings
• assemble the alternator.

Requirements

Tools/Instruments Materials
• Trainee’s tools kit - 1 No. • Kerosene - as reqd.
• Socket spanner set - 1 No. • Emery paper - as reqd.
• 12 volt lead acid battery - 1 No. • Rotor - as reqd.
• Test lamp and cables - as reqd. • Banian cloth - as reqd.
Equipments/Machines • Grease - as reqd.
• Diodes - as reqd.
• Diesel Engine - 1 No. • Bearing - 2 Nos.

Procedure

TASK 1: Removing alternator

1 Disconnect the earth cable of the battery.
2 Disconnect the wires from the alternator.
3 Dismount the bolts which secure the alternator with the bracket.
4 Take out the alternator

TASK 2: Dismantling (Fig 1)
1 Mark a line across both the end shields (14 & 9) and the stator to facilitate alignment during reassembling.
2 Remove the cover securing studs and nuts (1 & 2) and lift the cover. (Fig 1)

3 Disconnect the regulator leads (3) and (5) ( +ve, -ve).
4 Remove the screw securing the regulator(4) to the brush box and remove the regulator (4).
5 Remove both the brushes (6) & (7). Note down the position of the sealing pad.
6 Remove the screws securing the brush-box (8) to the slipping end bracket (11) and lift out the brush-box (8).
7 Release the stator winding cable ends from the rectifier by applying a hot soldering iron to the terminal tags of
the rectifier.
8 Gently pull out the cable end when the solder melts.
9 Remove the screws securing the rectifier assembly (11) to the slip-ring end bracket and lift out the rectifier
assembly.
10 Remove the fixing bolts.
11 Take out the slip-ring end bracket (11).
12 Take out the stator assembly (13) from the drive end bracket (14).

169

CITS : Automotive - Mechanic Diesel - Exercise 10.1