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Alternator Testing and Troubleshooting

The document outlines procedures for testing and troubleshooting alternators, including rotor, stator, heat sink, and diode-trio testing using an ohmmeter. It details steps for alternator wiring tests to assess system loss and provides instructions for the alternator replacement test to ensure proper functionality. Key checks include ensuring clean connections and measuring voltage and current outputs against specifications.

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Kyaw Kyaw
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8 views9 pages

Alternator Testing and Troubleshooting

The document outlines procedures for testing and troubleshooting alternators, including rotor, stator, heat sink, and diode-trio testing using an ohmmeter. It details steps for alternator wiring tests to assess system loss and provides instructions for the alternator replacement test to ensure proper functionality. Key checks include ensuring clean connections and measuring voltage and current outputs against specifications.

Uploaded by

Kyaw Kyaw
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Alternator Testing and

Troubleshooting
MSTC Diesel Technology
Rotor Testing
• Use ohmmeter to check rotor
field resistance. Place
ohmmeter leads on the two
slip rings on the rotor shaft to
make this check ( Figure 15 1. DE FRAME
). Refer to 2. ROTOR FRAME
SPECIFICATIONS, 11.0. for 3. SLIP RINGS
proper value. Also, use 4. ROTOR SHAFT
ohmmeter to check for a
grounded field by touching
one lead to a slip ring and
one lead to the rotor casting
( Figure 15 ). Reading should
be infinite (open) to show
that field is not grounded. If
field resistance is outside
specifications or if field is
grounded, replace rotor.
Stator Testing
• Use ohmmeter to perform
electrical check on stator (
Figure 10 ). There should
be no continuity between
any of the stator leads and
the stator laminations
Heat Sink Testing
1. GROUNDED HEAT SINK
• Place negative ohmmeter lead
on grounded heat sink. Touch 2. INSULATED HEAT SINK
positive ohmmeter lead firmly to 3. DIODE TRIO CLIPS
metal diode clips that surround
each of the 3 threaded studs. All
3 readings should be the same,
and indicate open circuits.
Switch leads and repeat. All 3
new readings should indicate
continuity
• Repeat checks using insulated
(positive) heat sink in place of
grounded heat sink. With
negative ohmmeter lead on
insulated heat sink, all 3
readings should indicate
continuity. Switch leads and
repeat. All 3 new readings
should indicate open circuits
Diode-trio Testing
• Use ohmmeter to check diode 1. INSULATED ATTACHING SCREW
trio ( Figure 11 ). Place 2. RECTIFIER BRIDGE STRAPS
3. DIODE TRIO
negative ohmmeter lead on 4. REGULATOR STRAP
regulator strap and use
positive ohmmeter lead to
check for continuity to each of
the three rectifier bridge
straps. All three readings
should indicate continuity.
Reverse the ohmmeter leads
and perform checks again.
Readings should all indicate
open circuits. On some
ohmmeters the polarity of the
leads is reversed from above.
Alternator Testing
Before beginning test procedures: check battery cables and
alternator wiring (especially grounds) for clean, tight connections.
Wires and connectors should not be damaged or corroded.

NOTE: Batteries should be fully charged for the following test.

Alternator Wiring Test Part 1

Alternator Wiring test Part 2

Alternator Replacement Test


Alternator Wiring Test Part 1
• BATTERY Voltage
(step 4)
• minus ALTERNATOR
Voltage (step 6)
• equals SYSTEM
LOSS
• If system loss is less
than 0.7V , go to
Alternator Replaceme
nt Test
• If system loss is
greater than 0.7V , go
to
Alternator Wiring Test
(Part 2).
Alternator Wiring test Part 2
• POSITIVE CIRCUIT LOSS
(step 2)
• PLUS NEGATIVE
CIRCUIT LOSS (step 4)
• equals TOTAL SYSTEM
LOSS
• If system loss is less than
0.7V , go to
Alternator Replacement Te
st.
• If system loss is greater
than 0.7V , repair circuit(s)
defects then go to
Alternator Replacement Te
st.
Alternator Replacement Test
• 1. If the wiring tests have been
performed (circuits OK), adjust
alternator belt and tighten mounting
bolts and ground connections.
• 2. With vehicle at shop temperature,
connect the carbon pile and the
ammeter as shown. To use an ammeter
without induction clamp, connect meter
leads to same terminals as the carbon
pile.
• 3. With NO electrical loads turned ON,
start the engine. Fast idle until voltage
stabilizes (does not increase for 2
minutes). Voltage then should not
exceed 15V.
• 4. Speed up the engine and turn ON the
carbon pile until the ammeter shows
output has reached the highest value.
Record the value A. Turn OFF carbon
pile and the engine.
• 5. Rated output is stamped on the
alternator case or on a tag. If current
output measured is not within 10% of
rated output or the voltage exceeds
15V, replace the alternator.

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