ELECTRICAL 13 ELECTRICAL 8.3.2 ALTERNATOR GENERAL DESCRIPTION: The alternator is a rotary machine that transforms mechanical energy into electrical energy. It is 12-pole synchronous generator with integrated rectifier in three-phase current bridge circuit with voltage-limiting Zener diode and attached multifunction controller. The alternator is air cooled and be able to function in the engine compartment of the vehicle. PRECAUTIONS: DO’S The operation of the alternator is only permissible with assembled regulator and with connected 12V battery. The alternator is mounted in the vehicle with a bracket directly onto the engine. The alternator has to be driven by a V-belt or a poly V-belt. The tensioning of the belt can be performed by tilting the alternator or by a separate belt-tensioning pulley. Correct alternator operation can only be achieved when the specified direction of rotation and the belt tension is maintained. DON’TS Swapping of the battery connections even for a short period only can result in pre-damage or functional failure of the alternator and is therefore NOT PERMISSIBLE!! Dismantling of the battery cables can lead to the loosening of the battery positive cable bolt on the alternator side. It is necessary to fasten the bolt to the specified torque It is not permitted to make a direct connection between the positive and ground with the alternator rotating. Plug in connection: Insufficient contact can lead to failed output signal hence it is necessary to ensure proper plug in connection. Axial load on the alternator rotor shaft is not permitted especially not by hitting as this can cause pre-damaged bearings. The alternator must not be dropped or exposed to any shocks out of normal conditions. The function of the alternator is not guaranteed afterwards. When the pulley is mounted by the customer the dimensional tolerances and the tightening torque must be kept within specified limits. Otherwise the pulley can become loose or the drive shaft can be damaged. It is not allowed to store the alternator in wet condition. This applies for installed as well as for not installed alternators. If the alternator is exposed to an engine cleaning process, a drying process should be done prior to storage of the engine. Do not disconnect the battery cable while engine is running. REGULAR MAINTENANCE: Check the general condition of the battery. Ensure correct battery electrolyte level. Ensure electrical connections are tight and secure. Check and ensure mounting bolts are tightened properly. Ensure the belt of the alternator is in good condition. Check the belt tension ensure it should be neither too tight nor too loose. Ensure alternator cooling slots are clear. Check and ensure alternator +ve terminal bolt tightened properly with torque 1.5 Kgm
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