WO NUMBER UNIT CODE
ASSEMBLY CHECK SHEET ENG. MODEL SITE
ALTERNATOR ENGINE S/N DATE
COMP. S/N PAGE 1/5
START
PROCESS ASSEMBLY BY
FINISH
Before assembly , wash and clean all parts , check for dirt or damage coat the sliding and rotating
surfaces of all parts with engine oil and coat seal ring with grease (G2-L1) before installing.
CHECK NOTES, DIAGRAMS
No. PARTS CONDITIONS TO BE CHECKED SPEC. Check
POINT COMMENTS
1 Assy Cover Confirm that Cover are free from
Rear Cover dirt, crack , Worn and corrosion.
Front Cover Install front cover and make sure that
the position is true, check by
specification.
2 Fan and Pulley Confirm that Fan and Pulley are
Pulley free from dirt, Crack and corrosion.
Pulley must be free from worn or
scratch.
3 Rotor Rotor Confirm that Rotor is free from dirt,
crack and corrosion.
4 Stator Coil Coil Confirm that Stator Coil is free from
dirt , Corrosion , wire fitting and
damage.
Standard Terminal RST : min 20 MΩ
Actual Terminal R-Body : MΩ Use
Terminal S-Body : MΩ Insulating
Terminal T-Body : MΩ Tester
(500 V/1000 MΩ)
Check resistance stator cable for all
condition RST. Act : Ω Max.0.5 Ω
Use multitester
(Ω)
5 Field Coil Coil Confirm that Field coil is free from
Assy dirt, corrosion , wire fitting and
damage.
Standard :
Terminal F-Core/body min 20 MΩ
Terminal N-Core/body min 20 MΩ
Actual : Use
Terminal F-Core/body : MΩ Insulating
Terminal N-Core/body: MΩ Tester
(500 V/1000 MΩ
Alternator Assembling Check Sheet
WO NUMBER UNIT CODE
ASSEMBLY CHECK SHEET ENG. MODEL SITE
ALTERNATOR ENGINE S/N DATE
COMP. S/N PAGE 2/5
CHECK NOTES, DIAGRAMS
No. PARTS CONDITIONS TO BE CHECKED SPEC. Check
POINT COMMENTS
Measuring rotor coil by using
multitester (Ω) :
- rotor 90 A = Ω 5 – 10 Ω
- rotor 75A/50A/35A = Ω 10 ~ 20 Ω
Actual : Terminal F-N = Ω
6 All Parts New Parts Check all parts before installed
Old Parts Confirm that Parts are in good
Condition and have been measured
before.
7 Assembly Coil Install coil assy in Bracket assy ,
Bracket Rear screwed and Tighten.
Assy Be careful contact with body
8 Regulator Ass’y Regulator Install regulator in Bracket rear
assy, screwed and tighten.
Check regulator condition by using
multitester.
Actual : Std:
- terminal B-R
90A = Ω 100 ± 2 Ω
35A/50A/75A = Ω 142 ± 2 Ω
- terminal B-E = KΩ Measurement of
range KΩ
- terminal R-E = Ω Measurement of
range KΩ
- Terminal B, R, E (+) to terminal
RST (-). Act. : MΩ 1 ~ up MΩ
- Terminal B, R, E (-) to terminal
RST (+). Act. : M Ω 0.1 ~ Up M Ω
- Terminal F – N = M Ω 1 ~ Up M Ω
- Terminal B, R, E to terminal
1 ~ Up M Ω
N= MΩ
- Terminal B – F= Ω 142 ± 2 Ω
R – F= Ω Connected
(Measurement
E – F= KΩ
range) KΩ
- Terminal F (-)to terminal R,S,T (+)
= MΩ 0.1 ~ Up MΩ
- Terminal F (+)to terminal R,S,T (-)
= MΩ 1 ~ Up MΩ
- Terminal N(-)to terminal R,S,T (+)
= MΩ 1 ~ Up MΩ
- Terminal N(+)to terminal R,S,T (-)
1 ~ Up MΩ
= MΩ
Alternator Assembling Check Sheet
WO NUMBER UNIT CODE
ASSEMBLY CHECK SHEET ENG. MODEL SITE
ALTERNATOR ENGINE S/N DATE
COMP. S/N PAGE 3/5
CHECK NOTES, DIAGRAMS
No. PARTS CONDITIONS TO BE CHECKED SPEC. Check
POINT COMMENTS
Install regulator in bracket rear assy
Tighten bolt mounting
Install regulator cable (-) on
regulator mounting bolt (body)
9 Stator Install stator coil on Rear Bracket.
Coil
Check condition stator coil and make Using
sure that body contact. multitester
position Ω
10 Heat Sink or Install heat sink assy (-) in Bracket
Rectifier rear connect on RST stator coil
and solder.
Check code heat sink.
Heat sink (-) Only black
circle on under
Heat sink (+) Red circle on
under and Black
line on foot diode
Check condition heat sink (+) : Using
Leat red to plate and leat black to multitester
foot diode not connect and then digital
leat read to foot diode and leat
black to plate must be connect
Check condition heat sink (-)
Leat red to plate and leat black to
foot diode must be connect and
then leat read to foot diode and leat
black to plate not connect
If using multitester manual, position
leat red & black must be change for
upper condition.
Install insulator on Heat Sink (-)
Install Heat Sink (+) on insulator
Be careful, check condition insulator
Install Stator coil on Heat Sink (+).
Install RST cable from regulator to
RST Coil Stator and connect on
heat sink (+).
Install Screw on heat sink assy and
tighten it.
Alternator Assembling Check Sheet
WO NUMBER UNIT CODE
ASSEMBLY CHECK SHEET ENG. MODEL SITE
ALTERNATOR ENGINE S/N DATE
COMP. S/N PAGE 4/5
CHECK NOTES, DIAGRAMS
No. PARTS CONDITIONS TO BE CHECKED SPEC. Check
POINT COMMENTS
Install cable (+) Regulator on heat
sink (+) and install insulator.
Install cable (R) regulator on
Terminal R on body that has been
installed.
Installed bolt stud connector (+)
Which Connected on heat sink (+)
by using support and give insulator
on stud bolt to avoid From
contact with body
Install nut on Bolt Stud Connector
(+) and Tighten the nut.
11 Assembly Seal Install seal in Bracket front
Front
Bracket Assy Bearing Install bearing in Bracket front Coat with
Loctite
Bearing
Seal Install seal in cover bearing
0-ring Install O-ring in cover
Cover Install cover in Bracket front then
install bolt and tighten. Using
Rotor Install Rotor Assy in Bracket Front Press
Assy that has Been assembled Machine
Install collar , fan , pulley , washer
plate , Spring and nut then tighten.
12 Assembling Front Install Front Bracket Assembly in
Front and Bracket Rear Bracket
Rear Bracket
Install Front Bracket Bolt and rear
bracket then tighten.
Act. : kgm 0.8 – 1.2 Kgm
Install cover rear bearing
Install screw in cover then tighten
Install cover housing and screwed
then Tighten
13 Alternator Put Alternator on Test Bench
testing Install batteray cable (+) in
connector (+) Alternator
Install batteray cable (-) in connector
alternator, measured condition before
running.
Alternator Assembling Check Sheet
WO NUMBER UNIT CODE
ASSEMBLY CHECK SHEET ENG. MODEL SITE
ALTERNATOR ENGINE S/N DATE
COMP. S/N PAGE 5/5
CHECK NOTES, DIAGRAMS
No. PARTS CONDITIONS TO BE CHECKED SPEC. Check
POINT COMMENTS
- terminal B-E = VDC Min.24 Volt
- terminal R-E = VDC 2 ~ 6 Volt
Install V-Belt
Turn-On Test Bench Motor
Measure terminal (R-E)
Act. : VDC R-E 27.5 ~29.5
VDC
Measure terminal (B-E)
Act. : VDC B-E 27.5 ~ 29.5
VDC
Lead time running 15 ± 5 menit
Note :
APPROVED BY CHECKED BY ASSEMBLY BY
(Mechanic)
(Supervisor) (leader / QA Officer)
Alternator Assembling Check Sheet
