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3 Crucial Things You Must Do When Overhauling an Alternator

3 Crucial Things You Must Do When Overhauling an Alternator

Overhauling is an integral step in ensuring good generator maintenance. An overhaul can be done on the generator itself, the engine that drives it, or the alternator. When it comes to overhauling the alternator, particularly, technical knowledge and skills are usually needed.

The alternator is the heart of the generator. It is responsible for producing electrical energy from the mechanical energy it gets from the engine. The alternator has two primary components: the stator and the rotor. Because it is an essential part of the generator, regularly checking and maintaining the alternator is necessary.

Here are some of the most important steps that must be done when overhauling the alternator:

1. Examine the Rotor

When overhauling an alternator, one of the first things you need to do is inspect the rotor. The rotor is the moving component that rotates inside the alternator via the pulley and drives the belt system. It moves around the iron plates of the stator in order to generate an alternating current (AC).

One of the most important things that you should check on the rotor is its surface. If the rotor surface has discolouration, it may indicate local overheating on the iron core or retaining ring.

Aside from discolouration, it would be best to look for rust, dust, and grease, especially on the fan blade. Checking the balance block on the rotor, which should be fixed firmly without changing position, is also necessary.

2. Disassemble the Body and Remove the Rotor

If you have found an issue with the rotor, the next thing that you should do is to take it out after disassembling the body. Before disassembly, it is necessary that you mark the screw, pin, gasket, and cable head. The cable head also needs to be wrapped with a clean cloth after it has been disassembled.

When taking out the rotor, it is crucial to ensure that it does not collide or rub with the stator. After the rotor has been taken out, it needs to be placed on a stable hardwood pad. The rotor ring should also be wrapped with neutral Vaseline oil and green shell paper.

3. Repair the Stator

Inspecting the stator is another crucial step. The stator is the stationary component of the generator responsible for converting the rotating magnetic field into an electric current. It is one of the most vital parts found within the alternator.

If the cables situated in the stator malfunction, the whole generator would stop operating. In such a case, generator rewinding may be necessary.

One of the most important things you should do when inspecting the stator is to check its core, winding, and inside frame for any dust, oil, dirt, or damage. The completeness and integrity of the stator and its parts need to be thoroughly checked as well.


Ultimately, generator overhauling is a complicated procedure that requires technical knowledge and skills. When overhauling the alternator of a generator, it is necessary to know the basic processes and the fundamental steps to ensure a smooth and effective maintenance procedure. To be sure, it is always best to hire a professional to do the job.

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