TRACKER ALTERNATOR

 
1. Rear Housing (End Frame) 6. Bearing
2. Voltage Regulator/Brush Holder 7. Retainer
3. Stator Coil 8. Rotor (Magnet Assembly)
4. Pully 9. Rectifier
5. Front Housing 10. Brush & Spring
To replace the alternator, simply remove it and replace it with an already rebuilt, new, or better alternator.

INSPECTION & REFURBISHMENT
1. Remove the alternator from the vehicle
2. Mark the relationship of the end frames to ensure they are assembled correctly.
3. Remove the four rear housing screws.

4. Using a 200Watt soldering iron, apply heat to the end bearing box area on the rear housing.  When the tempurature is
    at 122 - 140degrees.
1. END FRAME       2. BEARING BOX       3. 200watt IRON
5. Pry the front housing from the the stator core.

6. Remove the B+ post, then remove the stator-to-rear frame screws and detach the atator from the rear frame.
7. Separate the Regulator/Brush holder, then unsolder the leads from the brushes.
8. Measure the length of each brush. If they are not in specification length, replace the brushes.
    a. Standard Length - 0.63in (16mm)
    b. Minimum Length - 0.08in (2mm)
9. Install the new brushes by reversing the removal procedure, making sure they are installed in the correct relationship with
    the slip rings.
10. If the regulator is faulty, replace it along with a new set of brushes.
11. Set new regulator/brush holder in position, lower the stator back into the end frame, and install the screws.
12.Compress the brushes into the brush holder and pass a rigid wire (straightened-out paperclip) through the small
     hole in the end frame and into the brush holder.  This will keep the brushes out of the way of the rotor slip rings as the
     alternator is reassemble, and is why the hole is there..
13. Once again, heat the rear bearing box of the end frame with the iron, and allow it to reach the same temp as stated
      before.  Assemble the two halves, making sure the previously applied marks are ligned-up.
14. Install the four screws and tighten them securely.
15. Remove the wire.
16. Install the alternator, belts, and whatever else.


When I leave items on in the vehicle, and start it up after a week, the Belt slips at the Alternator.  This is due to the extra load on the Alternator to charge the battery, and run the devices.  If I turn EVERYTHING off, the belt stops slipping, and it's fine.   The extra load slows the Alternator pully, and the belt slids on by, and is actually moving faster than the alternator pully.

The Tracker Alternator is only rated at 60amps.  There are adapters and rebuild kits to mount Standard AC DELCO 120amp units, or to rebuild the existing to a higher rating.

Since I run Two 200watt amps, two power inverters, alarm system, and a PalmTop PC (always on), my belt starts to slip unless I turn turn the Inverter off (running the PC), and keep the radio and everything else off till the battery charges up..