Alternator: Service and Repair
REPLACEMENT1. SEPARATE BATTERY NEGATIVE TERMINAL
2. REMOVE AIR CLEANER INLET NO.1
3. REMOVE V-BANK COVER
4. REMOVE FAN AND GENERATOR V BELT
5. REMOVE ENGINE UNDER COVER
6. REMOVE VANE PUMP PULLEY
a. Using SST, remove the nut and vane pump pulley.
SST 09960-10010 (09962-01000, 09963-01000)
7. REMOVE GENERATOR
a. Disconnect the generator connector.
b. Remove the rubber cap and nut, and disconnect the generator wire.
c. Disconnect the engine wires and PS hose.
d. Remove the nut, bolt, stay and generator
e. Remove the 2 clamps from the cord clips on the generator.
8. INSTALL GENERATOR
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
9. INSTALL VANE PUMP PULLEY
Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)
SST 09960-10010 (09962-01000, 09963-01000)
10. INSTALL ENGINE UNDER COVER
11. INSTALL FAN AND GENERATOR V BELT
12. INSTALL V-BANK COVER
13. INSTALL AIR CLEANER INLET NO.1
14. CONNECT BATTERY NEGATIVE TERMINAL
OVERHAUL
1. REMOVE GENERATOR REAR END COVER
2. REMOVE GENERATOR BRUSH HOLDER ASSY
3. REMOVE GENERATOR REGULATOR ASSY
4. REMOVE GENERATOR HOLDER W/RECTIFIER
5. REMOVE GENERATOR PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010
39 N.m (400 kgf.cm, 29 ft.lbf)
b. Check that SST (A) is secured to the rotor shaft.
c. Mount SST (C) in a vise.
d. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
NOTE: To prevent the rotor shaft from damage, do not loosen the pulley nut more than one-half of a turn.
f. Remove the generator from SST (C).
g. Turn SST (B), and remove SST (A and B).
h. Remove the pulley nut and pulley.
6. REMOVE GENERATOR RECTIFIER END FRAME
a. Remove the 3 nuts and cord clip.
b. Using SST remove the rectifier end frame.
SST 09286-46011
c. Remove the generator washer from the rotor.
7. REMOVE GENERATOR ROTOR ASSY
8. INSPECT GENERATOR ROTOR ASSY
a. Check the rotor for open circuit.
1. Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance: 2.1 -2.5 Ohm at 20 °C (68 °F)
If there is no continuity, replace the rotor.
b. Check the rotor for ground.
1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
If there is continuity, replace the rotor.
c. Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
d. Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than the minimum, replace the rotor.
9. INSPECT GENERATOR RECTIFIER END FRAME
a. Check the stator for open circuit.
1. Using an ohmmeter, check that there is continuity between the coil leads.
If there is no continuity, replace the drive end frame assembly.
b. Check the stator for ground.
1. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.
10. INSPECT GENERATOR BRUSH HOLDER ASSY
a. Using vernier calipers, measure the exposed brush length.
Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than the minimum, replace the brush holder assembly.
11. INSPECT GENERATOR HOLDER W/RECTIFIER
a. Check the positive (+) rectifier.
1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (1).
3. Check that one shows continuity and the other shows no continuity.
If the continuity is not as specified, replace the rectifier holder.
b. Check the negative (-) rectifier.
1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (1).
3. Check that one shows continuity and the other shows no continuity.
If the continuity is not as specified, replace the rectifier holder.
12. INSPECT GENERATOR DRIVE END FRAME BEARING
a. Check the bearing is not rough or worn.
If necessary, replace the bearing.
b. Replace the bearing.
1. Remove the 4 screws, bearing retainer and bearing.
2. Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00260, 09952-06010, 09951-00520)
c. Using SST and a press, press in a new bearing.
d. Install the bearing retainer with the 4 screws.
Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf)
13. INSPECT GENERATOR ROTOR BEARING
a. Check the bearing is not rough or worn.
If necessary, replace the bearing.
b. Replace the bearing.
1. Using SST, remove the bearing cover (outside) and bearing.
SST 09820-00021
NOTE: Be careful not to damage the fan.
2. Remove the bearing cover (inside).
3. Place the bearing cover (inside) on the rotor.
4. Using SST and a press, press in a new bearing.
SST 09820-00030
5. Using SST, push in the bearing cover (outside).
SST 09285-76010
14. INSTALL GENERATOR ROTOR ASSY
15. INSTALL GENERATOR RECTIFIER END FRAME
a. Place the generator washer on the rotor.
b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
c. Install the cord clip and 3 nuts, and temporarily tighten the 3 nuts.
16. INSTALL GENERATOR PULLEY
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
c. Check that SST (A) is secured to the pulley shaft.
d. Mount SST (C) in a vise.
e. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
f. To tighten the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110.5 N.m (1,125 kgf.cm, 82 ft.lbf)
g. Remove the generator from SST (C).
h. Turn SST (B), and remove SST (A and B).
17. INSTALL GENERATOR HOLDER W/RECTIFIER
a. Install the 4 rubber insulators on the lead wires.
NOTE: Be careful of the rubber insulators installation direction.
b. Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.94 N.m (30 kgf.cm, 26 in.lbf)
c. Install the cord clip and nut.
d. Tighten the 4 nuts.
Torque:
4.5 N.m (46 kgf.cm, 40 in.lbf) for A
5.4 N.m (55 kgf.cm, 48 in.lbf) for B
18. INSTALL GENERATOR REGULATOR ASSY
19. INSTALL GENERATOR BRUSH HOLDER ASSY
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
NOTE: Be careful of the holder installation direction.
20. INSTALL GENERATOR REAR END COVER
a. Place the brush holder cover on the brush holder.
b. Install the end cover and plate terminal with the bolt and 3 nuts.
Torque:
4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
3.8 N.m (39 kgf.cm, 34 in.lbf) for bolt
c. Install the terminal insulator with the nut.
Torque: 6.5 N.m (66 kgf.cm, 58 in.lbf)
21. INSPECT GENERATOR ROTOR BEARING
a. Check that the generator pulley rotates smoothly.