Assembly Procedure
Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause problems in the future. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
- Connect and solder the stator leads to the positive (+) diodes of rectifier (1) .
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| Illustration 1 | g03230839 |
(1) Rectifier (2) Stator | |
- Position the insulators on the rectifier terminal studs. Position rectifier (1), and stator (2) into the rear frame, and install the three screws. Install the terminal insulators, washers, and nuts. Position wave washer (3) into the bearing bore of the rear frame.
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| Illustration 2 | g03230840 |
(1) Rectifier (2) Stator (3) Position wave washer | |
- Install slip ring (5) on the rotor. Connect and solder the rotor leads to the slip ring (5). Install rear bearing (4) .
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| Illustration 3 | g03230842 |
(4) Rear bearing (5) Slip ring | |
- Install bearing cover (6), front bearing (8), and spacer (7) on the rotor.
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| Illustration 4 | g03230845 |
(6) Bearing cover (7) Spacer (8) Front bearing | |
- Install rotor (9) and the four screws into the front frame.
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| Illustration 5 | g03230846 |
(9) Rotor | |
- Assemble front frame and rotor assembly (11) into rear frame and stator assembly (10). Make sure that the wave washer is fixed in the rear frame bearing bore. Align the front and rear frame marks made at disassembly for correct assembly. Install the four screws.
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| Illustration 6 | g03230848 |
(10) Stator assembly (11) Rotor assembly | |
- Install the key, fan (13), pulley (12), washer, and pulley nut. Tighten the nut to a torque of:
3E-7295 Charging Alternator Gp, and 9X-0341 Charging Alternator Gp ... 70 ± 5 N·m (52 ± 4 lb ft)
8C-5535 Charging Alternator Gp, 7T-2876 Charging Alternator Gp, 2Y-4212 Charging Alternator Gp, and 2Y-8310 Charging Alternator Gp ... 35 ± 10 N·m (26 ± 7 lb ft)
9W-3043 Charging Alternator Gp ... 50 ± 5 N·m (37 ± 4 lb ft)
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| Illustration 7 | g03230896 |
(12) Pulley (13) Fan | |
- Install the capacitor and connect capacitor lead (14) to the back of the alternator.
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| Illustration 8 | g03230899 |
(14) Capacitor lead (15) Regulator | |
- Install regulator (15) .
End By: Install the alternator on the machine. Refer to Disassembly and Assembly, "Alternator - Install" for the machine that is being serviced.