Alternator - Assemble
Assembly Procedure
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| Tooling that is needed | A | B | |
|---|---|---|---|
| Soldering iron (180 watt) | |||
| Vise or clamping support with vee blocks | |||
| Press | |||
| 8H-8581 | Feeler Gauges | 3 | |
| 1P-0510 | Driver Set | 1 | |
| 1P-0466 | Plate | 1 | |
| 1P-0529 | Handle | 1 | |
| 6L-5897 | Bolt | 1 | |
- Install the roller bearing (1) with tooling (B) .
Note: If necessary, apply grease to the bearing.
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| Illustration 1 | g00871248 |
- Install the ring (2) in the rear frame.
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| Illustration 2 | g00871460 |
- Install the insulators for terminal "B+" and terminal "D+".
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| Illustration 3 | g00871252 |
- Install the "R" terminal, if the "R" terminal was replaced.
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| Illustration 4 | g00871347 |
- Install the rectifier (3) in the rear frame.
- Install the two screws. Solder the sleeve (4) over terminal "R".
- Install the following components on terminals: "D+", "B+" and B-: terminal insulators, washers and nuts.
- Position the stator frame (7) on the rear frame (5). Use the marks on the alternator that were made in the disassembly procedure for alignment.
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| Illustration 5 | g00871376 |
- Solder the leads for the stator winding (8) to the terminals for the rectifier (6) .
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| Illustration 6 | g00871382 |
- Install the bearing (9) in the rear frame.
Note: The bearing is a loose fit.
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| Illustration 7 | g00871385 |
- Install the intermediate ring (10) .
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| Illustration 8 | g00871389 |
- Install the field winding (11). The leads for the winding must fit in the deep groove. Install the six screws on the reverse side of the frame.
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| Illustration 9 | g00871402 |
- Apply the epoxy putty 5P-3321 Adhesive over the lead and the groove.
- Install the spacer ring (12) .
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| Illustration 10 | g00871407 |
- Install the rotor assembly (13) in the drive end frame (14).
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| NOTICE |
|---|
In the next step you must support the spacer ring. The spacer ring is supported in order to support the bearing inner race. |
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| Illustration 11 | g00871415 |
- Heat the bearing race (15) to 135 °C (275 °F). Install the bearing race on the shaft.
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| Illustration 12 | g00871417 |
- Connect the drive end and the rotor (16) to the rear housing and the stator frame (17). The marks that were made during the disassembly procedure will help align the alternator. Install the four hex socket screws. Do Not Tighten the hex socket screws.
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| Illustration 13 | g00871447 |
- Insert three 0.3 mm (0.01 inch) feeler gauges (18) between the rotor and the stator. Tighten the screws to a torque of 4.8 ± .7 N·m (3.5 ± .5 lb ft).
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| Illustration 14 | g00871452 |
- Connect the lead for the field coil to the regulator (21). The screw is large in diameter (19) .
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| Illustration 15 | g00871457 |
- Connect the lead for the rectifier and the remaining lead for the field coil (20) to the regulator terminal.
Note: In order to maintain the proper polarity, one lead for the field coil has a hole that is small in diameter.
- Install the regulator (21) on the rear frame assembly. Install the two screws for the regulator.
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| Illustration 16 | g00871458 |
- Install the lead for the suppression capacitor on the "D+" terminal (22) .
- Install the regulator cover (23). Install the screws for the regulator cover.
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| Illustration 17 | g00871459 |
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