A-O-H DISASSAMBLY

Alternator Overhaul

Disassembly

Disassembly Components 1. Remove Alternator Pulley

2. Remove Alternator Brush Holder Assembly (1) Alternator terminal insulator (2) Brush holder (3) Rear end cover

3. Remove Alternator Regulator Assembly

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Alternator Overhaul

Disassembly 4. Remove Alternator Holder w/Rectifier

5. Remove Alternator Rotor Assembly (1) Drive end frame (2) Rotor (3) Rear end frame

(1/1) Remove Alternator Pulley When the pulley lock nut is loosened, it turns together with the shaft. Hold the nut with SST and turn the shaft to remove the nut. 1. Remove alternator pulley (1) Install SST1-A and SST1-B on the tip of the pulley shaft. Tighten the SST1-A and SST1-B with the specified torque and hold SST1-A to the pulley shaft. Torque: 39.2 N-m (400kgf-cm) SST1-A (Alternator rotor shaft wrench-A) SST1-B (Alternator rotor shaft wrench-B)

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Alternator Overhaul

Disassembly (2) Hold the SST2 in a vise and then with SST1-A and SST1-B installed on the alternator, insert the pulley lock nut into the hexagonal part of SST. SST1 (Alternator rotor shaft wrench) SST2 (Alternator pulley set nut wrench) Pulley lock nut

(1/2) (3) Turn SST1-A clockwise to loosen the pulley lock nut. HINT: With SST2 (pulley lock nut) held, turning SST1-A clockwise relatively loosens the pulley lock nut. SST1 (Alternator rotor shaft wrench) SST2 (Alternator pulley set nut wrench) SST1-A (Alternator rotor shaft wrench-A) SST1-B (Alternator rotor shaft wrench-B)

(4) Remove the alternator from SST2 and then while holding SST1-B, turn SST1-A clockwise to loosen itself, and remove SST1-A and SST1-B from the alternator. Remove the pulley nut and alternator pulley. SST1 (Alternator rotor shaft wrench) SST1-A (Alternator rotor shaft wrench-A) SST1-B (Alternator rotor shaft wrench-B)

(2/2)

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Alternator Overhaul

Disassembly REFERENCE: For Pulleys with One-way Clutches For pulley with one-way clutches, hold the shaft and turn the pulley to remove the pulley. 1. Remove alternator pulley (1) Set SST (A) and SST (B). SST (A) (Alternator rotor shaft wrench) SST (B) (Alternator pulley wrench)

(2) Remove the cap, insert SST (A) into the shaft and fit each of the three tabs of SST (B) into each of the three holes of the alternator pulley. HINT: • •

The pulley with a one-way clutch has a cap. This cap is not reusable, so when installing, install a new cap. SST (A) (Alternator rotor shaft wrench) SST (B) (Alternator pulley wrench) Tab Hole Pulley Cap

(3) Hold the tip (chamfer part) of SST (A) in a vice. SST (A) (Alternator rotor shaft wrench) SST (B) (Alternator pulley wrench) Pulley

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Alternator Overhaul

Disassembly (4) Turn the pulley with SST (B) to loosen the pulley. NOTICE: Because using an impact wrench will damage the pulley, be sure to use SST. SST (A) (Alternator rotor shaft wrench) SST (B) (Alternator pulley wrench) Pulley

(1/1) Remove Alternator Rotor Assembly Since the end frame is engaged with the rotor bearing, it needs to be disengaged using SST. 1. Remove rear end frame Hook the claw of SST to remove the rear end frame. SERVICE HINT: Parts pressed in (See “Basic Skills” of “Basics of Overhaul” on PDF page 19-25) SST (Injection pump spline shaft puller) Claw of SST End frame Rotor bearing

2. Remove alternator rotor assembly Remove the rotor from the drive end frame by tapping it with a hammer. NOTICE: When hammering, the rotor drops, so spread a cloth under it beforehand. Rotor Drive end frame Cloth Hammer

(1/1)

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