repair-manuals

Acura RL V6 3.5L 1998 Alarm Module Locations

2015-01-28T05:50:00.003-08:00

DESCRIPTION

Immobilizer Control Unit
C427 (3-BLK)
C804 (2-YEL)
C425 (2-BRN/GRY)
Turn Signal Light Diode

Underside of Steering Column

Acura RL 2001 Testing and Inspection Guide (Horn Relay)

2015-01-27T05:49:00.002-08:00

Alarm Horn Relay: Testing and Inspection

Normally-open Type B

Check for continuity between the No. 1 and No. 3 terminals when power and ground are connected to the No. 2 and No. 4 terminals
There should be no continuity between the No. 1 and No. 3 terminals when power is disconnected

Acura TL V6 2009 Alarm Module Locations

2015-01-26T04:48:00.000-08:00

DESCRIPTION

Component Location Index
Immobilizer System Component Location Index

For the Keyless Access System, refer to Keyless Access System

Driver Under-Dash Fuse/Relay Box
Immobilizer Indicator
Immobilizer-Keyless Control Unit (Has built-in Receiver)
IMOES Unit (Built into the driver's MICU)

Acura TL V6 3.7L 2010 Alarm Module Locations

2015-01-25T06:46:00.001-08:00

DESCRIPTION

Immobilizer System Component Index

For the Keyless Access System, refer to Keyless Access System, Component Location Index Circuit Diagram

Driver Under-Dash Fuse/Relay Box
Immobilizer Indicator
Immobilizer-Keyless Control Unit (Has built-in receiver)

Symptom Troubleshooting
Registration
Input Test
Replacement

IMOES Unit (Built into the driver's MICU)

Replacement

Acura TL 1995 G25A4 FI Alarm Module Locations

2015-01-24T03:21:00.003-08:00

DESCRIPTION

A (26-GRY)
Transmission Control Module
B (22-GRY)
Security Control Unit

Acura TL V6 2007 Alarm Module Locations

2015-01-23T07:41:00.001-08:00

DESCRIPTION

Starter Cut Relay 1 [Wire Colors: WHT, BLU, BLU/WHT, and BLU/GRN]
Starter Cut Relay 2 [Wire Colors: BLU, BLK/WHT, BLU/WHT and BLU/GRN]
Display Panel Control Unit (Built into the audio-HVAC display module assembly)
Audio-HVAC Display Module Assembly [Consists of the audio system, the climate control system and the navigation system (if equipped)]
Climate Control Unit
IG2 Cut Relay (A/T) [Wire Colors: GRN, BLU/WHT, BLK/RED and BLU/GRN]
ACC Cut Relay (A/T) [Wire Colors: YEL, BLU/WHT, WHT/RED and BLU/GRN]
Immobilizer Control Unit-Receiver
Gauge Control Module
Audio Unit

Acura TL SOHC 1997 Alarm Module Locations

2015-01-22T03:58:00.002-08:00

DESCRIPTION

A (26-GRY)
Transmission Control Module (TCM)
B (22-GRY)
Security Control Unit

Acura TL V6 3.2L 1998 Alarm Module Locations

2015-01-21T06:38:00.002-08:00

DESCRIPTION

Security Control Unit
Connector A (18-GRY)
Connector B (12-GRY)

Acura TL 2004 Alarm Module Locations

2015-01-20T03:41:00.001-08:00

DESCRIPTION

Gauge Control Module
Display Panel Control Unit

Built into the audio-HVAC display module assembly

Audio-HVAC Display Module Assembly

Consists of the audio system, the climate control system, and the navigation system (if equipped)

Climate Control Unit
Immobilizer Control Unit-Receiver
Audio Unit

Acura TL Type S 2002 Alarm Horn Relay Locations

2015-01-19T09:04:00.000-08:00

DESCRIPTION

Keyless Entry/Security Alarm System - Component Location Index

Lock Button
Trunk Button
Unlock Button
Panic Button
Transmitter
Horn Relay
Under-hood Fuse/Relay Box
Tail light Relay
Headlight Relay 1
Headlight Relay 2
Security Indicator
Security Horn Relay
Headlight
Hood Switch

Acura CL Type S 2001 Alarm Module Locations

2015-01-18T09:50:00.001-08:00

DESCRIPTION

Contains the following locations for:

Navigation Display Unit
Climate Control Unit
Audio Unit
Immobilizer Receiver Unit

Acura CL 1997 Security Control Unit Repair Manual

2015-01-13T05:37:00.002-08:00

INCLUDES LOCATIONS FOR:

Horn Relay
Power Window Master Switch
SRS Unit
ECM/PCM
Security Control Unit
Cigarette Lighter Relay

Acura CL 1998 In Line 4 Alarm Module Locations

2015-01-10T04:23:00.002-08:00

DESCRIPTION

Horn Relay
SRS airbag unit
Security Control Unit
Cigarette Lighter Relay

Acura 3.2CL V6 2003 Alarm Module Location

2015-01-09T07:30:00.000-08:00

DESCRIPTION

Relay And Control Unit Locations - Dashboard

Acura ZDX V6-3.7L (2010) Alarm Module Locations

2015-01-07T05:03:00.000-08:00

DESCRIPTION

Multiplex Integrated Control System Component Location Index

Acura ZDX V6-3.7L Alarm Module Locations

Acura SLX V6 1996 Alarm Module Locations Repair Manual

2015-01-06T05:19:00.000-08:00

Manufacturer: Acura (Honda)
Model: SLX V6
Year: 1996

Bosch Alternators 1974

2015-01-03T07:40:00.000-08:00

Car Manufacturers Covered:

Alfa Romeo
Audi
BMW
Capri
Fiat 128 & X1/9
Mercedes-Benz
Opel
Porsche
Saab
Volkswagen
Volvo 4 Cylinder

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION, BATTERY CHARGING, OR USING A BOOSTER BATTERY TO START ENGINE - Reversed polarity or excessive voltage will result in damage to alternator system. Note the following to prevent damage:

Battery Installation - Negative battery terminal must be connected to ground. Positive terminal must be connected to starter lead. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from the battery. DO NOT use a Quick Charger to provide starting voltage.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to negative terminal of battery and positive lead to positive terminal of battery. DO NOT reverse battery leads.

APPLICATIONS

Model Type No. Part No.

Alfa Romeo ................ K1 14V 45A 22 ............. * 0 120 400 848

Audi .................................. ... ............................. ** 059 903 017D

BMW

2002, 2002A .......... K1 14V 45A 22 ............. * 0 120 400 752

2002 tii ................... K1 14V 45A 22 ............. * 0 120 400 794

3.0 .......................... K1 14V 45A 20 ............. * 0 120 400 702

Capri

4 Cyl. W/A.C ............... ... .............................. *** D4RY-C

4 Cyl. All Others ......... ... .............................. *** D4RY-B

V6 W/ A.C. .................. ... .............................. *** D4RY - D

V6 All Others .............. ... .............................. ***D4RY-A

Fiat 128 & X1/9 ................ ... ............................. * 0120 300 568

Mercedes Benz

230, 240D .................... ... .............................. **** 0041 546 902

280 ........................ K1 14V 55A 20 .............. **** 0041 541 802

450 ........................ K1 14V 55A 20 .............. **** 0031 545 602

Opel ................................ ... ................................ * 0 120 400 620

Porsche

4 Cyl .......................... ... ................................ ***** 022 903 023

6 Cyl .......................... ... ................................ *****911 603 118 00

Saab

99 .............................. ... ................................. *0120 400 850

V4 ............................. ... ................................. *0120 400 657

Volkswagen

Type 1 ........................ ... ................................ * 0120 400 836 or 862

Type 2 & 4 ................. ... ................................ * 0120 400 721

Dasher ........................ ... ................................ * 0120 489 532 or 535

Volvo

140 ............................. ... ................................ * 0120 400 756

164 ............................. ... ................................ * 0190 601 011

* - Bosch Part No.

** - Audi Part No.

*** - Motorcraft Part No.

**** - Mercedes Benz Part No.

***** - VW Part No.

DESCRIPTION

Bosche alternators are conventional three-phase, self-rectifying type alternators. Nine rectifier diodes are connected to the stator windings (three to each phase lead). The diodes change the alternator A.C. voltages to D.C. voltages coming out of the "B+" and "D+" terminals of the alternator.

SPECIFICATIONS

Alternator* Amp Output @ RPM Max Current

G1 14V 33A 27 ................... 33 @ 5000 ................................... 40A

K1 14V 35A 20 ................... 23 @ 2000 .................................... 35A

K1 14V 45A 20 .................... 30 @ 2000 ................................... 45A

K1 14V 45A 20 .................... 30 @ 2200 ................................... 45A

K1 14V 50A 20 .................... 33 @ 2000 ................................... 50A

K1 14V 55A 20 .................... 36 @ 2000 ................................... 55A

K1 14V 55A 22 .................... 36 @ 2200 ................................... 55A

* - Charging voltage: 14.

Field Coil Resistance - 4.0 ohms + 10% measured at slip rings at normal ambient temperature.

Stator Windings Resistance - .2 ohms + 10% measured between the phase output terminals

ON VEHICLE TESTING

NOTE - Off vehicle testing is explained as part of Overhaul procedure in this article.

WIRING CONTINUITY TEST

Disconnect terminal plug from rear of alternator and connect a voltmeter negative terminal to ground. With Ignition "ON", connect positive lead to each of the connector wires, in turn. Voltmeter should read battery voltage as each positive connection is made. If proper voltage is not read, trace each wire to find fault.

VOLTAGE DROP TEST - GROUND SIDE

Connect voltmeter between negative terminal of battery and alternator housing. Start engine and run at approximately 3000 RPM. If voltmeter reading exceeds .25 Volts, a high resistance in negatvie side of charging circuit is indicated. If so, check for loose, dirty, or corroded connections.

OUTPUT TEST

Disconnect terminal plug from rear of alternator and connect ammeter, in series between alternator center terminal and corresponding socket in terminal plug. Also connect a jumper lead between the "D+" terminal and its corresponding socket in terminal plug. Start engine and run at approximately 3000 RPM. Turn on headlights and leave on for five minutes. Ammeter should read maximum alternator amperage at normal operating temeperature.

REGULATOR CONTROL VOLTAGE TEST

Connect a voltmeter between main terminals of battery. Connect an ammeter, in series, between "B+" terminal of alternator and corresponding terminal of connector plug. Connect a jumper lead between alternator "D+" terminal and corresponding terminal of connector plug. Start engine and increase speed to approximately 3000 RPM. Run engine until charging rate falls below 10 amps. The voltmeter should then read 14.1 - 14.4 Volts. If these readings are not obtained, replace regulator.

NOTE - The test cables should not be removed or the load excessively reduced during the diodes. The control lamp should not go on at any time during the test.

BOSCH ALTERNATOR (TYPICAL)

OVERHAUL

DISASSEMBLY

NOTE - On 0 120 400 600 series alternators, lift carbon brushes with hook and secure them, prior to disassembly (see illustrations).

1) Remove nut, pulley, hub and key. Mark location of alternator in blower housing. Unscrew brush

LIFTING CARBON BRUSHES
(0 120 400 600 Series)

plate assembly and remove from alternator. Remove bolts from end frame, then remove frame and field rotor. Press rotor out of end frame. Press ball bearing off rotor. Remove insulating conduit from wires and cut wires as close to soldered joints as possible.

2) The diodes may be tested at this point, prior to further disassembly. Care should be exercised with insulating busings under positive diode carrier. To remove negative carrier, extract threaded studs. When one rectifying diode has been damaged due to short circuiting, the three complementing diodes must be replaced also. Unscrew nuts on both "B+" terminal bolts and lift positive diode carrier (heat sink) up and back.

TESTING & REPAIRING

Diode Assemblies - test diodes with a suitable alternator tester (EFAW 192) before dismantling slip ring end frame further. CAUTION - Do not lay positive diode carrier on housing or false reading will be obtained. Disconnect conductor from "D+" to the exciter diodes at the exciter diodes heat sink. Unscrew spring and brush holder and remove from alternator. Unsolder stator lead and negativediode connection. Unscrew exciter diodes heat sink and remove together with positive diodes heat sink.

NOTE - Before further testing, lightly clean all components in gasoline or trichlorethylene, but do not soak.

Stator - Test stator for short circuits to ground, using suitable tester (EFAW 84). Test voltage should be 40V AC. Measure resistance of stator windings between phase connections. See specifications for proper value.

Rotor - 1) Test claw pole rotor for short circuits to ground. Test voltage should be 40V AC. Measure resistance of exciter (field coil) in rotor with ohmmeter. See Specifications for proper value. Turn down slip rings on a lathe, using suitable tailstock chuck (EFAW 75 or GDF 85 R 3).

2) After turning, check concentricity of slip rings with dual gauge. Runout should not exceed .001" (.03 mm). Minimum diameter of slip rings may be 1.25" (31.5 mm). Maximum runout of pole wheel must not exceed .002" (.05 mm).

Diode Replacement - 1) On all except 0 120 400 600 series alternators, set diode plate on press die and force diodes out with plunger. Place diode plate (without diodes) onto suitable guide pilot (EFLJ 57/0/5) and set diode seat with suitable sleeve (EFLJ 57/0/3). Smear silicone oil on diode seat, place diode palte on press die and press diodes into position. After pressing in, test all diodes.

2) On 0 120 400 600 series alternators, set slip ring end frame on press die and force out defective diode. Coat diode seat with silicone oil and press in new diode. Test all diodes after replacement.

Drive End Frame - Check ball bearings for wear and replace as necessary. Lubricate bearings on one side. Press ball bearing into drive end frame with shielded side downward. Screw on retainer plate. Press ball bearing onto rotor (slip ring end), then press drive end frame onto rotor.

Carbon Brushes - Unsolder and replace carbon brushes. Do not allow solder to run into copper stands of brush leads. Minimum brush length is .55" (14 mm). After installation of new brushes, test for free movement.

REASSEMBLY & TESTING

1) On all except 0 120 400 600 series alternators (steps 1 through 4), fit negative diodes heat sink and clamps. Screw in double end bolts (shorter threads outward). NOTE - Left clamp is longer than right. Replace insulating washers and bushings. Test terminal bolt "B+" for short circuit to ground. Test voltage should be 80V AC.

2) Position positive diodes heat sink (carrier) and secure with insulating and spring washers. NOTE -

INSTALLATION OF DIODES

Use insulating cap NO. 1 120 502 000 instead of insulating washer on bolt nest to terminal marked "D+/61". Tighten hex nuts.

3) Place stator in slip ring end frame. Draw positive and negative diode leads together and lip through an insulating sleeve. Push sleeve over lead of exciter diode and stator connections cable. Crimp a metal ring around end of leads and solder. Cut off any excess wire protruding through ring. Reposition wiring and attach in holding clamps.

4) Side insulating sleeve over exciter diode terminal. Insulating sleeves of stator connection lead must project over edge of negative diodes heat sink. Clamp connections firmly.

5) On 0 120 400 600 series alternators (step 5 through 7), test both "B+" terminal bolts for short circuit to ground. Test voltage should be 80V AC. Before fitting exciter diodes heat sink (carrier), solder three positive diode terminal leads onto heat sink from below.

6) After fitting exciter diodes heat sink, solder stator leads, negative and exciter diodes to the "COMB". NOTE - Use caution, do not overheat negative diodes. Install brush holder. Raise and secure carbon brushes before installing. Screw conductor "D+" onto exciter diodes heat sink.

7) Place wave spring washer into ball bearing fit. Rub ball bearing seat with suitable lubricant. Insert rotor with drive end bearing into slip ring end frame and secure. Springs are to be set onto carbon brushes by pressing on brush with a screwdriver. Brush spring pressure will seat brushes automatically.

8) Rub suitable lubricant into ball bearing seat of slip ring end frame. Install claw pole rotor with drive end frame. Check position of stator relative to end frame. Position brush holder plate. Tighten screws. Install fan belt pulley. Coat newly installed positive diodes with chlorinated rubber lacquer.

1991 INFINITI Q45 SERVICE REPAIR MANUAL

2014-06-05T06:08:00.001-07:00

The first generation Q45 came to market in 1989 as a 1990 model. Car magazines and reviewers were

INFINITY Q45 1991

impressed by the Q45′s performance such as a 0–60 mph acceleration time of 6.7 seconds and handling. Its high-output 4.5 L V8 engine is rated at 278 hp (207 kW) and 292 lb·ft (396 N·m).

The car’s interior was crafted to appeal to the sense of touch, using padded surfaces throughout the vehicle, with stark color contrasts such as a pearl white exterior with white leather upholstery, interior door panels, and carpeting with black floor mats, center console and dashboard.

Download

INFINITI QX56 2009 – 2011 SERVICE REPAIR MANUAL

2014-06-05T06:01:00.000-07:00

Service Manual Covers:

General Information

INFINITY QX56
Engine Mechanical
Engine Lubrication System
Engine Cooling System
Engine Control System
Fuel System
Exhaust System
Starting System
Accelerator Control System
Hybrid Control System
Hybrid Battery System
Hybrid Brake System
Clutch
Transaxle & Transmission
Driveline
Front Axle
Rear Axle
Front Suspension
Rear Suspension
Suspension Control System
Road Wheels & Tires
Brake System
Parking Brake System
Brake Control System
Steering System
Steering Control System
Seat Belt
Seat Belt Control System
SRS Airbag
SRS Airbag Control System
Ventilation System
Heater & Air Conditioning System
Heater & Air Conditioning Control System
Interior
Instrument Panel
Seat
Automatic Drive Positioner
Door & Lock
Security Control System
Glass & Window System
Power Window Control System
Roof
Hood
Exterior
Body Repair
Mirrors
Exterior Lighting System
Interior Lighting System
Wiper & Washer
Defogger
Horn
Power Outlet
Body Control System
LAN System
Power Control System
Charging System
Power Supply, Ground & Circuit Elements
Meter, Warning Lamp & Indicator
Warning Chime System
Sonar System
Audio, Visual & Navigation System
Cruise Control System
Driver Assistance System
Drive Mode System
Maintenance

Download >> 2009 >> 2010 >> 2011

NISSAN VERSA 2012 HATCHBACK & SEDAN SERVICE MANUAL

2014-06-05T05:49:00.001-07:00

General Information

NISSAN VERSA 2012 SEDAN
EngineMechanical
EngineLubrication System
EngineCooling System
Engine Control System
Fuel System
Exhaust System
Starting System
Accelerator Control System
Clutch
Transaxle & Transmission
Driveline
FrontAxle
Rear Axle
Front Suspension
Rear Suspension
SuspensionControl System
Road Wheels &Tires
Brake System
ParkingBrake System
Brake Control System
SteeringSystem
SteeringControlSystem
Seat Belt
Seat Belt ControlSystem
SRSAirbag
SRS AirbagControlSystem
VentilationSystem
Heater & Air ConditioningSystem
Heater & Air ConditioningControl System
Interior
InstrumentPanel
Seat
Automatic Drive Positioner
Door&Lock
Security Control System
Glass & WindowSystem
PowerWindowControl System
Roof
Exterior
BodyRepair Manual
Mirrors
ExteriorLighting System
InteriorLightingSystem
Wiper& Washer
Defogger
Horn
PowerOutlet
BodyControlSystem
LAN System
PowerControl System
ChargingSystem
Power Supply,Ground & CircuitElements
Meter,Warning Lamp & Indicator
WarningChime System
Sonar System
Audio,Visual& Navigation System
Cruise Control System
Maintenance

Download : Hatchback – Sedan

Nissan Titan 2010 Factory Service Manual

2014-06-05T05:47:00.000-07:00

General Information

NISSAN TITAN 2010
Engine Mechanical
Engine Lubrication System
Engine Cooling System
Engine Control System
Fuel System
Exhaust System
Starting System
Accelerator Control System
Hybrid Control System
Hybrid Battery System
Hybrid Brake System
Transaxle & Transmission
Driveline
Front Axle
Rear Axle
Front Suspension
Rear Suspension
Suspension Control System
Road Wheels & Tires
Brake System
Parking Brake System
Brake Control System
Steering System
Steering Control System
Seat Belt
Seat Belt Control System
SRS Airbag
SRS Airbag Control System
Ventilation System
Heater & Air Conditioning System
Heater & Air Conditioning Control System
Interior
Instrument Panel
Seat
Automatic Drive Postioner
Adjustable Pedal
Door & Lock
Security Control System
Glass & Window System
Power Window Control System
Roof
Exterior
Body Repair Manual
Mirrors
Exterior Lighting System
Interior Lighting System
Wiper & Washer
Defogger
Horn
Power Outlet
Body Control System
LAN System
Power Control System
Charging System
Power Supply, Ground & Circuit Elements
Meter, Warning Lamp & Indicator
Warning Chime System
Sonar System
Audio, Visual & Navigation System
Cruise Control System
Maintenance

Download

S.E.V. Motorola Alternators 1968-73

2014-06-02T05:09:00.000-07:00

Renault (1969-73)
Simca (1969-70)
Volvo (1968-73)

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION & OTHER ELECTRICAL REPAIRS CAUTION - Reverse polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage:

Battery Installation - Negative battery terminal must be connected to ground (negative ground system) and positive terminal must be connected to starter. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from the battery. DO NOT use a Quick Charger to provide starting voltage.

Circuit Interruption - The battery must NEVER be disconnected while alternator is running.

Alternator Removal - Always disconnect battery ground before replacement of alternator.

High Voltage - DO NOT use a high voltage source to test diodes.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to negative battery terminal and positive lead to positive terminal. DO NOT reverse battery leads.

Field Terminal - NEVER ground field energizing terminal on alternator, regulator, or connecting lead.

Voltage Regulator - NEVER operate voltage regulator without a good ground connection or immediate damage will result.

DESCRIPTION

SEV Motorola alternators are conventional three-phase, self rectifying type alternators. Six silicone diodes (three positive and three negative) are used to rectify AC currrent. The 35 ampere alternator use one isolation diode mounted in a heat sink attached to end frame. The 55 ampere unit incorporates two isolation diodes (connected in parallel) which are mounted on exterior. Isolation diodes (when used) have two functions: They prevent battery from discharging through regulator and alternator field, and they provide a simple means of operating charge warning lamp.

APPLICATION
Model *Part No.
Renault
R-12
1971-72.....................7122-8302
1973.....................77 00 559 308
R-15
1972-73...............77 00 532 831
R-16
1969-70....................** A 12/30
1971-72...............77 00 500 295
R-17
1972.....................77 00 529 484
1973.....................77 00 559 309
Simca
1204
1969-70..................*** S 34266
Volvo
140 Series
1968-71.....................14V-26641
1972................................419420
1973...................................33525
164
1969-71.....................14V-34833
1972.................................419420
1973...........................14V-34833
1800
1972.................................460085
1973...................................33525
* - Each number listed is either Renault part number, Simca part number or Volvo part number.
** - Type Number.
*** - Standard, optional part number is S 30479

SPECIFICATIONS

Nominal Output
Application Amps. @ RPM Volts
7122-8302..................30 @3000.............13.2
77 00 559 308............30 @ 3000.............13.2
77 00 532 831............30 @ 3000.............13.2
A 12/30......................35 @ .... ................. ....
77 00 500 295............. ............ ................13.2
S 34266....................... ........... ................. ....
14V-26641.................35 ... .......................13
419420.......................35 @ 5000.............14.2
33525.........................48 @ 3000.............13.2
14V-34833.................48 @ 3000...............14
460085.......................55 @ 4000...............14
* - Charging Voltage
Coil Resistance (Ohms)
Application Rotor Stator
7122-8302.................5.2......................... *
77 00 559 308...........5.2......................... *
77 00 532 831...........5.2......................... *
A 12/30.....................5.2......................... *
77 00 500 295........... ... ......................... ..
77 00 529 484........... ... ......................... *
77 00 559 309...........5.2......................... *
S 34266..................... ... ......................... ..
14V-26641................5.2......................... *
419420......................5.2......................... *
33525........................3.7......................... *
14V-34833................3.7......................... *
460085......................3.7......................... *
* - See stator testing in Overhaul.

TESTING

ON CAR TEST

Connect alternator as shown in illustration, Check that current through field winding (rotor) is 3.5 amps. If

ALTERNATOR TESTING CIRCUIT

current is not 3.5 amps, check field winding condition and brush holder. Run engine speed to 3000 RPM. Alternator should then produce the specified current. Measure voltage at terminal "B+" and at terminal "61". Voltage should be .8-.9 volts more at terminal "61". If not, isolation diodes are faulty and should be replaced.

OVERHAUL

DISASSEMBLY

1) Release two screws holding brush holder and remove isolation plate (if equipped). Pull out brush holder.

2) Hold pulley with belt in a vise with soft jaws, and remove the nut and washer. Lift off pulley, fan, key and spacer washer.

3) Remove nuts and washers on terminal 61 and the corresponding terminal on the other side of isolation diode. Mark drive shield, stator and slip ring end shield for correct reassemly position.

CHECKING BRUSH HOLDER

4) Remove four attaching screws. Remove rotor and drive end shield with help of two screwdrivers, which are inserted in two sockets between stator and drive end shield. CAUTION - The screwdrivers may not be inserted deeper than 1/14" (2 mm) otherwise stator may be damaged.

5) Release three screws holding support plate of drive end bearing. Release bearing by knocking end of shaft against a piece of wood.

6) Remove nuts and washers for the diode holder for negative diodes. Remove stator and diode holders for slip ring end shield.

S.E.V. MOTOROLA ALTERNATOR (TYPICAL)

TESTING

Stator - Check stator for short-circuiting. If one or more of the coils are burned, there must be a short-circuit in stator. Connect test lamp (12 volt, 2-5 watt) between stator plates and terminal on stator (see illustration). If lamp lights, isolation between stator winding and stator plates must be burned, in which case stator should be replaced. NOTE - Use only test lamp as specified. DO NOT use a 110-volt or 220-volt test lamp on this or any alternator test procedure

STATOR CHECK

Diodes - Check diodes with a diode tester. If any of the rectified diodes are shorted or open, the diode holder must be replaced. If any isolation diode is faulty, replace holder, complete with isolation diodes. If diode tester is not available, diode should be unsoldered and tested with an ohmmeter. Diodes should show high resistance in reverse direction and low resistance in flow direction.

Rotor - Check to make sure slip rings are not dirty or burned. Check winding for breakage or damage isolation. Measure resistance between slip rings. It should be as specified. If winding is faulty, rotor must be replaced. NOTE - It is recommended that bearings be replaced whenever alternator is disassembled.

Brush Holder - Connect a test lamp between the brushes. Lamp should not light. Next connect test lamp between "DF" terminal and the "+" brush. Lamp should give steady light even if brush or terminal cable is moved (see illustration). Connect test lamp between brush holder frame and "-" brush. Lamp should give steady light. If test results are not satisfactory or brush length is less than 3/16" (5 mm), replace brush holder. NOTE - Brush length is measured between brush contact surface and holder, with brush resting against spring.

PARTS REPLACEMENT

Diodes - Mark leads connecting stator to diodes, then unsolder leads. Place new diode holder in exact position of holder being replaced. Solder new leads, holding with pliers (this is to conduct heat from soldering point, to avoid damaging new diode). Use a minimum 100-watt, well-heated soldering iron. Never change places of diode holders. Positive holder is isolated from frame by means of isolation washers and sleeves and its diodes are marked in red. Negative diode holder is not isolated and its diodes are marked in black.

REASSEMBLY

Alternator is reassembled by reversing order of disassembly, noting the following: Rotor must be pressed into drive end shield. Connect a test lamp between "B+" terminal and alternator frame, then reverse connections. Lamp should light only in one direction. After completion of reassembly, test run alternator on bench, using same procedure as described for On Car Testing.

Citroen Paris Rhone Alternators

2014-06-01T12:29:00.000-07:00

Citroen....................A13R52, A13R59, A13R92
CHANGES, CAUTIONS & CORRECTIONS
BATTERY INSTALLATION, BATTERY CHARGING, CIRCUIT INTERRUPTION, ALTERNATOR REMOVAL, HIGH VOLTAGE, OR USING A BOOSTER BATTERY TO START ENGINE CAUTION - Reversed polarity or excessive voltage will result in extensive damage to alternator system. NOTE the following to prevent damage.
Battery Installation - Negative battery terminal must be connected to ground (Negative ground systems), and Positive terminal connected to ground (Positive ground systems). Do not reverse battery leads.
Battery Charging - If a "Fast Charger" is used, both of the car's battery cables must be disconnected from battery. Do not use "Fast Charger" to provide starting voltage.
Circuit Interruption - The battery must Never be disconnected while alternator is running.
Alternator Removal - Always disconnect battery ground before replacement of alternator.
High Voltage - Do not use a high voltage source to test diodes.
Booster Battery (Used to Start Engine) - Booster Battery must be connected with negative lead to negative terminal of battery and positive lead to positive terminal of battery. Do not reverse battery leads.
Field Terminal - Never ground field energizing terminal on alternator or connecting lead.

DESCRIPTION

Paris-Rhone Alternators used on Citroen vehicles are conventional thee phase self-rectifying type alternators. Six silicone diodes (three positive and three negative) are used to rectify A.C. current. Paris-Rhone regulator specifications are included in the specification chart.

TESTING

ALTERNATOR
NOTE - Before performing any test or checks on charging system, it is important to stabilize temperature of the components. This can be done by operating system at varous speeds for 30 minutes.

Disconnect negative battery terminal. Connect test equipment as shown in illustration. Reconnect negative battery terminal. Start engine and slowly increase speed to lowest RPM listed. See "Output" under specification table. Adjust rheostat to obtain 14 volts. Current output should be as listed. Raise engine speed to next level (see specifications) and adjust rheostat to gain 14 volts. If current output at these engine RPM's cannot be obtained, inspect alternator.

REGULATOR TESTING CIRCUITS

REGULATOR
Disconnect negative battery terminal. Connect test equipment as shown in illustration. Reconnect negative battery terminal. Start engine and slowly increase speed to RPM shown. See "Regulating Voltage" under specification chart. Adjust rheostat to obtain current value listed. Voltage reading should be within specifications. Increase current setting and record reading. If alternator is known to be good and regulating voltage is not correct, regulator is defective. NOTE - Successive voltage readings during this test should be obtained by increasing current steps only. NEVER decrease current during test.

Nippondenso Toyota Alternators 1965-73

2014-06-01T10:37:00.004-07:00

For Toyota Models (1965-73)

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION & OTHER ELECTRICAL SYSTEM

REPAIR CAUTIONS-Reversed polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage.

Battery Installation - Negative battery terminal must be connected to ground (negative ground systems) and positive terminal must be connected to starter. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from battery. DO NOT use a Quick Charger to provide starting voltage.

NIPPONDENSO ALTERNATOR (TYPICAL)

Circuit Interruption - Battery must NEVER be disconnected while alternator is running.

Alternator Removal - Always disconnect battery ground before replacement of alternator.

High Voltage - DO NOT use a high voltage source to test diodes.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to positive battery terminal. DO NOT reverse battery leads.

DESCRIPTION

Nippondenso alternators are conventional, three-phase, self rectifying type alternators. Six diodes (three positive and three negative) are used to rectify current

APPLICATION

Model Toyota Part No.

KC (1969-70)

Corolla 1100 Before 2/69 .......................... 22010

Corolla 1100 After 2/69.............................. 22011

3K-C (1970-73)
Corolla 1200 (1970-72)............................ *22011
All Models W/ 3K-C Eng. (1973)............... 24031
2T-C (1971-72)
Corolla (1971-72)...................................... 25010
Carina (1972)........................................................
All Models W/2T-C Eng. (1973)................ 25010
BR-C (1969-71)
Corona Mk II.............................. 33010 & 33030
Hi-Lux.............................. 22011, 31031 &31032
Corona & Celica......................................... 33011
3R-B (1965-67)
1900 Sedan................................................. 21011
Corona & Crown
Before Eng. 3R 479894............................ 21010
After Eng. 3R 479894................................ 21011
Stout Pickup
Before Eng. 3R 590915............................ 40010
After Eng. 3R 590915.............................. 40011
3R-C (1968-70)
Corona & Hilux
Before 6/68.............................................. 21011
After 6/68................................................ 40060
18R-C (172-73)
Corona & Celica (1972).............................. 33011
Corona Mk II (1972).................................. 33030
Hi-Lux (1972)............................................. 31032
All 1973 BR-C Eng. ................................... 33030
M (1965-68)
Crown Before 11/68.................................... 41011
2M (1968-71)
Crown
After 11/68............................................... 41011
After 9/69................................................. 41012
4M (1971-73)
Crown (1971-72).................................... **41032
Corona (1971-72)................................. ***41032
All 4M Eng. (1973)..................................... 45020
F (1965-73)
From Eng. F224280.................................... 60021
From Eng. F243298............................**** 60031
From Eng. F270964.................................... 60040
From 1/71.........................................***** 60033
All F Eng. (1973)........................................ 60040
* - All part numbers start with 27020 prefix
** - Part number 22012 is optional.
*** - Part number 45010 is optional.
**** - Part numbers 60012, 60040 & 60022 are iotuibak,
***** - Part number 60040 is optional.

SPECIFICATIONS

Rated Output @ 3500 RPM
Application* Amps. **Volts
21010...........................40.....................14
21011...........................40.....................14
22010...........................25.....................14
22011.....................***25.....................14
22012...........................30.....................14
24031...........................35.....................14
25010...........................40.....................14
31031...........................30.....................14
31032...........................30.....................14
33010...........................40..........13.5-14.8
33011...........................40.....................14
33030...................****45.....................14
40010...........................40.........13.5-14.8
40011...........................40.........13.5-14.8
40060...........................40.........13.5-14.8
41010...........................40.........13.5-14.8
40011...........................40.........13.5-14.8
40012...........................40.........13.5-14.8
41032...........................45.........13.5-14.8
45010...........................55....................14
45020...........................55....................14
60012...........................35....................14
60021...........................50....................14
60022...........................50....................14
60031...........................40....................14
60032...........................40....................14
60033...........................40....................14
60040...........................55....................14
* - All part numbers start with 27020 prefix.
** - Nominal voltage, 12.
*** - Optional for part number 27020 22011 is 30 amps.
**** - Amps for part number 27020 33030 ub 1973 us 50.
Coil Resistance (Ohms)
Application Rotor Stator
21010......................3.6...............................
21011......................3.6...............................
22010......................4.2...............................
22012......................4.2...............................
24031......................4.2...............................
25010......................4.2........................0.24
31031......................4.2...............................
31032......................4.2...............................
33010......................4.2........................0.37
33011......................4.2........................0.37
33030......................4.8........................0.24
40010......................3.6...............................
40011......................3.6...............................
40060......................3.6...............................
41010..........................................................
41011......................4.2........................0.24
41012......................4.2........................0.24
41032......................4.2........................0.37
45010......................4.2........................0.37
45020......................4.2........................0.37
60012.........................................................
60021.........................................................
60022.........................................................
60031......................4.2..............................
60032.........................................................
60033......................4.2..............................
60040......................4.8..............................
* - All part numbers start with 27020 prefix.
Minimum Brush Length
Application* In. (mm)
21010, 21011, 22010................. .354 (9)
22011, 22012, 24031................. .354 (9)
40010, 40011, 40060................. .354 (9)
25010, 31031, 31032.............. .334 (8.5)
33010, 33011, 33030.............. .334 (8.5)
41010, 41011, 41012.............. .334 (8.5)
41032, 45010, 45020.............. .334 (8.5)
60012, 60021, 60022.............. .217 (5.5)
60031, 60032, 60033.............. .217 (5.5)
60040...................................... .217 (5.5)
* - All part numbers start with 27020 prefix.

TESTING

ON CAR TEST

TEST CIRCUIT FOR LOAD TEST

Preliminary Inspection - Check alternator mounting and belt tension. Inspect turn signal fuse and gauge fuse. Check alternator and regulator wire connections for tightness
No-Load Test - 1) Connect test meters as shown in illustration. Start engine and increase speed to 2300 RPM (gradually). Read the "B" terminal voltage. It should be 13.8-14.8 volts with current draw of not more than 10 Amps. If current is over 10 Amps the battery is discharged or internally shorted.
2) If voltage reading is not steady, it indicates regulator points are dirty, or defective connection exists at "F" terminal.
3) If voltage reading is too high, it indicates the following problems: Regulator low speed gap is too wide. High speed point gap is too wide. High speed point resistance is too high. Open circuit regulator coil or

CHECKING VOLTAGE BETWEEN "F" &
"E" TERMINALS

voltage relay coil. Open circuited regulator coil or voltage relay coil. Open circuited regulator "N" terminal or "B" terminal. Low speed point contact tension too heavy. Loose regulator ground connection.
"F" Terminal Voltage Test - Stop Engine, disconnect alternator wiring connector, turn ignition switch to "ON" and measure voltage between "F" and "E" terminals of connector. Voltage should be 12 volts. If voltage is zero or very low, note the following possible causes: blown fuse, regulator "IG" terminal open, or regulator high speed points are burned.
Regulator Circuit Resistance - Disconnect regulator connector plug and check resistance between regulator "IG" and "F" terminals with an ohmmeter. If there is any resistance, the low speed contact in regulator is defective.
Load Test - Connect test meter as shown in illustration. Start engine, load system by turning all lights and accessories on. Run engine at 1100 RPM. Read amperage and voltage, it should be as specified. If battery is fully charged and reading is low, discharge battery by cranking engine (without spark) for about 15 seconds. Now if amperage is low, the rectifiers are open, shorted, or stator coil is open or shorted.

OVERHAUL

DISASSEMBLY

TESTING DIODES

1) Remove three retaining screws and insert screwdrivers into notches in drive end frame, pry with screwdrivers to separate drive end frame from stator. If necessary, tap lightly o drive end frame with a mallet.
2) Secure rotor core in padded vise, remove pulley attaching nut, and withdraw pulley, fan, and spacer. Remove rotor from drive end frame, utilizing a press. Remove bearing retainer from drive end frame, then remove bearing, felt cover and felt ring.
3) Remove four rectifier holder securing nuts and two brush holder securing screws; separate stator with rectifier holders and brush holders from rectifier end frame. Remove brush lead terminal and stator coil "N" terminal from brush holder, utilizing a small screwdriver. CAUTION - When removing brush holder assembly, do not remove it by cutting "N" terminal lead or melting the solder.
TESTING
Rotor - Check rotor for open field windings by connecting an ohmmeter across the slip rings. Coil resistance should be approximately as specified. Next check bearing and replace if necessary. Check slip rings for rough condition.

ALTERNATOR GENERATING CIRCUIT
(WITH VOLTAGE RELAY)

Stator - Use ohmmeter to check stator coil for ground. To check stator for open circuit, stator leads must be disconnected from diode leads. To disconnect leads from diodes, unsolder as quickly as possible and with a low-watt iron. Check four leads of stator coil for conduction, stator coil is open and must be replaced. Resistance should be zero.
Diode Test - With diode assembly on bench, make test connections as illustrated, using an ohmmeter. Contact diode plate with one probe and contact each of the three diode leads with other probe. Not ohmmeter reading, then reverse probes and repeat test. Check both positive and negative diodes in this manner. All diodes should show a low reading in one direction and no reading in opposite direction. If any one rectifier is defective, always replace positive or negative holder assembly.
PARTS REPLACEMENT

ALTERNATOR GENERATING CIRCUIT
(WITHOUT VOLTAGE RELAY)

Brushes - Check for cracks and wear. If brushes are worn beyond specifications, replace. Brushes should slide smoothly. Install new brush spring when replacing brush. Solder brush lead wire keeping protruded length to .51" (13 mm).
REASSEMBLY
Reassemble alternator by reversing disassembly procedure, noting the following points:
1) Press brushes, against spring tension, into brush holder. Insert a wire through access hole in rectifier and frame, and into hole in brush holder. This will prevent brushes from falling. Remove wire after assembly to end frame is completed.
2) Pack multipurpose grease into rear beraing and press bearing onto rotor shaft.
3) Install felt ring and felt cover so that convex surface of cover will face toward pulley side onto drive end frame. Next pack multipurpose grease into bearing and install bearing.

Motorcraft Alternators 1972-73

2014-06-01T03:56:00.001-07:00

Models Covered

Ford Courier (1972-73)
Pantera (1973)

ALTERNATOR OUTPUT TEST CONNECTIONS

SERVICE CAUTION: When testing or servicing alternator or regulator, take the following precautions to avoid damage to components.

Battery - Do not reverse battery connections. Negative terminal must be connected to ground. When charging battery, cables must be disconnected from battery before connecting charger. DO NOT use a charger as a booster for starting engine. If a booster battery is used to start engine, negative cable of booster battery must be connected to car battery negative terminal.

Alternator - DO NOT ground field circuit between alternator and regulator or operate alternator on an
open circuit with field winding energized. DO NOT ground output terminal or attempt to polarize alternator as polarization is not required.

Regulator - Turn ignition switch off when working on regulator. Use care to prevent a short circuit between voltage regulator, relay and regulator base when working on regulator. Use an insulated tool when making adjustments.

IDENTIFICATION AND SPECIFICATIONS

Alternator is ink stamped with "FoMoCo" or "Motorcraft" trademarks. Rated output is stamped on frame (35A & 61A).

Application Motorcraft No. Amps (RPM)

Ford Courier

Prior to 9/1/73 ........... GLE-105 ....................... 35 (2900)

From 9/1/73 ............. GLE-105-A .................... 35 (2900)

Pantera (1973) ............... GL-95 .......................... 35 (2900)

TESTING

NOTE - Following test (except diodes) are made with a Rotunda ARE 27-38 volt-amp. alternator tester. If equivalent tester is used, follow manufacturer's instructions.

OUTPUT TEST (ON CAR)

STATOR NEUTRAL VOLTAGE TEST CONENCTION

1) Check drive belt tension. Connect test equipment as shown in illustration, making sure field rheostat know is in off position. Close battery adapter switch, start engine then open adapter switch. Increase engine speed to approximately 2000 RPM. Turn off all lights and accessories. Turn field rheostat clockwise until voltmeter indicates 15 volts. Turn master control clockwise until voltmeter indicates 11-12 volts, hold master control in this position and turn field rheostat clockwise to maximum position, finally turn master control counterclockwise until voltmeter indicates 15 volts. Note ammeter reading, add 2 amperes to this reading to obtain alternator output.

2) If rated output cannot be obtained, increase engine speed to 2900 RPM and repeat test procedure as in Step 1) (above). If rated output obtained, return field rheostat knob to off, release master control know and stoop engine. If output not within specifications, alternator must be disassembled for necessary bench test. An output of 2-5 amperes below specifications, indicates an open diode. Output of 10 amperes below specifications indicates a shorted diode. If diode shorted, alternator will usually whine.

STATOR TEST (ON CAR)

To test for stator neutral voltage, disconnect regulator connector plug from regulator. Connect test equipment as shown in illustration. Start engine and run at 1000 RPM, turn off all lights and accessories. Rotate field rheostat clockwise until 6 volts indicated an voltmeter. If 6 volts or more cannot be obtained remove alternator and perform diode and stator test to determine defect.

STATOR TEST (ON BENCH)

1) To test for open stator, set ohmmeter multily-by knob at 1. Connect probes between each pair of stator leads. if ohmmeter does not shown equal readings between each pair of stator is open and must be replaced.

2) To test for grounded stator, set ohmmeter multiply-by know at 1000. Connect brobes between one othe stator leads and stator core. Ohmmeter should not show continuity (no reading). If reading shown, stator winding is grounded and must be replaced.

FIELD TEST

FIELD TEST

1) Connect on ohmmeter as shown. Set ohmmeter multiply knob at 1. Contact alternator field terminal with one probe and ground terminal with other probe, then spin pulley, ohmmeter reading should be between 4 and 250 ohms, and should flactuate while pulley is turning.

2) An infinite reading (no meter movement) indicates and open brush lead, worn or stuck brushes, or bad rotor assembly. An ohmmeter reading of less than 4 ohms indicates a grounded brush assembly, a grounded field terminal, or a bad rotor.

Alternator Field Current

Alternator Amps Field Current Volts

35................................. 2.4 ......................12

61................................. 2.9 ......................12

DIODE TEST

DIODE TEST CONNECTIONS (TYPICAL)

Disassemble alternator and disconnect diode assembly from stator. Connect test equipment as shown in illustration. NOTE - Make sure ohmmeter multiply-by knob set at 10. Place one test probe on diode place and contact each of the three stator lead terminals with other probe. Note ohmmeter reading, then reverse probes and repeat test. Check both positive and negative diodes in this matter. All 6 test (8 tests on 61 amp alternators) should show a low reading of 60 ohms in one direction and infinite reading (no needle movement) in opposite direction.

NOTE - Ford Motor Co. also recommends a voltmeter test procedure. The following article covers the volt ammeter test bank method of testing. See following pages for the voltmeter method of testing.

VOLTMETER TEST PROCEDURES

NOTE - When performing charging system test with a voltmeter, turn of all lights and electrical components. Be sure battery specific gravity is at least 1.200

1) Connect negative lead of voltmeter to negative battery clamp, and positive lead to positive battery cable clamp. Record battery voltage.

REGULATOR PLUG JUMPER WIRE CONNECTION

2) Hook up tachometer and start engine. Operate at 1500 RPM with no electrical load. The voltmeter reading should increase one volt and not exceed two volts above earlier reading. Reading should be taken when voltmeter needle stops moving.

3) With engine running, turn on heater or A/C blower motor to high speed and headlights to high beam. Increase RPM to 2000, voltmeter should indicate a minimum of .5 volt increase over original reading. If system conforms to these reading it is operating normally.

TEST RESULT

TESTING FIELD CIRCUIT WITH OHMMETER

1) If voltmeter reading indicates over voltage (more than two volts above battery voltage), stop engine adn check ground connections between regulator and alternator and/or regulator and engine. Clean and tighten connections securely and repeat tests.

2) If over voltage still exists, disconnect regulator wiring plug and repeat test. If over voltage condition disappears, replace voltage regulator and repeat test.

3) If over voltage still exist with regulator disconnected, a short is indicated in wiring harness between alternator and regulator.

4) If voltmeter reading does not increase at least one volt check for presence of battery voltage at alternator "BAT" terminal, and at regulator plug "A" terminal. If no voltage is present, an open wire is indicated.

5) Before performing other tests, the field circuit (regulator plug to alternator) must be checked for a
grounding condition. If the field circuit is grounded and the jumper wire is used as a check at regulator wiring plug from "A" to "F" terminals, excessive current will cause heat damage to regulator wiring plug terminals and may burn the jumper wire (see illustration). Also if the field circuit was grounded, then connector wire inside the regulator will be burned open and on under voltage condition will result.

TESTING REGULATOR FOR BURNED OPEN WIRE

6) The field circuit should be check with the regulator wiring plug disconnected and an ohmmeter connected from the "F" terminal of regulator wiring plug to battery ground. The ohmmeter should indicate between 4 and 250 ohms (see illustration)

7) A check for regulator burned open wire is made by connecting an ohmmeter from "I" to "F" terminals on regulator (see illustration). If reading indicates approximately 10 ohms, the connector inside the regulator is burned open. Field circuit round condition must be found and repaired before installing a new regulator.

8) If field circuit is satisfactory, disconnect regulator wiring plug at regulator and connect a jumper wire between "A" and "F" terminals on regulator wiring plug. Repeat voltmeter test procedures. If a problem of

JUMPER WIRE CONNECTION

under voltage still exists, remove jumper wire at regulator plug and leave plug disconnected from regulator; then, connect a jumper wire to the "FLD" and "BAT" terminals on the alternator (see illustration). Repeat voltmeter test procedure, If results are now satisfactory, repair the wiring harness from alternator to regulator.

9) If voltmeter test still indicate under voltage, repair or replace the alternator.

OVERHAUL

G.P.D. Rear Terminal - 1) Mark both end housings and stator with a scribe mark for assembly. Remove thru bolts. Separate front housing and rotor from stator and rear housing. Remove all nuts and insulator from rear housing and remove rear housing from stator.

2) Remove brush holder mounting screws, and remove holder brushes, springs, insulator, and terminal. If replacements is necessary, press bearing from rear housing, supporting housing on inner bore. If rectifier assembly requires replacement, unsolder stator leads from printed circuit board and separate stator from rectifier. Use a 100 watt soldering iron.

3) Original production alternator will have on of three types of rectifier circuit boards; one has a circuit board spaced away from diode plates with diodes exposed, a second type is a single circuit board with build in diodes, and the third type has built in diodes with an additional booster diode plate containing two diodes (used on 61 Amp. alternators only).

4) If alternator rectifier has an exposed diode circuit board, remove screws from rectifier by rotating bolt heads 1/4 turn clockwise to unlock and remove them. Push stator terminal screw straight out on a rectifier with diodes built into circuit board, avoid turning screw while removing to make certain that the straight knurl will engage insulators when installing. Do not remove grounded screw.

REMOVING ALTERNATOR PULLEY

5) On 61 Amp. alternator rectifier, press stator temrinal screw from circuit board with a vise, back up terminal board with a 1/2" drive 1/2" socket. Leave nut on end of temrinal to keep from damaging threads. When terminal has moved about 1/4" remove nut, and lift screw from board.

6) Remove pulley as shown in illustration. Then pull lockwasher, pulley, fan, fan spacer, front housing, and rotor from shaft.

7) Remove front bearing retainer. If bearing is damaged or has lost its lubricant, support housing close to bearing boss and press out old bearing. With alternator now fully disassembled perform a diode test.

REASSEMBLY

1) Rotor, stator bearings must not be cleaned with solvent, simply wipe with a clean cloth. Press front bearing in front housing, put pressure on outer race only, and install retainer. If stop ring on rotor drive was damaged, install a new one. Push new ring on shaft and into groove, do not open snap ring with pliers as it will stretch.

INSTALLING BRUSHES IN BRUSH
HOLDER

2) Position rotor stop on drive shaft with recessed side against stop ring. Position front housing, fan, spacer, pulley, and lock washer on drive shaft and install retaining nut. If rear housing bearing was removed, support housing on inner boss and press new bearing flush with outer end surface.

3) Place brush springs, brushes, brush terminal and terminal insulator in brush holder. Hold brushes in place by inserting a stiff piece of wire in brush holder (see illustration). Position brush holder assembly in reaer housing, and install mounting screws. Wrap the three stator winding leads around circuit board terminals and solder them in place, be sure to use rosin core solder.

4) Position stator neutral lead eyelet on stator terminal screw and install screw in rectifier assembly. For a rectifier with diodes exposed, insert the special screws thru wire lug, dished washers and circuit board. Turn 1/4 turn counterclockwise to lock. For single circuit boards with built in diodes, insert screws straight thru wire lug, insulating washer, and rectifier into square hole in rectifier into the insulator. Dished washers are used on exposed diode circuit boards only.

5) For a rectifier with a booster diode plate (61 Amp), position stator wire terminal on stator terminal screw and position screw into rectifier. Position squire insulator over screw and into squire hole in rectifier. Rotate terminal screw until it locks into position, hten press screw in finger tight. install stator wire. Now press terminal screw into rectifier and insulator, using a vise and 3/8" drive 3/8" socket.

STATOR LEAD CONNECTIONS

6) Position radio noise suppression capacitor on rectifier terminals. On circuit boards with exposed diodes, install "STA" and "BAT" (see illustration) terminal insulators. On single circuit boards, position the square stator terminal insulator in the square hole in rectifier assembly. Position "BAT" terminal insulator.

7) Position stator and rectifier assembly in rear housing, make certain all terminal insulators are seated properly in the recesses. Position the "STA" (black), "BAT" (red), and "FLD" (orange) insulators on terminal bolts and install retaining nuts.

8) Position rear housing and stator assembly over rotor and align scribe marks made prior to assembly. Seated machined portion of stator core into step in both end housings. Install thru bolts. Remove brush retracting wire, and put a doub of water proof cement over hole to seal it.