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Removal and Installation


WARNING: HYDROGEN AND OXYGEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION. THIS GAS MIXTURE CAN EXPLODE IF FLAMES, SPARKS OR LIGHTED TOBACCO ARE BROUGHT NEAR THE BATTERY. WHEN CHARGING OR USING A BATTERY IN AN ENCLOSED SPACE, ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES.

WARNING: KEEP OUT OF REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID, AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN, EYES OR CLOTHING, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF FIFTEEN MINUTES. IF ACID IS SWALLOWED, DRINK LARGE QUANTITIES OF MILK OR WATER, FOLLOWED BY MILK OF MAGNESIA, A BEATEN EGG, OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.

31-44-5 Alternator-165 Ampere--Leece Neville 31-44-5

REMOVAL AND INSTALLATION (Continued)

Alternator

Removal
1. Disconnect battery ground cable.

2. Disconnect the wire harness attachments to the alternator/regulator assembly.
3. Loosen the alternator pivot bolt. Remove the adjustment bolt from the alternator.
4. Disengage the alternator drive belt from the alternator pulley.
5. Remove the alternator pivot bolt and alternator/ regulator assembly.
6. Remove the alternator fan shield, if so equipped. Installation
1. Position the alternator/regulator assembly on the engine.
2. Install the alternator pivot and adjuster arm bolts, but do not tighten the bolts until the belt is tensioned.
3. Install the drive belt over the alternator pulley.
4. Adjust the belt tension and tighten the adjuster and pivot bolts to specification. Check belt tension using Belt Tension Gauge T63L-8620-A or Rotunda Belt Tension Gauge 021-00019 or equivalent. Apply pressure to alternator from housing only when adjusting belt tension. Refer to Section 27-06, Accessory Drive Belts.
5. Connect the wiring harness to the alternator/ regulator assembly.
6. Attach the alternator fan shield to the alternator, if so equipped.




Regulator Removal
1. Remove the diode trio lead from the regulator terminal.
2. Remove the two 6-32 nuts holding the regulator and the positive and negative jumpers.
3. Slowly pull the regulator from the holder and remove the regulator.
4. The brushes can now be checked. Replace the brushes or regulator if necessary. Brushes less than must be replaced.




Installation
1. Before reinstalling the regulator, insert the outer brush into the housing and compress the brush spring using a small screwdriver or similar tool. While holding the spring compressed, insert a pin through the top hole in the rear of the housing so that the spring will be held in a compressed position. (A suitable pin can be made using drill rod material or a 1/32 inch diameter drill). Install and compress the remaining brush in a similar manner. Hold the springs in a compressed position by pushing the pin farther into the brush housing.




2. Slowly push the regulator into the brush housing making sure that the respective screws go through the positive and negative jumpers. Install the lockwashers and 6-32 nuts and hand tighten. Remove brush pin, then tighten the nuts.
CAUTION: DO NOT TIGHTEN NUTS WITH BRUSH PIN IN PLACE AS DAMAGE TO THE REGULATOR WILL RESULT.
3. Reinstall the diode trio, and install the lead to the regulator terminal.

31-44-6 Alternator-165 Ampere Leece Neville 31-44-6
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