Page 204 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Electrical Power
AMM
Detail Steps/Work Items Key Items/References
(8) Remove the alternator: S Remove the 2 nuts from the attachment bolts. S Remove the 2 washers. S Remove the 2 bolts, washers and spacers which attach the alternator to the mounting bracket. S Move the alternator clear of the engine. Hold the alternator.
B. Install the Alternator
Detail Steps/Work Items Key Items/References
(1) Put the alternator in position in the alternator mounting. Hold the alternator in position.
(2) Install the alternator mounting bolts: S Install the washer on the front mounting bolt. S Put the bolt through the link plate, alternator mounting bracket and the alternator. S Install the washer on the rear mounting bolt. S Put the bolt through the alternator, spacers and mounting bracket. S Install the washers on the bolts. S Install the 2 nuts on the attachment bolts but do not tighten the nuts. From the front. From the rear.
(3) Install the washer on the adjusting bolt and install the adjusting bolt through the adjusting bracket and into the alternator. Do not tighten the adjusting bolt.
CAUTION: DO NOT MAKE THE FLEXIBLE BELT TOO TIGHT. TOO MUCH TENSION IN THE BELT CAN DAMAGE THE BEARINGS IN THE ALTERNATOR AND CAUSE ALTERNATOR FAILURE.
Doc # 6.02.01 Page 205
Rev. 4 09 Jan 2003
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AMM
DA 40 Series
Detail Steps/Work Items Key Items/References
(4) Install the flexible belt: S Move the alternator up and towards the engine. S Put the flexible drive belt into position over the alternator pulley and the drive pulley. S Move the alternator down and away from the engine until the flexible belt tension is correct. S Then tighten the adjusting bolt and the adjusting bracket attachment bolt. S Lock the bolt heads to the adjusting bracket with lock-wire. Make sure that the flexible belt is correctly seated in the Vee groove. Belt movement = 5 mm (0.2 in.) with 3 kp (6.5 lbf.) load applied.
(5) Tighten the 2 alternator mounting bolts and install the cotter pins.
(6) Connect the electrical cables to the alternator. Refer to Chapter 92 for the wiring diagrams.
(7) Connect the battery. Make sure that you connect the positive lead first. Refer to Section 24-31.
(8) Install the engine cowlings. Refer to Section 71-10.
(9) Do a function test of the alternator. Refer to Paragraph 6.
5. Remove/Install the Voltage Regulator
A. Remove the Voltage Regulator
Detail Steps/Work Items Key Items/References
(1) Set the ALT/BAT switch to OFF.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the battery. Make sure that you disconnect the negative terminal first. Refer to Section 24-31.
Page 206 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Electrical Power
AMM
Detail Steps/Work Items Key Items/References
(4) Disconnect the electrical connections to the regulator. At the in-line connector.
(5) Remove the 4 nuts and washers which attach the voltage regulator to the mounting bracket. Hold the regulator!
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