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26SI Series Alternator – Alternator – Disassemble

Disassembly Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-7070     Digital Multimeter     1    
B         Variable Power Supply     1    

Start By:

  1. Remove the alternator. Refer to Disassembly and Assembly, “Alternator – Remove” for the machine that is being serviced.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

  1. Remove the pulley nut, the washer, the pulley, and the fan.

    Illustration 1 g00627790

  1. Remove 4 screws (1). Remove plate (2) .

    Illustration 2 g00627792

  1. Remove 7 screws (3). Remove cover (4) .

    Illustration 3 g00627794

  1. Remove gasket (5) .

    Illustration 4 g00627796

  1. Remove 2 insulated screws (6). Remove the 3 leads.

    Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is removed, reapply the grease.

  1. Remove nut (7) .

    Illustration 5 g00627804

  1. Remove grounded mounting screw (8) .
  1. Remove regulator (9) .

    Illustration 6 g00627808

  1. Remove mounting plate (10). The mounting plate may be stuck to the regulator.

    Illustration 7 g00627810

    Note: The 3 output diodes (11) are located in heat sink (12). These diodes are identical in polarity. Diode (11) has red insulation on the wire. The 3 ground diodes (13) are located in housing (14). These diodes are identical in polarity. Diode (13) has black insulation on the wire.

  1. Remove 3 nuts (15). Disconnect 3 stator phase leads. Disconnect 3 phase leads. Disconnect 6 diode leads.

    Table 2
    Alternator Ground     Current Flow of the Output Diodes     Current Flow of the Ground Diodes    
    Negative     Lead to the Heat Sink     Housing to the Lead    
    Red Wire Black Wire    


    Illustration 8 g00627820

  1. Remove the screw and insulator (16). Disconnect capacitor lead (17) .

    Illustration 9 g00627832

  1. Remove the 3 screws and insulators (18). Disconnect wire (19) .
  1. If the “R” terminal is used, remove the following components: nut (20), lead (21), the washer and terminal (21) .

    Illustration 10 g00627840

  1. Remove screw (23) and remove diode trio (24) .
  1. Remove the nut and washer (25). Remove insulator (26). Remove alternator output terminal (27) .
  1. Remove separator (28) .