BA Service Manual
Contents
1. Type B Type C Alternator a Loosen the R terminal nut b Remove the screw to remove the R terminal c Remove R terminal 9 Removing the rectifier a Loosen the B terminal nut b Remove the screw from the rectifier s negative terminal c Remove the 4 screws to remove the rectifier Type B Type C Fig 4 18 Removing the R terminal 3 Fig 4 19 Removing the R terminal 4 Fig 4 20 Removing the rectifier 1 Fig 4 21 Removing the rectifier 2 d Remove rectifier Fig 4 22 Removing the rectifier 3 10 Removing the terminal Type B Only a Loosen the I terminal nut to remove the I terminal Rear Frame Fig 4 23 Removing the I terminal 1 b Remove I terminal Rear Frame Fig 4 24 Removing the I terminal 2 11 Removing the exciting coil a Remove 3 screws to remove the exciting coil from the rear frame Fig 4 25 Removing the exciting coil 1 b Remove exciting coil 12 Removing the rear bearing Using JIG E and a hydraulic or manual press remove the rear bearing from the rear frame NOTE Do not reuse the rear bearing Fig 4 26 Exciting Coil Removing the exciting coil 2 JIG E for press 7 y PRESS Fig 4 27 ct ho Removing the rear bearing JIG E for Support Fig 4 28 Fig 4 29 Fig 4 30 Fig 4 31 Stator Inspecting the stator 1 Inspecting the stator 2 Inspecting the exciting coil2. 1 Inspecting the exciting coil 2 4 4 INSPECTION 1 Inspecting the stator a Using an ohmmeter measure the resistance between the coil outlet terminals U N V N W N Standard value 0 01 0 10 Q b Using an ohmmeter measure the resistance be tween the coil outlet terminal and core Standard value 1M Q minimum 2 Inspecting the exciting coil a Using an ohmmeter measure the resistance be tween the coil outlet terminal Standard value 2 3 Q 12V system 7 9 Q 24V system b Using an ohmmeter measure the resistance be tween the coil outlet terminal and core Standard value 1M Q minimum 3 Inspecting the rotor a Using a micrometer measure the outer diameter of the portion that presses into the front bearing Standard value 25 00 25 01mm Limit 24 99mm b Using a micrometer measure the outer diameter of the portion that presses into the rear bearing Standard value 16 99 17 00mm Limit 16 98mm c Using a micrometer measure the outer diameter of the portion that joins with the pulley Standard value 22 19 22 20mm Limit 22 18mm 4 Inspecting the rectifier a Using an ohmmeter check for continuity between the B terminal and the heat sink Standard When polarity is changed there is continuity in one direction only Fig 4 32 Inspecting the rotor 1 Fig 4 33 Inspecting the rotor 2 Fig 4 34 Inspecting the rotor 3 Fig 4 35 Inspecting the recti
3. ELECTRICAL EQUIPMENT Brushless Alternator Service Manual FOREWORD This manual which describes the construction operation and maintenance procedure for the brushless alterna tors listed below has been prepared to assist in servicing these products in a correct efficient and safe manner Part Number Nominal Output 101211 8100 12V 90A 101211 8110 12V 105A vev 1998 DENSO CORPORATION All Rights Reserved This book may not be reproduced or copied in whole or in part without the written permission of the publisher TABLE OF CONTENTS OVERVIEW oee a a 1 CONSTRUCTION rsa R EOR 2 OPERATION rsp E EEE l 3 1 Self Exciting and CM AIQING ee resten 4 3 2 Regulating the Output Voltage rrrrrnnnrrnnnnnrnrnnnnnnrnnnrenrnnnnnnnnnnennnnnnenn 4 SERVICE AND REPAIR sv 5 4 1 Special NS NE srcagesste cap esccencnoasascecsesveueece pauses EEE ETEEN EIEN an iE 5 4 2 Disassembled VIEW rrrrrrnnnrnnnnrennnnnnvnnnrnnnnnnnnnnrnnnnnennnnnnnnnnsnnnnnrnnnnnennnnee 5 DANN med 6 4 A MEET 13 4 5 Assembly of Main Components rrrrrnnnrrnnnnnrnrnnnrnnnnnnrenrnnnrnnnnnnennnnnnee 16 PERFORMANCE TEST urne sdden 19 PRECAUTIONS Gen 20 TROUBLESHOOTING unnnnnnnnnnnnnnnnnunnnunnnvnnnnnnunnnunnnvnnvunnunnnunnnvnnnn 21 1 OVERVIEW This alternator has been developed specifically for construction equipment and or trucks which demand a high level of durability In order to decrease maintenance the brushes and slip ri
4. ed meas ure the voltage Fig 5 4 Verifying the regulator s regulated voltage Standard 9 pg 9 9 9 12V system 14 0 14 4V or 13 7 14 3V 24V system 27 0 29 0V 6 PRECAUTIONS 1 Precautions during operation Do not disconnect the battery while the alternator is rotating Do not operate the alternator with the alternator s B terminal output terminal disconnected Do not expose the alternator to water 2 Other precautions Make sure to disconnect the battery terminal before inspecting the alternator Do not interchange the polarity of the battery cables when replacing the battery Make sure to disconnect the cables and charge the battery separately when using a charger Never use a Mega Ohm tester on the alternator Make sure to disconnect the wiring to the alternator when performing a megaohm test on the vehicle s wiring 7 TROUBLESHOOTING Location of Malfunction Possible Cause Action Symptom Alternator No charging Faulty regulator Replace regulator Faulty stator coil Replace stator open or short circuit Faulty exciting coil Replace exciting coil open or short circuit Faulty rectifier Replace rectifier diode open or short circuit Poor contact at connections Repair or replace Wiring Open circuit in wiring Repair or replace Blown fuse or fusible link Constantly Alternator Faulty stator coil Replace stator 1 phase open or short circuit undercharging battery becomes dis Faulty rectif
5. fier 1 b Using an ohmmeter check for continuity between the negative terminal and the heat sink Standard When polarity is changed there is continuity in one direction only Fig 4 36 Inspecting the rectifier 2 c Using an ohmmeter check for continuity between the auxiliary diode terminal and the heat sink Standard When polarity is changed there is continuity in one direction only Fig 4 37 Inspecting the rectifier 3 5 Inspecting the front bearing Verify that the bearing does not create any unusual Front noise or does not bind or have excessive play when Bearing rotated Replace the bearing if any of the above exist Fig 4 38 Inspecting the front bearing 4 5 ASSEMBLY OF MAIN COMPONENTS 1 Assembling the front bearing a Using JIG D and a hydraulic or manual press press the front bearing into the drive frame b Using 3 screws install the bearing cover Tightening torque 2 9 4 9N m 30 50kgf cm 2 Assembling the rotor a Insert the collar onto the rotor shaft b Using JIG B and a hydraulic or manual press press the rotor into the bearing in the drive frame NOTE 1 Press the rotor while making sure that the rotor s shaft is perpendicular to the bearing 2 During pressing make sure not to damage the portion of the rotor that presses into the rear bearing 3 Tightening the pulley a Insert the collar and fan onto the rotor shaft b Secure the pulley with belt using a vi
6. he pulley 1 b Remove the pulley from the shaft Fig 4 8 Removing the pulley 2 c Remove the fan and collar Fig 4 9 Removing the fan and collar 4 Removing the rotor Using JIG A and a hydraulic or manual press remove the rotor from the drive frame NOTE Do not drop the rotor 5 Removing the front bearing a Remove 3 screws to remove the bearing cover b Using JIG C and a hydraulic or manual press remove the front bearing from the drive frame NOTE Do not drop the front bearing 6 Separating the rear frame and stator Remove the rear frame from the stator Fig 4 10 Fig 4 11 for press Fig 4 12 Removing the rotor Bearing Removing the front bearing 1 Front Beari for Su Removing the front bearing 2 Rear Frame Fig 4 13 Separating the rear frame and stator Ng pport Stator Screw pa Fig 4 14 Removing the regulator 1 Fig 4 15 Removing the regulator 2 Grommet R Terminal Fig 4 16 Removing the R terminal 1 R Terminal Fig 4 17 Removing the R terminal 2 WF O 7 Removing the regulator a Remove 3 screws to separate the rectifier the exciting coil outlet terminal and the regulator b Remove 2 screws to remove the regulator c Remove regulator 8 Removing the R terminal Type A Alternator a Remove the grommet b Remove the screw to remove the R terminal c Remove R terminal
7. ier Replace rectifier charged diode open or short circuit Poor contact at connections Repair or replace Excessive current demand Increase alt output pene A large electric load is used Reduce the electric load Insufficient tension Tighten or replace Alternator Faulty regulator Replace regulator Poor contact at voltage detection Repair or replace Constantly overcharging battery electrolyte is portion depleted in a short time Battery Faulty battery Replace battery Alternator Faulty stator coil Replace stator short Abnormal noise Faulty bearing s Improper belt tension NOTES DENSO SALES CALIFORNIA INC Technical Services Department Long Beach California DSCA P N LA990009 0332 Second Issue May 1998 Kariya Aichi Printed in U S A C DNJP Publication No N5ZGS 01 DSCA Publication No LA990009 0332 Printed in USA
8. ion make sure to use a fully charged battery 1 Magnetizing Momentarily connect an appropriate battery 12V or 24V to the L terminal plus and F terminal minus of the regulator as shown in the figure L Terminal 12V type alternator 12V battery 24V type alternator 24V battery Fig 5 1 Magnetizin a oe 2 Measuring the self excited starting rom a Turn Switch 1 ON b Gradually increase the alternator rom c Measure the rpm starting rom at which the charg ing current starts to flow It is normal if under 1500 rom however with the 12V 130A alternator only under 2000 rpm Fig 5 2 Measuring the self excited starting rom 3 Measuring the rated output a Turn Switch 1 and Switch 2 ON b Maintain the alternator rom at a constant 5000 rpm c While observing a voltmeter regulate the load vari able resistance R so that a 12V system outputs 13 5V and a 24V system outputs 27 0V d At this time measure the output current it is nor mal if more than the rated output current is ob tained Switch 2 Fig 5 3 Measuring the rated output 4 Verifying the regulator s regulated voltage a In the state in which the rated output was meas ured turn Switch 2 OFF NOTE At this time reduce the current that flows to the Switch 2 PD load variable resistance R to the minimum and turn Switch 2 OFF b When the output current is less than 10A the charging current to the battery is reduc
9. nal Tightening torque 1 6 2 0N m 16 20kgf cm b Tighten the R terminal nut Tightening torque 1 6 2 0N m 16 20kgf cm 9 Assembling the regulator a Using 2 screws install the regulator Tightening torque 2 9 4 9N m 30 50kgf cm b Using 3 screws install the rectifier and the excit ing coil outlet terminal to the regulator Tightening torque 1 6 2 0N m 16 20kgf cm 10 Assembling the stator and the rear frame Slowly insert the stator while maintaining it perpen dicular to the rear frame 11 Assembling the drive and rear frame a Apply a thin coat of NSK EA5 grease on the rear bearing portion of the rotor shaft b Slowly insert the rear frame while maintaining it perpendicular to the rotor shaft NOTE To prevent damage to the rear bearing do not apply excessive force during the insertion c Install 4 through bolts Tightening torque 6 5 9 3N m 66 95kgf cm d Using 4 screws install the stator outlet terminal to the rectifier Tightening torque 1 9 2 5N m 19 25kgf cm e Using 3 screws install the rear cover Rear Frame Fig 4 43 Assembling the stator and the rear frame Fig 4 44 Assembling the front and rear portions 1 Fig 4 45 Assembling the front and rear portions 2 Fig 4 46 Assembling the front and rear portions 3 5 PERFORMANCE TEST Using a bench tester perform a performance test according to the procedure described below NOTE During this inspect
10. ngs which wear in time have been eliminated from the brushless alternator To generate electricity this alternator adopts a system in which the alternator s internal residual magnetism is used for initial activation Once the alternator starts operating the electrical power that the alternator itself gener ates is supplied to the exciting coil which is used for self excitation This alternator is equipped with an internal regulator voltage regulator The voltage regulator monitors the voltage that is generated during operation of the alternator and regulates the current that is supplied to the exciting coil thus maintaining the constant output voltage Doesn t come with a pulley Fig 1 1 External View 2 CONSTRUCTION The interior of the alternator is self cooled by a rotating fan The alternator consists of the following parts a stator rotor exciting coil regulator rectifier frames etc Front Bearing Rectifier Ye ill Pulley Lock Nut Rotor Rear Frame Fig 2 1 Internal View 1 Stator The stator consists of an insulating sheet which is inserted into the slotted portion of a laminated steel core The core contains a coil providing a three phase stator Y type winding connection The stator coil receives magnetism from the exciting coil the rotor which generates an alternating current a three phase alternating current 2 Exciting Coil The exciting coil consists of a coil that is wound over a don
11. or has I terminal Fig 3 1 Circuit Diagram 3 1 SELF EXCITING AND CHARGING 1 When the engine is started the alternator s rotor rotates and the residual magnetic field generates voltage in the stator coil 2 AS generated voltage increases with the increase in the engine rom the electric current flows from the auxiliary diode to the exciting coil Thus a strong magnetic field is created by the exciting coil causing the voltage that is generated in the stator coil to increase suddenly to the battery voltage NOTE The excitation by residual magnetism changes over to that of self generated excitation This is called self excited starting and the alternator rom at this time is called turn on speed 3 Simultaneously with self excited starting the charging current flows from the alternator s B terminal to the battery and starts the charging of the battery 3 2 REGULATING THE OUTPUT VOLTAGE 1 As the charging of the battery advances and the battery terminal voltage reaches the regulator s regulating voltage the regulator shuts off the current that flows to the exciting coil 2 When the current that flows to the exciting coil is shut off the magnetic field that is generated in the exciting coil weakens causing the voltage that is generated in the stator coil to decrease which reduces the alternator s output voltage 3 When the voltage that is generated in the stator coil becomes lower than the regulator s regulated
12. se as shown in the figure tighten the pulley lock nut with speci fied torque Tightening torque 117 6 137 2N m 1200 1400kgf cm 4 Assembling the rear bearing Using JIG E and a hydraulic or manual press press a new rear bearing into the rear frame NOTE Once a bearing is removed do not reuse it Front Bearing Drive R Frame E Fig 4 39 Assembling the front bearing Lie Drive Frame JIG B for press for support Fig 4 40 Assembling the rotor Fig 4 41 Tightening the pulley JIG E for press Rear Bearing Rear Frame JIGE for press Fig 4 42 Assembling the rear bearing 5 Assembling the exciting coil Using 3 screws install the exciting coil on the rear frame Tightening torque 2 9 4 9N m 30 50kgf cm 6 Assembling the I terminal Type B only Install the I terminal on the rear frame and tighten the nut Tightening torque 1 6 2 0N m 16 20kgf cm 7 Assembling the rectifier a Using 4 screws install the rectifier Tightening torque 2 9 4 9N m 30 50kgf cm b Using a screw install the rectifier s terminal Tightening torque 2 9 4 9N m 30 50kgf cm c Tighten the B terminal nut Tightening torque 7 8 10 8N m 80 110kgf cm 8 Assembling the R terminal Type A Alternator a Using a screw install the R terminal Tightening torque 1 6 2 0N m 16 20kgf cm b Install the grommet Type B Type C Alternator a Using a screw install the R termi
13. ut shaped insulated core An electric current flows through the coil to produce a magnetic field 3 Rotor The rotor houses a non magnetic ring made of stainless steel in between two claw shaped cores which face each other The claw shaped cores are welded together and then press fitted over a shaft The rotor rotates in the space between the exciting coil and the stator in order to transfer the magnetic field that is generated in the exciting coil to the stator in the form of magnetic flux 4 Frame The frame is a component of the alternator that encloses the stator and rotor The frame consists of a drive frame and a rear frame The drive frame contains a ball bearing while the rear frame contains a roller bearing Both bearings support the rotor for proper rotation In addition the frame houses the rectifier assy regulator etc 5 Regulator The function of the regulator is to regulate the voltage that is generated by the alternator and to keep the voltage constant The regulator is constructed of an aluminum fin case plastic terminal board transistors and diodes The case is sealed to prevent the semi conductor elements from coming into contact with air E Voltage Regulator Top B Terminal Lamp Terminal E Voltage Regulator Bottom Ground Terminal Fig 2 2 Regulator 3 OPERATION side Diode Auxiliary Regulator Ignition Switch E Battery R Exciting Coil Only B type regulat
14. voltage the regulator allows the current to flow to the exciting coil As a result the magnetic field that is generated in the exciting coil strengthens causing the voltage in the stator coil to increase 4 The operations described in steps 1 to 3 above are repeated continuously at high speeds thus controlling regu lating the alternator s output voltage to a constant level 4 SERVICE AND REPAIR 4 1 SPECIAL TOOLS J IG REFERENCE DIMENSION OF EACH JIG JIG A JIG B JIG C for support for press for press for support Mi 952 aie 088 pma JE 7 087 064 5 1 20 140mm E 30mm 7 i 120mm JIG E for press for support arm ll Fig 4 1 Disassembled View 4 3 DISASSEMBLY 1 Removing the rear cover Remove 3 screws from the rear cover 2 Separating the front and rear portions a Remove 4 screws and separate the stator outlet terminal and the rectifier assembly b Remove 4 through bolts c While keeping the stator and the rear frame to gether lift away from the drive frame Fig 4 2 Removing the rear cover Fig 4 3 Separating the front and rear portions 1 Through Bolt Fig 4 4 Separating the front and rear portions 2 Stator Rear Frame Drive Frame Fig 4 5 Separating the front and rear portions 3 d Drive and rear frames separated 3 Removing the pulley fan and collar a Remove the pulley lock nut using an impact wrench Fig 4 7 Removing t
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