INDEX

Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-1

21–126E–05

Models J05C-TD, J08C-TP and J08C-TR

TROUBLESHOOTING ................................................................ 21- 2

ALTERNATOR ............................................................................ 21- 3

21
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21-2 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

TROUBLESHOOTING

Symptom Possible cause Remedy/Prevention

Charge warning lamp does Fuse blown ............................................... Determine cause and replace fuse
not light with starter
switch ON and engine off Lamp burned out ...................................... Replace lamp

Wiring connection loose ........................... Tighten loose connections

Charge lamp relay faulty .......................... Check relay

IC regulator faulty ..................................... Replace IC regulator

Charge warning lamp does Drive belt loose or worn ........................... Adjust or replace drive belt
not go out with engine
running Battery cables loose, corroded ................ Repair or replace cables
(Battery requires frequent or worn
recharging)
Fuse blown ............................................... Determine cause and replace fuse

Fusible link blown ..................................... Replace fusible link

Charge lamp relay, IC regulator ............... Check charging system

or alternator faulty

Wiring faulty ............................................. Repair wiring

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Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-3

ALTERNATOR

1 3
2

11

5 12
6
7 13
8 10
9

14

15

16
17
18

19

20
21
SM21-365
22

1. Cover 9. Condenser 17. Bearing

2. Terminal B sub assembly 10. Insulator (outer) 18. Bearing cover
3. Insulator (inner) 11. Rear end frame 19. Drive end frame
4. Rectifier (positive side) 12. Field coil 20. Collar
5. Insulator 13. Stator 21. Fan
6. Rectifier (negative side) 14. Field coil set screw 22. Pulley
7. Regulator 15. Rotor
8. Through bolt 16. Retainer plate

Fig. 21-1
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21-4 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

DISASSEMBLY
1. SEPARATING DRIVE END FRAME AND REAR END
FRAME
1) Remove rear cover.

REAR END FRAME

Fig. 21-2 SM21-314

2) Remove the 3 through-bolts.

Fig. 21-3 SM21-315

3) Remove rear end frame by lifting it together with
stator.

DRIVE END FRAME

Fig. 21-4 SM21-316

4) Separate drive end frame and rear end frame.

REAR END FRAME DRIVE END FRAME

Fig. 21-5 SM21-317

2. DISASSEMBLY OF DRIVE END FRAME
1) Removing pulley:
a. Remove pulley fastening nut.
NOTE: On removing the nut, wind V-belt around pul-
ley groove and grip it securely in a vice so
that the pulley is held with V-belt as a cush-
ion.

Fig. 21-6 SM21-318

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Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-5

b. Pull out pulley and remove fan.

Fig. 21-7 SM21-319

c. Remove collar.

Fig. 21-8 SM21-320

2) Remove rotor from drive end frame, using a press.
NOTE: Hold rotor by hand so that it will not fall off.

Fig. 21-9 SM21-321

3) Removing front bearing:
a. Remove retainer plate.

Fig. 21-10 SM21-322

b. Attach the jig to inner race of the front bearing
and remove front bearing, using a press.

Fig. 21-11 SM21-323

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21-6 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

3. DISASSEMBLY OF REAR END FRAME

"P'" LEAD
1) Removing regulator:
a. Unsolder lead wire P’ from stator and remove it
by pulling gently.
b. Unsolder and disconnect wirings (R. L and P)
P' R P from coupler.
L

Fig. 21-12 SM21-324

c. Remove the 2 set screws.
d. Remove regulator.

Fig. 21-13 SM21-325

2) Removing rectifier (positive side):
a. Unsolder wiring connections at stator and diode,
and take off excess solder.
b. Spread claws apart at the connections and dis-
connect stator lead wires.

Fig. 21-14 SM21-326

c. Remove the 4 set screws.
d. Take out rectifier (positive side).

Fig. 21-15 SM21-327

e. Remove the other rectifier (positive side).

Fig. 21-16 SM21-328

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Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-7

3) Removing terminal B:
a. Loosen and remove terminal B fastening nut.
b. Remove insulator (outer).
c
d c. Remove terminal B sub assembly.
d. Remove insulator (inner).

a b

Fig. 21-17 SM21-329

4) Removing rectifier (negative side):
a. Remove insulator.
b. Take out rectifier (negative side).

Fig. 21-18 SM21-330

5) Separate rear end frame and stator.

Fig. 21-19 SM21-331

6) Removing field coil:
a. Loosen the 3 set screws for field coil.

Fig. 21-20 SM21-332

b. Remove field coil.

Fig. 21-21 SM21-333

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21-8 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

U INSPECTION
1. INSPECTION OF STATOR
1) Resistance value of coil.
V W
Measure the resistance between coil terminals
(W) (P) P
(U-V, V-W, W-U), using a circuit tester.
(U) The measured values should be within the range of
(V)
0.068 to 0.82

Fig. 21-22 SM21-334

2) Insulating resistance value of coil.
Measure the insulation resistance between coil ter-
minal and core, using a megohmmeter.
The measured value should be 1 M or more.
(P)
(U)
(W) (V)

Fig. 21-23 SM21-335

2. INSPECTION OF FIELD COIL
1) Resistance value of coil.
Measure the resistance between coil terminals, us-
ing a circuit tester.
The measured value should be within the range of
2.1 to 2.5 .

Fig. 21-24 SM21-336

2) Insulating resistance value of coil.
Measure the insulation resistance between coil ter-
minal and core, using a megohmmeter.
The measured value should be 1 M or more.

Fig. 21-25 SM21-337

3. INSPECTION OF ROTOR
1) Outer diameter of shaft (front)
Measure the shaft diameter at the part contacting the
front bearing, using a micrometer.
Standard Diameter: 25.0 mm(0.9843 in.)
Service Limit: 24.98 mm(0.9835 in.) or less

Fig. 21-26 SM21-338

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Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-9

2) Outer diameter of shaft (rear)

Measure the shaft diameter at the part contacting the
roller bearing, using a micrometer.
Standard Diameter: 17.0 mm(0.6693 in.)
Service Limit: 16.98 mm(0.6685 in.) or less

Fig. 21-27 SM21-339

4. INSPECTION OF DIODE
1) Terminal-to-terminal resistance:
LEAD BAR
Measure the resistance between diode terminal and
rectifier, using a circuit tester.
Normal resistance (negative side)
Forward direction: 10
Reverse direction: infinity
NOTE: The forward direction is the arrangement
of measurement condition as shown in fig.
Fig. 21-28 SM21-340 21-28. The reverse direction is the arrange-
ment where contacting of tester probes is
reversed.
The positive side rectifier has directional
characteristic opposite to the negative
side.
2) On using a diode checker, apply electric current in
the reverse direction and measure the leakage cur-
rent.
Reverse directional characteristics:
Fig. 21-29 SM21-341 It should be -1 mA or less when 200 V is applied.
5. INSPECTION OF CONDENSER
1) Terminal-to-terminal resistance value:
Measure the resistance between terminal and body,
using a circuit tester. Tester should first show about
800 k and then infinity immediately after.

Fig. 21-30 SM21-342

6. INSPECTION OF BEARING
NOTE: Skip inspection of a bearing which has un-
der gone 2 years of use and proceed straight
to replacing with a new one.
1) Rotating condition:
See that the bearing makes no abnormal noise when
rotated by hand and that the rotation is smooth.

Fig. 21-31 SM21-343

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21-10 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

7. INSPECTION OF REGULATOR
1) Terminal-to-terminal resistance
P' F R
Measure the resistance between terminals F-E, us-
B ing circuit tester. The measured value should be as
shown in the following table.
The regulator is faulty if the reading is 0 .

E
Resistance value
+Lead –Lead +Lead
Fig. 21-32 SM21-344
Terminal F Terminal E Approx. 10
Terminal E Terminal F Infinity

2) When using a regulator checker, measure the regu-

lated voltage.
Regulated voltage: 14.3 ± 0.3 V (14.0–14.6)

Fig. 21-33 SM21-345

ASSEMBLY
For assembly, follow the disassembly sequence backward,
observing in particular the following steps in doing the
work.
1. DRIVE END FRAME
1) Installation of front bearing:
a. Insert bearing cover in drive end frame.
b. Attach the jig to the outer race of front bearing
and press-fit the bearing, using a press.
Fig. 21-34 SM21-346
c. Install retainer plate.
Tightening torque: 19 – 25 kg·cm (1.4 – 1.8 lb·ft)

Fig. 21-35 SM21-347

2) Installation of rotor
Press-fit rotor in drive end frame, using a press.
SHAFT
NOTE: See that the press-fitting direction is square.
Take care not to damage the shaft (surface at
the rear: as indicated by arrow).

Fig. 21-36 SM21-348

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Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-11

3) Tightening pulley.
Wind V-belt around pulley and grip it securely in a
vice so that it is held with V-belt as a cushion.
Tightening torque: 1,300 – 1,600 kg·cm (95 – 115 lb·ft)

Fig. 21-37 SM21-349

2. REAR END SIDE
1) Installation of rear bearing
JIG
Attach the jig to rear bearing and press-fit rear bear-
ing, using a press.
NOTE: See that the press-fitting direction is square.
REAR BEARING
The bearing must be replaced with a new one
after being removed once.
JIG

Fig. 21-38 SM21-350

2) Installation of field coil:
a. Install field coil on rear end frame, aligning them
at the pilot.

Fig. 21-39 SM21-351

b. Tighten the 3 set screws.
Tightening torque: 19 – 25 kg·cm (1.4 – 1.8 lb·ft)

Fig. 21-40 SM21-352

3) Tightening of terminal B.
Tightening torque:
Lower nut: 33 – 45 kg·cm (2.4 – 3.2 lb·ft)
LOWER
Upper nut: 60 – 80 kg·cm (4.4 – 5.7 lb·ft)
NUT

UPPER NUT

Fig. 21-41 SM21-353

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21-12 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

4) Installation of rectifiers
NOTE: Reconfirm the assembled position of rectifi-
ers. (Negative side down and positive side
up).
Tightening torque: 30 – 50 kg·cm (2.2 – 3.6 lb·ft)

Fig. 21-42 SM21-354

5) Installation of regulator
Fit regulator in place and tighten the 2 set screws.
Tightening torque: 19 – 25 kg·cm (1.4 – 1.8 lb·ft)

Fig. 21-43 SM21-355

3. ASSEMBLING DRIVE END FRAME AND REAR END
FRAME
1) Apply grease lightly to the rear side of rotor shaft,
and connect drive end frame and rear end frame.

Fig. 21-44 SM21-356

2) Tighten the 3 through-bolts.
Tightening torque: 66 – 95 kg·cm (4.8 – 6.8 lb·ft)

Fig. 21-45 SM21-357

3) Install rear cover.
Tightening torque: 19 – 25 kg·cm (1.4 – 1.8 lb·ft)

Fig. 21-46 SM21-358

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Models J05C-TD, J08C-TP and J08C-TR ALTERNATOR 21-13

CONFIRMATION AFTER ASSEMBLY

1. CHECKING ROTATING CONDITION
Rotate pulley by hand and ensure that there is no friction
of parts inside and that rotation is smooth.
2. CHECKING INSULATION AT OUTPUT TERMINAL
Measure the resistance between terminals F-E and P-E,
using a circuit tester.
The measured value should be as shown in the following
table.
Fig. 21-47 SM21-359
There is a fault if the reading is 0

Resistance value:
B
+Lead –Lead +Lead
E Terminal B Terminal E Approx. 20
Terminal E Terminal B Infinity
Terminal P Terminal E Approx. 7
Terminal E Terminal P Infinity

Fig. 21-48 SM21-360

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21-14 ALTERNATOR Models J05C-TD, J08C-TP and J08C-TR

PERFORMANCE TEST
For testing performance, set the alternator on a bench tester wiring arranged as shown in the diagram.
NOTE: Use fully charged batteries.
Do not fail to connect a lamp (1.5–3 W/12V) at terminal L.

1. TESTING LAMP INDICATION AND REGULATOR OP-

CL ERATION
SW0
SW2 a. Keep alternator still.
B A b. Close SW0 and confirm that the lamp is lighted.
E
L R SW1 c. Close SW1 and confirm that electric current flows
P V R (4 – 6A) using ammeter.

Fig. 21-49 SM21-361

2. MEASURING OF CHARGE INITIATION RPM
CL a. Close SW0 and SW1 in the said order.
SW0
SW2 b. Gradually increase the alternator speed.
B A c. Open SW1 when charging current has shifted from
E
L R SW1 –0.5 to 0.5 A.
P R d. From this state, gradually increase the speed further
V
and confirm that the speed is 900 rpm or less when
voltmeter shows 13.5 V.

Fig. 21-50 SM21-362

3. MEASURING RATED OUTPUT RPM
CL a. Close SW0, SW1 and SW2.
SW0
SW2 b. Increase the alternator speed.
A
B c. Adjust the load (variable resistance: R) until voltage
E
L R SW1 reaches 13.5 V.
P R d. Confirm that the speed is 4,000 rpm or less when
V
output current has attained 80 A, which is the rated
output current.

Fig. 21-51 SM21-363

4. TESTING REGULATED VOLTAGE OF REGULATOR
CL a. Open SW2 maintaining the measuring condition of
SW0
SW2 step 3 above.
B A b. Confirm that, with the output current at 5 A or less,
E
L R SW1 voltage is 14.0–14.6 V, which is the regulated volt-
P V
R age.

Fig. 21-52 SM21-364