Komatsu 930E-2, Shop Manual

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BF4822 STATOR SERVICE TOOL INSTRUCTIONS
Function of Service Tool
This tool has been designed to remove and install
stators in alternators. The user of this tool must be
familiar with basic disassembly and reassembly tech-
niques of dual stator alternators. Proper assembly and
use of this tool will result in correct placement of stators
inside the shell (indexing of stator, with respect to
stator leads). Read through these instructions to
familiarize yourself with the names of various tool
components prior to attempting stator removal or
installation.
STATOR REMOVAL AND REPLACEMENT
Shell Assembly Preparation (Refer to Figure 13-41)
The field coil and shell studs must be removed from
the shell assembly before a stator can be removed.
REMINDER: A narrow, 1 – 3” wide, support ring is in
the tool package (not pictured). This ring is used when
necessary, to provide additional tool height to prevent
the jack screw from protruding through the bottom
thrust plate and preventing proper tool use.
1. Position the bottom thrust plate in work area.
2. Place the first support ring on the bottom thrust
plate.Make sure the support ring seats in the
mating groove in the bottom thrust plate.
3. Place the shell assembly on the support ring with
the stator to be removed, facing up.
4. Place the second support ring on top of the shell
assembly.Reach inside the support ring and po-
sition the stator leads inside and away from the
top of the shell assembly.
Pressure Plate Set-up (Refer to Figure 13-42)
5. Thread the 3/8” diameter guide pin into the pres-
sure plate, from the hub side of the pressure plate.
The threaded hub on the pressure plate faces up,
toward the top thrust plate.
6. Lay the top thrust plate on the pressure plate as
you pass the guide pin through the curved slot in
the top thrust plate.
7. After properly placing the thrust washer (not
shown on drawing) on the jack screw, insert the
jack screw through the top thrust plate and thread
the jack screw into the pressure plate about 1”.
8. Lift the top thrust plate up and off the guide pin.
Turn the top thrust plate so that the guide pin does
not re-enter the slot.Lower the top thrust plate and
allow it to rest on top of the guide pin.
9. Lubricate approximately 1” of the jack screw
where it enters the pressure plate with white lube
or a wheel bearing type of grease. Also place a
dab of this grease on both sides of the thrust
washer that is placed under the hex head of the
jack screw.
10. Position the stator leads so that they will not snag
on the pressure plate when the pressure plate is
being inserted into, then through, the stator. Bend
the stator leads over the top of the support ring
(this will help to eliminate interference).
11. Wrap a clean shop towel around the jack screw
and lift the pressure plate/jack screw/top thrust
plate assembly. Insert the pressure plate into and
through the top stator assembly. Position the
pressure plate in the space between the two
stators, where the field coil had been. Turn the
pressure plate to align the poles of the pressure
plate with the poles of the stator. This is easily
done by grasping both the jack screw and guide
pin and twisting. The pressure plate will then
rotate. Before releasing the assembly, make sure
the top thrust plate will once again rest on the end
of the guide pin, not the support ring.
12. Position the stator leads inside the support ring.
Firmly grab the top thrust plate at the outer edge,
twist slightly until the guide pin enters the curved
slot. Lower the top thrust plate onto the support
ring. The top of the support ring should enter the
mating groove in the top thrust plate.
13. Thread the jack screw in, until the head of the jack
screw contacts the top thrust plate.
14. Look through the large diameter holes (torque arm
holes) in the thrust plate to confirm the proper
seating of the pressure plate steps against the
stator. Adjust the pressure plate as necessary.
NOTE: The pressure plate is properly seated when the
outer edge of the pressure plate presses against the
field coil mounting tabs on the stator. Make sure that
ALL field coil mounting tabs are in contact with the
pressure plate.
15. Continue threading the jack screw in, until signifi-
cant resistance is felt. Check position of the pres-
sure plate again.
M13-26 Niehoff Alternator Overhaul Manual M13003 04/01