Mechanical Adjustments
Alternator Brush Replacement
1. Remove user-right side cover
2. Remove brown wire from W3 (FLD BRN) post of alternator.
3. Loosen ¼” bolts on W3 post, or alternator brush assembly
4. Verify brush length and quality. We recommend replacing brushes that are ¼” or less.
Alternator Replacement
1. Remove side covers.
2. (Optional) Remove a step shaft, allowing top-down access for transmission removal.
3. Remove poly-V belt from inner transmission and alternator pulleys.
4. Remove the transmission bracket, between transmission and alternator, from the alternator body.
5. Remove W3 (brown), W4 (blue), W5 (white), and W6 (black) wires from posts of the alternator.
6. Remove the Nyloc nut, screw, spacer and hardware that mount the alternator onto the chassis of the machine.
7. Mount the new alternator onto the pivot assembly.
8. Reconnect the transmission bracket to the alternator body.
9. Reconnect W3 (brown), W4 (blue), W5 (white), and W6 (black) wires to the corresponding posts of the alternator.
10. Reconnect the poly-V belt between the transmission and alternator and ensure proper alignment and tension.
11. Once proper belt tension is set tighten the alternator adjustment bolt on the transmission bracket of the alternator,
and pivot assembly hardware.
12. Replace side covers.
Transmission Replacement
1. Remove side covers.
2. Remove drive chain master link and chain from transmission / upper sprocket.
3. (Optional) Remove a step shaft, allowing top-down access for transmission removal.
4. Remove poly-V belt from inner transmission and alternator pulleys
5. Remove the transmission brace from the transmission body, leaving the other end connected to the machine
chassis.
6. Remove the transmission bracket, between transmission and alternator, from the transmission body.
7. Loosen the 4 bolts that mount the transmission to the chassis of the machine. Take note of the rubber pad that
sits between the transmission and machine.
8. Remove transmission and remove the sprocket, idler arm assembly, and inner pulley and key for use on the new
transmission.
9. Assemble transmission parts from Step 7 onto new/replacement transmission.
10. Bolt new transmission onto the chassis of the machine, ensuring to replace the rubber pad.
11. Reconnect the transmission bracket from the alternator and the brace from the chassis.
12. Align the inner transmission pulley, so it is in alignment with the alternator pulley, and tighten the set screw.
13. Reconnect the poly-V belt between the transmission and alternator and ensure proper alignment and tension.
14. Reconnect drive chain and master link.
15. Replace side covers.
Last revised 10/5/15
