Disassembly and Assembly
DISASSEMBLY1. Remove the generator.
2. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator connections.
4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
CAUTION: If the stator connections are not welded, melt the lead. Avoid excessive heating, as it can damage the diodes in the rectifier bridge.
5. Pry off the baffle.
6. Remove the rectifier/regulator/brush holder assembly screws.
7. Remove the brush holder assembly and the regulator.
NOTE: If the brush can be reused, reassemble the brush to the holder with the retaining pin, after cleaning the brush with a soft, clean cloth.
8. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.
9. Retest by connecting the ohmmeter terminals in reverse.
10. Replace the rectifier bridge, if each reading is the same.
11. Test the remaining two diodes after the above procedure.
12. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the reading is the same, the rectifier bridge should be replaced.
NOTE: Some kinds of digital ohmmeters are not suited for the test of the bridge diode. In this case, consult the manufacturer regarding the test capacity.
13. Remove the generator through - bolts.
14. Move to the drive end of the generator and remove the drive end bearing nut.
NOTE: The fastening torque of this nut is 81 Nm (60 lb-ft) and may not normally be unfastened using hand strength.
15. Remove the pulley and the collars.
16. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading should be sufficiently high, or the rotor must be replaced.
17. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 ohms, or the rotor should be replaced.
18. Remove the drive end frame from the shaft.
19. For vehicles with an internal generator fan, remove the drive end frame and the fan.
20. Remove the rotor assembly.
21. Remove the stator.
22. Test the stator for an open circuit using the ohmmeter.
23. Remove the ring in the slip ring end frame.
ASSEMBLY
1. Install the new ring in the slip ring end frame.
2. Install the stator.
3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 inch).
4. Install the generator through-bolts.
Tighten:
Tighten the generator through-bolts to 10 Nm (89 lb-in).
5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.
Tighten:
Tighten the generator drive end bearing nut to 81 Nm (60 lb-ft).
6. Install the generator. Refer to Generator Installation.
7. Weld the brush holder terminal to the regulator terminal, if removed.
8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
9. Apply silicone grease between the bridge and the end frame for radiation purposes.
10. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
11. Punch the new baffle with the pin into the brush.
12. Weld the connectors of the rectifier bridge.
CAUTION: Take care to prevent damage to the vehicle by protecting the diode in the rectifier bridge from excessive heat while welding.