Disassembly Procedure
- Remove the generator. Refer to Generator Replacement .
- Mark a match line that cannot easily be removed on the end frame to make assembly easier.
- Pry off the plastic cover to expose the stator connections.
- Remove the stator connections from the rectifier bridge terminals by cutting the wires.
- Pry off the baffle.
- Remove the rectifier/regulator/brush hold assembly screws.
- Remove the brush holder assembly and the regulator.
- Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.
- Retest by connecting the ohmmeter terminals in reverse.
- Replace the rectifier bridge, if each reading is the same.
- Test the remaining 2 diodes after the above procedure.
- 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.
- Remove the generator through-bolts.
- Move to the drive end of the generator and remove the drive end bearing nut.
- Remove the pulley and the collars.
- 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.
- Test the rotor for an open and short circuits. The readings should be 1.7-2.3 ohms, or the rotor should be replaced.
- Remove the drive end frame from the shaft.
- For vehicles with an internal generator fan, remove the drive end frame and the fan.
- Remove the rotor assembly.
- Remove the stator.
- Test the stator for an open circuit using the ohmmeter.
- Remove the ring in the slip ring end frame.
Notice: If the stator connections are welded in, use just enough heat to melt the lead. Avoid using to much heat as it can damage the diodes.
Important: 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.
Important: 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.
Important: The fastening torque of this nut is 81 N·m (60 lb ft) and may not normally be unfastened using hand strength.
Assembly Procedure
- Install the new ring in the slip ring end frame.
- Install the stator.
- 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 m (0.075 in).
- Install the generator through-bolts.
- Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.
- Install the generator. Refer to Generator Replacement .
- Weld the brush holder terminal to the regulator terminal, if removed.
- Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
- Apply silicone grease between the bridge and the end frame for radiation purposes.
- Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
- Punch the new baffle with the pin into the brush.
- Weld the connectors of the rectifier bridge.
Caution: Refer to Safety Glasses Caution in the Preface section.
Notice: Refer to Fastener Notice in the Preface section.
Tighten
Tighten the generator through-bolts to 10 N·m (89 lb in).
Tighten
Tighten the generator drive and end bearing nut to 81 N·m (60 lb ft).
Notice: Protect the diode in the rectifier bridge from excessive heat while welding. Overheating the diode will cause damage to the rectifier bridge.
