Generator Overhaul CS-144

Notice: Do not pry against the stator or the slip ring end frame during generator disassembly. Damage to the generator may result.

1. Make scribe marks on the following components in order to ease in assembly:

•	The slip ring end frame

•	The drive end frame




2. Remove the 4 through bolts.

Notice: On models with a slip ring end ball bearing on the rotor shaft, this bearing must be replaced with a new bearing any time the two halves of the generator are separated. If not replaced, the bearing may bind and fail due to distortion of its outer tolerance rings. This does not apply to roller-type slip ring end frame bearings.

3. Separate the slip ring end frame and the drive end frame.



4. Remove the nuts holding the stator to the heat sink.
5. Remove the stator from the slip ring end frame.
6. Unsolder the following connections to the voltage regulator:

•	The connector strap

•	The brush holder




7. Remove the brush holder insulator screw.
8. Remove the voltage regulator screw.
9. Remove the following components from the slip ring end frame:

•	The voltage regulator

•	The brush holder with the dust shield




10. Remove the following components from the brush holder:

•	The brushes

•	The dust shield

11. Clean the brushes with a dry soft cloth.



12. Remove the rectifier bridge and the capacitor as a unit:

•	Remove the bolts.

•	Remove the washers.

•	Disconnect the leads.

•	Remove the bridge and capacitor assembly.




13. Remove the slip ring end frame bearing.



14. Remove the following from the drive end frame:

•

The nut

•	The washer

•	The pulley

•	The fan collar

•

The fan

•	The outside collar

•

The rotor

15. Remove the inside collar from the rotor.

1. Inspect the drive end bearing. If the bearing is rough or worn, replace the generator drive end frame assembly.
2. Inspect the slip ring end bearing. If the bearing is rough or worn, replace with a new bearing.



3. Inspect the rotor for grounds (1), opens (2), or shorts (2).



4. Inspect the stator for grounds.



5. Inspect the rectifier bridge for continuity.

1. Install the inside collar into the rotor.
2. Install the rotor into the drive end frame.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the following components onto the rotor shaft:

•	The outside collar

•

The fan

•	The fan collar

•	The pulley

•	The washer

•	The generator shaft nut

Tighten
The nut to 100 N·m (74 lb ft).




4. Install the bearing into the slip ring end frame from the outside, until the bearing is flush with the outside shoulder of the slip ring end frame.




Important: In order to insure proper operation of the unit, install the slip ring end frame components in the correct order.

5. Install the rectifier bridge.

Important: Install the capacitor with the insulator material resting against the drive end frame.

6. Install the capacitor.
7. Install the washers.

Important: Ensure that the insulated bolt, that is located at the capacitor/rectifier bridge, attaches the capacitor strap and the rectifier bridge to the slip ring end frame. Ensure that the metal side of the capacitor strap is against the regulator connection.

8. Install the bolts.



9. Install the brushes onto the brush holder with the retaining pin.
10. Install the dust shield onto the brush holder.



11. Install the following components into the slip ring end frame as one unit:

•	The voltage regulator

•	The brush holder

12. Tap the plastic retaining pin on the dust shield into the retaining clip. Ensure that the brush retaining pin goes through the access hole to the outside of the slip ring end frame for removal after the generator is assembled.
13. Install the regulator bolt.
14. Install the brush holder bolt.
15. Assemble the connector strap to the voltage regulator solder clip. Assemble the brush holder connection to the other voltage regulator solder clip.

Notice: Avoid excessive heat when soldering connections, as this can cause voltage regulator damage.

16. Crimp, then solder, the voltage regulator connections.



17. Place the stator terminals over the rectifier bridge terminals in order to assemble the stator.
18. Install the stator lead nuts.



19. Assemble the slip ring and drive end frames. Note the scribe marks.
20. Install the slip ring end bearing outer race into the bearing well in the slip ring end frame casting.
21. Install the through bolts.
22. Remove the retaining pin in order to release the brushes against the slip rings.