Disassembly and Reassembly

Disassembly Procedure




1. Remove the generator.
2. Remove the driveshaft nut.




3. Remove the pulley and the collar from the driveshaft.




4. Pry off the plastic cover that encloses the rectifier and the regulator/brush holder assemblies. Inspect the cover for damage.




5. Remove the generator through-bolts.




6. Remove the bolts which secure the rectifier assembly and the regulator/brush holder assembly to the slip ring end frame.




7. To remove the regulator/brush holder and the rectifier assemblies, first melt the solder of the lead connecting the regulator/brush holder assembly to the rectifier assembly lead to the stator. Do the same to the other rectifier assembly leads to the stator, (as shown).




8. Test each of the three diodes of the rectifier assembly for continuity. Connect the ohmmeter probes on each side of the diode. Retest by connecting the ohmmeter probes reversely. If the readings are the same, replace the rectifier.




9. Mark a line perpendicular to the crack between the case of the drive end frame and that of the slip ring end frame.
10. Pry open the drive end frame from the slip ring end frame.
11. Remove the collar.




12. Remove the fan.




13. Separate the rotor from the slip ring end frame.




14. Using an ohmmeter, test the stator for ground. If the reading is low, replace the stator. Also, check the stator for an open circuit by placing the probes on two terminals. If the reading is high (infinite), replace the stator.




15. Using an ohmmeter, test the rotor for an open circuit. Check that there is continuity between the slip rings. Standard resistance (cold) is 2.8 to 3.0 ohms. If there is no continuity, replace the rotor.




16. Using an ohmmeter, inspect the rotor for ground. Check that there is no continuity between the rotor and the slip ring.

Assembly Procedure




1. Check the bearing on the fan side of the rotor assembly. Replace the bearing if it is rough or worn, and especially if the generator was diagnosed as having a noisy bearing with the vehicle running.
2. If required, install a new bearing and insert the bearing retainer on the rotor assembly shaft.




3. Press on the rotor assembly into the end frame.
4. Install the fan on the rotor shaft.




5. Install the collar.




6. Install the slip ring end frame assembly by lining up the terminal ends of the stator with the end frame cover holes and then lining up the previously made marks on the drive end frame case and the slip ring end frame case before the two cases were separated.
7. Install the generator through-bolts.

Tighten
Tighten the generator through-bolts to 25 Nm. (18 lb.ft).




8. Install the rectifier assembly by first soldering its terminals to the stator terminal ends.
9. It the brushes are worn, solder the terminal of the new brush holder assembly to the regulator assembly.




10. Solder the terminal of the regulator/brush holder assembly to the rectifier assembly and fasten the rectifier and the regulator/brush holder assemblies to the slip ring end frame with the bolts.
11. Tighten the rectifier and regulator/brush holder assembly bolts until they are touching their respective mounting plates. Then, tighten the bolts an additional quarter turn.




12. Snap on the cover.
13. Install the collar and the pulley on the drive end shaft.




14. Install the driveshaft nut.

Tighten
Tighten the generator driveshaft nut to 100 Nm. (74.lb.ft).

15. Install the generator.