Unit Repair
REMOVE OR DISCONNECTTOOL REQUIRED:
J 22912-01 Bearing Remover
Generator Housing Matchmarks:
1. Scribe matchmarks on the front and rear housing to ensure proper reassembly.
Generator Housing Bolts:
2. Four generator housing bolts from the front housing.
Removing Front Housing (With Drive Pulley And Rotor):
3. Using a flat-bladed tool, gently pry off the front housing (with drive pulley and rotor) from the stator coil and rear housing.
4. Place the front housing and rotor into a vise, facing the drive pulley up.
NOTE: To prevent damage to the rotor, place clean shop cloths between the rotor and vise.
5. Drive pulley retaining nut.
6. Drive pulley washer and drive pulley from rotor.
7. Front housing and rotor from vise.
8. Rotor and spacer from front housing.
Front Bearing Retainer Screws:
9. Four screws, front bearing retainer and front bearing from front housing.
Removing Rear Bearing:
10. Rear bearing from rotor using a J 22912-01 and a press.
Battery Terminal Retaining Nut:
11. Battery terminal retaining nut from rear housing.
Stator Retaining Screws:
12. Four retaining screws and stator from rear housing.
13. Rectifier from rear housing.
14. Regulator and brush holder from rear housing.
15. Brush holder from regulator.
Removing Brushes From Regulator:
16. Brushes from regulator.
A. Remove brush lead wire cover.
B. Using a soldering iron, heat and disconnect brush lead wires from regulator terminals.
C. Remove brushes and brush springs from regulator.
MEASURE
TOOL REQUIRED:
J 34029-A Digital Multimeter
J 26900-5 Vernier Caliper
Measuring Rotor Slip Ring Resistance:
1. Resistance between the rotor slip rings using a J 34029-A. If resistance is greater than 3.5 ohms, replace the rotor.
Measuring Rotor Slip Ring-to-Rotor Resistance:
2. Resistance between the rotor slip ring and the rotor using the J 34029-A. If resistance is less than 5 ohms, replace the rotor.
Measuring Stator Lead Resistance:
3. Resistance between all stator leads using the J 34029-A. If resistance is greater than 5 ohms for any measurement, replace the stator.
Measuring Stator Lead-to-Stator Core Resistance:
4. Resistance between all stator leads and the stator core using the J 34029-A. If resistance is less than 5 ohms, replace the stator.
Measuring Brush Length:
5. Length of each brush using a J 26900-5. Standard brush length is 16 mm (0.63 inch). If the length is less than 2 mm (0.08 inch), replace the brush.
Measuring Rectifier Upper Body-to-Diode Lead Resistance:
6. Resistance between rectifier upper body and each diode lead using the J 34029-A. Reverse the probes and measure resistance again. If resistance is not less than 5 ohms in one measurement and greater than 5 ohms in the other measurement, replace the rectifier.
Measuring Rectifier Lower Body-to-Diode Lead Resistance:
7. Resistance between rectifier lower body and each diode lead using the J 34029-A. Reverse the probes and measure resistance again. If resistance is not less than 5 ohms in one measurement and greater than 5 ohms in the other measurement, replace the rectifier.
Measuring Rectifier Diode Trio Resistance:
8. Resistance between both leads of each rectifier diode trio using the J 34029-A. Reverse the probes and measure resistance again. If resistance is not less than 5 ohms in one measurement and greater than 5 ohms in the other measurement, replace the rectifier.
Measuring Condenser Capacity:
9. Condenser capacity using a digital capacitor meter. If condenser capacity is not 0.5 micro F, replace the rectifier.
Inspect
^ Rotor slip rings for roughness or scoring. If slip rings are rough or scored, replace the rotor.
INSTALL OR CONNECT
Installing Brushes To Regulator:
1. Brushes to regulator.
A. Install brush springs and brushes to regulator so that the label on each brush is 2 to 3 mm (0.008 inch to 0.012 inch) from the rectifier.
B. Solder brush lead wires to regulator terminals.
C. Install brush lead wire cover.
2. Brush holder to regulator.
3. Regulator and brush holder to rear housing.
4. Remove hole plug from rear housing.
Supporting Brushes With Wire:
5. Support brushes with a wire inserted through the hole in the rear housing.
6. Rectifier to rear housing.
7. Stator to rear housing; secure with four retaining screws.
8. Battery terminal retaining nut to rear housing.
Tighten
^ Battery terminal retaining nut to 10 N.m (89 lb. in.).
9. Rear bearing to rotor.
10. Front bearing and front bearing retainer to front housing; secure with four screws.
11. Rotor with spacer to front housing.
12. Place the front housing and rotor into a vise, facing the drive pulley end up.
NOTE: To prevent damage to the rotor, place clean shop cloths between the rotor and vise.
13. Drive pulley and drive pulley washer to rotor; secure with retaining nut.
Tighten
^ Drive pulley retaining nut to 65 N.m (48 lb. ft).
14. Remove the front housing and rotor from the vise.
15. Using a heat gun, heat the rear housing to 50 to 60°C (122 to 140°F).
16. Front housing (with drive pulley and rotor) to stator coil and rear housing, aligning generator housing match marks; secure with four generator housing bolts.
Tighten
^ Generator housing bolts to 30 N.m (22 lb. ft).
17. Remove the brush support wire and install the hole plug into the rear housing.
Inspect
^ Make sure that the rotor rotates smoothly by turning the drive pulley.