Unit Repair
REMOVE OR DISCONNECTTOOL REQUIRED:
J 35452 Generator Pulley Remover/Installer
J 28509-A Puller
Generator Terminal Nut Removal:
1. One nut and terminal insulator.
Rear End Cover:
2. Three nuts and end cover.
Brush Holder And IC Regulator:
3. Five screws, brush bolder and IC regulator.
4. Brush holder cover from brush bolder.
Rectifier Bridge Removal:
5. Four screws and rectifier bridge.
Removing Rubber Insulators:
6. Four rubber insulators.
7. Pulley nut by holding J 35452 with a 1/2-inch breaker bar and loosen by turning clockwise.
8. Pulley with J 28509-A.
Rectifier End Frame:
9. Four nuts and two cord clamps securing rectifier end frame to drive end frame.
10. Rectifier end frame using J 28509-A.
11. Rotor from drive end frame.
INSPECT
TOOLS REQUIRED:
J 26900-5 Vernier Caliper
J 39200 Digital Multimeter
Inspecting Generator Slip Rings:
1. Slip rings for continuity using J 39200. If resistance is not 2.8 to 3.0 ohms, replace the rotor.
Inspecting Rotor Insulation:
2. Slip rings and rotor for continuity using J 39200. If continuity exists, replace the rotor.
3. Slip rings for scoring. If slip rings are rough or scored, replace the rotor.
Measuring Slip Ring Diameter:
4. Measure the diameter of both slip rings with J 26900-5. If the diameter of either slip ring is less than 12.8 mm (0.504 inch), replace the rotor.
Inspecting Stator Leads:
5. Stator for continuity between all leads with J 39200. If there is no continuity, replace the drive end frame assembly.
Inspecting Drive End Frame Insulation:
6. Insulation between the stator and the drive end frame with J 39200. If continuity exists, replace the drive end frame assembly.
Measuring Exposed Brush Length:
7. Measure the brush length exposed from the brush holder with J 26900-5. If the brush length is less than 1.5 mm (0.059 inch), replace the brush holder.
Removing Rubber Insulators:
8. Rectifier positive (+) terminals and stud for continuity using J 39200. Connect one test probe to the positive (+) stud and the other to each rectifier positive (+) terminal.
Rectifier End Frame:
9. Repeat the test after reversing the polarity of the test probes. If the multimeter does not register continuity in only one direction, replace the rectifier.
Inspecting Rectifier (Part 3 Of 4):
10. Rectifier negative (-) terminals for continuity using J 39200. Connect one test probe to each rectifier negative (-) terminal and the other probe to each rectifier positive (+) terminal.
Inspecting Rectifier (Part 4 Of 4):
11. Repeat the test after reversing the polarity of the multimeter's probes. If the multimeter does not register continuity in only one direction, replace the rectifier.
12. Rear bearing for smooth rotation. If any abnormalities are detected, replace the rear bearing.
Disassemble
TOOLS REQUIRED:
J 28509-A Puller
J 38276 Puller Adapter
^ Rear bearing and rear bushing using J 28509-A and J 38276.
Assemble
TOOL REQUIRED:
J 35419 Bearing Installer
^ Rear bearing to rotor shaft using J 35419.
13. Front bearing for rough operation, excessive wear or damage. Replace as necessary.
Disassemble
A. Four screws and bearing retainer from bearing.
B. Bearing from drive end frame assembly.
Assemble
A. Bearing to drive end frame assembly.
B. Bearing retainer to bearing; secure with four screws.
INSTALL OR CONNECT
TOOL REQUIRED:
J 35452 Generator Pulley Remover/Installer
1. Rotor to drive end frame assembly.
2. Lightly tap the rectifier end frame to the drive end frame using a plastic hammer.
3. Rectifier end frame-to-drive end frame; secure with four nuts and two cord clamps.
Tighten
^ Rectifier end frame-to-drive end frame nuts to 4.5 N.m (40 lb. in.).
4. Pulley to the rotor shaft; secure with pulley nut.
Tighten
^ Pulley nut to 110 N.m (81 lb. ft.) using a J 35452 with a 1/2-inch breaker bar.
5. Rubber insulators to lead wires.
6. Rectifier bridge to rectifier end frame; secure with four screws.
7. Brush holder cover to brush holder.
8. IC regulator and brush holder to rectifier end frame; secure with five screws.
9. End cover to rectifier end frame; secure with three nuts.
Tighten
^ End cover nuts to 4.4 N.m (39 lb. in.).
10. Terminal insulator; secure with one nut.
Tighten
^ Terminal insulator nut to 4 N.m (33 lb. in.).