Generators & Regulators: Overhaul: Generator: Assembly

1. Check bearing on fan side of rotor assembly. Replace bearing if it is rough or worn, and especially if generator was diagnosed as having a noisy bearing with vehicle running. If required, install a new bearing and insert bearing retainer on rotor assembly shaft. Press on rotor assembly into end frame. Install fan on rotor shaft. Install collar.
2. Install slip ring end frame assembly by lining up terminal ends of stator with end frame cover holes and then lining up previously made marks on drive end frame case and slip ring end frame case before two cases were separated. Install generator through-bolts. Tighten generator through-bolts to 25 N.m (18 ft. lbs.). Install rectifier assembly by first soldering its terminals to stator terminal ends. See Fig 12 .
3. If brushes are worn, solder terminal of new brush holder assembly to regulator assembly. Solder terminal of regulator/brush holder assembly to rectifier assembly and fasten rectifier and regulator/brush holder assemblies to slip ring end frame with bolts. Tighten rectifier and regulator/brush holder assembly bolts until they are touching their respective mounting plates. Then, tighten bolts an additional quarter turn. Snap on cover. Install collar and pulley on drive end shaft.
4. Install pulley nut. Tighten generator pulley nut to 100 N.m (74 ft. lbs.). Install generator.

Fig 1: Removing Pulley Nut

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Fig 2: Removing Pulley & Collar

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Fig 3: Removing Rectifier Cover

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Fig 4: Removing Generator Through-Bolts

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Fig 5: Removing Regulator/Brush Holder Bolts

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Fig 6: Removing Regulator/Brush Holder & Rectifier Assemblies

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Fig 7: Testing Diodes

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Fig 8: Removing Spacer

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Fig 9: Testing Stator Windings

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Fig 10: Testing Slip Ring

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Fig 11: Checking Continuity Between Rotor & Slip Ring

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Fig 12: Soldering Rectifier Assembly

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