Generators & Regulators: Overhaul: Generator: Disassembly

1. Remove the generator. See GENERATOR  under REMOVAL & INSTALLATION.
2. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator connections. See Fig 1.
CAUTION: If the stator connections are not welded, melt the lead. Avoid excessive heating, as it can damage the diodes in the rectifier bridge.
4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
5. Pry off the baffle.
6. Remove the rectifier/regulator/brush holder assembly screws. See Fig 2.
NOTE: If the brush can be reused, reassemble the brush to the holder with the retaining pin, after cleaning the brush with a soft, clean cloth.
7. Remove the brush holder assembly and the regulator.
8. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink. See Fig 3.
9. Retest by connecting the ohmmeter terminals in reverse.
10. Replace the rectifier bridge, if each reading is the same.
11. Test the remaining two diodes after the above procedure.
NOTE: Some kinds of digital ohmmeters are not suited for the test of the bridge diode. In this case, consult the manufacturer regarding the test capacity.
12. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the reading is the same, the rectifier bridge should be replaced. See Fig 3.
13. Remove the generator through bolts. See Fig 4.
14. Move to the drive end of the generator and remove the drive end bearing nut. See Fig 5.
15. Remove the pulley and the collars.
16. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading should be sufficiently high, or the rotor must be replaced. See Fig 6.
17. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 ohms, or the rotor should be replaced. See Fig 7.
18. Remove the drive end frame from the shaft.
19. For vehicles with an internal generator fan, remove the drive end frame and the fan. See Fig 8.
20. Remove the rotor assembly. See Fig 9.
21. Remove the stator. See Fig 10.
22. Test the stator for an open circuit using the ohmmeter. See Fig 11.
23. Remove the ring in the slip ring end frame. See Fig 12.

Fig 1: Removing Plastic Cover

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Fig 2: Removing Brush Holder Assembly And Regulator

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Fig 3: Testing Rectifier Bridge

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Fig 4: Removing Generator Through Bolts

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Fig 5: Removing Pulley And Collars

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Fig 6: Testing Rotor For An Open Circuit (1 of 2)

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Fig 7: Testing Rotor For An Open Circuit (2 of 2)

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Fig 8: Removing Drive End Frame And Fan

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Fig 9: Removing Rotor Assembly

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Fig 10: Removing Stator

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Fig 11: Testing Stator For An Open Circuit

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Fig 12: Removing Ring Slip Ring And Frame

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