Generators & Regulators: Overhaul: Generator: Reassembly

1. If end housing bearing (1) is removed, install it.
2. Check end housing bearing (1) turns smoothly. See Fig 1 .
3. If stator (4) is removed, install stator (4) and tighten stud bolts (1).
4. If drive end bearing (3) is removed, install it.
5. Check drive end bearing (3) turns smoothly. If OK, install drive end bearing retaining plate (2). See Fig 2 .
6. Place drive end frame (2) on pulley, and install rotor (1) to drive end frame (2). See Fig 3 .
7. Install rear frame (1) to drive end frame (2). See Fig 4 .
8. Tighten 4 nuts to the specifications. See TORQUE SPECIFICATIONS  .
9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to the specifications. See Figure .
10. Install 4 rubber insulators (1). See Figure .
CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades.
11. Install rectifier (1). See Figure .
12. Install brush holder cover to brush holder. See Fig 5 and Fig 6 .
13. Place the IC regulator (1) together with the brush holder (2) horizontally on the rear end frame (3).
14. Install the 5 screws until there is a clearance of approximately .04" (1 mm) between the brush holder (2) and connector. See Fig 7 .
15. Install rear end cover (1) and terminal plate (4).
16. Install insulator (2) and tighten (B) terminal inner nut (3) to the specified torque. See Fig 8 .
17. Ensure that rotor turns smoothly. See Fig 9 .

Fig 1: Checking End Housing Bearing

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Fig 2: Installing Drive End Bearing Retaining Plate

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Fig 3: Installing Rotor To Drive End Frame

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Fig 4: Installing Rear End Frame to Drive End Frame

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Fig 5: Installing Brush Holder Cover To Brush Holder (1 of 2)

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Fig 6: Installing Brush Holder Cover To Brush Holder (2 of 2)

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Fig 7: Installing 5 Screws Between The Brush Holder

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Fig 8: Installing Insulator

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Fig 9: Checking Rotor Rotation

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