- Remove generator. Mark a match line that cannot easily be removed on end frame to make assembly easier. Pry off plastic cover to expose stator connections. See Figure
.
NOTE:
If stator connections are not welded, unsolder connection. Avoid excessive heating, as it can damage diodes in rectifier bridge.
- Remove stator connections from rectifier bridge terminals by cutting wires. Remove generator through-bolts.
CAUTION:
Fastening torque of this nut is 81 N.m (60 ft. lbs.) and may not normally be unfastened using hand strength.
- Remove pulley and collars. Test rotor for an open circuit by using ohmmeter with drive end frame assembled. Reading should be sufficiently high, or rotor must be replaced. Test rotor for open and short circuits. Reading should be 1.7 to 2.3 ohms, or rotor should be replaced. Remove drive end frame from shaft.
- For vehicles with an internal generator fan remove drive end frame and fan. Remove rotor assembly. Remove stator. Test stator for an open circuit using ohmmeter. Pry off baffle. Remove rectifier/regulator/brush holder assembly screws. Remove brush holder assembly and regulator, cutting terminal between regulator and rectifier bridge.
CAUTION:
If brush can be reused, reassemble brush to holder with retaining pin, after cleaning brush with a soft, clean cloth.
- Test rectifier bridge by connecting ohmmeter terminals to bridge and heat sink . Retest by connecting ohmmeter terminals in reverse. Replace rectifier bridge, if each reading is same. Test remaining two diodes after above procedure. See Figure
.
NOTE:
Some kinds of digital ohmmeters are not suited for test of bridge diode. In this case, consult manufacturer regarding test capacity.
- Test diodes by connecting ohmmeter terminals to bridge terminal and base plate. If reading is same, rectifier bridge should be replaced. Remove ring in slip ring end frame.