Charging Systems: Alternators: Overhaul: Reassembly
- Place grease retainer on rotor shaft and press retainer onto shaft until tool (C 4330-1, 100 amp or C 3921, all others) bottoms on shaft. Position rectifier end shield bearing on top of bearing. With top part of tool (C 4330-2, 100 amp or C 4201, all others) placed on end shield, press bearing into place until it bottoms.
- Insert drive end bearing in drive end shield and install bearing retainer plate to hold bearing in place. Position bearing and drive end shield on rotor shaft, and while supporting base of rotor shaft, press bearing end shield into position on rotor shaft with an arbor press and adapter (C 3858) or equivalent.
CAUTION: Make sure bearing is installed squarely.
- Install pulley on rotor shaft. Shaft of rotor must be supported so all pressing force is on pulley hub and rotor shaft, and not on bearings. Do not hammer pulley on.
- If removed, install output terminal stud and insulator thru end shield. Be sure mica insulators are in place and undamaged. Install positive heat sink assembly over studs; guide rectifier straps over studs on terminal block. Install capacitor. Slide negative rectifier and heat sink assembly into place, position straps and install screws.
- Position stator over rectifier end shield and install winding terminals on terminal block and press stator pins into each end shield. Route leads so they cannot contact rotor or sharp edges of negative heat sink. Position rotor and drive end shield over stator and rectifier end shield and install thru bolts. Compress both ends manually and tighten through bolts evenly to 40-60 INCH lbs.
- Install field brushes in insulated holders. Position vertical and horizontal field brushes in proper location in rectifier end shield. Place an insulating washer on each field brush terminal and install lockwashers. Be sure that brushes are not grounded. Rotate pulley slowly by hand to be sure rotor fan blades do not hit stator winding leads.