Disassembly and Assembly
Alternator
Disassembly
1. Hold pulley with a strap wrench and remove shaft nut with an impact gun. Remove pulley, fan, woodruff key, and fan spacer.
2. Remove the diode trio lead from the top of the regulator, and remove the 5/16-18 and 1/4-20 nuts from the positive and negative alternator output terminals which will free the regulator jumpers, for the regulator and brush holder housing assembly removal.
3. Remove the four 8-32 screws holding the regulator/brush holder assembly in place. Carefully remove this assembly.
NOTE: Due to the application of Loctite to the four
(4) brush housing screws, it may be necessary, in some cases, to apply heat to assist in the removal of these screws. Use a large soldering iron or gun (300 to 500 watts) and hold the iron on each screw head for 40-50 seconds (a drop of solder on the iron's tip will help heat transfer). After applying heat to the screw head, remove immediately with a screwdriver.
4. Remove three screws and lift diode trio off of AC terminal board.
5. Remove three self locking nuts and through bolts.
6. Remove rotor and drive end housing assembly from stator and slip ring end housing assembly. If drive end housing binds on stator, loosen by tapping gently on mounting ear with fibre hammer. Be sure that drive end housing separates from stator and that stator remains attached to slip ring end housing to avoid damage to stator leads.
7. Remove three nuts which secure stator leads to terminals and remove stator.
8. Remove nuts from positive and negative output terminal bolts and remove these bolts.
9. Remove hex screws and remove capacitor connected between the heat sinks.
10. Remove two screws, lockwashers, guardwashers, and insulating washers which retain lower end of heat sinks. Remove heat sinks. Note location of insulating washers and bushings.
11. Remove terminal stud insulating washers from housing. There are two bushings in each terminal hole.
12. Using a puller or arbor press, remove the drive end housing bearing assembly from the rotor shaft.
13. Remove four screws and bearing retainer, and press bearing out of drive end housing.
31-44-7 Alternator-165 Ampere-Leece Neville 31-44-7
DISASSEMBLY AND ASSEMBLY (Continued)
Slip Ring Bearing Replacement
1. With a soldering iron remove the wire that connects the rotor coil to the outside slip ring. Bend the unsoldered wire so that it is parallel to the shaft. Unsolder the wire from the inside slip ring, and with a gear puller or an arbor press pull off the slip ring assembly and the insulation washer.
2. Remove the bearing by using a gear puller, an arbor press may also be used with fixture plates behind the bearing. While replacing the bearing keep the new slip ring in a warm place so it will press on easily without cracking. Install the new bearing by using a pipe or tube to press on the inner race of the bearing.
3. After the new bearing has been pressed on the rotor shaft, press on the new slip ring assembly making sure the slot lines up with the slot in the shaft. The new slip ring assembly should be pressed on the shaft with enough pressure to prevent the insulation washer from turning. (All the way to the shoulder). Solder the rotor coil leads to the new slip ring assembly.
4. Put the rotor assembly in a lathe and take a light cut from the circumference of the slip rings to make sure that they are concentric with the shaft. Concentricity of the slip rings with the bearing surfaces of the shaft should be held to within .002 inch total indicator reading.
Assembly
1. Place slip ring end of rotor shaft in an arbor press insuring that slip rings are not damaged, and press the drive end housing on the rotor shaft. Use a sleeve or pipe to insure that pressure is applied on the drive end bearing INNER RACE ONLY.
2. Place the positive and negative rectifier assemblies in the slip ring end housing and install the lower mounting screws, Do not tighten the screws at this time.
3. Install the positive and negative output terminals as shown.
4. Tighten the two screws on the bottom of the two rectifier assemblies to complete installation.
5. Install capacitor and capacitor terminals to the bottom of rectifier assemblies with self tapping screws. Clean paint from around holes before installing leads.
6. Place a positive rectifier terminal and a negative rectifier terminal on each of the three terminal screws on the terminal board. Route the leads as shown.
31-44-8 Alternator-165 Ampere-Leece Neville 31-44-8
DISASSEMBLY AND ASSEMBLY (Continued)
7. Inspect O-ring in the bearing bore in the slip ring end housing and replace if necessary. Place the stator on the slip ring end housing and place the stator leads on the three terminal board screws. Insure that assembly screw holes in the stator and the slip ring end housing are aligned and install rectifier leads and stator leads with self locking nuts.
8. Support the slip ring end housing on flat plates in an arbor press insuring that clearance is provided for the slip rings to pass through. Press the slip ring end bearing in slip ring end housing by pressing on the rotor shaft. Insure that assembly screw holes are aligned in the slip ring end housing, stator and the drive end housing. Install the three assembly screws and fasten alternator together with elastic stop nuts tightened to 5.08-5.65 N-m (45-50 in.lbs.).
9. Install brush holder with four # 8 round head screws. Apply Threadlock Sealer E0AZ-19554- AA (ESE-M4G204-A Type II) or equivalent. Insure that sealing ring is properly installed between the brush holder and the slip ring end housing.
10. Press brushes in brush openings and temporarily pin them in place with a 1/32 inch diameter drill or a piece of stiff wire.
11. Install regulator with # 6 nuts, belleville washers and jumpers. Remove pin to release brush springs then tighten nuts to secure the regulator to the brush holder. Install jumpers to negative and positive output terminals and to regulator terminals with nuts and lockwashers.
12. Install diode trio (with copper contact pads pointing away from alternator) with pan head screws and washers. Install lead to regulator terminal with # 10 nut and lockwasher.
13. Slide fan spacer on shaft and install woodruff key, fan, pulley, and nut. Hold the pulley with a strap wrench and tighten nut with an impact gun. Torque to 25.8-29.5 N-m (35-40 ft.lbs.).
Testing After Assembly Because of the integral regulator used on this alternator, the test block hook-up is very simple, consisting of connecting the positive and negative output leads. If a commercial test block is not available, the test setup shown may be used.
Before beginning the test and after the battery has been connected, momentarily flash the field by connecting a jumper between the diode trio terminal (charge indicator light terminal) and the alternator positive output terminal. This will restore the residual magnetism which may have been weakened by handling or repair procedures.
31-44-9 Alternator-165 Ampere-Leece Neville 31-44-9
DISASSEMBLY AND ASSEMBLY (Continued)
The cut-in speed of the alternator is that rotor speed at which the unit first begins to produce output. This speed should not be higher than 1500 rotor RPM.
SPECIFICATIONS
Output Curves
SPECIAL SERVICE TOOLS