Delphi CS 144 (KG9)

Generator Through-Bolt/Screw Location:

Generator Slip Ring End Frame View:

Testing Generator Rotor:

Testing Generator Stator:

Removing Generator Voltage Regulator And Generator Brush Holder:

Testing Generator Rectifier Bridge:

Delphi CS 144 (KG9) Generator:

Generator Slip Ring End End Frame Components:

Generator Brush Retained In Generator Brush Holder:

TOOLS REQUIRED:
J 39200 Digital Multimeter or equivalent
J 35669 Strut Rod Nut Remover and installer

DISASSEMBLE
1. Make scribe marks on generator slip ring end frame and generator drive end frame to ease reassembly.
2. Generator through-bolts/screws and separate generator slip ring end frame and generator drive end frame.
3. Generator rotor slip ring end frame bearing from rotor shaft.
Measure
^ Generator rotor for grounds, opens and shorts.

Important:
^ Test should be performed at approximately 21°C (70°F). A different temperature may result in inaccurate digital multimeter (DMM) readings.

A. Connect the DMM to slip ring and clean metal grounding surface on frame of generator rotor to check for grounds.
^ The DMM should read infinity (open). If not, replace the generator rotor.
B. Connect the DMM to both slip rings to check for shorts and opens.
^ The DMM should read 1.7 to 2.1 ohms. If not, replace the generator rotor.
4. Stator lead attaching nuts.
5. Generator stator from generator slip ring end frame.
Measure
^ Generator stator for grounds.
A. Connect the DMM to generator stator terminal and to clean metal ground on laminations.
B. The DMM should read infinity (open). If not, replace the generator stator.
6. Regulator attaching bolt/screw and generator brush holder bolt/screw.
7. Tap the plastic dust shield retaining pin inward from the outside of the generator slip ring end frame until the retaining clips are released. It is not necessary to push this clip all the way through. If the pin comes out of the shield, save it for later reassembly.
8. Generator voltage regulator and generator brush holder with dust shield from generator slip ring end frame.
9. Dust shield from generator brush holder.
Clean
^ Generator brush with soft, dry cloth.
10. If necessary, unsolder connections at regulator connector strap and generator brush holder to generator voltage regulator.

Important
^ Avoid excessive heat.

Measure
^ Generator rectifier bridge for continuity.
A. Connect the DMM to grounded heat sink and flat metal clip at generator rectifier bridge.
B. Reverse the DMM leads. One reading should be high (open) and one low (continuity). If both readings are the same, replace generator rectifier bridge.
C. Repeat test between grounded heat sink and clips at two other generator rectifier bridge terminals.
D. Repeat test between insulated heat sink and at generator rectifier bridge terminals.
11. Rectifier bridge bolts/screws.
12. Generator capacitor/rectifier bridge bolts/screws.
13. Generator capacitor and generator rectifier bridge.
14. Generator rotor slip ring end frame bearing from generator slip ring end frame by pushing through to outside.
15. Generator rotor shaft drive end nut, using J 35669.
16. Generator rotor shaft drive end washer, generator pulley, generator rotor drive end fan collar, generator fan and generator rotor drive end bearing outside collar.
17. Generator rotor from generator drive end frame.
18. Generator rotor drive end inside collar from generator rotor.

ASSEMBLE
1. Generator rotor drive end inside collar onto generator rotor.
2. Generator rotor to generator drive end frame.
3. Generator rotor drive end hearing outside collar, generator fan, generator rotor drive end fan collar, generator pulley and generator rotor shaft drive end washer onto rotor shaft.
4. Generator rotor shaft drive end nut using J 35669.
Tighten
^ Nut to 100 N.m (74 lb. ft.).
5. Generator rotor slip ring end frame hearing into generator slip ring end frame from outside, until flush with outside shoulder of generator slip ring end frame.

Important
^ Installation of the generator slip ring end frame electrical components must be done m the following order to ensure proper operation of the unit. Assembly in any other manner will result in either no output from generator or a direct internal ground in the generator.

6. Generator rectifier bridge.
7. Generator capacitor.
8. Generator rectifier bridge bolts/screws.
Tighten
^ Bolts/screws to 2.5 N.m (22 lb. in.).
9. Generator capacitor/rectifier bridge bolts/screws.
Tighten
^ Bolts/screws to 2.5 N.m (22 lb. in.).
10. Generator rectifier bridge stud.
11. Generator rectifier bridge to stud with generator battery terminal nut.
Tighten
^ Nut to 10 N.m (89 lb. in.).

Important
^ The generator capacitor has an insulated material on one side which must rest against the generator drive end frame (ground).
^ The generator capacitor/rectifier bridge insulated attaching bolt/screw must be installed in the proper hole, attaching the generator capacitor strap and generator rectifier bridge to the generator slip ring end frame.

12. Generator brush into generator brush holder with brush retaining pin.
13. Regulator connector strap to generator voltage regulator solder clip, and generator brush holder connection to other generator voltage regulator solder clip.
^ Crimp and solder generator voltage regulator solder clip connections.

NOTE: Avoid excessive heat when soldering connections, as this can cause generator voltage regulator damage.

14. Dust shield onto generator brush holder.
15. Generator voltage regulator, generator and brush holder with dust shield, generator brush and brush retaining pin installed into generator slip ring end frame.

Important
^ The metal side of the capacitor strap must be against the regulator connection.

16. Tap plastic retaining pin on dust shield into retaining clip.
^ Be sure brush retaining pin goes through access hole to outside of generator slip ring end frame for removal after generator is assembled.
17. Generator regulator attaching bolt/screw.
Tighten
^ Bolt/screw to 2.5 N.m (22 lb. in.).
18. Generator brush holder bolt/screw.
Tighten
^ Bolt/screw to 2.5 N.m (22 lb. in.).
19. Generator stator, placing stator terminals over generator rectifier bridge terminals.
20. Generator stator lead attaching nuts.
Tighten
^ Nut to 2.5 N.m (22 lb. in.).
21. Generator slip ring end frame and generator drive end frame, noting scribe marks.
22. Generator through-bolts/screws.
Tighten
^ Bolts/screws to 5.5 N.m (49 lb. in.).
23. Remove brush retaining pin to release generator brush against slip rings.