Generator Overhaul A-Type : Mando

1. Remove the generator. Refer to Generator Replacement .
2. Remove the front bracket and rear bracket.
3. Remove the through-bolts (1).



4. Pry front bracket downwards using a screwdriver (1).
5. Separate the front bracket and rear bracket (2).



6. Cover the rotor assembly with the cloth (4).
7. Place the pulley upward and vice the rotor (3).
8. Remove the pulley nut (2).
9. Remove the pulley (1).



10. Remove the large collar (1).
11. Remove the rotor from the front bracket (3).
12. Remove the small collar from the rotor shaft (2).



13. Remove the support plate screws (1).
14. Remove the plate (3).
15. Remove the front bearing using the press (2).



16. Remove the battery positive terminal nut (1) from the rear bracket.
17. Remove the washer (2).



18. Remove the rectifier screw (3).
19. Remove the brush holder and regulator assembly screws (1).
20. Remove the stator assembly from the rear bracket with the rectifier/brush holder/regulator (2).



21. Remove the rectifier/brush holder/regulator connections (2).

Notice: If the stator connections are welded in, use just enough heat to melt the lead. Avoid using to much heat as it can damage the diodes.

22. Remove the stator and rectifier connections (1).

1. Assemble the stator assembly into the rear bracket and rotor assembly (1).

•	Brushes (2)

•

Hole (3)

Notice: Refer to Fastener Notice in the Preface section.




2. Install the brush holder/regulator/rectifier screws (1).

Tighten
Tighten the brush holder/regulator/rectifier screws to 9-12 N·m (80-106 lb in).

3. Install the battery positive terminal nut (2).

Tighten
Tighten the battery positive terminal nut to 4-7 N·m (35-62 lb in).




4. Install the front bearing spot plate screws (1).

Tighten
Tighten the front bearing spot plate screws to 6-8 N·m (53-71 lb in).




5. Install the generator pulley nut (1).

Tighten
Tighten the generator pulley nut to 80-110 N·m (59-81 lb ft).

6. Install the through-bolts (2).

Tighten
Tighten the through-bolts to 4-6 N·m (35-53 lb in).

Generator Overhaul B-Type : DAC

1. Remove the generator. Refer to Generator Replacement .
2. Remove the battery positive terminal nut (2).
3. Remove the cover (3) and cover latch (1).



4. Remove the stator coil lead and rectifier diode lead connections (1).



5. Remove the rectifier bolts (1).
6. Remove the rectifier/regulator screw (2).
7. Remove the brush holder/regulator screw (3).
8. Remove the regulator screw (4).
9. Remove the regulator/brush holder/rectifier assembly (5).



10. Remove the rectifier and regulator connection (2).
11. Remove the regulator and brush holder connection (1).
12. Visibly inspect the rectifier (3)/regulator (4)/brush holder (5) for damage or if broken.



13. Remove the shield (3).
14. Remove the through-bolts (1).
15. Remove the frame from the drive end bracket (2).



16. Cover the rotor with the cloth (4).
17. Place the pulley upwards and vice the rotor (3).
18. Remove the pulley nut (2).
19. Remove the pulley (1).
20. Remove the pulley and rotor assembly from the drive end bracket.



21. Remove the collar (4).
22. Remove the rotor from the driver end bracket (2).
23. Remove the collar from the rotor shaft (3).
24. Inspect the front bearing for corrosion, wear, noise, and other damage (1).
25. Remove the drive end bracket, rotor, and space.



26. Remove the remains (1) after the welding.
27. Remove the stator assembly (2) from the frame.

1. Install the stator assembly (2) to the frame.



2. Install the space, rotor and drive end bracket.
3. Install the collar to the rotor shaft (3).
4. Install the rotor to the driver end bracket (2).
5. Install the collar (4).



6. Install the pulley and rotor assembly to the drive end bracket.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the pulley (1) and pulley nut (2).

Tighten
Tighten the pulley nut to 80-110 N·m (59-81 lb ft).




8. Install the frame to the driver end bracket (2).
9. Install and tighten the through bolts (1).
10. Install the shield (3).



11. Install the regulator and brush holder connection (2).
12. Install the rectifier (3) and regulator connection (2).



13. Install the regulator/brush holder/rectifier assembly (5).
14. Install and tighten the regulator screw (4).

Tighten
Tighten the regulator screw to 9-12 N·m (80-108 lb in).

15. Install and tighten the brush holder/regulator screw (3).

Tighten
Tighten the brush holder/regulator screw to 9-12 N·m (80-108 lb in).

16. Install and tighten the rectifier/regulator screw (2).

Tighten
Tighten the rectifier/regulator screw to 9-12 N·m (80-108 lb in).

17. Install and tighten the rectifier bolts (1).

Tighten
Tighten the rectifier bolts to 9-12 N·m (80-108 lb in).




18. Install the stator coil lead and rectifier diode lead connections (1).



19. Install the cover (3) and cover latch (1).
20. Install and tighten the battery positive terminal nut (2).
21. Install the generator. Refer to Generator Replacement .