Rear Terminal Models: Reassembly
- Rotor, stator and bearing must not be cleaned with solvent. Wipe these parts off with a clean, lint free cloth. Press front bearing in front housing bearing boss, putting pressure on bearing outer race only.
- Install bearing retainer. If stop-ring on rotor drive shaft is damaged, install new stop-ring. Push new ring on shaft and into groove.NOTE: Do not open ring with snap ring pliers, as permanent damage will result.
- Position bearing spacer on rotor shaft with recessed side against stop ring. Position front housing, fan spacer, fan, pulley and lock washer on rotor shaft and install retaining nut. Tighten nut.
- If rear housing bearing was removed, support housing on inner boss and press a new bearing flush with outer end surface. Place brush springs, brushes, brush terminal and terminal insulator in brush holder.
- Hold brushes in position by inserting small piece of stiff wire in brush holder. Position brush holder assembly in rear housing and install mounting screws. Position brush leads in holder. See Figs. 7 & 8.
- Wrap 3 stator winding leads around rectifier terminals and solder using 100 watt soldering iron and resin core solder. On 65 amp models, push terminals of stator wires onto circuit board terminals and solder. Position stator neutral lead eyelet on stator terminal screw and install screw in rectifier assembly. See Fig. 4.
- For rectifier with diodes exposed, insert special screws through wire lug, dished washers and circuit board. Turn screws 1/4 turn counterclockwise to lock. For single circuit boards with built-in diodes, insert screws straight through wire lug, insulating washer and rectifier, into insulator.NOTE: Dished washers are to be used only on circuit board with exposed diodes. If dished washers are used on single circuit board, short circuit will occur. Flat insulating washers are to be used between stator terminal and board when single circuit board is used.
- Position capacitor on rectifier terminals. On circuit board with exposed diodes, install "STA" and "BAT" terminal insulators. On single circuit board, position square stator terminal insulator in rectifier assembly.
- Position "BAT" terminal insulator on "BAT" terminal. Position stator and rectifier assembly in rear housing. Make certain all terminal insulators are seated properly in appropriate recesses. Position "STA" (Black), "BAT" (Red), and "FLD" (Orange) isolators on terminal bolts and install retaining nuts.
- Wipe rear end bearing of rotor shaft with clean, lint free cloth. Position rear housing and stator assembly over rotor and align scribe marks made during initial disassembly. Seat machined portion of stator core into step in both end housings. Install housing through bolts. Remove brush retracting wire, and put small amount of water-proof cement over hole to seal from moisture.