Charging Systems: Alternators: Overhaul: Reassembly
- Place grease retainer on rotor shaft and press retainer onto shaft until suitable tool (C-3921) bottoms on shaft. Position rectifier end shield bearing on base of suitable tool (C-4201) and alternator end shield on top of bearing so it is properly aligned. With top part of tool placed on end shield, press 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 suitable adapter (C-3858).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 through end shield. Be sure mica insulators are in place and undamaged. Install positive heat sink assembly over studs and then guide rectifier straps over studs on terminal block. Install capacitor over end stud and install shoulder insulator. Ground bracket to end shield with metal screw, then install and tighten positive heat sink nut and lock washer assemblies.
- 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. Install winding terminals nuts. 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 through bolts. Compress both ends manually and tighten through bolts evenly to 40-60 INCH lbs.
- Install field brushes in insulated holders and position vertical and horizontal field brushes in proper location in rectifier end shield. Place an insulating washer on each field brush terminal before installing lock washers and screws. Be sure that brushes are not grounded. Rotate pulley slowly by hand to be sure rotor fan blades do not hit stator winding leads.