key «on 10» loosen the nut...
... and remove the insulating washer from the output «30» generator.
key «at 19» Loosen the alternator pulley nut. We hold the rotor from turning with a screwdriver by the ledge of the impeller (don't bend the blades).
Let's take the puck...
... pulley parts,...
...adjustment ring...
...and the impeller.
With a small chisel, remove the key from the groove of the shaft...
... and remove the ring installed behind it.
key «on 10» loosen four screws...
... and take out the bolts tightening the generator covers.
Remove the front cover.
If the rotor shaft sits tightly in the bearing, while holding the generator on weight by the front cover, we knock out the axle through a soft metal mandrel.
We remove the adjusting washer. When assembling, do not forget to install it in place.
To replace the front bearing with a wrench «for 8» unscrew four nuts. During assembly, they were locked - the ends of the studs were crumpled. If the nuts are damaged during loosening, new ones will be required during assembly.
Remove the outer and inner covers along with the studs.
Through the mandrel knock out the front bearing.
We install a new bearing by applying light blows to its outer ring through a mandrel, which can be used as a suitable head or sleeve.
We install the bearing caps, tighten the nuts...
... and counter them again with a beard or chisel.
Remove the brush holder (see Generator brush replacement).
Knock out the rotor from the back cover with a soft metal drift. The rotor is removed together with the bearing.
Rear bearing replacement is rarely required. If necessary, we pull it off the rotor shaft with a puller.
We press in a new bearing, striking through the mandrel - and only on its inner ring.
head «for 8» unscrew the three nuts securing the stator leads to the rectifier unit.
Using a thin screwdriver, tighten the plug lock «zero» wires...
... remove the stator.
Removing the output bolt «30».
Remove three bolts from the back cover along with insulating gaskets...
...and take out the rectifier unit.
To check the rectifier unit, see section Generator check.
Valve (diode) has unidirectional conduction. A faulty one usually passes current in both directions. Replacing individual valves is possible, but they will need to be repressed into a holder - an operation that requires accuracy and skill. Therefore, in the event of failure of its elements, we recommend replacing the rectifier unit as an assembly.
Alternately connecting the ohmmeter probes to the stator terminals, we check its windings for an open...
...and short circuit on the case.
Replace defective stator
Before assembly, we clean all parts from oil, dirt and coal dust. We wipe the contact rings with a cloth moistened with gasoline or solvent. With strong oxidation and burning, we clean the rings with the finest sandpaper.
We assemble the generator in the reverse order of disassembly. Before installing the stator, insert the plug into the back cover «zero» wires (pre-bending its latch) into the generator connector.