Pic. 7-11. Removing the protective casing of the generator:
1 - casing fastening screw; 2 - insulating bushings; 3 - air intake; 4 - protective cover; 5 - output extension «30» generator; 6 - output wire «61» generator; 7 - generator.
Lock the alternator pulley with the grip included in the tool kit 67.7823.9504, unscrew the pulley fastening nut and press the pulley with a puller. Remove the pulley key and taper washer.
Tool 67.7823.9504 includes a conventional puller and gripper. The latter consists of two steel half rings, which are inserted into the pulley stream. The half rings have the same section as the alternator drive belt. On the one hand, they are hinged, and on the other, they are equipped with levers that are compressed with one hand when removing the pulley.
Disconnect the wire from the plug «IN» voltage regulator. Disconnect the regulator and capacitor wires from the terminal «30» generator, unscrew the screws securing the regulator 1 (pic. 7-12) tension and remove it. For alternators manufactured before 1996, in order not to break the brushes when removing the brush holder, insert a screwdriver blade between the regulator body 2 and the brush holder and partially slide the regulator out of the generator, leaving the brush holder in place. After that, tilt and remove the regulator together with the brush holder from the generator. Remove the capacitor 20 by unscrewing the fastening screw.
Pic. 7-12. Generator details:
1 - voltage regulator assembly with brush holder for generators manufactured since 1996; 2 - voltage regulator and brush holder for generators manufactured before 1996; 3 - terminal block for additional diodes; 4 - insulating bushings; 5 - rectifier block; 6 - contact bolt; 7 - stator; 8 - rotor; 9 - remote bushing; 10 - inner washer for fastening the bearing; 11 - cover on the drive side; 12 - pulley; 13 - outer washer for fastening the bearing; 14 - coupling bolt; 15 - front ball bearing of the rotor; 16 - bushing; 17 - cover from the side of slip rings; 18 - buffer sleeve; 19 - clamping sleeve; 20 - capacitor.
Unscrew the nuts of the coupling bolts 14 and remove the cover 11 of the generator and the rotor 8. Unscrew the nuts of the bolts connecting the tips of the valves with the stator winding leads and remove the stator 7 from the cover 17 of the generator.
Unscrew the nut of the contact bolt 6, disconnect the plug of the wire of additional diodes from the block 3 and remove the rectifier unit 5.