Fig. 7-11. Removing the generator protective cover:
1 - casing mounting screw; 2 - insulating bushings; 3 - air intake; 4 - protective cover; 5 - Generator terminal "30" extension; 6 - wire of the generator output "61"; 7 - generator.
Lock the alternator pulley with the grip included in the 67.7823.9504 tool kit, unscrew the pulley mounting nut and press the pulley with a puller. Remove the pulley key and conical washer.
The 67.7823.9504 tool kit includes a standard puller and a grip. The latter consists of two steel half rings that are inserted into the pulley groove. The half rings have the same cross-section as the generator drive belt. On one side, they are connected by a hinge, and on the other, they are equipped with levers that are squeezed with one hand when removing the pulley.
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Disconnect the wire from the "B" plug of the voltage regulator. Disconnect the wires of the regulator and capacitor from the "30" terminal of the generator, unscrew the screws securing the voltage regulator 1 (Fig. 7-12) and remove it. For generators manufactured before 1996, in order not to break the brushes when removing the brush holder, insert a screwdriver blade between the body of the regulator 2 and the brush holder and partially pull the regulator out of the generator, leaving the brush holder in place. Then tilt and remove the regulator together with the brush holder from the generator. Remove the capacitor 20 by unscrewing the fastening screw.
Fig. 7-12. Generator parts:
1 - voltage regulator assembly with brush holder for generators produced since 1996.; 2 - voltage regulator and brush holder for generators produced before 1996.; 3 - additional diode output block; 4 - insulating bushings; 5 - rectifier block; 6 - contact bolt; 7 - stator; 8 - rotor; 9 - spacer sleeve; 10 - inner bearing mounting washer; 11 - drive side cover; 12 - pulley; 13 - outer bearing mounting washer; 14 - tension bolt; 15 - Front rotor ball bearing; 16 - bushing; 17 - cover from the contact ring side; 18 - buffer bushing; 19 - pressure sleeve; 20 - capacitor.
Loosen the nuts of the tie bolts 14 and remove the generator cover 11 and rotor 8. Loosen the nuts of the bolts connecting the valve tips to the stator winding terminals and remove the stator 7 from the generator cover 17.
Unscrew the nut of the contact bolt 6, disconnect the plug of the additional diode wire from the block 3 and remove the rectifier block 5.