Assembly Procedure

ASSEMBLY PROCEDURE



1. Install the inside collar into the rotor.
2. Install the rotor into the drive end frame.

NOTE: Refer to Fastener Notice in Cautions and Notices.

3. Install the following components onto the rotor shaft:
- The outside collar
- The fan
- The fan collar
- The pulley
- The washer
- The generator shaft nut

Tighten
Tighten the generator shaft nut to 100 N.m (74 lb ft).




4. Install the bearing into the slip ring end frame from the outside, until the bearing is flush with the outside shoulder of the slip ring end frame. Use tooling to make sure that force is applied to the outer bearing race only.

IMPORTANT: In order to ensure proper operation of the unit, install the slip ring end frame components in the correct order.




5. Install the rectifier bridge.

IMPORTANT: Install the capacitor with the insulator material resting against the drive end frame.

6. Install the capacitor.

IMPORTANT: Make sure that the insulated bolt, located at the capacitor/rectifier bridge, attaches the capacitor strap and the rectifier bridge to the slip ring end frame. Make sure that the metal side of the capacitor strap is against the regulator connection.

7. Install the bolts.

Tighten
Tighten the bolts to 2.5 N.m (22 lb in).




8. Install the brushes into the brush holder with the retaining pin.

NOTE: Avoid excessive heat during the soldering and unsoldering procedures. Excessive heat will damage the voltage regulator.

9. Install the connector strap and the brush holder onto the regulator. Make sure the solder clips fit snugly. Solder the clips in place.
10. Install the dust shield onto the brush holder.




11. Install the voltage regulator, the brush holder, the dust shield, and the connector strap assembly into the slip ring end frame as one unit.
12. Tap the plastic retaining pin on the dust shield into the retaining clip until flush with the outside of the housing. Make sure that the brush retaining pin goes through the access hole to the outside of the slip ring end frame for removal after the generator is assembled.
13. Install the insulated regulator bolt.

Tighten
Tighten the insulated regulator bolt to 2.5 N.m (22 lb in).

14. Install the brush holder bolt.

Tighten
Tighten the brush holder bolt to 2.5 N.m (22 lb in).




15. Place the stator terminals over the rectifier bridge terminals in order to assemble the stator.
16. Install the stator lead nuts.

Tighten
Tighten the stator lead nuts to 2.5 N.m (22 lb in).




17. Assemble the slip ring (2) and drive end (1) frames. Note the scribe marks (3).
18. Install the through bolts.

Tighten
Tighten the through bolts to 8 N.m (71 lb in).

19. Remove the retaining pin in order to release the brushes against the slip rings.