HEAVY DUTY ALTERNATORS
12. Insert outer brush and spring assembly into the
housing and compress the brush spring, using a
small screwdriver or similar tool. While holding the
spring compressed, insert a pin through the hole in
the rear of the housing so that the spring will be held
in a compressed position. (A suitable pin can be
made from a piece of 1.6 mm [1/16"] drill rod.) Install
and compress the remaining brush and spring
assembly in a similar manner. Hold the spring in a
compressed position by pushing the pin farther into
the housing (See Figure 24).
Figure 24 - Using Pin to Hold Brush
13. Position regulator above regulator holder and install
RED lead to LEFT regulator terminal with lockwasher
and nut. Install the BLACK lead to RIGHT regulator
Attach blue regulator lead to "IGN." terminal screw
by placing the spade terminal under the head of the
screw. Tighten nut on terminal screw (See Figure
6). Install regulator.
Be sure that the red and black leads are properly
routed through their slots in the regulator housing.
Install four regulator screws. Withdraw brush
retaining pin before tightening these screws.
14. Install spacer, key, fan, pulley and nut. Torque nut to
95-108 N-m (70-80 ft. lbs.). Due to the design of the
alternator, a certain amount of shaft end play will be
present in new or rebuilt units. This end play is
designed into the unit and will vary between 0.1 to
0.3 mm (.004-.012 inch).
CAUTION - DO NOT FORCE OR POUND PULLEY
Because of the integral regulator used on this alternator,
the test bench hookup is very simple, consisting of
connecting the positive and negative output leads. If a
commercial test bench is not available, the test setup
shown in Figure 25 may be used.
Figure 25 - Bench Test Wiring Diagram.
CTS-4043A - Chapter II - Page 11