HEAVY DUTY ALTERNATORS12. Insert outer brush and spring assembly into thehousing and compress the brush spring, using asmall screwdriver or similar tool. While holding thespring compressed, insert a pin through the hole inthe rear of the housing so that the spring will be heldin a compressed position. (A suitable pin can bemade from a piece of 1.6 mm [1/16"] drill rod.) Installand compress the remaining brush and springassembly in a similar manner. Hold the spring in acompressed position by pushing the pin farther intothe housing (See Figure 24).Figure 24 - Using Pin to Hold BrushSprings Depressed.13. Position regulator above regulator holder and installRED lead to LEFT regulator terminal with lockwasherand nut. Install the BLACK lead to RIGHT regulatorterminal.Attach blue regulator lead to "IGN." terminal screwby placing the spade terminal under the head of thescrew. Tighten nut on terminal screw (See Figure6). Install regulator.Be sure that the red and black leads are properlyrouted through their slots in the regulator housing.Install four regulator screws. Withdraw brushretaining pin before tightening these screws.14. Install spacer, key, fan, pulley and nut. Torque nut to95-108 N-m (70-80 ft. lbs.). Due to the design of thealternator, a certain amount of shaft end play will bepresent in new or rebuilt units. This end play isdesigned into the unit and will vary between 0.1 to0.3 mm (.004-.012 inch).CAUTION - DO NOT FORCE OR POUND PULLEYON SHAFT.TESTINGBecause of the integral regulator used on this alternator,the test bench hookup is very simple, consisting ofconnecting the positive and negative output leads. If acommercial test bench is not available, the test setupshown in Figure 25 may be used.Figure 25 - Bench Test Wiring Diagram.CTS-4043A - Chapter II - Page 11
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