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Alternator & Regulator: Overhaul: Reassembly

  1. Position "BAT" terminal stud in end frame with molded plastic insulator outside and fiber insulator inside. Place rectifier bridge in end frame and secure it with a nut and washer at one end and a screw and washer at other. Install capacitor to end frame and heat sink.
  2. Position regulator in rectifier end frame. Install indicator lamp resistor and brush holder over regulator and install screws securing regulator. Place diode trio on rectifier bridge and attach it to regulator with an insulated screw.
  3. Place stator on end frame, with leads over rectifier bridge studs. Secure with nuts. Install brush springs and brushes in holder. Insert a straight wire or pin through hole in end frame and holes in bottom of brush holder.
    NOTE: This will hold brushes in place until rotor is assembled into frame.
  4. Place rotor in a vise with drive end up. DO NOT  overtighten vise. Install end frame, fan, pulley, and washer over rotor shaft and secure with a nut. Tighten nut to 40-60 ft. lbs. (54-81 N.m). Install rotor to rectifier end frame, aligning scribe marks. Remove wire holding brushes. Install 4 through bolts through end frames and tighten.
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