Generator Mitsubishi
Pic. 12.1. Generator Mitsubishi
1. Remove the generator as described above.
2. Unscrew the pulley nut, remove the spring washer, pulley and metal shield.
3. Mark the location of the front and rear covers and the stator relative to each other.
4. Unscrew the coupling bolts, remove the front cover from the rotor axis, then the metal shield and gasket.
5. Remove the rotor from the back cover and stator.
6. Remove the cover, unscrew the lock nut securing the extended clamp «IN» to the back cover, remove the clamp. From inside the back cover and stator assembly, remove the three screws and remove the back cover from the stator. Remove the plastic shield.
7. Now you can check the length of the brushes. The wear limit line on each brush corresponds to the minimum brush length given in the Specifications (Pic. 12.2).
Pic. 12.2. Generator brush wear limit marks
8. If the brushes require replacement, remove the insulator. Solder the wires, try not to overheat the brushes. Replace the brush springs along with the brushes.
9. Solder the wires at the wear marks 2 mm from the holder.
10. Wipe the generator rings with alcohol; if they are very dirty, use fine sandpaper.
11. Assembly is carried out in reverse order.
Generator Lucas/Magneti
Pic. 12.3. Generator Lucas/Magneti Marelli: 1. Smoothing capacitor; 2. Voltage regulator/brush holder assembly; 3. Slip ring; 4. Bearing; 5. Rectifier assembly; 6. Insulating washer; 7. Main output contact and insulating washer; 8. Generator rings; 9. Rotor; 10. Stator; 11. Tightening bolts; 12. Drive side suspension; 13. Gaskets; 14. Drive side bearing; 15. Pulley nut and gaskets.
Marelli
12. Brushes and voltage regulator can be replaced without removing the generator from the engine. Always disconnect the negative battery cable before working.
13. Remove the three small screws securing the regulator and brush holder assembly to the rear of the generator.
14. Lift the assembly. Disconnect the electrical wiring clamp, remove the regulator and brush holder from the generator.
15. Measure the length of the brushes coming out of the brush holder, replace the brush holder and regulator assembly if the brushes are worn or have a length less than specified in Specifications.
16. Clean the generator rings.
17. Install the brush holder and regulator assembly and tighten it with three screws. If the alternator is on the vehicle, connect the negative battery cable.