SkyTrak 6036 Service Manual - Manual (Page 222)

Section 10. Electrical System
10-28 Model 6036 S/N 9B0499 and Before
frame with a hollow cylinder to prevent breakage of
the end frame. Be extremely careful to avoid
misalignment or otherwise placing undue stress on
the bearing.
If the seal is separate from the bearing, it is
recommended that a new seal be installed when-
ever the bearing is replaced. Press the seal in with
the lip of the seal toward the rotor when assembled,
that is, away from the bearing. Lightly coat the
seal lip with oil to facilitate assembly of the shaft
into the bearing.
l. Alternator Reassembly
Reassembly is the reverse of disassembly.
1. Place the rotor in a vise, position the drive end
frame on the rotor, and install shaft nut (18,
Fig. 10.28).
2. Remove protective tapes which were applied
during alternator disassembly, refer to para-
graph d. To install the slip ring end frame
assembly to the rotor and drive end frame
assembly, remove the tape over the bearing
and shaft, and make sure the shaft is perfectly
clean after removing the tape.
3. Insert a pin through the holes to hold up the
brushes.
4. Carefully install the shaft into the slip ring end
frame assembly to avoid damage to the seal.
5. Join the halves of the alternator by installing
the four thru bolts and nuts.
6. After tightening the thru-bolts remove the brush
retaining pin to allow the brushes to fall down
onto the slip rings.
7. Remember when assembling the pulley to
secure the rotor in a vise only tight enough to
permit tightening the shaft nut to 40-60 lb- ft
(54-81 N m). If excessive pressure is applied
against the rotor, the assembly may become
distorted.
m. Alternator Bench Check
To check the alternator in a test stand, proceed as
follows:
1. Make connections as shown in Fig. 10.36,
except leave the carbon pile battery tester
disconnected.
IMPORTANT: Ground polarity of battery and
alternator must be the same. Use a fully charged
battery, and a 10 ohm resistor rated at six watts or
more between the alternator No. 1 terminal and the
battery.
2. Slowly increase the alternator speed and
observe the voltage.
3. If voltage is uncontrolled with speed and
increases above 15.5 volts on a 12-volt
system, test regulator with an approved
regulator tester, and check field winding.
NOTE: The battery must be fully charged when
making this check.
4. If voltage is below 15.5 volts on a 12-volt
system, connect the carbon pile as shown.
5. Operate the alternator at moderate speed as
required and adjust the carbon pile as required
to obtain maximum current output.
6. If output is within 10 amperes of rated output
as stamped on the alternator frame, alternator
is good.
7. If output is not within 10 amperes of rated
output, keep battery loaded with carbon pile,
and ground alternator field, Fig. 10.27.
8. Operate alternator at moderate speed and
adjust carbon pile as required to obtain maxi-
mum output.
9. If output is within 10 amperes of rated output,
test regulator with an approved regulator tester,
and check field winding.
10. If output is not within 10 amperes of rated
output, check the field winding, diode trio,
rectifier bridge, and stator as previously
covered.
n. Alternator Installation
1. If necessary, install pulley (21, Fig. 10.28), belt
(20), washer (19), and hex nut (18).
2. If necessary, install stud (17), bracket (16),
washers (15) and washers (14).
3. Position alternator (22) on the engine and
install sleeve (12), sleeve (11), screw (10),
washer (9), self-locking nut (8).
4. Install spacer (7), lever (6), lock washer (5),
and screw (4).
5. Install washer (3), lock washer (2) and screw
(1).
6. Connect negative (–) cable (2, Fig. 10.38) to
batteries.