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ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)
TROUBLESHOOTING AND REPAIR
F-73 F-73
CLASSIC® 300D & 300G
FIGURE F.11 - DRILL SPOT LOCATIONS
BRUSH HOLDER
DRILL SPOT
LOCATION
STATOR/END BRACKET
MOUNTING BOLT
STATOR END BRACKET
DRILL SPOT
16. With the 5/8" wrench, remove the four
bolts mounting the stator/end bracket
assembly to the generator frame. Note
the "drill spot" for reassembly. See Figure
F.11.
17. With the 7/16" wrench, loosen (do not
remove) the generator brush holder
clamping bolt. Note the drill spot for
reassembly. See Figure F.11.
18. Carefully pry the stator/end bracket
assembly away from the generator frame.
NOTE: The generator brush holder assembly
will also be removed.
Replacement
19. Mount the stator/end bracket assembly to
the generator frame. Line up the mating
parts at the stator end bracket drill spot.
Tighten the four mounting bolts with the
5/8" wrench.
20. Check armature air gap. Minimum gap is
.035." Loosen the four mounting bolts;
adjust and re-tighten if necessary.
21. Tighten the generator brush holder
assembly with the 7/16" wrench. Note
brush holder drill spot.
22. Connect the four heavy cables from the
generator frame coils to the generator
brush holders.
23. Install the eight commutator brushes
according to how you marked their posi-
tions at disassembly.
24. Attach the black lead to the positive termi-
nal of the field rectifier bridge. Attach the
red lead to the negative terminal.
25. Attach the white auxiliary power lead to
the 115 VAC receptacle. Attach the red
auxiliary power lead to the CB4 circuit
breaker. Attach the black auxiliary power
lead to the current transformer. Tape the
bolted connection.
26. Connect the two yellow leads to the field
bridge and to the field fuse holder.
Connect the white and yellow wires at the
in-line connectors.
27. Install the commutator wraparound, the
bottom alternator cover, the battery, and
the alternator brush holder assembly.
28. Install the alternator rotor according to the
reassembly directions in the Alternator
Rotor Removal and Replacement pro-
cedure. Before installing the case top and
sides, replace any cable ties cut for disas-
sembly.
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