CYLINDER GP-SHEAR 2405484 - Caterpillar

Apply a cloth to the rotor and set it in a vise.
Remove the pulley nut and then pull out the pulley and spacer.
Remove the rotor from the front bracket.Removing statorNote: Unsoldering must be finished as quickly as possible. Extended heating will damage the diodes.
Illustration 25 g02241277
(47) Rectifier (48) Soldering
Cut off the joint of the stator and remove the stator from the rectifier.
Unscrew the rectifier mounting screws, and dismount the rectifier.Inspecting rectifier
Illustration 26 g02241278
Check that diodes in a rectifier function properly. To check, measure both negative (-) and positive (+) resistance alternately twice. If both infinite negative and infinite positive resistances are observed, the diode is open circuited. If measured value is close to 0Ω, the diode is short-circuited. In either case, replace the rectifier with a new one.Note: Use a wide measuring range as much as possible. The current flow during test is much lower than the current that normally flows in the rectifier, by which the accurate resistance may not be measured using a tester. This tendency is noticeable if the measuring range is small.Inspecting rotor
Illustration 27 g02241279
Check that there is continuity between slip rings. If no continuity is observed, replace the rotor with a new one.
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Check that there is no continuity between the slip ring and the shaft (or the core). If continuity is observed, replace the rotor with a new one.Inspecting stator
Illustration 29 g02241281
Checking continuity between lead wires Check that there is continuity between a pair of lead wires. Also check that there is no continuity between a pair of lead wires and other pair of lead wires. If defective, replace the stator.
Illustration 30 g02241282
Checking insulation between lead wire and core Check that there is no continuity between each lead wire and the stator core. If continuity is observed, replace the stator.Note: The core cannot be replaced as a single item.Inspecting brushes for wear
Illustration 31 g02241283
(49) Wear limit lineMeasure the length of the brushes. If the measured value is less than the limit, replace both the brush holder assembly and the brush assembly with new ones.
Table 9
Item     Standard     Limit    
Brush length    
18.50 mm (0.728 inch)    
5.00 mm (0.197 inch)    Replacing brushes
Illustration 32 g02241284
(48) Soldering
To remove the brush and the spring, unsolder the brush lead.
Illustration 33 g02241285
To install a new brush, push the brush into the brush holder as shown in the Illustration, and then solder the lead to the brush.Reassembling alternator
Illustration 34 g02241286
(50) Wire (51) Rear bracket (52) BrushAssemble the alternator in reverse order of disassembly. Key assembly steps follow
Locate the eccentric groove on the periphery of the rear bearing. Insert the rotation retaining snap ring so that the highest protruded section of the ring is positioned at the deepest section of the groove.
When replacing the rear bearing, press-fit the rear bearing so that the groove on the periphery of the bearing faces the snap ring side.
When press-fitting the rear bearing into the rear bracket, heat the rear bracket to 50 to 60 °C (122 to 108 °F) first.
Before installing the rotor to the rear