Alternator & Regulator: Overhaul Chevrolet Pickup K1500

OVERHAUL

Note. CS130 is not serviceable. Replacement is required.

Scheme 6

1. Clamp mounting flange of alternator in vise. Mark slip ring end frame and drive end frame for reassembly reference. (Scheme 6) Remove 4 through bolts. Separate rotor and drive end frame assembly from slip ring end frame.
2. Secure, but DO NOT overtighten, rotor and drive end frame assembly in vise. Remove pulley nut and washer from rotor shaft. Remove pulley, fan collar, fan and outside collar from rotor shaft. Remove drive end frame and inside collar from rotor shaft. Remove three screws and retainer from drive end frame.
3. Press front bearing from drive end frame. Using Bearing Remover (J-28509-A), remove rear bearing from rotor shaft. (Scheme 7) Remove 3 stator lead nuts and remove stator. Remove one screw from brush holder and 2 screws from regulator connector. Remove brush holder, regulator and regulator connector as an assembly from slip ring end frame. NOTE: If brush holder, regulator or regulator connector is faulty, components must be unsoldered from each other using as little heat as possible to prevent damage to regulator. (Scheme 8)
4. Remove BAT terminal nut from insulated heat sink. Remove 2 screws and washers from grounded heat sink. Remove capacitor and rectifier bridge from slip ring end frame. Remove BAT terminal from outside of slip ring end frame.

Scheme 7

Scheme 8

Reassembly (CS144)

1. Install BAT terminal onto outside of slip ring end frame. Install rectifier bridge and capacitor into slip ring end frame, ensuring insulated side of capacitor is against frame. Install 2 screws and washers through grounded heat sink. Install BAT terminal nut with flat side down to insulated heat sink. NOTE: A design change in brush holder and slip ring end frame prevents early design brush holders from being installed in later design slip ring end frames. To modify brush holder, remove two locators from brush holder and file jagged edges down to level of surrounding material ensuring loose particles are kept out of brush slots.
2. Assemble brush holder, regulator and regulator connector together, crimping connections of components. (Scheme 8) Solder connections using very little heat to avoid damage to regulator. Install brush holder, regulator and regulator connector assembly into slip ring end frame, ensuring regulator connection rests against metal side of capacitor strap.
3. Install one screw into brush holder and 2 screws into regulator connector. Install brushes into brush holder. Retract brushes in brush holder and retain with pin or toothpick, ensuring pin or toothpick extends through slip ring end frame for later removal.
4. Install stator into slip ring end frame. Position 3 stator leads to 3 rectifier bridge terminals. Install and tighten 3 stator lead nuts. Install front bearing into drive end frame by pressing against outer race. Install retainer onto drive end frame using 3 screws.
5. Install NEW rear bearing onto rotor, pressing against inner race until stop is reached. Install rotor into drive end frame sliding rotor shaft through inside collar and drive end frame. Install outside collar, fan and fan collar onto rotor shaft. Install pulley, washer and pulley nut onto rotor shaft. Tighten pulley nut to 75 ft. lbs. (100 N.m).
6. Assemble rotor and drive end frame assembly to slip ring end frame matching marks made during disassembly and carefully guiding rear bearing into slip ring end frame. Install and tighten 4 through bolts. Remove pin or toothpick retaining retracted brushes through slip ring end frame, enabling brushes to contact slip rings.