SI SERIES GENERATORS 6D1 -7
N O TIC E: The ro to r m ay b e d is to rte d if th e vise is
o v e rtig h te n e d .
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Pulley nut (22).
• Insert a hex head wrench in the end of the rotor
shaft to counteract the force of rotation when
removing the pulley nut.
W asher (23).
Pulley (43).
Fan (44).
Front collar (34).
Rotor (42).
Rear collar (35).
Bearing retainer bolts (24).
Bearing retainer (37).
Bearing (32).
• Support the bearing housing when pressing out
the bearing.
INSPECTION AND REPAIR
Clean
All metal parts except the voltage regulator, rectifier
bridge, stator, rotor and bearing assem blies in a suit
able solvent.
— Wipe or blow the parts dry.
Inspect
Brush holder for damage.
IJ J I Clean
— Brush holder. Make sure the brush pockets are
clean.
— Brushes with a soft dry cloth.
Insulating sleeves on the insulated screws for splits or
wear.
Brushes for wear. If the brushes are worn to one half
or less of their original length, replace them.
Brush leads for broken wires, corrosion or chafing.
Slip ring end bearing for grease. If the grease supply
is used up, replace the bearing. DO NOT relubricate
the bearing.
Slip ring end of the rotor shaft for overheating or scor
ing. If the signs of overheating or scoring are present,
replace the bearing and rotor.
Drive end bearing for roughness, looseness, and seal
condition. If the condition of the bearing is doubtful,
replace it.
W indings for burned insulation. Replace the rotor or
stator if either looks burned.
• Burned insulation appears as a very dark or
blackened wiring. A strong acrid odor will be
apparent.
Terminal connectors for corrosion or breaks.
W indings on the stator for chipped insulation. If the
chipped area is small and the rest of the stator is OK,
repair the stator with insulating varnish.
Slip rings for scoring, wear or pitting.
• If the rings are dirty, clean with a 400 grain, or
finer, polishing cloth.
— Spin the rotor and hold the polishing cloth
against the slip rings until they are clean.
• If scored, worn, or pitted, true the rings in a lathe
to 0.05 mm (0.002-inch).
— Finish with 400 grain or finer polishing
cloth. Blow away all dust.
12. Rotor and stator w indings electrically as described
later under “ Electrical T ests.”
13. Generator housing for cracks, warping, or other dam
age.
ELECTRICAL TESTS
E xcept as stated, m ake the fo llo w in g tests w ith an
ohm meter on the low range scale.
ROTOR FIELD WINDING CHECKS (Figure 10)
The rotor may be checked electrically with a 110-volt test
lamp or an ohm meter.
Open Winding
To check for opens, connect the test lamp or ohm m eter
to each slip ring. If the lamp fails to light, or if the ohm m eter
reading is high (infinite), the winding is open.
Ground Winding
Connect a test lamp or ohm m eter from one slip ring to the
shaft. If the lamp lights, or if the reading is low, the rotor
winding is grounded.
Short Circuit or Resistance Check
The winding is checked for short-circuits or excessive
resistance by connecting a battery and am m eter in series
with the edge of the two slip rings. Note the am m eter read
ing and refer to “ Specifications” at the end of this section.
An amm eter reading above the specified value indicates
shorted windings; a reading below the specified value indi
cates excessive resistance. An alternate m ethod is to
check the resistance of the field by connecting an ohm m e
ter to the two slip rings. If the resistance reading is above
the specified value the winding has excessive resistance.
Note the reading and refer to “ S pecifications” at the end of
this section.
Summary of Contents for 1989 Light Duty Truck
Page 1: ...vr V Light Duty Truck Unit Repair Manual...
Page 2: ......
Page 11: ...GENERAL INFORMATION OA 5 Figure 8 RV Models...
Page 13: ...GENERAL INFORMATION OA 7 Figure 11 ST Models...
Page 18: ......
Page 44: ......
Page 76: ...1B3 18 R 4 AIR CONDITIONING COMPRESSOR N...
Page 114: ......
Page 162: ......
Page 176: ...4B3 14 91 2 INCH RING GEAR...
Page 192: ...4B5 4 DANA REAR AXLES Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...
Page 218: ......
Page 220: ...4B6 2 12 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components...
Page 229: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools...
Page 230: ...4B6 12 12 INCH RING...
Page 240: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 260: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing...
Page 273: ...T TRUCK FRONT AXLE 4C3 3 F 05785 Figure 1 Axle Components...
Page 291: ...K TRUCK FRONT AXLE 4C4 3 Figure 1 Front Axle Com ponents K 15 25 Models...
Page 293: ...K TRUCK FRONT AXLE 4C4 5 Figure 3 Front Axle Com ponents K35 Models...
Page 318: ...C4 30 K TRUCK FBOHT AXLE...
Page 334: ......
Page 361: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components...
Page 363: ...2 5 LITER L4 ENGINE 6A1 7 F 05715 Figure 5 Block and Components...
Page 395: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram...
Page 396: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram...
Page 424: ...6A2 32 2 8 LITER V 6...
Page 427: ...I 4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857...
Page 451: ...4 3 LITER V 6 6A3 27 SPECIFICATIONS ENGINE SPECIFICATIONS F 6344...
Page 457: ...4 8 LITER L6 6A4 3 Figure 2 Lubrication Diagram Front View...
Page 460: ...6A4 6 4 8 LITER L6 C 1 107 112 fK 108 3 109 165 129 B 05056 Figure 5 Block and Components...
Page 490: ...Ml...
Page 493: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines...
Page 494: ...6A5 4 V8 ENGINE Figure 2 Lubrication Diagram 5 0L and 5 7L Engines...
Page 530: ...6A5 40 V8 ENGINE Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components...
Page 571: ...6 2 LITER DIESEL 6A7 35 Figure 58 Vacuum Pump Installed...
Page 576: ......
Page 582: ...6C1 6 MODEL 1MEF CARBURETOR Figure 9 Monojet Model 1MEF...
Page 604: ...6C2 6 MODEL M4MEF CARBURETOR Figure 9 Model M4MEF...
Page 640: ...6C4 8 MODEL 700 THROTTLE BODY...
Page 652: ...nmm...
Page 672: ......
Page 693: ...DISTRIBUTORS 6D5 13 Figure 27 Testing the Pickup Coil Figure 28 Testing the Ignition Coil...
Page 696: ......
Page 698: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts J H 0 0 5 3 7 0 0 R 4 R 2...
Page 745: ...700 R4 AUTOMATIC TRANSMISSION 7A1 49...
Page 762: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts H H 0021 400 R 3...
Page 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0 0 4 3 4 0 0 R 2...
Page 797: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assem bly...
Page 803: ...400 475 AUTOMATIC TRANSMISSION 7A2 43 Figure 104 Bushing Replacement Procedure...
Page 808: ...J c I i sal...
Page 838: ......
Page 840: ......
Page 842: ......
Page 850: ...7B1 12 HM 290 MANUAL TRANSMISSION J i t i a x V L...
Page 856: ...7B1 18 HM 290 MANUAL TRANSMISSION...
Page 892: ...7B1 54 HM 290 MANUAL TRANSMISSION Figure 93 Special Tools...
Page 897: ...HM 117 TRANSMISSION 7B2 5...
Page 901: ...HM 117 TRANSMISSION 7B2 9 B 05180 Figure 17 Installing the 1st and 2nd Synchronizer...
Page 912: ...20 HM...
Page 924: ...7B3 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS...
Page 927: ...BORG WARNER TRANSMISSIONS 7B4 3 Figure 2 77 mm Transmission and Components...
Page 940: ...i ii iii m i in m i...
Page 944: ...7D1 4 TRANSFER CASE FO 5688 Figure 3 NP205 Transfer Case...
Page 952: ...7D1 12 TRANSFER CASE...
Page 963: ...NEW PROCESS 241 TRANSFER CASE 7D2 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes...
Page 964: ...7D2 12 NEW PROCESS 241 TRANSFER CASE Figure 18 NP 241 Transfer Case Cut Away...
Page 978: ......
Page 981: ...BORG WARNER 1370 TRANSFER CASE 7D4 3 J...
Page 992: ...7D4 14 BORG WARNER 1370 TRANSFER CASE Figure 26 Installing the Rear Output Yoke...
Page 993: ...BORG WARNER 1370 TRANSFER CASE 7D4 15 Figure 27 BW 1370 Transfer Case...
Page 997: ......
Page 998: ...X 8937...