ASSEMBLING A PX-5650 PX-5RD REAR HOUSING ASSEMBLY WITHOUT STATOR

Transcription

1 ASSEMBLING A PX-5RD REAR HOUSING ASSEMBLY WITHOUT STATOR

2 ALWAYS WEAR SAFETY GLASSES WHEN IN THE SHOP. DO NOT OPERATE TOOLS OR ASSEMBLE PARTS WITHOUT PROPER SUPERVISION. 1 Start with a bare PX-5 rear housing that already has the six negative diodes installed: PennTex part PX

3 2 3 When installing the PX-2506 brush holder assembly, make sure that the brush retainer pin is in this slot in the housing. 4 NOTICE THE SLOTS IN THE BRUSH HOLDER Note how the white negative diode leads are bent. Install the PX-2506 brush holder assembly as shown. An earlier model white brush holder is not acceptable. 2

4 5 6 Install the PX-1097 brush holder retaining screws, PX-1100 lock washers, and PX-1098 flat washers on each side of the brush holder. Push the brush holder toward the case center so the screws are at the top of the slots. 7 Run the retaining screws down with a 1/4 nut driver. The screws will be torqued later. 3

5 8 9 Installing a PX-4511 capacitor is next. They are not directional and either end can be installed first. Bend one end as shown and put a PX-1096 screw in it. 10 Install the capacitor in this location and align it as shown. Run the retaining screw down with a nut driver. Finish tightening this screw and the two brush holder mount screws with a torque driver. 4

6 PX-1295 BOLT 13 While holding the PX-1295 bolt in the hole with one hand, start the first PX-1196 Keps nut on the bolt. Tighten this nut with a torque driver. 14 Install the PX-1103 flat washer and the second PX-1196 Keps nut on the bolt. Hand tighten the nut to keep it in place during shipping. 5

7 15 Apply industrial grade silicone to the brush holder mount screws and capacitor attaching screw to hold them in place. Let the housing sit for 24 hours if possible to allow the silicone to dry. PX-1070 Black Insulator PX-1071 Red Fiber Washer PX /16 Flat Washer 16 BOTH WASHERS INSTALLED PX-1091 Install the PX-1116 flat washer and PX-1071 red fiber washer on the PX-2544 left positive heat sink stud. Be sure that the PX-1091 white shoulder insulators (arrows) are on the bottom of the heat sink. 6

8 17 Bend all six negative diode leads straight again. Place the PX-2544 left positive heat sink in the rear housing. Go under the blue brush holder wire and be careful not to pinch it. 18 PX-1072 white heat sink insulators Place the white PX-1072 heat sink insulators in the rear housing as shown. 7

9 19 Install the PX-1116 flat washers and the PX-1071 red fiber washers on the PX-2540 right positive heat sink. Insulators are visible Place the PX-2540 right positive heat sink in the rear housing as shown. Look through the mounting holes and confirm that the PX-1072 insulators are still in place. 8

10 PX-1097 Screw PX-1108 Flat Washer PX-1049 Black Insulator 21 Place the 4 screw / flat washer / insulators in the heat sink mounting holes and tighten them loosely with a 1/4 nut driver. 22 Place the black PX-1070 battery post insulators on the PX-5 alternator output studs. Confirm that the shoulder of the insulators are down inside the hole and that they are seated firmly against the case. 9

11 23 Attach the two bottom negative diode leads to the heat sinks as shown. 24 Install the PX-1352 small rectifier strap 10

12 25 Install one PX-1099 Keps nut on the left side of the rectifier strap. No nut will be installed on the right side until the stator is installed. 26 Tighten down the four heat sink retaining screws with a torque driver. 11

13 27 Attach the four remaining negative diode leads and the blue brush holder lead to the heat sink posts as shown. The leads are bent over in the same locations they were bent originally. 28 Install the PX-1351 medium rectifier strap. It may have to be bent slightly to fit properly. It should not touch the rear housing. 12

14 29 Install the PX-1350 large rectifier strap as shown. 30 X X X Install the third PX-1099 Keps nut on the left side of the PX-1350 large rectifier strap. No Keps nuts are installed on the right side. 13

15 31 Tighten the three left side rectifier strap Keps nuts with a torque driver. 32 Finish tightening the three left side rectifier strap Keps nuts with a 1/4 drive inch-pound torque wrench set to 50 inchpounds using a 3/8 socket on a short extension. If the torque wrench won t be used again, return the setting from 50 inchpounds to zero. 14

16 33 Fasten the PX-4511 Capacitor to the right side positive heat sink as shown using a PX-1096 screw. Run the screw down with a 1/4 nut driver. 34 Finish tightening the PX-1096 Capacitor screw with a torque driver. 15

17 35 Tighten the output post jam nuts with a torque wrench set to 200 inchpounds. When finished with the torque wrench, return the setting to zero. 36 PUSH POWER BUTTON TO TURN ON. 37 SET DIAL HERE. Check the diodes in the housing for shorts using this meter. With the black lead on the housing and the red lead touching one post there should be a reading of 700 to 900 ohms. Anything different indicates a problem. Check both posts. 16

18 38 Apply a small bead of industrial grade silicone as shown to help support the capacitor. 39 Apply a bead of industrial grade silicone to the four heat sink retaining screws (one of four shown). DONE 17