﻿GET_GEVOMechL2_09_01_01_48 - ANIMATION Screen
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Describe how to perform running maintenance related to the alternator.

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Every 92 days, the 5GMG203, 5GMG205, and 5GMG206 alternators should be inspected.

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Brushes, brush length, and the surface condition of the collector rings should be checked.

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Brush Inspection

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Ensure that the pigtails are positioned correctly.

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They must be parallel with, but not rubbing against, the pressure arm.

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Ensure that the pigtail terminal bolts are tight.

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Move the brushes up and down several times in the brush holders to release any carbon dust or foreign matter in the carbon ways that could prevent free movement of the brushes.

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Brush Removal

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1. Unlatch the brush pressure spring thumb loop.

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2. Loosen the terminal bolt on the brush holder.

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3. Slide the brush out of the brush holder.

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Brush Installation

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1. Insert each brush into a brush holder so that the contour of the brush or its riding surface matches that of the collector ring.

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2. Position the pigtail terminal under the terminal screw and parallel to the brush pressure arm.

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3. Tighten the terminal screw, and torque it to 6-8 lb.-ft. (8.13-10.85 Nm).

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4. Latch the brush pressure spring thumb loop over the detent in the brush holder body.

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5. Dress the pigtail leads such that the pigtail wires do not interfere with the action of the pressure arm, rub against each other, or rub against adjacent brush holders.

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Brush Holder Inspection

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Check for loose, broken, bent, or overheated pressure arms.

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Overheating will cause the arms to discolor and result in improper brush arm pressure.

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Annually verify brush arm force.

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If it is below 4.25-4.75 lbs. (1.93-2.15 kg), replace the brush holder.

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Ensure that the thumb loop on the coiled brush pressure spring is in position with the spring end placed into the detent.

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Inspect the brush holder mounting arrangement, and ensure the clamp pads are in place and tight against the brush holder stud.

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If they are not in place, locate the clamp pads and torque the clamp bolts.

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Check the brush holder-to-collector ring clearance.

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If the clearance is not between 0.089 and 0.091 inches (2.2-2.3 mm), adjust the clearance as discussed in the Brush Holder and Stud Assembly Alignment section of this module.

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Inspect the brush holder assembly for broken connection straps or bus rings.

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Replace, if necessary, as discussed in the Brush Holder and Stud Assembly Removal and the Brush Holder and Stud Assembly Installation sections of this module.

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Check by hand the tightness of the bus ring to the brush holder bolts.

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If loose, torque the bolts.

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Brush Holder Stud Inspection

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Wipe the brush holder studs clean.

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Inspect the brush holder stud for cracked, discolored, or worn insulation.

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Replace the complete stud if insulation is found to be faulty.

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If brush holders are found to be loose or are moveable by hand, inspect the stud for discoloration and wear.

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Replace the stud, if damaged.

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If there is no damage, reinstall the stud as discussed in the Brush Holder and Stud Assembly Installation section of this module.

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Brush Holder and Stud Assembly Maintenance

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If a single brush holder or a brush holder stud needs to be replaced, remove the entire brush holder and stud assembly from the alternator, replace the faulty component, and return the whole assembly to the alternator.

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1. With the brush holder/collector ring cover removed, blow out the compartment with clean, dry and compressed air.

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2. Wipe off the insulation between the collector rings and the collector ring studs with a clean, dry rag.

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3. Using an appropriate solvent, wipe away any residue from the brush holders with a clean, dry and lint-free cloth.
