Overhaul

Generator:

DISASSEMBLY




1. REMOVE GENERATOR PULLEY
SST 09820-63011 (09820-06010), 09820-06021




a. Tighten SST 1-B to the specified torque, and then fix SST 1-A on the generator rotor shaft.
Torque:39 N.m (400 kgf.cm, 29 ft.lbf)

NOTE: Securely fix SST on the generator rotor shaft.




b. Clamp SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, and then fix the generator pulley nut into SST 2.




d. Turn SST 1-A in the direction shown, and then loosen the generator pulley nut.

NOTE: If the generator pulley nut is turned by more than a half turn, the generator rotor shaft may be damaged.

e. Remove the generator from SST 2.




f. Fix SST 1-B, and then loosen SST 1-A in the direction shown. Remove SST 1-A and B from the generator.




g. Remove the generator pulley nut and generator pulley.




2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Place the generator on the generator pulley.
b. Remove the 3 nuts and generator rear end cover.




c. Remove the terminal insulator.




d. Remove the 2 screws and generator brush holder.




3. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the bolt and cord clip.




b. Remove the 4 bolts.




c. Using SST, remove the generator drive end frame.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010)




d. Remove the generator rotor from the generator rectifier end frame.




e. Remove the washer from the generator rectifier end frame.

REASSEMBLY




1. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator pulley.
b. Install the washer onto the generator rectifier end frame.




c. Install the generator rotor onto the generator rectifier end frame.




d. Using a 32 mm socket wrench and press, slowly push the generator drive end frame on to the generator rectifier end frame.




e. Tighten the 4 bolts.
Torque:5.8 N.m (60 kgf.cm, 51 in.lbf)




f. Install the cord clip with the bolt.
Torque:4.56 N.m (45 kgf.cm, 40 in.lbf)




2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.




b. Install the generator brush holder with the 2 screws.
Torque:1.76 N.m (15 kgf.cm, 16 in.lbf)

c. Pull the 1.0 mm (0.039 in.) pin out of the generator brush holder.




d. Install the terminal insulator onto the generator rectifier end frame.




e. Install the generator rear end cover with the 3 nuts.
Torque:4.6 N.m (45 kgf.cm, 41 in.lbf)




3. REMOVE GENERATOR PULLEY
SST 09820-63011 (09820-06010), 09820-06021

a. Install the generator pulley onto the generator rotor shaft, and then temporarily tighten the generator pulley nut by hand.







b. Tighten SST 1-B to the specified torque, and then fix SST 1-A on the generator rotor shaft.
Torque:39 N.m (400 kgf.cm, 29 ft.lbf)

NOTE: Securely fix SST on the generator rotor shaft.




c. Clamp SST 2 in a vise.
d. Insert SST 1-A and B into SST 2, and then fix the generator pulley nut into SST 2.




e. Turn SST 1-A in the direction shown, and then loosen the generator pulley nut.
Torque:110.3 N.m (1,125 kgf.cm, 82 ft.lbf)

f. Remove the generator from SST 2.




g. Fix SST 1-B, then loosen SST 1-A in the direction shown. Remove SST 1-A and B from the generator.
h. Turn the generator pulley, and then check that the generator pulley moves smoothly.