Disassembly and Reassembly

OVERHAUL







1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)

a. Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque.

Torque: 39 Nm (400 kgf.cm, 29 ft.lbf)

NOTE: Check that SST is secured to the rotor shaft.




b. Clamp SST 2.in a vise.
c. Insert SST (1-A, B) into SST (2), and attach the pulley nut to SST (2).




d. To loosen the pulley nut, turn SST (1-A) in the direction shown in the illustration.

NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn.

e. Remove the generator from SST (2).




f. Turn SST (1-B) and remove SST (1-A, B).
g. Remove the pulley nut and generator pulley.




2. REMOVE GENERATOR REAR END COVER
a. Place the generator on the generator pulley.
b. Remove the 3 nuts and generator rear end cover.




3. REMOVE TERMINAL INSULATOR
a. Remove the terminal insulator from the generator rectifier end frame.




4. REMOVE GENERATOR BRUSH HOLDER ASSY
a. Remove the 2 screws and generator brush holder.




5. REMOVE GENERATOR RECTIFIER END FRAME
a. Remove the 4 bolts.




b. Using SST, remove the generator rectifier end frame.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)




6. REMOVE GENERATOR ROTOR ASSY
a. Remove the generator washer and generator rotor.




7. INSPECT GENERATOR BRUSH HOLDER ASSY
a. Check the brush length.
1. Using a vernier caliper, measure the exposed brush length.
Specified brush length:
4.5 to 10.5 mm (0.177 to 0.413 in.)
If the exposed brush length is less than the minimum, replace the brush holder assy.




8. INSPECT GENERATOR ROTOR ASSY
a. Check that the bearing is not rough or worn. If necessary, replace the rotor assy.




b. Check if the rotor has an open circuit.
1. Measure the resistance between the slip ring.
Standard: 2.3 to 2.7 ohm at 20 °C (68 °F)
If the result is not as specified, replace the rotor assy.




c. Check if the rotor is grounded.
1. Measure the resistance between the slip ring and the rotor core.
Standard: 10 kohm or higher
If the result is not as specified, replace the generator rotor.

d. Inspect slip rings.
1. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor assy.




e. Check the slip ring diameter.
1. Using a vernier caliper, measure the slip ring diameter.
Specified diameter:
14.0 to 14.4 mm (0.551 to 0.567 in.)
If the diameter is less than minimum, replace the rotor assy.




9. INSPECT GENERATOR DRIVE END FRAME BEARING
a. Check that the bearing is not rough or worn.
If necessary, replace the bearing.




10. REMOVE GENERATOR DRIVE END FRAME BEARING
a. Remove the 4 screws and retainer.




b. Using SST, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)




11. INSTALL GENERATOR DRIVE END FRAME BEARING
a. Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)




b. Install the retainer with the 4 screws.

Torque: 2.3 Nm (23 kgf.cm, 20 in.lbf)




12. INSTALL GENERATOR ROTOR ASSY
a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor and generator washer.




13. INSTALL GENERATOR RECTIFIER END FRAME
a. Using a 21 mm deep socket wrench and a press, press in the generator rectifier end frame carefully.




b. Install the 4 bolts.

Torque: 5.8 Nm (59 kgf.cm, 51 in.lbf)




14. INSTALL GENERATOR BRUSH HOLDER ASSY
a. While pushing the 2 brushes into the brush holder, insert a pin (1.0 mm (0.039 in.)) into the brush holder hole.




b. Install the generator brush holder with the 2 screws.

Torque: 1.8 Nm (18 kgf.cm, 16 in.lbf)

c. Pull out the pin from the generator brush holder.




15. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator to the generator rectifier end frame.

NOTE: Pay attention to the mounting orientation of the terminal insulator.




16. INSTALL GENERATOR REAR END COVER
a. Install the end cover with the 3 nuts.

Torque: 4.6 Nm (47 kgf.cm, 41 in.lbf)







17. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)

a. Install the generator pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque.

Torque: 39 Nm (400 kgf.cm, 29 ft.lbf)

NOTE: Check that SST is secured to the rotor shaft.




c. Clamp SST 2 in a vise.
d. Insert SST (1-A, B) into SST (2), and attach the pulley nut to SST (2)




e. Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration.

Torque: 110 Nm (1,122 kgf.cm, 81 ft.lbf)

f. Remove the generator from SST (2).




g. Turn SST (1-B), and remove SST (1-A, B).
h. Turn the generator pulley and check that the generator pulley moves smoothly.