Overhaul
DISASSEMBLY1. REMOVE GENERATOR PULLEY
a. Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque.
SST 09820-63010 (09820-06010, 09820-06020)
Torque: 39 N.m (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 ASSEMBLY
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 ASSEMBLY
a. Remove the generator washer and generator rotor.
7. 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)
REASSEMBLY
1. 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 N.m (23 kgf.cm, 20 in.lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor and generator washer.
3. 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 N.m (59 kgf.cm, 51 in.lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes into the brush holder, insert a pin (Dia 1.0 mm (0.039 in.)) into the brush holder hole.
b. Install the generator brush holder with the 2 screws.
Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
c. Pull out the pin from the generator brush holder.
5. 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.
6. INSTALL GENERATOR REAR END COVER
a. Install the end cover with the 3 nuts.
Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
7. INSTALL GENERATOR PULLEY
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.
SST 09820-63010 (09820-06010, 09820-06020)
Torque: 39 N.m (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 N.m (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.