Disassembly and Inspection

DISASSEMBLY




1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the screw, 3 nuts, plate terminal and end cover.




2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
a. Remove the brush holder cover from the brush holder.
b. Remove the 5 screws, brush holder and voltage regulator.




3. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.
c. Remove the seal plate.

4. REMOVE PULLEY




a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63010
Torque: 39 Nm (400 kg.cm, 29 ft.lb)
b. Check that SST (A) is secured to the rotor shaft.




c. Mount SST (C) in a vise.
d. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).




e. To loosen the pulley nut, turn SST (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 of a turn.

f. Remove the generator from SST (C).




g. Turn SST (B), and remove SST (A and B).
h. Remove the pulley nut and pulley.

5. REMOVE RECTIFIER END FRAME




a. Remove the 4 nuts and cord clip.




b. Using SST, remove the rectifier end frame.
SST 09286-46011
c. Remove the generator washer.

6. REMOVE ROTOR FROM DRIVE END FRAME

INSPECTION
Rotor




1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance:
2.1 - 2.5 Ohms at 20° C (68° F)
If there is no continuity, replace the rotor.




2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
If there is continuity, replace the rotor.




3. INSPECT SLIP RINGS
a. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor.
b. Using a vernier caliper, measure the slip ring diameter.
Standard diameter:
14.2 - 14.4 mm (0.55-0.567 in.)
Minimum diameter:
12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.

Stator (Drive End Frame)




1. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the coil leads.
If there is no continuity, replace the drive end frame assembly.




2. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.

Brushes

INSPECT EXPOSED BRUSH LENGTH
Using a vernier caliper, measure the exposed brush length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes and brush holder assembly.

Rectifiers (Rectifier Holder)




1. INSPECT POSITIVE RECTIFIER
a. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
b. Reverse the polarity of the tester probes and repeat step (a).
c. Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.




2. INSPECT NEGATIVE RECTIFIER
a. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
b. Reverse the polarity of the tester probes and repeat step (a).
c. Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.