Overhaul
DISASSEMBLY
1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Install SST1-A to the pulley shaft.
b. Install SST1-B to SST1-A.
c. Hold SST1-A on the pulley shaft area, and tighten SST1-B to the specified torque.
Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Securely fix SST1-A to the pulley shaft.
HINT: Read SST1-B tightening torque by using the reactive torque of SST1-A.
d. Mount 2 faces of SST2 in a vise.
e. With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
f. To loosen the pulley nut, rotate SST1-A in the generator's normal rotation direction.
NOTE: With SST2 (pulley nut) fixed in place, the pulley lock nut will loosen due to the rotation of SST1-A in the normal direction.
g. Remove the generator from SST2.
h. Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.
i. Remove the pulley lock nut and generator pulley.
2. REMOVE GENERATOR REAR END COVER
a. Remove the 3 nuts and generator rear end cover from the generator coil.
3. REMOVE GENERATOR TERMINAL INSULATOR
a. Remove the generator terminal insulator from the generator coil.
4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the 2 screws and generator brush holder from the generator coil.
5. REMOVE GENERATOR COIL ASSEMBLY
a. Remove the 4 through bolts.
b. Using SST, remove the generator coil.
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.
b. Remove the generator rotor assembly from the drive end frame.
7. REMOVE GENERATOR ROTOR BEARING
a. Remove the 4 screws, and remove the retainer from the drive end frame.
b. Using SST and a hammer, remove the generator rotor bearing from the drive end frame.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07100)
REASSEMBLY
1. INSTALL GENERATOR ROTOR BEARING
a. Using SST and a press, press a new generator rotor bearing into the drive end frame.
SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)
b. Align the protrusions of the retainer with the drive end frame's cutouts, and then install the retainer with the 4 screws.
Torque: 3.0 N.m (30 kgf.cm, 27 in.lbf)
2. INSTALL GENERATOR ROTOR ASSEMBLY
a. Install the generator rotor assembly.
b. Install the generator washer.
3. INSTALL GENERATOR COIL ASSEMBLY
a. Using SST and a press, press the generator coil into the drive end frame.
SST 09612-70100
b. Tighten the 4 through bolts.
Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Insert a pin (diameter 1.0 mm) into the generator brush holder assembly to fix the 2 brushes in place.
b. Install the generator brush holder to the generator coil with the 2 screws.
Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
c. Remove the pin (diameter 1.0 mm).
5. INSTALL GENERATOR TERMINAL INSULATOR
a. Install the generator terminal insulator to the generator coil.
6. INSTALL GENERATOR REAR END COVER
a. Install the generator rear end cover to the generator coil with the 3 nuts.
Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
7. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Install the generator pulley, and temporarily install the pulley lock nut.
b. Install SST1-A to the pulley shaft.
c. Install SST1-B to SST1-A.
d. Hold SST 1-A on the pulley shaft area, and tighten SST 1-B to the specified torque.
Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Securely fix SST1-A to the pulley shaft.
HINT: Read SST1-B tightening torque by using the reactive torque of SST1-A.
e. Mount 2 faces of SST2 in a vise.
f. With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
g. To tighten the pulley nut, rotate SST1-A in the generator's reverse rotation direction.
Torque: 133 N.m (1351 kgf.cm, 98 ft.lbf)
h. Remove the generator from SST2.
i. Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.
j. Check that the pulley rotates smoothly.