Overhaul
OVERHAUL1. REMOVE GENERATOR PULLEY
SST 09820-63011 (09820-06010), 09820-06021
a. Tighten SST 1-B to the specified torque, 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, then fix the generator pulley nut into SST 2.
d. Turn SST 1-A in the direction shown, 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, then loosen SST 1-A in the direction shown. Remove SST 1-A and B from the generator.
g. Remove the generator pulley nut, then remove the generator pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Place the generator on the generator pulley.
b. Remove the 3 nuts, then remove the generator rear end cover.
c. Remove the terminal insulator.
d. Remove the 2 screws, then remove the generator brush holder.
3. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the bolt, then remove the 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.
4. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
a. Check the brush length.
1. Using vernier calipers, measure the brush length.
Standard: 9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum: 4.5 mm (0.177 in.)
If the brush length is less than minimum, replace the generator brush holder.
5. INSPECT GENERATOR ROTOR ASSEMBLY
a. Check the resistance.
1. Using an ohmmeter, measure the resistance between the slip rings.
Standard: 2.3 to 2.7 Ohms at 20°C (68°F)
If the result is not as specified, replace the generator rotor.
2. Using an ohmmeter, measure the resistance between the slip ring and rotor core.
Standard: 1 MOhms or higher
If the result is not as specified, replace the generator rotor.
b. Check the slip ring diameter.
1. Using vernier calipers, measure the slip ring diameter.
Standard: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum: 14.0 mm (0.551 in.)
If the slip ring diameter is less than minimum, replace the generator rotor.
c. Check the appearance.
1. Check that the bearing is not rough or worn.
If necessary, replace the generator rotor.
6. INSPECT GENERATOR DRIVE END FRAME BEARING
a. Check the appearance.
1. Check that the bearing is not rough or worn.
If necessary, replace the bearing.
b. Replace the bearing.
1. Remove the 4 screws, then remove the bearing retainer plate.
2. Using SST, push the bearing out of the generator drive end frame.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
3. Using SST and a press, press a new bearing into the generator drive end frame.
SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
4. Align the protrusions of the bearing retainer plate with the cutouts of the generator drive end frame, then install the bearing retainer plate with the 4 screws.
Torque: 2.26 N.m (25 kgf.cm, 20 in.lbf)
7. 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 onto 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)
8. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes into the generator brush holder, insert a pin (Dia 1.0 mm (0.039 in.)) 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 pin (Dia 1.0 mm (0.039 in.)) 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)
9. INSTALL GENERATOR PULLEY
SST 09820-63011 (09820-06010), 09820-06021
a. Install the generator pulley onto the generator rotor shaft, then temporarily tighten the generator pulley nut by hand.
b. Tighten SST 1-B to the specified torque, 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, then fix the generator pulley nut into SST 2.
e. Turn SST 1-A in the direction shown, 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, then check that the generator pulley moves smoothly.