Overhaul

OVERHAUL




1. REMOVE GENERATOR W/CLUTCH PULLEY
a. Using a screwdriver, remove the generator pulley cap.




b. Set SST (A) and (B).

SST 09820-63020

1. Set the rotor shaft to SST (A).
2. Mount SST (A) in a vise.




c. Install the generator with the SST as shown in the illustration.
d. Turn SST (B) clockwise, and loosen the generator pulley.
e. Remove the generator from SST.
f. Remove the pulley from the rotor shaft.




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




3. REMOVE TERMINAL INSULATOR
a. Remove the terminal insulator.




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




5. REMOVE GENERATOR COIL ASSEMBLY
a. Remove the 4 bolts.




b. Using SST, remove the generator coil assembly.

SST 09950- 40011 (09951- 04020, 09952- 04010,09953- 04020, 09954- 04010, 09955- 04071,09957-04010, 09958-04011)

c. Remove the generator washer.

6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator rotor assembly.




7. INSPECT GENERATOR W/CLUTCH PULLEY
a. When rotating the generator pulley, check that it turns counterclockwise and does not turn clockwise.




8. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
a. Using vernier calipers, measure the exposed brush length.

Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 4.5 mm (0.177 in.)

If the exposed length is less than the minimum, replace the generator brush holder assembly.




9. INSPECT GENERATOR ROTOR ASSEMBLY
a. Check that the generator rotor bearing is not rough or worn.
If necessary, replace the generator rotor.




b. Check the generator rotor for an open circuit.
1. Using an ohmmeter, measure the resistance between the slip rings.

Standard resistance: 2.3 to 2.7 Ohms at 20°C (68°F)

If the result is not as specified, replace the generator rotor assembly.




c. Check the generator rotor for a short circuit.
1. Using an ohmmeter, measure the resistance between the each slip ring and rotor.

Standard resistance: 1 MOhm or higher

If the result is not as specified, replace the generator rotor assembly.




d. Using vernier calipers, measure the slip ring diameter.

Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)

If the diameter is less than the minimum, replace the generator rotor assembly.




10. INSPECT GENERATOR DRIVE END FRAME BEARING
a. Check the generator drive end frame bearing is not rough or worn.
If necessary, replace the generator drive end frame bearing.




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




b. Using SST and a hammer, tap out the generator drive end frame bearing.

SST 09950- 60010 (09951- 00250), 09950- 70010 (09951-07100)




12. INSTALL GENERATOR DRIVE END FRAME BEARING
a. Using SST and a press, press in a new generator drive end frame bearing.

SST 09950- 60010 (09951- 00470), 09950- 70010 (09951-07100)




b. Install the bearing retainer with the 4 screws.

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

13. INSTALL GENERATOR ROTOR ASSEMBLY
a. Install the generator rotor assembly and generator washer to the drive end frame.




14. INSTALL GENERATOR COIL ASSEMBLY
a. Using deep socket wrench (21 mm) and a press, slowly press in the generator coil assembly.




b. Install the 4 bolts.

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




15. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes to the inside of the generator brush holder assembly, insert a Dia. 1.0 mm (0.039 in.) pin into the generator brush holder hole.




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

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

c. Remove the pin from the brush holder assembly.




16. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator.

NOTE: Pay attention to installation direction of the terminal insulator.




17. 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)




18. INSTALL GENERATOR W/CLUTCH PULLEY
a. Set SST (A) and (B).

SST 09820-63020

1. Set the rotor shaft to SST (A).
2. Mount SST (A) in a vise.




b. Install the generator with the SST as shown in the illustration.
c. Turn SST (B) counterclockwise, and tighten the generator pulley.

SST 09820-63020

Torque: 87 N.m (891 kgf.cm, 64 ft.lbf)

NOTE: Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).

d. Remove the generator from the SST.

NOTE: Check that the generator pulley rotates smoothly.

e. Install a new generator pulley cap.