Overhaul
DISASSEMBLY1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
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 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 a half turn.
e. Remove the generator from SST 2.
f. Turn SST 1-B, then remove SST 1-A and B.
g. Remove the pulley nut, then remove the generator pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the nut, then remove the terminal insulator.
b. Remove the screw and nut, then remove the terminal plate.
c. Remove the 2 nuts, then remove the rear end cover.
d. Remove the generator brush cover from the generator brush holder.
e. Remove the 2 screws, then remove the generator brush holder.
f. Remove the generator plate seal from the generator rectifier end frame.
3. REMOVE GENERATOR REGULATOR ASSEMBLY
a. Remove the 3 screws, then remove the generator regulator.
4. REMOVE GENERATOR HOLDER W/RECTIFIER
a. Remove the 4 screws, then remove the generator holder with rectifier.
5. REMOVE GENERATOR RECTIFIER END FRAME
a. Remove the 4 terminal insulators from the generator rectifier end frame.
b. Remove the 4 nuts and generator cord clip.
c. Using SST, remove the generator rectifier end frame.
SST 09286-46011
6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator washer from the generator rotor.
b. Remove the generator rotor from the generator drive end frame.
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor onto the generator drive end frame.
c. Install the generator washer onto the generator rotor.
2. INSTALL GENERATOR RECTIFIER END FRAME
a. Using a socket wrench 29 and a press, slowly push the generator rectifier end frame in.
b. Install the generator cord clip and 4 nuts.
Torque:
Nut A : 4.5 N.m (46 kgf.cm, 40 in.lbf)
Nut B : 5.4 N.m (55 kgf.cm, 48 in.lbf)
c. Install the 4 terminal insulators onto the generator rectifier end frame.
3. INSTALL GENERATOR HOLDER W/RECTIFIER
a. Install the generator holder with rectifier with the 4 screws.
Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
4. INSTALL GENERATOR REGULATOR ASSEMBLY
a. Install the generator regulator with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Install the generator plate seal onto the generator rectifier end frame.
b. Install the generator brush holder with the 2 screws.
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
NOTE: Make sure that the generator brush holder is in the correct direction.
c. Install the generator brush cover onto the generator brush holder.
d. Install the generator rear and cover it with the 2 nuts.
Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf)
e. Install the terminal plate.
Torque:
Bolt 3.9 N.m (40 kgf.cm, 35 in.lbf)
Nut 4.4 N.m (45 kgf.cm, 39 in.lbf)
f. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
6. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Install the generator pulley onto the rotor shaft by tightening the pulley nut by hand.
b. Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
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 attach the pulley nut to SST 2.
e. Tighten the pulley nut, then turn SST 1-A in the direction shown in the illustration.
Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf)
f. Remove the generator from SST 2.
g. Turn SST 1-B, then remove SST 1-A and B.
h. Turn the generator pulley, then check that the generator pulley moves smoothly.