Generator ASSY: Overhaul

1. Remove the 3 nuts and end cover.
2. Remove the terminal insulator.
   Fig 1: Locating Nut Of Generator Rear End Cover

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1. Remove the rear seal plate from the brush holder.
2. Remove the 2 screws and brush holder.
3. Remove the front seal plate from the coil.
   Fig 2: Removing Generator Brush Holder Assy

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1. Hold SST (A) with a torque wrench and tighten SST (B) clockwise to the specified torque.

   SST 09820-63011

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

2. Check that SST (A) is secured to the rotor shaft.
   Fig 3: Holding SST With Torque Wrench And Tightening SST Clockwise

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3. Mount SST (C) in a vise.
4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
   Fig 4: Inserting SST Into SST And Attaching Pulley Nut To SST

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5. 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.
6. Remove the generator from SST (C).
   Fig 5: Turning SST

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7. Turn SST (B) and remove SST (A and B).
8. Remove the pulley nut and pulley.
   Fig 6: Turning SST And Removing SST

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1. Remove the 4 bolts.
   Fig 7: Identifying Generator Bolt

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2. Using SST, remove the coil.

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

3. Remove the generator washer.
   Fig 8: Removing Coil Using SST

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

      Standard: 2.1 to 2.5 Ω at 20°C (68°F) 

      If the resistance is not as specified, replace the generator rotor.

      Fig 9: Measuring Resistance Between Slip Rings Using Ohmmeter

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2. Check if the rotor is grounded.
   1. Using an ohmmeter, measure the resistance between the slip ring and the rotor core.

      Standard: 10 kΩ or higher 

      If the resistance is not as specified, replace the generator rotor.

      Fig 10: Measuring Resistance Between Slip Ring And Rotor Core Using Ohmmeter

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3. Inspect slip rings.
   1. Check that the slip rings are not rough or scored.

   If rough or scored, replace the rotor assy.

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

   Specified diameter: 

   12.8 to 14.4 mm (0.504 to 0.567 in.) 

   If the diameter is less than the minimum, replace the rotor assy.

   Fig 11: Measuring Slip Ring Diameter Using Vernier Caliper

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1. Using vernier calipers, measure the exposed brush length.

   Specified exposed length: 

   1.5 to 11.5 mm (0.059 to 0.453 in.) 

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

Fig 12: Measuring Exposed Brush Length Using Vernier Caliper

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1. Check that the bearing is not rough or worn.

If necessary, replace the bearing.

1. Remove the 4 screws, bearing retainer and bearing.
   Fig 13: Locating Screw Of Front Bearing

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2. Using SST and a press, press out the bearing.

   SST 09223-00010

   Fig 14: Pressing Out Bearing Using SST

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3. Using SST and a press, press in a new bearing.

   SST 09950-60010 (09951-00480)

4. Install the bearing retainer with the 4 screws.

   Torque: 2.3 N.m (24 kgf.cm, 20 in. lbf) 

   Fig 15: Pressing In Bearing Using SST

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1. Using SST, remove the bearing cover (outside) and bearing.

   SST 09820-00021

   NOTE: Be careful not to damage the fan.
2. Remove the bearing cover (inside).
   Fig 16: Removing Bearing Cover (Outside) Using SST

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3. Place the bearing cover (inside) on the rotor.
   Fig 17: Placing Bearing Cover (Inside) On Rotor

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4. Using SST and a press, press in a new bearing.

   SST 09820-00031

   Fig 18: Pressing In Bearing Using SST

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5. Using SST, push in the bearing cover (outside).

   SST 09285-76010

   Fig 19: Pushing In Bearing Cover (Outside) Using SST

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1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame
   Fig 20: Identifying Pulley

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1. Place the generator washer on the rotor.
   Fig 21: Placing Generator Washer On Rotor

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2. Using a 29 mm socket wrench and press, slowly press in the coil.
   Fig 22: Pressing In Coil Using Socket Wrench

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3. Install the coil with the 4 bolts.

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

   Fig 23: Identifying Bolt

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1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

   SST 09820-63010

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

3. Check that SST (A) is secured to the pulley shaft.
   Fig 24: Installing Generator Pulley

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4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
   Fig 25: Mounting SST In Vise

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6. To tighten the pulley nut, turn SST (A) in the direction shown in the illustration.

   Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf) 

7. Remove the generator from SST (C).
   Fig 26: Removing Generator From SST

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8. Turn SST (B) and remove SST (A and B).
   Fig 27: Turning SST And Removing SST

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1. Place the front seal plate onto the coil.
   Fig 28: Placing Front Seal Plate Onto Coil

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2. Place the brush holder on the coil.
   NOTE: Be careful of the holder's installation direction.
3. Install the 2 screws.

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

4. Place the real seal plate on the brush holder.
   Fig 29: Placing Real Seal Plate On Brush Holder

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1. Install the terminal insulator.
2. Install the end cover with the 3 nuts.

   Torque: 4.6 N.m (47 kgf.cm, 41 in. lbf) 

   Fig 30: Identifying Nuts Of Generator Rear End

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