Generator ASSY: Overhaul

SST 09820-63010 (09820-06010, 09820-06020)

HINT:

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

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

   Fig 1: Holding SST 1-A With A Torque Wrench, And Tightening SST 1-B Clockwise

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   NOTE: Check that SST is secured to the rotor shaft.
2. Clamp SST 2 in a vise.
3. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.
   Fig 2: Inserting SST 1-A And B Into SST 2

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4. 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 one-half turn.
5. Remove the generator from SST 2.
   Fig 3: Removing Generator From SST 2

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6. Turn SST 1-B, and remove SST 1-A and B.
7. Remove the pulley nut and generator pulley.

Fig 4: Removing Pulley Nut And Generator Pulley

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1. Place the generator on the generator pulley.
2. Remove the 3 nuts and the generator rear end cover.

Fig 5: Placing Generator On Generator Pulley

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1. Remove the terminal insulator from the generator rectifier end frame.

Fig 6: Removing Terminal Insulator From Generator Rectifier End Frame

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1. Remove the 2 screws and the generator brush holder.

Fig 7: Removing 2 Screws And Generator Brush Holder

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1. Remove the 4 bolts.
   Fig 8: Removing 4 Bolts

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2. Using SST, remove the generator rectifier end frame.

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

Fig 9: Removing Generator Rectifier End Frame

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1. Remove the generator washer and the generator rotor.

Fig 10: Removing Generator Washer

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

   Standard exposed brush length: 

   10.5 mm (0.413 in.) 

   Minimum exposed brush length: 4.5 mm (0.177 in.) 

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

Fig 11: Measuring Brush Length

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1. Check the bearing is not rough or worn.

   If necessary, replace the generator rotor.

   Fig 12: Checking Bearing

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

   Resistance: 

   2.3 to 2.7 Ω at 20°C (68°F) for 130A 

   1.5 to 1.9 Ω at 20°C (68°F) for 150A 

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

   Fig 13: Measuring Resistance Between Slip Ring

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3. Check the rotor for ground.
   1. Using an ohmmeter, check that there is no continuity between the slip ring and the rotor core.

   If there is continuity, replace the generator rotor.

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

   If rough or scored, replace the generator rotor.

   Fig 14: Checking Continuity Between Slip Ring And Rotor Core

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5. Check the slip ring diameter.
   1. 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 minimum, replace the generator rotor.

Fig 15: Measuring Slip Ring Diameter

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1. Check the bearing is not rough or worn.

If necessary, replace the bearing.

Fig 16: Checking Generator Drive End Frame Bearing

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1. Remove the 4 screws and the retainer plate.
   Fig 17: Removing 4 Screws And Retainer Plate

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2. Using SST, tap out the bearing.

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

Fig 18: Tapping Out Bearing

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

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

   Fig 19: Installing Generator Drive End Frame Bearing

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2. Install the retainer plate with the 4 screws.

   Torque: 2.6 N.m (27 kgf.cm, 23 in.lbf) 

Fig 20: Installing Retainer Plate With 4 Screws

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1. Place the generator drive end frame on the generator pulley.
2. Install the generator rotor and the generator washer.

Fig 21: Installing Generator Rotor And Generator Washer

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1. Using deep socket wrench 21 and a press, press in the generator rectifier end frame carefully.
   Fig 22: Installing Generator Rectifier End Frame Carefully

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2. Tighten the 4 bolts.

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

Fig 23: Tightening 4 Bolts

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1. While pushing the 2 brushes to inside the brush holder, insert a pin (1.0 mm (0.039 in.)) into the brush holder hole.
   Fig 24: Installing Generator Brush Holder Assy

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2. Install the generator brush holder with the 2 screws.

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

3. Pull out the pin (1.0 mm (0.039 in.)) from the generator brush holder.

Fig 25: Pulling Out Pin From Generator Brush Holder

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1. Install the terminal insulator to the generator rectifier end frame.

Fig 26: Installing Terminal Insulator To Generator Rectifier End Frame

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1. Install the generator rear end cover with the 3 nuts.

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

Fig 27: Installing Generator Rear End Cover With 3 Nuts

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SST 09820-63010 (09820-06010, 09820-06020)

HINT:

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

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

   Fig 28: Installing Generator Pulley To Rotor Shaft By Tightening Pulley Nut

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   NOTE: Check that SST is secured to the rotor shaft.
3. Clamp SST 2 in a vise.
4. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2
   Fig 29: Inserting SST 1-A And B Into SST 2

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5. Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

   Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf) 

6. Remove the generator from SST 2.
   Fig 30: Tightening Pulley Nut By Turning SST 1-A

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7. Turn SST 1-B, and remove SST 1-A, B.
8. Turn the generator pulley, and check that the generator pulley moves smoothly.

Fig 31: Turning SST 1-B And Removing SST 1-A, B

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