Generator ASSY: Overhaul

1. Remove the 3 nuts and end cover.
2. Remove the terminal insulator.
   Fig 1: Removing 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.
   1. SST 09820-6301 1
   2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
   Fig 3: Tightening SST

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2. Check that SST (A) is secured to the rotor shaft.
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 (B) Into SST (C)

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5. To loosen the pulley nut, turn SST (A) in the direction shown in Fig 5 .
   NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
   Fig 5: Turning SST (A) To Loosen Pulley Nut

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6. Remove the generator from SST (C).
7. Turn SST (B) and remove SST (A and B).
   Fig 6: Turning SST (B) And Remove SST (A & B)

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8. Remove the pulley nut and pulley.

1. Remove the 4 bolts.
   Fig 7: Removing Bolts

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2. Using SST, remove the coil.
   1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-0401 1)
   Fig 8: Removing Coil Using SST

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3. Remove the generator washer.

1. Check the rotor for open circuit.
   1. Using an ohmmeter, measure the resistance between the slip rings.
   1. Standard: 2.1 to 2.5 Ω at 20°C (68°F) 

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

   Fig 9: Checking Rotor For Open Circuit

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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.
   1. Standard: 10 kΩ or higher 
   Fig 10: Checking Rotor Is Grounded

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

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

   If rough or scored, replace the rotor assy.

   Fig 11: Inspecting Slip Rings

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4. Using a vernier caliper, measure the slip ring diameter.
   1. 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.

1. Using a vernier caliper, measure the exposed brush length.
   1. Specified exposed length: 1.5 to 11.5 mm (0.059 to 0.453 in.) 

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

   Fig 12: Inspecting Generator Brush Holder Assy

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

If necessary, replace the bearing.

1. Remove the 4 screws and bearing retainer.
   Fig 13: Removing Bearing Retainer

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2. Using SST and a press, press out the bearing.
   1. SST 09223-00010
   Fig 14: Pressing Out Bearing

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3. Using SST and a press, press in a new bearing.
   1. SST 09950-60010 (09951-00480)
   Fig 15: Pressing In New Bearing

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4. Install the bearing retainer with the 4 screws.
   1. Torque: 2.3 N.m (24 kgf.cm, 20 in.lbf) 

1. Using SST, remove the bearing cover (outside) and bearing.
   1. SST 09820-00021
   NOTE: Be careful not to damage the fan.
   Fig 16: Removing Bearing Cover (Outside) & Bearing

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2. Remove the bearing cover (inside).
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.
   1. SST 09820-00031
   Fig 18: Pressing In Bearing

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5. Using SST, push in the bearing cover (outside).
   1. SST 09285-76010
   Fig 19: Pushing In Bearing Cover (Outside)

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1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
   Fig 20: Installing Generator Rotor Assy

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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

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3. Install the coil with the 4 bolts.
   1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) 
   Fig 23: Installing Coil

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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.
   1. SST 09820-63010
   2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
   Fig 24: Tightening SST Clockwise

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3. Check that SST (A) is secured to the pulley shaft.
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
   Fig 25: Inserting SST (B) Into SST (C)

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6. To tighten the pulley nut, turn SST (A) in the direction shown in the illustration.
   1. Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf) 
7. Remove the generator from SST (C).
   Fig 26: Turning SST (A) To Tighten Pulley Nut

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

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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.
   Fig 29: Placing Brush Holder On Coil

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3. Install the 2 screws.
   1. Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf) 
4. Place the real seal plate on the brush holder.

1. Install the terminal insulator.
2. Install the end cover with the 3 nuts.
   1. Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf) 
   Fig 30: Installing Generator Rear End Cover

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