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) 

   NOTE: Check that SST is secured to the rotor shaft.
   Fig 1: Tightening SST 1 - B Clockwise

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2. Clamp SST 2 in a vise.
3. Insert SST 1s - A and B into SST 2, and attach the pulley nut to SST 2.
   Fig 2: Clamping SST 2 In Vise

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4. To loosen the pulley nut, turn SST 1 - A in the direction shown in the illustration.
   Fig 3: Loosening Pulley Nut

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   NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.
5. Remove the generator from SST 2.
6. Turn SST 1 - B, and remove SST 1 - A and B.
7. Remove the pulley nut and pulley.
   Fig 4: Turning SST 1 - B

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1. Remove the nut and terminal insulator.
2. Remove the bolt, 3 nuts and plate terminal, and then remove the end cover.
   Fig 5: Removing Rear End Cover

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1. Remove the brush holder cover from the brush holder.
2. Remove the 2 screws and brush holder.
3. Remove the 3 screws and generator regulator.
   Fig 6: Removing Generator Brush Holder & Generator Regulator

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1. Remove the 4 screws and holder with rectifier.
   Fig 7: Removing Generator Holder W Rectifier

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1. Remove the 4 rubbers insulator.
2. Remove the seal plate.
3. Remove the 4 nuts and clip code.
   Fig 8: Removing 4 Nuts

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4. Using SST, remove the rectifier end frame.

   SST 09286-4601 1

   Fig 9: Removing Rectifier End Frame Using SST

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1. Remove the generator washer from the rotor.
2. Remove the rotor from the drive end frame.
   NOTE: Do not drop the rotor.

1. Using an ohmmeter, check for continuity between terminals F and B.

   Standard: When the positive and negative poles between terminals F and B are switched over, there is continuity in one direction but no continuity in another direction. 

   If the continuity in not as specified, replace the generator regulator.

   Fig 10: Checking Continuity Between Terminals F & B

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2. Using an ohmmeter, check for continuity between terminals F and E.

   Standard: When the positive and negative poles between terminals F and E are switched over, there is continuity in one direction but no continuity in another direction. 

   If the continuity is not as specified, replace the generator regulator.

   Fig 11: Checking Continuity Between Terminals F & E

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1. Check the resistance.
   1. Using an ohmmeter, check the resistance between the slip rings.

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

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

      Fig 12: Checking Resistance Between Slip Rings

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2. Check for continuity.
   1. Using an ohmmeter, check the resistance between the slip ring and rotor.

      Standard resistance: 10 kΩ or higher 

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

      Fig 13: Checking Resistance Between Slip Ring & Rotor

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3. Inspect 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: 12.8 mm (0.504 in.) 

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

      Fig 14: Measuring Slip Ring Diameter

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4. Check for roughness or wear.
   1. Check the bearing is not rough or worn.

      If necessary, replace the generator rotor.

1. Inspect the positive (+) rectifier.
   1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
      Fig 15: Connecting One Tester Probe To Positive (+) Terminal & Other To Each Rectifier Terminal

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   2. Reverse the polarity of the tester probes and repeat step (1).
   3. Check that one shows continuity and the other shows no continuity.

      If continuity is not as specified, replace the rectifier holder.

2. Inspect the negative (-) rectifier.
   1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
      Fig 16: Connecting One Tester Probe To Each Negative (-) Terminal & Other To Each Rectifier Terminal

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   2. Reverse the polarity of the tester probes and repeat step (1).
   3. Check that one shows continuity and the other shows no continuity.

      If continuity is not as specified, replace the rectifier holder.

1. Check the stator coil for open circuit.
   1. Using an ohmmeter, check that there is continuity between the coil leads.

      If there is no continuity, replace the generator assy.

      Fig 17: Checking Continuity Between Coil Leads

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2. Check the stator for ground.
   1. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.
      Fig 18: Checking No Continuity Between Coil Lead & Drive End Frame

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      If there is continuity, replace the drive end frame.

3. Inspect the bearing.
   1. Inspect the bearing is not rough or worn.

      If necessary, replace the generator assy.

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

   Standard exposed length: 

   9.5 to 11.5 mm (0.374 to 0.453 in.) 

   Minimum exposed length: 4.5 mm (0.177 in.) 

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

   Fig 19: Measuring Exposed Brush Length

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1. Install the generator rotor.
2. Install the generator washer onto the rotor.

1. Using a 19 mm socket wrench and press, slowly press in the rectifier end frame.
2. Install the 4 nuts and clip code.

   Torque: 

   4.5 N.m (46 kgf.cm, 40 in.lbf) for nut A 

   5.4 N.m (55 kgf.cm, 48 in.lbf) for nut B 

3. Install the seal plate onto the rectifier end frame.
   Fig 20: Installing Generator Rectifier End Frame

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4. Install the 4 rubber insulators onto the lead wires.
   NOTE: Be careful that the rubber insulators are in the right direction.
   Fig 21: Installing Rubber Insulator

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1. Install the rectifier holder while pushing it with the 4 screws.

   Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf) 

1. Install the 3 screws and generator regulator.

   Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf) 

1. Install the 2 screws and brush holder.

   Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf) 

   NOTE: Be careful that the holder is in the right direction when installing.
   Fig 22: Installing Generator Brush Holder

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2. Install the brush cover.

1. Install the end cover and plate terminal with the bolt and 3 nuts.

   Torque: 

   3.9 N.m (40 kgf.cm, 34 in.lbf) for bolt 

   4.4 N.m (45 kgf.cm, 39 in.lbf) for nut 

2. Install the terminal insulator with the nut.

   Torque: 3.6 N.m (37 kgf.cm, 32 in.lbf) 

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

HINT:

1. Install the pulley onto 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) 

   NOTE: Check that SST is secured to the pulley shaft.
   Fig 23: Tightening SST 1 - B Clockwise

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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 24: Clamping SST 2 In Vise

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5. Tighten the pulley nut, turn 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 25: Turning SST 1 - A

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7. Turn SST 1 - B, and remove SST 1 - A and B.
8. Turn the pulley, and check that the pulley moves smoothly-
   Fig 26: Turning SST 1 - B

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