Overhaul

OVERHAUL








1. REMOVE GENERATOR PULLEY

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

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

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

NOTE: Check that SST is secured to the rotor shaft.




b. Clamp SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, and 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 one-half turn.

e. Remove the generator from SST 2.




f. Turn SST 1-B, and remove SST 1-A and B.
g. Remove the pulley nut, and then remove the generator pulley.




2. REMOVE GENERATOR REAR END COVER
a. Place the generator on the generator pulley.
b. Remove the 3 nuts, and then remove the generator rear end cover.




3. REMOVE TERMINAL INSULATOR
a. Remove the terminal insulator from the generator coil.




4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. 100A Generator
1. Remove the 2 screws, and then remove the generator brush holder.




b. 130A Generator
1. Remove the generator plate seal.
2. Remove the 2 screws, and then remove the generator brush holder.
3. Remove the generator plate seal.




5. REMOVE GENERATOR COIL ASSEMBLY
a. Remove the 4 bolts.




b. Using SST, remove the generator coil.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)




6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator washer and the generator rotor.




7. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
a. Check the brush length.(100A Generator)
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.




b. Check the brush length.(130A Generator)
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.




8. INSPECT GENERATOR ROTOR ASSEMBLY
a. Check that bearing is not rough or worn.
If necessary, replace the generator rotor.(100A Generator) If necessary, replace the generator rotor bearing.(130A Generator)




b. Check if the rotor has open circuit.
1. Using an ohmmeter, measure the resistance between the slip ring.

Resistance:
2.3 to 2.7 ohm at 20 °C (68 °F) for 100A Generator
1.5 to 1.9 ohm at 20 °C (68 °F) for 130A Generator

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




c. Check if the rotor has ground.
1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor core.
If there is continuity, replace the generator rotor.

d. Inspect slip rings.
1. Check that the slip rings are not rough or scored.If rough or scored, replace the generator rotor.




e. 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.




9. REMOVE GENERATOR ROTOR BEARING (130A GENERATOR)
a. Using SST, remove the generator bearing cover (outside) and bearing.
SST 09820-00021

NOTE: Be careful not to damage the fan.

b. Remove the generator bearing cover (inside).




10. INSTALL GENERATOR ROTOR BEARING (130A GENERATOR)
a. Place the generator rotor on the generator pulley.
b. Install the generator bearing cover (inside).
c. Using SST and a press, press in a new bearing.
SST 09820-00031




d. Using SST, push in the generator bearing cover (outside).
SST 09285-76010




11. INSPECT GENERATOR DRIVE END FRAME BEARING
a. Check that bearing is not rough or worn.If necessary, replace the bearing.




12. REMOVE GENERATOR DRIVE END FRAME BEARING
a. Remove the 4 screws, and remove the retainer plate.




b. Using SST, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)




13. INSTALL GENERATOR DRIVE END FRAME BEARING
a. Using SST and a press, press in a new bearing.




b. Install the retainer plate with the 4 screws.

Torque: 2.3 Nm (23 kgf.cm, 20 in.lbf)

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




14. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor and the generator washer.




15. INSTALL GENERATOR COIL ASSEMBLY
a. 100A Generator
1. Using deep socket wrench 21 and a press, press in the coil carefully.
b. 130A Generator
1. Using deep socket wrench 20 and a press, press in the coil carefully.




c. Tighten the 4 bolts.

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




16. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. 100A Generator
1. While pushing the 2 brushes to inside the brush holder, insert a pin (dia 1.0 mm (0.039 in.)) into the brush holder hole.




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

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

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




b. 130A Generator
1. Install the generator plate seal (inside).
2. Place the generator brush holder with the pin facing upward.

NOTE: Be careful of the generator brush holder installing direction.

3. Tighten the 2 screws.

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

4. Align the pins of the generator brush holder with the holes of the generator plate seal (outside), and install the generator plate seal (outside).




17. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator.

NOTE: pay attention the mounting orientation of the terminal insulator.




18. INSTALL GENERATOR REAR END COVER
a. Install the generator rear end cover with the 3 nuts.

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







19. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)

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

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

NOTE: Check that SST is secured to the rotor shaft.




c. Clamp SST 2 in a vise.
d. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2




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

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

f. Remove the generator from SST 2.




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