130 A
OVERHAUL1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
a. 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.
b. Mount SST 2 in a vise.
c. Insert SST 1-A, 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 of a turn.
e. Remove the alternator from SST 2.
f. Turn SST 1-B, and remove SST 1-A, B.
g. Remove the pulley nut and pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the 3 nuts and end cover.
b. Remove the rear seal plate.
c. Remove the 2 screws and brush holder.
d. Remove the front seal plate.
3. REMOVE COIL ASSEMBLY ALTERNATOR
a. Remove the 4 bolts.
b. Using SST, remove the coil assembly.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-04011)
4. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the alternator washer from the rotor.
b. Remove the rotor from drive end frame.
NOTE: Do not drop the rotor.
5. INSPECT GENERATOR ROTOR ASSEMBLY
a. Inspect rotor for open circuit.
1. Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance: 2.3 - 2.7 ohm at 20 °C (68 °F)
If there is no continuity, replace the rotor.
b. Inspect rotor for ground.
1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
If there is continuity, replace the rotor.
c. Inspect slip rings.
1. Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the rotor.
6. INSPECT BRUSH
a. Using vernier calipers, measure the exposed brush length.
Standard exposed length: 9.5 - 11.5 mm (0.374 - 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.
7. INSTALL GENERATOR ROTOR ASSEMBLY
a. Install the generator rotor.
b. Install the alternator washer to the rotor.
8. INSTALL COIL ASSEMBLY ALTERNATOR
a. Using a 17 mm socket wrench and press slowly press in the coil assembly.
b. Install the coil assembly with the 4 bolts.
Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
9. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Place the front seal plate to the coil assembly.
b. Install the 2 screws and brush holder.
Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
NOTE: Be careful of the holder installation direction.
c. Place the rear seal plate on the brush holder.
d. Install the 3 nuts and end cover.
Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
10. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
HINT:
a. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
b. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified to torque.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Check that SST is secured to the pulley shaft.
c. Mount SST 2 in a vise.
d. Insert SST 1-A, B into SST 2, and attach the pulley nut to SST 2.
e. 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)
f. Remove the alternator from SST 2.
g. Turn SST 1-B, and remove SST 1-A, B.
h. Turn the pulley, and check that the pulley moves smoothly.