Overhaul
DISASSEMBLY1. REMOVE GENERATOR PULLEY WITH CLUTCH
a. Remove the cap from the pulley.
1. Using a screwdriver, puncture the center of the cap and pry it off.
NOTE: Do not reuse the cap.
b. Install SST to the pulley and vise as shown in the illustration.
SST 09820-63020
c. Mount SST (A) in a vise.
d. Turn SST (B) clockwise to loosen the pulley.
e. Remove the pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the nut and terminal insulator.
b. Remove the nut, screw and rectifier plate.
c. Remove the 2 nuts and rear end cover.
d. Remove the brush cover from the generator brush holder assembly.
e. Remove the 3 screws and generator brush holder.
f. Remove the plate seal.
3. REMOVE GENERATOR REGULATOR ASSEMBLY
a. Remove the 2 screws and generator regulator assembly.
4. REMOVE GENERATOR HOLDER WITH RECTIFIER
a. Remove the 3 screws and generator holder with rectifier.
5. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the 3 terminal insulators from the rectifier end frame.
b. Remove the 4 nuts.
c. Using SST, remove the rectifier end frame.
SST 09286-46011
d. Remove the plate retainer.
e. Remove the generator rotor assembly from the drive end frame.
NOTE: Do not drop the generator rotor assembly.
HINT: If the generator rotor is engaged too firmly, lightly tap the generator rotor shaft to remove it using a plastic-faced hammer.
REASSEMBLY
1. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the drive end frame on the generator rotor assembly.
NOTE: Do not drop the generator rotor assembly.
b. Install the generator rotor assembly and plate retainer.
c. Using a 17 mm socket wrench and press, slowly press in the rectifier end frame.
d. Install the 4 nuts.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
e. Install the 3 terminal insulators to the rectifier end frame.
2. INSTALL GENERATOR HOLDER WITH RECTIFIER
a. Install the generator holder with rectifier with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
3. INSTALL GENERATOR REGULATOR ASSEMBLY
a. Install the generator regulator with the 2 screws.
Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Install the plate seal.
b. Install the generator brush holder with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 17 in.lbf)
c. Install the brush cover on the generator brush holder assembly.
d. Install the rear end cover with the 2 nuts.
Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf)
e. Install the rectifier plate with the nut and screw.
Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
Torque: 3.9 N.m (40 kgf.cm, 34 in.lbf) for screw
f. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
5. INSTALL GENERATOR PULLEY WITH CLUTCH
a. Install the pulley by hand.
b. Install SST to the pulley and vise as shown in the illustration.
SST 09820-63020
c. Turn SST (B) counterclockwise to tighten the pulley.
Torque: 110 N.m (1121 kgf.cm, 80 ft.lbf)
d. Install a new cap to the pulley.
e. Check that the generator pulley rotates smoothly.