Generator ASSY: Overhaul

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

HINT:

1. Hold SST1 - A with a torque wrench, and tighten SST1 - 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: Holding SST1 - A With Torque Wrench And Tightening SST1 - B Clockwise

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2. Clamp SST2 in a vise.
3. Insert SST1s - A and B into SST2, and attach the pulley nut to SST2.
   Fig 2: Inserting SST1s - A And B Into SST2

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4. To loosen the pulley nut, turn SST1 - A in the direction shown in Fig 3.
   NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.
   Fig 3: Turning SST1 - A

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5. Remove the generator from SST2.
6. Turn SST1 - B, and remove SST1 - A and B.
   Fig 4: Turning SST1 - B And Removing SST1 - A And B

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7. Remove the pulley nut and pulley.

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 Brush Holder And Generator Regulator Screws

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

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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 Clip Code

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4. Using SST, remove the rectifier end frame.

   SST 09286-46011

   Fig 9: Removing Rectifier End Frame

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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 Generator Regulator Terminals F And 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 Generator Regulator Terminals F And 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 Generator Rotor 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 Generator Slip Ring And 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 And 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 And 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 For Continuity Between Starter 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.

   If there is continuity, replace the drive end frame.

   Fig 18: Checking For No Continuity Between Coil Lead And Drive End Frame

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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.
   Fig 20: Pressing In Rectifier End Frame

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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.
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 Insulators Onto Lead Wires

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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 Screws And 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 SST1 - A with a torque wrench, and tighten SST1 - 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: Holding SST1 - A With Torque Wrench And Tightening SST1 - B Clockwise

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3. Clamp SST2 in a vise.
4. Insert SST1 - A and B into SST2, and attach the pulley nut to SST2.
   Fig 24: Inserting SST1 - A And B Into SST2

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5. Tighten the pulley nut, turn SST1 - A in the direction shown in Fig 25.

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

   Fig 25: Tightening Pulley Nut And Turning SST1 - A

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6. Remove the generator from SST2.
7. Turn SST1 - B, and remove SST1 - A and B.
8. Turn the pulley, and check that the pulley moves smoothly.
   Fig 26: Turning SST1 - B And Removing SST1 - A And B

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