GENERATOR DISASSEMBLY

PROCEDURE


  1. REMOVE GENERATOR PULLEY CAP


    1. B004LMC

      Remove the generator pulley cap from the generator pulley with clutch.

      Note


      • Do not reuse the generator pulley cap.

      • If the generator pulley cap is removed, replace the generator pulley cap and generator pulley with clutch with new ones as the correct grease amount cannot be confirmed.

      Tech Tips

      Although grease will be observed when the generator pulley cap is removed, this does not indicate a malfunction.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH


    1. Secure the generator drive end frame in a vise between aluminum plates.

    2. B004JUIN02

      Install SST (A) to SST (B) as shown in the illustration.

      SST
      09820-63021
    3. B004MUUC01
      *a Rotor Shaft

      Fit the rotor shaft end into SST (A).

    4. B004KPBC01
      *1 Generator Pulley with Clutch

      Fit SST (B) to the generator pulley with clutch.

    5. B004KDIC01
      *a Turn
      *b Hold

      Loosen the generator pulley with clutch by turning SST (B) as shown in the illustration.

      Note


      • Check that the generator drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

    6. Remove SST (A) and (B) from the generator pulley with clutch.

    7. Remove the generator pulley with clutch from the rotor shaft.

    8. Remove the generator drive end frame from the vise.

  3. REMOVE GENERATOR REAR END COVER


    1. B004O4C

      Place the generator assembly on the generator pulley with clutch.

    2. B004K9A

      Remove the 3 bolts and generator rear end cover from the generator coil assembly.

  4. REMOVE GENERATOR TERMINAL INSULATOR


    1. B004I3Y

      Remove the generator terminal insulator from the generator coil assembly.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. B004MR2

      Remove the 2 screws and generator brush holder assembly from the generator coil assembly.

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. B004LJ1

      Remove the 4 bolts.

    2. B004I3KC01
      *a Hold
      *b Turn

      Using SST, remove the generator coil assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
    3. B004NQM

      Remove the bearing cover packing.

      Note

      If the bearing cover packing breaks, remove the broken pieces completely.

      Tech Tips

      The bearing cover packing may be installed on the generator rotor assembly.

  7. REMOVE GENERATOR ROTOR ASSEMBLY


    1. B004MVMC01
      *1 Generator Rotor Assembly
      *2 Generator Drive End Frame

      Remove the generator rotor assembly.

      Note

      Do not drop the generator rotor assembly.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING

    Click here

  9. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. B004JJ9

      Remove the 4 screws and retainer plate from the generator drive end frame.

    2. B004LHRE01

      Using SST and a hammer, tap out the generator drive end frame bearing.

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07100 )