GENERATOR(for DENSO Made) DISASSEMBLY

PROCEDURE


  1. REMOVE GENERATOR PULLEY CAP


    1. A01VE17E01
      Text in Illustration
      *1 Generator Pulley Cap

      Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.

      Note

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH


    1. Secure the generator housing stay in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A01VELEE01
      Text in Illustration
      *1 Generator Rotor Assembly Shaft

      Install SST1 to the generator rotor assembly shaft as shown in the illustration.

      SST
      09820-63021
    3. A01VJRQE02
      Text in Illustration
      *1 Generator Pulley with Clutch

      Install SST2 to the generator pulley with clutch.

      Note

      Hold SST to the generator pulley with clutch tightly during the operation.

    4. A01VE4KE03
      Text in Illustration
      *a Hold
      *b Turn

      Loosen the generator pulley with clutch by turning SST2 in the direction 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.

    5. Remove SST from the generator pulley with clutch.

    6. Remove the generator pulley with clutch from the generator rotor assembly shaft.

    7. Remove the generator assembly from the vise.

  3. REMOVE GENERATOR REAR END COVER


    1. Place the generator assembly on the generator pulley with clutch.

    2. A01VLZN

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

  4. REMOVE GENERATOR TERMINAL INSULATOR


    1. A01VIJY

      Remove the generator terminal insulator from the generator coil assembly.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01VH4F

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A01VLEC

      Remove the 4 bolts.

    2. A01VM14E21
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the generator coil assembly from the generator drive end frame assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
      09550-60010   ( 09951-00250 )

      Note

      Apply grease to the threads and tip of the SST center bolt before use.

    3. A01VFPA

      Remove the generator bearing cover packing from the generator coil assembly.

      Note

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

      Tech Tips

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

  7. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A01VGCV

      Remove the generator rotor assembly from the generator drive end frame assembly.

      Note

      Do not drop the generator rotor assembly.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A01VLQ7

      Check that the generator drive end frame bearing is not rough or worn.

      If the generator drive end frame bearing does not rotate smoothly, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A01VI96

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

    2. A01VGKVE14
      Text in Illustration
      *a Wooden Block

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

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

      Tech Tips

      Keep the generator drive end frame assembly horizontal.