GENERATOR(for DENSO Made) DISASSEMBLY

PROCEDURE


  1. REMOVE GENERATOR PULLEY CAP


    1. A004AIXC02
      *1 Generator Pulley Cap

      Using a thin-bladed 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 drive end frame in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. A0047TXC06
      *a Rotor Shaft

      Fit the rotor shaft end into SST1.

      SST
      09820-63021
    3. A0046UPC06
      *1 Generator Pulley with Clutch

      Fit SST2 to the generator pulley with clutch.

      Note

      Securely attach SST to the generator pulley with clutch.

    4. A004BK3C04
      *a Turn
      *b Hold

      Loosen the generator pulley with clutch by turning SST2 as shown in the illustration.

      Note


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

      • Hold SST1 tightly during the operation.

    5. Remove SST1 and SST2 from the generator pulley with clutch.

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

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

  3. REMOVE GENERATOR REAR END COVER


    1. Place the generator drive end frame on the generator pulley with clutch.

    2. A00475O

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

  4. REMOVE GENERATOR TERMINAL INSULATOR


    1. A0048JT

      Remove the generator terminal insulator from the generator coil assembly.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A004B6N

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

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A004AJC

      Remove the 4 through bolts.

    2. A0049E1C03
      *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 )

      Note

      Apply grease to the threads and tip of the SST center bolt (09953-04020) before use.

    3. A0047EU

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

      Note

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

  7. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A0047GR

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

      Note

      Do not drop the generator rotor assembly.

  8. INSPECT GENERATOR DRIVE END FRAME BEARING


    1. A0048AZ

      Check that the generator drive end frame bearing is not rough or worn and that it rotates smoothly. If the generator drive end frame bearing is rough or worn, or does not rotate smoothly, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A004925

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

    2. A004AHHC03
      *a Wooden Block

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

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

      Tech Tips

      Level the generator drive end frame.