GENERATOR (for 60A Type) DISASSEMBLY


  1. REMOVE GENERATOR PULLEY


    1. Mount the generator assembly in a vise between aluminum plates.

    2. A01CH8AE01

      Install SST 1-A and SST 1-B to the generator assembly.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )

      Tech Tips

      SST 1-A and 1-B 09820-06010
      SST 2 09820-06021

    3. Hold SST 1-A with a torque wrench and tighten SST 1-B clockwise to the specified torque.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Note

      Check that SST is securely fitted onto the generator rotor shaft.

    4. A01CHAVE01

      Insert SST 2 and attach it to the generator pulley nut.

    5. A01CH6OE01
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      To loosen the generator pulley nut, turn SST 1-A in the direction shown in the illustration.

      Note

      To prevent damage to the rotor shaft, do not loosen the generator pulley nut by more than one half turn.

    6. Remove SST 2 from the generator assembly.

    7. A01CJ2ZE01
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Turn SST 1-B in the direction shown in the illustration, and then remove SST 1-A and SST 1-B.

    8. Remove the generator pulley nut and generator pulley.

  2. REMOVE NO. 2 GENERATOR REAR END COVER


    1. Place the generator assembly on the generator pulley.

    2. Remove the 3 nuts and No. 2 generator rear end cover.

  3. REMOVE GENERATOR REAR END COVER


    1. A01CJCX

      Remove the bolt, 2 nuts, generator terminal plate and generator rear end cover.

  4. REMOVE GENERATOR TERMINAL INSULATOR


    1. A01CIW2

      Remove the nut and generator terminal insulator.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. Remove the generator brush cover.

    2. A01CIM7

      Remove the 2 screws and generator brush holder assembly.

  6. REMOVE GENERATOR REGULATOR ASSEMBLY


    1. A01CIAD

      Remove the 3 screws and generator regulator assembly.

    2. Remove the generator plate seal from the generator rectifier end frame.

  7. REMOVE GENERATOR HOLDER WITH RECTIFIER


    1. A01CJ43

      Remove the 4 screws and the generator holder with rectifier.

  8. REMOVE GENERATOR RECTIFIER END FRAME


    1. Remove the 4 terminal insulators.

    2. A01CIWM

      Remove the 4 nuts.

    3. A01CHHBE04
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Using SST, remove the generator rectifier end frame.

      SST
      09286-46011

  9. REMOVE GENERATOR ROTOR ASSEMBLY


    1. A01CJ56

      Remove the generator washer.

    2. A01CHQM

      Remove the generator rotor assembly.

      Note

      Do not drop the generator rotor assembly.

  10. INSPECT GENERATOR ROTOR BEARING


    1. Check that the generator rotor bearing is not rough or worn.

      If necessary, replace the generator rotor bearing.

  11. REMOVE GENERATOR ROTOR BEARING


    1. A01CH9UE01
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Using SST, remove the generator rotor bearing and bearing cover.

      SST
      09820-00021

  12. INSPECT GENERATOR DRIVE END FRAME BEARING


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

      If necessary, replace the generator drive end frame bearing.

  13. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. Remove the 4 screws and retainer plate.

    2. A01CI3IE01

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

      SST
      09950-60010   ( 09951-00320 )
      09950-70010   ( 09951-07100 )