GENERATOR DISASSEMBLY

PROCEDURE

  1. REMOVE GENERATOR PULLEY CAP

    1. A302304

      Using a screwdriver, puncture the center of the generator pulley cap and pry it off.

      Note:

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH

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

    2. A390665E01

      Install SST A and B to the generator pulley with clutch as shown in the illustration.

      09820-63021

      Table 1. Text in Illustration

      *1

      Rotor Shaft
      Note:

      Securely attach SST to the generator pulley with clutch and rotor shaft.

    3. A302306E02

      Using a wrench to hold SST A, turn SST B counterclockwise to loosen the generator pulley with clutch.

      Table 2. Text in Illustration

      *a

      Hold
      V100135

      Turn
      Note:

      Be careful as the generator pulley with clutch or rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

    4. Remove SST from the generator assembly.

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

  3. REMOVE GENERATOR REAR END COVER

    1. A302307

      Place the generator assembly on the generator pulley with clutch.

    2. A302308

      Remove the 3 bolts and generator rear end cover.

  4. REMOVE TERMINAL INSULATOR

    1. Remove the terminal insulator from the generator coil assembly.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

    1. A258130

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

  6. REMOVE GENERATOR COIL ASSEMBLY

    1. A258131

      Remove the 4 bolts.

    2. A302309E02

      Using SST, remove the generator coil assembly.

      09950-40011

      09951-04020

      09952-04010

      09953-04020

      09954-04010

      09955-04071

      09957-04010

      09958-04011

      Table 3. Text in Illustration

      *a

      Hold
      V100135

      Turn

  7. REMOVE BEARING COVER PACKING

    1. A284548

      Remove the bearing cover packing.

      Note:

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

      Tip:

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

  8. REMOVE GENERATOR ROTOR ASSEMBLY

    1. A153384

      Remove the generator rotor assembly.

  9. INSPECT GENERATOR DRIVE END FRAME BEARING

    1. A302311

      Check that the bearing is not rough or worn and that it rotates smoothly.

      If necessary, replace the generator drive end frame bearing.

  10. REMOVE GENERATOR DRIVE END FRAME BEARING

    1. A153385

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

    2. A302310E02

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

      09950-60010

      09951-00250

      09950-70010

      09951-07100