GENERATOR DISASSEMBLY

PROCEDURE


  1. REMOVE GENERATOR REAR END COVER


    1. A004JKA

      Remove the 4 through bolts.

    2. A004JDME01
      Text in Illustration
      *1 Heat gun

      Using the heat gun, heat the generator rear end cover.

      Heating Temperature
      Item Temperature
      Generator Rear End Cover 50 to 60°C (122 to 140°F)
    3. A004HTV

      Insert the 2 screw drivers, and remove the generator rear end cover as shown in the illustration.

  2. REMOVE GENERATOR PULLEY


    1. A004HISE01
      Text in Illustration
      *1 Aluminium plate

      Mount the generator in a vise between aluminum plates.

    2. A004H92

      Remove the nut and generator pulley.

  3. REMOVE GENERATOR DRIVE END FRAME ASSEMBLY


    1. A004IU3

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

  4. REMOVE GENERATOR DRIVE END FRAME BEARING


    1. A004I2CE01

      Mount the generator drive end frame assembly in a vise between aluminum plates.

    2. Remove the 4 bolts and bearing retainer.

      Text in Illustration
      *1 Aluminium plate
    3. A004JQAE17

      Using SST and a hammer, tap out the bearing.

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

  5. REMOVE GENERATOR ROTOR BEARING


    1. A004J1SE02
      Text in Illustration
      *1 Wooden block

      Set the SST to the generator rotor assembly between wooden blocks.

      SST
      09387-00041
    2. A004JK1E03
      Text in Illustration
      *1 SST Nut
      *2 SST Bolt
      *a Hold
      *b Turn

      Hold the SST nut, and turn the SST bolt to remove the generator rotor bearing.

  6. REMOVE GENERATOR COIL ASSEMBLY


    1. A004IK5

      Remove the 6 bolts and generator coil assembly.

  7. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A004JFJ

      Remove the 4 bolts and generator brush holder assembly.

  8. REMOVE BRUSH


    1. A004I74

      Remove the cover A from the brush holder assembly.

    2. A004JNM

      Remove the cover B from the brush holder assembly.

    3. A004K64E02
      Text in Illustration
      *1 Soldering iron

      Using a soldering iron, separate the 2 brushes from the brush holder assembly.

  9. REMOVE GENERATOR HOLDER WITH RECTIFIER


    1. A004KXH

      Remove the terminal cover.

    2. A004IK8

      Remove the nut and the terminal.

    3. A004IVB

      Remove the 3 bolts and the generator holder with rectifier.