Denso Made
OVERHAUL (FOR DENSO MADE)
1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. 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)
NOTE: Check that SST is secured on the rotor shaft.
b. Mount SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.
d. To loosen the 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 pulley nut more than one-half turn.
e. Remove the generator from SST 2.
f. Turn SST 1-B, and remove SST 1-A and B.
g. Remove the pulley nut and pulley.
2. REMOVE GENERATOR REAR END COVER
a. Place the generator on the pulley.
b. Remove the 3 nuts, then remove the rear end cover.
3. REMOVE TERMINAL INSULATOR
4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the plate seal.
b. Remove the 2 nuts, then remove the brush holder.
c. Remove the plate seal.
5. REMOVE GENERATOR COIL ASSEMBLY
a. Remove the 4 bolts.
b. Using SST, remove the coil.
SST 09950-40011 (09951-04020, 09952-04010,09953-04020, 09954-04010, 09955-04071,09957-04010, 09958-04011)
6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator washer and the generator rotor.
7. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
a. Using vernier calipers, measure the exposed brush length.
Standard exposed brush length: 10.5 mm (0.413 in.)
Minimum exposed brush length: 4.5 mm (0.177 in.)
If the exposed brush length is less than the minimum, replace the brush holder.
8. INSPECT GENERATOR ROTOR ASSEMBLY
a. Check the rotor for an open circuit.
1. Using an ohmmeter, measure the resistance between the slip rings.
Standard: 2.3 to 2.7 Ohms at 20 °C (68 °F)
If the result is not as specified, replace the rotor.
b. Check the rotor for ground.
1. Using an ohmmeter, measure the resistance between the slip ring and rotor.
Standard: 10 kOhms or higher
If the result is not as specified, replace the rotor.
c. Inspect the slip rings.
1. Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
2. Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than the minimum, replace the rotor.
9. INSPECT GENERATOR ROTOR BEARING
a. Check the bearing whether it is rough or worn.
If necessary, replace the generator rotor.
10. INSPECT GENERATOR DRIVE END FRAME BEARING
a. Check the bearing whether it is rough or worn. If necessary, replace the bearing.
11. REMOVE GENERATOR DRIVE END FRAME BEARING
a. Remove the 4 screws, then remove the retainer plate.
b. Using SST, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
12. INSTALL GENERATOR DRIVE END FRAME BEARING
a. Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
b. Install the retainer plate with the 4 screws.
Torque: 2.2 N.m (22 kgf.cm, 19 in.lbf)
13. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the drive end frame on the rotor.
b. Install the rotor and washer.
14. INSTALL GENERATOR COIL ASSEMBLY
a. Using a deep socket wrench 21 and a press, in the generator rectifier end frame carefully.
b. Install the 4 bolts.
Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
15. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. While pushing the 2 brushes to inside the brush holder,insert a pin (Dia. 1.0 mm (0.039 in.)) into the brush holder hole.
b. Install the generator brush holder with the 2 screws.
Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
c. Pull out the pin (Dia. 1.0 mm (0.039 in.)) from the generator brush hold
16. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator to the generator rectifier end frame.
NOTE: Pay attention the mounting orientation of the terminal insulator.
17. INSTALL GENERATOR REAR END COVER
a. Install the rear end cover with the 3 nuts.
Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
18. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Install the pulley onto the rotor shaft by tightening the pulley nut by hand.
b. 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)
NOTE: Check that SST is secured to the rotor shaft.
c. Mount SST 2 in a vise.
d. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.
e. Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.
Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf)
f. Remove the generator from SST 2.
g. Turn SST 1-B, and remove SST 1-A and B.
h. Turn the pulley and check that the pulley moves smoothly.