Page 1049 of 2543
(e) To loosen the pulley nut, turn SST (A) in the direction shown
in the illustration.
NOTICE: To prevent damage to the rotor shaft, do not loosen
the pulley nut more than one±half of a turn.
(f) Remove the generator from SST (C).
(g) Turn SST (B), and remove SST (A and B).
(h) Remove the pulley nut and pulley.
6. REMOVE RECTIFIER END FRAME
(a) Remove the 3 nuts.
(b) Using SST, remove the rectifier end frame.
SST 09950±40010
(c) Remove the generator washer.
7. REMOVE ROTOR FROM DRIVE END FRAME CH±12
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Page 1050 of 2543

GENERATOR INSPECTION AND REPAIR
Rotor
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between
the slip rings.
Standard resistance:
2.8±3.0 at 20°C (68°C)
If there is no continuity, replace the rotor
2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity be-
tween the slip ring and rotor.If there is continuity, replace the
rotor.
3. INSPECT SLIP RINGS
(a) Check that the slip rings are not rough or scored. If rough or
scored, replace the rotor.
(b) Using a vernier caliper, measure the slip ring diameter.
Standard diameter:
14.2±14.4 mm (0.559±0.567 in.)
Minimum diameter:
12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.
Stator (Drive End Frame)
1. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between
the coil leads.If there is no continuity, replace the drive end
frame assembly.
2. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity be-
tween the coil lead and drive end frame.If there is continuity,
replace the drive end frame assembly. CH±13
± CHARGING SYSTEMGENERATOR
Page 1051 of 2543

Brushes
INSPECT EXPOSED BRUSH LENGTH
Using a vernier caliper, measure the exposed length.
Standard exposed length:
10.5 mm (0.413 in.)
Minimum exposed length:
1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush
holder.
Rectifiers (Rectifier Holder)
1. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the positive
(+) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no
continuity.If continuity is not as specified, replace the rectifier
holder.
2. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each
negative (±) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no con-
tinuity.
If continuity is not as specified, replace the rectifier holder.
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
± CHARGING SYSTEMGENERATORCH±14
Page 1052 of 2543
2. IF NECESSARY. REPLACE FRONT BEARING
(a) Remove the 4 screws, bearing retainer and bearing.
(b) Using a socket wrench and press, press out the bearing.
(c) Using SST and a press, press in a new bearing.
SST 09608±20012 (09608±00030)
(d) Install the bearing retainer with the 4 screws.
3. INSPECT REAR BEARING
Check that the bearing is not rough or worn.
4. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover (outside) and bearing.
SST 09820±00021
NOTICE: Be careful not to damage the fan.
(b) Remove the beating cover (inside). CH±15
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Page 1053 of 2543
(c) Place the bearing cover (inside) on the rotor.
(d) Using SST and a press, press in a new bearing.
SST 09820±00030
(e) Using SST, push in the bearing cover(outside).
SST 09285±76010
GENERATOR ASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO RECTIFIER END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Place the generator washer on the rotor.
± CHARGING SYSTEMGENERATORCH±16
Page 1054 of 2543
(b) Using a 29 mm socket wrench and press, slowly press in the
rectifier end frame.
(c) Install the 3 nuts.
Torque: 4.5 NVm (46 kgfVcm, 40 in.Vlbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley nut
by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (b)
clockwise to the specified torque.
SST 09820±63010
Torque: 39 NVm (400 kgfVcm, 29 ftVlbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to SST
(C).
(f) To torque the pulley nut, turn SST (A) in the direction shown
in the illustration.
Torque: 110 NVm (1,125 kgfVcm, 81 ftVlbf)
(g) Remove the generator from SST (C). CH±17
± CHARGING SYSTEMGENERATOR
Page 1055 of 2543
(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Install the 4 rubber insulators on the lead wires.
(b) Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.0 NVm (20 kgfVcm, 17 in.Vlbf)
6. INSTALL WIRE CLIP
Install the wire clip with the nut.
Torque: 4.5 NVm (46 kgfVcm, 40 in.Vlbf)
7. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
(a) Place the seal plate on the rectifier end frame.
± CHARGING SYSTEMGENERATORCH±18
Page 1056 of 2543
(b) Place the voltage regulator and brush holder on the rectifier
end frame.
NOTICE: Be careful of the holder installation direction.
(c) Install the 5 screws until there is a clearance of approx. 1 mm
(0.04 in.) between the brush Holder and voltage regulator.
(d) Place the brush holder cover on the brush holder.
8. INSTALL REAR END COVER
(a) Install the end cover and plate terminal with the bolt and 3
nuts.
Torque:
Nut
4.5 NVm (46 kgfVcm, 40 in.Vlbf)
Bolt
3.9 NVm (40 kgfVcm, 35 in.Vlbf)
(b) Install the terminal insulator with the nut.
Torque: 6.5 NVm (66 kgfVcm, 58 in.Vlbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY CH±19
± CHARGING SYSTEMGENERATOR