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Old 08-29-2018, 10:00 PM   #1
Clem Clement
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Default generator with stuck on pulley

Looking for ideas about removing a pulley. a flange is broken so the pully needs to go. It has been soaking in Kroil for a week
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Old 08-29-2018, 10:02 PM   #2
J Franklin
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Default Re: generator with stuck on pulley

Try a chisel.
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Old 08-29-2018, 11:29 PM   #3
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Default Re: generator with stuck on pulley

Maybe try a 'pulley-puller', but the cheaper way is as J. Franlklin says and crack it with a chisel - just try not to scare the generator armature shaft.
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Old 08-30-2018, 05:42 AM   #4
Patrick L.
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Default Re: generator with stuck on pulley

I think anyone would get scared if they saw someone with a hammer and chisel coming after them, so i think the pulley would feel the same. [ smiley face]. Sorry, couldn't resist.
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Old 08-30-2018, 05:51 AM   #5
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Default Re: generator with stuck on pulley

Pulley up, generator down. Holding pulley, hit shaft with hammer. Weight of generator and shock should drop generator. Has always worked for me. Enjoy.
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Old 08-30-2018, 08:24 AM   #6
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Default Re: generator with stuck on pulley

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Quote:
Originally Posted by WHN View Post
Pulley up, generator down. Holding pulley, hit shaft with hammer. Weight of generator and shock should drop generator. Has always worked for me. Enjoy.
Sounds good but... Back the nut off to where it is almost flush with the end of the armature shaft, and it will protect the threads somewhat. Also, a piece of brass or some softer that steel metal between the shaft and hammer is not a bad idea to further protect the saft from swelling when hit. Heat the pulley if you must, but don't allow the armature to get too hot for obvious reasons.

Since the old pulley is broken and scrap, you can consider more drastic measures if needed, like drilling some small pressure relief holes around it next to the shaft, cutting or breaking it in two, etc.(depends if it is cast iron, or cast steel, etc.)

Perservere, you will get it, and all of us will come to you when our crap gets stuck and you will be our hero.
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Old 08-30-2018, 08:39 AM   #7
Clem Clement
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Default Re: generator with stuck on pulley

The bolt is not good. I have tried lightly with the slightly loose bolt and a brass drift. The pulley is not quite fully on the armature shaft making me think it is the wrong pully. I'm going to use a small socket so the pressure is on the shaft end edges and not over the threaded hole area. We'll see
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Old 08-30-2018, 09:40 AM   #8
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Default Re: generator with stuck on pulley

screw a bolt into the threaded hole, all the way so it is almost bottomed (tightening it all the way may get into partial threads that can distort the end of the bolt , this will protect the end of the shaft
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Old 08-30-2018, 09:49 AM   #9
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Default Re: generator with stuck on pulley

Quote:
The pulley is not quite fully on the armature shaft making me think it is the wrong pully.
Pulley is a taper fit, so it doesn't have to "bottom".
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Old 08-30-2018, 10:55 AM   #10
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Default Re: generator with stuck on pulley

I screw a longer bolt, like 2", into the shaft until it lightly bottoms, then hit the bolt head hard while holding the generator by the pulley. Usually one or tow hits will knock it loose. Only one time I had a really stuck pulley that took about 20 really hard blows to knock it loose.
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Old 08-30-2018, 12:46 PM   #11
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Default Re: generator with stuck on pulley

Don't let that heavy sucker land on your toes. The joy of getting it loose will be short lived. Chap
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Old 08-30-2018, 01:18 PM   #12
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Default Re: generator with stuck on pulley

This is where you need nice soft earth and kneal down holding the gen by the pulley about an inch above the dirt and whack the pulley. I just removed 4 doing this method in about 6 whacks.

I take the bolt completely out - your whacking the end of the pulley so it sends shockwaves down the taper. no chance of hurting the threads this way and if it falls it falls an inch into soft stuff.

Could do the same hovering it over a box of bubble wrap or box of old towels on the bench top.
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Old 08-30-2018, 09:16 PM   #13
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Default Re: generator with stuck on pulley

The problem with hammering directly on the pulley center is cast iron can easily be broken.
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Old 08-30-2018, 09:18 PM   #14
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Default Re: generator with stuck on pulley

I looked it over and figured I'd do it my way. I put an attachment bracket in my vice and moved the chip in the pulley where I could get a good shot at the inside of the pulley with a brass drift. Then I told the pulley" if you don't jump off, I'll melt you into a chebby part." It jumped!!

Thanks all.
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