Disassembly and Reassembly

Generator Disassembly




1. Remove "B" terminal inner nut (3) and insulator (2).
2. Remove rear end cover (1).




3. Remove 2 screws (3) and pull out brush holder assembly (4).
4. Remove 3 screws (1) and IC regulator (2).
5. Remove brush holder cover from brush holder.




6. Remove 4 screws, 1 bolt and rectifier (1).




7. Remove 4 rubber insulators (1).




8. Hold shaft by using hexagonal box wrench (2) and remove pulley nut, and then pull out pulley (1).

CAUTION:
- To hold shaft, use hexagonal box. Duodecimal box may cause slipping and consequential shaft or tool damage.
- Do not attempt to hold pulley by using vise or pipe wrench so as not to distort it.




9. Remove 4 rear end frame nuts (3).
10. Drive out rear end frame (1) with tapping rotor shaft (2) lightly by using plastic hammer (4).
11. Separate rear end frame (1) from rotor evenly by using plastic hammer (4).

CAUTION: Do not hit shaft at slip ring side, when separating rotor and rear end frame.




12. If required, use bearing puller (2) to remove end housing bearing (1) and bearing cover (3).

CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller.




13. If required, remove 4 screws, retainer plate (2) and then drive out drive end bearing (3).
14. If required, remove stud bolts (1) and then pull out stator (4).

NOTE: Heating drive end frame may facilitate removal of stator.

Reassembly




1. If end housing bearing (1) is removed, install it.
2. Check end housing bearing (1) turns smoothly.




3. If stator (4) is removed, install stator (4) and tighten stud bolts (1).
4. If drive end bearing (3) is removed, install it.
5. Check drive end bearing (3) turns smoothly. If OK, install drive end bearing retaining plate (2).

Tightening torque
Stator stud bolt (a): 8.8 N.m (0.88 kg-m, 6.5 lb-ft)
Drive end bearing retaining plate screw (b): 2.6 N.m (0.26 kg-m, 2.0 lb-ft)




6. Place drive end frame (2) on pulley, and then install rotor (1) to drive end frame (2).




7. Install rear end frame (1) to drive end frame (2).
8. Tighten 4 nuts to specified torque.

Tightening torque
Rear end frame nut (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft)




9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to specified torque.

Tightening torque
Generator pulley nut (a): 111 N.m (11.1 kg-m, 80.5 lb-ft)




10. Install 4 rubber insulators (1).




11. Install rectifier (1).

CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades.

Tightening torque
Rectifier screw (a): 2 N.m (0.2 kg-m, 1.5 lb-ft)
Rectifier "B" bolt (b): 3.9 N.m (0.39 kg-m, 3.0 lb-ft)




12. Install brush holder cover (1) to brush holder (2).




13. Place the IC regulator (1) together with the brush holder (2) horizontally on the rear end frame (3).
14. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder (2) and connector.

Tightening torque
Regulator and brash holder screw (a): 2 N.m (0.2 kg-m, 1.5 lb-ft)




15. Install rear end cover (1) and terminal plate (4).

Tightening torque
Rear end cover nut (a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft)
Terminal plate bolt (b): 3.8 N.m (0.38 kg-m, 3.0 lb-ft)

16. Install insulator (2) and tighten "B" terminal inner nut (3) to specified torque.

Tightening torque
"B" terminal inner nut (C): 4.2 N.m (0.42 kg-m, 3.0 lb-ft)




17. Make sure that rotor turns smoothly.