Disassembly and Reassembly
DISASSEMBLY1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the bolt 3 nuts, plate terminal and end cover.
2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
a. Remove the brush holder cover from the brush holder.
b. Remove the 2 screws and brush holder.
c. Remove the seat plate from the rectifier end frame
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.
5. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 0982-63010
Torque: 39 Nm (400 kg.cm, 29 ft.lb)
b. Check that SST (A) is secured to the rotor shaft.
c. Mount SST (C) in a vise.
d. Install the generator to SST (C).
e. To loosen the pulley nut, turn SST (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 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 4 nuts.
b. Using SST, remove the rectifier end frame.
SST 0928-46011
7. REMOVE ROTOR FROM DRIVE END FRAME
REASSEMBLY
1. PLACE DRIVE END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
a. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
b. Install the 4 nuts.
Torque: 4.5 Nm (46 kg.cm, 40 in.lb)
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 Nm (400 kg.cm, 29 ft.lb)
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 Nm (1,125 kg.cm, 81 ft.lb)
g. Remove the generator from SST (C).
h. Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
a. Install the 4 rubber insulators on the lead wires.
NOTE: Be careful of the rubber insulators installation direction.
b. Install the rectifier with the 4 screws.
Torque: 2.94 Nm (30 kg.cm, 26 in.lb)
c. Place the seal plate on the rectifier end frame.
d. Place the voltage regulator and brush holder on the rectifier end frame.
NOTE: Be careful of the brush holder installation direction.
e. Install the 5 screws.
Torque: 1.96 Nm (20 kg.cm, 17 in.lb)
f. Place the brush holder cover on the brush holder.
6. INSTALL REAR END COVER
a. Install the end cover and plate terminal with the bolt and 3 nuts.
Torque:
- Bolt: 3.85 Nm (39 kg.cm, 34 in.lb)
- Nut: 4.4 Nm (46 kg.cm, 39 in.lb)
b. Install the terminal insulator with the nut.
Torque: 4.1 Nm (41.5 kg.cm, 36 in.lb)
7. CHECK THAT ROTOR ROTATES SMOOTHLY