Disassembly and Reassembly
DISASSEMBLY
1. 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 5 screws, brush holder and voltage regulator.
c. Remove the seal plate from the rectifier end frame.
3. REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.
4. REMOVE PULLEY
a. 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)
b. Check that SST (A) is secured to the rotor shaft.
c. Mount SST (C) in a vise.
d. Insert SST (B) into SST (C), and attach the pulley nut 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.
5. REMOVE RECTIFIER END FRAME
a. Remove the 4 nuts and wire clip.
b. Using SST, remove the rectifier end frame.
SST 09286-46011
c. Remove the generator washer from the rotor
6. REMOVE ROTOR FROM DRIVE END FRAME
REASSEMBLY
1. INSTALL ROTOR TO DRIVE END FRAME
a. Place the drive end frame on the pulley.
b. Install the rotor to the drive end frame.
2. INSTALL RECTIFIER END FRAME
a. Place the generator washer on the rotor.
b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.
c. Install the wire clip and 4 nuts.
Torque:
Nut A: 4.5 Nm (46 kg.cm, 40 in.lb)
Nut B: 5.4 Nm (55 kg.cm, 48 in.lb)
3. 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: 111 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).
4. 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 holder while pushing it with the 4 screws
Torque: 2.9 Nm (30 kg.cm, 26 in.lb)
5. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
a. Place the seal plate on the rectifier end frame
b. Place the voltage regulator and brush holder on the rectifier end frame.
NOTE: Be careful of the holder installation direction.
c. Install the 5 screws.
Torque: 2.0 Nm (20 kg.cm, 18 in.lb)
d. 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:
Nut: 4.4 Nm (45 kg.cm, 39 in.lb)
Bolt: 3.9 Nm (39 kg.cm, 35 in.lb)
b. Install the terminal insulator with the nut.
Torque: 4.1 Nm (42 kg.cm, 36 in.lb)
7. CHECK THAT ROTOR ROTATES SMOOTHLY
REPLACEMENT
1. REPLACE FRONT BEARING
a. Remove the 4 screws, bearing retainer and bearing.
b. Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00350), 09950-70010 (09951-7100)
c. Using SST and a press, press in a new bearing.
SST 0995-60010 (09951-00530), 0995-70010 (09951-07100)
d. Install the bearing retainer with the 4 screws.
Torque: 3.0 Nm (31 kg.cm, 27 in.lb)
2. REPLACE REAR BEARING
a. Using SST remove the bearing cover (outside) and bearing.
SST 09820-00021
NOTE: Be careful not to damage the fan.
b. Remove the bearing cover (inside).
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