Disassembly and Reassembly
DISASSEMBLY1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the 3 nuts, and end cover.
2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
Remove the 5 screws, bush holder and voltage regulator.
3. REMOVE RECTIFIER HOLDER
Remove the bolt, 4 screws and rectifier holder.
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 N.m (400 kgf.cm, 29 ft.lbf)
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.
5. REMOVE RECTIFIER END FRAME
a. Remove the 4 nuts.
b. Using SST, remove the rectifier end frame.
SST 09286-46011
6. 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. 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 4 nuts.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
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 N.m (400 kgf.cm, 29 ft.lbf)
c. Check that SST (A) is secured to the pulley shaft.
d. Mount SST (C) in a vise.
e. Install the generator to SST (C).
f. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110 N.m (1,125 kgf.cm, 81 ft.lbf)
g. Remove the generator from SST (C).
h. Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
Install the rectifier holder with the bolt and 4 screws.
Torque:
1.96 N.m (20 kgf.cm, 17.4 in.lbf) for screw
3.9 N.m (40 kgf.cm, 34.7 in.lbf) for bolt
6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER
a. Install the brush holder cover to the brush holder.
NOTE: Be careful of the holder installation direction.
b. Place the voltage regulator together with the brush holder horizontally on the rectifier end frame.
c. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector.
Torque: 1.96 N.m (20 kgf.cm, 17.4 in.lbf)
7. INSTALL REAR END COVER
a. Install the end cover with the 3 nuts.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
b. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY
REPLACEMENT
1. REPLACE BRUSHES
a. Unsolder and remove the brush and spring.
b. Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder.
c. Solder the brush wire to the brush holder at the specified exposed length.
Exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.)
d. Check that the brush moves smoothly in the brush holder.
e. Cut off the excess wire.
f. Apply insulation paint to the soldered area.
2. 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 (09951-00260, 09952-06010)
c. Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00500)
d. Install the bearing retainer with the 4 screws.
Torque: 2.6 N.m (26.5 kgf.cm, 23 in.lbf)
3. 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