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
a. Remove the 2 screws, brush holder and cover.
b. Remove the brush holder cover from the brush holder.
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 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. 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 on-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 0928-06011
c. Remove the generator washer from the rectifier end frame.
7. REMOVE ROTOR FROM DRIVE END FRAME
REASSEMBLY
1. PLACE RECTIFIER 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, 39 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. 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: 110.5 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
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: 1.96 N.m (20 kgf.cm, 18 in.lbf)
6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR
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 voltage regulator.
Torque:1.96 N.m (20 kgf.cm, 18 in.lbf)
d. Fit the brush holder cover.
7. INSTALL REAR END COVER
a. Install the end cover with the 3 nuts.
Torque: 4.4 N.m (45 kgf.cm, 39 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