Disassembly and Reassembly
DISASSEMBLY1. 12 V 90 A type:
REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
2. 12 V 100 A type:
REMOVE REAR END COVER
Remove the 3 nuts and terminal insulator.
3. 12 V 90 A type:
REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
a. Remove the 5 screws, brush holder and voltage regulator.
b. Remove the seal plate from the rectifier end frame.
4. 12 V 100 A type:
REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
a. Remove the terminal insulator.
b. Remove the 2 screws and brush holder.
5. 12 V 90 A type:
REMOVE RECTIFIER HOLDER
a. Remove the 4 screws and rectifier holder.
b. Remove the 4 rubber insulators.
6. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
SST 09820-63011
Torque: 39 N.m (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.
7. 12 V 90 A type:
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.
8. 12 V 100A type:
REMOVE RECTIFIER END FRAME
a. Remove the 4 bolts.
b. Remove the bolt and cord clip.
c. Using SST, remove the rectifier end frame.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071)
d. Remove the alternator washer from the rotor.
9. REMOVE ROTOR FROM DRIVE END FRAME
REPLACEMENT
1. REPLACE FRONT BEARING
a. Remove the 4 screws and bearing retainer.
b. Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
c. Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07100)
d. Install the bearing retainer with the 4 screws.
Torque:
3.0 N.m (31 kg.cm, 27 in.lb) for 12 V 90 A type
2.3 Nm (23 kgf.cm, 20 in.lbf) for 12 V 100 A type
2. 12 V 90 A type:
REPLACE REAR BEARING
a. Using SST, remove the bearing cover (outside) and bearing.
SST 09821-00021
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 09820-00031
e. Using SST, push in the bearing cover (outside).
SST 09825-76010
REASSEMBLY
1. 12 V 90 A type:
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. 12 V 100 A type:
INSTALL ROTOR TO DRIVE END FRAME
a. Place the drive end frame on the pulley.
b. Install the rotor to the drive end frame.
3. 12 V 90 A type:
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:
4.5 N.m (46 kg.cm, 40 in.lb) for without wire clip
5.4 N.m (55 kg.cm, 48 in.lb) for with wire clip
4. 12 V 100 A type:
INSTALL RECTIFIER END FRAME
a. Place the alternator washer on the rotor.
b. Using a 21 mm socket wrench and press, slowly press in the rectifier end frame.
c. Tighten the 4 bolts.
Torque: 5.8 Nm (59 kgf.cm, 51 in.lbf)
d. Install the cord clip with the bolt.
Torque: 4.5 Nm (46 kgf.cm, 40 in.lbf)
5. 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 09820-63011
Torque: 39 N.m (398 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 N.m (1,132 kg.cm, 82 ft.lb)
g. Remove the generator from SST (C).
h. Turn SST (B), and remove SST (A and B).
6. 12 V 90A type:
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 N.m (30 kg.cm, 26 in.lb)
7. 12 V 90 A type:
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 N.m (20 kg.cm, 18 in.lb)
8. 12 V 90 A type:
INSTALL BRUSH HOLDER AND TERMINAL INSULATOR
a. While pushing the 2 brushes to inside the brush holder, insert a pin (Dia 1.0 mm (0.039 in.)) into the brush holder hole.
b. Install the brush holder with the 2 screws.
Torque: 1.8 Nm (18 kgf.cm, 16 in.lbf)
c. Pull out the pin (Dia 1.0 mm (0.039 in.)) from the brush holder.
d. Install the terminal insulator to the rectifier end frame.
9. 12 V 90 A type:
INSTALL REAR END COVER
a. Place the brush holder cover on the brush holder.
b. Install the end cover and plate terminal with the bolt and 3 nuts.
Torque:
4.4 N.m (45 kg.cm, 39 in.lb) for nut
3.9 N.m (40 kg.cm, 35 in.lb) for bolt
c. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kg.cm, 36 in.lb)
10. 12 V 100 A type:
INSTALL REAR END COVER
Install the end cover with the bolt and 3 nuts.
Torque: 4.6 Nm (47 kgf.cm, 41 in.lbf)
11. CHECK THAT ROTOR ROTATES SMOOTHLY