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.
c. Remove the brush holder cover from the brush holder.
2. REMOVE BRUSH HOLDER
a. Remove the 2 screws and brush holder.
b. Remove the seal plate from the rectifier end frame.
3. REMOVE VOLTAGE REGULATOR AND RECTIFIER HOLDER
a. Remove the 3 screws and voltage regulator.
b. Remove the 4 screws and rectifier holder.
c. 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 09820-63011
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 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
c. Remove the generator washer from the rectifier end frame.
6. REMOVE ROTOR FROM DRIVE END FRAME
INSPECTION
1. INSPECT VOLTAGE REGULATOR
a. Using an ohmmeter, check the continuity between terminals F and B.
Standard:
When the positive and negative poles between terminals F and B are exchanged, there is continuity in one way but no continuity in another way.
If the continuity is not as specified, replace the regulator.
b. Using an ohmmeter, check the continuity between terminals F and E.
Standard:
When the positive and negative poles between terminals F and E are exchanged, there is continuity in one way but no continuity in another way.
If the continuity is not as specified, replace the regulator.
2. INSPECT ROTOR FOR OPEN CIRCUIT
a. Check the rotor for open circuit.
Using an ohmmeter, check that there is continuity between the slip rings.
Standard resistance: 2.1 to 2.5 Ohms at 20 °C (68 °F)
If there is no continuity, replace the rotor.
b. Check the rotor for ground.
Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
If there is continuity, replace the rotor.
c. Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
d. Using vernier calipers, measure the slip ring diameters.
Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.
3. INSPECT STATOR FOR OPEN CIRCUIT
a. Check the stator for open circuit.
Using an ohmmeter, check that there is continuity between the coil leads.
If there is no continuity, replace the drive end frame assembly.
b. Check the stator for ground.
Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.
4. INSPECT POSITIVE RECTIFIER
a. Check the positive (+) rectifier.
1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (a).
3. Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.
b. Check the negative (-) rectifier.
1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (a).
3. Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.
5. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush length.
Standard exposed length: 9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush holder assembly.
6. INSPECT BEARING
Check that the bearing is not rough or worn.
If necessary, replace the drive end frame assembly (front bearing) or rotor assembly (rear bearing).
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 09820-63011
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 while pushing it with the 4 screws.
Torque: 1.96 N.m (20 kgf.cm, 17 in.lbf)
6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR
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 brush holder installation direction.
c. Install the 5 screws.
Torque: 1.96 N.m (20 kgf.cm, 17 in.lbf)
7. 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:
Bolt: 3.85 N.m (39 kgf.cm, 34 in.lbf)
Nut: 4.4 N.m (46 kgf.cm, 39 in.lbf)
c. Install the terminal insulator with the nut.
Torque: 4.1 N.m (41.5 kgf.cm, 36 in.lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY