Disassembly and Reassembly
DISASSEMBLY1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. Remove the 3 nuts, bolt, plate terminal and rear 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 nut and cord clip.
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 09820-63010
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Check that SST (A) is secured to the rotor shaft
c. As shown in the illustration, mount SST (C) in a vise, and install the generator to SST (C).
d. To loosen the pulley nut, turn SST (A) in the direct 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.
e. Remove the generator from SST (C).
f. Turn SST (B), and remove SST (A and B).
g. Remove the pulley nut and pulley.
5. REMOVE RECTIFIER END FRAME
a. Remove the 3 nuts and cord clip
b. Using SST, remove the rectifier end frame. SST 0928-46011
c. Remove the generator washer.
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. Temporarily install the cord clip and 3 nuts.
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 O9820-63010
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
c. Check that SST (A) is secured to the pulley shaft.
d. As shown in the illustration, mount SST (C) in a vise, and install the generator to SST (C).
e. To torque the pulley nut, turn SST (A) in the direction, shown in the illustration.
Torque: 110.5 N.m (1,128 kgf.cm, 81 ft.lbf)
f. Remove the generator from SST (C).
g. Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
a. Install the 4 rubber insulators on the lead wires.
b. Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.94 N.m (30 kgf.cm, 26 in.lbf)
c. Install the cord clip and nut. Tighten the 4 nuts.
Torque:
A: 4.5 N.m (46 kgf.cm, 40 in.lbf)
B: 5.4 N.m (55 kgf.cm, 48 in.lbf)
6. 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.
holder: 2.0 N.m (20 kgf.cm, 17 in.lbf)
d. Place the brush holder cover on the brush holder.
7. INSTALL REAR END COVER
a. Install the end cover and plate terminal with the 3 nuts and bolt.
Torque:
Bolt: 3.8 N.m (39 kgf.cm, 34 in.lbf)
Nut: 4.4 N.m (45 kgf.cm, 39 in.lbf)
b. Install the terminal insulator with the nut.
Torque: 6.5 N.m (66 kgf.cm, 58 in.lbf)
8. CHECK THAT ROTOR ROTATES SMOOTHLY