Disassembly and Reassembly

DISASSEMBLY




1. 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 O9820-63010

Torque: 39 Nm (400 kg.cm, 29 ft.lb)

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 with SST (A) and (B) to SST (C).

d. 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.

e. Remove the generator with SST (A) and (B) from SST (C).
f. Turn SST (B) and remove SST (A) and (B).
g. 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 09286-46011
c. Using snap ring pliers, remove the generator washer from the rectifier end frame.

7. REMOVE ROTOR FROM DRIVE END FRAME

REASSEMBLY




1. INSTALL ROTOR TO DRIVE END FRAME
a. Place the rectifier end frame on the pulley.
b. Install the rotor to the rectifier end frame.

2. 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 Nm (45 kg.cm, 39 in.lb)

3. 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 Nm (400 kg.cm, 29 ft.lb)

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 with SST (A) and (B) to SST (C).
e. To torque the pulley nut, turn SST (A) in the direction shown in the illustration.

Torque: 110 Nm (1,125 kg.cm, 81 ft.lb)

f. Remove the generator with SST (A) and (B) from SST (C).
g. Turn SST (B) and remove SST (A) and (B).




4. 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: 2.0 Nm (20 kg.cm, 18 in.lb)

5. 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. Install the voltage regulator and brush holder to the rear end frame horizontally as shown in the illustration.

HINT: Check that the brush holder's cover doesn't slip to one side during installation.




c. Tighten the 5 screws until there is a clearance of at least 1 mm (0.04 in.) between the brush holder cover and connector.

6. INSTALL REAR END COVER




a. Install the end cover with the 3 nuts.

Torque: 4.5 Nm (45 kg.cm, 39 in.lb)

b. Install the terminal insulator with the nut.

Torque: 4.1 Nm (42 kg.cm, 36 in.lb)

7. 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 a socket wrench and press, press out the bearing.




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 Nm (27 kg.cm, 23 in.lb)

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