Disassembly and Reassembly
DISASSEMBLY1. REMOVE REAR END COVER
a. Remove the nut and terminal insulator.
b. 70 A type:
Remove the 3 nuts and end cover.
c. 100 A type:
Remove the bolt 3 nuts, plate terminal and end cover.
2. REMOVE BRUSH HOLDER
a. 100 A type:
Remove the brush holder cover from the brush holder.
b. Remove the 2 screws and brush holder.
c. 70 A type:
Remove the brush holder cover from the brush holder.
d. 100 A type:
Remove the seal plate from the rectifier end frame.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
a. Remove the nut and cord clip.
b. 70 A type:
Remove the 4 screws, bolt and rectifier holder.
c. 100 A type:
Remove the 4 screws and rectifier holder.
d. 100 A type:
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 09820-63011
Torque: 39 Nm (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.
6. REMOVE RECTIFIER END FRAME
a. Remove the 3 nuts.
b. Using SST, remove the rectifier end frame.
SST 09286-46011
c. Remove the generator washer from the rectifier end frame.
7. REMOVE ROTOR FROM DRIVE END FRAME
REPLACEMENT
1. 70 A type:
REPLACE BRUSHES
a. Unsolder and remove the brush and spring.
b. Run the wire of the brush through 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 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 oft the excess wire.
f. Apply insulation paint to the soldered point.
2. REPLACE FRONT BEARING
a. Remove the 4 screws and bearing retainer.
b. Using SST and a press, press out the bearing.
SST 09950-60010 (09951-00260, 09952-06010)
c. 70 A type:
Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00460)
d. 100 A type:
Using SST and a press, press in a new bearing.
SST 09950-60010 (09951-00520)
e. Install the bearing retainer with the 4 screws.
Torque: 2.6 Nm (26.5 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
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 3 nuts.
Torque: 4.5 Nm (46 kg.cm, 39 in.lb)
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 Nm (400 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: 110.5 Nm (1,125 kg.cm, 81 ft.lb)
g. Remove the generator from SST (C).
h. Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
a. 100 A type:
Install the 4 rubber insulators on the lead wires.
NOTE: Be careful of the rubber insulators installation direction.
b. 70 A type:
Install the rectifier with the 4 screws and bolt.
Torque:
Screw: 1.96 Nm (20 kg.cm, 17 in.lb)
Bolt: 3.9 Nm (40 kg.cm, 34 in.lb)
c. 100 A type:
Install the rectifier with the 4 screws.
Torque: 2.94 Nm (30 kg.cm, 26 in.lb)
d. Install the cord clip with the nut.
Torque: 5.4 Nm (55 kg.cm, 48 in.lb)
6. INSTALL BRUSH HOLDER AND VOLTAGE REGULATOR
a. 70 A type:
Install the brush holder cover to the brush holder.
NOTE: Be careful of the holder installation direction.
b. 70 A type:
Place the voltage regulator together with the brush holder horizontally on the rectifier end frame.
c. 70 A type:
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 Nm (20 kg.cm, 17 in.lb)
d. 70 A type:
Fit the brush holder cover.
e. 100 A type:
Place the seal plate on the rectifier end frame.
f. 100 A type:
Place the voltage regulator and brush holder on the rectifier end frame.
NOTE: Be careful of the brush holder installation direction.
g. 100 A type:
Install the 5 screws.
Torque: 1.96 Nm (20 kg.cm, 17 in.lb)
h. 100 A type:
Place the brush holder cover on the brush holder.
7. INSTALL REAR END COVER
a. 70 A type:
Install the end cover with the 3 nuts.
Torque: 4.4 Nm (46 kg.cm, 39 in.lb)
b. 100 A type:
Install the end cover and plate terminal with the bolt and 3 nuts.
Torque:
Bolt: 3.85 Nm (39 kg.cm, 34 in.lb)
Nut: 4.4 Nm (46 kg.cm, 39 in.lb)
c. Install the terminal insulator with the nut.
Torque: 4.1 Nm (41.5 kg.cm, 36 in.lb)
8. CHECK THAT ROTOR ROTATES SMOOTHLY