Disassembly and Reassembly

DISASSEMBLY




1. REMOVE REAR END COVER
a. Remove the 3 nuts the and end cover.
b. Remove the terminal insulator.

2. REMOVE BRUSH HOLDER
a. Remove the 2 screws and brush holder.




3. REMOVE PULLEY
a. Hold SST (A) with a torque wrench, and tighten (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.




4. REMOVE COIL ASSEMBLY
a. Remove the 4 bolts.




b. Using SST, remove the coil assembly.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-04011)

c. Remove the generator washer.

5. REMOVE ROTOR FROM DRIVE END FRAME

REASSEMBLY




1. 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. INSTALL COIL ASSEMBLY
a. Place the generator washer on the rotor.




b. Using SST and a press, slowly press in the coil assembly.
SST 09285-76010




c. Install the coil assembly with the 4 bolts.

Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)




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 09820-63011

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 (A) 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: 110.3 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).




i. Place the brush holder on the coil assembly with the pin facing upward.

NOTE: Be careful of the holder installation direction.

j. Install the 2 screws.

Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)




4. INSTALL REAR END COVER
a. Install the terminal insulator.

NOTE: Be careful of the terminal insulator installation direction.




b. Install the end cover with the 3 nuts.

Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)

5. CHECK THAT ROTOR ROTATES SMOOTHLY