Disassembly and Assembly

Unit Repair:

COMPONENTS

DISASSEMBLY




1. Remove B terminal inner nut and insulator.




2. Remove rear end cover.
3. Remove 2 screws and pull out brush holder assembly.
4. Remove 3 screws and IC regulator.
5. Remove brush holder cover from brush holder.




6. Remove rectifier.




7. Remove 4 rubber insulators (Type B).




8. Hold shaft by using hexagonal box wrench and remove pulley nut, and then pull out pulley.

CAUTION:
- To hold shaft, use hexagonal box. Duodecimal box may cause slipping and consequential shaft or tool damage.
- Do not attempt to hold pulley by using vise or pipe wrench so as not to distort it.




9. Remove 4 rear end frame nuts.
10. Drive out rear end frame with rotor tapping shaft lightly by using plastic hammer.
11. Separate rear end frame from rotor evenly by using plastic hammer.

CAUTION: Do not hit shaft at slip ring side, when separating rotor and rear end frame.




12. If required, use bearing puller to remove end housing bearing and bearing cover.

CAUTION: Care must be exercised so as not to distort cooling fan blade while applying puller.




13. If required, remove 4 screws, retainer plate and then drive out drive end bearing.
14. If required, remove stud bolts and then pull out stator.

NOTE: Heating drive end frame may facilitate removal of stator.

ASSEMBLY




1. If end housing bearing is removed, install it.
2. Check end housing bearing turns smoothly.




3. If stator is removed, install stator and tighten stud bolts.
4. If drive end bearing is removed, install it.
5. Check drive end bearing turns smoothly.

Tightening Torque
(a): 8.8 N.m (0.88 kg-m, 6.5 lb-ft)
(b): 2.6 N.m (0.26 kg-m, 2.0 lb-ft)




6. Place drive end frame on pulley, and then install rotor to drive end frame.




7. Install rear end frame to drive end frame.
8. Tighten 4 nuts to specified torque.

Tightening Torque: 4.5 N.m (0.45 kg-m, 3.5 lb-ft)




9. Install pulley and tighten pulley nut with holding shaft by using hexagonal box wrench to specified torque.

Tightening Torque: 113 N.m (11.3 kg-m, 81.5 lb-ft)




10. Install 4 rubber insulators.




11. Install rectifier.

CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades.

Tightening Torque: 2.9 N.m (0.29 kg-m, 2.0 lb-ft)




12. Install brush holder cover to brush holder.




13. Place the IC regulator together with the brush holder horizontally on the rear end frame.
14. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector.

Tightening Torque: 2.0 N.m (0.2 kg-m, 1.5 lb-ft)




15. Install rear end cover and terminal plate (Type B).

Tightening Torque
(a): 4.5 N.m (0.45 kg-m, 3.5 lb-ft)
(b): 3.8 N.m (0.38 kg-m, 3.0 lb-ft) (Type B)

16. Install insulator and tighten "B" terminal inner nut to specified torque.

Tightening Torque
(c): 4.2 N.m (0.42 kg-m, 3.0 lb-ft)




17. Make sure that rotor turns smoothly.