GENERATOR(for 100A Type) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01WBHHN01

      Using SST and a press, press in a new generator drive end frame bearing.

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01W89VC01
      *a Tab
      *b Cutout

      Fit the tabs on the retainer plate into the cutouts on the generator drive end frame.

    3. Install the retainer plate with the 4 screws.

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Place the generator drive end frame on the generator pulley.

    2. Install the generator rotor assembly to the generator drive end frame.

  3. INSTALL GENERATOR BEARING COVER PACKING

    Note

    A new generator coil assembly comes with a generator bearing cover packing. Therefore, it is not necessary to install a new generator bearing cover packing when installing a new generator coil assembly.


    1. A01WAHZC05
      *a Protrusions
      *b Grooves

      Install a new generator bearing cover packing to the generator coil assembly.

      Note

      Align the protrusions of the generator bearing cover packing with the grooves of the generator coil assembly when installing.

  4. INSTALL GENERATOR COIL ASSEMBLY


    1. A01W9EAC01
      *a 21 mm Deep Socket Wrench

      Using a 21 mm deep socket wrench and press, slowly press in the generator coil assembly.

    2. Install the generator coil assembly with the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01WAU2C14
      *a Pin

      While pushing the 2 brushes into the generator brush holder assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

    2. A01W8GQC01
      *a Pin

      Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

    3. Pull out the pin from the generator brush holder assembly.

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01LAZC

      Install the terminal insulator to the generator coil assembly.

      Note

      Make sure that the generator terminal insulator is installed with the correct orientation.

  7. INSTALL GENERATOR REAR END COVER


    1. Install the generator rear end cover to the generator coil assembly with the 3 bolts.

      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }

  8. INSTALL GENERATOR PULLEY


    1. Temporarily install the generator pulley by hand.

    2. Mount the generator assembly in the vise between aluminum plates.

    3. A01W99BC05
      *a Hold
      B0068HS Turn

      Install SST 1-A and B to the generator pulley shaft.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )
      SST 1-A and B 09820-06010
      SST 2 09820-06021

    4. Install SST 1-B to SST 1-A.

    5. Hold SST 1-A with a torque wrench and turn SST 1-B clockwise with the specified torque.

      Note

      Make sure that SST is secured to the generator rotor shaft.

    6. A01WAR6C01
      B0068HS Insert

      Insert SST 2 and attach it to the pulley nut.

    7. A01W8XVC01
      *a Hold
      B0068HS Turn

      Tighten the pulley nut by turning SST 1-A as shown in the illustration.

      Torque:
      132.5 N*m  { 1351 kgf*cm, 98 ft.*lbf }

    8. Remove SST 2 from the generator assembly.

    9. A01WAT3C06
      *a Hold
      B0068HS Turn

      Turn SST 1-B as shown in the illustration and remove SST 1-A and B.

    10. Turn the generator pulley and check that the generator pulley moves smoothly.

    11. Remove the generator assembly from the vise.