GENERATOR(for 150 A Type) REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   

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

      09950-60010

      09951-00520

      09950-70010

      09951-07100

   2. Install the bearing retainer with the 4 screws.

      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 with clutch.

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

3. INSTALL GENERATOR COIL ASSEMBLY

   1. 

      *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.

      5.6 N*m

      57 kgf*cm

      50 in.*lbf

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   1. 

      *a

      Pin

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

   2. 

      *a

      Pin

      Install the generator brush holder assembly with the 2 screws.

      1.8 N*m

      18 kgf*cm

      16 in.*lbf

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

5. INSTALL TERMINAL INSULATOR

   1. Install the terminal insulator to the generator coil assembly.

6. INSTALL GENERATOR REAR END COVER

   1. Install the generator rear end cover with the 3 bolts.

      4.6 N*m

      47 kgf*cm

      41 in.*lbf

7. INSTALL GENERATOR PULLEY WITH CLUTCH

   1. Temporarily install the generator pulley with clutch by hand.

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

   3. 

      *a	Gnerator Rotor Shaft

      Install SST (A) and (B) to the generator pulley with clutch as shown in the illustration.

      09820-63021

   4. 

      *a	Hold
      *b	Fulcrum Length
      	Turn

      Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley with clutch.

      without SST

      80 N*m

      816 kgf*cm

      59 ft.*lbf

      with SST

      64 N*m

      653 kgf*cm

      47 ft.*lbf

      Tip:

      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification.

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      • Make sure SST and the wrench are connected in a straight line.

      Note:

      Be careful as the generator pulley with clutch or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

   5. Remove SST from the generator.

   6. Check that the generator pulley with clutch rotates smoothly.

8. INSTALL GENERATOR PULLEY CAP

   1. 

      Install a new generator pulley cap to the generator pulley with clutch.