GENERATOR (for 80A Type) REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. Install the generator rotor to the generator drive end frame.

      Note

      Do not drop the generator rotor assembly.

    2. Install the washer to the generator rotor.

    3. A01DNAIE01
      Text in Illustration
      *1 17 mm Socket Wrench

      Using a 17 mm socket wrench and press, slowly press on the rectifier end frame.

    4. Install the 4 nuts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

    5. Install the 3 terminal insulators to the rectifier end frame.

  2. INSTALL GENERATOR HOLDER WITH RECTIFIER


    1. Install the generator holder with rectifier with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

  3. INSTALL GENERATOR REGULATOR ASSEMBLY


    1. Install the generator regulator with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. Install the plate seal.

    2. Install the generator brush holder with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

    3. Install the brush cover to the generator brush holder.

    4. Install the terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 in.*lbf }

    5. Install the generator rear end cover with the 2 nuts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

    6. Install the rectifier plate with the nut and screw.

      Torque:
      for nut
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
      for screw
      3.9 N*m  { 39 kgf*cm, 34 in.*lbf }

  5. INSTALL GENERATOR WITH CLUTCH PULLEY


    1. Temporarily install the generator with clutch pulley to the generator rotor shaft by hand.

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

    3. A01DNN4E01
      Text in Illustration
      *1 Rotor Shaft

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

      SST
      09820-63021

      Note

      Securely attach SST to the generator with clutch pulley and generator rotor shaft.

    4. A01DNTCE03
      Text in Illustration
      *a Hold
      *b Torque Wrench Fulcrum Length
      A01DQPB Turn

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

      Torque:
      Specified tightening torque
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      Note

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

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using SST (fulcrum length of 100 mm (3.9 in.)) + torque wrench (fulcrum length of 400 mm (15.7 in.)):

        64 N*m (653 kgf*cm, 47 ft.*lbf)

    5. Remove SST from the generator.

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

  6. INSTALL GENERATOR PULLEY CAP


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