GENERATOR (for 100A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01DP3OE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01DQZ8E02
      Text in Illustration
      *1 Claw

      Align the claws of the retainer plate with the grooves inside the 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. Install the generator rotor to the drive end frame.

    2. Install the washer to the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01DNYPE02
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

      Using a deep socket wrench (21 mm) and press, slowly press on the generator coil.

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

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01DTD6E05
      Text in Illustration
      *1 Pin

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

    2. A01DSN5E01
      Text in Illustration
      *1 Pin

      Install the generator brush holder with the 2 screws.

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

    3. Pull out the pin from the brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. A01DPY8

      Install the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


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

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

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


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

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

    3. A01DM91E01
      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. A01DTCWE07
      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.

  8. INSTALL GENERATOR PULLEY CAP


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