GENERATOR(for 100 A Type) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A004TINE02

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )

  2. INSTALL RETAINER PLATE


    1. Install the retainer plate to the generator drive end frame assembly with the 4 screws.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

  3. INSTALL GENERATOR ROTOR ASSEMBLY


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

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

  4. INSTALL GENERATOR BEARING COVER PACKING


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

      Note

      Align the protrusion of the generator bearing cover packing with the groove of the generator coil assembly when installing.

  5. INSTALL GENERATOR COIL ASSEMBLY


    1. A004OLBE01
      Text in Illustration
      *a 21 mm Deep Socket Wrench

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

    2. Install the 4 through bolts.

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

  6. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A004MP5E05
      Text in Illustration
      *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 generator brush holder assembly hole.

    2. A004P1XE02
      Text in Illustration
      *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 hole.

  7. INSTALL TERMINAL INSULATOR

    A004OYZ

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

  8. 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 }

  9. INSTALL GENERATOR PULLEY


    1. Temporarily install the generator pulley to the generator rotor shaft.

    2. Secure the generator drive end frame assembly and generator coil assembly in a vise between aluminum plates.

    3. A004TZFE02
      Text in Illustration
      *1 Generator Rotor Shaft

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

      SST
      09820-63021

      Note

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

    4. A004PNKE01
      Text in Illustration
      *a Fulcrum Length
      *b Hold
      A004NPW Turn

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

      Torque:
      without SST
      111 N*m  { 1132 kgf*cm, 82 ft.*lbf }
      with SST
      89 N*m  { 908 kgf*cm, 66 ft.*lbf }

      Note

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

      Tech Tips


      • 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 Click here.

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

    5. Remove SST (A) and (B) from the generator pulley.

    6. Check that the generator pulley rotates smoothly.

  10. INSTALL GENERATOR PULLEY CAP


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