GENERATOR(for 180 A Type) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01WPV2E01

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

      SST
      09950-60010   ( 09951-00500 )
      09950-70010   ( 09951-07100 )

    2. Install the retainer plate with the 4 screws.

      Torque:
      3.0 N*m  { 30 kgf*cm, 26 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


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

    2. Place a new generator washer on the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01WTIJE01
      Text in Illustration
      *a 21 mm Deep Socket Wrench

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

    2. Install the 4 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01WUCJE06
      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 hole.

    2. A01WQHSE05
      Text in Illustration
      *a Pin

      Install the generator brush holder 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.

  5. REMOVE TERMINAL INSULATOR


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

      Note

      Pay attention to the mounting orientation of 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 PULLEY


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

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

    3. A01WS3PE07
      Text in Illustration
      *a Hold
      B0018FC Turn

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

      SST
      09820-63011   ( 09820-06010, 09820-06021 )

      Tech Tips

      SST 1-A and B 09820-06010
      SST 2 09820-06021

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

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is secured to the generator rotor shaft.

    5. A01WU5SE01

      Insert SST 2 and attach it to the pulley nut.

      Text in Illustration
      B0018FC Insert
    6. A01WQOVE02
      Text in Illustration
      *a Hold
      B0018FC Turn

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

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

      Tech Tips

      Hold the adjustable wrench against a vise and tighten the generator nut securely.

    7. Remove SST 2.

    8. A01WWWQE06
      Text in Illustration
      *a Hold
      B0018FC Turn

      Turn SST 1-B in the direction shown in the illustration, and then remove SST 1-A and SST 1-B.

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