GENERATOR(for 100A Type) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR ROTOR BEARING


    1. A01M2NAE02

      Using SST and a press, press in a new generator rotor bearing.

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01M2UOC05
      *a Tab
      *b Cutout

      Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

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

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A01LWK8

      Place the generator drive end frame on the generator with clutch pulley.

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01LYKH

      Install a new bearing cover packing.

      Note

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

    2. A01LX9TC04
      *a 21 mm Socket Wrench

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

    3. A01M0WY

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01LWEMC09
      *a Pin (1.0 mm)

      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 hole.

    2. A01M0YA

      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. A01M0QTC04
      *a Pin (1.0 mm)

      Pull out the pin from the generator brush holder assembly hole.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01LY0L

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Be sure to install the generator terminal insulator in the correct direction.

  6. INSTALL GENERATOR REAR END COVER


    1. A01LY5U

      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 }

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


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

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

    3. A01LWBBC07
      *a Rotor Shaft

      Place the rotor shaft end into SST (A).

      SST
      09820-63021

    4. Fit SST (B) to the generator with clutch pulley.

    5. A01M0DXC05
      *a Hold
      *b Turn
      *c Length of SST 100 mm (3.94 in.)
      *d Length of Torque Wrench 255 mm (10.0 in.)

      Tighten the generator with clutch pulley by turning SST (B) as shown in the illustration.

      Torque:
      without SST [Torque (N*m(kgf*cm, ft.*lbf))]
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST [Reading of Torque wrench (N*m(kgf*cm, ft.*lbf))]
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Tech Tips


      • The "with SST" torque value is effective when SST is parallel to the torque wrench.

      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 255 mm (10.0 in.).

      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

        Click here

    6. Remove SST from the generator with clutch pulley.

    7. 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.