GENERATOR (for 180 A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A0159JOE01

      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. A015DX1

      Using a 22 mm socket wrench and 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. A0156KWE02
      Text in Illustration
      *1 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. A0157Q2E04
      Text in Illustration
      *1 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. INSTALL 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. A01596UE01

      Install SST 1-A and SST 1-B to the 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 }
      Text in Illustration
      *a Hold
      A015DIT Turn

      Note

      Check that SST is secured to the rotor shaft.

    5. A015ACRE01

      Insert SST 2 and attach it to the pulley nut.

      Text in Illustration
      A015DIT Insert
    6. A0157OGE01
      Text in Illustration
      *a Hold
      *b 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 the vise and tighten the nut securely.

    7. Remove SST 2.

    8. A0157PLE01
      Text in Illustration
      *a Hold
      A015DIT 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 pulley moves smoothly.