GENERATOR (for 80A Type) REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


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

      Note

      Do not drop the generator rotor assembly.

    2. Install the washer to the generator rotor.

    3. A009B49E01
      Text in Illustration
      *1 17 mm Socket Wrench

      Using a 17 mm socket wrench and press, slowly press on the rectifier end frame.

    4. Install the 4 nuts.

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

    5. Install the 3 terminal insulators to the rectifier end frame.

  2. INSTALL GENERATOR HOLDER WITH RECTIFIER


    1. Install the generator holder with rectifier with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

  3. INSTALL GENERATOR REGULATOR ASSEMBLY


    1. Install the generator regulator with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. Install the plate seal.

    2. Install the generator brush holder with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 17 in.*lbf }

    3. Install the brush cover to the generator brush holder.

    4. Install the terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 in.*lbf }

    5. Install the generator rear end cover with the 2 nuts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

    6. Install the rectifier plate with the nut and screw.

      Torque:
      for nut
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
      for screw
      3.9 N*m  { 39 kgf*cm, 34 in.*lbf }

  5. INSTALL GENERATOR WITH CLUTCH PULLEY


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

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

    3. A0095MNE01
      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. A0094X7E02
      Text in Illustration
      *1 Fulcrum Length
      *a Hold
      A009BSG Turn

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

      Torque:
      without SST
      111 N*m  { 1127 kgf*cm, 81 ft.*lbf }
      with SST
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }

      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 wrench are connected in a straight line.

      Tech Tips

      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.

    5. Remove SST from the generator.

    6. Check that the generator with clutch pulley rotates smoothly.

  6. INSTALL GENERATOR PULLEY CAP


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