GENERATOR (for 100A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A009AC7E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A0097HIE02
      Text in Illustration
      *1 Claw

      Align the claws of the retainer plate with the grooves inside the drive end frame.

    3. Install the retainer plate with the 4 screws.

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

  2. INSTALL GENERATOR ROTOR ASSEMBLY


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

    2. Install the washer to the generator rotor.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A0096FIE02
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

      Using a deep socket wrench (21 mm) and press, slowly press on the generator coil.

    2. Install the generator coil with the 4 through bolts.

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A0098H0E05
      Text in Illustration
      *1 Pin

      While pushing the 2 brushes into the generator brush holder, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the generator brush holder hole.

    2. A0094WTE01
      Text in Illustration
      *1 Pin

      Install the generator brush holder with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

    3. Pull out the pin from the brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. A00963D

      Install 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 WITH CLUTCH PULLEY


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

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

    3. A00944EE01
      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. A009B38E02
      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.

      Note

      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.

  8. INSTALL GENERATOR PULLEY CAP


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