GENERATOR(for 100A Type) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A005HT5E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A005LABE10
      Text in Illustration
      *1 Tab
      *2 Cutout

      Fit the tabs on the generator bearing retainer plate into the cutouts on the generator drive end frame.

    3. Install the generator bearing 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. Place the drive end frame on the generator clutch pulley.

    2. A005LXU

      Install the generator rotor assembly onto the generator drive end frame.

    3. A005IVV

      Install a new generator washer on the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A005HYNE01

      Using SST and a press, slowly press in the generator coil assembly.

      SST
      09612-70100   ( 09612-07240 )
    2. A005LTY

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A005KY3E15
      Text in Illustration
      *1 Pin (1.0 mm (0.0394 in.)) diameter

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

    2. A005IRR

      Install the brush holder assembly to the generator coil assembly with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }
    3. A005LOUE01
      Text in Illustration
      *1 Pin (1.0 mm (0.0394 in.)) diameter

      Pull out the pin from the generator brush holder assembly.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A005JBM

      Install the generator terminal insulator onto the generator coil assembly.

      Note

      Be sure to install the generator terminal insulator as shown in the illustration.

  6. INSTALL GENERATOR REAR END COVER


    1. A005HJH

      Install the generator rear end cover onto the generator coil assembly with the 3 bolts.

      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }

  7. INSTALL GENERATOR CLUTCH PULLEY


    1. Temporarily install the generator clutch pulley onto the rotor shaft.

    2. Clamp the generator drive end frame in a vise tightly.

    3. A005JAQE02
      Text in Illustration
      *1 Rotor Shaft

      Place the rotor shaft end into SST (A).

      SST
      09820-63021
    4. A005KQGE02
      Text in Illustration
      *1 Generator Clutch Pulley

      Fit SST (B) to the generator clutch pulley.

    5. A005ILAE01
      Text in Illustration
      *a Hold
      *b Turn
      *c Length 100 mm
      *d Length 318 mm

      Tighten the pulley by turning SST (B) in the direction shown in the illustration.

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Note


      • Check that the generator drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).

      • This torque value is effective when SST 100 mm (5.12 in.) is parallel to the torque wrench.

    6. Remove SST from the generator assembly.

    7. Check that the clutch pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. Install a new generator pulley cap onto the generator clutch pulley.