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GENERATOR (for 100 A Type) REASSEMBLY

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  1. Click here

    INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01IOHNE02

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

      09950-60010 09951-00470
      09950-70010 09951-07100
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    INSTALL RETAINER PLATE


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

      2.2 N*m 22 kgf*cm 19 in.*lbf
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    INSTALL GENERATOR ROTOR ASSEMBLY


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

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

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    INSTALL BEARING COVER PACKING


    1. Install a new bearing cover packing to the generator coil assembly.

      Note:

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

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    INSTALL GENERATOR COIL ASSEMBLY


    1. A01INEUE01

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

      Table 1. Text in Illustration
      *a 21 mm Deep Socket Wrench

    2. Install the 4 through bolts.

      5.6 N*m 57 kgf*cm 50 in.*lbf
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    INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01IO2JE03

      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.

      Table 2. Text in Illustration
      *a Pin
    2. A01IPOFE01

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

      1.8 N*m 18 kgf*cm 16 in.*lbf
      Table 3. Text in Illustration
      *a Pin

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

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    INSTALL TERMINAL INSULATOR


    1. A01ISGM

      Install the terminal insulator to the generator coil assembly.

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    INSTALL GENERATOR REAR END COVER


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

      4.6 N*m 47 kgf*cm 41 in.*lbf
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    INSTALL GENERATOR WITH CLUTCH PULLEY


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

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

    3. A01INX7E01

      Install SST (A) and (B) to the generator with clutch pulley as shown in the illustration.

      09820-63021
      Table 4. Text in Illustration
      *1 Generator Rotor Shaft
      Note:

      Securely attach SST to the generator with clutch pulley and generator rotor shaft.

    4. A01IUDZE01

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

      without SST
      111 N*m 1132 kgf*cm 82 ft.*lbf
      with SST
      89 N*m 908 kgf*cm 66 ft.*lbf
      Table 5. Text in Illustration
      *a Fulcrum Length
      *b Hold
      A01ISM9 Turn
      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.

      Tip:

      • 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 torque wrench are connected in a straight line.

    5. Remove SST (A) and (B) from the generator with clutch pulley.

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

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    INSTALL GENERATOR PULLEY CAP


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