GENERATOR(for 100 A Type) REASSEMBLY

PROCEDURE

  1. INSTALL GENERATOR DRIVE END FRAME BEARING

    A192789E01
    1. Using SST and a press, press in a new generator drive end frame bearing.

      09950-60010

      09951-00520

      09950-70010

      09951-07100

    2. Install the bearing retainer with the 4 screws.

      2.3 N*m

      23 kgf*cm

      20 in.*lbf

  2. INSTALL GENERATOR ROTOR ASSEMBLY

    1. A192790

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

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

  3. INSTALL GENERATOR BEARING COVER PACKING

    Note:

    A new generator coil assembly comes with a generator bearing cover packing. Therefore, it is not necessary to install a new generator bearing cover packing when installing a new generator coil assembly.

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

      Note:

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

  4. INSTALL GENERATOR COIL ASSEMBLY

    1. A192792C07

      *a

      21 mm Deep Socket Wrench

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

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

      5.6 N*m

      57 kgf*cm

      50 in.*lbf

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    1. A158992C22

      *a

      Pin

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

    2. A192793C08

      *a

      Pin

      Install the generator brush holder assembly with the 2 screws.

      1.8 N*m

      18 kgf*cm

      16 in.*lbf

    3. Pull the pin out of the generator brush holder assembly.

  6. INSTALL GENERATOR REAR END COVER

    1. Install the terminal insulator to the generator coil assembly.

    2. Install the generator rear end cover with the 3 bolts.

      4.6 N*m

      47 kgf*cm

      41 in.*lbf

  7. INSTALL GENERATOR PULLEY WITH CLUTCH

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

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

    3. A298996N01

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

      09820-63021

    4. A298997C03

      *a

      Hold

      *b

      Fulcrum Length

      V100135

      Turn

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

      without SST

      80 N*m

      816 kgf*cm

      59 ft.*lbf

      with SST

      64 N*m

      653 kgf*cm

      47 ft.*lbf

      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.

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      • Make sure SST and the wrench are connected in a straight line.

      Note:

      Be careful as the generator pulley with clutch 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 pulley with clutch rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP

    1. A298998

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