GENERATOR (for 100A Type) > REASSEMBLY

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1. INSTALL GENERATOR DRIVE END FRAME BEARING


    A219779E01

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

    SST
    09950-60010   (09951-00470)
    09950-70010   (09951-07100)



    A219780E01

  1. Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
    Text in Illustration 
    *a
    		Tab
    *b
    		Cutout

  1. Install 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 clutch pulley.



    A153384

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



    A118365E01

  1. Place the generator washer on the generator rotor.



3. INSTALL GENERATOR COIL ASSEMBLY


    A219781E01

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

    SST
    09612-70100   (09612-07240)



    A219774

  1. Install the 4 bolts.

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



4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    A158992E10

  1. While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.0394 in.) pin into the brush holder hole.
    Text in Illustration 
    *1
    		Pin (φ1.0 mm)



    A219782

  1. Install the brush holder assembly onto the generator coil with the 2 screws.

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



    A219783

  1. Pull out the pin from the generator brush holder.



5. INSTALL GENERATOR TERMINAL INSULATOR


    A219784

  1. Install the terminal insulator onto the generator coil.

    NOTICE:
    Pay attention to installation direction of the terminal insulator.



6. INSTALL GENERATOR REAR END COVER


    A219771

  1. Install the generator rear end cover onto the generator coil with the 3 nuts.

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



7. INSTALL GENERATOR CLUTCH PULLEY

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

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



    A128069E02

  1. Confirm SST (A) and (B) shown in the illustration.

    SST
    09820-63021  



    A219767E01

  1. Place the rotor shaft end into SST (A).
    Text in Illustration 
    *1
    		Rotor Shaft



    A219768E01

  1. Fit SST (B) to the clutch pulley.
    Text in Illustration 
    *1
    		Clutch Pulley



    A219785E01

  1. Tighten the pulley by turning SST (B) in the direction shown in the illustration.
    Text in Illustration 
    *a
    		Hold
    *b
    		Length 100 mm
    *c
    		Length 318 mm
    *d
    		Turn

    Torque:
    without SST:
    80 N*m{ 816 kgf*cm , 59 ft.*lbf }
    with SST:
    61 N*m{ 622 kgf*cm , 45 ft.*lbf }

    NOTICE:
    1. Check that the drive end frame is secured in the vise tightly.
    2. Hold SST (A) tightly during the operation.

    HINT:
    1. Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).
    2. This torque value is effective when SST 100 mm (5.12 in.) is parallel to the torque wrench.

  1. Remove the generator assembly from SST.

  1. Check that the clutch pulley rotates smoothly.

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