Disassembly and Reassembly

DISASSEMBLY




1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)




a. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

NOTE: Check that SST is secured to the rotor shaft.




b. Clamp SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.




d. To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.

NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn.

e. Remove the generator from SST 2.




f. Turn SST 1-B, and remove SST 1-A and B.
g. Remove the pulley nut, and then remove the generator pulley.




2. REMOVE GENERATOR REAR END COVER
a. Place the generator on the generator pulley.
b. Remove the 3 nuts, and then remove the generator rear end cover.




3. REMOVE TERMINAL INSULATOR
a. Remove the terminal insulator from the generator coil.

4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY




a. 100A Generator
1. Remove the 2 screws, and then remove the generator brush holder.




b. 130A Generator
1. Remove the generator plate seal.
2. Remove the 2 screws, and then remove the generator brush holder.
3. Remove the generator plate seal.

5. REMOVE GENERATOR COIL ASSEMBLY




a. Remove the 4 bolts.




b. Using SST, remove the generator coil.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)




6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator washer and the generator rotor

REASSEMBLY

1. REMOVE GENERATOR DRIVE END FRAME BEARING




a. Remove the 4 screws, and remove the retainer plate.




b. Using SST, tap out the bearing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)

2. INSTALL GENERATOR DRIVE END FRAME BEARING




a. Using SST and a press, press in a new bearing.




b. Install the retainer plate with the 4 screws.

Torque: 2.3 N.m (23 kgf.cm, 20 in.lbf)

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




3. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor and the generator washer.

4. INSTALL GENERATOR COIL ASSEMBLY




a. 100A Generator
1. Using deep socket wrench 21 and a press, press in the coil carefully.

b. 130A Generator
1. Using deep socket wrench 20 and a press, press in the coil carefully.




c. Tighten the 4 bolts.

Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)

5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. 100A Generator




1. While pushing the 2 brushes to inside the brush holder, insert a pin (Dia 1.0 mm (0.039 in.)) into the brush holder hole.




2. 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 (Dia 1.0 mm (0.039 in.)) from the generator brush holder.




b. 130A Generator
1. Install the generator plate seal (inside).
2. Place the generator brush holder with the pin facing upward.

NOTE: Be careful of the generator brush holder installing direction.

3. Tighten the 2 screws.

Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)

4. Align the pins of the generator brush holder with the holes of the generator plate seal (outside), and install the generator plate seal (outside).




6. INSTALL TERMINAL INSULATOR
a. Install the terminal insulator.

NOTE: Pay attention the mounting orientation of the terminal insulator.




7. INSTALL GENERATOR REAR END COVER
a. Install the generator rear end cover with the 3 nuts.

Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)




8. INSTALL GENERATOR PULLEY

SST 09820-63010 (09820-06010, 09820-06020)
SST 1-A and B 09820-06010
SST 2 09820-06020




a. Install the generator pulley to the rotor shaft by tightening the generator pulley nut by hand.

b. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise with the specified torque.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

NOTE: Check that SST is secured to the rotor shaft.




c. Clamp SST 2 in a vise.
d. Insert SST 1-A and B into SST 2, and attach the generator pulley nut to SST 2




e. Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.

Torque: 111 N.m (1,125 kgf.cm, 81 ft.lbf)

f. Remove the generator from SST 2.




g. Turn SST 1-B, and remove SST 1-A, B.
h. Turn the generator pulley, and check that the generator pulley moves smoothly.