Generator Disassembly and Reassembly: Reassembly

Reference: GENERATOR INSPECTION 

1. Press-fit drive end bearing by using special tool and hydraulic press (1).

   Special Tool 

   1. 09913-76010 
   Fig 1: Pressing Drive End Bearing Using Special Tool

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2. Install bearing retainer (1) to drive end frame (2) and tighten bearing retainer screws (3) to specified torque.

   Tightening torque 

   Bearing retainer screw (a): 2.3 N.m (0.23 kg-m, 2.0 lbf-ft) 

   Fig 2: Identifying Bearing Retainer, Drive End Frame And Bearing Retainer Screws

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3. Install rotor (1) to drive end frame (2)
   Fig 3: Identifying Rotor And Drive End Frame

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4. Hold rotor (1) by using vise (2), install pulley (3) and tighten pulley nut (4) to specified torque.
   CAUTION:

   • When using vise, put clean cloth (5) and aluminium plate (6) between rotor and vise so as not to cause damage to rotor.
   • Be sure to hold the location (7). Do not hold the location (8) as it does not have enough structural strength.

   Tightening torque 

   Pulley nut (a): 110 N.m (11.2 kg-m, 81.5 lbf-ft) 

   Fig 4: Tightening Pulley Nut

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5. Install wave washer (1) and stator assembly (3) to rotor assembly (2) in alignment with matchmark drawn before disassembly.
   Fig 5: Identifying Wave Washer, Stator Assembly And Rotor Assembly

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6. Tighten stator assembly bolts (1) to specified torque.

   Tightening torque 

   Stator assembly bolt (a): 6.0 N.m (0.61 kg-m, 4.5 lbf-ft) 

   Fig 6: Identifying Stator Assembly Bolts

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7. Install brush holder assembly to stator assembly as follows.
   1. Depress brush (1) and install pin (2) while brush is depressed.
      Fig 7: Identifying Brush And Pin

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   2. Install brush holder assembly (1) to stator assembly (2) and tighten brush holder screws (3) to specified torque.

      Tightening torque 

      Brush holder screw (b): 2.0 N.m (0.20 kg-m, 1.5 lbf-ft) 

      Fig 8: Identifying Brush Holder Assembly, Stator Assembly And Brush Holder Screws

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   3. Remove pin from brush holder assembly.
8. Install rear end cover (1) to stator assembly and tighten rear end cover nuts (2) to specified torque.

   Tightening torque 

   Rear end cover nut (a): 4.5 N.m (0.46 kg-m, 3.5 lbf-ft) 

9. Install terminal bushing (3).
   Fig 9: Identifying Rear End Cover And Rear End Cover Nuts

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10. Check that rotor turns smoothly.