Generator Disassembly and Reassembly

Precautions: Precautions for Handling Battery · Precautions for Replacing Battery · General safety (00)

Reference: Generator Removal and Installation:D16AA

Reference: Generator Components:D16AA

Disassembly

1)Remove pulley cover (1).

2)Remove pulley using the following procedure:

a)Hold generator (1), using vise with aluminum plates.

b)Using special tool, loosen pulley (2) and then remove pulley.

Special Tool

(A): 09932–96511

3)Remove rear end cover (1).

4)Remove “B” terminal inner nut (1) and spacer (2).

5)Remove IC regulator assembly (5) by removing screws (3) and nut (4).

Reassembly

Reference: Generator Inspection:D16AA

1)Place IC regulator assembly (1) on rear end frame.

2)Tighten IC regulator screws (2) and nut (3) to specified torque.

Tightening torque

IC regulator screw (a): 2.0 N·m (0.20 kgf-m, 1.5 lbf-ft)
IC regulator nut (b): 2.0 N·m (0.20 kgf-m, 1.5 lbf-ft)

3)Install spacer (4), and then tighten “B” terminal inner nut (5) to specified torque.

Tightening torque

“B” terminal inner nut (c): 3.6 N·m (0.37 kgf-m, 3.0 lbf-ft)

4)Install rear end cover (1).

5)Install new pulley (1) using the following procedure:

a)Hold generator (2), using vise with aluminum plates.

b)Install new pulley to generator.

c)Using special tool, tighten pulley to specified torque.

NOTICE:

If the pulley is tightened using the attachment until the torque wrench reads the specified torque below, the pulley may be damaged.

Follow the steps below to tighten the pulley to specified torque using the attachment.

Special Tool

(A): 09932–96511

Tightening torque

Pulley (a): 80 N·m (8.2 kgf-m, 59.0 lbf-ft)

i)Measure length (L1) of torque wrench (1).

ii)Measure length (L2) of attachment (2).

iii)Calculate reading value (M) of the torque wrench using the following formula.

Formula for torque wrench reading value when using attachment
M = T x L1 ÷ (L1 + L2)
M: Torque wrench reading value when using attachment
T: Specified torque
L1: Torque wrench length
L2: Dimension of attachment

d)Tighten pulley (1) until torque wrench reads the value obtained in the above Step c).

6)Check that rotor turns smoothly.

7)Install new pulley cover (1).