GENERATOR REASSEMBLY

PROCEDURE

  1. INSTALL GENERATOR DRIVE END FRAME BEARING

    1. A237642N06

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

      09950-60010

      09951-00470

      09950-70010

      09951-07100

    2. A347477C01

      *a

      Tab

      *b

      Cutout

      Fit the tabs of the retainer plate into the cutouts of the generator drive end frame to install the retainer plate.

    3. Install the 4 screws.

      2.3 N*m

      23 kgf*cm

      20 in.*lbf

  2. INSTALL GENERATOR ROTOR ASSEMBLY

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

    2. A383004C01

      *1

      Generator Rotor Assembly

      *2

      Generator Drive End Frame

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

  3. INSTALL GENERATOR COIL ASSEMBLY

    1. A314531C07

      *a

      Protrusion

      *b

      Groove

      Install a new bearing cover packing.

      Note:

      Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

    2. A285303C06

      *a

      21 mm Deep Socket Wrench

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

    3. Install the 4 bolts.

      5.6 N*m

      57 kgf*cm

      50 in.*lbf

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    1. A153827C22

      *a

      Pin (1.0 mm)

      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 hole.

    2. A334792C01

      *a

      Pin (1.0 mm)
      V100136

      Pull out

      Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

      1.8 N*m

      18 kgf*cm

      16 in.*lbf

    3. Pull out the pin from the generator brush holder assembly hole.

  5. INSTALL GENERATOR TERMINAL INSULATOR

    1. A329883

      Install the generator terminal insulator to the generator coil assembly.

      Note:

      Be sure to install the generator terminal insulator in the correct orientation.

  6. INSTALL GENERATOR REAR END COVER

    1. A347480

      Install the generator rear end cover to the generator coil assembly with the 3 bolts.

      4.6 N*m

      47 kgf*cm

      41 in.*lbf

  7. INSTALL GENERATOR PULLEY WITH CLUTCH

    1. Secure the generator drive end frame in a vise between aluminum plates.

    2. Temporarily install the generator pulley with clutch to the rotor shaft.

    3. A284135N03

      Install SST (A) to SST (B) as shown in the illustration.

      09820-63021

    4. A204357C12

      *a

      Rotor Shaft

      Fit the rotor shaft end into SST (A).

    5. A378461C01

      *1

      Generator Pulley with Clutch

      Fit SST (B) to the generator pulley with clutch.

    6. A337506C04

      *a

      Torque Wrench Fulcrum Length

      *b

      Turn

      *c

      Hold

      Tighten the generator pulley with clutch by turning SST (B) as shown in the illustration.

      Specified tightening torque

      80 N*m

      816 kgf*cm

      59 ft.*lbf

      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (1.312 ft.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

    7. Remove SST (A) and (B) from the generator pulley with clutch.

    8. Check that the generator pulley with clutch rotates smoothly.

    9. Remove the generator drive end frame from the vise.

  8. INSTALL GENERATOR PULLEY CAP

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