GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01W3KHE03

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. A01VZ5ZE01
      Text in Illustration
      *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.

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. Place a new washer on the generator rotor assembly.

    2. A01W4KUE05
      Text in Illustration
      *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.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01W0YGE41
      Text in Illustration
      *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. A01W3H9E09
      Text in Illustration
      *a Pin
      B001OAO Pull out

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

      Torque:
      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 REAR END COVER


    1. Install the generator terminal insulator to the generator coil assembly.

      Note

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

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

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

  6. INSTALL GENERATOR PULLEY WITH CLUTCH


    1. Secure the generator assembly in a vise between aluminum plates.

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

    3. A01W0SSE04
      Text in Illustration
      *a Rotor Shaft

      Fit the rotor shaft end into SST (A).

      SST
      09820-63021
    4. A01W30PE04
      Text in Illustration
      *a Generator Pulley with Clutch

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

    5. A01W22KE04
      Text in Illustration
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold

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

      Torque:
      Specified tightening torque
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      Note


      • Check that the generator assembly is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

      Tech Tips


      • 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)

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

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

    8. Remove the generator assembly from the vise.

  7. INSTALL GENERATOR PULLEY CAP


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