GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. B004J28N02

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )
    2. B004IF2C02
      *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. B004HI2C01
      *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. B004IFEC08
      *a 21 mm Deep Socket Wrench

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

    3. Install the 4 bolts.

      Torque:
      5.6 N*m  { 57 kgf*cm, 50 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. B004O6HC22
      *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. B004O0SC09
      *a Pin (1.0 mm)
      B006ZY0 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 bolts.

      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. B004JYBC05
      *a Rotor Shaft

      Install SST (A) and (B) to the generator pulley with clutch as shown in the illustration.

      SST
      09820-63021
    4. B004LGPC01
      *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 (15.7 in.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

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

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

    7. 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.