GENERATOR(for TMC Made Cold Area Specification Vehicles) REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01VFP9E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01VIFDE01
      Text in Illustration
      *a Tab
      *b Cutout

      Fit the tabs on the generator bearing retainer plate into the cutouts on the generator drive end frame.

    3. Install the generator bearing retainer plate to the generator drive end frame with the 4 screws.

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY

    A01VH9E

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

    2. Install the generator rotor assembly onto the generator drive end frame.

    3. A01VLY5

      Install a new generator washer on the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01VEKSE03

      Using SST and a press, slowly press in the generator coil assembly.

      SST
      09612-70100   ( 09612-07240 )
    2. A01VFP7

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01VEI3E10
      Text in Illustration
      *1 Pin (φ1.0 mm)

      While pushing the 2 brushes into the generator brush holder assembly, insert a φ1.0 mm (0.0394 in.) pin into the brush holder hole.

    2. A01VF95

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

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }
    3. A01VKCWE01
      Text in Illustration
      *1 Pin (φ1.0 mm)

      Pull out the pin from the generator brush holder hole.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01VGE8

      Install the terminal insulator onto the generator coil assembly.

      Note

      Pay attention to installation direction of the terminal insulator as shown in the illustration.

  6. INSTALL GENERATOR REAR END COVER


    1. A01VKXF

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

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

  7. INSTALL GENERATOR CLUTCH PULLEY

    A01VE5ME02
    Text in Illustration
    *1 Rotor Shaft

    1. Temporarily install the generator clutch pulley onto the rotor shaft.

    2. Clamp the generator drive end frame in a vise tightly.

    3. Place the rotor shaft end into SST (A).

      SST
      09820-63021
    4. A01VEQPE08
      Text in Illustration
      *1 Generator Clutch Pulley

      Fit SST (B) to the generator clutch pulley.

    5. A01VIZ9E03
      Text in Illustration
      *a Hold
      *b Turn
      *c Length 100 mm
      *d Length 318 mm

      Tighten the pulley by turning SST (B) in the direction shown in the illustration.

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }

      Note


      • Check that the generator drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 318 mm (12.52 in.).

      • This torque value is effective when SST 100 mm (5.12 in.) is parallel to the torque wrench.

    6. Remove SST from the generator assembly.

    7. Check that the clutch pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. Install a new generator pulley cap onto the generator clutch pulley.