GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


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

      Tech Tips

      If the generator rotor is difficult to engage, lightly tap it using a plastic hammer.

    2. Place the generator washer on the rotor.

    3. A01CHF2E01

      Using a 30 mm socket wrench and press, slowly press in the rectifier end frame.

    4. A01CGRG

      Install the 4 nuts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }
    5. A01CGW8

      Install the 4 rubber insulators on the lead wires.

      Note

      Make sure each rubber insulator is oriented as shown in the illustration.

  2. INSTALL GENERATOR HOLDER WITH RECTIFIER


    1. Place the generator holder with rectifier on the rectifier end frame.

    2. Push the generator holder with rectifier down and install it with the 4 screws.

      Torque:
      2.9 N*m  { 30 kgf*cm, 26 in.*lbf }

  3. INSTALL GENERATOR REGULATOR ASSEMBLY


    1. Place the plate seal on the generator holder with rectifier.

    2. A01CIXIE01

      Install the generator regulator assembly with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. Install the generator brush holder assembly with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

      Note

      Be careful of the holder installation direction.

    2. Place the generator brush cover on the generator brush holder assembly.

    3. A01CIK0E01

      Install the rear end cover and the terminal plate with the 2 nuts and bolt.

      Torque:
      Bolt
      3.9 N*m  { 39 kgf*cm, 35 in.*lbf }
      Nut
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
    4. A01CGKQ

      Install the terminal insulator with the nut.

      Torque:
      3.6 N*m  { 37 kgf*cm, 32 in.*lbf }

    5. Install the No. 2 generator rear end cover with the 3 nuts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 38 in.*lbf }

  5. INSTALL GENERATOR PULLEY

    A01CGX2E01

    1. Install the generator pulley onto the rotor shaft by tightening the generator pulley nut by hand.

    2. While holding the nut below SST 1-A with a torque wrench, turn and tighten SST 1-B clockwise to the specified torque.

      SST
      09820-63010   ( 09820-06010, 09820-06020 )

      Tech Tips

      SST 1-A and 1-B 09820-06010
      SST 2 09820-06020
      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is secured to the rotor shaft.

    3. A01CI8HE01

      Mount SST 2 in a vise.

    4. Insert SST 1-A and 1-B into SST 2, and attach the generator pulley nut to SST 2.

    5. Tighten the generator pulley nut by turning SST 1-A in the direction shown in the illustration.

      Torque:
      133 N*m  { 1351 kgf*cm, 98 ft.*lbf }
    6. A01CHJ2E01

      Remove the generator from SST 2.

    7. While holding the nut below SST 1-B, turn and remove SST 1-A and 1-B.

    8. Turn the generator pulley, and check that the generator pulley moves smoothly.