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 engaged firmly, lightly tap it using a plastic hammer.

    2. Place the generator washer on the rotor.

    3. A01CHF2E02
      Text in Illustration
      *1 30 mm Socket Wrench

      Using a 30 mm socket wrench and a 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. A01CJ43

      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. A01CH2R

      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. A01CIG7E01
      Text in Illustration
      *1 Upward
      *2 Brush Holder

      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. A01CIK0E02
      Text in Illustration
      *1 Terminal Plate

      Install the rear end cover and 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


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

    2. A01CH4ME01
      Text in Illustration
      *1 SST 1-A
      *2 SST 1-B
      *3 Hold
      *4 Turn

      Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.

      Tech Tips

      SST 1-A and 1-B 09820-06010
      SST 2 09820-06020
      SST
      09820-63011   ( 09820-06010, 09820-06020 )
      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Firmly secure SST on the generator rotor shaft.

    3. A01CIMKE02
      Text in Illustration
      *1 Insert
      *2 SST 2

      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. A01CJHME02
      Text in Illustration
      *1 SST 1-A and 1-B
      *2 Turn

      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. A01CI5ZE01
      Text in Illustration
      *1 SST 1-A
      *2 SST 1-B
      *3 Turn
      *4 Hold

      Remove the generator from SST 2.

    7. Turn SST 1-B, and remove SST 1-A and 1-B.

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