GENERATOR (for 60A Type) REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01CI2ME01

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

      SST
      09950-60010   ( 09951-00520 )
      09950-70010   ( 09951-07100 )

    2. Install the retainer plate with the 4 screws.

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

  2. INSTALL GENERATOR ROTOR BEARING


    1. Place the generator rotor assembly on the generator pulley.

    2. A01CHKPE01

      Using SST and a press, press in a new generator rotor bearing.

      SST
      09820-00031
    3. A01CHT7E01

      Using SST, press in the bearing cover.

      SST
      09820-00031

  3. INSTALL GENERATOR ROTOR ASSEMBLY


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

      Tech Tips

      If the generator rotor is engaged firmly, lightly tap it using a plastic-faced hammer.

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

  4. INSTALL GENERATOR RECTIFIER END FRAME


    1. A01CHF2E03
      Text in Illustration
      *1 30 mm Socket Wrench

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

    2. Install the 4 nuts.

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

      Install the 4 terminal insulators on the lead wires.

      Note

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

  5. INSTALL GENERATOR HOLDER WITH RECTIFIER


    1. Place the generator holder with rectifier on the generator 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 }

  6. INSTALL GENERATOR REGULATOR ASSEMBLY


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

    2. Install the generator regulator assembly with the 3 screws.

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

  7. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01CH7ME01
      Text in Illustration
      *1 Generator Brush Holder Assembly
      *a Top

      Install the generator brush holder assembly with the 2 screws.

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

      Note

      Make sure that the generator brush holder is oriented correctly.

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

  8. INSTALL GENERATOR TERMINAL INSULATOR


    1. Install the generator terminal insulator with the nut.

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

  9. INSTALL GENERATOR REAR END COVER


    1. A01CHC7

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

      Torque:
      for bolt
      3.9 N*m  { 40 kgf*cm, 35 in.*lbf }
      for nut
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
      Text in Illustration
      A01CHW8 Nut
      A01CHIJ Bolt

  10. INSTALL NO. 2 GENERATOR REAR END COVER


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

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

  11. INSTALL GENERATOR PULLEY


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

    2. Install the generator pulley to the generator rotor shaft by tightening the generator pulley nut by hand.

    3. A01CH8AE01

      Hold SST 1-A and SST 1-B to the generator pulley as shown in the illustration.

      SST
      09820-63011   ( 09820-06010, 09820-06021 )

      Tech Tips

      SST 1-A and 1-B 09820-06010
      SST 2 09820-06021

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

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Note

      Check that SST is securely fitted onto the generator rotor shaft.

    5. A01CHAVE01

      Insert SST 2 and attach it to the generator pulley nut.

    6. A01CIDLE01
      Text in Illustration
      *a Hold
      A01CHW8 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 }

    7. Remove SST 2 from the generator assembly.

    8. A01CJ2ZE01
      Text in Illustration
      *a Hold
      A01CHW8 Turn

      Turn SST 1-B in the direction shown in the illustration, and then remove SST 1-A and SST 1-B.

    9. Turn the generator pulley and check that the generator pulley moves smoothly.