GENERATOR REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   
   

   1. 

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

      SST

      09950-60010   ( 09951-00470 )

      09950-70010   ( 09951-07100 )

   2. 

      Text in Illustration

      *a	Tab
      *b	Cutout

      Fit the tabs on the retainer plate into the cutouts on the generator drive end frame assembly 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 assembly on the generator pulley with clutch.

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

3. INSTALL GENERATOR BEARING COVER PACKING

   
   

   1. Install a new generator bearing cover packing to the generator coil assembly.

      Note

      Align the protrusion of the generator bearing cover packing with the groove of the generator coil assembly when installing.

4. INSTALL GENERATOR COIL ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a	Deep Socket Wrench (21 mm)

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

   2. Install the 4 bolts.

      Torque:

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

5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   
   
   1. 

      Text in Illustration

      *a

      Pin

      While pushing the 2 brushes into the generator brush holder assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the brush holder hole.

   2. 

      Text in Illustration

      *a

      Pin

      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.

6. INSTALL TERMINAL INSULATOR

   
   

   1. 

      Install the terminal insulator to the generator coil assembly.

      Note

      Make sure that the terminal insulator is installed with the correct orientation.

7. INSTALL GENERATOR REAR END COVER

   
   

   1. Install the generator rear end cover to the generator coil assembly with the 3 bolts.

      Torque:

      4.6 N*m  { 46 kgf*cm, 40 in.*lbf }

8. INSTALL GENERATOR PULLEY WITH CLUTCH

   
   

   1. Temporarily install the generator pulley with clutch by hand.

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

   3. 

      Text in Illustration

      *1	Rotor Shaft

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

      SST

      09820-63021

      Note

      Securely attach SST to the generator pulley with clutch and rotor shaft.

   4. 

      Text in Illustration

      *a	Fulcrum Length
      *b	Hold
      	Turn

      Using a wrench to hold SST A, turn SST B clockwise to tighten the generator pulley with clutch.

      Torque:

      without SST

      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      with SST

      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Note

      Be careful as the generator pulley with clutch or rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

      Tech Tips

      
      

      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

   5. Remove SST from the generator assembly.

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

9. INSTALL GENERATOR PULLEY CAP

   
   

   1. Install a new generator pulley cap to the generator pulley with clutch.