GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A003F44E01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A003CP3E01
      Text in Illustration
      *a Tab
      *b Cutout

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

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

  3. INSTALL GENERATOR BEARING COVER PACKING

    Note

    A new generator coil assembly comes with a generator bearing cover packing. Therefore, it is not necessary to install a new generator bearing cover packing when installing a new generator coil assembly.


    1. A003D72E01
      Text in Illustration
      *a Protrusion
      *b Groove

      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. A003C5PE01

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

    2. Install the generator coil assembly with the 4 bolts.

      Torque:
      5.6 N*m  { 59 kgf*cm, 52 in.*lbf }

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A003DMZE01
      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 generator brush holder hole.

    2. A003HTDE01
      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 GENERATOR TERMINAL INSULATOR


    1. Install the generator terminal insulator to the generator coil assembly.

      Note

      Make sure that the generator 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  { 47 kgf*cm, 41 in.*lbf }

  8. INSTALL GENERATOR PULLEY WITH CLUTCH


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

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

    3. A003E3VE01
      Text in Illustration
      *a Generator Rotor Shaft

      Install SST A and SST 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 generator rotor shaft.

    4. A003HL4E01
      Text in Illustration
      *a Hold
      *b Torque Wrench Fulcrum Length
      *c SST Fulcrum Length
      A003DCD Turn

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

      Torque:
      Specified tightening torque
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      Note

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

      Tech Tips


      • Calculate the torque wrench reading when charging the fulcrum length of the torque wrench. ( Click here.

      • When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.8 in.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

    5. Remove SST from the generator assembly.

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

    7. Remove the generator assembly from the vise.

  9. INSTALL GENERATOR PULLEY CAP


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