GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR ROTOR BEARING

    A001DKXE03

    1. Using SST and a press, press a new generator rotor bearing into the drive end frame.

      SST
      09950-60010   ( 09951-00500 )
      09950-70010   ( 09951-07100 )
    2. A001DHZ

      Align the protrusions of the retainer with the drive end frame's cutouts, and then install the retainer with the 4 screws.

      Torque:
      3.0 N*m  { 30 kgf*cm, 27 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY

    A0019PB

    1. Install the generator rotor assembly.

    2. A001FIK

      Install the generator washer.

  3. INSTALL GENERATOR COIL ASSEMBLY

    A001AX1E03

    1. Using SST and a press, press the generator coil into the drive end frame.

      SST
      09612-70100
    2. A001CNN

      Tighten the 4 through bolts.

      Torque:
      5.8 N*m  { 59 kgf*cm, 51 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    A001CPBE01
    *1 Pin (diameter 1.0 mm)

    1. A001AGGE03
      *1 Pin (diameter 1.0 mm)

      Insert a pin (diameter 1.0 mm (0.039 in.)) into the generator brush holder assembly to fix the 2 brushes in place.

    2. Install the generator brush holder to the generator coil with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

    3. Remove the pin (diameter 1.0 mm (0.039 in.)).

  5. INSTALL GENERATOR TERMINAL INSULATOR

    A001FII

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

  6. INSTALL GENERATOR REAR END COVER

    A001E2R

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

      Torque:
      4.6 N*m  { 47 kgf*cm, 41 in.*lbf }

  7. INSTALL GENERATOR PULLEY

    A001C0SE01
    *1 Turn
    *2 Hold
    SST
    09820-63010   ( 09820-06010, 09820-06020 )

    1. Install the generator pulley, and temporarily install the pulley lock nut.

    2. Install SST1-A to the pulley shaft.

    3. Install SST1-B to SST1-A.

    4. Hold SST 1-A on the pulley shaft area, and tighten SST 1-B to the specified torque.

      Torque:
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Securely fix SST1-A to the pulley shaft.

      Tech Tips

      Read SST1-B tightening torque by using the reactive torque of SST1-A.

    5. A001FSAE01

      Mount 2 faces of SST2 in a vise.

    6. With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.

    7. A001FK8

      To tighten the pulley nut, rotate SST1-A in the generator's reverse rotation direction.

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

    8. Remove the generator from SST2.

    9. A001FI5E08
      *1 Turn
      *2 Hold

      Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.

    10. Check that the pulley rotates smoothly.