GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01X0LJE01

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

      SST
      09950-60010   ( 09951-00500 )
      09950-70010   ( 09951-07100 )

    2. Install the retainer plate with the 4 screws.

      Torque:
      2.3 N*m  { 23 kgf*cm, 20 in.*lbf }

  2. INSTALL GENERATOR ROTOR ASSEMBLY


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

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01X231

      Using a 22 mm socket wrench and press, slowly press in the generator coil.

    2. Install the 4 bolts.

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01X5RGE02
      Text in Illustration
      *1 Pin

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

    2. A01XA17E04
      Text in Illustration
      *1 Pin

      Install the brush holder with the 2 screws.

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

    3. Pull out the pin from the brush holder.

  5. INSTALL TERMINAL INSULATOR


    1. Install the terminal insulator to the generator coil.

      Note

      Pay attention to the mounting orientation of the terminal insulator.

  6. INSTALL GENERATOR REAR END COVER


    1. A01X2QX

      Install the generator rear end cover with the 3 nuts.

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

  7. INSTALL GENERATOR PULLEY


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

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

    3. A01X54JE03

      Install SST 1-A to the pulley shaft.

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

      Tech Tips

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

    4. Install SST 1-B to SST 1-A.

    5. Hold SST 1-A with a torque wrench and turn SST 1-B clockwise with the specified torque.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
      Text in Illustration
      *a Hold
      B001XPG Turn

      Note

      Check that SST is secured to the rotor shaft.

    6. A01X0K2E04

      Insert SST 2 and attach it to the pulley nut.

      Text in Illustration
      B001XPG Insert
    7. A01X5V2E01
      Text in Illustration
      *a Hold
      *b Turn

      Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

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

      Tech Tips

      Hold the adjustable wrench against the vise and tighten the nut securely.

    8. Remove SST 2 from the generator.

    9. A01X0IQE03
      Text in Illustration
      *a Hold
      B001XPG Turn

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

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