GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01T8NWE01

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

      SST
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )
    2. A01T8F8C01
      *a Tab
      *b Cutout

      Fit the tabs of the retainer plate into the cutouts on the generator drive end frame.

    3. Install the retainer plate to the generator drive end frame with 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 with clutch pulley.

    2. A01TCJD

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01TDET

      Install a new bearing cover packing.

      Note

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

    2. A01TCVGC01
      *a 21 mm Deep Socket Wrench

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

    3. Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01TBD0C17
      *a Pin (1.0 mm)

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

    2. A01TB4D

      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. A01T9IOC02
      *a Pin (1.0 mm)

      Pull out the pin from the generator brush holder assembly.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01TDJG

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Be sure to install the generator terminal insulator in the correct direction.

  6. INSTALL GENERATOR REAR END COVER


    1. A01TBR2

      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 }

  7. INSTALL GENERATOR WITH CLUTCH PULLEY


    1. Temporarily install the generator with clutch pulley to the rotor shaft.

    2. Secure the generator drive end frame in a vise between aluminum plates.

    3. A01T8GVC04
      *a Rotor Shaft

      Place the rotor shaft end to SST (A).

      SST
      09820-63021
    4. A01TAKTC02
      *1 Generator with Clutch Pulley

      Fit SST (B) to the generator with clutch pulley.

      Note

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

    5. A01TDQBC01
      *a Hold
      *b Turn
      *c Length of SST 100 mm (3.94 in.)
      *d Length of Torque Wrench 255 mm (10.0 in.)

      Tighten the pulley by turning SST (B) as shown in the illustration.

      Torque:
      without SST [Torque (N*m(kgf*cm, ft.*lbf))]
      111 N*m  { 1132 kgf*cm, 82 ft.*lbf }
      with SST [Reading of Torque wrench (N*m(kgf*cm, ft.*lbf))]
      84 N*m  { 857 kgf*cm, 62 ft.*lbf }

      Tech Tips


      • The "with SST" torque value is effective when SST is parallel to the torque wrench.

      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 255 mm (10.0 in.).

      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

        Click here

    6. Remove SST from the generator with clutch pulley.

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

  8. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A01TAN6

      Install the wire harness clamp bracket with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }