GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01VA3GN01

      Using SST and a press, press in a new bearing.

      SST
      09950-60010   ( 09951-00470 )
      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. A01V70L

      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. A01V9R2C02
      *1 New Washer

      Place a new washer on the generator rotor assembly.

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A01V9FOC02
      *1 21 mm Deep Socket Wrench

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

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

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01VA06C16
      *1 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. A01V8FMC02
      *1 Pin

      Install the generator brush holder 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.

  5. INSTALL GENERATOR TERMINAL INSULATOR


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

  6. INSTALL GENERATOR REAR END COVER


    1. 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 WITH CLUTCH


    1. Temporarily install the generator pulley with clutch.

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

    3. A01V9S9C03
      *1 Generator Rotor Shaft

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

      SST
      09820-63021

      Note

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

    4. A01VAYMC03
      *1 Fulcrum Length
      *a Hold
      A01V9RL Turn

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

      Torque:
      without SST
      111 N*m  { 1127 kgf*cm, 81 ft.*lbf }
      with SST
      88 N*m  { 897 kgf*cm, 65 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


      • 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. Check that the generator pulley rotates smoothly.

  8. INSTALL GENERATOR PULLEY CAP


    1. A01V89Q

      Install a new generator pulley cap.