GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. B0067KMN02

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. B006833C01
      *a Tab
      *b Cutout

      Fit the tabs of the retainer plate into the cutouts of 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 COIL ASSEMBLY


    1. Place a new washer on the generator rotor assembly.

    2. B006708N03

      Using SST and a press, slowly install in the generator coil assembly.

      SST
      09612-70100   ( 09612-07240 )
    3. B006619

      Install the 4 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. B00659PC12
      *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. B0067WKC01
      *a Pin (1.0 mm)

      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.

  5. INSTALL GENERATOR TERMINAL INSULATOR


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

      Note

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

  6. INSTALL GENERATOR REAR END COVER


    1. B00674D

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

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

  7. INSTALL GENERATOR PULLEY WITH CLUTCH


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

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

    3. B0067HUC01
      *a Rotor Shaft

      Place the rotor shaft end into SST (A).

      SST
      09820-63021
    4. B0067EGC01
      *1 Generator Pulley with Clutch

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

    5. B00678OC01
      *a Torque Wrench Fulcrum Length
      *b Turn
      *c Hold

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

      Torque:
      Specified tightening torque
      132.5 N*m  { 1351 kgf*cm, 98 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing 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 (1.312 ft.)): 106 N*m (1081 kgf*cm, 78 ft.*lbf)

    6. Remove SST (A) and (B) from the generator pulley with clutch.

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

    8. Remove the generator drive end frame from the vise.