GENERATOR REASSEMBLY

Info Added 2017-10-06

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A001UY9N04

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A001WSLC11
      *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. A001W6DC06
      *1 Generator Rotor Assembly
      *2 Generator Drive End Frame

      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. A001VDQC01
      *a Protrusion
      *b Groove

      Install a new bearing cover packing.

      Note

      Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.

    2. A001YBPN03

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

      SST
      09612-70100   ( 09612-07240 )

    3. Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A001TLXC12
      *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. A001V8QC02
      *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 hole.

  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 direction.

  6. INSTALL GENERATOR REAR END COVER


    1. 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 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. A001VWXN03

      Confirm SST (A) and (B) shown in the illustration.

      SST
      09820-63021
    4. A001SK5C12
      *a Rotor Shaft

      Place the rotor shaft end into SST (A).

    5. A001T5BC05
      *1 Generator Pulley with Clutch

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

    6. A001UZ5C06
      *a Hold
      *b Torque Wrench Fulcrum Length
      *c SST Fulcrum Length
      B00495X Turn

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

      Torque:
      Specified tightening torque
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

      Note

      Be careful as the generator pulley with clutch or rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

      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 (15.7 in.)): 64 N*m (653 kgf*cm, 47 ft.*lbf)

    7. Remove SST from the generator pulley with clutch.

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

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

  8. INSTALL GENERATOR PULLEY CAP


    1. Install a new generator pulley cap to the generator pulley with clutch.