GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01G8VOE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01G6JNE04
      Text in Illustration
      *a Tab
      *b Cutout

      Fit the tabs on the bearing retainer into the cutouts on the generator drive end frame to install the bearing retainer.

    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. A01G69LE01

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

  3. INSTALL GENERATOR PULLEY WITH CLUTCH


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

    2. Mount the generator drive end frame in a vise tightly.

    3. A01G8R2E03
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

      SST
      09820-63021
    4. A01G54DE02
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

      Place the rotor shaft end into SST (A).

    5. A01G9NQE02
      Text in Illustration
      *1 Generator Pulley with Clutch
      *2 SST (B)
      *3 SST (A)

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

    6. A01G58PE02
      Text in Illustration
      *1 SST (B)
      *2 SST (A)
      *a

      Fulcrum Length

      100 mm (3.94 in.)
      *b

      Fulcrum Length

      255 mm (10.0 in.)

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

      Torque:
      without SST
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
      with SST
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.) and a torque wrench with a fulcrum length of 255 mm (10.0 in.) Click here.

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

      • Check that the generator drive end frame is secured in the vise tightly.

      • Hold SST (A) tightly during the operation.

    7. Remove SST from the generator assembly.

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

  4. INSTALL GENERATOR PULLEY CAP


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

  5. INSTALL GENERATOR COIL ASSEMBLY


    1. A01G4YEE01

      Place a new generator washer on the generator rotor assembly.

    2. A01G9RZE05
      Text in Illustration
      *1 Deep Socket Wrench (21 mm)

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

    3. A01G4HR

      Install the 4 bolts.

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

  6. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01G4S3E18
      Text in Illustration
      *1 Pin

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

    2. A01G95KE05
      Text in Illustration
      *1 Pin

      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.

  7. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01G5FZE01

      Install the generator terminal insulator to the generator coil assembly.

      Note

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

  8. INSTALL GENERATOR REAR END COVER


    1. A01G7EJ

      Install the generator rear end cover with the 3 nuts.

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