GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY


    1. A015DGS

      Place the drive end frame on the pulley.

    2. Install the rotor to the drive end frame.

  2. INSTALL GENERATOR COIL ASSEMBLY


    1. A015C4AE01

      Place the generator washer on the rotor.

    2. A0159UQ

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

    3. A015DICE01

      130 A Type and 150 A Type:

      Install the 4 bolts.

      Torque:
      5.8 N*m  { 59 kgf*cm, 51 in.*lbf }

    4. 180 A Type:

      Install the 4 bolts.

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

  3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01580SE01

      While pushing the 2 brushes toward the inside of the brush holder, insert a pin (diameter: 1.0 mm (0.0394 in.)) into the brush holder hole.

    2. A01597RE01

      Install the generator brush holder 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.

  4. INSTALL GENERATOR REAR END COVER


    1. A0159NQE01

      Install the terminal insulator to the generator rectifier end frame.

      Note

      Pay attention to the mounting orientation of the terminal insulator.

    2. A015622E01

      Install the end cover with the 3 nuts.

      Torque:
      4.6 N*m  { 46 kgf*cm, 40 in.*lbf }

  5. INSTALL GENERATOR PULLEY

    A0159V8E01
    SST
    09820-63011   ( 09820-06010, 09820-06021 )

    Tech Tips

    SST 1-A and 1-B 09820-06010
    SST 2 09820-06021

    1. Install the pulley onto the rotor shaft by tightening the pulley nut by hand.

    2. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is secured to the rotor shaft.

    3. A015D1JE01

      Mount SST 2 in a vise.

    4. Insert SST 1-A and B into SST 2, and attach the pulley nut to SST 2.

    5. A0156E1E01

      Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

      Torque:
      133 N*m  { 1351 kgf*cm, 98 ft.*lbf }

    6. Remove the generator from SST 2.

    7. A015BLZE01

      Turn SST 1-B, and remove SST 1-A and 1-B.

    8. Turn the pulley and check that the pulley moves smoothly.