GENERATOR REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY

    A0118GO

    1. Place the drive end frame on the generator rotor assembly.

      Note

      Do not drop the generator rotor assembly.

    2. Install the generator rotor assembly and plate retainer.

    3. A011BX1E03
      Text in Illustration
      *1 30 mm Socket Wrench

      Using a 30 mm socket wrench and press, slowly press in the rectifier end frame.

    4. A011BTUE01
      Text in Illustration
      *1 Terminal Insulator

      Install the 4 nuts.

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

    5. Install the 3 terminal insulators onto the rectifier end frame.

  2. INSTALL GENERATOR HOLDER WITH RECTIFIER

    A01183L

    1. Install the generator rectifier holder with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  3. INSTALL GENERATOR REGULATOR ASSEMBLY

    A0118KP

    1. Install the generator regulator assembly with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

    A0119BJ

    1. Install the plate seal.

    2. Install the generator brush holder assembly with the 3 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    3. Install the brush cover onto the generator brush holder assembly.

  5. INSTALL GENERATOR REAR END COVER


    1. A0117GW

      Install the rear end cover with the 2 nuts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

    2. Install the rectifier plate with the nut and bolt.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf, for nut }
      Torque:
      3.9 N*m  { 40 kgf*cm, 35 in.*lbf, for bolt }

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. A011BL3

      Install the terminal insulator with the nut.

      Torque:
      4.1 N*m  { 42 kgf*cm, 36 in.*lbf }

  7. INSTALL GENERATOR PULLEY

    A0117U8E02
    Text in Illustration
    *1 Turn
    *2 Hold
    SST
    09820-63011   ( 09820-06010, 09820-06021 )

    Tech Tips

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

    1. Clamp the generator housing stay in a vise.

    2. Install the generator pulley onto the generator rotor shaft by tightening the generator pulley nut by hand.

    3. 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 securely fitted onto the generator rotor shaft.

    4. A011BCQE02
      Text in Illustration
      *1 Insert

      Insert SST 2, and attach the pulley nut to SST 2.

    5. A0116X9E02
      Text in Illustration
      *1 Turn
      *2 Hold

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

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }

      Tech Tips

      Hold the adjustable wrench against the vise and tighten the nut securely.

    6. Remove SST 2 from the generator.

    7. A011BD4E02
      Text in Illustration
      *1 Turn
      *2 Hold

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

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