GENERATOR REASSEMBLY

PROCEDURE


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A005LKJE02

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A005LABE10
      Text in Illustration
      *1 Tab
      *2 Cutout

      Fit the tabs of the bearing retainer into the cutouts on the generator drive end frame assembly 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 assembly on the generator pulley.

    2. A005I8K

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

  3. INSTALL GENERATOR COIL ASSEMBLY


    1. A005KW7

      Install a new bearing cover packing on the generator coil assembly.

    2. A005JGME02

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

      SST
      09612-70100   ( 09612-07240 )
    3. A005H07

      Install the 4 bolts.

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

  4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A005KY3E10
      Text in Illustration
      *1 Pin (1.0 mm) diameter

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

    2. A005IRR

      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. A005LOUE04
      Text in Illustration
      *1 Pin (1.0 mm) diameter

      Pull out the pin from the generator brush holder assembly.

  5. INSTALL GENERATOR TERMINAL INSULATOR


    1. A005H1W

      Install the generator terminal insulator to the generator coil assembly.

      Note

      Be sure to install the terminal insulator as shown in the illustration.

  6. INSTALL CLAMP


    1. A005IW8

      Install the clamp with the bolt.

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

  7. INSTALL GENERATOR REAR END COVER


    1. A005HJH

      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 }

  8. INSTALL GENERATOR PULLEY


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

    2. A005KX2E10
      Text in Illustration
      *a SST (A)
      *b SST (B)

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

      SST
      09820-63021
    3. A005HCOE02
      Text in Illustration
      *1 Rotor Shaft
      *a SST (A)

      Place the rotor shaft end into SST (A).

    4. A005GSIE02
      Text in Illustration
      *1 Clutch Pulley
      *a SST (B)

      Fit SST (B) to the generator clutch pulley.

    5. A005LJEE02
      Text in Illustration
      *a SST (A)
      *b SST (B)
      *c Fulcrum Length 318 mm
      *d Fulcrum Length 100 mm

      Tighten the pulley 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
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }

      Note


      • Use a torque wrench with a fulcrum length of 318 mm (1.043 ft.).

      • This torque value is effective when SST is parallel to the torque wrench.

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

      • Hold SST (A) tightly during the operation.

    6. Remove the generator assembly from SST.

    7. Check that the clutch pulley rotates smoothly.

  9. INSTALL GENERATOR PULLEY CAP


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