GENERATOR REASSEMBLY


  1. INSTALL GENERATOR DRIVE END FRAME BEARING


    1. A01EUVSE01

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

      SST
      09950-60010   ( 09951-00470 )
      09950-70010   ( 09951-07100 )
    2. A01EW4GE04
      Text in Illustration
      *a Tab
      *b Cutout

      Fit the tabs on the retainer plate into the cutouts on the 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. Place the drive end frame on the generator pulley with clutch.

    2. A01ETQ1E01

      Install the generator rotor assembly to the drive end frame.

  3. INSTALL GENERATOR CLUTCH PULLEY


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

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

    3. A01EWJ9E03
      Text in Illustration
      *1 SST (A)
      *2 SST (B)

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

      SST
      09820-63021
    4. A01EU8YE02
      Text in Illustration
      *1 Rotor Shaft
      *2 SST (A)

      Place the rotor shaft end into SST (A).

    5. A01EV0JE02
      Text in Illustration
      *1 Clutch Pulley
      *2 SST (B)
      *3 SST (A)

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

    6. A01EXV7E02
      Text in Illustration
      *1 SST (B)
      *2 SST (A)
      *a

      Fulcrum Length

      100 mm (3.94 in.)
      *b

      Fulcrum Length

      255 mm (10.04 in.)

      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
      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 (10.04 in.) Click here.

      • The "with SST" 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.

    7. Remove SST from the generator assembly.

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

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

  4. INSTALL GENERATOR COIL ASSEMBLY


    1. A01EYD1E01

      Place a new generator washer on the generator rotor.

    2. A01EWJWE05
      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. A01EVYF

      Install the 4 bolts.

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

  5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01EZ1GE18
      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. A01EW4FE05
      Text in Illustration
      *1 Pin

      Install the brush holder assembly to the generator coil 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.

  6. INSTALL GENERATOR TERMINAL INSULATOR


    1. A01EWNKE01

      Install the generator terminal insulator to the generator coil.

      Note

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

  7. INSTALL GENERATOR REAR END COVER


    1. A01EWB5

      Install the generator rear end cover to the generator coil with the 3 nuts.

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