GENERATOR (for BOSCH Made) REASSEMBLY


  1. INSTALL GENERATOR ROTOR ASSEMBLY

    Note

    Do not drop the generator rotor assembly.


    1. A01E22WE02

      Set the spacer ring, drive end frame, generator rotor assembly and SST1 to SST2 as shown in the illustration.

      SST
      09285-76010
      09630-00014   ( 09631-00061 )

    2. Using SST1, SST2 and a press, slowly press the generator rotor into the drive end frame and spacer ring.

  2. INSTALL GENERATOR PULLEY


    1. Fix the generator in a vise between aluminum plates.

      Note

      Do not damage the generator.

    2. Temporarily install the washer and generator pulley with the nut.

    3. A01DXFWE01

      Set SST, a ball joint lock nut wrench and an 8 mm bi-hexagon wrench as shown in the illustration.

      SST
      09820-30020

    4. Hold the 8 mm bi-hexagon wrench in place and turn SST and the ball joint lock nut wrench clockwise to tighten the nut.

      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf, without ball joint lock nut wrench }
      53 N*m  { 540 kgf*cm, 39 ft.*lbf, with ball joint lock nut wrench }

      Note

      Do not use a tool such as an impact wrench or equivalent.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).

      • Make sure the ball joint lock nut wrench and torque wrench are connected in a straight line.

    5. Check that the generator pulley rotates smoothly.

  3. INSTALL FITTING RING


    1. A01E2J2

      Align the 3 cutouts of the fitting ring with the stator generator with rectifier.

  4. INSTALL GENERATOR STATOR SUB-ASSEMBLY WITH RECTIFIER


    1. Align the key of the drive end frame with the keyway of the generator stator.

    2. A01DVYT

      Install the stator with the 4 bolts.

      Torque:
      4.3 N*m  { 44 kgf*cm, 38 in.*lbf }

  5. INSTALL GENERATOR REGULATOR SUB-ASSEMBLY WITH BRUSH


    1. A01DZNT

      Attach the brushes and terminals to the rectifier end frame of the regulator.

    2. Install the regulator with the 3 screws.

      A01E0ETE01
      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf, for screw A }
      1.2 N*m  { 12 kgf*cm, 11 in.*lbf, for screw B }

      Tech Tips

      Install screw B to the position shown in the illustration.

  6. INSTALL GENERATOR REAR END COVER


    1. A01DXQ5E01

      Install the rear end cover with the 2 nuts and screw.

      Note

      The protective tower must be attached on the end cover.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf, for nut A }
      12 N*m  { 122 kgf*cm, 9 ft.*lbf, for nut B }
      2.4 N*m  { 24 kgf*cm, 21 in.*lbf, for screw }
    2. A01E2Z5

      Install the 2 terminal covers by turning them clockwise.