GENERATOR REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   1. 

      Using SST and a press, press in a new bearing.

      09950-60010

      09951-00470

      09950-70010

      09951-07100

   2. Install the retainer plate with the 4 screws.

      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 with clutch.

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

   3. 

      *1	New Washer

      Place a new washer on the generator rotor assembly.

3. INSTALL GENERATOR COIL ASSEMBLY

   1. 

      *1	21 mm Deep Socket Wrench

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

   2. Install the generator coil assembly with the 4 bolts.

      5.9 N*m

      60 kgf*cm

      52 in.*lbf

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   1. 

      *1

      Pin

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

   2. 

      *1

      Pin

      Install the generator brush holder assembly with the 2 screws.

      1.8 N*m

      18 kgf*cm

      16 in.*lbf

   3. Pull out the pin from the generator brush holder assembly.

5. INSTALL GENERATOR TERMINAL INSULATOR

   1. Install the generator terminal insulator to the generator coil assembly.

6. INSTALL GENERATOR REAR END COVER

   1. Install the generator rear end cover with the 3 nuts.

      4.6 N*m

      46 kgf*cm

      40 in.*lbf

7. INSTALL GENERATOR PULLEY WITH CLUTCH

   1. Temporarily install the generator pulley with clutch.

   2. Mount the generator assembly in a vise between aluminum plates.

   3. 

      *1	Generator Rotor Shaft

      Install SST (A) and (B) to the generator pulley with clutch as shown in the illustration.

      09820-63021

      Note:

      Securely install SST to the generator pulley with clutch and generator rotor shaft.

   4. 

      *1	Fulcrum Length
      *a	Hold
      	Turn

      Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley with clutch.

      without SST

      111 N*m

      1127 kgf*cm

      81 ft.*lbf

      with SST

      88 N*m

      897 kgf*cm

      65 ft.*lbf

      Note:

      Be careful as the generator pulley with clutch or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

      Tip:

      • Use a torque wrench with a fulcrum length of 400 mm (15.7 in.). When using a torque wrench with a fulcrum length that is not 400 mm (15.7 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification.

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      • Make sure SST and the wrench are connected in a straight line.

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

8. INSTALL GENERATOR PULLEY CAP

   1. 

      Install a new generator pulley cap.