GENERATOR REASSEMBLY

PROCEDURE

1. INSTALL GENERATOR DRIVE END FRAME BEARING

   1. 

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

      09950-60010

      09951-00470

      09950-70010

      09951-07100

   2. 

      Fit the tabs on the retainer plate into the cutouts on the generator drive end frame assembly to install the retainer plate.

      Table 1. Text in Illustration

      *a	Tab
      *b	Cutout

   3. Install 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. INSTALL BEARING COVER PACKING

   1. Install a new bearing cover packing to the generator coil assembly.

      Note:

      Align the protrusion of the bearing cover packing with the groove of the generator coil assembly when installing.

4. INSTALL GENERATOR COIL ASSEMBLY

   1. 

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

      Table 2. Text in Illustration

      *a	Deep Socket Wrench (21 mm)

   2. Install the 4 bolts.

      5.6 N*m

      57 kgf*cm

      50 in.*lbf

5. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

   1. 

      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.

      Table 3. Text in Illustration

      *a

      Pin

   2. 

      Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

      1.8 N*m

      18 kgf*cm

      16 in.*lbf

      Table 4. Text in Illustration

      *a

      Pin

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

6. INSTALL TERMINAL INSULATOR

   1. 

      Install the terminal insulator to the generator coil assembly.

      Note:

      Make sure that the terminal insulator is installed with the correct orientation.

7. INSTALL GENERATOR REAR END COVER

   1. Install the generator rear end cover to the generator coil assembly with the 3 bolts.

      4.6 N*m

      46 kgf*cm

      40 in.*lbf

8. INSTALL GENERATOR PULLEY WITH CLUTCH

   1. Temporarily install the generator pulley with clutch by hand.

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

   3. 

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

      09820-63021

      Table 5. Text in Illustration

      *1	Rotor Shaft

      Note:

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

   4. 

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

      without SST

      80 N*m

      816 kgf*cm

      59 ft.*lbf

      with SST

      64 N*m

      653 kgf*cm

      47 ft.*lbf

      Table 6. Text in Illustration

      *a	Fulcrum Length
      *b	Hold
      	Turn

      Note:

      Be careful as the generator pulley with clutch or 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 (Click here).

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

   5. Remove SST from the generator assembly.

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

9. INSTALL GENERATOR PULLEY CAP

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