INSTALL GENERATOR DRIVE END FRAME BEARING
Using SST and a press, press in a new generator drive end frame bearing.
Fit the tabs on the retainer plate into the cutouts on the drive end frame to install the retainer plate.
Install the retainer plate with the 4 screws.
INSTALL GENERATOR ROTOR ASSEMBLY
Place the generator drive end frame on the generator pulley with clutch.
Install the generator rotor assembly to the generator drive end frame.
INSTALL GENERATOR BEARING COVER PACKING
A new generator coil assembly comes with a generator bearing cover packing. Therefore, it is not necessary to install a new generator bearing cover packing when installing a new generator coil assembly.
Install a new generator bearing cover packing to the generator coil assembly.
Align the protrusion of the generator bearing cover packing with the groove of the generator coil assembly when installing.
INSTALL GENERATOR COIL ASSEMBLY
|*a||21 mm Deep Socket Wrench|
Using a 21 mm deep socket wrench and press, slowly press on the generator coil assembly.
Install the generator coil assembly with the 4 through bolts.
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
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.
Install the generator brush holder assembly to the generator coil assembly with the 2 screws.
Pull out the pin from the generator brush holder assembly.
INSTALL GENERATOR REAR END COVER
Install the generator rear end cover to the generator coil assembly with the 3 bolts.
INSTALL TERMINAL INSULATOR
Install the terminal insulator to the generator coil assembly.
Make sure that the terminal insulator is installed with the correct orientation.
INSTALL GENERATOR PULLEY WITH CLUTCH
Mount the generator assembly in the vise between aluminum plates.
Temporarily install the generator pulley with clutch by hand.
|*a||Generator Rotor Shaft|
Install SST A and SST B to the generator pulley with clutch as shown in the illustration.
Securely attach SST to the generator pulley with clutch and generator rotor shaft.
|*b||Torque Wrench Fulcrum Length|
|*c||SST Fulcrum Length|
Using a wrench to hold SST A, turn SST B clockwise to tighten the generator pulley with clutch.
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.
Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
When using SST (fulcrum length of 100 mm (3.94 in.)) + torque wrench (fulcrum length of 400 mm (15.8 in.)):
88.4 N*m (901 kgf*cm, 65 ft.*lbf)
Remove SST from the generator assembly.
Check that the generator pulley with clutch rotates smoothly.
Remove the generator assembly from the vise.
INSTALL GENERATOR PULLEY CAP
Install a new generator pulley cap to the generator pulley with clutch.