INSTALL GENERATOR DRIVE END FRAME BEARING

INSTALL GENERATOR ROTOR ASSEMBLY

INSTALL GENERATOR COIL ASSEMBLY

INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

INSTALL TERMINAL INSULATOR

INSTALL GENERATOR REAR END COVER

INSTALL GENERATOR PULLEY

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

• SST
• 09950-60010(09951-00500)
  09950-70010(09951-07100)

Install the retainer plate with the 4 screws.

• Torque:
• 2.3 N*m{ 23 kgf*cm, 20 in.*lbf}

Install the generator rotor to the drive end frame.

Place a new generator washer on the generator rotor.

Using a 22 mm socket wrench and press, slowly press in the generator coil.

Install the 4 bolts.

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

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

Install the brush holder with the 2 screws.

• Torque:
• 1.8 N*m{ 18 kgf*cm, 16 in.*lbf}

Pull out the pin from the brush holder.

Install the terminal insulator to the generator coil.

• NOTICE:

• Pay attention to the mounting orientation of the terminal insulator.

Install the generator rear end cover with the 3 nuts.

• Torque:
• 4.6 N*m{ 46 kgf*cm, 40 in.*lbf}

Temporarily install the generator pulley with the pulley nut by hand.

Mount the generator in a vise between aluminum plates.

Install SST 1-A to the pulley shaft.

• SST
• 09820-63011(09820-06010,09820-06021)

• HINT:

Install SST 1-B to SST 1-A.

Hold SST 1-A with a torque wrench and turn SST 1-B clockwise with the specified torque.

• Torque:
• 39 N*m{ 398 kgf*cm, 29 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

• NOTICE:

• Check that SST is secured to the rotor shaft.

Insert SST 2 and attach it to the pulley nut.

Text in Illustration

Insert

Tighten the pulley nut by turning SST 1-A in the direction shown in the illustration.

• Torque:
• 133 N*m{ 1351 kgf*cm, 98 ft.*lbf}

• HINT:

• Hold the adjustable wrench against the vise and tighten the nut securely.

Remove SST 2 from the generator.

Turn SST 1-B, and then remove SST 1-A and B.

Text in Illustration

*a	Hold
	Turn

Turn the generator pulley and check that the pulley moves smoothly.