PROCEDURE
INSTALL GENERATOR DRIVE END FRAME BEARING
Using SST and a press, press in a new generator drive end frame bearing.
Fit the tabs of the retainer plate into the cutouts on the generator drive end frame.
*a | Tab |
*b | Cutout |
Install the retainer plate to the generator drive end frame with the 4 screws.
INSTALL GENERATOR ROTOR ASSEMBLY
Place the generator drive end frame on the generator with clutch pulley.
Install the generator rotor assembly to the generator drive end frame.
INSTALL GENERATOR COIL ASSEMBLY
Install a new bearing cover packing.
Align the protrusion of the bearing cover packing with the groove of the generator coil assembly when installing.
Using a 21 mm deep socket wrench and press, slowly press the generator coil assembly to install it.
*a | 21 mm Deep Socket Wrench |
Install the 4 bolts.
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.
*a | Pin (1.0 mm) |
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.
*a | Pin (1.0 mm) |
INSTALL GENERATOR TERMINAL INSULATOR
Install the generator terminal insulator to the generator coil assembly.
Be sure to install the generator terminal insulator in the correct direction.
INSTALL GENERATOR REAR END COVER
Install the generator rear end cover to the generator coil assembly with the 3 bolts.
INSTALL GENERATOR WITH CLUTCH PULLEY
Temporarily install the generator with clutch pulley to the rotor shaft.
Secure the generator drive end frame in a vise between aluminum plates.
Place the rotor shaft end to SST (A).
*a | Rotor Shaft |
Fit SST (B) to the generator with clutch pulley.
*1 | Generator with Clutch Pulley |
Securely attach SST to the generator with clutch pulley and rotor shaft.
Tighten the pulley by turning SST (B) as shown in the illustration.
*a | Hold |
*b | Turn |
*c | Length of SST 100 mm (3.94 in.) |
*d | Length of Torque Wrench 255 mm (10.0 in.) |
The "with SST" torque value is effective when SST is parallel to the torque wrench.
The "with SST" torque value is effective when using SST with a fulcrum length of 100 mm (3.94 in.).
The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 255 mm (10.0 in.).
If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.
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Remove SST from the generator with clutch pulley.
Check that the generator with clutch pulley rotates smoothly.
INSTALL WIRE HARNESS CLAMP BRACKET
Install the wire harness clamp bracket with the bolt.