Charging Systems: Generator: Reassembly

1. Using SST and a press, press a new generator rotor bearing into the drive end frame.

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

   Fig 1: Pressing Generator Rotor Bearing Into Drive End Frame

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2. Align the protrusions of the retainer with the drive end frame's cutouts, and then install the retainer with the 4 screws.

   Torque: 3.0 N*m (30 kgf*cm, 27 in.*lbf) 

   Fig 2: Loosening Pulley Nut

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1. Install the generator rotor assembly.
   Fig 3: Locating Generator Rotor Assembly

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2. Install the generator washer.
   Fig 4: Locating Generator Washer

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1. Using SST and a press, press the generator coil into the drive end frame.

   SST 09612-70100 

   Fig 5: Pressing Generator Coil Into Drive End Frame

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2. Tighten the 4 through bolts.

   Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) 

   Fig 6: Locating Through Bolts

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1. Insert a pin (diameter 1.0 mm) into the generator brush holder assembly to fix the 2 brushes in place.
   Fig 7: Identifying Pin Into Generator Brush Holder Assembly

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

   Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) 

   Fig 8: Locating Generator Brush Holder Screws

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3. Remove the pin (diameter 1.0 mm).

1. Install the generator terminal insulator to the generator coil.
   Fig 9: Identifying Generator Terminal Insulator To Generator Coil

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

   Torque: 4.6 N*m (47 kgf*cm, 41 in.*lbf) 

   Fig 10: Locating Generator Rear End Cover To Generator Coil

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

1. Install the generator pulley, and temporarily install the pulley lock nut.
Fig 11: Installing Generator Pulley
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2. Install SST1 - A to the pulley shaft.
3. Install SST1 - B to SST1 - A.
4. Hold SST 1-A on the pulley shaft area, and tighten SST 1-B to the specified torque.

   Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf) 

   NOTE: Securely fix SST1-A to the pulley shaft.

   HINT:

   Read SST1-B tightening torque by using the reactive torque of SST1-A.

5. Mount 2 faces of SST2 in a vise.
Fig 12: Inserting Pulley Lock Nut Into Hexagon Portion Of SST2
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6. With SST1 - A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
7. To tighten the pulley nut, rotate SST1-A in the generator's reverse rotation direction.

   Torque: 133 N*m (1351 kgf*cm, 98 ft.*lbf) 

   Fig 13: Removing Generator

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8. Remove the generator from SST2.
9. Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.
Fig 14: Removing SST1-A And B Of Generator
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10. Check that the pulley rotates smoothly.