Generator Reassembly

Reference: GENERATOR DISMOUNTING AND REMOUNTING 

Reference: GENERATOR COMPONENTS 

Reference: GENERATOR DISASSEMBLY 

Reference: GENERATOR INSPECTION 

1. If end housing bearing (1) is removed, install it.
2. Check end housing bearing (1) turns smoothly.
   Fig 1: Identifying End Housing Bearing, Rotor & Bearing Cover

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3. If stator (4) is removed, install stator (4) and tighten stud bolts (1).
4. If drive end bearing (3) is removed, install it.
5. Check drive end bearing (3) turns smoothly. If OK, install drive end bearing retaining plate (2).

   Tightening torque 

   Stator stud bolt a: 8.8 N.m (0.88 kg-m, 6.5 lb-ft) 

   Drive end bearing retaining plate screw b: 2.6 N.m (0.26 kg-m, 2.0 lb-ft) 

   Fig 2: Identifying Drive End Bearing, Retaining Plate, Stator & Bolts

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6. Place drive end frame (2) on pulley, and then install rotor (1) to drive end frame (2).
   Fig 3: Identifying Rotor & Drive End Frame

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7. Install rear end frame (1) to drive end frame (2).
8. Tighten 4 nuts to specified torque.

   Tightening torque 

   Rear end frame nut a: 4.5 N.m (0.45 kg-m, 3.5 lb-ft) 

   Fig 4: Identifying Rear End Frame, Drive End Frame & Nuts

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9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to specified torque.

   Tightening torque 

   Generator pulley nut a: 111 N.m (11.1 kg-m, 80.5 lb-ft) 

   Fig 5: Identifying Pulley & Hexagonal Box Wrench

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10. Install 4 rubber insulators (1).
    Fig 6: Identifying Rubber Insulators

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11. Install rectifier (1).
    CAUTION: When installing rectifier, check to confirm that stator leads have enough clearance with cooling fan blades.

    Tightening torque 

    Rectifier screw a: 2 N.m (0.2 kg-m, 1.5 lb-ft) 

    Rectifier "B" bolt b: 3.9 N.m (0.39 kg-m, 3.0 lb-ft) 

    Fig 7: Identifying Rectifier

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12. Install brush holder cover (1) to brush holder (2).
    Fig 8: Identifying Brush Holder Cover And Brush Holder

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13. Place the IC regulator (1) together with the brush holder (2) horizontally on the rear end frame (3).
14. Install the 5 screws until there is a clearance "a" of approx. 1 mm (0.04 in.) between the brush holder (2) and connector.

    Tightening torque 

    Regulator and brash holder screw a: 2 N.m (0.2 kg-m, 1.5 lb-ft) 

    Clearance between the brush holder and connector 

    "a": 1 mm (0.04 in.) 

    Fig 9: Identifying IC Regulator, Brush Holder & Rear End Frame

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15. Install rear end cover (1) and terminal plate (4).

    Tightening torque 

    Rear end cover nut a: 4.5 N.m (0.45 kg-m, 3.5 lb-ft) 

    Terminal plate bolt b: 3.8 N.m (0.38 kg-m, 3.0 lb-ft) 

16. Install insulator (2) and tighten "B" terminal inner nut (3) to specified torque.

    Tightening torque 

    "B" terminal inner nut c: 8 N.m (0.8 kg-m, 6.0 lb-ft) 

    Fig 10: Identifying Insulator, Rear End Cover, Inner Nut & Terminal Plate

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17. Make sure that rotor turns smoothly.
    Fig 11: Identifying Rotor Turns Smoothly

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