A) Using a press, press the rotor together with the wave lock washer into the back cover of the generator.
b) Assemble the alternator drive side cover and rear cover (from the rectifier side).
V) (For generator models 40A, 45A and 50A). Make sure the wires do not touch the rear cover of the generator (from the rectifier side).
G) Install 2 bolts and 2 nuts (for models 40A, 45A and 50A) or 4 nuts (for models 55A, 60A and 70A).
2. Install the alternator pulley.
A) Install the pulley on the alternator shaft and tighten the pulley nut by hand.
b) Holding a special tool (A) torque wrench, tighten the lever (IN) clockwise.
- Tightening torque - 39 Nm
V) Make sure the special tool (A) securely fixed to the rotor shaft.
G) Clamp special tool (WITH) in a vise and install the generator in it, as shown in the figure.
d) Tighten the alternator pulley nut by turning the special tool (A) in the direction shown in the figure.
- Tightening torque - 110 Nm
e) Remove the generator from the tool (WITH) and remove the previously installed devices from it (A and B).
3. Install the rectifier box (For generator models 40A, 45A and 50A). Install the rectifier. Bend the 4 wires of the stator winding as shown in the figure.
Tighten the 4 screws securing the rectifier unit.
(For generator models 55A, 60A and 70A). Install 4 rubber insulators on the stator winding wire leads.
Install the rectifier unit and tighten the 4 screws.
4. Install brush holder and electronic voltage regulator.
A) Install the brush holder cover on the brush holder.
b) Install the electronic voltage regulator and brush holder horizontally as shown in the figure.
V) Tighten 5 screws.
G) Check that the gap between the brush holder and slip ring is at least 1 mm.
d) Install the brush holder cover on the generator cover from the rectifier side.
5. Install the back cover of the generator, tighten the three bolts (for models 40A, 45A and 50A) or nuts (for models 55A, 60A and 70A). Fasten the generator electrical outlet insulator with a nut.
6. Check that the rotor rotates freely.