Toro Reelmaster 5010- H Service Manual page 238

C. Lubricate new O- ring (item 2) with dielectric lubri-
cant (see Special Tools in this chapter) and install
into groove in housing bearing bore.
IMPORTANT: The rotor magnets are very power-
ful and can cause the rotor to shift position very
rapidly during installation. Use generator rotor
tool set (see Special Tools in this chapter) to in-
stall rotor. Be cautious during rotor installation
to prevent component damage or personal inju-
ry.
D. Use generator rotor tool set (see Special Tools in
this chapter) to carefully install rotor assembly into
housing. Make sure that rotor bearing is fully seated
in housing.
E. Lubricate new O- rings (items 7 and 8) with di-
electric lubricant (see Special Tools in this chapter)
and install O- rings into grooves in cover. Place wave
washer in cover bearing bore.
F. Install cover to housing and secure with six (6)
flange head screws. Torque screws from 170 to 190
in- lb (19.3 to 21.4 N- m).
G. Make sure that rotor rotates before continuing
with motor/generator assembly.
3. Install motor/generator fan:
A. Position woodruff key (item 16) into slot on rotor
shaft.
B. Slide spacer, motor/generator fan and then sec-
ond spacer onto motor/generator shaft.
C. Secure fan to motor/generator shaft with nut
(item 19). Torque nut from 95 to 105 ft- lb (129 to
142 N- m).
4. Lubricate new O- ring with dielectric lubricant (see
Special Tools in this chapter) and install into groove on
isolator.
Electrical System
5. Install controller onto motor/generator:
A. Lower controller onto motor/generator and route
both controller and motor/generator harness con-
nectors out opening in controller.
IMPORTANT: When securing stator conductors
to controller connectors, make sure that flange
head screws do not pinch electrical harnesses.
B. Loosely install three (3) flange head screws (item
4) that secure motor/generator stator conductors to
controller connectors. Make sure that controller and
motor/generator harnesses are positioned away
from the screws.
C. Secure controller with cap screws (item 11), flat
washers (item 9) and flange nuts (item 10).
D. Torque three (3) flange head screws (item 4) to 75
in- lb (8.5 N- m).
E. Pack controller harness connector with dielectric
lubricant (see Special Tools in this chapter). Plug
motor/generator connector into controller connector.
Insert harnesses and connectors to the right side of
the three (3) terminals in the controller.
6. Lubricate new cover gasket (item 8) with dielectric lu-
bricant (see Special Tools in this chapter). Install gasket
into groove in access cover (item 7) and then install cov-
er to controller. Secure cover with two (2) washer head
screws. Torque screws from 70 to 80 in- lb (8.0 to 9.0
N- m).
7. Install motor/generator cover (item 3) to motor/gen-
erator assembly and secure with washer head screws.
Torque screws from 70 to 80 in- lb (8.0 to 9.0 N- m).
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