Toro Reelmaster 5010- H Service Manual page 237

Disassembly (Fig. 99)
1. Remove motor/generator cover (item 3) from motor/
generator assembly.
2. Remove access cover (item 7) and cover gasket
from controller. Discard cover gasket.
3. Carefully remove motor/generator and controller
harness connectors from controller opening. Note posi-
tion of connectors and wire harnesses for assembly pur-
poses. Unplug connectors.
4. Remove three (3) flange head screws (item 4) that
secure motor/generator stator conductors to controller
connectors.
5. Remove cap screws (item 11), flat washers (item 9)
and flange nuts (item 10) that secure controller to motor/
generator assembly. Lift controller from motor/genera-
tor. Remove and discard O- ring (item 15).
NOTE: If controller (item 1) damage exists, controller
replacement is necessary. Internal controller compo-
nents are not available separately.
6. Remove nut (item 19) that secures fan to motor/gen-
erator shaft.
7. Remove motor/generator fan and two (2) spacers
from motor/generator shaft. Locate and retrieve
woodruff key.
8. Remove internal motor/generator assembly compo-
nents (Fig. 100):
A. Remove six (6) flange head screws that secure
cover to housing. Leave cover on rotor shaft.
IMPORTANT: The rotor magnets are very power-
ful and can cause the rotor to shift position very
rapidly during removal. Use generator rotor tool
set (see Special Tools in this chapter) to remove
rotor. Be cautious during rotor removal to pre-
vent component damage or personal injury.
B. Use generator rotor tool set (see Special Tools in
this chapter) to carefully remove rotor assembly in-
cluding cover from housing. Follow removal proce-
dure listed in Special Tool section.
C. Remove cover from rotor assembly. Remove O-
rings and wave washer from cover. Discard O- rings.
D. Remove and discard O- ring from housing groove
in bearing bore.
E. If necessary, remove bearings from rotor. Discard
bearings if removed.
F. If necessary, remove isolator from housing as-
sembly.
Reelmaster 5010- H
35 to 45 in- lb
(4.0 to 5.0 N- m)
6
7
9
8
10
1. Housing/stator assembly
2. O- ring
3. Bearing
4. Rotor assembly
5. Bearing
6. Wave washer
7. O- ring
8. O- ring
9. Inspect rotor assembly for wear or damage. Also, in-
spect motor/generator housing/stator assembly for evi-
dence of damage.
NOTE: If motor/generator housing/stator damage ex-
ists, motor/generator assembly replacement is neces-
sary. The motor/generator housing and stator are not
available separately.
Assembly (Fig. 99)
1. Make sure that all motor/generator components are
cleaned before assembly.
2. Install internal motor/generator assembly compo-
nents (Fig. 100):
A. If bearings were removed from rotor assembly,
install new bearings onto rotor shaft. Make sure that
new bearings are fully pressed onto rotor shaft.
B. If isolator was removed, lubricate new gasket
with dielectric lubricant (see Special Tools in this
chapter) and install to isolator. Fit isolator to housing
assembly making sure that stator conductors and
stator harness are correctly positioned in isolator.
Secure isolator with spacers and screws. Torque
screws from 35 to 45 in- lb (4.0 to 5.0 N- m).
Page 5 - 97
11
13
15
5
2
3
4
170 to 190 in- lb
(19.3 to 21.4 N- m)
Figure 100
9. Cover
10. Flange screw (6 used)
11. Screw (2 used)
12. O- ring
13. Spacer (2 used)
14. Isolator
15. Gasket
Electrical System
12
14
1