Reassembly

1UR-FSE CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR ROTOR BEARING





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

SST : 09950-60010

09951-00500

SST : 09950-70010

09951-07100

(b) 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 Nm (30 kgf-cm, 27 in-lbf)

2. INSTALL GENERATOR ROTOR ASSEMBLY





(a) Install the generator rotor assembly.

(b) Install the generator washer.





3. INSTALL GENERATOR COIL ASSEMBLY





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

SST : 09612-70100

(b) Tighten the 4 through bolts.





Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

4. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY





(a) Insert a pin (diameter 1.0 mm) into the generator brush holder assembly to fix the 2 brushes in place.

(b) Install the generator brush holder to the generator coil with the 2 screws.





Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf)

(c) Remove the pin (diameter 1.0 mm).

5. INSTALL GENERATOR TERMINAL INSULATOR





(a) Install the generator terminal insulator to the generator coil.

6. INSTALL GENERATOR REAR END COVER





(a) Install the generator rear end cover to the generator coil with the 3 nuts.

Torque : 4.6 Nm (47 kgf-cm, 41 in-lbf)

7. INSTALL GENERATOR PULLEY

SST : 09820-63011

09820-06010

09820-06021





(a) Install the generator pulley, and temporarily install the pulley lock nut.

(b) Install SST1-A to the pulley shaft.

(c) Install SST1-B to SST1-A.

(d) Hold SST 1-A on the pulley shaft area, and tighten SST 1-B to the specified torque.

Torque : 39.2 Nm (400 kgf-cm, 29 ft-lbf)

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

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

(e) Mount 2 faces of SST2 in a vise.





(f) With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.

(g) To tighten the pulley nut, rotate SST1-A in the generator's reverse rotation direction.





Torque : 133 Nm (1351 kgf-cm, 98 ft-lbf)

(h) Remove the generator from SST2.

(i) Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.





(j) Check that the pulley rotates smoothly.