1ZR-FE BATTERY / CHARGING  GENERATOR  REASSEMBLY  


PROCEDURE

Hide 27310B 1.INSTALL GENERATOR DRIVE END FRAME BEARING

a.
A183132
1.073,0.677 0.531,0.281 0.531,0.281 0.948,1.042 false 2.354,0.677 1.865,0.323 1.865,0.323 2.156,0.833 false 0.219,0.198 0.583,0.365 0.365,0.167 10 SST 1.573,0.24 1.958,0.427 0.385,0.188 10 SST

Using SST and a press, install a new generator drive end frame bearing.

SST
09950-60010  (09951-00470)
09950-70010  (09951-07100)


b.
A153389
2.729,1.344 2.448,2 2.448,2 2.208,2 true 2.74,0.865 2.031,0.302 2.031,0.302 1.813,0.302 false 1.615,0.219 1.781,0.365 0.167,0.146 10 false *a 2.042,1.906 2.208,2.063 0.167,0.156 10 false *b
*a Tab
*b Cutout


Fit the tabs of the retainer plate into the cutouts of the generator drive end frame assembly to install the retainer plate.


c.

Install the 4 screws.

Torque:
2.3 N*m (23 kgf*cm, 20 in.*lbf)


Hide 27330 2.INSTALL GENERATOR ROTOR ASSEMBLY

a.

Place the generator drive end frame assembly on the generator pulley.


b.
A238333

Install the generator rotor assembly to the generator drive end frame assembly.


Hide 27360 3.INSTALL GENERATOR COIL ASSEMBLY

a.
A314531
1.938,0.5 2.448,0.5 true 1.927,1.448 2.438,1.448 true 2.49,0.417 2.802,0.573 0.313,0.156 10 false *a 2.479,1.385 2.792,1.542 0.313,0.156 10 false *b
*a Protrusion
*b Groove


Install a new bearing cover packing.

NOTICE:

Align the protrusions of the bearing cover packing with the grooves of the generator coil assembly when installing.



b.
A285303
2.635,0.563 2.792,0.177 2.792,0.177 2.969,0.177 false 1.188,0.688 0.844,0.24 0.844,0.24 0.594,0.24 false 3.031,0.083 3.406,0.313 0.375,0.229 10 false SST 0.292,0.146 0.729,0.344 0.438,0.198 10 false SST

Using SST and a press, slowly press the generator coil assembly to install it.

SST
09612-70100  (09612-07240)


c.

Install the 4 bolts.

Torque:
5.6 N*m (57 kgf*cm, 50 in.*lbf)


Hide 27370A 4.INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

a.
A153827
0.427,0.219 0.708,0.219 0.708,0.219 0.927,0.521 false 1.594,0.229 1.875,0.229 1.875,0.229 2.479,0.708 false 0.26,0.115 0.438,0.281 0.177,0.167 10 false *a 1.417,0.146 1.594,0.313 0.177,0.167 10 false *a
*a Pin (1.0 mm)


While pushing the 2 brushes into the generator brush holder assembly, insert a 1.0 mm (0.0394 in.) pin into the generator brush holder assembly hole.


b.
A311263
1.76,0.75 2.135,0.26 2.135,0.26 2.417,0.26 false 2.479,0.156 2.792,0.354 0.313,0.198 10 false *a
*a Pin (1.0 mm)


Install the generator brush holder assembly to the generator coil assembly with the 2 screws.

Torque:
1.8 N*m (18 kgf*cm, 16 in.*lbf)


c.

Pull out the pin from the generator brush holder assembly hole.


Hide 27387B 5.INSTALL GENERATOR TERMINAL INSULATOR

a.
A264636

Install the generator terminal insulator to the generator coil assembly.

NOTICE:

Be sure to install the generator terminal insulator in the correct direction.



Hide 27039 6.INSTALL GENERATOR REAR END COVER

a.

Install the generator rear end cover to the generator coil assembly with the 3 bolts.

Torque:
4.6 N*m (47 kgf*cm, 41 in.*lbf)


Hide 27411 7.INSTALL GENERATOR PULLEY

a.

Install the generator pulley to the rotor shaft by tightening the nut by hand.


b.
A201414
3.167,0.927 3.167,0.771 3.167,0.771 2.927,0.427 false 2.073,0.125 2.281,0.125 2.281,0.125 2.74,0.229 false 2.813,0.927 3.406,1.24 0.594,0.313 10 SST 1-B 1.385,0.042 1.948,0.344 0.563,0.302 10 SST 1-A 2.5,1.25 2.813,1.406 0.313,0.156 10 *a 0.365,0.948 0.677,1.104 0.313,0.156 10 *b
*a Turn
*b Hold


Hold SST 1-(A) with a torque wrench, and tighten SST 1-(B) clockwise to the specified torque.

SST
09820-63011  (09820-06010, 09820-06021)

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)

Item Part No.
SST 1-(A) and 1-(B) 09820-06010
SST 2 09820-06021

NOTICE:

Check that SST is secured to the rotor shaft.



c.

Secure the generator assembly in a vise between aluminum plates.


d.
A201413
1.729,1.25 1.271,2.625 1.271,2.625 1.094,2.625 false 1.927,1.125 1.833,0.177 1.833,0.177 1.75,0.177 false 0.677,2.542 1.094,2.844 0.417,0.302 10 false SST 2 0.667,0.094 1.76,0.406 1.094,0.313 10 false SST 1-A and 1-B 2.781,2.802 3.094,2.958 0.313,0.156 10 false *a 1.667,2.51 1.979,2.667 0.313,0.156 10 false *b
*a Turn
*b Hold


Place the rotor shaft end into SST 1-(A) and 1-(B).


e.

Fit SST 2 to the generator pulley.


f.

Tighten the nut, then turn SST 1-(A) and 1-(B) as shown in the illustration.

Torque:
133 N*m (1356 kgf*cm, 98 ft.*lbf)

NOTICE:
·

Check that the generator drive end frame assembly is secured in the vise tightly.

·

Hold SST 2 tightly during the operation.




g.

Remove SST 2 from the generator assembly.


h.

Remove the generator assembly from the vise.


i.
A062756
2.198,0.135 0.917,0.135 false 0.76,0.313 0.396,0.688 0.396,0.688 0.396,0.813 false 2.229,0.052 2.781,0.208 0.552,0.156 10 SST 1-A 0.031,0.854 0.583,1.01 0.552,0.156 10 SST 1-B 2.896,1.292 3.208,1.448 0.313,0.156 10 *a 0.896,1.094 1.208,1.25 0.313,0.156 10 *b
*a Turn
*b Hold


While holding SST 1-(B), turn SST 1-(A) and remove SST 1-(A) and 1-(B).


j.

Turn the generator pulley and check that the generator pulley moves smoothly.