Generator ASSY: Overhaul

REMOVE GENERATOR REAR END COVER
1. Remove the 3 nuts and end cover.
2. Remove the terminal insulator.
  
  Fig 1: Removing Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSY
1. Remove the rear seal plate from the brush holder.
2. Remove the 2 screws and brush holder.
3. Remove the front seal plate from the coil.
  
  Fig 2: Removing Generator Brush Holder Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR PULLEY
1. Hold SST (A) with a torque wrench and tighten SST (B) clockwise to the specified torque.
  SST 09820-63011
  
  Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
2. Check that SST (A) is secured to the rotor shaft.
  
  Fig 3: Holding SST (A) With Torque Wrench & Tighten SST (B) Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Mount SST (C) in a vise.
4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 4: Inserting SST (B) Into SST (C) & Attaching Pulley Nut To SST (C)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. To loosen the pulley nut, turn SST (A) in the direction shown in Fig 5.
  NOTE: To prevent damage to the rotor shaft, do not turn the pulley nut more than one-half turn.
  
  Fig 5: Loosening Pulley Nut By Turning SST (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the generator from SST (C).
7. Turn SST (B) and remove SST (A and B).
  
  Fig 6: Turning SST (B) & Removing SST (A & B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the pulley nut and pulley.
REMOVE GENERATOR COIL ASSY
1. Remove the 4 bolts.
  
  Fig 7: Removing Generator Coil Assy Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the coil.
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-04011)
  
  Fig 8: Removing Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the generator washer.
REMOVE GENERATOR ROTOR ASSY
INSPECT GENERATOR ROTOR ASSY
1. Check that the rotor does not have an open circuit.
  1. Using an ohmmeter, measure the resistance between the slip rings.
    Standard: 2.1 to 2.5 Ω at 20°C (68°F)
    
    If the result is not as specified, replace the rotor assy.
    
    Fig 9: Checking Rotor Does Not Have An Open Circuit
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the rotor is not grounded.
  1. Using an ohmmeter, measure the resistance between the slip ring and rotor core.
    Standard: 10 k Ω or higher
    
    If the result is not as specified, replace the rotor assy.
    
    Fig 10: Checking Rotor Is Not Grounded
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Inspect the slip rings.
  1. Check that the slip rings are not rough or scored.
    If rough or scored, replace the rotor assy.
4. Using a vernier caliper, measure the slip ring diameter.
  Diameter: 12.8 to 14.4 mm (0.504 to 0.567 in.)
  
  If the diameter is less than the minimum, replace the rotor assy.
  
  Fig 11: Measuring Slip Ring Diameter Using Vernier Caliper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR BRUSH HOLDER ASSY
1. Using a vernier caliper, measure the exposed brush length.
  Exposed brush length: 1.5 to 11.5 mm (0.059 to 0.453 in.)
  
  If the length is less than the minimum, replace the brush holder assy.
  
  Fig 12: Inspecting Generator Brush Holder Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BEARING
1. Check that the bearing is not rough or worn.
  If rouge or worn, replace the bearing.
REPLACE FRONT BEARING
1. Remove the 4 screws and bearing retainer.
  
  Fig 13: Removing Front Bearing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press out the bearing.
  SST 09223-00010
  
  Fig 14: Pressing Out Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in a new bearing.
  SST 09950-60010 (09951-00480
  
  Fig 15: Pressing In New Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the bearing retainer with the 4 screws.
  Torque: 2.3 N.m (23 kgf.cm, 20 in.lbf)
REPLACE REAR BEARING
1. Using SST, remove the bearing cover (outside) and bearing.
  SST 09820-00021
  
  NOTE: Be careful not to damage the fan.
  
  Fig 16: Removing Bearing Cover (Outside) & Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bearing cover (inside).
3. Place the bearing cover (inside) on the rotor.
  
  Fig 17: Placing Bearing Cover (Inside) On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press in a new bearing.
  SST 09820-00031
  
  Fig 18: Pressing In New Bearing Using SST & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, push in the bearing cover (outside).
  SST 09285-76010
  
  Fig 19: Pushing In Bearing Cover (Outside) Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ROTOR ASSY
1. Place the drive end frame on the pulley.
2. Install the rotor to the drive end frame.
  
  Fig 20: Installing Generator Rotor Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR COIL ASSY
1. Place the generator washer on the rotor.
  
  Fig 21: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 29 mm socket wrench and press, slowly press in the coil.
  
  Fig 22: Pressing In Generator Coil Using Socket Wrench & Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the coil with the 4 bolts.
  Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
  
  Fig 23: Installing Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR PULLEY
1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.
2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  SST 09820-63010
  
  Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
  
  Fig 24: Holding SST (A) With Torque Wrench & Tightening SST (B) Clockwise To Specified Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check that SST (A) is secured to the pulley shaft.
4. Mount SST (C) in a vise.
5. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
  
  Fig 25: Inserting SST (B) Into SST (C) & Attaching Pulley Nut To SST (C)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. To tighten the pulley nut, turn SST (A) in the direction shown in Fig 26.
  Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf)
  
  Fig 26: Turning SST (A) Tightening Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator from SST (C).
8. Turn SST (B) and remove SST (A and B).
  
  Fig 27: Turning SST (B) & Removing SST (A & B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRUSH HOLDER ASSY
1. Place the front seal plate onto the coil.
  
  Fig 28: Placing Front Seal Plate Onto Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place the brush holder on the coil.
  NOTE: Be careful of the holder's installation direction.
3. Install the 2 screws.
  Torque: 1.8 N.m (18 kgf.cm, 16 in.lbf)
4. Place the rear seal plate on the brush holder.
  
  Fig 29: Placing Rear Seal Plate On Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR REAR END COVER
1. Install the terminal insulator.
2. Install the end cover with the 3 nuts.
  Torque: 4.6 N.m (47 kgf.cm, 41 in.lbf)
  
  Fig 30: Installing Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK THAT ROTOR ROTATES SMOOTHLY