Charging Systems: Charging: Generator: Disassembly

REMOVE GENERATOR REAR END COVER
1. Remove the 3 nuts and end cover.
2. Remove the terminal insulator.
  
  Fig 1: Locating Generator Rear End Cover And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
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: Locating Rear Seal Plate From Brush Holder
  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 (400 kgf*cm, 29 ft.*lbf)
2. Check that SST (A) is secured to the rotor shaft.
  
  Fig 3: Removing Generator Pulley
  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: Attaching Pulley Nut To SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
  NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
6. Remove the generator from SST (C).
  
  Fig 5: Loosening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn SST (B) and remove SST (A and B).
8. Remove the pulley nut and pulley.
  
  Fig 6: Removing Pulley Nut And Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 7: Locating Generator Coil 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)
3. Remove the generator washer.
REMOVE GENERATOR ROTOR ASSEMBLY

Fig 8: Removing Coil
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR ROTOR ASSEMBLY
1. Check the rotor for an open circuit.
  1. Using an ohmmeter, measure the resistance between the slip rings.
    Standard resistance:
    
    2.1 to 2.5 Ω at 20°C (68°F)
    
    If the result is not as specified, replace the generator rotor.
    
    Fig 9: Measuring Resistance Between Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check if the rotor is grounded.
  1. Using an ohmmeter, measure the resistance between the slip ring and the rotor core.
    Standard resistance:
    
    10 kΩ or higher
    
    If the result is not as specified, replace the generator rotor.
    
    Fig 10: Measuring Resistance Between Slip Ring And Rotor Core
    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 assembly.
4. Using a vernier caliper, measure the slip ring diameter.
  Standard diameter:
  
  12.8 to 14.4 mm (0.504 to 0.567 in.)
  
  If the diameter is less than the minimum, replace the rotor assembly.
  
  Fig 11: Checking Slip Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Using a vernier caliper, measure the exposed brush length.
  Standard exposed 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 assembly.
INSPECT BEARING
1. Check that the bearing is not rough or worn. If necessary, replace the bearing.
  
  Fig 12: Measuring Exposed Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002