Charging (Service Information): Generator: Disassembly: Disassembly

REMOVE GENERATOR PULLEY
- SST: 09820-63011
  - 09820-06010
  - 09820-06021
Fig 1: Removing Generator Pulley
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install SST1-A to the pulley shaft.
2. Install SST1-B to SST1-A.
3. Hold SST 1-A on the pulley shaft area, and tighten SST 1-B to the specified torque.
  Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf)
  
  NOTE:
  Securely fix SST1-A to the pulley shaft.
  
  HINT:
  
  Read SST1-B tightening torque by using the reactive torque of SST1-A.
4. Mount 2 faces of SST2 in a vise.
  
  Fig 2: Mounting Faces Of SST2 In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
6. To loosen the pulley nut, rotate SST1-A in the generator's normal rotation direction.
  
  Fig 3: Loosening Pulley Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  With SST2 (pulley nut) fixed in place, the pulley lock nut will loosen due to the rotation of SST1-A in the normal direction.
7. Remove the generator from SST2.
8. Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.
  
  Fig 4: Removing Pulley Lock Nut And Generator Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the pulley lock nut and generator pulley.
REMOVE GENERATOR REAR END COVER

Fig 5: Locating Generator Rear End Cover Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 3 nuts and generator rear end cover from the generator coil.
REMOVE GENERATOR TERMINAL INSULATOR

Fig 6: Locating Generator Terminal Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the generator terminal insulator from the generator coil.
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

Fig 7: Locating Generator Brush Holder Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 screws and generator brush holder from the generator coil.
REMOVE GENERATOR COIL ASSEMBLY

Fig 8: Locating Through Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4 through bolts.
2. Using SST, remove the generator coil.
  - SST: 09950-40011
    - 09951-04020
    - 09952-04010
    - 09953-04020
    - 09954-04010
    - 09955-04071
    - 09957-04010
    - 09958-04011
  Fig 9: Removing Generator Coil
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 10: Locating Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly from the drive end frame.
  
  Fig 11: Locating Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR BEARING
1. Remove the 4 screws, and remove the retainer from the drive end frame.
  
  Fig 12: Locating Generator Rotor Bearing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, remove the generator rotor bearing from the drive end frame.
  - SST: 09950-60010
    - 09951-00270
  - SST: 09950-70010
    - 09951-07100
  Fig 13: Removing Generator Rotor Bearing Of Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002