Overhaul
OVERHAUL1. REMOVE GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Securely fix SST on the generator rotor shaft.
b. Clamp SST 2 in a vise.
c. Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
d. To loosen the pulley nut, turn SST 1-A in the direction shown in the illustration.
NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than a half turn.
e. Remove the generator from SST 2.
f. Turn SST 1-B, then remove SST 1-A and B.
g. Remove the pulley nut, then remove the generator pulley.
2. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
a. Remove the nut, then remove the terminal insulator.
b. Remove the screw and nut, then remove the terminal plate.
c. Remove the 2 nuts, then remove the rear end cover.
d. Remove the generator brush cover from the generator brush holder.
e. Remove the 2 screws, then remove the generator brush holder.
f. Remove the generator plate seal from the generator rectifier end frame.
3. REMOVE GENERATOR REGULATOR ASSEMBLY
a. Remove the 3 screws, then remove the generator regulator.
4. REMOVE GENERATOR HOLDER W/RECTIFIER
a. Remove the 4 screws, then remove the generator holder with rectifier.
5. REMOVE GENERATOR RECTIFIER END FRAME
a. Remove the 4 terminal insulators from the generator rectifier end frame.
b. Remove the 4 nuts and generator cord clip.
c. Using SST, remove the generator rectifier end frame.
SST 09286-46011
6. REMOVE GENERATOR ROTOR ASSEMBLY
a. Remove the generator washer from the generator rotor.
b. Remove the generator rotor from the generator drive end frame.
7. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
a. Check the brush length.
1. Using vernier calipers, measure the exposed brush length.
Standard exposed brush length : 9.5 to 11.5 mm (0.374 to 0.453 in.)
Minimum exposed brush length : 4.5 mm (0.177 in.)
If the exposed brush length is less than minimum, replace the generator brush holder.
8. INSPECT GENERATOR REGULATOR ASSEMBLY
a. Check the resistance.
1. Using an ohmmeter, measure the resistance between terminals F and B.
Standard:
When the positive and negative poles of terminals F and B are switched over, there is a resistance of below 1 Ohm in one direction but 10 kOhms or higher in the other direction.
If the result is not as specified, replace the generator regulator.
2. Using an ohmmeter, measure the resistance between terminals E and F.
Standard:
When the positive and negative poles of terminals F and E are switched over, there is a resistance of below 1 Ohm in one direction but 10 kOhms or higher in the other direction.
If the result is not as specified, replace the generator regulator.
9. INSPECT GENERATOR HOLDER W/RECTIFIER
a. Check the resistance.
1. Using an ohmmeter, measure the resistance between the positive (+) terminal and each rectifier terminal.
Standard:
When the positive and negative poles of the positive (+) terminal and each rectifier terminal are switched over, there is a resistance of below 1 Ohm in one direction but 10 kOhms or higher in the other direction.
If the result is not as specified, replace the generator holder with rectifier.
2. Using an ohmmeter, measure the resistance between the negative (-) terminal and each rectifier terminal.
Standard:
When the positive and negative poles of the negative (-) terminal and each rectifier terminal are switched over, there is a resistance of below 1 Ohm in one direction but 10 kOhms or higher in the other direction.
If the result is not as specified, replace the generator holder with rectifier.
10. INSPECT GENERATOR ROTOR ASSEMBLY
a. Check for roughness or wear.
1. Check that the bearing is not rough or worn.
- If necessary, replace the bearing. (1ZZ-FE ENGINE TYPE)
- If necessary, replace the generator rotor. (2ZZ-GE ENGINE TYPE)
b. Check the resistance.
1. Using an ohmmeter, measure the resistance between the slip rings.
Standard resistance: 2.1 to 2.5 Ohms at 20 °C (68 °F)
If the resistance is not as specified, replace the generator rotor.
2. Using an ohmmeter, measure the resistance between the slip ring and rotor.
Standard: 1MOhm or higher
If the result is not as specified, replace the generator rotor shaft.
c. Check the appearance.
1. Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor.
d. Inspect the slip ring diameter.
1. Using vernier calipers, measure the slip ring diameter.
Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
Minimum diameter: 14.0 mm (0.551 in.)
If the diameter is less than minimum, replace the generator rotor.
11. INSPECT GENERATOR RECTIFIER END FRAME
a. Check for roughness or wear.
1. Check that the bearing is not rough or worn.
- If necessary, replace the bearing. (1ZZ-FE ENGINE TYPE)
- If necessary, replace the generator drive end frame. (2ZZ-GE ENGINE TYPE)
b. Check the resistance.
1. Using an ohmmeter, measure the resistance between the coil wires.
Standard: Below 1 Ohm
If the result is not as specified, replace the generator drive end frame.
2. Using an ohmmeter, measure the resistance between the coil wire and body.
Standard: 1 MOhm or higher
If the result is not as specified, replace the generator drive end frame.
12. REMOVE GENERATOR ROTOR BEARING (1ZZ-FE ENGINE TYPE)
a. Clamp the generator rotor in a vise.
b. Using SST, remove the generator bearing cover (outside) and bearing.
SST 09820-00021
NOTE: Be careful not to damage the fan.
c. Remove the generator bearing cover (inside) from the generator rotor.
13. INSTALL GENERATOR ROTOR BEARING (1ZZ-FE ENGINE TYPE)
a. Place the generator rotor on the generator pulley.
b. Install the generator bearing cover (inside) onto the generator rotor.
c. Using SST and a press, push a new bearing in.
SST 09820-00031
d. Using SST, push the generator bearing cover (outside) in.
SST 09285-76010
14. REMOVE GENERATOR DRIVE END FRAME BEARING (1ZZ-FE ENGINE TYPE)
a. Remove the 4 screws, then remove the retainer plate.
b. Using SST and a press, push the bearing out.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
15. INSTALL GENERATOR DRIVE END FRAME BEARING (1ZZ-FE ENGINE TYPE)
a. Using SST and a press, push a new bearing in.
SST 09950-60010 (09951-00530), 09950-70010 (09951-07100)
b. Install the retainer plate with the 4 screws.
Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf)
16. INSTALL GENERATOR ROTOR ASSEMBLY
a. Place the generator drive end frame on the generator pulley.
b. Install the generator rotor onto the generator drive end frame.
c. Install the generator washer onto the generator rotor.
17. INSTALL GENERATOR RECTIFIER END FRAME
a. Using a socket wrench 29 and a press, slowly push the generator rectifier end frame in.
b. Install the generator cord clip and 4 nuts.
Torque:
4.5 N.m (46 kgf.cm, 40 in.lbf) for nut A
5.4 N.m (55 kgf.cm, 48 in.lbf) for nut B
c. Install the 4 terminal insulators onto the generator rectifier end frame.
18. INSTALL GENERATOR HOLDER W/RECTIFIER
a. Install the generator holder with rectifier with the 4 screws.
Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
19. INSTALL GENERATOR REGULATOR ASSEMBLY
a. Install the generator regulator with the 3 screws.
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
20. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
a. Install the generator plate seal onto the generator rectifier end frame.
b. Install the generator brush holder with the 2 screws.
Torque: 2.0 N.m (20 kgf.cm, 18 in.lbf)
NOTE: Make sure that the generator brush holder is in the correct direction.
c. Install the generator brush cover onto the generator brush holder.
d. Install the generator rear and cover it with the 2 nuts.
Torque: 4.4 N.m (45 kgf.cm, 39 in.lbf)
e. Install the terminal plate.
Torque:
3.9 N.m (40 kgf.cm, 35 in.lbf) for bolt
4.4 N.m (45 kgf.cm, 39 in.lbf) for nut
f. Install the terminal insulator with the nut.
Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf)
21. INSTALL GENERATOR PULLEY
SST 09820-63010 (09820-06010, 09820-06020)
a. Install the generator pulley onto the rotor shaft by tightening the pulley nut by hand.
b. Hold SST 1-A with a torque wrench, then tighten SST 1-B counterclockwise to the specified torque.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
NOTE: Securely fix SST on the generator rotor shaft.
c. Clamp SST 2 in a vise.
d. Insert SST 1-A and B into SST 2, then attach the pulley nut to SST 2.
e. Tighten the pulley nut, then turn SST 1-A in the direction shown in the illustration.
Torque: 111 N.m (1,132 kgf.cm, 82 ft.lbf)
f. Remove the generator from SST 2.
g. Turn SST 1-B, then remove SST 1-A and B.
h. Turn the generator pulley, then check that the generator pulley moves smoothly.