Charging System (Service Information): Generator: Disassembly: Disassembly

REMOVE GENERATOR PULLEY CAP
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Remove Generator Pulley Cap With Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR WITH CLUTCH PULLEY

Mount the generator in a vise between aluminum plates.
Install SST (A) and SST (B) to the generator with clutch pulley as shown in the illustration.
- SST: 09820-63021
Fig 2: View of Generator Clutch Pulley Using SST (A & B)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*1 Rotor Shaft

NOTE:
Securely attach SST to the generator with clutch pulley and generator rotor shaft.

Use a wrench to hold SST (A) and turn SST (B) counterclockwise to loosen the generator with clutch pulley.

Fig 3: Identifying SST (A & B) Generator, Clutch Pulley, Generator Rotor Shaft, Clutch Pulley & Wrench

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Hold
	Turn

NOTE:

Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

Remove SST from the generator.
Remove the generator with clutch pulley from the rotor shaft.

REMOVE GENERATOR REAR END COVER
1. Remove the nut and cord clip.
  
  Fig 4: Locating Nut And Cord Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 5: Identifying Nuts And Generator Rear End Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 6: Identifying Generator Coil & Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and brush holder from the generator coil.
  
  Fig 7: Identifying Generator Coil, Brush Holder & Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR COIL ASSEMBLY

Remove the 4 bolts.

Fig 8: Identifying Generator Coil Assembly & Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, remove the generator coil assembly.

Fig 9: Identifying SST & Generator Coil

SST: 09950-40011
1. 09951-04020
2. 09952-04010
3. 09953-04020
4. 09954-04010
5. 09955-04071
6. 09957-04010
7. 09958-04011

TEXT IN ILLUSTRATION

*a	Hold
	Turn

REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 10: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly.
  
  Fig 11: Identifying Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING
1. Check that the drive end frame bearing is not rough or worn.
  
  Fig 12: Inspecting Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If necessary, replace the generator drive end frame bearing.
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and retainer plate from the drive end frame.
  
  Fig 13: Identifying Generator Drive End Frame Bearing, Retainer Plate & Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the drive end frame bearing from the drive end frame.
  - SST: 09950-60010
    1. 09951-00250
  - SST: 09950-70010
    1. 09951-07100
  Fig 14: Tapping Out Drive End Frame Bearing From Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002