TOYOTA LAND CRUISER 1996 J80 Workshop Manual

CH0HO−01
−
CHARGING GENERATOR
CH−9
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the 3 nuts, bolt, rectifier plate and rear end cover.
2. REMOVE BRUSH HOLDER
(a) Remove the brush holder cover from the brush holder.
(b) Remove the 2 screws and brush holder.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
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P03807
HoldSST (B)
SST (A)
Turn
P08242
SST (C)
CH−10
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
4. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
(c) Remove the seal plate.
5. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.
(c) Mount SST (C) in a vise.
(d) Install the generator to SST (C).
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P08243
SST (C)Turn
SST (A)
P03794
−
CHARGING GENERATOR
CH−11
1996 LAND CRUISER (RM451U)
(e) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE:
To prevent damage to the rotor shaft, do not loosen the
pulley nut more than one −half of a turn.
(f) Remove the generator from SST (C).
(g) Turn SST (B) and remove SST (A and B).
(h) Remove the pulley nut and pulley.
6. REMOVE RECTIFIER END FRAME
(a) Remove the 4 nuts.
(b) Using SST, remove the rectifier end frame. SST 09286−46011
(c) Remove the generator washer.
7. REMOVE ROTOR FROM DRIVE END FRAME
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CH0784
ContinuityOhmmeter
CH0HP
−01
CH0783
No Continuity Ohmmeter
CH0192
P00484
Continuity
Ohmmeter
P00482
No Continuity
Ohmmeter
CH−12
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
slip rings.
Standard resistance (At 20 °C (68° F): 2.8 − 3.0 Ω
If there is no continuity, replace the rotor.
2. INSPECT ROTOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the slip ring and rotor.
If there is continuity, replace the rotor.
3. INSPECT SLIP RINGS
(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 14.2 − 14.4 mm (0.559 − 0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.
4. INSPECT STATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
coil leads.
If there is no continuity, replace the drive end frame assembly.
5. INSPECT STATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the coil lead and drive end frame.
If there is continuity, replace the drive end frame assembly.
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P13535
Length
Z04143
Positive (+)
Terminal
Rectifier
Terminal
Ohmmeter
Z04144
Negative (− )
Terminal
Ohmmeter
P00644
CH1026
−
CHARGING GENERATOR
CH−13
1996 LAND CRUISER (RM451U)
6. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes
and brush holder assembly.
7. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the posi- tive (+) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
8. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each negative ( −) terminal and the other to each rectifier termi-
nal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.
9. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
10. INSPECT REAR BEARING
Check that the bearing is not rough or worn.
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CH0HQ−01
P22368
SST
P22369
SST
N00581
SST
CH−14
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Remove the 4 screws and bearing retainer.
(b) Using SST and a press, press out the bearing. SST 09950−60010 (09951 −00260, 09952−06010)
(c) Using SST and a press, press in a new bearing. SST 09950−60010 (09951 −00500)
(d) Install the bearing retainer with the 4 screws. Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf)
2. REPLACE REAR BEARING
(a) Using SST , remove the bearing cover (outside) and bear-
ing.
SST 09820−00021
NOTICE:
Be careful not to damage the fan.
(b) Remove the bearing cover (inside).
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P05052
Bearring Cover
N00578
SST
P00074
SST
−
CHARGING GENERATOR
CH−15
1996 LAND CRUISER (RM451U)
(c) Place the bearing cover (inside) on the rotor.
(d) Using SST and a press, press in a new bearing.
SST 09820−00030
(e) Using SST, push in the bearing cover (outside). SST 09285−76010
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P03802
CH06M−03
P03794
P03807
Hold SST (A)
SST (B)
Turn
P08242
SST (C)
CH−16
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Place the generator washer on the rotor.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 4 nuts. Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Install the generator to SST (C).
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P08244
SST (A)
SST (C)
Turn
−
CHARGING GENERATOR
CH−17
1996 LAND CRUISER (RM451U)
(f) To torque the pulley nut turn SST (A) in the direction
shown in the illustration.
Torque: 110.5 N·m (1,128 kgf·cm, 81 ft·lbf)
(g) Remove the generator from SST (C).
(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Place the seal plate on the rectifier end frame.
(b) Install the 4 rubber insulators on the lead wires.
(c) Install the rectifier holder with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 25 in.·lbf)
6. INSTALL VOLTAGE REGULATOR
Install the voltage regulator on the rectifier end frame with the
3 screws. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)
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CH−18
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
7. INSTALL BRUSH HOLDER
(a) Install the brush holder on the rectifier end frame with the
2 screws.
NOTICE:
Be careful of the holder installation direction. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)
(b) Place the brush holder cover on the brush holder.
8. INSTALL REAR END COVER
(a) Install the end cover together with the rectifier plate. (1) Hand tighten the bolt first for positioning the plate.
(2) Tighten the 3 nuts and bolt.
Torque:
Bolt: 3.8 N·m (39 kgf·cm, 34 in.·lbf)
Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf)
(b) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY
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