Overhaul

190CC-01

1. REMOVE GENERATOR PULLEY

SST 09820-63010 (09820-06010, 09820-06020)

HINT:

SST1 - A, B

09820-06010

SST2

09820-06020

(a) Hold SST 1 - A with a torque wrench, and tighten SST 1 - B clockwise to the specified torque.

Torque: 39 Nm (398 kgfcm, 29 ftlbf) NOTICE:

Check that SST is secured to the rotor shaft.

(c) Insert SST 1 - A, B into SST 2, and attach the pulley nut to SST 2.

(d) To loosen the pulley nut, turn SST 1 - 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.

(e) Remove the alternator form SST 2.

(g) Remove the pulley nut and pulley.

2. REMOVE GENERATOR BRUSH HOLDER ASSY

(a) Remove the nut and terminal insulator.

(b) Remove the screw, nut and terminal plate.

(c) Remove the 2 nuts and rear end cover.

(d) Remove the brush cover from the brush holder.

(e) Remove the 2 screw and brush holder.

(f) Remove the plate seal.

3. REMOVE GENERATOR REGULATOR ASSY (a) Remove the 3 screws and regulator.

4. REMOVE GENERATOR HOLDER W/RECTIFIER (a) Remove the 4 screws and holder w/ rectifier.

5. REMOVE GENERATOR RECTIFIER END FRAME

(a) Remove the plate seal from the rectifier end frame.

(b) Remove the 4 terminal insulator, 4 nuts and cord clip

(c) Using SST, remove the rectifier end frame. SST 09286-46011

6. REMOVE GENERATOR ROTOR ASSY

(a) Remove the washer from the rotor.

(b) Remove the rotor from drive end frame.

Toyota Forklift Regulator Assy Generator

7. INSPECT GENERATOR REGULATOR ASSY

(a) Using an ohmmeter, check the continuity between terminals F and B. Standard:

When the positive and negative poles between terminals F and B are exchanged, there is continuity in one way but no continuity in another way.

(b) Using an ohmmeter, check the continuity between terminals F and E.

Standard:

When the positive and negative poles between terminals F and E are exchanged, there is continuity in one way but no continuity in another way.

8. INSPECT GENERATOR REGULATOR ASSY

(a) Using an ohmmeter, check that there is continuity be tween the slip rings.

(b) Using an ohmmeter, check that there is no continuity between the slip ring and rotor.

(c) Using a vernier calipers, 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.)

9. INSPECT BRUSH

(a) Using a vernier calipers, measure the exposed brush length.

Standard exposed length:

Minimum exposed length: 1.5 mm (0.059 in.)

10. INSTALL GENERATOR ROTOR ASSY

(a) Install the rotor to the drive end frame.

(b) Install the washer on the rotor.

Corolla Frame Replacment

(c) Using a socket wrench 29 and press, slowly press in the rectifier end frame.

(d) Install the cord clip and 4 nuts. Torque:

Nut A 4.5 Nm (46 kgfcm, 40 in.lbf) Nut B 5.4 Nm (55 kgfcm, 48 in.lbf)

11. INSTALL GENERATOR HOLDER W/RECTIFIER

(a) Install the holder w/ rectifier with 4 screws. Torque: 2.9 Nm (30 kgfcm, 26 in.lbf)

12. INSTALL GENERATOR REGULATOR ASSY (a) Install the regulator with the 3 screw.

13. INSTALL GENERATOR BRUSH HOLDER ASSY

(a) Place the plate seal on the brush holder.

(b) Install the brush holder with the 2 screws. Torque: 2.0 Nm (20 kgfcm, 18 in.lbf)

NOTICE:

Pay attention to the holder installation direction.

Place the brush cover on the brush holder. Install the rear end cover with the 2 nuts. Torque: 4.4 N- m (45 kgf cm, 39 in. • Ibf) Install the terminal plate with the screw and nut. Torque:

Bolt 3.9 N - m (40 kgf cm, 35 in.lbf) Nut 4.4 N- m (45 kgf cm, 39 in. - lbf)

Install the terminal insulator withe the nut. Torque: 4.1 N- m (42 kgf- cm, 36 in. - lbf)

14. INSTALL GENERATOR PULLEY

SST 09820-63010 (09820-06010, 09820-06020)

HINT:

SST1 - A, B

09820-06010

SST2

09820-06020

(a) Install the pulley to the rotor shaft by tightening the pulley nut by hand.

(b) Hold SST 1 - A with a torque wrench, and tighten SST 1 - B clockwise to the specified torque.

Torque: 39 Nm (398 kgfcm, 29 ftlbf) NOTICE:

Check that SST is secured to the pulley shaft.

Electrical Symbols Generator Grounding

(d) Insert SST 1 - A, B into SST 2, and attach the pulley nut to SST 2.

Electrical Symbols Generator Grounding

(e) Tighten the pulley nut, turn SST 1 - A in the direction shown in the illustration.

Torque: 111 Nm (1,132 kgfcm, 82 ftlbf)

(f) Remove the alternator form SST 2.

(h) Turn the pulley, and check that the pulley moves smoothly.

E GLOSSARY OF TERMS AND SYMBOLS

BATTERY

Stores chemical energy and converts it into electrical energy. Provides DC current for the auto's various electrical circuits.

GROUND

The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow.

CAPACITOR (Condenser)

A small holding unit for temporary storage of electrical voltage.

CIGARETTE LIGHTER

An electric resistance heating element.

2. DOUBLE FILAMENT

HEADLIGHTS 1 SINGLE Current flow causes a headlight ' FILAMENT filament to heat up and emit light. A headlight may have either a single (1) filament or a double (2) filament

2. DOUBLE FILAMENT

CIRCUIT BREAKER

Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset.

HORN

An electric device which sounds a loud audible signal.

DIODE

A semiconductor which allows current flow in only one direction.

IGNITION COIL

Converts low-voltage DC current into high-voltage ignition current for firing the spark plugs.

DIODE, ZENER

A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator.

PHOTODIODE

The photodiode is a semiconductor which controls the current flow according to the amount of light.

DISTRIBUTOR, IIA

Channels high-voltage current from the ignition coil to the individual spark plugs.

FUSE

A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage.

FUSIBLE LINK

(for Medium Current Fuse) A heavy-gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit.

The numbers indicate the crosssection

(for High Current Fuse or

Fusible Link)

LIGHT

Current flow through a filament causes the filament to heat up and emit light.

LED (LIGHT EMITTING DIODE)

Upon current flow, these diodes emit light without producing the heat of a comparable light.

METER, ANALOG

Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration.

METER, DIGITAL

Current flow activates one or many LED's, LCD's, or fluorescent displays, which provide a relative or digital display.

MOTOR

A power unit which converts electrical energy into mechanical energy, especially rotary motion.

FUEL

RELAY

Basically, an electrically operated

1. NORMALLY switch which may be normally CLOSED closed (1) or open (2).

Current flow through a small coil creates a magnetic field which either opens or closes an attached switch.

2. NORMALLY OPEN

RELAY, DOUBLE THROW

A relay which passes current through one set of contacts or the other.

SPEAKER

An electromechanical device which creates sound waves from current flow.

SWITCH, MANUAL

1. NORMALLY OPEN

2. NORMALLY CLOSED

Opens and closes circuits, thereby stopping (1) or allowing (2) current flow.

RESISTOR

An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value.

SWITCH, DOUBLE THROW

A switch which continuously passes current through one set of contacts or the other.

RESISTOR, TAPPED

A resistor which supplies two or more different non adjustable resistance values.

RESISTOR, VARIABLE or RHEOSTAT

A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat.

Ignition Switch Replacement 2004 Corolla

SWITCH, IGNITION

A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational.

SWITCH, WIPER PARK

Automatically returns wipers to the stop position when the wiper switch is turned off.

(Reed Switch Type)

SENSOR, SPEED

Uses magnetic impulses to open and close a switch to create a signal for activation of other components.

TRANSISTOR

A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at "base".

TRANSISTOR

A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at "base".

SHORT PIN

Used to provide an unbroken connection within a junction block.

WIRES

CONNECTED

SOLENOID

An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc.

(2) SPLICED

Wires are always drawn as straight lines on wiring diagrams.

Crossed wires (1) without a black dot at the junction are not joined;

crossed wires (2) with a black dot or octagonal ( ) mark at the junction areO spliced (joined) connections.

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  • yerusalem
    How to test of toyota corolla alternator rectifier?
    8 years ago

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