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Inspection [10/2015 - ]: Procedure

  1. INSPECT GENERATOR PULLEY WITH CLUTCH 
    1. Hold the center of the generator pulley with clutch, and confirm that the outer ring turns counterclockwise and does not turn clockwise.
      GTY515420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Free
      *b Lock

      If the result is not as specified, replace the generator pulley with clutch.

  2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Using a vernier caliper, measure the brush length.
      GTY423027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Brush Length

      Standard exposed length

      9.5 to 11.5 mm (0.374 to 0.453 in.)

      Minimum exposed length

      4.5 mm (0.177 in.)

      If the brush length is less than the minimum, replace the generator brush holder assembly.

  3. INSPECT GENERATOR ROTOR ASSEMBLY 
    1. Check that the generator rotor bearing of the generator rotor assembly is not rough or worn and that it rotates smoothly.
      GTY457062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace the generator rotor assembly.

    2. Check the generator rotor assembly for an open circuit.
      GTY500911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Slip Ring
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Slip ring - Slip ring 20°C (68°F) 1.36 to 1.76 Ω

        If the result is not as specified, replace the generator rotor assembly.

    3. Check the generator rotor assembly for a short to ground.
      GTY503599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Slip Ring
      *b Rotor Core
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Slip ring - Rotor core Always 10 MΩ or higher

        If the result is not as specified, replace the generator rotor assembly.

    4. Check each slip ring.
      1. Check that the slip rings are not rough or scored.

        If the slip rings are rough or scored, replace the generator rotor assembly.

      2. Using a vernier caliper, measure the slip ring diameter.
        GTY521040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Diameter

        Standard diameter

        14.2 to 14.8 mm (0.559 to 0.583 in.)

        Minimum diameter

        14.0 mm (0.551 in.)

        If the diameter is less than the minimum, replace the generator rotor assembly.

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