Charging System - Generators & Regulators: Generator: Inspection

Inspect Voltage Regulator
1. Using an ohmmeter, check the continuity between terminals F and B.
  1. Standard:
  2. 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.
  If the continuity is not as specified, replace the voltage regulator.
  
  Fig 1: Checking Continuity Between Terminals F & B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an ohmmeter, check the continuity between terminals F and E.
  1. Standard:
  2. 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.
If the continuity is not as specified, replace the voltage regulator.

Fig 2: Checking Continuity Between Terminals F & E
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Rotor For Open Circuit
Using an ohmmeter, check that there is continuity between the slip rings.
1. Standard resistance:
2. 2.7 - 3.1 Ohms at 20°C (68 °F)
If there is no continuity, replace the rotor.

Fig 3: Checking Continuity Between Slip Springs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

Fig 4: Inspecting Rotor For Ground
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Slip Rings
1. Check that the slip rings are not rough or scored.
  If rough or scored, replace the rotor.
2. Using a vernier caliper, measure the slip ring diameter.
  1. Standard diameter:
  2. 14.2 - 14.4 mm (0.559 - 0.567 in.)
  3. Minimum diameter:
  4. 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.

Fig 5: Measuring Slip Ring Diameter Using Vernier Caliper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Stator (Drive End Frame) 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

Fig 6: Checking Continuity Between Coil Leads
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Stator (Drive End Frame) 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

Fig 7: Checking For No Continuity Between Coil Lead & Drive End Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Exposed Brush Length
Using vernier calipers, measure the exposed brush length.
1. Standard exposed length:E
2. 9.5 ~ 11.5 mm (0.374 ~ 0.453 in.)
3. Minimum exposed length:
4. 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brush holder assembly.

Fig 8: Measuring Exposed Brush Length Using Vernier Caliper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Positive Rectifier Holder
1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (a).
3. Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.

Fig 9: Inspecting Positive Rectifier Holder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Negative Rectifier Holder
1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (a).
3. Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.

Fig 10: Inspecting Negative Rectifier Holder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Front Bearing
Check that the bearing is not rough or worn.

Fig 11: Checking Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If Necessary, Replace Front Bearing
1. Remove the 4 screws, bearing retainer and bearing.
  
  Fig 12: Locating Screws For Front Bearing Replacement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a socket wrench and press, press out the bearing.
  
  Fig 13: Pressing Bearing Out Using Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in a new bearing.
  SST 09950-60010 (09951-00500)
4. Install the bearing retainer with the 4 screws.
  1. Torque:
  2. 3.0 N.m (31 kgf.Cm, 27 in..lbf)
Fig 14: Pressing New Bearing Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Inspect Rear Bearing
Check that the bearing is not rough or worn.

Fig 15: Inspecting rear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If Necessary, Replace Rear Bearing
1. Using SST, remove the bearing cover (outside) and bearing.
  SST 09820-00021
  
  NOTE: Be careful not to damage the fan.
2. Remove the bearing cover (inside).
  
  Fig 16: Displaying Bearing Cover Removal (Outside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the bearing cover (inside) on the rotor.
  
  Fig 17: Locating Bearing Cover (Inside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press in a new bearing.
  SST 09820-00031
  
  Fig 18: Pressing In New Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, push in the bearing cover (outside). SST 09285-76010
  
  Fig 19: Pushing In Bearing Cover (Outside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002