Charging System (2ZZ-GE): Generator: Inspection

INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Check the brush length.
  1. Using vernier calipers, measure the exposed brush length.
    
    Fig 1: Measuring Exposed Brush Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard exposed brush length: 9.5 to 11.5 mm (0.374 to 0.453 in.)
    
    Minimum exposed brush length: 4.5 mm (0.177 in.)
    
    If the exposed brush length is less than minimum, replace the generator brush holder.
INSPECT GENERATOR REGULATOR ASSEMBLY
1. Check the resistance.
  1. Using an ohmmeter, measure the resistance between terminals F and B.
    
    Fig 2: Measuring Resistance Between Terminals F And B
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: When the positive and negative poles of terminals F and B are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator regulator.
  2. Using an ohmmeter, measure the resistance between terminals E and F.
    Standard resistance: When the positive and negative poles of terminals F and E are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator regulator.
    
    Fig 3: Measuring Resistance Between Terminals E And F
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR HOLDER W/RECTIFIER
1. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the positive (+) terminal and each rectifier terminal.
    
    Fig 4: Measuring Resistance Between Positive Terminal And Each Rectifier Terminal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: When the positive and negative poles of the positive (+) terminal and each rectifier terminal are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator holder with rectifier.
  2. Using an ohmmeter, measure the resistance between the negative (-) terminal and each rectifier terminal.
    Standard resistance: When the positive and negative poles of the negative (-) terminal and each rectifier terminal are switched over, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
    
    If the result is not as specified, replace the generator holder with rectifier.
    
    Fig 5: Measuring Resistance Between Negative Terminal And Each Rectifier Terminal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR ROTOR ASSEMBLY
1. Check for roughness or wear.
  1. Check that the bearing is not rough or worn. If necessary, replace the generator rotor.
    
    Fig 6: Checking Bearing Roughness Or Wear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the slip rings.
    Standard resistance: 2.1 to 2.5 Ω at 20°C (68°F)
    
    If the resistance is not as specified, replace the generator rotor.
    
    Fig 7: Measuring Resistance Between Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using an ohmmeter, measure the resistance between the slip ring and rotor.
    Standard resistance: 1 MΩ or higher
    
    If the result is not as specified, replace the generator rotor shaft.
3. Check the appearance.
  1. Check that the slip rings are not rough or scored.
    If rough or scored, replace the generator rotor.
    
    Fig 8: Checking Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect the slip ring diameter.
  1. Using vernier calipers, measure the slip ring diameter.
    Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.)
    
    Minimum diameter: 14.0 mm (0.551 in.)
    
    If the diameter is less than minimum, replace the generator rotor.
    
    Fig 9: Measuring Slip Ring Diameter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR RECTIFIER END FRAME
1. Check for roughness or wear.
  1. Check that the bearing is not rough or worn. If necessary, replace the generator drive end frame.
    
    Fig 10: Checking Bearing Roughness Or Wear
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the resistance.
  1. Using an ohmmeter, measure the resistance between the coil wires.
    
    Fig 11: Measuring Resistance Between Coil Wires
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: Below 1Ω
    
    If the result is not as specified, replace the generator drive end frame.
  2. Using an ohmmeter, measure the resistance between the coil wire and body.
    
    Fig 12: Measuring Resistance Between Coil Wire And Body
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Standard resistance: 1 MΩ or higher
    
    If the result is not as specified, replace the generator drive end frame.