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Charging System (Service Information): Generator: Inspection: Inspection

  1. INSPECT GENERATOR CLUTCH PULLEY 
    1. Hold the center of the generator clutch pulley and check that the outer ring turns counterclockwise and does not turn clockwise.
      Fig 1: Inspecting Generator Clutch Pulley Rotation
      GTY176829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Free
      Lock

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

  2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Using a vernier caliper, measure the brush length.
      Fig 2: Measuring Brush Length Using A Vernier Caliper
      GTY167490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a 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 is not rough or worn.
      Fig 3: Inspecting Generator Rotor Assembly
      GTY125344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace the generator rotor assembly.

    2. Check the generator rotor for an open circuit.
      Fig 4: Inspecting Generator Rotor For Open Circuit
      GTY184981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.
        TEXT IN ILLUSTRATION

        *1 Slip Ring

        Standard Resistance

        Tester Connection Condition Specified Condition
        Slip Ring - Slip Ring 20°C (68°F) 2.3 to 2.7 Ω

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

    3. Check if the generator rotor is grounded.
      Fig 5: Checking Generator Rotor Ground
      GTY179275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance according to the value(s) in the table below.
        TEXT IN ILLUSTRATION

        *1 Slip Ring
        *2 Rotor Core

        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. Using a vernier caliper, measure the slip ring diameter.
      Fig 6: Measuring Slip Ring Diameter Using Vernier Caliper
      GTY182895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a 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 the minimum, replace the generator rotor assembly.

  4. INSPECT GENERATOR DRIVE END FRAME BEARING 
    1. Check that the drive end frame bearing is not rough or worn.
      Fig 7: Inspecting Generator Drive End Frame Bearing
      GTY146430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace the generator drive end frame bearing.

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