Charging System (2ZR-FE) (Service Information): Generator: Inspection: Inspection

INSPECT GENERATOR CLUTCH PULLEY
1. Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise.
  
  Fig 1: Inspecting Generator Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If the result is not as specified, replace the clutch pulley.
INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Using a vernier caliper, measure the length of the exposed brushes.
  
  Fig 2: Measuring Exposed Brush Length Using Vernier Calipers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 exposed length is less than the minimum, replace the brush holder assembly.

INSPECT GENERATOR ROTOR ASSEMBLY

Check the generator rotor for an open circuit.

Fig 3: Measuring Resistance Between Slip Rings

GTY165207

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, measure the resistance between the slip rings.

Standard Resistance

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

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

Check the rotor for a short to ground.

Fig 4: Measuring Resistance Between Slip Ring And Rotor

GTY120759

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, measure the resistance between one of the slip rings and the rotor.

Standard Resistance

Tester Connection	Condition	Specified Condition
Slip ring - Rotor	-	1 MΩ or higher

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

Check that the generator rotor bearing is not rough or worn.

Fig 5: Checking Generator Rotor Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If necessary, replace the generator rotor assembly.
Using a vernier caliper, measure the slip ring diameter.

Fig 6: Measuring Slip Ring Diameter Using Vernier Calipers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

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