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Charging Systems: Charging: Generator: 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.
  If the result is not as specified, replace the clutch pulley.
  
  Fig 1: Inspecting Generator Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Using vernier calipers, measure the length of the exposed brushes.
  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.
  
  Fig 2: Measuring Length Of Exposed Brushes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT GENERATOR ROTOR ASSEMBLY

Check that the generator rotor bearing is not rough or worn.
If necessary, replace the generator rotor assembly.

Fig 3: Checking Generator Rotor Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the generator rotor for an open circuit.

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

Standard resistance

RESISTANCE SPECIFICATION

Condition	Specified condition
Approx. 20°C (68°F)	2.3 to 2.7 Ω

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

Fig 4: Measuring Resistance Between Slip Rings

G04975800

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Check the rotor for a short to ground.

Using an ohmmeter, measure the resistance between the slip ring and rotor.

Standard resistance

RESISTANCE SPECIFICATION

Tester condition	Specified condition
Slip ring - Rotor	1 MΩ or higher

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

Fig 5: Measuring Resistance Between Slip Ring And Rotor

G04975801

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 the minimum, replace the generator rotor assembly.

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

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