Charging Systems: Charging: Generator: Inspection

INSPECT GENERATOR ROTOR ASSEMBLY
1. Check the rotor for open circuit.
  1. Using an ohmmeter, check that there is continuity between the slip rings.
    Standard resistance:
    
    2.3 to 2.7 Ω at 20°C (68°F)
    
    If there is no continuity, replace the rotor.
    
    Fig 1: Checking Rotor For Open Circuit
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the rotor for ground.
  1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor.
3. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor.
  
  Fig 2: Checking Rotor For Ground
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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 rotor.
  
  Fig 3: Measuring Slip Ring Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Using vernier caliper, measure the exposed brush length.
  Standard exposed length:
  
  10.5 mm (0.413 in.)
  
  Minimum exposed length:
  
  4.5 mm (0.177 in.)
  
  If the exposed length is less than minimum, replace the brushes and brush holder assembly.
  
  Fig 4: Measuring Exposed Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING
1. Check the bearing is not rough or worn. If necessary, replace the bearing.
INSPECT GENERATOR ROTOR BEARING
1. Check the bearing is not rough or worn. If necessary, replace the bearing.
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws, bearing retainer and bearing.
  
  Fig 5: Locating Bearing Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the bearing.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
  
  Fig 6: Tapping Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new bearing.
  SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
2. Install the bearing retainer with the 4 screws.
  Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf)
  
  Fig 7: Pressing In Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ROTOR 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 8: Removing Bearing Cover (Outside) And Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the bearing cover (inside) on the rotor.
Fig 9: Identifying Bearing Cover (Inside)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ROTOR BEARING
1. Using SST and a press, press in a new bearing.
  SST 09820-00031
  
  Fig 10: Pressing In Generator Rotor Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, push in the bearing cover (outside).
  SST 09285-76010
  
  Fig 11: Pushing In Bearing Cover (Outside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002