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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: Identifying 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.
  
  Fig 2: Measuring Length Of Exposed Brushes 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

Fig 3: Identifying Generator Rotor Assembly

G05268569

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Check the generator rotor for an open circuit.

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

Fig 4: Measuring Resistance Between Slip Rings Using Ohmmeter

G05268570

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard resistance

GENERATOR ROTOR ASSEMBLY (OPEN CIRCUIT)

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.

Check the rotor for a short to ground.

Fig 5: Measuring Resistance Between Slip Ring & Rotor Using Ohmmeter

G05268571

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard resistance

GENERATOR ROTOR ASSEMBLY (SHORT TO GROUND)

Tester condition	Specified condition
Slip ring - Rotor	1 M Ω or higher

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

Using vernier calipers, 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

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