Inspection [09/2014 - ]: Procedure

INSPECT GENERATOR PULLEY WITH CLUTCH

Hold the center of the generator pulley with clutch, and confirm that the outer ring turns counterclockwise and does not turn clockwise.

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	Free
	Lock

The outer ring turns counterclockwise and does not turn clockwise.

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

INSPECT GENERATOR BRUSH HOLDER ASSEMBLY

Using a vernier caliper, measure the length of the exposed brushes.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Length

Standard Exposed Brush Length

9.5 to 11.5 mm (0.374 to 0.453 in.)

Minimum Exposed Brush Length

4.5 mm (0.177 in.)

If the brush length is less than the minimum, replace the generator brush holder assembly.

INSPECT GENERATOR ROTOR ASSEMBLY

Check the generator rotor assembly for an open circuit.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Slip Ring

Measure the resistance according to the value(s) in the table below.

Standard Resistance

Tester Connection	Condition	Specified Condition
Slip ring - Slip ring	Approx. 20°C (68°F)	1.36 to 1.76 Ω

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

Check the generator rotor assembly for a short to ground.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Slip Ring
*b	Rotor

Measure the resistance according to the value(s) in the table below.

Standard Resistance

Tester Connection	Condition	Specified Condition
Slip ring - Rotor	Always	10 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 and that it rotates smoothly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the generator rotor bearing is rough or worn, or does not rotate smoothly, replace the generator rotor assembly.

Check the slip ring.

Check that the slip rings are not rough or scored.
If the slip rings are rough or scored, replace the generator rotor assembly.

Using a vernier caliper, measure the slip ring diameter.

Diameter

Standard Diameter

14.2 to 14.8 mm (0.559 to 0.583 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

Check that the generator drive end frame bearing is not rough or worn and that it rotates smoothly.

If the generator drive end frame bearing is rough or worn, or does not rotate smoothly, replace the generator drive end frame bearing.