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

  1. 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
      G05399863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Using a vernier caliper, 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
      G04975798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT GENERATOR ROTOR ASSEMBLY 
    1. Check the generator rotor for an open circuit.
      1. Using an ohmmeter, measure the resistance between the slip rings.

        Standard Resistance 

        TESTER CONNECTION SPECIFIED CONDITON CHART

        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.

        Fig 3: Measuring Resistance Between Slip Rings
        G06036090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the rotor for a short to ground.
      1. Using an ohmmeter, measure the resistance between one of the slip rings and the rotor.

        Standard Resistance 

        TESTER CONNECTION SPECIFIED CONDITON CHART

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

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

        Fig 4: Measuring Resistance Between One Of Slip Rings And Rotor
        G04975801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that the generator rotor bearing is not rough or worn.

      If necessary, replace the generator rotor assembly.

      Fig 5: Checking Generator Rotor Bearing
      G05399867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a vernier caliper, 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
      G05399868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT GENERATOR DRIVE END FRAME BEARING 
    1. Check that the bearing is not rough or worn. If necessary, replace the generator drive end frame bearing.
      Fig 7: Inspecting Generator Drive End Frame Bearing
      G05399869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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