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

Check the generator rotor for an open circuit.

Fig 3: Measuring Resistance Value

GTY165207

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard resistance

Tester connection	Condition	Specified condition
Slip ring - Slip ring	20°C (68°F)	2.3 to 2.7 kΩ

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

Check the rotor for ground.

Fig 4: Measuring Resistance Between Slip Ring & Rotor Using Ohmmeter

GTY120759

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Standard resistance

Tester connection	Specified condition
Slip ring - Rotor	1 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.

Fig 5: Checking Generator Rotor Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If necessary, replace the generator rotor assembly.
Using vernier calipers, measure the slip ring diameter.

Fig 6: Measuring Slip Ring Diameter
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
1. Check that the bearing is not rough or worn.
  
  Fig 7: Inspecting Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If necessary, replace the generator drive end frame bearing.