Charging System - Generators & Regulators: Generator: Inspection

INSPECT VOLTAGE REGULATOR
1. Using an ohmmeter, check the continuity between terminals F and B.
  
  Fig 1: Checking Continuity Between Terminals F & B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Standard: When the positive and negative poles between terminals F and B are exchanged, there is continuity in one way but no continuity in another way.
  If the continuity is not as specified, replace the voltage regulator.
2. Using an ohmmeter, check the continuity between terminals F and E.
  
  Fig 2: Checking Continuity Between Terminals F & E
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Standard: When the positive and negative poles between terminals F and E are exchanged, there is continuity in one way but no continuity in another way.
  If the continuity is not as specified, replace the voltage regulator.
INSPECT ROTOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the slip rings.
1. Standard resistance: At 20°C (68°F): 2.1 - 2.5 Ω
If there is no continuity, replace the rotor.

Fig 3: Inspecting Rotor For Ground
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT ROTOR FOR GROUND
1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor.
2. If there is continuity, replace the rotor.
Fig 4: Ensuring There Is No Continuity Between Slip Ring & Rotor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SLIP RINGS
1. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor.
2. Using vernier calipers, measure the slip ring diameters.
  1. Standard diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.)
  2. Minimum diameter: 12.8 mm (0.504 in.)
  If the diameter is less than the minimum, replace the rotor.
  
  Fig 5: Measuring Rotor Diameter To Determine Replacement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT STATOR FOR OPEN CIRCUIT
1. Using an ohmmeter, check that there is continuity between the coil leads.
  
  Fig 6: Inspecting Stator For Open Circuit
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If there is no continuity, replace the drive end frame assembly.
INSPECT STATOR FOR GROUND
1. Using an ohmmeter, check that there is no continuity between the coil leads and drive end frame.
  
  Fig 7: Inspecting Stator For Ground
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. If there is continuity, replace the drive end frame assembly.
INSPECT EXPOSED BRUSH LENGTH
Using a scale, measure the exposed brush length.
1. Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.452 in.)
2. Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than the minimum, replace the brushes.

Fig 8: Inspecting Length Of Exposed Brushes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
IF NECESSARY, REPLACE BRUSHES
1. Unsolder and remove the brush and spring.
  
  Fig 9: Determining If Brushes Need Replacement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Run the wire of the brush through the hole in the brush holder, and insert the spring and brush into the brush holder.
3. Solder the brush wire to the brush holder at the exposed length.
  
  Fig 10: Soldering Brush Wire To Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Exposed length: 9.5 - 11.5 mm (0.374 - 0.452 in.)
4. Check that the brush moves smoothly in the brush holder.
5. Cut off the excess wire.
6. Apply insulation paint to the soldered point.
INSPECT POSITIVE RECTIFIER
1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
  
  Fig 11: Inspecting Positive Rectifier For Continuity
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Reverse the polarity of the tester probes and repeat step (a).
3. Check that one shows continuity and the other shows no continuity.
  If continuity is not as specified, replace the rectifier holder.
INSPECT NEGATIVE RECTIFIER
1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
2. Reverse the polarity of the tester probes and repeat step (a).
3. Check that one shows continuity and the other shows no continuity.
  If continuity is not as specified, replace the rectifier holder.
INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
IF NECESSARY, REPLACE FRONT BEARING
1. Remove the 4 screws and bearing retainer.
2. Using a press and socket wrench, press out the front bearing.
  
  Fig 13: Using Socket Wrench To Press Out Front Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press the front bearing into the drive end frame.
  1. SST 09950-60010 (09951-00500)
4. Install the bearing retainer with the 4 screws.
  
  Fig 14: Using SST To Press Font Bearing Into Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR BEARING
Check that the bearing is not rough or worn.
IF NECESSARY, REPLACE REAR BEARING
1. Using SST, remove the bearing cover and bearing.
  
  Fig 15: Using SST To Remove Bearing Cover & Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. SST 09820-00021
2. Remove the bearing cover (inside).
3. Place the bearing cover (inside) on the rotor.
  
  Fig 16: Placing Bearing Cover Inside On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press in a new bearing and the bearing cover.
  
  Fig 17: Using SST To Press New Bearing & Bearing Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. SST 09820-00031
5. Using SST, push in the bearing cover (outside).
  1. SST 09285-76010
  Fig 18: Using SST To Push In Bearing Cover (Outside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Place the generator washer on the rotor.
  
  Fig 19: Placing Generator Washer On Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002