Charging System: Generator: Inspection

Inspect Voltage Regulator
1. Remove the voltage regulator (See DISASSEMBLY ).
  
  Fig 1: Inspecting Voltage Regulator (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an ohmmeter, check the continuity between terminals F and B.
  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.
3. Using an ohmmeter, check the continuity between terminals F and E.
  
  Fig 2: Inspecting Voltage Regulator (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
4. Install the voltage regulator (See REASSEMBLY ).
Inspect Rotor For Open Circuit
Using an ohmmeter, check that there is continuity between the slip rings.

Standard resistance: 2.1 - 2.5 Ω at 20°C (68°F)

If there is no continuity, replace the rotor.
Inspect Rotor For Ground
Using an ohmmeter, check that there is no continuity between the slip ring and rotor.

Fig 3: Inspecting Rotor For Ground
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If there is continuity, replace the rotor.
Inspect Slip Rings
1. Check that the slip rings are not rough or scored.
  If rough or scored, replace the rotor.
2. Using a vernier caliper, measure the slip ring diameter.
  
  Fig 4: Measuring Slip Ring Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Standard diameter: 14.2 - 14.4 mm (0.559-0.567 in.)
  
  Minimum diameter: 12.8 mm (0.504 in.)
  
  If the diameter is less than minimum, replace the rotor.
Inspect Stator For Open Circuit
Using an ohmmeter, check that there is continuity between the coil leads.

Fig 5: Inspecting Stator For Open Circuit
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If there is no continuity, replace the drive end frame assembly.
Inspect Stator For Ground
Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.

Fig 6: Inspecting Stator For Ground
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If there is continuity, replace the drive end frame assembly.
Inspect Exposed Brush Length
Using a vernier caliper, measure the exposed brush length.

Fig 7: Inspecting Exposed Brush Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard exposed length: 10.5 mm (0.413 in.)

Minimum exposed length: 1.5 mm (0.059 in.)

If the exposed length is less than minimum, replace the brushes and brush holder assembly.
Inspect Positive Rectifier
1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
  
  Fig 8: Inspecting Positive Rectifier
  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.
  
  Fig 9: Inspecting Negative Rectifier
  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 Front Bearing
Check that the bearing is not rough or worn.

Fig 10: Inspecting Front Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If Necessary, Replace Front Bearing
1. Remove the 4 screws, bearing retainer and bearing.
  
  Fig 11: Removing Screws, Bearing Retainer & Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a socket wrench and press, press out the bearing.
  
  Fig 12: Pressing Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00500)
  
  Fig 13: Pressing In A New Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the bearing retainer with the 4 screws.
  Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf)
Inspect Rear Bearing
Check that the bearing is not rough or worn.

Fig 14: Inspecting Rear Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If Necessary, Replace Rear Bearing
1. Using SST, remove the bearing cover (outside) and bearing.
  SST 09820-00021
  
  Fig 15: Removing Bearing Cover (Outside) And Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the fan.
2. Remove the bearing cover (inside).
3. Place the bearing cover (inside) on the rotor.
  
  Fig 16: Placing Bearing Cover On Rotor (Inside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press in a new bearing.
  SST 09820-00031
  
  Fig 17: Pressing In A New Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, push in the bearing cover (outside).
  SST 09285-76010
  
  Fig 18: Pushing In Bearing Cover (Outside)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002