Charging System: Generator: Inspection

INSPECT GENERATOR WITH CLUTCH PULLEY
1. When rotating the generator pulley, check that it turns counterclockwise and does not turn clockwise.
  
  Fig 1: Inspecting Generator With Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Using vernier calipers, measure the exposed brush length.
  Standard exposed length:
  
  10.5 mm (0.413 in.)
  
  Minimum exposed length:
  
  4.5 mm (0.177 in.)
  
  If the exposed length is less than the minimum, replace the generator brush holder assembly.
  
  Fig 2: Measuring Exposed Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR ROTOR ASSEMBLY
1. Check that the generator rotor bearing is not rough or worn.
  If necessary, replace the generator rotor.
  
  Fig 3: Inspecting Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the generator rotor for an open circuit.
  1. Using an ohmmeter, measure the resistance between the slip rings.
    Standard resistance:
    
    2.3 to 2.7 Ω at 20°C (68°F)
    
    If the result is not as specified, replace the generator rotor assembly.
    
    Fig 4: Measuring Resistance Between Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the generator rotor for a short circuit.
  1. Using an ohmmeter, measure the resistance between the each slip ring and rotor.
    Standard resistance:
    
    1 MΩ or higher
    
    If the result is not as specified, replace the generator rotor assembly.
    
    Fig 5: Measuring Resistance Between Slip Ring And Rotor
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using vernier calipers, 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING
1. Check the generator drive end frame bearing is not rough or worn.
  If necessary, replace the generator drive end frame bearing.
  
  Fig 7: Inspecting Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002