Charging (3MZ-FE): Generator: Inspection

1. Check the brush length. (100A Generator)
   1. Using vernier calipers, measure the exposed brush length.
   Fig 1: Measuring Exposed Brush Length (100A Generator)

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   Standard exposed brush length: 

   10.5 mm (0.413 in.) 

   Minimum exposed brush length: 

   4.5 mm (0.177 in.) 

   If the exposed brush length is less than minimum, replace the generator brush holder.

2. Check the brush length. (130A Generator)
   1. Using vernier calipers, measure the exposed brush length.
   Fig 2: Measuring Exposed Brush Length (130A Generator)

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   Standard exposed brush length: 

   10.5 mm (0.413 in.) 

   Minimum exposed brush length: 

   4.5 mm (0.177 in.) 

   If the exposed brush length is less than minimum, replace the generator brush holder.

1. Check that bearing is not rough or worn.

   If necessary, replace the generator rotor. (100A Generator)

   If necessary, replace the generator rotor bearing. (130A Generator)

   Fig 3: Checking Generator Rotor Bearing

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2. Check if the rotor has open circuit.
   1. Using an ohmmeter, measure the resistance between the slip ring.

      Resistance: 

      2.3 to 2.7Ω at 20°C (68°F) for 100A 

      Generator 

      1.5 to 1.9Ω at 20°C (68°F) for 130A 

      Generator 

      If the resistance is not as specified, replace the generator rotor.

   Fig 4: Measuring Resistance Between Slip Ring

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3. Check if the rotor has ground.
   1. Using an ohmmeter, check that there is no continuity between the slip ring and rotor core.

   If there is continuity, replace the generator rotor.

4. Inspect slip rings.
   1. Check that the slip rings are not rough or scored.

   If rough or scored, replace the generator rotor.

   Fig 5: Checking Continuity Between Slip Ring And Rotor Core

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5. Check the slip ring diameter.
   1. Using vernier calipers, measure the slip ring diameter.
   Fig 6: Measuring Slip Ring Diameter

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   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 minimum, replace the generator rotor.

1. 130A generator
   1. Using SST, remove the generator bearing cover (outside) and bearing.
      Fig 7: Removing Generator Bearing Cover (Outside) And Bearing (130A Generator)

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      SST 09820-00021 

      NOTE: Be careful not to damage the fan.
   2. Remove the generator bearing cover (inside).

1. 130A generator
   1. Place the generator rotor on the generator pulley.
   2. Install the generator bearing cover (inside).
   3. Using SST and a press, press in a new bearing.
      Fig 8: Installing Generator Rotor Bearing

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      SST 09820-00031 

   4. Using SST, push in the generator bearing cover (outside).

   SST 09285-76010 

   Fig 9: Installing Generator Bearing Cover (Outside)

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1. Check that bearing is not rough or worn.

If necessary, replace the bearing.

Fig 10: Checking Generator Drive End Frame Bearing

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