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Inspection [12/2017 - ]: Procedure

  1. INSPECT GENERATOR PULLEY WITH CLUTCH 
    1. Hold the center of the generator pulley with clutch, and confirm that the outer ring turns counterclockwise and does not turn clockwise.
      GTY464049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Free
      Lock

      OK

      The outer ring turns counterclockwise and does not turn clockwise.

      If the result is not as specified, replace the generator pulley with clutch.

  2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Using a vernier caliper, measure the length of the exposed brushes.
      GTY769002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Length

      Standard Exposed Brush Length

      9.5 to 11.5 mm (0.374 to 0.453 in.)

      Minimum Exposed Brush Length

      4.5 mm (0.177 in.)

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

  3. INSPECT GENERATOR ROTOR ASSEMBLY 
    1. Check the generator rotor assembly for an open circuit.
      GTY468093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Slip Ring
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Slip ring - Slip ring Approx. 20°C (68°F) 1.36 to 1.76 Ω

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

    2. Check the generator rotor assembly for a short to ground.
      GTY468816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Slip Ring
      *b Rotor
      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance

        Tester Connection Condition Specified Condition
        Slip ring - Rotor Always 10 kΩ or higher
        NOTE:

        Perform the check on the fan portion of the rotor core that has not been coated with insulation paint.

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

    3. Check that the generator rotor bearing is not rough or worn and that it rotates smoothly.
      GTY457062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the generator rotor bearing is rough or worn, or does not rotate smoothly, replace the generator rotor assembly.

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

        If the slip rings are rough or scored, replace the generator rotor assembly.

      2. Using a vernier caliper, measure the slip ring diameter.
        GTY464727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Diameter

        Standard Diameter

        14.2 to 14.8 mm (0.559 to 0.583 in.)

        Minimum Diameter

        14.0 mm (0.551 in.)

        HINT: 

        If the slip ring surface is dirty, polish it with sandpaper (400-grit).

        If the diameter is less than the minimum, replace the generator rotor assembly.

  4. INSPECT GENERATOR DRIVE END FRAME BEARING 
    1. Check that the generator drive end frame bearing is not rough or worn and that it rotates smoothly.
      GTY100843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the generator drive end frame bearing is rough or worn, or does not rotate smoothly, replace the generator drive end frame bearing.

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