Charging System (3MZ-FE): Generator: Inspection

INSPECT GENERATOR BRUSH HOLDER ASSEMBLY
1. Using vernier calipers, measure the exposed brush length.
  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 the minimum, replace the brush holder assembly.
  
  Fig 1: Measuring Exposed Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR ROTOR ASSEMBLY
1. Check that the bearing is not rough or worn. If necessary, replace the rotor assembly.
  
  Fig 2: Inspecting Generator Rotor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check if the rotor has an open circuit.
  1. Measure the resistance between the slip rings.
    Resistance:
    
    2.3 to 2.7 Ω at 20°C (68°F)
    
    If the resistance is not as specified, replace the generator rotor.
    
    Fig 3: Measuring Resistance Between Slip Rings
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the rotor for ground.
  1. Measure the resistance between the slip ring and rotor core.
    Resistance:
    
    1 MΩ or higher
    
    If the resistance is not as specified, replace the rotor assembly.
    
    Fig 4: Measuring Resistance Between Slip Ring And Rotor Core
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor assembly.
5. 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 rotor assembly.
  
  Fig 5: Measuring Slip Ring Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING
1. Check that the bearing is not rough or worn. If necessary, replace the bearing.
  
  Fig 6: Inspecting Generator Drive End Frame Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and retainer plate.
  
  Fig 7: Locating Screws And Retainer Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a wooden block, tap out the bearing.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
  
  Fig 8: Tapping Out Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR DRIVE END FRAME BEARING
1. Using SST and a press, press in a new bearing.
  SST 09950-60010 (09951-00470), 09950-70010 (09951-07100)
  
  Fig 9: Pressing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the retainer plate with the 4 screws.
  Torque: 2.3 N*m (23 kgf*cm, 20 in.*lbf)
  
  Fig 10: Locating Retainer Plate And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002