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Charging Systems: Inspection

  1. Inspect rotor for open circuit.  Using an ohmmeter, check that there is continuity between the slip rings. If there is no continuity, replace the rotor.
    1. Standard Resistance:  2.1-2.5 Ω at 20°C (68°F)
    Fig 1: Inspecting Rotor For Open Circuit
    G03138870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Inspect rotor for ground.  Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor.
    Fig 2: Inspecting Rotor For Ground
    G03138871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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. If the diameter is less than minimum, replace the rotor.
      1. Standard Diameter:  14.2-14.4 mm (0.559-0.567 in.)
      2. Minimum Diameter:  12.8 mm (0.504 in.)
    Fig 3: Inspecting Slip Rings
    G03138872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Inspect stator for open circuit.  Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly.
    Fig 4: Inspecting Stator For Open Circuit
    G03138873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Inspect stator for ground.  Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly.
    Fig 5: Inspecting Stator For Ground
    G03138874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Inspect exposed brush length.  Using a vernier caliper, measure the exposed brush length. If the exposed length is less than minimum, replace the brushes and brush holder assembly.
    1. Standard Exposed Length:  10.5 mm (0.413 in.)
    2. Minimum Exposed Length:   1.5 mm (0.059 in.)
    Fig 6: Measuring Exposed Brush Length
    G03138875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Inspect positive rectifier. 
    1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
    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.
    Fig 7: Inspecting Positive Rectifier
    G03138876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Inspect negative rectifier. 
    1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
    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.
    Fig 8: Inspecting Negative Rectifier
    G03138877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Inspect front bearing.  Check that the bearing is not rough or worn.
    Fig 9: Inspecting Front Bearing
    G03138878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. If necessary, replace front bearing. 
    1. Remove the 4 screws, bearing retainer and bearing.
      Fig 10: Removing Front Bearing Retainer
      G03138879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a socket wrench and press, press out the bearing.
      Fig 11: Pressing Out Front Bearing
      G03138880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST (SST 09950-60010/09951-00500) and a press, press in a new bearing.
      Fig 12: Pressing In NEW Front Bearing
      G03138881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the bearing retainer with the 4 screws.
      1. Torque:  3.0 N.m (31 kgf.cm, 27 in. lbf)
  11. Inspect rear bearing.  Check that the bearing is not rough or worn.
    Fig 13: Inspecting Rear Bearing
    G03138882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. If necessary, replace rear bearing. 
    1. Using SST (SST 09820-00021), remove the outside bearing cover and bearing.
      NOTE: Be careful not to damage the fan.
      Fig 14: Removing Outside Bearing Cover & Rear Bearing
      G03138883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bearing cover (inside).
    3. Place the bearing cover (inside) on the rotor.
      Fig 15: Identifying Inside Bearing Cover
      G03138884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST (SST 09820-00030) and a press, press in a new bearing.
      Fig 16: Pressing In NEW Bearing
      G03138885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST (SST 09285-76010), push in the bearing cover (outside).
    Fig 17: Pushing In Outside Bearing Cover
    G03138886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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