Charging Systems: Generator: Inspection

1. Remove the voltage regulator (See step  2 under DISASSEMBLY).
2. Using an ohmmeter, check the continuity between terminals F and B.
   Fig 1: Using Ohmmeter To Inspect Voltage Regulator (1 Of 2)
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Standard: 
   2. When the positive and negative poles between terminals F and B are exchanged, there is continuity in one direction, but not the other. 

   If the continuity is not as specified, replace the voltage regulator.

3. Using an ohmmeter, check the continuity between terminals F and E.
   Fig 2: Using Ohmmeter To Inspect Voltage Regulator (2 Of 2)
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Standard: 
   2. When the positive and negative poles between terminals F and E are exchanged, there is continuity in one direction, but not the other. 

   If the continuity is not as specified, replace the voltage regulator.

4. Install the voltage regulator (See REASSEMBLY ).

Using an ohmmeter, check that there is continuity between the slip rings.

1. Standard resistance: 2.1 - 2.5 Ohms at 20°C (68°F) 

If there is no continuity, replace the rotor.

Fig 3: Using Ohmmeter To Inspect Rotor

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an ohmmeter, check that there is no continuity between the slip ring and rotor.

If there is continuity, replace the rotor.

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.
   Fig 4: Measuring Slip Ring Diameter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Standard diameter: 14.2 - 14.4 mm (0.559-0.567 in.) 
   2. Minimum diameter: 12.8 mm (0.504 in.) 

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

Using an ohmmeter, check that there is continuity between the coil leads.

Fig 5: Using Ohmmeter To Inspect Stator (1 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If there is no continuity, replace the drive end frame assembly.

Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.

Fig 6: Using Ohmmeter To Inspect Stator (2 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If there is continuity, replace the drive end frame assembly.

Using a vernier caliper, measure the exposed brush length.

Fig 7: Measuring Exposed Brush Length

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Standard exposed length: 10.5 mm (0.413 in.) 
2. Minimum exposed length: 1.5 mm (0.059 in.) 

If the exposed length is less than minimum, replace the brushes and brush holder assembly.

1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal.
   Fig 8: Using Ohmmeter To Inspect Rectifier (1 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal.
   Fig 9: Using Ohmmeter To Inspect Rectifier (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

Check that the bearing is not rough or worn.

Fig 10: Inspecting Front Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 screws, bearing retainer and bearing.
   Fig 11: Replacing Front Bearing (1 Of 3)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a socket wrench and press, press out the bearing.
   Fig 12: Replacing Front Bearing (2 Of 3)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, press in a new bearing.

   SST 09950-60010 (09951-00500)

4. Install the bearing retainer with the 4 screws.
   Fig 13: Replacing Front Bearing (3 Of 3)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 3.0 N.m (31 kgf.cm, 27 in.lbf) 

Check that the bearing is not rough or worn.

Fig 14: Inspecting Rear Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the bearing cover (outside) and bearing.

   SST 09820-00021

   NOTE: Be careful not to damage the fan.
2. Remove the bearing cover (inside).
   Fig 15: Replacing Rear Bearing (1 Of 4)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place the bearing cover (inside) on the rotor.
   Fig 16: Replacing Rear Bearing (2 Of 4)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, press in a new bearing.

   SST 09820-00031

   Fig 17: Replacing Rear Bearing (3 Of 4)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, push in the bearing cover (outside).

   SST 09285-76010

   Fig 18: Replacing Rear Bearing (4 Of 4)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002