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Charging System (2GR-FE) (Except Hybrid): Generator: Inspection

  1. INSPECT GENERATOR CLUTCH PULLEY 
    1. Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise.

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

      Fig 1: Turning Clutch Pulley For Checking Outer Ring Locks
      G04975772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT GENERATOR DRIVE END FRAME BEARING 
    1. Check that the bearing is not rough or worn.

      OK: The bearing rotates smoothly. 

      If the bearing does not rotate smoothly, replace the bearing.

      Fig 2: Checking If Generator Drive End Frame Bearing Is Not Rough Or Worn
      G04975803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Using vernier calipers, measure the length of the exposed brushes.

      Standard exposed length: 9.5 to 11.5 mm (0.374 to 0.453 in.) 

      Minimum exposed length: 4.5 mm (0.177 in.) 

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

      Fig 3: Measuring Length Of Exposed Generator Brushes Using Vernier Calipers
      G04975798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT GENERATOR ROTOR ASSEMBLY 
    1. Check that the generator rotor bearing is not rough or worn.

      If necessary, replace the generator rotor assembly.

      Fig 4: Checking If Generator Rotor Bearing Is Not Rough Or Worn
      G04975799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the generator rotor for an open circuit.
      1. Using an ohmmeter, measure the resistance between the slip rings.

        Standard resistance: w/o Towing Package and Rear Heater Assembly 

        Fig 5: Measuring Resistance Between Slip Rings Using Ohmmeter
        G04975800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      RESISTANCE SPECIFICATION TABLE

      Condition Specified Condition
      Approx. 20°C (68°F) 2.3 to 2.7 Ω (100 A and 130 A type)

      w/ Towing Package or Rear Heater Assembly 

      RESISTANCE SPECIFICATION TABLE

      Condition Specified Condition
      Approx. 20°C (68°F) 1.5 to 1.9 Ω (150 A type)

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

    3. Check the rotor for a short to ground.
      1. Using an ohmmeter, measure the resistance between the slip ring and rotor.
        Fig 6: Measuring Resistance Between Slip Ring & Rotor Using Ohmmeter
        G04975801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance 

      RESISTANCE SPECIFICATION TABLE

      Tester Condition Specified Condition
      Slip ring - Rotor 1 MΩ or higher

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

    4. 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 generator rotor assembly.

      Fig 7: Measuring Slip Ring Diameter Using Vernier Calipers
      G04975802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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