GENERATOR(for TMC Made except Cold Area Specification Vehicles) INSPECTION

PROCEDURE


  1. INSPECT GENERATOR CLUTCH PULLEY


    1. A01VM1VE06
      Text in Illustration
      *a Free
      *b Lock

      Hold the center of the generator clutch pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise.

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

  2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY

    A01VJCYE01
    Text in Illustration
    *a Length

    1. Using a vernier caliper, 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 generator brush holder assembly.

  3. INSPECT GENERATOR ROTOR ASSEMBLY

    A01VM0GE01

    1. Check the generator rotor for open circuits.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Slip ring - Slip ring 20°C (68°F) 1.7 to 2.1 Ω
        Text in Illustration
        *1 Slip Ring

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

    2. A01VFLBE01
      Text in Illustration
      *1 Slip Ring
      *2 Rotor

      Check the generator rotor for short circuits.


      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 MΩ or higher

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

    3. A01VH0I

      Check that the generator rotor bearing is not rough or worn.

      If necessary, replace the generator rotor assembly.

    4. A01VKXPE01
      Text in Illustration
      *a Diameter

      Using a vernier caliper, 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.

    5. A01VG67

      Check that the slip rings are not rough or scored.

      If rough or scored, replace the generator rotor assembly.

  4. INSPECT GENERATOR DRIVE END FRAME ASSEMBLY

    A01VICOE02

    1. Inspect the stator coil for open circuits.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Coil lead - Coil lead Always Below 1 Ω

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

    2. A01VF1PE02

      Inspect the stator coil for ground.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Coil lead - Generator drive end frame assembly Always 10 kΩ or higher

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

    3. A01VH1V

      Inspect the generator drive end frame bearing.


      1. Check that the bearing is not rough or worn.

        If necessary, replace the generator assembly.

  5. INSPECT GENERATOR HOLDER WITH RECTIFIER

    A01VGDZE12

    1. Check the resistance.


      1. Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        P1, P2, P3 and B Always Resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.
        P1, P2, P3 and E Always Resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.

        If the result is not as specified, replace the generator holder with rectifier.

  6. INSPECT GENERATOR REGULATOR ASSEMBLY


    1. Check the resistance.


      1. A01VGU4E01

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminals F - Terminals B Always When the positive and negative poles between terminals F and B are exchanged, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.

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

      2. A01VEBXE03

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminals E - Terminals F Always When the positive and negative poles between terminals E and F are exchanged, there is a resistance of below 1 Ω in one direction but 10 kΩ or higher in the other direction.

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