Alternator: Testing and Inspection

2ZR-FE BATTERY / CHARGING: GENERATOR: INSPECTION

1. INSPECT GENERATOR CLUTCH PULLEY

(a) Hold the center of the pulley, and confirm that the outer ring turns counterclockwise and does not turn clockwise.





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

2. INSPECT GENERATOR BRUSH HOLDER ASSEMBLY

(a) 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.)

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

3. INSPECT GENERATOR ROTOR ASSEMBLY

(a) Check the generator rotor for an open circuit.





(1) Using an ohmmeter, measure the resistance between the slip rings.

Standard Resistance:





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

(b) Check the rotor for a short to ground.





(1) Using an ohmmeter, measure the resistance between one of the slip rings and the rotor.

Standard Resistance:





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

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





(d) If necessary, replace the generator rotor assembly.

(e) 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.)

(f) If the diameter is less than the minimum, replace the generator rotor assembly.

4. INSPECT GENERATOR DRIVE END FRAME BEARING

(a) Check that the bearing is not rough or worn.





(b) If necessary, replace the generator drive end frame bearing.