DESCRIPTION & OPERATION
The generator is a small, high RPM, high performance type with an internal Integrated Circuit (IC) voltage regulator to control charging system voltage. A transistor inside IC regulator controls generator output to maintain a constant voltage. Charging system voltage is maintained within an operating range of 13.2-14.8 volts.
When ignition is turned on, battery voltage flows from generator terminal "L" through IC regulator to ground, causing discharge warning light to come on. When engine starts, generator RPM increases, which increases generator output voltage. When generator output voltage is greater than battery voltage, voltage to recharge battery flows from terminal "B". At the same time, voltage at terminal "L" increases and the potential difference between battery and terminal "L" ceases, causing discharge warning light to go off.
ADJUSTMENTS
Note. New belt refers to a belt which has been used 5 minutes or less on a running engine. Used belt refers to a belt which has been used more than 5 minutes on a running engine. After installing new belt(s), run engine for at least 5 minutes and recheck tension.
BELT TENSION
Serpentine drive belt uses an automatic belt tensioner. No adjustment is necessary, but belt must be properly installed. For belt routing (Scheme 1)
Scheme 1
TROUBLE SHOOTING
Note. See CHARGING SYSTEM - GENERAL TROUBLE SHOOTING article in GENERAL INFORMATION.
Check all fuses, fusible links, ignition switch and appropriate relays (if equipped). Check generator output. See NO-LOAD TEST under ON-VEHICLE TESTING.
NO-LOAD TEST
- Disconnect battery-to-generator terminal "B" wire. (Scheme 2) Using an ammeter and voltmeter, connect negative ammeter lead to disconnected generator terminal "B" wire end, and connect positive ammeter lead to generator terminal "B".
- Connect voltmeter positive lead to generator terminal "B" and negative lead to ground. (Scheme 2) Start engine and increase engine speed to 2000 RPM. Both meters should read within specification. See «GENERATOR SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__generator-specifications). If voltage is more than specified, replace voltage regulator. If voltage reading is less than specified, check voltage regulator. See «VOLTAGE REGULATOR»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__voltage-regulator).
Scheme 2
LOAD TEST
Note. If battery is fully charged, generator load test results may be less than 30 amps.
- Connect an ammeter as described in «NO-LOAD TEST»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__no-load-test), step 1. (Scheme 2) Start engine. Turn on high beam headlights and place heater blower control on HI. Increase engine speed to 2000 RPM.
- Check ammeter reading. See «GENERATOR SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__generator-specifications). If amperage is less than specified, repair or replace generator.
BRUSHES
- Brushes should slide smoothly in holders. Replace brushes if damaged or worn. See «GENERATOR SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__generator-specifications) .
- If exposed brush length is less than minimum, replace brushes and brush holder assembly. Install new brush springs when replacing brushes.
DIODES
Testing information not available from manufacturer.
ROTOR
- Check rotor for open field windings by using an ohmmeter across slip rings. Rotor resistance should be within specification. See «GENERATOR SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__generator-specifications) .
- Check rotor for shorts to ground by connecting ohmmeter between slip ring and rotor shaft. Ohmmeter should indicate no continuity. Check slip rings for wear or pitting. See «GENERATOR SPECIFICATIONS»(/toyota/land-cruiser/100-2002-2005/remont/charging-system/#charging-system-generators-regulators__generator-specifications) . If slip rings are shorted to rotor shaft, rough or scored, replace rotor.
STATOR
Testing information not available from manufacturer.
VOLTAGE REGULATOR
Testing information not available from manufacturer.
Removal & Installation
- Drain engine coolant. Loosen belt tension by turning belt tensioner counter-clockwise and remove drive belt.
- Remove engine under cover sub-assembly No. 1. Remove radiator. See appropriate COOLING SYSTEM (MECHANICAL) article in ENGINES.
- Disconnect battery cables. Remove power steering pump pulley. Disconnect generator wire harness connector. Remove nut and wire from "B" terminal on back of generator.
- Disconnect wire harness clamp clip from generator. Remove bolt and 2 nuts. Remove generator.
To install reverse removal procedure. Tighten generator bolts to specification. See TORQUE SPECIFICATIONS. Install drive belt. (Scheme 1)
Disassembly
- Remove rear end cover. (Scheme 4) Remove brush holder. Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to remove generator pulley.
- To remove pulley, install SST "A" and "B" to rotor shaft. Tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). (Scheme 5) Place SST "C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. (Scheme 5) To prevent damage to rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST "A" and "B", remove pulley nut and pulley.
- Remove coil assembly using Puller (SST 09950-40011). (Scheme 3) Remove generator washer (if equipped). Remove rotor from drive end frame.
Scheme 3
Scheme 4
Assembly
To assemble, reverse disassembly procedure. Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to install generator pulley. Place SST "C" securely into a vise. Install SST "A" and "B" and generator into SST "C". (Scheme 5) Tighten pulley nut in opposite direction of disassembly. See TORQUE SPECIFICATIONS. After completing assembly, verify that rotor turns smoothly.
Scheme 5
GENERATOR SPECIFICATIONS
| Application | Specification | ||
|---|---|---|---|
| Exposed Brush Length | |||
| Standard | .413 in. (10.5 mm) | ||
| Limit (Minimum) | More Than .177 in. (4.5 mm) | ||
| Rotor | |||
| Resistance (1) | 2.3-2.7 ohms | ||
| Slip Ring Diameter | |||
| Standard | .559-.567 Inches (14.2-14.4 mm) | ||
| Minimum | .551 Inches (14.0 mm) | ||
| Generator Regulated Output | |||
| Amperage | |||
| Without Load | 10 Or Less Amps | ||
| With Load | 30 Or More Amps | ||
| Voltage | 13.2-14.8 Volts | ||
| (1) Measured @ 68°F (20°C). | |||
| (1) | Measured @ 68°F (20°C). |
GENERATOR SPECIFICATIONS
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) | ||
|---|---|---|---|
| Fan Fluid Coupling Nut | 21 (29) | ||
| Generator Mounting Bolt | |||
| Bolt | 29 (39) | ||
| Nut | |||
| 8mm | 11 (15.5) | ||
| 10mm | 29 (39) | ||
| Generator Pulley Nut | 81 (110) | ||
| Power Steering Pump Bolt | 13 (17) | ||
| INCH Lbs. (N.m) | |||
| Battery Wire Terminal Nut | 87 (9.8) | ||
| Bearing Retainer Bolt | 23 (2.6) | ||
| Brush Holder | 16 (1.8) | ||
| End Frame Bolt (1) | 51 (5.8) | ||
| Fan Shroud Bolt | 44 (5.0) | ||
| Generator Rear End Cover Nut | 41 (4.6) | ||
| (1) May also be referred to as coil assembly. | |||
| (1) | May also be referred to as coil assembly. |
TORQUE SPECIFICATIONS
2003
For 2003 models, go to STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.
2004
For 2004 models, go to STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.