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Charging system

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Charging system

  1. 1. CHARGING SYSTEM CH-1
  2. 2. PRECAUTION 1. Check that the battery cables are connected to the correct terminals. 2. Disconnect the battery cables when the battery is given a quick charge. 3. Do not perform tests with a high voltage insulation resistance tester. 4. Never disconnect the battery while the engine is running. SYSTEM CIRCUIT -CHARGING SYSTEM PRECAUTION CH-2
  3. 3. PRECAUTION 1. Check that the battery cables are connected to the correct terminals. 2. Disconnect the battery cables when the battery is given a quick charge. 3. Do not perform tests with a high voltage insulation resistance tester. 4. Never disconnect the battery while the engine is running. SYSTEM CIRCUIT -CHARGING SYSTEM SYSTEM CIRCUIT CH-2
  4. 4. PREPARATION SST (SPECIAL SERVICE TOOLS) Rotor front bearing 09285-76010 Injection Pump Camshaft Bearing Cone Replacer (09608-00030) Replacer 09608-20012 Front Hub & Drive Pinion Bearing Tool Set 09820-63010 Alternator Pulley Set Nut Wrench Set 09286-4601 1 Injection Pump Spline Shaft Puller 09820-00030 Alternator Rear Bearing Replacer RECOMMENDED TOOLS 09820-00021 Alternator Rear Bearing Puller 09082-00050 TOYOTA Electrical Tester Set Battery specific gravity gauge 09200-00010 Engine Adjust Kit Belt tension gauge 09905-00013 Snap Ring Pliers EQUIPMENT Rotor rear bearing cover Rotor (Slip ring), BrushVernier calipers Torque wrench Rectifier end frame Rotor rear bearing Generator washer -CHARGING SYSTEM PREPARATION CH-3
  5. 5. 2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link and fuses for continuity. Fusible link: MAIN 2.0L H-fuse: ALT 100A AM1 50A Fuse: AM2 15A GAUGE 15A IGN 7.5A ALT-S 7.5A ON-VEHICLE INSPECTION 1. CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell. If insufficient, refill with distilled (or purified) water. (b) Check the specific gravity of each cell. Standard specific gravity: 1.25 - 1.27 at 20°C (68°F) If the specific gravity is less than specifications, charge the battery. HINT: Check the indicator as shown in the illustration. 3. INSPECT DRIVE BELT (a) Visually check the drive belt for excessive wear, frayed cords etc. If any defect is found, replace the drive bolt. HINT: Cracks on the rib side of a drive belt are consid- ered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. -CHARGING SYSTEM ON-VEHICLE INSPECTION CH-4
  6. 6. (b) Using a belt tension gauge, check the drive belt ten- sion. Belt tension gauge: Nippondenso BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: New belt 160 ± 20 lbf Used belt 100 ± 20 lbf If necessary, adjust the drive belt tension. HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing a belt, check that it fits properly in the ribbed grooved. • Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 4. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the gener- ator while the engine is running. -CHARGING SYSTEM ON-VEHICLE INSPECTION CH-5
  7. 7. 6. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, con- nect the tester to the charging circuit as per manufacturer’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: • Disconnect the wire from terminal B of the gener- ator and connect it to the negative (-) tester probe of the ammeter. • Connect the positive (+) tester probe of the am- meter to terminal B of the generator. • Connect the positive (+) tester probe of the voltmeter to terminal B of the generator. • Ground the negative (-) tester probe of the volt- meter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.9 - 15.1 V at 25°C (77°F) 13.5 - 14.3 V at 115° C (239° F) If the voltmeter reading is greater than standard volt- age, replace the voltage regulator. If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows: • With terminal F grounded, start the engine and check the voltmeter reading of terminal B. 5. INSPECT CHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. (b) Turn off all accessories. (c) Turn the ignition switch ’ON’. Check that the charge warning light is lit. (d) Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the charge light circuit. -CHARGING SYSTEM ON-VEHICLE INSPECTION CH-6
  8. 8. 7. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ’Hl”. (b) Check the reading on the ammeter. Standard amperage: 30 A or more • If the voltmeter reading is greater than standard voltage, replace the voltage regulator. • If the voltmeter reading is less than standard voltage, check the generator. If the ammeter reading is less than the standard am- perage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. -CHARGING SYSTEM ON-VEHICLE INSPECTION CH-7
  9. 9. GENERATOR GENERATOR REMOVAL 1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY CAUTION (w/ SRS): Work must be started after 90 sec- onds from the time the ignition switch is turned to the ” LOCK” position and the negative (-) terminal cable is disconnected from the battery. 2. DISCONNECT CONNECTOR AND WIRE FROM GENERATOR (a) Disconnect the connector from the generator. (b) Remove the connector cover and nut, and disconnect the wire from the generator. 3. REMOVE DRIVE BELT Loosen the pivot bolt and adjusting bolt, and remove the drive belt. 4. REMOVE GENERATOR (a) Remove the pivot bolt, nut and adjusting bolt. (b) Remove the generator. -CHARGING SYSTEM GENERATOR CH-8
  10. 10. GENERATOR DISASSEMBLY (See Components for Disassembly and Assembly) 1. w/ Dust Cover: REMOVE DUST COVER Remove the 3 bolts and dust cover. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY 2. REMOVE REAR END COVER (a) Remove the nut and terminal insulator. -CHARGING SYSTEM GENERATOR CH-9
  11. 11. 3. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR (a) Remove the 5 screws, brush holder and voltage regu- lator. 4. REMOVE RECTIFIER HOLDER (a) Remove the 4 screws and rectifier holder. (b) Remove the brush holder cover from the brush holder. (b) Remove the 4 rubber insulators. (b) Remove the 3 nuts and end cover. -CHARGING SYSTEM GENERATOR CH-10
  12. 12. 5. REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 N-m (400 kgf-cm, 29 ft-lbf) (b) Check that SST (A) is secured to the rotor shaft. (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. (f) Remove the generator from SST (C). (c) Mount SST (C) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. -CHARGING SYSTEM GENERATOR CH-1 1
  13. 13. (c) Using snap ring pliers, remove the generator washer from the rectifier end frame. (b) Using SST, remove the rectifier end frame. SST 09286-46011 6. REMOVE RECTIFIER END FRAME (a) Remove the 4 nuts. 7. REMOVE ROTOR FROM DRIVE END FRAME -CHARGING SYSTEM GENERATOR CH-12
  14. 14. Stator (Drive End Frame) 1. INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. 2. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. 3. INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (b) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 14.2 - 14.4 mm (0.558 - 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. GENERATOR INSPECTION AND REPAIR Rotor 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.8 - 3.0W at 20°C (68°F) If there is no continuity, replace the rotor. 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. -CHARGING SYSTEM GENERATOR CH-13
  15. 15. Brushes 1. INSPECT EXPOSED BRUSH LENGTH Using a scale, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes. 2. IF NECESSARY, REPLACE BRUSHES (a) Unsolder and remove the brush and spring. (b) Run the wire of a new brush through the spring and the hole in the brush holder, and insert the spring and brush into the brush holder. Rectifiers (Rectifier Holder) 1. INSPECT POSITIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeal step (a). (c) Check that one shows continuity and the other show: no continuity. If continuity is not as specified, replace the rectifier holder. (c) Solder the brush wire to the brush holder at specified exposed length. Exposed length: 10.5 mm (0.413 in.) (d) Check that the brush moves smoothly in the brush holder. (e) Cut off the excess wire. (f) Apply insulation paint to the soldered area. -CHARGING SYSTEM GENERATOR CH-14
  16. 16. 2. INSPECT NEGATIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. Bearings 1. INSPECT FRONT BEARING Check that the bearing is not rough or worn. (b) Using a socket wrench and press, press out the bear- ing. 2. IF NECESSARY, REPLACE FRONT BEARING (a) Remove the 4 screws, bearing retainer and bearing. (c) Using SST and a press, press in a new bearing. SST 09608-20012 (09608-00030) -CHARGING SYSTEM GENERATOR CH-15
  17. 17. 4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). (d) Using SST and a press, press in a new bearing. SST 09820-00030 (d) Install the bearing retainer with the 4 screws. Torque: 2.6 N-m (27 kgf-cm, 23 in.-lbf) 3. INSPECT REAR BEARING Check that the bearing is not rough or worn. (c) Place the bearing cover (inside) on the rotor. -CHARGING SYSTEM GENERATOR CH-16
  18. 18. 3. INSTALL RECTIFIER END FRAME (a) Install the generator washer to the rectifier end frame. NOTICE: Be careful of the generator washer installation direction. GENERATOR ASSEMBLY (See Components for Disassembly and Assembly) 1. PLACE RECTIFIER END FRAME ON PULLEY (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (e) Using SST, push in the bearing cover (outside). SST 09285-76010 2. INSTALL ROTOR TO DRIVE END FRAME -CHARGING SYSTEM GENERATOR CH-17
  19. 19. (b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 N-m (400 kgf-cm, 29 ft-lbf) (c) Check that SST (A) is secured to the pulley shaft. (f) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 N-m (1,125 kgf-cm. 81 ft-lbf) (g) Remove the generator from SST (C). (d) Mount SST (C) in a vise. (e) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). 4. INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (d) install the 4 nuts. Torque: 4.5 N-m (46 kgf-cm, 40 in.-lbf) -CHARGING SYSTEM GENERATOR CH-18
  20. 20. 6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Install the brush holder cover to the brush holder. NOTICE: Be careful of the holder installation direction. 5. INSTALL RECTIFIER HOLDER (a) Install the 4 rubber insulators on the lead wires. NOTICE: Be careful of the rubber insulators installation direction. (b) Install the rectifier holder while pushing it with the 4 screws. Torque: 3.06 N-m (31 kgf-cm, 27 in.-lbf) (b) Place the voltage regulator together with the brush holder horizontally on the rectifier end frame. (h) Turn SST (B), and remove SST (A and B). -CHARGING SYSTEM GENERATOR CH-19
  21. 21. (c) Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and voltage regulator. Torque: 2.04 N-m (21 kgf-cm, 18 in.-lbf) 8. w/ Dust Cover: INSTALL DUST COVER Install the dust cover with the 3 bolts. Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf) 7. INSTALL REAR END COVER (a) Install the end cover with the 3 nuts. Torque: 4.5 N-m (46 kgf-cm, 40 in.-lbf) (b) Install the terminal insulator with the nut. Torque: 4.1 N-m (42 kgf-cm, 36 in.-lbf) (d) Fit the brush holder cover. -CHARGING SYSTEM GENERATOR CH-20
  22. 22. GENERATOR INSTALLATION 1. INSTALL GENERATOR Mount the generator on the generator bracket with the pivot bolt, nut and adjusting bolt. Do not tighten the bolts yet. 2. INSTALL DRIVE BELT (a) Adjust the drive belt tension. (See page CH-5 ) (b) Tighten the pivot bolt and adjusting bolt. Torque: 41 N-m (420 kgf-cm, 30 ft-lbf) for pivot bolt 12 N-m (120 kgf-cm, 9 ft-lbf) for adjusting bolt 4. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY 5. PERFORM ON-VEHICLE INSPECTION (See steps 5 to 7 on pages CH-6 and CH-7 ) 3. CONNECT CONNECTOR AND WIRE TO GENERATOR 9. CHECK THAT ROTOR ROTATES SMOOTHLY -CHARGING SYSTEM GENERATOR CH-21
  23. 23. 12V 60 A, 12V 70A 2.8 - 3.0 W 14.2 - 14.4 mm (0.559 - 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) SERVICE SPECIFICATIONS SERVICE DATA Rated output Rotor coil resistance Slip ring diameter Brush exposed length TORQUE SPECIFICATIONS Rectifier holder x Coil lead on rectifier end frame Voltage regulator x Rectifier end frame Rectifier end frame x Drive end frame Bearing retainer x Drive end frame Terminal insulator x Rectifier holder at 25°C (77°F) at 115°C (239° F) Brush holder x Rectifier end frame Rear end cover x Rectifier holder Dust cover x Rectifier end frame Generator x Generator bracket Generator x Adjusting lever Dust cover x Drive end frame 13.9 - 15.1 V 13.5 - 14.3 V Generator pulley x Rotor 160 ± 20 Ibf 100 ± 20 lbf STD Limit STD Limit Voltage regulator Regulating voltage New belt Used belt Specific gravity at 20°C (68°F) Part tightened 1.25 - 1.27 Drive belt Generator 40 in.-lbf 48 in.-lbf 48 in.-lbf 40 in.-lbf 36 in.-lbf 18 in.-lbf 18 in.-lbf 23 in.-lbf 27 in.-lbf Tension Battery kgf-cm 1,125 ft lbf 2.04 2.04 3.06 420 110 120 5.4 5.4 2.6 4.5 4.5 -CHARGING SYSTEM SERVICE SPECIFICATIONS CH-22

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