Unformatted text preview: CH1 CHARGING SYSTEM CH2
CHARGING SYSTEM PRECAUTION PRECAUTION
CH00K09 1. 2. 3. 4. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not do tests with a high voltage insulation resistance testor. Never disconnect the battery while the engine is running. EQUIPMENT
Vernier calipers Torque wrench Rotor (Slip ring)
CH00V0B RECOMMENDED TOOLS SST (SPECIAL SERVICE TOOLS) PREPARATION CHARGING SYSTEM PREPARATION CH3 CH00T0D CH00R07 CH4
CHARGING SYSTEM ONVEHICLE INSPECTION ONVEHICLE INSPECTION
CH08101 1. CHECK BATTERY ELECTROYTE LEVEL AND VOLTAGE (a) Check the electrolyte quantity of each cell. If under the lower level, replace the battery (or add distilled water if possible.). Need to check the charging system. (b) Measure the battery voltage between the terminals negative () and positive (+) of the battery.
Standard voltage: At 20C (68F): 12.712.9 V HINT: Before measuring the voltage, turn the ignition switch OFF and turn off the electrical systems (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. If the vehicle has been running, wait 5 minutes or more after the vehicle stops before measuring the battery voltage. If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. 2. CHECK BATTERY TERMINALS AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fuses for continuity.
Hfuse: ALT 100A AM1 40A Fuse: AM2 15A ALT SENSING 7.5A GAUGE 15A CH5
CHARGING SYSTEM ONVEHICLE INSPECTION 3. INSPECT DRIVE BELT HINT: A belt tensioner is used, so checking the belt tension is not necessary. (a) Visually check the drive belt for excessive wear, frayed cords, etc. If necessary, replace the drive belt. HINT: Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. The drive belt tension can be released by turning the belt tensioner clockwise. (b) Check the belt tensioner operation. Check that the belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approx. 98 N (10 kgf, 22.0 lbf) of force. Check the alignment of the belt tensioner pulley to make sure the drive belt will not slip off the pulley. If necessary, replace the belt tensioner. Check that the arrow mark on the belt tensioner falls within area A of the scale. If it is outside area A, replace the drive belt. HINT: When a new belt is installed, it should lie within area B. If not, the drive belt is not correct. 4. After installing a drive belt, check that it fits properly in the ribbed grooves. Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. REMOVE ENGINE UNDER COVER CH6
CHARGING SYSTEM ONVEHICLE INSPECTION 5. 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 generator while the engine is running. 6. (a) (b) (c) CHECK CHARGE WARNING LIGHT CIRCUIT Warm up the engine and then turn it off. Turn off all accessories. 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. 7. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect 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 generator, and connect it to the negative () probe of the ammeter. Connect the positive (+) probe of the ammeter to terminal B of the generator. Connect the positive (+) probe of the voltmeter to terminal B of the generator. Ground the negative () probe of the voltmeter. (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: At 25C (77F): 13.614.8 V At 115C (239F): 13.214.0 V If the voltmeter reading is more than standard voltage, replace the voltage regulator. CH7
CHARGING SYSTEM ONVEHICLE INSPECTION 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. If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard voltage, check the generator. 8. 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 "HI". (b) Check the reading on the ammeter.
Standard amperage: 30 A or more 9. If the ammeter reading is less than the standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. REINSTALL ENGINE UNDER COVER CH8
CHARGING SYSTEM GENERATOR
COMPONENTS FOR REMOVAL AND INSTALLATION CH9
CHARGING SYSTEM GENERATOR CH08201 GENERATOR REMOVAL
1. 2. Installation is in the reverse order of removal. REMOVE ENGINE UNDER COVER REMOVE DRIVE BELT Loosen the belt tension by turning the drive belt tensioner clockwise, and remove the drive belt. INSTALLATION NOTICE: Do an onvehicle inspection. (See steps 6 to 8 in onvehicle inspection) 3. REMOVE GENERATOR (a) Disconnect the generator connector. (b) Remove the rubber cap and nut, and disconnect the generator wire. (c) Disconnect the generator wire clamp from the wire clip on the generator. (d) Remove the bolt and pipe clamp, and disconnect the 2 A/T oil cooler pipes from the generator. (e) Remove the bolt, nut, pipe bracket and generator.
Torque: 37 Nm (380 kgfcm, 27 ftlbf) CH10
CHARGING SYSTEM GENERATOR
CH03R0A COMPONENTS FOR DISASSEMBLY AND ASSEMBLY CH08301 GENERATOR DISASSEMBLY
1. REMOVE REAR END COVER (a) Remove the nut and terminal insulator. (b) Remove the bolt, 3 nuts, plate terminal and end cover. CH11
CHARGING SYSTEM GENERATOR 2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR (a) Remove the brush holder cover from the brush holder. (b) Remove the 5 screws, brush holder and voltage regulator. (c) Remove the seal plate from the rectifier end frame. 3. REMOVE WIRE CLIP Remove the nut and wire clip. 4. REMOVE RECTIFIER HOLDER (a) Remove the 4 screws and rectifier holder. CH12
CHARGING SYSTEM GENERATOR (b) Remove the 4 rubber insulators. 5. REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 0982063010
Torque: 39 Nm (400 kgfcm, 29 ftlbf) (b) Check that SST (A) is secured to the rotor shaft. (c) Mount SST (c) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (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 onehalf of a turn. (f) Remove the generator from SST (C). (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. CH13
CHARGING SYSTEM GENERATOR 6. REMOVE RECTIFIER END FRAME (a) Remove the 3 nuts. (b) Using SST, remove the rectifier end frame. SST 0995040010 (c) 7. Remove the generator washer. REMOVE ROTOR FROM DRIVE END FRAME CH08401 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 (Cold): 2.83.0 W 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. CH14
CHARGING SYSTEM GENERATOR 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: 14.214.4 mm (0.5590.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. 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. Brushes
INSPECT EXPOSED BRUSH LENGTH Using a vernier caliper, measure the exposed 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 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 repeat step (a). CH15
CHARGING SYSTEM GENERATOR (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 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. 2. IF NECESSARY, REPLACE FRONT BEARING (a) Remove the 4 screws, bearing retainer and bearing. (b) Using a socket wrench and press, press out the bearing. CH16
CHARGING SYSTEM GENERATOR (c) Using SST and a press, press in a new bearing. SST 0960820012 (0960800030) (d) Install the bearing retainer with the 4 screws. 3. INSPECT REAR BEARING Check that the bearing is not rough or worn. 4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing cover and bearing. SST 0982000021
NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). (c) Place the bearing cover (inside) on the rotor. (d) Using SST and a press, press in a new bearing. SST 0982000030 CH17
CHARGING SYSTEM GENERATOR (e) Using SST, push in the bearing cover (outside). SST 0928576010 CH08501 GENERATOR ASSEMBLY
1. 2. PLACE RECTIFIER END FRAME ON PULLEY INSTALL ROTOR TO RECTIFIER END FRAME 3. INSTALL RECTIFIER END FRAME (a) Place the generator washer on the rotor. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (c) Install the 3 nuts.
Torque: 4.5 Nm (46 kgfcm, 40 in.lbf) CH18
CHARGING SYSTEM GENERATOR 4. INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 0982063010
Torque: 39 Nm (400 kgfcm, 29 ftlbf) (c) Check that SST (A) is secured to the pulley shaft. (d) Mount SST (C) in a vise. (e) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (f) To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Torque: 110 Nm (1,125 kgfcm, 81 ftlbf) (g) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B). 5. INSTALL RECTIFIER HOLDER (a) Install the 4 rubber insulators on the lead wires. CH19
CHARGING SYSTEM GENERATOR (b) Install the rectifier holder while pushing it with the 4 screws.
Torque: 2.94 Nm (29 kgfcm, 26 in.lbf) 6. INSTALL WIRE CLIP Install the wire clip with the nut.
Torque: 4.5 Nm (46 kgfcm, 40 in.lbf) 7. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Place the seal plate on the rectifier end frame. (b) Place the voltage regulator and brush holder on the rectifier end frame.
NOTICE: Be careful of the holder installation direction. (c) Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and voltage regulator. (d) Place the brush holder cover on the brush holder. CH20
CHARGING SYSTEM GENERATOR 8. INSTALL REAR END COVER (a) Install the end cover and plate terminal with the bolt and 3 nuts.
Torque: Nut: Bolt: 4.5 Nm (46 kgfcm, 40 in.lbf) 3.9 Nm (40 kgfcm, 35 in.lbf) (b) Install the terminal insulator with the nut.
Torque: 6.5 Nm (66 kgfcm, 58 in.lbf) 9. CHECK THAT ROTOR ROTATES SMOOTHLY TORQUE SPECIFICATIONS SERVICE DATA SERVICE SPECIFICATIONS Generator x Cylinder block Generator x Water pump Generator pulley x Rotor Voltage Regulator Generator Battery Voltage Terminal insulator x Rectifier holder Plate terminal x Rectifier holder Rear end cover x Rectifier holder Regulating voltage Rectifier holder x Coil lead on rectifier end frame Rectifier end frame x Drive end frame Brush exposed length Rated output Rotor coil resistance Slip ring diameter Part tightened CHARGING SYSTEM at 25C (77F) 13.614.8 V at 115C (239F) 13.214.0 V at 20C (68F) 12.712.9 V STD Minimum STD Minimum SERVICE SPECIFICATIONS 12 V 80 A 2.83.0 W 14.214.4 mm (0.5590.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 2.94 Nm 110 6.5 3.9 4.5 4.5 37 37 kgfcm 1,125 380 380 66 40 46 29 46 58 in.lbf 35 in.lbf 40 in.lbf 26 in.lbf 40 in.lbf ftlbf 81 27 27 CH21 CH01B0N CH01D0J CH22 MEMO ...
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This note was uploaded on 05/03/2010 for the course BUSINESS econ203 taught by Professor Shivaggo during the Spring '10 term at Columbia College.
- Spring '10