Home

08 Toyota Charging Systems with questions

image

Contents

1. Page 15 OPERATION CHECK Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Ignition Main Relay The ignition main relay is located in the relay box under the instrument panel The following steps are used to check this relay 1 Check relay continuity Connect the ohmmeter leads between terminals 1 and 3 Continuity no resistance should be indicated Connect the ohmmeter leads between terminals 2 and 4 No continuity infinite resistance should be indicated If relay continuity is not as specified replace the relay 2 Check relay operation e Apply battery voltage across terminals I and d Connect the ohmmeter leads between terminals 2 and A Continuity no resistance should be indicated If relay operation is not as specified replace the relay IGNITION MAIN RELAY RELAY CONTINUITY CHECK OPERATION CHECK SS Page 16 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS ALTERNATOR BENCH TESTS If the on vehicle checks have indicated that the alternator is defective it should be removed for bench testing and replacement Specific procedures for removal disassembly inspection and assembly are noted in the appropriate repair manuals Only the electrical bench tests are covered here Always disconnect the battery ground cable before removing the alternator Refer to the appropriate repair manua
2. the alternator s output must remain even not too much nor too little The regulator controls alternator output by increasing or decreasing the strength of the rotor s magnetic field It does so by controlling the amount of current from the battery to the rotor s field coil The electromechanical regulator does its job with a magnetic coil and set of contact points The IC regulator does its job with diodes transistors and other electronic components Page5 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Alternator Operation GENERAL The operation of the Toyota compact high speed alternator is shown in the following circuit diagrams IGNITION ON ENGINE STOPPED j l 1 J IC REGULATOR Monolithic Integrated Circuit IGN SAV MIC DETECTS Tr ON MAINTAINED AT 0 2A INITIAL EXCITEMENT ON BY INTERMITTENT OF ROTOR COIL TERM IG VOLT ON OFF OPERATION NO TERM P VOLT CHARGE LAMP ON Page6 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS ALTERNATOR BEGINS OPERATING Regulated voltage not achieved d OC ROTOR COIL TERM P VOLT MIC DETECTS TERM P VOLT ROTOR COIL Tro ON EXCITATION CURRENT Tra OFF CHARGING CURRENT CHARGE LAMP OFF ALTERNATOR OPERATING Regulated voltage exceeded STATOR COIL 1 CHARGE j LAMP TERM P VOLT ABOVE ABOUT 145
3. A sine wave voltage B battery voltage C field current D output current 2 In an alternator alternating current is converted to direct current by the A stator B brushes C rectifier D regulator 3 If the charging system indicator lamp goes on with the engine running the cause may be loss of voltage at terminal A IG B S C L D F 4 With the engine not running and the ignition ON the charge lamp should light If it doesn t this may indicate a A burned out bulb B grounded bulb C loose drive belt D overcharged battery 5 Which alternator terminal can be grounded for test purposes A B B IG C S D F Page 20 6 When performing a visual inspection of the charging system the alternator drive belt should be checked for proper tension Technician A says that new belt tension specs are higher than those for used belts Technician B says that the belt tension is different for different Toyota models Who is right A Only A B Only B C Both A and B D Neither A nor B 7 The amount of current the alternator must supply or ignition and accessories is about A four amps B six amps C eight amps D ten amps 8 In an alternator output test under load the output should be A about 10 amps B about 30 amps C within 10 of rated output D within 20 of rated output 9 To check for excessive voltage drop on the insulated side of the alternato
4. BATTERY ELECTRICAL CHOKE HEATING COIL VEHICLE LOADS VEHICLE LOADS Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS CHARGING CIRCUIT RELAY TESTS Various charging system layouts are used on Toyota vehicles The indicator lamp circuit may or may not be controlled by a relay Depending on the model when a relay is used it may be a separate lamp relay the ignition main relay or the engine main relay Each is checked using an ohmmeter Charge Lamp Relay When used the charge lamp relay is located on the right cowl side of the vehicle The following steps are used to check this relay 1 Check relay continuity Connect the ohmmeter positive lead to terminal 4 the negative lead to terminal 3 Continuity no resistance should be indicated Reverse the polarity of the ohmmeter leads No continuity infinite resistance should be indicated Connect the ohmmeter leads between terminals 1 and 2 No continuity infinite resistance should be indicated If the relay continuity is not as specified replace the relay 2 Check relay operation Apply battery voltage across terminals 3 and 4 NOTE Make sure polarity is as shown Connect the ohmmeter leads between terminals 1 and 2 Continuity no resistance should be indicated If relay operation is not as specified replace the relay CHARGE LAMP RELAY CONTINUITY CHECK
5. Page 12 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS TROUBLESHOOTING THE COMPACT HIGH SPEED ALTERNATOR Check Battery First Check for improper contact in alternator connectors B IG S and L or open circuit in wiring including IG and CHARGE circuit fuses or a short circuit Turn ignition off Check for a short circuit in load between L and Ground Electric choke element emission computer etc Start engine and check battery voltage at engine speed of 2000 rpm All other electrical loads off Is voltage 14 5V 0 6V Note When regulator temperature is above 80 F voltage range is 13 0 15 5V Check alternator output using a carbon pile tester Sun VAT 40 or equivalent When loaded battery voltage no lower than 12V is current output within 10 of alternator rated output YES If charge lamp is still on check charge lamp circuit again Repair fault and start engine Is charge lamp turned on Repair or replace load device between L and ground Ground alternator F terminal and raise engine speed to 1200 rpm Is B terminal voltage above 13V Replace IC Repair alternator regulator Tr1 Open in coil open etc brushes etc Repair alternator Defective diode stator etc Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS VOLTAGE DROP TESTS Voltage drop testing can detect excessive resistance in the char
6. Page 9 5 D Terminal F is the only terminal that can be grounded Never ground alternator output terminal B It has battery voltage present at all times even with the engine off Page 9 Page 21 C A new belt is one that has been used for less than 5 minutes It is installed with more tension than a used belt because it will stretch some during use Methods of checking are different for different models Page 10 B The reading should be about six amps This is the amount of current the alternator must supply for ignition and accessories Page 12 C With the alternator operating at maximum output the reading should be within 1096 of rated output Page 12 ID To check for the insulated circuit voltage drop connect the voltmeter leads to the battery s terminal and the alternator output B terminal Page 14 10 C Excessive resistance is most likely caused by loose or corroded connections Page 14 Taken with permission from the Toyota Basic Electrical Course 622 Toyota Motor Sales U S A Inc All Rights Reserved
7. Defective battery or battery connections Blown fuse or fusible link GA Check fuse and fusible link replace as needed Check charging system output and component operation as needed Check voltage drop A Defective relay regulator or alternator Defective wiring Loose or worn drive belt Check drive belt adjust or replace as needed Replace the alternator Replace the alternator Worn alternator bearings Defective diode ON eI Page 9 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS VISUAL INSPECTION A visual inspection should always be your first step in checking the charging system A number of problems that would reduce charging performance can be identified and corrected CHECK THE BATTERY Check for proper electrolyte level and state of charge When fully charged specific gravity should be between 1 25 and 1 27 at 80 F 26 7 C Check the battery terminals and cables The terminals should be free of corrosion and the cable connections tight CHECK THE FUSES AND FUSIBLE LINK Check the fuses for continuity These include the Engine fuse 10A Charge fuse 7 5A and Ignition fuse 7 5A Check the fusible link for continuity INSPECT THE DRIVE BELT Check for belt separation cracks fraying or glazing If necessary replace the drive belt Check the drive belt tension using the proper tension gauge Ni
8. arrangement Through electromagnetic induction the alternator changes this mechanical energy into electrical energy The alternating current generated is converted into direct current by the rectifier a set of diodes which allow current to pass in only one direction VOLTAGE REGULATOR Without a regulator the alternator will always operate at its highest output This may damage certain components and overcharge the battery The regulator controls the alternator output to prevent overcharging or undercharging On older models this is a separate electromechanical component which uses a coil and contact points to open and close the circuit to the alternator On most models today this is a built in electronic device REGULATOR ALTERNATOR Page 2 BATTERY The battery supplies current to energize the alternator During charging the battery changes electrical energy from the alternator into chemical energy The battery s active materials are restored The battery also acts as a shock absorber or voltage stabilizer in the system to prevent damage to sensitive components in the vehicle s electrical system INDICATOR The charging indicator device most commonly used on Toyotas is a simple ON OFF warning lamp It is normally off It lights when the ignition is turned on for a check of the lamp circuit And it lights when the engine is running if the charging system is undercharging A voltmeter is used on current Supra and C
9. CHARGING SYSTEMS General The charging system converts mechanical energy into electrical energy when the engine is running This energy is needed to operate the loads in the vehicle s electrical system When the charging system s output is greater than that needed by the vehicle it sends current into the battery to maintain the battery s state of charge Proper diagnosis of charging system problems requires a thorough understanding of the system components and their operation ELECTRIC CHOKE HEATING COIL Page 1 Operation When the engine is running battery power energizes the charging system and engine power drives it The charging system then generates electricity for the vehicle s electrical systems At low speeds with some electrical loads on e g lights and window defogger some battery current may still be needed But at high speeds the charging system supplies all the current needed by the vehicle Once those needs are taken care of the charging system then sends current into the battery to restore its charge BATTERY VEHICLE LOADS Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Toyota Charging Systems Typical charging system components include IGNITION SWITCH When the ignition switch is in the ON position battery current energizes the alternator ALTERNATOR Mechanical energy is transferred from the engine to the alternator by a grooved drive belt on a pulley
10. RCUITED C TWO DIODES G ONE PHASE STATOR SHORT CIRCUITED COIL DISCONNECTED SAME POLARITY D ONE DIODE H TWO PHASE STATOR OPEN COILS SHORT CIRCUITED Page 18 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Open and shorted diodes can also be located using an shorted If infinite resistance is seen in both directions ohmmeter Touch one ohmmeter lead to P and the other the diode is open Repeat the same test for P P and P lead to the B terminal to check the positive diode or to the E terminal to check the negative diode Then NOTE Most digital meters have a position marked reverse the leads The meter should show no resistance MI for diode testing Refer to the meter instruc in one direction infinite resistance in the other If no tions for specific readings resistance is seen in both directions the diode is DIODE TESTS INSPECT POSITIVE SIDE RECTIFIER INSPECT NEGATIVE SIDE RECTIFIER Page 19 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS This brief self test will help you measure your understanding of The Charging System The style is the same as that used for A S E certification tests Each incomplete statement or question is followed by four suggested completions or answers In each case select the one that best completes the sentence or answers the question 1 A regulator controls alternator output voltage by regulating
11. V MIC DETECTS Tr OFF TERM S VOLT MIC DETECTS Tn OFF T14 5V E TERM S VOLT Noon BELOW ABOU 3 TERM S VOLT R CHARGING CURRENT Page 7 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS TERMINAL S DISCONNECTED DS CHARGE ROTOR COIL Tt LAMP DISCONNECTION OF REGULATOR SENSOR MIC DETECTS CHARGE LAMP ON CONNECTOR GOEN MIC DETECTS TERM P VOLT T OFF TERM P VOLT ABOVE ABOUT 16 V TERM P VOLT BELOW ABOUT 16 V CHARGING CURRENT TERM P VOLT TERMINAL B DISCONNECTED STATOR COIL TERM S VOLT MIC DETECTS TERM P VOLT TERM S VOLT ABOVE ABOUT 13 V MAINTAINED AT TERM S VOLT ABOUT 20 V BELOW ABOUT 13 V MAINTAINED AT ABOUT 16 V TERM S VOLT CHARGE LAMP ON e Se Page 8 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Diagnosis and Testing Always disconnect battery cables negative first when the battery is given a quick charge The charging system requires periodic inspection 2p and service Specific problem symptoms their Never operate an alternator on an open circuit possible cause and the service required are listed battery cables disconnected in the chart below The service actions require a f h thorough visual inspection Problems identified Always follow specs for engine speed when must be corrected before proceeding with grounding terminal F to bypass t
12. e performed whenever manuals detail the testing procedures with an an overcharging or undercharging problem is ammeter and voltmeter Follow the manufacturer s suspected Output current and voltage should instructions when using special testers although meet the specifications of the alternator If not the most are operated similarly The following steps alternator or regulator IC or external may require outline a typical procedure for performing the replacement alternator output test using a Sun VAT 40 KE a S SR Page 11 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Charging Without Load 1 Prepare the tester Rotate the Load Increase control to OFF Check each meter s mechanical zero Adjust if necessary Connect the tester Load Leads to the battery terminals RED to positive BLACK to negative Set Volt Selector to INT 18V Set Test Selector to 2 CHARGING Adjust ammeter to read ZERO using the electrical Zero Adjust control Connect the clamp on Amps Pickup around the battery ground cables 2 Turn the ignition switch to ON engine not running and read the amount of discharge on the ammeter This is a base reading for current the alternator must supply for ignition and accessories before it can provide current to charge the battery NOTE The reading should be about six amps 3 Start the engine and adjust the speed to about 2000 rpm Some models may re
13. elica models to indicate system voltage It is connected in parallel with the battery An ammeter in series with the battery was used on older Toyotas FUSING A fusible link as well as separate fuses are used to protect circuits in the charging system SE m cm IGNITION SWITCH Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Alternator Construction GENERAL Two different types of alternators are used on Toyota vehicles A conventional alternator and separate voltage regulator were used on all Toyotas prior to 1979 A new compact high speed alternator with a built in IC regulator is now used on most models Both types of alternators are rated according to current output Typical ratings range from 40 amps to 80 amps CONVENTIONAL ALTERNATOR This type of alternator is currently used on some 1986 Tercel models and all Toyotas prior to 1979 STATOR WINDING HEAT SINK DIODES SLIP RINGS BEARING e SLIP RING END HOUSING CARBON BRUSHES a CO DAN STATOR CORE THROUGH BOLT DRIVE END HOUSING PULLEY ZZ Be Kn THROUGH BOLT Page 3 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS TOYOTA COMPACT HIGH SPEED ALTERNATOR Beginning with the 1983 Camry a compact high speed alternator with a built in IC regulator is used on Toyota vehicles Corolla models with the 4A C engine use a different alternator wit
14. ging system These tests determine the voltage drop in the alternator output circuit Both sides of the circuit should be checked insulated side as well as ground side Excessive voltage drop caused by high resistance in either of these circuits will reduce the available charging current Under heavy electrical loads the battery will discharge A Sun VAT 40 tester or a separate voltmeter can be used The following steps outline a typical procedure for performing voltage drop tests using a voltmeter Output Circuit Insulated Side 1 Connect the voltmeter positive lead to the alternator s output terminal B and the voltmeter s negative lead to the battery s positive terminal Ca CHARGE LAMP BATTERY ELECTRICAL CHOKE Page 14 2 Start the engine and adjust the speed to approximately 2000 rpm 3 Read the voltmeter The voltage drop should be less than 0 2 volt If it is more locate and correct the cause of the high resistance Output Circuit Ground Side 1 Connect the voltmeter s negative lead to the alternator s frame and the voltmeter s positive lead to the battery s negative terminal 2 Start the engine and run at specified speed about 2000 rpm 3 Read the voltmeter The voltage drop should be 0 2 volt or less If it is more locate and correct the cause of high resistance Excessive resistance is most likely caused by loose or corroded connections GROUND SIDE gt CHARGE 4 LAMP
15. h an integral IC regulator This new alternator is compact and lightweight It provides better performance as well as improved warning functions If either the regulator sensor terminal S or the alternator output terminal B become disconnected the warning lamp goes on It also provides better serviceability The rectifier brush holder and IC regulator are bolted onto the end frame Ic REGULATOR STATOR BRUSHES SLIP RINGS PULLEY a Ss RECTIFIER Page 4 Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Alternator Terminals ALTERNATOR TERMINALS Toyota s high speed alternator has the following terminals B IG S U and 17 When the ignition switch is on battery current is supplied to the regulator through a wire connected between the switch and terminal IG When the alternator is charging the charging current flows through a large wire connected between terminal B and the battery At the same time battery voltage is monitored for the MIC regulator through terminal S The regulator will increase or decrease rotor field strength as needed The indicator lamp circuit is connected through terminal U If there is no output the lamp will be lit The rotor field coil is connected to terminal P which is accessible for testing purposes through a hole in the alternator end frame ELECTROMECHANICAL Regulator REGULATOR While engine speeds and electrical loads change
16. he regulator electrical tests These electrical tests include an High speeds may cause excess output that could alternator output test charging circuit voltage damage components drop tests a voltage regulator non IC test EE charging circuit relay lamp ignition engine tests Never ground alternator output terminal B It has and alternator bench tests battery voltage present at all times even with the engine off PRECAUTIONS SN Make sure battery cables are connected to Do not perform continuity tests with a high Correct terminals voltage insulation resistance tester This type of ohmmeter could damage the alternator diodes CHARGING SYSTEM TROUBLESHOOTING PROBLEM POSSIBLE CAUSE ACTION Check CHARGE IGN AND ENGINE fuses replace as needed after correcting cause 2 Replace lamp 3 Check voltage drop in circuit tighten loose connections 4 Check relays if used for continuity and proper operation 5 Check alternator output Blown fuse Warning lamp does not light with ignition ON and engine off 2 Lamp burned out 3 Wiring connections loose Defective relay 5 Defective regulator Warning lamp does Loose or worn drive belt not go out with engine running battery overcharged or undercharged Check drive belt adjust or replace as needed after correcting cause Check battery and its connections 2
17. l for test specifications An ohmmeter is used for electrical bench tests on the rotor stator and diode rectifier The following steps are typical Rotor Tests Check the rotor for an open circuit by measuring for resistance between the slip rings Some resistance less than 5 ohms indicates continuity If there is no continuity infinite resistance replace the rotor Check the rotor for grounded circuits by measuring for resistance between the rotor and slip ring Any amount of resistance indicates a ground continuity The resistance should be infinite O ohms If not replace the rotor Page 17 ROTOR TESTS OPEN CIRCUIT GROUNDED CIRCUIT CHECK STATOR TESTS OPEN CIRCUIT GROUNDED CIRCUIT CHECK Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS Diode Tests Diodes can be checked with the alternator on the c two diodes of the same polarity short circuited vehicle using a scope Scope testing can identify open or shorted diodes as well as problems in the arouse diode Opel stator coils e two diodes open The scope patterns shown below include f one phase of the stator coil short circuited a Normal alternator output g one phase of the stator coil disconnected and b one diode short circuited h two phases of the stator coil short circuited SCOPE TESTING A NORMAL E TWO DIODES OPEN B ONE DIODE F ONE PHASE STATOR SHORT CIRCUITED COIL SHORT CI
18. ppondenso BTG 20 CHECK BATTERY CORRECT UPPER LEVEL LOWER LEVEL CHECK FUSES FUSIBLE LINKS Page 10 INSPECT ADJUST DRIVE BELT Refer to the appropriate repair manual for proper drive belt tension New belts used less than 5 minutes on a running engine are installed with greater tension than used belts Tension specs are different for different models INSPECT THE ALTERNATOR Check the wiring and connections Replace any damaged wires tighten any loose connections Check for abnormal noises Squealing may indicate drive belt or bearing problems Defective diodes can produce a whine or hissing noise because of a pulsating magnetic field and vibration CHECK THE WARNING LAMP CIRCUIT With the engine warm and all accessories off turn the ignition to ON The warning lamp should light With the engine started and the ignition in RUN the warning lamp should be off If the lamp does not operate as specified check the bulb and check the lamp circuit INSPECT ALTERNATOR WRONG EPLACE MC x is x ES BELT TENSION GAUGE NIPPONDENSO WARNING LAMP Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS ALTERNATOR OUTPUT TEST The alternator output test checks the ability of the A Sun VAT 40 tester similar testers or a separate alternator to deliver its rated output of voltage and voltmeter and ammeter can be used Toyota repair current This test should b
19. quire a different speed setting 4 After about 3 4 minutes read the ammeter and voltmeter Add this ammeter reading and the reading found in step 2 engine not running NOTE The total current should be less than 10 amps If it is more the alternator may still be charging the battery Once the battery is fully charged you should get specified results The voltage should be within the specs for the alternator This is usually between 13 and 15 volts Refer to the appropriate repair manual If the voltage is more than specified replace the regulator If the voltage is less than specified ground the alternator field terminal F and check the voltmeter reading This bypasses the regulator so do not exceed the specified test speed If the reading is still less than specified check the alternator 5 Remove ground from terminal F Charging With Load 6 With the engine running at specified speed adjust the Load Increase control to obtain the highest ammeter reading possible without causing the voltage to drop lower than 12 volts 7 Read the ammeter NOTE The reading should be within 1096 of the alternator s rated output If it is less the alternator requires further testing or replacement F TERMINAL LOCATION VARIOUS TOYOTA ALTERNATORS F TERMINAL F TERMINAL ALTERNATOR WITH ADD ON IC REGULATOR COMPACT HIGH SPEED ALTERNATOR WITH BUILT IN IC REGULATOR ALTERNATOR WITH BUILT IN IC REGULATOR
20. r s output circuit you would connect a voltmeter between the A battery B battery C battery D battery terminal and ignition switch terminal and ground terminal and alternator S terminal terminal and alternator B terminal 10 High resistance in an alternator output circuit is often caused by A a discharged battery B a shorted diode C loose or corroded connections D a bad regulator Toyota Motor Sales U S A Inc All Rights Reserved CHARGING SYSTEMS SELF TEST ANSWERS For the preceding self test on The Charging System the following best complete the sentence or answer the question In cases where you may disagree with the choice or may simply want to reinforce your understanding please review the appropriate workbook page or pages noted 1 C The regulator controls alternator output by increasing or decreasing the amount of current from the battery to the rotor field coil Page 5 2 C The alternating current is changed into direct current by the rectifier a set of diodes which allow current to pass in only one direction Page 2 3 B If either the regulator sensor terminal S or the alternator output terminal B become disconnected the warning lamp goes on Page 4 4 A If the warning lamp does not light with the ignition ON and the engine not running the possible causes include a blown fuse burned out lamp loose connections or faulty relay or regulator

Download Pdf Manuals

image

Related Search

Related Contents

ROAD BUDDY 10  KIEN5000 Industrial Ethernet Switch User`s Manual  有価証券報告書 - マースエンジニアリング  La voix des participants - Participation d`adultes en formation: mode  mode d`emploi  GUÍA AVANZADA DEL USUARIO    fauteuils de repos releveurs instructions d"i nstallati on et  Owner`s Manual  FRAN Ç AIS - MagiKitch`n  

Copyright © All rights reserved.
Failed to retrieve file