t'.

-
--. r,-. -.-. - rlg{rl

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Pago

t GHARGING SYSTEM GlRculT -.-. ---..-."""' 9-2

ON-VEHICLE INSPECTfON .." " "o""' or' o.. ..' 9-3o

I ALTERNATOR ..I" ..',O' O'' 9-7'

9-21

t Itr

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Link

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Altor nttor RcArulator

{'
lC Regnllator Type

Ciirgp
Wrniry
Light
CHARGE
Furr

60
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.9
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 lniPection
CHARGING SYSTEM '- On'Vehicle

ON-VEHICLE INSPECTION .'

Check the f ollowing systerrl components

1 Drive trclt def lection
(Exr:ePt USA & Carracja)
Drive belt def loction
7 - 11 mm at 10 kg
(0.28 :0.43 in') (22 lb)

O.,.a.i,'
(USA tlr Canada )

ffi Using a borroughs tension gauge, BT'33'73f

Oriyen belt dsfloction: 80 I20 lbl.
.

----2,. F uses

i.
i
Flu nstallat ion of the alternaror and regulator

m'
I

w i'r ing, '1:. '

t
t
 !!'t'
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I

CHARGING S.VSTEM - On.Vehicle Inspoction

lrl

;U
'4, Battery terminal and fusible ink,
a

f '
n
'..
' ,t.:

Loose e rl. f
Corrosion :
t.

Burnt
,

rr
r

F ig. $7 ',
Specific gravity: 1.25; | ,27 at zO"C
: (68'r l

Upper Levef
Lower Level

6'' -t

m ,r*
a

,#

Fig, 9.9

I Tes minal

- Note -
Bc caisful not to crust I rherL: , ,,,
.: ,

I
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 CHARGING SYSI'EM ;-On.Vehicle Inrpection 9-5

t Fig, 9-10
No-load Perfon i .rncs Test
Regulatcd yoltfgs: 13.8 - l4'8 V
Current:
-l
Lcrr then 10 A
Enginc rpeed: ldling to 2,000 rPm

200

Fig. $11
.1
':
; Lgad Performanco Tost
l. Run the engine at 2,000 rgrn.
2,:' Turn on the treaClights and alf accessories.
Rrgrubtod volugr:
13.8 14.8 y-
Curront: Mon tfrrn 20 A

'#'
.!

F ig, 9- 1? PERFORMANCE TEST BY ALTER.

NATOR'CHECKER
a

Disconnect the alternator r6gulator connector

and connect SST.
* SST logffil.o@il1
Purtr 20 V rwitch.

t
'

Fig. $13
J1iffi'l 1. Check vof tage at terminal, B.
l:n ll
l-

--!tt
t I

Pu*r I rwitdr.
Raise engine speed frbm idling to 2,300 rprn.
- Voltagc:
sTD
13.8 -'14,8 V
lf not within standard, probable cause is the
alternator regulator.
o

'li'l.P

t
e'-6 CI{I\RSING $Y$TEM -- On.Vshicle f nlPgotlon

it
Flg.9'14
2, Check voltage at terminal F. 1
Purh F rwitch.' a{t
Raise engine speed from idling to 2,000 lpm.
The checker reading should gradually de
,l crease f rom l2 to 3 volts.
lf decrease is not registered, probable cause
is al ternatot.l*r,.tor.

:"

. .l

3. Check voltage at terminal N. .

Du$ Irf rwltch,

Maintain enging. speed - at aPproximately
1,500 rqrn. Ths iointer bhould be 8t I half
of terminal B voftagb,
Voltege:
STD 6.9 - 7.4 V
lf the voltage iq higher, the cause is the
positive (+l rectifier.
lf .lhe voltage is lowet, the cause is the nega'
tive (-l rectif ier.

.ril
o
*

#
 CHABGfNG $YS'[EM - AltcrnEtor 9-7

ALTEf,NTATOR
DISASSEMBLY
l, Dis8sselnble tlre parrts ilr llttl rrttlfltrit'ill ttl tlttt
shown in the f igure.

F iS, 9.1 6

3OA Tvco only

1 Fis. st8
D
J
+

t
a

4
65 Fb. g.20

f. Driw End Fnmo Arrcrnblv

Z Fulhy, Frn & Coflrr
3. Ftoor & Colfrr
f. Rur Erarlng
6. Front Boring
6. oitw End Frrynr

{h.
7
rr
$
-
l
 9'.8 CHAHGING SYSTEM - Atternator

2. Disassembfe the parts in the numericaf order'

shown in the figure.

Fig, g-17

I ris. g,zl

s
0
oo
30A

Fig. 9-21
b
, 8F.
@
ffii
d0& 45A

9 Fis. 9.2t

I flrl
wt

;.-!.'
50A
'
.h"'

I ri1, g'?t

a.

with lC Regulator

I rie. e.zl
.-'
7. Rear End Cover & Insulator
10. f C Regutaror
Stator Coil, Rectif ier Holder & Insulatbr I l. Condanrer
Brurh Hotsls.l & Recrifier Holdsr
 9-9

ffiHfy A
the drive end'frarnr-trOrn the-statOr,3od tap
I I .,1 t\.
jt
-IZ
IJ
-

;.T:il, no, to prv on thc rtttor coil.

F{S, $19

.i

.a

Flg. S21
t: ,Unsolder each stator lead to the rectif ier.
t,:
. ,', -''

- Crution -
Prorct tnr roctlflrr fTom trrrt'

o
|ff{"=-

SYSTEU r Alrernator

3.9 - 4.1 s}
2.8 - 3.0 O

. Flg. $23

Flg. S34

I
Open cirbuit test
check that thsre is continuity between each
coil lead.

.a

'.:

,#;:
 c.HAnglNs SYSTEM- Afrtnrtor 9-l I

9.26
Ground te3t
chck that there is no coltinuitY'between
each coil lead and stator cot:e.

6.5,mm
f0,r217 ln.t
. 1:

'.
q.

:-

':
rtls28 Raplrcq ttia brush.

t o

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|' '
-C
ri#
l16
't{i

rb s?.0
Effil Roctftlsr,(30,' 40 & 4EA'TYPe}
lP:,U j' ' R*tiiier holder positive positivo loaA;tU,.
I gide
Conn*t an *r111totg( ,
{+l
.,..tormiRal..!, and fia. negative: (-)'fead to tfi0
".4
';.
-... ' ' A"':t .

rectifier termlnal,, f f, there is nO continuity,

the rectifier asssmbly mus! be replaced.
C :.'
l'.
l

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ta.,:

. .,, ._,,h1 .i ,
9-12 CHARGING SYSTEM - Atternator

Flg. S-30
{}
Reverse polarity of the test leads and check I
fifl1 '
.i
again. lf there is continuity, the rectif ier 1t

assembf y must b reptaced. l ,'r

o
Flg. S31
Rectifier holder negative side
Connect ar! ohmmetpi;' po$itivs"['+l fead to
the rectifiei termf*li,bnd ihe, Qeg?tive (*l
lead to terminat E, lf there is no continuity,
thq rectifier asernbf y must,bs, rgplaced.

Fh, $32
-'4; - -fiwerse polarity of the tFfiads and chck
t.
assembly must be replacCId.

-:t
r. $
I

Diode (with fC Regulatorl

I. 'Connct an ohmmeter positive (+} lead ro
the resistor side, and the negntive (-) lead of
the meter to ths diode other side. f f there is
no continuity, the rrctifier asembf y must be
repf aced.

-*
:

r{
 CHARGING $YSTEM - Alternator 9-13

*
Fig. 9-34
Reverse pof ariry of test leads and chttck
'
2. 'again.
lf there is continuity,. the rectif rttr
assenrblY nlust be rePlaced.

l5'l Resistor (with lC Regulatorl

[B.U Check the resistor wire resistance using an
rectif ier
:.ohmmeter'|ftherg^il-'1ocontinuitY:
assembty must b rePlrced.
Rsdrnnot: 1.0 - a0 O

Fig. 9-36
Fiefd Diodes (with f C Regutatorl
. t.
I

m L Connect an ohmrnbtor poritive (+l lead to

terminqf L, and the nsgntivs {:-} 'la'd of
the meter to ths r.mtifisr termlnaf. lf there is
't*h,

?* jt

no continuity, the rectifier assembly must be

replaced.
l:
t
rt

Rwerse aritY of test leads and check

pof
again..ff there is continuitY, the rectif ier'
assembly must bs rePlaced.

t;
 9- l4 CHARGING SYSTEM * Alrernator

Fi* S38 iil

a
Rectifier (50A Typel a

l. Recrif ier holder positive side

Connect an ohmmeter positive (+) lead to
the rectifier hofder, and the negative 1-) lead
of the meter to the rect itier terminaf . . f f
there is no cootinuity, the rectif ier assembly
rnust be replaced.

Fig. 9-39
Reverse polarity of test leads and check
ffi2 again. lf there is continuity, the rectif
assembty must be repfaced,
ier

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a
a

'rq}
 9-15
CHARGING ,SY.STEM f AIISTNSIOT

*
3. Rectif ier holder negative sid: . :.
'on*meter pOsitive (+) [eacl tr')
ConneCt an
* f he recti f ier ter rn irral,
angf the nega t ive ( - )
lead of the nreter to. the rect if ier holtler . | |
tltere is no colltinuity, the rectifier assellllrll
'
tnust tle replat'ecf.

Flg. 941
4. Reverse ''polarity of test leads and check
agoin. f f thare is continuitv, the rectifier
assembly must be rePlacedr ,

nr

-t

t
 CHARGING SYSTEM -'Afternator

'ASSEMBLY
1. Assemble the parts in the numerical order
shown in the figure.

Fil' 9-4;
>1.-*

1 Fig. 944

0
0
30A

1 ris. 9.44

@.
s
40 & 45A

o
@

50A
7
l.Fig. g44
Fig. 9{F
946
@

50A

45Awith fC Regufrtor

1, Brush Hotder & Recrif ier Hotder , .{, Rcar End Covor & Insulator
2. Stator Coil, Rectif ier Hofder & Insulator 5, Condenrer
3, lC Regulstor

*
 :

CHARGINGT ;SYSTEM - Alternator 9-17

t a

thb parts in the rlurnerisat ofdi'r

Assernlbie
: sltown in tlre figtrre.

Fig. $43

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9 Fis. g4g 6
9-50 Fig.9-47

6.' Reer Bearing'

7. Front Bcaring & Drive End Frsmc :

8. Rotor & Coflar

9. fullqy, Fan & Collar
10. Drivc End Frarnc AsrcmHy

t
ij

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 j

9*18 CHARGTNG SYSTEM -- Alternatqr I

-^-
Fb 8!+4
Solder each lead wire L
a

onto the rectifier or ter' t

minal as strown in the
figu re.

w/lC Regulator
'....' i

A$sembfe the. rear end frame and rectifier, holder

with insulators.

Asgemble the rear end: cover with the insula tors.

-"}

Using
'a press, press the rear bearing onto the
rotor" shaf i.
:

*
 \

CHARGIN$ SYSTEM ; Altsrnstor 9- l9

* ,.1..

Using SST, Press and drive the 'nd f rame

l*--l assembly onto the rotor shaf t.
\'---7 tsr t096 t2-22ol ol

il
t

, '''" a
, '",-
,
,''

:. ,
,.

r'';:
Instalf, itra rotor thaft. , ', '

1. Bend
leck
ne iectifier iead wires away from
' the rolor.

\.,

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}
v

I
l4ff''--

9;20 CHARGING SYSTEM - Alternator -

il
lt.

Push in the brdshes and temporarily. lock .a

l.

them in place with a wire inserted through .g

the access hole in the rear i end frame.
a

ri'

',
i ,' "

rb 93

,';,

A ,t
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*
 CHARGING SYSTEM .. AlSrrnrtor Rrgulrtor 9-21
. -,;.;.. , , - .. .-:.

ALTERNATiOR REGULATOR
.I

Ffo. *E0

Fli 97

t t

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,.,
Gw

CH$RGfruA SYSTEM .- Atternator Resutator tl

.i

Check each point surface for burns or excessive 't

L'

damage, Replace if defective.

il;: ,

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.t

Voltage
t3|- relay loPtnoQ
t vrv 1i--
t -
t

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.;^1
'ii=l

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I
I

i
CHARGING SYSTEM - /rlternator Regulator 9-23

t Fig. 92
B_E
'-
t
vo*age ,t,ry

Fi* 9-.3

Open infinity
rlay
.Yo'tage Cfosed 0 O

Fh. . q{
N-E
Approx. 23 Q

rt It,

Ir

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a

It
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