•
|
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 perform tests with a high voltage
insulation resistance tester. |
•
|
Never disconnect the battery while the
engine is
running. | |
CHECK BATTERY VOLTAGE
1. |
if 20 minutes have not passed since the engine
was stopped, turn the ignition switch ON and turn on the electrical
system (headlamp, blower motor, rear defogger etc.) for 60 seconds
to remove the surface charge. |
2. |
Turn the ignition switch OFF and turn off the
electrical systems. |
3. |
Measure the battery voltage between the
negative (-) and positive (+) terminals of the battery.
Standard voltage : 12.5~12.9V at 20°C
(68°C)
|
If the voltage is less than specification,
charge the battery. |
CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
1. |
Check that the battery terminals are not loose
or corroded. |
2. |
Check the fusible link and fuses for
continuity. |
INSPECT DRIVE BELT
1. |
Visually check the belt for excessive wear,
frayed cords etc.
If any defect has been found, replace the
drive belt.
Cracks on the rib side of a belt are
considered acceptable. If the belt has chunks missing from the
ribs, it should be replaced. |

|
2. |
Using a belt tension gauge, measure the drive
belt tension.
DRIVE BELT TENSION
New
belt
|
539~637 N (121~143 lb)
|
Used
belt
|
343~490 N (77~110
lb)
|
If the belt tension is not as specified,
adjust it.


-
|
"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
grooves. |
-
|
Check with your 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. | | |
VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR
ABNORMAL NOISES
1. |
Check that the wiring is in good
condition. |
2. |
Check that there is no abnormal noise from the
generator while the engine is
running. |
CHECK DISCHARGE WARNING LIGHT CIRCUIT
1. |
Warm up the engine and then turn it
off. |
2. |
Turn off all
accessories. |
3. |
Turn the ignition switch "ON". Check that the
discharge warning light is lit. |
4. |
Start the engine. Check that the light goes
off. |
INSPECT CHARGING SYSTEM
PREPARATION
1. |
Turn the ignition switch to
"OFF".
To find abnormal conditions of the
connection, actions should not be taken on the two terminals
and each connection during the
test. | |
2. |
Connect a digital voltmeter between the
generator "B" terminal and battery (+) lead wire to the battery (+)
terminal. Connect the (+) lead wire of the voltmeter to the "B"
terminal and the (-) lead wire to the battery (+)
terminal.

|
CONDITIONS FOR THE TEST
2. |
Switch on the headlamps, blower motor and so
on. And then, read the voltmeter under this
condition. |
RESULT
1. |
The voltmeter may indicate the standard
value.
|
2. |
If the value of the voltmeter is higher than
expected (above 0.2V max.), poor wiring is suspected. In this case
check the wiring from the generator "B" terminal to the fusible link
to the battery (+) terminal. Check for loose connections, color
change due to an overheated harness, etc. Correct them before
testing again. |
3. |
Upon completion of the test, set the engine
speed at idle. Turn off the head lamps, blower motor and the
ignition switch. |
PREPARATION
1. |
Prior to the test, check the following items
and correct as necessary.
Check the battery installed in the vehicle to
ensure that it is in good condition. The battery checking method is
described in "BATTERY".
The battery that is used to test the output
current should be one that has been partially discharged. With a
fully charged battery, the test may not be conducted correctly due
to an insufficient load.
Check the tension of the generator drive belt.
The belt tension check method is described in the section
"COOLING". |
2. |
Turn off the ignition
switch. |
3. |
Disconnect the battery ground
cable. |
4. |
Disconnect the generator output wire from the
generator "B" terminal. |
5. |
Connect a DC ammeter (0 to 150A) in series
between the "B" terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected
output wire.
Tighten each connection securely, as a
heavy current will flow. Do not rely on
clips. | |
6. |
Connect a voltmeter (0 to 20V) between the "B"
terminal and ground. Connect the (+) lead wire to the generator "B"
terminal and (-) lead wire to a good
ground. |
7. |
Attach an engine tachometer and connect the
battery ground cable. |
8. |
Leave the engine hood open.


|
TEST
1. |
Check to see that the voltmeter reads as the
same value as the battery voltage. If the voltmeter reads 0V, and
the open circuit in the wire between the generator "B" terminal and
battery (-) terminal, a blown fusible link or poor grounding is
suspected. |
2. |
Start the engine and turn on the
headlights. |
3. |
Set the headlights to high beam and the heater
blower switch to HIGH, quickly increase the engine speed to 2,500
rpm and read the maximum output current value indicated by the
ammeter.
After the engine starts up, the charging
current quickly drops. Therefore, the above operation must be
done quickly to read the maximum current value
correctly. | |
RESULT
1. |
The ammeter reading must be higher than the
limit value. If it is lower but the generator output wire is in good
condition, remove the generator from the vehicle and test
it.
•
|
The nominal output current value
is shown on the nameplate affixed to the generator
body. |
•
|
The output current value changes
with the electrical load and the temperature of the
generator itself. Therefore, the nominal output current
may not be obtained. If such is the case, keep the
headlights on to cause discharge of the
battery.
The nominal output current may not
be obtained if the temperature of the generator itself
or ambient temperature is too high.
In such a case, reduce the
temperature before testing
again. | | |
2. |
Upon completion of the output current test,
lower the engine speed to idle and turn off the ignition
switch. |
3. |
Disconnect the battery ground
cable. |
4. |
Remove the ammeter and voltmeter and the
engine tachometer. |
5. |
Connect the generator output wire to the
generator "B" terminal. |
6. |
Connect the battery ground
cable. |
PREPARATION
1. |
Prior to the test, check the following items
and correct if necessary.
Check that the battery installed in the
vehicle is fully charged. For battery checking method, see
"BATTERY".
Check the generator drive belt tension. For
belt tension check, see "COOLING"
section. |
2. |
Turn ignition switch to
"OFF". |
3. |
Disconnect the battery ground
cable. |
4. |
Connect a digital voltmeter between the "B"
terminal of the generator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the generator. Connect the (-) lead
to good ground or the battery (-)
terminal. |
5. |
Disconnect the generator output wire from the
generator "B" terminal. |
6. |
Connect a DC ammeter (0 to 150A) in series
between the "B" terminal and the disconnected output wire. Connect
the (-) lead wire of the ammeter to the disconnected output
wire. |
7. |
Attach the engine tachometer and connect the
battery ground cable.


|
TEST
1. |
Turn on the ignition switch and check to see
that the voltmeter indicates the following value.
If it reads 0V, there is an open circuit in
the wire between the generator "B" terminal and the battery (-), or
the fusible link is blown. |
2. |
Start the engine. Keep all lights and
accessories off. |
3. |
Run the engine at a speed of about 2,500 rpm
and read the voltmeter when the generator output current drops to
10A or less. |
RESULT
1. |
If the voltmeter reading agrees with the value
listed in the Regulating Voltage Table below, the voltage regulator
is functioning correctly. If the reading is other than the standard
value, the voltage regulator or the generator is
faulty.
Regulating Voltage Table
Voltage regulator ambient
temperature °C (°F)
|
Regulating voltage
(V)
|
-20
(-4) 20 (68) 60 (140) 80
(176)
|
14.2 ~
15.4 14.0 ~ 15.0 13.7 ~ 14.9 13.5 ~
14.7
|
|
2. |
Upon completion of the test, reduce the engine
speed to idle, and turn off the ignition
switch. |
3. |
Disconnect the battery ground
cable. |
4. |
Remove the voltmeter and ammeter and the
engine tachometer. |
5. |
Connect the generator output wire to the
generator "B" terminal. |
6. |
Connect the battery ground
cable. | |