•
|
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 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 ALTERNATOR 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
alternator "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 alternator "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 alternator 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 alternator output wire from the
alternator "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 alternator "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 alternator "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 alternator output wire is in
good condition, remove the alternator from the vehicle and test
it.
Limit value :
50% of the rate voltage
|
•
|
The nominal output current value
is shown on the nameplate affixed to the alternator
body. |
•
|
The output current value changes
with the electrical load and the temperature of the
alternator 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 alternator 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 alternator output wire to the
alternator "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 alternator 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 alternator and ground. Connect the (+) lead of the
voltmeter to the "B" terminal of the alternator. Connect the (-)
lead to good ground or the battery (-)
terminal. |
5. |
Disconnect the alternator output wire from the
alternator "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 alternator "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 alternator 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 alternator 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. | |