Professional Documents
Culture Documents
Starting & Charging System
Starting & Charging System
SECTION SC MA
EM
LC
EC
CONTENTS FE
EL
IDX
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
SC-2
BATTERY
How to Handle Battery
LC
METHODS OF PREVENTING OVER-DISCHARGE NFSC0003S01
The following precautions must be taken to prevent over-discharg- EC
ing a battery.
I The battery surface (particularly its top) should always be kept
clean and dry. FE
I The terminal connections should be clean and tight.
I At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance” CL
and “maintenance-free”.
MEL040F
MT
I When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal. AT
AX
SU
BR
MEL041F
BT
HA
MEL042F
SC-3
BATTERY
How to Handle Battery (Cont’d)
I Remove the cell plug using a suitable tool.
I Add distilled water up to the MAX level.
MEL043F
Sulphation NFSC0003S0201
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been “sulphated”, note its volt-
age and current when charging it. As shown in the figure, less
current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into ser-
vice by means of a long, slow charge, 12 hours or more, fol-
lowed by a battery capacity test.
SEL709E
MEL042FA
SC-4
BATTERY
How to Handle Battery (Cont’d)
GI
MA
EM
LC
EC
FE
SEL007Z CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
EL
IDX
SC-5
BATTERY
Battery Test and Charging Chart
SEL754W
SC-6
BATTERY
Battery Test and Charging Chart (Cont’d)
CHART II NFSC0017S02
GI
MA
EM
LC
EC
FE
CL
MT
AT
SEL755W
AX
*: SC-6
SU
I Check battery type and determine the specified current using the following table.
Fig. 1 DISCHARGING CURRENT (Load Tester)
BR
Type Current (A)
ST
28B19R(L) 90
34B19R(L) 99
RS
46B24R(L) 135
55B24R(L) 135
BT
50D23R(L) 150
55D23R(L) 180 HA
65D26R(L) 195
80D26R(L) 195
75D31R(L) 210
95D31R(L) 240 EL
115D31R(L) 240
SC-7
BATTERY
Battery Test and Charging Chart (Cont’d)
A: SLOW CHARGE NFSC0017S03
SEL756W
130E41R(L)
115D31R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
CON-VERTED SPE-
CIFIC GRAVITY
9.0 14.0
Below 1.100 4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A) 10.0 (A)
(A) (A)
I Check battery type and determine the specified current using the table shown above.
I After starting charging, adjustment of charging current is not necessary.
Fig. 3 ADDITIONAL CHARGE (Slow charge)
SEL757W
SC-8
BATTERY
Battery Test and Charging Chart (Cont’d)
*: SC-7
CAUTION: GI
I Set charging current to value specified in Fig. 2. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
MA
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark. EM
I If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
LC
B: STANDARD CHARGE NFSC0017S04
EC
FE
CL
MT
AT
AX
SU
SEL758W
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
CON-VERTED SPE-
CIFIC GRAVITY
BT
8.0 13.0
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A)
(A)
9.0 (A)
(A) HA
7.0 11.0
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 8.0 (A)
(A) (A)
6.0 9.0
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 7.0 (A)
(A) (A)
EL
5.0 7.0
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A)
(A) (A)
IDX
I Check battery type and determine the specified current using the table shown above.
I After starting charging, adjustment of charging current is not necessary.
SC-9
BATTERY
Battery Test and Charging Chart (Cont’d)
Fig. 5 ADDITIONAL CHARGE (Standard charge)
SEL759W
*: SC-7
CAUTION:
I Do not use standard charge method on a battery whose specific gravity is less than 1.100.
I Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
SC-10
BATTERY
Battery Test and Charging Chart (Cont’d)
C: QUICK CHARGE =NFSC0017S05
GI
MA
EM
LC
SEL760W
*: SC-7 EC
Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge) FE
130E41R(L)
115D31R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
BATTERY TYPE CL
BR
Above 1.220 0.75 hours (45 min.)
I Check battery type and determine the specified current using the table shown above.
ST
I After starting charging, adjustment of charging current is not necessary.
CAUTION: RS
I Do not use quick charge method on a battery whose specific gravity is less than 1.100.
I Set initial charging current to value specified in Fig. 6. If charger is not capable of producing
specified current value, set its charging current as close to that value as possible. BT
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, HA
as this may cause a spark.
I Be careful of a rise in battery temperature because a large current flow is required during quick-
charge operation.
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
I Do not exceed the charging time specified in Fig. 6, because charging battery over the charging EL
time can cause deterioration of the battery.
IDX
SC-11
STARTING SYSTEM
System Description
SC-12
STARTING SYSTEM
System Description (Cont’d)
I through smart entrance control unit terminal 19
I to theft warning relay terminal 2.
If the theft warning system is not triggered, power is supplied GI
I through theft warning relay terminal 4
I to starter motor harness connector terminal 2. MA
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts. EM
Without theft warning system
Power is supplied at all times
I to ignition switch terminal 1 LC
I through 40A fusible link (letter c, located in the fuse and fusible link box).
With the ignition switch in the ON or START position, power is supplied through 15A fuse [No. 20, located in EC
the fuse block (J/B)]
I to park/neutral position relay terminal 1.
Also, with the ignition switch in the START position, power is supplied FE
I from ignition switch terminal 5
I to park/neutral position relay terminal 6. CL
With the selector lever in the P or N position, ground is supplied
I to park/neutral position relay terminal 2 through the park/neutral position switch
I from body grounds, F39 and F41. MT
Then park/neutral position relay is energized and power is supplied
I from park/neutral position relay terminal 7 AT
I through theft warning relay terminals 3 and 4
I to starter motor harness connector terminal 2.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
AX
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts.
SU
BR
ST
RS
BT
HA
EL
IDX
SC-13
STARTING SYSTEM
Wiring Diagram — START —
MEL889K
SC-14
STARTING SYSTEM
Trouble Diagnoses
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
EL
SEL761W
IDX
SC-15
STARTING SYSTEM
Construction
Construction NFSC0006
SEL456TF
SEL457T
INSTALLATION NFSC0007S02
To install, reverse the removal procedure.
SEL458T
SC-16
STARTING SYSTEM
Inspection
Inspection NFSC0019
MAGNETIC SWITCH CHECK
I Before starting to check, disconnect battery ground cable.
NFSC0019S01
GI
I Disconnect “M” terminal of starter motor.
1. Continuity test (between “S” terminal and switch body). MA
I No continuity ... Replace.
EM
SEL036H LC
2. Continuity test (between “S” terminal and “M” terminal).
I No continuity ... Replace.
EC
FE
CL
SEL038H
MT
PINION/CLUTCH CHECK NFSC0019S02
1. Inspect pinion teeth. AT
I Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
AX
I Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.) SU
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
I If it locks or rotates in both directions, or unusual resistance is BR
SEL630BA evident. ... Replace.
BRUSH CHECK NFSC0019S03 ST
Brush NFSC0019S0301
Check wear of brush.
Wear limit length: RS
Refer to SDS (SC-27).
I Excessive wear ... Replace.
BT
HA
SEL014Z
SEL015Z
SC-17
STARTING SYSTEM
Inspection (Cont’d)
Brush Holder NFSC0019S0303
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
I Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
I If brush holder is bent, replace it; if sliding surface is dirty,
clean.
SEL568B
SEL305H
SEL019Z
SEL020Z
SEL021Z
SC-18
STARTING SYSTEM
Inspection (Cont’d)
5. Check depth of insulating mold from commutator surface.
I Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in) GI
MA
EM
LC
EC
FE
CL
SEL022Z
MT
AT
AX
SU
BR
Assembly NFSC0020 ST
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions. RS
BT
HA
SEL026Z
SC-19
STARTING SYSTEM
Assembly (Cont’d)
I Not in the specified value ... Adjust by adjusting plate.
SEL633BA
SC-20
CHARGING SYSTEM
System Description
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
EL
IDX
SC-21
CHARGING SYSTEM
Wiring Diagram — CHARGE —
MEL890K
SC-22
CHARGING SYSTEM
Trouble Diagnoses
LC
EC
FE
CL
MT
AT
AX
SU
BR
SEL338V
ST
NOTE:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque.) RS
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty
parts with new ones.
BT
MALFUNCTION INDICATOR NFSC0011S02
The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following
symptoms occur while alternator is operating: HA
I Excessive voltage is produced.
I No voltage is produced.
EL
IDX
SC-23
CHARGING SYSTEM
Construction
Construction NFSC0012
SEL276VH
MEL384K
SC-24
CHARGING SYSTEM
Disassembly
Disassembly NFSC0021
REAR COVER
CAUTION:
NFSC0021S01
GI
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear MA
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly. EM
SEL032Z LC
REAR BEARING NFSC0021S02
CAUTION: EC
I Do not reuse rear bearing after removal. Replace with a
new one.
I Do not lubricate rear bearing outer race. FE
CL
MT
Inspection NFSC0022
ROTOR CHECK AT
NFSC0022S01
1. Resistance test
Resistance: Refer to SDS (SC-27). AX
I Not within the specified values ... Replace rotor.
2. Insulator test
I Continuity exists ... Replace rotor. SU
3. Check slip ring for wear.
Slip ring minimum outer diameter: BR
SEL033Z Refer to SDS (SC-27).
I Not within the specified values ... Replace rotor.
ST
RS
BT
HA
SEL631DA
SC-25
CHARGING SYSTEM
Inspection (Cont’d)
STATOR CHECK NFSC0022S03
1. Continuity test
I No continuity ... Replace stator.
SEL108E
2. Ground test
I Continuity exists ... Replace stator.
SEL109E
Assembly NFSC0023
RING FITTING IN REAR BEARING NFSC0023S01
I Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
SEL044Z
SEL048Z
SEL049Z
SC-26
SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
Battery NFSC0014
Starter EM
NFSC0015
S114-801D
LC
Type HITACHI make
Clearance “” between pinion front edge and pinion stopper 0.3 - 2.5 mm (0.012 - 0.098 in)
AT
Alternator NFSC0016
LR1100-725B
AX
Type
HITACHI make
Minimum revolution under no-load (When 13.5V is applied) Less than 950 rpm
BR
More than 35A/1,300 rpm
Hot output current (When 13.5V is applied) More than 83A/2,500 rpm ST
More than 95A/5,000 rpm
Brush spring pressure 1.000 - 3.432 N (102 - 350 g, 3.60 - 12.34 oz)
BT
Slip ring minimum outer diameter More than 26.0 mm (1.024 in)
EL
IDX
SC-27
NOTES