Vol.

16
Charging System
EAM
Step %
Pub .No . TTM 216EN
 FOREWORD

This Training M anual has been prepared for the use of techni cians emplo yed by Toyota's overseas
distrib ut ors and dealers. This manual. "C harging System ", is Volume 16 of the eig hteen Trainin g
M anuals w hi ch constit ute Step 2 of t he program of ski lls w hich all Toyot a New T EAM· tech nicians
sho uld master. It sho uld also be used by the instructor in co nj unction w ith the accompanying
Instruction Guide.

The titles of the New TEAM Step 2 Training M anuals are as foll ow s:

VOL. TRAIN ING MANUALS VOl. TRAIN ING MAN UALS

1 Gasol ine Engine 10 S uspen sio n Syste m

St ee ring Sys tem
2
3
Fuel System
Ign il ion System
"
12 Wheel Alig nment & Tires

4 Emission Contro l System 13 Brake Syste m

5 EFt ( Electro nic Fuel Injection ) 14 Fund ament als of Electncirv

5
7
a
Diesel Engine

Clutch & M anual Trensaxla / Transrnissicn

Propeller Shalt . Differential, Drive Shllfl & Axle

,.
15

17
Starti ng System

Cl1arging System

Body Electrical

9 Au tomatic rr ensextevt rensmfssto n 18 Heater & Air Condit ioni ng System

It is not eno ugh just to " know" or "u nderstand "- you need to master each task so tha t you can do
it. For this reason, theory and practice have been co mbined in this Training M anual. The top of each
page is marked eithe r wi th a
ind icate th at it is a Practice page.
C
symbo l to indicate t hat it is a Theory page or a symbol to n
No te that in regards to overhau l procedures, this Trainin g M anual contains only t he mai n poi nts to
be learned; pl ease refer to t he relevant Repair M anual (s) for detail s.

The following nota tions often occur in this m anual, with t he m eanings as ex plai ned:
A potent ial ly hazardous sit uation w hic h could result in inj ury to people
CAUTION m ay oc cur if i nstr ucti ons are not fo l lowed ,
Damaged to th e vehicle or com po nents m ay occ ur if i nst ruct io ns are
NOTICE no t foll ow ed.
NOTE Notes or co mments not in cl ud ed under the above two headin gs.
Inf orm at ion n ot required to pass th e TEA M cert if icatio n, but w hich may
REFER ENCE be useful to i nstr uct or s and to tra ine es w ho w is h to gain a deeper
knowl ed ge o f the subject.

' TEA M : TEAM stands 101"Tec hnical Education for Autumouv e M ast8ryH, w hich is a l.n,ning prO{Jrsm divrd ed inlo three steps ecco rdin q
to Ih8 technician's tecbnic allevet Th is prog,am makes it possib le tor tec hnic tens 10 receive the approp riate training for Iheir level in a
syslemalic manner so as 10 help them achieve Ihe ski llS and eff iciency of skilled technicians in the shortest possible tim!).
This Trainin g M anual explai ns various auto motive mechanisms based on the Toyota Corolla (AE
Series). However. representative models other than the Corolla have sometimes been selected to
explain mechanisms not found on t he Coro lla . In this w ay. explanations of as many mechanisms
as possible have been included.

For th ose mechanisms w hich have not been in clu ded in thi s manual, pl ease refer to t he Repair
M anual for the relevant model and appl y the k no w ledge acq uired through st udying t he Training
M anual to carry out the necessary work.

All information contained in thi s manual is t he most up -I o -d ate at the time of publicat ion. How ever.
w e reserve the right to make changes wi thout prior not ice.

TOYOTA MOTOR CORPORATION

Cl2001 TOYOTA MOTOR CORPORATION

All r igh ts r eserved . Th i s b oo k may not be
repr od uc ed or co pied, i n who le or i n part.
w it ho ut the writ te n p ermissio n o f r cvct e
M otor Cor p orat ion .
 TABLE OF CONTENTS
Page
C HARGING SYSTEM
Description , .. , ,. . . 1

PR INCIPLE OF GENE RA T ION OF ELECTR IC ITY

Electromagn et ic Induction 2
Directi on of Electr omot ive Force ,. .. . ... 3
Amo unt of Electrom ot ive Force , , ....• ... . " 4
Princi ple of the Generator ,. ,.. . 5
Al ternating -current Generator ,. . . . .. . . . 6

ALTERN ATOR
Princi ple of the Alternator , ,. 7
Alte rnator w ith Neutral - point Diodes , 11
a-erode Exciting Alt ernato r 12
Voltage Regulation , 13
Construction of the Alt ernator 15
Compact Alternator 17

REGULATOR
Two - point Type Regulator 20
Voltage Relay (Charge Lamp Relay) 21
Characteri stic s of the Reg ulator 22

IC REGU LATOR
Descripti on 24
Operating Principle of IC Reg ulato r 24
Characteristics of IC Regulato r 25

C H ARG I NG SYSTEM
W ith Tw o -point Typ e Regulato r 27
W it h A -typ e IC Regul ator 31
W ith B-typ e IC Regulator , 32
W ith M -type IC Regu lator 34

TROUBLESHOOTING
Classification of Charging System Probl ems 41
Alternato r w it h Point Ty pe Regula to r 42
Al ternato r w it h M-type IC Regulat or 49

pjON -VEH ICLE IN S PECTI O N 53

pjOVERHAUL 62
• Pre- inspection , 63
• Conventional Type , .. ,. , . . 66
• Hi-speed Compact Type , .. 71
 CHARG ING SYSTEM - Descri ptio n

CHARGING SYSTEM
DESCRIPTION
The fu ncti on of the autom ob ile battery is to sup - The charging system prod uces electricity to both
ply a suff icient amount of electrici ty to th e auto - re-charge t he battery and to supply t he electrical
mobil e's electr ical components suc h as the starter components wit h t he am ount of electricity
mot or, headlig hts and wipers. How ever, the bat - requ i red w hile th e autom obile's en gi ne is in
tery is limited in its capacity and is not capable of operatio n.
provid ing, on a continui ng basis, all the powe r
required by the automobi le. Whi le the co nve ntional alternator and the poi nt-
ty pe vo ltage regu lator were used in the past,
It is necessary, therefore, for the battery to always recent vehicle s m ain ly use a m ore compact
be fully charged in order for it to supply the nec es- alterna tor w ith a built-in IC regulator .
sary amount of electricity at the requi red time to
each of the electrical co mpo ne nts. Consequen tly,
the automobile requ ires a charging system to pro -
duce electr icity and keep t he battery charged.

Ignition
switch
......-ConventionaJalternator

Point type regulator Discharge warni ng light

(Charge warni ng lamp)

,.-1I
I L..1
'O J /
'",

-",0--- Conventional
alternator

....
,-,
\ \
---- /'

'" < >

"" .... _7
-
--
"<,
" Battery
_.lo

......~ / /
»>
/ / ,
 PRINCIPLE OF GENERATION OF ELECT RICITY - El ectromagnetic Induction

PRINCIPLE OF GENERATION OF ELECTRICITY

ELECTROMAGN ETIC IN D UCTI ON
Wh en magne tic fl ux is cut by an electrical co n-
duc tor mo ving w ithin a magn etic field, electro-
mo ti ve force (in duction vo ltage) w ill be created
in the co nd uctor, and a current wi ll flo w if the
conductor is part of a complete ci rcuit.
,-- - ---- - --- - .-,
As shown in the ill ustrati on, t he needle of a qat-
vanometer (an ammeter which is act ivated by
even the slightest amoun t of current ) will move
du e to the electromot ive force created w hen a
cond uctor is mo ved back and fo rth betwee n mag -
netic north and sou t h poles. From this actio n w e
can observe that:
• The needle of the galva nometer w ill mo ve
w hen eith er th e conductor or a magnet is
mov ed.
• The di recti on in wh ich the needle defl ects w ill
vary w ith the direction the co nductor or mag -
net is moved .
• The extent of needle deflection w ill be greater
in proporti on to the speed o f mo vement.
• The need le wil l not move w hen mo vement is
stop ped .

Galvano meter If. by some means. th e co nductor is caused to

pass through th e magnetic flu x. electromagnetic
.> force will be created in the conductor. This phe-
Condu ctor OHP 2
nomeno n is referred to as "e lectromag netic in -
ductio n". The generator prod uces elect romo tive
force by means of electromagnetic induct ion. and
turn s th is in to electrical power (voltage and cur-
rent) .

2
 PRINCIPLE OF GENERATION OF ELECTRICITY - Direction of Electromoti ve Force

DIRECTION OF
ELECTROMOTIVE FORCE
The direct ion o f the electromotive force generated FLEM ING 'S RIGHT-HAND RULE
in a con duc tor w ithin a magn etic field will vary W ith the thu mb. fo refinger and middle finger o f
wi th cha ng es in the direct io n of the magnetic flu x one's rig ht hand are outstretched at right angles
and the directi on in wh ich the conductor moves. to each other. the forefinger w ill indi cate th e di -
If a co nduc tor is moved (in the di rect ion indicated recti on o f th e magnetic fl ux (mag netic lines of
by the large arrow in th e ill ustration below) be- force) , the th umb the direction o f conducto r
twee n the mag netic north and sou t h po les. th e movement, and the middle finger the direct ion of
electromotive force w ill flow from righ t to lett (the th e etectromotfve force.
directio n o f t he magnetic flu x is from the no rth to
the south pol e).
The di rection of the elect romo tiv e force can be
understood by use of H emi nq' s Rig ht - hand Rul e.

Directi on of Ilu x

t
~~
I
I
I
I
I
-
Direct ion of cu rrent
Dhec ucn o f motion

I
I
I
I
I
,
I
'L..-- "l/"-}

DHP 2 DH P 2

3
 PRINCIPLE OF GE NE RA T IO N OF ELECTRICITY - Amou nt of Electromotive Force

AMOUNT O F
ELECTROMOT IVE FORCE
The amou nt of th e electromotive force generate d
when a conductor cuts (passes th ro ug h) the
mag neti c fl ux w ithi n a magnetic field is propor-
tio nal to th e nu mber of magn etic li nes of for ce
w hic h are cut w ithin a given u nit of ti me. For
example. if N number of li nes are cut w ith in t
seco nds and t he electromotive force is E volts,
thi s can be exp ressed i n the fo llowing form ula
(th e symbol o: means " is prop ortio nal to ") :
E <X N
t 180"H
If t he cond uctor is moved along a circular path
w it hin the mag netic field, the amo unt of the elec -
tromotive force w i ll cha ng e co nstantly . In thi s il-
lustrat ion, the cond uctor is moved in a ci rcle at a
co nstant speed from poi nt A to po int L between
the magn etic north and south poles. In thi s case,
th e largest number o f magn etic lines of force are
cut betwe en po ints D and E and between point s
J and K. but no lines are cut betw een points A and
B or po ints G and H.

'"
N 90°-1 •
,
1270 S

-'-"-
B • A

N OHP 3
s
N

Thus, if the electro mo tive force generated w hen

OH P 3
the cond uctor is movi ng in a cir cle is expressed in
In a magn etic fi eld of un ifo rm densi ty, the amoun t a graph, it can be seen that the extent of th is force
of t he generated electromotive fo rce wi ll vary w it h is constantly undergoing a change (increasing
th e direction of th e mov ement of th e co nducto r and decreasing ) . Further, the direct ion of t he cur-
even if the speed of the conductor remains co n - rent generated by this electromot ive force w ill
stant. As shown in th e illu strati on. a cond uct or is change wi t h each half turn of t he co nductor.
move d from po ints A to B to C to D and back to
A.
However. it cuts th e fl ux only w hen movin g from
$
po int s A to B and from C to D. In ot her w ords.
t
alt hough th e conductor is moving at the same
speed between each po int, electro mot ive fo rce is
being gene rated only w hile it moves betw een A
and B and between C and D. I
e
B c QH P 3

A o
OH P 3
4
 P RI N CI P LE OF GE NE RAT IO N O F ELECTR IC ITY - Princip le 01 t he Generator
PRINC IP LE OF T HE GEN ERATOR
A lt hough electromotive fo rce is prod uced w hen
a sin gle conductor is revolved in a m agnetic
fie ld. the amou nt of force pro duced is actually
very smal l.
N
OH P 4
How ever, if two conductors are jo ined end -to -
end. electro motive force w ill be created in bot h
and, c onsequently, be dou bled. Thu s. the mo re
conduct ors revolving w it hi n a mag net ic fi eld, the
more electromotive force wil l be g enerated .
N Gener ati on of electromotive force:
s o W hen
~" ," .
OHP 4
If th e co nd uctor is in the for m o f a co il, the total
amou nt of g enerated electromotive fo rce will be
greater as will th e amo un t o f t he electricity
(voltage and current) pro du ced . The generator
produces electricity by revo lv ing a coil w ithi n a
magn et ic field.
Th ere are t w o ty pes o f electrici ty, dir ect curr ent
and alternati ng current and, depe nding on the
method of prod ucing electricity, ge nerators are
eithe r dir ect -curren t or alte ma ti nq-cu rrent ty pes.
N
OHP 4
NOTE - - - - - - - - - - ,
a co nd uc to r m ove s i n t he
m ag netic f ield , elec tro mo tive force is
cr eate d in the conducto r.
o Wh en th e di rect io n o f th e co nduc tor
m ov em ent changes, th e direction of the
c u rrent t hat is generat ed by t he
electo ro motive force also ch ang es.
Size of e lectromot ive force:
o Th e larg er t he m ag netic f ield, the larger
t he elec tromotive force .
• The faster t he cond uctor m ovem ent, t he
larger th e electromotive fo rce.
o The hig he r the n um ber of co nductors (coil
w in ding s), t he larg er t he elect ro mot ive
for ce.
5
 PRINC IPL E OF GEN ERAT IO N OF ELECT RICIT Y - A lternati ng -current Generator

ALT ERNATING- CUR RENT G ENERATOR

Wh en electricity generated by a coil is supplied
through slip rings and brushes (so t he coil can
ro tate). the am oun t of current flowi ng to th e Slip ring -,f.;:~'::
lamp w ill chang e and, at the same tim e, so w ill
the fl ow direction.

Brush

B B

L 111
J 12l
L J '31 OHP 5

As the coil rotates, the current generated on the (jJ

first half of the t urn w il l be supplied from the
bru sh on side A, pass through th e lamp and then t
return to the brush on side B.
o O. 90 · 36 0·
On the latter half of the tu rn, the current w ill be
supp l ied fro m side B and return to side A.
j
e t
131

In thi s fashion. the alternating -current generator

suppl ies the current gen erated by the co il in a
magnetic field. The alternator used in the charg - $
ing system of an automo bi le utiliz es diodes to
rectify th e curr ent (i.e.• change it to direct cu rrent)
t
immediately befo re it is supplied to the charging
system.

REFERE NC E - - - - - - - - """>,
I
e
In an ac tual generato r. several magnet s and
co ils are used to prevent the amou nt of the
current from cha nging.

6
 ALTERNATOR - Principle of the Al ternator

ALTERNATOR
PRINCIPLE OF TH E A LTERNATOR

1. MAGNET REVOLVES IN A COIL IG

Ie regulator

Rotor co il

The prev io us sect io n de scr ibed how rotati ng
t he co il in a m ag net ic field ge nerates elect ric ity
in th e co il. N ote ho w ever, that elect ricity can
al so be generated in t he coil if t he coil m erely
interr upts t he li nes of magn et ic fo rce. To do so,
w it h th e co il rem ainin g stati onary, th e ma g net
ca n be rotated to generat e electric ity in th e co il.
A lso, by doi ng so, th e co nst ruct io n of t he qen-
erating dev ice can be ma de m or e sim ple.
Theref ore, all alt ern ators used on auto m ob ile s
t oday ut ilize a gen eratin g co il (stato r co il) w it h
an intern ally rotat ing m ag net (rot or coi l* ).
T hus, t he alternat ing current generated in the
stator coil is changed int o d irect cu rrent by t he
rect if ier.
* The roto r co il m ay also be called a " field
coil " , ind icati ng th e ty pe of coil that is used
fo r creat ing m ag net ic po les in an electr ical
m otor or generator .

Stator CO i l -J.f,;::::::2;~~"'ll

Rotor coil §

r - _ ..J +#--(F ierd coil)

- - O HP 7

7
 ALT ERNATOR - Principle o f the A lterna tor
2. COIL PRODUCES
ELECTROMAGN ET
No rmally, the electrical components of an euto -
mobil e utiliz e either 12 or 24 volts of elect rici ty,
and the alterna tor for th e charging system must
supply thi s voltage.
Electr icity is generated when a mag net is rotated
wi thi n a coi l and the amo unt of th is electrici ty
varies wi th the speed of mag net ro tatio n. Thus,
thr ou gh the process of electromagnetic indue-
tton. the faster th e coil cuts the magn etic lines o f
force from the magne t, the mo re electromotive
force the coil w il l generate. We can see, then, that
vol tage changes depending on the speed wit h
whic h t he mag net rot ates.
Accordi ngly, to obta in a constant voltage, it is
necessary to rot ate the magnet at a constant
speed. However, bec ause th e engine operates at
various speeds. dependi ng on the driving co ndi -
tions, the speed 0 1 t he alternator cannot be kept
con stant.
Brush
Stator coil
Battery
8
To sol ve this di fficu lty, an electromag net can be
used instead of a permanent magnet to maintain
a fixed volt age. The electromagnet changes the
amou nt of magnetic flu x (number of magnetic
lines o f force) i n accordance with the rpm of the
alternator .
The electromag net has an iro n core w ith coils
w rapped around it. W hen current flow s th rough
the coi ls, the core is magnetized . The extent of th e
generate d magnet ism varies wi th th e amount of
current flow ing through the coi l. Thus, when the
alternator is rota ting at a low speed, current is
increased and, conversely, current is decreased
w hen the alternator is tu rni ng at hig h rpm. The
curre nt flow ing throu gh the electromagnet is sup -
plied by the batte ry and the amount is controlled
by the voltage regul ato r. For th is reason, the alt er-
nator suppli es a co nstant vo lt age regardless o f the
eng ine speed.
5
 ALT ERNATOR - Princi ple of the A lternato r

3. TH REE-PHAS E ALT ERNATING

CURRE NT

W hen a magnet rotates wit hin a co il. a vo ltage
w ill be created betw een each end of the coi l. This
w ill give rise to an alternating current.
OHP 8
To generate electric ity more eff icie ntly, the auto-
mo bi le alternato r uses three coils arranged as
show n in t he illu stration .
Each co il, A, B, and C, is spaced 120· apart.
W hen th e magnet is rotated amo ng th em, alter-
nating current is generated in each coil. The Ht us-
tratio n shows the relationship betw een th e three
alternating currents and the magn et. Elect ricity
having three alternating currents like t his is re-
ferred to as "three -phase alternati ng current"; all
modern auto mo bile alt ernators generate t hree-
phase alternati ng current.

Th e relati onship betwe en the current generated in A

th e co il and the posi tio n of the magnet is as
shown in the ill ustratio n. The largest amount of
current is generated w hen the N and S poles of
t he magnet are cl osest to the coi l. How ever, the
current flo w s in op po site directio n wit h each half
tu rn o f the magnet. Current w hich forms a sine
w ave in t his manner is called "s ingle phase alt er-
nating cu rrent". A change of 360· in the graph is
referred to as one cycle and the number of 120' OHP 8
changes occ uring in one second is called the
" frequency" .
A B c

OHP B

I
I8l
OHP 8

9
 ALTERNATOR - Prin ci ple of th e A lternato r

4 . RECTIF ICATION

The elect rical co mponents of an automo bile re-
qui re di rect current for operat ion and the battery
needs direct current fo r charging .
The alternato r prod uces th ree-phase alte rnating
current but the charging system of t he aut omobile
cann ot use this electric ity unless it is co nver ted to
di rect current.
Thus. we can see that although the current from
each coil to t he diodes is co nstantly changing
dire ction in the three lead w ires. t he di rection of
t he cu rrent fr om the diodes does not change and
it form s a circuit with unvaryin g polarity.

Con vert ing alternating current to direct current is T

I
called rectifi cation. Rectificati on can be acco m - ..L
plished in several ways but the automo bile alter-
nator uses a simple but eff ect ive diod e.

A d iode allows current to flow in one direction

only. A s show n in the illu strat io n. w hen six diodes
,-
?~
-.,.-
are used. the three- phase alternating current is
T T
I
..L
converted to direct current by full wav e rectific a- . j.

tion . A s the auto mobile alte rnato r has built - in

diodes. the electrici ty out put is di rect current.

- ..., T
I -TI I
..L
t,

e - OHP 9

T
I
..L

v OHP 10
®
NOTlCE - - - - - - - - - - "
t 1 . Some hi gh -perform an c e alte rna t o rs
em p loy more th an six d iod es
2. If th e b att ery co nne c t ions are r e-
v ersed , th e diod es will b e dam ag ed
I du e to a la rg e curren t fl ow.
e
OHP 9

10
 ALTE RNATOR - A lt ernator wi th Neutral -poin t Diodes

ALTERNATOR WI TH
NEUT RAL-POINT DIODES
1 . NE UTRAL- POI NT VOLTAGE With neutral oint diodes
(AI
A conventio nal alternator uses six diodes to rec -
tify th ree- ph ase AC into DC. The output vo ltage
w hich is generat ed at the neutral po int is ut ilized
as an electrical sou rce for the cha rge lamp relay.
It is kn ow n that the mean vol tage of th e neutral
point is 1 /2 of th e output DC voltage. W hil e the
ou tpu t current is flow ing through the alte rnato r.
the voltage at the neutral point is mostly DC. bu t
o 1000 2000 3000 4000 5000 6000
it also inc ludes an AC portion. - Alternator rotating speed (rpm)
The AC por tion is induced in each ph ase by th e
PERFORMANCE CH ARA CT ERI STI CS
flow of outp ut current. W hen the rot atio nal speed
(EXAMP LE) OHP 11
of the alternator exceeds 2.000 to 3.000 rpm. the
peak value of this AC po rtio n exceeds the DC 2. CIRCUITR Y AND CONSTRUCTION
outpu t vo ltage. In order to add the po tential variati on at thi s neu -
tral po int to the DC vo ltage outpu t by the altema-
tor w ith neutral -poi nt di odes. tw o recti ficati on
diodes are provided betw een ou tput termin al (B)
and earth ( E) and connected to the neutral point.
Portion of neutral point votteqe exceeding
These diodes are installed on th e rectifier ho lder.
(v)1 output vcltepe at high speeds
I /

~141 _
- - Output voltage

.-
At low Neutral point
speeds voltage
...... , _ Neutral point
r---o B
~ 7' . mean voltage Neutral

t ol- -
-
- --\'l",r: - - -.....,,j--
360·
Rotational angle
- - Ground
potential
diodes
<
~~i~~al I----:~_
point

'-----'11'-'1''-4
VO LTAGE WAVE APP EAR ING AT NEUTRAL
POI NT U ND ER LOAD ' -- - - - -"-+-.l-fl'-O E

OHP 11
Thi s means that, compared w ith the outp ut char- L -- - - - - --QF
acteristics of the alte rnato r wi thout a neutral-
po int diode. the outp ut gradually incr eases from CI RCU ITRY OF AL T ERN A TO R W IT H
mi dway by 10 to 15% at a normal rated revolu tion NE UT RAL PO IN T D (O DES (EXAM PLE)

speed of about 5.000 rpm. OHP 11

11
 A LT ERN A T O R - 3 -diode Exc iting A lt ernator

3-D IODE EXCITING

Neut ral po int
Neutral point ALTERNATOR
diode
diode (plus (minus side)
side) Thi s altern ator is provided w ith th ree field diod es
in orde r to exci te th e field coil, i n addi tion to th e
Outp ut usual six ou tp ut dio des fo r rectif ication.
d iodes Outp ut
(p lus side) .7;;,.....", d iode s In th is alt ernator, tu rni ng the ign iti on sw itch ON
",,,,,,.., ~V~1J- (minus side) sup plies f ield curr ent through the reverse current
prev ention diode and ini t ial exciting resistor, from
3, O PERA TI ON the IG termin al.
Since t he in it ial exciting resistor is con tained in
W hen th e vo lt age at the neutral poi nt beco mes th e circu it. the field c urrent is as small as 0.5 A
hig her t han th e ou tput DC voltag e or low er th an when t he alternato r stops wi th t he ignition sw itc h
zero volt s, a curre nt flows throug h the neutral ON ,
po int diode, and this is ad ded to the out put cur- Therefore, the disch arge from the batter y is small.
rent. (This co rrespo nds to the shaded port ion in W hen th e alte rnato r starts to generate, a portion
"V O LTAG E W A V E A PPEA RIN G AT NEUTR A L of the generated c urrent is supp lied directly from
POI NT UN D ER LOAD " graph on the p rev ious the th ree field diod es d uring po w er generatio n.
page ), The red uctio n in the fie ld cur rent becomes less
du e to the resistan ce of external wi ring and the
0 14 V
like and, t herefore, it is possible to improv e the
..
......
- " .. -. , .. ,
out pu t.
D,c -
"
I
,
J; .... ..
-.0-
- '0
0
Th e th ree fi eld diodes, t he init ial exc iti ng resistor
and th e di ode for preventing reverse cu rrent fl ow
(j) 15 V
- 0

,1 , , • -'
" are all insta lled on the rectifier hol der.
,
t ,
D, 'I '
" ,

.( . , .. . d Exciti ng Reverse current

Output die e di d prevention diode
- ," '0 e .,

NE UT RA L POIN T V O LTA G E ABO VE 14 V

OVOHP 12
I~ - "/
B

IG
,e, ~~itial
'1("J." , I
,,
, l;Ixc itinQ
resistor
,,
L

0 14 V
Field coil ,
.. • - ....., r;"-
rc ~
'
D , ~gula tor

I it: , I .. - -
- - •
- s
'0
Ci RC UIT DIA GRAM O F 3 - DIODE EXC IT ING

r " ,I:
0
8 1V .•... " • ALTE RN ATO R OHP 13
-L
.. ....... ...
' '

D, !
.. .. , .... .......... ..
- .. .. '

OV
OHP12 ~"tf~~fl:.- Excit ing
NEUTRAL PO INT V OLTA G E BELO W 0 V d iodes

Ini ti alng
exciti ~~~~~~
resistor

RECTIFI ER HOLD ER A SSEM BLY

12
 ALT ERNATOR - Vo ltage Regulation

VOLTAGE REGULATION
The vo ltage o f the current produced by the alter-
nator varies with th e speed w hich the alternator is
turnin g and the extent of the load (output cur-
rent) on the alt ernator.
How ever. becau se th e eng ine rpm is co ntinuously
changing, the rpm of the alternator does no t re-
main co nstant. Further, the loads (lam ps. w ipe rs,
heater, etc.) on th e alternato r are always cha nging
along wit h th e chargi ng cond ition of the battery.
Therefore, in order for the alte rnator to supply
electrici ty at a constant "standard" voltage, is it
necessary to co ntrol the amou nt o f voltage w ith a
regu lato r and, consequently, the chargi ng system
of the automobi le uses a voltage regula tor (gen-
erator regul ator) along w ith the alternator.
As th e electromagnet co nsists of an iron core with
coils w rapp ed arou nd it the iron core is magn e-
tized and ge nerates magnetic lines of force (mag -
netic flux ) w hen it is supplied with current.
The amount of the magn etic lines o f force is in
proportion to the amo unt of current suppl ied to
the co il around the iro n core. In ot her words, the
gen erator ensures t hat the alterna tor (stator coil)
is prod uci ng a constant volt age by supplying a
larger amo unt of current to th e ro tor coil ( field
co il) w hen the alternator is tu rning at a low rpm
or w hen it is un der a heavy load. and by reduci ng
th e amount o f current w hen the alt ernat or is t urn -
ing faster or w hen it is und er a li ght load.

~ '-< r----------------l
, I ;
~ , I
I R. ~
t y
Stator coils
I
~.J ~

.,.
- '-
I
I P, ~ I
I
-L
N
... II ~o vj ngl Po in t

-
P,
.-< --:::>
,\~ !P I -
ce -- I
I
I
-
-
- -
Regulator coil

s I
Rotor coil
'----- f-- - - - - - - - - -'
OHPt4

NOTE: Some alternato rs h av e b ui l t in r eg - The regulator controls the supply o f current to the
ul at ors. such as the Ie se m ic o n- rot or coil bv pulli ng and releasing the moving
ductor t y p e. poi nt in accordance with the vo ltag e applied to
the regulator coil.
The regulator suppl ies current to the electromaq- When the alterna to r is tu rni ng at a low rpm and a
net (rot or coil ) w hich pro duces the necessary heavy load is applied, th e vol tage at th e stater
magn et ic fl ux for the th ree coi ls (stato r co i l) of the coil wi l l beco me low er th an the regu lat ing
alte rnator to generate three-p hase alternat ing vo lt age (approximately 14 Vl at the regulator.
current. Accordingly, the movi ng point w ill m ake co ntact
w it h P" thu s allow ing the battery current to flo w
to the rotor coil thro ugh P,.
13
 ALTERNATOR - Voltage Regulation
On t he other hand. when the alternator is turni ng
at a high rpm and the voltag e of the stator coi l
rises abov e th at of th e reg ulating vo ltage
(ap pro xim ately 14 Vj at the regulat o r, thi s
voltage is applied to the regulator coil so it is
affected by a g reate r pul l ing fo rce whic h
separate s it from Pl.
-~
R R
.-J P,
P,r-l
j::::
r-- Regu lat or coil
'-
. .
W hen the movin g poi nt moves away fro m PI. th e
current flowi ng to the rotor coi l passes throug h
resisto r R and therefore is reduced in intensit y.
Less cu rrent to the roto r co il wi ll cause the stator
coil to generate less voltage and, co nsequently,
th ere w ill be reduc ed pullin g force on th e co il, so
th e mo vi ng point w ilt return and make contact
w ith Pl ' This, in turn, causes a rise i n th e current
to the ro to r coil and the movin g point again
moves away from PI-
14
Whe n the alternato r tur ns at an even faster speed,
the vo ltage generated by th e stator coil w ill rise,
apply ing more pulling fo rce to the regul ator coil
so that it makes contact w ith P2 • Therefo re, th e
cu rrent through resistor R will then flow to P2 and
not to the rot or coil.
rr= -,.-
P,
~
l P,
I-
j:: Regulator coil
'--
Wh en there is no longer any current to the rotor
coil, the stator can no t generate electromotive
force, so th e voltage of the altern ator drops and
the moving poi nt moves away from P2 . Thus, once
again the alt ernato r voltage w ill rise and the mov-
ing poin t w ill be pulled.
In other words, when the alte rnato r is turn ing at a
low speed. the movi ng point wil l increase or de-
crease current to the rotor coil by making contact
w it h or movi ng away from PI' W hen the alternato r
is t urning at a high rpm, cu rrent w ill be supplied
intermittent ly to the rotor co il depend ing on
w hether the mov ing point is making contact w ith
or has moved aw ay fro m P2 .
 ALT ERNATOR - Construct ion of the Al ternat or

CONSTRUCTION O F T HE ALTERNATOR
The funct ion of t he alte rnator is to co nvert me-
chanical energy from the eng ine i nt o electric ity.
M ech anical energy from the engine is relayed by
a pu lley, w hich revolves a ro tor and generates
alternati ng current in the stator. This alternating
current is recti fie d to direct current by the di od es.

The main co mpo nents of the alte rnator are the

ro tor w hic h produces electromagnetism, t he sta-
tor w hich pro duces electric current, and th e
di od es w hich rectify the current.

In add ition, there are also the brushes w hich sup -

ply current to t he rotor for productio n o f magnetic
flux, the bearin gs w hich allow the rotor to rot ate
smoothly, and a fan to cool the ro to r, stator and
diodes, All o f these co mpo nents are held by front
and rear frames.

Brush holde r

Bearing

Rear frame
Front frame Rect ifier (diod e) holder
Fan

• Bearing
Brush

Stator
Spacer
Rotor

OHP 15
Spacer
Pull ey

15
 ALTERNATOR - Con struction of the A lternator

1. ROTOR
Stato r core
The ro tor is composed of two cores (magn et ic
pol es) , a field coil (also called a roto r co il ), sli p
ring s, and a rotor shaft.

Th e field coil is wound in the same di rect ion as

rotation, and each end of th e co il is connected to
a sli p rin g. The two cores are installed at each end
of the co il so as to enc lose th e field coil.
M agne tic flu x is produced as cu rrent flow s
throug h th e co il and one p ole becomes th e N pole
and the o ther the S po le. The sl ip ring s are made
of metal suc h as stainless steel w ith a highly fi n-
ished brush co ntac ti ng surface. They are insu -
lated fro m the rotor shaft.
Stato r
co il
* Stator co il's output termi nals (to ou t put dio de)
3. DIOD ES
Three positive diodes and three negative diodes
are co ntained in their respect ive diode holders.
The current generated by the alternator is sup -
pl ied from the posit ive side diode holder so it is
insulated from the end frames.
During rectificati on, th e diodes become hot. so
the diode holders act to radiate this heat away
and prevent the di odes from ov erheatin g.

Diod e holder
Field coil (Rotor coil)
Pole core
Slip ring
Bearing

2. STATOR
The stato r is co mposed of the stato r co re and Diod e
stato r coils, and is secured to the fron t and rear Semiconductor
end s of th e frame. The stator core consists of t hin
layers of steel plating (strat ified iron cor e) . The
inner side has slo ts in w hich t here are three inde-
pendent stato r coils.

The stato r co re acts as a passage whi ch allows

the fl ux effec tively cross 10 the stator coil from the
rotor cores . DIOD E

16
 ALT ERNATOR - Compa ct Al ternator

COMPACT ALTERNATOR 2) Consolidation of Fan and Rotor

A co mpact alte rnato r with built -i n IC regulator is
17% smaller and 26% lighter than a standard-size
altern ator.
The co mpact alternator w ith built -i n IC regulator
is cons truc ted in t he same w ay as a standard- size
alternato r (bu t the operation of the IC regulator is,
o f course, different from that of an ordinary point
type regu lator) .
The con struc tion and features are described here
and compared w ith those of conventiona l alter-
nators.
1 . FEA T U RES
1) Smaller and lighter
Improvements in the magnetic ci rcuit. suc h as
air gap reducti on betw een roto r and stator and
modi fication of th e shape of th e rotor po le
co res, have been perfo rmed to achieve com -
pactn ess and lig htness.
The rotational speed of th e co mpact alternator
is mu ch faster than that o f a standard -size
alternator.
To cope w it h th is ch ang e, the fan, wh ich wa s
con ventio nally placed outside. has been com -
bi ned wi th the rotor with in the alternator, re-
sult ing in improved cooling performance and
safety.
3) Improved Servi ceab ili ty
The recti fier. bru sh hold ers and IC regulator
are secured to th e end frame w it h bolt s for
easy remov al and installation.
4) Simp lif ied Chargi ng System
The use of a m ult iple-fu nc tion Ie regul ator
simplifies t he charging system, thu s im prov -
ing reliab ility.

Stator
Connector
Rear end frame
--...,,--<>-
Drive end frame

:!oo>-- Brush
~"- S l i p ring

!>..-_- Rectifier

Rear end cover

Bearing
V-ribbed pulley
OHP 16

17
 ALTERNATOR - Compact Altern ator

2. CONSTRUCTION

Drive end frame

Front bearing

PUlley ~
® \2IJ
..\1
Rectifi er holder rc regulator
Brush holder
(with cover)

~ ~~
Rear end frame - , @:-
. \

9
Brush

11 Rotor 2) End Fram es

The roto r fun ct io ns as a f ield mag net and The fra me s have tw o fun ct ions: to suppo rt
ro tates int egrally w ith the shaft . The ro tor t he rotor and to act as a m ount to the en-
assembly is com pos ed of a m agnetic core, g ine.
fi eld coi l, sli p ring shaft and fan. Differing Bot h of them have several air passages t o
fro m co nvent io nal altern ators, th e ro to r has im prove coo li ng efficiency. Th e rect if ier,
int egr al fans o n bo t h sid es. br ush hold er, lC regu lator, etc., are bo lted t o
t he back side of t he rear end fr am e.
Po le core
31 St ato r
The stato r assem bly is co mposed of the sta-
tor co re and stato r co il. It is pressure-fitted
to (integral wi t h) the dr ive end fram e. The
heat gen erated by t he stat or is t ransm itted
to t he d rive end fram e to im prove coo ling
eff icie ncy.

18
 REGU LATOR - One-p oin t Type Reg ulato r

Rear end frame

Drive end f rame 5) IC regu lato r
The altern ato r has a built-in co m pact IC reg -
ulator. The intern al ci rcuit ry of t he IC reg ula-
to r inclu des a high -qu ality, monolith ic inte -
grat ed ci rcuit (IC) t o prov ide improved
Stator cor e
rel iability and charging,

Screw hole Screw ho le

f" s
Screw hole

c:> Cool air
4) Rectifi er
Th e rectif ier is de sig ned w it h a pro trusio n
o n it s surface to help im prove rad iati on of
the heat ge nerated d ue to t he o utput cu r-
rent .
Al so. due to its m o no-body st ructure and
th e term inal -in sulated con nect io ns be-
tw een t he d iod e ele ments. the rectifier is
very compact.
Te rminal B
NOTICE - -- - - - - - - - ,
The IC reg ulat or is installed o n th e att eme-
t or w ith severa l screw s, which are used not
only t o secure th e IC regulator, but a lso to
conne ct the alte rnat or t o t he termin als E, P,
F and B of th e Ie regul ator.
Therefore, if the screws are not securely
tig hten ed, ther e will be imp roper terminal
contact. ca using a drop in power qenera -
t ion and charging .
61 V-Rib bed Pulley
T he pu ll ey rat io has been increased abo ut
25% by use o f a v -ribbed pu lley wh ich p ro-
vides bett er hig h-speed effic iency.

Diode

19
 REGULATOR - Tw o -p oint Type Regulator

REGULATOR

The reg ul ato r increases and decreases t he
am ou nt of fi eld current to t he rot or in o rde r to
co nt ro l th e amo unt of vo ltage produc ed by t he
alte rn at or.
It is co m posed of poin ts, a m agn eti c co il and a
resistor.
A s t he voltag e incr eases, t he m ag net ic fo rce
w il l becom e stronge r, causin g th e m ov ing
point and th e low -speed point (P , ) to o pen .
W hen th e po ints are o pen, current w ill pass
throu g h t he resistor (Rl, and curr ent t o t he fie ld
co il is t her eby redu ced.

A s t he vol tage increa ses furthe r, reachin g t he

reg ulat ing vo lt ag e of t he regu lator, th e moving
po int co mes into co nta ct wi th t he hi gh -speed
po int W 2) .
Wh en t he moving po int is in con tact wit h the
hi gh -speed point , f ield current ceases to flow.

A char acte rist ic of t he two-po int t ype is th at

OHP 17
REFEREN CE - - - - - - - - - - - . ,
Th ere are also po intl ess ty pe regula tor s.
They ut ilize sem icondu ctors (trans istors,
les, etc. ) to cont rol th e current to t he rotor.
th ere is bot h a low-speed o perat ing range and
a hi gh -speed ope rati ng range.
W hile t he po in t-type volt age reg ulato r was
used in the past. m ost veh icl es now use an Ie
reg ula to r (see page 24).

TWO POINT TYPE REGULATOR

Th e two point ty pe has a resistor (R) co nnected
in series wi th th e fi eld co il (F) of th e rotor.
Wh en t he vo ltag e gene rated by t he alte rnato r
Standard
is low, t he magnetic force of t he mag net co il v vo ltage A

j!
~
(Ml is w eak, and th e moving poi nt an d th e low - .Pl ' .!, I .!, .!,
speed po int (P'l l are in co ntact. Th e cu rre nt
fro m t he field co il fl ow s throu gh th ese points.
g l'p
I"
I
, ~ ---e-
',1' 'j'
'if 1J
2 '..... Field current
Mov i ng .... "1. ..... . /

J
point

- - - •• r pm
.... - .... __
--
Altern ator
H :r-:r--,,---- - -e P1
<, OHP 18
Movi ng poin t
P,
F
I M

If

OHP 18

20
 REG ULATOR - Vo ltage Relay (Charge Lamp Relay)

V OLTA G E R ELAY ( CHARG E LAM P R ELAY)

Instead of usi ng only a regulator to control the
vol tage generated by the alternator, chargi ng sys-
tems oft en emplo y a two -element co mb ination o f
a vottaqe regulator and a voltage relay.
If there wer e no vo ltage relay, there would occur
a drop in vo ltag e in th e magnetic c oil because I he
vol tage is applied 10 a lo ng ci rcuit via the ignition
sw itc h. A redu ction in vo ltag e wo uld cause a pro -
pcrticnate decrease in magn etic farce of the mag -

I"t~,.--- Vo ltag e relay net co il so the moving points would na t be pu lled

suffi ci ently. As a result, a lterna tor vo ltag e would
raise too high .

Because t he charge lamp light blin ks in accor-

dance w it h voltage relay operation , the vo lt age
relay is also called the ch arge lamp relay.

The magn etic co il o f the vol tage relay is operated

by the neutral voltage o f the stator co il and. com -
pared w ith the magn etic co il o f th e voltaq e regu -
E lator. it pull s the po ints with less voltage.
A vo lt age relay in sures acc urate voltage regula-
tion. Because the magnet ic coil of the vcl taqe NOTE- - - - - - - - - - - ,
regul ator operat es in accordance with the voltage N eu tral volt ag e is hal f of t h e n o rmal al -
generated by the alte rnator. it is necessary to in - te rnator ou tput v o lt age.
sure tha t there is no drop in alternator vo ltag e.

Charge warn ing lam p

(Discharge warni ng lamp)
Fuse
Fuse Fuse

- ------< N'>--4----{ Switch

,
I
I

,,
I

FUSibl. m
link l1J
l oad
. ..., B .
L:='.~,WI 0-1-< E} -- --r-- ---.,
I
...... atterv Ir
,
-A"'-'.-m-.-'o-,- Regulator
Voltage regulator Voltage relay I 1
=
OHP 19

21
 REGULATOR - Characteristi cs of the Reg ulator

CHARACTERISTICS OF T HE REGULATOR
The fu nction of the regulator is to maintain the
vo ltag e generated by t he alternator at a co nstant
level. Actually, how ever, due to the characteristics
of the generator, volt age does not remain co n -
stant but flu ctuates. For t he point type (Tirril) reg -
ulator, there are various reasons wh y volt age flu c -
tuates but th e primary causes are du e to its
hysteresis and temperatu re characte ristics. and it
is imp ortant to be awa re of these before atte mpt -
ing to adjust th e regulator.
1. THE HYSTERESIS
CHARACTER ISTIC
W hen th e movin g po in ts chan ge from t he hig h -
speed point (side) to the lo w -speed point, a lo w -
ering of voltage occurs. This is called the hys-
W hen the movi ng point is operating at either the
low -speed or hig h-speed posit ion, a change oc -
curs in the armature gap and angle gap and thi s
ch ange results in an i ncrease or decrease in mag -
net ic resistance, Also, w hen the moving poi nt
changes from the high -speed side to t he low-
speed side, residual magnet ism from hig h -speed
operation remains in t he co il co re and cont inues
to pullan the moving point for a short tim e, These
tw o phenomena cause the alternator out put
vol tage to decli ne.
Armature gap
,
I
,
I

I
,,
Angle gap

teresis effect. I
Magnetic I
flu x I
,
I

t
Low-speed High-speed OHP 20
1
Low -speed High -speed

I, point
- 1'
. .; . c . . . . . . . :
po int
NDTE:- - -
side
-
side
- - - -
No at t emp t shou ld be m ad e to adj ust th e
- - - --.

,
v / ~-t-e,-e-s;-s--- regu lator when vo lta ge is droppin g du e
to thi s hysteresi s eff ec t . Gen erally. a 12 -
vo lt sy st em wi ll d rop from 0.5 t o 1.0
v o lts.
1
o _ rpm
DHP 20

22
 REGU LATOR - Characte risti cs of th e Regu lator

2. T HE TEMPE RATUR E CHA RA CTE RISTIC

The magn eti c co il of the vol tage reg u lato r ern -
ploys co pper w iring , and if the temperature o f this
w ire rises, resistance wi ll be increased and t here
wi ll be a red ucti o n in th e pu lli ng force (ele ctro -
magnetic force) of t he magn et ic coi l. result ing in
a higher alterna t or output vo ltage .
To prevent such a rise in vona qe. th e regu lator
utilizes eit her a resist or or a bi -metal element fo r
tem perature co m pensatio n, but some reg u lators
use both ,
Th e bi -m etal element is used together with a
spri ng wh ich supports the moving point. Th e bi -
metal element red uces the spri ng tension as the
temperatu re rises. After the reg ul at or begi ns oper -
ation ing, t he v oltage w ill fl uctua te u n til the tem -
perature stabilizes. Once the reg u lator beg in s op -
erating. th e c urrent causes th e temp erature of the
magn etic co il to rise immed iately. How ever, the
rise in the temperature of th e bi- me ta l element is
slig htl y retard ed so spring tensio n is stro ng and
vo ltage inc reases.

The resistor has eit her a Ni chrome w ire or a car -

Leaf spring
bon element w ith a low temp eratur e resistance /'
coeff ic ient, and is con nected in series to th e coi l.
It red uc es th e ratio of th e o verall resistance in Bi -rneta I
etemen t
accordance w ith th e temperatu re fluc tuat io n.

~
~ 0
, , ~ ~
I I -

--
Sprin 9
bI
V
Co mpensati ng
L,...resistor
6 F OHP 20

0.5 - 0.6 V Standard voltage

I .,J,.
- :::-l ::::-
~ _
6 F
v

I L Approx . 15 min s.

A ppro/(. 30 sec,

--_. time OHP 20

NOTE - - - - - - - - - - "">,
No rm a lly. it takes 5 to' 5 mi nut es f o r t he
vo lt ag e t o st a b ilize. No a tte m pt s ho uld
be m ad e to adju st t he re gu la t or d u r ing
t h is t im e ,

23
 Ie REGULATOR - Descripti on , Operat ing Princi ple of lC Regu lator

rc REGULATOR
DESCRIPTION
Both the point type regulator and the IC' regula-
tor have t he same basic purp ose: they limit the
voltage that is ou tp ut by the alternato r by co n -
troll ing th e field current w hich flow s t hroug h th e
rotor coi l.
The main difference is that in th e fC regulator, t he
field current is interrupted by an IC instead of by
a relay as in the poi nt ty pe regu lator.
OPERATING PRINCIPLE OF
IC REGULATOR
In t he ci rcuit di agram for the IC regu lator in the
illustration. w hen the ou tp ut voltage at termin al B
is low, the batt ery vol tage is appl ied to t he base of
'r r, through resisto r A. and Trl turn s on; at the
same time. field current to th e rotor coil flow s
from B -10 rot or co il _ F _ Tr, -10 E.

REFERENCE - - - - - - - -___, Alternator IC regulator

" IC
~- - ~'.i)---.---..-+-..,
An IC (Integrated Circuit) . is a miniturized ci r-
cu it composed of many small electrical or elec - r
,
rf;6~lt or'
troni c components (transistors, di odes. resis- R
tors, capac itors. etc. ) mo unted onto or built , ZD
Rotor coil
into a substrate (th at is. a base materi al suc h as
a circuit board or sil ico n chip) .
,,
The IC regul ator is co mpact and light we ig ht. and
L:::-__-<~----+--'---+-+
,
has excelle nt reliabili ty due to its lack of mec hen - PRINCIP LE OF IC REGU LATOR (1 )
ical poi nts. Co mpared with t he point typ e, it has OHP 21
the fo llowi ng featu res:
W hen the output voltage at terminal B is hig h, a

ADVA NTAG ES higher voltage is applied to the Zener diode (Z D)

• A narro w er out put vol tage range and litt le vari -
ati o n w ith time in output voltage.
NO TE ----------~
Re -adju st m en t i s n o t req u i red . (I n f ac t .
n o adj us t ment mech an ism is provlded . )
and w hen thi s vo ltage reaches the Zener vo ltage' .
the ZD bec omes conductive. Ac cordi ngly, as Tr2
tu rns on, Tr, turns off . Th is interru pts the field
current. regulati ng the outp ut vo ltage .
Alternator IC reg ulator

~-- ~.--r-;-~
• Goo d resistance to vibratio n and hi gh durabil -
ity due to lack of moving parts.
,
! rf~6~lt or'
• Since it s output vol tage becomes low er as its
temp eratur e rises. proper charging of th e bat-
Ro tor coil
tery can be performed.

,,
DISADVA N TAGE
• Suscept ib le to unusually high vo ltages and L:::-__-<(0-+-----+--'---+-+
temperatu res.
PRINC IPL E OF IC REGUL ATOR (2 )

24
 Ie REGULATOR - Characteristics of IC Regulator

REFERENCE - - - - - -------. CHA RACT ERIST ICS OF IC

"Zener voltage REGULATOR
W hen a vo ltag e is applied to t he Zener diode in
the forwa rd dir ecti on (from A to B in the fig ure 1. BATTERY LOAD
CHA RA CT ERISTICS
below ), a current flo w s, in the same way as
with norm al dio des; however, w hen any There is litt le or no variatio n in output voltage (no
voltage less tha n a certain level is appl ied in the mo re than 0.1 to 0.2 V) w ith changes in altern ator
reverse di rectio n (from B to A) , the Zener diod e speed, and no hysteresis characteristics as w ith
is not con du ctive, and a cu rrent does not flow. th e po int type.
The differenc e betwe en th e Zener di ode and a
no rmal di ode is that w hen any volt age more

--7~~==~:-
than a certai n level is applied in the reverse
direct ion, t he Zener dio de will become co nd uc - • -=
tive and w ill allow a current to flow .
.IJ'"
~ Apcrox. 0.1 V to 0.2 V
The vo ltag e at w hic h the Zener diode changes
~
from non -conducti ve to co nductive in th e re- 5
o
verse direction is called th e "Zener breakdown
voltage". I
- Alternator speed

A
-h" B
OHP 23

-
OHP 22

A h-" B B A
VI.
( - - - - ~l

t
. ~- - - - - . ,
:
1I I -y 1:\'V'-:-
I '; \
II
I
II -_~ ~-
I , -,
I I " \" I
I I I
1~ J
,-- -- ---,

OHP 22

25
 Ie REG U LATQ R - Ch aracteri st ics of IC Regulator

2. EXTE RN A L LOAD 3.T EMP ERATURE

CHARACTERISTICS CHARACTER ISTICS

Out put vo ltage becomes low er as the load current
increases. There are no hysteresis characte ristics
as wi t h th e point type regulator: volt age variation,
even at the rated load, or maxim um output cu rrent
o f the alt ernator, is betw een 0.5 V and 1 V.
NOTICE' - - - - - - - - - ------..,
If a l oad ex ceed i ng th e al te rn ator's ca -
p acity i s ap p lie d , the output vo lta g e wi ll
su dden ly drop, as in th e case o f t h e p o int
ty p e reg u lato r . For t his reason , ne ver ap-
p ly an excess ive lo ad when c heck i ng th e
o u t pu t vo lt ag e .
Since the Zener di ode used for regu latin g the c ut-
put voltage tends to become more c onductive as
th e ambient temperatu re rises. the output vo lt age
generally becom es low er as the temperature rises.
Since th e outp ut vo ltag e drops at high tempera-
tu res (e.g .• during summer) and rises at low tem -
peratures (e.g., duri ng w inter), proper ch arging
suited to the battery's chara cteristics is perfo rmed
at alt ti mes.
Standard rang e of
outp ut voltag e

14.7V

14.3V I,
j r-~'7:===:.:
App rox .
J:;; -- I
I
~ O, 5 V to l V I

"
I>
a"
I
I

- 40 - 20 0 20 40 60 80 (Oe )
- Temperature at Ie reg ulator

OHP 23
Load curren t
OHP 23 NOTE -------- -~
In ord er t o charge th e b attery in a sta ble
m ann er, w it h out b eing affected by th e t em -
pe ra t ure of th e b attery. it is n ecessary to
vary th e voltag e in accord ance w it h th e
t emp eratu re.
Wh en th e b att ery's t emp eratu re rises, th e
elect ro lyte in it react s m ore act ive ly, an d re-
du ces t he ba tte ry's intern al resistance. For
th is reaso n, if th e sam e v oltage as t ha t used
at lo w er t em p eratures is app lie d at a hi gh
t em per ature, excess am pe rage w ill flow t o
the b attery, p ossibly overch ar gin g t he b at -
t ery.
Conver sely, w he n th e b attery's t emper a-
tu re fall s, it s i nternal resi stan ce in cr eases.
thu s slo w in g th e flo w of th e ele ct rica l cur-
rent.

26
 CHARGING SYSTEM - Wit h Tw o -point Type Regulator

CHARGING SYSTEM
WITH TWO -POIN T TYP E REGU LATOR
Fusible link
Regulator

Betterv
Chargewarning lamp
(Discharge warning light>

Alternator

Ignition switch

OH P 24

This is a circui t diagram for a charging system
employi ng a tw o-point regu lator.
The po w er required for the alternator rotor to pro-
duce magn etic flux is suppl ied from termin al F.
This power (c urrent) is con troll ed (increased or
decreased ) by the regulator in accordance w ith
termi nal B voltage. The current produced by th e
stator o f the alt ernator is supplied from terminal B,
and is used to resuppl y the lo ads created by the
headlight s, wipers, radio , etc., in addit ion to
recharging the batt ery. The charge warning lamp
co mes on w hen the alternator is not sup plyi ng t he
norm al amo unt of cu rrent that is, wh en the
vol tage of termin al N of the alternator is less than
the speci fied amount.
If the IG term inal fuse A blows ou t, current w ill
not be supplied to the rotor and, co nseq uentl y,
th e altern ator will n ot generate current. Th e
alternato r will fun ction , how ever, even if the
charge lamp fuse B shou ld blowo ut.

Fuse A
Fu se" Fuse B

10 l

==~N)--------~

'.
I Ro:~r coil
Alternator Regulator

OHP 24
• Some m odels only

27
 CHARG ING SYSTEM - With Tw o-point Type Regulator

1. IGNITION SWITC H O N . ENG I NE STOPPED

Fuse

~,
Fuse

.. ~

[j" N N ,
"'a: ~,
R
,0 I
I
s" I
I
8 8
"or
0 I

~~~' b le[]
P,
P,

, F F ,, T '
L=,.mCO
il I Battery I

~
I I
E E ..... I

11
..
A lternato r Regulator

-
OHP 25

W hen the igniti on sw itc h is turned to ON, f ield

current from t he battery fl ow s to the roto r and
exci tes the rotor coi l. At the same time, battery
current also flo w s to the charge wa rning lamp and
the lamp comes on.

CD I Balt ery ( +) Terminal H Fusible Link ~l lg n itj on Swi tc h ~l Fuse H Reg ulator Terminal IG I--
Poi nts PL1 Poi nts PLo Regulator Term inal F Alternat or Terminal F Brushe

Rotor Coil Altern ator Terminal E

( Field Cu rrent)

®j Batt ery (+) Terminal ~ Fusible Link Igni tio n Swi tch Charg e Warnin g Lamp

Regulator Terminal L ~I Point Po ~I Point PI H Regulator Terminal E H Gro und I

(Charg e Warni ng
Lamp Current )

28
 C HAR GI NG SYS TE M - W ith Tw o -poi nt Type Regulato r

2. EN GIN E OPERATIN G; LOW SPEE D TO MI DDL E SPEED

Fuse
Fuse

- - - --{N} -- --+- --{

~F)----{
Fusible
link

.
~~<con )--J'-{E }-- - - ,- - -{ E }-_+-'--'-_-'-_"-'~
'"""";
A" lt-
.,-:nC"
,,"o-:
r Regulato r
Voltage regul ator Voltage relay

A fter the engine is started and t he rot or is tu rning.
voltage is generated in the stator coils. and neutral
voltage is applied to the vol tage relay so the
charg e wa rnin g lamp goe s out. At t he same time.
output vo ltage is acting on the voltage regulator .
Field current to the ro tor is cont rolled (incr eased
or decreased ) in accordance w ith the out put
vo ltage act ing on t he vo ltage regulato r. Thus. de -
pendi ng on th e cond itio n o f point Pt-e. the field
current eith er passes throug h or does not pass
t hrough t he resistor ( R) .
NOTE ----------~
W h en mo vin g poi nt Po o f th e vo ltage re-
lay m ak es co n t act wi th p oin t P2 • eq ua l
v o lt ag e is app l ie d t o t h e c i rcu it b efore
and aft er t he ch arge w a rn i ng l am p so
cu rre nt w ill n o t fl o w to th e lam p an d it
w i ll n o t li gh t up .

ill I Alt ernator Terminal N

H Regulator Terminal N H M agnet Coil of Voltage Relay H Regulator
Terminal E H Ground I (Neutral Voltage)

®I A lt ernator Terminal B ~I Regulator Terminal B H Poi nt P2 ~I Point Po H M agnetic Coil of Voltage

Regulator H Regulator Terminal E H Grou nd I (Output Voltage)

@[ A lternator Terminal B H Ignition Sw itch H Fuse H Regulator Terminal lG •

~ Point PL1 Point Pl.o Regulato r Terminal F A lternator Terminal F

or
L Resistor R

Rotor Coil H Alternator Terminal E t---l Ground I (Field Current)

®I A lternator Terminal B H Batt ery and /or Load ~l Ground I (Output Current )

29
 CHARGING SYSTEM - W ith Two -poi nt Type Regu lato r

3. ENGIN E OPERATING; MIDDLE SPEED TO HIG H SP EED

Fuse
Fuse
~,
~,
I
,,
I

C:~' CO;l
I
-r Battery :

-=A7.,,"'"e,:n:::a::,oC", Regulator

11 OHP 27

As eng ine rpm incre ases. the vo ltage generated by NOTE- - - - - - - - - - - ,

the stator co il rises. and th e pull ing fo rce of the
magnetic co il (i n the vo ltage reg ulator ) becom es
stro nger. With a st ro nger pu lling force. fi eld cu r-
rent t o the roto r w ill fl ow in termittently. In other
words. mov ing po int Plo o f t he volta ge reg ulator
in termitt entl y makes contact w ith po int PL 2 •
Wh en mov ing p o i n t P lo o f t h e r egul at o r
m a ke s co n tact w ith po in t PL2 • f ield c ur -
r ent i s te rm i n at ed . How ev er. p oi nt Po o f
the vo l t ag e r el ay wi ll n ot m ove away
from p oint Pz b ecause n eutr a l v o ltag e i s
m aintain ed i n th e r esidu a l flu x of t h e r o -
tor .

CDI Alternalor Terminal N H Regulator Terminal N H Magnetic Coil of Voltage Relay 1-------
I Regulator Terminal E ~l Ground I (Neutral Voltage)
CV I Alternator Terminal B H Regulator Terminal B H Point P H Point Po H Magnetic Coil of Voltage
2

Regulator H Regu lator Terminal E H Ground I (Output Voltage)

@I All ernator Terminal B H Ignition SWitch H Fuse H Regulator Terminal IG 1- - --- - - - - •

Resistor R Regulator Terminal F Alternator Terminal F Rotor Coil
or

"""'::-::-::-"""::-~Lj
~~'-p"oi~n~'~p::L,=H~ Point PL2 H Ground I (No Field Current)
I Alternator Terminal E H Ground I (Field Current)
(1)[ Alternator Terminal B H Banery and/or Load ~I Ground 1(Output Current)
30
 CHARGI NG SYSTEM - With A·ty pe IC Regu lato r

WITH A -TYP E rc REGULATOR

Th is typ e of alt ernator is a fi eld -di ode s exciting
alte rnator w ith neutral point diod es. and th e Ie
regulator with wh ich it is pro vided is the basic
A -type regulator. (T his type of f C reg ulator is not
m uc h used at present.)
The charg e lamp relay is the ope n/close (alw ays
open ) poi nt type.
The A -type IC regulator is a solid- state device
w hi ch consists o f two transisto rs, three resistors
and two diode s. The fun ction o f th e regu lato r is to
keep the output vo ltage of t he alte rnator w ithin a
rang e of specified values. Th is is performed by
con trolhnq th e field c urrent fl o w in g through the
field co il.
IC regulator
Fi el d Curr en t Cont rol
Field cu rrent is controlled by inte rrupting th e
ground side (t erminal F) of the rot or c oil by
means of Trl ' W hen Trl turns on and the ground
c ircuit is cl osed. excitm q curr ent fl ow s t hrough
the rotor coil . Wh en the ground ci rc uit is opened.
exciti ng c urrent ceases 10 fl ow t hrough the rotor
coil.
Outp ut Vol t a g e S ensing
A lt ern ator outp ut vol tage is app lied to t he Zener
diod e (ZD ) through a resistor ( A) . If the output
v oltage is hig her than a pre-determin ed voltage.
the Zener diod e allows a signa l to pass to Tr2' Th is
sig nal interru pts the rotor co il ground ci rcuit via
Tr, and Tr,.

S L F

Field diodes (Exciting diodesl

;\ Initial exciting resistor
Ne" '!1 point diodes
----- __ ; L c:rent prevention diode ~~~ Ign ition sw itch on,

I
( ..
\
/ ~ ,' \ ( "oJ \ IG IG S/W
engine stopped
, , , , , ......
~-' " ~- '" Engine operating;
, .
;--,
L
the output voltage
increases. causing
the field cu rrent
(~Cl '-T
S
flow to be cut off.
,
,, L:'- ....+_' tG
., ' J...
,,
Rotor coil
R, R
F r-,
Tr, <~ZD ...!:. / E
;..
~
,
E i
--

IC regulator
/ Cha rge light
relay

31
 CHARGI N G S YS TE M - Wit h Bvtvpe IC Regu lator

WI TH B -TV PE rc R EG ULATO R
Th is is a field-diodes exc iting alte rnator w ith neu- The B-type Ie regulator is based on the A-ty pe Ie
tra l point d iodes . The Bctvpe f C reg u lator, w hich regu lator in term s of its circuitry, but is different
is an improved versio n of the A -ty pe, is used. in t he follow ing points:
Fo r t he charge lam p relay, t he o pen/close poi nt • While the A-typ e Ie re gul ator dete cted the
type is described, since it is generally used. vo ltage at term inal B of the alternator to
regulate vo ltage. the B-type detects the voltage
at the battery terminal by way of terminal S.
t hu s pro v idin g mo re accurate vo ltage
F
requlatlon.
• An open circuit in the rotor coi l is detected via
circuit A and th e resistor (Ad), tu rn ing on the
discharge w arning light.

Ne' tra( point diode
Field diodes
(Exciting diodes)
Init ial excit ing resistor
Reverse-current prevention diode
- --
Resistor for rotor co il

,--, -t;;;i
r J, B open circuit detecti on

, IG I IG §!.W
I

I
I n k- , _ ~\
I ,
I
,
' ... ,,
'/

-;... '
,
51
-o-

R, 0,
"" I j-r"'1
I , LI
I
I
!~ ~ , 5
( D.. . ,
I I
I , I
, ,
I
L
-- ---
I
I
,
I
I
I
I
'- - ,
I
IG CL
--T
,
' -' -'-
I
e.- ,
,'R3 1" , · ..
,
Ii
Rotor coil
I
I
R,
. _ ' t~;
\.3'~
:'~~ .')1
, ~ -
,
F
Cp
Tr,
ZD -
'§«
__ I
eA E

--
Ei
--
I
~
Tr,
_, .
U

-
]J
_ ~'T..rJ
Charge lam p
)

-
-=- -
~ e,.
Di ode for exciting
Ie regulator voltage detection relay
Resistor for exciting voltage detectio n

32
 CHARGING SYSTE M - W ith Bvtvpe f C Reg ulator

• If termi nal S of th e alt erna tor becomes

detached, circuit A in terrupt s the current that
flows to the rotor coil, thu s sto pping the
generation of electr icity. At the sam e tim e, it
turns on the discharge warning light.
If term inal B of t he altern ator becomes
detached, th e resistor (R3) and diode (D3) act to
limit t he curre nt that flows to the roto r coil in
order to pro tect the alternato r and regulator
from excess voltage.

33
 CHARGING SYSTEM - Wit h M -Iype IC Regulalor

W ITH M -TVP E ic If any of the follo w ing tro ubles occurs, the M -
REGULATOR type Ie reg ulato r ca uses th e ch arge wa rn ing lam p
to go on:
The alt ernato r is a compact alt ernato r w ith neutral • Open i n rotor coi l circuitry.
point diodes. Th e difference between it and the • Open in regu lato r sensor (t er m inal Sl ci rcuitry.
alte rnato r w ith a B-type Ie regulator is that the • Voltage at termin als drop be low 13 V.
three fiel d diodes and init ial exci ting resistor are
elim inated . and t he Ie reg ulator is made to co ntrol
1. TE MP ERATURE CHA RACT ERISTICS
the exc it ing cu rrent.
Of th e vario us ty pes of Ic regulators that are The temp erature characteristics of this reg ulator
use d, th is sect ion w ill describe t he basic, are diff erent from those of the A - and Bvtvp es.
m ult ip le-funct io n M -type regu lator. M ost being in step form. This improves th e chargi ng
prese nt-da y Toy ot as use the M -ty pe regu lato r. perf ormance.

The M -type Ie regu lator co nsists of a hybrid Ie IV) Standard rang e

having a built -in monolithic integrated circuit r--~ of outp ut voltage
~ 15.0
( M IC) . Th e M -type d iffers fro m the B type in th at fl
the tC funct ion s as a rotor co il open -ci rcui t detec -
tor and fo r charge lamp wa rning . D ue to the eli m -
g
g, 14.
'5
h. ,,,
.
ination of the field dio des and ini tial exci ting reo o
stato r. the cha rging system is somew hat
simplified. ....30 0 30 60 1201:35" ' "C)
Regulator temperature

Neutral poin t diodes

,
--
\
-- -- 8
Stato r coil I ' __ IG 5 / W
.
,
,
IG

~~ , 8 IG _. ,
,
0 5 '5
,
,,
~ ~=-,
-~ ,, D,
rr" ,
,,
0
L(
,,
~
F
,0 L L I
....L.
-. ~
MIC
,,

,,
I Roto r coil
P
,, r-,
I
~ ,,

_.~
L _.
~ b-
E
- --
--
rc regulator
--
-
34 OH P 28
 CHARGIN G SYSTEM - W it h M -Iype IC Regulal or

2. IGNITION SWITCH ON . EN GIN E Charg e W arnin g l amp

STOPPED
Since gen e ration of electricity has not yet beg un.
Turning the ignitio n sw itch ON applies battery term inal P vo ltage is zero . Th is is detected by the
vo ltage to terminal IG of the Ie regulator. Th is MI C. w hich turn s Trl off . and Tr] on , causing the
battery vo ltage is detect ed by the M IG and Tr 1 is charge warning la mp to come on .
turn ed on, causing the initial exciting cu rrent to
flow to th e rotor coil via the battery and term inal
B. In order to reduce the battery di scharge cur-
rent w hen the ig nit io n switch is on at this time.
the MIC keeps the exciting current to a value as
small as abo ut 0.2 A by intermittent ly turn ing Trl
on and off.

Stator coil
IG
B IG ,
s 'S

F
MIC

,
, PM I

L EL- __._
--- + E- ---- - -- ---- -'
"~
Ie regulator

-~
OHP 29

I GN S/ W M IC OETECTS TI, : ON (M A INTA INED AT 0.2 A INITIA L EXCITEM ENT

t- I--
ON
l- TEAM rc VOLT. t.r BY INTEAM ITTENT
ON/ OFF OPEAATION )
OF AOTOR COIL

<- NO TERM . P VOLT.

I t-, ON H CHA RGE WAR NIN G LAM P ON I

35
 CHARGIN G SYSTEM - With M ·type IC Regulator

3 . G ENERATIO N O F CU RR ENT B Y Charge W a rnin g l amp

ALT ER NATOR ( Less t ha n
Sta n da rd Vo ltag e) Whe n termin al P vo ltage rises. th e M IC t urns TrJ
off and Tr2 on. Si nce there is then no potential
When the altern ator starts generating current and
difference betw een bot h ends of the charge
terminal P vo ltage rises, the MI C sw itches Tr 1
wa rning lamp, the lamp goes out.
from an intermittent on-off state to a conti nuous
on state, ca using sufficie nt exci ti ng current to be
suppl ied by the batt ery 10 the rotor coi l. Therefore,
the generated cu rrent inc reases suddenly.

Sta tor coil

I B

-- QH P 30

M IC DETECTS:
ROTOR COi l I CHARG ING CURRENT I
I TERM . P VOLT.
I- TERM. P VOLT.
EXCITATIO N CURREN T

ICHARGE WARNING LAM P OFF I

REFE RENCE - - - - - - - - - - - - - - - - - - - - - - - - - - ,
Vehicles w it h a carbu ret or use t he ter mi nal L vo ltage to operat e t he aut om ati c cho ke. Therefore,
afte r t he eng ine is started and the alterna to r starts generati ng, Tr2t urns on and the batt ery vo lt age
wi ll be app lied to term inal L.
Because ve hic les with EFI do not use an auto matic cho ke, t hey d o not need Tr2; they on ly use Tr3
to co ntrol th e charge warning lamp.

36
 CHARGIN G SYSTEM - With M -type IC Regulator

4 . G EN ERATIO N OF C U RRE NT BY C ha rg e W a rn in g La m p
A LT ERN A T O R ( St an d ar d V ol t ag e
Re ach ed) Since P- termi nal vo ltage is hig h. the M IC keeps
Tr3 off and Tr2 on, so the charge wa rning lamp
W hen Tr 1 sl ays o n and te rmi nal S vo ltage reaches
remain s un -lighted.
the standard voltag e. th is co nd itio n is detected by
the M IC and Tr, is turned off .
W hen term ina lS voltage drops below the stan-
dard range. the M IC detects th is drop and turns
Tr, on again . By the repetition of th is proc ess.
S-termina l voltaqe is kept at the stan da rd voltaqe .

-- -- --
--------------- ---------- ------------------- B --------- ------~,,
Stator co il I ,
IG IG S /W ,,
,
B IG i-----------·_---- , ------ ,--------
-I,
~ ,,, -- ,,I ,,,

1"
<i!>.- ~ ,,
,,
S 'S
,. ........--- -- -._--- , ,
-,, ,
~- r i-- - --- l

-;:QJ. ," (
.--\
I I,
.
:,
:
I

F Ir;;t; ! L L
,,
,,
,,
(

I Rot or coil ,, ?:- MIC

~
, -- ,, ______J
:=-
Tr)~ ,
,, I
P
__=!J
L -- ~
E
E
'---

--
Ie regulator
--
-
OHP 31

~ ~
TERM P. VOLT. MIC DETECTS: MIC DETECTS:
TERM. 5 VOLT.
ABOVE A BOUT
TERM . S VOLT, I T" OFF BELOW ABO UT 145 V TERM . S VOLT.
14.5 V
I CHARGING CURRENT Tr, : ON

37
 CH ARG ING SYSTEM - With M ·type lC Regulator

5. OPEN IN REGU LATO R SENSOR Ch arg e W arnin g la m p

(Termi nal S) CI RCUITR Y
W hen the M IC detect s " no input from terminal S"
If an open develop s in t he reg ulator sensor it turns Tr2 off and Tn on , causing the charge
ci rcuit ry w hi le the alternato r is running, " no warning lamp to come on.
in put from terminal S" is detected by th e MIC,
and Trr is turn ed o n and off to ma intai n the
termi nal P v oltage between 13.3 and 16,3 V. As a
res ult, te rm ina l B will be m aintained a t
ap proximately the sa me voltage .
Th is prevents the ou tput voltage from rising un -
usually high, t hus pro tecti ng t he alte rnato r, IC
regulator and ot her electrical com po nents.

~- - - ---- -- ------ ----~

Sta tor coil I
i B
s

L...- .. _ _
Ie regulator
-~-_ ..

OHP 32

MIG DETECTS: 1-- _. I CHARGE WARNIN G LAMP ON I

N O TERM 5
TE RM. P VO LT, POWER IN PUT TE RM. P VOLT. MIC DETECTS:
ABOVE ABOUT 13.3· l6.JV Tr, OFF BELOW ABOUT 133· 16.3 V TER M. P VOLT.
TEAM . P VOLT.

CHARGING CURRENT I T" , ON 1- -J

38
 CHARG IN G SYS TEM - Wit h M -type IC Reg ulator

6 . OP EN IN ALT ERNATOR T ERMINAL B Ch arg e W arnin g Lam p

CIRCUITRY
Chargi ng of th e battery is not performed, so th e
M IC keeps term in al B vo ltag e to 20 volts on th e
basis of te rm ina l P vo ltag e by tu rning Tr, on and
off . This prevents t he outp ut vo lt age from rising
unusually hig h. thus protecti ng t he alte rnator and
tC reg ulator .
If charging of t he batte ry is not continuous ly per-
formed. th e battery v olt age dro ps in t he course
o f t ime. W hen term inal S voltage (batte ry
voltage) d rops below 13 volts. it is detecte d by
the MI C, w hich turn s Tn off and Tr3 on, causing
the charg e w arning lam p to come on.

. - - - -- - - - - --- - - - - --- - - - B~
Stator coi l
c...,.,,....,...,,,,,,
1 IG IG S/W

~ B IG -- 5 :5 r------ 1
i~ ~ : ;-----------:-- ----~~J--~ J
i
!,
F
r, .,( ~ , ~ ,. - -
Tr,
M IC
~L
~
Tr3 ," __ ,
L -, (
..1
i
l
1
i I - VI
Rotor COli
:
: : : 'I
i
: ' I
:
I

l ---------------------------------, tu
, I I

1f
- - - -,

I ,ti
:

, ,------------------------- ----------..p·T-11"1--------" =.Jit! I

L --
_L.
-
E
EL
--
_
IC regu lator
----

OH P 33

ITERM. 5 VOLT.
A BOVE ABOUT 13 V
I M IC DETE CTS:
TERM . 5 VOLT.
TERM. P VOLT.
M AI NTAIN ED AT
f--I TERM. 5 VOLT.
BELOW AB OUT 13 V
~
A BOUT 20 V
TERM. P VOLT.
MAINTAINED AT
A80UT 13.3· 16.3 1/
I-- MI C DETECTS
TERM , 5 , VOLT
I CHA RGE WAR NI NG LAM P ON Tr, : OFF I
TrJ : ON I'

~ RE FE REN CE
-- B
On some typ es of IC regulato rs, term inal B
voltage is incorporated in t he MI C inside th e IG IG
B
Ie regulator. Wit h t his type of IC regulator, in --51 S
case of an open ci rcu it at te rm inal S or term i-
nal B, t he MI C wi ll regulate th e vo ltag e at ter-
!, -I !, ,,
M IC ~ L
m inal 8, instead of term inal P, to be app roxl- F t--
m ately 14V.
I t;f-1 L

39
 CHARGING SY STE M - W ith M· l ype IC Regulator

7. OP EN IN ROTOR COIL CIRCUIT RY Ch ar ge W arn ing l amp

If an open circuit develops in the rotor coil cir- W hen gen eration of electricity stops and term inal
cuitry, g eneration of electricity stops . Also, te rm i- P voltage becom es zero, thi s cond ition is detect-
nal P output voltage beco mes zero. ed by the MIC, w hich turns Tn off and T r3on.

r-- --- - - - -- -- - - - --- - - - B

Stator coil I IG S/ W
IG
,
S 'S

.d
~ L
Open circuit
r
Tr,
M IC
L

I ~
Rotor coil

E ___ ---l

QHP 34

40
 TR OUBLESHOOTING - Classificatio n of Charging System Probl ems
TROU BLESHOOTING
Normally, the driver w ill first become aw are that
something is w rong w ith t he charging system
when the charge w arning lamp comes on . In ad -
di t ion. it is oft en discov ered that the charg ing sys-
tem is abnormal w hen the engine cannot be
cranked due to a w eak batt ery or w hen the lumi-
nositv of the head lights changes.
In any case, w henever it is suspected that the
charging system is faulty, the cause must be lo-
cated and the faulty compo nent repaired or re-
placed.
A w eak (undercharged ) batt ery is often due to an
abnormality in the batt ery itself, such as insuff i-
cient electrolyte in the cells or deteriorated plates.
Or, it co uld be caused by insuff icie nt tension in
th e drive belt, w hic h is causi ng the belt to slip .
Ho wever, there are also cases whe n prob lems are
caused by the manner in wh ic h the veh ic le is used
and not by a faulty batt ery or chargi ng system. For
example, such problems could occur if t he vehic le
is used for short-distance trips on ly. In such a
case, the battery current is consummed by fre-
q uent engine start ing and. because th e trips are
short, the battery doesn't have time to full y
rech arge. This wo uld be especially true if the ve-
hicle is used in thi s manner at nig ht because al -
most all current generated by th e alternator is
supp lied to the headlights. resulting in i nsufficent
recharging of th e batt ery.
W hen troubleshooti ng the charging system. it is
essential to have a good com prehension of the
problem and to confirm its symptoms.
CLASSIFICATION OF
CHARGING SYSTEM
PRO BL EM S
For charg ing systems uti lizin g a charge w arning
lamp, problems can be classified into the fol low -
ing four categories:
'l . A bnormal operat ion of c har ge warning
l amp (discharg e warning light I
a. Lamp does not come on when igni tion
sw itc h is turn ed to ON position .
b. Lamp does not go o ut after engine starts.
c. Lamp lights fain tly w hite engi ne is runn ing.
d . Lamp someti mes comes on wh ile engine is
runn ing.
2. W eak ( d isc ha rged ) battery
a. Cannot crank en gin e wi th starter.
b. Head light s are dim
3. Ov ercharg ed battery
Batt ery electrol yte is used up qu ickly.
4 . Abnormal n oi se
a. Abno rmal no ise from alternato r.
b. Static in radio.
4'
 TROUBLESHOOTING - Al tern ator w it h Point Typ e Regu lator

ALTERNATOR WITH POINT TYPE REGULATOR

Once the symptoms o f th e problem are con firmed. For examp le. when trying to locate the cause of
the cause must be dete rmi ned. There are various svmptom. you shoul d check each of the main
method s doing th is but the qu ickest and most points as fo llows:
accurate method should be used. In this respect
it is very important that the related areas be
checked in cor rect order.

1 . Abnorma l O p er at io n of Charg e W arnin g Lamp (Discharge Warning Light)

a . Ch arg e w arn in g l am p do es n o t come on wh en ign itio n switch turned to O N .

CD Inspect fuse Repair or replace

Blo wn or bad co ntact
j OK

Check regulator
tV connectors Repair
Loose or faulty
I OK

® Check alternator

I OK
Bad -/ Repair
I
® Check charge wa rni ng tamp

I OK
Burnt out I Repl ace (or repair)
I
Replace reg ul ator

CD Check for a blown fuse or fault y con tact in the ate. and the moving po in t w ill be pulled so the
charge war ning lamp circuit. charge wa rning lamp w ill not l ight).

® Check for loose or faul ty regul ator connectors.
@ Check for a short -ci rcui t in t he posit ive diodes
of the alternator.
• If the cha rge warning lamp lights when the
three-pin co nnector of the alt ernator is dis-
connected. the diodes are sho rt- circui ted .
( Even if only one pos itive di ode is sho rt -ci r-
cuited. battery current w ill flow from termi -
nal B to termi nal N vi a the bad diode. This
current w i ll cause the v olt age relay to op er-
42
@ Check for burnt ou t bulb o f charge warn ing
lamp .
• Wi th the regul ator connected. gro un d
terminal L of the co nnecto r. If the cha rge
w arni ng tam p comes on. the regulator is
bad. If the charge w arning lam p does not
co me on, eithe r a burnt ou t bu lb or a faulty
wi re harness is indi cated.
NOTE: The layou t o f th e w iring h arn ess d e-
p end s o n t h e ve hicle. b ut a c h eck
sh o u ld b e m ad e of all c o n nect o r s be -
twee n t h e ign ition sw i tc h and th e
regu lator.
 T RO U B LESHOOTIN G - A lte rna tor with Point Ty pe Regulator

b . Ch arge wa rning lam p does not go out af ter eng in e st arts .

Th is symptom indicates that the alternato r is ei-

ther not generating elect ric ity or is overcha rgi ng.

CD Check dri ve belt Adj ust or repl ace

Incorrect
OK

® Check fuse Repair or replace

Blown or bad co ntact
OK

Check vo ltage @ M easure vol tage at

® at termi nal B terminal N
Over 15 V
Under 13 V 1 In correct

rID Check voltag e at Repair or replace 0K

termin al F OK alternator

Inco rrect Repair or replace

regulator

® M easure voltage
at IG termi nal
OK
Incorrect ,I Repair wire harness
I
Repair or replace regulator

CD Check the drive belt for damage or sli pping.
® Check if the f use con nected to t he
regula tor's IG term ina l is blown or loose.
@ M easure ou tp ut volt age at terminal B of al-
ternator .
• If voltage is less than specified (13.8 -
14.8 V), the alt ernator is not generatin g
electricity . If voltage is in exc ess o f thi s
speci fic atio n, th e alte rnator is overcharg-
in g.
If th e vo lt age relay is not operating ,
vo lt age is not being co ntro lled by th e
vo ltag e regulator, result ing in ov ercha rq -
ing of the batte ry.
@ M easure the ne utral vo ltage at termin al N of
the regulator connector,
• Vo lt age indicates a broken coi l in the reg -
ulator voltag e relay. No vo ltage ind icates
an op en in th e neutral ci rcu it of th e alt er-
nator.
® M easure the field voltag e at termi nal F of the
regu lator conne cto r.
• Vo ltage indica tes a broke n coil in t he rotor
or faulty brush con tact in th e alternator. If
th ere is no volt age, measure t he vo ltage at
the IG terminal.
@ M easure the batt ery vo lt age at th e IG termi-
nal of th e regulator connector.
• Voltage in dicates a bad regu lator . No
vo ltag e indicates dam age to t he w ire
harness betw een t he ign it ion sw itch and
regulator co nnecto r.
43
 TROUB LESHOOTIN G - Altern ato r w it h Point Type Reg ulato r

c. Ch arge warning lamp li gh t s faintly w he n engine is runn ing.

Ignition
Th is sy m pt om so me times ind icates t hat Charge warni ng lamp sw itch
t here is a revers e cu rr ent fr o m term i nal L
of t he reg ul ato r via the ch arge warni ng Alternator
@ ~
L ,t. .
- :. .. 1
._ 6 _
~Af " Balle,Y
lam p.
Other component Fuse

CD Check fuse Repair or replace

Blown
I OK

@ Check ignit ion

sw itch

I OK
Bad ·1
Repair or replace
I
® Check wi re harness

CD Check the charge w arning lamp circuit fo r a the resistance between terminals A M and
blo w n fuse or bad fuse co ntact. IG of the connecte r.
• This fuse is not only for t he charge wa rn- If t here is much contact resistance in the
ing lamp circuit bu t also protects ot her ign it ion swi tch. the vo lta ge app lied to the
electr ical com po nents. W hen the ignitio n fuse w il l be reduc ed. Therefore. as w hen
sw itch is turned to ON. current is supplied there is a blow n fuse. current from termi-
to these co mpone nts. If this fuse is blown nal L w il l be reversed and th e charge
or if it is no t makin g proper contact. cu r- wa rning lamp will shine faint ly.
rent w i ll not flow via th e ignit ion sw itc h.
@ Check for faul ty contact at each co nnector of
However. if the alternato r is generati ng
the w ire harness.
etectricit v. the vol tage relay w i ll operate
• M easure the volt age of each connector of
and current w ill flow from termina l L to the
the wire harness betw een the batt ery and
components via the points and the charge
the charge warn ing lamp circ uit fuse. If
warnin g lam p. causi ng the charge
volt age is unusuall y low . it indicates a bad
wa rning lamp to light faintly. The lamp
co ntact.
wi ll shine brighter at higher engine speeds
because mo re vo ltage will be generated. As w hen t here is excessive resistance in
th e ignition sw itc h. voltage will also be
® M easure the internal resistance of the igni- reduced if there is much resistance in t he
t ion sw itch. w iring harness. and current w ill flow in
• Discon nect t he ig nition swi tch connecto r reverse from terminal L vi a the charge
and. w ith the ignition sw itc h ON. measure w arning lamp .

44
 TROUBLESHOOTING - A lte rna to r w ith Poin t Typ e Reg ulato r

d . Charg e warning lamp sometimes com es on while engin e is running .

This symp to m somet imes indi cates tha t th e alter -

nator is not generating.

CD Check connectors

I OK
Bad ·1 Repair
I
® Check regulator Repair or replace
Bad
J OK

@ Check alternator

CD Check the alter nato r and regulator con necto r
for loose or bad connecti ons.
• light ly tap the alternato r and reg ulator con -
nector. It the charge lamp blinks, connector
co ntact is poo r.
If th e connecto r termina ls are not making
proper contact due to vib ration , the curr ent
to th e termina ls wi ll be int errup ted, so the
alternator w ill not be able to gen erate
power and the charge wa rnin g lamp w ill
come on.
® Check the contact co nd ition of each point of
the regulator and the resistance between each
terminal.
• M easure the resistance between each ter -
mi nal in accorda nce w ith the procedures
listed in th e repair manual. In parti cular,
check the con di tio n o f the hig h -speed
point and the resistor.
® Check the co ntact conditio n o f the brushes.
• Disassemble the alternator in accorda nce
w it h the pro cedur es listed in th e repair
man ual and chec k th e brush w ear and
co nt act condition of the slip rin gs.
It th e bru shes are worn beyond th e allow -
able l imit, spring tensio n w ill be redu ced,
causi ng poo r brush c ontact. If this hap -
pens, field current to t he rotor w il l be in -
terrup ted. and the alternator w ill not be
able to generate pow er, causing the
charge warn ing lam p to come on.

45
 TROUBL ESHO OTIN G - Al te rnator w it h Point Ty pe Regu lator

2. W eak (d isch arg ed) Batte r y

Th is prob lem wi ll occur wh en th e alternato r is not
generating sufficie nt current to re-charge the bat-
tery. As a result, the engine cannot be started w ith
the starter. In add ition, t he headlig hts w ill be dim.
Howe ver, because the alt ernator is sti ll generating
a litt le current, the charge wa rnin g lamp wi ll go
out aft er the engi ne is started.
As there are several po ssib le reasons w hy the al -
ternato r is not generating enough current , it is
im portant tha t proper tro ub lesho oting procedures
be fo llowed. The first thi ng to do is investig ate
how the vehicl e has been used (d riving co ndi-
tio ns). In order for the alternator to rech arge th e
battery, it is necessary that th e vehic le be driven
continuous ly for a ce rtai n lengt h of time. This is
especi ally tr ue at nig ht bec ause the batt ery w ill
no t be co mpletely recharged if the vehicle is fre-
quently driven for only short peri ods. This prob -
lem w il l also occur if the vehicle is equi pped w it h
several pow er co nsum mi ng accessories. In such
cases, it may be necessary to replace th e alterna-
tor wi th one of a larger capacity .

I
CD Check batt ery
Sad I
Clean or replace

1 OK
® Check drive belt

j OK
Sad 'I Adj ust or replac e
I
® Check reg ulator Ad j ust or replace
Sad
j OK
@ Check alternato r

CD Check the condition of th e batt ery. pin g if t he sides are w orn. In this case, the
• Check the batt ery termi nals for dirtiness belt should be replaced.)
and co rrosio n. If necessary, add elec-
® Check the standard vo ltag e of the reg ulato r
t rolyte.
(alt ernator output volta ge).
( Dirtiness or corro sion of the battery ter-
• Check that the output voltage o f th e alter-
minals w i ll cause increased resistance to
nator (vo ltage at termin al B) is wi thin
the flo w of current. A lso, if th e battery is
specification. Refer to " On- vehicl e ln .
very old , t he plates w ill self -discharge. In
spectio n".
t his case, it is recommend ed to replace t he
(If th e alternator o utput volta ge is less
battery w it h a new one.)
t han spec ified, there w il l not be suff icie nt
CV Check t he tension of the drive belt vol tage to recharge the battery. Under
• Check th e alternator drive belt for prop er normal conditions, th e batte ry vo ltage w ill
tensio n. be at least 13 V, so if the standard vo ltage
(A loose drive belt w i ll slip, preventing t he (alte rnato r ou tp ut volt age) is no t above
alt ernato r from tu rning fast enou gh to this amo un t, cu rrent w i ll n ot flow to the
generate suff icient electrici ty. Even w ith battery. A lso, if output volta ge is too low ,
correct belt tension , the belt may be sli p - current w ill not be able to flow to the
headlights, causing them to be dim.)

46
 TROU B l ESHOOT 1NG - Alterna tor with Poin t Type Reg ulator

@ Check the output current of the alternator.

• Check to see w hether the alternator out-
put current is with in speci ficat ion. Refer to
the " On -vehicle Inspecti on" ,
(The alternator utilize s diodes for rectify-
ing current. If there is a short or open ci r-
cuit. all of the current generated by the
stator coi l cannot be supplied to the bat -
tery.)

REF ERENCE - - - - - -- - - - - - - -- - - - - - - - - - --t--,

Of cou rse. alternato r outp ut volta ge and neutral
vo ltage can be measured w ith an ordi nary volt -
meter, but it can be don e more quickly and easi ly
w ith a Toyota Alternat or Checker (SST 0908 1·
0001 1) . With th is checker, the reg ulator can
also be checked by measuring the voltage at
terminal F.

If there is no problem w ith the diodes, the

neutral voltage at terminal N will be half of the
outp ut voltage. To perform a simple check,
com pare the vo ltage at the termina l N to the Alt ernator checker

normal vo ltage . and if the termin al N vo ltage is

higher, t he + diodes can be judged faulty. If,
H H

ho weve r, jud ged terminal N voltage is lower,

the "-" diodes can be j udged fau lty.

47
 TROUBLESHOOTING - Altern ato r w it h Poi nt Type Regul ator

3 . Overcharg ed Battery 4. Abnorm al Noise

Batte ry overcharging is ind icated by the necessit y Abnormal noise in t he charging system orig inates
to frequently add batt ery elect rolyte. w it h the alt ernator , There are tw o diff erent types
Also. headlight luminosity w ill change w ith en- of noises and these must be distinguished befo re
gine rpm . This problem is caused by excessively beginning troubleshoot ing:
high regulator standard vo ltage (alt ernator output
The f irst type of noise is mechanical noise caused
voltage) . If the output voltage of th e alternator is
either by the drive belt slipping at the alt ernator
greater tha n specifie d, th e batte ry w il l overcharge,
pu lley, or wo rn or damaged alternator bearings.
causi ng a rise in battery temperatu re and rapid
consumption of th e electrol yte. The seco nd type is magn etic resonance, caused
either by a layer short in the stator co il or faulty
In add ition, w hen the engi ne is runn ing at a high
d iodes. In t he case of mag netic resonance, radio
rpm, excessive current w i ll flow to the headlights
stat ic w ill oft en be synchronized wi th eng ine ro -
and th ey w ill shine brigh ter. In extreme cases,
tati on .
there w ill be so much current to the lamps that it
w ill cause the bulbs to burn out. Except for drive belt noise, it is necessary to disas-
semble the alternator , inspect each com po nent
Tro ubleshoot in g thi s prob lem involves measuring
and repair as necessary.
th e output voltage of the alternator and checking
and/or adjusti ng the regu lator. Refer to " On -ve-
hicle Inspect ion",

48
 TROUBLESHOOTING - Alt ernator wi th M -type IC Regula to r

ALTERNATOR WITH M -TVPE rc REGULATOR

Before assuming th at th e alt ernator w ith IC reg ulator is faulty. alw ays check th e fuses, w ire harness, and
connectors fi rst.

1. Ch arg e w arning lamp does not come on wh en ignition switch ed turn ed to ON .

Does engi ne start?

YES
Are the fuses and fusi ble li nks related to the charg ing
system and the charge wa rning lamp normal?
YES
A fter turni ng engi ne off.
discon nect 3 -pole
con nector. Turn igniti on
swi tc h to ON .

NO
Is t here batter y voltag e W ire harness is fault y.
at co nnecto r side IG
termin al?

YES
In above condition,
ground termin al L
of con necto r.

1 NO
Does charge warning lamp light up? W ire harness or lamp is faulty.
"-
YES
Reco nnect 3- po le connector.

/ Turn ign ition sw itch off. \

the n turn ign ition sw itch
back on and w iggl e 3 · pole
connecto r.

I YES
Does lamp glow ( 3-pole con necto r is faulty . )
bright ly or bli nk?

NO (lamp stays off )=-

(Repeat 2- 3 times.)
Regu lator is faul ty. )

49
 T RO U B LES H OOT IN G - Al ternator w ith M · type IC Regulator

2 . Charg e w a r ning la m p does n ot go o ut a fte r e ngi n e is started.

Charge wa rning lamp does not

go out after engine is started.
YES
<No load. engine at 2.000 rpm "
Is battery vol tage normal?
(Sta ndard value = 13.0 to 15.1 V)
Go to next page I Voltage normal
I
NO
I
Voltag e too low Voltage 10 0 hi gh
(1 3.0 V or lower) (15.2 V or hig her)

NO
W ire harness
Is there batt ery volt age at B terminal ? ~l or fuse ( Disconnect 3·pole connecto r. )
is faulty.
YES
Disconnect 3· pole conn ecto r. Is there batt ery
vol tage av
S terminal?
Is th ere batt ery voltage at NO W ire harness NO
f----I or fuse
YES
IG and S termi nals?
is faulty. ( W ire harness is faul ty )
I YES
/ Wi th engine running. connect \ ( Reconnect 3·pole connect or .
F terminal of alternato r (reg ulato r)
\ to gro und " I ITurn IG swi tch off .\
Th en start eng ine
and w igg le 3 · pole
YES \ connector. I
Does battery vo ltage rise?
NO I
Does battery
Is contact at alternato r
I N~ ( Wire harness is faulty . voltage fl uctuate?
YES
B termina l normal?
NO Repeat 2 3 times.
YES
Disconnect battery \i) terminal. )
I( 3. pole connector is faulty. )
L.-(Replace regulator. )
Is there con tinuity betw een NO I
W ire harness is faulty. ) Does the charge warning lamp
alternato r and battery?
stay on?
I YES YES
( Alternato r is faulty. )
Alternator is faulty .)

• The voltage w ill fluctuate w ild ly, so this should be do ne in a short time (within 30 seconds) .
However, if it rises to 20 V or greater, stop the test immediately.

50
 TROUBL ESHOOTIN G - Alternator wit h M ·type IC Regulator

Voltage is normal.

Charge w arning lamp Charge wa rning lamp

lig hts faintly. glo w s bright ly.

Turn IG switc h on after / Oisconnect a-cote connector after\

turning engine off . turni ng engine off , then tu rn
\ ignition sw itch to ON .
I
YES
I Does lamp glow brig htly?
I NO Does lamp glow brightly?~Y ES

Disconn ect 3·pole connecto r. ) NO

( W ire harness is faulty.)

Is L terminal voltage NO
~ W ire harness is faulty . Is 3- pole connect or vo lt age normal?
2 V or hig her?
S termin al: Battery voltag e
YES IG termin al: Battery vol tage
L terminal: 2 V or hi gher
(G round L terrntnat)
YES JNO
NO
( Wire harness is faulty.)
Does lamp glow brig ht ly? Wir e harness is faul ty.)
YES ( Recon nect S vpole co nnecto r.

<Reconnect 3-pole connector. )

Ij W ith ignition sw itch off, w iggle
\ Scpole connector, th en start the)
./ W ith ign ition sw itch off , \ engme.
start the engine and w iggle
\ 3·pole co nnector, I Repeat 2 - 3 times.
Does the charge warn ing lamp
YE Svpo !e connector ) go offl
Does lamp go off or bli nk ?
is faulty . jYES
No (lamp stays on.)
No (cont inues to glow dimly.)
( Co nnecto r or w ire
(Rep eat 2 - 3 ti rnes.) harness is faulty . ../
Regu lator is faulty.

Regu lator is faulty.

51
 TROUBL ESHOOTING - Al ternato r w ith M · type IC Regulator

3 . Exc essiv e c o nsu m p t io n of batte r y electro ly te

<No load. eng ine at 2,000 rpm.

j
Check battery voltage, Is it normal? YES
( Standard value: 13.0 to 15.1 V) I
Battery is at end of
No (voltage is too hig h [ 15.2 V or higher]. ) I service life or is faUlty"...,,)
Wigg le a- pole con necto r. YES '\
W ire harness is faulty. )
Does vo ltage fl uct uate?

NO
Is charge w arning lamp on?
YES
Replace regulator. )
NO
/ A fter turn ing off engine. discon nect \ I
a-pore co nnector and measure resistance Does t he charge w arning
betw een S termi nal and battery lamp stay on?
\ $ terminal. I I YES
Alt ernato r is fault y. )

Is resistance almost 0 ohm?

(About the same as when t here is a short ci rcuit)
NO
YES
Regulator is faulty, )

52
 ON -VEH ICLE IN S PECT IO N

ON-VEHICLE INSPECTION
O BJ ECTIVE To learn t he procedure for co mprehensive on -vehicle inspectio n of the
chargi ng system.
PREPARATIONS • Repair M anu al (for the model used in trainin g)
• SST
09081·00011 Al ternato r Checker
092 16 · 00020 Belt Tension Gauge (Reco m mended tool)
092 16 -00030 Belt Tension Gauge Cable (Recommende d tool)
l or Nippo nde nsc BTG-20 195506-000201, Bo rrough s No. BT-33-73FI
• Eng ine Tachome ter
• Circuit Tester (Volt- and Ohm me ter or M ult i-m eter )
• Ammeter (50 A)
• Battery Hydrom eter
APPLICABLEMOOEL Y series eng ine (A ug., 19851

PROCED URE: - - - - -- - - - - - - - - - - -- - - - - - - - ....,

If th e alternator is under charg ing or overcha rging and it is tho ug ht that th e charg ing system is faulty ,
the alt ernato r or regulato r shou ld not be immedi ately removed fro m the vehicle.
First. an on -v ehicle in spect ion shou ld be performed to determi ne w hether the cause is actually the
alt ernator on t he regu lator or if th ere is ano ther cause. Then the techn ici an should proceed to in spect ion
of individual co mpo nents.

CH ECK A N D I NSPECTI ON ITEM S

1 Check Batt ery Specific Gravity

2 Check Battery Terminals, Fusib le Links and Fuses
3 Inspect Drive Belt
4 Visually check A lte rnato r W iring and Listen for A bnormal Noises
5 Inspect Charge Warn ing Lig ht Circu it
6 Check Charging Circui t wi tho ut Load
7 Check Charging Circu it wi th Load

53
 ON -VEHICL E INS PECT ION

NOTICES WHEN HANDLING THE CHARGING SYSTEM

1) Be carefu l of th e polarity of t he battery. Do not co nnect th e battery wi th th e po les reversed .

2) Since batte ry vo ltag e is always ap plied to th e B term inal o f the alternator. th e B termin al must never
be ground ed .

3) If the batt ery is cha rged rap idl y using a q uick charger. it co uld d amage t he diod es. Be sure to
disco nnect the battery cab les whe n using a quick charger.

4) Be careful no t to get w ater on the alternator or other electrical components when wa shing the veh ic le.

5) The eng ine shou ld never be cranked w it h the B terminal of th e alt ernator disc onnected . Thi s is
bec ause vo ltage regulat ion is no t occ urring at suc h a time. so the neutral terminal voltage (the votteqe
at th e N terminal ) co u ld rise and bu rn out the relay co il. If th e B terminal is di sconnected, the wire
co nnec ted to the F termi nal (alternator co nnector) sho u ld always be disconnected too.

6) Th e alternator and reg ulator should be securely ground ed. If t hey are no t secu rely gro un d ed. it could
cause ove rcha rging. fli ckeri ng of th e lig hts. oscillati ng of the ammeter need le. etc.

7) A co ndenser shou ld never be con nec ted to th e F terminal to prevent noise. etc., as thi s co uld cause
a deposit to b uild u p on th e regulato r con tact poi nts .

8) The F term inal and IG termi nal sho u ld not be connected in reverse for any reason. If they are
connected in reverse, it co u ld ca use th e w ire harn ess to burn up.

9) Si nce the case of the f C regu lator shou ld have t he electrica l p otent ial o f gro und, be sure to tighten
the bo lts to t he alternator securely and make sure it is grounded.

54
ON -V EHICLE IN SP ECTION

1. CH ECK BATT ERY SP ECI FIC GR AVITY

(a) Chec k the specific gravity of each cell.
St and ard specific grav i t y
Wh en fully ch arg ed at 20"C (68"F): 1 .25 - 1. 27
(b) Check th e amou nt of electrolyte in each cell.
If insuff icient, refill w ith distilled (or purif ied ) w ater,

2. CHEC K BATTERY T ERM IN ALS. FUSIBLE LINKS

AND FUS ES
(a) Chec k that th e batt ery termin als are no t loose or
co rroded.
(b ) Check th e fusib le links and f uses to r co ntin uit y.

3. INSP ECT DRIV E BELT

(a) Visually check the belt for separati on of t he adhesive
rubber above and below th e core, core separating
from the belt side. severed core, separation of th e
ribs from th e adhesive ru bb er. cracking or separat ion
of the rib s, torn or w orn ri bs or cracks in t he inner
ridge s of th e ribs. If necessary, replace t he drive belt.

(b) Check th e drive belt def lection by pressing on the

belt at the point s ind icat ed in th e fig ure w it h 10 kg
(22.0 Ib ) of pressure.
Drive b elt d ef lec ti on:
New be lt 5 - 7 mm (0 .20 - 0.28 in .)
Used belt 7 - 8 mm (0 .28 - 0.31 in .)
If necessary. adjust the drive belt def lecti on

REFERENCE -----------~
Using the SST. che ck t he drive belt tension.
SST 09216 ·00020 and 09 216 ·00030
D rive b elt t ens io n :
New belt 53 - 73 kg
Used be lt 26 - 46 kg
If necessary, adj ust the drive belt tensio n.

55
 ON -V EHICL E IN SP ECTION

NOTE:
• " New belt " refers to a belt w hic h has been used less
th an 5 minutes on a running engine.
• " Used belt" refers to a belt w hich has been used on a
runni ng engine for 5 minutes or mo re.
• After installing the drive belt check to see th at it fit s
prope rly in the rib bed grooves .
CO RR ECT WRO NG
• Check w it h yo ur hand to confirm that t he belt has not
sli pped ou t of the grooves on th e bottom of the crank
pulley .
• After installing the be lt. run the eng ine for approx . 5
minutes and recheck the deflect io n or tensio n.

4. VISUALLY CHECK A LT ERNATOR WIRING AND

LISTEN FO R ABNORMAL NO ISES
(a) Check tha t the wiri ng is in good co ndition.
(b) Check that there are no abnormal no ises from the
alternator wh ile t he eng ine is running .

Hi-speed co m pact type

5. INSPECT CHARGE WARNING LA MP CIRCUIT

(a) W arm up th e engine and then turn if off .
(b) Turn off all accessories.
(c) Turn the ignition switch to " ON" . Check tha t the
charge warni ng lam p is lit.
(d) Start the eng ine. Check that the light goes out.
If th e lig ht does no t operate as specified, tro ublesho ot
t he cha rge w arn i ng lam p circuit.

56
 ON -VEHICLE IN S PECT IO N

6. CHECK CHARGING CIRCUIT WITHOUT LOA D

Ammeter
NOTE: If a battery/alte rnato r tester is available, con -
-i<..-"~=b~A~I~
lern ator nect the tester to th e ch arging circu it as per manufac -
B tur er's instruc tions.
o (a) If such a tester is not available. con nect a voltmeter
o and ammeter to the ch arging circ uit as foll ow s:
~

Battery : • Disco nnect the w ire from termi nal B of the alter-
~

nator and connect it to the negative probe o f Ihe

.I am meter.
• Co nnect the test probe from the po sitive termi nal
o f th e ammeter to termin al B of t he alte rnato r.
• Co nnect the positi ve probe of th e vo ltme ter to
term inal B of th e alte rnato r.
• Connect the negative probe of th e vo lt meter to
gro und.

w /o Ie Regulator (b) Check t he charging cir cu it as foll ow s:

With the engi ne running from idle to 2,000 rpm,
check the read ing on the ammeter and voltmeter.

~
\O. 2P JO"o
Without I C Regu lator
- "" .'tJ Stand ard am pe ra ge: Less than 10 A
Stand ard vo ltag e: 13 .8 - 14 .8 V at 2S·C (77·F)
,

' -- - - - - - - - -O HP 35

w /o Ie Regulator ' If t he vol tag e reading is no t w ithi n standard. adjust th e

reg ulator or replace it.

w I Ie Regu la t o r W ith IC Regu l ator

Stand ard am pe ra ge: Less than 10 A
14 15 Stand ard vol t ag e:
H i -speed compact type
13.5 - 15,1 Vat 25'C In 'F)
If the voltage readi ng is greater than standard replace the
IC regu lator.

' -- - - - - - - - - OHP 35
57
 ON -V EHI C LE IN S P ECTI ON

w I Ie Re gula t or It the voltage reading is less than stand ard. check the Ie
(co nvention a l type) regu lator and alte rnato r as foll ows:
Terminal F • W it h termi nal F gro unded. start the eng ine and
check the voltage reading of termin al B.

'--- - - - - - - - -'--OHP 35

' - -- - - - - - - - OHP 35
• If the vol tage reading is greater than standard
vo ltage. replace the Ie regulator.
• If the vo ltage readin g is less th an standard. ch eck
the alt ernato r.

7. C HE C K CH ARGING CIRCUIT WITH LOAD

(a) With the engine running at 2,000 rpm, turn on th e
hi qh -beam headli ght s and place the heater fan con -
trol sw itch 10 "H I".
(b) Check the readi ng on the ammeter.
St andard amperage: More than 30 A

If the ammete r reading is less than 30 A. repair the alte r-

20 nato r,
30
NOTE: Wi th th e batt ery full y charged. the indication
will sometimes be less than 30 A

58
 ON -VEH ICLE INSPECTION - Inspection of Al ternato r Regulator

IN SPECTI ON O F ALTERNATOR
o
T ype A T ype B
REGULATOR
~ 1 . REMOVE ALTERNATOR REGULATOR COVER
~

2. INSPECT POI NT SUR FAC ES FO R BURN ING OR

DAM AGE
If defective. replace t he regu lator.

3. INSPECT RESISTANCE BETWEEN TERMINALS

(a) Using an ohmmeter. measure the resistance between
terminals IG and F.
o Resi stanc e (vo ltage r egu l ator) :
At rest 0 n
Pu ll ed in App r o x . 11 n

(b) Using an ohmm eter. measure the resistance betw een

termin als L and E.
Resi st anc e (vo lt ag e re g u la t or ):
A t rest 0 n
Pulled in A pp ro x . 100 n

(c) Using an ohmmeter. measure the resistance betw een

termin als B and E.
Resist ance (voltag e r el ay ) :
At rest Infin ity
Pull ed i n Approx . 100 {}

59
 ON -VEHICLE INSPECTION - Inspection o f A lternato r Regulator

(d) Using an ohm meter, measure the resistance be-

tw een terminals B and L.
Resi st an c e (vo lt ag e r elay) :
At rest Infinity
Pu lle d i n Appro x . 0 n

(e) Using an ohm meter, measure the resistance be-

tween terminals Nand E.
App rox . 24 Q
o Resi st an c e:
If any of the above checks are not posit ive, replace the
alternator regulator.

4. ADJUST VOLTAG E REGULATOR

(a) Ad j ust the vo ltage regulato r by bending t he regula-
tor adjusting arm.
St and ard voltag e : 13 .8 - 14 .8 V

(b) Ad just th e voltage relay by bendi ng t he relay adj ust -

ing arm.
Rel ay ac t u a t i n g vo ltage : 4.0 - 5.8 V

5. INSTALL A LT ERNATOR REGULATOR CO V ER

60
 ON -V EHICLE IN SPECTI ON -el nspection of Ignition M ain Relay

2 IN SPECTI O N O F IG NITIO N MAIN

RELAY

4 3

1 . IN SP ECT RELAY C ONT IN UITY

No co ntinu ity Contln uitv
(a) Check that th ere is contin uity between terminals 1 and
III n 1 I, ~~ 3.

I ii °II::' LOo~, (b ) Check that there is no continuity between terminals 2

and 4,
If co ntinuity is not as specified, replace the relay.

~
"- -
' >...P

Conti nu ity 2. INSP ECT RELAY O PERATIO N

: n : (a) Apply batt ery voltage across terminals 1 and 3.
0
(b) Check t hat th ere is cont inuity betw een terminals 2 and
O ..0~ h 4.
If continuity is not as specified. replace th e relay.

®
\ @: I~

61
 OV ERHAU L

OVERHAUL
O BJECTIVE To learn how to overhaul t he alt ernator and regulator
PREPARATIO NS • Repair Ma nua l (fo r the model used in traini ng)
• SST
09285 -76010 Injection Pump Camshafl Bearin g Con e ( fo r rotor rear
bearing replacement)
09286 -46011 Injecti on Pump Spline Shaft Puller
( fo r rear bearing removal)
09608 ·20012 Front Hub & Drive Pinion Bearing Too l Set ( fo r alte rnator
rear bearing remo val)
09820 -63010 A lternato r Pulley Set Nut W rench Set ( for com pact
alt ernato r only )
09820 ·0002 1 A lterna tor Rear Bearing Puller (for compac t alte rnato r on ly )
• Electrical Solder
• Circu it Tester (Volt -and Ohmmeter, Multi -me ter)
• Vernier Calipers 32.5 mm (1 .280 in)
• Torq ue W rench 1.125 kg -em (29 It-Ib, 110 Nm)
• H igh -t emp erature Grease

Convent ion al type

Fl-
~ L
~
,

t~
B l IG B
Ig nition
~

B~@
main
relay 3 4 F_f
~

1t~~ U
Hi -speed compact typ e
- A lternator Aile rnator -
regulator

r::>1

~Ll
1-

~
"
/g n,ition (

•
malO
relay 3
L
njL"'L
.L "
_ ~o ,

- - Alternato r -•

62
 QVERHAUl - Pre-in spection
PRE-INSPECTION
Before d isassemb li ng the alternat or. perform the
follow in g pre-ch ecks. The results of these pre-
checks will prove helpful w hen in spec ting each
ind iv idual co mpo nent later on.
1 . A BN ORM A L N OI SE TEST
Turn t he alt ernato r by hand. Check for smoo th
rotatio n and listen for any abnormal noise.
The alternator has bearing s i nside, If these bear-
ings are damaged i n some wa y, t he alte rnato r wi ll
no t tu rn smo ot hly and you w ill hear a noise. A lso.
you can tell to some extent if the bru shes or slip
ring s are damaged by turn ing the alt ernator .
Thi s same test should also be done aft er reassem -
bli ng the alte rnator to ch eck that it has been re-
assembled properly .
2. CON TINU IT Y TEST
The circuit tester utilizes dry celt batteries. A very
small amou nt of current wi ll flow whe n t he tester
probes make c ontact w it h the cir cuit to be tested.
and the resistance value of the circui t can be mea-
sured by the extent of th is current.
NEGATIVE SIDE RECTIFIER SHORT TEST
By checking the continuity betwee n termina ls N
and E of the alternator, it is possible to find out if
t he positive side diodes are short-ci rcuited or not.
The circ uit tester uti lizes dry celt batte ries. A very
small amou nt of current w ill flow whe n th e tester
prob es make contact w ith the ci rcuit to be tested.
and the resistance value of the circu it can be mea-
sured by measuri ng the amo unt of this cu rrent.
W hen the tw o tester probes make contact w ith
terminals N and E o f the alternator, the ind icator
needle o f the tester mayor may not fluc tua te,
depending on w hether or not there is batte ry cur-
rent fl ow ing .
63
 OVERHAU L - Pre-inspect ion

W hen the posit iv e pro ve is touched to term inal N
and the negati ve probe to term inal E, there w ill
be a flow of battery current and the tester needl e
w ill sw ing to w ard s zero if t here is conti nuity
between all diodes on the negative side.
Conversely. if there is no co nti nuit y betw een the
negative side diodes. no batt ery cu rrent w il l fl ow
w hen the negative pro be is touc hed to terminal N
and the po sit ive probe is tou c hed to terminal E. If
t he tester need le d oes move. it means that th ere is
curr ent fl owing and t here are one or more short-
circuit ed di od es on the neg ative sid e.

If the diodes are normal. c urrent w i ll fl ow in one

direct io n on ly. If c urrent flows in bo th d irect ion s,
the di odes are defect ive and this is called a short -
ci rc uit. On th e ot her hand. if current d oes not f low

:r
00 0
N in either directio n. it is called an open cir cu it.

• ("
ir=. 00 0

~
N

If..
F
+
, :::!..J
OHP 36

If..
F
,
OHP 36

o
e @
n
e '"
OHP 36

NOTE: T h e amou n t of c urre nt , that is th e REFERE NCE - - - - - - - -_____

res istance of t he diod es. w ill W hen m easurin g res ista nce w ith a ci rc u it
c h an ge. d epe n d i ng o n th e se lected tester, th e cu rrent is o utp ut t h ro ugh t he neg -
ra n ge of the c i rcuit teste r. Th ere - ativ e term i nal if an ana log teste r is use d. On
f o re, it i s difficu l t to te ll if a s em i- so me d igita l testers, the c u rrent is out pu t
co nductor. such as a diode. is bad or t h ro ug h the po sitive termi n al.
n o t by th e r esist an c e v alu e al o ne. W ith m o st d igital teste rs , the ran g e fo r
diodes m ust b e se lected be fore a d io de can
be tested.

64
 OVERHA U L - Pre-inspect io n
POSITI VE SiDE RECT IF IER SHO RT
CIRC UIT TEST
You can find out of if there is a short circuit in t he
po sit iv e side di odes by checking t he continuity
betw een terminals N and B of the alternator.
If all the diodes on t he po sitive sid e are norm al.
the tester needl e wi ll not mo ve w hen th e negative
tester probe is to uc hed to termi nal B and the pos-
it ive probe to termi nal N. If the needle does move,
th at is, if there is co ntinuity, a sho rt ci rcuit is lndi -
cated in the po sitive sid e dio des.
ec
I
o
" <!J
If th e po sit ive tester prob e is touch ed to terminal
B and th e negative probe to termina l N, battery
current w ill flow and the tester needle w il l sw ing
to zero under normal con ditions. In other words,
there w i ll be co nt inu ity between termi nals B and
N.
However, if there is an open ci rcuit betw een all
the positive side diod es (thoug h th is rarely hap -
pens). the tester needle w ill no t move w hen the
probes are touc hed to the terminals. In thi s case,
the charg e wa rni ng lamp will go out just as w hen
the engine is started, but the battery w il l not be
recharg ed because there is no output current from
termin al B of the alternator.
ROTO R CO IL RESISTAN C E T EST
By checking for continuity between terminals F
and E of the alterna tor, yo u can f ind out whet her
or no t t here is an open in t he rotor coil or if ther e
is bad co nt act betw een th e bru shes and slip rin gs,
" ==<N
--:;;
00 0
rr==
If.
F
c QHP 36
E n
<!J
"
As field cur rent for the rotor coi l is flo w in g in the
ci rcuit betwee n termin als F and E, th ere should be
continu ity betw een these tw o termina ls, and the
resistanc e value sho uld be arou nd 4 o hms.
If th ere is no cont inu ity, th ere is either an open in
th e rot or coil or poo r contact betw een the bru shes
and slip rings.
With th is test, the posi tiv e and negative prob es
may touch either terminal Ear F. In other words.
because th e rotor co il is not a semiconduc tor,
tester battery current can flow in eith er d irectio n.
65
 OVERHAU L - A lternator (Co nven tional Type)

ALTERNATOR ( Co nvent i o nal Type )

• Y series engine (Aug ., 1985)
COMPONENTS

Spacer ring
Fan (for 50 A and 55 A typ es) (for 50 A and 55 A types) Rear bearing

Drive end frame Rotor

Spacer co llar Prom bearing Snap ring

..,
Stator
Rect ifier end frame
Spacer ring Terminal insulato r
1 (for 40 A and 45 A types)
In sulator w asher
Recti fier holder 1 .. .' ..
b Q

(w / o rc regul ator) 0 ' ~ .-1.::>'",,-

Spring " ~

(~:,": v ¥I Condenser
Fan A and 45 A types) BUrg1"" .l ' .'
!:r' ~~ 0
Lead w ire cli p

Rect ifi er ho ld er
(wI IC regulator)
~ r:::JP-
-W ~ IC regulalor

MAIN PO INT IN ALT ERN A TO R OV ERHAU L

DI SASS EMBLY OF ALT ERNATOR
1. REM OVE ORIVE ENO FRAME AN O ROT OR
ASSEMBLY FROM STATOR
(a) Remove the th ree throu gh screws .

(b ) Using a screw driver. pry th e end frame and remove

it tog ether w ith the rotor.
NOTICE: 00 not pry on th e c o il w ir es .
2. REMOVE RECTIFIER HOLDER
Hold t he recti fier terminal w it h needle-no se pliers and
un solder the leads.
NOTICE: Protect t he re c tifi er fr om he at .
As the rectifi er is very se ns it ive to heat , a lw a ys
us e ne edle -nose p liers to p rot e ct it when so lde r-
in g as s hown t o th e le ft . Also, c arry o ut th e s o l-
dering as qu ic kly a s po ss ibl e to preven t th e rect i-
fi er from over heat ing .

66
 OVERHAUl - Al ternator (Con ventional Type)

INSP ECTION OF ALTERNATOR

Rotor
1. INSPECT ROTOR FOR OPEN CIRCU IT
Using an ohmmeter, check that there is conti nuity be-
twee n th e slip rings.
St and ard r esi stance (co ld) :
w l o Ie Regu lator 3.9 - 4 .1 Q
Con tinui ty w i IC Regul ator 2.8 - 3.0 Q
' - - - - - - - - - -OHP 37 If there is no co nt inuity, repl ace the rotor .

2. IN SPECT THAT ROTOR IS GROUNDED

Usi ng an ohm meter, check that the re is no continuity
between the sli p ring and the rot or.
If there is contin uity, replace the rotor .

No cont inu ity

' -- - - - - - - - - OHP 37
3. INSPECT SLIP RINGS
(a) Check tha t the sl ip rings are no t rough or sc ored.
If roug h or scored, replace the rotor.
(b) Using calipers, measure the sli p ring d iameter.
Stand ard dia met er : 32 .3 - 32.5 mm
(1 .272 - 1.280 in .)
M inimu m d iam ete r : 32 ,1 m m (1 .264 in .)
If th e dia meter is less than min im um, replace the rotor,

Stato r
1, INS PECT STATOR FOR OPEN CIRCU IT
Using an oh mmeter, che ck that t here is cont inuity be-
tw een the coil leads.
If there is no con ti nuity, replace th e stator.

2. INS PECT T HAT STATOR IS GRO UNDED

Using an ohmmeter, check that there is no con tinuity
betw een the coil leads and stator co re.
If there is continuity, repl ace t he stator.

No co nt in uity

67
 OV ERH A U L - A lt ernator (Co nventi o nal Type)

Brushes
1. M EA SUR E EX PO SE D B RUS H LENGTH
Using a scale. measure the leng th of the exposed brush.
St and ar d ex p ose d len g t h :
w l o Ie Regu lat o r 12.5 mm (0.492 i n .)
w I Ie Regul at o r 1 6.5 m m (0.650 in .)
M i n imu m ex p osed len g t h : 5 .5 mm (0 .217 i n .)
If the length is less than minimu m. replace th e brushes.

2. IF N EC ES SAR Y , RE PL A C E B R U S H ES
(a) Unsolder and remo ve the brush and spring.

( b) Insert the brush w ire throug h the spring.

(e ) Install th e brush in the brush ho lder.
(d) Solder th e wi re to the brush holder at spec ifield
exposed length.
Exposed len g t h :
w l o IC Regul ato r 1 2.5 m m (0 .492 in .)
w I IC Regulat or 16.5 mm (0.650 in .)
(e) Check that th e brush moves smo ot hly in the brush
hold er.
(f) Cut off any excess w ire.
40 A and 45 A types
Rec tifi ers (R ectifi er Hold er)
Rect ifie r terminals 1. IN S PECT POSITIVE RECT I FIER
(a) Using an oh mmeter, co nnect the one test probe to
each recti fier termin al and the other to pos itive ter-
Ohmmeter
minal.
(b) Reverse the polarity of the prob es. and repeat step
Pcsiti....e ( +
terminal
) _J:c:5;;;;;""'~ (a) .
(stud bolt) "'",",' (c) Check that one sho w s contin ulrv and t he other
sho ws no con tinuity .

50 A and 55 A types
If con ti nui ty is not as specified. replace the rect ifier
hol der.
Rectif ier terminal

Ohmmeter
I
I

Positiv e ( + ) terminal
(stud bolt head) OHP 38

68
 OV ERHAUl - A ltern ator (Convent ional Typ e)

40 A a nd 45 A t ype s 2. INSPECT NEG ATIVE RECTIFIER

Rectif ier terminals
Ln ] (a) Using an ohmmeter, connect t he one test probe to
each rectifier terminal and the oth er to the negati ve
,O ,"It---.. termi nal.
I _ d
1'.
(b) Reverse the polarity of the test probes, and repeat
Ohmm eter step (a) .
(c) Check that one shows co ntin uity and t he other
sho w s no conti nuity.
If conti nuit y is no t as specif ied, replace t he recti fier
holder.

50 A a nd 55 A types [ n J
Recti f ier termi nals r - 0'
10 ©
o - t- - - ,

l---EI
Ohmmeter

Be arin g s
1. INSP ECT REAR BEAR ING
Check th at the bearing is not roug h or w orn ,

2. IF NECE SSARY, REPLACE REAR BEARING

(a) Using the SST, remov e th e bearing.
SS T 09286·46011

(b) Usi ng a press, press in a new bearing .

69
 OVERH A UL - Alternator (Convent ional Type)

ASSEMBLY OF ALTERNATOR
1. INSTALL RECTI FIER HOLO ER TO STATOR
Hold th e rectifier terminal with needle- nose pliers whi le
soldering the leads.
NOTICE: Prot ect t he rect ifier f r o m heat.

2. ASSEMBLE ORIVE ENO FRAME A NO RECTI FIER

END FRAME
(a ) Bend the rectif ier lead wires back to clear th e rotor,
(b) Using a curved tool, push the brushes in as far as
they w il l go and hold them in place by inserting a
st iff w ire th rough the access hole in the rect ifi er end
frame.

(c) Assemble t he drive end frame and th e recti fier end

frame by inserting the rear bearing on th e rotor shaft
into the rectifier end frame.

(d) Install th e th ree th roug h screws .

(e) Remove the stiff w ire from the access hole.

(f) Check that the rotor rotates smoothly.

(g) Seal the access hole.

70
 OVERHAUL - Alternator (Hi -speed Co mpact Type)

ALTERNATOR (Hi -speed Compact Ty p e)

• V series engine (Aug., 1985)
COMPON ENTS

40 A a nd 45 A types
Drive end lram~ront bea,;ng ~
Roto, Rea'ta';,
n
g
i
I ~ ..
Retainer ' . ~
F { '. . Wave was her
~~ Beertnq cover

Brush ho lder
(w ith cover )
Ie regulalor

Terminal insu lator -------'\1

.
Rect if ier holder
\ - -- Rear end cover

Rect if ier end frame

Brush

Here w e wi ll discu ss only those parts of th e pro cedure

that di ffer from t hat for the conventional type alternator.

DISASSE MBLY OF ALTERNATOR

SST (B)~ SST (A) REMOV E PULLEY

(a) Ho ld SST (A) wi th a torque w rench. and tighten
SST ( B) clo ckw ise to the specified torque.

/~'0
- J SST D9820 -63010
To rqu e: 400 kg -em (29 It- lb. 39 N -m)
(b) Check that SST ( A) is secured to the rotor shaft.

(c) A s sho wn in the figu re. mou nt SST (C) in a vise. and
install the alternator to SST (C) .
(d ) To loosen the pulley nut turn SST (A) in t he direc-
tion sho w n in the figure.
NOTICE: T o prevent d am ag e to th e r oto r
sh aft. do not lo o sen t he pull ey nut more that on e-
half o f a turn .
(e) Remove th e alternator from SST (C) .
(f) Turn SST ( 6 ) and remove SSTs (A) and ( 6 ) .
(g ) Remove the pull ey nut and pu lley.
71
 OV ERHAUL - Alt ernator ( Hi-speed Compact Type)

IN SP ECT ION ANO REPAIR O F A LT ERNATOR

Ro t o r. stat or. & Rec ti f ier
Inspection of the rotor, stator, and recti fier is the same as
for the alternato r w ithout IC reg ulator.

Bru sh es
1. M EAS U RE EXPOS ED BRUS H LENGTH
Using a scale. measure th e lengt h of the exposed brush.
St andar d ex p osed l en gth : 10.5 mm (0.413 i n .)
Minimum ex p osed len g th : 4.5 mm (0 .177 ln .]
If t he exposed length is less than minimum, replace the
brushes.

2. IF N ECESSARY. REPLA CE BRU SHES

(a) Unsold er and remov e the brush and spring .
(b) Run the w ire of t he brush throug h the hole in th e
brush holder. and insert the spring and brush into
the brush hol der.

(c) Solder the brush w ire to the brush hold er at t he

exposed length .
Expos ed len gth: 10.5 mm (0 .413 in .)
(d) Check th at t he brush moves smoo thly in the brush
holder.
(e ) Cut off the excess wire.
(f) Ap ply insulation paint to t he soldered poi nt.

Bea rin g s
1. IN SPECT REAR BEARING
Check that the bearing is not rough or wo rn.

2. IF N ECESSARY, REPLAC E B EARIN G

(a) Using t he SST, remove t he bearing cove r and cov er.
SST 09820 -00021
NOTICE: Be carefu l not to d am ag e t he f an.
(b) Using th e SST and a press, press in the bearing and
bearing cover.
SST 09 285-76010

72
 OVER HA UL - Alternator ( Hi -speed Comp act Type)

ASSEMBLY O F A LT ERNAT O R
1. INSTA LL PULLEY
(a) Install the pulley to th e rot or shaft by tig htening the
pulley nut by hand.
(b) Hold SST (A) w ith a torque wrench. and tighte n
SST ( 8) clockw ise to t he specified torque.
SST 09820 -63010
Torq ue: 400 kg- em (29 ft -Ib, 39 N -m ]
(c) Check that SST (A ) is secured to the pulley shaft.
(d ) As shown in the fig ure. mount SST (C) in a vise. and

,.~ install the alterna tor to SST ( C) .

(e) To tighten the pulley nut, tu rn SST (A) in the direc -
tion show n in the figure.

SST (C)
ill Torq ue: 1.1 25 kg -em (81 It -l b. 110 N'm )
(f ) Remove th e alternator from SST (C) .
(g) Turn SST ( B) and remove SSTs (A and B).

2. INSTALL BRU SH HOLOER A N D rc REGUL ATOR

(a) Install the brush holder cover to t he brush holder.
(b) Install the Ie regulato r toget her wi th t he brush
holder as shown,

~~~~~~::"BrUSh
), holder
Ie regulator -

(c) Install the fiv e screws ,

(d) Check that the clearance betwee n th e brush holder
and th e connecto r is 1 mm (0,04 in.) or more.

(e) Install the brush holder cover to th e rear end frame.

73
 @TOYOTA L..- _
~

OVERSEAS SERVICE DIVISION

TOYOTA MOTOR CORPORATION
PAINTED IN JAPAN rn
900 2·N4-0 109 NAME