Page 64 of 800
CHARGING SYSTEM
ENGINE ELECTRICAL16-2
CHARGING SYSTEM
GENERAL INFORMATIONM1161000100522
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.
OPERATION
AKX00183
VoltageTime
Approximately
14.4 V
AC
Rota tion of the excited fi eld coil gene rates AC volt-
age in the sta t or .
This alternatin g cur r ent is rectified throu gh diodes to
DC volt
age h a ving a waveform sh own in t he illustra
-
tion.
The average outpu t volt a ge flu c tua t es slightly with
the alternato
r load con d ition.
When the ign i tion switch is t u rned on, current flows in
the field coil and initial e
x cit a tion of the field coil
occurs.
When the st ator coil beg ins to gen erate p o wer af ter
the eng
ine is st a r ted, th e fie l d coil is excited by th e
output
curren t of th e st ator coil.
The alternator outpu t volt a ge rises as th e fie l d cur-
rent increa ses and it falls a s the field cu rrent
decre
ases. Whe n the b a ttery volt a ge (alternato r "S"
terminal volt
ag e) reaches a regulated volt ag e of
approximately 14.4
V , the field current is cut o f f.
When th
e batte ry volt age drop s be low the regulated
volt
ag e, the volt ag e regulator re gulat es th e outp u t
volt
ag e to a const ant level by contro lling the field cur
-
rent.
In addition, when th e fie l d current is const a n t, the
altern
ator ou tput volt age rise s as the e ngine spe ed
increase
s .
SYSTEM DIAGRAM
AK400308
Alternator
B
Stator coil
Engine-ECU or
Engine-A/T-ECU
G
SL
FR
<4G1>
Voltage regulator Charge warning lightIgnition switch
Battery
Field coil
+
–
AB
AL TERNA T O R SPECIFICA T IONS
Item4G14G6
Ty p eBattery voltage sensing
Rated output V/A12/8012/110
Voltage regulatorElectronic built-in type
Page 73 of 800
CHARGING SYSTEM
ENGINE ELECTRICAL16-11
Example 3
AKX00193
Broken wire in
stator coil
Examp l e 4
AKX00194
Shor t in st ator
coil
Exampl e 5
AKX00195
At this time, the charg i ng warn ing lamp is illuminated .
Open
suppleme
n t a ry
d
i ode
Abn o rm al waveform P roble m caus e
Page 76 of 800
Page 78 of 800
Page 79 of 800
CHARGING SYSTEM
ENGINE ELECTRICAL16-17
>>B<< ROTOR INSTALLATION
AK202779
Wire
AB
Remove the br ush holding wire af ter the rotor ha s
been inst
alled.
INSPECTION
M1161 0017 0015 2
ROTO R
AK202735
1. Measure th e resist a n ce b e tween the two slip rings
of the rot o r coil to check t he co ntinu i ty between
th em.
Repla c e th e r o to r if th e resist ance is no t within the
st
a ndard valu e range .
St andard va lue: 3 − 5 Ω
2.Check t he co ntinu i ty between the slip rings and
core.
AK202736
3. If cont inuity is pre s ent, repla c e th e rotor .
STA T OR
AK202716
1.Check t he co ntinu i ty between coil le ads.
If there is no con t inuity , replace the st a t or .
AK202717
2.Check t he co ntinu i ty between coil and core .
If there is no con t inuity , replace the st a t or .
RECTIFIER ASSEBMLY
AK202803
1.Check t he co ndition o f the (+) h eat sink by
checkin g contin uity be twe en t he (+) heat sink and
e a ch o f the st a t or coil lead conn ecting termina l s.
If cont inuity is pre s ent for both terminals, the
d
i ode is shorte d. Repla c e th e rectifie r assembly .
Page 81 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-19
STARTING SYSTEM
GENERAL INFORMATIONM1162000100202
If the ignition switch is turned to the "START" posi-
tion, current flows in the pull-in and holding coils pro-
vided inside magnetic switch, attracting the plunger,
When the plunger is attracted, the lever connected to
the plunger is actuated to engage the starter clutch.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
When the ignition switch is returned to the "ON" posi-
tion after starting the engine, the starter clutch is dis-
engaged from the ring gear.
An overrunning clutch is provided between the pinion
and the armature shaft, to prevent damage to the
starter.
SYSTEM DIAGRAM
AK202970
Pull-in coilHolding coil
Plunger
Lever
Pinion gear
Overrunning clutch
Yo k e
Brush Armature
Ignition switch
Battery
+
–
AB
B
M S
Page 85 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-23
STARTER MOTOR ASSEMBLY INSPECTION
M1162001100205
PINION GAP ADJUSTMENT
AK300648AB
<4G1>
Switch
S M
Wire Battery
Starter
motor
B
AKX01238
<4G6>
B
M S
battery Switch
Starter
motorWire
AG
1.
Disco nnect the field coil wire f r om th e M-te rmin al
of the magnet ic switch.
2.Conn ect a 12-volt b a ttery between the S-termina l
an d M-t e rminal.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.
AKX00198
Stopper
Pinion gap
Pinion
AC
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge.
Standard value: 0.5 − 2.0 mm
AKX00199
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the
magnetic switch and front bracket.
MAGNETIC SWITCH PULL-IN TEST
AK300649AB
<4G1>
SM
Wire Battery
Starter
motor
B
AKX01242
<4G6>
SB
M
Battery
Starter
motorWire
AF
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the magnetic switch.
Page 86 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-24
MAGNETIC SWITCH HOLD-IN TEST
AK300650AB
<4G1>S
B MWire
Battery
Starter
motor
AKX01244
<4G6>
SB
M
Battery
Starter
motorWire
AF
1.
Disco nnect the field coil wire f r om th e M-te rmin al
of the magnet ic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper position.
4. If the pinion remains out, everything is in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
FREE RUNNING TEST
AK300651AB
<4G1>
S
A
M
V
B
Carbon-pile rheostat
Battery
Voltmeter Ammeter
Starter
motor
AKX01246
<4G6> S
M B Ammeter
Carbon-pile
rheostat
Battery
Starter
motor Voltmeter
AF
A
V
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the battery
(+) terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery c able from the battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns
smoothly and freely.
Current:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
