Starting & Charging System
Starting & Charging System
Starting & Charging System
SECTION SC MA
EM
LC
EC
CONTENTS FE
EL
IDX
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG”
SC-2
BATTERY
How to Handle Battery
LC
METHODS OF PREVENTING OVER-DISCHARGE NMSC0003S01
The following precautions must be taken to prevent over-discharg- EC
ing a battery.
I The battery surface (particularly its top) should always be kept
clean and dry. FE
I The terminal connections should be clean and tight.
I At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance” CL
and “maintenance-free”.
MEL040F
MT
I When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal. AT
PD
AX
SU
MEL041F
RS
BT
MEL042F
IDX
SC-3
BATTERY
How to Handle Battery (Cont’d)
I Remove the cell plug using a suitable tool.
I Add distilled water up to the MAX level.
MEL043F
Sulphation NMSC0003S0201
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been “sulphated”, note its volt-
age and current when charging it. As shown in the figure, less
current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into ser-
vice by means of a long, slow charge, 12 hours or more, fol-
lowed by a battery capacity test.
SEL709E
MEL042FA
SC-4
BATTERY
How to Handle Battery (Cont’d)
GI
MA
EM
LC
EC
FE
SEL007Z CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
HA
EL
IDX
SC-5
BATTERY
Battery Test and Charging Chart
SEL754W
SC-6
BATTERY
Battery Test and Charging Chart (Cont’d)
CHART II NMSC0017S02
GI
MA
EM
LC
EC
FE
CL
MT
AT
SEL755W
PD
*: SC-6
AX
I Check battery type and determine the specified current using the following table.
SU
Fig. 1 Discharging Current (Load Tester) NMSC0017S0201
34B19R(L) 99 ST
46B24R(L) 135
55B24R(L) 135 RS
50D23R(L) 150
55D23R(L) 180 BT
65D26R(L) 195
80D26R(L) 195 HA
75D31R(L) 210
95D31R(L) 240
115D31R(L) 240
EL
95E41R(L) 300
130E41R(L) 330
IDX
SC-7
BATTERY
Battery Test and Charging Chart (Cont’d)
A: SLOW CHARGE NMSC0017S03
SEL756W
BATTERY TYPE
130E41R(L)
115D31R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
CON-VERTED SPE-
CIFIC GRAVITY
9.0 14.0
Below 1.100 4.0 (A) 5.0 (A) 7.0 (A) 8.0 (A) 10.0 (A)
(A) (A)
I Check battery type and determine the specified current using the table shown above.
I After starting charging, adjustment of charging current is not necessary.
SC-8
BATTERY
Battery Test and Charging Chart (Cont’d)
Fig. 3 Additional Charge (Slow Charge) =NMSC0017S0302
GI
MA
EM
LC
SEL757W
*: SC-7 EC
CAUTION: FE
I Set charging current to value specified in Fig. 2. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged. CL
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its MT
temperature is below 60°C (140°F).
B: STANDARD CHARGE NMSC0017S04
AT
PD
AX
SU
BR
ST
RS
SEL758W BT
EL
IDX
SC-9
BATTERY
Battery Test and Charging Chart (Cont’d)
Fig. 4 Initial Charging Current Setting (Standard Charge) =NMSC0017S0401
BATTERY TYPE
130E41R(L)
115D31R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
CON-VERTED SPE-
CIFIC GRAVITY
8.0 13.0
1.100 - 1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A)
(A) (A)
7.0 11.0
1.130 - 1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 8.0 (A)
(A) (A)
6.0 9.0
1.160 - 1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 7.0 (A)
(A) (A)
5.0 7.0
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A)
(A) (A)
I Check battery type and determine the specified current using the table shown above.
I After starting charging, adjustment of charging current is not necessary.
Fig. 5 Additional Charge (Standard Charge) NMSC0017S0402
SEL759W
*: SC-7
CAUTION:
I Do not use standard charge method on a battery whose specific gravity is less than 1.100.
I Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).
SC-10
BATTERY
Battery Test and Charging Chart (Cont’d)
C: QUICK CHARGE =NMSC0017S05
GI
MA
EM
LC
SEL760W
*: SC-7 EC
Fig. 6 Initial Charging Current Setting and Charging Time (Quick Charge) NMSC0017S0501
FE
130E41R(L)
115D31R(L)
50D23R(L)
55D23R(L)
65D26R(L)
80D26R(L)
75D31R(L)
95D31R(L)
28B19R(L)
34B19R(L)
46B24R(L)
55B24R(L)
95E41R(L)
CL
BATTERY TYPE
MT
CURRENT [A] 10 (A) 15 (A) 20 (A) 30 (A) 40 (A)
CONVERTED SPECIFIC GRAVITY
IDX
SC-11
STARTING SYSTEM
System Description
SC-12
STARTING SYSTEM
Wiring Diagram — START —
GI
MA
EM
LC
EC
FE
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
HA
EL
TSC007 IDX
SC-13
STARTING SYSTEM
Trouble Diagnoses
SEL761W
SC-14
STARTING SYSTEM
Construction
Construction NMSC0006
GI
MA
EM
LC
EC
FE
CL
MT
AT
MEL462N
PD
AX
SU
BT
MEL463N
INSTALLATION NMSC0007S02
HA
To install, reverse the removal procedure.
EL
IDX
MEL464N
SC-15
STARTING SYSTEM
Inspection
Inspection NMSC0019
MAGNETIC SWITCH CHECK NMSC0019S01
I Before starting to check, disconnect battery ground cable.
I Disconnect “M” terminal of starter motor.
1. Continuity test (between “S” terminal and switch body).
I No continuity ... Replace.
SEL555E
SEL556E
SEL014Z
SEL015Z
SC-16
STARTING SYSTEM
Inspection (Cont’d)
Brush Holder NMSC0019S0303
1. Perform insulation test between brush holder (positive side)
and its base (negative side). GI
I Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
MA
I If brush holder is bent, replace it; if sliding surface is dirty,
clean.
EM
SEL568B LC
YOKE CHECK NMSC0019S04
Magnet is secured to yoke by bonding agent. Check magnet to see EC
that it is secured to yoke and for any cracks. Replace malfunction-
ing parts as an assembly.
CAUTION: FE
Do not clamp yoke in a vice or strike it with a hammer.
CL
SEL305H
MT
ARMATURE CHECK NMSC0019S05
1. Continuity test (between two segments side by side). AT
I No continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
PD
I Continuity exists. ... Replace.
AX
SU
SEL019Z
ST
RS
BT
SEL020Z
EL
IDX
SEL021Z
SC-17
STARTING SYSTEM
Inspection (Cont’d)
5. Check depth of insulating mold from commutator surface.
I Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
SEL022Z
Assembly NMSC0020
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.
SEL497D
SEL573B
SC-18
CHARGING SYSTEM
System Description
CL
MT
AT
PD
AX
SU
BR
ST
RS
BT
HA
EL
IDX
SC-19
CHARGING SYSTEM
Wiring Diagram — CHARGE —
TSC008
SC-20
CHARGING SYSTEM
Trouble Diagnoses
LC
EC
FE
CL
MT
AT
PD
AX
SU
SEL338V
BR
NOTE:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque.) ST
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty
parts with new ones.
RS
MALFUNCTION INDICATOR NMSC0011S02
The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following
symptoms occur while alternator is operating: BT
I Excessive voltage is produced.
I No voltage is produced.
HA
EL
IDX
SC-21
CHARGING SYSTEM
Construction
Construction NMSC0012
MEL466N
MEL467N
INSTALLATION NMSC0013S02
To install, reverse the removal procedure.
MEL468N
SC-22
CHARGING SYSTEM
Disassembly
Disassembly NMSC0021
REAR COVER
CAUTION:
NMSC0021S01
GI
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear MA
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly. EM
SEL032Z LC
REAR BEARING NMSC0021S02
CAUTION: EC
I Do not reuse rear bearing after removal. Replace with a
new one.
I Do not lubricate rear bearing outer race. FE
CL
MT
Inspection NMSC0022
ROTOR CHECK AT
NMSC0022S01
1. Resistance test
Resistance: Refer to SDS (SC-25). PD
I Not within the specified values ... Replace rotor.
2. Insulator test
I Continuity exists ... Replace rotor. AX
3. Check slip ring for wear.
Slip ring minimum outer diameter: SU
SEL033Z Refer to SDS (SC-25).
I Not within the specified values ... Replace rotor.
BR
ST
RS
BT
IDX
SEL631DA
SC-23
CHARGING SYSTEM
Inspection (Cont’d)
STATOR CHECK NMSC0022S03
1. Continuity test
I No continuity ... Replace stator.
SEL108E
2. Ground test
I Continuity exists ... Replace stator.
SEL109E
Assembly NMSC0023
RING FITTING IN REAR BEARING NMSC0023S01
I Fix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
SEL044Z
SEL048Z
SEL049Z
SC-24
SERVICE DATA AND SPECIFICATIONS (SDS)
Battery
Battery NMSC0014
For Australia GI
Applied model
Standard
Type 46B24R MA
Capacity V-AH 12-48
Starter EM
NMSC0015
S114-827
LC
Type HITACHI make
Clearance between bearing metal and armature shaft 0.2 mm (0.008 in)
AT
Movement “” in height of pinion assembly 0.3 - 2.5 mm (0.012 - 0.098 in)
Alternator PD
NMSC0016
A2TB3991
Type
MITSUBISHI make
AX
Nominal rating 12V-80A
Slip ring minimum outer diameter More than 22.1 mm (0.870 in)
BT
Rotor (Field coil) resistance 2.2 - 2.6Ω
HA
EL
IDX
SC-25
NOTES