CH-1

CHARGING SYSTEM
Page
PRECAUTIONS CH-2
TROUBLESHOOTING CH-2
CHARGING SYSTEM CIRCUIT CH-3
ON-VEHICLE INSPECTION CH-5
ALTERNATOR CH-8
CH-2 CHARGING SYSTEM - Precautions, Troubleshooting

PRECAUTIONS
1. Check that the battery cables are connected to the
correct terminals.

2. Disconnect the battery cables when the battery is

given a quick charge.

3. Do not perform tests w i t h a high voltage insulation

resistance tester.

4. Never disconnect the battery while the engine is run-

ning.

TROUBLESHOOTING
Problem Possible cause Remedy Page
Discharge warning light Fuse blown Check fuses
does not light with Light burned out Replace light
starter switch at "ON"
and engine not running Wiring connection loose Tighten loose connection
IC regulator faulty Replace IC regulator CH-8
Discharge warning light Drive belt loose or worn Adjust or replace drive belt CH-5
does not go out with Battery cables loose, corroded or Repair or replce cables
engine running worn
(battery requires
frequent recharging) Fuse blown Check fuse
Fusible link blown Replace fusible link
IC regulator or alternator faulty Check charging system CH-5
Wiring faulty Repair wiring
 CHARGING SYSTEM - Charging System Circuit CH-3

CHARGING SYSTEM CIRCUIT

PZJ 70, 73, 75 and HZJ 70, 73, 75

Starter Switch
AM

IG

FL Fuse
AM1 ENGINE
1.25B 15A

(w/ Tachometer) (w/o Tachometer)

Battery
Stator Coil

Battery Fuse
CHG
(24 V Type) 7.5A
Rotor Coil

Alternator

HZJ 80 and HDJ 80

Starter Switch

FL Fuse
AM1 IGN
50A 7.5A
FL FL
MAIN AM1
2.0L 1.25B

Stator Coil
Battery Fuse
CHG
7.5A
Rotor Coil

Alternator

ST0884
ST0883
CH-4 CHARGING SYSTEM - Charging System Circuit

CHARGING SYSTEM CIRCUIT

(Cont'd)
HZB 30 and HDB 30

Starter Switch

AM

FL IG Fuse
AM1 ENGINE
1.0Y 10A
Fuse
GAUGE
FL 7.5A
MAIN
2.0L

Battery
Stator Coil
Fuse
Battery CHG
(24 V Type) 7.5A

Rotor Coil

Alternator
 CHARGING SYSTEM On-Vehicle Inspection CH-5

Upper
ON-VEHICLE INSPECTION
Level 1. INSPECT BATTERY SPECIFIC GRAVITY AND
ELECTROLYTE LEVEL
(a) Check the specific gravity of each cell.
Standard specific gravity:
When fully charged at 20°C (68°F)
Lower 1.25-1.27 (ex. (95D31 R and 95D31L))
Level 1.27 -1.29 (95D31R and 95D31L)
CH0864 If not as specified, charge the battery.
(b) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND
FUSES
(a) Check that the battery terminals are not loose or
corroded.
(b) Check the fusible links and fuses for continuity.

CH0865

3. INSPECT DRIVE BELTS

CORRECT WRONG
(a) Visually check each belt for cracks, oiliness or wear.
Check that the belt does not touch the bottom of the
pulley groove.
If one belt has any of the above defects, replace both belts.
Clearance

CH0872

(b) Check the drive belt deflection by pressing on the belt

at the points indicated in the illustration with 10 kg
(22.0 Ib, 98 N) of pressure.
Drive belt deflection:
New belt 6 - 7 mm (0.24-0.28 in.)
Used belt 8-11 mm (0.31 -0.43 in.)
If the deflection is not as specified, adjust it.
HINT:
• "New belt" refers to a belt which has been used 5
CH0866 minutes or less on a running engine.
• "Used belt" refers to a belt which has been used on a
running engine for 5 minutes or more.
• After installing a new belt, run the engine for about 5
minutes and recheck the deflection.
CH-6 CHARGING SYSTEM - On-Vehicle Inspection

(c) (Reference)
SST
Using SST, measure the drive belt tension.
SST 09216-00020 and 09216-00030
Drive belt tension: New belt 45-55 kg
Used belt 20-35 kg
SST If the belt tension is not as specified, adjust it.

EC0003 EC0004

4. VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the
alternator while the engine is running.

5. INSPECT DISCHARGE WARNING LIGHT CIRCUIT

(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the starter switch to "ON". Check that the
discharge warning light is lit.
(d) Start the engine. Check that the light goes out.
If the light does not operate as specified, troubleshoot the
discharge light circuit.

Disconnect Wire
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
Ammeter from Terminal B HINT: If a battery/alternator tester is available, connect
the tester to the charging circuit as per manufacturer's
instructions.
(a) If a tester is not available, connect a voltmeter and
ammeter to the charging circuit as follows:
Battery • Disconnect the wire from terminal B of the alterna-
Alternator tor and connect it to the negative (-) lead of the
Voltmeter ammeter.
CH0837 • Connect the positive ( + ) lead of the ammeter to
terminal B of the alternator.
• Connect the positive ( + ) lead of the voltmeter to
terminal B of the alternator.
• Ground the negative (-) lead of the voltmeter.
 CHARGING SYSTEM - On-Vehicle Inspection CH-7

(b) Check the charging circuit as follows:

26.0 28.7 V With the engine running from idling to 2,000 rpm,
13.5 15.0V check the reading on the ammeter and voltmeter.
10 A
Standard amperage: 10 A or less
Standard voltage:
12 V type 14.0-15.0 V at 25°C (77°F)
13.5-14.3 V at 135°C (275° F)
24 V type 27.7-28.7 V at 25°C (77°F)
26.0-28.7 V at 135°C (275°F)
CH0704 If the voltmeter reading is more than standard voltage,
replace the IC regulator.
If the voltmeter reading is less than standard voltage, check
the IC regulator and alternator as follows:
• With terminal F grounded, start the engine and
check the voltmeter reading of terminalB.
• If the voltmeter reading is greater than standard ,
voltage, replace the IC regulator.
• If the voltmeter reading is less than standard volt-
age, check the alternator.
CH0894

7. INSPECT CHARGING CIRCUIT WITH LOAD

(a) With the engine running at 2,000 rpm, turn on the
high beam headlights and place the heater blower
switch at "HI".
(b) Check the reading on the ammeter.
Standard amperage:
12 V 45, 55, 60, 80 A type 30 A or more
12 V 100 A type 40 A or more
24 V 30 A type 15 A or more
CH0838 24 V 55 A type 30 A or more
If the ammeter reading is less than standard amperage,
repair the alternator. (See page CH-8)
HINT: With the battery fully charged, the indication will
sometimes be less than standard amperage.

CH0839
CH-8 CHARGING SYSTEM Alternator

ALTERNATOR
COMPONENTS
Type A

Retainer
Drive End Frame (Stator)

Pulley
Alternator Washer
Bearing cover

Rotor Rear Bearing

Rear End Cover

Front Bearing

Terminal Insulator

Seal Plate
Rectifier End Frame

Brush Holder Cover

Brush Holder
IC Regulator

Rectifier Holder

Type B Rubber Insulator

Drive End Frame (Stator)

Bearing Cover

Pulley Rear Bearing

Rotor Rear End Cover

Retainer
Brush Holder
Front Bearing

Terminal Insulator

Rectifier End Frame

Brush Holder Cover

Spring
Brush
IC Regulator

Rectifier Holder

Rubber Insulator CH0857

CH0858
 CHARGING SYSTEM - Alternator CH-9

DISASSEMBLY OF ALTERNATOR
(See page CH-8)
1. REMOVE REAR END COVER
(a) (PZJ, HZJ and HDJ)
Remove the nut, condenser lead wire and terminal
insulator.
(b) (HZB and HDB)
Remove the nut and terminal insulator.
CH0846

(c) Remove the three nuts and end cover.

CH0845

Type A 2. REMOVE BRUSH HOLDER AND IC REGULATOR

(a) (Type A)
Remove the brush holder cover from the brush holder.

CH0869

(b) Remove the five screws, brush holder, holder cover

and IC regulator.

CH0876

3. REMOVE RECTIFIER HOLDER

(a) Remove the four screws and rectifier holder.

CH0892
CH-10 CHARGING SYSTEM - Alternator

(b) Remove the four rubber insulator.

CH0852

Type A
(c) (Type A)
Remove the seal plate.

CH0854

4. REMOVE PULLEY
SST
SST (B) (A) (a) Hold SST (A) with a torque wrench, and tighten SST
(B) clockwise to the specified torque.
SST 09820-63010
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
(b) Check that SST (A) is secured to the rotor shaft.

CH0882

(c) As shown in the illustration, mount SST (C) in a vise,

and install the alternator to SST (C).
(d) To loosen the pulley nut, turn SST (A) in the direction
shown in the illustration.
NOTICE: To prevent damage to the rotor shaft, do
not loosen the pulley nut more that one-half of a turn.
SST (C)
(e) Remove the alternator from SST (C).
(f) Turn SST (B) and remove SST (A and B).
(g) Remove the pulley nut and pulley.
CH0853 CH0874

5. REMOVE RECTIFIER END FRAME

(a) (PZJ, HZJ and HDJ)
Remove the four nuts and condenser.
(b) (HZBandHDB)
Remove the four nuts.

CH0855
 CHARGING SYSTEM - Alternator CH-11

(c) Using SST, remove the rectifier end frame.

SST 09286-46011

SST

CH0870

Type A (d) (Type A)

Remove the alternator washer.

CH0879

6. REMOVE ROTOR FROM DRIVE END FRAME

CH0851
CH-12 CHARGING SYSTEM - Alternator

INSPECTION AND REPAIR OF ALTERNATOR

Rotor
1. INSPECT ROTOR FOR OPEN CIRCUIT
Ohmmeter Using an ohmmeter, check that there is continuity between
the slip rings.
Standard resistance (cold): 12VType 2.7-3.1 Q
24 V Type 1.0-1.4Q
Continuity
CH0784
If there is no continuity, replace the rotor.

2. INSPECT ROTOR FOR GROUND

Using an ohmmeter, check that there is no continuity
between the slip ring and the rotor.
If there is continuity, replace the rotor.
Ohmmeter

No continuity

CH0783

3. INSPECT SLIP RINGS

(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using vernier calipers, measure the slip ring diameters.
Standard diameter: 14.2-14.4 mm
(0.559-0.567 in.)
Minimum diameter: 12.8 mm (0.504 in.)
If the diameter is less than minimum, replace the rotor.
CHOI 92

Ohmmeter Stator (Drive End Frame)

1. INSPECT STATOR FOR OPEN CIRCUIT
Continuity Using an ohmmeter, check that there is continuity between
the coil leads.
If there is no continuity, replace the drive end frame
assembly.

CH0806

Ohmmeter 2. INSPECT STATOR FOR GROUND

Using an ohmmeter, check that there is no continuity
between the coil leads and drive end frame.
No continuity If there is continuity, replace the drive end frame assembly.

CH0803
 CHARGING SYSTEM - Alternator CH-13

Type A Brushes
1. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers or scale, measure the exposed brush
length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the
brushes and brush holder assembly (Type A) or brushes
CH0722 (Type B).

Type B

CH0247

2. (Type B)
IF NECESSARY, REPLACE BRUSHES
(a) Unsolder and remove the brush and spring.
(b) Run the wire of the brush through the hole in the
brush holder, and insert the spring and brush into the
brush holder.

CH0248

(c) Solder the brush wire to the brush holder at the

exposed length.
Exposed length: 10.5 mm (0.413 in.)
(d) Check that the brush moves smoothly in the brush
holder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered point.

CH0414

Ohmmeter Rectifiers (Rectifier Holder)

1. INSPECT POSITIVE SIDE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the
positive ( + ) terminal and the other to each rectifier
Positive ( + ) Terminal
terminal.

Rectifier
Terminal
CH0465
CH-14 CHARGING SYSTEM - Alternator

Ohmmeter (b) Reverse the polarity of the tester probes and repeat
step (a).
(c) Check that one shows continuity and the other shows
no continuity.
If continuity is not as specified, replace the rectifier holder.

CH0466

Ohmmeter 2. INSPECT NEGATIVE SIDE RECTIFIER

(a) Connect one tester probe to each rectifier terminal and
Negative (-) Terminal the other to each rectifier negative ( —) terminal.

CH0467

Ohmmeter (b) Reverse the polarity of the tester probes.

(c) Check that one shows continuity and the other shows
no continuity.

If continuity is not as specified, replace the rectifier holder.

CH0468

Bearings

1. INSPECT FRONT BEARING

CH0867
Check that the bearing is not rough or worn.

2. IF NECESSARY, REPLACE FRONT BEARING

(a) Remove the four screws, and bearing retainer.

CH0868
 CHARGING SYSTEM - Alternator CH-15

(b) Using a press and socket wrench, press out the front
Socket Wrench bearing.

CH0856

(c) Using SST and a press, press in a new bearing.

SST
SST 09608-20012 (09608-00030)

CH0880

(d) Install the bearing retainer with the four screws.

CH0868

3. INSPECT REAR BEARING

Check that the bearing is not rough or worn.

CH0199

4. IF NECESSARY, REPLACE REAR BEARING

(a) Using SST, remove the bearing cover and bearing.
SST 09820-00021
SST NOTICE: Be careful not to damage the fan.

CH0200
CH-16 CHARGING SYSTEM - Alternator

(b) Using SST and a press, press in a new bearing and

bearing cover.
SST SST 09285-76010

CH0201

ASSEMBLY OF ALTERNATOR
(See page CH-8)
1. INSTALL ROTOR TO DRIVE END FRAME
Pulley (a) Place the rectifier end frame on the pulley.
(b) Install the rotor to the rectifier end frame.

CH0850

Type A
2. INSTALL RECTIFIER END FRAME
(a) (Type A)
Place the alternator washer on the rotor.

CH0879

(b) Using a plastic-faced hammer, lightly tap in the end

frame.

CH0871

(c) (PZJ, HZJ and HDJ)

Install the codenser and four nuts.
(d) (HZBandHDB)
Install the four nuts.

CH0855
 CHARGING SYSTEM Alternator CH-17

3. INSTALL PULLEY
SST
SST (a) Install the pulley to the rotor shaft by tightening the
pulley nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST
(B) clockwise to the specified torque.
SST 09820-63010
Torque: 400 kg-cm (29 ft-lb, 39 Nm)
(c) Check that SST (A) is secured to the pulley shaft.
CH0882

(d) As shown in the illustration, mount SST (C) in a vise,

and install the alternator to SST (C).
(e) To torque the pulley nut, turn SST (A) in the direction
shown in the illustration.
Torque: 1,125 kg-cm (81 ft-lb, 110 N-m)
SST (C)
(f) Remove the alternator from SST (C).
(g) Turn SST (B) and remove SST (A and B).

CH0853 CH0873

4. INSTALL RECTIFIER HOLDER

(a) (Type A)
Place the seal plate on the rectifier end frame.

CH0854

(b) Install the four rubber insulators on the lead wires.

CH0852

(c) Install the rectifier holder with the four screws.

CH0892
CH-18 CHARGING SYSTEM - Alternator

Type A 5. INSTALL IC REGULATOR AND BRUSH HOLDER

Upward (Type A)
(a) Place on the IC regulator and brush holder on the
rectifier end frame.
NOTICE: Be careful about the holder installation di-
rection.
(b) Install the five screws until there is a clearance of
approx. 1.1 mm (0.043 in.) between the brush holder
and connector.
CH0877

Type A
(c) Place the brush holder cover on the brush holder.

CH0869

(Type B)
Type B
(a) Install the brush holder cover to the brush holder.
NOTICE: Be careful about the holder installation di-
Upward rection.
(b) Place the IC regulator together with the brush holder
horizontally on the rectifier end frame.

CH0878

(c) Install the five screws until there is a clearance of

Type B
approx. 1.1 mm (0.043 in.) between the brush holder
and connector.

CH0881

Type B (d) Fit the brush holder cover.

CH0875
CHARGING SYSTEM - Alternator CH-19

6. INSTALL REAR END COVER

(a) Install the rear end cover with the three nuts.

CH0845

(b) (PZJ, HZJ and HDJ)

Install the terminal insulator, condenser lead wire with
nut.
(c) (HZB and HDB)
Install the terminal insulator with the nut.

CH0846

7. CHECK THAT ROTOR ROTATES SMOOTHLY

CH0836