Section 5

The Charging System

The charging system has two essential functions: Charging
System
• Generate electrical power to run the vehicle’s electrical systems
• Generate current to recharge the vehicle’s battery Electrical power − At low engine
speeds, the battery may supply some of the power the vehicle needs. At high engine speeds, the
charging system handles all of the vehicle’s electrical requirements.
Charging − Alternator (generator) output is higher than battery voltage to recharge the
battery.
Charging System
The alternator supplies
power for the vehicle
when the engine is
running and engine speed
is above idle.
Fig. 5-01
TL623f501
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Section 5
Charging System These components make up the charging system: Components
• Alternator
• Voltage regulator
• Battery
• Charging indicator
Charging System
Components
This figure shows the
major components of the
charging system.
Fig. 5-02
TL623f500
5-2
TOYOTA Technical Training
The Charging System
Alternator The alternator contains these main components:
• Stator (attached to alternator housing, remains stationary)
• Rotor (spins inside the stator)
• Rectifier
• Voltage regulator
Slip rings and brushes make an electrical connection to the spinning rotor.
The alternator generates electricity through these steps:
• Engine power drives the alternator rotor through a pulley and drive belt.
• The alternator rotor spins inside the windings of the stator.
• The stator windings generate an alternating current.
• Rectifier diodes change the alternating current (AC) into direct current (DC).
Alternator
Exploded view of the
alternator’s main
components.
Fig. 5-03
TL623f503
Electrical Circuit Diagnosis - Course 623
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 Section 5
Voltage Regulator The voltage regulator controls the alternator’s output current to
prevent over−charging and under−charging of the battery. It does this by regulating the current
flowing from the battery to the rotor’s field coil.
Today’s IC voltage regulator is a fully electronic device, using resistors and diodes.
Voltage Regulator
The voltage regulator
controls the alternator’s
output current.
Fig. 5-04
TL623f504
5-4
TOYOTA Technical Training
 The Charging System
Battery The battery supplies current to energize the alternator field coil. The battery also
acts as a voltage stabilizer. The battery must always remain attached to the electrical system
while the engine is running.
Battery
The battery supplies
current to energize the
alternator’s field coil.
Fig. 5-05
TL623f505
Electrical Circuit Diagnosis - Course 623
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Section 5
Charging Indicator The charging indicator is usually an ON/OFF warning lamp. When
the system is running, the light should be OFF. The lamp lights when the charging system is not
providing sufficient charge.
Charging
Indicator
The charging indicator
lights when the charging
system is not supplying
enough power to charge
the battery.
Fig. 5-06
TL623f506c
5-6
TOYOTA Technical Training
 The Charging System
Charging System Current in the charging system changes for these three different
Operation operating conditions:
• Ignition switch to ON − engine stopped
• Ignition switch to ON − engine running alternator output below desired voltage
• Ignition switch to ON − engine running alternator output above desired voltage
Ignition switch to ON − engine stopped:
• As soon as the ignition switch is turned to ON, the IC regulator causes a current of
about 0.2 amps through the rotor’s field coil.
• The IC regulator turns on the charging indicator.
• There is no output from the stator because the rotor is not turning.
Ignition Switch
to ON - Engine
Stopped
The IC regulator causes a
small current through the
alternator rotor field coil.
 Fig. 5-07
TL623f507c
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Section 5
Ignition switch to ON − engine running, alternator output below desired voltage:
• The windings in the stator generate a voltage any time the rotor is energized and
spinning.
• Voltage generated in the stator is applied to the voltage regulator.
• If the alternator output voltage is below 14.5 volts, the voltage regulator responds by
increasing current through the field coil of the rotor. This causes the voltage to increase.
• A charging current is sent to the battery.
Ignition ON
- Output Voltage
Below 14.5 volts
The windings in the stator
generate a voltage, and a
charging current is sent
to the battery.
Fig. 5-08
TL623f508c
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TOYOTA Technical Training

The Charging System

Ignition switch to ON − engine running alternator output above desired voltage:
When the voltage regulator senses alternator output at or above 14.5 volts:
• It reduces current through the rotor field coil.
• This reduces alternator output voltage.
• No charging current goes to the battery.
Ignition ON
 - Output
Voltage High
The regulator reduces
current through the field
coil; no charging current
goes to the battery.
Fig. 5-09
TL623f509c
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Section 5
Safeguards are built into the alternator in case the connection to Terminal B or Terminal
S is lost:
• Terminal S is an input to the regulator to monitor voltage levels.
• Terminal B is alternator output.
Terminal S disconnected:
• The voltage regulator does not detect voltage.
• The voltage regulator regulates voltage at Terminal B to 16 volts and lights the
Charging Indicator.
Terminal S
Disconnected
The voltage regulator
regulates voltage at
Terminal B to 16 volts
and lights the
charging indicator.
Fig. 5-10
TL623f510c
5-10
TOYOTA Technical Training

The Charging System

 Terminal B disconnected:
• No charging voltage available for battery.
• This condition could result in voltage regulator damage.
Terminal B
Disconnected
An open circuit in the
B terminal results in no
charging output for
the battery and
could damage the
voltage regulator.
Fig. 5-11
TL623f511c
Electrical Circuit Diagnosis - Course 623
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Section 5
Diagnosis The charging system requires little maintenance. The battery should and
Testing be fully charged and connections kept clean and tight.
Diagnosis of charging system problems is typically straightforward.
Problems may be electrical or mechanical.
The troubleshooting flow diagram on the next page lists the most common charging
system problems, the possible cause, and recommended actions to resolve the problem.
Begin with a thorough visual inspection. If this fails to turn up the possible cause, several
tests are available to help you find the problem:
• Alternator output test (no load)
• Alternator output test (with load)
• Voltage drop tests
• Charging current relay test
• Diode tests
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 The Charging System
Troubleshooting Use this flow diagram to troubleshoot charging systems with compact,
Flow Diagram high speed alternators.
Troubleshooting
Flow Diagram
Fig. 5-12
TL623f512
Electrical Circuit Diagnosis - Course 623
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 Section 5
Charging System Include the following items in a visual inspection of the charging
system: Visual Inspection 1. Battery
2. Fusing
3. Alternator Drive Belt
4. Alternator Wiring
5. Noise
6. Charging Indicator
Item 1: Battery
Inspect the battery for
the defects shown
in this figure.
Fig. 5-13
TL623f513c
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TOYOTA Technical Training
 The Charging System
Other Battery Checks
State of Charge − Check the specific gravity of the electrolyte to determine the battery’s
state of charge.
• Specific gravity should be between 1.25 and 1.27 (at 80°F/26.7°C).
Condition − Check overall battery condition with a battery analyzer.
Other Battery
Checks
A hydrometer can tell
you the battery’s state
of charge.
Fig. 5-14
TL623f514
Electrical Circuit Diagnosis - Course 623
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 Section 5
Item 2: Fusing
• Refer to the EWD to identify fuses and fusible links in the charging system for the
vehicle under test.
• Check these components for continuity.
Item 2: Fusing
Fusible links must be part
of the visual inspection of
the charging system.
Fig. 5-15
TL623f515
5-16
TOYOTA Technical Training

The Charging System

Item 3: Alternator Drive Belt
• Good condition
• Correct alignment
• Proper tension
Item 3: Alternator Drive Belt
Alternator drive belts must be in
good condition and be properly
aligned and tensioned.
Fig. 5-16
TL623f516c
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Section 5
Item 4: Alternator Wiring
• Make sure all connections are clean and tight.
• Check wiring for frayed insulation and other physical damage.
Item 4:
Alternator Wiring
Inspect wires and
connections at
the alternator.
Fig. 5-17
TL623f517
5-18
TOYOTA Technical Training
 The Charging System
Item 5: Alternator Noise
Listen for any unusual noise while the alternator is operating:
• Squealing may indicate a bearing problem or a worn or improperly tensioned and
adjusted drive belt.
• Hissing may be a sign that one or more of the diodes are defective, because of a
pulsating magnetic field and vibration.
Item 5:
Alternator Noise
Alternator noise may be
important in diagnosing
potential problems.
Fig. 5-18
TL623f518
Electrical Circuit Diagnosis - Course 623
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 Section 5
Item 6: Charging Indicator
• Indicator lights with ignition ON and engine not running.
• Indicator goes off with engine running.
If the indicator does not operate as described above, refer to the appropriate EWD and
check the indicator circuit.
Item 6:
Charging
Indicator
The Charging indicator
should be on with the
ignition on and the engine
not running and off with
the engine running.
Fig. 5-19
TL623f519c
5-20
TOYOTA Technical Training
 The Charging System
Alternator Output Use the following steps to perform the test with a Sun VAT−40 or
VAT−60
Test (No Load) tester:
1. Set the tester’s Load control to OFF.
2. Connect the tester leads.
• Red lead to positive terminal.
• Black lead to negative terminal.
• Clamp the ammeter clamp−on probe onto the battery’s ground cable.
3. Set the tester’s voltage range to the appropriate setting.
4. Zero both meters on the tester, if needed.
5. Turn the ignition switch to ON (do not start the engine).
Alternator Output
Test (No Load)
A VAT-40 Battery Tester
is connected for the no
load output test.
Fig. 5-20
TL623f520c
Electrical Circuit Diagnosis - Course 623
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Section 5
6. Record the ammeter reading.
• This is the discharge current (typically about 6 amps).
• Alternator must supply this amount of current before it can provide charging current to
the battery.
7. Start the engine and adjust engine speed to about 2,000 RPM.
8. Allow engine to warm up for 3 to 4 minutes.
9. Record the ammeter reading.
• Add the discharge current (from Step 4) to the reading now on the ammeter. The total
should be less than 10 amps.
• The battery may not have been fully charged if the total current is more than 10 amps.
Monitor the ammeter; the reading should decrease as the battery charges.
10. Record the voltmeter reading.
• The voltmeter reading should be within specification for the alternator during the entire
test. This value is typically between 13 and 15 volts; refer to the appropriate service manual for
the correct specification.
• If the voltmeter reading is higher than specified, the voltage regulator is probably
defective. Replace the regulator if possible or replace the alternator.
• If the voltmeter reading is lower than specified, the cause could be a bad regulator or a
fault in the alternator windings. Replace the alternator if it has an internal voltage regulator.
• For alternators with externally mounted regulators, confirm the cause by grounding
Terminal F on the alternator. This bypasses the regulator. If voltage increases, the voltage
regulator is probably defective. If the voltage remains low, replace the alternator; there is a
problem with the windings.
11. Remove ground from alternator Terminal F.
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The Charging System

Alternator Output Use the following steps to perform the test with a Sun VAT−40 or
Test (With Load) VAT−60 tester:
1. Keep the tester connections as for the alternator output test with no load.
2. Adjust engine speed to specified RPM (refer to the appropriate service manual).
3. Adjust the tester’s load control to obtain the highest ammeter reading possible while
keeping the voltage reading at or above 12 volts.
4. Record the highest ammeter reading.
• The reading should be within 10% of the alternator’s rated output.
 • Replace the alternator if the reading is more than 10% below the value specified.
Alternator Output Test
(With Load)
This figure shows the location of the “F”
terminal for various alternator types.
Fig. 5-21
TL623f521
Electrical Circuit Diagnosis - Course 623
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Section 5
Voltage Drop Test Voltage drop tests can isolate unwanted high resistance in the
charging system. High resistance can cause these symptoms:
• Charging system cannot fully charge battery.
• Abnormally high current is drawn from battery under high load conditions.
Use a DMM to perform a voltage drop test on the positive side of the battery as follows:
1. Connect the red meter lead to Terminal B on the alternator.
2. Connect the black meter lead to the positive battery terminal.
3. Start the engine; adjust engine speed to 2,000 RPM.
4. Note the voltage reading.
• The voltage drop should be less than 0.2 volts.
• If the reading is higher, look for poor connections at the alternator and at the battery.
Also, look for damaged wires or corroded wires.
Test for voltage drop on the ground side of the battery as follows: 5. Keep the engine
running at 2.000 RPM.
6. Connect the red meter lead to the negative (ground) battery terminal.
7. Connect the black meter lead to the alternator frame.
8. Note the voltage reading.
• The voltage drop should be less than 0.2 volts.
• If the reading is higher, look for poor connections between the battery and ground and
from the alternator frame to ground.
Also, look for a damaged or corroded battery ground cable.
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The Charging System
Voltage Drop Test
Voltage drop tests can
isolate high resistance in
the charging system. Test
voltage drop on the
positive and the ground
side of the battery.
Fig. 5-22
TL623f522c
Electrical Circuit Diagnosis - Course 623
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Section 5
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TOYOTA Technical Training
ApikasidalamSistemPengisian (Charging System)

Charging System

Gambardiatasmenunjukansirkuit/ranngkaiandari system pengisian yang memakai regulator

duatitikkontak.Kebutuhantenagauntukmenghasilkanmedan magnet (magnetic flux) pada rotor
alternator  disuplaidari terminal F. Arusinidiaturdalamartiditambah  ataudikurangioleh regulator
sesuaidengantegangan terminal B. Listrikdihasilkanoleh stator alternator yang disuplaidari
terminal B, dandipakaiuntukmensuplaikembalibeban-beban yang terjadipadalampu-lampu besar
(head lamps), wipers, radio, dan lain-lain dalampenambahanuntukmengisikembalibaterai.
Lampupengisianakanmenyala, bilaaltenatortidakmengirimkanjumlahlistrik yang normal. Hal
tersebutterjadiapabilategangandariteminal N alternator kurang darijumlah yang ditentukan.