丰田培训系列:充电系统(原版英文)

2023年12月25日发(作者：雷克萨斯gx460值得买吗)

CHARGING SYSTEMS

GeneralThe charging system converts mechanical energy

into electrical energy when the engine is running.

This energy is needed to operate the loads in the

vehicle\'s electrical system. When the charging

system\'s output is greater than that needed by the

vehicle, it sends current into the battery to maintain

the battery\'s state of charge. Proper diagnosis of

charging system problems requires a thorough

understanding of the system components and their

operation.

OperationWhen the engine is running, battery power

energizes the charging system and engine power

drives it. The charging system then generates

electricity for the vehicle\'s electrical systems. At

low speeds with some electrical loads \"on\" (e.g.,

lights and window defogger), some battery current

may still be needed. But, at high speeds, the

charging system supplies all the current needed by

the vehicle. Once those needs are taken care of,

the charging system then sends current into the

battery to restore its charge.

Page 1

CHARGING SYSTEMS

Toyota Charging SystemsTypical charging system components include:

IGNITION SWITCH

When the ignition switch is in the ON position,

battery current energizes the alternator.

ALTERNATORMechanical energy is transferred from the engine

to the alternator by a grooved drive belt on a pulley

arrangement. Through electromagnetic induction,

the alternator changes this mechanical energy into

electrical energy. The alternating current

generated is converted into direct current by the

rectifier, a set of diodes which allow current to

pass in only one direction.

VOLTAGE REGULATOR Without a regulator, the alternator will always

operate at its highest output. This may damage

certain components and overcharge the battery.

The regulator controls the alternator output to

prevent overcharging or undercharging. On older

models, this is a separate electromechanical

component which uses a coil and contact points to

open and close the circuit to the alternator. On

most models today, this is a built-in electronic

device.

BATTERYThe battery supplies current to energize the

alternator. During charging, the battery changes

electrical energy from the alternator into chemical

energy. The battery\'s active materials are restored.

The battery also acts as a \"shock absorber\" or

voltage stabilizer in the system to prevent damage

to sensitive components in the vehicle\'s electrical

system.

INDICATORThe charging indicator device most commonly used

on Toyotas is a simple ON/OFF warning lamp. It is

normally off. It lights when the ignition is turned

\"on\" for a check of the lamp circuit. And, it lights

when the engine is running if the charging system

is undercharging. A voltmeter is used on current

Supra and Celica models to indicate system voltage

... it is connected in parallel with the battery. An

ammeter in series with the battery was used on

older Toyotas.

FUSINGA fusible link as well as separate fuses are used

to protectcircuits in the charging 2

CHARGING SYSTEMS

Alternator ConstructionGENERALTwo different types of alternators are used on

Toyota vehicles. A conventional alternator and

separate voltage regulator were used on all

Toyotas prior to 1979. A new compact, high-speed

alternator with a built-in IC regulator

is now used on most models. Both types of

alternators are rated according to current output.

Typical ratings range from 40 amps to 80 amps.

CONVENTIONAL ALTERNATOR

This type of alternator is currently used on some

1986 Tercel models, and all Toyotas prior to 1979.

Page 3

CHARGING SYSTEMS

TOYOTA COMPACT,

HIGH-SPEED ALTERNATOR

Beginning with the 1983 Camry, a compact, high-speed alternator with a built-in IC regulator is used

on Toyota vehicles. Corolla models with the 4A-C

engine use a different alternator with an integral IC

regulator.

This new alternator is compact and lightweight. It

provides better performance, as well as improved

warning functions. If either the regulator sensor

(terminal \"S\") or the alternator output (terminal \"B\")

become disconnected, the warning lamp goes on.

It also provides better serviceability. The rectifier,

brush holder, and IC regulator are bolted onto the

end frame.

Page 4

CHARGING SYSTEMS

Alternator TerminalsToyota\'s high-speed alternator has the following

terminals: \"B\", \"IG\", \"S\", \"U\', and \"17\".

When the ignition switch is \"on,\" battery current is

supplied to the regulator through a wire connected

between the switch and terminal \"IG\". When the

alternator is charging, the charging current flows

through a large wire connected between terminal

\"B\" and the battery. At the same time, battery

voltage is monitored for the MIC regulator through

terminal \"S\". The regulator will increase or

decrease rotor field strength as needed. The

indicator lamp circuit is connected through terminal

\"U\'. If there is no output, the lamp will be lit. The

rotor field coil is connected to terminal \"P, which is

accessible for testing purposes through a hole in

the alternator end frame.

RegulatorWhile engine speeds and electrical loads change,

the alternator\'s output must remain even - not too

much, nor too little.

The regulator controls alternator output by

increasing or decreasing the strength of the rotor\'s

magnetic field. It does so, by controlling the amount

of current from the battery to the rotor\'s field coil.

The electromechanical regulator does its job with a

magnetic coil and set of contact points. The IC

regulator does its job with diodes, transistors, and

other electronic components.

Page 5

CHARGING SYSTEMS

Alternator OperationGENERALThe operation of the Toyota compact, high-speed

alternator is shown in the following circuit

diagrams.

IGNITION ON, ENGINE STOPPEDPage 6

CHARGING SYSTEMS

Page 7

CHARGING SYSTEMS

Page 8

CHARGING SYSTEMS

Diagnosis and TestingThe charging system requires periodic inspection

and service. Specific problem symptoms, their

possible cause, and the service required are listed

in the chart below. The service actions require a

thorough visual inspection. Problems identified

must be corrected before proceeding with

electrical tests. These electrical tests include: an

alternator output test, charging circuit voltage-drop tests, a voltage regulator (non-IC) test,

charging circuit relay (lamp, ignition, engine) tests,

and alternator bench tests.

PRECAUTIONS? Make sure battery cables are connected to

correct terminals.

? Always disconnect battery cables (negative

first!) when the battery is given a quick charge.

? Never operate an alternator on an open circuit

(battery cables disconnected).

? Always follow specs for engine speed when

grounding terminal \"F to bypass the regulator.

High speeds may cause excess output that could

damage components.

? Never ground alternator output terminal \"B.\" It has

battery voltage present at all times, even with the

engine off.

? Do not perform continuity tests with a high- voltage insulation resistance tester. This type of

ohmmeter could damage the alternator diodes.

Page 9

CHARGING SYSTEMS

VISUAL INSPECTIONA visual inspection should always be your first

step in checking the charging system. A number of

problems that would reduce charging performance

can be identified and THE BATTERY? Check for proper electrolyte level and state of

charge. When fully charged, specific gravity

should be between 1.25 and 1.27 at 80?F

(26.7?C).? Check the battery terminals and cables. The

terminals should be free of corrosion and the

cable connections THE FUSES AND FUSIBLE LINK? Check the fuses for continuity. These include the

Engine fuse (10A), Charge fuse (7.5A), and

Ignition fuse (7.5A).? Check the fusible link for T THE DRIVE BELT? Check for belt separation, cracks, fraying, or

glazing. If necessary, replace the drive belt.? Check the drive belt tension using the proper

tension gauge, Nippondenso BTG-20Refer to the appropriate repair manual for proper

drive belt tension. \"New\" belts (used less than 5

minutes on a running engine) are installed with

greater tension than \"used\" belts. Tension specs

are different for different T THE ALTERNATOR? Check the wiring and connections. Replace any

damaged wires, tighten any loose connections.? Check for abnormal noises. Squealing may

indicate drive belt or bearing problems. Defective

diodes can produce a whine or hissing noise

because of a pulsating magnetic field and

THE WARNING LAMP CIRCUIT? With the engine warm and all accessories off,

turn the ignition to ON. The warning lamp should

light.? With the engine started and the ignition in RUN,

the warning lamp should be off.? If the lamp does not operate as specified, check

the bulb and check the lamp 10

CHARGING SYSTEMS

ALTERNATOR OUTPUT TESTThe alternator output test checks the ability of the

alternator to deliver its rated output of voltage and

current. This test should be performed whenever

an overcharging or undercharging problem is

suspected. Output current and voltage should

meet the specifications of the alternator. If not, the

alternator or regulator (IC or external) may require

replacement.A Sun VAT-40 tester, similar testers, or a separate

voltmeter and ammeter can be used. Toyota repair

manuals detail the testing procedures with an

ammeter and voltmeter. Follow the manufacturer\'s

instructions when using special testers, although

most are operated similarly. The following steps

outline a typical procedure for performing the

alternator output test using a Sun VAT-40:Page 11

CHARGING SYSTEMS

Charging Without Load1. Prepare the tester:? Rotate the Load Increase control to OFF,? Check each meter\'s mechanical zero. Adjust, if

necessary.? Connect the tester Load Leads to the battery

terminals; RED to positive, BLACK to negative.? Set Volt Selector to INT 18V.? Set Test Selector to #2 CHARGING.? Adjust ammeter to read ZERO using the electrical

Zero Adjust control.? Connect the clamp-on Amps Pickup around the

battery ground (-) cables.2. Turn the ignition switch to \"ON\" (engine not

running) and read the amount of discharge on

the ammeter. This is a base reading for current

the alternator must supply for ignition and

accessories before it can provide current to

charge the : The reading should be about six ter. Add this ammeter reading and the

reading found in step 2 (engine not running).NOTE: The total current should be less than 10

amps. If it is more, the alternator may still be

charging the battery. Once the battery is fully

charged, you should get specified voltage should be within the specs for the

alternator. This is usually between 13 and 15 volts.

Refer to the appropriate repair manual. If the

voltage is more than specified, replace the

regulator. If the voltage is less than specified,

ground the alternator field terminal \"F\" and check

the voltmeter reading. This bypasses the regulator,

so do not exceed the specified test speed. If the

reading is still less than specified, check the

alternator.5. Remove ground from terminal \"F.\"Charging With Load6. With the engine running at specified speed,

adjust the Load Increase control to obtain the

highest ammeter reading possible without

causing the voltage to drop lower than 12 volts.7. Read the : The reading should be within 10% of the

alternator\'s rated output. If it is less, the alternator

requires further testing or replacement.3. Start the engine and adjust the speed to about

2000 rpm. Some models may require a different

speed setting.4. After about 3-4 minutes, read the ammeter and

Page 12

CHARGING SYSTEMS

Page 13

CHARGING SYSTEMS

VOLTAGE-DROP TESTSVoltage-drop testing can detect excessive

resistance in the charging system. These tests

determine the voltage drop in the alternator output

circuit. Both sides of the circuit should be checked

... insulated side as well as ground side.

Excessive voltage drop caused by high resistance

in either of these circuits will reduce the available

charging current. Under heavy electrical loads, the

battery will discharge.A Sun VAT-40 tester or a separate voltmeter can

be used. The following steps outline a typical

procedure for performing voltage-drop tests using

a voltmeter:Output Circuit - Insulated Side1. Connect the voltmeter positive lead to the

alternator\'s output terminal \"B\" and the

voltmeter\'s negative lead to the battery\'s

positive (+) terminal.2. Start the engine and adjust the speed to

approximately 2000 rpm.3. Read the voltmeter. The voltage drop should be

less than 0.2 volt. If it is more, locate and correct

the cause of the high Circuit - Ground Side1. Connect the voltmeter\'s negative lead to the

alternator\'s frame and the voltmeter\'s positive

lead to the battery\'s negative (-) terminal.2. Start the engine and run at specified speed

(about 2000 rpm).3. Read the voltmeter. The voltage drop should be

0.2 volt or less. If it is more, locate and correct

the cause of high resistance. Excessive

resistance is most likely caused by loose or

corroded 14

CHARGING SYSTEMS

CHARGING CIRCUIT RELAY TESTSVarious charging system layouts are used on

Toyota vehicles. The indicator lamp circuit may or

may not be controlled by a relay. Depending on the

model, when a relay is used, it may be a separate

lamp relay, the ignition main relay, or the engine

main relay. Each is checked using an ohmmeter.

Charge Lamp RelayWhen used, the charge lamp relay is located on

the right cowl side of the vehicle. The following

steps are used to check this relay:

1. Check relay continuity.

? Connect the ohmmeter positive (+) lead to

terminal \"4,\" the negative (-) lead to terminal \"3.\"

Continuity (no resistance) should be indicated.

? Reverse the polarity of the ohmmeter leads. No

continuity (infinite resistance) should be indicated.

? Connect the ohmmeter leads between terminals 1

and \"2.\" No continuity (infinite resistance) should

be indicated.

If the relay continuity is not as specified, replace

the relay.

2. Check relay operation.

? Apply battery voltage across terminals \"3\" and

\"4.\"

NOTE: Make sure polarity is as shown.

? Connect the ohmmeter leads between terminals

“1” and \"2.\" Continuity (no resistance) should be

indicated.

If relay operation is not as specified, replace the

relay.

Page 15

CHARGING SYSTEMS

Ignition Main RelayThe ignition main relay is located in the relay box

under the instrument panel. The following steps

are used to check this relay:

1. Check relay continuity.

? Connect the ohmmeter leads between terminals

“1” and \"3.\" Continuity (no resistance) should be

indicated.

? Connect the ohmmeter leads between terminals

\"2\" and \"4.\" No continuity (infinite resistance)

should be indicated.

If relay continuity is not as specified, replace the

relay.

2. Check relay operation.

? Apply battery voltage across terminals \"l \" and

\"3.\"

? Connect the ohmmeter leads between terminals

\"2\" and \'A.\" Continuity (no resistance) should be

indicated.

If relay operation is not as specified, replace the

relay.

Page 16

CHARGING SYSTEMS

ALTERNATOR BENCH TESTS

If the on-vehicle checks have indicated that the

alternator is defective, it should be removed for

bench testing and replacement. Specific

procedures for removal, disassembly, inspection,

and assembly are noted in the appropriate repair

manuals. Only the electrical bench tests are

covered here.

? Always disconnect the battery ground (-) cable

before removing the alternator.

? Refer to the appropriate repair manual for test

specifications.

An ohmmeter is used for electrical bench tests on

the rotor, stator, and diode rectifier. The following

steps are typical:

Rotor Tests

? Check the rotor for an open circuit by measuring

for resistance between the slip rings. Some

resistance (less than 5 ohms) indicates

continuity. If there is no continuity (infinite

resistance), replace the rotor.

? Check the rotor for grounded circuits by

measuring for resistance between the rotor and slip ring. Any amount of resistance indicates a

ground (continuity). The resistance should be

infinite ( 0 ohms ). If not, replace the rotor.

Page 17

CHARGING SYSTEMS

Diode TestsDiodes can be checked with the alternator on the

vehicle using a scope. Scope testing can identify

open or shorted diodes, as well as problems in the

stator coils.

The scope patterns shown below include:

a) Normal alternator output;

b) one diode short-circuited;

c) two diodes of the same polarity short-circuited;

d) one diode open;

e) two diodes open;

f) one phase of the stator coil short-circuited;

g) one phase of the stator coil disconnected; and,

h) two phases of the stator coil short-circuited.

Page 18

CHARGING SYSTEMS

Page 19

CHARGING SYSTEMS

This brief self-test will help you measure your

understanding of The Charging System. The style

is the same as that used for A.S.E. certification

tests. Each incomplete statement or question is

followed by four suggested completions or

answers. In each case, select the one that best

completes the sentence or answers the question.

1. A regulator controls alternator output voltage by

regulating:

A. sine-wave voltageB. battery voltageC. field currentD. output current2. In an alternator, alternating current is converted

to direct current by the:

A. statorB. brushesC. rectifierD. regulator3. If the charging system indicator lamp goes on

with the engine running, the cause may be loss

of voltage at terminal:

A. \"IG\"B. \"S\"C. \"L\"D. \"F4. With the engine not running and the ignition ON,

the charge lamp should light. If it doesn\'t, this

may indicate a:

A. burned out bulbB. grounded bulbC. loose drive beltD. overcharged battery5. Which alternator terminal can be grounded for

test purposes?

A. \"B\"

B. \"IG\"C. “S\"D. \"F6. When performing a visual inspection of the

charging system, the alternator drive belt should

be checked for proper tension.

Technician \"A\" says that new-belt tension

specs are higher than those for used belts.

Technician \"B\" says that the belt tension is

different for different Toyota models.

Who is right?

A. Only AB. Only BC. Both A and BD. Neither A nor B7. The amount of current the alternator must supply

or ignition and accessories is about:

A. four ampsB. six ampsC. eight ampsD. ten amps8. In an alternator output test under load, the output

should be:

A. about 10 ampsB. about 30 ampsC. within 10% of rated outputD. within 20% of rated output9. To check for excessive voltage drop on the

insulated side of the alternator\'s output circuit,

you would connect a voltmeter between the:

A. batteryB. batteryC. batteryD. battery

terminal and ignition switchterminal and groundterminal and alternator \"S\" terminalterminal and alternator \"B\" terminal10. High resistance in an alternator output circuit is

often caused by:

A. a discharged batteryB. a shorted diodeC. loose or corroded connectionsD. a bad regulatorPage 20

CHARGING SYSTEMS

SELF-TEST ANSWERSFor the preceding self-test on The Charging

System, the following best complete the

sentence or answer the question. In cases where

you may disagree with the choice - or may simply

want to reinforce your understanding - please

review the appropriate workbook page or pages

noted.

1 . \"C\" - The regulator controls alternator output by

increasing or decreasing the amount of current

from the battery to the rotor field coil. (Page 5.)

2. \"C\" - The alternating current is changed into

direct current by the rectifier, a set of diodes

which allow current to pass in only one

direction. (Page 2.)

3. \"B\" - If either the regulator sensor (terminal \"S\")

or the alternator output (terminal \"B\") become

disconnected, the warning lamp goes on. (Page

4.)

4. \"A\" - If the warning lamp does not light, with the

ignition ON and the engine not running, the

possible causes include a blown fuse, burned

out lamp, loose connections, or faulty relay or

regulator. (Page 9.)

5. \"D\" - Terminal \"F is the only terminal that can be

grounded. Never ground alternator output

terminal \"B. It has battery voltage present at all

times, even with the engine off. (Page 9.)

6. \"C\" - A \"new belt\" is one that has been used for

less than 5 minutes. It is installed with more

tension than a used belt, because it will stretch

some during use. Methods of checking are

different for different models. (Page 10.)

7. \"B\" -The reading should be about six amps. This

is the amount of current the alternator must

supply for ignition and accessories. (Page 12.)

8. \"C\" - With the alternator operating at maximum

output, the reading should be within 10% of

rated output. (Page 12.)

9. \"ID\" - To check for the insulated circuit voltage

drop, connect the voltmeter leads to the

battery\'s (+) terminal and the alternator output

(B) terminal. (Page 14.)

10. \"C\" - Excessive resistance is most likely

caused by loose or corroded connections.

(Page 14.)

Taken with permission from the

Toyota Basic Electrical Course#622,Page 21

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