92Rocky-CH-Charging_System-Part1
| 
| 
|
|
DAIHATSU
Rocky
CHARGING SYSTEM
_ COMPONENTS CH- 2 . CHARGING SYSTEM CIRCUIT CH- 3 . TROUBLE SHOOTING CH- 3 _ DESCRIPTION CH- 4 . IN-VEHICLE INSPECTION CH- 7 . REMOVAL CH-11 . DISASSEMBLY CH-12 . INSPECTION CH-14 . ASSEMBLY CH-20 . INSTALLATION CH-23
|
|
CHARGING SYSTEM
1. COMPONENTS
Alternator assembly Pully lock nut
Alternator puliy (D Drive end frame
Stud bolt
C1) Retainer plate
© Alternator rotor assembly
(9) Washer Bearing Bearing cover Wave washer
Rectifier end frame assembly
Rectifier holder Regulator assembly Brush Spring Brush holder GE Rear end cover
|
|
CHARGING SYSTEM
2. CHARGING SYSTEM CIRCUIT
Ignition switch
Fuse block
ENGINE fuse
10 A
GAUGE fuse
7.5 A
Charge
Battery
LiL
3. TROUBLE SHOOTING
Problem Possible causes
Remedies
Fuse blown
Charge warning lamp will not Lamp bulb burnt glow even if ignition switch is
Open wire
IC regulator faulty
Check gauge fuse.
Replace bulb.
Repair poor connection of wiring.
Repair or replace.
Replace regulator assembly.
Charge warning lamp will not go out even if engine has FUSG
staffed- Fusibse unk brown
Wiring faulty
Drive belt loose or worn
Battery cables loose, corroded or worn
lC regulator or alternator faulty
Adjust or replace.
Repair or repiace cables, 'Check gauge fuse.
Repiace fusible link.
Check charging system.
Repair or replace.
|
|
CHARGING SYSTEM
4. DESCRIPTION
The charging device consists of an alternator and a regulator. The alternator produces alternating current (AC), which is con- verted to direct current (DC) by a rectifier. The battery supplies power tor operating the starter as well as power required while the engine is stopped. The alternator recharges the battery so as to maintain it in an operational state at all times. The alternator also furnishes power for the electric equipment.
Electricity is produced when a magnet is moved in the vicinity of a coil. When the magnet is getting close to the coil, voltage is produced in one direction. However, when the magnet is leaving the coil, the direction of the voltage changes. This type of current is generally called alternating current, for the direc- tion of the current is alternating. The main purpose of a generator for motor vehicles is to charge the battery. Hence, a generator which produces alternating current is not suited for this purpose It is, therefore, necessary to convert alternating current to direct current. As semiconduc- tor technology has advanced, today it has become possible to convert alternating current to direct current at a low cost. Con- sequently, alternators (AC generators) have been commonly used. The following are advantages of alternators compared with DC generators. (1) Compact design, light Weight and remarkable vibration
resistant characteristics (2) Capable of withstanding high-speed rotation, quick ac
celeration and deceleration. (3) Being endurabie under severe environment prevailing with
dirt, dust and moisture, etc. (4) Having a fewer number of consuming parts and being easy
to repair The alternator has three pairs of stator coils and rotor (coil) and produces three-phase current. The alternator employs six rec- tifiers, which performs three-phase full-vvave rectification. The generated voltage (electromotive force) is in proportion to the strength of the magnetic field (magnet). This means that the voltage is proportional to the current of the rotor coil and to the rotation speed, i.e. the moving speed of the magnet. The generated voltage varies as the engine revolution speed of the vehicle changes. It is, therefore. necessary to regulate the voltage so that the battery can be charged. For this pur- pose, the current of the rotor coil is regulated, thereby produc- ing a regulated generator voltage. To achieve this operation, a regulator has been employed. The regulator is of an lC (integrated circuit) type and it is built inside the alternator itself.
(8)
III Cl Loa
(D)
(C)
I
III
attery
|
|
The eleorromotive force generated in a coil is generally ex- pressed by the following formula.
Where,
e : Induced electromotive force in coil (V) N : Number of turns of wire in coil
6%? Rate of change in magnetic flux (<15) per unit time
- : This means voltage is generated in such a direction that the change in magnetic flux is prevented, The magnetic flux increases in proportion to the current of the rotor coil. However. as the magnetic flux is reaching a satura- tion point, the increase ofthe magnetic flux is no longer propor- tional to the current.
_ _ d The output of the alternator Increases as the rotation (-0%)
increases, eventually reaching a saturation point. This saturation is believed to be caused by the decline of the
rate of change (-ga?) i.e. the rate of change in magnetic flux (Q5)
per unit time when the magnetic flux of the rotor is applied to the stator coil. Besides the controiiing bythe magnetic flux and rotation speed described above, the output is restricted by the electric resis- tance of the stator coil. This resistance, mainly attributable to the induction reactance of ac current, increases as the frequen- cy (rotation speed) rises.
The alternator is so designed that its electromotive force is generated at the stator coii. Therefore, the alternator features easy cooling and virtually trouble-free operation. r To connect the three pairs of stator coils, a “Y” connecting method is employed. Although this Y connecting method is inferior to a Delta-type connecting method in the maximum output current, the Y connecting method has a greater electromotive force at lower speeds. Moreover, the Y connect- ing method has an advantage of use ofthe neutral point. For these reasons, the Y connecting method has been widely used on small capacities less than 1 kW. The stator assembly is made up ofa laminated iron frame. This construction has been adopted so as to hold the stator coil and allow the magnetic flux from the rotor to pass through the coil easily (improvement of permeability). The installation of an iron core in the coil increases the self inoluctance. This causes an increase ot the inductive reactance in the case of AC current, resulting in reduced elecfromotive force. However, in the case of comparatively-iow frequencies, the installation of iron core has more favorable effects in in- creasing the electromotive force which is attained by improved permeability, even counteracting the aforesaid disadvantage. For this reason, the iron core is generally pur- pose of slots provided at the core is to retain the wound stator coil. These slots also serve as magnetic flux passages which have been so designed that the rotor magnetic flux intersects the stator coil effectively.
en
ge
ut curr
Fixed volta
Stator
coil
Slot
Pole cores (magnet poles)
CHARGING SYSTEM
Output reaches saturation
Output Characteristics
pomt at a certain revoiution speed
Revolution speed
Y conxnecting method Dena connecting
method
or coil (field coil)
|
|
QHARGING SYSTEM
Tneoreticaily speaking, six pieces of diodes are sufficient for fuli-wave rectification. However, the latest aiternators have employed two more diodes for the purpose of utilizing the electromotlve force at the neutral point. As a result, the latest alternator can produce a greater output current than the con- ventional alternators.
CH-6
OF oN OB
Neutral diode
Uffen
age
Neutral diode not provided.
Alternator rotation speed (rpm)
|
|
CHARGING SYSTEM
5. IN-VEHICLE INSPECTION
CAUTION: o Never touch at the battery terminals immediately after
the vehicle has been operated. Be certain to turn OFF the ignition key switch during the
inspection.
(1) Check the battery case for proper installing condition and
cracks. If the batter case exhibits improper installing condition or cracks, replace or repair the battery, as required.
(2) Check to see if the battery terminals exhibit corrosion and/or
loose condition. If the battery terminals exhibit corrosion and/or loose con- dition, remove the battery cable terminals from the terminal ot the battery. Remove any rust, using a wire brush or a fine abrasive paper. After the battery terminals have been con- nected, coat these terminal with a thin film of lithium grease. NOTE: - After the battery terminals have been cleaned, make
sure that no rust particle remains on the terminals.
(3) Check battery specific gravity and electrolyte level
Check the color of the l-lyolrometer.
REFERENCE (For Delco battery): Green dot is visible:
The battery is adequately charged.
NOTE:
o On the Delco battery, it is impossible to add the
electrolyte, for it is permanently sealed.
(4) Check of battery terminals
Visualiy check the battery terminals for corrosion
Hydrome-ter
|
|
CHARGING SYSTEM
If the inside of the clamp at the cable side becomes corroded, clean out the terminal with a wire brush or coarse ernery cloth.
NOTE:
Coat the terminal sections of the battery with a thin film of grease. This is an effective method to prevent rust formation.
(5) inspection of drive belt
Q) Visuaiiy check the belt for separation of the adhesive
rubber above and beiovv the core, core separation form _ the adhesive rubber, cracking or separation ofthe ribs, torn or vvorn ribs or cracks in the inner ridges of the ribs. . \. V If necessary replace the drive belt.
Measurement amount of belt deflection Push the midpoint of the drive belt between the alter- nator pulley and the water pump pulley by applying a force of 22 lb (10 kg). Measure the deflection of the drive beit. Specified Beit Deflection New belt: 4.0 - 5.0 mm (0.16 - 0.19 inch)
(With a pressed force of 22 Ib (10 kg) applied to a point indicated in figure) Used belt: 5.0 6.0 mm (0.20 - 0.23 inch)
(With a pressed force of 22 lb (10 kg) applied to a point indicated in figure) Adjust the drive belt tension, if necessary.
NOTE:
“New belt” refers to a belt which has been used less than 5 minutes on a running engine. “Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After replacing the drive belt, check that if fits properly in the ribbed grooves, especially in the places difficult to see. Alter installing a new belt, run the engine for about 5 minutes and then recheck the tension.
Alternator pulley
|
|
CHARGING SYSTEM
(6)
(7)
(8)
(9)
Check of fuses for continuity Fusible link Fusible link block EFI No. 1 fuse Engine fuse Gauge fuse Checking alternator wiring and listening for abnormal noises Q) Check to see lt the alternator Wlre is connected properly
to the alternator. Q2) Ensure that the alternator emits no abnormal noise while
the engine is running.
Check of charge warning lamp circuit G) Turn OFF all accessory switches. C2) Start the engine and vvarm up the engine thoroughiy.
Turn OFF the ignition switch. © the ignition switch is turned ON, ensure that the
charge Warning lamp goes on. After the engine has started, ensure that the charge
Warning lamp goes out. If the Warning lamp does not function as specified, troubleshoot warning lamp circuit.
Check ot charging circuit under no-loaded state NOTE: 0 If a battery/alternator tester is available, ccnnect such tester to the charging circuit according to the manufacturer’s instructions,
It such a tester is not availabte, connect a voltrneter and an ammeter to the alternator wiring and alternator as follows: 0 Disconnect the battery ground cabte from the negative
(-) terminal ot the battery. Connect an ammeter in series between the alternator wire terminal B and the alternator as indicated in the right figure. - Connect the positive (-) terminal of a voltmeter to the
terminal B as indicated in the right figure. Connect the negative '(-) terminal of the voltmeter tothe
engine ground. Wind vinyl tape around each connection section so as
to prevent short. 0 Reconnect the battery ground cabie to the negative (-)
terminal of the battery.
___| I Terminal B
|
|
CHARGING SYSTEM
10)
(2) Raise the engine speed from the idle speed to 2000 rpm. Take the readings of the ammeter and voitmeter. Standard Amperage: Not to exceed 10 A Standard Voltage: 13.5 - 14.3 V
Check the charging circuit as foilovvs: 1
F __
(1) Start the engine and Warm it up. @ _ (2) Raise the engine speed from the idle speed to 2000 E if rpm. Take the readings of the ammeter and _ , -25 voitmeter. I 5’
lt the voltage reading ls greater than the standard voltage, replace IC regulator.
It the voltage reading is less than the standard voltage, ground the terrninal F as indicated in the right figure, Proceed to start the engine. If the voltage reading becomes greater than the standard voltage under this setting, replace the IC regulator. lt the voltage reading is still less than the standard voltage under this setting, check the alternator.
Check of charging circuit under loaded state
G) Start the engine. Maintain the engine speed at 2000
rpm. Turn ON the high beams of the headlamps and set the blower fan motor switch to the Hi position. Take the reading of the ammeten Standard Amperage: 30 A or more
if the ammeter reading is less than 30 A, repair the alter- nator. (See page CH-8.) NOTE: When the battery is in a fully charged state, the ammeter reading may be less than 30 A during the aforesaid test.
CH-10
Terminal F
