DAIHATSU Rocky CHARGING SYSTEM 1, COMPONENTS ... CH 2 2. CHARGING SYSTEM CIRCUIT CH 3 3. TROUBLE SHOOTING CH- 3 4. DESCRIPTION .... CH. 4 5. IN-VEHICLE INSPECTION CH-7 6. REMOVAL 7. DISASSEMBL' 8. INSPECTION .. 9. ASSEMBLY 0. INSTALLATION .. CHCHARGING SYSTEM 1. COMPONENTS © Atternator assembly @ Pally lock nut ® @ Atternator pully @ Drive end frame © Stud bolt © Bearing © Retainer plate @ Atternator rotor assembly © Washer @ Bearing 2 © Bearing cover enon ® Wave washer @ Rectifier end frame assembly @ Rectifier holder @ Regulator assembly Brush ® Spring @ Brush holder @ Rear end cover CH-2CHARGING SYSTEM 2. CHARGING SYSTEM CIRCUIT atery| GRE ae Pe ia oe of = cage me So) icrequto at -----------4 3. TROUBLE SHOOTING Problem Possible causes T Remedies 7 Fuse blown = (Check gauge fuse. Charge waning tap wil not | Lamp bulb burt Replace bub gw van i igationSwCN S| Poor conection of wing Repair poor connection of wing Open wie opal or place IC regulator fauty Replace requitor assembly, [Dive betace or wor Tt or resiace | Battery cables loose, corroded or worn Repair or replace cables. Charge warring lamp wi nt go out event engine as | Fuse blown Check gauge fuse, started. Fusible link blown, Replace fusible link. IC rogultor raterator fauty Check charging sytem Wing fauty Repair or replace CHS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 for 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. Its, 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 altemators 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 endurable 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-wave 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 IC (integrated circuit) type and it is built inside the alternator itself CH-4 IC regulator @ ©) «© @CHARGING SYSTEM The electromotive force generated in a coil is generally ex- pressed by the following formula e : Induced electromotive force in coil (V) N_: Number of turns of wire in coil 28 Rate of change in magnetic flux (#) per unit ime — : 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 of the magnetic flux is no longer propor- tional to the current. db, dt The output of the alternator increases as the rotation ( increases, eventually reaching a saturation point. This saturation is believed to be caused by the decline of the rate of change (22) i, the rate of change in magnetic fox (6) per unit time when the magnetic flux of the rotor is applied to the stator coil. Besides the controlling by the 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 coil. Therefore, the alternator features easy cooling and virtually trouble-free operation. To connect the three pairs of stator coils, a “Y" connecting method is employed. Although this Y connecting method is inferior to @ 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 of the 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 of a 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 coll easily (improvement of permeability). The installation of an iron core in the coil increases the self inductance. This causes an increase of the inductive reactance in the case of AC current, resulting in reduced electromotive force. However, in the case of comparatively-low 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 employed. The 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. CHS (Output reaches saturation Output Characteristics point at 3 certain revolution speed Output current Revolution speed WTR Pole cores (magnet poves),CHARGING SYSTEM Theoretically speaking, six pieces of diodes are sufficient for full-wave rectification. However, the latest alternators have employed two more diodes for the purpose of utilizing the electromotive force at the neutral point. As a result, the latest alternator can produce a greater output current than the con- ventional alternators. CHS Field coll 3 z (Fixed voltage) Neutral diode | provided Neutral diode not provided. Allemator rotation speed (rom)5. IN-VEHICLE INSPECTION CAUTION: + 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 andjor loose condition. If the battery terminals exhibit corrosion andjor loose con- dition, remove the battery cable terminals from the terminal of the battery. Remove any rust, using a wire brush or a fine abrasive paper. Aiter 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. (8) Check battery specitic gravity and electrolyte level Check the color of the Hydrometer. REFERENCE (For Delco battery): Green dot is visible: ‘The battery is adequately charged. Dark (The green dot is invisible.): The battery must be charged. Clear or light yellow: Replace the battery. NOTE: * On the Delco battery, it is impossible to add the electrolyte, for itis permanently sealed. (4) Check of battery terminals © Visually check the battery terminals for corrosion. If necessary, clean and flush the terminals, using a brush with baking soda solution. CH? CHARGING SYSTEM wreCHARGING SYSTEM @ If the inside of the clamp at the cable side becomes corroded, clean out the terminal with a wire brush or coarse emery 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 © Visually check the belt for separation of the adhesive rubber above and below the core, core separation form the adhesive rubber, cracking or separation of the ribs, torn or worn ribs or cracks in the inner ridges of the ribs. 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 Ib (10 kg). Measure the deflection of the drive belt. Specified Belt Deflection New belt: 4.0 - 5.0 mm (0.16 - 0.19 inch) (With a pressed force of 22 lo (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: lew 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. ‘+ After installing a new belt, run the engine for about 5 minutes and then recheck the tension. CHS CL _- Water pump pulley 10 kg (2b) Deflection, Alternator pulley wrun.ciorCHARGING SYSTEM (6) Check of fuses for continuity Fusible link Fusible link block EFI No. 1 fuse Engine fuse Gauge fuse (7) Checking alternator wiring and listening for abnormal noises @® Check to see if the alternator wire is connected properly to the alternator. @® Ensure that the alternator emits no abnormal noise while the engine is running, wun. (8) Check of charge warning lamp circuit ® Tur OFF all accessory switches. ® Start the engine and warm up the engine thoroughly. Turn OFF the ignition switch. — @ When the ignition switch is turned ON, ensure that the charge warning lamp goes on. @ After the engine has started, ensure that the charge Seatac warning lamp goes out. If the warning lamp does not function as specified, troubleshoot warning lamp circuit (9) Check of charging circuit under no-loaded state NOTE: + If a battery/alternator tester is available, connect such tester to the charging circuit according to the manufacturer's instructions. @® If such a tester is not available, connect a voltmeter and an ammeter to the alternator wiring and alternator as follows: ‘* Disconnect the battery ground cable from the negative (©) terminal of 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 to the engine ground * Wind vinyl tape around each connection section so as to prevent short. * Reconnect the battery ground cable to the negative (-) terminal of the battery. CH-9CHARGING SYSTEM @® Check the charging circuit as follows: (1) Start the engine and warm it up. (2) Raise the engine speed from the idle speed to 2000 rpm. Take the readings of the ammeter and voltmeter. Standard Amperage: Not to exceed 10 A Standard Voltage: 13.5 - 14.3 V If the voltage reading is greater than the standard voltage, replace IC regulator. If the voltage reading is less than the standard voltage, ground the terminal 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. If the voltage reading is stil less than the standard voltage under this setting, check the alternator. (10) Check of charging circuit under loaded state © Start the engine. Maintain the engine speed at 2000 rom. Turn ON the high beams of the headlamps and set the blower fan motor switch to the Hi position, Take the reading of the ammeter. 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6. REMOVAL (1) Disconnect the ground cable terminal from the negative (-) terminal of the battery. (2) Disconnection of wires from alternator @ Remove the nut and wire from the alternator. @® Disconnect the connector from the alternator. (3) Removal of alternator drive belt Loosen the alternator attaching bolts. Remove the drive belt (4) Removal of alternator ® Remove the alternator attaching bolts. ® Remove the alternator from the engine compartment. CH+11 CHARGING SYSTEM Hycrometer wrmeororCHARGING SYSTEM 7. DISASSEMBLY (1) Remove the alternator pulley lock nut by means of an im- pact wrench. NOTE: Be sure to use an impact wrench having a hexagonal hole. (2) Removal of rear end cover ® Remove the nut and terminal insulator. ® Remove the three screws. © Remove the rear end cover. (3) Remove the brush holder. cH-12(4) Remove the regulator assembly. (5) Removal of rectifier holder ® Remove the attaching screws. @ Straighten the stator wire @ Remove the rectifier holder. (6) Remove the rectifier end frame from the drive end frame by removing the two nuts and bolts, NOTE: + Be very careful not to damage the stator wire + Ifany difficulty is encountered in the removal, lightly tap the shaft with a plastic hammer to facilitate the removal. (7) Remove the rotor from the drive end frame assembly, CHA3 CHARGING SYSTEMCHARGING SYSTEM 8. INSPECTION (1) Rotor ® Inspection of rotor for open circuit Using an ohmmeter, check to see if specified resistance exists between the rotor slip rings. Standard Resistance: 2.9+ 0.2.0 If no specified resistance exists, replace the rotor, ®@ Inspection of rotor for ground Ensure that no continuity exists between the rotor slip rings and the rotor core. If continuity exists, replace the rotor. TROT © Inspection of stip rings a. Check to see if the slip ring surface exhibits rough- ness, abnormal wear and/or burning Replace the rotor, if necessary. b. Measure the outer diameter of the slip ring, using vernier calipers. Standard Diameter: 14.4 mm (0.57 inch) Minimum Diameter: 14 mm (0.55 inch) If the slip ring diameter is less than the minimum diameter, replace the rotor assembly. CHa(2) Stator ® Inspection of stator for open circuit Using an chmmeter, check to see if any open circuit of the stator coil is present between the leads. If no continuity exists, replace the end frame assembly. Specified Resistance: About 0.2 2 @® Inspection of stator for short circuit Using an ohmmeter, check to see if any short circuit of the stator coil is present between the coil lead and the drive end frame. 'F continuity exists, replace the drive end frame assemb- ly, (3) Brush and Brush Holder @ Measurement of exposed brush length Measure the exposed brush length, using a scale. Standard Exposed Length: 10.5 mm Minimum Exposed Length: 1.5 mm If the exposed length is less than the minimum require- ment, replace the brushes. @® Replacement of brushes (If necessary) a. Remove the brush and spring from the brush holder by melting the solder by means of a soldering iron. NOTE: * Prior to the operation, remove the painting film at the solder surface with a knife or the like. * For this operation, it is advisable to use a soldering iron with a capacity of about 40 W. b. Install the brush cord in the brush holder with the spring fitted in place. NOTE: + Using a knife, etc., remove the soldered section of the brush holder to form a flat surface until the bare metal is exposed. CH-5 CHARGING SYSTEMCHARGING SYSTEM ¢. Solder the brush cord in the brush holder in such way that the exposed length of the brush meets the specification. Standard Exposed Length: 10.5 mm NOTE: + Prior to the operation, let solder flow onto the forward end of the brush wire. + To facilitate soldering: Route the wire through the holder hole and adjust the exposed length of the brush to the specification. Bend the wire at its forward end on which solder has been applied inthe preceding step. Then, solder the wire to the holder. d. Ensure that the brush moves freely in the brush holder. @. Cut off any excess remaining wire and apply an insulation paint. CHAE(4) Rectifier ® Inspection of rectifier at positive ® side a. While using an ohmmeter, connect one tester probe to the positive stud. Also, connect the other probe to each of the rectifier terminals. b, Repeat the same steps described in a. above with the polarity of the tester probes reversed this time. ¢. Ensure that continuity exists either in the step a. or in the step b. and no continuity exists at the other test. If not, replace the rectifier holder. @® Inspection of rectifier at negative © side a. While using an ohmmeter, connect one tester probe to each rectifier negative terminal, Also, connect the other probe to each rectifier terminal. b. Repeat the same steps described in a. above with the polarity of the tester probes reversed this time. ©. Ensure that continuity exists either in the step a. or in the step b. and no continuity exists at the other test. If not, replace the rectifier holder. CHAT CHARGING SYSTEMCHARGING SYSTEM (5) Bearings ® Inspection of front bearing Ensure that the bearing turns smoothly. Replace the bearing, if necessary. @® Replacement of front bearing (If necessary) a. Remove the four screws and retainer plate. b. Remove the front bearing from the drive end frame, using a socket wrench in conjunction with a press. ©. Press the new front bearing into the drive end frame, using suitable socket wrench. d. Attach the retainer plate to the drive end frame with the four screws. CheCHARGING SYSTEM @ Inspection of rear bearing Ensure that the bearing turns smoothly. Replace the bearing, if necessary. @ Replacement of rear bearing (if necessary) a. Remove the rear bearing and bearing cover from the rotor, using the armature bearing puller. NOTE: * Be very careful not to damage the fan during the removal. b. Press a new rear bearing with spacer, using a hydraulic press. ©. Press a new bearing cover, using a suitable steel pipe. CHI TaoCHARGING SYSTEM 9. ASSEMBLY (1) Install the rotor into the drive end frame assembly, (2) Installation of rectifier end frame on drive end frame. Install the rectifier end frame on the drive end frame with the two bolts and two nuts. NOTE: + Be very careful not to damage the stator wire during the installation. * If some resistance is encountered during the insertion, lightly tap the frame with a plastic hammer. (3) Installation of rectifier holder, regulator assembly and brush holder. @ Attach the rectifier holder to the end frame with the coil wires passed through the aperture of the rectifier holder. ® Wind the coil wire around the installing section of the rectifier attaching screws. @ Secure the four attaching screws. CH-20 WORCHARGING SYSTEM (4) Install the regulator assembly with the three attaching screws, (8) Install the brush holder in such a way that a gap of at least ‘1mm (0.04 inch) is provided between the brush holder and the regulator assembly. Secure the brush holder with the two screws, (6) Installation of rear cover © Install the rear end cover with the three attaching screws. @ Install the terminal insulator and tighten it with the nut. (7) Attach the pulley to the alternator shaft. (8) Tighten the SST B to the specified torque. Secure the the SST B to the alternator shaft. SSTs: 09820-87201-000 Specified Torque: 39 Nem (4 kgf-m) (9) Clamp the SST C in a vise. Tighten the nut by turning the SST B. Specified Torque: 110 Nem (11.25 kgt-m) (10) Remove the SSTs A and B. CHat TAROCHARGING SYSTEM (11) Ensure that the rotor turns smoothly. CH22CHARGING SYSTEM 10. INSTALLATION (1) Temporarily install the alternator on the engine with the two attaching bolts. (2) Connection of wire to alternator @® Connect the connectors to the alternator. ® Install the wire and nut to the alternator. TAOS (3) Installation of alternator drive belt © Install the alternator drive belt properly NoTe: * Make sure that the alternator drive belt is properly engaged in the grooves of each pulley. ze) Water pump pulley Alternator pulley TAO ® Tension adjustment of drive belt ‘Adjust the belt tension in such a way that the deflection of the drive belt meets the specification when you push the midpoint of the drive belt between he alternator pully and the water pump pully by applying a force | | nn | dag Leah of 10 kg (22 Ib). Specified Belt Deflection Correct Wrong Wrong New belt: 4.0 - 5.0 mm (0.16 - 0.20 inch) Used belt: 5.0 - 6.0 mm (0.20 - 0.24 inch) NoTE: Ta + ‘New belt” refers to a belt with 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 § minutes or more. * If belt replaced with new one, run the engine for about 5 minutes and then recheck the tension. CH-23CHARGING SYSTEM (4) Reconnect the ground cable terminal to the negative (-) terminal of the battery. cH24