Description and operation
The charging system includes a battery, an alternator with a built-in regulator,
and the charging indicator light and wire.
The Alternator has eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery
voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor
brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.
| Alternator Management System |
Alternator management system controls the charging voltage set point in order
to improve fuel economy, manage alternator load under various operating conditions,
keep the battery charged, and protect the battery from over-charging. ECM controls
generating voltage by duty cycle (charging control, discharging control, normal
control) based on the battery conditions and vehicle operating conditions.
The system conducts discharging control when accelerating a vehicle. Vehicle
reduces an alternator load and consumes an electric power form a battery.
The system conducts charging control when decelerating a vehicle. Vehicle increases
an alternator load and charges a battery.
Components and components location
1. ECM
2. Battery
3. Alternator
4. Starter
|
5. Instrument
Cluster
6. Ignition switch or start/stop button
7. Battery sensor
8. Hood switch
|
Troubleshooting
| •
|
Be careful not to short-circuit the wiring by the body or other
wirings.
|
| •
|
In case of discharging problem, measure dark current at all
times.
(Charging System - "Dark Current Inspection").
|
| •
|
When checking the alternator main fuse, perform continuity test
and voltage test between terminals as well as visual check to
confirm normal operation.
|
| •
|
When checking the ground, repair or replace after inspecting
for defective ground cable, defective installation or defective
contact due to foreign object.
|
| •
|
It is not recommended to use non-authentic parts as installing
non-authentic parts may cause malfunction of charging system.
|
| •
|
Be careful as misassembly may cause short-circuit of wiring,
which may result in battery discharge.
|
| •
|
As it will reset and appear as normal if the battery negative
(-) terminal is disconnected while measuring dark current, measure
by using a hook meter without disconnecting the negative (-)
terminal.
|
| •
|
Note that there may be various phenomenons / possible causes
/ repair measures apart from above.
|
| •
|
For more effective repairs, refer to DTC guide and ETM.
|
|
Symptom
|
Suspected Area
|
Remedy
|
Charging warning lamp does not turn on during IG ON.
|
Broken alternator main fuse
|
Inspect / Repair / Replace fuse.
|
Broken instrument cluster fuse
|
Inspect / Repair / Replace fuse.
|
Broken instrument cluster internal bulb
|
Inspect / Repair / Replace instrument cluster.
|
Defective connection of wiring connector
|
Inspect / Repair / Replace wiring connection.
|
Defective voltage regulator or alternator
|
Inspect / Repair / Replace voltage regulator or alternator.
|
Defective connection of battery terminal
|
Inspect tightening of (+) and (-) battery terminals to specified torque.
|
Communication error
|
Inspect wiring between regulator and ECM.
|
Inspect transmission signal of ECM.
|
Inspect / Repair / Replace alternator if the wiring and ECM are normal.
|
Charging warning lamp does not turn off during engine running.
|
Worn drive belt or lack of tension
|
Inspect / Repair / Replace drive belt.
|
Defective connection, corroded or worn battery cable
|
Inspect connection of battery cable and Inspect / Repair / Replace cable.
|
Broken alternator main fuse
|
Inspect / Replace alternator main fuse or battery cable.
|
Defective voltage regulator or alternator
|
Inspect / Replace voltage regulator or alternator.
|
Defective wiring
|
Inspect / Replace wiring.
|
Defective instrument cluster
|
Inspect / Replace instrument cluster
|
Slip in alternator pulley
|
Inspect / Replace alternator pulley.
|
Adjust tension / Replace drive belt.
|
Defective connection of battery terminal
|
Inspect tightening of (+) and (-) battery terminals to specified torque.
|
Charging warning lamp turns on.
|
Slip, worn or lack of tension in drive belt
|
Adjust tension / Replace drive belt.
|
Inspect / Replace auto tensioner (only for auto tensioner type).
|
Error in Alternator Management System (AMS) voltage
|
Inspect battery sensor connecting harness and connection with body.
|
Error in battery sensor
|
Inspect / Repair / Replace battery sensor.
|
Short between battery sensor wiring and body
|
Inspect / Repair / Replace battery sensor.
|
Defective alternator L terminal output power
|
Inspect / Repair / Replace alternator or regulator.
|
Degradation due to defective contact of battery (+) terminal
|
Check tightening to specified torque / Inspect / Repair / Replace battery
wiring.
|
Short in alternator connecting extension connector internal pin
|
Inspect / Repair / Replace wiring.
|
|
Short circuit between body and mission ground
|
Inspect / Repair / Replace ground.
|
Communication error
|
Inspect / Repair / Replace wiring between regulator and ECM.
|
Inspect transmission signal of ECM.
|
Inspect / Repair / Replace alternator if wiring and ECM are normal.
|
Short in the middle of connection to alternator L terminal
(L terminal applied vehicle model)
|
Inspect / Repair / Replace wiring.
|
Drive belt rotation stops due to slip in crankshaft damper pulley or defective
pulley.
|
Inspect or replace crankshaft damper pulley / Inspect, repair or replace
drive belt tensioner bearing.
|
Slip, worn or lack of tension in drive belt
|
Adjust tension / Inspect / Repair / Replace drive belt.
|
Defective voltage regulator
|
Inspect / Repair / Replace voltage regulator.
|
Defective alternator
|
Inspect / Repair / Replace alternator.
|
Broken alternator main fuse
|
Inspect / Repair / Replace alternator main fuse or battery wiring cable.
|
Defective ground
|
Inspect / Repair / Replace ground.
|
Discharged battery
|
Adjust tension / Inspect / Repair / Replace drive belt.
|
Inspect / Repair / Replace wiring connection.
|
Inspect / Repair / Replace alternator main fuse.
|
Inspect / Repair / Replace alternator.
|
Inspect / Repair / Replace voltage regulator.
|
Inspect / Repair / Replace battery unit.
|
Inspect for dark current / Repair / Replace.
|
Learn / Inspect / Repair / Replace battery sensor.
|
Inspect for short / Repair / Replace battery cable.
|
Inspect / Repair / Replace ECM.
|
Inspect / Repair / Replace body electrical related parts.
|
Inspect / Repair / Replace installation status of alternator connector.
|
Inspect / Repair / Replace tightening of (+) and (-) battery terminals to
specified torque.
|
Swollen battery
|
Defective battery
|
Inspect / Replace battery.
|
Defective voltage regulator or alternator
|
Inspect / Repair / Replace voltage regulator or alternator.
|
Defective charging related parts or wiring
|
Inspect / Repair / Replace charging related parts and wiring.
|
After inspection, repair or replace related parts in case of malfunction.
|
Schematic diagrams
Repair procedures
| • |
Battery efficiency inspection
|
| • |
Battery voltage inspection
|
| • |
Charging voltage insptection
|
| • |
Terminal tightening state inspection
|
| • |
Engine/ transaxle ground state inspection
|
| • |
Wiring harness ground state inspection
|
| • |
Electrical Specified Value Inspection
|
| • |
Vehicle parasitic current inspection
|
| • |
Battery capacity inspection
|
Battery Efficiency Inspection
| •
|
Check that the battery cables are connected to the correct terminals.
|
| •
|
Disconnect the battery cables when the battery is given a quick
charge.
|
| •
|
Never disconnect the battery while the engine is running.
|
|
| •
|
Inspect the battery test using the load tester and battery tester.
|
|
Battery Voltage Inspection
|
1. |
After having driven the vehicle and in the case that 20 minutes have
not passed after having stopped the engine, turn the ignition switch
ON and turn on the electrical system (headlamp, blower motor, rear defogger
etc.) for 60 seconds to remove the surface charge.
|
|
2. |
Turn the ignition switch OFF and turn off the electrical systems.
|
|
3. |
Measure the battery voltage between the negative (-) and positive (+)
terminals of the battery.
|
Standard voltage : About 12.5 - 12.9V (20°C)
|
If the voltage is less than specification, charge the battery.
|
General Inspection
|
1. |
Check that the battery terminals are not loose or corroded.
(Refer to Charging System - "Battery")
|
|
2. |
Check the fuses for continuity.
Alternator Fuse
|
(1) |
Check the alternator fuse for continuity.
|
|
(2) |
Measure the voltage as shown in the image below.
|
Standard value : Approximately 0V
|
|
|
(3) |
If the alternator fuse is blown, replace it as in the procedure
below:
|
a. |
Turn ignition switch OFF and disconnect the battery
negative (-) terminal.
|
|
b. |
Remove the battery positive (+) cable mounting nuts
(A).
|
|
c. |
Remove the battery positive (+) cable (B).
|
|
d. |
Replace the norminal alternator fuse or battery cable.
|
|
e. |
Install in the reverse order of removal.
|
|
Battery Sensor Fuse
|
(4) |
Check the battery sensor fuse for continuity.
|
|
(5) |
If the alternator fuse is blown, replace the battery sensor
fuse.
|
|
(6) |
Measure the voltage.
|
Standard value : Approximately 0V
|
|
|
|
3. |
Inspect Drive Belt
|
(1) |
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
|
• |
Cracks on the rib side of a belt are considered
acceptable. If the belt has chunks missing from
the ribs, it should be replaced.
|
|
|
|
|
4. |
Measure and adjust drive belt tension.
(Refer to Engine Mechanical System - "Drive Belt")
|
|
5. |
Visually check alternator wiring and listen for abnormal noises.
|
(1) |
Check that the wiring is in good condition.
|
|
(2) |
Check that there is no abnormal noise from the alternator while
the engine is running.
|
|
|
6. |
Check Discharge Warning Light Circuit
|
(1) |
Warm up the engine and then turn it off.
|
|
(2) |
Turn off all accessories.
|
|
(3) |
Turn the ignition switch "ON". Check that the discharge warning
light is lit.
|
|
(4) |
Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the
discharge light circuit.
|
|
Terminal Tightening State Inspection
| •
|
Alternator B+ terminal state
|
| •
|
Alternator B+ termina tightening nut
|
| •
|
Battery positive (+) terminal state
|
| •
|
Battery positive (+) terminal tightening nut state
|
| •
|
Battery negative (-) terminal state
|
| •
|
Battery negative (-) terminal tightening nut state
|
| •
|
Battery negative (-) terminal mounting bolt tightening state
(Chassis ground)
|
| •
|
Battery sensor negative (-) terminal state (With battery sensor)
|
| •
|
Battery sensor negative (-) terminal tightening nut state (With
battery sensor)
|
| •
|
Battery sensor negative (-) terminal mounting bolt tightening
state (Chassis ground) [With battery sensor]
|
| •
|
Engine room fuse & relay box positive (+) harness state
|
| •
|
Engine room fuse & relay box positive (+) harness tightening
nut state
|
| •
|
Check the status of ground fault by chassis paint
|
|
| Inspection Component Location |
1. Alternator
B+ terminal
2. Engine room fuse & relay box positive (+) terminal
3. Battery positive (+) terminal
|
4. Battery negative
(-) terminal
5. Chassis ground
|
Engine / Transmission Ground State Inspection
| •
|
Mounting bolt tightening state (Chassis)
|
| •
|
Mounting bolt tightening state (Engine)
|
| •
|
Check the status of ground fault by chassis paint
|
|
Wiring harness ground state inspection
| •
|
Mounting bolt tightening state (Chassis)
|
| •
|
Mounting bolt tightening state (Engine)
|
| •
|
Check the status of ground fault by chassis paint
|
|
Electrical Specified Value Inspection (Using the Voltmeter and Ammeter)
|
1. |
Voltage Drop Test of Alternator Output Wire
This test determines whether or not the wiring between the alternator
"B" terminal and the battery (+) terminal is good by the voltage drop
method.
|
(1) |
Preparation
|
a. |
Turn the ignition switch to "OFF".
|
|
b. |
Disconnect the output wire from the alternator "B" terminal.
Connect the (+) lead wire of ammeter to the "B" terminal
of alternator and the (-) lead wire of ammeter to the
output wire. Connect the (+) lead wire of voltmeter
to the "B" terminal of alternator and the (-) lead wire
of voltmeter to the (+) terminal of battery.
|
|
|
(2) |
Test
|
b. |
Turn on the headlamps and blower motor, adjust the engine
speed until the ammeter indicates 20A and read the voltmeter.
|
|
|
(3) |
Result
|
a. |
The voltmeter may indicate the standard value.
|
Standard value : 0.2V max
|
|
|
b. |
If the value of the voltmeter is higher than expected
(above 0.2V max.), poor wiring is suspected. In this
case check the wiring from the alternator "B" terminal
to the battery (+) terminal. Check for loose connections,
color change due to an over-heated harness, etc. Correct
them before testing again.
|
|
c. |
Upon completion of the test, set the engine speed at
idle.Turn off the headlamps, blower motor and the ignition
switch.
|
|
|
|
2. |
Output Current Test
This test determines whether or not the alternator gives an output current
that is equivalent to the normal output.
|
(1) |
Preparation
|
a. |
Prior to the test, check the following items and correct
as necessary.
Check the battery installed in the vehicle to ensure
that it is in good condition. Refer to the "Battery"
section for checking battery.
The battery used to test the output current should be
partially discharged.
With a fully charged battery, the test may not be conducted
correctly due to an insufficient load.
Check the tension of the alternator drive belt. Refer
to the "Inspect drive belt" section for checking the
belt tension.
|
|
b. |
Turn off the ignition switch.
|
|
c. |
Disconnect the battery ground cable.
|
|
d. |
Disconnect the alternator output wire from the alternator
"B" terminal.
|
|
e. |
Connect a DC ammeter (0 to 90A) in series between the
"B" terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected
output wire.
|
• |
Tighten each connection securely, as
a heavy current will flow. Do not rely
on clips.
|
|
|
|
f. |
Connect a voltmeter (0 to 20V) between the "B" terminal
and ground. Connect the (+) lead wire to the alternator
"B" terminal and (-) lead wire to a good ground.
|
|
g. |
Connect the battery ground cable.
|
|
h. |
Leave the engine hood open.
|
|
|
(2) |
Test
|
a. |
Check to see that the voltmeter reads the same value
as the battery voltage. If the voltmeter reads 0V, open
circuit in the wire between alternator "B" terminal
and battery (+) terminal or poor grounding is suspected.
|
|
b. |
Start the engine and turn on the headlamps.
|
|
c. |
Set the headlamps to high beam and the heater blower
switch to HIGH, quickly increase the engine speed to
2,500 RPM and read the maximum output current value
indicated by the ammeter.
|
• |
After the engine start up, the charging
current quickly drops. Therefore, the
above operation must be done quickly
to read the maximum current value correctly.
|
|
|
|
|
(3) |
Result
|
a. |
The ammeter reading must be higher than the limit value.
If it is lower despite the alternator output wire is
in good condition, remove the alternator from the vehicle
and test it.
|
Limit value : 60% of the voltage rate
|
|
• |
The nominal output current value is
shown on the nameplate affixed to the
alternator body.
|
|
|
• |
The output current value changes with
the electrical load and the temperature
of the alternator itself. Therefore,
the nominal output current may not be
obtained. If such is the case, keep
the headlamps on to discharge the battery
or use lights of other vehicles to increase
the electrical load.
The nominal output current may not be
obtained if the temperature of the alternator
itself or ambient temperature is too
high. In such a case, reduce the temperature
before testing again.
|
|
|
|
b. |
Upon completion of the output current test, lower the
engine speed to idle and turn off the ignition switch.
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Remove the ammeter and voltmeter and the engine tachometer.
|
|
e. |
Connect the alternator output wire to the alternator
"B" terminal.
|
|
f. |
Connect the battery negative (-) terminal.
|
|
|
|
3. |
Regulated Voltage Test
The purpose of this test is to check that the electronic voltage regulator
controls voltage correctly.
|
(1) |
Preparation
|
a. |
Prior to the test, check the following items and correct
if necessary.
Check that the battery installed on the vehicle is fully
charged. Refer to the "Battery" section for checking
the battery.
Check the alternator drive belt tension. Refer to the
"Inspect drive belt" section for checking the belt tension.
|
|
b. |
Turn ignition switch to "OFF".
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Connect a digital voltmeter between the "B" terminal
of the alternator and ground. Connect the (+) lead of
the voltmeter to the "B" terminal of the alternator.
Connect the (-) lead to good ground or the battery (-)
terminal.
|
|
e. |
Disconnect the alternator output wire from the alternator
"B" terminal.
|
|
f. |
Connect a DC ammeter (0 to 90A) in series between the
"B" terminal and the disconnected output wire. Connect
the (-) leadwire of the ammeter to the disconnected
output wire.
|
|
g. |
Connect the battery negative (-) terminal.
|
|
|
(2) |
Test
|
a. |
Turn on the ignition switch and check to see that the
voltmeter indicates the following value.
|
Voltage : Battery voltage
|
If it reads 0V, there is an open circuit in the wire
between the alternator "B" terminal and the battery
and the battery (-) terminal.
|
|
b. |
Start the engine. Keep all lights and accessories off.
|
|
c. |
Run the engine at a speed of about 2,500 RPM and read
the voltmeter when the alternator output current drops
to 10A or less
|
|
|
(3) |
Result
|
a. |
If the voltmeter reading doesn't agree with the standard
value, the voltage regulator or the alternator is faulty.
|
Regulated Voltage : 11.7 - 15.3V
|
|
|
b. |
If the voltmeter reading doesn't agree with the standard
value, the voltage regulator or the alternator is faulty.
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Remove the voltmeter and ammeter.
|
|
e. |
Connect the alternator output wire to the alternator
"B" terminal.
|
|
f. |
Connect the battery negative (-) terminal.
|
|
|
Electrical Specified Value Inspection (Using the Voltmeter and Clamp type Ammeter)
|
1. |
Voltage Drop Test of Alternator Output Wire
This test determines whether or not the wiring between the alternator
"B" terminal and the battery (+) terminal is good by the voltage drop
method.
|
(1) |
Preparation
|
a. |
Turn the ignition switch to "OFF".
|
|
b. |
Install the clamp type ammeter between battery positive
(+) and alternator "B" terminal.
|
|
c. |
Connect the (+) lead wire of voltmeter to the "B" terminal
of alternator and the (-) lead wire of voltmeter to
the (+) terminal of battery.
|
|
|
(2) |
Test
|
b. |
Turn on the headlamps and blower motor, adjust the engine
speed until the ammeter indicates 20A and read the voltmeter.
|
|
|
(3) |
Result
|
a. |
The voltmeter may indicate the standard value.
|
Standard value : 0.2V max
|
|
|
b. |
If the value of the voltmeter is higher than expected
(above 0.2V max.), poor wiring is suspected. In this
case check the wiring from the alternator "B" terminal
to the battery (+) terminal. Check for loose connections,
color change due to an over-heated harness, etc. Correct
them before testing again.
|
|
c. |
Upon completion of the test, set the engine speed at
idle.Turn off the headlamps, blower motor and the ignition
switch.
|
|
|
|
2. |
Output Current Test
This test determines whether or not the alternator gives an output current
that is equivalent to the normal output.
|
(1) |
Preparation
|
a. |
Prior to the test, check the following items and correct
as necessary.
Check the battery installed in the vehicle to ensure
that it is good condition. Refer to the "Battery" section
for checking the battery.
The battery used to test the output current should be
partially discharged.
With a fully charged battery, the test may not be conducted
correctly due to an insufficient load.
Check the tension of the alternator drive belt. Refer
to the "Inspect drive belt" section for checking the
belt tension.
|
|
b. |
Turn off the ignition switch.
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Install the clamp type ammeter between battery positive
(+) and alternator "B" terminal.
|
|
e. |
Connect a DC ammeter (0 to 90A) in series between the
"B" terminal and the disconnected output wire. Be sure
to connect the (-) lead wire of the ammeter to the disconnected
output wire.
|
• |
Tighten each connection securely, as
a heavy current will flow. Do not rely
on clips.
|
|
|
|
f. |
Connect a voltmeter (0 to 20V) between the "B" terminal
and ground. Connect the (+) lead wire to the alternator
"B" terminal and (-) lead wire to a good ground.
|
|
g. |
Connect the battery negative (-) terminal.
|
|
h. |
Leave the engine hood open.
|
|
|
(2) |
Test
|
a. |
Check to see that the voltmeter reads the same value
as the battery voltage. If the voltmeter reads 0V, open
circuit in the wire between alternator "B" terminal
and battery (+) terminal or poor grounding is suspected.
|
|
b. |
Start the engine and turn on the headlamps.
|
|
c. |
Set the headlamps to high beam and the heater blower
switch to HIGH, quickly increase the engine speed to
2,500 RPM and read the maximum output current value
indicated by the ammeter.
|
• |
After the engine start up, the charging
current quickly drops. Therefore, the
above operation must be done quickly
to read the maximum current value correctly.
|
|
|
|
|
(3) |
Result
|
a. |
The ammeter reading must be higher than the limit value.
If it is lower despite the alternator output wire is
in good condition, remove the alternator from the vehicle
and test it.
|
Limit value : 60% of the voltage rate
|
|
• |
The nominal output current value is
shown on the nameplate affixed to the
alternator body.
|
|
|
• |
The output current value changes with
the electrical load and the temperature
of the alternator itself. Therefore,
the nominal output current may not be
obtained. If such is the case, keep
the headlamps on to discharge the battery
or use lights of other vehicles to increase
the electrical load.
The nominal output current may not be
obtained if the temperature of the alternator
itself or ambient temperature is too
high. In such a case, reduce the temperature
before testing again.
|
|
|
|
b. |
Upon completion of the output current test, lower the
engine speed to idle and turn off the ignition switch
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Remove the ammeter and voltmeter and the engine tachometer.
|
|
e. |
Connect the alternator output wire to the alternator
"B" terminal.
|
|
f. |
Connect the battery negative (-) terminal.
|
|
|
|
3. |
Regulated Voltage Test
The purpose of this test is to check that the electronic voltage regulator
controls voltage correctly.
|
(1) |
Preparation
|
a. |
Prior to the test, check the following items and correct
if necessary.
Check that the battery installed on the vehicle is fully
charged. Refer to the "Battery" section for checking
the battery.
Check the alternator drive belt tension. Refer to the
"Inspect drive belt" section for checking the belt tension.
|
|
b. |
Turn ignition switch to "OFF".
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Connect a digital voltmeter between the "B" terminal
of the alternator and ground. Connect the (+) lead of
the voltmeter to the "B" terminal of the alternator.
Connect the (-) lead to good ground or the battery (-)
terminal.
|
|
e. |
Disconnect the alternator output wire from the alternator
"B" terminal.
|
|
f. |
Connect a DC ammeter (0 to 90A) in series between the
"B" terminal and the disconnected output wire.Connect
the (-) lead wire of the ammeter to the disconnected
output wire.
|
|
g. |
Connect the battery negative (-) terminal.
|
|
|
(2) |
Test
|
a. |
Turn on the ignition switch and check to see that the
voltmeter indicates the following value.
|
Voltage : Battery voltage
|
If it reads 0V, there is an open circuit in the wire
between the alternator "B" terminal and the battery
and the battery (-) terminal.
|
|
b. |
Start the engine. Keep all lights and accessories off.
|
|
c. |
Run the engine at a speed of about 2,500 RPM and read
the voltmeter when the alternator output current drops
to 10A or less
|
|
|
(3) |
Result
|
a. |
If the voltmeter reading does not agree with the standard
value, the voltage regulator or the alternator is faulty.
|
Regulated Voltage : 11.7 - 15.3V
|
|
|
b. |
If the voltmeter reading does not agree with the standard
value, the voltage regulator or the alternator is faulty.
|
|
c. |
Disconnect the battery negative (-) terminal.
|
|
d. |
Remove the voltmeter and ammeter.
|
|
e. |
Connect the alternator output wire to the alternator
"B" terminal.
|
|
f. |
Connect the battery negative (-) terminal.
|
|
|
Vehicle parasitic current inspection
[Using the Ammeter]
|
1. |
Turn the all electric devices OFF, and then turn the ignition switch
OFF.
|
|
2. |
Close all doors except the engine hood, and then lock all doors.
|
(1) |
Disconnect the hood switch connector.
|
|
(3) |
Close the doors or remove the door switches.
|
|
|
3. |
Wait for a few minutes until the vehicle’s electrical systems go to
sleep mode.
|
• |
For an accurate measurement of a vehicle parasitic current,
all electrical systems should go to sleep mode. (It
takes at least one hour or at most one day.) However,
an approximate vehicle parasitic current can be measured
after 10-20 minutes.
|
|
|
|
4. |
Connect an ammeter in series between the battery (-) terminal and the
ground cable, and then disconnect the clamp from the battery (-) terminal
slowly.
|
• |
Be careful that the lead wires of an ammeter do not
come off from the battery (-) terminal and the ground
cable to prevent the battery from being reset. In case
the battery is reset, connect the battery cable again,
and then start the engine or turn the ignition switch
ON for more than 10 sec. Repeat the procedure from No.
1.
To prevent the battery from being reset during the inspection:
|
|
1) |
Connect a jump cable between the battery (-) terminal
and the ground cable.
|
|
2) |
Disconnect the ground cable from the battery (-) terminal.
|
|
3) |
Connect an ammeter between the battery (-) terminal
and the ground cable.
|
|
4) |
After disconnecting the jump cable, read the current
value of the ammeter.
|
|
|
|
5. |
Read the current value of the ammeter.
| •
|
If the parasitic current is over the limit value, search for
abnormal circuit by removing the fuses one by one and checking
for parasitic current.
|
| •
|
Reconnect only the fuse suspected of parasitic current and search
for the trouble unit by removing the components connected to
the circuit one by one until the parasitic draw drops below
limit value.
|
|
Limit value (after 10 - 20 min.) : Below 50mA
|
|
[Using the Clamp type Ammeter]
|
6. |
Turn the all electric devices OFF, and then turn the ignition switch
OFF.
|
|
7. |
Close all doors except the engine hood, and then lock all doors.
|
(1) |
Disconnect the hood switch connector.
|
|
(3) |
Close the doors or remove the door switches.
|
|
|
8. |
Wait for a few minutes until the vehicle’s electrical systems go to
sleep mode.
|
• |
For an accurate measurement of a vehicle parasitic current,
all electrical systems should go to sleep mode. (It
takes at least one hour or at most one day.) However,
an approximate vehicle parasitic current can be measured
after 10 - 20 minutes.
|
|
|
|
9. |
Install the clamp type ammerter on battery negative (-) terminal.
|
|
10. |
Read the current value of the ammeter.
| •
|
If the parasitic current is over the limit value, search for
abnormal circuit by removing the fuses one by one and checking
for parasitic current.
|
| •
|
Reconnect only the fuse suspected of parasitic current and search
for the trouble unit by removing the components connected to
the circuit one by one until the parasitic draw drops below
limit value.
|
|
Limit value (after 10 - 20 min.) : Below 50mA
|
|
Alternator. Description and operation
The Alternator has eight built-in diodes, each rectifying AC current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery
voltage detection system.
The alternator is regulated by the battery voltage detection system.
The main components of the alternator are the rotor, stator, rectifier, capacitor
brushes, bearings and V-ribbed belt pulley.
The brush holder contains a built-in electronic voltage regulator.
1. Brush
2. Drive belt pully
3. Rotor
4. Stator
|
Alternator. Specifications
Item
|
Specification
|
Rated voltage
|
13.5V , 130A
|
Speed in use
|
1,000 - 18,000rpm
|
Pin
|
1 (LIN)
|
Pulley Type
|
OAP pulley
|
Alternator. Repair procedures
| •
|
Be careful not to damage the parts located under the vehicle
(floor under cover, fuel filter, fuel tank and canister) when
raising the vehicle using the lift.
(Refer to General Information - "Lift and Support Points")
|
|
|
1. |
Turn the ignition switch OFF and disconnect the battery (-) terminal.
|
|
2. |
Remove the drive belt.
(Refer to Engine Mechanical System - "Drive Belt")
|
|
3. |
Disconnect the alternator connector (A).
|
|
4. |
Remove the cable nut (A) from the alternator "B" terminal.
|
Tightening torque :
18.6 - 24.5 N.m (1.9 - 2.5 kgf.m, 13.7 - 18.1 Ib-ft)
|
|
|
5. |
Remove the alternator mounting bolts.
|
Tightening torque :
49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 Ib-ft)
|
|
|
6. |
Remove the alternator (A).
|
|
1. |
Install in the reverse order of removal.
|
|
1. |
Remove the shaft cap (A).
|
• |
When installing, replace with new shaft cap.
|
|
|
|
2. |
Remove the OAP pulley (A).
|
|
3. |
Remove the alternator cover (A) after loosening the mounting nut.
|
|
4. |
Remove the regulator assembly (A).
|
|
5. |
Remove the stator leads (A).
|
|
6. |
Remove the 4 through bolts (A).
|
|
7. |
Separate the rotor (A) and cover (B).
|
|
1. |
Reassemble in the reverse order of disassembly.
|
• |
When installing, replace with new shaft cap.
|
|
|
Rotor
|
1. |
Check that there is continuity between the slip rings (C).
|
|
2. |
Check that there is no continuity between the slip rings and the rotor
(B) or rotor shaft (A).
|
|
3. |
If the rotor fails either continuity check, replace the alternator.
|
Stator
|
1. |
Check that there is continuity between each pair of leads (A).
|
|
2. |
Check that there is no continuity between each lead and the coil core.
|
|
3. |
If the coil fails either continuity check, replace the alternator.
|
Battery. Description and operation
AGM Battery
AGM battery is used for especially heavy load on the vehicle network depending
on equipment and requirements. AGM stands for Absorbent Glass Material Battery;
that is absorbent glass fibre fleece. AGM batteries are fitted in models with
electrical loads/consumers which have a high energy demand.The constantly increasing
energy demand of modern vehicle electrical systems calls for ever more powerful
battery solutions.The power consumption is considerable even when the vehicle
is parked.The somewhat higher price compared with a battery of similar size
is fully balanced by the following benefits :
| – |
Significantly longer service life
|
| – |
Increased starting reliability at low temperatures
|
| – |
100 % freedom from maintenance
|
| – |
Low risk in event of an accident (reduced risk to the environment)
|
[AGM70L]
| •
|
After disconnecting then reconnecting the battery negative cable,
reset some parts that require the reset procedures.
(Refer to Body Electrical System - "General Information")
|
|
CMF Battery
The CMF (Closed Maintenance Free) battery is, as the name implies, totally maintenance
free and has no removable battery cell caps.
The CMF (Closed Maintenance Free) battery does not require water replenishment
for the repair.
The battery is completely sealed, except for small vent holes in the cover.
[CMF68L]
Battery. Troubleshooting
Battery. Specifications
â–· CMF68L-DIN
Item
|
Specification
|
Model type
|
CMF68L-DIN
|
Capacity [20HR/5HR] (AH)
|
68 / 54
|
Cold Cranking Amperage (A)
|
600
|
Reserve Capacity (Min)
|
110
|
Specific Gravity
|
1.25 - 1.31 [25°C (77°F)]
|
Voltage (V)
|
12
|
â–· AGM70L-DIN
Item
|
Specification
|
Model type
|
AGM70L-DIN
|
Capacity [20HR/5HR] (AH)
|
70 / 56
|
Cold Cranking Amperage (A)
|
760 (SAE) / 760 (EN)
|
Reserve Capacity (Min)
|
120
|
Specific Gravity
|
1.30 ~ 1.32 [25°C (77°F)]
|
Voltage (V)
|
12
|
| •
|
Model type description
|
| •
|
Cold Cranking Ampere (CCA) : A rating used in the battery industry
to define a battery's ability to start an engine in cold temperatures.
|
| –
|
The rating is the number of amps a new, fully charged battery
can deliver at -18°C (-0.4°F) for 30 seconds, while maintaining
a voltage of at least 7.2 volts for a 12 volt battery.
|
| –
|
The higher the CCA rating, the greater the starting power of
the battery.
|
| •
|
RESERVE CAPACITY (RC) : A battery industry rating, defining
a battery's ability to power a vehicle with an inoperative alternator
or fan belt.
|
| –
|
The rating is the number of minutes a battery at 26.7°C (80°F)
can be discharged at 25 amps and maintain a voltage of 10.5
volts for a 12 volt battery.
|
| –
|
The higher the reserve rating, the longer your vehicle can operate
should your alternator or fan belt fail.
|
|
|
BCI Type
Capacity
(5HR/20HR)
|
Length
|
Width
|
Height
|
Total Height
|
L (mm)
|
W (mm)
|
T (mm)
|
TH (mm)
|
28/35
|
188 - 192
|
126 - 130
|
198 - 202
|
218 - 222
|
32/40
|
194 - 198
|
133 - 137
|
199 - 203
|
223 - 227
|
36/45
|
203 - 207
|
173 - 177
|
200 - 204
|
221 - 225
|
44/55
|
213 - 217
|
173 - 177
|
198 - 202
|
218 - 222
|
48/60
|
228 - 232
|
173 - 177
|
200 - 204
|
221 - 225
|
54/68
|
258 - 262
|
173 - 177
|
198 - 202
|
220 - 224
|
56/70
|
258 - 262
|
173 - 177
|
198 - 202
|
223 - 227
|
64/80
|
274 - 278
|
170 - 174
|
198 - 202
|
221 - 225
|
70/88
|
349 - 353
|
172 - 176
|
186 - 200
|
183 - 187
|
72/90
|
300 - 304
|
170 - 174
|
200 - 204
|
221 - 225
|
76/95
|
294 - 298
|
172 - 176
|
198 - 202
|
220 - 224
|
80/100
|
326 - 330
|
170 - 174
|
203 - 207
|
225 - 229
|
[DIN Type]
Capacity
(5HR/20HR)
|
Length
|
Width
|
Height
|
Total Height
|
L (mm)
|
W (mm)
|
T (mm)
|
TH (mm)
|
36/45
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
48/60
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
54/68
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
64/80
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
72/90
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
80/100
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
88/110
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
[AGM DIN Type]
Capacity
(5HR/20HR)
|
Length
|
Width
|
Height
|
Total Height
|
L (mm)
|
W (mm)
|
T (mm)
|
TH (mm)
|
40/50
|
205 - 207
|
173 - 175
|
164 - 168
|
188 - 190
|
48/60
|
227 - 229
|
173 - 175
|
164 - 168
|
188 - 190
|
56/70
|
276 - 278
|
173 - 175
|
164 - 168
|
188 - 190
|
64/80
|
312 - 314
|
173 - 175
|
164 - 168
|
188 - 190
|
72/90
|
351 - 353
|
173 - 175
|
164 - 168
|
188 - 190
|
84/105
|
392 - 394
|
173 - 175
|
164 - 168
|
188 - 190
|
|
Battery. Repair procedures
Battery
|
1. |
Turn the ignition switch OFF and disconnect the battery (-) terminal
(A).
|
Tightening torque :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 Ib-ft)
|
|
|
2. |
Disconnect the battery (+) terminal (A).
|
Tightening torque :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 Ib-ft)
|
|
|
3. |
Remove the battery mouting bracket.
|
Tightening torque :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 Ib-ft)
|
|
|
4. |
Remove the battery (A).
|
Battery Tray
|
2. |
Remove the air cleaner assembly.
(Refer to Engine Mechanical System - "Air Cleaner")
|
|
3. |
Remove the engine control module (ECM).
(Refer to Engine Control / Fuel System - "Engine Control Module (ECM)")
|
|
4. |
Remove the battery tray (A).
|
Tightening torque :
7.8 - 10.8 N.m (0.8 - 1.1 kgf.m, 5.8 - 8.0 Ib-ft)
|
|
|
1. |
Install in the reverse order of removal.
|
• |
When installing the battery, fix the mounting bracket
on the tray correctly.
|
|
|
• |
After disconnecting then reconnecting the battery negative
cable, reset some parts that require the reset procedures.
(Refer to Body Electrical System - "General Information")
|
|
|
• |
ISG (Idle stop & go) system equipped vehicle always
use the AGM battery only. If flooded battery has installed,
this can potentially lead to engine electrical trouble
or ISG system error.
|
|
• |
Replace same capacity of the AGM battery.
|
|
|
• |
Do not open the AGM battery.
|
|
• |
The AGM battery must not be opened under any circumstances
as the introduction of oxygen from the air will cause
the battery to lose its chemical equilibrium and rendered
non-operational.
|
|
|
Battery Condition
Check the battery for damage or deformation. If severe damage, deformation or
leakage is found, replace the battery.
Vehicle parasitic current inspection
[Using the Ammeter]
|
1. |
Turn the all electric devices OFF, and then turn the ignition switch
OFF.
|
|
2. |
Close all doors except the engine hood, and then lock all doors.
|
(1) |
Disconnect the hood switch connector.
|
|
(3) |
Close the doors or remove the door switches.
|
|
|
3. |
Wait a few minutes until the vehicle’s electrical systems go to sleep
mode.
|
• |
For an accurate measurement of a vehicle parasitic current,
all electrical systems should go to sleep mode. (It
takes at least one hour or at most one day.) However,
an approximate vehicle parasitic current can be measured
after 10-20 minutes.
|
|
|
|
4. |
Connect an ammeter in series between the battery (-) terminal and the
ground cable, and then disconnect the clamp from the battery (-) terminal
slowly.
|
• |
Be careful that the lead wires of an ammeter do not
come off from the battery (-) terminal and the ground
cable to prevent the battery from being reset. In case
the battery is reset, connect the battery cable again,
and then start the engine or turn the ignition switch
ON for more than 10 sec. Repeat the procedure from No.
1.
To prevent the battery from being reset during the inspection,
|
|
1) |
Connect a jump cable between the battery (-) terminal
and the ground cable.
|
|
2) |
Disconnect the ground cable from the battery (-) terminal.
|
|
3) |
Connect an ammeter between the battery (-) terminal
and the ground cable.
|
|
4) |
After disconnecting the jump cable, read the current
value of the ammeter.
|
|
|
|
5. |
Read the current value of the ammeter.
| •
|
If the parasitic current is over the limit value, search for
abnormal circuit by removing a fuse one by one and checking
the parasitic current.
|
| •
|
Reconnect the suspected parasitic currentdraw circuit fuse only
and search for suspectedunit by removing the component connected
with thecircuit one by one until the parasitic draw dropsbelow
limit value.
|
|
Limit value (after 10 - 20 min.) : Below 50 mA
|
|
[Using the Clamp type Ammeter]
|
1. |
Turn the all electric devices OFF, and then turn the ignition switch
OFF.
|
|
2. |
Close all doors except the engine hood, and then lock all doors.
|
(1) |
Disconnect the hood switch connector.
|
|
(3) |
Close the doors or remove the door switches.
|
|
|
3. |
Wait a few minutes until the vehicle’s electrical systems go to sleep
mode.
|
• |
For an accurate measurement of a vehicle parasitic current,
all electrical systems should go to sleep mode. (It
takes at least one hour or at most one day.) However,
an approximate vehicle parasitic current can be measured
after 10-20 minutes.
|
|
|
|
4. |
Install the clamp type ammerter on battery negative (-) terminal.
|
|
5. |
Read the current value of the ammeter.
| •
|
If the parasitic current is over the limit value, search for
abnormal circuit by removing a fuse one by one and checking
the parasitic current.
|
| •
|
Reconnect the suspected parasitic currentdraw circuit fuse only
and search for suspectedunit by removing the component connected
with thecircuit one by one until the parasitic draw dropsbelow
limit value.
|
|
Limit value (after 10 - 20 min.) : Below 50 mA
|
|
The Micro 570 Analyzer provides the ability to test the charging and starting
systems, including the battery, starter and alternator.
|
※ Because of the possibility of personal injury, always use extreme
caution and appropriate eye protection when working with batteries.
※ When charging battery by test result, Battery must be fully charged.
To get accurate test result, battery surface voltage must have subsided
ahead before test when you test battery after charged. (See following
Battery Test Results)
|
Keypad
The Micro 570 button on the key pad provide the following functions :
Battery Test Procedure
|
1. |
Connect the tester to the battery.
| –
|
Red clamp to battery positive (+) terminal.
|
| –
|
Black clamp to battery negative (-) terminal.
|
|
• |
Connect clamps securely. If "CHECK CONNECTION" message
is displayed on the screen, reconnect clamps securely.
|
|
|
|
2. |
The tester will ask if the battery is connected "IN-VEHICLE" or "OUT-OF-VEHICLE".
Make your selection by pressing the arrow buttons; then press ENTER.
|
|
3. |
Select CCA and press the ENTER button.
|
• |
CCA : Cold cranking amps, is an SAE specification for
cranking batteried at -0.4°F (-18°C).
|
|
|
|
4. |
Set the CCA value displayed on the screen to the CCA value marked on
the battery label by pressing up and down buttons and press ENTER.
|
• |
The battery ratings (CCA) displayed on the tester must
be identical to the ratings marked on battery label.
|
|
|
|
5. |
The tester will conduct battery test.
|
|
6. |
The tester displays battery test results including voltage and battery
ratings.
Refer to the following table and take the appropriate action as recommended
by the Micro 570.
Battery Test Results
Result On Printer
|
Remedy
|
GOOD BATTERY
|
No action is required.
|
GOOD RECHARGE
|
Battery is in a good state.
Recharge the battery and use.
※ You have to follow instruction below when you charge battery and
retest, otherwise test result can be inaccurate. (See ‘Charge and
Retest method after battery charge’ below.)
|
CHARGE & RETEST
|
Battery is not charged properly.
|
– |
Charge and test the battery again.
|
※ You have to follow instruction below when you charge battery and
retest, otherwise test result can be inaccurate. (See ‘Charge and
Retest method after battery charge’ below.)
|
REPLACE BATTERY
|
Replace battery and recheck the charging system.
|
– |
Improper connection between battery and vehicle cables
may cause "REPLACE BATTERY". Retest the battery after
removing cables and connecting the tester to the battery
terminal directly prior to replacing the battery.
|
|
BAD CELL-REPLACE
|
Charge and retest the battery.
|
– |
If the Micro 570 recommends "REPLACE BATTERY", replace
the battery and recheck the charging system.
|
|
[Charge and Retest method after battery charge]
Battery charge
Set battery charger to ‘Auto Mode’ (The Mode that charging current drops
as the battery charges.) and charge battery until charging current down
close to zero or the charger alerts you with an alarm when charge is
complete.
(Minimum charging time recommended: More than 3 hours with Auto Mode
that explained above)
| •
|
If battery is not fully charged, battery surface voltage will
be high while the amount of current charged (CCA) in battery
is low. If you measure the battery under this condition, tester
may misjudge that battery sulfation occurred because the amount
of current in battery is too low in comparison with battery
voltage.
* Surface voltage: When battery is charged electrolyte temperature
increases and chemical reaction become active resulting in an
excessive increase of battery voltage.
It is known that it takes approximate one day to subside this
increased surface voltage completely.
|
Battery Test after charge
Do not test battery right after the charge. Test battery after battery
surface voltage has subsided as instructed in the following procedure.
|
(1) |
When battery charge is complete, install the battery in the
vehicle.
|
|
(2) |
Put IG key to ON position and turn on head lamp with low beam,
and wait 5 minutes. (Discharge for 5 minutes)
|
|
(3) |
Turn off the head lamp and IG key, and wait 5 minutes. (Waiting
for 5 minutes)
|
|
(4) |
Remove +, - cable from the battery and test battery.
|
|
• |
Whenever filing a claim for battery, the print out of
the battery test results must be attached.
|
|
Starter Test Procedure
|
|
7. |
After the battery test, press ENTER immediately for the starter test.
|
|
8. |
Start the engine.
|
|
9. |
Cranking voltage and starter test results will be displayed on the screen.
Refer to the following table and take the appropriate action as recommended
by the Micro 570.
Starter Test Results
Result On Printer
|
Remedy
|
CRANKING VOLTAGE NORMAL
|
System shows a normal starter draw.
|
CRANKING VOLTAGE LOW
|
Cranking voltage is lower than normal level.
|
CHARGE BATTERY
|
The state of battery charge is too low to test.
|
– |
Charge the battery and retest.
|
|
REPLACE BATTERY
|
Replace battery.
|
– |
If the vehicle is not started though the battery condition
of "GOOD BATTERY" is displayed, check wiring for open
circuit, battery cable connection, starter and repair
or replace as necessary.
|
|
– |
If the engine does crank, check fuel system.
|
|
|
• |
When testing the vehicle with old diesel engines, the
test result will not be favorable if the glow plug is
not heated. Conduct the test after warming up the engine
for 5 minutes.
|
|
Charging System Test Procedure
|
|
10. |
Press ENTER to begin charging system test.
|
|
11. |
The tester displays the actual voltage of alternator.
Press ENTER to continue.
|
|
12. |
Turn off all electrical load and rev engine for 5 seconds with pressing
the accelerator pedal. (Follow the instructions on the screen)
|
|
13. |
The message that engine RPM is detected will be displayed on the screen.
Press ENTER to continue.
|
|
14. |
If the engine RPM is not detected, press ENTER after revving engine.
|
|
15. |
The tester will conduct charging system test during loads off.
|
|
16. |
Turn on electrical loads (air conditioner, lamps, audio and etc). Press
ENTER to continue.
|
|
17. |
The tester will conduct charging system test during loads on.
|
|
18. |
Rev engine for 5 seconds with pressing the accelerator pedal. (Follow
the instructions on the screen)
|
|
19. |
The message that engine RPM is detected will be displayed on the screen.
Press ENTER to continue.
|
|
20. |
If the engine RPM is not detected, press ENTER after revving engine.
|
|
21. |
Turn off electrical loads (air conditioner, lamps, audio and etc). Turn
the engine off.
|
|
22. |
Charging voltage and charging system test results will be displayed
on the screen.
Shut off engine end disconnect the tester clamps from the battery. Refer
to the following table and take the appropriate action as recommended
by the Micro 570.
Charging System Test Results
Result On Printer
|
Remedy
|
CHARGING SYSTEM NORMAL / DIODE RIPPLE NORMAL
|
Charging system is normal.
|
NO CHARGING VOLTAGE
|
Alternator does not supply charging current to battery.
|
– |
Check belts, connection between alternator and battery
and replace belts or cable or alternator as necessary.
|
|
LOW CHARGING VOLTAGE
|
Alternator does not supply charging current to battery and electrical
load to system fully.
|
– |
Check belts and alternator and replace as necessary.
|
|
HIGH CHARGING VOLTAGE
|
The voltage from alternator to battery is higher than normal limit
during voltage regulating.
|
– |
Check connection and ground and replace regulator as
necessary.
|
|
– |
Check electrolyte level in the battery.
|
|
EXCESS RIPPLE DETECTED
|
One or more diodes in the alternator is not functioning properly.
|
– |
Check alternator mounting and belts and replace as necessary.
|
|
|
The MDX-670P Analyzer
The MDX-670P battery conductance and electrical system analyzer tests batteries
as well as starting and charging systems for vehicle.
It displays the test results in seconds and features a built-in printer to provide
a copy of the results.
| 1) |
Because of the possibility of personal injury, always use extreme
caution and appropriate eye protection when working with batteries.
|
| 2) |
When charging battery by test result, Battery must be fully
charged. To get accurate test result, battery surface voltage
must have subsided ahead before test when you test battery after
charged. (See following Battery Test Results)
|
|
| •
|
When testing the vehicle with old diesel engines, the test result
will not be favorable if the glow plug is not heated. Conduct
the test after warming up the engine for 5 minutes.
|
|
|
1. |
Connect the red clamp to the positive (+) terminal and the black clamp
to the negative (–) terminal.
|
• |
For a proper connection, rock the clamps back and forth.
The tester requires that both sides of each clamp be
firmly connected before testing. A poor connection will
produce a CHECK CONNECTION or WIGGLE CLAMPS message.
If the message appears, clean the terminals and reconnect
the clamps.
|
|
|
|
2. |
Scroll to and select IN VEHICLE or OUT OF VEHICLE for a battery not
connected to a vehicle.
|
• |
Following an IN VEHICLE test you will be prompted to
test the starting and charging systems.
|
|
|
|
3. |
Scroll to and select REGULAR FLOODED, AGM FLAT PLATE, or AGM SPIRAL
where applicable.
|
• |
If the vehicle equipped with ISG function, select the
AGM FLAT PLATE.
|
|
|
|
4. |
Scroll to and select the battery’s rating system.
|
• |
Mostly, the CCA value is marked on the battery label,
but sometimes marked EN or SEA value. Select one of
them.
|
|
| –
|
CCA : Cold Cranking Amps, as specified by SAE. The most common
rating for cranking batteries at 0°F (-17.8 °C).
|
| –
|
SAE : Society of Automotive Engineers, the European labeling
of CCA
|
|
|
5. |
Set the selected rating value displayed on the screen to the value marked
on the battery label by pressing up and down arrow buttons.
|
|
6. |
Press ENTER to start test.
|
|
7. |
After several seconds the tester displays the decision on the battery’s
condition and the measured voltage. The tester also displays your selected
battery rating and the rating units.
Battery Test Results
Result On Printer
|
Remedy
|
GOOD BATTERY
|
No action is required.
|
GOOD RECHARGE
|
Battery is in a good state. Recharge the battery and use.
※ You have to follow instruction below when you charge battery and
retest, otherwise test result can be inaccurate. (See ‘Charge and
Retest method after battery charge’ below.)
|
CHARGE & RETEST
|
Battery is not charged properly.
|
– |
Charge and test the battery again.
|
※ You have to follow instruction below when you charge battery and
retest, otherwise test result can be inaccurate. (See ‘Charge and
retest method after battery charge’ below.)
|
REPLACE BATTERY
|
Replace battery and recheck the charging system.
|
– |
Improper connection between battery and vehicle cables
may cause "REPLACE BATTERY", retest the battery after
removing cables and connecting the tester to the battery
terminal directly prior to replacing the battery.
|
|
BAD CELLREPLACE
|
Charge and retest the battery.
|
– |
If recommends "REPLACE BATTERY", replace the battery
and recheck the charging system.
|
|
[Charge and Retest method after battery charge]
Battery charge
Set battery charger to ‘Auto Mode’ (The Mode that charging current drops
as the battery charges.) and charge battery until charging current down
close to zero or the charger alerts you with an alarm when charge is
complete.(Minimum charging time recommended: More than 3 hours with
Auto Mode that explained above)
| •
|
If battery is not fully charged, battery surface voltage will
be high while the amount of current charged (CCA) in battery
is low. If you measure the battery under this condition, tester
may misjudge that battery sulfation occurred because the amount
of current in battery is too low in comparison with battery
voltage.
* Surface voltage: When battery is charged electrolyte temperature
increases and chemical reaction become active resulting in an
excessive increase of battery voltage.
It is known that it takes approximate one day to subside this
increased surface voltage completely.
|
Battery Test after charge
Do not test battery right after the charge. Test battery after battery
surface voltage has subsided as instructed in the following procedure.
|
(1) |
When battery charge is complete, install the battery in the
vehicle.
|
|
(2) |
Put IG key to ON position and turn on head lamp with low beam,
and wait 5 minutes. (Discharge for 5 minutes)
|
|
(3) |
Turn off the head lamp and IG key, and wait 5 minutes. (Waiting
for 5 minutes)
|
|
(4) |
Remove +, - cable from the battery and test battery.
|
|
• |
For an in-vehicle test, the display alternates between
the test results and the message "PRESS FOR STARTER
TEST".
|
|
|
• |
Before starting the test, inspect the alternator drive
belt. A belt that is glazed or worn, or lacks the proper
tension, will prevent the en¬gine from achieving the
rpm levels needed for the test.
|
|
|
|
8. |
Press the ENTER button to proceed with the starter test.
|
|
9. |
Start the engine when prompted.
|
|
10. |
The tester displays the decision on the starter system, cranking voltage,
and cranking time in milliseconds.
Starter Test Results
Result On Printer
|
Remedy
|
CRANKING VOLTAGE NORMAL
|
System shows a normal starter draw.
|
CRANKING VOLTAGE LOW
|
Cranking voltage is lower than normal level.
|
CHARGE BATTERY
|
The state of battery charge is too low to test.
|
– |
Charge the battery and retest.
|
|
REPLACE BATTERY
|
Replace battery.
|
– |
If the vehicle is not started though the battery condition
of "GOOD BATTERY" is displayed, check wiring for open
circuit, battery cable connection, starter and repair
or replace as necessary.
|
|
– |
If the engine does crank, check fuel system.
|
|
|
• |
For an in-vehicle test, the display alternates between
the test results and the message "PRESS FOR CHARGING
TEST.
|
|
Step 3 : Charging System Test
|
|
11. |
Press the ENTER button to proceed with the charging test.
|
|
12. |
Rev the engine with loads off. (Following the on-screen prompts)
|
|
13. |
The message that engine RPM is detected will be displayed on the screen,
idle the engine.
|
|
14. |
Turn on electrical loads (air conditioner, lamps, audio and etc). Press
ENTER to continue.
|
|
15. |
Turn on electrical loads (air conditioner, lamps, audio and etc). Press
ENTER to continue.
|
|
16. |
The message that engine RPM is detected will be displayed on the screen,
idle the engine.
|
|
17. |
Turn off loads and engine.
|
|
18. |
The Charging System decision is displayed at the end of the procedure.
Result On Printer
|
Remedy
|
NO PROBLEMS
|
System is showing normal output from the alternator.
|
NO OUTPUT
|
No alternator output detected.
|
– |
Check all connections to and from the alternator, especially
the connection to the battery. If the connection is
loose or heavily corroded, clean or replace the cable
and retest.
|
|
– |
If the belts and connections are in good working condition,
replace the alternator. (Older vehicles use external
voltage regulators, which may require only replacement
of the voltage regulator.)
|
|
LOW OUTPUT
|
Alternator does not supply charging current to battery and electrical
load to system fully.
|
– |
Check belts and alternator and replace as necessary.
|
|
HIGH OUTPUT
|
The voltage from alternator to battery is higher than normal limit
during voltage regulating.
|
– |
Check connection and ground and replace regulator as
necessary.
|
|
– |
Check electrolyte level in the battery.
|
|
EXCESSIVE RIPPLE
|
The voltage from alternator to battery is higher than normal limit
during voltage regulating.
|
– |
Check alternator mounting and belts and replace as necessary.
|
|
CHARGE BATTERY
|
The starter voltage is low and the battery is discharged. Fully
charge the battery and repeat the starter system test.
|
REPLACE BATTERY
|
Battery must be replaced before the starting system can be tested.
|
|
|
19. |
Press the BACK/PRINT button to print the test results or MENU to return
to the Options Menu.
|
|
1. |
Make sure that the ignition switch and all accessories are in the OFF
position.
|
|
2. |
Disconnect the battery cables (negative first).
|
|
3. |
Remove the battery from the vehicle.
|
• |
Care should be taken in the event the battery case is
cracked or leaking, to protect your skin from the electrolyte.
Heavy rubber gloves (not the household type) should
be wore when removing the battery.
|
|
|
|
4. |
Inspect the battery tray for damage caused by the loss of electrolyte.
If acid damage is present, it will be necessary to clean the area with
a solution of clean warm water and baking soda. Scrub the area with
a stiff brush and wipe off with a cloth moistened with baking soda and
water.
|
|
5. |
Clean the top of the battery with the same solution as described above.
|
|
6. |
Inspect the battery case and cover for cracks. If cracks are present,
the battery must be replaced.
|
|
7. |
Clean the battery posts with a suitable battery post tool.
|
|
8. |
Clean the inside surface of the terminal clamps with a suitable battery
cleaning tool. Replace damaged or frayed cables and broken terminal
clamps.
|
|
9. |
Install the battery in the vehicle.
|
|
10. |
Connect the cable terminals to the battery post, making sure tops of
the terminals are flush with the tops of the posts .
|
|
11. |
Tighten the terminal nuts securely.
|
|
12. |
Coat all connections with light mineral grease after tightening.
|
• |
When batteries are being charged, an explosive gas forms
beneath the cover of each cell. Do not smoke near batteries
being charged or which have recently been charged. Do
not break live circuit at the terminals of batteries
being charged.
A spark will occur when the circuit is broken. Keep
open flames away from battery.
|
|
|
Battery Sensor. Description and operation
Vehicles have many control units that use more electricity. These units control
their own system based on information from various sensors. It is important
to provide a stable power supply as these sensors bring diverse information.
Battery sensor is mounted on battery (-) terminal. It transmits battery voltage,
current, temperature information to ECM. ECM controls generating voltage by
duty cycle based on these signals.
Battery Sensor. Repair procedures
|
1. |
Turn the ignition switch OFF and disconnect the battery (-) terminal.
|
|
2. |
Disconnect the battery sensor connector (A).
|
|
3. |
Remove the battery sensor (A).
|
Tightening torque :
26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 Ib-ft)
|
|
|
1. |
Install in the reverse order of removal.
|
• |
For the vehicle equipped with a battery sensor, be careful
not to damage the battery sensor when the battery is
replaced or recharged.
|
|
1) |
When replacing the battery, the new battery should be
of the same type, capacity and brand with the previous
one. If a battery of a different type is replaced, the
battery sensor may recognize the battery to be abnormal.
|
|
2) |
When installing the ground cable on the negative post
of battery, tighten the clamp to the specified torque.
An excessive tightening can damage the PCB internal
circuit and the battery terminal.
|
|
3) |
When recharging the battery, ground the negative terminal
of the booster battery to the vehicle body.
|
|
|
Battery Sensor Recalibration Procedure
After reconnecting the battery negative cable, AMS function does not operate
until the system is stabilized, for about 4 hours. If disconnecting the negative
(-) battery cable from the battery during repair work for the vehicle equipped
with AMS function, Battery sensor recalibration procedure should be performed
after finishing the repair work.
|
1. |
Turn the Iginition switch ON and OFF.
|
|
2. |
Park the vehicle for about 4 hours with the hood and all doors closed.
|
DC DC converter
Description and operation
Due to the considerably more frequent occurrence of starting operations, the
electrical load that occurs often leads to voltage dips in the vehicle network.In
order to stabilize the power supply for certain voltage-sensitive electrical
components, a DC/DC converter is used in conjunction with the ISG function.The
DC DC converter supplies the relay with a voltage that also remains constant
during the starting operation.
The DC/DC converter is fitted at the behind of the glove box.Via the test leads
for input voltage and the start relay , the electronics decide whether the power
is supplied to the output via the bypass or the DC/DC converter.In the bypass
mode, the on-board supply voltage is not fed across the DC/DC converter, rather
is transferred directly to the outputs. In the booster phase, the vehicle voltage
is adapted.
Components and components location
1. DC/DC Converter
[200W, 450W]
|
|
Specifications
[200W]
Type
|
|
Specifications
|
Switching mode
|
Input voltage range
|
7 - 16
|
Battery powered (B+) output voltage
|
11.4 - 12.6 [Max 15A, Max power 200W]
|
ACC output voltage
|
11 - 13 [Max 3 A]
|
Time (sec)
|
Max 1
|
[450W]
Type
|
|
Specifications
|
Switching mode
|
Input voltage range
|
7 - 16
|
Battery powered (B+) output voltage
|
11.4 - 12.6 [Max 30A, Max power 450W]
|
ACC output voltage
|
11 - 13 [Max 3 A]
|
Time (sec)
|
Max 1
|
Schematic diagrams
[200W]
[450W]
[200W]
PIn
|
Description
|
1
|
Battery power (B+) input
|
2
|
Battery power (B+) output
|
3
|
IGN1 input
|
4
|
ISG signal input
|
5
|
ACC input
|
6
|
ACC output
|
7
|
Ground
|
[450W]
PIn
|
Description
|
PIn
|
Description
|
1
|
Ground
|
6
|
IGN1 input
|
2
|
Ground
|
7
|
ISG signal input
|
3
|
Battery power (B+) output
|
8
|
ACC input
|
4
|
Battery power (B+) input
|
9
|
ACC output
|
5
|
Battery power (B+) input [Current Cut Off]
|
10
|
Battery power (B+) output [AMP]
|
Repair procedures
|
1. |
Turn the ignition switch OFF and disconnect the battery (-) terminal.
|
|
2. |
Remove the heater & A/C control unit.
(Refer to Heating, Ventilation and Air Conditioning - "Heater & A/C
Control Unit")
|
|
3. |
Disconnect the DC/DC converter connector (A).
|
|
4. |
Remove the DC/DC converter (B).
|
| •
|
After reconnecting the battery negative cable, ISG function
does not operates until the system is stabilized, about 4 hours.
If disconnecting the negative (-) battery cable from the battery
during repair work for the vehicle equipped with AMS function,
Battery sensor recalibration procedure should be performed after
finishing the repair work.
|
|
|
1. |
Install in the reverse order of removal.
|
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Hyundai Santa Fe (TM): Charging System
Specifications
Starting System