Diagnosis and repair workflow
Work flow (with exp-800 ni or gr8-1200 ni)
CHARGING SYSTEM DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI
To test the charging system, use the following special service tools:
NOTE:
Refer to the applicable Instruction Manual for proper charging system diagnosis procedures.
Revision:
OVERALL SEQUENCE
DETAILED FLOW
NOTE:
To ensure a complete and thorough diagnosis, the battery, stater and generator test segments must be done as a set from start to finish.
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-20, "Diagnosis Procedure".
>> GO TO 2.
2.STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Stop the operation of the power generation voltage variable control in either of the following procedures.
>> GO TO 3.
3.DIAGNOSIS WITH EXP-800 NI OR GR8-1200 NI
Perform the charging system test using Multitasking battery and electrical diagnostic station GR8-1200 NI or Battery and electrical diagnostic analyzer EXP-800 NI. Refer to the applicable Instruction Manual for proper testing procedures.
Test result
NO PROBLEMS>>Charging system is normal and will also show “DIODE RIPPLE” test result.
NO VOLTAGE>>GO TO 4.
LOW VOLTAGE>>GO TO 12.
HIGH VOLTAGE>>GO TO 14.
EXCESSIVE RIPPLE, OPEN PHASE, OPEN DIODE or SHORTED DIODE>>Replace the generator. Refer to CHG-29, "Removal and Installation". Perform “DIODE RIPPLE” test again using Multitasking battery and electrical diagnostic station GR8-1200 NI or Battery and electrical diagnostic analyzer EXP-800 NI to confirm repair.
4.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate? YES >> GO TO 6.
NO >> GO TO 5.
5.“L” TERMINAL CIRCUIT (OPEN) INSPECTION
Check “L” terminal circuit (open). Refer to CHG-24, "Diagnosis Procedure".
Is the “L” terminal circuit normal? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> Repair as needed.
6.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF? YES >> GO TO 9.
NO >> GO TO 7.
7.“L” TERMINAL CIRCUIT (SHORT) INSPECTION
Check “L” terminal circuit (short). Refer to CHG-26, "Diagnosis Procedure".
Is the “L” terminal circuit normal? YES >> GO TO 8.
NO >> Repair as needed.
8.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-27, "Diagnosis Procedure".
Is the “S” terminal circuit normal? YES >> GO TO 10.
NO >> Repair as needed.
9.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 3,000 RPM)
Increase and maintain the engine speed at 3,000 rpm.
Does the charge warning lamp remain off? YES >> GO TO 11.
NO >> GO TO 10.
10.INSPECTION OF GENERATOR PULLEY
Check generator pulley. Refer to CHG-30, "Inspection".
Is generator pulley normal? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> Repair as needed.
11.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to CHG-23, "Diagnosis Procedure".
Is “B” terminal circuit normal? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> Repair as needed.
12.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to CHG-23, "Diagnosis Procedure".
Is “B” terminal circuit normal? YES >> GO TO 13.
NO >> Repair as needed.
13.INSPECTION OF GENERATOR PULLEY
Check generator pulley. Refer to CHG-30, "Inspection".
Is generator pulley normal? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> Repair as needed.
14.“S” TERMINAL CIRCUIT INSPECTION
Check “S” terminal circuit. Refer to CHG-27, "Diagnosis Procedure".
Is the “S” terminal circuit normal? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> Repair as needed.
Work flow (without exp-800 ni or gr8-1200 ni).
OVERALL SEQUENCE
Before performing a generator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test.
DETAILED FLOW
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-20, "Diagnosis Procedure".
>> GO TO 2.
2.STOP POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Stop the operation of the power generation voltage variable control in either of the following procedures:
>> GO TO 3.
3.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS TURNED ON)
When ignition switch is turned ON.
Does the charge warning lamp illuminate?
YES >> GO TO 4.
NO >> GO TO 10.
4.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle
Does the charge warning lamp turn OFF? YES >> GO TO 5.
NO >> GO TO 6.
5.INSPECTION WITH CHARGE WARNING LAMP (ENGINE AT 2,500 RPM)
Increase and maintain the engine speed at 2,500 rpm.
Does the charge warning lamp illuminate? YES >> GO TO 8.
NO >> Inspection End.
6.“L” TERMINAL CIRCUIT (SHORT) INSPECTION
Check terminal “L” circuit for (short). Refer to CHG-26, "Diagnosis Procedure".
Is the inspection result normal? YES >> GO TO 7.
NO >> Repair as needed.
7. “S” TERMINAL CIRCUIT INSPECTION
Check terminal “S” circuit. Refer to CHG-27, "Diagnosis Procedure".
Is the inspection result normal? YES >> GO TO 8.
NO >> Repair as needed.
8.MEASURE “B” TERMINAL VOLTAGE
Start engine. With engine running at 2,500 rpm, measure “B” terminal voltage.
What voltage does the measurement result show? Less than 13.0 V>>GO TO 9.
More than 16.0 V>>Replace generator. Refer to CHG-29, "Removal and Installation".
9.“B” TERMINAL CIRCUIT INSPECTION
Check “B” terminal circuit. Refer to CHG-23, "Diagnosis Procedure".
Is the inspection result normal? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> Repair as needed.
10.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH
IS ON)
Does the charge warning lamp illuminate? YES >> Replace generator. Refer to CHG-29, "Removal and Installation".
NO >> GO TO 11.
11.CHECK “L” TERMINAL CIRCUIT (OPEN)
Check “L” terminal circuit (OPEN). Refer to CHG-26, "Diagnosis Procedure".
>> Repair as needed.
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Exploded View
Clamp
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Clamp
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Electric throttle control actuator
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Water hose
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