Electrical System of Engine
G1-1
Charging System ....................................... GI-2
Installation/Removal of Battery ........ GI-2
Inspection of Battery ......................... GI-2
Pre-charging of Battery ..................... GI-3
Removal/Installation of Generator .... GI-3
Removal/Installation Instruction of
Generator .......................................... GI-3
Inspection of Generator..................... GI-3
Removal/Installation of Ignition Coil ......
.......................................................... GI-4
Inspection of Ignition Coil ................ GI-5
Starting system .......................................... GI-6
Removal/Installation of Starting System .
.......................................................... GI-6
Inspection of Starter .......................... GI-6
Electrical System of Engine
G1-2
Charging System
Installation/Removal of Battery
1. Remove bracket (See External
Accessories - Cowl Grille Removal/
Installation)
2. Remove in order as shown in figure.
3. Install in reverse order as of removal.
Inspection of Battery
1 Battery clamp
2 Clamp bolt
3 Battery
4 Tray of battery
Battery
1 Inspect batty in order shown below.
Step
Inspection Result Action
1
Measure terminal
voltage of battery (V)
＞12.4
Go to
step 3
＜12.4
Go to
next step
2
Conduct 30 min
quick charging, and
measure terminal
voltage of battery (V)
＞12.4
Go to
next step
＜12.4
Replace
Step
Inspection Result Action
3
Conduct discharging
test (See Table of
Discharging Test),
record battery
terminal voltages
after 15 sec. Is the
voltage above
specified range?
Y Normal
N Replace
Positive voltage of battery after discharging
Approx. temperature
of battery
Min. Voltage
21℃ (70°F) 9.6
15℃ (59°F) 9.5
10℃ (50°F) 9.4
4℃ (39°F) 9.3
-1℃ (30°F) 9.1
-7℃ (19°F) 8.9
12℃ (10°F) 8.7
18℃ (0°F) 8.5
Table of Discharging test
Battery Discharging current (A)
75D23L 195
Dark current
1. Turn ignition switch to ON position and
then take off the key.
2. Disconnect negative battery cable.
Caution:
l Current tester may be damaged if any
electrical appliance is in use during
test.
3. Measure natural discharging current
between negative terminal and negative
cable.
Dark current
20m A max (≤20m A)
4. If the dark current is above the upper
limit, remove main fuse block and fuse in
it in sequence to measure dark current.
5. If dark current reduces, service harness
and connector related to that fuse.
Electrical System of Engine
G1-3
Pre-charging of Battery
Caution:
l Negative battery cable must be
disconnected at first and installed at
last to avoid damage of electrical
components and battery.
l Plug of battery should be removed to
avoid damage or deformation of
battery during charging.
l Quick charging must not be more than
30min or the battery may be damaged.
1. Place battery in a basin with water to
avoid battery overheating.
2. Water level should be in any case above
mid height of battery.
3. Water level should never be above top of
battery.
4. Connect the battery charger with the
battery.
5. Adjust charging current according to
table below.
Battery
model
(5h rate
capacity)
Trickle
Charging
(A)
Quick
charging
(A)/(30min)
75D23L 5.5-6.5 35
6. After pre-charged, measure positive
voltage of battery and make it maintained
for more than 1h.
l If the voltage is lower than specified
value, please replace the battery.
Standard:
＞12.4V
Removal/Installation of Generator
(The part is the same with HM483Q Engine
Maintenance Manual for details)
Warning
l If terminal B of generator contacts
vehicle body with battery cable
connected, spark may be generated
resulting in personal injury and
damage of electric components. So,
battery cable must be disconnected
before proceeding with following steps.
1. Remove negative battery cable.
2. Remove front portion of exhaust pipe
(See Exhaust System, Removal/
installation of Exhaust System)
3. Remove in order as shown in figure.
4. Install in reverse order as of removal.
5. Inspect deformation/tension of belt (See
Drive Belt, Inspection of Drive Belt).
Removal/Installation Instruction of
Generator
1. Remove middle section of exhaust pipe
from bracket with rubber cushion, then
remove/install generator.
Inspection of Generator
Charging Alarm Indicator
1. Make sure that battery has been fully
charged.
2. Make sure that deformation/tension of
belt is within the specification (Refer to
Drive Belt, Inspection of Drive Belt).
3. Turn ignition switch to ON position;
charging alarm indicator should be lit.
Battery charger
Battery
Electrical System of Engine
G1-4
l If not, inspect the charging alarm
indicator, harness between the battery,
indicator and terminals of generator. If
charging alarm indicator and harness
is both normal, replace the generator
4. Make sure that the charging alarm
indicator turns off when engine runs
normally.
Voltage of Generator
1. Make sure that battery has been fully
charged.
2. Make sure that deformation/tension of
belt is within the specified range (Refer
to Drive Belt, Inspection of Drive Belt).
3. Turn off all electrical appliances.
4. Start engine, make sure that the generator
operates smoothly without any abnormal
noise.
5. Measure voltage between terminals
shown in figure.
l If it is incorrect, repair or replace the
generator.
Connector at Harness Side of Generator
(Observe from harness side)
Standard voltage
Unit: V
Terminal
With ignition
switch at ON
position
When
idling, 20°C
(68F)
B B+ 13-15
P Approx. 1 Approx. 3-8
D Approx. 0
Turn on the following appliances, and verify
whether voltage rises under this condition.
l Headlamp
l Blower motor
l Rear windshield defroster.
Current
1. Make sure that battery has been fully
charged.
2. Make sure that deformation/tension of
belt is within the specified range (Refer
to Drive Belt, Inspection of Drive Belt).
3. Disconnect the negative battery cable.
4. Connect a current meter with 120A or
bigger range between terminal B of
generator and harness.
5. Connect the negative battery cable.
6. Turn off all electrical appliances.
7. Turn on the generator and accelerate to
2000-3500rpm.
8. Turn on following appliances; make sure
that reading of current meter increases.
(1) Headlamp
(2) Blower motor
(3) Rear window defroster.
l If the current doses not increase,
repair or replace the generator.
Attention
l Current output of generator varies
with load.
Test conditions:
Ambient temperature: 20℃ (68°F)
Voltage: 13. 5V
Engine Warming-up
Engine speed (rpm)
Current on terminal B
(A)
1,000 0～59
2,000
0～59
0 A is not allowed.
Removal/Installation of Ignition Coil
(The part is the same with HM483Q Engine
Maintenance Manual for details)
Caution:
l Spark plug cap is easy to be torn
during removal of ignition coil and
plug cap. Be careful not to tear or
damage the cap during removal when
replacement is necessary.
1. Disconnect the negative battery cable.
2. Remove in order as shown in figure.
Electrical System of Engine
G1-5
3. Install in reverse order of removal.
1
Ignition Coil
2
Spark plug
See Removal /Installation of Spark plug
3
Positive Crankcase Ventilation (PCV)
valve See Inspection of PCV Valve
Inspection of Ignition Coil
(The part is the same with HM483Q Engine
Maintenance Manual for details)
Ignition
1. Spark Test
Refer to EMS Control System,
Operation Inspection, Spark Test
Operation Inspection of Ignition Coil
1. Disconnect the negative battery cable.
2. Examine input voltage of ignition coils
(between terminals 1A and 2A).
l If it can not reach specified range,
inspect power supply system harness.
(Terminals 1A and 2A of ignition coil,
terminals E and F of ignition switch,
including short jumper)
Standard: B+ (Positive voltage of battery)
Inspect ground voltage of ignition coil
(between terminals 1B and 2B)
l If it is incorrect, inspect ground system
harness
(Between terminals 1B, 2B and ground
point on vehicle body)
Standard value: 0(V)
4. Use a needle tool (terminal remover) to
push terminals 1C and 2C out of ignition
coil connector.
5. Remove the spark plug, high-voltage line
and ignition coil.
6 Connect the ignition coil, spark plug and
high-voltage line to special tester.
Needle tool
(terminal remover)
Starting system
G1-6
Starting system
(The part is the same with HM483Q Engine
Maintenance Manual for details)
Removal/Installation of Starting
System
Warning
l If terminal B of generator connects
with vehicle body with battery cable
connected, spark may be generated
resulting in personal injury and
damage of electric components. So,
battery cable must be disconnected
before proceeding with following steps.
1. Disconnect the negative battery cable.
2. Remove the air intake manifold bracket.
3. Remove in order as shown in figure.
4. Install in reverse order as of removal.
1 Cable of terminal B
2 Cable of terminal S
3 Starter
Inspection of Starter
(The part is the same with HM483Q Engine
Maintenance Manual for details)
On-board Inspection
1. Make sure that battery has been fully
charged.
2. Turn on starter and make sure it operates
smoothly without abnormal noise.
l If it is incorrect, turn ignition switch to
START position, examine voltage
between terminals S and B.
l If the voltage is within specified range,
remove starter, inspect electromagnetic
switch and starter.
Standard value: >8V
Zero–Load Test
1. Make sure that battery has been fully
charged.
2. Connect starter, battery, voltmeter and
amperemeter properly as shown in figure.
3. Operates starter, verify whether it
operates smoothly.
4. In the operation of starter, measure
voltage and current
l If it is incorrect, repair or replace internal
parts as required.
Standard:
Voltage (V) 11
Current (A) < 90
-
1
-
2
-
3
-
4
-
5
-
6
