Almera Tino V10 (2003 year). Manual — part 237

Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick charge)

BATTERY

TYPE

28B19R(L)

34B19R(L)

46B24R(L)

55B24R(L)

50D23R(L)

079

[YUASA

type

code]

55D23R(L)

65D26R(L)

80D26R(L)

025

[YUASA

type

code]

027

[YUASA

type

code]

063

[YUASA

type

code]

065

[YUASA

type

code]

075

[YUASA

type

code]

067

[YUASA

type

code]

096

[YUASA

type

code]

096L

[YUASA

type

code]

010S

[YUASA

type

code]

75D31R(L)

95D31R(L)

1

15D31R(L)

1

10D26R(L)

95E41R(L)

130E41R(L)

CURRENT [A]

10 (A)

15 (A)

20 (A)

25 (A)

30 (A)

40

(A)

CONVER

TED

SPECIFIC

GRA

VITY

1.100 -

1.130

2.5 hours

1.130 -

1.160

2.0 hours

1.160 -

1.190

1.5 hours

1.190 -

1.220

1.0 hours

Above

1.220

0.75 hours (45 min.)

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Check battery type and determine the specified current using the table shown above.

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After starting charging, adjustment of charging current is not necessary.

CAUTION:

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Do not use quick charge method on a battery whose specific gravity is less than 1.100.

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Set initial charging current to value specified in Fig. 6. If charger is not capable of producing
specified current value, set its charging current as close to that value as possible.

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Keep battery away from open flame while it is being charged.

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When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.

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Be careful of a rise in battery temperature because a large current flow is required during quick-
charge operation.
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its
temperature is below 60°C (140°F).

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Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.

BATTERY

Battery Test and Charging Chart (Cont’d)

SC-12

System Description

NLSC0004

M/T MODELS

NLSC0004S01

Power is supplied at all times

I

through 40A fusible link (letter J, located in the fuse and fusible link box)

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to ignition switch terminal 1.

With the ignition switch in START position, power is supplied

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from ignition switch terminal 5

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to smart entrance control unit terminal 59

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from smart entrance control unit terminal 58

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to starter motor harness connector terminal 1.

The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts.

A/T MODELS

NLSC0004S02

Power is supplied at all times

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through 40A fusible link (letter J, located in the fuse and fusible link box)

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to ignition switch terminal 1.

With the ignition switch in the START position, power is supplied

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from ignition switch terminal 5

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to park/neutral position relay terminal 5.

With the ignition switch ON or START position, power is supplied

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through 10A fuse [No. 20, located in the fuse block (J/B)]

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to park/neutral position (PNP) relay terminal 1.

With the selector lever in the P or N position, ground is supplied

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to park/neutral position relay terminal 2 through the park/neutral position switch

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from body ground F10.

Then park/neutral position relay is energized and power is supplied

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from park/neutral position relay terminal 3

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to starter motor harness connector terminal 1.

The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts.

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STARTING SYSTEM

System Description

SC-13

Wiring Diagram — START —

NLSC0005

M/T MODELS

NLSC0005S06

YEL052E

STARTING SYSTEM

Wiring Diagram — START —

SC-14

A/T MODELS

NLSC0005S07

YEL053E

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STARTING SYSTEM

Wiring Diagram — START — (Cont’d)

SC-15

Trouble Diagnoses

NLSC0018

If any abnormality is found, immediately disconnect battery negative terminal.

SEL761W

STARTING SYSTEM

Trouble Diagnoses

SC-16

Construction

NLSC0006

SEL027UC

YEL149E

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STARTING SYSTEM

Construction

SC-17

MEL136L

YEL150E

STARTING SYSTEM

Construction (Cont’d)

SC-18

NEL642

Removal and Installation

NLSC0007

YEL151E

YEL152E

REMOVAL

NLSC0007S01

1.

Remove intake air duct and air cleaner assembly.

2.

Disconnect starter harness.

3.

Remove starter bolts (two).

4.

Remove starter.

INSTALLATION

NLSC0007S02

To install, reverse the removal procedure.

MEL138L

Inspection

NLSC0019

MAGNETIC SWITCH CHECK

NLSC0019S01

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Before starting to check, disconnect battery ground cable.

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Disconnect “M” terminal of starter motor.

1.

Continuity test (between “S” terminal and switch body).

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No continuity ... Replace.

2.

Continuity test (between “S” terminal and “M” terminal).

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No continuity ... Replace.

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STARTING SYSTEM

Removal and Installation

SC-19

MEL139L

PINION/CLUTCH CHECK

NLSC0019S02

1.

Inspect pinion teeth.

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Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)

2.

Inspect reduction gear teeth (If equipped).

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Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)

3.

Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.

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If it locks or rotates in both directions, or unusual resistance is
evident. ... Replace.

SEL014Z

BRUSH CHECK

NLSC0019S03

Brush

NLSC0019S0301

Check wear of brush.

Wear limit length:

Refer to SDS (SC-31).

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Excessive wear ... Replace.

SEL015Z

Brush Spring Check

NLSC0019S0302

Check brush spring pressure with brush spring detached from
brush.

Spring pressure (with new brush):

Refer to SDS (SC-31).

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Not within the specified values ... Replace.

SEL016Z

Brush Holder

NLSC0019S0303

1.

Perform insulation test between brush holder (positive side)
and its base (negative side).

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Continuity exists. ... Replace.

2.

Check brush to see if it moves smoothly.

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If brush holder is bent, replace it; if sliding surface is dirty,
clean.

STARTING SYSTEM

Inspection (Cont’d)

SC-20

SEL018Z

YOKE CHECK

NLSC0019S04

Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunction-
ing parts as an assembly.

CAUTION:

Do not clamp yoke in a vice or strike it with a hammer.

SEL019Z

ARMATURE CHECK

NLSC0019S05

1.

Continuity test (between two segments side by side).

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No continuity ... Replace.

2.

Insulation test (between each commutator bar and shaft).

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Continuity exists. ... Replace.

SEL020Z

3.

Check commutator surface.

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Rough ... Sand lightly with No. 500 - 600 emery paper.

SEL021Z

4.

Check diameter of commutator.

Commutator minimum diameter:

Refer to SDS (SC-31).

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Less than specified value ... Replace.

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STARTING SYSTEM

Inspection (Cont’d)

SC-21

SEL022Z

5.

Check depth of insulating mold from commutator surface.

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Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)

Assembly

NLSC0020

Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.

SEL026Z

PINION PROTRUSION LENGTH ADJUSTMENT

NLSC0020S01

Clearance (QG engine models)

NLSC0020S0101

With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “



” between the front edge

of the pinion and the pinion stopper.

Clearance “



”:

Refer to SDS (SC-31).

MEL140L

Movement (YD engine models)

NLSC0020S0102

Compare movement “



” in height of pinion when it is pushed out

with magnetic switch energized and when it is pulled out by hand
until it touches stopper.

Movement “



”:

Refer to SDS, (SC-31).

STARTING SYSTEM

Inspection (Cont’d)

SC-22

SEL633BA

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Not in the specified value ... Adjust by adjusting plate.

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STARTING SYSTEM

Assembly (Cont’d)

SC-23

System Description

NLSC0009

The alternator provides DC voltage to operate the vehicle’s electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to alternator terminal 4 (S) through:

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10A fuse (No. 39, located in the fuse and fusible link box).

Terminal B supplies power to charge the battery and operate the vehicle’s electrical system. Output voltage
is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected
by the 100A fusible link.
The alternator is grounded to the engine block.
With the ignition switch in the ON or START position, power is supplied

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through 10A fuse [No. 30, located in the fuse block (J/B)]

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to combination meter terminal 2

Ground is supplied to terminal 46 of the combination meter through terminal 3 (L) of the alternator. With power
and ground supplied, the charge warning lamp will illuminate. When the alternator is providing sufficient volt-
age with the engine running, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a fault is indicated.

CHARGING SYSTEM

System Description

SC-24

Wiring Diagram — CHARGE —

NLSC0010

YEL054E

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CHARGING SYSTEM

Wiring Diagram — CHARGE —

SC-25

Trouble Diagnoses

NLSC0011

Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test. The alternator can be checked easily by referring to the Inspec-
tion Table.

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Before starting, inspect the fusible link.

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Use fully charged battery.

WITH IC REGULATOR

NLSC0011S01

SEL338V

NOTE:

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If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque.)

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When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty
parts with new ones.

MALFUNCTION INDICATOR

NLSC0011S02

The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following
symptoms occur while alternator is operating:

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Excessive voltage is produced.

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No voltage is produced.

CHARGING SYSTEM

Trouble Diagnoses

SC-26

Construction

NLSC0012

MEL141LA

MEL497L

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CHARGING SYSTEM

Construction

SC-27