Toyota — ELECTRICAL CIRCUIT DIAGNOSIS Course 623 Technician Handbook

Table of Contents 623 Electrical Circuit Diagnosis Gear Reduction Starter Operation .................................................... 182 PS Starters ....................................................................................... 185 PS Starter Construction ................................................................ 186 Starter Operation .............................................................................. 188 Cranking Hold Feature ..................................................................... 192 Operation ......................................................................................

192 Protections .................................................................................... 193 Diagnosis ...................................................................................... 193 Diagnosis and Testing ...................................................................... 194 Visual Inspection .............................................................................. 195 Battery .......................................................................................... 195 Starter Motor .................................................................................

195 Ignition Switch .............................................................................. 195 Starter Motor Current Draw Test ...................................................... 196 Voltage Drop Tests ........................................................................... 197 Battery Positive Circuit ................................................................. 197 Battery Negative Circuit ................................................................ 198 Magnetic Switch ........................................................................... 199 Sources of Excessive Resistance ................................................

199 Starter Control Circuit ................................................................... 200 Starter Relay Tests ........................................................................... 201 Park/Neutral Position Switch Adjustment ......................................... 202 Clutch Start Switch Adjustment ........................................................ 203 Clutch Start Cancel Switch Testing .................................................. 204 Starter Motor Bench Tests ................................................................ 205 Pull-in and Hold-in Tests ..............................................................

205 No-load Performance Test ........................................................... 206 Repair Service Starter Kit Inspection ............................................ 207 Armature Assembly Inspection ..................................................... 208 Commutator End Frame Assembly Inspection ............................. 209 Motor Terminal Starter Kit Inspection ........................................... 210 Section 8: The Charging Section 8 Topics ............................................................................... 217 Charging System ..............................................................................

218 Charging System Components ......................................................... 219 System Alternator ...................................................................................... 220 Voltage Regulator ......................................................................... 221 Battery Function in Charging System ............................................ 222 Charging Indicator ........................................................................ 222 Charging System Operation ............................................................. 223 Ignition ON, Engine OFF ..............................................................

223 Output Voltage Low ...................................................................... 224 Output Voltage High ..................................................................... 225 Charging System Safeguards ........................................................... 226 Terminal S Disconnected ............................................................. 226 Terminal B Disconnected ............................................................. 227 Technical Training iii