Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1715
6D3-18 STARTING AND CHARGING SYSTEM
Reassembly
Generator
(a) Press new bearing onto slipring end of the rotor taking care
to aplly the force to the bearing inner race only, otherwise
the bearing will be noisy and it's life will be shortened.
(b) Fit a new bearing to the drive end housing, fit the bearing
plate, and four retaining screws, press the rotor into the
bearing, using a support tool to take the thrust against the
bearing inner.
The support is fitted from the pulley side of the bearing. In
this way the thrust is not taken by the drive end housing.
(c) To fit pulley, mount an 8mm Allen key in the vice with the
short end upwards, place a 24mm ring spanner on the shaft
nut, position the internal hexagon of the rotor shaft onto the
Allen key, tighten the nut to the required torque(See torque
chart)
(d) Inspect the bearing support ring for signs of damage, if in
doubt replace the ring by pressing it into the housing by
hand, do not use excessive force.
(e) To refit the rectifier, fit new mica washers to the positive
heatsink B+ bolt and retaining screw each washer must
have heatsink compound applied to both surfaces before
fitting.
Fit the three retaining screws to the rectifier then install into
slipring end housing. Tighten the B+ bolt to the reuired
torque.
(f) To refit the stator, make sure the spigot surface are clean
and free from damage, fit the stator into the slipring end
housing noting the correct lead connection positioning. Fit
the stator leads into the wire loops in the recrifier. Using a
pair of pliers squeeze the loop to retain the stator lead prior
to soldering. Repeat for each lead in turn, solder the leads
into position using 60/40 resin cored solder. Make sure the
leads will be clear of the internal fan when the rotor is
assmebled into the stator.
(g) Carefully install the rotor into the stator/slipring end housing
assembly, noting the alignment of the housings and through
bolt holes. Fit the through bolts making sure the stator is
seated correctly, tighten the through bolts to the correct
torque setting (uneven torque can produce magnetic noise
levels above normal).
(h) Fitting the regulator. Compress the brushes into the brush
holder by hand, slip the regulator through the opening in the
rear of the slipring end housing until the brushes come in
contact with the slipring. Press the regulator towards the
slipring until the holes are aligned then fit the retaining
screws and tighten.
STARTING AND CHARGING SYSTEM 6D3-19
Inspection
Generator
Before any in field testing can be undertaken it is important that
the battery's conditions is established and the terminals are
clean and tight.
Check the condition of the generator drive belt and ensure that
it is adjusted in accordance with the engine manufacturer's
recommnedations.
Battery conditions:
Note: This assessment may be difficult with maintenance free
assemblies.
Test the specific gravity of the individual cells the readings
should be within 10 points of each other, it is recommended
that the average SG should be 1.260 or higher.
A load test should be carried out to determine the ability of the
battery to supply and accept current. This is a good indicator
as to the general condition of the battery.
A load equal to the normal starting current should be placed
across the battery, the duration of this load test should not
exceed 10 seconds, during this time the terminal voltage
across the battery should not drop below 9.6 volts. Observe
each cell for signs of excessive gas liberation, usuall an
indication of cell failure.
If the battery test is clear proceed with the Generator tests as
follows.
Care should be taken when making the following connections.
It is recommended that the battery negative terminal be
disconnected before the test meters are connected, and
reconnecting the negative terminal when the meters are
inserted into the circuit under test. The warning lamp in the D+
circuit should not exceed 2 watts.
Regulating voltage test on the vehicle.
Connect a voltmeter to the generator, the positive lead to the
B+ terminal and the nagative lead to the generator casing.
Select the voltage range to suit the system, i.e. 20v for 12 volt
sysytems or 40v for 24 volt systems. Connect an ammeter in
series with the main output cable from the B+ terminal on the
generator, the range selected must be capable of reading the
maximum output from the generator.
Note the voltmeter reading before starting the engine. This
reading should increase when the engine is running indicating
generator output, start the engine and increase the engine
speed until the generator is running at 4000 rpm, switch on
vehicle loads of 5-10 A is indcated on the ammeter, the
voltmeter shoud read 14.0-14.2 v for a 12 volt system, for a 24
volt system the readings should be 5-10 A and 27.7-28.5 volts.
6D3-20 STARTING AND CHARGING SYSTEM
Load regulation test
Increase the engine speed until the generator is running at
6000 rpm, increase the load to 90% of full output a decrease in
the regulating voltage should not exceed 0.50 volts for 12 v
and 0.70 v for 24 v regulators of the readings obtained in the
previous test. If so, the regulator is defective.
Generator output test at full load
Increase engine speed until the altenator is running at 6000
rpm, switch on electrical loads until the generator voltage drops
to 13.5 volts for 12 v systems and 26 volts for 24 v systems, full
outut should be obtained under these conditions. It may be
necessary to adjust engine speed to maintain altenator speed.
If sufficient electrical loads are not available a carbon pile
resistance can be connected across the battery and adjusted
until maximum output is obtained.
Keep the time for this test to a minimum to avoid undue
heating and high engine speeds.
STARTING AND CHARGING SYSTEM 6D3-21
Technical Data
(mm)
Brush wear -
Minimum Length
3.8
Sliprings
-
Minimum Diameter 26.7
Sliprings
-
Trueness
<0.06
Pole claws
-
Trueness
<0.05(93.25
±0.05)
Torque
N.m(kgf
⋅m)
Pulley retaining nut
54-68(5.5-6.9)
Capacitor retaining screw
2.7-3.8(0.3-0.4)
Capacitor whiz nut
1.5-2.2(0.1-0.2)
B+ terminal nut M8
7.5-8.5(0.8-0.9)
B+ terminal rectifier nut
6.0-7.5(0.6-0.8)
Regulator retaining screw
1.6-2.3(0.1-0.2)
Rectifier retaining screw
1.6-2.3(0.1-0.2)
Bearing retaining plate screw 2.1-3.0(0.2-0.3)
Through bolt
3.8-5.5(0.4-0.6)
Winding resistance(between phases)
(
Ω)
Stator
Rotor
70 Amp generator
0.086+10%
2.6
±0.13
85 Amp generator
0.058+10%
2.6
±0.13
90 Amp generator
0.056+10%
2.6
±0.13
Warning lamp fault indication
Fault running
Generator not
running Ignition ON
Generator
Iginiton ON
Generator out cable
O/C
ON
ON
Battery "S" cable O/C
ON
ON
Battery overcharged
ON
ON
Positive diode short
OFF
ON
Negative diode short
ON
ON
Positive diode open
ON
OFF
Negative diode open
ON
OFF
Phase voltage sensing
ON
ON
cable open circuit
Power transistor
shorted
ON
ON
Warnign lamp driver
O/C
OFF
OFF
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