Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1712

6D3-6  STARTING AND CHARGING SYSTEM

Continuity of Contacts

With the plunger faced downward, push down the magnetic
switch. In this state, check for continuity between terminals B
and M. Replace, if there is no continuity (i.e., contacts are
faulty).

Pinion

Check if the pinion rotates smoothly in drive direction by hand,
or if it is locked when it is rotated in reverse. If not, replace the
pinion.

Characteristic Test

For easily confirming the characteristics, conduct the noload
test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. When the switch is closed, the current flows and
the starter runs under no load. At this time, measure current,
voltage and speed to check if they satisfy the standard.

Legend

1 Volt Meter
2 Revolution Indicator
3 Battery
4 Ammeter
5 Switch

STARTING AND CHARGING SYSTEM  6D3-7

Charging System

General Description

The charging system is an IC integral regulator charging
system and its main components are connected as shown in
illustration.
The regulator is a solid state type and it is mounted along with
the brush holder assembly inside the generator installed on the
rear end cover.
The generator does not require particular maintenance such as
voltage adjustment. The rectifier connected to the stator coil
has eight diodes to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.

Legend

1 Startor assembly
2 Housing
3 Slipring
4 Screws (2)
5 Regulator
6.Bolt (4)

7 Rectifier assembly
8 Retaining assembly
9 B+ terminal nut and washer

10 Pulley
11 Rotor assembly
12 Ball bearing

2

11

12

2

8

5

4

3

1

11

7

6

10

9

6D3-8  STARTING AND CHARGING SYSTEM

General On-Vehicle Inspection

The operating condition of charging system is indicated by the
charge warning lamp. The warning lamp comes on when the
starter switch is turned to "ON" position. The charging system
operates normally if the lamp goes off when the engine starts.
If the warning lamp shows abnormality or if undercharged or
overcharged battery condition is suspected, perform diagnosis
by checking the charging system as follows:
1. Check visually the belt and wiring connector.

2. With  the  engine  stopped,  turn  the  stator  switch  to  "ON"

position and observe the warning lamp.

If lamp does not come on:

Disconnect  wiring  connector  from  generator,  and  ground

the terminal "L" on connector side.

If lamp comes on:

Repair or replace the generator.

Generator

Removal

1. Disconnect battery ground cable.

2. Move  drive  belt  tensioner  to  loose  side  using  wrench  then

remove drive belt.

3. Disconnect terminal "B" wiring connector and connector.

4. Remove generator assembly.

Generator Power and Circuit Diagram

Inspection

Legend

1 Load resistor, set parallel to battery
2 Battery
3 Voltmeter
4 Ammeter
5 Ignition Lock
6 Charge Telltale
7 Generator

1. Disconnect battery.

2. Close off connecting cable from alternator terminal "B+".

3. Set ammeter (measuring range 100A) in disconnected line.

4. Connect controllable load resistor to battery terminal.

5. Set  resistor  in  front  of  connection  to  "O";  connect  first  to

battery, then to resistor.

6. Connect tachometer.

7. Connect 

oscilloscope 

according 

to 

manufacturer's

instructions.

8. Connect battery.

9. Start engine and read off resulting current at various engine

speeds.

STARTING AND CHARGING SYSTEM  6D3-9

Generator Power

1. Adjust  load  resistor,  if  the  required  load  currents  are  not

attained.

2. The  shape  of  the  voltage  curves  on  oscilloscope  curve

should be regular.

3. Test value: 5 to 7A.

4. If the required minimum current intensity is not attained, or if

the  oscilloscope  picture  shows  variations,  the  alternator

should be overhauled.

Regulated Voltage Circuit Diagram

Legend

1 Battery
2 Ignition Lock
3 Charge Telltale
4 Resistor, for attainment of load current with the battery set in

series

5 Voltmeter
6 Ammeter
7 Generator

Installation

1. Install generator assembly and bring generator assembly to

the position to be installed.

2. Install  generator  assembly  and  tighten  to  the  specified

torque.

Torque:

Long bolt: 35 N

⋅⋅⋅⋅m (3.6 kgf⋅⋅⋅⋅m)

Short bolt: 20 N

⋅⋅⋅⋅m (2.0 kgf⋅⋅⋅⋅m)

3. Connect wiring harness connector.

4. Move drive belt tensioner to loose side using a wrench, then

install drive belt to normal position.

5. Reconnect battery ground cable.