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