Isuzu N-Series. Manual - part 412

6D3-16 CHARGING SYSTEM

The valve must move smoothly.
If it does not, the check valve must be replaced.

2) Apply compressed air to the “A” side.

Check for air leakage from the check valve.
If there is air leakage, the valve must be re-
placed.

Reassembly

1. Install the vanes to the rotor slits.

The rounded side of the vanes must be facing the
rotor housing.

2. Install the rotor with the concave side facing the

center plate.

3. Install the center plate to the rotor housing.

Be sure to use a new O-rings.

Reassembly

1. Rear Cover
2. Brush and IC Regulator
3. Rectifier
4. Fan Guide
5. Stator

Air Pressure

kPa (kg/cm

2

/psi)

98 — 490 (1 — 5/14.22 — 71.10)

N6A1069E

N6A1070E

N6A1071E

N6A1067E

CHARGING SYSTEM 6D3-17

1) Solder together the rectifier and stator leads.

Hold the rectifier lead near the rectifier with a
pair or long-nose pliers to protect the rectifier
from heat.
Complete the soldering procedure as quickly
as possible.

2) Install the IC regulator/stator assemblies to the

rear cover.
Be absolutely sure that the washers and the in-
sulators are reinstalled to their original posi-
tions.
Hold the stator coil against the rear cover.

6. Terminal Nut and Bolt
7. Rotor
8. Rear Ball Bearing
9. Front Cover

10. Front Ball Bearing
11. Bearing Retainer
12. Spacer
13. Fan
14. Pulley
15. Pulley Nut

1) Carefully clamp the rotor and cover assembly in

a vise.

2) Install the pulley and the pulley nut.

3) Tighten the pulley to the specified torque.

Tighten:
Pulley nut to 98 N

⋅m (10.0 kg⋅m / 72 lb⋅ft)

Notice:
Take care not to damage the rotor when clamping it in a
vise.

16. Stator and Rear Cover Assembly

17. Rotor and Front Cover Assembly
18. Through Bolt

1) Prepare a brush holding wire or a pin.
2) Set the holding wire or the pin to the brushes

from the vacuum pump side.

3) Push the brushes into the holder.

N6A1074E

N6A1075E

N6A1076E

6D3-18 CHARGING SYSTEM

4) Bend the wire end to hold the brushes.

If the holding wire does not hold the brushes
properly, the brushes will be damaged.

5) Tape the rotor shaft spline.

This will prevent oil seal damaged.

6) Place the bearing retainer ring.

Ring projection must be less than 0.65 mm
(0.025 in)

7) Install the front cover and rotor assembly to the

rear cover.
Take care not to damage the rotor, the coil
leads, the oil seal lip, and the splines.

8) Place the guide bar into the rear cover bracket

hole.
Align the front cover bracket hole with the guide
bar.

9) Install the through bolts.
10) Tighten the through bolts to the specified

torque.

Tighten:
Through bolt to 4 N

⋅m (0.4 kg⋅m / 35 lb⋅in)

11) Carefully remove the holding wire from the rear

cover.

Legend

1. Brush holding wire or pin
2. Brush

Legend

1. Taping 

N6A1077E

N6A1078E

Legend

1. Retainer ring
2. Bearing outer race

N6A1079E

N6A1080E

CHARGING SYSTEM 6D3-19

19. Vacuum Pump Assembly

1) Position the pump rotor together with the pump

housing on the center plate.
The rotor serrated side must be facing up.

2) Rotate the rotor to align the rotor bore with the

center plate bore.

3) Install the housing, the rotor, and the center

plate.
The O-ring must not be projecting beyond the
center plate slot.
Take care not to scratch the vanes.

4) Turn the housing to align it with the center

plate.

5) Tighten the vacuum pump fixing bolts.

Tighten:
Vacuum pump fixing bolt to 7 N

⋅m (0.7 kg⋅m / 61 lb⋅in)

6) Add 5cc of engine oil through the filler port.
7) Check that the generator spins smoothly by

turning it with your hand.

Inspection

Performance Test

1. Generator

• Connect the generator as shown in the illustra-

tion.

• Use a fully charged battery to conduct the mea-

surement with the current outputted from the
battery terminals at 5A or less.

Notice:
When conducting the performance test:
For the connection between the generator B terminal
and the battery (+) terminal and between the E terminal
and the battery (

−) terminal, use a lead wire with a cross

section of 8 mm

2

 and the length of 2.5 m or less.

2. Adjusting voltage measurement

• Open SW1 and close SW2.
• With the number of the generator rotations

raised up to its rated rotations of 5,000 rpm,
measure the adjusting voltage.

Adjusting voltage = 28 - 29V

• Check to see if the fluctuation in the adjusting

voltage is not caused by the increased number
of rotations.

3. Measurement of the number of rotations at 27V

• Open SW1 and close SW2.

N6A1081E

N6A1082E

N6A1082E