Alternator circuit ISUZU TF SERIES 2004 Workshop Manual

8A-4 ELECTRICAL-BODY AND CHASSIS
GENERAL INFORMATION
The body and chassis electrical system operates on a twelve volt power supply with negative ground polarity.
The main harness consists of the engine harness, the instrument harness, the body harness, and the chassis
harness.
The harnesses use a split corrugated tube to protect the wires from the elements.
Wire size is determined by current flow, circuit length, and voltage drop.
All wires have color-coded insulation.
Wire color-codes are shown in the circuit diagrams.
This makes it easier to trace circuits and to make the proper connections.
Each circuit consists of the following:
1. Power source - The battery and the alternator
2. Wires - To carry electrical current through the circuit
3. Fuses - To protect the circuit against current overload
4. Relays - To protect voltage drop between the battery and the circuit parts and to protect the switch points against
burning
5. Switches - To open and close the circuit
6. Load - Any device, such as a light or motor, which converts the electrical current into useful work
7. Ground - To allow the current to flow back to the power source

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, o
r
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.

6D3-10 STARTING AND CHARGING SYSTEM
The generator has four external connections; the "B+" lead to
battery positive, "L" lead to the warning lamp circuit(max. 2
watts), "S" lead to battery positive terminal for battery sensing
and an earth connection.

Explanation of type inscripiton
Example:KC-A--> 14V 50-90A.

K = Code for Stator OD(126mm OD).
C = Compact Generator.
A = Ausland (countries other than Germany)
> = Direction of rotation(clockwise).
14V = Generator Operating Voltage.
50A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.
90A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.

Generator Connetions.
B+ : Battery Main Connection (battery positive)
S : Battery Sense Connection(battery positive)
L : Waring lamp(via warning lamp to Ignition switch)


BATT.SENSE
REGULATOR ASSEMBLYHYBR10ALTERNATOR ASSEMBLY
12V BATT.1GN.SW.
300a* WARN.LAMP
1.2 WATT
L S8+SUPPRESSOR
CAPACITOR
0.5

f
NOTE: * RESISTOR IS RECOMMENDED TO
ENSURE THAT THE GENERATOR
REMAINS FUNCTIONAL IN CASE OF
WARNING LAMP FAILURE

DIAGNOSIS (JR405E) 7A2-43
DTC P0560 (Flash Code 16) System Voltage Failure
TCM


A1 (+B)



B5

B15

H23 (15)C95 (5)
(15)
BLK/YEL
BLK
BLK
Battery
C94
(1)
BLK


Setting Condition:

The supply voltage is below 10V and the engine speed exceeds 1000 rpm for more than 1 second.

Fail Safe:

When the vehicle is running, the gear position selected at the trouble detection is held and the lock-up is
inhibited.

After the vehicle stopped, all solenoid operations stop (OFF) and the gear is fixed to the 3rd. (In case of fail-safe
valve failure, gear shift to 4th (over-drive) is inhibited.)

Possible Cause:

Alternator or battery malfunction.

Power supply wire open circuit or short circuit to ground between power supply and TCM terminal A1 (C94).

Ground wire open circuit or short circuit to battery between ground location and TCM terminal B5 (C95) or B15
(C95).

Poor connection of each connector.