charging ISUZU TROOPER 1998 Service Owner's Guide

6D3±8STARTING AND CHARGING SYSTEM
NOTE: In disassembling the yoke assembly, hold the
armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.
065RW007
15. Remove dust cover(17).
16. Remove a dust cover and shift lever(16) from the gear
case.
065RW008
17. Remove ball bearing(19).
18. Remove bearing cover(20).
19. Remove a ball bearing and bearing cover from the
gear case(18).
065RW021
20. Internal gear(21).
21. Remove internal gear and planet gear(3) (22).
065RW009

6D3±9 STARTING AND CHARGING SYSTEM
22. Remove an E±ring(23) from the pinion shaft using a
flat blade screwdriver.
065RW010
23. Holding the pinion shaft, push pinion toward the
center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.
24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft.
065RW011
Inspection and Repair
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Standard: 33.0 mm (1.30 in)
Limit: 32.0 mm (1.26 in)
065RS014Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).
065RS015

6D3±10STARTING AND CHARGING SYSTEM
Check for continuity between commutator and shaft.
Also, check for continuity between commutator and
armature core,armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).
065RS016Measure runout of armature core and commutator with a
dial gauge. Repair or replace, if it exceeds the limit.
Armature
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
Commutator
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
065RS017
Polish the commutator surface with sandpaper #500 to
#600 if it is rough.
065RW012Measure the depth of insulator in commutator. Repair, if it
is below the limit.
Standard: 0.05 mm to 0.8 mm (0.02 in to 0.03 in)
Limit: 0.2 mm (0.008 in)
065RW013
Legend
(1) Steel Saw
(2) Insulator
(3) Commutator Segments

6D3±11 STARTING AND CHARGING SYSTEM
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Standard: 16 mm (0.63 in)
Limit: 11 mm (0.43 in)
065RW014
Brush Holder
Check for continuity between brush holder (+) (4) and
base (±). Replace, if there is continuity (i.e., insulation is
broken).
065RW015
Magnetic Switch
Check for continuity of shunt coil between terminals S and
M.
Replace, if there is no continuity (i.e., coil is
disconnected).
065RW016
Continuity of Series Coil
Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is
disconnected).
065RW017

6D3±12STARTING 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).
065RW018
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.
065RS025
Yoke Assembly
Check a magnet inside the yoke.
Replace the yoke assembly if it is broken.
065RS026
Ball Bearing
Clamp the inner race of the ball bearing with your finger,
and check for sticking or play when rotating the outer
race.
Replace, if abnormality is found.
065RS027

6D3±13 STARTING AND CHARGING SYSTEM
Measure inner diameter of bushing in the rear cover, and
replace if it exceeds the limit.
Standard: 12.50 mm to 12.527 mm (0.492 in to
0.4932 in)
Limit: 12.60 mm (0.4961 in)
065RS028Measure inner diameter of bushing in the center bracket
(P), and replace if it exceeds the limit.
Standard: 18.01 mm to 18.127 mm (0.7091 in to
0.7137 in)
Limit: 18.15 mm (0.7146 in)
065RS029
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places

Bushing in rear cover and center bracket

Gears in reduction gear

Shift lever operating portion

Sliding portion of pinion

Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly
Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
Torque
Torque for each part (See Torque Specifications in
this section)
Pinion Jump±out Dimension
Connect the ª+º cable of battery to terminal S and the ª±º
cable to terminal M. Turn the switch on, and measure
pinion travel dimension in thrust direction from the
jump±out position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
0.06 in)
065RS030

6D3±14STARTING AND CHARGING SYSTEM
If the measured value is out of standard, insert dust cover,
or disassemble and adjust.
065RW019
Characteristic Test
For easily confirming the characteristics, conduct the no
load 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.
065RW020
Legend
(1) Volt Meter
(2) Tachometer
(3) Battery
(4) Ammeter
(5) Switch

6D3±15 STARTING AND CHARGING SYSTEM
Main Data and Specifications
General Specifications
ModelHITACHI GD002350
Rating
Voltage12 V
Output1.4 Kw
Time30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion)Clockwise
Weight(approx.)34 N
No load characteristics
Voltage /Current 11V/90A or less
Speed 2700rpm or more
Load characteristics
Voltage/current 8.4V/250A
Torque 7.3N´m(64lb´in.) or more
Speed 1200rpm or more
Locking characteristics
Voltage/current 3V/750A or less
Torque19N´m(14lb´in) or more

6D3±16STARTING AND CHARGING SYSTEM
Torque Specifications
N´m (Kg´m/lb ft)

E06RW044

6D3±17 STARTING AND CHARGING SYSTEM
N´m (Kg´m/lb ft)

150RW100