charging ISUZU TROOPER 1998 Service Service Manual

6D3±18STARTING AND CHARGING SYSTEM
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in the 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.
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 ªONº 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
ªONº position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal ªLº on connector side.
If lamp comes on:
Repair or replace the generator.
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6D3±19 STARTING AND CHARGING SYSTEM
Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3. Disconnect the wire from terminal ªBº and disconnect
the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).
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Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to ªONº
and connect a voltmeter between connector terminal
L (2) and ground or between terminal IG (1) and
ground.
066RW001If voltage is not present, the line between battery and
connector is disconnected and so requires repair.
3. Reconnect the wiring connector to the generator, run
the engine at middle speed, and turn off all electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., head lights). At this
time, the voltage must not be less than 13V.
Installation
1. Install generator assembly to the position to be
installed.
2. Install generator assembly and tighten the fixing bolts
to the specified torque.
Torque:
M10 bolt: 41 N´m (4.2 Kg´m/30 lb ft)
M8 bolt: 21 N´m (2.1 Kg´m/15 lb ft)
3. Connect wiring harness connector and direct terminal
ªBº.
4. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
5. Reconnect battery ground cable.

6D3±20STARTING AND CHARGING SYSTEM
Disassembled View
066RW007
Legend
(1) Pulley Nut
(2) Pulley
(3) Front Cover Assembly
(4) Rotor Assembly
(5) Rear End Cover(6) Rectifier
(7) Terminal Insulator and Nut
(8) Regulator Assembly
(9) Brush Holder Assembly
(10) Rear Cover

6D3±21 STARTING AND CHARGING SYSTEM
Disassembly
1. Terminal insulator and nut(2).
2. Remove three nuts(1) on the rear cover and a nut on
terminal B and insulator, then remove the rear
cover(3).
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3. Remove two screws that fix the brush holder(5) and
rectifier, then remove the brush holder assembly(4).
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4. Remove three screws on the IC regulator, then the IC
regulator assembly(6).
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5. Remove four screws that fix rectifier(7) and stator
lead wires.
066RW004

6D3±22STARTING AND CHARGING SYSTEM
6. Secure the pulley directly in the vise between two
copper plates, and remove the nut and pulley.
066RS010
7. Remove four nuts(8) that secure the front cover
assembly and rear end cover, and an insulator(9).
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8. Use the puller to remove the rear end cover.
9. Rotor assembly
066RS012
10. Pull the rotor assembly(10) off the front cover
assembly(12) using a bench press(11).
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6D3±23 STARTING AND CHARGING SYSTEM
Inspection and Repair
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500Ð600
sandpaper.
066RS014
2. Measure the slip ring diameter, and replace if it
exceeds the limit.
066RS015
3. Check resistance between slip rings, and replace if
there is no continuity.
066RS016
4. Check for continuity between slip ring and rotor core.
In case of continuity, replace the rotor assembly.
066RS017

6D3±24STARTING AND CHARGING SYSTEM
Stator Coil
1. Measure resistance between respective phases.
2. Measure insulation resistance between stator coil
and core with a mega±ohmmeter.
If less than standard, replace the coil.
066RS018
Brush
Measure the brush length.
If more than limit, replace the brush.
Standard: 10.mm (0.4134 in)
Limit: 8.4.mm (0.3307 in)
066RS019
Rectifier Assembly
Check for continuity across ªPº and ªEº in the y 100W
range of multimeter.
066RW002Change polarity, and make sure that there is continuity in
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the rectifier
assembly.
IC Regulator Assembly
Check for continuity across ªBº and ªFº in the y 100W
range of multimeter.
066RS021Change polarity, and make sure that there is continuity in
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the IC regulator
assembly.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

6D3±25 STARTING AND CHARGING SYSTEM
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
066RS022
2. Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified torque.
Torque: 111 N´m (11.3 Kg´m/82 lb ft)
066RS010
Bench Test
Conduct a bench test of the generator.
066RS023
Preparation
Remove generator from the vehicle (see ªGenerator
removalº).
1. Secure generator to the bench test equipment and
connect wires.
Terminal ªIGº for energization
Terminal ªLº for neutral (warning lamp)
Terminal ªBº for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
B06RW001

6D3±26STARTING AND CHARGING SYSTEM
Main Data and Specifications
General Specifications
Parts Number (Nippon denso)102211Ð5030
ModelACHD04
Rated voltage12 V
Rated output75 A
Rotating direction (As viewed from pulley)Clockwise
Pulley effective diameter50 mm (1.97 in)
Weight44 N (33 lb)

6E±298
ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the MAP sensor from the mounting bracket.
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Installation Procedure
1. Install the MAP sensor in the mounting bracket.
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2. Install the mounting bracket retaining bolt on the
common chamber.
3. Connect the MAP electrical connector.
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4. Connect the negative battery cable.
Malfunction Indicator Lamp
(MIL)
Removal and Installation Procedure
Refer to Warning light bulb, indicator light valve,
illumination light bulb, A/T indicator light bulb in Meter and
Gauge.
Powertrain Control Module
(PCM)
Service Precaution
NOTE: To p r e ve n t p ossible electrostatic discharge
damage to the PCM, do not touch the connector pins or
soldered components on the circuit board.
Electrostatic Discharge (ESD)
Damage
Electronic components used in the control systems are
often designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause