ISUZU AXIOM 2002 Service Repair Manual

6D3±9
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
9. Remove the return spring from the magnetic switch.
065R100014
10. Remove the steel ball from the overrunning clutch.
065RY00058
11. Remove the idle pinion from the magnetic switch.
065R100015
12. Remove the retainer from the magnetic switch.
065R100016
13. Remove the magnetic switch.

6D3±10
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
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: 30 mm (1.1811 in)
Limit: 29 mm (1.1417 in)
065RS014Check for continuity between segment and segment on
the commutator. Replace commutator if there is no
continuity (i.e., disconnected).
065RS015
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 the commutator with a dial gauge.
Repair or replace, if it exceeds the limit.
Limit: 0.4 mm (0.0157 in)
065RY00061

6D3±11
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Polish the commutator surface with sandpaper #500 to
#600 if it is rough.
065RW012Measure the depth of insulator in commutator. Replace, if
it is below the limit.
Standard: 0.45 mm to 0.75 mm (0.0177 in to
0.0295 in)
Limit: 0.2 mm (0.008 in)
065RY00070
Legend
(1) Insulator
(2) Depth of Insulator
(3) Commutator Segments
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Standard: 15 mm (0.5906 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

6D3±12
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Brush Spring
Use spring balancer to measure the spring setting force
when remove the spring from the brush.
Standard: 17.65±23.54 N (38.9±51.9 lb)
Limit: 11.77 N (25.9 lb)
Magnetic Switch
Temporarilly connect the magnetic switch between the
overrunning clutch and housing.
Perform the steps described below in 3 to 5 seconds.
1. Pull in test
Connect the ground (±) to terminal C and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal 50.
065R100017
2. Hold in test
Observe that the pinion stays when the lead wire is
disconnected from terminal C.
065R100018
3. Return test
Connect the ground (±) to terminal 50 and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal C and the pinion pulls
away when the lead wire is disconnected from
terminal 50.
065R100019
Field Coil
1. Check for continuity between the end of the field coil
and yoke body.
Replace the field coil, if there is continuity.
065RY00065

6D3±13
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
2. Check continuity between the lead wire of terminal C
and brush.
Replace the yoke assembly, if there is no continuity.
065RY00066
Overrunning Clutch
1. Visual check for excessive wear or damage.
2. Test the pinion rotation, it must rotate smoothly when
rotated clockwise and it shouldn't rotate when turned
counterclockwise.
065RY00067
Bearing
1. Inspect excessive wear or damage.
Replace the bearing if an abnormal noise is heard
under normal operating condition.
065RY00068
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places

Bearing in rear cover

Gears in reduction gear

Sliding portion of pinion

6D3±14
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Main Data and Specifications
General Specifications
ModelSpecification
Rating
Voltage12 V
Output1.4 Kw
Time30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion)Clockwise
Weight(approx.)37 N
No±load characteristics
Condition: Voltage 11.5V
Current 90A or less
Speed 3000rpm or more
Load characteristics
Condition: Voltage/Torque 8.5V/13.2 N´m (113 lb in)
Current Maximum 350A
Speed 1000rpm or more
Locking characteristics
Condition: Voltage 2.4V
Current Maximum 500A
Torque11.8N´m or more

6D3±15
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Torque Specifications
065R100013

6D3±16
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
150R100012

6D3±17
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in 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 diodes to
transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
F06RX002
General On±Vehicle Inspection
A basic wiring diagram is shown in the illustration. When
operating normally, the indicator bulb will come on when
the switch is turned on, and will then go out when the
engine starts. If the indicator operates abnormally, or if an
undercharged or overcharged battery condition occurs,
the following procedure may be used to diagnose the
charging system. Remember that an undercharged
battery is often caused by accessories being left on
overnight, or by a defective switch which allows a bulb,
such as a trunk or glove box light, to stay on.
Observe the following procedure:
1. Visually check belt and wiring.
2. Go to step 5. for vehicles without charge indicator
light.
3. Switch on, engine stopped, light should be on. If not,
detach harness at generator, ground ªLº terminal
lead.a. Lamp lights, replace or repair generator.
b. Lamp dose not light, locate open circuit between
grounding lead and ignition switch. Bulb may be
open.
4. Switch on, engine running at moderate speed. Light
should be off. If not, detach wiring harness at
generator.
a. If light goes off, replace or repair generator.
b. If light stays on, check for grounded ªLº terminal
wire in harness.
5. Battery undercharged or overcharged.
a. Detach wiring harness connector from generator.
b. With switch on, engine not running connect
voltmeter from ground to ªLº terminal in wiring
harness, and to ªIGº terminal. If used. Wiring
harness may connect to either ªLº or ªIGº or both.
c. Zero reading indicates open circuit between
terminal and battery. Connect as required.

6D3±18
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
d. Re-connect harness connector to generator, run
engine at moderate speed, with electrical
accessories turned off.
e. Measure voltage across battery. If above 16.0V,
replace or repair generator.
f. Connect ammeter at generator output terminal.
Turn on accessories, load battery with carbon pile
to obtain maximum amperes output.
Maintain voltage at 13.0V or above.
1. If within 15 amperes of rated output, generator is
OK.2. If not within 15 amperes of rated output, replace or
repair generator.
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).
060RW002
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 (1) and ground or between terminal S (2) and
ground.
066RX002If there is no voltage present, then perform
appropriate repair.
3. Reconnect the wiring connector to the generator, run
the engine at must indicate idle 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., headlights). At this
time the amperes must not be less than 15A and the
voltage must not be less than 13V.