ISUZU TF SERIES 2004 Workshop Manual

ENGINE ELECTRICAL 6D – 13
STATOR COIL ASSEMBLY
1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal “N” and the Coil Ends
(Reference) ohms
Standard 0.1

066RY00022 2. Check for continuity between each stator coils and the
stator core.
If there is continuity, the stator coils must be replaced.
066RY00023


RTW46DSH004801
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference) mm (in)

Standard Limit
25 (1.0) 6.5 (0.25)



RTW46DSH001201
Rectifier


Tester wire
E BAT
U, V, and WN ⊕  U, V, and WN⊕ 
⊕ ----- Conductivity ⊕ ----- No
conductivity

No
conductivity -----
 Conductivity -----
Negative side diode check Positive side diode check

6D – 14 ENGINE ELECTRICAL
RECTIFIER ASSEMBLY



RTW46DSF000301

1. Voltmeter
2. Switch 1
3. DC regulated power supply
4. Lamp 2
5. Lamp 1
6. Switch 3
7. Switch 2
8. Pulse generator
9. Output signal

Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1~5. If all the items are OK, the IC
regulator is normal.

Circuit components
1 DC regulated power supply 0~20 volts variable with output of 1 ampere or more
2 Lamps (2) 12 volts, 1.4~3.4 watts
3 Switches (3) -----
4 DC voltmeter 0~30 volts, 0.5 grade
5 Pulse generator (Oscillator) 5~30 volt output at a frequency of 1kHz

Judgment criteria
Lamp condition
No. Switch
1 Switch
2 Switch
3 Voltmeter
reading
Lamp 1 Lamp 2Remarks
1 ON OFF OFF On
(dim) ON Initial excitation check
2 ON ON OFF 12V
On or
flashingFull excitation check
3 ON ON OFF 16V Off or
on (dim)OFF
Lamp 1 off or dimly lit when the
voltmeter shows less than 12 volts or
16 volts
4 OFF ON OFF 12V On or
flashingStator and brush separation check
5 ON ON ON 18V On ON
Excess voltage check

ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.


Oil Seal Replacement
1. Push the old oil seal from the rear bracket outside
holes.
2. Use the insertion tool to press the new oil seal into
place. Follow the procedure shown in Figures A, B, C
and D.

Position the oil seal beneath the shaft and the
guide lip.

Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.

After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution





Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.





Take care not to damage the D surface.





Under no circumstances may the original oil seal
be reused.





The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.







RTW46DSF000101

6D – 16 ENGINE ELECTRICAL



RTW46DSH000901

















Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump
housing.
2. Remove the vacuum pump rotor and the vanes from
the housing.


Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.



Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.


Rotor
1. Inspect the rotor for excessive wear, abrasion, and
scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash.
Replace the rotor if backlash is present.














RTW46DSH005201
Check Value
1. Carefully force the valve from the “B” side as shown in
the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the “A” side.
Air Pressure kPa (kg/cm
2/psi)
98 - 490 (1-5/14 – 71)

Check for air leakage from the check valve.
If there is air leakage, the valve must be replaced.

ENGINE ELECTRICAL 6D – 17


RTW46DSH001801
Vacuum Pump Reassembly
1. Install the vanes to the rotor slits.
The rounded side of the vanes must be facing the
rotor housing.



RTW46DSH001901
2. Install the rotor with the concave side facing the center
plate.



RTW46DSH002001
3. Install the center plate to the rotor housing.
Be sure to use a new O-ring.

6D – 18 ENGINE ELECTRICAL
REASSEMBLY



RTW46DLF000501


Reassembly Step
1.
Front cover
2.
Rear rotor bearing
3.
Rotor Assembly
4.
Pulley
5.
Rectifier Assembly
6.
Stator Assembly
7.
Rear cover
8.
B Terminal nuts
9.
Through bolt
10.
O-ring
11.
Vacuum pump

ENGINE ELECTRICAL 6D – 19


RTW46DSH000401
Important Operations
2. Rear rotor bearing

Re-use improper parts.


5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.



RTW46DSH002101







3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque Nm (kgm/lbft)
83.3  98.0 (8.5  10.0 / 61  72)





RTW46DSH006001
Remove the tape from the splines.









RTW46DSH004901
The rear ball bearing is pressed into the wheel eccentric
groove. The bearing ring projects from the groove.

During installation, rotate the bearing to the point of
minimum bearing ring projection.

Inspect the rear cover bearing box and replace it if it is
damaged.

6D – 20 ENGINE ELECTRICAL

RTW46DSH002201
NOTE: Be sure to attach a cooler to B terminal.




RTW46DSH005301
Insert the pin from the outside of the rear cover. Press the
brushes into the brush holder. Complete the assembly
procedure.

Remove the pin after completion of the assembly
procedure.

ENGINE ELECTRICAL 6D – 21




RTW06DSH000201











9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the
front cover and the rear cover.
2. Install the through bolts and tighten them to the
specified torque.
Through Bolt Torque Nm (kgm/lbft)
3.1  3.9 (0.32  0.41 / 2.6  3.5)


11. Vaccum Pump
To install the generator -

1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the
3 generator fixing points.
3. Twist the fixing points down and to the left to align
them with the middle of the center plate and the rotor.




RTW46DSH006101
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.



RTW46DSH002401
Install the vacuum pump housing.
Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.



RTW46DSH002501













Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque Nm (kgm/lbft)
5.9  6.9 (0.6  0.7 / 5.2  6.1)

6D – 22 ENGINE ELECTRICAL
STARTER MOTOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.























Important Operations - Removal
Starter Motor
1. Disconnect the battery cable and the ground cable at the battery terminals.
2. Disconnect the magnetic switch cable at the terminal bolts.
3. Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
4. Remove the starter motor from the engine.

Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.









Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N m (kg m/lb ft)
85 (8.7/63)

3. Reconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
4. Reconnect the battery cable and the ground cable at the battery terminals.