charging ISUZU TF SERIES 2004 Owner's Manual

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-5
Starter
Removal
1. Battery ground cable.
2. Disconnect left heated O
2 sensor connector.
3. Remove exhaust front left pipe.
4. Remove dust cover.
5. Disconnect starter wiring connector from terminals
“30" and “50".
6. Remove starter assembly mounting bolts on inside
and outside.
7. Remove starter assembly toward the bottom o
f
engine.



065RY00050
Legend
(1) Terminal "30"
(2) Terminal "50"
(3) Fixing Bolts
(4) Starter Assembly


Installation
1. Install starter assembly.
2. Install mounting bolts and tighten bolts to specified
torque.
Torque: 40 N




m (4.1 kg




m/30 lb ft)
3. Reconnect the connectors to terminals “30" and
“50" and tighten Terminals “30" to specified torque.
Torque: 9 N




m (0.9 kg




m/7 lb ft)
4. Install dust cover.





065RY00050
Legend
(1) Terminal "30"
(2) Terminal "50"
(3) Fixing Bolts
(4) Starter Assembly


5. Install exhaust front left pipe and tighten bolts and
nuts to specified torque(2).
Stud Nuts
Torque: 67 N




m (6.8 kg




m/49 lb ft)
Nuts
Torque: 43 N




m (4.4 kg




m/32 lb ft)
6. Connect heated O
2 sensor connector.
7. Reconnect the battery ground cable.

6D3-6 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Disassembled View



065R100012
Legend (7) Housing
(1) Lead Wire (8) Over Running Clutch
(2) Through Bolt (9) Return Spring
(3) Yoke Assembly (10) Steel Ball
(4) Yoke Cover (11) Idle Pinion
(5) Brush and Brush Holder (12) Retainer
(6) Armature (13) Magnetic Switch

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-7
Disassembly
1. Remove the lead wire (1) from the magnetic switch.
2. Remove the through bolts (2).



065RY00053
Legend
(1) Lead Wire
(2) Through Bolt


3. Remove the yoke from the magnetic.
4. Remove the yoke cover.
5. Use the long nose pliers to remove the brush and
brush holder.



065RY00054





065RY00055
Legend
(1) Spring
(2) Brush


6. Remove the armature.
7. Remove the housing.
8. Remove the overrunning clutch from the housing.



065RY00056

6D3-8 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.

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-9
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)



065RS014
Check 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).





065RS016
Measure runout of the commutator with a dial gauge.
Repair or replace, if it exceeds the limit.
Limit: 0.4 mm (0.0157 in)



065RY00061

6D3-10 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Polish the commutator surface with sandpaper #500 to
#600 if it is rough.


065RW012
Measure 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

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-11
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

6D3-12 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

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-13
Main Data and Specifications
General Specifications

Model ADX4IH
Rating
Voltage 12 V
Output 1.4 Kw
Time 30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion) Clockwise
Weight(approx.) 3.8kg (8.4lb)
No–load characteristics
Voltage /Current 11.5V/90A or less
Speed 3000rpm or more
Load characteristics
Voltage/current 8.5V/350A or less
Torque 13.2Nm (1.35kgm/9.77lb in.) or more
Speed 1000rpm or more
Locking characteristics
Voltage/current 2.4V/500A or less
Torque 11.8N




m (1.2kg




m/8.68lb in) or more

6D3-14 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Torque Specifications
N




m (kg




m/lb ft)




RTW46DLF000101