1995 ISUZU TROOPER Workshop Manual

2,5 3
6 4
CHARGING SYSTEM 603 - 5
Removal steps
1. Front under cover
2. Loosen generator fixing bolt
3. Fan belt
4. Adjuster
5. Remove generator fixing bolt
in step 2. 6. Wiring connector
7. AC generator assembly
Installation steps To install, follow the removal
steps in
the reverse order.
Fig. 603-6
E] REMOVAL
Preparation
• Battery ground cable
1. Front under cover
2. Generator fixing bolt
• Loosen fixing bolt.
3. Fan Belt
• Loosen lock bolt.
•
Loosen adjust bolt.
4. Adjuster
5. Generator fixing bolt
• Remove the fixing bolt.
6. Wiring connector
• Disconect terminal "B" and connector.
• From generator, supporting generator assem­
bly by hand.
7. Generator assembly
• Take out generator below.
EJ INSTALLATION
7. Generator assembly
• Direct terminal "B" to below side and bring
generator assembly to the position to be in­
stalled.
6. Wiring connector
• Connect harness connector and direct termi­
nal "B" to above side.
5. Generator fixing bolt
• Temporarily secure with bolts.
4. Adjuster
3. Fan Belt
• Refer to item "Drive belt adjustment" in the 10
page of section 6B-1 0.
2. Fan belt
1. Front under cover
• Battery ground cable

603-6 CHARGING SYSTEM
UNIT REPAIR
8
Fig. 603-7
l•!•l DISASSEMBLY
1. Terminal insulator and nut
2. Rear cover
• Remove three nuts on the rear cover and a nut
on terminal 8 and insulator, then remove the
rear cover. (Fig. 603-8)
3 Removal steps
1. Terminal insulator and nut 2. Rear cover
3. Brush holder assembly
4. Regulator assembly
5. Rectifier
6.
Pulley nut
7. Pulley 8. Rear end cover
9. Rotor assembly
10. Front cover assembly
Installation
steps
To install, follow the removal steps in the reverse order.
•

Terminal insulator and Nut
Nut
Rear cover .
Fig. 603-8
3. Brush holder assembly
• Remove two screws that fix the brush holder
and rectifier, then remove the brush holder
assembly. (Fig. 603-9)
Brush holder
~ Brush
rush
holder
Fig. 603-9
4. Regulator assembly
• Remove three screws on the IC regulator, then
the IC regulator. (Fig. 603-10)
IC regurator assembly
Fig. 603-10
CHARGING SYSTEM 603 - 7
5. Rectifier
• Removefourscrewsthatfix rectifier and stator
lead wires. (Fig. 603-11)
Rectifire
Fig. 603-11
6. Pulley nut
7. Pulley
• Cover the vise with copper plates, clamp the
pulley in the vise, and remove the nut. (Fig.
603-12)
Fig. 603-12

603 - 8 CHARGING SYSTEM
8. Rear end cover
• Remove four nuts that secure the front cover
assembly and rear end cover, and an insula­
tor. (Fig. 603-13)
Fig. 603-13
W CAUTION
Take care not to elongate the stator wire when
removing a bushing.
• Use the puller to remove the rear end cover.
(Fig.
603-14)
Fig. 603-14
9. Rotor assembly
10.
Front cover assembly
• Pull the rotor assembly off the front cover
assembly using a bench press. (Fig. 603-15)
Press
Rotor assembly
Fig. 603-15
~ 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 contamina­
tion and roughness. If rough, polish with #500-
600
sandpaper. (Fig. 603-16)
Fig. 603-16
2. Measure the slip ring diameter, and replace if it
exceeds the limit. (Fig. 603-17)
•

CHARGING SYSTEM 603 - 9
Fig. 603-19
In case of continuity, replace the rotor assembly.
Fig. 603-17 STATOR COIL
1. Measure resistance between respective phases.
---------r-----:-:--:---'m;.;..;.;...;.m""'"(.....,..in) (Fig. 603-20)
limit Standard
14.4 (0.51)
12.8 (0.51)
3. Check resistance between slip rings, and replace if
there is no continuity. (Fig. 603-18)
Fig. 603-18
Standard 2.9
or more
4. Check for continuity between slip ring and rotor
core. (Fig. 603-19) Fig.
603-20
Standard
0.1
2. Measure insulation resistance between stator coil
and core with a mega-ohmmeter.
Standard
Mn 1 or more
If less than standard, replace the coil.

603 -10 CHARGING SYSTEM
BRUSH
Measure the brush length. (Fig. 603-21)
Fig. 603-21
mm (in)
Standard
Limit
10.5 (0.41) 8.4 (0.33)
If more than limit, replace the brush.
RECTIFIER ASSEMBL V
Check for continuity across "P" and "E" in the x 100Q
range of multimeter. (Fig.603-22)
"B" terminal r---....... /
®
Fig. 603-22
• Change polarity, and make sure that there is con­
tinuity in one direction, and not in the reverse
direction.
In case of continuity in both directions,
replace the rectifier assembly.
IC REGULATOR ASSEMBL V
Check for continuity across "B" and "F" in the x 100Q
range of multimeter. (Fig. 603-23)
Fig. 603-23
• Change polarity, and make sure that there is con­
tinuity in one direction, and not in the reverse
direction.
In case of continuity in both directions,
replace
the IC regulator assembly.
l•!•l REASSEMBLY
To reassemble, follow the disassembly steps in the
reverse order,
noting the following points:
1) Front cover assembly
• Using a press with a socket wrench attached,
reassemble
rotor and rear end cover assembly in
the
front cover. (Fig. 603-24)
Fig. 603-24
•