2004 ISUZU TF SERIES charging

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-17
Disassembled View



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Legend (6) Rectifier
(1) Pulley Nut (7) Terminal Insulator and Nut
(2) Pulley (8) Regulator Assembly
(3) Front Cover Assembly (9) Brush Holder Assembly
(4) Rotor Assembly (10) Rear Cover


Disassembly
1. Terminal insulator and nut (2).

6D3-18 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
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.



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STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-19
6. Secure the pulley directly in the vise between two
copper plates, and remove the nut and pulley.




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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




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10. Pull the rotor assembly(10) off the front cover
assembly(12) using a bench press(11).





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6D3-20 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
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 #500—600
sandpaper.



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2. Measure the slip ring diameter, and replace if it
exceeds the limit.


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3. Check resistance between slip rings, and replace i
f
there is no continuity.




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4. Check for continuity between slip ring and rotor
core.
In case of continuity, replace the rotor assembly.




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STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-21
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.





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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)






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Rectifier Assembly
Check for continuity across “P" and “E" in the
100W
range of multimeter.





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Change 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 rectifie
r
assembly.
IC Regulator Assembly
Check for continuity across “B" and “F" in the
100W
range of multimeter.




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Change 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 regulato
r
assembly.

6D3-22 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in
the front cover.





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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)





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Bench Test
Conduct a bench test of the generator.





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Preparation
Remove generator from the vehicle (see “Generator
removal").
1. Secure generator to the bench test equipment and
connect wires.
Terminal “IG" for energization
Terminal “L" for neutral (warning lamp)
Terminal “B" 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.




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STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-23
Main Data and Specifications
General Specifications
Parts Number 102211-1740
Model ACJV74
Rated voltage 12 V
Rated output 90 A
Rotating direction (As viewed from pulled) Clockwise
Pulley effective diameter 57.5 mm (2.26 in)
Weight 5.1 kg (11 lb)

6D3-24 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
MEMO