Alternator Hitachi

ALTERNATOR - HITACHI
1986 Isuzu Trooper II
1986 Alternators & Regulators

HITACHI ALTERNATORS
Isuzu
DESCRIPTION
Hitachi alternators are conventional 3-phase, self-rectifying
alternators. Three positive and 3 negative diodes are used to rectify
current. Most models are equipped with Integrated Circuit (IC) voltage
regulators, except Isuzu gasoline engine equipped models.
The IC voltage regulator consists of integrated circuits
using transistors. These transistors control current flow to
alternator rotor, thus maintaining alternator output voltage at a
constant value.
On the charge indicator light circuit, a diode monitors
alternating voltage at the stator. When monitored voltage and charging
voltage are equal, the charge indicator light is turned off.
ALTERNATOR APPLICATION

Model Hitachi No.
Isuzu
I-Mark ......................................... (1) 8-94211-350-0
Impulse (2) .................................... (1) 8-94231-307-2
PUP
Gasoline ...................................... (1) 8-94140-595-0
Diesel ........................................ (1) 8-94246-957-0
Trooper II ......................................... 8-94127-186-0
(1) - Vehicle manufacturer’s part number.

(2) - With G200Z engine. Impulse with 4ZC1-T engine uses
Nippondenso alternator.
Fig. 1: Exploded View of Typical Hitachi Alternator
TESTING
ISUZU (ON-VEHICLE)
Alternator Test (Without IC Regulator)
1) Disconnect negative battery cable. Disconnect all wiring
from alternator. Using ohmmeter, measure rotor resistance between "F"
and "E" terminals. Reading must be 4-5 ohms.
2) If resistance is high, there is poor contact between
brushes and slip rings. If no continuity exists, problem may be an
open rotor winding, sticking brushes or broken lead wire. If
resistance is low, rotor winding is shorted or grounded.
3) Connect ohmmeter positive lead to alternator "N" terminal,
and negative lead to alternator "A" terminal. If continuity is
indicated, one or more positive diodes are shorted.
4) Connect ohmmeter positive lead to alternator "E" terminal,
and negative lead to alternator "N" terminal. If continuity is
indicated, one or more negative diodes are shorted.
NOTE: Alternator test will not indicate if diodes are open.

Ohmmeter will indicate continuity regardless of diode
conditions.
Alternator Output Test (With IC Voltage Regulator)

1) Check alternator wire harness connections and drive belt
tension. Battery must be fully charged prior to test. Set Alternator
Tester (J-35311) switch to 12-volt position.
2) Connect alternator harness to tester. See Fig. 2. Connect
White/Red wire to alternator harness. Connect harness to alternator
"L" wire (White/Red).
Fig. 2: Isuzu Alternator Tester Hookup
3) Connect Black alligator clip to negative battery terminal.

Connect Red alligator clip to positive battery terminal. Turn ignition
switch on and check instrument panel charge indicator light.
4) Start and run engine at 1500 RPM. Turn headlights on low
beam. After 10 seconds, check alternator tester lights. Tester will
indicate alternator condition. See Fig. 3.
NOTE: After starting or stopping engine, the Yellow light on

tester may come on for about 5 seconds. This condition is
normal.
Fig. 3: Isuzu Alternator Tester Diagnostic Charts
OVERHAUL
DISASSEMBLY
1) Remove vacuum pump (if equipped). Remove brush cover (if
equipped). Remove through bolts. Separate front cover from rear cover
by lightly tapping on front cover with plastic hammer.
NOTE: To facilitate rear cover removal, heat center of rear cover

using a 200-watt soldering iron.
2) Place front cover and rotor assembly in protected vise

with pulley nut up. Remove pulley nut, washer, pulley, fan and
spacer(s). Press out rotor. Remove screws from front cover. Lift out
bearing retainer and bearing.
3) Remove rear cover or condenser (if used), nuts, and
insulator(s). Lift stator, diode assembly, and brush assembly from
rear cover. On diesel engine alternators, if oil seal is damaged, pry
out oil seal from rear cover.
4) Unsolder stator leads from diode assembly. Disconnect
diode assembly from IC regulator by removing rivet and unsoldering
end terminal. If IC regulator is being replaced, remove 2 bolts. DO
NOT remove bolts if regulator is NOT being replaced.
Fig. 4: Exploded View of Typical Hitachi Diesel Engine Alternator
NOTE: Melting of solder should be done as rapidly as possible to

prevent damage to diodes and IC regulator.
BENCH TESTING
NOTE: Also see GENERAL SERVICING in this section.
IC Voltage Regulator (Isuzu Models Except Impulse)

1) Connect test equipment to IC regulator. See Fig. 4. Use a
10-ohm 3-watt resistor at "R1", a 0-300-ohm 3-watt variable resistor
at "Rv", two 12-volt batteries, and a voltmeter.
2) Check voltage "V1". If voltage is not 10-13 volts, charge
or replace battery as necessary.
3) Disconnect lead at "S" terminal and check voltage "V2"
between terminals "F" and "E". If less than 2.0 volts, regulator is
functioning properly. If higher, replace IC regulator.
Fig. 5: Isuzu Impulse IC Regulator Test
4) Measure total voltage of batteries 1 and 2 at "V3". If

not 20-26 volts, recharge or replace batteries.
5) Starting at zero, gradually increase variable resistance
at "Rv" and check voltage "V2" between terminals "F" and "E". Voltage
reading should increase to 10-13 volts to equal "V1" reading, measured
in step 2). If variation does not occur in "V2" voltage reading,
replace IC regulator.
6) Measure voltage "V4" between center tap of variable
resistor "Rv" and terminal "E". With resistance fixed, voltage should
be as shown in REGULATED VOLTAGE SPECIFICATIONS table.
REGULATED VOLTAGE SPECIFICATIONS TABLE

Application Volts
Isuzu
Diesel ................................................. 14.0-14-6
Gasoline ............................................... 13.8-14.8

7) Remove test lead from terminal "S" and connect to
terminal "B". Gradually increase voltage with variable resistor "Rv".
Measure voltage "V4" between terminals "B" and "E". Voltage should
increase to 10-13 volts. If not, IC regulator is defective and should
be replaced.
8) Measure voltage "V4" between center tap of variable
resistor "Rv" and terminal "E", without moving variable resistor.
Voltage should now be .50-2.0 volts higher than regulated voltage. If
voltage is incorrect, replace IC regulator.
IC Voltage Regulator (Isuzu Impulse)

Connect test equipment to IC regulator. See Fig. 5. Use a
3.4-watt 12-volt test lamp, a 10 to 20-volt variable power source,
and a voltmeter. Gradually increase voltage and check to see if test
lamp turns off between 13.8-14.4 volts. If not, replace IC regulator.
NOTE: Ensure "S" terminal is connected before connecting "L"

terminal, as damage to regulator may result.
Rotor
Connect ohmmeter to rotor slip rings. If reading is 4-5 ohms
(3 ohms on Impulse), rotor continuity is satisfactory. If not, rotor
is defective. Connect ohmmeter between one slip ring and rotor core.
If continuity exists, replace rotor assembly.
Stator
Using ohmmeter, check continuity between stator core leads.
If there is is no continuity between leads, replace stator. Connect
ohmmeter between stator core and to each stator lead. If there is no
continuity, stator is good. If continuity exists, stator is grounded
and must be replaced.
Diodes
Using an ohmmeter, check continuity on all diodes in both
directions. Current should flow in one direction only. If current
flows in both directions, diode is shorted. If current does not flow
in either direction, diode is open. If any diode is defective,
replace entire diode assembly.
Brushes
1) Inspect brushes for freedom of movement in holder. Clean
brush holder if necessary. Check brushes for cracks and wear. Check
brush springs for corrosion or damage.
2) On Isuzu Impulse, wear limit is .22" (5.6 mm). On Isuzu
diesel engine alternators, wear limit is .55" (14 mm). On all other
alternators, replace brush holder assembly if brush wear has reached
limit line on brush.
3) Test brush holder to ensure no continuity exists between
holder and brush.
REASSEMBLY
1) To reassemble, reverse disassembly procedure. On diesel
engine alternators, install oil seal (if removed). Install IC
regulator on brush holder and install bolts. Solder IC regulator
terminal to diode assembly and install rivet.
2) Solder stator leads to terminals of diode assembly.
Install diode assembly, IC regulator and stator. On most alternators,
push brushes into holder. Retain brushes in position by inserting a
wire through hole in alternator.
3) Install bearing, rotor, fan and pulley on front cover.
Tighten pulley nut to 29-43 ft. lbs. (39-59 N.m). On some alternators,
fit ring into groove of rear bearing. See Fig. 6.
4) Assemble front and rear covers. Insert and tighten
through bolts to 24-36 INCH lbs. (3-4 N.m). Remove brush retaining
wire. On diesel engine alternators, install brush holder and cover
(if equipped). Install vacuum pump. Tighten vacuum pump bolts to
24-36 INCH lbs. (3-4 N.m).
Fig. 6: Installing Rear Bearing Ring

Alternator Hitachi

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ALTERNATOR - HITACHI

1986 Isuzu Trooper II

1986 Alternators & Regulators

(1) - Vehicle manufacturer’s part number.

Fig. 1: Exploded View of Typical Hitachi Alternator

NOTE: Alternator test will not indicate if diodes are open.

Alternator Output Test (With IC Voltage Regulator)

Fig. 2: Isuzu Alternator Tester Hookup

3) Connect Black alligator clip to negative battery terminal.

NOTE: After starting or stopping engine, the Yellow light on

Fig. 3: Isuzu Alternator Tester Diagnostic Charts

NOTE: To facilitate rear cover removal, heat center of rear cover

2) Place front cover and rotor assembly in protected vise

Fig. 4: Exploded View of Typical Hitachi Diesel Engine Alternator

NOTE: Melting of solder should be done as rapidly as possible to

IC Voltage Regulator (Isuzu Models Except Impulse)

Fig. 5: Isuzu Impulse IC Regulator Test

4) Measure total voltage of batteries 1 and 2 at "V3". If

REGULATED VOLTAGE SPECIFICATIONS TABLE

IC Voltage Regulator (Isuzu Impulse)

NOTE: Ensure "S" terminal is connected before connecting "L"

Fig. 6: Installing Rear Bearing Ring

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