charging ISUZU KB P190 2007 Workshop Owners Manual

Charging System – V6 Page 6D1-1-9

2.5 Charging System Inoperative /
Malfunctioning
Diagnostic Table Notes
Reference to following information will assist when diagnosing charging system faults.
1 For all wiring harness fault diagnoses, refer to 8A Electrical Body and Chassis.
2 For wiring harness repairs, refer to 8A Electrical Body and Chassis.
3 Refer to 8A Electrical Body and Chassis for harness routing.
4 Ensure the battery, cables and connections are in good order. Refer to 6D1-3 Battery – V6.
Diagnostic Table 120A Generator
Step Action Yes No
1 Did you review 1.3 System Operation?
Go to Step 2 Go to 1.3
System Operation
2 Did you read 2.3 Diagnostic Systems Check
Go to Step 3 Go to 2.3
Diagnostic
Systems Check
3 Perform the Generator On-vehicle Checks
W as the generator serviceable? Go to step 4 Replace the
generator.
Go to Step 5
4 Perform the Charging Circuit Voltage Drop Test.
W as the wiring serviceable? Go to 8A Electrical
Body and Chassis
Go to Step 5 Repair as required
(refer to Note 2).
Go to Step 5
5 Operate the system to verify the repair.
Did you correct the condition? System OK Go to Step 2
When all diagnosis and repairs are completed, check the system for correct operation.

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Charging System – V6 Page 6D1-1-10

3 Minor Service Operations
3.1 Safety Precautions
Observe the following precautions. Failure to observe these precautions will result in serious damage to the generator.
• Only use the generator and voltage regulator in a negative ground system.
• Always refer to 1.2 W ARNING, CAUTION and NOTES before disconnecting the battery.
• W hen installing a battery, fit the positive (+) cable to the battery before fitting the negative cable.
• W hen a slave battery is used for starting purposes, ensure that both batteries are connected in parallel. That is,
positive terminals connected and negative terminals connected.
• Only use jumper leads that have surge protection.
• Disconnect both battery cables when charging the battery. This isolates the generator from the battery and from
the external charging equipment.
• Do not operate the generator within an open circuit or without a battery in the circuit.
• Do not disconnect the battery while the generator is running.
• Do not attempt to polarise the generator.
• Do not connect generator connector E-4 pin 1 to 12 V (the battery or ignition circuits).
• Some battery powered timing lights can produce high transient voltages when connected or disconnected.
Only disconnect or connect timing lights when the engine is switched off.

Ensure the generator connector E-4 pin 1 has
a maximum sinking current of 50mA.
3.2 Maintenance
Regular Checks
Check the following at regular intervals:
• generator terminals – for corrosion and loose connections,
• wiring – for continuity and damaged insulation,
• mounting bolts – for tightness,
• drive belt – for alignment and wear, and
• drive pulley – for damage and warping.
NOTE
The drive-belt adjustment for the engine
ancillaries (i.e. generator and water pump) is
provided by a spring-loaded tensioner. Therefore,
the drive belt does not require manual
adjustment.
Lubrication
High tolerance bearings are used in this generator. If the bearings are removed during the generator disassembly, new
bearings must be installed to restore the generator to original specification. The ball bearings supporting the rotor shaft
are pre-lubricated and sealed. Do not attempt to lubricate these during servicing.

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Charging System – V6 Page 6D1-1-11

3.3 On-vehicle Testing
Generator On-vehicle Checks
Prerequisites
Before testing the generator output, ensure that:
• all generator circuit connections are clean and tight,
• the generator is always connected to the battery during testing (to prevent damage to the diodes),
• the battery is fully charged, and
• the specific gravity does not vary more than 0.025 between cells. (It is recommended the average specific gravity
is 1.260 or higher). Refer to 6D1-3 Battery – V6.
Carry out a load test on the battery to determine its ability to supply and accept current. This is a good indicator of the
general condition of the battery. For details of battery testing, refer to 6D1-3 Battery – V6.
Inspect the drive belt and tensioner markings to determine if the drive belt is within operating limits. Replace the belt if it
is excessively worn or outside the operating range of the tensioner.
For further details, refer to 6A1 Engine Mechanical – V6.
Generator Test
Regulating Voltage Test
NOTE
Leave the generator E-4 wiring harness
connector connected, as it provides initial field
excitation.
1 Ensure the ignition switch is in the OFF position and all electrical equipment is turned off.

Refer to 1.2 WARNING, CAUTION and
NOTES before disconnecting the battery.
2 Disconnect the battery ground cable P-5 at the battery.
3 Disconnect the generator positive lead P-9 from the generator . Connect the positive lead of a multimeter
set to measure current (1) to P-9 (2).
4 Connect that multimeter’s negative lead to the disconnected generator positive lead (3).
5 Connect the positive lead of a multimeter set to measure voltage (4) to P-9 (5).
6 Connect that multimeter’s negative lead to a good ground connection on the generator housing (6).

Insulate the terminal of the generator
positive lead P-9 to prevent contact with any
metal part of the vehicle. If the terminal is
grounded, damage to the charging circuit
can result when the battery is reconnected.
Figure 6D1-1 3

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Charging System – V6 Page 6D1-1-12


7 Reconnect the battery ground cable P-5.
8 Fit a loading device (7) across the battery terminals, e.g. an adjustable carbon pile.

The loading device must have a minimum
power consumption of 1000 W.
9 Record the voltage reading before starting the engine. (This reading should increase when the engine is running, indicating generator output.).
10 Start the engine.
11 Increase the engine speed to the value outlined in the chart below.
12 Using the reading from the multimeter set to measure current, adjust the loading device to apply a load within the range outlined in the chart below.
13 Using the multimeter set to measure voltage, check the generator output voltage against the specification.
Engine RPM ........................................................... 1300
Load ................................................................ 5.0 – 10 A
Output Voltage ........................................... 13.8 – 15.4 V

Load Regulation Test
NOTE
The decrease in the voltage recorded during this
test should not exceed 0.5 V from the readings
obtained for the Regulating Voltage Test. If the
decrease in the regulating voltage is greater than
0.5 V, the regulator is defective. Replace the
regulator.
14 Increase the engine speed to the value outlined in the chart below.
15 Using the reading from the multimeter set to measure current, adjust the loading device to apply a load of about 90% of the generator’s full output.
16 Using the multimeter set to measure voltage, check the generator output voltage against the specification.
Engine RPM............................................................ 1900
Load ......................................................................... 90 A
Output Voltage ........................................... 13.8 – 15.4 V
Full Load Output Test

Keep the time for this test to a minimum to
avoid undue heating and high engine speeds.
17 Increase the engine speed to the value outlined in the chart below .
18 Using the reading from the multimeter set to measure voltage, adjust the loading device to increase the load until the generator output voltage drops to 13.5 V. Full generator output, outlined in the chart below, is required.
19 Record the current reading displayed on the multimeter set to measure current.

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20 Reduce the engine speed to idle.

On completion of the generator output test,
return the engine to idle and disconnect the
loading device from the battery terminals.
This prevents excessive battery discharge.
21 Stop the engine.
22 Disconnect the battery ground cable P-5 at the battery.
23 Remove the multimeters.
24 Reconnect the generator positive lead P-9.
25 Reconnect the battery ground cable P-5 to the battery.
Engine RPM............................................................ 1900
Load ................................................................ 5.0 – 10 A
Output Voltage ........................................... 13.8 – 15.4 V
Charging Circuit Voltage Drop Test
Prerequisites
Before testing the generator output, ensure that:
• all generator circuit connections are clean and tight,
• the generator is always connected to the battery during testing (to prevent damage to the diodes),
• the battery is fully charged, and
• the specific gravity does not vary more than 0.025 between cells. (It is recommended the average specific gravity
is 1.260 or higher). Refer to 6D1-3 Battery – V6.
Carry out a load test on the battery to determine its ability to supply and accept current. This is a good indicator of the
general condition of the battery. For details of battery testing, refer to 6D1-3 Battery – V6.
Inspect the drive belt and tensioner markings to determine if the drive belt is within operating limits. Replace the belt if it
is excessively worn or outside the operating range of the tensioner.
For further details, refer to 6A1 Engine Mechanical – V6.
Voltage Drop Test

Ensure the generator connections are clean
and tight.
1 Connect the positive lead of a multimeter set to measure voltage to the generator terminal P-9.
2 Connect the negative lead of the multimeter to the battery positive post.
3 Switch the headlamps on.
4 Start the engine.
5 Increase the engine speed to approximately 2500 r.p.m.
6 Record the voltage reading.
7 Reduce the engine speed to idle.

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Charging System – V6 Page 6D1-1-14

8 Connect the positive lead of a multimeter set to measure voltage to the battery negative post.
9 Connect the negative lead of the multimeter to the generator housing.
9 Increase the engine speed to approximately 2500 r.p.m.
10 Record the voltage reading.
11 Reduce the engine speed to idle.
12 Check the two readings. If the readings exceed 0.3 V, there is a high resistance in the charging circuit.
13 Trace the cause and correct the problem, refer to 8A Electrical Body and Chassis.

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4 Major Service Operations
4.1 Generator
Remove

Refer to 1.2 WARNING, CAUTION and NOTES
before disconnecting the battery.
1 Disconnect the battery ground lead P-5. Refer to 8A Electrical Body and Chassis.
2 Insert a ½ inch drive socket bar into the tensioner arm and rotate the tensioner arm clockwise.
3 Remove the drive belt from the generator pulley and release the tensioner. Refer to 6A1 Engine Mechanical – V6 for further details as required.
4 Pull the battery harness cap back from generator terminal P-9 (3), remove the nut (4) and remove the
positive lead (2) from the generator (5).
5 Disengage the connector retaining clip and remove the connector E-4, (1) from the generator.
Figure 6D1-1 4
6 Remove the three bolts (1, 2, 4) retaining the generator (3) to the generator bracket.

7 Remove the generator assembly from the vehicle.
Figure 6D1-1 5

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Reinstall
Reinstallation of the generator is the reverse of the removal procedure, noting the following:
1 Tighten all fasteners to the correct torque specification.
2 Reconnect the battery ground lead.
3 Start the engine.
4 Check the generator warning indicator operation.
5 Check the drive belt is correctly routed and aligned.
6 Check the generator output. Refer to 3.3 On-vehicle Testing.
7 Check the voltage regulator operation. Refer to 3.3 On-vehicle Testing.
8 Turn the ignition switch off.
Generator mounting bolts ........................... (1) 58.0 Nm
Generator mounting bolts ........................... (2) 58.0 Nm
Generator mounting bolts ........................... (4) 58.0 Nm
Battery harness to P-9 pin B nut
torque specification ...................................7.1 – 13.3 Nm

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4.2 Generator Mounting Bracket
Remove
1 Remove the idler pulley bolt (7) then the idler pulley (6), Refer to 4.1 Generator.
2 Remove the bolts (1, 2, 3 ,4); five places attaching the generator mounting bracket (5) to the engine block.
3 Remove the generator mounting bracket from the vehicle.


Figure 6D1-1 6
Reinstall
Reinstallation of the generator mounting bracket and generator is the reverse of the removal procedure, noting the
following:
1 Tighten all fasteners to the correct torque specification.
2 Reinstall the generator, refer to 4.1 Generator.
Generator mounting bracket bolts ... (1) 40.0 – 60.0 Nm
Generator mounting bracket bolts ... (2) 100.0 Nm
Generator mounting bracket bolts ... (3) 40.0 – 60.0 Nm
Generator mounting bracket bolts ... (4) 40.0 – 60.0 Nm
Idler pulley bolt................................. (7) 58.0 Nm

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4.3 Drive Belt Routing
Without Air Conditioning
Ensure the drive belt ribs are correctly positioned in all pulleys and the crankshaft balancer.
NOTE
For detailed information relating to drive belt
service procedure, refer to 6A1 Engine
Mechanical.
Figure 6D1-1 7 shows the drive belt routing for the HFV6 engine without air-conditioning.

Figure 6D1-1 7
Legend
1 Water Pump
2 Generator
3 Idler 4 Power Steering
5 Crankshaft
6 Tensioner

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