clutch ISUZU KB P190 2007 Workshop Owners Manual

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS

Charging System ................................................ 6D-2
Servicing Cautions .......................................... 6D-2
Important Generator Components and
Function.......................................................... 6D-2
Troubleshooting .............................................. 6D-5
Diagnosis......................................................... 6D-7
Specifications .................................................. 6D-8
Unit Se rv ic ing (4 JJ 1) ....................................... .... ..6D -9
Disassembly .................................................... 6D-10
Inspection and Repair ..................................... 6D-11 Rotor Assembly ........................................... 6D-11
Stator Coil .................................................... 6D-12
Brushes ....................................................... 6D-12
Rectifier ....................................................... 6D-13
Regulator Assembly..................................... 6D-13
Measuring Procedure .................................. 6D-13
Reassembly..................................................... 6D-14
Final Assembly ................................................ 6D-14
Starter Motor ...................................................... 6D-15 Starting Circuit Diagram .................................. 6D-15
Removal and Installation ................................. 6D-15 Important Operations – Removal................. 6D-15
Important Operations – Installation.............. 6D-15
Disassembly .................................................... 6D-16 Disassembly Steps ...................................... 6D-16
Important Operations ................................... 6D-17
Inspection and Repair ..................................... 6D-20 Armature ...................................................... 6D-20
Yoke............................................................. 6D-21
Brush and Brush Holder .............................. 6D-22
Overrunning Clutch...................................... 6D-22
Bearing ........................................................ 6D-23
Reassembly..................................................... 6D-24 Reassembly Steps ....................................... 6D-24
Important Operations ................................... 6D-25
Inspection After Assembly ........................... 6D-26
Magnetic Switch .............................................. 6D-27
Torque Specifications...................................... 6D-28

Pre-Heating System ........................................... 6D-29 Inspection and Repair ..................................... 6D-29 Visual Check................................................ 6D-29
Glow Relay .................................................. 6D-29
Glow Plug .................................................... 6D-29


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ISUZU KB P190 2007

6D-16 ENGINE ELECTRICAL (4JK1/4JJ1)
Disassembly



RTW 460LF000201
Disassembly Steps
1. Lead W ire
2. Bolt
3. Magnetic Switch Assembly
4. Torsion Spring
5. Plunger
6. Dust Cover
7. Magnetic Switch
8. Screw
9. Through Bolt
10. Rear Cover
11. Motor Assembly
12. Brush Holder
13. Yoke 14. Armature
15. Bolt
16. Bearing Retainer
17. Pinion Assembly
18. Pinion Stopper Clip
19. Pinion Stopper
20. Return Spring
21. Pinion Shaft
22. Clutch
23. Dust Cover
24. Shift Lever
25. Gear Case

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ISUZU KB P190 2007

6D-22 ENGINE ELECTRICAL (4JK1/4JJ1)



RTW 46DSH003901
Brush and Brush Holder
1. Use a vernier caliper to measure the brush length
(four brushes).
Replace the brushes as a set if one or more of the brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)



RTW 46DSH004001
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the othe
r
probe to the positive brush holder.
There should be no continuity.




RTW 46DSH004101
3. Inspect the brushes for excessive wear.
If the negative brushes have excessive wear, the entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire yoke must be replaced.
Overrunning Clutch
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.







065RY00035


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ISUZU KB P190 2007

6D-24 ENGINE ELECTRICAL (4JK1/4JJ1)
Reassembly




RTW 46DLF000601
Reassembly Steps
1. Magnetic Switch Assembly
2. Magnetic Switch
3. Dust Cover
4. Plunger
5. Torsion Spring
6. Shift Lever
7. Gear Case
8. Dust Cover
9. Bolt
10. Pinion Assembly
11. Clutch
12. Pinion Shaft
13. Return Spring 14. Pinion Stopper
15. Pinion Stopper Clip
16. Bearing Retainer
17. Bolt
18. Motor Assembly
19. Armature
20. Yoke
21. Brush Holder
22. Rear Cover
23. Screw
24. Through Bolt
25. Lead W ire

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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-27
Magnetic Switch
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickl
y
as possible (within three to five seconds).

Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid switch body and the M terminal. W hen
current is applied to the S terminal from the batter
y
positive terminal, the pinion should flutter.



RTW 46DSH004601
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should continue to flutter.



RTW 46DSH005901
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.


RTW 46DSH004701


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ISUZU KB P190 2007

6E-24 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
A/C Control System and Glow Control System
RTW76EXF001701
9 C-107C-58
X-14
X-14 A/C
compressor
relay
13
5 2 X-5
X-5
H-4 Glow
relay
42
1
3
ECM
Ignition
signal
Thermo
relay
signal X-15
X-15 Thermo
relay
Refrigerant
pressure
switch 0.5
GRN/
YEL 0.5
GRN/
BLK 0.5
GRN/
ORN
0.5
GRN/
BLK 0.5
GRN/
ORN
3
BLK/
RED
Glow
plug
Compressor
clutch
Relay
control Relay
control
H-4
E-3
( )=A/T 0.5
BRN
0.5
GRN/
RED 0.5
BLK/
BLU
0.5
WHT/
GRN 3
RED/
WHT
3
BLK/
RED
0.5
GRN/
BLK
0.5
BRN
0.5
BRNEB-13
A/C
10A Fuse/
relay
box
(Engine room)
0.5
BRN
23 1
5
1 SBF8
Glow
60A Fuse/
relay
box
(Cabin)
C-6
Engine
10A
0.5
WHT/
GRN
0.5
WHT/
GRN
Starter
cut
relay Refer to
Power distribution
15 19
(28)
E-49
72
37
55
4

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ISUZU KB P190 2007

6E-32 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Engine Control Module (ECM)-J2
Pin No. Wire ColorPin Function
58 YEL CKP sensor signal
59 PNK Fuel filter switch signal
60 — Not used
61 BLU/ GRN IAT sensor low reference
62 BRN EGR drive voltage
63 YEL EGR control low side
64 BLK CMP sensor shield ground
65 — Not used
66 ORN/ BLK Turbocharger nozzle control
solenoid valve control
67 YEL Swirl control solenoid valve
control
68 WHT FRP sensor signal
69 BLK FRP sensor low reference
70 BLU/ RED FRP regulator low side
71 RED Cylinder #2 fuel injector charge
voltage
72 PNK Cylinder #4 fuel injector charge
voltage
73 BLK Ground
Connector No. C-58
Connector Color Black
Test Adapter No. J-35616-64A
Pin No. Wire Color Pin Function
1 ORN Brake switch 2 signal
2 BLK/ GRN Diagnostic request switch
RTW76ESH003101
12345678910111213141516
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
Pin No. Wire Color
Pin Function
3 RED/ GRN P or N range switch (A/T)
BLK/ WHT Neutral switch (M/T)
4 GRN/ BLK Thermo relay signal
5 — Not used
6 — Not used
7 BLU APP sensor 3 5V reference
8 BL/ UWHT APP sensor 3 signal
9 ORN APP sensor 2 5V reference
10 BLU/ GRN APP sensor 2 signal 11 WHT APP sensor 1 5V reference
12 RED APP sensor 1 signal
13 GRY/ GRN Cruise cancel switch signal
14 WHT/ GRN Cruise main switch signal
15 — Not used
16 — Not used
17 — Not used
18 — Not used
19 YEL Clutch switch signal
20 — Not used
21 RED Brake switch 1 signal
22 — Not used
23 BLU/ RED APP sensor 3 low reference
24 BLK APP sensor 3 shield ground
25 ORN/ BLU APP sensor 2 low reference
26 BLK APP sensor 2 shield ground
27 BLK APP sensor 1 low reference
28 BLK APP sensor 1 shield ground
29 BRN/ YEL Cruise resume switch signal
30 LT GRN Cruise set switch signal
31 — Not used
32 — Not used
33 BLK/ RED Engine speed signal output
34 — Not used
35 ORN/ BLU Starter cut relay control
36 — Not used
37 BLK/ BLU Glow relay control
38 — Not used
39 — Not used
40 — Not used
41 — Not used
42 — Not used

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-35
Brake SwitchClutch Switch
Camshaft Position (CMP) Sensor
Connector No.
E-107
Connector Color Black
Test Adapter No. J-35616-64A
Pin No. Wire Color Pin Function
1 YEL Sensor signal
2 BLU Sensor low reference
3 GRN Sensor 5V reference
Connector No. C-44
Connector Color White
Test Adapter No. J-35616-40 (Pin1-2)
J-35616-2A (Pin3-4)
Pin No. Wire Color Pin Function
1GRN Switch 1 (stop lamp switch)
battery voltage feed
2 RED Switch 1 (stop lamp switch) signal
3 ORN Switch 2 signal
4WHT/ GRN Brake switch 2 ignition voltage
feed
RTW76ESH000801
12
34Connector No. C-77
Connector Color White
Test Adapter No. J-35616-42
Pin No. Wire Color Pin Function
1 WHT/ GRN Ignition voltage feed
2 YEL Switch signal
LNW46ESH000801
1
2
RTW76ESH000701
123

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-49
Cam/ Crank Sensor Signal Synchronization Status Asynchronous/ No
Crank Signal/ Synchronous Synchronous Synchronous
Engine Runtime Time (hour: minute: second) Va r i e s
Va r i e s
Vehicle Speed km/h / MPH0 km/h / 0 MPH 0 km/h / 0 MPH
Transmission Gear Out of gear/ 1st/ 2nd/ 3rd/ 4th/ 5th Out of gear
Out of gear
Starter Switch On/OffOn On
Ignition Switch On/OffOn On
Ignition Voltage Volts11.0 to 15.0 volts 11.0 to 15.0 volts
Battery Voltage Volts11.0 to 15.0 volts 11.0 to 15.0 volts
Fuel Pump Relay Command On/ Off OnOn
Swirl Control Solenoid Command On/ Off OnOn
Fuel Filter Switch On/ OffOn On
A/C Request Signal On/ OffOff Off
A/C Relay Command On/ OffOff Off
Park/ Neutral Switch Neutral/ In Gear NeutralNeutral
Glow Relay Command On/ OffOff Off
Glow Plug Lamp Command On/ Off OffOff
Brake Switch 1 Applied/ Released Released Released
Brake Switch 2 Applied/ Released Released Released
Clutch Pedal Switch Applied/ Released ReleasedReleased
Cruise Main Lamp Command On/ Off OffOff
Cruise Main Switch On/ OffOff Off
Cruise Cancel Switch On/ OffOn On
Cruise Resume Switch On/ OffOff Off
Cruise Set Switch On/ OffOff Off
MIL Command (Malfunction Indicator Lamp) On/ Off
Off Off
SVS Lamp Command (Service Vehicle Soon) On/ Off
Off Off
Limp Home Mode None/ 1/ 2/ 3/ 4 None None
Distance While MIL is Activated km/ Mile 0 km/ 0 Mile0 km/ 0 Mile
Engine Runtime With MIL Active minutes 00
Total Engine Overspeed Event Counter VariesVaries
Total Engine Coolant
Overtemperature Event Counter
Varies Varies
Total Fuel Temperature
Overtemperatrure Event Counter
Varies Varies
Total Intake Air Temperature Overtemperaure Event Counter
Varies Varies
Immobilizer Function Programmed Ye s / N o
Ye s Ye s
Wrong Immobilizer Signal Yes/ NoNo No
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle Typical Data Value at 2000RPM

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-53
Cam/ Crank Sensor Signal/ Synchronization Status
This parameter displays the synchronization state of
the crankshaft position (CKP) sensor signal and
camshaft position (CMP) sensor signal. Asynchronous
indicates the CMP sensor signal is not detected or only
CKP sensor signal is detected. No Crank Signal
indicates CMP sensor signal is detected but CKP
sensor signal is not detected. Synchronous indicates
both sensor signals are detected correctly.
Engine Runtime
This parameter displays the time elapsed since the
engine start. The scan tool will display the time in
hours, minutes and seconds. The engine run time will
reset to zero as soon as the ignition switch is OFF.
Vehicle Speed
This parameter indicates the vehicle speed calculated
by the ECM using the signal from the vehicle speed
sensor (VSS). The scan tool will display a low value at
lower vehicle speeds, and a high value at higher
vehicle speeds.
Transmission Gear
This parameter displays the estimated transmission
gear position as calculated by the ECM based on
inputs from the vehicle speed and the engine speed.
Starter Switch
This parameter displays the input status of the starter
switch to the ECM. When the ignition switch is turned at
START position, the scan tool displays On.
Ignition Switch
This parameter displays the input status of the ignition
switch to the ECM. When the ignition switch is turned
ON position, the scan tool displays On.
Ignition Voltage
This parameter displays the ignition voltage measured
at the ignition feed circuit of the ECM. Voltage is
applied to the ECM when the ignition switch is ON
position.
Battery Voltage
This parameter displays the battery voltage measured
at the ECM main relay switched voltage feed circuit of
the ECM. Voltage is applied to the ECM when the ECM
main relay is energized.
Fuel Pump Relay Command
This parameter displays the commanded state of the
fuel pump relay control circuit. On indicates the fuel
pump relay control circuit is being grounded by the
ECM, allowing fuel pumping from the tank.
Swirl Control Solenoid Command
This parameter displays the commanded state of the
swirl control solenoid control circuit. On indicates the
swirl control solenoid control circuit is being grounded
by the ECM, allowing vacuum pressure to the swirl
control
actuator. Fuel Filter Switch
This parameter displays the input state of the fuel
pressure switch to the ECM. When the large vacuum
pressure is generated in the fuel suction line such as
clogged fuel filter, the scan tool displays Off.
A/C Request Signal
This parameter displays the input state of the air
conditioning (A/C) request to the ECM from the
heating, ventilation, and air conditioning (HVAC)
controls. When the HVAC system is requesting to
ground the A/C compressor clutch, the scan tool
displays On.
A/C Relay Command
This parameter displays the commanded state of the A/
C compressor relay control circuit. On indicates the A/C
compressor relay control circuit is being grounded by
the ECM, allowing voltage to the A/C compressor.
Park/ Neutral Switch
This parameter displays the input state of the neutral
switch to the ECM. When the transmission gear is Park
or Neutral, the scan tool displays Neutral.
Glow Relay Command
This parameter displays the commanded state of the
glow relay control circuit. On indicates the glow relay
control circuit is being grounded by the ECM, allowing
voltage to the glow plugs.
Glow Plug Lamp Command
This parameter displays the commanded state of the
glow indicator lamp control circuit. The glow indicator
lamp should be On when the scan tool indicates
command On. The glow indicator lamp should be Off
when the scan tool indicates command Off.
Brake Switch 1
This parameter displays the input state of the brake
pedal switch 1 to the ECM. When the brake pedal is
depressed, scan tool displays Applied.
Brake Switch 2
This parameter displays the input state of the brake
pedal switch 2 to the ECM. When the brake pedal is
depressed, scan tool displays Applied.
Clutch Pedal Switch
This parameter displays the input state of the clutch
pedal switch to the ECM. When the clutch pedal is
depressed, scan tool displays Applied.
Cruise Main Lamp Command
This parameter displays the commanded state of the
cruise main lamp control circuit. The cruise main lamp
should be On when the scan tool indicates command
On. The cruise main lamp should be Off when the scan
tool indicates command Off.
Cruise Main Switch
This parameter displays the input state of the cruise
main switch to the ECM. When the Cruise Main switch
is pushed, the scan tool displays On.

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ISUZU KB P190 2007