check 4wd ISUZU KB P190 2007 Workshop User Guide

7D1-6 TRANSFER CONTROL SYSTEM
the 4×2 - 4 ×4 shift rod. W hen moving in 4 ×2 direction, a spring
standby mechanism is provided between the rod and sleeve so
that the rod is positioned at the 4 ×2 position, while the sleeve is
at the 4 ×4 position.
This mechanism is provided to protect the shift mechanism
from the force and to prevent movement of the sleeve
(torsional torque etc. of the drive system). By releasing the
preventive force, the sleeve can move to the 4 ×2 state by the
spring force.

Neutral switch
The neutral switch detects the movement of the shift rod
driving the high-low sleeve.
PUSH close is achieved with the PUSH close switch when the
shift rod is positioned between the High and the Low, at the
neutral state.

High-Low Sleeve & Arm
The spring standby mechanism is provided for the high-low
sleeve in both directions of the high-low shift rod. Therefore,
the rod position and the actual sleeve position may be offset in
some cases.
This system is provided to protect the shift mechanism from a
collision due to coincidence of the high and low phases of the
engaged splines. By giving rotational force to the preventing
phase coincidence, the splines are moved to the proper
engagement position by the spring force.

Shift actuator
The output shaft is rotated by the built-in motor and the transfer
position is switched.
Detection (limit) switches to detect the rotating angle of the
output shaft that is provided to the actuator at 4 positions.
These are connected to the transfer controller through the
vehicle harness to constantly transmit the actuator operating
angle and changes in its transfer status.

7B4-PDF2
4WD indicator (in meter panel)
This lamp indicates the following items:
Valve check
Drive condition (2W D-4W D)
Operating condition (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz, including indication of
interrupted operation due
to excessive load)

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TRANSFER CONTROL SYSTEM 7D1-7
7B4-PDF3
4L indicator (in meter panel)
This lamp indicates following items:
Valve check
Driving status (High-Low)
Operating status (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz)






















RTW 77DSH000601
Neutral indicator (in operation switch panel)
This LED indicates following items:
LED check
Driving status (Neutral)
Operating status (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz)
7B4-PDF5
Check 4WD warning light (in meter panel)
This light indicates following items:
Valve check
Faulty actuator limit SW , and circuit related faults with the limit
switch



RTW 77DSH000501
4WD switch
Switch to transmit a switching command to the 2H, 4H,
Neutral, or 4L position.
It comprises 3 PUSH momentary switches. By pushing the 2H
and 4L switches for 10 seconds,
operation is changed to the neutral position.
To shift from the neutral to another position, push another
switch for 10 seconds.



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7D1-12 TRANSFER CONTROL SYSTEM
Functions of Switch and indicator Lamp
Transfer-related indicator lamp and switch function

Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H position
for 0.1
second 1,0,1,0 Open Open Open Switch
operation sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro) Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro and
retrial
During
operation (Axle
drive) Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
Axle
waiting Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
4L start
of
operation On Off Off Off 4L position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation On Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Closed Closed 4H to 4L
through neutral
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4H to 4L
through neutral
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4H to 4L
through neutral
4L
waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation 1,1,0,1 Closed Open Closed -----
4H start of
operation On Off Off Off 4H position
for 0.1
second 1,1,0,1 Closed Open Closed Switch
operation sensor

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TRANSFER CONTROL SYSTEM 7D1-13
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
During
operation On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving
4H
waiting Off Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed
4L to 4H
while
waiting
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
2H start of
operation On Off Off Off 2H position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open Open Closed Axle drive
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation 1,0,1,0 Open Open Closed Axle
waiting
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----


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7D1-14 TRANSFER CONTROL SYSTEM
2H to 4H retrial

Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H
position for 0.1
second 1,0,1,0 Open Open Open -----
Start of
operation Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro)
(Go to 4H if synchro
complete) Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial X 2
Abandoned
operation (2H) Blinking
(4HZ) Off Off Off No
operation 1,0,1,0 Open Open Open Return to
2H
2H
indication
after
10second
s
Off Off Off Off No
operation1,0,1,0 Open Open Open -----

• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.

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7D1-16 TRANSFER CONTROL SYSTEM
Transfer-related indicator lamp and switch function
Skip operation
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
4L start of
operation Off Off Off Off 4L
position for 0.1
second 1,0,1,0 Open Open Open
Switch
operation sensor
Start of
operation Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro) Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial
During
operation (Passing through 4H) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open -----
During
operation (Passing through 4H) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1
0,1,0,1 Closed Open Open -----
During
operation
(N)
On Blinking
(2HZ) Off Off No
operation
0,0,1,1
0,1,0,1 Closed Open Closed -----
During
operation (N) On
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Open Closed Switch
operation sensor
During
operation (N) On
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Closed 4H to 4L
while
driving
During
operation (Axle
drive) Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open
-----
Axle
waiting Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open -----
4L waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation1,1,0,1 Closed Open Closed -----

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TRANSFER CONTROL SYSTEM 7D1-17
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
lamp 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H start
of
operation On On Off Off 2H
position for 0.1
second 1,1,0,1 Closed Open Closed
Switch
operation sensor
During
operation Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (Passing through N) On
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation (Passing through N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation (4H
waiting) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation (Axle) Off while
waiting for start of H shift Blinking
(2HZ) while
waiting for start of H shift Off Off
No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) at
end of H shift Off at end
of H shift Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,0,1,0 Open Open Closed -----
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----

• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.


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TRANSFER CONTROL SYSTEM 7D1-19
Transfer-related indicator lamp and switch function
2H→Neutral →2H
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
Neutral
start of
operation Off Off Off Off Neutral
position for 10
seconds 1,0,1,0 Open Open Open
Switch
operation sensor
Start of
operation Off Off Blinking
(2HZ) Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open
2H to 4H
while
driving
During
operation
(Synchro) Off Off
Blinking
(2HZ) Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial
During
operation (Passing through 4H) Off Off
Blinking
(2HZ) Off No
operation 0,0,1,1 Closed Open Closed -----
During
operation (Passing through 4H) Off Off
Blinking
(2HZ) Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation
(N)
Off Off Blinking
(2HZ) Off No
operation
0,0,0,1
0,1,0,1 Closed Closed Closed
4H to 4L
through
neutral
During
operation (N) Off Off
Blinking
(2HZ) Off No
operation 0,1,0,0 Closed Closed Closed Switch
operation sensor
Neutral Off Off On Off No
operation0,1,0,0 Closed Closed Open -----
2H start of
operation Off Off On Off 2H
position for 10
seconds 0,1,0,0 Closed Open Closed
Switch
operation sensor
During
operation (Passing through N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving

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7D1-20 TRANSFER CONTROL SYSTEM
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches LS1,
LS2,
LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
During
operation (4H
waiting) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open Open Closed
Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,0,1,0 Open Open Closed -----
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----

• Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (H ←→Neutral ←→L).

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7D1-46 TRANSFER CONTROL SYSTEM
Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shift on the fly) If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz. At the same
time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes out.
Cause of excessive synchronous shifting load
• Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization).
• High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.
1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline in transfer case.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.
1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and the axle, connecting the front
wheel and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed
∗, the indicator flashes at
a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, check it is safe around the vehicle and then accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.

2. When shifting from 4H to 2H
2-1 When 4WD indicator continues flashing at 2Hz
W hen shifting from 4H to 2H, the 4W D indicator continues flashing at 2Hz until separation in the transfer and
the separation of the front wheel axle are completed∗. W hen torsional torque is accumulated in the drive
system, separation in the transfer and separation of the front axle∗ is difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, check it is safe around the vehicle and then accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.

∗: Shift on the fly only.


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