warning ISUZU KB P190 2007 Workshop Workshop Manual

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-351
Notice:If the ECM is replaced to new one, VIN does
not displayed. Input correct VIN reading from stamped
VIN or affixed VIN plate on the vehicle. If the ECM from
another vehicle is installed, input correct VIN by same
way.
g. Highlight Engine on the Select System Typescreen, then click "Next", if on-screen
instruction displayed.
h. Complete the following information based on the service ID plate on the Validate Vehicle
Data screen until "Next" is highlighted, then
click "Next".
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
i. Verify your selection on the Summary screen.
Notice: Refer to Service Bulletin and Description
column before service programming is performed if the
bulletins are listed along with the calibration files.
Notice: Select Cancel if you receive a message stating
that the calibration selected is already the current
calibration in the ECM and reprogramming with the
same download is not allowed.
j. Click "Reprog".
k. The Transfer Data screen will appear until the progress bar reaches 100%.
5. Close the application and return to the TIS application selection screen after the download is
completed.
6. Turn OFF the scan tool and disconnect from the terminal.
7. Transfer the data from the scan tool to the ECM using the following procedure:
a. Install a scan tool.
b. Turn ON the ignition, with the engine OFF.
c. Select Service Programming System (SPS) > Program ECU.
d. Turn OFF all accessories and press "Continue".
e. Programming in Process will appear until the progress bar reaches 100%.
Notice: Some warning lamp may turn ON or blink while
programming the ECM since communication between
the ECM and other modules are interrupted. Clear DTC
in any module after programming.
f. Press "Continue" and exit the program after thescan tool displays "Programming Was
Successful".
8. Turn OFF the ignition.
9. Turn OFF the scan tool and disconnect from the vehicle.Service Programming System (SPS) (Pass-
Thru Procedure)
Pass-Thru programming allows the scan tool to remain
connected to the terminal and to the vehicle throughout
the programming process. The vehicle must be in close
proximity to the terminal while using Pass-Thru.
1. Launch the TIS application.
2. Select the Service Programming System at the main screen.
3. Highlight the following information on the Select Diagnostic Tool and Programming Process screen,
then click "Next":
• Select Diagnostic Tool-Select Pass - Thru
• Select Programming Process - Identify whether as existing ECM is being reprogrammed or an
ECM is being replaced with a new one.
• Select ECU Location - Vehicle
4. Complete all vehicle data on the Preparing for Communication/ Determine Vehicle screen until
"Next" is highlighted, then click "Next".
5. Follow the instruction on the Preparing for Communication screen, then click "Next".
Notice: In order to reduce the potential for signal loss,
the RS-232 cable should not be more than 25 feet long.
6. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen, then click "Next".
Notice: If the ECM is replaced to new one, VIN does
not displayed. Input correct VIN reading from stamped
VIN or affixed VIN plate on the vehicle. If the ECM from
another vehicle is installed, input correct VIN by same
way.
7. Highlight Engine on the Select System Type screen, then click "Next", if on-screen instruction
displayed.
8. Complete the following information based on the service ID plate on the Validate Vehicle Data
screen until "Next" is highlighted, then click "Next".
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
9. Verify your selection on the Summary screen.
Notice: Refer to Service Bulletin and Description
column before service programming is performed if the
bulletins are listed along with the calibration files.
Notice: Select Cancel if you receive a message stating
that the calibration selected is already the current
calibration in the ECM and reprogramming with the
same download is not allowed.
10. Click "Reprog".

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ISUZU KB P190 2007

6E-352 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
11. The Transfer Data screen will appear until theprogress bar reaches 100%.
Notice: Some warning lamp may turn ON or blink while
programming the ECM since communication between
the ECM and other modules are interrupted. Clear DTC
in any module after programming.
12. Close the application and return to the TIS application selection screen after the download is
completed.
13. Turn OFF the ignition.
14. Turn OFF the scan tool and disconnect from the vehicle.

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ISUZU KB P190 2007

6B-6 ENGINE COOLING

















Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
level should be between the "MIN" and "MAX" lines of reserve
tank when the engine is cold. If low, check for leakage and add
engine coolant up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator cap or
radiator filler hole, and the engine coolant should also be free
from oil.
Replace the engine coolant if excessively dirty.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
2. Remove the radiator cap.
WARNING: TO AVOID THE DANGER OF BEING BURNED,
DO NOT REMOVE THE CAP WHILE THE ENGINE AND
RADIATOR ARE STILL HOT. SCALDING FLUID AND
STEAM CAN BE BLOWN OUT UNDER PRESSURE.
3. Disconnect all hoses from the engine coolant reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it. Install
the reserve tank and hoses.
4. Refill the cooling system with the engine coolant using a solution that is at least 50 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the engine coolant reserve tank to "MAX" line when the engine is cold.
6. Block the drive wheels and firmly apply the parking brake and place the shift lever in the "NEUTRAL" position.
7. Remove the radiator cap. Start the engine and warm it up at 2,500 - 3,000 rpm for about 30 minutes.
8. W hen the air comes out from the radiator filler neck and the engine coolant level has gone down, replenish with the
engine coolant. Repeat this procedure until the engine
coolant level does not go down. Then stop the engine and
install the radiator cap. Let the engine cool down.
9. After the engine has cooled, replenish with engine coolant up to the "MAX" line of the reserve tank.
10. Start the engine. W ith the engine running at 3,000 rpm, make sure there is no running water sound from the heate
r
core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to 10.


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ISUZU KB P190 2007

6D1-4 ENGINE ELECTRICAL

Battery Charging
Observe the following safety precautions when charging the
battery:
1. Never attempt to charge the battery when the fluid level is
below the lower level line on the side of the battery. In this
case, the battery must be replaced.
2. Pay close attention to the battery during charging procedure.
Battery charging should be discontinued or the rate o
f
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate o
f
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on batter
y
charging capacity.
5. The sealed battery used on this vehicle may be either quick charged or slow charged in the same manner as othe
r
batteries.
W hichever method you decide to use, be sure that you completely charge the battery. Never partially charge the
battery.































Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an attempt to
start it. Serious damage to the emission system as well as
other vehicle parts will result.
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the jump starting procedure, being careful
at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP
STARTING PROCEDURE COULD RESULT IN THE
FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery acid, o
r
an electrical fire.
3. Damage to the electronic components of one or both vehicles particularly.
Never expose the battery to an open flame or electrical spark.
Gas generated by the battery may catch fire or explode.
Remove any rings, watches, or other jewelry before working
around the battery. Protect your eyes by wearing an approved
set of goggles.
Never allow battery fluid to come in contact with your eyes or
skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.

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ENGINE ELECTRICAL 6D1-5











































Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly rinse
the affected area with clean tap water.
Never allow metal tools or jumper cables to come in contact
with the positive battery terminal, or any other metal surface of
the vahicle. This will protect against a short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake and place the shift lever in the
"NEUTRAL" position.
Turn "OFF" the ignition.
Turn "OFF" all lights and any other accessory requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is completel
y
clear, do not try to jump start.
3.
Attach the end of one jumper cable to the positive terminal
of the booster battery.

Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the
charging procedure.
Be sure that the booster battery has a 12 volt rating.
4.
Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket o
r
the generator mounting bracket) of the vehicle with the
discharged battery.
The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being
charged.
WARNING: NEVER ATTACH THE END OF THE JUMPER
CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE
DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories have been turned "OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in reverse order.
Be sure to first disconnect the negative cable from the vehicle with the discharged battery.


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6D3-8 STARTING AND CHARGING SYSTEM
General On-Vehicle Inspection
The operating condition of charging system is indicated by the
charge warning lamp. The warning lamp comes on when the
starter switch is turned to "ON" position. The charging system
operates normally if the lamp goes off when the engine starts.
If the warning lamp shows abnormality or if undercharged or
overcharged battery condition is suspected, perform diagnosis
by checking the charging system as follows:
1. Check visually the belt and wiring connector.
2. W ith the engine stopped, turn the stator switch to "ON" position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and ground the terminal "L" on connector side.
If lamp comes on:
Repair or replace the generator.




Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench then remove drive belt.
3. Disconnect terminal "B" wiring connector and connector.
4. Remove generator assembly.

Generator Power and Circuit Diagram


Inspection
Legend
1 Load resistor, set parallel to battery
2 Battery
3 Voltmeter
4 Ammeter
5 Ignition Lock
6 Charge Telltale
7 Generator

1. Disconnect battery.
2. Close off connecting cable from alternator terminal "B+".
3. Set ammeter (measuring range 100A) in disconnected line.
4. Connect controllable load resistor to battery terminal.
5. Set resistor in front of connection to "O"; connect first to battery, then to resistor.
6. Connect tachometer.
7. Connect oscilloscope according to manufacturer's instructions.
8. Connect battery.
9. Start engine and read off resulting current at various engine speeds.


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ISUZU KB P190 2007

6D3-10 STARTING AND CHARGING SYSTEM
The generator has four external connections; the "B+" lead to
battery positive, "L" lead to the warning lamp circuit(max. 2
watts), "S" lead to battery positive terminal for battery sensing
and an earth connection.

Explanation of type inscripiton
Example:KC-A--> 14V 50-90A.

K = Code for Stator OD(126mm OD).
C = Compact Generator.
A = Ausland (countries other than Germany)
> = Direction of rotation(clockwise).
14V = Generator Operating Voltage.
50A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.
90A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.

Generator Connetions.
B+ : Battery Main Connection (battery positive)
S : Battery Sense Connection(battery positive)
L : W aring lamp(via warning lamp to Ignition switch)


BATT.SENSE
REGULATOR ASSEMBLYHYBR10 ALTERNATOR ASSEMBLY
12V BATT. 1GN.SW .
300a*
W ARN.LAMP
1.2 W ATT L
S 8+
SUPPRESSOR
CAPACITOR
0.5 µf
NOTE: * RESISTOR IS RECOMMENDED TO
ENSURE THAT THE GENERATOR
REMAINS FUNCTIONAL IN CASE OF
W ARNING LAMP FAILURE


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STARTING AND CHARGING SYSTEM 6D3-11
Warning
Do not reverse S and L connections as this will destroy the
warning lamp circuit of the regulator.
Ensure good electrical contact beween generator earth and
battery negative,

Operation
W ith the Iginiton switch turnded "ON", current is supplied via
the warning lamp to the "L" terminal of the regulator. Base
current is fed to T15 causing it to turn on, current then flows
from B+ through the rotor winding via the regulator brushes
and the collector emitter junction of T15 to earth completing
the circuit. The current in the rotor causes a magnetic field
between adjacent poles to be created, this field is rotated and
cuts the windings of the stator at right angles inducing a
voltage into them.
As the speed is increased this induced voltage increases and
results in curent being rectified in the 3 phase diode bridge and
supplied as DC to the B+ output and hence to the battery.
W hen the voltage at the B+ terminal of the battery reaches
around 14.2 volts, this voltage is monitored by the "S" lead and
turns the regulator Hybrid base current to T15 OFF removing
rotor current, resulting in a decrease in output voltage to below
the regulating voltage, T15 base current turns ON and the
whole cycle is repeated very rapidly.
D38 protects T15 and the regulator against the back voltage
developed across the rotor winding when T15 turns OFF.
The new generated EP regulators incorporate current limiting
in the warning lamp circuit.

Backup Regulation
The EP regulator will limit the output voltage to a safe level
should either the main B+ cable or the battery sense wire
become decoupled, the output voltage will be slightly above the
normal setting(1-3 volts).

Start up phase
W hen the Iginition switch is turned on and the engine is not
running, the current to the rotor is reduced by switching it on
and off at a 50% duty cycle, the frequency is approximately 4
KHz and may be audible at times.
This is quite normal, once the engine is started normal
regulation commences.

Warning lamp failure
Should the warning lamp fail, the generator will self excite by
deriving a small current from the phase connecion allowing the
voltage to build up to regulating level.
Note: no filed current will flow when the engine is cranking.


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6D3-12 STARTING AND CHARGING SYSTEM
Diagnosis
The EP regulator incorporates diagnostics which will illuminate
the warning lamp as a result of fault conditions in the generator
and external circuitry.

These conditions include:
1.
An open circuit in the regulator battery sensing wire (S
Terninal)
2. An open circuit or excessive voltage drop in the B+ cable.
3. An open circuit in the generator phase connection.
4. Overcharging of the battery.
5. Regulator output stage short circuit.
6. Open circuit rotor.

The regulator compares the voltage at B+ with the voltage at
the "S" terminal connceted to battery positive. If the voltage
differential exceeds a predetermined threshold, the regulator
will operate in backup mode to limit the output voltage to a safe
level. The warning lamp; will remain illuminated as along as
these conditions prevail.
Sources of high resistance which will trigger the warning lamp
are:

a. Poor contact in wiring harness connectors.
b. Poor contact between rectifier and regulator.
c. High resistance in fusible link assembly.

Caution:
When bench testing the generator it is important that the
warning lamp wattage of 2 watts is not exceeded.
Reversal of the "S" and "L" on the regulator will damage
the regulator.
The correct plug for the regulator is a 9 122 067 011 for the
Bosch tye and for the Shinagawa connector the number is
X02FW.

See appendix 1 for daignostic matrix.
Before testing or disassembling the generator please observe
the following points.

1. W hen testing the diodes with AC type testers the RMS.
Vlotage output must not exceed 12.0 volts, it is
recommended that the stator should be disconnected
during this test.
2. W here zener power diodes are used, the breakdown voltage should be tested to ensure all diodes have the
same zener voltage.
3. Insulation tests on the rotor and stator should use a voltage not exceeding 110v for a series test lamp. The rectifie
r
must be disconnected from the stator prior to testing.
4. W hen carrying out repairs to the charging system always disconnected the battery negative first, and reconnect it
last.


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STARTING AND CHARGING SYSTEM 6D3-13
5. During current output tests please make sure that the
ammeter is securely connceted into the charge circuit.
6. Some battery powered timing lights can produce high transient voltages when connected or disconnected. Onl
y
disconnect or connect timing lights when the engine is
switched off.
7. Make sure the warning lamp circuit is functioning normall
y
before commencing tests.
8. Battery isolation switches must only be operated when the engine is stopped.
9. To protect the charging system when using 240 volt chargers it is recommeneded that the battery is
disconnected whilst charging.
10. Due to the very low resistance value of the stator winding it may not be possible to obtain accurate readings without
special equipment.
11. 12 volts must never be connected to the "L" terminal of the regulator as this will damage the lamp driver circuit.
12. No loads apart from the warning lamp can be connected to the "L" termainal. The "W " terminal is provided for this
purpose.

Disassembly
1. Mark the relative positions of the end housings in relation to the stator assembly to aid reassembly. Use a permanent
marking pen do not use centre punched as this can cause
misalignmnet of the housings.
2. Remove the EP regulator from the slipring end housing b
y
removing the two screws. Tilt the regulator slightly from the
plug connection until the regulator clears the housing, then
lift clear.
3. Remove the four through bolts.
4. Carefully remove the stator assembly along with the slipring end housing taking care not to put strain on the stator wires.
5. To disconnect the stator from the rectifier assembly, grasp the stator wires close to the wire loop with a pair of long
nosed pliers, heat the joint with a soldering iron, when the
point becomes plastic apply a slight twisting motion to the
wires, then pull upwards to release the wires. Remove the
stator.
This procedure opens the wire loop to release the stato
r
connections easily.
6. To remove the rectifier remove the three retaining scre
w
and the B+ terminal nut and washers.

Note: the B+ bolt and the positive heatsink retaining screw are
fitted with mica insulating washers.
These must be discarded and replaced with new washers and
heatsink compound.


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