2007 ISUZU KB P190 belt

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 6D1-1-13

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 6D1-1-15

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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Charging System – V6 Page 6D1-1-16


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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Charging System – V6 Page 6D1-1-18

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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Automatic Transmission – 4L60E – Electrical Diagnosis Page 7C2–36
When the TCM detects low voltage, DTC P0562 sets. DTC P0562 is a type C DTC.
Refer to 2 W iring Diagrams and Connector Chart to aid in diagnosis.
Conditions for Running the DTC
The engine speed is greater than 1,200 r.p.m.
Conditions for Setting the DTC
The TCM detects system voltage less than 11 V for 10 seconds.
Action Taken When the DTC Sets
• The TCM does not request the engine control module (ECM) to illuminate the MIL.
• The TCM records the operating conditions when the conditions for setting the DTC are met. The TCM records this
information as a Failure Record.
• The TCM stores DTC P0562 in TCM history.
Conditions for Clearing the DTC
• The TCM clears the DTC from TCM history if the vehicle completes 40 warm-up cycles without a non-emission
related diagnostic fault occurring.
• Tech 2 can clear the DTC.
Diagnostic Aids
• Observe the instrument cluster’s multi-function display messaging that would indicate the electrical system requires
service.
• Inspect for the following conditions:
• Loose or damaged terminals at the generator, and
• Loose or worn generator drive belt.
Test Description
The following numbers refer to the step numbers in the diagnostic table:
3 The alternator warning indicator will illuminate if there is a problem with the charging system of the vehicle.
4 Checks the charging system voltage with a nominal load.
5 Checks if the ignition voltage measurement reported by the TCM is within acceptable parameters.
7 Checks if there is battery voltage supplied to the TCM.
8 Checks if there is battery voltage supplied through the ignition circuit to the TCM.
9 Checks the ground circuits of the TCM.
DTC P0562 Diagnostic Table
Step Action Yes No
1 Has the Diagnostic System Check been performed?
Go to Step 2 Refer to
4.7 Diagnostic
System Check

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ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Bulb No. Rated Power
V-W Number
of Bulbs Lens
Color Remarks
P16W 12-21 2 W hite Regular cab Backup light
P21W 12-16 2 W hite Extend cab, Crew cab
License plate light W 5W 12-5 2 W hite
A/C-Heater control light - 12-0.7 1 -
Dome light - 12-10 1 W hite
Spotlight/ Map light - 12-5 2 W hite

Light Name Rated Power
V-W Luminous Color Remarks
ILLUMINATION
LIGHT LED W hite
MULTI FUNCTION DISPLAY LCD Light blue
TURN SIGNAL LED Green
HIGH BEAM LED Blue
LOW FUEL LED Amber
A/T OIL TEMP LED Red
BRAKE LED Red
4W D LED Green
SEAT BELT LED Red
CHECK ENGINE LED Amber
OIL LED Red
FUEL FILTER LED Green
ABS LED Amber
SEDIMENTER LED Red
SRS LED Red
CHARGE LED Red
CHECK TRANS LED Red
CHECK 4W D LED Red
POW ER DRIVE LED Amber
3RD START LED Green
4W D-LOW LED Green
DOOR AJAR LED Red
P LED/LCD Green
R LED/LCD Green
N LED/LCD Green
D LED/LCD Green
3 LED/LCD Green
2 LED/LCD Green
A/T shift
indicator
L LED/LCD Green LED: Indicated on
the gauge
panel
LCD: Indicated on the
tachometer
panel
Meter
Illumination
light,
Indicator
light,
W arning
light

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