2007 ISUZU KB P190 Workshop Repair Manual

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Page 2153 of 6020

ISUZU KB P190 2007 Workshop Repair Manual STARTING AND CHARGING SYSTEM 6D3-5

Inspection and Repair
Repair or replace necessary parts if extreme wear or damage
is found during inspection.
Armature
Check for continuity between comm

Page 2154 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 6D3-6 STARTING AND CHARGING SYSTEM

Continuity of Contacts
W ith the plunger faced downward, push down the magnetic
switch. In this state, check for continuity between terminals B
and M. R

Page 2155 of 6020

ISUZU KB P190 2007 Workshop Repair Manual STARTING AND CHARGING SYSTEM 6D3-7

Charging System
General Description
The charging system is an IC integral regulator charging
system and its main components are connected as shown in
illus

Page 2156 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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

Page 2157 of 6020

ISUZU KB P190 2007 Workshop Repair Manual STARTING AND CHARGING SYSTEM 6D3-9

Generator Power
1. Adjust load resistor, if the required load currents are not attained.
2. The shape of the voltage curves on oscilloscope curve should

Page 2158 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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 posit

Page 2159 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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

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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ISUZU KB P190 2007

Page 2160 of 6020

ISUZU KB P190 2007 Workshop Repair Manual 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 cir

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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