2007 ISUZU KB P190 BATTERY

STARTING AND CHARGING SYSTEM 6D3-3


Starter
Removal
1. Remove the battery ground cable.
2. Remove harness connectors (1) and (2).


3. Remove bolts from starter.


Installation
1. Install starter assembly.
2. Install mounting bolts and tighten bolts to specified torque.
Torque: 51 N ⋅
⋅⋅
⋅
m (5.2 kgf ⋅
⋅⋅
⋅
m)
3. Connect harness.
4. Reconnect the battery ground cable.


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ISUZU KB P190 2007

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. Replace, if there is no continuity (i.e., contacts are
faulty).




Pinion
Check if the pinion rotates smoothly in drive direction by hand,
or if it is locked when it is rotated in reverse. If not, replace the
pinion.




Characteristic Test
For easily confirming the characteristics, conduct the noload
test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. W hen the switch is closed, the current flows and
the starter runs under no load. At this time, measure current,
voltage and speed to check if they satisfy the standard.
Legend
1 Volt Meter
2 Revolution Indicator
3 Battery
4 Ammeter
5 Switch


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ISUZU KB P190 2007

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

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 be regular.
3. Test value: 5 to 7A.
4. If the required minimum current intensity is not attained, o
r
if the oscilloscope picture shows variations, the alternator
should be overhauled.

Regulated Voltage Circuit Diagram

Legend
1 Battery
2 Ignition Lock
3 Charge Telltale
4 Resistor, for attainment of load current with the battery set in series
5 Voltmeter
6 Ammeter
7 Generator




Installation
1. Install generator assembly and bring generator assembly to the position to be installed.
2. Install generator assembly and tighten to the specified torque.
Torque:
Long bolt: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m)
Short bolt: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m)
3. Connect wiring harness connector.
4. Move drive belt tensioner to loose side using a wrench, then install drive belt to normal position.
5. Reconnect battery ground cable.


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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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ISUZU KB P190 2007

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

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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ISUZU KB P190 2007