2007 ISUZU KB P190 battery

Engine Management – V6 – Service Operations Page 6C1-3–37

Test

Under no circumstances should battery
voltage be applied to the heated oxygen
sensor (HO2S) heater.

To prevent component damage use connector
test adaptor kit J 35616-A.
Heater Resistance Check – Six Wire HO2S
1 Connect a digital ohmmeter using connector test adaptor kit J 35616-A to the HO2S.
2 Measure the resistance across terminals 3 and 4.
3 Compare the reading against the specification.
HO2S heater resistance @ 20°C ................ 8.0 – 10.0 Ω
4 If the resistance is not within specification, replace the
HO2S.
Figure 6C1-3 – 47
Heater Resistance Check – Four Wire HO2S
1 Connect a digital ohmmeter using connector test
adaptor kit J 35616-A to the HO2S.
2 Measure the resistance across terminals 1 and 2.
3 Compare the reading against the specification.
HO2S heater resistance @ 20°C ................ 8.0 – 10.0 Ω
4 If the resistance is not within specification, replace the
HO2S.
Figure 6C1-3 – 48

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ISUZU KB P190 2007

Engine Management – V6 – Service Operations Page 6C1-3–47

2.21 Schrader Valve – Fuel Pressure Gauge
Connection Point

If the Schrader valve is to be removed but not
replaced immediately, it is advisable to
disconnect the battery to avoid possible fuel
discharge if an accidental attempt is made to
start the engine.
Disconnection of the battery affects vehicle
electronic systems. Refer to 6D1-3 Battery –
V6 before disconnecting the battery.
Remove
1 Depressurise the fuel system, refer to 6C Fuel System - V6.
2 Turn the ignition off.

A small amount of fuel may be released when
servicing the fuel pressure test point. To
reduce the chance of personal injury, cover
the fuel pressure test point with a shop towel
to absorb any fuel spillage when the Schrader
valve sealing cap and Schrader valve are
removed. After the procedure, place the towel
in an approved container for disposal.
3 Remove the Schrader valve sealing cap (1).
4 Remove the Schrader valve (2) using a standard valve core removal tool.
Figure 6C1-3 – 65
Reinstall
Reinstallation of the Schrader valve is the reverse of the removal procedure, noting the following:
1 Inspect the fuel rail and quick connect fitting for leaks, refer to 6C Fuel System - V6.
2 Road test the vehicle and check for correct operation.

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ISUZU KB P190 2007

Charging System – V6 Page 6D1-1-3

1 General Information
1.1 Components
Generator
The Mitsubishi generator can be identified visually by its two lower and one upper mounting lugs.
It is mounted to the lower right-hand side of the engine block. It is driven by the same drive belt that drives other engine
ancillaries and requires no periodic drive belt adjustment.
The generator has three phases, incorporating a rotor with six pole pairs fitted and two internal cooling fans; one on the
drive-end and one on the slip-ring end. The rotor is supported by ball bearings in both the drive and slip-ring end
housings. Surrounding the rotor is a stator, which has a three phase delta connected output winding construction on a
ring shaped lamination pack.
The output of the stator winding is rectified by eight diodes that are contained within the slip-ring end housing. Excitation
current is supplied to the rotor field coil via the voltage regulator, the brushes and slip-rings. The electronic voltage
regulator requires no adjustment in service.
The generator has four external connections (refer to Figure 6D1-1 1):
• Generator – Terminal P-9 to the battery positive terminal P-1 via fuse SBF1,
• Generator – E-4 pin 1 to the ECM connection E-60 pin 43 – regulator monitoring,
• Generator – E-4 pin 2 to the ECM connection E60 pin 21 – battery voltage sensing, and
• ground connection via the installation bolts.
Generator Types
The vehicle is fitted with a 120 amp generator.


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Charging System – V6 Page 6D1-1-5

• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is
ignored, the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
• Present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.

1.3 System Operation
Operation
W ith the ignition switch in the ON position and the engine at rest, current is supplied via the regulator to generator
connector E-4 pin 1 and to the engine control module ECM connector E-60 pin 43. This initiates current flow (within the
regulator) from the generator connection P-9, to the brushes and rotor winding, to ‘excite’ the circuit.
The current in the rotor winding creates magnetic fields between adjacent rotor poles.
W ith the engine running, the rotor spins, the stator windings cut through this field and induce voltage. As the engine
speed is increased, this induced voltage increases. Current then flows through the three-phase diode bridge in the
rectifier to convert the AC voltage to DC. This is supplied to the generator connector P-9 output and then to the battery
terminal via fuse SBF1.
The regulator monitors the voltage to the battery. W hen this voltage reaches approximately 14.5 V, the regulator opens
the circuit through the rotor winding, causing the generator output voltage to drop. W hen the regulator senses a voltage
below a preset voltage, the regulator closes the circuit through the rotor winding and voltage to the battery again
increases. This cycle repeats very rapidly.

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Charging System – V6 Page 6D1-1-7

2 Diagnosis
2.1 Diagnostic General Information
Basic Diagnostic Tools Required

Use of incorrect electrical circuit diagnostic
tools when performing the generator
diagnostic procedures could result in
incorrect diagnostic results or damage to
components.
The following electrical circuit testing tools are required to perform the diagnostic procedures detailed in this Section:
• digital multimeter with 10 mega ohms impedance, and
• connector test adapter kit Tool No. KM609.
For further information on the use of these tools, refer to 8A Electrical Body and Chassis.
2.2 Tech 2 Data List
The Tech 2 displays the status of certain charging system parameters.
To view the data list:
1 Connect Tech 2 to the DLC.
2 On Tech 2 select: Engine / V6 Engine / Data Display / Data List / Electrical/Theft Data .
Tech 2 Parameter Units Displayed Typical Display Values
Alternator L Terminal D Percentage Various
2.3 Diagnostic Systems Check
Step Action Yes No
1 1 Connect Tech 2 to the DLC.
2 Ignition ON, engine OFF.
3 On Tech 2 select: Engine / V6 Engine / Diagnostic Trouble codes / Read
DTC’s.
Are there any set DTC’s? Go to the
appropriate DTC table in 6C1-2 Engine
Management – V6 – Diagnostics. Refer to 2.5
Charging
System Inoperative / Malfunctioning

Reference to following information will assist when diagnosing charging circuit faults:
• for battery testing, refer to 6D1-3 Battery – V6,
• for wiring diagram details, refer to Figure 6D1-1 2, and
• for electrical component locations, refer to 8A Electrical Body and Chassis.

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Charging System – V6 Page 6D1-1-9

2.5 Charging System Inoperative /
Malfunctioning
Diagnostic Table Notes
Reference to following information will assist when diagnosing charging system faults.
1 For all wiring harness fault diagnoses, refer to 8A Electrical Body and Chassis.
2 For wiring harness repairs, refer to 8A Electrical Body and Chassis.
3 Refer to 8A Electrical Body and Chassis for harness routing.
4 Ensure the battery, cables and connections are in good order. Refer to 6D1-3 Battery – V6.
Diagnostic Table 120A Generator
Step Action Yes No
1 Did you review 1.3 System Operation?
Go to Step 2 Go to 1.3
System Operation
2 Did you read 2.3 Diagnostic Systems Check
Go to Step 3 Go to 2.3
Diagnostic
Systems Check
3 Perform the Generator On-vehicle Checks
W as the generator serviceable? Go to step 4 Replace the
generator.
Go to Step 5
4 Perform the Charging Circuit Voltage Drop Test.
W as the wiring serviceable? Go to 8A Electrical
Body and Chassis
Go to Step 5 Repair as required
(refer to Note 2).
Go to Step 5
5 Operate the system to verify the repair.
Did you correct the condition? System OK Go to Step 2
When all diagnosis and repairs are completed, check the system for correct operation.

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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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