2007 ISUZU KB P190 engine

6D-14 ENGINE ELECTRICAL (4JK1/4JJ1)
Reassembly
Follow the disassembly steps in reverse order to
reassemble the generator. Pay close attention to the
items below.
• Be very careful not to reverse battery polarity.
Reversed battery polarity will destroy the rectifie
r
diodes.
• Do not ground the generator B-terminal. Heat and
fire damage to the harness will result.
• If using a fast charge procedure, be sure to
disconnect the battery positive cable. If you do not,
the rectifier diodes will be exposed to high positive
voltage that will destroy them.
• Be very careful to reassemble the parts to thei
r
original positions. Particular care must be taken
with insulated parts.
• Carefully clean all insulated parts so that they are
completely free of oil and/or grease.
• Be sure that B-terminal twist-type stoppers (round
terminal) are securely inserted before tightening
the nuts.
Final Assembly
1. Use a bench press to install the rotor and rear
cover to the front cover.




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2. Install the pulley to the rotor shaft and tighten the
bolt to the specified torque.

Pulley bolt torque N
⋅m (kg⋅m / lb ft)
111 (11.3 / 81.7)





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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-15
Starter Motor
Starting Circuit Diagram



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Removal and Installation
Read this Section carefully before performing any
removal and installation procedure. This Section gives
you important points as well as the order of operation.
Be sure that you understand everything in this Section
before you begin.
Important Operations - Removal
Starter Motor
1. Disconnect the battery cable and the ground cable at the battery terminals.
2. Remove the A/T oil level gage.
3. Remove the Engine oil level gage.
4. Disconnect the magnetic switch cable at the terminal bolts.
5. Disconnect the battery cable at the starter moto
r
and the ground cable at the cylinder body.
6. Remove the starter motor from the engine.

Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention
to the important points during the installation procedure.

Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N⋅m (kg ⋅m/lb ft)
85 (8.7 / 63)
3. Install the Engine oil level gage.
4. Install the A/T oil level gage.
5. Reconnect the battery cable at the starter moto
r
and the ground cable at the cylinder body.
6. Reconnect the battery cable and the ground cable at the battery terminals.



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ISUZU KB P190 2007

6D-16 ENGINE ELECTRICAL (4JK1/4JJ1)
Disassembly



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Disassembly Steps
1. Lead W ire
2. Bolt
3. Magnetic Switch Assembly
4. Torsion Spring
5. Plunger
6. Dust Cover
7. Magnetic Switch
8. Screw
9. Through Bolt
10. Rear Cover
11. Motor Assembly
12. Brush Holder
13. Yoke 14. Armature
15. Bolt
16. Bearing Retainer
17. Pinion Assembly
18. Pinion Stopper Clip
19. Pinion Stopper
20. Return Spring
21. Pinion Shaft
22. Clutch
23. Dust Cover
24. Shift Lever
25. Gear Case

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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-17
Important Operations
1. Lead W ire
Disconnect the lead wire at the magnetic switch.





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2. Magnetic Switch Assembly
Remove the magnetic switch bolts, then remove the switch from the shift lever.



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Remove the torsion spring from the magnetic
switch.







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3. Through Bolt
4. Screw
5. Rear Cover
Remove the through bolts, then remove the rea
r
cover.


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ISUZU KB P190 2007

6D-18 ENGINE ELECTRICAL (4JK1/4JJ1)
6. Motor Assembly
Remove the four brushes from the brush holders.






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Remove the yoke along with the armature and the
brush holder from the gear case.
Remove the brushes and commutator carefully so as not to allow them in contact with the adjacent
parts.






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7. Brush Holder
8. Yoke
9. Armature
Remove the brush holder and pull out the armature assembly free from the yoke.



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10. Bearing Retainer
11. Pinion Assembly
12. Dust Cover
13. Shift Lever
14. Gear Case 1) Remove the bearing retainer.
2) Remove the pinion from the gear case.








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3) Use a screwdriver to remove the stopper clip.
Then disassemble the pinion assembly.

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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-19







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ISUZU KB P190 2007

6D-20 ENGINE ELECTRICAL (4JK1/4JJ1)
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacement if excessive wear or damage is discovered
during inspection.
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out mm (in)
Standard Limit
0.05 (0.002) 0.25 (0.010)







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2. Check the commutator mica segments for
excessive wear.
3. Measure the mica segment depth.
Mica Segment Depth mm (in)
Standard Limit
0.5 - 0.8 (0.020 - 0.030) 0.2 (0.008)
If the mica segment depth is less than the standard but more than the limit, the commutato
r
may be reground.
If the mica segment depth is less than the limit, the commutator must be replaced.


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Legend
1. Insulator
2. 0.5 - 0.8 mm (0.020 - 0.030 in)
3. Commutator Segments
4. Correct
5. Incorrect

4. Measure the commutator outside diameter.
Commutator Outside Diameter mm (in)
Standard Limit
36.5 (1.44) 35.5 (1.40)
If the measured outside diameter is less than the
specified limit, the commutator must be replaced.





HCW 51ESH000901


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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-21
5. Use a circuit tester to check the armature for
grounding.
1) Hold one probe of the circuit tester against the commutator segment.
2) Hold the other circuit tester probe against the armature core.
If the circuit tester indicates continuity, the armature is grounded.
The armature must be replaced.





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6. Use the circuit tester to check the armature for
continuity.
1) Hold the circuit tester probes against two commutator segments.
2) Repair Step 1 at different segments of the armature core.
There should be continuity between all segments of the commutator.
If there is not, the armature must be replaced.




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Yoke
1. Use a circuit tester to check the field winding
ground.
1) Hold one circuit tester probe against the field winding end or brush.
2) Hold the other circuit tester probe against the bare surface of the yoke body.
There should be no continuity. If there is continuity, the field coil is grounded. The yoke
must be replaced.


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2. Use the circuit tester to check the field winding
continuity.
1) Hold one circuit tester probe against the “M” terminal lead wire.
2) Hold the other circuit tester probe against the field winding brush.
There should be continuity.If there is no continuity, the yoke must be replaced.

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ISUZU KB P190 2007