2007 ISUZU KB P190 Engine

6D-22 ENGINE ELECTRICAL (4JK1/4JJ1)



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Brush and Brush Holder
1. Use a vernier caliper to measure the brush length
(four brushes).
Replace the brushes as a set if one or more of the brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)



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2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the othe
r
probe to the positive brush holder.
There should be no continuity.




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3. Inspect the brushes for excessive wear.
If the negative brushes have excessive wear, the entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire yoke must be replaced.
Overrunning Clutch
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.







065RY00035


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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-23
Bearing
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.





RTW 46DSH004401


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ISUZU KB P190 2007

6D-24 ENGINE ELECTRICAL (4JK1/4JJ1)
Reassembly




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

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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-25

Important Operations
1. Magnetic Switch Assembly
1)
Attach the torsion spring to the hole in the
magnetic switch as illustrated.
2) Insert the shift lever into the plunger hole of the magnetic switch.




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2. Gear Case
3. Dust Cover 1) Install the magnetic switch assembly in the gear case.
2) Install the dust cover.
Dust Cover Bolt Torque N⋅m (kg ⋅m/lb in)
8 (0.8 / 69)









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4. Pinion Assembly

Apply a coat of grease to the reduction gear and
install the pinion assembly to the armature shaft.


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5. Brush Holders
1) Install the brushes into the brush holder with raising the spring end of the brush spring.
Take care not to damage the commutator face.
2) Install the brush holder with aligning the peripheries of the yoke and the brush holder.





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6. Through Bolt
Install the through bolts in the rear cover and tighten them to the specified torque.
Through Bolt Torque N⋅m (kg ⋅m/lb in)
8.1 (0.83 / 69.7)


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ISUZU KB P190 2007

6D-26 ENGINE ELECTRICAL (4JK1/4JJ1)







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7. Lead W ire
Connect the lead wire in the magnetic switch and tighten the terminal nut to the specified torque.
Lead W ire Terminal Nut Torque N ⋅m (kg ⋅m/lb in)
8.6 (0.88 / 74.9)






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Inspection After Assembly
Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft
end and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.1 – 2.0 (0.004 – 0.078)










RTW 46DSH005801


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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-27
Magnetic Switch
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickl
y
as possible (within three to five seconds).

Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid switch body and the M terminal. W hen
current is applied to the S terminal from the batter
y
positive terminal, the pinion should flutter.



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2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should continue to flutter.



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3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.


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ISUZU KB P190 2007

6D-28 ENGINE ELECTRICAL (4JK1/4JJ1)
Torque Specifications
N⋅
⋅⋅
⋅
m (kg ⋅
⋅⋅
⋅
m/lb in)




RTW 76DLF000101


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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-29
Pre-Heating System
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacement if excessive wear of damage is discovered
during inspection.
Visual Check
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
Glow Relay
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94 - 114

















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Glow Plug
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9



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ISUZU KB P190 2007