Page 1017 of 6020

6D – 16 ENGINE ELECTRICAL
RTW46DSH000901
Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump housing.
2. Remove the vacuum pump rotor and the vanes from the housing.
Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.
Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.
Rotor
1. Inspect the rotor for excessive wear, abrasion, and scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash. Replace the rotor if backlash is present.
RTW46DSH005201
Check Value
1. Carefully force the valve from the
“B ” side as shown in
the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the “A ” side.
Air Pressure kPa (kg/cm
2/psi)
98 - 490 (1-5/14 – 71)
Check for air leakage from the check valve.
If there is air leakage, the valve must be replaced.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1018 of 6020
ENGINE ELECTRICAL 6D – 17
RTW46DSH001801
Vacuum Pump Reassembly
1. Install the vanes to the rotor slits.
The rounded side of the vanes must be facing the
rotor housing.
RTW46DSH001901
2. Install the rotor with the concave side facing the center
plate.
RTW46DSH002001
3. Install the center plate to the rotor housing.
Be sure to use a new O-ring.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1019 of 6020
6D – 18 ENGINE ELECTRICAL
REASSEMBLY
RTW46DLF000501
Reassembly Step
1.
Front cover
2.
Rear rotor bearing
3.
Rotor Assembly
4.
Pulley
5.
Rectifier Assembly
6.
Stator Assembly
7.
Rear cover
8.
B Terminal nuts
9.
Through bolt
10.
O-ring
11.
Vacuum pump
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1020 of 6020
ENGINE ELECTRICAL 6D – 19
RTW46DSH000401
Important Operations
2. Rear rotor bearing
• Re-use improper parts.
5. Rectifier
6. Stator Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.
RTW46DSH002101
3. Rotor Assembly
4. Pulley Assembly Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque N ⋅m (kg ⋅m/lb ⋅ft)
83.3 ∼ 98.0 (8.5 ∼ 10.0 / 61 ∼ 72)
RTW46DSH006001
Remove the tape from the splines.
RTW46DSH004901
The rear ball bearing is pressed into the wheel eccentric
groove. The bearing ring projects from the groove.
During installation, rotate the bearing to the point of
minimum bearing ring projection.
Inspect the rear cover bearing box and replace it if it is
damaged.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1021 of 6020
6D – 20 ENGINE ELECTRICAL
RTW46DSH002201
NOTE: Be sure to attach a cooler to B terminal.
RTW46DSH005301
Insert the pin from the outside of the rear cover. Press the
brushes into the brush holder. Complete the assembly
procedure.
Remove the pin after completion of the assembly
procedure.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1022 of 6020

ENGINE ELECTRICAL 6D – 21
RTW06DSH000201
9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the front cover and the rear cover.
2. Install the through bolts and tighten them to the specified torque.
Through Bolt Torque N ⋅m (kg ⋅m/lb ⋅ft)
3.1 ∼ 3.9 (0.32 ∼ 0.41 / 2.6 ∼ 3.5)
11. Vaccum Pump To install the generator -
1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the 3 generator fixing points.
3. Twist the fixing points down and to the left to align them with the middle of the center plate and the rotor.
RTW46DSH006101
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.
RTW46DSH002401
Install the vacuum pump housing.
Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.
RTW46DSH002501
Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque N ⋅m (kg ⋅m/lb ⋅ft)
5.9 ∼ 6.9 (0.6 ∼ 0.7 / 5.2 ∼ 6.1)
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1023 of 6020

6D – 22 ENGINE ELECTRICAL
STARTER MOTOR
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. Disconnect the magnetic switch cable at the terminal bolts.
3. Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
4. 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. Reconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
4. Reconnect the battery cable and the ground cable at the battery terminals.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 1024 of 6020
ENGINE ELECTRICAL 6D – 23
DISASSEMBLY
RTW460LF000201
Disassembly Step
1.
Lead wire
14. Armature
2.
Bolt 15. Bolt
3.
Magnetic switch assembly 16. Bearing retainer
4.
Torsion spring 17. Pinion assembly
5.
Plunger 18. Pinion stopper clip
6.
Dust cover 19. Pinion stopper
7.
Magnetic switch 20. Return spring
8.
Screw 21. Pinion shaft
9.
Through bolt 22. Clutch
10.
Rear cover 23. Dust cover
11.
Motor assembly 24. Shift lever
12.
Brush holder 25. Gear case
13.
Yoke
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007