2007 ISUZU KB P190 oil

6D – 10 ENGINE ELECTRICAL




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Important Operations
1. Vacuum Pump
1. Loosen the vacuum pump fixing screws.
2. Support the vacuum pump O-ring.
3. Carefully remove the O-ring.
2. Cover





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3. Through Bolt
1. Remove the M5 through bolt.
2. Separate the front and rear sides of the vacuum pump.
3. Insert the tips of 2 ordinary screwdrivers into the space between the front cover and the stator core. Remove
the front cover and rotor together with the rear cover
and stator.
If removal is difficult, push the rear cover to the side and
lightly tap the end of the shaft with a plastic hammer to
loosen it.
 The front cover oil seal must be replaced with a new
one when the front cover is removed.
 Take care not to damage the stator core with the
screwdriver tips.




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4. Pulley
1. Carefully clamp the rotor assembly in a vise.
2. Loosen the pulley nut.
3. Remove the pulley and the front cover from the rotor.


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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 11



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7. Rotor Assembly
1. Remove the rotor from front cover assembly.

Remove the front cover stator and rectifier.




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8. Front Cover Assembly
1. Remove the front cover bearing retainer screws.
2. Remove the bearing.




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9. Rear rotor bearing
 Re-use improper parts.
10. Rectifier 1. Disconnect the stator coil leads between each rectifier by melting the solder connection.
Hold the lead wire between the solder and the rectifier
with a pair of long nose pliers.
This will prevent heat transfer and resultant damage to
the rectifier.



RTW46DSH000401



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6D – 12 ENGINE ELECTRICAL
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.

ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting. Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter mm (in)
Standard Limit



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31.6 (1.245) 30.6 (1.183)















If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.

3. Measure the rotor coil resistance.
Rotor Coil Resistance at 20 °C (68 °F) ohms
Standard 3.8



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4. Check for continuity between the slip rings and the
rotor core or shaft.
If there is continuity, the entire rotor assmbly must be
replaced.



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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 13
STATOR COIL ASSEMBLY
1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal “N ” and the Coil Ends
(Reference) ohms
Standard 0.1

066RY00022 2. Check for continuity between each stator coils and the stator core.
If there is continuity, the stator coils must be replaced.
066RY00023


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BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference) mm (in)

Standard Limit
25 (1.0) 6.5 (0.25)



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Rectifier


Tester wire
E BAT
U, V, and WN ⊕  U, V, and WN⊕ 
⊕ ----- Conductivity ⊕ ----- No
conductivity

No
conductivity -----

Conductivity -----
Negative side diode check Positive side diode check



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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.


Oil Seal Replacement
1. Push the old oil seal from the rear bracket outside holes.
2. Use the insertion tool to press the new oil seal into place. Follow the procedure shown in Figures A, B, C
and D.

Position the oil seal beneath the shaft and the
guide lip.

Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.

After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution







Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.







Take care not to damage the D surface.







Under no circumstances may the original oil seal
be reused.







The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.







RTW46DSF000101

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ENGINE ELECTRICAL 6D – 19


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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.



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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)





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Remove the tape from the splines.









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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.

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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 21




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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.




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Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.



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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.



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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)




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ENGINE ELECTRICAL 6D – 27


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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 Repear 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