engine ISUZU KB P190 2007 Workshop Repair Manual

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



RTW 460LF000201
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.


RTW 46DSH002901


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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







RTW 46DSH003401



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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)







RTW 46DSH003501
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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ISUZU KB P190 2007

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

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




RTW 46DLF000601
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