Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1711

6D3-2  STARTING AND CHARGING SYSTEM

Starting System

General Description

Cranking Circuit

The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.

Starter

The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion shaft.
When the starter switch is turned on, the contacts of magnetic
switch are closed, and the armature rotates. At the same time,
the plunger is attracted, and the pinion is pushed forward by
the shift lever to mesh with the ring gear.
Then, the ring gear runs to start the engine. When the engine
starts and the starter switch is turned off, the plunger returns,
the pinion is disengaged from the ring gear, and the armature
stops rotation. When the engine speed is higher than the
pinion, the pinion idles, so that the armature is not driven.

Service Precaution

CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts and
systems.

Diagnosis

Condition

Possible cause

Correction

Starter does not run

Charging failure

Repair charging system

Battery Failure

Replace Battery

Terminal connection failure

Repair or replace terminal connector

and/or wiring harness

Starter switch failure

Repair or replace starter switch

Starter failure

Repair or replace starter

STARTING AND CHARGING SYSTEM  6D3-3

Starter

Removal

1. Remove the battery ground cable.

2. Remove harness connectors (1) and (2).

3. Remove bolts from starter.

Installation

1. Install starter assembly.

2. Install mounting bolts and tighten bolts to specified torque.

Torque: 51 N

⋅⋅⋅⋅m (5.2 kgf⋅⋅⋅⋅m)

3. Connect harness.

4. Reconnect the battery ground cable.

6D3-4  STARTING AND CHARGING SYSTEM

Disassembled View

Legend

1 Bolt
2 Magnetic Switch
3 Gear Case
4 Piston
5 Piston Shaft
6 Center Bracket

7 Armature
8 Yoke Assembly
9 Brush and Brush Holder

10 Washer
11 Rear Cover
12 Through Bolt

STARTING AND CHARGING SYSTEM  6D3-5

Inspection and Repair

Repair or replace necessary parts if extreme wear or damage
is found during inspection.

Armature

Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).

Check for continuity between commutator and shaft.
Also, check for continuity between commutator and armature
core, armature core and shaft. Replace commutator if there is
continuity (i.e., internally grounded).

Brush

Measure the length of brush.
Replace with a new one, if it is below the limit.

Brush Holder

Check for continuity between brush holder (+) (4) and base (-).
Replace, if there is continuity (i.e., insulation is broken).

Magnetic Switch

Check for continuity of shunt coil between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).

Continuity of Series Coil

Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).