Isuzu KB P190. Manual - part 908

Starting System – V6 

Page 6D1-2–24 

 

No Load Test 

1 

Clamp the starter motor securely to a test bench. 

2 

Connect the starter motor as shown in Figure 6D1-2 –  18, Close the start switch to activate the starter motor. 

4 

Record the speed of the planetary drive shaft, current draw and the voltage. 

5 

Check the readings are within the specifications. 

Minimum r.p.m. ....................................................... 2370 

Maximum current draw ............................................90 A 

M Terminal voltage .........................................12 

± 0.1 V 

6 

Disassemble and service the starter motor if the readings are not within the specifications, refer to 4.4 Starter 
Motor Disassemble and Reassemble. 

 

Figure 6D1-2 –  18 

Legend 

1 Battery 

2 Carbon 

Pile 

3 

Shaft Speed Indicator 

4 

Multimeter set to measure current 

5 

Multimeter set to measure voltage 

6 Start 

Switch 

7 

Solenoid Switch P – 3 pin 1 

8 

Solenoid Switch P – 4 pin B 

9 

Solenoid Switch M terminal 

Starting System – V6 

Page 6D1-2–25 

 

4.4 

Starter Motor Disassemble and 
Reassemble 

Disassemble 

1 

Clamp the starter motor, by the mounting lug in the 
drive-end housing, in a vice with soft jaws. 

2 

Remove the nut (1) and washer (2) from the 
solenoid switch M terminal (3). 

3 

Remove the braided cable (4) from the M terminal. 

Figure 6D1-2 –  19 

4 

Scribe aligning marks (1) on the drive-end 
housing (2) and the solenoid switch housing (3) to 
aid reassembly. 

 

When using an impact driver, avoid 
damaging the drive-end housing or 
rounding the screw slots of the solenoid 
switch mounting screws. 

5 

Remove the two solenoid switch mounting 
screws (4). It may be necessary to loosen the 
mounting screws using an impact driver. 

Figure 6D1-2 –  20 

6 

Remove the solenoid switch from the drive-end 
housing. 

 

Do not lose the plunger return spring. 

7 

Unhook and remove the solenoid switch plunger (1) 
from the drive assembly fork lever (2). 

Figure 6D1-2 –  21 

 

Starting System – V6 

Page 6D1-2–26 

 

Reassemble 

1 

Reassemble the solenoid in the reverse order of the disassembly procedure noting the following points. 

 

Dry all parts thoroughly before assembly, 
taking care not to breathe in any vapours. 

2 

Lightly coat the solenoid switch plunger with 10% molybdenum disulphide grease. 

 

Excess grease can enter the contact chamber 
of the solenoid switch and cause contact 
problems. Do not use too much grease. 

3 

Hook the plunger over the fork lever. 

4 

Insert the return spring into the plunger. 

5 

Slide solenoid switch over the plunger. 

6 

Align the solenoid switch with drive-end housing ensuring the solenoid switch terminal P – 4 faces away from the 
pole housing. 

7 

Install and tighten the solenoid switch mounting screws. 

Solenoid switch mounting screw 
torque specification .....................................4.1 – 7.6 Nm 

8 

With the starter motor reassembled, perform a No Load Test, refer to 4.3  Starter Motor Bench Tests. 

9 

If the starter motor fails the No Load Test specification, replace the starter motor. 

4.5 

Solenoid Switch Tests  

Test the Solenoid Switch 

1 

Inspect the solenoid switch for any external 
damage. 

2 

Replace the solenoid switch if it displays 
significant damage. 

3 

Install the return spring and plunger into the 
solenoid switch. 

4 

Check the movement of the plunger, as follows: 

a 

Depress the plunger fully. 

b 

Release the plunger. 

c 

If the plunger sticks or binds in the switch 
bore, clean or replace the solenoid switch 
assembly as required. 

Figure 6D1-2 –  22 

Starting System – V6 

Page 6D1-2–27 

 

5 

Connect a multimeter set to measure resistance 
between the solenoid switch M terminal (1) and 
the solenoid switch terminal P – 3 (2). 

6 

Record the resistance reading. 

7 

Replace the solenoid switch if the resistance is 
outside the specification. 

 

 

Pull-in winding  
resistance @ 20

°C................................0.33 – 0.37 Ω 

Figure 6D1-2 –  23 

8 

Connect a multimeter set to measure resistance 
between the solenoid switch housing (1) and the 
solenoid switch terminal P – 3 (2). 

9 

Replace the solenoid switch if the resistance is 
outside the specification. 

 

 

Hold-in winding  
resistance @ 20

°..................................0.75 – 0.87 Ω 

Figure 6D1-2 –  24