Trouble Shooting

Specification

Starting motor Nominal output 12V 12V - 2.5kW Alternator Nominal output 12V 12V, 60A

Glow plug Type Sheathed type Voltage, amperage 12V 10.5V, 16.5A

Troubleshooting

Trouble Possible Cause Action to be Taken Starting motor does not turn, or turns too slowly to start the engine

Starting motor turns, but the engine does not start

Starting motor turns, but pinion gear does not mesh with ring gear

Starting motor turns continuously and does not stop

Battery discharge

Overcharged battery Battery and related parts • Faulty contact of battery terminals • Faulty grounding of negative cable • Voltage drop caused by discharging • Insufficient voltage caused by faulty battery Engine switch (ignition switch) • Faulty contact on engine switch • Loose engine switch wiring and connectors • Broken wire between engine switch and magnetic switch Magnetic switch and related parts • Loose wiring and connectors • Faulty contact of magnetic switch contact plate • Broken wire of magnetic switch pull-in coil • Broken wire of magnetic switch holding coil Starting motor and related parts • Faulty contact of brushes • Fatigued brush spring • Faulty grounding of field coil • Faulty soldering of field coil • Faulty commutator • Faulty grounding of armature • Wear on parts Insufficient battery capacity Quick start system and related parts • Faulty glow plug relay control unit • Faulty glow plug relay • Faulty glow plug • Tip of overrunning clutch pinion is worn • Raced overrunning clutch • Faculty sliding surface of spline • Worn bushing • Worn ring gear • Sticking contact plate of magnetic switch • Layer short of magnetic switch coil • Engine (ignition) switch does not return properly • Loose V-belt • Grounded or broken stator coil • Broken rotor coil • Faulty contact between brush and slip ring • Faulty rectifier • Faulty IC regulator • Insufficient or unsuitable battery electrolyte • Faulty battery electrode (internal shortcircuit) • Faulty contact of battery terminal • Excessive electric load

• Faulty IC regulator • Clean and tighten • Clean and repair • Charge • Charge

• Replace • Repair • Repair or replace

• Repair • Replace • Replace • Replace

• Repair replace • Replace • Replace • Repair • Repair • Replace • Replace • Charge

• Replace • Replace • Replace • Replace • Replace • Repair or replace • Replace • Replace • Replace • Replace • Replace • Adjust • Replace • Replace • Clean or replace • Replace • Replace • Adjust • Replace • Clean, tighten • Check power consumption • Replace