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6.
PROBLEM SOLVING
6.1
P
ROBLEM SOLVING CHART
The chart helps to solve mechanical and electrical problems.
It is assumed that the engine is in good condition and that there is
adequate fuel flow to the filter and injection equipment.
An electrical fault must be traced by an electrician.
Make sure that the wires are not damaged and that they are clamped
tight to their terminals.
Problem
1. Lamps (H1, H2) do not
light up when switching
(S1) to Ó I Ó and applying
lamp test.
2. General alarm lamp (H2)
does not light up when
switching (S1) to
Ó I Ó; lamp (H1) lights up
when applying lamptest.
3. Temperature alarm lamp
(H1) does not light up when
switching (S1) to
Ó I Ó and applying lamp test.
4. Starter motor (S) does not
crank engine (E) after
switching (S1) to
.
5. Starter motor cranks engine
when switching S1 to
but engine does not fire.
Possible faults
a. Discharged or defective battery.
b. Loose battery cable(s) or oxidised terminals.
c. Loose connection or damaged wiring.
d. Contact switch (S1) defective.
e. Circuit breaker (F1) defective.
a. Lamp (H2) blown.
b. Alternator (A)/regulator defective.
a. Lamp (H1) blown.
b. See fault 1d.
a. Low battery output.
b. Contact switch (S1) defective.
c. Alternator output relay (K4) defective.
d. Start solenoid (K0) or starter motor defective.
a. Contact switch (S1) defective.
b. Fuel solenoid (Y1) defective.
c. Low battery output.
6.2
A
LTERNATOR PRECAUTIONS
1. Never reverse the polarity of the battery or the alternator.
2. Never break any alternator or battery connections while the
engine is running.
3. When recharging the battery, disconnect it from the alternator.
Before using booster cables to start the engine, be sure of the
polarity and connect the batteries correctly.
4. Never operate the engine without the main or voltage sensing
cables connected in the circuit.
Corrective actions
a. Check electrolyte level and charge battery. If
no cells are shorted and battery is discharged,
trace cause and correct.
b. Check and correct as necessary.
c. Check wiring and connections, correct as
necessary.
d. With (S1) switched in Ó I Ó, check voltage
between earth and respectively each of the
terminals of (S1). Voltage must register at
each of the terminals; if not, replace (S1).
e. Replace circuit breaker.
a. Replace lamp.
b. Disconnect the wire from alternator terminal
D+ and connect it to terminal D--. If (H1)
lights up, replace the alternator; if not, test
(S1); see remedy 1d.
a. Replace lamp.
b. See 1d.
a. See remedy 1a.
b. With (S1) in
and respectively each of the terminals of (S1).
Voltage must register at each of the terminals;
if not, replace (S1).
c. Replace (K4).
d. Check start solenoid (K0). Have starter motor
repaired.
a. See remedy 5b.
b. Check solenoid and its valve; correct or
replace as necessary.
c. see 1a.
I
M
NSTRUCTION
ANUAL
, check voltage between earth
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