| STEPS
FOR CHECKING |
|
CAUSE
AND CORRECTIVE ACTION |
A.
Ensure that the battery is fully charged. Check Specific
gravity of electrolyte in each cell. It should be as
specified on page no.3.
B.
Fuse (10A) to be intact.
C.
All terminal screws/nuts at the starter motor. Earthing
point on the engine, battery starter relay and the neutral
switch should be clean and tightened adequately.
D.
Ignition switch must be in ‘ON’ position
and engine kill switch in run position.
E.
Start button pressed. |
|
|
| |
|
|
1.1.
Check for 12 V D.C. supply at the starter motor terminal
S+ with a voltmeter (VM) D.C. Range. 25V. |
|
1.1.1.
No response indicates that 12 V D.C. supply is not available
at the starter motor (S.M.) terminal S+. The starter circuit
needs to be checked. Refer clause 1.2 below. |
| |
|
1.1.2.
If the V.M. indicates 12V.D.C. supply at the S.M. Terminal
S+, then the S.M. is faulty. 1.1.3 To cross check connect
battery +VE terminal B1 directly to the S.M. +VE terminal
S+ with a6 SQ mm cable. (similar to cable P. No. 06
20 1262) If the S.M. does not respond then it should
be replaced. |
| 1.2.
If the S.M. is checked as per 1.1.1 and no supply is
available at the S+ terminal then cover the following
steps. Hear for click noise of the starter relay while
pressing starter button.a) Refer 1.2..1 & 1.2.2
if click noise comesb) Refer 1.3 if click does not come |
|
1.2.1.
If the click noise is present it indicates that the
relay is operating but there is no output from the Relay
Check for 12 VD.C. supply between the input (R1) of
the Relay and chassis ground. (Starter button not pressed)
If the supply is present then the cover the following
steps. |
| |
|
1.2.2.
Check for 12V DC supply between R2 and Ground. If
the supply is present, Check for voltage drop between
R1 & R2. If the drop is more than 2V, (start button
pressed) then relay is faulty, replace the same To
cross check, refer 1.1.3. If starter motor is ok,
check continuity of wire from relay to starter motor.
|
| 1.3.
Relay operation not present (click noise of Relay operation
not heard) |
|
1.3.1.
Check for 12 V.D.C. supply at the Relay coil terminals
(Soldered points C1 and C2: Refer circuit diagram).
If the supply is indicated on the V.M. then the Starter
Relay is faulty. Replace the same. |
| |
|
1.3.2.
If the 12 V.D.C. supply is not indicated on the V.M.
then check for the supply between point C1 and chassis
ground. If supply is indicated on the V.M. then it indicates
that the point C2 is not getting grounded property through
the neutral switch. (Refer clause 1.4 below.) |
| |
|
1.3.3.
If the V.M. doesn’t show 12 V.D.C. supply between
C1 and chassis ground then it indicates that the battery
supply is not reaching the relay coil terminal C1. To
cross check connect the battery +ve B1 to C1 directly
by a1 Sq. mm cable. If the S.M. responds then check
for the control circuit as follows. |
| |
|
1.3.4.
Ensure the 10 A fuse in the fuse holder is intact. |
| |
|
1.3.5.
Check for 12V DC supply between Red/White in the coupler
for Ignition Switch and chassis ground. If the meter does
not show supply then cable from fuse to the Ignition switch
coupler may be open. (To cross check, check from continuity
between Red/White wire in switch coupler and point F2).If
12V DC is indicated on the meter, check for 12V DC supply
between the Red wire in the Ignition switch coupler and
chassis ground. If there is no supply then the Ignition
switch is faulty. Replace the same. |
| |
|
1.3.6.
If the Voltmeter indicate 12V DC supply, then ensure proper
fitment of the 3 pole natural coupler below the ‘T’
nose and the 3 pole Red coupler below the top cover. If
both are OK then check for proper functioning of the start
button as follows: |
| |
|
1.3.7.
Remove the 2 screws of the L.H. control switch. Check
for 12 V.D.C. supply between the soldered Terminal (red
wire) and chassis ground (Starter button not pressed).
The V.M. should indicate 12V D.C. supply if the above
clauses 1.3.4 and 1.3.5 are OK. |
| |
|
1.3.8.
Keeping the start button pressed check for the 12 V.D.C.
supply between the red/yellow (Crimped terminal) and chassis
ground. If the V.M. does not indicate supply then it implies
that the start button is faulty. Replace the same. |
1.4.
Neutral switch checking. |
|
1.4.1.
Adjust continuity range on a multimeter. Connect the multimeter
across the neutral switch with one probe on the switch
terminal (black wire) and the other probe on the gear
shifter. If continuity is not observed then it indicates
that the neutral switch may be faulty. Take the following
steps. |
| |
|
1.4.2.
Remove the neutral switch from the Gear shifter housing.
Check whether there is any oil layer on the plunger of
the switch. Clean it and again check for continuity. If
there is no continuity then the neutral switch is faulty.Replace
the same. |
| |
|
1.4.3.
If continuity is observed then check whether the plunger
of the switch has got compressed and as such is not making
contact with the Gear Shifter. In that case also replace
the switch. |
| |
|
|
