Chapter III Malfunction Diagnosis and Troubleshooting
Great Wall Baoding Internal Combustion Engine
Manufacturing Company Limited
105
Phenomenon and Cause of Malfunction
Troubleshooting
Weak
starting of
the starter,
unable to
start the
diesel engine
(1) Insufficient capacity of the
storage battery
(2) Bad contact of the wire
(3) Burning damage or oil stain on
the commutator surface.
(4) Excessive wear or insufficient
elasticity of the carbon brush,
leading to its poor contact with the
commutator
(5) Ablation and bad contact of the
electromagnetic switch main contact
(6) Excessive wear of the bearing,
armature rubbing the shell
(1) Charge the storage battery as specified.
(2) Screw up the wire joints.
(3) Polish the commutator surface or clean off the
oil stain.
(4) Replace the carbon brush or adjust the
carbon brush spring pressure.
(5) Polish the
electromagnetic switch main contact
with 0# non-metal abrasive paper.
(6) Check and replace the bearing.
Starter
keeping
rotating and
making
sharp noise
after the
diesel engine
is started
(1) Adhesion of the copper contact
disc in the starter relay with the two
contacts
(2) Breakage or bending of the
starter armature shaft
(3) Sticking or galling of the gear
teeth face
(1) Disconnect the power supply immediately;
check, fasten the circuit and repair the contacts.
(2) Disconnect the power supply immediately and
replace the starter.
(3) Disconnect the power supply immediately and
repair the gear teeth face.
15. Working Starter but Non-working Diesel Engine
Checking Item and
Part
Cause of Malfunction
Troubleshooting
Storage battery
(1) Looseness of the storage battery
terminal due to
oxidization
(2) Storage battery uncharged or
inadequately charged
(1) Clean and/or refasten the storage
battery terminal.
(2) Recharge or replace the storage
battery as specified.
Starter
(1) Damage of the pinion
(2) Malfunction of the electromagnetic
switch
(3) Damage of the electrical brush or
too soft electrical brush spring
(1) Replace the pinion.
(2) Repair or replace the
electromagnetic switch.
(3) Replace the electrical brush and/or
the electrical brush spring.
Diesel engine
Sticking of the piston and the
crankshaft bearing or damage of other
parts
Overhaul or replace the corresponding
parts of diesel engine.
Anti-theft system
Unable to remove the anti-theft
protection
Overhaul the anti-theft system.
Main relay
Damage of the main relay
Replace the main relay.
