- do not engage any gear, turn on the ignition;
- shunt wire (cross section not less than 4 mm2) terminals 30 and 50 on the starter, see also wiring diagram Wiring diagram for starter, alternator, battery (DD 601 / 604 / 605).
If at the same time the starter starts normally, then the malfunction lies in the wires going to the starter. In this case, check the starter in the removed state.
Test condition: connections must be tightened to failure and they must not be oxidized.
CAUSE | SOLUTION |
Starter does not turn when ignition switch and starter are actuated | |
The battery is empty | Charge the battery. |
Line 50 to the ignition switch and starter is broken, starter switch is faulty | Repair gap, replace faulty parts. |
Broken wire or connection to housing; discharged battery | Check battery wires and connections, measure battery voltage, charge if necessary. |
Insufficient current flow due to loose or oxidized connections | Clean the poles and battery terminals. |
No voltage at terminal 50 (traction relay) | Repair the fused connections between the battery, starter motor and vehicle body. |
The starter turns too slowly and does not start the engine | |
The battery is empty | Charge the battery. |
The engine does not have winter or all-weather oil | Fill with multigrade oil. |
Insufficient current flow due to loose or oxidized connections | Clean the poles and battery terminals and clean the connections on the starter, tighten the connections taut. |
The carbon brushes do not adhere to the commutator, the terminals in their contact surfaces are worn, broken, oily or dirty | Check, clean or replace carbon brushes, check contact surfaces. |
Insufficient gap between carbon brushes and commutator | Replace the carbon brushes and clean the contact surfaces of the carbon brushes. |
Collector scratched or burned and dirty | Grind the commutator or replace the anchor. |
No voltage at terminal 50 (minimum 8 V) | Check the ignition and starter switch or traction relay. |
Faulty traction relay | Replace the traction relay. |
The starter starts and retracts, the motor shaft does not rotate or rotates only in jerks | |
Faulty gear train | Replace gear. |
Gear dirty | Clean the gear. |
Faulty gear rim on the flywheel | Modify the gear rim, if necessary, replace the flywheel. |
Gear not working | |
Dirty or defective gear or twisted thread | Clean the gear train, replace it if necessary. |
Faulty traction relay | Replace the traction relay. |
Weak or broken return spring | Restore the return spring. |
The starter continues to run after the ignition key has been turned off | |
Traction relay hangs, does not turn off | Switch off the ignition immediately, replace the traction relay. |
Ignition and instrument switch won't turn off | Immediately disconnect the wires from the battery terminals, replace the ignition and instrument switch |