Work Flow (With GR8-1200 NI)

DIAGNOSIS AND REPAIR WORK FLOW

Work Flow (With GR8-1200 NI)


STARTING SYSTEM DIAGNOSIS WITH GR8-1200 NI

To test the starting system, use the following special service tool:
- GR8-1200 NI Multitasking battery and electrical diagnostic station
NOTE:
Refer to the diagnostic station Instruction Manual for proper starting system diagnosis procedures.

OVERALL SEQUENCE







DETAILED FLOW

NOTE:
To ensure a complete and thorough diagnosis, the battery, starter motor and alternator test segments must be done as a set from start to finish.

1. DIAGNOSIS WITH MULTITASKING BATTERY AND ELECTRICAL DIAGNOSTIC STATION GR8-1200 NI

Perform the starting system test with Multitasking battery and electrical diagnostic station GR8-1200 NI. For details and operating instructions, refer to diagnostic station Instruction Manual.
Test result
CRANKING NORMAL-GO TO 2.
LOW VOLTAGE-GO TO 5.
CHARGE BATTERY-Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12
hours.) Perform battery test again. Refer to diagnostic station instruction manual.
REPLACE BATTERY-Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again. Refer to diagnostic station instruction manual. If second test result is
"REPLACE BATTERY", then do so. Perform battery test again to confirm repair.

2. CRANKING CHECK

Check that the starter motor operates correctly.
Does the engine crank normally?
YES- GO TO 3.
NO- GO TO 4.

3. ENGINE START CHECK

Check that the engine starts.
Does the engine start?
YES- Starter motor is OK. INSPECTION END
NO- Perform further diagnosis of engine mechanical or engine control system. Refer EM and EC sections. Once resolved, perform battery test again.

4. STARTER MOTOR ACTIVATION

Check that the starter motor operates.
Does the starter motor turn?
YES- Check ring gear and starter motor drive pinion. Once resolved, perform battery test again.
NO- GO TO 7.

5. COMPARISON BETWEEN ENGINE COOLANT AND CRANKING VOLTAGE

Compare the engine coolant temperature and the cranking voltage with the specifications.
Minimum Specification of Cranking Voltage Referencing Coolant Temperature





Is the voltage less than the specified value?
YES- GO TO 7.
NO- GO TO 6.

6. STARTER OPERATION

Check the starter operation status.
Does the starter motor turn smoothly?
YES- Starter motor is OK. INSPECTION END
NO- GO TO 7.

7. "B" TERMINAL CIRCUIT INSPECTION

Check "B" terminal circuit. Refer to "Diagnosis Procedure" B Terminal Circuit.
Is "B" terminal circuit normal?
YES- GO TO 8.
NO- Repair as needed.

8. "S" CONNECTOR CIRCUIT INSPECTION

Check "S" connector circuit. Refer to "Diagnosis Procedure" S Connector Circuit.
Is "S" connector circuit normal?
YES- GO TO 9.
NO- Repair as needed.

9. ENGINE ROTATION STATUS

Check that the engine can be rotated by hand.
Does the engine turn freely by hand?
YES- Replace starter motor. Refer to "Removal and Installation" Removal and Installation.
NO- Perform further diagnosis of engine mechanical or powertrain mechanism. Once resolved, perform battery test again using Multitasking battery and electrical diagnostic station GR8-1200 NI.
Refer to the diagnostic station Instruction Manual for proper testing procedures.