Troubleshooting the Starter Issue in the Daewoo 802 Plus

[MikePhua]

The Daewoo 802 Plus is a well-regarded mini excavator that is commonly used in construction, landscaping, and other heavy-duty applications. However, like any piece of machinery, it can encounter issues from time to time. One such problem is a starter issue, which can prevent the machine from starting or cause it to stall after starting. In this article, we’ll explore common reasons why the Daewoo 802 Plus starter may fail and how to resolve the problem.
Understanding the Daewoo 802 Plus Starter System
Before diving into the troubleshooting, it’s important to understand how the starter system works in the Daewoo 802 Plus. The starter motor is responsible for turning over the engine when the ignition key is turned. Once the engine begins to run, the starter disengages, allowing the engine to continue running without assistance. The Daewoo 802 Plus typically uses a 12-volt electrical system, and the starter motor is activated by the starter relay.
A starter issue can stem from a variety of components, and identifying the root cause is essential for getting the machine back to work.
Common Causes of Starter Issues
Several factors can lead to starting problems in the Daewoo 802 Plus. Let’s explore the most common issues:
1. Dead or Weak Battery
One of the most common reasons a starter won’t engage is a dead or weak battery. A battery that doesn’t have enough charge will fail to provide the necessary power to turn the starter motor. This can often be accompanied by a clicking sound when attempting to start the machine, which indicates that the solenoid is trying to engage but lacks sufficient power to turn the engine.

• Symptoms: The starter solenoid may click, but the engine won’t turn over. In some cases, the engine may turn over very slowly or not at all.
  
• Solution: Check the battery voltage with a multimeter. A fully charged 12V battery should read around 12.6V. If the voltage is significantly lower (below 12V), recharge or replace the battery.
  

2. Faulty Starter Solenoid
The starter solenoid is an integral component of the starting system. It acts as a switch that activates the starter motor when the ignition key is turned. If the solenoid fails, the starter motor won’t receive the electrical current needed to start the engine. A faulty solenoid can be caused by internal wear, corrosion, or a bad electrical connection.

• Symptoms: You may hear a clicking sound when trying to start the machine, but the engine won’t turn over.
  
• Solution: Test the starter solenoid for continuity using a multimeter. If the solenoid is faulty, it will need to be replaced.
  

3. Corroded or Loose Wiring
Corroded or loose wiring can cause poor electrical connections, preventing the starter motor from receiving the required voltage. Over time, wires can become corroded, especially if the machine is exposed to the elements. Loose connections or frayed wires can also cause intermittent starting problems.

• Symptoms: The starter may work intermittently, or the engine may crank slowly or not start at all.
  
• Solution: Inspect the wiring connected to the starter motor, battery, and solenoid. Look for signs of corrosion or loose connections. Clean or replace corroded connectors, and tighten any loose connections.
  

4. Faulty Starter Motor
If the starter motor itself is faulty, it will fail to turn over the engine. Starter motors can wear out over time, especially if the machine is used extensively. When the motor is worn, it may spin very slowly or fail to engage completely.

• Symptoms: The starter motor may spin, but it won’t turn the engine over, or it might spin very slowly.
  
• Solution: To determine if the starter motor is faulty, you can bypass the solenoid to directly power the starter motor. If the motor still doesn’t turn the engine over, it may need to be replaced.
  

5. Ignition Switch Issues
Sometimes the issue may lie with the ignition switch itself. The ignition switch controls the power flow to the starter solenoid. If the switch is worn or malfunctioning, it may not engage the starter motor when the key is turned.

• Symptoms: Turning the key results in no response, with no clicking or cranking of the engine.
  
• Solution: Inspect the ignition switch for any signs of wear or damage. If the switch is faulty, it should be replaced to restore proper function.
  

6. Defective Fuses or Relays
The fuses or relays controlling the starter circuit can sometimes blow or fail, causing the starter to fail. These components are designed to protect the electrical system, but when they malfunction, they can interrupt the power flow needed to engage the starter motor.

• Symptoms: No electrical activity when the key is turned, or the engine fails to start even with a fully charged battery.
  
• Solution: Check the relevant fuses and relays in the starter circuit. Replace any blown fuses or faulty relays to restore power to the starter motor.
  

Step-by-Step Troubleshooting Process
If you’re experiencing starting issues with your Daewoo 802 Plus, follow this step-by-step process to identify and resolve the problem:
Step 1: Check the Battery Voltage
Start by checking the battery voltage. If the voltage is below 12.6V, the battery may be weak or discharged. Recharge or replace the battery as needed.
Step 2: Inspect the Wiring
Check the wiring connections to the starter motor, solenoid, and battery. Look for signs of corrosion, loose connections, or damaged wires. Clean any corroded connectors and tighten loose connections.
Step 3: Test the Starter Solenoid
Use a multimeter to test the starter solenoid for continuity. If it fails the test, replace the solenoid.
Step 4: Inspect the Starter Motor
If the solenoid is functioning correctly but the engine still won’t start, test the starter motor. Bypass the solenoid to test the motor directly. If the motor fails to turn over, replace it.
Step 5: Check the Ignition Switch
If the starter motor is in good condition, check the ignition switch for wear or malfunction. If the switch is faulty, replace it.
Step 6: Inspect Fuses and Relays
Finally, inspect the fuses and relays associated with the starting system. Replace any blown fuses or faulty relays to restore power to the system.
Real-World Example: Daewoo 802 Plus Starter Issue
A contractor shared his experience with the Daewoo 802 Plus starter issue. He explained that the machine failed to start after a long period of inactivity. He initially suspected a dead battery, but after testing it, he found that the battery was fully charged. He then checked the wiring and found a corroded connection near the starter solenoid. After cleaning the connections and replacing a blown fuse, the machine started up without issue.
This story highlights the importance of regular maintenance and the need for thorough troubleshooting when dealing with electrical components.
Conclusion: Resolving Daewoo 802 Plus Starter Problems
Starting issues with the Daewoo 802 Plus can usually be traced to a few common culprits, such as a weak battery, faulty solenoid, or corroded wiring. By following the troubleshooting steps outlined in this article, you can identify the root cause of the issue and restore your equipment to full operation. Regular inspection and maintenance of the electrical system can help prevent starter-related problems and ensure the longevity of your Daewoo 802 Plus mini excavator.
If the problem persists after performing these checks, it may be advisable to consult a professional mechanic or technician who specializes in heavy equipment to further diagnose and repair the issue.