Service Manual Manual

Electrical System
9-12
G10-55A, G12-55A
9.6 ENGINE START CIRCUIT
9.6.1 Starter
a. Testing the Starter on the Engine
If starter (1) does not engage when ignition key switch is
turned, check following:
1. The main fuse may be blown, requiring replacement.
Check for cause of blown fuse.
2. There may be a defect in ignition key switch, ignition
wiring or starter solenoid.
3. Check batteries condition. Clean batteries posts and
connectors at each end of battery cables.
4. Check for broken wiring and damaged insulation on
wiring. Replace all broken or damaged wiring.
5. Check all connections at starter solenoid, key
switch and wiring harness plugs. Clean and tighten
all connections.
6. If starter still does not operate after these checks
have been performed, check starting circuit.
b. Starter Circuit Checks
1. Check wires and connections for looseness,
corrosion, damage, etc.
2. If a “whirring” noise is heard but engine does not turn
over, starter is spinning but not engaging flywheel.
The starter drive or solenoid that pushes drive
forward to engage flywheel may be defective.
Missing or damaged teeth on flywheel can also
prevent starter from cranking engine.
3. If starter only “clicks” it may indicate that battery is
discharged, or that there is a loose or corroded
battery cable connection. Check battery state of
charge and battery condition first, then check cables
and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.5, “Electrical System Schematics.”
c. Starter Removal
1. Park machine on a firm, level surface, level machine,
fully retract the boom, lower the boom, place
transmission control lever in (N) NEUTRAL, engage
park brake and shut engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
3. Open engine cover. Allow system fluids to cool.
4. Properly disconnect the batteries.
5. Remove positive (+) cable/wire from the solenoid
stud.
6. Remove negative (-) battery cable from starter.
7. Label and disconnect wire from starter solenoid
housing stud. Record how wires are installed to
ensure correct installation later.
8. Loosen, but DO NOT remove, fasteners securing
starter to flywheel housing. Support starter securely,
as it is relatively heavy and will fall if not supported.
9. Support starter and remove fasteners securing
starter to engine. Remove negative (-) ground cable.
10. Remove starter from machine.
d. Starter Installation
1. Position the starter in its mounting opening on
flywheel housing.
2. Install negative (-) ground cable to starter.
3. Secure starter with the three fasteners.
4. Connect the positive (+) battery cable to upper
solenoid stud. Install wires to solenoid stud and
secure with lock washer and nut.
5. Connect wires removed earlier to the solenoid
mounting stud.
6. Properly connect batteries.
7. Close and secure engine cover.
8. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
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