Service Manual User Manual

Electrical System
10-39
Model 3606 • Origin 10/99
10.6.1 Testing the Starter on the Engine
If the starter does not engage when the ignition key is
turned, check the following:
1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
2. There may be a defect in the ignition switch, ignition
wiring, or starter solenoid.
3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
Also check the ground cable behind the starter
mounting bolt and the frame ground stud, just above
the hydraulic oil reservoir fill cap.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
switch, and wiring harness plugs. Clean and tighten
all connections.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
Starter Circuit Checks
1. Check wires and connections for looseness,
corrosion, damage, etc.
2. If a "whirring" noise is heard, but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the engine.
3. If the starter only "clicks", it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the battery
state of charge and battery condition first, then check
the cables and cable connections.
10.6.2 Starter
The starter (Fig. 10– 29) is located on the left side of the
engine (the right side of the vehicle), just inboard of the
hydraulic oil reservoir.
The starter operates when the attached starter solenoid
engages a gear on the starter pinion shaft to mesh with
the flywheel, and the starter pinion and gear begin to
spin, in turn rotating the flywheel, crankshaft and related
components within the engine.
The starter is grounded indirectly via the negative (-)
battery. The cable is routed from the battery to the main
ground stud, located on a triangular weldment
(Fig. 10– 29) above the hydraulic reservoir. Other ground
wires are connected to this stud, including the starter
ground cable, secured to the engine by one of the starter
mounting bolts.
a. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Disconnect the negative (-) battery cable at its
battery terminal (Fig. 10– 28).
Figure 10– 28. Disconnect the negative (-) battery cable.
2. Label and disconnect the positive (+) battery cable
and other wiring from the starter solenoid. Note how
the wires are installed for ease of installation later.
3. Loosen, but DO NOT remove, the three hex fasteners
securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
fall if not supported.
4. Support the starter and remove the fasteners
securing the starter to the engine. Remove the
negative (-) ground cable from its starter mounting
bolt (Fig. 10– 28).
5. Remove the starter from the vehicle.
OS1040
Negative (-)
Terminal