Lull 944E-42 Service Manual - Manual (Page 674)

Electrical System
9.164 Model 644E-42/944E-42 Rev. 6/04
9.11.2 Starter
The starter (1) is located on the left side of the engine, just
inboard of the hydraulic oil reservoir.
The starter (1) 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 (1) is grounded via the negative (-) battery
cable (2) and the engine ground strap (3). The
negative (-) battery cable is routed from the battery to the
starter ground stud. The engine ground strap is routed
from behind the ground buss bar on the engine block to
the frame ground stud, located on the support channel on
the firewall.
a. Testing the Starter on the Engine
If the starter does not engage when the ignition switch 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, ignition
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.
b. 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.
4. For additional information on the starting circuit refer
to Section 9.8.25, “644E-42 Engine Start Circuit &
Troubleshooting.”
MU6540
1
MU6550
2
3
1