ELECTRIC SYSTEM
CD5515-2/YB5515-2 SERVICE MANUAL
3-6
Published 1-20-2017, Control# 483-02
Charging the Battery
1.
Always connect the positive wire (normally red) of the
battery charger to the positive (+) terminal of the battery
first.
2.
Connect the negative wire (normally black) of the battery
charger to the engine or frame, far enough away from
the battery to inhibit explosion should a spark occur.
NOTE:
Sparks occur when current moves from the positive
to the negative terminals of the charger. If you
disconnect either of the connections, the current in
both wires is stopped.
3.
When disconnecting the charger, always remove the
negative (-) or ground connection first. Wait
approximately one minute after the charger has stopped
before disconnecting the chargers positive (+) wire. This
procedure will decrease the possibility of explosion of
hydrogen gas around the battery.
STARTING CIRCUIT
The starting circuit includes the battery, starter motor and
solenoid, auxiliary start solenoid, starter relay, park brake
switch, and the ignition switch.
General Inspections
Many starting problems can be found by making the
following checks:
1.
Check that the parking brake is engaged.
2.
Check battery condition. Charge or replace the battery
as necessary. Clean battery posts and cable connectors.
3.
Inspect wiring for worn insulation or other damage.
Inspect all connections at the starter motor, starter
solenoid, starter relay, and wire harness plugs. Clean
and tighten all connections and replace any bad wiring.
4.
If the starter still does not operate after correcting the
circuit, perform the Starting Circuit Check.
Starting Circuit Check
NOTE:
If the starter will not crank the engine, the following
checks will help find a faulty component in the
starting circuit. Use a test lamp or voltmeter to
perform the checks.
1.
Place the ignition switch in the OFF position and
disengage
the parking brake.
2.
See the electrical schematic at the end of this manual.
Momentarily connect a jumper cable to the “B” and “S”
terminals on the starter solenoid.
a.
If the starter operates, the starter and solenoid are
good. The problem is somewhere between the
solenoid and the ignition switch. Go to step 3.
b.
If the starter does not operate, connect the jumper
cable to the “B” and “M” terminals on the starter
solenoid. If the starter operates correctly, the
problem is in the starter solenoid. Replace the
solenoid. If the starter still does not operate, the
starter is bad and must be repaired or replaced.
3.
Check the voltage at the “BAT” terminal of the ignition
switch. If no voltage is indicated, there are wrong
connections or damage to the wiring between the starter
and the ignition switch. If voltage is indicated, go to step
4.
4.
Turn the ignition switch to the START position and check
voltage at the start “ST” terminal. Go to step 5 if voltage
is indicated. If no voltage is indicated, replace the
ignition switch.
5.
Make sure that the parking brake is engaged. Have
someone hold the key switch in the START position,
check for voltage at wires 156 and 2 on the neutral start
relay located under the instrument panel. If voltage is
indicated at the relay wire 2, go to step 6. If there is no
voltage at wire 156, check the wire to the ignition switch.
If there is voltage at wire 156 and no voltage at wire 2,
replace the relay.
6.
Turn the ignition switch to the START position. Connect
a jumper wire between wires 2 and “B” on the starter
solenoid. If the starter operates, the starter relay is
defective and must be replaced. If the starter did not
operate, go to step 7.
7.
With the ignition switch in the START position, check for
voltage at the switch “S” terminal of the starter solenoid.
If there is no voltage, the problem is in the wire from the
starter relay to the starter solenoid. Repair or replace the
wiring. If voltage is indicated, the problem is in the starter
solenoid.
WARNING
Batteries produce explosive gases. Keep sparks, flame
and lit smoking materials away. Ventilate when charging
or using batteries in an enclosed place. Always wear eye
protection when working near batteries.
CAUTION
The ignition switch must be in the OFF position when
performing steps 1 and 2. If the switch is in the ON
position, the engine may start if the parking brake is
engaged. Personal injury is possible.
Reference Only
