Hello all. Haven't been on Mud for awhile since I last owned my 3x'd 40th about 12 years ago.
Jumped back into the obsession with both feet with a 3x'd 1991 HDJ81.
I was mid upgrade and had just finished installing a winch in the ARB bumper when my troubles began. I killed the battery winding the cable back in, I threw a charger on it while I went to work on something else. When I came back I think I started the truck up and reeled in the remainder of the cable. A few starts later, my starter stuck. I ran around banging on it and trying to pull the battery cables to get it to stop grinding away. Finally got cables pulled and got it shut down. A starter contactor build was in my future..........after a steep learning curve on 24VDC starting systems!!! The starter contacts were indeed fused together and the rebuild was simple. I slapped in the starter and went to fire up "Turbo." Nothing.......nada......well not nothing, the 24 combo relay seems to be the only thing clicking under the hood when keyed to start.
I have the FSM and am fairly good with electrical circuits, so I figured I'd be able to located the issue w/an afternoon and my DMM. So far I have tested or changed the following:
This evening I'll verify voltage at the starter and inspect the block ground. This may address the issue w/jump starting from the starter relay, but doesn't address the non-key start issue. Any ideas, experiences, or something I've missed?
Thanks.
Jumped back into the obsession with both feet with a 3x'd 1991 HDJ81.
I was mid upgrade and had just finished installing a winch in the ARB bumper when my troubles began. I killed the battery winding the cable back in, I threw a charger on it while I went to work on something else. When I came back I think I started the truck up and reeled in the remainder of the cable. A few starts later, my starter stuck. I ran around banging on it and trying to pull the battery cables to get it to stop grinding away. Finally got cables pulled and got it shut down. A starter contactor build was in my future..........after a steep learning curve on 24VDC starting systems!!! The starter contacts were indeed fused together and the rebuild was simple. I slapped in the starter and went to fire up "Turbo." Nothing.......nada......well not nothing, the 24 combo relay seems to be the only thing clicking under the hood when keyed to start.
I have the FSM and am fairly good with electrical circuits, so I figured I'd be able to located the issue w/an afternoon and my DMM. So far I have tested or changed the following:
- New batteries.
- All fuses are good.
- Bypassed the AM1 fusible links and problem remains, are there fusible links elsewhere. The only ones I see are on the DS battery 1 for the glow plugs and double pin plug.
- Checked (what I think was the) neutral safety switch, and it was fine.
- Followed FSM troubleshooting for 24 combo relay and starter relay both were functional.
- I pulled the key switch and it tested good.
- I actually pinned out the voltage converter timer (That's an absolute biatch!) and it tested ok, voltages were in the 5-7VDC range and not 12VDC but manual did not state what voltage you would have at the pins, just said VOLTAGE YES/NO for the tests.
This evening I'll verify voltage at the starter and inspect the block ground. This may address the issue w/jump starting from the starter relay, but doesn't address the non-key start issue. Any ideas, experiences, or something I've missed?
Thanks.