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SERIES 638 NO VOLTAGE TO STARTER SOLENOID

To determine if no voltage to the starter solenoid is causing the engine to crank slowly or not crank, perform the following steps: ‪

  1. Visually check the battery cables for exposed or cut wires.
    1. If the battery cables are exposed or cut, repair as necessary (refer to section ) and proceed with step of inspection.
    2. If the battery cables are not exposed or cut, reuse the component and proceed with step of inspection.
  2. Visually check the solenoid cables for exposed or cut wires.
    1. If the solenoid cables are exposed or cut, repair as necessary. Refer to section .
    2. If the solenoid cables are not exposed or cut, check the starting circuit connections. Refer to section .

Repair of Cable Using the Splice Method

Perform the following steps to repair cable(s) using the splice method: ‪

  1. To repair straight leads using the splice method:
    1. Locate broken wire.
    2. Remove insulation as required; be sure exposed wire is clean and not corroded.
    3. Slide a sleeve of shrink wrap on the wire long enough to cover the splice and overlap the wire insulation.
  2. To repair leads using solder is an optional method:
    1. You must use rosin core solder.
    2. Check the exposed wire before the splice is crimped in its connector. The exposed wire must be clean before splice is crimped.
    3. Use a suitable electronic soldering iron to heat the wires. Apply the solder to the heated wire (not the soldering iron) allowing sufficient solder flow into the splice joint.
    4. Pull on connector to ensure crimping and soldering integrity.
  3. Verify repairs. Refer to section .

Test Engine with Repaired Cables

Perform the following to determine if the repaired battery cables resolved the fault: ‪

  1. Attempt to start and run the engine.
    1. If the engine failed to start and run, check for loose or corroded starting circuit connections. Refer to section .
    2. If the engine started and ran, no further troubleshooting is required.