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Old 05-17-2015, 04:31 PM   #1
edwards
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Default 2001 workhorse starting circuit troubleshooting

I have a 2001 ST 480 workhorse that stopped starting. Continuity through key switch ok and continuity through accelerator micro switch also checked out (0 ohms when key on and accelerator to the floor). Battery fine. Does not turn over or click.

One weird thing is that there is only 2V at the green wire that normally plugs into the key switch on/off, when the accelerator is pressed to the floor. And this is correctly 0 V volt when the accelerator is not pressed. Shouldn't this be 12V at the green wire with accelerator to the floor?

Also, when all hooked up and the key is on and the accelerator is to the floor, I am getting no volts at the blue wire small lead to the solenoid (completes the circuit coming from the key switch and micro switch).

Does this mean there is a short or something between the accelerator microswitch and the fuse box, bleeding off the 12 volts that should be delivered to the green wire to the key switch? For the life of me I cannot figure this out. I would just pay someone to fix it but I live in the middle of nowhere and I have to deliver the STC to the nearest repair man...don't have a truck so I am stuck. HELP!
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Old 05-18-2015, 09:02 PM   #2
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Default Re: 2001 workhorse starting circuit troubleshooting

if you jump the solenoid, will it crank?
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Old 05-18-2015, 09:07 PM   #3
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Default Re: 2001 workhorse starting circuit troubleshooting

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Old 05-19-2015, 05:51 PM   #4
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Default Re: 2001 workhorse starting circuit troubleshooting

Yes, starts right up and if the key is on and the pedal to the floor it runs fine (after jumping the solenoid).
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Old 05-19-2015, 06:37 PM   #5
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Default Re: 2001 workhorse starting circuit troubleshooting

What if you unhook the wire coming from the pedal to the solenoid and apply 12v to that solenoid terminal....... will it start and run?
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Old 05-19-2015, 06:43 PM   #6
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Default Re: 2001 workhorse starting circuit troubleshooting

Follow the trouble shooting steps on page L-4 of this manual:

http://products.jacobsen.com/img/manuals/605586.pdf

That should isolate and identify the problem for you.
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Old 05-19-2015, 08:02 PM   #7
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Default Re: 2001 workhorse starting circuit troubleshooting

I did all of that and everything checked out. That is my problem. I have the manual.

Does the fact that the voltage at the key switch (when the micro switch is closed) only reads 2V, suggest that there is a problem with a bare wire somewhere I cannot find, or should it be only 2V? I don't get why there would only be 2V at that switch. I looked and I cannot find bare wires grounded or bad connections.

Thanks and sorry I am not smart enough to figure this out.
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Old 05-19-2015, 08:36 PM   #8
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Default Re: 2001 workhorse starting circuit troubleshooting

I am fairly certain that it should be 12v. The trigger voltage of the solenoid should be 12v as well since the pedal micro switch provides power to the ignition circuitry.
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Old 05-20-2015, 09:41 PM   #9
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Default Re: 2001 workhorse starting circuit troubleshooting

THANKS SO MUCH!

I tried to put 12 V on the pedal wire at the solenoid after removing the wire, and it turned over. So that proves it is not the solenoid, right? Too bad I just ordered a new one!

Ok, so if it should be 12V but it is only 2V at the key switch, and I checked continuity through the key and the microswitch and it was 0 ohms, then the only way that all can be true is if there is bare wire somewhere in the starting circuit getting grounded out,...does that seem right?

I've learned a lot in the last few weeks trying to make this work. Thanks again for your pointers.
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Old 05-21-2015, 06:53 AM   #10
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Default Re: 2001 workhorse starting circuit troubleshooting

Yes it sounds like it's grounding out somewhere along the leg from the pedal
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