Starting Issue

AC-HD6G

New User
Alright I'm going to list everything I have done and do my best to explain. AC HD6G Track Loader. 24 volt system, two brand new batteries hooked up in series 1000 CCA(each batt.) at 32 degrees. Ground strap #1 attached to the frame below the gas tank I pulled the starter sent it to TX Alternator and Starter in Austin TX, manual solenoid rebuilt, replaced brushes, New gear. Hooked everything back up the way it was and hit the peg(kick a peg to start it) and nothing. No click or spinning, absolutely nothing. Took the starter back off and took it back up and it tested fine. The guy at TX Alt said that the bolt sticking off the end of the starter was for ground. I thought it may have been grounded through the case because I had heard of that and there was nothing hooked up to that post before, although the bolt was resting up against the oil filter housing base so it might have been grounded there(or not, I don't know.) So he made me a ground strap and I grounded it to the frame. It turned over one turn of the engine and thats it. It would barely turn the motor. Each battery terminal and the starter terminals get pretty warm to the touch. I cleaned all the terminals and connections. Where I have the new ground strap #2 hooked to has been scraped good with a wire brush. Right now I hit the peg and it just makes a clank noise. Any ideas or suggestions are appreciated. I was told the set-up is pretty straight forward with it being such an old machine. If you need pics let me know and I can post some tomorrow. Hopefully we can figure this out. Thanks again.
 
(quoted from post at 20:33:28 03/23/15) Internal corrosion in the battery cable? Try a new one.

That is the only thing I have not done..I will try it tomorrow and let you know how it turns out.
 
It's not impossible that one of your new batteries is
defective unless you have put a load tester on each
one to confirm.
 

Both batteries were tested under load and they are perfectly fine, I pulled both cables off and had them checked out they are both pretty much knew so no issues there. Voltage is good to the solenoid and through to the starter when I hit the peg starter. Every once in a while the motor will crank one revolution or maybe two then it just makes the clanking sound like a starter gear is engaging but doesn't have enough juice to spin the motor. I am thinking maybe I should disconnect the new ground strap and grind down the surface on the frame and then hook it back up. I already scrubbed the hell out of it with a wire brush before I hooked it up the first time...
 

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