Ford 6610 - Wire melting

FRanch · Oct 6, 2021

Hello all,

Struggling with an issue on a new to me Ford 6610. The starter/relay wires that came on the tractor were pretty rough looking and appeared to be melted slightly. Every time I would go to start the tractor the starter would spin a few times before it would engage the flywheel.

Decided to replace the old wires (with 10 gauge) and it fired right up with no issues, so I thought I fixed the issue. The starter seemed to turn faster too.

Went out today to fire up the tractor and it slowly spun over, then I see smoke building up and the wires are melted again. Is this a relay or starter problem? I know the relay isn't factory on these tractors but I just can't pinpoint the problem. I thought maybe I have a battery going out but I can't imagine that would be burning up wires. All the connections are super clean as well.

Photo of the wires after I replaced them.

Steve@Advance · Oct 6, 2021

Wish I could see where the wires are connected...

But I suspect they are not connected where they should be.

When an aux solenoid is added,it should only carry power to the small terminal on the original solenoid that energizes the solenoid.

If it is connected to the big battery terminal, the small wire is trying to carry the entire starter load, which it can not do!

FRanch · Oct 6, 2021

Thanks for the reply!

Here is a photo to where those wires are going. They attach to the solenoid on top of the starter. I think the positive battery cable is big connection you see on top. Not sure what that little ground bracket is for on the bottom?

Are these wires not supposed to be connected to the solenoid in this way? I just took them off and replaced them how they were originally...which is obviously not correct.

This post was edited by FrogCreekRanch on 10/06/2021 at 06:29 pm.

FRanch · Oct 6, 2021

Steve@Advance · Oct 6, 2021

No, that is not right. I can't see that do anything but spin the starter
disengaged.

Move the bottom wire to the small spade terminal just right of the battery
connection.

jm. · Oct 6, 2021

Steve that was my very first thoughts and looks like the photo proves it. He is not actuating the starter solenoid at all. His secondary is carrying the starter load. One of those wires should go to the small terminal we are not seeing on the starter solenoid. I do not see how it ever started.

grizz02 · Oct 6, 2021

get rid of the first relay the starter has an solenoid with a spade connector just run a wire from a starter button or key switch that has a start position all you need is to put 12 volts to that spade on the solenoid

FRanch · Oct 6, 2021

Ok thank you! I will give that try.

Ideally I just need to get a different connector on the end of the wire so that it will fit the small spade terminal?

FRanch · Oct 6, 2021

(quoted from post at 18:44:45 10/06/21) Steve that was my very first thoughts and looks like the photo proves it. He is not actuating the starter solenoid at all. His secondary is carrying the starter load. One of those wires should go to the small terminal we are not seeing on the starter solenoid. [b:31bf0f7c19]I do not see how it ever started[/b:31bf0f7c19].

Haha, I guess that is a mystery. It would usually "spin" the starter 2 or 3 times before finally engaging. The previous owner told me it's just the way the tractor is, which didn't seem right to me.

grizz02 · Oct 6, 2021

why would you need a relay when it has an solinoid ? those 10 gage wires are trying to carry the load of 4 ga

used red MN · Oct 6, 2021

You can keep the added solenoid, remove the wire coming
off of it connected to the bottom post on the factory starter
solenoid. Install a female spade terminal on it an plug it on
the male spade on the factory solenoid. Sometimes
solenoids are added in start circuits, so the higher current
for the solenoid coil is not being fed through the ingnition
switch and other safety switches in then circuit.

Steve@Advance · Oct 6, 2021

Yes, and be sure to secure the wire with a zip tie or some way to keep the weight
of the wire and vibration from unplugging it.

There is a possibility there was some other problem with the starter that
prompted the previous owner to add the solenoid. If it still doesn't work, look
into the starter. Maybe a bad solenoid. Symptom would be a major clunk with no
starter rotation.

And sometimes an aux solenoid is added to overcome voltage drop to the solenoid.
The starter mounted solenoid requires a substantial current to energize it.
Sometimes there is too much resistance between the switch, neutral switch, and
small wire between them. The aux solenoid helps overcome the problem.

phil25 · Oct 7, 2021

Quote: Is this a relay or starter problem?....it is both, given the age of the tractor good chance its time
for a bit of starter service(bushings/brushes/cleaning) and good chance the solenoid itself could use a set
of contacts or have them cleaned/rotated. The extra solenoid is connected across to the starter solenoid
contacts and is carrying full/partial current, remove it and repair the wiring from key switch to solenoid
start terminal.
keep your stick on the ice.

Bob Bancroft · Oct 7, 2021

My advice would be to trash that Lucas starter and put something else on there. I think it was a Bosch I found to cure the same
problem on my 655A TLB.

matthies · Oct 7, 2021

It takes the load off of the key switch, very common on large trucks.

Ford 6610 - Wire melting

FRanch

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Steve@Advance

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FRanch

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FRanch

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Steve@Advance

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jm.

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grizz02

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FRanch

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FRanch

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grizz02

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used red MN

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Steve@Advance

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phil25

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Bob Bancroft

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matthies

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