wont start until cycle headlights 763

[gearmaker2003]

2002 763G 1800 hrs. I have had this about 4 months. Bought it for $1000 and had to replace the spool seals and a few adjustments and she ran great until a couple of weeks ago. I have dug my foundation with it and moved about 300 yds of dirt. I was sitting on my porch and the Bics lights were going off and on ,loader was out in the pasture. Did not seem to affect loader but it kept clicking. Now , today will not operate starter until I cycle the head lights, front, rear, off, then it will start. Everything works I will start moving and the loader will crash to a halt and kill the engine as if traction lock applied. I did not see any broken wires. Still will only start if I cycle head lights, any thoughts? thanks, David 1920 hours now

 

[OldMachinist]

Sounds like a bad battery ground. Clean the battery cables on both ends and check the cab ground wire.

 

[gearmaker2003]

Sounds like a bad battery ground. Clean the battery cables on both ends and check the cab ground wire.

Okay checked All grounds, Pulled both right and left console checked plugs and sockets. Boards looked good no contamination. No 12 c power to the key switch either. In fact no Protected power at all. Pulled bics and cleaned box J3 has power at A1 ,A2 (unswitched power) but no protected power at J2 which feeds cab I think wire number 1200. Fuses good back of fuse box after removing rubber boot clean. Power at Fuse #4 computer power and Fuse #9 unswitched. should I have protected power at J2 F1 of the bics unit? Can I jumper power to Cab via 1200 red/white wire to known supply and test the components? Thanks for help David

 

[gearmaker2003]

Okay checked All grounds, Pulled both right and left console checked plugs and sockets. Boards looked good no contamination. No 12 c power to the key switch either. In fact no Protected power at all. Pulled bics and cleaned box J3 has power at A1 ,A2 (unswitched power) but no protected power at J2 which feeds cab I think wire number 1200. Fuses good back of fuse box after removing rubber boot clean. Power at Fuse #4 computer power and Fuse #9 unswitched. should I have protected power at J2 F1 of the bics unit? Can I jumper power to Cab via 1200 red/white wire to known supply and test the components? Thanks for help David

Okay I found the problem. As I was taught when younger man " Follow the money" Power. In connector J2 the crimp was bad leading to high resistance but I could not find this with the multimeter I found it with test load. Made a new crimp and all problems solved. Good news is every connector has been serviced and all crud is out of BICS box! Thanks, David

 

[OldMachinist]

Okay I found the problem. As I was taught when younger man " Follow the money" Power. In connector J2 the crimp was bad leading to high resistance but I could not find this with the multimeter I found it with test load. Made a new crimp and all problems solved. Good news is every connector has been serviced and all crud is out of BICS box! Thanks, David

Glad you found the problem. I knew it sounded like a bad connection. When you cycled the headlights it likely arced the connection to get the juice temporarily flowing.