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Read and study intently the TM that I sent to you. These machines are designed very well, and the more that you get to know yours the easier it gets to troubleshoot things like you’re dealing with. I’m a little confused about your starter. So you have a new one that is causing the battery cables...
I would read the TM to find out. One other question that I have. When you say that you get "sparks" while connecting your battery cables, are they high current sparks or low current sparks? Is the master control switch in the off position?
https://www.steelsoldiers.com/attachments/tm-5-6115-585-12-pdf.631487/ I would read pages 134 - 141 in this TM. It has a lot of good information about the starter. BUT...if you are getting high current sparks when connecting your batteries EVEN WITH all of the wires and the cables removed from...
Are all of the cables and wires remover from the starter and the starter solenoid? If so, then your problem is somewhere else. I would double check the way that your batteries are being connected. In 24VDC you should have two 12V batteries connected in series.
Another way that you can find out what wire or what cable is connected incorrectly is to remove all of them. Connect your batteries as normal and then, one by one connect each wire or cable to your starter the way that you believe they should go. When you connect one incorrectly you will see...
Something must be connected wrong at the starter, the starter solenoid, the ground cables etc. You will need to familiarize yourself with the electrical schematics and check that each of the wires/cables in the starter area are connected properly. It's virtually impossible for anybody here to...