Dorman 85936 Key Style Metal Electrical Starter Switch User Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of the Dorman 85936 Key Style Metal Electrical Starter Switch. This product is designed for various automotive and industrial applications requiring a reliable ignition starter switch. Please read this manual thoroughly before proceeding with installation or operation.

Dorman 85936 Key Style Metal Electrical Starter Switch with four keys

Image 1.1: The Dorman 85936 Key Style Metal Electrical Starter Switch, shown with its accompanying set of four keys.

2. Safety Information

Adherence to safety precautions is crucial during installation and operation to prevent injury or damage to the product and vehicle.

Disconnect Power: Always disconnect the vehicle's battery before attempting any electrical installation or maintenance.
Proper Tools: Use appropriate tools for installation to avoid damage to the switch or surrounding components.
Wiring: Ensure all wiring connections are secure and correctly insulated to prevent short circuits. Refer to the vehicle's specific wiring diagram if available.
Professional Assistance: If you are unsure about any part of the installation or wiring process, consult a qualified automotive technician.
Voltage Compatibility: This switch is designed for 12-volt systems. Verify compatibility with your application's voltage requirements.

3. Package Contents

Verify that all components are present in the package:

Dorman 85936 Electrical Starter Switch (1 unit)
Keys (4 units)

4. Specifications

Key technical specifications for the Dorman 85936 Starter Switch:

Feature	Specification
Operation Mode	Manual
Current Rating	30 Amps
Operating Voltage	12 Volts
Contact Type	Normally Closed
Connector Type	Plug In
Terminal Type	Solder
Dimensions (L x W x H)	5.3 x 4 x 1.9 inches
Circuit Type	1-way
Actuator Type	Push Button (Key Style)
Contact Material	Metal
International Protection Rating	IP54
Number of Positions	2 (Note: While listed as 2, the switch functionally provides OFF, ACC, IGN, and START positions. Refer to wiring for full functionality.)
Item Weight	0.01 ounces

5. Installation and Setup

Follow these steps for proper installation of the Dorman 85936 Starter Switch:

Preparation:
- Ensure the vehicle's battery is disconnected to prevent electrical hazards.
- Identify the mounting location for the switch. The switch requires a circular opening for mounting.
- Gather necessary tools: wrenches, wire strippers, crimpers, electrical tape, and a multimeter for testing.
Mounting the Switch:
- Insert the switch body into the prepared mounting hole.
- Secure the switch using the provided retaining nut on the front side. Tighten firmly but do not overtighten.
Image 5.1: Side view of the switch, illustrating the mounting nut and terminal posts.
Wiring Connections:
The Dorman 85936 switch typically features four terminal posts on the rear, labeled for specific functions. Refer to the image below for terminal identification.
Image 5.2: Bottom view of the switch, showing the labeled terminal posts.
- BAT (Battery): Connect this terminal to the main positive (+) 12V power source from the battery, typically through a fused circuit.
- IGN (Ignition): Connect this terminal to the ignition system components that require power when the key is in the "IGN" or "RUN" position (e.g., engine spark, gauges, charging feedback).
- ACC (Accessory): Connect this terminal to accessories that require power when the key is in the "ACC" position (e.g., radio, wipers). Note that the ACC terminal may lose power during the "START" position to protect accessories.
- START (Unmarked Middle Post): This is the momentary contact terminal. Connect this to the starter solenoid trigger wire. This terminal is active only when the key is turned to the "START" position and springs back to "IGN" when released.
Ensure all connections are clean, tight, and properly insulated. Verify correct polarity before reconnecting the battery.
Final Check:
- Double-check all wiring against your vehicle's diagram and the switch's terminal functions.
- Reconnect the vehicle's battery.
- Test the switch functionality as described in the "Operation" section.

6. Operation

The Dorman 85936 Key Style Metal Electrical Starter Switch operates with four key positions:

Top view of Dorman 85936 Starter Switch showing keyhole

Image 6.1: Top view of the switch, showing the keyhole.

OFF Position:
- This is the default position where the key can be inserted or removed.
- All electrical circuits connected to IGN, ACC, and START terminals are de-energized.
ACC (Accessory) Position:
- Turn the key clockwise from OFF to the ACC position.
- This position provides power to accessory circuits (e.g., radio, wipers) without engaging the ignition.
IGN (Ignition/RUN) Position:
- Turn the key clockwise from ACC to the IGN position.
- This position energizes the ignition system and other essential vehicle components.
- The engine will run in this position.
START Position:
- From the IGN position, turn the key further clockwise to the momentary START position.
- This engages the starter motor.
- Release the key once the engine starts; it will automatically spring back to the IGN position.

7. Maintenance

The Dorman 85936 Starter Switch is designed for durability and requires minimal maintenance.

Regular Inspection: Periodically check the wiring connections at the back of the switch to ensure they remain tight and free from corrosion.
Cleaning: Keep the exterior of the switch clean and free from dirt, dust, and moisture. Use a dry cloth for cleaning.
Key Care: Avoid excessive force when inserting or turning the key. Do not use damaged or bent keys.

8. Troubleshooting

If you encounter issues with your Dorman 85936 Starter Switch, consider the following troubleshooting steps:

Problem	Possible Cause	Solution
Engine does not start when key is in START position.	Loose or corroded wiring connections. Faulty starter solenoid or starter motor. Low or dead battery. Incorrect wiring to the START terminal.	Check and secure all wiring connections, especially to the START terminal. Test battery voltage and charge if necessary. Inspect starter solenoid and motor for proper function. Verify wiring against vehicle's diagram.
Accessories (radio, wipers) do not work in ACC position.	Incorrect wiring to the ACC terminal. Blown fuse in the accessory circuit. Faulty accessory component.	Check wiring to the ACC terminal. Inspect and replace any blown fuses. Test the accessory component directly.
Key sticks or is difficult to turn.	Debris in the key cylinder. Worn key or switch mechanism. Improper installation causing binding.	Attempt to clean the key cylinder with a specialized lock lubricant (avoid oil-based lubricants). Ensure the switch is mounted correctly and not under stress. If persistent, the switch mechanism may be worn and require replacement.
Starter remains engaged after engine starts (key returns to IGN).	Faulty switch mechanism (internal spring not returning). Starter solenoid sticking.	Immediately turn the key to OFF to disengage the starter. Inspect the switch for proper mechanical return. If it does not return freely, the switch may be defective and require replacement. Check the starter solenoid for proper operation.

9. Warranty and Support

Dorman products are manufactured to high-quality standards. For specific warranty information or technical support, please refer to the official Dorman website or contact Dorman customer service directly. Keep your purchase receipt for warranty claims.

Dorman Products: www.dormanproducts.com

Dorman 85936