1999 Ford/NH 545D PTO and Safety Switch Wiring

[PapeCAT]

Good day fellow TBN forum members:

Alright so I traded my 2006 Deere 110 with 2100 hours for a 1999 Ford 545D with 900 original hours. I had no need for the backhoe, but did need at least 3500 lb loader lift cap for setting 2x2x6 concrete blocks and also a tad more PTO power for my 7' Harley Rake. Bonus was that the Ford can fit in my garage/shop vs. sitting out in the elements.

The machine looks great and is tight overall. When I inspected it, the PTO cap was on and the PO indicated he had never used it since 2004 when he bought it used. Anyway, I pulled the cap and low and behold, the PTO spins all the time no matter what. I thought, well ok maybe I'll hook the Harley Rake up to it and load it up and see if the PTO stops. Well I never got that far because according to the Placard on the left / "driver side" fender, the lever in AFT position is PTO disengaged and the FWD position is engaged. The problem is that the tractor only starts with the PTO lever in the FWD/engaged position. I tested the PTO safety switch and the continuity to a couple of the connectors up by the bulkhead, and found that the switch was NO (aka normally open) when PTO lever in FWD/engaged position and CLOSED when PTO lever in AFT/disengaged position. I'm about to pay 60 bucks to download the Service manual for this tractor. But just wanted to start this thread as I dive into the PTO issue, leading up to potentially splitting the thing and repairing that little PTO brake pad.

 

[joecdeere]

I’ll look in my “C” series manual in the morning, but I believe there’s supposed to be a micro switch behind the sheet metal surrounding the pto lever that it depresses when the lever is back in to off position that allows it to start

 

[PapeCAT]

Thanks - that is correct. I pulled the switch out, tested it as well. It seems the logic is reversed in the wiring somewhere because it only starts when the switch is not depressed aka PTO lever in FWD position. No starter turnover with PTO stowed to the rear / disengaged. My switch is NO / Normally open, and when depressed, the circuit is closed. In order for it to work properly the switch needs to function in the opposite, I believe. I just wonder if the wrong switch is in there or if there is some other wiring mishap downstream.

 

[joecdeere]

I'll go down to the shop in the morning and see what the manual says

 

[joecdeere]

As usual with a Ford manual, not much info, I went ahead and scanned what pages had the wiring for that circuit and then one of the complete harness,
to keep from killing every ones computer I put them in a Google file, hope this helps, let me know if I can do more

click for pictures - Ford 345,445, & 545C Wiring - Google Photos

 

[PapeCAT]

Thank you!

At first glance it basically just looks like the switches are supposed to be in the Closed position to complete the starter signal. So basically if the transmission isn't in N or if the PTO is engaged, those safety switches are in the Open position. This helps and proves that the switch is operating normally. Just not sure why the tractor starts when the PTO safety switch is in the OPEN position, makes no sense per the drawing as it is in series with the transmission switch and starter circuit. I'll do some more testing today.

 

[PapeCAT]

Ok So I disassembled the switch. It has 3 terminals, middle and side is normally open / closed when depressed. This was the setting I needed. But for some reason it wasn't closing the circuit with button depressed. I had to repair the switch from the inside to get the contacts to operate correctly. I'm guessing that after the switch failed, they just rewired it and it would start the tractor but in the incorrect PTO setting (engaged)

All good now, thanks for the drawings.

 

[joecdeere]

Cheap fix is always good!

 

[Seven Gables]

Glad to hear you got the switch fixed so it starts in the off position . Curious though if the pto shuts off ? I've got 2 545d's and they are awesome tractors.

 

[PapeCAT]

The PTO always runs. This one has 900 hours and I'm the third owner. The PO said he had it since 2004 and never used the PTO. I'm not sure about the original owner. But at some point the little PTO brake wore out so it just runs all of the time. I have my 7' harley rake on there now and it starts fine with it sitting on the ground (doesn't run with some resistance) but once I lift it off the ground, it starts spinning on its own. I spoke with Bob from Ohio who was a prototype tester on these tractors decades ago and he said that it isn't worth splitting the tractor to replace the PTO brake, it will soon wear out in short order again.

I needed to get the switch fixed so I didn't start it in the ON position as I will most always have the Harley rake installed vs. box blade.

The 545D will be my last tractor. I've bought and sold many over the past 10 years. Branson 2800H, Branson 3725H, Mahindra 1626, John Deere 110 TLB, John Deere 1025R FILB.

There is nothing else besides a Fermec 650B that has the loader lift capacity and a PTO. (except for perhaps much larger Utility Tractors) I prefer the ford 8x8 transmission (made by Kubota) to the hydrostat on the Fermec for Harley Raking. I need to maintain a consistent ground speed and Engine RPM for the best results. Fitting the FORD 545D in my 8' garage is a bonus to keep it nice.