2008 5600T Will Not Start

[GitchiGummi]

2008 Toolcat 5600T

We had a big storm here with lots of blown down trees. I was moving branches and limbs with the forklift attachment on a hot day (85 is hot here in Northern MN). I was turning the machine on and off every half hour or so for time on the chainsaw. After multiple cycles, the Toolcat failed to start. I could hear a clicking sound from the engine compartment. I assumed this was the starter solenoid. I tightened the connection of the main battery cable on the start solenoid and checked all of the ground connections and still experienced the same conditions when turning the key. Finally, I jumped from the battery directly to the starter and was able to get the machine started.

I worked for a few more hours leaving it running the entire time. Near the end of that time I got a low battery light. Upon shutting it off again it would not start just like before. Battery was under 12 V. I was able to charge the battery and jumped to the starter to get the machine running again. Voltage at battery with machine running was under 13. This led me to think that the alternator (original one is in there) may not be charging the battery and that may be why the battery wasn't moving the starter. Also, I cracked the insulator on the starter solenoid when I tightened the connection (will use two wrenches next time).

I took the 2 year old battery to the auto parts store where I bought it. It tested "good, needs charge". I charged it.

I replaced the starter with a new starter (not re-manufactured).

I have full battery voltage at the main terminal in to the start solenoid (the big red wire that comes from the battery).

I have voltage at the solenoid switch terminals when the key is turned to start.

Voltage at the starter drops rapidly when the solenoid engages and the starter does nothing.

I checked ground connections at the starter and frame on the starter side and at the battery. They appear clean and are tight.

I have yet to change the alternator out. If you have this machine, you know that getting to the alternator requires some contortion, passenger seat removal, etc.

Does anyone have any advice or thoughts about this situation?

How does the armrest switch prevent starting?

 

[GitchiGummi]

Update:

I swapped out the battery for another known good battery. Upon jumping from the positive battery terminal to the starter solenoid, I am able to start the engine with the key. This is with the cable from the battery disconnected from the starter. This leads me to believe that there is a problem between the battery and the starter in the cable or something else is draining power along that path.

 

[GitchiGummi]

The terminal on the positive battery cable at the battery was corroded internally. It is swedged on at that point and really did not look like it could fail internally. I finally diagnosed this using the multimeter to check Ohms across various points. I started with one lead on the battery post and one on the terminal which checkout fine. When placing one lead through the insulation just past the terminal and one on the terminal, I found resistance. I cut the terminal off and replaced it. I am back in action. I am glad to not have to replace the entire battery cable.

 

[itsafarm]

I'm having the same issues