D1105 Starter Issues

[JWR]

In replying, I meant to mention your statement and expand a little - then forgot. The OP'S problem description just sounds SOoo much like what I went through with starters, I can't imagine the relay won't fix his problem.
Hopefully he gets it straightened out.

At least with my BX2200 the insufficient voltage at the solenoid primary was the culprit (and sounds like it was with your starter issues too.)
When that is the problem, the starter or solenoid or one of the relays prior to all that will make some clicking noises but the engine will not turn. In OTHER kinds of issues (e.g. like my B2150 where I have to whack the starter some once in while to get it to turnover there IS NO NOISE at all. ) So we just don't know.

The OP's problem might not be the low voltage getting to the solenoid but something else instead. That's why I suggested he try a battery charger (normally putting around 13.8v on the battery terminals) to see if it would then start. If it does that would confirm he has the "low voltage at the solenoid" type of issue. [And using the battery charger is to get the higher voltage, NOT implying anything wrong with the battery at all.] If the charger does NOT cause it to start, then he has some other kind of issue. OP has not mentioned whether he gets any kind of noise when trying to start and it fails (or not.) He has had 2 starters on and off multiple times and has to be frustrated big time by now. Let's hope he has the "low primary side voltage to the solenoid" type of problem because that is easy to fix and relatively cheap. However, with no mention of the noise when trying to start I fear it is some other problem.

 

[RjCorazza]

In my early years in the fire dept, we did have an engine with a hammer chained to the vehicle for whacking the starter! There was also an air hose that had to keep the air brake pressure up, and a garden hose trickling water into the tank to keep it full. It was a disaster.
I honestly am not certain, but my low voltage starter problem may have made slight solenoid clicks, or no sounds at all sometimes. It was several years ago.

 

[aesmith]

Don't need a heavy cable just 12 vdc on the small connector. I believe it is a single wire and grounded through the starter.

That's correct, just a single wire and although it has a special latching connector, a standard 1/4" spade is a good fit for test purposes. For a quick test that could just be jumped to the 8mm stud where the main battery cable connects to the starter.

I was thinking more about the teeth and meshing. If this particular starter doesn't turn to ensure it meshes, but just pushes the stationary pinion towards the crank, is it intended that the bevels on the pinion teeth guide the meshing, pushing the pinion clear? If that's the case then maybe if there's a bit of resistance to turning the pinion that could cause it to either block, or to need more force to engage. I think that would be fairly easy to check by taking the back off the solenoid and pushing it in, if the teeth are blocking then it will be at least an inch short of full travel.

Unfortunately neither of these tests can be done until it next fails.

 

[aesmith]

When that is the problem, the starter or solenoid or one of the relays prior to all that will make some clicking noises but the engine will not turn. In OTHER kinds of issues (e.g. like my B2150 where I have to whack the starter some once in while to get it to turnover there IS NO NOISE at all. ) So we just don't know.
...
OP has not mentioned whether he gets any kind of noise when trying to start and it fails (or not.)

Sorry I missed this. I would say in general it makes no noise at all when the key is turned to "start", I just see the instrument lights dim a little which shows it's drawing current. However sometimes there's a click when I release the key. I am not sure if that could be the heater plug relay though.

 

[JWR]

Sorry I missed this. I would say in general it makes no noise at all when the key is turned to "start", I just see the instrument lights dim a little which shows it's drawing current. However sometimes there's a click when I release the key. I am not sure if that could be the heater plug relay though.

I hesitate to say because I do not know what differences there are between your engine and the one in the BX2200 and the small John Deere. When I had the "insufficient voltage getting to the solenoid" it would click rapidly when you turned the key part way and then when you turned it further (to the point where the engine should crank) it went silent. I'm thinking with your's not clicking or making noise at all yet drawing some current you have some other kind of problem with your starter.

 

[aesmith]

Cheers, I would think any noise before the crank position is probably irrelevant. Our machine make regular clicks as soon as it's On, from the fuel pump.
Referring to earlier comment turning I've tested onto Heat only and there's no sound either when heat come on or off. So maybe trying the starter there's no noise because the solenoid hasn't travelled fully, rather than hitting an obstacle. The a click when the key's released as it springs back.