DK45 HST blues

[Harry in Ky]

More good news today. I had it running for a little while with good results. It shifts without issue, has forward, neutral, and reverse. No leaks (not yet anyway) that I noticed. I didn't run it long and couldn't do much without steering, but the transmission seems to be okay so far, The floor plate is back on, the steering column, brake pedals, and all that assembly is back in place. The lines to the steering valve took up most of the afternoon. I'm certainly no fan of BSPP fittings. I think it's the fine thread that makes them so difficult to start. They have to be lined up nearly perfect for a thread to catch. Not very forgiving. There's still a lot of electrical to hook back up, dash, switches and all that.

Going to let it sit until next week sometime. I feel pretty good about my chances of getting away from it now. I do think the bulk of the frustration is behind me.

 

[Harry in Ky]

So much for what I think. Things are pretty much all assembled now, except for the plastic panels around the steering column. I have (at least) one more issue to resolve under there. The dreaded "no start" condition. As in "no signal to the starter solenoid". This was there the first time I had it back together, but I didn't really get too excited about it, figuring I could sort that out sooner or later. I just used a remote start button for my purposes and moved on.

Now I need to sort it out. Two stumbling blocks I can't seem to get past. 1) Part of the start signal goes through the operator aggravation module. Somewhere in there is a second start relay that evidently only activates when the module is satisfied with all that it oversees. I see no easy way to test that. 2) There is a range shift safety switch involved as well. This is the biggest obstacle at the moment. I've spent most of this afternoon studying the Bobcat electrical section and its included diagrams, in addition to the PDF on the DK45. In neither of them is there a clear picture of how that switch fits into all this. It doesn't show up on any diagrams in either manual. I see references to it in the Bobcat manual, but not in any context to show where or how it connects.

The actual start relay is on the firewall in the engine bay. It has power to the main terminal. The load circuit does lead to the starter. The coil circuit has ground on one side. There is no power coming to other side in start position. There a few "creative"options here, but I'd like to keep as much as possible of the safety features in place. The range shift switch for sure, if I could just figure out what wires to look for and where to look for them. In the end I may end up running new wires back there and working them in as needed.

 

[Harry in Ky]

A little more studying last night and I made a couple more discoveries. The range shift sensor (that's what they call it) isn't directly tied into the start circuit at all. I finally found it on the diagram off in a corner near the cruise control/preheat unit. It operates mainly through that unit, and its function is to select (and illuminate) an indicator light on the dash. Four lights, actually. L, M, H, and N. When the N light is on a signal is supplied the aggravation module. That in turn decides what the start and fuel stop relays do. Gotta love these simple little tractors. This darn diagram is all condensed down onto one page, a reprint at that, and rather feint in color. I have a lighted high power magnifying glass and really have to work to read any part of it.

So armed with that I plan to take another shot at it today. If the diagram and color coding match the tractor, I expect it to start with the key today, one way or a another.

 

[Harry in Ky]

Well I feel better today. I think I'm finally separated from the ball and chain. I went through the motions again, the neutral light is on, both brake pedal switches are working, PTO is off. Still the module refuses to let the starter operate. I'm done chasing circuits. The creative option was the order of the day. The start signal wires in and out of the module are now externally connected, and it starts with the key.

Miller time.