Starter trouble

I am working on my hesston 980. I have had trouble with this starter for many years on and off. I can always start it by jumping the solenoid with a screwdriver. Using the start keyswitch i get the click click routine solenoid attempting to pull in but wont start. Battery is good, cables are new and starter was rebuilt last fall. All these attempts have not fixed the problem. When it works the starter turns the engine over and it starts great.

Sounds like a bad solenoid.

Do a continuity check on the switch and any connections from the switch to starter . On a tractor that age someone could have crimped a butt connector or spade connector somewhere in the circuit those can lose connection and cause the trouble you?re having

I had a John Deere mower that was like that. Running voltage checks, every time it went though a safety switch, I lost voltage. I had a total of 5 safety switches between the key switch and the starter.
By the time it got to the starter solenoid, I was down to 8.6 volts. Used wd40 to clean up the switches and worked them manually to clean them up. By the time I got done cleaning everything, I was back up to 12.4 volts. You may have some dirty safety switches or as others have said maybe some bad connections along the way. Time to get the multimeter out and go to work.

Will try to fill in some more info. I have it in the shop at the moment. I have been checking voltages looking for a bad wire trying to test and figure this out. Voltages under load are fine all the way through the key switch and clutch safety switch down to the solenoid. I have replaced ring terminals at the solenoid. Current draw to the solenoid is about 12 amps with the key engaged/ starter not turning and voltage at about 11.9 down from 12.4 with the key switch engaged.

Could it be possible the starter/solenoid is working normal but hanging up and not engaging the ring gear but hung up.

I agree it appears as a bad solenoid type symptom but the new solenoid on the freshly rebuilt starter acts no different than the previous solenoid.

One thought i just had is i need to check the current draw to the starter with the solenoid engaged. Cause 11.9 is somewhat low for a 12 amp draw right?

I have put a couple of Denzo starters onto my Case tractors. I had to run the starter wire from key switch to a separate solenoid, wired with #8 wire from bat to the start terminal on the starter solenoid to get enough current to activate the starter solenoid.-----Loren

I had that thought as well. It may be the fix for it but when i use a pliers and attempt to ground the hot battery terminal to the start terminal on the solenoid i get the same results... no start just click.

This has been a problem for 10 or more years on this tractor but just lately it has reached the point it wont start more than it will. Always been a very random problem but could always jump across the solenoid to start.

Yesterday i took the starter off and wired it back to the battery but not through the keyswitch ( may try that next ) just manually jumping, it started the starter with good torque and ran well.

Why not taker it to a starter repair shop? My starter/generator guy is usually in the $100 ballpark new bushings and cleaned up wiring makes a big difference on an old starter.

A couple things you can do...

First, I would take the starter off, completely disassemble it.

Look for any signs of wear or binding. Look at the spiral grooves where the drive slides on the shaft. Imagine what happens when the fork pushes against the drive. Put it through the motions feeling for any binding. Could be the shaft has some wear, or the inside splines of the drive are worn.

Look at the plunger, does it slide freely into the solenoid? Can you feel it contact the button in the end, and is it pushing the button far enough to make the contacts? A good solenoid can fully seat the plunger even if the gear does not fully engage the flywheel. Theory is, once the contact is made, the drive will turn just enough to go ahead and engage without grinding.

Be thorough in your investigation, don't assume anything without verifying. Take measurements, observe all the motions. There is always a possibility the rebuilders did not do a thorough job, or there was a parts mismatch in the starter from the factory.

If the rear main is leaking, oil inside the starter can cause problems, especially in cold weather. Cold oil makes the plunger hard to pull in. Oily, sticky, worn brushes can mimic solenoid problems, but usually result in a "nothing" situation, no click.

The new solenoid, I'm assuming this is a Delco starter, was it a Delco brand? If not, that could be a problem. Might try finding a factory brand name solenoid over an aftermarket.

And, if all looks good, as others have said, add a primary relay to give full battery voltage to the solenoid. I would use the old Ford fender mount solenoid. Keep the wiring short and heavy, at least #10 or #8, solder on heavy duty ends. The heavy duty solenoid will give better contact than a screw driver across the terminals, so that may do the trick.

(quoted from post at 20:10:05 05/23/19) I have put a couple of Denzo starters onto my Case tractors. I had to run the starter wire from key switch to a separate solenoid, wired with #8 wire from bat to the start terminal on the starter solenoid to get enough current to activate the starter solenoid.-----Loren

Click to expand...

I've done the same on my NH and has worked since. From what I understand it's become more common with all of the safety switches and electronics in a lot of newer equipment and the big trucks.

The guy with the JD mower that had issues might be close to what's happening. JD even offered a kit for the lawn mowers that adds a relay into the system.
Easy enough to make up your own kit. But ask a local JD dealer about the kit for the mowers as it comes with instructions.

If you can start it by jumping the solenoid the starter Is not the problem it is in the key switch or the circuit from the key key switch to starter . There is probably some safety switches on the tractor to make sure the tractor is in park the pto is off before it will start with the key switch