Kris,
Besides the solenoid on the starter itself, there is the Battle Short Switch S7 which connects to the Speed Switch 9-1 and a Diode CR3 (I think only on precise units) which supply power to the crank relay K3 when Switch S2 is held in Start Position.
True. But when CR3 goes bad, its bad. Never an intermediate fault. Works, or doesn't work. So I would toss that one out of the equation. As S7 doesn't have to move, its more or less there in parallel to the circuit, I would tend to not suspect it.
S9-1 is at the instant of turning the S2, in the closed position, (or not). In the norm, it works or it doesn't. Its closed and the engine spins, or its open, and nothing happens. So I would not think its part of the problem. Repeated use of the S2 will have no impact on the S9-1. It cant make it move until the engine turns. I would start with the S2, and we have tested it, (doesn't mean its not the problem). Only if I tested S2 under power, would I trust it. So we need to do that. I would also test K3. And under power. Ohms is all well and good, but its not reliable. In German, we call an ohm meter a Lügen sager. A teller of lies. The only true way to test, is under power. That leaves only the L4, start solenoid.
If Brian has a S2, Kris could borrow it and try it. The K3 is a very normal part on lots of equipment. The only problem I see is it has to be 24 volts. If you could borrow one and try it, that would be nice. The L4 is more or less mounted to the starter. You could take the starter to a shop, but that not cheap, and we can try other things first. Above all, all connections need to be tight. I would check that first. When I get done eating, I will write up how we can test S2 and S7 And K3 under load.
Crank Relay K3 then activates the Starter Solenoid.
so, we got four or five different possible devices for failure.
I am sure Guy knows the easiest way to trouble shoot this. I recently had a customer with a similar problem on his 803A and in that case it turned out to be failing crank relay.
Can we rule out your wire fix issue you had in SP Box for good? That would have to be the first thing to rule when properly fixed.
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