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Message: <blockquote data-quote="mustang2105" data-source="post: 7567" data-attributes="member: 628"><p>Well i thought i killed the machine the other day with the starter and all. Went there today and it fired right up! I got about 3 hours out of it before it started doing the same thing. Popping that 20 amp breaker. I took the panel apart and switched the breakers but still popped on another breaker so i guess it ain't the breaker. I noticed the breaker pops at the same time the fuel solenoid pulls. So i disconnected it and breaker stayed in. HMmm maybe it that fuel solenoid. It was hot as heck when i touched it. I tried putting a wet rag on it too cool it down. Breaker stayed in and machine starter for about a minute. I tried starting it again and saw smoke coming out the engine compartment. Uh oh i jumped out to make sure i wasn't having a melt down. Didn't see any wires burnt but now the igniton key won't turn over the engine. I found the starter relay and tried to touch the white terminal with 12volts but nothing happened. So i took the 16 gauge wire and went dirrecty to starter solenoid. The damn wire started to burn but i'm thinking maybe it did it because i was touhing it by hand and it carries high amps. I came back five minutes later and tried it again. Starter turned engine over. Tried it again wire started burning again....... Anyway i looked at the electrical schmatics in the parts book. Seems this machine has 2 starter relays which i think is stupid. It has one going from the ingition key to relay in left side indicator panel. then it goes from relay output to another relay in the engine compartment. I think the two starter relays i think may have to do with safety system. One thing is find extremely distubing is that the wire on the starter solenoid is 16 gauge or less! A gasoline engine on a car carries at least a 10 gauge! So i'm thinking that hurts the starter and makes for the tough cranking and clicking. Maybe even overheating. I tried jumping battery to starter motor directly and that was a bad idea starter motor was turning without engaging flywheel and when it took the power off it was still turning by itself. Is that supposed to happen? Well my next step is to get a remote starter switch to see if i can get the starter to work. If not i guess i'll be taking starter out. Man that looks like a bitch they didn't leave much room for access and i can get the arms up if engine won't start. Either way i plan to bypass all those starter relays and install a momentary push button switch directly from starter to battery with a fuse by battery with 10 gauge wire. Does anyone think this is a bad idea? That eliminates the top man and middle man. I think the stalling may have something to do with that fuel solenoid. Why must they put electrical stuff on a diesel engine. I'm going to have to find out how to rig the injector pump lever in the on position and see if it still dies out since i changed the filters and they look clear and the problem seems intermittent. I checked the batterry and alternator. Battery is good. Alternator wasn't putting out so i tapped it with a hammer and it starter working. Maybe be the bad connection on the trigger wire but it was fine after that. So since the starter turned over without hesitation next day does that mean it overheated? Because it was turning over but slow liek the battery was shot. But next day worked like a charm until the breaker started popping and machine shut off. The it started with the slow routine again. Anyway let me run a 10 gauge to starter and see what happens. All input is greatly appreciated. Thank You Everyone</p></blockquote><p></p>

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