DR Brush Mower will not crank

[RobertEH]

I am not the most mechanically astute person so bear with me.

Equipment info
• DR Power Field and Brush Mower Pro 26 14.5 HP
• Brush Mower Model: AT45026BEN
• Engine Model: 31R6770017G1 (Model 310000 in the manual)

Situation
I have a DR Mower Pro26. It has mostly sat for the last year - inside in the garage. Oil is clean and fresh, Battery was on a trickle charger over the winter and shows charged ~12 volts.

I went to use it a week ago. It cranked fine and started right up. I had it in first gear and mowed about a 20 foot section. I attempted to shift into reverse to back up and the cable used to downshift broke. the engine remained on but I was unable to downshift out of first. I shut down the engine and pushed it back to the garage.

I jerry-rigged a temp fix for the cable while I awaited the replacement cable. I am now able to move thru all the gears.

Problem
Now to Problem. When I turn the key, nothing happens. no buzzing, no attempt to start, nothing.

Troubleshooting so far
1. I went back to the manual and re-read the starting instructions. PTO must be disengaged to start, and the gear must be in neutral. There is also a "plug" for the neutral disengage switch below the handlebars on the lower part of the engine area that appears to be solidly plugged in.
- I verified that all of these seemed fine. When in gear it is very difficult to roll the mower by pushing, and when it is in neutral, it of course rolls well. So I am positive the engine is in neutral when I am trying to start it
2. Verified the battery connections are secure and the battery has at least 12 volts. All check out
3. Verified the PTO was disengaged
4. Verified the switch for the key has all the connections still securely attached.
5. For what it is worth, I tried cranking with and without the "operator present" handle engaged with no effect (even though this is irrelevant to the normal starting procedure).


So... My guess is, that because it was cranking, starting, running fine, and then, after a clean shut down following a shifting problem, it stopped working, my theory is that some kind of safety switch has disabled the ability to crank. Likely either something is telling the machine it is still in gear, or the PTO is on when it is not. I have exhausted the checks I can think of. I will be removing some of the cowlings and such to replace that cable so perhaps something will pop out to me when I do that.

Anyone have this issue before or have ideas to check?

 

[2manyrocks]

First guess is the neutral safety switch somehow got out of position when the new cable was installed. Try adjusting the cable to be sure the switch operates as intended.

Another possibility is the wiring to the neutral switch got disconnected.

Check Engine kill switch and its wiring.

 

[RobertEH]

I will bust it open to put the new cable in hopefully today and have more insights. I will see if I can find the kill switches and check for operability.

 

[5030]

12 volts static charge don't cut it. Battery is shot. Should show 12.7 volts static.

 

[Squirrel's242]

Sounds like you've covered all the switches that would be suspect, might as well replace that battery. It may just be done. Perhaps although it was on a trickle charger, that last crank up used the juice and it wasn't running long enough to replenish it. And now even on a charger it just won't take.

 

[RobertEH]

I don't think it was at exactly 12 volts - that is why I noted "at least 12 volts" above. I will check the exact voltage when I get back out there.

It is not outside the realm of possibility that the battery needs replacement however I would be surprised. It cranked with authority when I started it the day the cable broke. Then the very next time I tried, I get nothing. no clicks, no pops, no cranks. Really makes me think there is something with one of the safety switches. I may see if I can bypass the neutral switch to see if it starts to eliminate that from the equation.

I should note that I also checked the fuse and it was fine.

Alas, Monday I ended up with a task list from the wife to address, and then on Tuesday I had a Dr appt that blew my afternoon. I am very hopeful I can get to this over the weekend and do more work on it. I have the new cable in hand.

 

[Squirrel's242]

Well, I'm curious to see what the issue ends up being. My DR 30xl Mower is doing the rpm surging. I troubleshot it a few days ago and it'll only run wide open/edge of choke. So, looks like I need to get into the carb and do a clean.

 

[RobertEH]

Well, I finally had an hour to sit down and troubleshoot the mower. Very odd (in my opinion)
I replaced the cable that broke - that was easier than I thought. I verified I could shift through all the gears with it. Still would not start (not surprised)

Next, I bypassed the neutral safety switch. Would not crank (remember, it was not even trying to crank, no whirring, no popping, nothing.)

I decided to bypass the battery and jump it off of another battery. Started right up.

So, it looks like the battery is totally dead. This is odd to me as it strongly cranked without issue last time that I started it and the shift cable broke - just about a week or so ago.

So you nailed it 5030!

 

[Richard001]

Here is the problem why your battery failed:

Battery was on a trickle charger over the winter and shows charged ~12 volts.

A trickle charger can not/should not be used to maintain a battery over a long period of time. You need to get a battery maintainer.

Something like this:

https://www.northerntool.com/products/batteryminder-plus-battery-charger-trickle-charger-desulfator-12-volt-1-amp-model-12117tc-167981?cm_mmc=Google-LIA&utm_source=Google_LIA&utm_medium=Automotive%20%3E%20Batteries%20%26%20Chargers%20%2B%20Jump%20Starters%20%3E%20Battery%20Maintainers&utm_campaign=BatteryMINDer&utm_content=167981&ogmap=SHP%7CLIA%7CGOOG%7CSTND%7Cc%7CSITEWIDE%7C%7CAutoAccessories%7C%7Badgroup%7D%7C%7C856744483%7C42214677263&gad_source=1&gad_campaignid=856744483&gbraid=0AAAAADpPfbNueTV410y41HVdcx-Yh8s-n&gclid=CjwKCAjwx8nCBhAwEiwA_z__0-IvApJoXrGByyg2l3Y7Znu8_rfCvxkLRbQUIrZ3m9gPIvMkWrtW1xoC6jIQAvD_BwE&gclsrc=aw.ds

Richard