Mahindra 5500 won't start, no headlights or horn

Tooler969 · Nov 21, 2016

Hello everyone. I'm new to the forum. I'm having a starting problem with my 2005 Mahindra 5500. I was using the tractor the other day, and it was working/starting fine, I had to stop and get off of it for a few minutes to do something. I got back on it, in a hurry or course, and turned the key to start it not thinking to put the hi/lo into neutral. Of course it didn't start, and I realized I didn't have it in neutral, so being in a hurry I held the ignition switch to the starting position and pulled the hi/lo lever to neutral. It made a brief starting noise then stopped. Now it won't turn over or anything. I've checked 9 fuses, all are good. I've checked the starter relay and the KSB relay and they are reading correctly and pulling in and out. I don't have any lights, headlights, dash lights or horn. The battery is reading 12.68vDC. I've got power to the timer relay, but I don't get any reading on the brown heater wire or any of the other prongs on the other side of the relay. Or should I with it not started or running? Any help would be appreciated. Thanks in advance.

JerryK · Nov 21, 2016

The majority of the time, it is battery or battery cable related. A failing cable or connection can finally breath it's last breath while you are running the tractor and putting shock stress on the large wiring. While it could be anything, I'd start by putting a voltmeter on the large terminal on the starter to ground while you are trying to turn the lights on. Do this also from the negative battery post [ not the connector on the post ] to the frame. Battery cables can fail internally from being exposed to the corrosive gasses from the battery. If that all checks out, then you can start looking for problems with an inline fuse or broken wire/etc. Good luck... Jerry

Tooler969 · Nov 21, 2016

Thanks Jerry

RNeumann · Nov 22, 2016

Based on your story I would be looking at the relay you thought was questionable. With the battery showing proper voltage but nothing in the dash area working (lights, ignition etc) it could also be a fusible link or wire- however you don't see those much anymore- and I don't know that tractor specifically.

While it could be a maintenance item like a cable (others have had issues with the cables) the fact that you were holding the ignition switch in the start position and then shifting the machine to neutral leads me to believe the failure is in that circuit/system and was caused by the non standard sequence of events.

Good luck and keep us posted. This will be an interesting one to see what the final verdict is.

RNeumann · Nov 22, 2016

Just to help me understand- is the timer relay for the glow plugs or something else?

Also- typically safely switches go to ground. Does the relay in question have a good ground (for testing purposes since you say it is getting power)? If not, maybe the neutral safety switch arced when it was moved into neutral and is no longer making good contact.

Tooler969 · Nov 22, 2016

The timer relay has a leg that goes to what the print calls a heater.
I unhooked the plug that goes to the neutral safety switch and jumped out the wire to bypass the switch already.

Tooler969 · Nov 22, 2016

Yes, I'm guessing that something grounded out. Does anyone know what HWS on the print means? I see a lot of wires going to something called HWS.

RNeumann · Nov 22, 2016

I don't know if it grounded out or a switch has carbon on it that is preventing good contact.

Can you attach a photo of the diagram with HWS on it?

Have you swapped the relay in question.

Have you traced the wires that go to the safety switch to see where they go?

Good luck and thanks for keeping us in the loop.

Tooler969 · Nov 22, 2016

I haven't swapped the relay in question, it's $200+ so I want to be sure before I swap it. Here's a pic of the wiring diagram

RNeumann · Nov 23, 2016

From the looks of the wire diagram English was not its first language. HWS is probably a mislabel as it goes to Head Light and Turn Signal Fuse.

It also appears that the diagram show 2 10a fuses that are not a part of the labeled fuse panel. Were you able to locate those as they could be buried.

It also doesn't show a fuse between the battery (positive shows it comes off the starter) and the Ign switch. Hopefully that is not the case. Does the ign switch have power? If not try a jumper between the battery and the ignition switch.

Have you called your dealer? Maybe they have seen or heard of this. I'm not suggesting you give up. Just a quick call for some possible easy places to look.