Older Bad Boy Commercial machine with Cat Diesel fuel cutoff problems

[Deanes]

The machine randomly just stops like someone turned the key off. Sometimes it restarts ok, but other times it just cranks and cranks. I have removed and tested the fuel shutoff selenoid. It seems ok when I use a jumper to it from the battery. I suspect it is a wiring problem, but the wires disappear into a big sheathed cable, so I don't know how to find the culprit.
My question is it ok to bypass the wiring system and run a switched line directly from the solenoid to the battery or the key?
Changing parts to find the problem is prohibitive. That little solenoid costs over $600.00!

 

[Gator6x4]

The machine randomly just stops like someone turned the key off. Sometimes it restarts ok, but other times it just cranks and cranks. I have removed and tested the fuel shutoff selenoid. It seems ok when I use a jumper to it from the battery. I suspect it is a wiring problem, but the wires disappear into a big sheathed cable, so I don't know how to find the culprit.
My question is it ok to bypass the wiring system and run a switched line directly from the solenoid to the battery or the key?
Changing parts to find the problem is prohibitive. That little solenoid costs over $600.00!

Is this a diesel or gas engine.

Gas and diesel engine have different causes for sudden stop.

 

[oldnslo]

I would use a fused switched wire to power the fuel shutoff solenoid.

Is your solenoid a 2 wire or three wire version? If 3 wire you need to determine which wire is start and which is hold or run circuit. Since you say it sometimes won’t start I would check for power to the solenoid when it won’t start or run to verify this is the problem.

 

[Gator6x4]

Bad boy says they use Perkins Diesel engines is the reason I asked if the engine was gas or diesel.

If the engine is a Perkins the Solenoid cost is not that bad.

Google Search

If a Cat Diesel, Bad boy wants $259.95..

Replacement Fuel Cut-Off Solenoid | Bad Boy 063-3002-00

Purchase a replacement fuel cut-off solenoid for your Bad Boy mower online! This solenoid is designed for riding mowers with a Caterpillar engine.

www.badboypartsonline.com

 

[oldnslo]

I believe CAT bought Perkins several years ago so could be both.

 

[Deanes]

Is this a diesel or gas engine.

Gas and diesel engine have different causes for sudden stop.

Cat Diesel

 

[Deanes]

I would use a fused switched wire to power the fuel shutoff solenoid.

Is your solenoid a 2 wire or three wire version? If 3 wire you need to determine which wire is start and which is hold or run circuit. Since you say it sometimes won’t start I would check for power to the solenoid when it won’t start or run to verify this is the problem.

It's 2 wires. Thanks for the info.

 

[Deanes]

Bad boy says they use Perkins Diesel engines is the reason I asked if the engine was gas or diesel.

If the engine is a Perkins the Solenoid cost is not that bad.

Google Search

If a Cat Diesel, Bad boy wants $259.95..

Replacement Fuel Cut-Off Solenoid | Bad Boy 063-3002-00

Purchase a replacement fuel cut-off solenoid for your Bad Boy mower online! This solenoid is designed for riding mowers with a Caterpillar engine.

www.badboypartsonline.com

It is a Cat 28 hp diesel. Maybe that solenoid would work, but this engine calls for part 015-2504-00. Over $600.00

 

[Gator6x4]

It is a Cat 28 hp diesel. Maybe that solenoid would work, but this engine calls for part 015-2504-00. Over $600.00

Sounds like your luck is the same as mine. Only the most expensive part will work. Bummer.

 

[Gator6x4]

On most of the small diesel engines you have a fused relay powering a device called a controller which in turn powers the solenoid. The two wire coming to the solenoid both have voltage. When you turn the key on the voltage is applied to the solenoid by one of the wires. this extends the plunger which moves he spring load rail in the pump allowing diesel to flow. With a OHM meter with the ground on the negative battery post check the wires for voltage with the switch. The other wire is a holding wire to hold the solenoid with pressure on the rail to keep it open,

You can usually remove the solenoid and stick you little finger in the hole and push the fuel rail open and start the unit and when you finger is extracted the rail closes and the engine stops. a firm piece of stiff rubber hose will work also just be careful and don't start cramming and pushing and damage internal pump components.

Your voltage should go from the relay to the controller to the solenoid. Trace the wire backward from the solenoid and you should find the controller. A lot of the controllers are white .

Hope i haven't confused you to much.