Truck no go - did a silly thing

**101RRS** · 15th December 2010, 01:22 PM

I have been doing a few things to the 101 over the last month or so but had to stop when the rain started in a big way just over two weeks ago.

The weather is now a bit better so I went to start work again only to find I had left the ignition on and all three batteries were dead. With the ignition on, the draw from the two starter batteries would have been a couple of relays and some dash instruments (24v alternator was not connected). The draw from the 12v deep cycle would have been ignition coil and ignition amplifier, clock, and exciter coils in the 12v alternator, the LPG system and 12v instruments.

The 24v battery system was completely dead with one battery showing -2v and the other 5v (the visual indicators still showed green though). The deep cycle was still showing 12v and was able to provide power but the indicator was red. When the cranking batteries ran down various relays would have shut down so stopping power from the 12v deep cycle before it discharged completely.

Put all batteries on a smart charger and all have come back, however while I now have power on both circuits, the starter motor will not turn over - no click, no nothing. I have replaced the starter batteries with alternatives and still no starter.

So is there something in the army stuff that could have been damaged with having ignition power on for so long that would be stopping the starter from going - - maybe a relay in addition to then starter solenoid.

Hoping for an easy answer before I have to go and climb under it and start tracking stuff through.

Thanks

Garry

**Blknight.aus** · 15th December 2010, 06:10 PM

there may be a handfull of relays that have burnt the contacts on and are now not playing.

**101RRS** · 15th December 2010, 09:52 PM

Thats what I am thinking as well - all the standard relays are located in the drivers footwell I guess I need to get the test light and multimeter out and start checking - what a pain.

Thanks

Garry

**lardy** · 15th December 2010, 10:00 PM

I remember on Petrol stuff leaving the ignition on would burn your coil out, but not the starter unless you get power down to the solenoid on that stage as oppossed to the actual cranking stage.
So must be a relay for load I could phone my mate tomorrow with regards his 101 starter system would that help?

**justinc** · 15th December 2010, 11:08 PM

Garry, have you checked that there is power to the starter relay from the ignition switch? The constant load in the 'on' position may have overheated the actual ignition switch, (like a melting Defender headlamp switch

), and could just have a contact problem.

Try jumping terminals on the starter solenoid and see if it turns over.

JC

**101RRS** · 16th December 2010, 05:03 PM

Thanks to everyone - was hoping for an easy reply to save me doing the work but I guess I need to get dirty and go looking. Been occupied with something else and will now have to leave things until after Christmas.

Is a bit odd as everything that seems to run when just the ignition is on seems to be working but the starter circuit which with just the ignition on is inactive is not now working. I really do not want to pull the dash out to check the ignition switch - is a real pain as all the wires are too short behind it and they need to be reinstalled with long nose pliers and mirrors to get it all connected again.

I will get the wiring diagrams out tonite and track stuff back.

Cheers

Garry

**PeterP** · 16th December 2010, 08:58 PM

All these relays have earth connections on the mounting screws. I would be checking all these earths and any other starter related connections first. You've had a bit of rain down there, we've just had liquid sunshine here. So with the ignition on (potential electrical flow) and lots of moisture a bad connection problem seems a very strong possibility.
Working behind the 101 dash is akin to torture! Best of luck.

**Blknight.aus** · 16th December 2010, 09:08 PM

hang about I just had a brain kick..

dual system yeah....

12v and 24v start.

theres a 12v feed relay that switches the 24v power for the 24v charging system. This same relay also turns the signal power for the 24v aux relay that drives the startermotor solenoide...

bet that ones the culprit.

Dont ask me where it is.

**101RRS** · 16th December 2010, 09:50 PM

Originally Posted by Blknight.aus

hang about I just had a brain kick..

dual system yeah....

12v and 24v start.

theres a 12v feed relay that switches the 24v power for the 24v charging system. This same relay also turns the signal power for the 24v aux relay that drives the startermotor solenoide...

bet that ones the culprit.

Dont ask me where it is.

I think you have picked the right relay but for the wrong reason - my truck was originally all 24v. When I pulled out the 24v dissy and coil I just used the standard 24v feed to the old coil to switch 12v via a relay to the new ignition system - so the engine cranking system is unchanged.

Maybe I need to get the engine cranking handle (when I get one) out and use that.

Thanks for the thought as it was what I was thinking - all the original everyday non army stuff relays live on the side of the drivers footwell.

Garry

**Blknight.aus** · 16th December 2010, 10:36 PM

Im actually not basing that off of a 101...

its off of a stairs truck at work... we had this same fault last week but the relay had died from being immersed in hyd fluid that came out of the emergancy pumps lowering control which had spat its screw valve out and hosed the underside of everything with OM 33.

24V truck with 12v accessories and not a wiring diagram to be found anywhere as the original company went bust and the AAP for the vehicle says "refer to OEM documentation in E format AND the online (E format) stuff says "Item is manufacturer managed, OEM manuals are not available, repair works to be contracted to Manufacturer at manufacturers expense during warranty period"

Always makes me want to ask... "If I'm not allowed to repair something unless I have the Publication detailing the task work how do i fix this?"

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