Hard starting/cranking Ford 4400 diesel

mrdrew

New User
I have a 1972 Ford 4400 industrial tractor with a 3 cylinder Perkins that I use on our property
for driveway maintenance and snow clearing. I have owned this tractor for almost 5 years
and it is always (and I do mean always) difficult to start - often either clicks like the battery is
weak or the starter "clunks" like the motor is bound up if I just turn the key. I have a new
1300 cca battery that I put in this fall (2nd time I have replaced battery) and even with the
new battery (and the block heater plugged in for 30 minutes if under 40/45 degrees) I still
always need to connect my 1500 amp jump pack to get the engine to turn over with any kind
of real effort. Why is it requiring so much battery? Is the starter wearing out? Do I have a
short? Once I hook up the jump pack and a decent battery it will start and it runs really nice
with excellent power, but the whole starting ritual is a major headache I would like to solve.
 
MrDrew,
Welcome to the forum.
I would bring the starter in and have it tested.
By the way, that is NOT a Perkins engine.
It is a Ford designed and Ford built engine.
 
First off, let me assure you, that is no Perkins engine in there. Look close and you'll see "Ford" on the block.

With regards to the starting issues, you most likely have excessive voltage drop (loss) in your key switch control circuit. Best way to tell is to bypass the key switch circuit with a heavy duty remote start switch (or a screwdriver). MAKE SURE the tranny is in neutral when you do this. If it cranks every time when you bypass it this way, then the problem is in your control circuit.

The problem is most likely a series of bad connections (i.e. high resistance) in the key switch circuit, including the harness connectors and at the neutral safety switch. My quick fix for that is the installation of a relay near the starter. Problem goes away and yet the neutral safety system is still functioning.
 
First, a 4400 has a Ford made 3 cylinder engine, not a Perkins.

Second, remove the starter from the tractor and take it to a competent small motor shop where they should be able to diagnose any actual problems with the starter itself. It does sound like the starter has issues but you gett hat verified before spending money for a new starter.

Since you say that it is going through batteries, next I would test the charging system to find out if it is properly charging the battery. Does it still have the original generator and external voltage regulator or has all that been replaced by an alternator?
 
Yes, it still has the original generator and voltage regulator - thanks for clearing up my misunderstanding on the motor manufacturer
 
Bern, Thanks for clearing up my misunderstanding on the motor manufacturer I never noticed the insignia on the block - apparently everyone else knows this is not a Perkins diesel except me.

Okay, so if I understand right you think my issue is largely due to a bad key switch or wiring at the switch - did I understand that right? Excuse my dumb questions, but to test this theory am I jumping the starter with the screwdriver and/or where do I hook in a remote switch (and what qualities/specs does the switch need to function properly? Am I buying a new key switch and swapping out the old or???) I know enough to be dangerous, but not exactly Mr mechanic, and electrical systems have always baffled me). Thanks for your help and patience - I appreciate it - hopefully with a little more guidance I can get this Ford to start reliably on command - that would be fantastic!
 
Yes, you understood me correctly - the problem is most likely in the key switch/neutral safety switch circuit.

A remote start switch is something you can pick up at most auto parts stores. It is not imperative to have one, just convenient. A jumper wire with alligator clips works nearly as well. If you buy a switch, buy a heavy duty one, not the cheapest one you can find.

The link below shows where to jump across the solenoid to bypass the key switch. If the starter cranks normally every time when jumped in this fashion, the problem is in your key switch circuit. If the starter still clicks, the problem is either in your solenoid or motor. Suggest at that point to get a reman starter or have it rebuilt.

MAKE SURE the transmission is in neutral before you jump across the starter! More than one person has been killed by not following that advice.
Jumping starter
 

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