John Deere Commercial 14hp Kawasaki Electrical Issue

Odd title; I know.

I have a GS45 John Deere with a 14 HP Kawasaki Engine. I’m the second owner; mower has seen homeowner use its entire life.

Over the summer, the mower started, then stalled out. I was able to start it a few more times, it ran briefly, then stalled. It then came to the point where it would not start at all. I investigated and no spark. I was able to get the mower running again by unplugging the ground from the coil. However, once I did that, it lost the ability to shut it off with the key and the safety switch no longer works. Basically, if you take your hands off the controls, the mower still runs. However, the blade will shut off. And you still need the key if you want to turn the blade on (it’s an electric PTO switch).

I know enough about electrics to be dangerous! I have a feeling some switch along the way is bad, just not sure which one or where to look. I did manage to find the factory service manual online: http://golftechs.us/Manuals/Tm1598.pdf

Any thoughts are welcome.

 

No help as usual...But that is one clean lawn mower!!

 

Thanks! Not bad for 20+ years old!

 

Seems like the ground or the switch are the problem. If bypassing them gets the machine to run, I'd replace those and see if that brought you back to normal operating order.

 

Per the wiring diagram, where did you unplug the coil ground?
My 1st guess would be the K2 Magneto relay...but if you want to fix it quick n dirty, just wire an on/off switch between ground and the coil...

 

Thanks! Right from the coil itself. I pulled off the recoil and engine shroud to access it. It’s a white wire with a spade connector to the coil.

 

brenndatomu has a lot of knowledge!!

 

Took a pic of the relay setup yesterday. OEMs are Hella units. I’d like to stick with OEM for electronics! Anyone have a good online source for Hella relays? I’m having trouble locating these particular ones; even with Hella’s online catalog. Found a bunch of non Hella’s on Amazon, but don’t want to go that route.

 

Swap those relays, see if the problem follows the relay.
No help here with finding Hella relays...I'd have no problem using another brand though.

 

Good call on swapping those out for now!

 

This looks like it would do.

 

I see plenty of hella relays out there. Just theys made in China….

 

Thanks guys. Ordered a two pack of the “HD Switch” brand from Amazon. I’ll see if it works and have a spare just in case.

 

I take it switching K1/K2 relays moved the problem too? Otherwise replacing relay(s) does nothing, other than lighten your wallet.

 

Thanks guys. Will try swapping relays later this week. I have the new ones…but returnable just in case.

 

Started on this today after mowing/leaf mulching:


Now I’m feeling a bit deflated. How the heck does one remove the relay? I pulled the tab(s) apart and it would not budge. Then this happened:







Here’s the new relay next to the current:


Mower still runs without the coil ground (white wire plugged in).

I apparently need help in the simple task of removing a relay. (Insert embarrassed emoji here).

 

It must be a lil corroded, or maybe even melted in there...they can be a bugger to get out sometimes...not annihilating the plug in the process can be a challenge sometimes too.
They generally do fit kinda tight, the terminals need to make a good connection to be able to carry 20 amps (+) reliably.

 

Maybe a little heat from a hair dryer?