Toro wheelhorse Demystification Electical wiring diagrams for all WheelHorse tractors
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Transcript of Toro wheelhorse Demystification Electical wiring diagrams for all WheelHorse tractors
TABLE OF CONTENTS
iDemystification Guide
REAR ENGINE RIDERSMODEL YEAR PAGE825 . . . . . . . . . . . . . . . . . . . . .
825 . . . . . . . . . . . . . . . . . . . . .
825 RER . . . . . . . . . . . . . . . . . .
825 RER . . . . . . . . . . . . . . . . . .
825 RER . . . . . . . . . . . . . . . . . .
825 RER . . . . . . . . . . . . . . . . . .
825 RER . . . . . . . . . . . . . . . . . .
10-32 & 12-32 . . . . . . . . . . . . . . .
832 & 10-32 & 12-32 . . . . . . . . . . . .
832 RER . . . . . . . . . . . . . . . . . .
108-4, 108-5, & 111-6 . . . . . . . . . . . .
112-C . . . . . . . . . . . . . . . . . . . .
11-32 & 13-32 . . . . . . . . . . . . . . .
12-32 RER . . . . . . . . . . . . . . . . .
1996 - 1998 . . . . . . . . . . . . . . 4-1
1989 - 1992 . . . . . . . . . . . . . . 4-5
1993 - 1995 (70040 & 70060) . . . . . 4-8A
1996 - 1997 (70040 & 70060) . . . . . 4-8G
1998 (70040) . . . . . . . . . . . . . 4-8G
1998 (70041 & 70060). . . . . . . . . 4-8M
1999 - 2001 . . . . . . . . . . . . . 4-9
1994 - 1995 . . . . . . . . . . . . 4-14A
1991 - 1992 . . . . . . . . . . . . . 4-15
1993 (70042) . . . . . . . . . . . . 4-18A
1988 . . . . . . . . . . . . . . . . 4-19
1988 . . . . . . . . . . . . . . . . 4-23
1996 - 1998 . . . . . . . . . . . . . 4-27
1999 - 2001 . . . . . . . . . . . . . 4-31
Safety Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Time Savers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
LAWN TRACTORSMODEL YEAR PAGE208-4SB, 211-5SB, 211-4 & 212-5 . . . . . .
210-5 & 210-H . . . . . . . . . . . . . . .
210-5 & 210-H . . . . . . . . . . . . . . .
212-H . . . . . . . . . . . . . . . . . . . .
210-5 & 210-H . . . . . . . . . . . . . . .
212-5 & 212-H . . . . . . . . . . . . . . .
212-5 & 212-H . . . . . . . . . . . . . . .
212-5 . . . . . . . . . . . . . . . . . . . .
212-6 . . . . . . . . . . . . . . . . . . . .
212-6 . . . . . . . . . . . . . . . . . . . .
10-32XL & 12-38XL . . . . . . . . . . . . .
12-32XL & 12-38HXL . . . . . . . . . . . .
1988 - 1989 . . . . . . . . . . . . . . 5-1
1990 . . . . . . . . . . . . . . . . . 5-1
1991 & 1993 - 1995 . . . . . . . . . 5-7
1992 . . . . . . . . . . . . . . . . . 5-7
1992 . . . . . . . . . . . . . . . . . 5-11
1991 . . . . . . . . . . . . . . . . . 5-15
1990 . . . . . . . . . . . . . . . . . 5-21
1992 . . . . . . . . . . . . . . . . . 5-27
1988 . . . . . . . . . . . . . . . . . 5-31
1987 . . . . . . . . . . . . . . . . . 5-37
1993 . . . . . . . . . . . . . . . . . 5-43
1993 - 1995 . . . . . . . . . . . . . 5-43
TABLE OF CONTENTS
ii Demystification Guide
LAWN TRACTORS (continued)MODEL YEAR PAGE13-38HXL . . . . . . . . . . . . . . . . .
13-38HXL & 15-44HXL . . . . . . . . . . .
XL . . . . . . . . . . . . . . . . . . . . . .
XL . . . . . . . . . . . . . . . . . . . . . .
252-H . . . . . . . . . . . . . . . . . . . .
257-H . . . . . . . . . . . . . . . . . . . .
1994 . . . . . . . . . . . . . . . . . 5-43
1995 . . . . . . . . . . . . . . . . . 5-47
1996 - 1998 . . . . . . . . . . . . . 5-47
1999 - 2001 . . . . . . . . . . . . 5-50A
1988 . . . . . . . . . . . . . . . . . 5-51
1988 . . . . . . . . . . . . . . . . . 5-57
YARD & GARDEN TRACTORSMODEL YEAR PAGE244 . . . . . . . . . . . . . . . . . . . . .
246-H . . . . . . . . . . . . . . . . . . . .
264-6 . . . . . . . . . . . . . . . . . . . .
264-H & 265-H . . . . . . . . . . . . . . .
265-6 . . . . . . . . . . . . . . . . . . . .
265-6 . . . . . . . . . . . . . . . . . . . .
265-H . . . . . . . . . . . . . . . . . . .
265-H . . . . . . . . . . . . . . . . . . .
266-H . . . . . . . . . . . . . . . . . . . .
266-H . . . . . . . . . . . . . . . . . . . .
266-H . . . . . . . . . . . . . . . . . . . .
267-H . . . . . . . . . . . . . . . . . . . .
268-H . . . . . . . . . . . . . . . . . . .
268-H . . . . . . . . . . . . . . . . . . .
269-H . . . . . . . . . . . . . . . . . . . .
270-H . . . . . . . . . . . . . . . . . . .
270-H . . . . . . . . . . . . . . . . . . .
270-H . . . . . . . . . . . . . . . . . . . .
1993 . . . . . . . . . . . . . . . . . 6-1
1992 . . . . . . . . . . . . . . . . . 6-1
1994 - 1995 . . . . . . . . . . . . . . 6-7
1994 - 1998 . . . . . . . . . . . . . 6-15
1996 - 1998 . . . . . . . . . . . . . 6-23
1999 - 2000 . . . . . . . . . . . . 6-29A
2000 - 2001 . . . . . . . . . . . . 6-30A
1999 . . . . . . . . . . . . . . . . 6-31A
1995 . . . . . . . . . . . . . . . . . 6-33
1994 . . . . . . . . . . . . . . . . . 6-41
2001 . . . . . . . . . . . . . . . . 6-48A
1996 - 1998 . . . . . . . . . . . . . 6-49
1999 . . . . . . . . . . . . . . . 6-57A
2000 - 2001 . . . . . . . . . . . . 6-58A
1996 - 1998 . . . . . . . . . . . . . 6-59
2001 . . . . . . . . . . . . . . . . 6-66A
2000 . . . . . . . . . . . . . . . . 6-67
1999 . . . . . . . . . . . . . . . . 6-77
GARDEN TRACTORSMODEL YEAR PAGE308-8 . . . . . . . . . . . . . . . . . . . .
310 . . . . . . . . . . . . . . . . . . . . .
310-8 . . . . . . . . . . . . . . . . . . . .
312-8 . . . . . . . . . . . . . . . . . . . .
1988 . . . . . . . . . . . . . . . . . 7-1
1989 - 1991 . . . . . . . . . . . . . 7-5
1988 . . . . . . . . . . . . . . . . . 7-11
1998 . . . . . . . . . . . . . . . . . 7-17
TABLE OF CONTENTS
iiiDemystification Guide
GARDEN TRACTORS (continued)MODEL YEAR PAGE312-8 . . . . . . . . . . . . . . . . . . . .
310-8 . . . . . . . . . . . . . . . . . . . .
312-8 . . . . . . . . . . . . . . . . . . .
314-8 . . . . . . . . . . . . . . . . . . . .
312-8 . . . . . . . . . . . . . . . . . . . .
312-8 . . . . . . . . . . . . . . . . . . . .
312-H & 312-8 . . . . . . . . . . . . . . . .
312-A & 312-8 . . . . . . . . . . . . . . .
312-H . . . . . . . . . . . . . . . . . . .
314-H . . . . . . . . . . . . . . . . . . .
314-8 . . . . . . . . . . . . . . . . . . . .
314-8 . . . . . . . . . . . . . . . . . . . .
416-8 . . . . . . . . . . . . . . . . . . . .
416-H . . . . . . . . . . . . . . . . . . .
416-H & 416-8 . . . . . . . . . . . . . . .
416-8 . . . . . . . . . . . . . . . . . . .
416-8 . . . . . . . . . . . . . . . . . . .
416-8 . . . . . . . . . . . . . . . . . . .
414-8 . . . . . . . . . . . . . . . . . . .
414-8 & 416-8 . . . . . . . . . . . . . . .
414-8 . . . . . . . . . . . . . . . . . . .
520-H . . . . . . . . . . . . . . . . . . .
520-H . . . . . . . . . . . . . . . . . . .
520-8 . . . . . . . . . . . . . . . . . . .
518-H & 520-H . . . . . . . . . . . . . . .
516-H & 520-HC . . . . . . . . . . . . . .
518-xi . . . . . . . . . . . . . . . . . . .
518-xi . . . . . . . . . . . . . . . . . . .
520-xi & 522-xi . . . . . . . . . . . . . . .
520-xi & 522-xi . . . . . . . . . . . . . . .
520L-xi . . . . . . . . . . . . . . . . . . .
520L-xi . . . . . . . . . . . . . . . . . . .
1999 - 2001 . . . . . . . . . . . . 7-22A
1992 - 1993 . . . . . . . . . . . . . 7-23
1992 - 1997 . . . . . . . . . . . . . 7-23
1993 . . . . . . . . . . . . . . . . . 7-23
1989 . . . . . . . . . . . . . . . . . 7-27
1987 - 1988 . . . . . . . . . . . . . 7-33
1990 - 1991 . . . . . . . . . . . . . 7-39
1986 . . . . . . . . . . . . . . . . . 7-45
1992 . . . . . . . . . . . . . . . . . 7-53
1993 - 1997 . . . . . . . . . . . . . 7-53
1994 - 1997 . . . . . . . . . . . . . 7-53
1999 - 2001 . . . . . . . . . . . . 7-56A
1992 - 1997 . . . . . . . . . . . . . 7-57
1992 - 1997 . . . . . . . . . . . . . 7-57
1990 - 1991 . . . . . . . . . . . . . 7-61
1989 . . . . . . . . . . . . . . . . . 7-67
1986 . . . . . . . . . . . . . . . . . 7-71
1985 . . . . . . . . . . . . . . . . . 7-77
1989 . . . . . . . . . . . . . . . . . 7-81
1987 - 1988 . . . . . . . . . . . . . 7-87
1986 . . . . . . . . . . . . . . . . . 7-91
1991 - 1997 . . . . . . . . . . . . . 7-97
1990 . . . . . . . . . . . . . . . . 7-105
1990 . . . . . . . . . . . . . . . . 7-113
1988 - 1989 . . . . . . . . . . . . 7-119
1988 - 1989 . . . . . . . . . . . . 7-127
1998 . . . . . . . . . . . . . . . . 7-133
1999 - 2001 . . . . . . . . . . . . 7-138A
1998 . . . . . . . . . . . . . . . . 7-139
1999 - 2001 . . . . . . . . . . . . 7-146A
1998 . . . . . . . . . . . . . . . . 7-149
1999 - 2001 . . . . . . . . . . . . 7-155
TABLE OF CONTENTS
iv Demystification Guide
GARDEN TRACTORS (continued)MODEL YEAR PAGE523Dxi . . . . . . . . . . . . . . . . . . .
523Dxi . . . . . . . . . . . . . . . . . . .
1998 . . . . . . . . . . . . . . . . 7-157
1999 - 2001. . . . . . . . . . . . . 7-165
ZERO TURN RIDERSMODEL YEAR PAGETimeCutter Z . . . . . . . . . . . . . . . . 2001 . . . . . . . . . . . . . . . . . 8-1
Avoid amputations and lacerations... When troubleshooting,you may encounter non- functioning safety systems. Alwayscheck to ensure the PTO is off, the transmission is in neutral,and that you and bystanders are clear before starting.
Avoid burns... Remove all jewelry before troubleshooting.The battery contains sufficient power to melt rings, bracelets,and chains causing serious burns in the process.
Avoid electric shock... While most voltages are relativelylow, the ignition coil secondary produces close to 20,000volts. Avoid contacting the spark plug wire while the engineis turning.
SAFETY INFO
Demystification Guide 1-1
This page intentionally left blank
1-2 Demystification Guide
Table Of Contents
Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Using a VOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Troubleshooting Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Troubleshooting Short Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
TIME SAVERS
Demystification Guide 2 - 1
The components are listedalphabetically by noun, followedby any adjectives. if you havetrouble finding a component, usethe index at the front of theglossary section.
These three sections should beall you need to diagnoseproblems on individualcomponents.
The glossary containsinformation on virtually everyelectrical part used on Tororiding products.
You may see multiple partnumbers here if the informationis identical to other parts.
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2 - 2 Demystification Guide
Each product group has its ownsection including:- Info List- Parts Used- Wiring Diagrams- Circuit Diagrams
Drawing helps you quicklyidentify product sections.
Each product section has its own"table of contents" to keep thingssimple. The "Info List" is the first page of
each product section.
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Demystification Guide 2 - 3
The description is the name given tothe part in the book only.
All Toro electrical parts are called outin this section
The glossary page numbers refer tothe most recent part number
This part has been cross referenced,the old part number is listed here.
This is the most recent part numberavailable at press time.
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2 - 4 Demystification Guide
Each product sectionincludes the origionalwiring diagram.
The wiring diagramclosely represents thewiring harness and isvery useful indiagnosingcircuits.
short
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Demystification Guide 2 - 5
Each circuit is shownindividually. Componentsnot essential for circuitfunction are shown.not
Circuits are drawn suchthat current alwaysflows from left to right(the same way youread).
Additional information iscalled out beneath thetitle in parenthesis.
Solid lines indicatewires that carry current.
Components withinternal circuitry areenclosed with a dashedline.
Each component isnamed additionalinformation is suppliedbelow in parentheses.
and
Wire colors are calledout at each component(where you're mostlikely to use them!)
Each component (ieswitches, relays,solenoids) are drawn inthe position necessary tomake the circuit function.
Dashed lines representwires that are importantto the circuit but do notcarry current.
Each circuit diagrampage has a color codelegend.
Circuit Diagrams maketroubleshooting easyand fun because eachcircuit is drawn individually.Thay make troubleshootingopen circuits a snap.
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2 - 6 Demystification Guide
Wh Re Re Re Re Bk
10026
Fuse(25 amp)
Battery(12 volt)
A B
Ignition Switch(in "run")
Alternator(15 amp)
RegulatorRectifier
AC
ACB+
Always start by selecting the properscale. For instance, on this meter weselected the 25 volt scale.
Use the AC scales to measureunrectified voltage straight from analternator or from a wall outlet.
Battery voltage is always D.C.
If you measure from ground to groundor have an open circuit, your readingwill be 0.
Use D.C. scales to measure voltagesthat have been changed to D.C. by arectifier or diode.
The ohmmeter is powered by aninternal battery. Replace it if theneedle will not move full scale.
The integrity of the ignition coils andelectric clutches can often be checkedusing an ohmmeter.
Make sure your VOM reads 0 ohms(full scale right) when the leads aretouching together to insure accurateresistance readings.
Always disconnect components fromthe circuit when resistance checking.Otherwise you could get a falsereading. This switch should readinfinite ( ) resistance.
Do not use the ohmmeter to test Torointerlock modules! The battery currentcould damage the module.
2Checking Resistance
Checking Voltage
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Demystification Guide 2 - 7
Wh Re Re Re Re Bk
10026
Fuse(25 amp)
Battery(12 volt)
A B
Ignition Switch(in "run")
Alternator(15 amp)
RegulatorRectifier
AC
ACB+
Most ammeters can measure only .1amp. The current in Toro ridingproducts generally is from 3-90 amps.This is sufficient to destroy mostVOMs!
3What about checking current?
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2 - 8 Demystification Guide
244 electric clutch will not engage. (This time
we’ll solve it faster.)
Sample Problem: 244 electric clutch will not engage.
Trou
ble
sh
ootin
gO
pe
nC
ircu
its
Same Sample
Problem:
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Demystification Guide 2 - 9
Sample Problem: This 244 won't turn over. The customer parked it in the
garage and turned it off. When he tried to start it a week
later, he heard one click. After that , nothing would
happen when he turned the key.
We know it is a short circuit because we found the 25
amp fuse blown.
STEP 1. Interview the customer. Anyinformation we get will help isolate theproblem.
STEP 2. Isolate the suspect area.Notice what we did to the wiringdiagram at right.
Highlight the suspect area on a copyof the wiring diagram.
If the short was in the white wire, the30 amp fuse would have blown.
If the short was between the batteryand the 25 amp fuse, we would havemelted these wires.
If the pink wire or electric clutchshorted we would have blown the 15amp fuse. Eliminate all the black wires as
possibilities because they'reto go to ground!
supposed
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Cir
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2 - 10 Demystification Guide
Trou
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Demystification Guide 2 - 11
Conclusion:
Tro
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hort
Cir
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2 - 12 Demystification Guide
Glossary Contents(by description) Cross-
Part Referenced
Description Number From Page
Alternator, 15 Amp (Kohler) . . . . . . . . . KH10091 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Alternator, 20 Amp (with terminals - Onan) . 57-9440 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
92-0967
Clutch, Electric . . . . . . . . . . . . . . . . 78-6990 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
113997
92-6885
93-3160
115629
116277
119930
Coil, Ignition . . . . . . . . . . . . . . . . . 71-6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Coil, Ignition (Kohler) . . . . . . . . . . . . . KH10321 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Coil, Ignition . . . . . . . . . . . . . . . . . NN10730 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Condenser (capacitor) . . . . . . . . . . . . 59-1180 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Diode (replacement kit) . . . . . . . . . . . 78-1630 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Diode (with leads - Kohler) . . . . . . . . . . KH10315 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Gauge, Hourmeter . . . . . . . . . . . . . . 78-0020 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
113469
94-3723
Gauge, Tachometer . . . . . . . . . . . . . 113476 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
78-0060
Gauge, Voltmeter . . . . . . . . . . . . . . . 78-0030 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Horn . . . . . . . . . . . . . . . . . . . . . 116749 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Light, Oil Level Indicator . . . . . . . . . . . 117185 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Module, Interlock . . . . . . . . . . . . . . . 28-7890 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
95-0659
Module, Light Circuit . . . . . . . . . . . . . 114825 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
115207
79-2130
Module, Trigger (Onan) . . . . . . . . . . . 71-6380 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
NN10444
Regulator/Rectifier (20 amp - Onan) . . . . . 57-9430 . . . . . . . NN10261 . . . . . . . . . . . . . 3-15
Regulator/Rectifier (Kohler) . . . . . . . . . KH10215 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Relay . . . . . . . . . . . . . . . . . . . . . 48-4700 . . . . . . . . . 116397 . . . . . . . . . . . . . 3-16
116397
Rotor, Ignition . . . . . . . . . . . . . . . . . 71-6010 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Sender, Fuel Level . . . . . . . . . . . . . . 113358 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Solenoid . . . . . . . . . . . . . . . . . . . 47-1910 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Glo
ssa
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GLOSSARY
Demystification Guide 3 - 1
Glossary Contents(by description)
Cross-
Part Referenced
Description Number From Page
Starter, Electric . . . . . . . . . . . . . . . . 71-6040 . . . . . . . . NN10268 . . . . . . . . . . . . 3-19
NN10889
62-2710
79-6570
Starter, Electric . . . . . . . . . . . . . . . NN10739 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Switch, Air Cleaner Pressure . . . . . . . . . 114270 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Switch, Engine Temperature . . . . . . . . NN10274 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Switch, Float (kit) (Kohler) . . . . . . . . . . KH10826 . . . . . . . . KH10138 . . . . . . . . . . . . 3-27
Switch, Ignition . . . . . . . . . . . . . . . . 103990 . . . . . . . . . 11216 . . . . . . . . . . . . . 3-27
Switch, Ignition . . . . . . . . . . . . . . . . 103991 . . . . . . . . . 11215 . . . . . . . . . . . . . 3-28
Switch, Ignition . . . . . . . . . . . . . . . . 116338 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Switch, Ignition . . . . . . . . . . . . . . . . 117292 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Switch, Ignition . . . . . . . . . . . . . . . . 23-0660 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Switch, Interlock . . . . . . . . . . . . . . . . 38-1420 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Switch, Light . . . . . . . . . . . . . . . . . . 102138 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Switch, Light . . . . . . . . . . . . . . . . . . 113191 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
92-9844
Switch, Micro . . . . . . . . . . . . . . . . . 40-8200 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Switch, Neutral . . . . . . . . . . . . . . . . 28-4250 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Switch, Neutral/Parking Brake . . . . . . . . . 116237 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Switch, Neutral/Parking Brake . . . . . . . . . 116822 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Switch, Oil Pressure . . . . . . . . . . . . . NN10520 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Switch, Oil Pressure . . . . . . . . . . . . . NN10813 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Switch, Oil Pressure . . . . . . . . . . . . . NN10824 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Switch, PTO/Clutch . . . . . . . . . . . . . . 116716 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Switch, PTO/Clutch . . . . . . . . . . . . . . 111332 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Switch PTO/Clutch . . . . . . . . . . . . . . 116716 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Switch, PTO/Clutch . . . . . . . . . . . . . . 78-3030 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Switch, PTO/Clutch . . . . . . . . . . . . . . 78-9670 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Switch, Seat . . . . . . . . . . . . . . . . . . 116194 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Switch, Test . . . . . . . . . . . . . . . . . . 116752 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Switch, Test . . . . . . . . . . . . . . . . . . 116796 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Switch, Transmission Oil . . . . . . . . . . . 113193 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
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GLOSSARY
3 - 2 Demystification Guide
Glossary Contents(by part number)
Cross-
Part Referenced
Number From Description Page
102138 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Light . . . . . . . . . . . . . . . . . . . 3-30
103990 . . . . . . . . 111216 . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-27
103991 . . . . . . . . 111215 . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-28
111332 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . . 3-35
113191 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Light . . . . . . . . . . . . . . . . . . . 3-30
113193 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Transmission Oil . . . . . . . . . . . . . 3-38
113358 . . . . . . . . . . . . . . . . . . . . . . . . Sender, Fuel Level . . . . . . . . . . . . . . . . 3-17
113469 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Hourmeter . . . . . . . . . . . . . . . . . 3-9
113476 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Tachometer . . . . . . . . . . . . . . . 3-10
113997 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
114270 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Air Cleaner Pressure . . . . . . . . . . . 3-26
114825 . . . . . . . . . . . . . . . . . . . . . . . . Module, Light Circuit . . . . . . . . . . . . . . . 3-12
115207 . . . . . . . . . . . . . . . . . . . . . . . . Module, Light Circuit . . . . . . . . . . . . . . . 3-12
115629 . . . . . . . . 112849 . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
116194 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Seat . . . . . . . . . . . . . . . . . . . 3-37
116237 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Neutral/Parking Brake . . . . . . . . . . 3-32
116277 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
116338 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-28
116397 . . . . . . . . . . . . . . . . . . . . . . . . Relay . . . . . . . . . . . . . . . . . . . . . . . 3-16
116716 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . . 3-34
116716 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . . 3-35
116749 . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . 3-11
116752 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Test . . . . . . . . . . . . . . . . . . . . 3-37
116796 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Test . . . . . . . . . . . . . . . . . . . . 3-38
116822 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Neutral/Parking Brake . . . . . . . . . . 3-32
117185 . . . . . . . . . . . . . . . . . . . . . . . . Light, Oil Level Indicator . . . . . . . . . . . . . 3-11
117292 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-29
119930 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
23-0660 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-29
28-4250 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Neutral . . . . . . . . . . . . . . . . . . 3-31
28-7890 . . . . . . . . . . . . . . . . . . . . . . . . Module, Interlock . . . . . . . . . . . . . . . . . 3-12
38-1420 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Interlock . . . . . . . . . . . . . . . . . 3-30
40-8200 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Micro . . . . . . . . . . . . . . . . . . . 3-31
47-1910 . . . . . . . . 110167 . . . . . . . . . . . Solenoid . . . . . . . . . . . . . . . . . . . . . 3-18
48-4700 . . . . . . . . 116397 . . . . . . . . . . . Relay . . . . . . . . . . . . . . . . . . . . . . . 3-16
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GLOSSARY
Demystification Guide 3 - 3
Glossary Contents(by part number)
Cross-
Part Referenced
Number From Description Page
57-9430 . . . . . . . . NN10261 . . . . . . . . . . Regulator/Rectifier (20 amp - Onan) . . . . . . . 3-15
57-9440 . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 20 Amp (with terminals - Onan) . . . . 3-5
59-1180 . . . . . . . . . . . . . . . . . . . . . . . . Condenser (capacitor) . . . . . . . . . . . . . . . 3-8
62-2710 . . . . . . . . . . . . . . . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19
71-6000 . . . . . . . . . . . . . . . . . . . . . . . . Coil, Ignition . . . . . . . . . . . . . . . . . . . . 3-6
71-6010 . . . . . . . . . . . . . . . . . . . . . . . . Rotor, Ignition . . . . . . . . . . . . . . . . . . 3-17
71-6040 . . . . . . . . NN10268 . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19
71-6380 . . . . . . . . . . . . . . . . . . . . . . . . Module, Trigger (Onan) . . . . . . . . . . . . . 3-13
78-1630 . . . . . . . . . . . . . . . . . . . . . . . . Diode (replacement kit) . . . . . . . . . . . . . . 3-8
78-3030 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . 3-36
78-9670 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . 3-36
78-6990 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
79-2130 . . . . . . . . . . . . . . . . . . . . . . . . Module, Light Circuit . . . . . . . . . . . . . . . 3-12
79-6570 . . . . . . . . . . . . . . . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19
92-0967 . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 20 Amp (with terminals - Onan) . . . . 3-5
92-9844 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Light . . . . . . . . . . . . . . . . . . . 3-30
92-6885 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
93-3160 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6
94-3723 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Hourmeter . . . . . . . . . . . . . . . . . 3-9
95-0659 . . . . . . . . . . . . . . . . . . . . . . . . Module, Interlock . . . . . . . . . . . . . . . . 3-12
78-0060 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Tachometer . . . . . . . . . . . . . . . 3-10
78-0030 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Voltmeter . . . . . . . . . . . . . . . . 3-10
78-0020 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Hourmeter . . . . . . . . . . . . . . . . . 3-9
KH10091 . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 15 Amp (Kohler) . . . . . . . . . . . . 3-5
KH10215 . . . . . . . . . . . . . . . . . . . . . . . Regulator/Rectifier (Kohler) . . . . . . . . . . . 3-15
KH10315 . . . . . . . . . . . . . . . . . . . . . . . . Diode (with leads - Kohler) . . . . . . . . . . . . 3-9
KH10321 . . . . . . . . . . . . . . . . . . . . . . . . Coil, Ignition (Kohler) . . . . . . . . . . . . . . . 3-7
NN10730 . . . . . . . . . . . . . . . . . . . . . . . . Coil, Ignition . . . . . . . . . . . . . . . . . . . . 3-7
KH10826 . . . . . . . . KH10138 . . . . . . . . . . Switch, Float (kit) (Kohler) . . . . . . . . . . . . 3-27
NN10274 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Engine Temperature . . . . . . . . . . . 3-26
NN10444 . . . . . . . . . . . . . . . . . . . . . . . . Module, Trigger (Onan) . . . . . . . . . . . . . 3-13
NN10520 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . 3-33
NN10739 . . . . . . . . . . . . . . . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-23
NN10813 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . 3-33
NN10824 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . 3-34
NN10889 . . . . . . . . NN10519 . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19
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GLOSSARY
3 - 4 Demystification Guide
Part Numbers
KH10091
Purpose
The stator generates 15 amps of alternating current.
How It Works
Whenever a magnet passes by a coil of wire on an iron core, electricity isproduced. The amount will depend on the thickness of the wire, thenumber of windings on each coil, the strength of the magnet, and thespeed at which the magnet is moving.
This particular coil has 18 poles to produce 15 amps at 28 or more voltsA.C. when the engine is running at 3600 rpm. The current produced isalternating current since no diode or rectifier is internal to the stator.
Note: This stator kit comes with mounting screws and terminals so that itwill retrofit to a number of different Kohler engines.
Testing
1. Remove the connector from the regulator rectifier. Measure the voltageacross the two A.C. Ieads on the alternator side of the connector withthe engine running at 3600 rpm. If voltage is less than 28 volts,proceed to the next step. Otherwise, stator is OK.
2. With the stator still disconnected and the engine off, measure theresistance across the two A.C. Ieads running to the stator. Theresistance should be .1 to .2 ohms. If not, replace the stator.
Part Numbers
57-9440, 92-0967
Purpose
This stator generates alternating current whenever the engine is running.
How It Works
Whenever a magnet passes by a coil of wire on an iron core, electricity isproduced. The amount will depend on the thickness of the wire, thenumber of windings on each coil, the strength of the magnet, and thespeed at which the magnet is moving.
This particular coil has 18 poles to produce 20 amps at 57 volts A.C. whenthe engine is running at 3600 rpm. The current produced is alternatingcurrent since no diode or rectifier is internal to the stator.
Testing
1. Disconnect the alternator from the regulator/rectifier.
2. Measure the voltage across the A.C. terminals on the alternator side ofthe connector. The voltage should read as shown in Figure A.
3. Check for a short in the alternator by checking between either of theA.C. terminals and ground. If you do not get infinite resistance, replacethe alternator.
4. Check for an open alternator circuit by checking the resistance betweenthe two A.C. Ieads coming from the alternator. You should find theresistance as called out in Figure A. If you have not found the problem,test the regulator/rectifier, check for poor connections, and test therotor for poor magnetism.
Alternator
15 Amp
(Kohler)
Alternator
20 Amp(with terminals)
(Onan)
Stator Output* Stator Resistance
more than 28VDC @ 3600 rpm
.1 - .2 Ohms
*With regulator/rectifier disconnected
Item Specification
Battery 12-13 VDC
Stator Voltage Approximately 29 VDC@ 1800 RPM.Approximately 57 VDC@ 3600 RPM.
StatorResistance
0.10 + 0.19 Ohms
Figure A
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GLOSSARY
Demystification Guide 3 - 5
Part Numbers
78-6990, 113997, 92-6885, 93-3160, 115629,116277, 119930
Purpose
This clutch electrically controls the engagement and disengagement of thePTO pulley.
How It Works
The PTO clutch is composed of three major components: the field, theclutch plate, and the friction plate. The clutch plate always turns with theengine. The field is a coil of wire on an iron core which becomes anelectro-magnet when power is applied. The friction plate is the only piecethat can slide up and down on the crankshaft axis. It is normally springloaded so that it is not in contact with the clutch plate and is pressedagainst the brake material opposite the clutch. When power is applied, thefriction plate is drawn toward the clutch plate and the two rotate as one.
Testing
1. Disconnect the PTO clutch from the harness.
2. Connect a charged 12 volt battery to the clutch (polarity makes nodifference.) You should hear a click, the clutch should engage. If not,check the wiring and connectors leading into the field. If no problemscan be found, replace the field.
3. Resistance Check: The field should have a resistance as listed in thetable on the left.
Mechanical Adjustment: The gap between the clutch and friction platesshould be set at .012-.015 inches. Adjust by rotating the three nutsattached to the field.
Part Numbers
71-6000
Purpose
The coil boosts voltage from 12 volts to in excess of the 20,000 voltsnecessary to fire spark plugs.
How It Works
The coil is actually two separate coils of wire wrapped around a commoniron core. One coil, the primary, has fewer windings and thicker wire. Theother coil, the secondary, has many windings, and uses a much finer wire.With this arrangement, whenever a small voltage change is made to the pri-mary, a large voltage change results in the secondary. There is a catch,though. The coil can only produce large “spikes” in the secondary whenthere is a rapid change in the primary.
Therefore, the coil relies on the trigger module to produce this change byquickly opening the primary circuit at the precise moment the plugs aresupposed to fire.
Testing
1. Test the resistance of the primary winding by connecting an ohmmeteracross the “+” and “-” terminals on the coil. The resistance shouldread between 2.90 and 3.60 ohms.
2. Check the resistance of the secondary coil by connecting one VOMlead in each of the two spark plug wire cable holes. The resistanceshould read between 14,500 and 19,800 ohms.
3. If either of the above readings were out of specification, replace thecoil.
Clutch
Electric
Coil
Ignition
Clutch # Resistance
78-6990 2.5� ± 20%
115629 2.5� ± 20%
113997 2.2� ± 20%
116277 2.2� ± 20%
119930 2.2� ± 20%
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GLOSSARY
3 - 6 Demystification Guide
Part Numbers
KH10321
Purpose
The coil boosts voltage from around 12 volts to in excess of 20,000 volts.
How It Works
The coil is actually two separate coils of wire wrapped around a commoniron core. One coil, the primary, has fewer windings and thicker wire. Theother coil, the secondary, has many windings, and uses a much finer wire.With this arrangement, whenever a small voltage change is made to the pri-mary, a large voltage change results in the secondary. There is a catch,though. The coil can only produce large “spikes” in the secondary whenthere is a rapid change in the primary.
Therefore, the coil relies on the trigger module (packed inside the coil) toproduce this change by quickly opening the primary circuit at the precisemoment the tests are supposed to fire.
Testing
1. If no spark is present, verify that the flywheel magnet is OK by holding aflat bladed screwdriver about 1/4", from the magnet. It should bedrawn in. Also verify that the air gap is set at .012" to .016".
2. Test the resistance of the primary winding by connecting an ohmmeteracross the kill lead and the core. The resistance should read between1 and 1.3 ohms.
3. Check the resistance of the secondary coil by connecting one VOMlead to the spark plug wire and the other lead to the core. Theresistance should read between 7900 and 10,850 ohms.
4. If either of the above readings were out of specification, replace the coil.
Caution: Do NOT connect 12 volt to the ignition coil as it will damage thetrigger module.
Part Numbers
NN10730
Purpose
The coil boosts voltage from around 12 volts to in excess of 20,000 volts.
How It Works
The coil is actually two separate coils of wire wrapped around a commoniron core. One coil, the primary, has fewer windings and thicker wire. Theother coil, the secondary, has many windings and uses a much finer wire.With this arrangement, whenever a small voltage change is made to the pri-mary, a large voltage change results in the secondary. There is a catch,though. The coil can only produce large “spikes” in the secondary whenthere is a rapid change in the primary.
Therefore, the coil relies on the trigger module (packed inside the coil) toproduce this change by quickly opening the primary circuit at the precisemoment the plug is supposed to fire.
Testing
1. Verify that the air gap is .020".
2. Disconnect the kill wire and the spark plug connectors.
3. Check the primary coil resistance by measuring across the kill wire andthe core. The resistance should be 1.0 ohms.
4. Check the secondary coil resistance by placing on the spark plug cableand the core. You should get approximately 9,500 ohms. If either meas-urement is out of specification, replace the coil.
Coil
Ignition
(Kohler)
Coil
Ignition
Ignition Coil
Ignition Coil
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GLOSSARY
Demystification Guide 3 - 7
Part Numbers
59-1180
Purpose
The condenser (or capacitor) protects the trigger module.
How It Works
In order to get the spark plug to fire, about 20,000 volts must be present atthe plug. This is accomplished by using primary and secondary windingsin the coil. The primary is low voltage while the secondary is highervoltage. However, by themselves neither can produce 20,000 volts. Atrigger module is necessary to turn the primary on and off. By quicklyturning the primary off, a 20,000 volt “spike” is created in the secondarywhich fires the plug. What does this have to do with the condenser?
The turning on and off of the primary can be hard on some of thecomponents in the trigger. The condenser (capacitor) lowers the “spikes”seen in the primary and enhances trigger module life.
Testing
There is really no way to easily test this .3 micro farad, 200 volts A.C.capacitor. However, if you have experienced a trigger module failure,replacing the condenser is recommended because of the nominal cost.
Part Numbers
78-1630
Purpose
Converts alternating current into pulsating direct current and preventsbattery current from feeding back through the alternator.
How It Works
A diode is merely a one-way valve for electricity. Coming straight from thealternator, the current is half positive and half negative as shown indiagram “1" at left. The diode ”filters" out the negative half of the wave togive you the waveform you see in diagram “2". Why then does your VOMread a steady direct current when you check the output? The reason is thatthe meter is designed to read an average voltage when the current israpidly changing.
When you read 14 volts, keep in mind that the peak voltage is closer to 20volts. IMPORTANT: The silver band must be oriented as shown in diagram3. Otherwise, current will feed back through the alternator.
Testing
1. Disconnect the diode assembly from the wiring harness.
2. Check terminals “a” and “b” for continuity with a VOM. Note the result.
3. Reverse the VOM attached to “a” and “b” and again note theresults. You should have found continuity in one direction, but not theother. If not, replace the diode assembly.
Condenser
(capacitor)
Diode
(replacement kit)
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GLOSSARY
3 - 8 Demystification Guide
Part Numbers
KH10315
Purpose
This diode ensures that no battery voltage is applied to the ignition module.
How It Works
A diode is a “one-way valve", for current. It allows current to flow in onedirection, but not in the other. The specifications for the diode are IN4002GIGP 8532. The banded end should go to the harness (away from the coil.)
Testing
1. Remove the diode assembly from the harness.
2. Test the diode for continuity first one way, then the other. It shouldconduct in one direction, but not the other. If not, replace it.
Part Numbers
78-0040
Purpose
This gauge indicates fuel level.
How It Works
The meter movement moves proportional to the amount of resistanceprovided by the fuel level sender in the tank. The movement is dampenedto compensate for movement of the fuel in the tank.
Testing
1. With the gauge still connected to the harness, turn the key to the “run’’position.
2. Using a VOM set to a scale capable of reading 12 volts D.C., connectthe negative lead to ground to verify the conditions in the table.
If your voltage readings are different from above, check the fuel levelsender and the wiring. If all readings are correct, the gauge must bereplaced as it is not serviceable.
Part Numbers
78-0020, 113469, 94-3723
Purpose
The hourmeter keeps track of how long the key has been in the “run”position.
How It Works
Since a normal clock might be affected by variations in voltage andcurrent, the hourmeter is made up of a combination of an electric “winder”and a mechanical clock movement. When power is applied, a relay isenergized. The contact moves far enough to wind the movement. Themovement unwinds in about two seconds. As it finishes its rotation, itre-energizes the relay so that the cycle can start over.
Testing
Verify that 12 volts is present across the two terminals when the key is on. Ifso, and the meter is not running, replace the meter. It is a permanentlysealed unit.
Diode
(with leads)
(Kohler)
Gauge
Fuel
Gauge
Hourmeter
Diode Heat ShrinkTubing
To Kill SwitchOr Off PositionOr Key switch Coated
FiberglassSleeving
Terminal
Terminal Reading
I 12 volts*
G 0 volts
S 2.5 volts tank full
S 7.5 volts tank empty
*All voltage readings should be within 20%
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GLOSSARY
Demystification Guide 3 - 9
Part Numbers
113476, 78-0060
Purpose
This gauge indicates engine speed.
How It Works
The tachometer measures the number of rotations of the crankshaft bymonitoring the B+ terminal of the voltage regulator. The alternating currentproduced by the alternator allows the circuitry to “count” the revolutions,then deflect the meter movement appropriately. Keep in mind that thistachometer does not key off the ignition coil, but rather the charging coil.
Testing
1. With the tachometer still connected to the harness, start the engine.
2. Using a known good electronic tachometer or “Vibratach”, determinethe actual engine speed. Compare it to the tachometer in theequipment.
3. If they are not within 10%, check for loose connections, a bad stator, orflywheel magnet.
4. If no problems are found, the gauge must be replaced as it is notserviceable.
Part Numbers
78-0030
Purpose
This gauge indicates the voltage across the battery.
How It Works
The meter movement moves proportional to the voltage level across thetwo terminals of the battery. This is accomplished by placing a resistor inparallel with the meter movement.
Testing
1. With the meter still connected to the harness, turn the key to the “run”position.
2. Verify the conditions in the table. If they are not met, replace thevoltmeter, as it is not serviceable.
Gauge
Tachometer
Gauge
Voltmeter
Terminal Condition
I 12 volts DC ± 20%
G 0 volts DC ± 20%
Table 1
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GLOSSARY
3 - 10 Demystification Guide
Part Numbers
116749
Purpose
The horn produces a loud tone to let the operator know that the engine isoverheating.
How It Works
When 12 volts is applied to the two terminals, a plate inside the hornoscillates which produces a loud, audible tone.
Testing
1. Disconnect the horn from the wiring harness.
2. Apply 12 volts to the two terminals on the backside of the horn. (It doesnot matter which way you connect the wires.) If the horn does notsound, replace the horn since it is not serviceable.
Part Numbers
117185
Purpose
This simple incandescent bulb is used to indicate to the operator that a lowoil level has been detected during starting.
How It Works
The filament glows when 12 volts is applied. There is no polarity althoughthe lamp comes with a ground ring and male terminal already attached.
Testing
1. Disconnect the lamp from the wiring harness.
2. Apply 12 volts from a known good source. If the lamp does not light,replace it.
Horn
Light
0il Level Indicator
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GLOSSARY
Demystification Guide 3 - 11
Part Numbers
28-7890, 95-0659
Purpose
The module monitors the status of the safety switches and prevents sparkif an “unsafe” condition is encountered.
How It Works
The module “steals” a small amount of current from the ignition coilprimary (through the kill wire.) It sends current through the orange andyellow wires to monitor the status of the safety switches. If EITHER of thefollowing two conditions are met, the module will allow spark (by notgrounding the kill wire).
1. There is continuity from the orange to the yellow wire through thetransmission and deck switches.
2. The orange wire is grounded through the seat switch.
If both circuits are open, the module “connects” the light blue kill wire toground. Note: There is no time delay in this module.
Testing
Caution: When using jumpers to simulate a safe condition, be sure thatthe transmission and PTO lever are disengaged before starting.
The following steps assume your unit does not produce spark. (If the unitruns in an unsafe mode, check to ensure that the module has a goodground to the chassis and that the kill wire is not broken.)
1. Disconnect the module from the wiring harness. Jump from the lightblue wire on the module, to the light blue wire on the harness. Thisallows the module to control spark. Verify now that the unit will notproduce spark when attempting to start.
2. Simulate a safe deck and transmission circuit by jumping across theyellow and orange wires. The unit should now produce spark.
3. Disconnect the jumper from step 2 and simulate an operator on theseat by connecting a jumper from the orange wire to the chassis. Theunit should produce spark. If the module failed any of these threetests, it should be replaced.
NOTE: We have never seen a case of two bad modules in a row. Ifreplacing the module doesn’t cure it, it wasn’t the module.
Module
Interlock
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GLOSSARY
3 - 12 Demystification Guide
Part Numbers
114825, 115207, 79-2130
Purpose
The circuit board drives the dash indictor lights. It monitors the status ofswitches and does not affect normal operation.
How It Works
The light circuit module (printed circuit board) uses an array of resistor anddiodes to get each of the light emitting diodes (LEDs) to light under theright conditions. While the board itself is complex, understanding theconditions needed to light the LEDs is not difficult. It is just a matter ofeither grounding or applying 12 volts D.C. to the appropriate terminals onthe edge of the card.
Testing
Use the circuit diagrams in the back half of this book to troubleshoot themodule.
Important! All tractor electrical systems will operate normally with the lightcircuit module completely disconnected.
Part Numbers
71-6380, NN10444
Purpose
The ignition control opens the primary circuit as the magnet passes by toinduce spark at the proper time.
How It Works
This engine is equipped with an electronic battery ignition system. Bothspark plugs fire simultaneously, thus the need for a distributor iseliminated. The electronic ignition module is located on the engine gearcover behind the flywheel. The module receives a timing signal frommagnets within the trigger ring which rotates with the engine crankshaft(Figure 1). If the electronic ignition is suspected of malfunctioning, proceedas follows.
Testing
1. Check all electrical connections to be sure they are clean and tight. Ifall connections are good and wiring is intact, go to Step 2.
Warning: The electronic ignition will deliver full voltage to the sparkplugs even when rotated by hand. Care should be taken to avoid anelectrical shock.
Warning: Failure to remove spark plugs before turning the engineover may result in engine starting and may cause severe personalinjury.
Warning: Failure to ground spark tester away from the spark plughole may result in ignition of cylinder gases and may cause severepersonal injury.
Module
Trigger
(Onan)
TriggerRing
IgnitionModule
Figure 1
Module
Light Circuit
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GLOSSARY
Demystification Guide 3 - 13
2. Pull spark plug wires off spark plugs and remove spark plugs. Connectan approved spark tester to each of the spark plug wires and groundthem away from the spark plug hole. Turn the key on and crank theengine over for 5 seconds while watching for spark. If a spark occursregularly, the problem is not in the ignition system. If no spark occurs,go to step 3.
Caution: Never put jumper lead to the coil negative terminal. This willcause failure of the electronic ignition module.
3. Connect a jumper lead directly from the positive battery terminal to thepositive (+) coil terminal (smaller diameter of the two threaded posts).Crank the engine over while watching for spark. If spark occurs, theproblem is in the low oil pressure cut out switch (if equipped) orrelating wiring, the lubricating system (low oil pressure), or in the othercircuitry bringing voltage to the coil. If no spark occurs, go to step 4.
4 . Refer to IGNITION COIL section to test coil for proper resistance. If coilchecks out good, go to step 5.
5. Connect positive side of voltmeter to negative (-) coil terminal (largerdiameter of the two threaded posts) and negative side of voltmeter toengine ground. Turn the key on and rotate flywheel slowly by handwhile observing voltmeter. Voltage should switch between batteryvoltage and 1-1.5 for each revolution. If voltage does not switchproperly, replace ignition module.
Caution: Never put B+ lead to the coil negative terminal. This willcause failure of the electronic ignition module.
6. Install spark plugs and wires. If ignition module is being replaced, besure to connect red lead from new ignition module to positive (+)terminal of coil, black lead from module to negative (-) terminal of coil.
FlywheelTimingMark
Blower HousingTiming Marks
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GLOSSARY
3 - 14 Demystification Guide
Part Numbers
57-9430
Purpose
The regulator/rectifier prevents battery boiling by shutting off the current sothat the battery sees only positive current and voltage (see Figure A).
How It Works
The voltage level across the battery is very near constant because thebattery has very low impedance (Figure B). This regulator/rectifier, likemany others, must be connected to the battery to function. Once thevoltage level of the battery has surpassed 13.6 to 14.5 volts, the voltageregulator shuts off all current and no charging takes place (Figure C).When the voltage again drops below the specified level, the voltageregulator turns the current back on at the rated amperage of the alternator.
Testing
Check the battery before checking the regulator/rectifier for properoperation. The battery must be fully charged and in good condition for theregulator/rectifier to operate properly.
Refer to Table 1. Start the engine and check the regulator/rectifier output bymeasuring the battery voltage at the battery terminals with a voltmeter. Ifvoltage is within that specified in Table 1, the regulator/rectifier is good. Ifthe DC voltage is greater than that specified in Table 1, replace regulator/rectifier. If D.C. voltage is less than that specified, shut the engine off.Examine all wires for loose, corroded, broken connections, short circuits,etc. Check fuses. Make certain all circuits are complete from regulator/rectifier B+ terminal to the battery positive terminal; and the batterynegative terminal is properly grounded. Start the engine and check D.C.voltage again. If the D.C. voltage is still less than that specified, test thealternator. If the stator is good, replace the regulator/rectifier.
Part Numbers
KH10215
Purpose
The regulator/rectifier prevents battery boiling by shutting off the currentwhen the battery has reached 14.7 volts.
How It Works
The voltage regulator rectifies the current so that the battery sees onlypositive current and voltage (see Figure A). The voltage level across thebattery is very near constant because the battery has very low impedance(Figure B). This regulator/rectifier, like many others, must be connected tothe battery to function. Once the voltage level of the battery has surpassed14.7 volts, the voltage regulator shuts off all current and no charging takesplace (figure C). When the voltage again drops below the specified level,the voltage regulator turns the current back on at the rated amperage ofthe alternator.
Regulator/Rectifier
(20 Amp)
(Onan)
Regulator/Rectifier
(Kohler)
Test Reading
Primary coil resistance 1.0 Ohm
Secondary coil resistance 9.5 K Ohms
Battery voltage 12 to 13 Volts DC
2.5 amp stator resistance 0.33 Ohms
20 amp stator resistance Appriximately 29 volts AC @ 1800 RPMApproximately 57 volts AC @ 3600 RPM
20 amp stator resistance 0.10 to 0.19 Ohms
Regulator/rectifier output 13.6 to 14.7 volts
Table 1
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GLOSSARY
Demystification Guide 3 - 15
Testing
1. Make sure that the battery is fully charged. (The voltage across thebattery terminals should be 13.6 volts or more.)
2. Insert an ammeter (capable of measuring 20 amps) in series with theB+ lead coming from the voltage regulator.
3. Observe the charging current with the engine running at 3600 rpm (itshould be low).
4. Attach a 2.5 ohm, 100 watt resistor across the battery terminals tosimulate a load. If the reading on the ammeter goes up, the chargingsystem is OK, otherwise proceed to the next step.
5. Remove the connector from the rectifier/regulator. With the enginerunning at 3600 rpm, measure the voltage across the stator terminals.If the voltage is greater than 28 volts, the stator is OK and the regulatoris bad. Otherwise, see the alternator section for further testinginformation.
BATTERY CHARGES CONTINUOUSLY AT HIGH RATE: Measure thevoltage from B+ to ground using a VOM on D.C. scale. If the voltage ismore than 14.7 volts, replace the regulator.
Part Numbers
48-4700, 116397
Purpose
The relay monitors current in one circuit. If current is present, it flips anSPDT switch to the other position.
How It Works
A relay is actually two simpler parts working together.
1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts tothese terminals energizes the coil turning it into an electromagnet.
2. SPDT Switch: Terminals 30, 87, and 87a are all actually part of a singlepole, double throw switch. Terminal 30 is the common lead. The switchis spring loaded so that 30 and 87a are closed when the coil is notenergized. When the coil is energized, the switch is “thrown” and 30and 87 connected. For a simpler explanation, see below:
Testing
1. Disconnect the relay from the circuit.
2. Verify the “not energized’’ conditions above with a VOM.
3. Apply 12 volts to terminals 85 and 86 to energize the coil.
4. Verify the “energized” conditions above with a VOM.
5. Replace relay if any of the conditions in Table 1 were not met.
Relay
Coil Terminals30 + 87
Terminals30 + 87a
Not
Energized
Open Closed
Energized Closed Open
Table 1
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GLOSSARY
3 - 16 Demystification Guide
Part Numbers
71-6010
Purpose
It is part of the system that tells the coil when to fire.
How It Works
Any time a magnet passes by a coil of wire on an iron core, electricity isproduced. The “ignition rotor” is simply two magnets molded into a plastichousing which properly positions it on the crankshaft. As the crankshaftrotates, the magnets pass by the “ignition control” which houses a coil andthe “trigger” circuitry. This generates the small amount of electricityneeded to run the ignition control. In addition, the orientation of themagnets on the crankshaft provides “timing” for the engine.
Testing
Two simple tests can be performed with a flat bladed screwdriver:
1. Pinch the handle end of a flat bladed screwdriver between your thumband forefinger so that the screwdriver dangles. Bring the flat part ofthe blade to within 1/4 inch of one of the magnets. The screwdrivershould be drawn toward the rotor.
2. With the rotor removed, each magnet should be able to support theweight of the rotor when hung from the blade of a flat bladedscrewdriver. If the rotor fails either test, the magnet has lost itsstrength and should be replaced.
Part Numbers
113358
Purpose
This electrical component monitors the level of fuel in the tank.
How It Works
A float is attached to a pivoting lever. This lever rotates a potentiometer (adevice much like the volume control on your stereo) to vary the resistance.The resistance will be 25 to 200 ohms, plus or minus 20%.
Testing
1. Before removing the unit, verify that the float has not sunk. Replace thefloat if it has sunk.
2. Disconnect the sender unit from the wiring harness, and remove it fromthe tank.
3. Verify that it matches the resistances in the table.
Rotor
Ignition
Sender
Fuel Level
Float Position Resistance
Full 25� ± 20%
Empty 200� ± 20%
Table 1
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GLOSSARY
Demystification Guide 3 - 17
Part Numbers
47-1910
Purpose
The solenoid’s purpose is simply to protect the ignition switch from thehigh current drawn by the starter motor.
How It Works
The solenoid has really only two parts. One is a coil of wire wrappedaround an iron core. Whenever 12 volts is applied to the coil, it becomes amagnet. The other part is a steel bar type switch. Because it is made ofsteel it can easily handle the high current loads produced by the startermotor. So how does it protect the ignition switch? When 12 volts is appliedto the coil, it becomes an electromagnet. This quickly pulls the steel bartoward the contacts and closes the switch. When power is removed fromthe coil, the spring loaded bar returns to its “normally open” position. Note:The solenoid closes and opens the switch very quickly. This minimizes the“arcing” that can damage other type switches.
Testing
1. Disconnect the solenoid from the wiring harness.
2. Check to ensure that terminals “c” and “d” are not continuous.
3. Apply a 12 volt power source to “a” and “b” terminals. You should beable to hear the solenoid switch “click” when you make the connection.
4. Verify that the switch has closed by making sure that terminals “c” and“d” are closed when power is applied to terminals “a” and “b”.
Solenoid
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GLOSSARY
3 - 18 Demystification Guide
Part Numbers
71-6040, NN10889, 62-2710, 79-6570
Purpose
The starter motor pushes the starter pinion into engagement with theflywheel, then rotates the starter motor to start the engine.
How It Works
The starter motor is really just a collection of simple parts:
FIELD: A coil of wire on an iron core that becomes an electromagnet whencurrent is applied. It surrounds the armature.
ARMATURE: Eight coils of wire on an iron core that becomeelectromagnets when current is applied. The end of each coil isconnected to a section of the commutator. The armature rotates.
COMMUTATOR: The commutator is the connection point between thebrushes and the coils in the armature. The sections are divided such thatonly one armature coil is “on” at a time. This sets the armature to rotatingbecause the electromagnetic field in the field coil will oppose the one in thearmature.
BRUSHES: Supply power to the commutator.
Starter
Electric
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GLOSSARY
Demystification Guide 3 - 19
Testing
(USE TESTING SECTION FROM ONAN MANUAL, PAGES 9-3 THROUGH9-5.)
Inspect the starter components for mechanical defects before testing forgrounds or shorts.
Testing Armature for Grounds: Connect 1 lead of an ohmmeter to thearmature shaft or core. Touch the other ohmmeter lead to each of thecommutator bars in turn (Figure 1). A low ohmmeter reading indicates agrounded armature. Replace grounded armature.
Testing Armature for an Open Circuit: Using an ohmmeter, check forcontinuity between the commutator segments. If there is no continuity(high resistance), the segments are open and armature must be replaced.
Testing Armature for a Short Circuit: Use growler for locating shorts in thearmature (Figure 2). Place armature in growler and hold a thin steel blade(e.g. hacksaw blade) parallel to the core and just above it while slowlyrotating armature in growler. A shorted armature will cause the blade tovibrate and be attracted to the core. If the armature is shorted, replacewith a new one.
Commutator Inspection: If the commutator is dirty or discolored, clean withnumber 00 to 000 commutator paper. Blow grit out of armature aftercleaning.
If the commutator is scored, rough, or worn, turn it down in a lathe.
Field Coil: Use an ohmmeter to check for continuity between brushes. Ifthere is not continuity, the field coil is open and must be replaced. With thefield coil mounted in the frame, check for continuity between the field coiland frame. Replace frame assembly if there is continuity.
Brushes: Clean around brushes and holders, wiping off all brush dust anddirt. If brushes are worn shorter than .4528 inch (11.5 mm), replace them(Figure 3).
Check for shorts between positive side of brush holder and brush holderbase. If there is continuity, replace holder assembly. Check for freemovement of brushes. All brushes should move freely in the brush holders.
Commutator Bars
Figure 1
HacksawBlade
Growler
Figure 2
.4528 inch(11.5 mm)
Brushes
Wear Limit
Figure 3
Starter
Electric
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GLOSSARY
3 - 20 Demystification Guide
Overrunning Clutch: Inspect pinion and spline teeth for wear or damage.
If pinion gear is worn or damaged, inspect flywheel ring gear also. Rotatepinion. It should turn free when turned in one direction and locked whenturned in the opposite direction.
CAUTION: Do not clean overrunning clutch in solvent or liquid cleaningsolution. Washing the clutch will cause the grease to leak out.
Solenoid: Push solenoid plunger in and release it. The plunger shouldreturn to its original position. While holding plunger all the way in, checkfor continuity between terminals “M” and “B”. If there is no continuity,replace the solenoid (Figure 4). After replacing solenoid check pinionclearance.
Bushings: If either the front or rear bushing show signs of wear ordamage, replace them. Bushing and rear bracket are replaced as anassembly. Check armature shaft thrust gap if rear bracket is replaced.
Remove front bushing by tapping bushing from inside with a 6/16 inch tap.Do not remove cap from front bracket. Thread cap screw, same size astap, into bushing. Using a slide hammer, remove bushing from frontbracket. Press new bushing into front bracket. Use care not to distortinside diameter of bushing.
Figure 4
Overrunning
Clutch
Solenoid
Terminal “S” Terminal “B”
Terminal “M”
Figure 5 Glo
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GLOSSARY
Demystification Guide 3 - 21
How It Works
The starter motor is really just a collection of simple parts:
FRAME: Houses the permanent magnets which produce a magnetic field.This field surrounds the armature and causes it to rotate.
ARMATURE: Eight coils of wire on an iron core that becomeelectromagnets when current is applied. The end of each coil is connectedto a section of the commutator. Thearmature rotates.
COMMUTATOR: The commutator is the connection point between thebrushes and the coils in the armature. The sections are divided such thatonly one armature coil is “on” at a time. This sets the armature to rotatingbecause the electromagnetic field in the field coil will oppose the one in thearmature.
BRUSHES: Supply power to the commutator.
Troubleshooting Guide
PROBLEM POSSIBLE FAULT CORRECTION
STARTERFAILS
TO ENERGIZE
WIRING1. Clean corroded connections and tighten loose connections.2. Replace wires in poor condition and with frayed or broken
insulation.
STARTER SWITCHOR SOLENOID
Bypass the switch or solenoid with a jumper wire. If startercranks normally, replace the faulty parts.
BATTERY Check specific gravity of battery. If low, recharge or replacebattery as necessary.
STARTERENERGIZESBUT TURNS
SLOWLY
BATTERY Check specific gravity of battery. If low, recharge or replacebattery as necessary.
BRUSHESCheck for excessively dirty or worn brushes and commutator.Clean using a coarse cloth (not emery paper). Replace brushesif excessively or unevenly worn.
TRANSMISSIONOR
ENGINE
Make sure the clutch or transmission is disengaged or placed inneutral. This is especially important on equipment withhydrostatic drive. The transmission must be exactly in neutral toprevent resistance which would keep the engine from starting.Check for seized engine components such as bearings,connecting rod, and piston.
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GLOSSARY
3 - 22 Demystification Guide
Part Numbers
NN10739
Purpose
The starter motor pushes the starter pinion into engagement with theflywheel, then rotates the starter motor to start the engine.
How It Works
The starter motor is really just a collection of simple parts:
FIELD: A coil of wire on an iron core that becomes an electromagnet whencurrent is applied. It surrounds the armature.
ARMATURE: Eight coils of wire on an iron core that becomeelectromagnets when current is applied. The end of each coil is connectedto a section of the commutator. The armature rotates.
COMMUTATOR: The commutator is the connection point between thebrushes and the coils in the armature. The sections are divided such thatonly one armature coil is “on” at a time. This sets the armature to rotatingbecause the electromagnetic field in the field coil will oppose the one in thearmature.
BRUSHES: Supply power to the commutator.
Testing
With the starter assembled, disconnect the connecting lead from thestarter solenoid C terminal. Connect a jumper lead from the connectinglead to the battery positive terminal. Connect a jumper lead momentarilybetween the starter motor housing and the battery negative terminal. If themotor doesn’t run, check the motor for problems.
Starter
Electric
Solenoid Mounting Nut
ThroughBoltsMagnet Switch
Mounting Nuts
Starter DriveHousing
ConnectingLead
Brush
Insulator
Brush Holder
Brush Spring
End Frame
Starter Body
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GLOSSARY
Demystification Guide 3 - 23
SOLENOID
Inspection/Service
Attraction Test: Connect a jumper lead from the ST terminal to the positiveterminal of a 6 volt battery. Connect a jumper lead between the C terminaland negative terminal of a 6 volt battery. If the plunger pulls in and holdsstrongly, the solenoid is good. If it doesn’t, replace the solenoid.
Retention Test: Connect a jumper lead from the ST terminal to the positiveterminal of a 6 volt battery. Connect a jumper lead between the solenoidbody and negative terminal of a 6 volt battery. Push the plunger in andrelease it. If the plunger stays in, the solenoid is good. If it doesn’t, replacethe solenoid.
ARMATURE
Inspection/Service
Continuity Between Segments: Refer to Figure 1. Check for continuitybetween the segments of the commutator. If there is no continuity, replacethe armature.
Armature Coil Core and Commutator Continuity: Refer to Figure 2.Check for no continuity between the commutator and the armature coilcore. If continuity exists, replace the armature.
Armature’s Shaft and Commutator Continuity: Refer to Figure 3. Checkfor no continuity between the commutator and armature’s shaft. Ifcontinuity exists, replace the armature.
Armature Shaft and Bushing Clearance: Refer to Figures 4 and 5.Measure the bushing inside diameter in the starter drive housing and endframe. Measure the armature shaft outside diameter on the pinion side andcommutator side. If the clearance is not as specified in Table 1, replace thebushing.
Starter
Electric(continued)
Figure 5
Figure 4
Figure 3
Figure 2
Figure 1
CommutatorSegments
ArmatureCoil Core
Commutator
CommutatorArmature
Shaft
Bushing
Starter DriveHousing
Pinion side ofArmature Shaft
Electrical System Factory Min. SpecificationMax.
Allowable Limit
Commutator O.D. 1.102(28.0)
1.063(27.0)
Difference ofCommutator O.D.’s
Less than 0.00027(Less than 0.05)
0.016(0.4)
Armature’s Shaft toBushing Clearance
0.0008(0.02)
0.0027(0.07)
0.0079(0.20)
Mica Undercut 0.0177(0.45)
0.0295(0.75)
0.008(0.2)
Table 1
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GLOSSARY
3 - 24 Demystification Guide
COMMUTATOR AND MICA
Inspection/Service
Commutator: Refer to Figure 6. Clean commutator surface withsandpaper. Measure the commutator outside diameter at several points. Ifthe difference of the outside diameter is not as specified in Table 1, correctthe commutator on a lathe to factory specifications. If the minimum outsidediameter is less than the allowable limit, replace the armature.
Mica: Refer to Figure 7. Measure the mica undercut depth. If the undercutis less than that specified in Table 1, use a saw blade to increase the depthand then chamfer the segment edges.
OVERRUNNING CLUTCH
Inspection/Service
CAUTION: Do not clean overrunning clutch in liquid cleaning solutions. asit will damage the starter.
Refer to Figure 8. Inspect the pinion and spline teeth for wear anddamage. If wear or damage exists, replace pinion. Rotate the pinionclockwise and see if it turns freely. Replace pinion if it doesn’t. Rotate thepinion counterclockwise to see if it locks. Replace pinion if it doesn’t.
BRUSHES
Inspection/Service
Refer to Figure 9. Clean the brush face with sandpaper. Measure the brushlength. If the length is not as specified in Table 1, replace the starter bodyand brush holder.
STARTER BODY
Inspection/Service
Refer to Figure 10. Check for continuity across the starter body andbrushes. There are four brushes in the starter body. The two that are notgrounded are 180° apart starting at the terminal which connects to thesolenoid. The two that are grounded are located 90° from the non-grounded terminals. If continuity exists at the non-grounded terminals,replace the starter body. If continuity does not exist at the groundedterminals, replace the starter body.
Assembly
Assemble the starter in the reverse of disassembly, but apply grease to theparts indicated.
• solenoid joint
• drive lever
• pinion gear teeth
• armature shaft
Figure 10
Figure 8
Figure 7
Figure 6
Figure 9
Commutator
Micaundercut
depth
SegmentEdges
SawBlade
Pinion
Brush
Starterbody
Brush
Non-GroundedTerminal
GroundedTerminal(hidden)
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GLOSSARY
Demystification Guide 3 - 25
Part Numbers
114270
Purpose
This switch monitors vacuum in the air cleaner box to determine if the aircleaner is plugged.
How It Works
The switch is turned on by a slight vacuum applied to the inlet. This isaccomplished by a small electrical contact that is connected to adiaphragm inside the switch. Note: Switch comes with one femalecrimp-on connector.
Testing
1. Verify that the hose is connected to the “vacuum” side of the switch.(Notice that there is also a pressure side.)
2. Disconnect the wiring harness and the hose.
3. Verify that there is no continuity across the two terminals.
4. Connect a vacuum gauge to the switch and evacuate slightly. Thereshould be continuity.
Part Numbers
NN10274
Purpose
The engine temperature switch turns on an indicator light when the headtemperature reaches the temperature specified below.
How It Works
The contacts inside the switch are normally open. As the body of theswitch warms, the clearance between the contacts narrows, until theswitch closes at 320-340 degrees F. It does not reopen until thetemperature falls to 280-310 degrees F.
Testing
1. Remove the switch from the harness.
2. Using a VOM or a test light, check the circuit between the body of theswitch and the terminal. There should not be continuity at roomtemperature.
3. The point at which the switch turns on can be tested by heating to300 degrees F. Slowly raise the temperature of the switch, noting thepoint at which the switch turns on. It should close between 320 and340 degrees F. Keep track of the temperature as the switch cools andnote the point at which it again opens. It should open between 280and 310 degrees F.
Switch
Air CleanerPressure
Switch
Engine Temperature
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GLOSSARY
3 - 26 Demystification Guide
Part Numbers
Purpose
The float switch is wired into the starter motor circuit to prevent starting in alow oil situation. It will not kill the engine once running!
How It Works
The float switch houses a small magnet which pulls the contacts closedwhen the float is down. When the float is up, the contacts are open.
Testing
1. Verify that the flats on the switch body are vertical and the letters N.C.are on the top side.
2. Disconnect the switch from the harness and test for continuity. Theswitch should be open with the oil at a safe level. Note: If testing with aVOM, expect to see some resistance when the switch is closed.
3. Drain the oil from the engine, then retest for continuity. The switchshould be closed (and will probably show some resistance which isnormal). If the switch fails either of these tests, it should be replaced.
TIPS FOR REMOVAL/INSTALLATION:
1. Drain oil before rotating switch.
2. Use a continuous motion when turning, stopping only with the flatsvertical.
3. Rotate by hand as soon as possible to prevent damage if the floatcatches something.
4. Use a sealant on the threads when reinstalling.
5. Make sure that the flats are vertical and the letters N.C. are on the topside!
Part Numbers
103990
Purpose
This component provides the proper switching for the starter, ignition, PTO,safety, and accessory circuits if so equipped.
How It Works
Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so the cylinder automatically returns to run oncethe key is released.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
3. Check each of the terminals to ground. There should be nocontinuity.
Switch
Float (kit)
(Kohler)
Switch
Ignition
Position Condition
Off None
Run B+I+A+R
Start B+S+I+R
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GLOSSARY
Demystification Guide 3 - 27
Part Numbers
103991
Purpose
This component provides the proper switching for the starter, ignition, PTO,safety, and accessory circuits.
How It Works
Detents inside the switch give it three positions: off, run, and start The startposition is spring loaded so the cylinder automatically returns to run oncethe key is released.
Note: The letters shown in the illustration are written on the side of theterminals.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the following conditions in the table.
3. Check for continuity between each of the terminals and the switch case.Only the ground terminal should show continuity.
Part Numbers
116338
Purpose
116338 provides the proper switching for the starter, ignition, and safetyinterlock circuits.
How It Works
Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so that the cylinder automatically returns to “run”.
Note that this switch does not come with a key. The case is connected tothe ground terminal.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Note: The letters stamped on the switch terminals may not be correct. Usethe diagram at the left to identify the individual terminals.
Switch
Ignition
Switch
Ignition
Position Condition
Off G+M+A
Run B+A+R
Start B+S
Position Condition
Off G+M
Run B+L
Start B+L+S1
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GLOSSARY
3 - 28 Demystification Guide
Part Numbers
117292
Purpose
This component provides the proper switching for the starter, Ignition,PTO, safety, and accessory circuits.
How It Works
Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so the cylinder automatically returns to run oncethe key is released.
Note: This switch does not have the labels shown at the left and does notcome with a key.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
3. Check for continuity between each of the terminals and the switch case.There should be no continuity.
Part Numbers
23-0660
Purpose
23-0660 provides the proper switching for the starter, ignition, and safetyinterlock circuits.
How It Works
Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so that the cylinder automatically returns to “run".
Note: This switch does not come with a key. The case is connected to theground terminal.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
3. Check each of the terminals to the switch body. There should be nocontinuity except for the ground (G) terminal.
Switch
Ignition
Switch
Ignition
Position Condition
Off M+G
Run B+A
Start B+A, S1+S2
Position Condition
Off G+M
Run B+L
Start B+S
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GLOSSARY
Demystification Guide 3 - 29
Part Numbers
38-1420
Purpose
This switch monitors whether or not an operator is in the seat.
How It Works
The switch is open without an operator and closed with an operator. Theribbon operates a friction mechanism which, in turn, activates the switch.A removable cover provides access to the switch contacts.
Testing
Note: Because of the friction mechanism, it is possible to get falsereadings with the switch removed from the seat. Perform testing with theswitch in place.
1. Disconnect the switch from the circuit, but do not remove from the seat.
2. Verify the conditions in the table.
Part Numbers
102138
Purpose
Typically used to provide switching for the lights.
How It Works
Contacts inside the switch physically connect the two terminals to providecontinuity. It is an SPST switch with a load capacity of 3 Amps at 250 V, and6 amps at 125 V.
Testing
1. Remove the switch from the wiring harness.
2. Using a VOM or test lamp, test the switch with the lever in one positionand note whether or not there is continuity.
3. Flip the switch, then recheck to ensure that the status has changed.
Part Numbers
113191, 92-9844
Purpose
This rocker switch is typically used to provide switching for lights.
How It Works
The switch has contacts inside which connect the two terminals in oneposition while disconnecting them in the other. It is an SPST type rockerswitch with 8 amp capacity at 12 volts.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the following:
a. the terminals are not continuous when off.
b. the terminals are continuous when the switch is on.
Switch
Interlock
Switch
Light
Switch
Light
Condition Status
Operator On Closed
Operator Off Open
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GLOSSARY
3 - 30 Demystification Guide
Part Numbers
40-8200
Purpose
Used as part of the safety interlock circuit, it is typically used to monitorwhether or not an operator is in the seat.
How It Works
This SPDT micro switch has three terminals. The lever is spring loaded inthe “up” position. When the button is pushed down, continuity switchesfrom COM and NC to COM and NO.
Testing
1. Disconnect the switch from the harness.
2. Verify the conditions in the table.
Part Numbers
28-4250
Purpose
This switch monitors whether the transmission in in neutral or in gear.
How It Works
This unique SPST switch is actuated by a ball that rides against a pivotingbracket. When the transmission is in neutral, the ball falls into a hole whichcloses the switch. When the transmission is in gear, the bracket depressesthe ball which, in turn, opens the switch.
Testing
1. Disconnect the switch from the wiring harness, but do not remove.
2. Check first to ensure that there is NO continuity between either terminaland ground. (This type failure can produce some VERY unusualsymptoms.)
3. With the transmission in neutral, verify that the terminals have continuity.
4. With the transmission in gear, make sure that the terminals are notcontinuous.
5. If the switch failed step 3 or 4, remove the switch and depress the ballmanually to test. If the switch passes, the shift bracket is probably thesource of the difficulty.
Switch
Micro
Button Condition
Up COM+NC
Down COM+no
Switch
Neutral
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GLOSSARY
Demystification Guide 3 - 31
Part Numbers
116237
Purpose
To ensure that the parking brake is on when 1. starting 2. the operatorleaves the seat.
How It Works
Two small mercury switches inside the potted container provide continuitywhen the parking brake is engaged. When disengaged, the assembly isrotated to another position which opens both switches inside. This is aDPST switch.
Testing
1. Disconnect the switch from the wiring harness, but DO NOT REMOVE ITfrom the parking brake bracket.
2. With the parking brake on, verify that there is continuity across the twoterminals in each connector.
3. With the parking brake off, there should be no continuity across theterminals in each connector.
Part Numbers
116822
Purpose
To insure that the parking brake is on when 1. starting 2. the operatorleaves the seat.
How It Works
Two small mercury switches inside the potted container are oriented toprovide one open and one closed switch when the parking brake isengaged. When disengaged, the assembly is rotated to another positionwhich reverses the switch conditions.
Note: This switch is similar in construction to 116237, except that theswitches provide opposing conditions rather than the same. This isnecessary because the Briggs and Stratton engine uses mag style ignitioninstead of the coil type in the Onan’s.
Testing
1. Disconnect the switch from the wiring harness, but do not remove itfrom the parking brake bracket.
2. With the parking brake on, verify the conditions in the table.
Note: The male pins connect with the orange and white wires on theharness, while the female pins connect with the purple and light blue pins.
Switch
Neutral/Parking Brake
Switch
Neutral/Parking Brake
BrakePosition
MalePins
FemalePins
On Closed Open
Off Open Closed
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GLOSSARY
3 - 32 Demystification Guide
Part Numbers
NN10520
Purpose
The oil pressure switch on the 724 turns on the hourmeter. This ensuresthat the hourmeter is not accidentally left running.
How It Works
When the engine is not running, the switch is open. Once the engine hasbeen started, oil enters through a small hole on the threaded end. Thispresses on a diaphragm which moves a switch contact on the dry side ofthe diaphragm. When pushed far enough, the contacts close. Note: Thecontact is adjustable so that the switching pressure can be varied. It is setto close from the factory at 5 psi + 2 psi.
Testing
1. Disconnect the switch from the system.
2. Verify the conditions in the table.
3. If the switch is opening when the machine is idling, verify that you haveproper oil pressure at idle (consult your engine manual.) If so, slowlyrotate the adjusting screw on the back of the switch until the switchjust closes.
4. If the switch is operating intermittently, check for a loose electrical wire,or an obstruction to the orifice on the threaded end of the switch.
Part Numbers
NN10813
Purpose
This switch is optional on the 200 series tractors and could be used to turnon an hourmeter.
How It Works
When the engine is not running, the switch is open. Once the engine hasbeen started, oil enters through a small hole on the threaded end. Thismoves the diaphragm which moves a switch contact on the dry side of thediaphragm. When pushed far enough, the switch contacts close. Note:The contact is adjustable by turning the small set screw at the base of theterminal. It is set to close at 1 psi ± ½ psi from the factory.
Testing
1. Disconnect the switch from the system.
2. Verify the conditions in the table.
3. If the switch is opening when the machine is idling, verify that you haveproper oil pressure at idle (consult your engine manual.) If so, slowlyrotate the adjusting screw on the back of the switch until the switchjust closes.
4. If the switch is operating intermittently, check for a loose electrical wire,or an obstruction to the orifice on the threaded end of the switch.
Switch
Oil Pressure
Engine Switch
No Oil Pressure Open
Oil Pressure OK Closed
Switch
Oil Pressure
Engine Switch
No Oil Pressure Open
Oil Pressure OK Closed
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GLOSSARY
Demystification Guide 3 - 33
Part Numbers
NN10824
Purpose
The low oil pressure switch turns off the oil pressure indicator light andturns on the hourmeter.
How It Works
The mechanism inside the switch is simply a lever that is moved by adiaphragm. When there is no oil pressure, the NO switch is open, and theNC switch is closed. Once oil pressure is present at the pressure switchorifice, the diaphragm moves the lever and reverses the status of each ofthe switches. The switch should change status at 5 psi ± 2 psi.
Testing
1. Disconnect the harness from the switch.
2. Verify the conditions in the table.
3. If the switch is failing intermittently, verify proper oil pressure at idle(consult your engine manual.) The switch is set to change status at 5psi ± 2 psi. Also check to ensure that nothing is obstructing the orificeon the threaded end of the switch.
4. If one or both switches are switching at the incorrect pressure, thecontacts can be adjusted. Use the set screws at the base of eachterminal to get the desired results. Once adjusted, prevent undesiredrotation by sealing with a small amount of fingernail polish.
Part Numbers
116716
Purpose
Typically used to turn on the electric blade clutch and to function as part ofthe safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. One of theSPDT switches is connected to the electric PTO clutch. When in the offposition, this side of the switch is open. The other half of the switch isused by the safety interlock system. When the clutch is off, this side of theswitch is closed. This allows current to keep the kill relay energized so thatthe mag is not grounded out.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Switch
Oil Pressure
Oil Pressure NC Switch NO Switch
No Pressure Closed Open
Pressure OK Open Closed
Switch
PTO/Clutch
Lever Condition
Up Open
Down Closed
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GLOSSARY
3 - 34 Demystification Guide
Part Numbers
111332
Purpose
Used as part of the safety interlock circuit, it is typically used to monitor theposition of the PTO or brake lever.
How It Works
This SPDT microswitch has three terminals. The lever is spring loaded inthe “up” position. When the lever on top of the switch is pushed, continuityswitches from COM1 and NC2 to COM1 and NO3.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Part Numbers
116716
Purpose
Typically used to turn on the electric blade clutch and to function as part ofthe safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. One of theSPDT switches is connected to the electric PTO clutch. When in the offposition, this side of the switch is open. The other half of the switch is usedby the safety interlock system. When the clutch is off, this side of the switchis closed. This allows current to keep the kill relay energized so that themag is not grounded out.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Switch
PTO/Clutch
Button Condition
Up COM+NC2
Down COM+NO3
Switch
PTO/Clutch
Position Lever Condition
Off Down b+a, e+d
On Up b+c, e+f
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GLOSSARY
Demystification Guide 3 - 35
Part Numbers
78-3030
Purpose
Typically used to turn on the electric blade clutch and to function as part ofthe safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. One of theSPDT switches is connected to the electric PTO clutch. When in the “off”position, this side of the switch is open. The other half of the switch is usedby the safety interlock system. When the clutch is “off”, this side of theswitch is closed. This allows current to keep the kill relay energized so thatthe mag is not grounded out.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Part Numbers
78-9670
Purpose
This switch is typically used to turn on the electric blade clutch and tofunction as part of the safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. In the 724, oneside of the switch is used to ensure that the PTO switch is in the “off”position during starting. The other side is used to turn on the clutch and toprevent spark if the operator is out of the seat when the switch is in the“on” position.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Switch
PTO/Clutch
Position Lever Condition
Off Down b+a, e+d
On Up b+c, e+f
Switch
PTO/Clutch
Position Lever Condition
Off Down b+a, e+d
On Up b+c, e+f
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GLOSSARY
3 - 36 Demystification Guide
Part Numbers
116194
Purpose
This normally closed switch opens when an operator sits on the seat.
How It Works
This DPST switch has two sets of two contacts inside. When at rest, oneset of contacts is closed while the other set is open. The opposite is truewhen the button is depressed. The normally closed set of terminals is smallwhile the normally open side are larger.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Part Numbers
116752
Purpose
This switch is used to test the operation of the engine temperature horn.
How It Works
It is an SPST rocker type switch that is spring loaded in the open position.The hole for backlighting is not used.
Testing
1. Disconnect the switch from the wiring harness.
2. Check the two terminals for continuity. There should be none.
3. Hold the rocker and verify that the two terminals are now continuous.
Switch
Seat
Button Condition
At Rest a+b
Depressed c+d
Switch
Test
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GLOSSARY
Demystification Guide 3 - 37
Part Numbers
116796
Purpose
This SPDT switch is typically used to test the lights on the interlock board.When it is pushed in, the lights should come on.
How It Works
This small push button type switch is spring loaded so that the C and NCterminals are connected. When the button is pushed, C and NC open, andC and NO close. The switch is rated for 3 amps at 250 volts or 6 amps at125 volts.
Testing
1. Disconnect the switch from the harness.
2. Verify the conditions in the table.
Part Numbers
113193
Purpose
Contacts on switch close when the switch body reaches a predeterminedtemperature. (Usually used for hydraulic fluid.)
How It Works
A bimetal post inside the switch bends as the temperature rises. Once thetemperature is high enough, the top of the post makes contact with theterminal to close the switch. The switch is set to close at 200° F. Normal oiltemperature is 180° F.
Testing
1. Disconnect the switch from the wiring harness.
2. Test the continuity between the body of the switch and the terminal atroom temperature. There should not be continuity.
3. If you have the ability to measure high temperatures, you can verifyoperation of the switch in a liquid heated to the “switching”temperature.
Caution: Be careful not to contact the heated liquid.
Switch
Test
Switch
Transmission Oil
Button Condition
At Rest C+NC
Depressed C+NO
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GLOSSARY
3 - 38 Demystification Guide
rev. 4-03
rev. 4-03
rev. 4-03
rev. 4-03
1989 - 1992 825
rev. 4-03
4 - 5Demystification Guide
825 Information List (1989 - 1992)
Wiring Diagram . . . . . . . . . . . . . . 4-6Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-7Spark Circuit . . . . . . . . . . . . . 4-7Kill Circuit . . . . . . . . . . . . . . 4-7Charging Circuit . . . . . . . . . . . 4-8
825 1989 - 1992
Wiring Diagram rev. 4-03
4 - 6 Demystification Guide
rev. 4-03
4 - 7Demystification Guide
Start Motor Circuit(ignition switch in “start”)
1989 - 1992 825
Spark Circuit(ignition switch in “start” or “run”)
Kill Circuit(ignition switch “off”)
rev. 4-03
4 - 8 Demystification Guide
Charging Circuit
825 1989 - 1992
1993 - 1995 825 RER(70040 & 70060)
rev. 4-03
4 - 8ADemystification Guide
825 Information List (1993 - 1995)
Wiring Diagram . . . . . . . . . . . . . . 4-08BCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-08CSpark Circuit . . . . . . . . . . . . . 4-08DSpark Circuit . . . . . . . . . . . . . 4-08ECharging Circuit . . . . . . . . . . . 4-08F
825 RER 1993 - 1995(70040 & 70060)
Wiring Diagram rev. 4-03
4 - 8B Demystification Guide
rev. 4-03
4 - 8CDemystification Guide
1993 - 1995 825 RER(70040 & 70060)
Starter Motor Circuit
rev. 4-03
4 - 8D Demystification Guide
Spark Circuit(ignition switch in “run”)
825 RER 1993 - 1995(70040 & 70060)
4 - 8EDemystification Guide
1993 - 1995 825 RER(70040 & 70060)
Spark Circuit(ignition switch in “start” or “run”)
rev. 4-03
Charging Circuit
825 RER 1993 - 1995(70040 & 70060)
rev. 4-03
4 - 8F Demystification Guide
1996 - 1997 825 RER(70040 & 70060)
1998 (70040)
rev. 4-03
4 - 8GDemystification Guide
825 Information List (1996 - 1997)(1998)
Wiring Diagram . . . . . . . . . . . . . . 4-08HCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-08ISpark Circuit . . . . . . . . . . . . . 4-08JSpark Circuit . . . . . . . . . . . . . 4-08KCharging Circuit . . . . . . . . . . . 4-08L
825 RER 1996 - 1997(70040 & 70060)(70040) 1998
Wiring Diagram rev. 4-03
4 - 8H Demystification Guide
4 - 8IDemystification Guide
1996 - 1997 825 RER(70040 & 70060)
1998 (70040)
rev. 4-03 Starter Motor Circuit
rev. 4-03
4 - 8J Demystification Guide
Spark Circuit(ignition switch in “run”)
825 RER 1996 - 1997(70040 & 70060)(70040) 1998
4 - 8KDemystification Guide
rev. 4-03
1996 - 1997 825 RER(70040 & 70060)
1998 (70040)
Spark Circuit(ignition switch in “start” or “run”)
Charging Circuit rev. 4-03
4 - 8L Demystification Guide
825 RER 1996 - 1997(70040 & 70060)(70040) 1998
1998 825 RER(70041 & 70060)
rev. 4-03
4 - 8MDemystification Guide
825 Information List (1998)
Wiring Diagram . . . . . . . . . . . . . . 4-08NCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-08OSpark Circuit . . . . . . . . . . . . . 4-08PSpark Circuit . . . . . . . . . . . . . 4-08QCharging Circuit . . . . . . . . . . . 4-08R
825 RER 1998(70041 & 70060)
Wiring Diagram rev. 4-03
4 - 8N Demystification Guide
rev. 4-03
4 - 8ODemystification Guide
1998 825 RER(70041 & 70060)
Starter Motor Circuit
Spark Circuit(ignition switch in “run”)
825 RER 1998(70041 & 70060)
Demystification Guide4 - 8P
rev. 4-03
4 - 8QDemystification Guide
1998 825 RER(70041 & 70060)
Spark Circuit(ignition switch in “start”)
rev. 4-03
Charging Circuit
825 RER 1998(70041 & 70060)
rev. 4-03
4 - 8R Demystification Guide
1999 - 2001 825 - RER
rev. 4-03
4 - 9Demystification Guide
825 - RER Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . . . . . 4-10Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-11Run Circuit (Forward) . . . . . . . . . . 4-12Run Circuit (Reverse) . . . . . . . . . . 4-13Charging Circuit . . . . . . . . . . . . 4-14
825 - RER 1999 - 2001
Wiring Diagram rev. 4-03
4 - 10 Demystification Guide
rev. 4-03
4 - 11Demystification Guide
1999 - 2001 825 - RER
Starter Motor Circuit(ignition switch in start)
Run Circuit (Forward)(PTO “on”)
825 - RER 1999 - 2001
Demystification Guide4 - 12
rev. 4-03
4 - 13Demystification Guide
1999 - 2001 825 - RER
Run Circuit (Reverse)(PTO “on” - NMIR “on”)
rev. 4-03
Charging Circuit
825 - RER 1999 - 2001
Demystification Guide4 - 14
rev. 4-03
1994 - 1995 10-32 & 12-32
rev. 4-03
4 - 14ADemystification Guide
10-32 & 12-32 Information List (1994 - 1995)
Wiring Diagram . . . . . . . . . . . . . . 4-14BCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-14CSpark Circuit . . . . . . . . . . . . . 4-14CKill Circuit . . . . . . . . . . . . . . 4-14CCharging Circuit . . . . . . . . . . . 4-14D
10-32 & 12-32 1994 - 1995
Wiring Diagram rev. 4-03
4 - 14B Demystification Guide
1994 - 1995 10-32 & 12-32
rev. 4-03
4 - 14CDemystification Guide
Charging Circuit
10-32 & 12-32 1994 & 1995
rev. 4-03
4 - 14D Demystification Guide
1991 - 1992 832 & 10-32 & 12-32
rev. 4-03
4 - 15Demystification Guide
832 & 10-32 & 12-32 Information List (1991 - 1992)
Wiring Diagram . . . . . . . . . . . . . . 4-16Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-17Spark Circuit . . . . . . . . . . . . . 4-17Spark Circuit . . . . . . . . . . . . . 4-17Charging Circuit . . . . . . . . . . . 4-17
rev. 4-03
rev. 4-03
This page intentionally left blank
4 - 18 Demystification Guide
1993 832 RER(70042)
rev. 4-03
4 - 18ADemystification Guide
825 Information List (1993)
Wiring Diagram . . . . . . . . . . . . . . 4-18BCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-18CSpark Circuit . . . . . . . . . . . . . 4-18DSpark Circuit . . . . . . . . . . . . . 4-18ECharging Circuit . . . . . . . . . . . 4-18F
832 RER 1993(70042)
Wiring Diagram rev. 4-03
4 - 18B Demystification Guide
rev. 4-03
1993 832 RER(70042)
Starter Motor Circuit
Demystification Guide 4 - 18C
rev. 4-03
4 - 18D Demystification Guide
Spark Circuit(ignition switch in “run”)
832 RER 1993(70042)
4 - 18EDemystification Guide
1993 832 RER(70042)
Spark Circuit(ignition switch in “start”)
rev. 4-03
Charging Circuit
832 RER 1993(70042)
rev. 4-03
4 - 18F Demystification Guide
108-4, 108-5, & 111-6 Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 4-20
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 4-21
Spark Circuits . . . . . . . . . . 4-21 & 4-22
Charging Circuit . . . . . . . . . . . . . 4-22
Gauge Circuit . . . . . . . . . . . . . . . 4-22
In
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1988 108-4, 108-5, & 111-6
Demystification Guide 4 - 19
Wiring Diagram
Wir
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108-4, 108-5, & 111-6 1988
4 - 20 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
1988 108-4, 108-5, & 111-6
Demystification Guide 4 - 21
Charging Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
Cir
cu
its
Spark Circuit
(ignition switch in “run”)
108-4, 108-5, & 111-6 1988
4 - 22 Demystification Guide
112-C Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 4-24
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 4-25
Spark Circuits . . . . . . . . . . 4-25 & 4-26
Charging Circuit . . . . . . . . . . . . . 4-26
Gauge Circuit . . . . . . . . . . . . . . . 4-26
In
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1988 112-C
Demystification Guide 4 - 23
Wiring Diagram
Wir
ing
Dia
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m
112-C 1988
4 - 24 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
1988 112-C
Demystification Guide 4 - 25
Gauge Circuit
(ignition switch in “run”)
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Spark Circuit
(ignition switch in “run”)
112-C 1988
4 - 26 Demystification Guide
1996 - 1998 11-32 & 13-32
rev. 4-03
4 - 27Demystification Guide
11-32 & 13-32 Information List (1996 - 1998)
Wiring Diagram . . . . . . . . . . . . . . 4-28Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-29Spark Circuits . . . . . . . . . . . . . 4-29Spark Circuits . . . . . . . . . . . . . 4-30Charging Circuit . . . . . . . . . . . . 4-30
rev. 4-03
rev. 4-03
rev. 4-03
4 - 30 Demystification Guide
Spark Circuit(ignition switch in “run”)
11-32 & 13-32 1996 - 1998
Charging Circuit
1999 - 2001 12-32 - RER
rev. 4-03
4 - 31Demystification Guide
12-32 - RER Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . . . . . 4-32Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-33Run Forward . . . . . . . . . . . . . 4-34Run Reverse . . . . . . . . . . . . . 4-35Charging Circuit . . . . . . . . . . . . 4-35
12-32 - RER 1999 - 2001
Wiring Diagram rev. 4-03
4 - 32 Demystification Guide
rev. 4-03
4 - 33Demystification Guide
1999 - 2001 12-32 - RER
Starter Motor Circuit(ignition switch in “start”)
Run Forward(PTO “on”)
12-32 - RER 1999 - 2001
Demystification Guide4 - 34
rev. 4-03
4 - 35Demystification Guide
1999 - 2001 12-32 - RER
Run Reverse(PTO “on” - NMIR override)
rev. 4-03
Charging Circuit
Demystification Guide4 - 36
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Information List
208-4SB, 211-5SB, 211-4 & 212-5 (1988-1989)
210-5 & 210-H (1990)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-2
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-3
Spark Circuits . . . . . . . . . . . . 5-3 & 5-4
Charging Circuit . . . . . . . . . . . . . . 5-5
Electric Clutch . . . . . . . . . . . . . . . 5-5
Light Circuit . . . . . . . . . . . . . . . . 5-5
Voltmeter Circuit . . . . . . . . . . . . . 5-5
In
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t1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5
1990 210-5 & 210-H
Demystification Guide 5 - 1
Wiring Diagram
Wir
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Dia
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m208-4SB, 211-5SB, 211-4, & 212-5 1988 - 1989
210-5 & 210-H 1990
5 - 2 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5
1990 210-5 & 210-H
Demystification Guide 5 - 3
Electric Clutch
(ignition switch in “run”)Cir
cu
its
Charging Circuit
(ignition switch in “run”)Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Spark Circuit
(ignition switch in “run”)
208-4SB, 211-5SB, 211-4, & 212-5 1988 - 1989
210-5 & 210-H 1990
5 - 4 Demystification Guide
Voltmeter Circuit
(ignition switch in “run”)
Cir
cu
its
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Light Circuit
(ignition switch in “run”)
1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5
1990 210-5 & 210-H
Demystification Guide 5 - 5
This page intentionally left blank
5 - 6 Demystification Guide
1991 & 1993 - 1995 210-5 & 210-H1992 212-H
rev. 4-03
5 - 7Demystification Guide
210-5 & 210-H Information List (1991 & 1993 - 1995)212-H (1992)
Wiring Diagram . . . . . . . . . . . . . . 5-8Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 5-9Spark Circuit . . . . . . . . . . . 5-9 & 5-10Charging Circuit . . . . . . . . . . . 5-10Electric Clutch Circuit . . . . . . . . . 5-10
210-5 & 210-H 1991 & 1993 - 1995212-H 1992
Wiring Diagram rev. 4-03
5 - 8 Demystification Guide
rev. 4-03
210-5 & 210-H 1991 & 1993 - 1995212-H 1992
5 - 10 Demystification Guide
rev. 4-03Spark Circuit(ignition switch in “run”)
Charging Circuit
Electric Clutch(ignition switch in “run”)
210-5 & 210-H Information List (1992)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-12
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-13
Spark Circuits . . . . . . . . . . 5-13 & 5-14
Charging Circuit . . . . . . . . . . . . . 5-14
Electric Clutch Circuit . . . . . . . . . . 5-14
In
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1992 210-5
Demystification Guide 5 - 11
Wiring Diagram
Wir
ing
Dia
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210-5 1992
5 - 12 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1992 210-5
Demystification Guide 5 - 13
Cir
cu
its
Spark Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
Charge Circuit
(ignition switch in “run”)
210-5 1992
5 - 14 Demystification Guide
212-5 & 212-H Information List (1991)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-16
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-17
Spark Circuits . . . . . . . . . . . 5-17 & 5-18
Charging Circuit . . . . . . . . . . . . . . 5-18
Electric Clutch . . . . . . . . . . . . . . . 5-18
Light Circuit . . . . . . . . . . . . . . . . 5-19
In
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1991 212-5 & 212-H
Demystification Guide 5 - 15
Wiring Diagram
Wir
ing
Dia
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m
212-5 & 212-H 1991
5 - 16 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
1991 212-5 & 212-H
Demystification Guide 5 - 17
Spark Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
Electric Clutch
(ignition switch in “run”)
Cir
cu
its
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
212-5 & 212-H 1991
5 - 18 Demystification Guide
Light Circuit
(ignition switch in “run”)
Cir
cu
its
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
1991 212-5 & 212-H
Demystification Guide 5 - 19
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5 - 20 Demystification Guide
212-5 & 212-H Information List (1990)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-22
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-23
Spark Circuits . . . . . . . . . . . . . . . 5-23
Charging Circuit . . . . . . . . . . . . . . 5-24
Electric Clutch . . . . . . . . . . . . . . . 5-24
Gauge Circuit . . . . . . . . . . . . . . . 5-24
Kill Circuit . . . . . . . . . . . . . . . . . 5-24
Light Circuit . . . . . . . . . . . . . . . . 5-25
In
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1990 212-5 & 212-H
Demystification Guide 5 - 21
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
Spark Circuit
(ignition switch in “run”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
1990 212-5 & 212-H
Demystification Guide 5 - 23
Charging Circuit
Electric Clutch
(ignition switch in “run”)
Cir
cu
its
Gauge Circuit
(ignition switch in “run”)
Kill Circuit
(ignition switch in “off”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
212-5 & 212-H 1990
5 - 24 Demystification Guide
Light Circuit
(ignition switch in “run”)
Cir
cu
its
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
1990 212-5 & 212-H
Demystification Guide 5 - 25
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5 - 26 Demystification Guide
212-5 Information List (1992)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-28
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-29
Spark Circuits . . . . . . . . . . 5-29 & 5-30
Charging Circuits . . . . . . . . . . . . . 5-30
Electric Clutch Circuit . . . . . . . . . . 5-30
In
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1992 212-5
Demystification Guide 5 - 27
212-5 1992
Wiring Diagram rev. 4-03
5 - 28 Demystification Guide
rev. 4-03
5 - 29Demystification Guide
1992 212-5
Starter Motor Circuit(ignition switch in “start”)
Spark Circuit(ignition switch in “start”)
rev. 4-03
5 - 30 Demystification Guide
Spark Circuit(ignition switch in “run”)
212-5 1992
Charging Circuit
Electric Clutch Circuit(ignition switch in “run”)
212-6 Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-32
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-33
Spark Circuits . . . . . . . . . . . . . . 5-33
Charging Circuit . . . . . . . . . . . . . 5-34
Oil Pressure Light Circuit . . . . . . . . . 5-34
Gauge Circuit . . . . . . . . . . . . . . . 5-34
Electric Clutch Circuit . . . . . . . . . . 5-35
In
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1988 212-6
Demystification Guide 5 - 31
Wiring Diagram
Wir
ing
Dia
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212-6 1988
5 - 32 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “run”)
1988 212-6
Demystification Guide 5 - 33
Cir
cu
its
Gauge Circuit
(ignition switch in “run”)
Oil Pressure Light Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
212-6 1988
5 - 34 Demystification Guide
Cir
cu
its
Electric Clutch Circuit
(ignition switch in “run”)
1988 212-6
Demystification Guide 5 - 35
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5 - 36 Demystification Guide
212-6 Information List (1987)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-38
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-39
Spark Circuits . . . . . . . . . . 5-39 & 5-40
Charging Circuit . . . . . . . . . . . . . 5-40
Oil Pressure Light Circuit . . . . . . . . . 5-41
Light Circuit . . . . . . . . . . . . . . . . 5-41
Gauge Circuit . . . . . . . . . . . . . . . 5-42
Electric Clutch Circuit . . . . . . . . . . 5-42
In
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1987 212-6
Demystification Guide 5 - 37
Starter Motor Circuit
(ignition switch in “start”)
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
1987 212-6
Demystification Guide 5 - 39
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Spark Circuit
(ignition switch in “run”)
212-6 1987
5 - 40 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run”)
Oil Pressure Light Circuit
(ignition switch in “run”)
1987 212-6
Demystification Guide 5 - 41
Electric Clutch Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
Cir
cu
its
212-6 1987
5 - 42 Demystification Guide
1993 10-32XL & 12-38XL1993 - 1995 12-32XL & 12-38HXL1994 13-38HXL
rev. 4-03
5 - 43Demystification Guide
10-32XL & 12-38XL Information List (1993)12-32XL & 12-38HXL (1993 - 1995)
13-38HXL (1994)
Wiring Diagram . . . . . . . . . . . . . . . 5-44Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 5-45Spark Circuit . . . . . . . . . . . . . 5-45Spark Circuit . . . . . . . . . . . . . 5-46Charging Circuit . . . . . . . . . . . . 5-46
Information List
13-38HXL & 15-44HXL (1995)
ALL XL UNITS (1996 - 1998)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-48
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-49
Spark Circuits . . . . . . . . . . 5-49 & 5-50
Charging Circuit . . . . . . . . . . . . . 5-50
Headlight Circuit . . . . . . . . . . . . . 5-50
In
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t1995 13-38HXL & 15-44HXL
1996 - 1998 ALL XL UNITS
Demystification Guide 5 - 47
Wiring Diagram
Wir
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m13-38HXL & 15-44HXL 1995
ALL XL UNITS 1996 - 1998
5 - 48 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
1995 13-38HXL & 15-44HXL
1996 - 1998 ALL XL UNITS
Demystification Guide 5 - 49
Charging Circuit
Headlight Circuit
(ignition switch in “start”)
Cir
cu
its
Spark Circuit
(ignition switch in “run”)
13-38HXL & 15-44HXL 1995
ALL XL UNITS 1996 - 1998
5 - 50 Demystification Guide
1999 - 2001 XL
rev. 4-03
5 - 50ADemystification Guide
XL Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . 5-50B, 5-50CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 5-50DRun Circuit (Forward) . . . . . . . . . . 5-50ERun Circuit (Reverse) . . . . . . . . . . 5-50FCharging Circuit . . . . . . . . . . . . 5-50FLight Circuit . . . . . . . . . . . . . 5-50G
XL 1999 - 2001
Wiring Diagram rev. 4-03
5 - 50B Demystification Guide
1999 - 2001 XL
Wiring Diagramrev. 4-03
Demystification Guide 5 - 50C
Starter Motor Circuit(ignition switch in “start”)
XL 1999 - 2001
Demystification Guide5 - 50D
rev. 4-03
5 - 50EDemystification Guide
1999 - 2001 XL
Run Forward(PTO “on”)
rev. 4-03
Run Reverse(PTO “on” NMIR override)
XL 1999 - 2001
Demystification Guide5 - 50F
rev. 4-03
Charging Circuit
5 - 50GDemystification Guide
1999 - 2001 XL
Light Circuitrev. 4-03
rev. 4-03
Demystification Guide6 - 50H
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252-H Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-52
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-53
Spark Circuits . . . . . . . . . . . . . . 5-53
Charging Circuit . . . . . . . . . . . . . 5-54
Oil Pressure Light Circuit . . . . . . . . . 5-54
Gauge Circuit . . . . . . . . . . . . . . . 5-54
Electric Clutch Circuit . . . . . . . . . . 5-55
In
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1988 252-H
Demystification Guide 5 - 51
Wiring Diagram
Wir
ing
Dia
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m
252-H 1988
5 - 52 Demystification Guide
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “run”)
1988 252-H
Demystification Guide 5 - 53
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
Oil Pressure Light Circuit
(ignition switch in “run”)
252-H 1988
5 - 54 Demystification Guide
Electric Clutch Circuit
(ignition switch in “run”)
Cir
cu
its
1988 252-H
Demystification Guide 5 - 55
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5 - 56 Demystification Guide
257-H Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 5-58
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 5-59
Spark Circuits . . . . . . . . . . 5-59 & 5-60
Charging Circuit . . . . . . . . . . . . . 5-60
Oil Pressure Light Circuit . . . . . . . . 5-61
Light Circuit . . . . . . . . . . . . . . . 5-61
Gauge Circuit . . . . . . . . . . . . . . 5-62
Electric Clutch Circuit . . . . . . . . . . 5-62
In
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1988 257-H
Demystification Guide 5 - 57
Starter Motor Circuit
(ignition switch in “start”)
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
1988 257-H
Demystification Guide 5 - 59
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Spark Circuit
(ignition switch in “run”)
257-H 1988
5 - 60 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run”)
Oil Pressure Light Circuit
(ignition switch in “run”)
1988 257-H
Demystification Guide 5 - 61
Electric Clutch Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
Cir
cu
its
257-H 1988
5 - 62 Demystification Guide
1993 2441992 246-Hrev. 4-03
6 - 1Demystification Guide
244 Information List (1993)246-H (1993)
Wiring Diagram . . . . . . . . . . . . . . . 6-2Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-3Spark Circuits . . . . . . . . . . . 6-3 & 6-4Charging Circuit . . . . . . . . . . . . 6-4Electric Clutch Circuit . . . . . . . . . . 6-5Light Circuit . . . . . . . . . . . . . . 6-5
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6 - 6 Demystification Guide
264-6 Information List (1994 - 1995)
Wiring Diagram . . . . . . . . . . . . . . . . . . 6-8
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . 6-9
Spark Circuits . . . . . . . . . . . 6-9 & 6-10
Charging Circuit . . . . . . . . . . . . . 6-10
Electric Clutch Circuit . . . . . . . . . . 6-10
Light Circuit . . . . . . . . . . . . . . . . 6-11
Hourmeter Circuit . . . . . . . . . . . . 6-11
Park Brake Light Circuit . . . . . . . . . 6-11
Battery Light Circuit . . . . . . . . . . . 6-12
PTO Light Circuit . . . . . . . . . . . . . 6-12
Oil Pressure Light Circuit . . . . . . . . . 6-13
In
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1994-1995 264-6
Demystification Guide 6 - 7
Wiring Diagram
Wir
ing
Dia
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m
264-6 1994-1995
6 - 8 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1994-1995 264-6
Demystification Guide 6 - 9
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
Spark Circuit Circuit
(ignition switch in run”)
264-6 1994-1995
6 - 10 Demystification Guide
rev. 4-03
6 - 11Demystification Guide
1994-1995 264-6
Light Circuit(ignition switch in “run”)
Hourmeter Circuit(ignition switch in “run”)
Park Brake Light Circuit*(ignition switch in “run”)
Cir
cu
its
PTO Light Circuit*
(ignition switch in “run”)
Battery Light Circuit
(ignition switch in “run”)
264-6 1994-1995
6 - 12 Demystification Guide
Cir
cu
its
Oil Pressure Light Circuit*
(ignition switch in “run”)
1994-1995 264-6
Demystification Guide 6 - 13
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6 - 14 Demystification Guide
264-H & 265-H Information List (1994 - 1998)
Wiring Diagram . . . . . . . . . . . . . . . . . 6-16
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 6-17
Spark Circuits . . . . . . . . . . 6-17 & 6-18
Charging Circuit . . . . . . . . . . . . . 6-18
Electric Clutch Circuit . . . . . . . . . . 6-18
Light Circuit . . . . . . . . . . . . . . . . 6-19
Hourmeter Circuit . . . . . . . . . . . . 6-19
Park Brake Light Circuit . . . . . . . . . 6-19
Battery Light Circuit . . . . . . . . . . . 6-20
PTO Light Circuit . . . . . . . . . . . . . 6-20
Oil Pressure Light Circuit . . . . . . . . . 6-21
In
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1994 - 1998 264-H & 265-H
Demystification Guide 6 - 15
Wiring Diagram
Wir
ing
Dia
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m
264-H & 265-H 1994 - 1998
6 - 16 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1994 - 1998 264-H & 265-H
Demystification Guide 6 - 17
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
Spark Circuit Circuit
(ignition switch in run”)
264-H & 265-H 1994 - 1998
6 - 18 Demystification Guide
rev. 4-03
6 - 19Demystification Guide
1994-1995 264-6
Light Circuit(ignition switch in “run”)
Hourmeter Circuit(ignition switch in “run”)
Park Brake Light Circuit*(ignition switch in “run”)
Cir
cu
its
PTO Light Circuit*
(ignition switch in “run”)
Battery Light Circuit
(ignition switch in “run”)
264-H & 265-H 1994 - 1998
6 - 20 Demystification Guide
Cir
cu
its
Oil Pressure Light Circuit*
(ignition switch in “run”)
1994 - 1998 264-H & 265-H
Demystification Guide 6 - 21
This page intentionally left blank
6 - 22 Demystification Guide
265-6 Information List (1996 - 1998)
Wiring Diagram . . . . . . . . . . . . . . . . . 6-24
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 6-25
Spark Circuits . . . . . . . . . . 6-25 & 6-26
Charging Circuit . . . . . . . . . . . . . 6-26
Hourmeter Circuit . . . . . . . . . . . . 6-26
Electric Clutch Circuit . . . . . . . . . . 6-27
Light Circuit . . . . . . . . . . . . . . . . 6-27
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1996-1998 265-6
Demystification Guide 6 - 23
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1996-1998 265-6
Demystification Guide 6 - 25
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Spark Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
265-6 1996-1998
6 - 26 Demystification Guide
Electric Clutch Circuit
(ignition switch in “run”)
Cir
cu
its
Light Circuit
(ignition switch in “run”)
1996-1998 265-6
Demystification Guide 6 - 27
This page intentionally left blank
6 - 28 Demystification Guide
1999 - 2000 265-6
rev. 4-03
6 - 29ADemystification Guide
265-6 Information List (1999 - 2000)
Wiring Diagram . . . . . . . . . . . . . . . 6-29CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . 6-29ESpark Circuit . . . . . . . . . . . . . . . 6-29ERun Forward . . . . . . . . . . . . . . . 6-29FRun Reverse . . . . . . . . . . . . . . . 6-29GCharging Circuit . . . . . . . . . . . . . . 6-29HLight Circuit . . . . . . . . . . . . . . . 6-29H
265-6 1999 - 2000
Wiring Diagram rev. 4-03
6 - 29B Demystification Guide
1999 - 2000 265-6
Wiring Diagramrev. 4-03
6 - 29CDemystification Guide
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Brake Switch(brake applied)
Seat Switch(operator on) Start Relay
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Starter Solenoid(energized)
Starter Motor(energized)
Kill Relay(energized)
Park Brake Switch(Brake Engaged)
Neutral Switch(in Neutral)
Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
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YY
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BuGy
Gy
B
I
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(disengaged)
Brake Switch(brake applied)
Kill Relay(energized)
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Park Brake Switch(Brake Engaged)
Neutral Switch(in Neutral)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
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Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
R
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Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in forward)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
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Fuel Solenoid(energized)
Kill Relay(energized)
Y Bk
Bk
Triggermodule
Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
A
L
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in reverse)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Bk
T
T
Bk
Bk
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
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B+AC BatteryFuse
(30 amp)Fuse(25 amp)
IgnitionSwitch(in run)
Re
Or
Pk
Bk
Pk
Pk
VioVioB
R
I
Regulator/RectifierAlternator
Fuel Solenoid(energized)
B+
VoltageComparator
Battery Light Module
Battery Light
Battery Fuse(30 amp)
Fuse(10 amp)
Headlights(on)
IgnitionSwitch
(in run/lights)
Re Or Or BkRe
B L
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rev. 4-03
6 - 30ADemystification Guide
265-H Information List (2000 - 2001)
Wiring Diagram . . . . . . . . . . . 6-30B, 6-30CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-30ESpark Circuit . . . . . . . . . . . . . 6-30ERun Circuit (Forward) . . . . . . . . . . 6-30FRun Circuit (Reverse) . . . . . . . . . . 6-30GCharging Circuit . . . . . . . . . . . . 6-30HLight Circuit . . . . . . . . . . . . . 6-30H
265-H 2000 - 2001
Wiring Diagram rev. 4-03
Demystification Guide6 - 30B
2000 - 2001 265-H
Wiring Diagramrev. 4-03
Demystification Guide 6 - 30C
Demystification Guide6 - 30D
This page intentionally left blank
6 - 30EDemystification Guide
2000 - 2001 265-H
Starter Motor Circuit(ignition switch in “start”)
rev. 4-03
Spark Circuit(ignition switch in “start”)
Run Forward(PTO “on”)
265-H 2000 - 2001
Demystification Guide6 - 30F
rev. 4-03
6 - 30GDemystification Guide
2000 - 2001 265-H
Run Reverse(PTO “on” NMIR override)
rev. 4-03
Charging Circuit
265-H 2000 - 2001
Demystification Guide6 - 30H
rev. 4-03
Light Circuit
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Wiring Diagram rev. 4-03
Demystification Guide6 - 31B
1999 265-H
Wiring Diagramrev. 4-03
Demystification Guide 6 - 31C
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Switch(in start)
Re RePk Pk
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Bu
BuGy
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InterlockRelay
(energized)Fuse
(10 amp) PTO Switch(disengaged)
Brake Switch(brake applied)
Seat Switch(operator on) Start Relay
(energized)
Starter Solenoid(energized)
Starter Motor(energized)
Kill Relay(energized)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
BnBk
Y
Y
Bu
BuGy
Gy
B
I
S Fuse(10 amp) PTO Switch
(disengaged)
Brake Switch(brake applied)
Kill Relay(energized)
Triggermodule
Ignition CoilDashed lines do not carry current
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Kill Relay(energized)
Y Bk
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Triggermodule
Triggermodule
Ignition Coil Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
R
I
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in forward)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Fuel Solenoid(energized)
Kill Relay(energized)
Y Bk
Bk
Triggermodule
Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
A
L
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in reverse)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Bk
T
T
Bk
Bk
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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B+AC BatteryFuse
(30 amp)Fuse(25 amp)
IgnitionSwitch(in run)
Re
Or
Pk
Bk
Pk
Pk
VioVioB
R
I
Regulator/RectifierAlternator
Fuel Solenoid(energized)
B+
VoltageComparator
Battery Light Module
Battery Light
Battery Fuse(30 amp)
Fuse(10 amp)
Headlights(on)
IgnitionSwitch
(in run/lights)
Re Or Or BkRe
B L
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Blue Bu
Brown Bn
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Orange Or
Pink Pk
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266-H Information List (1995)
Wiring Diagram . . . . . . . . . . . . . . . . . 6-34
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 6-35
Spark Circuits . . . . . . . . . . 6-35 & 6-36
Charging Circuit . . . . . . . . . . . . . 6-36
Electric Clutch Circuit . . . . . . . . . . 6-36
Light Circuit . . . . . . . . . . . . . . . . 6-37
Oil Pressure Switch Circuit . . . . . . . 6-37
Parking Brake Switch Circuit . . . . . . . 6-37
Cruise Control Circuits . . . . . . 6-38 & 6-39
In
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1995 266-H
Demystification Guide 6 - 33
Wiring Diagram
Wir
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m
266-H 1995
6 - 34 Demystification Guide
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
1995 266-H
Demystification Guide 6 - 35
Spark Circuit
(ignition switch in “run”)
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
266-H 1995
6 - 36 Demystification Guide
Light Circuit
(ignition switch in “run”)
Cir
cu
its
Oil Pressure Switch Circuit
(ignition switch in “run”)
Parking Brake Switch Circuit
(parking brake applied)
1995 266-H
Demystification Guide 6 - 37
Cir
cu
its
Cruise Control Circuit
(activating cruise)
Cruise Control Circuit
(in cruise mode)
266-H 1995
6 - 38 Demystification Guide
Cir
cu
its
Cruise Control Circuit
(deactivation by applying the brake)
1995 266-H
Demystification Guide 6 - 39
This page intentionally left blank
6 - 40 Demystification Guide
266-H Information List (1994)
Wiring Diagram . . . . . . . . . . . . . . . . . 6-42
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 6-43
Spark Circuits . . . . . . . . . . 6-43 & 6-44
Charging Circuit . . . . . . . . . . . . . 6-44
Electric Clutch Circuit . . . . . . . . . . 6-44
Light Circuit . . . . . . . . . . . . . . . . 6-45
Hourmeter Circuit . . . . . . . . . . . . 6-45
Parking Brake Switch Circuit . . . . . . . 6-45
Battery Light Circuit . . . . . . . . . . . 6-46
PTO Light Circuit . . . . . . . . . . . . . 6-46
Oil Pressure Light Circuit . . . . . . . . . 6-47
In
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1994 266-H
Demystification Guide 6 - 41
Wiring Diagram
Wir
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Dia
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m
266-H 1994
6 - 42 Demystification Guide
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
1994 266-H
Demystification Guide 6 - 43
Spark Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
Cir
cu
its
266-H 1994
6 - 44 Demystification Guide
Cir
cu
its
Parking Brake Switch Circuit*
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
Light Circuit
(ignition switch in “run”)
1994 266-H
Demystification Guide 6 - 45
Cir
cu
its
Battery Light Circuit*
(ignition switch in “run”)
PTO Light Circuit*
(ignition switch in “run”)
266-H 1994
6 - 46 Demystification Guide
Cir
cu
its
Oil Pressure Light Circuit*
(ignition switch in “run”)
1994 266-H
Demystification Guide 6 - 47
This page intentionally left blank
6 - 48 Demystification Guide
2001 266-H
rev. 4-03
6 - 48ADemystification Guide
266-H Information List (2001)
Wiring Diagram . . . . . . . . . . . . . . 6-48BCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-48CSpark Circuit . . . . . . . . . . . . . 6-48CRun Forward . . . . . . . . . . . . . 6-48DRun Reverse . . . . . . . . . . . . . 6-48ECharging Circuit . . . . . . . . . . . 6-48F
266-H 2001
Wiring Diagram rev. 4-03
6 - 48B Demystification Guide
rev. 4-03
6 - 48CDemystification Guide
2001 266-H
Starter Motor Circuit(ignition switch in “start”)
Spark Circuit(ignition switch in “start”)
rev. 4-03
6 - 48D Demystification Guide
Run Forward(PTO “on”)
266-H 2001
2001 266-H
6 - 48EDemystification Guide
Run Reverse(PTO “on” NMIR override)
rev. 4-03
Charging Circuit
266-H 2001
rev. 4-03
6 - 48F Demystification Guide
267-H Information List (1996 - 1998)
Wiring Diagram . . . . . . . . . . . . . . . . . 6-50
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 6-51
Spark Circuits . . . . . . . . . . 6-51 & 6-52
Charging Circuit . . . . . . . . . . . . . 6-52
Electric Clutch Circuit . . . . . . . . . . 6-52
Light Circuit . . . . . . . . . . . . . . . . 6-53
Oil Pressure Switch Circuit . . . . . . . 6-53
Parking Brake Switch Circuit . . . . . . . 6-53
Hourmeter Circuit . . . . . . . . . . . . 6-54
Cruise Control Circuits . . . . . . 6-54 & 6-55
In
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1996 - 1998 267-H
Demystification Guide 6 - 49
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
1996 - 1998 267-H
Demystification Guide 6 - 51
Spark Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
Cir
cu
its
267-H 1996 - 1998
6 - 52 Demystification Guide
Light Circuit
(ignition switch in “run”)
Cir
cu
its
Oil Pressure Switch Circuit
(ignition switch in “run”)
Parking Brake Switch Circuit
(parking brake applied)
1996 - 1998 267-H
Demystification Guide 6 - 53
Cruise Control Circuit
(activating cruise)
Hourmeter Circuit
(ignition switch in “run”)
267-H 1996 - 1998
6 - 54 Demystification Guide
Cir
cu
its
Cruise Control Circuit
(in cruise mode)
Cruise Control Circuit
(deactivation by applying the brake)
1996 - 1998 267-H
Demystification Guide 6 - 55
This page intentionally left blank
6 - 56 Demystification Guide
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Wiring Diagramrev. 4-03
Demystification Guide 6 - 57C
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Switch(in start)
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Bn
Bk
Bn
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Bu
BuGy
Gy
B
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InterlockRelay
(energized)Fuse
(10 amp) PTO Switch(disengaged)
Brake Switch(brake applied)
Seat Switch(operator on) Start Relay
(energized)
Starter Solenoid(energized)
Starter Motor(energized)
Kill Relay(energized)
Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
BnBk
Y
Y
Bu
BuGy
Gy
B
I
S Fuse(10 amp) PTO Switch
(disengaged)
Brake Switch(brake applied)
Kill Relay(energized)
Triggermodule
Ignition Coil
Triggermodule
Ignition CoilDashed lines do not carry current
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
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Switch(in run)
Re Re Pk
Pk
Bu
Bu
Bk
BkBk
BkBu
Bu
Bu
Y T
T
Y
Pk
Pk
B I
Cruise Magnet(energized)
Cruise Switch(energized)
Cruise Lamp(on)
Cruise Disengage Switch(opens when brake is depresed)
Cruise Relay(energized) Momentary Switch
(energizes cruise relay)
AC
B+AC BatteryFuse
(30 amp)Fuse(25 amp)
IgnitionSwitch(in run)
Re
Or
Pk
Bk
Pk
Pk
VioVioB
R
I
Regulator/RectifierAltenator
Fuel Solenoid(energized)
B+
VoltageComparator
Battery Light Module
Battery Light
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Battery Fuse(30 amp)
Fuse(10 amp)
Headlights(on)
IgnitionSwitch
(in run/lights)
Re Or Or BkRe
B L
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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2000 - 2001 268-H
rev. 4-03
6 - 58ADemystification Guide
268-H Information List (2000 - 2001)
Wiring Diagram . . . . . . . . . . . 6-58B, 6-58CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-58DSpark Circuit . . . . . . . . . . . . . 6-58DRun Circuit (Forward) . . . . . . . . . . 6-58ERun Circuit (Reverse) . . . . . . . . . . 6-58FCruise Control Circuit . . . . . . . . . . 6-58GCharging Circuit . . . . . . . . . . . . 6-58GLight Circuit . . . . . . . . . . . . . 6-58H
268-H 2000 - 2001
Wiring Diagram rev. 4-03
Demystification Guide6 - 58B
2000 - 2001 268-H
Wiring Diagramrev. 4-03
Demystification Guide 6 - 58C
Starter Motor Circuit(ignition switch in “start”)
268-H 2000 - 2001
Demystification Guide6 - 58D
rev. 4-03
Spark Circuit(ignition switch in “start”)
6 - 58EDemystification Guide
2000 - 2001 268-H
Run Forward(PTO “on”)
rev. 4-03
Run Reverse(PTO “on” NMIR override)
268-H 2000 - 2001
Demystification Guide6 - 58F
rev. 4-03
6 - 58GDemystification Guide
2000 - 2001 268-H
Cruise Control Circuit(ignition switch in “run”)
rev. 4-03
Charging Circuit
6 - 58HDemystification Guide
2000 - 2001 268-H
Light Circuitrev. 4-03
2000 - 2001* 268-H
Demystification Guide 6 - 58I* May apply to later models, see Table Of Contents
Light Circuit
Battery Fuse(30 amp)
Fuse(10 amp)
Headlights(on)
IgnitionSwitch
(in run/lights)
Re Or Or BkRe
B L
Legend
Black BkBlue BuBrown BnGreen GnGrey GyOrange OrPink PkRed ReTan TViolet VioWhite WYellow Y
Circ
uits
6 - 58J Demystification Guide
This page intentionally left blank
269-H Information List (1996 - 1998)
Wiring Diagram . . . . . . . . . . . . . . . . . 6-60
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 6-61
Spark Circuits . . . . . . . . . . 6-61 & 6-62
Charging Circuit . . . . . . . . . . . . . 6-62
Light Circuit . . . . . . . . . . . . . . . . 6-63
Hourmeter Circuit . . . . . . . . . . . . 6-63
Oil Pressure Switch Circuit . . . . . . . . 6-63
Parking Brake Light Circuit . . . . . . . 6-64
Pump Circuit . . . . . . . . . . . . . . . 6-64
Electric Clutch Circuit . . . . . . . . . . 6-65
Cruise Control Circuits . . . . . . 6-65 & 6-66
In
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1996 - 1998 269-H
Demystification Guide 6 - 59
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1996 - 1998 269-H
Demystification Guide 6 - 61
Charging Circuit
(ignition switch in “run”
Cir
cu
its
Spark Circuit
(ignition switch in “run”)
269-H 1996 - 1998
6 - 62 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
Oil Pressure Switch Circuit
(ignition switch in “run”)
1996 - 1998 269-H
Demystification Guide 6 - 63
Cir
cu
its
Parking Brake Light Circuit
(ignition switch in “run”)
Pump Circuit
(ignition switch in “run”)
269-H 1996 - 1998
6 - 64 Demystification Guide
Electric Clutch Circuit
(ignition switch in “run”)
Cir
cu
its
Cruise Control Circuit
(activating cruise)
1996 - 1998 269-H
Demystification Guide 6 - 65
Cruise Control Circuit
(in cruise mode)
Cruise Control Circuit
(deactivation by applying the brake)
Cir
cu
its
269-H 1996 - 1998
6 - 66 Demystification Guide
2001 270-H
rev. 4-03
6 - 66ADemystification Guide
270-H Information List (2001)
Wiring Diagram . . . . . . . . . . . 6-66B, 6-66CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-66DRun Circuit . . . . . . . . . . . . . 6-66DClutch Circuit (forward PTO “on”) . . . . . . 6-66EClutch Circuit (reverse PTO “on”) . . . . . . 6-66FCruise Control Circuit . . . . . . . . . . 6-66GLift Circuit . . . . . . . . . . . . . . 6-66GCharging Circuit . . . . . . . . . . . . 6-66HLight Circuit . . . . . . . . . . . . . 6-66H
270-H 2001
Wiring Diagram rev. 4-03
6 - 66B Demystification Guide
2001 270-H
Wiring Diagramrev. 4-03
Demystification Guide 6 - 66C
Starter Motor Circuit(ignition switch in “start”)
270-H 2001
Demystification Guide6 - 66D
rev. 4-03
Run Circuit(operator “on”)
6 - 66EDemystification Guide
2001 270-H
Clutch Circuit(forward PTO “on”)
rev. 4-03
Clutch Circuit(reverse PTO “on” override key switch engaged)
270-H 2001
Demystification Guide6 - 66F
rev. 4-03
6 - 66GDemystification Guide
2001 270-H
Cruise Control Circuitrev. 4-03
Lift Circuit
Charging Circuit
270-H 2001
Demystification Guide6 - 66H
rev. 4-03
Light Circuit
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Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
Bn
Bn
Bk
Bn
Or
OrY
Y
Or Or Gn
Gn
T
Bu
BuGy
Gy Vio
B
I
S
InterlockRelay
(energized)Fuse
(10 amp) PTO Switch(disengaged)
Brake Switch(brake applied)
Neutral Switch(in neutral)
Seat Switch(operator on) Start Relay
(energized)
Starter Solenoid(energized)
Starter Motor(energized)
Kill Relay(energized)
Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
BnBk
Or
OrY
Y
Bu
BuGy
Gy Vio
B
I
S Fuse(10 amp) PTO Switch
(disengaged)
Brake Switch(brake applied)
Neutral Switch(in neutral)
Kill Relay(energized)
Triggermodule
Ignition Coil
Triggermodule
Ignition CoilDashed lines do not carry current
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Fuel Solenoid(energized)
Kill Relay(energized)
Y Bk
Bk
Triggermodule
Triggermodule
Ignition Coil Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
R
I
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in forward)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Fuel Solenoid(energized)
Kill Relay(energized)
Y Bk
Bk
Triggermodule
Ignition Coil
Triggermodule
Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
A
L
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in reverse)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Bk
T
T
Bk
Bk
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Battery Fuse(10 amp) Ignition
Switch(in run)
Re Re Pk
Pk
Bu
Bu
Bk
BkBk
BkBu
Bu
Bu
Y T
T
Y
Pk
Pk
B I
Cruise Magnet(energized)
Cruise Switch(energized)
Cruise Lamp(on)
Cruise Disengage Switch(opens when brake is depresed)
Cruise Relay(energized) Momentary Switch
(energizes cruise relay)
Battery Fuse(30 amp)
Fuse(25 amp)
Lift Pump(Energized)
IgnitionSwitch(in run)
Lift Switch(in operation)
Re Re Pk Bu
Or
W
Bu
Bk
Bk
Bk
Bu
B I
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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AC
B+AC BatteryFuse
(30 amp)
Fuse(10 amp)
Fuse(25 amp)
IgnitionSwitch(in run)
Re
Or
Pk
Bk
Pk
Pk
VioVioB
R
I
Regulator/RectifierAlternator
Fuel Solenoid(energized)
B+
VoltageComparator
Battery Light Module
Battery Light
Battery Fuse(30 amp)
Fuse(10 amp)
Headlights(on)
IgnitionSwitch
(in run/lights)
Re Or Or BkRe
B L
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
Bn
Bn
Bk
Bn
Y
Y Y T
Y
Or Or Gn
Gn
Bu
BuGy
Gy
B
I
S
InterlockRelay
(energized)Fuse
(10 amp) PTO Switch(disengaged)
Brake Switch(brake applied)
Seat Switch(operator on) Start Relay
(energized)
Starter Solenoid(energized)
Starter Motor(energized)
Kill Relay(energized)
Battery Fuse(30 amp) Ignition
Switch(in start)
Re RePk Pk
BnBk
Y
Y
Bu
BuGy
Gy
B
I
S Fuse(10 amp) PTO Switch
(disengaged)
Brake Switch(brake applied)
Kill Relay(energized)
Triggermodule
Ignition Coil
Triggermodule
Ignition CoilDashed lines do not carry current
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Fuel Solenoid(energized)
Kill Relay(energized)
Y Bk
Bk
Triggermodule
Triggermodule
Ignition Coil Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
R
I
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in forward)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Fuel Solenoid(energized)
Kill Relay(energized)
Y Bk
Bk
Triggermodule
Ignition Coil
Triggermodule
Ignition Coil
Battery Fuse(30 amp) Fuse
(10 amp)IgnitionSwitch(in run)
Re RePk
Vio
Vio Vio
PkOrTPk
Gn
Bu
Bu Bn Bk
Bk
Bk
W
W
Bu
B
A
L
Interlock Realy(not energized)
Seat Switch(operator on)
Dashed lines do not carry current
No Mow In Reverse Module
(NMIR)
Reverse Switch(in reverse)
PTO Switch(engaged)
PTO Light(on)
PTO Clutch(engaged)
Fuse(25 amp) W
Bk
T
T
Bk
Bk
Park Switch(park brake
not engaged)
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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Battery Fuse(10 amp) Ignition
Switch(in run)
Re Re Pk
Pk
Bu
Bu
Bk
BkBk
BkBu
Bu
Bu
Y T
T
Y
Pk
Pk
B I
Cruise Magnet(energized)
Cruise Switch(energized)
Cruise Lamp(on)
Cruise Disengage Switch(opens when brake is depresed)
Cruise Relay(energized) Momentary Switch
(energizes cruise relay)
Battery Fuse(30 amp)
Fuse(25 amp)
Lift Pump(Energized)
IgnitionSwitch(in run)
Lift Switch(in operation)
Re Re Pk Bu
Or
W
Bu
Bk
Bk
Bk
Bu
B I
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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AC
B+AC BatteryFuse
(30 amp)
Fuse(10 amp)
Fuse(25 amp)
IgnitionSwitch(in run)
Re
Or
Pk
Bk
Pk
Pk
VioVioB
R
I
Regulator/RectifierAlternator
Fuel Solenoid(energized)
B+
VoltageComparator
Battery Light Module
Battery Light
Battery Fuse(30 amp)
Fuse(10 amp)
Headlights(on)
IgnitionSwitch
(in run/lights)
Re Or Or BkRe
B L
Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re
Tan T
Violet Vio
White W
Yellow Y
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308-8 Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . . . 7-2
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . 7-3
Spark Circuit . . . . . . . . . . . . . . . . 7-3
Charging Circuit . . . . . . . . . . . . . . 7-3
Hourmeter Circuit . . . . . . . . . . . . . 7-4
Light Circuit . . . . . . . . . . . . . . . . . 7-4
In
fo
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1988 308-8
Demystification Guide 7 - 1
Wiring Diagram
Wir
ing
Dia
gra
m
308-8 1988
7 - 2 Demystification Guide
Charging Circuit
(ignition switch in “run”)
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
Starter Motor Circuit
(ignition switch in “start”)
1988 308-8
Demystification Guide 7 - 3
Hourmeter Circuit
(ignition switch in “run”
Cir
cu
its
Light Circuit
(ignition switch in “run”)
308-8 1988
7 - 4 Demystification Guide
310 Information List (1989 - 1991)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-6
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-7
Spark Circuit . . . . . . . . . . . . . . . 7-7
Charging Circuit . . . . . . . . . . . . . . 7-8
Oil Indicator Light Test Circuit . . . . . . . 7-8
Oil Circuit . . . . . . . . . . . . . . . . . 7-9
Accessories Circuit . . . . . . . . . . . . 7-9
In
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1989 - 1991 310-8
Demystification Guide 7 - 5
Wiring Diagram
Wir
ing
Dia
gra
m
310-8 1989 - 1991
7 - 6 Demystification Guide
Starter Motor Circuit
(with ignition switch in “start” )
Spark Circuit
(ignition switch in “start” or “run” position)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
1989 - 1991 310-8
Demystification Guide 7 - 7
Oil Indicator Light Test Circuit
(with test switch depressed)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Charging Circuit
(ignition switch in “run”)
Cir
cu
its
310-8 1989 - 1991
7 - 8 Demystification Guide
Oil Circuit
(with ignition switch in “start”)(prevents starting if oil is low)
Accessories Circuit
(including lights, voltmeter and optional hourmeter) -(ignition switch in “run)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
1989 - 1991 310-8
Demystification Guide 7 - 9
This page intentionally left blank
7 - 10 Demystification Guide
310-8 Information List (1988)
Wiring Diagram . . . . . . . . . . . . . . . . 12-12
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-13
Spark Circuit . . . . . . . . . . . . . . . 7-13
Charging Circuit . . . . . . . . . . . . . . 7-14
Oil Indicator Light Test Circuit . . . . . . . 7-14
Oil Circuit . . . . . . . . . . . . . . . . . 7-15
Accessories Circuit . . . . . . . . . . . . 7-15
In
fo
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nLis
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1988 310-8
Demystification Guide 7 - 11
Wiring Diagram
Wir
ing
Dia
gra
m
310-8 1988
7 - 12 Demystification Guide
Starter Motor Circuit
(ignition switch in “start” )
Spark Circuit
(ignition switch in “run” or “start”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
1988 310-8
Demystification Guide 7 - 13
Oil Indicator Light Test Circuit
(test switch depressed)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Charging Circuit
(ignition switch in “run”)
Cir
cu
its
310-8 1988
7 - 14 Demystification Guide
Oil Circuit
(ignition switch in “start”)(prevents starting if oil is low)
Accessories Circuit
(including lights, voltmeter, and optional hourmeter) -(ignition switch in “run")
Cir
cu
its
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
1988 310-8
Demystification Guide 7 - 15
This page intentionally left blank
7 - 16 Demystification Guide
312-8 Information List (1998)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-18
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-19
Spark Circuits . . . . . . . . . . 7-19 & 7-20
Charging Circuit . . . . . . . . . . . . . 7-20
Hourmeter Circuit . . . . . . . . . . . . 7-20
Light Circuit . . . . . . . . . . . . . . . 7-21
In
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rm
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t
1998 312-8
Demystification Guide 7 - 17
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1998 312-8
Demystification Guide 7 - 19
Cir
cu
its
Spark Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
312-8 1998
7 - 20 Demystification Guide
Light Circuit
(ignition switch in “run”)
Cir
cu
its
1998 312-8
Demystification Guide 7 - 21
This page intentionally left blank
7 - 22 Demystification Guide
1999 - 2001 312-8
rev. 4-03
7 - 22ADemystification Guide
312-8 Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . 7-22B, 7-22CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-22ESpark Circuit . . . . . . . . . . . . . 7-22ERun Forward (PTO “on”) . . . . . . . . . 7-22FRun Reverse (PTO “on” NMIR override) . . . 7-22GCharging Circuit . . . . . . . . . . . . 7-22HLight Circuit . . . . . . . . . . . . . 7-22H
312-8 1999 - 2001
Wiring Diagram rev. 4-03
7 - 22B Demystification Guide
1999 - 2001 312-8
Wiring Diagramrev. 4-03
Demystification Guide 7 - 22C
rev. 4-03
Demystification Guide7 - 22D
This page intentionally left blank
7 - 22EDemystification Guide
1999 - 2001 312-8
Starter Motor Circuit(ignition switch in “start”)
rev. 4-03
Spark Circuit(ignition switch in “start”)
Run Forward(PTO “on”)
312-8 1999 - 2001
Demystification Guide7 - 22F
rev. 4-03
7 - 22GDemystification Guide
1999 - 2001 312-8
Run Reverse(PTO “on” NMIR override)
rev. 4-03
Charging Circuit
312-8 1999 - 2001
Demystification Guide7 - 22H
rev. 4-03
Light Circuit
rev. 4-03
7 - 23Demystification Guide
310-8 Information List (1992 - 1993)312-8 Information List (1992 - 1997)314-8 Information List 1992 (1993)
Wiring Diagram . . . . . . . . . . . . . . 7-24Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-25Spark Circuit . . . . . . . . . . . . . 7-25Charging Circuit . . . . . . . . . . . 7-26Light Circuit . . . . . . . . . . . . . 7-26Hourmeter Circuit . . . . . . . . . . 7-26
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997
Wiring Diagram rev. 4-03
7 - 24 Demystification Guide
rev. 4-03
7 - 25Demystification Guide
Starter Motor Circuit(ignition switch in “start” with low oil level)
Spark Circuit(ignition switch in “start”)
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997
rev. 4-03
7 - 26 Demystification Guide
Charging Circuit(ignition switch in “run”)
Light Circuit(ignition switch in “run”)
Hourmeter Circuit(ignition switch in “run”)
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997
312-8 Information List (1989)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-28
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-29
Spark Circuit . . . . . . . . . . . . . . . 7-29
Gauge Circuit . . . . . . . . . . . . . . . 7-30
Charging Circuit . . . . . . . . . . . . . . 7-30
Light Circuit . . . . . . . . . . . . . . . . 7-30
Oil Circuit . . . . . . . . . . . . . . . . . 7-31
In
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t1989 312-8
Demystification Guide 7 - 27
Wiring Diagram
Wir
ing
Dia
gra
m312-8 1989
7 - 28 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
1989 312-8
Demystification Guide 7 - 29
Gauge Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
Light Circuit
(ignition switch in “run”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
312-8 1989
7 - 30 Demystification Guide
Oil Circuit
(with ignition switch in “start”)(prevents starting if oil is low)
Cir
cu
its
1989 312-8
Demystification Guide 7 - 31
This page intentionally left blank
7 - 32 Demystification Guide
312-8 Information List (1987 - 1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-34
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-35
Spark Circuit . . . . . . . . . . . . . . . 7-35
Charging Circuit . . . . . . . . . . . . . 7-36
Gauge Circuit . . . . . . . . . . . . . . . 7-36
Light Circuit . . . . . . . . . . . . . . . . 7-36
Oil Circuit . . . . . . . . . . . . . . . . . 7-37
In
fo
rm
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t
1987 - 1988 312-8
Demystification Guide 7 - 33
Wiring Diagram
Wir
ing
Dia
gra
m
312-8 1987 - 1988
7 - 34 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1987 - 1988 312-8
Demystification Guide 7 - 35
Cir
cu
its
Gauge Circuit
(ignition switch in “run”)
Light Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
312-8 1987 - 1988
7 - 36 Demystification Guide
Cir
cu
its
Oil Circuit
(with ignition switch in “start”)(prevents starting if oil is low)
1987 - 1988 312-8
Demystification Guide 7 - 37
This page intentionally left blank
7 - 38 Demystification Guide
312-H & 312-8 Information List (1990 - 1991)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-40
Circuit Diagrams
Starter Motor Circuits . . . . . . . . . . . 7-41
Spark Circuit . . . . . . . . . . . . . . . 7-42
Charging Circuit . . . . . . . . . . . . . 7-42
Gauge Circuit . . . . . . . . . . . . . . . 7-42
Light Circuit . . . . . . . . . . . . . . . 7-43
In
fo
rm
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t
1990 - 1991 312-H & 312-8
Demystification Guide 7 - 39
Wiring Diagram
Wir
ing
Dia
gra
m
312-H & 312-8 1990 - 1991
7 - 40 Demystification Guide
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
Charging Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
312-H & 312-8 1990 - 1991
7 - 42 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run”)
1990 - 1991 312-H & 312-8
Demystification Guide 7 - 43
This page intentionally left blank
7 - 44 Demystification Guide
312-A & 312-8 Information List (1986)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-46
Circuit Diagrams
Starter Motor Circuits . . . . . . . . . . . 7-47
Spark Circuit . . . . . . . . . . . . . . . 7-48
Charging Circuit . . . . . . . . . . . . . 7-48
Gauge Circuit . . . . . . . . . . . . . . . 7-48
Light Circuit . . . . . . . . . . . . . . . 7-49
Oil Light Test Circuit . . . . . . . . . . . 7-49
In
fo
rm
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t
1986 312-A & 312-8
Demystification Guide 7 - 45
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Starter Motor Circuit
(ignition switch in “start” with low oil level)
1986 312-A & 312-8
Demystification Guide 7 - 47
Gauge Circuit
(ignition switch in “run”)
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
Charging Circuit
(ignition switch in “run”)
312-A & 312-8 1986
7 - 48 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run”)
Oil Light Test Circuit
(ignition switch in “run”)
1986 312-A & 312-8
Demystification Guide 7 - 49
This page intentionally left blank
7 - 50 Demystification Guide
312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997rev. 4-03
7 - 53Demystification Guide
312-H Information List (1992)314-H (1993 - 1997)314-8 (1994 - 1997)
Wiring Diagram . . . . . . . . . . . . . . 7-54Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-55Spark Circuits . . . . . . . . . . 7-55 & 7-56Charging Circuit . . . . . . . . . . . . 7-56Charging Circuit . . . . . . . . . . . 7-56
Wiring Diagram rev. 4-03
7 - 54 Demystification Guide
312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997
rev. 4-03
7 - 55Demystification Guide
Starter Motor Circuit(ignition switch in “start”)
Spark Circuit(ignition switch in “start”)
312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997
rev. 4-03
7 - 56 Demystification Guide
Spark Circuit(ignition switch in “run”)
Charging Circuit
Light Circuit(ignition switch in “run”)
312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997
1999 - 2001 314-8
rev. 4-03
7-56ADemystification Guide
314-8 Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . 7-56B, 7-56CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-56DSpark Circuit . . . . . . . . . . . . . 7-56DRun Forward (PTO “on”) . . . . . . . . . 7-56ERun Reverse (PTO “on” NMIR override) . . . 7-56FCharging Circuit . . . . . . . . . . . . 7-56GLight Circuit . . . . . . . . . . . . . 7-56GLow Oil Pressure Light Circuit . . . . . . 7-56GHourmeter . . . . . . . . . . . . . . 7-56H
314-8 1999 - 2001
Wiring Diagram rev. 4-03
7 - 56B Demystification Guide
1999 - 2001 314-8
Wiring Diagramrev. 4-03
Demystification Guide 7 - 56C
Starter Motor Circuit(ignition switch in “start”)
314-8 1999 - 2001
Demystification Guide7 - 56D
rev. 4-03
Spark Circuit(ignition switch in “start”)
7 - 56EDemystification Guide
1999 - 2001 314-8
Run Forward(PTO “on”)
rev. 4-03
Run Reverse(PTO “on” NMIR override)
314-8 1999 - 2001
Demystification Guide7 - 56F
rev. 4-03
7 - 56GDemystification Guide
1999 - 2001 314-8
Charging Circuitrev. 4-03
Light Circuit
Low Oil Pressure Light Circuit(ignition switch in “run”)
Hourmeter(ignition switch in “run” )
314-8 1999 - 2001
Demystification Guide7 - 56H
rev. 4-03
1992 - 1997 416-81992 - 1997 416-Hrev. 4-03
7 - 57Demystification Guide
416-8 Information List (1992 - 1997)416-H (1992 - 1997)
Wiring Diagram . . . . . . . . . . . . . . . 7-56Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-59Spark Circuit . . . . . . . . . . . . . 7-59Charging Circuit . . . . . . . . . . . . 7-59Oil Pressure Switch Circuit . . . . . . . . 7-60Light Test Circuit . . . . . . . . . . . . 7-60Voltmeter Circuit . . . . . . . . . . . . 7-60
416-8 1992-1997416-H 1992-1997
Wiring Diagram rev. 4-03
7 - 58 Demystification Guide
rev. 4-03
7 - 59Demystification Guide
Starter Motor Circuit(ignition switch in “start”)
Spark Circuit(ignition switch in “start”)
416-8 1992-1997416-H 1992-1997
Charging Circuit
rev. 4-03
7 - 60 Demystification Guide
Oil Pressure Switch Circuit(ignition switch in “run”)
Light Test Circuit(ignition switch in “run”)
Voltmeter Circuit(ignition switch in “run”)
416-8 1992-1997416-H 1992-1997
416-H & 416-8 Information List (1990 - 1991)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-62
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . 7-63
Spark Circuit . . . . . . . . . . . . . . . 7-63
Charging Circuit . . . . . . . . . . . . . . 7-63
Light Circuit . . . . . . . . . . . . . . . . 7-64
Seat Light Circuit . . . . . . . . . . . . . 7-64
Parking Brake Light Circuit . . . . . . . . 7-64
Neutral/Clutch Light Cirtcuit . . . . . . . 7-65
PTO Light Circuit . . . . . . . . . . . . . 7-65
PTO and Neutral/Clutch Circuit . . . . . . 7-65
Low Oil Pressure Light Circuit . . . . . . 7-66
Hourmeter Circuit . . . . . . . . . . . . . 7-66
Voltmeter Circuit . . . . . . . . . . . . . . 7-66
In
fo
rm
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nLis
t
1990 - 1991 416-H & 416-8
Demystification Guide 7 - 61
Wiring Diagram
Wir
ing
Dia
gra
m
416-H & 416-8 1990 - 1991
7 - 62 Demystification Guide
Starter Motor Circuit
(ignition switch in “start” )
Spark Circuit
(ignition switch in “start” or “run”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Charging Circuit
Cir
cu
its
1990 - 1991 416-H & 416-8
Demystification Guide 7 - 63
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
Seat Light Circuit
(ignition switch in “start” or “run”)(lights when operator is not in seat)
Light Circuit
(ignition switch in “run”)
Parking Brake Light Circuit
(ignition switch in “run)(only on with ignition in “run” when parking brake is engaged)
416-H & 416-8 1990 - 1991
7 - 64 Demystification Guide
Neutral/Clutch Light Cirtcuit
(ignition switch in “start”)(lights when motion lever is in gear or clutch is not depressed)
PTO and Neutral/Clutch Circuit
(ignition switch in “start”)(lights when BOTH the PTO is engaged and unit is not clutched or in neutral)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
PTO Light Circuit
(ignition switch in “start”)(lights when PTO is engaged)
1990 - 1991 416-H & 416-8
Demystification Guide 7 - 65
Low Oil Pressure Light Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
Voltmeter Circuit
(ignition switch in “run”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
416-H & 416-8 1990 - 1991
7 - 66 Demystification Guide
416-8 Information List (1989)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-68
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-69
Spark Circuit . . . . . . . . . . . . . . . 7-69
Charging Circuit . . . . . . . . . . . . . 7-69
Gauge Circuit . . . . . . . . . . . . . . . 7-70
Light Circuit . . . . . . . . . . . . . . . . 7-70
In
fo
rm
atio
nLis
t
1989 416-8
Demystification Guide 7 - 67
Wiring Diagram
Wir
ing
Dia
gra
m
416-8 1989
7 - 68 Demystification Guide
Cir
cu
its
Charging Circuit
Spark Circuit
(ignition switch in “start”)
Starter Motor Circuit
(ignition switch in “start”)
1989 416-8
Demystification Guide 7 - 69
Cir
cu
its
Gauge Circuit
(ignition switch in “run”
Light Circuit
(ignition switch in “run”)
416-8 1989
7 - 70 Demystification Guide
416-8 Information List (1986)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-72
Circuit Diagrams
Starter Motor Circuits . . . . . . . . . . . 7-73
Spark Circuit . . . . . . . . . . . . . . . 7-74
Charging Circuit . . . . . . . . . . . . . 7-74
Gauge Circuit . . . . . . . . . . . . . . . 7-74
Light Circuit . . . . . . . . . . . . . . . . 7-75
In
fo
rm
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nLis
t
1986 416-8
Demystification Guide 7 - 71
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start” with low oil level)
Starter Motor Circuit
(ignition switch in “start”)
1986 416-8
Demystification Guide 7 - 73
Cir
cu
its
Spark Circuit
(ignition switch in “start”)
Charging Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
416-8 1986
7 - 74 Demystification Guide
Light Circuit
(ignition switch in “run”)
Cir
cu
its
1986 416-8
Demystification Guide 7 - 75
This page intentionally left blank
7 - 76 Demystification Guide
416-8 Information List (1985)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-78
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-79
Spark Circuit . . . . . . . . . . . . . . . 7-79
Charging Circuit . . . . . . . . . . . . . 7-79
Gauge Circuit . . . . . . . . . . . . . . . 7-80
Lights Circuit . . . . . . . . . . . . . . . 7-80
In
fo
rm
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1985 416-8
Demystification Guide 7 - 77
Wiring Diagram
Wir
ing
Dia
gra
m
416-8 1985
7 - 78 Demystification Guide
Spark Circuit
(ignition switch in “start”)
Charging Circuit
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
1985 416-8
Demystification Guide 7 - 79
Cir
cu
its
Gauge Circuit
(ignition switch in “run”)
Lights Circuit
(with engine running)
416-8 1985
7 - 80 Demystification Guide
414-8 Information List (1989)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-82
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-83
Spark Circuit . . . . . . . . . . . . . . . 7-83
Light Circuit . . . . . . . . . . . . . . . . 7-84
Gauge Circuit . . . . . . . . . . . . . . . 7-84
Charging Circuit . . . . . . . . . . . . . . 7-84
Oil Circuit . . . . . . . . . . . . . . . . . 7-85
In
fo
rm
atio
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t1989 414-8
Demystification Guide 7 - 81
Wiring Diagram
Wir
ing
Dia
gra
m414-8 1989
7 - 82 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
1989 414-8
Demystification Guide 7 - 83
Gauge Circuit
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Cir
cu
its
Light Circuit
(ignition switch in “run”)
414-8 1989
7 - 84 Demystification Guide
Legend
Black Bk
Blue Bu
Brown Br
Dark Blue Dk Bu
Dark Green Dk Gn
Green Gn
Gray Gy
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye
Oil Circuit
(with ignition switch in “start”)(prevents starting if oil is low)
1989 414-8
Demystification Guide 7 - 85
This page intentionally left blank
7 - 86 Demystification Guide
414-8 & 416-8 Information List (1987 - 1988)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-88
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-89
Spark Circuit . . . . . . . . . . . . . . . 7-89
Charging Circuit . . . . . . . . . . . . . 7-90
Gauge Circuit . . . . . . . . . . . . . . . 7-90
Light Circuit . . . . . . . . . . . . . . . . 7-90
In
fo
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t
1987 - 1988 414-8 & 416-8
Demystification Guide 7 - 87
Wiring Diagram
Wir
ing
Dia
gra
m
414-8 & 416-8 1987 - 1988
7 - 88 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1987 - 1988 414-8 & 416-8
Demystification Guide 7 - 89
Cir
cu
its
Charging Circuit
Gauge Circuit
(ignition switch in “run”)
Light Circuit
(ignition switch in “run”)
414-8 & 416-8 1987 - 1988
7 - 90 Demystification Guide
414-8 Information List (1986)
Wiring Diagram . . . . . . . . . . . . . . . . . 7-92
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-93
Spark Circuit . . . . . . . . . . . . . . . 7-93
Charging Circuit . . . . . . . . . . . . . 7-94
Gauge Circuit . . . . . . . . . . . . . . . 7-94
Light Circuit . . . . . . . . . . . . . . . . 7-94
Oil Light Test Circuit . . . . . . . . . . . . 7-95
In
fo
rm
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t
1986 414-8
Demystification Guide 7 - 91
Wiring Diagram
Wir
ing
Dia
gra
m
414-8 1986
7 - 92 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1986 414-8
Demystification Guide 7 - 93
Gauge Circuit
(ignition switch in “run”)
Cir
cu
its
Charging Circuit
(ignition switch in “run”)
Light Circuit
(ignition switch in “run”)
414-8 1986
7 - 94 Demystification Guide
Cir
cu
its
Oil Light Test Circuit
(ignition switch in “run”)
1986 414-8
Demystification Guide 7 - 95
This page intentionally left blank
7 - 96 Demystification Guide
520-H Information List (1990)
Wiring Diagram . . . . . . . . . . . . . . . . 7-106
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-107
Spark Circuit . . . . . . . . . . . . . . 7-107
Charging Circuit . . . . . . . . . . . . 7-107
Oil Pressure Light Circuit . . . . . . . . 7-108
Hydrostat Temperature Light Circuit . . 7-108
Air Filter Indicator Light . . . . . . . . . 7-108
Meter Light Circuit . . . . . . . . . . . 7-109
Parking Brake Light Circuit . . . . . . 7-109
Engine Temperature Light Circuit . . . 7-109
Hourmeter Circuit . . . . . . . . . . . 7-110
Headlight Circuit . . . . . . . . . . . . 7-110
Fuel Gauge . . . . . . . . . . . . . . . 7-110
Tachometer Circuit . . . . . . . . . . . 7-111
In
fo
rm
atio
nLis
t
1990 520-H
Demystification Guide 7 - 105
Wiring Diagram
Wir
ing
Dia
gra
m
520-H 1990
7 - 106 Demystification Guide
Cir
cu
its
Oil Pressure Light Circuit
(ignition switch in “run”
Hydrostat Temperature Light Circuit
(ignition switch in “run”)
Air Filter Indicator Light
(ignition switch in “run”)
520-H 1990
7 - 108 Demystification Guide
Engine Temperature Light Circuit
(ignition switch in “run”)
Cir
cu
its
Parking Brake Light Circuit
(parking brake applied)
Meter Light Circuit
(ignition switch in “run”)
1990 520-H
Demystification Guide 7 - 109
Hourmeter Circuit
(ignition switch in “start”)
Cir
cu
its
Fuel Gauge
(ignition switch in “start”)
Headlight Circuit
(headlight “on”)
520-H 1990
7 - 110 Demystification Guide
Tachometer Circuit
(ignition switch in “start”)
Cir
cu
its
1990 520-H
Demystification Guide 7 - 111
This page intentionally left blank
7 - 112 Demystification Guide
520-8 Information List (1990)
Wiring Diagram . . . . . . . . . . . . . . . . 7-114
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-115
Spark Circuit . . . . . . . . . . . . . . 7-115
Charging Circuit . . . . . . . . . . . . 7-115
Oil Pressure Light Circuit . . . . . . . . 7-116
Air Filter Indicator Light . . . . . . . . . 7-116
Meter Light Circuit . . . . . . . . . . . 7-116
Parking Brake Light Circuit . . . . . . 7-117
Engine Temperature Light Circuit . . . 7-117
Hourmeter Circuit . . . . . . . . . . . 7-117
Headlight Circuit . . . . . . . . . . . . 7-118
Fuel Gauge Circuit . . . . . . . . . . . 7-118
In
fo
rm
atio
nLis
t
1990 520-8
Demystification Guide 7 - 113
Wiring Diagram
Wir
ing
Dia
gra
m
520-8 1990
7 - 114 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Charging Circuit
Cir
cu
its
1990 520-8
Demystification Guide 7 - 115
Oil Pressure Light Circuit
(ignition switch in “run”
Cir
cu
its
Meter Light Circuit
(ignition switch in “run”)
Air Filter Indicator Light
(ignition switch in “run”)
520-8 1990
7 - 116 Demystification Guide
Engine Temperature Light Circuit
(ignition switch in “run”)
Cir
cu
its
Hourmeter Circuit
(ignition switch in “start”)
Parking Brake Light Circuit
(parking brake applied)
1990 520-8
Demystification Guide 7 - 117
Headlight Circuit
(headlight “on”)
Fuel Gauge Circuit
(ignition switch in “start”)
Cir
cu
its
520-8 1990
7 - 118 Demystification Guide
518-H & 520-H Information List (1988 - 1989)
Wiring Diagram . . . . . . . . . . . . . . . . 7-120
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-121
Spark Circuit . . . . . . . . . . . . . . 7-121
Lights Circuit . . . . . . . . . . . . . . 7-121
Seat Light Circuit . . . . . . . . . . . . 7-122
Oil Pressure Indicator Circuit . . . . . . 7-122
Air Filter Light Circuit . . . . . . . . . . 7-122
Hydrostat Temperature Light Circuit . . 7-123
Tachometer Circuit . . . . . . . . . . . 7-123
Fuel Gauge Circuit . . . . . . . . . . . 7-123
Hourmeter Circuit . . . . . . . . . . . . 7-124
Voltmeter Circuit . . . . . . . . . . . . . 7-124
Indicator Light Test Circuit . . . . . . . 7-124
High Engine TemperatureIndicator Light Circuit . . . . . . . . . 7-125
In
fo
rm
atio
nLis
t
1988 - 1989 518-H & 520-H
Demystification Guide 7 - 119
Wiring Diagram
Wir
ing
Dia
gra
m
518-H & 520-H 1988 - 1989
7 - 120 Demystification Guide
Air Filter Light Circuit
(ignition switch in “run”)
Seat Light Circuit
(ignition switch in or “run”)
Oil Pressure Indicator Circuit
(ignition switch in “run”)
Cir
cu
its
518-H & 520-H 1988 - 1989
7 - 122 Demystification Guide
Hydrostat Temperature Light Circuit
(ignition switch in “start” or “run”)
Cir
cu
its
Tachometer Circuit
(ignition switch in “run”)
Fuel Gauge Circuit
(ignition switch in “run”)
1988 - 1989 518-H & 520-H
Demystification Guide 7 - 123
Voltmeter Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
Cir
cu
its
Indicator Light Test Circuit
(ignition switch in “run”)
518-H & 520-H 1988 - 1989
7 - 124 Demystification Guide
Cir
cu
its
High Engine Temperature Indicator Light Circuit
(ignition switch in “run”)
1988 - 1989 518-H & 520-H
Demystification Guide 7 - 125
This page intentionally left blank
7 - 126 Demystification Guide
516-H & 520-HC Information List (1988 - 1989)
Wiring Diagram . . . . . . . . . . . . . . . . 7-128
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-129
Spark Circuits . . . . . . . . . . . . . 7-129
Charging Circuit . . . . . . . . . . . . 7-130
Oil Pressure Light Circuit . . . . . . . . 7-130
Fuel Gauge . . . . . . . . . . . . . . . 7-130
Light Circuit . . . . . . . . . . . . . . . 7-131
Meter Light Circuit . . . . . . . . . . . 7-131
Hourmeter Circuit . . . . . . . . . . . 7-131
Tachometer Circuit . . . . . . . . . . . 7-132
In
fo
rm
atio
nLis
t
1988 - 1989 516-H & 520-HC
Demystification Guide 7 - 127
Wiring Diagram
Wir
ing
Dia
gra
m
516-H & 520-HC 1988 - 1989
7 - 128 Demystification Guide
Cir
cu
its
Charging Circuit
AlternatorFuse Battery
(12 Volt)
BkBk
(30 amp)
AC
ACB+
Regulator/Rectifier
Oil Pressure Light Circuit
(ignition switch in “run”
Fuel Gauge
(ignition switch in “run”)
516-H & 520-HC 1988 - 1989
7 - 130 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run”)
Meter Light Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “start”)
1988 - 1989 516-H & 520-HC
Demystification Guide 7 - 131
Cir
cu
its
Tachometer Circuit
(ignition switch in “start”)
516-H & 520-HC 1988 - 1989
7 - 132 Demystification Guide
518xi Information List (1998)
Wiring Diagram . . . . . . . . . . . . . . . . 7-134
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-135
Spark Circuits . . . . . . . . . 7-135 & 7-136
Charging Circuit . . . . . . . . . . . . . 7-136
Light Circuit . . . . . . . . . . . . . . . 7-136
Electric Clutch Circuit . . . . . . . . . . 7-137
Hourmeter Circuit . . . . . . . . . . . . 7-137
Gauge Circuit . . . . . . . . . . . . . . 7-137
In
fo
rm
atio
nLis
t
1998 518xi
Demystification Guide 7 - 133
Wiring Diagram
Wir
ing
Dia
gra
m
518xi 1998
7 - 134 Demystification Guide
Spark Circuit
(ignition switch in “start” position)
Spark Circuit
(ignition switch in “run” position, operator on)
Starter Motor Circuit
(ignition switch in “start” position)
Cir
cu
its
1998 518xi
Demystification Guide 7 - 135
Spark Circuit
(ignition switch in “run” position, operator off)
Charging Circuit
(Ignition Switch in “run”)
Light Circuit
(ignition switch in “run/lights”)
Cir
cu
its
518xi 1998
7 - 136 Demystification Guide
Electric Clutch Circuit
(ignition switch in “start” or “run”)
Cir
cu
its
Hourmeter Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
1998 518xi
Demystification Guide 7 - 137
This page intentionally left blank
7 - 138 Demystification Guide
1999 - 2001 518xi
rev. 4-03
7-138ADemystification Guide
518xi Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . 7-138B, 7-138CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-138ERun Circuit (operator “on”) . . . . . . . . 7-138EClutch Circuit (forward PTO “on”) . . . . . 7-138FClutch Circuit (fwd/rev PTO “on”) . . . . . 7-138GCharging Circuit . . . . . . . . . . . 7-138GLight Circuit . . . . . . . . . . . . . 7-138HGauge Circuit . . . . . . . . . . . . 7-138HHourmeter Circuit . . . . . . . . . . . 7-138H
518xi 1999 - 2001
Wiring Diagram rev. 4-03
7 - 138B Demystification Guide
1999 - 2001 518xi
Wiring Diagramrev. 4-03
Demystification Guide 7 - 138C
Demystification Guide7 - 138D
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7 - 138EDemystification Guide
1999 - 2001 518xi
Starter Motor Circuit(ignition switch in “start”)
rev. 4-03
Run Circuit(operator “on”)
Clutch Circuit(forward PTO “on” )
518xi 1999 - 2001
Demystification Guide7 - 138F
rev. 4-03
7 - 138GDemystification Guide
1999 - 2001 518xi
Clutch Circuit(forward/reverse PTO “on” - after override switch activated)
rev. 4-03
Charging Circuit(ignition switch in “run”)
Light Circuit(ignition switch in “run/lights” )
518xi 1999 - 2001
Demystification Guide7 - 138H
rev. 4-03
Gauge Circuit(ignition switch in “run” )
Hourmeter Circuit(ignition switch in “run” )
520xi & 522xi Information List (1998)
Wiring Diagram . . . . . . . . . . . . . . . . 7-140
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-140
Spark Circuit . . . . . . . . . 7-141 & 7-142
Charging Circuit . . . . . . . . . . . . . 7-143
Electric Clutch . . . . . . . . . . . . . . 7-143
Light Circuit . . . . . . . . . . . . . . . 7-143
Reverse Light Circuit . . . . . . . . . . 7-144
Hourmeter Circuit . . . . . . . . . . . 7-1424
Gauge Circuit . . . . . . . . . . . . . . 7-145
Cruise Control Circuit . . . . . . . . . . 7-145
Park Light Circuit . . . . . . . . . . . . 7-145
In
fo
rm
atio
nLis
t
1998 520xi & 522xi
Demystification Guide 7 - 139
Wiring Diagram
Wir
ing
Dia
gra
m
520xi & 522xi 1998
7 - 140 Demystification Guide
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
Cir
cu
its
1998 520xi & 522xi
Demystification Guide 7 - 141
Cir
cu
its
Spark Circuit
(ignition switch in “run” position, operator on)
Spark Circuit
(ignition switch in “run” position, operator off)
520xi & 522xi 1998
7 - 142 Demystification Guide
Cir
cu
its
Light Circuit
(ignition switch in “run/lights”)
Electric Clutch
(ignition switch in “run”)
Charging Circuit
(ignition switch in “run”)
1998 520xi & 522xi
Demystification Guide 7 - 143
Cir
cu
its
Reverse Light Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
520xi & 522xi 1998
7 - 144 Demystification Guide
Cir
cu
its
Cruise Control Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
Park Light Circuit
(ignition switch in “run”)
1998 520xi & 522xi
Demystification Guide 7 - 145
This page intentionally left blank
7 - 146 Demystification Guide
1999 - 2001 520xi & 522xi
rev. 4-03
7-146ADemystification Guide
520xi & 522xi Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . 7-146B, 7-146CCircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-146ERun Circuit (operator “on”) . . . . . . . . 7-146EClutch Circuit (forward PTO “on”) . . . . . 7-146FClutch Circuit (fwd/rev PTO “on”) . . . . . 7-146GCharging Circuit . . . . . . . . . . . 7-146GLight Circuit . . . . . . . . . . . . . 7-146HGauge Circuit . . . . . . . . . . . . 7-146HHourmeter Circuit . . . . . . . . . . . 7-146H
520xi & 522xi 1999 - 2001
Wiring Diagram rev. 4-03
7 - 146B Demystification Guide
1999 - 2001 520xi & 522xi
Wiring Diagramrev. 4-03
Demystification Guide 7 - 146C
Demystification Guide7 - 146D
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7 - 146EDemystification Guide
1999 - 2001 520xi & 522xi
Starter Motor Circuit(ignition switch in “start”)
rev. 4-03
Run Circuit(operator “on”)
Clutch Circuit(forward PTO “on” )
520xi & 522xi 1999 - 2001
Demystification Guide7 - 146F
rev. 4-03
7 - 146GDemystification Guide
1999 - 2001 520xi & 522xi
Clutch Circuit(forward/reverse PTO “on” - override switch activated)
rev. 4-03
Charging Circuit(ignition switch in “run”)
Light Circuit(ignition switch in “run/lights” )
520xi & 522xi 1999 - 2001
Demystification Guide7 - 146H
rev. 4-03
Gauge Circuit(ignition switch in “run” )
Hourmeter Circuit(ignition switch in “run” )
520Lxi Information List (1998)
Wiring Diagram . . . . . . . . . . . . . . . . 7-150
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . 7-151
Spark Circuit . . . . . . . . . 7-151 & 7-152
Charging Circuit . . . . . . . . . . . . . 7-152
Light Circuit . . . . . . . . . . . . . . . 7-152
Electric Clutch Circuit . . . . . . . . . . 7-153
Gauge Circuit . . . . . . . . . . . . . . 7-153
Cruise Control Circuit . . . . . . . . . . 7-153
Hourmeter Circuit . . . . . . . . . . . . 7-154
Park Light Circuit . . . . . . . . . . . . 7-154
Reverse Light Circuit . . . . . . . . . . 7-154
In
fo
rm
atio
nLis
t
1998 520Lxi
Demystification Guide 7 - 149
Wiring Diagram
Wir
ing
Dia
gra
m
520Lxi 1998
7 - 150 Demystification Guide
Cir
cu
its
Starter Motor Circuit
(ignition switch in “start”)
Spark Circuit
(ignition switch in “start”)
1998 520Lxi
Demystification Guide 7 - 151
Cir
cu
its
Light Circuit
(ignition switch in “run/lights”)
Charging Circuit
(ignition switch in “run”)
Spark Circuit
(ignition switch in “run”)
520Lxi 1998
7 - 152 Demystification Guide
Cir
cu
its
Cruise Control Circuit
(ignition switch in “run”)
Gauge Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run”)
1998 520Lxi
Demystification Guide 7 - 153
Cir
cu
its
Park Light Circuit
(ignition switch in “run”)
Hourmeter Circuit
(ignition switch in “run”)
Reverse Light Circuit
(ignition switch in “run”)
520Lxi 1998
7 - 154 Demystification Guide
1999 - 2001 520Lxi
rev. 4-03
7-155Demystification Guide
520Lxi Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . 7-156, 7-156ACircuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-156BRun Circuit (operator “on”) . . . . . . . . 7-156BClutch Circuit (forward PTO “on”) . . . . . 7-156CClutch Circuit (fwd/rev PTO “on”) . . . . . 7-156DCharging Circuit . . . . . . . . . . . 7-156DLight Circuit . . . . . . . . . . . . . 7-156EGauge Circuit . . . . . . . . . . . . 7-156ECruise Control Circuit . . . . . . . . . 7-156EHourmeter Circuit . . . . . . . . . . . 7-156FPark Light Circuit . . . . . . . . . . . 7-156F
520Lxi 1999 - 2001
Wiring Diagram rev. 4-03
7 - 156 Demystification Guide
1999 - 2001 520Lxi
Wiring Diagramrev. 4-03
Demystification Guide 7 - 156A
Starter Motor Circuit(ignition switch in “start” )
520Lxi 1999 - 2001
Demystification Guide7 - 156B
rev. 4-03
Run Circuit(operator “on” )
7 - 156CDemystification Guide
1999 - 2001 520Lxi
Clutch Circuit(forward PTO “on”)
rev. 4-03
Clutch Circuit(forward / reverse PTO “on” - override switch activated )
520Lxi 1999 - 2001
Demystification Guide7 - 156D
rev. 4-03
Charging Circuit(ignition switch in “run” )
7 - 156EDemystification Guide
1999 - 2001 520Lxi
Light Circuit(ignition switch in “run/lights”)
rev. 4-03
Gauge Circuit(ignition switch in “run”)
Cruise Control Circuit(ignition switch in “run”)
Hourmeter Circuit(ignition switch in “run”
520Lxi 1999 - 2001
Demystification Guide7 - 156F
rev. 4-03
Park Light Circuit(ignition switch in “run” )
523Dxi Information List (1998)
Wiring Diagram . . . . . . . . . . . . . . . . 7-158
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-159
Injection Pump Circuits . . . . . . . . . 7-159
Charging Circuit . . . . . . . . . . . . 7-160
Glow Plug Circuit . . . . . . . . . . . . 7-160
Light Circuit . . . . . . . . . . . . . . . 7-160
Electric Clutch Circuit . . . . . . . . . 7-161
Gauge Circuit . . . . . . . . . . . . . . 7-161
Cruise Control Circuit . . . . . . . . . . 7-162
Park Light Circuit . . . . . . . . . . . . 7-162
Hourmeter Circuit . . . . . . . . . . . . 7-162
Reverse Light Circuit . . . . . . . . . . 7-163
Temperature Light Circuit . . . . . . . . 7-163
In
fo
rm
atio
nLis
t
1998 523Dxi
Demystification Guide 7 - 157
Wiring Diagram
Wir
ing
Dia
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m
523Dxi 1998
7 - 158 Demystification Guide
Cir
cu
its
Injection Pump Circuit
(ignition switch in “run”)
Starter Motor Circuit
(ignition switch in “run”)
Injection Pump Circuit
(ignition switch in “start”)
1998 523Dxi
Demystification Guide 7 - 159
Cir
cu
its
Glow Plug Circuit
(ignition switch in “on” )
Charging Circuit
(ignition switch in “run”)
Light Circuit
(ignition switch in “run/lights”)
523Dxi 1998
7 - 160 Demystification Guide
Cir
cu
its
Gauge Circuit
(ignition switch in “run”)
Electric Clutch Circuit
(ignition switch in “run” or “start)
1998 523Dxi
Demystification Guide 7 - 161
Cir
cu
its
Hourmeter Circuit
(ignition switch in “start” )
Cruise Control Circuit
(ignition switch in “run”)
Park Light Circuit
(ignition switch in “run”)
523Dxi 1998
7 - 162 Demystification Guide
Temperature Light Circuit
(ignition switch in “run” )
Reverse Light Circuit
(ignition switch in “run” )
Cir
cu
its
1998 523Dxi
Demystification Guide 7 - 163
This page intentionally left blank
7 - 164 Demystification Guide
1999 - 2001 523Dxi
rev. 4-03
7-165Demystification Guide
523Dxi Information List (1999 - 2001)
Wiring Diagram . . . . . . . . . . . . 7-166, 7-167Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-169Run Circuit (operator “on”) . . . . . . . . 7-169Clutch Circuit (forward PTO “on”) . . . . . 7-170Clutch Circuit (fwd/rev PTO “on”) . . . . . 7-171Charging Circuit . . . . . . . . . . . 7-171Light Circuit . . . . . . . . . . . . . 7-172Gauge Circuit . . . . . . . . . . . . 7-172Hourmeter Circuit . . . . . . . . . . . 7-172Glow Plug Circuit . . . . . . . . . . . 7-173Cruise Control Circuit . . . . . . . . . 7-173Temperature Light Circuit . . . . . . . . 7-174Park Light Circuit . . . . . . . . . . . 7-174
523Dxi 1999 - 2001
Wiring Diagram rev. 4-03
7 - 166 Demystification Guide
1999 - 2001 523Dxi
Wiring Diagramrev. 4-03
Demystification Guide 7 - 167
Demystification Guide7 - 168
This page intentionally left blank
7 - 169Demystification Guide
1999 - 2001 523Dxi
Starter Motor Circuit(ignition switch in “start”)
rev. 4-03
Run Circuit(operator “on”)
Clutch Circuit(forward PTO “on”
523Dxi 1999 - 2001
Demystification Guide7 - 170
rev. 4-03
7 - 171Demystification Guide
1999 - 2001 523Dxi
Clutch Circuit(forward/reverse PTO “on” - override switch activated)
rev. 4-03
Charging Circuit(ignition switch in “run”)
Light Circuit(ignition switch in “run/lights” )
523Dxi 1999 - 2001
Demystification Guide7 - 172
Gauge Circuit(ignition switch in “run” )
Hourmeter Circuit(ignition switch in “run” )
rev. 4-03
7 - 173Demystification Guide
1999 - 2001 523Dxi
Glow Plug Circuit(ignition switch in“on”)
rev. 4-03
Cruise Control Circuit(ignition switch in “run”)
Temperature Light Circuit(ignition switch in “run” )
523Dxi 1999 - 2001
Demystification Guide7 - 174
Park Light Circuit(ignition switch in “run” )
rev. 4-03
2001200120012001 TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z
Demystification Guide 8 - 1
TimeCutter Z (2001)
Wiring Diagram (Briggs & Stratton) . . . . . . . . . . . . . . . . . . . 8-2Wiring Diagram (Kohler). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . 8-4Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4Charging Circuit (Kohler) . . . . . . . . . . . . . . . . . . . . 8-5Charging Circuit (Briggs & Stratton). . . . . . . . . . . . . 8-5
Info
rmatio
n L
ist
TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z 2001200120012001
8 - 2 Demystification Guide
Wiring Diagram
Wir
ing
Dia
gra
m
2001200120012001 TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z
Demystification Guide 8 - 3
Wiring Diagram
Wirin
g D
iag
ram
TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z 2001200120012001
8 - 4 Demystification Guide
Starter Motor Circuit(ignition switch in “start”)
Run Circuit(PTO engaged)
Kill Relay(energized)
Y
W
Battery Fuse(30 amp)
PTOSwitch
(off)
Brake Switch(parking brake
engaged)
Neutral Switch(in neutral)
Neutral Switch(in neutral)
IgnitionSwitch
(in start)
Re RePk
BuB
S
I
Solenoid(energized)
Starter Motor(energzized)
Kill Relay(energized)
YY
W
Battery Fuse(30 amp)
Brake Switch(parking brakedisengaged)
Seat Switch(operator on)
PTO Switch(pto on)
Fuel Solenoid(energized)
IgnitionSwitch(in run)
Re Re
Bk
Pk
Or
Or Vio
Pk
BY
X
I
Triggermodule
Ignition Coil
Dashed lines do not carry current
Bk
PTO Clutch(engaged)
Cir
cu
its
Legend
Black BkBlue BuBrown BnGreen GnGrey GyOrange OrPink PkRed ReTan TViolet VioWhite WYellow Y
2001200120012001 TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z
Demystification Guide 8 - 5
Charging Circuit(Kohler)
Charging Circuit(Briggs & Stratton)
BatteryAlternatorVoltage Regulator
Fuse(30 amp)
Fuse(25 amp) Ignition
Switch(in run)
ReVio Vio Re
BA
AC
B+AC
Circ
uits
Legend
Black BkBlue BuBrown BnGreen GnGrey GyOrange OrPink PkRed ReTan TViolet VioWhite WYellow Y
8 - 6 Demystification Guide
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Riding Products Demystification
Guide
Form No.