Anda di halaman 1dari 546

TABLE OF CONTENTS

Safety Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Time Savers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

REAR ENGINE RIDERS


MODEL YEAR PAGE
825 . . . . . . . . . . . . . . . . . . . . . 1996 - 1998 . . . . . . . . . . . . . . 4-1
825 . . . . . . . . . . . . . . . . . . . . . 1989 - 1992 . . . . . . . . . . . . . . 4-5
825 RER . . . . . . . . . . . . . . . . . . 1993 - 1995 (70040 & 70060) . . . . . 4-8A
825 RER . . . . . . . . . . . . . . . . . . 1996 - 1997 (70040 & 70060) . . . . . 4-8G
825 RER . . . . . . . . . . . . . . . . . . 1998 (70040) . . . . . . . . . . . . . 4-8G
825 RER . . . . . . . . . . . . . . . . . . 1998 (70041 & 70060) . . . . . . . . . 4-8M
825 RER . . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . . 4-9
10-32 & 12-32 . . . . . . . . . . . . . . . 1994 - 1995 . . . . . . . . . . . . 4-14A
832 & 10-32 & 12-32 . . . . . . . . . . . . 1991 - 1992 . . . . . . . . . . . . . 4-15
832 RER . . . . . . . . . . . . . . . . . . 1993 (70042) . . . . . . . . . . . . 4-18A
108-4, 108-5, & 111-6 . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . 4-19
112-C . . . . . . . . . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . 4-23
11-32 & 13-32 . . . . . . . . . . . . . . . 1996 - 1998 . . . . . . . . . . . . . 4-27
12-32 RER . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . . 4-31

LAWN TRACTORS
MODEL YEAR PAGE
208-4SB, 211-5SB, 211-4 & 212-5 . . . . . . 1988 - 1989 . . . . . . . . . . . . . . 5-1
210-5 & 210-H . . . . . . . . . . . . . . . 1990 . . . . . . . . . . . . . . . . . 5-1
210-5 & 210-H . . . . . . . . . . . . . . . 1991 & 1993 - 1995 . . . . . . . . . 5-7
212-H . . . . . . . . . . . . . . . . . . . . 1992 . . . . . . . . . . . . . . . . . 5-7
210-5 & 210-H . . . . . . . . . . . . . . . 1992 . . . . . . . . . . . . . . . . . 5-11
212-5 & 212-H . . . . . . . . . . . . . . . 1991 . . . . . . . . . . . . . . . . . 5-15
212-5 & 212-H . . . . . . . . . . . . . . . 1990 . . . . . . . . . . . . . . . . . 5-21
212-5 . . . . . . . . . . . . . . . . . . . . 1992 . . . . . . . . . . . . . . . . . 5-27
212-6 . . . . . . . . . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . . 5-31
212-6 . . . . . . . . . . . . . . . . . . . . 1987 . . . . . . . . . . . . . . . . . 5-37
10-32XL & 12-38XL . . . . . . . . . . . . . 1993 . . . . . . . . . . . . . . . . . 5-43
12-32XL & 12-38HXL . . . . . . . . . . . . 1993 - 1995 . . . . . . . . . . . . . 5-43

Demystification Guide i
TABLE OF CONTENTS
LAWN TRACTORS (continued)
MODEL YEAR PAGE
13-38HXL . . . . . . . . . . . . . . . . . 1994 . . . . . . . . . . . . . . . . . 5-43
13-38HXL & 15-44HXL . . . . . . . . . . . 1995 . . . . . . . . . . . . . . . . . 5-47
XL . . . . . . . . . . . . . . . . . . . . . . 1996 - 1998 . . . . . . . . . . . . . 5-47
XL . . . . . . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . 5-50A
252-H . . . . . . . . . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . . 5-51
257-H . . . . . . . . . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . . 5-57

YARD & GARDEN TRACTORS


MODEL YEAR PAGE
244 . . . . . . . . . . . . . . . . . . . . . 1993 . . . . . . . . . . . . . . . . . 6-1
246-H . . . . . . . . . . . . . . . . . . . . 1992 . . . . . . . . . . . . . . . . . 6-1
264-6 . . . . . . . . . . . . . . . . . . . . 1994 - 1995 . . . . . . . . . . . . . . 6-7
264-H & 265-H . . . . . . . . . . . . . . . 1994 - 1998 . . . . . . . . . . . . . 6-15
265-6 . . . . . . . . . . . . . . . . . . . . 1996 - 1998 . . . . . . . . . . . . . 6-23
265-6 . . . . . . . . . . . . . . . . . . . . 1999 - 2000 . . . . . . . . . . . . 6-29A
265-H . . . . . . . . . . . . . . . . . . . 2000 - 2001 . . . . . . . . . . . . 6-30A
265-H . . . . . . . . . . . . . . . . . . . 1999 . . . . . . . . . . . . . . . . 6-31A
266-H . . . . . . . . . . . . . . . . . . . . 1995 . . . . . . . . . . . . . . . . . 6-33
266-H . . . . . . . . . . . . . . . . . . . . 1994 . . . . . . . . . . . . . . . . . 6-41
266-H . . . . . . . . . . . . . . . . . . . . 2001 . . . . . . . . . . . . . . . . 6-48A
267-H . . . . . . . . . . . . . . . . . . . . 1996 - 1998 . . . . . . . . . . . . . 6-49
268-H . . . . . . . . . . . . . . . . . . . 1999 . . . . . . . . . . . . . . . 6-57A
268-H . . . . . . . . . . . . . . . . . . . 2000 - 2001 . . . . . . . . . . . . 6-58A
269-H . . . . . . . . . . . . . . . . . . . . 1996 - 1998 . . . . . . . . . . . . . 6-59
270-H . . . . . . . . . . . . . . . . . . . 2001 . . . . . . . . . . . . . . . . 6-66A
270-H . . . . . . . . . . . . . . . . . . . 2000 . . . . . . . . . . . . . . . . 6-67
270-H . . . . . . . . . . . . . . . . . . . . 1999 . . . . . . . . . . . . . . . . 6-77

GARDEN TRACTORS
MODEL YEAR PAGE
308-8 . . . . . . . . . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . . 7-1
310 . . . . . . . . . . . . . . . . . . . . . 1989 - 1991 . . . . . . . . . . . . . 7-5
310-8 . . . . . . . . . . . . . . . . . . . . 1988 . . . . . . . . . . . . . . . . . 7-11
312-8 . . . . . . . . . . . . . . . . . . . . 1998 . . . . . . . . . . . . . . . . . 7-17

ii Demystification Guide
TABLE OF CONTENTS
GARDEN TRACTORS (continued)
MODEL YEAR PAGE
312-8 . . . . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . 7-22A
310-8 . . . . . . . . . . . . . . . . . . . . 1992 - 1993 . . . . . . . . . . . . . 7-23
312-8 . . . . . . . . . . . . . . . . . . . 1992 - 1997 . . . . . . . . . . . . . 7-23
314-8 . . . . . . . . . . . . . . . . . . . . 1993 . . . . . . . . . . . . . . . . . 7-23
312-8 . . . . . . . . . . . . . . . . . . . . 1989 . . . . . . . . . . . . . . . . . 7-27
312-8 . . . . . . . . . . . . . . . . . . . . 1987 - 1988 . . . . . . . . . . . . . 7-33
312-H & 312-8 . . . . . . . . . . . . . . . . 1990 - 1991 . . . . . . . . . . . . . 7-39
312-A & 312-8 . . . . . . . . . . . . . . . 1986 . . . . . . . . . . . . . . . . . 7-45
312-H . . . . . . . . . . . . . . . . . . . 1992 . . . . . . . . . . . . . . . . . 7-53
314-H . . . . . . . . . . . . . . . . . . . 1993 - 1997 . . . . . . . . . . . . . 7-53
314-8 . . . . . . . . . . . . . . . . . . . . 1994 - 1997 . . . . . . . . . . . . . 7-53
314-8 . . . . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . 7-56A
416-8 . . . . . . . . . . . . . . . . . . . . 1992 - 1997 . . . . . . . . . . . . . 7-57
416-H . . . . . . . . . . . . . . . . . . . 1992 - 1997 . . . . . . . . . . . . . 7-57
416-H & 416-8 . . . . . . . . . . . . . . . 1990 - 1991 . . . . . . . . . . . . . 7-61
416-8 . . . . . . . . . . . . . . . . . . . 1989 . . . . . . . . . . . . . . . . . 7-67
416-8 . . . . . . . . . . . . . . . . . . . 1986 . . . . . . . . . . . . . . . . . 7-71
416-8 . . . . . . . . . . . . . . . . . . . 1985 . . . . . . . . . . . . . . . . . 7-77
414-8 . . . . . . . . . . . . . . . . . . . 1989 . . . . . . . . . . . . . . . . . 7-81
414-8 & 416-8 . . . . . . . . . . . . . . . 1987 - 1988 . . . . . . . . . . . . . 7-87
414-8 . . . . . . . . . . . . . . . . . . . 1986 . . . . . . . . . . . . . . . . . 7-91
520-H . . . . . . . . . . . . . . . . . . . 1991 - 1997 . . . . . . . . . . . . . 7-97
520-H . . . . . . . . . . . . . . . . . . . 1990 . . . . . . . . . . . . . . . . 7-105
520-8 . . . . . . . . . . . . . . . . . . . 1990 . . . . . . . . . . . . . . . . 7-113
518-H & 520-H . . . . . . . . . . . . . . . 1988 - 1989 . . . . . . . . . . . . 7-119
516-H & 520-HC . . . . . . . . . . . . . . 1988 - 1989 . . . . . . . . . . . . 7-127
518-xi . . . . . . . . . . . . . . . . . . . 1998 . . . . . . . . . . . . . . . . 7-133
518-xi . . . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . 7-138A
520-xi & 522-xi . . . . . . . . . . . . . . . 1998 . . . . . . . . . . . . . . . . 7-139
520-xi & 522-xi . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . 7-146A
520L-xi . . . . . . . . . . . . . . . . . . . 1998 . . . . . . . . . . . . . . . . 7-149
520L-xi . . . . . . . . . . . . . . . . . . . 1999 - 2001 . . . . . . . . . . . . 7-155

Demystification Guide iii


TABLE OF CONTENTS
GARDEN TRACTORS (continued)
MODEL YEAR PAGE
523Dxi . . . . . . . . . . . . . . . . . . . 1998 . . . . . . . . . . . . . . . . 7-157
523Dxi . . . . . . . . . . . . . . . . . . . 1999 - 2001. . . . . . . . . . . . . 7-165

ZERO TURN RIDERS


MODEL YEAR PAGE
TimeCutter Z . . . . . . . . . . . . . . . . 2001 . . . . . . . . . . . . . . . . . 8-1

iv Demystification Guide
SAFETY INFO

Avoid amputations and lacerations... When troubleshooting,


you may encounter non- functioning safety systems. Always
check 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 relatively


low, the ignition coil secondary produces close to 20,000
volts. Avoid contacting the spark plug wire while the engine
is turning.

Demystification Guide 1-1


This page intentionally left blank

1-2 Demystification Guide


TIME SAVERS

Table Of Contents
Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Using a VOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Troubleshooting Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Troubleshooting Short Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Demystification Guide 2-1


TIME SAVERS

The glossary contains


information on virtually every
electrical part used on Toro You may see multiple part
riding products. numbers here if the information
is identical to other parts.

The components are listed


alphabetically by noun, followed
by any adjectives. if you have
trouble finding a component, use
the index at the front of the
glossary section.

These three sections should be


all you need to diagnose
problems on individual
components.
Using this Manual

2-2 Demystification Guide


TIME SAVERS

Each product group has its own


section including:
- Info List
- Parts Used
- Wiring Diagrams
- Circuit Diagrams

Drawing helps you quickly


identify product sections.

Each product section has its own


"table of contents" to keep things
simple. The "Info List" is the first page of
each product section.

Using this Manual

Demystification Guide 2-3


TIME SAVERS

All Toro electrical parts are called out


in this section

The description is the name given to


the part in the book only.

This is the most recent part number


available at press time.

This part has been cross referenced,


the old part number is listed here.
Using this Manual

The glossary page numbers refer to


the most recent part number

2-4 Demystification Guide


TIME SAVERS

Each product section


includes the origional
wiring diagram.

The wiring diagram


closely represents the
Using this Manual
wiring harness and is
very useful in
diagnosing short
circuits.

Demystification Guide 2-5


TIME SAVERS

Each circuit is shown Circuits are drawn such


individually. Components that current always
not essential for circuit flows from left to right
function are not shown. (the same way you
read).

Additional information is
called out beneath the
title in parenthesis.

Each component is Dashed lines represent


Solid lines indicate
named and additional wires that are important
wires that carry current.
information is supplied to the circuit but do not
below in parentheses. carry current.

Wire colors are called


Components with out at each component
internal circuitry are (where you're most
enclosed with a dashed likely to use them!)
line.
Each circuit diagram
page has a color code
legend.
Using this Manual

Each component (ie


switches, relays,
solenoids) are drawn in
the position necessary to
make the circuit function.

Circuit Diagrams make


troubleshooting easy
and fun because each
circuit is drawn individually.
Thay make troubleshooting
open circuits a snap.

2-6 Demystification Guide


TIME SAVERS

1 Checking Voltage
Use the AC scales to measure
unrectified voltage straight from an
Battery voltage is always D.C.

alternator or from a wall outlet.

Using a VOM
Always start by selecting the proper
scale. For instance, on this meter we
selected the 25 volt scale.

AC
Wh A B Re Re Re Re Bk
B+
AC
Fuse Battery
Alternator Regulator Ignition Switch (25 amp) (12 volt)
(15 amp) Rectifier (in "run") If you measure from ground to ground
or have an open circuit, your reading 10026
will be 0.

Use D.C. scales to measure voltages


that have been changed to D.C. by a
rectifier or diode.

Checking Resistance

2 The ohmmeter is powered by an


The integrity of the ignition coils and
electric clutches can often be checked
using an ohmmeter.

internal battery. Replace it if the


needle will not move full scale.

Make sure your VOM reads 0 ohms


(full scale right) when the leads are
touching together to insure accurate
resistance readings.

Always disconnect components from


the circuit when resistance checking.
Otherwise you could get a false
reading. This switch should read
infinite ( ) resistance.

Do not use the ohmmeter to test Toro


interlock modules! The battery current
could damage the module.

Demystification Guide 2-7


TIME SAVERS

What about checking current?

3
Using a VOM

AC
Wh A B Re Re Re Re Bk
B+
AC
Fuse Battery
Alternator Regulator Ignition Switch (25 amp) (12 volt)
(15 amp) Rectifier (in "run")
10026

Most ammeters can measure only .1


amp. The current in Toro riding
products generally is from 3-90 amps.
This is sufficient to destroy most
VOMs!

2-8 Demystification Guide


TIME SAVERS

Sample Problem: 244 electric clutch will not engage.

Troubleshooting Open Circuits


Same Sample 244 electric clutch will not engage. (This time
Problem: we’ll solve it faster.)

Demystification Guide 2-9


TIME SAVERS

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
Troubleshooting Short Circuits

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. Any


information we get will help isolate the
problem. If the short was in the white wire, the
30 amp fuse would have blown.
STEP 2. Isolate the suspect area.
Notice what we did to the wiring
If the short was between the battery
diagram at right.
and the 25 amp fuse, we would have
Highlight the suspect area on a copy melted these wires.
of the wiring diagram.

If the pink wire or electric clutch


shorted we would have blown the 15
amp fuse. Eliminate all the black wires as
possibilities because they're supposed
to go to ground!

2 - 10 Demystification Guide
TIME SAVERS

Troubleshooting Open Circuits

Demystification Guide 2 - 11
TIME SAVERS

Conclusion:
Troubleshooting Short Circuits

2 - 12 Demystification Guide
GLOSSARY

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

Glossary
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

Demystification Guide 3-1


GLOSSARY

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
Glossary

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

3-2 Demystification Guide


GLOSSARY

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

Glossary
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

Demystification Guide 3-3


GLOSSARY

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
Glossary

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

3-4 Demystification Guide


GLOSSARY

Alternator Part Numbers


15 Amp KH10091

(Kohler) 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 is
produced. The amount will depend on the thickness of the wire, the
number of windings on each coil, the strength of the magnet, and the
speed at which the magnet is moving.

This particular coil has 18 poles to produce 15 amps at 28 or more volts


A.C. when the engine is running at 3600 rpm. The current produced is
alternating current since no diode or rectifier is internal to the stator.

Stator Output* Stator Resistance Note: This stator kit comes with mounting screws and terminals so that it
will retrofit to a number of different Kohler engines.
more than 28 .1 - .2 Ohms
VDC @ 3600 rpm Testing
1. Remove the connector from the regulator rectifier. Measure the voltage
*With regulator/rectifier disconnected
across the two A.C. Ieads on the alternator side of the connector with
the 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 the
resistance across the two A.C. Ieads running to the stator. The
resistance should be .1 to .2 ohms. If not, replace the stator.

Alternator Part Numbers


57-9440, 92-0967
20 Amp
(with terminals) Purpose
This stator generates alternating current whenever the engine is running.
(Onan)
How It Works
Whenever a magnet passes by a coil of wire on an iron core, electricity is
produced. The amount will depend on the thickness of the wire, the

Glossary
number of windings on each coil, the strength of the magnet, and the
speed at which the magnet is moving.

This particular coil has 18 poles to produce 20 amps at 57 volts A.C. when
the engine is running at 3600 rpm. The current produced is alternating
current since no diode or rectifier is internal to the stator.

Item Specification Testing


1. Disconnect the alternator from the regulator/rectifier.
Battery 12-13 VDC
2. Measure the voltage across the A.C. terminals on the alternator side of
Stator Voltage Approximately 29 VDC the connector. The voltage should read as shown in Figure A.
@ 1800 RPM.
Approximately 57 VDC 3. Check for a short in the alternator by checking between either of the
@ 3600 RPM. A.C. terminals and ground. If you do not get infinite resistance, replace
the alternator.
Stator 0.10 + 0.19 Ohms
Resistance 4. Check for an open alternator circuit by checking the resistance between
the two A.C. Ieads coming from the alternator. You should find the
Figure A
resistance as called out in Figure A. If you have not found the problem,
test the regulator/rectifier, check for poor connections, and test the
rotor for poor magnetism.

Demystification Guide 3-5


GLOSSARY

Clutch Part Numbers


78-6990, 113997, 92-6885, 93-3160, 115629,116277, 119930
Electric
Purpose
This clutch electrically controls the engagement and disengagement of the
PTO pulley.
How It Works
The PTO clutch is composed of three major components: the field, the
clutch plate, and the friction plate. The clutch plate always turns with the
engine. The field is a coil of wire on an iron core which becomes an
electro-magnet when power is applied. The friction plate is the only piece
that can slide up and down on the crankshaft axis. It is normally spring
loaded so that it is not in contact with the clutch plate and is pressed
against the brake material opposite the clutch. When power is applied, the
Clutch # Resistance friction plate is drawn toward the clutch plate and the two rotate as one.
78-6990 2.5W ± 20%
Testing
115629 2.5W ± 20% 1. Disconnect the PTO clutch from the harness.
113997 2.2W ± 20% 2. Connect a charged 12 volt battery to the clutch (polarity makes no
116277 2.2W ± 20% difference.) You should hear a click, the clutch should engage. If not,
check the wiring and connectors leading into the field. If no problems
119930 2.2W ± 20% can be found, replace the field.
3. Resistance Check: The field should have a resistance as listed in the
table on the left.
Mechanical Adjustment: The gap between the clutch and friction plates
should be set at .012-.015 inches. Adjust by rotating the three nuts
attached to the field.

Coil Part Numbers


Ignition 71-6000
Purpose
The coil boosts voltage from 12 volts to in excess of the 20,000 volts
necessary to fire spark plugs.
How It Works
Glossary

The coil is actually two separate coils of wire wrapped around a common
iron core. One coil, the primary, has fewer windings and thicker wire. The
other 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 when
there is a rapid change in the primary.
Therefore, the coil relies on the trigger module to produce this change by
quickly opening the primary circuit at the precise moment the plugs are
supposed to fire.
Testing
1. Test the resistance of the primary winding by connecting an ohmmeter
across the “+” and “-” terminals on the coil. The resistance should
read between 2.90 and 3.60 ohms.
2. Check the resistance of the secondary coil by connecting one VOM
lead in each of the two spark plug wire cable holes. The resistance
should read between 14,500 and 19,800 ohms.
3. If either of the above readings were out of specification, replace the
coil.
3-6 Demystification Guide
GLOSSARY

Coil Part Numbers


Ignition KH10321
Purpose
(Kohler) 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 common
iron core. One coil, the primary, has fewer windings and thicker wire. The
other 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 when
there is a rapid change in the primary.
Therefore, the coil relies on the trigger module (packed inside the coil) to
Ignition Coil produce this change by quickly opening the primary circuit at the precise
moment the tests are supposed to fire.
Testing
1. If no spark is present, verify that the flywheel magnet is OK by holding a
flat bladed screwdriver about 1/4", from the magnet. It should be
drawn in. Also verify that the air gap is set at .012" to .016".
2. Test the resistance of the primary winding by connecting an ohmmeter
across the kill lead and the core. The resistance should read between
1 and 1.3 ohms.
3. Check the resistance of the secondary coil by connecting one VOM
lead to the spark plug wire and the other lead to the core. The
resistance 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 the
trigger module.

Coil Part Numbers


NN10730
Ignition
Purpose
The coil boosts voltage from around 12 volts to in excess of 20,000 volts.

Glossary
How It Works
The coil is actually two separate coils of wire wrapped around a common
iron core. One coil, the primary, has fewer windings and thicker wire. The
other 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 when
there is a rapid change in the primary.
Therefore, the coil relies on the trigger module (packed inside the coil) to
Ignition Coil produce this change by quickly opening the primary circuit at the precise
moment 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 and
the core. The resistance should be 1.0 ohms.
4. Check the secondary coil resistance by placing on the spark plug cable
and the core. You should get approximately 9,500 ohms. If either meas-
urement is out of specification, replace the coil.

Demystification Guide 3-7


GLOSSARY

Condenser Part Numbers


59-1180
(capacitor)
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 at
the plug. This is accomplished by using primary and secondary windings
in the coil. The primary is low voltage while the secondary is higher
voltage. However, by themselves neither can produce 20,000 volts. A
trigger module is necessary to turn the primary on and off. By quickly
turning the primary off, a 20,000 volt “spike” is created in the secondary
which 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 the
components 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.

Diode Part Numbers


78-1630
(replacement kit)
Purpose
Converts alternating current into pulsating direct current and prevents
battery current from feeding back through the alternator.
How It Works
A diode is merely a one-way valve for electricity. Coming straight from the
alternator, the current is half positive and half negative as shown in
diagram “1" at left. The diode ”filters" out the negative half of the wave to
give you the waveform you see in diagram “2". Why then does your VOM
read a steady direct current when you check the output? The reason is that
Glossary

the meter is designed to read an average voltage when the current is


rapidly changing.

When you read 14 volts, keep in mind that the peak voltage is closer to 20
volts. IMPORTANT: The silver band must be oriented as shown in diagram
3. 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 the
results. You should have found continuity in one direction, but not the
other. If not, replace the diode assembly.

3-8 Demystification Guide


GLOSSARY

Diode Part Numbers


(with leads) KH10315
Purpose
(Kohler) This diode ensures that no battery voltage is applied to the ignition module.
Diode Heat Shrink
Tubing
How It Works
A diode is a “one-way valve", for current. It allows current to flow in one
direction, but not in the other. The specifications for the diode are IN4002GI
GP 8532. The banded end should go to the harness (away from the coil.)

To Kill Switch Terminal Testing


Or Off Position 1. Remove the diode assembly from the harness.
Or Key switch Coated
Fiberglass 2. Test the diode for continuity first one way, then the other. It should
Sleeving conduct in one direction, but not the other. If not, replace it.

Gauge Part Numbers


78-0040
Fuel
Purpose
This gauge indicates fuel level.
How It Works
The meter movement moves proportional to the amount of resistance
provided by the fuel level sender in the tank. The movement is dampened
to 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’’
Terminal Reading position.
I 12 volts* 2. Using a VOM set to a scale capable of reading 12 volts D.C., connect
the negative lead to ground to verify the conditions in the table.
G 0 volts
S 2.5 volts tank full If your voltage readings are different from above, check the fuel level
sender and the wiring. If all readings are correct, the gauge must be
S 7.5 volts tank empty
replaced as it is not serviceable.
*All voltage readings should be within 20%

Glossary
Gauge Part Numbers
Hourmeter 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 and
current, the hourmeter is made up of a combination of an electric “winder”
and a mechanical clock movement. When power is applied, a relay is
energized. The contact moves far enough to wind the movement. The
movement unwinds in about two seconds. As it finishes its rotation, it
re-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. If
so, and the meter is not running, replace the meter. It is a permanently
sealed unit.

Demystification Guide 3-9


GLOSSARY

Part Numbers
Gauge 113476, 78-0060
Tachometer Purpose
This gauge indicates engine speed.
How It Works
The tachometer measures the number of rotations of the crankshaft by
monitoring the B+ terminal of the voltage regulator. The alternating current
produced by the alternator allows the circuitry to “count” the revolutions,
then deflect the meter movement appropriately. Keep in mind that this
tachometer 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”, determine
the actual engine speed. Compare it to the tachometer in the
equipment.
3. If they are not within 10%, check for loose connections, a bad stator, or
flywheel magnet.
4. If no problems are found, the gauge must be replaced as it is not
serviceable.

Part Numbers
78-0030
Gauge
Purpose
Voltmeter This gauge indicates the voltage across the battery.
How It Works
The meter movement moves proportional to the voltage level across the
two terminals of the battery. This is accomplished by placing a resistor in
parallel with the meter movement.
Testing
Glossary

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 the
voltmeter, as it is not serviceable.

Terminal Condition

I 12 volts DC ± 20%

G 0 volts DC ± 20%

Table 1

3 - 10 Demystification Guide
GLOSSARY

Horn Part Numbers


116749
Purpose
The horn produces a loud tone to let the operator know that the engine is
overheating.
How It Works
When 12 volts is applied to the two terminals, a plate inside the horn
oscillates 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 does
not matter which way you connect the wires.) If the horn does not
sound, replace the horn since it is not serviceable.

Part Numbers
Light 117185
0il Level Indicator Purpose
This simple incandescent bulb is used to indicate to the operator that a low
oil level has been detected during starting.
How It Works
The filament glows when 12 volts is applied. There is no polarity although
the 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.

Glossary

Demystification Guide 3 - 11
GLOSSARY

Module Part Numbers


28-7890, 95-0659
Interlock
Purpose
The module monitors the status of the safety switches and prevents spark
if an “unsafe” condition is encountered.
How It Works
The module “steals” a small amount of current from the ignition coil
primary (through the kill wire.) It sends current through the orange and
yellow wires to monitor the status of the safety switches. If EITHER of the
following two conditions are met, the module will allow spark (by not
grounding the kill wire).
1. There is continuity from the orange to the yellow wire through the
transmission 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 to
ground. Note: There is no time delay in this module.
Testing
Caution: When using jumpers to simulate a safe condition, be sure that
the transmission and PTO lever are disengaged before starting.

The following steps assume your unit does not produce spark. (If the unit
runs in an unsafe mode, check to ensure that the module has a good
ground to the chassis and that the kill wire is not broken.)
1. Disconnect the module from the wiring harness. Jump from the light
blue wire on the module, to the light blue wire on the harness. This
allows the module to control spark. Verify now that the unit will not
produce spark when attempting to start.
2. Simulate a safe deck and transmission circuit by jumping across the
yellow and orange wires. The unit should now produce spark.
3. Disconnect the jumper from step 2 and simulate an operator on the
seat by connecting a jumper from the orange wire to the chassis. The
unit should produce spark. If the module failed any of these three
Glossary

tests, it should be replaced.


NOTE: We have never seen a case of two bad modules in a row. If
replacing the module doesn’t cure it, it wasn’t the module.

3 - 12 Demystification Guide
GLOSSARY

Module Part Numbers


Light Circuit 114825, 115207, 79-2130
Purpose
The circuit board drives the dash indictor lights. It monitors the status of
switches and does not affect normal operation.
How It Works
The light circuit module (printed circuit board) uses an array of resistor and
diodes to get each of the light emitting diodes (LEDs) to light under the
right conditions. While the board itself is complex, understanding the
conditions needed to light the LEDs is not difficult. It is just a matter of
either grounding or applying 12 volts D.C. to the appropriate terminals on
the edge of the card.
Testing
Use the circuit diagrams in the back half of this book to troubleshoot the
module.

Important! All tractor electrical systems will operate normally with the light
circuit module completely disconnected.

Part Numbers
Module 71-6380, NN10444
Trigger Purpose
The ignition control opens the primary circuit as the magnet passes by to
(Onan) induce spark at the proper time.
How It Works
This engine is equipped with an electronic battery ignition system. Both
Trigger spark plugs fire simultaneously, thus the need for a distributor is
Ring
eliminated. The electronic ignition module is located on the engine gear
cover behind the flywheel. The module receives a timing signal from
magnets within the trigger ring which rotates with the engine crankshaft
(Figure 1). If the electronic ignition is suspected of malfunctioning, proceed
as follows.

Glossary
Testing
1. Check all electrical connections to be sure they are clean and tight. If
all connections are good and wiring is intact, go to Step 2.
Warning: The electronic ignition will deliver full voltage to the spark
plugs even when rotated by hand. Care should be taken to avoid an
electrical shock.
Ignition
Module Warning: Failure to remove spark plugs before turning the engine
over may result in engine starting and may cause severe personal
Figure 1
injury.
Warning: Failure to ground spark tester away from the spark plug
hole may result in ignition of cylinder gases and may cause severe
personal injury.

Demystification Guide 3 - 13
GLOSSARY

2. Pull spark plug wires off spark plugs and remove spark plugs. Connect
an approved spark tester to each of the spark plug wires and ground
them away from the spark plug hole. Turn the key on and crank the
engine over for 5 seconds while watching for spark. If a spark occurs
regularly, the problem is not in the ignition system. If no spark occurs,
go to step 3.

Flywheel Caution: Never put jumper lead to the coil negative terminal. This will
Timing cause failure of the electronic ignition module.
Mark
3. Connect a jumper lead directly from the positive battery terminal to the
positive (+) coil terminal (smaller diameter of the two threaded posts).
Crank the engine over while watching for spark. If spark occurs, the
Blower Housing problem is in the low oil pressure cut out switch (if equipped) or
Timing Marks relating wiring, the lubricating system (low oil pressure), or in the other
circuitry 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 coil
checks out good, go to step 5.
5. Connect positive side of voltmeter to negative (-) coil terminal (larger
diameter of the two threaded posts) and negative side of voltmeter to
engine ground. Turn the key on and rotate flywheel slowly by hand
while observing voltmeter. Voltage should switch between battery
voltage and 1-1.5 for each revolution. If voltage does not switch
properly, replace ignition module.
Caution: Never put B+ lead to the coil negative terminal. This will
cause failure of the electronic ignition module.
6. Install spark plugs and wires. If ignition module is being replaced, be
sure to connect red lead from new ignition module to positive (+)
terminal of coil, black lead from module to negative (-) terminal of coil.
Glossary

3 - 14 Demystification Guide
GLOSSARY

Regulator/Rectifier Part Numbers


(20 Amp) 57-9430
Purpose
(Onan) The regulator/rectifier prevents battery boiling by shutting off the current so
that 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 the
battery has very low impedance (Figure B). This regulator/rectifier, like
many others, must be connected to the battery to function. Once the
voltage level of the battery has surpassed 13.6 to 14.5 volts, the voltage
regulator shuts off all current and no charging takes place (Figure C).
When the voltage again drops below the specified level, the voltage
regulator turns the current back on at the rated amperage of the alternator.
Testing
Check the battery before checking the regulator/rectifier for proper
operation. The battery must be fully charged and in good condition for the
regulator/rectifier to operate properly.
Refer to Table 1. Start the engine and check the regulator/rectifier output by
measuring the battery voltage at the battery terminals with a voltmeter. If
voltage is within that specified in Table 1, the regulator/rectifier is good. If
the 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 battery
negative 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 the
alternator. If the stator is good, replace the regulator/rectifier.
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 RPM
Approximately 57 volts AC @ 3600 RPM

Glossary
20 amp stator resistance 0.10 to 0.19 Ohms
Regulator/rectifier output 13.6 to 14.7 volts

Table 1

Regulator/Rectifier Part Numbers


KH10215
(Kohler)
Purpose
The regulator/rectifier prevents battery boiling by shutting off the current
when the battery has reached 14.7 volts.
How It Works
The voltage regulator rectifies the current so that the battery sees only
positive current and voltage (see Figure A). The voltage level across the
battery is very near constant because the battery has very low impedance
(Figure B). This regulator/rectifier, like many others, must be connected to
the battery to function. Once the voltage level of the battery has surpassed
14.7 volts, the voltage regulator shuts off all current and no charging takes
place (figure C). When the voltage again drops below the specified level,
the voltage regulator turns the current back on at the rated amperage of
the alternator.

Demystification Guide 3 - 15
GLOSSARY

Testing
1. Make sure that the battery is fully charged. (The voltage across the
battery terminals should be 13.6 volts or more.)
2. Insert an ammeter (capable of measuring 20 amps) in series with the
B+ lead coming from the voltage regulator.
3. Observe the charging current with the engine running at 3600 rpm (it
should be low).
4. Attach a 2.5 ohm, 100 watt resistor across the battery terminals to
simulate a load. If the reading on the ammeter goes up, the charging
system is OK, otherwise proceed to the next step.
5. Remove the connector from the rectifier/regulator. With the engine
running at 3600 rpm, measure the voltage across the stator terminals.
If the voltage is greater than 28 volts, the stator is OK and the regulator
is bad. Otherwise, see the alternator section for further testing
information.
BATTERY CHARGES CONTINUOUSLY AT HIGH RATE: Measure the
voltage from B+ to ground using a VOM on D.C. scale. If the voltage is
more than 14.7 volts, replace the regulator.

Relay Part Numbers


48-4700, 116397
Purpose
The relay monitors current in one circuit. If current is present, it flips an
SPDT switch to the other position.
Glossary

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 to
these terminals energizes the coil turning it into an electromagnet.
2. SPDT Switch: Terminals 30, 87, and 87a are all actually part of a single
Coil Terminals Terminals pole, double throw switch. Terminal 30 is the common lead. The switch
30 + 87 30 + 87a
is spring loaded so that 30 and 87a are closed when the coil is not
Not Open Closed energized. When the coil is energized, the switch is “thrown” and 30
Energized
and 87 connected. For a simpler explanation, see below:
Energized Closed Open

Table 1 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.

3 - 16 Demystification Guide
GLOSSARY

Part Numbers
71-6010
Rotor
Purpose
Ignition
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 is
produced. The “ignition rotor” is simply two magnets molded into a plastic
housing which properly positions it on the crankshaft. As the crankshaft
rotates, the magnets pass by the “ignition control” which houses a coil and
the “trigger” circuitry. This generates the small amount of electricity
needed to run the ignition control. In addition, the orientation of the
magnets 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 thumb
and forefinger so that the screwdriver dangles. Bring the flat part of
the blade to within 1/4 inch of one of the magnets. The screwdriver
should be drawn toward the rotor.
2. With the rotor removed, each magnet should be able to support the
weight of the rotor when hung from the blade of a flat bladed
screwdriver. If the rotor fails either test, the magnet has lost its
strength and should be replaced.

Sender Part Numbers


113358
Fuel Level
Purpose
This electrical component monitors the level of fuel in the tank.
How It Works

Glossary
A float is attached to a pivoting lever. This lever rotates a potentiometer (a
device 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 the
float if it has sunk.
Float Position Resistance
2. Disconnect the sender unit from the wiring harness, and remove it from
Full 25W ± 20% the tank.
Empty 200W ± 20%
3. Verify that it matches the resistances in the table.
Table 1

Demystification Guide 3 - 17
GLOSSARY

Solenoid Part Numbers


47-1910
Purpose
The solenoid’s purpose is simply to protect the ignition switch from the
high current drawn by the starter motor.
How It Works
The solenoid has really only two parts. One is a coil of wire wrapped
around an iron core. Whenever 12 volts is applied to the coil, it becomes a
magnet. The other part is a steel bar type switch. Because it is made of
steel it can easily handle the high current loads produced by the starter
motor. So how does it protect the ignition switch? When 12 volts is applied
to the coil, it becomes an electromagnet. This quickly pulls the steel bar
toward the contacts and closes the switch. When power is removed from
the 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 be
able 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”.
Glossary

3 - 18 Demystification Guide
GLOSSARY

Starter Part Numbers


71-6040, NN10889, 62-2710, 79-6570
Electric
Purpose
The starter motor pushes the starter pinion into engagement with the
flywheel, 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 when


current is applied. It surrounds the armature.

ARMATURE: Eight coils of wire on an iron core that become


electromagnets when current is applied. The end of each coil is
connected to a section of the commutator. The armature rotates.

COMMUTATOR: The commutator is the connection point between the


brushes and the coils in the armature. The sections are divided such that
only one armature coil is “on” at a time. This sets the armature to rotating
because the electromagnetic field in the field coil will oppose the one in the
armature.

BRUSHES: Supply power to the commutator.

Glossary

Demystification Guide 3 - 19
GLOSSARY

Testing
Starter (USE TESTING SECTION FROM ONAN MANUAL, PAGES 9-3 THROUGH
9-5.)
Electric
Commutator Bars
Inspect the starter components for mechanical defects before testing for
grounds or shorts.

Testing Armature for Grounds: Connect 1 lead of an ohmmeter to the


armature shaft or core. Touch the other ohmmeter lead to each of the
commutator bars in turn (Figure 1). A low ohmmeter reading indicates a
grounded armature. Replace grounded armature.

Testing Armature for an Open Circuit: Using an ohmmeter, check for


continuity between the commutator segments. If there is no continuity
(high resistance), the segments are open and armature must be replaced.
Figure 1
Testing Armature for a Short Circuit: Use growler for locating shorts in the
armature (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 slowly
rotating armature in growler. A shorted armature will cause the blade to
vibrate and be attracted to the core. If the armature is shorted, replace
HacksawBlade with a new one.

Commutator Inspection: If the commutator is dirty or discolored, clean with


Growler number 00 to 000 commutator paper. Blow grit out of armature after
cleaning.

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. If


there is not continuity, the field coil is open and must be replaced. With the
Figure 2 field coil mounted in the frame, check for continuity between the field coil
and frame. Replace frame assembly if there is continuity.

Brushes: Clean around brushes and holders, wiping off all brush dust and
Glossary

Brushes dirt. 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 holder
base. If there is continuity, replace holder assembly. Check for free
.4528 inch movement of brushes. All brushes should move freely in the brush holders.
(11.5 mm)

Wear Limit

Figure 3

3 - 20 Demystification Guide
GLOSSARY

Overrunning Clutch: Inspect pinion and spline teeth for wear or damage.
Overrunning
Clutch If pinion gear is worn or damaged, inspect flywheel ring gear also. Rotate
pinion. It should turn free when turned in one direction and locked when
turned in the opposite direction.

CAUTION: Do not clean overrunning clutch in solvent or liquid cleaning


solution. Washing the clutch will cause the grease to leak out.

Figure 4

Solenoid: Push solenoid plunger in and release it. The plunger should
Solenoid return to its original position. While holding plunger all the way in, check
for continuity between terminals “M” and “B”. If there is no continuity,
Terminal “B” replace the solenoid (Figure 4). After replacing solenoid check pinion
Terminal “S”
clearance.

Bushings: If either the front or rear bushing show signs of wear or


damage, replace them. Bushing and rear bracket are replaced as an
assembly. 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 as
Terminal “M” tap, into bushing. Using a slide hammer, remove bushing from front
Figure 5 bracket. Press new bushing into front bracket. Use care not to distort
inside diameter of bushing.

Glossary

Demystification Guide 3 - 21
GLOSSARY

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 become


electromagnets when current is applied. The end of each coil is connected
to a section of the commutator. The
armature rotates.

COMMUTATOR: The commutator is the connection point between the


brushes and the coils in the armature. The sections are divided such that
only one armature coil is “on” at a time. This sets the armature to rotating
because the electromagnetic field in the field coil will oppose the one in the
armature.

BRUSHES: Supply power to the commutator.

Troubleshooting Guide
PROBLEM POSSIBLE FAULT CORRECTION

1. Clean corroded connections and tighten loose connections.


WIRING 2. Replace wires in poor condition and with frayed or broken
insulation.
STARTER
FAILS STARTER SWITCH Bypass the switch or solenoid with a jumper wire. If starter
TO ENERGIZE OR SOLENOID cranks normally, replace the faulty parts.

BATTERY Check specific gravity of battery. If low, recharge or replace


battery as necessary.
Glossary

BATTERY Check specific gravity of battery. If low, recharge or replace


battery as necessary.

STARTER Check for excessively dirty or worn brushes and commutator.


ENERGIZES BRUSHES Clean using a coarse cloth (not emery paper). Replace brushes
BUT TURNS if excessively or unevenly worn.
SLOWLY
Make sure the clutch or transmission is disengaged or placed in
TRANSMISSION neutral. This is especially important on equipment with
OR hydrostatic drive. The transmission must be exactly in neutral to
ENGINE prevent resistance which would keep the engine from starting.
Check for seized engine components such as bearings,
connecting rod, and piston.

3 - 22 Demystification Guide
GLOSSARY

Starter Part Numbers


NN10739
Electric
Purpose
The starter motor pushes the starter pinion into engagement with the
flywheel, 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 when


current is applied. It surrounds the armature.

ARMATURE: Eight coils of wire on an iron core that become


electromagnets when current is applied. The end of each coil is connected
to a section of the commutator. The armature rotates.

COMMUTATOR: The commutator is the connection point between the


brushes and the coils in the armature. The sections are divided such that
only one armature coil is “on” at a time. This sets the armature to rotating
because the electromagnetic field in the field coil will oppose the one in the
armature.

BRUSHES: Supply power to the commutator.


Testing
With the starter assembled, disconnect the connecting lead from the
starter solenoid C terminal. Connect a jumper lead from the connecting
lead to the battery positive terminal. Connect a jumper lead momentarily
between the starter motor housing and the battery negative terminal. If the
motor doesn’t run, check the motor for problems.

Solenoid Mounting Nut

Through
Magnet Switch Bolts
Mounting Nuts

Glossary
Starter Drive
Housing

Connecting
Lead
End Frame

Insulator

Brush Spring
Brush Holder
Starter Body
Brush

Demystification Guide 3 - 23
GLOSSARY

Starter SOLENOID

Electric Inspection/Service
(continued)
Commutator Attraction Test: Connect a jumper lead from the ST terminal to the positive
Segments
terminal of a 6 volt battery. Connect a jumper lead between the C terminal
and negative terminal of a 6 volt battery. If the plunger pulls in and holds
strongly, the solenoid is good. If it doesn’t, replace the solenoid.

Retention Test: Connect a jumper lead from the ST terminal to the positive
terminal of a 6 volt battery. Connect a jumper lead between the solenoid
body and negative terminal of a 6 volt battery. Push the plunger in and
release it. If the plunger stays in, the solenoid is good. If it doesn’t, replace
Figure 1 the solenoid.

ARMATURE
Armature
Coil Core
Inspection/Service

Commutator Continuity Between Segments: Refer to Figure 1. Check for continuity


between the segments of the commutator. If there is no continuity, replace
the armature.

Figure 2 Armature Coil Core and Commutator Continuity: Refer to Figure 2.


Commutator
Check for no continuity between the commutator and the armature coil
Armature core. If continuity exists, replace the armature.
Shaft
Armature’s Shaft and Commutator Continuity: Refer to Figure 3. Check
for no continuity between the commutator and armature’s shaft. If
continuity 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 end
frame. Measure the armature shaft outside diameter on the pinion side and
Figure 3
commutator side. If the clearance is not as specified in Table 1, replace the
Glossary

bushing.

Electrical System Factory Min. Specification Allowable Limit


Max.
Bushing
Commutator O.D. 1.102 1.063
Starter Drive (28.0) (27.0)
Housing
Figure 4 Difference of Less than 0.00027 0.016
Commutator O.D.’s (Less than 0.05) (0.4)

Armature’s Shaft to 0.0008 0.0027 0.0079


Bushing Clearance (0.02) (0.07) (0.20)

Mica Undercut 0.0177 0.0295 0.008


(0.45) (0.75) (0.2)

Pinion side of
Armature Shaft Table 1

Figure 5

3 - 24 Demystification Guide
GLOSSARY

COMMUTATOR AND MICA

Inspection/Service

Commutator: Refer to Figure 6. Clean commutator surface with


sandpaper. Measure the commutator outside diameter at several points. If
the difference of the outside diameter is not as specified in Table 1, correct
Commutator the commutator on a lathe to factory specifications. If the minimum outside
Figure 6 diameter is less than the allowable limit, replace the armature.

Mica: Refer to Figure 7. Measure the mica undercut depth. If the undercut
Segment
Edges is less than that specified in Table 1, use a saw blade to increase the depth
and then chamfer the segment edges.
Mica
undercut
depth OVERRUNNING CLUTCH

Inspection/Service
Saw CAUTION: Do not clean overrunning clutch in liquid cleaning solutions. as
Blade
it will damage the starter.
Figure 7 Refer to Figure 8. Inspect the pinion and spline teeth for wear and
damage. If wear or damage exists, replace pinion. Rotate the pinion
clockwise and see if it turns freely. Replace pinion if it doesn’t. Rotate the
Pinion pinion 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 brush
Figure 8 length. If the length is not as specified in Table 1, replace the starter body
and brush holder.
STARTER BODY

Inspection/Service

Glossary
Refer to Figure 10. Check for continuity across the starter body and
brushes. There are four brushes in the starter body. The two that are not
grounded are 180° apart starting at the terminal which connects to the
solenoid. The two that are grounded are located 90° from the non-
grounded terminals. If continuity exists at the non-grounded terminals,
Brush
replace the starter body. If continuity does not exist at the grounded
terminals, replace the starter body.
Figure 9
Assembly
Grounded Non-Grounded Assemble the starter in the reverse of disassembly, but apply grease to the
Terminal Terminal parts indicated.
(hidden)
Brush • solenoid joint
• drive lever
• pinion gear teeth
Starter • armature shaft
body

Figure 10

Demystification Guide 3 - 25
GLOSSARY

Switch Part Numbers


114270
Air Cleaner
Pressure Purpose
This switch monitors vacuum in the air cleaner box to determine if the air
cleaner is plugged.
How It Works
The switch is turned on by a slight vacuum applied to the inlet. This is
accomplished by a small electrical contact that is connected to a
diaphragm inside the switch. Note: Switch comes with one female
crimp-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. There
should be continuity.

Switch Part Numbers


NN10274
Engine Temperature
Purpose
The engine temperature switch turns on an indicator light when the head
temperature reaches the temperature specified below.
How It Works
The contacts inside the switch are normally open. As the body of the
switch warms, the clearance between the contacts narrows, until the
switch closes at 320-340 degrees F. It does not reopen until the
temperature falls to 280-310 degrees F.
Testing
Glossary

1. Remove the switch from the harness.


2. Using a VOM or a test light, check the circuit between the body of the
switch and the terminal. There should not be continuity at room
temperature.
3. The point at which the switch turns on can be tested by heating to
300 degrees F. Slowly raise the temperature of the switch, noting the
point at which the switch turns on. It should close between 320 and
340 degrees F. Keep track of the temperature as the switch cools and
note the point at which it again opens. It should open between 280
and 310 degrees F.

3 - 26 Demystification Guide
GLOSSARY

Switch Part Numbers


Float (kit)
Purpose
(Kohler) The float switch is wired into the starter motor circuit to prevent starting in a
low oil situation. It will not kill the engine once running!
How It Works
The float switch houses a small magnet which pulls the contacts closed
when 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. The
switch should be open with the oil at a safe level. Note: If testing with a
VOM, expect to see some resistance when the switch is closed.
3. Drain the oil from the engine, then retest for continuity. The switch
should be closed (and will probably show some resistance which is
normal). 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 flats
vertical.
3. Rotate by hand as soon as possible to prevent damage if the float
catches 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 top
side!

Part Numbers
Switch 103990

Glossary
Ignition 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 start
position is spring loaded so the cylinder automatically returns to run once
the key is released.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.
Position Condition
3. Check each of the terminals to ground. There should be no
Off None continuity.
Run B+I+A+R
Start B+S+I+R

Demystification Guide 3 - 27
GLOSSARY

Part Numbers
Switch 103991
Ignition 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 start
position is spring loaded so the cylinder automatically returns to run once
the key is released.

Note: The letters shown in the illustration are written on the side of the
terminals.

Position Condition
Testing
Off G+M+A 1. Disconnect the switch from the wiring harness.
Run B+A+R
2. Verify the following conditions in the table.
Start B+S
3. Check for continuity between each of the terminals and the switch case.
Only the ground terminal should show continuity.

Switch Part Numbers


116338
Ignition
Purpose
116338 provides the proper switching for the starter, ignition, and safety
interlock circuits.
How It Works
Detents inside the switch give it three positions: off, run, and start. The start
position 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 to
the ground terminal.
Glossary

Position Condition
Off G+M Testing
1. Disconnect the switch from the wiring harness.
Run B+L
Start B+L+S1 2. Verify the conditions in the table.
Note: The letters stamped on the switch terminals may not be correct. Use
the diagram at the left to identify the individual terminals.

3 - 28 Demystification Guide
GLOSSARY

Switch Part Numbers


117292
Ignition
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 start
position is spring loaded so the cylinder automatically returns to run once
the key is released.

Position Condition Note: This switch does not have the labels shown at the left and does not
Off M+G come with a key.
Run B+A Testing
Start B+A, S1+S2 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
Switch 23-0660
Ignition Purpose
23-0660 provides the proper switching for the starter, ignition, and safety
interlock circuits.
How It Works
Detents inside the switch give it three positions: off, run, and start. The start
position 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 the
ground terminal.
Testing

Glossary
1. Disconnect the switch from the wiring harness.
Position Condition
Off G+M 2. Verify the conditions in the table.
Run B+L 3. Check each of the terminals to the switch body. There should be no
Start B+S continuity except for the ground (G) terminal.

Demystification Guide 3 - 29
GLOSSARY

Switch Part Numbers


Interlock 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. The
ribbon operates a friction mechanism which, in turn, activates the switch.
A removable cover provides access to the switch contacts.
Condition Status
Testing
Operator On Closed
Note: Because of the friction mechanism, it is possible to get false
Operator Off Open readings with the switch removed from the seat. Perform testing with the
switch 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
Switch 102138
Light Purpose
Typically used to provide switching for the lights.
How It Works
Contacts inside the switch physically connect the two terminals to provide
continuity. It is an SPST switch with a load capacity of 3 Amps at 250 V, and
6 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 position
and note whether or not there is continuity.
3. Flip the switch, then recheck to ensure that the status has changed.
Glossary

Part Numbers
Switch 113191, 92-9844

Light 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 one
position while disconnecting them in the other. It is an SPST type rocker
switch 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.

3 - 30 Demystification Guide
GLOSSARY

Switch Part Numbers


40-8200
Micro
Purpose
Used as part of the safety interlock circuit, it is typically used to monitor
whether or not an operator is in the seat.
How It Works
This SPDT micro switch has three terminals. The lever is spring loaded in
the “up” position. When the button is pushed down, continuity switches
Button Condition from COM and NC to COM and NO.
Up COM+NC
Testing
Down COM+no
1. Disconnect the switch from the harness.
2. Verify the conditions in the table.

Part Numbers
Switch 28-4250

Neutral 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 pivoting
bracket. When the transmission is in neutral, the ball falls into a hole which
closes the switch. When the transmission is in gear, the bracket depresses
the 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 terminal
and ground. (This type failure can produce some VERY unusual
symptoms.)
3. With the transmission in neutral, verify that the terminals have continuity.
4. With the transmission in gear, make sure that the terminals are not

Glossary
continuous.
5. If the switch failed step 3 or 4, remove the switch and depress the ball
manually to test. If the switch passes, the shift bracket is probably the
source of the difficulty.

Demystification Guide 3 - 31
GLOSSARY

Part Numbers
Switch 116237
Neutral/Parking Brake Purpose
To ensure that the parking brake is on when 1. starting 2. the operator
leaves the seat.
How It Works
Two small mercury switches inside the potted container provide continuity
when the parking brake is engaged. When disengaged, the assembly is
rotated to another position which opens both switches inside. This is a
DPST switch.
Testing
1. Disconnect the switch from the wiring harness, but DO NOT REMOVE IT
from the parking brake bracket.
2. With the parking brake on, verify that there is continuity across the two
terminals in each connector.
3. With the parking brake off, there should be no continuity across the
terminals in each connector.

Part Numbers
Switch 116822
Neutral/Parking Brake Purpose
To insure that the parking brake is on when 1. starting 2. the operator
leaves the seat.
How It Works
Two small mercury switches inside the potted container are oriented to
provide one open and one closed switch when the parking brake is
engaged. When disengaged, the assembly is rotated to another position
which reverses the switch conditions.

Brake Male Female Note: This switch is similar in construction to 116237, except that the
Position Pins Pins switches provide opposing conditions rather than the same. This is
Glossary

On Closed Open
necessary because the Briggs and Stratton engine uses mag style ignition
instead of the coil type in the Onan’s.
Off Open Closed
Testing
1. Disconnect the switch from the wiring harness, but do not remove it
from 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 the
harness, while the female pins connect with the purple and light blue pins.

3 - 32 Demystification Guide
GLOSSARY

Part Numbers
Switch NN10520
Oil Pressure Purpose
The oil pressure switch on the 724 turns on the hourmeter. This ensures
that the hourmeter is not accidentally left running.
How It Works
When the engine is not running, the switch is open. Once the engine has
been started, oil enters through a small hole on the threaded end. This
presses on a diaphragm which moves a switch contact on the dry side of
the diaphragm. When pushed far enough, the contacts close. Note: The
contact is adjustable so that the switching pressure can be varied. It is set
to close from the factory at 5 psi + 2 psi.
Engine Switch
No Oil Pressure Open Testing
1. Disconnect the switch from the system.
Oil Pressure OK Closed
2. Verify the conditions in the table.
3. If the switch is opening when the machine is idling, verify that you have
proper oil pressure at idle (consult your engine manual.) If so, slowly
rotate the adjusting screw on the back of the switch until the switch
just 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 Part Numbers


NN10813
Oil Pressure
Purpose
This switch is optional on the 200 series tractors and could be used to turn
on an hourmeter.
How It Works
When the engine is not running, the switch is open. Once the engine has
been started, oil enters through a small hole on the threaded end. This

Glossary
moves the diaphragm which moves a switch contact on the dry side of the
diaphragm. When pushed far enough, the switch contacts close. Note:
The contact is adjustable by turning the small set screw at the base of the
terminal. It is set to close at 1 psi ± ½ psi from the factory.
Engine Switch
Testing
No Oil Pressure Open
1. Disconnect the switch from the system.
Oil Pressure OK Closed
2. Verify the conditions in the table.
3. If the switch is opening when the machine is idling, verify that you have
proper oil pressure at idle (consult your engine manual.) If so, slowly
rotate the adjusting screw on the back of the switch until the switch
just 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.

Demystification Guide 3 - 33
GLOSSARY

Part Numbers
Switch NN10824
Oil Pressure Purpose
The low oil pressure switch turns off the oil pressure indicator light and
turns on the hourmeter.
How It Works
The mechanism inside the switch is simply a lever that is moved by a
diaphragm. When there is no oil pressure, the NO switch is open, and the
NC switch is closed. Once oil pressure is present at the pressure switch
orifice, the diaphragm moves the lever and reverses the status of each of
the switches. The switch should change status at 5 psi ± 2 psi.
Oil Pressure NC Switch NO Switch Testing
No Pressure Closed Open 1. Disconnect the harness from the switch.
Pressure OK Open Closed 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 5
psi ± 2 psi. Also check to ensure that nothing is obstructing the orifice
on the threaded end of the switch.
4. If one or both switches are switching at the incorrect pressure, the
contacts can be adjusted. Use the set screws at the base of each
terminal to get the desired results. Once adjusted, prevent undesired
rotation by sealing with a small amount of fingernail polish.

Part Numbers
Switch 116716

PTO/Clutch Purpose
Typically used to turn on the electric blade clutch and to function as part of
the safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. It
Glossary

is actually just two SPDT switches tripped by a single lever. One of the
SPDT 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
Lever Condition used by the safety interlock system. When the clutch is off, this side of the
Up Open switch is closed. This allows current to keep the kill relay energized so that
Down Closed the mag is not grounded out.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.

3 - 34 Demystification Guide
GLOSSARY

Switch Part Numbers


111332
PTO/Clutch
Purpose
Used as part of the safety interlock circuit, it is typically used to monitor the
position of the PTO or brake lever.
How It Works
This SPDT microswitch has three terminals. The lever is spring loaded in
the “up” position. When the lever on top of the switch is pushed, continuity
Button Condition switches from COM1 and NC2 to COM1 and NO3.
Up COM+NC2 Testing
Down COM+NO3 1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.

Part Numbers
116716
Switch
Purpose
PTO/Clutch Typically used to turn on the electric blade clutch and to function as part of
the safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. It
is actually just two SPDT switches tripped by a single lever. One of the
SPDT 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 used
by the safety interlock system. When the clutch is off, this side of the switch
is closed. This allows current to keep the kill relay energized so that the
mag is not grounded out.
Testing
1. Disconnect the switch from the wiring harness.

Glossary
2. Verify the conditions in the table.

Position Lever Condition


Off Down b+a, e+d
On Up b+c, e+f

Demystification Guide 3 - 35
GLOSSARY

Switch Part Numbers


PTO/Clutch 78-3030
Purpose
Typically used to turn on the electric blade clutch and to function as part of
the safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. It
is actually just two SPDT switches tripped by a single lever. One of the
SPDT 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 used
by the safety interlock system. When the clutch is “off”, this side of the
switch is closed. This allows current to keep the kill relay energized so that
the mag is not grounded out.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.

Position Lever Condition


Off Down b+a, e+d
On Up b+c, e+f

Switch Part Numbers


78-9670
PTO/Clutch
Purpose
This switch is typically used to turn on the electric blade clutch and to
function as part of the safety interlock system.
How It Works
Contacts inside this DPDT switch electrically connect various terminals. It
is actually just two SPDT switches tripped by a single lever. In the 724, one
Glossary

side 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 to
prevent 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.

Position Lever Condition


Off Down b+a, e+d
On Up b+c, e+f

3 - 36 Demystification Guide
GLOSSARY

Switch Part Numbers


Seat 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, one
set of contacts is closed while the other set is open. The opposite is true
when the button is depressed. The normally closed set of terminals is small
while the normally open side are larger.
Testing
1. Disconnect the switch from the wiring harness.
2. Verify the conditions in the table.

Button Condition
At Rest a+b
Depressed c+d

Switch Part Numbers


Test 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.

Glossary
2. Check the two terminals for continuity. There should be none.
3. Hold the rocker and verify that the two terminals are now continuous.

Demystification Guide 3 - 37
GLOSSARY

Switch Part Numbers


116796
Test
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 NC
terminals are connected. When the button is pushed, C and NC open, and
Button Condition C and NO close. The switch is rated for 3 amps at 250 volts or 6 amps at
At Rest C+NC 125 volts.
Depressed C+NO Testing
1. Disconnect the switch from the harness.
2. Verify the conditions in the table.

Switch Part Numbers


113193
Transmission Oil
Purpose
Contacts on switch close when the switch body reaches a predetermined
temperature. (Usually used for hydraulic fluid.)
How It Works
A bimetal post inside the switch bends as the temperature rises. Once the
temperature is high enough, the top of the post makes contact with the
terminal to close the switch. The switch is set to close at 200° F. Normal oil
temperature 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 at
room temperature. There should not be continuity.
3. If you have the ability to measure high temperatures, you can verify
Glossary

operation of the switch in a liquid heated to the “switching”


temperature.
Caution: Be careful not to contact the heated liquid.

3 - 38 Demystification Guide
rev. 4-03
rev. 4-03
rev. 4-03
rev. 4-03
1989 - 1992 825

rev. 4-03

825 Information List (1989 - 1992)

Wiring Diagram . . . . . . . . . . . . . . 4-6


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-7
Spark Circuit . . . . . . . . . . . . . 4-7
Kill Circuit . . . . . . . . . . . . . . 4-7
Charging Circuit . . . . . . . . . . . 4-8

Demystification Guide 4-5


825 1989 - 1992

Wiring Diagram rev. 4-03

4-6 Demystification Guide


1989 - 1992 825

rev. 4-03 Start Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start” or “run”)

Kill Circuit
(ignition switch “off”)

Demystification Guide 4-7


825 1989 - 1992

Charging Circuit rev. 4-03

4-8 Demystification Guide


1993 - 1995 825 RER
(70040 & 70060)

rev. 4-03

825 Information List (1993 - 1995)

Wiring Diagram . . . . . . . . . . . . . . 4-08B


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-08C
Spark Circuit . . . . . . . . . . . . . 4-08D
Spark Circuit . . . . . . . . . . . . . 4-08E
Charging Circuit . . . . . . . . . . . 4-08F

Demystification Guide 4 - 8A
825 RER 1993 - 1995
(70040 & 70060)

Wiring Diagram rev. 4-03

4 - 8B Demystification Guide
1993 - 1995 825 RER
(70040 & 70060)

rev. 4-03 Starter Motor Circuit

Demystification Guide 4 - 8C
825 RER 1993 - 1995
(70040 & 70060)

Spark Circuit rev. 4-03


(ignition switch in “run”)

4 - 8D Demystification Guide
1993 - 1995 825 RER
(70040 & 70060)

rev. 4-03 Spark Circuit


(ignition switch in “start” or “run”)

Demystification Guide 4 - 8E
825 RER 1993 - 1995
(70040 & 70060)

Charging Circuit rev. 4-03

4 - 8F Demystification Guide
1996 - 1997 825 RER
(70040 & 70060)
1998 (70040)

rev. 4-03

825 Information List (1996 - 1997)


(1998)

Wiring Diagram . . . . . . . . . . . . . . 4-08H


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-08I
Spark Circuit . . . . . . . . . . . . . 4-08J
Spark Circuit . . . . . . . . . . . . . 4-08K
Charging Circuit . . . . . . . . . . . 4-08L

Demystification Guide 4 - 8G
825 RER 1996 - 1997
(70040 & 70060)
(70040) 1998

Wiring Diagram rev. 4-03

4 - 8H Demystification Guide
1996 - 1997 825 RER
(70040 & 70060)
1998 (70040)

rev. 4-03 Starter Motor Circuit

Demystification Guide 4 - 8I
825 RER 1996 - 1997
(70040 & 70060)
(70040) 1998

Spark Circuit rev. 4-03


(ignition switch in “run”)

4 - 8J Demystification Guide
1996 - 1997 825 RER
(70040 & 70060)
1998 (70040)

rev. 4-03 Spark Circuit


(ignition switch in “start” or “run”)

Demystification Guide 4 - 8K
825 RER 1996 - 1997
(70040 & 70060)
(70040) 1998

Charging Circuit rev. 4-03

4 - 8L Demystification Guide
1998 825 RER
(70041 & 70060)

rev. 4-03

825 Information List (1998)

Wiring Diagram . . . . . . . . . . . . . . 4-08N


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-08O
Spark Circuit . . . . . . . . . . . . . 4-08P
Spark Circuit . . . . . . . . . . . . . 4-08Q
Charging Circuit . . . . . . . . . . . 4-08R

Demystification Guide 4 - 8M
825 RER 1998
(70041 & 70060)

Wiring Diagram rev. 4-03

4 - 8N Demystification Guide
1998 825 RER
(70041 & 70060)

rev. 4-03 Starter Motor Circuit

Demystification Guide 4 - 8O
825 RER 1998
(70041 & 70060)

Spark Circuit rev. 4-03


(ignition switch in “run”)

4 - 8P Demystification Guide
1998 825 RER
(70041 & 70060)

rev. 4-03 Spark Circuit


(ignition switch in “start”)

Demystification Guide 4 - 8Q
825 RER 1998
(70041 & 70060)

Charging Circuit rev. 4-03

4 - 8R Demystification Guide
1999 - 2001 825 - RER

rev. 4-03

825 - RER Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . . . . . 4-10


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-11
Run Circuit (Forward) . . . . . . . . . . 4-12
Run Circuit (Reverse) . . . . . . . . . . 4-13
Charging Circuit . . . . . . . . . . . . 4-14

Demystification Guide 4-9


825 - RER 1999 - 2001

Wiring Diagram rev. 4-03

4 - 10 Demystification Guide
1999 - 2001 825 - RER

rev. 4-03 Starter Motor Circuit


(ignition switch in start)

Demystification Guide 4 - 11
825 - RER 1999 - 2001

Run Circuit (Forward) rev. 4-03


(PTO “on”)

4 - 12 Demystification Guide
1999 - 2001 825 - RER

rev. 4-03 Run Circuit (Reverse)


(PTO “on” - NMIR “on”)

Demystification Guide 4 - 13
825 - RER 1999 - 2001

Charging Circuit rev. 4-03

4 - 14 Demystification Guide
1994 - 1995 10-32 & 12-32

rev. 4-03

10-32 & 12-32 Information List (1994 - 1995)

Wiring Diagram . . . . . . . . . . . . . . 4-14B


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-14C
Spark Circuit . . . . . . . . . . . . . 4-14C
Kill Circuit . . . . . . . . . . . . . . 4-14C
Charging Circuit . . . . . . . . . . . 4-14D

Demystification Guide 4 - 14A


10-32 & 12-32 1994 - 1995

Wiring Diagram rev. 4-03

4 - 14B Demystification Guide


1994 - 1995 10-32 & 12-32

rev. 4-03

Demystification Guide 4 - 14C


10-32 & 12-32 1994 & 1995

Charging Circuit rev. 4-03

4 - 14D Demystification Guide


1991 - 1992 832 & 10-32 & 12-32

rev. 4-03

832 & 10-32 & 12-32 Information List (1991 - 1992)

Wiring Diagram . . . . . . . . . . . . . . 4-16


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-17
Spark Circuit . . . . . . . . . . . . . 4-17
Spark Circuit . . . . . . . . . . . . . 4-17
Charging Circuit . . . . . . . . . . . 4-17

Demystification Guide 4 - 15
rev. 4-03
rev. 4-03
This page intentionally left blank

4 - 18 Demystification Guide
1993 832 RER
(70042)

rev. 4-03

825 Information List (1993)

Wiring Diagram . . . . . . . . . . . . . . 4-18B


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-18C
Spark Circuit . . . . . . . . . . . . . 4-18D
Spark Circuit . . . . . . . . . . . . . 4-18E
Charging Circuit . . . . . . . . . . . 4-18F

Demystification Guide 4 - 18A


832 RER 1993
(70042)

Wiring Diagram rev. 4-03

4 - 18B Demystification Guide


1993 832 RER
(70042)

rev. 4-03 Starter Motor Circuit

Demystification Guide 4 - 18C


832 RER 1993
(70042)

Spark Circuit rev. 4-03


(ignition switch in “run”)

4 - 18D Demystification Guide


1993 832 RER
(70042)

rev. 4-03 Spark Circuit


(ignition switch in “start”)

Demystification Guide 4 - 18E


832 RER 1993
(70042)

Charging Circuit rev. 4-03

4 - 18F Demystification Guide


1988 108-4, 108-5, & 111-6

Information List
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

Demystification Guide 4 - 19
108-4, 108-5, & 111-6 1988

Wiring Diagram
Wiring Diagram

4 - 20 Demystification Guide
1988 108-4, 108-5, & 111-6

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 4 - 21
108-4, 108-5, & 111-6 1988

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

Gauge Circuit
(ignition switch in “run”)

4 - 22 Demystification Guide
1988 112-C

Information List
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

Demystification Guide 4 - 23
112-C 1988

Wiring Diagram
Wiring Diagram

4 - 24 Demystification Guide
1988 112-C

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 4 - 25
112-C 1988

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

Gauge Circuit
(ignition switch in “run”)

4 - 26 Demystification Guide
1996 - 1998 11-32 & 13-32

rev. 4-03

11-32 & 13-32 Information List (1996 - 1998)

Wiring Diagram . . . . . . . . . . . . . . 4-28


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-29
Spark Circuits . . . . . . . . . . . . . 4-29
Spark Circuits . . . . . . . . . . . . . 4-30
Charging Circuit . . . . . . . . . . . . 4-30

Demystification Guide 4 - 27
rev. 4-03
rev. 4-03
11-32 & 13-32 1996 - 1998

Spark Circuit rev. 4-03


(ignition switch in “run”)

Charging Circuit

4 - 30 Demystification Guide
1999 - 2001 12-32 - RER

rev. 4-03

12-32 - RER Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . . . . . 4-32


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 4-33
Run Forward . . . . . . . . . . . . . 4-34
Run Reverse . . . . . . . . . . . . . 4-35
Charging Circuit . . . . . . . . . . . . 4-35

Demystification Guide 4 - 31
12-32 - RER 1999 - 2001

Wiring Diagram rev. 4-03

4 - 32 Demystification Guide
1999 - 2001 12-32 - RER

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Demystification Guide 4 - 33
12-32 - RER 1999 - 2001

Run Forward rev. 4-03


(PTO “on”)

4 - 34 Demystification Guide
1999 - 2001 12-32 - RER

rev. 4-03 Run Reverse


(PTO “on” - NMIR override)

Charging Circuit

Demystification Guide 4 - 35
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4 - 36 Demystification Guide
1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5
1990 210-5 & 210-H

Information List
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

Demystification Guide 5-1


208-4SB, 211-5SB, 211-4, & 212-5 1988 - 1989
210-5 & 210-H 1990

Wiring Diagram
Wiring Diagram

5-2 Demystification Guide


1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5
1990 210-5 & 210-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Legend
Circuits
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

Demystification Guide 5-3


208-4SB, 211-5SB, 211-4, & 212-5 1988 - 1989
210-5 & 210-H 1990

Spark Circuit
(ignition switch in “run”)

Charging Circuit
Legend
(ignition switch in “run”) Black
Blue
Bk
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
Circuits

Yellow Ye

Electric Clutch
(ignition switch in “run”)

5-4 Demystification Guide


1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5
1990 210-5 & 210-H

Light 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

Circuits
Light Blue Lt Bu
Orange Or
Pink Pi
Purple Pu
Red Rd
Tan Ta
White Wh
Yellow Ye

Demystification Guide 5-5


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5-6 Demystification Guide


1991 & 1993 - 1995 210-5 & 210-H
1992 212-H
rev. 4-03

210-5 & 210-H Information List (1991 & 1993 - 1995)


212-H (1992)

Wiring Diagram . . . . . . . . . . . . . . 5-8


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 5-9
Spark Circuit . . . . . . . . . . . 5-9 & 5-10
Charging Circuit . . . . . . . . . . . 5-10
Electric Clutch Circuit . . . . . . . . . 5-10

Demystification Guide 5-7


210-5 & 210-H 1991 & 1993 - 1995
212-H 1992

Wiring Diagram rev. 4-03

5-8 Demystification Guide


rev. 4-03
210-5 & 210-H 1991 & 1993 - 1995
212-H 1992
Spark Circuit rev. 4-03
(ignition switch in “run”)

Charging Circuit

Electric Clutch
(ignition switch in “run”)

5 - 10 Demystification Guide
1992 210-5

Information List
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

Demystification Guide 5 - 11
210-5 1992

Wiring Diagram
Wiring Diagram

5 - 12 Demystification Guide
1992 210-5

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 5 - 13
210-5 1992

Spark Circuit
(ignition switch in “run”)

Charge Circuit
(ignition switch in “run”)

Electric Clutch Circuit


Circuits

(ignition switch in “run”)

5 - 14 Demystification Guide
1991 212-5 & 212-H

Information List
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

Demystification Guide 5 - 15
212-5 & 212-H 1991

Wiring Diagram
Wiring Diagram

5 - 16 Demystification Guide
1991 212-5 & 212-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits
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

Demystification Guide 5 - 17
212-5 & 212-H 1991

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)

Electric Clutch
Circuits

(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

5 - 18 Demystification Guide
1991 212-5 & 212-H

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

Circuits

Demystification Guide 5 - 19
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5 - 20 Demystification Guide
1990 212-5 & 212-H

Information List
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

Demystification Guide 5 - 21
1990 212-5 & 212-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Spark Circuit
(ignition switch in “run”)

Legend
Circuits
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

Demystification Guide 5 - 23
212-5 & 212-H 1990

Charging Circuit

Electric Clutch
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)
Circuits

Kill Circuit Legend


Black Bk
(ignition switch in “off”) 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

5 - 24 Demystification Guide
1990 212-5 & 212-H

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

Circuits

Demystification Guide 5 - 25
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5 - 26 Demystification Guide
1992 212-5

Information List
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

Demystification Guide 5 - 27
212-5 1992

Wiring Diagram rev. 4-03

5 - 28 Demystification Guide
1992 212-5

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Demystification Guide 5 - 29
212-5 1992

Spark Circuit rev. 4-03


(ignition switch in “run”)

Charging Circuit

Electric Clutch Circuit


(ignition switch in “run”)

5 - 30 Demystification Guide
1988 212-6

Information List
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

Demystification Guide 5 - 31
212-6 1988

Wiring Diagram
Wiring Diagram

5 - 32 Demystification Guide
1988 212-6

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Spark Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 5 - 33
212-6 1988

Charging Circuit
(ignition switch in “run”)

Oil Pressure Light Circuit


(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)
Circuits

5 - 34 Demystification Guide
1988 212-6

Electric Clutch Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 5 - 35
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5 - 36 Demystification Guide
1987 212-6

Information List
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

Demystification Guide 5 - 37
1987 212-6

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 5 - 39
212-6 1987

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

5 - 40 Demystification Guide
1987 212-6

Oil Pressure Light Circuit


(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 5 - 41
212-6 1987

Gauge Circuit
(ignition switch in “run”)

Electric Clutch Circuit


(ignition switch in “run”)
Circuits

5 - 42 Demystification Guide
1993 10-32XL & 12-38XL
1993 - 1995 12-32XL & 12-38HXL
1994 13-38HXL

rev. 4-03

10-32XL & 12-38XL Information List (1993)


12-32XL & 12-38HXL (1993 - 1995)
13-38HXL (1994)

Wiring Diagram . . . . . . . . . . . . . . . 5-44


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 5-45
Spark Circuit . . . . . . . . . . . . . 5-45
Spark Circuit . . . . . . . . . . . . . 5-46
Charging Circuit . . . . . . . . . . . . 5-46

Demystification Guide 5 - 43
1995 13-38HXL & 15-44HXL
1996 - 1998 ALL XL UNITS

Information List
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

Demystification Guide 5 - 47
13-38HXL & 15-44HXL 1995
ALL XL UNITS 1996 - 1998

Wiring Diagram
Wiring Diagram

5 - 48 Demystification Guide
1995 13-38HXL & 15-44HXL
1996 - 1998 ALL XL UNITS

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 5 - 49
13-38HXL & 15-44HXL 1995
ALL XL UNITS 1996 - 1998

Spark Circuit
(ignition switch in “run”)

Charging Circuit

Headlight Circuit
(ignition switch in “start”)
Circuits

5 - 50 Demystification Guide
1999 - 2001 XL

rev. 4-03

XL Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 5-50B, 5-50C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 5-50D
Run Circuit (Forward) . . . . . . . . . . 5-50E
Run Circuit (Reverse) . . . . . . . . . . 5-50F
Charging Circuit . . . . . . . . . . . . 5-50F
Light Circuit . . . . . . . . . . . . . 5-50G

Demystification Guide 5 - 50A


XL 1999 - 2001

Wiring Diagram rev. 4-03

5 - 50B Demystification Guide


1999 - 2001 XL

rev. 4-03 Wiring Diagram

Demystification Guide 5 - 50C


XL 1999 - 2001

Starter Motor Circuit rev. 4-03


(ignition switch in “start”)

5 - 50D Demystification Guide


1999 - 2001 XL

rev. 4-03 Run Forward


(PTO “on”)

Demystification Guide 5 - 50E


XL 1999 - 2001

Run Reverse rev. 4-03


(PTO “on” NMIR override)

Charging Circuit

5 - 50F Demystification Guide


1999 - 2001 XL

rev. 4-03 Light Circuit

Demystification Guide 5 - 50G


rev. 4-03

This page intentionally left blank

6 - 50H Demystification Guide


1988 252-H

Information List
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

Demystification Guide 5 - 51
252-H 1988

Wiring Diagram
Wiring Diagram

5 - 52 Demystification Guide
1988 252-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Spark Circuit

Circuits
(ignition switch in “run”)

Demystification Guide 5 - 53
252-H 1988

Charging Circuit
(ignition switch in “run”)

Oil Pressure Light Circuit


(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)
Circuits

5 - 54 Demystification Guide
1988 252-H

Electric Clutch Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 5 - 55
This page intentionally left blank

5 - 56 Demystification Guide
1988 257-H

Information List
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

Demystification Guide 5 - 57
1988 257-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 5 - 59
257-H 1988

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

5 - 60 Demystification Guide
1988 257-H

Oil Pressure Light Circuit


(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 5 - 61
257-H 1988

Gauge Circuit
(ignition switch in “run”)

Electric Clutch Circuit


(ignition switch in “run”)
Circuits

5 - 62 Demystification Guide
1993 244
1992 246-H
rev. 4-03

244 Information List (1993)


246-H (1993)

Wiring Diagram . . . . . . . . . . . . . . . 6-2


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-3
Spark Circuits . . . . . . . . . . . 6-3 & 6-4
Charging Circuit . . . . . . . . . . . . 6-4
Electric Clutch Circuit . . . . . . . . . . 6-5
Light Circuit . . . . . . . . . . . . . . 6-5

Demystification Guide 6-1


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6-6 Demystification Guide


1994-1995 264-6

Information List
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

Demystification Guide 6-7


264-6 1994-1995

Wiring Diagram
Wiring Diagram

6-8 Demystification Guide


1994-1995 264-6

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6-9


264-6 1994-1995

Spark Circuit Circuit


(ignition switch in run”)

Charging Circuit
(ignition switch in “run”)

Electric Clutch Circuit


Circuits

(ignition switch in “run”)

6 - 10 Demystification Guide
1994-1995 264-6

rev. 4-03 Light Circuit


(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)

Park Brake Light Circuit*


(ignition switch in “run”)

Demystification Guide 6 - 11
264-6 1994-1995

Battery Light Circuit


(ignition switch in “run”)

PTO Light Circuit*


(ignition switch in “run”)
Circuits

6 - 12 Demystification Guide
1994-1995 264-6

Oil Pressure Light Circuit*


(ignition switch in “run”)

Circuits

Demystification Guide 6 - 13
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6 - 14 Demystification Guide
1994 - 1998 264-H & 265-H

Information List
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

Demystification Guide 6 - 15
264-H & 265-H 1994 - 1998

Wiring Diagram
Wiring Diagram

6 - 16 Demystification Guide
1994 - 1998 264-H & 265-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6 - 17
264-H & 265-H 1994 - 1998

Spark Circuit Circuit


(ignition switch in run”)

Charging Circuit
(ignition switch in “run”)

Electric Clutch Circuit


Circuits

(ignition switch in “run”)

6 - 18 Demystification Guide
1994-1995 264-6

rev. 4-03 Light Circuit


(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)

Park Brake Light Circuit*


(ignition switch in “run”)

Demystification Guide 6 - 19
264-H & 265-H 1994 - 1998

Battery Light Circuit


(ignition switch in “run”)

PTO Light Circuit*


(ignition switch in “run”)
Circuits

6 - 20 Demystification Guide
1994 - 1998 264-H & 265-H

Oil Pressure Light Circuit*


(ignition switch in “run”)

Circuits

Demystification Guide 6 - 21
This page intentionally left blank

6 - 22 Demystification Guide
1996-1998 265-6

Information List
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

Demystification Guide 6 - 23
1996-1998 265-6

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6 - 25
265-6 1996-1998

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

Hourmeter Circuit
(ignition switch in “run”)

6 - 26 Demystification Guide
1996-1998 265-6

Electric Clutch Circuit


(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 6 - 27
This page intentionally left blank

6 - 28 Demystification Guide
1999 - 2000 265-6

rev. 4-03

265-6 Information List (1999 - 2000)


Wiring Diagram . . . . . . . . . . . . . . . 6-29C
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . 6-29E
Spark Circuit . . . . . . . . . . . . . . . 6-29E
Run Forward . . . . . . . . . . . . . . . 6-29F
Run Reverse . . . . . . . . . . . . . . . 6-29G
Charging Circuit . . . . . . . . . . . . . . 6-29H
Light Circuit . . . . . . . . . . . . . . . 6-29H

Demystification Guide 6 - 29A


265-6 1999 - 2000

Wiring Diagram rev. 4-03

6 - 29B Demystification Guide


1999 - 2000 265-6

rev. 4-03 Wiring Diagram

Demystification Guide 6 - 29C


 

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Starter Motor
(energized)
Starter Solenoid
Bn (energized)

Gy Y Y T Or Or Gn

Gy Brake Switch Y Seat Switch


(operator on) Bn Start Relay
Bu (brake applied) (energized)
I Pk Pk
Re Re
Bu Interlock
Bn
B
S Fuse Relay
Battery Fuse (10 amp) PTO Switch (energized)
(30 amp) Ignition
Switch (disengaged)
(in start)
Gn Bk

Kill Relay
(energized)

Park Brake Switch Neutral Switch


(Brake Engaged) (in Neutral)

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Trigger
module

Ignition Coil
Dashed lines do not carry current

&LUFXLWV
Bk

Gy Y Y

Gy Brake Switch Kill Relay


Bu (brake applied) (energized)
I Pk Pk
Re Re
Bn Bu
B Fuse
S
Battery Fuse (10 amp) PTO Switch
(30 amp) Ignition
Switch (disengaged) Park Brake Switch Neutral Switch
(in start) (Brake Engaged) (in Neutral)

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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Trigger Trigger
module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)
Fuse
W
(25 amp)
R Vio Bk
Re Re
Pk Pk
B T Or
I Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch Park Switch
(30 amp)
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) not engaged) (energized)
Interlock Realy
(not energized)

Bu Bn Bk
PTO Clutch
(engaged)
Bu W

PTO Switch
Legend (engaged)
W Bk
Bu
Black Bk
Blue Bu
PTO Light
Brown Bn
(on)
Green Gn
Grey Gy
Orange Or
Pink Pk No Mow In Reverse Module
Red Re (NMIR)
Tan T
Violet Vio
White W Gn
Yellow Y
&LUFXLWV

Reverse Switch
(in forward)
Bk

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Trigger
module

Ignition Coil
Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)

Fuse
W
(25 amp)
A Vio Bk
Re Re
Pk Pk
B T Or
L Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch Park Switch
(30 amp)
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) not engaged) (energized)
Interlock Realy
(not energized)

Bu Bn Bk
PTO Clutch
(engaged)
Bu W
Legend
Black Bk PTO Switch
Blue Bu (engaged)
W Bk
Brown Bn Bu
Green Gn
Grey Gy PTO Light
Orange Or (on)
Pink Pk
Red Re
Tan T No Mow In Reverse Module
Violet Vio
White W
(NMIR)
Yellow Y

Gn T Bk

&LUFXLWV
Reverse Switch
(in reverse)
Bk T
Bk Bk

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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Voltage Or Pk
Comparator
Battery Light
Pk
B+

Bk

Battery Light Module

Pk
AC I B
Re
Vio Vio
B+ R
AC
Fuse Battery
Fuse Ignition (30 amp)
Alternator Regulator/Rectifier (25 amp) Switch
(in run)

Fuel Solenoid
(energized)

/LJKW&LUFXLW

Re Re Or Or Bk
B L
Battery Fuse Fuse
(30 amp) Ignition (10 amp)
Switch
(in run/lights) Headlights
&LUFXLWV

(on)

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2000 - 2001 265-H

rev. 4-03

265-H Information List (2000 - 2001)

Wiring Diagram . . . . . . . . . . . 6-30B, 6-30C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-30E
Spark Circuit . . . . . . . . . . . . . 6-30E
Run Circuit (Forward) . . . . . . . . . . 6-30F
Run Circuit (Reverse) . . . . . . . . . . 6-30G
Charging Circuit . . . . . . . . . . . . 6-30H
Light Circuit . . . . . . . . . . . . . 6-30H

Demystification Guide 6 - 30A


265-H 2000 - 2001

Wiring Diagram rev. 4-03

6 - 30B Demystification Guide


2000 - 2001 265-H

rev. 4-03 Wiring Diagram

Demystification Guide 6 - 30C


This page intentionally left blank

6 - 30D Demystification Guide


2000 - 2001 265-H

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Demystification Guide 6 - 30E


265-H 2000 - 2001

Run Forward rev. 4-03


(PTO “on”)

6 - 30F Demystification Guide


2000 - 2001 265-H

rev. 4-03 Run Reverse


(PTO “on” NMIR override)

Demystification Guide 6 - 30G


265-H 2000 - 2001

Charging Circuit rev. 4-03

Light Circuit

6 - 30H Demystification Guide


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Wiring Diagram rev. 4-03

6 - 31B Demystification Guide


1999 265-H

rev. 4-03 Wiring Diagram

Demystification Guide 6 - 31C


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Starter Motor
(energized)
Starter Solenoid
Bn (energized)

Gy Y Y T Or Or Gn

Gy Brake Switch Y Seat Switch


(operator on) Bn Start Relay
Bu (brake applied) (energized)
I Pk Pk
Re Re
Bu Interlock
Bn
B
S Fuse Relay
Battery Fuse (10 amp) PTO Switch (energized)
(30 amp) Ignition
Switch (disengaged)
(in start)
Gn Bk

Kill Relay
(energized)

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Trigger
module

Ignition Coil
Dashed lines do not carry current

Gy Y

Gy Brake Switch
Bu (brake applied)
I Pk Pk
Re Re Bk
Bn Bu
B Fuse
S
Battery Fuse (10 amp) PTO Switch
(30 amp) Ignition Y
Switch (disengaged)
(in start) Kill Relay
(energized)

&LUFXLWV
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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Trigger Trigger
module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)
Fuse
W
(25 amp)
R Vio Bk
Re Re
Pk Pk
B T Or
I Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch Park Switch
(30 amp)
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) not engaged) (energized)
Interlock Realy
(not energized)

Bu Bn Bk
PTO Clutch
(engaged)
Bu W

PTO Switch
Legend (engaged)
W Bk
Bu
Black Bk
Blue Bu
PTO Light
Brown Bn
(on)
Green Gn
Grey Gy
Orange Or
Pink Pk No Mow In Reverse Module
Red Re (NMIR)
Tan T
Violet Vio
White W Gn
Yellow Y
&LUFXLWV

Reverse Switch
(in forward)
Bk

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Trigger
module

Ignition Coil
Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)

Fuse
W
(25 amp)
A Vio Bk
Re Re
Pk Pk
B T Or
L Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch Park Switch
(30 amp)
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) not engaged) (energized)
Interlock Realy
(not energized)

Bu Bn Bk
PTO Clutch
(engaged)
Bu W
Legend
Black Bk PTO Switch
Blue Bu (engaged)
W Bk
Brown Bn Bu
Green Gn
Grey Gy PTO Light
Orange Or (on)
Pink Pk
Red Re
Tan T No Mow In Reverse Module
Violet Vio
White W
(NMIR)
Yellow Y

Gn T Bk

&LUFXLWV
Reverse Switch
(in reverse)
Bk T
Bk Bk

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Voltage Or Pk
Comparator
Battery Light
Pk
B+

Bk

Battery Light Module

Pk
AC I B
Re
Vio Vio
B+ R
AC
Fuse Battery
Fuse Ignition (30 amp)
Alternator Regulator/Rectifier (25 amp) Switch
(in run)

Fuel Solenoid
(energized)

/LJKW&LUFXLW

Re Re Or Or Bk
B L
Battery Fuse Fuse
(30 amp) Ignition (10 amp)
&LUFXLWV

Switch
(in run/lights) Headlights
(on)

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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1995 266-H

Information List
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

Demystification Guide 6 - 33
266-H 1995

Wiring Diagram
Wiring Diagram

6 - 34 Demystification Guide
1995 266-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6 - 35
266-H 1995

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

Electric Clutch Circuit


(ignition switch in “run”)

6 - 36 Demystification Guide
1995 266-H

Light Circuit
(ignition switch in “run”)

Oil Pressure Switch Circuit


(ignition switch in “run”)

Parking Brake Switch Circuit

Circuits
(parking brake applied)

Demystification Guide 6 - 37
266-H 1995

Cruise Control Circuit


(activating cruise)

Cruise Control Circuit


(in cruise mode)
Circuits

6 - 38 Demystification Guide
1995 266-H

Cruise Control Circuit


(deactivation by applying the brake)

Circuits

Demystification Guide 6 - 39
This page intentionally left blank

6 - 40 Demystification Guide
1994 266-H

Information List
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

Demystification Guide 6 - 41
266-H 1994

Wiring Diagram
Wiring Diagram

6 - 42 Demystification Guide
1994 266-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6 - 43
266-H 1994

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)

Electric Clutch Circuit


Circuits

(ignition switch in “run”)

6 - 44 Demystification Guide
1994 266-H

Light Circuit
(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)

Parking Brake Switch Circuit*

Circuits
(ignition switch in “run”)

Demystification Guide 6 - 45
266-H 1994

Battery Light Circuit*


(ignition switch in “run”)

PTO Light Circuit*


(ignition switch in “run”)
Circuits

6 - 46 Demystification Guide
1994 266-H

Oil Pressure Light Circuit*


(ignition switch in “run”)

Circuits

Demystification Guide 6 - 47
This page intentionally left blank

6 - 48 Demystification Guide
2001 266-H

rev. 4-03

266-H Information List (2001)

Wiring Diagram . . . . . . . . . . . . . . 6-48B


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-48C
Spark Circuit . . . . . . . . . . . . . 6-48C
Run Forward . . . . . . . . . . . . . 6-48D
Run Reverse . . . . . . . . . . . . . 6-48E
Charging Circuit . . . . . . . . . . . 6-48F

Demystification Guide 6 - 48A


266-H 2001

Wiring Diagram rev. 4-03

6 - 48B Demystification Guide


2001 266-H

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Demystification Guide 6 - 48C


266-H 2001

Run Forward rev. 4-03


(PTO “on”)

6 - 48D Demystification Guide


2001 266-H

rev. 4-03 Run Reverse


(PTO “on” NMIR override)

Demystification Guide 6 - 48E


266-H 2001

Charging Circuit rev. 4-03

6 - 48F Demystification Guide


1996 - 1998 267-H

Information List
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

Demystification Guide 6 - 49
1996 - 1998 267-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6 - 51
267-H 1996 - 1998

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)

Electric Clutch Circuit


Circuits

(ignition switch in “run”)

6 - 52 Demystification Guide
1996 - 1998 267-H

Light Circuit
(ignition switch in “run”)

Oil Pressure Switch Circuit


(ignition switch in “run”)

Parking Brake Switch Circuit

Circuits
(parking brake applied)

Demystification Guide 6 - 53
267-H 1996 - 1998

Hourmeter Circuit
(ignition switch in “run”)

Cruise Control Circuit


(activating cruise)

6 - 54 Demystification Guide
1996 - 1998 267-H

Cruise Control Circuit


(in cruise mode)

Cruise Control Circuit


(deactivation by applying the brake)

Circuits

Demystification Guide 6 - 55
This page intentionally left blank

6 - 56 Demystification Guide
 +

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rev. 4-03 Wiring Diagram

Demystification Guide 6 - 57C


 +

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Starter Motor
(energized)
Starter Solenoid
Bn (energized)

Gy Y Y T Or Or Gn

Gy Brake Switch Y Seat Switch


(operator on) Bn Start Relay
Bu (brake applied) (energized)
I Pk Pk
Re Re
Bu Interlock
Bn
B
S Fuse Relay
Battery Fuse (10 amp) PTO Switch (energized)
(30 amp) Ignition
Switch (disengaged)
(in start)
Gn Bk

Kill Relay
(energized)

6SDUN&LUFXLW
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Trigger Trigger
module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Gy Y

Gy Brake Switch
Bu (brake applied)
I Pk Pk
Re Re Bk
Bn Bu
B Fuse
S
Battery Fuse (10 amp) PTO Switch
(30 amp) Ignition Y
Switch (disengaged)
(in start) Kill Relay
(energized)

&LUFXLWV
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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Pk

Re Re Pk Y T
B I Pk Y
Battery Fuse
(10 amp) Ignition Bu Pk
Cruise Relay
Switch
(in run) (energized) Momentary Switch
(energizes cruise relay)
Bu
Bk
Bu Bu

Cruise Lamp
Cruise Switch (on)
Bu
(energized)
T
Cruise Magnet
(energized) Cruise Disengage Switch
Bk (opens when brake is depresed)

Bk Bk

&KDUJLQJ&LUFXLW

Voltage Or Pk Legend
Comparator
Black Bk
Battery Light Blue Bu
Pk
B+ Brown Bn
Green Gn
Bk Grey Gy
Orange Or
Pink Pk
Red Re
Battery Light Module Tan T
Violet Vio
White W
&LUFXLWV

Yellow Y

Pk
AC I B
Re
Vio Vio
B+ R
AC
Fuse Battery
Fuse Ignition (30 amp)
Altenator Regulator/Rectifier (25 amp) Switch
(in run)

Fuel Solenoid
(energized)

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Re Re Or Or Bk
B L
Battery Fuse Fuse
(30 amp) Ignition (10 amp)
Switch
(in run/lights) Headlights
(on) 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

&LUFXLWV

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This page intentionally left blank

- 'HP\VWLILFDWLRQ*XLGH
2000 - 2001 268-H

rev. 4-03

268-H Information List (2000 - 2001)

Wiring Diagram . . . . . . . . . . . 6-58B, 6-58C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-58D
Spark Circuit . . . . . . . . . . . . . 6-58D
Run Circuit (Forward) . . . . . . . . . . 6-58E
Run Circuit (Reverse) . . . . . . . . . . 6-58F
Cruise Control Circuit . . . . . . . . . . 6-58G
Charging Circuit . . . . . . . . . . . . 6-58G
Light Circuit . . . . . . . . . . . . . 6-58H

Demystification Guide 6 - 58A


268-H 2000 - 2001

Wiring Diagram rev. 4-03

6 - 58B Demystification Guide


2000 - 2001 268-H

rev. 4-03 Wiring Diagram

Demystification Guide 6 - 58C


268-H 2000 - 2001

Starter Motor Circuit rev. 4-03


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

6 - 58D Demystification Guide


2000 - 2001 268-H

rev. 4-03 Run Forward


(PTO “on”)

Demystification Guide 6 - 58E


268-H 2000 - 2001

Run Reverse rev. 4-03


(PTO “on” NMIR override)

6 - 58F Demystification Guide


2000 - 2001 268-H

rev. 4-03 Cruise Control Circuit


(ignition switch in “run”)

Charging Circuit

Demystification Guide 6 - 58G


2000 - 2001 268-H

rev. 4-03 Light Circuit

Demystification Guide 6 - 58H


2000 - 2001* 268-H

Light Circuit

Re Re Or Or Bk
B L
Battery Fuse Fuse
(30 amp) Ignition (10 amp)
Switch
(in run/lights) Headlights
(on) 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

Circuits

Demystification Guide 6 - 58I


* May apply to later models, see Table Of Contents
This page intentionally left blank

6 - 58J Demystification Guide


1996 - 1998 269-H

Information List
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

Demystification Guide 6 - 59
1996 - 1998 269-H

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 6 - 61
269-H 1996 - 1998

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”
Circuits

6 - 62 Demystification Guide
1996 - 1998 269-H

Light Circuit
(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)

Oil Pressure Switch Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 6 - 63
269-H 1996 - 1998

Parking Brake Light Circuit


(ignition switch in “run”)

Pump Circuit
(ignition switch in “run”)
Circuits

6 - 64 Demystification Guide
1996 - 1998 269-H

Electric Clutch Circuit


(ignition switch in “run”)

Cruise Control Circuit


(activating cruise)

Circuits

Demystification Guide 6 - 65
269-H 1996 - 1998

Cruise Control Circuit


(in cruise mode)

Cruise Control Circuit


(deactivation by applying the brake)
Circuits

6 - 66 Demystification Guide
2001 270-H

rev. 4-03

270-H Information List (2001)

Wiring Diagram . . . . . . . . . . . 6-66B, 6-66C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 6-66D
Run Circuit . . . . . . . . . . . . . 6-66D
Clutch Circuit (forward PTO “on”) . . . . . . 6-66E
Clutch Circuit (reverse PTO “on”) . . . . . . 6-66F
Cruise Control Circuit . . . . . . . . . . 6-66G
Lift Circuit . . . . . . . . . . . . . . 6-66G
Charging Circuit . . . . . . . . . . . . 6-66H
Light Circuit . . . . . . . . . . . . . 6-66H

Demystification Guide 6 - 66A


270-H 2001

Wiring Diagram rev. 4-03

6 - 66B Demystification Guide


2001 270-H

rev. 4-03 Wiring Diagram

Demystification Guide 6 - 66C


270-H 2001

Starter Motor Circuit rev. 4-03


(ignition switch in “start”)

Run Circuit
(operator “on”)

6 - 66D Demystification Guide


2001 270-H

rev. 4-03 Clutch Circuit


(forward PTO “on”)

Demystification Guide 6 - 66E


270-H 2001

Clutch Circuit rev. 4-03


(reverse PTO “on” override key switch engaged)

6 - 66F Demystification Guide


2001 270-H

rev. 4-03 Cruise Control Circuit

Lift Circuit

Demystification Guide 6 - 66G


270-H 2001

Charging Circuit rev. 4-03

Light Circuit

6 - 66H Demystification Guide


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Starter Motor
(energized)
Starter Solenoid
Bn (energized)

Gy Vio Or T Or Or Gn

Gy Brake Switch Y Or Seat Switch


(operator on) Bn Start Relay
Bu (brake applied) (energized)
I Pk Pk Neutral Switch
Re Re
Bu (in neutral) Interlock
Bn
B
S Fuse Relay
Battery Fuse (10 amp) PTO Switch (energized)
(30 amp) Ignition
Switch (disengaged)
(in start)
Gn Bk

Kill Relay
(energized)

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module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Gy Vio Or

Gy Brake Switch Y Or
Bu (brake applied)
I Pk Pk Neutral Switch
Re Re Bk
Bn Bu (in neutral)
B Fuse
S
Battery Fuse (10 amp) PTO Switch
(30 amp) Ignition Y
Switch (disengaged)
(in start) Kill Relay
(energized)

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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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Trigger Trigger
module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)
Fuse
W
(25 amp)
R Vio Bk
Re Re
Pk Pk
B T Or
I Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch
(30 amp) Park Switch
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) not engaged) (energized)
Interlock Realy
(not energized)

Bu Bn Bk
PTO Clutch
(engaged)
Bu W

Legend PTO Switch


Black Bk
(engaged)
W Bk
Blue Bu Bu
Brown Bn
Green Gn
PTO Light
Grey Gy (on)
Orange Or
Pink Pk
Red Re No Mow In Reverse Module
Tan T (NMIR)
Violet Vio
White W
Yellow Y Gn
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Reverse Switch
(in forward)
Bk

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module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)

Fuse
W
(25 amp)
A Vio Bk
Re Re
Pk Pk
B T Or
L Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch
(30 amp) Park Switch
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) (energized)
Interlock Realy not engaged)
(not energized)

Legend Bu Bn Bk
Black Bk PTO Clutch
Blue Bu (engaged)
Bu W
Brown Bn
Green Gn PTO Switch
Grey Gy (engaged)
Orange Or W Bk
Bu
Pink Pk
Red Re PTO Light
Tan T (on)
Violet Vio
White W
Yellow Y
No Mow In Reverse Module
(NMIR)

Gn T Bk

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Reverse Switch
(in reverse)
Bk T
Bk Bk

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Re Re Pk Y T
B I Pk Y
Battery Fuse
(10 amp) Ignition Bu Pk
Cruise Relay
Switch
(in run) (energized) Momentary Switch
(energizes cruise relay)
Bu
Bk
Bu Bu

Cruise Lamp
Cruise Switch (on)
Bu
(energized)
T
Cruise Magnet
(energized) Cruise Disengage Switch
Bk (opens when brake is depresed)

Bk Bk

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Bu

Bk
Re Re Pk Bu Lift Pump
B I Bk (Energized)
Battery Fuse Fuse
(30 amp) Ignition (25 amp) Bu
Switch
(in run) W
Lift Switch
&LUFXLWV

(in operation)
Bk
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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Voltage Or Pk
Comparator
Battery Light
Pk
B+

Bk

Fuse
Battery Light Module (10 amp)

Pk
AC I B
Re
Vio Vio
B+ R
AC
Fuse Battery
Fuse Ignition (30 amp)
Alternator Regulator/Rectifier (25 amp) Switch
(in run)

Fuel Solenoid
(energized)

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Re Re Or Or Bk
B L
Battery Fuse Fuse
Ignition

&LUFXLWV
(30 amp) (10 amp)
Switch
(in run/lights) Headlights
(on)

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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Starter Motor
(energized)
Starter Solenoid
Bn (energized)

Gy Y Y T Or Or Gn

Gy Brake Switch Y Seat Switch


(operator on) Bn Start Relay
Bu (brake applied) (energized)
I Pk Pk
Re Re
Bu Interlock
Bn
B
S Fuse Relay
Battery Fuse (10 amp) PTO Switch (energized)
(30 amp) Ignition
Switch (disengaged)
(in start)
Gn Bk

Kill Relay
(energized)

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module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Gy Y

Gy Brake Switch
Bu (brake applied)
I Pk Pk
Re Re Bk
Bn Bu
B Fuse
S
Battery Fuse (10 amp) PTO Switch
(30 amp) Ignition Y
Switch (disengaged)
(in start) Kill Relay
(energized)

&LUFXLWV
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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Trigger Trigger
module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)
Fuse
W
(25 amp)
R Vio Bk
Re Re
Pk Pk
B T Or
I Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch
(30 amp) Park Switch
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) not engaged) (energized)
Interlock Realy
(not energized)

Bu Bn Bk
PTO Clutch
(engaged)
Bu W

Legend PTO Switch


Black Bk
(engaged)
W Bk
Blue Bu Bu
Brown Bn
Green Gn
PTO Light
Grey Gy (on)
Orange Or
Pink Pk
Red Re No Mow In Reverse Module
Tan T (NMIR)
Violet Vio
White W
Yellow Y Gn
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Reverse Switch
(in forward)
Bk

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module module

Ignition Coil Ignition Coil


Dashed lines do not carry current

Vio Vio Fuel Solenoid


(energized)

Fuse
W
(25 amp)
A Vio Bk
Re Re
Pk Pk
B T Or
L Pk Y Bk
Battery Fuse
Ignition Fuse Seat Switch
(30 amp) Park Switch
Switch (10 amp) (operator on) (park brake Kill Relay
(in run) (energized)
Interlock Realy not engaged)
(not energized)

Legend Bu Bn Bk
Black Bk PTO Clutch
Blue Bu (engaged)
Bu W
Brown Bn
Green Gn PTO Switch
Grey Gy (engaged)
Orange Or W Bk
Bu
Pink Pk
Red Re PTO Light
Tan T (on)
Violet Vio
White W
Yellow Y
No Mow In Reverse Module
(NMIR)

Gn T Bk

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Reverse Switch
(in reverse)
Bk T
Bk Bk

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Pk

Re Re Pk Y T
B I Pk Y
Battery Fuse
(10 amp) Ignition Bu Pk
Cruise Relay
Switch
(in run) (energized) Momentary Switch
(energizes cruise relay)
Bu
Bk
Bu Bu

Cruise Lamp
Cruise Switch (on)
Bu
(energized)
T
Cruise Magnet
(energized) Cruise Disengage Switch
Bk (opens when brake is depresed)

Bk Bk

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Bu

Bk
Re Re Pk Bu Lift Pump
B I Bk (Energized)
Battery Fuse Fuse
(30 amp) Ignition (25 amp) Bu
Switch
(in run) W
Lift Switch
&LUFXLWV

(in operation)
Bk
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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Voltage Or Pk
Comparator
Battery Light
Pk
B+

Bk

Fuse
Battery Light Module (10 amp)

Pk
AC I B
Re
Vio Vio
B+ R
AC
Fuse Battery
Fuse Ignition (30 amp)
Alternator Regulator/Rectifier (25 amp) Switch
(in run)

Fuel Solenoid
(energized)

/LJKW&LUFXLW

Re Re Or Or Bk
B L
Battery Fuse Fuse
Ignition

&LUFXLWV
(30 amp) (10 amp)
Switch
(in run/lights) Headlights
(on)

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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 'HP\VWLILFDWLRQ*XLGH
1988 308-8

Information List
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

Demystification Guide 7-1


308-8 1988

Wiring Diagram
Wiring Diagram

7-2 Demystification Guide


1988 308-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits
Charging Circuit
(ignition switch in “run”)

Demystification Guide 7-3


308-8 1988

Hourmeter Circuit
(ignition switch in “run”

Light Circuit
(ignition switch in “run”)
Circuits

7-4 Demystification Guide


1989 - 1991 310-8

Information List
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

Demystification Guide 7-5


310-8 1989 - 1991

Wiring Diagram
Wiring Diagram

7-6 Demystification Guide


1989 - 1991 310-8

Starter Motor Circuit


(with ignition switch in “start” )

Spark Circuit
(ignition switch in “start” or “run” position)

Circuits
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

Demystification Guide 7-7


310-8 1989 - 1991

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

Oil Indicator Light Test Circuit


(with test switch depressed)
Circuits

7-8 Demystification Guide


1989 - 1991 310-8

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)

Circuits
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

Demystification Guide 7-9


This page intentionally left blank

7 - 10 Demystification Guide
1988 310-8

Information List
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

Demystification Guide 7 - 11
310-8 1988

Wiring Diagram
Wiring Diagram

7 - 12 Demystification Guide
1988 310-8

Starter Motor Circuit


(ignition switch in “start” )

Spark Circuit
(ignition switch in “run” or “start”)

Circuits
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

Demystification Guide 7 - 13
310-8 1988

Charging Circuit
(ignition switch in “run”)

Oil Indicator Light Test Circuit


(test switch depressed)
Circuits

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

7 - 14 Demystification Guide
1988 310-8

Oil Circuit
(ignition switch in “start”)
(prevents starting if oil is low)

Accessories Circuit
(including lights, voltmeter, and optional hourmeter) -
(ignition switch in “run")

Circuits
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

Demystification Guide 7 - 15
This page intentionally left blank

7 - 16 Demystification Guide
1998 312-8

Information List
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

Demystification Guide 7 - 17
1998 312-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 19
312-8 1998

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)
Circuits

7 - 20 Demystification Guide
1998 312-8

Light Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 7 - 21
This page intentionally left blank

7 - 22 Demystification Guide
1999 - 2001 312-8

rev. 4-03

312-8 Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 7-22B, 7-22C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-22E
Spark Circuit . . . . . . . . . . . . . 7-22E
Run Forward (PTO “on”) . . . . . . . . . 7-22F
Run Reverse (PTO “on” NMIR override) . . . 7-22G
Charging Circuit . . . . . . . . . . . . 7-22H
Light Circuit . . . . . . . . . . . . . 7-22H

Demystification Guide 7 - 22A


312-8 1999 - 2001

Wiring Diagram rev. 4-03

7 - 22B Demystification Guide


1999 - 2001 312-8

rev. 4-03 Wiring Diagram

Demystification Guide 7 - 22C


rev. 4-03

This page intentionally left blank

7 - 22D Demystification Guide


1999 - 2001 312-8

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Demystification Guide 7 - 22E


312-8 1999 - 2001

Run Forward rev. 4-03


(PTO “on”)

7 - 22F Demystification Guide


1999 - 2001 312-8

rev. 4-03 Run Reverse


(PTO “on” NMIR override)

Demystification Guide 7 - 22G


312-8 1999 - 2001

Charging Circuit rev. 4-03

Light Circuit

7 - 22H Demystification Guide


310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993
312-8 - - - - - - - - - - 1992-1997

rev. 4-03

310-8 Information List (1992 - 1993)


312-8 Information List (1992 - 1997)
314-8 Information List 1992 (1993)

Wiring Diagram . . . . . . . . . . . . . . 7-24


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-25
Spark Circuit . . . . . . . . . . . . . 7-25
Charging Circuit . . . . . . . . . . . 7-26
Light Circuit . . . . . . . . . . . . . 7-26
Hourmeter Circuit . . . . . . . . . . 7-26

Demystification Guide 7 - 23
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993
312-8 - - - - - - - - - - 1992-1997

Wiring Diagram rev. 4-03

7 - 24 Demystification Guide
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993
312-8 - - - - - - - - - - 1992-1997
rev. 4-03 Starter Motor Circuit
(ignition switch in “start” with low oil level)

Spark Circuit
(ignition switch in “start”)

Demystification Guide 7 - 25
310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993
312-8 - - - - - - - - - - 1992-1997
Charging Circuit rev. 4-03
(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)

7 - 26 Demystification Guide
1989 312-8

Information List
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

Demystification Guide 7 - 27
312-8 1989

Wiring Diagram
Wiring Diagram

7 - 28 Demystification Guide
1989 312-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits
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

Demystification Guide 7 - 29
312-8 1989

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

Light Circuit
Circuits

(ignition switch in “run”)

7 - 30 Demystification Guide
1989 312-8

Oil Circuit
(with ignition switch in “start”)
(prevents starting if oil is low)

Circuits

Demystification Guide 7 - 31
This page intentionally left blank

7 - 32 Demystification Guide
1987 - 1988 312-8

Information List
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

Demystification Guide 7 - 33
312-8 1987 - 1988

Wiring Diagram
Wiring Diagram

7 - 34 Demystification Guide
1987 - 1988 312-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 35
312-8 1987 - 1988

Charging Circuit
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)
Circuits

7 - 36 Demystification Guide
1987 - 1988 312-8

Oil Circuit
(with ignition switch in “start”)
(prevents starting if oil is low)

Circuits

Demystification Guide 7 - 37
This page intentionally left blank

7 - 38 Demystification Guide
1990 - 1991 312-H & 312-8

Information List
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

Demystification Guide 7 - 39
312-H & 312-8 1990 - 1991

Wiring Diagram
Wiring Diagram

7 - 40 Demystification Guide
312-H & 312-8 1990 - 1991

Spark Circuit
(ignition switch in “start”)

Charging Circuit
(ignition switch in “run”)

Gauge Circuit
Circuits

(ignition switch in “run”)

7 - 42 Demystification Guide
1990 - 1991 312-H & 312-8

Light Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 7 - 43
This page intentionally left blank

7 - 44 Demystification Guide
1986 312-A & 312-8

Information List
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

Demystification Guide 7 - 45
1986 312-A & 312-8

Starter Motor Circuit


(ignition switch in “start”)

Starter Motor Circuit


(ignition switch in “start” with low oil level)

Circuits

Demystification Guide 7 - 47
312-A & 312-8 1986

Spark Circuit
(ignition switch in “start”)

Charging Circuit
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)
Circuits

7 - 48 Demystification Guide
1986 312-A & 312-8

Light Circuit
(ignition switch in “run”)

Oil Light Test Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 7 - 49
This page intentionally left blank

7 - 50 Demystification Guide
312-H . . . 1992 314-8 . . . 1994 - 1997
314-H . . . 1993 - 1997
rev. 4-03

312-H Information List (1992)


314-H (1993 - 1997)
314-8 (1994 - 1997)
Wiring Diagram . . . . . . . . . . . . . . 7-54
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-55
Spark Circuits . . . . . . . . . . 7-55 & 7-56
Charging Circuit . . . . . . . . . . . . 7-56
Charging Circuit . . . . . . . . . . . 7-56

Demystification Guide 7 - 53
312-H . . . 1992 314-8 . . . 1994 - 1997
314-H . . . 1993 - 1997
Wiring Diagram rev. 4-03

7 - 54 Demystification Guide
312-H . . . 1992 314-8 . . . 1994 - 1997
314-H . . . 1993 - 1997
rev. 4-03 Starter Motor Circuit
(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Demystification Guide 7 - 55
312-H . . . 1992 314-8 . . . 1994 - 1997
314-H . . . 1993 - 1997
Spark Circuit rev. 4-03
(ignition switch in “run”)

Charging Circuit

Light Circuit
(ignition switch in “run”)

7 - 56 Demystification Guide
1999 - 2001 314-8

rev. 4-03

314-8 Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 7-56B, 7-56C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-56D
Spark Circuit . . . . . . . . . . . . . 7-56D
Run Forward (PTO “on”) . . . . . . . . . 7-56E
Run Reverse (PTO “on” NMIR override) . . . 7-56F
Charging Circuit . . . . . . . . . . . . 7-56G
Light Circuit . . . . . . . . . . . . . 7-56G
Low Oil Pressure Light Circuit . . . . . . 7-56G
Hourmeter . . . . . . . . . . . . . . 7-56H

Demystification Guide 7-56A


314-8 1999 - 2001

Wiring Diagram rev. 4-03

7 - 56B Demystification Guide


1999 - 2001 314-8

rev. 4-03 Wiring Diagram

Demystification Guide 7 - 56C


314-8 1999 - 2001

Starter Motor Circuit rev. 4-03


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

7 - 56D Demystification Guide


1999 - 2001 314-8

rev. 4-03 Run Forward


(PTO “on”)

Demystification Guide 7 - 56E


314-8 1999 - 2001

Run Reverse rev. 4-03


(PTO “on” NMIR override)

7 - 56F Demystification Guide


1999 - 2001 314-8

rev. 4-03 Charging Circuit

Light Circuit

Low Oil Pressure Light Circuit


(ignition switch in “run”)

Demystification Guide 7 - 56G


314-8 1999 - 2001

Hourmeter rev. 4-03


(ignition switch in “run” )

7 - 56H Demystification Guide


1992 - 1997 416-8
1992 - 1997 416-H
rev. 4-03

416-8 Information List (1992 - 1997)


416-H (1992 - 1997)

Wiring Diagram . . . . . . . . . . . . . . . 7-56


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-59
Spark Circuit . . . . . . . . . . . . . 7-59
Charging Circuit . . . . . . . . . . . . 7-59
Oil Pressure Switch Circuit . . . . . . . . 7-60
Light Test Circuit . . . . . . . . . . . . 7-60
Voltmeter Circuit . . . . . . . . . . . . 7-60

Demystification Guide 7 - 57
416-8 1992-1997
416-H 1992-1997

Wiring Diagram rev. 4-03

7 - 58 Demystification Guide
416-8 1992-1997
416-H 1992-1997
rev. 4-03 Starter Motor Circuit
(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Charging Circuit

Demystification Guide 7 - 59
416-8 1992-1997
416-H 1992-1997
Oil Pressure Switch Circuit rev. 4-03
(ignition switch in “run”)

Light Test Circuit


(ignition switch in “run”)

Voltmeter Circuit
(ignition switch in “run”)

7 - 60 Demystification Guide
1990 - 1991 416-H & 416-8

Information List
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

Demystification Guide 7 - 61
416-H & 416-8 1990 - 1991

Wiring Diagram
Wiring Diagram

7 - 62 Demystification Guide
1990 - 1991 416-H & 416-8

Starter Motor Circuit


(ignition switch in “start” )

Spark Circuit
(ignition switch in “start” or “run”)

Charging Circuit Circuits


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

Demystification Guide 7 - 63
416-H & 416-8 1990 - 1991

Light Circuit
(ignition switch in “run”)

Seat Light Circuit


(ignition switch in “start” or “run”)
(lights when operator is not in seat)

Parking Brake Light Circuit


(ignition switch in “run)
(only on with ignition in “run” when parking brake is engaged)
Circuits

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

7 - 64 Demystification Guide
1990 - 1991 416-H & 416-8

Neutral/Clutch Light Cirtcuit


(ignition switch in “start”)
(lights when motion lever is in gear or clutch is not depressed)

PTO Light Circuit


(ignition switch in “start”)
(lights when PTO is engaged)

Circuits
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

Demystification Guide 7 - 65
416-H & 416-8 1990 - 1991

Low Oil Pressure Light Circuit


(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)
Circuits

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

7 - 66 Demystification Guide
1989 416-8

Information List
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

Demystification Guide 7 - 67
416-8 1989

Wiring Diagram
Wiring Diagram

7 - 68 Demystification Guide
1989 416-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits
Charging Circuit

Demystification Guide 7 - 69
416-8 1989

Gauge Circuit
(ignition switch in “run”

Light Circuit
(ignition switch in “run”)
Circuits

7 - 70 Demystification Guide
1986 416-8

Information List
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

Demystification Guide 7 - 71
1986 416-8

Starter Motor Circuit


(ignition switch in “start”)

Starter Motor Circuit


(ignition switch in “start” with low oil level)

Circuits

Demystification Guide 7 - 73
416-8 1986

Spark Circuit
(ignition switch in “start”)

Charging Circuit
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)
Circuits

7 - 74 Demystification Guide
1986 416-8

Light Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 7 - 75
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7 - 76 Demystification Guide
1985 416-8

Information List
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

Demystification Guide 7 - 77
416-8 1985

Wiring Diagram
Wiring Diagram

7 - 78 Demystification Guide
1985 416-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits
Charging Circuit

Demystification Guide 7 - 79
416-8 1985

Gauge Circuit
(ignition switch in “run”)

Lights Circuit
(with engine running)
Circuits

7 - 80 Demystification Guide
1989 414-8

Information List
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

Demystification Guide 7 - 81
414-8 1989

Wiring Diagram
Wiring Diagram

7 - 82 Demystification Guide
1989 414-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits
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

Demystification Guide 7 - 83
414-8 1989

Light Circuit
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)
Circuits

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

7 - 84 Demystification Guide
1989 414-8

Oil Circuit
(with ignition switch in “start”)
(prevents starting if oil is low)

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

Demystification Guide 7 - 85
This page intentionally left blank

7 - 86 Demystification Guide
1987 - 1988 414-8 & 416-8

Information List
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

Demystification Guide 7 - 87
414-8 & 416-8 1987 - 1988

Wiring Diagram
Wiring Diagram

7 - 88 Demystification Guide
1987 - 1988 414-8 & 416-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 89
414-8 & 416-8 1987 - 1988

Charging Circuit

Gauge Circuit
(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)
Circuits

7 - 90 Demystification Guide
1986 414-8

Information List
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

Demystification Guide 7 - 91
414-8 1986

Wiring Diagram
Wiring Diagram

7 - 92 Demystification Guide
1986 414-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 93
414-8 1986

Charging Circuit
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)

Light Circuit
(ignition switch in “run”)
Circuits

7 - 94 Demystification Guide
1986 414-8

Oil Light Test Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 7 - 95
This page intentionally left blank

7 - 96 Demystification Guide
1990 520-H

Information List
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

Demystification Guide 7 - 105


520-H 1990

Wiring Diagram
Wiring Diagram

7 - 106 Demystification Guide


520-H 1990

Oil Pressure Light Circuit


(ignition switch in “run”

Hydrostat Temperature Light Circuit


(ignition switch in “run”)

Air Filter Indicator Light


Circuits

(ignition switch in “run”)

7 - 108 Demystification Guide


1990 520-H

Meter Light Circuit


(ignition switch in “run”)

Parking Brake Light Circuit


(parking brake applied)

Engine Temperature Light Circuit

Circuits
(ignition switch in “run”)

Demystification Guide 7 - 109


520-H 1990

Hourmeter Circuit
(ignition switch in “start”)

Headlight Circuit
(headlight “on”)

Fuel Gauge
(ignition switch in “start”)
Circuits

7 - 110 Demystification Guide


1990 520-H

Tachometer Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 111


This page intentionally left blank

7 - 112 Demystification Guide


1990 520-8

Information List
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

Demystification Guide 7 - 113


520-8 1990

Wiring Diagram
Wiring Diagram

7 - 114 Demystification Guide


1990 520-8

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Charging Circuit

Circuits

Demystification Guide 7 - 115


520-8 1990

Oil Pressure Light Circuit


(ignition switch in “run”

Air Filter Indicator Light


(ignition switch in “run”)
Circuits

Meter Light Circuit


(ignition switch in “run”)

7 - 116 Demystification Guide


1990 520-8

Parking Brake Light Circuit


(parking brake applied)

Engine Temperature Light Circuit


(ignition switch in “run”)

Circuits
Hourmeter Circuit
(ignition switch in “start”)

Demystification Guide 7 - 117


520-8 1990

Headlight Circuit
(headlight “on”)

Fuel Gauge Circuit


(ignition switch in “start”)
Circuits

7 - 118 Demystification Guide


1988 - 1989 518-H & 520-H

Information List
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 Temperature
Indicator Light Circuit . . . . . . . . . 7-125

Demystification Guide 7 - 119


518-H & 520-H 1988 - 1989

Wiring Diagram
Wiring Diagram

7 - 120 Demystification Guide


518-H & 520-H 1988 - 1989

Seat Light Circuit


(ignition switch in or “run”)

Oil Pressure Indicator Circuit


(ignition switch in “run”)

Air Filter Light Circuit


(ignition switch in “run”)
Circuits

7 - 122 Demystification Guide


1988 - 1989 518-H & 520-H

Hydrostat Temperature Light Circuit


(ignition switch in “start” or “run”)

Tachometer Circuit
(ignition switch in “run”)

Fuel Gauge Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 7 - 123


518-H & 520-H 1988 - 1989

Hourmeter Circuit
(ignition switch in “run”)

Voltmeter Circuit
(ignition switch in “run”)

Indicator Light Test Circuit


(ignition switch in “run”)
Circuits

7 - 124 Demystification Guide


1988 - 1989 518-H & 520-H

High Engine Temperature Indicator Light Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 7 - 125


This page intentionally left blank

7 - 126 Demystification Guide


1988 - 1989 516-H & 520-HC

Information List
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

Demystification Guide 7 - 127


516-H & 520-HC 1988 - 1989

Wiring Diagram
Wiring Diagram

7 - 128 Demystification Guide


516-H & 520-HC 1988 - 1989

Charging Circuit

AC
Bk Bk
B+
AC Fuse Battery
Alternator Regulator/Rectifier (30 amp) (12 Volt)

Oil Pressure Light Circuit


(ignition switch in “run”

Fuel Gauge
(ignition switch in “run”)
Circuits

7 - 130 Demystification Guide


1988 - 1989 516-H & 520-HC

Light Circuit
(ignition switch in “run”)

Meter Light Circuit


(ignition switch in “run”)

Circuits
Hourmeter Circuit
(ignition switch in “start”)

Demystification Guide 7 - 131


516-H & 520-HC 1988 - 1989

Tachometer Circuit
(ignition switch in “start”)
Circuits

7 - 132 Demystification Guide


1998 518xi

Information List
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

Demystification Guide 7 - 133


518xi 1998

Wiring Diagram
Wiring Diagram

7 - 134 Demystification Guide


1998 518xi

Starter Motor Circuit


(ignition switch in “start” position)

Spark Circuit
(ignition switch in “start” position)

Spark Circuit

Circuits
(ignition switch in “run” position, operator on)

Demystification Guide 7 - 135


518xi 1998

Spark Circuit
(ignition switch in “run” position, operator off)

Charging Circuit
(Ignition Switch in “run”)

Light Circuit
(ignition switch in “run/lights”)
Circuits

7 - 136 Demystification Guide


1998 518xi

Electric Clutch Circuit


(ignition switch in “start” or “run”)

Hourmeter Circuit
(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 7 - 137


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7 - 138 Demystification Guide


1999 - 2001 518xi

rev. 4-03

518xi Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 7-138B, 7-138C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-138E
Run Circuit (operator “on”) . . . . . . . . 7-138E
Clutch Circuit (forward PTO “on”) . . . . . 7-138F
Clutch Circuit (fwd/rev PTO “on”) . . . . . 7-138G
Charging Circuit . . . . . . . . . . . 7-138G
Light Circuit . . . . . . . . . . . . . 7-138H
Gauge Circuit . . . . . . . . . . . . 7-138H
Hourmeter Circuit . . . . . . . . . . . 7-138H

Demystification Guide 7-138A


518xi 1999 - 2001

Wiring Diagram rev. 4-03

7 - 138B Demystification Guide


1999 - 2001 518xi

rev. 4-03 Wiring Diagram

Demystification Guide 7 - 138C


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7 - 138D Demystification Guide


1999 - 2001 518xi

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Run Circuit
(operator “on”)

Demystification Guide 7 - 138E


518xi 1999 - 2001

Clutch Circuit rev. 4-03


(forward PTO “on” )

7 - 138F Demystification Guide


1999 - 2001 518xi

rev. 4-03 Clutch Circuit


(forward/reverse PTO “on” - after override switch activated)

Charging Circuit
(ignition switch in “run”)

Demystification Guide 7 - 138G


518xi 1999 - 2001

Light Circuit rev. 4-03


(ignition switch in “run/lights” )

Gauge Circuit
(ignition switch in “run” )

Hourmeter Circuit
(ignition switch in “run” )

7 - 138H Demystification Guide


1998 520xi & 522xi

Information List
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

Demystification Guide 7 - 139


520xi & 522xi 1998

Wiring Diagram
Wiring Diagram

7 - 140 Demystification Guide


1998 520xi & 522xi

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 141


520xi & 522xi 1998

Spark Circuit
(ignition switch in “run” position, operator on)

Spark Circuit
(ignition switch in “run” position, operator off)
Circuits

7 - 142 Demystification Guide


1998 520xi & 522xi

Charging Circuit
(ignition switch in “run”)

Electric Clutch
(ignition switch in “run”)

Light Circuit
(ignition switch in “run/lights”)

Circuits

Demystification Guide 7 - 143


520xi & 522xi 1998

Reverse Light Circuit


(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “run”)
Circuits

7 - 144 Demystification Guide


1998 520xi & 522xi

Gauge Circuit
(ignition switch in “run”)

Cruise Control Circuit


(ignition switch in “run”)

Park Light Circuit

Circuits
(ignition switch in “run”)

Demystification Guide 7 - 145


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7 - 146 Demystification Guide


1999 - 2001 520xi & 522xi

rev. 4-03

520xi & 522xi Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 7-146B, 7-146C


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-146E
Run Circuit (operator “on”) . . . . . . . . 7-146E
Clutch Circuit (forward PTO “on”) . . . . . 7-146F
Clutch Circuit (fwd/rev PTO “on”) . . . . . 7-146G
Charging Circuit . . . . . . . . . . . 7-146G
Light Circuit . . . . . . . . . . . . . 7-146H
Gauge Circuit . . . . . . . . . . . . 7-146H
Hourmeter Circuit . . . . . . . . . . . 7-146H

Demystification Guide 7-146A


520xi & 522xi 1999 - 2001

Wiring Diagram rev. 4-03

7 - 146B Demystification Guide


1999 - 2001 520xi & 522xi

rev. 4-03 Wiring Diagram

Demystification Guide 7 - 146C


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7 - 146D Demystification Guide


1999 - 2001 520xi & 522xi

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Run Circuit
(operator “on”)

Demystification Guide 7 - 146E


520xi & 522xi 1999 - 2001

Clutch Circuit rev. 4-03


(forward PTO “on” )

7 - 146F Demystification Guide


1999 - 2001 520xi & 522xi

rev. 4-03 Clutch Circuit


(forward/reverse PTO “on” - override switch activated)

Charging Circuit
(ignition switch in “run”)

Demystification Guide 7 - 146G


520xi & 522xi 1999 - 2001

Light Circuit rev. 4-03


(ignition switch in “run/lights” )

Gauge Circuit
(ignition switch in “run” )

Hourmeter Circuit
(ignition switch in “run” )

7 - 146H Demystification Guide


1998 520Lxi

Information List
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

Demystification Guide 7 - 149


520Lxi 1998

Wiring Diagram
Wiring Diagram

7 - 150 Demystification Guide


1998 520Lxi

Starter Motor Circuit


(ignition switch in “start”)

Spark Circuit
(ignition switch in “start”)

Circuits

Demystification Guide 7 - 151


520Lxi 1998

Spark Circuit
(ignition switch in “run”)

Charging Circuit
(ignition switch in “run”)
Circuits

Light Circuit
(ignition switch in “run/lights”)

7 - 152 Demystification Guide


1998 520Lxi

Electric Clutch Circuit


(ignition switch in “run”)

Gauge Circuit
(ignition switch in “run”)

Cruise Control Circuit


(ignition switch in “run”)

Circuits

Demystification Guide 7 - 153


520Lxi 1998

Hourmeter Circuit
(ignition switch in “run”)

Park Light Circuit


(ignition switch in “run”)

Reverse Light Circuit


Circuits

(ignition switch in “run”)

7 - 154 Demystification Guide


1999 - 2001 520Lxi

rev. 4-03

520Lxi Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 7-156, 7-156A


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-156B
Run Circuit (operator “on”) . . . . . . . . 7-156B
Clutch Circuit (forward PTO “on”) . . . . . 7-156C
Clutch Circuit (fwd/rev PTO “on”) . . . . . 7-156D
Charging Circuit . . . . . . . . . . . 7-156D
Light Circuit . . . . . . . . . . . . . 7-156E
Gauge Circuit . . . . . . . . . . . . 7-156E
Cruise Control Circuit . . . . . . . . . 7-156E
Hourmeter Circuit . . . . . . . . . . . 7-156F
Park Light Circuit . . . . . . . . . . . 7-156F

Demystification Guide 7-155


520Lxi 1999 - 2001

Wiring Diagram rev. 4-03

7 - 156 Demystification Guide


1999 - 2001 520Lxi

rev. 4-03 Wiring Diagram

Demystification Guide 7 - 156A


520Lxi 1999 - 2001

Starter Motor Circuit rev. 4-03


(ignition switch in “start” )

Run Circuit
(operator “on” )

7 - 156B Demystification Guide


1999 - 2001 520Lxi

rev. 4-03 Clutch Circuit


(forward PTO “on”)

Demystification Guide 7 - 156C


520Lxi 1999 - 2001

Clutch Circuit rev. 4-03


(forward / reverse PTO “on” - override switch activated )

Charging Circuit
(ignition switch in “run” )

7 - 156D Demystification Guide


1999 - 2001 520Lxi

rev. 4-03 Light Circuit


(ignition switch in “run/lights”)

Gauge Circuit
(ignition switch in “run”)

Cruise Control Circuit


(ignition switch in “run”)

Demystification Guide 7 - 156E


520Lxi 1999 - 2001

Hourmeter Circuit rev. 4-03


(ignition switch in “run”

Park Light Circuit


(ignition switch in “run” )

7 - 156F Demystification Guide


1998 523Dxi

Information List
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

Demystification Guide 7 - 157


523Dxi 1998

Wiring Diagram
Wiring Diagram

7 - 158 Demystification Guide


1998 523Dxi

Starter Motor Circuit


(ignition switch in “run”)

Injection Pump Circuit


(ignition switch in “run”)

Circuits
Injection Pump Circuit
(ignition switch in “start”)

Demystification Guide 7 - 159


523Dxi 1998

Charging Circuit
(ignition switch in “run”)

Glow Plug Circuit


(ignition switch in “on” )

Light Circuit
Circuits

(ignition switch in “run/lights”)

7 - 160 Demystification Guide


1998 523Dxi

Electric Clutch Circuit


(ignition switch in “run” or “start)

Gauge Circuit
(ignition switch in “run”)

Circuits

Demystification Guide 7 - 161


523Dxi 1998

Cruise Control Circuit


(ignition switch in “run”)

Park Light Circuit


(ignition switch in “run”)

Hourmeter Circuit
(ignition switch in “start” )
Circuits

7 - 162 Demystification Guide


1998 523Dxi

Reverse Light Circuit


(ignition switch in “run” )

Temperature Light Circuit


(ignition switch in “run” )

Circuits

Demystification Guide 7 - 163


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7 - 164 Demystification Guide


1999 - 2001 523Dxi

rev. 4-03

523Dxi Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . . 7-166, 7-167


Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . 7-169
Run Circuit (operator “on”) . . . . . . . . 7-169
Clutch Circuit (forward PTO “on”) . . . . . 7-170
Clutch Circuit (fwd/rev PTO “on”) . . . . . 7-171
Charging Circuit . . . . . . . . . . . 7-171
Light Circuit . . . . . . . . . . . . . 7-172
Gauge Circuit . . . . . . . . . . . . 7-172
Hourmeter Circuit . . . . . . . . . . . 7-172
Glow Plug Circuit . . . . . . . . . . . 7-173
Cruise Control Circuit . . . . . . . . . 7-173
Temperature Light Circuit . . . . . . . . 7-174
Park Light Circuit . . . . . . . . . . . 7-174

Demystification Guide 7-165


523Dxi 1999 - 2001

Wiring Diagram rev. 4-03

7 - 166 Demystification Guide


1999 - 2001 523Dxi

rev. 4-03 Wiring Diagram

Demystification Guide 7 - 167


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7 - 168 Demystification Guide


1999 - 2001 523Dxi

rev. 4-03 Starter Motor Circuit


(ignition switch in “start”)

Run Circuit
(operator “on”)

Demystification Guide 7 - 169


523Dxi 1999 - 2001

Clutch Circuit rev. 4-03


(forward PTO “on”

7 - 170 Demystification Guide


1999 - 2001 523Dxi

rev. 4-03 Clutch Circuit


(forward/reverse PTO “on” - override switch activated)

Charging Circuit
(ignition switch in “run”)

Demystification Guide 7 - 171


523Dxi 1999 - 2001

Light Circuit rev. 4-03


(ignition switch in “run/lights” )

Gauge Circuit
(ignition switch in “run” )

Hourmeter Circuit
(ignition switch in “run” )

7 - 172 Demystification Guide


1999 - 2001 523Dxi

rev. 4-03 Glow Plug Circuit


(ignition switch in“on”)

Cruise Control Circuit


(ignition switch in “run”)

Demystification Guide 7 - 173


523Dxi 1999 - 2001

Temperature Light Circuit rev. 4-03


(ignition switch in “run” )

Park Light Circuit


(ignition switch in “run” )

7 - 174 Demystification Guide


2001 TIMECUTTER Z

Information List
TimeCutter Z (2001)

Wiring Diagram (Briggs & Stratton) . . . . . . . . . . . . . . . . . . . 8-2


Wiring Diagram (Kohler). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Circuit Diagrams
Starter Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Charging Circuit (Kohler) . . . . . . . . . . . . . . . . . . . . 8-5
Charging Circuit (Briggs & Stratton). . . . . . . . . . . . . 8-5

Demystification Guide 8-1


TIMECUTTER Z 2001

Wiring Diagram
Wiring Diagram

8-2 Demystification Guide


2001 TIMECUTTER Z

Wiring Diagram

Wiring Diagram

Demystification Guide 8-3


TIMECUTTER Z 2001

Starter Motor Circuit


(ignition switch in “start”)

Starter Motor
Solenoid (energzized)
(energized)

S Pk
Re Re W
Bu
B
I
Battery Fuse
(30 amp) Ignition
Y
Switch
(in start)
PTO Brake Switch Neutral Switch Neutral Switch
Switch (parking brake (in neutral) (in neutral)
Kill Relay
(off) engaged) (energized)

Run Circuit
(PTO engaged)

Pk

Trigger
Fuel Solenoid module

(energized)
Ignition Coil

Dashed lines do not carry current

Bk

W
PTO Switch PTO Clutch
(pto on) (engaged)
I
Pk
Re Re Y
B Or
X
Battery Fuse Y Y Bk
(30 amp) Ignition
Or Vio
Switch
Circuits

(in run) Kill Relay


Seat Switch
(energized)
(operator on)

Brake Switch
(parking brake
disengaged)

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

8-4 Demystification Guide


2001 TIMECUTTER Z

Charging Circuit
(Kohler)

AC
Vio Vio Re Re
B+
AC A B
Fuse Fuse
Alternator Battery
Voltage Regulator (25 amp) Ignition (30 amp)
Switch
(in run)

Charging Circuit
(Briggs & Stratton)

Legend
Black Bk
Blue Bu
Brown Bn
Green Gn
Grey Gy
Orange Or
Pink Pk
Red Re

Circuits
Tan T
Violet Vio
White W
Yellow Y

Demystification Guide 8-5


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8-6 Demystification Guide


Riding Products
Demystification
Guide

Form No.