Toro wheelhorse Demystification Electical wiring diagrams for all WheelHorse tractors

TABLE OF CONTENTS

iDemystification Guide

REAR ENGINE RIDERSMODEL YEAR PAGE825 . . . . . . . . . . . . . . . . . . . . .

825 . . . . . . . . . . . . . . . . . . . . .

825 RER . . . . . . . . . . . . . . . . . .

825 RER . . . . . . . . . . . . . . . . . .

825 RER . . . . . . . . . . . . . . . . . .

825 RER . . . . . . . . . . . . . . . . . .

825 RER . . . . . . . . . . . . . . . . . .

10-32 & 12-32 . . . . . . . . . . . . . . .

832 & 10-32 & 12-32 . . . . . . . . . . . .

832 RER . . . . . . . . . . . . . . . . . .

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

112-C . . . . . . . . . . . . . . . . . . . .

11-32 & 13-32 . . . . . . . . . . . . . . .

12-32 RER . . . . . . . . . . . . . . . . .

1996 - 1998 . . . . . . . . . . . . . . 4-1

1989 - 1992 . . . . . . . . . . . . . . 4-5

1993 - 1995 (70040 & 70060) . . . . . 4-8A

1996 - 1997 (70040 & 70060) . . . . . 4-8G

1998 (70040) . . . . . . . . . . . . . 4-8G

1998 (70041 & 70060). . . . . . . . . 4-8M

1999 - 2001 . . . . . . . . . . . . . 4-9

1994 - 1995 . . . . . . . . . . . . 4-14A

1991 - 1992 . . . . . . . . . . . . . 4-15

1993 (70042) . . . . . . . . . . . . 4-18A

1988 . . . . . . . . . . . . . . . . 4-19

1988 . . . . . . . . . . . . . . . . 4-23

1996 - 1998 . . . . . . . . . . . . . 4-27

1999 - 2001 . . . . . . . . . . . . . 4-31

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

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

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

LAWN TRACTORSMODEL YEAR PAGE208-4SB, 211-5SB, 211-4 & 212-5 . . . . . .

210-5 & 210-H . . . . . . . . . . . . . . .

210-5 & 210-H . . . . . . . . . . . . . . .

212-H . . . . . . . . . . . . . . . . . . . .

210-5 & 210-H . . . . . . . . . . . . . . .

212-5 & 212-H . . . . . . . . . . . . . . .

212-5 & 212-H . . . . . . . . . . . . . . .

212-5 . . . . . . . . . . . . . . . . . . . .

212-6 . . . . . . . . . . . . . . . . . . . .

212-6 . . . . . . . . . . . . . . . . . . . .

10-32XL & 12-38XL . . . . . . . . . . . . .

12-32XL & 12-38HXL . . . . . . . . . . . .

1988 - 1989 . . . . . . . . . . . . . . 5-1

1990 . . . . . . . . . . . . . . . . . 5-1

1991 & 1993 - 1995 . . . . . . . . . 5-7

1992 . . . . . . . . . . . . . . . . . 5-7

1992 . . . . . . . . . . . . . . . . . 5-11

1991 . . . . . . . . . . . . . . . . . 5-15

1990 . . . . . . . . . . . . . . . . . 5-21

1992 . . . . . . . . . . . . . . . . . 5-27

1988 . . . . . . . . . . . . . . . . . 5-31

1987 . . . . . . . . . . . . . . . . . 5-37

1993 . . . . . . . . . . . . . . . . . 5-43

1993 - 1995 . . . . . . . . . . . . . 5-43

TABLE OF CONTENTS

ii Demystification Guide

LAWN TRACTORS (continued)MODEL YEAR PAGE13-38HXL . . . . . . . . . . . . . . . . .

13-38HXL & 15-44HXL . . . . . . . . . . .

XL . . . . . . . . . . . . . . . . . . . . . .

XL . . . . . . . . . . . . . . . . . . . . . .

252-H . . . . . . . . . . . . . . . . . . . .

257-H . . . . . . . . . . . . . . . . . . . .

1994 . . . . . . . . . . . . . . . . . 5-43

1995 . . . . . . . . . . . . . . . . . 5-47

1996 - 1998 . . . . . . . . . . . . . 5-47

1999 - 2001 . . . . . . . . . . . . 5-50A

1988 . . . . . . . . . . . . . . . . . 5-51

1988 . . . . . . . . . . . . . . . . . 5-57

YARD & GARDEN TRACTORSMODEL YEAR PAGE244 . . . . . . . . . . . . . . . . . . . . .

246-H . . . . . . . . . . . . . . . . . . . .

264-6 . . . . . . . . . . . . . . . . . . . .

264-H & 265-H . . . . . . . . . . . . . . .

265-6 . . . . . . . . . . . . . . . . . . . .

265-6 . . . . . . . . . . . . . . . . . . . .

265-H . . . . . . . . . . . . . . . . . . .

265-H . . . . . . . . . . . . . . . . . . .

266-H . . . . . . . . . . . . . . . . . . . .

266-H . . . . . . . . . . . . . . . . . . . .

266-H . . . . . . . . . . . . . . . . . . . .

267-H . . . . . . . . . . . . . . . . . . . .

268-H . . . . . . . . . . . . . . . . . . .

268-H . . . . . . . . . . . . . . . . . . .

269-H . . . . . . . . . . . . . . . . . . . .

270-H . . . . . . . . . . . . . . . . . . .

270-H . . . . . . . . . . . . . . . . . . .

270-H . . . . . . . . . . . . . . . . . . . .

1993 . . . . . . . . . . . . . . . . . 6-1

1992 . . . . . . . . . . . . . . . . . 6-1

1994 - 1995 . . . . . . . . . . . . . . 6-7

1994 - 1998 . . . . . . . . . . . . . 6-15

1996 - 1998 . . . . . . . . . . . . . 6-23

1999 - 2000 . . . . . . . . . . . . 6-29A

2000 - 2001 . . . . . . . . . . . . 6-30A

1999 . . . . . . . . . . . . . . . . 6-31A

1995 . . . . . . . . . . . . . . . . . 6-33

1994 . . . . . . . . . . . . . . . . . 6-41

2001 . . . . . . . . . . . . . . . . 6-48A

1996 - 1998 . . . . . . . . . . . . . 6-49

1999 . . . . . . . . . . . . . . . 6-57A

2000 - 2001 . . . . . . . . . . . . 6-58A

1996 - 1998 . . . . . . . . . . . . . 6-59

2001 . . . . . . . . . . . . . . . . 6-66A

2000 . . . . . . . . . . . . . . . . 6-67

1999 . . . . . . . . . . . . . . . . 6-77

GARDEN TRACTORSMODEL YEAR PAGE308-8 . . . . . . . . . . . . . . . . . . . .

310 . . . . . . . . . . . . . . . . . . . . .

310-8 . . . . . . . . . . . . . . . . . . . .

312-8 . . . . . . . . . . . . . . . . . . . .

1988 . . . . . . . . . . . . . . . . . 7-1

1989 - 1991 . . . . . . . . . . . . . 7-5

1988 . . . . . . . . . . . . . . . . . 7-11

1998 . . . . . . . . . . . . . . . . . 7-17

TABLE OF CONTENTS

iiiDemystification Guide

GARDEN TRACTORS (continued)MODEL YEAR PAGE312-8 . . . . . . . . . . . . . . . . . . . .

310-8 . . . . . . . . . . . . . . . . . . . .

312-8 . . . . . . . . . . . . . . . . . . .

314-8 . . . . . . . . . . . . . . . . . . . .

312-8 . . . . . . . . . . . . . . . . . . . .

312-8 . . . . . . . . . . . . . . . . . . . .

312-H & 312-8 . . . . . . . . . . . . . . . .

312-A & 312-8 . . . . . . . . . . . . . . .

312-H . . . . . . . . . . . . . . . . . . .

314-H . . . . . . . . . . . . . . . . . . .

314-8 . . . . . . . . . . . . . . . . . . . .

314-8 . . . . . . . . . . . . . . . . . . . .

416-8 . . . . . . . . . . . . . . . . . . . .

416-H . . . . . . . . . . . . . . . . . . .

416-H & 416-8 . . . . . . . . . . . . . . .

416-8 . . . . . . . . . . . . . . . . . . .

416-8 . . . . . . . . . . . . . . . . . . .

416-8 . . . . . . . . . . . . . . . . . . .

414-8 . . . . . . . . . . . . . . . . . . .

414-8 & 416-8 . . . . . . . . . . . . . . .

414-8 . . . . . . . . . . . . . . . . . . .

520-H . . . . . . . . . . . . . . . . . . .

520-H . . . . . . . . . . . . . . . . . . .

520-8 . . . . . . . . . . . . . . . . . . .

518-H & 520-H . . . . . . . . . . . . . . .

516-H & 520-HC . . . . . . . . . . . . . .

518-xi . . . . . . . . . . . . . . . . . . .

518-xi . . . . . . . . . . . . . . . . . . .

520-xi & 522-xi . . . . . . . . . . . . . . .

520-xi & 522-xi . . . . . . . . . . . . . . .

520L-xi . . . . . . . . . . . . . . . . . . .

520L-xi . . . . . . . . . . . . . . . . . . .

1999 - 2001 . . . . . . . . . . . . 7-22A

1992 - 1993 . . . . . . . . . . . . . 7-23

1992 - 1997 . . . . . . . . . . . . . 7-23

1993 . . . . . . . . . . . . . . . . . 7-23

1989 . . . . . . . . . . . . . . . . . 7-27

1987 - 1988 . . . . . . . . . . . . . 7-33

1990 - 1991 . . . . . . . . . . . . . 7-39

1986 . . . . . . . . . . . . . . . . . 7-45

1992 . . . . . . . . . . . . . . . . . 7-53

1993 - 1997 . . . . . . . . . . . . . 7-53

1994 - 1997 . . . . . . . . . . . . . 7-53

1999 - 2001 . . . . . . . . . . . . 7-56A

1992 - 1997 . . . . . . . . . . . . . 7-57

1992 - 1997 . . . . . . . . . . . . . 7-57

1990 - 1991 . . . . . . . . . . . . . 7-61

1989 . . . . . . . . . . . . . . . . . 7-67

1986 . . . . . . . . . . . . . . . . . 7-71

1985 . . . . . . . . . . . . . . . . . 7-77

1989 . . . . . . . . . . . . . . . . . 7-81

1987 - 1988 . . . . . . . . . . . . . 7-87

1986 . . . . . . . . . . . . . . . . . 7-91

1991 - 1997 . . . . . . . . . . . . . 7-97

1990 . . . . . . . . . . . . . . . . 7-105

1990 . . . . . . . . . . . . . . . . 7-113

1988 - 1989 . . . . . . . . . . . . 7-119

1988 - 1989 . . . . . . . . . . . . 7-127

1998 . . . . . . . . . . . . . . . . 7-133

1999 - 2001 . . . . . . . . . . . . 7-138A

1998 . . . . . . . . . . . . . . . . 7-139

1999 - 2001 . . . . . . . . . . . . 7-146A

1998 . . . . . . . . . . . . . . . . 7-149

1999 - 2001 . . . . . . . . . . . . 7-155

TABLE OF CONTENTS

iv Demystification Guide

GARDEN TRACTORS (continued)MODEL YEAR PAGE523Dxi . . . . . . . . . . . . . . . . . . .

523Dxi . . . . . . . . . . . . . . . . . . .

1998 . . . . . . . . . . . . . . . . 7-157

1999 - 2001. . . . . . . . . . . . . 7-165

ZERO TURN RIDERSMODEL YEAR PAGETimeCutter Z . . . . . . . . . . . . . . . . 2001 . . . . . . . . . . . . . . . . . 8-1

Avoid amputations and lacerations... When troubleshooting,you may encounter non- functioning safety systems. Alwayscheck to ensure the PTO is off, the transmission is in neutral,and that you and bystanders are clear before starting.

Avoid burns... Remove all jewelry before troubleshooting.The battery contains sufficient power to melt rings, bracelets,and chains causing serious burns in the process.

Avoid electric shock... While most voltages are relativelylow, the ignition coil secondary produces close to 20,000volts. Avoid contacting the spark plug wire while the engineis turning.

SAFETY INFO

Demystification Guide 1-1

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1-2 Demystification Guide

Table Of Contents

Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

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

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

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Demystification Guide 2 - 1

The components are listedalphabetically by noun, followedby any adjectives. if you havetrouble finding a component, usethe index at the front of theglossary section.

These three sections should beall you need to diagnoseproblems on individualcomponents.

The glossary containsinformation on virtually everyelectrical part used on Tororiding products.

You may see multiple partnumbers here if the informationis identical to other parts.

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2 - 2 Demystification Guide

Each product group has its ownsection including:- Info List- Parts Used- Wiring Diagrams- Circuit Diagrams

Drawing helps you quicklyidentify product sections.

Each product section has its own"table of contents" to keep thingssimple. The "Info List" is the first page of

each product section.

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The description is the name given tothe part in the book only.

All Toro electrical parts are called outin this section

The glossary page numbers refer tothe most recent part number

This part has been cross referenced,the old part number is listed here.

This is the most recent part numberavailable at press time.

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Each product sectionincludes the origionalwiring diagram.

The wiring diagramclosely represents thewiring harness and isvery useful indiagnosingcircuits.

short

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Each circuit is shownindividually. Componentsnot essential for circuitfunction are shown.not

Circuits are drawn suchthat current alwaysflows from left to right(the same way youread).

Additional information iscalled out beneath thetitle in parenthesis.

Solid lines indicatewires that carry current.

Components withinternal circuitry areenclosed with a dashedline.

Each component isnamed additionalinformation is suppliedbelow in parentheses.

and

Wire colors are calledout at each component(where you're mostlikely to use them!)

Each component (ieswitches, relays,solenoids) are drawn inthe position necessary tomake the circuit function.

Dashed lines representwires that are importantto the circuit but do notcarry current.

Each circuit diagrampage has a color codelegend.

Circuit Diagrams maketroubleshooting easyand fun because eachcircuit is drawn individually.Thay make troubleshootingopen circuits a snap.

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Wh Re Re Re Re Bk

10026

Fuse(25 amp)

Battery(12 volt)

A B

Ignition Switch(in "run")

Alternator(15 amp)

RegulatorRectifier

AC

ACB+

Always start by selecting the properscale. For instance, on this meter weselected the 25 volt scale.

Use the AC scales to measureunrectified voltage straight from analternator or from a wall outlet.

Battery voltage is always D.C.

If you measure from ground to groundor have an open circuit, your readingwill be 0.

Use D.C. scales to measure voltagesthat have been changed to D.C. by arectifier or diode.

The ohmmeter is powered by aninternal battery. Replace it if theneedle will not move full scale.

The integrity of the ignition coils andelectric clutches can often be checkedusing an ohmmeter.

Make sure your VOM reads 0 ohms(full scale right) when the leads aretouching together to insure accurateresistance readings.

Always disconnect components fromthe circuit when resistance checking.Otherwise you could get a falsereading. This switch should readinfinite ( ) resistance.

Do not use the ohmmeter to test Torointerlock modules! The battery currentcould damage the module.

2Checking Resistance

Checking Voltage

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Wh Re Re Re Re Bk

10026

Fuse(25 amp)

Battery(12 volt)

A B

Ignition Switch(in "run")

Alternator(15 amp)

RegulatorRectifier

AC

ACB+

Most ammeters can measure only .1amp. The current in Toro ridingproducts generally is from 3-90 amps.This is sufficient to destroy mostVOMs!

3What about checking current?

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244 electric clutch will not engage. (This time

we’ll solve it faster.)

Sample Problem: 244 electric clutch will not engage.

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Same Sample

Problem:

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Sample Problem: This 244 won't turn over. The customer parked it in the

garage and turned it off. When he tried to start it a week

later, he heard one click. After that , nothing would

happen when he turned the key.

We know it is a short circuit because we found the 25

amp fuse blown.

STEP 1. Interview the customer. Anyinformation we get will help isolate theproblem.

STEP 2. Isolate the suspect area.Notice what we did to the wiringdiagram at right.

Highlight the suspect area on a copyof the wiring diagram.

If the short was in the white wire, the30 amp fuse would have blown.

If the short was between the batteryand the 25 amp fuse, we would havemelted these wires.

If the pink wire or electric clutchshorted we would have blown the 15amp fuse. Eliminate all the black wires as

possibilities because they'reto go to ground!

supposed

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Conclusion:

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Glossary Contents(by description) Cross-

Part Referenced

Description Number From Page

Alternator, 15 Amp (Kohler) . . . . . . . . . KH10091 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Alternator, 20 Amp (with terminals - Onan) . 57-9440 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

92-0967

Clutch, Electric . . . . . . . . . . . . . . . . 78-6990 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

113997

92-6885

93-3160

115629

116277

119930

Coil, Ignition . . . . . . . . . . . . . . . . . 71-6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Coil, Ignition (Kohler) . . . . . . . . . . . . . KH10321 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Coil, Ignition . . . . . . . . . . . . . . . . . NN10730 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Condenser (capacitor) . . . . . . . . . . . . 59-1180 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Diode (replacement kit) . . . . . . . . . . . 78-1630 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Diode (with leads - Kohler) . . . . . . . . . . KH10315 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Gauge, Hourmeter . . . . . . . . . . . . . . 78-0020 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

113469

94-3723

Gauge, Tachometer . . . . . . . . . . . . . 113476 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

78-0060

Gauge, Voltmeter . . . . . . . . . . . . . . . 78-0030 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Horn . . . . . . . . . . . . . . . . . . . . . 116749 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Light, Oil Level Indicator . . . . . . . . . . . 117185 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Module, Interlock . . . . . . . . . . . . . . . 28-7890 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

95-0659

Module, Light Circuit . . . . . . . . . . . . . 114825 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

115207

79-2130

Module, Trigger (Onan) . . . . . . . . . . . 71-6380 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

NN10444

Regulator/Rectifier (20 amp - Onan) . . . . . 57-9430 . . . . . . . NN10261 . . . . . . . . . . . . . 3-15

Regulator/Rectifier (Kohler) . . . . . . . . . KH10215 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Relay . . . . . . . . . . . . . . . . . . . . . 48-4700 . . . . . . . . . 116397 . . . . . . . . . . . . . 3-16

116397

Rotor, Ignition . . . . . . . . . . . . . . . . . 71-6010 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Sender, Fuel Level . . . . . . . . . . . . . . 113358 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Solenoid . . . . . . . . . . . . . . . . . . . 47-1910 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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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

Switch, Neutral/Parking Brake . . . . . . . . . 116822 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Switch, Oil Pressure . . . . . . . . . . . . . NN10520 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33



Switch, PTO/Clutch . . . . . . . . . . . . . . 116716 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Switch, PTO/Clutch . . . . . . . . . . . . . . 111332 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Switch PTO/Clutch . . . . . . . . . . . . . . 116716 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Switch, PTO/Clutch . . . . . . . . . . . . . . 78-3030 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Switch, PTO/Clutch . . . . . . . . . . . . . . 78-9670 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Switch, Seat . . . . . . . . . . . . . . . . . . 116194 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Switch, Test . . . . . . . . . . . . . . . . . . 116752 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Switch, Test . . . . . . . . . . . . . . . . . . 116796 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Switch, Transmission Oil . . . . . . . . . . . 113193 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

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GLOSSARY


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



116749 . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . 3-11

116752 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Test . . . . . . . . . . . . . . . . . . . . 3-37

116796 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Test . . . . . . . . . . . . . . . . . . . . 3-38

116822 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Neutral/Parking Brake . . . . . . . . . . 3-32

117185 . . . . . . . . . . . . . . . . . . . . . . . . Light, Oil Level Indicator . . . . . . . . . . . . . 3-11

117292 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-29

119930 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6

23-0660 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Ignition . . . . . . . . . . . . . . . . . . 3-29

28-4250 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Neutral . . . . . . . . . . . . . . . . . . 3-31

28-7890 . . . . . . . . . . . . . . . . . . . . . . . . Module, Interlock . . . . . . . . . . . . . . . . . 3-12

38-1420 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Interlock . . . . . . . . . . . . . . . . . 3-30

40-8200 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Micro . . . . . . . . . . . . . . . . . . . 3-31

47-1910 . . . . . . . . 110167 . . . . . . . . . . . Solenoid . . . . . . . . . . . . . . . . . . . . . 3-18

48-4700 . . . . . . . . 116397 . . . . . . . . . . . Relay . . . . . . . . . . . . . . . . . . . . . . . 3-16

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GLOSSARY


Glossary Contents(by part number)

Cross-

Part Referenced

Number From Description Page

57-9430 . . . . . . . . NN10261 . . . . . . . . . . Regulator/Rectifier (20 amp - Onan) . . . . . . . 3-15

57-9440 . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 20 Amp (with terminals - Onan) . . . . 3-5

59-1180 . . . . . . . . . . . . . . . . . . . . . . . . Condenser (capacitor) . . . . . . . . . . . . . . . 3-8

62-2710 . . . . . . . . . . . . . . . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19

71-6000 . . . . . . . . . . . . . . . . . . . . . . . . Coil, Ignition . . . . . . . . . . . . . . . . . . . . 3-6

71-6010 . . . . . . . . . . . . . . . . . . . . . . . . Rotor, Ignition . . . . . . . . . . . . . . . . . . 3-17

71-6040 . . . . . . . . NN10268 . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19

71-6380 . . . . . . . . . . . . . . . . . . . . . . . . Module, Trigger (Onan) . . . . . . . . . . . . . 3-13

78-1630 . . . . . . . . . . . . . . . . . . . . . . . . Diode (replacement kit) . . . . . . . . . . . . . . 3-8

78-3030 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . 3-36

78-9670 . . . . . . . . . . . . . . . . . . . . . . . . Switch, PTO/Clutch . . . . . . . . . . . . . . . 3-36

78-6990 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6

79-2130 . . . . . . . . . . . . . . . . . . . . . . . . Module, Light Circuit . . . . . . . . . . . . . . . 3-12

79-6570 . . . . . . . . . . . . . . . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19

92-0967 . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 20 Amp (with terminals - Onan) . . . . 3-5

92-9844 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Light . . . . . . . . . . . . . . . . . . . 3-30

92-6885 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6

93-3160 . . . . . . . . . . . . . . . . . . . . . . . . Clutch, Electric . . . . . . . . . . . . . . . . . . . 3-6

94-3723 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Hourmeter . . . . . . . . . . . . . . . . . 3-9

95-0659 . . . . . . . . . . . . . . . . . . . . . . . . Module, Interlock . . . . . . . . . . . . . . . . 3-12

78-0060 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Tachometer . . . . . . . . . . . . . . . 3-10

78-0030 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Voltmeter . . . . . . . . . . . . . . . . 3-10

78-0020 . . . . . . . . . . . . . . . . . . . . . . . . Gauge, Hourmeter . . . . . . . . . . . . . . . . . 3-9

KH10091 . . . . . . . . . . . . . . . . . . . . . . . . Alternator, 15 Amp (Kohler) . . . . . . . . . . . . 3-5

KH10215 . . . . . . . . . . . . . . . . . . . . . . . Regulator/Rectifier (Kohler) . . . . . . . . . . . 3-15

KH10315 . . . . . . . . . . . . . . . . . . . . . . . . Diode (with leads - Kohler) . . . . . . . . . . . . 3-9

KH10321 . . . . . . . . . . . . . . . . . . . . . . . . Coil, Ignition (Kohler) . . . . . . . . . . . . . . . 3-7

NN10730 . . . . . . . . . . . . . . . . . . . . . . . . Coil, Ignition . . . . . . . . . . . . . . . . . . . . 3-7

KH10826 . . . . . . . . KH10138 . . . . . . . . . . Switch, Float (kit) (Kohler) . . . . . . . . . . . . 3-27

NN10274 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Engine Temperature . . . . . . . . . . . 3-26

NN10444 . . . . . . . . . . . . . . . . . . . . . . . . Module, Trigger (Onan) . . . . . . . . . . . . . 3-13

NN10520 . . . . . . . . . . . . . . . . . . . . . . . . Switch, Oil Pressure . . . . . . . . . . . . . . . 3-33

NN10739 . . . . . . . . . . . . . . . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-23



NN10889 . . . . . . . . NN10519 . . . . . . . . . . Starter, Electric . . . . . . . . . . . . . . . . . . 3-19

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GLOSSARY


Part Numbers

KH10091

Purpose

The stator generates 15 amps of alternating current.

How It Works

Whenever a magnet passes by a coil of wire on an iron core, electricity isproduced. The amount will depend on the thickness of the wire, thenumber of windings on each coil, the strength of the magnet, and thespeed at which the magnet is moving.

This particular coil has 18 poles to produce 15 amps at 28 or more voltsA.C. when the engine is running at 3600 rpm. The current produced isalternating current since no diode or rectifier is internal to the stator.

Note: This stator kit comes with mounting screws and terminals so that itwill retrofit to a number of different Kohler engines.

Testing

1. Remove the connector from the regulator rectifier. Measure the voltageacross the two A.C. Ieads on the alternator side of the connector withthe engine running at 3600 rpm. If voltage is less than 28 volts,proceed to the next step. Otherwise, stator is OK.

2. With the stator still disconnected and the engine off, measure theresistance across the two A.C. Ieads running to the stator. Theresistance should be .1 to .2 ohms. If not, replace the stator.

Part Numbers

57-9440, 92-0967

Purpose

This stator generates alternating current whenever the engine is running.

How It Works

Whenever a magnet passes by a coil of wire on an iron core, electricity isproduced. The amount will depend on the thickness of the wire, thenumber of windings on each coil, the strength of the magnet, and thespeed at which the magnet is moving.

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

Testing

1. Disconnect the alternator from the regulator/rectifier.

2. Measure the voltage across the A.C. terminals on the alternator side ofthe connector. The voltage should read as shown in Figure A.

3. Check for a short in the alternator by checking between either of theA.C. terminals and ground. If you do not get infinite resistance, replacethe alternator.

4. Check for an open alternator circuit by checking the resistance betweenthe two A.C. Ieads coming from the alternator. You should find theresistance as called out in Figure A. If you have not found the problem,test the regulator/rectifier, check for poor connections, and test therotor for poor magnetism.

Alternator

15 Amp

(Kohler)

Alternator

20 Amp(with terminals)

(Onan)

Stator Output* Stator Resistance

more than 28VDC @ 3600 rpm

.1 - .2 Ohms

*With regulator/rectifier disconnected

Item Specification

Battery 12-13 VDC

Stator Voltage Approximately 29 VDC@ 1800 RPM.Approximately 57 VDC@ 3600 RPM.

StatorResistance

0.10 + 0.19 Ohms

Figure A

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GLOSSARY


Part Numbers

78-6990, 113997, 92-6885, 93-3160, 115629,116277, 119930

Purpose

This clutch electrically controls the engagement and disengagement of thePTO pulley.

How It Works

The PTO clutch is composed of three major components: the field, theclutch plate, and the friction plate. The clutch plate always turns with theengine. The field is a coil of wire on an iron core which becomes anelectro-magnet when power is applied. The friction plate is the only piecethat can slide up and down on the crankshaft axis. It is normally springloaded so that it is not in contact with the clutch plate and is pressedagainst the brake material opposite the clutch. When power is applied, thefriction plate is drawn toward the clutch plate and the two rotate as one.

Testing

1. Disconnect the PTO clutch from the harness.

2. Connect a charged 12 volt battery to the clutch (polarity makes nodifference.) You should hear a click, the clutch should engage. If not,check the wiring and connectors leading into the field. If no problemscan be found, replace the field.

3. Resistance Check: The field should have a resistance as listed in thetable on the left.

Mechanical Adjustment: The gap between the clutch and friction platesshould be set at .012-.015 inches. Adjust by rotating the three nutsattached to the field.

Part Numbers

71-6000

Purpose

The coil boosts voltage from 12 volts to in excess of the 20,000 voltsnecessary to fire spark plugs.

How It Works

The coil is actually two separate coils of wire wrapped around a commoniron core. One coil, the primary, has fewer windings and thicker wire. Theother coil, the secondary, has many windings, and uses a much finer wire.With this arrangement, whenever a small voltage change is made to the pri-mary, a large voltage change results in the secondary. There is a catch,though. The coil can only produce large “spikes” in the secondary whenthere is a rapid change in the primary.

Therefore, the coil relies on the trigger module to produce this change byquickly opening the primary circuit at the precise moment the plugs aresupposed to fire.

Testing

1. Test the resistance of the primary winding by connecting an ohmmeteracross the “+” and “-” terminals on the coil. The resistance shouldread between 2.90 and 3.60 ohms.

2. Check the resistance of the secondary coil by connecting one VOMlead in each of the two spark plug wire cable holes. The resistanceshould read between 14,500 and 19,800 ohms.

3. If either of the above readings were out of specification, replace thecoil.

Clutch

Electric

Coil

Ignition

Clutch # Resistance

78-6990 2.5� ± 20%

115629 2.5� ± 20%

113997 2.2� ± 20%

116277 2.2� ± 20%

119930 2.2� ± 20%

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GLOSSARY


Part Numbers

KH10321

Purpose

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

How It Works

The coil is actually two separate coils of wire wrapped around a commoniron core. One coil, the primary, has fewer windings and thicker wire. Theother coil, the secondary, has many windings, and uses a much finer wire.With this arrangement, whenever a small voltage change is made to the pri-mary, a large voltage change results in the secondary. There is a catch,though. The coil can only produce large “spikes” in the secondary whenthere is a rapid change in the primary.

Therefore, the coil relies on the trigger module (packed inside the coil) toproduce this change by quickly opening the primary circuit at the precisemoment the tests are supposed to fire.

Testing

1. If no spark is present, verify that the flywheel magnet is OK by holding aflat bladed screwdriver about 1/4", from the magnet. It should bedrawn in. Also verify that the air gap is set at .012" to .016".

2. Test the resistance of the primary winding by connecting an ohmmeteracross the kill lead and the core. The resistance should read between1 and 1.3 ohms.

3. Check the resistance of the secondary coil by connecting one VOMlead to the spark plug wire and the other lead to the core. Theresistance should read between 7900 and 10,850 ohms.

4. If either of the above readings were out of specification, replace the coil.

Caution: Do NOT connect 12 volt to the ignition coil as it will damage thetrigger module.

Part Numbers

NN10730

Purpose

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

How It Works

The coil is actually two separate coils of wire wrapped around a commoniron core. One coil, the primary, has fewer windings and thicker wire. Theother coil, the secondary, has many windings and uses a much finer wire.With this arrangement, whenever a small voltage change is made to the pri-mary, a large voltage change results in the secondary. There is a catch,though. The coil can only produce large “spikes” in the secondary whenthere is a rapid change in the primary.

Therefore, the coil relies on the trigger module (packed inside the coil) toproduce this change by quickly opening the primary circuit at the precisemoment the plug is supposed to fire.

Testing

1. Verify that the air gap is .020".

2. Disconnect the kill wire and the spark plug connectors.

3. Check the primary coil resistance by measuring across the kill wire andthe core. The resistance should be 1.0 ohms.

4. Check the secondary coil resistance by placing on the spark plug cableand the core. You should get approximately 9,500 ohms. If either meas-urement is out of specification, replace the coil.

Coil

Ignition

(Kohler)

Coil

Ignition

Ignition Coil

Ignition Coil

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GLOSSARY


Part Numbers

59-1180

Purpose

The condenser (or capacitor) protects the trigger module.

How It Works

In order to get the spark plug to fire, about 20,000 volts must be present atthe plug. This is accomplished by using primary and secondary windingsin the coil. The primary is low voltage while the secondary is highervoltage. However, by themselves neither can produce 20,000 volts. Atrigger module is necessary to turn the primary on and off. By quicklyturning the primary off, a 20,000 volt “spike” is created in the secondarywhich fires the plug. What does this have to do with the condenser?

The turning on and off of the primary can be hard on some of thecomponents in the trigger. The condenser (capacitor) lowers the “spikes”seen in the primary and enhances trigger module life.

Testing

There is really no way to easily test this .3 micro farad, 200 volts A.C.capacitor. However, if you have experienced a trigger module failure,replacing the condenser is recommended because of the nominal cost.

Part Numbers

78-1630

Purpose

Converts alternating current into pulsating direct current and preventsbattery current from feeding back through the alternator.

How It Works

A diode is merely a one-way valve for electricity. Coming straight from thealternator, the current is half positive and half negative as shown indiagram “1" at left. The diode ”filters" out the negative half of the wave togive you the waveform you see in diagram “2". Why then does your VOMread a steady direct current when you check the output? The reason is thatthe meter is designed to read an average voltage when the current israpidly changing.

When you read 14 volts, keep in mind that the peak voltage is closer to 20volts. IMPORTANT: The silver band must be oriented as shown in diagram3. Otherwise, current will feed back through the alternator.

Testing

1. Disconnect the diode assembly from the wiring harness.

2. Check terminals “a” and “b” for continuity with a VOM. Note the result.

3. Reverse the VOM attached to “a” and “b” and again note theresults. You should have found continuity in one direction, but not theother. If not, replace the diode assembly.

Condenser

(capacitor)

Diode

(replacement kit)

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GLOSSARY


Part Numbers

KH10315

Purpose

This diode ensures that no battery voltage is applied to the ignition module.

How It Works

A diode is a “one-way valve", for current. It allows current to flow in onedirection, but not in the other. The specifications for the diode are IN4002GIGP 8532. The banded end should go to the harness (away from the coil.)

Testing

1. Remove the diode assembly from the harness.

2. Test the diode for continuity first one way, then the other. It shouldconduct in one direction, but not the other. If not, replace it.

Part Numbers

78-0040

Purpose

This gauge indicates fuel level.

How It Works

The meter movement moves proportional to the amount of resistanceprovided by the fuel level sender in the tank. The movement is dampenedto compensate for movement of the fuel in the tank.

Testing

1. With the gauge still connected to the harness, turn the key to the “run’’position.

2. Using a VOM set to a scale capable of reading 12 volts D.C., connectthe negative lead to ground to verify the conditions in the table.

If your voltage readings are different from above, check the fuel levelsender and the wiring. If all readings are correct, the gauge must bereplaced as it is not serviceable.

Part Numbers

78-0020, 113469, 94-3723

Purpose

The hourmeter keeps track of how long the key has been in the “run”position.

How It Works

Since a normal clock might be affected by variations in voltage andcurrent, the hourmeter is made up of a combination of an electric “winder”and a mechanical clock movement. When power is applied, a relay isenergized. The contact moves far enough to wind the movement. Themovement unwinds in about two seconds. As it finishes its rotation, itre-energizes the relay so that the cycle can start over.

Testing

Verify that 12 volts is present across the two terminals when the key is on. Ifso, and the meter is not running, replace the meter. It is a permanentlysealed unit.

Diode

(with leads)

(Kohler)

Gauge

Fuel

Gauge

Hourmeter

Diode Heat ShrinkTubing

To Kill SwitchOr Off PositionOr Key switch Coated

FiberglassSleeving

Terminal

Terminal Reading

I 12 volts*

G 0 volts

S 2.5 volts tank full

S 7.5 volts tank empty

*All voltage readings should be within 20%

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Part Numbers

113476, 78-0060

Purpose

This gauge indicates engine speed.

How It Works

The tachometer measures the number of rotations of the crankshaft bymonitoring the B+ terminal of the voltage regulator. The alternating currentproduced by the alternator allows the circuitry to “count” the revolutions,then deflect the meter movement appropriately. Keep in mind that thistachometer does not key off the ignition coil, but rather the charging coil.

Testing

1. With the tachometer still connected to the harness, start the engine.

2. Using a known good electronic tachometer or “Vibratach”, determinethe actual engine speed. Compare it to the tachometer in theequipment.

3. If they are not within 10%, check for loose connections, a bad stator, orflywheel magnet.

4. If no problems are found, the gauge must be replaced as it is notserviceable.

Part Numbers

78-0030

Purpose

This gauge indicates the voltage across the battery.

How It Works

The meter movement moves proportional to the voltage level across thetwo terminals of the battery. This is accomplished by placing a resistor inparallel with the meter movement.

Testing

1. With the meter still connected to the harness, turn the key to the “run”position.

2. Verify the conditions in the table. If they are not met, replace thevoltmeter, as it is not serviceable.

Gauge

Tachometer

Gauge

Voltmeter

Terminal Condition

I 12 volts DC ± 20%

G 0 volts DC ± 20%

Table 1

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Part Numbers

116749

Purpose

The horn produces a loud tone to let the operator know that the engine isoverheating.

How It Works

When 12 volts is applied to the two terminals, a plate inside the hornoscillates which produces a loud, audible tone.

Testing

1. Disconnect the horn from the wiring harness.

2. Apply 12 volts to the two terminals on the backside of the horn. (It doesnot matter which way you connect the wires.) If the horn does notsound, replace the horn since it is not serviceable.

Part Numbers

117185

Purpose

This simple incandescent bulb is used to indicate to the operator that a lowoil level has been detected during starting.

How It Works

The filament glows when 12 volts is applied. There is no polarity althoughthe lamp comes with a ground ring and male terminal already attached.

Testing

1. Disconnect the lamp from the wiring harness.

2. Apply 12 volts from a known good source. If the lamp does not light,replace it.

Horn

Light

0il Level Indicator

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Part Numbers

28-7890, 95-0659

Purpose

The module monitors the status of the safety switches and prevents sparkif an “unsafe” condition is encountered.

How It Works

The module “steals” a small amount of current from the ignition coilprimary (through the kill wire.) It sends current through the orange andyellow wires to monitor the status of the safety switches. If EITHER of thefollowing two conditions are met, the module will allow spark (by notgrounding the kill wire).

1. There is continuity from the orange to the yellow wire through thetransmission and deck switches.

2. The orange wire is grounded through the seat switch.

If both circuits are open, the module “connects” the light blue kill wire toground. Note: There is no time delay in this module.

Testing

Caution: When using jumpers to simulate a safe condition, be sure thatthe transmission and PTO lever are disengaged before starting.

The following steps assume your unit does not produce spark. (If the unitruns in an unsafe mode, check to ensure that the module has a goodground to the chassis and that the kill wire is not broken.)

1. Disconnect the module from the wiring harness. Jump from the lightblue wire on the module, to the light blue wire on the harness. Thisallows the module to control spark. Verify now that the unit will notproduce spark when attempting to start.

2. Simulate a safe deck and transmission circuit by jumping across theyellow and orange wires. The unit should now produce spark.

3. Disconnect the jumper from step 2 and simulate an operator on theseat by connecting a jumper from the orange wire to the chassis. Theunit should produce spark. If the module failed any of these threetests, it should be replaced.

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

Module

Interlock

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Part Numbers

114825, 115207, 79-2130

Purpose

The circuit board drives the dash indictor lights. It monitors the status ofswitches and does not affect normal operation.

How It Works

The light circuit module (printed circuit board) uses an array of resistor anddiodes to get each of the light emitting diodes (LEDs) to light under theright conditions. While the board itself is complex, understanding theconditions needed to light the LEDs is not difficult. It is just a matter ofeither grounding or applying 12 volts D.C. to the appropriate terminals onthe edge of the card.

Testing

Use the circuit diagrams in the back half of this book to troubleshoot themodule.

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

Part Numbers

71-6380, NN10444

Purpose

The ignition control opens the primary circuit as the magnet passes by toinduce spark at the proper time.

How It Works

This engine is equipped with an electronic battery ignition system. Bothspark plugs fire simultaneously, thus the need for a distributor iseliminated. The electronic ignition module is located on the engine gearcover behind the flywheel. The module receives a timing signal frommagnets within the trigger ring which rotates with the engine crankshaft(Figure 1). If the electronic ignition is suspected of malfunctioning, proceedas follows.

Testing

1. Check all electrical connections to be sure they are clean and tight. Ifall connections are good and wiring is intact, go to Step 2.

Warning: The electronic ignition will deliver full voltage to the sparkplugs even when rotated by hand. Care should be taken to avoid anelectrical shock.

Warning: Failure to remove spark plugs before turning the engineover may result in engine starting and may cause severe personalinjury.

Warning: Failure to ground spark tester away from the spark plughole may result in ignition of cylinder gases and may cause severepersonal injury.

Module

Trigger

(Onan)

TriggerRing

IgnitionModule

Figure 1

Module

Light Circuit

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

Caution: Never put jumper lead to the coil negative terminal. This willcause failure of the electronic ignition module.

3. Connect a jumper lead directly from the positive battery terminal to thepositive (+) coil terminal (smaller diameter of the two threaded posts).Crank the engine over while watching for spark. If spark occurs, theproblem is in the low oil pressure cut out switch (if equipped) orrelating wiring, the lubricating system (low oil pressure), or in the othercircuitry bringing voltage to the coil. If no spark occurs, go to step 4.

4 . Refer to IGNITION COIL section to test coil for proper resistance. If coilchecks out good, go to step 5.

5. Connect positive side of voltmeter to negative (-) coil terminal (largerdiameter of the two threaded posts) and negative side of voltmeter toengine ground. Turn the key on and rotate flywheel slowly by handwhile observing voltmeter. Voltage should switch between batteryvoltage and 1-1.5 for each revolution. If voltage does not switchproperly, replace ignition module.

Caution: Never put B+ lead to the coil negative terminal. This willcause failure of the electronic ignition module.

6. Install spark plugs and wires. If ignition module is being replaced, besure to connect red lead from new ignition module to positive (+)terminal of coil, black lead from module to negative (-) terminal of coil.

FlywheelTimingMark

Blower HousingTiming Marks

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Part Numbers

57-9430

Purpose

The regulator/rectifier prevents battery boiling by shutting off the current sothat the battery sees only positive current and voltage (see Figure A).

How It Works

The voltage level across the battery is very near constant because thebattery has very low impedance (Figure B). This regulator/rectifier, likemany others, must be connected to the battery to function. Once thevoltage level of the battery has surpassed 13.6 to 14.5 volts, the voltageregulator shuts off all current and no charging takes place (Figure C).When the voltage again drops below the specified level, the voltageregulator turns the current back on at the rated amperage of the alternator.

Testing

Check the battery before checking the regulator/rectifier for properoperation. The battery must be fully charged and in good condition for theregulator/rectifier to operate properly.

Refer to Table 1. Start the engine and check the regulator/rectifier output bymeasuring the battery voltage at the battery terminals with a voltmeter. Ifvoltage is within that specified in Table 1, the regulator/rectifier is good. Ifthe DC voltage is greater than that specified in Table 1, replace regulator/rectifier. If D.C. voltage is less than that specified, shut the engine off.Examine all wires for loose, corroded, broken connections, short circuits,etc. Check fuses. Make certain all circuits are complete from regulator/rectifier B+ terminal to the battery positive terminal; and the batterynegative terminal is properly grounded. Start the engine and check D.C.voltage again. If the D.C. voltage is still less than that specified, test thealternator. If the stator is good, replace the regulator/rectifier.

Part Numbers

KH10215

Purpose

The regulator/rectifier prevents battery boiling by shutting off the currentwhen the battery has reached 14.7 volts.

How It Works

The voltage regulator rectifies the current so that the battery sees onlypositive current and voltage (see Figure A). The voltage level across thebattery is very near constant because the battery has very low impedance(Figure B). This regulator/rectifier, like many others, must be connected tothe battery to function. Once the voltage level of the battery has surpassed14.7 volts, the voltage regulator shuts off all current and no charging takesplace (figure C). When the voltage again drops below the specified level,the voltage regulator turns the current back on at the rated amperage ofthe alternator.

Regulator/Rectifier

(20 Amp)

(Onan)

Regulator/Rectifier

(Kohler)

Test Reading

Primary coil resistance 1.0 Ohm

Secondary coil resistance 9.5 K Ohms

Battery voltage 12 to 13 Volts DC

2.5 amp stator resistance 0.33 Ohms

20 amp stator resistance Appriximately 29 volts AC @ 1800 RPMApproximately 57 volts AC @ 3600 RPM

20 amp stator resistance 0.10 to 0.19 Ohms

Regulator/rectifier output 13.6 to 14.7 volts

Table 1

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Testing

1. Make sure that the battery is fully charged. (The voltage across thebattery terminals should be 13.6 volts or more.)

2. Insert an ammeter (capable of measuring 20 amps) in series with theB+ lead coming from the voltage regulator.

3. Observe the charging current with the engine running at 3600 rpm (itshould be low).

4. Attach a 2.5 ohm, 100 watt resistor across the battery terminals tosimulate a load. If the reading on the ammeter goes up, the chargingsystem is OK, otherwise proceed to the next step.

5. Remove the connector from the rectifier/regulator. With the enginerunning at 3600 rpm, measure the voltage across the stator terminals.If the voltage is greater than 28 volts, the stator is OK and the regulatoris bad. Otherwise, see the alternator section for further testinginformation.

BATTERY CHARGES CONTINUOUSLY AT HIGH RATE: Measure thevoltage from B+ to ground using a VOM on D.C. scale. If the voltage ismore than 14.7 volts, replace the regulator.

Part Numbers

48-4700, 116397

Purpose

The relay monitors current in one circuit. If current is present, it flips anSPDT switch to the other position.

How It Works

A relay is actually two simpler parts working together.

1. Coil: Terminals 85 and 86 are connected to a coil. Applying 12 volts tothese terminals energizes the coil turning it into an electromagnet.

2. SPDT Switch: Terminals 30, 87, and 87a are all actually part of a singlepole, double throw switch. Terminal 30 is the common lead. The switchis spring loaded so that 30 and 87a are closed when the coil is notenergized. When the coil is energized, the switch is “thrown” and 30and 87 connected. For a simpler explanation, see below:

Testing

1. Disconnect the relay from the circuit.

2. Verify the “not energized’’ conditions above with a VOM.

3. Apply 12 volts to terminals 85 and 86 to energize the coil.

4. Verify the “energized” conditions above with a VOM.

5. Replace relay if any of the conditions in Table 1 were not met.

Relay

Coil Terminals30 + 87

Terminals30 + 87a

Not

Energized

Open Closed

Energized Closed Open

Table 1

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Part Numbers

71-6010

Purpose

It is part of the system that tells the coil when to fire.

How It Works

Any time a magnet passes by a coil of wire on an iron core, electricity isproduced. The “ignition rotor” is simply two magnets molded into a plastichousing which properly positions it on the crankshaft. As the crankshaftrotates, the magnets pass by the “ignition control” which houses a coil andthe “trigger” circuitry. This generates the small amount of electricityneeded to run the ignition control. In addition, the orientation of themagnets on the crankshaft provides “timing” for the engine.

Testing

Two simple tests can be performed with a flat bladed screwdriver:

1. Pinch the handle end of a flat bladed screwdriver between your thumband forefinger so that the screwdriver dangles. Bring the flat part ofthe blade to within 1/4 inch of one of the magnets. The screwdrivershould be drawn toward the rotor.

2. With the rotor removed, each magnet should be able to support theweight of the rotor when hung from the blade of a flat bladedscrewdriver. If the rotor fails either test, the magnet has lost itsstrength and should be replaced.

Part Numbers

113358

Purpose

This electrical component monitors the level of fuel in the tank.

How It Works

A float is attached to a pivoting lever. This lever rotates a potentiometer (adevice much like the volume control on your stereo) to vary the resistance.The resistance will be 25 to 200 ohms, plus or minus 20%.

Testing

1. Before removing the unit, verify that the float has not sunk. Replace thefloat if it has sunk.

2. Disconnect the sender unit from the wiring harness, and remove it fromthe tank.

3. Verify that it matches the resistances in the table.

Rotor

Ignition

Sender

Fuel Level

Float Position Resistance

Full 25� ± 20%

Empty 200� ± 20%

Table 1

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Part Numbers

47-1910

Purpose

The solenoid’s purpose is simply to protect the ignition switch from thehigh current drawn by the starter motor.

How It Works

The solenoid has really only two parts. One is a coil of wire wrappedaround an iron core. Whenever 12 volts is applied to the coil, it becomes amagnet. The other part is a steel bar type switch. Because it is made ofsteel it can easily handle the high current loads produced by the startermotor. So how does it protect the ignition switch? When 12 volts is appliedto the coil, it becomes an electromagnet. This quickly pulls the steel bartoward the contacts and closes the switch. When power is removed fromthe coil, the spring loaded bar returns to its “normally open” position. Note:The solenoid closes and opens the switch very quickly. This minimizes the“arcing” that can damage other type switches.

Testing

1. Disconnect the solenoid from the wiring harness.

2. Check to ensure that terminals “c” and “d” are not continuous.

3. Apply a 12 volt power source to “a” and “b” terminals. You should beable to hear the solenoid switch “click” when you make the connection.

4. Verify that the switch has closed by making sure that terminals “c” and“d” are closed when power is applied to terminals “a” and “b”.

Solenoid

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Part Numbers

71-6040, NN10889, 62-2710, 79-6570

Purpose

The starter motor pushes the starter pinion into engagement with theflywheel, then rotates the starter motor to start the engine.

How It Works

The starter motor is really just a collection of simple parts:

FIELD: A coil of wire on an iron core that becomes an electromagnet whencurrent is applied. It surrounds the armature.

ARMATURE: Eight coils of wire on an iron core that becomeelectromagnets when current is applied. The end of each coil isconnected to a section of the commutator. The armature rotates.

COMMUTATOR: The commutator is the connection point between thebrushes and the coils in the armature. The sections are divided such thatonly one armature coil is “on” at a time. This sets the armature to rotatingbecause the electromagnetic field in the field coil will oppose the one in thearmature.

BRUSHES: Supply power to the commutator.

Starter

Electric

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Testing

(USE TESTING SECTION FROM ONAN MANUAL, PAGES 9-3 THROUGH9-5.)

Inspect the starter components for mechanical defects before testing forgrounds or shorts.

Testing Armature for Grounds: Connect 1 lead of an ohmmeter to thearmature shaft or core. Touch the other ohmmeter lead to each of thecommutator bars in turn (Figure 1). A low ohmmeter reading indicates agrounded armature. Replace grounded armature.

Testing Armature for an Open Circuit: Using an ohmmeter, check forcontinuity between the commutator segments. If there is no continuity(high resistance), the segments are open and armature must be replaced.

Testing Armature for a Short Circuit: Use growler for locating shorts in thearmature (Figure 2). Place armature in growler and hold a thin steel blade(e.g. hacksaw blade) parallel to the core and just above it while slowlyrotating armature in growler. A shorted armature will cause the blade tovibrate and be attracted to the core. If the armature is shorted, replacewith a new one.

Commutator Inspection: If the commutator is dirty or discolored, clean withnumber 00 to 000 commutator paper. Blow grit out of armature aftercleaning.

If the commutator is scored, rough, or worn, turn it down in a lathe.

Field Coil: Use an ohmmeter to check for continuity between brushes. Ifthere is not continuity, the field coil is open and must be replaced. With thefield coil mounted in the frame, check for continuity between the field coiland frame. Replace frame assembly if there is continuity.

Brushes: Clean around brushes and holders, wiping off all brush dust anddirt. If brushes are worn shorter than .4528 inch (11.5 mm), replace them(Figure 3).

Check for shorts between positive side of brush holder and brush holderbase. If there is continuity, replace holder assembly. Check for freemovement of brushes. All brushes should move freely in the brush holders.

Commutator Bars

Figure 1

HacksawBlade

Growler

Figure 2

.4528 inch(11.5 mm)

Brushes

Wear Limit

Figure 3

Starter

Electric

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Overrunning Clutch: Inspect pinion and spline teeth for wear or damage.

If pinion gear is worn or damaged, inspect flywheel ring gear also. Rotatepinion. It should turn free when turned in one direction and locked whenturned in the opposite direction.

CAUTION: Do not clean overrunning clutch in solvent or liquid cleaningsolution. Washing the clutch will cause the grease to leak out.

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

Bushings: If either the front or rear bushing show signs of wear ordamage, replace them. Bushing and rear bracket are replaced as anassembly. Check armature shaft thrust gap if rear bracket is replaced.

Remove front bushing by tapping bushing from inside with a 6/16 inch tap.Do not remove cap from front bracket. Thread cap screw, same size astap, into bushing. Using a slide hammer, remove bushing from frontbracket. Press new bushing into front bracket. Use care not to distortinside diameter of bushing.

Figure 4

Overrunning

Clutch

Solenoid

Terminal “S” Terminal “B”

Terminal “M”

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How It Works


FRAME: Houses the permanent magnets which produce a magnetic field.This field surrounds the armature and causes it to rotate.

ARMATURE: Eight coils of wire on an iron core that becomeelectromagnets when current is applied. The end of each coil is connectedto a section of the commutator. Thearmature rotates.



Troubleshooting Guide

PROBLEM POSSIBLE FAULT CORRECTION

STARTERFAILS

TO ENERGIZE

WIRING1. Clean corroded connections and tighten loose connections.2. Replace wires in poor condition and with frayed or broken

insulation.

STARTER SWITCHOR SOLENOID

Bypass the switch or solenoid with a jumper wire. If startercranks normally, replace the faulty parts.

BATTERY Check specific gravity of battery. If low, recharge or replacebattery as necessary.

STARTERENERGIZESBUT TURNS

SLOWLY

BATTERY Check specific gravity of battery. If low, recharge or replacebattery as necessary.

BRUSHESCheck for excessively dirty or worn brushes and commutator.Clean using a coarse cloth (not emery paper). Replace brushesif excessively or unevenly worn.

TRANSMISSIONOR

ENGINE

Make sure the clutch or transmission is disengaged or placed inneutral. This is especially important on equipment withhydrostatic drive. The transmission must be exactly in neutral toprevent resistance which would keep the engine from starting.Check for seized engine components such as bearings,connecting rod, and piston.

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Part Numbers

NN10739

Purpose

The starter motor pushes the starter pinion into engagement with theflywheel, then rotates the starter motor to start the engine.

How It Works


FIELD: A coil of wire on an iron core that becomes an electromagnet whencurrent is applied. It surrounds the armature.

ARMATURE: Eight coils of wire on an iron core that becomeelectromagnets when current is applied. The end of each coil is connectedto a section of the commutator. The armature rotates.



Testing

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

Starter

Electric

Solenoid Mounting Nut

ThroughBoltsMagnet Switch

Mounting Nuts

Starter DriveHousing

ConnectingLead

Brush

Insulator

Brush Holder

Brush Spring

End Frame

Starter Body

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SOLENOID

Inspection/Service

Attraction Test: Connect a jumper lead from the ST terminal to the positiveterminal of a 6 volt battery. Connect a jumper lead between the C terminaland negative terminal of a 6 volt battery. If the plunger pulls in and holdsstrongly, the solenoid is good. If it doesn’t, replace the solenoid.

Retention Test: Connect a jumper lead from the ST terminal to the positiveterminal of a 6 volt battery. Connect a jumper lead between the solenoidbody and negative terminal of a 6 volt battery. Push the plunger in andrelease it. If the plunger stays in, the solenoid is good. If it doesn’t, replacethe solenoid.

ARMATURE

Inspection/Service

Continuity Between Segments: Refer to Figure 1. Check for continuitybetween the segments of the commutator. If there is no continuity, replacethe armature.

Armature Coil Core and Commutator Continuity: Refer to Figure 2.Check for no continuity between the commutator and the armature coilcore. If continuity exists, replace the armature.

Armature’s Shaft and Commutator Continuity: Refer to Figure 3. Checkfor no continuity between the commutator and armature’s shaft. Ifcontinuity exists, replace the armature.

Armature Shaft and Bushing Clearance: Refer to Figures 4 and 5.Measure the bushing inside diameter in the starter drive housing and endframe. Measure the armature shaft outside diameter on the pinion side andcommutator side. If the clearance is not as specified in Table 1, replace thebushing.

Starter

Electric(continued)

Figure 5

Figure 4

Figure 3

Figure 2

Figure 1

CommutatorSegments

ArmatureCoil Core

Commutator

CommutatorArmature

Shaft

Bushing

Starter DriveHousing

Pinion side ofArmature Shaft

Electrical System Factory Min. SpecificationMax.

Allowable Limit

Commutator O.D. 1.102(28.0)

1.063(27.0)

Difference ofCommutator O.D.’s

Less than 0.00027(Less than 0.05)

0.016(0.4)

Armature’s Shaft toBushing Clearance

0.0008(0.02)

0.0027(0.07)

0.0079(0.20)

Mica Undercut 0.0177(0.45)

0.0295(0.75)

0.008(0.2)

Table 1

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COMMUTATOR AND MICA

Inspection/Service

Commutator: Refer to Figure 6. Clean commutator surface withsandpaper. Measure the commutator outside diameter at several points. Ifthe difference of the outside diameter is not as specified in Table 1, correctthe commutator on a lathe to factory specifications. If the minimum outsidediameter is less than the allowable limit, replace the armature.

Mica: Refer to Figure 7. Measure the mica undercut depth. If the undercutis less than that specified in Table 1, use a saw blade to increase the depthand then chamfer the segment edges.

OVERRUNNING CLUTCH

Inspection/Service

CAUTION: Do not clean overrunning clutch in liquid cleaning solutions. asit will damage the starter.

Refer to Figure 8. Inspect the pinion and spline teeth for wear anddamage. If wear or damage exists, replace pinion. Rotate the pinionclockwise and see if it turns freely. Replace pinion if it doesn’t. Rotate thepinion counterclockwise to see if it locks. Replace pinion if it doesn’t.

BRUSHES

Inspection/Service

Refer to Figure 9. Clean the brush face with sandpaper. Measure the brushlength. If the length is not as specified in Table 1, replace the starter bodyand brush holder.

STARTER BODY

Inspection/Service

Refer to Figure 10. Check for continuity across the starter body andbrushes. There are four brushes in the starter body. The two that are notgrounded are 180° apart starting at the terminal which connects to thesolenoid. The two that are grounded are located 90° from the non-grounded terminals. If continuity exists at the non-grounded terminals,replace the starter body. If continuity does not exist at the groundedterminals, replace the starter body.

Assembly

Assemble the starter in the reverse of disassembly, but apply grease to theparts indicated.

• solenoid joint

• drive lever

• pinion gear teeth

• armature shaft

Figure 10

Figure 8

Figure 7

Figure 6

Figure 9

Commutator

Micaundercut

depth

SegmentEdges

SawBlade

Pinion

Brush

Starterbody

Brush

Non-GroundedTerminal

GroundedTerminal(hidden)

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Part Numbers

114270

Purpose

This switch monitors vacuum in the air cleaner box to determine if the aircleaner is plugged.

How It Works

The switch is turned on by a slight vacuum applied to the inlet. This isaccomplished by a small electrical contact that is connected to adiaphragm inside the switch. Note: Switch comes with one femalecrimp-on connector.

Testing

1. Verify that the hose is connected to the “vacuum” side of the switch.(Notice that there is also a pressure side.)

2. Disconnect the wiring harness and the hose.

3. Verify that there is no continuity across the two terminals.

4. Connect a vacuum gauge to the switch and evacuate slightly. Thereshould be continuity.

Part Numbers

NN10274

Purpose

The engine temperature switch turns on an indicator light when the headtemperature reaches the temperature specified below.

How It Works

The contacts inside the switch are normally open. As the body of theswitch warms, the clearance between the contacts narrows, until theswitch closes at 320-340 degrees F. It does not reopen until thetemperature falls to 280-310 degrees F.

Testing

1. Remove the switch from the harness.

2. Using a VOM or a test light, check the circuit between the body of theswitch and the terminal. There should not be continuity at roomtemperature.

3. The point at which the switch turns on can be tested by heating to300 degrees F. Slowly raise the temperature of the switch, noting thepoint at which the switch turns on. It should close between 320 and340 degrees F. Keep track of the temperature as the switch cools andnote the point at which it again opens. It should open between 280and 310 degrees F.

Switch

Air CleanerPressure

Switch

Engine Temperature

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Part Numbers

Purpose

The float switch is wired into the starter motor circuit to prevent starting in alow oil situation. It will not kill the engine once running!

How It Works

The float switch houses a small magnet which pulls the contacts closedwhen the float is down. When the float is up, the contacts are open.

Testing

1. Verify that the flats on the switch body are vertical and the letters N.C.are on the top side.

2. Disconnect the switch from the harness and test for continuity. Theswitch should be open with the oil at a safe level. Note: If testing with aVOM, expect to see some resistance when the switch is closed.

3. Drain the oil from the engine, then retest for continuity. The switchshould be closed (and will probably show some resistance which isnormal). If the switch fails either of these tests, it should be replaced.

TIPS FOR REMOVAL/INSTALLATION:

1. Drain oil before rotating switch.

2. Use a continuous motion when turning, stopping only with the flatsvertical.

3. Rotate by hand as soon as possible to prevent damage if the floatcatches something.

4. Use a sealant on the threads when reinstalling.

5. Make sure that the flats are vertical and the letters N.C. are on the topside!

Part Numbers

103990

Purpose

This component provides the proper switching for the starter, ignition, PTO,safety, and accessory circuits if so equipped.

How It Works

Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so the cylinder automatically returns to run oncethe key is released.

Testing

1. Disconnect the switch from the wiring harness.

2. Verify the conditions in the table.

3. Check each of the terminals to ground. There should be nocontinuity.

Switch

Float (kit)

(Kohler)

Switch

Ignition

Position Condition

Off None

Run B+I+A+R

Start B+S+I+R

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Part Numbers

103991

Purpose

This component provides the proper switching for the starter, ignition, PTO,safety, and accessory circuits.

How It Works

Detents inside the switch give it three positions: off, run, and start The startposition is spring loaded so the cylinder automatically returns to run oncethe key is released.

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

Testing


2. Verify the following conditions in the table.

3. Check for continuity between each of the terminals and the switch case.Only the ground terminal should show continuity.

Part Numbers

116338

Purpose

116338 provides the proper switching for the starter, ignition, and safetyinterlock circuits.

How It Works

Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so that the cylinder automatically returns to “run”.

Note that this switch does not come with a key. The case is connected tothe ground terminal.

Testing



Note: The letters stamped on the switch terminals may not be correct. Usethe diagram at the left to identify the individual terminals.

Switch

Ignition

Switch

Ignition

Position Condition

Off G+M+A

Run B+A+R

Start B+S

Position Condition

Off G+M

Run B+L

Start B+L+S1

Glo

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GLOSSARY


Part Numbers

117292

Purpose

This component provides the proper switching for the starter, Ignition,PTO, safety, and accessory circuits.

How It Works

Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so the cylinder automatically returns to run oncethe key is released.

Note: This switch does not have the labels shown at the left and does notcome with a key.

Testing



3. Check for continuity between each of the terminals and the switch case.There should be no continuity.

Part Numbers

23-0660

Purpose

23-0660 provides the proper switching for the starter, ignition, and safetyinterlock circuits.

How It Works

Detents inside the switch give it three positions: off, run, and start. The startposition is spring loaded so that the cylinder automatically returns to “run".

Note: This switch does not come with a key. The case is connected to theground terminal.

Testing



3. Check each of the terminals to the switch body. There should be nocontinuity except for the ground (G) terminal.

Switch

Ignition

Switch

Ignition

Position Condition

Off M+G

Run B+A

Start B+A, S1+S2

Position Condition

Off G+M

Run B+L

Start B+S

Glo

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GLOSSARY


Part Numbers

38-1420

Purpose

This switch monitors whether or not an operator is in the seat.

How It Works

The switch is open without an operator and closed with an operator. Theribbon operates a friction mechanism which, in turn, activates the switch.A removable cover provides access to the switch contacts.

Testing

Note: Because of the friction mechanism, it is possible to get falsereadings with the switch removed from the seat. Perform testing with theswitch in place.

1. Disconnect the switch from the circuit, but do not remove from the seat.


Part Numbers

102138

Purpose

Typically used to provide switching for the lights.

How It Works

Contacts inside the switch physically connect the two terminals to providecontinuity. It is an SPST switch with a load capacity of 3 Amps at 250 V, and6 amps at 125 V.

Testing

1. Remove the switch from the wiring harness.

2. Using a VOM or test lamp, test the switch with the lever in one positionand note whether or not there is continuity.

3. Flip the switch, then recheck to ensure that the status has changed.

Part Numbers

113191, 92-9844

Purpose

This rocker switch is typically used to provide switching for lights.

How It Works

The switch has contacts inside which connect the two terminals in oneposition while disconnecting them in the other. It is an SPST type rockerswitch with 8 amp capacity at 12 volts.

Testing


2. Verify the following:

a. the terminals are not continuous when off.

b. the terminals are continuous when the switch is on.

Switch

Interlock

Switch

Light

Switch

Light

Condition Status

Operator On Closed

Operator Off Open

Glo

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GLOSSARY


Part Numbers

40-8200

Purpose

Used as part of the safety interlock circuit, it is typically used to monitorwhether or not an operator is in the seat.

How It Works

This SPDT micro switch has three terminals. The lever is spring loaded inthe “up” position. When the button is pushed down, continuity switchesfrom COM and NC to COM and NO.

Testing

1. Disconnect the switch from the harness.


Part Numbers

28-4250

Purpose

This switch monitors whether the transmission in in neutral or in gear.

How It Works

This unique SPST switch is actuated by a ball that rides against a pivotingbracket. When the transmission is in neutral, the ball falls into a hole whichcloses the switch. When the transmission is in gear, the bracket depressesthe ball which, in turn, opens the switch.

Testing

1. Disconnect the switch from the wiring harness, but do not remove.

2. Check first to ensure that there is NO continuity between either terminaland ground. (This type failure can produce some VERY unusualsymptoms.)

3. With the transmission in neutral, verify that the terminals have continuity.

4. With the transmission in gear, make sure that the terminals are notcontinuous.

5. If the switch failed step 3 or 4, remove the switch and depress the ballmanually to test. If the switch passes, the shift bracket is probably thesource of the difficulty.

Switch

Micro

Button Condition

Up COM+NC

Down COM+no

Switch

Neutral

Glo

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GLOSSARY


Part Numbers

116237

Purpose

To ensure that the parking brake is on when 1. starting 2. the operatorleaves the seat.

How It Works

Two small mercury switches inside the potted container provide continuitywhen the parking brake is engaged. When disengaged, the assembly isrotated to another position which opens both switches inside. This is aDPST switch.

Testing

1. Disconnect the switch from the wiring harness, but DO NOT REMOVE ITfrom the parking brake bracket.

2. With the parking brake on, verify that there is continuity across the twoterminals in each connector.

3. With the parking brake off, there should be no continuity across theterminals in each connector.

Part Numbers

116822

Purpose

To insure that the parking brake is on when 1. starting 2. the operatorleaves the seat.

How It Works

Two small mercury switches inside the potted container are oriented toprovide one open and one closed switch when the parking brake isengaged. When disengaged, the assembly is rotated to another positionwhich reverses the switch conditions.

Note: This switch is similar in construction to 116237, except that theswitches provide opposing conditions rather than the same. This isnecessary because the Briggs and Stratton engine uses mag style ignitioninstead of the coil type in the Onan’s.

Testing

1. Disconnect the switch from the wiring harness, but do not remove itfrom the parking brake bracket.

2. With the parking brake on, verify the conditions in the table.

Note: The male pins connect with the orange and white wires on theharness, while the female pins connect with the purple and light blue pins.

Switch

Neutral/Parking Brake

Switch

Neutral/Parking Brake

BrakePosition

MalePins

FemalePins

On Closed Open

Off Open Closed

Glo

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GLOSSARY


Part Numbers

NN10520

Purpose

The oil pressure switch on the 724 turns on the hourmeter. This ensuresthat the hourmeter is not accidentally left running.

How It Works

When the engine is not running, the switch is open. Once the engine hasbeen started, oil enters through a small hole on the threaded end. Thispresses on a diaphragm which moves a switch contact on the dry side ofthe diaphragm. When pushed far enough, the contacts close. Note: Thecontact is adjustable so that the switching pressure can be varied. It is setto close from the factory at 5 psi + 2 psi.

Testing

1. Disconnect the switch from the system.


3. If the switch is opening when the machine is idling, verify that you haveproper oil pressure at idle (consult your engine manual.) If so, slowlyrotate the adjusting screw on the back of the switch until the switchjust closes.

4. If the switch is operating intermittently, check for a loose electrical wire,or an obstruction to the orifice on the threaded end of the switch.

Part Numbers

NN10813

Purpose

This switch is optional on the 200 series tractors and could be used to turnon an hourmeter.

How It Works

When the engine is not running, the switch is open. Once the engine hasbeen started, oil enters through a small hole on the threaded end. Thismoves the diaphragm which moves a switch contact on the dry side of thediaphragm. When pushed far enough, the switch contacts close. Note:The contact is adjustable by turning the small set screw at the base of theterminal. It is set to close at 1 psi ± ½ psi from the factory.

Testing

1. Disconnect the switch from the system.


3. If the switch is opening when the machine is idling, verify that you haveproper oil pressure at idle (consult your engine manual.) If so, slowlyrotate the adjusting screw on the back of the switch until the switchjust closes.

4. If the switch is operating intermittently, check for a loose electrical wire,or an obstruction to the orifice on the threaded end of the switch.

Switch

Oil Pressure

Engine Switch

No Oil Pressure Open

Oil Pressure OK Closed

Switch

Oil Pressure

Engine Switch

No Oil Pressure Open

Oil Pressure OK Closed

Glo

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GLOSSARY


Part Numbers

NN10824

Purpose

The low oil pressure switch turns off the oil pressure indicator light andturns on the hourmeter.

How It Works

The mechanism inside the switch is simply a lever that is moved by adiaphragm. When there is no oil pressure, the NO switch is open, and theNC switch is closed. Once oil pressure is present at the pressure switchorifice, the diaphragm moves the lever and reverses the status of each ofthe switches. The switch should change status at 5 psi ± 2 psi.

Testing

1. Disconnect the harness from the switch.


3. If the switch is failing intermittently, verify proper oil pressure at idle(consult your engine manual.) The switch is set to change status at 5psi ± 2 psi. Also check to ensure that nothing is obstructing the orificeon the threaded end of the switch.

4. If one or both switches are switching at the incorrect pressure, thecontacts can be adjusted. Use the set screws at the base of eachterminal to get the desired results. Once adjusted, prevent undesiredrotation by sealing with a small amount of fingernail polish.

Part Numbers

116716

Purpose

Typically used to turn on the electric blade clutch and to function as part ofthe safety interlock system.

How It Works

Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. One of theSPDT switches is connected to the electric PTO clutch. When in the offposition, this side of the switch is open. The other half of the switch isused by the safety interlock system. When the clutch is off, this side of theswitch is closed. This allows current to keep the kill relay energized so thatthe mag is not grounded out.

Testing



Switch

Oil Pressure

Oil Pressure NC Switch NO Switch

No Pressure Closed Open

Pressure OK Open Closed

Switch

PTO/Clutch

Lever Condition

Up Open

Down Closed

Glo

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GLOSSARY


Part Numbers

111332

Purpose

Used as part of the safety interlock circuit, it is typically used to monitor theposition of the PTO or brake lever.

How It Works

This SPDT microswitch has three terminals. The lever is spring loaded inthe “up” position. When the lever on top of the switch is pushed, continuityswitches from COM1 and NC2 to COM1 and NO3.

Testing



Part Numbers

116716

Purpose


How It Works

Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. One of theSPDT switches is connected to the electric PTO clutch. When in the offposition, this side of the switch is open. The other half of the switch is usedby the safety interlock system. When the clutch is off, this side of the switchis closed. This allows current to keep the kill relay energized so that themag is not grounded out.

Testing



Switch

PTO/Clutch

Button Condition

Up COM+NC2

Down COM+NO3

Switch

PTO/Clutch

Position Lever Condition

Off Down b+a, e+d

On Up b+c, e+f

Glo

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GLOSSARY


Part Numbers

78-3030

Purpose


How It Works

Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. One of theSPDT switches is connected to the electric PTO clutch. When in the “off”position, this side of the switch is open. The other half of the switch is usedby the safety interlock system. When the clutch is “off”, this side of theswitch is closed. This allows current to keep the kill relay energized so thatthe mag is not grounded out.

Testing



Part Numbers

78-9670

Purpose

This switch is typically used to turn on the electric blade clutch and tofunction as part of the safety interlock system.

How It Works

Contacts inside this DPDT switch electrically connect various terminals. Itis actually just two SPDT switches tripped by a single lever. In the 724, oneside of the switch is used to ensure that the PTO switch is in the “off”position during starting. The other side is used to turn on the clutch and toprevent spark if the operator is out of the seat when the switch is in the“on” position.

Testing



Switch

PTO/Clutch


Off Down b+a, e+d

On Up b+c, e+f

Switch

PTO/Clutch


Off Down b+a, e+d

On Up b+c, e+f

Glo

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GLOSSARY


Part Numbers

116194

Purpose

This normally closed switch opens when an operator sits on the seat.

How It Works

This DPST switch has two sets of two contacts inside. When at rest, oneset of contacts is closed while the other set is open. The opposite is truewhen the button is depressed. The normally closed set of terminals is smallwhile the normally open side are larger.

Testing



Part Numbers

116752

Purpose

This switch is used to test the operation of the engine temperature horn.

How It Works

It is an SPST rocker type switch that is spring loaded in the open position.The hole for backlighting is not used.

Testing


2. Check the two terminals for continuity. There should be none.

3. Hold the rocker and verify that the two terminals are now continuous.

Switch

Seat

Button Condition

At Rest a+b

Depressed c+d

Switch

Test

Glo

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GLOSSARY


Part Numbers

116796

Purpose

This SPDT switch is typically used to test the lights on the interlock board.When it is pushed in, the lights should come on.

How It Works

This small push button type switch is spring loaded so that the C and NCterminals are connected. When the button is pushed, C and NC open, andC and NO close. The switch is rated for 3 amps at 250 volts or 6 amps at125 volts.

Testing

1. Disconnect the switch from the harness.


Part Numbers

113193

Purpose

Contacts on switch close when the switch body reaches a predeterminedtemperature. (Usually used for hydraulic fluid.)

How It Works

A bimetal post inside the switch bends as the temperature rises. Once thetemperature is high enough, the top of the post makes contact with theterminal to close the switch. The switch is set to close at 200° F. Normal oiltemperature is 180° F.

Testing


2. Test the continuity between the body of the switch and the terminal atroom temperature. There should not be continuity.

3. If you have the ability to measure high temperatures, you can verifyoperation of the switch in a liquid heated to the “switching”temperature.

Caution: Be careful not to contact the heated liquid.

Switch

Test

Switch

Transmission Oil

Button Condition

At Rest C+NC

Depressed C+NO

Glo

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GLOSSARY


rev. 4-03

rev. 4-03

rev. 4-03

rev. 4-03

1989 - 1992 825

rev. 4-03

4 - 5Demystification Guide

825 Information List (1989 - 1992)

Wiring Diagram . . . . . . . . . . . . . . 4-6Circuit Diagrams

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

825 1989 - 1992

Wiring Diagram rev. 4-03


rev. 4-03


Start Motor Circuit(ignition switch in “start”)

1989 - 1992 825

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

Kill Circuit(ignition switch “off”)

rev. 4-03


Charging Circuit

825 1989 - 1992

1993 - 1995 825 RER(70040 & 70060)

rev. 4-03

4 - 8ADemystification Guide


Wiring Diagram . . . . . . . . . . . . . . 4-08BCircuit Diagrams

Starter Motor Circuit . . . . . . . . . . 4-08CSpark Circuit . . . . . . . . . . . . . 4-08DSpark Circuit . . . . . . . . . . . . . 4-08ECharging Circuit . . . . . . . . . . . 4-08F

825 RER 1993 - 1995(70040 & 70060)


4 - 8B Demystification Guide

rev. 4-03

4 - 8CDemystification Guide

1993 - 1995 825 RER(70040 & 70060)

Starter Motor Circuit

telstjj

Rectangle

rev. 4-03

4 - 8D Demystification Guide

Spark Circuit(ignition switch in “run”)

825 RER 1993 - 1995(70040 & 70060)

telstjj

Rectangle

4 - 8EDemystification Guide

1993 - 1995 825 RER(70040 & 70060)


rev. 4-03

telstjj

Rectangle

Charging Circuit

825 RER 1993 - 1995(70040 & 70060)

rev. 4-03

4 - 8F Demystification Guide

1996 - 1997 825 RER(70040 & 70060)

1998 (70040)

rev. 4-03

4 - 8GDemystification Guide

825 Information List (1996 - 1997)(1998)

Wiring Diagram . . . . . . . . . . . . . . 4-08HCircuit Diagrams

Starter Motor Circuit . . . . . . . . . . 4-08ISpark Circuit . . . . . . . . . . . . . 4-08JSpark Circuit . . . . . . . . . . . . . 4-08KCharging Circuit . . . . . . . . . . . 4-08L

825 RER 1996 - 1997(70040 & 70060)(70040) 1998


4 - 8H Demystification Guide

4 - 8IDemystification Guide

1996 - 1997 825 RER(70040 & 70060)

1998 (70040)

rev. 4-03 Starter Motor Circuit

telstjj

Rectangle

rev. 4-03

4 - 8J Demystification Guide


825 RER 1996 - 1997(70040 & 70060)(70040) 1998

telstjj

Rectangle

4 - 8KDemystification Guide

rev. 4-03

1996 - 1997 825 RER(70040 & 70060)

1998 (70040)


telstjj

Rectangle

Charging Circuit rev. 4-03

4 - 8L Demystification Guide

825 RER 1996 - 1997(70040 & 70060)(70040) 1998

1998 825 RER(70041 & 70060)

rev. 4-03

4 - 8MDemystification Guide

825 Information List (1998)

Wiring Diagram . . . . . . . . . . . . . . 4-08NCircuit Diagrams

Starter Motor Circuit . . . . . . . . . . 4-08OSpark Circuit . . . . . . . . . . . . . 4-08PSpark Circuit . . . . . . . . . . . . . 4-08QCharging Circuit . . . . . . . . . . . 4-08R

825 RER 1998(70041 & 70060)


4 - 8N Demystification Guide

rev. 4-03

4 - 8ODemystification Guide

1998 825 RER(70041 & 70060)



825 RER 1998(70041 & 70060)

Demystification Guide4 - 8P

rev. 4-03

4 - 8QDemystification Guide

1998 825 RER(70041 & 70060)

Spark Circuit(ignition switch in “start”)

rev. 4-03

telstjj

Rectangle

Charging Circuit

825 RER 1998(70041 & 70060)

rev. 4-03

4 - 8R Demystification Guide

1999 - 2001 825 - RER

rev. 4-03


825 - RER Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . . . . . 4-10Circuit Diagrams

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

825 - RER 1999 - 2001



rev. 4-03


1999 - 2001 825 - RER

Starter Motor Circuit(ignition switch in start)

Run Circuit (Forward)(PTO “on”)

825 - RER 1999 - 2001

Demystification Guide4 - 12

rev. 4-03


1999 - 2001 825 - RER

Run Circuit (Reverse)(PTO “on” - NMIR “on”)

rev. 4-03

Charging Circuit

825 - RER 1999 - 2001


rev. 4-03

1994 - 1995 10-32 & 12-32

rev. 4-03


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


Starter Motor Circuit . . . . . . . . . . 4-14CSpark Circuit . . . . . . . . . . . . . 4-14CKill Circuit . . . . . . . . . . . . . . 4-14CCharging Circuit . . . . . . . . . . . 4-14D

10-32 & 12-32 1994 - 1995



1994 - 1995 10-32 & 12-32

rev. 4-03


Charging Circuit

10-32 & 12-32 1994 & 1995

rev. 4-03


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

rev. 4-03


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


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

rev. 4-03

rev. 4-03



1993 832 RER(70042)

rev. 4-03


825 Information List (1993)


Starter Motor Circuit . . . . . . . . . . 4-18CSpark Circuit . . . . . . . . . . . . . 4-18DSpark Circuit . . . . . . . . . . . . . 4-18ECharging Circuit . . . . . . . . . . . 4-18F

832 RER 1993(70042)



rev. 4-03

1993 832 RER(70042)


Demystification Guide 4 - 18C

rev. 4-03



832 RER 1993(70042)


1993 832 RER(70042)


rev. 4-03

Charging Circuit

832 RER 1993(70042)

rev. 4-03


108-4, 108-5, & 111-6 Information List (1988)

Wiring Diagram . . . . . . . . . . . . . . . . . 4-20

Circuit Diagrams

Starter Motor Circuit . . . . . . . . . . . 4-21

Spark Circuits . . . . . . . . . . 4-21 & 4-22

Charging Circuit . . . . . . . . . . . . . 4-22

Gauge Circuit . . . . . . . . . . . . . . . 4-22

In

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


Wiring Diagram

Wir

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Dia

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m

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



(ignition switch in “start”)

Spark Circuit


Cir

cu

its

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


Charging Circuit

(ignition switch in “run”)

Gauge Circuit


Cir

cu

its

Spark Circuit


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


112-C Information List (1988)

Wiring Diagram . . . . . . . . . . . . . . . . . 4-24

Circuit Diagrams


Spark Circuits . . . . . . . . . . 4-25 & 4-26


Gauge Circuit . . . . . . . . . . . . . . . 4-26

In

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1988 112-C


Wiring Diagram

Wir

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112-C 1988




Spark Circuit


Cir

cu

its

1988 112-C


Gauge Circuit


Cir

cu

its

Charging Circuit


Spark Circuit


112-C 1988


1996 - 1998 11-32 & 13-32

rev. 4-03




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

rev. 4-03

rev. 4-03

rev. 4-03



11-32 & 13-32 1996 - 1998

Charging Circuit

1999 - 2001 12-32 - RER

rev. 4-03


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


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

12-32 - RER 1999 - 2001



rev. 4-03


1999 - 2001 12-32 - RER

Starter Motor Circuit(ignition switch in “start”)

Run Forward(PTO “on”)

12-32 - RER 1999 - 2001


rev. 4-03


1999 - 2001 12-32 - RER

Run Reverse(PTO “on” - NMIR override)

rev. 4-03

Charging Circuit



Information List

208-4SB, 211-5SB, 211-4 & 212-5 (1988-1989)

210-5 & 210-H (1990)

Wiring Diagram . . . . . . . . . . . . . . . . . 5-2

Circuit Diagrams


Spark Circuits . . . . . . . . . . . . 5-3 & 5-4

Charging Circuit . . . . . . . . . . . . . . 5-5

Electric Clutch . . . . . . . . . . . . . . . 5-5

Light Circuit . . . . . . . . . . . . . . . . 5-5

Voltmeter Circuit . . . . . . . . . . . . . 5-5

In

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t1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5

1990 210-5 & 210-H


Wiring Diagram

Wir

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m208-4SB, 211-5SB, 211-4, & 212-5 1988 - 1989

210-5 & 210-H 1990




Spark Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

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1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5

1990 210-5 & 210-H


Electric Clutch

(ignition switch in “run”)Cir

cu

its

Charging Circuit

(ignition switch in “run”)Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Spark Circuit


208-4SB, 211-5SB, 211-4, & 212-5 1988 - 1989

210-5 & 210-H 1990


Voltmeter Circuit


Cir

cu

its

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Light Circuit


1988 - 1989 208-4SB, 211-5SB, 211-4, & 212-5

1990 210-5 & 210-H




1991 & 1993 - 1995 210-5 & 210-H1992 212-H

rev. 4-03


210-5 & 210-H Information List (1991 & 1993 - 1995)212-H (1992)


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

210-5 & 210-H 1991 & 1993 - 1995212-H 1992



rev. 4-03

210-5 & 210-H 1991 & 1993 - 1995212-H 1992


rev. 4-03Spark Circuit(ignition switch in “run”)

Charging Circuit

Electric Clutch(ignition switch in “run”)

210-5 & 210-H Information List (1992)

Wiring Diagram . . . . . . . . . . . . . . . . . 5-12

Circuit Diagrams


Spark Circuits . . . . . . . . . . 5-13 & 5-14


Electric Clutch Circuit . . . . . . . . . . 5-14

In

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1992 210-5


Wiring Diagram

Wir

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210-5 1992


Cir

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Spark Circuit


1992 210-5


Cir

cu

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Spark Circuit


Electric Clutch Circuit


Charge Circuit


210-5 1992



Wiring Diagram . . . . . . . . . . . . . . . . . 5-16

Circuit Diagrams


Spark Circuits . . . . . . . . . . . 5-17 & 5-18


Electric Clutch . . . . . . . . . . . . . . . 5-18

Light Circuit . . . . . . . . . . . . . . . . 5-19

In

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1991 212-5 & 212-H


Wiring Diagram

Wir

ing

Dia

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212-5 & 212-H 1991




Spark Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

1991 212-5 & 212-H


Spark Circuit


Charging Circuit


Electric Clutch


Cir

cu

its

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

212-5 & 212-H 1991


Light Circuit


Cir

cu

its

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

1991 212-5 & 212-H





Wiring Diagram . . . . . . . . . . . . . . . . . 5-22

Circuit Diagrams


Spark Circuits . . . . . . . . . . . . . . . 5-23


Electric Clutch . . . . . . . . . . . . . . . 5-24

Gauge Circuit . . . . . . . . . . . . . . . 5-24

Kill Circuit . . . . . . . . . . . . . . . . . 5-24

Light Circuit . . . . . . . . . . . . . . . . 5-25

In

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1990 212-5 & 212-H




Spark Circuit


Cir

cu

its

Spark Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

1990 212-5 & 212-H


Charging Circuit

Electric Clutch


Cir

cu

its

Gauge Circuit


Kill Circuit

(ignition switch in “off”)

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

212-5 & 212-H 1990


Light Circuit


Cir

cu

its

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

1990 212-5 & 212-H




212-5 Information List (1992)

Wiring Diagram . . . . . . . . . . . . . . . . . 5-28

Circuit Diagrams


Spark Circuits . . . . . . . . . . 5-29 & 5-30

Charging Circuits . . . . . . . . . . . . . 5-30


In

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1992 212-5


212-5 1992



rev. 4-03


1992 212-5



rev. 4-03



212-5 1992

Charging Circuit

Electric Clutch Circuit(ignition switch in “run”)


Wiring Diagram . . . . . . . . . . . . . . . . . 5-32

Circuit Diagrams


Spark Circuits . . . . . . . . . . . . . . 5-33


Oil Pressure Light Circuit . . . . . . . . . 5-34

Gauge Circuit . . . . . . . . . . . . . . . 5-34


In

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1988 212-6


Wiring Diagram

Wir

ing

Dia

gra

m

212-6 1988




Cir

cu

its

Spark Circuit


Spark Circuit


1988 212-6


Cir

cu

its

Gauge Circuit


Oil Pressure Light Circuit


Charging Circuit


212-6 1988


Cir

cu

its



1988 212-6





Wiring Diagram . . . . . . . . . . . . . . . . . 5-38

Circuit Diagrams


Spark Circuits . . . . . . . . . . 5-39 & 5-40



Light Circuit . . . . . . . . . . . . . . . . 5-41

Gauge Circuit . . . . . . . . . . . . . . . 5-42


In

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1987 212-6




Cir

cu

its

Spark Circuit


1987 212-6


Cir

cu

its

Charging Circuit


Spark Circuit


212-6 1987


Cir

cu

its

Light Circuit




1987 212-6




Gauge Circuit


Cir

cu

its

212-6 1987


1993 10-32XL & 12-38XL1993 - 1995 12-32XL & 12-38HXL1994 13-38HXL

rev. 4-03


10-32XL & 12-38XL Information List (1993)12-32XL & 12-38HXL (1993 - 1995)

13-38HXL (1994)


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

Information List

13-38HXL & 15-44HXL (1995)

ALL XL UNITS (1996 - 1998)

Wiring Diagram . . . . . . . . . . . . . . . . . 5-48

Circuit Diagrams


Spark Circuits . . . . . . . . . . 5-49 & 5-50


Headlight Circuit . . . . . . . . . . . . . 5-50

In

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1996 - 1998 ALL XL UNITS


Wiring Diagram

Wir

ing

Dia

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ALL XL UNITS 1996 - 1998




Spark Circuit


Cir

cu

its

1995 13-38HXL & 15-44HXL

1996 - 1998 ALL XL UNITS


Charging Circuit

Headlight Circuit


Cir

cu

its

Spark Circuit


13-38HXL & 15-44HXL 1995

ALL XL UNITS 1996 - 1998


1999 - 2001 XL

rev. 4-03


XL Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 5-50B, 5-50CCircuit Diagrams

Starter Motor Circuit . . . . . . . . . . 5-50DRun Circuit (Forward) . . . . . . . . . . 5-50ERun Circuit (Reverse) . . . . . . . . . . 5-50FCharging Circuit . . . . . . . . . . . . 5-50FLight Circuit . . . . . . . . . . . . . 5-50G

XL 1999 - 2001



1999 - 2001 XL

Wiring Diagramrev. 4-03



XL 1999 - 2001

Demystification Guide5 - 50D

rev. 4-03


1999 - 2001 XL


rev. 4-03

Run Reverse(PTO “on” NMIR override)

XL 1999 - 2001

Demystification Guide5 - 50F

rev. 4-03

Charging Circuit


1999 - 2001 XL

Light Circuitrev. 4-03

rev. 4-03

Demystification Guide6 - 50H


252-H Information List (1988)

Wiring Diagram . . . . . . . . . . . . . . . . . 5-52

Circuit Diagrams


Spark Circuits . . . . . . . . . . . . . . 5-53



Gauge Circuit . . . . . . . . . . . . . . . 5-54


In

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1988 252-H


Wiring Diagram

Wir

ing

Dia

gra

m

252-H 1988


Cir

cu

its

Spark Circuit




Spark Circuit


1988 252-H


Cir

cu

its

Charging Circuit


Gauge Circuit




252-H 1988




Cir

cu

its

1988 252-H





Wiring Diagram . . . . . . . . . . . . . . . . . 5-58

Circuit Diagrams


Spark Circuits . . . . . . . . . . 5-59 & 5-60


Oil Pressure Light Circuit . . . . . . . . 5-61

Light Circuit . . . . . . . . . . . . . . . 5-61

Gauge Circuit . . . . . . . . . . . . . . 5-62


In

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1988 257-H




Cir

cu

its

Spark Circuit


1988 257-H


Cir

cu

its

Charging Circuit


Spark Circuit


257-H 1988


Cir

cu

its

Light Circuit




1988 257-H




Gauge Circuit


Cir

cu

its

257-H 1988


1993 2441992 246-Hrev. 4-03


244 Information List (1993)246-H (1993)


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



264-6 Information List (1994 - 1995)

Wiring Diagram . . . . . . . . . . . . . . . . . . 6-8

Circuit Diagrams

Starter Motor Circuit . . . . . . . . . . . . 6-9

Spark Circuits . . . . . . . . . . . 6-9 & 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


In

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1994-1995 264-6


Wiring Diagram

Wir

ing

Dia

gra

m

264-6 1994-1995


Cir

cu

its



Spark Circuit


1994-1995 264-6


Cir

cu

its

Charging Circuit




Spark Circuit Circuit

(ignition switch in run”)

264-6 1994-1995


rev. 4-03


1994-1995 264-6

Light Circuit(ignition switch in “run”)

Hourmeter Circuit(ignition switch in “run”)

Park Brake Light Circuit*(ignition switch in “run”)

Cir

cu

its

PTO Light Circuit*


Battery Light Circuit


264-6 1994-1995


Cir

cu

its

Oil Pressure Light Circuit*


1994-1995 264-6




264-H & 265-H Information List (1994 - 1998)

Wiring Diagram . . . . . . . . . . . . . . . . . 6-16

Circuit Diagrams


Spark Circuits . . . . . . . . . . 6-17 & 6-18



Light Circuit . . . . . . . . . . . . . . . . 6-19


Park Brake Light Circuit . . . . . . . . . 6-19




In

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1994 - 1998 264-H & 265-H


Wiring Diagram

Wir

ing

Dia

gra

m

264-H & 265-H 1994 - 1998


Cir

cu

its



Spark Circuit


1994 - 1998 264-H & 265-H


Cir

cu

its

Charging Circuit




Spark Circuit Circuit

(ignition switch in run”)

264-H & 265-H 1994 - 1998


rev. 4-03


1994-1995 264-6



Park Brake Light Circuit*(ignition switch in “run”)

Cir

cu

its

PTO Light Circuit*


Battery Light Circuit


264-H & 265-H 1994 - 1998


Cir

cu

its



1994 - 1998 264-H & 265-H





Wiring Diagram . . . . . . . . . . . . . . . . . 6-24

Circuit Diagrams


Spark Circuits . . . . . . . . . . 6-25 & 6-26




Light Circuit . . . . . . . . . . . . . . . . 6-27

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1996-1998 265-6


Cir

cu

its



Spark Circuit


1996-1998 265-6


Cir

cu

its

Charging Circuit


Spark Circuit


Hourmeter Circuit


265-6 1996-1998




Cir

cu

its

Light Circuit


1996-1998 265-6




1999 - 2000 265-6

rev. 4-03



Wiring Diagram . . . . . . . . . . . . . . . 6-29CCircuit Diagrams

Starter Motor Circuit . . . . . . . . . . . . 6-29ESpark Circuit . . . . . . . . . . . . . . . 6-29ERun Forward . . . . . . . . . . . . . . . 6-29FRun Reverse . . . . . . . . . . . . . . . 6-29GCharging Circuit . . . . . . . . . . . . . . 6-29HLight Circuit . . . . . . . . . . . . . . . 6-29H

265-6 1999 - 2000



1999 - 2000 265-6



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Battery Fuse(30 amp) Ignition

Switch(in start)

Re RePk Pk

Bn

Bn

Bk

Bn

Y

Y Y T

Y

Or Or Gn

Gn

Bu

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B

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S

InterlockRelay

(energized)Fuse

(10 amp) PTO Switch(disengaged)

Brake Switch(brake applied)

Seat Switch(operator on) Start Relay

(energized)

Starter Solenoid(energized)

Starter Motor(energized)

Kill Relay(energized)

Park Brake Switch(Brake Engaged)

Neutral Switch(in Neutral)


Switch(in start)

Re RePk Pk

Bn

Bk

YY

Bu

BuGy

Gy

B

I

S Fuse(10 amp) PTO Switch

(disengaged)



Triggermodule

Ignition CoilDashed lines do not carry current

Park Brake Switch(Brake Engaged)

Neutral Switch(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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Fuel Solenoid(energized)


Y Bk

Bk

Triggermodule

Triggermodule

Ignition Coil Ignition Coil

Battery Fuse(30 amp) Fuse

(10 amp)IgnitionSwitch(in run)

Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

R

I

Interlock Realy(not energized)

Seat Switch(operator on)

Dashed lines do not carry current

No Mow In Reverse Module

(NMIR)

Reverse Switch(in forward)

PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W

Park Switch(park brake

not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

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Bk

Triggermodule

Ignition Coil



Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

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Bk

Bk

W

W

Bu

B

A

L





(NMIR)

Reverse Switch(in reverse)

PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W

Bk

T

T

Bk

Bk


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

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B+AC BatteryFuse

(30 amp)Fuse(25 amp)

IgnitionSwitch(in run)

Re

Or

Pk

Bk

Pk

Pk

VioVioB

R

I

Regulator/RectifierAlternator


B+

VoltageComparator

Battery Light Module

Battery Light

Battery Fuse(30 amp)

Fuse(10 amp)

Headlights(on)

IgnitionSwitch

(in run/lights)

Re Or Or BkRe

B L

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rev. 4-03


265-H Information List (2000 - 2001)


Starter Motor Circuit . . . . . . . . . . 6-30ESpark Circuit . . . . . . . . . . . . . 6-30ERun Circuit (Forward) . . . . . . . . . . 6-30FRun Circuit (Reverse) . . . . . . . . . . 6-30GCharging Circuit . . . . . . . . . . . . 6-30HLight Circuit . . . . . . . . . . . . . 6-30H

265-H 2000 - 2001


Demystification Guide6 - 30B

2000 - 2001 265-H






2000 - 2001 265-H


rev. 4-03



265-H 2000 - 2001


rev. 4-03


2000 - 2001 265-H


rev. 4-03

Charging Circuit

265-H 2000 - 2001


rev. 4-03

Light Circuit

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1999 265-H



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Switch(in start)

Re RePk Pk

Bn

Bn

Bk

Bn

Y

Y Y T

Y

Or Or Gn

Gn

Bu

BuGy

Gy

B

I

S

InterlockRelay

(energized)Fuse




(energized)




Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y


Switch(in start)

Re RePk Pk

BnBk

Y

Y

Bu

BuGy

Gy

B

I


(disengaged)



Triggermodule


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Bk

Triggermodule

Triggermodule




Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

R

I





(NMIR)


PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

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Bk

Triggermodule

Ignition Coil



Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

A

L





(NMIR)


PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W

Bk

T

T

Bk

Bk


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

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B+AC BatteryFuse



Re

Or

Pk

Bk

Pk

Pk

VioVioB

R

I



B+

VoltageComparator


Battery Light


Fuse(10 amp)

Headlights(on)

IgnitionSwitch

(in run/lights)

Re Or Or BkRe

B L

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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



Wiring Diagram . . . . . . . . . . . . . . . . . 6-34

Circuit Diagrams


Spark Circuits . . . . . . . . . . 6-35 & 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

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Wiring Diagram

Wir

ing

Dia

gra

m

266-H 1995


Spark Circuit


Cir

cu

its



1995 266-H


Spark Circuit


Cir

cu

its

Charging Circuit




266-H 1995


Light Circuit


Cir

cu

its

Oil Pressure Switch Circuit


Parking Brake Switch Circuit

(parking brake applied)

1995 266-H


Cir

cu

its

Cruise Control Circuit

(activating cruise)


(in cruise mode)

266-H 1995


Cir

cu

its


(deactivation by applying the brake)

1995 266-H





Wiring Diagram . . . . . . . . . . . . . . . . . 6-42

Circuit Diagrams


Spark Circuits . . . . . . . . . . 6-43 & 6-44



Light Circuit . . . . . . . . . . . . . . . . 6-45






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1994 266-H


Wiring Diagram

Wir

ing

Dia

gra

m

266-H 1994


Spark Circuit


Cir

cu

its



1994 266-H


Spark Circuit


Charging Circuit




Cir

cu

its

266-H 1994


Cir

cu

its

Parking Brake Switch Circuit*


Hourmeter Circuit


Light Circuit


1994 266-H


Cir

cu

its

Battery Light Circuit*


PTO Light Circuit*


266-H 1994


Cir

cu

its



1994 266-H




2001 266-H

rev. 4-03




Starter Motor Circuit . . . . . . . . . . 6-48CSpark Circuit . . . . . . . . . . . . . 6-48CRun Forward . . . . . . . . . . . . . 6-48DRun Reverse . . . . . . . . . . . . . 6-48ECharging Circuit . . . . . . . . . . . 6-48F

266-H 2001



rev. 4-03


2001 266-H



rev. 4-03



266-H 2001

2001 266-H



rev. 4-03

Charging Circuit

266-H 2001

rev. 4-03



Wiring Diagram . . . . . . . . . . . . . . . . . 6-50

Circuit Diagrams


Spark Circuits . . . . . . . . . . 6-51 & 6-52



Light Circuit . . . . . . . . . . . . . . . . 6-53

Oil Pressure Switch Circuit . . . . . . . 6-53




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1996 - 1998 267-H


Spark Circuit


Cir

cu

its



1996 - 1998 267-H


Spark Circuit


Charging Circuit




Cir

cu

its

267-H 1996 - 1998


Light Circuit


Cir

cu

its



Parking Brake Switch Circuit


1996 - 1998 267-H



(activating cruise)

Hourmeter Circuit


267-H 1996 - 1998


Cir

cu

its


(in cruise mode)



1996 - 1998 267-H




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Switch(in start)

Re RePk Pk

Bn

Bn

Bk

Bn

Y

Y Y T

Y

Or Or Gn

Gn

Bu

BuGy

Gy

B

I

S

InterlockRelay

(energized)Fuse




(energized)





Switch(in start)

Re RePk Pk

BnBk

Y

Y

Bu

BuGy

Gy

B

I


(disengaged)



Triggermodule

Ignition Coil

Triggermodule


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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Switch(in run)

Re Re Pk

Pk

Bu

Bu

Bk

BkBk

BkBu

Bu

Bu

Y T

T

Y

Pk

Pk

B I

Cruise Magnet(energized)

Cruise Switch(energized)

Cruise Lamp(on)

Cruise Disengage Switch(opens when brake is depresed)

Cruise Relay(energized) Momentary Switch

(energizes cruise relay)

AC

B+AC BatteryFuse



Re

Or

Pk

Bk

Pk

Pk

VioVioB

R

I

Regulator/RectifierAltenator


B+

VoltageComparator


Battery Light

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

&LUFXLWV


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XLWV

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Fuse(10 amp)

Headlights(on)

IgnitionSwitch

(in run/lights)

Re Or Or BkRe

B L

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

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2000 - 2001 268-H

rev. 4-03




Starter Motor Circuit . . . . . . . . . . 6-58DSpark Circuit . . . . . . . . . . . . . 6-58DRun Circuit (Forward) . . . . . . . . . . 6-58ERun Circuit (Reverse) . . . . . . . . . . 6-58FCruise Control Circuit . . . . . . . . . . 6-58GCharging Circuit . . . . . . . . . . . . 6-58GLight Circuit . . . . . . . . . . . . . 6-58H

268-H 2000 - 2001



2000 - 2001 268-H




268-H 2000 - 2001


rev. 4-03



2000 - 2001 268-H


rev. 4-03


268-H 2000 - 2001


rev. 4-03


2000 - 2001 268-H

Cruise Control Circuit(ignition switch in “run”)

rev. 4-03

Charging Circuit

6 - 58HDemystification Guide

2000 - 2001 268-H

Light Circuitrev. 4-03

2000 - 2001* 268-H

Demystification Guide 6 - 58I* May apply to later models, see Table Of Contents

Light Circuit


Fuse(10 amp)

Headlights(on)

IgnitionSwitch

(in run/lights)

Re Or Or BkRe

B L

Legend

Black BkBlue BuBrown BnGreen GnGrey GyOrange OrPink PkRed ReTan TViolet VioWhite WYellow Y

Circ

uits

6 - 58J Demystification Guide



Wiring Diagram . . . . . . . . . . . . . . . . . 6-60

Circuit Diagrams


Spark Circuits . . . . . . . . . . 6-61 & 6-62


Light Circuit . . . . . . . . . . . . . . . . 6-63


Oil Pressure Switch Circuit . . . . . . . . 6-63

Parking Brake Light Circuit . . . . . . . 6-64

Pump Circuit . . . . . . . . . . . . . . . 6-64



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1996 - 1998 269-H


Cir

cu

its



Spark Circuit


1996 - 1998 269-H


Charging Circuit

(ignition switch in “run”

Cir

cu

its

Spark Circuit


269-H 1996 - 1998


Cir

cu

its

Light Circuit


Hourmeter Circuit




1996 - 1998 269-H


Cir

cu

its

Parking Brake Light Circuit


Pump Circuit


269-H 1996 - 1998




Cir

cu

its


(activating cruise)

1996 - 1998 269-H



(in cruise mode)



Cir

cu

its

269-H 1996 - 1998


2001 270-H

rev. 4-03




Starter Motor Circuit . . . . . . . . . . 6-66DRun Circuit . . . . . . . . . . . . . 6-66DClutch Circuit (forward PTO “on”) . . . . . . 6-66EClutch Circuit (reverse PTO “on”) . . . . . . 6-66FCruise Control Circuit . . . . . . . . . . 6-66GLift Circuit . . . . . . . . . . . . . . 6-66GCharging Circuit . . . . . . . . . . . . 6-66HLight Circuit . . . . . . . . . . . . . 6-66H

270-H 2001



2001 270-H




270-H 2001


rev. 4-03

Run Circuit(operator “on”)


2001 270-H

Clutch Circuit(forward PTO “on”)

rev. 4-03

Clutch Circuit(reverse PTO “on” override key switch engaged)

270-H 2001


rev. 4-03


2001 270-H

Cruise Control Circuitrev. 4-03

Lift Circuit

Charging Circuit

270-H 2001


rev. 4-03

Light Circuit

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Switch(in start)

Re RePk Pk

Bn

Bn

Bk

Bn

Or

OrY

Y

Or Or Gn

Gn

T

Bu

BuGy

Gy Vio

B

I

S

InterlockRelay

(energized)Fuse



Neutral Switch(in neutral)


(energized)





Switch(in start)

Re RePk Pk

BnBk

Or

OrY

Y

Bu

BuGy

Gy Vio

B

I


(disengaged)




Triggermodule

Ignition Coil

Triggermodule


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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Y Bk

Bk

Triggermodule

Triggermodule




Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

R

I





(NMIR)


PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

&LUFXLWV

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Y Bk

Bk

Triggermodule

Ignition Coil

Triggermodule

Ignition Coil



Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

A

L





(NMIR)


PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W

Bk

T

T

Bk

Bk


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y


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Switch(in run)

Re Re Pk

Pk

Bu

Bu

Bk

BkBk

BkBu

Bu

Bu

Y T

T

Y

Pk

Pk

B I



Cruise Lamp(on)





Fuse(25 amp)

Lift Pump(Energized)


Lift Switch(in operation)

Re Re Pk Bu

Or

W

Bu

Bk

Bk

Bk

Bu

B I

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

&LUFXLWV


�� +

&LUF

XLWV

&KDUJLQJ�&LUFXLW

/LJKW�&LUFXLW

AC

B+AC BatteryFuse

(30 amp)

Fuse(10 amp)

Fuse(25 amp)


Re

Or

Pk

Bk

Pk

Pk

VioVioB

R

I



B+

VoltageComparator


Battery Light


Fuse(10 amp)

Headlights(on)

IgnitionSwitch

(in run/lights)

Re Or Or BkRe

B L

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y




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Switch(in start)

Re RePk Pk

Bn

Bn

Bk

Bn

Y

Y Y T

Y

Or Or Gn

Gn

Bu

BuGy

Gy

B

I

S

InterlockRelay

(energized)Fuse




(energized)





Switch(in start)

Re RePk Pk

BnBk

Y

Y

Bu

BuGy

Gy

B

I


(disengaged)



Triggermodule

Ignition Coil

Triggermodule


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


��+ ��




Y Bk

Bk

Triggermodule

Triggermodule




Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

R

I





(NMIR)


PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

&LUFXLWV


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Y Bk

Bk

Triggermodule

Ignition Coil

Triggermodule

Ignition Coil



Re RePk

Vio

Vio Vio

PkOrTPk

Gn

Bu

Bu Bn Bk

Bk

Bk

W

W

Bu

B

A

L





(NMIR)


PTO Switch(engaged)

PTO Light(on)

PTO Clutch(engaged)

Fuse(25 amp) W

Bk

T

T

Bk

Bk


not engaged)

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y


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Switch(in run)

Re Re Pk

Pk

Bu

Bu

Bk

BkBk

BkBu

Bu

Bu

Y T

T

Y

Pk

Pk

B I



Cruise Lamp(on)





Fuse(25 amp)

Lift Pump(Energized)


Lift Switch(in operation)

Re Re Pk Bu

Or

W

Bu

Bk

Bk

Bk

Bu

B I

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y

&LUFXLWV


�� +

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XLWV

&KDUJLQJ�&LUFXLW

/LJKW�&LUFXLW

AC

B+AC BatteryFuse

(30 amp)

Fuse(10 amp)

Fuse(25 amp)


Re

Or

Pk

Bk

Pk

Pk

VioVioB

R

I



B+

VoltageComparator


Battery Light


Fuse(10 amp)

Headlights(on)

IgnitionSwitch

(in run/lights)

Re Or Or BkRe

B L

Legend

Black Bk

Blue Bu

Brown Bn

Green Gn

Grey Gy

Orange Or

Pink Pk

Red Re

Tan T

Violet Vio

White W

Yellow Y





Wiring Diagram . . . . . . . . . . . . . . . . . . 7-2

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . . 7-3


Hourmeter Circuit . . . . . . . . . . . . . 7-4

Light Circuit . . . . . . . . . . . . . . . . . 7-4

In

fo

rm

atio

nLis

t

1988 308-8


Wiring Diagram

Wir

ing

Dia

gra

m

308-8 1988


Charging Circuit


Cir

cu

its

Spark Circuit




1988 308-8


Hourmeter Circuit


Cir

cu

its

Light Circuit


308-8 1988



Wiring Diagram . . . . . . . . . . . . . . . . . 7-6

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-7


Oil Indicator Light Test Circuit . . . . . . . 7-8

Oil Circuit . . . . . . . . . . . . . . . . . 7-9

Accessories Circuit . . . . . . . . . . . . 7-9

In

fo

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1989 - 1991 310-8


Wiring Diagram

Wir

ing

Dia

gra

m

310-8 1989 - 1991



(with ignition switch in “start” )

Spark Circuit

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

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

1989 - 1991 310-8


Oil Indicator Light Test Circuit

(with test switch depressed)

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Charging Circuit


Cir

cu

its

310-8 1989 - 1991


Oil Circuit

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

Accessories Circuit

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

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

1989 - 1991 310-8





Wiring Diagram . . . . . . . . . . . . . . . . 12-12

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-13


Oil Indicator Light Test Circuit . . . . . . . 7-14

Oil Circuit . . . . . . . . . . . . . . . . . 7-15

Accessories Circuit . . . . . . . . . . . . 7-15

In

fo

rm

atio

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1988 310-8


Wiring Diagram

Wir

ing

Dia

gra

m

310-8 1988



(ignition switch in “start” )

Spark Circuit

(ignition switch in “run” or “start”)

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

1988 310-8


Oil Indicator Light Test Circuit

(test switch depressed)

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Charging Circuit


Cir

cu

its

310-8 1988


Oil Circuit

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

Accessories Circuit

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

Cir

cu

its

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

1988 310-8





Wiring Diagram . . . . . . . . . . . . . . . . . 7-18

Circuit Diagrams


Spark Circuits . . . . . . . . . . 7-19 & 7-20



Light Circuit . . . . . . . . . . . . . . . 7-21

In

fo

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1998 312-8


Cir

cu

its



Spark Circuit


1998 312-8


Cir

cu

its

Spark Circuit


Charging Circuit


Hourmeter Circuit


312-8 1998


Light Circuit


Cir

cu

its

1998 312-8




1999 - 2001 312-8

rev. 4-03




Starter Motor Circuit . . . . . . . . . . 7-22ESpark Circuit . . . . . . . . . . . . . 7-22ERun Forward (PTO “on”) . . . . . . . . . 7-22FRun Reverse (PTO “on” NMIR override) . . . 7-22GCharging Circuit . . . . . . . . . . . . 7-22HLight Circuit . . . . . . . . . . . . . 7-22H

312-8 1999 - 2001



1999 - 2001 312-8



rev. 4-03




1999 - 2001 312-8


rev. 4-03



312-8 1999 - 2001


rev. 4-03


1999 - 2001 312-8


rev. 4-03

Charging Circuit

312-8 1999 - 2001


rev. 4-03

Light Circuit

rev. 4-03


310-8 Information List (1992 - 1993)312-8 Information List (1992 - 1997)314-8 Information List 1992 (1993)


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

310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997

310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997



rev. 4-03


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


310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997

rev. 4-03


Charging Circuit(ignition switch in “run”)



310-8 - - - - - - - - - - 1992-1993 314-8 - - - - - - - - - - 1993312-8 - - - - - - - - - - 1992-1997


Wiring Diagram . . . . . . . . . . . . . . . . . 7-28

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-29

Gauge Circuit . . . . . . . . . . . . . . . 7-30


Light Circuit . . . . . . . . . . . . . . . . 7-30

Oil Circuit . . . . . . . . . . . . . . . . . 7-31

In

fo

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atio

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t1989 312-8


Wiring Diagram

Wir

ing

Dia

gra

m312-8 1989




Spark Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

1989 312-8


Gauge Circuit


Charging Circuit


Light Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

312-8 1989


Oil Circuit


Cir

cu

its

1989 312-8





Wiring Diagram . . . . . . . . . . . . . . . . . 7-34

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-35


Gauge Circuit . . . . . . . . . . . . . . . 7-36

Light Circuit . . . . . . . . . . . . . . . . 7-36

Oil Circuit . . . . . . . . . . . . . . . . . 7-37

In

fo

rm

atio

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1987 - 1988 312-8


Wiring Diagram

Wir

ing

Dia

gra

m

312-8 1987 - 1988


Cir

cu

its



Spark Circuit


1987 - 1988 312-8


Cir

cu

its

Gauge Circuit


Light Circuit


Charging Circuit


312-8 1987 - 1988


Cir

cu

its

Oil Circuit


1987 - 1988 312-8




312-H & 312-8 Information List (1990 - 1991)

Wiring Diagram . . . . . . . . . . . . . . . . . 7-40

Circuit Diagrams

Starter Motor Circuits . . . . . . . . . . . 7-41

Spark Circuit . . . . . . . . . . . . . . . 7-42


Gauge Circuit . . . . . . . . . . . . . . . 7-42

Light Circuit . . . . . . . . . . . . . . . 7-43

In

fo

rm

atio

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1990 - 1991 312-H & 312-8


Wiring Diagram

Wir

ing

Dia

gra

m

312-H & 312-8 1990 - 1991


Cir

cu

its

Spark Circuit


Charging Circuit


Gauge Circuit


312-H & 312-8 1990 - 1991


Cir

cu

its

Light Circuit


1990 - 1991 312-H & 312-8




312-A & 312-8 Information List (1986)

Wiring Diagram . . . . . . . . . . . . . . . . . 7-46

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-48


Gauge Circuit . . . . . . . . . . . . . . . 7-48

Light Circuit . . . . . . . . . . . . . . . 7-49

Oil Light Test Circuit . . . . . . . . . . . 7-49

In

fo

rm

atio

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1986 312-A & 312-8


Cir

cu

its




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

1986 312-A & 312-8


Gauge Circuit


Cir

cu

its

Spark Circuit


Charging Circuit


312-A & 312-8 1986


Cir

cu

its

Light Circuit


Oil Light Test Circuit


1986 312-A & 312-8




312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997rev. 4-03


312-H Information List (1992)314-H (1993 - 1997)314-8 (1994 - 1997)


Starter Motor Circuit . . . . . . . . . . 7-55Spark Circuits . . . . . . . . . . 7-55 & 7-56Charging Circuit . . . . . . . . . . . . 7-56Charging Circuit . . . . . . . . . . . 7-56



312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997

rev. 4-03




312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997

rev. 4-03



Charging Circuit


312-H . . . 1992 314-8 . . . 1994 - 1997314-H . . . 1993 - 1997

1999 - 2001 314-8

rev. 4-03

7-56ADemystification Guide



Starter Motor Circuit . . . . . . . . . . 7-56DSpark Circuit . . . . . . . . . . . . . 7-56DRun Forward (PTO “on”) . . . . . . . . . 7-56ERun Reverse (PTO “on” NMIR override) . . . 7-56FCharging Circuit . . . . . . . . . . . . 7-56GLight Circuit . . . . . . . . . . . . . 7-56GLow Oil Pressure Light Circuit . . . . . . 7-56GHourmeter . . . . . . . . . . . . . . 7-56H

314-8 1999 - 2001



1999 - 2001 314-8




314-8 1999 - 2001


rev. 4-03



1999 - 2001 314-8


rev. 4-03


314-8 1999 - 2001


rev. 4-03


1999 - 2001 314-8

Charging Circuitrev. 4-03

Light Circuit

Low Oil Pressure Light Circuit(ignition switch in “run”)

Hourmeter(ignition switch in “run” )

314-8 1999 - 2001


rev. 4-03

1992 - 1997 416-81992 - 1997 416-Hrev. 4-03


416-8 Information List (1992 - 1997)416-H (1992 - 1997)


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

416-8 1992-1997416-H 1992-1997



rev. 4-03




416-8 1992-1997416-H 1992-1997

Charging Circuit

rev. 4-03


Oil Pressure Switch Circuit(ignition switch in “run”)

Light Test Circuit(ignition switch in “run”)

Voltmeter Circuit(ignition switch in “run”)

416-8 1992-1997416-H 1992-1997

416-H & 416-8 Information List (1990 - 1991)

Wiring Diagram . . . . . . . . . . . . . . . . . 7-62

Circuit Diagrams


Spark 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 and Neutral/Clutch Circuit . . . . . . 7-65

Low Oil Pressure Light Circuit . . . . . . 7-66

Hourmeter Circuit . . . . . . . . . . . . . 7-66

Voltmeter Circuit . . . . . . . . . . . . . . 7-66

In

fo

rm

atio

nLis

t

1990 - 1991 416-H & 416-8


Wiring Diagram

Wir

ing

Dia

gra

m

416-H & 416-8 1990 - 1991




Spark Circuit

(ignition switch in “start” or “run”)

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Charging Circuit

Cir

cu

its

1990 - 1991 416-H & 416-8


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

Seat Light Circuit

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

Light Circuit



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

416-H & 416-8 1990 - 1991


Neutral/Clutch Light Cirtcuit

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

PTO and Neutral/Clutch Circuit

(ignition switch in “start”)(lights when BOTH the PTO is engaged and unit is not clutched or in neutral)

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

PTO Light Circuit

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

1990 - 1991 416-H & 416-8


Low Oil Pressure Light Circuit


Hourmeter Circuit


Voltmeter Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

416-H & 416-8 1990 - 1991



Wiring Diagram . . . . . . . . . . . . . . . . . 7-68

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-69


Gauge Circuit . . . . . . . . . . . . . . . 7-70

Light Circuit . . . . . . . . . . . . . . . . 7-70

In

fo

rm

atio

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t

1989 416-8


Wiring Diagram

Wir

ing

Dia

gra

m

416-8 1989


Cir

cu

its

Charging Circuit

Spark Circuit




1989 416-8


Cir

cu

its

Gauge Circuit


Light Circuit


416-8 1989



Wiring Diagram . . . . . . . . . . . . . . . . . 7-72

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-74


Gauge Circuit . . . . . . . . . . . . . . . 7-74

Light Circuit . . . . . . . . . . . . . . . . 7-75

In

fo

rm

atio

nLis

t

1986 416-8


Cir

cu

its


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



1986 416-8


Cir

cu

its

Spark Circuit


Charging Circuit


Gauge Circuit


416-8 1986


Light Circuit


Cir

cu

its

1986 416-8





Wiring Diagram . . . . . . . . . . . . . . . . . 7-78

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-79


Gauge Circuit . . . . . . . . . . . . . . . 7-80

Lights Circuit . . . . . . . . . . . . . . . 7-80

In

fo

rm

atio

nLis

t

1985 416-8


Wiring Diagram

Wir

ing

Dia

gra

m

416-8 1985


Spark Circuit


Charging Circuit

Cir

cu

its



1985 416-8


Cir

cu

its

Gauge Circuit


Lights Circuit

(with engine running)

416-8 1985



Wiring Diagram . . . . . . . . . . . . . . . . . 7-82

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-83

Light Circuit . . . . . . . . . . . . . . . . 7-84

Gauge Circuit . . . . . . . . . . . . . . . 7-84


Oil Circuit . . . . . . . . . . . . . . . . . 7-85

In

fo

rm

atio

nLis

t1989 414-8


Wiring Diagram

Wir

ing

Dia

gra

m414-8 1989




Spark Circuit


Cir

cu

its

Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

1989 414-8


Gauge Circuit


Charging Circuit


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Cir

cu

its

Light Circuit


414-8 1989


Legend

Black Bk

Blue Bu

Brown Br

Dark Blue Dk Bu

Dark Green Dk Gn

Green Gn

Gray Gy

Light Blue Lt Bu

Orange Or

Pink Pi

Purple Pu

Red Rd

Tan Ta

White Wh

Yellow Ye

Oil Circuit


1989 414-8





Wiring Diagram . . . . . . . . . . . . . . . . . 7-88

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-89


Gauge Circuit . . . . . . . . . . . . . . . 7-90

Light Circuit . . . . . . . . . . . . . . . . 7-90

In

fo

rm

atio

nLis

t

1987 - 1988 414-8 & 416-8


Wiring Diagram

Wir

ing

Dia

gra

m

414-8 & 416-8 1987 - 1988


Cir

cu

its



Spark Circuit


1987 - 1988 414-8 & 416-8


Cir

cu

its

Charging Circuit

Gauge Circuit


Light Circuit


414-8 & 416-8 1987 - 1988



Wiring Diagram . . . . . . . . . . . . . . . . . 7-92

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . . 7-93


Gauge Circuit . . . . . . . . . . . . . . . 7-94

Light Circuit . . . . . . . . . . . . . . . . 7-94

Oil Light Test Circuit . . . . . . . . . . . . 7-95

In

fo

rm

atio

nLis

t

1986 414-8


Wiring Diagram

Wir

ing

Dia

gra

m

414-8 1986


Cir

cu

its



Spark Circuit


1986 414-8


Gauge Circuit


Cir

cu

its

Charging Circuit


Light Circuit


414-8 1986


Cir

cu

its

Oil Light Test Circuit


1986 414-8





Wiring Diagram . . . . . . . . . . . . . . . . 7-106

Circuit Diagrams

Starter Motor Circuit . . . . . . . . . . 7-107

Spark Circuit . . . . . . . . . . . . . . 7-107

Charging Circuit . . . . . . . . . . . . 7-107


Hydrostat Temperature Light Circuit . . 7-108

Air Filter Indicator Light . . . . . . . . . 7-108

Meter Light Circuit . . . . . . . . . . . 7-109

Parking Brake Light Circuit . . . . . . 7-109

Engine Temperature Light Circuit . . . 7-109

Hourmeter Circuit . . . . . . . . . . . 7-110

Headlight Circuit . . . . . . . . . . . . 7-110

Fuel Gauge . . . . . . . . . . . . . . . 7-110

Tachometer Circuit . . . . . . . . . . . 7-111

In

fo

rm

atio

nLis

t

1990 520-H


Wiring Diagram

Wir

ing

Dia

gra

m

520-H 1990


Cir

cu

its



Hydrostat Temperature Light Circuit


Air Filter Indicator Light


520-H 1990


Engine Temperature Light Circuit


Cir

cu

its



Meter Light Circuit


1990 520-H


Hourmeter Circuit


Cir

cu

its

Fuel Gauge


Headlight Circuit

(headlight “on”)

520-H 1990


Tachometer Circuit


Cir

cu

its

1990 520-H





Wiring Diagram . . . . . . . . . . . . . . . . 7-114

Circuit Diagrams


Spark Circuit . . . . . . . . . . . . . . 7-115



Air Filter Indicator Light . . . . . . . . . 7-116


Parking Brake Light Circuit . . . . . . 7-117

Engine Temperature Light Circuit . . . 7-117


Headlight Circuit . . . . . . . . . . . . 7-118

Fuel Gauge Circuit . . . . . . . . . . . 7-118

In

fo

rm

atio

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t

1990 520-8


Wiring Diagram

Wir

ing

Dia

gra

m

520-8 1990




Spark Circuit


Charging Circuit

Cir

cu

its

1990 520-8




Cir

cu

its

Meter Light Circuit


Air Filter Indicator Light


520-8 1990


Engine Temperature Light Circuit


Cir

cu

its

Hourmeter Circuit




1990 520-8


Headlight Circuit

(headlight “on”)

Fuel Gauge Circuit


Cir

cu

its

520-8 1990


518-H & 520-H Information List (1988 - 1989)

Wiring Diagram . . . . . . . . . . . . . . . . 7-120

Circuit Diagrams


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


Fuel Gauge Circuit . . . . . . . . . . . 7-123


Voltmeter Circuit . . . . . . . . . . . . . 7-124

Indicator Light Test Circuit . . . . . . . 7-124

High Engine TemperatureIndicator Light Circuit . . . . . . . . . 7-125

In

fo

rm

atio

nLis

t

1988 - 1989 518-H & 520-H


Wiring Diagram

Wir

ing

Dia

gra

m

518-H & 520-H 1988 - 1989


Air Filter Light Circuit


Seat Light Circuit

(ignition switch in or “run”)

Oil Pressure Indicator Circuit


Cir

cu

its

518-H & 520-H 1988 - 1989


Hydrostat Temperature Light Circuit


Cir

cu

its

Tachometer Circuit


Fuel Gauge Circuit


1988 - 1989 518-H & 520-H


Voltmeter Circuit


Hourmeter Circuit


Cir

cu

its

Indicator Light Test Circuit


518-H & 520-H 1988 - 1989


Cir

cu

its

High Engine Temperature Indicator Light Circuit


1988 - 1989 518-H & 520-H




516-H & 520-HC Information List (1988 - 1989)

Wiring Diagram . . . . . . . . . . . . . . . . 7-128

Circuit Diagrams


Spark Circuits . . . . . . . . . . . . . 7-129



Fuel Gauge . . . . . . . . . . . . . . . 7-130

Light Circuit . . . . . . . . . . . . . . . 7-131




In

fo

rm

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t

1988 - 1989 516-H & 520-HC


Wiring Diagram

Wir

ing

Dia

gra

m

516-H & 520-HC 1988 - 1989


Cir

cu

its

Charging Circuit

AlternatorFuse Battery

(12 Volt)

BkBk

(30 amp)

AC

ACB+

Regulator/Rectifier



Fuel Gauge


516-H & 520-HC 1988 - 1989


Cir

cu

its

Light Circuit


Meter Light Circuit


Hourmeter Circuit


1988 - 1989 516-H & 520-HC


Cir

cu

its

Tachometer Circuit


516-H & 520-HC 1988 - 1989


518xi Information List (1998)

Wiring Diagram . . . . . . . . . . . . . . . . 7-134

Circuit Diagrams


Spark Circuits . . . . . . . . . 7-135 & 7-136


Light Circuit . . . . . . . . . . . . . . . 7-136



Gauge Circuit . . . . . . . . . . . . . . 7-137

In

fo

rm

atio

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1998 518xi


Wiring Diagram

Wir

ing

Dia

gra

m

518xi 1998


Spark Circuit

(ignition switch in “start” position)

Spark Circuit

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


(ignition switch in “start” position)

Cir

cu

its

1998 518xi


Spark Circuit

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

Charging Circuit

(Ignition Switch in “run”)

Light Circuit

(ignition switch in “run/lights”)

Cir

cu

its

518xi 1998




Cir

cu

its

Hourmeter Circuit


Gauge Circuit


1998 518xi




1999 - 2001 518xi

rev. 4-03


518xi Information List (1999 - 2001)


Starter Motor Circuit . . . . . . . . . . 7-138ERun Circuit (operator “on”) . . . . . . . . 7-138EClutch Circuit (forward PTO “on”) . . . . . 7-138FClutch Circuit (fwd/rev PTO “on”) . . . . . 7-138GCharging Circuit . . . . . . . . . . . 7-138GLight Circuit . . . . . . . . . . . . . 7-138HGauge Circuit . . . . . . . . . . . . 7-138HHourmeter Circuit . . . . . . . . . . . 7-138H

518xi 1999 - 2001



1999 - 2001 518xi






1999 - 2001 518xi


rev. 4-03


Clutch Circuit(forward PTO “on” )

518xi 1999 - 2001


rev. 4-03


1999 - 2001 518xi

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

rev. 4-03


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

518xi 1999 - 2001


rev. 4-03

Gauge Circuit(ignition switch in “run” )

Hourmeter Circuit(ignition switch in “run” )

520xi & 522xi Information List (1998)

Wiring Diagram . . . . . . . . . . . . . . . . 7-140

Circuit Diagrams


Spark Circuit . . . . . . . . . 7-141 & 7-142


Electric Clutch . . . . . . . . . . . . . . 7-143

Light Circuit . . . . . . . . . . . . . . . 7-143

Reverse Light Circuit . . . . . . . . . . 7-144


Gauge Circuit . . . . . . . . . . . . . . 7-145

Cruise Control Circuit . . . . . . . . . . 7-145

Park Light Circuit . . . . . . . . . . . . 7-145

In

fo

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atio

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t

1998 520xi & 522xi


Wiring Diagram

Wir

ing

Dia

gra

m

520xi & 522xi 1998




Spark Circuit


Cir

cu

its

1998 520xi & 522xi


Cir

cu

its

Spark Circuit

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

Spark Circuit

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

520xi & 522xi 1998


Cir

cu

its

Light Circuit


Electric Clutch


Charging Circuit


1998 520xi & 522xi


Cir

cu

its

Reverse Light Circuit


Hourmeter Circuit


520xi & 522xi 1998


Cir

cu

its



Gauge Circuit


Park Light Circuit


1998 520xi & 522xi




1999 - 2001 520xi & 522xi

rev. 4-03


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


Starter Motor Circuit . . . . . . . . . . 7-146ERun Circuit (operator “on”) . . . . . . . . 7-146EClutch Circuit (forward PTO “on”) . . . . . 7-146FClutch Circuit (fwd/rev PTO “on”) . . . . . 7-146GCharging Circuit . . . . . . . . . . . 7-146GLight Circuit . . . . . . . . . . . . . 7-146HGauge Circuit . . . . . . . . . . . . 7-146HHourmeter Circuit . . . . . . . . . . . 7-146H

520xi & 522xi 1999 - 2001



1999 - 2001 520xi & 522xi






1999 - 2001 520xi & 522xi


rev. 4-03


Clutch Circuit(forward PTO “on” )

520xi & 522xi 1999 - 2001


rev. 4-03


1999 - 2001 520xi & 522xi

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

rev. 4-03



520xi & 522xi 1999 - 2001


rev. 4-03



520Lxi Information List (1998)

Wiring Diagram . . . . . . . . . . . . . . . . 7-150

Circuit Diagrams


Spark Circuit . . . . . . . . . 7-151 & 7-152


Light Circuit . . . . . . . . . . . . . . . 7-152


Gauge Circuit . . . . . . . . . . . . . . 7-153





In

fo

rm

atio

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t

1998 520Lxi


Wiring Diagram

Wir

ing

Dia

gra

m

520Lxi 1998


Cir

cu

its



Spark Circuit


1998 520Lxi


Cir

cu

its

Light Circuit


Charging Circuit


Spark Circuit


520Lxi 1998


Cir

cu

its



Gauge Circuit




1998 520Lxi


Cir

cu

its

Park Light Circuit


Hourmeter Circuit




520Lxi 1998


1999 - 2001 520Lxi

rev. 4-03

7-155Demystification Guide

520Lxi Information List (1999 - 2001)

Wiring Diagram . . . . . . . . . . . 7-156, 7-156ACircuit Diagrams

Starter Motor Circuit . . . . . . . . . . 7-156BRun Circuit (operator “on”) . . . . . . . . 7-156BClutch Circuit (forward PTO “on”) . . . . . 7-156CClutch Circuit (fwd/rev PTO “on”) . . . . . 7-156DCharging Circuit . . . . . . . . . . . 7-156DLight Circuit . . . . . . . . . . . . . 7-156EGauge Circuit . . . . . . . . . . . . 7-156ECruise Control Circuit . . . . . . . . . 7-156EHourmeter Circuit . . . . . . . . . . . 7-156FPark Light Circuit . . . . . . . . . . . 7-156F

520Lxi 1999 - 2001



1999 - 2001 520Lxi


Demystification Guide 7 - 156A

Starter Motor Circuit(ignition switch in “start” )

520Lxi 1999 - 2001


rev. 4-03

Run Circuit(operator “on” )


1999 - 2001 520Lxi

Clutch Circuit(forward PTO “on”)

rev. 4-03

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

520Lxi 1999 - 2001


rev. 4-03

Charging Circuit(ignition switch in “run” )


1999 - 2001 520Lxi

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

rev. 4-03

Gauge Circuit(ignition switch in “run”)


Hourmeter Circuit(ignition switch in “run”

520Lxi 1999 - 2001


rev. 4-03

Park Light Circuit(ignition switch in “run” )

523Dxi Information List (1998)

Wiring Diagram . . . . . . . . . . . . . . . . 7-158

Circuit Diagrams


Injection Pump Circuits . . . . . . . . . 7-159


Glow Plug Circuit . . . . . . . . . . . . 7-160

Light Circuit . . . . . . . . . . . . . . . 7-160

Electric Clutch Circuit . . . . . . . . . 7-161

Gauge Circuit . . . . . . . . . . . . . . 7-161





Temperature Light Circuit . . . . . . . . 7-163

In

fo

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1998 523Dxi


Wiring Diagram

Wir

ing

Dia

gra

m

523Dxi 1998


Cir

cu

its

Injection Pump Circuit




Injection Pump Circuit


1998 523Dxi


Cir

cu

its

Glow Plug Circuit

(ignition switch in “on” )

Charging Circuit


Light Circuit


523Dxi 1998


Cir

cu

its

Gauge Circuit



(ignition switch in “run” or “start)

1998 523Dxi


Cir

cu

its

Hourmeter Circuit




Park Light Circuit


523Dxi 1998


Temperature Light Circuit

(ignition switch in “run” )


(ignition switch in “run” )

Cir

cu

its

1998 523Dxi




1999 - 2001 523Dxi

rev. 4-03

7-165Demystification Guide

523Dxi Information List (1999 - 2001)

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

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

523Dxi 1999 - 2001



1999 - 2001 523Dxi






1999 - 2001 523Dxi


rev. 4-03


Clutch Circuit(forward PTO “on”

523Dxi 1999 - 2001


rev. 4-03


1999 - 2001 523Dxi

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

rev. 4-03



523Dxi 1999 - 2001




rev. 4-03


1999 - 2001 523Dxi

Glow Plug Circuit(ignition switch in“on”)

rev. 4-03


Temperature Light Circuit(ignition switch in “run” )

523Dxi 1999 - 2001


Park Light Circuit(ignition switch in “run” )

rev. 4-03

2001200120012001 TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z


TimeCutter Z (2001)

Wiring Diagram (Briggs & Stratton) . . . . . . . . . . . . . . . . . . . 8-2Wiring Diagram (Kohler). . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Circuit Diagrams

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

Info

rmatio

n L

ist

TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z 2001200120012001


Wiring Diagram

Wir

ing

Dia

gra

m



Wiring Diagram

Wirin

g D

iag

ram

TIMECUTTER ZTIMECUTTER ZTIMECUTTER ZTIMECUTTER Z 2001200120012001



Run Circuit(PTO engaged)


Y

W


PTOSwitch

(off)

Brake Switch(parking brake

engaged)



IgnitionSwitch

(in start)

Re RePk

BuB

S

I

Solenoid(energized)

Starter Motor(energzized)


YY

W


Brake Switch(parking brakedisengaged)


PTO Switch(pto on)



Re Re

Bk

Pk

Or

Or Vio

Pk

BY

X

I

Triggermodule

Ignition Coil


Bk

PTO Clutch(engaged)

Cir

cu

its

Legend




Charging Circuit(Kohler)

Charging Circuit(Briggs & Stratton)

BatteryAlternatorVoltage Regulator

Fuse(30 amp)

Fuse(25 amp) Ignition

Switch(in run)

ReVio Vio Re

BA

AC

B+AC

Circ

uits

Legend




Riding Products Demystification

Guide

Form No.

Documents

Toro wheelhorse Demystification Electical wiring diagrams for all WheelHorse tractors