electrical vol 3 manual - grasshopper dealers

Price $12.00

ALL MODELSSERIAL NUMBERS 6300000 AND UP

SERVICE MANUALELECTRICAL TROUBLESHOOTING

VOLUME 3

Form 172112-160216Printed in U.S.A.

THE GRASSHOPPER COMPANYMoundridge, Kansas 67107 U.S.A.

(620) 345-8621GRASSHOPPERMOWER.COM

2

This manual has been developed to diagnose component failures only. It will not indicate a problem in the wiring or terminals. For ex-ample, if the troubleshooting guide indicates that the left steering switch is defective and replacing the left steering switch does not solve the problem; then you may have bad terminals or wiring to that switch.

Consult the operator's manual wiring diagram for the specific year and model of the ma-chine you are working on for troubleshooting. For further assistance, contact The Grass-hopper Company, service department at (620)345-8621.

Copyright © 2017, 2016 & 2015 by The Grasshopper Company. The following material is proprietary information. All rights reserved. Repro-duction or dissemination in any form by any means is prohibited, except by express written permission from The Grasshopper Company.

INTRODUCTION

3

PAGEINTRODUCTION 2

SWITCH FUNCTIONS 5-6

FUNCTION OF A RELAY 7

TROUBLESHOOTING CONTROL RELAYS All Kubota Gasoline Models ..............................................................................................8 All Kubota Diesel Models ..................................................................................................8 Control Relay - All Kubota Models ..................................................................................10 Circuit Board Diode Problems - All Models .....................................................................10

TESTING SAFETY SYSTEM FOR PROPER OPERATION All Briggs & Kohler Models .............................................................................................12 All Kubota Models ...........................................................................................................13

BATTERY CHARGING SYSTEM All Briggs Models & Kohler Models excluding Kohler EFI Models ..................................14 All Kubota Models with Smooth Alternators . .................................................................15 All Kubota Models with Aluminum/Finned Alternators .....................................................16

ENGINE WILL NOT CRANK 124, 126, 226V and 616T Series Models ................................................................. 18-19 125 Kohler, 200 Series Models except 226V, All Briggs Big Block Models, 620T & 623T Models and all 700 Kohler Models................. ..................................... 20-21 All Kubota Models ..................................................................................................... 22-23

ENGINE WILL CRANK, BUT NOT START All Briggs & Kohler Models ..............................................................................................24 All Kubota Gasoline Models ...........................................................................................25 All Kubota Diesel Models except those with D902 Engines. ..........................................26 Kubota Diesel Models with D902 Engines ......................................................................27

ENGINE STARTS, BUT DIESWHEN STEERING LEVERS ARE BROUGHT IN OR PTO SWITCH IS ENGAGED All Models ........................................................................................................................28 ENGINE STARTS, BUT DIESWHEN KEY SWITCH IS RELEASED All Kubota Diesel Models except those with D902 Engines. ..................................... 30-31 Kubota Diesel Models with D902 Engines ......................................................................32 Briggs & Kohler Models ...................................................................................................33

TABLE OF CONTENTS

(continued)

4

TABLE OF CONTENTS(CONTINUED)

ENGINE STARTS AND RUNS, BUT WILL NOT SHUT OFF Kubota Diesel Models with D902 Engines ................................................................ 34-35

TROUBLESHOOTING PTO CLUTCH All Models except Kubota ................................................................................................36 All Kubota Models ..........................................................................................................37 Acceptable Clutch Resistance Range in Ohms ..............................................................38 High Temperature Clutch Cutout Wiring ..........................................................................39

TROUBLESHOOTING ELECTRIC LIFT Electric Lift Does Not Operate ................................................................................... 40-43 Wiring Diagram ...............................................................................................................44

HYDRAULIC LIFT DOES NOT WORK Hydraulic Dozer Electrical Troubleshooting ....................................................................45 One Piece Tilt Switch/Delay Timer Style ................................................................... 46-47

JOYSTICK WIRING TROUBLESHOOTING Joystick Wiring Troubleshooting - Total Loss of Motion...................................................48 Joystick Wiring Troubleshooting - Loss of Motion in One Direction ................................49

TRACTOR ACCESSORY HARNESS TROUBLESHOOTING All Models .................................................................................................................. 50-52

5

Ignition switch, part no. 183806.(All Briggs, Kawasaki & Kohler Models). M Magneto terminal. S Starter terminal. B Battery terminal. L Lights, accessory terminal. G Ground terminal.

Ignition switch, part no. 183827.(All Kubota Models). 30 Battery terminal. 50 Starter terminal. AC Accessory terminal. 17 Glow plug terminal (Diesel only). 19 Glow plug indicator terminal (Diesel only).

Brake switch, part no. 183894.NC (normally closed) - means that the con-

tact is closed and current will fl ow between these two terminals. When the button is depressed, these two terminals become open.

NO (normally open) - means that the contact is open with the switch mechanism released. When the button is depressed, these two terminals become closed.

The dotted line indicates an electrical connec-tion between the two terminal posts.

SWITCH FUNCTIONS

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NC NO

NC NO

RELEASED

DEPRESSED

6

Left and right steering switch, part no. 183860.NC (normally closed) - means that the con-

tact is closed with the switch mechanism released. The contact position is reversed when the switch lever is depressed.

NO (normally open) - means that the contact is open with the switch mechanism re-leased. The contact position is reversed when the switch lever is depressed.

The dotted line indicates an electrical con-nection between the two terminal posts.

PTO switch, part no. 183925.The dotted line indicates an electrical con-nection between the two terminal posts.

Seat switch, part no. 183871.The dotted line indicates an electrical con-nection between the two terminal posts.

SWITCH FUNCTIONS

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7

FUNCTION OF A RELAY

87

87A86 85

30

87a

87

30

87

87A86 85

30

86

85

87a

87

30NON-ENERGIZED

ENERGIZED

NON-ENERGIZED - Means that terminal 30 and terminal 87a are connected when the relay is not energized

ENERGIZED - Means that terminal 30 and terminal 87 are connected when the relay is energized

CONTROL RELAY OPERATION FRONT MOUNT

Run Relay - Accessory

Start Relay

High Temp - Output from the Temp Gauge“Latch Up Relay”

High Temp - OpensClutch Circuit

Universal Harness - Opens Clutch Circuit

MID MOUNT


Start Relay

High Temp - Output from the Temp Gauge“Latch Up Relay”

High Temp - OpensClutch Circuit

Switches +12 Volts toDeck Height Pump

A

B

C

D

E

8

ALL KUBOTA GASOLINE MODELS 1. Control relay - inspection. A. Control relay A has 2 red wires, 2 black

wires, 1 yellow wire and 2 green wires in the relay socket.

B. Control relay B has 3 blue wires and 1 green wire in the relay socket.

2. Assuming the main fuse, PTO fuse, ignition fuse are good, failure of control relay A or associated wiring will be evidenced by the following three symptoms:

A. PTO clutch will not engage. B. Hourmeter will not run. C. Ignition coil will not have voltage on the

positive terminal*

3. Assuming the start fuse is good, failure of control relay B or associated wiring will re-sult in starter solenoid not engaging; thus the starter motor will not operate.

ALL KUBOTA DIESEL MODELS 1. Control relay - inspection. A. Control relay A has 2 red wires, 1 black

wire, 1 yellow wire and 1 green wire in the relay socket.

B. Control relay B has 3 blue wires and 1 green wire in the relay socket.

2. Assuming the main fuse, PTO fuse, ignition fuse are good, failure of control relay A or associated wiring will be evidenced by the following three symptoms:

A. PTO clutch will not engage. B. Hourmeter will not run. C. Fuel solenoid will pull in but not hold.

3. Assuming the start fuse is good, failure of control relay B or associated wiring will re-sult in starter solenoid not engaging; thus the starter motor will not operate.

TROUBLESHOOTING CONTROL RELAYS

* (On 432 and 932, the plug which leads to igniter assembly will not have voltage).

This wire goes to ground when:1. Driver on seat and parking brake released,2. or PTO off, both steering levers out,3. or both of the above.

Red w/White

Yellow w/Brown

Green

Red

Black

+12 volts with keyswitch in ‘RUN’position

To mainfuse

To padA of PCboard

Relay C

To pad M of PC board

To PTO fuse &ignition fuse+12 volts with relay

‘A’ is energized

To G terminal on Voltmeter

Gauge

Green

To I terminal on Voltmeter

GaugeBlack


Green w/Yellow

Blue

Blue

This wire goes toground with steeringlevers out and PTO off

+12 volts with keyswitch in ‘START’position

To padR of PCboard

To startfuse

Startersolenoid

+12 volts with relay‘B’ is energized

Start Relay

Figure 1

Figure 2

9

Purple +12 volts withkey in the ‘RUN’position

This wire goes toground whenthe temp gaugeneedle gets into the red.

Relay D

Temp Light

C

Relay A

This is a ground wire

To Pad Gof PC Board

To Relay A

To Relay D

Purple

Purple

Green

Green

Black

Black

High Temp Relay - Temp. Gauge Circuit

Brown +12 volts with‘PTO’ Switch on

To Temp Gauge

To Relay CD

To Relay E

To Pad Pof PC Board

To Pad M on PC Board

To Relay CPurple

Black

Black

Purple

Brown

+12 volts with‘PTO’ Switch on

This wire goes toground whenthe temp gaugeneedle gets into the red.

+12 volts withkey in the ‘RUN’position

High Temp Relay - Clutch Circuit

To UniversalHarness

This is aground wire

E

To Relay D

To UniversalHarness

To PTOSwitchGreen

Brown

Brown

Brown

+12 volts with‘PTO’ Switch on

+12 volts with‘PTO’ switch on

Switched +12 volts from

Universal Harness

Universal Harness Relay - Clutch Circuit

Figure 3

Figure 4

Figure 5

10

CONTROL RELAY - ALL KUBOTA MODELSAssuming a normal diode on the circuit, board, relay B is affected by a problem in the circuit containing the PTO switch, and left and right steering switches.

Assuming a normal diode on the circuit board, relay A is affected by a problem in the circuit containing the PTO switch, and left and right steering switches. It is also affected by a problem in the circuit containing the parking brake switch and seat switch.

FUNCTION OF A DIODEThe function of a diode is to allow an electric current to pass in one direction (called the diode's forward direction). A diode can be referred as an electronic check valve.

CIRCUIT BOARD DIODE PROBLEMS - ALL MODELSRefer to the illustration below (fi gure 7) to lo-cate the diode on the circuit board between pad R and A.

Open Diode

An open diode will result in the following symptoms:

Assuming steering levers out and PTO switch off, engine can be cranked and started only with driver on the seat and the parking brake in the 'OFF' position.

If driver gets off of the seat or puts parking brake to the 'ON' position, the engine will die.

Shorted Diode

Assuming an operator on the seat and parking brake is 'OFF', engine can be cranked and started with PTO switch in the 'ON' position or steering levers in.

Circuit Board with Diode

A

R

Symbol for a diode. The arrowindicates the current flow. Current will not flow in the other direction if the diode isworking properly.

SYMBOLS USED ON WIRING DIAGRAMS

Figure 6

Figure 7

11

THIS PAGE IS INTENTIONALLY LEFT BLANK

12

TESTING SAFETY SYSTEM FOR PROPER OPERATION

ALL BRIGGS MODELSALL KOHLER MODELS

Notes: Proper operation of the safety system indicates that:

1. To start the engine, both steering levers must be out, and the PTO switch must be off.

2. With the engine running and the opera-tor off the seat, the engine will die if either steering lever is brought in or the PTO switch is turned on.

3. The engine will also die if the operator gets off the seat with either steering lever in or the PTO switch turned on.

4. The engine will die if the steering levers are brought in with the parking brake on.

Steering levers out, PTO switch 'OFF'. If engine starts, all of the above switches are functioning in

their closed position.

Turn engine 'OFF'.

Does engine crank with only left steering

lever 'IN'?

Adjust or replace left steering switch.

Yes

NoDoes engine crank

with only right steering lever 'IN'?

Does engine crank with only the PTO switch turned 'ON'?

Steering levers out, PTO switch 'OFF', operator OFF seat, parking brake 'OFF' and engine running.

Does engine die when one or both steering levers are

brought 'IN'?

No

Replace relay A.

Replace PTO switch.Yes

No

Steering levers out, PTO switch 'OFF', operator ON seat, parking brake 'ON'

and engine running. Does engine die when one or both steering levers are

brought 'IN'?

Replace brake switch.

No

Yes

Adjust or replace right steering switch.

Yes

All safety systems are functioning

properly.

Yes

No

13

TESTING SAFETY SYSTEM FOR PROPER OPERATION

ALL KUBOTA MODELS

Notes: Proper operation of the safety system indicates that:

1. To start the engine, both steering levers must be out, and the PTO switch must be off. The engine will start with the operator on or off the seat and the parking brake either on or off.

2. With the engine running and the opera-tor off the seat, the engine will die if either steering lever is brought in or the PTO switch is turned on.

3. The engine will also die if the operator gets off the seat with either steering lever in or the PTO switch turned on.

4. The engine will die if the steering levers are brought in with the parking brake on.

Steering levers out, PTO switch 'OFF',

parking brake 'OFF', operator OFF seat and engine running.

Does engine die when left steering

lever is brought 'IN'?

Adjust or replace left steering switch.

Does engine die when right steering lever is brought 'IN'?

Yes

NoAdjust or replace

right steering switch.

No

Does engine die when the PTO switch

is turned 'ON'?

Yes

Replace PTO switch.

No

YesTo A

ASteering levers out, PTO switch 'OFF',

parking brake 'ON', operator ON seat

and engine running.

Does engine die when steering levers

are brought 'IN'?

Replace brake switch.

Yes

No

Steering levers in, PTO switch 'OFF',

parking brake 'OFF', operator ON seat

and engine running.

Does engine die when operator raises

up off the seat?

Replace seat switch.

Yes

No

All safety systems

properly.are functioning

14

ALL BRIGGS MODELS*ALL KOHLER MODELS EXCLUDING KOHLER EFI MODELS

Notes: 1. Voltage tests are performed with a DC/AC

voltmeter. 2. Tests are performed after regulator fuse is

checked. 3. AC voltage tests are performed with engine

at 3600 rpm.

BATTERY CHARGING SYSTEM

*NOTE: For a battery charging problem with a Kohler EFI engine, consult the engine repair manual.

Engine is not running.

Attach DC voltmeter to negative and positive

posts of battery.

Does voltmeter read12.5 DC volts or above?

Test and rechargebattery.

Battery is in goodcondition.

Yes

No

Start engine andobserve batteryvoltage at full

throttle.

Is voltage at batterybetween 13 and 14.7

DC volts?

Does voltage appear at the B+ teminalof the regulator - rectifier. See diagram for location. Fig 8

NoDisconnect regulator - rectifier plug. Place AC voltmeter across AC Terminals in plug

and read voltage. Fig 8

Charging system isfunctioning properly.

Yes

Service stator.Yes

No

Does voltage readless than 28 volts ACwith engine running?

If AC voltage measures more than

28 volts replace regulator - rectifier.

For more detailedtesting consult the

engine repairmanual.

Problem is in supplywire from regulatorfuse to regulatorrectifier.

No

Yes

B+ AC

Red

Yello

wYe

llow

BriggsRegulator

B+ AC

Whi

te

Pur

ple

Whi

te

AC

Kohler RegulatorPlug

Figure 8

15*voltage may vary + or - 3 volts.


ALL KUBOTA MODELS WITH SMOOTHALTERNATORS W/TWO WIRES

Notes: 1. Voltage tests are performed with a DC/AC

voltmeter. 2. Tests are performed after regulator fuse is

checked. 3. AC voltage tests are performed with engine

at full RPM.


Attach DC voltmeter to negative and positive

posts of battery.

Does voltmeter read 12.2 DC volts or above?

Test and recharge battery.

Battery is in good condition.

Yes

No

Start engine and observe battery voltage at full

throttle.

Is voltage at battery between 13 and 14.7

DC volts?

Does AC voltage appear between the

2 blue wires from alternator?

A. 10 volts* at idle?B. 36 volts* AC at full

throttle?

No

Replace alternator.

Charging system is functioning properly.

Yes

No

Does DC voltage appear on white wire to voltage regulator

plug to ground?

Does voltage appear on terminal AC of

ignition switch to ground?

No

Yes

Does green wire on the regulator plug

between the two blue wires show ground

when tested to battery positive?

Check ground connection.

No

Yes

Check ignition switch for continuity from

terminal AC to terminal 30.

No

Check white wire and terminals from terminal AC of

ignition switch to voltage regulator.

Yes Is voltage at red wire of voltage regulator

13-14.7 DC volts to ground?

Replace voltage regulator.

No

Check red wire, regulator fuse andterminals from terminal 30 of ignition switch to voltage regulator.

Yes

Yes

Rev. 02-16

16

ALL KUBOTA MODELS WITH ALUMINUM/FINNED ALTERNATORS

Notes: 1. Tests are performed after regulator fuse is

checked. 2. Set voltmeter to DC voltage for testing on

this page.


Attach voltmeter to negative andpositive posts

of battery.

Does voltmeter read 12.5 volts

or above?

Test and rechargebattery.

Battery is in good condition.

Yes

No

Start engine and observe battery voltage at full

throttle.

Is voltage at battery between

13 and 14.7 volts?

Test for voltageat red wire to

alternator

No

Charging systemis functioning

properly.

Yes

Yes


NoProblem is with

In-line FuseWire

Does voltageappear on whitewire to alternatorwith ignition key

in the “run” position?

Yes

No

Check connectionsof white wire from

alternator to the circuit board.

Does green wire at alternator show

ground when tested to battery

positive?

Yes

No

Check groundconnections.

Yes Service AlternatorRegulatorAssembly

17


18

ENGINE WILL NOT CRANK

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Test battery for condition and

charge.

Steering levers out, PTO switch 'OFF'. Voltage tests are performed with a

voltmeter or test light to battery ground.

Key switch is in'START' position for

each test.

Does voltage appear from terminal 'C' of

start fuse?(See Figure 9)

Problem is the key switch or the power to the key switch.

Replace start fuse.

Does voltage appear from terminal 'D' of

start fuse?

Yes If there is voltage at terminal 'D' of start fuse, there should also be voltage on blue wire at starter

solenoid.

Yes

No

YesTo A

continues on next page

No

124 & 126 BRIGGS226V BRIGGS616T BRIGGS

Notes: 1. Voltage tests are performed with a DC voltme-

ter.

Warning! Before starting test, remove blue wire from

starter solenoid to prevent accidental cranking of engine while testing.

Reconnect this blue wire upon completion of the test.

Figure 9

19

Fuse Block Test Points

ENGINE WILL NOT CRANK(CONTINUED)

STA

RT

FUS

E

30

7.5

RE

GU

LATO

R F

US

E

LIG

HT

FUS

E

GHCDAB

10P

TO F

US

E

EF

7.5

AKey switch is in

'OFF' position foreach test. You are

now testing a groundcircuit. All tests will

be to the batterypositive side.

Does the yellow wire at starter solenoid show ground when

tested?

Does either yellow wire on PTO switch show ground when

tested?

Check starter solenoid. Problem

could be starter solenoid or starter.

Yes

No

Replace PTO switch.Yes

Do either yellow wires on right

steering switch show ground when tested?

No

Right steering switch is defective or out of

adjustment.

Yes

Do either yellow wires on left steering switch show ground

when tested?

No

Left steering switch is defective or out of

adjustment.

Yes

Check ground junction with green

wires on engine.

No

continued from previous page

124 & 126 BRIGGS226V BRIGGS616T BRIGGS

Fuse block styles will vary.Be sure you are checking designated fuse.

Figure 10

Rev. 02-16

20


125 & 225V KOHLERALL 200 SERIES MODELS EXCEPT 226V329B, 335B, 729BT6 & 735BT6 BRIGGS BIG BLOCK MODELS620T & 623T KOHLERALL 700 SERIES KOHLER MODELSNotes: 1. A 30 amp MASTER fuse is present on all 700 series except 723T.

This fuse is in the upper level of fuse block on right side of tractor frame next to seat. Voltage will not reach the key switch if this fuse is blown.

2. Do not forget to plug starter relay back in when fi nished testing.

Warning! Before starting test, remove blue wire from starter solenoid to pre-

vent accidental cranking of engine while testing.

Reconnect this blue wire upon completion of the test.

KEYSWITCH(in start position)

PTOSWITCH(PTO OFF)

STEERING SWITCHES

RIGHT LEFT (Steering levers out)

BLUE START FUSE

RED

INLINE FUSEHOLDER

STARTERRELAY

STARTERGREEN / YELLOW

RTSTR

LTSTR

SM

B G

L 8786 87a85

30

YELLOW YELLOW

YELLOW

RED

RED

BLUE

BLUE

KEYSWITCH(in start position)

PTOSWITCH(PTO OFF)

STEERING SWITCHES

RIGHT LEFT (Steering levers out)

BLUE START FUSE

REDINLINE

FUSEHOLDER

STARTERRELAY

STARTERGREEN / YELLOW

RTSTR

LTSTR

SM

B G

L 8786 87a85

30

YELLOW YELLOW

YELLOW

RED

RED

BLUE

BLUE

ALL EXCEPT 125 & 225V 125 & 225V

Figure 11 Figure 12

Test battery forcondition and

charge.

Steering levers out,PTO switch 'OFF'.

Voltage test isperformed with a

voltmeter or test lightto battery ground.

Does voltage appear from terminal 'C' ofstart fuse?

Problem is the keyswitch or the powerto the key switch.

Replace start fuse.

Does voltage appear from terminal 'D' ofstart fuse?

Yes

No

Does voltage appear on

terminal 85 ofstarter relay?

Yes

No

YesTo A

continues onnext page

Check wires from start

fuse to starter relay.

No

OK

Does voltage appear on terminal 87 (inline fuse

wire) of starter relay?

Check 30 amp in-line fuse

in wire between starter relay and starter solenoid.

No

Yes


each test.

Rev. 02-16

21


125 & 225V KOHLERALL 200 SERIES MODELS EXCEPT 226V329B, 335B, 729BT6 & 735BT6 BRIGGS BIG BLOCK MODELS620T & 623T KOHLERALL 700 SERIES KOHLER MODELS

Blu

e W

ire

Blue Wire

Yellow Wire

To input terminal of starterTo pad S of circuit board

Fuse clip toregulator fuse

To batteryterminal ofstarter

Fuse holderTo pad T of circuit board

If all safety switches are correct,terminal 86 is grounded.Terminal 87 is 12 volts.Terminal 85 is +12 volts when key switch is in ‘START’ position.Terminal 30 is +12 volts whenrelay is energized.

•

••

•

30

8787a

858630

Starter Relay Testing


STA

RT

FUS

E

30

7.5

RE

GU

LATO

R F

US

E

LIG

HT

FUS

E

GHCDAB

10P

TO F

US

E

EF

7.5

700 Series Kohler Models except 723T

125 & All 200 Series Models(Regulator fuse absent on 125 & 225V)

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

ADoes voltage appear

on terminal 30 ofstarter relay?

continuedfrom

previouspage

Check startersolenoid.

Problem couldbe starter

solenoid orstarter.

Remove the starterrelay. It is located on

the inside of theframe, on the leftside of the engineon Kohler models.

Does the yellow wirewithout the in-linefuse show ground

when tested?

Replace thestarter relay.

ReplacePTO switch.

Does either yellowwire on PTO switchshow ground when

tested?

Does either yellowwire on right

steering switch showground when tested?

Right steeringswitch is

defective orout of

adjustment.

Does either yellowwire on left steeringswitch show ground

when tested?

Check groundat engine.

Left steeringswitch is

defective orout of

adjustment.

Key switch is in'OFF' position foreach test. You are




REGULATOR FUSE - 30 AMP.

LIGHT/AUX FUSE - 7.5 AMP.PTO FUSE - 10 AMP.

START FUSE - 30 AMP.

UNIVERSAL HARNESS FUSE - 10 AMP

MASTER FUSE - 30 AMP.

ACCESSORY FUSE

ACCESSORY FUSE

G

B

C

D

A

E

FH

Figure 15

Figure 14

Figure 13

Rev. 02-16

22

Test battery for condition and

charge.

Steering levers out, PTO switch 'OFF'. Voltage test is performed with a

voltmeter or test light to battery ground.

Does voltage appear from terminal 'I' of

start fuse?

Problem is the key switch or the power to the key switch.

Replace start fuse.

Does voltage appear from terminal 'J' of

start fuse?

Yes

No

Does voltage appear on blue wire at

starter solenoid?

Yes

No

Yes

To A


Check starter solenoid. Problem

could be starter solenoid or starter.No

OK


each test.


ALL KUBOTA MODELS

Note:Check 30 amp MASTER fuse in lower level of fuse block on right side of tractor frame next to seat. Voltage will not reach key switch if this fuse is blown.

Warning! Before starting test, remove blue

wire from starter solenoid to prevent accidental cranking of engine while testing.

Reconnect this blue wire upon com-pletion of the test.

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IGNITION FUSE - 7.5 AMP.PTO FUSE - 10 AMP.

MAIN FUSE - 15 AMP.

ACCESSORY FUSE - 10AMP.


G

B

A

I

J

H

Figure 16

Rev. 02-16

23

ALL KUBOTA MODELS

*+*+�

,-

*.*/


Relay B


Does the green/ yellow wire on the

plug of relay 'B' show ground when tested?

Do both wires on left steering switch show ground when tested?

Replace relay 'B'.Yes

NoDo both yellow wires

on right steering switch show ground

when tested?

Yes

Before replacing the steering switch,

check adjustment. If it does not click

when steering levers are moved in and out

adjust the switch.

No

Replace left steering switch.

No

Remove relay 'B'. It is the relay with 3 blue wires and 1 yellow wire in the

plug.

A

Replace PTO switch.

Before replacing the steering switch,

check adjustment. If it does not click

when steering levers are moved in and out

adjust the switch.

No

Replace right steering switch.

Yes


Key switch is in'OFF' position foreach test. You are






MAIN FUSE - 15 AMP.



G

B

A

I

J

H

Figure 18

Figure 17

Rev. 02-16

24

If engine cranks, butwill not run; the

safety switches arefunctioning properly.

Test engine forspark. Does spark

occur at spark plug?

Disconnect yellowsafety wire* fromengine and retest.Does spark nowoccur at spark plug?

Reconnect yellowsafety wire. There

is an engineignition related

problem. Consultengine repair

manual.

Reconnect yellow safety wire. Replace safety relay in console.

Use part number 184271 relay for all 100, 200, 300 & 600 tractors.

Use part number 184271 relay for

700 series tractors with serial number 6399999 & below.

Use part number 184266 relay for 700 series tractors with serial

number 6400000 & above.

Yes

No

Check for fuelsystem problem or

engine failure.

Yes

No

Warning!

* Briggs engine excluding Briggs Big Block:

Kohler & Briggs Big Block engine:

Single yellow wire on left side of engine.

Disconnect plug on left side of engine.Using a small screwdriver, release thelock tab on yellow wire in tractor side plugand remove wire. Reconnect the plug.

With the yellow wire disconnected from the engine, all safetyfunctions and the key switch will be inoperable in their ability toshutoff the engine. This step is performed for test purposes only.Under no conditions should the PTO be turned ON or the machinebe driven with the yellow wire disconnected! Always reconnectthe yellow wire to the engine after this test.

ENGINE WILL CRANK, BUT NOT START

ALL BRIGGS MODELSALL KOHLER MODELS

Notes: 1. Tests are performed after LIGHT/AUX

fuse has been checked on all models.

25


ALL KUBOTA GASOLINE MODELS

Notes: 1. All tests are made with wires in place on

their respective switches. 2. Refer to fuse block diagram for terminal

locations. 3. Refer to “Troubleshooting Control Relays”

for information on the diode and control relays.

4. If engine will crank, control relay “B” is functioning properly. This means that the PTO switch, right steering switch and left steering switch are functioning properly.


� � �

�

� � �

� �

� ' � � � ) � �

� � � � � � �

� � ' � � � "

! " � � �

� $ % � � � ' %� ' � "

� � & � � � � �

� � & � � � � �

� ! " � � �

� �

� � � � � �� . � � � � � � � � � � �

/ � � %

) # �

� $ % � � � ' %

) # �

� " � � � �

� " " ' �

& � ! � ' � %

�

�

* For models 329/729 & 432/932, test for volt-age at red wire in white 2-way plug located di-rectly below carburetor on engine.

No

Yes

Yes

No

Yes

No

Yes

No

No

Yes

Steering levers out,

PTO switch 'OFF'.

Voltage tests are

performed with a

voltmeter or test light

to battery ground

(negative post).

Key switch is in

'RUN' position for

each test until

otherwise noted.

Does voltage appear

from black wire on

positive terminal of

ignition coil to

ground? *

Problem is in ignition

coil or distributor.

Consult Kubota

engine manual for

repair.

Replace control relay

A.

Does voltage appear

from terminal 'G' of

ignition fuse to

ground?

Replace ignition

fuse.

Does voltage appear

from terminal 'A' of

main fuse to ground?

Does voltage appear

from terminal 'B' of


Replace main fuse.Does voltage appear

from terminal 30

(battery) of key

switch to ground?

Test battery.

Replace key switch.




MAIN FUSE - 15 AMP.



G

B

A

I

J

H

Figure 19

Figure 20

26

Steering levers out,

PTO switch 'OFF'.

Voltage tests are

performed with a

voltmeter or test light

to battery ground

(negative post).

Key switch is held in

'START' position for

each test until

otherwise noted.

No

Does voltage appear

from 'PULL' wire of

the fuel solenoid to

ground?

Does fuel solenoid

engage while

cranking?

No

Test in-line fuse and

fuse holder.

Yes Problem is in ignition

coil or distributor.

Consult Kubota

engine manual for

repair.

Yes This is an engine

related problem.

Consult engine

repair manual for

further information.

Yes

No

Key switch is OFF

during each test.

Does 'COMM'

terminal of fuel

solenoid show

ground?

No

Repair ground

connection to

'COMM' terminal of

fuel solenoid.

Does resistance

measure

approximately .2 to

.5 ohms from 'PULL'

terminal to 'COMM'

terminal of fuel

solenoid?

Yes

No

Replace fuel

solenoid.

Fuel solenoid

linkage is binding or

sticking.

Yes


ALL KUBOTA DIESEL MODELSEXCEPT THOSE WITH D902 ENGINESNotes: 1. All tests are made with wires in place on

their respective switches. 2. Refer to fuse block diagram for terminal

locations. 3. Refer to “Troubleshooting Control Relays”

for information on the diode and control relays.

4. If engine will crank, control relay “B” is functioning properly. This means that the PTO switch, right steering switch and left steering switch are functioning properly.

1

17 30

24

HO

LD

1950

AC

-

+3

CO

MMRELAY A

PU

LL

TO SAFETYSWITCHES

STARTER

BATTERY CABLE

FUELSOLENOID

FUELSOLENOIDMODULE

IN-LINEFUSEHOLDER

RED

KEYSWITCH(In run position)

RED / WHITE

RED / WHITE

RED

RED

BLACK

BLACK

BLACK

BLACK WHITE

BLACK

GREENYELLOW/ BROWN

MAINFUSE

SOLENOIDFUSE

Figure 21

27


KUBOTA DIESEL MODELS WITH D902 ENGINES

If engine will crank, control relay "B" is func-tioning properly. This means that the PTO switch, right steering switch and left steering switch are functioning properly.

Check if fuel solenoid is binding or has a bro-ken spring. See Owner's Manual for location of the manual fuel stop lever. If lever can be pushed forward against spring pressure, fuel solenoid is operating properly. If lever is already forward, is binding, or has no spring resistance, replace fuel solenoid.

28

ENGINE STARTS, BUT DIES WHEN STEERING LEVERS ARE BROUGHT IN OR PTO SWITCH IS ENGAGED

ALL MODELS

Notes:If engine will crank and start, the PTO switch, right steering switch and left steering switch are functioning properly. The problem must be the parking brake or seat switch.

NC NO

YELLOW

GREEN

Brake switch view

Brake Switch Test Points

Figure 22

Rev. 02-16

Steering levers IN,seat switch manuallyactivated to simulate

operator ON seat,parking brake ‘OFF’.

Test will be to thebattery positive side.

If neither side of the seat switch shows ground, replace

parking brake switch.

Does only one side of the seat switch

show ground?(Note: wires must be installed on switch and switch must be

activated.)

No

Replace seat switch.Yes

29


30

012,

ALL KUBOTA DIESEL MODELSEXCEPT THOSE WITH D902 ENGINES


their respective switches. 2. Problem is in the 'HOLD' circuit of the fuel

solenoid. 3. Relay A is the relay with 1 yellow, 2 black

and 2 red wires.

Fuse Block Test PointsFuel Solenoid ModuleTest Points

ENGINE STARTS, BUT DIES WHEN KEY SWITCH IS RELEASED



IGNITION / SOLENOID FUSE - 7.5 AMP.PTO FUSE - 10 AMP.

MAIN FUSE - 15 AMP.



G

B

A

I

J

H

Figure 23 Figure 24

Rev. 12-16

Steering levers OUT,PTO switch 'OFF',

parking brake 'OFF'.Voltage tests areperformed with a

voltmeter or test lightto battery ground

(negative post) unless otherwise noted.

Replace key switch.

Does voltage appear from terminal 'A' of

main fuse to ground? (Refer to figure 24)

No

Yes

Key switch is in 'RUN' position for each test unless otherwise noted.

No

Replace main fuse.

Does voltage appear from terminal 'B' of


No

Yes Does voltage appear from terminal '1' of

fuel solenoid module to ground? (Refer to

figure 23)

No

Yes

Does voltage appear from terminal 'G' of

ignition/solenoid fuse to ground?

No

Yes

Replace control relay A. This is the relay

with 1 yellow, 2 black and 2 red wires.

Replace ignition/solenoid

fuse.

To A


31

ALL KUBOTA DIESEL MODELSEXCEPT THOSE WITH D902 ENGINES

1

17 30

24

HO

LD

1950

AC

-

+3

CO

MMRELAY A

PU

LL

TO SAFETYSWITCHES

STARTER

BATTERY CABLE

FUELSOLENOID

FUELSOLENOIDMODULE

IN-LINEFUSEHOLDER

RED


RED / WHITE

RED / WHITE

RED

RED

BLACK

BLACK

BLACK

BLACK WHITE

BLACK

GREENYELLOW/ BROWN

MAINFUSE

SOLENOIDFUSE

ENGINE STARTS, BUT DIES WHENKEY SWITCH IS RELEASED (CONTINUED)

Figure 25

Rev. 02-16

A

Does ground appearfrom terminal '2' of

fuel solenoid moduleto battery

positive side?

No

Yes

Repair ground.

Does voltage appear from terminal '4' of

fuel solenoid module to ground?

No

Yes Does voltage appear from 'HOLD' wire of

fuel solenoid to ground?

No

Yes

Check fuel solenoid plug connection.

Replace fuel solenoid. Solenoid 'HOLD' to 'COMM' wires should test

approximately 11 to 16 ohms resistance.


Replace fuel solenoid MODULE.

IMPORTANT: If fuel solenoid module must be

replaced, check fuel solenoid ohms. A defective

fuel solenoid could burn out a new fuel

solenoid module. Solenoid 'HOLD' to 'COMM'

wires should test approximately 11 to 16 ohms

resistance.

32



their respective switches. 2. Problem is in the 'HOLD' circuit of the

fuel solenoid. 3. Relay A is the relay with 1 yellow, 2 black

and 2 red wires.


Fuel Solenoid ModuleTest Points

ABC

D E

Steering levers OUT,PTO switch 'OFF',

parking brake 'OFF'.Voltage tests areperformed with a

voltmeter or test lightto battery ground

(negative post).

Does voltage appearfrom terminal 'D' of

fuel solenoid moduleto ground?

(Refer to figure 26)

No

Yes

Key switch is in'RUN' position foreach test unlessotherwise noted.

No

Does voltage appearfrom terminal 'E' of

fuel solenoid moduleto ground?

No

Yes

Does voltage appearfrom terminal 'G' of

ignition fuse toground?

No

YesReplace ignition

fuse.

Does voltage appearfrom terminal 'A' of

main fuse to ground?(Refer to figure 27)

No

Replace key switch.

Replace control relayA. This is the relay

with 1 yellow, 2 blackand 2 red wires.

YesDoes voltage appearfrom terminal 'B' of


No

Replace main fuse.

Yes Check for brokenwire between fuse

block and fuel solenoid module.

Call GrasshopperService Department





MAIN FUSE - 15 AMP.



G

B

A

I

J

H

Figure 26 Figure 27

33

BRIGGS & KOHLERMODELSNotes: 1. If engine cranks and starts but dies when

key switch is released, then PTO switch, right and left steering switches, carbure-tor solenoid and stop relay are functioning properly.

2. Problem is a blown light/aux. fuse, a fuse block connection or a bad key switch.

3. All tests are made with wires in place on their respective switches.

Does voltage appearat top of

light/aux fuse to ground?

No

Does voltageappear from terminal

'L' of key switchto ground?

Yes Yes Problem is fuse

clip or wire to

carburetor solenoid.

Yes

No

Problem is light/auxfuse clip or wire from key switch to fuse.

Replace fuse.

Key switch is in'RUN' position for each test.

Steering levers out, PTO switch 'OFF'. Voltage tests are performed with a

voltmeter or test light to ground

(negative post).

No

Replace Key switch

Does voltage appearon bottom of

light/aux fuse to ground?

Yes


34

Yes continues onnext pageTO A

Turn key switch on, then off. Does

voltage appear on terminal B of stop solenoid module to battery ground for

approx. 10 seconds from timekey was

turned off?

Does coil resistance of stop solenoid measure approx.

1 Ohm to ground?

Replace stop solenoid.

Check linkage to fuel shutoff

for binding.

Key switch is in RUN position for

each test, but engine is not

running.

No

Yes

No

Yes

ENGINE STARTS AND RUNS, BUT WILL NOT SHUT OFF


Fuse Block Test PointsFuel Solenoid ModuleTest Points

Notes: 1. Check STOP SOLENOID fuse (15 amp).

The engine will not shut off if this fuse is blown or if fuse block terminals are loose or corroded.

2. IMPORTANT: A. For the tests on this page, unplug stop solenoid. B. Before performing tests, check ground source for fuel solenoid module. The starter plate on the right side of the engine has two ground bolts. The fuel solenoid module ground wire is green with a yellow tracer and is connected to the TOP bolt. Tighten this connec-

tion if it is loose. If connection is already tight, check for damaged wire at eyelet. 3. Check for DC voltage in all tests. 4. Steering levers out, PTO off for all tests. 5. Remember to reconnect stop solenoid when

testing is completed.

CB

A

D

E




MAIN FUSE - 15 AMP.



G

B

A

I

J

H

Figure 28 Figure 29

35

Yes

No

Yes

continued fromprevious pageA

No

No

Yes

Does voltage appear from terminal D of stop solenoid

module to ground?

Does voltage appear from terminal E of stop solenoid

module to ground?

Does voltage appear from terminal G of IGN/Relay A

fuse to ground?

Replace relay A

Does voltage appear from terminal H of IGN/Relay A

fuse to ground?

Replace IGN/Relay A

fuse

Check for loose terminal in fuse block

or broken wire.

Replace fuel solenoid

module

Does voltage appear from terminal A of main fuse to

ground?

Replace key switch.

Does voltage appear from terminal B of main fuse to

ground?

Replace main fuse.

Check for loose

terminal in fuse block or broken

wire.

Yes

No

No No

Yes Yes

IN RUN POSITION

BLACK

YELLOW

RED/WHITE

GREEN/YELLOW

RED

RED/WHITE

BATTERY

BLACK

BLACK

RELAY A

KEY

SWITCH

SOLENOID

RED

STOP

TO SAFETTY SWITCHES

MAIN

FUSE

FUSE

RELAY A

MODULE

SOLENOID

STOP

STOP

SOLENOID

FUSE

AE

D B

C

WHITE/RED

BLUE/WHITE

RED

RED

BATTERYCABLE

IGN/


ENGINE STARTS AND RUNS, BUT WILL NOT SHUT OFF(CONTINUED)

Figure 30

36

TROUBLESHOOTING PTO CLUTCH

ALL MODELS EXCEPT KUBOTANotes:WARNING! DO NOT HAVE ENGINE RUNNING DURING ANY PART OF THIS TEST. 1. If the tractor is equipped with a PowerFold® deck, be sure the safety switch

on the bottom of the actuator switch mount is fully depressed when the mount is down on the actuator rod. If the plunger is not fully depressed when down, the clutch will not operate. Loosen the switch mount pivot bolt if needed to allow spring pressure to hold the mount down fi rmly on the rod. If voltage is present at terminal 85 on Relay E when the plunger is fully depressed, con-tact Grasshopper Service. (See Figure 31. This relay is located inside the console or on the left side of the frame near the brake switch.)

2. Test clutch by reading ohm's across clutch plug. Remove wire connector at clutch plug. See chart on page 38 for acceptable resistance readings.


ST

AR

T F

US

E

30

7.5

RE

GU

LA

TO

R F

US

E

LIG

HT

FU

SE

GHCDAB

10

PT

O F

US

E

EF

7.5

Choose the style that matchesthe style on the unit you are

troubleshooting.Fuse block styles will vary.Be sure you are checking

designated fuse.

30 AMP.REGULATOR FUSE

10 AMP.

LIGHT/AUX FUSE

30 AMP

7.5 AMP.PTO FUSE

START FUSE

UNIVERSAL HARNESS FUSE

30 AMP.MASTER FUSE

ACCESSORY FUSE

ACCESSORY FUSE10 AMP

Figure 32

Figure 33

MB

S

G

L


RED BLACK BROWN BROWN

GR

EE

N-

+

PTOSWITCH

(PTO on)CLUTCH

PTOFUSE

Figure 31

E

BROWN

BROWN

GR

EE

N

BR

OW

N

TO UNIVERSALHARNESS

TO UNIVERSALHARNESS

BROWN

8787A86 85

30

RELAYTERMINAL

REFERENCE

600 Series 700 Series

Rev. 02-16

No

Yes

No No

Yes

No

Yes

Yes

Steering levers OUT,PTO switch ‘ON’.Voltage tests areperformed with a voltmeter or test light to battery

ground(negative post)

unless otherwisenoted.

Key switch is in‘RUN’ position for

each test, butengine is not

running.

Does voltage appearfrom terminal ‘E’ of

PTO fuse to ground?

Does voltage appearfrom terminal ‘F’ of

PTO fuse to ground?

Does voltage appearfrom brown wire atPTO clutch plug to

ground?

Problem is the keyswitch or wiring fromkey switch to PTO

fuse.

Replace PTO fuse. Replace PTO switch.

Does green wire oftractor harness plugshow ground whentested to batterypositive side?

Test PTO clutch andterminals

(see note above).

Repair clutchground circuit.

37

TROUBLESHOOTING PTO CLUTCH

ALL KUBOTA MODELSNotes:WARNING! DO NOT HAVE ENGINE RUNNING DURING ANY PART OF THIS TEST. 1. If the temperature light is on, turn to page 39 for troubleshooting steps. 2. If the tractor is equipped with a PowerFold® deck, be sure the safety switch

on the bottom of the actuator switch mount is fully depressed when the mount is down on the actuator rod. If the plunger is not fully depressed when down, the clutch will not operate. Loosen the switch mount pivot bolt if needed to allow spring pressure to hold the mount down fi rmly on the rod. If voltage is present at terminal 85 on Relay E when the plunger is fully depressed, contact Grasshopper Service. (See Figure 35. This relay panel is located inside the console.)

3. If engine starts and runs, relay 'A' is working properly. 4. Test clutch by reading ohm's across clutch plug. Remove wire connector

at clutch plug. See chart on page 38 for acceptable resistance readings. 5. Voltage tests are performed with the seat switch wires removed and a

jumper installed across the two wires.Warning! Jumper must be removed and wires reinstalled on seat switch after test is

complete and before machine is returned to operation.


MAIN

FUSE

TO SAFETY

SWITCHES

SWITCH

RELAY A

(in run position)

BROWN

GR

EE

N

CLUTCH

PTO

SWITCH(PTO on)

PTOFUSE

BROWN

RED

YELLOW/ BROWN

RED / WHITE

RED / WHITE

BLACK

RED

50

AC

3017

19

KEY

Fuse block styles will vary.

Be sure you are checking designated fuse.

START FUSE30 AMP.

10 AMP.

7.5 AMP.

15 AMP.

IGNITION FUSE

PTO FUSE

MAIN FUSE

10 AMP.ACCESSORY FUSE

30 AMP.MASTER FUSE

Figure 36

Figure 34

Steering levers OUT,PTO switch 'ON'.Voltage tests areperformed with avoltmeter or test lightto battery ground(negative post)unless otherwisenoted.

Replace PTO fuse.

Does voltage appear from bottom terminal

of PTO fuse to ground?

No

Yes

Key switch is in 'RUN' position for

each test, but engine is not

running .

Replace PTO switch.

Does voltage appear from brown wire at PTO clutch plug to ground?

No

Yes

No

YesDoes green wire of tractor harness plug show ground when tested to battery positive?

Repair clutchground circuit.

Test PTO clutch and terminals (see note above).

Figure 35

DC E

4

5

3 6

2

1

TEMP.G I

BROWN

PU

RP

LEG

RE

EN

PANEL PAD M

PURPLE

BROWN

BR

OW

N

GR

EE

N

BR

OW

N

TO UNIVERSAL

BLACK

GREENGREEN

HARNESSTO UNIVERSALHARNESS

BLACK

BLA

CK

BLACK

PANEL PAD G

PURPLE

PURPLE

BROWN

14071

A B

REAR OF TRACTOR

FRONT OF TRACTOR

8787A86 85

30

RELAYTERMINAL REFERENCE

CLUTCH

Rev. 02-16

38

ACCEPTABLE CLUTCH RESISTANCE RANGE IN OHMSFOR TRACTORS WITH SERIAL NUMBER 6300000 & ABOVE

1" Clutches 1.125" Clutches1" Clutch with 1.125" Clutch withCenter Stop* Center Stop

& 1" Spot & 1.125" Spot Brake Clutch** Brake Clutch**

100

Series225V & 226V

200

300

400

Series

except225V & 226V

616T

620T

&623T

700 Series

with Kohler

engines

& Briggs

Big Block

engines

All 700 & 900

Series

KubotaModels

* 'Center Stop' refers to the stainless steel piece located between the hold magnets. To check if the clutch has this stop, look on the front side of the anti-rotation flange.** The Spot Brake Clutch can be identified by a one piece plate bolted on the front side of the anti-rotation flange.

2.6 - 3.0

1.6 - 2.0

2.6 - 3.0 -

- 1.6 - 2.0

-

-

FRO

NT

MO

UN

TSM

ID M

OU

NTS

1.6 - 2.0

1.6 - 2.0 -

-

39

HIGH TEMPERATURE CLUTCH CUTOUT WIRING

When the engine overheats, the temperature gauge shows hot. This triggers a ground through the purple wire of the temperature gauge. This ground activates the temperature light AND causes the clutch to disengage.When ground via the purple wire activates relay D, voltage to the clutch is terminated at this relay. Relay C is also activated, and hard ground is diverted to its center terminal. This relay will therefore remain grounded and prevent the purple wiring from losing ground. The circuit will remain in this state until the key switch is turned off again. The ground at the purple wire will then be eliminated, but only if the engine has cooled to a safe operating temperature. The clutch will then operate again.If the clutch does not work after the system has been reset by turning the key switch off, contact Grasshopper Service.

DC E

4

5

3 6

2

1

TEMP.G I

BROWN

PU

RP

LE

GR

EE

N

PANEL PAD M

PURPLE

BROWN

BR

OW

N

GR

EE

N

BR

OW

N

TO UNIVERSAL

BLACK

GREENGREEN

HARNESS TO UNIVERSALHARNESS

BLACK

BLA

CK

BLACK

PANEL PAD G

PURPLE

PURPLE

BROWN

14071

A B

REAR OF TRACTOR

FRONT OF TRACTOR

87

87A86 85

30

RELAYTERMINAL REFERENCE

CLUTCH

VERIFICATION OF WHETHER THIS CIRCUIT IS SHUTTING DOWN THE CLUTCH FUNCTION

Rev. 02-16

Using a DC voltmeter, check from battery negative.

Is voltage present on brownwire at terminal 85 on Relay E?

Yes

Using a DC voltmeter, check from battery positive.

Is ground present on double purple wire at terminal 86 on Relay D?

The high temperature clutch cutout wiringis not shutting down the clutch function.

See NOTE 2 on page 37 fortroubleshooting guidelines.

No

Yes

The high temperature clutch cutout wiring is not shutting down the clutch function.See page 37 for troubleshooting guideline for possible causes of clutch malfunction.

Engine overheating is the cause. Ground at terminal 86will disappear when the system resets. If confirmed that the engine has cooled down to a safe operating

temperatue but the system does not reset, contact Grasshopper Service.

No

40

TROUBLESHOOTING ELECTRIC LIFT (STRAP STYLE)PAGE 1 OF 5

ELECTRIC LIFT DOES NOT OPERATENotes: 1. For testing refer to 6-way Weather-pack

located next to the brake lever. 2. Connector view is from back (wire side)

(see Figure 37). 3. Toggle switch is not activated.

Does voltage appearon terminal B of 6-way connector to ground?

(red/white wire)

NO

YESYESYES

NO

NOTE:

NO

NO NO NO

YES

NO

Does terminal F on6-way connectorshow ground to

battery positive side?(green/yellow wire)

Key switch is in ‘RUN’position for remainder

of test.Dose voltage appear

on terminal D of 6-wayconnector to ground?

(black wire)Check 40 AMP inline

fuse (Universal Harness) Faulty ground in Universal Wiring Harness

Check accy fusein fluseblock

Disconnect two wires from winch motor. If fuse repeatedly blows, check for pinched wires.Be sure to reconnect wires to winch. If fuse does not blow with wires disconnected,

winch motor may be defective.

Does voltage appear on

red/white wireof relay ‘A’ and ’B’

to ground?

Does green/yellow wire of relay ‘A’ and ’B’

show ground to battery

positive side?

Activate electriclift switch to downposition. Does

blue wire of relay ‘A’show ground

to batterypositive side?

YESActivate electriclift switch to up

position. Doespurple wire of relay ‘B’

show ground to battery

positive side?

YES YES

Check wiringbetween

6-way and relay

Check groundin Universal

Wiring HarnessReplace relay ‘A’ Replace relay ‘B’

Go to page 41

NOTE:All tests areperformed withplug connected.

To accessWeather-Packterminals, use asmall screwdriverto release latcheson either side ofcover. Flip upcover and slidegreen cable sealsup the wires to expose terminals.

Do notpenetrate wirecovering totest. This canlead to wiringcomponentfailure.

Figure 37

Figure 39Figure 38

GREEN/YELLOW

A B C D E F

BLACKYELLOW

RED/WHITEBLACK

GREEN/YELLOW

GREEN/YELLOW

BLUE

YELLOW/BROWN

RED/WHITERELAY A

GREEN/YELLOW

A

RED/WHITE

GREEN/YELLOW

RELAY B

GREEN/YELLOW

PURPLE

BLACK/WHITE

YELLOW B

41


YESYES

YES

What is theposition of the

winch

Is winch in the up position

and will notlower?

Is winch positioned between

upper and lowerlimit switches?But won’t raise

or lower?

Is winchin the down position

and will not raise?

Go to page 42 Go to page 43Redo teston previous

page

42


Figure 40

Figure 41

RED/WHITE

GREEN/YELLOW

RELAY B

GREEN/YELLOW

PURPLE

BLACK/WHITE

YELLOW B

97056

YESYESYES

NO

NO NO

Activate electriclift switch to

down position

Does black/whitewire of Relay ‘B’show voltage to

ground?

Does yellow wireof Relay ’B’ show

ground to battery positive

side?

Does purple wireof winch motorshow voltageto ground?

Faultywinch motor

Replacetoggleswitch

Replace lowerlimit switch.Lower limitswitch is

nearest winch(see Figure 41)

ReplaceRelay ‘B’

43


Figure 43

Figure 42

GREEN/YELLOW

GREEN/YELLOW

BLUE

YELLOW/BROWN

RED/WHITE RELAY A

GREEN/YELLOW

A

97056

NO

NONO NO

YESYESYESActivate electric

lift switch toup position.

Does voltageappear on

yellow/brownwire of

switch to ground?

Does yellow/brown

wire of Relay ‘A’show voltage

to ground?

Does blue wireof winch motorshow voltageto ground?

Faultywinch motor

Replace toggleswitch

Replace Relay ‘A’

Does voltage appearon both yellow/brown

wires of upperlimit switch?

Upper limit switch isfarthest fromwinch motor

(see Figure 43).Be sure wire terminalsare tight and installed

correctly.

Replace upperlimit switch

44


WIRING DIAGRAM

Item Order DescriptionNo. No.

Item Order DescriptionNo. No.

605859 Wiring Assembly (includes items 1 & 3-7) 1 184969 Connector - 6 way 2 183855 Switch 3 202105 Diode 4 184177 Switch - Rocker 184083 Switch

5 604712 Relay 6 184926 Connector - 5 way Female Terminal 7 425217 Eyelet Insulator 8 604515 Lift Drive Assembly 9 184919 Connector - Pin Housing 10 184921 Connector - Housing

7

8

10

6

9

4

5

5

1

2 2

RED/WHITE

GREEN/YELLOW

RELAY MOUNT

BLACK/WHITE

YELLOW

BLUE

SNOWTHROWER LIFT

YELLOW

PURPLE

SWITCH

GREEN/YELLOW

MUST BE DISCONNECTED FOR

TOWARD TRACTORTOWARD AERAVATOR

YELLOW/BROWN

LOWER LIMIT

BLUE

SWITCH

BLACK

BLACK

YELLOW/BROWN

6-WAY MALE BLACK PLUG FROM

SWITCH BOX

UPPER LIMIT

UNIVERSAL TRACTOR HARNESS6-WAY FEMALEBLACK PLUG

WHEN REMOVING AERA-VATOR FROM TRACTOR DISCONNECT WIRING AT THIS POINT

BLACK

MUST BE CONNECTED FORAERA-VATOR LIFT

07036A6

3

A B C D E FABCDEF

THIS IS A DOUBLE BLACK WIRE ON 184083 SWITCH

A B

45

HYDRAULIC DOZER ELECTRICAL TROUBLESHOOTINGThe hydraulic dozer blade wiring harness contains six diodes for con-trolling the direction of current fl ow. When a diode allows voltage to reach the solenoids, oil pressure controls the up and down functions. When a diode stops voltage from reaching the solenoids, oil pressure controls the left and right functions.

Note: 1. Voltage tests are performed with

a DC voltmeter. All voltage tests are from the battery negative ter-minal.

2. If a diode must be replaced, lo-cate the ring on the diode and orient the same way as the exist-ing diode.

Problem: Direction of movement is erratic when switch activated to go DOWN or LEFT. May go down of left randomly. Diode between '1' and '2' OR at '7" is shorted.

Solution: *Replace shorted diode.

Problem: Direction of movement is erratic when switch activated to go UP or RIGHT. May go up or right randomly. Diode between '4' and '5' OR at '8' is shorted.

Solution: *Replace shorted diode.

*Checking for shorted diode:Place meter on ohms and check for resistance both ways. A good diode will show continuity in one direction only. A shorted diode will show continuity in both directions.

Problem: Dozer blade goes LEFTwhen switch activated

to go DOWN.Is voltage present at

location ‘1’?

YesYes

Check for poor connection at location ‘3’. Replace diode.

Is voltage presentat location ‘2’?

NoNo

Contact GrasshopperService Department.

Problem: Dozer blade goes RIGHT

when switch activated to go UP.

Is voltage present atlocation ‘4’?

YesYes

Check for poor connection at location ‘6’.

Replace diode.

Is voltage presentat location ‘5’?

NoNo

Contact GrasshopperService Department.

11101

FE

FEDCBA

DA B CF E D C B A

A B

CD

YELLOW/BROWN

RED/WHITEGREEN/YELLOW

YELLOW/BROWN

GREEN/YELLOW

RED/WHITE

GREEN/YELLOW

YELLOW/BROWN

GREEN/YELLOW

GREEN/YELLOWGREEN

BLACKRED/WHITE

BLACK

BLU

E/W

HIT

E

BLU

E

WHITE

WHITE

BLACK/WHITE

BLA

CK

WH

ITE

BLACK/WHITE

Relay 1 Relay 212

7

6

54

38

46

HYDRAULIC LIFT DOES NOT WORKONE PIECE TILT SWITCH / DELAY TIMER STYLE

Notes: 1. "Hydraulic switch" refers to either the push

button switch in the steering lever or the toggle switch in the console.

Voltage tests areperformed with a

voltmeter to battery ground(negative post)

unless otherwise noted. Raise the

tractor seat to access the

hydraulic lift solenoid valve.

Yes

No

Yes

Hydraulic switchno longer needs to be activated, but keyswitch is

in "RUN" position.Does ground

appear atyellow/brown

wire at solenoidto battery positive

(hot post)?

Keyswitch is in "RUN" position

AND hydraulic switchis activated for

each test.Does voltage

appear at purple wire at solenoid

to ground?

Does voltage appear at black wire at hydraulic switch to ground?

Replace accessoryfuse.

Yes

Remove right fenderto access hydrauliclift wiring assembly.

Keyswitch is in "RUN" position.

Does voltage appearat point 1 of 3-way

connection to ground?

Check plug connections.

No

No

NoNo

continues onnext page

TO A

Remove solenoid andreconnect wires with key

in "RUN" position, butengine NOT running.Does solenoid valvemove when hydraulicswitch is activated?

Service orreplace

hydraulicpump.

Replace solenoid.

Yes

Replacehydraulicswitch.

Yes

47

Yes

Does groundappear at

point 5 to battery positive

(hot side)?

Check engineground.

No

Yes

continued fromprevious pageA

Does ground appear at


(hot side)?



(hot side)?

Does groundappear at


(hot side)?

Check plug connections.

Replace tiltswitch box.

No No

Yes

Clean plug connections.

No

Yes

Check forbroken wire

between 3-wayplug and solenoid

valve.

HYDRAULIC LIFT DOES NOT WORK ONE PIECE TILT SWITCH / DELAY TIMER STYLE

(CONTINUED)

Figure 44

BoxTilt Switch

GREEN

BLACK BLACK

PURPLE

GROUND TO ENGINE

FUSE BLOCK

YELLOW/BROWN

CA B

CBA

BLACK

RED

YELLOW

Solenoid

Fuse

1

2

3

4

56

Hydraulic

Switch

NOTE:

All tests are performedwith plug connected.

To access Weather-Packterminals, use a smallscrewdriver to releaselatches on either sideof cover. Flip cover upand slide green cableseals up the wires toexpose terminals.

Do not penetrate wire

covering to test. This

can lead to wiring

component failure.

48

JOYSTICK WIRING TROUBLESHOOTINGTOTAL LOSS OF MOTION

Notes:Check battery voltage. Battery voltage should read a minimum of 12.5 DC volts.All tests are performed with key in the run position, steering levers out and PTO switch off.All tests are with a DC voltmeter from battery negative unless otherwise noted.

Disconnect the 6-way weather-pack connector next to the brake lever on the left side of the frame. Test is performed on the tractor side 6-way.

Yes

Does voltageappear at

red/white wireat terminal B?

Check 40 amp inline fuse wire from positive battery cable

terminal of starter.

No

Yes Does voltageappear at black wire

at terminal D?


green/yellow wireat terminal Ffrom battery

positive?

Check either the Universal WiringHarness fuse or

Accessory fuse in the fuse block.*

Check ground wire connection

at engine.

No No

Yes

Contact GrasshopperService Department

*There may be more than one Accessory fuse.If so, check all Accessory fuses.

TOENGINE

GROUND

BLACK

BROWN

MALE TERMINALS

6 WAY WEATHER-PACK

RED/WHITE

GREEN/YELLOW

CONNECTOR

40

CONNECTS TO ACCESSORY OR UWH FUSE IN FUSE BLOCK

CONNECTS TO POSITIVE BATTERY CABLE TERMINAL OF STARTER

D E FA CB

UNIVERSAL WIRING HARNESSOR

LIMITED UNIVERSAL HARNESS

49

JOYSTICK WIRING TROUBLESHOOTINGLOSS OF MOTION IN ONE DIRECTION

Notes:The following troubleshooting guidelines assume all directions except one function properly.This assumes the required voltage is reaching all relays, including the malfunctioning relay.All tests are performed with key in the run position, steering levers out and PTO switch off.Access the 4 relays inside the relay box for these tests.Use a DC voltmeter and check from battery positive.

BLACK

GR

EE

N

GREENGREEN GREEN

BLACK

RED

RED/ WHITE

RED/WHITE RED/WHITE RED/WHITE

BLACK

BLACKBLACK

BLA

CK

/WH

ITE

WH

ITE

BLU

E

BLU

E/W

HIT

E

GREEN

GREEN

GREEN

D

To Wiring Assembly 605973

COM

NO

NC

COM

NO

NC

COM

NO

NC

COM

NO

NC

B A

C D

To Universal Wiring Harness orLimited Universal Harness

C B AF DE

C B AF DE

CA B11032A

BROWNWHITE

C D

B A

BLACK

RED/WHITE40

Connects to Accessory or UWH Fuse in Fuse Block

Groundto

Engine

GREEN/YELLOW

Connects toPositive BatteryCable Terminalof Starter

Activate joystickswitch for leftmovement.

Is ground presentat SINGLE blackwire at Relay A?

Replace joystickswitch.

No

YesReplace Relay.

No left movement:

Activate joystickswitch for right

movement.Is ground present

at white wire at Relay B?


No

YesReplace Relay.

No right movement:

Activate joystickswitch for down

movement.Is ground present

at brownwire at Relay C?


No

YesReplace Relay.

No down movement:

Activate joystickswitch for upmovement.

Is ground presentat red

wire at Relay D?


No

YesReplace Relay.

No up movement:

50

TRACTOR ACCESSORY HARNESS TROUBLESHOOTINGThis is a general check for loss of electrical power to any attachment which relies on a tractor accessory harness for its power source. The tractor harnesses include the Universal Wiring Har-ness, Limited wiring Harness and Power Harness.

If the attachment has lost electrical power, disconnect the tractor accessory harness connector located either on the tractor frame to the left of the seat or under the seat.

Notes: 1. Voltage tests are performed with a DC voltmeter. 2. Place key switch in the run position for this test.

Using a DC voltmeter, check the following:

From battery negative, check for voltage at the red/white wire at terminal B (terminal A of Power Harness). If voltage is not present, locate the starter solenoid post with the battery positive cable attached. On this same post you will fi nd a 14 gauge wire with a 40 amp inline fuse. Check if this fuse is blown. If the fuse is good, check the inline fuse terminals for corrosion or for a poor connection.

From battery negative, check for voltage at the black wire at terminal D (terminal B of Power Har-ness). If voltage is not present, check the 7.5 amp accessory fuse in the fuse block. If the fuse is good, check the fuse terminals for corrosion or for a poor connection. Note: There may be more than one accessory fuse present. If so, check all accessory fuses to ensure you have checked the fuse for this black wire.

From battery POSITIVE, check the green/yellow wire for ground at terminal F (terminal C of Pow-er Harness). If ground is not present, check the ground source at the negative battery terminal.

If the above steps do not solve the electrical problem, check the Table of Contents to see if a more specifi c test is available for the electrical problem you are troubleshooting.

POWER HARNESS181475Fuse

GREEN

THIS CONNECTOR STAYS WITH TRACTOR

RED/WHITE

3 WAY WEATHER-PACK 3 WAY WEATHER-PACK

BLACK

WITH THE ACCESSORY HARNESS

GROUNDTHIS CONNECTOR COMES TO

NEGATIVE

MALE TERMINALS FEMALE TERMINALS

BATTERY TERMINAL

40

B

B A

CA

C

51

UNIVERSAL WIRING HARNESS

184415Double Tab

Adapter

181475Fuse

184271Relay


BROWN

TO P

TO C

LUTC

H S

WIT

CH

WITH THE ACCESSORY HARNESS

CONNECTOR EXISTING PTO CLUTCH

FROM WIRING HARNESS EXISTING CONNECTOR

TOENGINE

GROUND

GREEN

THIS CONNECTOR COMES

PURPLE

GR

EEN

/YEL

LOW

REAR CORNER OF FRAME RELAY MOUNTS IN LEFT

BLACK

GREEN

BROWN

BRO

WN

MALE TERMINALS

6 WAY WEATHER-PACK

HYDRAULIC DECK LIFT SOLENOID

EXISTING WIRE TO DECK LIFT SWITCH

BRO

WN

ON 600'S, REMOVEDOUBLE BROWN WIREFROM TAB ADAPTER AND INSTALL TAB ADAPTER ON LIGHT SWITCH

RED/WHITE

GREEN/YELLOW

CLUTCH

BROWN

CONNECTOR 6 WAY WEATHER-PACK

FEMALE TERMINALS

CONNECTOR

40

E C B AF D

D FA B EC

01012C

YELLOW

NOTE: THIS IS A SINGLEBROWN WIRE FOR504786

E

TRACTOR ACCESSORY HARNESS TROUBLESHOOTING

52

1

2


BROWN

TO P

TO C

LUTC

H S

WIT

CH

CONNECTOR EXISTING PTO CLUTCH

EXISTING CONNECTOR

FROM WIRING HARNESS

TOENGINE

GROUND

GREEN

THIS CONNECTOR COMES WITH THE

ACCESSORY HARNESS

GR

EEN

/YEL

LOW

6 WAY WEATHER-PACK

CONNECTOR FEMALE TERMINALS

05066

REAR CORNER OF FRAME RELAY MOUNTS IN LEFT

BLACK

GREEN

BROWN

6 WAY WEATHER-PACKCONNECTOR

MALE TERMINALS

BROWN

CLUTCH

BRO

WN

GREEN/YELLOW

RED/WHITE

C E

A

40

BA

F CD B

D F

E

E

LIMITED UNIVERSAL HARNESS

TRACTOR ACCESSORY HARNESS TROUBLESHOOTING

electrical vol 3 manual - grasshopper dealers

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