Kässbohrer - Squarespace
Contents
1.2.
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4. 1358 bl 1 ES 1389 bl 1 15 f c 5 io o ER Er t A yu 45 1 22 E Optional Equipment 6M Compactor o SS 7 Centering
5. I mplement control board D 8 749 081 000 Top 1362 bl 1 Di AA Ee LED ERROR are Ready 69 69 69 69 C9 Tha bl m 0 20500 P603 P602 P601 Front B Lj 0 75 EE iller G GI Pvg B E Ee A Lower A o iga e q Connector for Park Bully LN To DO C Tit Left 4 An u a m i l Te is Sn sl e M 21 Front ball valve C
6. Engine Brake Relay Pin 10 1584 ge 1 a 15 1 58 se ji Plug pin positions LL u n vA Sb on drive card 07 L ZS 100 100 Power supply SS 57 e re aS 200 with main light un En y Gi Plug E c ex 3 3 switch on 2 38 stat 2 m 10V EE Is 21 ks i 41 208 ad sligt o o 2 557 oe 9 9 d 1560 ib T doc A we D g IS s 0 SP 10 dua o G nn E td N 1398 gel Fone I a c omo S FFE L 1 3 25 ES u 18 145 20 BBO O19 M TTT a 2 uL qo ez h E a 7 9 9 D Op N LJ _ El zL 3 1 d N tal U U 5 1593 ge sag 1553 ge 1 E 1594 gef Voltage Regulator a 3581 36 lt E LO 7 267 208 000 gn Ca E LEE
7. 8 749 079 000 F SE 8 749 231 000 BIC d 2 E B 1178 ws 1 ha M m 1179 wei BEE B Alternator 7 421 356 000 p 7 1 r i i 4 H 1159 ws 1 kelko NS N RI a d e 1 EN NEE A NEE RE mee gemeng emm mmm dm A Sms i 5 5 d saga m Yyyvyvy zn S 3 63 TEI HH i rr i Xd LAS gjeje 5 2 Le 2 le d 5 to 8 Y z LH Uz R E III m 2 Ic dg ce 22 E 2 S E w gt H 3 34 14 d EZ 55 i 337 o 27227 iz Warning Lamp Cluster a al 4 2 6 4 5 96 2 W 3 ADM 2 3 5 S d lt u lt 2 z 35 IN EN och 8 H h dy i i i i ES t i i 4 i 1 1 i i i t t 4 i y cic t t W B Ei D H L4 X ppl 1 LEE pa 2330355 al 5 l P 5 E E S tx n 1015 ws 1 5015 ws 1 SE 13 l X 3 ji 790 we M We L L 6 3 1014 ws 1 5014 ws 1
8. 3 3lue VI Violet 3 3rown WS White Plug pin positions GE Yellow GR Gray Power supply G Green LI Purple on drive card Esa SW Eiger with key on OR Orange S 15 3 SE S GI It Note Relay K10 amp switches S2 S19 2 E E E used in KFS vehicles 3 8 95 ee m HI Do ipo THUAFU EUH UU EUR o i e g 308 A a CDs Steering Trim Buzzer N E C 10b 241 131 111121 gd Le 122 EAR 231 D oss 9 w 2 e Y u n 9 v Cu du a T gen d a zt ot 2 6 2 558 z Fuse 2A F 7 R hi 1 7 Se g n 1 F S s o A o KFS N M x o x OO Si 9 pin connector Relay y C E D B E I 7 FES 3 WE gt LJ 22172 BA e si SE A A a B 10 24 13 1 12 9 16 1602 ce Connector 1601 ge 1 1589 ge E 1516 ge 1 male pin Drive card S u J ge one wire 8 749 175 000 le d 42 26 she a o a4 am 0 023 703 007 E 9 gp res 5 two w
9. Tiller potentiometer 8 743 877 000 forward reverse switch potentiometers Color Code Power supply lue VI Violet with key on rown WS White GE Yellow GR Gray G Green Ll AS ed SW Black OR Orange g 15 5 El ale Y EC bue o gt ES See 2 2 c 3 EA SZ i9 2 zo Ege 3 7 a mT d ar E S 2 Oo po VY ow T To 2 982 ae co 3095 T o cl gt Toh 244 sb bool gd 116 223 251 231 S gee N A AZ a E m Vi T DR 4 os L a Dee e d e BM E Ie en 5 x Bee yp 9 E O E el E To E en 2 L FEO J X oi ui UD Wei A pu ELE ER 22A A 25 23 T ol 2 10 24 13 H ZA 9 167 1317 bl 1 230 e 2 i 1601 ge 1 v o v 7 Scal sed 1574 2 N N N A co 4 uU aL A 1516 ge 1 2 d O e o 1693 ge 1 M E WE S die 3 pe M OF 2 2 To Tiller a 21 61 107 l l LO age SEN T 3 7 E el a ER ae ic S16 GE o A In Stick N o CH Dm 5 9 9o O3 A 8 Machine O 2 4 5 T 1 I L 7014 812 Ge K10 Y T 7 S 187 94 d Se g e 7 i i nn LO tO o wy 10
10. Plug pin positions 8 749 175 000 on drive card 3 25 14 gt 100k 1004 OOOO Se Trim Buzzer 20d C CONNECTION Fuse CA F TO STEERI NG T M 9 pin connector D POTENTIOMETER st tot spt ah or p ah PIN 6 na SOIT Ee jL Blue VI Violet E K B Brown WS White HI HIE allze E Ge Yellow GR Gray O agnus To steering LCD Display GN Green LI Purple daag sio o pot wiper ed SW Black Oil yo 0 S 9 Om Orange ee page Im HI ul ul ui DE MI al Ee 4 3 6 718191 10 Ber O RN d oi YN Transition all ll Seele iller Active O Tonca Dad Moog Plug 3393 sug 7 231 110 000 BIALDI CI E gi een ALBI C D IST EN or Al Left AT Valve 8 Hydraulic Pump Hydraulic Motor Connector male pin l one wire 0 023 703 007 Servo Right Servo Left two wire 0 023 703 008 8 749 152 000 8 749 152 000 female pin one wire 0 023 716 001 two wire 0 023 716 002 Page 10 Brake sender input for tiller safety shut off with key on Ki DRIVE CONTROL STICK CONTROLS om 2310570 Alarm rocker switch 7 331 164 000 Power supply Symbol 7 331 137 109 Back up alarm 7 711 208 000
11. 21 22 25 24 14 15 16 1 18 19 20 8 9 10 11 12 13 1 2 Si 4 5 6 H Meas Bushing 2 i k 1 hoard Connection Block under dashboard 1558 ge Pin 25 4 GE E Connection Block under dashboard eT Tha 903 5 5 z 3 2 si H E ye 5 z9 se Eg Pin 9 8 ta Drive Tiler Electronics ze 15 100 502 wei MR Zei 1032 5032 A 5 3 2 E E 23 Y E Svs 3 3 9 Be Oey Ces p Pin 25 18 3 usl 1008 5008 3 151 103 5033 5 Is 23 2 E SS 22 3 E 85 ES amp 51 51 20 Lg 2Ipol brown N 4 104 SI 4 wsl 1034 5034 ZS 5 y S 33 E 83 S E 5 S S SA 191 sei D ER iz CR 3 35 u 22 3 Ge KR Be ER e De Bg B8 Tao S br rt 1005 5005 S bll 1305 5325 E 3 5 5 z Ae 3 a I 55 55 ER ER 53 sg SE 32 pan Be 32 FE B i 5 5 85 ER gt ES FRE Fuel Level es a 8 Z Ps SILBER Foot Throttle pH Soe E B Interior Light Rear 33 f gs E 8 ZS fe gs 3 ea of Sender SA ER 7d GIE H Ke 5 5 E am 8 ES 3 d 120 barT v y 18pol gray Sr 10 8 5l E J 8 T kb gt x 2 LG SS T 1 1 TG MONTEG Hand 9 wi 1003 1009 1 509 Grid Heater 3 2 3 5 5 a PM HE aa 3 Throttle E 10 151 1010 5m el 10 bli oun 1330 1330 1 5330 5 1 5 ho OK PHA OLA A hH Fo Switch E s9 1 wei 10 Sn Fuel tank level 11 bl V9 12315331 H v e BTC M 15pol dolet MWA 9 12 ws 1 1012 5012 5012 1 J d 12 NI WNR 1332 5332 d T
12. E ADM2 PB EDGE 7 under dash de 825 4100 180 13 Higt d 3i 4 idd 1 4 TT ADM2 BEEN Mini Diag plug Power supply with ignition key on 123 i Engine brake relay de M44 7 375 209 000 9 A2 1 losen under dash A1 RH o HE 5034 Engine brake valve left side of engine ENGI NE FAN ELECTRIC SHIFT Plug Wire P N s Fan Side Plug Vehicle Side fan to PLD 1 ea 7 231 310 099 plastic 90 l ea 8 357 000 039 Harness Pin 1 low speed power yellow nme 1 ea 7 231 311 098 4 pin plastic plug Fd pecu dono ee Pin 3 high speed power white 4 ea 7 231 311 097 male term Pin Pin 4 high speed ground brown F 12 9hms 4 ea 7 231 310 101 yellow rubber seal 1 ea 7 231 311 000 plastic twist lock ring Electric Fan Hub Assembly K SE 8 357 072 000 E NL xd A Ca WAR L e zi T a d T Te repli ef THE f ME d d EE Ga elt En FX Iech E ALL Sensors and Analysis Output Stage ee E Boost ch Air Oil P EE JP Si SE leap l a Oil Coolant Fus 5 P 3 4 RICK 2 RUK ONE BND BAND oV E AGND Temp pu ues quam TC
13. ignition key on To grid 15 heat relay Connector in steering column Power to 18 horn relay 1008 ws 1 LO 1071 ws 1 5 of 8 vc pa Directional light stalk 2 814 4100 130 05 T VI L 7 5 4110 iy e 497 49a W I S 7 MEM 490 M5 1 ies ER SU 5 30 DTS R L o6a 56b 56 t l K1 C2 c y S Directional light relay EN ow od 7 371 083 000 VI L 5 6 9T 141 81 Wires to headlight high low beam y A 1096 1 ws 1 S 1097 1ws 1 5 iei o iB do 1219 1 ws 1 SAST n 1098 1 ws 1 5 2 3 MEE EEE Sch el E I 1099 1 ws 1 5 n wl esr li DAE ie 3 3 55383 9433 28 11 12 15 14 15 16 18 SIE vi s EE Connector for Electronic Stick Conversion To front wiper motor SHE Indicator light bulb 7 584 172 000 1 1087 ws NO O br 1 1088 ws 1 br Directional light assembly u amber 7 521 162 000 Bulb 24V 21w 7 581 164 000 1 Left front Left rear Right rear Right front Page 30 FRONT WINDSHIELD HEATING Heater wire element in glass E Glass 3 431 164 701 5 Color Code OS B Blue VI Violet 216 H Brown WS White GE Yellow GR Gray Indicator bulb o Y S She dd Hr e 7 584 172 000 lt OR ae A ES R
14. 5 D 1358 bl 1 S 1389 bl 1 Rear Hitch Steerin Z 8 Tiller Tiller o os 2 m ea itc e 9 Sec Fire UP Down Float Lift Lower MR ee Optional Equipment 6M Compactor Zo Button witch 55 o wo coc oo Tiller Depth z zz Left Right 358 u Zong Up Down Float Auto Lift In SE d Vi t Vv 85 1359 bl 1 Switch GE gj G 5 1393 bl 1 1394 bl 1 EY oc u 15 Connector plug t E 5 b1 g bl 1 bl 1 4 1390 b 1393 8 1 SR S Y Hw yas Y mM lol Su 201 3 4 107 l 201 3 An 10 y 01 5 65 1 201 3 4m 1 201 3 A 10 10 4 3 102 TOK T5 1 74 EE for wheel veh J ad d Sr l IE L o II u S E 2 iud tet ee a 96 1 12 aay 59 Zei Ge d 552 v i 4 s5 Pl u CE B121 SI 7 DER TF I hU gt2h 9 A RY UT 9 vate IK c gt l o a a u B u 1397 bl 1 l i 1398 bl 1 399 Hi YY ial 12 isha 14 ni ni 5 1401 bl 1 1402 bl 1 403 bl 1 w 17 Ed 21 8 fig OU PES v a d j la 4 I bod SEH 37 SC 404 bl 1 Y Y Cab latch B 5 5 aa VII VIII VIII VIII x i DI wo Ee E RR D d IR as 8 a d ed 2 switch de sg ag 3 a 23 33 je i ih Ad 5 S9 9 27 Se 1 Z S 7 311 143 000 EN gt S n EE A 2 2 5 5 E all ag y Y vily M Li u ad A To Drive Electronic E r 5 B z i T 4 TT A s 25 a 2 sa 5 S 7 B E Backup Alarm Relay K25 misa u S 7 u 5 zz NN es ed g ek S Off EH Se y ve H 5 7 d a ls ji a O Or 00 m S 5 Se 5 l zl g z 3 Power supply z 2 32 died s EB
15. FRONT IMPLEMENT ELECTRICAL SYSTEM PARK BULLY JOYSTICK Manual toggle to lift rear implement Mounted on vehicle behind grill R P Tiller Fire Button To R H Anal Tiller Soave Proximity Switch Bl ue button 8 026 108 140 Joystick buttons qi 1362 01 Ge Implement LL r Tiller of VC sug cum Eee control board Jp Down Pressure z eaay Ready NS x Float ler Lift Lower zm n m 29
16. o z lo oo v ad S O a a o 9 O 0 OF Y vu o y T OO O D X2 X1 O JUN ll el el ed O Ew Ug ty gg co 3 5 a Si uo M N di 21 2 iD 0 GI O 00 OO OO g O o o 0 O O oo a ao J el aad sl sl ei Salus 10814 Pa el Ve 120 Wie IPS Wl BoM CL H Ne aad 3 E oo ao E E 2 ER E E E e 5 SEN S f gt 0 SC E E o C i a 5 Lo gt Ze E Loo o a 0 ra o Eg o D a o J C Emergency stop button actuator 7 311 183 000 Contact assembly 7 311 180 000 Stick assembly complete 8 749 166 000 Servos left amp right 8 749 152 000 Connection Explanations Connecti Connecti Connecti Connecti Connecti Connection on on on on on Fuse 2 5A 0 026 011 002 Drive Card 8 749 175 000 Co eN Ul vi ROUER Stegring Trim O Wve asny 292208 i D 9 pin connector Dod LCD Displa x LED Display Error O Transition Tiller Active O Touch Pad Plug at Drive Tiller Electronics equipped with Steering Wheel FFE L Plug at Drive Tiller Electronics equipped with Steering Sticks FFE S Plug to install wiring from Steering Sticks X Block Ill to convert from Sticks to Steering Wheel Block Ill to convert from Steering Wheel to Sticks P
17. BE Engine Control Module PLD KL KI KL 50 15 30 30 Starter LI pn Voltage atmospheric sensor integrated Sensors and Analysis Output Stage Top Dead Center Output Stage Injection Pum Atmospheric Pro ortional Valve Identification Pressure Oil Pressure Oil Boost Charge Air Oil Pressure PROS ERA ERUPE aS L Sensor Mechanical Level Pressure Temp Electronic Oil Coolant Fuel 3 4 RCK 1 2 RICK E C BK H5V E AGND 5V_ E AGND 5V E AGND E AGND 5V E AGNDAGND 35V E AGND Temp Temp Temp T 13 2822 11 27 L d ry g LT EEE bd a g Xe XP XP X2 XP x2 xa xe a i LET 4 N ara y y y y Le u ei ws gine Electronic E 5 33 E R A lla Y TI i 313 mm PLD Plugs 9 9 d 33 3 2 Fas J 5 5 RE zs MEM e as oO 3 214 Ae 14 3h ah de E q f De ih 1 le S E E a wa L7 e LJ L LJ e oo Fuel injectors a v M Em N oo D oO Suo oO LO uU G e uU o Y e wD T LEDDET o o au TA Ou So Ken VA e gt 2 o E i O 5 zt O ee ooo tm
18. agnet energized seat belt will retract freely but will not pull out EH agnet not energized seat belt will retract and pull out freely st P S N a Seat belt 8 454 974 000 KFS LON S D Qi O O u 00 S35 SE 1051 sw 6 30 00 O 5 o L E zl 6 1059 ws 2 5 Or o 15 1060 sw 4 5 19 32 30 Power with key on Page 24 FRONT TOP LIGHTS HI GH LOW amp PARK LI GHTS EAM ESSET Ignition switch Power to directional Relay Main fuse 80A lights and horn N 7 375 201 000 SCH _ 0 026 010 007 Power supply with ignition S35 lt E key on i 80 31 Power supply with main light switch on 059 ws 25 060 sw 4 054 1055 2 xrt 4 a TS 1064 gr 4 UE E je o d 2118 3 ES F S La Directional light stalk Ve high itch ENS 1002 sw 25 MICHI A TS n 1003 rt 25 814 4100 130 05 e lo L En E T ua Light switch 7 331 155 000 10 T 7 7 375 197 000
19. K10 K13 K14 K15 K16 K1 K22 Directional lights Horn Circuits ON ONLY with engine running Main lighting Headlights Rear lights Available Rear Window Heater Wiper interval front Front blower KFS vehicles 2 speed trail 200 Park Bully rear power angle Park Bully blade elec roll B Park Bully blade elec roll A Wiper interval rear Page 7 Base 7 375 182 000 250 0 023 706 001 188 0 023 706 032 Ze ig e SI ZE PART NR 10A 0 026 012 005 20A 0 026 012 007 30A 0 026 012 009 EL FUSE BLOCK BRIDGE 7 253 030 001 High beam lights front Low beam lights front Left front light inside position Right front light inside position Gauge lights right taillight Under console light left taillight stick control stop button light Front xenon fog lights Rear top lights Drive electronics backup alarm stick control Tiller amp drive bypass switch Front plug KFS power seat belt lock Rear wiper comp bar switches Park Bully relays Front wipers 24v stereo Tach instr cluster gauges Rear lights hand spotlight Aux hydraulic elec board Available Turn signals horn flash lights grid heat Heater blower Engine electronic Engine electronic Engine electronic 24 12V Converter Engine electronic Engine electronic 24v accessory plug Starter Relay Relay K3 ON w eng running side glass heat mirror heat Rear glass heat Front window heater Ro
20. DRIVE CONTROL CARD TO CAB STEERI NG WHEEL Alarm rocker switch 7 331 164 000 Symbol 7 331 137 109 Back up alarm from s n 823 10670 Plug pin positions on drive card 7 711 208 000 15 L L O oO JE 100 1100 C 3 ds 75 c e 5 200 A se IS geet g a ob co asx A 6 8 e sj Se gt Dt PECH s u 24 GI Ek alot zt gt Manual Backup 1560 S2 1 1557 1 EE u 5
21. 34 24 64 54 v Wiper interval relay L sa 15 ES variable 8 0 7 375 210 000 Nb 5 see operator s manual x SR E Horn relay x S3b53 T 7 375 201 000 2 3053 A jor N 53b to case 2 5 to 16 ohms 53 to case 3 2 to 4 7 ohms Horns 31 to case 0 ohms Low pitch 7 711 130 000 31b to case 2 2 to 8 2 ohms High pitch 7 711 131 000 7 731 143 000 53ato case open Page 35 REAR WIPERS Power supply with ignition key on Rear wiper switch 7 331 197 000 Symbol 7 331 137 221 CJ 1114 ws 15 N Connection at Wiper interval relay 7 371 072 000 Rear wiper motor 7 131 000 255 Page 36 2 tiller switch gt 0 CNN VIII yl EE Si s 7 E sori Two time e N ipe button M 7 311 071 000 Button on left stick controls 1113 ws 1 8 026 108 142 To front wiper relay Color Code lue VI Violet rown WS White E Yellow GR Gray G Green Ll Purple ed SW Black OR Orange ENGI NE GRID HEATER Tachometer 8 749 231 000 ADM2 PB EDGE 825 4100 180 13 Grid heater square light Grid heater light bulb 7 584 065 000 in tachometer emblem 7 331 140 333 ADM 2 uses engine electronic socket 7 558 051 000 g temp sender to control grid heat 9 o o
22. FOG Light assembly 7 513 018 000 Bulb H 3 7 586 202 000 XENON Page 26 REAR TOP LIGHTS amp HAND SPOTLIGHT Power supply with ignition key on Power supply with main lighting rocker on 38 SE a Rear light switch 7 ws 1 7 331 192 000 iu i 01 2 T 137 208 1 58 A HX Bulb 2 529 182 a a 10 7 586 202 000 Em Ge en SE A 7 n Relay 7 375 197 000 pom 86 87 870 KINN 1 N 35 so ke x To EN Light Complete 7 517 136 000 1 a 2 2 8 EX 9 8 d Jil B ail Diode S HV 09 C 7 261 050 000 5 EB Ra CM r qd ME mM E E of E E z z 9 9 High Low Beam Bulb H 4 70 75w 24V To back up alarm relay for lights in reverse 1 586 206 000 Light assembly 7 512 030 000 Page 27 BEACON LIGHTS Power supply on at all times SU 30 t Switch bulb power from fuse 12 1131 ws 1 via rear wiper rocker switch Power to interior ight and clock 2 Tgl Her e d Beacon switch 7 331 164 000 01 1 Mo gh Symbol u 7 331 137 206 I ES Je 10 Hele ge Oe 3lue VI Violet rown WSs White GE Yellow GR Gray O n G Green Fale eq SW Black ml um OR Orange a i Beacon light 7 521 420 000 Lens only 7 521 420 004 Bulb
23. o AAA bb Ah A ME an 2 db _ E EM 33 Po ER a a P WV 5 n 6 4 SL E gt l l i d l j B Wt Sal II I G X e x og i 1063 ws 1 5 T L E s Ignition Jn Main Fuse Box Power supply with switch lnc 7 253 016 000 ignition key 4 ee 20A Fuse 8 0 026 010 007 Phe l 1008 as Power supply at all times e Connection to starter motor A Inline fuse inside d positive lead conn box left side y R of engine Bt Fuse 0 026 010 001 a 823 4100 151 01 DE TP s MN Grid heater 1 in air pipe 823 4100 150 01 Grid heater relay 100 amp fuse 7 375 212 000 Holder 7 253 040 000 Fuse 0 026 010 008 Page 37 ENGI NE BRAKE Engine throttle set rocker 7 331 171 000 Symbol 7 331 137 127 Connection to digital drive card plug on left side of card Connection at drive card dongel pin 8 1604 ge 1
24. er s as sl NE 7 gt Tachometer Tyr Z N S o 2 o 2 z 5 DI t P E a 5 SE T oy UZ E Se ul wy y 5 ag p m VV d d dr cd NN MEM EE A A as E dd ZN i ZN ZN E l e U LI E eens L l I ne Ste Engine electronic 196 1 amp S M i ES ES ES m 0 A under dash mE o AE 69 1 PESE RES MEE MOM MK EDD DE M ON MM M COM COMMUN oe UM ge U pq N 1 A W 1 W S ast 74 3 6 6 Teva 2014 ws 1 B 14 S g H7 ws 1 S z ads BHUI fee 24V when alternator is charging dag Kee PN Ln ges E a a y Ka HN 14 gt de Hie N 27 o 30 1054 1055 2 xrt 4 Relay 7 375 201 000 Power supply at all times Page 22 RADIO amp DRIVERS SEAT Voltage converter behind passenger seat Power with key on 7 161 000 093 or 09 106 ws 25 Vehicle prepped for 2 way radio Plug behind seat 1108wsl o IC V To front wipers Radio w CD 7 761 076 000 24V Radio AM FM cass 82 7 65200 12V Radio w CD 7 761 072 000 12V 1105 Connection les d 1254 ws 1 E t ao No L eost or t Radio i i 0 MN Max H Du 64 Radio T 24 V eA es Co c LUC xD i un EE pe E EA L ub Lol e ES u OD E Ge 1 ek x A ur W Au z ON 0 N CO OU OU
25. i E e e E H JS 171 5 bil QV 1305 5305 d Y 3 S S 388 3 yl Y 9 E 2 ls T T 1 bab d T t 1 t t t t 1 Z 6 N VI 1306 5306 a E A n g 5 E g gt z 5 25 25 5 272 8 88 S 23 3 3 2 Doe zw wo om f d 3 B El 8 3 LZ e247 HP 3 Tiller D g 5 E 3 8 E i5 23g e E PH B at So Ge ES H A E cates lle S 5 E 8 E d Am 8 ADMe SR F vyyyyy eem mam d a des Z si EE otis p Mi S 2 3 ES Box u HL an sou Cu 3 L 2 5 4 4 are 64 les Neve de LS a ES z g x See S S 12 bl 13195312 S Y 14 15 16 00 3 12 u ope 53 n QT P i 4 1 rot i Fit i y on 13 bu 13135313 E D o ap glo 01 59 Er 109 NG d So Hl 3 Id elt al 14 b gesu Je Jr 11 H K A a 31 sis Eom 3 g g g 33 S FERE S Y 4 15 b op zap 8 E 69s Fr 95 v A Auxiliary T E E g R 16 b 1316 5316 t y 2 zen A Q e A a 17 bl 1917 5317 1 9 EET E M gie Coolant S 7 Y A 7 siis acd 18 bu 1318 5318 Clock wsl ws Ae 1 ws 1 Level Temp e E IS es 1 x 19 bu 1319 5319 1144 ws 15 K 1147 ws 15 Gauge Gauge A E GES b NA 20 bli 1320 1320 1 5320 E L 1 ws x al 1321 5321 5 R 18 y 20 bll Res j Dg wi Worning Lamp Cluster 1 wi uo SS PS 103 x 15 b 22 bli Ges 1302 5328 1171 ws 1 O Connection Block III L dashboard Mete 1 aa i n JE Su eter 00 A d 2 2 E HR T e J Jim 1503 5503 3948 1503 1 5508 y IS 11 yY e aa gj 4 gel 1504 5504 4 gel 1504 11506 1 5504 Z 3 A K S gel 1505 5505 5 gel 1503 L1505 1 5505 8
26. Pa Page 32 SIDE WINDOW amp MIRROR HEATING Left heated glass 8 771 489 003 Right mirror Right heated glass 8 771 489 001 Left mirror pe ee U SE SE I Y a dg 85 Switch and contact assembly on Mirror head complete 8 688 100 000 37 7 RE ee Glass only 8 688 100 253 El Heat pad 8 688 062 213 su h jle Hh Side glass heat n x las TET switch 7 331 164 000 SC TT JS in Symbol 7 331 137 235 1 3p P o JM NE ME 35 3 IEA R AOS ps T 698 a YYYXzyx 1144 ws 1 9 1147 ws e _ y see teque L A Aw 4 cM Alternator D term E 24v when charging P N S Diode lt lt 78 7 261 050 000 30 Relay 7 375 201 000 oeh alternator Power supply at ging all times Page 33 CAB HEATER Power supply with ignition key on K CJ Cab heater switch 7 331 162 000 Knob 7 331 162 002 LOS ys Up HAD ZA A A Ni ER N gt 3 CORONA Eo pala 3 Sus SI Violet LD 3 Brown WS White E G YS WOM ASE ESE ES Green Lat EE eo ex L d O Heater blower 8 754
27. Under Console Ignition 6 gel 1506 5506 6 gel 1506 1 5506 E al ud ig 7 Drive Tiller Electronics witch 7 gel 1507 5507 7 gel 1507 11509 1 5507 i s E 83 4120 000 11C d S 4q de 4 the oi 1507 d Z E 3 ha 833 4122 000 126 Vd 2 9 E ad larler enz d lt E a 3 d zii 4 ss TE B gel 1508 5508 8 gel S se S 3 E 1 J S a 3 zz VE A 7 d ds 9 3332 E NR Pau Di cree E EEE 43 8 3 EN a 8 S 8 S 23933 2 i E 10 gel 1510 5510 10 gel 1510 1 5510 B 4 asa po Lab E 11 gel IIL 1511 1 S51 IL gel RI 551 E I x st 12 gel 1512 1512 1 5512 12 gel 1512 1 5512 d 4 38842 SE DS 13 gel 1513 15134 5513 13 gel 1513 5513 5513 1 ir ls gt 17lel 28 le 1 0 IRIS S aa 2 T 14 gel 1514 1514 1 5514 14 gel 1514 5514 5514 1 al S g Wa 27 le l Doc pj 15 gel 1515 1515 2 5515 5515 1 15 gel 1515 5515 pi 9515 2 y E a de Di 1060 sw 4 Sk 16 gel 1516 1516 1 5516 16 gel 1516 5916 5516 1 E 1054 1055 2xrt 4 ES 17 ge15 1517 1517 1 5517 17 gel 51517 5917 5517 1 S 30 80 18 gel 1518 1518 1 5518 18 gel 1518 5518 5518 1 1056 or 4 19 gel 1515 1519 1 5519 19 gel 1519 5519 5519 1 58 1064 gr 4 4 Pn 3 20 geL5 1520 1520 1 5520 20 gel 1520 1 5520 1 ER eel BL HLS es NN Le LS Res RL ke 30 S slel Sie I7 el ls ls 8119 S ez SI ZU Ka l ee its 22 bil S Res 1802 5802 22 b11 5 Res 1802 1 5802 1008 ws 1 A j L 4 ix ER IS gr Connector VI L Connector VI S TOS 1059 15 25 L vel 1096 H 1 wei 10961 g G ji 4 a d m 2 wsl
28. br a m Ks t CT n m vi a N 00 TP o 5 o 2 a 3 Park Bully relays B B 2 UN dus 3 3 B R R T amp MV plugs bl D D gt A 119 15 16 17 La 19 eg Je per F SG 5 5 5 5 5 5 5 5 5 ls 5 5 E 5 E T A br Right Wing E i u E d m E T E T E K E A Ki Ki K ISE Ki Ki A e Es Stand By Rear Hydraulic Flow Contro Lift Lower Blade Float Roll a MV 8 MV9 and MV11 MV 3 MV 10 MV 5 g g Color Code Mounted on vehicle behind grill T no Front Hydraulic BR Grown MS White Valves on main block left side of engine ellow ray Il GN Green LI Purple D MV2 MVS MV4 MVS MV6 MV10 Co RT Red SW Black Top Button 1 1 1 W H OR Orange Bottom Button 1 1 1 Float Switch 7 t 8 Coil only 8 025 971 824 Connector pigtail Connector pigtail 7 235 107 000 7 235 102 000 Page 15 Front joystick complete 8 026 131 000 2001 buttons Yellow button 8 026 108 139 Red button 8 026 108 142 Rocker sw 8 026 108 145 Blade float switch 7 331 163 000 Symbol 7 331 140 508
29. 484 000 under cover behind passenger seat Page 34 FRONT WIPERS amp HORN Power supply with ignition key on Stalk assembly 814 4100 130 05 it To directional lights 10 Sek 2 1071 ws 1 5 Connection B o 2 at tiller switc o 2 13 211 V L LT E S al Z 7 534 115 T HL d 2 V a a i f uuo H J 31b 5361553 Rem J Ja P I EE O 2 ha m ViI L M2 T 4T 3T 21 122 Two time wipe button 4 n a we 7 311 071 000 anon OR S S o 1096 1 ws 1 Button on left be n AAA stick controls AR o h ones atatia Y 8 026 108 142 I S 1099 1 ws 1 5 e Koa n ir K 2 o Qi lel INN alo AJO e o S k r 1 E X E Ka q S LA oo 50 112131415 fe 171819 non LEM 1 EM TO rear WIper relay zd dB 85 87 87 vs ea real K 9 y 2 OY Lo Connector for Electronic Stick Conversion X 2 mE 7 3 24 al 4 S S o i
30. 5 1099 2 wel 1099 1 3 2 s d 1 Ji us 25 xs 25 3 wsLS 1098 3 ws15 108 1 3 D 3 3 38 x vH Master i 45 10 T 4 wsLS 1097 4 wei 1097 1 5 bk Vit A R al 3 SE J 4 wei ws 15 ze S wsl 1083 1 1084 S wsl 1083 1083 1 E i i Tiller On Off 49 quoe EN E dg is d dd qq 4 d 6 wsl 1085 1086 1 amp ws1 1006 1086 1 7 3 8 kW 2 3 Wer iyu E ER b 9 E I I E Hal 13 7 wsL5 1071 7 wel 1071 1 3 Se 5 E co 56 4 W 415A H 3 33 33 g 3 ia iy ya e Ka 8 wei 8 1069 8 wsLS 1070 1 2 al al g E amp 8 E E DE S 9 wsL5 1072 5724 al g i SL MEM Qu id Tl s A T 10 wsl 5 1082 10 wsL5 1082 1 Is a ppal x1 fai i ss y E 7 prie lee 3 1L wsLS 1095 1 wsL5 1095 1 D By 2 Continuous Y Erde UU H Grid Heater 12 wsl 1219 12 wei 1219 1 Y 2 1 witel D i 80 1 T ce 36 4 Bp 7 dd 107 94 13 D 5 ame op nre y 2 dh av S HP 3 SS A gg d 4 5 i Tp 5 14 wsl 5 1073 1 14 wsis 1073 1 P H 1 T T Front Wiper 4 3 a3 i R e Y v 5052 sw 16 S ses lu to like J i Neier E vi H 3 8 on IT un a u Ad q E Connector VIIL colunn E EE E 9X dui R g L 1 I wiper T KK 1069 ws L5 1067 ws 1 K d asda 2 9 d KE 1 F Ch M T 3 button Y yt mid yet AL L x94 g J 329 3 al Ee 2 gel 1562 elle gt ses Ha at S am e E y pu 8 BB8388 ag 5 353 ws 25 3 gel 1563 x A Engine Broke Reloy St vs 25 Det aes E 3 gt 7 gel S ER D 6 gel 1566 a aa 33 RER i d 33 5 een 3 44 as J T Sch SL 7 gel 1567 fr 9 S d 4 d 2 EE 1 9 33 R Radio E 99 9 9
31. Bottery Shut Off fa 1568 5 2 al a el ce Nal lt q E ined M aa di a E WH x Switch 9 gelS 1569 E g g 3 SON S 3 g 1113 vs 3 aa 33 3 10 gel 1570 S J J 1096 1 us 1 IL gel 157 E mE d Se 1097 tws 15 198 t E ES 12 A 1572 S ws ZE G t NS P 1219 1 ws 1 BEER 135 AH 600 A 13 gel 1573 4 i be 7 MABLI 3 f miss sa fda EE E P EE TE T m A G 2 E sj a PE 2 dk Fi peus 313133333 dada de dg S E n 3 eli 15 ls le lo lu T 16 gel 1576 Connector IX column mox re 3 EBE ag Al d 23 338 Sg g E el a la x ku i aa xe Xi xxu xi pv Gm 18671 7 1 Ly N e PO eta el Ale s 58335 EE ep Tw YU g HHH LIT TS M 600 A 18 Bl 1368 2 dan ot o E dus id 4 S amp Ss y ao 30 12345 6 789 1011121314 U E r PLD Stort soj 5 88 EEE ET Dashboard O Due m t 2 6 EES 33 i 4 ii it Turn Signol Front High Low Beam engine Control Modu e Motor Dio Ta el HI 1371 5 3 3 urn Signol ja 2 A E t 86 e M S Horn Front Windshield Wipers Start Stop gnose ECH Starter Voltage Ela 22 wei 114 TI Interval wper 6 H IS Res 1806 K 4 GC Connector for Electronic Stick Conversion 0 Engine Block J44 4 d a E 4 S S ag y E 4 En E gh l NETA ES Atmospheric 53 ly SSC 8 J 3 E Sensors ond Analysis Pres ena Van op Dead Cen Qutput Stage injection Pumps Sue 253 grand Strop e d 5 5 k 4 3 Ol Pressure OB Boost Charge Ar Ai Preute EN ME ta eu Sensor de 3 n El D Weenaned A n Zi BA Oi Coolant a s a c pl xe Km 8 3 25 amp 7 ar e aonol sv E acn
32. OU OU QU AU QU AJ 4 herd S meer Page 23 Speakers 7 761 573 000 Antenna 7 761 649 000 RADIO amp DRIVERS SEAT w Alpine CDA 9820 XM Radio up to Fall 2004 Change fuse to Power with pm power supply on key on ER SE E Move fuse bridge from 22 amp 23 to 23 amp 24 liim Existing voltage converter loz 2 behind passenger seat 7 761 000 093 br 23 y 106 ws 2 9 Pin Connect to exterior temp gauge wire ws1154 Use avail term 15 at base of fuse 19 3 Connect to Alpine d 24 12 reducer ow ELON Wille pin 7 761 040 007 Connect to Alpine red wire Add relay interrupt wire 1216 w relay Ce pi GC Ra ES d u a 1254 ws 1 Vehicle prepped for pedis bones 2 way radio en Radio Alpine XM Radio w CD amp XM p n 82 7 65310 Existing on Ex speakers 7 161 573 000 riaht left Parts reg to add XM radio Existing antenna 1 82 7 65310 CDA 9820 XM radio II 1 82 7 65311 American Int XM antenna AMLEN ouo UU 1 7 761 040 007 Small 24 12 reducer 16 0 023 706 019 Fem spade terminal 1 0 025 030 001 Connector strip 2 0 023 703 008 Fem pin term Large 1 7 375 197 000 Relay 1 7 375 112 001 Base 5 0 023 706 00
33. Ref Log Dote Name ER e x 5 3 3 Z a 3 3 Eod Dim uon wd z 3 d H G We el E 3 3 5 3 Kissbohrer Al Terrain Vehicles Inc i f or Se I 0 2 b E See z S 5 z 532113 5 3 a 8 A rm E o o 35 o amp Q Q Rear working lights e go S e 323 e 3 5 x m 5 5 5 d 5 S a2 CAD T T 3 CG E 3 3 E 5 C ES Fuel Inject Replacement for Replaced by Turn Signal Lights F Se Inner 5 a t 5 B 8 e Sz Wee ER ER 24 1 5 3 7 5 5 7 8 9 10 11 12 Front Top Uhnts 13 14 15 16 17 18 9 20 2 Page 42 TEST FOR OPEN OHMMETER SERIES CIRCUIT The ohmmeter section of your multimeter can be used to check for continuity between two points in a circuit Ignition switch Ads DIGITAL MULTIMETER STEP 1 Before proceeding with test you must isolate the component or segment of the circuit that you will test The current source must be disconnected This can be done by turning the ignition switch to the off position or removing the circuit fuse if circuit is powered at all times STEP 2 Turn selector switch to OHMs scale section Q STEP 3 Connect meter probes to points A and B 1 A break or open between A and B will indicate a high infinite resistance which will appear on your meter as DIGITAL MULTIMETER 2 If there is continuity between points A and B no break a very low resistance
34. a gt pc ai o E 2 2 Y 8 m with key on V S 227 o o5 1 A 1 15 251 4122123424 11 N 4 DA 1 14 1 2 2 3 9 6 7 air 1144 87 vi 1 B X3p X3 1 reo ZU x3 SH Xe WR WA Xe l 1X3 LO Xe L 1 2 TX3_ 7X3 ZZ 1 122 xet LAZ pX3 pe External button id E 1406 bl 1 e Ln b ad Ca um 56 j E H HscLey DEE br o p p 8 L 1012 1 ws as V A 8 312 088 126 I 8 1325 bl 1 bt bl 100mV 200mA Xe Electonic Control Auxilary Hydraulic AHYD E31 8 49 081 000 P1 preset factory T Tiller Circuit ee SS P2 Set Down Pressgre to 40 bar P3 Set Up P re to 40 Bar 1 m e p ressu Tiller o Q Mek e mang m e hk e mw C99 e mK e mek Tu pe vu KZH Cup 85 5 20 E2 E2 Ce ES E3 E3 E3 E3 EE Ne es D Dis 119 Vig 153 T22 bis in 170 L 7 85 Lo 11457 1 Ss por bl i H 1 ity xe xe Xe Xe x Xe X xe xP x3 NN xa 1x5 x3 Txe 1x4 s 5 Right proximl ool D E A J4 44 p switch 4 E a ES En z 77777 d i 22 ws 0 75 m Za zZ T a rz 3 3 z 5 5 5 aaa D 2 a 33 ws 0 75 cp 7 346 041 000 N m Ye N 00 o S dud ai o AN ar Sl ws 0 75 Loe 5 o o o o S o fe fe e N M G B 5 5 BF ga m Sr bl 0 75 cp 7 2 E ue 2 m S m 2 a n 2 x bz xa pss es IE br 0 75 cy iv IV bl 0 75 y E Way diy hy dy Aw uy Day ty dy dy ba LI EN E c an E E E zi WT IT Y IV IV I TIVTIVT 532 6 bl 0 75 Implement side C ct bl a i u E 4 A tJ A to G Tiller On onnector O i v i T e S d E o u al S a o 3 3 a 5 5319 bh 2 bl 0 75 N
35. and point A Some possibilities could be a blown fuse batteries not connected or dead ignition switch open broken connection or wires etc If voltage is present then proceed as follows Leave negative meter probe connected to ground and move positive probe to point B If the meter shows voltage here it indicates that the conductor from point A to B is complete If not check connections at each end and the wire for a break See page on continuity check If the above check indicated voltage at point B move meter probe to point C If there is no voltage at this point this might be caused by faulty contacts or the wire may have been connected to the wrong contact on the switch Determine normal position of switch contacts Normally open or closed and perform continuity check Follow on through to points D and E If voltage is available at point E and the circuit component or lamp in this case is still inoperative then the problem lies in open circuit between point E and F ground Check connections at each end and the wire for a break see continuity test If point F is inaccessible it may be necessary to run an alternate line from point E to a suitable grounding point Page 45 LOCATING A SHORT IN PARALLEL CIRCUITS An open in a branch of a parallel circuit disables only that A short across a branch of a parallel circuit disables branch of the circuit the entire circuit OPEN FUSE E n SHORT CIRCUIT ONE BRANCH DIS
36. dE Starter Relay 1060 sw 4 S Ig under dash 2 cw 08082 1056 gr 4 D 22 2 26 5052 sw 16 1001 ws 15 c 1022 ws 25 hb 231 ws 2 p Remote Engine y FBc Wel ws 15 y 4 Sal Start Stop 2 2 L 2 30032 ws ACA 3 gas il 2094 ws 2 9 99892 el a Pe Engine buttons r iF idu d C 70 oT Battery Main Switch uN EE 4y5yer 7 1 2 8 312 088 126 p 1 Ha PTIT Pf 7 341 110 000 ER n cts a Y n i E PM E E A gt br 2 5 Key only 3 8 85 gom Bm pu sg vi ler s IIIA 7 341 110 002 wu E c B 135 AH 600 A u un i S XM d i sa c v t 13 1 314 2 8 2 1815 5 6 9 t ar Ca T 4 a GL M AR Wu int al ia X1 X1 X1 X1 He Y _ REESE eae Al HIN tt NEE LI os AH 600 A e Start Stop S0 82 25 1 RR KK I x F4 M KL 90 RE ZA E JAM 7 Engine Dia CAN Starter i Voltage S y NN Start Stop ij gnose Fort Gio ji Supply to xx G 5 Cabin Engine Block Ee EE oe Output Stage Injection Pumps Atmospheric sw 0 BE eid Ground Strap d cg C BKI EG B D BK2 FH Z pq pp 0 5 en ae Vehicle Chassis Starter 5 16 46v 4945 44v v9 38 v37 e NR ug wong WT 8 312 088 014 Page 8 Relay Back Up Alarm 7 375 161 000 Voltage Regulator 7 267 208 000 Bb Cluster assembly 8 749 118 000 Ka Load Limit Bypass Switch 7 331 179 000 Symbol 7 331 137 201 Under Dash Brake sender input for tiller safety shut off
37. only 8 025 971 824 tank x 7 346 O41 000 Cakin Lift Lower 1 1 0 1 D Io a MV MVI MV2 h z E S Snow Flap 1 1 0 0 o o 1 switc Snow Flap 1 Du 0 1 o 0 1 Optional switches 0 D 1 1 1 1 7 346 041 000 Optional switches 1 0 o 1 1 1 1 1 7 z Optional switches U 1 U 1 1 1 1 3 Optional switches 0 0 1 1 1 1 1 Junction box 7 241 003 000 Page 17 Center float Front joystick Up float down Rear up down Tiller steerin on left sticks handle complete pressure switch rocker switch Gs p n 02012 8 749 131 000 in joystick 8 026 108 145 Potentiometer uttons on le 8 026 108 172 zu we up down pressure 8 026 108 142 Tiller start Tiller depth Auto lift in reverse lock out 8 749 114 000 button red 7 331 171 000 7 331 179 000 Power supply symbol symbol with key on 8 026 108 142 7 331 137 227 7 331 140 522 8 749 081 000 Board
38. the same gauge wire A smaller wire will not carry the required current and overheat will result 1 Test for open broken wire 2 Test for short bare wire touching frame check for blown fuse 3 Test for short two bare wires in contact BLOWN FUSES RESULTS IF WIRE IS DEFECTIVE A to B A to C Infinite resistance A to D A to D Zero resistance A to C Infinite resistance A to B Zero resistance if wire is still intact but grounded A to B Infinite resistance if wire is broken and grounded A to C Zero resistance A to B Zero resistance A to D Infinite resistance A blown fuse does not necessarily mean you have a short circuit Some other possible causes for a blown fuse are 1 A temporary circuit overload caused by a malfunctioning component 2 Use of incorrect size fuse 3 Poor contacts in the electrical circuit or component Page 47 RESISTOR COLOR CODING 1234 3 3 3 4 2 4 2 4 Y 2 4 1 First significant digit 2 Second significant digit 3 Multiplier value 4 Tolerance RETMA color code for resistors 1 2 4 FIRST SECOND SIGNIFICANT SIGNIFICANT DIGIT Blue urple 7 7 390000 Gray Wwe s f s rwo NOMINAL PERCENT BAND VALUE TOLERANCE TOLERANCE RANGE 22 000 Q 20 No band 17 600 26 400 Q Gold 95 105 Q 9 11 0 1140 1260 Q 5 44 8 16 Q Wheel diagram for selecting the proper equation for CURRENT VOLTAGE RESISTANCE and POWER SYMBOL QUANTIT
39. 1 Terminal 1229 ws 226 ws 227 wS 1228 ws Add antenna XM 82 7 65311 RADIO amp DRIVERS SEAT w Alpine CDA 9820 XM Radio from Fall 2006 or CDA 9883 Change fuse to Power with power supply on key on at all times Move fuse bridge from 22 amp 23 to 23 amp 24 Existing voltage converter Jes Js behind passenger seat 7 761 000 093 hr en 15 wsl 24 V eA CO OU Radio w CD amp XM 1e5 wsl 5 1258wsi0 p n 82 7 65310 K7 relay new in Tee ON Y RS wie M EET PB EDGE fall 2006 Bs BEN zu i m See onnections ze Vehicle prepped for Acie tu 2 way radio ea he j XMDirect optional Hi T Existing speakers 7 761 573 000 1 82 7 65310 CDA 9820 XM radio en x no wired iPod plug 701 049 New for 2007 1 82 7 65325 CDA 9883 Radio with iPod plug 1 82 7 65335 Extension cord radio to iPod optional 1 82 7 65340 XMbDirect tuner box PUNE He a LA req only for XM DRIVERS SEAT BELT TENSION LOCK STICK CONTROLS amp WINCH VEHICLES Seat belt lock switch 7 331 159 000 Symbol 7 331 137 113 Seat belt locking device switch only used with Electronic Sticks ws 1 1 S9
40. 1 eo amp mv2 C93 C9 mva H amp H C9 vvh amp mif H C9 mvs H amp H amp wve H amp H A pF ZN AN amp euo es amp A K OH amp uve DH 69 mva IH GI IMvii 8H E4 E4 E5 E5 E ES Ce es I Es TI E6 i ES ES E6 SS 244 ad 221 23 20 8 U 151 4 4 16 7 18 X4 X4 X4 X4 X4 X4 S A om gel ui cm 789 S I 12 X4 X4 x3 x3 X3 i u H L 1336 2 bi T 1336 1 b A S z 5 5 2 5 5 5 5 wo lt o m N D S F o N 00 bei M m be m m e m 3 m m m a S ue 2 pal R m pe 1330 1 bl 1 1 f i T I 1 I 1 1 IS i l 153 141 104 131 121 y 201 211 16 4 174 184 ER a 5335 bi f J zi 2 br t c gt zi 5 5 D o A N oo E E 5334 D Mt A 2 e o e oO a ive i o m D 2 5 5 3 8 bri m m ke W 0 0 E bl E 3 iD lt D D gt y N Lio bis 1 5 16 17 US 19 10 411412 EE F or a 5 5 5 5 5 5 5 5 E bs s ls b Is I IU vm po Diode a is E 5 5 l5 E 5 E E z Ele a b 5 7 261 050 000 E ls E E ki K Ki K Ki Kl lt A 2 Ki lt N jl li fl ll fl T T M fi fi MV 3 V 10 v5 ve P Ariel MV 8 MV 9 MV 11 Lift Lower Blade Float Rol Win Blade Rear Gente Blade Electric Roll Stand by Rear Hydraulic Flow Control Valves on main block left side of engine Plug 7 235 101 000 Connector pigtail 7 235 107 000 Front Hydraulico a O I D MV2 MV3 MV4 MVS MV6 MV10 amp o Button I 1 1 1 qu Button Il 1 1 1 N Float Switch 1 sj l V 1 2 A B MV8 Roll Front 1 1 1 Roll B
41. 14 H im N MVB MV9 SES ES S P a5 Y ve Q Cou Qus mi C MV1A0S SR amp UD k Mvi C9 GO HSG Ex ac tension p2 v7 62 Go Gn rocker switch M3 Q Q mv3 A A MV4 7 331 179 000 9 99 88988 symbol na o NF LU Ve OU E E Connector X4 Black 25 Pin 7 787 031 000 Front Hydraulic X41 X4T EET X4 o Ag AHYD E31 IMPLEMENT CONTROL BOARD 8 749 081 000 GO rao r9 Q a cio WB X wy 8 FS ee wy 9 F9 X uv u F9 E3 L6 e ES E6 4l 4 I I F X4 X4 aT aT ch x Color Code BL Blue VI Violet BR Brown WS White H GE Yellow GR Gray 229 GN Green Ll Purple RT Red SW Black OR Orange B J Track Tensioning E gt N Track Tension Brake Un MV Track Retract 1 1 Pigtail conn S S E 7 235 102 000 Track tension valve mounted right side of engine i coil only 8 025 971 824 Page 20 Test 3 ohms when empty Sender 8 749 255 000 3001 GAUGES SENDERS amp HOUR METER 8 749 263 000 190L Outside temp sensor 185 ohms when full Or Ze 7 231 395 000 Sender plug 8 749 037 000 mounted Fuel tank sender d 7 231 310 162 Term pin to right mirror bracket 190L tank 7 231 310 182 Rubb z 4 8 743 755 000 i B gt A Open in sensor loop QV TT e display 22 on gauge 1 Instrument cluster ADM 2 engine control under dash 825 4100 180 13
42. 332338 5 8 749 081 000 D Me vii ji i d M T De Front Blade d o Ll 1 Tiller amp amp ENG Ka Lift L to Left Wi 5 a E Wing Ge i 1 19 y CID W i san Se eo T1 mg MAQ 52 ND Lem Rocker sw 8 026 108 172 L 4 e S R E 4 Ale W s me Ele 13 Front Blade lol ea H 5b gl 9 ne 2 tiller steer rocker 8 026 108 144 e om I pur f 1 M20 Gr Gul Electric Blade Roll JA in EA Wees Q D p d E Black 25 Pin Green button 2 E E MV Q amp ap S Rear Hydraulic 3 d Wi VQ 8 026 108 141 3 EK 2 S 3 E M G2 Qw C r sA Agah de A Ss 7 ir Rel MIR MV3 TK GEN OK ENN C D vy Connection 9 elays Ze P lt 2 69 69 69 69 69 69 CO 14 4 front class heat L5 39 9 E 7 375 122 000 Seo 9 925 amp Toggle switch a a lt a 9 eee S558 L d switch o Rear Hydraulic F A 7 331 227 000 e CH Circuit N oO Oo EMI Breaker E ka A Lower 9 e D H Tei B Lift d ek ND C Tilt Left B 1327 1 bl 1 CY Mc D Tilt Right 1328 1 bi 1 Sla lt Hose only Ge J EC DD B Roll Out Front Hydraulic 819 4100 203 89 C Swing Left 2 1 11 3 5 6 6 D Swing Right XAT H EAR T u _ A X4 4X4 X4 IA Left Wing In r IB Left Wing Out 2 L 8 elen IC Right Wing In F y P Ug ID Right Wing Out 7 231 151 000 ic a o ee GC 1499 1 bl 1499 2 bl 1 Electronic Control Auxiliary Hydraulic AHD ES1 8 749 081 000 E E ES K15 730 ach K16 230 861 K17 730 867 9 1
43. ABLED ALL BRANCHES DISABLED A short circuit has almost no resistance since it by passes circuit resistance This permits the flow of an extremely large amount of current When this current exceeds the fuse current rating the fuse blows opens and disables the entire circuit With all branch circuits disabled each branch must be examined separately to locate the short OPEN HERE FOR BRANCH ISOLATION Leg Isolate branch circuits at fuse STEP 2 Set meter for OHMs Q STEP 3 Connect one meter probe to ground frame STEP 4 Connect other probe to one end of circuit leg 4 1 A high resistance indicates no short 4 2 A very low resistance usually zero OHMs indicates a short in that leg of the circuit STEP 5 Repeat step 4 for each leg of the circuit and each branch as necessary to locate short Page 46 WIRING HARNESS TEST FOR DEFECTIVE WIRE WIRING HARNESS ground A wiring harness is the main branch with leads which feed the electric circuits Wires enter a common sheath joining other wires and emerge at other points in the circuit Individual wires in a harness may be replaced by cutting off the defective wire at each end of the harness Discard the removed ends of the wire Run new wire along the existing harness and attach with plastic clips and electrical tape Do not attempt to thread the wire through the harness as this may cause damage to other wires CAUTION When replacing a defective wire always use
44. B to C Auto Lift 5 2 o E S E S e 2 S S E T Fr B to K Flex Tiller under dash ia 3 D 6 o 6 D D 6 r r E 22338 e 5318 bl 1 14 bl 075 Gl 5 WN 0 o o wo al g 5217 bl 1 E bl 0 75 K br1 ws 0 75 e 13 pin plu i 2 13 la L5 ls 17 sL 94 elt 14 el 31 fia L15 Vie L17 fie 119 oo ox 22 di Yo da de ds a bl 075 cG ln H pug b k 55 E K b BR b P K b B Bb m 5 b E vi o5 7 235 109 000 VY ER MV B MV A MV 1 A MV2 v4 MV6 MV7 MV PVB Pin only GG S I i5 lo 5 lo 5 lo 5 i 5 la 5 5 E 5 E 5 E E Da TE Ea i Pm Pm e e UE e go ii 7 235 109 006 La 21 4 p 6 u 1 IS Bl 1 A br A B Selector Valve Lift Load Check Lift Lower Centering Steering Float Depth of Cut Steering Side to Side Up Pressue Up Down Proportional ear Control Block Main Control Block Valve S3 S32 S16 S42 S19 S17 i Function 1 2 0 1 2 2 12 1 2 1 S1 S2 S3 S4 mvalmvs MVi MV1A MV2 MV3 MV4 MV6 MV7 PV8 mval MV9 MV11 T a MV X BI 0 Do lo Sw Lift at top 1 0 0 0 1 0 1 0 0 9 K Litt 1 1 e S 1 o i 1 1 1 Optional Valve br Lower to SZ 1 0 0 op o 1 1 1 1 Se Color Code With Snow Flap Lower from S2 1 DIT o 0 1 1 Q 1 1 u Down Pressure 1 1 1 ol o 1 9 0 0 O l ew 1 24 ere a BL Blue VI Violet Up Pressure 1 1 1 9 0 1 o L5 0 ul BR Brown WS White Steer Left 1 9 U 1 O U Ac Steer Right 1 ol o 1 1 olo g GE Yellow GR Gray Tiller Depth Up OI 0 1 0 0 c E Green Ll Purple Tiller Depth Down 710 0 o fo amp b d P imi Auto Lift TO 0 i a cory RT Red SW Black L
45. Diagram For Electrical Equations Windshield Windshield Heat Rocker Wiper Motor Front Wiper Motor Rear Page 51 13 14 13 14 13 14 19 19 21 19 21 17 18 13 14 13 14 13 14 9 11 20 12 29 17 18 17 18 23 9 11 22 22 49 31 31 35 36 JU Pit Z i Di Pagid All Terrain Vehicles Inc ock Blvd Reno Nevada 89502 775 857 5000
46. Drive Tiller Electronics equipped with Steering Wheel FFE L 1588 gel var L rl Connection Plug at Drive Tiller Electronics equipped with Steering Sticks FFE S e Connection Plug to install wiring from Steering Sticks X zd 1589 ge 1 Connection Explanations Connection Block Ill to convert from Sticks to Steering Wheel Ill L E E Connection Block lll to convert from Steering Wheel to Sticks II S c Connection Plug wire loom supply to Steering Column VII K13 S T 3 444 4 co 823 41 25 000 12 C Forward Reverse 423 Y A AAA Steering Switch 7 331 166 002 23 i 3 3 5 Potentiometer Symbol S ii 885848888 8 49 087 000 7 331 137 217 18 3 2 1 1 10 920 6198 7 gt 4 11 189 13 14 15 16 Connection Plug for Electronic Stick Conversion Track Speed Potentiometer 8 743 876 000 Page 9 DRIVE CONTROL STEERI NG WHEEL CARD TO CHASSIS Drive Card
47. E 8 3 1 v 0 Sel ib 3929 m o Mo O gt TUS CR SS S E Q8 24393 a g n Tu yellow a z SS II S 2 2 ITT d g Go oo i 3 o VeL A Be LA PEU al of ad al of 9 Bu s 30 O lk A S 124 411 S SA AA 8 Sf EX ELE 71819501 L 4 2 CD eree amp r S 6 9 e ZN 7 2 p ec Im Bea a a amp nO o o 1600 ge 1 94 2 1 E5 1 eil cl 7 DDD e 1510 gel vs PES seem perg 4 ds 5 S T ei 95 S 1506 ge H 1 ML Ill L Se a ni TA MES i hi2 ER sa 5 AAAS soo a _ VUM VIII mE gi ui SABA 44748 mess 588 o oj o o LO O LO LO WO Q LO LO o o WI LO LO CH O LO LO LO UO 8 gt 9 99d Cluster assembly d g o dad ans B 4933 B 19 LO LO LO CO wo LO LO LO ua SC La 8 749 118 000 l ELA e 001 5 e7 10 A A F Throttle Position Servo valve right L O E Signal From ADM 2 dz S35 EL Sai a EN A E MU Connection for Engine we IT C D 2 Cae 1j Speed Signal from ADM 2 A 5 Servo valve left K13 1587 ge 1 1588 ge 1 7 1589 ge 1 Pd Load Limit Bypass Switch 7 331 179 000 Symbol 7 331 137 201 ELSA Under Dash Armrest button switch 7 311 184 000 1589 1 gel 141556 1 ge 1563 1 ge O N lm N N O c5 WO PS 00 Q CA CO N oa EN 1 1694 U gt 1 1 1 1 1 1 1 1
48. E B I 3 be ma PWM D PWM D l 13 01 1013 103 1 93 Cebin lock switch 13 bil mun 1333 5333 gt SES 14 51 ET Alternator Terminal D 14 ut WO 1334 5334 B 31619 5 EE D J IS el mam Alternator Terminal W Iw NO 1335 5935 E t E e 44 4 E y 4 1epol green 9 Seat belt lock sticks amp winch K wl 106 50 Hydraulic Oil Temperature 16 bl ng 1336 1336 1 3339 7 x8 s z i El dag ag 4 d E D RI E E y ala 1 17 ei 107 5017 Air filter restriction indicator 17 H V9 1337 5337 H iol on s 23 a 3 a 3 ERE B a al a sl z E B e 18 151 198 S8 Hydraulic oil level sender 18 bil VID 1338 5338 10402 ba E b as TT E d g 3 3 8 E S 8 5 a 7 as Y dl 19 19 bl Fun Park 1809 5999 2 Zl 9 al 1 ibe gt A ad de 20 20 bIL Fun Park 1340 5340 ls 2 i Lx E zwein Was 7 21 bil Fun Pork 1341 5341 am E E a a i I ei Lei 22 W 25 102 52 Si 22 bil 1342 5342 52 5 L i b E i 18 1178 ws 1 wl BLS Wes 1821 5821 ER sa A i u 1 1179 ws KE E WIS Res 1822 5822 22 i 1 U ORO 158 vi LES y Junction box left 35 1 2 13 5 9 y side of fuel ton 28 E _ um ED EE k sl lt z ECHT Hemos Connection Block IV under dashboard C m D Y 3 a y E m x 8 S Y 1 N vb 1301 5301 3 y s d Ha y L J lt a a 2 bl mu 1302 5302 T t S 8 E S g J J d j A gt pius SX quz lt ER S s 313 3 Y S 3 3 bl WI 1303 5303 I 3 J H s P 994942 a 3 S Yyyy ot Heot Relay 85 EST g 999 E E 5 lh De 4 H QVO 1304 5304
49. E z d s ur 43 ws 3888 gay e Se Electronic PLD Za d B BEER RE 3 E special order item e sw 70 y H d Eater RUE DI br 23 1 br 25 T 50 3 E E 1135 AH 600 A sl a MR R RRE K Page 40 ENGI NE BLOCK HEATER Plug end male 110V ps bad 110V 7 235 103 000 l SW gn WS SW ge gn bl SW gn ws SE E Q e P U 14 0 hl 5 5 Hydraulic tank heater optional 8 441 312 000 Engine block heater for freeze plug 1000w 8 441 517 000 Page 41 s PB EDGE MAIN VEHI CLE ELECTRICAL PAIS
50. EE ll E Ir a a eo a ME re EB OLD 39 34 369 Za 41014 43 2 oi 950950 7 29 2321 48 x232 10x2 1oxe 13 vn xe Xe NL xe Xe Xe xe x XcXo Xe XA Xc Xe xc X a oo E ER dw due la Pel lees gt u 2 a EI 2S CD o lt LC ua e Jw c 314 1 C LL 43 L Pa fe FREI XL y X gt Low High Air boost amp temp Fa Speed Coolant temp 8 312 088 113 sensor 02050 NS Page 39 Engine throttle set ENGINE FUEL I NJ ECTI ON WIRING rocker 7 331 171 000 elpol brown Pin 25 4 Pin 9 8 Pin 25 18 engine speed Throttle sensor for aluminum pedal 825 4100 110 22 new inline plug style Color lue 3rown MA Yellow Green Q AJ Q OQ UJ UJ J
51. H 1 70w 24V 7 586 201 000 Left beacon M light Page 28 INTERIOR LIGHT CLOCK amp UNDER CONSOLE LIGHT Interior Dome Light 7 552 031 000 24V Bulb 7 583 066 000 calor Blue GJG Ww DFOWN Yellow Green ed Orange Code VI Violet WS White GR Gray Ch Purple SW Black Power supply on at all times Power supply with m lighting rocker on ws 1151 br rt 1206 ws Teenz jor 1 1153 ws Door Switches for Interior Light 7 315 130 000 Connection at warning cluster 1151 ws 1 1152 ws 1 br aem MO 00 714 qus Cp qiu qu2 7 97 Hi T Clock 8 749 077 000 __ Bulb 7 584 061 000 To beacon light rocker al Mi eL Light Under Console RN 7 552 028 000 x 24V Bulb 7 583 066 000 50 ele 308 d Ze To gauge lights To taillights Page 29 DIRECTIONAL LIGHTS Power supply with
52. Hour t 1063 ws 1 5 14 0 A WA ws 1 Meter gnition gt switch 1255 ws 1 E Relay 7 375 201 000 bier eutidly l E ower SU on y HAINE PP Y E i n on when alternator Ja with key on d ata Imes 2 e A 55352 S35 f j pc M charging 3233 1051 sw 6 55 E ly K K3 sss S S 7 2 14e o 5 i Sek 30 i 054 1055 2 x rt 4 EE 58 1064 gr 4 8750 056 gr 4 m Bg 17 85 Ka 001 ws 1 5 052 gr 4 053 ws 2 5 falli l Aa 445 d d T ot po Power with main SS x Geh Light switch 7 331 155 000 i S K A J light switch on E7187 ss Sch Symbol 7 331 140 202 9 Coolant temp gauge gt y 1 4 8 743 803 000 Fuel gauge ae 067 ws 1 ol PE EPI PLD control box Tiller depth gauge 353 3 on engine 13 11314 12 8 1218155 6 9 11 H also on page 19 8i B qu T DS ee NUT special order item D LD Start Stop Iso E Z i E KI KI KI KI KI star Stop pm SCH Starter Bean d Propartional Valve Tdentieuten iii u Pumps E Seeler GE SE SE DE Guinan E E T P Sensor Temp Temp E CE EG p D T 2 50r SAGA IE Lo S lig 54y 53l Y16 had m v9 sal 137 ERE d i S i N35 H N3 XTNS NS NSN3 INsN3 NS N3 NS N4 NS N3N3 NAT N3 M i INS 8 312 089 078 Z gt rt gel ws ge N sw1 E br J swl de J Engine coolant temp sender l l 02050 Tachometer input signal Page 21 Cab latch switch 7 311 143 000 Air fil
53. IQNt SWITC A lt T ol in S4 Symbol 7 331 140 202 De Be E EE aran E sal AA I ees E f E Q o 2 S ME ke C CO COLIT C ED a e 1 Y n E e 2 B veces Elei 86 d T E B Blue VI Violet Ld mE ee E d e pg 3 B Brown WS White 00 ol 968 a La PER GE Yellow GR Groa S ai Ze e _ Ns 31 Parking light bulb GN Green L EE A a a Me u 7 584 067 000 RT Red SW Black 3o d 3 E 1067 ws 1 ion ee SES SE Kl D SR el 3 M 1069 ws 1 5 K L ue o Ee G O O CU 0 S o d 2 E a S Lens 7 512 000 009 oO Ken Te a E E Se E S olo o3 la High low beam bulb H 4 70 75w 24V e KR S 3 i 7 586 206 000 He ka EN es z DES T SC Xe E g RS e Gi lech O U un Un Y Ui L u ee nn er ee PP C ae heb te wWisishduhanae D x In N co Sg o A A E EE EE O S S S Parking light bulb us Turn Signal Front High Low Beam 7 584 067 000 Horn Front Windshield Wipers A Connector for Electronic Stick Conversion 23 A Pa e Fre S IS E Lens 7 517 112 003 IESSE E E ee ae ee Low beam bulb H 1 70w 24V 54 E n 7 586 201 000 High beam indicator light H 4 bulbs H 1 bulbs bulb 7 584 172 000 FRONT FOG XENON LIGHTS OPTI ONAL Power supply with main lighting rocker on Sle EL y Fog light switch o p R 7 331 164 000 u SEN Symbol We 7 331 141 205 di So 54 6 10 Right Left
54. J el a Aarm SWYS ger Ala p Only KFS Drive Card c n 01 51 104 N E T 38 2 vehicles have 8 749 175 000 D iB T ed 1558 1 ge 1 bx D d g FFES1 e v ISA 44 204 6 A A19 o D la relays plugged in a Je mit a 4 B 8 L To left servo ALE s 4 li Li Pin D dis Fuse 2 5A R E MEE 0 026 011 002 co i ia Aa 1599 ge 1 ri 1593 gel S 1594 qe 1 el HRRHHIP PARRA d el EH ES Sa 3 Steering Trim w red S x 8 2 asi y 2 a P N E zu 8 _3 a a da sg itt o SO A 2 D S sp y i3 a z3 el e M EN H LX yellow Ta E M 31 9 pin connector gt O ceu e ui v gt in M Z jj IH D Burt 2 Se eb _ amp 1600 ge 1 ru z nn wa a4 8 5 M 3 S 2 895 L HI M s R HR 2 a E y SE ac amp U 7 xm JE IES gt 5 Z 7 E 5 aL 18908 27 d gu VILVIL VEL VIII S iz T TITTS 2 W oq T AN 1584 ge 1 ge I hk Di qe ZEE 7 UI 5 el a E Connection for Engine Speed lt E R LCD Display Ou w SS SH Scd C j 4 S e a ha aa Signal from ADM Under Dash B SP 40 1 1717 H auus ws 1 ap NA x a a sem co LED Displ A bl 1 bl 1 zi zz o i isplay 00 5 ET 105 5 sy 8 E E Throttle Position AS Yr 9j 3 1476 Ve K N et 6p Pr 10 Signal From ADM 4 sil S33 7111 AJ 90 1120 d ff EN Y E 4 d Neh UE EC ADM 2 m BE AA 7010 9c N To third pump 825 4100 180 13 control drawing 1562 qe 1 ge 1 ci 1987 gel rl Fe Y l Si FEP 1 Connection Plug at
55. L peces EI n n n 2 2 7 E 3 SIE 2 5317 bl 1 13 bl 0357 542 14 ws 3 12 ws 0 751 13 pin plug i le 13 A L5 ls 17 el 9 1 i 11 m 34 fis 115 117 m 119 mm mm quM 11 bl 0 75 G U 5l B IS a Is a 5 lo 5 lo E NOE i bd 10 bl 0 75 7 235 109 000 bl 1 x MVB MVA MVIA MV2 MV4 MV 3 MV6 MV7 MV1 PVB Yr Pin only 8 i 5 B ls 5 Is 5 15 5 15 5 15 5 15 5 E is E 5 E 7 235 109 006 j i j j NR u a bri 7 bl s 1 a 4 2 4 B 6 Do RET Ln ors A B Selector Valve ift Load Check Lift Lower Centering Steering Float Depth of Cut Steering Side to Side Up Pressure AUp Down Proportional Valve bl 3 lo 5 MV X SW S32 S16 342 S191 S17 Rear Control Block Main Control Bloc i lt Br Sunetion 1 2 0 1 2 1 212 1 2 1 S7 S2 S3 S4 uva uvel mvil mvi A mv2 mv3l mval mve mv7 Pv8 mval wvo Mv11 Optional Valve 0 With Snow Flap UR at top 1 0 oll 1 9 1 0 0 o e or Pigtail conn Ce o1 o 1 g zi 7 Color Code 6M Vario Bar 7 235 102 000 Lower to S2 1 0 0 olo 1 1 1 aS Ze SC is Mod 5 a Lower from S2 1 0 1 ol o 1 o t1 1 Kr Down Pressure 1 1 1 o o 1 0 BL 0 0 ar ie D Up Down Float 1 1 1 0 O U U 0 D N RT Red SW Black Up Pressure 1 1 1 0 U 1 0 Q D Ly OR Orange Steer Left 1 10 U 1 D 0 i ty Steer Righi EC i oto g unction box Left proximi Tiller Depth Up 1 X a x Tiller Depth Down 10 T Da B left side of fuel switch Auto Lift 1 L4 AI Centering i D 0 011212 l Deck proximity Side to Side Float 1 1 S 1 GTR TR G Coil
56. Located In SS 2 E Mi 25 amp 2 Dag Float ME Right Armrest 1359 bl 1 5 5 E 1393 bl 1 1294 bl 1 19 Di S SE 53 bi 1 pee b 1 wus bl 1 S g 1390 bi 1391 bi 3 Bin y V KS diio YS Y NL 1 201 ab 4p 10 201 3 4g 10p 201 3 aj 1p QUA PA UD Jy s 67 107 201 3 an 10 201 3 Ar 10 10 94 3 102 TOK NN NE ILLI CES X EE LUI E _ SS UN T Gi o E D I ELT Ill E be or del Je elle 39 15 S43 s42 50 set I Sr ete CS I ie Li 7L at o ERE T 7 DEA T Y bt g 289 Wid sU 9 7 DEG de 7 YA Y 4 T o Y VA i ala al 2 de 397 bl 1 1398 bl 1 M 399 bl 1 Y Bu D 4 S 401 bil 1 1402 bl 1 403 bl 1 P PP c 9 8 y Y Cab latch switch ower SUpp y 88 5 1 A Drivers Seat i SI 1404 bl 1 atc SWIC 2 vit Y vill vill vill o D 0 20 21 18 19 aa a pn o with key on Bn J Kb Sp 7 e 7 311 143 000 iQ um 2 1s GE 7 on 22 2 23 2 ux n W al zx iu KK sl o A all cal 358 ES zz 22 _ E 5058 ws ON ld aen e VH a oO I I I o a 2 5 a T e 2 H X unm H o oi o el N 0 dv A X A de ed Nas ea XA X AXA XA 5 2 e Qu 0 2 2 9 a m i i To Drive Electronic 75 L Sai Io NN 0 ol o 12 13 16 14 d e es s e uw o 4 N N R o E Backup Alarm Relay K25 KE Ee S v SS Ad 2 gt 0 o o 9 H1 54 ae q X j a E JJ 3 R SI S O12 Em a 2 a 14 j s we 442 d feel e d 28 dai S A 5 S 2 1 26 585 WH 4412 a S SEL a q E o o Sf SI g 3 V ars 1 Bom 2 e 3 Cab tilt 12 13 19 15 25 122123 24 11 3 4 al Na 2 2 3 9 6 u l
57. O AR id 27 Beacon ie EE 28 Interior Light Clock amp Under Console Light 29 Bireetlonal Lighis ss genen Deere 30 Front Windshield Heating WEE 31 Rear Window E Le Le WEE 32 Side Window Heating amp Mirror Heating ee e e e K nennen nenn nnen nennen nennen nennen 33 Cab Healer EE 34 PRONE VV pers and POI EE 35 Rear EE 36 An el en 37 Engine Brake aa a E E E Ent 38 Engine Fan eleetric shi za oe eme ird eos om tae cue vr had cana See 39 Engine Fuet nigeliort VVIFIEIG Basel 40 Engine Block e E EE EE 41 Complete Main Electrical PB EDGE EE 42 Circuit Testmg PIOCGedules ds 43 Resistor Color Ee 48 Wheel Diagram For Electrical Equations 49 Ja qe ELE 50 USING THIS MANUAL The entire electrical system has been broken down into its individual circuits A table of contents is provided at the start of the manual to aid the reader to quickly locate a particular circuit A section has been included on techniques for testing basic circuit failures Each individual circuit has been drawn in diagramatic form using electrical symbols However each symbol is identified by an illustration along with part name and part number When possible the actual component location is also illustrated Relays are identified by a K and a number Example K7 Fuses are identified by their number and switches are identified by an S and the number Example S22 A glossary of the fuses and relays has been included Each electrical compo
58. SERVICE TROUBLESHOOTING MANUAL GUIDE VEHICLE ELECTRICAL SYSTEM Kassbohrer Pisten Bully EDGE Mercedes OM926LA Powered Groomer amp Park Bully from s n 823 10670 USA Trail EDGE from s n 823 10731 USA SE E L K T Ce A SES S d d Cu d CD Part 82 5 20220 Book Part 82 5 20220B Edition 12 Feb 10 PLEASE READ CAREFULLY GENERAL INFORMATION All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication The right is reserved to make changes at any time without notice TESTING SAFETY Most circuits are energized at a maximum of 24 volts This is a relatively low voltage but safety is still an important consideration in troubleshooting Only skilled personnel familiar with electrical equipment should be permitted to do the work There may be hazards present not only from electrical energy but also from mechanical and fluid power equipment It is important to know the condition of all sections of the machine before starting troubleshooting work CIRCUIT GROUND LOCATIONS The ground network for the electrical system consists of the main frame engine block subframe of platform and steel framework of cab Because of the numerous ground points involved it is not feasible to show the actual location on the vehicle where each ground wire terminates In the following circuit diagrams ground connections are sh
59. Temp Gauge Parking Lights Pigtail Connectors Plug Front 7 Pin Plug Front 8 Pin Plug Rear 13 Pin Proximity Switches Radio and Driver s Seat Rear Glass Rear Glass Heat Rocker Rear Implement Electrical System Rear Light Rocker Rear Steering Buttons Rear Steering Toggle Rear Top Lights Rear Window Heating Rear Wiper Relay Fuse Index Relay K1 Relay K2 Relay K3 Relay K4 Relay K5 Relay K6 Relay K7 Relay K8 Relay K9 Relay K10 Relay K11 Relay K12 Relay K13 Relay K14 Relay K15 Relay K16 Relay K17 Relay K22 Resistor Color Coding Seat Belt Tension Lock Servo Moog Side Window Heating Side Window Heating Rocker Starter Relay Starter Motor Steering Potentiometer Stereo Tachometer INDEX PB EDGE 8 33 33 40 21 25 15 16 17 18 13 14 15 16 17 18 17 18 23 32 32 17 18 27 18 17 27 32 36 7 7 30 7 35 7 31 32 33 1 25 7 25 1 27 7 7 32 7 35 8 40 8 40 23 21 Third Pump Control Tiller Card Drive Card Tiller Pump Controller Tiller Depth Adjustment Circuit Tiller Depth Gauge Tiller Depth Potentiometer Tiller Depth Rocker Tiller Forward Reverse Rocker Tiller On Off Rocker Tiller Speed Potentiometer Track Speed Potentiometer Track Tension Trail 2 Speed Drive Motors Under Console Light Up Down Pressure Rocker Up Pressure Potentiometer Voltage Converter 24v 12v Voltage Regulator electronics Warning Light Cluster Warning Lights and Buzzer Wheel
60. Y UNIT OF MEASUREMENT E Voltage Volts D Power Watts Page 49 American Wire Gauge AWG sizes may be determined by measuring the diameter of the conductor the bare wire with the insulation removed Metric Stranding Wire Approximate Wire Dia per Strand Overall Diameter Size 7 0121 1 039 1 0403 71 0152 1 045 7 017 1 0508 7 0192 1 055 7 021 1 0641 7 0242 1 071 1 027 1 0808 71 0305 1 089 71 034 1 1019 7 0385 1 109 71 042 1 1144 7 0432 1 1285 7 0486 1 141 71 054 1 1443 71 0545 1 162 7 0612 71 068 71 0688 11 0772 71 085 19 052 19 1 32 71 0867 7 2 20 7 0974 12 47 7 100 12 54 19 061 19 1 55 19 0664 19 1 69 19 073 19 1 85 19 0745 19 1 89 19 0837 19 2 13 19 086 19 2 18 19 094 19 2 39 37 0673 37 1 71 19 101 19 2 57 37 072 37 1 83 19 1055 19 2 68 INDEX PB EDGE Alarm Rocker Switch 9 11 Function Chart Rear 17 18 Alternator 8 21 Fuse 1 7 25 Alternator Charge Light 8 22 Fuse 2 7 25 Antenna 23 Fuse 3 7 25 Auto Lift Reverse Rocker 17 18 Fuse 4 7 25 Back Up Alarm Relay 9 Fuse 5 7 21 25 29 Batteries 8 Fuse 6 7 11 25 Battery Main Switch 8 Fuse 7 7 25 Beacon Lights 28 Fuse 8 7 27 Beacon Rocker Switch 28 Fuse 9 7 9 11 Blade Float Rocker 15 16 Fuse 10 7 9 11 13 14 Brake Pressure Sender 22 Fuse 11 7 13 14 Buttons T Handle 15 Fuse 12 7 16 17 18 36 Cab Heater 34 Fuse 13 7 23 35 Cab Latch Switch 17 18 Fuse 14 7 21 22 Cam Position Sensor 40 Fuse 15 7 27 Center Floa
61. ack 1 1 1 8 026 110 000 Rear power angle diverter mounted on left main frame near rear block 8 026 109 000 Electric blade roll Coil only 8 025 971 824 A B valve mounted behind chassis grill i Connector pigtail 7 235 102 000 Page 16 REAR I MPLEMENT ELECTRI CAL SYSTEM deeg amp FRONT BALL HANDLE Connector for joystick equipped vehicl Connector plug for stick control vehicle 8 749 081 000 Board Tiller up down Tiller eeh Up float down Auto lift in reverse lock out 7 331 174 000 7 331 171 000 pressure switch 7 331 179 000 Center float symbol symbol 7 331 192 102 symbol l 7 331 174 000 7 331 137 226 7 331 137 227 symbol 7 331 140 522 with key on symbol 7 331 137 226 7 331 140 511 Toggle tiller Power supply steering 7 331 227 000 Potentiometer up down pressure 8 749 114 000
62. e 11 44 2 JA OG BI eer eg te RT VTT ep a pe xe 1X pa PE LT r ple x3 d ch External button br mu X3 br ec Za y Elo ben usd 9 1320 1 bi cab pump JJ J a L 1013 1 ws 1 GER Y X3 bl 8 1325 bh _ 115 bl 8 312 088 126 Xe Electronic Control Auxilary Hydraulic AHYD E31 8 749 081 000 100mY 200m4 P1 preset factory By Pass Switch lif t lower P2 Set Down Pressure to 40 bar iller Circuit Rear Implement P3 Set Up Pressure to 40 Bar Ctiller NEN ES i T T 0 43 Frose e R619 Z Z Q mek e mako mk e m e Tuva GT e ug e us e mH va K PV8 Ze E2 E2 E6 E5 E3 E3 E3 E3 Z x Li Lie Lio Lo 123 122 L15 EN 120 T7 ks Ee bab 7 d Emi bli Xe Xe Xe Xe Xe Xe Xe Xe Xe x3 X3 X3 X3 x2 N 4 Reserve sw x X4 l E q7 7 br ox Ri ht d A 7 E B E A B 2 d 4444 54 7 ara ight proximity SS E 2 m a a zl a 2 a 5 21 ri ws 0 75 a K lt 5 5 Fa a n a D a 3 a a 3 5 al 2 3 2 A e Ws UVA E 20 1 0 75 gt 5 a 2 i o g 5 2 3 o a 3 3331333J335 13 b ozs tf en Connector block SI 2 2 E 2 2 B S 2 2 2 on be 075 cy 7 346 041 000 Liv Liv Liv Liv Liv Liv Liv Liv Liv Liv Liv IVA IVA IVA VS vd vv let E Jumpers on under dash Ba Iv T2 73 K i K B J7 b i b i 10 Ta 3 1171215714715 12716117718719 20 5320 18 bise s prp merum side SI 7 2 E J _ _ E A aa as 1 B to C Auto Lift s a 4 4 a 4 4 4 4 2 a A a AS 2 5519 h 90 15 N B to K Flex Tiller G a SN mM w 1 14 2 S 3 2 8 3 2 d 3 7 99992 E aam u
63. eft proximity Centering 1 U 0 1 0 D 0 OR Orange x RN a Pigtail conn Cabin OFE ower i Hon i ot 3 un mus switch Snow Flap i 0 0 0 0 Rear up down rocker 7 235 102 000 snow Fop 1 o o 1 o 0 1 7 346 041 000 Optional switch g 5 2 1 1 1 SW 8 026 1 8 145 Optional switch oe 2 Opti it 1 0 1 0 RIE 1 1 det fa Optional switch holo cn ER J unction box Deck proximity i left side of fuel switch tank 7 346 041 000 Up press rocker sw 8 026 108 172 AR i J unction box 7 241 003 000 Page 18 TILLER DEPTH AD USTMENT CIRCUIT Potentiometer 8 212 676 752 in hydraulic cylinder 3 pin plug tied to harness left side of fuel tank i LA Is 5 u Tee Pin male 7 231 000 077 Pin fem 7 231 000 073 Plug male 7 231 000 072 po Plug fem 7 231 000 076 90 Plastic plug Male 7 231 117 000 Fem 7 231 122 000 a 2033 ws 1 HE US ws 1 PO Connector male pin one wire 0 023 703 007 two wire 0 023 703 008 10ST ws 3 1032 ws 1 1033 ws 1 Ground wire female pin to fuel gauge one wire 0 023 716 001 EE two wire 0 023 716 002 Tiller depth gauge SE 8 749 085 000 a n
64. elay gt en 9 10 min time delay 7 375 176 000 Resistor D Lo 7 261 078 000 30 L86 G85 Olea en 7 331 157 000 ER LU Von Wire to charge A A indicator light Alternator D term 24v when charging z 1162 1014 ws 1 E 5014 ws 1 P Eet 87187 86 x az Pa LO 800 T M Relay 7 375 201 000 a on when alternator 295 charging c c 20 Power supply at all times Page 31 REAR WINDSHIELD HEATING Heater wire element in glass Glass 825 7720 110 05 a 2 N Diode 7 7 261 050 000 2 Relay 7 375 201 000 Rear glass heat switch 7 331 154 000 D De RR JE REH prise Ir VYYYXY EN a i i E KN en i e e i Ws s A A A HT 7 E olaa we 15 E ae 1 W B l A B D a S Alternator D term Peg 24v when charging 1014 ws 1 2014 ws 1 u o 14 x hale le s gt o i 30 oo 83 T U Relay 7 375 201 000 i Lo on when alternator E 28 charging EL 30 Power supply at l all times Diode 7 261 050 000
65. fei D D in To relay K11 1218 gell E 151 il 16h psp 19 1600 ge 1 d a Se Erw oa 1698 ge 1 id o a a J ga e gi od Jo i 4 m N 7 Ob op de o m a o Sei GO ag lt 3 S n o 3232 35 o t Se S M Ge C F 9 Ia 131 156 ai 174 To stick conversion plug X o6 t dal i e SECH TT VIO VIII M VT T T 31 3 a Tu n ua o9 T m 10 nu ha pa o s p 14 15 8 Gi gt e sl sal sE Qn u N gH s13710 SE 2 gt a a n A o a ol H iO le lt EN E EB Ti o ce to T8 NIN a fe o b AA L 25 C DAE an TE 01 55 67 10 o 5 10g 128 114 T 4 Ge L Magnet A 12 24 T Top m Im 7 8128 gl 517 H 9 Reverse uU ech N c ge E Magnet B E il v 2 Bottom Forward d Tiller on ligh ge 1 br 1 br 1 Tiller F R switch Controller 7 331 159 002 8 048 370 598 Symbol 7 331 137 232 Tiller on off 7 331 164 000 Symbol 7 331 137 302 Connections to drive Light behind Note Relay K10 switches S2 S19 used in KFS vehicles Connector male pin one wire 0 023 703 007 two wire 0 023 703 008 female pin one wire 0 023 716 001 two wire d 0 023 716 002 hal Le Front 7 pin plug 7 235 063 000 8 048 346 581 Page 13 Controller magnet THIRD PUMP CONTROL W STICK DRIVE CONTROLS iom 823 1067 Color Code
66. i D o LL O Dashboard Z E Ground GroundN Strap Strap z 50 RR 1135 AH 600 A MM sw 70 Chassis Red Orange Alternator 7 421 356 000 Code VI Violet WS White R Gray Purple SW Black Starter Relay under dash 8 312 088 132 Starter motor 8 312 088 014 ae Symbol 7 331 137 127 a throttle position Spo ry To drive electronics Spol violet R 1 4 7 i0 3 PWM D Stetten be 24 A To coolant 2pol green E temp gauge i SS lt l l i d sad ADM 2 engine electronic under dash ake 93 Eee 825 4100 180 13 Buzzer ground for a SEN S B cluster f EE 3 gag 33 MEE a E 5 eur En 1 T SN NE ADM2 ECH s p s Sg E 4i 2 us Tachometer aq AT ol An K e CS m E 333 S Mio ws 1 5015 ws 1 ITE ET Diagnostic socket 5 Sa l under dash for Mini Diag woi Ignition CM S Air boost amp temp switch Sa A Bosch 8 312088113 D E sensor 02050 NES dd Ranco amp Bosch 8 312 097 031 4 d4 dl fag TZ Oil press temp sensor Fuel temp sensor as da a e di g dese SNR 8 312 088 010 bm d Flywheel sensor e e A al BS 8 312 089 078 16 su 4 Ss 054 1055 exrt 4 24V socket 156 gr 4 7 235 033 000 zb Q0 ws 15 Se 231 ws 2 9 I 002 ws 25 02l ws 15 N Wu HAZ Le KREE Cam sensor 8 312 089 078 Engine buttons 8 312 088 126 4 p c ul va D CH Y 8 3
67. ire ees o ud S GES ge e Deng 9 O 2 of fF g gA de 7 SES EE 5 5 B 0 023 703 008 L 4 1299 FN i NU SE af Si al Y N ol ol L S b D DR nee NR NINE O female pin LCD Display ig 000 om 0 0 t0 IER Y E 7 one wire S 0 023 716 001 VI Vo m s N EN r i LED Display 2 BI EST T al p two wire y i NA A IT I 0 023 716 002 Error O 600 oe 1 8 N 9 AX da 8 Transition e a 2 1 N j FF 00 J OF 3 iller Active Key Pad d T 1 Jo 1 S H i 7 nd 3 Thai sb bau Italia VIII vul vill Vill Mill VIII VIII 9 o Ta L Tiller spinning light 10 Tey 124 A13 14A 15 9 A H st WI o T sp S26 1 o D og o fg d o 318 10 ES oo S 2 d Ta od SES Wigs 5 g dd 3 23 48 5 N o ea du 1 26 CDA E E MI 3 i E 001 54 Go 10 K esp A We dee u I Front 7 pin plug 2 K S17 7 235 063 000 ZS 820 9 SE D 1 ol d T Tiller on light Tiller on off rocker switch Tiller F R switch Controller 7 331 164 000 7 331 159 002 8 048 370 598 Symbol 7 331 137 302 Symbol 7 331 137 232 Tiller potentiometer 8 749 169 000 Controller magnet 8 048 346 581 Page 14 attemate buttons FRONT IMPLEMENT ELECTRICAL SYSTEM BALL HANDLE OX 7 331 227 000 toggle _ 8 026 108 142 red button aae float switch T Handle buttons 7 331 163 000 8 025 764 682 Symbol 7 331 140 508 Manual toggle to lift rear implement
68. jg 5 d 2 ul m Ile Coe Suar 25 1 o n ch u N SE 5 IB Roll Out 5h A4 3 2 1 2 S Y Connector X2 v2 amp o Gi V8 d 8 025 966 000 IC Swing Left LI LI U Yellow 25 Pin a Swing Right L Rear Hydraulic ES UW VIAS DA 8 wL Connector X3 e in n E 5 Pin IB Left Wing Out MV1 GI amp ul Ss ER m E IIC Right Wing In je 25 m mvid IID Right Wing Out 13 B Wu Qa Qmd a La C mv3 6 Qw 14 D vd E c S OMS 2988 8898 Complete harness y s S ET S TR So 2 083 5 x oY 819 4100 002 01 Plug 7 235 101 000 i EE Q S my m u ir Hose only Es T Breaker l 819 4100 202 01 1329 1 bi 5 1328 1 bl 1 5 7 1327 1 bl 1 Connector X4 o Black 25 Pin Front Hydraulic Plug 7 231 151 000 2 1 3 gl 5 6 6 X4 1 LX41 X3 X4T d X4 p p X4 X41 n 2 a o fi E 1499 1 b N 1599 2 b 7 Electronic Control Auxiliary Hydraulic AHYD E31 8 749 081 000 K15 4 K16 K17 3O 86 207 88 207 86 Q mz e IR ui e mg en T VVS e uve BH 7k ba Q BK 99 e ax KH amp nv 29 amp uva HEH Q MH ES E4 E5 ES E6 E6 E3 Ee i E4 E5 Ee J 244 U L U 201 gd zT 141 4 el q I ai o x Y4 Bio Y 87 Y85 874 Y87 Y85 87d Y 87 CBR la xA X4 di i Ys a 8 9 1336 2 HI 1536 T bl 1 E 3 B a R 5 E 5 3 5 19 x o m e e 3 e N Ke ei bei m m M Kei Ke M Si Si M m M 2 2 A 2 ic 2 5 2 2 2 2 S 1330 1 bl 1 bl i 1 I T T 1 I Il i I 1 15 14 10 13 11 12 19 20 21 22 16 17 18 i I i i i i i i i i N a 15335 bl 1
69. lug wire loom supply to Steering Column VIII Track Speed 4 Potentiometer p n 02013 Il KE Hl S Page 11 2 SPEED TRAIL DRIVE MOTORS tee SED T with sticks Connection forward reverse switch e Rocker switch 7 331 154 000 gd Symbol 7 331 140 533 pepeti EA Relay 7 375 181 000 1990 ge n 13 Js ESA ra e 4 b 7 ow II L 20 z III S 20 pa Connector pigtail L E 7 235 102 000 Too T7 1 Page 12 Plug pin positions on drive card 25 14 Y Ge Steering Trim TD Hp UD rb Buzzer O Fuse 2A F 9 pin connector En O Drive card 8 749 175 000 O L LCD Display LED Display Error O Transition O Tiller Active O Key Pad Tiller spinning light THIRD PUMP CONTROL STEERING WHEEL
70. n Ee Color Code 5 lue VI Violet 43 11 BR Brown WS White Calibration screw in gauge S le ed SW black OR Orange To outside temp gauge 14lo Power with s key on d 08 Power with main To right tail light light switch on amp air filter restriction light Page 19 TRACK TENSION Track tension indicator light TRACK SWITCH FUNCTIONS 1 RETRACT POSITION W LUCKING DEVICE Connector X2 0 POSITION Yellow 25 Pin TRACK AUTO ADJUST 7 787 015 000 c Rear Hydraulic EN LED ERROR Ready C9 amp CG 69 amp Connector X3 Toggl i mi O s 0 5 0 ee ee e En Guest Steuer IC G PV Rear Hydraulic DE SEDE a Wun CO 69 E L D 9 E MVA C9 Sm Elo
71. nent s terminal markings have been identified and each wire has been color coded A color code chart has been placed on most circuits as a reference aid Often times a number will immediately follow the color code on a wire Example BL 75 The number 5 indicates the area size of the wire in millimeters The electrical circuitry of the PB EDGE has centralized points of connection These connectors are identified by Roman numerals and their location is noted on Page 6 Please note example below for an explanation of their use in the electrical drawings Electrical wire harness connection points are shown with a ROMAN NUMERAL and NUMBER EXAMPLE Ill 2 The ROMAN NUMERALS refer to specific plastic connection blocks located in the vehicle BLOCKS I II IH IV are located under center console BLOCK VIII is located inside steering column The NUMBER adjacent to the Roman Numeral refers to specific embossed number located on the block surface Page 4 This manual is provided not with the intent to circumvent but rather to supplement the electrical system wiring schematics provided in your vehicle s service manual It should also be used in conjunction with the PB EDGE Operator s Manual which describes the location and function of the individual switches and electrical components In conclusion it is hoped that this manual will provide the following benefits 1 To provide a learning aid to newcomers unfamiliar with the Pis
72. oles E AND E AGND ERa NE AND Temp Temp Temp T assis 4 4 SV HA d 4 44 4 J Y d 9 9 d d d d UR lk obs 23 ke zf tat at bis G i WEI E 3 Sei gt gt a ka a N ae 2822 1278 31 265 33149 7 led eaei J48 xA 10 15 3 xe xe xe xi xe Xe Xe xe XeXe Xex xe Xi i fa a E E rr g 99 E 9 8 d g s g g g g eee Kex Keka xe e e qe Tolerance Scale Weight S 3 zl Je 4 be El 3 S Si sS 5 E d d U s Ca TMK E 1 1 SE 88 F 2 amp 8 DRM J Ad 33 Ad 3 II T zh SIS Material Description ER TTT ngine Electronic alo SS 34 39 4 au 9 Bi l DEE i i x IE E z a p PLO Plugs dd sz 9 3 2 55 qa a 833 12 WH 5 8 EE Row Material PB EDGE with OM926 ADM L 28 El amp t y 284 I S S x x d H ge inne EE i L e 1h 3d 44 de Jig D E E 3 ef i US H1 i 8 i i i x Sal KE Dote Name Description E E 3 ZS dj j ll s I 174 4 Mk P WI l Drwnl29 01 02 HANN i i ri MAIN ELECTRICAL PB EDGE left right Sos S EOS 3 3 3 Wiper Motor Reor 4 S ai Ctrl Pz g 2 SS 3 amp r Es 5 E 1 1 t Eg E S 5 E Rotating Beacon LZ Bo i4 E S 5 E E EU T e 5 5 P S 3 R o3 E Wiper Motor Front Hom E 3 8 8 P S a s 105357 25 04 03 DANN Nor page Ou og Ze E E 3 3 a 9 te 3 D o 2 g 5 g a S w M x N i a dE 5 2 E de EO 4 04 S F EN SZ o 522 3 E Sz s 5 5 a i 2 S Ze E 3 3 E 5 105207 19 02 03 HANN amp Drawing Number 99 M f s Z H E S 8 E s 2 e e CS Eg T P S 8 2 S SE 5 5 5 E E E E E E
73. own with the conventional symbol CIRCUITS AND SERIAL NUMBERS Although the majority of the electrical circuits are common within the different serial number ranges of the PB EDGE certain circuits are not Circuits that are applicable to a specific serial number range have been identified as such It is important to identify your vehicle serial number prior to use of this book in order to insure that the correct circuit is referenced TABLE OF CONTENTS PAGE Using This Manual eg ee ee ere 4 Component POC AMON erstes tae ias 6 Relay v E Tae nas bid 7 Ignition Switch Starting Charging Circuit ee ee e e e mmm 8 Drive Control Card to Cab Steering Wee 9 Drive Control Card to Chassis Steering Wee 10 Drive Control SUck Controls iii gg Ee 11 Trai 2 5peedJDrvesvlolOfS ar ida 12 Third Pump Control Steering Wheel ee eee 13 Third Pump Control Stick Drive Control 14 Front Implement Electrical System Ball Handel 15 Front Implement Electrical System Park Bully Joystick eee eee 16 Rear Implement Electrical System Groomer e ee e K e e K K ee 17 Rear Implement Electrical System Park Bully e e e Ense nenne nennen nennen en nn nennen 18 Tiller Depth Adjustment EE 19 rack MET e RE 20 Gauges senders and Hour EE 21 Warning bigbts Tere BEE 22 Radio and Divers EE 23 Seat Belt Tension Lock Stick erer re EE 24 Front Top Erghis ec Park LIONS EE 25 Front Foo Xenon Lights eer Lei BEE 26 Hear Top Lights Hand peH a Ta azer
74. t Rocker 17 18 Fuse 16 7 17 18 Circuit Testing Procedures 43 Fuse 17 7 Clock 29 Fuse 18 7 30 35 37 Complete Electrical PB EDGE 42 Fuse 19 7 34 Controllers Moog 10 11 Fuse 20 7 40 Coolant Temp Gauge 21 Fuse 21 7 40 Coolant Temp Sender 21 39 40 Fuse 22 7 40 Directional Light Relay 30 Fuse 23 7 23 Directional Light Stalk 30 Fuse 24 7 40 Directional Lights 30 Fuse 25 7 40 Door Switches 22 Fuse 26 7 8 40 Drive Card 9 10 11 13 14 Fuse 27 7 21 31 32 33 Drive Control Card to Cab 9 Fuse 28 7 32 Drive Control Card to Chassis 10 Fuse 29 7 31 Driver s Seat 23 Fuse 30 7 28 29 Engine Fan electric shift 39 Gauges and Senders 21 Engine Grid Heater 37 Grid Heater 37 Engine Speed Transmitter 40 Hand Spotlight 27 Flywheel Pick up 40 Headlights Upper 25 Foot Throttle Transmitter 40 Heater Blower 34 Forward Reverse Switch 9 Horns 35 Front Ball Valve 15 Hour Meter 21 Front Fog Xenon Light Rocker 26 Hydraulic Level Temp Sender 22 Front Fog Xenon Lights 26 Ignition Switch Starting Charging Circuit 8 Front Implement Electrical System 15 16 Implement Control Card 15 16 17 18 Front Top Lights 25 Interior Dome Light 29 Front Windshield Heating 31 Joystick Control 16 18 Front Wipers and Horn 35 Junction Box Rear 17 18 Fuel Gauge 21 Lighting Rocker Main 25 Fuel Tank Sender 21 Load Limit Bypass Switch 9 11 Function Chart Front 15 16 Load Limit Card 9 10 11 13 14 Page 50 Main Fuse Box Mirror Heat Rocker Mirror Heating Oil Pressure Sender Outside
75. tary beacons interior light clock Instrument Cluster 8 749 118 000 Engine Electronic ADM 2 Load Color V 3lue Brown Yellow Green L 0 LL L ed Orange special order item KT MI Violet WS White GR Gray Ll Purple SW Black IGNITION SWITCH STARTI NG CHARGING CIRCUIT Main Fuse Box 7 253 016 000 SOA Fuse 0 026 010 007 Batteries 7 471 054 102 under dash 825 4100 180 13 De E IONS d A di A a M E L Ie O j 5 amp u UZ S C C E Si gt YT Y la Z TE TL T bd EF oa 1 5 T 2 gt K 4 ke a Ww e a ET x S amp 5 zo Y E 0 Ln sal ie et feu er La Hi 21 eo s ig 3353 SS m eoe e 1015 ws 1 eu Ne l iy lem I Qa la 15 1014 ws 1 9014 ws 1 1063 ws 15 ra LO Ignition SN SB Switch rob 1051 sw ren Ul G2 F 7 345 042 051 000 ale a tilo Gi SS 6 Wien
76. ten Bully EDGE electrical system and thus reduce familiarization time 2 To provide a means for someone wishing to further develop their understanding of the electrical system 3 To insure that proper wiring connections are made when components are replaced 4 To provide a means to quickly locate components and their part numbers 5 To enable the reader to quickly visualize how and which particular components are interconnected in a particular circuit 6 To provide an aid in troubleshooting 7 To increase communication effectiveness between parts and service personnel when dealing with the electrical system Page 5 NWN C MODO TI COMPONENT LOCATION FROM SER 823 10670 USA SWITCH RELAY DIGITAL DRIVE CARD REAR FRONT IMPL CARD BACK UP ALARM RELAY ENGINE BRAKE RELAY VOLTAGE REGULATOR MINI DIAG CONNECTOR ENGINE ADM 2 under dash CONNECTORS CONNECTOR VITI GLASS HEAT MAIN FUSES RELAY K1 under dash K1 RELAYS K17 FRONT GLASS S el HEAT RELAY ve INTERM WIPER bes JE RELAY REAR PLUG X FOR O STICK CONTROLS STARTER RELAY Page 6 24V 10 20A D 332204201 BOSCH RELAY amp FUSE I NDEX FROM SER 823 10670 USA RELAYS Term Term Base 7 375 112 001 Term 250 0 023 706 001 14 7 375 197 000 86 snp 7 375 201 000 86 um 7 375 181 000 AD ES 2 4 1
77. ter vacuum sender 8 319 170 000 oo unused wiring coolant tank level a Air filter emblem 7 558 044 253 Cab lock not engaged Park brake on Oil pressure below 10 psi Not used Hyd tank temp above 80 c Hyd level low S10 e Door switches WARNI NG LI GHTS amp BUZZER Power supply with ignition key on Cluster assembly 8 749 118 000 Bulb small 7 584 172 000 Bulb center 7 584 173 000 IN Hyd filter sender 9 Brake pressure sender 7 315 130 000 ch See 116 000 120 bar 7 314 111 000 j i SC from S N 823 11128 Hydraulic level amp temp sender 8 749 080 000 za z ER ce VR D T n a D oA OA E SE O M mm mn 1 i 1 1 i k 2 baru 1 3 2 To interior Ju R T 7 au mM light 2 3 3 2 i M Oil pressure light wire 9 do i S gt unused i Me tal His Th 1158 ws 1 1180 ws 1 DZ WS BES A E 1159 ws 1 ol win S d
78. usually zero OHMs will appear on your meter as Page 43 TEST FOR OPEN OHMMETER PARALLEL CIRCUIT LEFT DIVERTER ROCKER SWITCH RIGHT DIVERTER ROCKER SWITCH LEFT DIVERTER RIGHT DIVERTER VALVE VALVE DISCONNECT HERE FOR BRANCH ISOLATION LEFT DIVERTER ROCKER SWITCH RIGHT DIVERTER ROCKER SWITCH LEFT DIVERTER VALVE RIGHT DIVERTER VALVE Page 44 A series circuit as shown on the previous page has only one current path However a parallel circuit as shown at the left can have several current paths You must keep this in mind when troubleshooting parallel circuits Unlike a series circuit an open in a parallel circuit does not disable the entire circuit The branch to be tested must be isolated from the other branches You can do this by disconnecting the other branches at the fuse terminal as shown at the left Once you have isolated the branch circuits from each other you may then proceed to test for continuity open using an ohmmeter as described on the previous page for series circuits TEST FOR OPEN USING A VOLTMETER IGNITION SWITCH En F BATTERY GROUND m sd frame Turn selector switch on multimeter to DC volts scale 2 Connect negative probe of meter to suitable ground vehicle frame Connect positive meter probe to point A to determine if there is voltage available from the source If no voltage is indicated an open is present between ground
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