Energy Systems Test Area (ESTA) Electrical Power … 2 Table of Contents 1.0 Introduction .....4
ELECTRICAL TABLE OF CONTENTS
Transcript of ELECTRICAL TABLE OF CONTENTS
Electrical Table of Contents - 203
ELECTRICAL TABLE OF CONTENTS Electrical
Table of Contents
General Information......................................205Reading Electrical Schematics...................205Theory Of Operation Information................206Diagnostic Information................................206Wire Color Abbreviation Chart....................206Common Circuit Tests................................207Conductors For 12 Volt Circuits .................207
Specifications ...............................................208Electrical.....................................................208
Component Location....................................209Component Location - L100/L110/L120 .....209Component Location - L130 .......................210
System Schematics ......................................211Schematic and Wiring Harness Legend - L100/L110/L120 .........................................211Main Wiring Schematic L100/L110/L120....212W1 and W2 Hiring Harnesses - L100/L110/L120 .........................................214W1 Front Main Wire Harness Color Codes - L100/L110/L120 .........................................216W2 Rear Main Wire Harness Color Codes - L100/L110/L120 .........................................216Schematic And Wiring Harness Legend - L130 ...........................................................217Main Wiring Schematic L130......................218W1 and W2 Wiring Harness 130 ................220W1 Front Main Wire Harness Color Codes - L130 ....................................222W2 Rear Main Wire Harness Color Codes - L130 ....................................222W3 and W4 Jumper Wiring Harnesses - All ...............................................................223W5 Headlight Wiring Harness - All .............223L110W6 Engine Wiring Harness - L100 .....224W6 Engine Wiring Harness, Stator and N1 Voltage Regulator/Rectifier - L110/L130 ....224W6 Engine Wiring Harness - L120/L130 ....225G2 Stator and N1 Voltage Regulator/Rectifier - L100 ..........................225G2 Stator and N1 Voltage Regulator/Rectifier - L120/L130 .................225Y1 PTO Clutch - L130 ................................226Y2 Fuel Shutoff Solenoid............................226N1 Voltage Regulator/Rectifier...................226
Diagnostics and Operation ......................... 227Power Circuit Operation - L100/L110/L120 ........................................ 227Power Circuit Electrical Schematic - L100/L110/L120......................................... 228Power Circuit Diagnosis - L100/L110/L120......................................... 229Power Circuit Operation - L130 ................ 232Power Circuit Electrical Schematic - L130 ....................... 233Power Circuit Diagnosis - L130 ................. 234Cranking Circuit Operation - L100/L110/L120/L130................................ 237Cranking Circuit Electrical Schematic - L100/L110/L120/L130................................ 238Cranking Circuit Diagnosis - L100/L110/L120/L130................................ 239Ignition and Shutoff Circuit Operation - L100/L110/L120/L130................................ 240Ignition and Shutoff Circuit Electrical Schematic - L100/L110/L120/L130............ 242Ignition and Shutoff Circuit Diagnosis - L100/L110/L120/L130................................ 243Charging Circuit Operation - L100/L110/L120/L130................................ 248Charging Circuit Electrical Schematic - L100/L110/L120/L130................................ 249Charging Circuit Diagnosis - L100/L110/L120/L130................................ 250PTO Clutch Circuit Operation - L130 ......... 251PTO Clutch Circuit Electrical Schematic - L130........................................................... 252PTO Clutch Circuit Diagnosis - L130 ......... 253PTO with RIO Circuit Operation - L100/L110/L120......................................... 254PTO with RIO Circuit Schematic - L100/L110/L120......................................... 255PTO with RIO Circuit Diagnosis - L100/L110/L120......................................... 256PTO with RIO Circuit Operation - L130 ..... 259PTO with RIO Circuit Schematic - L130 .... 260PTO with RIO Circuit Diagnosis - L130 ..... 261Headlight Circuit Operation - L100/L110/L120/L130................................ 263Headlight Circuit Electrical Schematic - L100/L110/L120/L130................................ 264Headlight Circuit Diagnosis - L100/L110/L120/L130................................ 265
Electrical Table of Contents - 204
ELECTRICAL TABLE OF CONTENTS
Hour Meter/Service Light Circuit Operation - L100/L110/L120/L130 ................................266Hour Meter/Service Light Circuit Schematic - L100/L110/L120/L130 ................................267Hour Meter/Service Light Circuit Diagnosis - L100/L110/L120/L130 ................................267
Tests and Adjustments ................................268Ground Circuit Tests ..................................268Battery Voltage and Specific Gravity Tests.................................268Battery - Charge .........................................269Battery - Load Test.....................................270Starting Solenoid Test ................................270Starting Motor Amperage Draw - Loaded ..........................271Starting Motor Amperage Draw - No-Load ........................271Flywheel Magnet Test ................................272Regulated Voltage Test..............................272Alternator Output Test ................................272Voltage Regulator/Rectifier Test - L110/L130 ..................................................273Regulated Amperage Test .........................273Relay Test ..................................................274Key Switch Test..........................................274PTO/Brake Switch Test - L100/L110/L120 .........................................275PTO Switch Test - L130 ............................275RIO Switch Test .........................................276RIS Switch Test .........................................276Seat Switch Test ........................................277Diode Test - Ignition Coil ............................277Spark Test ..................................................278Fuel Shutoff Solenoid Test .........................278Electric PTO Clutch Test ............................279Armature Air Gap Adjustment ....................279
Electrical General Information - 205
ELECTRICAL GENERAL INFORMATION
General Information
Reading Electrical Schematics
The schematic is made up of individual circuits laid out in a
sequence of related functions. It is formatted with all power
wires (A) across the top and all ground wires (B) across the
bottom. Current flow is generally from top to bottom
through each circuit and component. All components are
shown in the OFF position. The diagram does not list
connector (C) information unless needed to avoid
confusion. If the connector is shown, the number next to it
is the terminal pin location (D) in the connector.
Each component is shown by a symbol (E), its name (F),
and an identification code (G). The identification code
contains a device identifying letter (H) and number (I).
The identifying letter is always the same for a specific
component, but the identifying numbers are numbered
consecutively from upper left to lower right. The terminal
designation (J) is placed directly outside the symbol next to
the connecting wire path. Switch positions (K) are also
placed directly outside the symbol. The solid line (L) shows
the position the switch is currently in and dash lines (M)
represent other switch positions.
Each circuit is identified at the bottom of the drawing by a
section number (N) and section name (O).
The circuit number (P) and wire color (Q) of the wires are
shown directly next to the wire path.
The same component name and identification code are
used consistently on all diagrams in this section.
Components can be easily cross-referenced.
LinkFusibleF1
M1Starting Motor
B S
M
G1
X1
W1ShieldedGround
Battery
StartK1
Relay
S1 KeySwitch
Off
Run
Start
210
Red
721
Red
Blk
215Org
F3
Fuse15 Amp
F2
Fuse15 Amp
Red
414Yel/
800 Pink
E2SparkPlug
T2IgnitionCoil
T1IgnitionCoil
X4
IgnitionK2
SeatS2
Switch
F
Relay
6
X3710
D
X3
H
805 Pnk/Blk
X3
X2
Pur/
Red
1
X2
X3
E
Seat
Off
Seat
On
Yel/Wht
Yel/Wht
Blk/YelWht
X3
C
X5Yel/Wht
WhtB
Wht
105 Blk
Blk
SE1-Power and Starting Circuit SE2-Ignition and Interlock Circuit SE3-PTO and Interlock
Pur
W2Engine
E1SparkPlug
Yel/Wht
HarnessWiring
S1
Wht
M
87
85
30
86
L K
A
D
J
P
Q
NO C
I
H
B
FE
G
Electrical General Information - 206
ELECTRICAL GENERAL INFORMATION
Theory Of Operation Information
The theory of operation stories divide the electrical system
into individual circuits by function. Each circuit is isolated
from the main wiring schematic and only shows the
components that are used in it. The story contains
information on function, operating conditions, and theory of
operation. The circuit schematics are drawn with the
components in the operating position, with the power, or
battery positive, into them across the top and the ground, or
battery negative, across the bottom.
Diagnostic Information
The diagnostic procedures is used to test the complete
circuit regardless of the problem or complaint. Select a
symptom or system from the quick check or
troubleshooting chart and follow the test procedures under
that heading.
The diagnostic procedure lists:
• Test conditions
• Test sequence
• Test location
• Normal reading
• Check or test to perform if reading is not normal
When performing the test or check, be sure to set your
machine up to the TEST POINT/PROCEDURES listed in
the first column and follow the sequence carefully. The
middle RESULTS column gives the reading or condition
that should be obtained in BOLD print. If the results of the
test or check are not normal, perform the test, check, or
adjustment listed below the BOLD print. The system
diagram that accompanies each test procedure is drawn to
resemble machine components. The leader line points to
the exact point the test is to be made.
Wire Color Abbreviation Chart
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Grn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Gry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gray
Org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tan
Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
Blk/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
Blu/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/White
Brn/Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow
Dk Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Dk Brn/Lt Grn . . . . . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red . . . . . . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . . . . . .Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Lt Blue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Purple/White
Red/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow/White
Electrical General Information - 207
ELECTRICAL GENERAL INFORMATION
Common Circuit Tests
Shorted Circuit:
MIF
A shorted circuit may result in the wrong component
operating (i.e. improper wire-to-wire contact). To test for a
shorted or improperly wired circuit:
1. Turn component switch ON.
2. Start at the controlling switch of the component that
should not be operating.
3. Follow the circuit and disconnect wires at connectors
until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.
High Resistance or Open Circuit:
MIF
High resistance or open circuits usually result in slow, dim
or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component will
be low when the component is in operation. To test for high
resistance and open circuits:
1. Check all terminals and grounds of the circuit for
corrosion.
2. If terminals are not corroded or loose, the problem is in
the component or wiring.
Grounded Circuit:
MIF
Grounded circuits usually result in no component operation
or a blown fuse.
Conductors For 12 Volt Circuits
Stranded Conductors For 12 Volt Circuits
Sae Wire Size (Gauge) 20 18 16 14 12 10
Metric Wire Size (mm) 0.5 0.8 1.0 2.0 3.0 5.0
Typical Stranding 7 X 28 16 X 30 19 X 29 19 X 27 19 X 25 19 X 23
Minimum Conductor Area In
Circular Mils
1072 1537 2336 3702 5833 9343
Electrical Specifications - 208
ELECTRICAL SPECIFICATIONS
Specifications
Electrical
Battery:
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
CCA Amps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 amps
Ignition (Briggs & Stratton):
Spark Plug (Briggs & Stratton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC12YC
Spark Plug (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN14YC
Spark Plug Gap (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Spark Plug Torque (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (240 lb-in.)
Air gap (Briggs & Stratton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 - 0.3 mm (0.008 - 0.012 in.)
Air gap (Kohler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 - 0.6 mm (0.015 - 0.023 in.)
Starting Motor:
Type - L100/L110/L120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inertia Drive
Type - L130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Starting motor amp draw - L100/L120 (on machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 - 100 amps
Starting motor amp draw - L110/L130 (on machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 amp
Starting motor no-load amp draw L100/L120 (free running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps (maximum)
Starting motor no-load amp draw L110/L130 (free running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps (maximum)
Stator - L100:
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 amp
Regulated Amperage (Minimum) at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 amps
Unregulated Voltage (Minimum) at Fast idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 volts AC
Stator - L110/L130:
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Amp
Regulated Amperage (Minimum) at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15 amps
Unregulated Voltage (Minimum) at Fast idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 volts AC
Stator - L120:
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 amp
Regulated Amperage (Minimum) at Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16 amps
Unregulated Voltage (Minimum) at Fast idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 volts AC
Electric PTO Clutch - L130:
Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 - 2.7 ohms
Current Draw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 amps
Lighting:
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GE 1156 or equivalent
Electrical Component Location - 209
ELECTRICAL COMPONENT LOCATION
Component Location
Component Location - L100/L110/L120
MIF
A - S1 Key Switch
B - P1 Hourmeter/Service Light
C - S2 PTO Switch
D - X3 ACC Power Port
E - S4 RIS Switch
F - W1 Shielded Ground
G - N1 Voltage Regulator/Rectifier
H - T1 and T2 (L120 only) Magneto Ignition
I - G2 Stator
J - Y1 Fuel Shutoff Solenoid
K - X4 Headlight Connector
L - M1 Starting Motor
M - K1 Starting Motor Solenoid
N - K2 RIO Latch Relay
O - S3 Brake Switch
P - G1 Battery
Q - S6 RIO Switch
R - S5 Seat Switch
A
B
CD
F
G
I
J
KL
M
N
O
P
Q
R
E
H
Electrical Component Location - 210
ELECTRICAL COMPONENT LOCATION
Component Location - L130
A - S1 Key Switch
B - P1 Hourmeter/Service Light
C - S2 PTO Switch
D - X3 ACC Power Port
E - S4 RIS Switch
F - W1 Shielded Ground
G - N1 Voltage Regulator/Rectifier
H - T1 and T2 Magneto Ignition
I - G2 Stator
J - Y2 Fuel Shutoff Solenoid
K - X4 Headlight Connector
L - M1 Starting Motor
M - K1 Starting Motor Solenoid
N - Y1 PTO Clutch
O - K1 RIO Latch Relay
P - S3 Brake Switch
Q - G1 Battery
R - S6 RIO Switch
S - S5 Seat Switch
A B
CD
S
F
G
H
J
KL
N
P
Q
R
M
E
I
O
Electrical System Schematics - 211
ELECTRICAL SYSTEM SCHEMATICS
System Schematics
Schematic and Wiring Harness Legend - L100/L110/L120
E1 - RH Headlight (SE2, W1)
E2 - LH Headlight (SE2, W1)
E3 - Spark Plug (SE4, W6)
E4 - Spark Plug (SE4, W6)(L120 only)
F1 - Fuse 20 Amp (SE1, W1)
G1 - Battery (SE1, W1)
G2 - Alternator (SE4, W6)
K1 - Starting Motor Solenoid (SE1, W1)
K2 - RIO Latch Relay (SE3, W1)
M1 - Starting Motor (SE1, W1)
N1 - Voltage Regulator/Rectifier (SE4, W6)
P1 - Hourmeter/Service Light (SE1, W1)
S1 - Key Switch (SE1, W1)
S2 - PTO Switch (SE3, W1)
S3 - Brake Switch (SE3, W1)
S4 - RIS Switch (SE3, W1)
S5 - Seat Switch (SE3, W1)
S6 - RIO Switch (SE3, W1)
T1 -Magneto Ignition (SE4, W6)
T2 - Magneto Ignition (SE4, W6)(L120 only)
V1 - Diode (SE4, W6)(B&S engines only)
V2 - Diode (SE4, W6)(L120 only)
W1 - Shielded Ground (SE1, W1)
Y1 - Fuel Shutoff Solenoid (SE4, W6)
Connectors:
X1 - W1 Front Main Wiring Harness to W3 Positive Jumper
Wiring Harness (SE1, W1)
X2 - W1 Front Main Wiring Harness to W4 Negative
Jumper Wiring Harness (SE1, W1)
X3 - W1 Front Main Wiring Harness to ACC Power port
(SE1, W1)
X4 - W1 Front Main Wiring Harness to W5 Headlight Wiring
Harness (SE2, W1)
X5 - W1 Front Main Wiring Harness to W2 Rear Main
Wiring Harness (SE3, W1)
X6 - W1 Front Main Wiring Harness to W6 Engine Wiring
Harness (SE3, W1)
X7 - W6 Engine Wiring Harness to Y1 Fuel Shutoff
Solenoid (SE4, W6)
X8 - W6 Engine Wiring Harness to T1 and T2 Magneto
Ignition (SE4, W6)
X9 - W6 Engine Wiring Harness to N1 Voltage Regulator/
Rectifier (SE4, W6)(B&S engines only)
WIRING HARNESSES:
W1 - Front Main Wiring Harness
W2 - Rear Main Wiring Harness
W3 - Positive Jumper Wiring Harness
W4 - Negative Jumper Wiring Harness
W5 - Headlight Wiring Harness
W6 - Engine Wiring Harness
Electrical System Schematics - 212
ELECTRICAL SYSTEM SCHEMATICS
Main Wiring Schematic L100/L110/L120
SE 1 - Starting SE 2 - Headlights
110Blk
105
S1 Key
G1 Battery
W1
GroundShielded
StartingK1
StartingM
Motor
M1
200Red
941Wht
700960
200Red
710
Pur100
140
Switch
125 Blk
105Blk
Blk
MotorSolenoid
Blk
Yel/
Blk
(0) Off(1) Run w/ Lights(2) Run w/o Lights(3) Start
0, 1 0
2 1 03GSA2 A1
L B M
Pur
Splice #2
220Red
Blk
115 Blk
F1
X1
Fuse
201Red
Red
/Blk
100
S3 BrakeSwitch
705 Pur/Wht
(Off)
(On)
943 Wht
945 Wht/Blk942 Wht
949 Wht/Blk
705 Pur/Wht
120
Blk
960Yel
X4
X4
E1 and E2Headlight
W5 Headlight
Wiring Harness
Wht
410 Yel20 A401
115 Blk
110 Blk
/Wht
451
940 Wht941 Wht
943Wht
942Wht
Yel/Wht
405 Yel
Yel
X3 ACCPower Port
P1Hour Meter
140Blk /Service Light
401
710 Pur
X2
Splice#1
Blk
W4 Negative JumperWiring Harness
W3 PositiveJumper WiringHarness
Yel
700 Pur
S2 PTOSwitch
(Off)
(On)
451 Yel/Wht
220 Red/Blk
Electrical System Schematics - 213
ELECTRICAL SYSTEM SCHEMATICS
SE 3 - Magneto Kill & Start Interlock SE 4 - Engine Ignition/ Charging
111
S5 SeatSwitch
130
951 Blk/Wht
945 Wht/Blk
Blk
K2 RIOLatchRelay
957 Wht410Yel
951 Blk/Wht952 Wht/Blk
451 Yel/Wht
402 Yel
940 Wht
220 Red/Blk
Y1 Fuel
X6W6 Engine WiringHarness - L100
X7
Red
Wht
Grn
Red
Pur
SparkPlug
E3T1MagnetoIgnition
Wht
Diode
V1
X8
ShutoffSolenoid
953
X5
949Wht/Blk
X5
Blk/Wht
X5
957 Wht
S6 RIOSwitch
Forward/
Reverse
Neutral
W2 Rear Main Wiring Harness
954
S4 RISSwitch
402 Yel
Wht
954Wht
X5110 Blk
G2Stator
G
Yel
U
X9
Blk
Red
X9
Y1 Fuel
X6W6 Engine WiringHarness - L110
X7
Red
Wht
Grn
Red
SparkPlug
E3
T1MagnetoIgnition
Wht
X8
ShutoffSolenoid
U
Red
G2Stator
G
Wht Wht
Operator Off
Operator On
Blk
940 Wht
949 Wht/Blk
410 Yel
451 Yel/Wht
220 Red/Blk
V2
Diode
SparkPlug
E4
T2MagnetoIgnition
W6 Engine Wiring Harness - L120
Electrical System Schematics - 214
ELECTRICAL SYSTEM SCHEMATICS
W1 and W2 Hiring Harnesses - L100/L110/L120
201
20 AFuseF1
201
200220
952953
953
402410
954957
949951
Splice #1
941942
943
940
X4 to W5
120
960
Headlights
110
957
951945
402
940
220451
X5 to W2 RearMain Wiring Harness
X6 to W6Engine Wiring Harness
K2 RIOLatch Relay
X1 to W3 PositiveJumper Wiring Harness
957110130
S6RIO Switch
945
957
951 110
X5 to W1 FrontMain Wiring Harness
111
S5Seat Switch
130111 945
951W2 Rear Main Wiring Harness
Wiring Harness
Electrical System Schematics - 215
ELECTRICAL SYSTEM SCHEMATICS
SwitchS2 PTO
P1 Hour Meter
SwitchS3 Brake
705710
945
S1
Key
Switch
200700
941
960
401
451
100140
405
405
140
/Service Light
942
105
710
K1 Starting Motor
K1 Starting Motor
125
120
110
105
125
115
100
X3 to
115
401410
ACC Power Port
S4
952
RISSwitch
954
Splice #2
W1 Front Main Wiring Harness
X2 to W4 NegativeJumper Wiring Harness
Solenoid Positive
Solenoid Negative
705700
949943
Electrical System Schematics - 216
ELECTRICAL SYSTEM SCHEMATICS
W1 Front Main Wire Harness Color Codes - L100/L110/L120
W2 Rear Main Wire Harness Color Codes - L100/L110/L120
Size/No./Color Wire Connection Points
0.5 100 Blk S1, X3
0.5 105 Blk K1, Splice #2
0.8 110 Blk Splice #2, X5
0.8 115 Blk K1, X3
0.5 120 Blk Splice #2, X4
1.0 125 Blk Splice #2, X2
0.5 140 Blk S1, P1
1.0 200 Red F1, S1
1.0 201 Red X1, F1
1.0 220 Red/Blk F1, X6
0.8 401 Yel S1, X3
0.5 402 Yel K2, X6
0.5 405 Yel S1, P1
0.8 410 Yel X3, K2
0.5 451 Yel/Wht S1, X6
0.5 700 Pur S1, S2
0.5 705 Pur/Wht S2, S3
0.5 710 Pur S3, K1
0.5 940 Wht Splice #1, X6
0.5 941 Wht Splice #1, S1
0.5 942 Wht Splice #1, S3
0.5 943 Wht Splice #1, S2
0.5 945 Wht/Blk S3, X5
0.5 949 Wht/Blk K2, S2
0.5 951 Blk/Wht K2, X5
0.5 952 Wht/Blk K2, S4
0.5 953 Blk/Wht K2, K2
0.5 954 Wht S4, K2
0.5 957 Wht K2, X5
0.5 960 Yel S1, X4
Size/No./Color Wire Connection Points
0.5 110 Blk S6, X5
0.5 111 Blk S5, S5
0.5 130 Blk S5, S6
0.5 945 Wht/Blk X5, S5
0.5 951 Blk/Wht S5, X5
0.5 957 Wht S6, X5
Electrical System Schematics - 217
ELECTRICAL SYSTEM SCHEMATICS
Schematic And Wiring Harness Legend - L130
E1 - RH Headlight (SE2, W1)
E2 - LH Headlight (SE2, W1)
E3 - Spark Plug (SE4, W6)
E4 - Spark Plug (SE4, W6)
F1 - Fuse 20 Amp (SE1, W1)
G1 - Battery (SE1, W1)
G2 - Alternator (SE4, W6)
K1 - Starting Motor Solenoid (SE1, W1)
K2 - RIO Latch Relay (SE3, W1)
M1 - Starting Motor (SE1, W1)
N1 - Voltage Regulator/Rectifier (SE4, W6)
P1 - Hourmeter/Service Light (SE1, W1)
S1 - Key Switch (SE1, W1)
S2 - PTO Switch (SE3, W1)
S3 - Brake Switch (SE3, W1)
S4 - RIS Switch (SE3, W1)
S5 - Seat Switch (SE3, W1)
S6 - RIO Switch (SE3, W1)
T1 - Magneto Ignition (SE4, W6)
T2 - Magneto Ignition (SE4, W6)
V1 - Diode (SE4, W6)
V2 - Diode (SE4, W6)
W1 - Shielded Ground (SE1, W1)
Y1 - PTO Clutch (SE3, W2)
Y2 - Fuel Shutoff Solenoid (SE4, W6)
Connectors:
X1 - W1 Front Main Wiring Harness to W3 Positive Jumper
Wiring Harness (SE1, W1)
X2 - W1 Front Main Wiring Harness to W4 Negative
Jumper Wiring Harness (SE1, W1)
X3 - W1 Front Main Wiring Harness to ACC Power port
(SE1, W1)
X4 - W1 Front Main Wiring Harness to W5 Headlight Wiring
Harness (SE2, W1)
X5 - W1 Front Main Wiring Harness to W2 Rear Main
Wiring Harness (SE3, W1)
X6 - W2 Rear Main Wiring Harness to Y1 PTO Clutch
(SE3, W2)
X7 - W1 Front Main Wiring Harness to W6 Engine Wiring
Harness (SE3, W1)
X8 - W6 Engine Wiring Harness to Y2 Fuel Shutoff
Solenoid (SE4, W6)
X9 - W6 Engine Wiring Harness to T1 and T2 Magneto
Ignition (SE4, W6)
X10 - W6 Engine Wiring Harness to N1 Voltage Regulator/
Rectifier (SE4, W6)
WIRING HARNESSES:
W1 - Front Main Wiring Harness
W2 - Rear Main Wiring Harness
W3 - Positive Jumper Wiring Harness
W4 - Negative Jumper Wiring Harness
W5 - Headlight Wiring Harness
W6 - Engine Wiring Harness
Electrical System Schematics - 218
ELECTRICAL SYSTEM SCHEMATICS
Main Wiring Schematic L130
401 Yel
SE 1 - Starting SE 2 - Headlights
S1 Key
G1 Battery
W1
GroundShielded
StartingK1
StartingMotor
M1
200Red
941Wht
700960
200Red
710
Pur100
140
Switch
125 BlkBlk
MotorSolenoid
Blk
Yel/
Blk
(0) Off(1) Run w/ Lights(2) Run w/o Lights(3) Start
0, 1 0
2 1 03GSA2 A1
L B M
Pur
Splice #2
220Red
115 Blk
F1
X1
Fuse
201Red
Red
/Blk
100
S3 BrakeSwitch
705 Pur/Wht
(Off)
(On)
Off
On
943 Wht
945 Wht/Blk942 Wht
949 Wht/Blk
501 Yel
SwitchS2 PTO
705 Pur/Wht
120
Blk
960Yel
X4
X4
E1 and E2Headlight
W5 Headlight
Wiring Harness
500 Yel
Wht
410 Yel20 A401
115 Blk
110 Blk
/Wht
451
940 Wht941 Wht
943Wht
942Wht
Yel/Wht
405 Yel
Yel
X3 12VDC ACCPower Port
P1Hour Meter
140Blk /Service Light
500
710 Pur
110Blk
X2
Splice#1
Blk
W4 Negative JumperWiring Harness
W3 PositiveJumper WiringHarness
Yel
700 Pur
X5
410 Yel
451 Yel/Wht
940 Wht
949Wht/Blk
220 Red/Blk
B S
M
Electrical System Schematics - 219
ELECTRICAL SYSTEM SCHEMATICS
SE 3 - Magneto Kill & Start Interlock SE 4 - Engine Ignition/ Charging
111
S5 SeatSwitch
130 Blk
951 Blk/Wht
945 Wht/Blk
Blk
K2 RIOLatchRelay
957 Wht410Yel
951 Blk/Wht952 Wht/Blk
451 Yel/Wht
402 Yel
940 Wht
220 Red/Blk
Y2 Fuel
X7
X8
Red
Wht
Grn
Red
G2Stator
G
Yel Yel
SparkPlug
E3
T1MagnetoIgnition
Wht
V2
Diode
Diode
SparkPlug
E4
V1
T2MagnetoIgnition
X9
ShutoffSolenoid
U
N1 Voltage
Regulator
/Rectifier953
X5
949Wht/Blk
X5
Blk/Wht
Y1 PTO
X5
X5
501
520 Blk
X6957 Wht
Clutch S6 RIOSwitch
Forward/
Reverse
Neutral W2 Rear Main
Wiring Harness
954
S4 RISSwitchReleased
Pushed
402 Yel
Wht
954Wht
Yel
X10
Blk Blk
Red
X6
Blk
Blk
X10
Operator Off
Operator On
Pur
110Blk
945 Wht/
501 Yell
410 Yel
451 Yel/Wht
940 Wht
949 Wht/Blk
Blk
W6 Engine WiringHarness
Electrical System Schematics - 220
ELECTRICAL SYSTEM SCHEMATICS
W1 and W2 Wiring Harness 130
201
20 AFuseF1
201
200220
952953
953
402410
954957
949951
Splice #1
941942
943
940
X4 to W5
120
960
Headlights
110
957
951945
402
940
220451
X5 to W2 RearMain Wiring Harness
X6 to W6Engine Wiring Harness
K2 RIOLatch Relay
X1 to W3 PositiveJumper Wiring Harness
957520130
S6RIO Switch
945
957
951110
X5 to W1 FrontMain Wiring Harness
111
S5Seat Switch
130111 945
951
W2 Rear Main Wiring Harness
Wiring Harness
501
501
501
520110
X6 to Y1PTO Clutch
Electrical System Schematics - 221
ELECTRICAL SYSTEM SCHEMATICS
P1 Hour Meter
SwitchS3 Brake
705710
945
S1
Key
Switch
200700
941
960
401
451
100140
405
405
140
/Service Indicator
942
105
710
K1 Starting Motor
K1 Starting Motor
125
115
100
X3 to
115
401410
ACC Power Port
S4
952
RISSwitch
954
W1 Front Main Wiring Harness
X2 to W4 NegativeJumper Wiring Harness
Solenoid Positive
Solenoid Negative
SwitchS2 PTO
401501
943
949
700 705
500
120
110
105
125
Splice #2
Electrical System Schematics - 222
ELECTRICAL SYSTEM SCHEMATICS
W1 Front Main Wire Harness Color Codes - L130
W2 Rear Main Wire Harness Color Codes - L130
Size/No./Color Wire Connection Points
0.5 100 Blk S1, X3
0.5 105 Blk K1, Splice #2
0.8 110 Blk Splice #2, X5
0.8 115 Blk K1, X3
0.5 120 Blk Splice #2, X4
1.0 125 Blk Splice #2, X2
0.5 140 Blk S1, P1
1.0 200 Red F1, S1
1.0 201 Red X1, F1
1.0 220 Red/Blk F1, X7
0.8 401 Yel S2, X3
0.5 402 Yel K2, X7
0.5 405 Yel S1, P1
0.8 410 Yel X3, K2
0.5 451 Yel/Wht S1, X7
0.8 500 Yel S1, S2
0.8 501 Yel S2, X5
0.5 700 Pur S1, S2
0.5 705 Pur/Wht S2, S3
0.5 710 Pur S3, K1
0.5 940 Wht Splice #1, X7
0.5 941 Wht Splice #1, S1
0.5 942 Wht Splice #1, S3
0.5 943 Wht Splice #1, S2
0.5 945 Wht/Blk S3, X5
0.5 949 Wht/Blk K2, S2
0.5 951 Blk/Wht K2, X5
0.5 952 Wht/Blk K2, S4
0.5 953 Blk/Wht K2, K2
0.5 954 Wht S4, K2
0.5 957 Wht K2, X5
0.5 960 Yel S1, X4
Size/No./Color Wire Connection Points
0.5 110 Blk X5, X6
0.5 111 Blk S5, S5
0.5 130 Blk S5, S6
0.8 501 Yel X5, X6
0.8 520 Blk S6, X6
0.5 945 Wht/Blk X5, S5
0.5 951 Blk/Wht S5, X5
0.5 957 Wht S6, X5
Size/No./Color Wire Connection Points
Electrical System Schematics - 223
ELECTRICAL SYSTEM SCHEMATICS
W3 and W4 Jumper Wiring Harnesses - All
W5 Headlight Wiring Harness - All
W3 Positive JumperWiring Harness Red
G1 BatteryPositive Terminal
K1 StartingMotor Solenoid
X1 to W1 FrontMain Wiring Harness
W4 Negative JumperWiring Harness Blk
G1 BatteryNegative Terminal
W1 ShieldedGround
X2 to W1 FrontMain Wiring Harness
Headlight
E2 LH
E1 RH
Headlight
X4 To W1 Front MainWiring Harness
YelBlk
Yel
Blk
Electrical System Schematics - 224
ELECTRICAL SYSTEM SCHEMATICS
L110W6 Engine Wiring Harness - L100
W6 Engine Wiring Harness, Stator and N1 Voltage Regulator/Rectifier - L110/L130
T1 Magneto
Ignition Coil
WhtV1 Diode
W6 EngineWiring Harness
451
940220402
X6 To W1 FrontMain Wiring Harness
Y1 Fuel
402
Shutoff Solenoid
X9 to N1 VoltageRegulator/Rectifier
(L100)
220451
to N1 Voltage
X6 To W1 FrontMain Wiring Harness
Wht
Regulator/Rectifier
Wht
Red
Wht
451220
940
402
T1 MagnetoIgnition Coil
Y1 FuelShutoff Solenoid
Grn
W6 EngineWiring Harness(L110)
N1 VoltageRegulator/Rectifier
Electrical System Schematics - 225
ELECTRICAL SYSTEM SCHEMATICS
W6 Engine Wiring Harness - L120/L130
G2 Stator and N1 Voltage Regulator/Rectifier - L100
G2 Stator and N1 Voltage Regulator/Rectifier - L120/L130
T1 Magneto
Ignition Coil
Wht
T2 MagnetoIgnition Coil
V1 Diode
V2 Diode
451
940220402
X7 To W1 FrontMain Wiring Harness
Y2 Fuel
402
Shutoff Solenoid
220
X10 to N1 VoltageRegulator/Rectifier
W6 EngineWiring Harness(L120/L130)
451
X9 To N1 VoltageRegulator/Rectifier
Blk
G2 Stator(L100)
Red
Yel
N1 VoltageRegulator/Rectifier(L100)
X9 to W6 EngineWring Harness
X9 to G2Stator
X10 to N1 VoltageRegulator/Rectifier
Blk
Blk
G2 Stator(L120/L130)
Red
Yel
Yel
N1 VoltageRegulator/Rectifier(L120/L130)
X10 to W6 EngineWring Harness
X10 to G2Stator
Electrical System Schematics - 226
ELECTRICAL SYSTEM SCHEMATICS
Y1 PTO Clutch - L130
Y2 Fuel Shutoff Solenoid
N1 Voltage Regulator/Rectifier
X6 To W2 RearMain Wiring Harness
Y1PTO Clutch
Yel
Blk
Red
X7 To W6 EngineWiring Harness
Y2 FuelShutoff Solenoid
RedX7 To W6 EngineWiring Harness
(L100/L120)
Y2 FuelShutoff Solenoid(L110/L130)
X8 To W6 EngineWiring Harness (L130)
(L100/L120)
N1 VoltageRegulator/Rectifier
Yel
Red
N1 VoltageRegulator/Rectifier
X10 to Engine
X10 toEngine Stator Red
Yel
YelX9 toEngine Stator
X9 to Engine
N1 VoltageRegulator/Rectifier
Wht toStator
Wht toStator
Red
(L100) (L120)(L110/L130)
Wiring Harness Wiring Harness
Electrical Diagnostics and Operation - 227
ELECTRICAL DIAGNOSTICS AND OPERATION
Diagnostics and Operation
Power Circuit Operation - L100/L110/L120
Function:
Provides unswitched power to primary components and
switched power to secondary components whenever the
battery is connected.
Operating Conditions, Unswitched Circuits:
Voltage must be present at the following components with
the key switch in the OFF position:
• Battery Positive Terminal
• Starting Motor Solenoid Positive Contact Stud
• Key Switch
• Red Wire at Voltage Regulator/Rectifier Connector
The positive battery cable connects the battery to the
starting motor solenoid bolt.
The ground cable connection is as important as the positive
cable. Proper starting operation depends on these cables
and connections to carry the high current for its operation.
The 201 Red wire, F1 fuse and 200 Red wire provide
unswitched voltage to the key switch.
The F1 fuse and 220 Red/Blk wire provide unswitched
voltage to the voltage regulator/rectifier.
Operating Conditions, Switched Circuits:
Placing the key switch in the RUN position provides voltage
from 200 Red wire through the key switch to the 401, 405,
410 and 402 Yel wires, the hour meter, X3 ACC power port,
K2 RIO latch relay and the Y1 fuel shutoff solenoid.
The 405 Yel wire provides power to the hour meter. The
401 Yel wire provides power to the X3 ACC power port. The
410 Yel wire provides power to the K2 RIO latch relay. The
K2 relay will not energize until a ground is provided to the
coil. The 402 Yel wire provides power to the Y1 fuel shutoff
solenoid coil.
Electrical Diagnostics and Operation - 228
ELECTRICAL DIAGNOSTICS AND OPERATION
Power Circuit Electrical Schematic - L100/L110/L120
SE 1 - STARTING SE 3 - MAGNETO KILL & START INTERLOCK SE 4 - ENGINE IGNITION/ CHARGING
105
S1 Key
G1 Battery
W1
GroundShielded
StartingK1
StartingM
Motor
M1
200Red
K2 RIOLatchRelay
200Red
100
140
Switch
125 Blk
105Blk
Blk
MotorSolenoid
Blk
410Yel
Blk
(0) Off(1) Run w/ Lights(2) Run w/o Lights(3) Start
0, 1 0
2 1 03GSA2 A1
L B M
Splice #2
220Red
Blk
115 Blk
F1
X1
Fuse
201Red
Red
/Blk
100
402 Yel
220 Red/Blk
Y1 Fuel
X6
X7
Red
Grn
Red
ShutoffSolenoid
410 Yel
20 A
401115 Blk
405 Yel
Yel
X3 ACCPower Port
P1Hour Meter
140Blk /Service Light
401
X2
Blk
402 Yel
Yel
U
N1 Voltage
Regulator
/Rectifier
Red
X9
Electrical Diagnostics and Operation - 229
ELECTRICAL DIAGNOSTICS AND OPERATION
Power Circuit Diagnosis - L100/L110/L120
Test Procedure A
Test Conditions:
• Key switch in OFF position
• Park brake engaged
Between (G1) battery posts, test voltage. Voltage 12.4 VDCor more, go to next
step.
• Less than 12.4 volts, clean battery
terminals and retest. 12.4 volts or above.
• Less than 12.4 volts, charge battery and
retest. 12.4 volts or above.
• Replace battery.
MIF
(K1) Starting motor solenoid at battery
terminal, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, clean, check
and tighten connections for battery cable
and retest. Less than battery voltage,
replace battery cable.
MIF
(S1) Key switch at 200 Red wire, test
voltage.
Battery voltage, go to next step.
• No battery voltage, check F1 fuse,
replace if failed, and retest battery voltage.
• Less than battery voltage, check 200
Red wire and connections and retest battery
voltage.
MIF
(X6) Engine Connector at 220 Red/Blk wire,
test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 220
Red/Blk wire and connections and retest
battery voltage.
• Less than battery voltage, replace wiring
harness.
MIF
G1
K1
200 Red
S1
X6
220 Red/Blk
Electrical Diagnostics and Operation - 230
ELECTRICAL DIAGNOSTICS AND OPERATION
Test Procedure B
(G1) battery negative post to ground cable
frame connection, test resistance.
Less than 0.1 ohm resistance.
Go to Test Procedure B.
• Check and clean negative battery
terminal and retest. Less than 0.1 ohm
resistance.
• More than 0.1 ohm resistance, check
and clean harness wires and connections to
frame and retest. Less than 0.1 ohm
resistance.MIF
G1
Test Conditions:
• Key switch in RUN position.
• Engine OFF
(S1) Key switch at 401, 405 Yel wires, test
voltage.
Battery voltage, go to next step.
• Less than battery voltage, replace key
switch.
MIF
(P1) Hourmeter at 405 Yel wire, test voltage. Battery voltage, go to next step.
• Less than battery voltage, check 405 Yel
wire and connections and retest battery
voltage.
MIF
(X3) ACC power port at 401 and 410 Yel
wires, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 401 Yel
wire and connections and retest battery
voltage.
MIF
401 Yel
S1
405 Yel
405 Yel
P1
401 Yel
X3
410 Yel
Electrical Diagnostics and Operation - 231
ELECTRICAL DIAGNOSTICS AND OPERATION
(K2) RIO latch relay at 410 and 402 Yel
wires, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 410 and
401 Yel wires and connections and retest
battery voltage.
MIF
(Y2) Fuel shutoff solenoid at 402 Yel wire,
test voltage.
Battery voltage, fuel shutoff solenoid
clicks. Test Complete.
• Less than battery voltage, check 402,
410 and 401 Yel wires and connections and
retest. Battery voltage.
• Fuel shutoff solenoid does not click, See
Fuel Shutoff Solenoid Test. Replace as
needed. Test Complete.
MIF
402 Yel
K2
410 Yel
402 Yel
X7 X7
Red
Electrical Diagnostics and Operation - 232
ELECTRICAL DIAGNOSTICS AND OPERATION
Power Circuit Operation - L130
Function:
Provides unswitched power to primary components and
switched power to secondary components whenever the
battery is connected.
Operating Conditions, Unswitched Circuits:
Voltage must be present at the following components with
the key switch in the OFF position:
• Battery Positive Terminal
• Starting Motor Solenoid Positive Contact Stud
• Key Switch
• Red Wire at Voltage Regulator/Rectifier Connector
The positive battery cable connects the battery to the
starting motor solenoid bolt.
The ground cable connection is as important as the positive
cable. Proper starting operation depends on these cables
and connections to carry the high current for its operation.
The 201 Red wire, F1 fuse and 200 Red wire provide
unswitched voltage to the key switch.
The F1 fuse and 220 Red/Blk wire provide unswitched
voltage to the voltage regulator/rectifier.
Operating Conditions, Switched Circuits:
Placing the key switch in the RUN position provides voltage
from 200 Red wire through the key switch to the 500, 405,
401, 410 and 402 Yel wires, the hour meter, S2 PTO switch,
X3 ACC power port, K2 RIO latch relay and the Y1 fuel
shutoff solenoid.
The 405 Yel wire provides power to the hour meter. The
500 Yel wire provides power to the S2 PTO switch. The 401
Yel wire provides power to the X3 ACC power port. The 410
Yel wire provides power to the K2 RIO latch relay. The K2
relay will not energize until a ground is provided to the coil.
The 402 Yel wire provides power to the Y1 fuel shutoff
solenoid coil.
Electrical Diagnostics and Operation - 233
ELECTRICAL DIAGNOSTICS AND OPERATION
Power Circuit Electrical Schematic - L130
401 Yel
Off
On
SwitchS2 PTO
500 Yel
SE 1 - STARTING SE 3 - MAGNETO KILL & START INTERLOCK SE 4 - ENGINE IGNITION/ CHARGING
105
S1 Key
G1 Battery
W1
GroundShielded
StartingK1
StartingM
Motor
M1
200Red
K2 RIOLatchRelay
200Red
100
140
Switch
125 Blk
105Blk
Blk
MotorSolenoid
Blk
410Yel
Blk
(0) Off(1) Run w/ Lights(2) Run w/o Lights(3) Start
0, 1 0
2 1 03GSA2 A1
L B M
Splice #2
220Red
Blk
115 Blk
F1
X1
Fuse
201Red
Red
/Blk
100
402 Yel
220 Red/Blk
Y1 Fuel
X6
X8
Red
Grn
Red
ShutoffSolenoid
410 Yel
20 A
401115 Blk
405 Yel
Yel
X3 ACCPower Port
P1Hour Meter
140Blk /Service Light
401
X2
Blk
402 Yel
Yel
U
N1 Voltage
Regulator
/Rectifier
Red
X10
Electrical Diagnostics and Operation - 234
ELECTRICAL DIAGNOSTICS AND OPERATION
Power Circuit Diagnosis - L130
Test Procedure A
Test Conditions:
• Key switch in OFF position
• Park brake engaged
• PTO in OFF position
Between (G1) battery posts, test voltage. Voltage 12.4 VDC or more, go to next
step.
• Less than 12.4 volts, clean battery
terminals and retest. 12.4 volts or above.
• Less than 12.4 volts, charge battery and
retest. 12.4 volts or above.
• Replace battery.
MIF
(K1) Starting motor solenoid at battery
terminal, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, clean, check
and tighten connections for battery cable
and retest. Less than battery voltage,
replace battery cable.
MIF
(S1) Key switch at 200 Red wire, test
voltage.
Battery voltage, go to next step.
• No battery voltage, check F1 fuse,
replace if failed, and retest. Battery voltage.
• Less than battery voltage, check 200
Red wire and connections and retest.
Battery voltage.
MIF
(X6) Engine Connector at 220 Red/Blk wire,
test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 220
Red/Blk wire and connections and retest.
Battery voltage.
• Less than battery voltage, replace wiring
harness.
MIF
G1
K1
200 Red
S1
X6
220 Red/Blk
Electrical Diagnostics and Operation - 235
ELECTRICAL DIAGNOSTICS AND OPERATION
Test Procedure B
(G1) battery negative post to ground cable
frame connection, test resistance.
Less than 0.1 ohm resistance. Go to Test
Procedure B.
• Check and clean negative battery
terminal and retest. Less than 0.1 ohm
resistance.
• More than 0.1 ohm resistance, check
and clean harness wires and connections to
frame and retest. Less than 0.1 ohm
resistance.. MIF
G1
Test Conditions:
• Key switch in RUN position.
• Engine OFF
• PTO in OFF position.
• Park brake engaged.
(S1) Key switch at 401, 405 Yel wires, test
voltage.
Battery voltage, go to next step.
• Less than battery voltage, replace key
switch.
MIF
(P1) Hourmeter at 405 Yel wire, test voltage. Battery voltage, go to next step.
• Less than battery voltage, check 405 Yel
wire and connections and retest battery
voltage.
MIF
(S2) PTO switch at 500 and 401 Yel wires,
test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 500 Yel
wire and connections and retest battery
voltage.
MIF
401 Yel
S1
405 Yel
405 Yel
P1
500 Yel
S2
401 Yel
Electrical Diagnostics and Operation - 236
ELECTRICAL DIAGNOSTICS AND OPERATION
(X3) ACC power port at 401 and 410 Yel
wires, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 401 Yel
wire and connections and retest battery
voltage.
MIF
(K2) RIO latch relay at 410 and 402 Yel
wires, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 410 and
401 Yel wires and connections and retest
battery voltage.
MIF
(Y2) Fuel shutoff solenoid at 402 Yel wire,
test voltage.
Battery voltage. Test Complete.
• Less than battery voltage, check 402,
410 and 401 Yel wires and connections and
retest battery voltage.
• Fuel shutoff solenoid does not click, See
Fuel Shutoff Solenoid Test. Replace as
needed. Test Complete. MIF
401 Yel
X3
410 Yel
402 Yel
K2
410 Yel
402 Yel
X8 X8
Red
Electrical Diagnostics and Operation - 237
ELECTRICAL DIAGNOSTICS AND OPERATION
Cranking Circuit Operation - L100/L110/L120/L130
Function:
To energize the starting motor solenoid and engage the
starting motor which cranks the engine.
Operating Conditions:
To crank the engine the key switch must be in the START
position, the brake must be ON and the PTO must be in the
OFF (disengaged) position. The operator does not have to
be on the seat to crank the engine with the brake on.
Theory of Operation:
Current flows from the battery through F1 fuse to the key
switch. With key switch in the START position, current flows
through the key switch, through 700 Pur wire, PTO switch
contacts (switch in the OFF position), 705 Pur/Wht wire,
brake switch contacts (brake ON), and 710 Pur wire to the
starting motor solenoid coil.
The ground circuit for the solenoid coil is provided through
the 105 and 125 Blk wires X2 connector and Blk wire to W1
shielded ground
With the solenoid coil energized, the solenoid contacts
close and high battery current flows across the solenoid
contacts to the starting motor, causing it to crank the
engine.
Electrical Diagnostics and Operation - 238
ELECTRICAL DIAGNOSTICS AND OPERATION
Cranking Circuit Electrical Schematic - L100/L110/L120/L130
SE 1 - STARTING SE 3 - MAGNETO KILL & START INTERLOCK
105
S1 Key
G1 Battery
W1
GroundShielded
StartingK1
StartingM
Motor
M1
200Red
700
200Red
710
Pur
Switch
125 Blk
105Blk
Blk
MotorSolenoid
(0) Off(1) Run w/ Lights(2) Run w/o Lights(3) Start
0, 1 0
2 1 03GSA2 A1
L B M
Pur
Splice #2
Blk
F1
X1
Fuse
201Red
Red
S3 BrakeSwitch
705 Pur/Wht
(Off)
(On)
705 Pur/Wht
20 A
710 Pur
X2
700 Pur
S2 PTOSwitch
(Off)
(On)
Off
On
SwitchS2 PTO
705 Pur/Wht700 Pur
Used on L130 w/electric PTO
Used on L100/L110/L120 w/manual PTO
Electrical Diagnostics and Operation - 239
ELECTRICAL DIAGNOSTICS AND OPERATION
Cranking Circuit Diagnosis - L100/L110/L120/L130
Test Procedure A
Test Procedure B
Test Conditions:
• Key switch in OFF position
• Park brake engaged
• PTO in OFF position
(K1) Negative battery terminal at 105 Blk
wire, test resistance.
0.2 ohm resistance or less, go to Test
Procedure B.
• More than 0.2 ohms, check 105 and 125
Blk wires and connections. Check X2
connector and W4 negative jumper wiring
harness and connections. Retest. 0.2 ohms
or less.
MIF
105 Blk
K1
c CAUTION: Avoid injury! To help prevent starting
of engine during this test procedure:
Disconnect fuel shutoff solenoid connector (X7
or X8 on L130) located near voltage regulator/
rectifier. Stay clear of parts that may rotate on
the starting motor and engine.
Test Conditions:
• Fuel shutoff solenoid DISCONNECTED.
• Key switch in START position during each test.
• PTO in OFF position.
• Park brake engaged.
(S1) Key switch at 700 Pur wire, test voltage Battery voltage, go to next step.
• Less than battery voltage, replace key
switch.
MIF
(S2) PTO switch at 705 Pur/Wht wire, test
voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 700 Pur
wire and connections. If OK, replace PTO
switch.
MIF
700 PurS1
705
S2 manual PTO
Pur/Wht
705Pur/Wht
S2 electric PTO
Electrical Diagnostics and Operation - 240
ELECTRICAL DIAGNOSTICS AND OPERATION
Ignition and Shutoff Circuit Operation - L100/L110/L120/L130
Function:
To create a spark at the correct time that ignites the fuel/air
mixture in the cylinder. To keep the engine running by
eliminating ground paths to both sides of the ignition
module primary coil.
Operating Conditions:
To produce a spark, the key switch must be in the START or
RUN position. The operator can be ON or OFF the seat;
however, the PTO must be disengaged and the brake
switch must be ENGAGED (brake pedal depressed or park
brake on) to start the engine.
Once the engine is running, the operator must be ON the
seat to disengage the brake or engage the PTO.
The engine will shutoff when the key switch is turned to the
OFF position, the operator leaves the seat without locking
the parking brake, and disengaging the PTO, or the
operator places the machine in reverse with the PTO
engaged and not pressing the RIS switch to its momentary
ON position to energize the RIO latch relay.
(S3) Brake switch at 710 Pur wire, test
voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 705
Pur/Wht wire and connections. If OK,
replace brake switch.
MIF
(K1) Starting motor solenoid at 710 Pur
wire, test voltage.
Battery voltage, go to next step.
• Less than battery voltage, check 710 Pur
wire and connections and retest battery
voltage.
MIF
(K1) Starting motor solenoid at Red cable to
starting motor, test voltage
Battery voltage, go to next step.
• Less than battery voltage, test solenoid
and replace as necessary. Retest battery
voltage.
MIF
(M1) Starting motor at Red cable from
starting motor solenoid
Battery voltage, starting motor cranking.
Test complete.
• Less than battery voltage, clean cable
ends, ensure connections are tight to
starting motor, solenoid and battery. Battery
voltage and starting motor cranks, test
complete.
• Starting motor NOT cranking, repair or
replace starting motor as necessary. Battery
voltage and starting motor cranks, test
complete.MIF
710 Pur S3
710 Pur
K1
Red
K112 VDC
M1
Red
Electrical Diagnostics and Operation - 241
ELECTRICAL DIAGNOSTICS AND OPERATION
System Operation:
The ignition system is a transistor-controlled magneto
design. Ignition timing is controlled by the transistor and is
not adjustable. The engine is shut off by grounding both
sides of the ignition primary coil. With the ignition primary
coil grounded, a spark cannot be produced.
When the engine is turning over, the flywheel magnet
induces current into the magneto ignition coil, which in turn
produces current high enough to jump the spark plug gap,
creating spark to ignite the engine fuel/air mixture.
Placing the key switch in the START or RUN position
eliminates the path to ground for the Wht wire from the
engine magneto, 940 and 941 Wht wires, key switch
contacts (normally closed), 100, 115, 105, and 125 Blk
wires.
The seat switch controls two paths to ground. When the
operator is ON the seat, the brake and PTO switches can
be either on OR off. These paths are eliminated when the
operator is ON the seat (seat switch open). This conditions
breaks the ground circuit 940, 942 Wht wires, brake switch,
945 Wht/Blk, seat switch, and 111, 130, 110, and 125 Blk
wires. This conditions also breaks the ground circuit 940,
943 Wht wires, PTO switch, 949 Wht/Blk, 951 Blk/Wht, seat
switch, and 130, 110, and 125 Blk wires.
If the operator is OFF the seat (seat switch closed), then
the brake switch must be ON (park brake engaged) and the
PTO must be OFF (disengaged).
If the operator is OFF the seat and the brake switch is also
OFF this creates the ground circuit path 940, 942 Wht
wires, brake switch, 945 Wht/Blk, seat switch, and 111,
130, 110, and 125 Blk wires.
If the operator is OFF the seat and the PTO is ON, this
creates the ground circuit 940, 943 Wht wires, PTO switch,
949 Wht/Blk, 951 Blk/Wht, seat switch, and 130, 110, and
125 Blk wires.
An additional path to ground will be created with the engine
running, if the operator places the machine in reverse while
the PTO is engaged and the RIS switch is not pressed to its
momentary ON position to energize the RIO latch relay.
This conditions also creates the ground circuit 940, 943
Wht wires, PTO switch, 949 Wht/Blk, RIO latch relay
(normally closed contacts) 957 Wht, RIO switch (normally
open contacts), and (520 Blk on L130), 110, and 125 Blk
wires.
Electrical Diagnostics and Operation - 242
ELECTRICAL DIAGNOSTICS AND OPERATION
Ignition and Shutoff Circuit Electrical Schematic - L100/L110/L120/L130
SE 1 - STARTING SE 3 - MAGNETO KILL & START INTERLOCK SE 4 - ENGINE IGNITION/ CHARGING
111
Operator Off
S5 SeatSwitch
Operator On
130
951 Blk/Wht
945 Wht/Blk
Blk
105
S1 Key
G1 Battery
W1
GroundShielded
StartingK1
200Red
941Wht
K2 RIOLatchRelay
200Red
100
Switch
957
125 Blk
105Blk
Blk
MotorSolenoid
Blk
410Yel
(0) Off(1) Run w/ Lights(2) Run w/o Lights(3) Start
0, 1 0
2 1 03GSA2 A1
L B M
Splice #2
Blk
951
952 Wht/Blk
115 Blk
F1
X1
Fuse
201Red
Red
100
S3 BrakeSwitch
(Off)
(On)
943 Wht
945
949 Wht/Blk
940 Wht X6 W6 Engine WiringHarness
Wht
SparkPlug
E3T1MagnetoIgnition
Diode
V1
X8
410 Yel20 A
401
953
949Wht/Blk
X5
110 Blk
940Wht
Blk/Wht
Yel
957 WhtX2
S6 RIOSwitch
Forward/
Reverse
Neutral
Splice#1
Blk
954
S4 RISSwitch
Released
Pushed
Wht
954Wht
S2 PTOSwitch
(Off)
(On)
X5110 Blk
X6 W6 Engine WiringHarness - L110
Wht
SparkPlug
E3
T1MagnetoIgnition
X8
SparkPlug
E3
V2
Diode
Diode
SparkPlug
E4
V1
X8
X6W6 Engine WiringHarness
Wht
T1 MagnetoIgnition
T2 MagnetoIgnitionBlk
L100
942Wht
X5
Wht
Blk/Wht
X5
Wht/Blk
L120/L130
Electrical Diagnostics and Operation - 243
ELECTRICAL DIAGNOSTICS AND OPERATION
Ignition and Shutoff Circuit Diagnosis - L100/L110/L120/L130
Test Procedure A
Test Procedure B
Test Conditions:
• Engine running.
• Park brake ON.
• PTO in OFF position.
• Ignition test tools installed.
Engine spark plugs. Install ignition tester
and check spark output. See “Spark Test” in
Tests and Adjustments Section
Good spark, Test Complete.
• If spark not good, go To Step (1) of Test
Procedure B.
D-05351ST
Test Conditions:
• Key switch in OFF position
• Park brake ON
• PTO in OFF position
• Engine cool to avoid burns
Visually inspect spark plug. Check air gap. Spark plug not fouled or damaged.
• Check air gap and perform spark test.
• Spark plug fouled, replace spark plug.
MIF
Electrical Diagnostics and Operation - 244
ELECTRICAL DIAGNOSTICS AND OPERATION
Magneto to flywheel magnets air gap. Air gap within specification. Go to Step
(3).
• Specification: Air gap 0.2 - 0.3 mm
(0.008 - 0.012 in.). If not within specification
adjust as needed. Go to Step (3).
MIF
Disconnect S3 brake switch. Measure for
continuity between 945 Wht/Blk wire at S3
brake switch plug and ground.
Continuity to ground. Go To Step (4).
• Check 100, 115, 105, and 125 Blk wires
and connections. Check X2 connector.
Repeat test, continuity to ground, Go To
Step (4).
MIF
X6 Front main wiring harness connector.
Measure for continuity between 940 Wht
wire and ground.
Continuity to ground, Go To Step (1) of
Test Procedure C.
• No continuity to ground, replace key
switch. Go To Step (1) of Test Procedure
C.
• Check 941 and 940 Wht wires and
connections. Repeat test, continuity to
ground, Go To Step (1) of Test Procedure
C. MIF
FlywheelMagnet
Air Gap
Magneto
Plug to S1100 Blk
X6
940 Wht
Electrical Diagnostics and Operation - 245
ELECTRICAL DIAGNOSTICS AND OPERATION
Test Procedure C
Test Conditions:
• Key Switch in RUN position engine NOT running.
• Park brake OFF
• PTO in OFF position
• Operator OFF Seat
Disconnect S3 brake switch. Measure for
continuity between 945 Wht/Blk wire at S3
brake switch plug and ground.
Continuity to ground. Go To Step (2).
• No continuity to ground, replace seat
switch. Go To Step (2).
• Check 945 Wht/Blk, 111, 130, 110, and
125 Blk wires and connections. Check X2
and X5 connectors. Repeat test, continuity
to ground, Go To Step (2).
MIF
X6 Front main wiring harness connector.
Measure for continuity between 940 Wht
wire and ground.
Continuity to ground, Go To Step (1) of
Test Procedure D.
• No continuity to ground, replace brake
switch. Go To Step (1) of Test Procedure
D.
• Check 942 and 940 Wht wires and
connections. Repeat test, continuity to
ground, Go To Step (1) of Test Procedure
D. MIF
Plug to S3
945 Wht/Blk
X6
940 Wht
Electrical Diagnostics and Operation - 246
ELECTRICAL DIAGNOSTICS AND OPERATION
Test Procedure D
Test Conditions:
• Key Switch in RUN position engine NOT running.
• Park brake ON
• PTO in ON position
• Operator OFF Seat
Disconnect S2 PTO switch. Measure for
continuity between 949 Wht/Blk wire at S2
PTO switch plug and ground.
Continuity to ground. Go To Step (2).
• No continuity to ground, replace seat
switch. Go To Step (2).
• Check 949 Wht/Blk, 951 Blk/Wht, 130,
110, and 125 Blk wires and connections.
Check X2 and X5 connectors. Repeat test,
continuity to ground, Go To Step (2).
MIF
X6 Front main wiring harness connector.
Measure for continuity between 940 Wht
wire and ground.
Continuity to ground, Go To Step (1) of
Test Procedure E.
• No continuity to ground, replace PTO
switch. Go To Step (1) of Test Procedure
E.
• Check 943 and 940 Wht wires and
connections. Repeat test, continuity to
ground, Go To Step (1) of Test Procedure
E. MIF
Plug to S2manual PTO
Plug to S2electric PTO
949 Wht/Blk
949Wht/Blk
X6
940 Wht