Beruflich Dokumente
Kultur Dokumente
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
UNDER-HOOD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10
10.1
ELECTRICAL
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
NON-EFI COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 10.22
EFI COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
10.2
ELECTRICAL
GENERAL INFORMATION
Special Tools
Part Number
Tool Description
PV-43568
2870630
Timing Light
2870836
Battery Hydrometer
2460761
2871745
PU-47063
PU-47471
Under-Hood Components
A
B
G
10
A. Power Distribution Module (PDM)
B. Starter Solenoid
E
D
C. Terminal Block
D. Positive Battery Cable
10.3
ELECTRICAL
SWITCHES / CONTROLS
Headlamp Switch
1.
2.
3.
4.
4.
HEADLAMP SWITCH
Differential Solenoid
2.
3.
10.4
ELECTRICAL
Differential Solenoid Circuit Operation
CAUTION
AWD / Diff-Lock
Switch
Brake Switch
Key-On
Power
PDM
PDM Connector
2.
3.
4.
The parking brake switch is located under the dash or under the
hood. Follow the parking brake lever under the dash to locate
the switch.
Parking Brake Switch
10
10.5
ELECTRICAL
The switch remains in the open position when the park brake
lever is not applied.
3.
Parking Brake
Switch
Parking Brake
Not Applied
BN
The switch makes contact when the park brake is applied and
provides a ground path to illuminate the Park Brake Light in
the indicator panel.
OG/RD
Ground
Parking Brake
Applied
TESTING PARK BRAKE SWITCH
1.
Key-On Power
2.
Overheat Input
BN
OG/RD
Indicator Panel
Temperature
10.6
Reverse
Neutral
Low
High
ELECTRICAL
Indicator Lamp Replacement
HEAD LIGHTS
1.
2.
3.
4.
1.
25 ft.
(7.6 m)
2.
3.
4.
Replacement Bulbs
PN 4010416
5.
10
10.7
ELECTRICAL
6.
WARNING
Due to the nature of light utility vehicles and
where they are operated, headlight lenses
become dirty. Frequent washing is necessary to
maintain lighting quality. Riding with poor
lighting can result in severe injury or death.
2.
3.
2.
3.
4.
4.
10.8
ELECTRICAL
Headlamp Housing Installation
1.
Lamp Replacement
2.
If the tail light / brake light does not work the lamp assembly
may need to be replaced.
1.
3.
4.
From the rear of the tail light remove two screws holding
lens cover in place and remove lens cover. (T-20 Torx)
2.
Tail Light
RD and BN
Brake Light
OG and RD
Replacement Bulbs
PN 4030040
3.
4.
10.9
10
ELECTRICAL
POWER DISTRIBUTION MODULE (NON-EFI MODELS)
PDM Operation
10.10
ELECTRICAL
PDM Block Diagram
Check DC volts across positive and negative battery terminals. Voltage should be above 12 VDC.
10.11
10
ELECTRICAL
Ground Test
GROUND Test
Test Procedure
The PDM uses pin N for a ground wire; it connects to the PDM through connector SSCB # 1. Check for
continuity between the brown wire at SSCB # 1 and the terminal block ground post. There should be
continuity to ground on the wire to pass.
Disconnect the stator wire harness connector from the PDM. Measure resistance () between each of the
three yellow leads, for example: Y1 to Y2, Y1 to Y3, Y2 to Y3. Resistances should be 0.43 20%
with no continuity to ground to pass this test.
Test Procedure
The ignition switch must be turned to "ON" before completing this test. Disconnect PDM connector SSCB
# 2. Using a multimeter, check for continuity between the orange wire leaving this connector and the red/
white wire returning to this PDM connector; there should be continuity to pass this test. There should be
no continuity to ground to pass this test.
What does passing The RUN Signal wires, harness and connections are functioning normally. Problem likely exists in PDM
this test indicate? or Main PDM connection.
What does failing
There may be a problem with the wire harness, switches, connections or splice block.
this test indicate?
Test Procedure
Place the unit in Park and start the unit. Disconnect the stator connection and measure the AC Voltage
from each stator leg. Separately test each leg of the stator by connection the meter leads to the wires
leading from the stator (Y to Y/R, Y to Y/B, Y/R to Y/B). AC voltage output should be 17 VAC 25%
@ 1300 RPM, 40 VAC 25% @ 3000 RPM, and 65 VAC 25% @ 5000 RPM.
What does passing Passing this test indicates the stator is sufficiently supplying AC voltage to the PDM. If a charging system
this test indicate? problem exists, the cause may be the PDM, wire harness, battery, or fusible link.
What does failing Failing this test indicates there is a problem with one or more of the stator legs not providing sufficient
this test indicate? AC Voltage to the PDM. If a charging system problem exists, the stator or flywheel is likely the cause.
10.12
ELECTRICAL
Battery + Test
BAT + Test
Test Procedure
1: Complete the Battery Voltage and GROUND Tests; note your results. Disconnect PDM connector
SSCB # 1 and check for DC Volts on the red wire entering pin H at the PDM. The voltage should be at
or near Battery Voltage.
2: Check the resistance of the red wire between the battery and PDM connector SSCB # 1. There should
be no open leads or shorts to ground.
Test Procedure
The ignition switch must be turned to the "ON" position before completing this test.
1. Complete the BAT + Test and note your results.
2. An Orange wire exits the PDM on pin M in SSCB #2. Check for DC Volts on this Orange wire at the
ignition switch; the voltage should be at or near BAT + voltage to pass.
What does passing 1: The PDM is supplying the correct amount of protected battery voltage to the orange wire.
this test indicate? 2: The wiring harness and connections are good.
1: The PDM may not be receiving a RUN signal from splice block 1 on Pin B on SSCB #2.
What does failing
2: If voltage at the orange wire entering the ignition switch differs significantly from BAT + voltage, there
this test indicate?
may be a problem in the wiring harness or PDM.
The ignition switch must be turned to the "ON" position before completing this test.
1. Check for DC voltage on the red/white wires leaving the ignition switch; the voltage should be at or
near PROTECTED BAT + voltage to pass.
10.13
10
ELECTRICAL
Accessory Power Test
ACCESORY POWER Test
Test Procedure
The ignition switch must be turned to the "ON" position before completing this test. Measure DC volts
at the orange/white accessory terminal post leading from pin J on the PDM SSCB #1 connector.
Measurement should be at or near Battery voltage when RUN Signal is present at PDM (Ignition Switch
in the "ON" position). RUN Signal can be removed from the PDM by turning the Ignition Switch "OFF",
damaged wiring, or a faulty PDM.
Test Procedure
This test should be conducted with the vehicle Parking brake set and the Vehicle in Neutral with the engine
running. The PDM supplies power to the fan motor via pin K on SSCB # 1. To test the PDM for FAN
output, unplug the thermistor at the connector near the left side of the engine cylinder head. Measure the
DC voltage on the orange/black wire at the fan connector. Voltage should be at or near battery voltage.
Test Procedure
Disconnect the fan connector. Verify the fan is free to rotate before proceeding. Connect a DC ammeter
in-line with the orange/black wire. Ground the brown wire leaving the fan motor connector. Unplug the
thermistor at the left side of the engine cylinder head. With the vehicle parking brake set and the vehicle
in Neutral, start the engine. The cooling fan should start running. The ammeter should show a constant
current draw of 8.8 A or less.
What does passing A current measurement of 8.8 A or less indicates the fan motor is in good condition and is operating
this test indicate? properly.
A current draw of 0 A (the fan is not spinning) indicates that the fan motor is inoperative or it is not
receiving voltage from the PDM. If PDM to FAN Output Test has already been passed, replace the fan
What does failing
motor; if not, proceed to the PDM to FAN Output Test after checking the fan for obstructions. Current
this test indicate?
draw greater than 8.8 A indicates that the fan motor should be replaced, but only after checking the fan
for obstructions.
10.14
ELECTRICAL
Static Thermistor Test
Static Thermistor Test
Test Procedure
This test should be conducted with the engine near room temperature. Measure the resistance between
the two yellow/black wires on Pins E and F of SSCB #1 . The thermistor resistance should be 2200-2700
ohms when the engine is at room temperature.
What does passing A resistance between 2200-2700 ohms indicates the thermistor is functioning normally and the connection
this test indicate? with the thermistor is in good condition.
If an open or short circuit is found, this test should be repeated between the two yellow/black wires at the
What does failing thermistor connector leading directly into the thermistor. An open or short here means there is a problem
this test indicate? inside the thermistor and it must be replaced. If no short or open is found here, the problem is in the yellow/
black wires between the PDM and thermistor.
Test Procedure
To perform this test, the thermistor will need to be removed from the unit. Place an appropriate container
on a hot plate, add enough water to the container to submerge a thermistor; begin to apply heat. Place the
thermistor and a thermometer in the water. As the water heats, measure the thermistor resistance. To pass
this test, resistance should be 622 - 760 at 131o F (55o C), 339 - 414 at 167o F (75o C), and 196
- 240 at 203o F (95o C).
With the ignition switch on and the thermistor and indicator panel unplugged, Check for continuity from
the Blue/white wire at the indicator panel to ground. There should be continuity to ground to pass this test.
The PDM is properly providing a ground path for the HOT LAMP. If the unit passes the test and the HOT
What does passing
LAMP will not illuminate with the indicator panel and PDM plugged in, and the thermistor unplugged,
this test indicate?
inspect the hot lamp bulb and indicator panel, and indicator power source.
If there is no continuity to ground, you may not be testing to a known good ground. There may be damage
What does failing to the blue/white wire or connections between the indicator panel and PDM. It is also possible that the
this test indicate? PDM may not be providing a proper ground path. Replace the PDM only after verifying a good ground
path, wiring harness, and connections.
10.15
10
ELECTRICAL
Differential Solenoid Test
Differential Solenoid Test
Test Procedure
Using a known good 12V power source, connect directly to the Differential Solenoid at the harness
connection located near the left hand frame rail. Connect battery positive to the solenoid side of the
harness on the Orange/Red and Battery negative on the Blue wire. Audible operation of the solenoid
should be noted. Caution: DO NOT POWER THE SOLENOID WITH 12V FOR MORE THAN 1
SECOND OR DAMAGE TO THE SOLENOID MAY OCCUR.
With the ignition and AWD switches in the "on" position. Disconnect the connector going to the AWD
hub coil. Use a Digital Multimeter to check for power on the harness side of the connector on the Gray
wire. Your reading should be at or near battery voltage.
Test Procedure
The following tests must be performed with the Ignition switch in the ON position.
1. Verify switch is properly lighting. There will be one small light at the bottom of the switch illuminated
at all times. A larger light will illuminate when the switch is placed in AWD.
2. Place the switch is in the lowest or "Turf" mode position. Using a Digital Multimeter, verify the white/
green wire leaving the switch is at or near battery voltage. With the switch in the top or AWD position,
verify the gray wire leaving the switch is at or near battery voltage.
What does passing 1. Passing this test indicates there is a power source to the AWD/Turf Switch.
this test indicate? 2. Passing both of these tests indicates the switch is functioning normally.
1. Failing this test indicates they may be a problem with the power source to the switch; verify the wire
What does failing harness. If there is power at the switch and no illumination replace the switch.
this test indicate? 2. Failing either of these tests indicates the switch is not operating normally. If test 1 has been completed
and passed, replace the switch.
10.16
ELECTRICAL
Differential Out Test
Diff OUT Test
Test Procedure
The following test must be performed with the key switch in the "on" position. Disconnect the solenoid
from the harness. Using a Digital Mutimeter check for DC power on the orange/white wire on the harness
side of the connector. The measurement should be at or near battery voltage.
Test Procedure
Perform the following test with the Ignition switch ON and AWD/Turf Mode switch in the on or lowest
position. Unplug the harness leading to the differential solenoid. Using a Digital Multimeter check the
resistance to ground at the Blue wire on the harness side of the connection. The reading will be
approximately 5.5k. With the Ignition switch in the off position or the AWD/Turf switch in center or
upper positions the resistance reading will be approximately 15.5k.
Test Procedure
Using Digital Multimeter check for DCV on the pink wire at the back of the hour meter. Immediately after
the Ignition switch is turned to the on position (Engine off) a reading of at or near battery voltage will be
present for 5 seconds. After 5 seconds the reading will drop to 0 DCV. A reading of at or near battery
voltage will be present on the pink wire at all times when AC signal is present at the PDM from the stator
(Engine running).
10
10.17
ELECTRICAL
POWER DISTRIBUTION MODULE (EFI MODELS)
PDM Operation
BAT +
Description
Used to carry DC current to and from
the battery and PDM. DC output from
the PDM is used to charge the battery.
DC input to the PDM is used for power
distribution.
FAN
DIFF OUT
DIFF
GROUND
GROUND
Description
Description
COIL 1
RUN
FUEL
ENABLE
FUEL PUMP
COIL 2
BRAKE
SWITCH
COIL 3
AWD
DIFF IN
HUB COIL +
HUB COIL -
FAN ON
EFI
N
P
10.18
ELECTRICAL
PDM Function Overview
Functional Description
The Polaris PDM integrates many electronic features designed
for Polaris RANGERs. These features include the rectifier /
regulator, battery protected output, accessory power output,
ignition relay output, fan relay controller, ECU relay output, fuel
pump drive, differential solenoid drive, hub safety interlock,
and a starter diode.
Rectifier / Regulator
Accessory Power
10.19
10
ELECTRICAL
Differential Solenoid
The differential solenoid driver provides a current-regulated
low-side drive for the solenoid coil. The low side driver sinks
current from the inductive load that is sourced internally via the
ACCESSORY POWER output. To activate the solenoid driver,
the DIFF IN input and the BRAKE SWITCH must be high.
Once enabled, the driver provides an initial pull-in current for
a pre-determined time and then lowers to a hold current until
the DIFF IN input or the BRAKE SWITCH goes low. The
positive side of the differential solenoid is current limited via
ACCESSORY POWER. The solenoid driver provides shut
down to shorts to battery.
10.20
ELECTRICAL
TIMING CHECK PROCEDURE
(NON-EFI MODELS)
1.
Stator Adjustment
3.
Direct the timing light at the ignition timing check hole and
check the ignition timing. NOTE: Do not allow the engine
to warm up. The timing will retard approximately 2 when
the engine is warm.
If the ignition timing is not within the specified range, adjust the
stator plate position as described in Stator Adjustment.
Timing
Inspection
Hole
Flywheel
Rotation
1.
2.
3.
Rotation
Retard
Advance
32
10
Timing
Pointer
30
28
EH50PL
30o
Ignition Timing
30 2 BTDC@5000 RPM
10.21
ELECTRICAL
COOLING SYSTEM
Non-EFI Cooling System Break-Out Diagram
PDM
Overheat Indicator
Output
Thermister
Input
Fan 12 V
Output
SSCB#1
SSCB#2
Key-On
12 V Power
RD / WH
10.22
ELECTRICAL
EFI Cooling System Break-Out Diagram
Key-On
12 V Power
RD / WH
10
PDM
10.23
ELECTRICAL
Fan Control Circuit Operation / Testing
(Non-EFI Models)
The cooling fan is controlled through the Power Distribution
Module and thermistor. Perform the tests in the next two
sections if you are experiencing problems with the cooling fan
operation.
2.
3.
If the fan does not run or runs slowly, check the fan motor
wiring, connections, ground path, 12V power input, and fan
motor condition. (Refer to Fan Motor Current Draw in
the next section of this chapter) Repair or replace as
necessary. If the fan runs with the sensor harness
disconnected, but will not turn on when the engine is hot,
verify the coolant level is correct and check the coolant
temperature sensor and connector terminals
2.
3.
If the fan does not run or runs slowly, check the fan motor
wiring, connections, ground path, 12V power input, and fan
motor condition. (Refer to Fan Motor Current Draw in
the next section of this chapter) Repair or replace as
necessary. If the fan runs while the ening is running with
the sensor harness disconnected, but will not turn on when
the engine is hot, verify the coolant level is correct and
check the coolant temperature sensor and connector
terminals.
10.24
If the thermistor circuit is open the engine hot light and fan will
both come on. With engine cold, disconnect lead and measure
resistance of sensor between the two Yellow/Black connector
terminals. There should be no continuity or very high resistance
(see chart below).
Situation
Ohms
Reading
Diagnosis / Action
Hot light ON
& Fan ON
Above 50k
Hot light ON
Below 185
Temperature
Hot Light On
185 3%
215 F (102 C)
Fan On (Temp +
245 3%
195 F (91 C)
307 3%
180 F (82 C)
Room Temperature
2000 3%
77 F (25 C)
Condition
ELECTRICAL
DC / CDI IGNITION SYSTEM (NON-EFI MODELS)
DC / CDI Ignition System Overview
Operation Overview:
Maximum Timing
NOTE:
DC/CDI systems and
components are not
interchangeable with
any other system.
10.25
10
ELECTRICAL
Cranking Output Tests Using
Peak Reading Adaptor or Volt Ohm Meter
The following peak voltage tests will measure the amount of
output directly from each component. A peak reading voltmeter
can be used to perform the tests. A variety of peak reading
adaptors are commercially available for use with the Fluke 77
Digital Multimeter (PV-43568) and other digital VOMs which
will allow peak voltage tests to be performed accurately. Follow
the directions provided with the adaptor. All measurements are
indicated in DC Volts. Readings obtained without a peak reading
adaptor will be significantly different.
CDI Output
Resistance Tests
Perform these tests using an Ohm meter or multimeter with the
ignition key turned off. All readings are in Ohms.
Connect Meter Wires
Reading In Ohms
To:
White / Red and White
185 20%
White / Red and Ground
Open
Yellow and Yellow
0.43 20%
Yellow and Ground
Open
Test
Pulser Coil
Pulser Coil
Charge Coil
Charge Coil
Flywheel Identification
Locate the CDI module under the drivers side seat. Make sure
all stator and CDI wires are connected. Remove the CDI output
wire (White/Blue) from the ignition coil primary terminal.
Using the test table below crank the engine to check for proper
CDI output.
Ground
Key-On Power
Engine Application
EH500PLE
10.26
Wattage
250W
ELECTRICAL
Ignition System Testing Flow Chart
Whenever troubleshooting an electrical problem first check all terminal connections to be sure they are clean and tight. Also be sure
that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance values are also
given on the specification pages.
Condition: No spark or intermittent spark.
Verify 12 Volt DC power is present on the red wire entering the CDI module. Replace Spark Plug.
Disconnect the black wire from the 3 wire connector
attached to the CDI module to isolate the ignition
from the kill system. Verify the CDI has a good
ground path (Brown) for operation.
No
No
Yes
No
Yes
Disconnect and check the ignition coil.
Resistance values should be:
Primary Side - Primary Wire Tab to Ground
(on coil mount or engine): 0.11
Secondary Side - High Tension Wire to Engine Ground
Cap installed - 11,700
Cap removed - 6700
No
10
10.27
ELECTRICAL
Components of DC / CDI Ignition
NOTE: CDI boxes may look the same but have
different internal circuitry. Be sure to always use
the correct CDI box part number.
Resistor
Cap
Meter
5k
Ignition
Coil
Stator
Plate
CDI Box
Meter
6.7 k
Flywheel and
Ring Gear Casting
Refer To Wiring Diagrams For
Specified Stator Coil Resistance
10.28
ELECTRICAL
EFI DIAGNOSTICS
CAUTION
CHARGING SYSTEM
Current Draw - Key Off
CAUTION
WARNING
30 Amp
2.
3.
With engine off and the key, kill switch, and lights in the
ON position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive reading
is indicated.
4.
5.
6.
7.
With lights and other electrical loads off, the break even
point should occur at approximately 1500 RPM or lower.
8.
9.
10.29
10
ELECTRICAL
Charging System Alternator Tests
1.
Carb Model
Test
Connect Meter
Leads To:
Ohms Reading
Y1, Y2, or Y3
to Ground
Open Line
(Infinity)
Y3
1.
2.
3.
EFI Model
4.
1300
18 VAC 25 %
3000
42 VAC 25 %
1.
5000
64 VAC 25 %
Y1
Y2
Y3
Test
Connect Meter
Leads To:
Ohms Reading
Y1 to Y2
0.43 20%
Y1 to Y3
0.43 20%
Y2 to Y3
0.43 20%
10.30
ELECTRICAL
Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good
condition, connected and not exposed or pinched.:
Using a multitester set on D.C. volts, measure the battery open circuit voltage (See
earlier test). It should be 12.4 volts or more.
Is it?
No
Remove the battery and properly service. Reinstall the fully charged battery
or a fully charged shop battery.
Yes
Yes
Yes
Meter Setting: DC Volts
No
Yes
Meter Setting: DC Volts
No
Yes
If all of the previous tests indicate a good
condition, but the charging voltage does not
rise above battery voltage at the connector
or wire harness, replace the voltage regulator.
10.31
10
ELECTRICAL
BATTERY TERMINAL BLOCK
Battery Identification
The terminal block is located under the front hood next to the
battery. The terminal block provides easy access to the main
battery and starting cables. The terminal block also provides
easy hookup for accessories.
TERMINAL BLOCK
Orange/White
Orange/White
(Accessories)
Black
Red
Black
(Ground)
Red
(Battery+)
Top View
=T
Electrolyte Level
Indicator
BATTERY SERVICE
Side View
SEALED LOW
MAINTENANCE BATTERY
No Caps
(Non-removable
sealed Top)
Top View
Polaris Sticker
Apply
Nyogel
Side View
10.32
ELECTRICAL
CONVENTIONAL BATTERY
Battery Activation
WARNING
4.
Battery Inspection
The battery is located under the hood.
WARNING
The gases given off by a battery are explosive.
Any spark or open flame near a battery can
cause an explosion which will spray battery acid
on anyone close to it. Should there be contact
with battery acid, wash the affected area with
large quantities of cool water and seek
immediate medical attention.
To ensure maximum service life and performance from a new
battery, perform the following steps. NOTE: Do not service the
battery unless it will be put into regular service within 30 days.
After initial service, add only distilled water to the battery.
Never add electrolyte after a battery has been in service.
Inspect the battery fluid level. When the battery fluid nears the
lower level, remove the battery and fill with distilled water only
to the upper level line. To remove the battery:
Maintain
between upper
and lower level
marks
10
10.33
ELECTRICAL
Battery Removal
1.
2.
CAUTION
Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and
reinstall the negative cable last!
3.
4.
Conventional
Lead-Acid
YuMicron Type
100% Charged
12.60 V
12.70 V
75% Charged
12.40 V
12.50 V
50% Charged
12.10 V
12.20 V
25% Charged
11.90 V
12.0 V
0% Charged
less than
11.80 V
less than
11.9 V
Battery Installation
1.
2.
3.
4.
5.
Detail A
1.20
1.25
10.34
1.30
ELECTRICAL
Using a wire brush or knife, remove any corrosion from
the cables and terminals.
SPECIFIC GRAVITY
State of Charge*
Conventional
Lead-Acid
YuMicron Type
100% Charged
1.265
1.275
75% Charged
1.210
1.225
50% Charged
1.160
1.175
25% Charged
1.120
1.135
0% Charged
* At 80 F
NOTE: Subtract .01 from the specific gravity reading at 40 F.
Load Test
CAUTION
To prevent shock or component damage,
remove spark plug high tension leads and
connect securely to engine ground
before proceeding.
NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
properly.
A battery may indicate a full charge condition in the OCV test
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop
below 9.5 volts. If the beginning voltage is 12.6 volts or higher
and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
-75 F
1.225
-35 F
1.200
-17 F
1.150
+5 F
1.100
+18 F
1.050
+27 F
Charging Procedure
1.
2.
3.
Dielectric Grease
Freezing Point
(PN 2871329)
4.
WARNING
To avoid the possibility of explosion, connect
positive (+) cable first and negative (-) cable last.
10.35
10
ELECTRICAL
5.
6.
7.
1.
2.
Battery Inspection
1.
2.
3.
3.
Battery Removal
1.
2.
CAUTION
Low Maintenance batteries are permanently sealed at the time of
manufacture. The use of lead-calcium and AGM technology
instead of lead-antimony allows the battery acid to be fully
absorbed. For this reason, a Low Maintenance battery case is
dark and the cell caps are not removable, since there is no need
to check electrolyte level.
10.36
ELECTRICAL
Battery Installation
1.
2.
3.
4.
Load Test
Battery Testing
Whenever a service complaint is related to either the starting or
charging systems, the battery should be checked first.
Following are two tests which can easily be made on a Sealed
Low Maintenance battery to determine its condition: OCV Test
and a Load Test.
CAUTION
To prevent shock or component damage,
remove spark plug high tension leads and
connect securely to engine ground
before proceeding.
NOTE: This test can only be performed on machines
with electric starters. This test cannot be performed
with an engine or starting system that is not working
properly.
A battery may indicate a full charge condition in the OCV test
and the specific gravity test, but still may not have the storage
capacity necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same
manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for 15
seconds. During cranking the observed voltage should not drop
below 9.5 volts. If the beginning voltage is 12.6 volts or higher
and the cranking voltage drops below 9.5 volts during the test,
replace the battery.
Maintenance
Free
YuMicron Type
100%
13.0 V
12.70 V
75% Charged
12.80 V
12.50 V
50% Charged
12.50 V
12.20 V
25% Charged
12.20 V
12.0 V
0% Charged
10
* At 80 F
NOTE: Subtract .01 from the specific gravity reading at 40 F.
10.37
ELECTRICAL
Off-Season Storage
Battery Charging
NOTE: Always verify battery condition before and 12 hours after the end of charging.
Freezing Point
1.265
-75 F
1.225
-35 F
1.200
-17 F
1.150
+5 F
1.100
+18 F
1.050
+27 F
10.38
WARNING
An overheated battery could explode, causing
severe injury or death. Always watch charging
times carefully. Stop charging if the battery
becomes very warm to the touch.
Allow it to cool before resuming charging.
Battery Charging Reference Table
State of
Charge
Voltage
Action
Charge Time
None, check
voltage at 3 mos.
100%
12.8-13 V
None Required
after manufacture
date
May need slight
75-100% 12.5-12.8 V
3-6 hours
charge
50-75% 12.0-12.5 V Needs Charge
5-11 hours
At least 13
25-50% 11.5-12.0 V Needs Charge
hours, verify
state of charge
0-25%
11.5 V or less Needs Charge
At least 20 hours
WARNING
To avoid the possibility of sparks and explosion,
connect positive (red) cable first and negative
(black) cable last.
ELECTRICAL
STARTER SYSTEM
Troubleshooting
1.
2.
3.
10
To perform the test, place the meter on DC volts and place the
meter leads across the connection to be tested. Refer to the chart
on 10.27 to perform voltage drop tests on the starter system.
during
10.39
ELECTRICAL
Brush Inspection / Replacement
7.
Install the O-Ring over the bolt. Make sure the O-ring is
fully seated.
8.
Brush Set
1.
2.
Armature Testing
1.
2.
10.40
ELECTRICAL
4.
5.
6.
Starter Drive
Pinion Gear - Anti Kick-out Shoe, Garter Spring Replacement
If the garter spring is damaged, the overrun clutch may fail to
return properly. The replacement spring is (PN 7042039). Use
either of the following methods to remove and install a new
garter spring
Rear Brkt Assy
Washer Set
Starter Reassembly
1.
2.
3.
4.
5.
6.
7.
Carbon
Brush
Set
Armature
Rubber Rings
Washer
O-ring
CAUTION
Use care when handling starter housing.
Do not drop or strike the housing as magnet
damage is possible. If magnets are damaged,
starter must be replaced.
2.
10.41
10
ELECTRICAL
Starter System Test Flow Chart
Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing
of starter system. A digital multitester must be used for this test.
NOTE: The footbrake must be compressed to the starter circuit to engage.
With the tester on the VDC position, place the tesRemove battery and properly service.
ters black lead on the battery negative and the red
Install fully charged shop battery to
No
lead on the battery positive.
continue test.
Reading should be 12.4 or greater.
Yes
Disconnect the White/Red and Orange coil engagement wires from the starter solenoid. Connect black
tester wire to battery ground. Connect red tester
lead to White/Red harness wire. Turn the ignition
switch as if starting the vehicle. Tester should read
battery voltage on White/Red wire.
Yes
No
Check voltage on both sides of circuit breaker and ignition switch. The voltage on both
sides should be the same. NOTE: The
ignition switch actuated. Replace the
defective component.
Brake Pressure
Switch Testing Test A
Test B (Next Page)
Locate the brake pressure switch near the steering
gearbox along the frame member. The switch is
installed in a junction block. Perform the Brake
Light Switch Test on Page 10.5.
No
No
Repair wiring.
10.42
ELECTRICAL
Starter System Test Flow Chart, contd.
Test B (from previous page)
Voltage Drop Testing
No
Yes
No
No
Yes
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the starter
must be removed for static testing and inspection.
10
10.43
ELECTRICAL
ELECTRIC BOX LIFT ACTUATOR
DIAGNOSIS (if equipped)
1. Disconnect the wiring harness to the
box lift actuator.
Disconnect Harness
YES
NO
NO
10.44
YES
ELECTRICAL
ELECTRICAL BREAKOUT DIAGRAMS (EFI MODELS)
Starting Circuit
10
10.45
ELECTRICAL
Transmission Switch Circuit
10.46
ELECTRICAL
Charging System Circuit
10
10.47
ELECTRICAL
AWD Circuit
10.48