Service Manual

ManualsBrandsToro ManualsLawn TractorsToro 74571

TABLE OF CONTENTS

Demystification Glossary 1 - 1

CHAPTER PAGE

Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

(2004) 12-32XL, 16-38XL, 16-38HXL, 17-44HXL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

(2005) XL320, XL320 (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

(2005) XL380H (Int’), XL380, XL380H, XL440H (Int’l), XL440H . . . . . . . . . . . . . . . . . . . . 5-1

(2004) 315-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

(2005) Classic GT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

(2004) 416XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

(2005) GT410. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

(2004) 417XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

(2005) GT420, GT420 (Int’l). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

(2004) 419XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

(2005) GT430, GT430 (Int’l). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

(2004) 520xi, 522xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

(2005) GT550. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

(2005) GT560 (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

(2004) 14-38Z, 16-42Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

(2005) Z380 (Int’l), Z380, Z420, Z420 (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

(2004) 17-42Z, 18-44Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

(2004) 18-44ZX, 18-52ZX, 19-52ZX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

(2005) Z480, Z440 (Int’l). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

(2005) ZX480, ZX525 (Int’l), ZX525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

(2004) 1332-G (Int’l). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

(2005) G132 (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Summary of content (200 pages)

PAGE 1
TABLE OF CONTENTS CHAPTER PAGE Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Time Savers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 (2004) 12-32XL, 16-38XL, 16-38HXL, 17-44HXL . . . . . . . . . . .
PAGE 2
TABLE OF CONTENTS CHAPTER PAGE (2004) 1332-H (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 (2005) H132 (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 (2004) 170-D (Int’l), 150-D (Int’l) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1 (2005) DH210 (Int’l), DH200 (Int’l) . . . . . . . . . . . . . . . . . . . . . . .
PAGE 3
TIME SAVERS Table of Contents Using this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Using a VOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
Using this Manual TIME SAVERS 2-2 Demystification Glossary
PAGE 5
TIME SAVERS Using this Manual Demystification Glossary 2-3
PAGE 6
Using this Manual TIME SAVERS 2-4 Demystification Glossary
PAGE 7
TIME SAVERS Using this Manual Demystification Glossary 2-5
PAGE 8
Using this Manual TIME SAVERS 2-6 Demystification Glossary
PAGE 9
TIME SAVERS 1 Demystification Glossary Checking Resistance Using a VOM 2 Checking Voltage 2-7
PAGE 10
TIME SAVERS Using a VOM 3 What about checking current? 2-8 Demystification Glossary
PAGE 11
TIME SAVERS Sample Problem: 266-H electric clutch will not engage Troubleshooting Same Sample Problem: 266-H electric clutch will not engage (this time) Demystification Glossary 2-9
PAGE 12
TIME SAVERS Troubleshooting Sample Problem: This XL lawn tractor won’t turn over. The customer parked it in the garage and turned it off. When he tried to start it a week later, he heard one click. After that, nothing would happen when he turned the key. We know it is a short circuit because we found the 10 amp fuse blown.
PAGE 13
TIME SAVERS Troubleshooting Demystification Glossary 2 - 11
PAGE 14
Troubleshooting TIME SAVERS 2 - 12 Demystification Glossary
PAGE 15
TIME SAVERS Troubleshooting Demystification Glossary 2 - 13
PAGE 16
This page intentionally left blank 2 - 14 Demystification Glossary
PAGE 17
GLOSSARY Table of Contents DESCRIPTION PAGE Clutch, Electric (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Gauge, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4 Gauge, Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 18
GLOSSARY Table of Contents DESCRIPTION PAGE Switch, Neutral Adjustable - Plunger Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25 Switch, PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 26 Switch, Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27 Glossary Switch, Seat . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 19
GLOSSARY Clutch, Electric (PTO) 4. Connect the meter lead wires to the wires in the clutch connector (Figure 1). Purpose This clutch electrically controls the engagement and disengagement of the Power Take Off (PTO) pulley. How It Works The PTO clutch is composed of three major components; the field, the clutch plate, and the friction plate. The clutch plate always turns with the engine. The field is a coil of wire on an iron core, which becomes an electromagnet when power is applied.
PAGE 20
GLOSSARY 8. Gauge, Fuel If the meter reading is 3.5 amps or above, the system is functioning properly. If the meter reading is below 3.5 amps, check the electrical system for problems (i.e., the battery, ignition switch, PTO switch, or wiring harness may be malfunctioning). Figure 3 mvc-104 Purpose This gauge indicates fuel level (Figure 3). Figure 2 3-7 Clutch Burnishing Procedure Glossary The clutch should be burnished as part of the predelivery service, or whenever a new clutch is installed.
PAGE 21
GLOSSARY Gauge, Voltmeter Testing 1. With the gauge still connected to the harness, turn the key to the “RUN” position. 2. Using a VOM, set scale capable of reading 12 volts D.C., connect the negative lead to ground (Figure 4) to verify the conditions in the table below. Terminal Reading G 0 volts I 12 volts* S 2.5 volts tank full S 7.5 volts tank empty Figure 5 * All voltage readings should be within 20%. mvc-106 Purpose This gauge indicates the voltage across the battery (Figure 5).
PAGE 22
GLOSSARY Hourmeter Testing 1. With the meter still connected to the harness, turn the key to the “RUN” position. 2. Verify the conditions in the table below. If they are not met, replace the voltmeter as it is not serviceable (Figure 6). Terminal Condition I 12 volts DC +/- 20% G 0 volts DC Figure 7 mvc-110 Purpose The hourmeter keeps track of the actual engine hours (Figure 7). This is accomplished by connecting the hourmeter to the engine oil pressure switch.
PAGE 23
GLOSSARY Magnet Assembly - Cruise Control Figure 8 Microswitches Figure 9 mvc-123 mvc-677X Purpose Purpose When engaging cruise control, the magnet assembly engages a cruise control plate that locks the control linkage to the speed that is set (Figure 8). Microswitches are used to monitor whether or not a lever or pedal is in the correct position (Figure 9). How It Works How it Works When the desired forward speed is obtained, push the cruise control switch on the dash.
PAGE 24
GLOSSARY KeyChoice™ Reverse Operating System This interlock feature is provided to prevent unintentional engine-powered attachment operation in reverse. If the tractor is shifted into reverse while the mower blade or other Power Take Off (PTO) driven attachment is engaged, the electric clutch will disengage or the engine will stop, depending on the model. DO NOT MOW WHILE BACKING UP UNLESS ABSOLUTELY NECESSARY.
PAGE 25
GLOSSARY 3. 4. While the engine is running, move the PTO lever to the “engage” position, on gear shift models, move the gear shift lever in reverse, and on Hydro models, move the forward/reverse pedal to reverse. Move the PTO lever to the “disengage” position and move the gear shift lever to neutral on gear shift models. Depress the clutch/brake pedal on the Hydro’s. 2. Now start the engine. 3. Move the PTO lever to the “engage” position and turn the KeyChoice™ key, located around the seat area. 4.
PAGE 26
GLOSSARY Testing - No Power To Circuit (With Module Out of Circuit) Meter Scale Meter Probe Negative Meter Probe Positive Meter Reading Ohms Pin 3 Pin 5 Open (More than 100K ohms) Diode* Pin 3 Pin 6 .5 to 1 Volt Diode* Pin 3 Pin 1 .5 to 1 Volt Diode* Pin 3 Pin 4 .5 to 1 Volt Ohms Pin 1 Pin 4 350 to 400 ohms Ohms Pin 2 Pin 4 Open (more the 100K ohms) *Note: If the multimeter does not have a diode test feature, this test can not be performed.
PAGE 27
GLOSSARY Module, KeyChoice™ Reverse Operating System (Electric PTO Clutch) Purpose The KeyChoice™ Reverse Operating System Module (Figure 11) works with the KeyChoice™ switch, PTO switch, and the reverse switch. It responds to the reverse switch. If the override switch (KeyChoice™ switch) is not activated and the PTO is engaged, it will stop the electric PTO clutch. How It Works The KeyChoice™ Reverse Operating System Module is made up of several components, such as diodes and relays.
PAGE 28
GLOSSARY Testing - No Power To Circuit (With Module Out of Circuit) Meter Scale Meter Probe Negative Meter Probe Positive Meter Reading Ohms Pin 3 Pin 5 Open (More than 100K ohms) Diode* Pin 3 Pin 6 .5 to 1 Volt Diode* Pin 3 Pin 1 .5 to 1 Volt Diode* Pin 3 Pin 4 .5 to 1 Volt Ohms Pin 1 Pin 4 350 to 400 ohms Ohms Pin 2 Pin 4 Open (more the 100K ohms) *Note: If the multimeter does not have a diode test feature, this test can not be performed.
PAGE 29
GLOSSARY Module, KeyChoice™ Reverse Operating System (Manual PTO Clutch) Testing The Key Choice™ Reverse Operating System module must be removed from the circuit. Using a multimeter check the following: Purpose The Key Choice™ Reverse Operating System module works with the KeyChoice™ switch, PTO switch, and the reverse switch. It responds to the reverse switch; if the override switch (KeyChoice™ switch) is not activated and the PTO is engaged, it will stop the engine (Figure 13).
PAGE 30
GLOSSARY Module, Low Voltage Relay Purpose Purpose The illumination of the battery light on the dash indicates the battery voltage is too low. This is controlled by the low voltage module (Figure 15). The relay is used in a variety of ways to turn circuits on and off. How It Works How it works A relay is an electrically actuated switch. The low voltage module is a voltage comparator, checking the charge voltage from the engine regulator/ rectifier system. If the charge voltage is less than 11.
PAGE 31
GLOSSARY 3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 (Figure 17). 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87a. Apply +12 VDC to terminal 85.
PAGE 32
GLOSSARY Sender, Fuel Solenoid (P/N 95-3971) Purpose The solenoid’s purpose is simply to connect the battery to the starter motor when the ignition switch is turned to “START”. The solenoid is used to protect the ignition switch from the high current drawn by the starter motor. How it Works The solenoid has two primary parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet. The other part is a bar type switch (Figure 20).
PAGE 33
GLOSSARY Switch, Brake Testing 1. Disconnect the solenoid from the wiring harness. 2. With a multimeter (ohms setting), check to ensure that terminals “c” and “d” are open (no continuity) (Figure 20). 3. Apply +12 VDC to terminal “a” and ground terminal “b”. Terminals “c” and “d” should now be closed (continuity) (Figure 20). 4. You should be able to hear the solenoid switch “click” when you make the connection. D A This double pole plunger switch has four terminals.
PAGE 34
GLOSSARY Switch, Cruise Control Testing P/N 93-0527 and P/N 94-7602 1. Disconnect the switch from the wiring harness. 2. Using a VOM or test lamp, test the continuity of the terminals using the following diagrams (Figure 25 and Figure 26).
PAGE 35
GLOSSARY Switch, Key P/N 94-7602 (P/N 88-9830 or 104-2541) Purpose “OFF” Position no continuity This component provides the proper switching for the starter, ignition, accessories, and safety circuits (Figure 27). A B Y S X “START” Position continuity between terminals 2-3 / 5-6 I Figure 27 mvc-166art How it Works Detents inside the switch give it 3 positions: OFF, RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released.
PAGE 36
GLOSSARY Switch, Key Testing 1. Disconnect the switch from the wiring harness. 2. Verify that continuity exists between the terminals listed for the switch position. Verify that there is NO continuity between terminals not listed for the switch position (Figure 28).
PAGE 37
GLOSSARY Switch, Key Testing 1. Disconnect the switch from the wiring harness. 2. Verify that continuity exists between the terminals listed for the switch position. Verify that there is NO continuity between terminals not listed for the switch (Figure 30). B (P/N 92-6785) Purpose This component provides the proper switching for the starter, ignition, accessories, and safety circuits (Figure 31).
PAGE 38
GLOSSARY Switch, KeyChoice™ Reverse Operating System Testing 1. Disconnect the switch from the wiring harness. 2. Verify that continuity exists between the terminals listed for the switch position. Verify that there is NO continuity between terminals not listed for the switch position (Figure 32). This switch is used in the Key Choice™ Reverse Operating System circuit. When turned to the On position, it allows the operator to mow in reverse.
PAGE 39
GLOSSARY Switch, Light Testing 1. Disconnect the switch from the wiring harness. 2. Using a VOM or test lamp, test the continuity of the terminals, using the diagrams below (Figure 35). “OFF” Position no continuity Figure 34 mvc-108 Purpose This rocker switch is typically used to provide switching for the lights (Figure 34). How it Works The switch has contacts inside which connect two terminals in one position while disconnecting the other two.
PAGE 40
GLOSSARY Switch, Neutral Switch, Neutral - Plunger Type Purpose Purpose Used to ensure the transmission is in neutral when starting the unit. It is activated when the clutch/brake pedal is depressed. Used to ensure the transmission is in neutral when starting the unit. It is activated when the brake pedal is depressed. How It Works How it Works This single pole plunger type switch has two terminals.
PAGE 41
GLOSSARY Testing 1. Disconnect the switch from the wiring harness. 2. Using a multimeter, follow the procedure listed below (Figure 38): A C B D Switch, Neutral Adjustable - Plunger Type Figure 39 mvc-122 Purpose Figure 38 Neutral Switch Note: Terminals on actual switch not labeled.
PAGE 42
GLOSSARY Switch, PTO Testing Purpose The PTO switch is typically used to turn on the Electric PTO Clutch and to function as part of the safety interlock system. How it Works When the PTO switch is pulled out to the “ON” position, contacts inside the switch electrically connect various terminals. One terminal is connected to the wire that goes directly to the electric clutch. When the PTO is pulled out to the “ON” position, voltage flows to the electric clutch and engages. 1.
PAGE 43
GLOSSARY Switch, Reverse Switch, Seat Purpose Purpose This switch works in the Key Choice™ Reverse Operating System circuit when the mower (PTO) is engaged. The switch is in the safety circuit. If the engine is running and the operator vacates the seat with either PTO engaged or the parking brake off, the engine will shut down. How It Works This single pole plunger type switch has two terminals.
PAGE 44
GLOSSARY How It Works When the seat is vacated, the switch is open and there is no continuity between the two terminals. When the seat is occupied, the switch closes and there should be continuity between the two terminals. Testing 1. Disconnect the switch from the wiring harness. 2. With a multimeter, check the continuity between the two terminals of the switch. There should be NO continuity. 3. With weight or pressure on the seat, check the continuity again on the two terminals of the switch.
PAGE 45
2004 2005 12-32XL, 16-38XL, 16-38 HXL, 17-44HXL XL320, XL320 (Int’l) Information List Information List (2004 - 2005) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . 4-3 Spark Circuit . . . . . . . . . . . . . . . . . . 4-3 - 4-6 Charging Circuit . . . . . . . . . . . . . . . . . . . . 4-6 Light Circuit . . . . . . . . . . . . . . . . . . . . . . .
PAGE 46
12-32XL, 16-38XL, 16-38 HXL, 17-44HXL XL320, XL320 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 4-2 Demystification Guide
PAGE 47
2004 2005 12-32XL, 16-38XL, 16-38 HXL, 17-44HXL XL320, XL320 (Int’l) Starter Motor Circuit (ignition switch in “start) Spark Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 4-3
PAGE 48
12-32XL, 16-38XL, 16-38 HXL, 17-44HXL XL320, XL320 (Int’l) 2004 2005 Spark Circuit (ignition switch in “run”) Legend Bk Bu Bn Gn Gy Or Pk Re T Violet White Yellow Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan 4-4 Demystification Guide
PAGE 49
2004 2005 12-32XL, 16-38XL, 16-38 HXL, 17-44HXL XL320, XL320 (Int’l) Spark Circuit (In reverse, PTO “on”) Spark Circuit (In reverse, override key switch activated) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 4-5
PAGE 50
12-32XL, 16-38XL, 16-38 HXL, 17-44HXL XL320, XL320 (Int’l) 2004 2005 Spark Circuit (In reverse, PTO “on”, override mode) Charging Circuit Circuits Light Circuit Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 4-6 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 51
2005 XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H Information List Information List (2005) Wiring Diagrams. . . . . . . . . . . . . . . . . . . . 5-2 & 5-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . 5-4 Spark Circuits . . . . . . . . . . . . . . . . . . . 5-4 & 5-5 Reverse Operating System Circuits . . 5-6 - 5-10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . 5-10 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 52
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Wiring Diagram Wiring Diagram 5-2 Demystification Guide
PAGE 53
2005 XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H Wiring Diagram Wiring Diagram Demystification Guide 5-3
PAGE 54
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Starter Motor Circuit (ignition switch in “start”) Spark Circuit (ignition switch in “start” position) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 5-4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 55
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 5-5
PAGE 56
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 5-6 Demystification Guide
PAGE 57
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 5-7
PAGE 58
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 5-8 Demystification Guide
PAGE 59
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 5-9
PAGE 60
XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Charging Circuit (ignition switch in “run”) 5 - 10 Demystification Guide
PAGE 61
2005 XL380H (Int’l), XL380, XL380H XL440H (Int’l), XL440H Light Circuit (ignition switch in “run/lights”) Circuits Demystification Guide 5 - 11
PAGE 62
This page intentionally left blank 5 - 12 Demystification Guide
PAGE 63
2004 2005 315-8 Classic GT Information List Information List (2004 - 2005) Wiring Diagrams. . . . . . . . . . . . . . . . . . . . 6-2 & 6-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . 6-4 Spark Circuits . . . . . . . . . . . . . . . . . . . 6-4 & 6-5 Reverse Operating System Circuits. . 6-6 - 6-10 Battery Charge Circuit . . . . . . . . . . . . . . . . 6-10 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Low Oil Pressure Light Circuit . . . . . . . .
PAGE 64
315-8 Classic GT 2004 2005 Wiring Diagram Wiring Diagram 6-2 Demystification Guide
PAGE 65
2004 2005 315-8 Classic GT Wiring Diagram Wiring Diagram Demystification Guide 6-3
PAGE 66
315-8 Classic GT 2004 2005 Starter Motor Circuit (ignition switch in “start”) Spark Circuit (ignition switch in “start” position) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 6-4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 67
2004 2005 315-8 Classic GT Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 6-5
PAGE 68
315-8 Classic GT 2004 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 6-6 Demystification Guide
PAGE 69
2004 2005 315-8 Classic GT Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 6-7
PAGE 70
315-8 Classic GT 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 6-8 Demystification Guide
PAGE 71
2004 2005 315-8 Classic GT Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 6-9
PAGE 72
315-8 Classic GT 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Battery Charge Circuit (ignition switch in “run”) 6 - 10 Demystification Guide
PAGE 73
2004 2005 315-8 Classic GT Light Circuit Low Oil Pressure Light Circuit (ignition switch in “run”) (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y 6 - 11 Circuits Hourmeter
PAGE 74
This page intentionally left blank 6 - 12 Demystification Guide
PAGE 75
2004 2005 416XT GT410 Information List Information List (2004 - 2005) Wiring Diagrams. . . . . . . . . . . . . . . . . . . . 7-2 & 7-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . 7-4 Spark Circuits . . . . . . . . . . . . . . . . . . . 7-5 & 7-6 Reverse Operating System Circuits . . 7-7 - 7-11 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Battery Charge Circuit . . . . . . . . . . . . . . . . 7-12 Hourmeter . . . . . . . . . . . . . . . . . . . . .
PAGE 76
416XT GT410 2004 2005 Wiring Diagram Wiring Diagram 7- 2 Demystification Guide
PAGE 77
2004 2005 416XT GT410 Wiring Diagram Wiring Diagram Demystification Guide 7- 3
PAGE 78
416XT GT410 2004 2005 Starter Motor Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 7- 4 Demystification Guide
PAGE 79
2004 2005 416XT GT410 Spark Circuit (ignition switch in “start” position) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 7- 5
PAGE 80
416XT GT410 2004 2005 Spark Circuit (ignition switch in “run”) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 7- 6 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 81
2004 2005 416XT GT410 Reverse Operating System Circuit (PTO “off”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 7- 7
PAGE 82
416XT GT410 2004 2005 Reverse Operating System Circuit (PTO “on”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 7- 8 Demystification Guide
PAGE 83
2004 2005 416XT GT410 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 7- 9
PAGE 84
416XT GT410 2004 2005 Reverse Operating System Circuit (Override key switch “activated”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 7- 10 Demystification Guide
PAGE 85
2004 2005 416XT GT410 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Light Circuit Demystification Guide 7- 11 Circuits (ignition switch in “run/lights”)
PAGE 86
416XT GT410 2004 2005 Battery Charge Circuit (ignition switch in “run”) Hourmeter (ignition switch in “run”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 7- 12 Demystification Guide
PAGE 87
2004 2005 417XT GT420, GT420 (Int’l) Information List Information List (2004 - 2005) Wiring Diagrams. . . . . . . . . . . . . . . . . . . . 8-2 & 8-3 Circuit Diagrams Starter Motor Circuit. . . . . . . . . . . . . . . . . . . . 8-4 Spark Circuits . . . . . . . . . . . . . . . . . . . 8-4 & 8-5 Reverse Operating System Circuits . . 8-6 - 8-10 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Battery Charge Circuit . . . . . . . . . . . . . . . . 8-11 Hourmeter Circuit . . . . . . . . .
PAGE 88
417XT GT420, GT420 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 8-2 Demystification Guide
PAGE 89
2004 2005 417XT GT420, GT420 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 8-3
PAGE 90
417XT GT420, GT420 (Int’l) 2004 2005 Starter Motor Circuit (ignition switch in “start”) Spark Circuit Circuits (ignition switch in “start” position) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 8-4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 91
2004 2005 417XT GT420, GT420 (Int’l) Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 8-5
PAGE 92
417XT GT420, GT420 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 8-6 Demystification Guide
PAGE 93
2004 2005 417XT GT420, GT420 (Int’l) Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 8-7
PAGE 94
417XT GT420, GT420 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 8-8 Demystification Guide
PAGE 95
2004 2005 417XT GT420, GT420 (Int’l) Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 8-9
PAGE 96
417XT GT420, GT420 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Light Circuit (ignition switch in “run/lights”) 8 - 10 Demystification Guide
PAGE 97
2004 2005 417XT GT420, GT420 (Int’l) Battery Charge Circuit (ignition switch in “run”) Hourmeter Circuit (ignition switch in “run”) Oil Pressure Light Circuit (ignition switch in “run”) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y 8 - 11
PAGE 98
417XT GT420, GT420 (Int’l) 2004 2005 Cruise Control Circuit (ignition switch in “run”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 8 - 12 Demystification Guide
PAGE 99
2004 2005 419XT GT430, GT430 (Int’l) Information List Information List (2004 - 2005) Wiring Diagrams. . . . . . . . . . . . . . . . . . . . 9-2 & 9-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . 9-4 Spark Circuits . . . . . . . . . . . . . . . . . . . 9-4 & 9-5 Reverse Operating System Circuits . . 9-6 - 9-10 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Battery Charge Circuit . . . . . . . . . . . . . . . . 9-11 Hourmeter Circuit . . . . . . . . .
PAGE 100
419XT GT430, GT430 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 9-2 Demystification Guide
PAGE 101
2004 2005 419XT GT430, GT430 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 9-3
PAGE 102
419XT GT430, GT430 (Int’l) 2004 2005 Starter Motor Circuit (ignition switch in “start”) Spark Circuit Circuits (ignition switch in “start” position) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 9-4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 103
2004 2005 419XT GT430, GT430 (Int’l) Spark Circuit (ignition switch in “run”) Legend Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 9-5
PAGE 104
419XT GT430, GT430 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 9-6 Demystification Guide
PAGE 105
2004 2005 419XT GT430, GT430 (Int’l) Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 9-7
PAGE 106
419XT GT430, GT430 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 9-8 Demystification Guide
PAGE 107
2004 2005 419XT GT430, GT430 (Int’l) Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 9-9
PAGE 108
419XT GT430, GT430 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Light Circuit (ignition switch in “run/lights”) 9 - 10 Demystification Guide
PAGE 109
2004 2005 419XT GT430, GT430 (Int’l) Battery Charge Circuit (ignition switch in “run”) Hourmeter Circuit (ignition switch in “run”) Oil Pressure Light Circuit (ignition switch in “run”) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y 9 - 11
PAGE 110
419XT GT430, GT430 (Int’l) 2004 2005 Lift Pump Circuit (ignition switch in “run”) Cruise Control Circuit Circuits (ignition switch in “run”) Legend 9 - 12 Black Blue Brown Green Grey Orange Pink Bk Bu Bn Gn Gy Or Pk Red Tan Violet White Yellow Re T Vio W Y Demystification Guide
PAGE 111
2004 2005 520xi, 522xi GT550 Information List Information List (2004 - 2005) Wiring Diagrams. . . . . . . . . . . . . . . . . . 10-2 & 10-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . 10-4 Spark Circuits . . . . . . . . . . . . . . . . . 10-4 & 10-5 Reverse Operating System Circuits 10-6 - 10-10 Charging Circuit . . . . . . . . . . . . . . . . . . . . 10-10 Hourmeter Circuit . . . . . . . . . . . . . . . . . . . 10-11 Light Circuit . . . . . . . . . . . . . . . . . . . . .
PAGE 112
520xi, 522xi GT550 2004 2005 Wiring Diagram Wiring Diagram 10 - 2 Demystification Guide
PAGE 113
2004 2005 520xi, 522xi GT550 Wiring Diagram Wiring Diagram Demystification Guide 10 - 3
PAGE 114
520xi, 522xi GT550 2004 2005 Starter Motor Circuit (ignition switch in “start”) Spark Circuit (ignition switch in “start” position) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 10 - 4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 115
2004 2005 520xi, 522xi GT550 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 10 - 5
PAGE 116
520xi, 522xi GT550 2004 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 10 - 6 Demystification Guide
PAGE 117
2004 2005 520xi, 522xi GT550 Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 10 - 7
PAGE 118
520xi, 522xi GT550 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 10 - 8 Demystification Guide
PAGE 119
2004 2005 520xi, 522xi GT550 Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 10 - 9
PAGE 120
520xi, 522xi GT550 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Charging Circuit (ignition switch in “run”) 10 - 10 Demystification Guide
PAGE 121
2004 2005 520xi, 522xi GT550 Hourmeter Circuit (ignition switch in “run”) Light Circuit (ignition switch in “run/lights”) Gauge Circuit (ignition switch in “run”) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y 10 - 11
PAGE 122
520xi, 522xi GT550 2004 2005 Cruise Control Circuit (cruise “off”/ignition switch in “run”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 10 - 12 Demystification Guide
PAGE 123
2004 2005 520xi, 522xi GT550 Cruise Control Circuit (cruise “activated”/ignition switch in “run”) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y 10 - 13
PAGE 124
520xi, 522xi GT550 2004 2005 Cruise Control Circuit Circuits (cruise “on”/ignition switch “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 10 - 14 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 125
2004 2005 520xi, 522xi GT550 Cruise Control Circuit (cruise “deactivated”/ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide 10 - 15 Circuits Park Light Circuit (ignition switch in “run”)
PAGE 126
This page intentionally left blank 10 - 16 Demystification Guide
PAGE 127
2005 GT560 (Int’l) Information List Information List (2005) Wiring Diagrams . . . . . . . . . . . . . . . . . . . . .11-2 & 11-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . . 11-4 Injection Pump Circuits . . . . . . . . . . . . . 11-4 - 11-5 Spark Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Reverse Operating System Circuits . . 11-6 - 11-10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . 11-11 Glow Plug Circuit . . . . . . . . . . . . .
PAGE 128
GT560 (Int’l) 2005 Wiring Diagram Wiring Diagram 11 - 2 Demystification Guide
PAGE 129
2005 GT560 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 11 - 3
PAGE 130
GT560 (Int’l) 2005 Starter Motor Circuit (ignition switch in “run) Injection Pump Circuit (ignition switch in “run”) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 11 - 4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 131
2005 GT560 (Int’l) Injection Pump Circuit (ignition switch in “start”) Spark Circuit (ignition switch in “run”) Legend Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 11 - 5
PAGE 132
GT560 (Int’l) 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 11 - 6 Demystification Guide
PAGE 133
2005 GT560 (Int’l) Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 11 - 7
PAGE 134
GT560 (Int’l) 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 11 - 8 Demystification Guide
PAGE 135
2005 GT560 (Int’l) Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 11 - 9
PAGE 136
GT560 (Int’l) 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 11 - 10 Demystification Guide
PAGE 137
2005 GT560 (Int’l) Charging Circuit (ignition switch in “run”) Glow Plug Circuit (ignition switch in “on”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 11 - 11
PAGE 138
GT560 (Int’l) 2005 Light Circuit (ignition switch in “run/lights”) Gauge Circuit (ignition switch in “run”) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 11 - 12 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 139
2005 GT560 (Int’l) Cruise Control Circuit (ignition switch in “run”) Park Light Circuit (ignition switch in “run”) Circuits Demystification Guide 11 - 13
PAGE 140
GT560 (Int’l) 2005 Hourmeter Circuit (ignition switch in “start”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Temperature Light Circuit Circuits (ignition switch in “run”) 11 - 14 Demystification Guide
PAGE 141
2004 2005 14-38Z, 16-42Z Z380 (Int’l), Z380, Z420, Z420 (Int’l) Information List Information List (2004 - 2005) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . 12-3 Spark Circuits . . . . . . . . . . . . . . 12-3 & 12-4 Battery Charge Circuit . . . . . . . . . . . . . . 12-4 PTO Clutch Circuit . . . . . . . . . . . . . . . . .
PAGE 142
14-38Z, 16-42Z Z380 (Int’l), Z380, Z420, Z420 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 12 - 2 Demystification Guide
PAGE 143
2004 2005 14-38Z, 16-42Z Z380 (Int’l), Z380, Z420, Z420 (Int’l) Starter Motor Circuit (ignition switch in “start) Spark Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 12 - 3
PAGE 144
14-38Z, 16-42Z Z380 (Int’l), Z380, Z420, Z420 (Int’l) 2004 2005 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Battery Charge Circuit Circuits (ignition switch in “run”) PTO Clutch Circuit (ignition switch in “run”) 12 - 4 Demystification Guide
PAGE 145
2004 17-42Z, 18-44Z Information List Information List (2004) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . 13-3 Spark Circuits . . . . . . . . . . . . . . 13-3 & 13-4 Battery Charge Circuit . . . . . . . . . . . . . . 13-4 PTO Clutch Circuit . . . . . . . . . . . . . . . . .
PAGE 146
17-42Z, 18-44Z 2004 Wiring Diagram Wiring Diagram 13 - 2 Demystification Guide
PAGE 147
2004 17-42Z, 18-44Z Starter Motor Circuit (ignition switch in “start) Spark Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 13 - 3
PAGE 148
17-42Z, 18-44Z 2004 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Battery Charge Circuit Circuits (ignition switch in “run”) PTO Clutch Circuit (ignition switch in “run”) 13 - 4 Demystification Guide
PAGE 149
2004 18-44ZX, 18-52ZX, 19-52ZX Information List Information List (2004) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . 14-3 Spark Circuits . . . . . . . . . . . . . . 14-3 & 14-4 Battery Charge Circuit . . . . . . . . . . . . . . 14-4 PTO Clutch Circuit . . . . . . . . . . . . . . . . .
PAGE 150
18-44ZX, 18-52ZX, 19-52ZX 2004 Wiring Diagram Wiring Diagram 14 - 2 Demystification Guide
PAGE 151
2004 18-44ZX, 18-52ZX, 19-52ZX Starter Motor Circuit (ignition switch in “start) Spark Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 14 - 3
PAGE 152
18-44ZX, 18-52ZX, 19-52ZX 2004 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Battery Charge Circuit (ignition switch in “run”) PTO Clutch Circuit (ignition switch in “run”) 14 - 4 Demystification Guide
PAGE 153
2005 Z480, Z440 (Int’l) Information List Information List (2005) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 15-2 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . 15-3 Spark Circuits . . . . . . . . . . . . . . 15-3 & 15-4 PTO Clutch Circuit . . . . . . . . . . . . . . . . .
PAGE 154
Z480, Z440 (Int’l) 2005 Wiring Diagram Wiring Diagram 15 - 2 Demystification Guide
PAGE 155
2005 Z480, Z440 (Int’l) Starter Motor Circuit (ignition switch in “start) Spark Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 15 - 3
PAGE 156
Z480, Z440 (Int’l) 2005 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y PTO Clutch Circuit Circuits (ignition switch in “run”) 15 - 4 Demystification Guide
PAGE 157
2005 ZX480, ZX525 (Int’l), ZX525 Information List Information List (2005) Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 16-2 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . 16-3 Spark Circuits . . . . . . . . . . . . . . 16-3 & 16-4 Battery Charge Circuit . . . . . . . . . . . . . . 16-4 PTO Clutch Circuit . . . . . . . . . . . . . . . . .
PAGE 158
ZX480, ZX525 (Int’l), ZX525 2005 Wiring Diagram Wiring Diagram 16 - 2 Demystification Guide
PAGE 159
2005 ZX480, ZX525 (Int’l), ZX525 Starter Motor Circuit (ignition switch in “start) Spark Circuit (ignition switch in “start”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 16 - 3
PAGE 160
ZX480, ZX525 (Int’l), ZX525 2005 Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Battery Charge Circuit Circuits (ignition switch in “run”) PTO Clutch Circuit (ignition switch in “run”) 16 - 4 Demystification Guide
PAGE 161
2004 2005 1332-G (Int’l) G132 (Int’l) Information List Information List (2004 - 2005) Wiring Diagrams . . . . . . . . . . . . . . . . . 17-2 & 17-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . 17-4 Spark Circuits . . . . . . . . . . . . . . . 17-4 - 17-7 Battery Charge Circuit . . . . . . . . . . . . . . 17-8 Bag Full Circuit . . . . . . . . . . . . . . . . . . .
PAGE 162
1332-G (Int’l) G132 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 17 - 2 Demystification Guide
PAGE 163
2004 2005 1332-G (Int’l) G132 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 17 - 3
PAGE 164
1332-G (Int’l) G132 (Int’l) 2004 2005 Starter Motor Circuit (ignition switch in “start) Spark Circuit Circuits (ignition switch in “start”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 17 - 4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 165
2004 2005 1332-G (Int’l) G132 (Int’l) Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Bk Bu Bn Green Grey Orange Pink Red Tan Violet White Yellow Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 17 - 5
PAGE 166
1332-G (Int’l) G132 (Int’l) 2004 2005 Spark Circuit (in reverse, PTO “on”) Spark Circuit (in reverse, override key switch activated) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 17 - 6 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 167
2004 2005 1332-G (Int’l) G132 (Int’l) Spark Circuit (in reverse, PTO “on”, override mode) Legend Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 17 - 7
PAGE 168
1332-G (Int’l) G132 (Int’l) 2004 2005 Battery Charge Circuit Bag Full Circuit (ignition switch in “run”) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 17 - 8 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 169
2004 2005 1332-H Int’l) H132 (Int’l) Information List Information List (2004 - 2005) Wiring Diagrams . . . . . . . . . . . . . . . . . . 18-2 & 18-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . 18-4 Spark Circuits . . . . . . . . . . . . . . . .18-4 - 18-7 Battery Charge Circuit . . . . . . . . . . . . . . 18-7 Bag Full Circuit . . . . . . . . . . . . . . . . . . . .
PAGE 170
1332-H (Int’l) H132 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 18 - 2 Demystification Guide
PAGE 171
2004 2005 1332-H Int’l) H132 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 18 - 3
PAGE 172
1332-H (Int’l) H132 (Int’l) 2004 2005 Starter Motor Circuit (ignition switch in “start) Spark Circuit Circuits (ignition switch in “start”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 18 - 4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 173
2004 2005 1332-H Int’l) H132 (Int’l) Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Bk Bu Bn Green Grey Orange Pink Red Tan Violet White Yellow Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 18 - 5
PAGE 174
1332-H (Int’l) H132 (Int’l) 2004 2005 Spark Circuit (in reverse, PTO “on”) Spark Circuit Circuits (in reverse, override key switch activated) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 18 - 6 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 175
2004 2005 1332-H Int’l) H132 (Int’l) Spark Circuit (in reverse, PTO “on”, override mode) Battery Charge Circuit Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y 18 - 7
PAGE 176
1332-H (Int’l) H132 (Int’l) 2004 2005 Bag Full Circuit (ignition switch in “run”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 18 - 8 Demystification Guide
PAGE 177
2004 2005 170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) Information List Information List (2004 - 2005) Wiring Diagrams . . . . . . . . . . . . . . . . . . 19-2 & 19-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . 19-4 Spark Circuits . . . . . . . . . . . . . . . . . . 19-4 & 19-5 Reverse Operating System Circuits .19-6 - 19-10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . 19-10 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 178
170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) 2004 2005 Wiring Diagram Wiring Diagram 19 - 2 Demystification Guide
PAGE 179
2004 2005 170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 19 - 3
PAGE 180
170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) 2004 2005 Starter Motor Circuit (ignition switch in “start”) Spark Circuit (ignition switch in “start” position) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 19 - 4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 181
2004 2005 170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 19 - 5
PAGE 182
170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 19 - 6 Demystification Guide
PAGE 183
2004 2005 170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Bk Bu Bn Gn Gy Or Pk Re T Violet White Yellow Vio W Y Circuits Demystification Guide 19 - 7
PAGE 184
170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 19 - 8 Demystification Guide
PAGE 185
2004 2005 170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 19 - 9
PAGE 186
170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) 2004 2005 Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Legend Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Charging Circuit (ignition switch in “run”) 19 - 10 Demystification Guide
PAGE 187
2004 2005 170-D (Int’l), 150-D (Int’l) DH210 (Int’l), DH210 (Int’l) Light Circuit (ignition switch in “run/lights”) Hourmeter Circuit (ignition switch in “run”) Bag Full Circuit (ignition switch in “run”) Legend Demystification Guide Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 19 - 11
PAGE 188
This page intentionally left blank 19 - 12 Demystification Guide
PAGE 189
2004 2005 190-D (Int’l) DH220 (Int’l) Information List Information List (2004 - 2005) Wiring Diagram . . . . . . . . . . . . . . . . . . . 20-2 & 20-3 Circuit Diagrams Starter Motor Circuit . . . . . . . . . . . . . . . . . . . . 20-4 Spark Circuits . . . . . . . . . . . . . . . . . . . . . . . . 20-4 Reverse Operating System Circuits . .20-6 - 20-10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . 20-10 Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 190
2004 2005 190-D (Int’l) DH220 (Int’l) Wiring Diagram Wiring Diagram 20 - 2 Demystification Guide
PAGE 191
2004 2005 190-D (Int’l) DH220 (Int’l) Wiring Diagram Wiring Diagram Demystification Guide 20 - 3
PAGE 192
2004 2005 190-D (Int’l) DH220 (Int’l) Starter Motor Circuit (ignition switch in “start”) Spark Circuit (ignition switch in “start” position) Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 20 - 4 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 193
2004 2005 190-D (Int’l) DH220 (Int’l) Spark Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 20 - 5
PAGE 194
2004 2005 190-D (Int’l) DH220 (Int’l) Reverse Operating System Circuit (PTO “off”, in forward) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 20 - 6 Demystification Guide
PAGE 195
2004 2005 190-D (Int’l) DH220 (Int’l) Reverse Operating System Circuit (PTO “on”, in forward) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 20 - 7
PAGE 196
2004 2005 190-D (Int’l) DH220 (Int’l) Reverse Operating System Circuit (PTO “on”, in reverse) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 20 - 8 Demystification Guide
PAGE 197
2004 2005 190-D (Int’l) DH220 (Int’l) Reverse Operating System Circuit (Override key switch “activated”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Demystification Guide 20 - 9
PAGE 198
2004 2005 190-D (Int’l) DH220 (Int’l) Reverse Operating System Circuit (PTO “on”, in reverse, override mode) Circuits Charging Circuit (ignition switch in “run”) Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 20 - 10 Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide
PAGE 199
2004 2005 190-D (Int’l) DH220 (Int’l) Light Circuit Hourmeter Circuit Bag Full Circuit Circuits Legend Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Demystification Guide 20 - 11
PAGE 200
4 2005 190-D (Int’l) DH220 (Int’l) Cruise Control Circuit (ignition switch in “run”) Legend Bk Bu Bn Gn Gy Or Pk Re T Vio W Y Circuits Black Blue Brown Green Grey Orange Pink Red Tan Violet White Yellow 20 - 12 Demystification Guide