ELECTRICAL SERVICE MANUAL WHEEL HORSE
Contents
1. PEDAL E INTERLOCK I SWITCH BATTERY HOUR METER vit OPTIONAL ON L _ B 115 B 165 YELLOW KILL _ I RELAY gt LIGHT SWITCH W A B OPTIONAL B 82 B 112 z H INTERLOCK Q BLUE SWITCH a i i FUSE 6 AMP L 4 D C ACCESSORIES A D C ACCESSORIES RECTIFIER _ I L BLACK IGNITION L I BROWN x SEAT BLUE START O SWITCH S V BATTERY lt ORANGE BATTERY LF IGNITION m B V Y RED OE THER TWIN CYLINDER ENGINE SHOWN CIRCUIT CHARGING LW 2 S T gT 5 GPHONAL ON B 82 8 112 WIRING DIAGRAM 1980 81 B SERIES Q SWITCH ELECTRICAL CONN 4 4 POSITION BETWEEN TERMINALS OF NONE MAGNETO 5 RUN PLUG START 5 I SPARK I PLUG STARTER I ALT E A C 2 E OUTPUT 2 FUSE 20 ALT el D C OUTPUT BLACK PEDAL s INTERLOCK SWITCH 5 BATTERY AJ Le 1 a I HOUR METER 1 OPTIONAL ON L _ B 115 165 l YELLOW g OPTIONAL ON 82 112 ol zl PTO INTERLOCK W BLUE SWITCH L FUSE 6 4 1 m a BLUE j TW START S EN BATTERY ORANGE BATTERY XO L IGNITION 2 RED TWIN CYLINDER ENGINE SHOW D C ACCESSORIES A D C ACCESSORIES BL2. START B S HEADLIGHTS SOLENOID PEDAL INTERLOCK SWITCH ra ALT A C r OUTPUT BATTERY I N OUTPUT CONTACTS CLOSED WHEN 5 SEAT UNOCCUPIED WT SWITCH LIGHT SWITCH N O CONTACTS CIRCUIT RUN WITH PTO ENGAGED CLOSED WHEN N C CONTACTS CLOSED WHEN HOUR METER PTO DISENGAGED FUSE 6 _ SEAT SWITCH KILL CIRCUIT PTO ENGAGED WIRE 5 D C ACCESSORIES D C ACCESSORIES Bu BATTERY B A RECTIFIER BATTERY FUSE 15 AMP WIRE 4 START S MAGNETO GROUND G 5 START UNUSED TWIN CYLINDER ENGINE SHOWN WIRE 1 RECTIFIER R WIRE 3 MAGNETO Ne 1 5 06 2 2 2 WIRING DIAGRAM 1982 83 C Series COIL 9 BREAKER POINTS HEADLIGHTS SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS P s OFF NONE O r RUN B R I A STARTER START B R I S I HOUR METER OPTIONAL e serius N 1 REGULATOR FUSE RECTIFIER 6 AMP PEDAL INTERLOCK SWITCH BATTERY ele a 21 Zo al FUSE sig H LIGHT SWITCH 15 AMP AMMETER gt peg B SC AMD W FUSE eC WIRE 2 SEAT MOD TAILLIGHTS SWITCH A e SEAT SWITCH C 175 ONLY Ez WIRE 43 IGNIT
3. zu TEN TES ci a I L FUSE 6 AMP dq pee D C ACCESSORIES D C ACCESSORIES BLACK RECTIFIER V x SEAT BLUE START SWITCH S BATTERY ORANGE BATTERY Oy IGNITION VY RED TWIN CYLINDER ENGINE SHOWN CIRCUIT OFF 2 61 STI 91 2 OPTIONAL ON B 82 B 112 WIRING DIAGRAM 1980 81 B SERIES SWITCH ELECTRICAL CONN dh POSITION BETWEEN TERMINALS 4 5 r START B R I S ALT EEE OUTPUT FUSE 20 ALT NA D C OUTPUT K PEDAL INTERLOCK SWITCH BATTERY HOUR METER OPTIONAL ON _ B 115 B 165 YELLOW KILL _ i RELAY OPTIONAL ON B 82 B 112 al 2 ci O I i a L FUSE 6 AMP 4L 4 D C ACCESSORIES A D C ACCESSORIES RECTIFIER BLACK IGNITION I BROWN SEAT T 1 SWITCH BLUE START 5 oj IGNITION NN RED TWIN CYLINDER ENGINE SHOWN CIRCUIT START ORANGE BATTERY B 06 LT 9 4 OPTIONAL ON 82 112 WIRING DIAGRAM 1980 81 B SERIES MAGNETO peel iudi irn cc SPARK i ol PLUG I SPARK PLUG STARTER I ALT OUTPUT OLENOIDg FUSE 20 AMP ALT D C OUTPUT BLACK u E
4. E 25 AMP SOLENOID M FUSE oc REGULATOR lt RECTIFIER PEDAL a a INTERLOCK SWITCH BATTERY tc ORANGE N D P ON gt 49 2 cr FUSE 5 PTO 20 ORANGE _ INTERLOCK E RED SWITCH 5 ku l ACCESSORIES A ACCESSORIES RECTIFIER N 59 BATTERY k SWITCH CIRCUIT CHARGING SWITCH QC gc 874 WIRING DIAGRAM 1978 81 C SERIES HEADLIGHTS COIL BREAKER POINTS SWITCH ELECTRICAL CONN Vr Qu POSITION BETWEEN TERMINALS or NONE ot RUN B R IrA 4 3 START B R 1 S I HOUR METER OPTIONAL i REGULATOR RECTIFIER A 14 INTERLOCK m F SWITCH l FUSE I 6 AMP i i Ha Ar 74 1 YELLOW z rood LIGHT L As LS m TAILLIGHTS _ _ INTERLOCK SWITCH BLACK IGNITION i NER ACCESSORIES RED START RECTIFIER 5 7 5 LT GREEN BATTERY CN BATTERY IGNITION ORANGE noe SWITCH CIRCUIT RUN WITH PTO ENGAGED SWITCH 66 92 8 4 WIRING DIAGRAM 1982 A 51 RR 532 RECOIL START RIDER 7 enmon SWITCH SEAT SWITCH MAGNETO PTO INTERLOCK SWITCH TRANSMISSION INTERLOCK SWITCH NOTE INTERLOCK SWITCHES ARE THE NORMALLY CLOSED NC TYPE SWITCHES ARE i ELECTRICALLY OPEN WHEN THE SWITCH BUTTON IS DEPRESSED ENGINE 1983 A SERIES SWITCH POSI
5. 1 ba 3 RECTIFIER START dd S S START LT GREEN BATTERY BATTERY B IGNITION GNITION SWITCH CIRCUIT OFF SEAT SWITCH ORANGE RECTIFIER R 96 314 WIRING DIAGRAM 1978 81 C SERIES TAILLIGHTS BLACK IGNITION RED START S LT GREEN BATTERY B ORANGE RECTIFIER R ACCESSORIES A HEADLIGHTS COIL BREAKER POINTS Q a h i I Dc I i 5 IL i SOLENOID KJ HOUR METER OPTIONAL i REGULATOR l RECTIFIER PEDAL INTERLOCK SWITCH l I 1 FUSE 6 AMP ORANGE I I ap au 577 YELLOW i puse AMP d 5 sues PTO INTERLOCK SWITCH Mii o ACCESSORIES RECTIFIER IGNITION SWITCH CIRCUIT START 2 IGNITION LIGHT GREEN lt START BATTERY SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS RUN B R I A START B R I S RED SEAT SWITCH 6 vc 2 WIRING DIAGRAM 1978 81 C SERIES HEADLIGHTS HOUR METER OPTIONAL s s TAILLIGHTS BLACK IGNITION RED START S LT GREEN BATTERY B ORANGE RECTIFIER R COIL epo BREAKER POINTS Ape SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS RUN X B R I A START B R 1 S ENGINE STARTER
6. After battery has been placed in service add only water Do not add acid PROCEDURE FOR TESTING BATTERIES STEP 1 Visual Inspection Check for obvious damage such as cracked or broken case that shows loss of electrolyte terminal damage Obvious Damage No Obvious Damage 1 UE Replace Battery Check electrolyte level Below top of plates more cells Electrolyte level above top of plates in all cells Proceed Step 2 Add water to proper level Charge for 15 min 15 25 amps with non safety vent caps removed Proceed to Step 2 NAR STEP 2 HYDROMETER TEST i 50 points or more variation between Less than 50 points highest and lowest cell variation between highest and lowest cell Recharge battery If 50 points variation persists replace battery Specific Gravity Specific Gravity Below 1 225 Above 1 225 Battery OK Charge until all cells are at least 1 225 if unable to obtain Specific Gravity 1 225 in all cells replace battery 25 SECTION II CHARGING SYSTEM de ALTERNATOR CHARGING SYSTEMS KOHLER ONAN ENGINES The alternator system provides electrical energy to charge the battery and for operation of accessory circuits A solid state rectifier regulator is mounted externally on the engine or on the equipment powered by the engine The system also includes an alternator stator and permanent magnet ring inside the
7. CIRCUIT TRANS IN GEAR 52 N 1983 A SERIES SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS G M A SWITCH CASE GROUNDED B R A BATTERY B START S TAN RED ACCESSORIES A UNUSED RECTIFIER R WHITE MAGNETO M BLUE IGNITIO SWITCH TRANSMISSION SEAT SWITCH N C CONTACTS CONTACTS CLOSED WHEN BLACK TRANSMISSION CONTACTS CLOSED WHEN IN NEUTRAL SEAT UNOCCUPIED ORANGE PTO INTERLOCK ORANGE SWITCH CONTACTS N C CONTACTS CLOSED WHEN CLOSED WHEN PTO DISENGAGED PTO ENGAGED BLUE REL PURPLE SOLENOID BLUE _ Nes ALTERNATOR 4 MAGNETO ALL WIRES BLACK WITH COLOR DC OUTPUT STRIPE AS SHOWN ENGINE CHARGING SYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION WHEEL HORSE WHEEL TH oie CHARGING CIRCUIT 55 7 HEADLIGHTS WIRING DIAGRAM 1982 83 B LT GT SERIES B Series Shown Basically the Same for LT amp GT Series o SWITCH ELECTRICAL CONN S POSITION BETWEEN TERMINALS 2 ul CASE GROUNDED 9 B R A r S z 2 OUTPUT ALT D C OYTEUT CONTACTS CLOSED WHEN SEAT UNOCCUPIED LIGHT SWITCH ERLOCK CONTACTS f CLOSED WHEN eco WIEN PTO DISENGAGE
8. or mechanical problem 2 no spark check breaker points and magneto 45 Step 3 If the engine started with the magneto wire removed we have to assume we are having problems in our kill relay circuit First oN connect a test light or meter to the black wire located on the ignition switch I terminal Try starting the unit If we show voltage continue to Step 4 Fig 43 Step 4 Inspect the connections to the kill relay and PTO interlock switch Make sure the kill relay has a good ground Fig 44 46 Step 5 Connect test light or meter to the kill relay s terminal violet wire try starting the unit if you show current replace the kill relay switch 47 Product information and specifications are shown herein as of the time of printing Wheel Horse Products Inc r serves the right to change product specifications designs and standard equipment without notice and without incurring obligation WHEEL HORSE WORK HORSE lawn amp gardentractors by Wheel Horse P
9. ACK p D RECTIFIER BLUE START SEAT SWITCH CIRCUIT RUN WITH PTO ENGAGED o 0 67 6T 9 4 WIRING DIAGRAM 1980 82 A 111 1982 RR 832 ELECTRIC START RIDER UIS START RED E M GREEN GROUND lt G RECTIFIER R E ot ACCESSORIES A UNUSED UNUSED GREEN MAGNETO M POSITION BETWEEN TERMINALS or G Mea _ RUN ernea 8 5 FUSE 20A INTERLOCK MODULE O INTERLOCK SWITCH TRANSMISSION INTERLOCK SWITCH YELLOW ENGINE CHARGING SYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION BATTERY YELLOW SOLENOID RED ALT D C OUTPUT STARTER CIRCUIT OFF GREEN MAGNETO 02 WIRING DIAGRAM 1980 82 A 111 1982 RR 832 ELECTRIC START RIDER START EDS M GREEN GROUND IGNITION lt SWITCH 9 G G RECTIFIER lt N ACCESSORIES A WHITE UNUSED UNUSED GREEN MAGNETO NEGATIVE POSITIVE M SWITCH BROWN SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS BROWN Su ER RUN 3 START 28 YELLOW z FUSE 20A START ES Hs H PTO INTERLOCK SWITCH gt 9 BROWN TRANSMISSION INTERLOCK SWITCH ENGINE CHARGING SYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION e a BATTERY RED ALT D C OUTP
10. CCUPIED TAN PTO INTERLOCK SWITCH N C CONTACTS CLOSED WHEN PTO ENGAGED N O CONTACTS CLOSED WHEN PTO DISENGAGED PURPLE 9 amp SOLENOID BLUE STARTER BLUE ALL WIRES BLACK WITH COLOR STRIPE AS SHOWN WHITE ALTERNATOR MAGNETO DC OUTPUT ENGINE CHARGING SYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION WHEEL HORSE lawn amp garden tractors KILL CIRCUIT PTO ENGAGED 1983 A SERIES ERE REST pel SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS BATTERY B START S TAN RED G M A RECTIFIER R ACCESSORIES A WHITE UNUSED SWITCH CASE GROUNDED RUN B R A MAGNETO M GROUND BLACK BLUE START B S WHITE R M B IGNITION SWITCH TAN TRANSMISSION INTERLOCK SWITCH CONTACTS CLOSED WHEN TRANSMISSION IN NEUTRAL N C CONTACTS CLOSED WHEN TRANSMISSION IN GEAR CONTACTS CLOSED WHEN SEAT UNOCCUPIED ORANGE TAN PTO INTERLOCK SWITCH N O CONTACTS CLOSED WHEN PTO DISENGAGED N C CONTACTS CLOSED WHEN PTO ENGAGED FUSE 15 STARTER WHITE ALTERNATOR MAGNETO DC OUTPUT CHARGING SYSTEM 15 NOT DESIGNED FOR ACCESSORY OPERATION ALL WIRES BLACK WITH COLOR STRIPE AS SHOWN WHEEL HORSE amp tractors KILL
11. D HOUR METER PTO ENGAGED OPTIONAL FUSE G AMP WIRE 5 D C ACCESSORIES D C ACCESSORIES BATTERY B A IHE A RECTIFIER BATTERY FUSE 15 AMP START S j 3V MAGNETO GROUND G 5 START UNUSED TWIN CYLINDER ENGINE SHOWN WIRE 1 RECTIFIER R WIRE 3 MAGNETO CIRCUIT OFF 6 ST HEADLIGHTS ALT A C OUTPUT 4 LIGHT SWITCH HOUR METER OPTIONAL J WIRING DIAGRAM 1982 83 B LT GT SERIES B Series Shown Basically the Same for LT amp GT Series SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS MAGNETO 5 z I G M A 2 SWITCH CASE GROUNDED D B R A il 590 8 a USE zo BATTERY ALT i D C TPUT CONTACTS CLOSED WHEN SEAT po SEAT UNOCCUPIED SWITCH PTO INTERLOCK SWITCH N C CONTACTS CLOSED WHEN PTO ENGAGED N O CONTACTS CLOSED WHEN i PTO DISENGAGED FUSE 6 AMP WIRE 5 D C ACCESSORIES D C ACCESSORIES BATTERY T AMP GE E A RECTIFIER zy BATTERY FUSE 15 START S MAGNETO GROUND START UNUSED TWIN CYLINDER ENGINE SHOWN WIRE 1 RECTIFIER R WIRE 3 MAGNETO CIRCUIT START WIRING DIAGRAM 1982 83 B LT GT SERIES B Series Shown Basically the Same for LT amp GT Series SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS SWITCH CASE GROUNDED RUN B RHA
12. ELECTRICAL SERVICE MANUAL WHEEL HORSE Table of Contents Page 1 of 1 INTRODUCTION SECTION BATTERY HOW IT WORKS HOW TO USE A HYDROMETER HOW TO PREPARE A DRY CHARGED BATTERY FOR SERVICE PROCEDURE FOR TESTING BATTERIES SECTION II CHARGING SYSTEM ALTERNATOR CHARGING SYSTEMS KOHLER ONAN ENGINES BRIGGS amp STRATTON ALTERNATOR SYSTEMS TECUMSEH 7 AMP REGULATED CHARGING SYSTEM LT 1032 SECTION COMPONENTS SECTION IV WIRING DIAGRAMS SECTION V TROUBLE SHOOTING EXAMPLES ELECTRICAL SERVICE MANUAL o WHEEL H lawn amp garden INTRODUCTION This manual covers A and B Series 1980 83 and C Series 1978 83 Tractors For 1984 and later tractors refer to Section 18 in Parts and Service manuals for electrical components and wiring diagrams CONTENTS SECTION BATTERY 1 5 How It Works EE 1 How To Use a Hydrometer MUI 2 How To Prepare a Dry Charged Battery 3 Procedure For Testing Batteries 4 SECTION Il CHARGING SYSTEM 6 10 Alternator Charging Systems Kohler pe act 6 Onan Engines SECTION Ili COMPONENTS 11 16 SECTION IV WIRING DIAGRAMS 17 40 SECTION V TROUBLE SHOOTING EXAMPLES 4 47 SECTION I BATTERY HOW IT WORKS A battery produces electricity as the result of a chemical reaction
13. ION 1 IGNITION ACCESSORIES Se BATTERY WIRE 4 START S p ea SEAT SWITCH SWITCH WIRE 1 ACCESSORIES R CIRCUIT OFF WIRING DIAGRAM 1982 83 C Series COIL EEE BREAKER POINTS HEADLIGHTS SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS Y Y poem OFF NON B R i S START B R I S HOUR METER I OPTIONAL i SOLENOID 1 REGULATOR FUSE RECTIFIER E 6 AMP PEDAL oie INTERLOCK P c SWITCH BATTERY i 3 A EMI RIGHT SWITCH 1 Boo AMMETER gt u 25 2 2 Rl FUSE WIRE 2 SEAT TAILLIGHTS SWITCH A C 175 ONLY WIRE 3 IGNITION 1 WIRE 4 START S WIRE 5 BATTERY 8 NEN IGNITION WIRE 1 ACCESSORIES R CIRCUIT START IGNITION 8 ACCESSORIES 9 BATTERY SEAT SWITCH START SEAT SWITCH V eS T ce 2 D WIRING DIAGRAM 1982 83 C Series COIL 9 BREAKER POINTS HEADLIGHTS SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS TRUN START HOUR OPTIONAL i SOLENOID 1 REGULATOR FUSE RECTIFIER 6 AMP PEDAL INTERLOCK SWITCH BATTERY i 21 Zo 3l zi 1 LIGHT SWITCH oo AMMETER __ E ug Sz d _ scu 25 z TWIN CYLINDER FUSE
14. TION BATTERY B START 5 TAN RED ELECTRICAL CONN BETWEEN TERMINALS RECTIFIER R ACCESSORIES A UNUSED SWITCH CASE GROUNDED B R A MAGNETO M BLUE IGNITION SWITCH TRANSMISSION INTERLOCK SWITCH N C CONTACTS BLACK SEE EN CLOSED WHEN TRANSMISSION CONTACTS CLOSED WH TRANSMISSION IN GEAR SEAT UNOCCUPIED IN NEUTRAL ORANGE lt ORANGE PTO INTERLOCK SWITCH N O CONTACTS CLOSED WHEN PTO DISENGAGED N C CONTACTS CLOSED WHEN PTO ENGAGED i RED FUSE 15 AMP SOLENOID STARTER WHITE ALTERNATOR MAGNETO DC OUTPUT ENGINE CHARGING SYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION ALL WIRES BLACK WITH COLOR STRIPE AS SHOWN WHEEL HORSE lawn amp garden tractors START CIRCUIT 10 1983 A SERIES SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS GtMtA SWITCH CASE GROUNDED BATTERY B RED START 5 TAN ACCESSORIES A UNUSED MAGNETO M BLUE IGNITION SWITCH TRANSMISSION INTERLOCK SWITCH N O CONTACTS CLOSED WHEN TRANSMISSION IN NEUTRAL SEAT SWITCH N C CONTACTS CLOSED WHEN TRANSMISSION IN GEAR ORANGE ORANGE BLACK CONTACTS CLOSED WHEN SEAT UNO
15. The sulfuric acid in the electrolyte combines with the positive and negative plates to form a new chemical compound called lead sulfate The amount of sulfuric acid consumed by the plates is pro portional to the amount of electricity produced Therefore the more electricity produced the less sulfuric acid remains in the electrolyte The gradual weakening of the electrolyte lets us measure with a hydrometer the amount of unused acid in the water and thus how much potential energy is left FULLY CHARGED GOING DOWN Acid in water gives electrolyte As battery discharges acid specific gravity of 1 265 begins to lodge in plates Specific gravity drops END LIFE DISCHARGED Battery half discharged Acid almost entirely in More acid in plates less in plates leaving weak electro electrolyte Starting lyte behind Specific gravity i i lower almost that of water failure likely i BATTERY CHEMISTRY HOW TO USE A HYDROMETER The hydrometer is a direct reading instrument used to measure the specific gravity Spg In reading a hydrometer the barrel must be held vertically To apply the test it is only necessary to draw a sample of electrolyte from a cell and jiggle the hydrometer to be sure the indicator is floating free and record the indicated Spg DO NOT MAINTAIN LIQUID LEVEL IN THE HYDROMETER BY SQUEEZING THE BULB AS THIS GIVES INACCURATE READINGS The float should not touch any part of the barrel A fu
16. UT GREEN MAGNETO CIRCUIT START 1 0 12 814 WIRING DIAGRAM 1980 82 A 111 1982 RR 832 ELECTRIC START RIDER BRUN SAMT ear M GREEN SEAT SWITCH B RED GROUND S BROWN RECTIFIER T UNUSED USED GREEN MIETEN ELECTRICAL CONN BETWEEN TERMINALS SWITCH POSITION F BRA stant Rep Aa lt EU lt INTERLOCK l SWITCH ul k gt 2 i z x Bs E PH O BROWN ENGINE CHARGING SYSTEM IS NOT DESIGNED FOR ACCESSORY OPERATION INTERLOCK SWITCH BATTERY m RED ALT D C OUTPUT CIRCUIT CHARGING GREEN MAGNETO 2 2 D WIRING DIAGRAM 1978 81 C SERIES HEADLIGHTS COIL Hor BREAKER POINTS SWITCH ELECTRICAL CONN b AE POSITION BETWEEN TERMINALS ENGINE NON _ RUN BrR IrA 4 4 r START B R I S I ST STARTER I L4 25 i 1 SOLENOID FUSE HOUR METER OPTIONAL RED x REGULATOR lt I RECTIFIER PEDAL z INTERLOCK j 1 SWITCH BATTERY 1 eu 1 FUSE i qi 6 AMP i ORANGE I I t _ 1 2 L AD E fA I 1 cum YELLOW FUSE 2505 sm TAILLIGHTS gt
17. WIRE 42 SEAT MODELS TAILLIGHTS SWITCH A C 175 ONLY IGNITION WIRE 3 IGNITION I ACCESSORIES VM BATTERY WIRE 4 START S T SEAT SWITCH SEAT WIRE 5 BATTERY B NN IGNITION START S Iru WIRE 1 ACCESSORIES R CIRCUIT CHARGING 07 dld 2 WIRING DIAGRAM 1982 83 C Series COIL BREAKER POINTS HEADLIGHTS SWITCH ELECTRICAL CONN POSITION BETWEEN TERMINALS RUN B R I A B R I S START HOUR METER OPTIONAL SOLENOID 1 REGULATOR FUSE RECTIFIER 6 AMP r PEDAL INTERLOCK m SWITCH I LA n p s Ae e LIGHT SWITCH gt ug p pec NE o 25 AMP t s z IN FUSE WIRE 42 SEAT n TAILLIGHTS SWITCH A K C 175 ONLY WIRE 3 IGNITION I IGNITION ACCESSORIES Re WIRE 4 START S a SEAT SWITCH WIRE 5 BATTERY B SA IGNITION START SWITCH WIRE 1 ACCESSORIES R CIRCUIT RUN WITH PTO ENGAGED W SEAT SWITCH 4 2 PROBLEM 1 SECTION V TROUBLE SHOOTING EXAMPLES Customer Complaint Every time he uses his C 85 1981 tractor it won t start He has to put jumper cables on the parter and jump start the tractor Fig 34 STEP 1 Visually Inspect All Connections A Blown Fuse B Loose Broken Wires Fig 35 s Step 2 Check the Battery A Visua
18. connector plug Current for lights is available at the second terminal of this plug The plug is polarized to prevent improper connections The return circuit for both alternators is through ground to the engine block 1 Checking Dual Circuit Alternator A Testing Alternator Charging Output Install an ammeter in Series with charging lead Start engine Ammeter should indicate output The charge range is dependent upon the condition of the battery ammeter shows no charge or shows a discharge test stator and diode ENGINE RUNNING 3000 RPM REI Jl lt Testing for Short in Alternator SyS rem Disconnect charging lead from battery and connect charge lead test lamp in Series between battery and charge lead DO NOT START ENGINE Test lamp should not light If it does light stator charging lead is shorted or diode is defective Disconnect charge lead connector at alternator If test light does not go out the wire leading back to the battery is shorted If light goes out diode is defective See section for testing diode Testing Diode Disconnect charge lead plug from charge lead Using multimeter set on resistance scale check diode by attach ing one meter lead to red stator lead wire a needle may be used to pierce stator lead wire insulation Touch the other multimeter lead to diode pin in plastic connector then reverse meter leads The meter should show continuity in
19. fly wheel With the exception of the magnet ring which revolves around the stator these systems have no moving parts and are therefore virtually service free the only required service is an occasional check to make sure that all electrical connec tions are tight and that wires are not frayed or cracked co m AC ALTERNATOR OUTPUT Li SOLENOID i a 1 ooo ooo BATTERY Ri E REGULATOR RECTIFIER eee IGNITION SWITCH TROUBLE SHOOTING 15 AMP SYSTEM TEST WITH ENGINE RUNNING AT 3400 RPM NO LOAD Condition No Charge to Battery Test A With B cable connected check B at terminal on rectifier regulator to ground with DC volt meter If 13 8 volts or higher place minimum load of 5 amps on battery to reduce voltage 1 If charge rate increases A 2 If charge rate does not increase Test B Unplug leads at rectifier regulator connect VOM Multimeter across AC leads check AC voltage 1 If less than 28 volts B 2 If more than 28 volts Condition Battery Continuously Charges at High Rate Test C Check B to ground with DC volt meter C l If over 14 7 volts 2 If under 14 7 Possible Fault Remedy 1 Indicates alternator System OK battery was fully charged A 2 Check for defective stator or rectifier regulator Test B Possible Fault Remedy 1 Defective stator replace B 2 Defective rectif
20. ied To Start Engine On Electric Start A amp RR Series Fig 10 PTO SWITCH B SERIES 1982 83 A SERIES 1980 81 di MPO LT GT SERIES 1982 83 BER A SERIES 1983 RRES 1962 EN C SERIES 1982 83 eom SERIES 198081 C SERIES 1978 81 N O M BLACK BOTTOM EE NARROW TERMINALS NC WHITE BOTTOM FUNCTION Prevents Engine From Starting With PTO Engaged Fig 11 ELT PEDAL SWITCH B SERIES 1981 C SERIES 1981 C SERIES 1981 B C SERIES 1982 83 amp SPEED AUTOMATIC FUNCTION Prevents Engine From Starting When Pedal 15 Released SECTION IV WIRING DIAGRAMS WIRING DIAGRAM 1981 A 51 and A 81R RECOIL START RIDER RED WHITE IGNITION SWITCH INTERLOCK MODULE YELLOW TRANSMISSION INTERLOCK SWITCH Fig 14 17 8I 9 4 OPTIONAL ON B 82 B 112 WIRING DIAGRAM 1980 81 B SERIES SWITCH ELECTRICAL CONN 4 POSITION BETWEEN TERMINALS OFF NONE MAGNETO RUN B R lI A I o START B R I S 1 PANK START I PLUG STARTER I AT PN FUSE 20 AMP al OUTPUT SOLENOID C ALT BLACK tu I OUTPUT 5 gt I uM lt PEDAL INTERLOCK SWITCH 5 HOUR METER N P OPTIONAL ON L 115 B 165 YELLOW i KILL _ RELAY OPTIONAL ON v B 82 B 112
21. ier regulator replace with new unit Possible Fault Remedy C l Rectifier regulator not functioning properly Replace C 2 Alternator system OK Battery unable to hold charge Check speci fic gravity of battery Replace if necessary Turn lights on or simulate load by placing a 2 5 OHM 100 Watt resistor across battery terminals Briggs amp Stratton Alternator Systems A amp RR Series electric start engines have a single DC output alternator used for battery charging only The dual circuit alternator used on amp GT Series and some C Series tractors is actually two separate alternators A single ring of magnets inside the flywheel supplies the magnetic field for both of them One alternator uses a solid state rectifier and provides battery charging current The other alternator feeds alternating current directly to the lights Since the two are electrically inde pendent use of the lights does not reduce the charge entering the battery Current for the lights is available as long as the engine is running The output depends upon the engine speed so the brightness of the light changes with the engine speed The current from the battery charging alternator is unregulated and is rated at 3 amps The output rises from 2 amps at 2400 RPM to 3 amps at 3600 RPM and uses less than 2 of a horsepower There is one external connection The battery charging current connection is made through one terminal of a two
22. l inspection B Charge the battery C Hydrometer test Fig 36 Step 3 If battery checks out OK and tractor will now start with fully charged battery check the following A Start unit and check charging systems 1 Ammeter for Charge Step 4 If no charge indicated at the Ammeter check voltage at battery terminals with the engine running at 3 4 to full throttle D C voltage should show increase to approximately 14 volts D C Fig 38 Step 5 No voltage increase unplug the rectifier regulator with the meter set for A C current the meter should read around 28 volts AC if less than 28 volts A C Defective stator replace if more than 28 volts A C Defective rectifier regulator replace with new unit u W Fig 39 4 PROBLEM 2 Customer Complaint 1981 GT 2500 Anniversary Special the engine cranks over but won t start After some investigation you find the battery is in good condition Fig 40 Step 1 Always check the obvious Blown Fuse B Loose or Broken Wire Connection Fig 41 44 Step 2 the magneto wire from the engine and try starting f A If the unit starts continue on to Step 3 NOTE Remember you will have to reconnect the magneto wire to kill the engine If it doesn t start the problem is with the engine not the wiring harness 1 Check the engine for spark if spark there is some carburetor
23. ll charge battery equals 1 265 specific gravity Spg unless otherwise specified Replace battery if there is 50 0 050 or more points variation between highest and lowest cell Spg varies with temperature so for correct readings the electrolyte temperature should be at 60 F or higher High float left means high Correct method of specific gravity Low float reading hydrometer means low specific gravity Eye on level with liquid surface Dis regard curvature of liquid against glass parts Do not tilt hydrometer while reading Keep float vertical READING HYDROMETER HOW TO PREPARE A DRY CHARGED BATTERY FOR SERVICE A Remove vent caps Remove or destroy any sealing device which may have been used to close or restrict the vent openings Fill each cell of the battery with 1 265 specific gravity electrolyte to the proper level Note Temperature of battery and electrolyte at time of filling should be above 60 Never fill battery in _the vehicle Fill with electrolyte until it becomes visible at bottom of filling tube Allow battery to stand for 15 at room temperature before charging Place on charger for 10 minutes at a 15 amp rate If a fast rate charger is not available charge for one half hour at a 7 amp rate After charging check acid levels in all cells and fill with acid to the top of split ring ledge Install battery in the vehicle Remember always connect the negative terminal last
24. one direction only If meter shows a reading in both directions or does not show continuity in either direction the diode is defective and must be replaced Testing Stator Charging Coils Remove blower housing flywheel etc and examine red lead wire for cuts damaged insulation or obvious short on leads if bare spots cannot be repaired replace stator Stator should also be checked for continuity as follows Use multimeter set on resistance scale Touch one meter lead to stator laminations touch the other meter lead to red stator charge lead wire Pierce red wire insulation with a needle to insure meter lead contact Meter should show continuity Next remove screw which attaches stator ground wires to stator laminations Be certain ground wire does not touch laminations and repeat previous test Meter should not show continuity If meter does not show continuity in first test or shows continuity during second test stator is defective and must be replaced Note Discoloration of stator coils does not mean stator is defective A shorted diode will pass battery current through stator coils to ground which discolors coils due to heat Replacing diode would normally restore alternator without replacing stator 9 Tecumseh 7 Amp Regulated Charging System LT 1032 The Tecumseh 7 amp charging system is similar to the 15 amp system used on Kohler and Onan engines Follow the test procedure for these engines with the following exce
25. ptions Test B AC voltage value should be at least 21 VAC The blower shroud must be removed the rectifier regulator moved to place it outside the housing and the blower housing reinstalled to make this test Test C Do not perform this test If AC voltage check is OK and battery is not being charged replace the rectifier regulator 10 SECTION 111 COMPONENTS B 8 C SERIES 1979 81 A 81E A 111 ee eee B C SERIES 1982 83 LT GT SERIES 1982 83 FUNCTION Protects Wires From Heat When a Electric Short or Overload lt Occurs Fig 1 FUNCTION Rectifies A C To D C Current For Charging Battery Regulates Charging Current To Prevent Overcharging Fig 2 Nux Fig 3 LIGHT SWITCH AND FUSE rcuit Wiring FUNCTION Protects Pon Short or Fig 4 12 INTERLOCK MODULE A B1E A 111 1980 82 FUNCTION Stops Engine When Operator Vacates Seat With iy ah SE s Is Fig 5 7 ACTUATED Fig 7 Normally open N O Switch Fig 9 Normally closed N C Switch 13 SEAT SWITCH B SERIES 1980 81 A SERIES 1980 81 A SERIES 1983 B SERIES 1982 83 LT GT SERIES 1982 83 NIC SILVER B BLACK KNOB RED KNOB FUNCTION Stops Engine When Seat Is Vacated With PTO Engaged Seat Must Be Occup
Download Pdf Manuals
Related Search