TANK - S ELECTRICAL SYSTEM

TANK - S ELECTRICAL SYSTEM Mode Year 2009

TANK - S ELECTRICAL SYSTEM TABLE OF CONTENTS: PAGE 3 ) PIMARY WIRE COLOR DESIGNATION: Red. Green. Orange. Yeow. Bue. PRIMARY COMPONENTS: Battery. Fuses. Seat Switch. PAGE 4 ). PRIMARY COMPONENTS: cont. Ignition Switch. Reay Switch. PAGE 5 ). PRIMARY COMPONENTS: cont. Brake Switch. PTO Switch. Wire Harness. PAGE 6 ). CIRCUIT ROUTING: PAGE 7 ). WIRE DIAGRAM: PAGE 8 ). DIAGNOSTICS: Prevention. Symptom / Diagnostics. 2 of 8

PIMARY WIRE COLOR DESIGNATION: RED or Combination as Red w/ Back Stripe. POSITIVE (+) power suppy. Circuit runs from battery, thru a fuse, to the ignition switch for distribution to components as Starter Soenoid (orange wire), Reays and Charging System. GREEN: NEGATIVE (-) main Ground Circuit. Main Circuit runs from Battery to Engine Bock and to components requiring constant ground. ORANGE or Combination as Orange w/ Back or White Stripe. POSITIVE (+) power suppy to activate the engine starter soenoid. Circuit begins at the ignition switch and is tied directy into safety switches before ending at the starter soenoid. Exampe, when the brake is engaged, the brake switch makes the orange wire circuit and aows the current to fow to the next component. When the brake is off the circuit is broken within the switch and the current cannot fow to the next component, therefore the engine starter wi not engage. YELLOW or Combination as Yeow w/ Back or White Stripe. NEGATIVE (-) circuit ground to engine magneto. Circuit begins at the ignition switch and is tied directy into safety switches and reays before ending at the engine. This circuit provides a means to ground the engine magneto which in turn does not aow the engine to provide spark to the spark pugs. BLUE or Other Coors: These are secondary circuits providing current to components and accessories. Exampe, BLUE Wire provides positive (+) current to activate the PTO cutch. PRIMARY COMPONENTS: BATTERY: 12 Vot, CA @ 32 deg.f = 320, CCA @ 0 deg.f = 260. NEGATIVE CABLE to the engine bock mounting bot. POSITIVE CABLE to the engine starter soenoid. POSITIVE WIRE, main circuit to fuse and ignition switch. Note: On Diese, EFI or DFI engines, some components are connected directy to the battery with their own circuit and fuse. Consut the appropriate wire schematic for routing. FUSE: Bade Type, Automotive, 20 amp for main circuit from battery to ignition switch. Note: On TANK-S Units the fuse & abeed hoders are mounted on the inside ip of the RH side contro pane next to the battery. SEAT SWITCH: The operator presents (seat) switch is integrated in the seat cushion. When the operator is in the seat, a positive circuit is competed sending current to a reay or other safety component within the system. 3 of 8

PRIMARY COMPONENTS: Cont. IGNITION SWITCH: Poe Contact per Key Position. OFF G Green is Ground + M, Yeow Wire the Magneto. + R Accessory. Are Cosed Circuits. Engine Magneto is grounded and wi not produce spark to spark pugs. B Red Positive is isoated. Not feeding other circuits. ON B Red Positive from Battery to L Red Wire to feed circuits & R Positive to Acc. Positive Current is sent to components as PTO switch, reay, seat, and engine harness. Magneto is no onger grounded at key switch but is sti depending on safety switches to aow the engine to produce spark to spark pugs. S Orange Wire has no current. START B Red Positive from Battery + S Orange Wire to Engine Starter Soenoid + L Red to feed circuits. Positive current is routed thru the orange wire to activate the engine starter soenoid. The compete circuit is dependent on the safety switch system in order to activate the starter. Positive Current is sent to components as PTO switch, reay, seat, and engine harness. Magneto is no onger grounded at key switch but is sti dependent on safety switches to aow the engine to produce spark to spark pugs. IGNITION SWITCH: 6 poe, key activated. View From POLE Side Poe S, + Orange Wire, Starter Soenoid. Poe M, - Yeow Wire, Engine Magneto. Poe B, + Red From Battery. Poe R, + Accessory. Poe L, + Red Wire, + Line to Components. Poe G, - Green Wire from Eng. RELAY SWITCH: This type of switch is activated by current introduction. In our system, it s used to open or cose a circuit, (positive or negative), transfer current or to stabiize amperage to protect reated components. In the TANK-S harness, the reay feeds a ground from 2 yeow eads to the engine magneto. Engine wi not start with yeow magneto circuit grounded. When the operator sits in the seat the positive circuit is cosed and current is sent to the reay to open the yeow wire magneto ground circuit. View From Contact End (87) Not used in MMZ circuit. Open when no current present. Cosed to circuit (30) with current. (86) RED (+) Current From Seat Switch (85) GREEN (-) Because of coi, cosed to (86 +). (30) Ground to Magneto (87a) Yeow/White. Cosed circuit to (30) when no current present. Open when current present 4 of 8

BRAKE SWITCH: This is a manuay operated safety switch. When the brake is in the engaged position, switch button in, the orange wire (starter circuit) is cosed aowing current to pass thru from the ignition switch. The circuit between the green ground and yeow (magneto) is open. With the brake disengaged, the open and cosed circuits are reversed. Yeow Wire to Reay (87a). Cosed to Ground, Brake Off Green Ground to Yeow w/ Brake Off. Orange from Ignition Switch to PTO Switch. Open Circuit when Brake is Off PTO SWITCH: A manuay activated switch to provide current (+) to the PTO cutch with provisions to reguate the starter and magneto circuits. With switch in the off position, orange circuit (starter) is cosed. The green (ground) to yeow (magneto) circuit and red (+) to bue (PTO cutch) are open. This aows the current to fow to the starter. When the switch is engaged, the orange circuit (starter) is open, green (ground) to yeow (magneto) is cosed and red (+) to bue (PTO cutch) is aso cosed. This disabes the starter circuit and enabes the PTO cutch to engage. The cosed or grounded magneto circuit which normay woud shut the engine down is opened at the reay via the seat switch which brakes the ground circuit to the engine. View From Contact End 9 5 4 Yeow Poe (5) & Green Poe (2). Open Orange: To Starter Soenoid when Switch is off. 9 + 3 Circuit Cosed when Switch is off. Aows Eng. Red +(1) & Bue (4) Soenoid to Activate. Cosed Circuit when switch Is on Activating 3 2-5 1-4 the PTO Cutch. WIRE HARNESS: The main wire harness is common for a AIR COOLED ENGINES. It is configured to match a Koher Engine interna starter soenoid and suppy pug. The same harness is used for Kawasaki Engines by adding a short pig tai to the engine pug matching the Kawasaki wire group and eads to suppy the externa starter soenoid. The TANK-S Unit has a hydrauic oi cooing system incorporating a heat exchanger and cooing fan. The fan circuit is a red wire tied into the positive circuit at the engine votage reguator and grounded to the engine bock. The fan is activated when the ignition key switch is turned on. EFI, DFI, COMPUTERIZED ENGINES as Kawasaki Horiz.. Liquid Cooed use the same basic wire coor-coding. But, because of the computer, fue pump and indicator ights, 2 reays and 1 fuse have been added to feed and protect these additiona components. The DIESEL UNIT wire harnesses are unique to that unit. The engine is shut down thru positive (+) current not magneto grounding as a gasoine engine. Because of the many supportive components as indicator ights, cooing fan, gow pugs etc. additiona fuses and reays are incorporated in the system. The PTO CLUTCH can generate current that can feed back into the system. The current spike can damage components as reays and computers. Units with EFI, DFI and Diese engines have a diode in the circuit suppying current to the cutch. Consut the wire diagram for detai routing. 5 of 8

CIRCUIT ROUTING, TANK-S AIR COOLED ENGINES: RED (+) Battery Fuse To Ign. Switch (B ) Ign. Switch From (L) PTO Switch (1) Seat Switch Reay (86) Engine Harness ORANGE (Starter) Ignition Switch (S) Brake Switch PTO Switch (3&9) Engine Harness ( Starter Soenoid) Harness To Engine Koher Mating Pug Connection From Harness to Engine Harness - Engine Orange / Back to Red & Bue ( 2 wires ) Starter Soenoid Red to Red Yeow to White & White (2 wires) Magneto Green to Yeow (2 wires) Eng. Harness Pug GREEN ( ) Engine Bock Reay (85) Brake Switch Ignition Switch (G) PTO Switch (2) PTO Cutch PTO Switch (5) YELLOW WHITE YELLOW Reay (87a) (Magneto) Brake Switch Ignition Switch (M) Reay (30) Engine Harness Pug (Magneto) BLUE ( PTO CLUTCH ) PTO Switch (4) PTO Cutch Kawasaki Extension Pugged Into Koher Harness Harness - Engine Orange / Back to Starter Soenoid Red to Red (2 wires) Yeow to White & Back (2 wires) Magneto Green to Soenoid Mounting Bracket 6 of 8

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DIAGNOSTICS: PREVENTION: The cause of most eectrica issues are moisture resuting in corrosion, oose wires or contacts ( mainy ground wires & cabes ) or damaged wires. It is highy recommended that a part of reguar service is to inspect the eectrica system incuding a reated components. This is especiay true in areas of high humidity, exposure to awn chemicas, units stored outdoors or units that are pressure washed frequenty. Begin at the ignition switch, service a switches, reays and timers aong the wire harness. Unpug each component and cean with eectrica contact ceaner. Inspect the pug connectors to be sure a wires are secure within the housing. Coat connections and mating surfaces with Di-Eectric Grease and reassembe. As you go through the eectrica system check wiring for damaged insuation and crushed or crimped wires. Repair or repace as required. SYMPTOM / DIAGNOSIS: BEFORE DIAGNOSING ELECTRICAL SYSTEMS, ALWAYS, CHECK GROUND CONNECTIONS AND BATTERY CONDITION. Engine Starter Wi Not Turn Over. ( Brake On, PTO Switch Off, Operator in Seat) 1) Pu Switch to Engage PTO. Cick Yes = Current in System. - Go to #3 Cick NO = No Current in System. - Go to #2 2) Check Fuse. Bad = Repace ( May Bow Again if Short In System) Good = OK Current From Battery to Ignition Switch. Go to #3 3) Check Current, Orange Wire @ Starter Soenoid. Key in Start Position. Current Reading 10 12 vots = Possibe fauty soenoid or starter. Current Reading Less Than 10 12 vots = Low Battery or Current Drop thru Components. No Current Reading. = Dead Battery or Fauty Orange Wire Circuit. Trace Orange Wire Circuit from Ignition Switch thru System. Engine Starter Wi Turn Over, Engine Wi Not Start.. ( Brake On, PTO Switch Off, Operator in Seat) 1) Fue in System and Tank Fue Vaves Open. 2) Turn Key from Off to On Position. - Listen for Cick at Engine Carb. No Cick = Fauty Afterfire Soenoid or No Current to Soenoid. Yes Cick = Afterfire Soenoid Functiona 3) Check Engine Spark. Yes Spark to Spark Pugs = Non Starting not Due to Eectrica Probem. No Spark to Spark Pugs = Possibe Yeow Wire Grounding Magneto. 4) Disconnect Yeow Wire From Engine Circuit at Engine Harness Pug. No Spark to Spark Pugs = No Spark not Due to ( Yeow Wire) Grounding Magneto. Yes Spark to Spark Pugs = Harness ( Yeow Wire) Grounding Magneto. Trace Yeow Wire Circuits from Ignition Switch to Reay and Yeow / White Wire Brake, PTO Switches to Reay. Engine Shuts Down When Brake is Reeased or PTO Switch is Engaged. ( Brake On, PTO Switch Off, Operator in Seat) The primary cause of this symptom is current not going to the reay via the seat switch or a fauty reay. 1) Unpug seat switch and ( For Diagnostic Purpose Ony) Insta a Jumper Wire Between the Contacts in the Harness Seat Pug. System Operates Normay = Fauty Seat Switch. Symptom Sti Present = Reay not Operating Propery. Check Circuits and Operation. 8 of 8

NOTES