Operation Function: Provides power to the headlights, tail lights, hazard lights, work light and dash lights in different combinations depending upon the position the light switch is placed in. Operating Conditions: A properly connected and operating unswitched power circuit. and The light switch in either the HAZARD, WORK or ROAD position. Road Position: In the Road position, current is provided to the headlights, tail lights and dash lights through the same circuits as the light switch in the Work position, however the work lights are not powered. The turn/hazard lights receive current through the same circuits as they do with the light switch in the Hazard position. Theory of Operation: The light switch has 4 positions. OFF, HAZARD, WORK and ROAD. The light switch receives unswitched power from the battery through the 211, 212, 214, 95 and 96 / wires and is protected by the F1 40 amp fuse. Dash s The dash lights are used to illuminate the control panel. When the S5 light switch is in the WORK or ROAD position, voltage is provided through the light switch and F5 20 amp fuse to the H6 dash lights (15, 13, and 563 wires). Hazard Position: In the Hazard position current flows from the light switch through the (light switch) connector, 11 and 12 wires, F3 10 Amp fuse, and the 29, 103, and 104 wires, V7 diode, and 24 wire to the K6 flasher (terminals A and ). Intermittent current flows from the flasher (terminal I) through the 31, 30, and 32 Yel wires to the H4 left turn indicator light and the E3 left turn/hazard light. Intermittent current also flows from the flasher (terminal H) through the 34, 33, and 35 wires to the H5 right turn indicator light and the E1 right turn/hazard light. Work Position: In the Work position current flows from the S5 light switch through the 9 wire, F5 20 amp fuse, and the 15, 17, 18, 19, 106, and 14 wires to the E6 right headlight, E5 left headlight, E2 right tail light and the E4 left tail light. The 13 and 563 wires also provides current to the H6 dash lights. The Work position of the light switch also provides current to the E7 work light. The E7 work light receives current through the 68 Yel wire, F4 10 Amp fuse, and 69 Yel wire. Electrical Diagnostics & Operation - 160
Schematic ELECTRICAL DIAGNOSTICS & OPERATION / S1 Key X1 213 212 M1 Starting Motor F1 Fuse 211 X2 R1 G1 attery R2 / M / C1 / Start On Off C2 214 X8 Y1 Starting Motor Solenoid 73 82 W1 Frame Ground 95 X3 96 / Yel/ Yel/ Yel/ S5 S5 Power (Unswitched) S5 D J Power (ed) 24 A K6 Flasher 68 Yel 9 10 11 V7 Diode 103 H4 Turn I H K 31 Yel 34 88 F4 Fuse 69 Yel F5 Fuse 12 / F3 Fuse 29 104 30 Yel 33 591 Grn /Yel 145 144 Ground (Unswitched) H6 Dash 594 H5 Turn 13 146 563 142 71 15 17 147 106 35 X13 E1 Turn/ Hazard 32 Yel X16 E5 Head Control Panel Wiring Harness E3 Turn/ Hazard 18 80 14 19 E6 Head X20 E7 Work (Option) X20 X14 E2 Tail X15 87 X17 E4 Tail X18 84 90 Electrical Diagnostics & Operation - 161
Diagnosis ELECTRICAL DIAGNOSTICS & OPERATION switch in HAZARD position s - Hazard s A 1. Is battery voltage present at the S5 light switch (A)? No: Test F1 fuse. Check 211, 212, 214, 95, and 69 / wire and E F 5. Is intermittent battery voltage present at the H4 left turn light socket (E)? No: Check 31 and 30 Yel wires and If OK, replace K6 flasher. 6. Is continuity to ground present at the H4 left turn light socket (F)? No: Check 145, 142, 71, and 73 wires and 2. Is battery voltage present at the K6 flasher ()? No: Test F3 fuse. Test V7 Diode. Check 11, 12, 29, 103, and 24 wires and If OK, replace light switch. 3. Is battery voltage present at the K6 flasher (C)? No: Test F3 fuse. Check 11, 12, 29, 103, and 104 wires and If OK, replace light switch. 4. Is continuity to ground present at the K6 flasher (D)? No: Check 88 and 82 wires and D C H 7. Is intermittent battery voltage present at the H5 right turn light socket (G)? No: Check 34 and 33 wires and If OK, replace K6 flasher. 8. Is continuity to ground present at the H5 right turn light socket (H)? No: Check 144, 142, 71, and 73 wires and 9. Is intermittent battery voltage present at the E1 right turn/hazard light (I)? G I J Electrical Diagnostics & Operation - 162
No: Check 34 and 35 wires and If OK, replace K6 flasher. 10. Is continuity to ground present at the E1 right turn/ hazard light (J)? No: Check 87 and 82 wires and L K N O 2. Is battery voltage present at the E7 work light (N)? No: Check F4 fuse. Check 68 and 69 Yel wires and If OK replace light switch. 3. Is continuity to ground present at the E7 work light (O)? No: Check 90 and 82 wires and 11. Is intermittent battery voltage present at the E3 left turn/hazard light (K)? No: Check 31 and 32 Yel wires and If OK, replace K6 flasher. 12. Is continuity to ground present at the E3 left turn/ hazard light (L)? Yes: Go to next test condition. No: Check 84 and 82 wires and switch in WORK position s - Work s Q P 4. Is battery voltage present at the E2 right tail light (P)? No: Test F5 fuse. Check 9, 15, and 106 wires 5. Is continuity to ground present at the E5 right tail light (Q)? No: Check 87 and 82 wires and M 1. Is battery voltage present at the S5 light switch (M)? No: Test F1 fuse. Check 211, 212, 214, 95, and 69 / wire and Electrical Diagnostics & Operation - 163
6. Is battery voltage present at the E4 left tail light (R)? No: Test F5 fuse. Check 9, 15, and 14 wires 7. Is continuity to ground present at the E4 left tail light (S)? No: Check 84 and 82 wires and T U 8. Is battery voltage present at the H6 dash lights sockets (T)? No: Test F5 fuse. Check 9, 15, 13, and 563 wires 9. Is continuity to ground present at the H6 dash lights sockets (U)? Yes: Test bulb(s). Go to next step. No: Check 147, 146, 142, 71, and 73 wires and U R S T V 10. Is battery voltage present at the E6 right headlight (V)? No: Test F5 fuse. Check 9, 17, and 19 wires 11. Is continuity to ground present at the E6 right headlight (W)? No: Check 80 and 73 wires and X W Y 12. Is battery voltage present at the E5 left headlight (X)? No: Test F5 fuse. Check 9, 17, and 18 wires 13. Is continuity to ground present at the E5 left headlight (Y)? Yes: Test bulb. Go to next test. No: Check 80 and 73 wires and switch in ROAD position s - Road s 1. Are the hazard lights flashing? No: See s - Hazard s on page 162. 2. Are the headlights and taillight illuminated? Yes: Test complete. No: See s - Work s on page 163. Electrical Diagnostics & Operation - 164