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Grasshopper 6700000 Service Manual
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Grasshopper 6700000 Service Manual

Grasshopper 6700000 Service Manual

Electrical troubleshooting
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SERVICE MANUAL
E
V
4
A
S
6700000
THE GRASSHOPPER COMPANY
Moundridge, Kansas 67107 U.S.A.
(620) 345-8621
GRASSHOPPERMOWER.COM
Printed in U.S.A.

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Summary of Contents for Grasshopper 6700000

  • Page 1 SERVICE MANUAL 6700000 THE GRASSHOPPER COMPANY Moundridge, Kansas 67107 U.S.A. (620) 345-8621 GRASSHOPPERMOWER.COM Printed in U.S.A.

  • Page 2: Introduction

    Copyright © 2023-2020 by The Grasshopper Company. The following material is proprietary information. All rights reserved. Reproduction or dissemination in any form by any means is prohibited, except by express written permission from The Grasshopper Company.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS PAGE INTRODUCTION SWITCH FUNCTIONS FUNCTION OF A RELAY TROUBLESHOOTING CONTROL RELAYS All Kubota Gasoline Models ....................8 All Kubota Diesel Models ....................8 Control Relay - All Kubota Models ..................10 Circuit Board Diode Problems - All Models ..............10 TESTING SAFETY SYSTEM FOR PROPER OPERATION All Briggs &...
  • Page 4 TABLE OF CONTENTS (CONTINUED) ENGINE STARTS AND RUNS, BUT WILL NOT SHUT OFF Kubota Diesel Models with D902 Engines ..............36-37 TROUBLESHOOTING PTO CLUTCH All Models except Kubota ....................38 All Kubota FrontMount Models ..................39 All Kubota MidMount Models ..................40 Acceptable Clutch Resistance Range in Ohms ..............41 High Temperature Clutch Cutout Wiring ................42 TROUBLESHOOTING HYDRAULIC DOZER ...............43 TROUBLESHOOTING HYDRAULIC LIFT ...............

  • Page 5: Switch Functions

    SWITCH FUNCTIONS Ignition switch, part no. 183806. (All Briggs, Kawasaki & Kohler Models). M Magneto terminal. S Starter terminal. B Battery terminal. L Lights, accessory terminal. G Ground terminal. Ignition switch, part no. 183827. (All Kubota Models). 30 Battery terminal. 50 Starter terminal.
  • Page 6 SWITCH FUNCTIONS Left and right steering switch, part no. 183860. NC (normally closed) - means that the con- tact is closed with the switch mechanism released. The contact position is reversed when the switch lever is depressed. NO (normally open) - means that the contact is open with the switch mechanism re- leased.

  • Page 7: Function Of A Relay

    FUNCTION OF A RELAY NON-ENERGIZED NON-ENERGIZED - Means that terminal 30 and terminal 87a are connected when the relay is not energized ENERGIZED ENERGIZED - Means that terminal 30 and terminal 87 are connected when the relay is energized...

  • Page 8: Troubleshooting Control Relays

    TROUBLESHOOTING CONTROL RELAYS ALL KUBOTA GASOLINE MODELS ALL KUBOTA DIESEL MODELS 1. Control relay - inspection. 1. Control relay - inspection. A. Control relay A has 3 red wires, 2 black A. Control relay A has 3 red wires, 2 black wires, 1 yellow wire and 2 green wires wire, 1 yellow wire and 2 green wire in in the relay socket.
  • Page 9 Figure 3 Figure 4 Figure 5...

  • Page 10: Control Relay - All Kubota Models

    CONTROL RELAY - ALL KUBOTA CIRCUIT BOARD DIODE MODELS PROBLEMS - ALL MODELS Assuming a normal diode on the circuit, Refer to the illustration below (fi gure 7) to lo- board, relay B is aff ected by a problem in the cate the diode on the circuit board between circuit containing the PTO switch, and left pad R and A.
  • Page 11 THIS PAGE IS INTENTIONALLY LEFT BLANK...

  • Page 12: Testing Safety System For Proper Operation

    TESTING SAFETY SYSTEM FOR PROPER OPERATION ALL BRIGGS MODELS ALL KOHLER MODELS Notes: Proper operation of the safety system indicates that: 1. To start the engine, both steering levers must be out, and the PTO switch must be off . 2.

  • Page 13: All Kubota Models

    TESTING SAFETY SYSTEM FOR PROPER OPERATION ALL KUBOTA MODELS Notes: Proper operation of the safety system indicates that: 1. To start the engine, both steering levers must be out, and the PTO switch must be off . The engine will start with the operator on or off...

  • Page 14: Battery Charging System

    BATTERY CHARGING SYSTEM ALL BRIGGS MODELS *ALL KOHLER MODELS EXCLUDING KOHLER EFI MODELS Notes: 1. Voltage tests are performed with a DC/AC voltmeter. 2. Tests are performed after regulator fuse is checked. 3. AC voltage tests are performed with engine at 3600 rpm.

  • Page 15: All Kubota Models With Smooth Alternators

    BATTERY CHARGING SYSTEM ALL KUBOTA MODELS WITH SMOOTH ALTERNATORS W/TWO WIRES Notes: 1. Voltage tests are performed with a DC/AC voltmeter. 2. Tests are performed after regulator fuse is checked. 3. AC voltage tests are performed with engine at full RPM. *voltage may vary + or - 3 volts.

  • Page 16: All Kubota Models With Aluminum/Finned Alternators

    BATTERY CHARGING SYSTEM ALL KUBOTA MODELS WITH ALUMINUM/FINNED ALTERNATORS Notes: 1. Tests are performed after regulator fuse is checked. 2. Set voltmeter to DC voltage for testing on this page.
  • Page 17 THIS PAGE IS INTENTIONALLY LEFT BLANK...

  • Page 18: Engine Will Not Crank

    ENGINE WILL NOT CRANK 124 & 126 226V 524V Notes: 1. Voltage tests are performed with a DC voltmeter. Warning! Before starting test, remove blue wire from starter solenoid to prevent accidental cranking of engine while testing. Reconnect this blue wire upon completion of the test. Figure 9...
  • Page 19 ENGINE WILL NOT CRANK (CONTINUED) 124 & 126 226V Fuse Block Test Points Fuse block styles will vary. Be sure you are checking designated fuse. Figure 10...

  • Page 20: 225 Kohler, 226Vg4 Briggs, All 300 Air Cooled Models, And 623T Kohler

    ENGINE WILL NOT CRANK 225 Kohler 226VG4 Briggs All 300 Air Cooled Models 623T Kohler Notes: 1. A 30 amp in-line MASTER fuse holder may be present on some models. It will be attached to the positive battery cable post of the starter solenoid.
  • Page 21 ENGINE WILL NOT CRANK (CONTINUED) 225 Kohler 226VG4 Briggs All 300 Air Cooled Models 623T Kohler Fuse block styles will vary. Be sure you are checking designated fuse. Figure 12 Starter Relay Testing Figure 13...
  • Page 22 ENGINE WILL NOT CRANK 125, 225V, 225VG4, 227V, 227VG4, Kohler, 526V Briggs Notes: 1. Do not forget to plug starter relay back in when fi nished testing. Warning! Before starting test, remove blue wire from starter solenoid to pre- vent accidental cranking of engine while testing. Reconnect this blue wire upon completion of the test.

  • Page 23: 125, 225V, 225Vg4, 227V, Kohler, 227Vg4, And 526V Briggs

    ENGINE WILL NOT CRANK (CONTINUED) 125, 225V, 225VG4, 227V, 227VG4 Kohler, 526V Briggs Fuse block styles will vary. Be sure you are checking designated fuse. Figure 15 Starter Relay Testing Figure 16...

  • Page 24: 700 & 900 Series Air Cooled Models

    ENGINE WILL NOT CRANK 700 Series Air Cooled Models 900 Series Air Cooled Models Notes: 1. A 30 amp in-line MASTER fuse holder will be attached to the positive battery cable post of the starter solenoid. Also, a 30 amp MASTER fuse will be located in the tractor fuse block.
  • Page 25 ENGINE WILL NOT CRANK (CONTINUED) 700 Series Air Cooled Models 900 Series Air Cooled Models Figure 18 Figure 19 Starter Relay Testing Figure 20...
  • Page 26 ENGINE WILL NOT CRANK ALL KUBOTA MODELS Note: A 30 amp in-line MASTER fuse holder will be attached to the positive battery cable post of the starter solenoid. Also, a 30 amp MASTER fuse will be located in the tractor fuse block. Voltage will not reach the key switch if this fuse is blown.
  • Page 27 ENGINE WILL NOT CRANK (CONTINUED) ALL KUBOTA MODELS Fuse Block Test Points Figure 26...

  • Page 28: Engine Will Crank, But Not Start

    ENGINE WILL CRANK, BUT NOT START ALL BRIGGS MODELS ALL KOHLER MODELS Notes: 1. Tests are performed after the LIGHT/AUX or IGN./FUEL fuse has been checked on all models.

  • Page 29: All Kubota Gasoline Models

    ENGINE WILL CRANK, BUT NOT START ALL KUBOTA GASOLINE MODELS Notes: 1. All tests are made with wires in place on their respective switches. 2. Refer to fuse block diagram for terminal locations. 3. Refer to “Troubleshooting Control Relays” for information on the diode and control relays.

  • Page 30: All Kubota Diesel Models

    ENGINE WILL CRANK, BUT NOT START ALL KUBOTA DIESEL MODELS EXCEPT THOSE WITH D902 ENGINES Notes: 1. All tests are made with wires in place on their respective switches. 2. Refer to fuse block diagram for terminal locations. 3. Refer to “Troubleshooting Control Relays” for information on the diode and control relays.

  • Page 31: Engine Starts, But Dies

    ENGINE STARTS, BUT DIES WHEN STEERING LEVERS ARE BROUGHT IN OR PTO SWITCH IS ENGAGED ALL MODELS Notes: If engine will crank and start, the PTO switch, right steering switch and left steering switch are functioning properly. The problem must be the parking brake or seat switch.

  • Page 32: Engine Starts, But Dies When Key Switch Is Released

    ENGINE STARTS, BUT DIES WHEN KEY SWITCH IS RELEASED ALL KUBOTA DIESEL MODELS EXCEPT THOSE WITH D902 ENGINES Notes: 1. All tests are made with wires in place on their respective switches. 2. Problem is in the 'HOLD' circuit of the fuel solenoid.

  • Page 33: All Kubota Diesel Models Except Those With D902 Engines

    ENGINE STARTS, BUT DIES WHEN KEY SWITCH IS RELEASED (CONTINUED) ALL KUBOTA DIESEL MODELS EXCEPT THOSE WITH D902 ENGINES Figure 34...

  • Page 34: Kubota Diesel Models With D902 Engines

    ENGINE STARTS, BUT DIES WHEN KEY SWITCH IS RELEASED KUBOTA DIESEL MODELS WITH D902 ENGINES Notes: 1. All tests are made with wires in place on their respective switches. 2. Relay A is the relay with 1 yellow, 2 black, 2 green, and 3 red wires.

  • Page 35: Briggs & Kohler Models

    ENGINE STARTS, BUT DIES WHEN KEY SWITCH IS RELEASED BRIGGS & KOHLER MODELS Notes: 1. If engine cranks and starts but dies when key switch is released, then PTO switch, right and left steering switches, carbure- tor solenoid and stop relay are functioning properly.

  • Page 36: Engine Starts And Runs, But Will Not Shut Off

    ENGINE STARTS AND RUNS, BUT WILL NOT SHUT OFF KUBOTA DIESEL MODELS WITH D902 ENGINES Notes: 1. Check STOP SOLENOID fuse (15 amp). The engine will not shut off if this fuse is blown or if fuse block terminals are loose or corroded.
  • Page 37 ENGINE STARTS AND RUNS, BUT WILL NOT SHUT OFF (CONTINUED) KUBOTA DIESEL MODELS WITH D902 ENGINES Figure 39...

  • Page 38: Troubleshooting Pto Clutch

    TROUBLESHOOTING PTO CLUTCH ALL MODELS EXCEPT KUBOTA Notes: WARNING! DO NOT HAVE ENGINE RUNNING DURING ANY PART OF THIS TEST. 1. If the tractor is equipped with a PowerFold ® deck, be sure the safety switch on the bottom of the actuator switch mount is fully depressed when the mount is down on the actuator rod.

  • Page 39: All Kubota Frontmount Models

    TROUBLESHOOTING PTO CLUTCH ALL KUBOTA FRONT MOUNT MODELS Notes: WARNING! DO NOT HAVE ENGINE RUNNING DURING ANY PART OF THIS TEST. 1. If the temperature light is on, turn to page 41 for troubleshooting steps. 2. If the tractor is equipped with a PowerFold ® deck, be sure the safety switch on the bottom of the actuator switch mount is fully depressed when the mount is down on the actuator rod.

  • Page 40: All Kubota Midmount Models

    TROUBLESHOOTING PTO CLUTCH ALL KUBOTA MID MOUNT MODELS Notes: WARNING! DO NOT HAVE ENGINE RUNNING DURING ANY PART OF THIS TEST. 1. If the temperature light is on, turn to page 41 for troubleshooting steps. 2. If engine starts and runs, relay 'A' is working properly. 3.

  • Page 41: Acceptable Clutch Resistance Range In Ohms

    ACCEPTABLE CLUTCH RESISTANCE RANGE IN OHMS FOR TRACTORS WITH SERIAL NUMBER 6700000 & ABOVE...

  • Page 42: High Temperature Clutch Cutout Wiring

    The clutch will then operate again. If the clutch does not work after the system has been reset by turning the key switch off , contact Grasshopper Service. VERIFICATION OF WHETHER THIS CIRCUIT IS SHUTTING DOWN THE CLUTCH FUNCTION...

  • Page 43: Troubleshooting Hydraulic Dozer

    HYDRAULIC DOZER ELECTRICAL TROUBLESHOOTING The hydraulic dozer blade wiring harness contains six diodes for con- trolling the direction of current fl ow. When a diode allows voltage to reach the solenoids, oil pressure controls the up and down functions. When a diode stops voltage from reaching the solenoids, oil pressure controls the left and right functions.

  • Page 44: Troubleshooting Hydraulic Lift

    HYDRAULIC LIFT DOES NOT WORK ONE PIECE TILT SWITCH / DELAY TIMER STYLE Notes: 1. "Hydraulic switch" refers to either the push button switch in the steering lever or the toggle switch in the console.
  • Page 45 HYDRAULIC LIFT DOES NOT WORK ONE PIECE TILT SWITCH / DELAY TIMER STYLE (CONTINUED) Figure 44...

  • Page 46: Joystick Wiring Troubleshooting Total Loss Of Motion

    JOYSTICK WIRING TROUBLESHOOTING TOTAL LOSS OF MOTION Notes: Check battery voltage. Battery voltage should read a minimum of 12.5 DC volts. All tests are performed with key in the run position, steering levers out and PTO switch off . All tests are with a DC voltmeter from battery negative unless otherwise noted. Disconnect the 6-way weather-pack connector next to the brake lever on the left side of the frame.

  • Page 47: Joystick Wiring Troubleshooting Loss Of Motion In One Direction

    JOYSTICK WIRING TROUBLESHOOTING LOSS OF MOTION IN ONE DIRECTION Notes: The following troubleshooting guidelines assume all directions except one function properly. This assumes the required voltage is reaching all relays, including the malfunctioning relay. All tests are performed with key in the run position, steering levers out and PTO switch off . Access the 4 relays inside the relay box for these tests.

  • Page 48: Tractor Accessory Harness Troubleshooting

    TRACTOR ACCESSORY HARNESS TROUBLESHOOTING This is a general check for loss of electrical power to any attachment which relies on a tractor accessory harness for its power source. The tractor harnesses include the Universal Wiring Har- ness, Limited wiring Harness and Power Harness. If the attachment has lost electrical power, disconnect the tractor accessory harness connector located either on the tractor frame to the left of the seat or under the seat.
  • Page 49 TRACTOR ACCESSORY HARNESS TROUBLESHOOTING UNIVERSAL WIRING HARNESS...
  • Page 50 TRACTOR ACCESSORY HARNESS TROUBLESHOOTING LIMITED UNIVERSAL HARNESS...