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X495 electrical problems

5.8K views 14 replies 5 participants last post by  Bob L  
Another add on question. I see from wiring diagram that there is a fusible link between the red wire from battery at the starter solenoid to connect to the control wiring assembly. Does anybody know where this is located and how to identify it?
Thanks again
How to locate the fusible link;

1. Look for a section of the wire which appears to either have been damaged or the wire covering is melted or looks like it got hot. The wire coloring could be discolored. The fusible link is usually the same color as the wire in which it is located. Note, the wire is only going to appear differently if in fact, the link is broken / blown / shorted, whatever one wants to call it.

2. The fusible links often have printing directly on them to indicate their size. Some even say "Fuse Link .8mm" or something similar.

3. They are in a primary wire which carries direct voltage to a primary function component.

4. The wire may appear to be slightly smaller in size than the rest of the wire, which is often where the fusible link exists. Note, the smaller diameter is often less than 1/2" in length so its not real obvious.

5. Technical Service Manuals (TSM) for the particular machine are helpful for the specific location of the fusible link.

6. Fusible links can have printing on them, indicating their size or their part number.

7. This is important and often misunderstood, A factory fusible link doesn't look like something which has been added or spliced in when they are in a factory wiring harness. Many people think its something which is obvious, like when an inline fuse holder is added and has a wire connector on each end. A factory wiring harness fusible link does not appear this way.........

Look for a mid section in the wire which appears to be smaller for a short run, 1" or less, and that's likely the fusible link. You can use a 12V test light or MM and check the voltage in the wire on different sections and see if the presence of power continues through the wire.

Please note, depending upon how a fusible link is "blown", you may or may not see the damage in the wire. However, fusible links are usually an all or nothing type of connection, They either are connected and work or they are blown or burned through and do not work.

Replacing a Fusible Link
Fusible links can be cut out of the wire and replaced, which is how they are repaired. However, its very important to properly replace the fusible link with the proper size fusible link for the wire size and designed wire loads. The fusible link protects the wire from an electrical fire if there is a dead short, etc. It must be repaired correctly and with another fusible link of the correct size.

I have to be honest and tell you that fusible link failures are not very common and rarely the source of the electrical problems people have with their tractor equipment.
 
Bob L,
Answers to these questions would be helpful in helping you with your machine issue. I numbered the questions so you can post the answer simply by using the question number.

1. Have the seat switch and other safety switches been modified / altered or "bypassed"?

2. Have your machine's safety switches been ruled out as the source of trouble?

3. How long have you had the machine?

4. How many hours are on the machine? (New dash / old dash / combined)

5. What's the machine's serial number?
( as there are differences in the electrical wiring based upon 2 or 3 serial number ranges. Posting the machines serial number would be helpful.)

6. It sounds like a machine which is used very infrequently. How many hours a year do you run the machine?

7. Do you keep the machine or battery connected to a battery maintainer between machine use? (like a battery tender, NOCO, etc.?)

8. Have you or the technicians ever found signs of "nests" or wires chewed upon anywhere on the machine?

9. Where is the machine stored (inside, outside, in a heated building, in an unheated building.?

10. Have any of the "boards" or "modules" been replaced? If so, which ones and what was the result?

These will get us started in finding an answer for you.............