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ELECTRICAL
CHAPTER 15 ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 COMPONENTS UNDER HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 COMPONENTS BEHIND DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 COMPONENTS UNDER CENTER CONSOLE / PASSENGER SEAT BASE . . . . . . . . 10.3
ALL WHEEL DRIVE (AWD) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
AWD / 2WD / TURF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 AWD COIL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
WORK, TILT LOCK AND AUX. SWITCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 WORK, TILT LOCK AND AUX. SWITCH WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . 10.12 BOX LIFT SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 BOX LIFT SWITCH WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
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INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18 INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24 INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24 HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25 HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25 HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26 HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
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HYDRAULIC OIL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 HYDRAULIC TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 PTO CONTROLS (HDPTO MODEL ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
PTO ENGAGEMENT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 PTO CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
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BOX LIFT SWITCH (HD AND HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
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FUEL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 TRANSMISSION (GEAR POSITION) SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 PUMP NEUTRAL (TREADLE) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 IGNITION (KEY) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 WORK, TILT LOCK AND AUX SWITCHES (HD AND HDPTO) . . . . . . . . . . . . . . . . . . 10.12
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DIFFERENTIAL SOLENOID OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 DIFFERENTIAL SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
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ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GLOW PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TWO SPEED MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
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10.4 10.4 10.5 10.5 10.6
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15.1
ELECTRICAL
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 FAN CONTROL CIRCUIT BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
HVAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
HVAC SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 HVAC CONTROL CIRCUIT OPERATION / THEORY . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 AC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
FUSE, RELAY, CIRCUIT BREAKER AND TVS DIODE LOCATIONS. . . . . . . . . . . . . 10.33 RELAY BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34 RELAY POWER FLOWCHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 FUSE / RELAY BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38 EXTERNAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41 CHARGING SYSTEM "BREAK EVEN" TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41 CHARGING SYSTEM ALTERNATOR WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . 10.42 ALTERNATOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43 ALTERNATOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43 BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44 GENERAL BATTERY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44 BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44 BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44 BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44 BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45 BATTERY CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46 BATTERY TERMINAL BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
STARTER SYSTEM AND WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48 STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49 STARTER MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49 STARTER MOTOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51 STARTER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52 STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53 STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
DIGITAL WRENCH® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW. . . . . . . . . . . . . . . . . . 10.54 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54 ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54 GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54 DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54 DIAGNOSTIC CONNECTOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55 DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 10.55 DIGITAL WRENCH® VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55 DIGITAL WRENCH® UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56 DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57 ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . 10.58 SPECIAL TESTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60 DATA ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61
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CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
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FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32 FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKERS / TVS DIODES . . . . . . . . . . . 10.33
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ELECTRICAL
GENERAL INFORMATION
Special Tools
Part Number PV-43568 PV-43526 2870630 2460761 2871745 PU-50296 PU-49466 Tool Description FlukeTM 77 Digital Multimeter Connector Test Kit Timing Light Hall Effect Sensor Probe Harness Static Timing Light Harness Battery Conductance Analyzer (MDX-610P) Relay Bypass
Components Under Hood
The following electrical components can be accessed under the hood. · Headlight Connectors · Terminal Block
Components Behind Dash Panel
· Instrument Cluster (Speedometer) · AWD/2WD/TURF Switch · Headlight Switch
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
Electrical Service Notes
Keep the following notes in mind when diagnosing an electrical problem: · Refer to wiring diagram for electrical component resistance specifications.
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· When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance.
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· Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner's Manual included with your meter for more information.
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· Voltage, amperage, and resistance values included in this manual are obtained with a FlukeTM 77 Digital Multimeter (PV-43568). This meter is used when diagnosing electrical problems. Readings obtained with other meters may differ. · Pay attention to the prefix on the multimeter reading (K, M, etc.) and the position of the decimal point.
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· Ignition Key Switch · Dump Box Switch · Cargo Box Lift Relay · Fuse / Relay Boxes · Terminal Block · ECU
· 12 VDC Accessory Power Points
· Cargo Box Lift Circuit Breaker
Components Under Center Console / Passenger Seat Base
The following electrical components can be accessed with the passenger seat base / center console removed. · Battery / Battery Cables
· Digital Wrench® Diagnostic Connector · Transient-Voltage Suppression (TVS) Diodes
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The following electrical components can be accessed with the upper dash panel removed.
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· For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply.
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ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU)
Located under the middle passenger seat on the BRUTUS model and under the center console on the BRUTUS HD and HDPTO models, the ECU manages the fuel pull solenoid, the fuel hold solenoid, the fuel pump, and glow plug operation. The ECU stores the logic for hot lamps, radiator fan, 2-speed shift strategy, AWD control, and starter lockout. Digital Wrench® also reports on the following items: · AWD and Diff Lock Status · Battery Voltage · Brake Switch (on/off) · Cooling Fan Relay Driver · Crankshaft Signal Present · Engine RPM, Temperature and Run-Time · Fuel Pump (on/off) · Gear Switch Voltage · PTO Status / RPM · Seat Switch (Operator Present) Input / Output · Treadle / Pump Neutral Sensor Status · Two Speed Shift Coil Duty Cycle · Vehicle Speed
CRANKSHAFT POSITION SENSOR (CPS)
The CPS is used to provide the ECU with engine speed for AWD operation and to determine PTO speed.
CPS Location
1. Disconnect the main harness from the sensor harness pigtail. 2. Connect an ohmmeter between the CPS pin terminals shown below and compare to the spec below. The reading should be taken at room temperature.
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ECU Removal
1. Turn the ignition switch to the off position.
2. Remove the passenger seat or center console.
3. Remove the four plastic rivets retaining the ECU to the base.
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4. Disconnect the harness to the ECU and remove the ECU from the vehicle.
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CPS Resistance Specification: 1000 ± 10%
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CPS Testing
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The CPS is located on the transmission side of the engine on the bell housing.
ELECTRICAL
GLOW PLUGS
The glow plugs are located on the engine assembly below the valve cover. The valve cover will need to be removed if the glow plugs are to be tested or replaced.
TWO SPEED MANIFOLD
The two speed manifold modifies pressure and flow to the shift plate in the pump motor depending on selected gear and speed. There are two distinctive ramps per drive gear.
Glow Plug Testing
1. Disconnect the air intake hose going to the valve cover. 2. Remove the nine 10 mm bolts retaining the valve cover to the engine and lift the valve cover off. 3. Remove the nuts (Item 1) retaining the sub-harness to the glow plugs.
Two Speed Manifold Location
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5. If glow plugs require replacement, torque glow plug fasteners to specification.
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Glow Plug resistance: 0.4
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4. Using an ohmmeter, put the red lead on the glow plug connector and the black lead to engine ground.
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
Two Speed Manifold Testing
The two speed manifold should be tested for proper operation using Digital Wrench®. Go to the Special Tests menu - Output State Control and select Command a Duty Cycle.
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Glow Plug M10: 12 ft-lbs M4 nut: 15 in-lbs
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The two speed manifold is located under the driver's seat above the fuel tank in the same block as the steering priority and steering relief valves.
ELECTRICAL
REAR DIFFERENTIAL SOLENOID
Differential Solenoid Overview
The differential solenoid is located on the rear portion of the transmission case. The solenoid actuates a shift fork with an engagement dog, which locks and unlocks the rear differential. Reference Chapter 9 for more information.
ALL WHEEL DRIVE (AWD) SYSTEM
AWD / 2WD / TURF Switch
1. Disconnect the AWD / 2WD / TURF switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring.
· Move the switch to 2WD. There should be no continuity between pins 1 and 2; 2 and 3. · Move the switch to TURF. There should be continuity between switch pins 1 and 2.
NOTE: Pins 7 and 3 provide power and ground for the AWD indicator. Pins 1 and 7 provide power and ground for the Turf indicator.
AWD Coil Overview Differential Solenoid Circuit Operation
The Rear Diff Solenoid Relay is attached to the rear portion of the main frame and can be accessed by tilting the rear cargo box. When the switch is pushed to activate "TURF", a ground signal is provided to the ECU from the AWD switch.
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Depending on engine speed and gear position criteria, the ECU energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid. If the rear diff fails to switch from operational modes:
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When the AWD switch is "ON", 12 VDC power is present at the hub coil and if the criteria is met, the ECU provides a ground path on brown/white. The AWD icon should display on the instrument cluster.
AWD Testing
1. Verify AWD switch is functional and that a minimum of 11 volts is present at the hub coil. 2. Verify AWD hub coil is functional. Test the AWD hub coil using an ohm meter. See specifications below: Test AWD Coil AWD Coil Connect Meter Ohms Reading Leads To: GY to BN/WH GY to Ground ~ 24 ± 5% Open Line (OL)
· Check for power from the relay connector, to ensure the solenoid has power to be activated.
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· Check the solenoid and relay connectors. Look for loose wires or bad connections.
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· Check the AWD connections.
switch
wires
3. Verify the wiring harness, wiring, connectors, connector pins and grounds are undamaged, clean and connected properly. 4. Verify continuity of wire connections with a volt/ohm meter. IMPORTANT: Verify all wires and wiring connections have been tested properly before suspecting a component failure. 80% of electrical issues are caused by bad/failed connections and grounds.
· Remove solenoid from rear differential and ensure the solenoid plunger is actuating.
CAUTION
Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid.
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· Move the switch to AWD. There should be continuity between switch pins 2 and 3.
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2. Test between the 2 sets of outputs (AWD / TURF). If any of the tests fail, replace the switch assembly.
ELECTRICAL
AWD / Turf Circuit Break-Out Diagram
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ELECTRICAL
FUEL SOLENOID
The pull coil is a strong coil that is energized to pull the solenoid contacts together. The hold coil is a much weaker coil that only needs to be strong enough to keep the contacts closed.
VEHICLE SPEED SENSOR
The speed sensor is located on the ride side of the transmission, accessed through the right rear wheel well.
Vehicle Speed Sensor Testing
1. Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission.
The fuel solenoid is located on the engine block below the air intake duct.
Fuel Solenoid Pull Coil Testing
1. Disconnect the fuel solenoid.
2. Ohm across pins P1 and P3 on the solenoid. Pull Coil: 0.33
Fuel Solenoid Hold Coil Testing
1. Disconnect the fuel solenoid.
2. Ohm across pins P2 and P3 on the solenoid.
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Hold Coil: 24.5
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Fuel Solenoid Location
2. Connect the wires from the Static Timing Light Harness (PN 2871745) to the sensor 3 pin connector using the Hall Sensor Probe Harness (PN 2460761). 3. Pass a screwdriver back and forth in front of the sensor tip. 4. Be sure connections are good and 9V battery is in good condition. If the light flashes, the sensor is good.
NOTE: Some units may have a shim between the speed sensor and the gearcase housing. If a shim is removed, a shim should be installed on reassembly.
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ELECTRICAL
TRANSMISSION (GEAR POSITION) SWITCH
Transmission (Gear Position) Switch
The transmission switch is located on the right side of the transmission. The switch can be accessed through the right rear wheel well opening. 1. Disconnect the transmission switch harness by lifting the connector lock and pulling on the 2-pin connector. Do not pull on the wiring. 2. Test transmission switch for continuity in each gear position and compare to the specifications below.
PUMP NEUTRAL (TREADLE) SWITCH
The Pump Neutral Switch is used for starting, speed sensor, and AWD logic. The switch is normally closed (treadle pedal is not being pushed).
Pump Neutral Switch Location
1. Put the cargo box in the fully open position. 2. Disconnect the main harness from the pump neutral switch flying lead.
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
3. Using an ohmmeter, with the treadle pedal in the neutral position there should be continuity between the black (A) and blue (C) wires on the pump neutral switch wiring. 4. The switch should read OL when the treadle pedal is pushed in the forward or reverse position.
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Pump Neutral Switch Testing
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The Pump Neutral Switch is located under the plastic covering on the hydraulic pump housing.
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15.9
ELECTRICAL
ENGINE OIL PRESSURE SWITCH
The engine oil pressure switch closes and sends a ground signal to the ECU if engine oil pressure is below the 8 PSI. The ECU then signals the instrument cluster to display the low oil pressure indicator light and the LCD displays "CK ENG". The switch is normally open.
IGNITION (KEY) SWITCH
Ignition Key Switch Testing
1. Disconnect the key switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring.
· Turn the ignition key to ON. There should be continuity between switch pins C and D. · Turn the ignition key to START. There should be continuity between switch pins A and B; C and D.
1
1. Disconnect the pink wire on the vehicle harness going to the engine oil pressure switch. 2. Start the engine and let it run for at least 5 seconds.
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3. Ohm the connection on the sensor to chassis ground. It should read OL. Continuity would indicate low oil pressure or a faulty switch.
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Engine Oil Pressure Switch Testing
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The engine oil pressure switch (Item 1) is located on the engine block below the throttle cable bracket.
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Engine Oil Pressure Switch Location
2. Test between the 3 sets of outputs (OFF / ON / START). If any of the tests fail, replace ignition switch assembly.
ELECTRICAL
HEADLAMP SWITCH
The headlamp switch is located on the upper dash panel.
BRAKE LIGHT SWITCH
The brake light switch senses pressure off the brake master cylinder to determine if the brake pedal is depressed. The switch is normally open.
Headlamp Switch Testing
1. Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring. 2. Test between the 3 sets of outputs (HIGH / LOW / OFF). If any of the tests fail, replace headlamp switch assembly. · Move the switch to HIGH. There should be continuity between switch pins 2 and 3; 5 and 6. · Move the switch to LOW. There should be continuity between switch pins 2 and 3; 4 and 5. · Move the switch to OFF. There should be continuity between switch pins 1 and 2; 4 and 5.
Brake Light Switch Location
Brake Light Switch Testing
1. Disconnect the vehicle harness (Item 1) from the brake switch (Item 2).
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1 2 2. Connect an ohmmeter across switch contacts. Reading should be infinite (OL). 3. Apply foot brake and check for continuity between switch contacts. If there is no continuity or if resistance is greater than 0.5 ohms, clean the switch contacts and re-test. Replace switch if necessary. 4. Refer to Chapter 14 if replacing the brake switch, as the brake bleeding procedure will need to be performed.
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The brake light switch (A) is located on the front brake line banjo bolt of the master cylinder. The brake switch can be accessed through the front left wheel well opening.
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NOTE: Pins 7 and 8 provide power and ground to light the switch lamp.
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ELECTRICAL
WORK, TILT LOCK AND AUX SWITCHES (HD AND HDPTO)
Work, Tilt Lock and Aux. Switch Testing
1. Remove the plastic rivets retaining center console cover to get access to the work, tilt lock and aux. switches. 2. Disconnect the harness to each switch. 3. Using an ohmmeter, test the pins on the switch according to the wiring diagram.
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Work, Tilt Lock and Aux. Switch Wiring Diagram
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ELECTRICAL
BOX LIFT SWITCH (HD AND HDPTO)
Box Lift Switch Testing
1. Remove the upper dash cover to get access to the box lift switch. 2. Disconnect the harness to the box lift switch. 3. Using an ohmmeter, test the pins on the switch according to the wiring diagram.
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Box Lift Switch Wiring Diagram
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ELECTRICAL
HYDRAULIC OIL SWITCH
The hydraulic pressure switch will check if the hydraulic oil filter is plugged and illuminate the Oil Pressure indicator and "CK HYD" will display on the LCD. The switch is normally closed.
HYDRAULIC TEMPERATURE SENSOR
The hydraulic temperature sensor (Item 2) will check hydraulic oil temperature at the hydraulic filter housing. If the temperature gets too high, the Oil Temperature indicator will illuminate on the instrument cluster and "CK HYD" will display on the LCD.
Hydraulic Oil Switch Location
The hydraulic oil switch (Item 1) is located on the hydraulic oil filter housing behind the driver's seat.
Hydraulic Temperature Sensor Location
Hydraulic Oil Switch Testing
1. Disconnect the vehicle harness from the hydraulic oil switch. 2. Connect an ohmmeter from chassis ground to the switch contact. The switch is closed when adequate pressure is present. An OL reading would indicate a plugged hydraulic oil filter or a bad switch.
The hydraulic temperature sensor (Item 2) is located on the hydraulic filter housing under the driver's seat between the cargo box and the cab.
Hydraulic Temperature Sensor Testing
2. Using an ohmmeter, place one lead on a pin on the sensor. Compare readings to the chart. Temperature 32° F (0° C) 77° F (25° C) Resistance ~815 ~1000 ~1700 Temperature 197° F (92° C) 185° F (85° C) 201° F (94° C) 199° F (93° C) 190° F (88° C) 185° F (85° C) 205° F (96° C)
1
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15.14
Hydraulic Lamp Starts Blinking Hydraulic Lamp Stops Blinking Cooling Fan On Cooling Fan Off Engine Shutdown
(when temp is sustained for 60 sec)
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212° F (100° C) Function Hydraulic Lamp On Solid Hydraulic Lamp Off
1. Disconnect the vehicle harness from the hydraulic temperature sensor.
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ELECTRICAL
PTO CONTROLS (HDPTO MODEL ONLY)
The PTO system is designed so the PTO clutch will disengage when the PTO Engagement switch is ON and the driver is not sitting on the seat.
Seat Switch
Located under the driver's seat base, the seat switch disengages the PTO clutch when pressure is lost on the driver's seat.
PTO Engagement Switch
The PTO Engagement Switch is located on the center console.
Seat Switch Testing
3. Check for less than 1 to ground on pin C of the main harness. 4. Pin B will be the signal wire. It will have 5 V dc on it when the switch is actuated and ground when the switch is released.
2. With the switch if the off position, ohm pins A to C on the switch. The reading should be OL.
3. Engage the PTO switch. There should now be continuity between pins A and C and the reading should be less than 1 .
PTO Clutch
2. Using a ohmmeter, ohm the two pins going to the PTO clutch.
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1. Disconnect the PTO clutch from the main harness.
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Located between the PTO gearcase and the PTO shaft, the PTO clutch engages when the PTO engagement switch is in the ON position. A minimum of 12 Vdc is required to engage the PTO clutch.
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1. Disconnect the PTO Engagement switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring.
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2. Using a multimeter, check for battery voltage on pin A on the main harness.
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1. Lift the driver's seat and disconnect the seat switch harness.
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Test
Connect Meter Ohms Reading Leads To: Blk to Blk Blk to Ground ~ 2.4 ± 5% Open Line (OL)
PTO Clutch
PTO Clutch
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ELECTRICAL
INSTRUMENT CLUSTER
Overview
The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions.
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NOTE: Some features are not applicable to all models.
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ELECTRICAL
Rider Information Display
The rider information display is located in the instrument cluster. All segments will light up for 1 second at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 1. Vehicle Speed Display - Analog display of vehicle speed in MPH or km/h. 2. Information Display Area - Service Info - LCD display of the service hour interval, total vehicle miles or km., total engine hours, a trip meter, engine RPM and engine temperature. 3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is displayed when the instrument cluster is in the Metric mode. 4. High Beam Indicator - LED icon illuminates whenever the Headlamp switch is in the high beam position. 5. Fuel Level Indicator - LCD bar graph indicating current fuel level. All segments will flash when the last segment is cleared indicating a low fuel warning. 11. Hour Meter - Illuminates when the display (2) is showing hours. 12. Low Oil Pressure Indicator - LED icon illuminates when low engine oil pressure is sensed or the hydraulic filter is plugged. If the engine oil pressure is low, "CK ENG" will display on the LCD. If the hydraulic filter is plugged, "CK HYD" will display.
H = High L = Low
N = Neutral P = Park
6. Clock / PTO RPM - Displays current time in either 12hour or 24-hour formats. When the PTO is engaged, PTO RPM will be indicated instead of the clock.
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8. PTO Indicator - PTO is engaged when this is illuminated. PTO RPM will be displayed in the Clock field (6) ONLY when engine RPM is displayed in the Information Display Area (2).
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7. Engine / Hydraulic Fluid Temperature Indicator LED icon illuminates when the ECM determines the engine or hydraulic oil is too hot. "CK ENG" will display on the LCD if the engine oil temperature is too high and "CK HYD" will display if the hydraulic oil is too hot. The indicators will initially be on solid to indicate overheating. The indicators will start blinking if a severe overheating condition exists.
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-- = Gear Signal Error (shifter stuck between gears)
14. Power Steering System MIL - N/A on this model. 15. Glow Plug Indicator - Illuminated when the glow plugs are active. Light goes out when the engine is ready to start. 16. Seat Belt Indicator - LED icon illuminates for several seconds when the key is turned to the ON position. The lamp is a reminder to the operator to ensure all riders are wearing seat belts before operating the vehicle. 17. AWD/TURF Indicator - Illuminate to indicate how many drive wheels are active. This will tell you if you are in AWD, 2WD, or Turf. 18. ADC Indicator - N/A on this model.
19. Service Interval Indicator - Preset at the factory and adjustable by the user, a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed. The wrench icon will flash for 10 seconds upon startup once it reaches 0. 20. Unit of Measurement - Indicates the measurement (Trip 1, Trip 2, KM, MI, RPM) being displayed in the Information Display Area (Item 2).
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9. Check Engine MIL - Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system. 10. Unit Lock - N/A on this model.
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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13. Gear Position Indicator - Displays gear selector position.
ELECTRICAL
Instrument Cluster Pinouts Information Display Area
The LCD portion of the instrument cluster is the information display area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock.
Distance Time
Miles (MPH) 12-Hour Clock
Kilometers (KM/H) Celsius 24-Hour Clock
Temperature Fahrenheit FUNCTION CAN High CAN Low Switched Power (Vdc) Constant Power (Vdc) Ground High Beam Input Park Brake Engine Oil Pressure Input Fuel Level Sensor Mode Function Input Hydraulic Oil Pressure Input Hydraulic Oil Temperature Input Treadle Reverse Input PIN 1 2 3 4 5 8 9 10 11 13
To change between Standard and Metric units of measurement, follow these steps: 1. Turn the key to the OFF position. 2. Press and hold the MODE button while turning the key to the ON position. 3. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.
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14 15 16 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings.
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Units of Measurement
ELECTRICAL
Odometer Tachometer (RPM)
The odometer records and displays the total distance traveled by the vehicle. The odometer can not be reset.
Engine RPM can be displayed digitally.
Trip Meter
PTO RPM, when engaged, is indicated after the gear icon and will only display when engine RPM is shown.
The trip meter records the miles traveled by the vehicle on each trip. To reset the trip meter: 1. Toggle the MODE button to TRIP 1.
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2. To reset to 0, push and hold the MODE button until the distance display changes to 0.
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Engine Hours
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Shows current engine temperature. Engine temperature can be displayed in ° F or ° C. Refer to "Units of Measurement" to change the format.
Engine Temperature
Clock
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The clock displays the time in a 12-hour or 24-hour format. Refer to "Units of Measurement" to change the format (Standard 12-hour / Metric-24 hour). To set the clock: 1. Toggle the MODE button until the odometer is displayed. 2. Press and hold the MODE button until the hour segment flashes. Release the button. Engine hours are logged anytime the engine is running. Total hours can not be reset.
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ELECTRICAL
3. With the segment flashing, tap the MODE button to advance to the desired setting. 4. Press and hold the MODE button until the next segment flashes. Release the button. 5. Repeat steps 3-4 twice to set the 10 minute and 1 minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.
Programmed Service Interval
This warning indicates that the vehicle is operating at an RPM too low to keep the battery charged, the electrical loads are too high, or there is a charging system failure. Battery Voltage Low
To change the hour setting or reset the function, follow these steps: 1. Toggle the MODE button until the wrench icon is displayed in the information area. 2. Press and hold the MODE button until the information display area begins to flash. 3. Toggle the MODE button to increase the service interval hours in 5 hour increments to a maximum of 100 hours. 4. To turn off the service interval function, toggle the MODE button until "OFF" is displayed.
If battery voltage drops below 11 volts, a warning screen will display "Lo" and provide the present battery voltage. If voltage drops below 8.5 volts, LCD backlighting and icons will turn off. Battery Voltage High
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If battery voltage rises above 15 volts, a warning screen will display "OV" and provide the present battery voltage. If voltage rises above 16.5 volts, LCD backlighting and icons will turn off.
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Check Hydraulic
Indicates too low of hydraulic oil pressure caused by a plugged/blocked hydraulic oil filter or too high of hydraulic oil temperature. The Oil or Temperature light will illuminate along with this message.
Check Engine / Trouble Code Display
The diagnostic mode is accessible only when the check engine MIL has been activated.
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The initial factory service interval setting is 50 hours. Each time the engine is started, the engine hours are subtracted from the service interval hours. When the service interval reaches 0, the LCD wrench icon will flash for approximately 10 seconds each time the engine is started.
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Battery Under / Over Voltage
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ELECTRICAL
Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate. Diagnostic trouble codes will remain stored in the gauge (even if MIL turns off) until the key is turned off. 1. If the trouble codes are not displayed, use the MODE button to toggle until "CK ENG" displays on the information display area. 8. If more than one code exists, press the MODE button to advance to the next trouble code. 9. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded.
2. Press and hold the MODE button to enter the diagnostics code menu. 3. A set of three numbers will appear in the information area. 4. The first number (located far left) can range from 0 to 9. This number represents the total number of trouble codes present (example: 2 means there are 3 codes present).
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6. The third number (located bottom right) can be 1 to 2 digits in length. This number equates to the fault mode (FMI).
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5. The second number (located top right) can be 2 to 6 digits in length. This number equates to the suspected area of fault (SPN).
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7. Use the Diagnostic Trouble Code Table on the following pages for a description of each code.
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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ELECTRICAL
Diagnostic Trouble Codes
Component
Vehicle Speed Signal
Condition
Data Erratic or Intermittent (or missing) Voltage Too High
SPN
84
FMI
2 3
Digital Wrench® P-Code
P0503 P0118
Temperature Too High System Power (Battery Potential / Power Input) Gear Sensor Signal Crankshaft Position Sensor (CPS) Voltage Too High Voltage Too Low Voltage Too Low Plausibility Fault Driver Circuit Open / Grounded Rear Differential Output Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open / Grounded Fan Relay Driver Circuit Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open / Grounded Fuel Pump Driver Circuit Driver Circuit Short to B+ Driver Circuit Grounded 746 168 523 636
16 3 4 4 2 5 3 4 5 3 4 5 3 4 5 1888 3 4 3597 3 4 3 4 16 5536 0 19 5 520207 3 4 5 520272 3 4 5 520273 3 4
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1071 1347 3598
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Driver Circuit Open / Grounded PTO Solenoid Driver Circuit Driver Circuit Short to B+ Driver Circuit Grounded ECU 3.3V Output Supply Voltage
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Voltage Too High Voltage Too Low
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ECU 5V Output Supply Voltage
Voltage Too High Voltage Too Low
Temperature Too High Hydraulic Over-temp Shutdown Received Hydraulic Oil Temp Has Error Driver Circuit Open / Grounded
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Hydraulic Oil Temperature Sensor
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All Wheel Drive Control Circuit (AWD)
Driver Circuit Short to B+
Driver Circuit Grounded Driver Circuit Open / Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open / Grounded
Glow Plug Relay Driver Circuit
Fuel Pull Solenoid Relay Driver Circuit
Driver Circuit Short to B+ Driver Circuit Grounded
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P0217 P0563 P0562 P0916 P0335 P1691 P1692 P1693 P1481 P1482 P1483 P0230 P0232 P0231 P1310 P1311 P1312 P16A2 P16A1 P16A9 P16A8 P1218 P121A P121B P1836 P1835 P1834 P1385 P1384 P1383 P125A P125D P125C
Engine Temperature Sensor (ECT)
Voltage Too Low
110
4
P0117
ELECTRICAL
Component Condition
Driver Circuit Open / Grounded Two Speed Shift Coil Driver Circuit Driver Circuit Short to B+ Driver Circuit Grounded Operator Presence Switch Hydraulic Oil Pressure Sensor / Switch Voltage Too High Hydraulic Oil Filter Plugged 524070 524075 524076 520274
SPN
FMI
5 3 4 3 17 17
Digital Wrench® P-Code
P1750 P1751 P1752 P251C
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Engine Oil Pressure Sensor / Switch Oil Level Low
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P150F P151F
ELECTRICAL
Instrument Cluster Removal
NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens. 1. Remove the push rivets (Item 1) and upper dash panel (Item 2) from the vehicle. 1
Instrument Cluster Installation
1. Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the rubber mount more easily.
2
3 2. Disconnect the wire harness connector (Item 3) from the back side of the instrument cluster.
2. Be sure the rubber mount is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash panel. 3. Hold the dash panel securely and insert the instrument cluster into the dash panel. Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster. Apply pressure on the bezel while pressing on the instrument cluster. 4. Connect the wire harness to the instrument cluster. 5. Install the upper dash panel and push rivets.
3. Push the instrument cluster (Item 4) out of the lower dash panel, while securely holding the panel and rubber mount (Item 5).
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NOTE: The instrument cluster bezel (Item 6) is a snap-on assembly and is a serviceable part.
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ELECTRICAL
HEADLIGHTS
Headlight Adjustment
1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 6. Once the beam is set to the position, tighten the adjustment screw. Repeat the procedure to adjust the other headlight.
WARNING
Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death.
X1
X2
8 in. (20 cm)
Headlight Bulb Replacement
1. Remove the hood from the front cab.
2. Measure the distance from the floor to the center of the headlight (X1) and make a mark on the wall at the same height (X2). 3. With the vehicle in Park, start the engine and turn the headlight switch to the LOW position. 4. The most intense part of the LOW headlight beam should be aimed 8 in. (20 cm) below the mark placed on the wall in Step 2.
NOTE: Rider weight must be included in the seat while performing this procedure.
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5. Remove the hood and locate the adjustment screw (Item 1) on the side of the headlight housing (Item 2). Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height.
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3. Turn the bulb counterclockwise and remove it from the headlight housing.
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2. Locate the bulb on the back side of the headlight housing and Disconnect the harness (Item 3) from the bulb. Be sure to pull on the connector, not on the wiring.
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25 ft. (7.6 m)
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ELECTRICAL
4. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place. 5. Install the harness onto the new headlight bulb and install the hood. 7. Carefully push on the face of the headlight housing to disengage the housing tabs from the front fascia brackets. 8. Remove the headlight housing from the vehicle.
Headlight Housing Removal
1. Remove the hood from the front cab. 2. Remove the Torx-head screw and push rivet retaining the upper right portion of the front fender.
Headlight Housing Installation
2. Secure the headlight housing with the rubber O-rings (Item 3) on each side. Install the adjustment screw (Item 4). NOTE: Be sure to twist the O-rings upon installation as shown below.
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4 3. Carefully lift up the front fender far enough to access the entire headlight housing. 4. Disconnect the harness from the bulb (see "Headlight Bulb Replacement"). 5. Remove the O-rings (Item 1) from each side of the headlight housing.
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3. Connect the harness to the bulb. 4. Install the Torx-head screw and push rivet retaining the upper right portion of the front fender. 5. Install the hood. 6. Adjust headlights using the "Headlight Adjustment" procedure.
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2 6. Remove the adjustment screw (Item 2).
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1. Install the headlight housing by pressing the housing tabs back into the front fascia brackets.
ELECTRICAL
TAIL LIGHT / BRAKE LIGHT
LED Lamp Replacement
1. Open the rear tailgate. 2. Remove the two screws retaining the LED lamp assembly.
3. Remove the LED lamp from the rear cargo box and disconnect the tail light / brake light wire harness.
NOTE: Before replacing the LED lamp assembly, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present.
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4. Install the new LED lamp assembly by reversing this procedure.
5. Test the tail light / brake light after installation to verify proper function.
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ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram
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ELECTRICAL
Coolant Temperature Sensor
The Coolant Temperature Sensor is found on the top right side of the engine by the water pump housing.
Fan Control Circuit Operation / Testing
Power is supplied to the fan via the Orange/Black wire when the relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to "RELAYS" later in this chapter for more information on fan functions.
NOTE: The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system. Be sure cooling system is full and purged of air.
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1. Disconnect sensor. harness
1. With the engine and temperature sensor approximately 77°F (25°C), disconnect the harness. 2. With a multimeter set to ohms, place the meter leads onto the sensor contacts. 3. Use the Temperature / Resistance table to determine if the sensor needs to be replaced. Condition Engine Shutdown
(temp. is sustained for 25 seconds)
Fan Control Circuit Bypass Test
from coolant temperature
Approx.
1.22 k ± 2%
Coolant Hot Lamp (Blinking) Coolant Hot Lamp (On Solid) Cooling Fan On Cooling Fan Off
1.30 k ± 2%
1.45 k ± 2% 2.80 k ± 2% 3.40 k ± 2% 29.9 k ± 2%
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Room Temperature System Capacity
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Temperature 248° F (120° C) 240° F (116° C) 230° F (110° C) 194° F (90° C) 182° F (83° C) 77 °F (25 °C)
2. Turn the key on. After a few seconds, the fan should start running and the "Check Engine" indicator should display on the instrument cluster. This indicates all other components are working properly. 3. If the fan does not run or runs slowly, check the fan motor wiring, ground, motor condition, circuit breaker and relay for proper operation. Repair or replace as necessary. 4. If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals.
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Keep hands away from fan blades during operation. Serious personal injury could result.
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CAUTION
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Brutus / Brutus HD - 6.2 qts (5.9 L) Brutus HDPTO - 6.9 qts (6.5 L)
Radiator Cap Relief Pressure
13 PSI
NOTE: If the coolant temperature sensor or circuit malfunctions the radiator fan will default to 'ON' while the engine is running.
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
ELECTRICAL
HVAC SYSTEM
HVAC System Break-Out Diagram
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ELECTRICAL
HVAC Control Circuit Operation / Theory
Power is supplied to the HVAC system through the 30 amp fuse found in its own fuse holder outside of the main fuse box under the center console. The condenser fan is powered by a 20 amp circuit breaker through the condenser fan relay. The HVAC relay is powered by the 30 Amp HVAC fuse. When they key is in the ON position, the HVAC relay is energized. Power is sent on the Red/Green wires to the blower switch, the temperature knob (temp pot 10k) and the water valve. Power only travels from the blower switch to the AC switch on the white wire when the knob is in the low, medium or high setting. If the AC switch is ON, power is sent out on the blue wire to power the condenser fan relay and the thermostat on the AC evaporator. The evaporator thermostat will send power on the white wire to the HPCO (high pressure cut-out) switch located in the AC hose. The switch is normally closed. When the switch is closed, power is sent to the AC compressor. When the pressure in the AC line gets too high, the switch opens and the compressor cycles off. The condenser fan will always be running when the AC system is on and it is powered by a 20 Amp circuit breaker just outside the relay box. As the temperature knob is moved towards the warm setting, the voltage through the potentiometer is interpreted by the water valve to control the flow of warm water through the heater core to warm the air.
AC Switch
The AC Switch can be tested using an ohmmeter. 1. Disconnect harness from AC Switch. 2. With the meter in the ohms mode, place the leads on pins P1 and P3. 3. With the switch off, the reading should be OL.
4. With the switch on the reading should be less than 1 .
Blower Switch
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Temperature Control
Knob Position Full Cold Full Hot Any Position Between Cold/Hot
The Temperature Control potentiometer can be tested using an ohmmeter. 1. Disconnect the harness going to the Temperature Control potentiometer. 2. With the meter in the ohms mode, place the meter leads onto the potentiometer flying lead contacts. 3. Use the table to determine if the switch needs to be replaced. Pins A to B A to B A to B A to C Ohms Reading ~ 81.5k ~ 86.5k ~ 91.5k ~ 10k
The Blower Switch can be tested using an ohmmeter.
1. Disconnect the harness going to the Blower Switch.
3. Use the table to determine if the switch needs to be replaced.
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2. With the meter in the ohms mode, place the meter leads onto the switch contacts.
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Keep hands away from fan blades during operation. Serious personal injury could result.
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CAUTION
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ELECTRICAL
FUEL SENDER
Testing
1. Remove the fuel level assembly from the fuel tank (see Chapter 4 "Fuel Pick-Up / Sending Unit Removal").
3. Allow the sender float to sit in the empty position and compare to specification.
Fuel Sender - Full: 102 ± 2 5. If the readings are out of specification, or if the reading is erratic or LCD display "sticks", check the following before replacing the fuel level assembly:
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· Loose float
· Float contact with tank · Bent float rod
6. If none of the conditions exist, the fuel sender assembly is faulty. Replace the fuel level sender assembly (see Chapter 4).
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4. Slowly move the sender float to the full position and compare to specification.
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Fuel Sender - Empty: 6 ± 2
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2. Using an Ohm meter, measure the resistance of the fuel sender as shown below.
ELECTRICAL
FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKERS / TVS DIODES
Fuse, Relay, Circuit Breaker and TVS Diode Locations
Located under the center console, the fuses provide overload protection for wiring and components. The relays assist with high load component operation. A separate relay and 40 amp circuit breaker protects the cooling fan motor circuit and can be found outside of the relay / fuse boxes. On PTO models, a separate HVAC relay and 30 amp HVAC fuse can be found in a fuse holder just outside the relay / fuse boxes. If equipped, the box lift relay and 20 Amp circuit breaker is located under the upper dash cover near the box lift switch.
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1. Radiator / Cooling Fan Relay
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Component Descriptions
7. Relay Block - houses the fuel pull, ECM, PTO, glow plug, fuel hold, and chassis relays. All relays in this box are interchangeable. 8. TVS (transient-voltage-suppression) Diode - used to protect electrical components from voltage spikes. · PTO (HDPTO model only) · Hydraulic Solenoid (HD and HDPTO model only) · Fuel Solenoid / Fuel Pump · Start Solenoid
3. HVAC 30 Amp Fuse - HD and HDPTO models only. Provides power to the HVAC Relay
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2. HVAC Relay - HD and HDPTO models only. Provides power to the heating and air conditioning system.
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4. Radiator / Cooling Fan 40 Amp Circuit Breaker
5. Condenser Fan 20 Amp Circuit Breaker 6. Fuse / Relay Block - houses the condenser fan, starter and tilt lock relays as well as the glow plug, drive, fuel hold, fuel pull, ECU, PTO, hydro, acc. and light fuses.
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ELECTRICAL
Relay Box Detail
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ELECTRICAL
FUEL PULL SOLENOID RELAY provides power to the pull coil side of the fuel solenoid. FUEL PULL SOLENOID RELAY PIN 86 85 30 87 COLOR Red / Dark Blue Brown / Blue Red White FUNCTION 12 V switched power from ECM relay. ECU ground input to enable relay. 12 V circuit powered by the 30 Amp Fuel Pull Solenoid fuse through the 30 Amp Chassis fuse. Provides 12 V power for fuel pull solenoid coil. PIN 86 85 30 87 COLOR Red / Dark Blue Dark Green / Yellow Red / White Red / White ECM RELAY provides power to the ECU, Fuel Pull relay, Fuel Hold relay, Glow Plug relay, Cooling Fan relay, Seat Pressure switch (HDPTO model only), and Two Speed Manifold. ECM RELAY FUNCTION
PTO RELAY (HDPTO model only) PIN 86 85 30 87 COLOR FUNCTION
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PIN 86 COLOR Red / Dark Blue 85 30 Red Black / Red 87 · Drive (AWD / TURF) PIN 86 85 30 87 COLOR Orange Brown Red White
PTO RELAY provides power to the PTO Clutch and Tilt Lock Relay.
GLOW PLUG RELAY provides power to the Glow Plugs. GLOW PLUG RELAY FUNCTION
White / Orange 12 Vdc from PTO switch. White / Black Red / Dark Blue Red / Dark Blue ECU ground input to enable relay. 12 Vdc power from PTO fuse through PTO splice #1.
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Brown / Green ECU ground input to enable relay. 30 Amp Glow Plug fuse protected 12 Vdc constant battery voltage. Provides 12 Vdc power for glow plug operation.
Provides 12 Vdc power for PTO splice #2 for clutch engagement and tilt lock relay.
FUEL HOLD SOLENOID RELAY provides power to the fuel solenoid hold coil and the fuel pump.
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FUEL HOLD SOLENOID RELAY PIN 86 COLOR FUNCTION
CHASSIS RELAY provides power to the following systems: · Lights (Headlights / Taillights)
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12 V switched power from ECM Red/Dark Blue relay. Grey/Dark Green ECU ground input to enable relay. 12 V circuit powered by the 20 Amp Fuel Hold Solenoid fuse through the 30 Amp Chassis fuse. Provides 12 Vdc power for fuel pump and fuel solenoid hold coil.
· Accessory (12V Receptacles / Accessory Options) CHASSIS RELAY FUNCTION 12 Vdc power input from key switch to enable relay. Relay coil constant ground. BUSS Bar - 12 Vdc constant battery voltage Provides 12 Vdc power for lights, drive and accessory circuits.
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ECU ground input to enable relay. 20 Amp ECU fuse protected 12 Vdc constant battery voltage. Provides 12 Vdc power to the ECU relay B+ splice.
12 Vdc switched power from ECU relay.
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20 Amp ECU fuse protected 12 Vdc constant battery voltage.
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Red Red
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ELECTRICAL
Relay Power Flowcharts
Fuel Pull Relay, PTO Relay, Fuel Hold Relay
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ELECTRICAL
ECM Relay, Glow Plug Relay, Chassis Relay
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ELECTRICAL
Fuse / Relay Box Detail
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Fuse / Relay Box Detail
TILT LOCK RELAY provides power to the hydraulic control valve tilt lock when activated to prevent tilting of the hydraulic attachment when the PTO switch is engaged or when the tilt lock switch is turned on. TILT LOCK RELAY
85 30
Brown Beige / Black
Chassis Ground Provides 12 Vdc power for tilt spool lock when the tilt lock switch is engaged (relay unswitched) Provides 12 Vdc power for tilt spool lock when PTO is engaged. (relay switched) Power to control valve to lock the tilt spool. (relay unswitched)
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Beige / Black
87A Dark Green
STARTER RELAY provides power to the starter solenoid. STARTER RELAY PIN 86 85 30 87 COLOR White / Red (154) White / Red (E201) Red / White White / Red (111)
FUNCTION
12 Vdc switched power from key switch
CONDENSER FAN RELAY provides power to the air conditioner condenser fan. CONDENSER FAN RELAY (HDPTO model only) COLOR FUNCTION 12 Vdc power from AC switch. Chassis ground to enable relay. 20 Amp circuit breaker protected 12 Vdc constant battery power. Provides 12 Vdc power for condenser fan operation.
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20 Amp ECU fuse protected 12 Vdc constant battery voltage. Provides 12 Vdc power for starter solenoid operation.
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ECU ground input to enable relay.
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PIN 86 85 30 87
Blue
Brown
White / Black White / Grey
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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Red / Dark Blue
12 Vdc switched power from PTO fuse through the PTO switch.
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PIN
COLOR
FUNCTION
ELECTRICAL
External Relays
HVAC RELAY is found under the center console outside
of the relay boxes. The HVAC relay provides power to the following: · Blower Switch · Temperature Control Switch · Water Valve HVAC RELAY (HDPTO model only) PIN 86 85 30 87 COLOR Orange Brown Red / Dark Blue Red / Dark Green FUNCTION 12 Vdc switched power Chassis ground. 30 Amp HVAC fuse protected 12 Vdc constant battery power. Provides 12 Vdc power for HVAC operation. 87 Red 85 30 Brown Red PIN 86
CARGO BOX LIFT RELAY provides power to the cargo
box lift actuator and is mounted on the sub-harness for the cargo box lift switch under the upper dash cover. CARGO BOX LIFT RELAY COLOR Orange / White FUNCTION 12 Vdc switched power from 20A Accessory fuse
REAR DIFF SOLENOID RELAY provides power to the
rear differential solenoid and is located below the cargo box by the rear frame support. REAR DIFF SOLENOID RELAY FUNCTION
RADIATOR FAN RELAY is found outside the relay
boxes in the center console and provides power to the cooling fan COOLING FAN RELAY PIN 86 85 30 87 COLOR Red / Dark Blue Brown / Red Red Orange/Black
FUNCTION
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Red Blue
Brown
Dark Green / White ECU input to enable relay. Red / Dark Green 10-Amp fuse protected 12 Vdc battery voltage. Relay switched power to operate the Rear Diff Solenoid. Ground to energize the Rear Diff Solenoid.
BUSS Bar - 12 Vdc switched power from EFI relay.
40 Amp circuit breaker protected 12 Vdc constant battery power.
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Provides 12 Vdc power for fan operation.
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ECU ground input to enable relay.
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Relay coil ground.
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Chassis ground through the front terminal block.
20 Amp Circuit Breaker protected 12 Vdc constant battery power. Provides 12 Vdc power to the Box Lift switch for lift operation.
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ELECTRICAL
CHARGING SYSTEM
The BRUTUS alternator is rated 12v, 90A, 1215 watts (at 13.5 V nominal voltage).
Charging System "Break Even" Test CAUTION
Do not allow the battery cables to become disconnected while the engine is running. Follow the steps below as outlined to reduce the chance of damage to electrical components.
Current Draw - Key Off CAUTION
Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw.
Current Draw Inspection Key Off
30 Amp
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Current Draw - Key Off: Maximum of .01 DCA (10 mA)
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Never start the engine with an ammeter connected in series. Damage to the meter or meter fuse will result. Do not run test for extended period of time. Do not run test with high amperage accessories.
1. Using an inductive amperage metering device, (set to DC amps) connect to the negative battery cable. 2. With engine off, and the key switch and lights in the ON position, the ammeter should read negative amps (battery discharge). Reverse meter lead if a positive reading is indicated. 3. Shift transmission into neutral with the parking brake applied and start the engine. With the engine running at idle, observe meter readings. 4. Increase engine RPM while observing ammeter and tachometer. 5. Note RPM at which the battery starts to charge (ammeter indication is positive).
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WARNING
The "break even" point of the charging system is the point at which the alternator overcomes all system loads (lights, etc.) and begins to charge the battery. Depending on battery condition and system load, the br