SERVICE TROUBLESHOOTING

MANUAL GUIDE

VEHICLE ELECTRICAL SYSTEM

Kässbohrer
Pisten Bully
PB100 (Mercedes OM904LA Powered)
(Nordic, Trail & Utility Models)
(up to S/N 821-11305)

CD Part # 82.5.20180
Book Part # 82.5.20180B

Edition 14-Feb-12

Back to Main Menu

 PLEASE READ CAREFULLY!

GENERAL INFORMATION

All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. The right is reserved to
make changes at any time without notice.

TESTING SAFETY

Most circuits are energized at a maximum of 24 volts. This is a relatively low voltage but
safety is still an important consideration in troubleshooting.

Only skilled personnel familiar with electrical equipment should be permitted to do the
work. There may be hazards present, not only from electrical energy but also from
mechanical and fluid power equipment. It is important to know the condition of all sections
of the machine before starting troubleshooting work.

CIRCUIT GROUND LOCATIONS

The ground network for the electrical system consists of the main frame, engine block,
subframe of platform, and steel framework of cab. Because of the numerous ground
points involved, it is not feasible to show the actual location on the vehicle where each
ground wire terminates. In the following circuit diagrams, ground connections are shown
with the conventional symbol

CIRCUITS AND SERIAL NUMBERS

Although the majority of the electrical circuits are common within the different serial
number ranges and models of the PB100, certain circuits are not. Circuits that are
applicable to a specific serial number range or model have been identified as such. It is
important to identify your vehicle serial number prior to use of this book in order to
insure that the correct circuit is referenced.
 Page
Using This Manual ….………………………………………………………………………………….. 4
Component Location …………………………………………………………………………………… 6
Relay - Fuse Index up to s/n 821-10536 ..…………………………………………………..……….. 7
Relay - Fuse Index from s/n 821-10537 ...…………………………………………………..……….. 8
Ignition Switch Starting - Charging Circuit (Nordic, Trail & Utility) up to s/n 821-10536 ..……… 9
Ignition Switch Starting - Charging Circuit (Nordic & Trail) from s/n 821-10537 ..………………10
Drive Control (Card to Cab) up to s/n 821-10580 …………………..……………………………….11
Drive Control (Card to Cab) from s/n 821-10581 to 10650 ………..……………………………... 12
Drive Control (Card to Cab) from s/n 821-10651 to 11305 …………..…………………………... 13
Drive Control (Card to Chassis) up to s/n 821-10580 …………………………………………….. 14
Drive Control (Card to Chassis) from s/n 821-10581 .…………………………………………….. 15
Third Pump Control (Nordic 100)…………………………………………………………………….. 16
Front Implement Electrical System, (Nordic & Trail 100) up to s/n 821-10580 ..…….....……… 17
Front Implement Electrical System, (Nordic & Trail 100) from s/n 821-10581 ..….….....……… 18
Front Implement Electrical System (Utility 100)……………….…..…………………….…………. 19
Rear Implement Electrical System, (Nordic 100) up to s/n 821-10580 ..………………......…… 20
Rear Implement Electrical System, (Nordic 100) from s/n 821-10581 ..….……………......…… 21
Rear Implement Electrical System (Trail 100) up to s/n 821-10580 …………………….………. 22
Rear Implement Electrical System (Trail 100) up to s/n 821-10581 …………………….………. 23
Radio and Voltage Converter ……………………………………………………………….……….. 24
Driver’s Seat …………………..…………………….………………………………………………… 25
Tach & Multi-function Display (Nordic & Trail 100) up to s/n 821-10536 …………………….…. 26
Tach & Multi-function Display (Nordic & Trail 100) from s/n 821-10537 .…………………….…. 27
Tach & Multi-function Display (Utility 100) ..……………..……..… ………………………………. 28
Front Top Lights & Park Lights ………………………………………………………………………. 29
Front Xenon Lights ………….…………………………………………………………………………30
Rear Top Lights (Nordic & Trail 100) ……..……………………………………………….………… 31
Rear Top Lights (Utility 100) ……………....……………………………………………….………… 32
Beacon Lights (Nordic & Trail 100) …………………………………………………………………. 33
Beacon Lights (Utility 100) ………..…………………………………………………………………. 34
Interior Light & Under Console Light ……..…………………………………………………...……. 35
Directional Lights (Nordic & Trail 100) …………………………..……………………..…………… 36
Directional Lights (Utility 100) …………………………………………………………...…………… 37
Flashlight (12v) & 24v Plug ………….………………………………………………………….……38
Front Windshield Heating …………………..……………………………………………………….. 39
Rear Window Heating (Nordic & Trail 100 only) …………………………………………………… 40
Side Window Heating & Mirror Heating (up to s/n 821-10536) …..………………………………. 41
Side Window Heating & Mirror Heating (from s/n 821-10537) …..……………………….....……. 42
Cab Heater …….……………………………………..………………………………..…………….. 43
Front Wipers and Horn ……………………………………………………………………………… 44
Rear Wiper …………………………………………………………………………………………… 45
Engine Grid Heater (up to s/n 821-10536) …………………………….…………………………... 46
Engine Grid Heater (from s/n 821-10537) …………………………….…………………………... 47
Engine Fuel Injection Wiring (up to s/n 821-10536) .………………………………………….… 48
Engine Fuel Injection Wiring (from s/n 821-10537) .…………………………………………..… 49
Engine Block Heater ………………...………….………………..………………………………...... 50
Complete Main Electrical PB100 (Nordic & Trail 100) up to s/n 821-10536 ………………….. 51
Complete Main Electrical PB100 (Nordic & Trail 100) from s/n 821-10537 …………………... 52
Complete Main Electrical PB100 (Utility 100) ..…………..………..…………………………….. 53
Circuit Testing Procedures …………………………………………………………………………. 54
Resistor Color Coding ……………………………………………………………………………….. 59
Wheel Diagram For Electrical Equations ……………………………………..…………………... 60
Index …………………………………………………………………………………………………… 62

Page 3
 USING THIS MANUAL

The entire electrical system has been broken down into its individual circuits. A table of
contents is provided at the start of the manual to aid the reader to quickly locate a
particular circuit. A section has been included on techniques for testing basic circuit
failures. Each individual circuit has been drawn in diagramatic form using electrical
symbols. However, each symbol is identified by an illustration along with part name and
part number. When possible, the actual component location is also illustrated.

Relays are identified by a K and a number. Example: K7. Fuses are identified by their
number and switches are identified by an S and the number. Example: S22. A glossary of
the fuses and relays has been included.

Each electrical component's terminal markings have been identified and each wire has
been color coded. A color code chart has been placed on most circuits as a reference aid.
Often times, a number will immediately follow the color code on a wire: Example: BL.75.
The number .75 indicates the area size of the wire in millimeters.

The electrical circuitry of the PB100 has centralized points of connection. These
connectors are identified by Roman numerals, and their location is noted on Page 6.
Please note example below for an explanation of their use in the electrical drawings.

Electrical wire harness connection points are shown with a

ROMAN NUMERAL and NUMBER
EXAMPLE: III - 2
The ROMAN NUMERALS refer to specific
plastic connection blocks located in the vehicle.
BLOCKS -- I II III IV
are located under center console.
BLOCK ----- V
is located inside steering column.

The NUMBER adjacent to the

Roman Numeral refers to specific
embossed number located on
the block surface.

Page 4
This manual is provided, not with the intent to circumvent, but rather to supplement
the electrical system wiring schematics provided in your vehicle's manual. It
should also be used in conjunction with the PB100 Operator's Manual which
describes the location and function of the individual switches and electrical
components.

In conclusion, it is hoped that this manual will provide the following benefits:

1. To provide a learning aid to newcomers unfamiliar with the Pisten Bully

PB100 electrical system and thus reduce familiarization time.

2. To provide a means for someone wishing to further develop their

understanding of the electrical system.

3. To insure that proper wiring connections are made when components are
replaced.

4. To provide a means to quickly locate components and their part numbers.

5. To enable the reader to quickly visualize how and which particular

components are interconnected in a particular circuit.

6. To provide an aid in troubleshooting.

7. To increase communication effectiveness between parts and service

personnel when dealing with the electrical system.

Page 5
 COMPONENT LOCATION

A DIGITAL DRIVE CARD

B REAR/FRONT IMPL. CARD
C BACK UP ALARM RELAY
D GRID HEATER RELAY up to s/n 10536
D1 STARTER RELAY from s/n 10537
E VOLTAGE REGULATOR
F 24/12V CONVERTER
S SWITCH
K RELAY
(under dash)
CONNECTORS

CONNECTOR
V
(under dash)
MAIN FUSES
#1 FUSES #30

I II III IV
K1 RELAYS K16
D, D1

C E A B F
ENGINE
ADM

Page 6
 RELAY & FUSE INDEX
up to s/n 821-10536
RELAYS FUSES
Base 7.375.182.000
Term .250” 0.023.706.001
Term .188” 0.023.706.032

Base 7.375.112.001 SIZE PART NR.

Term .250” 0.023.706.001 10A 0.026.012.005
20A 0.026.012.007
7.375.197.000 30A 0.026.012.009

FUSE BRIDGE 7.253.030.001

1. (10A) High beam lights, front

7.375.201.000 2. (10A) Low beam lights, front
3. (10A) Left front light, outside position
4. (10A) Right front light, outside position
5. (10A) Gauge lights, right taillight
6. (10A) Under console light, left taillight
7. (20A) Front xenon lights (optional)
7.375.181.000 8. (20A) Rear top lights
9. (10A) Drive electronics, backup alarm
10. (10A)Tiller & drive bypass switch
11. (20A)Front plug, KFS power
12. (10A)Rear wipers
ALL 100 13. (10A)Front wipers, horn
K1 Front windshield heat 14. (10A)Tach, instr. cluster, gauges
K2 Front lights 15. (10A)Drivers seat, heater & pump
K3 Fuel heat 16. (20A)Aux. hydraulic elec. board
K4 Directional lights
K5 Circuits ON “ONLY” 17. (10A)Grid heat, 24/12V converter
with engine running 18. (10A)Plug socket
K6 Main lighting 19. (10A)Directional lights, flash lights
K7 Rear window heat 20. (20A)Heater blower
K8 Door & brake warning 21. (10A)Engine electronic
NORDIC & TRAIL 100
K9 -K12 Front blower (KFS)
22. (10A)Engine electronic
vehicles 23. (10A)Engine electronic
K13 Grid heat (wire N) 24. (10A)Engine electronic
K15 Wiper interval front 25. (10A)Engine electronic
K16 Wiper interval rear 26. (20A)Fuel preheater
UTILITY 100
K9 Grid heat (wire N)
27. (20A)Relay K3, ON w/eng. running, side
K9.5 Rear lights glass heat, mirrors
K10 Wiper interval front 28. (20A) Rear glass heat
K11 Wiper interval rear cabin 29. (30A) Front window heater
Page 7 30. (20A) Rotary beacons, interior light
 RELAY & FUSE INDEX
from s/n 821-10537
RELAYS FUSES
Base 7.375.182.000
Term .250” 0.023.706.001
Term .188” 0.023.706.032

Base 7.375.112.001 SIZE PART NR.

Term .250” 0.023.706.001 10A 0.026.012.005
20A 0.026.012.007
7.375.197.000 30A 0.026.012.009

FUSE BRIDGE 7.253.030.001

1. (10A)
High beam lights, front
7.375.201.000 2. (10A)
Low beam lights, front
3. (10A)
Left front light, outside position
4. (10A)
Right front light, outside position
5. (10A)
Gauge lights, right taillight
6. (10A)
Under console light, left taillight
7. (20A)
Front xenon lights (optional)
7.375.181.000 8. (20A)
Rear top lights
9. (10A)
Drive electronics, backup alarm
10. (10A)
Tiller & drive bypass switch
11. (20A)
Front plug, KFS power
12. (10A)
Rear wipers
13. (10A)
Front wipers, horn
NORDIC & TRAIL 100 14. (10A)
Tach, instr. cluster, gauges
15. (10A)
Drivers seat, heater & pump
K1 Front windshield heat 16. (20A)
Aux. hydraulic elec. board
K2 Front lights
K3 Directional lights 17. (10A)
Grid heat, 24/12V converter
K4 Circuits ON “ONLY” 18. (10A)
Plug socket, 12v flashlight
with engine running 19. (10A)
Directional lights, flash front lights
K5 Main lighting 20. (20A)
Heater blower
K6 Rear window heat 21. (10A)
Engine electronic
K7 Wiper interval front
K8 Door & brake warning
22. (10A)
Engine electronic
K9 -K12 Front blower (KFS) 23. (10A)
Engine electronic, alternator
vehicles 24. (10A)
Engine electronic
K16 Wiper interval rear 25. (10A)
Engine electronic
26. (30A)
Starter relay
27. (20A)
Relay K4, ON w/eng. running, side
glass heat, mirrors
28. (20A) Rear glass heat
29. (30A) Front window heater
Page 8 30. (20A) Rotary beacons, interior light
 IGNITION SWITCH STARTING - CHARGING CIRCUIT up to 821-10536
Alternator charge warning light
(complete cluster #1 8.749.136.000)
Bulb 7.584.172.000
Alternator 8.312.088.013

Engine Electronic “ADM 1”

(under dash) 821.4100.130.01

Main Fuse Box

7.253.016.000
80A Fuse
0.026.010.007
Relay 7.375.201.000
(energized when alter.
is charging)
Ignition
Switch
Power supply
7.345.(042-051).000
with key on

Power supply
at all times Battery Main Switch
Engine buttons 7.341.110.000
8.312.088.126 Key only
7.341.110.002

Relay on outside
of starter 8.312.088.132

Batteries 7.471.156.108 Starter

Engine Electronic (PLD) 8.312.088.014
(special order item)

Page 9
 IGNITION SWITCH STARTING - CHARGING CIRCUIT from 821-10537
Alternator charge warning light
(complete cluster #1 8.749.136.000)
Bulb 7.584.172.000
Alternator 8.312.088.206
Engine Electronic “ADM 2”
(under dash) 821.4100.180.11

Main Fuse Box

7.253.016.000
80A Fuse
0.026.010.007
Relay 7.375.201.000
(energized when alter.
is charging)
Ignition
Switch
7.345.(042-051).000
Power supply
with key on

Starter Relay (under dash)

Power supply 08082
at all times
Engine start/stop
buttons
8.312.088.126

Battery Main Switch

7.341.110.000
Key only
7.341.110.002

Batteries 7.471.036.102 Starter

Engine Electronic (PLD) 8.312.088.014
(special order item)

Page 10
 DRIVE CONTROL, CARD TO CAB up to s/n 821-10580
Brake sender input
for tiller shut-off Alarm rocker switch
(from 821-10365) (note: no alarm on Utility 100)
Relay, Back-Up Alarm 7.331.164.000
(note: no alarm on Utility 100) Symbol 7.331.137.109 Plug pin positions
7.375.161.000 on drive card

Fuse 2.5A
0.026.011.002

Drive Card
8.749.175.000

Voltage Regulator
7.267.208.000

Back up alarm Connections to Moog

7.711.208.000 controllers. See
“Drive control, card to chassis”

Indicator light
Cluster assembly #2
8.749.139.000 to s/n 10536 Capacitor
8.749.218.000 from s/n 10537 7.267.221.000
Bulb (small)
7.584.172.000

Throttle Position Connections for Engine Speed

Signal From ADM Signal from ADM (Under Dash)

Steering
Potentiometer
8.749.002.000 “ADM 1”
Load Limit Bypass 821.4100.130.01
Switch “ADM 2” from 10537
7.331.179.000 821.4100.180.11
Symbol
7.331.137.201 To third pump
Track Speed control drawing Forward/Reverse
Potentiometer Switch 7.331.166.002
(Under Dash) 8.743.876.000 Symbol
7.331.137.217

Page 11
 DRIVE CONTROL, CARD TO CAB from s/n 821-10581 to 10650
Alarm rocker switch
Brake sender input
(note: no alarm on Utility 100)
for tiller shut-off
7.331.164.000
(from 821-10365)
Symbol 7.331.137.109
Relay, Back-Up Alarm Plug pin positions
(note: no alarm on Utility 100) on drive card
7.375.161.000

Fuse 2.5A
0.026.011.002
Drive Card
8.749.175.000

Voltage Regulator
7.267.208.000 Connections to Moog
controllers. See “Drive
control, card to chassis”

Back up alarm
7.711.208.000 To relay K10 only
used in KFS vehicles

Indicator light
Cluster assembly Capacitor
8.749.139.000 7.267.221.000
Bulb (small)
7.584.172.000

Connections for Engine Speed

Throttle Position Signal from ADM (Under Dash)
Signal From ADM

500

Steering
Potentiometer
8.749.002.000
Load Limit Bypass
Switch “ADM 2”
7.331.179.000 821.4100.180.11
Symbol
7.331.137.201 To third pump
Track Speed control drawing
Potentiometer
(Under Dash) 8.743.876.000 Forward/Reverse
Switch 7.331.166.002
Symbol
7.331.137.217
Page 12
 DRIVE CONTROL, CARD TO CAB from s/n 821-10651 to 11305
Alarm rocker switch
Brake sender input
(note: no alarm on Utility 100)
for tiller shut-off
7.331.164.000
Symbol 7.331.137.109
Relay, Back-Up Alarm Plug pin positions
(note: no alarm on Utility 100) on drive card
7.375.161.000

Fuse 2.5A
0.026.011.002
Drive Card
8.749.226.000

Voltage Regulator
7.267.208.000 Connections to Moog
controllers. See “Drive
control, card to chassis”

Back up alarm
7.711.208.000 To relay K10 only
used in KFS vehicles

Indicator light Capacitor

Cluster assembly 7.267.221.000
8.749.139.000
Bulb (small)
7.584.172.000

Connections for Engine Speed

Signal from ADM (Under Dash)
Throttle Position
Signal From ADM

Steering
Potentiometer
8.749.002.000
Load Limit Bypass
Switch (under dash) To third pump “ADM 2”
7.331.179.000 control drawing 821.4100.180.11
Symbol
7.331.137.201

Track Speed Ground at third pump

Potentiometer On/off rocker
8.743.876.000
Forward/Reverse
Relay Switch 7.331.166.002
7.375.199.000 Symbol 7.311.183.000
7.331.137.217 7.311.180.000 Page 13
DRIVE CONTROL, CARD TO CHASSIS
Up to s/n 821-10580

Drive Card
Plug pin positions 8.749.175.000
on drive card

3 CONNECTIONS
TO STEERING
POTENTIOMETER

Moog Plug
7.231.110.000
Connector
male pin
(one wire) 0.023.703.007
(two wire) 0.023.703.008
female pin
(one wire) 0.023.716.001
(two wire) 0.023.716.002

Servo Right Servo Left Plastic Plugs

8.749.126.000 8.749.126.000 male 7.231.117.000
female 7.231.122.000

Page 14
DRIVE CONTROL, CARD TO CHASSIS
From s/n 821-10581

Drive Card
Plug pin positions 8.749.175.000
on drive card

2 CONNECTIONS
TO STEERING
POTENTIOMETER

Moog Plug
7.231.110.000
Connector
male pin
(one wire) 0.023.703.007
(two wire) 0.023.703.008
female pin
(one wire) 0.023.716.001
(two wire) 0.023.716.002

Servo Right Servo Left Plastic Plugs

8.749.126.000 8.749.126.000 male 7.231.117.000
female 7.231.122.000

Page 15
THIRD PUMP CONTROL (NORDIC PB100 ONLY)
Power supply
with key on

Plug pin positions

on drive card

Connector
male pin
(one wire)
0.023.703.007
(two wire)
0.023.703.008

female pin
Tiller spinning light (one wire)
0.023.716.001
(two wire)
0.023.716.002

Front 7-pin plug

7.235.063.000

(from s/n 10537)

Controller magnet
8.048.346.581
Tiller on light

Drive card
8.749.175.000
Tiller potentiometer
8.743.877.000 Tiller F/R switch Plug 7.231.125.000
7.331.159.002 Controller magnet
Tiller on/off Symbol 7.331.137.232 8.048.204.280 (up to s/n 10536)
7.331.164.000
Symbol 7.331.137.302

Connections to drive Light behind

forward/reverse switch potentiometers Page 16
FRONT IMPLEMENT ELECTRICAL SYSTEM (NORDIC & TRAIL PB100)
Up to s/n 821-10580
Blade float switch
Ball handle buttons 7.331.163.000
8.025.764.682 Symbol
7.331.140.508
Implement
control board
8.749.148.000

Front ball handle

8.749.142.000

Manual toggle to
lift rear implement

Coil only 8.025.971.824

Connector pigtail
7.235.102.000
Page 17
FRONT IMPLEMENT ELECTRICAL SYSTEM (NORDIC & TRAIL PB100)
From s/n 821-10581
Blade float switch
Ball Handle buttons 7.331.163.000
8.025.764.682 To rear lift/lower Symbol
rocker switch 7.331.140.508
Implement
control board
8.749.237.000

Front ball handle

8.749.164.000

Relay 7.375.181.000

Manual toggle to
lift rear implement

Coil only 8.025.971.824

Connector pigtail
7.235.102.000 Page 18
 FRONT IMPLEMENT ELECTRICAL SYSTEM
(UTILITY PB100)

Wires taped back

Front 7-pin plug here near relays
7.235.063.000 under dash

Connector
male pin
(one wire) 0.023.703.007
(two wire) 0.023.703.008
female pin
(one wire) 0.023.716.001
(two wire) 0.023.716.002

Starter 8.312.088.014

Page 19
 REAR IMPLEMENT ELECTRICAL SYSTEM (NORDIC PB100)
Up to s/n 821-10580
Tiller up/down
7.331.174.000 Center / float Up/float/down Float/down Tiller depth Tracksetting
symbol 7.331.174.000 pressure switch OR pressure switch 7.331.171.000 Potentiometer 10K pan switches
7.331.137.226 symbol 7.331.192.102 7.331.154.000 symbol up/down pressure 7.331.174.000
7.331.140.511 symbol symbol 7.331.137.227 8.749.114.000 symbol
From front ball 7.331.137.226 7.331.140.509 7.331.137.225
handle pin 9

Implement relay
board 8.749.148.000

Connector block
under dash

Switch in rear cylinder

8.212.678.750

Pigtail conn.
7.235.102.000 Junction box
Coil only 8.025.971.824 left rear frame

13 pin plug
7.235.109.000
Pin only
7.235.109.006

Page 20
 REAR IMPLEMENT ELECTRICAL SYSTEM (NORDIC PB100)
From s/n 821-10581
Tiller up/down
7.331.174.000 Center / float Up/float/down Float/down Tiller depth Tracksetting
symbol 7.331.174.000 pressure switch OR pressure switch 7.331.171.000 Potentiometer 10K pan switches
7.331.137.226 symbol 7.331.192.102 7.331.154.000 symbol up/down pressure 7.331.174.000
7.331.140.511 symbol symbol 7.331.137.227 8.749.114.000 symbol
From front ball 7.331.137.226 7.331.140.509 7.331.137.225
handle pin 9

Auto rear lift

bypass switch
7.331.179.000
7.331.140.522
Conn. to back
up alarm relay

Implement relay
board 8.749.237.000

Connector block
under dash

Switch in rear cylinder

8.212.678.750

Pigtail conn.
7.235.102.000 Junction box
left rear frame
Deck proximity
switch 13 pin plug
Coil only 8.025.971.824 7.346.041.000 7.235.109.000
Pin only
7.235.109.006

Page 21
 REAR IMPLEMENT ELECTRICAL SYSTEM (TRAIL PB100)
Up to s/n 821-10580
Rocker switches
7.331.174.000
Rocker switch symbol
7.331.174.000 7.331.137.201
From front ball symbol
handle pin 9 7.331.137.201

Implement relay
board 8.749.148.000

Connector block
under dash

Pigtail conn.
7.235.102.000
Junction box
Coil only 8.025.971.824 left rear frame

Page 22
 REAR IMPLEMENT ELECTRICAL SYSTEM (TRAIL PB100)
From s/n 821-10581
Rocker switches
7.331.174.000
Rocker switch symbol
7.331.174.000 7.331.137.201
From front ball symbol
handle pin 9 7.331.137.201

Connector block
under dash

Implement relay
board 8.749.237.000

Pigtail conn.
7.235.102.000
Junction box
Coil only 8.025.971.824 left rear frame

Page 23
RADIO & VOLTAGE CONVERTER
Power with
key on

Voltage converter 8 A
(under dash)
7.761.000.054

To grid heat control

Radio w/CD 7.761.076.000 (24V)

Radio AM/FM cass. 82.7.65200 (12V)
Radio w/CD 7.761.072.000 (12V)

Vehicle prepped
for 2-way radio

Speakers
7.761.573.000

Antenna 7.761.649.000
(mast only) 7.761.649.010

Page 24
 DRIVERS SEAT
(OPTIONAL HEAT & LUMBAR AIR ADJUSTMENT)
Compressor
8.811.130.002
Seat base heater
8.811.130.003

Back heater
8.811.130.001

Air switch assembly

8.811.130.006

Seat heater switch

7.331.154.000
Symbol
7.331.137.412

Power with
key on

Page 25
Outside temp sensor 8.749.037.000
(mounted to left mirror bracket)
Hydraulic temp/level
TACHOMETER, MULTI-FUNCTION DISPLAY &
Sender 8.749.080.000
WARNING LIGHTS (NORDIC & TRAIL 100)
Charge pressure
switches 7.314.113.000
Up to s/n 821-10536
Fuel tank sender
Brake press. switch Axle speed sensor 8.743.755.000
Test; 3 ohms when empty
7.314.111.000 8.749.137.000 185 ohms when full

To drive elec.
engine speed
Tachometer
signal
8.749.138.000
ADM (under dash)
821.4100.130.01
Alternator 8.312.088.013

Door switches
For interior lights
7.315.130.000

Relay 7.375.199.000
24V when alternator
Power supply is charging
Warning light cluster “2” with key on
8.749.139.000

Warning light cluster “1”

8.749.136.000
Power supply Digital gauge display
with main light 8.749.170.000 (Fahr.)
switch on
Relay 7.375.201.000

Charge Hyd. Hyd. Park

Pressure Temp Level Brake

Oil pressure sender Engine coolant Flywheel & cam

8.312.089.036 temp sender sensors 8.312.089.078
8.312.091.025

Page 26
Outside temp sensor 8.749.037.000 Hydraulic temp/level
TACHOMETER, MULTI-FUNCTION DISPLAY &
(mounted to left mirror bracket) Sender 8.749.080.000
WARNING LIGHTS (NORDIC & TRAIL 100)
Air filter vacuum
switch 8.319.170.000 Fuel tank sender
From s/n 821-10537
Brake press. switch Axle speed sensor 8.743.755.000 Test; 3 ohms when empty
7.314.111.000 8.749.137.000 185 ohms when full
unused wiring
coolant tank level
To drive elec.
engine speed
Tachometer signal
8.749.138.000
“ADM 2”
821.4100.180.11 Alternator 8.312.088.206

Door switches
For interior lights
7.315.130.000

24V when alternator

is charging

Power supply
Relay 7.375.199.000 with key on

Warning light cluster “2”

8.749.218.000

Warning light cluster “1”

8.749.136.000 Digital gauge display
to 10580 8.749.170.000 (-40 Fahr.)
from 10581 8.749.257.000 (-55 Fahr.)
Relay 7.375.201.000

Air Filter Hyd. Hyd. Park Power supply

Vacuum Temp Level Brake with main light
switch on

Oil level sender Oil pressure sender Flywheel & cam

Engine coolant
8.312.089.008 8.312.089.036 sensors 8.312.089.078
temp sender
8.312.091.025

Page 27
 Hydraulic temp/level
TACHOMETER, MULTI-FUNCTION DISPLAY &
Door switches
For interior lights
Sender 8.749.080.000
WARNING LIGHTS (UTILITY 100)
7.315.130.000
Fuel tank sender Test; 3 ohms when empty
Brake press. switch 8.743.755.000 185 ohms when full
7.314.111.000

To drive elec.
engine speed
Tachometer
signal
8.749.138.000
ADM (under dash)
821.4100.130.01
To interior Alternator 8.312.088.013
light

Relay 7.375.199.000

To rear plug pin “A”

for rear cabin
24V when alternator
Power supply is charging
Warning light cluster “2” with key on
8.749.139.000

Warning light cluster “1”

8.749.136.000
Power supply Digital gauge display
with main light (utility 100)
switch on 821.4100.110.04
Relay 7.375.201.000

Hyd. Hyd. Park

Temp Level Brake

Oil pressure sender Engine coolant Flywheel & cam

8.312.089.036 temp sender sensors 8.312.089.078
8.312.091.025

Page 28
 FRONT TOP LIGHTS - HIGH/LOW BEAM
& PARK LIGHTS
Power supply with ignition Main fuse 80A
key on Ignition switch 0.026.010.007
To under console
light Relay
7.375.201.000

Relay (50 A)
Power supply with 7.375.205.000
light switch on

Light switch 7.331.155.000

Symbol 7.331.140.202

Front parking
light bulb
7.584.067.000 Power to
directional lights Outside light switch
7.331.164.000
Symbol 7.331.137.207

Lens 7.517.130.000
bulb H-3 70w 24V
7.586.202.000

Directional light stalk

w/high beam switch
814.4100.130.05
Light assembly
7.526.326.000
Rear taillight bulb
7.581.165.000

H-4 bulbs H-3 bulbs Light assembly 7.512.030.000

High/low beam bulb H-4 70/75w
High beam indicator light 24V 7.586.206.000
Page 29
bulb 7.584.172.000
 FRONT XENON LIGHTS
(OPTIONAL, PRE-WIRED ON NORDIC 100)

Power supply with main

lighting rocker on

Xenon light switch

7.331.164.000
Symbol
7.331.141.205

Light assembly
7.517.134.000
Right Left Bulb
7.517.132.014

Page 30
 REAR TOP LIGHTS
(NORDIC & TRAIL PB100)
Power supply with main
lighting rocker on

Rear light switch

7.331.154.000
Symbol
7.331.137.208

Bulb H-3 24V 70W

7.586.202.000

Light assembly 7.517.127.000

Ground wires from taillights

Page 31
 REAR TOP LIGHTS
(UTILITY PB100) Power with
key on

Power supply with main

lighting rocker on

To 24v
power outlet

Rear light switch Diode

7.331.154.000 7.261.050.000
Symbol
7.331.137.208

Relay
7.375.197.000

To back up alarm
relay K25 pin 1

Lights on rear cabin

Connection in rear
electrical box

19 pin rear cannon plug

Bulb H-3 24V 70W
(male) 7.235.111.000
7.586.202.000

Light assembly 7.517.127.000

(female cabin plug)
7.231.226.000

Page 32
 BEACON LIGHTS
(NORDIC & TRAIL 100)
Power supply on
at all times

Switch bulb power from fuse #12

via rear wiper rocker switch

Power to
interior light

Beacon switch
7.331.164.000
Symbol
7.331.137.206

Beacon light 7.521.420.000

Lens only 7.521.420.004
Left Right Bulb H-1 70w 24V 7.586.201.000
beacon beacon
light light

Page 33
 BEACON LIGHTS
(UTILITY 100)
Power supply on
at all times

Power to rear cannon plug

(Webasto heater)

Switch bulb power from fuse #12

via rear wiper rocker switch

Power to
interior light

Beacon switch
7.331.164.000
Symbol
7.331.137.206

Connection in rear
electrical box

19 pin rear cannon plug

(male) 7.235.111.000

(female cabin plug)

7.231.226.000
On Rear Cabin
Beacon light 7.521.420.000
Lens only 7.521.420.004
Bulb H-1 70w 24V 7.586.201.000

Page 34
 INTERIOR LIGHT & UNDER CONSOLE LIGHT
Interior Dome Light
7.552.031.000 Door Switches for Interior Light
24V Bulb 7.583.066.000 7.315.130.000

To brake light switch

To multi-function
dash display pin 11

Light Under Console

7.552.028.000
24V Bulb 7.583.066.000
Relay
7.375.199.000

To multi-function
dash display pin 2

Power with
key on

Power supply on
at all times

Power supply with main

lighting rocker on

To left taillight & left front parklight

To beacon light switch

Page 35
 DIRECTIONAL LIGHTS
(NORDIC & TRAIL PB100)
Power supply with
ignition key on

Connector in steering column

Directional light stalk

814.4100.130.05

Wires to headlight
high/low beam

Directional light relay

7.371.083.000

Front turn signal

light assembly
7.521.162.000
Bulb 24v21w
7.581.164.000

Indicator light
bulb 7.584.172.000

Taillight assembly
Right front
Right rear

Left front

Left rear

7.526.326.000
Bulb 24v 21w 7.581.164.000

Page 36
 DIRECTIONAL LIGHTS
(UTILITY PB100)
Power supply with
ignition key on

Connector in steering column

Directional light stalk

814.4100.130.05

Wires to headlight
Directional light relay high/low beam
7.371.083.000

Front turn signal

light assembly
7.521.162.000
Bulb 24v21w
7.581.164.000
Right front

Left front

Connection in rear
electrical box

Indicator light
bulb 7.584.172.000

19 pin rear cannon plug

(male) 7.235.111.000
Taillight assembly
on rear cabin
(female cabin plug) 7.522.010.000
Right rear

Left rear

7.231.226.000 Bulb 24v 21w 7.581.164.000

Page 37
 FLASHLIGHT (12v) & 24v PLUG
from s/n 821-10537

Plug 24v
7.235.033.000

Charger base 12v

7.517.000.106

Flashlight (rechargable)
7.517.000.105

150 ohm resistor

7.261.098.000

Power supply with

ignition key on

Page 38
 FRONT WINDSHIELD HEATING

Heater wire element

in glass Glass 821.7710.110.01

Complete indicator
cluster 8.749.136.000
Bulb 7.584.172.000
Relay
10 min. time delay
7.375.176.000

Windshield heat switch

7.331.157.000
Symbol 7.331.141.202
Resistor
7.261.078.000

Alternator D+(L) term.

Wire to charge
24v when charging
indicator light

To grid heater
control relay to s/n 10536
(Relay K13 from s/n 10581)

Power supply at Relay 7.375.201.000

all times on when alternator
charging

Page 39
 REAR WINDSHIELD HEATING
(NORDIC & TRAIL PB100 ONLY)
Heater wire element
in glass Glass 821.7720.110.01

Note: diodes added to relays

fall 2001 production.
Diode
7.261.050.000

Relay 7.375.201.000
Rear glass heat
Switch 7.331.154.000
Symbol 7.331.141.202 (K6 from s/n 10537)

Alternator D+(L) term.

24v when charging

Relay 7.375.201.000
Wire to grid heater
on when alternator
brain to turn off to s/n 10536
charging
(Relay K13 from s/n 10581)

Power supply at
all times

(K4 from s/n 10537)

Page 40
 SIDE WINDOW & MIRROR HEATING
up to s/n 821-10536
Left heated glass 8.771.489.003
Right mirror Right heated glass 8.771.489.001

Left mirror

Switch and contact assembly on

window 8.771.483.184

Side glass heat

switch 7.331.164.000
Symbol 7.331.137.235

Alternator D+ term.
24v when charging

Relay 7.375.201.000
on when alternator
Power supply at
charging
all times

Page 41
 SIDE WINDOW & MIRROR HEATING
from s/n 821-10537
Left heated glass 8.771.489.003
Right mirror Right heated glass 8.771.489.001

Left mirror

Switch and contact assembly on

window 8.771.483.184

Side glass heat

switch 7.331.164.000
Symbol 7.331.137.235

Alternator L term.
24v when charging

Relay 7.375.201.000
on when alternator
Power supply at
charging
all times

Page 42
 CAB HEATER

Power supply with

ignition key on

Cab heater switch

7.786.056.000

Heater blower 8.754.484.000

(under cover beneath cab)

Page 43
 FRONT WIPERS & HORN
Power supply with
ignition key on

Power to drive
electronics

Connection
at tiller switch

Stalk assembly
814.4100.130.05

Two time
wipe button
7.311.071.000

To rear wiper relay

(Nordic & Trail 100)

Wiper interval relay

up to s/n 10536 7.371.072.000
from s/n 10537 7.375.210.000
(variable) (see operator’s manual)

53b to case = 2.5 to 16 ohms

Horn
53 to case = 3.2 to 4.7 ohms
7.711.130.000
Wiper motor 31 to case = 0 ohms
7.731.143.000
31b to case = 2.2 to 8.2 ohms
53a to case = open

Page 44
 REAR WIPERS
Power to drive
Power supply with
electronics
ignition key on

Connection at
tiller switch

Rear wiper switch 7.331.197.000

Symbol 7.331.137.221

Two time
wipe button
7.311.071.000

To front wiper
relay

Wiper interval relay

7.371.072.000

Rear wiper motor

7.731.000.255

Page 45
 ENGINE GRID HEATER
up to s/n 821-10536

Connection to
alternator D+, 24v
when charging
Grid heater lights
in light cluster
(complete 8.749.136.000)
Bulb 7.584.172.000
Red Amber

To relay K5

Ignition switch
Power supply with
Main Fuse Box
ignition key on
7.253.016.000
80A Fuse
0.026.010.007

Inline fuse (inside

conn. box left rear)
0.026.010.001
Power supply at all
To 24/12v converter times, connection
to starter motor
positive lead

Temp sender
(two spade terminal) Grid heater
8.749.125.000 in air pipe
(two round terminal) 8.312.089.081
8.749.151.000
100 amp fuse
Grid heater control relay
Grid heater relay Holder 7.253.040.000
(under dash) 825.4100.190.06
8.312.089.083 Fuse 0.026.010.008

Page 46
 ENGINE GRID HEATER
from s/n 821-10537

Grid heater lights

in light cluster
(complete 8.749.136.000)
Red Amber Bulb 7.584.172.000

ADM2 PB 100 “ADM 2” uses engine electronic

821.4100.180.11 temp sender to control grid heat

Main Fuse Box

7.253.016.000
80A Fuse
Ignition switch 0.026.010.007
Power supply with
ignition key on

Power supply at all

Inline fuse (inside times, connection
conn. box left rear) to starter motor
0.026.010.001 positive lead

To 24/12v converter

Grid heater
in air pipe
8.312.089.081

100 amp fuse

Grid heater relay
Holder 7.253.040.000
7.375.212.000
Fuse 0.026.010.008

Page 47
 ENGINE INJECTION WIRING (ADM 1)
Engine throttle set Up to 821-10536
rocker 7.331.171.000 To drive electronics
Symbol 7.331.137.127 (engine speed)
(throttle position)
To oil pressure gauge Throttle pedal assembly
To coolant 8.749.110.000
temp. gauge
ADM engine electronic
(under dash)
Buzzer ground for 821.4100.130.01
cluster
Alternator 8.312.088.013
Low oil pressure

Engine fault light

Coolant temp. sensor

(2 styles, see below) Ignition
Air boost & temp. ---- Diagnostic socket switch
Bosch 8.312.088.113 under dash for Mini-Diag
Oil pressure sensor or
Fuel temp sensor 4-wire
8.312.088.010 Ranco & Bosch ----
(2 styles, see below) “CAN link”
8.312.102.006
Flywheel sensor
(plug-in style no harness)
8.312.089.078

Cam sensor
(plug-in style no harness)
8.312.089.078 Engine buttons
Electronic PLD 8.312.088.126 Battery Main Switch
(special order item) 7.341.110.000
Start

Stop
Key only
7.341.110.002
Starter motor
8.312.088.014

Temp. Sensors

8.312.088.156 8.312.091.025

(atmospheric sensor integrated)

Coolant temp.

1 2 3 4
Flywheel sens.
Boost press.

Fuel injectors
Fuel temp.
Oil press.
Oil level

Air temp.

Oil temp.

Page 48
Cam /TDC
 ENGINE INJECTION WIRING (ADM 2)
Engine throttle set
ADM 2 engine electronic
(under dash) From 821-10537
rocker 7.331.171.000 821.4100.180.11 To drive electronics Throttle sensor for
To coolant Symbol 7.331.137.127 (engine speed) aluminum pedal
To oil pressure gauge temp. gauge (throttle position) 825.4100.121.13
or
825.4100.110.22
(new inline plug style)
Buzzer ground for
cluster
Low oil level

Low oil pressure

Engine fault light

Coolant temp. sensor Alternator 8.312.088.206

8.312.091.025 Ignition
---- switch
Air boost & temp. Diagnostic socket
Bosch 8.312.088.113 under dash for Mini-Diag 4-wire
Oil pressure sensor or “CAN link”
Fuel temp sensor
8.312.088.010 Ranco & Bosch ----
8.312.091.025
8.312.102.006
Flywheel sensor Starter Relay
(plug-in style no harness) (under dash)
8.312.089.078 8.312.088.132

Cam sensor
(plug-in style no harness) Engine buttons
8.312.089.078 8.312.088.126
Battery Main Switch

Start

Stop
Electronic PLD 7.341.110.000
(special order item) Key only
7.341.110.002

Starter motor
8.312.088.014

(atmospheric sensor integrated)

1 2 3 4
Flywheel sens.
Coolant temp.
Boost press.

Fuel injectors
Fuel temp.

Cam /TDC
Oil press.
Air temp.

Oil temp.
Oil level

Page 49
 ENGINE BLOCK HEATER

Plug end female 110V

Plug end male 110V
7.231.128.000
7.235.103.000

Hydraulic tank heater

(optional) Engine block heater
8.441.312.000 for freeze plug
(1000w)
8.441.517.000

Page 50
PB100 FULL VEHICLE ELECTRICAL
(NORDIC & TRAIL) up to #821-10536

Page 51
PB100 FULL VEHICLE ELECTRICAL
(NORDIC & TRAIL) from #821-10537

Page 52
PB100 FULL VEHICLE ELECTRICAL
(UTILITY ONLY)

Kässbohrer All Terrain Vehicles Inc.

Page 53
TEST FOR OPEN / OHMMETER - SERIES CIRCUIT

The ohmmeter section of your multimeter can be used to check for continuity between two points in a circuit.

FUSE

Ignition
B A switch

STEP 1
Before proceeding with test you must isolate the component or segment of the circuit
that you will test. The current source must be disconnected. This can be done
by turning the ignition switch to the off position or removing the circuit fuse if circuit is
powered at all times.

STEP 2 Turn selector switch to OHMs scale section (Ω)

STEP 3 Connect meter probes to points A and B.

1. A break or open between “A” and “B” will indicate a high infinite
resistance which will appear on your meter as

1. 0L
1. OR
000

2. If there is continuity between points “A” and “B” (no break) a

very low resistance, usually zero OHMs will appear on your
meter as
000

Page 54
TEST FOR OPEN / OHMMETER - PARALLEL CIRCUIT

FUSE

A series circuit as shown on the previous page has only

one current path. However, a parallel circuit as shown
at the left can have several current paths. You must
keep this in mind when troubleshooting parallel circuits.

Unlike a series circuit, an open in a parallel circuit does

not disable the entire circuit.

LEFT DIVERTER RIGHT DIVERTER

ROCKER SWITCH ROCKER SWITCH

LEFT DIVERTER RIGHT DIVERTER

VALVE VALVE

DISCONNECT HERE
FOR BRANCH The branch to be tested must be isolated from
ISOLATION the other branches. You can do this by disconnecting
the other branches at the fuse terminal as shown at the
left.

Once you have isolated the branch circuits from each

other you may then proceed to test for continuity (open)
using an ohmmeter as described on the previous page
for series circuits.

LEFT DIVERTER RIGHT DIVERTER

ROCKER SWITCH ROCKER SWITCH

LEFT DIVERTER RIGHT DIVERTER

VALVE VALVE

Page 55
 TEST FOR OPEN (USING A VOLTMETER)

FUSE

A B C
D E
IGNITION
SWITCH

F
BATTERY

GROUND
(frame)

1. Turn selector switch on multimeter to

DC volts scale.

2. Connect negative probe of meter to

suitable ground. (vehicle frame)

3. Connect positive meter probe to point A to determine if there is voltage available from the source. If no voltage is indicated,
an open is present between ground and point A. Some possibilities could be a blown fuse, batteries not connected or dead,
ignition switch open, broken connection or wires etc. If voltage is present, then proceed as follows.

4. Leave negative meter probe connected to ground, and move positive probe to point B. If the meter shows voltage here,
it indicates that the conductor from point A to B is complete. If not, check connections at each end, and the wire for a break.
See page on continuity check.

5. If the above check indicated voltage at point B, move meter probe to point C. If there is no voltage at this point this might
be caused by faulty contacts or the wire may have been connected to the wrong contact on the switch. Determine normal
position of switch contacts. (Normally open or closed) and perform continuity check.

6. Follow on through to points D and E. If voltage is available at point E and the circuit component or lamp in this case is still
inoperative then the problem lies in open circuit between point E and F (ground). Check connections at each end, and
the wire for a break (see continuity test). If point F is inaccessible, it may be necessary to run an alternate line from point E
to a suitable grounding point.

Page 56
 LOCATING A SHORT IN PARALLEL CIRCUITS
An open in a branch of a parallel circuit disables only that A short across a branch of a parallel circuit disables
branch of the circuit. the entire circuit.

OPEN FUSE
OPEN

SHORT CIRCUIT

ONE BRANCH DISABLED ALL BRANCHES DISABLED

A short circuit has almost no resistance since it by-passes circuit resistance. This permits the flow of an extremely large
amount of current. When this current exceeds the fuse current rating the fuse blows (opens) and disables the entire circuit.
With all branch circuits disabled, each branch must be examined separately to locate the short.

OPEN HERE FOR

BRANCH ISOLATION

Leg

STEP 1
Leg
Isolate branch circuits at fuse.

STEP 2
Set meter for OHMs (Ω)

STEP 3 Connect one meter probe to ground (frame).

STEP 4 Connect other probe to one end of circuit leg.

4.1 A high resistance indicates no short.
4.2 A very low resistance, usually zero OHMs indicates a short in that leg of the circuit.

STEP 5 Repeat step 4 for each leg of the circuit, and each branch as necessary to locate short.

Page 57
 WIRING HARNESS TEST FOR DEFECTIVE WIRE
WIRING HARNESS

C (ADJACENT WIRES)
BLUE

B
BLUE

FRAME
(ground)

OHM

A wiring harness is the main branch with leads which feed the electric circuits. Wires enter a common sheath joining other
wires and emerge at other points in the circuit.

Individual wires in a harness may be replaced by cutting off the defective wire at each end of the harness. Discard the
removed ends of the wire.

Run new wire along the existing harness and attach with plastic clips and electrical tape.

Do not attempt to thread the wire through the harness, as this may cause damage to other wires.

CAUTION! When replacing a defective wire, always use the same gauge wire. A smaller wire will not carry the required
current and overheat will result.

RESULTS IF WIRE IS DEFECTIVE

1. Test for open A to B
(broken wire) A to C Infinite resistance
A to D

A to D - Zero resistance
2. Test for short A to C - Infinite resistance
(bare wire touching frame) A to B - Zero resistance if wire is still intact but grounded
check for blown fuse A to B - Infinite resistance if wire is broken and grounded

3. Test for short A to C - Zero resistance

(two bare wires) A to B - Zero resistance
in contact A to D - Infinite resistance

BLOWN FUSES
A blown fuse does not necessarily mean you have a short circuit.

Some other possible causes for a blown fuse are:

1. A temporary circuit overload caused by a malfunctioning component.
2. Use of incorrect size fuse.
3. Poor contacts in the electrical circuit or component.

Page 58
 RESISTOR COLOR CODING

1. First significant digit

2. Second significant digit
3. Multiplier value
4. Tolerance

RETMA color code for resistors

1 2 3 4
COLOR FIRST SECOND
SIGNIFICANT SIGNIFICANT MULTIPLIER PERCENT TOLERANCE
DIGIT DIGIT
Silver 0.01 10
Gold 0.1 5
Black 0 1.0
Brown 1 1 10 1
Red 2 2 100 2
Orange 3 3 1,000 3
Yellow 4 4 10,000 4
Green 5 5 100,000
Blue 6 6 1,000,000
Purple 7 7 10,000,000
Gray 8 8 100,000,000
White 9 9 1,000,000,000
No color 20

EXAMPLES
NOMINAL PERCENT BAND
VALUE TOLERANCE 1 2 3 4 TOLERANCE RANGE
22,000 Ω =20 Red Red Orange No band =4,400 Ω 17,600-26,400 Ω
100 Ω =5 Brown Black Brown Gold =5 Ω 95-105 Ω
10 Ω =10 Brown Black Black Silver =1 Ω 9-11 Ω
1.2 k Ω =5 Brown Red Red Gold =60 Ω 1140-1260 Ω
6.8 M Ω =20 Blue Gray Green No band =1.36 M Ω 5.44-8.16 Ω

Page 59
 Wheel diagram for selecting the proper equation for
CURRENT, VOLTAGE, RESISTANCE, and POWER

SYMBOL QUANTITY UNIT OF MEASUREMENT

E Voltage Volts
I Current Amps
R Resistance Ohms
P Power Watts

Page 60
American Wire Gauge (AWG) sizes may be determined by measuring the diameter of the conductor (the bare wire) with the
insulation removed.

Awg. Metric Stranding/ Wire Approximate

Size Wire Dia. per Strand Overall Diameter
Size
mm2 in mm in mm
- 0.5 1/.032 1/.813 0.032 0.81
20 - 7/.0121 7/.307 0.036 0.91
- 0.75 1/.039 1/.991 0.039 0.99
18 - 1/.0403 1/1.02 0.04 1.02
18 - 7/.0152 7/.386 0.046 1.16
- 1 1/.045 1/1.14 0.045 1.14
- 1 7/.017 7/.432 0.051 1.3
16 - 1/.0508 1/1.29 0.051 1.29
16 - 7/.0192 7/.488 0.058 1.46
- 1.5 1/.055 1/1.40 0.055 1.4
- 1.5 7/.021 7/5.33 0.063 1.6
14 - 1/.0641 1/1.63 0.064 1.63
14 - 7/.0242 7/.615 0.073 1.84
- 2.5 1/.071 1/1.80 0.071 1.8
- 2.5 7/.027 7/.686 0.081 2.06
12 - 1/.0808 1/2.05 0.081 2.05
12 - 7/.0305 7/.775 0.092 2.32
- 4 1/.089 1/2.26 0.089 2.26
- 4 7/.034 7/.864 0.102 2.59
10 - 1/.1019 1/2.59 0.102 2.59
10 - 7/.0385 7/.978 0.116 2.93
- 6 1/.109 1/2.77 0.109 2.77
- 6 7/.042 7/1.07 0.126 3.21
9 - 1/.1144 1/2.91 0.1144 2.91
9 - 7/.0432 7/1.10 0.13 3.3
8 - 1/.1285 1/3.26 0.128 3.26
8 - 7/.0486 7/1.23 0.146 3.7
- 10 1/.141 1/3.58 0.141 3.58
- 10 7/.054 7/1.37 0.162 4.12
7 - 1/.1443 1/3.67 0.144 3.67
7 - 7/.0545 7/1.38 0.164 4.15
6 - 1/.162 1/4.11 0.162 4.11
6 - 7/.0612 7/1.55 0.184 4.66
- 16 7/.068 7/1.73 0.204 5.18
5 - 7/.0688 7/1.75 0.206 5.24
4 - 7/.0772 7/1.96 0.232 5.88
- 25 7/.085 7/2.16 0.255 6.48
- 25 19/.052 19/1.32 0.26 6.6
3 - 7/.0867 7/2.20 0.26 6.61
2 - 7/.0974 7/2.47 0.292 7.42
- 35 7/.100 7/2.54 0.3 7.62
- 35 19/.061 19/1.55 0.305 7.75
1 - 19/.0664 19/1.69 0.332 9.43
- 50 19/.073 19/1.85 0.365 9.27
1/0 - 19/.0745 19/1.89 0.373 9.46
2/0 - 19/.0837 19/2.13 0.419 10.6
- 70 19/.086 19/2.18 0.43 10.9
3/0 - 19/.094 19/2.39 0.47 11.9
3/0 - 37/.0673 37/1.71 0.471 12
- 95 19/.101 19/2.57 0.505 12.8
- 95 37/.072 37/1.83 0.504 12.8
4/0 - 19/.1055 19/2.68 0.528 13.4
 INDEX

ADM 6,9,10,11,12,25,26,27,47,48 Function Chart, (Rear) 19,20,21,22

Air Boost/Temp Sensor 47,48 Fuse 1 7,8,28
Alternator 8,9,25,26,27,47,48 Fuse 2 7,8,28
Alternator Charge Light 9,10 Fuse 3 7,8,28
Antenna 23 Fuse 4 7,8,28
Back Up Alarm Relay 11,12 Fuse 5 7,8,25,26,27,28
Batteries 9,10 Fuse 6 7,8,28,34
Battery Main Switch 9,10 Fuse 7 7,8,29
Beacon Lights 32,33 Fuse 8 7,8,30
Beacon Rocker Switch 32,33 Fuse 9 7,8,11,12
Blade Float Rocker 16,17 Fuse 10 7,8,11,12,15,43,44
Block Heater 49 Fuse 11 7,8,15
Boost Sensor 47,48 Fuse 12 7,8,44
Brake Pressure Sender 25,26,27 Fuse 13 7,8,43
Buttons, Ball Handle 16,17 Fuse 14 7,8,25,26,27
Cab Heater 42 Fuse 15 7,8,21,22
Cam Sensor 47,48 Fuse 16 7,8,23
Center/Float Rocker 19,20 Fuse 17 7,8,23,45
Circuit Testing Procedures 53 Fuse 18 7,8,37
Clock 25,26,27 Fuse 19 7,8,28,35
Complete Main Elec. PB100 Nordic & Trail 50,51 Fuse 20 7,8,42
Complete Main Elec. PB100 Utility 52 Fuse 21 7,8,47,48
Connectors, Electrical 13,14,15,16,17,18,19,20 Fuse 22 7,8,47,48
Controllers (Moog) 15 Fuse 23 7,8,47,48
Coolant Temp Gauge 25,26,27 Fuse 24 7,8,25,26,27,47,48
Coolant Temp Sender 47,48 Fuse 25 7,8,47,48
Directional Light Relay 35,36 Fuse 26 7,8,50
Directional Light Stalk 35,36 Fuse 27 7,8,9,10,25,26,40
Directional Lights 35,36 Fuse 28 7,8,39
Door Switches 25,26,27 Fuse 29 7,8,38
Drive Card 11,12,13,14 Fuse 30 7,8,32,33,34
Drive Control (Card to Cab) 11,12 Gauges and Senders 25,26,27,47,48
Drive Control (Card to Chassis) 13,14 Grid Heater 45,46
Driver's Seat 24 Headlights (Upper) 28
Engine Fuel Injection 47,48 Heater Blower 42
Engine Grid Heater 45,46 Horn 43
Engine Speed Transmitter 47,48 Hour Meter 25,26,27
Engine Start / Stop Buttons 47,48 Hydraulic Level/Temp Sender 25,26,27
Flywheel Sensor 47,48 Hydraulic Tank Heater (optional) 49
Forward/Reverse Switch 11,12 Ignition Switch Starting - Charging Circuit 9,10
Front Ball Valve 16,17 Implement Control Board 16,17,19,20,21,22
Front Xenon Light Rocker 29 Interior Dome Light 34
Front Xenon Lights 29 Junction Box, (Rear) 19,20
Front Implement Electrical System 16,17,18 Lighting Rocker (Main) 28
Front Top Lights 28 Load Limit Bypass Switch 11,12
Front Windshield Heating 38 Load Limit Card 11,12,13,14,15
Front Wipers and Horn 43 Main Fuse Box 6,9,10,28,45,46
Fuel Gauge 25,26,27 Mirror Heat 40,41
Fuel Injection 47,48 Oil Pressure Gauge 25,26,27,47,48
Fuel Tank Sender 25,26,27 Oil Pressure Sender 47,48
Function Chart, (Front) 16,17 Outside Temp Gauge 25,26,27

Page 62
 INDEX

Park Lights 28 Servo (Moog) 13,14

Pigtail Connectors 16,17,19,20,21,22 Side Window Heating 40,41
PLD 9,10,47,48 Side Window Heating Rocker 40,41
Plug, Front 7 Pin (KFS & Utility only) 15 Starter Motor 9,10
Plug, Rear 13 Pin 19,20 Steering Potentiometer 11,12
Power Socket, 24v 37 Stereo 23
Radio and Voltage Converter 23 Tachometer 25,26,27
Rear Glass 39 Third Pump Control 15
Rear Glass Heat Rocker 39 Throttle Position Sensor 47,48
Rear Implement Electrical System 19,20,21,22 Throttle Rocker Switch 47,48
Rear Light Rocker 30,31 Tiller Card (Drive Card) 15
Rear Top Lights 30,31 Tiller Pump Controller 15
Rear Window Heating 39 Tiller Depth Adjustment Circuit 19,20
Rear Wiper 44 Tiller Depth Rocker 19,20
Relay - Fuse Index 7,8 Tiller Forward/Reverse Rocker 15
Relay K1 7,8,38 Tiller On/Off Rocker 15
Relay K2 7,8,28 Tiller Speed Potentiometer 15
Relay K3 8,35 Track Speed Potentiometer 11,12
Relay K4 7,8,35,36,38,39,40 Under Console Light 34
Relay K5 7,8,9,28,38,39,40 Up/Down Pressure Rocker 19,20
Relay K6 7,8,29,39 Up-Pressure Potentiometer 19,20
Relay K7 7,8,39,43 Voltage Converter (24v-12v) 23
Relay K8 7,8,25,26,27 Voltage Regulator (electronics) 11,12
Relay K9 7,8 Warning Light Cluster 9,10,11,12,25,26
Relay K10 7,8,43 Warning Lights and Buzzer 9,10,11,12,25,26
Relay K11 7,8,44 Wheel Diagram For Electrical Equations 59
Relay K12 7,8 Windshield 38
Relay K13 7 Windshield Heat Rocker 38
Relay K15 7,43 Wiper Motor (Front) 43
Relay K16 7,8,44 Wiper Motor (Rear) 44
Resistor Color Coding 58

Page 63
 Kässbohrer All Terrain Vehicles Inc.
750A South Rock Blvd. Reno, Nevada 89502 (775) 857-5000