Power Harness Kit

Reelmaster® 3000 Series Traction Unit

Model No. 138-2993-Serial No. and Up

Installation

Preparing the Machine

Caution

If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or bystanders.

Remove the key from the ignition switch before you do any maintenance.

  1. Park the machine on a level surface.

  2. Engage the parking brake.

  3. Lower the cutting units.

  4. Shut off the engine and remove the key.

Disconnecting the Battery

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Figure 1

Warning

Electrical sparks can cause the battery gasses to explode, resulting in personal injury.

Incorrect battery cable routing could damage the machine and cables, causing sparks.

  • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

  • Always connect the positive (red) battery cable before connecting the negative (black) cable.

Warning

Battery terminals or metal tools could short against metal components, causing sparks.

  • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

  • Do not allow metal tools to short between the battery terminals and metal parts of the machine.

  • Always keep the battery strap in place to protect and secure the battery.

  1. Loosen the 2 knobs that secure the outer battery cover to the frame of the machine, and remove the cover (Figure 2).

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    Figure 2

    1. Knob
    2. Outer battery cover

  2. Remove the negative battery cable from the battery post (Figure 3).

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    Figure 3

    1. Negative battery cable
    2. Positive battery cable

  3. Remove the positive battery cable from the battery post (Figure 3).

Accessing the Machine

Opening the Hood

Unlatch and open the hood (Figure 4).

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Figure 4

Removing the Console Cover

  1. Ensure that the parking brake is engaged (Figure 5).

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    Figure 5

    1. Parking brake lever (engaged position)
    2. Magnet strike bracket
    3. Console cover

  2. Pull up the console cover to free the magnetic catch of the cover from the strike bracket on the console support (Figure 5).

  3. Remove the cover from the machine.

Removing the Inner Battery Cover

  1. Remove the 2 flange head bolts (1/4 x 5/8 inch) that secure the inner battery cover to the frame of the machine (Figure 6).

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    Figure 6

    1. Frame of the machine
    2. Inner battery cover
    3. Flange-head bolt (1/4 x 5/8 inch)

  2. Remove the inner battery cover from the machine (Figure 6).

Assembling the Relay and Fuse to the Power Harness

Parts needed for this procedure:

Power harness1
Relay1
Fuse1

  1. Assemble the relay into the 4-contact connector of the power harness (Figure 7).

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    Figure 7

    1. Relay
    2. 4-contact connector (power harness)
    3. Fuse (60 A)
    4. Fuse holder (power harness)

  2. Insert the fuse (60 A) into the socket of the fuse-holder for the power harness (Figure 7).

Connecting the Harness Adapter to the Power Harness

Reelmaster 3100 Series Traction Units Only

Parts needed for this procedure:

Harness adapter1

Connect the 3-socket connector of the harness adapter into the 3-pin connector of the power harness (Figure 8).

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Figure 8

  1. Spade terminal (harness adapter)
  2. 3-pin connector (power harness)
  3. 3-socket connector (harness adapter)

Routing the Power Harness

  1. Route the 2 ring terminals of the power harness through the opening where you removed the inner battery cover (Figure 9)

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    Figure 9

    1. Opening (inner battery cover)
    2. Ring terminals (power harness)

  2. Route the rest of the power harness along the wire harness of the machine and through the support channel (Figure 10).

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    Figure 10

    1. Machine wire harness
    2. Power harness
    3. Support channel

  3. Route the wire harness along the bottom of the control console and rearward to the roll bar (Figure 11).

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    Figure 11

    1. Ring terminals
    2. Power harness

  4. Route the power harness along the bottom of the fuel tank and up the right roll-bar tube (Figure 12).

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    Figure 12

    1. Fuel tank
    2. Power harness
    3. 2-socket connector
    4. Right roll-bar tube

Assembling the Ring Terminals to the Battery Cables

  1. At the positive and negative battery cables, remove the battery-clamp nuts from the short side of the battery clamp bolts.

  2. Assemble the ring terminal of the power harness for the wire labeled BATTERY (-) onto the battery clamp bolt for the negative battery cable with a battery-clamp nut (Figure 13).

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    Figure 13

    1. Battery clamp bolt (negative battery cable)
    2. Ring terminal—power harness BATTERY (-)
    3. Battery-clamp nuts
    4. Battery clamp bolt (positive battery cable)
    5. Ring terminal—power harness BATTERY (+)

  3. Assemble the ring terminal of the power harness for the wire labeled BATTERY (+) onto the battery clamp bolt for the positive battery cable with a battery-clamp nut (Figure 13).

    Note: Do not assemble the battery cables to the battery posts. You will connect the battery in a later step.

Connecting the Parking-Brake Switch to the Power Harness

Reelmaster 3550-D, 3555-D, and 3575-D Series Traction Units Only

  1. Disconnect the 3-socket connector of the parking-brake switch from the 3-pin connector of the machine wire harness (Figure 14).

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    Figure 14

    1. 3-pin connector (machine wire harness)
    2. 3-socket connector (parking-brake switch)

  2. Connect the 3-socket connector of the parking-brake switch into the 3-pin connector of the power harness (Figure 15).

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    Figure 15

    1. 3-socket connector (parking-brake switch)
    2. 3-pin connector (power harness)
    3. 3-pin connector (machine wire harness)
    4. 3-socket connector (power harness)

  3. Connect the 3-pin connector of the machine wire harness into the 3-socket connector of the power harness (Figure 15).

Connecting the Key Switch to the Power Harness/Harness Adapter

Reelmaster 3100 Series Traction Units Only

  1. Disconnect the spade terminal of the machine wire harness from Terminal C of the key switch (Figure 16).

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    Figure 16

    1. Key switch
    2. Terminal C (key switch)
    3. Spade terminal (machine wire harness)

  2. Connect the spade terminal of the harness adapter to Terminal C of the key switch (Figure 17).

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    Figure 17

    1. Key switch
    2. Terminal C (key switch)
    3. Spade terminal (harness adapter)

  3. Connect the spade terminal of the machine wire harness to the piggy back terminal of the harness adapter (Figure 18).

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    Figure 18

    1. Key switch
    2. Spade terminal (harness adapter)
    3. Spade terminal (machine wire harness)
    4. Piggy back terminal (harness adapter)

Connecting the Power Harness to the Sunshade Wire Harness

Parts needed for this procedure:

Cable tie1

  1. Plug the 2-socket connector of the power harness into the 2-pin connector for the sunshade wire harness (Figure 19).

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    Figure 19

    1. 2-pin connector (sunshade wire harness)
    2. 2-socket (power harness)
    3. Cable tie

  2. Secure the power harness to the roll-bar tube with a cable tie (Figure 19).

Securing the Power Harness to the Machine

Parts needed for this procedure:

Cable tie5

  1. Between the control console and the operator’s seat, secure the power harness to the wire harness of the machine with cable ties as shown in Figure 20.

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    Figure 20

    1. Cable ties

  2. At the opening where you removed the inner battery cover, secure the power harness to the wire harness of the machine with cable ties as shown in Figure 21.

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    Figure 21

    1. Cable ties

  3. Inside the control console, secure the solenoid to the wire harness of the machine with a cable tie (Figure 22).

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    Figure 22

    1. Solenoid
    2. Cable tie

Connecting the Battery

Warning

Electrical sparks can cause the battery gasses to explode, resulting in personal injury.

Incorrect battery cable routing could damage the machine and cables, causing sparks.

  • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

  • Always connect the positive (red) battery cable before connecting the negative (black) cable.

  1. Connect the positive cable to the battery and tighten the battery-clamp nut (Figure 23).

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    Figure 23

    1. Positive battery cable
    2. Negative battery cable

  2. Connect the negative cable to the battery and tighten the battery-clamp nut (Figure 23).

  3. Assemble the insulator over the positive battery terminal (Figure 23).

Installing the Inner Battery Cover

  1. Align the holes in the inner battery cover with the holes in the frame of the machine; refer to Figure 6 in Removing the Inner Battery Cover.

  2. Assemble the inner battery cover to the frame of the machine (Figure 6) with the 2 flange head bolts (1/4 x 5/8 inch).

  3. Torque the bolts to 10.2 to 12.4 N∙m (90 to 110 in-lb).

Installing the Console Cover and Closing the Hood

Installing the Console Cover

  1. Align the console cover over the console (Figure 24).

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    Figure 24

    1. Magnet strike bracket
    2. Console cover

  2. Align the slot in the cover with the parking brake handle (Figure 24).

  3. Lower the cover onto the console until the magnetic catch of the cover aligns with the strike bracket on the console support (Figure 24).

Closing the Hood

  1. Rotate the hood forward and carefully lower it to the machine (Figure 25).

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    Figure 25

  2. Secure the hood with the latches.

Install the Outer Battery Cover

  1. Align the holes in the outer battery cover with the holes in the frame of the machine; refer to Figure 2 in Disconnecting the Battery.

  2. Assemble the outer battery cover to the machine with the 2 knobs, and tighten the knobs by hand (Figure 2).