Controller Connector Kit

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine.

4. Disconnect the negative (-) battery cable before making any repairs; refer to your Operator’s Manual.

Parts needed for this procedure:

Note: If needed, order the terminal extraction tool (Part No. 134-6970) before installing this kit.

Use the following graphic to identify the parts in this kit.

Figure 1

1. Relay base assembly
2. Relay
3. Yellow wire
4. 6 mm (1/4 inch) receptacle
5. Small cable tie
6. Large cable tie
7. TPA connector lock (spare—may not be required)
8. 10-way connector (spare—may not be required)
9. Terminal (spare—may not be required)

1. Refer to the service manual for the procedure to access the wiring, the electronic control unit (ECU), and the front steering-tower light within the steering tower.

   Note: For better access, remove other connectors attached to the ECU. Make note of the connector locations for assembly after completing these instructions.

2. Identify the X165 connector on ECU circuit board and disconnect the connector from the circuit board (Figure 2).

   

   Figure 2

   1. X165 connector

3. Remove the TPA connector lock from the side of the connector where the pink and yellow wires are installed (Figure 3).

   

   Figure 3

   1. Connector
   2. TPA connector lock

   Note: Make note of the pink and yellow wire positions (Figure 4).

   

   Figure 4

   1. Connector
   2. Yellow wire
   3. Pink wire

4. If the connector or terminals on the pink or yellow wires are melted or damaged, replace the terminals.

   Note: If you are replacing the terminals, make note of the wire locations in the connector.Use the terminals and connector locks included in this kit as required.

5. Insert extraction tool (Part No. 134-6970) and remove the pink and yellow wires only (Figure 5, Figure 6, and Figure 7.

   

   Figure 5

   1. Yellow wire
   2. Pink wire
   

   Figure 6

   1. Connector
   2. Terminal extraction tool

6. Cut the terminals off the pink and yellow wires.

   Note: Do not shorten the wire, only remove the terminal.

   

   Figure 7

   1. Pink wire
   2. Yellow wire

7. Strip 5 mm (3/16 inch) of insulation off the pink and yellow wires.

8. Strip 5 mm (3/16 inch) of insulation off the new yellow cable supplied.

9. Crimp both yellow wires together in a new 6 mm (1/4 inch) receptacle (Figure 8).

10. Crimp the pink cable into a new 6 mm (1/4 inch) receptacle (Figure 8).

    

    Figure 8

    1. Pink wire
    2. Crimp the pink wire into a 6 mm (1/4 inch) receptacle.
    3. New yellow wire
    4. Crimp the yellow wires into a 6 mm (1/4 inch) receptacle.

11. Strip about 25 mm (1 inch) of the fabric insulation tape off the wires.

12. Insert the 6 mm (1/4 inch) receptacles into the new relay base, the yellow wires go into position 87 and the pink wires go into 30 position (Figure 9).

    

    Figure 9

    1. Insert the yellow, 6 mm (1/4 inch) receptacle into position 87.
    2. Insert the pink, 6 mm (1/4 inch) receptacle into position 30.

13. Insert the pink and yellow terminals into the X165 connector, using their original positions (Figure 10).

    

    Figure 10

    1. X165 connector
    2. Pink terminal
    3. Yellow terminal

14. Replace the TPA terminal lock into the connector (Figure 11)..

    

    Figure 11

    1. Connector
    2. Terminal lock

15. Identify X135 connector feeding the front light (Figure 12).

    

    Figure 12

    1. X135 connector

16. Remove the black wire receptacle from the connector, (Figure 13).

    

    Figure 13

    1. Black terminal
    2. X135 connector

17. Cut off the black wire receptacle, without shortening the wire.

18. Strip 5 mm (3/16 inch) of insulation off the black wire.

19. Strip 5 mm (3/16 inch) of insulation off the black wire from the new relay base.

20. Crimp both black wires together into a new 6 mm (1/4 inch) receptacle (Figure 14).

    

    Figure 14

    1. Black wire from the relay base
    2. Crimp the black wires into a 6 mm (1/4 inch) receptacle.
    3. X135 connector

21. Insert the black 6 mm (1/4 inch) receptacle into X135 connector and connect it to the light.

22. With some insulation tape (not supplied), tape the relay wires, and the connector X165 wires.

23. Insert the relay into the relay base and secure to the main cable harness with the small cable tie (Figure 15).

    

    Figure 15

    1. Relay base
    2. Insulation tape
    3. X165 wires
    4. Small cable tie
    5. Relay

24. Connect all connectors previously removed from the circuit boards into their original positions (Figure 16).

    

    Figure 16

    1. Electronic control unit (ECU)

25. Secure the relay to the relay base using the large cable tie provided to prevent the relay from becoming detached from the relay base.

26. Verify that all wires/relays bases are clear of the tilting steering column mechanism by tilting the steering column in both directions.

27. Connect the negative (-) battery cable and test to verify correct PTO operation.

    Note: If you remove the new relay, the PTO will not start.

28. Refer to the service manual to install the steering tower covers and ensure not to dislodge or pinch any of the wiring.

29. Advise the customer that an additional relay has been installed that works with the ECU to control the operation of the PTO and hopper wiper motor.