XJ 2025H keeps blowing Instrument/ Relay fuse

[jsf729]

While tilling one of my plots, the tractor suddenly shut down. Not sure if I hit a big rock, but even so, I have tilled this plot numerous times and hit large rocks. The tractor has shut down before (tiller has a slip clutch) but starts right back up again. Anyway, this time would not start. No indicators on the dash. Tractor will start if I turn key all the way to the right but dies as soon as I release. I replaced the 10A instrument/ Relay fuse, got dash indicator and started up and started tilling again. Hit another big rock (where the heck do these come from? I have tilled this 4 times now starting from a grass field. Planted 2 cover crops and removed tons of rocks and figured it was pretty clean). This time replaced fuse and it immediately blows. Tried 3 new fuses in a row. All blow immediately. Checked the battery voltage and load with a load tester. Although the tractor is over 5 years old, battery still checks out. Don't know if the tiller has anything to do with it or if it's just a coincidence. Maybe bad relay? Won't be able to get in touch with my dealer till Monday and was hoping to get this clover seed down over the weekend. Oh well. Any thoughts? Thanks in advance

 

[alexpops]

My XR4150 did something similar a few weeks ago. No dash lights on run position/new battery -- full/load tested fine. Cranked & ran on Crank position/died as soon as key released back to run. What I found, there is a plastic sleeve (chafe protection) around the wires going into the key switch, mine had water in it from rain that leaked into the panel via the hand throttle opening right above the sleeve. When I tipped it to pull the key switch for testing, water pour out of the sleeve, & everything went back to normal. Didn't take the sleeve off or explore further, but it might be that LS has some dodgy splices or connections inside that sleeve that are prone to shorting. You might want to check that.

 

[jsf729]

My XR4150 did something similar a few weeks ago. No dash lights on run position/new battery -- full/load tested fine. Cranked & ran on Crank position/died as soon as key released back to run. What I found, there is a plastic sleeve (chafe protection) around the wires going into the key switch, mine had water in it from rain that leaked into the panel via the hand throttle opening right above the sleeve. When I tipped it to pull the key switch for testing, water pour out of the sleeve, & everything went back to normal. Didn't take the sleeve off or explore further, but it might be that LS has some dodgy splices or connections inside that sleeve that are prone to shorting. You might want to check that.

Thanks for your reply. Yep, that’s exactly what I’m experiencing. When I pulled the panel off it was dry as a bone though. Did this occur when you were operating the tractor or after it sat through a rain storm? This happened during operation

 

[tomplum]

 

[alexpops]

Mine was after rainstorm. Thing is, if the wires had good insulation inside the sleeve, water shouldn't have mattered.

 

[jsf729]

View attachment 1288540

Mine was after rainstorm. Thing is, if the wires had good insulation inside the sleeve, water shouldn't have mattered.

View attachment 1288540

Thanks for this!

 

[jsf729]

Mine was after rainstorm. Thing is, if the wires had good insulation inside the sleeve, water shouldn't have mattered.

Still possible frayed wire/ bad splice could be causing dead short. I’ll also check coil resistance. Don’t know what it should be but it should have some resistance not short to ground

 

[jsf729]

Thanks to tomplum. The schematic was very helpful but still no luck. Key switch is fine. Temporarily disconnected glow plugs from the circuit. There was some water in the heat shrink on the wire loom going to the switch even though everything else was dry. Still blows fuse immediately. Calling the dealer today.

 

[tomplum]

Best of luck. Keep us in the loop please.

 

[GS650GL]

Have seen an intermittent short in the fuel solenoid on the injection pump cause this. Blows the same fuse and may start but dies when you release the key.

 

[jsf729]

Have seen an intermittent short in the fuel solenoid on the injection pump cause this. Blows the same fuse and may start but dies when you release the key.

Thanks for this. Will look into that as well. Went to the dealer and discussed a few scenarios. Bought an ignition relay since he said that once the relay is energized it should stay energized. Replaced it anyway - wasn't too expensive. No change.

 

[GS650GL]

Forgot to mention check the wire harness on the engine that goes to the fuel solenoid also. The way the engine vibrates like a paint shaker on this model causes the wires to rub through on anything they touch.

 

[jsf729]

Forgot to mention check the wire harness on the engine that goes to the fuel solenoid also. The way the engine vibrates like a paint shaker on this model causes the wires to rub through on anything they touch.

Yeah, I never let the rpm below 1200 when I park it

 

[jsf729]

Back in business! I called the dealer and updated him that the replacement relays didn’t solve the problem. He emailed me the full shop manual with schematics. The wire with the dead short fed 6 different switches/ modules. The first one that I tried went to the brake switch. Unplugged the switch and had continuity to the switch and the short cleared. Figured great! Bad switch. Reconnected the harness and still no short! Switch was clean and no sign of damage. Fired her up and went on my merry way! Go figure. Could never have done it without the schematic.