Calling all x595 (diesel 4x4) owners - HELP!

eKretz · Apr 8, 2014

Hi guys, my x595 (2004 I think) recently had an electrical failure. I've traced the problem to the small printed circuit board mounted under the radiator shroud on the right side of the tractor. There's a burned up resistor in the board that I can pretty easily replace but it's so charred that I can't read the color bands to determine the resistance. Can anyone take a good clear photo of their board for me so I can see the resistor colors? The shroud is very easy to pop out - it has only a small plastic peg pushed into a rubber grommet holding it in place. If you open the hood and pull out near the grommet the peg will pop right out. If your brake is set you can pivot the top of the shroud outwards and lift it right out by pulling upward. I would greatly appreciate it if any fellow x595 owner could help me out! Thanks in advance,

--Eric

Gator6x4 · Apr 9, 2014

Usually fried resistors happens because they were sacrificed to protect more expensive components.

eKretz · Apr 9, 2014

No, usually they are just a weak link in the chain. More expensive components can still be easily damaged in the time it takes to cook a resistor. A proper protective device should have failed to protect even the resistor - that's why there are fuses, MOVs, protective diodes, etc. None blew however. As far as that goes I have checked and all the other components are fine. The damage occurred when I attempted to jump a dead battery in the middle of winter. I made the mistake of using a car battery and got too much amperage flow I think. I have examined the burned resistor under magnification and can make out what appears to be two orange stripes. The rest is too badly charred to tell what the colors were. There's another resistor nearby that is Orange Orange Black Gold, so I'm going to try using the same to replace the burned one. FYI that's 33 ohms. I'll report back after the try-out. Hopefully nothing else further down the line in another area is damaged. I've investigated all the wiring and such and haven't found anything that looks damaged. One area I need to get to is under the floor panel - there's a big wire bundle going down there and I want to look and see what's down there before I try the board. With that many wires it must be an ECU I'd guess.

eKretz · Apr 12, 2014

After some further investigation it looks like there is a damaged relay on the circuit board. I'll replace it and that should do the trick.

AndyMA · Apr 12, 2014

As an electrical engineer it is hard to understand teh failure of a relay and resistor unless the resister was in series with the load the relay controls. I would find that load and I'll give you high odds it's a short circuit or close to it. Relays usually fail by their contacts burning together.

Andy

eKretz · Apr 13, 2014

Actually it seems that the coil in the relay has weakened. When I attempt to energize it to supply voltage to the starting relay it is only bouncing on the contact. I also checked the coil resistance on the other two identical relays and they are significantly different. If I remember correctly the good ones are either half or double the resistance of the bad one. The relay in question's function is only to energize a stouter relay further down the line. I've checked for both shorts and open circuits and found nothing.

eKretz · May 7, 2014

OK, a kind fellow forum member is helping me out with a picture of his board and in the meantime I've found I had a faulty DCM - Diesel Control Module - and a cooked battery. The battery read 12.9V with a multimeter but wasn't able to supply any amperage - very odd.

RetiredCarGuy · May 7, 2014

I'll be glad to photo my X575 board for you. Let me know.

eKretz · May 7, 2014

Hi RCG; I'm not sure if your board is the same part number as the 595 but if you want to take a pic and post it up I would be happy to see if so. I haven't heard back from the other member through PM yet but I have only replied back to him last night.