Nilfisk-Advance 56507009 Troubleshooting Manual Download Page 75

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FORM NO. 56043129 - SR 1900 -

ELECTRICAL SYSTEM

ENGINE HARNESS FOR GM 1.6L LPG

POWERRELAY

EPR CONNECTOR

LPG TEMPERATURE

GCP 90 WAY CONNECTOR

BOSCH THROTTLE

BATT +

GROUND

ALTERNATOR

ALTE

ALTERNATOR -

DIAGNOSTIC

CONNECTOR

CONNECTOR 1

VEHICLE INTERFACE CONNECTORS

CONNECTOR 2

EGO 2

EGO 1

ECT

BOSCH_TMAP

OIL PRESSURE SENSOR

IGNITION COIL

CRANK SENSOR

GROUND

EPR

IGNITION

STARTER RELAY

STARTER

SOLENOID

ECM

STARTER

VSW

LOCKOFF

Summary of Contents for 56507009

Page 1: ...SR 1900 Quick Start Troubleshooting Manual 2 09 Revised 8 12 FORM NO 56043129 Printed in USA Models 56507009 4 cyl LPG 56507010 4 cyl Petrol 56507011 4 cyl Diesel...

Page 2: ...EM 49 50 MISTING PUMP 49 50 ENGINE SYSTEM 51 56 ENGINE SPECIFICATIONS 51 52 ENGINE MAINTENANCE 52 CHECK ENGINE LIGHT TROUBLESHOOTING 53 MISCELLANEOUS ENGINE SYSTEM INFORMATION 55 GM 1 6L GASOLINE FUEL...

Page 3: ...ber and Serial Number of your machine are shown on the Nameplate on the machine This information is needed when ordering repair parts for the machine Use the space below to note the Model Number and S...

Page 4: ...and locate the hydrostatic pump at the rear of the engine Turn the valve 90 degrees this disengages the hydrostatic lock between the motor and pump WARNING The hydraulic propelling pump can be damaged...

Page 5: ...FORM NO 56043129 SR 1900 5...

Page 6: ...Slovakian Czech Polish Hungarian 56041666 Turkish English Quick Start Troubleshooting Manual 56043129 Cab Manuals Cab Addendum Operator Manual 56041789 Cab Addendum Parts List 56042515 Cab Addendum Se...

Page 7: ...system Turn the key switch off O and disconnect the batteries before servicing electrical components Never work under a machine without safety blocks or stands to support the machine Do not dispense...

Page 8: ...length 6 inches 15 2cm Hopper System Capacity 14 ft3 396L Lifting capacity 1000 lbs 454kg Dump height variable Max 60 inches 152cm Dump height with door open 52 75 inches 134cm Dust Control System Fil...

Page 9: ...S Specifications common to Engine Size English Metric Sound Level At operators ear 83 dBA Speed and Gradeability Maximum grade angle transport 25 14 Maximum grade angle sweeping 25 14 Maximum trailer...

Page 10: ...ly Reference the Parts List for engine type and filter part number AFTER USE 1 Shake the Hopper Dust Control Filter LL and empty the hopper 2 Check the maintenance schedule and perform all required ma...

Page 11: ...nge the engine oil after the first 35 hours of operation and every 150 hours after that Use any SF or SG rated oil meeting API specifications and suited to seasonal temperatures Refer to the Engine Sy...

Page 12: ...any cracks and holes that will allow non filtered air to enter the engine that will severely shorten the engine s useful life ENGINE MAINTENANCE 150 HOURS At 150 hour intervals it is recommended that...

Page 13: ...f the filter is usually caused by a hole in the filter or a damaged filter gasket 3 Unthread and remove the four Shaker Assembly Retainer Knobs 13 Lift off the Dust Filter Shaker Assembly 11 to access...

Page 14: ...Broom Raise Lower 12 Side Broom Raise Lower 13 Main Broom On Off 14 Side Broom On Off 15 Headlights Gauges and Optional Accessories example rotating beacon backup alarm 16 Dust Control Filter Shaker V...

Page 15: ...Filter SVR Life 1000 Hrs L Replace 45 Steer Spindle Drive Wheel motor open operator s seat Grease Spindle Zert D L 46 Rear Tire check lug nut torque 100 FT LB 135Nm Tire Pressure 90 psi L M W 47 Gaso...

Page 16: ...e location of an item mentioned in the text 1 Engine Compartment Cover 2 Left Side Main Broom Access Panel 3 Battery 4 Center Cover Assembly 5 Hopper Safety Support 6 Hopper Cover Latch 7 Head Light 8...

Page 17: ...nel 19 Oil Reservoir 20 Oil Reservoir Fuel Tank Cover 21 Fuel Tank LPG tank shown Gasoline tank is in same location 22 Coolant Recovery Tank diesel location 23 Radiator Cap 24 Engine Air Filter diesel...

Page 18: ...ARTMENT A Operator s Seat B Main Broom Lever C Main Broom Adjust Knob D Control Panel See Associated Pages E Steering Wheel F Brake Pedal Parking Brake G FWD REV Drive Pedal H Circuit Breaker Panel I...

Page 19: ...gine Speed Switch HH Side Broom ON Down OFF Up Switch II Dust Control Indicator JJ Dust Control Switch KK Plugged Filter Indicator optional LL Shaker Switch MM Hopper UP Indicator NN Open Dump Door Sw...

Page 20: ...blink flash a special fault error code sequence until the fault is corrected See Table A for a description of the fault indications Service Note Instructions on how to read the fault code service indi...

Page 21: ...box 8 2 4 Solenoid S8 dust control bypass overload Coil spec is 6 Ohms J1 8 1 Check S8 coil wiring for a short circuit Vio Brn 2 Check coil resistance if below 4 Ohms replace 3 Substitute a new A2 co...

Page 22: ...Main broom will not run 33 34 Side brooms will not run 35 36 Side brooms will not raise lower 37 Dust control impeller will not run 38 39 Shaker motor will not run 40 41 Hopper System 42 48 Hopper wil...

Page 23: ...e if defective Repair Red Tan wire to starter relay terminal 87 With starter relay removed test for 12V the relay terminals 85 86 wire colors Blue Pink Pink Black w key in the start mode Replace the d...

Page 24: ...ch circuit functions of start ignition terminals Repair and replace as needed the K4 relay coil test for 12v from the Gra Wht wire to Bat with key on Before testing the drive pedal sensor R2 follow th...

Page 25: ...pump gasoline only Replace defective fuses Engine still will not start No See the 1 6L Tier 2 Engine Service Manual form PSIP6LPFI A look up the specific DTC and use the T S chart for it to fix the pr...

Page 26: ...or missing Reference the 1 6L tier 2 engine service manual and follow the LPG system diagnosis Fuel System Checks for Gasoline Check fuel pump electrical circuit fuel pump pressure and fuel rail pres...

Page 27: ...ctor ground input continuity pins J3 1 J3 4 If speed switch checks open or closed all the time replace the membrane switch panel assembly Does speed SW test ok No No Substitute a good known working EC...

Page 28: ...el filter then next the fuel injection pump w engine cranking but bleed separately Does engine start With the engine cranking test for 12V the fuel pump With the engine cranking test for 12V oil press...

Page 29: ...actuator Does engine start Check the governor magnetic pickup voltage signal w engine cranking approx 1 2 3 7 VAC If no signal substitute a good known magnetic pickup sensor Does engine run Note Test...

Page 30: ...l box assembly Ribbon pin s test open Replace the touch pad switch panel No No Check for 12V s the A2 control box output pin J1 17 Gra Blu to Bat Grd Replace the A2 control box assembly Repair or repl...

Page 31: ...o low for application No wheel drive in either direction Check that pump bypass valve tow valve is in correct position Check connection of foot pedal linkage cable assembly to propulsion pump arm Worn...

Page 32: ...the steering unit that allows for manual steering if there is no hydraulic oil flow to the unit The relief valve for the steering system is located in the steering unit and is set to open at 1100 PSI...

Page 33: ...motor will not Run 1 Complete the above operator inputs to turn on main broom motor 2 Back probe the S2 L2 main broom solenoid coil wires Vio Grn Blk should read 12V s Check S2 coil wiring continuity...

Page 34: ...tic switch S2 must be open and also the hopper interlock switch S4 closed for the main broom system motors to run Main broom motor will not run Remove and disassemble L2 main broom motor valve cartrid...

Page 35: ...broom motor s will not Run 1 Complete the above operator inputs to turn on side broom motor s 2 Back probe the S3 side broom solenoid coil wires Vio Brn Blk should read 12V s Check S3 coil wiring con...

Page 36: ...the side broom s will lower automatically and turn ON rotate Note 2 By pressing the control panel side broom ON OFF switch during sweeping the side broom will be raised and turned OFF Side broom motor...

Page 37: ...oms Press the side broom off button or raise the main broom lever to raise the side brooms Side Broom s will not Raise or Lower Mechanical Visual Checks Inspect for possible mechanical binding of Side...

Page 38: ...c dust control motor troubleshooting section B Replace the S9 solenoid coil Replace the A2 control box assy Does the dust control motor run Ribbon pins test open replace the touch pad switch panel Rib...

Page 39: ...speed and the dust control switch pressed activated Dust control motor will not run Remove and disassemble L4 dust control motor valve cartridge Inspect clean and reinstall Does the motor run Substit...

Page 40: ...Does the shaker motor run Ribbon pins test open replace the touch pad switch panel Ribbon connector see Electrical System Figure 1 for detail pin call outs Check K3 relay coil wiring continuity Vio Y...

Page 41: ...haker motor will not run Test continuity of the CB4 20A circuit breaker its wiring Repair or replace defective parts Test for 12V s the M2 shaker motor wires Blu Grn Blk Test for 12V s the K3 Vio wire...

Page 42: ...ed Gry should read 12V s Check S5 coil wiring continuity repair if faulty Is there 12V s at the S5 coil Check S5 coil resistance Spec 9 Ohms See hydraulic hopper raise troubleshooting section B Replac...

Page 43: ...emove and disassemble L9 hopper lower valve cartridge Inspect clean and reinstall Replace the defective L5 hopper cylinder valve cartridge Does the hopper raise No No Is the hopper over loaded Weight...

Page 44: ...res Vio Yel Grn should read 12V s Check S9 coil wiring continuity repair if faulty Is there 12V s at the S9 coil Check S9 coil resistance Spec 9 Ohms See hydraulic hopper raise troubleshooting section...

Page 45: ...of Hopper linkage Hopper Cylinder Remove and disassemble L9 hopper lower valve cartridge Inspect clean and reinstall Does the hopper lower Replace the defective L9 hopper cylinder valve cartridge Doe...

Page 46: ...dump door solenoid coil wires Vio Blu Wht should read 12V s Check S1 coil wiring continuity repair if faulty Is there 12V s at the S1 coil Check S1 coil resistance Spec 9 Ohms See hydraulic hopper ra...

Page 47: ...olenoid coil wires Vio Blk Wht should read 12V s Check S7 coil wiring continuity repair if faulty Is there 12V s at the S7 coil Check S7 coil resistance Spec 9 Ohms See hydraulic hopper raise troubles...

Page 48: ...lose Replace the hydraulic hopper door cylinder Inspect for possible mechanical binding at Dump door hopper frame opening Dump door cylinder linkage Repair or replace damaged parts Does the door funct...

Page 49: ...e if defective Misting Pump will not work Test continuity of the Brn Blk wire Test continuity of the S26 misting pump relay switch Does switch test good Replace the S26 misting pump relay switch Test...

Page 50: ...eaker CB 7 10A reset or replace if defective Note 3 Check for plugged misting nozzles clean if needed Misting pump will not work Test continuity of the CB7 10A circuit breaker its wiring Repair or rep...

Page 51: ...more detailed engine specifications and service data Kubota Operator s Manual P N 16622 8916 3 Kubota Workshop Manual P N 97897 01640 ENGINE OIL DIESEL ENGINE Engine oil should be MIL L 2104C or have...

Page 52: ...tion Timing Fixed controlled by engine ECM Engine Rotation CCW flywheel end Valve lifters Hydraulic Oil Capacity 3 7 qts 3 5L with Oil Filter Oil Pressure 21 PSI minimum with engine hot at idle Coolin...

Page 53: ...uired tool to access the DTC codes codes may be retrieved without a laptop computer using the blink code function To enable this function follow the steps below 4 Turn the ignition key to the on posit...

Page 54: ...en Inactive 724 10 1171 LPG Pressure Higher Than Expected 520260 0 154 EGO 2 Open Inactive 520208 10 1172 LPG Pressure Lower Than Expected 520260 1 171 Adaptive Learn High Gasoline 520200 0 1173 EPR C...

Page 55: ...Engine Speed 2400 RPM Idle Engine Speed 1200 RPM GM 1 6L GASOLINE FUEL SYSTEM DESCRIPTION This engine is equipped with a fuel injector rail that does not have a pressure regulator Fuel pressure for th...

Page 56: ...56 FORM NO 56043129 SR 1900 1 2 4 3 1 2 3 4 1 4 2 3 Coil Pack Cylinders Firing Order 1 3 4 2 FIGURE 3 FIGURE 4 ENGINE SYSTEM...

Page 57: ...ressure and relief valve settings The readings are nominal figures and there will be variations due to manufacturer tolerances and system oil temperature If any reading varies greater than 20 there wi...

Page 58: ...ms running 6 1 2 9 2800 105 360 2500 Dump Door open close time 2 3 sec nothing else running 2800 Open20Close 50 Hopper Lift raise time 10 11 sec Empty 2800 2875 Hopper Lift lower time 7 sec Empty 380...

Page 59: ...cartridge main broom System coil 8 Ohms S3 Solenoid coil valve cartridge side broom system coil 8 Ohms S4 Solenoid coil valve cartridge dust control wand state coil 8 Ohms S5 Solenoid coil valve cartr...

Page 60: ...System Relief Valve 2500 PSI Dust Control Valve S4 Coil Adjustment Screw Lock nut Hydraulic Manifold top and bottom views shown Top view Bottom view S4 Cartridge X7 X8 X4 X5 X3 X6 X1 S4 X2 Shown with...

Page 61: ...oil must be warm engine at high speed 2400 RPM Activate the hopper lift raise or lower to dead head its cylinder to place the pump circuit into an overloaded condition CAUTION Do not test in the over...

Page 62: ...ly 5 Side Broom Cylinder Assembly Right 6 Main Broom Motor Assembly 7 Dust Control Motor Assembly 8 Sleeve 23 In Nylon 9 Manifold Assembly 10 Steering Cylinder Assembly 11 Hopper Door Cylinder Assembl...

Page 63: ...er Assy Left 3 Side Broom Motor Assembly 4 Valve Assembly 5 Tee Union 6 Hose Hydraulic 7 Tee Run O Ring 8 Hose Hydraulic 9 Hose Hydraulic Item Description 10 Hose Hydraulic 11 Hose Hydraulic 12 Hose H...

Page 64: ...64 FORM NO 56043129 SR 1900 THIS PAGE IS INTENTIONALLY BLANK...

Page 65: ...Dust Control Motor Assembly 3 Filter Assembly 4 Hopper Door Cylinder 5 Hopper Lift Cylinder 6 Oil Cooler 7 Main Broom Motor Assembly 8 Manifold Assembly 9 Pump Assembly 10 Reservoir Assembly 11 Side...

Page 66: ...LIFT 1 00x1 18x 50 A B B A P T L R STEERING 4 88 CIR STEERING 1 75x8 5x 75 1100 PSI MAIN BROOM SIDE BROOM DUST CONTROL DRIVE 037 S1 S3 S5 S6 S7 S8 25 PSI A T1 B C D E F G H J L K M N T P 100 PSI 6 10...

Page 67: ...Circuit Breaker 20 Amp Shaker CB7 Circuit Breaker 15 Amp Turn signal optional CB8 Circuit Breaker 10 Amp Misting Kit optional CB9 Circuit Breaker 40 Amp Cab optional H1 Horn K1 Relay Horn K2 Relay Lig...

Page 68: ...M9 MOTOR BLOWER MOTOR M M6 M9 MOTOR BLOWER MOTOR YEL RED ORN LP10 TROUBLE LAMP OPTIONAL LP10 TROUBLE LAMP OPTIONAL 1 2 1 2 X3 X3 A B C D S34 SWITCH PRESSURE S34 SWITCH PRESSURE 1 2 CB2 CIRCUIT BREAKE...

Page 69: ...T FROM ENGINE SYSTEM J3 1 J3 4 J3 5 J3 7 TOUCH PAD SWITCHES J4 9 J4 2 J4 10 TOUCH PAD DISPLAY J3 2 J3 3 J3 11 J3 8 J3 6 J3 10 J3 9 J4 7 J4 4 J4 3 J4 8 J2 14 J4 6 J1 9 J4 5 S3 SWITCH LOW LP PRESSURE S3...

Page 70: ...CIRCUIT BREAKER 15 AMP 1 2 S1 SWITCH IGN S1 SWITCH IGN ACC BAT ST IGN CB4 CIRCUIT BREAKER 20 A CB4 CIRCUIT BREAKER 20 A 1 2 CB1 CIRCUIT BREAKER 70 AMP CB1 CIRCUIT BREAKER 70 AMP 1 2 X2 X2 F F S28 SWIT...

Page 71: ...1 FROM X140 TO SP26 A 03377 WGL F WGL 12 21 06 UPDATE VIO WIRE CONNECTION FOR MISTING PUMP OPTION UPDATE REMOVE S29 X168 BLU ORN 18 3 A 03533 WGL G WGL 4 12 07 UPDATE 1 WAS 3 AND 3 WAS 1 AT S6 A 03568...

Page 72: ...L 16 1 BLK RED 16 1 PINK 16 7 PINK 16 4 TAN 18 1 GRA BLU 18 1 TAN BRN 16 1 GRN YEL 18 1 BLU PINK 16 1 PINK YEL 16 1 BLK RED 16 1 PINK 16 7 PINK 16 4 WHT GRA 18 1 RED BLK 18 1 YEL VIO 18 1 PINK 18 1 OR...

Page 73: ...72 PLUSG INTO X175 A C SYSTEM CONNECT TO X204 ON SHEET 1 UNPLUG X99 FROM L5 S5 HOPPER UP DOWN VALVE AND CONNECT IT TO X208 CONNECT X207 TO L5 X194 X194 R9 R9 1 2 SP28 SP28 1 1 2 2 3 2 1 X208 CONNECT T...

Page 74: ...INJECTOR 4 FUEL PUMP RELAY FUEL PUMP BATT GROUND ALTERNATOR ALTERNATOR ALTERNATOR DIAGNOSTIC CONNECTOR CONNECTOR 1 VEHICLE INTERFACE CONNECTORS CONNECTOR 2 B L H J I E D F G A K C EGO 2 EGO 1 ECT BOSC...

Page 75: ...WAY CONNECTOR BOSCH THROTTLE BATT GROUND ALTERNATOR ALTERNATOR ALTERNATOR DIAGNOSTIC CONNECTOR CONNECTOR 1 VEHICLE INTERFACE CONNECTORS CONNECTOR 2 N L H J I E D F G A K C EGO 2 EGO 1 ECT BOSCH_TMAP O...

Page 76: ...76 FORM NO 56043129 SR 1900 ENGINE HARNESS FOR GM 1 6L GAS Petrol Tier 3 ELECTRICAL SYSTEM...

Page 77: ...FORM NO 56043129 SR 1900 77 ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1 6L LPG Tier 3...

Page 78: ...L OUTPUT G START COMMAND F E FUEL PUMP D FUEL PUMP C ALT EXCITE B IGN SWITCH INPUT A X1 GRA BLU 18 1 TAN 18 1 S R P N M L THROTTLE INPUT K 12V FOR HIGH SPEED H G COOLANT TEMP OUTPUT F E D C B A X2 WHT...

Page 79: ...FORM NO 56043129 SR 1900 77 J1 connection J2 connection J3 11 pins Touch Pad Switches J4 9 pins Touch Pad Display Access windows J3 shown Pin 1 is labeled FIGURE 1 ELECTRICAL SYSTEM...

Page 80: ...Pressing and releasing the engine speed switch again will increase the deadband to the maximum range The next press will return the deadband to the minimum range The service indicator will be on stea...

Page 81: ...hold the shaker switch 3 While holding the shaker switch turn the main power key switch to the on position 4 Continue to hold the shaker switch until all indicators turn off approximately two seconds...

Page 82: ...Nilfisk Advance A S Sognevej 25 DK 2605 Br ndby Denmark Tel 45 43 23 81 00 Fax 45 43 43 77 00 www nilfisk advance com...

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