Nilfisk-Advance Condor XL Service Manual Download Page 191

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neutral position).

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Summary of Contents for Condor XL

Page 1: ... Condor XL AXP and Condor XL EcoFlex Models 3 3HWURO LHVHO 3 3HWURO LHVHO 3 3HWURO LHVHO 3 3HWURO LHVHO 3 3 3HWURO 3 LHVHO 3 3 3 3HWURO 3 LHVHO 3 3 3 3HWURO 3 LHVHO 3 3 3 3HWURO 3 LHVHO 3 3 3HWURO LHVHO 3 3HWURO LHVHO 3 3HWURO LHVHO 3 3HWURO LHVHO 1LO VN 5 DQG 5 0RGHOV 3 3HWURO LHVHO 3 3HWURO LHVHO ...

Page 2: ...rol System 38 Functional Description 38 Component Locations 39 Control Board Driver Box Connectors 40 Control Board Driver Box Programming Options 43 Troubleshooting 54 Electrical System 60 Functional Description 60 Component Locations 61 Troubleshooting 62 6SHFLÀFDWLRQV 64 Wiring Diagram GM Engine Drawing 56111804 D 79 Wiring Diagram Kubota Diesel Drawing 56111804 D 80 Wiring Schematic 1 of 2 81 ...

Page 3: ...mponent Locations 142 Daily Maintenance 143 Troubleshooting 143 Removal and Installation 144 6SHFLÀFDWLRQV 146 Special Tools 146 Scrub System Cylindrical 147 Functional Description 147 Component Locations 152 Troubleshooting 153 6SHFLÀFDWLRQV 158 Special Tools 159 Scrub System Right Side 160 Functional Description 160 Component Locations 163 Maintenance and Adjustments 165 Troubleshooting 166 6SHF...

Page 4: ...ctional Description 207 Component Locations 210 Maintenance and Adjustments 212 Troubleshooting 214 6SHFLÀFDWLRQV 216 Wheel System Non traction 217 Functional Description 217 Maintenance and Adjustments 218 Troubleshooting 219 6SHFLÀFDWLRQV 219 Wheel System Traction 220 Functional Description 220 Component Locations 224 Maintenance and Adjustments 225 Troubleshooting 227 Removal and Installation 2...

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Page 6: ...DFWXUHUV 7HFKQLFDO 0DQXDOV Manual Name Publication Number 36 7LHU 3 HUWL HG QJLQH 6HUYLFH 0DQXDO 3 PSI1P6LPFI A XERWD 9 7 LHVHO QJLQH 2SHUDWRU 0DQXDO QJOLVK UHQFK HUPDQ WDOLDQ 6SDQLVK 16622 8916 3 XERWD 9 7 LHVHO QJLQH 6HUYLFH 0DQXDO QJOLVK UHQFK HUPDQ 97897 01640 XERWD 9 7 LHVHO QJLQH 6HUYLFH 0DQXDO QJOLVK 97897 02432 LDJQRVWLF DQG 6HUYLFH 7RROV Q DGGLWLRQ WR D IXOO VHW RI PHWULF DQG VWDQGDUG WRR...

Page 7: ...ZZZ QLOÀVN FRP DQG RWKHU 1LOÀVN GYDQFH ZHEVLWHV 7KHVH WRROV DUH DOVR DYDLODEOH IURP 1LOÀVN GYDQFH QF FWXDWRU SRZHU FRUG DGDSWHU S Q 9DFXXP ZDWHU OLIW JDXJH S Q 36 HQJLQH VHUYLFH NLW S Q LQFOXGHV DQ 3 7HVW LW S Q DQG D LDJQRVWLF RPPXQLFDWLRQ DEOH DQG VRIWZDUH S Q PSI engine service kit p n 56109084 PSI LPG test kit p n 56504450 Diagnostic Communication Cable and software p n 56305647 ...

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Page 15: ...General Information 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 2YHUDOO LPHQVLRQV ...

Page 16: ... 0 IW OE IW OE 0 IW OE IW OE 0 IW OE IW OE Maintenance Maintenance Schedule HHS WKH PDFKLQH LQ WRS FRQGLWLRQ E FORVHO IROORZLQJ WKH PDLQWHQDQFH VFKHGXOH 0DLQWHQDQFH LQWHUYDOV JLYHQ DUH IRU DYHUDJH RSHUDWLQJ FRQGLWLRQV 0DFKLQHV XVHG LQ VHYHUH HQYLURQPHQWV PD UHTXLUH VHUYLFH PRUH RIWHQ Q JHQHUDO HHS WKH IXHO WDQN ÀOOHG JDVROLQH DQG GLHVHO 7KLV KHOSV WR UHGXFH FRQGHQVDWLRQ DQG PRLVWXUH HQWHULQJ WKH I...

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Page 19: ...FH YHU WR RXUV Maintenance Item Procedure QJLQH PDLQWHQDQFH DVROLQH DQG 3 RQO KDQJH WKH VSDUN SOXJV Radiator OXVK DQG UH OO UDGLDWRU ZLWK PL RI ZDWHU DQG DQWLIUHH H GUDXOLF RLO UHVHUYRLU KDQJH WKH UHVHUYRLU RLO DQG OWHU 0DLQWHQDQFH YHU RXUV Maintenance Item Procedure QJLQH PDLQWHQDQFH 3 DQG GLHVHO RQO 5HYLHZ WKH HQJLQH PDQXIDFWXUHU V DGGLWLRQDO PDLQWHQDQFH UHTXLUHPHQWV Note The engine maintenance ...

Page 20: ...ob Threads on Squeegee Mount grease Steering Rack grease Squeegee End Tool Wheel oil Squeegee End Tool Wheel oil Recovery Tank Latch oil Fuel Tank Cover Latch oil Brake Pedal parking brake Linkage oil Detergent Cover Latch oil Squeegee Caster Wheel Pivot grease Squeegee Caster Wheel Axle grease ...

Page 21: ...raise lower model option if equipped A B 13 Side broom s on off B L 14 Dust guard sweep dust control On Off model option if equipped A C L 15 Scrub system Raise Lower and auto scrubbing functions 16 Main scrub brushes On Off will drift 17 Scrub Brush pressure settings 1 2 and 3 A B 18 Solution control On Off and flow volume min max C D 19 Test and purge the detergent EcoFlex AXP system if so equip...

Page 22: ...C L 50 Gasoline Diesel fuel tank filter and lines Xx hours C L W 51 LP tank hoses and fittings L W 52 LP fuel filter service life 1500 Hrs C 53 LP fuel regulator lock off valve and hoses L 54 Diesel glow plug function light hard starting 55 Gasoline and Diesel fuel tank strainer yearly C 56 Brake cable and parking brake pedal A B 57 Circuit breaker panel D M W 58 Front tire check lug nut torque 10...

Page 23: ...cator Coolant 2YHUÀRZ Tank Engine Air Filter Engine Cover Latch Recovery Tank Drain Hose Recovery Tank Tilt out Latch Recovery Tank Tilt out Grip Left Side Skirt Double Scrub Skirt Holder Left Side Skirt Latch Fuel Tank petrol tank shown Fuel Tank Cover Latch Headlight Fuel Tank Cover Steering Wheel Operator Seat Adjustment Lever Operator Seat Solution Tank Fill Cover ...

Page 24: ... Pedal Parking Brake Drive Pedal Direction Speed Steering Wheel Tilt Adjust Lever Right Side Skirt Latch Tow Valve Lever Battery Solution Filter Squeegee Assembly Engine Oil Dipstick Engine Oil Filter Solution Tank Drain Hose Squeegee Height Adjust Knob Engine Cover Prop Rod Squeegee Tilt Adjust Knob Engine Oil Drain under radiator Hydraulic OIl Reservoir Filler Cap Oil Cooler Tilt out Latch Squee...

Page 25: ...WDO GLVSOD GLVSOD V WKH YDULRXV PDFKLQH VWDWXV LFRQV DQG LQIRUPDWLRQDO GLVSOD V Scrub On Scrub Mode Select Switch HQDEOHV WKH VFUXE VROXWLRQ DQG UHFRYHU V VWHPV DQG WKH VLGH EURRP EUXVK V VWHP DQG GHWHUJHQW V VWHP LI WKH PDFKLQH LV VR HTXLSSHG 1RWH WKDW WKH VFUXE EUXVK SUHVVXUH DQG VROXWLRQ ÁRZ ZLOO EH DW WKHLU ORZHVW OHYHOV 7KH VFUXE EUXVKHV ZLOO UXQ WKH VROXWLRQ ZLOO ÁRZ DQG WKH VTXHHJHH YDFXXP ...

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Page 27: ... WKH RSWLRQDO YDFXXP ZDQG LV HQDEOHG Left and Right Turn Indicators LQGLFDWH WKDW WKH FRUUHVSRQGLQJ WXUQ VLJQDO LV ÁDVKLQJ Warning Indicator OLJKWV LQ FRQMXQFWLRQ ZLWK WKH WR DOHUW WKH 2SHUDWRU RI D ZDUQLQJ RU IDXOW FRQGLWLRQ Attention Indicator OLJKWV LQ FRQMXQFWLRQ ZLWK WKH WR DOHUW WKH 2SHUDWRU RI D PDFKLQH FRQGLWLRQ UHTXLULQJ DWWHQWLRQ Scrub Pressure Indicators 1 2 and 3 LQGLFDWH WKH FXUUHQW V...

Page 28: ...LWFKHG RQ Headlight Indicator LQGLFDWHV WKDW WKH KHDGOLJKWV DUH VZLWFKHG RQ DustGuard Indicator LQGLFDWHV WKDW WKH XVW XDUG V VWHP LV HQDEOHG Engine Speed Indicator LQGLFDWHV WKDW WKH HQJLQH LV DW HLWKHU QRUPDO RSHUDWLQJ VSHHG RU 7XUERµ VSHHG 7KH OLJKW ZLOO EH RII ZKHQ WKH HQJLQH LV RII RU DW LGOH Side Broom Brush Indicator Emergency Flasher Indicator Headlight Indicator Engine Speed Indicator Dus...

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Page 30: ...KH PDFKLQH LV VR HTXLSSHG Side Broom Up Adjust Switch UDLVHV WKH VLGH EURRP V Side Broom Scrub On Off Switch HQDEOHV DQG GLVDEOHV WKH VLGH EURRP V DQG RU ULJKW VLGH VFUXE V VWHP 1RWH WKDW ZKHQ WKH VLGH EURRP V VFUXE EUXVK V VWHP LV HQDEOHG WKH XVW XDUG VSUD V VWHP ZLOO DOVR VZLWFK RQ DXWRPDWLFDOO OVR QRWH WKDW ZKHQ WKH VLGH EURRP V VFUXE EUXVK V VWHP LV HQDEOHG WKH EURRP V EUXVK ZLOO UHWXUQ WR WKH...

Page 31: ... while in idle override the automatic idle feature will be temporarily disabled until the next time the foot pedal is moved from the neutral position This can be useful during troubleshooting or if you want to run the machine at full speed to warm it up Key Switch PDLQ SRZHU LJQLWLRQ VZLWFK RQWURO 3DQHO QGLFDWRUV 1HZ 6W OH RQWURO 3DQHO Extended Scrub Indicator LQGLFDWHV WKDW WKH RSWLRQDO H WHQGHG ...

Page 32: ...cator LQGLFDWHV WKDW WKH VLGH EURRP EUXVK V VWHP LV HQDEOHG Emergency Flasher Indicator LQGLFDWHV WKDW WKH HPHUJHQF ÁDVKHUV DUH VZLWFKHG RQ Headlight Indicator LQGLFDWHV WKDW WKH KHDGOLJKWV DUH VZLWFKHG RQ DustGuard Indicator LQGLFDWHV WKDW WKH XVW XDUG V VWHP LV HQDEOHG Engine Speed Indicator LQGLFDWHV WKDW WKH HQJLQH LV DW HLWKHU QRUPDO RSHUDWLQJ VSHHG RU 7XUERµ VSHHG 7KH OLJKW ZLOO EH RII ZKHQ ...

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Page 36: ...36 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 KDVVLV 6 VWHP 0DMRU KDVVLV RPSRQHQWV Front Hood Rear Cover Assembly Floor Weldment Cover Support Assembly Chassis Weldment Front Floor Tank Heavy Bumper Assembly ...

Page 37: ... KDVVLV 6 VWHP 37 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 Rear Cover Rear Grille Cover Support Weldment RH Latch Latch Handle Heavy Bumper Weldment ...

Page 38: ...h the Engine System controller on the GM engine and the APECS 3000 Governor on the Kubota diesel to monitor engine parameters The Driver Box also communicates with the Relay PCB which provides the engine start and run signals RQWURO 6 VWHP LULQJ LDJUDP LUFXLW HVFULSWLRQ The Key Switch must be on to provide power to the Driver Box and Dashboard Panel The Driver Box and Dashboard Panel communicate o...

Page 39: ...6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 RPSRQHQW RFDWLRQV Driver Box Dashboard Panel Main Control Board Connector J3 Main Control Board Connector J1 Main Control Board Connector J2 K1 Power Relay Relay PCB Start Run Inhibit ...

Page 40: ... Open J1 14 Open J1 15 Open J1 16 18 1 RED BLK Input S29 Horn switch J1 17 Open J1 18 16 1 BLK ground Chassis ground X 49 J1 19 18 1 GRN ORN Input Sender hydraulic oil temperature J1 20 18 1 VIO WHT Input S6 Brake switch J1 21 18 1 VIO YEL Input S3 Solution empty switch J1 22 18 1 WHT BRN Output Relay PCB start inhibit pin J7 3 J1 23 Open J1 24 18 2 VIO BRN Input Ignition switch start position J1 ...

Page 41: ...N Input CB4 circuit breaker 20A J2 13 18 1 WHT ORN Output K4 glow plug relay coil J2 14 Open J2 15 Open J2 16 Open J2 17 16 2 BLK Input X49 control box ground J2 18 16 3 BLK Input X49 control box ground J2 19 Open J2 20 Open J2 21 Open J2 22 18 1 YEL GRN Output L10 solenoid valve main solution J2 23 18 3 GRN BRN Input CB5 circuit breaker 10A J2 24 18 1 ORN RED Output S7 scrub pressure proportional...

Page 42: ...ghts and taillights J3 9 16 1 GRA RED Input CB1 Circuit Breaker 20A J3 10 Open J3 11 16 4 BLK Input X49 control box ground J3 12 16 5 BLK Input X49 control box ground J3 13 16 6 BLK Input X49 control box ground J3 14 16 3 BLU Input CB2 Circuit Breaker 20A J3 15 16 2 BLU Input CB2 Circuit Breaker 20A J3 16 18 1 VIO Input CB3 Circuit Breaker 15A J3 17 18 1 WHT YEL Output Horn J3 18 16 1 YEL BLK Outp...

Page 43: ...ill read Neutral Deadband 3 Press the green Scrub On switch 7KH ÀUVW OLQH RI WKH will read Neutral Set The second line of the display will show the resistance value in ohms that the control board is reading through the rotary sensor Note that it s normal for this value to drift a little 4 Press the green Scrub On switch to set the nominal deadband resistance value The display will return to the pr...

Page 44: ... Flashers switch until all the display panel lights turn off approximately three seconds then release the switch 7KH ÀUVW OLQH RI WKH ZLOO UHDG CONFIGURATION DISPLAY 3 Press the Side Broom Up and Down switches to scroll through the displayed menu items as shown on the following pages 4 When the arrow is pointing to a menu item Press the green Scrub On switch to display the next level of menu items...

Page 45: ...Fault Codes Clear Fault Codes Are You Sure Press the Scrub On switch to clear the fault codes The display will show No Stored Codes Engine Type Undefined Propane Gasoline Diesel Undefined Propane Gasoline Diesel Installed Display Format Installed Not Installed Ratio Percentage EcoFlex System Installed Not Installed Side Scrub System Installed Not Installed Side Sweep System Installed Not Installed...

Page 46: ... of menu options 5 Press the Side Broom Up and Side Broom Down switches to select the desired option 6 When the arrow is pointing to an option Press the green Scrub On switch to select the option The display will then return to the previous menu level Press the red Scrub Off switch to return to the previous menu level without selecting the option 7 To save the new setting s turn the Key Switch to ...

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Page 48: ...e 5 to 30 seconds in 1 second increments 10 30 seconds Selects the vacuum off delay time 10 to 30 seconds in 1 second increments Normal Neutral Unlocked Control Locks Detergent Detergent Solution Side Scrub System Start Up State Off On Last State Appears only when the Side Scrub system is installed Side Sweep System Appears only when the Side Sweep system is installed Broom Start Up Off On Last St...

Page 49: ...ime 10 to 250 seconds in 1 second increments Back up Alarm Reverse Only Forward Reverse 10 250 seconds Extended Scrub System Start Up State Appears only when the Extended Scrub system is installed Operating Mode Off On Last State Use Anytime Use Clean First Side Sweep System Appears only when the Side Sweep system is installed Dust Guard Start Up Off On Last State ...

Page 50: ...n switches to select the desired option 7 KHQ WKH DUURZ LV SRLQWLQJ WR WKH FRQÀJXUDWLRQ RSWLRQ Press the green Scrub On switch to select the option The display will then return to the previous menu level Press the red Scrub Off switch to return to the previous menu level without selecting the option 8 Turn the ignition Key Switch to the off position to save the new setting s The new setting s will...

Page 51: ...Emergency Flashers and Headlight switches then turn the key switch on Installed Diesel Gas Propane Detergent System Not Installed Not Installed Installed EcoFlex System Side Scrub System Not Installed Installed Side Sweep System Not Installed Installed Display Format Undefined Ratio Percentage Installed ...

Page 52: ...nued Extended Scrub System Not Installed Not Installed Installed Back up Alarm Installed Not Installed Signal Lights Installed US Display Display Screen Global Display Off Operator Presence On Restore Defaults Are You Sure Press the Scrub On switch to restore the default settings ...

Page 53: ...tch is open for longer than one second If the engine is running it is switched Off by inhibiting the ignition and start signals If the Recovery system is On and the Scrub system is Off the Recovery system transitions to the Wand mode Pressing the Scrub Off switch turns the Scrub system Off Pressing the Scrub On switch has no effect Pressing the Wand Vacuum switch with the Scrub system Off transiti...

Page 54: ...N BRN and GRA ORN Check pump motors for short circuits replace as needed 00 C Extend scrub pump over current Check Pump motor M6 wiring for problems GRN BLU and GRA ORN Same fault line used for main solution pump M4 and M6 01 C Scrub brush pressure valve solenoids over current Check L5 down and L7 up pressure valve solenoid coils on same fault line for wiring problems L5 wire colors ORN and WHT VI...

Page 55: ...nd right side scrub solution valves and pump electrical ladder detail 08 NC Right side scrub solution solenoid valve over current Check L11 solenoid coil wiring for problems ORN and BLU YEL Check coil resistance If less than 10 ohms replace Also see main scrub and right side scrub solution valves and pump electrical ladder detail 09 C Vacuum fan solenoid over current Check L1 solenoid coil wiring ...

Page 56: ...e If less than 6 ohms replace Also see main scrub and right side scrub lift electrical ladder detail 19 NC Horn over current Check H4 horn wiring for problems ORN GRN and WHT YEL Check horn for short circuit spec 4A 12V replace as needed 20 NC Left turn signal lamp over current Check left turn signal wiring for problems YEL and BLK Check lamp for short see the I O table for circuit spec 21 NC Righ...

Page 57: ...LK RED Check pump motors for short circuit replace as needed 32 NC Detergent pump 2 over current See pump 1 33 C Engine hot fault Coolant temperature high causes engine fault sets on diesel machine only 34 C Hydraulic temperature fault Sets when hydraulic oil temperature exceeds 220 F for 15 seconds 35 C Low voltage fault battery One of the red display panel warning indicator lights See the explan...

Page 58: ...M5 over current X 05 No speed input 2200 RPM ECM 06 No speed input 2400 RPM ECM 07 Main solution solenoid valve L10 over current X X 08 Right side scrub solution solenoid L11 over current X 09 Vacuum fan solenoid L1 over current X X X X 10 Not used 11 Squeegee UP solenoid L3 over current X X X X 12 Squeegee DOWN solenoid L2 over current X X X X 13 Scrub motor solenoid L4 over current X X X 14 Glow...

Page 59: ... circuit breaker CB3 over current 28 20A circuit breaker CB4 over current 29 10A circuit breaker CB5 over current 30 Side sweep lift M7 actuator over current X 31 1 detergent pump M10 over current X 32 2 detergent pump M11 over current X 33 Engine hot fault diesel X X X X X X X X 34 Hydraulic oil temperature fault 35 Low voltage fault battery 36 Service engine fault GM non critical 37 Low oil pres...

Page 60: ...uit breaker CB6 must be closed to provide voltage to the Key Switch S1 The Ignition Key Switch S1 must be on to provide positive battery voltage to the K1 Relay Coil and certain inputs on the Driver Box The circuit breakers CB1 CB2 CB3 CB4 and CB5 must be closed to provide voltage to the side broom actuator lighting systems electric pump motors and solenoid valves S1 POWER RELAY KEY SWITCH PIN J2 ...

Page 61: ...wer Relay is mounted inside the control board assembly Note that a second identical power relay K4 is installed on diesel models as the glow plug power relay LUFXLW UHDNHUV The Circuit Breakers are mounted on the control board to the left of the Operator position Circuit Breakers K1 Power Relay ...

Page 62: ...played on LCD diesel engine only Glow plug relay K4 coil over current fault code 14 displayed Check K4 relay coil wiring for problems ORN GRN and WHT ORN Check coil resistance If less than 36 ohms replace Also see diesel glow plug starting circuit electrical ladder detail Fault code 20 displayed Left turn signal lamp over current Check left turn signal wiring for problems YEL and BLK Check lamp fo...

Page 63: ...ircuit fault for CB2 power for mist pump M5 and M8 wash hose pump Check for BLU wire shorted to ground Fault code 27 displayed 15A Circuit breaker CB3 over current Control board has sensed open circuit fault for CB3 power for side broom actuator motor M7 Check for VIO wire shorted to ground Fault code 28 displayed 20A Circuit breaker CB4 over current Control board has sensed open circuit fault for...

Page 64: ...ne run inhibit signal J7 8 ORN GRN Input B Module ignition relay Bat coil signal Note 7KH QRUPDO FRQGLWLRQ IRU WKH VWDUW LQKLELW LV LQ LWV QRQ LQKLELWHG VWDWH ÁRDW YROWDJH RI approximately 8V when referenced to B is measured when the key is in the start position KHQ LQKLELWHG WKH VLJQDO LV SXOOHG WR JURXQG ZLOO UHDG 9 DQG ZLOO SUHYHQW WKH HQJLQH IURP FUDQNLQJ 7KLV SUHYHQWV WKH VWDUWHU UHOD IURP EH...

Page 65: ...eat Switch Digital voltage 0V B Switch to ground Ground or open closes when Operator in seat J1 6 Not Used J1 7 Input Fuel Level Sensor gas diesel Variable resistance 0 40 1 66V B Variable resistance to ground 33 240 ohms Nominal voltage provided is subject to change if additional resolution is required Fuel Level Sensor LP Digital voltage 0V B Switch to ground Ground or open closed when tank is e...

Page 66: ...mpty Switch Digital voltage 0V B Switch to ground Ground or open closes when tank is empty J1 22 Output Start Inhibit Low side driver 0V B MOSFET gate on relay PCB assy 3 mA 12V URXQG RU ÀRDW J1 23 Ground J1 24 Input Start KEYPOS Switch Digital voltage B B System voltage From key switch J1 25 Input Check Engine Switch Digital voltage 0V B Engine Control Module low side output Switch to ground J1 2...

Page 67: ...20 C J2 3 Output Side Scrub Lift Solenoid Low side driver 0V B Hydraulic coil 1 5A 12V 8 ohms 20 C J2 4 Output Scrub Lock Solenoid Low side driver 0V B Hydraulic coil 1 5A 12V 8 ohms 20 C J2 5 Output Squeegee Down Solenoid Low side driver 0V B Hydraulic coil 1 5A 12V 8 ohms 20 C J2 6 Output Squeegee Up Solenoid Low side driver 0V B Hydraulic coil 1 5A 12V 8 ohms 20 C J2 7 Output Scrub Brush Soleno...

Page 68: ...noid 1 5A 12V 17W J2 23 Power B Circuit Breaker 5 VACC5 Power 12 1 5 VDC B System voltage Power from circuit breaker 5 10A J2 24 Output Scrub Pressure Up Low side PWM driver PWM 0 12V B Hydraulic coil 2 1A 12V 2 2 ohms 20 C J2 25 Ground J2 26 Output Scrub Pressure Down Low side PWM driver PWM 0 12V B Hydraulic coil 2 1A 12V 2 2 ohms 20 C J2 27 Ground J2 28 Ground J2 29 Output ECM Engine 2200 RPM H...

Page 69: ... VDC B System voltage Power from circuit breaker 1 20A J3 2 Output Main Solution Pump Low side PWM driver PWM 0 12V B Pump motor 11 5 FLA 12V 46 LRA 5KHz variable duty cycle J3 3 Ground J3 4 Output Side Sweep Actuator HI Red Lead H bridge driver 12V B Actuator motor 20 2 FLA 80 LRA est Bridge switching power ground for Down otherwise open J3 5 Output Side Sweep Actuator LO Black Lead H bridge driv...

Page 70: ...ower 12 15 VDC B System voltage Power from circuit breaker 3 15A J3 17 Output Horn Low side driver 0V B Electromagnetic horn 4A 12V J3 18 Output Side Sweep Mist Pump Low side driver 0V B Pump motor 3 9 FLA 24V 16 LRA 24V pump operated at 12V J3 19 Output Detergent Pump 2 H bridge driver 0 to B B 0 65A 12V Pulsed on and off at a rate less than 10 Hz J3 20 Output Detergent Pump 2 H bridge driver 0 t...

Page 71: ...al communication J1 3 ORN BLK CAN H CAN Bus 0 5V Differential serial data 2 50v key on User interface panel serial communication J1 4 Not Used J1 5 YEL Seat Switch Digital voltage 0V Switch to ground 12 8v off seat 0 008v on seat Ground or open closes when Operator in seat J1 6 Not Used J1 7 BRN WHT Fuel Level Sensor gas diesel Variable resistance 0 40 1 66V Variable resistance to ground 33 240 oh...

Page 72: ...IO WHT Brake Pedal Switch Digital voltage 0V Switch to ground 0 04v at rest 11 9v pressed Closes when brake pedal released J1 21 VIO YEL Solution Empty Switch Digital voltage 0V Switch to ground 0 004v empty 12 26v not empty Ground or open closes when tank is empty J1 22 WHT BRN Start Inhibit Low side driver 0V MOSFET gate on relay PCB assy 3 mA 12V 9 2v cranking normal 0 015v inhibited URXQG RU À...

Page 73: ...0V Switch to ground 11 7v key on Ground or open closed when tank is empty J1 34 YEL WHT Ignition Inhibit Low side driver 0V MOSFET gate on relay PCB assy 3 mA 12V 11 7v key on URXQG RU ÀRDW J1 35 Not Used J2 1 BLU GRN Main Power Relay Low side driver 0V Relay coil 0 29A 12V 0 33v key on 46 5 ohms J2 2 BLK WHT Side Sweep Scrub Solenoid S8 Low side driver 0V Hydraulic coil 1 5A 12V 11 9v Sol off 0 3...

Page 74: ... on This was pulsed on momentarily You may not see the change without a Min Max function on your voltmeter J2 11 BLU BLK Backup Audible Alarm Low side driver 0V Electronic alarm 0 25A 12V 14 4v off J2 12 ORN Circuit Breaker 4 VACC4 Power 12 15 VDC System voltage 14 5v Eng running Power from circuit breaker 4 20A J2 13 WHT ORN Glow Plug Relay Low side driver 0V Relay coil 0 29A 12V Not measured 46 ...

Page 75: ...ne 2200 RPM High side driver 12V Engine Control Module input 2 79v at idle 14 3v Mid 2 81v High 9 IRU 530 ÀRDW RWKHUZLVH J2 30 GRA BLU ECM Engine 2400 RPM High side driver 12V Engine Control Module input 2 79v at idle 2 79v Mid 14 3v high 9 IRU 530 ÀRDW RWKHUZLVH J2 31 YEL Left Front Turn Lamp High side driver 12V Incandescent lamp 0 33A 12V 0 004v off 12 3v on 0 4A 14 5V 4W turn lamp J2 32 GRN Ri...

Page 76: ...otor 20 2 FLA 80 LRA est Not Measured Bridge switching power ground for Down otherwise open J3 5 WHT RED Side Sweep Actuator LO Black Lead H bridge driver 0V Actuator motor 20 2 FLA 80 LRA est Not Measured Bridge switching power ground for Up otherwise open J3 6 Not Used J3 7 GRA VIO Side Sweep Actuator MID White Common Lead H bridge driver B or 0V Actuator motor 20 2 FLA 80 LRA est Not Measured B...

Page 77: ...p Mist Pump Low side driver 0V Pump motor 3 9 FLA 24V 16 LRA Not Measured 24V pump operated at 12V J3 19 BLK RED Detergent Pump 2 H bridge driver 0 to B 0 65A 12V 0 16v to 14 5v Pulsed on and off at a rate less than 10 Hz Normal scrub approx 0 2v Burst of power scrub approx 10 14v J3 20 BLK YEL Detergent Pump 2 H bridge driver 0 to B 0 65A 12V 0 16v to 14 5v Pulsed on and off at a rate less than 1...

Page 78: ...ub option with no side sweep Pin ID Wire Color Pin Assignment Real World Shop Measurements J7 1 VIO GRA B 12 3v key on J7 2 BLU PINK Engine Start 0 03v key on 10 7v cranking J7 3 WHT BRN Start Inhibit 0 2v key on 8 8v cranking J7 4 BLK Ground 0 005 key on 0 2v cranking J7 5 PINK Engine Run 12 3v key on 11 2v cranking 14 6v running J7 6 VIO BRN Start Key Pos 0 2v key on 11 2v cranking J7 7 YEL WHT ...

Page 79: ...RN YEL GRN YEL PINK RED YEL VIO YEL GRA YEL VIO WHT BLK BLK BLK BLK GRA ORN GRA ORN BLU PINK BLU PINK PINK PINK VIO GRA VIO BRN WHT BRN VIO RED VIO GRN BRN BLU GRN BRN ORN YEL BLK GRN ORN VIO BLU VIO BLU BLK WHT ORN PURPLE PINK GRA RED RED VIO GRA RED ORN GRN YEL WHT BRN WHT GRA VIO GRA BRN BLU GRA BLK YEL RED GRA VIO YEL GRA ORN GRA WHT RED BLU BRN BRN WHT YEL BRN ORN BRN ORN BRN GRN YEL RED YEL ...

Page 80: ...D GRA VIO YEL GRA ORN GRA WHT RED BLU BRN BRN WHT YEL BRN ORN BRN ORN BRN GRN YEL RED YEL BLK BRN GRN BLK BLK BRN BLK BRN BRN BLK VIO BRN ORN GRN ORN GRN PINK BLU PINK VIO GRA BLK YEL ORN BLK BLU GRN ORN GRN ORN GRN ORN GRN GRA BLU GRN BRN GRA ORN BLU RED BLU GRN BLU BLU RED BLK ORN GRN ORN GRN ORN GRN BLU BLK WHT YEL GRN BRN GRN BRN GRN BRN GRN BRN RED BLU RED WHT BLK RED BLK YEL BLU ORN BLU BRN ...

Page 81: ... SP16 1 2 A B H2 H2 SP4 SP4 1 2 A B C 1 2 X165 X165 A B C D E F L1 VALVE VAC FAN S1 L1 VALVE VAC FAN S1 S30 SWITCH SEAT S30 SWITCH SEAT 1 2 CB3 CIR BREAKER 15 AMP VACC3 CB3 CIR BREAKER 15 AMP VACC3 1 2 A B C D E F S7 SWITCH EXT SCRUB OPTIONAL S7 SWITCH EXT SCRUB OPTIONAL BLK WHT LP5 LAMP RIGHT FRONT TURN LP5 LAMP RIGHT FRONT TURN WHT BLK A B X73 X73 A B C R3 SENDER FUEL R3 SENDER FUEL 1 2 SP13 SP1...

Page 82: ...GRA 18 1 VIO BLU 18 1 GRN RED 8 1 BLK YEL 18 1 ORN BLK 18 1 GRA ORN 18 1 THROTTLE INPUT 12V FOR 2200 RPM B GRA ORN 18 1 SPEED SELECT 1 2400 RPM SPEED SELECT 2 2200 RPM B B B X1_ X1_ A B C D E F G H J K L M N P R S M13 STARTER M13 STARTER 30 50 D3 D3 E4 E4 1 2 X2_ X2_ A B C D E F G H J K L M N P R S SP28 SP28 1 2 2 X2 X2 A B C D E F G H J K L M N P R S SP26 SP26 1 2 2 X154 X154 A B C D t o S9 SWITC...

Page 83: ...H THROTTLE FUEL PUMP RELAY FUEL PUMP BATT GRO ALTERNA B L H J I E D F G K EGO 2 EGO 1 ECT BOSCH_TMAP OIL PRESSURE SENSOR IGNITION COIL CRANK SENSOR GROUND POWERRELAY IGNITION STARTER RELAY STARTER SOLENOID ECM STARTER VSW PEHU EHORZ ...

Page 84: ...G TEMPERATURE BOSCH THROTTLE BATT GRO ALTERN N L H J I E D F G K EGO 2 EGO 1 ECT BOSCH_TMAP OIL PRESSURE SENSOR IGNITION COIL CRANK SENSOR GROUND EPR IGNITION STARTER RELAY STARTER SOLENOID ECM STARTER VSW M LOCKOFF P PEHU EHORZ ...

Page 85: ...HULDO QXPEHU ...

Page 86: ...HULDO QXPEHU ...

Page 87: ...P VS N VS M AUX DIG 3 L AUX DIG 2 K GOV SELECT 1 J GOV SELECT 2 H AUX ANA PU1 G AUX ANA PU2 F AUX PWM 1 E GROUND D TACH C AUX PWM 5 B AUX PWM 5 RECIRC A UNUSED ECM Detail CONNECTOR 1 CONNECTOR 2 BLACK LT GREEN 18 LT GREEN RED 18 DK GREEN 18 ORANGE 18 BLUE PINK 18 BLUE WHITE 18 1 ANA RTN 2 5V REF 3 PC TX 4 PC RX 5 UNUSED 6 UNUSED 7 CAN1 8 CAN1 GASOLINE SENSOR INTERFACE MI START FUEL FUE A IGN SWI C...

Page 88: ...DQG WKH VWHHULQJ V VWHP RRGZDUG 3 6 RYHUQRU FRQWUROV WKH IXHO TXDQWLW WR PDLQWDLQ WKH VHOHFWHG 530 RU VKXW WKH HQJLQH RII LHVHO QJLQH 6WDUWHU LUFXLW LDJUDP 30 50 L I F S P DRIVE BOX PIN J1 22 PIN J1 34 PIN J1 10 PIN J1 31 PIN J1 11 Battery From F1 Fuse 100A CB6 15A S1 K2 K3 R1 START B1 IGN J7 6 J7 3 J7 7 J7 8 START INHIBIT RUN INHIBIT J7 4 J7 2 J7 5 K2 K3 DRIVE PEDAL SENSOR BAT BAT 3 J7 1 RELAY PC...

Page 89: ...DQJH RU WKH HQJLQH WR UXQ The Ignition_Inhibit UHOD PXVW QRW EH HQHUJL HG 7KLV PHDQV WKDW WKH Driver Box LV QRW SURYLGLQJ D JURXQG WR WKH FRLO WKURXJK J1 34 The Oil Pressure Switch S28 PXVW EH RSHQ 7KLV VZLWFK LV D VLQJOH SROH GRXEOH WKURZ 63 7 VZLWFK KHQ WKH RLO SUHVVXUH LV WRR ORZ WKH VZLWFK LV LQ WKH LQDFWLYDWHG VWDWH QRUPDOO FORVHG FRQWDFW LV FORVHG KHQ WKHUH LV RLO SUHVVXUH WKH VZLWFK DFWLYDW...

Page 90: ...QGRU 1LO VN 5 RPSRQHQW RFDWLRQV X1 and X2 Electrical Connectors Engine Ground Connection Oil Pressure Sensor DERYH RLO OWHU Coolant Temperature Sensor DERYH DOWHUQDWRU Governor Engine Speed Magnetic Pickup Woodward Governor and Throttle Actuator ...

Page 91: ... 10W 30 Below 32 F 0 C SAE 10W or 10W 30 Diesel Lubricating Oil Note LWK WKH HPLVVLRQ FRQWURO QRZ LQ HIIHFW WKH DQG OXEULFDWLQJ RLOV KDYH EHHQ GHYHORSHG IRU XVH ZLWK D ORZ VXOIXU IXHO XVHG LQ RQ URDG YHKLFOH HQJLQHV KHQ DQ RII URDG YHKLFOH HQJLQH UXQV RQ D KLJK VXOIXU IXHO LW LV DGYLVDEOH WR HPSOR WKH RU OXEULFDWLQJ RLO ZLWK D KLJK WRWDO EDVH QXPEHU I WKH RU OXEULFDWLQJ RLO LV XVHG ZLWK D KLJK VXO...

Page 92: ...G WKH RROLQJ 6 VWHP 7RRO RQWR WKH UDGLDWRU ÀOOHU QHFN WKHQ SUHVV WKH Air Switch 7KH FRPSUHVVHG DLU WUDYHOOLQJ WKURXJK WKH Venturi Tube Assembly ZLOO SXOO D YDFXXP RQ WKH FRROLQJ V VWHP WR UHPRYH DLU IURP WKH V VWHP 2QFH WKH YDFXXP UHDGLQJ RQ WKH Gauge UHDFKHV DSSUR LPDWHO RQ WKH JUHHQ VFDOH UHOHDVH WKH Air Switch 1RWH WKDW WKLV DOVR D JRRG RSSRUWXQLW WR FKHFN IRU FRROLQJ V VWHP OHDNV RQWLQXH WR KR...

Page 93: ...WR WKH FDQLVWHU XQWLO LW LV FRPSOHWHO GU 7URXEOHVKRRWLQJ HQHUDO 7URXEOHVKRRWLQJ Problem Cause Correction The yellow attention light and glow plug display icon will not go out Glow plug relay K4 coil over current fault code 14 displayed on the LCD Check K4 relay coil wiring for problems ORN GRN and WHT ORN Check coil resistance If less than 36 ohms replace Also see diesel glow plug starting circuit...

Page 94: ... EH FWLYH DXVLQJ WKH QJLQH 1RW WR UDQN ULYH SHGDO VHQVRU VZLWFK 5 QRW FDOLEUDWHG IROORZ SURJUDPPLQJ LQVWUXFWLRQV WR FDOLEUDWH IRRW SHGDO VHQVRU ULYH SHGDO DFWLYDWHG RXW RI QHXWUDO RXW RI WKH FDOLEUDWHG GHDGEDQG UDQJH 5HPRYH IRRW IURP GULYH SHGDO GMXVW RU UHSDLU WKH GUREDFN FDEOH DQG RU PDLQ SLVWRQ SURSXOVLRQ SXPS OLQNDJH 7KH FRQWURO SDQHO GLVSOD V WKH FULWLFDO IDXOW LFRQ VKRZLQJ FRGH 6HH WKH HQHUD...

Page 95: ...LQ DQG WKH HQJLQH ZLOO UHYHUW WR LGOH 6HH DGGLWLRQDO WURXEOHVKRRWLQJ QRWHV IRU FRQWURO FLUFXLW GHWDLOV Component Current Amps Coil Ohms Actuator 1 1 5 Amps 3 2 ohms Pin Wire Color Function Voltage at 1300 RPM Voltage at 2200 RPM Voltage at 2400 RPM J2 30 on Driver Box VIO Input from Driver Box 0 0 12 VDC J2 29 on Driver Box GRA Input from Driver Box 0 12 VDC 0 SPEED 1 2400 RED B B S1 TO ENGINE FLY...

Page 96: ...HFN LV 2 VXEVWLWXWH D QHZ ULYHU R PDLQ FRQWUROOHU DQG DVKERDUG 3DQHO KHFN WKH VWDWXV ODPS RQ WKH JRYHUQRU IRU IDXOW FRGHV 5HIHUHQFH WKH ÁDVK FRGH WDEOH IRXQG RQ WKH 3 6 ZHEVLWH 7HVW JRYHUQRU FRQWUROOHU DFWXDWRU RXWSXW YROWDJH DW GLIIHUHQW VSHHG VHOHFWLRQ PRGHV DSSUR LPDWH YDOXH 9 KHFN WKH FRQWLQXLW RI WKH IXHO FRQWURO DFWXDWRU ZLULQJ 7HVW WKH Fuel Solenoid Actuator VHH EHORZ IRU DQ RSHQ FLUFXLW WK...

Page 97: ...ction Pump Bosch MD type mini pump QJLQH ULQJ RUGHU 1 3 4 2 Injection Timing 19 degrees before TDC Oil Capacity 5 5 qt 5 2L Oil Pan depth 4 9 12 4 cm Cooling Capacity 8 qt 7 5L Horsepower 46 gross 2800 RPM 41 Int 2400 RPM Engine Speeds Idle 1300 RPM Normal Run 2200 RPM High Output Turbo 2400 RPM Actuator Current 1 to 1 5 amps Coil Resistance 3 2 ohms Note Refer to the engine manufacturer s Operato...

Page 98: ...QRUPDO FRQGLWLRQ IRU WKH VWDUW LQKLELW LV LQ LWV QRQ LQKLELWHG VWDWH ÁRDW YROWDJH RI approximately 8V when referenced to B is measured when the key is in the start position When inhibited the signal is pulled to ground will read 0V and will prevent the engine from cranking This prevents the starter relay from being energized Note 7KH QRUPDO FRQGLWLRQ IRU WKH UXQ LQKLELW LV LWV QRQ LQKLELWHG VWDWH ...

Page 99: ...KH WKURWWOH DQG LJQLWLRQ V VWHP DVROLQH HQJLQHV XVH IXHO LQMHFWRUV 7KH 3 HQJLQH XVHV DQ HOHFWURQLFDOO FRQWUROOHG YDSRUL HU SUHVVXUH UHJXODWRU 0 QJLQH 6WDUWHU LUFXLW DRIVE BOX PIN J1 22 PIN J1 34 PIN J1 10 PIN J1 31 PIN J1 11 Battery From F1 Fuse 100A CB6 15A S1 K2 K3 R1 START B1 IGN J7 6 J7 3 J7 7 J7 8 START INHIBIT RUN INHIBIT J7 4 J7 2 J7 5 K2 K3 DRIVE PEDAL SENSOR BAT BAT 3 J7 1 RELAY PCB START...

Page 100: ...H START COMMAND TO STARTER RELAY 7KH GULYH SHGDO PXVW EH LQ WKH QHXWUDO SRVLWLRQ DQG WKH Drive Pedal Sensor PXVW EH LQ WKH GHDGEDQG UDQJH RU WKH HQJLQH WR UXQ The K2 RELAY CONTROL SWITCH PXVW UHPDLQ FORVHG WR SURYLGH D JURXQG WR WKH IGN UHOD FRLO K2 7KLV NHHSV WKH K2 UHOD FRQWDFWV FORVHG WR PDLQWDLQ SRVLWLYH YROWDJH WR WKH IGN SW INPUT The Coolant Temperature Output PXVW QRW SURYLGH DQ RYHUKHDWµ V...

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Page 102: ...OLQH 3HWURO O2 Sensor in exhaust manifold pre CATCON ECT Engine Coolant Temperature Sensor Fuel Pump and Manifold mounted on fuel tank TMAP Sensor ETC Electronic Throttle Control Fuel Injectors and Connectors ECM and Oil Pressure Switch Crank Position Sensor O2 Sensor by exhaust pipe ...

Page 103: ...RU 1LO VN 5 DVROLQH 3HWURO 7KH DVROLQH 6HQVRU QWHUIDFH IXHO SUHVVXUH UHJXODWLRQ DQG WHPSHUDWXUH VHQVRU PDQLIROG DVVHPEO LV PRXQWHG RQ WKH IXHO WDQN DVROLQH 3HWURO DQG 3 Gasoline Sensor Interface X1 and X2 Electrical Connectors Engine Ground Connection ...

Page 104: ...GRU 1LO VN 5 3 Fuel Temperature Sensor mounted on EPR TMAP Sensor ETC Electronic Throttle Control EPR and Fuel Lockout and Filter O2 Sensors exhaust manifold pipe ECT Engine Coolant Temperature Sensor ECM and Oil Pressure Switch Crank Position Sensor ...

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Page 109: ...oubleshoot the throttle wire If still 0V substitute a good known controller and dashboard panel If 12V and no 2400 RPM throttle response test HQJLQH FRQWUROOHU RXWSXW WR VSHFL F WKURWWOH FRQWURO G LP D All machine systems shut down Coolant temperature high fault code 33 displayed on the LCD Refer to the QJLQH 2YHUKHDWLQJ 3UREOHPV section below The oil pressure has dropped to 3 7 psi fault code 37 ...

Page 110: ...VXUH VZLWFK FHVVLYH HQJLQH ZHDU RU GHIHFWLYH LQWHUQDO RLO SXPS UHOLHI YDOYH 3RVVLEOH DXVHV IRU 6WDUW QKLELW WR EH FWLYH DXVLQJ WKH QJLQH 1RW WR UDQN ULYH SHGDO VHQVRU VZLWFK 5 QRW FDOLEUDWHG IROORZ SURJUDPPLQJ LQVWUXFWLRQV WR FDOLEUDWH IRRW SHGDO VHQVRU ULYH SHGDO DFWLYDWHG RXW RII QHXWUDO RXW RI WKH FDOLEUDWHG GHDG EDQG UDQJH 5HPRYH IRRW IURP GULYH SHGDO GMXVW RU UHSDLU WKH GUREDFN FDEOH DQG RU P...

Page 111: ...UDWLRQ VHWWLQJV DQG HUURU FRGHV DQG GLVSOD V WKH HQJLQH VRIWZDUH DQG KDUGZDUH LQIRUPDWLRQ 1RWH WKDW WKLV LV WKH SUHIHUUHG ZD WR YLHZ WKH HQJLQH GLDJQRVWLF LQIRUPDWLRQ 7R XVH WKH RQWUROOHU QWHUIDFH LW QVWDOO WKH VRIWZDUH IURP WKH SURYLGHG RQWR RXU 3 RQQHFW WKH 86 FRQQHFWRU RQ WKH NLW FDEOH WR D 86 SRUW LQ RXU 3 5HPRYH WKH Protective Cap WKHQ FRQQHFW WKH NLW FDEOH WR WKH Communication Port RQ WKH HQ...

Page 112: ... WKH VRIWZDUH LQ WKH LDJQRVWLF RPPXQLFDWLRQV DEOH DQG 6RIWZDUH LW DUH DV IROORZV LQGRZV 3 RU 6 6HFRQG GLWLRQ RSHUDWLQJ V VWHP 0LQLPXP SURFHVVRU VSHHG 3HQWLXP 0 0LQLPXP 5 0 UHTXLUHPHQWV LQGRZV 3 0 LQGRZV 0 LQGRZV 6 0 W OHDVW RQH DYDLODEOH 56 VHULDO RU 86 SRUW 1RWH WKDW WKH 86 GULYHU GRHV QRW VXSSRUW LQGRZV 6 ...

Page 113: ... DQ 7 HQJLQH FRRODQW WHPSHUDWXUH KLJK YROWDJH FRQGLWLRQ ZRXOG EH LQGLFDWHG DV IROORZV D 7KH OLJKW ZLOO VKRZ RQH EOLQN D VKRUW SDXVH VL EOLQNV D VKRUW SDXVH ÀYH EOLQNV D VKRUW SDXVH WKHQ IRXU EOLQNV 1RWH WKDW WKLV VHTXHQFH LV QRW DQ HUURU FRGH EXW ZLOO EH UHSHDWHG WKUHH WLPHV WR LQGLFDWH WKH EHJLQQLQJ RI WKH HUURU FRGH QXPEHU GLVSOD VHULHV E 7KH OLJKW ZLOO VKRZ WKH ÀUVW DFWXDO HUURU FRGH LQ WKLV H ...

Page 114: ...9 BP Low Pressure 108 1 1165 LPG Cat Monitor 520213 10 134 EGO 1 Open 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 Comm Lost 520260 31 172 Adaptive Learn Low Gasoline 520200 1 1174 EPR Voltage Supply High 520260 3 182 Fuel Temp Gasoline Low Voltage ...

Page 115: ... B Engine ECU starter relay command J7 3 WHT BRN Input 0V Floats Engine start inhibit signal J7 4 BLK Input B Module relays coil ground supply J7 5 PINK Output B Engine ECU ignition run relay command J7 6 VIO BRN Input B Module starter relay Bat coil signal J7 7 YEL WHT Input 0V Floats Engine run inhibit signal J7 8 ORN GRN Input B Module ignition relay Bat coil signal Note 7KH QRUPDO FRQGLWLRQ IR...

Page 116: ... QJLQH 6 VWHP DVROLQH 3 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 6SHFLDO 7RROV Diagnostic Communication Cable and software p n 56305647 Cooling System Tool ...

Page 117: ... wheel The dual displacement low speed accessory pump is actually two separate pumps in one unit 1 20 and 0 58 CIR and powers the other machine components A system of electrically controlled solenoid valves directs the hydraulic oil to the various system components to perform the needed scrubbing sweeping and solution recovery functions Note The electrical wiring diagrams schematics use an L follo...

Page 118: ...4 PXVW EH RSHQ WR LQGLFDWH WKDW WKH K GUDXOLF ÀOWHU LV QRW SOXJJHG Fuse 100A Relay Power Dashboard Panel Driver Box J2 23 VACC5 J2 12 VACC4 J2 8 J2 5 J2 6 J2 22 J2 10 J2 7 J2 24 J2 26 J2 4 J2 3 J2 2 CB4 Circuit Breaker 20A K1 Battery 12 VDC F1 Circuit Breaker 15A CB6 CB5 Circuit Breaker 10A Vacuum Fan S1 Squeegee Down S2 L1 L2 Squeegee Up S3 L3 Valve Main Solution L10 Valve Right Solution L11 Scru...

Page 119: ... GUDXOLF 6 VWHP 119 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 GUDXOLF 6FKHPDWLF ...

Page 120: ... Assembly Reservoir Assembly Steering Pump Assembly Squeegee Cylinder Assembly Drive Motor Assembly Pump Assembly Low speed Valve Block Assembly Steer Cylinder Assembly Scrub Lift Cylinder Assembly Oil Cooler Assembly Pump Assembly Hydraulic Motor Assembly Hydraulic Motor Assembly Oil Filter Front ...

Page 121: ...der Assembly are located as shown GUDXOLF 0RWRUV The Vacuum Fan Motor Assembly Steering Pump Assembly Drive Motor Assembly and Main Brush Motor Assembly are located as shown Scrub Lift Cylinder Assembly Squeegee Cylinder Assembly Steer Cylinder Assembly Steering Pump Assembly Drive Motor Assembly Main Brush Motor Assembly Vacuum Fan Motor Assembly ...

Page 122: ...nected to the engine output shaft and are located as shown The Accessory Pump Assembly includes the two auxiliary hydraulic pumps GUDXOLF 9DOYH ORFN 0DQLIROG The Hydraulic Valve Block Manifold is located on the back of the machine as shown Propulsion transport Piston Pump Assembly Accessory Pump Assembly Front Bottom View Hydraulic Valve Block Manifold ...

Page 123: ... GUDXOLF 6 VWHP 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 The Solenoid Valves and System Relief Valves are located on the Hydraulic Valve Block Manifold as shown S2 top S3 bottom S1 S4 S7 ...

Page 124: ...ve S8 L8 controls the right side scrub sweep motor s S8 L8 is located above the front end of the Scrub Deck The Right Side Scrub Lift Cylinder Solenoid Valve S9 L9 controls the side scrub lift cylinder S9 L9 is located inboard of the Right Scrub Assembly Scrub Deck S8 L8 S9 L9 Right Scrub Assembly ...

Page 125: ...f coil 2 2 ohms R1 Solenoid coil and valve cartridge pressure relief vacuum fan 2700 psi R2 Solenoid coil and valve cartridge pressure relief scrub brush s 2700 psi L8 S8 Solenoid coil and valve cartridge right scrub sweep system coil 8 ohms L9 S9 Solenoid coil and valve cartridge right scrub lift cylinder coil 8 ohms Note The combined electrical solenoid and hydraulic valve cartridge assembly can...

Page 126: ...e oil level should not be higher than 12 7 mm above the bottom of WKH ÀOOHU VFUHHQ 3 KDQJH DQG ÁXVK WKH RLO LI PDMRU contamination from a mechanical failure occurs GUDXOLF 2LO OWHU 1 Release the latches and tip the Hydraulic Oil Cooler out away from the machine 2 Use a pan or other suitable container to catch any oil that may leak out when you remove the Hydraulic Oil Filter 3 Unscrew and remove t...

Page 127: ...hat is performing poorly Refer to the 6SHFL FDWLRQV WDEOHV WR GHWHUPLQH WKH PRWRU 530 I WKH PRWRU VSHHG LV FRUUHFW WKH SXPS LV SURGXFLQJ WKH FRUUHFW DPRXQW RI RLO ÁRZ RZHYHU WKLV GRHV QRW PHDQ that if a motor is running too slow the problem is in the pump 7KH IROORZLQJ LQIRUPDWLRQ VKRXOG EH XVHG WR FKHFN IRU FRUUHFW PRWRU 530 V VWHP SUHVVXUH DQG UHOLHI YDOYH VHWWLQJV 7KH UHDGLQJV DUH QRPLQDO ÀJXUH...

Page 128: ...ional psi reading is above the bypass psi but is below the operational psi FKHFN WKH EURRP DGMXVWPHQW DQG ZHDU Check the individual system 7URXEOHVKRRWLQJ sections of this manual for additional information TP 1 TP 3 TP 2 Upper Test Port TP 5 on the Scrub Lift Cylinder Lower Test Port TP 4 on the Scrub Lift Cylinder Accessory Pump Test Ports TP 5 TP 4 Scrub Lift Cylinder Test Ports TP 4 TP 5 ...

Page 129: ...Relief Setting Forward 3500 PSI Reverse 2500 PSI Charge Relief 200 250 PSI Dual Low speed Accessory Hydraulic Pump Ratings Displacement Front 0 58 CID Rear 1 20 CID Speed 3200 RPM max Rated Pressure 3000 PSI Max Pressure 3500 PSI 5HOLHI 3UHVVXUH 36 RQ SULRULW ÀRZ Accessory Pump 1 Circuits Displacement Cu In GPM RPM In RPM Out PSI Relief PSI Accessory pump 1 engine 2200 RPM no systems running test ...

Page 130: ...h engine 2200 RPM no systems running test port TP3 1 20 3 0 2200 296 1500 Steering unit driving and turning 4 5 500 7KH E SDVV SUHVVXUH LV WKH SUHVVXUH UHDGLQJ ZLWK QR PRWRU RU F OLQGHU RSHUDWLQJ ÁRZ WKURXJK Scrub brush system hydraulic pressure under load setting 3 maximum scrub pressure Test Port Pressure Type Controlled by Pressure Setting PSI Scrub lift cylinder 1 50 x 5 00 engine at 2200 RPM ...

Page 131: ...rushes On X Scrub Brush Pressure Setting 5HJXODU X X X Scrub Brush Pressure Setting HDY X X X Scrub Brush Pressure Setting WUHPH X X X Right Side Scrub Brush Pressure Settings 1 2 and 3 X X X X Scrub Brushes Off Right Scrub On X X Dual Side Broom Sweep On X X SAE JIC 37 Flare Fitting Torque Chart SAE Dash Thread Size Torque in ft lbs FFWR 4 7 16 20 11 2 5 1 2 20 14 2 6 9 16 18 20 1 1 4 8 3 4 16 43...

Page 132: ... GUDXOLF 6 VWHP 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 6SHFLDO 7RROV Hydraulic test gauge w connector 3000 psi range p n 56504516 ...

Page 133: ...n Illustration Detergent Bottles Back up Alarm Kit The Back up Alarm Kit includes the Back up Alarm Unit Pigtail Wire Assembly and mounting hardware Warning Beacon Kit The Warning Beacon Kit mounts directly on the machine and is designed for machines without an overhead guard ...

Page 134: ... Kit mounts onto the overhead guard Brake Signal Light Kit The Brake Signal Light Kit includes amber front signal lights red rear stop signal lights and wiring harnesses Extended Scrub Kit The Extended Scrub Kit includes the H WHQGHG VFUXE SXPS ÀRDW VZLWFK and strainer and the electrical and solution quick disconnects Fire Extinguisher Kit ...

Page 135: ...O VN 5 Description Illustration Foot Guard Kit Roller Bumper Kit Note that the right side roller bumper is standard on Condor XL 60 and 67 with right side scrub Wash Hose Kit shown mounted behind Operator seat Overhead Guard Kit warning beacon sold separately ...

Page 136: ... DQG FFHVVRULHV 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 Description Illustration Overhead Guard Canopy Kit overhead guard sold separately Rear Bumper Kit Recovery Tank Clean out Kit Recovery Tank Debris Tray Kit ...

Page 137: ...FFHVVRULHV 137 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 Description Illustration Drain Hose Extension Remote Foot actuated Horn Switch Kit 6ROXWLRQ XWR OO LW Right hand Dual Armrest Kit Seat Belt Kit for Standard Seat ...

Page 138: ... GYDQFH RQGRU 1LO VN 5 Description Illustration Deluxe Suspension Seat Kit includes right hand armrest and seat belt Under Hood Light Kit includes trouble light with magnetic base on an extendable cable Vacuum Wand Kit shown mounted on machine ...

Page 139: ... PDFKLQH PRWLRQ VWRSV 7KH YDFXXP IDQ PRWRU FDQ DOVR EH VZLWFKHG RQ LQGHSHQGHQW RI WKH VFUXE V VWHP E SUHVVLQJ WKH YDFXXP VZLWFK ROG VW OH FRQWURO SDQHO RU WKH YDFXXP ZDQG VZLWFK QHZ VW OH FRQWURO SDQHO 7KLV LV XVHG WR SLFN XS VROXWLRQ DOUHDG RQ WKH ÁRRU RU ZKHQ XVLQJ D ZDQG RQ WKH VTXHHJHH KRVH Refer to the 6TXHHJHH 6 VWHP VHFWLRQ IRU PRUH LQIRUPDWLRQ RQ WKH VTXHHJHH FRPSRQHQWV DQG RSHUDWLRQ 5HFRY...

Page 140: ...FWXDWHG WKH UHFRYHU V VWHP The Driver Box PXVW UHFHLYH D VLJQDO IURP WKH Drive Pedal Sensor R1 WKDW WKH GULYH SHGDO KDV EHHQ PRYHG IURP WKH QHXWUDO SRVLWLRQ The Recovery Full Switch S2 PXVW EH FORVHG UHFRYHU WDQN QRW IXOO 5HFRYHU 6 VWHP GUDXOLF LDJUDP Q HOHFWULF VROHQRLG S1 FRQWUROV WKH K GUDXOLF Vac Fan Control Valve ZKLFK FRQWUROV WKH K GUDXOLF RLO ÁRZ WR WKH YDFXXP IDQ PRWRU 9DFXXP DQ 2II Q WKH...

Page 141: ...KH K GUDXOLF RLO ÁRZ IURP WKH Aux DX LOLDU Pump through the Vacuum Fan PRWRU WKHQ WR WKH Reservoir The Pressure Relief Valve ZLOO RSHQ WR DOORZ WKH RLO WR ÁRZ EDFN LQWR WKH Propulsion Pump Charge Port LI D KLJK SUHVVXUH FRQGLWLRQ RFFXUV LQ WKH K GUDXOLF OLQHV EHIRUH WKH RLO HQWHUV WKH WDQN VWDOOHG PRWRU SOXJJHG KRVH HWF 0 1 0 2 3 4 5 0 0 2 0 6 7 5 5 8 9 8 0 5 5 0 4 8 9 5 ...

Page 142: ...QHHGHG WR SXOO WKH ZDVWHZDWHU IURP WKH VTXHHJHH DQG Squeegee Hose Assembly WKURXJK the Cuffed Hose Assembly DQG LQWR WKH Recovery Tank The Recovery Tank Cover Assembly RSHQV WR DOORZ DFFHVV WR WKH LQVLGH RI WKH Recovery Tank DQG WR WKH Vacuum Fan Assembly DQG KRVHV 7KH Recovery Tank Cover Assembly VHDOV RQ the Recovery Tank ZKHQ FORVHG WR PDLQWDLQ WKH YDFXXP LQVLGH RI WKH Recovery Tank The Drain H...

Page 143: ...etween the vacuum fan assembly and the recovery tank and tighten replace as necessary Check the gaskets and replace as necessary Check the recovery tank for damage Restrictions due to built up debris in the squeegee tool YDFXXP KRVHV RU ÀRDW FDJH 1 KHFN WKH VTXHHJHH WRRO YDFXXP KRVHV DQG ÀRDW cage for any accumulated dirt or debris and clean as necessary 2 KHFN WKH YDFXXP V VWHP DLUÀRZ SDWKZD ZKHU...

Page 144: ...U RU GDPDJH WR WKH UHFRYHU WDQN UDLQ WKH UHFRYHU WDQN Note If your machine is equipped with an extended scrub system you must disconnect the Float Switch Quick disconnect and Solution Quick disconnect Coupler before you can remove the recovery tank Refer to the 6ROXWLRQ 6 VWHP XQFWLRQDO HVFULSWLRQ WHQGHG 6FUXE 6 VWHP subsection Press the Skirt Latch DQG VZLQJ WKH OHIW KDQG Side Skirt Assembly out ...

Page 145: ...overy Tank WKHQ FDUHIXOO VZLQJ WKH Recovery Tank GRZQ DQG OLIW LW RII RI WKH PDFKLQH Note When you reinstall the 5HFRYHU 7DQN set the 7DQN onto the two 0RXQWLQJ 3LQV on the frame then tilt the 7DQN up and reattach the DEOH VVHPEO Front Mounting Pin Rear Mounting Pin Cable Assembly Recovery Tank ...

Page 146: ...Shaft Rotation Clockwise as viewed from shaft end Pressure Ratings 3000 PSI Continuous 4000 PSI Intermittent Displacement 0 129 CIR Vacuum Water Lift Sealed 33 7 inches H2 O 2200 RPM Vacuum Fan Solenoid Valve L1 Current 1 5 Amps Nominal Coil Resistance 8 ohms 6SHFLDO 7RROV Vacuum water lift gauge p n 56205281 ...

Page 147: ...scrub deck pressure OLQGULFDO 6FUXE 6 VWHP LULQJ LDJUDP LUFXLW HVFULSWLRQ For the scrub system to work the key switch must be on the engine must be running and the Driver Box must receive a signal from the Dashboard Panel via the CAN Bus that the Operator has actuated the scrub system Fuse 100A Relay Power Dashboard Panel Driver Box J2 7 J2 24 J2 26 J2 4 CB4 Circuit Breaker 20A K1 Battery 12 VDC F...

Page 148: ...rom pin J2 24 to the Scrub Pressure Proportional Up valve S7 to provide the down scrub pressure selected by the Operator Note that the Driver Box ground signals to S5 and S7 are pulse width modulated PWM signals which open the valves proportionally to produce the appropriate hydraulic pressures on both the piston and rod ends of the Scrub Lift Cylinder This combination of up and down forces on the...

Page 149: ...scrub motors are on the Accessory Pump 1 20 CID sends oil to the Priority Flow Divider which directs the oil to the energized closed Scrub Brush Valve L4 The oil is directed past the Scrub Brush Valve L4 and through the two Scrub Brush Motors causing them to rotate The oil travels from the Scrub Brush Motors through the Oil Cooler and Filter then to the Charge Circuit for the Main Piston propulsio...

Page 150: ...Cylinder Lock L6 valve The Brush Proportional Up L7 valve provides adequate oil pressure to the bottom port on the Scrub Lift Cylinder through the Scrub Cylinder Lock L6 valve to raise the scrub deck The de energized Scrub Brush Proportional Down L5 valve FORVHV RII WKH RLO ÁRZ WR WKH WRS port on the Scrub Lift Cylinder Any oil from the top port on the Scrub Lift Cylinder is directed to the Reserv...

Page 151: ... port on the Scrub Lift Cylinder The energized Scrub Brush Proportional Down L5 valve provides oil pressure ranging from approximately 333 to 499 psi depending on the scrub pressure selected to the top port on the Scrub Lift Cylinder The energized Scrub Cylinder Lock L6 valve opens to allow ELGLUHFWLRQDO RLO ÁRZ WKURXJK WKH valve Note The pressure differential between what the 6FUXE UXVK 3URSRUWLR...

Page 152: ... on the outside of the Brush Housing Weldment The removable Hopper collects any dirt or debris picked up by the scrub brushes The Screen Weldment sits in the Hopper and is connected to a vacuum hose that removes any accumulated water from the Hopper The Screen Weldment can be removed from the Hopper for cleaning Idler Assembly Right Skirt Assembly Hopper Left Skirt Assembly Scrub Lift Cylinder Ass...

Page 153: ...lors ORN and WHT VIO and L7 251 DQG 251 5 KHFN FRLO UHVLVWDQFH I OHVV WKDQ RKPV UHSODFH OVR VHH PDLQ VFUXE RQ DQG ULJKW VFUXE brushes deck pressure electrical ladder detail and IXUWKHU VSHFV Scrub brush motor solenoid over current fault code 13 displayed Check L4 solenoid coil wiring for problems ORN DQG 251 8 KHFN FRLO UHVLVWDQFH I OHVV WKDQ RKPV UHSODFH OVR VHH PDLQ VFUXE RQ DQG VLGH VZHHS ULJKW...

Page 154: ...ossible mechanical damage to the deck lift cylinder and deck lift OLQNDJH Remove the S5 and S7 scrub lift cylinder valve FDUWULGJHV IURP WKH PDQLIROG QVSHFW FOHDQ DQG RSHUDWH WKH FDUWULGJHV RXWVLGH RI WKH PDQLIROG I WKH FDUWULGJHV IXQFWLRQ 2 UHLQVWDOO I QRW UHSODFH DV QHFHVVDU Connect a hydraulic pressure gauge at the test ports TP4 and TP5 and check the system operating pressures See the table be...

Page 155: ...tch must be on The engine must be running The scrub on mode must be selected on the Dashboard Panel Component Current Amps Coil Resistance Ohms L5 PSV RKPV PSV RKPV L9 PSV RKPV 12VDC 12VDC 0V L6 B B from K1 Power Relay 12V DC B OUTPUT TOUCH PAD DASHBOARD PANEL CB4 20A ORN B B RED VIO DRIVER BOX PIN J2 26 MAIN SCRUB LIFT CYLINDER DOWN WHT VIO SCRUB CYLINDER LOCK PIN J2 4 YEL BLU B OUTPUT L5 S1 KEY ...

Page 156: ... Width Modulated Component Current Amps Coil Resistance Ohms L5 PSV RKPV PSV RKPV L7 PSV RKPV Pressure Setting L5 Coil Amp draw readings 10 1 DPSV varies with scrub setting selected 3 Pressure Setting L7 Coil Amp draw readings 10 1 WR DPSV all three scrub pressure settings 3 L6 B B from K1 Power Relay B OUTPUT PWM TOUCH PAD DASHBOARD PANEL CB4 20A ORN L7 B B RED VIO DRIVER BOX PIN J2 26 SCRUB PRES...

Page 157: ...e must be running The scrub on mode must be selected on the Dashboard Panel The drive pedal must be activated moved from the neutral position Component Current Amps Coil Resistance Ohms L4 PSV RKPV PSV RKPV 12VDC 12VDC PIN J2 7 L4 B B from K1 Power Relay B OUTPUT TOUCH PAD DASHBOARD PANEL CB4 20A BLK WHT ORN PIN J2 2 B OUTPUT L8 SIDE SWEEP RIGHT SCRUB ORN BLU B B DRIVER BOX MAIN SCRUB BRUSH S1 KEY...

Page 158: ...lve L7 XUUHQW DPSV 1RPLQDO RLO 5HVLVWDQFH RKPV 9ROWDJH 5DQJH 3 0 9 Main Broom Motors LVSODFHPHQW 5 GUDXOLF 9DOYH 3UHVVXUH DQG 6ROHQRLG RLO XUUHQW UDZ DW WKH 7KUHH 6FUXE 3UHVVXUHV Proportioning Valve Pressure Type Scrub Pressure Setting Hydraulic Pressure at Test Port TP4 Valve Solenoid Coil Current Draw S7 Scrub Pressure Up 1 750 to 774 psi WR DPSV all three scrub pressure settings WR SVL 3 745 to...

Page 159: ...6FUXE 6 VWHP OLQGULFDO 159 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 6SHFLDO 7RROV GUDXOLF WHVW JDXJH Z FRQQHFWRU SVL UDQJH S Q ...

Page 160: ...S8 5LJKW 6LGH 6FUXE 6 VWHP LULQJ LDJUDP LUFXLW HVFULSWLRQ For the right side scrub system to work the key switch must be on the engine must be running and the Driver Box must receive a signal from the Dashboard Panel via the CAN Bus that the Operator has actuated the main and right side scrub systems Fuse 100A Relay Power Dashboard Panel Driver Box J2 7 J2 24 J2 26 J2 4 CB4 Circuit Breaker 20A K1 ...

Page 161: ...KH VFUXE OLIW cylinder The Driver Box must provide the appropriate ground signal from pin J2 26 to the Scrub Pressure Proportional Down valve S5 and the appropriate ground signal from pin J2 24 to the Scrub Pressure Proportional Up valve S7 to extend the right side scrub lift cylinder and lower the right side scrub brush Once the right side scrub brush is retracted upward after scrubbing the Side ...

Page 162: ...crub Deck Lift Cylinder D to the lower chamber on the Side Scrub Lift Cylinder to raise the right side scrub brush The Side Scrub Lift Valve L9 directs the oil from the upper chamber on the Side Scrub Lift Cylinder E to the oil reservoir When the engine is switched off the de energized Scrub Cylinder Lock L6 Valve holds the oil pressure from the bottom chambers on both the Side Scrub Lift Cylinder...

Page 163: ...assembly The Right Side Scrub Lift Cylinder extends and retracts the Right Scrub Assembly in conjunction with the cylindrical scrub deck The Right Side Scrub Motor is plumbed into the hydraulic lines for the cylindrical deck brush motors and switches on and off with the cylindrical deck motors The Right Solution Solenoid Valve L11 controls the VROXWLRQ ÁRZ WR WKH Right Scrub Assembly E C D Side Sc...

Page 164: ...noid Valve S8 L8 controls the right side scrub motor S8 L8 is located above the front end of the Scrub Deck The Right Side Scrub Lift Cylinder Solenoid Valve S9 L9 controls the side scrub lift cylinder S9 L9 is located inboard of the Right Scrub Assembly Scrub Deck S8 L8 Right Scrub Assembly S9 L9 ...

Page 165: ... either Rod End to lengthen or shorten the Rod End Assembly as necessary to get the correct brush DQJOH WR WKH ÁRRU Note The nominal factory dimension between the Rod End stud centers is 7 5 06 190 5 mm 1 5 mm 4 Make sure the threaded stud on the Rod End will align with the matching hole in the Mounting Tab then tighten the Jam Nut 5 Reinstall the Rod End into the Mounting Tab 6 Run the brush up a...

Page 166: ...crub solution solenoid valve over current IDXOW FRGH GLVSOD HG KHFN VROHQRLG FRLO ZLULQJ IRU SUREOHPV 251 DQG 8 KHFN FRLO UHVLVWDQFH I OHVV WKDQ RKPV UHSODFH OVR VHH PDLQ VFUXE DQG ULJKW VLGH VFUXE VROXWLRQ YDOYHV DQG SXPS HOHFWULFDO ODGGHU GHWDLO 5LJKW VLGH VFUXE VZHHS motor solenoid valve over FXUUHQW IDXOW FRGH GLVSOD HG KHFN VROHQRLG FRLO ZLULQJ IRU SUREOHPV 251 DQG 7 KHFN FRLO UHVLVWDQFH I OH...

Page 167: ...st be on The engine must be running The scrub on mode and side broom scrub must be selected on the Dashboard Panel Component Current Amps RLO 5HVLVWDQFH 2KPV L5 PSV RKPV PSV RKPV L9 PSV RKPV 12VDC 12VDC 0V L6 B B from K1 Power Relay 12V DC B OUTPUT TOUCH PAD DASHBOARD PANEL CB4 20A ORN B B RED VIO DRIVER BOX PIN J2 26 MAIN SCRUB LIFT CYLINDER DOWN WHT VIO SCRUB CYLINDER LOCK PIN J2 4 YEL BLU B OUT...

Page 168: ...be running The scrub on mode and side broom scrub must be selected on the Dashboard Panel The drive pedal must be activated moved from the neutral position Component Current Amps Coil Resistance Ohms L4 PSV RKPV PSV RKPV 12VDC 12VDC PIN J2 7 L4 B B from K1 Power Relay B OUTPUT TOUCH PAD DASHBOARD PANEL CB4 20A BLK WHT ORN PIN J2 2 B OUTPUT L8 SIDE SWEEP RIGHT SCRUB ORN BLU B B DRIVER BOX MAIN SCRU...

Page 169: ...XUUHQW DPSV 1RPLQDO RLO 5HVLVWDQFH RKPV 6LGH 6ZHHS 6FUXE 6ROHQRLG 9DOYH XUUHQW DPSV 1RPLQDO RLO 5HVLVWDQFH RKPV 6LGH 6FUXE LIW 6ROHQRLG 9DOYH XUUHQW DPSV 1RPLQDO RLO 5HVLVWDQFH RKPV Right Side Scrub Motor LVSODFHPHQW 5 5RWDWLRQ ORFNZLVH DV YLHZHG IURP VKDIW HQG 3UHVVXUH 3RUW 6SHFLDO 7RROV GUDXOLF WHVW JDXJH Z FRQQHFWRU SVL UDQJH S Q ...

Page 170: ...verse KHQ WKH VFUXE V VWHP LV GLVDEOHG QR VROXWLRQ ZLOO ÁRZ WR WKH Scrub Brushes UHJDUGOHVV RI GULYH SHGDO RU VFUXE GHFN SRVLWLRQ 7KH RSHUDWRU FDQ HQDEOH WKH VROXWLRQ V VWHP LQGHSHQGHQW RI WKH VFUXE V VWHP WR SUH ZHW WKH ÁRRU EHIRUH HQDEOLQJ WKH VFUXE DQG RU UHFRYHU V VWHPV 7KH VROXWLRQ V VWHP DOVR SURYLGHV VROXWLRQ WR WKH IROORZLQJ RSWLRQDO HTXLSPHQW LI WKH PDFKLQH LV VR HTXLSSHG 5LJKW VLGH VFUXE...

Page 171: ... UDWH The Detergent Supply Line IURP WKH Detergent Cartridge is split into two OLQHV RQH IHHGLQJ HDFK Detergent Pump The two OLQHV IURP WKH Detergent Pumps merge into one Detergent Supply Line ZKLFK LV WKHQ FRQQHFWHG WR the Solution Hose upstream RI WKH Main Solution Solenoid Valve The Tee 1 E WKH Main Solution Solenoid Valve SURYLGHV VROXWLRQ WR WKH ULJKW IURQW VFUXE EUXVK LI WKH PDFKLQH LV VR HT...

Page 172: ...FDWLQJ WKDW WKH VROXWLRQ WDQN LV HPSW I WKH H WHQGHG VFUXE V VWHP LV FRQÀJXUHG WR WKH USE ANYTIME PRGH WKH VROXWLRQ WDQN HPSW VZLWFK 6 ZLOO KDYH QR HIIHFW 1RWH WKDW ZKHQ WKH PDFKLQH LV LQ WKH H WHQGHG VFUXE PRGH WKH Solution Pump ZLOO VZLWFK RII WKH Extended Scrub Pump ZLOO VZLWFK RQ DQG WKH GHWHUJHQW SXPSV ZLOO FRQWLQXH WR DGG GHWHUJHQW WR WKH UHFRYHUHG ZDWHU The Float Switch Quick disconnect and...

Page 173: ...arate Wand Pump M8 to pump solution IURP WKH VROXWLRQ WDQN WR the hose and Wash Hose Nozzle ORFDWHG EHKLQG the Operator seat The wash hose kit operates independently and does QRW UHTXLUH WKH 2SHUDWRU WR DFWXDWH WKH VHDW VZLWFK SUHVVXUH VZLWFK RQ WKH Wand Pump ZLOO VZLWFK RQ the Wand Pump when the Wash Hose Nozzle is opened and the solution pressure LQ WKH KRVH GURSV EHORZ psi When the Wash Hose No...

Page 174: ... Ignition J1 3 CAN J1 2 CAN J1 27 J1 5 J6 3 CAN J6 1 B J6 2 B J6 4 CAN Twisted Pair Twisted Pair 1 87 30 2 1 2 1 2 Switch Seat Switch Recovery Full opens when the recovery tank is full 1 2 S2 S30 J1 10 J1 31 J1 11 1 3 2 Drive Pedal Sensor 5K Ohm R1 J3 18 J3 23 J3 2 J2 35 J2 22 J2 10 J3 21 J3 22 CB4 Circuit Breaker 20A CB5 Circuit Breaker 10A CB2 Circuit Breaker 20A M5 M Pump Mist optional M8 M Pum...

Page 175: ...t the Operator has DFWXDWHG WKH VFUXE RU VROXWLRQ V VWHP The Driver Box PXVW UHFHLYH D VLJQDO IURP WKH Drive Pedal Sensor R1 WKDW WKH GULYH SHGDO KDV EHHQ PRYHG IURP WKH QHXWUDO SRVLWLRQ The Solution Empty Switch S3 PXVW EH RSHQ VROXWLRQ WDQN QRW HPSW Fuse 100A Relay Power Dashboard Panel Driver Box K1 Battery 12 VDC F1 Circuit Breaker 15A CB6 K1 B1 B 3 B Relay Power J2 1 Ignition_KeyPos J1 12 S1 ...

Page 176: ... WKH VHFRQG Detergent Pump WXUQLQJ RQ HQFH DQ LQWHUYDO RI LQGLFDWHV WKDW RQH SXPS VKRXOG WXUQ RQ ZLWKRXW GHOD ZKHQ WKH RWKHU SXPS WXUQV RII 7KH QWHUYDO 7LPH LV ZKDW FRQWUROV WKH FRPELQHG GHWHUJHQW ÁRZ UDWH IURP ERWK SXPSV DQG FRPHV IURP D ORRNXS WDEOH EDVHG RQ WKH FXUUHQW VROXWLRQ ÁRZ UDWH DQG detergent ratio 7KH IROORZLQJ FRQGLWLRQV PXVW EH PHW IRU WKH Detergent Pumps WR RSHUDWH 7KH GHWHUJHQW V V...

Page 177: ... the Operator has DFWXDWHG WKH VFUXE RU VROXWLRQ V VWHP The Driver Box PXVW UHFHLYH D VLJQDO IURP WKH Drive Pedal Sensor R1 WKDW WKH GULYH SHGDO KDV EHHQ PRYHG IURP WKH QHXWUDO SRVLWLRQ Fuse 100A Relay Power Dashboard Panel Driver Box K1 Battery 12 VDC F1 Circuit Breaker 15A CB6 K1 B1 B 3 B Relay Power J2 1 Ignition_KeyPos J1 12 S1 Switch Ignition J1 3 CAN J1 2 CAN J6 3 CAN J6 1 B J6 2 B J6 4 CAN ...

Page 178: ...G WKH PDLQ VFUXE DQG VLGH VFUXE V VWHPV The Driver Box PXVW UHFHLYH D VLJQDO IURP WKH Drive Pedal Sensor R1 WKDW WKH GULYH SHGDO KDV EHHQ PRYHG IURP WKH QHXWUDO SRVLWLRQ Fuse 100A Relay Power Dashboard Panel Driver Box K1 Battery 12 VDC F1 Circuit Breaker 15A CB6 K1 B1 3 B Relay Power J2 1 Ignition_KeyPos J1 12 S1 Switch Ignition J1 3 CAN J1 2 CAN J6 3 CAN J6 1 B J6 2 B J6 4 CAN Twisted Pair Twist...

Page 179: ...K KRVH GURSV WR SVL KHQ WKH ZDVK KRVH QR OH LV FORVHG DQG WKH SUHVVXUH LQ WKH ZDVK KRVH UHDFKHV SVL WKH SUHVVXUH VZLWFK VKXWV RII WKH Wand 3XPS 7KH NH VZLWFK PXVW EH RQ IRU WKH DQG 3XPS WR RSHUDWH Fuse 100A Relay Power Driver Box K1 Battery 12 VDC F1 Circuit Breaker 15A CB6 B1 3 B Ignition_KeyPos J1 12 S1 Switch Ignition Pressure Switch 1 87 30 2 1 2 J3 23 CB2 Circuit Breaker 20A Bat J1 18 M8 M Pu...

Page 180: ... has HQDEOHG WKH VLGH EURRPV The Driver Box PXVW UHFHLYH D VLJQDO IURP WKH Drive Pedal Sensor R1 WKDW WKH GULYH SHGDO KDV EHHQ PRYHG IURP WKH QHXWUDO SRVLWLRQ Fuse 100A Relay Power Dashboard Panel Driver Box K1 Battery 12 VDC F1 Circuit Breaker 15A CB6 K1 B1 3 B Relay Power J2 1 Ignition_KeyPos J1 12 S1 Switch Ignition J1 3 CAN J1 2 CAN J6 3 CAN J6 1 B J6 2 B J6 4 CAN Twisted Pair Twisted Pair 1 8...

Page 181: ...6ROXWLRQ 6 VWHP 181 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 RPSRQHQW RFDWLRQV Extended Scrub Pump M6 Extended Scrub Float Switch S7 Recovery Tank Full Switch S2 ...

Page 182: ...6ROXWLRQ 6 VWHP 182 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 Mist Pump M5 and Solution Filter Solution Pump M4 top Wand Pump M8 bottom Detergent Pumps M10 and M11 behind cover panel ...

Page 183: ...VROXWLRQ VKXWRII YDOYH Note 3ODFH D VXLWDEOH FRQWDLQHU XQGHUQHDWK WKH ÀOWHU WR FDWFK DQ VROXWLRQ WKDW PD OHDN IURP WKH hoses 2 8QVFUHZ WKH Filter Cover and remove the Filter Cover DQG VFUHHQ IURP WKH ÀOWHU EDVH OHDQ DQ DFFXPXODWHG GLUW RU GHEULV IURP WKH VFUHHQ 4 5HLQVWDOO WKH VFUHHQ LQWR WKH ÀOWHU EDVH 5 0DNH VXUH WKH UXEEHU ZDVKHU LV LQVWDOOHG FRUUHFWO LQ the Filter Cover then reinstall and hand...

Page 184: ...VH DV YLHZHG IURP WKH IURQW RI WKH PDFKLQH WR UHPRYH WKH Nozzle Cap Spray Nozzle and Check Valve Strainer IURP WKH Plastic Nozzle Adapter Rinse the Nozzle Cap Spray Nozzle and Check Valve Strainer LQ FOHDQ ZDWHU WR UHPRYH DQ DFFXPXODWHG GLUW RU VHGLPHQW I QHFHVVDU ULQVH RU VRDN WKH FRPSRQHQWV LQ YLQHJDU RU RWKHU FRPPHUFLDO FOHDQHU WR UHPRYH DQ mineral deposits 4 5HDVVHPEOH WKH XVW XDUG QR OHV E IR...

Page 185: ...D ÁRRU GUDLQ EHIRUH SXUJLQJ EHFDXVH D VPDOO DPRXQW RI GHWHUJHQW ZLOO EH GLVSHQVHG LQ WKH SURFHVV 7R 3XUJH KHQ KDQJLQJ HWHUJHQWV WKH VFUXE V VWHP PXVW EH RII 1 LVFRQQHFW DQG UHPRYH WKH GHWHUJHQW FDUWULGJH 2 7XUQ WKH NH VZLWFK RQ DQG ZDLW D IHZ VHFRQGV IRU WKH VWDUW XS VHTXHQFH WR ÀQLVK 3UHVV DQG KROG WKH GHWHUJHQW VZLWFK IRU DSSUR LPDWHO WZR VHFRQGV 4 5HOHDVH WKH VZLWFK ZKHQ WKH GHWHUJHQW Purge Ico...

Page 186: ...HWHUJHQW VZLWFK IRU DSSUR LPDWHO WZR VHFRQGV 5 5HOHDVH WKH VZLWFK ZKHQ WKH GHWHUJHQW Purge Icon DSSHDUV RQ WKH GLVSOD DQG WKH GHWHUJHQW LQGLFDWRU VWDUWV ÁDVKLQJ Note The HWHUJHQW R has Detergent HYHO 9LHZLQJ 6ORWV IRU YLHZLQJ WKH DPRXQW RI GHWHUJHQW UHPDLQLQJ LQ the HWHUJHQW DUWULGJH V When WKH GHWHUJHQW OHYHO LV QHDULQJ WKH ERWWRP RI WKH Detergent Level Viewing 6ORWV UHÀOO RU UHSODFH WKH Detergen...

Page 187: ...ZLWFK LV SUHVVHG 2Q FR OH V VWHPV WKH GHWHUJHQW PL WXUH ZLOO EH GLVSOD HG ZKHQHYHU WKH GHWHUJHQW V VWHP is on 2QFH VHW WKH GHWHUJHQW ÁRZ UDWH DXWRPDWLFDOO LQFUHDVHV DQG GHFUHDVHV ZLWK WKH VROXWLRQ ÁRZ UDWH EXW WKH GHWHUJHQW PL UDWLR ZLOO UHPDLQ WKH VDPH I DQ 2SHUDWRU ZRXOG SUHIHU WKH ÁH LELOLW RI VHWWLQJ GLIIHUHQW GHWHUJHQW GLOXWLRQV UDWLRV IRU GLIIHUHQW VROXWLRQ ÁRZ UDWHV WKLV VSHFLÀF SURJUDPPLQJ...

Page 188: ...heck L10 solenoid coil wiring for problems ORN and YEL GRN Check coil resistance If less than 6 ohms replace The solution shutoff valve is plugged or inoperative Clean or replace the solution shutoff valve Inadequate solution ÀRZ WR WKH PDLQ brushes 7KH VROXWLRQ OWHU VFUHHQ LV plugged OHDQ WKH VROXWLRQ OWHU VFUHHQ Plugged solution hose Check and clear the solution hoses as necessary No solution to...

Page 189: ...ch No voltage to the extended scrub pump 1 Check pump motors for short circuits and replace as necessary Check the wiring and circuit breakers upstream of the pump 2 Check the J2 35 output from the Driver Box The stainer in the recovery tank is dirty or plugged Remove and clean the strainer Note The Solution Pump line provides a switched ground return for the pump When the solution pump is ON a 7 ...

Page 190: ...and RED BLU 2 pump wire colors BLK YEL and BLK RED Check the detergent pump motors for short circuit and replace as necessary 1RWH 7KH VLJQDO FRQWUROOLQJ WKH GHWHUJHQW SXPS LV H WUHPHO FRPSOH DQG HOG troubleshooting should a take a functional approach Substitute with a known good detergent pump to check operation If the known good pump does not operate and the wiring and control inputs to the dete...

Page 191: ...XQQLQJ 7KH VFUXE RQ PRGH PXVW EH VHOHFWHG RQ WKH Dashboard Panel 7KH GULYH SHGDO PXVW EH DFWLYDWHG PRYHG IURP WKH neutral position L10 B B from K1 Power Relay B OUTPUT TOUCH PAD DASHBOARD PANEL CB4 20A ORN MAIN RIGHT SIDE SCRUB BRUSH SOLUTION VALVES PUMP L11 B CB5 10A GRN BRN B RED VIO RED VIO DRIVER BOX PIN J3 2 M4 MAIN SOLUTION PUMP GRN BLU MAIN SOLUTION VALVE RIGHT SIDE SOLUTION VALVE PIN J2 22...

Page 192: ...rrent 1 5 amps Nominal Coil Resistance 8 ohms Right Side Solution Solenoid Valve L11 Voltage 12 VDC Coil Power 11W Current 1 0 amps Nominal Coil Resistance 12 ohms Wand Pump M8 Voltage 12 VDC Max Current 12 5 amps 60 psi Flow Rate 2 0 GPM 50 psi Pressure Switch On 40 psi Off 60 psi Mist Pump M5 Voltage 24 VDC run at 12 VDC Max Current 3 9 amps DustGuard Spray Nozzles Standard nozzle size 015 dia F...

Page 193: ...l min 6 L min Setting 2 1 9 gal min 7 2 L min Setting 3 2 3 gal min 8 7 L min Setting 4 2 7 gal min 10 2 L min Setting 5 3 1 gal min 11 7 L min AXP EDS and EcoFlex detergent systems 5H OODEOH FDUWULGJH quantity 2 2 5 gal 9 5 L Available dilution ratios 03 04 05 07 08 1 0 1 5 2 0 3 0 3 8 300 1 256 1 200 1 150 1 128 1 100 1 64 1 50 1 32 1 26 1 ...

Page 194: ...LQJ LDJUDP LUFXLW HVFULSWLRQ For the squeegee system to work the key switch must be on the engine must be running and the Driver Box must receive a signal from the Dashboard Panel via the CAN Bus that the Operator has actuated the scrub system vacuum switch old style control panel or the vacuum wand switch new style control panel Fuse 100A Relay Power Dashboard Panel Driver Box J2 5 J2 6 K1 F1 Cir...

Page 195: ...n piston pump charge pressure relief valve and 7KH EDFN SUHVVXUH FUHDWHG E WKH UHWXUQ ÁRZ WKURXJK WKH FRROHU DQG ÀOWHU HQ URXWH WR WKH piston pump charge port 6TXHHJHH 8S To retract the squeegee scrub off recovery off machine in reverse the Squeegee Up Solenoid Valve L3 energizes to direct the oil to the bottom port on the Squeegee Lift Cylinder This retracts the Squeegee Lift Cylinder and raises ...

Page 196: ...h the Squeegee Down Solenoid Valve L2 and the Squeegee Up Solenoid Valve L3 are GH HQHUJL HG WR VKXW RII WKH ÁRZ RI RLO WR the Squeegee Lift Cylinder and lock the squeegee in the up position 250 psi Back Pressure Reservoir Squeegee Down Solenoid Valve L2 Squeegee Up Solenoid Valve L3 Squeegee Lift Cylinder ...

Page 197: ...as required Parallel Arms bushings bearings and fasteners connect the Squeegee Lift Weldment to the machine frame The Squeegee Tilt Adjust Knob and the Squeegee Height Adjust Knobs allow you to adjust the angle and height of the Squeegee Assembly to ensure that the wastewater is being picked up correctly Refer to the Squeegee Adjustment section in the Instructions for Use for adjustment procedures...

Page 198: ...I DQG 6TXHHJHH 8S electrical ladder detail Squeegee DN solenoid over current fault code 12 is displayed Check L2 solenoid coil wiring for problems GRN BRN and RED GRA Check coil resistance If less than 6 ohms replace Also see 9DFXXP DQ 2Q DQG 6TXHHJHH RZQ electrical ladder detail Squeegee will not rise Solenoid L3 is not energizing or has failed Check L3 solenoid coil wiring for problems GRN BRN a...

Page 199: ... be running The scrub on mode must be selected or the vacuum system switched on at the Dashboard Panel The drive pedal must be activated moved from the neutral position Component Current Amps Coil Resistance Ohms L1 1 5 Amps 8 ohms L2 1 5 Amps 8 ohms PIN J2 5 L2 SQUEEGEE DOWN B B from K1 Power Relay B OUTPUT TOUCH PAD DASHBOARD PANEL BRN YEL PIN J2 8 B OUTPUT L1 VACUUM FAN SOLENOID RED GRA B CB5 1...

Page 200: ...e moved to the reverse position squeegee will rise up The Vacuum Fan will shut off after a time delay once the drive pedal is in the neutral position Note that if the seat switch is open the Vacuum Fan will run continuously regardless of the drive pedal being in neutral to allow water pick up with the Wand attachment Component Current Amps Coil Resistance Ohms L3 1 5 Amps 8 ohms L2 B B from K1 Pow...

Page 201: ... 0DQXDO GYDQFH RQGRU 1LO VN 5 6SHFL FDWLRQV Component 6SHFL FDWLRQV Squeegee Down Solenoid Valve L2 Current 1 5 amps Nominal Coil Resistance 8 ohms Squeegee Up Solenoid Valve L3 Current 1 5 amps Nominal Coil Resistance 8 ohms ...

Page 202: ... Gear The steering wheel rotates the shaft on the steering pump which FRQWUROV WKH RLO ÁRZ WR WKH Steer Cylinder The Steer Cylinder extends and retracts the attached Rack which then rotates the Spur Gear and attached Drive Wheel Weldment to turn the Front Wheel Rack Hydraulic Connections to Steering Pump Spur Gear Steer Cylinder Front Wheel Drive Wheel Weldment ...

Page 203: ...alve which then directs the oil to the appropriate side of the Steer Cylinder to turn the front wheel in the corresponding direction The oil returns through the Steering Unit and returns to the Reservoir The Check Valve located in the Steering Unit allows manual steering when the engine is off Auxiliary Pump Reservoir Check Valve Steering Unit Metering Valve Steer Cylinder Priority Flow Divider Au...

Page 204: ...the Steering Unit Metering Valve or Steer Cylinder RPSRQHQW RFDWLRQV Steering Unit The Steering Unit is driven by the steering wheel and is located in the steering column The Steering Unit unit includes the internal metering valve Auxiliary Pump Reservoir Check Valve Steering Unit Metering Valve Steer Cylinder Priority Flow Divider Steering Unit ...

Page 205: ...J 6 VWHP 205 6HUYLFH 0DQXDO GYDQFH RQGRU 1LO VN 5 Steer Cylinder The Steer Cylinder is mounted horizontally and drives the rack and spur gear connected to the drive wheel assembly Steer Cylinder Steer Cylinder ...

Page 206: ...H UHPRYLQJ RU UHLQVWDOOLQJ DQ PDFKLQH FRPSRQHQWV PDNH VXUH WKH NH VZLWFK LV RII WKH NH LV UHPRYHG IURP WKH PDFKLQH DQG WKH SDUNLQJ EUDNH LV HQJDJHG Note If the steer cylinder is removed mark the teeth where the rack engages the spur gear so the rack and spur gear engage at the same location when the steer cylinder is reinstalled 6SHFL FDWLRQV Component 6SHFL FDWLRQV Steering URQW ZKHHO K GUDXOLF F...

Page 207: ...6 VWHP LULQJ LDJUDP LUFXLW HVFULSWLRQ For the side broom system to work the key switch must be on the engine must be running and the Driver Box must receive a signal from the Dashboard Panel via the CAN Bus that the Operator has actuated the main scrub system and has not disabled the side broom system Fuse 100A Relay Power Dashboard Panel Driver Box J2 7 CB4 Circuit Breaker 20A K1 Battery 12 VDC F...

Page 208: ...U For the side broom actuator to raise or lower the side broom s the Driver Box must provide voltage at the appropriate polarity from J3 4 RED extend or J3 5 BLK retract Pin J3 7 WHT is the common 6LGH URRP 6ZHHS 6 VWHP GUDXOLF LDJUDPV 6LGH URRP 0RWRU V 2II When the two Side Broom Motors or the Right Side Scrub Motor and left Side Broom Motor are off the Side Sweep Scrub Valve L8 is closed de ener...

Page 209: ...Sweep Scrub Valve L8 is energized to direct the oil from the discharge side of the Cylindrical Scrub Brush Motors to the Side Scrub Broom Motors The oil then travels from the discharge side of the Side Scrub Broom Motors to the oil Cooler DQG ÀOWHU Right Side Scrub Motor Side Broom Motor w dual sweep Side Broom Motor Side Sweep Scrub Valve L8 From Cylindrical Scrub Brush Motors To Cooler ...

Page 210: ...otor extends and retracts the pivot arm on the Side Broom Lift Weldment to raise and lower the Side Broom Assembly 7KH XVW XDUG Mist Pump M5 supplies solution to the Nozzle Assembly to reduce the dust generated during sweeping The Side Sweep Scrub Valve L8 controls the hydraulic oil to the Hydraulic Motor on the Side Broom Assembly to switch the Hydraulic Motor on and off Actuator Motor Side Sweep...

Page 211: ...r Motor extends and retracts the pivot arm on the Side Broom Lift Weldment to raise and lower the Side Broom Assemblies 7KH XVW XDUG Mist Pump M5 supplies solution to the two Nozzle Assemblies The Side Sweep Scrub Valve L8 controls the hydraulic oil to the Hydraulic Motors on the Side Broom Assemblies to switch the Hydraulic Motors on and off Actuator Motor Side Broom Assembly 2 Hydraulic Motor 2 ...

Page 212: ...H URRP LIW FWXDWRU 0RWRU 1 Assemble the jumper wire that you ll need to connect machine battery to the three wire connector on the actuator Refer to the adjacent Jumper Wire Assembly Schematic and Bill of Material Important Service Note The power cord adapter p n 56407502 normally used on all other two wire actuator motors should not be used on the side broom lift actuator motor The Jumper Wire As...

Page 213: ...urement with the OUT dimension shown 9 If the OUT measurement doesn t match the dimension shown it will be necessary to remove the rubber Adjuster Cover and rotate the outside hex adjuster underneath the Adjuster Cover Note Use a 1 2 13mm socket to turn the outside hex adjuster Each click of the adjuster cam will change the ULYH 1XW 7XEH travel 1 16 1 6mm To increase the Drive Nut Tube OUT dimensi...

Page 214: ...HT Check coil resistance If less than 6 ohms replace Also see the 0DLQ 6FUXE DQG 6LGH 6ZHHS 6FUXE On electrical ladder detail Side sweep lift actuator over current fault code 30 displayed Three wires supply power to the M7 side broom lift actuator motor check wiring for problems Wire colors J3 4 BLU RED DN otherwise open J3 5 WHT RED UP otherwise open J3 7 GRA VIO common wire UP and DN Test curren...

Page 215: ...e scrub on mode and side broom scrub must be selected on the Dashboard Panel The drive pedal must be activated moved from the neutral position Component Current Amps Coil Resistance Ohms L4 1 5 Amps 8 ohms L8 1 5 Amps 8 ohms 12VDC 12VDC PIN J2 7 L4 B B from K1 Power Relay B OUTPUT TOUCH PAD DASHBOARD PANEL CB4 20A BLK WHT ORN PIN J2 2 B OUTPUT L8 SIDE SWEEP RIGHT SCRUB ORN BLU B B DRIVER BOX MAIN ...

Page 216: ...HFL FDWLRQV Scrub Brush Solenoid Valve L4 Current 1 5 amps Nominal Coil Resistance 8 ohms Side Sweep Scrub Solenoid Valve L8 Current 1 5 amps Nominal Coil Resistance 8 ohms Side Broom Motor Displacement 17 9 Cu In Per Revolution Rotation Clockwise as viewed from shaft end Pressure Port A ...

Page 217: ...emblies are fastened to the Finished Spindles with four 3 8 16 x 75 Hex Screws The Finished Spindles are fastened to the machine frame with four 1 2 13 x 1 25 Hex Screws The Brake Cable Assembly connects the Brake Pedal Assembly to the Brake Bar Weldment The Brake Bar Weldment actuates the brake levers on the Brake Assemblies 3 8 16 x 75 Hex Screw Rear Wheel Assembly 3 8 16 x 75 Hex Screw 4 1 2 13...

Page 218: ...ut 5 Reinstall the Rod End into the brake pedal DVVHPEO WKHQ UHLQVWDOO DQG WLJKWHQ WKH Nyloc Nut 6 Check the brake tension as follows a Jack up the rear of the machine to get the rear wheels off of the ground DXWLRQ 0DNH VXUH WR IROORZ WKH LQVWUXFWLRQV LQ WKH General QIRUPDWLRQ DFNLQJ 7KH Machine VHFWLRQ DFN WKH PDFKLQH DW WKH GHVLJQDWHG ORFDWLRQV RQO b Manually rotate the rear wheels to check the...

Page 219: ...ings and spindle and replace as required The wheel and or spindle is damaged The brakes are not working correctly The brakes are out of adjustment Adjust the brake tension The brake linings are worn out Replace the brake linings 6SHFL FDWLRQV Component 6SHFL FDWLRQV Brakes service Mechanical drum brakes one on each rear wheel cable actuated Tire rear 2 load bearing Size 16 in x 4 in 406 mm x 101 m...

Page 220: ...dal actuates the Push Pull Control Cable which is connected to the Hydroback Centering Unit The Hydroback Centering Unit transfers the Push Pull Control Cable motion to the Piston Pump Lever Weldment attached to the Piston Pump to control machine direction and speed The Hydroback Centering Unit also returns the foot pedal and Piston Pump Lever Weldment to the neutral position when the foot pedal i...

Page 221: ...d bypasses the hydraulic circuit from the piston pump to the Traction Drive Motor to allow the Front Wheel to rotate freely when towing or pushing the machine OHFWULFDO 6FKHPDWLF Front Wheel Traction Drive Motor Fuse 100A Driver Box F1 Circuit Breaker 15A CB6 K1 B1 3 B Relay Power J2 1 S1 Switch Ignition J1 10 J1 31 J1 11 J1 18 1 3 2 Drive Pedal Sensor 5K Ohm R1 1 2 1 2 Battery 12 VDC ...

Page 222: ...UDXOLF LDJUDPV 7UDFWLRQ ULYH 0RWRU LQ 1HXWUDO When the foot pedal is in the neutral position with the engine running the Piston Pump is not sending any oil to the Traction Drive Motor 7RZ 9DOYH QJDJHG When the engine is off the Traction Drive Motor acts like a hydraulic pump and makes LW GLIÀFXOW WR URWDWH WKH IURQW ZKHHO 7KH machine is equipped with a Tow Valve to eliminate this problem when towi...

Page 223: ...nable to run in the forward direction for any reason front wheel stalled etc the Forward Relief Valve ZLOO RSHQ WR DOORZ RLO WR ÁRZ IURP DQG WR WKH Piston Pump bypassing the Traction Drive Motor to prevent damage to the hydraulic components If the Traction Drive Motor is unable to run in reverse the Reverse Relief Valve will open to bypass the Traction Drive Motor Piston Pump Traction Drive Motor ...

Page 224: ...he Hydroback Centering Unit is mounted on the left side of the Piston Pump The Rotary Sensor called the Drive Pedal Sensor on the electrical ladder diagram is fastened to the piston pump lever weldment 7UDFWLRQ ULYH 0RWRU The Traction Drive Motor is mounted to the drive wheel weldment underneath the front of the machine Piston Pump Hydroback Centering Unit Rotary Sensor Traction Drive Motor ...

Page 225: ...til the front drive wheel is off WKH ÁRRU 4 Place supports at the front corners of the machine 5 Start the engine and observe the direction of the drive wheel rotation 6 Loosen the two 5 16 18 Hex Head Screws holding the Hydroback Adjuster Plate to the chassis 7 Loosen the jam nut and turn the Adjustment Screw clockwise or counterclockwise to move the Hydroback Adjuster Plate and Hydroback Centeri...

Page 226: ...place the Rotary Sensor or Control Board Driver Box you will have to recalibrate the neutral deadband position and set the sensitivity as follows 1 Depress the foot pedal to the full reverse position then allow the pedal to slowly return to its neutral position Do not move the pedal during the remainder of this procedure 2 Press and hold the Engine Speed switch then turn the ignition Key Switch to...

Page 227: ...ntage value The display will return to the previous menu Press the red Scrub Off switch to return to the previous menu without changing the percentage value 9 Turn the Key Switch to the off position The new settings will be saved and remain in effect until they are changed again 7URXEOHVKRRWLQJ Problem Cause Correction The machine creeps forward or backward when the foot pedal is in the neutral po...

Page 228: ...e mounting fork by the foot pedal Loosen the jam nuts and remove the Push Pull Control Cable from the mounting fork 6 Disconnect the rod end on the old Push Pull Control Cable from the foot pedal assembly 7 Loosen the locknut then remove the rod end and locknut from the Push Pull Control Cable 8 Remove the two jam nuts and star washer from the old Push Pull Control Cable This will make it easier t...

Page 229: ...g fork then tighten the two jam nuts 18 Reinstall one jam nut and a star washer onto the Hydroback end of the new Push Pull Control Cable Only one jam nut is needed to fasten the Cable and Hydroback Centering Unit to the Hydroback Adjuster Plate 19 Remove the red plastic thread protector sleeve from the new Push Pull Control Cable then install the Cable into the Hydroback Centering Unit Note that ...

Page 230: ...ering Unit and the larger threads on the outside of the Cable will thread directly into the front of the Hydroback Centering Unit 7 Reinstall the locknut and Rod End onto the Push Pull Control Cable 8 Reinstall the Rod End into the Piston Pump Lever Weldment 9 Position the Push Pull Control Cable and attached Hydroback Centering Unit into the Hydroback Adjuster Plate by the Piston Pump Make sure t...

Page 231: ... the steering wheel all the way toward the left The ÀWWLQJV VKRXOG EH RQ WKH IURQW VLGH RI WKH PRWRU 3 Make sure the Hydraulic Hoses are routed up and inside the channel in the Drive Wheel Weldment as shown on WKH ULJKW DQG OLH ÁDW DJDLQVW WKH Bottom of the Frame as shown below 4 Make sure the Hydraulic Hoses are not twisted then WLJKWHQ WKH ÀWWLQJV RQ ERWK HQGV WR IW OEV 1RWH WKDW WKH ÀWWLQJV PXV...

Page 232: ... 1 drive steer Size 18 in x 6 in 457 mm x 152 mm P7 solid Traction Drive Motor Displacement 18 3 CIR Shaft Rotation Clockwise as viewed from slot end Wheel Drive Piston Pump Displacement 1 44 CIR Speed 3600 RPM Max Continuous Pressure 3000 psi Maximum Case Pressure 25 psi Relief Setting 2500 psi 3500 psi KDUJH 5HOLHI SVL KLJK ÀRZ ...

Page 233: ... cotter pin 16 Hex Jam Nut Torque to 150 ft lb 20 x 1 25 Hex Screw Use Loctite 242 torque to 90 ft lb 13 Nyloc Hex Nut Torque to 100 ft lb Drive Wheel Motor Spindle Nut Torque to 375 ft lb lubed or 475 ft lb dry then tighten to align cross hole Wheel Studs Torque to 100 ft lb Steering Castle Spindle Nut 16 Hex Jam Nut 20 x 1 25 Hex Screw 13 Nyloc Hex Nut Drive Wheel Motor Spindle Nut Wheel Studs ...

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Nilfisk-Advance Condor XL, Service Manual

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