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5

4000 Series Char-Lynn Motors

Disassembly

9 Remove valve plate.

10 Remove 88,6 mm [3.49 inch] I.D. seal from valve plate (see
Figure 5).

11 Remove valve drive (see Figure 5).

12 Remove Geroler. Retain rollers in outer Geroler ring if they are
loose.

13 Remove 2 seals from Geroler, 1 seal on each side of Geroler.

14 Remove drive.

15 Remove 88,6 mm [3.49 inch] I.D. seal from bearing housing.

17 Remove shaft seal, back-up ring (if used) and dust seal from flange.
Use a small screwdiver to remove dust seal. Do not damage bore of
flange.

16 Use a stud remover or vise grips to remove studs (earlier models
only). Clamp bearing housing in vise as shown in Figure 7. Loosen 8
screws. Remove screws, washers (discard washers, as they are not
required for reassembly), and mounting flange (see Figure 8).

Valve
Plate

Seal

Seal

Valve Drive

Figure 5

Figure 6

Seal

Seal

Geroler

Drive

Figure 7

Figure 8

Shaft
Seal

Back-up
Ring

Mounting
Flange

Dust
Seal

Figure 9

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Summary of Contents for 7400

Page 1: ...7400 Service Manual MM428 Rev 04 3 02 ...

Page 2: ...l replacement and electrical troubleshooting Hydraulics Valve replacement repair motor replacement repair cylinder replacement repair pump replacement repair filter replacement and hydraulics troubleshooting Engine G LPG Air filter replacement oil changing cooling system maintenance repair fuel system maintenance repair governor adjustment repair engine repair engine troubleshooting and engine rep...

Page 3: ...NTENANCE CHART DIESEL 1 12 PUSHING TOWING AND TRANSPORTING THE MACHINE 1 14 PUSHING OR TOWING THE MACHINE 1 14 TRANSPORTING THE MACHINE 1 15 MACHINE JACKING 1 17 STORING MACHINE 1 18 HARDWARE INFORMATION 1 19 STANDARD BOLT TORQUE CHART 1 19 METRIC BOLT TORQUE CHART 1 19 BOLT IDENTIFICATION 1 19 THREAD SEALANT AND LOCKING COMPOUNDS 1 19 HYDRAULIC FITTING INFORMATION1 20 HYDRAULIC TAPERED PIPE FITTI...

Page 4: ...GENERAL INFORMATION 1 2 7400 MM428 6 01 ...

Page 5: ...es and slippery surfaces Use care when reversing machine Do not carry passengers on machine Always follow safety and traffic rules Report machine damage or faulty operation immediately 5 Before leaving or servicing machine Stop on level surface Set parking brake Turn off machine and remove key 6 When servicing machine Avoid moving parts Do not wear loose jackets shirts or sleeves Block machine tir...

Page 6: ...ations indicated If these or any labels become damaged or illegible install a new label in its place EMISSIONS LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT 10783 FOR SAFETY LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT FLAMMABLE SPILLS LABEL LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT ...

Page 7: ...400 MM428 6 01 FAN AND BELT LABEL LOCATED ON THE ENGINE COMPARTMENT LINTEL 10783 STRONG VACUUM LABEL LOCATED ON THE VACUUM FAN HOUSING FLAMMABLE MATERIALS LABEL LOCATED NEXT TO THE SOLUTION TANK COVERS AND ON THE DETERGENT TANK ...

Page 8: ...rubbing path width 1140 mm 45 in Scrubbing path width with optional side brush 1450 mm 57 in Debris tray volume capacity 42 L 1 5 ft3 Solution tank 265 L 70 gal Recovery tank 272 L 72 gal Detergent tank option 25 L 6 7 gal Total capacity with ESt option 397 L 105 gal GVWR 2087 kg 4600 lb GENERAL MACHINE PERFORMANCE Item Measure Maximum forward speed 12 9 kmh 8 mph Maximum reverse speed 6 4 kmh 4 m...

Page 9: ... rated engine oil Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke Ford VSG 1 3 Piston Distributorless type spark 4 Natural 4 74 mm 2 91 in 75 mm 2 97 in Displacement Net power governed Net power maximum 1300 cc 79 cu in 23 2 kw 32 hp 2400 rpm 39 5 kw 53 hp 4000 rpm Fuel Cooling system Electrical system Gasoline 87 octane minimum unleaded Fuel tank 42 L 11 2 gal Water ethylene glycol an...

Page 10: ...luid Type Hydraulic reservoir 38 L 10 gal TENNANT part no 65869 above 7_ C 45_ F Hydraulic total 74 L 19 5 gal TENNANT part no 65870 below 7_ C 45_ F BRAKING SYSTEM Type Operation Service brakes Mechanical drum brakes 2 one per rear wheel cable actuated Parking brake Utilize service brakes cable actuated TIRES Location Type Size Pressure Front 1 Solid 460 x 130 mm 5 x 18 in Rear 2 Solid 460 x 130 ...

Page 11: ...ENERAL INFORMATION 1 9 7400 MM428 6 01 1327 mm 52 25 in 2460 mm 97 in 2045 mm 80 5 in 1475 mm 58 in 1525 mm 60 in 1260 mm 49 6 in 1610 mm 63 4 in 1483 mm 58 4 in 1686 mm 66 4 in 10919 MACHINE DIMENSIONS ...

Page 12: ...b brushes Check for damage and wear 1 7 Recovery tank Clean 1 7 Recovery tank ESt mode Clean ESt filter 1 5 Solution tank ESt mode Clean 1 50 Hours 10 Scrub brushes Rotate end for end or front to rear 1 100 Hours 6 Radiator Clean core exterior 1 Check coolant level WG 1 4 Engine crankcase Change oil and filter element EO 1 13 Cover seals Check for damage and wear 4 4 Engine Check fan belt tension ...

Page 13: ... adjust carburetor 1 j idle mixture Replace PCV valve Clean PCV 1 p hoses tubes and fittings Fuel filter gasoline 1 800 Hours 3 Hydraulic reservoir Replace filler cap 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 4 Hydraulic fluid filter Change filter element 1 Hydraulic hoses Check for wear and damage All 6 Cooling system Flush WG 1 1 Propelling motor HTorque shaft nut 1 1 Front wh...

Page 14: ...or damage and wear 2 10 Scrub brushes Check for damage and wear 1 7 Recovery tank Clean 1 7 Recovery tank ESt mode Clean ESt filter 1 5 Solution tank ESt mode Clean 1 50 Hours 10 Scrub brushes Rotate end for end or front to rear 1 4 Fuel pipes and clamps Check for tightness and wear 1 100 Hours 6 Radiator Clean core exterior 1 Check coolant level WG 1 4 Engine crankcase Change oil and filter EO 1 ...

Page 15: ...ridge 1 6 Cooling system Flush WG 1 800 Hours 3 Hydraulic reservoir Replace filler cap 1 y Replace suction strainer 1 Change hydraulic fluid HYDO 1 4 Hydraulic fluid filter Change filter element 1 Hydraulic hoses Check for wear and damage All 1 Propelling motor HTorque shaft nut 1 1 Front wheel HTorque wheel nuts 1 12 Battery HClean and tighten battery cable 1 y g y connections NOTE Also check pro...

Page 16: ...g pushed or towed This valve allows a disabled machine to be moved for a very short distance and at a speed to not exceed 1 6 kp h 1 mph The machine is NOT intended to be pushed or towed a long distance or at a high speed ATTENTION Do not push or tow machine for a long distance and without using the bypass valve or the machine hydraulic system may be damaged Turn the bypass valve 90_ from the norm...

Page 17: ...inch the machine onto the truck or trailer attach the winching chains in the holes at the bottom of the rear bumper If the machine has the optional rear tie down brackets attach the winching chains to them 4 Turn the bypass valve 90_ from the normal position before winching the machine onto the truck or trailer See PUSHING OR TOWING THE MACHINE section of this manual Make sure the machine is cente...

Page 18: ... tie down brackets use them to tie down the machine The rear tie down locations are in the holes at the bottom of the rear bumper If the machine has the optional rear tie down brackets use them to tie down the machine 7 If the loading surface is not horizontal or is higher than 380 mm 15 in from the ground use a winch to unload machine If the loading surface is horizontal AND is 380 mm 15 in or le...

Page 19: ...and block the tires before jacking the machine up FOR SAFETY Before leaving or servicing machine stop on level surface set parking brake turn off machine and remove key The front jacking location is the left front corner of the machine frame The rear jacking locations are the two rear corners of the machine frame FOR SAFETY When servicing machine block machine tires before jacking machine up FOR S...

Page 20: ...wed to lessen the chance of rust sludge or other undesirable deposits from forming 1 Drain and clean the solution and recovery tanks 2 ESt machines Run clean water through the solution system and the ESt solution pump 3 Raise the rear squeegee and the scrub head 4 Park the machine in a cool dry area 5 Remove or charge the battery every three months ...

Page 21: ...291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb _Nm Class 10 9 Torque ft lb Nm M4 2 3 3 4 M5 4 5 6 8 M6 7 9 10 14 M8 18 24 25 34 M10 32 43 47 64 M12 58 79 83 112 M14 94 127 133 180 M16 144 195 196 265 M20 260 352 336 455 M24 470 637 664 900 NOTE Decrease torque by ...

Page 22: ...ft lb 12 Nm 0 38 0 56 18 20 ft lb 27 Nm 0 50 0 75 16 30 ft lb 41 Nm 0 62 0 88 14 40 ft lb 54 Nm 0 75 1 12 12 70 ft lb 95 Nm 1 0 1 31 12 90 ft lb 122 Nm HYDRAULIC O RING FITTING TORQUE CHART Tube O D in Thread Size Minimum Torque Maximum Torque 0 25 0 44 20 6 ft lb 8 Nm 9 ft lb 12 Nm 0 38 0 56 18 13 ft lb 18 Nm 20 ft lb 27 Nm 10 ft lb 14 Nm 12 ft lb 16 Nm 0 50 0 75 16 20 ft lb 27 Nm 30 ft lb 41 Nm ...

Page 23: ...T ASSEMBLY 2 3 OPERATOR SEAT 2 4 STATIC DRAG CHAIN 2 4 BRAKES AND TIRES 2 5 SERVICE BRAKES 2 5 TO REPLACE BRAKE SHOES 2 5 REAR TIRES AND WHEELS 2 7 TO REPACK REAR WHEEL BEARINGS 2 7 FRONT TIRE AND WHEEL AND WHEEL SUPPORT 2 9 TO REPLACE FRONT DRIVE MOTOR 2 9 TO REPLACE FRONT WHEEL HOUSING PIVOT BEARINGS 2 11 ...

Page 24: ...CHASSIS 2 2 7400 MM428 12 98 ...

Page 25: ...CHASSIS 2 3 7400 MM428 12 98 INTRODUCTION This section includes information on the main chassis related components for example the seat steering brakes and tires ...

Page 26: ...four hex screws and nuts holding the seat assembly hinge to the seat support 3 Slide the prop rod to the opening in the slot and remove 4 Remove the seat assembly from the machine TO REPLACE SEAT ASSEMBLY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Position the seat assembly on the seat support 2 Reinstall the four hex sc...

Page 27: ...nd release the lever Lift Pull up on the seat mounting plate until the seat mount locks up Lower Pull on the release lever and lower the seat mounting plate STATIC DRAG CHAIN A static drag chain prevents the buildup of static electricity in the machine The chain is attached to the machine with a hex screw by the scrub head torque tube mount bearing Make sure the chain is touching the floor at all ...

Page 28: ...osen the jam nuts on the brake cable turn buckle Rotate the turn buckle to loosen the tension on the brake cable 5 Jack up one rear corner of the machine Place jack stands under machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 6 Remove the hub cap from the center of the tire and wheel assembly 7 Remove t...

Page 29: ...Spin the tire and wheel assembly The tire should spin freely 18 Reinstall the hub cap in the center of the wheel 19 Lower the machine NOTE Always replace brake shoes in sets 20 Repeat the procedure on the other wheel 21 Rotate the brake cable turn buckle until the brake cable is tight or until the brake pedal travels 25 50 mm 1 2 in before engaging brakes 22 Tighten the brake cable turn buckle jam...

Page 30: ...e from the operators compartment 4 Loosen the jam nuts on the brake cable turn buckle Rotate the turn buckle to loosen the tension on the brake cable 5 Jack up one rear corner of the machine Place jack stands under machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 6 Remove the hub cap from the center of t...

Page 31: ...Reinstall the hub cap in the center of the wheel 16 Lower the machine 17 Repeat the procedure on the other wheel 18 Rotate the brake cable turn buckle until the brake cable is tight or until the brake pedal travels 25 50 mm 1 2 in before engaging brakes 19 Tighten the brake cable turn buckle jam nuts 20 Reinstall the floor plate in the operators compartment 21 Operate the machine and check the rea...

Page 32: ...vel Surface Set Parking Brake Turn Off Machine And Remove Key 1 Engage parking brake block rear tires 2 Jack up front of machine Use jack stands to support machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 3 Remove the front tire and wheel assembly 4 Remove the cotter pin and slotted nut from the front wh...

Page 33: ...ws Torque to 90 117 Nm 70 85 ft lb 12 Reconnect the hydraulic hoses to the drive motor NOTE Make sure the square key is in place on the shaft of the new motor 13 Mount the drive hub to tapered motor shaft Tighten slotted nut to 500 Nm 375 ft lb Install the cotter pin 14 Install the front tire Torque the front wheel nuts to 142 156 Nm 105 115 ft lb 15 Remove jack stands and lower machine 16 Operate...

Page 34: ... the hydraulic hose clamp from the top of the wheel housing 7 Remove the one 3 4 in hex screw attaching the rod end of steering cylinder to the front wheel housing Retain the spacer 8 Remove the cotter pin and large slotted nut from the top of the pivot pin 9 Loosen the two M10 socket head bolts holding the pivot pin to the machine frame NOTE Use a floor jack to support the wheel housing before re...

Page 35: ...eel housing for play If pin is not seated tap with rubber mallet and re torque castle nut NOTE The wheel housing should rotate with a slight amount of drag 19 Torque the top socket screw with a hand torque wrench to 100 115 Nm 73 85 ft lb 20 Tighten the castle nut to the next slot and insert the cotter pin Torque not to exceed 100 Nm 75 ft lb 21 Check the casting to see if it rocks or binds If it ...

Page 36: ...lamp to the top of the wheel housing Tighten M8 hex screws to 18 5 24Nm 15 20 ft lb 26 Install the front tire Torque the front wheel nuts to 142 156 Nm 105 115 ft lb 27 Re connect battery cables start engine run propelling in both directions check for leaks 28 Remove jack stands lower machine to the ground ...

Page 37: ...R MOUNT PLATE 3 18 TO INSTALL MAIN BRUSH DRIVE MOTOR MOUNT PLATE 3 19 TO REPLACE OPTIONAL SIDE BRUSH 3 20 SQUEEGEES 3 21 TO REPLACE REAR SQUEEGEE LIFT CABLE 3 21 TO REPLACE REAR SQUEEGEE CENTERING SPRINGS 3 22 TO REMOVE REAR SQUEEGEE FRAME 3 23 TO INSTALL REAR SQUEEGEE FRAME 3 23 SQUEEGEE BLADES 3 24 REAR SQUEEGEE 3 24 TO REPLACE OR ROTATE REAR SQUEEGEE BLADES 3 24 TO ADJUST REAR SQUEEGEE BLADE DE...

Page 38: ...SCRUBBING 7400 MM428 12 98 3 2 ...

Page 39: ...through the solution valve to the two cylindrical scrub brushes The brushes scrub the floor As the machine is moved forward the squeegee wipes the dirty solution off the floor which is then picked up and drawn into the recovery tank by the vacuum fan There are three settings on the solution flow high low and off ...

Page 40: ...ilt it open 4 Disconnect the wires going to the float switch at the back of the LH solution tank 5 Remove the two hex screws from the rear tank bracket where it attaches to the LH solution tank 6 Remove the one hex screw from the rear lower corner of the LH tank This hex screw is located near the left hand taillight 7 Go to the front of the LH solution tank Disconnect the solution cross over line ...

Page 41: ...e for now 3 Reinstall the two M8 hex screws in the top rear of the LH solution tank in the rear tank bracket Leave hardware loose for now 4 Reinstall the one M8 hex screw in the rear bottom of the LH solution tank near the LH taillight 5 Tighten the five M8 hex screws to 18 24 Nm 15 20 ft lb 6 Reconnect the solution cross over line at the bottom of the tank NOTE Reconnect the vacuum hoses if remov...

Page 42: ... and TO REMOVE RECOVERY TANK instructions 2 Remove the one hex screw from the rear lower corner of the RH tank This hex screw is located under the frame above the drain cap 3 Place the operators seat in the raised position and engage the prop rod 4 Remove the two M8 hex screws from the front right corner of the RH solution tank where it attaches to the seat support 5 Disconnect any solution lines ...

Page 43: ... hex screw in the rear bottom of the RH solution tank This hex screw is located under the frame above the drain cap Leave hardware loose for now 3 Reinstall the two M8 hex screws from the front right corner of the RH solution tank where it attaches to the seat support Leave hardware loose for now 4 Reconnect any solution lines that were disconnected from the RH solution tank 5 The remain RH soluti...

Page 44: ... SOLUTION TANK instructions 4 Disconnect the vacuum and squeegee hoses from the front of the recovery tank 5 Remove the two hex screws holding the demister cover on the recovery tank Remove the demister cover 6 If the machine is equipped with an overhead guard it must be removed in order to remove the tank lintel NOTE The engine hood must be supported in the open position before the next step can ...

Page 45: ...ion line at the front of the recovery tank if the machine is equipped with the auto fill option 14 Disconnect the wires leading to the float switch that is located at the front right corner of the recovery tank NOTE Machines equipped with ES will have two switches on the float assembly 15 Disconnect the solution hose at the back of the tank if the machine is equipped with the ESt option 16 Unplug ...

Page 46: ...oler 20 Remove the two M8 hex screws attaching the rear tank bracket to the RH solution tank 21 Remove the one M8 hex screw under the rear of the tank just above the drain cap 22 Carefully push the recovery tank forward lift it up and remove it from the machine NOTE An overhead hoist or two people must be used when lifting the recovery tank out of the machine frame ...

Page 47: ...front of the recovery tank if machine is equipped with the auto fill option 4 Reconnect the float switches at the front of the recovery tank to the main harness See schematic in the ELECTRICAL section 5 Carefully pivot the radiator assembly back in position on the rear of the recovery tank Reinstall the hardware and tighten to 18 24 Nm 15 20 ft lb 6 Plug the ESt pump back in the main harness See s...

Page 48: ...Reinstall the two M8 hex screws and tighten to 18 24 Nm 15 20 ft lb 14 Reinstall the LH solution tank See TO INSTALL LH SOLUTION TANK instructions 15 Reconnect the two vacuum hoses to the front of the recovery tank 16 Reinstall the overhead guard if it was removed earlier 17 Reinstall the tank drain cover to the rear of the tanks Reinstall the hardware and tighten to 18 24 Nm 15 20 ft lb 18 Reinst...

Page 49: ...ball stud 4 Remove the two hair pins from the brush wrap attachment pins 5 Remove the M12 hex screw holding the brush idler plate arm to the lift tube 6 Remove the idler plate and side squeegee assembly from the machine NOTE Thread the mounting bolt into the idler arm removal hole if you are having trouble removing the idler arm 7 Pull the two main brushes off the drive plugs 6 Line up the drive e...

Page 50: ...material that will not easily blow away to a smooth level floor 2 Raise the scrub head Position the scrub head over the chalked area 3 Set the parking brake 4 Lower the scrub head for 15 to 20 seconds while keeping the scrub head in one spot in the chalked area NOTE If chalk or other material is not available allow the brushes to spin on the floor for two minutes A polish mark will remain on the f...

Page 51: ... width on that side of the scrub head Tighten the mounting bolts and check the pattern again and readjust if necessary The brush patterns should be the same width If one is narrower then the other the scrub head needs to be leveled from front to rear 8 Lengthen or shorten the leveling rods on both sides of the scrub head Lengthening the rods will increase the rear brush pattern width Shortening th...

Page 52: ...e idler plate and side squeegee assembly over Remove the cotter pins castle nuts and washers from the idler plugs 8 Use a puller to remove the idler plugs from the tapered shafts Remove and retain the square key 9 Remove the retaining rings from both ends of the idler shafts 10 Use a press to remove the tapered shafts from the idler plate Push the shafts out toward the direction of the idler plugs...

Page 53: ...the castle nut down hard until the slot in the nut lines up with the hole in the shaft Install a new cotter pin 19 Reinstall the brush arm and C clip if they were removed earlier 20 Reinstall the idler plate and side squeegee assembly in the machine NOTE Lift up on the brush wrap slightly when installing the idler plate in the machine so the attachment pins line up with the holes in the plate 21 A...

Page 54: ...hair pins from the brush wrap attachment pins 5 Remove the M12 hex screw holding the brush arm to the lift tube 6 Remove the three hex screws holding the side squeegee assembly to the motor mount plate Remove the side squeegee assembly NOTE For better access to the hydraulic drive motors remove the C clip and brush arm from the motor plate 7 Mark disconnect and plug the three hydraulic hoses leadi...

Page 55: ...ee schematic in HYDRAULICS section 4 Reinstall the brush arm and C clip if they were removed earlier 5 Align the two pins on the lift tube with the two holes in the brush motor plate arm 6 Reinstall the M12 hex screw in the brush motor plate arm Tighten to 64 83 Nm 47 61 ft lb NOTE Apply a small amount of grease to the threads on the bolt and in the tube 7 Reinstall the front of the leveling rod b...

Page 56: ...dow in the side brush motor mount plate 2 Reach in through the opening in the top of the side brush guard through the mount plate window and pinch the spring clips together 3 Drop the brush off the drive hub Remove the brush from the machine 4 Position the new side brush under the machine 5 Lift the side brush and line up the hub in the brush with the motor drive plug Snap the brush up in place 6 ...

Page 57: ...l Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the cotter pin and clevis pin from the squeegee lift cable where it attaches to the squeegee frame assembly 4 Remove the cotter pin and clevis pin from the squeegee lift cable where it attaches to the squeegee lift bellcrank located near the lift cylinder 5 Remove the clevis pin holding the cable roller to the frame Remove the ro...

Page 58: ...ill relax the tension on the springs 4 Remove the nyloc nuts from the squeegee rod ball joints where they are connected to the debris tray NOTE Remove both the upper and lower nuts on one side Do one side at a time 5 Remove and discard the old squeegee centering spring 6 Position a new squeegee centering spring on the upper and lower ball joint studs 7 Reinstall the two nyloc nuts and tighten to 3...

Page 59: ...elax the tension on the springs 6 Remove the four hex screws and nuts holding the squeegee frame to the squeegee lift assembly 7 Remove the squeegee frame from the machine TO INSTALL REAR SQUEEGEE FRAME FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Position the squeegee frame back under the lift assembly 2 Reinstall the fou...

Page 60: ...place any worn or damaged squeegee blades TO REPLACE OR ROTATE REAR SQUEEGEE BLADES 1 Make sure the squeegee is raised off the floor 2 Shut the engine off and set the parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Open the retaining band clamp and remove the squeegee blade 4 Replace or rotate the squeegee blade...

Page 61: ... front slotted squeegee blade should contact the floor with a slight deflection 5 mm 0 13 to 0 25 in 4 To adjust the amount of deflection unlock the height adjustment knobs on the two squeegee casters by sliding the locking bracket off to the side NOTE If the locking brackets won t slide over lift up the end of the squeegee to pick the caster up off the floor slightly Then slide the locking bracke...

Page 62: ...queegee blade 4 If the deflection is not the same over the full length of the blade loosen the locking nut on the two rear squeegee balljoints NOTE The rear squeegee links should be adjusted so there is 11 inches from the center lines of the two ball joints 5 Turn the balljoint adjustment nut clockwise from the rear of the machine to increase the deflection at the ends of the squeegee Turn the bal...

Page 63: ...nd set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 3 Remove the cotter pin clevis pin deflector and the retainer bracket from the front of the side squeegee 4 Pull the squeegee blade out the front of the squeegee frame 5 Slide the new squeegee blade onto the frame NOTE Lubricating the squeegee fram...

Page 64: ...ne and remove key 3 Remove the side brush guard 4 Remove the retainer clip from the end of the squeegee 5 Pull the squeegee blade out the front of the squeegee frame 6 Slide the new squeegee blade onto the frame NOTE Lubricating the squeegee frame where the squeegee makes contact will make it easier to install the squeegee blade 7 Install the retainer clip on the end of the squeegee 8 Install the ...

Page 65: ... Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Open the engine cover engine side door and the front cover 2 Loosen the hose clamp and remove the vacuum hose leading from recovery tank to the center of the vacuum fan housing 3 Mark disconnect and plug the four hydraulic hoses going to the vacuum fan NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 4 R...

Page 66: ... mounting holes in the vacuum fan housing with the three rubber isolators in the mounting brackets Reinstall the three M10 hex screws washers and nyloc nuts Tighten to 18 24 Nm 13 18 ft lb 3 Reconnect the hydraulic hoses to the vacuum fan motor See schematic in HYDRAULIC section 4 Reinstall vacuum hose from recovery tank to vacuum fan housing Hand tighten clamps 5 Start the engine and turn on the ...

Page 67: ...mpeller off shaft NOTE Remove and save the key and any shims that are on the motor shaft under the impeller 5 Install the shims key new fan impeller and crown nut Tighten nut to 34 47 Nm 25 35 ft lb NOTE Be sure the square key is on the motor shaft Super gluing the key to the shaft helps keep it in place when installing the impeller NOTE Use a small amount of blue loctite 242 on the motor shaft th...

Page 68: ...SCRUBBING 3 32 7400 MM428 12 98 ...

Page 69: ... PANEL DOES NOT POWER UP FLOW CHART 4 37 Page SCRUB BRUSH WILL NOT TURN ON AND OR DOWN SCHEMATIC 4 38 SCRUB BRUSH WILL NOT TURN ON AND OR DOWN FLOW CHART 4 39 SQUEEGEE AND VACUUM FAN NOT TURNING ON AND GOING DOWN SCHEMATIC 4 41 SQUEEGEE AND VACUUM FAN NOT TURNING ON AND GOING DOWN FLOW CHART 4 42 SIDE BRUSH WILL NOT TURN ON AND GO DOWN SCHEMATIC 4 44 SIDE BRUSH WILL NOT TURN ON AND GO DOWN FLOW CH...

Page 70: ...WILL NOT TURN ON OR OFF SCHEMATIC 4 67 ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN ON FLOW CHART 4 68 ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN OFF FLOW CHART 4 68 RECOVERY TANK FULL LIGHT WILL NOT TURN ON OR OFF SCHEMATIC 4 69 RECOVERY TANK FULL LIGHT WILL NOT TURN ON FLOW CHART 4 70 RECOVERY TANK FULL LIGHT WILL NOT TURN OFF FLOW CHART 4 70 FUEL GAUGE GAS AND DIESEL SCHEMATIC 4 71 FUEL...

Page 71: ... 3 7400 MM428 12 98 INTRODUCTION The machine electrical system consists of the battery relays instrument panels and related components This section includes information on these components and their troubleshooting ...

Page 72: ...onnections Use a strong solution of baking soda and water Brush the solution sparingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the cable connectors After cleaning apply a coating of clear battery post protectant to the terminals and the cable connectors Keep the tops of the batter...

Page 73: ...1 170 1 190 25 Charged 1 110 1 160 Discharged NOTE If the readings are taken when the battery electrolyte is any temperature other than 27_ C 80_ F the reading must be temperature corrected Add or subtract to the specific gravity reading 0 004 4 points for each 6_ C 10_ F above or below 27_ C 80_ F TO REPLACE BATTERY FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking ...

Page 74: ...the steering wheel in the lowest position 4 Open the front cover on the machine 5 Remove four M5 pan head screws holding the instrument panel to the dash panel 6 Pull the instrument panel back away from machine 7 Loosen the allen head screw in center of wire harness plug Disconnect the harness 8 Remove instrument panel from machine 9 Install the new instrument panel back on the dash panel with the...

Page 75: ...ble the touch panel case further remove the four smaller pan head screws from the center of case box 5 Remove the case box from the circuit board touch panel assembly 6 The O ring and connector gaskets can now be replaced in the case box if necessary 7 Remove the eight pan head screws unplug the flat connector and ground strap remove the touch panel from the circuit board 8 Any burned out lamps ca...

Page 76: ...ight pan head screws and lightly hand tighten 3 Turn the circuit board assembly over and place it back in the case box 4 Reinstall the four smaller pan head screws in center of case box Lightly hand tighten 5 Reinstall the touch panel case on the outer case 6 Reinstall the twelve pan head screws and lightly hand tighten 7 The instrument panel is now ready to be reinstalled in the machine See TO RE...

Page 77: ...steering motor 5 Lift up on the relay to harness locking tab 6 Pull the harness plug out of the relay 7 Remove the pan screw holding the relay to the operators compartment Remove and discard the old relay 8 Position the new relay on the operators compartment 9 Reinstall the pan screw holding the relay to the operators compartment 10 Reconnect the harness plug in the relay See schematic in the ELEC...

Page 78: ...of the circuit breaker 6 Disconnect the electrical wires on the back of the circuit breaker 7 Remove the steel retaining ring holding the circuit breaker to the dash panel Remove the circuit breaker 8 Position the new circuit breaker in the mounting hole on the dash panel 9 Install the retaining ring on the new circuit breaker Push the ring on all the way to the bottom of the circuit breaker 10 Re...

Page 79: ...OSES BELOW 40 PSI M7 REVERSE 85 86 83 BRN 10 GRY 15 BLU CB 1 15A 36 GRN 35 BRN 13H BLK 14 GRN 18A ORA N C H O N C H O GAS DIESEL 13P BLK 13B BLK C S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 STARTER RELAY M1 S 6 18A ORA 18A ORA 71C YEL 18C ORA 18 ORA 87 30 FLOW SWITCH 15 BLU M4 86 85 28 YEL C M5 57 GRN 5 0A S 15 23A GRY ES PUMP MTR DETERGENT METERING 85 86 REVERSE RECOVERY TANK S 8 S 1 M3 22 YEL 8...

Page 80: ...ELECTRICAL 4 12 7400 MM428 6 01 SHEET 2 GAS LPG ELECTRICAL SCHEMATIC ...

Page 81: ...B 5 15A CB 5 15A 36 GRN 35 BRN 13H BLK 14 GRN 18A ORA N C H O GAS DIESEL 13P BLK 13B BLK C S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 STARTER RELAY M1 18A ORA 18A ORA 18 ORA 87 30 FLOW SWITCH 15 BLU M4 86 85 28 YEL M5 57 GRN 5 0A S 15 23A GRY ES PUMP MTR DETERGENT METERING 85 86 REVERSE RECOVERY TANK S 8 S 1 M3 22 YEL 86 85 M3 1E REDCB 6 19 BLU A 2 ORA C IGNITION SWITCH S 3 CB 5 43 BLU 13L BLK 13...

Page 82: ...ELECTRICAL 4 14 7400 MM428 6 01 SHEET 4 DIESEL ELECTRICAL SCHEMATIC ...

Page 83: ...3K BLK 13R BLK 13F BLK 18C ORA 71C YEL CBA 10 GRY 42 YEL 62A YEL CBA AB A BC A B 1E RED HORN 1 RED TO BATTERY STARTER TO MAIN HARNESS 85 BLU 83 BRN 84 GRN 86 PUR 72C YEL 18D ORA 13E BLK 71C YEL 1D RED 20D BLU 20 BLU 10A GRY 10 GRY VIEW C C GOVERNOR CONTROL VIEW F F KEY SWITCH ALTERNATOR WATER TEMPERATURE SENDER 13A BLK SEE OPTIONS FUEL SENDER 42A YEL 13L BLK 1 RED BATTERY GAS AND DIESEL LOCATION T...

Page 84: ...UR 18 ORA 18C ORA 20 BLU 4 YEL 65 GRY 65A GRY 22 YEL 4A YEL 1C RED 59 BRN 59A BRN 20C BLU CIRCUIT BREAKERS CB 1 IGNITION CB 2 ES PUMP CB 3 HEADLIGHTS CB 4 BACK UP ALARM CB 5 HORN CB 6 INSTRUMENT PANEL 5 0A CB 7 SCRUB SOLENOIDS CB 8 SIDE BRUSH SOLENOIDS AND WATER VALVES CB 3 MAIN HARNESS CB 1 CB 2 CB 4 CB 5 CB 6 CB 7 CB 8 20B BLU 20A BLU 24 PUR 25A GRY 1E RED 21A GRY 21 GRY DIODE ASSY 19B BLU 13D B...

Page 85: ...SV 1 SCRUB BRUSH ON SV 2 VACUUM FAN ON SV 3 SQUEEGEE DOWN SV 4 DOWN PRESS PROPORTIONAL VALVE SV 5 SCRUB BRUSH DOWN SV 6 SIDE BRUSH ON SV 7 SCRUB BRUSH UP HOLD 58 BLU 83 BRN 1A RED 21B GRY 13S BLK 13T BLK 13U BLK 45 GRY 60 GRN 46 BRN 48 GRY 15 BLU 2 ORA 42 ORA 51 PUR 47 BRN 28 YEL 56 YEL 36 GRN 35 BRN 52 YEL 43 BLU 57 GRN 26 BRN 23 GRY 13A BLK 1B RED 2 ORA E S EXC L2 B P CONN A SOC NO 24 23 22 21 2...

Page 86: ...ELECTRICAL 4 18 7400 MM428 6 01 SHEET 8 GAS LPG WIRE HARNESS GROUP OPTIONS ...

Page 87: ...H NO C NC 62D BRN 13HH BLK 89A ORA BACK UP ALARM ES PUMP AUTO FILL ROT LIGHT SEE OPTIONS SHEET 12 DETERGENT PUMP 28 YEL 13J BLK 13K BLK 13M BLK 13J BLK 13R BLK 10 GRY 42 YEL 62A YEL CBA A BC 1E RED HORN 1 RED TO BATTERY STARTER 85 BLU 83 BRN 84 GRN 86 PUR 72C YEL 18D ORA 13E BLK 71C YEL VIEW C C GOVERNOR CONTROL VIEW F F KEY SWITCH ALTERNATOR WATER TEMPERATURE SENDER 13A BLK FUEL SENDER 42A YEL 13...

Page 88: ... CB 4 CB 5 CB 6 CB 7 CB 8 20B BLU 20A BLU 24 PUR 25A GRY 1E RED 21A GRY 21 GRY VIEW A A ROTATED DIODE ASSY 19B BLU 13D BLK A B AB RELAYS M2 FUEL PUMP M3 INSTRUMENT PANEL M4 HYD SOLENOIDS M5 ES PUMP M6 HEADLIGHTS M7 REVERSE 10A GRY 92 PUR M5 M6 M7 M2 M3 M4 93 ORA 62 YEL 58 BLU 19A BLK 65 GRY 57 GRN 66 BRN 59 BRN 60 GRN 14 GRN 15A BLU 18A ORA 18A ORA 22 YEL 19 BLU 18A ORA 23B GRY 1F RED 18A ORA 21 G...

Page 89: ...TIONAL VALVE SV 5 SCRUB BRUSH DOWN SV 6 SIDE BRUSH ON SV 7 SCRUB BRUSH UP HOLD MAIN INSTRUMENT PANEL SOCKET REAR VIEW 12 18 24 23 22 21 20 19 13 7 6 5 4 3 2 1 58 BLU 83 BRN 1A RED 21B GRY 13S BLK 13T BLK 13U BLK 45 GRY 60 GRN 46 BRN 48 GRY 15 BLU 2 ORA 42 ORA 51 PUR 47 BRN 28 YEL 56 YEL 36 GRN 35 BRN 52 YEL 43 BLU 57 GRN 26 BRN 23 GRY 13A BLK 1B RED 2 ORA E S EXC L2 B P CONN A SOC NO 24 23 22 21 2...

Page 90: ... C NC 62D BRN 13HH BLK 89A ORA BACK UP ALARM ES PUMP AUTO FILL ROT LIGHT SEE OPTIONS SHEET 12 DETERGENT PUMP 28 YEL 13J BLK 13K BLK 13M BLK 13J BLK 13R BLK 10 GRY 42 YEL 62A YEL CBA A BC 1E RED HORN 1 RED TO BATTERY STARTER 85 BLU 83 BRN 84 GRN 86 PUR 72C YEL 18D ORA 13E BLK 71C YEL VIEW C C GOVERNOR CONTROL VIEW F F KEY SWITCH ALTERNATOR WATER TEMPERATURE SENDER 13A BLK FUEL SENDER 42A YEL 13L BL...

Page 91: ...c system Each time the control board is powered up it performs a self test If the self test passes the OK light is illuminated This trouble shooting section describes the different operating modes that are available how to enter that mode and a detail description of how that mode works ...

Page 92: ...ld the Squeegee button until the maintenance light comes on 4 Release the Squeegee button Error Display Mode Display the cause of a self test failure More info pages 4 30 thru 4 32 1 Push and hold the Detergent button 2 Turn on the key 3 Hold the Detergent button until the maintenance light comes on 4 Release the Detergent button Pressure Adjust Mode Adjust the pressure levels for the three down p...

Page 93: ... main brushes will turn on and lower The down pressure setting will be the same used during the last scrub cycle The solution will flow at the high or low rate according to the water position switch 3 If the machine is in reverse the brushes will stay up until reverse is no longer sensed 4 If the side brush LED is on the side brush will turn on and lower The down pressure setting will be the same ...

Page 94: ...ill pass and then the squeegee will rise 6 Another small delay will pass and the vacuum fan will turn off SQUEEGEE BUTTON Pressing the squeegee button will start or stop the water pickup operation If the operator presses the squeegee button while the squeegee LED is currently not illuminated will cause the following actions 1 The squeegee LED will be illuminated 2 The squeegee will drop and the va...

Page 95: ...nk through a filter and pump it into the solution tank If the operator has turned on the ESt system and the recovery tank ESt float reads a full tank the ESt pump will begin to run The ESt pump will continue to run for about 30 seconds after the ESt float becomes uncovered OVERFLOW FLOAT In order for the recovery tank float to become active it must be consistently in the up position for at least 1...

Page 96: ...ill toggle the ESt pump on or off In the on position the ESt pump will run regardless of the state of the floats SIDE BRUSH BUTTON Pressing the Side Brush button will turn on and lower the side brush If the main brush is off the side brush will use the low pressure setting SQUEEGEE BUTTON Pressing the Squeegee button will turn on the vacuum fan and lower the squeegee Reverse is ignored ENGINE BUTT...

Page 97: ...ation of the Input Display Mode is as follows D SEGMENT 0 Rightmost segment of the gas gauge This segment displays the state of the ES float This segment will illuminate when this input is shorted to ground D SEGMENT 1 Second segment from the right of the gas gauge This segment displays the state of the recovery tank float This segment will be illuminated when this input is shorted to ground D SEG...

Page 98: ...ator can obtain the error code stored after the last startup diagnostic failure When the machine is in this mode the LED s on the operators panel will indicate which system experienced the failure If the operator pushes the button associated with an illuminated LED segments on the gas gauge will indicate which output failed and what type of failure occurred The operation of the Error Display Mode ...

Page 99: ... segments would indicate that the side brush motor output was open when the controller was trying to short it to ground SQUEEGEE LED Problem with the squeegee actuator or vacuum fan motor outputs If the operator pushes the squeegee button in this mode the panel would display one of the following codes D SEGMENT 0 Rightmost segment of the gas gauge This segment would indicate that the squeegee actu...

Page 100: ...hese segments would indicate that the main brush motor output was open when the controller was trying to short it to ground DETERGENT LED Problem with the headlight or detergent pump outputs If the operator pushes the detergent button in this mode the panel would display one of the following codes D SEGMENT 0 Rightmost segment of the gas gauge This segment would indicate that the detergent pump ou...

Page 101: ...e brush is inactive and the main brush is active the operator can adjust the down pressure for the main brush When the side brush and main brush are active the operator can adjust the down pressure for the side brush To store the new down pressure settings turn off the Side Brush and Scrub Panel LEDs on the touch panel Then turn off the key switch The operation of the Pressure Adjust Mode is as fo...

Page 102: ...aintenance light 5 While holding the Scrub button press and hold the Side Brush button 6 Wait for the maintenance light to go out 7 Release the Scrub and Side Brush buttons 8 Turn the key off 9 Restart the machine RESET SCRUB PRESSURES When the machine goes into this mode the controller replaces the current brush down pressure settings with factory defaults To initiate follow the entry sequence ho...

Page 103: ...AL 4 35 7400 MM428 12 98 TROUBLESHOOTING The following troubleshooting section is organized with the section of the electrical schematic that pertains to that particular problem first followed by the flow chart ...

Page 104: ...YEL 86 85 M3 1E RED CB 6 19 BLU IGNITION SWITCH S 3 20A BLU 20 BLU ELECTRONIC INSTRUMENT PANEL 17 50 BATT 30 19 ACC 13 BLK BATTERY 22 13S BLK INSTRUMENT PANEL DOES NOT POWER UP SCHEMATIC OPERATION KEY SWITCH ACTIVATES M3 AND M4 M3 CONTACT SUPPLIES 14VDC TO INSTRUMENT PANEL PIN 1 BATTERY LINE SWITCHED LINE ...

Page 105: ...ES NOT WORK REPLACE KEY SWITCH 1D RED IS OPEN FROM BATTERY TO KEY SWITCH CHECK FOR BAT VOLTAGE AT M3 PIN 30 22 YEL NO VOLTAGE WIRE 22 YEL CB 6 OR 1E RED ARE OPEN BATTERY VOLTAGE OPEN REPLACE DIODE OR REPAIR OPEN WIRES DISCONNECT INSTRUMENT PANEL CHECK CONTINUITY OF 23 GREY FROM M3 PIN 87 TO PIN 1 OF PANEL 13S BLACK FROM PIN 22 OF PANEL TO BAT NEG OK REPLACE INSTRUMENT PANEL GOOD CONTINUITY OPEN WI...

Page 106: ...SEC DELAY 11 4 SEC 16 19 2 15 AMP SV 1 SCRUB BR ON VALVE 87 30 M4 1F RED OPERATION SCRUB IS SELECTED ON TOUCH PANEL SCRUB SOLENOIDS ARE TURNED ON HEAD WILL LOWER BRUSHES WILL SPIN SCRUB BRUSH WILL NOT TURN ON AND OR DOWN SCHEMATIC 8 13R BLK 36 GRN FLOW SWITCH S 15 REVERSE 1 RED 19B BLU 1 13D BLK 23 GRY CB 1 15A 18A ORA 18 ORA 87 30 5 0A M3 22 YEL 86 85 M3 1E RED CB 6 19 BLU IGNITION SWITCH S 3 20 ...

Page 107: ...NGINE IS OFF KEY IS ON SCRUB SELECTED ALL 24 PUR WIRES 21B GRY 21 GRY 1F RED OR M4 CONTACTS ARE OPEN DISCONNECT SOLENOIDS CHECK VOLTAGE AT SV 1 SV 5 SV 7 AND SV 4 FROM 24 PUR TO GROUND VOLTAGE NO WIRE 24 PUR FROM CB 7 TO SOLENOIDS SV 1 SV 5 SV 7 OR SV 4 IS OPEN VOLTAGE ENGINE IS OFF KEY IS ON SCRUB SELECTED DISCONNECT SOLENOIDS CHECK VOLTAGE AT SV 1 SV 5 AND SV 7 FROM 24 PUR TO 46 BRN VOLTAGE ON A...

Page 108: ... THEN ON DOES THE OK LIGHT COME ON NO YES WIRE 48 GRY IS OPEN FROM SV 4 TO INST PANEL PIN 16 KEY IS OFF DISCONNECT INSTRUMENT PANEL CHECK CONTINUITY FROM 48 GRY TO GROUND OPEN CONTINUITY REPLACE PANEL WIRE 48 GRY IS SHORTED TO GROUND VOLTAGE CHECK TO SEE IF ALL FOUR SOLENOIDS ARE ON USE MAGNETISM TEST ON SV 1 SV 5 SV 7 AND SV 4 ALL ON ONE OR MORE NOT ACTIVATED REPLACE BAD SOLENOID HYDRAULIC PROBLE...

Page 109: ...R UP HOLD VALVE SV 3 SQUEEGEE DOWN VALVE CB 7 24B PUR 21B GRY SV 2 VAC FAN ON VALVE SV 4 SCRUB BR DN FORCE PROP VALVE SV 5 SCRUB BR DOWN VALVE 45 GRY 46A BRN 21 8 SEC DELAY 16 19 2 15 AMP SV 1 SCRUB BR ON VALVE 87 30 M4 1F RED 8 13R BLK 36 GRN FLOW SWITCH S 15 REVERSE 1 RED 19B BLU 1 13D BLK 23 GRY CB 1 15A 18A ORA 18 ORA 87 30 5 0A M3 22 YEL 86 85 M3 1E RED CB 6 19 BLU IGNITION SWITCH S 3 20 BLU ...

Page 110: ...ORK REPLACE INST PANEL GO INTO MANUAL MODE THE OUTPUTS WILL TURN ON REGARDLESS OF THE INPUTS TURN KEY OFF PUSH AND HOLD ES BUTTON TURN KEY ON KEEP HOLDING ES BUT TON UNTIL THE MAINTE NANCE LIGHT COMES ON RELEASE ES BUTTON NO CHECK VOLTAGE AT SV 3 FROM 24P PUR TO GRND AND SV 2 FROM 24 PUR TO GRND VOLTAGE NO VOLTAGE MANUAL MODE ENGINE OFF KEY ON SQ VAC SELECTED ON ARE SV 2 AND SV 3 TURNED ON USE MAG...

Page 111: ...ONTINUED FROM PREVIOUS PAGE TURN KEY OFF THEN ON IS THE OK LIGHT ON NO YES WIRE 47 BRN OR WIRE 45 GRY ARE OPEN KEY OFF PANEL DISCONNECTED CHECK CONTINUITY OF 47 BRN AND 45 GRY TO GROUND OPEN CONTINUITY RECONNECT PANEL KEY OFF THEN ON DOES THE OK PANEL LIGHT COME ON YES NO RE TEST SYSTEM REPLACE INSTRUMENT PANEL ...

Page 112: ... DOWN VALVE SV 6 SIDE BR ON VALVE 52 YEL 51A PUR 6 3 SEC DELAY 12 87 30 M4 1F RED SIDE BRUSH WILL NOT TURN ON AND GO DOWN SCHEMATIC OPERATION MACHINE MUST BE IN SCRUB MODE SIDE BRUSH BUTTON IS ACTIVATED AND WILL TURN ON AND LOWER SIDE BRUSH SV 6 SV 9 SV 8 SV 10 AND SV 11 WILL BE ON 8 13R BLK 36 GRN FLOW SWITCH S 15 REVERSE 1 RED 19B BLU 1 13D BLK 23 GRY CB 1 15A 18A ORA 18 ORA 87 30 5 0A M3 22 YEL...

Page 113: ...NE ON ACTIVATE THE SCRUB BUTTON DO THE SCRUB FUNCTIONS TURN ON YES NO ENGINE OFF KEY ON SCRUB SELECTED SIDE BRUSH SELECTED CHECK VOLTAGE AT SV 6 SV 8 SV 9 SV 10 AND SV 11 FROM 25 GRY TO GROUND VOLTAGE NO VOLTAGE ON ANY OR ALL ENGINE OFF KEY ON SCRUB SELECTED SIDE BRUSH SELECTED ALL FOUR SOLENOIDS DISCONNECTED CHECK VOLTAGE ACROSS SOLENOIDS SV 6 8 9 AND 11 FROM 25 GRY TO 51 PUR CONTINUED ON NEXT PA...

Page 114: ...K VOLTAGE AT SV 10 FROM 25 GRY TO 52 YEL CONTINUED FROM PREVIOUS PAGE NO VOLTAGE VOLTAGE WITH SOLENOID STILL DISCONNECTED TURN KEY OFF THEN ON DOES THE OK LIGHT COME ON NO YES WIRE 52 YEL IS SHORTED TO GROUND CONTINUITY OPEN REPLACE INSTRUMENT PANEL CHECK TO SEE IF ALL SOLENOIDS ARE TURNING ON USE THE MAGNETIC TEST ONE OR MORE OFF REPLACE BAD SOLENOIDS ALL SOLENOIDS ON HYDRAULIC PROBLEM SEE TROUBL...

Page 115: ...SV 11 SIDE BR UP HOLD VALVE SV 12 LOW WATER VALVE SV 13 HIGH WATER VALVE 95 BLU 96 GRY 21A GRY 15 AMP CB 8 51B PUR SV 14 SIDE BR WATER VALVE SV 10 SIDE BR DN FORCE PROP VALVE 25C GRY SV 9 SIDE BR OUT VALVE SV 8 SIDE BR DOWN VALVE SV 6 SIDE BR ON VALVE 52 YEL 51A PUR 6 3 SEC DELAY 12 87 30 M4 1F RED 8 13R BLK 36 GRN FLOW SWITCH S 15 REVERSE 1 RED 19B BLU 1 13D BLK 23 GRY CB 1 15A 18A ORA 18 ORA 87 ...

Page 116: ...FOR VOLTAGE AT SV 14 FROM 97 YEL TO GROUND CHECK FOR VOLTAGE AT SV 12 FROM 96 GRY TO GROUND CHECK FOR VOLTAGE AT SV 13 FROM 95 BLU TO GROUND NO VOLTAGE ON ANY WIRES 97 YEL 96 GRY 95 BLU 25 GRY OR SWITCH S 10 ARE OPEN FROM CB 8 TO SOLENOID WITH NO VOLTAGE VOLTAGE ON ALL SOLENOIDS KEY ON ENGINE OFF SOLENOIDS STILL DISCONNECTED SCRUB AND SIDE BRUSH ON CHECK VOLTAGE AT SV 14 FROM 97 YEL TO 51B PUR CHE...

Page 117: ...IL LHT L H TAIL LHT R H HEADLIGHT L H HEADLIGHT R H 15 20 23C GRY 60 GRN M6 LIGHTS 85 86 CB 1 15A IGNITION SWITCH S 3 20A BLU 20 BLU 17 50 BATT 30 19 ACC START 15B BLU 15 BLU 14 GRN 18A ORA 13P BLK 13B BLK S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 HEAD LIGHTS WILL NOT TURN ON SCHEMATIC OPERATION PIN 15 TO GROUND BY OIL PRESSURE SWITCH TURNS ON M6 1 RED 13 BLK BATTERY 22 13U BLK 23 24 18A ORA 1 2...

Page 118: ...E AT M6 PIN 87 FROM 59 BRN TO GROUND VOLTAGE NO VOLTAGE WIRE 20B BLU IS OPEN FROM KEY SWITCH TO CB 3 CHECK VOLTAGE AT HEAD LIGHTS FROM 62 YEL TO 13CC BLK OR FROM 62A YEL TO 13DD BLK HEAD LIGHT IS BAD 62 YEL 62A YEL 13CC BLK OR 13DD BLK ARE OPEN VOLTAGE NO VOLTAGE REPLACE M6 RELAY WORKS PROBLEM SOLVED NO LIGHTS VOLTAGE WIRE 23C GRY IS OPEN FROM M6 PIN 85 TO M3 PIN 87 IS THE ENGINE OIL PRESSURE WARN...

Page 119: ...INSTRUMENT PANEL 17 50 BATT 30 19 ACC START 66 BRN 13PP BLK AUTO FILL 65 GRY CB 2 ES PUMP M5 20A BLU 87 30 15 AMP MTR ESt PUMP NOT WORKING SCHEMATIC OPERATION IF ESt IS SELECTED ON PANEL AND S 17 AND S 18 CLOSE FOR 5 SECONDS M5 RELAY WILL ACTIVATE TURNING ON PUMP 13T BLK 13Y BLK 15 CB 1 15A 15B BLU 15 BLU 14 GRN 18A ORA 13P BLK 13B BLK S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 1 RED 13 BLK BATTE...

Page 120: ...N ON REGARDLESS OF THE INPUTS TURN KEY OFF PUSH AND HOLD ES BUTTON TURN KEY ON KEEP HOLDING ES BUTTON UNTIL THE MAINTENANCE LIGHT COMES ON RELEASE ES BUTTON NO YES DOES THE ES PUMP TURN ON AND OFF WITH THE ES BUTTON NOW INPUT OUTPUT REPLACE M5 CHECK VOLTAGE AT M5 PIN 30 FROM 65 GRY TO GROUND NO VOLTAGE CHECK VOLTAGE AT M5 PIN 85 FROM 23C GRY TO GROUND VOLTAGE 20A BLU CB 2 OR 65 GRY ARE OPEN FROM M...

Page 121: ...ACHINE IN MANUAL MODE CHECK VOLTAGE AT M5 PIN 87 FROM WIRE 66 BRN TO GROUND WITH ES ON AND MACHINE IN MANUAL MODE CHECK VOLTAGE AT ES PUMP FROM 66 BRN TO 13PP BLK NO VOLTAGE VOLTAGE MOTOR BAD WITH M5 REMOVED TURN KEY ON THEN OFF IS OK LIGHT ON NO YES PANEL DISCONNECTED POWER OFF M5 REMOVED REPLACE PANEL NO YES REMOVE SHORT TO GROUND ON 57 GRN CHECK CONTINUITY FROM 57 GRN TO GROUND ...

Page 122: ...87 30 CB 4 94 YEL 93B ORA 15 AMP BACK UP ALARM UNIT FLASHER REVERSE LIGHT OR ALARM NOT WORKING SCHEMATIC OPERATION GROUND AT PIN 8 WHEN MACHINE IS IN REVERSE TURNS ON M7 SUPPLIES POWER TO BACK UP ALARM LIGHT ELECTRONIC INSTRUMENT PANEL ES PUMP MTR 13T BLK 13Y BLK 22 13U BLK 23 24 13S BLK IGNITION SWITCH S 3 1D RED 20A BLU 20 BLU 17 50 BATT 30 19 ACC CB 1 15A 1 RED 13 BLK BATTERY 1 23 GRY 19 BLU 13...

Page 123: ... MACHINE IS IN REVERSE TURNS ON M7 SUPPLIES POWER TO BACK UP ALARM LIGHT PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING NO YES DOES THE BACK UP ALARM OR LIGHT WORK VOLTAGE NO VOLTAGE 93 ORA 93B ORA 94 YEL OR FLASHER ARE OPEN KEY ON REPLACE M7 STILL NOT WORKING REMOVE M7 AND CHECK VOLTAGE AT M7 PIN 30 FROM 92 PUR TO GROUND NO VOLTAGE VOLTAGE 92 PUR 20C BLU OR CB 4 ARE OPEN NO VOLTAGE 23C GRY IS OP...

Page 124: ... WITH THE MACHINE RUNNING AND IN REVERSE CONTINUED FROM PREVIOUS PAGE DISCONNECT INSTR PANEL WITH ENGINE RUNNING AND MACHINE IN REVERSE CHECK CONTINUITY AT INSTR PANEL CONNECTOR PIN 8 FROM 36 GRN TO GROUND WHEN MACHINE IS RUNNING CONTINUITY NO CONTINUITY YES NO DISCONNECT PANEL POWER OFF CHECK CONTINUITY OF 58 BLU REPLACE INSTR PANEL CONTINUITY OPEN REPAIR 58 BLU ...

Page 125: ...TTON IS ACTIVE IN LOW OR HIGH POSITION MACHINE IS IN SCRUB MODE DETERGENT PUMP WILL BE TURNED ON WITH A PULSE WIDTH MODULATED SIGNAL 18A ORA 87 30 5 0A M3 22 YEL 86 85 M3 CB 6 ELECTRONIC INSTRUMENT PANEL 13T BLK 13Y BLK 22 13U BLK 23 24 13S BLK IGNITION SWITCH S 3 1D RED 20 BLU 17 50 BATT 30 19 ACC CB 1 15A 1 RED 13 BLK BATTERY 1 23 GRY 19 BLU 13D BLK ...

Page 126: ...W CHART OPERATION PANEL DETERGENT BUTTON IS ACTIVE IN LOW OR HIGH POSITION MACHINE IS IN SCRUB MODE DETERGENT PUMP WILL BE TURNED ON WITH A PULSE WIDTH MODULATED SIGNAL PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING REPLACE TOUCH PANEL FACE STILL DOES NOT WORK REPLACE INST PANEL NO CAN THE DETERGENT METERING AND TOUCH PANEL SWITCHES BE TURNED ON AND OFF YES DOES THE DETERGENT METERING PUMP TURN O...

Page 127: ...RY ALTERNATOR GND OUT 1A RED STARTER RELAY M1 MTR ALTERNATOR BATTERY WARNING LIGHT STAYS ON WHEN ENGINE IS RUNNING SCHEMATIC OPERATION CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTER NATOR IS TURNED ON BATTERY POSITIVE AT PIN 14 TURNS OFF THE ALTERNATOR BATTERY INDICATOR 18A ORA 87 30 M3 22 YEL 86 85 M3 20 BLU CB 1 15A 19 BLU 1 23 GRY 13D BLK 5 0A CB 6 1E RED 13T BLK 13Y BLK 22 13U...

Page 128: ...T THE ALTERNATOR DOES THE ALTERNATOR LIGHT TURN OFF ALTERNATOR BATTERY WARNING LIGHT STAYS ON WHEN ENGINE IS RUNNING FLOW CHART OPERATION CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTER NATOR IS TURNED ON BATTERY POSITIVE AT PIN 14 TURNS OFF THE ALTERNATOR BATTERY INDICATOR ENGINE RUNNING CHECK VOLTAGE FROM L2 AT ALTERNATOR TO GROUND VOLTAGE NO VOLTAGE KEY ON ENGINE OFF YES NO TIGH...

Page 129: ... 14 TURNS OFF THE ALTERNATOR BATTERY INDICATOR 1E RED 1 RED 14 IGNITION SWITCH S 3 55A MAX CHARGE 1D RED 2 ORA L2 1B RED 12V 540 C C A ELECTRONIC INSTRUMENT PANEL 17 50 BATT 30 19 ACC START SENSE 13A BLK STARTER MOTOR 13 BLK BATTERY ALTERNATOR GND OUT 1A RED STARTER RELAY M1 MTR 18A ORA 87 30 M3 22 YEL 86 85 M3 20 BLU CB 1 15A 19 BLU 1 23 GRY 13D BLK 5 0A CB 6 1E RED 13T BLK 13Y BLK 22 13U BLK 23 ...

Page 130: ...PERATION CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTER NATOR IS TURNED ON BATTERY POSITIVE AT PIN 14 TURNS OFF THE ALTERNATOR BATTERY INDICATOR KEY ON ENGINE OFF REMOVE 2 ORA FROM ALTERNATOR PIN L2 GROUND WIRE 2 ORA DOES THE LIGHT TURN ON NO YES OPEN REPAIR AND REPLACE 2 ORA CONTINUITY REPLACE LAMP L8 INSIDE THE PANEL CHECK CONTINUITY 2 ORA FROM ALTERNATOR TO PIN 14 ...

Page 131: ...IGHT WILL NOT TURN ON OR OFF SCHEMATIC OPERATION 225 DEGREE F SE 2 80 OHMS COOLANT LIGHT TURNS ON 13T BLK 13Y BLK 22 13U BLK 23 24 13S BLK 1 RED IGNITION SWITCH S 3 1D RED 12V 540 C C A 17 50 BATT 30 19 ACC START 13 BLK BATTERY 18A ORA 87 30 M3 22 YEL 86 85 M3 20 BLU CB 1 15A 19 BLU 1 23 GRY 13D BLK 5 0A CB 6 1E RED ...

Page 132: ...E 43 BLU DOES LIGHT TURN ON YES NO WIRE 43 BLU IS OPEN FROM PIN 5 TO SE 2 IF ENGINE TEMP IS LESS THAN 225 DEGREES REPLACE SE 2 SYSTEM IS OK ENGINE TEMPERATURE LIGHT WILL NOT TURN OFF FLOW CHART OPERATION 225 DEGREE F SE 2 80 OHMS COOLANT LIGHT TURNS ON KEY ON ENGINE OFF DISCONNECT SE 2 LIGHT STILL ON LIGHT TURNS OFF POWER OFF DISCONNECT PANEL DISCONNECT SE 2 CHECK CONTINUITY 43 BLU TO GROUND OPEN ...

Page 133: ...IS AN OPTION HYDRAULIC HIGH PRESSURE INDICATOR LIGHT WILL NOT TURN ON OR OFF SCHEMATIC ELECTRONIC INSTRUMENT PANEL 13T BLK 13Y BLK 22 13U BLK 23 24 13S BLK 1 RED IGNITION SWITCH S 3 1D RED 12V 540 C C A 17 50 BATT 30 19 ACC START 13 BLK BATTERY 18A ORA 87 30 M3 22 YEL 86 85 M3 20 BLU CB 1 15A 19 BLU 1 23 GRY 13D BLK 5 0A CB 6 1E RED ...

Page 134: ... INSTR PANEL DISCONNECT S 14 AND GROUND WIRE 35 BRN DOES THE LIGHT COME ON YES NO WIRE 35 BRN IS OPEN REPLACE S 14 DISCONNECT S 14 DISCONNECT INSTR PANEL CHECK CONTINUITY 35 BRN TO GROUND OPERATION WHEN S 14 CLOSES LIGHT TURNS ON THIS LIGHT IS AN OPTION HYDRAULIC HIGH PRESSURE INDICATOR LIGHT WILL NOT TURN OFF FLOW CHART YES NO KEY ON ENGINE OFF DISCONNECT S 14 DOES LIGHT TURN OFF IF HYDRAULIC SYS...

Page 135: ...3C GRY 27 PUR 26 BRN RECOVERY TANK SOLUTION TANK S 18 N C H O S 17 N O H C N C H O 28 YEL M5 57 GRN ES PUMP 85 86 RECOVERY TANK S 8 IGNITION SWITCH S 3 13J BLK 1D RED 20 BLU ELECTRONIC INSTRUMENT PANEL 17 50 BATT 30 19 ACC START 13T BLK 13Y BLK 15 CB 1 15A 15B BLU 15 BLU 14 GRN 18A ORA 13P BLK 13B BLK S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 1 RED 13 BLK BATTERY 22 13U BLK 23 24 18A ORA 1 23 GR...

Page 136: ...IGHT WILL NOT TURN ON FLOW CHART YES NO REPLACE LAMP L1 INSIDE PANEL STILL NOT TURNING ON AT POWER UP REPLACE INSTR PANEL DISCONNECT OIL PRESSURE SWITCH S 4 GROUND WIRE 15 BLU DOES LIGHT SHUT OFF OPERATION PIN 15 IS PULLED TO GROUND WHEN OIL PRESSURE IS HIGH ENOUGH OIL LIGHT TURNS OFF ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN OFF FLOW CHART YES NO KEY ON ENGINE OFF REPLACE OIL PRESSURE LIGHT...

Page 137: ...O VAC FAN SHUT OFF 10 4 23C GRY N C H O 28 YEL M5 57 GRN ES PUMP 85 86 RECOVERY TANK S 8 IGNITION SWITCH S 3 13J BLK 1D RED 20 BLU ELECTRONIC INSTRUMENT PANEL 17 50 BATT 30 19 ACC START 13T BLK 13Y BLK 15 CB 1 15A 15B BLU 15 BLU 14 GRN 18A ORA 13P BLK 13B BLK S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 1 RED 13 BLK BATTERY 22 13U BLK 23 24 18A ORA 1 23 GRY 18A ORA 87 30 M3 22 YEL 86 85 M3 1E RED 1...

Page 138: ...O DOES THE LIGHT TURN ON MOMENTARILY AT POWER UP REPLACE LAMP L4 INSIDE THE PANEL DISCONNECT S 8 GROUND WIRE 28 YEL DOES THE LIGHT TURN ON YES NO WIRE 28 YEL IS OPEN FROM S 8 TO PANEL PIN 10 WHEN RECOVERY TANK IS FULL S 8 IS NOT CLOSING OR 13J BLK IS OPEN OPERATION IF S 8 CLOSES THE RECOVERY TANK IS FULL THE RECOVERY TANK LIGHT COMES ON SCRUB SQUEEGEE AND VACUUM FAN TURNS OFF RECOVERY TANK FULL LI...

Page 139: ...E GAS AND DIESEL SCHEMATIC 4 23C GRY M5 57 GRN ES PUMP 85 86 IGNITION SWITCH S 3 1D RED 20 BLU ELECTRONIC INSTRUMENT PANEL 17 50 BATT 30 19 ACC START 13T BLK 13Y BLK 15 CB 1 15A 15B BLU 15 BLU 14 GRN 18A ORA 13P BLK 13B BLK S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 1 RED 13 BLK BATTERY 22 13U BLK 23 24 18A ORA 1 23 GRY 18A ORA 87 30 M3 22 YEL 86 85 M3 1E RED 19 BLU 13D BLK 13S BLK 23 GRY 15 BLU ...

Page 140: ...PLACE INSTR PANEL IF GAUGE IS INACCURATE REPLACE THE FLOAT DISCONNECT 42A YEL AT SE 1 IS GAUGE FULL ON OPERATION S 6 IS NOT ON MACHINE SE 1 GREATER THE 90 OHMS FULL TANK SE 1 LESS THAN 10 OHMS EMPTY TANK FUEL GAUGE GAS AND DIESEL FLOW CHART YES NO KEY ON ENGINE OFF NO YES GAUGE STILL WAY OFF REPLACE INSTR PANEL REPLACE INSTR PANEL OPEN CONTINUITY CHECK CONTINUITY OF 42 YEL OK OPEN REPAIR 42 YEL ...

Page 141: ...BELOW 40 PSI N C H O S 6 C 4 23C GRY M5 57 GRN ES PUMP 85 86 IGNITION SWITCH S 3 1D RED 20 BLU ELECTRONIC INSTRUMENT PANEL 17 50 BATT 30 19 ACC START 13T BLK 13Y BLK 15 CB 1 15A 15B BLU 15 BLU 14 GRN 18A ORA 13P BLK 13B BLK S 4 OIL SWITCH 15A BLU FUEL PUMP 10A GRY M2 1 RED 13 BLK BATTERY 22 13U BLK 23 24 18A ORA 1 23 GRY 18A ORA 87 30 M3 22 YEL 86 85 M3 1E RED 19 BLU 13D BLK 13S BLK 23 GRY 15 BLU ...

Page 142: ...OM S 6 TO PANEL PIN 13 IF SYSTEM IS NOT WORKING PROPERLY REPLACE S 6 GROUND 42B YEL AT S 6 IS GAUGE FLASHING OPERATION S 6 IS OPEN GAUGE IS OFF S 6 IS CLOSED LEFT 2 SEGMENTS OF GAUGE FLASH SE 1 IS NOT ON MACHINE FUEL GAUGE LPG FLOW CHART YES NO KEY ON ENGINE OFF DISCONNECT S 6 IS GAUGE OFF NO YES OPEN CONTINUITY REPLACE INSTR PANEL REPAIR 42 YEL CONTINUITY OPEN REPLACE INSTR PANEL ...

Page 143: ... SLOW OR DOESN T RUN FLOW CHART 5 41 ENGINE FAN MOTOR SHAFT SEAL LEAKS FLOW CHART 5 42 MAIN BRUSH ON CIRCUIT SCHEMATIC 5 44 MAIN BRUSHES DO NOT TURN ON FLOW CHART 5 45 MAIN BRUSHES DO NOT TURN OFF FLOW CHART 5 46 Page MAIN BRUSHES DO NOT LOWER FLOW CHART 5 49 MAIN BRUSH LIFT CIRCUIT SCHEMATIC 5 50 MAIN BRUSH LOWER CIRCUIT SCHEMATIC 5 48 MAIN BRUSHES DO NOT RAISE FLOW CHART 5 51 MAIN BRUSHES DO NOT...

Page 144: ...HYDRAULICS 5 2 7400 MM428 12 98 ...

Page 145: ...HYDRAULICS 5 3 7400 MM428 12 98 INTRODUCTION The hydraulic system consists of the propel pump accessory pump control valve drive motors steering cylinder and vacuum fan motor ...

Page 146: ...ith a low level of hydraulic fluid in the reservoir Damage to the machine hydraulic system may result Drain and refill the hydraulic fluid reservoir with new hydraulic fluid every 800 hours of operation The hydraulic fluid filter is located at the bottom of the engine compartment Replace the filter element every 800 hours of operation The reservoir has a built in strainer outlet that filters hydra...

Page 147: ...he label on the hydraulic fluid reservoir ATTENTION Hydraulic components depend on system hydraulic fluid for internal lubrication Malfunctions accelerated wear and damage will result if dirt or other contaminants enter the hydraulic system HYDRAULIC HOSES Check the hydraulic hoses every 800 hours of operation for wear or damage Fluid escaping at high pressure from a very small hole can be almost ...

Page 148: ...tering spring to the propel bracket 6 Remove the spring assembly from bracket and position it up in the seat support area for disassembly access 7 Remove the ball joint and jam nuts 8 Unscrew the centering spring assembly from the directional control cable Discard the old spring NOTE The cable will have to be held to keep it from turning 9 Thread a new centering spring assembly all the way back on...

Page 149: ...front of the machine FOR SAFETY Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 15 Check neutral centering of pump by starting machine and observing front tire for any rotation If tire is rotating See TO ADJUST CENTERING SPRING instructions 16 Once the neutral centering has been set remove the jack stands lower the machin...

Page 150: ...spring assembly from the mount bracket and position it up in the seat support area for disassembly access 7 Remove the ball joint and jam nuts 8 Unscrew the centering spring assembly from the directional control cable Retain the old centering spring NOTE The cable will have to be held to keep it from turning 9 Remove the two hex screw holding the floor plate in the operators compartment Remove the...

Page 151: ... nut Tighten to 11 14 Nm 7 10 ft lb 18 Reach in through the floor plate opening and reinstall the cable ball joint in the forward reverse pedal arm Reinstall the nyloc nut and tighten to 11 14 Nm 7 10 ft lb 19 Use the large jam nut to lock the directional cable in place on the mount bracket 20 Reinstall the cable clamp that holds the directional cable to the operators compartment 21 Reinstall the ...

Page 152: ...position and engage the prop rod 4 Locate the centering spring adjustment bracket on the right side of the accessory pump Loosen the two M6 hex screws on top of the bracket 5 Loosen the two jam nuts on the hex screw that is used to move the adjustment bracket back and forth 6 Start the machine and observe the front tire for any rotation If the tire is rotating in either direction move the adjustme...

Page 153: ...directional spring bracket up far enough to allow accessory pump removal NOTE The main suction line to the accessory pump is held by plastic ties in a bundle of hoses near the main valve Remove the plastic ties to gain slack in the suction line to ease pump removal 7 The accessory pump can now be pulled out of the propel pump Do not disconnect the hydraulic hoses leading to the accessory pump 8 Ma...

Page 154: ...ocket screw Tighten to 18 24 Nm 15 20 ft lb 16 Reconnect the hydraulic hoses to the propel pump See the schematic in this section 17 Reinstall the accessory pump in the back of the propel pump Make sure the O ring is in place on the accessory pump 18 Place the directional spring bracket back on the flange of the accessory pump 19 Reinstall the two hex screws and washers Use a small amount of blue ...

Page 155: ...aulic hoses leading to the accessory pump NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 6 Remove the two hex screws holding the accessory pump to the propel pump 7 Lift the directional spring bracket up far enough to allow accessory pump removal 8 The accessory pump can now be pulled back out of the propel pump Remove the accessory pump from the machine 9 Remove the ...

Page 156: ...spring bracket 15 Reinstall the detergent tank in the seat support area 16 Reinstall the battery and reconnect the battery cables 17 Start the machine Check the accessory pump for leaks and proper operation TO REPLACE STEERING CYLINDER FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Turn the steering wheel to the left and ope...

Page 157: ...linder in the same orientation 8 Position new cylinder and balljoint assembly back in the machine with rod end pointed toward the drive motor casting 9 Reinstall the hex screw spacer and nyloc nut in the rod end of the steering cylinder and through the drive motor casting Tighten to 271 Nm 200 ft lb 10 Reinstall the hex screw and nyloc nut in the piston end of the steering cylinder and through the...

Page 158: ...6 hex screws holding the steering control valve to the steering column 4 Pull the steering valve out of the steering column and remove it from the machine 5 Remove the hydraulic fittings from old control valve and install in the new valve in the same orientation 6 Install the new steering valve back in the machine Position the ports in the same orientation as the old valve Reinstall the four M6 he...

Page 159: ...nder the vacuum fan Disconnect the 7 electrical solenoids on the main valve from the main harness 5 Mark remove and plug the hydraulic hoses leading to the main hydraulic valve NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 6 Remove the three M8 hex screws holding the main valve to the machine frame 7 The main valve can now be removed from the machine 8 Remove the hex...

Page 160: ...20 ft lb 12 Reconnect the hydraulic hoses to the main valve See schematic in this section 13 Reconnect the 7 electric solenoids to the main harness See ELECTRICAL section 14 Reinstall the LP tank 15 Reinstall the engine side door 16 Reconnect the battery cables and close the operators seat 17 Start the machine and check the main valve for any leaks ...

Page 161: ... LP gas tank cradle Disconnect the 4 electrical solenoids from the main harness 5 Mark remove and plug the hydraulic hoses leading to the side brush valve NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 6 Remove the three M8 hex screws holding the side brush valve to the LP tank cradle 7 The side brush valve can now be removed from the machine 8 Remove hydraulic fittin...

Page 162: ...e hydraulic cleanliness requirements when opening hydraulic lines 11 Reconnect the 4 electric solenoids to the main harness See ELECTRICAL section 12 Reinstall the LP tank 13 Reinstall the engine side door 14 Reconnect the battery cables and close the operators seat 15 Start the machine and check the side brush valve for any leaks ...

Page 163: ...d from the main harness 5 Remove the hex nut and rubber O ring from the cartridge stem NOTE The port marked SV 4 on the main valve and the port marked SV 10 on the side brush valve contain an extra washer on the cartridge stem between the top nut and O ring 6 Slide the electrical coil and rubber o ring off the stem NOTE Oil will run out of valve when the cartridge is removed 7 Loosen and unscrew t...

Page 164: ...hten to 170 Ncm 15 in lb 11 Reconnect the coil to the main harness See schematic in Electrical section 12 Reinstall the LP tank 13 Reinstall the engine side door 14 Reconnect the battery cables and close the operators seat 15 Start the machine and check the side brush valve for any leaks ...

Page 165: ...he fan blades and remove the four M6 hex screws holding the fan blade to the motor hub Set the fan blade down in the fan air chamber 7 Remove the 5 16 in nut and washer holding the fan blade hub to the motor shaft Remove the hub from the shaft Retain the square key from the motor shaft NOTE The fan blade hub is on a tapered shaft and may need to be pried off the motor 8 Remove the two M10 hex scre...

Page 166: ...the machine Reinstall the four M6 hex screws and tighten to 7 9 9 9 Nm 6 7 ft lb 13 Reinstall the hydraulic fittings in the fan motor in the same orientation as they were removed 14 Reconnect the hydraulic hoses to the fan motor See schematic in this section 15 Reinstall the air cleaner hose and vacuum fan hose 16 Reconnect the engine cover outer gas spring to lower ball 17 Start machine and check...

Page 167: ...ove the side squeegee 6 Remove the M12 hex screw holding the brush idler plate arm to the lift tube NOTE For better access to the hydraulic drive motors remove the C clip and brush arm from the motor plate 7 Mark disconnect and plug the three hydraulic hoses leading to the main brush drive motors NOTE Observe hydraulic cleanliness requirements when opening hydraulic lines 8 Remove the motor mount ...

Page 168: ...or shaft Put a small amount of grease on the taper of the shaft 18 Reinstall the drive plugs washers and castle nuts Hold the plug from turning and tighten the castle nut down to 37 48 Nm 26 34 ft lb and then until the slot in the nut lines up with the hole in the shaft Install a new cotter pin 19 Position the motor plate assembly back in the machine NOTE Lift up on the brush wrap slightly when in...

Page 169: ... of grease to the threads on the bolt and in the tube 25 Reinstall the front of the leveling rod ball joint to the machine frame 26 Reinstall the side squeegee assembly to the motor plate Tighten the three hex screws to 37 48 Nm 26 34 ft lb 27 Close the LH brush door and operate the machine Check the main brush motors for proper operation ...

Page 170: ...on the LH side 4 Locate the lift cylinder on the left side of the front scrub brush 5 Mark disconnect and plug the two hydraulic hoses going to the lift cylinder 6 Remove the two cotter pins and clevis pins 7 Remove the lift cylinder from the machine 8 Remove the hydraulic fittings from the lift cylinder and install in the new cylinder in the same orientation 9 Install the new cylinder in the mach...

Page 171: ... the four hex screws holding the side brush motor to the mount plate 6 Lift the motor straight up tilt back and remove it from the side brush assembly NOTE Make sure to note the orientation of the motor to the mount plate 7 Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation 8 Position the new motor back in the side brush assembly 9 Reinstall the f...

Page 172: ... and clevis pins holding the lift cylinder to the side brush assembly Remove the lift cylinder from the machine NOTE Make sure to note the orientation of the cylinder to the mount plate 6 Remove the hydraulic fittings from the old cylinder and install in the new cylinder in the same orientation 7 Position the new cylinder back in the side brush assembly 8 Reconnect the hydraulic hoses to the cylin...

Page 173: ...t assembly 5 Remove the cotter pin and clevis pin holding the other end of the swing cylinder to the machine frame 6 Pull the swing cylinder back out of the threaded sleeve and remove it from the machine 7 Remove the hydraulic fittings from the old cylinder and install in the new cylinder in the same orientation 8 Position the new cylinder back in the side brush assembly Position the rod end of th...

Page 174: ... the cotter pin and clevis pin from the rod end of lift cylinder and squeegee lift bellcrank 6 The cylinder can now be pulled up and off the pin and removed from the machine 7 Remove the hydraulic fittings from the old cylinder and install in the new cylinder in the same orientation 8 Position new cylinder back in the machine Place the hole in the piston end of the cylinder on the pin on the debri...

Page 175: ...an be re assembled correctly 4 Remove the crown nut on the impeller shaft Slide the impeller off the shaft NOTE Remove and save the key and any shims that are on the motor shaft under the impeller 5 Turn the housing over and remove the four nyloc nuts and washers from the motor mount plate Remove the motor mount plate from the housing NOTE Note the orientation of hydraulic motor and fittings for p...

Page 176: ...tall shims key fan impeller and crown nut Tighten nut to 34 47 Nm 25 35 ft lb NOTE Use a small amount of blue loctite 242 on the motor shaft threads 11 Reinstall the front housing on the rear housing Reinstall the six hex screws and tighten to 22 27 Nm 16 20 ft lb NOTE Tennant part no 57543 plastic shims must be used for proper fan to housing clearance Remove these shims after housing hardware has...

Page 177: ...HYDRAULICS 5 35 7400 MM428 6 01 A B C D E F G H I HYDRAULIC SCHEMATIC ...

Page 178: ...HYDRAULICS 5 36 7400 MM428 6 01 S 14 A B C D G H I F E HYDRAULIC SCHEMATIC ...

Page 179: ... P1 Scrub Brush Motors Steering Valve Control Valve Front Reservoir Vac Fan Wheel Drive Motor Flow Sensor Switch Cooling Fan Motor Scrub Head Lift Cylinder Rear SqueegeeLift Cylinder Pump Cooler Filter 2 3 4 5 6 7 8 9 10 1 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 1 1 1 7 HYDRAULIC HOSE GROUP ...

Page 180: ... 01 M3 G3 G1 T3 T1 M1 T4 C3 C1 C2 C4 P6 C7 C8 T2 T5 DR2 C5 C6 P5 P3 DR1 P2 M2 P1 SIDE BRUSH VALVE VACUUM FAN MOTOR MAIN CONTROL VALVE SIDE BRUSH MOTOR SIDE BRUSH LIFT CYL SIDE BRUSH SWING CYL HYDRAULIC HOSE GROUP SIDE BRUSH OPTION ...

Page 181: ...LICS 5 39 7400 MM428 12 98 TROUBLESHOOTING The following troubleshooting section is organized with the section of the hydraulic schematic pertaining to that particular problem first followed by the flow chart ...

Page 182: ...0 7400 MM428 12 98 ENGINE FAN STRAINER T E P R L RV7 1160 RV3 3 PSI RV6 85 PSI M 2400 RPM 3 7 GPM PSI ENGINE FAN CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F 400 PSI 3 7GPM x ...

Page 183: ...ET FLOW OK REPAIR OR REPLACE MOTOR REPAIR OR REPLACE STEERING CONTROL PUMP OUTLET FLOW OK PLUMBING OK REPAIR OR REPLACE PLUMBING YES NO NO REPAIR OR REPLACE PUMP ENGINE FAN SLOW OR DOESN T RUN FLOW CHART YES NO STEERING INLET PRESSURE OK NO YES ...

Page 184: ...HYDRAULICS 5 42 7400 MM428 12 98 MOTOR CASE PRESSURE OK 25 PSI REPAIR OR REPLACE MOTOR REPAIR OR REPLACE CASE DRAIN PLUMBING MOTOR YES NO ENGINE FAN MOTOR SHAFT SEAL LEAKS FLOW CHART ...

Page 185: ...HYDRAULICS 5 43 7400 MM428 12 98 ...

Page 186: ... P1 P2 G2 P7 RV3 3 PSI 8 5 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT MAIN BRUSH ON CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F x x LEVEL 1 800 PSI LEVEL 2 1000 PSI LEVEL 3 1300 PSI 8 4 GPM LEVEL 1 400 PSI LEVEL 2 550 PSI LEVEL 3 700 PSI 8 3 GPM ...

Page 187: ... OK SV1 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV1 STEM CARTRIDGE YES NO PUMP OUTLET FLOW OK MAIN BRUSHES DO NOT TURN ON FLOW CHART YES NO MOTOR INLET FLOW OK NO YES REPAIR OR REPLACE PLUMBING NO YES REPAIR OR REPLACE PUMP YES RV1 RELIEF CARTRIDGE OK 2500 PSI NO REPAIR OR REPLACE RV1 RELIEF CARTRIDGE NO ...

Page 188: ...HYDRAULICS 5 46 7400 MM428 12 98 SV1 STEM MAGNETIZED CHECK ELECTRICAL SYSTEM SV1 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV1 STEM CARTRIDGE YES NO MAIN BRUSHES DO NOT TURN OFF FLOW CHART NO ...

Page 189: ...HYDRAULICS 5 47 7400 MM428 12 98 ...

Page 190: ...2 G5 C4 C3 G4 M3 M2 T5 T2 T4 T1 M1 T3 G1 P1 P2 G2 P7 RV3 3 PSI 8 5 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT MAIN BRUSH LOWER CIRCUIT SCHEMATIC x PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F LEVEL 1 350 PSI LEVEL 2 500 PSI LEVEL 3 650 PSI ...

Page 191: ... OR REPLACE PR1 STEM CARTRIDGE C3 PORT PRESSURE OK 460 730 PSI SV5 STEM CARTRIDGE SHIFTING OK YES NO MAIN BRUSHES DO NOT LOWER FLOW CHART YES NO G5 PORT PRESSURE OK 300 PSI NO YES G4 PORT PRESSURE OK 460 730 PSI NO REPAIR OR REPLACE SV7 STEM CARTRIDGE NO YES REPAIR OR REPLACE SV5 STEM CARTRIDGE NO REPLACE SV4 STEM CARTRIDGE ...

Page 192: ...1 C2 G5 C4 C3 G4 M3 M2 T5 T2 T4 T1 M1 T3 G1 P1 P2 G2 P7 RV3 3 PSI 3 7 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT MAIN BRUSH LIFT CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F 300 PSI 1 0 GPM WHILE MOVING x 2 0 3 0 SEC ...

Page 193: ...PORT PRESSURE OK 25 PSI PLUMBING OK YES NO MAIN BRUSHES DO NOT RAISE FLOW CHART YES NO G5 PORT PRESSURE OK 300 PSI NO YES SV5 STEM CARTRIDGE SHIFTING OK NO REPLACE LIFT CYLINDER NO YES REPAIR OR REPLACE PLUMBING REPAIR OR REPLACE OR1 ORIFICE REPAIR OR REPLACE PR1 STEM CARTRIDGE NO YES REPAIR OR REPLACE SV5 STEM CARTRIDGE NO ...

Page 194: ...MAGNETIZED CHECK ELECTRICAL SYSTEM REPAIR OR REPLACE PLUMBING LIFT CYLINDER SEALS OK SV7 STEM CARTRIDGE SHIFTING SEAT OK REPAIR OR REPLACE SV7 STEM CARTRIDGE YES NO NO REPLACE LIFT CYLINDER MAIN BRUSHES DO NOT STAY UP FLOW CHART YES NO PLUMBING OK NO YES ...

Page 195: ...HYDRAULICS 5 53 7400 MM428 12 98 ...

Page 196: ...1 C2 G5 C4 C3 G4 M3 M2 T5 T2 T4 T1 M1 T3 G1 P1 P2 G2 P7 RV3 3 PSI 6 7 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT SCRUB FAN CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F 1700 PSI 6 3 GPM 11 000 1000 RPM x ...

Page 197: ...G OK SV2 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV2 STEM CARTRIDGE YES NO PUMP OUTLET FLOW OK SCRUB FAN DOES NOT TURN ON FLOW CHART YES NO MOTOR INLET FLOW OK NO YES REPAIR OR REPLACE PLUMBING NO YES REPAIR OR REPLACE PUMP YES RV2 RELIEF CARTRIDGE OK 2500 PSI NO REPAIR OR REPLACE RV2 RELIEF CARTRIDGE NO ...

Page 198: ...7400 MM428 12 98 SV2 STEM MAGNETIZED CHECK ELECTRICAL SYSTEM SV2 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV2 STEM CARTRIDGE YES NO SCRUB FAN DOES NOT TURN OFF FLOW CHART NO ROTOR SPEED 200 RPM SYSTEM NORMAL NO YES ...

Page 199: ...HYDRAULICS 5 57 7400 MM428 12 98 MOTOR CASE PRESSURE OK 25 PSI REPAIR OR REPLACE MOTOR REPAIR OR REPLACE CASE DRAIN PLUMBING MOTOR YES NO SCRUB FAN MOTOR SHAFT SEAL LEAKS FLOW CHART ...

Page 200: ... P1 P2 G2 P7 RV3 3 PSI 8 5 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT MAIN BRUSH ON CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F x x LEVEL 1 800 PSI LEVEL 2 1000 PSI LEVEL 3 1300 PSI 8 4 GPM LEVEL 1 400 PSI LEVEL 2 550 PSI LEVEL 3 700 PSI 8 3 GPM ...

Page 201: ... OK SV6 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV6 STEM CARTRIDGE YES NO PUMP OUTLET FLOW OK SIDE BRUSH DOES NOT TURN ON FLOW CHART YES NO MOTOR INLET FLOW OK NO YES REPAIR OR REPLACE PLUMBING NO YES REPAIR OR REPLACE PUMP YES RV2 RELIEF CARTRIDGE OK 2500 PSI NO REPAIR OR REPLACE RV2 RELIEF CARTRIDGE NO ...

Page 202: ...7400 MM428 12 98 SV6 STEM MAGNETIZED CHECK ELECTRICAL SYSTEM SV6 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV6 STEM CARTRIDGE YES NO SIDE BRUSH DOES NOT TURN OFF FLOW CHART NO BRUSH SPEED 10 RPM SYSTEM NORMAL NO YES ...

Page 203: ...HYDRAULICS 5 61 7400 MM428 12 98 ...

Page 204: ...2 T4 T1 M1 T3 G1 P1 P2 G2 P7 DR2 C7 C8 C5 C6 P6 P5 G6 SV09 SV11 SV08 SV10 PR2 300 PSI 100 800 PSI RV3 3 PSI SC1 8 5 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT SIDE BRUSH EXTEND CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F WITH MAIN BRUSHES ON x 300 PSI 1 0 GPM WHILE MOVING ...

Page 205: ... OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE DR2 PORT PRESSURE OK 25 PSI PLUMBING OK YES NO SIDE BRUSH DOES NOT GO OUT FLOW CHART YES NO C5 PORT PRESSURE OK 300 PSI NO YES SV9 STEM CARTRIDGE SHIFTING OK NO REPAIR CYLINDER LINKAGE OR SEALS NO YES REPAIR OR REPLACE PLUMBING NO REPAIR OR REPLACE SV9 STEM CARTRIDGE ...

Page 206: ...OES NOT GO IN FLOW CHART YES NO C5 PORT PRESSURE OK 300 PSI NO YES SV9 STEM CARTRIDGE SHIFTING OK NO REPAIR CYLINDER LINKAGE OR SEALS NO YES REPAIR OR REPLACE PLUMBING REPAIR OR REPLACE OR2 ORIFICE SC1 SHUTTLE CHECK CARTRIDGE SHIFTING OK NO YES REPAIR OR REPLACE SV9 STEM CARTRIDGE NO REPAIR OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE REPAIR OR REPLACE SHUTTLE CHECK CARTRIDGE YES NO ...

Page 207: ...HYDRAULICS 5 65 7400 MM428 12 98 ...

Page 208: ...1 P2 G2 P7 DR2 C7 C8 C5 C6 P6 P5 G6 SV09 SV11 SV08 SV10 PR2 300 PSI 100 800 PSI RV3 3 PSI SC1 8 5 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT SIDE BRUSH LOWER CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F WITH MAIN BRUSHES ON x LEVEL 1 210 PSI LEVEL 2 270 PSI LEVEL 3 320 PSI 1 0 GPM WHILE MOVING ...

Page 209: ...AGNETIZED CHECK ELECTRICAL SYSTEM REPAIR OR REPLACE PLUMBING LIFT CYLINDER SEALS OK SV11 STEM CARTRIDGE SHIFTING SEAT OK REPAIR OR REPLACE SV11 STEM CARTRIDGE YES NO NO REPLACE LIFT CYLINDER SIDE BRUSH DOES NOT STAY UP FLOW CHART YES NO PLUMBING OK NO YES ...

Page 210: ...OES NOT RAISE FLOW CHART YES NO C5 PORT PRESSURE OK 300 PSI NO YES SV8 STEM CARTRIDGE SHIFTING OK NO REPAIR LINKAGE OR REPLACE LIFT CYLINDER NO YES REPAIR OR REPLACE PLUMBING REPAIR OR REPLACE OR2 ORIFICE NO YES REPAIR OR REPLACE SV8 STEM CARTRIDGE NO SC1 SHUTTLE CHECK CARTRIDGE SHIFTING OK REPAIR OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE REPAIR OR REPLACE SHUTTLE CHECK CARTRIDGE YES NO ...

Page 211: ...R REPLACE PR2 PRESSURE CONTROL CARTRIDGE C7 PORT PRESSURE OK 200 PSI SV8 STEM CARTRIDGE SHIFTING OK YES NO SIDE BRUSH DOES NOT LOWER FLOW CHART YES NO C5 PORT PRESSURE OK 300 PSI NO YES G6 PORT PRESSURE OK 200 PSI NO REPAIR OR REPLACE SV11 STEM CARTRIDGE NO YES REPAIR OR REPLACE SV8 STEM CARTRIDGE NO REPLACE SV10 STEM CARTRIDGE ...

Page 212: ... C2 G5 C4 C3 G4 M3 M2 T5 T2 T4 T1 M1 T3 G1 P1 P2 G2 P7 RV3 3 PSI 3 7 GPM 2500 PSI 2500 PSI SV01 SV02 SV06 SV04 SV05 SV07 SV03 PR1 300 PSI S BR OPT SQUEEGEE LIFT CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F x 350 PSI 1 0 GPM WHILE MOVING ...

Page 213: ...LACE PC1 PILOT CHECK CARTRIDGE TV1 ORIFICE PLUGGED SV3 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV3 STEM CARTRIDGE YES NO LIFT CYLINDER SEALS OK SQUEEGEE DOES NOT LOWER FLOW CHART YES NO PC1 PILOT CHECK CARTRIDGE SHIFTING OK NO YES CLEAN OR REPLACE ORIFICE NO YES REPLACE LIFT CYLINDER NO ...

Page 214: ...LACE PC1 PILOT CHECK CARTRIDGE TV1 ORIFICE PLUGGED SV3 STEM CARTRIDGE SHIFTING OK REPAIR OR REPLACE SV3 STEM CARTRIDGE YES NO LIFT CYLINDER SEALS OK SQUEEGEE DOES NOT RAISE FLOW CHART YES NO PC1 PILOT CHECK CARTRIDGE SHIFTING OK NO YES CLEAN OR REPLACE ORIFICE NO YES REPLACE LIFT CYLINDER NO ...

Page 215: ...2 98 REPAIR OR REPLACE PLUMBING LIFT CYLINDER SEALS OK PC1 PILOT CHECK CARTRIDGE SHIFTING SEAT OK REPAIR OR REPLACE PC1 PILOT CHECK CARTRIDGE NO REPLACE LIFT CYLINDER SQUEEGEE DOES NOT STAY UP FLOW CHART YES NO PLUMBING OK NO YES ...

Page 216: ...E P R L RV7 1160 R F RV3 3 PSI RV5 4000 PSI RV6 85 PSI M 2400 RPM RV4 4000 PSI S 15 3 7 GPM PSI STEERING CIRCUIT SCHEMATIC PRESSURE RETURN SUCTION CASE DRAIN PRESSURE READINGS BASED ON 150 F x 750 PSI STATIONARY 850 PSI TURNING 1500 PSI HELD AT STOP ON STEERING WHEEL 3 7 GPM ...

Page 217: ...95 Eaton Medium Duty Piston Pump Repair Information Model 70142 70144 20 3 cm3 r 1 24 in3 r Displacement and 70145 23 6 cm3 r 1 44 in3 r Displacement Variable Displacement Piston Pump design code 01 02 with Valve Plate ...

Page 218: ...ess is extremely important Clean the port areas thoroughly before disconnecting the hydraulic lines Plug the pump ports and cover the open hydraulic lines immediately after they re disconnected Drain the oil and clean the exterior of the pump before making repairs Wash all metal parts in clean solvent Use compressed air to dry the parts Do not wipe them dry with paper towels or cloth The compresse...

Page 219: ...ton Pumps 23 6 cm3 r 1 44 in3 r with Gear Pump A B C D Single Pump Product Number 7 0 1 4 2 R A A 0 1 Required Tools 7 16 in Hex Key Allen 9 16 in End Wrench 1 in End Wrench 9 16 in Socket 1 2 in Socket Internal Retaining Ring Pliers straight 090 tip External Retaining Ring Pliers straight 070 tip O ring Pick Torque Wrench 135 6 N m 100 lbf ft capacity Hammer soft face Light Petroleum Jelly Seal D...

Page 220: ... assembly for rear pump of tandem Shaft assembly for single pump or front pump of tandem 50 50 1 51 51 1 1 7 7 8 8 8 8 9 10 10 9 10 10 11 11 13 13 14 15 15 16 17 17 22 23 24 25 30 29 48 12 6 Model 70142 70144 and 70145 Parts Drawing Figure 1 1 Right Side Left Side ...

Page 221: ...37 K4 4 2 1 2 2 26 26 21 20 18 19 19 1 19 19 1 18 2 27A 27B 28A 49 1 49 49 2 49 3 49 4 49 5 37 35 36 49 1 49 49 2 49 3 49 4 49 5 34 34 1 32 K2 1 K2 2 K2 3 32 K3 1 31 K3 2 33 K3 3 K3 K2 32 K4 1 K4 2 K4 3 K4 K1 1 32 K2 2 K2 3 K2 4 K1 46 46 No Groove design code 02 design code 01 design code 02 ...

Page 222: ...e for Port C 21 1 Relief Valve for Port D 22 1 Inner Race 23 1 Seal Cover 24 1 Trunnion Cover 25 1 Cover O ring 26 2 Dowel Pin 27 2 Cap Screws 5 16 18 50 8 mm 2 in Long 28 2 Cap Screws 5 16 18 63 5 mm 2 5 in Long 29 1 Key Drive Shaft 30 1 Key Camplate Trunnion 31 1 Cover Plate In K3 kit 32 1 O ring In K1 K2 K3 K4 kit 33 2 Cap Screws Cover Plate In K3 kit 34 1 Plug Assembly 34 1 1 O ring 2 21 mm Di...

Page 223: ... Dia x 468 in ID Mounting Kits K1 1 Tandem Piston Pump Mounting Kit K1 1 1 35T Coupler 36 8 mm 1 45 in long K1 2 1 O ring 1 59 mm Dia x 101 6 mm ID 0625 in Dia x 4 in ID K1 3 2 Cap Screws K1 4 2 Washer K2 1 Gear Pump Mounting Kit K2 1 1 O ring 1 59 mm Dia x 82 55 mm ID 0625 in Dia x 3 25 in ID K2 2 2 Washer K2 3 2 Cap Screws K3 1 Cover Plate Kit K3 1 1 O ring 1 59 mm Dia x 82 55 mm ID 0625 in Dia ...

Page 224: ...Flange End of Housing Figure 1 4 12 Discard the shaft seal gaskets and o rings from all assemblies Replace with new seals upon reassembly Disassembly The following instructions apply to a variable displacement piston pump with or without a gerotor charge pump A tandem pump assembly should be separated into individual pumps before disassembly 1 Position the pump into a protected jaw vise clamping o...

Page 225: ... with camplate Check all parts for proper position before proceeding 9 Clamp pump assembly in a protected jaw vise with the open end of the housing up Install gasket and two dowel pins onto housing 10 If necessary press new bearing and roll pin in backplate to dimension shown in figure 1 3 Bearing installed with the numbered end outward Roll pin installed with split oriented away from bearing 11 I...

Page 226: ... Gerotor Pocket 2 41 mm 095 in Flange Figure 1 2 Disassembly Charge Pump Adapter Assembly 1 Remove spring retainer spring and poppet from adapter assembly Inspection Inspect the charge pump relief valve seat inside the charge pump adapter Check to insure that seat is smooth and free of burrs or other defects Inspect the charge pump relief valve spring Inspect the bearing inside the charge pump ada...

Page 227: ...d the retaining ring should not be removed without compressing the spring safely The following parts are required to disassemble the piston block 2 ea 5 16 in I D x 15 16 in O D flat washers 1 ea 5 16 in x 2 7 8 in N C cap screw and 1 ea 5 16 in N C nut To remove spring place one of the flat washers over the 5 16 in x 2 7 8 in cap screw Put cap screw through the center of the piston block and appl...

Page 228: ...transmission problems Match the transmission symptoms with the problem statements and follow the action steps shown in the box diagrams This will give expedient aid in correcting minor problems eliminating unnecessary machine down time Following the fault logic diagrams are diagram action comments of the action steps shown in the diagrams Where applicable the comment number of the statement appear...

Page 229: ...vel Defective Below Level Repair or Replace Check System Pressure Reduce System Load High OK 9 Inspect Charge Relief Valve OK 11 Inspect Charge Pump 13 Inspect Motor 12 Inspect Inlet Screen or Filter Replace Clogged OK 8 Check Charge Pressure 10 Low OK OK Replace Pump Motor Inspect Dump Valve If used OK 7 Inspect Heat Exchanger By Pass Valve If used OK Defective Repair or Replace Defective Repair ...

Page 230: ...tom Operates in One Diection Only Inspect Servo Control If used OK OK OK 2 7 Defective Repair or Replace Inspect Motor 12 Replace Clogged Check Charge Pressure 10 Low OK Inspect Dump Valve If used Replace Pump Motor Defective Repair or Replace Inspect Inlet Screen or Filter OK OK OK 8 13 Defective Repair or Replace Inspect Charge Relief Valve 11 Inspect Charge Pump Defective Repair or Replace Defe...

Page 231: ...elief Valve OK 11 Inspect Charge Pump 13 Inspect Motor 12 Inspect Inlet Screen or Filter Replace Clogged OK 8 Check Charge Pressure 10 Low OK OK Replace Pump Motor Inspect Servo Control If used OK 2 Inspect Dump Valve If used OK Defective Repair or Replace Defective Repair or Replace Defective Repair or Replace Defective Repair or Replace Defective Repair or Replace High Reduce System Load Symptom...

Page 232: ...ent or broken c misadjusted damaged or broken neutral return spring 2 Inspect Servo Control Valve for if used a proper inlet pressure b misadjusted damaged or broken neutral return spring c galled or stuck control spool d galled or stuck servo piston 3 Inspect System Relief Valves for a improper pressure relief setting b damaged or broken spring c valve held off seat d damaged valve seat 4 Check O...

Page 233: ...injectors and turn the engine over for 15 seconds 5 Replace the coil wire or return the fuel flow to the injectors Place the transmission unit in the neutral position start the engine and run it at a low idle The charge pump should immediately pick up oil and fill the system If there is no indication of fill in 30 seconds stop engine and determine the cause 6 After the system starts to show signs ...

Page 234: ...18 18 Model 70142 70144 and 70145 Notes ...

Page 235: ...19 19 Model 70142 70144 and 70145 Notes ...

Page 236: ...4 Telephone 612 937 9800 Fax 612 937 7130 Hydraulics Division Eaton Ltd Glenrothes Fife Scotland KY7 4NW Telephone 44 592 771 771 Fax 44 592 773 184 Hydraulics Division Order parts from number 6 632 Parts Information booklet Each order must include the following information 1 Product and or Part Number 2 Serial Code Number 3 Part Name 4 Quantity ...

Page 237: ...No 7 118 May 1999 Char Lynn Disc Valve Motor 4000 Series Geroler Motors Std Whl and Brgl 004 Std and Whl 006 Repair Information ...

Page 238: ...oler Shaft Face Seal Bearingless Motor Mounting Flange Bearing Housing Wheel Motor Back up Washer if supplied O ring Poppet Spring Spring Sleeve Dash Pot Sleeve Dash Pot Shaft Seal Shuttle Two Way Shuttle Valve Location when Applicable Dust Seal Dust Seal Seal Guard Shaft and Bearing Kit 1 1 4 inch Straight Shaft and Bearing Kit 1 5 8 inch Tapered Shaft and Bearing Kit 1 1 4 inch 14 Tooth Splined ...

Page 239: ... Shaft seal installation tool 2 1 4 inch socket Torq wrench required for eight mounting flange screws replacement screws or 006 design No E10 The following tools are not necessary for disassembly and reassembly but are extremely helpfull Alignment studs 2 see dimensions below Available by special order contact Eaton Corp Hydraulics Division Service Dept 200 mm 8 inch Approx 13 5 6 3 25 Grind Flat ...

Page 240: ...otective device on vise such as special soft jaws pieces of hard rubber or board Although not all drawings show the motor in a vise it is recom mended that you keep the motor in the vise during disassembly Follow the clamping procedures explained throughout the manual 2 Remove 4 bolts from the valve housing 3 Lift valve housing straight up If done carefully the springs and balance ring subassembly...

Page 241: ... bearing housing 17 Remove shaft seal back up ring if used and dust seal from flange Use a small screwdiver to remove dust seal Do not damage bore of flange 16 Use a stud remover or vise grips to remove studs earlier models only Clamp bearing housing in vise as shown in Figure 7 Loosen 8 screws Remove screws washers discard washers as they are not required for reassembly and mounting flange see Fi...

Page 242: ... improperly installed shaft face seal could cause internal lubrication loss and subsequent parts wear 22 Install shaft and bearing assembly in bearing housing see Figure 12 Do not damage seal in bore of housing You may need a press to install shaft and bearing assembly 18 Remove shaft and bearing assembly You may need a press to remove shaft and bearing assembly see Figure 10 19 Remove shaft face ...

Page 243: ...Figure 13 If a press is not available use a plastic or rubber hammer to tap dust seal in place 25 Install 92 1 3 62 ID seal back up ring and shaft seal in retainer Flat or smooth side of shaft seal must face toward retainer as shown in Figure 13 Apply petroleum jelly to inside diameter of shaft seal after installing seal 26 Before installing retainer place a protective sleeve of bullet see note be...

Page 244: ...vides standard timing when pressurized as shown in Figure 17 39 Apply clean grease on balance ring assembly springs Install springs in 2 holes located inside bore face of valve housing see Figure 18 41 Apply a light film of petroleum jelly on 82 3 mm 3 24 inch I D seal Install seal in outside seal groove of valve housing 42 Apply petroleum jelly on inner and outer face seals Install seals on balan...

Page 245: ...g housing and retainer The mounting flange replaces the bearing housing see Figure 25 Follow same disassembly and reassembly procedures as rear section of standard motor Important Loctite information for bearingless motor on page 10 44 Insert your finger through port of housing Apply pressure to side of balance ring assembly Hold ring in position until valve housing is in place see Figure 21 Align...

Page 246: ... no 290 at top of threaded holes see Figure 26 Note Allow Loctite 5 minutes for thread penetration before installing motor on gear case Reassembly Figure 26 Attention Do not use more than 3 drops of Loctite on threaded portion Motors with Shuttle and or Seal Guard Piston Poppet Dash Pot Plug O ring S A 9 16 18 Torque to 41 Nm 360 lb in Lubricated Thread Enlarged Parts Drawing Plug O ring S A 9 16 ...

Page 247: ...0 9 9 205 12 5 245 15 0 310 19 0 395 24 0 495 30 0 110 6 7 625 38 0 109 1114 1115 1116 1117 1118 1119 1120 Ports 1 5 8 Inch Tapered 110 1081 1082 1083 1084 1085 1086 1087 1116 111 1033 1034 1035 1036 1037 1038 1039 1062 1 1 16 O ring Bearingless Wheel Motor 1 1 4 Inch 14 T Splined 111 1057 1 1 16 O ring 1 1 16 O ring 1 1 16 O ring 1215 1117 1063 109 1184 1185 1227 1224 1225 1189 1190 40 mm Straigh...

Page 248: ...73 184 Eaton Hydraulics Shanghai Co Ltd 388 Aidu Road Waigaogiao FTZ Pudong New Area Shanghai 200137 Peoples Republic of China Telephone 86 21 5046 0758 Fax 86 21 5046 0767 Eaton B V Boeing Avenue 11 1119 PC Schiphol Rijk The Netherlands Telephone 31 0 20 655 6776 Fax 31 0 20 655 6800 Jining Eaton Hydraulic Co Ltd 6 Ji Da Road Jining City Shandong Province 272131 Peoples Republic of China Telephon...

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Page 257: ...No 7 310 January 1995 Char Lynn Power Steering 2 Series Steering Control Unit 001 Repair Information T E L R P ...

Page 258: ...al Wear Plate Drive Gerotor Spacer Manual Steering Relief Valve O ring O ring O ring O ring Seal Ring End Cap Cap Screw 7 Plug Plug Check Ball Spring Retaining Ring Power Steering 2 Series Steering Control Units Tools Required 10 mm Socket 7 8 in Socket Torque Wrench 18 Nm 160 lb in Capacity Small Blade Screwdriver ...

Page 259: ...hown in Figure 1 2 Remove the plug and manual steering check as shown in Figure 1 Note The manual steering check may be a check ball or a check relief valve 3 Slide the spool and sleeve from the housing see Figure 2 4 Remove the thrust bearing and bearing races 5 Remove the quad seal 6 Using a small blade screwdriver carefully pry the dust seal from the housing Important Do not damage the dust sea...

Page 260: ...ers replacement parts and ordering information Important During reassembly lubricate the new seals with a petroleum jelly such as Vaseline Also lubricate machined surfaces and bearings with clean hydraulic fluid 9 Remove the retaining ring and springs Caution The centering springs are under tension Remove the retaining ring carefully 10 Install the quad seal Put one of the bearing races and sleeve...

Page 261: ...new o ring and tighten the plug to 17 Nm 150 lb in Quad Seal Figure 4 Dust Seal Thrust Bearing and Race 2 Figure 5 11 Lubricate and install the dust seal see Figure 4 for correct seal orientation 12 Install the centering springs in the spool It is best to install the two flat pieces first Next install the curved pieces three at a time 13 Fit the retaining ring over the centering springs 14 Apply a...

Page 262: ...5009 001 291 5010 001 291 5011 001 291 5012 001 291 5007 041 291 5008 041 291 5009 041 291 5010 041 291 5011 041 291 5012 041 291 5007 051 291 5008 051 291 5009 051 291 5010 051 291 5011 051 291 5012 051 291 5007 061 291 5008 061 291 5009 061 291 5010 061 291 5011 061 291 5012 061 291 5007 071 291 5008 071 291 5009 071 291 5010 071 291 5011 071 291 5012 071 291 1001 121 None 291 1002 121 291 1003 ...

Page 263: ...7 Power Steering 2 Series Steering Control Units ...

Page 264: ... 5 Quantity of Parts For More Detailed Information Contact Eaton Corp Hydraulics Division 15151 Highway 5 Eden Prairie MN 55344 Specifications and performance data Catalog No 11 872 Replacement part numbers and kit information Parts Information No 7 310 Power Steering 2 Series Steering Control Units Eaton Corporation Hydraulics Division 15151 Hwy 5 Eden Prairie MN 55344 Telephone 612 937 9800 Fax ...

Page 265: ... 15 CYLINDER HEAD 6 15 VALVE TAPPET CLEARANCE 6 15 CRANKCASE VENTILATION SYSTEM 6 15 GOVERNOR TROUBLESHOOTING 6 16 GOVERNOR 6 24 TO ADJUST GOVERNOR 6 24 DIGITAL CONTROLLER SET UP 6 25 IGNITION SYSTEM 6 26 SPARK PLUGS 6 26 TO REPLACE SPARK PLUGS 6 26 FORD DISTRIBUTORLESS IGNITION SYSTEM 6 27 SYNOPSIS 6 27 ENGINE TEMPERATURE 6 27 RUN MODE 6 28 SERVICING AND TESTING 6 28 FAILURE MODE OF DIS IGNITION ...

Page 266: ...ENGINE GAS LP 6 2 7400 MM428 12 98 ...

Page 267: ...ENGINE GAS LP 6 3 7400 MM428 12 98 INTRODUCTION This section includes repair information on the engine and related systems such as fuel electrical and drive belts ...

Page 268: ...d or block Keep the engine running while adding water Check the radiator hoses and clamps every 200 hours of operation Tighten the clamps if they are loose Replace the hoses and clamps if the hoses are cracked harden or swollen Check the radiator core exterior and hydraulic cooler fins for debris every 100 hours of operation Blow or rinse all dust which may have collected on the radiator in throug...

Page 269: ...ne reaches 5 kPa 20 in H2O and the SERVICE WHEN RED window is filled with red The indicator s red line may return to a lower reading on the scale when the engine shuts off The red line will return to a correct reading after the engine runs for a while Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element AIR FILTER...

Page 270: ...element FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water 9 After cleaning the air filter element inspect it for damage by placing a bright light inside The slightest rupture requires replacement of the filter Clean and inspect the seals on the ends of the element They should be unbroken and flexible Remember to replace the element after cleaning it ...

Page 271: ...d Check and adjust idle fuel mixture and idle speed every 100 hours of operation FOR SAFETY When Servicing Machine Keep Flames And Sparks Away From Fuel System Service Area Keep Area Well Ventilated The idle speed is controlled by a screw located on the side of the carburetor next to the throttle linkage Increase the engine speed by turning the screw clockwise Decrease the engine speed by turning ...

Page 272: ... 5 psi or greater the oil pressure switch permits an electrical current to open the fuel filter lock which allows LPG fuel to flow on to the vaporizer regulator The oil pressure switch is bypassed when the engine is being started allowing LPG fuel to flow The vaporizer section of the vaporizer regulator converts the liquid LPG fuel into a gaseous LPG fuel From the vaporizer section the gaseous LPG...

Page 273: ... sealant when reassembling Aging or high humidity does not affect this epoxy type sealant Be sure to follow application directions and apply proper torque when reconnecting fittings Never bypass safety components except to test If they are defective replace them before operating the machine Frosting does not occur before the engine reaches operating temperature Check after engine reaches operating...

Page 274: ...irt paint or other debris in the valve openings The following specific checks must also be made Filler Valve Check the valve for proper functioning and the presence of the handwheel Valve must be closed except during filling Liquid Service Valves Check the valve for proper functioning and presence of the handwheel The valve must be closed except when in service Tank Service Valve Coupling Check fo...

Page 275: ...area Do not attempt to make repairs to the tank regardless of condition Qualified personnel must make repairs or disposal The care an LPG fuel tank receives has a direct bearing on how long that tank can be used safely LPG fuel tanks must not be dropped or dragged across any surface To move LPG fuel tanks use a hand truck or roll the tank on its foot ring while it is being held in a position sligh...

Page 276: ...ings If abnormal wear is detected report the findings to the appropriate personnel TO CHANGE AN LPG FUEL TANK 1 Park the machine in a designated safe area 2 Close the tank service valve 3 Operate the engine until it stops from lack of fuel then set the machine parking brake FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 4 ...

Page 277: ...e pin locator in or out 11 Fasten the tank hold down clamp to lock the tank in position 12 Connect the LPG fuel line to the tank service coupling Make sure the service coupling is clean and free of damage Also make sure it matches the machine service coupling 13 Open the tank service valve slowly and check for leaks Close the service valve immediately if an LPG leak is found and tell the appropria...

Page 278: ...he parts and replace where needed Carefully reassemble the vaporizer regulator with the seal repair kit Check for proper operation CARBURETOR If any malfunction is found completely disassemble the carburetor Clean all the parts in alcohol Inspect all the parts and replace where needed Carefully reassemble the carburetor with the seal repair kit OIL PRESSURE SWITCH The engine oil pressure switch re...

Page 279: ...with liquid withdrawal tank Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune up engine Restricted air filter Clean or replace air filter element Vaporizer regulator out of adjustment Adjust vaporizer regulator CYLINDER HEAD A three stage torque procedure should be used when reassembling the cylinder head Tighten the cylinder ...

Page 280: ...vernor originate from the Ignition Control input leads They are the Yellow Wire 71 and the Yellow Wire 72 To test this use the governor test harness TENNANT Part No 66137 Once the harness is in place use a tach dwell meter to test for the proper RPM s and a flat ignition signal Test at the text plug at either Pin C or Pin D NOTE An inductive RPM pickup won t work for this test NOTE When checking t...

Page 281: ...e governor opens the carburetor wide open and the engine loses speed the problem is not in the governor The fuel system is at fault The purpose of the governor is to open the carburetor and to bring the engine to set RPM s depending on where you have the speed control switch set at After you have verified that the ignition system and the fuel system are not at fault go to the next step ...

Page 282: ... ORA Ground 13E BLK D I S Ignition Module 72C YEL 71C YEL 84 GRN 83 BRN ELECTRONIC GOVERNOR WIRING PICTORIAL Throttle actuator 86 PUP 85 BLU Electronic Instrument Panel A B C D E F G H A B C D E F G H A B C D E F G H TO HARNESS TO GOVERNOR TEST PLUG NOTE The wire colors of the test harness do not necessarily match the machine harness ...

Page 283: ...ts scale Then with your positive probe clamp it to battery positive Then with the negative probe move it to the above stated places on the machine The actuator is internally isolated and does not require that the cable be grounded 6 Start Up Check With the throttle switch in the engine start position turn the ignition switch to the on position The actuator should cycle the carburetor lever once NO...

Page 284: ...ontrol switch in start idle position Pin A Battery Voltage 2 Pin B 0 this is a ground Pin C Battery Voltage 2 Pin D Battery Voltage 2 Pin E Battery Voltage 2 Pin F Battery Voltage 2 Pin G Battery Voltage 2 Pin H 3 to 3 5 VDC Throttle control switch in the normal sweep position Pin G 1 VDC Pin H 7 to 9 VDC Throttle control switch in the Litter sweep position Pin G 1 VDC Pin H 1 VDC The following vo...

Page 285: ...ltage 2 Pin F 6 5 to 7 VAC Throttle control switch in the litter sweep position Pin C 1200 25 RPM Pin D 1200 25 RPM Pin E Battery Voltage 2 Pin F 7 to 7 5 VAC If you do not get these values Pin A Check battery wiring connections and also the charging system Pin B Check all grounds Pin C Check ignition system and fuel systems Pin D Check ignition system and fuel systems Pin E Possible control board...

Page 286: ...stment If all the above aspects in particular the linkage have been verified and the warmed up engine either a Hunts at running speed with the accessories off b Responds very sluggishly to switch changes an adjustment change in the control box may be necessary FOR ANALOG CONTROLLERS Cut and remove the RTV seal on the back of the box A slight adjustment of the surge screw may be necessary to correc...

Page 287: ...d in the engine will either hunt in a no load condition or over speed severely when the speed switch is actuated If too little sensitivity is adjusted in the engine will seem sluggish The engine speed will drop off when the load is increased and not recover promptly The engine speed should not drop off but you can have the three hunts of the engine If for some reason the sensitivity adjustment bec...

Page 288: ... Block machine tires before jacking machine up Jack machine up at designated locations only Block machine up with jack stands 2 Start the engine and warm to operating temperature 3 Move the speed switch to idle all accessories off 4 Move the speed switch to the fast position 5 For ANALOG CONTROLLER If engine speed surges occur turn the surge adjustment screw located on back of governor control box...

Page 289: ...ENGINE GAS LP 6 25 7400 MM428 3 02 rocker down O F F Set DIP switches according to controller label before installing controller 1 2 3 4 5 6 7 8 DIGITAL CONTROLLER SET UP ...

Page 290: ...r used should have the gaps checked and reset if necessary The proper spark plug gap is 1 mm 0 040 in TO REPLACE SPARK PLUGS FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set The Parking Brake Turn Off Machine And Remove Key 1 Open the engine cover and side door 2 Remove the spark plug wires from the four spark plugs NOTE Clean any dirt from the spark plug seat area before r...

Page 291: ...ne The degree of timing change needed is determined by electrical and vacuum input to the UESC these are The engine harness has a separate wire for the gas and another for the LPG machines Make sure you connect the correct wire for the type of fuel being used ENGINE LOAD FROM PRESSURE REDUCER Located in the intake manifold Minimum 21 KPA 6 22 Hg Maximum 101 KPA 29 91 Hg ENGINE TEMPERATURE The Engi...

Page 292: ...SERVICING 1 Every 400 hours remove the spark plugs and clean and adjust the electrode 2 Clean and visually check spark plug high tension leads and test for resistance The Ohm meter should read between 9 000 and 16 000 Ohms TESTING Secondary Coil Testing Remove the four 4 spark plug wires and measure the secondary coil resistance by placing the meter into plug wire terminal 1 4 at the coil 2 3 at t...

Page 293: ...e spark in varying degrees Under light to moderate load conditions no adverse effect will take place However run on or pre ignition may take place Term 4 10 Coolant Sensor Contrary to previous thoughts opening the lead doesn t noticeably affect the engine The timing only changes a few degrees Term 2 3 Crank Position Sensor Opening either of these leads kills the engine quickly and it will not star...

Page 294: ...Engine Coolant Sensor chart 1 2 6 7 OCT2 OCT1 6 6 68 Brown Cut and ground to set octane retard spark advance 18T Orange 12 6 Volts D C 8 9 V Batt Power Ground 16M 16I 57 13PP Black Ignition switch on 13QQ Black Batt 12 6 V DC 11 12 0 5 1 0 Ohms CDO Phase A CDO Phase B 852 71 Yellow 72 Gray 850A 852A HT HT 1 4 HT HT 2 3 Distributorless Ignition Coil 12 6 Volts D C Remove the coil connector and prob...

Page 295: ...0 281 000 10 14 158 000 168 000 0 32 95 000 105 000 10 50 58 750 68 750 20 68 37 300 47 300 30 86 24 270 34 270 40 104 16 150 26 150 50 122 10 970 20 970 60 140 7 600 17 600 70 158 5 360 15 360 80 176 3 840 13 840 90 194 2 800 12 800 100 212 2 070 12 070 110 230 1 550 11 550 120 248 1 180 11 180 130 266 930 10 930 140 284 701 10 701 150 302 550 10 550 ...

Page 296: ...ck of the alternator 5 Remove the hex screw from the top of the alternator 6 Loosen the lower hex screw and nyloc nut and push the alternator in toward the engine Remove the V belt from the alternator drive pulley 7 Remove the hex screw and nyloc nut from the bottom of the alternator Remove the alternator 8 If the new alternator does not have a drive pulley remove the hex nut and washer holding th...

Page 297: ...t Tighten the upper hex screw tight 13 Reconnect the wires to the back of the new alternator See schematic in the ELECTRICAL section 14 Reinstall the plastic belt cover to the front of the engine Hand tighten the hex screws tight 15 Reconnect the battery cables close the operators seat and start the machine 16 Check the new alternator for proper operation ...

Page 298: ...RUBBING section 5 Remove the air cleaner intake tube from the air cleaner and machine frame 6 Reach in through the left side of the engine and disconnect the battery cable and electrical wires leading to the starter 7 Reach in through the open seat support area and remove the three M10 hex screws holding the starter to the bellhousing NOTE The bottom hex screw has a nyloc nut on the starter side 8...

Page 299: ...efore Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Pivot the operators seat to the open position and engage the prop rod 2 Disconnect the battery cables and remove the battery NOTE The battery tray can also be removed for better access to the propel pump 3 Remove the detergent tank and the rubber sound flap from the machine 4 Remove the two...

Page 300: ...fan assembly can be removed for better access to the engine See TO REMOVE VACUUM FAN instructions in the SCRUBBING section NOTE The engine hood must be supported in the open position before the next step can be completed 11 Remove the clips on the bottom of the engine hood gas springs Remove the gas springs from the ball studs on the support channel 12 Remove the hex screws holding the support cha...

Page 301: ...es from the engine starter 20 Disconnect the fuel line at the fuel pump on a gas machine 21 Disconnect the fuel line from the LP tank at fuel lockoff vaporizer on an LPG machine 22 Using an overhead hoist hook a chain or strap through two or three pick up points on the engine Put a slight amount of tension on the chain 23 Remove the three M12 hex screws and nyloc nuts holding the motor mounts to t...

Page 302: ...ct the ground cable from the bellhousing to the machine frame 5 Reinstall the flow valve on the back left of the bellhousing 6 Reconnect the battery cable and electrical wires to the starter See schematic in the ELECTRICAL section 7 Reconnect the wire harness to engine components alternator governor actuator oil switch temperature sender distributor and ignition module See schematic in the ELECTRI...

Page 303: ...and vacuum housing 18 Reinstall the support channel to the tank lintel and hood lintel Reinstall the four hex screws and tighten to 18 24 Nm 15 20 ft lb 19 Reinstall the engine hood gas springs on the ball studs on the support channel Reinstall the two clips 20 Reconnect the battery cables 21 Disengage the prop rod and lower the seat 22 Reinstall the LP tank on a LPG machine 23 Jack up the front o...

Page 304: ... of the thermostat housing and slowly pull the hose off the neck 6 Keep the hose off the neck until coolant starts to flow out of the hose 7 Quickly place the hose back on the neck of the thermostat housing Re tighten the hose clamp 8 Start the machine and run it to operating temperature Shut off the engine 9 Let the machine cool down for and carefully re check the level of the radiator coolant Th...

Page 305: ...FILTER 7 4 TO REPLACE AIR FILTER ELEMENT 7 5 FUEL SYSTEM 7 6 FUEL FILTER 7 6 TO REPLACE THE FUEL FILTER CARTRIDGE 7 6 FUEL LINES 7 7 TO PRIME FUEL SYSTEM 7 7 TO REPLACE ENGINE ALTERNATOR 7 8 TO REPLACE ENGINE STARTER 7 10 TO REMOVE ENGINE 7 12 TO INSTALL ENGINE 7 14 TO PURGE AIR FROM RADIATOR 7 16 DIESEL ENGINE SERVICE MANUAL KUBOTA V1505 B E TENNANT Part Number 84660 ...

Page 306: ...ENGINE DIESEL 7 2 7400 MM428 12 98 ...

Page 307: ...ENGINE DIESEL 7 3 7400 MM428 12 98 INTRODUCTION This section includes repair information on the engine and related systems such as fuel electrical and drive belts ...

Page 308: ...or block Keep the engine running while adding water Check the radiator hoses and clamps every 200 hours of operation Tighten the clamps if they are loose Replace the hoses and clamps if the hoses are cracked harden or swollen Check the radiator core exterior and hydraulic cooler fins for debris every 100 hours of operation Blow or rinse all dust which may have collected on the radiator in through ...

Page 309: ...w is filled with red The indicator s red line may return to a lower reading on the scale when the engine shuts off The red line will return to a correct reading after the engine runs for a while Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element AIR FILTER The engine air filter housing has a dust cap and a dry c...

Page 310: ...element FOR SAFETY When Servicing Machine Wear Eye And Ear Protection When Using Pressurized Air Or Water 9 After cleaning the air filter element inspect it for damage by placing a bright light inside The slightest rupture requires replacement of the filter Clean and inspect the seals on the ends of the element They should be unbroken and flexible Remember to replace the element after cleaning it ...

Page 311: ...omize and inject proper amounts of fuel into the combustion chamber at the proper times Excess fuel is returned to the fuel tank through an overflow pipe FUEL FILTER The fuel filter cartridge filters impurities from the fuel It is located low on the left side of the engine block TO REPLACE THE FUEL FILTER CARTRIDGE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Br...

Page 312: ...NG FUEL SYSTEM Typical diesel fuel systems require priming to remove pockets of air in the fuel lines and fuel components This is usually required after running out of fuel changing fuel filter elements or repairing a fuel system component Air in the fuel system prevents smooth engine operation This fuel system however is self priming The return line comes from the top of the injector that causes ...

Page 313: ...ternator 5 Remove the hex screw from the top of the alternator 6 Loosen the lower hex screw and nyloc nut and push the alternator in toward the engine Remove the V belt from the alternator drive pulley 7 Remove the hex screw and nyloc nut from the bottom of the alternator Retain the spacer Remove the alternator 8 If the new alternator does not have a drive pulley remove the hex nut and washer hold...

Page 314: ... belt Tighten the upper hex screw tight 13 Reconnect the wires to the back of the new alternator See schematic in the ELECTRICAL section 14 Reinstall the belt cover to the front of the engine Hand tighten the hex screws tight 15 Reconnect the battery cables close the operators seat and start the machine 16 Check the new alternator for proper operation ...

Page 315: ...EMOVE VACUUM FAN instructions in the SCRUBBING section 4 Remove the air cleaner intake tube from the air cleaner and machine frame 5 Reach in through the left side of the engine and disconnect the battery cable and electrical wires leading to the starter 6 Reach in through the left side of the engine and remove the two hex screws holding the starter to the bellhousing 7 Remove the starter out thro...

Page 316: ...ir cleaner and machine frame 12 If the vacuum fan was removed reinstall See TO INSTALL VACUUM FAN instructions in the SCRUBBING section 13 Reconnect the battery cables to the battery and close the operators seat 14 Reinstall the engine side door and close the covers 15 Start the machine ...

Page 317: ...alve Remove the plastic ties to gain slack in the suction line to ease pump removal 5 Remove the two hex screws holding the hydraulic flow valve to back left of the engine mount Do not disconnect any hydraulic hoses 6 Pull the propel pump out of the bellhousing and drive coupler Do not disconnect any hydraulic hoses 7 Open the machine front cover engine cover and side door Remove the side door fro...

Page 318: ... manifold 16 Disconnect the wire harness from all of the engine components and place it out of the way 17 Disconnect the engine ground strap from frame 18 Disconnect the battery cable and electric wires from the engine starter 19 Disconnect the fuel line at the fuel filter water separator on the left side of the engine Disconnect the small fuel return line 20 Using an overhead hoist hook a chain t...

Page 319: ... 4 Reconnect the ground cable from the bellhousing to the machine frame 5 Reinstall the flow valve on the back left of the bellhousing 6 Reconnect the battery cable and electrical wires to the starter See schematic in the ELECTRICAL section 7 Reconnect the wire harness to engine components alternator governor actuator oil switch and temperature sender See schematic in the ELECTRICAL section 8 Rein...

Page 320: ...uum housing 17 Reinstall the support channel to the tank lintel and hood lintel Reinstall the four hex screws and tighten to 18 24 Nm 15 20 ft lb 18 Reinstall the engine hood gas springs on the ball studs on the support channel Reinstall the two clips 19 Reconnect the battery cables 20 Disengage the prop rod and lower the seat 21 Jack up the front of the machine and place jack stands under the fra...

Page 321: ...of the thermostat housing and slowly pull the hose off the neck 6 Keep the hose off the neck until coolant starts to flow out of the hose 7 Quickly place the hose back on the neck of the thermostat housing Re tighten the hose clamp 8 Start the machine and run it to operating temperature Shut off the engine 9 Let the machine cool down for and carefully re check the level of the radiator coolant The...

Page 322: ...ENGINE DIESEL 7 18 7400 MM428 12 98 ...

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