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FORM NO. 56043110 - Exterra™ -

ENGINE HARNESS FOR GM 1.6L GAS

ELECTRICAL SYSTEM

GASOLINE SENSOR INTERFACE

BOSCH THROTTLE

INJECTOR #1

INJECTOR #2

INJECTOR #3

INJECTOR #4

FUEL PUMP RELAY

FUEL PUMP

BATT +

GROUND

ALTERNATOR

ALTE

ALTERNATOR -

DIAGNOSTIC

CONNECTOR

CONNECTOR 1

VEHICLE INTERFACE CONNECTORS

CONNECTOR 2

EGO 2

EGO 1

ECT

BOSCH_TMAP

OIL PRESSURE SENSOR

IGNITION COIL

CRANK SENSOR

GROUND

POWERRELAY

IGNITION

STARTER RELAY

STARTER

SOLENOID

ECM

STARTER

VSW

GCP 90 WAY CONNECTOR

Содержание Exterra 56507000

Страница 1: ...10 07 revised 8 12 FORM NO 56043110 Exterra Quick Start Troubleshooting Manual Advance Models 56507000 3 cyl LPG 56507001 3 cyl Petrol 56507003 4 cyl LPG 56507004 4 cyl Petrol 56507005 4 cyl Diesel...

Страница 2: ...SYSTEM 54 61 ENGINE SPECIFICATIONS 54 55 ENGINE MAINTENANCE 55 CHECK ENGINE LIGHT TROUBLESHOOTING 56 MISCELLANEOUS ENGINE SYSTEM INFORMATION 58 GM 1 6L GASOLINE FUEL SYSTEM DESCRIPTION 58 3 CYL KUBOTA...

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

Страница 4: ...e illustration on the following page shows the location on 3 cylinder models and the bottom half shows the 4 cylinder model location Turn the valve 90 degrees this disengages the hydrostatic lock betw...

Страница 5: ...FORM NO 56043110 Exterra 5 3 CYLINDER MODELS 4 CYLINDER MODELS...

Страница 6: ...6041710 Cab Addendum Parts List 56042486 Cab Addendum Service Manual 56043118 Engine Manuals 1 6L Industrial Engine Operator Manual excerpt from 16LECSS 56041564 1 6L Industrial Engine Service Manual...

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

Страница 8: ...Side broom bristle length 6 inches 15 2cm Hopper System Capacity 14 ft3 396L Lifting capacity 1000 lbs 454kg Dump height variable Max 60 inches 152cm Dump height with door open 52 75 inches 134cm Dus...

Страница 9: ...ize English Metric 3 Cylinder models 4 Cylinder models Sound Level At operators ear 81 dBA 83 dBA Speed and Gradeability Maximum grade angle transport 20 11 25 14 Maximum grade angle sweeping 15 8 25...

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

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

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

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

Страница 14: ...B 11 Hopper Dump Door Open Close A B 12 Main Broom Raise Lower 13 Side Broom Raise Lower 14 Main Broom On Off 15 Side Broom On Off 16 Headlights Gauges and Optional Accessories example rotating beacon...

Страница 15: ...lter SVR Life 1000 Hrs L Replace 46 Steer Spindle Drive Wheel motor open operator s seat Grease Spindle Zert D L 47 Rear Tire check lug nut torque 100 FT LB 135Nm Tire Pressure 90 psi L M W 48 Gasolin...

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

Страница 17: ...rvoir 20 Oil Reservoir Fuel Tank Cover 21 Fuel Tank LPG tank shown Gasoline tank is in same location 22 Coolant Recovery Tank 3 cylinder diesel location 23 Radiator Cap 24 Engine Air Filter 3 cylinder...

Страница 18: ...n Broom Adjust Knob D Control Panel See Associated Pages E Steering Wheel F Brake Pedal Parking Brake G FWD REV Drive Pedal H Circuit Breaker Panel I Hopper Safety Support Handle J Operator Seat Adjus...

Страница 19: ...Indicator Light Diesel Only GG Engine Speed Switch HH Side Broom ON Down OFF Up Switch II Dust Control Indicator JJ Dust Control Switch KK Plugged Filter Indicator optional LL Shaker Switch MM Hopper...

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

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

Страница 22: ...leshooting check list 34 Steering System Troubleshooting guide 35 Sweep System 36 44 Main broom will not run 36 37 Side brooms will not run 38 39 Side brooms will not raise lower 40 Dust control impel...

Страница 23: ...nk Gra Wht If O V s Test for open in wiring to the K4 relay Repair wiring or replace the CB3 15A circuit breaker No Yes With key switch in start position test for 12V s the K4 neutral start relay Red...

Страница 24: ...t mode Blu Pink 12V s only engine cranking thru diode Red Yel 12V s from pink output to igniter Oil pressure S27 SW operational Engine still will not start No spark all cylinders substitute a new igni...

Страница 25: ...he engine speed switch check for continuity ribbon connector pins J3 1 J3 4 on the A2 control box assembly Ribbon pin s test open Replace the touch pad switch panel No No Repair or replace the defecti...

Страница 26: ...e if defective Repair Red Tan wire to starter relay terminal 87 With starter relay removed test for 12V the relay terminals 85 86 wire colors Blue Pink Pink Black w key in the start mode Replace the d...

Страница 27: ...ch circuit functions of start ignition terminals Repair and replace as needed the K4 relay coil test for 12v from the Gra Wht wire to Bat with key on Before testing the drive pedal sensor R2 follow th...

Страница 28: ...pump gasoline only Replace defective fuses Engine still will not start No See the 1 6L Tier 2 Engine Service Manual form PSIP6LPFI A look up the specific DTC and use the T S chart for it to fix the pr...

Страница 29: ...or missing Reference the 1 6L tier 2 engine service manual and follow the LPG system diagnosis Fuel System Checks for Gasoline Check fuel pump electrical circuit fuel pump pressure and fuel rail pres...

Страница 30: ...ctor ground input continuity pins J3 1 J3 4 If speed switch checks open or closed all the time replace the membrane switch panel assembly Does speed SW test ok No No Substitute a good known working EC...

Страница 31: ...el filter then next the fuel injection pump w engine cranking but bleed separately Does engine start With the engine cranking test for 12V the fuel pump With the engine cranking test for 12V oil press...

Страница 32: ...actuator Does engine start Check the governor magnetic pickup voltage signal w engine cranking approx 1 2 3 7 VAC If no signal substitute a good known magnetic pickup sensor Does engine run Note Test...

Страница 33: ...l box assembly Ribbon pin s test open Replace the touch pad switch panel No No Check for 12V s the A2 control box output pin J1 17 Gra Blu to Bat Grd Replace the A2 control box assembly Repair or repl...

Страница 34: ...o low for application No wheel drive in either direction Check that pump bypass valve tow valve is in correct position Check connection of foot pedal linkage cable assembly to propulsion pump arm Worn...

Страница 35: ...the steering unit that allows for manual steering if there is no hydraulic oil flow to the unit The relief valve for the steering system is located in the steering unit and is set to open at 1100 PSI...

Страница 36: ...motor will not Run 1 Complete the above operator inputs to turn on main broom motor 2 Back probe the S2 L2 main broom solenoid coil wires Vio Grn Blk should read 12V s Check S2 coil wiring continuity...

Страница 37: ...tic switch S2 must be open and also the hopper interlock switch S4 closed for the main broom system motors to run Main broom motor will not run Remove and disassemble L2 main broom motor valve cartrid...

Страница 38: ...broom motor s will not Run 1 Complete the above operator inputs to turn on side broom motor s 2 Back probe the S3 side broom solenoid coil wires Vio Brn Blk should read 12V s Check S3 coil wiring con...

Страница 39: ...the side broom s will lower automatically and turn ON rotate Note 2 By pressing the control panel side broom ON OFF switch during sweeping the side broom will be raised and turned OFF Side broom motor...

Страница 40: ...oms Press the side broom off button or raise the main broom lever to raise the side brooms Side Broom s will not Raise or Lower Mechanical Visual Checks Inspect for possible mechanical binding of Side...

Страница 41: ...c dust control motor troubleshooting section B Replace the S9 solenoid coil Replace the A2 control box assy Does the dust control motor run Ribbon pins test open replace the touch pad switch panel Rib...

Страница 42: ...speed and the dust control switch pressed activated Dust control motor will not run Remove and disassemble L4 dust control motor valve cartridge Inspect clean and reinstall Does the motor run Substit...

Страница 43: ...Does the shaker motor run Ribbon pins test open replace the touch pad switch panel Ribbon connector see Electrical System Figure 1 for detail pin call outs Check K3 relay coil wiring continuity Vio Y...

Страница 44: ...haker motor will not run Test continuity of the CB4 20A circuit breaker its wiring Repair or replace defective parts Test for 12V s the M2 shaker motor wires Blu Grn Blk Test for 12V s the K3 Vio wire...

Страница 45: ...ed Gry should read 12V s Check S5 coil wiring continuity repair if faulty Is there 12V s at the S5 coil Check S5 coil resistance Spec 9 Ohms See hydraulic hopper raise troubleshooting section B Replac...

Страница 46: ...emove and disassemble L9 hopper lower valve cartridge Inspect clean and reinstall Replace the defective L5 hopper cylinder valve cartridge Does the hopper raise No No Is the hopper over loaded Weight...

Страница 47: ...res Vio Yel Grn should read 12V s Check S9 coil wiring continuity repair if faulty Is there 12V s at the S9 coil Check S9 coil resistance Spec 9 Ohms See hydraulic hopper raise troubleshooting section...

Страница 48: ...of Hopper linkage Hopper Cylinder Remove and disassemble L9 hopper lower valve cartridge Inspect clean and reinstall Does the hopper lower Replace the defective L9 hopper cylinder valve cartridge Doe...

Страница 49: ...dump door solenoid coil wires Vio Blu Wht should read 12V s Check S1 coil wiring continuity repair if faulty Is there 12V s at the S1 coil Check S1 coil resistance Spec 9 Ohms See hydraulic hopper ra...

Страница 50: ...olenoid coil wires Vio Blk Wht should read 12V s Check S7 coil wiring continuity repair if faulty Is there 12V s at the S7 coil Check S7 coil resistance Spec 9 Ohms See hydraulic hopper raise troubles...

Страница 51: ...lose Replace the hydraulic hopper door cylinder Inspect for possible mechanical binding at Dump door hopper frame opening Dump door cylinder linkage Repair or replace damaged parts Does the door funct...

Страница 52: ...e if defective Misting Pump will not work Test continuity of the Brn Blk wire Test continuity of the S26 misting pump relay switch Does switch test good Replace the S26 misting pump relay switch Test...

Страница 53: ...eaker CB 7 10A reset or replace if defective Note 3 Check for plugged misting nozzles clean if needed Misting pump will not work Test continuity of the CB7 10A circuit breaker its wiring Repair or rep...

Страница 54: ...more detailed engine specifications and service data Kubota Operator s Manual P N 16622 8916 3 Kubota Workshop Manual P N 97897 01640 ENGINE OIL DIESEL ENGINE Engine oil should be MIL L 2104C or have...

Страница 55: ...l Gasoline 87 Octane Unleaded Gasoline with no more than 10 Ethanol by volume Fuel LP 33 Lbs Tank Size liquid withdrawal system fuel grade HD5 GPS Std Spark Plugs NGK BKR4E Gap 024 028 6 mm 7 mm Spark...

Страница 56: ...uired tool to access the DTC codes codes may be retrieved without a laptop computer using the blink code function To enable this function follow the steps below 4 Turn the ignition key to the on posit...

Страница 57: ...en Inactive 724 10 1171 LPG Pressure Higher Than Expected 520260 0 154 EGO 2 Open Inactive 520208 10 1172 LPG Pressure Lower Than Expected 520260 1 171 Adaptive Learn High Gasoline 520200 0 1173 EPR C...

Страница 58: ...PM 3 Cylinder Engine G P Speed Settings Fast Engine Speed 2800 RPM Idle Engine Speed 1500 RPM GM 1 6L GASOLINE FUEL SYSTEM DESCRIPTION This engine is equipped with a fuel injector rail that does not h...

Страница 59: ...FORM NO 56043110 Exterra 59 1 2 4 3 1 2 3 4 1 4 2 3 Coil Pack Cylinders Firing Order 1 3 4 2 FIGURE 3 FIGURE 4 ENGINE SYSTEM...

Страница 60: ...Use a digital tachometer to check and set the correct engine idle and high speed running specification Place the tachometer target tape onto the engine crankshaft pulley and aim the meter to pick up...

Страница 61: ...FORM NO 56043110 Exterra 61 E D B B A A C F G FIGURE 5 FIGURE 6 ENGINE SYSTEM...

Страница 62: ...are nominal figures and there will be variations due to manufacturer tolerances and system oil temperature If any reading varies greater than 20 there will be a noticeable loss of performance and shou...

Страница 63: ...raise time 10 11 sec Empty 2800 2875 Hopper Lift lower time 7 sec Empty 380 Steering System 4 88 2 0 2800 150 1100 Propulsion Pump Circuit for 3 cylinder models Hydrostatic pump 1 33 16 12 2800 2900...

Страница 64: ...cartridge main broom System coil 8 Ohms S3 Solenoid coil valve cartridge side broom system coil 8 Ohms S4 Solenoid coil valve cartridge dust control wand state coil 8 Ohms S5 Solenoid coil valve cartr...

Страница 65: ...System Relief Valve 2500 PSI Dust Control Valve S4 Coil Adjustment Screw Lock nut Hydraulic Manifold top and bottom views shown Top view Bottom view S4 Cartridge X7 X8 X4 X5 X3 X6 X1 S4 X2 Shown with...

Страница 66: ...speed 2400 RPM 4 cylinder models 2800 RPM 3 cylinder models Activate the hopper lift raise or lower to dead head its cylinder to place the pump circuit into an overloaded condition CAUTION Do not tes...

Страница 67: ...mbly 4 Filter Assembly 5 Drive Motor Assembly 6 Side Broom Motor Assembly 7 Side Broom Cylinder Assembly Right 8 Dust Control Motor Assembly 10 Manifold Assembly 11 Steering Cylinder Assembly 12 Hoppe...

Страница 68: ...ly 5 Side Broom Cylinder Assembly Right 6 Main Broom Motor Assembly 7 Dust Control Motor Assembly 8 Sleeve 23 In Nylon 9 Manifold Assembly 10 Steering Cylinder Assembly 11 Hopper Door Cylinder Assembl...

Страница 69: ...er Assy Left 3 Side Broom Motor Assembly 4 Valve Assembly 5 Tee Union 6 Hose Hydraulic 7 Tee Run O Ring 8 Hose Hydraulic 9 Hose Hydraulic Item Description 10 Hose Hydraulic 11 Hose Hydraulic 12 Hose H...

Страница 70: ...70 FORM NO 56043110 Exterra THIS PAGE IS INTENTIONALLY BLANK...

Страница 71: ...ol Motor Assembly 3 Filter Assembly 4 Hopper Door Cylinder 5 Hopper Lift Cylinder 6 Oil Cooler 7 Main Broom Motor Assembly 8 Manifold Assembly 9 Pump Assembly 3 cylinder pump shown 10 Reservoir Assemb...

Страница 72: ...15 125 x 1 25 SIDE BROOM LIFT 1 00 x 1 18 x 50 A B P T P T L R STEERING 4 88 CIR STEERING 1 75 x 8 5 x 75 1100 PSI MAIN BROOM SIDE BROOM DUST CONTROL DRIVE 037 S1 S3 S5 S6 S7 S8 65 PSI 25 PSI S4 A T1...

Страница 73: ...OM LIFT 1 00x1 18x 50 A B B A P T L R STEERING 4 88 CIR STEERING 1 75x8 5x 75 1100 PSI MAIN BROOM SIDE BROOM DUST CONTROL DRIVE 037 S1 S3 S5 S6 S7 S8 25 PSI A T1 B C D E F G H J L K M N T P 100 PSI 6...

Страница 74: ...20 Amp Shaker CB7 Circuit Breaker 15 Amp Turn signal optional CB8 Circuit Breaker 10 Amp Misting Kit optional CB9 Circuit Breaker 40 Amp Cab optional H1 Horn K1 Relay Horn K2 Relay Lights K3 Relay Sh...

Страница 75: ...2 3 4 S30 SWITCH FAN S30 SWITCH FAN B L M H C R3 SENDER FUEL R3 SENDER FUEL 1 2 M M6 M9 MOTOR BLOWER MOTOR M M6 M9 MOTOR BLOWER MOTOR YEL RED ORN LP10 TROUBLE LAMP OPTIONAL LP10 TROUBLE LAMP OPTIONAL...

Страница 76: ...T FROM ENGINE SYSTEM J3 1 J3 4 J3 5 J3 7 TOUCH PAD SWITCHES J4 9 J4 2 J4 10 TOUCH PAD DISPLAY J3 2 J3 3 J3 11 J3 8 J3 6 J3 10 J3 9 J4 7 J4 4 J4 3 J4 8 J2 14 J4 6 J1 9 J4 5 S3 SWITCH LOW LP PRESSURE S3...

Страница 77: ...H OIL PRESSURE S27 SWITCH OIL PRESSURE C NO NC 1 2 S7 SWITCH IGN S7 SWITCH IGN 17 19 50 30 AC D1 D1 X111 X111 D K7 COIL RELAY K7 COIL RELAY CB3 CIRCUIT BREAKER 15 AMP CB3 CIRCUIT BREAKER 15 AMP 1 2 S1...

Страница 78: ...1 FROM X140 TO SP26 A 03377 WGL F WGL 12 21 06 UPDATE VIO WIRE CONNECTION FOR MISTING PUMP OPTION UPDATE REMOVE S29 X168 BLU ORN 18 3 A 03533 WGL G WGL 4 12 07 UPDATE 1 WAS 3 AND 3 WAS 1 AT S6 A 0356...

Страница 79: ...AN BRN 16 1 GRN YEL 18 1 BLU PINK 16 1 PINK YEL 16 1 BLK RED 16 1 PINK 16 7 PINK 16 4 TAN 18 1 GRA BLU 18 1 TAN BRN 16 1 GRN YEL 18 1 BLU PINK 16 1 PINK YEL 16 1 BLK RED 16 1 PINK 16 7 PINK 16 4 WHT G...

Страница 80: ...NTO X175 A C SYSTEM CONNECT TO X204 ON SHEET 1 UNPLUG X99 FROM L5 S5 HOPPER UP DOWN VALVE AND CONNECT IT TO X208 CONNECT X207 TO L5 X194 X194 R9 R9 1 2 SP28 SP28 1 1 2 2 3 2 1 X208 CONNECT TO X99 AT L...

Страница 81: ...INJECTOR 4 FUEL PUMP RELAY FUEL PUMP BATT GROUND ALTERNATOR ALTERNATOR ALTERNATOR DIAGNOSTIC CONNECTOR CONNECTOR 1 VEHICLE INTERFACE CONNECTORS CONNECTOR 2 B L H J I E D F G A K C EGO 2 EGO 1 ECT BOSC...

Страница 82: ...WAY CONNECTOR BOSCH THROTTLE BATT GROUND ALTERNATOR ALTERNATOR ALTERNATOR DIAGNOSTIC CONNECTOR CONNECTOR 1 VEHICLE INTERFACE CONNECTORS CONNECTOR 2 N L H J I E D F G A K C EGO 2 EGO 1 ECT BOSCH_TMAP O...

Страница 83: ...FORM NO 56043110 Exterra 83 ENGINE HARNESS FOR GM 1 6L GAS Petrol Tier 3 ELECTRICAL SYSTEM...

Страница 84: ...84 FORM NO 56043110 Exterra ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1 6L LPG Tier 3...

Страница 85: ...L OUTPUT G START COMMAND F E FUEL PUMP D FUEL PUMP C ALT EXCITE B IGN SWITCH INPUT A X1 GRA BLU 18 1 TAN 18 1 S R P N M L THROTTLE INPUT K 12V FOR HIGH SPEED H G COOLANT TEMP OUTPUT F E D C B A X2 WHT...

Страница 86: ...FORM NO 56043110 Exterra 85 J1 connection J2 connection J3 11 pins Touch Pad Switches J4 9 pins Touch Pad Display Access windows J3 shown Pin 1 is labeled FIGURE 1 ELECTRICAL SYSTEM...

Страница 87: ...Pressing and releasing the engine speed switch again will increase the deadband to the maximum range The next press will return the deadband to the minimum range The service indicator will be on stea...

Страница 88: ...hold the shaker switch 3 While holding the shaker switch turn the main power key switch to the on position 4 Continue to hold the shaker switch until all indicators turn off approximately two seconds...

Страница 89: ......

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