Nilfisk-Advance Condor XL Service Manual
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Nilfisk-Advance Condor XL Service Manual

Nilfisk-Advance Condor XL Service Manual

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Condor XL
™

Service Manual

Advance Models:
56110000(LPG/48"), 56110001(Petrol/48"), 56110002(Diesel/48"), 56110003(LPG/60"),
56110004(Petrol/60"), 56110005(Diesel/60"), 56110006(LPG/62"), 56110007(Petrol/62"),
56110008(Diesel/62"), 56110009(LPG/67"), 56110010(Petrol/67"), 56110015(Diesel/67")
56111035(LPG-AXP/48"), 56111036(Petrol-AXP/48"), 56111037(Diesel-AXP/48")
56111038(LPG-AXP/60"), 56111039(Petrol-AXP/60"), 56111040(Diesel-AXP/60")
56111041(LPG-AXP/62"), 56111042(Petrol-AXP/62"), 56111043(Diesel-AXP/62")
56111044(LPG-AXP/67"), 56111045(Petrol-AXP/67"), 56111046(Diesel-AXP/67")
7/09 FORM NO. 56043124

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Summary of Contents for Nilfisk-Advance Condor XL

  • Page 1: Service Manual

    Condor XL ™ Service Manual Advance Models: 56110000(LPG/48”), 56110001(Petrol/48”), 56110002(Diesel/48”), 56110003(LPG/60”), 56110004(Petrol/60”), 56110005(Diesel/60”), 56110006(LPG/62”), 56110007(Petrol/62”), 56110008(Diesel/62”), 56110009(LPG/67”), 56110010(Petrol/67”), 56110015(Diesel/67”) 56111035(LPG-AXP/48”), 56111036(Petrol-AXP/48”), 56111037(Diesel-AXP/48”) 56111038(LPG-AXP/60”), 56111039(Petrol-AXP/60”), 56111040(Diesel-AXP/60”) 56111041(LPG-AXP/62”), 56111042(Petrol-AXP/62”), 56111043(Diesel-AXP/62”) 56111044(LPG-AXP/67”), 56111045(Petrol-AXP/67”), 56111046(Diesel-AXP/67”) 7/09 FORM NO. 56043124...

  • Page 3: Table Of Contents

    WIRING DIAGRAM ..............................94-95 WIRING SCHEMATIC ..............................96-97 ENGINE HARNESS GM 1.6L GAS ........................... 98 ENGINE HARNESS GM 1.6L LPG ........................... 99 WIRING HARNESS COMPONENT DESCRIPTION ...................... 100 SWITCH SEQUENCES FOR MAIN CONTROLLER PROGRAMMING OPTIONS ............101 FORM NO. 56043124 - Condor XL ™...

  • Page 4: Safety Instructions

    Use caution when moving this machine in below-freezing temperature conditions. Any water in the solution or recovery tanks or in the hose lines could freeze. Before use, close and latch all doors and hoods. SAVE THESE INSTRUCTIONS 4 - FORM NO. 56043124 - Condor XL ™...

  • Page 5: General Information

    Service Manual Purpose This manual is a technical resource that Nilfi sk-Advance expects to be utilized when servicing a Condor XL. It contains information deemed neces- sary to provide basic troubleshooting, maintenance and repairs within a reasonable timeframe (example - 2-3 hours). If your repair involves multiple visits to repair the same problem, or the repair cannot be completed within 3-4 hours, a call to Nilfi...

  • Page 6: Jacking The Machine

    (2-3 miles per hour) and for short distances only. If the machine is to be moved long distances, the front drive wheel needs to be raised off the fl oor and placed on a suitable transport dolly. FIGURE 2 6 - FORM NO. 56043124 - Condor XL ™...
  • Page 7  Kubota V1505TE Diesel Engine Operator Manual  (English, French, German, Italian, Spanish) ................16622-8916-3  Kubota V1505TE Diesel Engine Service Manual (English, French, German) ......97897-01640  Kubota V1505TE Diesel Engine Service Manual (English) ............97897-02432 FORM NO. 56043124 - Condor XL ™...

  • Page 8: Diagnostic And Service Tools

     These tools are also available from Nilfi sk-Advance, Inc.:  56407502 Actuator power cord adapter  56205281 Vacuum water lift gauge  56109084 PSI engine service kit (see photo)  56504450 PSI LP test kit (see photo) 8 - FORM NO. 56043124 - Condor XL ™...
  • Page 9  56305647 PSI diagnostic communication cable and software (see photo)  PSI diagnostics cable, 4-pin – 8-pin (Gen1 old style) (see photo)  56504516 Hydraulic test gauge w/con- nector 3000 psi range (see photo) FORM NO. 56043124 - Condor XL ™...

  • Page 10: Technical Specifications

    Transport ground clearance 3 inches (7.62 cm) when in transport Operator sound level @ operator ear 82.4 dBA @ 2200 RPM Vibration level @ steering wheel does not exceed .80 m/s Certifi cation 10 - FORM NO. 56043124 - Condor XL ™...
  • Page 11 FIGURE 4 FORM NO. 56043124 - Condor XL - 11 ™...
  • Page 12 ½”-13 Nyloc Hex Nut Torque to 100 ft.-lb. Torque to 375 ft.-lb. Drive Wheel Motor (lubed) or 475 ft.-lb. Spindle Nut (dry), then tighten to align cross hole. Wheel Studs Torque to 100 ft.-lb. 12 - FORM NO. 56043124 - Condor XL ™...

  • Page 13: Technical Specifications

    Standard nozzle size .015” dia. Flow volume – .033 gal/min (0.125 L/min) @ 40 psi. Dust Guard system (side broom dust control ) Optional nozzle size .026 Dia. Flow volume – .1 gal/min (.379 L/min) @ 40 psi. FORM NO. 56043124 - Condor XL - 13 ™...

  • Page 14: Maintenance

    Purge the chemical delivery lines Scrub deck skid plates Inspect for wear (replace if worn to inch Scrub brushes Rotate and flip the main scrub brushes Dust Guard Clean the dust control system spray nozzles 14 - FORM NO. 56043124 - Condor XL ™...

  • Page 15: Maintenance Schedule

    Note: The engine maintenance schedule shown lists the recommended engine service intervals. Refer to the OTHER MANUALS AVAILABLE/Engine Manuals sec- tion for list of available engine manufacturers’ service manuals. Refer to these manuals for more complete maintenance and service information and instructions. FORM NO. 56043124 - Condor XL - 15...
  • Page 16 FIGURE 6 LUBRICATION POINTS 16 - FORM NO. 56043124 - Condor XL ™...

  • Page 17: Hydraulic Oil

    If the oil buildup is signifi cant it can affect the function of the fuel control system. Note: Reference the Tier 2 PSI 1.6l PFI certifi ed engine service manual, form # PSI1P6LPFI-A, and follow the procedure to drain the EPR regulator. FORM NO. 56043124 - Condor XL - 17 ™...

  • Page 18: Engine Air Filter Maintenance

    (maximum pressure 100 psi) or wash it with water (maximum pressure 40 psi). DO NOT put the element back into the canister until it is completely dry. 18 - FORM NO. 56043124 - Condor XL ™...

  • Page 19: Maintenance

    Service Note: Follow the “To Purge Weekly” instructions above if the machine is going to be stored for an extended period of time, or if you plan to discontinue use of the detergent (AXP) system. FORM NO. 56043124 - Condor XL - 19...

  • Page 20: Pm Checklist

    Vacuum impellor motor & hose Recovery tank screen & float clean screen Recovery tank cover gasket Recovery tank drain hose & cap Squeegee pick-up hose back flush Page 1 of 2 Copyright 2009 Nilfisk-Advance 6/29/2009 20 - FORM NO. 56043124 - Condor XL ™...
  • Page 21 W worn out leaks WORK COMPLETED BY: ACKNOWLEDGED BY: Service Technician Signature Date Customer Signature Date Page 2 of 2 Copyright 2009 Nilfisk-Advance 6/29/2009 FORM NO. 56043124 - Condor XL - 21 ™...

  • Page 22: Know Your Machine

    Engine Air Filter 17 Fuel Tank Cover Engine Cover Latch 18 Operator Seat Adjustment Lever Recovery Tank Drain Hose 19 Steering Wheel 10 Recovery Tank Tilt Out Latch 20 Double Scrub Skirt Holder 22 - FORM NO. 56043124 - Condor XL ™...
  • Page 23 34 Tow Valve Lever 47 Right Scrub Skirt Retainer Knobs 35 Battery 48 Right Scrub Skirt Assembly 36 Solution Filter 49 Engine Oil Drain (under radiator) 37 Solution Tank Drain Hose FORM NO. 56043124 - Condor XL - 23 ™...

  • Page 24: Control Panel

    (scrub 3) Rate 1 Rate 2 Rate 3 press 1 time press 2 times press 3 times (scrub 1) (scrub 2) (scrub 3) press 1 time press 2 times press 3 times 24 - FORM NO. 56043124 - Condor XL ™...

  • Page 25: Control Panel Diagnostics

    High coolant temperature sensed causes and engine fault. Check for low coolant level in radiator, debris blocking airfl ow through the radiator, fan damage, loose fan belt, leaks, bad engine water pump, engine overload at high ambient temperature. FORM NO. 56043124 - Condor XL - 25 ™...
  • Page 26 The right side scrub system will shut off but the rest of the machine systems will continue to operate. 300:1 26 - FORM NO. 56043124 - Condor XL ™...

  • Page 27: Electrical System

    #2 Chemical pump M11 over current (AXP) Engine hot fault (diesel) Hydraulic oil temperature fault Low voltage fault (battery) Service engine fault GM (non critical) Low oil pressure (diesel engine) Engine fault (critical) Hydraulic filter fault (plugged) FORM NO. 56043124 - Condor XL - 27 ™...

  • Page 28: Main Control Board Fault Codes

    #1 pump wire colors (+RED/WHT and - RED/BLU), #2 (+ BLK/ YEL and - BLK/RED). Check pump motors for short circuit replace as needed. 32 NC Chemical pump #2 over current See pump #1 28 - FORM NO. 56043124 - Condor XL ™...
  • Page 29 T.S the throttle wire, then if still OV substitute a good know controller and dashboard panel. If 12V and no 2400 RPM throttle response test engine controller out put to specifi c throttle control G/LP/D. Not used FORM NO. 56043124 - Condor XL - 29 ™...
  • Page 30 Check K4 relay coil wiring for problems (+ ORN/GRN and - WHT/ORN). Check coil resistance; less than 36 ohms - replace. Also see diesel glow plug starting circuit electrical ladder detail. 30 - FORM NO. 56043124 - Condor XL ™...
  • Page 31 Sets to warn operator that oil fi lter is plugged and needs to be replaced. Note: Only activates when oil temperature is above 100 degrees F (this prevents false signal upon cold engine start up). FORM NO. 56043124 - Condor XL - 31 ™...

  • Page 32: Engine Electrical Component Locations - Gm 1.6 Gasoline

    ETC (Electronic Throttle Control) (pre CATCON) ECT (Engine Coolant Temperature) Fuel Injectors and Connectors Sensor Fuel Pump and Manifold ECM and Oil Pressure Switch Crank Position Sensor (mounted on fuel tank) 32 - FORM NO. 56043124 - Condor XL ™...

  • Page 33: Engine Electrical Component Locations - Gm 1.6 Lpg

    (mounted on EPR – LPG only) TMAP Sensor Sensor (in exhaust manifold) ECT (Engine Coolant Temperature) Sensor EPR and Fuel Lockout and Filter ECM and Oil Pressure Switch Crank Position Sensor FORM NO. 56043124 - Condor XL - 33 ™...

  • Page 34: Engine Electrical Component Locations - Kubota Diesel

    ELECTRICAL SYSTEM ENGINE ELECTRICAL COMPONENT LOCATIONS – KUBOTA DIESEL Oil Pressure Sensor (above oil fi lter) Coolant Temperature Sensor (above alternator) Governor Engine Speed Woodward Governor and Magnetic Pickup Throttle Actuator 34 - FORM NO. 56043124 - Condor XL ™...

  • Page 35: Electrical Component Locations

    ELECTRICAL SYSTEM ELECTRICAL COMPONENT LOCATIONS Extended Scrub Pump Extended Scrub Float Switch Recovery Tank Full Switch Drive Pedal Sensor FORM NO. 56043124 - Condor XL - 35 ™...

  • Page 36: Electrical Component Locations

    ELECTRICAL SYSTEM ELECTRICAL COMPONENT LOCATIONS Mist Pump (if so equipped) Solution Pump (top) and AXP Pumps Wash Pump (bottom) (behind cover panel) 36 - FORM NO. 56043124 - Condor XL ™...
  • Page 37 ELECTRICAL SYSTEM CONTROL BOARD ASSEMBLY Board Relay Start/Run Inhibit Power Relay FORM NO. 56043124 - Condor XL - 37 ™...

  • Page 38: Control Board Connectors

    Foot pedal position potentiometer (sensor wiper) J1-32 18-1 RED/YEL input S4 Hydraulic fi lter switch J1-33 18-1 BRN/BLU input S7 Extend scrub level switch J1-34 18-1 YEL/WHT output Relay PCB (ignition inhibit pin #J7-7) J1-35 Open 38 - FORM NO. 56043124 - Condor XL ™...
  • Page 39 Condor XL J2 Main Control Board Connectors Pin# Wire# Color Type Goes to J2-1 18-1 BLU/GRN - output K1 power relay coil J2-2 18-1 BLK/WHT - output S8 side sweep scrub solenoid coil J2-3 18-1 GRN/VIO - output S9 side scrub lift solenoid coil...

  • Page 40: Control Board Connectors

    M11 chemical pump 2 (AXP) J3-21 18-1 RED/BLU - output M10 chemical pump 1 (AXP) J3-22 18-1 RED/WHT + output M10 chemical pump 1 (AXP) J3-23 16-1 BLU/RED - output M8 wand pump 40 - FORM NO. 56043124 - Condor XL ™...

  • Page 41: Adjustments/Repairs

    Medium size insulated alligator clips (60 series) Small size insulated alligator clips (30 series) Normally Open snap switch part # 56385615 .250 (1/4) insulated female connectors part # 56244138 6-7/8" (175mm) 9-9/16" (243mm) FORM NO. 56043124 - Condor XL - 41 ™...

  • Page 42: Brake Tension Adjustment

    Rotary Sensor is out of the deadband due to the drive pedal being depressed. Dependable starting and responsive operation depends on the drive pedal and Piston Pump returning to a repeatable neutral position when the pedal is released. 42 - FORM NO. 56043124 - Condor XL ™...

  • Page 43: Foot Pedal/Hydroback Overview & Neutral Adjustment

    12 Turn the engine off, then see if it will restart. If engine will not start, the Rotary Sensor (F) is probably out of its neutral (deadband) range and needs to be recalibrated. See the FOOT PEDAL NEUTRAL/DEADBAND ADJUSTMENT section for programming instructions. 13 Lower the machine and reinstall the recovery tank. FIGURE 9 FORM NO. 56043124 - Condor XL - 43 ™...

  • Page 44: Push/Pull Control Cable Replacement

    Hydroback, then tighten the jam nut. 23 After installing a new Push/Pull Control Cable, set the foot pedal/Hydroback neutral position according to the instructions in the FOOT PEDAL/ HYDROBACK NEUTRAL ADJUSTMENT section. 44 - FORM NO. 56043124 - Condor XL ™...

  • Page 45: Hydroback Replacement

    Press the red Scrub Off Switch to return to the previous menu without changing the percentage value. • Turn the ignition key switch to the off position. The new settings will be saved and remain in effect until they are changed again. FORM NO. 56043124 - Condor XL - 45 ™...

  • Page 46: Side Brush Tilt Adjustment

    Turn the steering wheel all the way toward the left and right several times to make sure the Hoses are not rubbing against the surrounding components. Drive Wheel Weldment Hydraulic Hoses FIGURE 11 Bottom of Frame FIGURE 12 46 - FORM NO. 56043124 - Condor XL ™...

  • Page 47: General Machine Troubleshooting Guide Table Of Contents

    VACUUM FAN OFF AND SQUEEGEE UP ........................56 MAIN AND RIGHT SIDE SCRUB BRUSH SOLUTION VALVES AND PUMP ..............57 MAIN AND RIGHT SIDE SCRUB BRUSH(ES) DECK PRESSURE ................58 AXP PCB ASSEMBLY ..............................59 FORM NO. 56043124 - Condor XL - 47 ™...

  • Page 48: Troubleshooting Guides

    - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BAT (-) Component Current Amps Coil Ohms K1 Relay Coil .29 Amps @ 12V 46 ± 5 ohms 48 - FORM NO. 56043124 - Condor XL ™...

  • Page 49: Connector Callout - Engine Start Relay Module

     The operator control panel displays the critical fault icon 62E showing code #38. See main control board fault code table code 38 TS explana- tion and the engine section for engine code diagnostics. FORM NO. 56043124 - Condor XL - 49...
  • Page 50 RUN INHIBIT J7-4 BAT - PIN J1-10 PIN J1-31 PIN J1-11 DRIVE PEDAL SENSOR BAT - Note: See connector callout page for engine run/start relay module for more details on circuit functions. 50 - FORM NO. 56043124 - Condor XL ™...
  • Page 51 RUN INHIBIT J7-4 BAT - PIN J1-10 PIN J1-31 PIN J1-11 DRIVE PEDAL SENSOR BAT - Note: See connector callout page for engine run/start relay module for more details on circuit functions. FORM NO. 56043124 - Condor XL - 51 ™...
  • Page 52 Voltage at Voltage at Pin# Function Color 1300 RPM 2200 RPM 2400 RPM J2-30 on Driver Input from Driver Box +12 VDC J2-29 on Driver Input from Driver Box +12 VDC 52 - FORM NO. 56043124 - Condor XL ™...
  • Page 53 • Remove and inspect the magnetic speed pickup sensor for damage. When reinstalling, thread sensor in until it makes contact with the fl y wheel then back out a ½ turn. FORM NO. 56043124 - Condor XL - 53 ™...
  • Page 54 CYLINDER DOWN 12VDC TOUCH PAD YEL/BLU DASHBOARD PANEL PIN J2-4 B- OUTPUT SCRUB CYLINDER LOCK Component Current Amps Coil Ohms 2.1 Amps 2.2 ohms 1.5 Amps 8 ohms 1.5 Amps 8 ohms 54 - FORM NO. 56043124 - Condor XL ™...

  • Page 55: Main Scrub And Side Sweep/Scrub On

    B- OUTPUT TOUCH PAD MAIN SCRUB DASHBOARD PANEL BRUSH 12VDC BLK/WHT PIN J2-2 B- OUTPUT SIDE SWEEP/ RIGHT SCRUB Component Current Amps Coil Ohms 1.5 Amps 8 ohms 1.5 Amps 8 ohms FORM NO. 56043124 - Condor XL - 55 ™...

  • Page 56: Vacuum Fan On And Squeegee Down

    PIN J2-5 B- OUTPUT TOUCH PAD SQUEEGEE DASHBOARD PANEL DOWN 12VDC BRN/YEL PIN J2-8 B- OUTPUT VACUUM FAN SOLENOID Component Current Amps Coil Ohms 1.5 Amps 8 ohms 1.5 Amps 8 ohms 56 - FORM NO. 56043124 - Condor XL ™...

  • Page 57: Vacuum Fan Off And Squeegee Up

    RED/VIO KEY SWITCH DRIVER BOX 12VDC BRN/GRN PIN J2-6 B- OUTPUT SQUEEGEE UP SOLENOID TOUCH PAD DASHBOARD PANEL SQUEEGEE DOWN VACUUM FAN Component Current Amps Coil Ohms 1.5 Amps 8 ohms FORM NO. 56043124 - Condor XL - 57 ™...

  • Page 58: Main And Right Side Scrub Brush Solution Valves And Pump

    BLU/YEL PIN J2-10 B- OUTPUT RIGHT SIDE SOLUTION VALVE Component Current Amps Coil Ohms 1.5 Amps 8 ohms 1.0 Amps 12 ohms 11.5 Amps @ FLA *FLA = Full Load Amps 58 - FORM NO. 56043124 - Condor XL ™...

  • Page 59: Main And Right Side Scrub Brush(Es) Deck Pressure

    1.38 - 1.75 amps (varies with scrub setting selected) Pressure Setting L7 Coil Amp draw readings (± 10%) 1.45 to 1.75 amps (all three scrub pressure settings) *PWM = Pulse Width Modulated FORM NO. 56043124 - Condor XL - 59 ™...
  • Page 60 • Connect a hydraulic pressure gauge at the test ports TP4 & TP5 and check system operating pressures (see chart for specifi cations). • If after replacement of a valve cartridge(s) and the deck pressures still do not function correctly, replace the hydraulic lift cylinder. 60 - FORM NO. 56043124 - Condor XL ™...

  • Page 61: Axp Pcb Assembly

    B+. Measuring with a DC voltmeter will give a signal in the range of 0 to 12 volts. Changing the fl ow rate solution bars on the LCD should produce a relative increase or decrease of the meter reading. FORM NO. 56043124 - Condor XL - 61...

  • Page 62: Control Board Programming Options

    3 second power on sequence. PLACE PEDAL IN NEUTRAL Indicates that neutral position has been set. NEUTRAL SET NEUTRAL DEADBAND NEUTRAL_ DEADBAND: 2%, 3%, 4% ... 15% (2-15%, 1% increment) 2, 3, 4, ... 15 62 - FORM NO. 56043124 - Condor XL ™...
  • Page 63 NOT INSTA LLED, INSTA LLED Refers to all lights EXCEPT headlights. Headlights are standard on all models. LIGHTS LIGHTS_INSTALLED_FLG: 0 = not installed, 1 = installed NOT INSTA LLED, INSTA LLED FORM NO. 56043124 - Condor XL - 63 ™...
  • Page 64 9 - 26:1 9 - 3.8% NEUTRAL OFF DELAY 10 - LAST USED 10 - LAST USED SCRUB_OFF_DELAY: 0-30, default = 5 0.5 SE CON DS (0-3 SEC, INCREMENT= 0.5 SEC) 64 - FORM NO. 56043124 - Condor XL ™...

  • Page 65: Recovery System

    Only appears when BACKUP_ALARM_INSTALLED_FLG = 1 (from configuration menu) BACKUP_ALARM_OP_MODE: 0 = off, 1= reverse only, 2 = forward and reverse OFF, REVERSE, FORWARD & REVERSE LIGHTS LIGHTS_OP_MODE: normal, 1= always on NORMAL, ALWAYS O N FORM NO. 56043124 - Condor XL - 65 ™...
  • Page 66 LIGHTS LIGHTS_INSTALLED_FLG: 0 = not installed, 1 = installed NOT INSTALLED, INSTA LLED Restores all configuration and option values to their factory default state. RESTORE DEFAUL TS ARE YOU SURE ? 66 - FORM NO. 56043124 - Condor XL ™...

  • Page 67: Engine System

    46 gross @2800 RPM,41 Int @2400 RPM Idle Speeds Low idle 1300 RPM, High idle 2400 RPM Note: Refer to the engine manufacturer’s Operator and Service manuals for more detailed engine specifi cations and service data. FORM NO. 56043124 - Condor XL - 67 ™...

  • Page 68: Miscellaneous Engine Information

    fi lter and then enters the fuel pressure and temperature manifold assembly. Fuel fl ows through the feed circuit and is delivered to the fuel injector rail. Fuel that enters the bleed circuits through the bypass valve in the manifold is returned to the fuel tank. 68 - FORM NO. 56043124 - Condor XL ™...

  • Page 69: Engine Diagnostics

     Windows 2000 – 128 MB  Windows 98SE – 128 MB  At least one available RS232 serial or USB port. Note that the USB driver does not support Windows 98 SE. FORM NO. 56043124 - Condor XL - 69 ™...
  • Page 70 When all of the error code number sequences have been displayed, the light will blink the 1-6-5-4 sequence three times again to indicate the end of the error code number series. The light will then repeat steps a through c above. 70 - FORM NO. 56043124 - Condor XL ™...

  • Page 71: L Dtc Codes

    1628 CAN Address Confl ict Failure Oil Pressure Low 2111 Unable to Reach Lower TPS System Voltage Low 2112 Unable to Reach Higher TPS System Voltage High 2229 BP Pressure High Flash Checksum Invalid FORM NO. 56043124 - Condor XL - 71 ™...

  • Page 72: Gm 1.6L Engine Fuse Box & Wiring

    ENGINE SYSTEM 72 - FORM NO. 56043124 - Condor XL ™...

  • Page 73: Hydraulic System

    Drive Motor Ass’y Clamp, P Pump Assembly, Low Speed Elbow, 90 Bulkhead Union Valve Block Ass’y Nipple, Test Cylinder Assembly, Steer TEE, BULKHEAD RUN Scrub Lift Cyl. Ass’y Oil Cooler Ass’y FORM NO. 56043124 - Condor XL - 73 ™...

  • Page 74: Hydraulic Cylinders

    HYDRAULIC SYSTEM HYDRAULIC CYLINDERS Item Ref. No. Description 56110261 Squeegee Cylinder Ass’y 56110412 Cylinder Assembly, Steer 56110425 Scrub Lift Cylinder Ass’y 74 - FORM NO. 56043124 - Condor XL ™...

  • Page 75: Hydraulic Motors

    HYDRAULIC SYSTEM HYDRAULIC MOTORS Item Ref. No. Description 56110062 Vacuum Fan Motor Assembly 56111517 Steering Pump Assembly 56110369 Drive Motor Assembly 56110339 Main Broom Motor Assembly FORM NO. 56043124 - Condor XL - 75 ™...

  • Page 76: Hydraulic Pumps

    HYDRAULIC SYSTEM HYDRAULIC PUMPS Item Ref. No. Description 56111085 Propulsion (transport) Pump Assembly 56110372 Accessory Pump Assembly 76 - FORM NO. 56043124 - Condor XL ™...

  • Page 77: Hydraulic Valve Block/Manifold

    fi gures and there will be variations due to manufacturing tolerances and system oil temperature. If any reading varies greater than 20 percent, there will be a noticeable loss of performance and the problem should be corrected. FORM NO. 56043124 - Condor XL - 77...

  • Page 78: Test Port Nominal Pressure Readings

    Accessory Pump TP 2 TP 4 Test Ports Upper Test Port (TP 5) on the Scrub Lift Cylinder Lower Test Port (TP 4) on the Scrub Lift Cylinder TP 5 TP 4 78 - FORM NO. 56043124 - Condor XL ™...
  • Page 79 10 gallons Oil Type: 10W-30 * The bypass pressure is the pressure reading with no motor or cylinder operating (flow through). ** Scrub brush system hydraulic pressure under load setting #3 FORM NO. 56043124 - Condor XL - 79 ™...

  • Page 80: Scrub Lift Cylinder Overview

    Test Port Valve Type Current Draw Setting 333 to 346 psi Scrub 1.38 - 1.75 amps Pressure 393 to 412 psi (varies with scrub set- Down ting selected) 458 to 499 psi 80 - FORM NO. 56043124 - Condor XL ™...

  • Page 81: Hydraulic Truth Table

    Solenoid coil and valve cartridge, pressure relief, scrub brush(s), 2700 psi L8/S8 Solenoid coil and valve cartridge, right scrub/sweep system, coil 8 ohms L9/S9 Solenoid coil and valve cartridge, right scrub lift cylinder, coil 8 ohms FORM NO. 56043124 - Condor XL - 81 ™...
  • Page 82 HYDRAULIC SYSTEM 82 - FORM NO. 56043124 - Condor XL ™...
  • Page 83 HYDRAULIC SYSTEM FORM NO. 56043124 - Condor XL - 83 ™...

  • Page 84: Appendix

    PCB Assy. - 3 Ma@12V Start KEY- Digital Volt- System Volt- J1-24 Input From key switch POS Switch Check Engine Control Digital Volt- J1-25 Input Engine Module Low Switch to ground, Switch Side Output 84 - FORM NO. 56043124 - Condor XL ™...
  • Page 85 8 ohms @ 20°C Driver - 1.5A@12V Solenoid Side Scrub Solution Low Side J2-10 Solution Solenoid - Driver Solenoid 1.0A@12V Backup Elec- Low Side J2-11 Output Audible tronic Alarm Driver Alarm 0.25A@12V FORM NO. 56043124 - Condor XL - 85 ™...
  • Page 86 PWM Driver 12V, 46 LRA Side Sweep Actuator Motor Actuator H-Bridge Bridge (switching power/ground) J3-4 Output 20 ± 2FLA, - HI Driver (+) for Down, otherwise open 80LRA (Est.) (Red Lead) 86 - FORM NO. 56043124 - Condor XL ™...
  • Page 87 Pump 1(+) Driver than 10 Hz Pump Motor Wand Solu- Low Side J3-23 Output 12.5FLA@12V, tion Pump Driver 50 LRA Note: B- = Ground = 0V, B+ = system voltage = 12-15VDC FORM NO. 56043124 - Condor XL - 87 ™...

  • Page 88: Faults

    APPENDIX FAULTS 88 - FORM NO. 56043124 - Condor XL ™...

  • Page 89: Solution Flow Diagram - Standard With Right Front Scrub

    Solution Tank Solution Flow Control Valve Solution Filter Main Solution Pump (M4) Main Solution Valve (L10) *Right Solution Valve (L11) Solution Tank Drain Hose * = Only if equipped with Right Front Scrub. FORM NO. 56043124 - Condor XL - 89...

  • Page 90: Solution Flow Diagram - Accessories

    Wand Pump (M8) Mist Spray Nozzles Wash Hose Spray Gun A = Solution fl ow to the scrub deck see “Solution Flow Diagram – Standard with Right Front Scrub” for more details. 90 - FORM NO. 56043124 - Condor XL...

  • Page 91: Solution Flow Diagram - Axp

    Reducer Tee Y Barb Fitting Detergent Pumps (M10 & M11) Detergent Tank B = Location for the Right Front Scrub Tee if equipped. C = Location for the Extended Scrub Tee if equipped. FORM NO. 56043124 - Condor XL - 91...

  • Page 92: Solution Flow Diagram - Extended Scrub

    Solution Coupler Quick Disconnect Strainer Float Switch Float Wiring Quick Disconnect Recovery Tank B = Location for the Right Front Scrub Tee if equipped. D = Location for the AXP Tee if equipped. 92 - FORM NO. 56043124 - Condor XL...

  • Page 93: Hydraulic Schematic

    APPENDIX HYDRAULIC SCHEMATIC FORM NO. 56043124 - Condor XL - 93...

  • Page 94: Wiring Diagram

    2. DO NOT SCALE DRAWING. CONDOR XL W/GM ENGINE SYSTEM 3. ALL DIMENSIONS APPLY AFTER PLATING AND HEAT TREATING, BUT BEFORE PAINTING. 4. REMOVE ALL BURRS AND SHARP EDGES. DIM IN [ ] ARE MM 94 - FORM NO. 56043124 - Condor XL...

  • Page 95: Wiring Diagram

    8-18-08 3. ALL DIMENSIONS APPLY AFTER PROJ ENG PLATING AND HEAT TREATING, CONDOR XL W/KUBOTA DIESEL ENGINE SYSTEM BUT BEFORE PAINTING. APPROVED TITLE 4. REMOVE ALL BURRS AND SHARP DIAGR EDGES. APPROVED FORM NO. 56043124 - Condor XL - 95...

  • Page 96: Wiring Schematic

    ORN 18-12 4. REMOVE ALL BURRS AND SHARP EDGES. APPROVED ORN/RED 18-1 EF. LADDER DIAGRAM 56111804 DIM. IN [ ] ARE MM. APPROVED UNITS IN [ ] ARE ISO METRIC AS NOTED. 96 - FORM NO. 56043124 - Condor XL...

  • Page 97: Wiring Schematic

    ALTERNATOR ALTERNATOR GRA/BRN 18-1 RED 16-3 RED/YEL 18-7 X158 X158 SWITCH, OIL PRESSURE SWITCH, OIL PRESSURE X113 X113 X140 X140 STARTER STARTER RED 1-1 RED 6-2 BLK 1-1 BLK 4-1 X10.. X10.. FORM NO. 56043124 - Condor XL - 97...

  • Page 98: Engine Harness Gm 1.6L Gas

    STARTER SOLENOID CRANK SENSOR STARTER RELAY STARTER IGNITION POWERRELAY ALTERNATOR + BOSCH THROTTLE BATT + FUEL PUMP RELAY ALTERNATOR ALTERNATOR - GROUND FUEL PUMP INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 98 - FORM NO. 56043124 - Condor XL...

  • Page 99: Engine Harness Gm 1.6L Lpg

    OIL PRESSURE SENSOR VEHICLE INTERFACE CONNECTORS CONNECTOR 1 GROUND IGNITION COIL DIAGNOSTIC CONNECTOR STARTER SOLENOID CRANK SENSOR STARTER RELAY STARTER IGNITION POWERRELAY ALTERNATOR + BOSCH THROTTLE EPR CONNECTOR BATT + ALTERNATOR ALTERNATOR - GROUND FORM NO. 56043124 - Condor XL - 99...

  • Page 100: Wiring Harness Component Description

    BLK/GRN 18-1 DIAGNOSTIC CONNECTOR BLACK/LT GREEN 18 ANA RTN LT GREEN/RED 18 5V REF DK GREEN 18 PC TX ORANGE 18 PC RX UNUSED UNUSED BLUE/PINK 18 CAN1 + BLUE/WHITE 18 CAN1 - 100 - FORM NO. 56043124 - Condor XL...

  • Page 101: Switch Sequences For Main Controller Programming Options

    Engine Speed (51) Confi guration Display Emergency Flashers (67)  Scrub OFF Switch (55) User Options Menu  Scrub ON Switch (54)  Emergency Flashers (67) Confi guration Menu  Headlight (68) FORM NO. 56043124 - Condor XL - 101 ™...

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