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

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™
Advance Condor

Service Manual

Advance Condor XL, Condor XL AXP
™
and Condor XL EcoFlex
™
Models:
English
11/11 Form No. 56043157

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Summary of Contents for Nilfisk-Advance Condor XL

  • Page 1: Service Manual

    ™ Advance Condor Service Manual Advance Condor XL, Condor XL AXP ™ and Condor XL EcoFlex ™ Models: English 11/11 Form No. 56043157...
  • Page 2 General Information ........5 General Machine Description .
  • Page 3 Engine System, Gasoline/LPG....... 99 Functional Description ........99 Component Locations .
  • Page 4 Steering System ........202 Functional Description .

  • Page 5: General Information

    General Information The Advance Condor ™ ™ Parts List Model Instructions for Use Model Name Form Number Form Number Number Advance LPG/48” 56110000 56091002 - English 56042484 and Spanish Advance Petrol/48” 56110001 Advance Diesel/48” 56110002 Advance LPG/60” 56110003 Advance Petrol/60” 56110004 Advance Diesel/60”...
  • Page 6 General Information Parts List Model Instructions for Use Model Name Form Number Form Number Number Advance LPG X67 56381142 56091002 - English 56042484 and Spanish Advance Petrol X67 56381143 Advance Diesel X67 56381145 56111025 56091008 - English 56042494 56111026 56111027 56111028 56111029 56111030...
  • Page 7 General Information PSI engine service kit, p/n 56109084 PSI LPG test kit, p/n 56504450 Diagnostic Communication Cable and software, p/n 56305647...
  • Page 8 General Information PSI diagnostics cable, 4-pin – 8-pin (Generation 1 old style), p/n 56109083 Hydraulic test gauge w/connector 3000 psi range, p/n 56504516...
  • Page 9 General Information Nameplate Nameplate Nameplate Nameplate...
  • Page 10 General Information...
  • Page 11 General Information...
  • Page 12 General Information Tie Down/Jacking Tie Down/Jacking Location Location...
  • Page 13 General Information Engine Cover Tow Valve Lever...
  • Page 14 General Information Length Height 1.5 ft...
  • Page 15 General Information...
  • Page 16 General Information Engine speeds Transport speed reverse Size Plated Steel Stainless Steel 1/4“ 5/16” 3/8” Standard Torque 1/2” 3/4” Maintenance Maintenance Schedule...
  • Page 17 General Information ® ® Maintenance Item Procedure Engine...
  • Page 18 General Information Maintenance Item Procedure ™ ™ EcoFlex and AXP ™ Maintenance Item Procedure ™ ™ EcoFlex / AXP Cover Latch Maintenance Item Procedure Radiator and oil cooler Steering...
  • Page 19 General Information Maintenance Item Procedure connections. Maintenance Item Procedure Radiator Maintenance Item Procedure *Note: The engine maintenance schedule shown lists the recommended engine service intervals. Refer to the section for list of available engine manufacturers’ service manuals. Refer to these manuals for more complete maintenance and service information and instructions.
  • Page 20 General Information Brake Pedal Detergent (parking brake) Cover Latch Linkage (oil) (oil) Steering Rack (grease) Squeegee End Tool Wheel (oil) Fuel Tank Cover Latch (oil) Angle Squeegee Adjustment End Tool Knob Threads Wheel (oil) Recovery on Squeegee Tank Latch Mount (grease) (oil) Squeegee Caster...
  • Page 21 Advance Condor XL 48/60/62/67 and Nilfisk ER 1300/1600 PM Checklist Defect Codes Customer needs adjustment binding Address dirty or contaminated damaged, bent or torn City leaks missing Model Serial Hours W worn out Does OPERATIONAL INSPECTION ITEMS Defect Codes (circle)
  • Page 22 Dust guard spray nozzles and strainers clean Note: For additional service information see the Service Manual, form number 56042157, and Instructions for Use, form number 56091002 (Condor XL) or 56091008 (ER 1300/1600). Defect Codes needs adjustment dirty or contaminated...
  • Page 23 General Information Recovery Engine Solution Tank Cover Cover Tank Fill Cover Operator Engine Air Seat Filter Service Indicator Operator Seat Adjustment Lever Coolant Steering Wheel Tank Recovery Tank Tilt-out Engine Latch Filter Recovery Fuel Tank Tank Cover Drain Hose Latch Recovery Engine Tank Tilt-out...
  • Page 24 General Information Brake Pedal/ Parking Brake Circuit Control Breaker Panel Panel Steering Wheel Tilt Adjust Lever Drive Pedal Direction/ Speed Engine Oil Dipstick Detergent Cartridge Oil Cooler Compartment Tilt-out Latch Hydraulic OIl Reservoir Filler Cap Engine Right Tow Valve Oil Filter Scrub Lever Skirt...
  • Page 25 General Information Horn Switch Extended Detergent Scrub Switch Switch Extended Scrub Switch Horn Switch Solution Flow Increase Switch Detergent Switch Solution Switch Solution Flow Increase Switch Solution Flow Decrease Switch Wand Vacuum Switch Switch Solution Switch (optional) Solution Flow Decrease Switch Vacuum Switch Wand Switch Left...
  • Page 26 ™ Engine Speed Switch Note: The Condor XL and the ER 1300/1300 have an automatic idle feature that will reduce the engine speed to idle when the foot pedal has been in the neutral position for 20 seconds or more. The selected engine speed will automatically resume when the foot pedal is moved from neutral.
  • Page 27 General Information Extended Scrub Indicator Extended Detergent Scrub System Indicator Indicator Detergent System Indicator Solution System Solution System Indicator Indicator Vacuum System Indicator Wand Indicator Wand Vacuum Indicator System (optional) Indicator Left Right Turn Indicators Left Turn Right Turn Indicator Indicator Warning Indicator Warning...
  • Page 28 General Information Side Broom Brush/Broom Indicator Side Broom/ Emergency Brush Flasher Headlight Indicator Indicator Indicator Emergency Flasher Indicator Headlight Indicator DustGuard ™ Indicator ™ Engine Speed Indicator DustGuard™ Engine Indicator Speed Indicator...
  • Page 29 General Information Horn Switch Extended Detergent Horn Scrub Switch Switch Switch Extended Scrub Switch Solution Flow Increase Switch Detergent Switch Solution Switch Solution Flow Increase Switch Solution Flow Decrease Switch Vacuum/ EcoFlex™ Solution Switch Wand Switch Switch Solution Flow Decrease Switch EcoFlex ™...
  • Page 30 General Information Left Right Turn Signal Right Turn Left Turn Signal Signal Scrub On/Scrub Mode Select Switch Scrub On/Scrub Mode Select Switch Scrub Off Scrub On/ Scrub Off Switch Switch Scrub Mode Select Switch Side Broom Up Adjust Switch Emergency Flashers Headlight (optional)
  • Page 31 General Information Engine Speed Switch Note: The Condor XL and the ER 1300/1300 have an automatic idle feature that will reduce the engine speed to idle when the foot pedal has been in the neutral position for 20 seconds or more.
  • Page 32 General Information Left Right Turn Indicators Left Turn Right Turn Indicator Indicator Warning Indicator Warning Attention Attention Indicator Indicator Indicator (red) (yellow) Scrub Pressure Scrub Pressure Indicators 1 2 Indicators Side Broom Brush/Broom Side Broom/ Emergency Indicator Brush Flasher Headlight Indicator Indicator Indicator...
  • Page 33 General Information Hour Dilution Fuel Meter Ratio Gauge ™ ™ ™ Extended Scrub Indicator (optional) Attention Indicator Icon Condition Display Icon indicator and icon.
  • Page 34 General Information Icon Condition Display Icon Start Control Controller Non-critical Warning Indicator Icon Condition Display Icon Engaged...
  • Page 35 General Information Icon Condition Display Icon Engine Service Controller Critical section exceeded an average operating Engine Coolant...
  • Page 36 Front Hood Rear Cover Assembly Floor Weldment Cover Support Assembly Front Floor Tank Chassis Heavy Weldment Bumper Assembly...
  • Page 37 Rear Cover Rear Grille Latch Handle Latch Cover Support Weldment Heavy Bumper Weldment...
  • Page 38 Overview The Control System includes the Driver Box (main controller) and the Dashboard Panel. The Dashboard Panel communicates with the Driver Box via a CAN Bus. The Driver Box controls the machine electrical and hydraulic systems by actuating the appropriate pumps and solenoid valves to perform the required scrubbing, sweeping and drive functions.
  • Page 39 Dashboard Panel Driver Main Control Board Connector J3 Main Control Board Connector J2 Main Control Board Connector J1 Relay PCB Start/Run Inhibit K1 Power Relay...
  • Page 40 Pin# Wire# Color Type Goes To J1-1 18-1 Input Engine control module output J1-2 20-1 BLK/YEL -CANbus User interface panel (membrane switches) J1-3 20-1 ORN/BLK +CANbus User interface panel (membrane switches) J1-4 Open J1-5 18-3 Input Seat Switch (EcoFlex ™ only) J1-6 Open...
  • Page 41 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 J2-4 18-1 YEL/BLU - Output S6 scrub cylinder lock solenoid coil J2-5...
  • Page 42 Pin# Wire# Color Type Goes to J3-1 16-2 GRA/RED + Input CB1 Circuit Breaker, 20A J3-2 16-1 GRN/BLU - Output M4 solution pump J3-3 Open J3-4 16-1 BLU/BRN Output M7 side broom actuator extend (red wire) J3-5 16-1 WHT/RED Output M7 side broom actuator retract (black wire) J3-6 Open...
  • Page 43 Factory Default: 3% Range: 2% - 15% Whenever you change or repair the drive pedal linkage components or the hydrostatic unit, or if you replace the Rotary Sensor or Control Board (Driver Box), you will have to recalibrate the neutral deadband position and set the sensitivity as follows: Depress the foot pedal to the full reverse position, then allow the pedal to slowly return to its neutral position.
  • Page 44 Press the red Scrub Off switch to return to the previous menu without changing the percentage value. Turn the Key Switch to the off position. The new settings will be saved and remain in effect until they are changed again. PEDAL CALIBRATION Press and hold the Engine Speed switch, then turn the key switch on.
  • Page 45 Press and hold the Emergency Flashers switch, then turn the key switch CONFIGURATION DISPLAY on. Configuration display only – no changes to configuration allowed. Fault Codes Will be displayed if there are no No Stored Codes stored fault codes. Stored fault codes are displayed in a list. Display View Fault Codes format: XX (two-digit error code) and brief description.
  • Page 46 CONFIGURATION DISPLAY (continued) Signal Lights Installed / Not Installed Display Screen US Display / Global Display Operator Presence On / Off Pressing a control panel switch will light the corresponding LED User Interface Test indicator to confirm that the switch and indicator are working correctly. Turn the key switch off to exit the User Interface Test.
  • Page 48 USER OPTIONS MENU (continued) Recovery System Squeegee Up Delay Selects the squeegee up delay time – 5 - 30 seconds 5 to 30 seconds in 1-second increments. Vacuum Off Delay Selects the vacuum off delay time – 10 - 30 seconds 10 to 30 seconds in 1-second increments.
  • Page 49 USER OPTIONS MENU (continued) Appears only when the Side Sweep Side Sweep System system is installed. Dust Guard Start Up Last State Appears only when the Extended Scrub Extended Scrub System system is installed. Start Up State Last State Operating Mode Use Anytime Use Clean First Engine Idle Delay...
  • Page 50 Press and hold the Emergency Flashers and Headlight switches. Turn the ignition Key Switch to the run (on) position. Continue to hold the Emergency Flashers and Headlight switches until all the display panel lights turn off (approximately three seconds), then release the CONFIGURATION MENU Press the Side Broom Up and Side Broom Down switches to scroll through the When the arrow is pointing to the desired menu item, press the green Scrub On switch to...
  • Page 51 Press and hold the Emergency Flashers and Headlight switches, then CONFIGURATION MENU turn the key switch on. Engine Type Undefined Diesel Propane Detergent System Installed? Not Installed Installed Display Format Ratio Percentage EcoFlex System Not Installed Installed Side Scrub System Not Installed Installed Side Sweep System...
  • Page 52 CONFIGURATION MENU (continued) Extended Scrub System Not Installed Installed Back-up Alarm Not Installed Installed Signal Lights Not Installed Installed Display Screen US Display Global Display Operator Presence Restore Defaults Press the Scrub On switch to restore the Are You Sure? default settings.
  • Page 53 The newer machines have an Operator Presence Control (OPC) feature that works in conjunction with the OPC On When the OPC is enabled, the machine functions as follows: When the seat switch is closed (Operator in the seat): – The machine systems operate normally. –...
  • Page 54 – If the Recovery system is On, it transitions to the Wand mode. – Pressing the Scrub Off switch turns the Scrub system off. – Pressing the Scrub On switch has no effect. – Pressing the Wand/Vacuum switch with the Scrub system off transitions the Recovery system between Off and the Wand modes.
  • Page 55 Code# Fault Description Correction Check for 12V (+) from controller wire J2-29 (GRA/ORN) to battery ground (-) with the engine speed switch 51 active. Should read 12V. If 0V, troubleshoot the throttle wire. If still 0V, substitute a 05 C 2200 RPM no input @ ECM good known controller and dashboard panel.
  • Page 56 Code# Fault Description Correction Check K4 relay coil wiring for problems (+ ORN/GRN and - WHT/ORN). Glow plug relay K4 coil over 14 NC current. Check coil resistance. If less than 36 ohms, replace. Also see diesel glow plug starting circuit electrical ladder detail. Check L6 solenoid coil wiring for problems (+ ORN and - YEL/BLU).
  • Page 57 Code# Fault Description Correction Control board has sensed open circuit fault for CB3 power 15A Circuit breaker CB3 over 27 C for side broom actuator motor (M7). Check for Violet wire current shorted to ground. Control board has sensed open circuit fault for CB4 power 20A Circuit breaker CB4 over 28 C for hydraulic solenoid manifold coils (L4 - L11).
  • Page 58 The following table lists the systems that are disabled for each displayed fault code. Note: “X” indicates that the corresponding machine system is disabled (turned off). Fault Description Solution pump(s) M4 and M6 over current Scrub brush pressure valve solenoids over current (L5 and L7) Main power relay K1 over current Wash hose pump M8 over current DustGuard...
  • Page 59 Fault Description 20A circuit breaker CB1 over current 20A circuit breaker CB2 over current 15A circuit breaker CB3 over current 20A circuit breaker CB4 over current 10A circuit breaker CB5 over current Side sweep lift M7 actuator over current #1 detergent pump M10 over current #2 detergent pump M11 over current Engine hot fault (diesel) Hydraulic oil temperature fault...
  • Page 60 Overview The electrical system consists of the fuse, relay and circuit breakers not covered in the section or the other manual sections. K1 POWER RELAY ON POWER RELAY FUSE 100A RED/VIO SUPPLY + + + + + + + + + + + + + + + + +...
  • Page 61 is mounted inside K1 Power Relay the control board assembly. Note that a second identical power relay (K4) is installed on diesel models as the glow plug power relay. K1 Power Relay are mounted on the control board to Circuit Breakers the left of the Operator position.
  • Page 62 is tied up with the engine harness connectors 100-amp Fuse F1 and can be accessed by tipping out the recovery tank. 100-amp Fuse F1 Problem Cause Correction No power to the The 100-amp fuse Replace the fuse. machine open. No machine Main power relay K1 coil Check K1 relay coil wiring for problems (+ ORN/ systems will operate...
  • Page 63 Problem Cause Correction Fault code Left stop lamp over current Check left stop lamp wiring for problems (+ ORN/ displayed BRN and - BLK). Check lamps for short (see the I/O table for circuit spec). Fault code Right stop lamp over current Same as left stop lamp just different wire color displayed (+ YEL/RED and - BLK).
  • Page 64 Component Current – 0.29 Amps @ 12V K1 and K4 Relays Nominal Coil Resistance – 46 ± 5 ohms Pin# Color Type Voltage Pin Description and Function J7-1 VIO/GRA Input Module relays load power supply J7-2 BLU/PINK Output Engine ECU starter relay command J7-3 WHT/BRN Input...
  • Page 78 Shop measurement values can help you recognize “normal” values. The values in the table were measured on one propane engine model with the black voltmeter lead connected to battery negative and everything connected. The model had a right side scrub option with no side sweep. Wire Color Pin Assignment “Real World”...
  • Page 88 Overview ENGINE START/RUN RELAY PCB J7 for Diesel Battery (+) From F1 Fuse 100A & CB6 15A BLU/PINK + + + + + + + + + + + + START + + + + + + STARTER + + + + + + PINK J7-1 + + +...
  • Page 89 – The Key Switch S1 Glow Plug Relay K4 Relay Start Relay Run Relay – The Start_Inhibit Driver Box J1-22 – Drive Pedal Sensor – The Ignition_Inhibit Driver Box J1-34 – The Oil Pressure Switch S28 – The Coolant Temperature Switch S9 J1-25 Driver Box...
  • Page 90 Oil Pressure Sensor Engine Ground Connection Coolant Temperature Sensor X1 and X2 Electrical Connectors Governor Engine Speed Woodward Governor and Magnetic Pickup Throttle Actuator...
  • Page 91 * Important: Diesel Lubricating Oil Note Temperature Range Oil Weight Above 77 °F (25 °C) SAE 30 or 10W-30 32 °F to 77 °F (0 °C to 25 °C) SAE 20 or 10W-30 Below 32 °F (0 °C) SAE 10W or 10W-30 * Diesel Lubricating Oil Note: Low sulfur Fuel...
  • Page 92 Compressed Air Supply Line Compressed Air Gauge Supply Line Coolant Supply Line Switch Coolant Valve Coolant Valve Air Switch Venturi Tube Assembly Coolant Supply Venturi Line Tube Assembly Gauge Removing the Air from the Cooling System with Cooling System Tool Air Switch Gauge Coolant Valve...
  • Page 93 Engine Air Filter Service Indicator Do not Problem Cause Correction The yellow attention Glow plug relay K4 coil Check K4 relay coil wiring for problems (+ ORN/ light and glow plug over current (fault code 14 GRN and - WHT/ORN). display icon will not displayed on the LCD) Check coil resistance.
  • Page 94 – –...
  • Page 95 + + + + + + + + + + + + + + + + + + DRIVER BOX +12V (Engine Run Signal) FUEL RAIL & SHUT PIN J1-1 DOWN ACTUATOR PIN J2-30 RELAY PCB PIN J2-29 PIN J7-1 WOODWARD - - - - PIN J7-5...
  • Page 96 Fuel Solenoid Actuator Table for APECS 3000 Governor Magnetic Pickup Sensor AC Voltage Values Test condition Approximate AC Voltage Value Cranking 10-11 VAC 1300 RPM , Idle 34 VAC 2200 RPM, High Speed 44 VAC 2400 RPM, Turbo Speed 46 VAC Approximate resistance value Magnetic pick up sensor 2100K Ohms...
  • Page 97 Kubota V1505-B-1 Vertical, liquid cooled, four-cylinder, four-cycle diesel engine, Engine Type turbo-charged Displacement 91.41 cubic inches [1498cc] Fuel Diesel fuel No. 2-D (ASTM D975) Injection Pump Bosch MD type mini pump 1-3-4-2 Injection Timing 19 degrees before TDC Oil Capacity 5.5 qt.
  • Page 98 Pin# Color Type Voltage Pin Description and Function J7-1 VIO/GRA Input Module relays load power supply J7-2 BLU/PINK Output Engine ECU starter relay command J7-3 WHT/BRN Input 0V Floats Engine start inhibit signal * J7-4 Input Module relays coil ground supply J7-5 PINK Output...
  • Page 99 Overview ENGINE START/RUN RELAY PCB J7 Requirements: 1. First turn the S1 Key Switch to “Start” position, then released to it’s “Run” position. 2. Foot pedal in Neutral. Battery (+) From F1 Fuse 100A & CB6 15A + + + + + + START + + + + + + + + +...
  • Page 100 For the engine to start: – The and the Key Switch S1 START – The K2 RELAY CONTROL SWITCH sends IGN. SW INPUT Driver Box to the RUN INHIBIT J1-34 K2 RELAY CONTROL SWITCH IGN. SW INPUT – The K3 RELAY CONTROL SWITCH START START COMMAND TO STARTER RELAY sends a...
  • Page 102 Sensor (in exhaust manifold) TMAP Sensor ETC (Electronic Throttle Control) (pre CATCON) Sensor (by exhaust pipe) 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)
  • Page 103 Gasoline Sensor Interface X1 and X2 Electrical Connectors Engine Ground Connection...
  • Page 104 Fuel Temperature Sensor (mounted on EPR) TMAP Sensor ETC (Electronic Throttle Control) Sensors (exhaust manifold/pipe) ECT (Engine Coolant Temperature) Sensor EPR and Fuel Lockout and Filter ECM and Oil Pressure Switch Crank Position Sensor...
  • Page 106 Temperature Range Oil Weight Above 60° F (15° C) SAE 10W-30 Below 60° F (15° C) SAE 5W-30 Note: Have a small container handy to catch the oil you drain from the EPR. Electrical Connector LPG Fuel LPG Fuel Temperature Sensor Temperature Sensor Electrical...
  • Page 107 Note: form # PSI1P6LPFI-A. Service Note: The oil cooler tips out for easy cleaning. Compressed Air Supply Line Compressed Air Gauge Supply Line to the Coolant Supply Line Switch Coolant Valve (closed) Coolant Valve press the Air Switch Venturi Tube Assembly Coolant Supply...
  • Page 108 Gauge open the Coolant Valve Coolant Valve Gauge (open) Coolant Valve Filling Cooling System with Coolant Engine Air Filter Service Indicator Do not...
  • Page 109 Problem Cause Correction Engine will not run 2200 RPM no input @ ECM Check for 12V (+) from controller wire J2-29 at high speed (2200 (fault code 05 displayed) (GRA/ORN) to battery ground (-) with the engine RPM) speed switch 51 active. Should read 12V. If 0V, troubleshoot the throttle wire.
  • Page 110 – –...
  • Page 111 Diagnostic Communication Cable and software, p/n 56305647 Protective Cap Communication Port Communication Port TIER II Protective Cap...
  • Page 112 ® ® – ® – ® ® –...
  • Page 113 on the Warning Indicator Light Warning Indicator Light Protective Cap Communication Port Pin #1 Pin #4 Jumper across top row at outside pins ORN & BLK/GRN Communication Port Pin #4 Pin #1 TIER II Protective Cap Empty Warning Indicator Light Note: The light will always blink “1-6-5-4”...
  • Page 114 Description Description Code Code Code Code Code Code Crank Never Synced at Start RAM Failure Fuel Pump Low Voltage COP Failure Fuel Pump High Voltage External 5V Reference Low 1079 MAP Low Voltage External 5V Reference High 1079 MAP High Pressure Power Relay Open 1485 IAT Higher Than Expected 1...
  • Page 115 1.6 L GM Vertical, liquid cooled, four-cylinder, single overhead cam, Engine type distributor-less Displacement 98 cubic inches (1600 cc) 87-octane unleaded gasoline with no more than Gasoline 10% ethanol by volume Fuel 33-lb. tank size (liquid withdrawal system) Spark Plugs AC Delco p/n 93206675, gap .032 -.035 [0.8 mm-0.9 mm] Match numbered coil position to spark plug number (see the Spark Plug Wiring...
  • Page 116 Diagnostic Communication Cable and software, p/n 56305647 Cooling System Tool...
  • Page 117 Overview The hydraulic system powers the drive wheel motor, scrub brushes, vacuum fan and side brush/brooms (if the machine is so equipped). The hydraulic system also actuates the main scrub deck and side brush/broom lift cylinders, the squeegee lift cylinder and the drive wheel steering assembly. The engine drives the two hydraulic pumps that send the hydraulic oil to the various components: The main piston (propulsion) pump (1.44 CIR) is a variable-displacement pump that powers the drive wheel.
  • Page 118 Battery Circuit Breaker, 20A Fuse, 100A 12 VDC Relay, Power Circuit Breaker, 15A Circuit Breaker, 10A Switch, Ignition J2-1 J2-23 (VACC5) Relay, Power J2-12 (VACC4) J1-12 Ignition_KeyPos J2-8 Bat - Vacuum Fan S1 Driver Box J2-5 Bat - Squeegee Down S2 J2-6 Bat - J6-1 (B+)
  • Page 120 Steer Steering Cylinder Pump Fan Motor Assembly Assembly Assembly Pump Hydraulic Assembly Motor Pump Assembly Assembly, Low-speed Drive Motor Assembly Valve Hydraulic Block Reservoir Motor Assembly Assembly Assembly Scrub Lift Filter Cylinder Assembly Cooler Assembly Squeegee Cylinder Assembly...
  • Page 121 Squeegee Cylinder Steer Assembly Steer Cylinder Cylinder Assembly Scrub Lift Assembly Cylinder Assembly located as shown. Squeegee Cylinder Assembly Scrub Lift Cylinder Assembly Vacuum Fan Motor Vacuum Steering Assembly Steering Pump Motor Pump Assembly Drive Motor Assembly Assembly Assembly Main Brush are located Motor Assembly as shown.
  • Page 122 Propulsion (transport) Piston Pump Assembly Accessory Pump Assembly are connected to the engine output shaft and are located as shown. The Accessory includes the two auxiliary Pump Assembly hydraulic pumps. Propulsion (transport) Piston Pump Assembly Accessory Pump Assembly Hydraulic Valve Block/ is located on the back Manifold of the machine as shown...
  • Page 123 Solenoid Valves System Relief Valves located on the Hydraulic Valve Block/Manifold shown. S2 (top S3 (bottom)
  • Page 124 Right Side Scrub/Sweep Solenoid Valve controls the right side scrub/sweep S8/L8 motor(s). is located above the front S8/L8 end of the Scrub Deck Scrub Deck S8/L8 Right Side Scrub Lift Cylinder Solenoid controls the side scrub lift Valve S9/L9 cylinder. is located inboard of the S9/L9 Right Scrub Assembly...
  • Page 125 Item# Component Description and Hydraulic Circuit Function LI/S1 Solenoid coil and valve cartridge, vacuum fan motor, coil 8 ohms L2/S2 Solenoid coil and valve cartridge, squeegee lift cylinder DOWN (top), coil 8 ohms L3/S3 Solenoid coil and valve cartridge, squeegee lift cylinder UP (bottom), coil 8 ohms L4/S4 Solenoid coil and valve cartridge, scrub/sweep system motors, coil 8 ohms L5/S5...

  • Page 126: Hydraulic Oil

    Hydraulic Oil Open and prop the engine cover to access the Hydraulic Oil Reservoir Remove the from the tank and look to Fill Cap Fill Hydraulic screen is covered. (The oil level should not be higher than ½” [12.7 mm] above the bottom of Reservoir contamination from a mechanical failure occurs.
  • Page 127 Problem Cause Correction Fault code 34 Hydraulic temperature fault that sets when displayed on the hydraulic oil temperature exceeds 220 F for hydraulic oil cooler to ensure 15 seconds. Fault code 39 displayed on the replaced. Note: Only activates when oil temperature is above 100 degrees F (this prevents false signal upon cold engine start up).
  • Page 128 If the operational pressure is within range but the motor speed is too slow, the problem could be in the motor. If the broom motor operational psi reading is above the bypass psi but is below the operational psi, Check the individual system sections of this manual for additional information.
  • Page 129 Component Reservoir capacity 10 gal. [37.8 L] Fluid type 10W-30 engine oil Type – manually-variable displacement, axial piston Displacement – 1.44 CIR Speed – 3600 RPM max. Propulsion (Wheel Drive) Hydraulic Pump Ratings Continuous pressure – 3000 PSI max. Forward – 3500 PSI Relief Setting Reverse –...
  • Page 130 Displacement Relief Accessory Pump 2a Circuits Cu. In. Accessory Pump 2a non-priority branch, engine @ 1.20 8.42 2200 *370 2700 2200 RPM, no systems running (test port TP2) Main scrub brush motors (only) setting (A) no load A 850 1700** port TP1) 1880 (test port TP1)
  • Page 131 Hydraulic Reservoir Capacity Hydraulic reservoir capacity: 10 gallons Oil Type: 10W-30 Hydraulic Truth Table Electrical Solenoid’s Energized Status – Component to Operate Solenoid Functions Recovery Tank Fan Squeegee Down Squeegee Up Scrub Brushes On Scrub Brush Pressure Setting Scrub Brush Pressure Setting Scrub Brush Pressure Setting Right Side Scrub Brush Pressure Settings 1, 2 and 3...
  • Page 132 Hydraulic test gauge w/connector, 3000 psi range, p/n 56504516...
  • Page 133 Description Illustration Detergent Bottles Back-up Alarm Kit The Back-up Alarm Kit includes the Back-up Alarm Unit, Pigtail Wire Assembly and mounting hardware. Warning Beacon Kit The Warning Beacon Kit mounts directly on the machine and is designed for machines without an overhead guard.
  • Page 134 Description Illustration Overhead Guard Beacon Kit The Overhead Guard Beacon Kit mounts onto the overhead guard. Brake/Signal Light Kit The Brake/Signal Light Kit includes amber front signal lights, red rear stop/signal lights and wiring harnesses. Extended Scrub Kit The Extended Scrub Kit includes the and strainer, and the electrical and solution quick-disconnects Fire Extinguisher Kit...
  • Page 135 Description Illustration Foot Guard Kit Roller Bumper Kit Note that the right side roller bumper is standard on Condor XL 60” and 67” with right side scrub. Wash Hose Kit (shown mounted behind Operator seat) Overhead Guard Kit (warning beacon sold separately)
  • Page 136 Description Illustration Overhead Guard Canopy Kit (overhead guard sold separately) Rear Bumper Kit Recovery Tank Clean-out Kit Recovery Tank Debris Tray Kit...
  • Page 137 Description Illustration Drain Hose Extension Remote Foot-actuated Horn Switch Kit Right-hand/Dual Armrest Kit Seat Belt Kit for Standard Seat...
  • Page 138 Description Illustration Deluxe Suspension Seat Kit (includes right-hand armrest and seat belt) Under Hood Light Kit (includes trouble light with magnetic base on an extendable cable) Vacuum Wand Kit (shown mounted on machine)
  • Page 139 Refer to the Battery 12 VDC Fuse, 100A Relay, Power Circuit Breaker, 15A Circuit Breaker, 10A Switch, Ignition J1-12 Ignition_KeyPos Driver Box J2-8 Bat - J1-10 Vacuum Fan S1 J1-31 J1-11 Drive Pedal Sensor, 5K Ohm J6-1 (B+) J6-2 (B-) Dashboard Panel J1-3 CAN + J6-3 CAN +...
  • Page 140 Driver Box Dashboard Panel Driver Box Drive Pedal Sensor R1 Recovery Full Switch S2 Vac Fan Control Valve " ¦ ¡ ¢ £ £ ¤ ¥ ¡ ¦ & ¡ ¢ ¥ ¡ ¦ ¦ " ¡ " Vacuum Fan Control Valve Solenoid Off Aux.
  • Page 141 S1 Vacuum Fan Control Valve Solenoid On Aux. Pump through the Vacuum Fan Reservoir Pressure Relief Valve Propulsion Pump Charge Port...
  • Page 142 is on Recovery Tank Cuffed Hose Vacuum Fan Assembly Assembly Recovery Vacuum Fan Assembly Tank Vacuum Cover Hose Assembly Vacuum Fan Assembly Vacuum Hose Recovery Tank Recovery Tank Squeegee Hose Assembly Cuffed Hose Assembly Recovery Tank Recovery Tank Cover Assembly Squeegee Hose Assembly...
  • Page 143 Problem Cause Correction Poor water pickup Vacuum leak(s) due to: Check the drain hose cap and tighten/replace as necessary. Leaky drain hose cap Check the squeegee and recovery tank hoses and Leaky hose(s) tighten/replace as necessary. Bad gasket Check the vacuum hose and clamps between the vacuum fan assembly and the recovery tank and Damaged tank tighten/replace as necessary.
  • Page 144 Note: If your machine is equipped with an extended scrub system, you must disconnect the Float Switch Quick-disconnect and Solution Quick-disconnect Coupler before you can remove the recovery tank. (Refer to the subsection.) Press the Skirt Latch out of the Side Skirt Assembly Skirt Latch...
  • Page 145 Unhook the from the Cable Assembly Recovery Tank Recovery Tank Recovery Tank Cable Assembly Note: When you reinstall the , set the onto the two on the frame, then tilt the up and reattach the Front Rear Mounting Pin Mounting Pin...
  • Page 146 Component Shaft Rotation – Clockwise (as viewed from shaft end) Pressure Ratings: Fan Assembly Motor 3000 PSI – Continuous 4000 PSI –Intermittent Displacement – 0.129 CIR Vacuum Water Lift (Sealed) 33.7 inches H O @ 2200 RPM Current – 1.5 Amps Vacuum Fan Solenoid Valve Nominal Coil Resistance –...
  • Page 147 Overview The cylindrical scrub system includes the main scrub deck and hopper, the two hydraulic brush motors, the hydraulic lift cylinder that lowers and raises the deck, and the associated hydraulic solenoid valves. The dual-displacement, low-speed (accessory) pump (1.20 CID) powers the two scrub brush motors and the hydraulic scrub lift cylinder.
  • Page 148 For the scrub brush motors to run: must receive a signal from the that the drive pedal has been moved Driver Box Drive Pedal Sensor R1 from the neutral position. must provide a ground at pin to energize the solenoid valve which Driver Box J2-7...
  • Page 149 Scrub Brush When the scrub motors are off, the Motors (1.20 CID) sends Accessory Pump oil to the which Priority Flow Divider Cooler Scrub Brush directs the oil to the open Scrub Valve L4 . The oil travels Brush Valve L4 Filter through the Scrub Brush Valve L4...
  • Page 150 When the engine is shut Scrub Lift off, the de-energized Scrub Cylinder valve Cylinder Lock L6 Scrub holds the oil pressure Cylinder Lock L6 from the bottom port on Scrub Lift Cylinder support the Weight of The and prevent it Scrub Deck Weight of Scrub Deck...
  • Page 151 When the engine is running and Scrub Lift the scrub system is switched on, the Cylinder pumps the oil through Accessory Pump Scrub and to the Steering Unit Scrub Brush Cylinder Scrub Brush Lock L6 valve, the Proportional Up L7 Scrub Proportional Down L5...
  • Page 152 Brush Housing houses Weldment Left Skirt the scrub brushes, Assembly Drive Motor Assemblies the brush drive components. Hub- Scrub Lift Scrub Lift Broom Cylinder Cylinder Assembly Driver Assembly raises and lowers the scrub deck. Brush Left Right Housing Skirt Assemblies Weldment Drive are mounted on...
  • Page 153 Problem Cause Correction The scrub deck Scrub brush pressure valve Check L5 down and L7 up pressure valve solenoid will not extend solenoids over current (fault coils (on same fault line) for wiring problems, L5 downward, the code 01 displayed) wire colors (+ ORN and - WHT/VIO) and L7 ( + scrub brush motors will not operate and...
  • Page 154 Problem Cause Correction Scrub deck The scrub deck pressures pressures will not are set incorrectly in the (Refer to the change; inoperative in its three settings Menu Problem in the electrical Check the coil resistance on both L5 and L7 control circuit Check solenoid wiring continuity from Driver Box Check the current draw on both solenoids using an...
  • Page 155 The following conditions must be met for the Main Scrub Deck to move to the scrub (down) position: must be on. Key Switch The engine must be running. The scrub on mode must be selected on the Dashboard Panel B+ from RED/VIO K1 Power Relay (12V DC)
  • Page 156 The following conditions must be met for the Main Scrub Deck to apply the selected downward scrub pressure: must be on. Key Switch The engine must be running. The scrub on mode must be selected on the Dashboard Panel The drive pedal must be activated (moved from the neutral position). RED/VIO B+ from K1 Power Relay...
  • Page 157 The following conditions must be met for the Main Scrub Deck motors to run: must be on. Key Switch The engine must be running. The scrub on mode must be selected on the Dashboard Panel The drive pedal must be activated (moved from the neutral position). B+ from K1 Power Relay KEY SWITCH...
  • Page 158 Component Scrub Brush Solenoid Valve Scrub Pressure Proportional Down Solenoid Valve L5 Scrub Cylinder Lock Scrub Pressure Proportional Up Solenoid Valve L7 Main Broom Motors Scrub Hydraulic Proportioning Pressure Valve Solenoid Coil Pressure Pressure at Test Valve Type Current Draw Setting Port TP4 750 to 774 psi...
  • Page 160 Overview The right side scrub system (optional on some models) includes the right brush assembly, right brush hydraulic motor, the hydraulic scrub cylinder that lowers and raises the right scrub assembly, and the associated hydraulic solenoid valves. The right scrub lift cylinder is powered by the same hydraulic lines that actuate the main scrub lift cylinder, and is controlled by a separate side scrub lift solenoid valve S9.
  • Page 161 For the right side scrub brush motor to run: must receive a signal from the that the drive pedal has been moved Driver Box Drive Pedal Sensor R1 from the neutral position. The main scrub brush motors must be running to supply oil to right side scrub motor. must provide a ground from pin to the solenoid valve...
  • Page 162 From Cylindrical When the is on, the Right Side Scrub Motor Side Sweep/Scrub Valve Scrub Brush Motors is energized to direct the oil from the Cylindrical Scrub Brush through the . The oil then travels Motors Right Side Scrub Motor from the discharge side of the to the oil Right Side Scrub Motor...
  • Page 163 When the engine is running and the main scrub system and right side scrub To Reservoir brush are switched on, the Side Scrub Side Scrub Lift Valve L9 is de-energized to direct the Lift Valve L9 oil from the Upper Chamber on the Scrub From Upper Chamber on Scrub ) to extend the...
  • Page 164 Right Side Scrub/Sweep Solenoid Valve controls the right side scrub motor. S8/L8 is located above the front end of the S8/L8 Scrub Deck Scrub Deck S8/L8 Right Side Scrub Lift Cylinder Solenoid controls the side scrub lift Valve S9/L9 cylinder. is located inboard of the S9/L9 Right Scrub Assembly...
  • Page 165 Disconnect one of the two from its Rod Ends Mounting Loosen the Jam Nut Rod End Rotate either to lengthen or shorten the Rod End as necessary to get the correct brush End Assembly Rod End Assembly Mounting Note: The nominal factory dimension between Jam Nut the Rod End stud centers is 7.5”...
  • Page 166 Problem Cause Correction The side scrub Right Scrub System not Make sure the side scrub system is installed in the brush will not extend installed downward, the side scrub brush motor will not operate and Right side scrub solution there is no solution solenoid valve over current Note that a fault code 08, 16 or 18...
  • Page 167 The following conditions must be met for the Right Side Scrub Brush to move to the scrub (down) position: must be on. Key Switch The engine must be running. The scrub on mode and side broom/scrub must be selected on the Dashboard Panel B+ from RED/VIO...
  • Page 168 The following conditions must be met for the Right Side Scrub Brush motor to run: must be on. Key Switch The engine must be running. The scrub on mode and side broom/scrub must be selected on the Dashboard Panel The drive pedal must be activated (moved from the neutral position). B+ from K1 Power Relay KEY SWITCH...
  • Page 169 Component Right Side Scrub Motor...
  • Page 170 Overview The solution system delivers water, or detergent and water, to system. The standard , solution- Solution Tank Solution Solution Pump Solution Tank Shutoff Valve Solution Filter (M4), Solution Pump Main Solution Solenoid Valve Main Solution Solenoid Solution solution to the Scrub Valve Filter...
  • Page 171 ™ The AXP ™ detergent systems use dual diaphragm Detergent Main (M10 and M11) to Pumps Solution Solenoid pump detergent into the Valve Main Solution Solenoid (L10). Two Valve Detergent Tee (1) are used to ensure Pumps at the higher detergent Tee (2) Solution The Driver Box sends...
  • Page 172 the optional extended Float Solution Switch Tank Quick- disconnect Recovery Tank Solution Solution Quick- Pump disconnect system uses an additional Coupler (M6) Extended Scrub Pump Tee (1) Recovery Tank Note that the extended when the solution tank is empty ( Tee (2) USE CLEAN FIRST mode), or whenever the...
  • Page 173 with the optional Right Side , the solution is Scrub Brush system to the Right Solution (L11). The Solenoid Valve Right Solution Solenoid opens along with the Valve Right Main Solution Solenoid Valve Solution Solenoid Valve to the nozzle at the Right Side Scrub Brush Right...
  • Page 174 ™ ™ The DustGuard system uses a separate Mist Pump Mist (M5) to pump solution Mist Spray Pump to the Mist Spray Nozzles Nozzles Mist Pump Mist Pump when the solution tank Battery Circuit Breaker, 20A Fuse, 100A 12 VDC Relay, Power Circuit Breaker, 15A Circuit Breaker, 10A...
  • Page 175 Solution Pump M4 Main Solution Solenoid Valve L10 that on the Driver Box to the J3-2 Solution Pump M4 via the CAN Bus that the Operator has Driver Box Dashboard Panel Driver Box Drive Pedal Sensor R1 Solution Empty Switch S3 Battery Circuit Breaker, 20A Fuse, 100A...
  • Page 176 on the Driver Box. Note Detergent Pumps M10 J3-19 J3-20 J3-21 J3-22 that the voltage to the Detergent Pumps pump. Detergent Pump Detergent Pump detergent ratio. Detergent Pumps via the CAN Bus that the Operator has Driver Box Dashboard Panel Driver Box Drive Pedal Sensor R1 Battery...
  • Page 177 Extended Scrub Pump M6 mode, the USE CLEAN FIRST Solution Empty Switch S3 solution tank is empty). Extended Scrub (Float) Switch S7 via the CAN Bus that the Operator has Driver Box Dashboard Panel Driver Box Drive Pedal Sensor R1 Battery Circuit Breaker, 20A Fuse, 100A...
  • Page 178 to the optional right Right Solution Solenoid Valve L11 Solution Pump M4 via the CAN Bus that the Operator has Driver Box Dashboard Panel Driver Box Drive Pedal Sensor R1 Battery Circuit Breaker, 20A Fuse, 100A 12 VDC Relay, Power Circuit Breaker, 15A Circuit Breaker, 10A Switch, Ignition...
  • Page 179 when the wash hose Wand Pump M8 Wand Pump Wand Battery Fuse, 100A 12 VDC Relay, Power Circuit Breaker, 15A Circuit Breaker, 20A Switch, Ignition Driver Box Pressure Switch J3-23 Bat - J1-12 Ignition_KeyPos Pump, Wand (optional) J1-18...
  • Page 180 ™ pumps solution to the two DustGuard ™ Mist Pump M5 Mist Pump ™ The DustGuard via the CAN Bus that the Operator has Driver Box Dashboard Panel Driver Box Drive Pedal Sensor R1 Battery Fuse, 100A 12 VDC Relay, Power Circuit Breaker, 15A Circuit Breaker, 20A J3-18...
  • Page 181 Extended Scrub Pump M6 Extended Scrub (Float) Switch S7 Recovery Tank Full Switch S2...
  • Page 182 Mist Pump M5 and Solution Pump M4 (top) Detergent Pumps M10 and M11 Solution Filter Wand Pump M8 (bottom) (behind cover panel)
  • Page 183 Note: hoses. and remove the Filter Cover Filter Cover Solution Filter , then reinstall and hand-tighten the Filter Cover Filter Cover Filter Cover Rubber Washer Screen Filter Base...
  • Page 184 pressure. Note: hoses. Hold the with a Plastic Nozzle Adapter 7/8” Wrench when 7/8” Wrench Spray Nozzle Bracket you remove the . This will maintain the Nozzle Cap Spray Nozzle Plastic Nozzle Rotate the Nozzle Cap Adapter Nozzle Cap Spray Nozzle Nozzle Check Valve Strainer Plastic Nozzle Adapter...
  • Page 185 , make sure the is holding the Plastic Nozzle Adapter Brass Nozzle Adapter Plastic . Tighten the to the Nozzle Adapter Spray Nozzle Bracket Brass Nozzle Adapter Plastic Nozzle Adapter Service Note: Purge Icon Purge Icon Note: ™ ™...
  • Page 186 Purge Icon Note: The Detergent Dry Break . When Cap and Insert Detergent Level Viewing Detergent Detergent Cartridge (2) Detergent Detergent Level Viewing Slots...
  • Page 187 Detergent Ratio in the displayed ratio. The detergent system will Note: ™ ™ is on. section. Note: Service Note:...
  • Page 188 Problem Cause Correction No solution to the No voltage to the main 1. Check the wiring and circuit breakers upstream of main brushes solution pump the pump. 2. Check the J3-2 output from the Driver Box. Solution pump(s) over Check the M4 main solution pump wiring for current (fault code 00 problems;...
  • Page 189 Problem Cause Correction No solution to the The extended scrub function Install the extended scrub function in the main brushes in is not installed in the the extended scrub mode Solution pump(s) over Check the M6 extended scrub pump wiring for current (fault code 00 problems;...
  • Page 190 Problem Cause Correction The detergent system not the solution system menu. menu. The detergent supply lines Check the detergent lines and clean/replace as are clogged. necessary. The detergent cartridge is empty. insert into a full cartridge. No voltage to the detergent 1.
  • Page 191 Main Right Side Solution Valves Main Solution Pump Key Switch MAIN & RIGHT SIDE SCRUB BRUSH SOLUTION VALVES & PUMP Dashboard Panel RED/VIO B+ from K1 Power Relay neutral position). GRN/BRN RED/VIO KEY SWITCH DRIVER BOX GRN/BLU PIN J3-2 B- OUTPUT MAIN SOLUTION PUMP TOUCH PAD...
  • Page 192 Component Voltage – 12 VDC Max. Current – 11.5 amps @ 60 psi Solution Pump M4 Extended Scrub Pump M6 Open Flow – 3.4 GPM Internal Bypass – 60 psi Voltage – 12 VDC Coil Power – 17W Main Solution Solenoid Valve L10 Current –...
  • Page 193 Setting 1 – 1.6 gal/min [6 L/min] Setting 2 – 1.9 gal/min [7.2 L/min] Setting 3 – 2.3 gal/min [8.7 L/min] Setting 4 – 2.7 gal/min [10.2 L/min] Setting 5 – 3.1 gal/min [11.7 L/min] Available dilution ratios: 03%, .04%, .05%, .07%, .08%, 1.0%, 1.5%, ™...
  • Page 194 Overview The squeegee system includes the squeegee assembly, squeegee mounting assembly, squeegee lift weldment and the squeegee lift cylinder. Two squeegee blades (front and rear) pick up the water and direct it into the vacuum hose which carries it to the recovery tank.
  • Page 195 Squeegee When the main scrub or recovery system is Lift Cylinder actuated, the Squeegee Down Solenoid Valve L2 Squeegee energizes to direct the oil to the top port on the Down . This extends the Squeegee Lift Cylinder Squeegee and lowers the squeegee to the Lift Cylinder Squeegee Lift returns to the...
  • Page 196 When the squeegee is up (retracted), both Squeegee Lift Cylinder Squeegee Down Solenoid Valve L2 Squeegee Up Solenoid Valve L3 and lock the Squeegee Lift Cylinder squeegee in the up position. Squeegee Up Squeegee Down Solenoid Valve L3 Solenoid Valve L2 250 psi Back Pressure Reservoir...
  • Page 197 Squeegee Assembly mounts onto the Squeegee Mount Assembly Squeegee Lift Cylinder Squeegee Mount Assembly is fastened to the Squeegee . The Lift Weldment Squeegee is connected to Lift Cylinder Squeegee Lift Weldment and raises and lowers the Squeegee Lift Weldment attached Squeegee Assembly Parallel...
  • Page 198 Squeegee Down Solenoid Valve and the Squeegee Up Solenoid that control the Valve S3 Squeegee are located on the Lift Cylinder hydraulic manifold at the rear of the machine as shown. Squeegee Down Solenoid Valve S2 (top) Squeegee Up Solenoid Valve S3 (bottom) Problem Cause...
  • Page 199 The following conditions must be met for the Vacuum Fan to run and for the squeegee to be lowered to the pick-up position: must be on. Key Switch The engine must be running. The scrub on mode must be selected or the vacuum system switched on at the Dashboard Panel The drive pedal must be activated (moved from the neutral position).
  • Page 200 The following conditions must be met for the Vacuum Fan to shut off and for the squeegee to be raised to the travel position: must be on. Key Switch The engine must be running. The scrub off mode must be selected or the vacuum system switched off at the , or the Dashboard Panel drive pedal must be moved to the reverse position (squeegee will rise up).
  • Page 201 Component Current – 1.5 amps Squeegee Down Solenoid Valve L2 Nominal Coil Resistance – 8 ohms Current – 1.5 amps Squeegee Up Solenoid Valve L3 Nominal Coil Resistance – 8 ohms...
  • Page 202 Overview The steering system includes the Hydraulic steering unit, Steer Cylinder Rack Connections to Spur Gear Steering Pump The steering wheel rotates the shaft on the steering pump which Steer Rack Spur . The extends Cylinder Steer Cylinder Gear and retracts the attached Rack which then rotates the Spur Gear...
  • Page 203 When the engine is running and the Operator turns the steering wheel, sends Auxiliary Pump oil through the Priority Flow to the Divider Steering Unit Steering Unit directs Steering Unit the oil to the Metering , which then directs Valve Metering the oil to the appropriate Valve...
  • Page 204 Stationary When the steering wheel is Steering through the Steering Unit Unit Metering Valve Steer Cylinder Metering Valve Check Valve Steer Priority Cylinder Flow Divider Auxiliary Pump Reservoir Steering Unit is driven by the Steering Unit steering wheel and is located in the steering column.
  • Page 205 Steer Cylinder is mounted Steer Cylinder Steer horizontally and drives the rack Cylinder and spur gear connected to the drive wheel assembly Steer Cylinder...
  • Page 206 Problem Cause Correction The steering Backlash in the spur gear Adjust the rack so it’s closer to the spur gear. “wanders”. and rack The steering is hard Not enough oil to the or “jerky”. steering system the accessory/auxiliary pump. Note: If the steer cylinder is removed, mark the teeth where the rack engages the spur gear so the rack and spur gear engage at the same location when the steer cylinder is reinstalled.
  • Page 207 Overview The side broom sweep system is available with either with a single left-hand side broom (with right side ™ nozzles to spray solution in front of the broom(s) to minimize dust. The side broom hydraulic motors are powered by the oil from the discharge side of the two main scrub brush The side broom(s) use an electric lift actuator to raise and lower the broom(s).
  • Page 208 For the side broom motor(s) to run: must receive a signal from the that the drive pedal has been moved Driver Box Drive Pedal Sensor R1 from the neutral position. The main scrub brush motors must be running to supply oil to side broom motor(s). must provide a ground from pin to the solenoid valve...
  • Page 209 From Cylindrical When the two , or the Side Broom Motors Right Side Scrub Motor Scrub Brush Motors and left are on, the Side Broom Motor Side Sweep/Scrub Valve L8 energized to direct the oil from the discharge side of the Cylindrical to the .
  • Page 210 Mist Pump M5 The single (left-hand) sweep system is installed on the front of the machine Side in conjunction with a right-hand scrub Sweep/Scrub system. Valve L8 is mounted on Side Broom Assembly . The Side Broom Lift Weldment Actuator extends and retracts the pivot arm Motor on the...
  • Page 211 The dual sweep system Mist is installed on the front Pump M5 of the machine and uses Side Broom Assemblies with no right side scrub Side Sweep/Scrub motor. Valve L8 Side Broom Assemblies are mounted on the Side . The Broom Lift Weldment extends Actuator Motor...
  • Page 212 Right Side Scrub/Sweep Solenoid Valve controls the side sweep motor(s). S8/L8 is located above the front end of the Scrub Deck Scrub Deck S8/L8 Assemble the jumper wire that you’ll need to connect machine battery to the three-wire connector on the actuator.
  • Page 213 Connect the jumper wiring as shown to run the actuator motor in the mode. Retract (IN) Hold the steel Drive Nut Tube press the switch to run the Drive Nut toward the motor housing (its Tube limit). Measure the position of the Drive on the actuator shaft, then Nut Tube...
  • Page 214 Problem Cause Correction Side Sweep System Right side scrub/sweep Check L8 solenoid coil wiring for problems (+ ORN not working motor solenoid valve over and - BLK/WHT). current (fault code 16 Check coil resistance. If less than 6 ohms, replace. displayed) Also see the electrical ladder detail.
  • Page 215 The following conditions must be met for the Side Sweep Broom motor(s) to run: must be on. Key Switch The engine must be running. The scrub on mode and side broom/scrub must be selected on the Dashboard Panel The drive pedal must be activated (moved from the neutral position). B+ from K1 Power Relay KEY SWITCH...
  • Page 216 Component Current – 1.5 amps Scrub Brush Solenoid Valve Nominal Coil Resistance – 8 ohms Current – 1.5 amps Side Sweep/Scrub Solenoid Valve L8 Nominal Coil Resistance – 8 ohms Displacement – 17.9 Cu. In. Per Revolution Side Broom Motor Rotation - Clockwise (as viewed from shaft end) Pressure Port - A...
  • Page 217 The non-traction wheel system supports the rear of the machine and includes the braking system. Rear Wheel Assemblies are fastened to the Finished 3/8”-16 x .75” with a single Spindles 3/8”- Hex Screw 16 x .75” Hex Screw washer. Brake Assemblies Brake fastened to the Assembly...
  • Page 218 Remove the and remove the Nyloc ® from the brake pedal assembly. Loosen the and rotate the Jam Nut Rod End the appropriate direction to adjust the brake tension. tighten the Jam Nut Reinstall the into the brake pedal Rod End Nyloc ®...
  • Page 219 Problem Cause Correction The wheels are The wheel bearings are Check the wheel assembly, wheel bearings and making excess worn. spindle and replace as required. noise. The wheel and/or spindle is damaged. The brakes are not The brakes are out of Adjust the brake tension.
  • Page 220 Overview The traction wheel system includes the hydraulic traction drive motor and drive wheel, and the foot pedal/ hydroback system. The traction drive motor is driven Piston Pump by the variable-displacement Piston Lever Pump which allows speed Piston Pump Weldment and directional control.
  • Page 221 is an 18.3 Traction Drive Motor CIR hydraulic motor and drives Front Wheel A tow valve, when actuated, bypasses the hydraulic circuit from the piston pump to the to allow the Traction Drive Motor to rotate freely when Front Wheel towing or pushing the machine.
  • Page 222 For the engine to start, the must read a voltage through (rotary) that’s within Driver Box Drive Pedal Sensor the deadband range, indicating that the foot pedal is in the neutral position. Once the engine is running, the must read a voltage through indicating that the Driver Box Drive Pedal Sensor...
  • Page 223 When the engine is running and the machine is moving either forward or in reverse, the is sending oil to the Piston Pump Traction to drive the front wheel in the Drive Motor appropriate direction. Traction Piston Drive Pump Motor Traction Piston Drive...
  • Page 224 Piston Pump is the blue pump Piston Pump mounted directly in front of the engine. Hydroback Centering Unit mounted on the left side of the Piston Pump (called the Rotary Sensor Drive on the electrical Pedal Sensor Rotary ladder diagram) is fastened to the Sensor piston pump lever weldment.
  • Page 225 Note: When servicing the hydrostatic drive system, always check for any machine creeping (movement) when the machine is in neutral with the engine running. The machine must not move either forward or reverse after the foot pedal is released. If machine creeps in neutral, or if you replace the , pedal cable or , you will need to...
  • Page 226 12. Check the maximum forward and reverse wheel speeds and adjust the pedal stops as necessary. Refer to table in the section for nominal wheel speeds. 13. Turn the engine off, then see if it will restart. If engine will not start, the is probably out Rotary Sensor of its neutral (deadband) range and needs to be recalibrated.
  • Page 227 Press the Side Broom Up ( ) and Down ( ) switches to scroll through the available percentages. Note: The ideal neutral deadband percentage range is one that allows reliable starting, yet still actuates the scrub functions with minimal pedal travel. Increasing the percentage range will decrease the pedal neutral position sensitivity, but will increase the pedal travel required to start the scrub functions.
  • Page 228 Lower the side broom(s). Empty and remove the recovery tank. Block the rear wheels. Jack up the front of Piston Piston Pump the machine. This Pump Lever Weldment will make it easier to access the Push/ Pull Control Cable mounting hardware by the foot pedal Rod End assembly.
  • Page 229 Service Note: To thread the new from the foot pedal assembly to the Hydroback, we recommend that you SECURELY attach the new to the old , then carefully pull the new through the old routing path in the machine. This will eliminate a lot of disassembly and reassembly work. 13.
  • Page 230 Empty and remove the recovery tank. Loosen the jam nut holding the Push/ Piston Piston Pump Pull Control Cable Pump Lever Hydroback Centering Weldment in the Unit Hydroback by the Adjuster Plate Piston Pump Disconnect the Rod End from the Piston Pump Lever Weldment Push/Pull...
  • Page 231 If the traction drive motor or the to the motor are replaced or repaired, it’s important to Hydraulic Hoses route the correctly when reinstalled to prevent wear or damage to the Hydraulic Hoses Hydraulic Hoses surrounding components. When reinstalling the traction drive motor Hydraulic Hoses Install the Hydraulic Hoses...
  • Page 232 Component Tire (front 1) drive/steer Size 18 in x 6 in [457 mm x 152 mm] P7 solid Displacement – 18.3 CIR Traction Drive Motor Shaft Rotation – Clockwise (as viewed from slot end) Displacement – 1.44 CIR Speed – 3600 RPM Max. Continuous Pressure –...
  • Page 233 Description Steering Torque to 40 ft.- Steering Castle Castle lb.,then loosen to (Spindle) Nut (Spindle) Nut align cotter pin. ¾”-16 Hex Torque to 150 ft.-lb. Jam Nut ½”-20 x 1.25 Use Loctite ® 242, Hex Screw torque to 90 ft.-lb. ¾”-16 Hex Jam Nut ½”-13 Nyloc...