Chapters
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Troubleshooting
Related Manuals for Advance acoustic Exterra 56507000
Summary of Contents for Advance acoustic Exterra 56507000
- Page 1 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) 10/07 revised 8/12 FORM NO. 56043110...
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Page 2: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION ..............................3-6 SAFETY INSTRUCTIONS ..............................7 TECHNICAL SPECIFICATIONS ............................8-9 MAINTENANCE ................................10-13 PM CHECKLIST ................................14-15 KNOW YOUR MACHINE ...............................16-21 OPERATOR’S COMPARTMENT ............................18 CONTROL PANEL ................................19 CONTROL PANEL DIAGNOSTICS ..........................20-21 GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ..............22 ENGINE TROUBLESHOOTING FLOW CHARTS ......................23-33 WHEEL DRIVE SYSTEM .............................. -
Page 3: General Information
GENERAL INFORMATION INTRODUCTION This manual will help you get the most from your Advance rider Scrubber-Sweeper. Read it thoroughly before servicing the machine. Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 14-17 i.e. (B). This product is intended for commercial use only. -
Page 4: Transporting The Machine
GENERAL INFORMATION TRANSPORTING THE MACHINE CAUTION! Before transporting the machine on an open truck or trailer, make sure that . . . • All access doors are latched securely. • The machine is tied down securely - see tie-down locations (26). •... - Page 5 3 CYLINDER MODELS 4 CYLINDER MODELS FORM NO. 56043110 - Exterra ™...
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Page 6: General Information
OTHER MANUALS AVAILABLE The following manuals are available from the Advance Literature Service Department, for your Rider Scrubber/Sweeper: • General Information - Advance website (www.advance-us.com) - EzParts service/parts CD-ROM • Parts List - Form Number 56042471 (all systems w/optional kits & accessories) •... -
Page 7: Safety Instructions
CAUTIONS AND WARNINGS SYMBOLS Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and property. DANGER! Is used to warn of immediate hazards that will cause severe personal injury or death. WARNING! Is used to call attention to a situation that could cause severe personal injury. -
Page 8: Technical Specifications
TECHNICAL SPECIFICATIONS General Specifications common to All Models English (Metric) Dimensions Gas & Propane Length 93.75 inches (238cm) Width (minimum)* 64.5 (164cm) Height 58.5 inches (149cm) Height w/overhead guard 81.25 inches (206cm) Height w/cab 79 inches (201cm) Ground clearance 3.1 inches (7.8cm) Minimum ceiling height dumping clearance 101.4 inches (257.5cm) Weights Gross weight** 3 Cylinder... - Page 9 TECHNICAL SPECIFICATIONS Specifications common to Engine Size 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% / 14°...
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Page 10: Maintenance
MAINTENANCE MAINTENANCE SCHEDULE Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often. MAINTENANCE ITEM PERFORM DAILY Perform the “After Use” maintenance steps Check parking brake Check engine oil *Clean main and side broom(s) Check engine air filter indicator Check engine coolant level Check hydraulic oil level... - Page 11 MAINTENANCE IMPORTANT MACHINE LUBRICATION Rear Steering Yoke Bearing Assembly Once every 150 hours attach a grease gun to the yoke bearing pivot zert (location under operator’s seat) and pump a small amount of grease into bearing assembly. Also every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door hinges etc. Broom and hopper pivots use composite bearings lubrication is not required.
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Page 12: Engine Air Filter
MAINTENANCE ENGINE AIR FILTER The engine Air Filter (24) is located in the engine compartment. Check the air mechanical vacuum filter Service Indicator (27) before each use of the machine. Do not service the air filter unless the indicator is shown (red). CAUTION! When servicing the engine air filter elements, use extreme caution to prevent dust and dirt from entering the engine. -
Page 13: Maintenance
MAINTENANCE HYDRAULIC OIL WARNING! To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye protection when working with or near hydraulic system. Check the Hydraulic Oil Level. Unlatch and swing open the Oil Reservoir / Fuel tank Cover (20). Remove the reservoir cap to check the oil level. -
Page 14: Pm Checklist
Exterra 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) Work Check Neutral Safety/Sense Switch operation (To test depress drive pedal and start the engine, it should not start.) Engine Starting with pedal in neutral (if it will not start check sensor switch starts hard... - Page 15 Does VISUAL INSPECTION ITEMS (continued) Defect Codes Comments (circle) Work Circuit Breaker/Relay panel (inspect electrical connections) Hydrostatic Dump Valve Tow Valve Hopper Up Transport Speed control Cam/Cable Linkage Propulsion drive & Accessory Pumps Hydraulic Reservoir, System Hoses & fittings Propulsion Pump Hydro Back Cable & Clevis Connections B M W Engine, Oil Level, Hoses &...
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Page 16: Know Your Machine
KNOW YOUR MACHINE As you read this manual, you will occasionally run across a bold number in parentheses and underlined - example: (2). These numbers refer to an item on the next four pages. Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text. Engine Compartment Cover Left Side Main Broom Access Panel Battery... - Page 17 KNOW YOUR MACHINE (CONTINUED) 16 Hopper Cover 17 Hopper Cover Prop Rod 18 Right Side Main Broom Access Panel 19 Oil Reservoir 20 Oil Reservoir / Fuel Tank Cover 21 Fuel Tank (LPG tank shown / Gasoline tank is in same location) 22 Coolant Recovery Tank (3 cylinder &...
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Page 18: Operator's Compartment
KNOW YOUR MACHINE OPERATOR’S COMPARTMENT Operator’s Seat Main Broom Lever Main Broom Adjust Knob Control Panel (See Associated Pages) Steering Wheel Brake Pedal / Parking Brake FWD / REV Drive Pedal Circuit Breaker Panel Hopper Safety Support Handle Operator Seat Adjustment Lever Choke Cable* (3 Cylinder) *To start: 1. -
Page 19: Control Panel
KNOW YOUR MACHINE CONTROL PANEL AA Fuel Gauge (Gasoline and Diesel Only) LL Shaker Switch BB Horn Switch MM Hopper UP Indicator CC PROPANE Low Indicator Light NN Open Dump Door Switch DD Headlight Switch OO Hopper Over-temp Indicator (optional) PP Close Dump Door Switch EE Check Engine Light MIL (GM 1.6L Only) FF Glow Plug Indicator Light (Diesel Only) -
Page 20: Control Panel Diagnostics
EXTERRA CONTROL PANEL DIAGNOSTICS Function of the main controller’s service indicator fault blink code display light The A2 main controller will out put a flashing fault code to the operator display panel when or if there is a problem (current overloads) associated with specific electrical low current circuit controller output functions. Examples of circuits; hydraulic solenoid coils used to turn on & off hydraulic loads and numerous relays used for activating machine function such as the headlights, horn, shaker motor, back-up alarm etc. - Page 21 TABLE A Fault Service Fault Description Output Troubleshooting Action Number Pin # Blink Code 1. Check S1 coil wiring for a short circuit Vio + & Blu/Wht Solenoid S1 hopper close/open overload J1-1 -. 2. Check coil resistance if below 6 Ohms replace.3. Coil spec is 8 Ohms Substitute a new A2 control box.
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Page 22: General Machine Troubleshooting Guide Table Of Contents
GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE OF CONTENTS Engine System ................................23-33 Kubota 3 cylinder G/LP or 4 cyl diesel engine will not crank ................23 Kubota 3 cylinder engine G/LP will crank but not start ..................24 Kubota 3 cylinder engine will not run at high speed ..................25 1.6L GM 4 cylinder engine will not crank ......................26-27 1.6L GM 4 cylinder engine will crank but not start ..................28-29 1.6L GM engine will not run at high speed ...................... -
Page 23: Engine Troubleshooting Flow Charts
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Kubota 3 cylinder G/LP or 4 cylinder diesel engine will not crank Part A: Electrical Control and Load Circuit Note 1: To test the key switch must be in Start position and the foot-pedal in neutral. Note 2: Before T.S. -
Page 24: Engine System
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Kubota 3 cylinder engine G/LP will crank but not start Part A: Electrical Control Circuit Note 1: Check for 12V’s at the CB5 ignition circuit breaker 10A. If no input voltage @ the Orn/Grn wire repair or replace wiring or key switch. -
Page 25: Kubota 3 Cylinder Engine Will Not Run At High Speed
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom 3 Cylinder engine will not run at high speed Note: With the engine running at idle press the engine speed switch to activate the high speed engine function. Before troubleshooting inspect and test the 30A F2 fuse. If fuse condition is questioned substitute a new fuse. -
Page 26: L Gm 4 Cylinder Engine Will Not Crank
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom GM 1.6L 4 cylinder engine will not crank Part A: Electrical Control and Load Circuit Note 1: To test the key switch must be in Start position and the foot-pedal in neutral. Note 2: Before T.S. check the CB1 60 Amp circuit breaker & 12V ‘s @ key switch Bat terminal. Note 3: Before T.S. - Page 27 ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom GM 1.6L 4 cylinder engine will not crank Part B: Electrical Control and Load Circuit Note 1: To test the key switch must be in start position and the foot-pedal in neutral. Also reference Note: A below.
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Page 28: L Gm 4 Cylinder Engine Will Crank But Not Start
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom GM 1.6L 4 cylinder engine will crank but not start Part A: Note 1: Check for 12V’s at the CB5 ignition circuit breaker 10A. If no input voltage @ the Orn/Grn wire repair or replace wiring or key switch. Note 2: Check the fuel supply (empty tank). - Page 29 ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom GM 1.6L 4 cylinder engine will crank but not start Part B: Note 1: Check for 12V’s at the CB5 ignition circuit breaker 10A. If no input voltage @ the Orn/Grn wire repair or replace wiring or key switch. Note 2: Check the fuel supply (empty tank).
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Page 30: L Gm Engine Will Not Run At High Speed
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom 4 cylinder 1.6 GM engine will not run at high speed Note: With the engine running at idle press the engine speed switch to activate the high speed engine function.. 1.6 GM engine will not run at high speed Press the speed select Test the continuity of... -
Page 31: Diesel Engine Will Crank But Not Start
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Part1: Diesel engine will crank but not start Note1: Always use (activate) the glow plugs circuit to start an engine that is not up to its operating temperature. Note 2:Before troubleshooting inspect the 10A CB5 circuit breaker. Glow plug circuit T.S. - Page 32 ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Part 2: Diesel engine will crank but not start Note: Always use (activate) the glow plugs circuit to start an engine that is not up to its operating temperature. Note 1: Before troubleshooting inspect the 10A CB5 circuit breaker, replace if defective. Note 2: The engine uses a low oil pressure shut down feature.
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Page 33: Diesel Engine Will Not Run At High Speed
ENGINE SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Diesel engine will not run at high speed Note: With the engine running at idle press the engine speed switch to activate the high speed engine function. Diesel engine will not run at high speed Test for 12V’s (+) at the Press on &... -
Page 34: Wheel Drive System
WHEEL DRIVE SYSTEM Hydraulic Wheel Drive System Troubleshooting Check List Symptom Possible Cause Wheel drive functions sluggish or slow • Engine not operating in high-speed setting or engine speed is too slow (2400 RPM). • Air in hydraulic fluid (loose fittings). •... -
Page 35: Steering System
STEERING SYSTEM STEERING SYSTEM TROUBLESHOOTING OVERVIEW See Figure 1. A hydraulic steering unit, with the steering wheel mounted to it, controls the steer cylinder. The steering unit runs off the auxiliary pump assembly. The oil flows through a priority divider built into the manifold block assembly that divides the pump output and reduces the oil flow to 2.0 GPM for the steering system. -
Page 36: Sweeping System
SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Main broom motor will not run Part A: Electrical Control Circuit Note 1: Do all testing with the engine running at high speed, the main broom lowered (sweep position) and the drive pedal activated (machine moving). Note 2: The main broom magnetic switch S2 must be open and also the hopper interlock switch S4 closed, for the main broom system (motors) to run. -
Page 37: Main Broom
SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Main broom motor will not run Part B: Hydraulic Load Circuit Note 1: Do all testing with the engine running at high speed, the main broom lowered (sweep position) and the drive pedal activated (machine moving). Note 2: The main broom magnetic switch S2 must be open and also the hopper interlock switch S4 closed, for the main broom system (motors) to run. -
Page 38: Side Brooms
SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Side broom motor(s) will not run Part A: Electrical Control Circuit Note 1: Do all testing with the engine running at high speed, the main broom lowered (sweep position) and the drive pedal activated (machine moving). When the above steps are completed the side broom(s) will lower automatically and turn ON (rotate). - Page 39 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Side broom motor(s) will not run Part B: Hydraulic Load Circuit Note 1: Do all testing with the engine running at high speed, the main broom lowered (sweep position) and the drive pedal activated (machine moving). When the above steps are completed the side broom(s) will lower automatically and turn ON (rotate).
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Page 40: Side Brooms Will Not Raise/Lower
SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Side broom(s) will not raise or lower. Mechanical and Hydraulic functions Note 1: Do all testing with the engine running at high speed, the main broom lowered (sweep position) and the drive pedal activated (machine moving). Note 2: The main broom magnetic switch S2 must be open and also the hopper interlock switch S4 closed. -
Page 41: Dust Control Impeller
SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Dust control (impellor) motor will not run in the wand state Part A: Electrical Control Circuit Note: Do all testing with the engine running at high speed and the dust control switch pressed (activated). - Page 42 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Dust control (impellor) motor will not run in the wand state Part B: Hydraulic Load Circuit Note: Do all testing with the engine running at high speed and the dust control switch pressed (activated).
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Page 43: Shaker Motor
SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Shaker motor will not run Part A: Electrical Control Circuit Note: Do all testing with the key switch ON, then press the control panel shaker switch to activate turn on the shaker motor (shaker runs for approximately 15 seconds). Shaker motor will not run Test for 12V’s @... - Page 44 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Shaker motor will not run Part B: Electrical Load Circuit Note 1: Do all testing with the key switch ON, then press the control panel shaker switch to activate turn on the shaker motor (shaker runs for approximately 15 seconds). Shaker motor will not run Test for 12V’s @ the M2 Test for (+)12V’s...
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Page 45: Hopper System
HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper will not raise Part A: Electrical Control Circuit Note: Do all testing with the engine running at high speed and the hopper raise (UP) switch pressed and held. Hopper will not raise Press &... - Page 46 HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper will not raise Part B: Hydraulic Load Circuit Note: Do all testing with the engine running at high speed and the hopper raise (UP) switch pressed and held. Hopper will not raise Inspect for possible Repair or mechanical binding of:...
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Page 47: Hopper Will Not Lower
HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper will not lower Part A: Electrical Control Circuit Note: Do all testing with the engine running at high speed and the hopper lower (DN) switch pressed and held. Hopper will not lower Press &... - Page 48 HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper will not lower Part B: Hydraulic Load Circuit Note: Do all testing with the engine running at high speed and the hopper lower (DN) switch pressed and held. Hopper will not lower Inspect for possible mechanical...
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Page 49: Hopper Dump Door Will Not Open (Part A)
HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper dump door will not open Part A: Electrical Control Circuit Note: Do all testing with the engine running at high speed and the hopper dump door open switch pressed and held. Hopper dump door will not open Press &... -
Page 50: Hopper Dump Door Will Not Close (Part A)
HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper dump door will not close Part A: Electrical Control Circuit Note: Do all testing with the engine running at high speed and the hopper dump door close switch pressed and held. Hopper dump door will not close Press &... -
Page 51: Dump Door Cylinder
HOPPER SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Hopper dump door will not operate open or close Part B: Hydraulic Load Circuit Note: To test the engine must be running at high speed and the hopper door (open/close) switches pressed and held. Dump door will not operate open or close Inspect for possible... -
Page 52: Solution System
SOLUTION SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Misting Pump will not Work Part A: Electrical Control Circuit Note 1: Do all testing with the key switch ON, misting solution tank not empty, main broom lever lowered, drive pedal activated in Fwd or Rev and the M4 misting pump’s control switch S26 turned ON. -
Page 53: Solution System
SOLUTION SYSTEM TROUBLESHOOTING GUIDE Troubleshooting Guide Symptom Misting pump will not work Part B: Electrical Load Circuit Note 1: Do all testing with the key switch ON, misting solution tank not empty, main broom lever lowered, drive pedal activated in Fwd or Rev and the M4 misting pump’s control switch S26 turned ON. -
Page 54: Engine System
ENGINE SYSTEM ENGINE SPECIFICATIONS Kubota V1505-B-1 Engine Type Vertical, water cooled, 4-cycle diesel engine Displacement 91.41 cubic inches (1498cc) Fuel Diesel fuel No. 2-D (ASTM D975) Injection Pump Bosch MD type mini pump Engine firing order 1-3-4-2 Injection Timing (before TDC) 19 deg. -
Page 55: Engine Maintenance
ENGINE SYSTEM 1.6 liter GM Engine Specifications Engine type Liquid Cooled, 4 Cylinder, Single Overhead cam Distributor-less Displacement 98 Cubic inches (1600 cc) Fuel Gasoline 87 Octane Unleaded Gasoline with no more than 10% Ethanol by volume Fuel LP 33 Lbs. Tank Size (liquid withdrawal system) Spark Plugs AC DELCO PN 93206675, Gap .032 -.035 (.8 mm-.9 mm) Spark Plug wiring... -
Page 56: Check Engine Light Troubleshooting
ENGINE SYSTEM CHECK ENGINE LIGHT TROUBLESHOOTING FOR 1.6L GM ENGINE The engine ECM will light (turn on) the dash panel (UU) check engine light if there is a problem associated with the computerized engine control system. The following steps explain how to correctly access the engine controller’s fault code outputs. On the operator display panel the engine check light (MIL ) comes on steady will not shut off. - Page 57 ENGINE SYSTEM 1.6L DTC Code to SPN:FMI Code Cross Reference Description SPN Code Description SPN 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...
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Page 58: Miscellaneous Engine System Information
ENGINE SYSTEM MISCELLANEOUS ENGINE SYSTEM INFORMATION Additional Engine Troubleshooting Symptom Engine Overheating Use the checklist below as a guide, to thoroughly check the engine cooling system. • Check coolant level in overflow tank and radiator. • Inspect and clean radiator and hydraulic oil cooler. •... - Page 59 ENGINE SYSTEM FIGURE 3 Firing Order 1, 3, 4, 2 Coil Pack FIGURE 4 Cylinders - 59 FORM NO. 56043110 - Exterra ™...
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Page 60: Cyl Kubota Replacement Of The Engine Throttle Actuator
ENGINE SYSTEM 3 CYLINDER KUBOTA REPLACEMENT OF THE ENGINE THROTTLE ACTUATOR Removal: See Figure 5. Loosen the actuator throttle cable Anchor Hardware (A) and also loosen the wire cable end connection Screw (B) as shown. Remove the P-clamp (C) at the radiator shroud that is used to route the cable. Note the location of the actuator wiring harness wire connections at the bottom of the Actuator Control Module (D) for correct reassembly, then remove the wiring (see Figure 6). - Page 61 ENGINE SYSTEM FIGURE 6 FIGURE 5 - 61 FORM NO. 56043110 - Exterra ™...
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Page 62: Hydraulic System
HYDRAULIC SYSTEM HYDRAULIC SYSTEM TROUBLESHOOTING Accurate measurements are the key to troubleshooting a hydraulic system. Once measurements are obtained, they can be compared with specifications to analyze a problem. To troubleshoot the hydraulic system it is possible to use digital tachometers, flow gauges or pressure gauges. The pressure gauge should have a range of 0 – 3000 PSI (see Figure 2) and have a Parker Diagnostics connector number PD222. -
Page 63: General Hydraulic Specifications Table
HYDRAULIC SYSTEM GENERAL HYDRAULIC SPECIFICATIONS TABLE Relief Pump & Motor Circuits for 3 cylinder models DISPL in (in) (out) Auxillary Pump Circuit Engine @ 2800rpms No 10.6 2800 *380 2500 systems running Main Broom @ sweep position (Std Broom with a 2.0” pattern). Wet sweep Bypass (dust control off) & side 2.45 2800 1275... -
Page 64: Hydraulic Truth Table
HYDRAULIC SYSTEM Hydraulic Truth Table Electrical Solenoid’s energized Status Solenoid Functions Hopper Raise (UP) Hopper Lower (DN) Dump Door Open Dump Door Closed Main Broom State ON Main /Side Broom State ON Dust Control ON Wand State (**) Dust Control OFF Bypass (*) Side Broom Lower Side Broom Raise &... - Page 65 HYDRAULIC SYSTEM FIGURE 3 Hydraulic Manifold top and bottom views shown S4 Coil Dust Control Valve S4 Cartridge Adjustment Screw Lock-nut System Relief Valve 2500 PSI Shown with dashed lines behind S5 Top view Bottom view - 65 FORM NO. 56043110 - Exterra ™...
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Page 66: Pressure Relief Valve
HYDRAULIC SYSTEM PRESSURE RELIEF VALVE Instructions for testing and adjusting the main pressure relief valve that is built into the machines hydraulic manifold assembly: Insert hydraulic test gauge (3000 psi.) to the XT1 test port (location between pump & solenoid manifold). To check pressure the hydraulic oil must be warm &... -
Page 67: Hydraulic Diagram
HYDRAULIC SYSTEM Hydraulic System 3-Cylinder models Item Description Steering Cylinder Assembly Steering Control Unit Hopper Door Cylinder Assembly Main Broom Motor Assembly Hopper Lift Cylinder Assembly Reservoir Assembly Pump Assembly Filter Assembly Elbow, 90 O-Ring Drive Motor Assembly Sleeve Hydraulic Hose Side Broom Motor Assembly Sleeve, Nylon Side Broom Cylinder Assembly, Right... - Page 68 HYDRAULIC SYSTEM Hydraulic System 4-Cylinder models Item Description Steering Control Unit Hopper Door Cylinder Assembly Reservoir Assembly Hopper Lift Cylinder Assembly Drive Motor Assembly Pump Assembly Side Broom Motor Assembly Filter Assembly Side Broom Cylinder Assembly, Right Elbow, 90 O-Ring Sleeve Hydraulic Hose Main Broom Motor Assembly Dust Control Motor Assembly...
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Page 69: Hydraulic System Layout For Optional Left Side Broom
HYDRAULIC SYSTEM Left Hand Side Broom Option Item Description Item Description Hose, Hydraulic Instruction Sheet Hose, Hydraulic Left Hand Side Broom Option Hose, Hydraulic Side Broom Cylinder Assy, Left Hose, Hydraulic Side Broom Motor Assembly Hose, Hydraulic Valve Assembly Wire Tie (not shown) Tee, Union Hose Clamp, 1/4 Quadruple Hose, Hydraulic... - Page 70 THIS PAGE IS INTENTIONALLY BLANK 70 - FORM NO. 56043110 - Exterra ™...
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Page 71: Hydraulic Component Location
HYDRAULIC SYSTEM COMPONENT LOCATION Item Description Drive Motor Assembly Dust Control Motor Assembly Filter Assembly Hopper Door Cylinder Hopper Lift Cylinder Oil Cooler Main Broom Motor Assembly Manifold Assembly Pump Assembly (3 cylinder pump shown) Reservoir Assembly Side Broom Cylinder Assembly, Right Side Broom Motor Assembly Steering Control Unit Steering Cylinder... -
Page 72: Hydraulic Schematic
HYDRAULIC SYSTEM DUAL SIDE BROOM OPTION SIDE BROOM LIFT SIDE BROOM LIFT HYDRAULIC SCHEMATIC 1.00 x 1.18 x .50 1.00 x 1.18 x .50 3 CYLINDER MODELS 25 PSI 25 PSI SIDE BROOM SIDE BROOM 6.10 6.10 SIDE BROOM LIFT 1.00 x 1.18 x .50 25 PSI SIDE BROOM... - Page 73 HYDRAULIC SYSTEM DUAL SIDE BROOM OPTION SIDE BROOM LIFT SIDE BROOM LIFT 1.00x1.18x.50 1.00x1.18x.50 HYDRAULIC SCHEMATIC 4 CYLINDER MODELS 25 PSI 25 PSI SIDE BROOM LIFT 1.00x1.18x.50 SIDE BROOM SIDE BROOM 6.10 6.10 25 PSI SIDE BROOM HOPPER DUMP 1.5x3.75x.75 MAIN BROOM 2.45 .086...
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Page 74: Electrical Component Location
ELECTRICAL SYSTEM COMPONENT LOCATION Item Description Item Description Control Box Assembly Head Light, Right Battery, 12Vdc Head Light, Left Circuit Breaker, 70 Amp (Main) Motor, Shaker Circuit Breaker, 20 Amp (Headlights) Hourmeter Circuit Breaker, 15 Amp (Starter) Gauge, Fuel (not used on LPG models) Circuit Breaker, 20 Amp (Accessories) Drive Pedal Sensor, 5K Ohm Circuit Breaker, 10 Amp (Ignition) -
Page 75: Wiring Diagram
56507376-I Sheet 1 of 3 ELECTRICAL SYSTEM BATTERY, 12 Vdc BATTERY, 12 Vdc HEATER TEMP. RED/VIO VIO/GRA CONTROL WIRING DIAGRAM 1 of 3 M6/M9 M6/M9 CIRCUIT BREAKER, 20 A. CIRCUIT BREAKER, 20 A. RELAY, HVAC RELAY, HVAC VIO/GRA 1 BLOWER MOTOR FOR RED/WHT MOTOR, BLOWER MOTOR MOTOR, BLOWER MOTOR... - Page 76 ELECTRICAL SYSTEM 56507376-I Sheet 2 of 3 GLOW PLUG SIGNAL GRN/RED J1-11 (ACC INPUT) J2-6 GRN/RED WIRING DIAGRAM 2 of 3 (DIESEL ENGINE ONLY) PINK FROM IGNITION BLU/WHT (IGN. INPUT) J2-11 PINK J1-1 CIRCUIT Item Ref. No. Qty Description VALVE S1, HOPPER CLOSE/OPEN VALVE S1, HOPPER CLOSE/OPEN GRA/WHT J1-18...
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Page 77: Wiring Diagram
56507376-I Sheet 3 of 3 KUBOTA 972 ENGINE SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAM 3 of 3 BATTERY, 12 Vdc BATTERY, 12 Vdc Kubota 972 Engine System Item Ref. No. Qty Description +BAT FUSE, 40 A. FUSE, 40 A. Throttle Control Module +AUX -BAT THROTTLE INPUT... -
Page 78: Wiring Schematic
DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST. DWG. NO. SHEET 56507375 1 OF 3 REVISIONS REVISIONS DATE DATE DFTM APPD A-03095 6/14/06 RELEASED A-03183 8/14/06 ELECTRICAL SYSTEM UPDATE: CHANGE GENDER OF X127 AND X128... - Page 79 PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTH AGREES TO RETURN IT UPON REQUEST. DWG. NO. 56507375 SHEET 2 OF 3 A-03 SEE S A-03 ELECTRICAL SYSTEM SEE S A-03 KUBOTA 972 ENGINE SYSTEM SEE S A-03 RED 1-1...
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Page 80: Wiring Schematic
ELECTRICAL SYSTEM LP12. LP12. STROBE STROBE (OPTIONAL) (OPTIONAL) WIRING SCHEMATIC 1 of 3 CAB WIRING X191 X191 X190 X190 MOTOR ASM, WIPER MOTOR ASM, WIPER INCLUDES 2 SPEED SWITCH INCLUDES 2 SPEED SWITCH X178 X178 X203 X203 VIO/GRA 12-3 X189 X189 VIO/GRA 12-2 X182... -
Page 81: Engine Harness Gm 1.6L Gas
ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1.6L GAS GCP 90 WAY CONNECTOR EGO 2 EGO 1 GASOLINE SENSOR INTERFACE CONNECTOR 2 BOSCH_TMAP OIL PRESSURE SENSOR VEHICLE INTERFACE CONNECTORS CONNECTOR 1 GROUND DIAGNOSTIC IGNITION COIL CONNECTOR STARTER SOLENOID CRANK SENSOR STARTER RELAY STARTER IGNITION POWERRELAY... -
Page 82: Engine Harness Gm 1.6L Lpg
ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1.6L LPG GCP 90 WAY CONNECTOR EGO 2 EGO 1 LOCKOFF LPG TEMPERATURE CONNECTOR 2 BOSCH_TMAP OIL PRESSURE SENSOR VEHICLE INTERFACE CONNECTORS CONNECTOR 1 GROUND IGNITION COIL DIAGNOSTIC CONNECTOR STARTER SOLENOID CRANK SENSOR STARTER RELAY STARTER IGNITION POWERRELAY... -
Page 83: Engine Wiring Harness Gm Detail
ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1.6L GAS (Petrol) Tier 3 FORM NO. 56043110 - Exterra™ - 83... - Page 84 ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1.6L LPG Tier 3 84 - FORM NO. 56043110 - Exterra™...
- Page 85 ELECTRICAL SYSTEM Wiring Harness Wiring Harness Component Description Item ECM Wiring Connector (90 Pins) Gasoline/Petrol Fuel Sensor Interface Connector (fuel pressure ECM Detail regulation and temperature sensor manifold assembly) Machine Engine Diagnostic Communication Port (8 Pin) Harness Connectors Harness Connectors (MIL shorting location) Ignition Coil Pack Wiring Connector CONNECTOR 2...
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Page 86: Electrical System
ELECTRICAL SYSTEM FIGURE 1 connection connection 9 pins Touch Pad Display 11 pins Touch Pad Switches Pin 1 is labeled Access windows J3 shown - 85 FORM NO. 56043110 - Exterra ™... -
Page 87: Programmable Control Options
ELECTRICAL SYSTEM PROGRAMMABLE CONTROL OPTIONS Foot Pedal Neutral Position and Dead-band Adjustment: FACTORY DEFAULT: 2 RANGE: 1 - 3 The various scrub and sweep functions on the Falcon are activated when the foot pedal is moved from the neutral position. The engine neutral-start relay is also activated when the foot pedal is moved from the neutral position. - Page 88 ELECTRICAL SYSTEM PROGRAMMABLE CONTROL OPTIONS Automatic Shaker Operation: FACTORY DEFAULT: ON RANGE: ON, OFF The dust control filter shaker can be programmed to automatically activate each time the main broom is turned off to automatically clean the filter. To turn this feature on or off perform the following steps: Turn the main power key switch to the off position.
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