6600 / 6650 Service Manual Tennant Rider Floor Sweeper
Tennant-6600-Rider-Floor-Sweeper-Service-Manual tennant-6600-rider-floor-sweeper-service-manual tennant-6600-rider-floor-sweeper-service-manual 2774 file product_file sweepscrub 3:
2018-06-19
: Sweepscrub Tennant-6600-Rider-Floor-Sweeper-Service-Manual tennant-6600-rider-floor-sweeper-service-manual 2773 file product_file
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6600/6650 Service Information Manual (Paper Manual) 330915 Rev. 00 *330915* 330935 (CD-- ROM) Home Find... Go To.. This manual provides service information for the TENNANT Model 6600/6650. This machine will provide excellent service. However, the best results will be obtained at minimum costs if: D The machine is operated with reasonable care. D The machine is maintained regularly -- per the maintenance instructions provided. D The machine is maintained with TENNANT supplied or approved parts. Paper Manual Number -- 330915 CD--ROM Manual Number -- 330935 Revision: 00 Published: 9--03 CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Copyright E 2003 TENNANT, Printed in U.S.A. Home Find... Go To.. 6600 Electrical Troubleshooting Charts ....................................................................................... 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM ............................................................. 6600 DIESEL OVERALL ELECTRICAL DIAGRAM ................................................................... 6600 Key Switch ........................................................................................................................ 6600 Charging System .............................................................................................................. 6600 Gas/L.P. Start Circuit ........................................................................................................ 6600 Diesel Start Circuit ............................................................................................................ 6600 Gas/L.P. Power-Up Circuit ................................................................................................ 6600 Diesel Power-Up Circuit .................................................................................................... 6600 Gas/L.P. Check Engine Lamp Circuit ............................................................................... 6600 Gas/L.P. Oil Pressure & Hour Meter Circuit ...................................................................... 6600 Diesel Oil Pressure & Hour Meter Circuit .......................................................................... 6600 Vacuum Fan Circuit .......................................................................................................... 6600 Vacuum Restriction Warning Circuit ................................................................................. 6600 Gas/Diesel Fuel Sender Circuit ......................................................................................... 6600 Low L.P. Fuel Sender Circuit ............................................................................................ 6600 Shaker Motor Circuit ......................................................................................................... 6600 Thermo-Sentry Circuit ...................................................................................................... 6600 Hopper Door Switch Circuit ............................................................................................... 6600 with ZEEMS ...................................................................................................................... 6600 Gas/L.P. ZEEMS Check Engine Fault Codes ............................................................ 1 2 6 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 6600 Hydraulic Troubleshooting Charts ...................................................................................... 6600 OVERALL HYDRAULIC DIAGRAM .................................................................................. 6600 HYDRAULIC HOSE ROUTING ........................................................................................ 6600 MAIN BRUSH ................................................................................................................... 6600 MAIN & SIDE BRUSH ....................................................................................................... 6600 VACUUM FAN .................................................................................................................. 6600 RAISE HOPPER ............................................................................................................... 6600 LOWER HOPPER ............................................................................................................. 6600 OPEN HOPPER DOOR .................................................................................................... 6600 CLOSE HOPPER DOOR .................................................................................................. 6600 RIGHT TURN .................................................................................................................... 6600 LEFT TURN ...................................................................................................................... 6600 PROPEL SYSTEM ............................................................................................................ 29 30 32 33 34 35 36 37 38 39 40 41 42 6650 Electrical Troubleshooting Charts ....................................................................................... 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM ............................................................. 6650 DIESEL OVERALL ELECTRICAL DIAGRAM ................................................................... 6650 Key Switch ........................................................................................................................ 6650 Charging System .............................................................................................................. 6650 Gas/L.P. Start Circuit ........................................................................................................ 6650 Diesel Start Circuit ............................................................................................................ 6650 Gas/L.P. Power-Up Circuit ................................................................................................ 6650 Diesel Power-Up Circuit .................................................................................................... 6650 Gas/L.P. Check Engine Circuit ......................................................................................... 6650 Gas/L.P. High Engine Temperature Circuit ....................................................................... 6650 Diesel High Engine Temperature Circuit ........................................................................... 6650 Gas/L.P. Oil Pressure Circuit ............................................................................................ 6650 Diesel Oil Pressure Circuit ................................................................................................ 6650 Vacuum Fan Circuit .......................................................................................................... 6650 Vacuum Restriction Warning Circuit ................................................................................. 6650 Gas/Diesel Fuel Sender Circuit ......................................................................................... 6650 Low L.P. Fuel Sender Circuit ............................................................................................ 6650 Shaker Motor Circuit ......................................................................................................... 6650 Thermo-Sentry Circuit ...................................................................................................... 6650 Hopper Door Circuit .......................................................................................................... 6650 Hopper Up/Down Circuit ................................................................................................... 6650 Main Brush Stall Circuit ..................................................................................................... 6650 Main Brush On & Down Circuit ......................................................................................... 6650 Main & Side Brush On & Down Circuit .............................................................................. 6650 Interlocks ........................................................................................................................... 6650 Operational/Diagnostic/Maintenance Modes .................................................................... 43 44 48 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 69 70 71 72 73 74 75 77 Home Find... Go To.. Six Operational Modes ........................................................................................................ 6650 with ZEEMS ...................................................................................................................... 6650 ZEEMS Check Engine Fault Codes ........................................................................... 6650 Machine Control Board Pin Functions ........................................................................ 77 78 79 80 6650 Hydraulic Troubleshooting Charts ...................................................................................... 6650 OVERALL HYDRAULIC DIAGRAM .................................................................................. 6650 HYDRAULIC HOSE ROUTING ........................................................................................ 6650 MAIN BRUSH ................................................................................................................... 6650 MAIN & SIDE BRUSH ....................................................................................................... 6650 VACUUM FAN .................................................................................................................. 6650 RAISE HOPPER ............................................................................................................... 6650 LOWER HOPPER ............................................................................................................. 6650 OPEN HOPPER DOOR .................................................................................................... 6650 CLOSE HOPPER DOOR .................................................................................................. 6650 LOWER MAIN BRUSH ..................................................................................................... 6650 RAISE MAIN BRUSH ........................................................................................................ 6650 LOWER SIDE BRUSH ...................................................................................................... 6650 RAISE SIDE BRUSH ........................................................................................................ 6650 RIGHT TURN .................................................................................................................... 6650 LEFT TURN ...................................................................................................................... 6650 MAIN BRUSH STALL TRIGGERING PRESSURE SWITCH ............................................ 6650 PROPEL SYSTEM ............................................................................................................ 81 82 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 ECU - Black Connector .................................................................................................................. 101 ECU - White Connector .................................................................................................................. 102 ECU - Pin Descriptions .................................................................................................................. 103 Engine Maintenance Schedule ...................................................................................................... 104 Engine General Specifications ...................................................................................................... 106 ZEEMS - Zenith Electronic Engine Management System ........................................................... Overview .................................................................................................................................... Block Diagram ............................................................................................................................ ECU ........................................................................................................................................... Inputs ......................................................................................................................................... Inputs, RPM ......................................................................................................................... Inputs, ECT & IAT ................................................................................................................ Inputs, MAP ......................................................................................................................... Inputs, EGO ......................................................................................................................... Inputs Review ...................................................................................................................... Output Control ............................................................................................................................ Governor .............................................................................................................................. Fuel Injector ......................................................................................................................... Ignition Timing ..................................................................................................................... Open/Closed Loop ..................................................................................................................... Open & Closed Loop ........................................................................................................... Closed Loop to Open Loop .................................................................................................. Closed Loop Operation........................................................................................................ Review Questions and Answers .......................................................................................... System Operation ...................................................................................................................... Key On ................................................................................................................................. Cranking .............................................................................................................................. Running ............................................................................................................................... Diagnostics ................................................................................................................................ Failures ................................................................................................................................ ECU Quick Tests ................................................................................................................. Output Control Frequency Test ..................................................................................... Processor Quick Tests .................................................................................................. Input Sensor Quick Tests .................................................................................................... IAT and ECT Testing .................................................................................................... 107 109 112 113 116 117 119 122 127 132 133 134 142 147 150 150 152 153 155 156 156 157 158 162 162 163 164 165 167 168 Home Find... Go To.. MAP Testing ................................................................................................................. EGO Testing ................................................................................................................. Output Sensors Quick Test ................................................................................................. Failures ......................................................................................................................... Fuel Injector Testing ..................................................................................................... Governor Actuator Testing ............................................................................................ Ignition Timing Testing .................................................................................................. Diagnostic Review ........................................................................................................ Specifications ............................................................................................................................. Block Diagram Review ............................................................................................................... Operation Review ...................................................................................................................... 170 171 172 172 173 174 176 177 178 180 181 ZEEMS Troubleshooting Test Kit ................................................................................................. Gas Injector - Noid Light Tennant Part # 371780 .................................................................... LPG Injector - Noid Light Tennant Part # 371781 .................................................................... 185 188 188 Engine Controls .............................................................................................................................. AIR AND COOLANT SENSOR RESISTANCE .......................................................................... DIAGNOSTIC PROCEDURES .................................................................................................. Engine Idle Speed High ....................................................................................................... Engine Speed Spikes Intermittentl ................................................................................... Engine Runs Erratically, Poor Governor Performance ........................................................ Engine Runs, But Will Not Accelerate ................................................................................. Engine Wont Start - Gasoline ............................................................................................. Gasoline Fuel Pump Diagnosis ........................................................................................... Engine Wont Start - LPG .................................................................................................... Engine Wont Start Dual Fueel ............................................................................................ Engine Runs, Low Power, Lean or Misfires Gasoline ....................................................... LPG Lock-Off Diagnosis ...................................................................................................... Engine Runs Rich Gasoline ............................................................................................... Engine Runs, Low Power, Lean or Misfires LPG .............................................................. Engine Runs Rich LPG ...................................................................................................... 189 189 190 191 192 193 194 195 196 197 199 200 201 202 203 205 PSI - Operation and Maintenance ................................................................................................. Table of Contents ....................................................................................................................... Introduction ................................................................................................................................ How to Use this Manual ............................................................................................................. Engine Identification ................................................................................................................... Parts and Service ....................................................................................................................... Service Literature ....................................................................................................................... Operating Instructions ................................................................................................................ Controls ............................................................................................................................... Ignition Switch ............................................................................................................... Safety Gauges .............................................................................................................. Fuel Systems ................................................................................................................ Governors ..................................................................................................................... Instruments .......................................................................................................................... Oil Pressure Gaug ........................................................................................................ Voltmeter ....................................................................................................................... Tachometer/Hourmeter ................................................................................................. Starting the Engine .............................................................................................................. Carbureted, Mechanical Governor, Manual Choke ....................................................... Carbureted, Electric Choke, Electronic Governor ......................................................... LPG or NG Fuel Systems, Velocity Governors ............................................................. PSI Fuel Injection (Gasoline) ........................................................................................ PSI Fuel Injection (Gasoline/LPG)(Dual Fuel) .............................................................. Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor ............................... Stopping the Engine ............................................................................................................ Fuel Recommendations ....................................................................................................... Power Loss at Higher Elevations ......................................................................................... Carbureted Engines ...................................................................................................... Fuel Injected Engines ................................................................................................... MAINTENANCE INSTRUCTIONS ............................................................................................. Initial Start Up Maintenance ................................................................................................ 207 208 211 211 212 212 212 213 213 213 213 213 214 214 214 215 215 215 215 216 216 216 216 216 217 217 219 219 219 220 220 Home Find... Go To.. Routine Maintenance ........................................................................................................... Scheduled Preventive Maintenance .................................................................................... Engine Oil Level Check ....................................................................................................... Adding Engine Oil ................................................................................................................ Changing Engine Oil and Filter ............................................................................................ Engine Oil Quality ................................................................................................................ Oil Filter ............................................................................................................................... Engine Air Cleaner .............................................................................................................. Cooling System ................................................................................................................... Coolant Level ................................................................................................................ Radiator ........................................................................................................................ Fan Belts ....................................................................................................................... Serpentine Belt ............................................................................................................. V-Type Belt ................................................................................................................... Fuel Filter ............................................................................................................................. Carbureted Engines ...................................................................................................... TBI Engines .................................................................................................................. Ignition Systems .................................................................................................................. Ignition Timing ............................................................................................................... Spark Plugs ................................................................................................................... Storage ................................................................................................................................ One to Six Months ........................................................................................................ For Extended Periods ................................................................................................... Removing the Engine From Extended Storage ............................................................ GM Engine Timing Procedures ........................................................................................... Maintenance Schedule ........................................................................................................ Filter Chart ........................................................................................................................... Fuel System Chart ............................................................................................................... GENERAL SPECIFICATIONS ................................................................................................... 3.0L Engine Spark Plug Wire Routing ....................................................................................... 220 220 220 220 221 221 221 222 222 222 223 223 224 224 224 224 224 225 225 225 226 226 226 226 228 229 230 231 232 233 Torque Standards ........................................................................................................................... Inch Fasteners ........................................................................................................................... METRIC Fasteners .................................................................................................................... Nylon Insert Lock Nuts ............................................................................................................... Wheel Bolt and Nuts .................................................................................................................. Tightening Nuts on Tapered Shafts ........................................................................................... Shoulder Bolts ............................................................................................................................ Taper Lockr Bushings ................................................................................................................ Sequence Tightening ................................................................................................................. 244 235 237 239 240 241 242 243 244 Home Find... Go To.. MODEL 6600 ELECTRICAL Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual DURING TESTS: * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action Home Find... Go To.. 6600 07-2003 1 2 X X 34 S--2 3A Home 1C 1B 30 30 M--2 M--1 J7--A A 87 50B 87 6 Find... Go To.. D--1 J9--F 5EA J7--C 31EA BIT --A 1350 RPM LOW: HIGH 2000 RPM MED: 0V 2400 RPM HI GH: 0V L P5 6 27C 26A 29A 6600 NOT USED NOT USED LOW OIL PRESS. L P5 ENG. TEMP/CHECK 38B 5 J9--G J9--B J9--A J9--C J9--D J2 --12 C B D B A A A 58EA 59EA 60EA 61EA 63EA 64EA 65EA 66EA A J2 --4 J2 --17 J1 --8 J1 --18 J1 --10 COIL--A J2 --9 J1 --1 J1 --5 H20 GOV 27EB J2 --8 ANALOG HIGH ENGINE TEMP 28EA 27EA P1= WHITECONNECTOR P2 = BLACKCONNECTOR OIL J1 --4 SD2 FUEL EX +5V OXY COIL--B COIL--D MAP--B GAS MP--C 67 J7--D C 57EA J2 --20 MG--3 5EA 27EC C A A S--6 S--5 MTR2 S--4 S--3 SOL 4 67B A SOL 5 A B 56EA 67A A 55EA J2 --19 LP MAG2 29EA J2 --2 SPD1 LOW OIL PRESS. A 53EA J1 --20 B 68EA J2 --10 D J2 --21 MAG1 GND 83EB ENGINE HARNESS C 02 SENSOR STARTER SOLENOID COIL MT R1 STARTER MOTOR 13EH AIR TEMP SENSOR 13EM 13EE 13EL 13EJ 13EC 13ED 13EA B 13EG 13L 13M OIL PRESSURE SWITCH L.P. LOCK OUT VALVE FUEl PUMP GOVERNOR ACTUATOR 13EF 13EB B COOLANT TEMP SENSOR 2 B B 13F ENGINE BLOCK COOLANT TEMP SENSOR 1 13EK B B B C COIL PACK A MAP SENSOR MAG.PICK UP 13W ENGINE BLOCK ENGINE HARNESS J1 --21 RST GD2 J2 --11LOW CURRENT GROUND THROUGH THECONTROLLER KEY2 GD1 26EA J1 --12 ENG ENGINE TEMP/CHECK SPEED BIT ”A” J2 --5 J2 --3 J2 --16 B + 5V REF. 148EA 5 70EA J1 --3 O2--B KEY1 O2A 69EC J1 --15 INJ 54EA J1 --2 72EA NOT USED S--7 ENGINE SPEED SWITCH J7--E 38A 2 SPEED BIT ”B” 31A 3 J9--E 38B HOUR METER - GASINJECTOR SOL4 + J1 --23 8EG J1 --16 J1 --22 8EF 8EE 13F 82EA ZENITH ENGINE CONTROL B 8A 8B 8D 51A 51 85 GND. WITHENGINERUNNING WILL CLEAR FAULTCODES. 85 85 L.P.INJECTOR M--2 M--1 M--3 J1--14 ST SOL3 86 86 86 83EC J2--7 __SL 69EB 69EA 8K 8J KEY:START 3EA 87 A 8C 8L J7--B M--3 82E F--11 15A FUSE 8 N.O./ CLOSED = DOWN NEUTRAL START 30 A KEYSW 2 ACC 19 17 50 1EA STARTER MOTOR ASSEMBLY STARTER SOLENOID CONTACTS 83E X X X x = CLOSED CONTACT 30 X RUN START S--1 8C ALTERNATOR LIGHT 52 L P5 GROUND A 30A FUSE F--5 ENGINE HARNESS 28 ALT EX. POSITIVE BATTERY CABLE OUTPUT+ - 1A 1D 12 VDC + -- 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 1 of 4 1 ENGINE SPEED SELECTION BITS ’A’ AND ’B’ BIT --B 0V HIGH 0V 2 AUX #2 3 AUX. 2 RELAY AUX. 1 RELAY AUX #1 07-2003 Home Find... Go To.. F--20 15A FUSE S-- 10 3 2 FLASHER 95A 79/YEL 33 3 6 1 CODE 6600 07-2003 4 GRAY 7 8 WHITE BLUE PURPLE 6 GREEN YELLOW 3 5 BRN ORANGE 2 PINK 1 9 62/YEL 93/ORA 76/ORA 62BC/YEL 62BA/YEL 62BB/YEL 62B/YEL 62C/YEL 93B/ORA 62BA/YEL 90/GRY 9 89/BRN 8 88/GRN 4 87/PUR 7 62A/YEL GRY BLK GRN ............. S--11 BLK/ GRY BLU YEL RED COLOR OF WIRE IN HARNESS TAN COLOR RIGHT MOST DIGIT OF WIRE NUMBER 0 33A DIRECTIONALSWITCH 93A/ORA LIGHT SWITCH S--12 1 2 4 5 6 8 77/GRY 80/BLU ...........WIRING 95 95A N.O. / CLOSED = HORN S-- 9 HORN N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH 81A/YEL 1 4D/YEL 93/ORA N.O. / CLOSED = REVERSE REVERSE SWITCH L 81/YEL 4B/YEL 4A/YEL 4C/YEL 92 S-- 8 P 15A FUSE F--4 4/YEL 15A FUSE F--12 15A FUSE LP4 LP3 76B/ORA 76A/ORA TAIL LIGHT, L.H. TAILLIGHT, R.H. 88A/GRN 33B 33A 94/YEL 87A/PUR FLASHER REVERSEALARM LP9 LP8 LP7 LP6 LP5 LP2 LP1 HORN D--3 LP10 LOW MOUNTED BEACON REVOLVING LIGHT, OHG SIDE BRUSH LIGHT HEADLIGHT, L.H. HEADLIGHT,R.H. RUN LIGHT, L.H. RUN LIGHT, R.H. 13V LAMP_HEADLIGHT 13QQ 13NN 13LL 13KK 13BF 13BD 13BE 13S 13T 13FF 13GG 13U 13Q 13P 1 6 1D 1A 3 F--3 2 X 34A 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 2 of 4 AUX #1 3 AUX #1 4 6 F--19 Home LOWL.P. GND SEN 18A HIGH HOPPER TEMP IN FUEL GAUGE Find... Go To.. 7E 7 7H 7J 9 10 1 32 30 M--4 47A STALLED BRUSH CLOGGED VAC FAN 87 M.O.M. VAC/SHAKER SWITCH S--17 18 11 HOPPER DOOR CLOSED N.O./ CLOSED = HOPPER DN. LAMP(+) LAMP(--) S--16 HOPPER DOWN 8 7F 30A 6 5 4 7L 7L 2 7A 7B 7C 7A 16 15 14BA M--4 D--2 19BA 11BA NC COM S--15 THERMAL SENTRY SWITCH NO N.O. / CLOSED = LOW L.P. S--14A LOW L.P. S--14 FUEL SENDER 24 22 105 B+ LOAD INIT 3 (+) OUT (--) GND 1 SHAKER PULSE MODULE 2 1 2 6 3 SHAKER TIMER MODULE N.O./ CLOSED=STALLED S--19 STALLED BRUSH 13BA HOPPER STATIC GROUND N.O./ CLOSED=CLOGGED S--18 CLOGGED VACUUM FAN 47 48 7K 32 82 13BB N.O. / CLOSED = DOWN S--13 HOPPER DOOR GROUND FOR LAMP INSIDE SWITCH 19A 48BB 85 SHAKER SOLENOID SOL 1 47BB 86 13A 18A SOL 5 VAC.FAN SOLENOID B 19B 18B A 14 13H 13U 13C 13B 13A 13E 13R 13D 13L 13E 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 15A FUSE 7D 6600 07-2003 B+ Home Find... Go To.. BATTERY, B+ RED 50 RED 50A F-- 22 20A FUSE F--8 15A FUSE F-- 21 20A FUSE F--7 15A FUSE BRN 118/GRY YEL 111F/ORA 1 2 3 115/GRN 1 2 LOW HIGH 120/ORA 119/YEL AC [ON-- OFF] S-- 12 BRN 30 86 87 86 AC2 AC1 DEFROST FAN ORG/GRN YEL YEL GRN LOW MEDIUM HIGH DOME LIGHT WIPER SWITCH COM S-- 14 OFF S-- 11 CAB/PRESS. FAN SWITCH COM OFF S-- 15 111B/ORA 111D/ORA 111C/ORA 111/ORA 30 87 ORG 85 BLK YEL WHT 85 BLK BLK WINDSHIELD WIPER 13AAA/BLK 13EEE/BLK 13CCC/BLK 13DDD/BLK WHT SWITCH ORG YEL ORG YEL BLK D--6 GND BLK GND BLK 6600 GND GND COLOR OF WIRE IN HARNESS TAN PINK BRN ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE CODE ............. 13AAA/BLK UNLESS SPEC IFIED DIFFERENTLY ON SC HEMATIC 0 1 2 3 4 5 6 7 8 9 COLOR RIGHT MOST DIGIT OF WIRE NUMBER ...........WIRING O P TIONAL AC AND CAB HARNESSES CLUTCH SOL. AC CONDENSERFANS AC EVAP./CAB PRESS.FANS HIGH LOW HIGH LOW WHT BLU BLU BLK/WHT SWITCH BLK/WHT AC EVAP. TEMP AC CONDENSERPRESS. AC COMPRESSOR GND A B A B 112/PUR 113/YEL 111E/ORA 116/BLU DOME LIGHT 4 AUX #2 BATTERY, AUX #2 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 4 of 4 07-2003 5 6 8C 30 Home X=CLOSED CONTACT 42A 34 A TO ALTERNATOR F-- 11 1C 1B 30 30 M--2 M--1 AUX. 2 RELAY 87 50B AUX. 1 RELAY 87 6 Find... Go To.. 8A 8D NOT USED NOT USED NOT USED 15A FUSE N.O./ CLOSED = DOWN J9--B J9--G J7--E ENGINESPEED S ELECTION BIT A BIT B 0V 1350RPM LOW: HIGH 0V HIGH 2000RPM MED: H I GH: 0V 0V 2400RPM 6600 8K 8J 87 87a 86 3D 8BC M6A M 6C M 6B M8A M 8C 85 30 3067 85 87a 30 85 5 J7--D 67C 56 82 2 8BB 3 56 6 67B 67A 67 D--5 GND 1 38B 5 S--7 B B 86 86 M--2 51A D--1 13F 26 SPEED BIT ”B” 85 51 85 J9--C M--1 26A ENG. TEMP/CHECK LP5 J9--D FUEL PUMP 13BC 13BG 13BA N.O../CLOGGED = HIGH TEMP S--16 HIGH ENGINE TEMP. A 8BF 13L 13M 13F ENG. SPEED/MAG. PICK--UP B 13BA C 61 D 61A 13BF L.P. LOCK OUT VALVE GOVERNOR 59 E 60 F 29 G SPEED BIT ”A” H 31 J9--E 331A 629A THROTTLE ACTUATOR 38A 2 5 ENGINE SPEED SWITCH 38B J9--F -- 13BB 13BD ENGINE BLOCK ENGINE BLOCK CREATES DELAY BETWEEN ENGINE START ATTEMPTS. SOL5 IN IT B+ LOAD -+ 8B 30 86 55A 55 8BD D--3 M 8B M7A 13W ENGINE BLOCK ENGINE HARNESS ENGINE START TIMER MODULE 87 ENGINE HARNESS 83 OILPRESS. SWITCH 5A 5B A B N.O.OIL PRESSURE J7--C HOUR METER C 27 S3 LP5 27C J9--A N.C. OIL PRESSURE LOW OIL PRESS. + 3B 8BA 87 3A 86 M 7B MTR1 STARTER MOTOR STARTER SOLENOID COIL + -- 8BF 8BG 8BE 13BD 30 OPTIONAL GLOW PLUG LAMP J7--B 3C KEY:START LP1 J7--A GLOW PLUG X X 2 42 42A S--2 NEUTRAL START 3A GP -- 4 50 X 17 19 X X ACC 1K 42B GP -- 3 RUN GLOW PLUG START X S-- 1 ENGINE HARNESS -- -- STARTER MOTOR ASSEMBLY STARTERSOLENOID CONTACTS GP -- 2 KEYSW 52 LP5 GROUND GP -- 1 F--5 30A FUSE EX. 28 ALT -- ALTERNATOR LIGHT POSITIVE BATTERY CABLE OUTPUT+ A 1A 1D + 12 VDC 6600 DIESEL OVERALL ELECTRICAL DIAGRAM Part 1 of 4 1 ENGINE BLOCK 2 3 AUX #2 AUX #1 07-2003 3 Home 1D 1A F--3 Find... Go To.. 15A FUSE 6600 95A YELLOW 4 07-2003 9 8 WHITE GRAY PURPLE BLUE ORANGE 3 GREEN BRN 2 6 PINK 1 5 TAN 0 7 2 3 N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH ...........WIRING COLOR CODE ............. RIGHT MOST DIGIT COLOR OF WIRE OF WIRE NUMBER IN HARNESS 6 FLASHER 95 95A N.O. / CLOSED = HORN S-- 9 HORN 81A/YEL S-- 10 1 4D/YEL 33 3 6 1 33A 62BA/YEL 9 90/GRY 89/BRN 8 4 88/GRN 87/PUR 7 62A/YEL GRY BLK GRN 62/YEL S--11 BLK/ GRY BLU YEL RED DIRECTIONALSWITCH 93A/ORA LIGHT SWITCH S--12 1 2 4 5 6 8 77/GRY 80/BLU 79/YEL N.O. / CLOSED = REVERSE REVERSE SWITCH 93/ORA L F--20 81/YEL 4B/YEL 4A/YEL 4C/YEL 92 S-- 8 P 15A FUSE F--4 4/YEL 15A FUSE 34A F-- 12 76/ORA 62BC/YEL 62BA/YEL 62BB/YEL 62B/YEL 62C/YEL 93B/ORA 93/ORA LP4 LP3 76B/ORA 76A/ORA TAIL LIGHT, L.H. TAILLIGHT, R.H. 88A/GRN 33B 33A 94/YEL 87A/PUR FLASHER REVERSEALARM LP9 LP8 LP7 LP6 LP5 LP2 LP1 HORN D--3 LP10 LOW MOUNTED BEACON REVOLVING LIGHT, OHG SIDE BRUSH LIGHT HEADLIGHT, L.H. HEADLIGHT,R.H. RUN LIGHT, L.H. RUN LIGHT, R.H. 13V LAMP_HEADLIGHT 13QQ 13NN 13LL 13KK 13P 13BF 13BD 13BE 13S 13T 13FF 13GG 13U 13Q 1 X 2 15A FUSE 6600 DIESEL OVERALL ELECTRICAL DIAGRAM Part 2 of 4 AUX # 1 7 Home Find... Go To.. 7E 7 7H 30 STALLED BRUSH CLOGGED VAC FAN M--4 87 47A 32 M.O.M. S--17 VAC/SHAKER SWITCH 8 5 4 1 7J 2 6 18 7L 30A LAMP(+) LAMP(--) 7L 7F S--16 HOPPER DOWN 18A HIGH HOPPER TEMP 11 LOWL.P. GND FUEL GAUGE IN SEN HOPPER DOOR CLOSED N.O./CLOSED = HOPPER DN. 7A 7B 7C 7A M--4 D--2 48BB 105 85 19A B 19B SHAKER SOLENOID SOL1 47BB 86 13A 18A 18B A SOL 5 VAC. FAN SOLENOID 14 24 22 16 15 13BA N.O./ CLOSED = DOWN N.O. / CLOSED=LOW L.P. S--14A LOWL.P. S--14 FUEL SENDER (+) OUT (--) PULSE MODULE 1 1 TIMER MODULE HOPPER STATIC GROUND N.O./ CLOSED=STALLED S--19 STALLED BRUSH N.O./ CLOSED=CLOGGED S--18 CLOGGED VACUUM FAN 473 48 2 7K 3 32 6 82 2 GROUND FOR LAMP INSIDE SWITCH THERMAL SENTRY SWITCH 11BA NO 13BB COM S-- 15 NC 19BA 14BA S--13 GND LOAD F--19 B+ 8 6 9 10 INIT AUX #1 HOPPER DOOR 13H 13U 13C 13B 13A 13E 13R 13D 13L 13E 6600 DIESEL OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 7D 15A FUSE 6600 07-2003 Home Find... Go To.. B+ RED COLOR F-- 22 BLUE 6 6600 GRAY WHITE UNLESS SPECIFIED DIFFERENTLY ON SCHEMATIC 9 8 PURPLE 5 7 YELLOW GREEN 4 BRN ORANGE 3 PINK 2 1 OFF S-- 15 OFF S-- 11 115/GRN 120/ORA 119/YEL AC [ON-- OFF] S-- 12 YEL YEL GRN BRN 30 86 87 86 AC2 AC1 DEFROST FAN ORG/GRN LOW MEDIUM HIGH DOME LIGHT 1 2 3 WIPER SWITCH COM S-- 14 1 2 LOW HIGH 111B/ORA 111D/ORA 111C/ORA 111/ORA CAB/PRESS. FAN SWITCH COM ............. BRN 118/GRY YEL 111F/ORA CODE 20A FUSE F-- 10 15A FUSE F-- 21 20A FUSE F--7 15A FUSE RIGHT MOST DIGIT COLOR OF WIRE OF WIRE NUMBER IN HARNESS 0 TAN ...........WIRING BATTERY, #2 50 RED 50A 87 ORG 85 YEL 30 WHT BLK 85 BLK A 112/PUR 113/YEL 111E/ORA 116/BLU WHT SWITCH B BLU BLU D--6 GND BLK GND BLK 13AAA/BLK GND GND CLUTCH SOL. AC CONDENSOR FANS BLK/WHT SWITCH AC EVAP./CAB PRESS. FANS LOW HIGH ORG HIGH LOW WHT YEL ORG YEL 13AAA/BLK 13EEE/BLK 13CCC/BLK AC CONDENSER PRESS. AC COMPRESSOR GND A B BLK/WHT BLK AC EVAP. TEMP BLK WINDSHIELD WIPER DOME LIGHT 13DDD/BLK O P TIONAL AC AND CAB HARNESSES AUX B+ #2 4 BATTERY, AUX 6600 DIESEL OVERALL ELECTRICAL DIAGRAM Part 4 of 4 07-2003 9 6600 Key Switch 30 30 50 50 17 17 19 19 ACC ACC GLOW PLUG POSITION (Diesel Only) Spring loaded- Returns to "OFF" unless held OFF OFF RUN Glow Plug START RUN Glow Plug KEY SWITCH KEY SWITCH OFF OFF RUN Glow Plug 30 OFF POSITION START START RUN Glow Plug START KEY SWITCH 30 KEY SWITCH 50 50 17 17 19 19 ACC ACC RUN POSITION START POSITION Spring loaded-Returns to “RUN" unless held SWITCH TERMINAL MARKING KEY SWITCH POSITION 30 50 17 19 ACC GLOW PLUG OFF NO CONNECTIONS RUN START “. “ Indicates a common connection NOTE: Common connections in various switch positions should be less than 1ȍ 10 Home Find... Go To.. 6600 07-2003 6600 Charging System + - 28 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11, turn key to “RUN” position (KOEO-Key On, Engine Off) Is Alternator light lit? YES NO Start engine (KOER-Key On, Engine Running), run engine at high governed RPM Test ALTERNATOR LIGHT; Re-test battery, re-check battery terminals, connections, wiring, and fuses F-5 & F-11; Restart diagnostic steps With lights on, check voltage at battery terminalsIs it 13.5 to 16.5 Volts? YES YES Is Alternator light lit? NO NO System operating correctly Re-test battery, re-check battery terminals, connections, wiring, and fuses F-5 & F-11; Suspect faulty alternator PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6600 07-2003 Home Find... Go To.. 11 6600 Gas/L.P. Start Circuit + - POSITIVE BATTERY CABLE 28 1EA x x 83EC x x 83EA PIN 7 8 xx 8L 82EA 8EF Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 8EG PIN 14 WHITE CONNECTOR PIN 22 PIN 20 PIN 23 Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position YES Does STARTER MOTOR “click” or make any other noises? BLACK CONNECTOR PIN 21 13ED 13EC ZENITH ENGINE CONTROLLER NO CAUTION! Disconnect wire harness plug from DIS ignition coil and turn key to OFF position for next test. Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Repair or replace STARTER MOTOR With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLENOID studs (the STARTER SOLENOID is an integral part of the STARTER MOTOR) Re-check all connections, wiring and fuses F-5 & F11; Test relay M-3; Test Key Switch; Test for proper power & ground connections at ZENITH ENGINE CONTROLLER (refer to ZEEMS troubleshooting) YES 12 Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Repair or replace STARTER MOTOR As the remote start switch is engaged, does the STARTER MOTOR crank the engine? 6600 07-2003 Go To.. PLEASE Home NOTE: WhenFind... finished, please reconnect all wires disconnected during testing NO 6600 Diesel Start Circuit - + POSITIVE BATTERY CABLE 83 50 2 17 42 19 42A 13BB ACC 34 3C 8BE 42B Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 13M 8 8BC 5A 8D 8A Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position YES Does STARTER MOTOR “click” or make any other noises? CAUTION! Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR Re-check all connections, wiring and fuses F-5 & F-11; Test relays M-6, M7, & M8; Test ENGINE START TIMER MODULE; Test Key Switch Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR NO Turn key to OFF position for next test. With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLENOID studs (the STARTER SOLENOID is an integral part of the STARTER MOTOR) YES As the remote start switch is engaged, does the STARTER MOTOR crank the engine? 6600 07-2003 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing NO 13 6600 Gas/L.P. Power-Up Circuit + - 28 x x Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 8EF x x 8EG 8L xx 8 PIN 20 CONNECTOR PIN 23 13ED WHITE PIN 21 13EC ZENITH ENGINE CONTROLLER Check all connections, wiring, and fuses F-5 & F-11, turn key to “ON” position (KOEO-Key On, Engine Off) YES Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER 14 PIN 22 Is battery voltage measured across all power and ground connections at ZENITH ENGINE CONTROLLER? NO Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6600 07-2003 Home Find... Go To.. 6600 Diesel Power-Up Circuit - + 1D GOVERNOR CONTROLLER 28 PIN A 40A FUSE 2 PIN B 3A 3C 13BA 8BF 34 13BG Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 13M 13BF 5A 8A Check all connections, wiring, and fuses F-5 & F-11; Turn key to “ON” position (KOEO-Key On, Engine Off) YES Refer to PRECISION GOVERNOR troubleshooting to test GOVERNOR CONTROLLER Is battery voltage measured across all power and ground connections at GOVERNOR CONTROLLER? NO Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch 6600 07-2003 PLEASE NOTE: When finished, please reconnect Home Find... Go To.. all wires disconnected during testing 15 6600 Gas/L.P. Check Engine Lamp Circuit - + 8EF PIN 22 PIN 20 13ED 28 WHITE CONNECTOR 8EG 8L PIN 21 13EC 26EA x x x x PIN 23 PIN 12 xx ZENITH ENGINE CONTROLLER 8 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 8B 26A ENGINE TEMP / CHECK ENGINE LAMP Note: Lamp will light if engine overheats or if an engine system fault is detected Check all connections, wiring, and fuses F-5 & F-11, turn key to “ON” position (KOEO-Key On, Engine Off) YES Refer to “ZENITH ENGINE FAULT CODES” to diagnose engine or sensor faults 16 Is CHECK ENGINE LAMP flashing? NO Test CHECK ENGINE LAMP; Re-check all connections, wiring, and fuses F-5, & F-11; Test for proper power and ground connections at ZENITH ENGINE CONTROLLER; Test Key Switch; Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6600 07-2003 Home Find... Go To.. 6600 Gas/L.P. Oil Pressure & Hour Meter Circuit + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x x x OIL PRESSURE SWITCH 6 PSI 8D 13EG ZENITH ENGINE CONTROLLER xx BLACK CONNECTOR PIN 8 27EC 27EB 27EA 8A 27C Check all connections, wiring, and fuses F-5 & F-11, turn key to “ON” position (KOEO-Key On, Engine Off) Is LOW OIL PRESSURE lamp lit? YES YES With engine running, does lamp go out? NO Remove harness plug at OIL PRESSURE SWITCH and place a jumper wire across harness plug wires B & C NO Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH YES YES With engine running, is battery voltage measured across HOUR METER terminals? Is LOW OIL PRESSURE lamp lit? NO NO Replace OIL PRESSURE SWITCH Re-check HOUR METER connections and wiring; Suspect faulty OIL PRESSURE SWITCH Test or replace HOUR METER Test LOW OIL PRESSURE lamp; Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch 6600 07-2003 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 17 6600 Diesel Oil Pressure & Hour Meter Circuit + 1D Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 40A FUSE OIL PRESSURE SWITCH A B 8D 13BF 3434 8 8A C Check all connections, wiring, and fuses F-5 & F-11, turn key to “ON” position (KOEO-Key On, Engine Off) Is LOW OIL PRESSURE LED lit? YES YES With engine running, does lamp go out? NO Remove harness plug at OIL PRESSURE SWITCH and place a jumper wire across harness plug wires B & C NO Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH YES With engine running, does HOUR METER run? Is LOW OIL PRESSURE lamp lit? NO NO YES Verify proper oil pressure in engine; Suspect faulty HOUR METER; Suspect faulty OIL PRESSURE SWITCH Verify proper oil pressure in engine; System operating correctly 18 Replace OIL PRESSURE SWITCH Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch 6600 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 07-2003 6600 Vacuum Fan Circuit - + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x x x xx LED INSIDE SWITCH 3 POSITION VAC FAN & FILTER SHAKER SWITCH S W I T C H POS.1 – VAC FAN ON POS.2 – ALL FUNCTIONS OFF POS.3 – RUN SHAKER (MOMENTARY) 13A TO HIGH HOPPER TEMP LAMP HOPPER SWITCH (NORMALLY OPEN) SHOWN CLOSED (HOPPER DOWN) 13BB SHOWN WITH SWITCH IN “VAC FAN ON” POSITION 13E Check all connections, wiring, and fuses F-5, F-11 & F-19, have hopper in full “DOWN” position, turn key to “ON” position (KOEO-Key On, Engine Off) With switch in “VAC FAN ON” (position 1), is battery voltage measured across wires at VAC FAN SOLENOID (SOL5) plug? YES NO Repair or replace faulty hydraulic or mechanical components; Suspect faulty VAC FAN SOLENOID coil Re-check all power & ground connections and fuses F-5, F-11 & F-19; Test HOPPER SWITCH; Test THERMO-SENTRY SWITCH (see circuit chart); Test “3-POSITION” VAC FAN/SHAKER SWITCH; Test relay M-1; Test diodes D-1 & D-2; Test Key Switch PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 19 6600 Vacuum Restriction Warning Circuit - + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x 7D x x xx 7 22 VACUUM SWITCH (NORMALLY OPEN) SEE NOTE BELOW Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) 13U VACUUM SWITCH NOTE Vacuum switch closes if vacuum fan is running with any one of these conditions: - a blocked (dirty) vacuum panel filter - a blocked Perma-Filter - a closed hopper door Remove wire plug from VACUUM SWITCH and place a jumper wire across harness plug wires YES Is CLOGGED VAC FAN lamp lit? Test CLOGGED VAC FAN lamp; Re-check power & ground connections and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch Suspect faulty VACUUM SWITCH 20 NO PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 6600 Gas/Diesel Fuel Sender Circuit - + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x 7D x x xx S14 FUEL SENDER 0ȍ to 90ȍ 7C 13L 90ȍ = FULL TANK Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wires from FUEL SENDER at tank and watch FUEL GAUGE; Place jumper wire across FUEL SENDER wires and watch FUEL GAUGE again Does FUEL GAUGE needle deflect from FULL to EMPTY? YES 13D NO Suspect faulty FUEL SENDER Is battery voltage measured between wires “IN” & “GND” at FUEL GAUGE? YES Re-check wiring to FUEL SENDER ; Suspect faulty FUEL GAUGE NO Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 21 6600 Low L.P. Fuel Sender Circuit - + 28 x x x x 7D Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions xx 7B LOW L.P. 13R With a full L.P. tank properly connected to machine, with L.P. supply valve fully open, turn key to “ON” position (KOEO-Key On, Engine Off) YES Is LOW L.P. lamp lit? Check all connections and wiring; Suspect faulty LOW L.P. SWITCH NO Fully close L.P. supply valve on L.P. tank and run machine until engine runs out of fuel YES Is LOW L.P. lamp lit? NO Remove plug at LOW L.P. SWITCH and place a jumper wire across harness wires System operating properly YES Is LOW L.P. lamp lit? Test LOW L.P. LAMP; Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch Suspect faulty LOW L.P. SWITCH 22 NO PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 6600 Shaker Motor Circuit - + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x x x xx HOPPER DOWN SWITCH NORMALLY OPENCLOSED WITH HOPPER DOWN 3 POSITION VAC FAN & FILTER SHAKER SWITCH S W I T C H POS.1 – VAC FAN ON POS.2 – ALL FUNCTIONS OFF (CENTER) POS.3 – RUN SHAKER (MOMENTARY) 13B SHOWN WITH SWITCH IN “RUN SHAKER” POSITION 13C Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wire from #2 post of SHAKER PULSE MODULE; Momentarily push SHAKER SWITCH (position 3) Does SHAKER SOLENOID pulse as wire is tapped to ground? YES YES Momentarily push SHAKER SWITCH (position 3)- Is battery voltage measured across terminals #3 & #1 at SHAKER PULSE MODULE? Suspect faulty SHAKER PULSE MODULE NO Repair power or ground circuits leading to SHAKER PULSE MODULE NO Disconnect SHAKER SOLENOID plug; Connect one SHAKER SOLENOID wire to ground and the other to battery (+) Go to A Next Page PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 23 6600 Shaker Motor Circuit (continued) A Does SHAKER SOLENOID pulse as ground side wire is tapped to ground? YES NO Suspect faulty SHAKER SOLENOID Reconnect SHAKER SOLENOID to circuit – Push & hold SHAKER SWITCH (position 3) - Is battery voltage measured across posts #6 & #1 at SHAKER TIMER MODULE? YES NO Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test “3POSITION” VAC FAN/SHAKER SWITCH; Test relay M-1; Test diode D-1; Test Key Switch; Replace components as needed Momentarily push SHAKER SWITCH (position 3) - Is battery voltage measured across posts #85 & 86 at relay M-4? YES Re-check power & ground circuits to SHAKER TIMER MODULE; Suspect faulty SHAKER TIMER MODULE Re-check connections & power feed on post #30 at relay M-4; Suspect faulty relay M-4 24 NO PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 6600 Thermo-Sentry™ Circuit - + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x x x xx 7D 13E SOL 5 TO VAC. FAN SWITCH VAC. FAN SOLENOID Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wires from “NO” & “COM” terminals at THERMO-SENTRY SWITCH and connect wires with a jumper wire YES Is HIGH HOPPER TEMP LAMP lit? Reset or suspect faulty THERMO-SENTRY switch NO Test HIGH HOPPER TEMP LAMP; Recheck all power and ground circuits and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 25 6600 Hopper Door Switch Circuit - + Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 28 x x x x 7D xx 7C7A HOPPER DOOR SWITCH (NORMALLY OPEN) 14 13E CLOSED WITH HOPPER DOOR CLOSED Close Hopper Door; Turn key to “ON” position (KOEO-Key On, Engine Off) Is HOPPER DOOR CLOSED LAMP lit? YES NO Open Hopper Door; Turn key to “ON” position (KOEO-Key On, Engine Off) Remove wire harness plug from HOPPER DOOR SWITCH and place a jumper wire across harness wires Is HOPPER DOOR CLOSED LAMP lit? YES NO System operating properly Check all connections and wiring; Suspect faulty HOPPER DOOR SWITCH YES Suspect faulty HOPPER DOOR SWITCH 26 Is HOPPER DOOR CLOSED LAMP lit? NO Test HOPPER DOOR CLOSED LAMP; Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch PLEASE NOTE: When finished, please reconnect all wires disconnected during testing Home Find... Go To.. 6600 07-2003 6600 with ZEEMS (Zenith) Engine Management System Turn Key Off, Turn Key On, Engine Off (KOEO) Check Engine Light illumination for "12" will be as follows: on, medium off, on, short off, on; longer pause; on, medium off, on, short off, on; longer pause. on, medium off, on, short off, on. (other code readouts are similar) Blinks 12,12,12 Blinks Continuously Does Check Engine Light (either 0.5 seconds on then 1 second off or 1 second on then 1 second off) Blink Continuously, Blinks Another Sequence or Blink 12, 12, 12 ? No Engine Fault Codes Detected during KOEO (3 times only) Start and Run Engine Start and Run Engine Blinks another sequence (3 times only) Does engine "shut off" after 2-3 seconds or 40 seconds of running? (KOER) Tennant Engine Trouble Codes are: 14-ECT Sensor Open (Engine Coolant Sensor) 15-ECT Sensor Shorted (Engine Coolant Sensor) 23-ACT Sensor Open (Air Temperature Sensor) 24-ACT Sensor Shorted (Air Temperature Sensor) 33-MAP Sensor Open (Manifold Absolute Pressure) 34-MAP Sensor Shorted (Manifold Absolute Pressure) 44-O2 Sensor Lean (Oxygen Sensor) 45-O2 Sensor Rich (Oxygen Sensor) 2-3 Seconds 40 Seconds running then off running then off Low Oil Pressure automatic shutdown sequence activated Is Check Engine Light On during Key On, Engine Run? High Temperature automatic shutdown sequence activated Service and Repair as Required Home Find... Go To.. NO YES No Engine Fault Codes Detected during KOEO and KOER STOP Clear Codes by momentarily grounding 49/White "pigtail" while engine is running RETEST 6600 07-2003 27 6600 Gas/L.P. ZEEMS Check Engine Fault Codes MACHINE STATUS CHECK ENGINE LAMP Key On, Engine Off (KOEO) No engine faults detected Blinks “12,12,12” continuously Key On, Engine Running (KOER) No engine faults detected OFF Key On, Engine Running (KOER) Engine fault(s) detected ON Key On, Engine Off (KOEO) Engine fault(s) detected Blinks engine fault code (see chart below) Key On, Engine Running (KOER) High engine temperature sensed AUTOMATIC ENGINE SHUTDOWN OCCURS Blinks ON/OFF continuously (0.5 sec. ON, 1 sec. OFF) (Note: There is no separate high NOTE: If key switch is turned off and machine restarted, engine temp lamp for gas or L.P. engines) engine will run 40 seconds until another automatic shutdown Key On, Engine Running (KOER) Low engine oil pressure sensed AUTOMATIC ENGINE SHUTDOWN OCCURS NOTE: If key switch is turned off and machine restarted, Blinks ON/OFF continuously (1 sec. ON, 1 sec. OFF) and LOW OIL PRESSURE lamp turns on engine will run 2 to 3 seconds until another automatic shutdown CONDITION with Key On, Engine Off (KOEO) FAULT CODE DISPLAYED (ON CHECK ENGINE LAMP) Beginning of fault codes, or OK if no other codes displayed 12, 12, 12 Engine coolant sensor OPEN 14, 14, 14 Engine coolant sensor SHORTED 15, 15, 15 Air temp sensor OPEN 23, 23, 23 Air temp sensor SHORTED 24, 24, 24 MAP sensor OPEN, circuit voltage >4.98V 33, 33, 33 MAP sensor SHORTED 34, 34, 34 TO CLEAR FAULT CODES AND TURN OFF CHECK ENGINE LAMP Ground PIN # 16 of the WHITE CONNECTOR at the ZENITH ENGINE CONTROLLER while engine is running (Note: Some controllers have a wire pigtail that is connected to PIN # 16 28 Home Find... Go To.. 6600 07-2003 MODEL 6600 HYDRAULIC Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual * Engine & Hydraulic Oil Must Be At Normal Operating Temperatures after Running Machine and Hydraulics a Minimum of 5 Minutes * Examine Machine For Any Linkage Binding or Mechanical Problems DURING TESTS: * Maintain Normal Main Brush Pressure as Listed in Operator's Manual * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action 6600 Home Find... Go To.. 07-2003 29 6600 OVERALL HYDRAULIC DIAGRAM (Part 1 of 2) CV3 VACUUM FAN T STEERING SYSTEM CK5 12V DC R CV2 CYL4 L 2,0 x 08,0 in, RV6 P 600 psi RV8 1800 psi ,194 cu,in, PMP3 6.1 cu.in. MTR4 OUT BYD CV1 F E LIFT CV1C TV1 ,047 dia, CYL1 LIFT 2,50 x 15,0 in, CK4 D DOOR C CV1B CYL2 CLOSE MTR2 2,0 x 04,0 in, 379607 B A BROOMS CV1A 17,9 cu,in, SIDE BROOM MTR3 RV5 2400 psi IN 3.3 GPM @ 2000 RPM 3.9 GPM @ 2400 RPM MAIN BROOM 5.4 GPM @ 2000 RPM 5.4 GPM @ 2000 RPM 6.5 GPM @ 2400 RPM 6.5 GPM @ 2400 RPM 2,8 cu,in, 1 2 3 4 5 PLEASE NOTE: All specifications listed are for normal operating conditions 30 6600 Home Find... Go To.. 07-2003 6600 OVERALL HYDRAULIC DIAGRAM (Part 2of 2) 1 2 3 4 5 PMP1 CV4 1,44 cu,in, PMP1B CK1 ORnn RV2 4000 psi PROPEL SYSTEM PMP1A M 4000 psi RV3 SPEED 1 = 2000 RPM SPEED 2 = 2400 RPM 120 psi CK2 CV5 MTR1 ORnn PMP2C ,40 cu,in, PMP2B ,66 cu,in, PMP2A ,66 cu,in, PMP2 RV1 25 psi STRN1 RV7 RV4 3 psi FLTR HTX RES1 6600 EXPLANATION OF ABBREVIATIONS AUX..........Auxiliary CK............Check Valve CM............Centimeters CU............Cubic CV............Control Valve CYL..........Cylinder DC............Disconnect Coupler (Hydraulic) DC............Direct Current (Electrical) FLTR........Filter GPM.........Gallons per Minute HTX..............Heat Exchanger IN..................Inches LH.................Left Hand LPM..............Liters per Minute M..................Motor (Combustion) MTR.............Motor (Hydraulic) OR................Orifice PC.................Pilot Port Check Valve PMP..............Pump PSI................Pounds per Square Inch PSWITCH.........Pressure Switch RES..................Reservoir RH....................Right Hand RPM.................Revolutions per Minute RV....................Relief Valve STRN...............Strainer SV....................Solenoid Valve TV....................Throttle Valve V......................Volts PLEASE NOTE: All specifications listed are for normal operating conditions 6600 Home Find... Go To.. 07-2003 31 32 Home Find... Go To.. Side Brush Motor P T 24 16 Hopper Dump Door Cylinder L R Steering Valve 21 Hopper Lift Cylinder 22 5 15 7 10 Aux Pump 4 12 20 14 Propel Pump 17 OUT E A B 19 13 18 C Main Brush Motor Vac Fan Motor BYD Control Valve 11 Reservoir 6 IN 9 8 23 1 3 2 Wheel Drive Motor Steer Cylinder Cooler Filter 6600 HYDRAULIC HOSE ROUTING 6600 07-2003 6600 MAIN BRUSH BYD BROOMS VALVE BROOMS CV1A A HYDRAULIC FLOW METER 5.4 GPM (20 LPM) @ 2000 RPM 6.5 GPM (25 LPM) @ 2400 RPM (Flow readings +/- 5%) IN RV5 2400 PSI (166 BAR) 600 PSI (41 BAR) MAIN BRUSH 600 PSI (41 BAR) PRESSURE 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM RETURN SUCTION ACCESSORY PUMP RV7 25 PSI (1.7 BAR) STRAINER HEAT EXCHANGER RV4 3 PSI (0.2 BAR) FILTER RESERVOIR MAIN BRUSH RPM 460 RPM +/- 25 RPM @ 2000 RPM 550 RPM +/- 25 RPM @ 2400 RPM Note: Specs. shown are for main brush down with 2" (5 cm) brush pattern PLEASE NOTE: All specifications listed are for normal operating conditions 6600 Home Find... Go To.. 07-2003 33 6600 MAIN & SIDE BRUSH BYD BROOMS CV1A HYDRAULIC FLOW METER 5.4 GPM (20 LPM) @ 2000 RPM 6.5 GPM (25 LPM) @ 2400 RPM (Flow readings +/- 5%) B A SIDE BRUSH 200 PSI (14 BAR) IN RV5 2400 PSI 800 PSI (55 BAR) (166 BAR) 600 PSI (41 BAR) MAIN BRUSH 600 PSI (41 BAR) PRESSURE 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM RETURN SUCTION ACCESSORY PUMP RV7 25 PSI (1.7 BAR) STRAINER RV 4 3 PSI HEAT EXCHANGER (0.2 BAR) FILTER RESERVOIR MAIN BRUSH RPM 460 RPM +/- 25 RPM @ 2000 RPM 550 RPM +/- 25 RPM @ 2400 RPM SIDE BRUSH RPM 75 RPM +/- 10 RPM @ 2000 RPM 90 RPM +/- 10 RPM @ 2400 RPM Note: Specs. shown are for main & side brushes down, with 2" (5 cm) main brush pattern PLEASE NOTE: All specifications listed are for normal operating conditions 34 6600 Home Find... Go To.. 07-2003 6600 VACUUM FAN CV2 1000 PSI (69 BAR) RV8 1800 PSI (124 BAR) HYDRAULIC FLOW METER 5.4 GPM (20 LPM) @ 2000 RPM 6.5 GPM (25 LPM) @ 2400 RPM (Flow readings +/- 5%) VACUUM FAN 1000 PSI (69 BAR) 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP RV7 25 PSI STRAINER (1.7 BAR) HEAT EXCHANGER RV4 3 PSI (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6600 Home Find... Go To.. 07-2003 35 6600 RAISE HOPPER BYD CV1C LIFT CYLINDER E RESTRICTOR LIFT CK4 RV5 2400 PSI LIFT VALVE (166 BAR) PRESSURE RETURN SUCTION ACCESSORY PUMP 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM STRAINER RV 4 3 PSI HEAT EXCHANGER RV7 25PSI (0.2 BAR) (1.7 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 36 6600 Home Find... Go To.. 07-2003 6600 LOWER HOPPER BYD CV1C LIFT CYLINDER E RESTRICTOR LOWER RV5 2400 PSI LIFT VALVE (166 BAR) Note: Lowering of hopper is due to gravity (weight of hopper) PRESSURE RETURN SUCTION 5.4 GPM (20.4 LPM) @ 2000 RPM ACCESSORY PUMP 6.5 GPM (24.6 LPM) @ 2400 RPM ACCESSORY PUMP STRAINER RV 7 25 PSI RV 4 3 PSI HEAT EXCHANGER (1.7 BAR) (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6600 Home Find... Go To.. 07-2003 37 6600 OPEN HOPPER DOOR OUT BYD DOOR CV1B HOPPER DOOR CYLINDER C OPEN RV5 2400 PSI (166 BAR) 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION RV 7 25 PSI HEAT EXCHANGER (1.7 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 38 6600 Home Find... Go To.. 07-2003 6600 CLOSE HOPPER DOOR OUT BYD DOOR CV1B HOPPER DOOR CYLINDER C CLOSE Note: Arrows show direction of Fluid Flow, NOT Pressure (PSI) IN RV5 2400 PSI (166 BAR) 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI SUCTION RV 7 25 PSI HEAT EXCHANGER (1.7 BAR) (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6600 Home Find... Go To.. 07-2003 39 6600 RIGHT TURN T CV3 CK5 R RV 6 600 PSI STEERING SYSTEM L (41 BAR) P MTR/PMP3 PMP3 CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) PRESSURE 3.3 GPM (12.5 LPM) @ 2000 RPM 3.9 GPM (14.8 LPM) @ 2400 RPM RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI RV 7 25 PSI HEAT EXCHANGER (1.7 BAR) (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 40 6600 Home Find... Go To.. 07-2003 6600 LEFT TURN CV3 T CK5 R RV 6 600 PSI STEERING SYSTEM L (41 BAR) P PMP3 MTR/PMP3 CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) PRESSURE RETURN 3.3 GPM (12.5 LPM) @ 2000 RPM 3.9 GPM (14.8 LPM) @ 2400 RPM SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI RV 7 25 PSI HEAT EXCHANGER (1.7 BAR) (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6600 Home Find... Go To.. 07-2003 41 6600 PROPEL SYSTEM Propel Pump Assembly Charge Pump (to keep propel system full of oil) Propel Motor Assembly Tow Valve Propel Motor Propel Pump Engine Pick-up To Reservoir (Case drains) TO ADJUST DIRECTIONAL CONTROL LINKAGE 1. Engage the parking brake. 2. Jack up the rear of the machine. Place jack stands under the frame and lower the machine down. 3. Open engine hood and side door. 4. Locate the centering spring cam arms and cam on the propel pump, near the center frame tube. Loosen the M8 cam bolt. 5. Start the engine. 6. Adjust the cams so the rear wheel does not turn. Turning the cams toward the front of the machine will make the wheel go forward. Turning the cams toward the rear of the machine will make the wheel go backward. 7. Stop the engine. 8. Hold the cams in position and tighten the cam bolts. 9. Start the engine and test to verify adjustment. Repeat if necessary. 10. Lower the machine. 11. Start the engine. Move the directional control pedal forward and backward to make sure machine will not move when the directional control pedal is in neutral. Readjust as necessary. 12. Raise the hopper and engage hopper support bar. 13. The machine should travel 1.6 kmh (1 mph) maximum forward speed. To adjust, turn the speed control rod (directional control rod with a balljoint and a vibration isolator.) Turning the rod clockwise, as viewed from above, will slow machine. Turning it counterclockwise will speed machine. 14. Lower the hopper and stop the engine. 15. Check the gap between theNOTE: speed limiter bracket andlisted the contact surface operating as the drive linkage rod assembly is PLEASE All specifications are for normal conditions 1.5--3 mm (0.06 -- 0.12 in). 16. Adjust the balljoint on the end of the speed control rod to get the correct gap. Tighten all jam nuts. 6600 42 Home Find... Go To.. 07-2003 MODEL 6650 ELECTRICAL Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual DURING TESTS: * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action Home Find... Go To.. 6650 07-2003 43 44 F--5 + EX. 5 S--1 30 19 17 50 34 2 KEYSW KEY SWITCH 8A 15A FUSE F--11 3A 8 8A Home B J7--A ALTERNATOR 1C 1B 1A 30 30 M2B M1B 87 AUX. 1 RELAY 87 F--1 50B AUX. 2 RELAY 6 15AFUSE 85 Find... Go To.. 148EA WIRING COLOR CODE RIGHT MOST DIGIT OF WI RE NUMBER 0 1 2 3 4 5 6 7 8 9 COLOR OF WIRE IN HARNESS TAN PINK BRN ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE 34A BIT --A 1350RPM LOW: HIGH 2000RPM MED: 0V 2400RPM HIGH: 0V J1 --23 8EG O2--B J2 --2 29EA GOV H20 ENG OIL SPD1 SP2 FUEL EX +5V 65EA 64EA 63EA 61EA 60EA 59EA 58EA 57EA 56EA 55EA J2 --8 A A A B D B C C B A C 02 SENSOR 13EH 13EC 13ED ENGINE HARNESS 27EC C A S3 S1 6 B B B COOLANT TEMP SENSOR 2 13EB 13EG B OIL PRESSURE SWITCH L.P. LOCK OUT VALVE FUEL PUMP GOVERNOR ACTUATOR 13EA 13L 13M 13EK 13EF B COOLANT TEMP SENSOR B B 13EM 13EE 13EL S2 AIR TEMP SENSOR C COIL PACK A MAP SENSOR MAG.PICK UP S1 MT R2 SOL 4 67B A SOL 5 5EA A J7--D 27EB A B D 13G ENGINE BLOCK ENGINE BLOCK 13AC LOW CURRENT GROUND THROUGH CONTROLLER. 13EJ 53EA 68EA 66EA A J1 --467EA 67A A J1 --5 J1 --1 J2 --9 J1 --10 J1 --18 J1 --8 J2 --17 J2 --4 J2 --20 J2 --19 J2 --21 J2 --11 J1 --21 J1 --20 J1 = WHITECONNECTOR J2 = BLACK CONNECTOR J1 --12 J2 --16 31EA 26EA J2 --5 72EA OXY COIL--A COIL--B COIL--D MAP--B 70EA J1 --3 GAS MP--C MG--3 LP MAG2 MAG1 GND RST GD2 KEY2 GD1 J2 --12 J2 --10 MT R1 STARTERMOTOR STARTER SOLENOID COIL 83EB ENGINE HARNESS KEY1 O2A 69EC J1 --15 INJ 54EA 148EA J2 --3 GASINJECTOR L.P.INJECTOR J1 --2 J1 --16 J1 --22 8EF 8EE 13G ZENITH ENGINE CONTROL ”A” AND”B” BIT --B 0V HIGH 0V 51A D--1 ST SOL4 SOL3 85 M2A 51 __SL GND. WITHENGINERUNNING WILLCLEAR FAULTCODES. 85 M1A 85 82EA 83EC J2--7 ENGINE SPEED SELECTION BITS 86 86 M3A RELAY M3 B 87 J1--14 69EB 8D 8C 86 KEY:START 3EA 30 83EA 69EA 8H J7--B 1EA -- STARTERMOTORASSEMBLY STARTERSOLENOIDCONTACTS N.O./ CLOSED = DOWN S--2 INST. PANEL NEUTRAL START POSITIVEBATTERYCABLE X X X ACC x=CLOSED CONTACT X X X 20 OHM/ 40W R--1 GROUND 52A 52 - A 30A FUSEGLOW PLUG RUNSTART 1D ALT B ENGINEHARNESS OUTPUT + 12 VDC 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 1 of 4 1 A 28E N.C. OIL PRESSURE 27EA J9--A 27C J9--B 5EA J7--C 31EA 29EA SPEED BIT ”A” J9--D 72EA SPEED BIT ”B” CONFIG PIN J9--E J7--E J9--F NOT USED C N.O.OIL PRESSURE NOT USED ENGINE TEMP/CHECK J9--G NOT USED NOT USED J9--C 26A UNSWITCHED, B+ 6650 D 29A F 31A G NOT USED NOT USED SWITCHED, B+ 2 AUX #2 AUX #1 3 07-2003 Home 15A FUSE Find... Go To.. 34A 1 M5B 87 HORN 3 2 FLASHER N.O./ CLOSED = HORN S--8 15A FUSE 95A BRAKE PEDAL 95 95A SWITCH 81A/YEL S--9 81/YEL N.O. / CLOSED = BRAKING F--14 15A FUSE 4B/YEL 93 33 47 S--26 1 4 5 8 3 6 1 LIGHT SWITCH 6 2 77/GRY 80/BLU 79/YEL N.O. / CLOSED = REVERSE REVERSE SWITCH S--10 SHAKER RELAY 30 92 L F--2 46 4C/YEL 4/YEL F--3 F--12 P 1D 1D 1D F--6 15A FUSE 2 15A FUSE GRY BLK 62/YEL S--20 BLK/ GRY BLU GRN RED 90/GRY 89/BRN 88/GRN 87/PUR 62BA/YEL 62A/YEL 9 8 4 7 DIRECTIONAL SWITCH YEL 48BB SHAKER SOLENOID 47BB SOL 1 76/ORA 62BC/YEL 62BA/YEL 62BB/YEL 62B/YEL 62C/YEL 47A 48 105AA 93B 93A 3 2 LP4 LP3 (--) 33 33A 76B/ORA 76A/ORA TAIL LIGHT, L.H. TAILLIGHT, R.H. 88A/GRN 87A/PUR (+) OUT 1 94 SHAKER MODULE FLASHER LP9 LP8 LP7 LP6 LP5 LP2 LP1 LAMP_HEADLIGHT 13QQ 13NN 13KK 13LL LOW MOUNTED BEACON REVOLVING LIGHT, OHG SIDE BRUSH LIGHT HEADLIGHT, L.H. HEADLIGHT, R.H. RUN LIGHT, L.H. RUN LIGHT, R.H. 13H 13F HOPPER STATIC GND. HORN D--2 LP10 REVERSE ALARM 13V 13Q 13BF 13BD 13BE 13S 13FF 13T 13GG 13J 105AA 13R 1 X 34A 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 2 of 4 SWITCHED,B+ 3 6650 07-2003 45 AUX #1 46 6 6 Home 15A FUSE 15A UNSWITCHED, B+ F--17 14 SV--3 SV--8 14C 14D Find... Go To.. SV--9 86 15G 15B M5A 85 0 1 2 3 4 5 6 7 8 9 TAN PINK BRN ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE RIGHTMOSTDIGIT COLOROFWIRE OF WIRENUMBER INHARNESS WIRING COLOR CODE P1 --6 P1 --31 18 53 P1 --9 P1 --10 P1 --11 P1 --24 21 22 23 24 HOPPER TILT OUT HOPPER TILT IN NOT USED NOT USED P1 --30 P1 --12 P1 --19 P1 --18 P1 --17 P1 --8 20 P1 --7 P1 --23 73 19 P1 --5 P1 --4 17 16 NOT USED OPTIONAL WARNING ALARM SHAKER RELAY VACUUM FAN HOPPER DOWN HOPPER UP HOPPER DOOR OPEN SIDE BROOM DOWN SIDE BROOM AND MAIN BROOM ON MAIN BROOM ONLY DOWN MAIN BROOM ONLY ON ENABLE VALVE WARNING ALARM SV--6A 15F 15G SV--6B 15E SV--5 SV--7 14E 15D SV--2 SV--1 14B 14A A 15A FUSE OUTPUT13 F--20 OUTPUT12 P1 --3 29A P1 --2 OUTPUT14 OUTPUT11 OUTPUT17 OUTPUT16 OUTPUT15 OUTPUT18 OUTPUT10 OUTPUT9 OUTPUT8 OUTPUT7 OUTPUT6 OUTPUT5 OUTPUT4 OUTPUT3 OUTPUT2 OUTPUT1 12 VOLTS 12 VOLTS CONTROL POWER2 P1--20 7A G INPUT9 INPUT5 INPUT4 INPUT3 INPUT2 INPUT1 STATIC GND. CONTROL GND. POWER GND4 POWER GND3 POWER GND1 INPUT7 UNSWITHCED, 27C 15A FUSE 31A SPEED BIT ”B” P1--21 B+ SPEED BIT ”A” F INPUT9 INPUT8 P1 --32 26A 85 ENG OIL PRESS. P1--25 P1 --16 C P1--26 85 7 52A D F--19 ALTERNATOR LAMP S--4A 10A LOWL.P. 13K S--6 COM 13BB 13N 13AA N.O./ CLOSED=STALLEDED S--19 STALLED BROOM N.O./ CLOSED=CLOGGED 13X N.O./ CLOSED=FIRE CLOGGED VACUUM FAN N.O. S--5 THERMAL SENTRY 11BA 13Y 13A 13D 13C 13B N.O./ CLOSED = DOWN S--4 FUEL SENDER NOT USED 96 P1 --29 P1 --15 P1 --1412 P1 --1311 10 P1 --28 CHASSIS GROUND S--18 HOPPER DOWN N.O. / CLOSED= LOW L.P. 9 P1 --27 P1 --1 105 P1 --33 P1 --34 P1 --35 P1 --22 ENG TEMP/CHECK PAGE 1 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 TOUCH PANEL INCORPORATED INTO CONTROL BOARD INCLUDES LCD SIGNLE IN DISPLAY 6650 CONTROL BOARD 6 6650 07-2003 Home Find... Go To.. 34A SW ITCHE D,B+ 15A FUSE F--13 BATTERY, B+ AUX #2 108C/GRY 108B/GRY F--22 20A FUSE 15A FUSE F--10 F--21 20A FUSE OFF 6 2 S--16 6650 1 2 LOW HIGH S--17 115/GRN 110A/YEL 110B/YEL 8 4 5 1 107B/YEL 107A/YEL YEL YEL GRN 106B/ORA 106A/ORA 109B/BRN BRN 30 86 87 86 AC 2 AC 1 DEFROST FAN ORG/GRN 109A/BRN 120/ORA 119/YEL D.P.D.T., ON--OFF--ON 8 4 5 1 HIGH 1 2 LOW 3 MEDIUM AUX. SIDE BRUSH, D.P.S.T., ON--OFF--ON 6 2 S--12 ESS. SWITCH AUX. SIDE BRUSH, BRN COM S--15 OFF DOME LIGHT WIPER SWITCH COM S--14 S--11 AC [ON--OFF] 111B/ORA 111D/ORA 111C/ORA 111/ORA CAB FAN/PR 118/GRY YEL F--7 111F/ORA 15A FUSE 108/GRY RED 50 RED 50A 85 ORG BLK YEL WHT 107/YEL 110/YEL 87 30 85 BLK A WHT YEL HIGH ORG AUX. B BLU BLU BLK GND BLK GND AC CONDENSER D--6 BRUSH LEFT AUX. SIDE BRUSH SIDE 13AAA/BLK 13EEE/BLK 13CCC/BLK GND 13XX/BLK 13WW/BLK 13AAA/BLK FANS GND CLUTCH SOL. GND AC COMPRESSOR SWITC HBLK/WHT PRESS. AC EVAP./CAB PRESS.FANS LOW 106/ORA RIGHT LOW HIGH YEL ORG WHT A AC CONDENSER BLK WINDSHIELD WIPER DOME LIGHT BLK/WHT BLK B 109/BRN SWITC H AC EVAP. TEMP 113/YEL 111E/ORA 112/PUR 116/BLU 13DDD/BLK 4 FROM PAGE 1 BATTERY, B+ AUX #2 FROM PAGE 1 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 4 of 4 O PTIONAL AC AND CAB HARNESSES 07-2003 47 48 30 Home X KEYSW X X X x=CL OSEDCONTACT X F--11 8A 8 8A N.O. / CLOSED = DOWN NEUTRAL START 3A J7--A 13BD 3C Find... Go To.. 87a 86 3D 8BC 87 1A 1C 30 1B 30 M2B M1B 87 87 AUX.1 RELAY F--1 6 85 J9--E F G BIT A 1350RPM LOW: HIGH 0V 2000RPM MED: 2400 RPM HI GH: 0V 34A 50B SPEED BIT ”B” 8BG 8BF 60F 29G 31H A B C D 85 5 67 B + S3 27 61 13BA 8BF 26A J9--A 27C 13BA 13BE 13BF 13BC 13BG ENGINE BLOCK N.O./CLOSED HIGH TEMP 26 J9--C 13M 13BD ENGINE BLOCK ENGINE BLOCK 13BB S--16 HIGH ENGINE TEMP. NOT USED N.O.OILPRESSURE J7--C N.C.OIL PRESSURE B ENG.SPEED/MAG. PICK--UP 5A C 1 13AC ENGINE BLOCK ENGINE HARNESS CREATES DELAY BETWEEN ENGINE START ATTEMPTS. OILPRESS. SWITCH 5B A J7--D GND FUEL PUMP D--5 INIT 6 56 B+ LOAD 82 2 8BB 3 67C 67A A 56 61A 85 30 67 30 85 87a STARTER SOILENOID COIL ENGINE START TIMER MODULE - J9--D + 59E 83 ENGINE HARNESS 30 GOVERNOR M6A M6C M6B M8A M8C M8B M7A M7B 87 MTR1 STARTER MOTOR C SPEED BIT ”A” 29A 31A 86 30 55A 55 8BD D--3 87 THROTTLEACTUATOR 3B 8BA 3A 86 OPTIONAL GLOW PLUG LAMP KEY:START 8BE J7--B GP--4 15A FUSE 50 2 17 42 19 42A ACC 34 42A LP1 OW X S--2 42B 30 STARTER MOTOR ASSEMBLY STARTER SOLENOID CONTACTS GP--2 RUN GLOW PLUG START S--1 1K KEY SWITCH INST. PANEL 8A GLOW PLUGS GP--1 40A FUSE 5 R--1 20 OHM/ 40W GROUND 52 POSITIVE BATTERY CABLE EX. F--5 + 52A - A GP--3 1D ALT B ENGINE HARNESS OUTPUT 12 VDC + -- 6650 DIESEL OVERALL ELECTRICAL DIAGRAM Part 1 of 4 1 D J9--B J9--G NOT USED J7--E NOT USED NOT USED J9--F NOT USED - ENGINE SPEED SELECTION BIT B 0V HIGH 0V 2 B ALTERNATOR 3 SWITCHED, B+ AUX. #2 AUX. 2 RELAY AUX. #1 15A FUSE UNSWITCHED, B+ 4 6650 07-2003 Home F--3 Find... Go To.. F--2 34A 15A FUSE F--14 81/YEL 93 51A 85 M2A M5B 87 2 95 95A N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH S--9 3 FLASHER N.O. / CLOSED = HORN S--8 HORN 33 47 1 4 5 8 3 6 1 LIGHT SWITCH 6 2 S--26 77/GRY 80/BLU 79/YEL N.O. / CLOSED = REVERSE REVERSE SWITCH S--10 SHAKER RELAY 30 81A/YEL 1 95A 4B/YEL 4C/YEL 46 92 51 85 M1A L 15A FUSE 4/YEL 15A FUSE F--12 15A FUSE 86 86 P 1D 1D 1D 15A FUSE F--6 3 34A 2 X SOL1 GRY BLK 62/YEL 88/GRN 9 90/GRY 8 89/BRN 4 7 87/PUR 62BA/YEL 62A/YEL S--20 BLK/ GRY BLU GRN RED DIRECTIONAL SWITCH YEL 48BB SHAKER SOLENOID 47BB 76/ORA 62BC/YEL 62BA/YEL 62BB/YEL 62B/YEL 62C/YEL 47A 48 105AA 93B 93A 94 3 2 LP6 LP5 (+) ( -) D--2 LP2 6650 76B/ORA 76A/ORA TAIL LIGHT, L.H. LP11 LP10 LP9 LP8 LP7 LP4 LP3 33A HORN 33 1 TAILLIGHT, R.H. 88A/GRN 87A/PUR OUT SHAKER PULSE MODULE FLASHER REVERSE ALARM D--1 L.H. 13KK 13LL LOW MOUNTED BEACON REVOLVING LIGHT, OHG SIDE BRUSH LIGHT HEADLIGHT, HEADLIGHT, R.H. RUN LIGHT, L.H. RUN LIGHT, R.H. 13H 13F HOPPER STATIC GND. LAMP_HEADLIGHT 13QQ 13NN 13Q 13BF 13BD 13BE 13S 13FF 13T 13GG 13J 13V 13R 13G 1 8D 8C 6650 DIESEL OVERALL ELECTRICAL DIAGRAM Part 2 of 4 SWITCHED,B+ 4 07-2003 49 50 AUX #1 78 6 6 Home Find... Go To.. SV--5 M5A 0 1 2 3 4 5 6 7 8 9 TAN PINK BRN ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE NOT USED NOT USED HOPPER TILT OUT (800 ONLY) P1--30 P1--12 P1--19 P1--18 P1--17 P1--24 24 NOT USED P1--11 P1--10 P1--9 P1--8 P1--7 P1--31 P1--6 P1--23 P1--5 P1--4 23 22 21 20 19 53 18 73 17 16 HOPPER TILT IN (800 ONLY) OPTIONAL WARNING ALARM RELAY 85 SHAKER VACUUM FAN HOPPER DOWN HOPPER UP HOPPER DOOR OPEN SIDE BROOM DOWN SIDE BROOM AND MAIN BROOM ON MAIN BROOM DOWN MAIN BROOM ONLY ON ENABLE VALVE WARNING ALARM 86 1.7 AMPS SV--9 1.7 AMPS SV--6A 1.7 AMPS SV--6B 1.7 AMPS 15G 15B 15G 15F 15E 15D 1.7 AMPS SV--8 1.7 AMPS SV--3 1.7 AMPS SV--7 1.7 AMPS SV--2 WIRING COLOR CODE 15A 14D 14C 14E 14B 1.7 AMPS SV--1 OUTPUT14 OUTPUT11 OUTPUT17 OUTPUT16 OUTPUT15 OUTPUT18 OUTPUT10 OUTPUT9 OUTPUT8 OUTPUT7 OUTPUT6 OUTPUT5 OUTPUT4 OUTPUT3 OUTPUT2 OUTPUT1 12 VOLTS CONTROL 12 VOLTS POWER2 INPUT9 INPUT5 INPUT4 INPUT3 INPUT2 INPUT1 STATIC GND. CONTROL GND. POWER GND4 POWER GND3 POWER GND1 P1--29 P1--15 P1--14 P1--13 10 P1--28 96 13K 13BB 13N 13AA N.O./ CLOSED=STALLEDED S--19 STALLED BROOM N.O./ CLOSED=CLOGGED 13X N.O./ CLOSED=FIRE S--6 CLOGGED VACUUM FAN 11BA S--5 THERMAL SENTRY N.O./CLOSED = LOW L.P. S--4A LOW L.P. S--4 FUEL SENDER 13Y 13A 13D 13C 13B N.O./ CLOSED = DOWN S--18 HOPPER DOWN CHASSIS GROUND NOT USED 12 11 10A 9 105 13A 13D 13C 13B P1--27 P1--1 P1--33 P1--34 P1--35 P1--22 S- 1,LED1: ONE STEP S--2,LED2: VACUUM S-3,LED3: SHAKER S- 4,LED4: SIDE BRUSH S- 5,LED5: HOPPER UP S- 6,LED6: HOPPER DOWN S- 7,LED7: HOPPER DOOR CLOSE S- 8,LED8: HOPPER DOOR OPEN S- 9,LED9: HOPPER TILT OUT (800) S- 10,LED10: HOPPER TILT IN (800) S--11,LED11: ENGINE SPEED LOW S- 11,LED12: ENGINE SPEED MED. S- 11,LED13: ENGINE SPEED HIGH RIGHT MOSTDIGIT COLOR OF WIRENUMBER IN HARNESS 15A FUSE F--17 UNSWITCHED, B+ 14A A 14 OUTPUT13 15A FUSE 29A P1--3 E1 F--20 31A SPEED BIT ”B” P1--20 OUTPUT12 UNSWITHCED, B+ INPUT7 P1--2 SPEED BIT ”A” P1--21 INPUT9 27C 7A E1 INPUT8 15A FUSE G 26A P1--32 ENG OIL PRESSURE E1 P1--25 P1--16 F P1--26 85 7 52A C E1 F--19 ALTERNATOR LAMP D PAGE 1 ENG TEMP/CHECK 85 6650 DIESEL OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 NOTE: SEVENWARNINGCONDITION LEDS LED--14: THERMAL SENTRY LED--15: HO PPER DIFFERENTIALPRESSURE LED--16: LOW FUEL LED--17: HIGH ENGINETEMP. LED--18: LOW ENGINE OIL PRESSURE LED--19: ALTERNATOR LED-- 20: STALLED BROOM TOUCH PANEL INCORPORATED INTO CONTROL BOARD INCLUDES LCD SINGLE LINE DISPLAY. 6650 CONTROL BOARD 6 6650 07-2003 Home Find... Go To.. SWITCHE D,B+ 15A FUSE F--13 108/GRY BATTERY, B+ RED 50 RED 50A YEL COM 108C/GRY HIGH 1 2 LOW 6 2 S--16 6650 S--17 115/GRN 1 4 107B/YEL 5 107A/YEL 8 D.P.D.T., ON--OFF--ON YEL 86 YEL 87 GRN 86 106B/ORA 106A/ORA 109B/BRN BRN 30 AC 2 AC 1 DEFROST FAN ORG/GRN 109A/BRN 120/ORA 119/YEL AUX. SIDE BRUSH, D.P.S.T., ON--OFF--ON 6 2 HIGH 1 2 LOW MEDIUM 3 DOME LIGHT SWITC H OFF 1 4 110A/YEL 5 110B/YEL 8 CAB/PR ESS. FAN SWITC H S--15 OFF S--12 WIPER COM S--14 S--11 AC [ON--OFF] 111B/ORA 111D/ORA 111C/ORA 111/ORA AUX. SIDE BRUSH, BRN 118/GRY 108B/GRY F--22 20A FUSE 15A FUSE F--10 F--21 20A FUSE F--7 111F/ORA 15A FUSE BLK 107/YEL 110/YEL 87 ORG 85 BLK YEL 30 WHT 85 A WHT AUX. SIDE BLU BLU D--6 BLK GND BLK GND AC CONDENSER SWITCH LEFT AUX. SIDE BRUSH BRUSH GND 13XX/BLK 13WW/BLK 13AAA/BLK FANS GND CLUTCH SOL. GND 13AAA/BLK 13EEE/BLK 13CCC/BLK AC COMPRESSOR BLK/WHT B AC EVAP./CAB PRESS.FANS LOW HIGH ORG 106/ORA RIGHT LOW HIGH YEL ORG YEL WHT A AC CONDENSER PRESS. BLK WINDSHIELD WIPER DOME LIGHT BLK/WHT BLK B 109/BRN SWITC H AC EVAP. TEMP 113/YEL 111E/ORA 112/PUR 116/BLU 13DDD/BLK 4 AUX #2 BATTERY, B+ AUX #2 6650 DIESEL OVERALL ELECTRICAL DIAGRAM Part 4 of 4 OPTIONAL AC AND CAB HARNESS 34A 07-2003 51 6650 Key Switch 30 30 50 50 17 17 19 19 ACC ACC GLOW PLUG POSITION (Diesel Only) Spring loaded- Returns to "OFF" unless held OFF OFF RUN Glow Plug START RUN Glow Plug KEY SWITCH KEY SWITCH OFF OFF RUN Glow Plug 30 OFF POSITION START START RUN Glow Plug START KEY SWITCH 30 KEY SWITCH 50 50 17 17 19 19 ACC ACC RUN POSITION START POSITION Spring loaded-Returns to “RUN" unless held SWITCH TERMINAL MARKING KEY SWITCH POSITION 30 50 17 19 ACC GLOW PLUG OFF NO CONNECTIONS RUN START “. “ Indicates a common connection NOTE: Common connections in various switch positions should be less than 1ȍ 52 Home Find... Go To.. 6650 07-2003 6650 Charging System Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions - + 52A PIN 16 8A 15A FUSE 1A 5 PIN 32 85 F-1 6 15A FUSE 1B M1 F-19 13B PIN 33 8A 1D 13A PIN 22 7 7A PIN 2 13C PIN 34 13D PIN 35 PIN 3 6650 CONTROL BOARD 105 PIN 1 8 CHASSIS GROUND ALTERNATOR LED 8C Test battery, clean battery terminals, check all connections, wiring, Resistor R-1, and fuses F-1, F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Is ALTERNATOR LED lit? YES NO Start engine (KOER-Key On, Engine Running), run engine at high governed RPM Re-test battery, re-check battery terminals, connections, wiring, Resistor R-1, and fuses F-1, F-5, F-11 & F-19; Suspect faulty 6650 Control Board; Restart diagnostic steps With lights on, check voltage at battery terminalsIs it 13.5 to 16.5 Volts? YES YES 51 M1 Is ALTERNATOR LED lit? NO NO System operating correctly Re-test battery, re-check battery terminals, connections, wiring, Resistor R-1, and fuses F-1, F-5, F-11 & F-19; Suspect faulty alternator Home 53 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Gas/L.P. Start Circuit + - POSITIVE BATTERY CABLE 1D 28 1EA 83EC 83EA PIN 7 8 8H 82EA 8EF Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 8EG PIN 14 WHITE CONNECTOR PIN 22 PIN 20 PIN 23 YES PIN 21 13ED 13EC ZENITH ENGINE CONTROLLER Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position Does STARTER MOTOR “click” or make any other noises? BLACK CONNECTOR NO CAUTION! Disconnect wire harness plug from DIS ignition coil and turn key to OFF position for next test. Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLENOID studs (the STARTER SOLENOID is an integral part of the STARTER MOTOR) Re-check all connections, wiring and fuses F-5 & F11; Test relay M-3; Test Key Switch; Test for proper power & ground connections at ZENITH ENGINE CONTROLLER (refer to ZEEMS troubleshooting) YES 54 As the remote start switch is engaged, does the STARTER MOTOR crank the engine? NO Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Diesel Start Circuit - + POSITIVE BATTERY CABLE 83 50 2 17 42 19 42A 13BB ACC 34 3C 8BE 42B Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 13M 8 8A TO 6650 CONTROL BOARD Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position Does STARTER MOTOR “click” or make any other noises? YES NO CAUTION! Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR Turn key to OFF position for next test. With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLENOID studs (the STARTER SOLENOID is an integral part of the STARTER MOTOR) Re-check all connections, wiring and fuses F-5 & F-11; Test relays M-6, M7, & M8; Test ENGINE START TIMER MODULE; Test Key Switch YES As the remote start switch is engaged, does the STARTER MOTOR crank the engine? Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR Home NO 55 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Gas/L.P. Power-Up Circuit - + F-1 1A 1D 28 85 15A FUSE 5 1B F-19 6 7 PIN 22 13A 15A FUSE M1 8EF PIN 22 PIN 20 13ED 8EG PIN 23 PIN 21 13EC 8H WHITE 8 CONNECTOR 8C ZENITH ENGINE CONTROLLER 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D PIN 1 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions M1 6650 CONTROL BOARD 105 CHASSIS GROUND 13G 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to “ON” position (KOEO-Key On, Engine Off) Is battery voltage measured across all power and ground connections at ZENITH ENGINE CONTROLLER and 6650 CONTROL BOARD? YES Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER or suspect faulty 6650 CONTROL BOARD 56 Home NO Re-check all connections, wiring, and fuses F-1, F-5, F11 & F-19; Test Key Switch Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Diesel Power-Up Circuit - + F-1 1A 1D 15A FUSE 5 28 6650 CONTROL BOARD 85 1B F-19 6 7 PIN 22 13A 15A FUSE M1 40A FUSE 2 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D 3A 3C 8BF GOVERNOR CONTROLLER PIN A 34 PIN B PIN 1 105 CHASSIS GROUND Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 13BA 13BG 13M 8A 13BF TO 6650 CONTROL BOARD 8C M1 13G 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to “ON” position (KOEO-Key On, Engine Off) Is battery voltage measured across all power and ground connections at GOVERNOR CONTROLLER and 6650 CONTROL BOARD? YES Refer to PRECISION GOVERNOR troubleshooting to test GOVERNOR CONTROLLER or suspect faulty 6650 CONTROL BOARD Home NO Re-check all connections, wiring, and fuses F-1, F-5, F11 & F-19; Test Key Switch 57 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Gas/L.P. Check Engine Circuit - + F-1 1A 1D 28 LCD DISPLAY PANEL 85 CHECK ENGINE 15A FUSE 5 1B F-19 6 7 PIN 22 13A 15A FUSE M1 8EF PIN 20 13ED CONNECTOR PIN 21 13EC PIN 22 8H WHITE 8EG PIN 23 PIN 12 8 26A Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions ZENITH ENGINE CONTROLLER 8C M1 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D PIN 26 PIN 1 6650 CONTROL BOARD 105 CHASSIS GROUND 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to “ON” position (KOEO-Key On, Engine Off) YES Is CHECK ENGINE displayed on LCD panel? No faults detected by ZENITH ENGINE CONTROLLER; Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER Refer to “ZENITH ENGINE FAULT CODES” to diagnose engine or sensor faults 58 Home NO Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Gas/L.P. High Engine Temperature Circuit - + F-1 1A 1D 28 LCD DISPLAY PANEL 85 CHECK ENGINE 15A FUSE 5 1B F-19 6 7 PIN 22 13A 15A FUSE M1 8EF PIN 22 PIN 20 13ED 8EG PIN 23 PIN 21 13EC 8H WHITE 8 CONNECTOR PIN 12 8C ZENITH ENGINE CONTROLLER 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D PIN 26 PIN 1 26A Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions HIGH ENGINE TEMP LED M1 6650 CONTROL BOARD 105 CHASSIS GROUND 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to “ON” position (KOEO-Key On, Engine Off) YES Is CHECK ENGINE displayed on LCD panel? No faults detected by ZENITH ENGINE CONTROLLER; Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER Refer to “ZENITH ENGINE FAULT CODES” to diagnose engine or sensor faults Home NO 59 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Diesel High Engine Temperature Circuit - + F-1 1A 1D 28 LCD DISPLAY PANEL 85 CHECK ENGINE 15A FUSE 5 1B 6 M1 F-19 7 S-16 HIGH ENGINE TEMP Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions PIN 22 13A 15A FUSE 26 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D 26A PIN 26 PIN 1 6650 CONTROL BOARD N.O./CLOSED=HIGH TEMP 105 CHASSIS GROUND HIGH ENGINE TEMP LED Check all connections, wiring, and fuses F-1, F-5, & F19; Turn key to “ON” position (KOEO-Key On, Engine Off), and place jumper wire from wire 26A at HIGH ENGINE TEMP switch to chassis or frame ground YES Is CHECK ENGINE displayed on LCD panel? High engine temp. not detected by 6650 CONTROL BOARD; Recheck all connections, wiring, and fuses F-1, F-5, & F-19; Suspect faulty 6650 CONTROL BOARD System operating correctly; Suspect faulty HIGH ENGINE TEMP switch 60 Home NO Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Gas/L.P. Oil Pressure Circuit - + F-1 1A 1D 28 LCD DISPLAY PANEL 85 CHECK ENGINE 15A FUSE 5 1B F-19 6 7 PIN 22 13A 15A FUSE M1 8EF PIN 22 PIN 20 13ED 8EG PIN 23 PIN 21 13EC 8H WHITE CONNECTOR 8 BLACK Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions PIN 8 CONNECTOR 8C M1 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D 27EB 27EA 27C PIN 25 27EC A ZENITH ENGINE CONTROLLER 85 OIL PRESSURE SWITCH B PIN 1 6650 CONTROL BOARD 105 CHASSIS GROUND C 13EG LOW ENGINE OIL PRESSURE LED 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Is LOW OIL PRESSURE LED lit? YES YES With engine running, does lamp go out? NO Remove harness plug at OIL PRESSURE SWITCH and place a jumper wire across harness plug wires B & C NO Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH YES Verify proper oil pressure in engine; System operating correctly Is LOW OIL PRESSURE lamp lit? NO Replace OIL PRESSURE SWITCH Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch; Suspect faulty 6650 Control Board Home 61 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Diesel Oil Pressure Circuit - + F-1 1A 1D 28 LCD DISPLAY PANEL 85 CHECK ENGINE 15A FUSE 5 1B F-19 6 7 PIN 22 13A 15A FUSE M1 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D 27C PIN 25 PIN 1 6650 CONTROL BOARD Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions A S-3 27 C B LOW ENGINE OIL PRESSURE LED 105 CHASSIS GROUND 13BF ENGINE OIL PRESSURE SWITCH N.C./OPEN=OIL PRESSURE SENSED Check all connections, wiring, and fuses F-1, F-5, & F19; Turn key to “ON” position (KOEO-Key On, Engine Off), and place jumper wire from wire 27 at ENGINE OIL PRESSURE SWITCH to chassis or frame ground Is LOW OIL PRESSURE LED lit? YES With engine running, does lamp go out? NO YES NO Re-check all connections, wiring, and fuses F-1, F-5 & F-19; Test Key Switch; Suspect faulty 6650 Control Board Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH Verify proper oil pressure in engine; System operating correctly 62 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Vacuum Fan Circuit - + F-1 1A 1D 28 VACUUM FAN SWITCH 85 15A FUSE 5 1B F-19 6 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C PIN 10 PIN 35 13D 15A FUSE M1 6 SV-9 F-17 15A 8 15G 22 15A FUSE VACUUM FAN SOLENOID PIN 1 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 6650 CONTROL BOARD VACUUM FAN LED 8C M1 105 CHASSIS GROUND 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, have hopper in full “DOWN” position, turn key to “ON” position (KOEO-Key On, Engine Off) NOTE: DO NOT UNPLUG connector at VACUUM FAN SOLENOID (SV-9) when doing voltage tests. Unplugging connector will give false readings. YES Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Turn VACUUM FAN ON (VAC FAN LED should be lit); Is battery voltage measured across wires at VAC FAN SOLENOID (SV-9) plug? NO Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty VAC FAN SOLENOID coil Re-check all power & ground connections and fuses F-1, F-5, F-11 & F-19; Test HOPPER SWITCH; Test THERMO-SENTRY SWITCH (see circuit chart); Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board Home 63 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Vacuum Restriction Warning Circuit + F-1 1A 1D 28 85 15A FUSE 5 1B F-19 6 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 15A FUSE M1 VACUUM RESTRICTION LED 8 PIN 35 13D PIN 14 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 12 8C VACUUM SWITCH (NORMALLY OPEN) SEE NOTE BELOW M1 PIN 1 6650 CONTROL BOARD 105 CHASSIS GROUND 13X 51 Check all connections, wiring, and fuses F-1, F-5, & F-11, turn key to “ON” position (KOEO-Key On, Engine Off) VACUUM SWITCH NOTE Vacuum switch closes if vacuum fan is running with any one of these conditions: - a blocked (dirty) vacuum panel filter - a blocked Perma-Filter - a closed hopper door Remove wire plug from VACUUM SWITCH and place a jumper wire across harness plug wires YES Is CLOGGED DUST FILTER LED lit? Re-check power & ground connections and fuses F-1, F-5, & F-11; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board Suspect faulty VACUUM SWITCH 64 Home NO Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 + 6650 Gas/Diesel Fuel Sender Circuit - 1D 28 LCD DISPLAY PANEL F-1 1A 85 FUEL LEVEL 15A FUSE 5 1B F-19 6 M1 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 10 PIN 28 PIN 35 13D 15A FUSE 8 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions LOW FUEL LED PIN 1 6650 CONTROL BOARD 8C 10 M1 S-4 FUEL SENDER 105 CHASSIS GROUND 13N 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wires from FUEL SENDER at tank and watch FUEL GAUGE; Place jumper wire across FUEL SENDER wires and watch FUEL GAUGE again Does LOW FUEL LED light and FUEL GAUGE on LCD panel deflect from FULL to EMPTY? YES Re-check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Suspect faulty 6650 Control Board Suspect faulty FUEL SENDER Home NO 65 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 + 6650 Low L.P. Fuel Sender Circuit - 1D 28 LCD DISPLAY PANEL F-1 1A 85 FUEL LEVEL 15A FUSE 5 1B F-19 6 M1 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 10 PIN 28 PIN 35 13D 15A FUSE 8 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions LOW FUEL LED PIN 1 105 6650 CONTROL BOARD CHASSIS S-4A GROUND LOW FUEL PRESSURE SWITCH 13N 10A 13K NORMALLY OPEN / CLOSED WITH LOW L.P. FUEL PRESSURE 8C M1 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; With a full L.P. tank properly connected to machine, with L.P. supply valve fully open, turn key to “ON” position (KOEO-Key On, Engine Off) YES Is LOW FUEL LED lit? Check all connections and wiring; Suspect faulty LOW L.P. SWITCH YES Fully close L.P. supply valve on L.P. tank and run machine until engine runs out of fuel Is LOW FUEL LED lit? NO Remove plug at LOW L.P. PRESSURE SWITCH and place a jumper wire across harness wires System operating properly YES Is LOW FUEL LED lit? NO Re-check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch; Suspect faulty 6650 Control Board Suspect faulty LOW L.P. SWITCH 66 NO Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Shaker Motor Circuit - + F-1 1A 1D 15A FUSE 5 28 SHAKER SWITCH 85 1B F-19 6 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C PIN 11 PIN 35 13D 15A FUSE M1 6 SHAKER RELAY F-17 15A 8 15B M5 23 15A FUSE PIN 1 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions F-6 1D 15A FUSE 6650 CONTROL BOARD SHAKER LED 8C M1 105 CHASSIS GROUND 51 SHAKER MODULE 47 46 M5 47A Check all connections, wiring, and fuses F-1, F-5, F-6, F-11, F-17 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wire from #2 post of SHAKER PULSE MODULE; Momentarily push SHAKER button YES YES Momentarily push SHAKER SWITCH - Is battery voltage measured across terminals #3 & #1 at SHAKER PULSE MODULE? Does SHAKER SOLENOID pulse as wire is tapped to ground? NO NO Disconnect SHAKER SOLENOID plug; Connect one SHAKER SOLENOID wire to ground and the other to battery (+) Repair power or ground circuits leading to SHAKER MODULE Go to A Replace SHAKER MODULE Home Next Page 67 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Shaker Motor Circuit (continued) A Does SHAKER SOLENOID pulse as ground side wire is tapped to ground? YES NO Replace SHAKER SOLENOID Momentarily push SHAKER SWITCH - Is battery voltage measured across posts #85 & 86 at SHAKER RELAY M-5? YES NO Re-check all connections, wiring, and fuses F-1, F-5, F-6, F-11, F-17 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board Re-check connections & power feed on post #30 at SHAKER RELAY M-5; Suspect faulty relay M-5 68 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Thermo-Sentry™ Circuit - + F-1 1A 1D 28 85 15A FUSE 5 1B 6 M1 F-19 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 11 PIN 13 PIN 35 13D 15A FUSE 8 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions HIGH HOPPER TEMP LED PIN 1 6650 CONTROL BOARD 8C 105 CHASSIS GROUND 13BB S-5 NORMALLY OPEN / CLOSED WITH HIGH HOPPER TEMPERATURE M1 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wires from “NO” & “COM” terminals at THERMO-SENTRY SWITCH and connect wires with a jumper wire YES Is HIGH HOPPER TEMP LED lit? Reset or suspect faulty THERMO-SENTRY switch Home NO Re-check all power and ground circuits and fuses F-1, F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 69 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Hopper Door Circuit - + F-1 1A 1D 28 85 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 15A FUSE 5 1B F-19 6 M1 7 15A FUSE HOPPER DOOR SOLENOID 6 F-1715A PIN 34 13C SV-5 19 15D PIN 7 PIN 35 13D 15A FUSE F-20 14 15A FUSE 8 14A SV-1 16 PIN 4 6650 CONTROL BOARD HOPPER DOOR OPEN LED Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions HOPPER DOOR CLOSED LED 8C OPEN M1 NOTE: DO NOT UNPLUG connector at ENABLE SOLENOID (SV-1) or HOPPER DOOR SOLENOID (SV-5) when doing voltage tests. Unplugging connector will give false readings. YES PIN 1 105 ENABLE SOLENOID 51 CHASSIS GROUND CLOSE HOPPER DOOR OPEN/CLOSE SWITCHES (ON TOUCH PANEL) Check all connections, wiring, and fuses F-1, F-5, F-11, F-17 & F-19; Start engine and push HOPPER DOOR CLOSED button until HOPPER DOOR CLOSED LED is lit; Shut off engine; Turn key to “ON” position (KOEO-Key On, Engine Off) Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Push HOPPER DOOR OPEN button - Is battery voltage measured across wires at ENABLE SOLENOID (SV-1) plug and HOPPER DOOR OPEN SOLENOID (SV-5) plug? NO Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty HOPPER DOOR OPEN SOLENOID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-17 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 70 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Hopper Up/Down Circuit - + F-1 1A 1D 28 85 85 15A FUSE 5 1B F-19 6 M1 6 7 15A FUSE SV-6B HOPPER F-17 15A 15E UP SOLENOID 15A FUSE 15F F-20 14 F-11 15A FUSE 15A FUSE Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions HOPPER DOWN SOLENOID 21 PIN 9 ENABLE SOLENOID 8 7 PIN 2 7A PIN 3 20 PIN 8 SV-6A SV-1 14A PIN 32 16 PIN 4 PIN 22 13A PIN 33 13B PIN 34 13C PIN 35 13D PIN 1 105 9 PIN 27 CHASSIS GROUND HOPPER UP LED 6650 CONTROL BOARD 8C HOPPER DOWN LED UP DOWN S-18 HOPPER POSITION HOPPER UP/DOWN SWITCH SWITCHES(ON TOUCH PANEL) 9 13Y NORMALLY OPEN / CLOSED WITH HOPPER IN FULL DOWN POSITION 51 M1 NOTE: DO NOT UNPLUG connectors at ENABLE SOLENOID (SV-1) or HOPPER UP and DOWN SOLENOIDS (SV-6B & SV-6A) when doing voltage tests. Unplugging connector will give false readings. Check all connections, wiring, and fuses F-1, F-5, F-11, F-17 & F-19; Turn key to “ON” position (KOEO-Key On, Engine Off); Push and hold HOPPER UP button and measure voltage across wires at ENABLE SOLENOID (SV-1) plug, then HOPPER UP SOLENOID (SV-6B) plug. Push and hold HOPPER DOWN button and measure voltage across wires at ENABLE SOLENOID (SV-1) plug, then HOPPER DOWN SOLENOID (SV-6A). Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Is battery voltage measured across wires at HOPPER UP and DOWN SOLENOIDS (SV-6B & SV-6A)? YES Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty HOPPER UP or DOWN SOLENOID coil Home NO Re-check all power & ground connections and fuses F-1, F-5, F-11, F-17 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 71 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Main Brush Stall Circuit - + F-1 1A 1D 28 85 15A FUSE 5 1B F-19 6 M1 7 8 Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 96 PIN 29 PIN 35 13D 15A FUSE STALLED MAIN BRUSH LED 8C PIN 1 S-19 96 STALLED MAIN BRUSH 6650 CONTROL BOARD 105 CHASSIS GROUND 13AA NORMALLY OPEN / CLOSED WITH MAIN BRUSH STALL M1 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to “ON” position (KOEO-Key On, Engine Off) Remove wires from terminals at STALLED MAIN BRUSH SWITCH and connect wires with a jumper wire YES Is STALLED MAIN BRUSH LED lit? Suspect faulty STALLED MAIN BRUSH SWITCH 72 Home NO Re-check all power and ground circuits and fuses F-1, F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 + 6650 Main Brush On & Down Circuit F-1 1A 1D 28 85 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 16 PIN 4 PIN 35 13D 17 PIN 5 PIN 1 15A FUSE 5 1B F-19 6 M1 7 15A FUSE 6 F-20 14 SV-1 ENABLE 14A SOLENOID 15A FUSE 14B MAIN BRUSH ON SOLENOID 8 SV-7 14E Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions MAIN BRUSH 73 DOWN SOLENOID CHASSIS GROUND 6650 CONTROL BOARD ON/OFF NOTE: DO NOT UNPLUG connectors at ENABLE SOLENOID (SV-1), MAIN BRUSH ON SOLENOID (SV-2), or MAIN BRUSH DOWN SOLENOID (SV-7) when doing voltage tests. Unplugging connector will give false readings. 51 105 PIN 23 8C M1 YES SV-2 ONE STEP ON/OFF SWITCH ONE STEP LED Check all connections, wiring, and fuses F-1, F-5, F-11, F-19 & F-20; Turn key to “ON” position (KOEO-Key On, Engine Off); Push ONE-STEP button and measure voltage across wires at ENABLE SOLENOID (SV-1), MAIN BRUSH ON SOLENOID (SV-2), and MAIN BRUSH DOWN SOLENOID (SV-7) Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Is battery voltage measured across wires at ENABLE SOLENOID (SV-1), MAIN BRUSH ON SOLENOID (SV-2), and MAIN BRUSH DOWN SOLENOID (SV-7)? NO Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty SOLENOID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-19 & F-20; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board Home 73 Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Main & Side Brush On & Down Circuit + F-1 1A 1D 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C 16 PIN 4 PIN 35 13D SV-318 PIN 6 PIN 1 15A FUSE 5 28 85 1B F-19 6 M1 7 15A FUSE 6 F-20 14 SV-1 ENABLE 14A SOLENOID 15A FUSE SIDE & MAIN 14C BRUSH ON SOLENOID 8 SV-7 14E Note: Ignition Switch is illustrated in the “OFF” position. Please see Key Switch illustrations page for various operating positions 8C MAIN BRUSH 73 DOWN SOLENOID 14D SIDE BRUSH DOWN SOLENOID SV-8 53 PIN 23 6650 CONTROL PIN 31 BOARD SIDE BRUSH ON/OFF SWITCH NOTE: DO NOT UNPLUG connectors at ENABLE SOLENOID (SV-1), SIDE & MAIN BRUSH ON SOLENOID (SV-3), MAIN BRUSH DOWN SOLENOID (SV-7), or SIDE BRUSH DOWN SOLENOID (SV-8) when doing voltage tests. Unplugging connectors will give false readings. SIDE BRUSH ON LED 51 Check all connections, wiring, and fuses F-1, F-5, F-11, F-19 & F-20; Turn key to “ON” position (KOEO-Key On, Engine Off); Push ONE-STEP button (be sure that the SIDE BRUSH is also turned on) and measure voltage across wires at ENABLE SOLENOID (SV-1), SIDE & MAIN BRUSH ON SOLENOID (SV-3), MAIN BRUSH DOWN SOLENOID (SV-7), and SIDE BRUSH DOWN SOLENOID (SV-8) Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Is battery voltage measured across wires at ENABLE SOLENOID (SV-1), SIDE & MAIN BRUSH ON SOLENOID (SV-3), MAIN BRUSH DOWN SOLENOID (SV-7), and SIDE BRUSH DOWN SOLENOID (SV-8)? YES CHASSIS GROUND ONE STEP LED ONE STEP ON/OFF SWITCH M1 105 NO Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty SOLENOID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-19 & F-20; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 74 Home Find... Go To.. PLEASE NOTE: When finished, please reconnect all wires disconnected during testing 6650 07-2003 6650 Interlocks Condition Indication To START Main & side brushes (ON & DOWN) Turn on ONE-STEP button (causes the following:) • Main & side brush on & down (Note: Main brush must be on for the side brush to operate) • Vacuum fan on Solenoid Valves Energized: • Shaker system off SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 • Hopper door open ONE-STEP LED ON SIDE BRUSH LED ON VACUUM FAN LED ON ENG.SPEED #2 or #3 LED ON HOPPER OPEN LED ON To STOP Main & side brushes (OFF & UP) Note: Any one of the following will cause this to happen Turn off ONE-STEP button (causes the following:) • Main & side brush off & up • Vacuum fan off • Shaker system on • Hopper door closed Solenoid Valves Energized: SV-1(6 to 8 seconds), then NONE Select LOW ENGINE SPEED HOPPER CLOSED LED ON SHAKE FILTER LED ON (10 seconds) ENG.SPEED #1 LED ON Close the hopper door HOPPER CLOSED LED ON Excessive hopper temperature THERMO SENTRY LED ON HOPPER CLOSED LED ON Solenoid Valves Energized: SV-1, SV-6A or SV-6B Lift the hopper Condition HOPPER UP LED ON Indication To START Vacuum Fan (ON) Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 Turn on ONE-STEP button Solenoid Valves Energized: SV-9 Turn on VACUUM FAN button with ONE-STEP system OFF ONE-STEP LED ON SIDE BRUSH LED ON VACUUM FAN LED ON ENG.SPEED #2 or #3 LED ON HOPPER OPEN LED ON VACUUM FAN LED ON Note: This is the Vacuum Wand Mode – High engine speed is automatically selected To STOP Vacuum Fan (OFF) Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1(6 to 8 seconds), then NONE Turn off ONE-STEP button Turn off VACUUM FAN button Turn on SHAKER button Solenoid Valves Energized: NONE (W/ ONE-STEP SYSTEM OFF) Home HOPPER CLOSED LED ON SHAKE FILTER LED ON (10 seconds) VACUUM FAN LED OFF VACUUM FAN LED OFF SHAKER LED ON 75 Find... Go To.. 6650 07-2003 6650 Interlocks (continued) Condition Indication To START Shaker System (ON) Note: Any one of the following will cause this to happen Turn on SHAKER button SHAKE FILTER LED ON (10 seconds) Turn off VACUUM FAN button (Note: Triggers an automatic 10 second shake cycle) Solenoid Valves Energized: NONE (W/ ONE-STEP SYSTEM OFF) SHAKE FILTER LED ON (10 seconds) Solenoid Valves Energized: SV-1(6 to 8 seconds), then NONE HOPPER CLOSED LED ON SHAKE FILTER LED ON (10 seconds) Turn off ONE-STEP button (Note: Triggers an automatic 10 second shake cycle) To STOP Shaker System (OFF) Note: Any one of the following will cause this to happen Turn on ONE-STEP button Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 ONE-STEP LED ON (See prev. page) SHAKE FILTER LED OFF Turn on VACUUM FAN button Solenoid Valves Energized: SV-9 (W/ ONE-STEP SYSTEM OFF) VACUUM FAN LED ON SHAKE FILTER LED OFF Solenoid Valves Energized: NONE (W/ ONE-STEP SYSTEM OFF) SHAKE FILTER LED OFF Turn off SHAKER button SHAKER system times out Condition SHAKE FILTER LED OFF Indication To START Hopper Lift or Lower PUSH and HOLD HOPPER UP or DOWN button Solenoid Valves Energized: SV-1, SV-6A or SV-6B HOPPER UP or DOWN LED ON To STOP Hopper Lift or Lower Release HOPPER UP or DOWN button Solenoid Valves Energized: NONE HOPPER UP or DOWN LED OFF Note: The hopper will lift or lower only while the button is held or until the end of travel. Either operation will automatically cancel the OneStep operation. If engine is at low speed, it will automatically increase to medium. The hopper door is automatically closed when hopper is fully lowered and hopper down switch is closed. Condition Indication To OPEN Hopper Door Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1(6 to 8 seconds), then NONE Turn on HOPPER OPEN button Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 Turn on ONE-STEP button HOPPER OPEN LED ON ONE-STEP LED ON (See prev. page) HOPPER OPEN LED ON To CLOSE Hopper Door Note: Any one of the following will cause this to happen Turn on HOPPER CLOSE button Turn off ONE-STEP button Solenoid Valves Energized: SV-1(6 to 8 seconds), then NONE Fully lower hopper 76 Excessive hopper temperature HOPPER UP or DOWN LED ON Home Find... Go To.. HOPPER UP or DOWN LED ON HOPPER UP or DOWN LED ON THERMO-SENTRY LED ON 6650 07-2003 6650 Operational/Diagnostic/Maintenance Modes Six Operational Modes MODE & DESCRIPTION TO INITIATE 1) NORMAL MODE Use this mode to perform normal sweeping functions with machine 2) MANUAL MODE Use this mode to turn on any system without regard to the state of inputs, sensors or interlocks 3) INPUT DISPLAY MODE Use this mode to observe if the inputs to the machine control board are operating correctly - the LED’s on instrument panel will show the state of each input 4) SELF TEST / DISPLAY ERROR / DISPLAY SOFTWARE REVISION MODE Use this mode to run a self-test on all of the machine control board outputs – when test is complete, the software revision is displayed – if panel passes test, “OK” will also be displayed - if panel fails test, the pin number of the failed output(s) is also displayed 5) DISPLAY “CHECK ENGINE FAULTS” MODE Use this mode to decode any ZENITH ENGINE CONTROLLER (ZEEMS) faults when the words “CHECK ENGINE” are displayed on the LCD panel 6) CONTRAST ADJUST MODE Use this mode to adjust the contrast of the LCD panel display • Turn OFF machine • START and RUN Machine • Turn OFF machine • Press and hold SHAKER and ENGINE SPEED buttons • START and RUN Machine • Hold buttons for 5 seconds and release • The word “MANUAL” should be displayed on the LCD panel display • Turn OFF machine • Press and hold HOPPER OPEN and HOPPER CLOSED buttons • START and RUN Machine • Hold buttons for 5 seconds and release • The word “INPUT” should be displayed on the LCD panel display • Turn OFF machine • Press and hold VACUUM FAN and ENGINE SPEED buttons • START and RUN Machine • Hold buttons for 5 seconds and release • The software revision and any self-test faults should be displayed on the LCD panel display NOTE: If “OPEN LOAD” or “SHORT LOAD” is displayed after pin number, then the self-test found a load that is electrically open or shorted to BATTERY + (check output wires or replace load as needed) • Turn OFF machine • Press and hold SIDE BRUSH and ENGINE SPEED buttons • Turn key switch to “ON”, but DO NOT START the engine • Hold buttons for 5 seconds and release • The ZEEMS engine control faults will now be displayed by blinking the SHAKER LED (see “6650 ZEEMS ENGINE FAULT CODES”) • Turn OFF machine • Press and hold HOPPER UP and HOPPER DOWN buttons • Turn key switch to “ON”, but DO NOT START the engine • Hold buttons for 5 seconds and release • The word “CONTRAST” should be displayed on the LCD panel NOTE: Hold the HOPPER DOWN button to darken the LCD display Hold the HOPPER UP button to lighten the LCD display TO EXIT FROM ANY MODE, THE KEY SWITCH MUST BE CYCLED “OFF” Home 77 Find... Go To.. 6650 07-2003 6650 with ZEEMS (Zenith) Engine Management System Turn Key Off, Turn Key On, Engine Off (KOEO) Yes Is "Oil Pressure Light" or "High Temperature Light" also on? No Is "Check Engine" displayed on LCD panel? during KOEO No Shaker LED Light illumination for "14" will be as follows: on, medium off, on, short off, on, short off, on, short off, on; longer pause; on, medium off, on, short off, on, short off, on, short off, on; longer pause. on, medium off, on, short off, on, short off, on, short off, on; (other code readouts are similar) Yes READ ENGINE TROUBLE CODES - Turn Engine Off - Press and Hold Side Brush & Engine Speed Buttons - Turn Key on, do not start - Hold buttons for 5 seconds - Watch blinking Shaker LED for engine trouble codes Does engine "shut off" after 2-3 seconds or 40 seconds of running? 2-3 Seconds 40 Seconds running then off running then off Low Oil Pressure automatic shutdown sequence activated No Engine Fault Codes Detected Is "Check Engine" displayed on LCD panel with engine running? (KOER) Tennant Engine Trouble Codes are: 14-ECT Sensor Open (Engine Coolant Sensor) 15-ECT Sensor Shorted (Engine Coolant Sensor) 23-ACT Sensor Open (Air Temperature Sensor) 24-ACT Sensor Shorted (Air Temperature Sensor) 33-MAP Sensor Open (Manifold Absolute Pressure) 34-MAP Sensor Shorted (Manifold Absolute Pressure) 44-O2 Sensor Lean (Oxygen Sensor) 45-O2 Sensor Rich (Oxygen Sensor) High Temperature automatic shutdown sequence activated Start and Run Engine YES NO No Engine Fault Codes Detected during KOEO and KOER STOP Service and Repair as Required 78 Home Clear Codes by momentarily grounding 49/White "pigtail" while engine is running RETEST Find... Go To.. 6650 07-2003 6650 ZEEMS Check Engine Fault Codes MACHINE STATUS LCD PANEL Key On, Engine Off (KOEO) No engine faults detected Fuel level & hour meter reading displayed Key On, Engine Running (KOER) No engine faults detected Fuel level & hour meter reading displayed Key On, Engine Running (KOER) Engine fault(s) detected “CHECK ENGINE” displayed (see MODE 5 on previous page) Key On, Engine Off (KOEO) Engine fault(s) detected “CHECK ENGINE” displayed (see MODE 5 on previous page) Key On, Engine Running (KOER) High engine temperature sensed AUTOMATIC ENGINE SHUTDOWN OCCURS NOTE: If key switch is turned off and machine restarted, “CHECK ENGINE” displayed (see MODE 5 on previous page) engine will run 40 seconds until another automatic shutdown Key On, Engine Running (KOER) Low engine oil pressure sensed AUTOMATIC ENGINE SHUTDOWN OCCURS NOTE: If key switch is turned off and machine restarted, “CHECK ENGINE” displayed (see MODE 5 on previous page) engine will run 2 to 3 seconds until another automatic shutdown CONDITION NOTE: See MODE 5 on previous page FAULT CODE DISPLAYED (ON SHAKER LED) Beginning of fault codes, or OK if no other codes displayed 12, 12, 12 Engine coolant sensor OPEN 14, 14, 14 Engine coolant sensor SHORTED 15, 15, 15 Air temp sensor OPEN 23, 23, 23 Air temp sensor SHORTED 24, 24, 24 MAP sensor OPEN, circuit voltage >4.98V 33, 33, 33 MAP sensor SHORTED 34, 34, 34 TO CLEAR FAULT CODES AND TURN OFF “CHECK ENGINE” WARNING Ground PIN # 16 of the WHITE CONNECTOR at the ZENITH ENGINE CONTROLLER while engine is running (Note: Some controllers have a wire pigtail that is connected to PIN # 16) Home 79 Find... Go To.. 6650 07-2003 6650 Machine Control Board Pin Functions PIN # INPUT or OUTPUT 1 INPUT 2,3 INPUT 4,5,6,7,8,9, 10,11 OUTPUT 12 13,14,15,16 INACTIVE VOLTAGE Chassis ground Battery ground (B-) Battery ground (B-) Battery positive (B+) Battery positive (B+) 0 VDC 0 VDC Battery positive (B+) Low side drivers NOT PRESENTLY USED INPUT 17,18,19 DIGITAL - Activates when grounded 0 VDC 5 VDC NOT PRESENTLY USED OPEN Battery positive (B+) Battery ground (B-) Battery ground (B-) Low side drivers 0 VDC Battery positive (B+) INPUT DIGITAL - Activates when grounded 0 VDC 5 VDC 28 INPUT Fuel gauge input 29 INPUT DIGITAL - Activates when grounded 20,21 OUTPUT 22 INPUT 23,24 OUTPUT 25,26,27 30 80 ACTIVE VOLTAGE FUNCTION Governor speed control Battery ground (B-) >100 ohms = full tank <5 ohms = empty tank 0 VDC 5 VDC NOT PRESENTLY USED 31 OUTPUT Low side driver 0 VDC Battery positive (B+) 32 INPUT Memory storage Battery positive (B+) Battery positive (B+) 33,34,35 INPUT Battery ground (B-) Battery ground (B-) Battery ground (B-) Home Find... Go To.. 6650 07-2003 MODEL 6650 HYDRAULIC Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual * Engine & Hydraulic Oil Must Be At Normal Operating Temperatures after Running Machine and Hydraulics a Minimum of 5 Minutes * Examine Machine For Any Linkage Binding or Mechanical Problems DURING TESTS: * Maintain Normal Main Brush Pressure as Listed in Operator's Manual * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action 6650 Home Find... Go To.. 07-2003 81 6650 OVERALL HYDRAULIC DIAGRAM (Part 1 of 2) SIDE BRUSH LIFT/LOWER MAIN BRUSH LIFT/LOWER HOPPER LIFT/LOWER HOPPER DOOR OPEN/CLOSE MAIN BRUSH SIDE BRUSH (OPTIONAL) PLEASE NOTE: All specifications listed are for normal operating conditions 82 1 2 3 4 5 Home Find... Go To.. 6650 6 07-2003 6650 OVERALL HYDRAULIC DIAGRAM (Part 2 of 2) 1 2 3 4 5 6 EXPLANATION OF ABBREVIATIONS AUX..........Auxiliary CK............Check Valve CM............Centimeters CU............Cubic CV............Control Valve CYL..........Cylinder DC............Disconnect Coupler (Hydraulic) DC............Direct Current (Electrical) FLTR........Filter GPM.........Gallons per Minute HTX..............Heat Exchanger IN..................Inches LH.................Left Hand LPM..............Liters per Minute M..................Motor (Combustion) MTR.............Motor (Hydraulic) OR................Orifice PC.................Pilot Port Check Valve PMP..............Pump PSI................Pounds per Square Inch PSWITCH.........Pressure Switch RES..................Reservoir RH....................Right Hand RPM.................Revolutions per Minute RV....................Relief Valve STRN...............Strainer SV....................Solenoid Valve TV....................Throttle Valve V......................Volts PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 83 84 Home Find... Go To.. Side Brush Motor Side Brush Lift Cylinder 26 T P 30 24 Hopper Dump Door Cylinder L R Steering Valve 25 22 10 Hopper Lift Cylinder 15 Main Brush Lift Cylinder 7 23 21 Aux Pump 14 4 1 Propel Pump 12 Reservoir 29 28 18 6 Main Brush Motor 27 13 11 Vac Fan Motor 9 8 16 19 M2 P Control T3 Valve M1 2 20 C8 C1 C7 T1 3 T1 Wheel Drive Motor 5 Steer Cylinder C3 C5 17 C6 T2 Cooler Filter C2 6650 HYDRAULIC HOSE ROUTING 6650 07-2003 6650 MAIN BRUSH CV1 M2 HYDRAULIC FLOW METER 5.4 GPM (20 LPM) @ 2000 RPM 6.5 GPM (25 LPM) @ 2400 RPM (Flow readings +/- 5%) SV2 600 PSI MAIN BRUSH 600 PSI (41 BAR) SV1 (41 BAR) T1 RV1 2400 PSI (166 BAR) PRESSURE 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM RETURN SUCTION ACCESSORY PUMP RV7 25 PSI (1.7 BAR) STRAINER HEAT EXCHANGER RV4 3 PSI (0.2 BAR) FILTER RESERVOIR MAIN BRUSH RPM 460 RPM +/- 25 RPM @ 2000 RPM 550 RPM +/- 25 RPM @ 2400 RPM Note: Specs. shown are for main brush down with 2 inch (5 cm) brush pattern PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 85 6650 MAIN & SIDE BRUSH CV1 600 PSI M1 (41 BAR) SV3 SIDE BRUSH 200 PSI 800 PSI SV1 MAIN BRUSH 600 PSI (14 BAR) (55 BAR) T1 (41 BAR) HYDRAULIC FLOW METER 5.4 GPM (20 LPM) @ 2000 RPM 6.5 GPM (25 LPM) @ 2400 RPM (Flow readings +/- 5%) RV1 2400 PSI (165 BAR) P PRESSURE 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM RETURN SUCTION ACCESSORY PUMP RV7 25 PSI (1.7 BAR) STRAINER HEAT EXCHANGER RV4 3 PSI (0.2 BAR) FILTER RESERVOIR MAIN BRUSH RPM 460 RPM +/- 25 RPM @ 2000 RPM 550 RPM +/- 25 RPM @ 2400 RPM SIDE BRUSH RPM 75 RPM +/- 10 RPM @ 2000 RPM 90 RPM +/- 10 RPM @ 2400 RPM Note: Specs. shown are for main & side brushes down, with 2 inch (5 cm) main brush pattern PLEASE NOTE: All specifications listed are for normal operating conditions 86 6650 Home Find... Go To.. 07-2003 6650 VACUUM FAN SV9 HYDRAULIC FLOW METER 5.4 GPM (20 LPM) @ 2000 RPM 6.5 GPM (25 LPM) @ 2400 RPM (Flow readings +/- 5%) 1000 PSI (68 BAR) RV8 1800 PSI (124 BAR) VACUUM FAN 1000 PSI (69 BAR) 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN SUCTION ACCESSORY PUMP RV7 25 PSI STRAINER (1.7 BAR) HEAT EXCHANGER RV4 3 PSI (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 87 6650 RAISE HOPPER T2 CV1 C4 SV6B PC2 C3 RESTRICTOR SV6A SV1 RAISE T1 RV1 2400 PSI PRESSURE RETURN SUCTION (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM ACCESSORY PUMP FILTER RV7 25 PSI STRAINER (1.7 BAR) HEAT EXCHANGER RV4 3 PSI (0.2 BAR) RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 88 6650 Home Find... Go To.. 07-2003 6650 LOWER HOPPER T2 CV1 Note: Lowering of hopper is due to PILOT CHECK VALVE 2 (PC2) being unseated, and gravity (weight of hopper) SV6B C4 PC2 C3 RESTRICTOR SV6A SV1 LOWER T1 RV1 2400 PSI PRESSURE RETURN SUCTION (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM ACCESSORY PUMP FILTER RV7 25 PSI STRAINER (1.7 BAR) HEAT EXCHANGER RV4 3 PSI (0.2 BAR) RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 89 6650 OPEN HOPPER DOOR T2 OUT CV1 C2 DOOR SV5 PC1 C1 C CV1B SV1 HOPPER DOOR CYLINDER OPEN T1 RV1 2400 PSI (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION FILTER RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 90 6650 Home Find... Go To.. 07-2003 6650 CLOSE HOPPER DOOR T2 OUT CV1 C2 DOOR SV5 C1 C PC1 CV1B Note: Arrows show direction of Fluid Flow, NOT Pressure (PSI) SV1 HOPPER DOOR CYLINDER CLOSE T1 RV1 2400 PSI (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION FILTER RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 91 6650 LOWER MAIN BRUSH T2 OUT CV1 DOOR SV7 C6 C CV1B C5 SV1 MAIN BRUSH LIFT CYLINDER LOWER OPEN T1 RV1 2400 PSI (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION FILTER RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 92 6650 Home Find... Go To.. 07-2003 6650 RAISE MAIN BRUSH T2 OUT CV1 DOOR SV7 C CV1B C6 C5 SV1 MAIN BRUSH LIFT CYLINDER RAISE T1 RV1 2400 PSI (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION FILTER RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 93 6650 LOWER SIDE BRUSH T2 OUT CV1 DOOR SV8 C8 C CV1B C7 SV1 SIDE BRUSH LIFT CYLINDER LOWER OPEN T1 RV1 2400 PSI (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION FILTER RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 94 6650 Home Find... Go To.. 07-2003 6650 RAISE SIDE BRUSH T2 OUT CV1 DOOR SV8 C CV1B C8 C7 SV1 SIDE BRUSH LIFT CYLINDER RAISE T1 RV1 2400 PSI (166 BAR) P 5.4 GPM (20.4 LPM) @ 2000 RPM 6.5 GPM (24.6 LPM) @ 2400 RPM PRESSURE RETURN ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) SUCTION FILTER RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 95 6650 RIGHT TURN T CV3 CK5 R RV 6 600 PSI STEERING SYSTEM L (41 BAR) P MTR/PMP3 CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) PRESSURE 3.3 GPM (12.5 LPM) @ 2000 RPM 3.9 GPM (14.8 LPM) @ 2400 RPM RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI RV 7 25 PSI HEAT EXCHANGER (1.7 BAR) (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 96 6650 Home Find... Go To.. 07-2003 6650 LEFT TURN CV3 T CK5 R RV 6 600 PSI STEERING SYSTEM L (41 BAR) P CYLINDER MTR/PMP3 Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) PRESSURE RETURN 3.3 GPM (12.5 LPM) @ 2000 RPM 3.9 GPM (14.8 LPM) @ 2400 RPM SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI RV 7 25 PSI HEAT EXCHANGER (1.7 BAR) (0.2 BAR) FILTER RESERVOIR PLEASE NOTE: All specifications listed are for normal operating conditions 6650 Home Find... Go To.. 07-2003 97 6650 MAIN BRUSH STALL TRIGGERING PRESSURE SWITCH 2400 PSI (166 BAR) CV1 BRUSH 0 GPM/LPM SV2 STALLED 2400 PSI (166 BAR) 0 GPM/LPM PRESSURE SWITCH MAIN 2400 PSI (166 BAR) BRUSH SV3 TO BRUSH STALL WARNING LAMP 2400 PSI (166 BAR) CK2 SV1 0 GPM/LPM 5 PSI 2400 PSI (0.3 BAR) (166 BAR) SIDE BRUSH 0 GPM/LPM TO RESERVOIR RV1 2400 PSI (166 BAR) 0.0 PSI (0.0 BAR) Full Hydraulic Oil Flow 2400 PSI (166 BAR) Full Hydraulic Oil Flow NOTE: THESE CONDITIONS WILL OCCUR IF MAIN BRUSH STALLS WHEN SWEEPING WITH MAIN BRUSH ONLY OR WHEN SWEEPING WITH MAIN AND SIDE BRUSH FROM PUMP 98 6650 Home Find... Go To.. 07-2003 6650 PROPEL SYSTEM Propel Pump Assembly Charge Pump (to keep propel system full of oil) Propel Motor Assembly Tow Valve Propel Motor Propel Pump Engine Pick-up To Reservoir (Case drains) TO ADJUST DIRECTIONAL CONTROL LINKAGE 1. Engage the parking brake. 2. Jack up the rear of the machine. Place jack stands under the frame and lower the machine down. 3. Open engine hood and side door. 4. Locate the centering spring cam arms and cam on the propel pump, near the center frame tube. Loosen the M8 cam bolt. 5. Start the engine. 6. Adjust the cams so the rear wheel does not turn. Turning the cams toward the front of the machine will make the wheel go forward. Turning the cams toward the rear of the machine will make the wheel go backward. 7. Stop the engine. 8. Hold the cams in position and tighten the cam bolts. 9. Start the engine and test to verify adjustment. Repeat if necessary. 10. Lower the machine. 11. Start the engine. Move the directional control pedal forward and backward to make sure machine will not move when the directional control pedal is in neutral. Readjust as necessary. 12. Raise the hopper and engage hopper support bar. 13. The machine should travel 1.6 kmh (1 mph) maximum forward speed. To adjust, turn the speed control rod (directional control rod with a balljoint and a vibration isolator.) Turning the rod clockwise, as viewed from above, will slow machine. Turning it counterclockwise will speed machine. 14. Lower the hopper and stop the engine. 15. Check the gap between the speed limiter bracket and the contact surface as the drive linkage rod assembly is 1.5--3 mm (0.06 -- 0.12 in). 16. Adjust the balljoint on the end of the speed control rod to get the correct gap. Tighten all jam nuts. 6650 Home Find... Go To.. 07-2003 99 100 Home Find... Go To.. Home Find... Go To.. 101 +5V SENSOR REFERENCE 02 SENSOR INPUT POTENTIOMETER INPUT (0-5V) AIR TEMP SIGNAL COOLANT TEMP SIGNAL +5V SENSOR REFERENCE LOW LEVEL INPUT LOW LEVEL INPUT LOW LEVEL IMPUT HIGH LEVEL INPUT N/A PROGRAMING PORT 1 8 9 15 23 16 0-5V ATOO INPUT MAP SENSOR INPUT SHIELD GROUND LOW LEVEL INPUT CRANK SENSOR GROUND SENSOR GROUND CRANK SENSOR INPUT SENSOR GROUND N/A RCX TCX ECU - Black Connector 102 Home Find... Go To.. GASOLINE INJECTOR DRIVER DIGITAL OUT LP INJECTOR DRIVER HIGH LEVEL INPUT ALTERNATE FUEL REQUEST (+12V) FUEL PUMP/LOCKOFF OUPUT (+12V) GOVENOR OUTPUT (HIGH SIDE) ECU +12V OUT COIL DRIVER 1 LOW LEVEL DRIVER (.2A) COIL DRIVER 2 ECU +12V OUT 1 8 9 15 16 23 OEM LOW LEVEL INPUT HIGH LEVEL/12V A to D INPUT ENGI00 GROUND HIGH LEVEL OUTPUT (1A) ENGI00 GROUND CHECK ENGINE LAMP DRIVER (.2A) TACHOMETER INPUT (-)COIL DIGITAL INPUT DIGITAL OUTPUT IGNITION POWER (+12V) IGNITION POWER (+12V) ECU - White Connector Find... Go To.. Black Connector 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 21 22 23 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Pin Number White Connector Home 103 Description Coolant Temperature Sensor Signal Potentiometer Input Sensor Reference Sensor Reference to MAP sensor Low Level Input Programming Port High Level Input Low Level Input Intake Air Temperature Sensor Signal O2 Sensor Input Sensor Ground, MAP, CTS and IAT Sensor Ground Low Level Input N/A Low Level Input Input, from dash panel low, med, high RPM MAP Sensor Signal Input N/A Crank Sensor Input Crank Sensor Ground Shield Ground Receive Signal from data recording device Transmit Signal to data recording device Description Alternative Fuel Request High Level Input LP Injector Driver Fuel pump/lock off control Governor Output Coil Driver # 2 Coil Driver # 1 ECU 12 vDC out High level input Digital Out Signal Digital Input Check Engine Lamp Driver (0.2a) High level output Low Level Driver (0.2a) ECU 12 vDC out to fuel injector OEM Low Level Input High level / 12 A to D Input Digital Output Tachometer Input from Ignition Coil Engine Ground for governor, lockoff, fuel pump, distrubutor ground Engine Ground for governor, lockoff, fuel pump, distrubutor ground Ignition Power Ignition Power MAP IAT Acronym Used CTS Acronym Used 0 vDC 0 vDC 0 vDC 0 vDC 0-12 vDC 0-12 vDC Key Off, engine Off, Voltage 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC N/A 0 vDC 0 vDC 0 vDC N/A 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC Voltage Range, Nominal Voltage 0-5 vDC 0-5 vDC 5 vDC 5 vDC 5 vDC 0-5 vDC 0-12 vDC 5 vDC 0-5 vDC 0-1 vDC 0 vDC 0 vDC 0-5 vDC N/A 0-5 vDC 0-12 vDC 0-5 vDC N/A 0-5 vDC 0 vDC 0 vDC 0-5 vDC 0-5 vDC Key Off, engine Off, Voltage 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC Voltage Range, Nominal Voltage 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-12 vDC 0-5 vDC 0-12 vDC 0-12 vDC 0-250 vDC Key On, Engine Off Voltage 0-5 vDC 0-5 vDC 5 vDC 5 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0-5 vDC 0.45 vDC 0 vDC 0 vDC 0 vDC N/A 0 vDC 0 vDC 4.70 vDC N/A 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 12 vDC 12 vDC 0 vDC Key On, Engine Off Voltage 0 vDC 0 vDC 12 vDC 0 vDC 0 vDC, pulsed voltage 0 vDC 0 vDC 12 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 0 vDC 12 vDC Active Circuit Voltage 0-5 vDC 0-5 vDC 5 vDC 5 vDC 0-5 vDC 0-5 vDC 0-5 vDC 0-5 vDC 0-5 vDC 0-1 vDC 0 vDC 0 vDC 5 vDC N/A 5 vDC 5 vDC 0-5 vDC N/A 0-5 vDC 0 vDC 0 vDC 0-5 vDC 0-5 vDC 0 vDC 12 vDC 12 vDC 0 vDC Active Circuit Voltage 12 vDC 12 vDC 0 vDC 12 vDC 12 vDC 12 vDC 12 vDC 12 vDC 12 vDC Pulsed 12 vDC 12 vDC 12 vDC 12 vDC 12 vDC 5 vDC 12 vDC Pulsed 0-250 vDC Protected ground circuit Square wave Square wave Measure BARO with Key on engine off N/A Square wave Signal into ECU, to reprogram memory Signal from ECU to input sensors Signal from ECU to input sensors Notes Ground Power into ECU Power into ECU Ground On or off signal On or off signal Square wave On or off signal On or off signal On or off signal Sends 12 vDC to fuel injector Grounds circuit to "turn on" Sends 12 vDC to fuel pump or lock off Sends 12 vDC to governor, @210 hz, duty cycles varies Sends 12 vDC to coil Sends 12 vDC to coil Sends 12 vDC to ???? Notes Use only with dual fuel applications 2.0L, 2.2L, 3.0L, 4.3L, 5.71L, 7.4L, and 8.1L Engines Maintenance Schedule Power Solutions, Inc GM Powertrain Initial StartUp Sequence Checks Operation Daily Weekly Every 50 Hrs Every 100 Hrs Every 200 Hrs Every 400 Hrs Every 800 Hrs As Req'd 1 Check Engine Oil Level x 2 Check Coolant Level (4) x 3 Check Fluid Leaks x 4 Governor, Mechanical (Check oil level)(2) x Change Engine Oil & Filter (1) x 5 Battery, Check Charge & Fluid Level (3) x Inspect & Clean Radiator Exterior (3) x Clean Battery Cables (3) x 6 Check Belts and Belt Tension x Lubricate Throttle, Governor & Choke Linkage (Carbureted Engines Only) x Check & Adjust Idle Speed (Carbureted Engines Only) x Inspect and Clean Air Cleaner Element x Replace Primary Air Cleaner Element (1) x Replace Safety Air cleaner Element x Replace Engine Coolant (3)(4) x Replace Fuel Filter (5) x Spark Plugs, Clean, Adjust & Test or Replace (3) x Replace PCV Valve (If equipped)(3) x Check PCV Hoses, Tubes, Fittings (3) x Replace Spark Plugs (3) x Adjust Throttle & Governor (3) x 7 Check All Bolts & Nuts for Tightness (3) x (1) More frequent intervals may be required in dusty or dirty operating conditions. (2) Mechanical governor (belt driven). (3) Seasonal or as required. (4) Check engine coolant condition & protection, hoses & clamps annually (prior to cold weather). (5) More frequent intervals may be required with dirt in fuel system. 104 Home Find... Go To.. Home Find... Go To.. 105 Coolant Capacity With Radiator Engine Oil Capacity Without Filter Coolant Capacity Without Radiator 2.0L 2.2L 12 qt. 3.0L 5 qt. 4 qt. 17 qt. 4.3L 4.5 qt. 7 qt. 17.5 qt 5.7L 5 qt. 7.8 qt. 7.4L 8 qt. 14.5 qt. 28 qt 31 qt (Turbo 8.1L 8 qt. 14.5 qt General Specifications Power Solutions, Inc GM Powertrain Industrial Engines Engine Type Displacement cc (c.i.d) Compression Ratio Valve Configuration Valve Lifters Bore x Stroke mm(inches) Main Bearing Caps Balance method Intake Manifold Firing Order Oil Capacity With Oil Filter Oil Filter Coolant Capacity (Engine) Fuel Type Engine Rotation (Flywheel End) Ignition System Ignition Timing (Degrees BTDC) Gasoline (Carb) Gasoline (TBI) LPG NG Dual Fuel Spark Plugs Spark Plug Gap Gasoline (Carb) TBI LPG NG Dual Fuel Valve Clearance (Lash) Intake Exhaust Manufactured 106 Home 3.0L 3.0L L4 2966 (181) 9.2:1 Push Rod Actuated Overhead Valve Flat Follower 101.60x91.44(4.00x3.60) 2 Bolt External TBI, Carburetor, Mixer 1-3-4-2 5 qts. (4.7L) 5.5 qts. (5.2L) PF-25 or Equivalent 4 qts. (3.78L) Gasoline, LPG, NG CCW Solid State Distributor 0 0 10 (4 Europe) 10 0 AC Delco R46TS 0.04 1/2 to 1 Turn Down From 0 Lash Toluca, Mexico Find... Go To.. Home Find... Go To.. 107 Propane and Gasoline Electronic Fuel Injection Zenith Electronic Engine Management System ZEEMS ZEEMS 108 Home Find... Go To.. Home Page • ZEEMS System Advantages • Block Diagram • ECU, Electronic Control Unit • Inputs • Output Controls • System Operation • Diagnostics • No Start Diagnostics • Specifications ZEEMS Home Find... Go To.. 109 page 1 Achieves maximum power with lowest emissions Virtually eliminates “flat spots” and engine run-on (dieseling) Precise ignition timing control throughout all operating temperatures and conditions Precise fuel control throughout all operating temperatures and conditions The ZEEMS Advantages Overview ZEEMS 110 Home Find... Go To.. page 2 Speed-Density Discussion Engine RPM via throttle shaft actuator control Ignition timing via ECU and High Energy Ignition (HEI) system Fuel Delivery via fuel injector (gas, propane or both) The ZEEMS Control system electrically controls the following: Overview ZEEMS Home Find... Go To.. 111 page 2a to determine the optimum fuel and timing settings for the altitude and climatic conditions. (from atmospheric pressure and temperature of the air) and calculates the Density of the Air This system measures the engine RPM (speed of the engine) The ZEEMS system is a “Speed-Density” design. The ZEEMS System Overview ZEEMS 112 Home Find... Go To.. Fuel Tank, propane or gasoline Fuel Pressure Regulator, gasoline only Fuel Return, gasoline only Electrical fuel shut off/on, propane (LPG) Electric fuel pump, gasoline Fuel Injector Throttle Actuator Distributor Timing Advance RPM Input Sensors Electronic Control Unit ECU ZEEMS Block Diagram Block Diagram ZEEMS Home Find... Go To.. 113 page 1 The ECU monitors the input sensors, Electronic Control Unit ECU compares to programmed “look up tables” and then controls the output devices. The ECU is the ‘control center’ of the ZEEMS, sometimes called the processor or “brain box” (logic device) ECU ZEEMS 114 Home Find... Go To.. The Black Connector is used for low level current devices, such as input signals, transmit and receive signals, and other low voltage signals. page 2 Electronic Control Unit ECU ECU Battery Power Feed Pins 22 & 23 on White Connector Battery Ground Feed Pins 20 & 21 on White Connector The White Connector is used for high current loads, such as battery power and ground and controlling the out put devices. ZEEMS Home Find... Go To.. 115 One engine “event” is an ignition pulse (spark plug firing). The ECU monitors most input sensors once every distributor pulse or engine “event”, depending on engine RPM and operating conditions. Page 3 Electronic Control Unit ECU ECU Therefore: 500 RPM = 1000 events 1000 RPM = 2000 events 2000 RPM = 4000 events There are two distributor pulses (events) per engine revolution on a 4 cylinder, 4 cycle engine Engine Event Discussion ZEEMS 116 Home Find... Go To.. Introduction (if equipped) Exhaust Gas Oxygen Sensor (EGO) Manifold Absolute Pressure (MAP) Intake Air Temperature (IAT) Engine Coolant Temperature (ECT) Engine RPM ECU Inputs Electronic Control Unit ECU Lets examine each input sensor in depth The ZEEMS systems uses several input devices to monitor the engine and atmospheric conditions. Inputs ZEEMS Home Find... Go To.. 117 Engine RPM ECU Inputs Electronic Control Unit ECU RPM Inputs, RPM Engine RPM is determined from the distributor pulses generated by the magnetic pick up and converted to a digital pattern by the HEI (High Energy Ignition) module. Engine RPM page 1 ZEEMS 118 Home Find... Go To.. (AC Sine Wave) Magnetic Pick Up (Analog to Digital Converter A/D) Ignition Module Engine RPM ECU Inputs Electronic Control Unit ECU RPM Inputs, RPM One fuel injector pulse per “event”. The ECU then signals fuel injector to “turn on” and spray fuel. For every ignition pulse, a signal is received at the ECU. Engine RPM page 1a ZEEMS Home Find... Go To.. 119 page 1 ECT & IAT IAT ECT ECU Inputs Electronic Control Unit ECU Both sensors are two (2) wire sensors. The IAT is located in the throttle body assembly. The ECT is located in or near the water outlet from the engine block to the radiator. Engine Coolant Temp Sensor (ECT) , Intake Air Temp Sensor (IAT) ECT & IAT Inputs, ECT & IAT ZEEMS 120 Home Find... Go To.. page 2 ECT & IAT IAT ECT ECU Inputs Electronic Control Unit ECU A “NTC” thermistor resistance increases as the temperature decreases, and the resistance decreases as the temperature increases. A thermistor changes its internal resistance as the temperature changes. The ZEEMS system uses a Negative Temperature Coefficient (NTC) thermistors for the ECT and IAT sensors. Engine Coolant Temp Sensor (ECT) , Intake Air Temp Sensor (IAT) ECT & IAT Inputs, ECT & IAT ZEEMS Home Find... Go To.. 121 page 3 ECT & IAT IAT ECT ECU Inputs ECU monitors here ECU The ECU “monitors” the ECT and IAT wires to determine the temperature changes. Engine Coolant Temp Sensor (ECT) , Intake Air Temp Sensor (IAT) ECT & IAT Inputs, ECT & IAT ZEEMS 122 Home Find... Go To.. Manifold Absolute Pressure Sensor ECU Inputs page 1 Electronic Control Unit ECU MAP Routing to the intake manifold source is accomplished by a passage way drilled from the throttle bore directly into the MAP. This MAP sensor is a three (3) wire sensor similar in operation to a potentiometer. The MAP is located between the throttle body assembly and the ECU . Manifold Absolute Pressure Sensor MAP Inputs, MAP ZEEMS Home Find... Go To.. 123 Manifold Absolute Pressure Sensor ECU Inputs Electronic Control Unit ECU MAP Inputs, MAP MAP As the engine starts/runs, the MAP’s internal resistance changes causing the signal wire voltage to change. (KOER = Key On Engine Run). (KOEO=Key On Engine Off). The MAP sensor with the ECU calculates the barometric pressure when the key is turned on. The MAP changes its internal resistance as the atmospheric or intake manifold pressure changes. page 2 ZEEMS 124 Home Find... Go To.. Manifold Absolute Pressure Sensor ECU Inputs Electronic Control Unit ECU MAP Inputs, MAP MAP This sensor has two chambers internally. These chambers are isolated by a silicone diaphragm. page 3 ZEEMS Home Find... Go To.. 125 5 volt DC Reference Voltage Manifold Absolute Sensor ECU Inputs ECU monitors here Electronic Control Unit ECU MAP Inputs, MAP MAP The ECU “monitors” the signal wire to determine the barometric pressure and/or engine load changes. (intake manifold pressure). The ECU sends a fixed 5 vDC +/- 10% voltage to the MAP. page 3 ZEEMS 126 Home Find... Go To.. 5 volt DC Reference Voltage Manifold Absolute Sensor ECU Inputs ECU monitors here Electronic Control Unit ECU MAP Inputs, MAP MAP This is the “baro” voltage at this location. This number is constant depending on actual barometric pressure. Answer Question What voltage will be “seen” with the key on, KOEO? If voltage is not 5vDC +/-10%, suspect the ECU is faulty The ECU sends a fixed 5 vDC +/- 10% voltage to the MAP. This is a must! Manifold Absolute Pressure Sensor page 4a Discussion ZEEMS Home Find... Go To.. 127 Click here for a detailed explanation on Oxygen sensors Exhaust Gas Oxygen Sensor ECU Inputs Electronic Control Unit ECU (if equipped) EGO Inputs, EGO Exhaust Gas Oxygen Sensor EGO The ZEEMS system uses a heated EGO sensor. This sensor is a four (4) wire sensor. The EGO is located on the exhaust pipe within six (6) inches of the exhaust manifold. (15 cm) page 1 ZEEMS 128 Home Find... Go To.. Click here for a detailed explanation on Oxygen sensors Exhaust Gas Oxygen Sensor ECU Inputs Electronic Control Unit ECU (if equipped) EGO Inputs, EGO Exhaust Gas Oxygen Sensor EGO When the Oxygen (O2) content in the exhaust stream goes up the voltage goes down. Question If the engine is running with too much fuel and no misfires, will the EGO voltage be high or low? The EGO sensor generates a DC voltage (0-1vDC) that is proportional to the Oxygen content of the exhaust stream and ambient oxygen. page 1a ZEEMS Home Find... Go To.. 129 Click here for a detailed explanation on Oxygen sensors Exhaust Gas Oxygen Sensor ECU Inputs Electronic Control Unit ECU (if equipped) EGO Inputs, EGO Exhaust Gas Oxygen Sensor EGO The EGO heater is a 12v heater controlled by the ignition switch. This is not controlled by the ECU. These are the white wires going to sensor harness. An internal heater brings the EGO to its operating temp and maintains this temp if the exhaust gases temp decreases. When the EGO sensor approaches 600 degrees “F”/ 300 degrees “C” it starts to operate properly. page 2 ZEEMS 130 Home Find... Go To.. EGO Key Switch On EGO Heater ECU Inputs ECU monitors here Electronic Control Unit ECU (if equipped) EGO Inputs, EGO Exhaust Gas Oxygen Sensor EGO The ECU “monitors” the signal wire to determine the O2 content of the exhaust stream. The EGO generates voltages between 0-1vDC. page 3 ZEEMS Home Find... Go To.. 131 Bias voltage 0.440-0.460 vDC EGO Key Switch On EGO Heater ECU Inputs ECU monitors here Electronic Control Unit ECU (if equipped) EGO Inputs, EGO Exhaust Gas Oxygen Sensor EGO If the EGO generates a voltage higher than the bias voltage the ECU determines less fuel is required, if under the bias voltage, more fuel is required. The ECU internally sends a ‘bias’ voltage to the EGO signal wire. This ‘bias’ voltage is in the 0.4 - 0.5 vDC range. page 3a ZEEMS 132 Home Find... Go To.. Review (if equipped) Exhaust Gas Oxygen Sensor (EGO) Manifold Absolute Pressure (MAP) Engine Coolant Temperature (ECT) Intake Air Temperature (IAT) Engine RPM ECU Inputs Electronic Control Unit ECU Input Sensor Review The ZEEMS systems uses several input devices to monitor the engine and atmospheric conditions. Inputs ZEEMS Home Find... Go To.. 133 Introduction Lets examine each output device in depth Output Controls Electronic Control Unit ECU Ignition Timing Fuel Injector Governor Actuator ECU Outputs The ZEEMS systems uses three output devices. Commands to the outputs are determined from input conditions. Output Control ZEEMS 134 Home Find... Go To.. Governor A ground wire and the control circuit from the ECU. The governor uses two wires to control the actuator. The governor actuator motor is the only connection to the throttle plate. The Governor is an electric actuator which controls (turns) the throttle plate. Electronic Control Unit ECU Governor Outputs Governor Governor Actuator ECU Outputs page 1 ZEEMS Home Find... Go To.. 135 Governor The proper RPM for the mechanical stop is 750 RPM. The throttle plate has a mechanical stop and must be tested/reset at 1000-1200 hour intervals. The governor is located on the throttle body assembly and is the only part that is not field replaceable. Electronic Control Unit ECU Governor Outputs Governor Governor Actuator ECU Outputs page 2 ZEEMS 136 Home Find... Go To.. Governor From the RPM input (condition), the ECU commands the governor to increase or decrease the RPM depending on the engine load and other operating conditions to match the dash switch desired RPM. To control the governor, the ECU uses two inputs: •dash switch (2 or 3 speed) •engine RPM Electronic Control Unit ECU Governor Outputs Governor Governor Actuator ECU Outputs page 3 ZEEMS Home Find... Go To.. 137 The ECU controls the power side to the Governor with the ground coming from ECU. This circuit controls the ‘power side’ of the Governor Actuator Coil Engine RPM Dash Switch Command Governor ECU controls here Electronic Control Unit ECU Governor ECU Outputs page 4 “High Side” Switch Circuit Governor Actuator Coil Governor Outputs ZEEMS 138 Home Find... Go To.. One Cycle On 50% Off One Cycle XX% Off XX% On One Cycle XX% Off 25% On xx vDC Average 3 vDC Average 6 vDC Average The ECU controls the governor by changing the ‘on-time’ or pulse width modulation (PWM) (duty cycle change) during fixed frequency pulses. 50% Governor ECU controls here Electronic Control Unit ECU Governor ECU Outputs page 4a “High Side” Switch Circuit Governor Actuator Coil Governor Outputs ZEEMS Home Find... Go To.. 139 Governor The duty cycle must change as the demand for engine RPM is commanded. The duty cycle will vary according to the engine load, based on the throttle plate setting, ignition timing, quality of fuel and many other factors. The frequency of the governor control circuit is 240 hertz +/-2%. ECU controls here Electronic Control Unit ECU Governor ECU Outputs page 4b “High Side” Switch Circuit Governor Actuator Coil Governor Outputs ZEEMS 140 Home Find... Go To.. Governor This ‘idle setting relearn’ procedure is a ‘self-programming’ operation of the ECU If the ECU or throttle body/governor assembly is replaced or the base idle setting is altered, the ECU must relearn the base throttle setting. This procedure takes 24 minutes during normal operation. Electronic Control Unit ECU Governor Outputs Governor Governor ECU Outputs page 5 ZEEMS Home Find... Go To.. 141 The proper RPM for the mechanical stop is 750 RPM. •unplug the actuator (governor) •remove sealant over stop screw •start engine and monitor RPM •turn stop screw to desired RPM •turn engine off •connect actuator (gov) •restart engine, run for 2 minutes •re-run base RPM test (readjust) •reseal stop screw (engine must be over 171 degrees F) To adjust: Governor Electronic Control Unit ECU Governor Outputs Governor ECU Outputs Governor page 1 Adjustments ZEEMS 142 Home Find... Go To.. Fuel Injector The gasoline fuel injector is calibrated at 10 psi w/o EGO (0.69 bar) 15 psi with EGO (1.0 bar) and the propane fuel injector is calibrated at 24 psi. w/o EGO (1.65 bar) calibrated at 14 psi. with EGO (0.96 bar) No normal servicing is required. The Fuel Injector is an electric actuator which controls the fuel flow to the engine. Electronic Control Unit ECU Fuel Injector Outputs Fuel Injector Fuel Injector ECU Output page 1 ZEEMS Home Find... Go To.. 143 Fuel Injector Insert a narrow piece of thin cardboard under the fuel injector nozzle. Wait for 5-10 minutes, the cardboard should remain “stain free”, if the cardboard is stained, the injector is leaking. With the engine not running and the key in the off position. Electronic Control Unit ECU Fuel Injector page 1a Gasoline Fuel Injector Leak Test Fuel Injector Outputs ZEEMS 144 Home Find... Go To.. Fuel Injector The engine conditions are monitored by the input sensors and the the ECU commands the fuel injector with a longer or shorter pulse width (on time). The injector fires once per engine event and varies the pulse width (on-time) according to the engine conditions. To control the fuel injector, the ECU provides the power and controls the “ground side” of the circuit. Electronic Control Unit ECU Fuel Injector Outputs Fuel Injector Fuel Injector ECU Output page 2 ZEEMS Home Find... Go To.. 145 The injector “triggers” once for every distributor references pulse going into the ECU. HEI Module Operation Review Engine RPM Fuel Injector ECU controls here Electronic Control Unit ECU 12 vDC Fuel Injector Fuel Injector ECU Output page 3 “Low Side” Switch Circuit Fuel Injector Outputs ZEEMS 146 Home Find... Go To.. Engine RPM EGO MAP ECT The ECU varies the amount of on-time of the injector by looking at the various input sensors of the engine. IAT Fuel Injector ECU controls here Electronic Control Unit ECU 12 vDC page 4 Fuel Injector Off On The ECU varies the injector pulse width Fuel Injector ECU Output “Low Side” Switch Circuit Fuel Injector Outputs ZEEMS Home Find... Go To.. 147 Timing Control Gas Engine @1350 RPM 17 degrees BTDC +/- 2 deg LPG Engine @1350 RPM 25 degrees BTDC +/- 2 deg ECT IAT MAP EGO RPM Base Ignition Timing needs to be checked/reset at 1000-1200 hour intervals. The ECU controls the ignition timing based on the MAP, ECT, IAT and RPM inputs. Electronic Control Unit ECU page 1 Timing Timing Advance Discussion Ignition Timing ECU Output Ignition Timing Outputs ZEEMS 148 Home Find... Go To.. Ignition Module (AC Sine Wave) Magnetic Pick Up Analog to Digital Converter A/D Engine RPM Timing Control Ignition Coil Relay Control Advance page 2a Timing Electronic Control Unit ECU Cranking, up to 250-400 RPM Ignition Timing Outputs ZEEMS Home Find... Go To.. 149 (AC Sine Wave) Magnetic Pick Up (Analog to Digital Converter A/D) Ignition Module Engine RPM Timing Control Ignition Coil Relay Control Advance page 2b Timing Electronic Control Unit ECU Running, over 250-400 RPM Ignition Timing Outputs ZEEMS 150 Home Find... Go To.. Open & Closed Loop EGO IAT RPM MAP ECT Open Loop is defined as “no EGO control”. During warm-up the ECU controls in “open loop”. The ECU controls the outputs based on the MAP, ECT, IAT and RPM inputs. Open Loop Electronic Control Unit ECU Closed Loop Open & Closed Loop Open/Closed Loop page 1 ZEEMS Home Find... Go To.. 151 Open & Closed Loop EGO IAT RPM MAP ECT Open Loop Electronic Control Unit ECU Closed Loop is defined as the EGO is monitoring the the O2 content of the exhaust stream and the ECU is adjusting the fuel injector pulse width based on the EGO values. To achieve ‘closed loop’ these conditions must be meet: •engine fully warm •EGO hot and operating •engine running for 15-120 seconds Closed Loop Open & Closed Loop Open/Closed Loop page 2 ZEEMS 152 Home Find... Go To.. Open & Closed Loop MAP sensor changes are load dependent. ECT changes are coolant related. RPM changes are engine running conditions. ECT IAT MAP EGO RPM The ECU will move from Closed Loop to Open Loop if sudden changes in MAP, ECT, or RPM values occur. Open Loop Electronic Control Unit ECU Closed Loop Closed Loop to Open Loop Open/Closed Loop page 3 ZEEMS Open & Closed Loop ZEEMS Find... Go To.. EGO “Condition” Le a Ri n O ch u Le en t an Ou t ENGINE Electronic Control Unit ECU Move to Review Page Fuel Injector “Command” Closed Loop Operation Open/Closed Loop page 4 “R “L ich” e “ R an i ch ” ` ” Home 153 154 Home Find... Go To.. Open/Closed Loop Discussion Review Questions and Answers Review Questions and Answers ZEEMS Home Find... Go To.. 155 (actuator review) Name the three (3) output actuators (input sensor review) Name the five (5) input sensors (EGO review) If the MAP sensor signal voltage 2.8vDC, (KOEO) at what altitude is the machine located at? (MAP review) How does the EGO sensor produce voltage? If the engine coolant temperature is high, will the ECT resistance be high or low? (ECT review) Review Questions and Answers Review Questions and Answers ZEEMS 156 Home Find... Go To.. ECT IAT MAP •Altitude, barometric pressure •Coolant temperature •Ambient temperature Calculates or measures: Electronic Control Unit ECU Opens Fuel Lock Off (propane) or ECU Turns on Fuel Pump (gasoline) System Operation This will be “on” for 2 seconds if a RPM signal is not received. Listen and “feel” the pump run or the lock off to “turn on”. Key On Operation page 1 ZEEMS Home Find... Go To.. 157 ECT IAT MAP RPM Electronic Control Unit ECU Governor is starting to control Injector Firing (pump “pumping” or lock off “open”) Fuel is flowing System Operation Ignition Timing is at base timing setting Cranking Operation page 2 ZEEMS 158 Home Find... Go To.. ECT IAT MAP Dash Switch Command RPM Electronic Control Unit ECU Injector Firing (pump “pumping” or lock off “open”) Fuel is flowing Ignition Timing advancing Governor is at specified controlled RPM without EGO Sensor Running Operation page 3 without EGO System Operation ZEEMS Home Find... Go To.. 159 ECT IAT MAP Dash Switch Command EGO RPM Electronic Control Unit ECU Controlled Key On Not ECU Injector Firing (pump “pumping” or lock off “open”) Fuel is flowing Heater EGO Ignition Timing advancing Governor is at specified controlled RPM with EGO Sensor Running Operation page 4 with EGO System Operation ZEEMS 160 Home Find... Go To.. Review System Operation Review Questions and Answers Operation ZEEMS ZEEMS Diagnostics Home Find... Go To.. 161 162 Home Find... Go To.. • • • • 30% Wiring 25% Actuator Outputs 40% Input Sensors 5% ECU Failures 30% Wiring 40% Input sensors 25% Actuator outputs 5% ECU Failures • Failures Diagnostics ZEEMS Home Find... Go To.. 163 (KOEO, Black Connector Pin 4) • • • • • • Turn Key Off Remove wire harness to MAP Turn key on (KOEO) Voltmeter red lead to Terminal “C” on the MAP Sensor, black lead to Terminal “A” Results should be 5.0 vDC +/- 10% (4.5 - 5.5 vDC) MAP Sensor Review • Measure Reference voltage to MAP Sensor • • MAP Reference Voltage Test (These quick tests can determine whether the ECU can control correctly. These test/s have a high accuracy rating to determine a defective ECU.) • ECU Quick Tests Diagnostics Diagnostics, ECU Quick Tests ZEEMS 164 Home Find... Go To.. (KOER, White Connector Pin 5) • • • • • Turn Key Off Connect frequency meter red lead to Terminal “A” on Governor Actuator, black lead to Terminal “B” • Leave governor actuator connected in circuit Start Engine (KOER) Results should be 240 Hertz +/- 2% at stable RPM Governor Actuator Review • Measure Frequency to Governor Actuator • • Output Control Frequency Test Diagnostics Diagnostics, ECU Quick Tests ZEEMS Home Find... Go To.. 165 (if equipped) • • • • • • Turn Key Off Remove wire harness to EGO Turn key on Voltmeter red lead to Terminal “??” on EGO Sensor, black lead to Terminal “??” Results should be 0.4 - 0.5 vDC EGO Sensor Review • Measure “Bias” voltage to EGO Sensor • • EGO Bias Voltage Test (KOEO, Black Connector Pin 10) • Processor Quick Tests Diagnostics Diagnostics, ECU Quick Tests ZEEMS 166 Home Find... Go To.. • If all of these tests fail, suspect a faulty power or ground circuit/s to the ECU. • If one or two of these tests fail, suspect a faulty ECU. • Conclusion • Processor Quick Tests Diagnostics Diagnostics, ECU Quick Tests ZEEMS Home Find... Go To.. 167 • • • • • IAT Testing ECT Testing MAP Testing EGO Testing Distributor Reference • Input Sensor Quick Tests 40% Input Sensors Diagnostics, Input Sensors Quick Test ZEEMS 168 Home Find... Go To.. Temp F 266 230 212 176 140 104 68 32 -4 -40 Temp C 130 110 100 80 60 40 20 0 -20 -40 Nominal Resistance 84 144 189 349 693 1484 3481 9099 27050 93630 Minimum Resistance 80 139 182 334 657 1398 3254 8442 24910 85570 Maximum Resistance 88 151 199 369 734 1579 3719 9767 2910 101400 • Remove wiring harness from sensor/s • Install “test harness” to IAT or ECT sensor • Measure the resistance values in Ohms and compare to chart below • IAT and ECT Testing Diagnostics, Input Sensors Quick Test ZEEMS Home Find... Go To.. 169 • Black Voltmeter lead to “B”, red lead to “A” • Voltage should be 5 vDC +/- 10% (KOEO) • Remove wiring harness from sensor/s • Turn Key On (KOEO) • Measure voltage between terminals “A” & “B” of the wiring harness going to the IAT or ECT • IAT and ECT Testing Diagnostics, Input Sensors Quick Test ZEEMS 170 Home Find... Go To.. above Sea Level 0-1000 1000-2000 2000-3000 3000-4000 Nominal Voltage DC 5.00-4.60 4.60-4.10 4.10-3.60 3.60-3.20 • These voltages will vary according the current weather conditions at your location Altitude • Red lead to terminal “B”, black lead to ground • Measure the Voltage values and compare to chart • Complete ECU reference voltage test at MAP • With the MAP connected “in-circuit” • Connect a voltmeter as follows, key on (KOEO) • MAP Testing Diagnostics, Input Sensors Quick Test ZEEMS Home Find... Go To.. 171 (if equipped) • ‘Richen Mixture’ EGO voltage 0.8 vDC or higher • ‘Lean Mixture’ EGO voltage 0.3 vDC or lower • (EGO Sensor Review) • Complete EGO test in machine per EGO testing sequence • Red lead to terminal “XX”, black lead to ground • Complete EGO Bias voltage test • With the EGO connected “in-circuit” • Connect a voltmeter as follows, key on (KOEO) • EGO Testing Diagnostics, Input Sensors Quick Test ZEEMS 172 Home Find... Go To.. • • • • 30% Wiring 40% Input sensors 25% Actuator outputs 5% ECU Failures • Failures 25% Actuator Outputs Diagnostics, Output Sensors Quick Test ZEEMS Home Find... Go To.. 173 Testing • Complete fuel injector “tap test” • Volt meter red lead to terminal “A”, black lead to terminal “B”, turn key on (KOEO) • Voltage should be 9-14 vDC • Turn Key on and measure voltage on the harness • 1.2 - 1.4 Ohms is specification • Disconnect wire/s to fuel injector • Measure the resistance of the fuel injector • Fuel Injector Diagnostics, Output Sensors Quick Test ZEEMS 174 Home Find... Go To.. Testing • Volt meter red lead to terminal “A”, black lead to terminal “B”, turn key on (KOEO) • Voltage should be battery voltage (+/-0.4vDC) • Turn Key on and measure voltage on the harness • 3.0-4.5 Ohms is specification • Disconnect wire/s to Governor Actuator • Measure the resistance of the actuator • Governor Actuator Diagnostics, Output Sensors Quick Test ZEEMS Home Find... Go To.. 175 Testing • Measure governor actuator amperage draw • Specification is 0.5 - 2.5 amp when Governor actuator is “activated” (3 amps maximum draw) • If higher than three amp draw, suspect sticking throttle plates or other mechanical binding • Connect ammeter to one wire going to governor actuator • Turn key on (KOEO) • Governor Actuator Diagnostics, Output Sensors Quick Test ZEEMS 176 Home Find... Go To.. Testing 25 degrees BTDC +/- 2 deg • LPG Engine @1350 RPM 17 degrees BTDC +/- 2 deg • Gas Engine @1350 RPM • Set to lowest governed RPM (1350) • Start engine and monitor ignition timing • Ignition Timing Diagnostics, Output Sensors Quick Test ZEEMS Home Find... Go To.. 177 • • • • 30% Wiring 25% Actuator Outputs 40% Input Sensors 5% ECU Failures 30% Wiring 40% Input sensors 25% Actuator outputs 5% ECU Failures • Diagnostic Review Diagnostics ZEEMS 178 Home Find... Go To.. Nominal Voltage DC 5.0 - 4.7 4.7 - 4.3 4.3 - 4.1 4.1 - 3.9 3.9 - 3.8 MAP Temp C 130 110 100 80 60 40 20 0 -20 -40 Altitude above Sea Level 0-1000 1000-2000 2000-3000 3000-4000 4000-5000 Temp F 266 230 212 176 140 104 68 32 -4 -40 Nominal Resistance 84 144 189 349 693 1484 3481 9099 27050 93630 Maximum Resistance 88 151 199 369 734 1579 3719 9767 2910 101400 Gas 17 deg BTDC +/- 2 deg LPG 25 deg BTDC +/- 2 deg Timing @1350 RPM 1.2 - 1.4 Ohms Fuel Injector 14 psi. (0.96 bar) w/EGO 24 psi. (1.65 bar) w/o EGO 14 psi (0.96 bar) Propane 15 psi (1.0 bar) w/EGO 10 psi (0.69 bar) w/o EGO Gasoline Fuel Pressure 3.0-4.5 Ohms 3 amp max current draw Governor Actuator Minimum Resistance 80 139 182 334 657 1398 3254 8442 24910 85570 IAT and ECT Specifications ZEEMS Home Find... Go To.. 179 Review System Operation Review Questions and Answers Operation ZEEMS 180 Home Find... Go To.. Fuel Tank, propane or gasoline Fuel Pressure Regulator, gasoline only Fuel Return, gasoline only Electrical fuel shut off/on, propane (LPG) Electric fuel pump, gasoline Fuel Injector Throttle Actuator Distributor Timing Advance RPM Input Sensors Electronic Control Unit ECU ZEEMS Block Diagram Block Diagram Review ZEEMS Home Find... Go To.. 181 ECT IAT MAP Dash Switch Command EGO RPM Electronic Control Unit ECU Controlled Key On Not ECU Injector Firing (pump “pumping” or lock off “open”) Fuel is flowing Heater EGO System Operation Ignition Timing advancing Governor is at specified controlled RPM with EGO Sensor Running Operation Review ZEEMS 182 Home Find... Go To.. 550/1550 Engine Replacement Kit Numbers 392556 Perkins Diesel 392557 GM 3.0 L LPG 392558 GM 3.0 L Gas ZEEMS ZEEMS Home Find... Go To.. 183 Propane and Gasoline Electronic Fuel Injection END Zenith Electronic Engine Management System ZEEMS ZEEMS 184 Home Find... Go To.. ZEEMS Troubleshooting Test Kit Complete Test Kit – Tennant Part # 371772 – Zenith Part # C282-311 Pressure Gauge – Tennant Part # 371784 – Zenith Part # C190-181 Male Connector 45 Flare – Tennant Part # 371783 – Zenith Part # T220-17 Assly Street TEE w/fittings – Tennant Part # 371785 – Zenith Part # C210-7 Male Connector SAE 45 Flare – Tennant Part # 371786 – Zenith Part # T220-16 Connector Fitting – Tennant Part # 371787 – Zenith Part # T220-5 Male Pipe X Female Pipe Tee – Tennant Part # 371788 – Zenith Part # T270-7 Home Find... Go To.. 185 Service Connector – Air Temp Sensor – Tennant Part # 371773 – Zenith Part # C282-305 Service Connector – Coolant Temp Sensor – Tennant Part # 371774 – Zenith Part # C282-306 Service Connector – MAP Sensor – Tennant Part # 371775 – Zenith Part # C282-307 Service Connector – Governor – Tennant Part # 371776 – Zenith Part # C282-308 186 Home Find... Go To.. Service Connector – Gasoline Injector – Tennant Part # 371777 – Zenith Part # C282-309 Service Connector – LPG Injector – Tennant Part # 371778 – Zenith Part # C282-310 GM Micropak Coil Adapter – Tennant Part # 371779 – Zenith Part # C201-33 Home Find... Go To.. 187 Gas Injector - Noid Light – Tennant Part # 371780 – Zenith Part # C282-110 LPG Injector - Noid Light – Tennant Part # 371781 – Zenith Part # C282-109 Actuator Power Tool – Tennant Part # 371782 – Zenith Part # C282-113 188 Home Find... Go To.. Engine Controls AIR AND COOLANT SENSOR RESISTANCE Te m p deg F Te m p deg F Nominal Resistance ohms Minimum Resistance ohms Maximum Resistance ohms -40 -40 93630 85570 101400 -30 -22 49320 45250 53310 -20 -4 27050 24910 29160 -10 14 15420 14250 16580 0 32 9099 8442 9767 10 50 5546 5165 5939 20 68 3481 3254 3719 25 77 2787 2609 2974 30 86 2245 2106 2393 40 104 1484 1398 1579 50 122 1004 949 1065 60 140 693 657 734 70 158 488 465 516 80 176 349 334 369 90 194 255 244 268 100 212 189 182 199 110 230 144 139 151 120 248 109 105 114 130 266 84 80 88 Table 7:1 WIRING DIAGRAMS Refer to Section 3, Engine Electrical, for wiring diagrams. Note: The wiring diagrams are specific to the engine and machine application. If the following wiring diagrams do not match the machine being repaired contact Power Solutions, Inc., or the machine manufacturer for a copy of the diagram. Home Find... Go To.. 189 Engine Controls DIAGNOSTIC PROCEDURES Diagnostic procedures are listed separately for each fuel but, unlike mechanical fuel systems that require different thinking processes for gasoline and LPG, the diagnostic procedures for both the gasoline and LPG ZEEMS system follow the same thinking pattern. Diagnostic Procedure Engine Idle Speed High Engine Speed “Spikes” Intermittently Engine Runs Erratically, Poor Governor Performance Engine Runs but will not Accelerate Engine Won’t Start - Gasoline Gasoline Fuel Pump Diagnosis Engine Won’t Start - LPG Engine Won’t Start - Dual Fuel Engine Runs, Low Power, Lean or Misfire - Gasoline Engine Runs Rich - Gasoline Engine Runs, Low Power, Lean or Misfires - LPG Engine Runs Rich - LPG Pg. No. 4-36 4-37 4-38 4-39 4-40 4-41 4-42 4-44 4-45 4-46 4-47 4-48 Below is a brief list of items to check BEFORE entering the ZEEMS diagnostic charts that follow. Too often the tendency is to blame the most unfamiliar part of a new system and we forget to ‘get back to the basics’. The following is a quick check list of items to check. 9 Ignition System Operation 9 Ignition Timing 9 Fuel pressures 9 Fuel level 9 Electrical Connections 9 Alternator charging voltages 9 Battery condition 190 Home Find... Go To.. Engine Controls Diagnostic Procedures - Continued Engine Idle Speed High Check vacuum leaks: Intake manifold Throttle body Throttle adapter PCV valve NOTE: disconnect battery when servicing electrical components YES Does engine idle at 500 – 650 RPM with actuator unplugged? NO Back out idle stop screw one turn YES YES Does idle speed drop? YES NO Binding or stuck throttle Engine idle above 500-650 RPM with actuator connected Adjust idle stop to specifications SEE: Operating Spec. YES With ECT above 161 deg. F allow engine to idle for 2-5 1/2 min. to self learn idle speed SEE: Operating Spec. Home Find... Go To.. 191 Engine Controls Diagnostic Procedures - Continued Engine Speed “Spikes” Intermittently > 650 RPM Disconnect Governor Actuator. Engine idle speed 500-650 RPM? Adjust base idle screw to lower engine RPM < 650 RPM Is idle speed reduced? NO Verify ECU ignition supply is constant and uninterrupted. Constant? Repair faulty connection YES NO Remove Throttle body and inspect for binding/obstruction YES Adjust base idle screw to specifications NO Verify ECU ground is constant and uninterrupted. Constant? Clean and Tight? Repair faulty connection YES Allow unit to reach operating temperature (>160°F) and allow unit to “Self Learn” Repair fault in Speed Select wiring. REV 192 Home Find... Go To.. 3 Engine Controls Diagnostic Procedures - Continued Engine Runs Erratically, Poor Governor Performance Engine speed surges Correct charging system fault YES Charging system voltage surges? NO NO Repair ground ECU ground? YES SEE engine diagnostics YES Correct CKP sensor polarity System fuel pressures low? YES NO Ignition timing incorrect? Voltage reversed on CKP sensor? NO SEE engine diagnostics YES NO Va c u u m Leaks? Set timing to manufacturers specifications NO SEE engine idle speed high Home NO Throttle plate sticking? Find... Go To.. YES Replace throttle body 193 Engine Controls Diagnostic Procedures - Continued Engine Runs, But Will Not Accelerate NO Fuel Level SEE: Engine runs low power, lean or misfires diagnosis YES NO Map Sensor Replace YES NO *APP sensor or speed select output OK? *Refer to the applicable schematic in Section 3 to check the speed switch operation. Repair or replace accelerator pedal position sensor or speed select switch YES Governor actuator input OK? NO Repair wiring or replace ECU YES Governor actuator continuity (3-5 Ω) ? NO YES Check throttle plate rotation 194 Home Find... Go To.. Replace throttle body Engine Controls Diagnostic Procedures - Continued Engine Won’t Start - Gasoline Spark Present at Spark Plugs? NO Refer to Section 3, Engine Electrical YES NO Fuel Level? Add fuel YES See pump diagnosis NO Correct ignition system. Repair or replace ECU Momentary fuel pressure when key is on? YES YES Repair wiring or voltage souce Fuel pressure w/crank? Tach. signal to ECU? NO Injector light flashes? YES Replace fuel press regulator. NO Repair wiring or CKP sensor NO Injector sprays? Fuel press. 9-11 psi? Disconnect inj. Crank engine 15 sec. Injector leaks? NO Restrict fuel return line. Fuel press. 16 psi? NO YES YES Adjust Fuel press. 9-11 psi. YES YES Check ground or replace ECU Replace injector or o-rings NO YES NO 12V at injector? NO Replace fuel filter and/or pump NO Clean or replace plugs YES Home Are plugs fouled? Find... Go To.. Is engine flooded? 195 Engine Control Diagnostic Procedures - Continued Gasoline Fuel Pump Diagnosis Momentary 12v at pump when key is turned on? YES Ground continuity to frame? YES NO Repair or replace pump Repair wire to pump YES Momentary 12v from ECU when key is turned on? NO 12v to ECU? NO Repair 12v source to ECU YES Replace ECU YES Repair ground wire 196 NO Home Ground continuity? Find... Go To.. Engine Controls Diagnostic Procedures - Continued Engine Won’t Start - LPG NO Spark Present at Spark Plugs? Refer to Section 3, Engine Electrical YES Repair open circuit NO Does LP tank have fuel? Add Fuel Repair Open Circuit NO YES With key on, does ignition coil have power? NO Ignition ON. Does ECU have both ignition and ground? Turn ignition on and immediately observe LP lock-off voltage. Is voltage present for 2 seconds and turns off? NO YES NO Disconnect 4-pin connector from Distributor. Do spark plugs fire while cranking? YES Consult Engine Electrical Section YES YES Replace ECU and perform “Self-learning” NO Crank engine for 5 seconds and observe LP lock-off voltage. Does voltage remain constant for the 5 second crank? Repair wiring/loose connection NO Repair incorrect wiring Check ignition system. Do spark plugs fire while cranking? YES NO CONTINUITY Verify injector wires have continuity between ECU and injector YES Using an injector NOID light. Does light flash during cranking? NO Repair open circuit in distributor “reference” wiring to ECU CONTINUED ON NEXT PAGE OK YES Replace ECU Home Find... Go To.. REV A 197 Engine Controls Diagnostic Procedures - Continued Engine Won’t Start - LPG (Continued) OPEN CIRCUIT Using a digital multimeter, measure injector coil resistance. Resistance (1.2 - 1.6 ohms) Replace faulty injector CHECKS OK CAUTION: Extreme care should be taken when disconnecting fuel lines. Lines may be under pressure. Gasoline is highly flammable an should not be exposed to ignition sources or areas of high heat. Install fuel pressure gauge at Throttle Body fuel inlet. Fuel pressure OK when key is turned on? NO SEE LP REFER TO FUEL REGULATOR PUMP DIAGNOSIS DIAGNOSIS YES Restrict fuel return line and turntoignition on Turn ignition on momentarily “charge” to “charge”LP fuellock-off pressure. fuelmomentarily pressure. Disconnect Disconnect fuelengine. pump power and fuel crank power and crank Observe engine. Observe fuel pressure gauge. pressure gauge. Does fuel pressure drop rapidly while cranking? YES System operating properly REV A 198 Home Find... Go To.. NO Replace defective injector Engine Controls Diagnostic Procedures - Continued Engine Won’t Start — Dual Fuel Spark Present at Spark Plugs? NO Refer to Section 3, Engine Electrical YES Check fuel in both tanks YES Check fuel selector switch position YES Go to gasoline no start diagnostic NO GAS LPG YES Starts in alternate fuel? NO LPG GAS YES Go to LPG no start diagnostic NEITHER FUEL S TA R T S Momentary 12v at lock-off or gas pump when key is on YES Go to no start diagnostic NO Momentary 12v from ECU when key is turned on? YES Go to no start diagnostic Repair ground wire NO NO YES Ground continuity? 12v to ECU? NO Repair 12v source to ECU YES Replace ECU Home Find... Go To.. 199 Engine Controls Diagnostic Procedures - Continued START HERE Engine Runs, Low Power, Lean or Misfires — Gasoline Check vacuum leaks: Intake manifold Throttle body Throttle adapter PCV valve YES System voltage 13.5/14.7v? NO Repair charging system Replace fuel pressure regulator NO YES Fuel pressure 9-11 psi? NO 16 psi restricted fuel line NO YES Replace map sensor NO Map sensor ok? YES Set ignition timing SEE engine service manual NO Ignition timing ok? YES Replace module or ECU DIS ignition module in ECU NO Ignition module ok? YES Tune engine YES Repair wiring or CKP sensor NO Tach. signal input to ECU? YES Check restrictions: Air Filter Exhaust 200 Home Find... Go To.. Replace fuel pump and/ or filter Engine Controls Diagnostic Procedures - Continued LPG Lock-Off Diagnosis Momentary 12v at lock-off when key is turned on? YES Ground continuity to frame? YES NO Repair or replace lock-off Repair wire to lock-off YES Momentary 12v from ECU when key is turned on? NO 12v to ECU? NO Repair 12v source to ECU YES Replace ECU YES Repair ground wire NO Home Ground continuity? Find... Go To.. 201 Engine Controls Diagnostic Procedures - Continued START HERE Engine Runs Rich — Gasoline OK Check MAP sensor connections Check MAP sensor with alternate sensor OK Check coolant and air temperature sensor connection OK Check for leaky injector OK OK Check air/coolant sensors resistance as per chart Repair/replace fuel return line YES Fuel press. greater than 11 psi? Adjust timing or repair harness/ module. Refer to Section 3, Engine Electrical. NO Ign. timing retarded? Adjust press. reg. 9-11 psi NO Runs okay Home Restriction in fuel return line? NO YES 202 YES Find... Go To.. NO Replace fuel pressure regulator Engine Controls Diagnostic Procedures - Continued Engine Runs, Low Power, Lean or Misfires — LPG START HERE YES Fuel level? Tank oriented in correct position? NO Orientate tank for liquid withdrawal. NO YES Replace or fill tank. Service valve on liquid withdrawal side of tank? Replace injector. Change tanks. YES YES NO NO Secondary Regulator Pressure See Page 4-22 Regulator freeze-up? YES NO YES Primary Regulator Pressure See Page 4-22 Engine coolant level and circulation? YES Fuel pressure ok? Check restriction filter or lock-off. YES NO Adjust pressure or replace regulator. System voltage 13.5 - 14.7 V? NO Repair charging system. YES Check vacuum leaks: Intake manifold Throttle adapter Throttle body PCV valve OK continued Home Find... Go To.. 203 Engine Controls Diagnostic Procedures - Continued Engine Runs, Low power, Lean or Misfires — LPG (Continued) Map sensor okay? NO Replace map sensor. YES Ignition timing okay? NO Set ignition timing. Refer to Section 3 Engine Electrical. NO Replace module or ECU DIS ignition module in ECU NO Repair wiring or CKP sensor. YES Ignition Module okay? YES Tune engine. OK Tach. signal input to ECU? YES Check restrictions: Exhaust Air Filter OK Valve 204 Home Check clearances. Find... Go To.. Engine Controls Diagnostic Procedures - Continued START HERE Engine Runs Rich — LPG Check MAP sensor connections OK Check MAP sensor with alternate sensor OK Check coolant and air temperature sensor connection OK YES Replace fuel injectors. Leaky injector? OK Check air/coolant sensors resistance as per chart. NO NO Adjust/replace primary regulator Fuel press. primary reg. See Page 4-22 YES Adjust secondary reg. See Page 4-22 NO Adjust/replace secondary regulator. YES Adjust timing or repair harness/module Refer to Section 3, Engine Electrical NO Ignition timing ok? YES Runs ok. Home Find... Go To.. 205 206 Home Find... Go To.. Operation and Maintenance Manual PSI’s 4.3L OPU Industrial Gasoline and Alternate Fueled Engines 1.6L, 3.0L, 4.3L, 5.7L, 7.4L and 8.1L Engines A GM Powertrain Product by Power Solutions, Inc. Wood Dale, IL 60191 36100007/REV030101 Home Find... Go To.. 207 Table of Contents Page Introduction 1 How to Use This Manual Engine Identification Parts and Service Service Literature Operating Instructions Controls 3 3 Ignition Switch Safety Gauges Fuel Systems Governors Instruments Oil Pressure Gauge Temperature Gauge Voltmeter Tachometer/Hourmeter Starting the Engine Carbureted, Mechanical Governor, Manual Choke Carbureted, Electric Choke, Electronic Governor LPG or NG Fuel Systems, Velocity Governors PSI, Inc. Fuel Injection (Gasoline) Integral Governor PSI, Inc. Fuel Injection (Dual Fuel) Integral Governor Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor Stopping the Engine Normal Conditions Abnormal Conditions (Carbureted) Abnormal Conditions (Fuel Injected) Fuel Recommendations Fuel Quality Anti-Knock Index (Octane Rating) Gasohol and Alcohol/Gasoline Fuels Spark Plugs Power Loss at Higher Elevations Carbureted Engines Fuel Injected Engines Maintenance Instructions 208 1 2 2 2 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 6 7 7 7 7 7 7 8 8 8 9 9 9 10 Initial Start Up Maintenance 10 Routine Maintenance 10 Home Find... Go To.. Table of Contents (cont.) Scheduled Preventive Maintenance 10 Engine Oil Level Check 10 Adding Engine Oil 10 Changing Engine Oil and Filter 11 Engine Oil Quality 11 Engine Oil Recommendation 11 Oil Filter 11 Engine Air Cleaner 12 12 Safety Element Cooling System Coolant Level Radiator Fan Belts Sepentine Belt V-Type Belt Fuel Filter Carbureted Engines Fuel Injected Engines Ignition Systems Types of Ignition Systems Ignition Timing Spark Plugs Storage One to Six Months Extended Periods Removing the Engine From Storage 12 12 13 13 14 14 14 14 14 15 15 15 15 16 16 16 16 Appendix Timing Procedures I Maintenance Schedule II Capacities II Filter Chart III Fuel System Chart IV Governor Chart IV General Specifications Home Find... Go To.. V 209 Table of Contents (cont.) Spark Plug Wire Routing 3.0L 210 Home Find... Go To.. Introduction Power Solutions, Inc. is pleased that you have selected a GM Powertrain engine for your requirements. Power Solutions, Inc. takes great pride in our tradition of quality products produced from the GM Powertrain line of industrial gasoline and alternative fuel engines. Power Solutions engines are inspected and tested before leaving the factory. However, certain checks should be made before placing the engine into regular service. Please read the Initial Start-Up inspection requirements in the Maintenance Section of this manual. How to Use this Manual This manual contains instructions on the safe operation and preventive maintenance of your GM Powertrain industrial engine. We urge you to read this manual prior to start up or operation of the engine. The Table of Contents permits you to quickly open the manual to any section. Power Solutions, Inc., engines are built with a variety of standard and/or optional components to suit a broad range of customer requirements. This manual does not identify equipment as standard or optional. All the equipment described in this manual may not be found on your engine or power unit. Please pay special attention to the NOTES, CAUTIONS, and WARNINGS. WARNINGS remind you to be careful in areas where carelessness can cause personal injury. CAUTIONS are given to prevent you from error that could cause damage to the equipment. NOTES give you added information designed to help you. The descriptions and specifications contained in this manual were in effect at the time of publication. Power Solutions, Inc. reserves the right to discontinue models at any time, or to change specifications or design without notice and without incurring obligation. Power Solutions, Inc. 655 Wheat Lane Wood Dale, IL 60191 1 Home Find... Go To.. 211 Engine Identification An identification label is affixed to the right side of the engine on the rocker cover when looking at the engine from the flywheel end.. (The engine serial number is also stamped into the left side of the cylinder block near the engine flywheel.) The label contains the engine model number (i.e. 4.3L, 5.7L, etc.) and a serial number which identifies the engine from other GM Powertrain engines provided by Power Solutions, Inc. The engine model and serial number are required when seeking information concerning the engine and/or ordering replacement service parts. Insert Picture of the Label Parts and Service Replacement parts can be obtained from Power Solutions, Inc. by calling the Service Parts Department at 800-551-2938. The engine model and serial number will be required when seeking information and/or ordering parts. Service and technical support for GM Powertrain engines supplied by Power Solutions, Inc. can be obtained by contacting the Service Department at 800-551-2938. Service Literature Additional operator manuals and service manuals for specific GM Powertrain engines provided by Power Solutions, Inc. can be obtained by contacting the Parts or Service Department at 800-551-2938 2 212 Home Find... Go To.. Operating Instructions Controls Ignition Switch The ignition switch is located on the control panel. The switch is a 3 position switch, OFF, RUN and START. The OFF position disconnects the electrical system from the battery. The key can be removed from the switch when it is in this position. In the RUN position, the electrical system is activated. Engage the starter by turning the key to the START position. Release the key when the engine starts and it will return to the ON position. Safety Gauges Power Solutions, Inc., industrial power units are equipped with instrument panels which contain shut down gauges for High Engine Water Temperature and Low Engine Oil Pressure. A push button ‘Tattletale’ relay is utilized with this system. When starting the engine it is necessary to ‘depress’ the safety switch override button, until the engine starts and engine oil pressure is obtained (usually 2 to 5 seconds). The engine will continue to run when the button is released. CAUTION: If the engine does not continue to run when the button is released, it will be necessary to check the instrument panel fuse and/or the engine lubrication system (i.e. oil level, etc.) before restarting the engine. NOTE: Power Solutions, Inc. provides engines to many different original equipment manufacturers. Not all manufacturers use the PSI instrument panel. Please refer to the equipment Operators Manual for instructions on engine starting. Fuel Systems Several different fuel systems have been used on Power Solutions, Inc. GM Powertrain engines. A chart identifiying the different types of fuel systems used by engine model can be found in the back of this manual. NOTE: Some fuel systems are installed by the original equipment manufacturer. Therefore it may be necessary to contact the equipment manufacturer for information pertaining to your specific fuel system if it cannot be found in the chart. 3 Home Find... Go To.. 213 Governors As with fuel systems, several different governor controls have also been used with the Power Solutions, Inc. GM Powertrain engines. A chart identifying the different types of governor systems used is included at the back of this manual. NOTE: Some governors are installed by the original equipment manufacturer. If your governor is not included in the chart, it will be necessary to contact the equipment manufacturer. Instruments Insert Photo of the Instrument Panel Oil Pressure Gauge The oil pressure gauge show the engine lubrication system pressure in pounds per square inch (psi) and should be checked frequently to ensure that the system is functioning correctly. Should the pressure fluctuate or drop, stop the engine and find the cause. Do not operate the engine at lower than normal oil pressure (see maintenance schedule for minimum engine oil pressure). CAUTION: Do not continue to operate your engine below the normal operating range. Severe engine damage could occur. Temperature Gauge The temperature gauge registers the coolant temperature and will indicate overheating which may arise from low coolant level, plugged radiator, loose fan belt or faulty thermostat. Coolant level should be checked daily. CAUTION: If the engine continues to overheat, have the cooling system checked and serviced. 4 214 Home Find... Go To.. Instruments (cont.) Voltmeter The voltmeter indicates the battery charging voltage. If the meter consistently indicates less than 13 volts or more than 15.7 volts under normal operating conditions, you should have the engine electrical system checked by a qualified service technician. Tachometer/Hourmeter The tachometer indicates the engine speed in hundreds of revolutions per minute (rpm). It serves, as a guide to insure that engine speed is set correctly. The hourmeter records the hours of operation and is used to determine when periodic maintenance is required. Starting the Engine Warning: All internal combustion engines give off various fumes and gases while running. Do no start or run the engine in a closed or poorly ventilated building where exhaust gases can accumulate. Avoid breathing these gases as they may contain poisonous carbon monoxide, which can endanger your health or life if inhaled steadily for even a few minutes. If the engine is equipped with a manual clutch it must be disengaged prior to starting the engine. Starting the engine with the clutch engaged imposes unnecessary strain on the battery, starter, and driven components. CAUTION: If the engine stalls or falters during starting, wait 3 to 4 seconds before re-engaging the starter. This will prevent possible damage to the starter or the engine. DO NOT operate the starter for periods longer than 30 seconds at a time. An interval of at least 1-minute should be observed between cranking periods to protect the starter from overheating. Carbureted, Mechanical Governor, Manual Choke Pull the throttle cable out approximately ½ inch, and the choke out full. Turn the ignition key to the START position. After the engine starts, release the key, decrease the throttle setting and adjust the choke cable for fast idle warm-up. When the engine is at operating temperature, push the choke in all the way. When the engine is warm, it may not be necessary to use the choke for starting. 5 Home Find... Go To.. 215 Carbureted, Electric Choke, Electronic Governor Turn the On/Off switch on the instrument panel to the ON position. Turn the ignition key to the ON position. This allows the electric choke to pre-set prior to starting. Turn the ignition key to the START position. After the engine starts release the key to the ON position. Allow a few minutes for the engine to warm up. Move the governor control switch to the LOW position. Engage the clutch, then move the governor control switch to the HI position. LPG or NG Fuel Systems, Velocity Governors Turn on the gas supply to the engine. Turn the ignition key to the START position. After the engine starts release the key to the ON position. PSI Fuel Injection (Gasoline) Turn the ignition key to the ON position, this energizes the electric fuel pump to charge the fuel system with fuel. Turn the ignition key to the START position. After the engine starts release the key to the ON position. PSI Fuel Injection (Gasoline/LPG)(Dual Fuel) Select the desired fuel switch position for starting the engine (Gasoline/LPG). Turn the ignition key switch ON, then move ignition key to the START position. After the engine starts release the key to the ON position. Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor Turn the ignition key to the ON position to energize the fuel pump. Ensure that the Hi/Lo switch on the instrument is in the Lo position. Turn the ignition key to the START position. After the engine starts release the key to the ON position. Allowing a few minutes for engine warm-up, move the Hi/Lo switch to the Hi position. 6 216 Home Find... Go To.. Stopping the Engine Normal Conditions: Following normal operating conditions, lower the engine speed to idle, pushing the throttle cable in on mechanical systems or with electronic systems placing the Hi/Lo switch in the Lo position. If the machine is equipped with a clutch, move the clutch lever to the disengaged position. Run engine for a few minutes at idle to allow the coolant system to cool down before turning the ignition switch to the OFF position. Abnormal Conditions (Carbureted): Under abnormally overheated conditions, the engine may continue to run after the switch is turned OFF. If this is encountered, turn the ignition switch to the ON position immediately and allow the engine to run at idle until it has cooled down enough to stop. (Fuel Injected) Fuel injected engines generally will not after run, even if hot. These systems require that the fuel delivery be shut off completely when turning the ignition switch to the OFF position. WARNING: Avoid injury when checking a Hot Engine. Allow the engine to cool down before removing the radiator cap. CAUTION: Before restarting the engine ensure that both the coolant system and the engine oil level have been checked and re-filled if necessary. Fuel Recommendations Fuel Quality Using a high quality unleaded gasoline will help maintain the power, fuel economy and emissions performance of your engine. A properly formulated gasoline will be comprised of well refined hydrocarbons and chemical additives and will perform the following functions: Minimize varnish, lacquer, and other induction system deposits. Prevent gum formation or other deterioration during storage. Protect fuel tank and other fuel system components from corrosion or degradation. 7 Home Find... Go To.. 217 Fuel Recommendations (cont.) Provide the correct seasonally and geographically adjusted volatility which should provide easy starting in the winter and summer. Avoid fuel system icing. In addition, the fuel must be free of water, debris, and other impurities. It is recommended that the fuel supply be kept fresh when the engine is in storage (especially in hot weather). The fuel tank should be kept at least ¾ full. Fuel stored for more than two months should be drained, properly discarded, and the fuel tank re-filled. Anti-Knock Index (Octane Rating) This engine is designed to operate on unleaded 87 or 89 octane gasoline with an (R + M)/2”minimum anti-knock index. Federal regulations require that each retail gasoline dispensing pump must display a label bearing the minimum index rating. Use of unleaded gasoline with anti-knock index rating lower than 87 can cause persistent, heavy spark knock, which can lead to engine damage. If your engine knocks heavily when you use gasoline with an anti-knock index rating of 87 or higher, or if you hear continuous spark knock while maintaining constant operating speeds, consult a dealer or qualified technician. Gasohol and Alcohol/Gasoline Fuels Gasohol, a mixture of gasoline and ethanol (grain alcohol), is available in some areas. PSI, GM Powertrain engines should operate satisfactorily on gasohol blends containing no more than 10% ethanol by volume and having and anti-knock index of 87 or 89. CAUTION: In some cases, methanol (wood alcohol) or other alcohol’s may be added to gasoline. PSI GM Powertrain engines should operate satisfactorily on blends containing up to 5% methanol by volume when cosolvents and other necessary additives are used. DO NOT USE blends containing more than 5% methanol by volume or blends that do not contain cosolvents and corrosion inhibitors. CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if fuel system problems occur. Do not use such fuels unless they are UNLEADED. Spark plugs Always use the recommended spark plugs for your engine. Hotter or colder plugs, or similar plugs that are not exact equivalents to the recommended plugs, can cause permanent engine damage, reduce the engines useful life, and cause many other problems such as hard starting, spark knock and run-on. Installing new spark plugs regularly is one of the best ways to keep your engine at peak performance. 8 218 Home Find... Go To.. Power Loss at Higher Elevations All engines will experience power loss when operated at elevations above sea level, unless they are turbocharged or supercharged. Turbochargers and superchargers are mechanical pumps that put extra air into the engine to make up for the lower air density at higher elevations. Carbureted Engines Carbureted engines will loose power for two reasons. First, power is reduced 3.5% for each 1000 feet it is operated above sea level due to the decreased air density. With less dense air, the engine receives less oxygen to burn the fuel. The engine power is decreased in direct proportion to the reduction of available oxygen. Second, the reduced oxygen causes the fuel mixture to have too much fuel for the available oxygen. This is a rich mixture (rich with fuel) and not only causes the engine to produce sooty black exhaust, but causes additional loss of power and premature spark plug fouling. Engines that are operated over 3000 feet of elevation, that exhibit black smoke or produce less than optimum power should have the fuel system re-calibrated. For additional information on optimizing your engine for higher elevations contact your dealer or Power Solutions, Inc. at 800-551-2938. Caution: Engines re-calibrated for high elevations will run lean at lower elevations. Lean running can burn valves, will reduce valve and valve seat life and can cause engine overheating. Failures caused by these problems are not covered by warranty. Fuel Injected Engines Fuel injected engines will loose 3.5% power for every 1000 feet the engine is operated above sea level. All fuel injection systems installed by Power Solutions, Inc. are equipped with a “manifold absolute pressure sensor” (MAP Sensor). The MAP sensor senses barometric pressure and automatically corrects the fuel system calibration for changes in altitude. This means the air/fuel mixture will always be optimized, regardless of elevation (or barometric pressure), however, the engine will still loose 3.5% power for every 1000 feet increase in elevation. 9 Home Find... Go To.. 219 MAINTENANCE INSTRUCTIONS Initial Start Up Maintenance The initial start-up checks must be made before putting the engine into service. Please refer to the Maintenance Schedule on page II and perform the initial start-up operations in the sequence shown in column 1. Routine Maintenance Routine maintenance provides the best solution for making sure that the engine is ready when you are. The following are some routine service points: Keep the fuel tank filled. A full tank of fuel reduces the possibility of condensation forming in the fuel tank and moisture entering the fuel system Make frequent checks of the engine oil and coolant levels Repair any oil or coolant leaks immediately Check battery condition and cables frequently Keep the engine air filter clean Monitor engine coolant temperature Monitor engine oil pressure Check voltmeter and charging system Scheduled Preventive Maintenance Refer to the Maintenance Schedule on page II to ensure that all of the maintenance items listed are checked and replaced as recommended at the hours shown. Engine Oil Level Check The engine oil level should be checked daily. It is recommended that the oil be checked just before the engine is started for the first time for that day. The oil level should be between the ‘Add’ and the ‘Full’ marks on the dipstick. CAUTION: Do not operate the engine with the oil level below the bottom or ‘Add’ mark on the dipstick, or above the top or ‘Full’ mark on the dipstick. Adding Engine Oil It is normal to add some oil in the period of time between oil changes. The amount will vary with the severity of operation. When adding or replacing engine oil, be sure the oil meets or exceeds the recommended specification. 10 220 Home Find... Go To.. Changing Engine Oil and Filter The engine oil and filter must be changed every 200 hours or every 3 months whichever occurs first. Under normal operating conditions, you do not need to change them more often if you use oil and filters of the recommended quality. The oil and filter should be changed more often if the engine is operating in dusty or extremely dirty areas, or during cold weather. No oil additives or break-in oil change is required. Engine Oil Quality To achieve proper engine performance and durability, it is important that you use only engine lubricating oils of the correct quality in your engine. Proper quality oils also provide maximum efficiency for crankcase ventilation systems, which reduces pollution. Important: use only engine oils displaying the American Petroleum Institute (API) “Starburst” Certification Mark ‘FOR GASOLINE ENGINES’ on the container. Gasoline engines that are converted for LPG or NG fuels MUST use oils labeled ‘FOR GASOLINE ENGINES’. Do not use oils that are specifically formulated for Diesel Engines only. CC or CD classification oils, even when labeled Heavy Duty or for Natural Gas Engines, ARE NOT ACCEPTABLE. Engine Oil Recommendation Multi-viscosity oils are recommended. SAE 10W-30 is recommended for your engine from 0 degrees F (-18 degrees C) or above. If ambient temperatures are consistently below 0 degrees F, SAE 5W-30 oil can be used. Synthetic oils are not recommended for industrial or stationary engines. Oil Filter The PSI GM Powertrain engines use an AC Delco oil filter as original equipment. An equivalent oil filter must be used when servicing the engine (see Engine Specifications for the recommended oil filter for your engine). The filter protects your engine from harmful, abrasive, or sludgy particles without blocking the flow of oil to vital engine parts. To replace the filter, use a proper filter wrench to remove the filter. Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil. Hand tighten the filter until the gasket contacts the base, then tighten another ½ turn. Fill the engine with the correct amount of oil, run the engine and check for oil leaks at the drain plug and oil filter gasket. Tighten as necessary to stop any oil leakage noted. 11 Home Find... Go To.. 221 Engine Air Cleaner The engine air cleaner filters air entering the engine intake system and acts as a silencer and flame arrester when assembled to the intake system. Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe damage to the cylinder walls and piston rings. Damage to the cylinder walls and piston rings will cause high oil consumption and shorten engine life. A restricted or dirty air cleaner will also cause a rich fuel mixture. Thus, it is extremely important that the air cleaner be serviced properly at the recommended intervals. CAUTION: Service the air cleaner more frequently under severe dusty or dirty conditions. Remove the primary air cleaner element from the air cleaner assembly and inspect the element for foreign material restrictions or signs of excessive wear or damage. Replace the element if necessary. Remove all dust and foreign matter from the air cleaner housing. Reinstall the air cleaner element. Reinstall the air cleaner cup, and securely fasten the retaining clips. Safety Element If your engine is equipped with an air cleaner which utilizes a safety element, ensure that the element is properly in place before installing the primary element. Change the safety element annually. Cooling System Coolant Level Check the coolant level of the radiator daily and only when the engine is cool. Generally a good time to do this is just prior to starting the engine for the first time each day. Maintain the coolant level at ¾ to 1½ inches below the filler neck seat of the radiator when the coolant is cold. When ever coolant level checks are made inspect the condition of the radiator cap rubber seal. Make sure it is clean and free of any dirt particles which would keep it from seating on the filler neck seat. Rinse off with clean water if necessary. Also make sure that the filler neck seat is free of any dirt particles. 12 222 Home Find... Go To.. WARNING Never remove the radiator cap under any conditions while the engine is operating. Failure to follow these instruction could result in damage to the cooling system, engine, or cause personal injury. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme caution when removing the radiator cap from a hot radiator. If possible, wait until the engine has cooled, then wrap a thick cloth around the radiator cap and turn slowly to the first stop. Step back while the pressure is released from the cooling system. When all the pressure has been released, press down on the cap and remove it slowly. DO NOT add coolant to any engine that has become overheated until the engine cools. Adding coolant to an extremely hot engine can result in a cracked block or cylinder head. Use only a permanent-type coolant when refilling or flushing the coolant system. Recommended ethylene glycol mix 52/48 is normal up to a maximum of 60% glycol, 40% water. Refer to the mixture chart on the container for additional antifreeze protection information. DO NOT use alcohol or methanol antifreeze, or mix them with the specified coolant. Plain water may be used in an emergency (except in freezing temperatures), but replace it with the specified coolant as quickly as possible to avoid damage to the system. Radiator Inspect the exterior of the radiator for obstructions. Remove all bugs, dirt or foreign material with a soft brush or cloth. Use care to avoid damaging the core fins. If available, use low pressure compressed air or a stream of water in the opposite direction of the normal air flow. Check all hoses and connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they must be replaced. Fan Belts The water pump is usually belt driven. The same belt may also drive the fan and/or the alternator. The drive belts should be properly adjusted at all times. A loose belt can cause improper alternator, fan and water pump operation, in addition to overheating. 13 Home Find... Go To.. 223 Serpentine Belt Some GM Powertrain engines utilize serpentine belts on the front of the engine. This type of belt system incorporates a belt tensioning device which keeps the belt at the proper tension. This belt should be checked routinely for cracks or ‘checking’ on the groove side of the belt. If cracks or ‘checking’ are apparent the belt must be changed. V-Type Belt V-Type belts are generally tensioned by adjusting the alternator, or through a mechanical belt tensioner. The belt is generally correctly tensioned when there is an ½ inch of depression on the belt between the water pump and the crankshaft pulley. Fuel Filter Carbureted Engines On carbureted engines, an in-line fuel filter is incorporated into the fuel supply line. It is recommended that this filter be changed every 250 hours or every 6 months which ever occurs first. TBI Engines On PSI Fuel Injection or Fuel Injection/Dual Fuel two fuel filters are used in the gasoline fuel supply line to the engine TBI unit. A coarse fuel filter is located in the supply line between the fuel tank and the electric fuel pump. This filter protects the fuel pump from debris in the fuel tank. This filter must be changed every 200 hours or every 6 months which ever occurs first. A primary fuel filter is located between the fuel pump and the TBI unit on the engine. This filter protects the injectors from microscopic particles in the fuel which can cause plugging of the injectors. This filter MUST be changed every 500 hours or annually which ever occurs first. Zenith Z.E.E.M.S. TBI Fuel Injection requires an in-line fuel filter in the fuel supply line from the fuel tank to the TBI unit, ahead of the electric fuel supply pump. This filter must be changed every 200 hours or every 6 months which ever occurs first. CAUTION: Failure to change the fuel system filters as recommended can result in premature failure of the TBI fuel system components. NOTE: Some original equipment manufacturers install their own fuel systems. Please refer to the manufacturers manual if the gasoline fuel system is different than described here. 14 224 Home Find... Go To.. WARNING Use extreme care when changing the fuel filters on gasoline engines. Gasoline is highly flammable and should not be exposed to open flame, sparks, or hot engine components. Allow the engine to cool to ambient temperatures prior to changing fuel filters. Ignition Systems Types of Ignition Systems Three types of ignition systems are used on PSI GM Powertrain engines. Solid state electronic distributor, solid state electronic distributor with ECU (Electronic Control Unit) and distributor-less electronic ignition with ECU. Please refer to the General Specification chart to determine the ignition system used on your particular engine. Ignition Timing Proper adjustment of the ignition timing must be obtained to provide the optimum engine power output and economy. To properly adjust timing refer to the timing procedure section of this manual. Spark Plugs Spark plugs should be replaced at the recommended intervals described in the Maintenance Schedule. Use only the recommended spark plug or an equivalent as described in the General Specifications. Spark plug gap, should be adjusted as recommended in the General Specifications. When removing spark plugs, always note which cylinder each plug came out of. Look at the porcelain around the center electrode of each plug. You can detect many engine problems from the color and type of deposits that have built up on the white porcelain. For example, if the deposits are a glossy brown, that cylinder is burning excess oil. If the deposits are a very dark gray or sooty black color, your engine is running rich, and you are burning excess fuel. The optimum color of the deposits on the porcelain is light tan or light brown. This shows optimum fuel mixture and proper engine running conditions. If the deposits are almost white, the engine may be running excessively lean. Lean running is very detrimental to your engine life, and should be corrected immediately. If one or more cylinders are burning oil, the smoke from the engine will be a blue-gray color. Most common causes are piston rings (worn out or not broken in) and valve stem seals (cut, nicked, or worn out). If the engine is running rich the exhaust smoke will be a sooty black color and it will smell like gasoline (on gasoline engines). 15 Home Find... Go To.. 225 Storage One to Six Months If the engine or machine is to be placed in storage for a period of one to six months it is recommended that the following steps be followed: Add ‘Stabil’ or equivalent fuel conditioner to the fuel tank as recommended on the bottle. Run the engine for approximately 10 to 15 minutes to insure that the treated fuel is completely through the fuel system. Fill the fuel tank with fuel Protect the air cleaner inlet from water entry Protect the exhaust outlet or muffler outlet from water entry Check the coolant protection and top off radiator Store indoors if possible For Extended Periods Follow the above recommended procedures, plus do the following: Drain the engine crankcase and refill with recommended oil Change the oil filter Disconnect and remove the battery Clean exterior surface of the engine If the engine is equipped with an automotive type clutch or PTO clutch, make sure that the clutch is disengaged Removing the Engine From Extended Storage When removing the engine from extended storage: 226 Install a fully charged battery Remove all protective coverings from the air inlet, air cleaner, exhaust, and muffler openings Check the coolant level in the radiator and verify the protection level of the coolant 16 Home Find... Go To.. Removing the Engine From Extended Storage (cont.) Start the engine and allow it to run at slow idle. Verify engine oil pressure Run the engine at idle until the coolant temperature approaches 120 degrees F (49 degrees C) Run the engine a various speeds for approximately 15 minutes Shut the engine down, drain the oil, change the oil filter, and re-fill with the recommended grade of oil 17 Home Find... Go To.. 227 GM Engine Timing Procedures Carbureted, LPG an NG 3.0L, 4.3L, 5.7L, 7.4L PSI/GM Engines PSI Timing Connector Part Number 33000036 MUST be used when checking and adjusting the engine timing. 1. With the engine shut-off, plug the 33000036 Timing Connector into the distributor. DO NOT connect the alligator clip to any positive or negative terminal. (Connecting this wire to any battery terminal prior to starting the engine will cause the distributor module to fail when starting the engine.) 2. Start the engine and run at slow idle. 800 to 1000 rpm. 3. Connect the alligator clip to a B+ terminal. (This connection cancels the programmed timing advance from the distributor module. You will notice a change in engine sound and rpm when making this connection.) 4. Connect an electronic timing light to the No.1 spark plug wire. (The front cylinder on the 3.0L engine and the front cylinder on the left bank of the 4.3L, 5.7L and 7.4L engines.) 5. Check and adjust the distributor as necessary viewing the timing mark on the crankshaft pulley in relation to the pointer on the engine timing case. (On some engines there may be a timing port in the flywheel housing also.) 6. Refer to the General Specifications chart in this manual, for the initial timing specification for your engine and type of fuel being used. PSI Fuel Injected and Dual Fuel engines For engines equipped with this type of fuel system, the engine timing is controlled by the ECM (Engine Control Module). Checking the initial timing on engines equipped with PSI fuel injected and dual fuel engines incorporating and ECM can only be accomplished when using a laptop computer or a hand held diagnostic meter. It will be necessary to contact the OEM or PSI for the necessary equipment and instructions for checking and adjusting the engine timing. (CAUTION: Failure to follow the correct specified procedures when checking and adjusting the engine timing, can cause severe damage to the engine.) Zenith Z.E.E.M.S. Throttle Body Fuel Injected Engines Engine timing for Zenith TBI fuel injected engines is checked and adjusted following the procedures noted under Carbureted engines. Check the General Specifications chart for the correct engine timing. Generator Timing PSI/GM engines operating on generators are timed at 1800 RPM. Timing procedures are the same as for Carbureted engines. Check the General Specifications chart for the correct engine timing for the type of fuel being used. 228 Home Find... Go To.. Maintenance Schedule Power Solutions, Inc. GM Powertrain 1.6L, 3.0L, 4.3L, 5.7L, 7.4L, and 8.1L Engines Initial Start-Up Sequence Checks 1 2 3 4 5 6 7 (1) (2) (3) (4) (5) Operation Daily Check Engine Oil Level Check Coolant Level Check for Fluid Leaks Governor, Mechanical (Check oil level)(2) Change Engine Oil & Filter (1) Battery, Check Charge & Fluid Level Inspect & Clean Radiator Exterior Clean Battery Cables Check Belts and Belt Tension Lubricate Throttle, Governor & Choke Linkage (Carbureted Engines Only) Check & Adjust Idle Speed (Carbureted Engines Only) Inspect and Clean Air Cleaner Element Replace Primary Air Cleaner Element (1) Replace Safety Air Cleaner Element Check Coolant Protection & Tighten Hose Clamps Replace Engine Coolant (3) Replace Gasoline Fuel Filter (4) Replace LPG Filter – Zenith EFI (4) Replace PCV Valve (If Equipped) Check PCV Hoses, Tubes, and Fittings Replace Spark Plugs (3) Distributor Cap & Rotor (5) Secondary Ignition Wires Adjust Throttle & Governor (3) Check All Engine Bolts & Nuts for Tightness Weekly Every 50 hrs Every 100 hrs Every 200 hrs Every 400 hrs Every 800 hrs As Req. x x x x x x x x x x x x x x x x x x x x x x x x x More frequent intervals may be required in dusty or dirty operating conditions. Mechanical governor (belt driven). To be performed at specified interval or annually, whichever occurs first. More frequent intervals may be required with dirt in the fuel system. Does not apply to engines with DIS ignition. Capacities Engine Oil Capacity Without Filter Oil Capacity With Filter Coolant Capacity Without Radiator Coolant Capacity With Radiator 1.6L 3.4 qts. 3.7 qts. 3.5 qts. 10 qts. 3.0L 4 qts. 4.5 qts. 4 qts. 12 qts. 4.3L 4.5 qts. 5 qts. 7.75 qts. 17 qts. 5.7L 5 qts. 5.5 qts. 8.1 qts. 17.5 qts. 7.4L 8 qts. 9 qts. 14.5 qts. 28 qts. 31 qt (Turbo) 8.1L 8 qts. 9 qts. 14.5 qts. 28.5 qts. Revised 12/27/01 Home Find... Go To.. 229 230 Home Find... Go To.. Revised 05/31/00 Air Filter Primary (PSI Power Unit) Air Filter Safety (PSI Power Unit) Fuel Filter (Carbureted) Fuel Filter (PSI TBI Coarse) Fuel Filter (PSI TBI Fine) Fuel Filter Zenith Z.E.E.M.S Engine Oil Filter Gasoline C282-224 LPG C282-5 1.6L 94632619 32500292 P8228889 P829333 P822768 P822769 32500058 4.3L PF-47/PF-52 or Equivalent 32500020 (101021) 32500111 32500292 32500058 3.0L P-25 or Equivalent 32500020 (101021) 32500111 5.7L PF-1218 Equivalent Filter Chart GM Powertrain Industrial Engines Power Solutions, Inc. 7.4L/7.4LT PF-1218 or Equivalent 8.1L PF-454 or Equivalent Home Find... Go To.. 231 Revised 06/05/01 Hoof Mechanical (Belt Driven)(No Longer Available) Hoof Velocity Governor Aisan Velocity Governor Barber Colman Electronic Governors America Barber Colman Power Flow, PSI ECU Zenith Z.E.E.M.S. Fuel Injection Woodward Engine Engine Zenith Carburetor (013448) Manual Choke Zenith Carburetor (015017) Electric Choke Zenith Carburetor (015052) used w/Dual Fuel System Holley Carburetor (0-7448) Electric Choke Holley Carburetor(0-82010) Electric Choke Impco LPG Fuel System Nolff LPG Fuel System PSI Fuel Injection (Gasoline) PSI Fuel Injection/LPG Mixer (Dual Fuel) Impco Natural Gas Mixer Nolff Natural Gas Mixer Zenith Z.E.E.M.S Fuel Injection Integral 1.6L x x x x x 1.6 L 3.0L x x(NLA) x x x x Integral Governor Chart x x x x x x x 3.0L x x x x(NLA) x x x x Integral 4.3L x x x x x x x x x x 4.3L Fuel System Chart x x x x x 7.4L/T x x x x 5.7L x x 7.4L/T x x 5.7L GM Powertrain Industrial Engines Power Solutions, Inc. x x 8.1L x x 8.1L 232 Home Find... Go To.. Manufactured Revised 02/09/02 TBI LPG NG Dual Fuel Valve Clearance (Lash) Intake Exhaust Ignition Timing (Degrees BTDC) Gasoline (Carb) Gasoline (TBI) LPG NG Dual Fuel Ignition Timing (Degrees BTDC) Generators 1800 RPM LPG NG Spark Plugs Spark Plug Gap Coolant Capacity (Engine) Coolant Capacity (W/PSI Rad) Fuel Type Engine Rotation (Flywheel End) Ignition System .045 all ½ to 1 Turn Down From 0 Lash Toluca, Mexico No Adjustment OHC Engine Brazil 26 36 AC Delco R45TS .8mm-.9mm all AC Delco 93206675 DIS No Adjustment DIS No Adjustment 3.5 qts. 10 qts Gasoline, LPG CCW Distributor-less Electronic (ECU) 0 0 10 (4 Europe) 10 0 Hydraulic 79.0x81.5 (3.11x3.21) 2 Bolt External TBI 1-3-4-2 3.4 qts. (3.2L) 3.7 qts. (3.5L) Valve Lifters Bore x Stroke mm (inches) Main Bearing Caps Balance Method Intake Manifold Firing Order Oil Capacity With Oil Filter Oil Filter Minimum Oil Pressure (Hot) 21 psi @ idle 3.0L L4 2966 (181) 9.2:1 Push Rod Actuated Overhead Valve Flat Follower 101.60x91.44 (4.00x3.60) 2 Bolt External TBI, Carburetor, Mixer 1-3-4-2 4 qts. (3.8L) 5 qts. (4.7L) PF-25 or Equivalent 6 psi @ 1000 rpm 18 psi @ 2000 rpm 4 qts. (3.78L) 12 qts. (11.4L) Gasoline, LPG, NG CCW Solid State Distributor 1.6-2V 1600 (98) 9.4:1 Overhead Cam Type Displacement cc (c.i.d.) Compression Ratio Valve Configuration Tonawanda, NY Net Lash No Adjustment .035 .035 .035 .035 26 36 AC Delco R42LTS 10 0 0 (4 Europe) 10 0 4.3L V-6 4294 (262) 9.4:1 Push Rod Actuated Overhead Valve Hydraulic Roller 101.60x88.39 (4.00x3.48) 2 Bolt Internal Balance Shaft TBI, Carburetor, Mixer 1-6-5-4-3-2 4.5 qts. (4.3L) 5 qts. (4.7L) PF-47/PF-52 or Equivalent 6 psi @1000 rpm 18 psi @ 2000 rpm 7.75 qts. (7.3L) 17 qts. (16L) Gasoline, LPG, NG CCW Solid State Distributor 4.3L Toluca, Mexico 1 Turn Down From 0 Lash .035 .035 .035 .035 26 36 AC Delco R42LTS 10 0 0 (4 Europe) 10 0 5.7L V-8 GEN-1E 5735 (350) 9.4:1 Push Rod Actuated Overhead Valve Hydraulic Roller 101.60x88.39 (4.00x3.48) 2 Bolt External Mixer 1-8-4-3-6-5-7-2 4.5 qts. (4.3L) 5 qts. (4.7L) PF-1218 or Equivalent 6 psi @ 1000 rpm 18 psi @ 2000 rpm 8.1 qts (7.8L) 17.5 qts. (16.6L) LPG, NG CCW Solid State Distributor 5.7L GM Powertrain Industrial Engines 3.0L 1.6L Engine Power Solutions, Inc. GENERAL SPECIFICATIONS Tonawanda, NY Net Lash No Adjustment .035 .035 .035 26 36 AC Delco R42LTS 0 0 10 10 0 7.4L V-8 7441 (454) 8.9:1 Push Rod Actuated Overhead Canted Valve Hydraulic Roller 107.95x101.60 (4.25x4.00) 4 Bolt External Mixer 1-8-4-3-6-5-7-2 8 qts. (7.6L) 9 qts. (8.5L) PF-1218 or Equivalent 6 psi @ 1000 rpm 18 psi @ 2000 rpm 14.5 qts (13.7L) 28 (26.5L) LPG, NG CCW Solid State Distributor 7.4L/7.4L Turbo Tonawanda, NY Net Lash No Adjustment .030/.025T .030/.025T .030/.025T 26 30 AC Delco R42LTS DIS No Adjustment 8.1L V-8 8127 (496) 9.1:1 Push Rod Actuated Overhead Valve Hydraulic Roller 107.95x111 (4.25x4.37) 4 Bolt External Mixer 1-8-7-2-6-5-4-3 8 qts. (7.6L) 9 qts (8.5L) PF-454 or Equivalent 5 psi @ 1000 rpm 15 psi @ 2000 rpm 14.5 qts (13.7L) 28 qts (26.5L) LPG, NG CCW Distributor-less Electronic ECU 8.1L/8.1L Turbo Home Find... Go To.. 233 3.0L Engine Spark Plug Wire Routing 234 Home Find... Go To.. Torque Standard Inch Fasteners Thread Size SAE Grade 2 Carriage Bolts SAE Grade 1 Thread Cutting Thread Rolling SAE Grade 5 Socket and Stainless Steel SAE Grade 8 Headless Socket Set Screws Square Head Set Screws 4 (.112) (5) -- (6.5) (4) -- (6) 5 (.125) (6) -- (8) (9) -- (11) 6 (.138) (7) -- (9) (20) -- (24) (9) -- (11) 8 (.164) (12) -- (16) (40) -- (47) (17) -- (23) 10 (.190) (20) -- (26) (50) -- (60) (31) -- (41) 1/4 (.250) 4-- 5 5-- 6 7-- 10 7-- 10 10-- 13 6-- 8 17-- 19 5/16 (.312) 7-- 9 9-- 12 15-- 20 15-- 20 20-- 26 13-- 15 32-- 38 3/8 (.375) 13-- 17 16-- 21 27-- 35 36-- 47 22-- 26 65-- 75 7/16 (.438) 20-- 26 26-- 34 43-- 56 53-- 76 33-- 39 106-- 124 1/2 (.500) 27-- 35 39-- 51 65-- 85 89-- 116 48-- 56 162-- 188 5/8 (.625) 80-- 104 130-- 170 171-- 265 228-- 383 3/4 (.750) 129-- 168 215-- 280 313-- 407 592-- 688 1 (1.000) 258-- 335 500-- 650 757-- 984 1281-- 1489 I N C H P O N U D S F O O T P O U N D S Torque Foot Pounds (Inch Pounds) Zinc Plated Fasteners and Torque Control (10---90) Home Find... Go To.. 235 Torque Standard Inch Fasteners Mechanical Properties Fastener Identification Type Material SAE Grade 1 Machine Screws Low or Medium Carbon Steel SAE Grade 2 Carriage Bolts Low or Medium Carbon Steel Stainless Steel 18-- 8 Austenitic Stainless Steel Medium Carbon Steel Quenched Tempered SAE Grade 5 Socket Screws Nominal Size Medium Carbon Alloy Quenched Tempered Home Tensile Strength Min (PSI) 55,000 1/4 Thru 1 1/2 33,000 36,000 60,000 1/4 Thru 3/4 55,000 57,000 74,000 Over 3/4 Thru 1 1/2 33,000 36,000 60,000 50,000 90,000 1/4 Thru 1 85,000 92,000 120,000 Over 1 to 1 1/2 74,000 81,000 105,000 136,000 1/4 Thru 1 1/2 Fasteners and Torque Control (10---90) 236 Yield Strength Min (PSI) #2 Thru #10 High Carbon Alloy Steel Quenched Tempered SAE Grade 8 Proof Load (PSI) Find... Go To.. 120,000 160,000 130,000 150,000 Torque Standard METRIC Fasteners Thread Size M3 M4 M5 4.8/5.6 8.8 Stainless Steel 10.9 Set Screws 12.9 N 43-- 56 Ncm 99-- 128 Ncm 139-- 180 Ncm 166-- 215 Ncm 61-- 79 Ncm E W T 99-- 128 Ncm 223-- 290 Ncm 316-- 410 Ncm 381-- 495 Ncm 219-- 285 Ncm O N 193-- 250 Ncm 443-- 575 Ncm 624-- 810 Ncm 747-- 970 Ncm 427-- 554 Ncm M6 3.3-- 4.3 Nm 7.6-- 9.9 Nm 10.8-- 14 Nm 12.7-- 16.5 Nm 7.5-- 9.8 Nm M8 8.1-- 10.5 Nm 18.5-- 24 Nm 26.2-- 34 Nm 31-- 40 Nm M10 16-- 21 Nm 37-- 48 Nm 52-- 67 Nm 63-- 81 Nm M12 28-- 36 Nm 64-- 83 Nm 90-- 117 Nm 108-- 140 Nm M14 45-- 58 Nm 102-- 132 Nm 142-- 185 Nm 169-- 220 Nm M16 68-- 88 Nm 154-- 200 Nm 219-- 285 Nm 262-- 340 Nm M20 132-- 171 Nm 300-- 390 Nm 424-- 550 Nm 508-- 660 Nm M22 177-- 230 Nm 409-- 530 Nm 574-- 745 Nm 686-- 890 Nm M24 227-- 295 Nm 520-- 675 Nm 732-- 950 Nm 879-- 1140 Nm 18.3-- 23.7 Nm C E N T I M E T E R S N E W T O N M E T E R S Zinc Plated Conversion Tables Ncm to Inch Pound x 0.08851 Nm to Foot Pound x 0.7376 Inch Pound to Ncm x 11.2982 Foot Pound to Nm x 1.3558 Fasteners and Torque Control (10---90) Home Find... Go To.. 237 Torque Standard METRIC Fasteners Mechanical Properties Fastener Identification Type 8.8 A 10.9 Material 3.6/4.6 Carriage Bolts Low or Medium Carbon Steel 190 (27,550 PSI) 240 (34,800 PSI) 330 (47,850 PSI) 400 (58,000 PSI) 4.8 Pan Head Machine Screws Low or Medium Carbon Steel 340 (49,300 PSI) 420 (60,900 PSI) Austenitic Stainless Steel 450 (65,300 PSI) 700 (101,000 PSI) Stainless Steel 8.8 Hex Head (Grade 5) Medium Carbon Steel Quenched Tempered 10.9 Hex Head Flat Head (Grade 8) Medium Carbon Steel Quenched Tempered 12.9 Socket Head Alloy Steel < M16 640 800 (92,800 PSI) (116,000 PSI) > M16 660 830 (95,700 PSI) (120,350 PSI) 12.9 Conversion Table Mega Pascals to Pounds per Square Inch x 145.138 Fasteners and Torque Control (1---01) 238 Tensile Strength (Min) MPa Class A2-- 70 A2--- 70 Yield Point .2% Elongati (Min) MPa Nominal Yield Stress Size (Min) MPa Home Find... Go To.. 940 1040 (136,300 PSI) (150,800 PSI) 1100 1220 (159,500 PSI) (176,900 PSI) Torque Standard Nylon Insert Lock Nuts Nut-Hex Light THIN (Cad or Zinc Plated) Size Grade 2 Bolt Grade 5 Bolt 1/4---20 5---8 7---8 1/4---28 4---6 5---6 5/16---18 8---14 13---14 5/16---24 9---14 13---14 3/8---16 12---18 15---18 3/8---24 12---18 16---18 1/2---13 26---40 37---40 1/2---20 27---42 41---42 5/8---11 58---89 73---89 5/8---18 60---92 82---92 Torque in Foot Pounds Fasteners and Torque Control (10---90) Home Find... Go To.. 239 Torque Standard Wheel Bolt and Nuts Stud or Bolt Size and Thread Recommended Torque in Foot Pounds 7/16---20 75---85 1/2---20 75---85 9/16---18 80---90 5/8---18 140---170 Wheel Bearing Adjustment 1. Tighten the spindle nut to 12 ft lbs while turning the wheel assembly forward by hand to fully seat the bearings. 2. Back off the nut to the “just loose” position. 3. Hand tighten the spindle nut. Loosen the spindle nut until either hole in the spindle lines up with a slot in the nut. (Not more than 1/2 flat.) 4. Install the cotter pin. Bend the ends of the cotter pin against the nut, cut off extra length to ensure ends will not interfere with the dust cap. Fasteners and Torque Control (10---90) 240 Home Find... Go To.. Tightening Nuts on Tapered Shafts Example of recommended torque. +.0010 +0,025 .3730 -- .00000 /9,474 -- 0 1”-- 20 UNEF-- 2B SLOTTED KEY WIDTH HEX LOCKNUT PER SAE J-- 501 (EXCEPT 1.50/38,1 ACROSS FLATS). RECOMMENDED TOQUE TO 175 FT LB PLUS TORQUE REQUIRED TO ALIGN SLOTTED NUT TO SHAFT HOLE 2.27/57,7 CLEARANCE DIA. .156 3,96 P SHAFT DIA. DIA. THRU 1.500 + .002 TAPER PER FOOT/125 + 0,17 MM TAPER PER METER .750 + .010 19,05 + 0,25 1.890 48,01 3.00 76,2 Check with the manufacturer to see what the recommended maximum torque is. Tighten the slotted nut to a lower torque, and then tighten the nut to align the cotter pin hole with the slot on the nut. Do not exceed the recommended torque. Do not back off the nut to align the holes. Motor Tapered Shaft Nut Info. Torque Specification Recommendations A&H Series 1.00 dia. .75--16 UNF 1.107 Hex 150 ft lb dry 125 ft lb lubricated Plus torque to align for pin 2000 Series 1.25 dia. 1--20 UNEF 1.44 Hex 225 ft lb dry 225 ft lb lubricated PLUS torque to align for pin 4000 Series 1.625 dia. 1.25--18 UNEF 2.187 Hex 475 ft lb dry 375 ft lb lubricated PLUS torque to align for pin 6000 Series 1.75 dia. 1.25--18 UNEF 2.187 Hex 475 ft lb dry 375 ft lb lubricated PLUS torque to align for pin Fasteners and Torque Control (10---90) Home Find... Go To.. 241 Torque Standard Shoulder Bolts Nominal Diameter Thread Size Recommended Seating Torque .250 10 -- 24 45 In Lbs .312 1/4-- 20 9 Ft Lbs .375 5/16-- 18 19 Ft lbs .500 3/8-- 16 32 Ft Lbs .625 1/2-- 13 82 Ft Lbs .750 5/8 -- 11 164 Ft Lbs Metric Nominal Diameter Thread Size Recommended Seating Torque 6 M5x0.8 7 Nm 8 M6x1.0 12 Nm 10 M8x1.25 29 Nm 12 M10x1.5 57 Nm 16 M12x1.75 100 Nm Fasteners and Torque Control (10---90) 242 Home Find... Go To.. Taper Lockr Bushings IMPORTANT: Follow all these instructions carefully. This is necessary to insure satisfactory performance. C C 1008 to 3030 To Install 1. Clean shaft, bore and outside of bushing, and hub bore of all oil, lacquer, and dirt. 2. Insert bushing in hub. Match the hole pattern, not threaded holes (each hole will be threaded on one side only). 3. Oil setscrews and thread into those half threaded holes indicated by C on above diagram. 4. Alternately torque setscrews to recommended torque setting in chart below. 5. Using a block, sleeve, or drift, hammer large end of bushing (do not hammer bushing directly). 6. Repeat steps 4 and 5 until torque wrench reading after hammering is the same as before hammering. 7. Fill all unoccupied holes with grease. To Remove 1. Remove all setscrews. 2. Insert setscrews in holes indicated by D on the diagram. Loosen bushing by alternately tightening setscrews. 3. To reinstall, complete all seven (7) steps installation steps. Recommended Wrench Torque Wrench Torque Bushing No. Screws (Pound-Inch) 1008, 1108 1210, 1215, 1310 1610, 1615 2012 2517, 2525 3020, 3030 1/4” Setscrews 3/8” Setscrews 3/8” Setscrews 7/16” Setscrews 1/2” Setscrews 5/8” Setscrews 55 175 175 280 430 800 Hammer Size 6 lb 6 lb 6 lb 6 lb 6 lb 6 lb If two bushings are used on same component and shaft, fully tighten one bushing before working on the other. Fasteners and Torque Control (10---90) Home Find... Go To.. 243 Sequence Tightening On some assemblies, it is advisable to use a crisscross pattern. Always avoid starting in one spot and tightening one after another in a row. Remember that the object is to tighten the parts in such a manner that even stress is set up throughout, at the same time allowing the parts to be drawn together so that their mating surfaces will contact. 5 1 3 3 5 1 4 2 6 5 2 6 3 1 2 4 4 6 Torque in Steps 1. Run each fastener, in proper sequence, up to the recommended torque. 2. Repeat the process of running up each fastener, in proper sequence, up to the recommended torque. 3. If necessary, repeat step two until all the fasteners are tightened to the recommended torque. Fasteners and Torque Control (10---90) 244 Home Find... Go To..
Source Exif Data:
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