7400 Service Manual Tennant Rider Floor Scrubber
2018-06-13
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7400 Service Manual MM428 Rev. 04 (3-- 02) This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT Model 7400. This manual is organized into seven major groups: General Information, Chassis, Scrubbing, Electrical, Hydraulics, Engine--G/LPG and Engine--D. General Information: Machine transport, machine jacking, machine storage, machine specifications, and machine maintenance chart. Chassis: Tire/wheel replacement, brake adjustment and replacement, chassis lubrication, steering adjustment and replacement. Scrubbing: Scrubber head repair/replacement, brush repair/replacement. squeegee repair/replacement, and scrubber troubling shooting. Electrical: Battery maintenance and replacement, instrument panel replacement, and electrical troubleshooting. Hydraulics: Valve replacement/repair, motor replacement/repair, cylinder replacement/repair, pump replacement/repair, filter replacement, and hydraulics troubleshooting. Engine -- G/LPG: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine repairs. Engine -- D: Air filter replacement, oil changing, cooling system maintenance/repair, fuel system maintenance/repair, governor adjustment/repair, engine repair, engine troubleshooting, and engine repairs. Manual Number -- MM428 Revision: 04 Published: 3--02 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 1996, 1998, 2001, 2002 TENNANT, Printed in U.S.A. GENERAL INFORMATION CONTENTS Page SAFETY PRECAUTIONS . . . . . . . . . . . . . . 1--3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 1--6 GENERAL MACHINE DIMENSIONS/CAPACITIES . . . . . . 1--6 GENERAL MACHINE PERFORMANCE1--6 POWER TYPE . . . . . . . . . . . . . . . . . . . . . 1--7 STEERING . . . . . . . . . . . . . . . . . . . . . . . . 1--7 HYDRAULIC SYSTEM . . . . . . . . . . . . . . 1--8 BRAKING SYSTEM . . . . . . . . . . . . . . . . 1--8 TIRES . . . . . . . . . . . . . . . . . . . . . . . 1--8 MACHINE DIMENSIONS . . . . . . . . . . . . . . . 1--9 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 1--10 MAINTENANCE CHART / G/LP . . . . . 1--10 MAINTENANCE CHART / DIESEL . . 1--12 PUSHING, TOWING, AND TRANSPORTING THE MACHINE . . . 1--14 PUSHING OR TOWING THE MACHINE . . . . . . . . . . . . . . . . . 1--14 TRANSPORTING THE MACHINE . . . 1--15 MACHINE JACKING . . . . . . . . . . . . . . . 1--17 STORING MACHINE . . . . . . . . . . . . . . 1--18 HARDWARE INFORMATION . . . . . . . . . . 1--19 STANDARD BOLT TORQUE CHART 1--19 METRIC BOLT TORQUE CHART . . . 1--19 BOLT IDENTIFICATION . . . . . . . . . . . . 1--19 THREAD SEALANT AND LOCKING COMPOUNDS . . . . . . . . . . . . . . . . . 1--19 HYDRAULIC FITTING INFORMATION1--20 HYDRAULIC TAPERED PIPE FITTING (NPT) TORQUE CHART . . . . . . . . . . . . . . 1--20 HYDRAULIC TAPERED SEAT FITTING (JIC) TORQUE CHART . . . . . . . . . . . . . . 1--20 HYDRAULIC O--RING FITTING TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 1--20 7400 MM428 (6--01) 1-1 GENERAL INFORMATION 1-2 7400 MM428 (6--01) GENERAL INFORMATION SAFETY PRECAUTIONS The following precautions are used throughout this manual as indicated in their description: WARNING: To warn of hazards or unsafe practices which could result in severe personal injury or death. FOR SAFETY: To identify actions which must be followed for safe operation of equipment. The machine is suited to sweep disposable debris. Do not use the machine other than described in this Operator Manual. The machine is not designed for use on public roads. The following information signals potentially dangerous conditions to the operator or equipment: FOR SAFETY: 1. Do not operate machine: -- Unless trained and authorized. -- Unless operator manual is read and understood. -- If it is not in proper operating condition. -- In flammable or explosive areas unless designed for use in those areas. -- In areas with possible falling objects unless equipped with overhead guard. 2. Before starting machine: -- Check for fuel, oil, and liquid leaks. -- Keep sparks and open flame away from refueling area. -- Make sure all safety devices are in place and operate properly. -- Check brakes and steering for proper operation. 3. When starting machine: -- Keep foot on brake and directional pedal in neutral. 4. When using machine: -- Use brakes to stop machine. -- Go slow on inclines and slippery surfaces. -- Use care when reversing machine. -- Do not carry passengers on machine. -- Always follow safety and traffic rules. -- Report machine damage or faulty operation immediately. 7400 MM428 (6--01) 5. Before leaving or servicing machine: -- Stop on level surface. -- Set parking brake. -- Turn off machine and remove key. 6. When servicing machine: -- Avoid moving parts. Do not wear loose jackets, shirts, or sleeves. -- Block machine tires before jacking machine up. -- Jack machine up at designated locations only. Block machine up with jack stands. -- Use hoist or jack of adequate capacity to lift machine. -- Wear eye and ear protection when using pressurized air or water. -- Disconnect battery connections before working on machine. -- Avoid contact with battery acid. -- Avoid contact with hot engine coolant. -- Allow engine to cool. -- Keep flames and sparks away from fuel system service area. Keep area well ventilated. -- Use cardboard to locate leaking hydraulic fluid under pressure. -- Use Tennant supplied or approved replacement parts. WARNING: Engine emits toxic gases. Severe respiratory damage or asphyxiation can result. Provide adequate ventilation. Consult with your regulatory authorities for exposure limits. Keep engine properly tuned. WARNING: Flammable materials can cause an explosion or fire. Do not use flammable materials in tank(s). WARNING: Flammable materials or reactive metals can cause explosion or fire. Do not pick up. WARNING: Moving belt and fan. Keep away. WARNING: Strong Vacuum. Keep Away From Fan Inlet When Fan Is Running. 1-3 GENERAL INFORMATION The following safety labels are mounted on the machine in the locations indicated. If these or any labels become damaged or illegible, install a new label in its place. EMISSIONS LABEL -- LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT. FOR SAFETY LABEL -- LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT. 10783 FLAMMABLE SPILLS LABEL -- LOCATED ON THE SIDE OF THE OPERATOR COMPARTMENT. 1-4 7400 MM428 (6--01) GENERAL INFORMATION FAN AND BELT LABEL -- LOCATED ON THE ENGINE COMPARTMENT LINTEL. STRONG VACUUM LABEL -- LOCATED ON THE VACUUM FAN HOUSING. 10783 FLAMMABLE MATERIALS LABEL -- LOCATED NEXT TO THE SOLUTION TANK COVERS AND ON THE DETERGENT TANK. 7400 MM428 (6--01) 1-5 GENERAL INFORMATION SPECIFICATIONS GENERAL MACHINE DIMENSIONS/CAPACITIES Item Dimension/capacity Length 2460 mm (97 in) Width 1525 mm (60 in) Width with optional side brush 1590 mm (62.5 in) Height 1475 mm (58 in) Height with overhead guard 2045 mm (80.5 in) Main scrub brush diameter 280 mm (11 in) Main scrub brush length 1140 mm (45 in) Side scrub brush diameter (option) 410 mm (16 in) Squeegee width 1525 mm (60 in) Scrubbing path width 1140 mm (45 in) Scrubbing path width with optional side brush 1450 mm (57 in) Debris tray volume capacity 42 L (1.5 ft3) Solution tank 265 L (70 gal) Recovery tank 272 L (72 gal) Detergent tank (option) 25 L (6.7 gal) Total capacity with ESt (option) 397 L (105 gal) GVWR 2087 kg (4600 lb) GENERAL MACHINE PERFORMANCE Item Measure Maximum forward speed 12.9 kmh (8 mph) Maximum reverse speed 6.4 kmh (4 mph) Minimum aisle turn width 3190 mm (125.5 in) Minimum turning radius, right 2660 mm (104.75 in) Minimum turning radius, left 2030 mm (79.75 in) Maximum rated incline for scrubbing 6_ Maximum rated incline for transport of machine 8_ 1-6 7400 MM428 (6--01) GENERAL INFORMATION POWER TYPE Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke Kubota V1505--B (E) Piston Diesel 4 Natural 4 78.4 mm (3.08 in) 78 mm (3.07 in) Displacement Net power, governed Net power, maximum 1500 cc (91.4 cu in) 24.6 kw (34 hp) @ 2400 rpm 27.2 kw (37.5 hp) @ 3000 rpm Fuel Cooling system Electrical system Diesel Fuel tank: 42 L (11.2 gal) Water/ethylene glycol antifreeze 12 V nominal Total: 7.5 L (2 gal) 37 A alternator Radiator: 3.8 L (1 gal) Idle speed, no load (Fast) governed speed, under load Engine lubricating oil without filter 950 + 50 rpm 2400 + 50 rpm 6 L (6.35 qt) SAE--CC/CD rated engine oil Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke Ford VSG 1.3 Piston Distributorlesstype spark 4 Natural 4 75 mm (2.97 in) 7400 MM428 (6--01) 74 mm (2.91 in) Displacement Net power, governed Net power, maximum 1300 cc (79 cu in) 23.2 kw (32 hp) @ 2400 rpm 39.5 kw (53 hp) @ 4000 rpm Fuel Cooling system Electrical system Gasoline, 87 octane minimum, unleaded. Fuel tank: 42 L (11.2 gal) Water/ethylene glycol antifreeze 12 V nominal LPG, F l tank: Fuel t k 15 kg k (33 lb) Total: 7.5 L (2 gal) 50 A alternator Idle speed, no load (Fast) governed speed, under load Firing order 1350 + 250 rpm 2400 + 50 rpm 1--2--4--3, counterclockwise rotation Spark plug gap Valve clearance, cold Engine lubricating oil with filter 1 mm (0.04 in) 0.20 mm (0.008 in) intake 0.50 mm (0.002 in) exhaust 3.3 L (3.5 qt) 10W30 SAE--SG/SH Radiator: 3.8 L (1 gal) 1-7 GENERAL INFORMATION STEERING Type Power source Emergency steering Front wheel, hydraulic cylinder and rotary valve controlled Hydraulic accessory pump Manual HYDRAULIC SYSTEM System Capacity Fluid Type Hydraulic reservoir 38 L (10 gal) Hydraulic total 74 L (19.5 gal) TENNANT part no. 65869 -- above 7_ C (45_ F) TENNANT part no. 65870 -- below 7_ C (45_ F) BRAKING SYSTEM Type Operation Service brakes Mechanical drum brakes (2), one per rear wheel, cable actuated Parking brake Utilize service brakes, cable actuated TIRES Location Type Size Pressure Front (1) Solid 460 x 130 mm (5 x 18 in) -- Rear (2) Solid 460 x 130 mm (5 x 18 in) -- 1-8 7400 MM428 (6--01) GENERAL INFORMATION 2460 mm (97 in) 1686 mm (66.4 in) 1327 mm (52.25 in) 1610 mm (63.4 in) 1525 mm (60 in) 1483 mm (58.4 in) 2045 mm (80.5 in) 1475 mm (58 in) 1260 mm (49.6 in) MACHINE DIMENSIONS 7400 MM428 (6--01) 10919 1-9 GENERAL INFORMATION MAINTENANCE 6 13 13 5 7 13 4 5 13 8 9 3 2 10 11 12 1 MAINTENANCE CHART / G/LP Interval Dailyy Key 4 4 8 50 Hours 11 10 7 7 5 10 100 Hours 6 4 13 4 3 -8 8 1-10 Description Procedure Check indicator Empty dust cap Engine crankcase Check oil level Check for damage and wear Rear Squeegee q g Check deflection Side Squeegees Check for damage and wear Scrub brushes Check for damage and wear Recovery tank Clean Recovery tank, ESt mode Clean ESt filter Solution tank, ESt mode Clean Scrub brushes Rotate end-for-end or front-torear Clean core exterior Radiator Check coolant level Engine crankcase Change oil and filter element Cover seals Check for damage and wear Check fan belt tension Engine g Check and adjust idle speed Check and adjust idle mixture Hydraulic fluid reservoir Check fluid level Tires Check for damage Rear squeegee Check leveling Rear squeegee casters Lubricate Engine g air filter No. of Lubricant/ Service Points Fluid -1 -1 EO 1 -1 -1 -2 -1 -1 -1 -1 -1 -WG EO ----HYDO --SPL 1 1 1 4 1 1 1 1 3 1 2 7400 MM428 (6--01) GENERAL INFORMATION Interval Key Description 100 Hours 10 Scrub brush idlers 10 Scrub head skirts -Side brush skirt 6 Radiator hoses and clamps 200 Hours 4 Engine fan belt 2 Parking brake 2 Brake pedal 1 Front wheel support bearings 9 Rear wheel bearings 400 Hours 4 Engine g 800 Hours 3 Hydraulic y reservoir 4 -6 1 1 12 Hydraulic fluid filter Hydraulic hoses Cooling system Propelling motor Front wheel Battery y Procedure Lubricate Check for damage and wear Check for damage and wear Check for tightness and wear Check tension Check adjustment Check and adjust travel Lubricate Check, lubricate, and adjust Clean or replace p and adjust j spark plugs No. of Lubricant/ Service Points Fluid SPL 2 -2 -1 -2 -1 -1 -1 SPL 2 SPL -- 2 4 HCheck and adjust j valve clearance -- 8 Check and adjust idle speed Check and adjust j carburetor idle mixture --- 1 1 Replace p PCV valve. Clean PCV hoses, tubes, and fittings -- 1 Fuel filter, gasoline Replace filler cap Replace suction strainer Change hydraulic fluid Change filter element Check for wear and damage Flush HTorque shaft nut HTorque wheel nuts HClean and tighten g batteryy cable connections ---HYDO --WG ---- 1 1 1 1 1 All 1 1 1 1 NOTE: Also check procedures indicted (H) after the first 50-hours of operation. NOTE: More frequent intervals may be required in extremely dusty conditions. LUBRICANT/FLUID EO . . . . Engine oil, SAE--SG/SH rated HYDO . Tennant or approved hydraulic fluid WG . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F) SPL . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) DW . . . . Distilled water 7400 MM428 (6--01) 1-11 GENERAL INFORMATION 6 13 5 13 7 13 4 5 13 8 3 9 2 10 11 12 1 09076 MAINTENANCE CHART / DIESEL Interval Dailyy Key Description 4 Engine g air filter 4 8 50 Hours 11 10 7 7 5 10 100 Hours 4 6 4 4 3 -8 8 1-12 Procedure Check indicator Empty dust cap Engine crankcase Check oil level Check for damage and wear Rear Squeegee q g Check deflection Side Squeegees Check for damage and wear Scrub brushes Check for damage and wear Recovery tank Clean Recovery tank, ESt mode Clean ESt filter Solution tank, ESt mode Clean Scrub brushes Rotate end-for-end or front-torear Fuel pipes and clamps Check for tightness and wear Clean core exterior Radiator Check coolant level Engine crankcase Change oil and filter Engine fan belt Check tension Hydraulic fluid reservoir Check fluid level Tires Check for damage Rear squeegee Check leveling Rear squeegee casters Lubricate No. of Lubricant/ Service Points Fluid -1 -1 EO 1 -1 -1 -2 -1 -1 -1 -1 -1 --WG EO -HYDO --SPL 1 1 1 1 1 1 3 1 2 7400 MM428 (6--01) GENERAL INFORMATION Interval Key Description 100 Hours 13 Cover seals 10 Scrub brush idlers 10 Scrub head skirts -Side brush skirt 6 Radiator hoses and clamps 200 Hours 2 Parking brake 2 Brake pedal 1 Front wheel support bearings 400 Hours 800 Hours 9 4 6 3 Rear wheel bearings Fuel filter Cooling system Hydraulic y reservoir 4 -1 1 12 Hydraulic fluid filter Hydraulic hoses Propelling motor Front wheel Battery y Procedure Check for damage and wear Lubricate Check for damage and wear Check for damage and wear Check for tightness and wear Check adjustment Check and adjust travel Lubricate Check, lubricate, and adjust Replace cartridge Flush Replace filler cap Replace suction strainer Change hydraulic fluid Change filter element Check for wear and damage HTorque shaft nut HTorque wheel nuts HClean and tighten g batteryy cable connections No. of Lubricant/ Service Points Fluid -4 SPL 2 -2 -1 -2 -1 -1 SPL 2 SPL -WG --HYDO ------ 2 1 1 1 1 1 1 All 1 1 1 NOTE: Also check procedures indicted (H) after the first 50-hours of operation. NOTE: More frequent intervals may be required in extremely dusty conditions. LUBRICANT/FLUID EO . . . . Engine oil, SAE--CC/CD rated HYDO . Tennant Company or approved hydraulic fluid WG . . . Water and permanent-type ethylene glycol anti-freeze, --34_ C (--30_ F) SPL . . . Special lubricant, Lubriplate EMB grease (TENNANT part no. 01433--1) DW . . . . Distilled water 7400 MM428 (6--01) 1-13 GENERAL INFORMATION PUSHING, TOWING, AND TRANSPORTING THE MACHINE PUSHING OR TOWING THE MACHINE If the machine becomes disabled, it can be pushed from the front or rear, but towed only from the rear. The propelling pump has a bypass valve to prevent damage to the hydraulic system when the machine is being pushed or towed. This valve allows a disabled machine to be moved for a very short distance and at a speed to not exceed 1.6 kp/h (1 mph). The machine is NOT intended to be pushed or towed a long distance or at a high speed. ATTENTION! Do not push or tow machine for a long distance and without using the bypass valve, or the machine hydraulic system may be damaged. Turn the bypass valve 90_ from the normal position before pushing or towing the machine. The illustration shows the bypass valve in the pushing or towing position. 1-14 7400 MM428 (6--01) GENERAL INFORMATION TRANSPORTING THE MACHINE 1. Position the rear of the machine at the loading edge of the truck or trailer. 2. If the loading surface is not horizontal or is higher than 380 mm (15 in) from the ground, use a winch to load machine. If the loading surface is horizontal AND is 380 mm (15 in) or less from the ground, the machine may be driven onto the truck or trailer. 3. To winch the machine onto the truck or trailer, attach the winching chains in the holes at the bottom of the rear bumper. If the machine has the optional rear tie down brackets, attach the winching chains to them. 4. Turn the bypass valve 90_ from the normal position before winching the machine onto the truck or trailer. See PUSHING OR TOWING THE MACHINE section of this manual. Make sure the machine is centered. FOR SAFETY: When loading machine onto truck or trailer, use winch. Do not drive the machine onto the truck or trailer unless the loading surface is horizontal AND is 380 mm (15 in) or less from the ground. 7400 MM428 (6--01) 1-15 GENERAL INFORMATION 5. Position the machine onto the truck or trailer as far as possible. If the machine starts to veer off the centerline of the truck or trailer, stop and turn the steering wheel to center the machine. 6. Set the parking brake and block the machine tires. Tie down the machine to the truck or trailer before transporting. The front tie down locations are in the holes at the bottom of the front bumper. If the machine has the optional tie down brackets, use them to tie down the machine. The rear tie down locations are in the holes at the bottom of the rear bumper. If the machine has the optional rear tie down brackets, use them to tie down the machine. 7. If the loading surface is not horizontal or is higher than 380 mm (15 in) from the ground, use a winch to unload machine. If the loading surface is horizontal AND is 380 mm (15 in) or less from the ground, the machine may be driven off the truck or trailer. FOR SAFETY: When unloading machine off truck or trailer, use winch. Do not drive the machine off the truck or trailer unless the loading surface is horizontal AND 380 mm (15 in) or less from the ground. 1-16 7400 MM428 (6--01) GENERAL INFORMATION MACHINE JACKING Empty the recovery and the solution tanks before jacking the machine.You can jack up the machine for service at the designated locations. Use a hoist or jack that will support the weight of the machine. Always stop the machine on a flat, level surface and block the tires before jacking the machine up. FOR SAFETY: Before leaving or servicing machine; stop on level surface, set parking brake, turn off machine and remove key. The front jacking location is the left front corner of the machine frame. The rear jacking locations are the two rear corners of the machine frame. FOR SAFETY: When servicing machine, block machine tires before jacking machine up. FOR SAFETY: When servicing machine, jack machine up at designated locations only. Block machine up with jack stands. 7400 MM428 (6--01) 1-17 GENERAL INFORMATION STORING MACHINE When storing the machine for extended periods of time, the following procedures must be followed to lessen the chance of rust sludge, or other undesirable deposits from forming. 1. Drain and clean the solution and recovery tanks. 2. ESt machines: Run clean water through the solution system and the ESt solution pump. 3. Raise the rear squeegee and the scrub head. 4. Park the machine in a cool, dry area. 5. Remove or charge the battery every three months. 1-18 7400 MM428 (6--01) GENERAL INFORMATION HARDWARE INFORMATION The following charts state standard plated hardware tightening ranges for normal assembly applications. Decrease the specified torque by 20% when using a thread lubricant. Do not substitute lower grade hardware for higher grade hardware. If higher grade hardware than specified is substituted, tighten only to the specified hardware torque value to avoid damaging the threads of the part being threaded into, as when threading into speed nuts or weldments. STANDARD BOLT TORQUE CHART NOTE: Decrease torque by 20% when using a thread lubricant. Exceptions to the above chart: Check the machine for exceptions! BOLT IDENTIFICATION Identification Grade Marking Specification and Grade SAE--Grade 5 SAE--Grade 8 Thread Size SAE Grade 5 Torque ft lb (Nm) SAE Grade 8 Torque ft lb (Nm) 0.25 in 7--10 (9--14) 10--13 (14--38) 0.31 in 15--20 (20--27) 20--26 (27--35) 0.38 in 27--35 (37--47) 36--47 (49--64) 0.44 in 43--56 (58--76) 53--76 (72--103) 0.50 in 65--85 (88--115) 89--116 (121--157) THREAD SEALANT AND LOCKING COMPOUNDS 0.62 in 130--170 (176--231) 117--265 (159--359) Thread sealants and locking compounds may be used on this machine. They include the following: 0.75 in 215--280 (291--380) 313--407 (424--552) 1.00 in 500--650 (678--881) 757--984 (1026--1334) NOTE: Decrease torque by 20% when using a thread lubricant. METRIC BOLT TORQUE CHART Thread Size Class 8.8 Torque ft lb _Nm) Class 10.9 Torque ft lb (Nm) M4 2 (3) 3 (4) M5 4 (5) 6 (8) M6 7 (9) 10 (14) M8 18 (24) 25 (34) M10 32 (43) 47 (64) M12 58 (79) 83 (112) M14 94 (127) 133 (180) M16 144 (195) 196 (265) M20 260 (352) 336 (455) M24 470 (637) 664 (900) 7400 MM428 (6--01) ISO--Grade 8.8 ISO--Grade 10.9 01395 Locktite 515 sealant -- gasket forming material. TENNANT Part No. 75567,15 oz (440 ml) cartridge. Locktite 242 blue -- medium strength thread locking compound. TENNANT Part No. 32676, 0.5 ml tube. Locktite 271 red -- high strength thread locking compound. TENNANT Part No. 19857, 0.5 ml tube. 1-19 GENERAL INFORMATION HYDRAULIC FITTING INFORMATION HYDRAULIC TAPERED PIPE FITTING (NPT) TORQUE CHART NOTE: Ratings listed are when using teflon thread seal. HYDRAULIC O--RING FITTING TORQUE CHART Tube O.D. (in) Thread Size Minimum Torque Maximum Torque Size Minimum Torque Maximum Torque 0.25 0.44--20 6 ft lb (8 Nm) 9 ft lb (12 Nm) 1/4 NPT 10 ft lb (14 Nm) 30 ft lb (41 Nm) 0.38 0.56--18 1/2 NPT 25 ft lb (34 Nm) 50 ft lb (68 Nm) 13 ft lb (18 Nm) 20 ft lb (27 Nm) 3/4 NPT 50 ft lb (68 Nm) 100 ft lb (136 Nm) *10 ft lb (14 Nm) 12 ft lb (16 Nm) 20 ft lb (27 Nm) 30 ft lb (41 Nm) *21 ft lb (28 Nm) 24 ft lb (33 Nm) 0.50 0.75--16 HYDRAULIC TAPERED SEAT FITTING (JIC) TORQUE CHART Tibe O.D. (in) Thread Size Maximum Torque 0.62 0.88--14 25 ft lb (34 Nm) 40 ft lb (54 Nm) 0.25 0.44--20 9 ft lb (12 Nm) 0.75 1.12--12 0.38 0.56--18 20 ft lb (27 Nm) 45 ft lb (61 Nm) 70 ft lb (95 Nm) 0.50 0.75--16 30 ft lb (41 Nm) 1.0 1.31--12 0.62 0.88--14 40 ft lb (54 Nm) 60 ft lb (81 Nm) 90 ft lb (122 Nm) 0.75 1.12--12 70 ft lb (95 Nm) 1.0 1.31--12 90 ft lb (122 Nm) 1-20 NOTE: Do not use sealant on o--ring threads. *Aluminum bodied components 7400 MM428 (6--01) CHASSIS CONTENTS Page CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 TO REMOVE SEAT ASSEMBLY . . . . . 2-3 TO REPLACE SEAT ASSEMBLY . . . . . 2-3 OPERATOR SEAT . . . . . . . . . . . . . . . . . 2-4 STATIC DRAG CHAIN . . . . . . . . . . . . . . . . . 2-4 BRAKES AND TIRES . . . . . . . . . . . . . . . . . . 2-5 SERVICE BRAKES . . . . . . . . . . . . . . . . . 2-5 TO REPLACE BRAKE SHOES . . . . . . . 2-5 REAR TIRES AND WHEELS . . . . . . . . 2-7 TO REPACK REAR WHEEL BEARINGS . . . . . . . . . . . . . . . . . . . . . 2-7 FRONT TIRE AND WHEEL, AND WHEEL SUPPORT . . . . . . . . . . . . . . . . . 2-9 TO REPLACE FRONT DRIVE MOTOR 2-9 TO REPLACE FRONT WHEEL HOUSING PIVOT BEARINGS . . . 2-11 7400 MM428 (12--98) 2-1 CHASSIS 2-2 7400 MM428 (12--98) CHASSIS INTRODUCTION This section includes information on the main chassis related components for example the seat, steering, brakes, and tires. 7400 MM428 (12--98) 2-3 CHASSIS SEAT The seat assembly is adjustable forward and backward on the 7400. TO REMOVE SEAT ASSEMBLY FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Tilt the seat assembly forward and engage the prop rod. 2. Remove the four hex screws and nuts holding the seat assembly hinge to the seat support. 3. Slide the prop rod to the opening in the slot and remove. 4. Remove the seat assembly from the machine. TO REPLACE SEAT ASSEMBLY FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Position the seat assembly on the seat support. 2. Reinstall the four hex screws and nuts. Tighten to 18 -- 24Nm (15 -- 20 ft lb). 3. Slide the seat prop rod through large hole in slot. 4. Lower the seat. 2-4 7400 MM428 (12--98) CHASSIS OPERATOR SEAT The operator seat is a fixed back style with a forward-backward adjustment. Adjust: Pull the lever out, slide the seat backward or forward to the desired position and release the lever. Lift: Pull up on the seat mounting plate until the seat mount locks up. Lower: Pull on the release lever and lower the seat mounting plate. STATIC DRAG CHAIN A static drag chain prevents the buildup of static electricity in the machine. The chain is attached to the machine with a hex screw by the scrub head torque tube mount bearing. Make sure the chain is touching the floor at all times. 7400 MM428 (12--98) 2-5 CHASSIS BRAKES AND TIRES SERVICE BRAKES The mechanical service brakes are located on the rear wheels. The brakes are operated by the foot brake pedal. Check the brake adjustment every 200 hours of operation. TO REPLACE BRAKE SHOES FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Drain the solution and recovery tanks. 2. Make sure the parking brake is not engaged. 3. Remove floor plate from the operators compartment. 4. Loosen the jam nuts on the brake cable turn buckle. Rotate the turn buckle to loosen the tension on the brake cable. 5. Jack up one rear corner of the machine. Place jack stands under machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 6. Remove the hub cap from the center of the tire and wheel assembly. 7. Remove the cotter pin, slotted nut, flat washer, and bearing cone. 8. Remove the tire and wheel assembly from the machine. 9. Remove the two springs holding the brake shoes together. Remove the old brake shoes. 10. Position the new brake shoes on the brake mounting plate. 11. Reattach the two brake springs to the new brake shoes. 2-6 7400 MM428 (12--98) CHASSIS 12. Pack the wheel bearings with Lubriplate EMB grease. 13. Slide the tire and wheel assembly on the axle. 14. Slide the outer bearing, flat washer and nut on the shaft. 15. Tighten nut with hand wrench until wheel binds, then back nut off to nearest hole. 16. Insert a new cotter pin through nut and hole. 17. Spin the tire and wheel assembly. The tire should spin freely. 18. Reinstall the hub cap in the center of the wheel. 19. Lower the machine. NOTE: Always replace brake shoes in sets. 20. Repeat the procedure on the other wheel. 21. Rotate the brake cable turn buckle until the brake cable is tight or until the brake pedal travels 25--50 mm (1--2 in) before engaging brakes. 22. Tighten the brake cable turn buckle jam nuts. 23. Reinstall the floor plate in the operators compartment. 24. Operate the machine and check the brakes for proper operation. 7400 MM428 (12--98) 2-7 CHASSIS REAR TIRES AND WHEELS The standard machine rear tires are semi--pneumatic. Inspect the rear wheel bearings for seal damage, and repack and adjust every 1600 hours of operation. Use Lubriplate EMB grease (TENNANT part no. 01433--1). TO REPACK REAR WHEEL BEARINGS FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Drain the solution and recovery tanks. 2. Make sure the parking brake is not engaged. 3. Remove floor plate from the operators compartment. 4. Loosen the jam nuts on the brake cable turn buckle. Rotate the turn buckle to loosen the tension on the brake cable. 5. Jack up one rear corner of the machine. Place jack stands under machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 6. Remove the hub cap from the center of the tire and wheel assembly. 7. Remove the cotter pin, slotted nut, flat washer, and bearing cone. 8. Remove the tire and wheel assembly from the machine. 9. Pack the wheel bearings with Lubriplate EMB grease. 10. Slide the tire and wheel assembly on the axle. 11. Slide the outer bearing, flat washer and nut on the shaft. 2-8 7400 MM428 (12--98) CHASSIS 12. Tighten nut with hand wrench until wheel binds, then back nut off to nearest hole. 13. Insert a new cotter pin through nut and hole. 14. Spin the tire and wheel assembly. The tire should spin freely. 15. Reinstall the hub cap in the center of the wheel. 16. Lower the machine. 17. Repeat the procedure on the other wheel. 18. Rotate the brake cable turn buckle until the brake cable is tight or until the brake pedal travels 25--50 mm (1--2 in) before engaging brakes. 19. Tighten the brake cable turn buckle jam nuts. 20. Reinstall the floor plate in the operators compartment. 21. Operate the machine and check the rear wheels for proper operation. 7400 MM428 (12--98) 2-9 CHASSIS FRONT TIRE AND WHEEL SUPPORT The front wheel support pivots the front wheel. The support has one grease fitting for the bearings. The front wheel support bearings must be lubricated every 200 hours of operation. Use Lubriplate EMB grease (TENNANT part no. 01433--1). Torque the front wheel nuts to 142 -- 156 Nm (105 -- 115 ft lb) after the first 50-hours of operation, and every 800 hours thereafter. Torque the front wheel hub nut to (375 ft lb) TO REPLACE FRONT DRIVE MOTOR FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Engage parking brake, block rear tires. 2. Jack up front of machine. Use jack stands to support machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 3. Remove the front tire and wheel assembly. 4. Remove the cotter pin and slotted nut from the front wheel drive motor shaft. 5. Use a puller to remove the drive hub from the tapered shaft of the drive motor. 6. Remove and plug the hydraulic hoses leading to the front wheel drive motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 7. Remove the four drive motor mounting bolts. 8. Slide the motor out of front wheel housing. 2-10 7400 MM428 (12--98) CHASSIS 9. Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation. 10. Slide the new motor in the front wheel housing. Note the orientation of the motor. 11. Reinstall the four socket--head screws. Torque to 90 -- 117 Nm (70 -- 85 ft lb). 12. Reconnect the hydraulic hoses to the drive motor. NOTE: Make sure the square key is in place on the shaft of the new motor. 13. Mount the drive hub to tapered motor shaft. Tighten slotted nut to 500 Nm (375 ft lb). Install the cotter pin. 14. Install the front tire. Torque the front wheel nuts to 142 -- 156 Nm (105 -- 115 ft lb). 15. Remove jack stands and lower machine. 16. Operate the machine and check the front drive motor for any leaks. 7400 MM428 (12--98) 2-11 CHASSIS TO REPLACE FRONT WHEEL HOUSING PIVOT BEARINGS 1. Engage parking brake, block rear tires. 2. Disconnect the battery cables from the battery. 3. Jack up front of machine. Use jack stands to support machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 4. Remove the front tire and wheel assembly. 5. Remove and plug the hydraulic hoses leading to the front wheel drive motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6. Remove the hydraulic hose clamp from the top of the wheel housing. 7. Remove the one 3/4 in. hex screw attaching the rod end of steering cylinder to the front wheel housing. Retain the spacer. 8. Remove the cotter pin and large slotted nut from the top of the pivot pin. 9. Loosen the two M10 socket head bolts holding the pivot pin to the machine frame. NOTE: Use a floor jack to support the wheel housing before removing the pivot pin. The wheel housing and drive motor assembly is very heavy. 10. Remove the pivot pin from the bottom of the wheel support. NOTE: Do not loose the thrust washer from on top of the wheel housing. 11. Remove the wheel housing and drive motor assembly out of the main frame. 12. Use a steel punch and hammer to drive the old bearing cups out of the wheel housing. 2-12 7400 MM428 (12--98) CHASSIS 13. Install a new set of bearing cups in the wheel housing. Use a large press or a punch and hammer to install the cups. 14. Pack the new bearing cones with Lubriplate EMB grease. Coat the bearing cups with grease. 15. Position the new bearing cones in the wheel housing. 16. Position the thrust washer on top of the upper bearing cone. 17. Position the wheel housing back in the machine. 18. Slide the large pivot pin up through hole in the machine frame. Thread castle nut on the top of the pivot pin. Tighten to 34 -- 40 Nm (25 -- 30 ft lb). Check the wheel housing for play. If pin is not seated, tap with rubber mallet and re--torque castle nut. NOTE: The wheel housing should rotate with a slight amount of drag. 19. Torque the top socket screw with a hand torque wrench to 100 -- 115 Nm (73--85 ft lb). 20. Tighten the castle nut to the next slot and insert the cotter pin. Torque not to exceed 100 Nm (75 ft lb). 21. Check the casting to see if it rocks or binds. If it does, loosen top socket screw, move the casting to seat the bearings, and re--tighten the socket screw to 100 -- 115 Nm (73--85 ft lb). 22. Tighten the lower socket screw to 100 -- 115 Nm (73--85 ft lb). 23. Reinstall rod end of steering cylinder to the top of the wheel housing using the 3/4 in. x 3--1/4 in. hex screw,nyloc nut, and four flat washers. Tighten to 270 -- 300 Nm (200 -- 220 ft lb). 7400 MM428 (12--98) 2-13 CHASSIS 24. Reconnect the hydraulic hoses to the drive motor. 25. Reinstall the hose clamp to the top of the wheel housing. Tighten M8 hex screws to 18.5 -- 24Nm (15 -- 20 ft lb). 26. Install the front tire. Torque the front wheel nuts to 142 -- 156 Nm (105 -- 115 ft lb) 27. Re--connect battery cables, start engine, run propelling in both directions, check for leaks. 28. Remove jack stands, lower machine to the ground. 2-14 7400 MM428 (12--98) SCRUBBING CONTENTS Page INTRODUCTION . . . . . . . . . . . . . . . . . . . 3-3 SOLUTION TANKS . . . . . . . . . . . . . . . . . . . . 3-4 TO REMOVE LH SOLUTION TANK . . . 3-4 TO INSTALL LH SOLUTION TANK . . . 3-5 TO REMOVE RH SOLUTION TANK . . 3-6 TO INSTALL RH SOLUTION TANK . . . 3-7 RECOVERY TANK . . . . . . . . . . . . . . . . . . . . 3-8 TO REMOVE RECOVERY TANK . . . . . 3-8 TO INSTALL RECOVERY TANK . . . . . 3-11 SCRUB HEAD . . . . . . . . . . . . . . . . . . . . . . . 3-13 TO REPLACE MAIN SCRUB BRUSHES . . . . . . . . . . . . . . . . . . . . . 3-13 CHECKING AND ADJUSTING SCRUB BRUSH PATTERN . . . . . . . . . . . . . . 3-14 TO REPLACE MAIN BRUSH IDLER SHAFT BEARINGS . . . . . . . . . . . . . 3-16 TO REMOVE MAIN BRUSH DRIVE MOTOR MOUNT PLATE . . . . . . . . 3-18 TO INSTALL MAIN BRUSH DRIVE MOTOR MOUNT PLATE . . . . . . . . 3-19 TO REPLACE OPTIONAL SIDE BRUSH . . . . . . . . . . . . . . . . . . . . . . . 3-20 SQUEEGEES . . . . . . . . . . . . . . . . . . . . . . . . 3-21 TO REPLACE REAR SQUEEGEE LIFT CABLE . . . . . . . . . . . . . . . . . . . 3-21 TO REPLACE REAR SQUEEGEE CENTERING SPRINGS . . . . . . . . . 3-22 TO REMOVE REAR SQUEEGEE FRAME . . . . . . . . . . . . . . . . . . . . . . . 3-23 TO INSTALL REAR SQUEEGEE FRAME . . . . . . . . . . . . . . . . . . . . . . . 3-23 SQUEEGEE BLADES . . . . . . . . . . . . . . . . 3-24 REAR SQUEEGEE . . . . . . . . . . . . . . . . 3-24 TO REPLACE OR ROTATE REAR SQUEEGEE BLADES . . . . . . . . . . . 3-24 TO ADJUST REAR SQUEEGEE BLADE DEFLECTION . . . . . . . . . . . 3-25 TO LEVEL THE REAR SQUEEGEE . 3-26 SIDE SQUEEGEES . . . . . . . . . . . . . . . 3-27 TO REPLACE SIDE SQUEEGEE BLADES . . . . . . . . . . . . . . . . . . . . . . . 3-27 TO REPLACE SIDE BRUSH SQUEEGEE . . . . . . . . . . . . . . . . . . . 3-28 SIDE BRUSH SKIRT . . . . . . . . . . . . . . . 3-28 VACUUM FAN . . . . . . . . . . . . . . . . . . . . . . . 3-29 TO REMOVE VACUUM FAN . . . . . . . . 3-29 TO INSTALL VACUUM FAN . . . . . . . . 3-30 TO REPLACE VACUUM IMPELLER . 3-31 7400 MM428 (9--01) 3-1 SCRUBBING 3-2 7400 MM428 (12--98) SCRUBBING INTRODUCTION When the scrubbing mode is used, water flows from the solution tank through the solution valve to the two cylindrical scrub brushes. The brushes scrub the floor. As the machine is moved forward the squeegee wipes the dirty solution off the floor, which is then picked up and drawn into the recovery tank by the vacuum fan. There are three settings on the solution flow----high, low, and off. 7400 MM428 (12--98) 3-3 SCRUBBING SOLUTION TANKS The two solution tanks hold the clean water and detergent mixture that will be applied to the floor for the scrubbing operation. There is a LH and a RH solution tank. They are connected by a large diameter solution line. TO REMOVE LH SOLUTION TANK FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Empty the solution and recovery tanks. 2. Open the engine side door and engine cover. 3. Unlatch the rear radiator cover panel and tilt it open. 4. Disconnect the wires going to the float switch at the back of the LH solution tank. 5. Remove the two hex screws from the rear tank bracket where it attaches to the LH solution tank. 6. Remove the one hex screw from the rear, lower corner of the LH tank. This hex screw is located near the left hand taillight. 7. Go to the front of the LH solution tank. Disconnect the solution cross--over line from the bottom, front of the LH solution tank. NOTE: Access the the clamp on the cross--over line is made easier by removing the two vacuum hoses leading to the recovery tank. 8. Remove the two M8 hex screws from the front of the LH solution tank near the engine alternator. 9. The LH solution tank can now be lifted up and out of the machine frame. 3-4 7400 MM428 (12--98) SCRUBBING TO INSTALL LH SOLUTION TANK FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Position the LH solution tank back in the machine frame. NOTE: Be careful not to pinch hydraulic hoses or electrical wires during this procedure. 2. Reinstall the two M8 hex screws in the front of the LH solution tank near the engine alternator. Leave hardware loose for now. 3. Reinstall the two M8 hex screws in the top, rear of the LH solution tank in the rear tank bracket. Leave hardware loose for now. 4. Reinstall the one M8 hex screw in the rear, bottom of the LH solution tank near the LH taillight. 5. Tighten the five M8 hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 6. Reconnect the solution cross--over line at the bottom of the tank. NOTE: Reconnect the vacuum hoses if removed earlier. 7. Reconnect the wires to the float switch at the back of the LH solution tank. 8. Close the rear radiator cover panel and latch. 9. Close the engine side door and engine cover. 10. Fill the LH solution tank with water and check for leaks. 7400 MM428 (12--98) 3-5 SCRUBBING TO REMOVE RH SOLUTION TANK FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. The RH solution tank can only be removed after the LH solution and recovery tanks have been removed. See TO REMOVE LH SOLUTION TANK and TO REMOVE RECOVERY TANK instructions. 2. Remove the one hex screw from the rear, lower corner of the RH tank. This hex screw is located under the frame, above the drain cap. 3. Place the operators seat in the raised position and engage the prop rod. 4. Remove the two M8 hex screws from the front, right corner of the RH solution tank where it attaches to the seat support. 5. Disconnect any solution lines still attached to the RH solution tank. 6. The RH solution tank can now be lifted up and out of the machine frame. 3-6 7400 MM428 (12--98) SCRUBBING TO INSTALL RH SOLUTION TANK FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Position the RH solution tank back in the machine frame. NOTE: Be careful not to pinch hydraulic hoses or electrical wires during this procedure. 2. Reinstall the one M8 hex screw in the rear, bottom of the RH solution tank. This hex screw is located under the frame, above the drain cap. Leave hardware loose for now. 3. Reinstall the two M8 hex screws from the front, right corner of the RH solution tank where it attaches to the seat support. Leave hardware loose for now. 4. Reconnect any solution lines that were disconnected from the RH solution tank. 5. The remain RH solution tank hardware will be installed during the recovery tank installation. See TO INSTALL RECOVERY TANK and TO INSTALL LH SOLUTION TANK instructions. 7400 MM428 (12--98) 3-7 SCRUBBING RECOVERY TANK The recovery tank holds the used water and detergent solution pulled off the floor by the squeegee and scrubbing vacuum fan. TO REMOVE RECOVERY TANK FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Empty the solution and recovery tanks. 2. Place the operators seat in the raised position and engage the prop rod. 3. Remove the LH solution tank. See TO REMOVE LH SOLUTION TANK instructions. 4. Disconnect the vacuum and squeegee hoses from the front of the recovery tank. 5. Remove the two hex screws holding the demister cover on the recovery tank. Remove the demister cover. 6. If the machine is equipped with an overhead guard, it must be removed in order to remove the tank lintel. NOTE: The engine hood must be supported in the open position before the next step can be completed. 7. Remove the clips on the bottom of the engine hood gas springs. Remove the gas springs from the ball studs on the support channel. 8. Remove the hex screws holding the support channel to the tank lintel and hood lintel. Remove the support channel from the machine. 3-8 7400 MM428 (12--98) SCRUBBING 9. Remove the solution and recovery tank drain caps from the rear of the machine. 10. Remove the three hex screws holding the tank drain cover to the machine. Remove the cover. 11. Remove the hex screws holding the tank lintel to the frame, recovery tank, RH solution tank, and seat support. Remove the lintel from the machine. 12. Mark, disconnect, and plug the three hydraulic hoses leading to the engine fan hydraulic motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 13. Disconnect the solution line at the front of the recovery tank if the machine is equipped with the auto--fill option. 14. Disconnect the wires leading to the float switch that is located at the front, right corner of the recovery tank. NOTE: Machines equipped with ES will have two switches on the float assembly. 15. Disconnect the solution hose at the back of the tank if the machine is equipped with the ESt option. 16. Unplug the main electrical harness from the ESt pump at the rear of the tank. 17. Remove the ESt pump and cap assembly from the recovery tank. 18. Remove the one hex screw and two nyloc nuts holding the radiator assembly to the back of the recovery tank. Leave the black mount plate attached to the recovery tank. Do not disconnect the hoses from the radiator. 7400 MM428 (12--98) 3-9 SCRUBBING 19. Carefully pull the radiator assembly back and out of the way of the recovery tank. Let the radiator assembly lean against the oil cooler. 20. Remove the two M8 hex screws attaching the rear tank bracket to the RH solution tank 21. Remove the one M8 hex screw under the rear of the tank, just above the drain cap. 22. Carefully push the recovery tank forward, lift it up, and remove it from the machine. NOTE: An overhead hoist or two people must be. used when lifting the recovery tank out of the machine frame. 3-10 7400 MM428 (12--98) SCRUBBING TO INSTALL RECOVERY TANK FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. NOTE: An overhead hoist or two people must be used when positioning the recovery tank back in the machine frame. 1. Position the recovery tank back in the machine frame. NOTE: Be careful not to pinch hydraulic hoses or electrical wires during this procedure. 2. Reinstall the tank lintel in the machine. Reinstall the six M8 hex screws. Leave the hardware loose for now. 3. Reconnect the solution line at the front of the recovery tank if machine is equipped with the auto fill option. 4. Reconnect the float switches at the front of the recovery tank to the main harness. See schematic in the ELECTRICAL section. 5. Carefully pivot the radiator assembly back in position on the rear of the recovery tank. Reinstall the hardware and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 6. Plug the ESt pump back in the main harness. See schematic in the ELECTRICAL section. 7. Reinstall the hardware in the rear tank bracket where it attaches to the RH solution tank. 8. Reinstall the one M8 hex screw under the rear of the tank, just above the drain cap. 9. Reinstall the support channel to the tank lintel and hood lintel. Reinstall the four M8 hex screws. 10. Tighten the all of the M8 hex screws to 18 -- 24 Nm (15 -- 20 ft lb). 7400 MM428 (12--98) 3-11 SCRUBBING 11. Reinstall the engine hood gas springs on the ball studs on the support channel. Reinstall the two clips. 12. Reconnect the hydraulic hoses to the engine fan motor. See schematic in the HYDRAULIC section. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 13. Reinstall the demister cover on the recovery tank. Reinstall the two M8 hex screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 14. Reinstall the LH solution tank. See TO INSTALL LH SOLUTION TANK instructions. 15. Reconnect the two vacuum hoses to the front of the recovery tank. 16. Reinstall the overhead guard if it was removed earlier. 17. Reinstall the tank drain cover to the rear of the tanks. Reinstall the hardware and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 18. Reinstall the solution and recovery tank drain covers. 19. Partially fill the recovery tank with water and check for any leaks and for proper operation of the float switches. 3-12 7400 MM428 (12--98) SCRUBBING SCRUB HEAD The scrub head contains the two cylindrical brushes, hydraulic motors, brush idler plate, brush wrap, and side squeegees. Water from the solution tank flows to the center of of the scrub head brush wrap and is spread evenly in front of the scrub brushes. TO REPLACE MAIN SCRUB BRUSHES 1. Place the main scrub brushes in the raised position. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Open the RH brush door. 3. Pull back on the front ball joint locking collar on the leveling rod. Remove the leveling rod from the front ball stud. 4. Remove the two hair pins from the brush wrap attachment pins. 5. Remove the M12 hex screw holding the brush idler plate arm to the lift tube. 6. Remove the idler plate and side squeegee assembly from the machine. NOTE: Thread the mounting bolt into the idler arm removal hole if you are having trouble removing the idler arm. 7. Pull the two main brushes off the drive plugs. 6. Line up the drive end of the new or rotated brushes with the brush drive plugs. The cylindrical scrub brushes must be installed with the V-patterns on the brushes pointing towards each other. Slide the brushes onto the brush drive plugs. 8. Reinstall the idler plate and side squeegee assembly in the machine. NOTE: Lift up on the brush wrap slightly when installing the idler plate in the machine so the attachment pins line up with the holes in the plate. 7400 MM428 (12--98) 3-13 SCRUBBING 9. Align the two pins on the lift tube with the two holes in the brush idler plate arm. 10. Reinstall the M12 hex screw in the brush idler plate arm. Tighten to 64 -- 83 Nm (47 -- 61 ft lb). NOTE: Apply a small amount of grease to the threads on the bolt and in the tube. 11. Reinstall the two hair pins in the brush wrap attachment pins. 12. Reconnect the front of the leveling rod to the ball stud. 13. Close the RH brush door and operate the machine. Check the main brushes for proper operation. CHECKING AND ADJUSTING SCRUB BRUSH PATTERN 1. Apply chalk, or some other material that will not easily blow away, to a smooth, level floor. 2. Raise the scrub head. Position the scrub head over the chalked area. 3. Set the parking brake. 4. Lower the scrub head for 15 to 20 seconds while keeping the scrub head in one spot in the chalked area. NOTE: If chalk or other material is not available, allow the brushes to spin on the floor for two minutes. A polish mark will remain on the floor. 10355 5. Raise the scrub head, release the parking brake, and drive the machine away from the chalked area. 6. Observe the width of the brush pattern. If the brush patterns have parallel sides and are the same width, the brushes do not need taper adjustment. If one or both of the brush patterns are tapered, the scrub head will have to be adjusted to straighten the brush pattern. 3-14 10652 7400 MM428 (12--98) SCRUBBING 7. Loosen the three scrub head mounting bolts on the idler or drive side of the scrub head. Move the scrub head up to decrease the pattern width on that side of the scrub head. Move the scrub head down to increase the pattern width on that side of the scrub head. Tighten the mounting bolts and check the pattern again and readjust if necessary. The brush patterns should be the same width. If one is narrower then the other, the scrub head needs to be leveled from front to rear. 10653 8. Lengthen or shorten the leveling rods on both sides of the scrub head. Lengthening the rods will increase the rear brush pattern width. Shortening the rods will will increase the front brush pattern. 7400 MM428 (12--98) 3-15 SCRUBBING TO REPLACE MAIN BRUSH IDLER SHAFT BEARINGS 1. Place the main scrub brushes in the raised position. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Open the RH brush door. 3. Pull back on the front ball joint locking collar. Remove the leveling rod from the front ball stud. 4. Remove the two hair pins from the brush wrap attachment pins. 5. Remove the M12 hex screw holding the brush idler plate arm to the lift tube. 6. Remove the idler plate and side squeegee assembly from the machine. NOTE: For better access to the shaft and bearings----remove the C--clip and brush arm from the idler plate. 7. Turn the idler plate and side squeegee assembly over. Remove the cotter pins, castle nuts, and washers from the idler plugs. 8. Use a puller to remove the idler plugs from the tapered shafts. Remove and retain the square key. 9. Remove the retaining rings from both ends of the idler shafts. 10. Use a press to remove the tapered shafts from the idler plate. Push the shafts out toward the direction of the idler plugs. NOTE: Use a small amount of heat in the area of the bearings to help break the loctite loose. 11. Use a press to remove the bearing from the tapered end of the idler shaft. 12. Use a press to remove the bearing from the bearing housing in the idler plate. Discard the old bearings. 13. Use a press to install a new bearing in the bearing housing on the outside of the idler plate. The open face of the bearing points in. Use green loctite #680 on the outer diameter of the bearing before pressing in place. 3-16 7400 MM428 (12--98) SCRUBBING 14. Use a press to install a new bearing on the tapered shaft. The open face of the bearing points in. Reinstall the retaining ring on the tapered shaft next to the bearing. 15. Reinstall the tapered shaft and bearing in the bearing housing on the inside of the idler plate. Use green loctite #680 on the outer diameter of the bearing before pressing in place. 16. Reinstall the retaining ring on the flat end of the tapered shaft on the outside of the idler plate. 17. Reinstall the square key on the tapered shaft. Put a small amount of grease on the taper. 18. Reinstall the idler plugs, washers, and castle nuts. Hold the plug from turning and tighten the castle nut down hard until the slot in the nut lines up with the hole in the shaft. Install a new cotter pin. 19. Reinstall the brush arm and C clip if they were removed earlier. 20. Reinstall the idler plate and side squeegee assembly in the machine. NOTE: Lift up on the brush wrap slightly when installing the idler plate in the machine so the attachment pins line up with the holes in the plate. 21. Align the two pins on the lift tube with the two holes in the brush idler plate arm. 22. Reinstall the M12 hex screw in the brush idler plate arm. Tighten to 64 -- 83 Nm (47 -- 61 ft lb). NOTE: Apply a small amount of grease to the threads on the bolt and in the tube. 23. Reinstall the two hair pins in the brush wrap attachment pins. 24. Reconnect the front of the leveling rod to the ball stud. 25. Close the RH brush door and operate the machine. Check the main brushes for proper operation. 7400 MM428 (12--98) 3-17 SCRUBBING TO REMOVE MAIN BRUSH DRIVE MOTOR MOUNT PLATE 1. Place the main scrub brushes in the raised position. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Open the LH brush door. 3. Remove the front ball joint on the leveling rod from the machine frame. 4. Remove the two hair pins from the brush wrap attachment pins. 5. Remove the M12 hex screw holding the brush arm to the lift tube. 6. Remove the three hex screws holding the side squeegee assembly to the motor mount plate. Remove the side squeegee assembly. NOTE: For better access to the hydraulic drive motors----remove the C--clip and brush arm from the motor plate. 7. Mark, disconnect, and plug the three hydraulic hoses leading to the main brush drive motors. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. Remove the motor mount plate assembly from the machine. 3-18 7400 MM428 (12--98) SCRUBBING TO INSTALL MAIN BRUSH DRIVE MOTOR MOUNT PLATE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Position the motor plate assembly back in the machine. NOTE: Lift up on the brush wrap slightly when installing the motor plate in the machine so the attachment pins line up with the holes in the plate. 2. Reinstall the two hair pins in the brush wrap attachment pins. 3. Reconnect the hydraulic hoses to the brush motors. See schematic in HYDRAULICS section. 4. Reinstall the brush arm and C clip if they were removed earlier. 5. Align the two pins on the lift tube with the two holes in the brush motor plate arm. 6. Reinstall the M12 hex screw in the brush motor plate arm. Tighten to 64 -- 83 Nm (47 -- 61 ft lb). NOTE: Apply a small amount of grease to the threads on the bolt and in the tube. 7. Reinstall the front of the leveling rod ball joint to the machine frame. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. Reinstall the side squeegee assembly to the motor plate. Tighten the three hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 9. Close the LH brush door and operate the machine. Check the main brush motors for proper operation. 7400 MM428 (12--98) 3-19 SCRUBBING TO REPLACE OPTIONAL SIDE BRUSH FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Rotate the side brush by hand until the spring clips are visible through the window in the side brush motor mount plate. 2. Reach in through the opening in the top of the side brush guard, through the mount plate window, and pinch the spring clips together. 3. Drop the brush off the drive hub. Remove the brush from the machine. 4. Position the new side brush under the machine. 5. Lift the side brush and line up the hub in the brush with the motor drive plug. Snap the brush up in place. 6. Operate the machine and check the side brush for proper operation. 3-20 7400 MM428 (12--98) SCRUBBING SQUEEGEES The squeegee channels water into the vacuum fan suction. The front blade channels the water, and the rear blade wipes the floor. There are two types of squeegee blades available; one for smooth surfaces is standard on the machine, and one for rough surfaces is an option. The side squeegees control water spray and channel water into the path of the rear squeegee. Check the side squeegees for damage and wear daily. TO REPLACE REAR SQUEEGEE LIFT CABLE 1. Open the debris tray latch and swing the squeegee assembly out for better access. 2. Start engine, lower rear squeegee, shut off engine. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Remove the cotter pin and clevis pin from the squeegee lift cable where it attaches to the squeegee frame assembly. 4. Remove the cotter pin and clevis pin from the squeegee lift cable where it attaches to the squeegee lift bellcrank located near the lift cylinder. 5. Remove the clevis pin holding the cable roller to the frame. Remove the roller. 6. Remove and discard the old squeegee lift cable. 7. Position the new cable in the machine. Reinstall one end to the squeegee lift bellcrank located near the lift cylinder. Re--use the clevis and cotter pin. 8. Reinstall the other end to the squeegee pivot frame assembly. Re--use the clevis and cotter pin. 9. Reinstall the cable roller and clevis pin in the frame. 10. Start the machine and raise the squeegee. Swing the squeegee assembly back in. Check the lift cable for proper operation. 7400 MM428 (12--98) 3-21 SCRUBBING TO REPLACE REAR SQUEEGEE CENTERING SPRINGS 1. Open the debris tray latch and swing the squeegee assembly out for better access. 2. Start engine, lower rear squeegee, shut off engine. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Loosen the jam nuts on the squeegee down pressure spring rods. This will relax the tension on the springs. 4. Remove the nyloc nuts from the squeegee rod ball joints where they are connected to the debris tray. NOTE: Remove both the upper and lower nuts on one side. Do one side at a time. 5. Remove and discard the old squeegee centering spring. 6. Position a new squeegee centering spring on the upper and lower ball joint studs. 7. Reinstall the two nyloc nuts and tighten to 37 -- 48 Nm (26 -- 34 ft lb). 8. Repeat this procedure on the other side if needed. 9. Start the machine and raise the squeegee. Swing the squeegee assembly back in. Check the centering springs for proper operation. 3-22 7400 MM428 (12--98) SCRUBBING TO REMOVE REAR SQUEEGEE FRAME 1. Open the debris tray latch and swing the squeegee assembly out for better access. 2. Start engine, lower rear squeegee, shut off engine. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Remove vacuum hose from squeegee frame. 4. Remove the cotter pin and clevis pin from the squeegee lift cable where it attaches to the squeegee frame assembly. 5. Loosen the jam nuts on the squeegee down pressure spring threaded rods. This will relax the tension on the springs. 6. Remove the four hex screws and nuts holding the squeegee frame to the squeegee lift assembly. 7. Remove the squeegee frame from the machine. TO INSTALL REAR SQUEEGEE FRAME FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Position the squeegee frame back under the lift assembly. 2. Reinstall the four hex screws and nuts. Tighten to 37 -- 48 Nm (26 -- 34 ft lb). 3. Re--connect the squeegee lift cable to the frame assembly. Re--use the clevis and cotter pin. 4. Re--apply tension on the down pressure springs using the threaded rods and jam nuts. 5. Reinstall the vacuum hose on the squeegee frame. 6. Start the machine and raise the squeegee. Swing the squeegee assembly back in. 7400 MM428 (12--98) 3-23 SCRUBBING SQUEEGEE BLADES REAR SQUEEGEE Check the squeegee blades for damage and wear daily. Rotate or replace either of the squeegee blades if the leading edge is torn or worn half-way through the thickness of the blade. The rear squeegee has two squeegee blades. Each blade has four wiping edges. To use them all, start with one wiping edge. To use the next wiping edge, rotate the blade end-for-end. To use the next wiping edge, rotate the top edges down, bottom edges up. To use the last edge, rotate the blade end-for-end. Replace any worn or damaged squeegee blades. TO REPLACE OR ROTATE REAR SQUEEGEE BLADES 1. Make sure the squeegee is raised off the floor. 2. Shut the engine off and set the parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Open the retaining band clamp and remove the squeegee blade. 4. Replace or rotate the squeegee blade to allow a new edge to face the front of the machine. 5. Place the squeegee blade over the pins of the squeegee frame. 6. Position the retaining band over the squeegee blade. Latch the retaining band clamp. 7. Adjust the squeegee blade leveling and deflection. See TO ADJUST REAR SQUEEGEE BLADE DEFLECTION or TO LEVEL THE REAR SQUEEGEE instructions. 3-24 7400 MM428 (12--98) SCRUBBING TO ADJUST REAR SQUEEGEE BLADE DEFLECTION Deflection is the amount of curl the squeegee blade has when the machine travels forward with the squeegee lowered to the floor. The best deflection is when the squeegee wipes the floor just dry with a minimum amount of deflection. 1. Lower the squeegee and drive the machine forward. 5 mm (0.13 to 0.25 in) 15 to 20 mm (0.50 to 0.75 in) 2. Shut off the engine and set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 10918 3. Look at the deflection over the full length of the squeegee blade. The correct amount of deflection for the rear squeegee blade is 15 to 20 mm (0.50 to 0.75 in). The front slotted squeegee blade should contact the floor with a slight deflection, 5 mm (0.13 to 0.25 in). 4. To adjust the amount of deflection, unlock the height adjustment knobs on the two squeegee casters by sliding the locking bracket off to the side. NOTE: If the locking brackets won’t slide over, lift up the end of the squeegee to pick the caster up off the floor slightly. Then slide the locking bracket over. 5. Turn the adjustment knob clockwise to decrease deflection, turn the adjustment knob counter-clockwise to increase the deflection. Be sure to turn the knobs the same number of turns. 6. Start the engine and drive the machine forward again to check the squeegee blade deflection. Readjust the squeegee blade deflection if necessary. 7. Slide the locking brackets back to lock the height adjustment knobs. 8. Raise the squeegee when finished. 7400 MM428 (12--98) 3-25 SCRUBBING TO LEVEL THE REAR SQUEEGEE Leveling of the squeegee assures even contact over the length of the squeegee blade with the surface being scrubbed. Make sure this adjustment is done on an even, level floor. 1. Lower the squeegee and drive the machine forward. 2. Shut off the engine and set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Look at the deflection over the full length of the squeegee blade. 4. If the deflection is not the same over the full length of the blade, loosen the locking nut on the two rear squeegee balljoints. NOTE: The rear squeegee links should be adjusted so there is 11 inches from the center lines of the two ball joints. 11.00 in. 5. Turn the balljoint adjustment nut clockwise, from the rear of the machine, to increase the deflection at the ends of the squeegee. Turn the balljoint adjustment nut counter-clockwise, from the rear of the machine, to decrease the deflection at the ends of the squeegee blade. 6. Tighten the locking nuts. 7. Start the engine and drive the machine forward again to check the squeegee blade deflection. 8. Readjust the squeegee blade deflection if necessary. 3-26 7400 MM428 (12--98) SCRUBBING SIDE SQUEEGEES The side squeegees control water spray and channel water into the path of the rear squeegee. Check the side squeegees for damage and wear daily. Replace the side squeegee blades whenever they become damaged or lose their shape or resilience. Replace the squeegee deflectors whenever they become worn. TO REPLACE SIDE SQUEEGEE BLADES 1. Raise the scrub head. 2. Shut off the engine and set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Remove the cotter pin, clevis pin, deflector, and the retainer bracket from the front of the side squeegee. 4. Pull the squeegee blade out the front of the squeegee frame. 5. Slide the new squeegee blade onto the frame. NOTE: Lubricating the squeegee frame where the squeegee makes contact will make it easier to install the squeegee blade. 00000 6. Replace the retainer bracket, deflector, clevis pin, and cotter pin. 7. Repeat for the side squeegee on the other side of the scrub head. 7400 MM428 (12--98) 3-27 SCRUBBING TO REPLACE SIDE BRUSH SQUEEGEE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the side brush. 2. Shut off the engine and set the parking brake. FOR SAFETY: Before leaving or servicing machine; stop on level surface, set parking brake, turn off machine and remove key. 3. Remove the side brush guard. 4. Remove the retainer clip from the end of the squeegee. 5. Pull the squeegee blade out the front of the squeegee frame. 6. Slide the new squeegee blade onto the frame. NOTE: Lubricating the squeegee frame where the squeegee makes contact will make it easier to install the squeegee blade. 7. Install the retainer clip on the end of the squeegee. 8. Install the side brush guard. SIDE BRUSH SKIRT The side brush skirt is located behind the squeegee blade. Check the skirt for wear and damage every 100 hours of operation. 3-28 7400 MM428 (12--98) SCRUBBING VACUUM FAN The vacuum fan, when activated, creates a vacuum in the recovery tank. Water is pulled from the rear squeegee to the recovery tank through a vacuum hose. The vacuum fans impeller is driven with a high speed hydraulic motor. TO REMOVE VACUUM FAN FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the engine cover, engine side door, and the front cover. 2. Loosen the hose clamp and remove the vacuum hose leading from recovery tank to the center of the vacuum fan housing. 3. Mark, disconnect, and plug the four hydraulic hoses going to the vacuum fan NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 4. Remove three M10 hex screws, washers, and nyloc nuts holding vacuum fan to mounting brackets. 5. Remove the vacuum fan assembly from the machine. 7400 MM428 (12--98) 3-29 SCRUBBING TO INSTALL VACUUM FAN FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Position the vacuum fan assembly back in the machine 2. Align the three mounting holes in the vacuum fan housing with the three rubber isolators in the mounting brackets. Reinstall the three M10 hex screws, washers, and nyloc nuts. Tighten to 18 -- 24 Nm (13 -- 18 ft lb). 3. Reconnect the hydraulic hoses to the vacuum fan motor. See schematic in HYDRAULIC section. 4. Reinstall vacuum hose from recovery tank to vacuum fan housing. Hand tighten clamps. 5. Start the engine and turn on the vacuum fan. Check for leaks and proper operation. 3-30 7400 MM428 (12--98) SCRUBBING TO REPLACE VACUUM IMPELLER FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Remove the vacuum fan from the machine. See TO REMOVE VACUUM FAN instructions. 2. Place the vacuum fan assembly in a vice or some other holding device. 3. Remove the six hex screws holding the front housing to rear housing. Remove the front housing. NOTE: Mark the front housing in relation to the rear housing so it is re--assembled correctly. 4. Remove crown nut on impeller shaft. Slide impeller off shaft. NOTE: Remove and save the key and any shims that are on the motor shaft, under the impeller. 5. Install the shims, key, new fan impeller, and crown nut. Tighten nut to 34 -- 47 Nm (25 -- 35 ft lb). NOTE: Be sure the square key is on the motor shaft. Super gluing the key to the shaft helps keep it in place when installing the impeller. NOTE: Use a small amount of blue loctite 242 on the motor shaft threads. 6. Reinstall the front housing on the rear housing. Reinstall the six hex screws and tighten to 22 -- 27 Nm (16 -- 20 ft lb). NOTE: Tennant part no. 57543 plastic shims must be used for proper fan to housing clearance. Remove these shims after housing hardware has been tightened. 7. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN instructions. 7400 MM428 (12--98) 3-31 SCRUBBING 3-32 7400 MM428 (12--98) ELECTRICAL CONTENTS Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 TO REPLACE BATTERY . . . . . . . . . . . . 4-5 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . 4-6 TO REPLACE INSTRUMENT PANEL . 4-6 TO DISASSEMBLE INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 TO REASSEMBLE INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 TO REPLACE MACHINE RELAY . . . . . 4-9 TO REPLACE CIRCUIT BREAKER . . 4-10 GAS/LPG ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . 4-11 GAS/LPG ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . 4-12 DIESEL ELECTRICAL SCHEMATIC . 4-13 DIESEL ELECTRICAL SCHEMATIC . 4-14 GAS/LPG WIRE HARNESS GROUP . 4-15 GAS/LPG WIRE HARNESS GROUP (OPTIONS) . . . . . . . . . . . . . . . . . . . . 4-18 DIESEL WIRE HARNESS GROUP . . 4-19 DIESEL WIRE HARNESS GROUP (OPTIONS) . . . . . . . . . . . . . . . . . . . . 4-22 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . 4-23 OPERATING MODES . . . . . . . . . . . . . . . . 4-24 NORMAL MODE . . . . . . . . . . . . . . . . . 4-25 SCRUB BUTTON . . . . . . . . . . . . . . 4-25 SQUEEGEE BUTTON . . . . . . . . . 4-26 DETERGENT . . . . . . . . . . . . . . . . . 4-27 ESt BUTTON . . . . . . . . . . . . . . . . 4-27 OVERFLOW FLOAT . . . . . . . . . . . 4-27 MANUAL MODE . . . . . . . . . . . . . . . . . 4-28 ESt BUTTON . . . . . . . . . . . . . . . . 4-28 SIDE BRUSH BUTTON . . . . . . . . 4-28 SQUEEGEE BUTTON . . . . . . . . . 4-28 ENGINE BUTTON . . . . . . . . . . . . . 4-28 SCRUB BUTTON . . . . . . . . . . . . . . 4-28 DETERGENT BUTTON . . . . . . . . 4-28 INPUT DISPLAY MODE . . . . . . . . . . . 4-29 ERROR DISPLAY MODE . . . . . . . . . . 4-30 ESt LED . . . . . . . . . . . . . . . . . . . . . 4-30 SIDE BRUSH LED . . . . . . . . . . . . . 4-31 SQUEEGEE LED . . . . . . . . . . . . . . 4-31 SCRUB LED . . . . . . . . . . . . . . . . . . 4-32 DETERGENT LED . . . . . . . . . . . . . 4-32 PRESSURE ADJUST MODE . . . . . . 4-33 SCRUB BUTTON . . . . . . . . . . . . . . 4-33 RESET SCRUB PRESSURES . . . . . 4-34 TROUBLESHOOTING . . . . . . . . . . . . . . . 4-35 INSTRUMENT PANEL DOES NOT POWER UP (SCHEMATIC) . . . . . 4-36 INSTRUMENT PANEL DOES NOT POWER UP (FLOW CHART) . . . 4-37 7400 MM428 (9--01) Page SCRUB BRUSH WILL NOT TURN ON AND/OR DOWN (SCHEMATIC) . 4-38 SCRUB BRUSH WILL NOT TURN ON AND/OR DOWN (FLOW CHART) 4-39 SQUEEGEE AND VACUUM FAN NOT TURNING ON AND GOING DOWN (SCHEMATIC) . . . . . . . . . . . . . . 4-41 SQUEEGEE AND VACUUM FAN NOT TURNING ON AND GOING DOWN (FLOW CHART) . . . . . . . . . . . . 4-42 SIDE BRUSH WILL NOT TURN ON AND GO DOWN (SCHEMATIC) . . . . . . 4-44 SIDE BRUSH WILL NOT TURN ON AND GO DOWN (FLOW CHART) 4-45 WATER VALVES NOT OPERATING (SCHEMATIC) . . . . . . . . . . . . . . . . 4-47 WATER VALVES NOT OPERATING (FLOW CHART) . . . . . . . . . . . . . . . 4-48 HEAD LIGHTS WILL NOT TURN ON (SCHEMATIC) . . . . . . . . . . . . . . . . . 4-49 HEAD LIGHTS WILL NOT TURN ON (FLOW CHART) . . . . . . . . . . . . . . . 4-50 ESt PUMP NOT WORKING (SCHEMATIC) . . . . . . . . . . . . . . . . 4-51 ESt PUMP NOT WORKING (FLOW CHART) . . . . . . . . . . . . . . . 4-52 REVERSE LIGHT OR ALARM NOT WORKING (SCHEMATIC) . . . . . . 4-54 REVERSE LIGHT OR ALARM NOT WORKING (FLOW CHART) . . . . . 4-55 DETERGENT METERING PUMP IS NOT OPERATING (SCHEMATIC) . . . . 4-57 DETERGENT METERING PUMP IS NOT OPERATING (FLOW CHART) . . . 4-58 ALTERNATOR / BATTERY WARNING LIGHT STAYS ON WHEN ENGINE IS RUNNING (SCHEMATIC) . 4-59 ALTERNATOR / BATTERY WARNING LIGHT STAYS ON WHEN ENGINE IS RUNNING (FLOW CHART) 4-60 ALTERNATOR / BATTERY WARNING LIGHT WILL NOT TURN ON (SCHEMATIC) . . . . . . . . . . . . . . 4-61 ALTERNATOR / BATTERY WARNING LIGHT WILL NOT TURN ON (FLOW CHART) . . . . . . . . . . . . 4-62 ENGINE TEMPERATURE LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) . . . . . . . . . . . . . . 4-63 ENGINE TEMPERATURE LIGHT WILL NOT TURN ON (FLOW CHART) 4-64 ENGINE TEMPERATURE LIGHT WILL NOT TURN OFF (FLOW CHART) 4-64 4-1 ELECTRICAL Page HYDRAULIC (HIGH) PRESSURE INDICATOR LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) . . 4-65 HYDRAULIC (HIGH) PRESSURE INDICATOR LIGHT WILL NOT TURN ON (FLOW CHART) . . . . . . . . 4-66 HYDRAULIC (HIGH) PRESSURE INDICATOR LIGHT WILL NOT TURN OFF (FLOW CHART) . . . . . . . 4-66 ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) . . . . . . . . . 4-67 ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN ON (FLOW CHART) . . . . . . . . . . . . . 4-68 ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN OFF (FLOW CHART) . . . . . . . . . . . . . 4-68 RECOVERY TANK FULL LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) . . . . . . . . . . . . . . . 4-69 RECOVERY TANK FULL LIGHT WILL NOT TURN ON (FLOW CHART) . 4-70 RECOVERY TANK FULL LIGHT WILL NOT TURN OFF (FLOW CHART) 4-70 FUEL GAUGE (GAS AND DIESEL) (SCHEMATIC) . . . . . . . . . . . . . . . . . 4-71 FUEL GAUGE (GAS AND DIESEL) (FLOW CHART) . . . . . . . . . . . . . . . . 4-72 FUEL GAUGE (LPG) (SCHEMATIC) . 4-73 FUEL GAUGE (LPG) (FLOW CHART) 4-74 4-2 7400 MM428 (9--01) ELECTRICAL INTRODUCTION The machine electrical system consists of the battery, relays, instrument panels, and related components. This section includes information on these components and their troubleshooting. 7400 MM428 (12--98) 4-3 ELECTRICAL BATTERY The battery used in the machine is a low maintenance battery. It has been constructed with special materials and has extra electrolyte to reduce or eliminate maintenance. Its design reduces electrolyte loss and contamination. Do not add water, remove the battery vent plugs, or check the battery specific gravity. For specific instructions, see the battery label. Do not allow the battery to remain in discharged condition for any time. Do not operate the machine if the battery is in poor condition or discharged beyond 80%, specific gravity below 1.120. Periodically clean the top surface of the batteries and the terminals, and check for loose connections. Use a strong solution of baking soda and water. Brush the solution sparingly over the battery tops, terminals, and cable clamps. Do not allow any baking soda solution to enter the batteries. Use a wire brush to clean the terminal posts and the cable connectors. After cleaning, apply a coating of clear battery post protectant to the terminals and the cable connectors. Keep the tops of the batteries clean and dry. Keep all metallic objects off the top of the batteries, which may cause a short circuit. Replace any worn or damaged wires. The electrolyte level in regular non--sealed batteries can be checked. The level must always be above the battery plates. Never add acid to the batteries, only distilled water. Keep the battery caps on the batteries always except when adding water or taking hydrometer readings. FOR SAFETY: When Servicing Machine, Avoid Contact With Battery Acid. 4-4 7400 MM428 (12--98) ELECTRICAL Using a hydrometer to measure the specific gravity is a way to determine the charge level and condition of the batteries. If one or more of the battery cells test lower than the other battery cells (0.050 or more), the cell is damaged, shorted, or is about to fail. NOTE: Do not take readings immediately after adding distilled water. If the water and acid are not thoroughly mixed, the readings may not be accurate. Check the hydrometer readings against the following chart to determine the remaining battery charge level: SPECIFIC GRAVITY at 27_ C (80_ F) 1.260 -- 1.280 1.230 -- 1.250 1.200 -- 1.220 1.170 -- 1.190 1.110 -- 1.160 BATTERY CHARGE 100% Charged 75% Charged 50% Charged 25% Charged Discharged NOTE: If the readings are taken when the battery electrolyte is any temperature other than 27_ C (80_ F), the reading must be temperature corrected. Add or subtract to the specific gravity reading 0.004, 4 points, for each 6_ C (10_ F) above or below 27_ C (80_ F). TO REPLACE BATTERY FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the seat support and engage the prop rod. 2. Disconnect the negative then the positive battery cables. 3. Remove the battery hold down bracket from the machine. 4. Tilt the battery and lift it out of the machine. 5. Clean the cables and the posts on the new battery and install back in the machine. 6. Reinstall the battery hold down bracket. 7. Reconnect the positive then the negative battery cables and close the seat support. 7400 MM428 (12--98) 4-5 ELECTRICAL INSTRUMENT PANEL The instrument panel consists of a circuit board, a touch panel, and a water/dust resistant plastic enclosure. Its touch panel controls various machine functions, while its indicator lights keep the operator informed on machine performance. TO REPLACE INSTRUMENT PANEL FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the seat support and engage the prop rod. 2. Remove the battery cables from the battery. 3. Put the steering wheel in the lowest position. 4. Open the front cover on the machine. 5. Remove four M5 pan head screws holding the instrument panel to the dash panel. 6. Pull the instrument panel back away from machine. 7. Loosen the allen head screw in center of wire harness plug. Disconnect the harness. 8. Remove instrument panel from machine. 9. Install the new instrument panel back on the dash panel with the four M5 pan head screws and washers. Hand tighten snug. 10. Push the main harness plug back in the instrument panel. NOTE: Slot in panel must line up with notch on plug. Hand tighten the allen head screw. 11. Close the front cover. 12. Reconnect the battery cables and lower the seat support. 13. Start the machine and check for proper operation. 4-6 7400 MM428 (12--98) ELECTRICAL TO DISASSEMBLE INSTRUMENT PANEL 1. Remove panel from machine. See TO REPLACE INSTRUMENT PANEL instructions. 2. Place the instrument panel face down and remove the twelve larger pan head screws from the back. 3. The touch panel case can now be separated from the outer case and new O-ring gasket installed if necessary. 4. To disassemble the touch panel case further, remove the four smaller pan head screws from the center of case box. 5. Remove the case box from the circuit board / touch panel assembly. 6. The O--ring and connector gaskets can now be replaced in the case box if necessary. 7. Remove the eight pan head screws, unplug the flat connector and ground strap, remove the touch panel from the circuit board. 8. Any burned-out lamps can now be changed by turning them 1/4 turn counterclockwise and lifting out. 9. To replace the hour meter, unplug the two wires and remove the two pan head screws. 7400 MM428 (12--98) 4-7 ELECTRICAL TO REASSEMBLE INSTRUMENT PANEL 1. Position the circuit board over the touch panel. Feed the flat connector from panel through the slot in board, plug it in and reconnect the ground strap. 2. Reinstall the eight pan head screws and lightly hand tighten. 3. Turn the circuit board assembly over and place it back in the case box. 4. Reinstall the four smaller pan head screws in center of case box. Lightly hand tighten. 5. Reinstall the touch panel case on the outer case. 6. Reinstall the twelve pan head screws and lightly hand tighten. 7. The instrument panel is now ready to be reinstalled in the machine. See TO REPLACE INSTRUMENT PANEL instructions. 4-8 7400 MM428 (12--98) ELECTRICAL TO REPLACE MACHINE RELAY FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the seat support and engage the prop rod. 2. Remove the battery cables from the battery. 3. Open the front cover on the machine. 4. Locate the relays at the front of the operators compartment, near the hydraulic steering motor. 5. Lift up on the relay to harness locking tab. 6. Pull the harness plug out of the relay. 7. Remove the pan screw holding the relay to the operators compartment. Remove and discard the old relay. 8. Position the new relay on the operators compartment. 9. Reinstall the pan screw holding the relay to the operators compartment. 10. Reconnect the harness plug in the relay. See schematic in the ELECTRICAL section. 11. Reconnect the battery cables to the battery. 12. Lower the seat support. 13. Close the front cover on the machine. 14. Start and operate the machine, checking for proper operation. 7400 MM428 (12--98) 4-9 ELECTRICAL TO REPLACE CIRCUIT BREAKER FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the seat support and engage the prop rod. 2. Remove the battery cables from the battery. 3. Open the front cover on the machine. 4. Locate the circuit breakers at the front of the operators compartment, near the hydraulic steering motor. 5. Remove and retain the rubber boot on the front of the circuit breaker 6. Disconnect the electrical wires on the back of the circuit breaker. 7. Remove the steel retaining ring holding the circuit breaker to the dash panel. Remove the circuit breaker. 8. Position the new circuit breaker in the mounting hole on the dash panel. 9. Install the retaining ring on the new circuit breaker. Push the ring on all the way to the bottom of the circuit breaker. 10. Reconnect the wires to the back of the circuit breaker. See schematic in the ELECTRICAL section. 11. Reconnect the battery cables to the battery. 12. Lower the seat support. 13. Close the front cover on the machine. 14. Start and operate the machine, checking for proper operation. 4-10 7400 MM428 (12--98) ELECTRICAL BATTERY 1/RED M1 STARTER RELAY 1E/RED 1B/RED L2 SENSE A CB--5 1C/RED 2/ORA 15A 1D/RED HORN BUTTON S--1 5/YEL 4/YEL 10/GRY 10/GRY 50 18A/ORA 17 19 FUEL PUMP 15A/BLU M2 15B/BLU CB--1 65/BLU 4 7 20A/BLU 8 9 64/BRN 68/BRN 13PP/BLK 71B/YEL 18U/ORA 71C/YEL 72C/YEL 1E/ RED 22/ YEL CB--6 5.0A 30 M3 72C/YEL 18D/ORA 71C/YEL G C D THROTTLE ACTUATOR 84/GRN B E H F 13G/BLK 13E/BLK 86 19/BLU 19B/BLU 87 15/ 2/ ORA BLU 23B/GRY 23A/GRY 86/PUR 19A/BLU GOV CONTROL A M3 PLUGS 72B/GRY 18C/ORA 85 13F/BLK 70/GRN 12 86 T 10K OHMS 18T/ORA 11 M4 COOLANT TEMP. SENSOR 67/ORA 10 18/ORA VAR. RELUCTANCE SENSOR 66/GRN 3 6 S--4 OIL SWITCH 13B/BLK C 2 IGNITION SWITCH S--3 13P/BLK 15/BLU ELEC. SPARK CONT. 15A 18A/ ORA 13H/BLK STARTER RELAY 14/GRN 18A/ORA 18A/ ORA 85 55A MAX. CHARGE 10A/GRY START ACC 20/BLU 13A/BLK HORN M1 BATT. 30 12V 540 C.C.A. STARTER MOTOR MTR GND ALTERNATOR OUT 1A/RED 13/BLK 23/GRY DETERGENT METERING 56/ORA MTR 1 17 9 14 A 83/BRN 13D/BLK C PIN 9 SCRUB BR. MUST BE ON 15 23C/GRY ES PUMP 85 86 M5 ELECTRONIC INSTRUMENT PANEL 3 57/GRN 4 10 13 23C/GRY LIGHTS 85 86 M6 60/GRN 23C/GRY REVERSE 85 86 M7 58/BLU SOLUTION RECOVERY TANK TANK 27/PUR 13K/BLK 5 SEC. DELAY ES PUMP RUNS 30 SEC. S--17 N.O.H.C. S--18 N.C.H.O. RECOVERY TANK 13J/BLK 5 SEC. DELAY 28/YEL 1 MIN. TO VAC FAN SHUT--OFF S--8N.C.H.O. SE--1 13L/BLK FUEL SENDER 42/YEL 42A/YEL GAS--DIESEL 26/BRN 42B/YEL S--6 LP C N.C.H.O. 20 18 5 COOLANT TEMP SE--2 SENDER 43/BLU 7 35/BRN 8 36/GRN 13M/BLK CLOSES BELOW 40 PSI HYDRAULIC S--14 CLOSES AT225° F 13N/BLK FILTER SWITCH 13R/BLK S--15 REVERSE FLOW SWITCH PIN 20 TIED TO ENG. OIL PRESS. SHEET 1 GAS/LPG ELECTRICAL SCHEMATIC 7400 MM428 (6--01) 4-11 ELECTRICAL SHEET 2 GAS/LPG ELECTRICAL SCHEMATIC 4-12 7400 MM428 (6--01) ELECTRICAL BATTERY M1 STARTER RELAY 1/RED 1B/RED L2 SENSE A CB--5 1C/RED 2/ORA HORN BUTTON S--1 5/YEL 4/YEL 15A 1D/RED 10/GRY 10/GRY 50 17 55A MAX. CHARGE 13H/BLK STARTER RELAY 10A/GRY START 13A/BLK HORN M1 BATT. 30 12V 540 C.C.A. STARTER MOTOR MTR GND ALTERNATOR OUT 1A/RED 13/BLK FUEL PUMP 18A/ORA 7/YEL M2 14/GRN 13P/BLK 15A/BLU S--4 OIL SWITCH 13B/BLK 15/BLU 19 C CB--1 ACC 20/BLU 15A IGNITION SWITCH S--3 FU--1 GLOW PLUGS 8/GRN 40A 20A/BLU 18/ORA MAGNETIC PICKUP 18A/ ORA 1E/ RED CB--6 22/ YEL 5.0A M4 85 30 M3 M3 86 19A/BLU GOV CONTROL B G A C THROTTLE ACTUATOR 84/GRN D E H F 18C/ORA 86 13G/BLK 19/BLU 87 15/ 2/ ORA BLU 23B/GRY 23A/GRY 86/PUR 72C/GRY 18A/ ORA 85 71C/YEL 13Q/BLK 23/GRY DETERGENT METERING 56/ORA MTR 1 17 9 14 A 83/BRN 13D/BLK C 15 23C/GRY ES PUMP 85 86 M5 ELECTRONIC INSTRUMENT PANEL 3 57/GRN LIGHTS 23C/GRY 23C/GRY 85 86 60/GRN REVERSE 85 86 M7 58/BLU M6 S--17 4 10 SOLUTION RECOVERY TANK 27/PUR TANK 13K/BLK 26/BRN N.O.H.C. S--8 42/YEL 5 43/BLU 7 35/BRN 8 36/GRN 13J/BLK N.C.H.O. 42A/YEL SE--1 5 SEC. DELAY ES PUMP RUNS 30 SEC. 5 SEC. DELAY 1 MIN. TO VAC FAN SHUT--OFF 13L/BLK GAS--DIESEL FUEL SENDER 20 18 N.C.H.O. RECOVERY TANK 28/YEL 13 S--18 PIN 9 SCRUB BR. MUST BE ON COOLANT TEMP SE--2 SENDER S--14 HYDRAULIC FILTER SWITCH S--15 CLOSES AT225°F 13N/BLK REVERSE 13R/BLK FLOW SWITCH PIN 20 TIED TO ENG. OIL PRESS. SHEET 3 DIESEL ELECTRICAL SCHEMATIC 7400 MM428 (6--01) 4-13 ELECTRICAL SHEET 4 DIESEL ELECTRICAL SCHEMATIC 4-14 7400 MM428 (6--01) 13HH/BLK 89A/ORA 62D/BRN SEE OPTIONS ES PUMP SEE OPTIONS BLK GRN RED A BC CBA C 28/YEL 95/BLU VIEW B--B 25D/GRY 25A/GRY 25D/GRY WATER CONTROL SWITCH 71C/YEL A H 85/BLU 18D/ORA 13E/BLK C TO MAIN HARNESS H 50 DIODE FUEL SENDER 19 17 62A/YEL 62/YEL 13H/BLK KEY SWITCH 96/GRY WATER VALVE CONTROL 46/BRN 96B/GRY 46C/BRN HORN LOW R.H. HEADLIGHT 13CC/BLK 5/YEL 13H/BLK L.H. HEADLIGHT 62A/YEL 62B/YEL 13DD/BLK 13CC/BLK SIDE BRUSH VALVE OPTION 46C/BRN 95/BLU SIDE BRUSH VALVE LOW OPTION BRAKE SWITCH OPTION 30 VIEW F--F 10/GRY 10A/GRY 20D/BLU AC 1D/RED HIGH 20/BLU E GOVERNOR CONTROL E C MAIN PANEL RELAYS CIRCUIT BREAKERS 14/GRN 13P/BLK 42A/YEL 42/YEL 13L/BLK SEE MAIN SCRUB VALVE HYD. FILTER SWITCH OPTIONS FUEL PUMP 4/YEL 5/YEL HORN SWITCH 83/BRN 84/GRN VIEW C--C 86/PUR E 72C/YEL D GOVERNOR CONTROL 1/RED B WATER CONTROL SWITCH L.P. SWITCH F CIRCUIT 1 CIRCUIT 2 B 42A/YEL TO ENGINE 13/BLK BATTERY GAS AND DIESEL LOCATION SEE OPTIONS ROT. LIGHT 84/GRN 86/PUR BA AUTO FILL REC TANK -- INNER SWITCH NO NC 13G/BLK 13DD/BLK 13X/BLK 13Y/BLK 13B/BLK 13P/BLK 13TT/BLK 13M/BLK 13N/BLK 13F/BLK 13J/BLK 13R/BLK 36/GRN 13R/BLK A BC 13M/BLK ACTUATOR 1D/RED 1A/RED 1C/RED 1E/RED 10/GRY 15B/BLU 13B/BLK F 96/GRY 13K/BLK 13J/BLK DETERGENT PUMP FLOW SWITCH REVERSE D.I.S. ENGINE HARNESS STARTER 1 BACK--UP ALARM 62E/BRN 13II/BLK 89B/ORA SOLUTION SWITCHES OPTION 13F/BLK 18C/ORA 71C/YEL 72C/YEL 1/RED TO BATTERY OIL PRESSURE SWITCH BA BRN BLK RED R.H. TAIL--LIGHT L.H. TAIL--LIGHT BLK RED BRN ALTERNATOR 13A/BLK 43/BLU AB CBA 7400 MM428 (6--01) AB WATER TEMPERATURE SENDER ELECTRICAL SHEET 5 GAS/LPG WIRE HARNESS GROUP 4-15 4-16 B M5 2 72B/GRY 18U/BLK 71B/YEL B 3 13D/BLK 19B/BLU 4 64/BRN 70/GRN D.I.S. ENGINE HARNESS 5 DIODE ASSY COOLANT SENSOR MAIN HARNESS 4 DISTRIBUTORLESS IGNITION COIL A M4 AB SHEET 6 M6 M7 7 VARIBLE RELUCTANCE SENSOR VIEW A--A 18A/ORA 18A/ORA 18A/ORA 23C/GRY 23C/GRY 23C/GRY 18A/ORA 23B/GRY 21/GRY 66/BRN 62/YEL 93/ORA 10A/GRY M3 22/YEL 1F/RED 14/GRN 65/GRY 59/BRN 92/PUR 19/BLU 15A/BLU 19A/BLK 57/GRN 60/GRN 58/BLU M2 G 85 30 G TO MAIN HARNESS 13F/BLK CB A 71C/YEL 18C/ORA 72C/YEL SECTION B--B 87A 86 87 85 COIL+ 86 COIL -30 COMMON CONTACT 87 N.O. CONTACT 87A N.C. CONTACT FUEL PUMP INSTRUMENT PANEL HYD. SOLENOIDS ES PUMP HEADLIGHTS REVERSE UNIVERSAL ELECTRONIC SPARK CONTROL 65/BLU 66/GRN A M2 M3 M4 M5 M6 M7 RELAYS 24/PUR 25/GRY 25A/GRY 21/GRY 92/PUR 20C/BLU 20B/BLU VIEW G--G CB--3 72C/YEL 71C/YEL 70/GRN 13PP/BLK 18T/ORA 68/BRN 68/BRN 67/ORA 66/GRN 65/BLU CB--7 UNIVERSAL ELECTRONIC SPARK CONTROL 1 2 3 4 5 6 7 8 9 10 11 12 CB--8 21B/GRY 21A/GRY 59/BRN 59A/BRN CB--4 MAIN HARNESS CB--6 CB--2 20A/BLU CB--5 1E/RED 65/GRY 65A/GRY CB--1 22/YEL 4/YEL 4A/YEL 1C/RED 1F/RED 18/ORA 18C/ORA 20/BLU CB--1 IGNITION CB--2 ES PUMP CB--3 HEADLIGHTS CB--4 BACK--UP ALARM CB--5 HORN CB--6 INSTRUMENT PANEL (5.0A) CB--7 SCRUB SOLENOIDS CB--8 SIDE BRUSH SOLENOIDS AND WATER VALVES CIRCUIT BREAKERS ELECTRICAL 2 BA GAS/LPG WIRE HARNESS GROUP 7400 MM428 (6--01) ELECTRICAL BA AB SV3 BA AB SV4 AB SV7 24B/PUR BA SCRUB VALVE BLOCK 46A/BRN 24B/PUR 24B/PUR AB 48/GRY SV5 BA 47/BRN 46A/BRN 24B/PUR HYDRAULIC SOLENOID VALVES SV6 SV2 AB AB AB BA BA BA 45/GRY 24B/PUR 51C/PUR 25C/GRY 46A/BRN 24B/PUR MAIN HARNESS SV--1 SCRUB BRUSH ON SV--2 VACUUM FAN ON SV--3 SQUEEGEE DOWN SV--4 DOWN PRESS. PROPORTIONAL VALVE SV--5 SCRUB BRUSH DOWN SV--6 SIDE BRUSH ON SV--7 SCRUB BRUSH UP -- HOLD SV1 CONNECTOR WIRING 13 7 19 1 20 2 21 3 22 4 23 5 24 6 18 12 MAIN INSTRUMENT PANEL SOCKET REAR VIEW TO MAIN HARNESS P SOC. NO. 1 2 3 4 5 6 CONN. A. 23/GRY 21B/GRY 26/BRN 57/GRN 43/BLU 52/YEL 7 8 9 10 11 12 35/BRN 36/GRN 56/YEL 28/YEL 47/BRN 51/PUR 13 14 15 16 17 18 42/ORA 2/ORA 15/BLU 48/GRY 83/BRN 58/BLU 19 20 21 22 23 24 46/BRN 60/GRN 45/GRY 13U/BLK 13T/BLK 13S/BLK B 1A/RED 2/ORA 1B/RED L2 E EXC MANDO ALTERNATOR 60559 S 13A/BLK TO ENGINE BLOCK SHEET 7 GAS/LPG WIRE HARNESS GROUP 7400 MM428 (6--01) 4-17 ELECTRICAL SHEET 8 GAS/LPG WIRE HARNESS GROUP (OPTIONS) 4-18 7400 MM428 (6--01) 7400 MM428 (6--01) 13HH/BLK 89A/ORA BLK RED CIRCUIT 1 95/BLU VIEW B--B 25D/GRY WATER CONTROL SWITCH C 28/YEL A 18D/ORA 13E/BLK GOVERNOR CONTROL E H 85/BLU 86/PUR 83/BRN 84/GRN VIEW C--C D 71C/YEL 72C/YEL TO MAIN HARNESS BATTERY GAS AND DIESEL LOCATION ROT. LIGHT SEE OPTIONS SHEET 12 AUTO FILL REC TANK -- INNER SWITCH 13K/BLK NO NC 72E/GRN 20/BLU 1D/RED 7/YEL 10A/GRY 17 30 50 19 AC B 7A/YEL KEY SWITCH 13P/BLK FUEL PUMP 8/GRN 7/YEL E C 42A/YEL 42/YEL 13L/BLK E H HIGH GOVERNOR CONTROL C MAIN PANEL RELAYS CIRCUIT BREAKERS 14/GRN BRAKE SWITCH OPTION DIODE 46C/BRN 95/BLU SIDE BRUSH VALVE LOW OPTION FUEL SENDER SEE MAIN SCRUB VALVE HYD. FILTER SWITCH OPTIONS 4/YEL 5/YEL HORN SWITCH VIEW F--F WATER CONTROL 20D/BLU 10/GRY 1/RED TO ENGINE 13/BLK B SWITCH 84/GRN 86/PUR 8/GRN GLOW PLUGS F CIRCUIT 2 25D/GRY 25A/GRY 13B/BLK 13J/BLK BA 13Y/BLK ACTUATOR 10/GRY 1D/RED 1A/RED 1C/RED 1E/RED F 96/GRY ES PUMP DETERGENT PUMP A BC BACK--UP ALARM 13II/BLK 89B/ORA BLK RED CBA 13G/BLK 13DD/BLK 13X/BLK 13Y/BLK 13B/BLK 13P/BLK 13TT/BLK 13M/BLK 13N/BLK 13J/BLK 13R/BLK 36/GRN 13R/BLK MAGNETIC PICK--UP STARTER 1 62E/BRN RED BLK A BC 1/RED TO BATTERY BA BRN GRN REVERSE FLOW SWITCH 43/BLU SOLUTION SWITCHES 13A/BLK 15B/BLU R.H. TAIL--LIGHT L.H. TAIL--LIGHT 62D/BRN ALTERNATOR BRN SHEET 9 AB OIL PRESSURE SWITCH AB WATER TEMPERATURE SENDER 62A/YEL 62B/YEL 13DD/BLK 13CC/BLK WATER VALVE CONTROL 96/GRY 46/BRN 96B/GRY 46C/BRN 62/YEL 13H/BLK 62A/YEL 13CC/BLK 13H/BLK 5/YEL SIDE BRUSH VALVE OPTION LOW R.H. HEADLIGHT HORN L.H. HEADLIGHT ELECTRICAL DIESEL WIRE HARNESS GROUP 4-19 4-20 A M4 M5 M6 M7 2 B 3 13D/BLK 19B/BLU 4 2 5 MAIN HARNESS DIODE ASSY 6 7 ROTATED VIEW A--A 18A/ORA 18A/ORA 18A/ORA 23C/GRY 23C/GRY 23C/GRY 18A/ORA 23B/GRY 21/GRY 66/BRN 62/YEL 93/ORA 10A/GRY B M3 AB SHEET 10 14/GRN 22/YEL 1F/RED 65/GRY 59/BRN 92/PUR 57/GRN 60/GRN 58/BLU 15A/BLU 19/BLU 19A/BLK M2 A 85 87A 86 SECTION B--B 85 COIL+ 86 COIL -30 COMMON CONTACT 87 N.O. CONTACT 87A N.C. CONTACT 87 FUEL PUMP INSTRUMENT PANEL HYD. SOLENOIDS ES PUMP HEADLIGHTS REVERSE 30 M2 M3 M4 M5 M6 M7 RELAYS 24/PUR 25/GRY 25A/GRY 21/GRY 92/PUR 59/BRN 20C/BLU 20B/BLU CB--8 21A/GRY 59A/BRN 21B/GRY CB--4 CB--7 CB--3 MAIN HARNESS CB--6 CB--2 CB--5 18/ORA 18C/ORA 20/BLU 22/YEL 4/YEL 4A/YEL 1C/RED 1F/RED 65A/GRY CB--1 1E/RED 65/GRY 20A/BLU CB--1 IGNITION CB--2 ES PUMP CB--3 HEADLIGHTS CB--4 BACK--UP ALARM CB--5 HORN CB--6 INSTRUMENT PANEL (5.0A) CB--7 SCRUB SOLENOIDS CB--8 SIDE BRUSH SOLENOIDS AND WATER VALVES CIRCUIT BREAKERS ELECTRICAL BA DIESEL WIRE HARNESS GROUP 7400 MM428 (6--01) ELECTRICAL SCRUB VALVE BLOCK AB SV3 SV4 SV2 SV6 SV5 SV1 AB AB BA BA 24B/PUR 46A/BRN 24B/PUR HYDRAULIC SOLENOID VALVES SV--1 SCRUB BRUSH ON SV--2 VACUUM FAN ON SV--3 SQUEEGEE DOWN SV--4 DOWN PRESS. PROPORTIONAL VALVE SV--5 SCRUB BRUSH DOWN SV--6 SIDE BRUSH ON SV--7 SCRUB BRUSH UP -- HOLD AB BA AB 48/GRY BA 24B/PUR BA 47/BRN AB 24B/PUR 46A/BRN BA AB SV7 BA 24B/PUR 46A/BRN 51C/PUR 45/GRY 25C/GRY 24B/PUR MAIN HARNESS CONNECTOR WIRING 13 7 19 TO MAIN HARNESS P L2 20 2 21 3 22 4 23 TO ENGINE BLOCK 24 5 MANDO ALTERNATOR 60559 B 1A/RED 2/ORA 1 1B/RED EXC S E 13A/BLK 6 18 12 SHEET 11 MAIN INSTRUMENT PANEL SOCKET REAR VIEW SOC. NO. 1 2 3 4 5 6 CONN. A. 23/GRY 21B/GRY 26/BRN 57/GRN 43/BLU 52/YEL 7 8 9 10 11 12 35/BRN 36/GRN 56/YEL 28/YEL 47/BRN 51/PUR 13 14 15 16 17 18 42/ORA 2/ORA 15/BLU 48/GRY 83/BRN 58/BLU 19 20 21 22 23 24 46/BRN 60/GRN 45/GRY 13U/BLK 13T/BLK 13S/BLK DIESEL WIRE HARNESS GROUP 7400 MM428 (6--01) 4-21 4-22 13HH/BLK 89A/ORA BLK RED CIRCUIT 1 95/BLU VIEW B--B 25D/GRY WATER CONTROL SWITCH C 28/YEL A 18D/ORA 13E/BLK GOVERNOR CONTROL TO MAIN HARNESS BATTERY GAS AND DIESEL LOCATION ROT. LIGHT SEE OPTIONS SHEET 12 E H 85/BLU 86/PUR 83/BRN 84/GRN VIEW C--C D 71C/YEL 72C/YEL 72E/GRN AUTO FILL REC TANK -- INNER SWITCH 13K/BLK NO NC BA 13Y/BLK SWITCH 20/BLU 1D/RED 7/YEL 10A/GRY 17 30 50 19 AC B 7A/YEL KEY SWITCH 13P/BLK FUEL PUMP 8/GRN 7/YEL E C 42A/YEL 42/YEL 13L/BLK E H HIGH GOVERNOR CONTROL C MAIN PANEL RELAYS CIRCUIT BREAKERS 14/GRN BRAKE SWITCH OPTION DIODE 46C/BRN 95/BLU SIDE BRUSH VALVE LOW OPTION FUEL SENDER SEE MAIN SCRUB VALVE HYD. FILTER SWITCH OPTIONS 4/YEL 5/YEL HORN SWITCH VIEW F--F WATER CONTROL 20D/BLU 10/GRY 1/RED TO ENGINE 13/BLK B 8/GRN GLOW PLUGS 84/GRN 86/PUR ACTUATOR 10/GRY 1D/RED 1A/RED 1C/RED 1E/RED F CIRCUIT 2 25D/GRY 25A/GRY 13B/BLK 13J/BLK CBA 13G/BLK 13DD/BLK 13X/BLK 13Y/BLK 13B/BLK 13P/BLK 13TT/BLK 13M/BLK 13N/BLK 13J/BLK 13R/BLK 36/GRN 13R/BLK MAGNETIC PICK--UP STARTER F 96/GRY ES PUMP DETERGENT PUMP RED A BC BACK--UP ALARM 13II/BLK 89B/ORA RED BLK 62E/BRN REVERSE FLOW SWITCH GRN BLK A BC 15B/BLU 1 BRN SOLUTION SWITCHES 43/BLU 1/RED TO BATTERY BA R.H. TAIL--LIGHT L.H. TAIL--LIGHT 62D/BRN BRN ALTERNATOR 13A/BLK OIL PRESSURE SWITCH AB SHEET 12 AB WATER TEMPERATURE SENDER 62A/YEL 62B/YEL 13DD/BLK 13CC/BLK WATER VALVE CONTROL 96/GRY 46/BRN 96B/GRY 46C/BRN 62/YEL 13H/BLK 62A/YEL 13CC/BLK 13H/BLK 5/YEL SIDE BRUSH VALVE OPTION LOW R.H. HEADLIGHT HORN L.H. HEADLIGHT ELECTRICAL DIESEL WIRE HARNESS GROUP (OPTIONS) 7400 MM428 (6--01) ELECTRICAL DIAGNOSTICS The Model 7400 has an on--board diagnostic system. Each time the control board is powered up, it performs a self test. If the self test passes, the “OK” light is illuminated. This trouble shooting section describes the different operating modes that are available, how to enter that mode, and a detail description of how that mode works. 7400 MM428 (12--98) 4-23 ELECTRICAL OPERATING MODES The Model 7400 has 6 different operating modes. The machine operator can access each mode by pressing various buttons on the control panel, holding them, and turning on the key. The common operating modes are detailed in the following charts. Operating Modes Entry Sequence (how to activate) Normal Mode; Normal operation. More info pages 4--25 thru 4--27 Default (when key is turned on) Manual Mode; Manually operate discrete functions without interlocks. More info page 4--28 1. Push and hold the ES button 2. Turn on the key 3. Hold the ES button until the maintenance light comes on. 4. Release the ES button Input Display Mode; Display the state of floats, limit switches, and sensors. More info page 4--29 1. Push and hold the Squeegee button 2. Turn on the key 3. Hold the Squeegee button until the maintenance light comes on. 4. Release the Squeegee button Error Display Mode; Display the cause of a self--test failure. More info pages 4--30 thru 4--32 1. Push and hold the Detergent button 2. Turn on the key 3. Hold the Detergent button until the maintenance light comes on. 4. Release the Detergent button Pressure Adjust Mode; Adjust the pressure levels for the three down pressure settings. More info page 4--33 1. Push and hold the Side Brush button 2. Turn on the key 3. Hold the Side Brush button until the maintenance light comes on. 4. Release the Side Brush button Reset Scrub Pressures; Return the down pressure settings to the factory defaults. More info page 4--34 1. Push and hold the Scrub button 2. Turn on the key 3. Hold the scrub button 4. Wait for the maintenance light 5. While holding the Scrub button, press and hold the Side Brush button 6. Wait for the maintenance light to go out 7. Release the Scrub and Side Brush buttons 8. Turn the key off 9. Restart the machine 4-24 7400 MM428 (12--98) ELECTRICAL Operating Mode Normal Mode; Normal operation. Entry Sequence (how to activate) Default (when key is turned on) NORMAL MODE The purpose of the normal mode is for the general operation of the machine. The machine will normally start in this mode. What follows is a brief description of each of the operations in the normal mode. SCRUB BUTTON The purpose of the scrub button is to turn the scrubbing operations on and off and adjust the scrubbing down pressure. Pressing the scrub button while the scrubbing operation is currently inactive will initiate the following actions: 1. The engine speed will be set to high. 2. If the machine is not in reverse, the main brushes will turn on and lower. The down pressure setting will be the same used during the last scrub cycle. The solution will flow at the high or low rate according to the water position switch. 3. If the machine is in reverse, the brushes will stay up until reverse is no longer sensed. 4. If the side brush LED is on, the side brush will turn on and lower. The down pressure setting will be the same used during the last scrub cycle. 5. The vacuum fan will turn on. 6. If the machine is not in reverse, the squeegee will lower. 7. If the machine is in reverse, the squeegee will stay up until reverse is no longer sensed. 8. If any of the detergent LED’s are active, the water valves are turned on, and the machine is not in reverse, the detergent pump will run. The detergent pump will run at its slow rate if one LED is on. The detergent pump will run at its fast rate if two LED’s are on. 7400 MM428 (12--98) 4-25 ELECTRICAL SCRUB BUTTON (continued) If the operator pushes and holds the scrub button, the pressure settings will begin to scroll. The pressure settings displayed after releasing the scrub button will become the new default down pressure setting. If the scrub function was active and the operator pushes, then releases the scrub button, the following actions will take place: 1. The main brushes will turn off and rise. 2. The side brush will turn off and rise. 3. The solution flow will turn off. 4. The detergent pump will turn off. 5. A delay will pass, and then the squeegee will rise. 6. Another small delay will pass and the vacuum fan will turn off. SQUEEGEE BUTTON Pressing the squeegee button will start or stop the water pickup operation. If the operator presses the squeegee button while the squeegee LED is currently not illuminated will cause the following actions: 1. The squeegee LED will be illuminated. 2. The squeegee will drop and the vacuum fan will turn on, if the machine is not in reverse. If the machine goes into reverse while the squeegee is active, the squeegee will rise. Pressing the squeegee button while the squeegee LED is on will cause the following actions: 1. The squeegee LED will turn off. 2. The squeegee will raise. 3. There will be a 30 second delay. 4. The vacuum fan will turn off. 4-26 7400 MM428 (12--98) ELECTRICAL DETERGENT Pressing the detergent button will cause the detergent display to scroll through its three modes. The detergent pump will run only if the main scrub brushes are active and the solution switch is on. D Off (all LED’s off) -- detergent pump off. D Low (left LED is on) -- detergent pump on low. D High (both LED’s are on) -- detergent pump on high. ESt BUTTON Pressing the ESt button will enable or disable the ESt system. The ESt system will draw water from the recovery tank, through a filter and pump it into the solution tank. If the operator has turned on the ESt system, and the recovery tank ESt float reads a full tank, the ESt pump will begin to run. The ESt pump will continue to run for about 30 seconds after the ESt float becomes uncovered. OVERFLOW FLOAT In order for the recovery tank float to become active, it must be consistently in the up position for at least 10 seconds. If the scrub or vacuum fan are active and the tank full float becomes active, the following actions will occur: 1. The overflow light will begin to blink. 2. A one minute delay will pass. 3. The overflow light will stop blinking and stay on. 4. The Scrub and Squeegee functions will be canceled. 7400 MM428 (12--98) 4-27 ELECTRICAL Operating Mode Manual Mode; Manually operate discrete functions without interlocks. Entry Sequence (how to activate) 1. Push and hold the ESt button 2. Turn on the key 3. Hold the ESt button until the maintenance light comes on. 4. Release the ESt button MANUAL MODE The purpose of the manual mode is to allow the operator to exercise individual functions on the machine. NOTE: This mode disregards the effects of various interlocks. Do not scrub with the machine in this mode. FOR SAFETY: When Servicing Machine, Avoid Moving Parts. Do Not Wear Loose Jackets, Shirts, Or Sleeves. After entering the Manual Mode, the control buttons assume the following functions: ESt BUTTON Pressing the ESt button will toggle the ESt pump on or off. In the on position, the ESt pump will run regardless of the state of the floats. SIDE BRUSH BUTTON Pressing the Side Brush button will turn on and lower the side brush. If the main brush is off, the side brush will use the low pressure setting. SQUEEGEE BUTTON Pressing the Squeegee button will turn on the vacuum fan and lower the squeegee. Reverse is ignored. ENGINE BUTTON Pressing the Engine button will toggle the engine between high and low speed. SCRUB BUTTON Pressing the Scrub button will turn on and lower the main scrub head. Holding the Scrub button while scrub is active will cause the down pressure to scroll. DETERGENT BUTTON Pressing the Detergent button will cause the detergent LED’s to scroll. If no LED’s are on, the detergent pump will be off. If one LED is illuminated, the detergent pump will run in low speed. If both LED’s are on, the detergent pump will run in high speed. 4-28 7400 MM428 (12--98) ELECTRICAL Operating Mode Input Display Mode; Display the state of floats, limit switches, and sensors. Entry Sequence (how to activate) 1. Push and hold the Squeegee button 2. Turn on the key 3. Hold the Squeegee button until the maintenance light comes on. 4. Release the Squeegee button INPUT DISPLAY MODE In this mode, the operator can observe whether or not inputs to the panel are operating as intended. In the Input Display Mode, the segments of the gas gauge display the state of each input. If an input is open, the controller turns off the segment associated with that input. If an input is shorted to ground, the controller turns on the segment associated with that input. The operation of the Input Display Mode is as follows: D SEGMENT 0 -- Rightmost segment of the gas gauge. This segment displays the state of the ES float. This segment will illuminate when this input is shorted to ground. D SEGMENT 1 -- Second segment from the right of the gas gauge. This segment displays the state of the recovery tank float. This segment will be illuminated when this input is shorted to ground. D SEGMENT 2 -- Third segment from the right of the gas gauge. This segment displays the state of the reverse input. This segment will be illuminated when this input is shorted to ground. D SEGMENT 3 -- Forth segment from the right of the gas gauge. This segment displays the state of the forward input. This segment will be illuminated when this input is shorted to ground. D ENGINE TEMPERATURE LIGHT -- In the Input Display Mode, the engine temperature light will blink until the engine reaches operating temperature. 7400 MM428 (12--98) 4-29 ELECTRICAL Operating Mode Error Display Mode; Display the cause of a self--test failure. Entry Sequence (how to activate) 1. Push and hold the Detergent button 2. Turn on the key 3. Hold the Detergent button until the maintenance light comes on. 4. Release the Detergent button ERROR DISPLAY MODE Each time the operator starts the machine, the panel will run a self test on each output. If the panel passes the diagnostic, the “OK” indicator is illuminated. If the panel fails, a code is stored in a non volatile (preserved even after power down) memory. If the machine passes the diagnostic on the next startup cycle, the panel preserves the last failed code. In the Error Display Mode, the operator can obtain the error code stored after the last startup diagnostic failure. When the machine is in this mode, the LED’s on the operators panel will indicate which system experienced the failure. If the operator pushes the button associated with an illuminated LED, segments on the gas gauge will indicate which output failed and what type of failure occurred. The operation of the Error Display Mode is as follows: ESt LED Problem with the ESt output. If the operator pushes the headlight button in this mode, the panel will display one of the following codes: D SEGMENT 0 -- Rightmost segment of the gas gauge. This segment would indicate that the output was shorted to ground when the controller was expecting it to be open. D SEGMENT 0, 1 -- First and second segments from the right of the gas gauge. These segments would indicate that the output was open when the controller was trying to short it to ground. 4-30 7400 MM428 (12--98) ELECTRICAL SIDE BRUSH LED Problem with the side brush or side brush actuator outputs. If the operator pushes the side brush button in this mode, the panel would display one of the following codes: D SEGMENT 0 -- Rightmost segment of the gas gauge. This segment would indicate that the side brush actuator output was shorted to ground when the controller was expecting it to be open. D SEGMENT 0, 1 -- First and second segments from the right of the gas gauge. These segments would indicate that the side brush actuator output was open when the controller was trying to short it to ground. D SEGMENT 2 -- Third segment from the right of the gas gauge. This segment would indicate that the side brush motor output was shorted to ground when the controller was expecting it to be open. D SEGMENT 2, 3 -- Third and forth segments from the right of the gas gauge. These segments would indicate that the side brush motor output was open when the controller was trying to short it to ground. SQUEEGEE LED Problem with the squeegee actuator or vacuum fan motor outputs. If the operator pushes the squeegee button in this mode, the panel would display one of the following codes: D SEGMENT 0 -- Rightmost segment of the gas gauge. This segment would indicate that the squeegee actuator output was shorted to ground when the controller was expecting it to be open. D SEGMENT 0, 1 -- First and second segments from the right of the gas gauge. These segments would indicate that the squeegee actuator output was open when the controller was trying to short it to ground. D SEGMENT 2 -- Third segment from the right of the gas gauge. This segment would indicate that the vacuum fan motor output was shorted to ground when the controller was expecting it to be open. D SEGMENT 2, 3 -- Third and forth segments from the right of the gas gauge. These segments would indicate that the vacuum fan motor output was open when the controller was trying to short it to ground. 7400 MM428 (12--98) 4-31 ELECTRICAL SCRUB LED Problem with the main brush actuator or motor outputs. If the operator pushes the scrub button in this mode, the panel would display one of the following codes: D SEGMENT 0 -- Rightmost segment of the gas gauge. This segment would indicate that the main brush actuator output was shorted to ground when the controller was expecting it to be open. D SEGMENT 0, 1 -- First and second segments from the right of the gas gauge. These segments would indicate that the main brush actuator output was open when the controller was trying to short it to ground. D SEGMENT 2 -- Third segment from the right of the gas gauge. This segment would indicate that the main brush motor output was shorted to ground when the controller was expecting it to be open. D SEGMENT 2, 3 -- Third and forth segments from the right of the gas gauge. These segments would indicate that the main brush motor output was open when the controller was trying to short it to ground. DETERGENT LED Problem with the headlight or detergent pump outputs. If the operator pushes the detergent button in this mode, the panel would display one of the following codes: D SEGMENT 0 -- Rightmost segment of the gas gauge. This segment would indicate that the detergent pump output was shorted to ground when the controller was expecting it to be open. D SEGMENT 0, 1 -- First and second segments from the right of the gas gauge. These segments would indicate that the detergent pump output was open when the controller was trying to short it to ground. D SEGMENT 2 -- Third segment from the right of the gas gauge. This segment would indicate that the headlight output was shorted to ground when the controller was expecting it to be open. D SEGMENT 2, 3 -- Third and forth segments from the right of the gas gauge. These segments would indicate that the headlight pump output was open when the controller was trying to short it to ground. 4-32 7400 MM428 (12--98) ELECTRICAL Operating Mode Pressure Adjust Mode; Adjust the pressure levels for the three down pressure settings. Entry Sequence (how to activate) 1. Push and hold the Side Brush button 2. Turn on the key 3. Hold the Side Brush button until the maintenance light comes on. 4. Release the Side Brush button PRESSURE ADJUST MODE When the machine is in this mode, the operator can adjust the down pressures for the main and side brushes. When the operator adjusts down pressure number 3, pressures 1 and 2 are automatically calculated and stored. The operator may make independent adjustments to pressures 1 and 2 after storing number 3. These adjustments will influence only the currently displayed setting. The operator can change the pressure settings by pressing and holding the scrub button. When the side brush is inactive and the main brush is active, the operator can adjust the down pressure for the main brush. When the side brush and main brush are active, the operator can adjust the down pressure for the side brush. To store the new down pressure settings, turn off the Side Brush and Scrub Panel LEDs on the touch panel. Then turn off the key switch. The operation of the Pressure Adjust Mode is as follows: SCRUB BUTTON Pressing the Scrub button will start the normal scrub sequence. When scrub is active the following controls and displays take on alternate functions. D GAS GAUGE -- The gas gauge in the pressure adjust mode displays the relative down pressure of the main (when the side brush is inactive) or the side brush (when the side brush is active). D SQUEEGEE BUTTON -- Holding the squeegee button will decrease the down pressure. D DETERGENT BUTTON -- Holding the detergent button will increase the down pressure. NOTE: To return to the factory brush pressure settings, run RESET SCRUB PRESSURES from the Diagnostics menu. 7400 MM428 (12--98) 4-33 ELECTRICAL Operating Mode Reset Scrub Pressures; Return the down pressure settings to the factory defaults. Entry Sequence (how to activate) 1. Push and hold the Scrub button 2. Turn on the key 3. Hold the Scrub button 4. Wait for the maintenance light 5. While holding the Scrub button, press and hold the Side Brush button 6. Wait for the maintenance light to go out 7. Release the Scrub and Side Brush buttons 8. Turn the key off 9. Restart the machine RESET SCRUB PRESSURES When the machine goes into this mode, the controller replaces the current brush down pressure settings with factory defaults. To initiate, follow the entry sequence (how to activate). The pressures will automatically reset. 4-34 7400 MM428 (12--98) ELECTRICAL TROUBLESHOOTING The following troubleshooting section is organized with the section of the electrical schematic that pertains to that particular problem first, followed by the flow chart. 7400 MM428 (12--98) 4-35 ELECTRICAL INSTRUMENT PANEL DOES NOT POWER UP (SCHEMATIC) BATTERY 1/RED OPERATION: - KEY SWITCH ACTIVATES M3 AND M4 - M3 CONTACT SUPPLIES 14VDC TO INSTRUMENT PANEL (PIN 1) 13/BLK BATT. 30 50 17 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 20A/BLU 18/ORA 18A/ ORA 1E/ 22/ RED YEL CB--6 5.0A 85 30 M3 M3 86 19/BLU 23/GRY 1 BATTERY LINE 4-36 13D/BLK 19B/BLU 87 22 13S/BLK ELECTRONIC INSTRUMENT PANEL SWITCHED LINE 7400 MM428 (12--98) ELECTRICAL INSTRUMENT PANEL DOES NOT POWER UP (FLOW CHART) OPERATION: - KEY SWITCH ACTIVATES M3 AND M4 - M3 CONTACT SUPPLIES 14VDC TO INSTRUMENT PANEL (PIN 1) TURN KEY ON ENGINE NEED NOT BE RUNNING INSTALL NEW M3 RELAY REMOVE M3 RELAY NO VOLTAGE CHECK FOR BAT. VOLTAGE AT M3 (PIN 85) 18A/ORA WORKS DOES NOT WORK BATTERY VOLTAGE PROBLEM SOLVED NO VOLTAGE CHECK FOR BAT. VOLTAGE AT KEY SWITCH 20/BLU CHECK FOR BAT. VOLTAGE AT M3 (PIN 30) 22/YEL NO VOLTAGE CHECK FOR BAT. VOLTAGE AT KEY SWITCH 1D/RED BATTERY VOLTAGE WIRE 22/YEL, CB--6, OR 1E/RED ARE OPEN VOLTAGE VOLTAGE 20/BLUE, 18/ORA, OR CB--1 ARE OPEN NO VOLTAGE REPLACE KEY SWITCH CHECK CONTINUITY OF WIRES 19/BLU AND 13D/ BLK AND CHECK DIODE AT M3 (PIN 86) 19/BLU OPEN OK REPLACE DIODE OR REPAIR OPEN WIRES 1D/RED IS OPEN FROM BATTERY TO KEY SWITCH DISCONNECT INSTRUMENT PANEL CHECK CONTINUITY OF: 23/GREY FROM M3 (PIN 87) TO (PIN 1) OF PANEL 13S/BLACK FROM (PIN 22) OF PANEL TO BAT. NEG. OPEN WIRE REPAIR OR REPLACE OPEN WIRES 7400 MM428 (12--98) GOOD CONTINUITY REPLACE INSTRUMENT PANEL 4-37 ELECTRICAL SCRUB BRUSH WILL NOT TURN ON AND/OR DOWN (SCHEMATIC) BATTERY 1/RED OPERATION: - SCRUB IS SELECTED ON TOUCH PANEL - SCRUB SOLENOIDS ARE TURNED ON - HEAD WILL LOWER, BRUSHES WILL SPIN 13/BLK BATT. 30 50 17 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 18/ORA 85 M4 86 19A/BLU 18A/ ORA 85 1E/ 22/ RED YEL CB--6 5.0A M3 86 87 M3 23/GRY 1F/RED 21B/GRY M4 30 24B/PUR SV--1 SCRUB BR. ON VALVE 46A/BRN 24B/PUR SV--5 SCRUB BR. DOWN VALVE 46A/BRN 24B/PUR SV--7 SCRUB BR. UP HOLD VALVE 46A/BRN 24B/PUR SV--4 SCRUB BR. DN. FORCE PROP. VALVE 48/GRY 87 21/GRY 21B/ 24/ GRY PUR 24B/PUR CB--7 15 AMP 24B/PUR SV--3 SQUEEGEE DOWN VALVE 47/BRN SV--2 VAC FAN ON VALVE 45/GRY SV--6 SIDE BR. ON VALVE 4-38 13D/BLK 19/BLU 19B/BLU 30 ELECTRONIC INSTRUMENT 1 PANEL 22 23 24 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 2 46/ BRN 19 16 11 (4 SEC DELAY) 21 (8 SEC DELAY) REVERSE FLOW SWITCH 13R/BLK 8 36/GRN S--15 7400 MM428 (12--98) ELECTRICAL SCRUB BRUSH WILL NOT TURN ON AND/OR DOWN (FLOW CHART) OPERATION: - SCRUB IS SELECTED ON TOUCH PANEL - SCRUB SOLENOIDS ARE TURNED ON - HEAD WILL LOWER, BRUSHES WILL SPIN PANEL IS POWERED UP KEY IS ON ENGINE IS OFF NO CAN THE SCRUB BUTTON BE TURNED ON AND OFF ? YES REPLACE TOUCH PANEL FACE ENGINE IS ON ACTIVATE SQ. / VAC BUTTON DOES THE SQUEEGEE GO DOWN AND VAC FAN TURN ON ? NO STILL NOT TURNING ON/OFF YES ALL 24/PUR WIRES, 21B/GRY 21/GRY, 1F/RED, OR M4 CONTACTS ARE OPEN IS THE REC TANK LIGHT ON ? REPLACE INSTRUMENT PANEL YES NO ENGINE IS OFF KEY IS ON SCRUB SELECTED NO VOLTAGE DRAIN THE TANK DISCONNECT SOLENOIDS CHECK VOLTAGE AT SV--1, SV--5, SV--7, AND SV--4 FROM 24/PUR TO GROUND VOLTAGE WIRE 24/PUR FROM CB--7 TO SOLENOIDS SV--1, SV--5, SV--7, OR SV--4 IS OPEN ENGINE IS OFF KEY IS ON SCRUB SELECTED DISCONNECT SOLENOIDS CHECK VOLTAGE AT SV--1, SV--5, AND SV--7 VOLTAGE ON AT LEAST ONE SOLENOID FROM 24/PUR TO 46/BRN NO VOLTAGE AT ALL SOLENOIDS SOLENOID STILL DISCONNECTED TURN KEY SW. OFF THEN ON DOES THE ” OK” LIGHT COME ON ? 46/BRN IS OPEN FROM PANEL PIN TO SOLENOID WITHOUT VOLTAGE YES NO REPLACE INST. PANEL CONTINUED ON NEXT PAGE 7400 MM428 (12--98) WIRE 46/BRN IS SHORTED TO GROUND OPEN DISCONNECT INST. PANEL CHECK CONTINUITY OF WIRE 46/BRN FROM INST. PANEL HARNESS (PIN 19) TO GROUND WIRE 46/BRN IS OPEN FROM PANEL (PIN 19) CONTINUITY 4-39 ELECTRICAL CONTINUED FROM PREVIOUS PAGE KEY ON ENGINE OFF SCRUB SELECTED SV--4 DISCONNECTED CHECK VOLTAGE AT SV--4 FROM 24/PUR TO 48/BRN > 2 VOLTS NO VOLTAGE VOLTAGE SOLENOID STILL DISCONNECTED TURN KEY OFF, THEN ON DOES THE ”OK” LIGHT COME ON ? CHECK TO SEE IF ALL FOUR SOLENOIDS ARE ON----USE MAGNETISM TEST ON SV--1, SV--5, SV--7, AND SV--4 ALL ON YES NO ONE OR MORE NOT ACTIVATED HYDRAULIC PROBLEM KEY IS OFF DISCONNECT INSTRUMENT PANEL CHECK CONTINUITY FROM 48/GRY TO GROUND OPEN REPLACE PANEL WIRE 48/GRY IS OPEN FROM SV--4 TO INST. PANEL (PIN 16) CONTINUITY WIRE 48/GRY IS SHORTED TO GROUND REPLACE BAD SOLENOID 4-40 7400 MM428 (12--98) ELECTRICAL SQUEEGEE AND VACUUM FAN NOT TURNING ON AND GOING DOWN (SCHEMATIC) BATTERY 1/RED OPERATION: - SQ/VAC IS SELECTED ON TOUCH PANEL - WITH MACHINE IN FWD OF NEUT., SV-- 3 AND SV-- 2 ARE TURNED ON - SQ. LOWERS AND VAC TURNS ON 13/BLK BATT. 30 50 17 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 18/ORA 85 M4 86 18A/ ORA 19A/BLU 85 1E/ 22/ RED YEL CB--6 5.0A M3 86 M3 87 23/GRY 1F/RED 21B/GRY 30 M4 24B/PUR SV--1 SCRUB BR. ON VALVE 46A/BRN 24B/PUR SV--5 SCRUB BR. DOWN VALVE 46A/BRN 24B/PUR SV--7 SCRUB BR. UP HOLD VALVE 46A/BRN 24B/PUR SV--4 SCRUB BR. DN. FORCE PROP. VALVE 48/GRY 87 21/GRY 21B/ 24/ GRY PUR 24B/PUR CB--7 15 AMP 24B/PUR 7400 MM428 (12--98) 13D/BLK 19/BLU 19B/BLU 30 SV--3 SQUEEGEE DOWN VALVE 47/BRN SV--2 VAC FAN ON VALVE 45/GRY ELECTRONIC INSTRUMENT 1 PANEL 22 23 24 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 2 46/ BRN 19 16 11 (4 SEC DELAY) 21 (8 SEC DELAY) REVERSE FLOW SWITCH 13R/BLK 8 36/GRN S--15 4-41 ELECTRICAL SQUEEGEE AND VACUUM FAN NOT TURNING ON AND GOING DOWN (FLOW CHART) OPERATION: - SQ/VAC IS SELECTED ON TOUCH PANEL - WITH MACHINE IN FWD OF NEUT., SV-- 3 AND SV-- 2 ARE TURNED ON - SQ. LOWERS AND VAC TURNS ON PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING CAN THE SQ/VAC TOUCH PANEL BUTTON BE TURNED ON AND OFF? NO YES REPLACE TOUCH PANEL FACE GO INTO ”MANUAL MODE” THE OUTPUTS WILL TURN ON REGARDLESS OF THE INPUTS --TURN KEY OFF --PUSH AND HOLD ”ES” BUTTON --TURN KEY ON --KEEP HOLDING ”ES” BUTTON UNTIL THE MAINTENANCE LIGHT COMES ON --RELEASE ”ES” BUTTON YES STILL DOES NOT WORK REPLACE INST. PANEL DOES THE SQ. AND/OR VAC TURN ON/OFF WITH THE SQ/VAC BUTTON NOW ? NO NO VOLTAGE CHECK VOLTAGE AT SV--3 FROM 24P/PUR TO GRND. AND SV--2 FROM 24/PUR TO GRND. YES IS THE REC TANK FULL LIGHT ON ? VOLTAGE NO CHECK REVERSE INPUT --DISCONNECT INSTRUMENT PANEL --TURN ENGINE ON, MACHINE IN REVERSE --CHECK CONTINUITY AT THE INSTR. PANEL (PIN 8) FROM 36/GRN TO GROUND DRAIN TANK AND RE--TEST OPEN 24/PUR, 21/GRY, CB--7, OR M--4 CONTACTS ARE OPEN YES ELECTRONICS OK SEE HYDRAULIC TROUBLESHOOTING NO CONTINUITY VOLTAGE REPLACE THE PANEL 36/GRN, 13R/BLK, OR S--15 ARE OPEN NOTE: S--15 IS CLOSED IN REVERSE 4-42 --MANUAL MODE --ENGINE OFF --KEY ON --SQ/VAC SELECTED ”ON” ARE SV--2 AND SV--3 TURNED ON ? (USE MAGNETIZED TEST) REPLACE HYD. COIL THAT WILL NOT TURN ON----RE--TEST SYSTEM DISCONNECT HYD. COILS CHECK VOLTAGE ACROSS BOTH COILS, SV--2 FROM 24/PUR TO 45/GRY AND SV--3 FROM 24/PUR TO 47/BRN NO VOLTAGE CONTINUED ON NEXT PAGE 7400 MM428 (12--98) ELECTRICAL CONTINUED FROM PREVIOUS PAGE COILS STILL DISCONNECTED NO --TURN KEY OFF THEN ON IS THE ”OK” LIGHT ON ? YES KEY OFF PANEL DISCONNECTED CONTINUITY CHECK CONTINUITY OF 47/BRN AND 45/GRY TO GROUND WIRE 47/BRN OR WIRE 45/GRY ARE OPEN OPEN REMOVE THE SHORT TO GROUND ON 47/BRN AND/OR 45/GRY --RECONNECT PANEL --KEY OFF THEN ON DOES THE ”OK” PANEL LIGHT COME ON ? NO REPLACE INSTRUMENT PANEL 7400 MM428 (12--98) YES RE--TEST SYSTEM 4-43 ELECTRICAL SIDE BRUSH WILL NOT TURN ON AND GO DOWN (SCHEMATIC) BATTERY 1/RED OPERATION: - MACHINE MUST BE IN SCRUB MODE - SIDE BRUSH BUTTON IS ACTIVATED AND WILL TURN ON AND LOWER SIDE BRUSH - SV-- 6, SV-- 9, SV-- 8, SV-- 10, AND SV-- 11 WILL BE ON 13/BLK BATT. 30 50 17 19 CB--1 ACC 20/BLU 15A IGNITION SWITCH S--3 18/ORA 85 M4 86 18A/ ORA 19A/BLU 85 1E/ 22/ RED YEL CB--6 5.0A M3 86 87 M3 23/GRY 1F/RED M4 30 87 21/GRY 21A/ GRY SV--6 SIDE BR. ON VALVE 51C/PUR 51/PUR 25C/GRY SV--9 SIDE BR. OUT VALVE 25B/GRY SV--8 SIDE BR. DOWN VALVE 25/ GRY 25B/GRY CB--8 15 AMP 97/YEL S10 CIRCUIT 2 4-44 ELECTRONIC INSTRUMENT 1 PANEL 22 23 24 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 12 51A/PUR 51A/PUR SV--11 SIDE BR. UP HOLD VALVE 51A/PUR 25B/GRY CIRCUIT 1 S10 13D/BLK 19/BLU 19B/BLU 30 SV--14 SIDE BR. WATER VALVE 51B/PUR SV--12 LOW WATER VALVE 46B/BRN 96/GRY SV--13 HIGH WATER VALVE 46C/BRN 95/BLU SV--10 SIDE BR. DN. FORCE PROP. VALVE 52/YEL 25B/GRY 19 8 REVERSE FLOW SWITCH 13R/BLK 36/GRN S--15 6 (3 SEC. DELAY) 7400 MM428 (12--98) ELECTRICAL SIDE BRUSH WILL NOT TURN ON AND GO DOWN (FLOW CHART) OPERATION: - MACHINE MUST BE IN SCRUB MODE - SIDE BRUSH BUTTON IS ACTIVATED AND WILL TURN ON AND LOWER SIDE BRUSH - SV-- 6, SV-- 9, SV-- 8, SV-- 10, AND SV-- 11 WILL BE ON PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING CAN THE SCRUB AND SIDE BRUSH BUTTONS BE TURNED ON AND OFF NO YES REPLACE TOUCH PANEL FACE --ENGINE ON ACTIVATE THE SCRUB BUTTON DO THE SCRUB FUNCTIONS TURN ON ? NO GO TO SCRUB TROUBLESHOOTING FLOW CHART FIRST STILL DOES NOT WORK YES --ENGINE OFF --KEY ON --SCRUB SELECTED --SIDE BRUSH SELECTED CHECK VOLTAGE AT SV--6, SV--8, SV--9, SV--10, AND SV--11 FROM 25/GRY TO GROUND NO VOLTAGE ON ANY OR ALL REPLACE INST. PANEL VOLTAGE --ENGINE OFF --KEY ON --SCRUB SELECTED --SIDE BRUSH SELECTED --ALL FOUR SOLENOIDS DISCONNECTED CHECK VOLTAGE ACROSS SOLENOIDS SV--6, 8, 9, AND 11 FROM 25/GRY TO 51 PUR 25/GRY, 21A/GRY, OR CB--8 IS OPEN FROM SOLENOID TO M--4 (PIN 87) VOLTAGE ACROSS AT LEAST ONE SOLENOID VOLTAGE ACROSS ALL FOUR SOLENOIDS NO VOLTAGE ON ALL FOUR 51/PUR IS OPEN FROM PANEL (PIN 12) TO SOLENOID WITHOUT VOLTAGE --SOLENOIDS STILL DISCONNECTED --TURN KEY OFF, THEN ON DOES THE ”OK” LIGHT COME ON ? CONTINUED ON NEXT PAGE YES NO 51/PUR IS OPEN FROM PANEL TO ALL FOUR SOLENOID --DISCONNECT INSTRUMENT PANEL CHECK CONTINUITY OF 51/PUR FROM INSTR. PANEL (PIN 12) TO GROUND CONTINUITY WIRE 51/PUR IS SHORTED TO GROUND 7400 MM428 (12--98) OPEN REPLACE INST. PANEL 4-45 ELECTRICAL CONTINUED FROM PREVIOUS PAGE --KEY ON --ENGINE OFF --SCRUB AND SIDE BRUSH ON --SV--10 DISCONNECTED CHECK VOLTAGE AT SV--10 FROM 25/GRY TO 52/YEL > 2 VOLTS NO VOLTAGE VOLTAGE WITH SOLENOID STILL DISCONNECTED---TURN KEY OFF, THEN ON DOES THE :OK” LIGHT COME ON ? CHECK TO SEE IF ALL SOLENOIDS ARE TURNING ON USE THE MAGNETIC TEST NO YES ONE OR MORE OFF --KEY OFF PANEL DISCONNECTED CHECK CONTINUITY FROM 52/YEL TO GROUND WIRE 52/YEL IS OPEN FROM SV--10 TO INSTR. PANEL (PIN 6) REPLACE BAD SOLENOIDS OPEN ALL SOLENOIDS ON REPLACE INSTRUMENT PANEL CONTINUITY WIRE 52/YEL IS SHORTED TO GROUND HYDRAULIC PROBLEM SEE TROUBLESHOOTING 4-46 7400 MM428 (12--98) ELECTRICAL WATER VALVES NOT OPERATING (SCHEMATIC) OPERATION: - SCRUB FUNCTIONS MUST BE ON - WATER SWITCH IN POSITION #1 TURNS ON SV-- 12 LOW WATER VALVE AND SV-- 14 SIDE BRUSH VALVE - WATER SWITCH IN POSITION #2 TURNS ON SV-- 12, SV-- 14, AND SV-- 13 (HIGH WATER VALVE) BATTERY 1/RED 13/BLK BATT. 30 50 17 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 18/ORA 85 M4 86 18A/ ORA 19A/BLU 85 1E/ 22/ RED YEL CB--6 5.0A M3 86 87 M3 23/GRY 1F/RED M4 30 87 21/GRY 21A/ GRY SV--6 SIDE BR. ON VALVE 51C/PUR 51/PUR 25C/GRY SV--9 SIDE BR. OUT VALVE 25B/GRY SV--8 SIDE BR. DOWN VALVE 25/ GRY 25B/GRY CB--8 15 AMP 97/YEL S10 CIRCUIT 2 7400 MM428 (12--98) ELECTRONIC INSTRUMENT 1 PANEL 22 23 24 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 12 51A/PUR 51A/PUR SV--11 SIDE BR. UP HOLD VALVE 51A/PUR 25B/GRY CIRCUIT 1 S10 13D/BLK 19/BLU 19B/BLU 30 SV--14 SIDE BR. WATER VALVE 51B/PUR SV--12 LOW WATER VALVE 46B/BRN 96/GRY SV--13 HIGH WATER VALVE 46C/BRN 95/BLU SV--10 SIDE BR. DN. FORCE PROP. VALVE 52/YEL 25B/GRY 19 REVERSE FLOW SWITCH 13R/BLK 8 36/GRN S--15 6 (3 SEC. DELAY) 4-47 ELECTRICAL WATER VALVES NOT OPERATING (FLOW CHART) PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING OPERATION: - SCRUB FUNCTIONS MUST BE ON - WATER SWITCH IN POSITION #1 TURNS ON SV-- 12 LOW WATER VALVE AND SV-- 14 SIDE BRUSH VALVE - WATER SWITCH IN POSITION #2 TURNS ON SV-- 12, SV-- 14, AND SV-- 13 (HIGH WATER VALVE) ACTIVATE SCRUB AND SIDE BRUSH DO THEY BOTH TURN ON AND COME DOWN ? NO YES --ENGINE RUNNING --SCRUB AND SIDE BRUSH ON --WATER SWITCH ON POSITION #2 --SV--14, SV--12, AND SV--13 DISCONNECTED CHECK FOR VOLTAGE AT SV--14 FROM 97/YEL TO GROUND CHECK FOR VOLTAGE AT SV--12 FROM 96/GRY TO GROUND CHECK FOR VOLTAGE AT SV--13 FROM 95/BLU TO GROUND VOLTAGE ON ALL SOLENOIDS --KEY ON, ENGINE OFF --SOLENOIDS STILL DISCONNECTED --SCRUB AND SIDE BRUSH ON CHECK VOLTAGE AT SV--14 FROM 97/YEL TO 51B/PUR CHECK VOLTAGE AT SV--12 FROM 96/GRY TO 46B/BRN CHECK VOLTAGE AT SV--13 FROM 95/BLU TO 46C/BRN VOLTAGE ON ALL SOLENOIDS TROUBLESHOOT THE SCRUB FUNCTION AND SIDE BRUSH FUNCTION FIRST NO VOLTAGE ON ANY WIRES 97/YEL, 96/GRY, 95/BLU 25/GRY, OR SWITCH S--10 ARE OPEN FROM CB--8 TO SOLENOID WITH NO VOLTAGE NO VOLTAGE ON ANY --IF SV--14 IS NO VOLTAGE WIRE 51B/PUR FROM SV--14 TO (PIN 12) IS OPEN --IF SV--12 IS NO VOLTAGE WIRE 46B/BRN FROM SV--12 TO (PIN 19) IS OPEN --IF SV--13 IS NO VOLTAGE WIRE 46C/BRN FROM SV--13 TO (PIN 19) IS OPEN REPLACE ANY VALVE NOT OPERATING 4-48 7400 MM428 (12--98) ELECTRICAL HEAD LIGHTS WILL NOT TURN ON (SCHEMATIC) OPERATION: - (PIN 15) TO GROUND BY OIL PRESSURE SWITCH TURNS ON M6 BATTERY 1/RED 13/BLK 10A/GRY FUEL PUMP 14/GRN 18A/ORA 18A/ORA 15A/BLU M2 15B/BLU 13P/BLK 13B/BLK S--4 OIL SWITCH 18A/ ORA 1D/RED BATT. 30 50 85 22/ YEL M3 30 START 19/BLU 86 13D/BLK 87 M3 17 19 20/BLU ACC CB--1 15A IGNITION SWITCH S--3 20A/BLU 1E/ RED 1E/ RED 23/GRY ELECTRONIC INSTRUMENT 15 PANEL 1 LIGHTS 85 23C/GRY 24 86 M6 20 CB--3 15 AMP 62C/YEL 59/ BRN M6 62/YEL 89/ORG S--11 BRAKE SWITCH 7400 MM428 (12--98) REV/FLSH LIGHT LRC 62A/YEL 30 87 59A/BRN 13U/BLK 13S/BLK 13T/BLK 13Y/BLK 60/GRN CB--6 5.0A 20B/ BLU 22 23 15/BLU 62B/YEL HEADLIGHT L.H. 62E/BRN TAIL LHT R.H. 89B/ORA 62D/BRN 89A/ORA HEADLIGHT R.H. TAIL LHT L.H. 13KK/BLK 13CC/BLK 13DD/BLK 13II/ BLK 13HH/ BLK 4-49 ELECTRICAL HEAD LIGHTS WILL NOT TURN ON (FLOW CHART) OPERATION: - (PIN 15) TO GROUND BY OIL PRESSURE SWITCH TURNS ON M6 PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING CHECK VOLTAGE ON M6 AT (PIN 30) FROM 59/BRN TO GROUND NO VOLTAGE VOLTAGE WIRE 20B/BLU IS OPEN FROM KEY SWITCH TO CB--3 CHECK VOLTAGE AT M6 (PIN 87) FROM 59/BRN TO GROUND VOLTAGE NO VOLTAGE WORKS CHECK VOLTAGE AT HEAD LIGHTS FROM 62/YEL TO 13CC/BLK OR FROM 62A/YEL TO 13DD/BLK REPLACE M6 RELAY NO LIGHTS NO VOLTAGE PROBLEM SOLVED 62/YEL, 62A/YEL, 13CC/BLK, OR 13DD/ BLK ARE OPEN REMOVE M6 RELAY NO VOLTAGE CHECK VOLTAGE AT M6 (PIN 85) FROM 23C/GRY TO GROUND WIRE 23C/GRY IS OPEN FROM M6 (PIN 85) TO M3 (PIN 87) HEAD LIGHT IS BAD VOLTAGE IS THE ENGINE OIL PRESSURE WARNING LIGHT ”ON” ON THE INSTRUMENT PANEL ? YES NO OPEN WIRES 15/BLU, 13B/BLK, OR S--4 ARE OPEN, OR ENGINE OIL PRESSURE IS LOW DISCONNECT M6 AND CHECK CONTINUITY OF 60/GRN FROM M6 (PIN 86) TO INSTR. PANEL (PIN 20) CONTINUITY REPAIR 60/GRN NO --POWER OFF --DISCONNECT PANEL IS 60/GRN SHORTED TO GROUND ? NO DOES ”OK” LIGHT COME ON WHEN KEY IS TURNED ON ? YES YES REPLACE INSTR. PANEL REPAIR 60/GRN GROUND AT (PIN 15) REPLACE INSTR. PANEL 4-50 VOLTAGE --DISCONNECT THE INSTR. PANEL --START ENGINE CHECK FOR GROUND ON 15/BLU AT INSTR. PANEL ON (PIN 15) NO 15/BLU, S--4, OR 13B/BLK IS OPEN 7400 MM428 (12--98) ELECTRICAL ESt PUMP NOT WORKING (SCHEMATIC) OPERATION: - IF ESt IS SELECTED ON PANEL AND - S-- 17 AND S-- 18 CLOSE FOR 5 SECONDS - M5 RELAY WILL ACTIVATE, TURNING ON PUMP BATTERY 1/RED 13/BLK 10A/GRY 14/GRN 18A/ORA 18A/ORA M2 15A/BLU FUEL PUMP 13P/BLK 15B/BLU 13B/BLK S--4 OIL SWITCH 18A/ ORA 85 1D/RED 22/ YEL BATT. 30 M3 30 M3 86 19/BLU 13D/BLK 87 23/GRY 50 START 17 15/BLU 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 1E/ RED 20A/BLU 23/GRY ES PUMP 85 86 23C/GRY 57/GRN M5 1 15 ELECTRONIC INSTRUMENT PANEL 3 4 10 15/BLU RECOVERY SOLUTION TANK TANK 26/BRN 27/PUR 13K/BLK S--17 N.O.H.C. S--18 RECOVERY TANK 28/YEL S--8 22 23 24 20A/ BLU CB--2 15 AMP 7400 MM428 (12--98) M5 65/GRY 30 87 66/BRN N.C.H.O. N.C.H.O. 13J/BLK 13S/BLK 13T/BLK 13U/BLK 5 SEC. DELAY ES PUMP RUNS 30 SEC. 5 SEC. DELAY 1 MIN. TO VAC FAN SHUT--OFF 13Y/BLK ES PUMP MTR 13PP/BLK AUTO FILL 4-51 ELECTRICAL ESt PUMP NOT WORKING (FLOW CHART) OPERATION: - IF ESt IS SELECTED ON PANEL AND - S-- 17 AND S-- 18 CLOSE FOR 5 SECONDS - M5 RELAY WILL ACTIVATE, TURNING ON PUMP PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING CAN THE ES PUMP TOUCH PANEL BUTTON BE TURNED ON/OFF NO YES REPLACE TOUCH PANEL FACE GO INTO ”MANUAL MODE” THE OUTPUTS WILL TURN ON REGARDLESS OF THE INPUTS --TURN KEY OFF --PUSH AND HOLD ”ES” BUTTON --TURN KEY ON --KEEP HOLDING ”ES” BUTTON UNTIL THE MAINTENANCE LIGHT COMES ON --RELEASE ”ES” BUTTON INPUT KEY OFF YES DOES THE ES PUMP TURN ON AND OFF WITH THE ES BUTTON NOW ? CHECK FLOAT INPUT STILL DOES NOT WORK REPLACE INST. PANEL OUTPUT NO REPLACE M5 DISCONNECT INSTR. PANEL --CHECK FOR CONTINUITY AT INSTR. PANEL FROM 26/BRN (PIN 3) TO GROUND YES STILL NOT WORKING IN MANUAL MODE NO 26/BRN, S--17, 27/PUR, S--18, OR 13K/BLK OPEN NO VOLTAGE KEY ON PANEL CONNECTED YES GO TO INPUT MODE APPLY AND REMOVE GROUND TO (PIN 3) BY CLOSING S--17 AND S--18 CHECK VOLTAGE AT M5 (PIN 30) FROM 65/GRY TO GROUND 20A/BLU, CB--2, OR 65/GRY ARE OPEN FROM M5 (PIN 30) TO KEY SWITCH NO VOLTAGE SYSTEM O.K. VOLTAGE CHECK VOLTAGE AT M5 (PIN 85) FROM 23C/GRY TO GROUND NO 23C/GRY IS OPEN FROM M5 (PIN 85) TO M3 (PIN 87) REPLACE PANEL 4-52 VOLTAGE CONTINUED ON NEXT PAGE 7400 MM428 (12--98) ELECTRICAL CONTINUED FROM PREVIOUS PAGE WITH ES ON AND MACHINE IN MANUAL MODE CHECK VOLTAGE AT M5 (PIN 87) FROM WIRE 66/BRN TO GROUND VOLTAGE NO VOLTAGE WITH ES ON AND MACHINE IN MANUAL MODE CHECK VOLTAGE AT ES PUMP FROM 66/BRN TO 13PP/BLK WITH M5 REMOVED TURN KEY ON, THEN OFF IS ”OK” LIGHT ON ? NO VOLTAGE VOLTAGE YES NO 57/GRN IS OPEN FROM (PIN 4) ON INSTR. PANEL TO (PIN 86) WIRE 66/BRN OR 13PP/BLK ARE OPEN MOTOR BAD PANEL DISCONNECTED POWER OFF M5 REMOVED CHECK CONTINUITY FROM 57/GRN TO GROUND NO YES REPLACE PANEL REMOVE SHORT TO GROUND ON 57/GRN 7400 MM428 (12--98) 4-53 ELECTRICAL REVERSE LIGHT OR ALARM NOT WORKING (SCHEMATIC) OPERATION: - GROUND AT (PIN 8) WHEN MACHINE IS IN REVERSE - TURNS ON M7 - SUPPLIES POWER TO BACK-- UP ALARM/LIGHT BATTERY 1/RED 13/BLK 1D/RED BATT. 30 50 17 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 20A/BLU 18A/ 85 ORA 19/BLU M3 22/ YEL CB--6 5.0A 13D/BLK 86 87 30 M3 23/GRY 1 REVERSE 23C/GRY 85 86 22 23 24 58/BLU M7 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 18 ELECTRONIC INSTRUMENT PANEL 8 36/GRN ES PUMP MTR 13R/BLK S--15 20C/ BLU CB--4 15 AMP 4-54 M7 92/PUR 30 93/ORA REVERSE FLOW SWITCH FLASHER BACK--UP ALARM UNIT 13JJ/BLK 93A/ORA 87 94/YEL 13RR/BLK 93B/ORA 7400 MM428 (12--98) ELECTRICAL REVERSE LIGHT OR ALARM NOT WORKING (FLOW CHART) OPERATION: - GROUND AT (PIN 8) WHEN MACHINE IS IN REVERSE - TURNS ON M7 - SUPPLIES POWER TO BACK-- UP ALARM/LIGHT PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING DOES THE BACK--UP ALARM OR LIGHT WORK YES NO KEY ON NO VOLTAGE REPLACE M7 STILL NOT WORKING NO VOLTAGE CHECK THE VOLTAGE FROM THE ALARM OR LIGHT NOT WORKING TO GROUND VOLTAGE 93/ORA, 93B/ORA, 94/YEL OR FLASHER ARE OPEN REMOVE M7 AND CHECK VOLTAGE AT M7 (PIN 30) FROM 92/PUR TO GROUND VOLTAGE CHECK FOR VOLTAGE FROM ALARM OR LIGHTS WORKING WIRE OR 13JJ BLK, 13RR/BLK TO BATT POSITIVE VOLTAGE 92/PUR, 20C/BLU, OR CB--4 ARE OPEN NO VOLTAGE CHECK VOLTAGE AT M7 (PIN 85) FROM 23C/GRY TO GROUND REPLACE BAD ALARM OR FLASHER LIGHT REPAIR OR REPLACE 13JJ/BLK OR 13RR/BLK VOLTAGE 23C/GRY IS OPEN OPEN CHECK CONTINUITY OF WIRES 93/ORA, 93A/ORA, 93B/ORA, AND 94/YEL REPAIR OR REPLACE WIRES 93A/ORA, 93B/ORA, OR 94/YEL OK NO NO VOLTAGE M7 STILL REMOVED TURN KEY OFF THEN ON, IS ”OK LIGHT ON? YES POWER OFF DISCONNECT PANEL CHECK CONTINUITY ON WIRE 58/BLU TO GROUND YES 58/BLU IS SHORTED TO GROUND, REPAIR AND REPLACE 7400 MM428 (12--98) NO REPLACE PANEL CONTINUED ON NEXT PAGE 4-55 ELECTRICAL CONTINUED FROM PREVIOUS PAGE GO INTO ”INPUT” MODE IS THE 3RD SEGMENT FROM THE RIGHT TURNING ON WITH THE MACHINE RUNNING AND IN REVERSE ? NO YES DISCONNECT INSTR. PANEL WITH ENGINE RUNNING AND MACHINE IN REVERSE CHECK CONTINUITY AT INSTR. PANEL CONNECTOR (PIN 8) FROM 36/GRN TO GROUND WHEN MACHINE IS RUNNING --DISCONNECT PANEL --POWER OFF CHECK CONTINUITY OF 58/BLU CONTINUITY NO CONTINUITY CONTINUITY OPEN 36/GRN, 13R/BLK, OR S--15 ARE OPEN AND IN REVERSE REPLACE INSTR. PANEL REPLACE INSTR. PANEL REPAIR 58/BLU 4-56 7400 MM428 (12--98) ELECTRICAL DETERGENT METERING PUMP IS NOT OPERATING (SCHEMATIC) OPERATION: - PANEL DETERGENT BUTTON IS ACTIVE IN LOW OR HIGH POSITION - MACHINE IS IN SCRUB MODE - DETERGENT PUMP WILL BE TURNED ON WITH A PULSE WIDTH MODULATED SIGNAL BATTERY 1/RED 13/BLK 1D/RED BATT. 30 50 17 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 M3 18A/ 85 ORA 13D/BLK 86 22/ YEL CB--6 5.0A 19/BLU M3 87 30 23/GRY 1 22 23 24 23A/GRY MTR 56/ORA DETERGENT METERING 7400 MM428 (12--98) 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 9 ELECTRONIC INSTRUMENT PANEL 4-57 ELECTRICAL DETERGENT METERING PUMP IS NOT OPERATING (FLOW CHART) OPERATION: - PANEL DETERGENT BUTTON IS ACTIVE IN LOW OR HIGH POSITION - MACHINE IS IN SCRUB MODE - DETERGENT PUMP WILL BE TURNED ON WITH A PULSE WIDTH MODULATED SIGNAL PANEL IS POWERED UP KEY IS ON ENGINE IS RUNNING CAN THE DETERGENT METERING AND TOUCH PANEL SWITCHES BE TURNED ON AND OFF ? NO YES REPLACE TOUCH PANEL FACE GO INTO ”MANUAL MODE” THE OUTPUTS WILL TURN ON REGARDLESS OF THE INPUTS --TURN KEY OFF --PUSH AND HOLD ”ES” BUTTON --TURN KEY ON --KEEP HOLDING ”ES” BUTTON UNTIL THE MAINTENANCE LIGHT COMES ON --RELEASE ”ES” BUTTON ENGINE DOES NOT HAVE TO BE RUNNING SCRUB INPUTS YES STILL DOES NOT WORK REPLACE INST. PANEL DOES THE DETERGENT METERING PUMP TURN ON AND OFF WITH THE TOUCH PANEL SWITCH ? VERIFY THAT THE SCRUBBING SYSTEM IS FUNCTIONING IS 46/BRN AT INSTR. PANEL (PIN 19) GOING LOW AND TURNING ON SV--1, SV--5, AND SV--7 ? NO DISCONNECT DETERGENT PUMP NO VOLTAGE YES NO CHECK VOLTAGE AT DETERGENT PUMP FROM 23A/GRY TO GROUND VOLTAGE 23A/GRY IS OPEN FROM PUMP TO M3 (PIN 87) NO VOLTAGE TROUBLESHOOT SCRUB BRUSH SYSTEM FIRST --IN MANUAL MODE --KEY ON, ENGINE OFF CHECK VOLTAGE AT PUMP FROM WIRE 23A/ GRY TO 56/ORA VOLTAGE DETERGENT METERING TESTS OUT O.K. --POWER OFF --PANEL DISCONNECTED CHECK CONTINUITY OF 56/ORA FROM PANEL (PIN 9) TO PUMP CONTINUITY REPLACE PUMP OPEN REPAIR AND REPLACE 56/ORA REPLACE INST. PANEL 4-58 7400 MM428 (12--98) ELECTRICAL ALTERNATOR / BATTERY WARNING LIGHT STAYS ON WHEN ENGINE IS RUNNING (SCHEMATIC) M1 1B/RED MTR STARTER RELAY OUT 1A/RED 12V 13/BLK 540 C.C.A. BATTERY 1/RED 1E/RED OPERATION: - CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTERNATOR IS TURNED ON - BATTERY POSITIVE AT (PIN 14) TURNS OFF THE ALTERNATOR / BATTERY INDICATOR STARTER MOTOR 13A/BLK GND ALTERNATOR SENSE 55A MAX. CHARGE L2 1D/RED 1E/RED BATT. 30 50 START 18A/ 85 CB--1 ORA 15A 17 CB--6 5.0A 19 ACC 20/BLU IGNITION SWITCH S--3 7400 MM428 (12--98) 19/BLU M3 22/ YEL 13D/BLK 86 87 30 2/ORA M3 23/GRY ELECTRONIC INSTRUMENT 1 PANEL 14 22 23 24 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 4-59 ELECTRICAL ALTERNATOR / BATTERY WARNING LIGHT STAYS ON WHEN ENGINE IS RUNNING (FLOW CHART) OPERATION: - CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTERNATOR IS TURNED ON - BATTERY POSITIVE AT (PIN 14) TURNS OFF THE ALTERNATOR / BATTERY INDICATOR ENGINE RUNNING CHECK VOLTAGE FROM L2 AT ALTERNATOR TO GROUND VOLTAGE NO VOLTAGE NO VOLTAGE --ENGINE RUNNING --PANEL DISCONNECTED CHECK VOLTAGE OF WIRE 2/ORA AT (PIN 14) OF INSTR. PANEL VOLTAGE DISCONNECT INSTR. PANEL, THEN RECONNECT IF LIGHT STILL ON----REPLACE INSTR. PANEL WIRE 2/ORA IS OPEN KEY ON ENGINE OFF DISCONNECT WIRE 2/ORA AT THE ALTERNATOR TOUCH WIRE 2/ORA TO WIRE 1B/RED AT THE ALTERNATOR DOES THE ALTERNATOR LIGHT TURN OFF ? YES NO WIRE 2/ORA IS SHORTED TO BATTERY POSITIVE TIGHTEN ALTERNATOR BELT IF NECESSARY DOES LIGHT TURN OFF ? NO REPLACE ALTERNATOR 4-60 7400 MM428 (12--98) ELECTRICAL ALTERNATOR / BATTERY WARNING LIGHT WILL NOT TURN ON (SCHEMATIC) M1 1B/RED MTR STARTER RELAY OUT 1A/RED 12V 13/BLK 540 C.C.A. BATTERY 1/RED 1E/RED OPERATION: - CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTERNATOR IS TURNED ON - BATTERY POSITIVE AT (PIN 14) TURNS OFF THE ALTERNATOR / BATTERY INDICATOR STARTER MOTOR 13A/BLK 55A MAX. CHARGE GND ALTERNATOR SENSE L2 1D/RED 1E/RED BATT. 30 50 START 18A/ 85 CB--1 ORA 15A 17 CB--6 5.0A 19 ACC 20/BLU 19/BLU M3 22/ YEL 13D/BLK 86 87 30 2/ORA M3 23/GRY ELECTRONIC INSTRUMENT PANEL 1 14 IGNITION SWITCH S--3 7400 MM428 (12--98) 22 23 24 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 4-61 ELECTRICAL ALTERNATOR / BATTERY WARNING LIGHT WILL NOT TURN ON (FLOW CHART) OPERATION: - CONNECTION L2 ON ALTERNATOR GOES TO BATTERY POSITIVE WHEN ALTERNATOR IS TURNED ON - BATTERY POSITIVE AT (PIN 14) TURNS OFF THE ALTERNATOR / BATTERY INDICATOR KEY ON ENGINE OFF REMOVE 2/ORA FROM ALTERNATOR (PIN L2) GROUND WIRE 2/ORA DOES THE LIGHT TURN ON ? YES NO CHECK CONTINUITY 2/ORA FROM ALTERNATOR TO (PIN 14) OPEN ALTERNATOR IS SHORTED L2 TO BATTERY POSITIVE OR WIRE 2/ORA IS SHORTED TO BATTERY POSITIVE CONTINUITY REPLACE LAMP L8 INSIDE THE PANEL 4-62 REPAIR AND REPLACE 2/ORA 7400 MM428 (12--98) ELECTRICAL ENGINE TEMPERATURE LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) OPERATION: - 225 DEGREE F. SE-- 2 =<80 OHMS - COOLANT LIGHT TURNS ON 12V 13/BLK 540 C.C.A. BATTERY 1/RED 1D/RED 1E/RED BATT. 30 50 START 18A/ 85 CB--1 ORA 15A 17 ACC 22/ YEL CB--6 5.0A 19 19/BLU M3 13D/BLK 86 87 30 M3 20/BLU IGNITION SWITCH S--3 23/GRY 1 5 22 23 ELECTRONIC INSTRUMENT PANEL 7400 MM428 (12--98) 24 43/BLU COOLANT TEMP SE--2 SENDER 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 4-63 ELECTRICAL ENGINE TEMPERATURE LIGHT WILL NOT TURN ON (FLOW CHART) DOES THE LIGHT TURN ON MOMENTARILY AT POWER UP ? OPERATION: - 225 DEGREE F. SE-- 2 =<80 OHMS - COOLANT LIGHT TURNS ON NO YES DISCONNECT SE--2 AND GROUND WIRE 43/BLU DOES LIGHT TURN ON ? REPLACE LAMP L2 INSIDE PANEL RETEST NO STILL NOT TURNING ON AT POWER UP YES REPLACE INSTR. PANEL IF ENGINE TEMP IS LESS THAN 225 DEGREES REPLACE SE--2 SYSTEM IS OK WIRE 43/BLU IS OPEN FROM (PIN 5) TO SE--2 ENGINE TEMPERATURE LIGHT WILL NOT TURN OFF (FLOW CHART) OPERATION: - 225 DEGREE F. SE-- 2 =<80 OHMS - COOLANT LIGHT TURNS ON KEY ON ENGINE OFF DISCONNECT SE--2 LIGHT STILL ON LIGHT TURNS OFF POWER OFF IF ENGINE TEMP IS LESS THAN 225 DEGREES REPLACE SE--2 SYSTEM IS OK DISCONNECT PANEL DISCONNECT SE--2 CHECK CONTINUITY 43/BLU TO GROUND CONTINUITY OPEN REPLACE INSTR. PANEL 4-64 WIRE 43/BLU IS GROUNDED 7400 MM428 (12--98) ELECTRICAL HYDRAULIC (HIGH) PRESSURE INDICATOR LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) OPERATION: - WHEN S-- 14 CLOSES, LIGHT TURNS ON - THIS LIGHT IS AN OPTION 12V 13/BLK 540 C.C.A. BATTERY 1/RED 1D/RED 1E/RED BATT. 30 50 START 18A/ 85 CB--1 ORA 15A 17 ACC 22/ YEL CB--6 5.0A 19 19/BLU M3 13D/BLK 86 87 30 M3 20/BLU IGNITION SWITCH S--3 23/GRY 7 1 22 23 ELECTRONIC INSTRUMENT PANEL 7400 MM428 (12--98) 24 35/BRN HYDRAULIC 13N/BLK S--14 FILTER SWITCH 13S/BLK 13T/BLK 13U/BLK 13Y/BLK 4-65 ELECTRICAL HYDRAULIC (HIGH) PRESSURE INDICATOR LIGHT WILL NOT TURN ON (FLOW CHART) DOES THE LIGHT TURN ON MOMENTARILY AT POWER UP ? OPERATION: - WHEN S-- 14 CLOSES, LIGHT TURNS ON - THIS LIGHT IS AN OPTION NO YES REPLACE LAMP L5 INSIDE PANEL, THEN RETEST DISCONNECT S--14 AND GROUND WIRE 35/BRN DOES THE LIGHT COME ON ? YES DOES THE LIGHT TURN ON MOMENTARILY AT POWER UP ? NO REPLACE S--14 WIRE 35/BRN IS OPEN NO REPLACE INSTR. PANEL HYDRAULIC (HIGH) PRESSURE INDICATOR LIGHT WILL NOT TURN OFF (FLOW CHART) OPERATION: - WHEN S-- 14 CLOSES, LIGHT TURNS ON - THIS LIGHT IS AN OPTION KEY ON ENGINE OFF DISCONNECT S--14 DOES LIGHT TURN OFF ? YES IF HYDRAULIC SYSTEM OK REPLACE S--14 NO POWER OFF --DISCONNECT S--14 --DISCONNECT INSTR. PANEL CHECK CONTINUITY 35/BRN TO GROUND CONTINUITY OPEN REPLACE INSTR. PANEL 4-66 35/BRN IS SHORTED TO GROUND REPAIR AND REPLACE 35/BRN 7400 MM428 (12--98) ELECTRICAL ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) OPERATION: - (PIN 15) IS PULLED TO GROUND WHEN OIL PRESSURE IS HIGH ENOUGH - OIL LIGHT TURNS OFF BATTERY 1/RED 13/BLK 10A/GRY 18A/ORA FUEL PUMP 13P/BLK 14/GRN 18A/ORA M2 15A/BLU 15B/BLU 13B/BLK S--4 OIL SWITCH 18A/ ORA 85 1D/RED 22/ YEL BATT. 30 M3 30 86 19/BLU 13D/BLK 87 M3 23/GRY 50 START 17 15/BLU 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 1E/ RED 23/GRY ES PUMP 85 23C/GRY 86 57/GRN M5 1 15 ELECTRONIC INSTRUMENT PANEL 3 4 10 15/BLU RECOVERY SOLUTION TANK TANK 26/BRN 13K/BLK 27/PUR S--17 N.O.H.C. S--18 28/YEL RECOVERY TANK S--8 22 23 24 7400 MM428 (12--98) N.C.H.O. 5 SEC. DELAY ES PUMP RUNS 30 SEC. N.C.H.O. 13J/BLK 13S/BLK 13T/BLK 5 SEC. DELAY 1 MIN. TO VAC FAN SHUT--OFF 13Y/BLK 13U/BLK 4-67 ELECTRICAL ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN ON (FLOW CHART) DOES OIL LIGHT TURN ON MOMENTARILY AT POWER UP ? OPERATION: - (PIN 15) IS PULLED TO GROUND WHEN OIL PRESSURE IS HIGH ENOUGH - OIL LIGHT TURNS OFF NO YES REPLACE LAMP L1 INSIDE PANEL (PIN 15) IS GROUNDED CHECK OIL PRESSURE SWITCH OPERATION STILL NOT TURNING ON AT POWER UP REPLACE INSTR. PANEL ENGINE OIL PRESSURE WARNING LIGHT WILL NOT TURN OFF (FLOW CHART) OPERATION: - (PIN 15) IS PULLED TO GROUND WHEN OIL PRESSURE IS HIGH ENOUGH - OIL LIGHT TURNS OFF KEY ON ENGINE OFF DISCONNECT OIL PRESSURE SWITCH S--4 GROUND WIRE 15/BLU DOES LIGHT SHUT OFF ? YES NO WIRE 15/BLU IS OPEN FROM OIL PRESSURE SWITCH TO (PIN 15) 4-68 REPLACE OIL PRESSURE LIGHT 7400 MM428 (12--98) ELECTRICAL RECOVERY TANK FULL LIGHT WILL NOT TURN ON OR OFF (SCHEMATIC) OPERATION: - IF S-- 8 CLOSES, THE RECOVERY TANK IS FULL - THE RECOVERY TANK LIGHT COMES ON - SCRUB , SQUEEGEE, AND VACUUM FAN TURNS OFF BATTERY 1/RED 13/BLK 10A/GRY 18A/ORA FUEL PUMP 13P/BLK 14/GRN 18A/ORA M2 15A/BLU 15B/BLU 13B/BLK S--4 OIL SWITCH 18A/ ORA 85 1D/RED 22/ YEL BATT. 30 M3 30 M3 86 19/BLU 13D/BLK 87 23/GRY 50 START 17 15/BLU 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 1E/ RED 23/GRY 23C/GRY 15 15/BLU ELECTRONIC INSTRUMENT PANEL ES PUMP 85 1 86 57/GRN M5 4 10 28/YEL RECOVERY TANK S--8 22 23 24 7400 MM428 (12--98) N.C.H.O. 13J/BLK 13S/BLK 13T/BLK 5 SEC. DELAY 1 MIN. TO VAC FAN SHUT--OFF 13Y/BLK 13U/BLK 4-69 ELECTRICAL RECOVERY TANK FULL LIGHT WILL NOT TURN ON (FLOW CHART) DOES THE LIGHT TURN ON MOMENTARILY AT POWER UP ? OPERATION: - IF S-- 8 CLOSES, THE RECOVERY TANK IS FULL - THE RECOVERY TANK LIGHT COMES ON - SCRUB , SQUEEGEE, AND VACUUM FAN TURNS OFF NO YES REPLACE LAMP L4 INSIDE THE PANEL DISCONNECT S--8 GROUND WIRE 28/YEL DOES THE LIGHT TURN ON ? YES NO WHEN RECOVERY TANK IS FULL, S--8 IS NOT CLOSING OR 13J/BLK IS OPEN WIRE 28/YEL IS OPEN FROM S--8 TO PANEL (PIN 10) RECOVERY TANK FULL LIGHT WILL NOT TURN OFF (FLOW CHART) IF THE LIGHT IS STILL NOT TURNING ON MOMENTARILY AT POWER UP----REPLACE THE PANEL OPERATION: - IF S-- 8 CLOSES, THE RECOVERY TANK IS FULL - THE RECOVERY TANK LIGHT COMES ON - SCRUB , SQUEEGEE, AND VACUUM FAN TURNS OFF DISCONNECT S--8 DOES THE LIGHT TURN OFF ? YES NO RECOVERY TANK IS FULL SYSTEM OK, OR S--8 IS SHORTED --POWER OFF --DISCONNECT INSTR. PANEL DISCONNECT S--8 CHECK CONTINUITY FROM WIRE 28/YEL TO GROUND OPEN REPLACE INSTR. PANEL 4-70 CONTINUITY WIRE 28/YEL IS GROUNDED 7400 MM428 (12--98) ELECTRICAL FUEL GAUGE (GAS AND DIESEL) (SCHEMATIC) OPERATION: - S-- 6 IS NOT ON MACHINE - SE-- 1 GREATER THE 90 OHMS=FULL TANK - SE-- 1 LESS THAN 10 OHMS=EMPTY TANK BATTERY 1/RED 13/BLK 10A/GRY 14/GRN 18A/ORA 18A/ORA 15A/BLU 15B/BLU 13B/BLK S--4 OIL SWITCH 18A/ ORA 85 1D/RED 22/ YEL BATT. 30 M2 FUEL PUMP 13P/BLK M3 30 86 19/BLU 13D/BLK 87 M3 23/GRY 50 START 17 15/BLU 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 1E/ RED 23/GRY ES PUMP 85 23C/GRY 86 57/GRN 15 1 ELECTRONIC INSTRUMENT PANEL 42/YEL 13 42A/YEL SE--1 13L/BLK FUEL SENDER GAS--DIESEL 4 M5 22 23 24 7400 MM428 (12--98) 15/BLU 13S/BLK 13T/BLK 13Y/BLK 13U/BLK 4-71 ELECTRICAL FUEL GAUGE (GAS AND DIESEL) (FLOW CHART) OPERATION: - S-- 6 IS NOT ON MACHINE - SE-- 1 GREATER THE 90 OHMS=FULL TANK - SE-- 1 LESS THAN 10 OHMS=EMPTY TANK KEY ON ENGINE OFF YES DISCONNECT 42A/YEL AT SE--1 IS GAUGE FULL ON ? NO GROUND 42A/YEL AT SE--1 IS GAUGE FULL ON ? --POWER OFF --DISCONNECT SE--1 --DISCONNECT INSTR. PANEL CHECK CONTINUITY OF WIRE 42A/YEL TO GROUND OPEN REPLACE INSTR. PANEL YES NO CONTINUITY 42/YEL IS SHORTED TO GROUND IF GAUGE IS INACCURATE REPLACE THE FLOAT GAUGE STILL WAY OFF REPLACE INSTR. PANEL CHECK CONTINUITY OF 42/YEL OPEN OK REPLACE INSTR. PANEL REPAIR 42/YEL 4-72 7400 MM428 (12--98) ELECTRICAL FUEL GAUGE (LPG) (SCHEMATIC) OPERATION: - S-- 6 IS OPEN = GAUGE IS OFF - S-- 6 IS CLOSED = LEFT 2 SEGMENTS OF GAUGE FLASH - SE-- 1 IS NOT ON MACHINE BATTERY 1/RED 13/BLK 10A/GRY 18A/ORA M2 15A/BLU 15B/BLU 13B/BLK S--4 OIL SWITCH 18A/ ORA 19/BLU 85 M3 1D/RED 22/ YEL BATT. 30 FUEL PUMP 13P/BLK 14/GRN 18A/ORA 30 86 13D/BLK 87 M3 23/GRY 50 START 17 15/BLU 19 ACC 20/BLU CB--1 15A IGNITION SWITCH S--3 1E/ RED 23/GRY ES PUMP 85 23C/GRY 86 57/GRN 1 15 ELECTRONIC INSTRUMENT PANEL 42/YEL 13 4 42B/YEL S--6 M5 N.C.H.O. 22 23 24 7400 MM428 (12--98) 15/BLU LP 13M/BLK CLOSES BELOW 40 PSI C 13S/BLK 13T/BLK 13Y/BLK 13U/BLK 4-73 ELECTRICAL FUEL GAUGE (LPG) (FLOW CHART) OPERATION: - S-- 6 IS OPEN = GAUGE IS OFF - S-- 6 IS CLOSED = LEFT 2 SEGMENTS OF GAUGE FLASH - SE-- 1 IS NOT ON MACHINE KEY ON ENGINE OFF DISCONNECT S--6 IS GAUGE OFF ? YES NO CONTINUITY YES GROUND 42B/YEL AT S--6 IS GAUGE FLASHING ? --POWER OFF --DISCONNECT PANEL --DISCONNECT S--6 CHECK CONTINUITY OF 42B/YEL TO GROUND NO OPEN IF SYSTEM IS NOT WORKING PROPERLY---REPLACE S--6 42/YEL IS SHORTED TO GROUND REPLACE INSTR. PANEL --POWER OFF CHECK CONTINUITY OF 42B/YEL FROM S--6 TO PANEL (PIN 13) OPEN REPAIR 42 /YEL 4-74 CONTINUITY REPLACE INSTR. PANEL 7400 MM428 (12--98) HYDRAULICS CONTENTS Page HYDRAULIC FLUID RESERVOIR . . . . . . . . . . 5-3 HYDRAULIC FLUID . . . . . . . . . . . . . . . . . . . . . . 5-3 HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . 5-4 TO REPLACE DIRECTIONAL PEDAL CENTERING SPRING . . . . . . . . . . . . . . . . . 5-5 TO REPLACE DIRECTIONAL CONTROL CABLE . . . . . . . . . . . . . . . . . . . . 5-7 TO ADJUST CENTERING SPRING . . . . . 5-9 TO REPLACE PROPEL PUMP . . . . . . . . . . . 5-10 TO REPLACE ACCESSORY PUMP . . . . . . . 5-12 TO REPLACE STEERING CYLINDER . . . . . 5-14 TO REPLACE HYDRAULIC STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 TO REPLACE MAIN HYDRAULIC VALVE . . 5-16 TO REPLACE SIDE BRUSH HYDRAULIC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 TO REPLACE SOLENOID VALVE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . 5-20 TO REPLACE ENGINE COOLING FAN HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . 5-22 TO REPLACE MAIN SCRUB BRUSH HYDRAULIC MOTORS . . . . . . . . . . . . . . . 5-24 TO REPLACE SCRUB HEAD ASSEMBLY LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . 5-27 TO REPLACE OPTIONAL SIDE BRUSH HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . 5-28 TO REPLACE OPTIONAL SIDE BRUSH LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . 5-29 TO REPLACE OPTIONAL SIDE BRUSH SWING CYLINDER . . . . . . . . . . . . . . . . . . . 5-30 TO REPLACE SQUEEGEE LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 TO REPLACE VACUUM FAN HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . 5-35 HYDRAULIC HOSE GROUP . . . . . . . . . . . . . 5-37 HYDRAULIC HOSE GROUP/SIDE BRUSH OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 5-39 ENGINE FAN CIRCUIT (SCHEMATIC) . 5--40 ENGINE FAN SLOW OR DOESN’T RUN (FLOW CHART) . . . . . . . . . . . . . . . . . . 5--41 ENGINE FAN MOTOR SHAFT SEAL LEAKS (FLOW CHART) . . . . . . . . . . . 5--42 MAIN BRUSH ON CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . 5--44 MAIN BRUSHES DO NOT TURN ON (FLOW CHART) . . . . . . . . . . . . . . . . . . 5--45 MAIN BRUSHES DO NOT TURN OFF (FLOW CHART) . . . . . . . . . . . . . . . . . . 5--46 7400 MM428 (6--01) MAIN BRUSHES DO NOT LOWER (FLOW CHART) . . . . . . . . . . . . . . . . . . MAIN BRUSH LIFT CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . MAIN BRUSH LOWER CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . MAIN BRUSHES DO NOT RAISE (FLOW CHART) . . . . . . . . . . . . . . . . . . MAIN BRUSHES DO NOT STAY UP (FLOW CHART) . . . . . . . . . . . . . . . . . . SCRUB FAN CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . SCRUB FAN DOES NOT TURN ON (FLOW CHART) . . . . . . . . . . . . . . . . . . SCRUB FAN DOES NOT TURN OFF (FLOW CHART) . . . . . . . . . . . . . . . . . . SCRUB FAN MOTOR SHAFT SEAL LEAKS (FLOW CHART) . . . . . . . . . . . MAIN BRUSH ON CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT TURN ON (FLOW CHART) . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT TURN OFF (FLOW CHART) . . . . . . . . . . . . . . . . . . SIDE BRUSH EXTEND CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT GO OUT (FLOW CHART) . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT GO IN (FLOW CHART) . . . . . . . . . . . . . . . . . . SIDE BRUSH LOWER CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT STAY UP (FLOW CHART) . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT RAISE (FLOW CHART) . . . . . . . . . . . . . . . . . . SIDE BRUSH DOES NOT LOWER (FLOW CHART) . . . . . . . . . . . . . . . . . . SQUEEGEE LIFT CIRCUIT (SCHEMATIC) . . . . . . . . . . . . . . . . . . . SQUEEGEE DOES NOT LOWER (FLOW CHART) . . . . . . . . . . . . . . . . . . SQUEEGEE DOES NOT RAISE (FLOW CHART) . . . . . . . . . . . . . . . . . . SQUEEGEE DOES NOT STAY UP (FLOW CHART) . . . . . . . . . . . . . . . . . . STEERING CIRCUIT (SCHEMATIC) . . . EATON HYDRAULICS REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . Page 5--49 5--50 5--48 5--51 5--52 5--54 5--55 5--56 5--57 5--58 5--59 5--60 5--62 5--63 5--64 5--66 5--67 5--68 5--69 5--70 5--71 5--72 5--73 5--74 5--75 5-1 HYDRAULICS 5-2 7400 MM428 (12--98) HYDRAULICS INTRODUCTION The hydraulic system consists of the propel pump, accessory pump, control valve, drive motors, steering cylinder, and vacuum fan motor. 7400 MM428 (12--98) 5-3 HYDRAULICS HYDRAULIC FLUID RESERVOIR The reservoir is located in the front left corner of the machine. Mounted on top of the reservoir is a filler cap with a built-in breather and fluid level dipstick. Replace the cap every 800 hours of operation. Check the hydraulic fluid level at operating temperature every 100 hours of operation. Make sure the hopper is down when checking hydraulic fluid level. The end of the dipstick is marked with FULL and ADD levels to indicate the level of hydraulic fluid in the reservoir. Lubricate the filler cap gasket with a film of hydraulic fluid before putting the cap back on the reservoir. ATTENTION! Do not overfill the hydraulic fluid reservoir or operate the machine with a low level of hydraulic fluid in the reservoir. Damage to the machine hydraulic system may result. Drain and refill the hydraulic fluid reservoir with new hydraulic fluid every 800 hours of operation. The hydraulic fluid filter is located at the bottom of the engine compartment. Replace the filter element every 800 hours of operation. The reservoir has a built-in strainer outlet that filters hydraulic fluid before it enters the system. Replace the strainer every 800 hours of operation. HYDRAULIC FLUID The quality and condition of the hydraulic fluid play a very important role in how well the machine operates. Tennant’s hydraulic fluid is specially selected to meet the needs of Tennant machines. Tennant’s hydraulic fluids provide a longer life for the hydraulic components. There are two fluids available for different temperature ranges: Tennant part no. Ambient Temperature 65869 above 7_ C (45_ F) 65870 below 7_ C (45_ F) 5-4 7400 MM428 (12--98) HYDRAULICS The higher temperature fluid has a higher viscosity and should not be used at the lower temperatures. Damage to the hydraulic pumps may occur because of improper lubrication. The lower temperature fluid is a thinner fluid for colder temperatures. If a locally-available hydraulic fluid is used, make sure the specifications match Tennant hydraulic fluid specifications. Using substitute fluids can cause premature failure of hydraulic components. European manufactured machines are filled with locally available hydraulic fluids. Check the label on the hydraulic fluid reservoir. ATTENTION! Hydraulic components depend on system hydraulic fluid for internal lubrication. Malfunctions, accelerated wear, and damage will result if dirt or other contaminants enter the hydraulic system. HYDRAULIC HOSES Check the hydraulic hoses every 800 hours of operation for wear or damage. Fluid escaping at high pressure from a very small hole can be almost invisible, and can cause serious injuries. See a doctor at once if injury results from escaping hydraulic fluid. Serious infection or reaction can develop if proper medical treatment is not given immediately. FOR SAFETY: When servicing machine, use cardboard to locate leaking hydraulic fluid under pressure. If you discover a fluid leak, contact your mechanic/supervisor. 7400 MM428 (12--98) 5-5 HYDRAULICS TO REPLACE DIRECTIONAL PEDAL CENTERING SPRING FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Pivot the operators seat to the open position and engage the prop rod. 2. Disconnect the battery cables and remove the battery. 3. Locate the pedal centering spring on the right side of the accessory pump. 4. Remove the nyloc nut holding the centering spring balljoint to directional control arm on the propel pump. 5. Loosen the large jam nut holding the centering spring to the propel bracket. 6. Remove the spring assembly from bracket and position it up in the seat support area for disassembly access. 7. Remove the ball joint and jam nuts. 8. Unscrew the centering spring assembly from the directional control cable. Discard the old spring. NOTE: The cable will have to be held to keep it from turning 9. Thread a new centering spring assembly all the way back on the directional control cable. Leave 1/4 in. of threads showing on the larger diameter threads on the cable. 10. Install two 1/4 in. jam nuts on the end of the cable. Tighten one to the centering spring housing and the other one to the balljoint. Leave 1/16 in. between the two jam nuts. 11. Use the large jam nut to lock the centering spring assembly in place. 5-6 7400 MM428 (12--98) HYDRAULICS 12. Reinstall the spring assembly balljoint back in the directional control arm. Tighten the nyloc nut to 11 -- 14 Nm (7 -- 10 ft lb). 13. Reinstall the battery and reconnect the battery cables. 14. Jack up the front of the machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands 15. Check neutral centering of pump by starting machine and observing front tire for any rotation. If tire is rotating See TO ADJUST CENTERING SPRING instructions. 16. Once the neutral centering has been set, remove the jack stands, lower the machine, and close the operators seat. 7400 MM428 (12--98) 5-7 HYDRAULICS TO REPLACE DIRECTIONAL CONTROL CABLE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Pivot the operators seat to the open position and engage the prop rod. 2. Disconnect the battery cables and remove the battery. 3. Locate the pedal centering spring on the right side of the accessory pump. 4. Remove the hex screw and nyloc nut holding the centering spring balljoint to directional control arm on the propel pump. Retain the two steel sleeves. 5. Loosen the large jam nut holding the centering spring to the propel bracket. 6. Remove the spring assembly from the mount bracket and position it up in the seat support area for disassembly access. 7. Remove the ball joint and jam nuts. 8. Unscrew the centering spring assembly from the directional control cable. Retain the old centering spring. NOTE: The cable will have to be held to keep it from turning 9. Remove the two hex screw holding the floor plate in the operators compartment. Remove the floor plate. 10. Remove the clamp holding the directional cable to the operators compartment. 11. Reach in through the floor plate opening and remove the nyloc nut holding the directional control cable ball joint to the forward reverse pedal arm. Pull the directional control cable ball joint out of the pedal arm. 12. Loosen the large jam nut on the directional control cable. Drop the cable out of the slot. Remove the cable from the machine. 5-8 7400 MM428 (12--98) HYDRAULICS 13. Install the old centering spring assembly all the way back on the new directional control cable. Leave 1/4 in. of threads showing on the larger diameter threads on the cable. 14. Install two 1/4 in. jam nuts on the end of the cable. Tighten one to the centering spring housing and the other one to the balljoint. Leave 1/16 in. between the two jam nuts. 15. Reinstall the centering spring/directional cable assembly back in the machine. 16. Use the large jam nut to lock the centering spring assembly in place on the mount bracket. 17. Reinstall the spring assembly balljoint back on the directional control arm. Reinstall the hex screw, two steel sleeves, and nyloc nut. Tighten to 11 -- 14 Nm (7 -- 10 ft lb). 18. Reach in through the floor plate opening and reinstall the cable ball joint in the forward reverse pedal arm. Reinstall the nyloc nut and tighten to 11 -- 14 Nm (7 -- 10 ft lb). 19. Use the large jam nut to lock the directional cable in place on the mount bracket. 20. Reinstall the cable clamp that holds the directional cable to the operators compartment. 21. Reinstall the battery and reconnect the battery cables. 22. Jack up the front of the machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 23. Check neutral centering of pump by starting machine and observing front tire for any rotation. If tire is rotating See TO ADJUST CENTERING SPRING instructions. 24. Once the neutral centering has been set, remove the jack stands, lower the machine, and close the operators seat. 7400 MM428 (12--98) 5-9 HYDRAULICS TO ADJUST CENTERING SPRING FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine. 1. Jack up the front of the machine. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands 2. Check the neutral centering of the pump by starting the machine and observing the front tire for any rotation. 3. If tire is rotating, shut off the engine. Pivot the operators seat to the open position and engage the prop rod. 4. Locate the centering spring adjustment bracket on the right side of the accessory pump. Loosen the two M6 hex screws on top of the bracket. 5. Loosen the two jam nuts on the hex screw that is used to move the adjustment bracket back and forth. 6. Start the machine and observe the front tire for any rotation. If the tire is rotating in either direction, move the adjustment bracket backward or forward until rotation stops. Re--tighten the two jam nuts. Shut off the engine. 7. Once all the rotation has been eliminated, tighten the two M6 hex screws that hold the two brackets together. Tighten to 11 -- 14 Nm (7 -- 10 ft lb). 8. Lower the operators seat. 9. Remove the jack stands and lower the machine to the ground. 5-10 7400 MM428 (12--98) HYDRAULICS TO REPLACE PROPEL PUMP FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Pivot the operators seat to the open position and engage the prop rod. 2. Disconnect the battery cables and remove the battery. NOTE: The battery tray can also be removed for better access to the propel pump 3. Remove the detergent tank and the rubber sound flap from the machine. 4. Disconnect the tension spring leading from the directional spring bracket to the brush wrap. 5. Remove the two hex screws holding the accessory pump to the propel pump. 6. Lift the directional spring bracket up far enough to allow accessory pump removal. NOTE: The main suction line to the accessory pump is held, by plastic ties, in a bundle of hoses near the main valve. Remove the plastic ties to gain slack in the suction line to ease pump removal. 7. The accessory pump can now be pulled out of the propel pump. Do not disconnect the hydraulic hoses leading to the accessory pump. 8. Mark, remove, and plug the hydraulic hoses leading to the propel pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 9. Remove the one socket screw holding the propel pump directional arm and hub to the pump shaft. Remove the hub and arm from the pump. NOTE: The pump shaft is tapered so the hub may need to be removed with a puller. 10. Remove the two hex screws holding the propel pump to the engine bellhousing. 7400 MM428 (12--98) 5-11 HYDRAULICS 11. Pull the propel pump out of the bellhousing and drive coupler. Remove the pump from the machine. 12. Remove the fittings from the old propel pump and install in the new pump in the same orientation. 13. Place grease on the splines of the new pump and install back in the machine. 14. Reinstall the two hex screws and washers. Use a small amount of blue loctite 242 on the threads. Tighten to 31 -- 40 Nm (27 -- 35 ft lb). 15. Reinstall the propel pump directional arm and hub to the pump shaft. Reinstall the socket screw. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 16. Reconnect the hydraulic hoses to the propel pump. See the schematic in this section. 17. Reinstall the accessory pump in the back of the propel pump. Make sure the O--ring is in place on the accessory pump. 18. Place the directional spring bracket back on the flange of the accessory pump. 19. Reinstall the two hex screws and washers. Use a small amount of blue loctite 242 on the threads. Tighten to 31 -- 40 Nm (27 -- 35 ft lb). 20. Reconnect the tension spring to the brush wrap and directional spring bracket. 21. Reinstall the detergent tank in the seat support area. 22. Reinstall the battery and reconnect the battery cables. 23. Start the machine. Check the propel pump for leaks and proper operation. 5-12 7400 MM428 (12--98) HYDRAULICS TO REPLACE ACCESSORY PUMP FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Pivot the operators seat to the open position and engage the prop rod. 2. Disconnect the battery cables and remove the battery. 3. Remove the detergent tank from the machine. 4. Disconnect the tension spring leading from the directional spring bracket to the brush wrap. 5. Mark, remove, and plug the hydraulic hoses leading to the accessory pump. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6. Remove the two hex screws holding the accessory pump to the propel pump. 7. Lift the directional spring bracket up far enough to allow accessory pump removal. 8. The accessory pump can now be pulled back out of the propel pump. Remove the accessory pump from the machine. 9. Remove the fittings from the old accessory pump and install in the new pump in the same orientation. 10. Place grease on the splines of the new pump and install back in the machine. 11. Position the accessory pump back in the propel pump. Make sure the O--ring is in place on the accessory pump. 7400 MM428 (12--98) 5-13 HYDRAULICS 12. Reinstall the two hex screws and washers. Use a small amount of blue loctite 242 on the threads. Place the directional spring bracket back under the bolt heads. Tighten to 31 -- 40 Nm (27 -- 35 ft lb). 13. Reconnect the hydraulic hoses to the accessory pump. See the schematic in this section. 14. Reconnect the tension spring to the brush wrap and directional spring bracket. 15. Reinstall the detergent tank in the seat support area. 16. Reinstall the battery and reconnect the battery cables. 17. Start the machine. Check the accessory pump for leaks and proper operation. TO REPLACE STEERING CYLINDER FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Turn the steering wheel to the left and open the machine front cover. 2. Mark, remove, and plug the two hydraulic hoses leading to the steering cylinder. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5-14 7400 MM428 (12--98) HYDRAULICS 3. Remove the clamp holding the drive motor hoses to the drive motor casting. Move the hoses to gain access to steering cylinder attachment hardware. 4. Remove the large hex screw and nyloc nut holding the rod end of the steering cylinder to drive motor casting. Retain the spacer under the ball end. 5. Remove the large hex screw and nyloc nut holding the piston end of the steering cylinder to the machine frame. 6. Remove the steering cylinder from the machine. 7. Remove the fittings from the old cylinder and install in the new cylinder in the same orientation. 8. Position new cylinder and balljoint assembly back in the machine with rod end pointed toward the drive motor casting. 9. Reinstall the hex screw, spacer, and nyloc nut in the rod end of the steering cylinder and through the drive motor casting. Tighten to 271 Nm (200 ft lb). 10. Reinstall the hex screw and nyloc nut in the piston end of the steering cylinder and through the machine frame. Tighten to 271 Nm (200 ft lb). 11. Reconnect the hydraulic hoses to the steering cylinder. See schematic in this section. 12. Reinstall the clamp holding the drive motor hoses to the front casting. Tighten the hardware to 18 -- 24 Nm (15 -- 20 ft lb). 13. Start the machine and operate the steering. Check for any leaks and proper operation. Close the front cover. 7400 MM428 (12--98) 5-15 HYDRAULICS TO REPLACE HYDRAULIC STEERING VALVE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the machine front cover. 2. Mark, remove, and plug the five hydraulic hoses leading to the steering control valve. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 3. Remove the four M6 hex screws holding the steering control valve to the steering column. 4. Pull the steering valve out of the steering column and remove it from the machine. 5. Remove the hydraulic fittings from old control valve and install in the new valve in the same orientation. 6. Install the new steering valve back in the machine. Position the ports in the same orientation as the old valve. Reinstall the four M6 hex screws and tighten to 8 -- 10 Nm (5 -- 7 ft lb). 7. Reconnect hydraulic hoses to steering valve. See schematic in this section. 8. Start the machine and operate the steering. Check for any leaks and proper operation. 5-16 7400 MM428 (12--98) HYDRAULICS TO REPLACE MAIN HYDRAULIC VALVE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 3. If the machine is an LPG, remove the LP tank from the cradle. 4. Locate the main hydraulic valve under the vacuum fan. Disconnect the 7 electrical solenoids on the main valve from the main harness. 5. Mark, remove, and plug the hydraulic hoses leading to the main hydraulic valve. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6. Remove the three M8 hex screws holding the main valve to the machine frame. 7. The main valve can now be removed from the machine. 8. Remove the hex screws holding the main valve to the mount bracket. 9. Remove hydraulic fittings from the old valve and install in the new valve in the same orientation. 10. Reinstall the mount bracket on the new valve. Reinstall the three M8 hex screws and washers. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 7400 MM428 (12--98) 5-17 HYDRAULICS 11. Position the new valve back in the machine. Reinstall the three M8 hex screws and washers. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 12. Reconnect the hydraulic hoses to the main valve. See schematic in this section. 13. Reconnect the 7 electric solenoids to the main harness. See ELECTRICAL section. 14. Reinstall the LP tank. 15. Reinstall the engine side door. 16. Reconnect the battery cables and close the operators seat. 17. Start the machine and check the main valve for any leaks. 5-18 7400 MM428 (12--98) HYDRAULICS TO REPLACE SIDE BRUSH HYDRAULIC VALVE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 3. If the machine is an LPG, remove the LP tank from the cradle. 4. Locate the side brush hydraulic valve under the LP/gas tank cradle. Disconnect the 4 electrical solenoids from the main harness. 5. Mark, remove, and plug the hydraulic hoses leading to the side brush valve. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 6. Remove the three M8 hex screws holding the side brush valve to the LP tank cradle. 7. The side brush valve can now be removed from the machine. 8. Remove hydraulic fittings from the old valve and install in the new valve in the same orientation. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 9. Position the new valve back in the machine. Reinstall the three M8 hex screws and washers. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 7400 MM428 (12--98) C7 DR2 C6 P6 C8 P5 C5 5-19 HYDRAULICS 10. Reconnect the hydraulic hoses to the side brush valve. See schematic in this section. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 11. Reconnect the 4 electric solenoids to the main harness. See ELECTRICAL section. 12. Reinstall the LP tank. 13. Reinstall the engine side door. 14. Reconnect the battery cables and close the operators seat. 15. Start the machine and check the side brush valve for any leaks. 5-20 7400 MM428 (12--98) HYDRAULICS TO REPLACE SOLENOID VALVE CARTRIDGE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 3. If the machine is an LPG, remove the LP tank from the cradle. 4. Locate and identify the cartridge to be removed. Unplug the solenoid from the main harness. 5. Remove the hex nut and rubber O--ring from the cartridge stem. NOTE: The port marked SV--4 on the main valve and the port marked SV--10 on the side brush valve contain an extra washer on the cartridge stem between the top nut and O--ring. 6. Slide the electrical coil and rubber o--ring off the stem. NOTE: Oil will run out of valve when the cartridge is removed. 7. Loosen and unscrew the cartridge stem out of the valve body. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. Install a new or rebuilt cartridge stem back in the port. Tighten to 47 Nm (35 ft lb). NOTE: Make sure the new cartridge had an O--ring installed and oiled. 9. Slip the O--ring and coil back over the stem. 7400 MM428 (12--98) 5-21 HYDRAULICS 10. Install the 0--ring and hex nut on the stem and tighten to 170 Ncm (15 in lb). 11. Reconnect the coil to the main harness. See schematic in Electrical section. 12. Reinstall the LP tank. 13. Reinstall the engine side door. 14. Reconnect the battery cables and close the operators seat. 15. Start the machine and check the side brush valve for any leaks. 5-22 7400 MM428 (12--98) HYDRAULICS TO REPLACE ENGINE COOLING FAN HYDRAULIC MOTOR FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the engine cover and side door. 2. Remove the hose from the vacuum fan and recovery tank. 3. Remove the air cleaner hose from the air cleaner and carburetor. 4. Mark, disconnect, and plug the three hydraulic hoses going to the fan motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5. Remove the hydraulic fittings from the fan motor. Note the orientation of the fittings for proper reassembly in the new motor. 6. Reach in through the fan blades and remove the four M6 hex screws holding the fan blade to the motor hub. Set the fan blade down in the fan air chamber. 7. Remove the 5/16 in. nut and washer holding the fan blade hub to the motor shaft. Remove the hub from the shaft. Retain the square key from the motor shaft. NOTE: The fan blade hub is on a tapered shaft and may need to be pried off the motor. 8. Remove the two M10 hex screws and nyloc nuts holding the fan motor to the mount bracket. Remove the fan motor from the machine. 9. Install the new fan motor on the mount bracket. Reinstall the M10 hex screws and nyloc nuts (nylocs positioned on the motor side). Tighten to 37 -- 48 Nm (26 -- 34 ft lb). NOTE: The notch in the mount bracket is for the motor fitting. 10. Install the square key on the fan motor shaft. NOTE: A small amount of super glue helps keep the key in place when installing the fan hub. 7400 MM428 (12--98) 5-23 HYDRAULICS 11. Install the fan hub on the motor shaft. Reinstall the 5/16 in. nut and tighten to 18 -- 24 Nm (15 -- 20 ft lb). NOTE: Make sure key is in place on motor shaft. 12. Reinstall the fan blade back on the fan hub. The deep side of the fan blade points to the back of the machine. Reinstall the four M6 hex screws and tighten to 7.9 -- 9.9 Nm (6 -- 7 ft lb). 13. Reinstall the hydraulic fittings in the fan motor in the same orientation as they were removed. 14. Reconnect the hydraulic hoses to the fan motor. See schematic in this section. 15. Reinstall the air cleaner hose and vacuum fan hose. 16. Reconnect the engine cover outer gas spring to lower ball. 17. Start machine and check for leaks. Check the engine fan for proper rotation. (air blows out the back of machine). 5-24 7400 MM428 (12--98) HYDRAULICS TO REPLACE MAIN SCRUB BRUSH HYDRAULIC MOTORS 1. Place the main scrub brushes in the raised position. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Open the LH brush door. 3. Remove the front ball joint on the leveling rod from the machine frame. 4. Remove the two hair pins from the brush wrap attachment pins. 5. Remove the three hex screws holding the side squeegee assembly to the motor mount plate. Remove the side squeegee. 6. Remove the M12 hex screw holding the brush idler plate arm to the lift tube. NOTE: For better access to the hydraulic drive motors----remove the C--clip and brush arm from the motor plate. 7. Mark, disconnect, and plug the three hydraulic hoses leading to the main brush drive motors. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 8. Remove the motor mount plate assembly from the machine. 9. Turn the motor plate assembly over. Remove the cotter pins, castle nuts, and washers from the drive plugs. 10. Use a puller to remove the drive plug from the brush motors. Remove and retain the square key. 11. Remove the steel hydraulic tube running between the brush drive motors. 7400 MM428 (12--98) 5-25 HYDRAULICS 12. Remove the four hex screws holding each brush motor to the motor plate. NOTE: Make sure to note the orientation of the motor and fittings before removing the motors from the plate. 13. Remove the fittings from the old motor and install in the new motor in the same orientation. 14. Install the new brush motor and fittings in the motor plate in the same orientation as the old motor. 15. Reinstall the four hex screws and tighten to 37 -- 48 Nm (26 -- 34 ft lb). 16. Reinstall the steel hydraulic tube running between the brush drive motors. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 17. Reinstall the square key on the tapered motor shaft. Put a small amount of grease on the taper of the shaft. 18. Reinstall the drive plugs, washers, and castle nuts. Hold the plug from turning and tighten the castle nut down to 37 -- 48 Nm (26 -- 34 ft lb) and then until the slot in the nut lines up with the hole in the shaft. Install a new cotter pin. 19. Position the motor plate assembly back in the machine. NOTE: Lift up on the brush wrap slightly when installing the motor plate in the machine so the attachment pins line up with the holes in the plate. 20. Reinstall the two hair pins in the brush wrap attachment pins. 21. Reconnect the hydraulic hoses to the brush motors. See schematic in this section. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 22. Reinstall the brush arm and C--clip to the motor plate if they were removed earlier. 23. Align the two pins on the lift tube with the two holes in the brush arm. 5-26 7400 MM428 (12--98) HYDRAULICS 24. Reinstall the M12 hex screw in the brush arm. Tighten to 64 -- 83 Nm (47 -- 61 ft lb). NOTE: Apply a small amount of grease to the threads on the bolt and in the tube. 25. Reinstall the front of the leveling rod ball joint to the machine frame. 26. Reinstall the side squeegee assembly to the motor plate. Tighten the three hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 27. Close the LH brush door and operate the machine. Check the main brush motors for proper operation. 7400 MM428 (12--98) 5-27 HYDRAULICS TO REPLACE SCRUB HEAD ASSEMBLY LIFT CYLINDER 1. Start the engine and drop the main scrub brushes down until they just touch the floor. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Jack up the front of the machine and install jack stands under the frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 3. Go under the machine on the LH side. 4. Locate the lift cylinder on the left side of the front scrub brush. 5. Mark, disconnect, and plug the two hydraulic hoses going to the lift cylinder. 6. Remove the two cotter pins and clevis pins. 7. Remove the lift cylinder from the machine. 8. Remove the hydraulic fittings from the lift cylinder and install in the new cylinder in the same orientation. 9. Install the new cylinder in the machine. NOTE: The rod end of the cylinder points down. 10. Reinstall the upper and lower clevis and cotter pins. 11. Reconnect the hydraulic hoses to the new lift cylinder. See schematic in this section. 12. Remove the jack stands and lower the machine. 13. Start the machine and check the scrub head lift cylinder for proper operation. 5-28 7400 MM428 (12--98) HYDRAULICS TO REPLACE OPTIONAL SIDE BRUSH HYDRAULIC MOTOR 1. Remove the side brush. See TO REPLACE OPTIONAL SIDE BRUSH instructions in the SCRUBBING section. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 2. Remove the four hex screws holding the side brush guard to the machine frame. 3. Remove the hex screw holding the side brush drive hub to the side brush motor. Remove the drive hub from the motor. 4. Mark, disconnect, and plug the two hydraulic hoses going to the side brush motor. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5. Remove the four hex screws holding the side brush motor to the mount plate. 6. Lift the motor straight up, tilt back, and remove it from the side brush assembly. NOTE: Make sure to note the orientation of the motor to the mount plate. 7. Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation. 8. Position the new motor back in the side brush assembly. 9. Reinstall the four hex screws and tighten to 37 -- 48 Nm (26 -- 34 ft lb). 10. Reconnect the hydraulic hoses to the motor. See schematic in this section. 11. Reinstall the drive hub, washers, and hex screw. Tighten to 18 -- 24 Nm (15 -- 20 ft lb). 12. Reinstall the side brush. See TO REPLACE OPTIONAL SIDE BRUSH instructions. 13. Reinstall the side brush guard to the machine frame. Tighten the four hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 14. Operate the machine and check the side brush for proper operation. 7400 MM428 (12--98) 5-29 HYDRAULICS TO REPLACE OPTIONAL SIDE BRUSH LIFT CYLINDER 1. Remove the side brush. See TO REPLACE OPTIONAL SIDE BRUSH instructions. 2. Remove the four hex screws holding the side brush guard to the machine frame. 3. Remove the side brush hydraulic motor. See TO REPLACE OPTIONAL SIDE BRUSH HYDRAULIC MOTOR instructions. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 4. Mark, disconnect, and plug the two hydraulic hoses going to the lift cylinder. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 5. Remove the two cotter pins and clevis pins holding the lift cylinder to the side brush assembly. Remove the lift cylinder from the machine. NOTE: Make sure to note the orientation of the cylinder to the mount plate. 6. Remove the hydraulic fittings from the old cylinder and install in the new cylinder in the same orientation. 7. Position the new cylinder back in the side brush assembly. 8. Reconnect the hydraulic hoses to the cylinder. See schematic in this section. 9. Reinstall the side brush motor in the machine. See TO REPLACE OPTIONAL SIDE BRUSH HYDRAULIC MOTOR instructions. 10. Reinstall the side brush. See TO REPLACE OPTIONAL SIDE BRUSH instructions in the SCRUBBING section. 11. Reinstall the side brush guard to the machine frame. Tighten the four hex screws to 37 -- 48 Nm (26 -- 34 ft lb). 12. Operate the machine and check the side brush lift cylinder for proper operation. 5-30 7400 MM428 (12--98) HYDRAULICS TO REPLACE OPTIONAL SIDE BRUSH SWING CYLINDER FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Open the front cover on the machine. 2. Locate the swing cylinder down in front of the operators compartment. 3. Mark, disconnect, and plug the two hydraulic hoses going to the swing cylinder. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 4. Remove the cotter pin and clevis pin holding the rod end of the swing cylinder to the threaded sleeve and ball joint assembly. 5. Remove the cotter pin and clevis pin holding the other end of the swing cylinder to the machine frame. 6. Pull the swing cylinder back out of the threaded sleeve and remove it from the machine. 7. Remove the hydraulic fittings from the old cylinder and install in the new cylinder in the same orientation. 8. Position the new cylinder back in the side brush assembly. Position the rod end of the cylinder back in the threaded sleeve first, then install the clevis and cotter pin in the other end. 9. Reinstall the clevis and cotter pin in the rod end of the swing cylinder and through the hole in the threaded sleeve. 10. Reconnect the hydraulic hoses to the cylinder. See schematic in this section. 11. Operate the machine and check the side brush swing cylinder for proper operation. 7400 MM428 (12--98) 5-31 HYDRAULICS TO REPLACE SQUEEGEE LIFT CYLINDER 1. Open the debris tray latch and swing the squeegee assembly out for better access. 2. Start engine, lower rear squeegee, shut off engine. FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 3. Mark, disconnect, and plug the two hydraulic hoses going to the squeegee lift cylinder. NOTE: Observe hydraulic cleanliness requirements when opening hydraulic lines. 4. Remove the snap retaining ring from the pin on the debris tray at piston end of the cylinder. NOTE: The cylinder pin DOES NOT have a snap ring grove. 5. Remove the cotter pin and clevis pin from the rod end of lift cylinder and squeegee lift bellcrank. 6. The cylinder can now be pulled up and off the pin and removed from the machine. 7. Remove the hydraulic fittings from the old cylinder and install in the new cylinder in the same orientation. 8. Position new cylinder back in the machine. Place the hole in the piston end of the cylinder on the pin on the debris tray. Reinstall the snap ring retainer on the pin. NOTE: The cylinder pin DOES NOT have a snap ring grove. 9. Align the hole in rod end of the cylinder with the hole in squeegee lift bellcrank. Reinstall the clevis and cotter pin. 10. Reconnect the hydraulic hoses to the squeegee lift cylinder. See schematic in this section. 11. Start the machine and raise the squeegee. Swing the squeegee assembly back in. Check the lift cylinder for proper operation. 5-32 7400 MM428 (12--98) HYDRAULICS TO REPLACE VACUUM FAN HYDRAULIC MOTOR FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Remove the vacuum fan from the machine. See TO REMOVE VACUUM FAN instructions in the SCRUBBING section. 2. Place the vacuum fan assembly in a vice or some other holding device. 3. Remove the six hex screws holding the front housing to the rear housing. Remove the the front housing. NOTE: Mark the front housing in relation to the rear housing so it can be re--assembled correctly. 4. Remove the crown nut on the impeller shaft. Slide the impeller off the shaft. NOTE: Remove and save the key and any shims that are on the motor shaft, under the impeller. 5. Turn the housing over and remove the four nyloc nuts and washers from the motor mount plate. Remove the motor mount plate from the housing. NOTE: Note the orientation of hydraulic motor and fittings for proper re--assembly. 6. Remove the four flat head screws and nyloc nuts holding the hydraulic motor to the mount plate. Remove the old motor. 7. Install the new motor on the plate. Reinstall the flat head screws. Tighten to 9 -- 13 Nm (7 -- 10 ft lb). 8. Remove the hydraulic fittings from the old motor and install in the new motor in the same orientation. 7400 MM428 (12--98) 5-33 HYDRAULICS 9. Reinstall the motor and mounting plate on the rear housing. Reinstall the four nyloc nuts and tighten to 16 -- 22 Nm (12 -- 16 ft lb). NOTE: Be sure the square key is on the motor shaft. Super gluing the key to the shaft helps keep it in place when installing the impeller. 10. Turn the housing over and reinstall shims, key, fan impeller, and crown nut. Tighten nut to 34 -- 47 Nm (25 -- 35 ft lb). NOTE: Use a small amount of blue loctite 242 on the motor shaft threads. 11. Reinstall the front housing on the rear housing. Reinstall the six hex screws and tighten to 22 -- 27 Nm (16 -- 20 ft lb). NOTE: Tennant part no. 57543 plastic shims must be used for proper fan to housing clearance. Remove these shims after housing hardware has been tightened. 12. Reinstall the vacuum fan assembly in the machine. See TO INSTALL VACUUM FAN instructions in the SCRUBBING section. 5-34 7400 MM428 (12--98) HYDRAULICS AB C D F G H I E HYDRAULIC SCHEMATIC 7400 MM428 (6--01) 5-35 HYDRAULICS A B C D E F G H I S-- 14 HYDRAULIC SCHEMATIC 5-36 7400 MM428 (6--01) HYDRAULICS Front 6 Reservoir 3 7 Steering Valve T ER L P 1 4 IN OUT Vac Fan Filter 9 2 11 17 1 15 25 1 T2 20 21 18 M3 P7 T5 P3 DR1 P2 Control Valve 1 M2 G1 M1 T1 P1 T4 T3 C1 C3 C4 C2 Wheel Drive Motor 1 26 13 14 24 Flow Sensor Switch 19 8 Scrub Head Lift Cylinder 16 Cooling Fan Motor 7 23 Scrub Brush Motors 10 Pump 22 Rear SqueegeeLift Cylinder 5 Cooler 12 HYDRAULIC HOSE GROUP 7400 MM428 (6--01) 5-37 HYDRAULICS C7 C4 DR1 C2 C1 P3 MAIN CONTROL VALVE C3 G3 T4 T3 T5 SIDE BRUSH VALVE C8 C5 P5 C6 DR2 P6 VACUUM FAN MOTOR G1 M3 P2 M2 T2 M1 T1 P1 SIDE BRUSH LIFT CYL SIDE BRUSH MOTOR SIDE BRUSH SWING CYL HYDRAULIC HOSE GROUP / SIDE BRUSH OPTION 5-38 7400 MM428 (6--01) HYDRAULICS TROUBLESHOOTING The following troubleshooting section is organized with the section of the hydraulic schematic pertaining to that particular problem first, followed by the flow chart. 7400 MM428 (12--98) 5-39 HYDRAULICS ENGINE FAN CIRCUIT (SCHEMATIC) 400 PSI 3.7GPM x ENGINE FAN T RV7 1160 PSI E R L P PRESSURE SUCTION RETURN CASE DRAIN 3.7 GPM PRESSURE READINGS BASED ON 150 F M 2400 RPM RV6 85 PSI STRAINER RV3 3 PSI 5-40 7400 MM428 (12--98) HYDRAULICS ENGINE FAN SLOW OR DOESN’T RUN (FLOW CHART) YES MOTOR INLET FLOW OK? REPAIR OR REPLACE MOTOR NO YES NO STEERING INLET PRESSURE OK? REPAIR OR REPLACE STEERING CONTROL PLUMBING OK? REPAIR OR REPLACE PLUMBING YES NO NO PUMP OUTLET FLOW OK? REPAIR OR REPLACE PUMP 7400 MM428 (12--98) 5-41 HYDRAULICS ENGINE FAN MOTOR SHAFT SEAL LEAKS (FLOW CHART) YES REPAIR OR REPLACE MOTOR 5-42 MOTOR CASE PRESSURE OK? < 25 PSI NO REPAIR OR REPLACE CASE DRAIN PLUMBING & MOTOR 7400 MM428 (12--98) HYDRAULICS 7400 MM428 (12--98) 5-43 HYDRAULICS MAIN BRUSH ON CIRCUIT (SCHEMATIC) P3 DR1 SV03 C1 C2 P7 SV07 C4 PR1 300 PSI G2 PRESSURE SUCTION RETURN CASE DRAIN G5 SV05 C3 G4 M3 SV04 S.BR. SV06 OPT PRESSURE READINGS BASED ON 150 F M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P2 P1 T4 T3 T1 M1 MAIN BRUSHES G1 LEVEL #1 400 PSI LEVEL #2 550 PSI LEVEL #3 700 PSI 8.3 GPM 8.5 GPM LEVEL #1 800 PSI LEVEL #2 1000 PSI LEVEL #3 1300 PSI 8.4 GPM x x STRAINER FILTER RV3 3 PSI 5-44 7400 MM428 (12--98) HYDRAULICS MAIN BRUSHES DO NOT TURN ON (FLOW CHART) NO SV1 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES YES MOTOR INLET FLOW OK? REPAIR OR REPLACE MOTOR PUMP OUTLET FLOW OK? REPAIR OR REPLACE PUMP NO REPAIR OR REPLACE SV1 STEM CARTRIDGE NO YES NO SV1 STEM CARTRIDGE SHIFTING OK? PLUMBING OK? YES NO NO REPAIR OR REPLACE PLUMBING RV1 RELIEF CARTRIDGE OK? 2500 PSI REPAIR OR REPLACE RV1 RELIEF CARTRIDGE 7400 MM428 (12--98) 5-45 HYDRAULICS MAIN BRUSHES DO NOT TURN OFF (FLOW CHART) YES CHECK ELECTRICAL SYSTEM SV1 STEM MAGNETIZED? NO SV1 STEM CARTRIDGE SHIFTING OK? NO REPAIR OR REPLACE SV1 STEM CARTRIDGE 5-46 7400 MM428 (12--98) HYDRAULICS 7400 MM428 (12--98) 5-47 HYDRAULICS MAIN BRUSH LOWER CIRCUIT (SCHEMATIC) P3 DR1 SV03 C1 C2 P7 SV07 C4 PR1 300 PSI G2 G5 SV05 G4 M3 SV04 S.BR. SV06 OPT MAIN BRUSH LIFT x C3 LOWER LEVEL #1 350 PSI LEVEL #2 500 PSI LEVEL #3 650 PSI M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P1 8.5 GPM P2 T4 T3 T1 M1 MAIN BRUSHES G1 PRESSURE SUCTION RETURN CASE DRAIN PRESSURE READINGS BASED ON 150 F STRAINER RV3 3 PSI 5-48 7400 MM428 (12--98) HYDRAULICS MAIN BRUSHES DO NOT LOWER (FLOW CHART) NO SV4, SV5 & SV7 STEMS MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES YES C3 PORT PRESSURE OK? 460 -- 730 PSI G5 PORT PRESSURE OK? 300 PSI NO NO YES NO SV7 STEM CARTRIDGE SHIFTING OK? SV5 STEM CARTRIDGE SHIFTING OK? REPAIR OR REPLACE SV5 STEM CARTRIDGE NO REPAIR OR REPLACE PR1 STEM CARTRIDGE REPAIR OR REPLACE SV7 STEM CARTRIDGE 7400 MM428 (12--98) NO G4 PORT PRESSURE OK? 460 -- 730 PSI REPLACE SV4 STEM CARTRIDGE 5-49 HYDRAULICS MAIN BRUSH LIFT CIRCUIT (SCHEMATIC) P3 DR1 SV03 P7 SV07 G5 C4 PR1 300 PSI G2 300 PSI 1.0 GPM WHILE MOVING (2.0 - 3.0 SEC) C1 C2 SV05 x MAIN BRUSH LIFT C3 G4 M3 SV04 S.BR. SV06 OPT UP M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI 3.7 GPM P2 P1 T4 T3 T1 M1 MAIN BRUSHES G1 PRESSURE SUCTION RETURN CASE DRAIN PRESSURE READINGS BASED ON 150 F STRAINER RV3 3 PSI 5-50 7400 MM428 (12--98) HYDRAULICS MAIN BRUSHES DO NOT RAISE (FLOW CHART) YES SV5 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM NO YES YES C3 PORT PRESSURE OK? < 25 PSI G5 PORT PRESSURE OK? 300 PSI NO NO PLUMBING OK? YES NO LIFT CYLINDER SEALS OK? REPAIR OR REPLACE PLUMBING NO OR1 ORIFICE PLUGGED? YES SV5 STEM CARTRIDGE SHIFTING OK? NO REPLACE LIFT CYLINDER REPAIR OR REPLACE OR1 ORIFICE REPAIR OR REPLACE PR1 STEM CARTRIDGE 7400 MM428 (12--98) NO REPAIR OR REPLACE SV5 STEM CARTRIDGE 5-51 HYDRAULICS MAIN BRUSHES DO NOT STAY UP (FLOW CHART) YES SV7 STEM CARTRIDGE MAGNETIZED? CHECK ELECTRICAL SYSTEM NO YES NO PLUMBING OK? REPAIR OR REPLACE PLUMBING SV7 STEM CARTRIDGE SHIFTING & SEAT OK? REPAIR OR REPLACE SV7 STEM CARTRIDGE YES NO NO LIFT CYLINDER SEALS OK? REPLACE LIFT CYLINDER 5-52 7400 MM428 (12--98) HYDRAULICS 7400 MM428 (12--98) 5-53 HYDRAULICS SCRUB FAN CIRCUIT (SCHEMATIC) P3 DR1 SV03 C1 C2 P7 SV07 C4 PR1 300 PSI G2 G5 SV05 C3 1700 PSI 6.3 GPM 11,000 +/-- 1000 RPM G4 M3 SV04 S.BR. SV06 OPT M2 SV02 VACUUM FAN x T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P2 P1 T4 T3 T1 M1 G1 6.7 GPM PRESSURE SUCTION RETURN CASE DRAIN STRAINER PRESSURE READINGS BASED ON 150 F FILTER RV3 3 PSI 5-54 7400 MM428 (12--98) HYDRAULICS SCRUB FAN DOES NOT TURN ON (FLOW CHART) NO SV2 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES YES MOTOR INLET FLOW OK? REPAIR OR REPLACE MOTOR PUMP OUTLET FLOW OK? REPAIR OR REPLACE PUMP NO REPAIR OR REPLACE SV2 STEM CARTRIDGE NO YES NO SV2 STEM CARTRIDGE SHIFTING OK? PLUMBING OK? YES NO NO REPAIR OR REPLACE PLUMBING RV2 RELIEF CARTRIDGE OK? 2500 PSI REPAIR OR REPLACE RV2 RELIEF CARTRIDGE 7400 MM428 (12--98) 5-55 HYDRAULICS SCRUB FAN DOES NOT TURN OFF (FLOW CHART) NO YES CHECK ELECTRICAL SYSTEM SV2 STEM MAGNETIZED? ROTOR SPEED < 200 RPM YES SYSTEM NORMAL NO SV2 STEM CARTRIDGE SHIFTING OK? NO REPAIR OR REPLACE SV2 STEM CARTRIDGE 5-56 7400 MM428 (12--98) HYDRAULICS SCRUB FAN MOTOR SHAFT SEAL LEAKS (FLOW CHART) YES REPAIR OR REPLACE MOTOR 7400 MM428 (12--98) MOTOR CASE PRESSURE OK? < 25 PSI NO REPAIR OR REPLACE CASE DRAIN PLUMBING & MOTOR 5-57 HYDRAULICS MAIN BRUSH ON CIRCUIT (SCHEMATIC) P3 DR1 SV03 C1 C2 P7 SV07 C4 PR1 300 PSI G2 PRESSURE SUCTION RETURN CASE DRAIN G5 SV05 C3 G4 M3 SV04 S.BR. SV06 OPT PRESSURE READINGS BASED ON 150 F M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P2 P1 T4 T3 T1 M1 MAIN BRUSHES G1 LEVEL #1 400 PSI LEVEL #2 550 PSI LEVEL #3 700 PSI 8.3 GPM 8.5 GPM LEVEL #1 800 PSI LEVEL #2 1000 PSI LEVEL #3 1300 PSI 8.4 GPM x x STRAINER FILTER RV3 3 PSI 5-58 7400 MM428 (12--98) HYDRAULICS SIDE BRUSH DOES NOT TURN ON (FLOW CHART) NO SV6 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES YES MOTOR INLET FLOW OK? REPAIR OR REPLACE MOTOR PUMP OUTLET FLOW OK? REPAIR OR REPLACE PUMP NO REPAIR OR REPLACE SV6 STEM CARTRIDGE NO YES NO SV6 STEM CARTRIDGE SHIFTING OK? PLUMBING OK? YES NO NO REPAIR OR REPLACE PLUMBING RV2 RELIEF CARTRIDGE OK? 2500 PSI REPAIR OR REPLACE RV2 RELIEF CARTRIDGE 7400 MM428 (12--98) 5-59 HYDRAULICS SIDE BRUSH DOES NOT TURN OFF (FLOW CHART) NO YES CHECK ELECTRICAL SYSTEM SV6 STEM MAGNETIZED? BRUSH SPEED < 10 RPM YES SYSTEM NORMAL NO SV6 STEM CARTRIDGE SHIFTING OK? NO REPAIR OR REPLACE SV6 STEM CARTRIDGE 5-60 7400 MM428 (12--98) HYDRAULICS 7400 MM428 (12--98) 5-61 HYDRAULICS SIDE BRUSH EXTEND CIRCUIT (SCHEMATIC) (WITH MAIN BRUSHES ON) P3 DR1 SV03 C1 C2 P7 SV07 G5 C4 PR1 300 PSI G2 PRESSURE SUCTION RETURN CASE DRAIN SV05 C3 PRESSURE READINGS BASED ON 150 F G4 M3 SV04 S.BR. SV06 OPT M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P2 G1 P1 P6 8.5 GPM SV10 100-800 PSI SC1 T4 T3 T1 M1 SIDE BRUSH OPTION G6 P5 DR2 SV08 C7 SV11 PR2 300 PSI SV09 SIDE BRUSH LIFT C8 C5 C6 SIDE BRUSH EXTEND UP x EXTEND 300 PSI 1.0 GPM WHILE MOVING STRAINER RV3 3 PSI 5-62 7400 MM428 (12--98) HYDRAULICS SIDE BRUSH DOES NOT GO OUT (FLOW CHART) NO SV9 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES YES DR2 PORT PRESSURE OK? < 25 PSI C5 PORT PRESSURE OK? 300 PSI NO NO YES NO CYLINDER LINKAGE & SEALS OK? PLUMBING OK? REPAIR OR REPLACE PLUMBING NO REPAIR OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE REPAIR CYLINDER LINKAGE OR SEALS 7400 MM428 (12--98) NO SV9 STEM CARTRIDGE SHIFTING OK? REPAIR OR REPLACE SV9 STEM CARTRIDGE 5-63 HYDRAULICS SIDE BRUSH DOES NOT GO IN (FLOW CHART) YES SV9 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM NO YES YES C6 PORT PRESSURE OK? < 25 PSI C5 PORT PRESSURE OK? 300 PSI NO NO PLUMBING OK? YES NO CYLINDER LINKAGE & SEALS OK? REPAIR OR REPLACE PLUMBING NO OR2 ORIFICE PLUGGED? YES SV9 STEM CARTRIDGE SHIFTING OK? NO NO REPAIR CYLINDER LINKAGE OR SEALS REPAIR OR REPLACE OR2 ORIFICE YES REPAIR OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE 5-64 SC1 SHUTTLE CHECK CARTRIDGE SHIFTING OK? NO REPAIR OR REPLACE SV9 STEM CARTRIDGE REPAIR OR REPLACE SHUTTLE CHECK CARTRIDGE 7400 MM428 (12--98) HYDRAULICS 7400 MM428 (12--98) 5-65 HYDRAULICS SIDE BRUSH LOWER CIRCUIT (SCHEMATIC) (WITH MAIN BRUSHES ON) P3 DR1 SV03 C1 C2 P7 SV07 PRESSURE SUCTION RETURN CASE DRAIN C4 PR1 300 PSI G2 G5 SV05 C3 G4 M3 SV04 S.BR. SV06 OPT PRESSURE READINGS BASED ON 150 F M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P2 G1 P1 P6 8.5 GPM SV10 100-800 PSI SC1 T4 T3 T1 M1 SIDE BRUSH OPTION P5 G6 DR2 SV08 C7 SV11 PR2 300 PSI SV09 LEVEL #1 210 PSI LEVEL #2 270 PSI LEVEL #3 320 PSI 1.0 GPM WHILE MOVING x C8 C5 SIDE BRUSH LIFT DOWN C6 SIDE BRUSH EXTEND RETRACT STRAINER RV3 3 PSI 5-66 7400 MM428 (12--98) HYDRAULICS SIDE BRUSH DOES NOT STAY UP (FLOW CHART) YES SV11 STEM CARTRIDGE MAGNETIZED? CHECK ELECTRICAL SYSTEM NO YES NO PLUMBING OK? REPAIR OR REPLACE PLUMBING SV11 STEM CARTRIDGE SHIFTING & SEAT OK? REPAIR OR REPLACE SV11 STEM CARTRIDGE YES NO NO LIFT CYLINDER SEALS OK? REPLACE LIFT CYLINDER 7400 MM428 (12--98) 5-67 HYDRAULICS SIDE BRUSH DOES NOT RAISE (FLOW CHART) YES SV8 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM NO YES YES DR2 PORT PRESSURE OK? < 25 PSI C5 PORT PRESSURE OK? 300 PSI NO NO PLUMBING OK? YES NO LIFT CYLINDER LINKAGE & SEALS OK? REPAIR OR REPLACE PLUMBING NO OR2 ORIFICE PLUGGED? YES SV8 STEM CARTRIDGE SHIFTING OK? NO NO REPAIR LINKAGE OR REPLACE LIFT CYLINDER REPAIR OR REPLACE OR2 ORIFICE YES REPAIR OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE 5-68 SC1 SHUTTLE CHECK CARTRIDGE SHIFTING OK? NO REPAIR OR REPLACE SV8 STEM CARTRIDGE REPAIR OR REPLACE SHUTTLE CHECK CARTRIDGE 7400 MM428 (12--98) HYDRAULICS SIDE BRUSH DOES NOT LOWER (FLOW CHART) NO SV8, SV10 & SV11 STEMS MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES YES C7 PORT PRESSURE OK? > 200 PSI C5 PORT PRESSURE OK? 300 PSI NO NO YES NO SV11 STEM CARTRIDGE SHIFTING OK? SV8 STEM CARTRIDGE SHIFTING OK? REPAIR OR REPLACE SV8 STEM CARTRIDGE NO REPAIR OR REPLACE PR2 PRESSURE CONTROL CARTRIDGE REPAIR OR REPLACE SV11 STEM CARTRIDGE 7400 MM428 (12--98) NO G6 PORT PRESSURE OK? > 200 PSI REPLACE SV10 STEM CARTRIDGE 5-69 HYDRAULICS SQUEEGEE LIFT CIRCUIT (SCHEMATIC) 350 PSI 1.0 GPM WHILE MOVING x P3 DR1 SV03 C1 C2 P7 SV07 SQUEEGEE LIFT UP C4 PR1 300 PSI G2 G5 SV05 C3 G4 M3 SV04 S.BR. SV06 OPT M2 SV02 T5 T2 RV2 2500 PSI SV01 RV1 2500 PSI P1 G1 T1 M1 PRESSURE READINGS BASED ON 150 F 3.7 GPM P2 T4 T3 PRESSURE SUCTION RETURN CASE DRAIN STRAINER RV3 3 PSI 5-70 7400 MM428 (12--98) HYDRAULICS SQUEEGEE DOES NOT LOWER (FLOW CHART) NO SV3 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM YES YES NO PC1 PILOT CHECK CARTRIDGE SHIFTING OK? REPAIR OR REPLACE PC1 PILOT CHECK CARTRIDGE NO REPAIR OR REPLACE SV3 STEM CARTRIDGE YES NO LIFT CYLINDER SEALS OK? SV3 STEM CARTRIDGE SHIFTING OK? TV1 ORIFICE PLUGGED? NO YES CLEAN OR REPLACE ORIFICE REPLACE LIFT CYLINDER 7400 MM428 (12--98) 5-71 HYDRAULICS SQUEEGEE DOES NOT RAISE (FLOW CHART) YES SV3 STEM MAGNETIZED? CHECK ELECTRICAL SYSTEM NO YES NO PC1 PILOT CHECK CARTRIDGE SHIFTING OK? REPAIR OR REPLACE PC1 PILOT CHECK CARTRIDGE NO REPAIR OR REPLACE SV3 STEM CARTRIDGE YES NO LIFT CYLINDER SEALS OK? SV3 STEM CARTRIDGE SHIFTING OK? TV1 ORIFICE PLUGGED? NO YES CLEAN OR REPLACE ORIFICE REPLACE LIFT CYLINDER 5-72 7400 MM428 (12--98) HYDRAULICS SQUEEGEE DOES NOT STAY UP (FLOW CHART) YES NO PLUMBING OK? REPAIR OR REPLACE PLUMBING PC1 PILOT CHECK CARTRIDGE SHIFTING & SEAT OK? REPAIR OR REPLACE PC1 PILOT CHECK CARTRIDGE YES NO NO LIFT CYLINDER SEALS OK? REPLACE LIFT CYLINDER 7400 MM428 (12--98) 5-73 HYDRAULICS STEERING CIRCUIT (SCHEMATIC) T RV7 1160 PSI x R E STEERING SYSTEM L P 750 PSI (STATIONARY) 850 PSI (TURNING) 1500 PSI (HELD AT STOP ON STEERING WHEEL) 3.7 GPM PRESSURE SUCTION RETURN CASE DRAIN 3.7 GPM PRESSURE READINGS BASED ON 150 F RV4 4000 PSI PROPEL SYSTEM S-- 15 M 2400 RPM RV6 85 PSI F R RV5 4000 PSI STRAINER RV3 3 PSI 5-74 7400 MM428 (12--98) Eaton No. 7-623 July,1995 ® Medium Duty Piston Pump Repair Information Model 70142 / 70144, 20.3 cm3/r [1.24 in3/r] Displacement and 70145, 23.6 cm3/r [1.44 in3/r] Displacement Variable Displacement Piston Pump design code 01 02 with Valve Plate Model 70142 / 70144 and 70145 Introduction Table of Contents Introduction ....................................................................................................... 2 Identification ...................................................................................................... 3 Required Tools .................................................................................................. 3 Exploded View Drawing ..................................................................................... 4 & 5 Parts List ........................................................................................................... 6 & 7 Disassembly and Inspection .............................................................................. 8 Reassembly ....................................................................................................... 9 Appendix A: ....................................................................................................... 10 Appendix B: ....................................................................................................... 11 Fault-Logic Trouble Shooting ............................................................................ 12 - 16 Start-up Procedure ............................................................................................ 17 Introduction This manual provides service information for the Eaton Models 70142 / 70144 and 70145 Variable Displacement Piston Pumps. Step by step instructions for the complete disassembly, inspection, and reassembly of the pump are given. The following recommendations should be followed to insure successful repairs. Remove the pump from the application. Cleanliness is extremely important. Clean the port areas thoroughly before disconnecting the hydraulic lines. Plug the pump ports and cover the open hydraulic lines immediately after they're disconnected. Drain the oil and clean the exterior of the pump before making repairs. Wash all metal parts in clean solvent. Use compressed air to dry the parts. Do not wipe them dry with paper towels or cloth. The compressed air should be filtered and moisture free. Always use new seals when reassembling hydraulic pumps. For replacement parts and ordering information refer to parts list 6-632. Lubricate the new rubber seals with a petroleum jelly (vaseline) before installation. Torque all bolts over gasketed joints, then repeat the torquing sequence to make-up for gasket compression. Verifying the accuracy of pump repairs on an authorized test stand is essential. 2 Model 70142 / 70144 and 70145 Identification and Tools Required Identification Numbers Stamped on each unit. B - Rotation, R = Righthand, L = Lefthand C - Sequential Letters D - Design Code Number A - Product Number Discription 70142 = Piston Pump (20.3 cm /r [1.24 in /r]) with Gerotor 70144 = Piston Pump (20.3 cm /r [1.24 in /r]) without Gerotor 70145 = Piston Pump (23.6 cm /r [1.44 in /r]) with or without Gerotor 78113 = Tandem Piston Pumps (20.3 cm /r [1.24 in /r]) no Gear Pump 78114 = Tandem Piston Pumps (20.3 cm /r [1.24 in /r]) with Gear Pump 78115 = Tandem Piston Pumps (23.6 cm /r [1.44 in /r]) no Gear Pump 78116 = Tandem Piston Pumps (23.6 cm /r [1.44 in /r]) with Gear Pump 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Single Pump - Product Number Tandem Pumps - Product Number 70142 - RAA-01 A B C 78113 - RAB-01 D A B C D Serial Number Code: B 93 01 31 JB Revision level of parts list. Last two digits of year built. ( 93 for 1993 etc.) Testers Initials Day of Month (two digits) Month (two digits) Required Tools 7/16 in. Hex Key (Allen) 9/16 in. End Wrench 1 in. End Wrench 9/16 in. Socket 1/2 in. Socket Internal Retaining Ring Pliers (straight .090 tip) External Retaining Ring Pliers (straight .070 tip) O-ring Pick Torque Wrench (135.6 N.m [100 lbf.ft] capacity) Hammer (soft face) Light Petroleum Jelly Seal Driver Arbor Press 3 Model 70142 / 70144 and 70145 Parts Drawing - Figure 1-1 48 17 4 24 25 14 15 5 22 13 51 51-1 12 30 Date Code and Assembly Number Location 50-1 Left Side 50 Right Side 3-1 Shaft assembly for single pump or front pump of tandem. 3 13 1 29 15 16 23 17 6 8 10 9 10 8 1 11 7 6 7 4 11 8 10 9 10 8 Shaft assembly for rear pump of tandem. Model 70142 / 70144 and 70145 49-1 49-2 K2-4 49-3 49-4 49 49-5 K1 K2-3 19 19-1 K1-1 18 21 32 (K2-2) 28 27 28 K2 37 K2-3 design code 02 27 26 K2-2 32 20 26 2-2 2-1 (K2-1) 18 19-1 19 2 K4 K4-3 33 (K3-3) K4-2 37 K3 (K4-4) design code 32 (K4-1) 01 No Groove 34 34-1 31 32 (K3-2) (K3-1) 36 49-1 49-2 19 19-1 28A 27A 49-3 49-4 49 49-5 18 35 21 27B 46 design code 37 02 46 26 20 26 2-1 2-2 2 18 19-1 19 5 Model 70142 / 70144 and 70145 Parts List + + + + + + + + + + 6 Item Qty. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19-1 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 34-1 35 36 37 1 1 1 1 1 1 1 2 1 2 1 1 2 1 2 1 4 2 2 2 1 1 1 1 1 1 2 2 2 1 1 1 1 2 1 1 1 1 1 37 46 46 48 1 1 1 1 Drive Shaft Backplate Assembly Housing Assembly Rotating Kit Assembly Camplate Washer Retaining Ring Retaining Ring Thrust Bearing Bearing Race Shaft Seal, Drive Housing Gasket Needle Bearing O-ring, 3.175 mm Dia. x 31.75 mm ID. [.125 in. Dia. x 1.25 in. ID.] Washer Shaft Seal, Trunnion Screw, Pan Head Spring Plug Assembly O-ring, 2.38 mm Dia. x 22.23 mm ID. [.0937 in. Dia. x .875 in. ID.] Relief Valve for Port “C” Relief Valve for Port “D” Inner Race Seal Cover Trunnion Cover Cover, O-ring Dowel Pin Cap Screws, 5/16-18, 50.8 mm [2 in.] Long Cap Screws, 5/16-18, 63.5 mm [2.5 in.] Long Key, Drive Shaft Key, Camplate Trunnion Cover Plate (In K3 kit) O-ring (In K1, K2, K3 & K4 kit) Cap Screws, Cover Plate (In K3 kit) Plug Assembly O-ring, 2.21 mm Dia. x 16.36 mm ID. [.087 in. Dia. x .644 in. ID.] Molded O-ring Charge Pump Adaptor Gerotor set and coupler sub-assembly 6.9 cm3/r [.42 in3/r] displacement, 6.35 mm [.25 in ] width 13.8 cm3/r [.84 in3/r] displacement, 12.7 mm [.5 in] width 9 tooth coupler (In K4 kit) Mounting Bracket, Square shaped Mounting Bracket, “V” shaped Valve Plate Model 70142 / 70144 and 70145 Parts List Item 49 + 49-1 49-2 49-3 + 49-4 + 49-5 49 49-5 50 + 50-1 51 + 51-1 Qty. Description 1 1 1 1 1 1 1 1 1 1 1 1 Dump Valve sub-assembly Retaining Ring Separator Plug Separator O-ring, 1.59 mm Dia. x 9.53 mm I.D. [.0625 in. Dia. x .375 in. I.D.] O-ring, 2.46 mm Dia. x 19.18 mm I.D. [.097 in. Dia. x .755 in. I.D.] Plug Assembly O-ring, 2.46 mm Dia. x 19.18 mm I.D. [.097 in. Dia. x .755 in. I.D.] Plug Assembly O-ring, 1.98 mm Dia. x 11.89 mm ID. [.078 in. Dia. x .468 in. ID.] Plug Assembly O-ring, 1.98 mm Dia. x 11.89 mm ID. [.078 in. Dia. x .468 in. ID.] Mounting Kits K1 K1-1 K1-2 K1-3 K1-4 K2 K2-1 K2-2 K2-3 K3 K3-1 K3-2 K3-3 K4 K4-1 K4-2 K4-3 K4-4 1 1 1 2 2 1 1 2 2 1 1 1 2 1 1 1 2 2 Tandem Piston Pump Mounting Kit 35T Coupler, 36.8 mm [1.45 in.] long O-ring, 1.59 mm Dia. x 101.6 mm ID. [.0625 in. Dia. x 4 in. ID.] Cap Screws Washer Gear Pump Mounting Kit O-ring, 1.59 mm Dia. x 82.55 mm ID. [.0625 in. Dia. x 3.25 in. ID.] Washer Cap Screws Cover Plate Kit O-ring, 1.59 mm Dia. x 82.55 mm ID. [.0625 in. Dia. x 3.25 in. ID.] Cover Plate Cap Screws Gear Pump Mounting Kit with Coupler 9T Coupler O-ring, 1.59 mm Dia. x 101.6 mm ID. [.0625 in. Dia. x 4 in. ID.] Cap Screws Washer Seal Repair Kit 70142-938 Legend Seal Repair Kit for 70142, 70144 and 70145 piston pump. + Included in seal repair kit. 7 Model 70142 / 70144 and 70145 Disassembly Disassembly The following instructions apply to a variable displacement piston pump with or without a gerotor charge pump. A tandem pump assembly should be separated into individual pumps before disassembly. 1 Position the pump into a protected jaw vise, clamping onto the outer portion of the flange, with the input drive shaft down. Remove the four cap screws retaining charge pump adapter or backplate. No gerotor charge pump skip to step 6. 2 Lift the charge pump adapter assembly straight up off backplate, shaft, and gerotor. Gerotor may stay in adapter or on backplate. 3 Remove o-ring from charge pump adapter. 4 Remove outer gerotor ring from either the charge pump adapter or the inner gerotor ring. Refer to Appendix A for disassembly and inspection of charge pump adapter assembly. 5 Remove the inner gerotor ring and coupler assembly from shaft. 6 Lift backplate straight up off of shaft and housing. Remove valve plate from backplate or from rotating kit assembly, still in housing. 7 From backplate remove dump valve assembly or plug assembly, and relief valve assemblies. Note: Mark the relief valve in relationship to the cavity it was removed, for reassembly purposes. Backplate Inspection: • Check the bearing (press fit) in backplate. If needles remain in cage, move freely, and setting is at the dimension shown in figure 1-3, removal not required. • Check roll pin in backplate. If tight and set to the dimension shown in figure 1-3, removal not required. 8 Remove housing gasket from housing or backplate. 9 To remove rotating kit assembly from housing, first remove pump from vise holding the rotating kit assembly in position. Lower pump so that the shaft end (flange end) is up. Set the rear of housing onto table with housing flat and rotating kit assembly at rest on table. Hole in table for protruding shaft is required. Remove by lifting the housing and shaft from rotating kit assembly. Refer to Appendix B for disassembly and Inspection of rotating kit. 10 Remove retaining ring from the front of housing. Press the shaft, shaft seal or spacer, and washer from housing. Remove retaining ring, thrust washer, thrust bearing, second thrust washer, and second retaining ring from shaft. 11 To remove camplate from housing, remove the two screws from both sides of housing (four total) retaining seal cover and trunnion cover. Remove seal cover, shaft seal, washer, and bearing from housing. Remove trunnion cover, o-ring cover, oring, washer, inner race, and bearing from housing. Slide the camplate over to one side and remove thru the back side of housing. Camplate Inspection: • The finish on the piston shoe surfaces of the camplate should show no signs of scoring. Housing Inspection: • Check the bearing (press fit) in front of housing. If needles remain in cage, move freely, and setting at the dimension shown in figure 1-4, removal not required. Flange End of Housing Numbered End 1.78 mm [.07 in.] Numbered End 2.79 mm [.110 in.] 1.91 mm [.075 in.] Figure 1-4 Figure 1-3 8 12 Discard the shaft seal, gaskets, and o-rings from all assemblies. Replace with new seals upon reassembly. Model 70142 / 70144 and 70145 Reassembly Reassembly 1 All parts should be cleaned and critical moving parts lubricated before reassembly. 2 If necessary, press new bearing in housing to dimension shown in figure 1-4 with the numbered end of bearing outward. 3 Starting with the camplate, insert camplate into the housing with the long trunnion side down and to the appropriate side of linkage on the machine. 4 On the short trunnion side of camplate install bearing (bearing with numbered side to the inside of pump), bearing race (race with chamfer toward inside of pump), washer, o-ring, o-ring cover, trunnion cover, and retain with two screws. Torque screws 4.1 to 5.4 N.m [36 to 48 lbf.in]. 5 On the long trunnion side of camplate install bearing (bearing with numbered side to the inside of pump), washer, trunnion shaft seal, seal cover, and retain with two screws. Torque screws 4.1 to 5.4 N.m [36 to 48 lbf.in]. 6 To install shaft, place exterior retaining ring, thrust race, thrust bearing, second thrust race, and second retaining ring onto shaft. Position washer and shaft seal or spacer onto shaft. 7 Install shaft assembly into front of housing: For units with spacer, retain with interior retaining ring and go on to step 8. For units with shaft seal, seat seal into position with seal driver and retain with interior retaining ring. 13 Apply a small amount of petroleum jelly to the steel side of valve plate to hold in place for installation. Aligning the index pin, place the valve plate in position onto the backplate, with steel side against backplate. 14 Install backplate assembly onto housing assembly. Making sure valve plate and gasket stay in place. No gerotor charge pump, skip to step 17. 15 Install inner gerotor and coupler assembly. The coupler has a "V" groove on one end and this end of coupler should enter backplate first. Lubricate inner gerotor. Refer to Appendix A for reassembly of Charge relief valve in adapter plate. 16 Install o-ring and outer gerotor ring onto adapter plate. Lubricate both o-ring and outer gerotor ring to hold in position during assembly of adapter plate. Install adapter plate onto backplate. Make sure o-ring and gerotor ring stay in place. 17 Retain backplate and adapter plate (when used) with four cap screws, Torque 23 to 27 N.m [17 to 20 lbf.ft]. 18 Install new o-rings on all plugs. Install plugs into housing. Torque 9/16 in. - 18 plug 28 to 32 N.m [21 to 24 lbf.ft]. 19 Refer to start-up procedures on page 17. Refer to Appendix B for reassembly of rotating kit assembly. 8 With flange end of housing up, position rotating kit assembly onto shaft and into housing. Align the spline within the piston block with shaft internal spline. Make sure piston block is engaged fully to put piston shoes in contact with camplate. Check all parts for proper position before proceeding. 9 Clamp pump assembly in a protected jaw vise with the open end of the housing up. Install gasket and two dowel pins onto housing. 10 If necessary, press new bearing and roll pin in backplate to dimension shown in figure 1-3. Bearing installed with the numbered end outward. Roll pin installed with split oriented away from bearing. 11 Install new o-ring on relief valves. Install relief valve in its original cavity in backplate that it was removed. Torque 128 to 142 N.m [95 to 105 lbf.ft.] 12 Install new o-ring on dump valve or plug. Install dump valve or plug into backplate. Torque dump valve or plug to 36.6 to 40.7 N.m [ 27 to 30 lbf.ft] 9 Model 70142 and 70145 Appendix A - Charge Pump Adapter Assembly 36-4a 36-3a or 3b 36-2a Configuration for 13.8 to 17.2 bar [200 to 250 lbf/in2] or 17.2 to 20.7 bar [250 to 300 lbf/in2] Charge Relief Valve Pressure Check Port or Remote Charge Port 36-4 36-3 Configuration for 6.9 to 1.3 bar [100 to 150 lbf/in2] Charge Relief Valve 36-2 Charge Pump Suction Port Gerotor Pocket Depth Item 36 36-1 36-2 36-2a 36-3 36-3a 36-3b 36-4 36-4a Qty. 1 1 1 1 1 1 1 1 1 36-1 Displacement cm3/r [in3/r] Depth of Pocket mm [in.] Gerotor Ring Pocket 6.9 [.42] 13.8 [.84] 6.35 [.25] 12.7 [.50] (See chart for depth) Description Charge Pump Adapter Assy. Bearing (press fit) Poppet, Cup Poppet, Pin Spring, Tappered Spring, "Light Green" * Spring, "Pink" ** Spring Retainer Spring Retainer *200 to 250 lbf/in2 **250 to 300 lbf/in2 Disassembly - Charge Pump Adapter Assembly Bearing 36 Reassembly - Charge Pump Adapter Assembly 1 If necessary, press new bearing in adapter assembly. The bearing to dimension shown in figure 1-2 with the numbered end of bearing outward and closest to mounting flange. 2 Install cup poppet or pin poppet, spring, and spring retainer into charge pump adapter. Torque retainer 6.8 to 9.5 N.m [5 to 7 lbf.ft.] Flange Numbered End 1 Remove spring retainer, spring, and poppet from adapter assembly. Inspection: • Inspect the charge pump relief valve seat inside the charge pump adapter. Check to insure that seat is smooth and free of burrs or other defects. 2.41 mm [.095 in.] • Inspect the charge pump relief valve spring. • Inspect the bearing inside the charge pump adapter. The bearing needles must remain in the bearing cage and bearing at dimension shown in figure 1-2. • Inspect the gerotor pocket inside the charge pump adapter assembly. It should not be scored excessively. 10 Gerotor Pocket Figure 1-2 Model 70142 / 70144 and 70145 Appendix B 4-9 Rotating Kit Assembly 4-7 4-8 4-7 4-6 4 4-5 Item 4-4 4-2 4-3 4-1 Disassembly - Rotating Kit Assembly Disassembly of rotating assembly is required for inspection only. 1 Remove the nine piston assemblies, spider, and spider pivot from piston block. Inspection: • Examine the O.D. of the pistons for finish condition. They should not show wear or deep scratches. Inspect the shoes for a snug fit on the ball end of the pistons and a flat smooth surface that comes in contact with the camplate. Do not lap piston shoes. • Examine the spider for wear in the pivot area. • Examine the pivot to insure smoothness and no signs of wear. • Inspect the piston block surface that makes contact with valve plate. This surface should be smooth and free of deep scratches. Do not lap piston block. • The pistons should move freely in the piston block bore. If not free moving, examine the bore for scoring or contamination. 2 To inspect pins and spring Caution should be taken in removing spring. The spring is highly compressed and the retaining ring should not be removed without compressing the spring safely. 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 Qty. 9 1 1 1 1 3 2 1 1 Description Piston assemblies Spider Spider Pivot Retainer Piston Block Pins Washer Spring Retaining Ring The following parts are required to disassemble the piston block: 2 ea. 5/16 in. I.D. x 15/16 in. O.D. flat washers 1 ea. 5/16 in. x 2-7/8 in. N.C. cap screw, and 1 ea. 5/16 in. N.C. nut To remove spring, place one of the flat washers over the 5/16 in. x 2-7/8 in. cap screw. Put cap screw through the center of the piston block and apply the second washer. Let washer rest on the three pins and retain with nut. Turning nut and compressing spring inside the block. Use a pair of retaining ring pliers and remove the internal retaining ring. Remove nut, bolt, and the two washers from block. Removing the washer, spring, second washer, three pins, and pin keeper at the same time. Reassembly - Rotating Kit Assembly 1 To reassemble the rotating kit assembly complete the following: Compress the pin keeper and install in the spline of the piston block. Install the three pins with head end to the inside of the block and position in the special grooves of the piston block spline. 2 Install the washer, spring, and second washer into the piston block. Use the two 5/16 in. I.D. washers, nut, and 5/16 in. x 2-7/8 in. cap screw to compress the spring and retain with retaining ring. Remove the nut, cap screw, and the two washers. 3 Install the pivot onto the three pins, spider on the pivot, and piston assemblies thru the spider and into piston block, resting on spider. 11 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting This fault - logic trouble shooting guide is a diagnostic aid in locating transmission problems. Match the transmission symptoms with the problem statements and follow the action steps shown in the box diagrams. This will give expedient aid in correcting minor problems eliminating unnecessary machine down time. Following the fault - logic diagrams are diagram action comments of the action steps shown in the diagrams. Where applicable, the comment number of the statement appears in the action block of the diagrams. Explanatory Diagram Symptom: Action Step Comment Number Inspect ? 1 Decision Defective Solution Repair or Replace Recommended Gauge Locations Auxiliary Port Check Charge Pressure Charge Pump Suction Port Tee in line to check Inlet Vacuum Pressure Ports Tee in line to check System Pressure Drain Port Tee in line to check Case Pressure Figure 3-1 Gauges Recommended Inlet vacuum gauge: 207 bar to 0 bar [30 lbf/in2 to 30 inHg] System pressure gauge: 700 bar [10,000 lbf/in2] Charge pressure gauge: 0 to 50 bar [0 to 600 lbf/in2] Case pressure gauge: 0 to 25 bar [0 to 300 lbf/in2] 12 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Symptom: Neutral Difficult or Impossible to Find Inspect External Control Linkage 1 OK Inspect Servo Control (If used) 2 Defective Defective Repair or Replace Repair or Replace Symptom: System Operating Hot Check Oil Level in 4 Reservoir OK Inspect Heat Exchanger 5 OK Inspect Heat Exchanger By-Pass Valve 6 (If used) Below Level Defective Defective Fill to Proper Level Repair or Replace Repair or Replace Inspect OK Charge Pump 13 OK Replace Pump & Motor OK Inspect Inlet Screen or Filter 8 OK Check Charge 10 Pressure Low OK Inspect Charge Relief Valve 11 Defective Clogged Defective Repair or Replace Replace Repair or Replace Inspect Motor OK 12 Inspect OK Dump Valve (If used) 7 Defective Defective Repair or Replace Repair or Replace OK Check System Pressure 9 High Reduce System Load 13 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Symptom: Operates in One Diection Only Inspect External Control Linkage 1 OK Inspect Servo Control 2 (If used) OK Inspect System Relief Valves 3 Defective Defective Defective Repair or Replace Repair or Replace Repair or Replace Symptom: System Response Sluggish Check Charge 10 Pressure OK Low Inspect Charge Relief 11 Valve 14 OK Inspect Servo Control 2 (If used) OK Inspect Dump Valve 7 (If used) OK 12 Inspect Motor Defective Defective Defective Repair or Replace Repair or Replace Repair or Replace Inspect Inlet Screen 8 or Filter OK Inspect Charge 13 Pump Defective Clogged Defective Repair or Replace Replace Repair or Replace OK Replace Pump & Motor OK Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Symptom: System Will Not Operate In Either Direction Check Oil Level in 4 Reservoir OK Check External Control 1 Linkage OK Inspect Dump Valve 7 (If used) Below Level Defective Defective Fill to Proper Level Repair or Replace Repair or Replace Inspect OK Charge Pump 13 OK Replace Pump & Motor OK Inspect Inlet Screen or Filter 8 OK Check Charge 10 Pressure Low OK Inspect Charge Relief Valve 11 Defective Clogged Defective Repair or Replace Replace Repair or Replace Inspect Motor OK 12 Inspect OK Servo Control (If used) 2 OK Check System Pressure 9 Defective Defective High Repair or Replace Repair or Replace Reduce System Load 15 Model 70142 / 70144 and 70145 Fault - Logic Trouble Shooting Diagram Action Step Comments 1 Inspect External Control Linkage for: a. misadjusted or disconnected b. binding, bent, or broken c. misadjusted, damaged or broken neutral return spring 11 Inspect Charge Relief Valve for: a. improper charge relief pressure setting * b. damaged or broken spring c. poppet valve held off seat 2 Inspect Servo Control Valve for: (if used) a. proper inlet pressure b. misadjusted, damaged or broken neutral return spring c. galled or stuck control spool d. galled or stuck servo piston 12 Inspect Motor for: a. disconnected coupling 3 4 5 Inspect System Relief Valves * for: a. improper pressure relief setting b. damaged or broken spring c. valve held off seat d. damaged valve seat Check Oil Level in Reservoir: a. consult owner/operators manual for the proper type fluid and level Inspect Heat Exchanger for: a. obstructed air flow (air cooled) b. obstructed water flow (water cooled) c. improper plumbing (inlet to outlet) d. obstructed fluid flow 6 Inspect Heat Exchanger By-Pass Valve for: (if used) a. improper pressure adjustment b. stuck or broken valve 7 Inspect Dump Valve for: (if used) a. held in a partial or full open position 8 Inspect Inlet Screen or Filter for: a. plugged or clogged screen or filter element b. obstructed inlet or outlet c. open inlet to charge pump 13 Inspect Charge Pump for: a. broken or missing drive key b. damaged or missing o-ring c. excessive gerotor clearance d. galled or broken gerotor set * System/Charge Relief Valve Pressure Settings for Eaton’s Variable Displacement Controlled Piston Pumps Inlet Vacuum Case Pressure Charge Pressure System Pressure 6 inHg max. 25 lbf/in2 maximum 100 to 150 lbf/in2 Standard 200 to 250 lbf/in2 Optional 250 to 300 lbf/in2 Optional 5000 lbf/in2 maximum 3000 lbf/in2 continuous The high pressure relief valves are all factory preset and cannot be readjusted. The pressure setting and assembly number is stamped on each high pressure relief valve cartridge. Valve Identification Example: 9 Check System Pressure: a. See figure 3-1 for location of pressure gauge installation. b. consult owner/operators manual for maximum system relief valve settings 10 Check Charge Pressure: a. See figure 3-1 for location of pressure gauge installation. b. consult owner/operators manual for maximum charge relief valve settings 16 32060-IA 5000 Relief Valve Setting Relief Valve Assembly Number Model 70142 / 70144 and 70145 Start-up Procedure When initially starting a new or a rebuilt transmission system, it is extremely important that the start-up procedure be followed. It prevents the chance of damaging the unit which might occur if the system was not properly purged of air before start-up. 6 After the system starts to show signs of fill, slowly move pump camplate to a slight cam angle. Continue to operate system slowly with no load on motors until system responds fully. 1 After the transmission components have been properly installed, fill the pump housing at least half full with filtered system oil. Connect all hydraulic lines and check to be sure they are tight. 7 Check fluid level in the reservoir and refill if necessary to the proper level with an approved filtered oil. 2 8 Check all line connections for leaks and tighten if necessary. Install and adjust all control linkage. 9 3 Fill the reservoir with an approved oil that has been filtered through a 10 micron filter. Refer to Eaton Hydraulics Technical Data sheet number 3-401 titled Hydraulic Fluid Recommendations. 4 Gasoline or L.P. engines: remove the coil wire and turn the engine over for 15 seconds. Diesel engines: shut off the fuel flow to the injectors and turn the engine over for 15 seconds. The machine is now ready to be put into operation. 10 Frequent filter changes are recommended for the first two changes after placing the machine back into operation. Change the first filter in 3-5 hours and the second at approximately 50 hours approx. hours. Routinely scheduled filter changes are recommended for maximum life of the hydraulic system. 5 Replace the coil wire or return the fuel flow to the injectors. Place the transmission unit in the neutral position, start the engine and run it at a low idle. The charge pump should immediately pick up oil and fill the system. If there is no indication of fill in 30 seconds, stop engine and determine the cause. 17 Model 70142 / 70144 and 70145 Notes 18 Model 70142 / 70144 and 70145 Notes 19 Order parts from number 6-632 Parts Information booklet. Each order must include the following information. 1. Product and/or Part Number 2. Serial Code Number 3. Part Name 4. Quantity Eaton Corporation Hydraulics Division 15151 Hwy. 5 Eden Prairie, MN 55344 Telephone 612/937-9800 Fax 612/937-7130 Form No. 7-623 November, 1993 Eaton Ltd. Hydraulics Division Glenrothes, Fife Scotland, KY7 4NW Telephone 44/592-771-771 Fax 44/592-773-184 Copyright Eaton Corporation, 1993 All Rights Reserved Printed in USA Char-Lynn No. 7-118 May, 1999 ® Disc Valve Motor Repair Information 4000 Series Geroler® Motors -004 Std., Whl. and Brgl. -006 Std. and Whl. 4000 Series Char-Lynn Motors Shuttle (Two Way) Check Valve Plug Assembly Plug Assembly Balance Ring Poppet Spring Valve Plate Ball Sleeve, Dash Pot Housing, Bearing Seal Shaft Face Seal Seal Shuttle Valve Location when Applicable Inner Face Seal Plug Piston Shuttle Drive Plug Assembly Plug Assembly Seal Sleeve, Dash Pot Seal Valve Housing Spring Valve Outer Spring Face Seal Spring Plug Assembly Shaft and Bearing Kit (1-1/4 inch Straight) Seal Key Seal Shaft Seal Seal Valve Drive Dust Seal Geroler Geroler Seal Geroler Bearingless Motor Mounting Flange Retainer, Front (Flange) Seal Geroler O-ring Bearing Housing Wheel Motor Seal Back-up Washer (if supplied) Screw, Cap Retainer Retainer, Front (C Flange) Dust Seal Shaft and Bearing Kit (1-1/4 inch 14 Tooth Splined) Seal Guard Shaft and Bearing Kit (1-5/8 inch Tapered) Key Screw, Cap Screw, Cap 2 Nut 4000 Series Char-Lynn Motors Tools Wheel motor and bearingless motor repair information on page 9 and 10. Shuttle valve and seal guard repair information on page 10. Seal guard reference on page 10. Tools required for disassembly and reassembly — Torque wrench (68 Nm [600 lb-in] capacity) — 300 to 400 mm [12 to 16 inch] breaker bar — 3/4 inch and 1/2 inch sockets — Small screwdriver (150 to 200 mm [6 to 8 inch] long, 6 mm [.25 inch] blade) — 3/16 inch Hex Key — Hydraulic press — 1335 N [300 lbf] — Shaft face seal (-004) installation tool 600468 — Shaft face seal (-006) installation tool 600421-2 * — Bullet (600463) for 1-1/4 inch diameter shafts — Shaft seal installation tool (2 -1/4 inch socket) — Torq wrench required for eight mounting flange screws (replacement screws or -006 design) No. E10 The following tools are not necessary for disassembly and reassembly but are extremely helpfull — Alignment studs (2), see dimensions below * Available by special order, contact Eaton Corp., Hydraulics Division Service Dept. 200 mm [8 inch] Approx. 13 [.5] 6,3 [.25] 25 mm [1 inch] 11 mm [7/16 inch] Dia. Steel Rod Grind Flat Spots on Each Side 7/16-20 UNF 3 4000 Series Char-Lynn Motors Disassembly Cleanliness is extremely important when repairing a hydraulic motor. Work in a clean area. Before disconnecting the lines, clean port area of motor thoroughly. Use a wire brush to remove foreign material and debris from exterior joints of motor. Check shaft and keyway. Use 600 grit paper/cloth to remove all nicks, burrs, and sharp edges that might damage the shaft seals when installing retainer on shaft and bearing assembly. Before starting disassembly procedures, drain oil from inside of motor. 3 Lift valve housing straight up. If done carefully, the springs and balance ring subassembly will remain on valve for easy removal. Plug Assembly Valve Housing Seal Check Plug Assembly Seal Figure 3 Figure 1 4 Carefully remove the following from the valve housing: 1 seal, 82,3 mm [3.24 inch] I.D. 1 seal, 8,9 mm [.35 inch] I.D. 2 check valve plug assemblies (plug, seal, spring, ball) 1 plug (case drain) with seal. 1 Place motor in a vise with output shaft down. Clamp across edge of mounting flange, not on housing (see Figure 1). Excessive clamping pressure will cause distortion. When clamping, use some protective device on vise, such as special soft jaws, pieces of hard rubber or board. Spring Balance Ring Although not all drawings show the motor in a vise, it is recommended that you keep the motor in the vise during disassembly. Follow the clamping procedures explained throughout the manual. 2 Remove 4 bolts from the valve housing. Inner Face Seal Outer Face Seal Valve Figure 4 5 Remove 2 balance ring springs. 6 Remove balance ring subassembly. 7 Remove inner and outer face seals from the balance ring. Figure 2 4 8 Lift off valve. 4000 Series Char-Lynn Motors Disassembly Valve Drive Valve Plate Seal Seal Figure 7 Figure 5 9 Remove valve plate. 10 Remove 88,6 mm [3.49 inch] I.D. seal from valve plate (see Figure 5). 16 Use a stud remover or vise grips to remove studs (earlier models only). Clamp bearing housing in vise as shown in Figure 7. Loosen 8 screws. Remove screws, washers (discard washers, as they are not required for reassembly), and mounting flange (see Figure 8). 11 Remove valve drive (see Figure 5). Geroler Drive Figure 8 Seal Seal Figure 6 Mounting Flange 12 Remove Geroler. Retain rollers in outer Geroler ring if they are loose. Dust Seal 13 Remove 2 seals from Geroler, 1 seal on each side of Geroler. 14 Remove drive. 15 Remove 88,6 mm [3.49 inch] I.D. seal from bearing housing. Shaft Seal Back-up Ring Figure 9 17 Remove shaft seal, back-up ring (if used) and dust seal from flange. Use a small screwdiver to remove dust seal. Do not damage bore of flange. 5 4000 Series Char-Lynn Motors Disassembly Shaft Face Seal Shaft and Bearing Assembly 18 Remove shaft and bearing assembly. You may need a press to remove shaft and bearing assembly (see Figure 10). 19 Remove shaft face seal from bore of bearing housing (see Figure 10). Do not damage bore of bearing housing. Seal Note: Individual parts of the shaft and bearing assembly are not sold separately and must be replaced as a unit. Bearing Housing Figure 10 Note: Shaft face seal installation tool is available by special order. Contact Eaton Corporation, Hydraulics Division (Service Department). 600468 (-004) 600421-2 (-006). Reassembly Check all mating surfaces. Replace any parts that have scratches or burrs that couId cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe with cloth or paper towel because lint or other matter could get into the hydraulic system and cause damage. Do not use a coarse grit papers/cloth or try to file or grind motor parts. Check around the keyway and chamfered area of the shaft for burrs, nicks, or sharp edges that can damage the seals when reassembling the retainer. Note: Lubricate all seals (prior to installation) with petroleum jelly such as Vaseline®. Use new seals when reassembling the motor. Shaft and Bearing Assembly Bearing Housing Figure 12 22 Install shaft and bearing assembly in bearing housing (see Figure 12). Do not damage seal in bore of housing. You may need a press to install shaft and bearing assembly. Seal Driver Seal Tube Back-up Ring Shaft and Bearing Assembly Seal Face Seal Bearing Housing Dust Seal Lip Shaft Seal Flange Seal Seat Figure 11 Seal 21 Place bearing housing on smooth flat surface with largest open end of housing up. Apply petroleum jelly to shaft face seal. Install seal in seal seat. Seat seal properly in groove (see Figure 11). A damaged or improperly installed shaft face seal could cause internal lubrication loss and subsequent parts wear. 6 Shaft Face Seal Figure 13 4000 Series Char-Lynn Motors Reassembly 23 Apply petroleum jelly to 88,6 [3.49] ID seal. Install seal in seal groove of bearing housing (see Figure 13). 24 Use a small press, if available, to install dust seal in retainer. Metal side of dust seal must face toward flange, as shown in Figure 13. If a press is not available, use a plastic or rubber hammer to tap dust seal in place. 25 Install 92,1 [3.62] ID seal, back-up ring and shaft seal in retainer. Flat or smooth side of shaft seal must face toward retainer as shown in Figure 13. Apply petroleum jelly to inside diameter of shaft seal (after installing seal). 26 Before installing retainer, place a protective sleeve of bullet (see note below) over shaft. Grease inside diameter of dust and shaft seals. To prevent damage to seals, install retainer over shaft with a twisting motion. Do not cut or distort shaft seal. Damage to shaft seal will cause external leakage. Note: Bullet 600463 for 1-1/4 inch diameter shafts available by special order through Eaton Hydraulics Division service department. 2 4 7 6 5 8 3 1 Figure 14 27 Lubricate threads of 8 screws with a film of light oil. Install and finger tighten screws. Clamp bearing housing in vise. Torque screws to 6 Nm [50 lb-in] in sequence (see Figure 14). Then final torque to 34 Nm [300 lb-in], in sequence. Install key (when used) in keyway of shaft. Note: Full torque 34 Nm [300 lb-in] on one bolt at a time can damage bolt or retainer. 29 Pour a small amount of light oil inside the output shaft. 30 Apply a light film of petroleum jelly on 88,6 mm [3.49 inch] I.D. seal. Install seal in bearing housing. 31 Install drive in output shaft (insert longer splined end of drive first), (see parts drawing on page 2). 32 To help in the reassembly procedure, it is recommended using two alignment studs (see special tools page 3) diagonally opposed in the four bolt holes of the bearing housing. 33 Apply petroleum jelly on 2 seals, 9,3 mm [.25 inch] I.D. Install seals (1 on each side of Geroler) in case drain grooves of Geroler. Note: Installation at this point involves 3 steps in timing the motor. Timing determines the direction of rotation of the output shaft. Timing parts include: 1. Geroler 2. Valve drive 3. Valve Plate 4. Valve Rotate Valve Clockwise 1/2 Tooth to Engage Spline Anyone of 6 Ports Open to Outside of Valve Largest Open Pocket Geroler Valve Valve Plate Do Not Use as a drain hole Alignment Ref. Only Note: Case Drain Holes (2) Proper Alignment Shown Case Drain Hole Pressure Relief Hole Figure 16 Timing Alignment Timing Step No. 1 — Locate largest open pocket in Geroler. Then mark location of pocket on outside edge of Geroler (see Figure 16). 34 Align case drain hole and pressure relief hole in Geroler with case drain hole and pressure relief hole in bearing housing. Install Geroler on bearing housing (see Figure 16). Retain rollers in outer Geroler ring if they are loose. 35 Install valve drive in Geroler. Figure 15 28 Reposition motor in vise with output shaft down. Clamp across edges of retainer as shown in Fig. 15. 7 4000 Series Char-Lynn Motors Reassembly 36 Apply a light film of petroleum jelly on 88,6 mm [3.49 inch] I.D. seal. Install seal in valve plate. 41 Apply a light film of petroleum jelly on 82,3 mm [3.24 inch] I.D. seal. Install seal in outside seal groove of valve housing. 37 Align case drain hole in valve plate with case drain hole in Geroler. Install valve plate (seal side toward Geroler) on Geroler as shown in Figure 16. Pin Inner Seal Outer Seal Timing Step No. 2 — Locate slot opening in valve plate which is in line with largest open pocket of Geroler (see Figure 16). 38 Use the following procedure for installing the valve on the valve plate. Balance Ring Timing Step No. 3 — Locate any one of the side openings of the valve that goes through to the face of the valve. Line up this side opening in the valve with open slot of valve plate that is in line with largest open pocket of Geroler. Rotate valve clockwise (1/2 spIine tooth) to engage valve with the valve drive spline, alignment reference shown in Figure 17 (above). This procedure provides standard timing when pressurized as shown in Figure 17. Figure 19 42 Apply petroleum jelly on inner and outer face seals. Install seals on balance ring as shown in Figure 19. Important: Install face seals in the positions shown in Figure 19 or the motor will not operate properly. Do not force or bend these face seals. Any damage to these seals will affect the operation of the motor. Counter Clockwise Rotation Clockwise Rotation Figure 20 Figure 17 43 Align 2 pins of balance ring with 2 spring holes in valve housing as shown in Figure 20 . Install balance ring in valve housing. 39 Apply clean grease on balance ring assembly springs. Install springs in 2 holes located inside bore face of valve housing (see Figure 18). Balance Ring Spring Valve Housing Seal Seal Figure 18 40 Apply a light film of petroleum jelly on 8,9 mm [.35 inch] I.D. seal. Install seal in case drain groove of valve housing. 8 Figure 21 4000 Series Char-Lynn Motors Reassembly 44 Insert your finger through port of housing. Apply pressure to side of balance ring assembly. Hold ring in position until valve housing is in place (see Figure 21). Align case drain hole in housing with case drain hole in valve plate. Install valve housing against valve plate (see Figure 22). 45 Install and finger tighten 2 bolts (or studs for earlier models) opposite alignment studs. Remove alignment studs and install remaining bolts (or studs and 4 nuts for earlier models). Torque bolts (or nuts) to 85 Nm[750 lb-in], in sequence (see Figure 23). Note: After installing valve housing on valve plate, check between body parts of motor for unseated seals. Bolt Plug Assembly 4 1 2 3 7/16-20 Drain Plug Torque to 17 Nm [150 lb-in] (lubricated threads) Check Plug Torque to 7-14 Nm [60-120 lb-in] (lubricated threads) Figure 23 Check Plug Assembly Figure 22 46 Install 2 check plug assemblies (ball, spring, plug with seal). Also install case drain plug with seal, parts shown in Figure 22 (plug torque shown in Figure 24). Key Seal Retainer Dust Seal Wheel Motors A different bearing housing is used on wheel motors (see Figure 24). Other than this, the parts are the same as the standard motor and the same disassembly and reassembly procedures apply. Nut Shaft Seal Backup Ring Cap Screw Figure 24 Mounting Flange Bearingless Motors O-ring Seal This motor is the same as the standard without the shaft/bearing assembly, bearing housing and retainer. The mounting flange replaces the bearing housing (see Figure 25). Follow same disassembly and reassembly procedures as rear section of standard motor. Important: Loctite® information for bearingless motor on page 10. Drive Seal Seal Figure 25 9 4000 Series Char-Lynn Motors Reassembly Important: This motor requires Loctite in threaded holes of mounting flange. Follow these procedures: Attention: Do not use more than 3 drops of Loctite on threaded portion. Adequate Loctite penetration and sealing depend highly on cleanliness and dryness of threads. Use a non-petroleum base solvent to clean excess oil from threads of flange after disassembly. You may need to use a tap to clean threads of excess old Loctite. After you have fully reassembled the motor, apply 2 to 3 drops of Loctite no. 290 at top of threaded holes (see Figure 26). Note: Allow Loctite 5 minutes for thread penetration before installing motor on gear case. Figure 26 Motors with Shuttle and, or Seal Guard Plug/O-ring* S/A (9/16-18) Torque to 23 Nm [200 lb-in] (Lubricated Thread) Plug/O-ring S/A (3/8-24) Torque to 5 Nm [50 lb-in] (Lubricated Thread) Enlarged Parts Drawing Plug/O-ring S/A (9/16-18) Torque to 41 Nm [360 lb-in] (Lubricated Thread) Optioal Seal Guard Dash Pot Poppet Spring Piston *Plug/O-ring S/A must be removed and drain line added for shuttle valve operation. 10 Poppet Spring Dash Pot Plug/ O-ring S/A 4000 Series Char-Lynn Motors How to Order Replacement Parts Date Code Char-Lynn ® Each Order Must Include the Following: 00 0 Product number 4. Part Number 1. Product Number 2. Date Code 5. Quantity of Parts 3. Part Name For more detailed information contact Eaton Corp. Hydraulics Division 15151 Highway 5 Eden Prairie, MN 55344. Specifications and performance data, Catalog No. 11-878. Replacement part numbers and kit information — Parts Information No. 6-126. Product Number Last Number of Year 109 0000 000 110 0000 000 111 0000 000 Product Line Identification Number Product Numbers—4000 Series Motors Week of Year 01 Thru 52 Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 Product Identification Number Engineering Change Code Use digit prefix —109-, 110-, or 111- plus four digit number from charts for complete product number—Example 111-1057. Orders will not be accepted without three digit prefix. Displ. cm3/r [ in3/r] Product Number Mounting Shaft Ports 110 [ 6.7] 130 [ 7.9] 160 [ 9.9] 205 [12.5] 245 [15.0] 310 [19.0] 395 [24.0] 495 [30.0] 625 [38.0] 109-1100 -1101 -1102 -1103 -1104 -1105 -1106 -1212 -1215 3/4 inch Split Flange 109-1001 -1054 -1002 -1003 -1055 -1056 -1057 — — 109-1107 -1108 -1109 -1110 -1111 -1112 -1113 — — 3/4 inch Split Flange 109-1006 -1058 -1007 -1008 -1059 -1060 -1061 — — 109-1114 -1115 -1116 -1117 -1118 -1119 -1120 — — 3/4 inch Split Flange 109-1011 -1062 -1012 -1013 -1063 -1064 -1065 — — 40 mm Straight G 3/4 (BSP) 109-1184 -1185 -1227 -1224 -1225 -1189 -1190 — — 1-1/2 Inch 17 T Splined G 3/4 (BSP) 109-1191 -1192 -1193 -1194 -1195 -1196 -1197 — — 1-1/16 O-ring 110-1074 -1075 -1076 -1077 -1078 -1079 -1080 — -1122 3/4 inch Split Flange 110-1001 -1040 -1002 -1003 -1041 -1042 -1043 — — G 3/4 (BSP) 110-1108 -1109 -1110 -1111 -1112 -1113 -1125 — — 1-1/16 O-ring 110-1081 -1082 -1083 -1084 -1085 -1086 -1087 1116 -1117 3/4 inch Split Flange 110-1006 -1044 -1007 -1008 -1045 -1046 -1047 — — 110-1088 -1089 -1090 -1091 -1092 -1093 -1094 — — 3/4 inch Split Flange 110-1011 -1048 -1012 -1013 -1049 -1050 -1051 — — 1-1/16 O-ring 111-1033 -1034 -1035 -1036 -1037 -1038 -1039 -1062 -1063 3/4 inch Split Flange 111-1044 -1015 -1045 -1046 -1016 -1017 -1018 — — G 3/4 (BSP) -1053 -1054 -1055 -1056 -1057 -1058 — — 1-1/16 O-ring 1-1/4 inch Straight Standard SAE B-Mount 1-5/8 Inch Tapered 1-1/4 Inch 14 T Splined Standard SAE C-Mount 1-1/16 O-ring 1-1/16 O-ring 1-1/4 inch Straight 40 mm Straight Wheel Motor 1-5/8 Inch Tapered 1-1/4 Inch 14 T Splined Bearingless 1-1/16 O-ring 111-1052 111-1057 11 Disc Valve Motors 4000 Series Motors Eaton Corporation Hydraulics Division 15151 Hwy. 5 Eden Prairie, MN 55344 Telephone: 612/937-7254 Fax: 612/937-7130 Eaton Ltd. Hydraulics Division Glenrothes, Fife Scotland, KY7 4NW Telephone: [+44] (0)1592-771-771 Fax: [+44] (0)1592-773-184 Eaton B.V. Boeing Avenue 11 1119 PC Schiphol-Rijk The Netherlands Telephone: [+31] (0)20-655 6776 Fax: [+31] (0)20-655 6800 Sumitomo Eaton Hydraulic Co. 8 Temasek Blvd. 42-01 Suntec Tower Three Singapore 03988 Telephone: [+65] 832-7727 Fax: [+65] 832-7733 Sumitomo Eaton Hydraulic Company Ltd. Ooi-Cho Kameoka-Shi 621-0017 Kyoto Japan Telephone: [+81] 771-22-9601 Fax: [+81] 771-29-2020 Eaton Ltd. 7th Floor, Woo Duk Building 832-2 Yeoksam-Dong, Kangnam-Ku Soeul 135-750 Korea Telephone: [+82] 2-557-0595 Fax: [+82] 2-557-1634 Eaton Hydraulics (Shanghai) Co. Ltd. 388 Aidu Road, Waigaogiao FTZ Pudong New Area Shanghai 200137 Peoples Republic of China Telephone: [+86] 21-5046 0758 Fax: [+86] 21-5046 0767 Jining Eaton Hydraulic Co. Ltd. 6 Ji Da Road Jining City Shandong Province 272131 Peoples Republic of China Telephone: [+86] 537-2221288 Fax: [+86] 537-2221557 www.eatonhydraulics.com Form No. 7-118 Copyright Eaton Corporation 1981, 1992, 1995, 1997 and 1999 All Rights Reserved Printed in USA ACCREDITED BY THE DUTCH COUNCIL FOR CERTIFICATION Reg. No. 24 ISO-9001 CERTIFICATED FIRM DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS Qualitiy System Certified Products in this catalog are manufactured in an ISO-9001-certified site. Char-Lynn No. 7-310 January, 1995 ® Power Steering Repair Information T EL RP 2 Series Steering Control Unit 001 Power Steering 2 Series Steering Control Units Thrust Bearing O-ring Seal Housing Quad Seal Bearing Race (2) Dust Seal Check Ball O-ring Plug Manual Steering Relief Valve O-ring Spacer Plug Centerin Springs O-ring Drive Wear Plate Sleeve Pin Cap Screw (7) Spool Gerotor Spring Retaining Ring Tools Required • 10 mm Socket • 7/8 in. Socket • Torque Wrench (18 Nm [160 lb-in] Capacity) • Small Blade Screwdriver 2 O-ring Seal Ring O-ring Seal End Cap Power Steering 2 Series Steering Control Units End Cap Disassembly Cleanliness is extremely important when repairing hydraulic Steering Control Units (SCU). Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the SCU. Before disassembly, drain the oil, then plug the ports and thoroughly clean the exterior of the SCU. During repairs, always protect machined surfaces. O-ring Seal Wear Plate Cap Screw (7) Seal Ring Gerotor Drive O-ring O-ring Spacer O-ring Seal O-ring Plug Manual Steering Check/Relief Valve 1 Remove the seven cap screws and disassemble the SCU as shown in Figure 1. Figure 1 4 Remove the thrust bearing and bearing races. 5 Remove the quad seal. 2 Remove the plug and manual steering check as shown in Figure 1. Note: The manual steering check may be a check ball or a check/relief valve. 6 Using a small blade screwdriver, carefully pry the dust seal from the housing. Important: Do not damage the dust seal seat. 3 Slide the spool and sleeve from the housing (see Figure 2). Spool and Sleeve Thrust Bearing Housing Quad Seal Bearing Race (2) Dust Seal Figure 2 3 Power Steering 2 Series Steering Control Units Centering Springs and Spacers Sleeve Spring Retaining Ring Pin Spool Figure 3 7 Remove the pin that holds the spool and sleeve together (see Figure 3). 8 Carefully slide the spool out of the sleeve. The springs and retaining ring will stay with the spool as it's removed. 9 Remove the retaining ring and springs. Caution: The centering springs are under tension. Remove the retaining ring carefully. Reassembly Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressurized air. Do not wipe parts dry with paper towels or cloth as lint in a hydraulic system will cause damage. Note: Always use new seals when reassembling hydraulic steering control units. Refer to parts list 6-323 for seal kit part numbers, replacement parts, and ordering information. Important: During reassembly lubricate the new seals with a petroleum jelly such as Vaseline®. Also lubricate machined surfaces and bearings with clean hydraulic fluid. 10 Install the quad seal: • Put one of the bearing races and sleeve into the housing. • Together, the housing and bearing race create a groove into which the quad seal will be installed. • Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve. • Fit the quad seal into its seat through the input end of the housing. Be sure the seal is not twisted. • Remove the sleeve and bearing race. 4 Power Steering 2 Series Steering Control Units Thrust Bearing and Race (2) Dust Seal 20 Lubricate and install a new o-ring seal in the groove in the housing. 21 Install the wear plate and align the holes in the wear plate with threaded holes in the housing. Note: The holes in the wear plate are symmetrical. Quad Seal Figure 4 11 Lubricate and install the dust seal (see Figure 4 for correct seal orientation). 22 Install the drive, be sure the slot in the drive engages the pin. 23 Lubricate and install a new o-ring seal in the groove in the wear plate. 24 Install the gerotor and align the screw holes. 12 Install the centering springs in the spool. It is best to install the two flat pieces first. Next, install the curved pieces, three at a time. 13 Fit the retaining ring over the centering springs. 25 Lubricate and install a new o-ring seal in the groove in the gerotor ring. 26 Lubricate and install a new o-ring and seal ring in the groove in the gerotor star. 14 Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve. Be sure the centering springs fit into the notches in the sleeve. 27 Install the spacer. 15 Install the pin (see Figure 3). 28 Install end cap and seven cap screws. Tighten cap screws, in a crisscross pattern, to 16 -18 Nm [140 -160 lb-in]. 16 Apply a light coating of petroleum jelly to the inner edge of the dust and quad seals. 29 Remove the SCU from the vise. 17 Put the thrust bearing and races into the housing. The thrust bearing goes between the two races (see Figure 2). 30 Install the relief valve/check or check ball and plug. Use a new o-ring and tighten the plug to 17 Nm [150 lb-in]. 18 Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide it into the housing. Important: Do not damage the dust or quad seals. 19 Clamp the housing in a vise as shown in Figure 5. Use just enough clamping force to hold the housing securely. Figure 5 5 Power Steering 2 Series Steering Control Units Product Numbers 2 Series (Standard — 69 Bar [1000 PSI]) System Relief Valve Setting Bar [PSI] None 40 [ 580] 50 [ 725] 63 [ 914] 70 [1015] Displacement cm3/r [in3/r] and Product Number 9/16 -18 Inch SAE (4) Ports 31 [1.9] 39 [2.4] 51 [3.1] 63 [3.8] 74 [4.5] 100 [6.1] 291-1001-001 291-1001-041 291-1001-051 291-1001-061 291-1001-071 291-1002-001 291-1002-041 291-1002-051 291-1002-061 291-1002-071 291-1003-001 291-1003-041 291-1003-051 291-1003-061 291-1003-071 291-1004-001 291-1004-041 291-1004-051 291-1004-061 291-1004-071 291-1005-001 291-1005-041 291-1005-051 291-1005-061 291-1005-071 291-1006-001 291-1006-041 291-1006-051 291-1006-061 291-1006-071 None 40 [ 580] 50 [ 725] 63 [ 914] 70 [1015] 291-1007-001 291-1007-041 291-1007-051 291-1007-061 291-1007-071 291-1008-001 291-1008-041 291-1008-051 291-1008-061 291-1008-071 291-1009-001 291-1009-041 291-1009-051 291-1009-061 291-1009-071 291-1010-001 291-1010-041 291-1010-051 291-1010-061 291-1010-071 291-1011-001 291-1011-041 291-1011-051 291-1011-061 291-1011-071 291-1012-001 291-1012-041 291-1012-051 291-1012-061 291-1012-071 9/16 Inch Plug-O (5) None 40 [ 580] 50 [ 725] 63 [ 914] 70 [1015] 291-5001-001 291-5001-041 291-5001-051 291-5001-061 291-5001-071 291-5002-001 291-5002-041 291-5002-051 291-5002-061 291-5002-071 291-5003-001 291-5003-041 291-5003-051 291-5003-061 291-5003-071 291-5004-001 291-5004-041 291-5004-051 291-5004-061 291-5004-071 291-5005-001 291-5005-041 291-5005-051 291-5005-061 291-5005-071 291-5006-001 291-5006-041 291-5006-051 291-5006-061 291-5006-071 9/16 -18 Inch SAE (5) None 40 [ 580] 50 [ 725] 63 [ 914] 70 [1015] 291-5007-001 291-5007-041 291-5007-051 291-5007-061 291-5007-071 291-5008-001 291-5008-041 291-5008-051 291-5008-061 291-5008-071 291-5009-001 291-5009-041 291-5009-051 291-5009-061 291-5009-071 291-5010-001 291-5010-041 291-5010-051 291-5010-061 291-5010-071 291-5011-001 291-5011-041 291-5011-051 291-5011-061 291-5011-071 291-5012-001 291-5012-041 291-5012-051 291-5012-061 291-5012-071 9/16 Inch Plug-O (4) Open Center NonLoad Reaction Power Beyond NonLoad Reaction Dynamic Signal Load Sensing 9/16 Inch Plug-O (5) None 293-4001-001 293-4002-001 293-4003-001 293-4004-001 293-4005-001 293-4006-001 9/16 -18 Inch SAE (5) None 293-4007-001 293-4008-001 293-4009-001 293-4010-001 293-4011-001 293-4012-001 Product Numbers 2 Series (High Pressure — 103 Bar [1500 PSI]) Open Center NonLoad Reaction Power Beyond NonLoad Reaction Dynamic Signal Load Sensing 6 9/16 Inch Plug-O (4) None 80 [1160] 90 [1305] 100 [1450] 291-1001-121 291-1001-081 291-1001-091 291-1001-101 291-1002-121 291-1002-081 291-1002-091 291-1002-101 291-1003-121 291-1003-081 291-1003-091 291-1003-101 291-1004-121 291-1004-081 291-1004-091 291-1004-101 291-1005-121 291-1005-081 291-1005-091 291-1005-101 291-1006-121 291-1006-081 291-1006-091 291-1006-101 9/16 -18 Inch SAE (4) None 80 [1160] 90 [1305] 100 [1450] 291-1007-121 291-1007-081 291-1007-091 291-1007-101 291-1008-121 291-1008-081 291-1008-091 291-1008-101 291-1009-121 291-1009-081 291-1009-091 291-1009-101 291-1010-121 291-1010-081 291-1010-091 291-1010-101 291-1011-121 291-1011-081 291-1011-091 291-1011-101 291-1012-121 291-1012-081 291-1012-091 291-1012-101 9/16 Inch Plug-O (5) None 80 [1160] 90 [1305] 100 [1450] 291-5001-121 291-5001-081 291-5001-091 291-5001-101 291-5002-121 291-5002-081 291-5002-091 291-5002-101 291-5003-121 291-5003-081 291-5003-091 291-5003-101 291-5004-121 291-5004-081 291-5004-091 291-5004-101 291-5005-121 291-5005-081 291-5005-091 291-5005-101 291-5006-121 291-5006-081 291-5006-091 291-5006-101 9/16 -18 Inch SAE (5) None 80 [1160] 90 [1305] 100 [1450] 291-5007-121 291-5007-081 291-5007-091 291-5007-101 291-5008-121 291-5008-081 291-5008-091 291-5008-101 291-5009-121 291-5009-081 291-5009-091 291-5009-101 291-5010-121 291-5010-081 291-5010-091 291-5010-101 291-5011-121 291-5011-081 291-5011-091 291-5011-101 291-5012-121 291-5012-081 291-5012-091 291-5012-101 9/16 Inch Plug-O (5) None 293-4001-121 293-4002-121 293-4003-121 293-4004-121 293-4005-121 293-4006-121 9/16 -18 Inch SAE (5) None 293-4007-121 293-4008-121 293-4009-121 293-4010-121 293-4011-121 293-4012-121 Power Steering 2 Series Steering Control Units 7 Power Steering 2 Series Steering Control Units How to Order Replacement Parts Each Order Must Include the Following: 1. Product Number 2. Date Code 3. Part Name 4. Part Number 5. Quantity of Parts Char-Lynn® Product number Eaton Corp. Hydraulics Div. Eden Prairie, MN 55344 Product Number Specifications and performance data, Catalog No. 11-872 00 00 000 0000 000 000 0000 000 For More Detailed Information Contact Eaton Corp. Hydraulics Division 15151 Highway 5 Eden Prairie, MN 55344. Date Code 000 Product Line Identification Number Product Identification Number Replacement part numbers and kit information — Parts Information No. 7-310. Week of Year 01 Thru 52 Last Number(s) of Year Engineering Change Code Relief Valve Pressure Code 00 = None 04 = 40 Bar [ 580 PSI] 05 = 50 Bar [ 725 PSI] 06 = 63 Bar [ 914 PSI] 07 = 70 Bar [1015 PSI] 08 = 80 Bar [1160 PSI] 09 = 90 Bar [1305 PSI] 10 = 100 Bar [1450 PSI] ACCREDITED BY THE DUTCH COUNCIL FOR CERTIFICATION Reg. No. 24 Eaton Corporation Hydraulics Division 15151 Hwy. 5 Eden Prairie, MN 55344 Telephone 612/937-9800 Fax 612/937-7130 Form No. 7-310 Eaton Ltd. Hydraulics Division Glenrothes, Fife Scotland, KY7 4NW Telephone 01-592-771-771 Fax 01-592-773-184 Copyright Eaton Corporation, 1991, and 1995 All Rights Reserved Printed in USA Eaton GmbH Hydraulics Products Am Schimmersfeld 7 40880 Ratingen, Germany Telephone 02102-406-830 Fax 02102-406-800 ISO-9001 CERTIFICATED FIRM DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS Quality System Certified Products in this catalog are manufactured in an ISO-9001-certified site. ENGINE--GAS/LP CONTENTS Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . 6-3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . 6-4 ENGINE OIL . . . . . . . . . . . . . . . . . . . . 6-4 COOLING SYSTEM . . . . . . . . . . . . . . . . 6-4 ENGINE FAN BELT . . . . . . . . . . . . . . 6-5 AIR INTAKE SYSTEM . . . . . . . . . . . . . . 6-5 AIR FILTER INDICATOR . . . . . . . . . 6-5 AIR FILTER . . . . . . . . . . . . . . . . . . . . . 6-5 TO REPLACE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . 6-6 FUEL SYSTEM -- GASOLINE . . . . . . . . 6-7 FUEL FILTER . . . . . . . . . . . . . . . . . . . 6-7 CARBURETOR . . . . . . . . . . . . . . . . . 6-7 FUEL SYSTEM -- LPG . . . . . . . . . . . . . . 6-8 LP FUEL TANKS . . . . . . . . . . . . . . . 6-10 TO CHANGE AN LPG FUEL TANK . . . . . . . . . . . . . . . . . . . . . . 6-12 FUEL FILTER LOCK . . . . . . . . . . . . 6-14 VAPORIZER-REGULATOR . . . . . . 6-14 CARBURETOR . . . . . . . . . . . . . . . . 6-14 OIL PRESSURE SWITCH . . . . . . . 6-14 LPG FUEL TROUBLESHOOTING 6-15 CYLINDER HEAD . . . . . . . . . . . . . . . . . 6-15 VALVE TAPPET CLEARANCE . . . 6-15 CRANKCASE VENTILATION SYSTEM . . . . . . . . . . . . . . . . . . . 6-15 GOVERNOR TROUBLESHOOTING . . . . . . . 6-16 GOVERNOR . . . . . . . . . . . . . . . . . . . . . 6-24 TO ADJUST GOVERNOR . . . . . . . 6-24 DIGITAL CONTROLLER SET--UP 6-25 IGNITION SYSTEM . . . . . . . . . . . . . . . 6-26 SPARK PLUGS . . . . . . . . . . . . . . . . 6-26 TO REPLACE SPARK PLUGS . . . 6-26 FORD DISTRIBUTORLESS IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . 6-27 SYNOPSIS . . . . . . . . . . . . . . . . . . . . 6-27 ENGINE TEMPERATURE . . . . . . . 6-27 RUN MODE . . . . . . . . . . . . . . . . . . . 6-28 SERVICING AND TESTING . . . . . 6-28 “FAILURE MODE OF DIS” IGNITION HARNESS . . . . . . . . 6-29 FORD DIS IGNITION . . . . . . . . . . . 6-30 ENGINE COOLANT SENSOR . . . . . . 6-31 TO REPLACE ENGINE ALTERNATOR . . . . . . . . . . . . . . . . . 6-32 TO REPLACE ENGINE STARTER . . . 6-34 TO REMOVE ENGINE . . . . . . . . . . . . . 6-35 TO INSTALL ENGINE . . . . . . . . . . . . . . 6-38 TO PURGE AIR FROM RADIATOR . . 6-40 7400 MM428 (3--02) GAS ENGINE SERVICE MANUAL FORD VSG--411/413 TENNANT Part Number 38978 6-1 ENGINE--GAS/LP 6-2 7400 MM428 (12--98) ENGINE--GAS/LP INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and drive belts. 7400 MM428 (12--98) 6-3 ENGINE--GAS/LP LUBRICATION ENGINE OIL Check the engine oil level daily. Change the engine oil and oil filter every 100 hours of machine operation. Use 10W30 SAE--SG/SH rated engine oil. Fill the engine with oil to the level indicated on the oil dipstick. The engine oil capacity is 3.3 L (3.5 qt) including the oil filter. COOLING SYSTEM Check the radiator coolant level every 100 hours of operation. Use clean water mixed with a permanent-type, ethylene glycol antifreeze to a --34_ C (--30_ F) rating. FOR SAFETY: When Servicing Machine, Avoid Contact With Hot Engine Coolant. ATTENTION! Never pour cold water or cold antifreeze into the radiator of an overheated engine. Allow the engine to cool down to avoid cracking the cylinder head or block. Keep the engine running while adding water. Check the radiator hoses and clamps every 200 hours of operation. Tighten the clamps if they are loose. Replace the hoses and clamps if the hoses are cracked, harden, or swollen. Check the radiator core exterior and hydraulic cooler fins for debris every 100 hours of operation. Blow or rinse all dust, which may have collected on the radiator, in through the grille and radiator fins, opposite the direction of normal air flow. The grille and hydraulic cooler open for easier cleaning. Be careful not to bend the cooling fins when cleaning. Clean thoroughly to prevent the fins becoming encrusted with dust. Clean the radiator and cooler only after the radiator has cooled to avoid cracking. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 800 hours of operation, using a dependable cleaning compound. 6-4 7400 MM428 (12--98) ENGINE--GAS/LP ENGINE FAN BELT The engine fan belt is driven by the engine crankshaft pulley and drives the alternator pulley. Proper belt tension is 13 mm (0.50 in) from a force of 4 to 5 kg (8 to 10 lb) applied at the mid-point of the longest span. Check and adjust the belt tension every 100 hours of operation. AIR INTAKE SYSTEM AIR FILTER INDICATOR The air filter indicator shows when to clean or replace the air filter element. Check the indicator daily. The indicator’s red line will move as the air filter element fills with dirt. Do not clean or replace the air filter element until the red line reaches 5 kPa (20 in H2O) and the ”SERVICE WHEN RED” window is filled with red. The indicator’s red line may return to a lower reading on the scale when the engine shuts off. The red line will return to a correct reading after the engine runs for a while. Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element. AIR FILTER The engine air filter housing has a dust cap and a dry cartridge-type air filter element. Empty the dust cap daily. The air filter must be replaced whenever the filter element is damaged or has been cleaned three times. Service the air filter element only when the air filter indicator shows restriction in the air intake system. Do not remove the air filter element from the housing unless it is restricting air flow. 7400 MM428 (12--98) 6-5 ENGINE--GAS/LP TO REPLACE AIR FILTER ELEMENT FOR SAFETY: Before Leaving Or Servicing Machine: Stop On Level Surface, Set The Parking Brake, Turn Off Machine And Remove Key. 1. Open the engine cover and side door. 2. Unscrew the clamp ring on the filter. 3. Remove the dust cap. 4. Empty the dust cap. 5. Remove the filter wing nut. 6. Pull the filter element out of the filter housing. 7. Clean the interior of the air cleaner housing with a camp cloth. Clean the element housing sealing surfaces. 8. Using an air hose, direct dry, clean air maximum 205 kPa (30 psi) up and down pleats on the inside of the filter. Do not rap, tap, or pound dust out of the element. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. 9. After cleaning the air filter element, inspect it for damage by placing a bright light inside. The slightest rupture requires replacement of the filter. Clean and inspect the seals on the ends of the element. They should be unbroken and flexible. Remember to replace the element after cleaning it three times. 10. Install the new or cleaned filter element so the fins on the element are at the intake end of the air cleaner. Be careful not to damage the fins. Make sure the element is seating evenly. Tighten the element wing nut. 11. Install the dust cap with the arrows pointing up. Tighten the clamp ring to hold it in place. Check all intake hose connections for leaks or abrasions. 12. Reset the air filter restriction indicator. 13. Close the access doors. 6-6 7400 MM428 (12--98) ENGINE--GAS/LP FUEL SYSTEM -- GASOLINE FUEL FILTER The fuel filter trap fuel contaminants. The filter is located on the fuel line going into the carburetor. Replace the filter elements every 400 hours of operation. CARBURETOR The carburetor has two basic adjustments. Those adjustments are idle fuel mixture and idle speed. Check and adjust idle fuel mixture and idle speed every 100 hours of operation. FOR SAFETY: When Servicing Machine, Keep Flames And Sparks Away From Fuel System Service Area. Keep Area Well Ventilated. The idle speed is controlled by a screw located on the side of the carburetor next to the throttle linkage. Increase the engine speed by turning the screw clockwise. Decrease the engine speed by turning the screw counter--clockwise. Idle speed is 800 to 900 rpm for gasoline, and 900 to 1000 for LPG, with no power to the electronic governor. 7400 MM428 (2--94) 6-7 ENGINE--GAS/LP FUEL SYSTEM -- LPG The liquid withdrawal LPG fuel system has up of five components: the LPG fuel tank, pressure relief valve, fuel filter lock, vaporizer-regulator, and the carburetor. Liquid LPG fuel flows from the LPG tank, under its own pressure, to the pressure relief valve. Usually this valve is closed, preventing LPG fuel from escaping into the atmosphere. The valve opens to relieve pressure if the fuel pressure exceeds system limits. From the pressure relief valve, the liquid LPG fuel flows to the fuel filter lock. The fuel filter lock filters unwanted tank scale and deposits out of the LPG fuel. The fuel filter lock also stops the flow of LPG fuel when the engine is not operating. The oil pressure switch controls the fuel filter lock. When the engine oil pressure is 35 kPa (5 psi) or greater, the oil pressure switch permits an electrical current to open the fuel filter lock which allows LPG fuel to flow on to the vaporizer-regulator. The oil pressure switch is bypassed when the engine is being started, allowing LPG fuel to flow. The vaporizer section of the vaporizer-regulator converts the liquid LPG fuel into a gaseous LPG fuel. From the vaporizer section, the gaseous LPG fuel is sent to the primary regulator section of the vaporizer-regulator. The primary regulator section reduces the pressure of the LPG fuel. The secondary regulator section reduces the LPG fuel pressure to the level required by the carburetor. From the vaporizer-regulator, the LPG fuel is sent to the carburetor where it is finally metered into the air flow sent to the engine combustion chamber. Never operate an LPG powered machine if the LPG fuel system is leaking, or if any component in the fuel system is malfunctioning. Operating the machine under either of these conditions may cause a fire or explosion. 6-8 7400 MM428 (12--98) ENGINE--GAS/LP Check for frosting. If frosting occurs on or near any LPG component, there is a possible LPG fuel leak or malfunctioning component. To locate the leak, apply a soapy water solution to the suspected area. Watch for bubbles forming in this suspected area. This area may have an LPG fuel leak. Repair or replace the part. Use Loctite brand Stainless Steel PST thread sealant when reassembling. Aging or high humidity does not affect this epoxy-type sealant. Be sure to follow application directions and apply proper torque when reconnecting fittings. Never bypass safety components except to test. If they are defective, replace them before operating the machine. Frosting does not occur before the engine reaches operating temperature. Check after engine reaches operating temperature. Check routings of all LPG hoses. Keep them away from sharp edges, exhaust manifolds, or other hot surfaces. Check for signs of abrasion or deterioration. Replace worn or damaged hoses. 7400 MM428 (12--98) 6-9 ENGINE--GAS/LP LP FUEL TANKS The LPG fuel tanks should be inspected for sharp dents, gouges, leaks, and broken protecting rings whenever the tanks are refilled. All tank valves must be inspected for leaks using a soap solution. Valves must also be checked for dirt, paint, or other debris in the valve openings. The following specific checks must also be made: Filler Valve -- Check the valve for proper functioning and the presence of the handwheel. Valve must be closed except during filling. Liquid Service Valves -- Check the valve for proper functioning and presence of the handwheel. The valve must be closed except when in service. Tank Service Valve Coupling -- Check for proper functioning, thread condition, and damaged or missing washers or o-rings. 6-10 7400 MM428 (12--98) ENGINE--GAS/LP Safety Relief Valve -- Check for damage. Check for the presence of the relief valve elbow and the proper direction of the elbow. If the rain cap is missing, check for foreign matter and replace the rain cap. Do not tamper with the relief valve setting. Magnetic Liquid Level Gauge -- Check the operation against the maximum filling point as determined by weight. An LPG fuel tank with any of the stated defects must be removed from service and be repaired or destroyed accordingly. If an LPG fuel tank is damaged or leaking, it should be removed to a designated safe area. Do not attempt to make repairs to the tank, regardless of condition. Qualified personnel must make repairs or disposal. The care an LPG fuel tank receives has a direct bearing on how long that tank can be used safely. LPG fuel tanks must not be dropped or dragged across any surface. To move LPG fuel tanks, use a hand truck or roll the tank on its foot ring while it is being held in a position slightly off the vertical. Whether the storage is inside or outside, fuel tanks should not be stored near combustible materials or high temperature sources such as ovens and furnaces, since the heat may raise the pressure of the fuel to a point where the safety relief valves would function. Store the tanks in a way that if the safety relief valves do function, they will relieve vapor and not liquid. 7400 MM428 (12--98) 6-11 ENGINE--GAS/LP Valves on empty tanks must be closed during storage and transportation. Similar precautions should be taken in storing machines fitted with LPG fuel tanks. The machines may be stored or serviced inside buildings, provided there are no leaks in the fuel system and the tanks are not overfilled. While machines are being repaired inside a building, the shut-off valve on the tank must be closed, except when the engine has to be operated. Changing the tank is a chance for the machine operator to carefully check over the tank, fittings, and the fuel lines and fittings. If abnormal wear is detected, report the findings to the appropriate personnel. TO CHANGE AN LPG FUEL TANK 1. Park the machine in a designated safe area. 2. Close the tank service valve. 3. Operate the engine until it stops from lack of fuel, then set the machine parking brake. FOR SAFETY: Before Leaving Or Servicing Machine: Stop On Level Surface, Set The Parking Brake, Turn Off Machine And Remove Key. 4. Put on gloves and remove the quick-disconnect tank coupling. 5. Inspect the LPG fuel lines for wear or damage. 6. Remove the empty LPG fuel tank from the machine. 7. Check the tank for damage or wear. 8. Store the tank in a designated, safe area. 9. Select a filled LPG fuel tank and inspect it for damage or leaks. NOTE: Make sure the LPG fuel tank matches the fuel system (liquid tank with liquid system). 6-12 7400 MM428 (12--98) ENGINE--GAS/LP 10. Carefully put the LPG tank in the machine so that the tank centering pin enters the aligning hole in the tank collar. NOTE: If you cannot line up the centering pin, make sure you have the correct LPG fuel tank and then adjust the pin locator in or out. 11. Fasten the tank hold-down clamp to lock the tank in position. 12. Connect the LPG fuel line to the tank service coupling. Make sure the service coupling is clean and free of damage. Also make sure it matches the machine service coupling. 13. Open the tank service valve slowly and check for leaks. Close the service valve immediately if an LPG leak is found, and tell the appropriate personnel. 14. If no leaks are found, the engine is ready to start. 7400 MM428 (12--98) 6-13 ENGINE--GAS/LP FUEL FILTER LOCK The fuel filter lock filters the LPG fuel. It also stops the flow of LPG fuel to the engine when the engine is not operating or when the engine oil pressure is less than 35 kPa (5 psi). VAPORIZER-REGULATOR If any malfunction is found, completely disassemble the vaporizer-regulator. Clean all the parts in alcohol. Inspect all the parts and replace where needed. Carefully reassemble the vaporizer-regulator with the seal repair kit. Check for proper operation. CARBURETOR If any malfunction is found, completely disassemble the carburetor. Clean all the parts in alcohol. Inspect all the parts and replace where needed. Carefully reassemble the carburetor with the seal repair kit. OIL PRESSURE SWITCH The engine oil pressure switch requires no regular maintenance. Never bypass the oil pressure switch. The switch is a safety feature that prevents LPG fuel from flowing when the engine is not operating properly. 6-14 7400 MM428 (12--98) ENGINE--GAS/LP LPG FUEL TROUBLESHOOTING Problem Cause Remedy Engine will not start Out of fuel Replace fuel tank with full one Service valve opened too quickly -- check valve stopped fuel flow Close service valve and reopen slowly Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune-up engine Oil pressure switch failure Replace oil pressure switch Fuel lock valve failure Repair or replace fuel filter lock Vaporizer-regulator failure Repair or replace vaporizer-regulator Wrong type of fuel tank -- vapor withdrawal tank Replace vapor withdrawal tank with liquid withdrawal tank Plugged fuel filter Replace filter Kinked or restricted fuel line Straighten or replace fuel line Engine out of tune Tune-up engine Restricted air filter Clean or replace air filter element Vaporizer-regulator out of adjustment Adjust vaporizer-regulator Engine runs unevenly or lacks power CYLINDER HEAD A three-stage torque procedure should be used when reassembling the cylinder head. Tighten the cylinder head bolts seasonally. See Ford VSG 411/413 Engine Service Manual. VALVE TAPPET CLEARANCE Check and adjust the intake valve clearance to 0.22 mm (0.009 in), and the exhaust valve clearance to 0.32 mm (0.013 in) while the engine is cold the first 50 hours of operation and every 400 hours there after. See Ford VSG 411/413 Engine Service Manual. CRANKCASE VENTILATION SYSTEM Clean the crankcase ventilation hoses, tubes, and fittings and replace the PCV valve every 400 hours of operation. 7400 MM428 (12--98) 6-15 ENGINE--GAS/LP GOVERNOR TROUBLESHOOTING 1. The first step in this troubleshooting is to disconnect the throttle linkage at the carburetor and work the throttle at the carburetor by hand. If you can run the engine by hand and it works with no problems, go to step four. If the problem continues, it is not with the governor, it is with the ignition signal fuel systems or the engine itself. 2. Ignition Signal The DIS engine has no distributor, but the timing signals that drive the governor originate from the Ignition Control input leads. They are the Yellow Wire #71 and the Yellow Wire #72. To test this, use the governor test harness (TENNANT Part No. 66137). Once the harness is in place, use a tach/dwell meter to test for the proper RPM’s and a flat ignition signal. Test at the text plug at either Pin C, or Pin D. NOTE: An inductive RPM pickup won’t work for this test. NOTE: When checking the RPM’s at Pin C, and Pin D, the ignition signal will be half of the total RPM’s the engine is running at because of the DIS system. Your readings should be: TOTAL READING--GAS a. Start/Idle -- 800 RPM b. I -- 1350¦ 50 RPM c. II -- 2400¦ 50 RPM TOTAL READING--LPG a. Start/Idle -- 900 RPM b. I -- 1350¦ 50 RPM c. II -- 2400¦ 50 RPM 6-16 7400 MM428 (12--98) ENGINE--GAS/LP 3. Fuel System A common problem that has been encountered on LPG machines is a restricted fuel hose (a clogged fuel filter can have the same effect). If the governor opens the carburetor wide open and the engine loses speed, the problem is not in the governor. The fuel system is at fault. The purpose of the governor is to open the carburetor and to bring the engine to set RPM’s depending on where you have the speed control switch set at. After you have verified that the ignition system and the fuel system are not at fault, go to the next step. 7400 MM428 (12--98) 6-17 ENGINE--GAS/LP +12VDC Switched Ground D.I.S. Ignition Module Throttle actuator (18D/ORA) (A) + (13E/BLK) (B) -- (71C/YEL) (C) Signal (72C/YEL) (D) Signal (86/PUP) (E) Actuator + (84/GRN) (F) Actuator -- (83/BRN) (G) Speed (85/BLU) (H) Speed (+) (--) Electronic Instrument Panel High = + 9VDC Low = 0VDC ELECTRONIC GOVERNOR WIRING PICTORIAL A A B B C C D D E E F F G G H H TO: HARNESS TO: GOVERNOR A B C D E F G H TEST PLUG NOTE: The wire colors of the test harness do not necessarily match the machine harness. 6-18 7400 MM428 (12--98) ENGINE--GAS/LP 5. System Grounds The wire harness grounds on the machines with a DIS engine are routed to the stud on the alternator, and from there, a separate cable is routed to the bolt on the bell housing where the battery cable is attached. If a bad ground is present, the engine will tend to run over speed. The machine must have good grounds throughout from the battery cable to the control box. The battery cable must be clean and tight. There must not be a greater voltage drop than .2 volts between Pin B, on the test harness, the engine, the alternator, and the battery positive terminal and the battery negative terminal. To do this, take your voltmeter and set it on the DC volts scale. Then with your positive probe, clamp it to battery positive. Then with the negative probe, move it to the above-stated places on the machine. The actuator is internally isolated and does not require that the cable be grounded. 6. Start-Up Check With the throttle switch in the engine start position, turn the ignition switch to the on position. The actuator should cycle the carburetor lever once. NOTE: A cycle is to move from the off or idle position to the open position and then return to the off or idle position. If this does not happen, the power wiring to the control box is probably at fault or the control box is faulty. IT IS RARE TO HAVE A FAULTY CONTROL BOX, so proceed with the following voltage checks BEFORE REPLACING IT. 7. Throttle Control Switch Check If the engine doesn’t respond to the throttle switch control: a. With the engine running, disconnect Wire 86, purple wire, at the actuator. 7400 MM428 (12--98) 6-19 ENGINE--GAS/LP b. Connect a jumper wire from the battery terminal on the starter to the terminal where you removed Wire 86, purple wire, from the actuator. The engine should come up to operating speed. If the engine comes up to speed, replace the throttle control switch. If the engine doesn’t respond, go to the next step. 8. Operating Voltage The following voltage checks are done with the machine not running and using a Fluke or Beckman digital multimeter and the governor test harness. Throttle control switch in start/idle position: Pin A -- Battery Voltage ¦ .2 Pin B -- 0 -- this is a ground Pin C -- Battery Voltage ¦ .2 Pin D -- Battery Voltage ¦ .2 Pin E -- Battery Voltage ¦ .2 Pin F -- Battery Voltage ¦ .2 Pin G -- Battery Voltage ¦ .2 Pin H -- 3 to 3.5 VDC Throttle control switch in the normal sweep position: Pin G -- < 1 VDC Pin H -- 7 to 9 VDC Throttle control switch in the Litter sweep position: Pin G -- < 1 VDC Pin H -- < 1 VDC The following voltage and RPM readings are at the electric control box using the test harness with the machine running. NOTE: when you are testing if you should be in the DC or AC scale on your multimeter. You will also need your tach/dwell for the RPM checks. The readings are taken with either a Fluke or Beckman digital multimeter: 6-20 7400 MM428 (12--98) ENGINE--GAS/LP Throttle control switch in the start/idle position: Pin C -- 675 ¦ 100 RPM Pin D -- 675 ¦ 100 RPM Pin E -- Battery Voltage ¦ .2 Pin F -- 6 to 6.5 VAC Throttle control switch in the normal sweep position: Pin C -- 1100 ¦ 25 RPM Pin D -- 1100 ¦ 25 RPM Pin E -- Battery Voltage ¦ .2 Pin F -- 6.5 to 7 VAC Throttle control switch in the litter sweep position: Pin C -- 1200 ¦ 25 RPM Pin D -- 1200 ¦ 25 RPM Pin E -- Battery Voltage ¦ .2 Pin F -- 7 to 7.5 VAC If you do not get these values: Pin A -- Check battery, wiring/connections, and also the charging system. Pin B -- Check all grounds. Pin C -- Check ignition system and fuel systems. Pin D -- Check ignition system and fuel systems. Pin E -- Possible control board. Pin F -- Possible control board. Pin G -- Possible switch. Pin F -- Possible switch. 7400 MM428 (12--98) 6-21 ENGINE--GAS/LP The volt readings at the actuator with the machine running and using a Fluke or Beckman digital multimeter: At the terminal where Wire 84, green wire, is hooked to: Start/Idle -- 6 to 6.5 VAC ¦ .2 Normal -- 6.5 to 7 VAC ¦ .2 Litter -- 7 to 7.5 VAC ¦ .2 At the terminal where Wire 86, purple wire, is hooked to: Start/Idle -- 12 to 14.5 VDC ¦ .2 Normal -- 12 to 14.5 VDC ¦ .2 Litter -- 12 to 14.5 VDC ¦ .2 9. Control Box Adjustment If all the above aspects, in particular the linkage, have been verified and the warmed up engine either: a. Hunts at running speed with the accessories off. b. Responds very sluggishly to switch changes, an adjustment change in the control box may be necessary. FOR ANALOG CONTROLLERS: Cut and remove the RTV seal on the back of the box. A slight adjustment of the surge screw may be necessary to correct the conditions mentioned above. Turn the screw approximately 2_ at a time and wait for 30 seconds to verify the change. Be careful. Only a slight change is necessary, and the “pot” can be broken if too much force is used. 6-22 7400 MM428 (3--02) ENGINE--GAS/LP After the control throttle response is achieved, verify that the operating speeds are correct and adjust, if necessary. After the speeds are reset, the surge screw may have to be readjusted. In general, if a new box is being installed, a gasoline-equipped machine may require that the sensitivity be reduced slightly. When the sensitivity is adjusted, the run speed should not be affected. If the adjustment is too great, the start speed will be affected. Verify that the start speed is correct. If too much sensitivity is adjusted in, the engine will either hunt in a no load condition or over speed severely when the speed switch is actuated. If too little sensitivity is adjusted in, the engine will seem sluggish. The engine speed will drop off when the load is increased and not recover promptly. The engine speed should not drop off, but you can have the three hunts of the engine. If, for some reason, the sensitivity adjustment became grossly maladjusted, a good starting point can be obtained by rotating the pot fully counterclockwise and then back clockwise 45_. After the adjustments are made and verified, reassemble the back plate and reseat the plate with a bead of RTV to keep dust and moisture out of the box. FOR DIGITAL CONTROLLERS: See TO ADJUST GOVERNOR section of this manual. 7400 MM428 (3--02) 6-23 ENGINE--GAS/LP GOVERNOR The electronic governor controls engine speed. The governor consists of an ignition control assembly, a control box, and an actuator mounted on the engine. The ignition control assembly and control box regulate the actuator, which in turn controls the throttle. The electronic governor is factory set and is not user serviceable. TO ADJUST GOVERNOR 1. Raise the front of the machine and place jack stands under the frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands. 2. Start the engine and warm to operating temperature. 3. Move the speed switch to idle, all accessories off. 4. Move the speed switch to the fast position. 5. For ANALOG CONTROLLER: If engine speed surges occur, turn the surge adjustment screw (located on back of governor control box under hole plug) counterclockwise one-eighth of a turn. Repeat until surges do not occur. Replace hole plug if removed for adjustment. 6. For DIGITAL CONTROLLER: Follow the instructions on the DIGITAL CONTROLLER SET--UP diagram. 7. Remove the jack stands and lower the machine. 6-24 7400 MM428 (3--02) ENGINE--GAS/LP Set DIP switches according to controller label, before installing controller. O 1 F F 3 4 5 6 7 8 6-25 7400 MM428 (3--02) 2 rocker down DIGITAL CONTROLLER SET-- UP ENGINE--GAS/LP IGNITION SYSTEM SPARK PLUGS Clean or replace, and set the gap of the spark plugs every 400 hours of operation. A wire gauge is best for checking the spark plug gap. A flat gauge should not be used unless the electrode surfaces have been dressed with a small file to get parallel surfaces between the center and side electrode. Set the spark plug gap by bending the side electrode. All spark plugs, new or used, should have the gaps checked and reset if necessary. The proper spark plug gap is 1 mm (0.040 in). TO REPLACE SPARK PLUGS FOR SAFETY: Before Leaving Or Servicing Machine: Stop On Level Surface, Set The Parking Brake, Turn Off Machine And Remove Key. 1. Open the engine cover and side door. 2. Remove the spark plug wires from the four spark plugs. NOTE: Clean any dirt from the spark plug seat area before removing the spark plugs. 3. Remove the spark plugs from the engine 4. Clean the spark plug seat in the cylinder head. 5. Use a new seat gasket and screw the plug in by hand. 6. Tighten the spark plugs with a socket wrench of the correct size. 6-26 7400 MM428 (12--98) ENGINE--GAS/LP FORD DISTRIBUTORLESS IGNITION SYSTEM SYNOPSIS This is a troubleshooting guide for the Ford Distributorless Ignition System. Unlike a conventional system, the Ford Distributorless Ignition System (DIS) uses two coils that each fire one pair of spark plugs. The spark plugs are also fired on both the power and exhaust stroke. The DIS system also uses a Universal Electronic Spark Control (UESC) module which adjusts the timing of the engine. The degree of timing change needed is determined by electrical and vacuum input to the UESC, these are: The engine harness has a separate wire for the gas and another for the LPG machines. Make sure you connect the correct wire for the type of fuel being used. ENGINE LOAD -- FROM PRESSURE REDUCER: Located in the intake manifold. Minimum 21 KPA (6.22” Hg) Maximum 101 KPA (29.91” Hg) ENGINE TEMPERATURE The Engine Coolant Temperature Sensor (ECTS) located in the intake manifold water jacket sends engine temperature information to UESC. Minimum --39_ C 38_ F Maximum 112_ C 232_ F When the engine is starting, at 250 RPM or less, the timing is set at 10_ before top dead center (BTDC). 7400 MM428 (3--02) 6-27 ENGINE--GAS/LP RUN MODE In this mode the RPM is above 250 and the spark advance is calculated in three sections which are added together to maintain optimum running condition. The Base Spark Advance (BSA) is calculated by the UESC module looking at speed and load inputs. The Spark Advance Offset Temperature (SAOT) will change ignition timing. This is determined by the Engine Coolant Temperature (ECT). This allows the spark advance to be altered during cold engine conditions. SERVICING AND TESTING SERVICING: 1. Every 400 hours, remove the spark plugs and clean and adjust the electrode. 2. Clean and visually check spark plug high tension leads and test for resistance. The Ohm meter should read between 9,000 and 16,000 Ohms. TESTING: Secondary Coil Testing Remove the four (4) spark plug wires and measure the secondary coil resistance by placing the meter into plug wire terminal. 1 -- 4 at the coil 2 -- 3 at the coil On each test you should read 14,000 + 50 Ohms. Universal Spark Control Module Diaphragm Testing Using a vacuum pump, apply 15” Hg to the UESC and vacuum inlet. The diaphragm should hold the pressure. If it fails, replace UESC unit. To test the sensors and wiring harness, follow the direction on the next three pages. 6-28 7400 MM428 (12--98) ENGINE--GAS/LP “FAILURE MODE OF DIS” IGNITION HARNESS The Ford DIS Universal Spark Control was checked for “poor connection”. The results of open leads were: Term 11 or 12 Ignition Coil Signal Leads -The governor received 1/2 of its intended signal and caused the actuator to hold the carb arm wide open. At the same time, the engine missed due to incorrect firing of plugs, but the speed still climbed to about 3,000--4,000 rpm. When either of these leads were opened at the start speed, the engine missed slightly and rose to double the start speed or about 3,000 rpm. Term 9 Ground -- Any failure here killed the engine instantly or caused the engine to slow down if it were cycled. Term 6 & 7 Octane Selector -- Opening these terminals retards the spark in varying degrees. Under light to moderate load conditions, no adverse effect will take place. However, run-on or pre-ignition may take place. Term 4 & 10 Coolant Sensor -- Contrary to previous thoughts, opening the lead doesn’t noticeably affect the engine. The timing only changes a few degrees. Term 2 & 3 Crank Position Sensor -Opening either of these leads kills the engine quickly and it will not start. Term 8 Power Lead -- Opening this lead kills the engine and it will not start. In summary, no alarming effect happens except if the coil signal leads are interrupted. These are the end leads on the module and if the harness has too much tension on it, the signal will become intermittent and cause the engine to overspeed. The only obvious damage will probably occur to the propelling pump, as the fan is rated for operation to 10,000 rpm. If the acc. are on when the lead becomes intermittent, the engine will not develop enough power to overspeed excessively. 7400 MM428 (12--98) 6-29 ENGINE--GAS/LP 65 Blue 200---600 Ohms 2 VRS + 3 VRS --- Variable reluctance sensor (crank position sensor) 66 Green 105,000 Ohms See Engine Coolant Sensor chart 64 Brown 67 Orange 1 10K Ohm 2 4 ECT1 10 ECT2 70 Green Engine coolant temperature sensor in ice water bath 68 Brown 0 Ohms 6 7 OCT2 6 Cut and ground to set octane (retard spark advance) 6 OCT1 Ignition switch on 18T Orange 12.6 8 16M V Batt + 16I Batt 12.6 V Volts + D.C. --- DC Power Ground --- 57 9 13PP Black 0.5 --- 1.0 11 Ohms 12 71 Yellow CDO (Phase A) HT 1 850A 852 CDO (Phase B) 852A 72 Gray HT Distributorless Ignition Coil HT HT 2 12.6 13QQ Black 4 3 Remove the coil connector and probe the center female terminal Volts + D.C. --- To Pin #9 FORD DIS IGNITION 6-30 7400 MM428 (12--98) ENGINE--GAS/LP ENGINE COOLANT SENSOR Temperature _C _F Sensor (Ohms) + .02_ Sensor & Harness (Ohms) + .03_ --30 ---22 481,000 491,000 --20 4 271,000 281,000 --10 14 158,000 168,000 0 32 95,000 105,000 10 50 58,750 68,750 20 68 37,300 47,300 30 86 24,270 34,270 40 104 16,150 26,150 50 122 10,970 20,970 60 140 7,600 17,600 70 158 5,360 15,360 80 176 3,840 13,840 90 194 2,800 12,800 100 212 2,070 12,070 110 230 1,550 11,550 120 248 1,180 11,180 130 266 930 10,930 140 284 701 10,701 150 302 550 10,550 7400 MM428 (12--98) 6-31 ENGINE--GAS/LP TO REPLACE ENGINE ALTERNATOR FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine engine cover and side door. Remove the side door from the machine. 3. Remove the two hex screws holding the plastic fan belt cover to the front of the engine. Remove the cover. 4. Disconnect the wires from the back of the alternator. 5. Remove the hex screw from the top of the alternator. 6. Loosen the lower hex screw and nyloc nut and push the alternator in toward the engine. Remove the V--belt from the alternator drive pulley. 7. Remove the hex screw and nyloc nut from the bottom of the alternator. Remove the alternator. 8. If the new alternator does not have a drive pulley----remove the hex nut and washer holding the drive pulley to the old alternator. Install the drive pulley on the new alternator and tighten tight. 9. Install the new alternator back in the machine. Reinstall the lower hex screw and nyloc nut. Leave loose for now. 10. Reinstall the hex screw in the upper arm and the top of the alternator. Leave loose for now. 6-32 7400 MM428 (12--98) ENGINE--GAS/LP 11. Reinstall the V--belt on the alternator drive pulley. 12. Pull the alternator away from the engine to tighten the V--belt. Tighten the upper hex screw tight. 13. Reconnect the wires to the back of the new alternator. See schematic in the ELECTRICAL section. 14. Reinstall the plastic belt cover to the front of the engine. Hand tighten the hex screws tight. 15. Reconnect the battery cables, close the operators seat and start the machine. 16. Check the new alternator for proper operation. 7400 MM428 (12--98) 6-33 ENGINE--GAS/LP TO REPLACE ENGINE STARTER FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 3. If the machine is an LPG, remove the LP tank from the cradle. 4. The vacuum fan assembly can be removed for better access to the starter. See TO REMOVE VACUUM FAN instructions in the SCRUBBING section. 5. Remove the air cleaner intake tube from the air cleaner and machine frame. 6. Reach in through the left side of the engine and disconnect the battery cable and electrical wires leading to the starter. 7. Reach in through the open seat support area and remove the three M10 hex screws holding the starter to the bellhousing. NOTE: The bottom hex screw has a nyloc nut on the starter side. 8. Remove the starter out through the area of the vacuum fan and engine oil filter. 9. Position the new starter in the machine. 10. Reinstall the three M10 hex screws and one nyloc nut. The nyloc nut goes on the bottom hex screw. Tighten to 31 -- 40 Nm (27 -- 35 ft lb). 11. Reconnect the battery cable and electrical wires to the starter. See schematic in the ELECTRICAL section. 6-34 7400 MM428 (12--98) ENGINE--GAS/LP 12. Reinstall the air cleaner intake tube to the air cleaner and machine frame. 13. If the vacuum fan was removed----reinstall. See TO INSTALL VACUUM FAN instructions in the SCRUBBING section. 14. Reconnect the battery cables to the battery and close the operators seat. 15. If the machine is an LPG----reinstall the LP tank. 16. Reinstall the engine side door and close the covers. 17. Start the machine. TO REMOVE ENGINE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Pivot the operators seat to the open position and engage the prop rod. 2. Disconnect the battery cables and remove the battery. NOTE: The battery tray can also be removed for better access to the propel pump. 3. Remove the detergent tank and the rubber sound flap from the machine. 4. Remove the two hex screws holding the propel pump to the engine bellhousing NOTE: The main suction line to the accessory pump is held, by plastic ties, in a bundle of hoses near the main valve. Remove the plastic ties to gain slack in the suction line to ease pump removal. 7400 MM428 (12--98) 6-35 ENGINE--GAS/LP 5. Remove the two hex screws holding the hydraulic flow valve to the back, left of the bellhousing. Do not disconnect any hydraulic hoses. 6. Pull the propel pump out of the bellhousing and drive coupler. Do not disconnect any hydraulic hoses. 7. If the machine is an LPG, remove the LP tank from the cradle. 8. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 9. Remove the vacuum hose from the vacuum fan and the recovery tank. 10. The vacuum fan assembly can be removed for better access to the engine. See TO REMOVE VACUUM FAN instructions in the SCRUBBING section. NOTE: The engine hood must be supported in the open position before the next step can be completed. 11. Remove the clips on the bottom of the engine hood gas springs. Remove the gas springs from the ball studs on the support channel. 12. Remove the hex screws holding the support channel to the tank lintel and hood lintel. Remove the support channel from the machine. 13. Drain the radiator coolant. 14. Remove the radiator hoses where they connect to the engine. 15. Drain the engine oil. NOTE: Disconnect the engine oil drain hose from the oil pan before lifting the engine completely out of the machine. 6-36 7400 MM428 (12--98) ENGINE--GAS/LP 16. Disconnect the exhaust pipe at the engine manifold. 17. Disconnect the wire harness from all of the engine components and place it out of the way. 18. Disconnect the engine ground strap from frame. 19. Disconnect the battery cable and electric wires from the engine starter. 20. Disconnect the fuel line at the fuel pump on a gas machine. 21. Disconnect the fuel line from the LP tank at fuel lockoff / vaporizer on an LPG machine. 22. Using an overhead hoist, hook a chain or strap through two or three pick--up points on the engine. Put a slight amount of tension on the chain. 23. Remove the three M12 hex screws and nyloc nuts holding the motor mounts to the rubber isolators on the machine frame. 24. Engine can now be carefully lifted out. 7400 MM428 (12--98) 6-37 ENGINE--GAS/LP TO INSTALL ENGINE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Using a overhead hoist, hook a chain or strap through two or three pick--up points on top of the engine. Carefully position the engine back in the engine compartment. 2. Carefully Lower the engine assembly down on the the motor mounts. NOTE: Make sure the hoses, wire harness, exhaust pipe, and propel pump are pulled back out of the way when lowering the engine assembly in place. 3. Reinstall the three M12 hex screws in the three motor mount isolators. Tighten to 64 -- 83 Nm (50 -- 60 ft lb) 4. Reconnect the ground cable from the bellhousing to the machine frame. 5. Reinstall the flow valve on the back, left of the bellhousing. 6. Reconnect the battery cable and electrical wires to the starter. See schematic in the ELECTRICAL section. 7. Reconnect the wire harness to engine components, alternator, governor actuator, oil switch, temperature sender, distributor, and ignition module. See schematic in the ELECTRICAL section. 8. Reinstall the propel pump back in the bellhousing. Use a small amount of blue loctite 242 on the threads. Reinstall the two hex screws. Tighten to 64 -- 83 Nm (50 -- 60 ft lb). NOTE: Make sure the splines on pump line up with splines in coupler when installing pump. 9. Reinstall the detergent tank in the seat support area. 10. Reinstall the battery tray and battery. 11. Reinstall the exhaust pipe back on the manifold. Reinstall the muffler clamp and tighten tight. 6-38 7400 MM428 (12--98) ENGINE--GAS/LP 12. Reconnect the fuel line at the fuel pump on a gas machine. 13. Reconnect the fuel line from the LP tank at fuel lockoff / vaporizer on an LPG machine. 14. Fill the engine with the proper grade of oil. 15. Reinstall the radiator hoses to the engine and fill the radiator with coolant. See TO PURGE AIR FROM RADIATOR instructions. 16. If the vacuum fan was removed----reinstall. See TO INSTALL VACUUM FAN instructions in the SCRUBBING section. 17. Reinstall the vacuum hose on the recovery tank and vacuum housing. 18. Reinstall the support channel to the tank lintel and hood lintel. Reinstall the four hex screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 19. Reinstall the engine hood gas springs on the ball studs on the support channel. Reinstall the two clips. 20. Reconnect the battery cables. 21. Disengage the prop rod and lower the seat. 22. Reinstall the LP tank on a LPG machine. 23. Jack up the front of the machine and place jack stands under the frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands 24. Start the machine. Check the engine, hydraulic motors, and pumps for leaks. 25. Reinstall the engine side door and close the covers. 7400 MM428 (12--98) 6-39 ENGINE--GAS/LP TO PURGE AIR FROM RADIATOR FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Make sure that both radiator hoses are connected to the engine. 2. Remove the radiator cap and pour in approximately 1--1/2 gallons of coolant. 3. Open the engine cover and side door. 4. Loosen the hose clamp on the upper radiator hose. This is the hose on the thermostat housing. 5. Break the hose loose from the neck of the thermostat housing and slowly pull the hose off the neck. 6. Keep the hose off the neck until coolant starts to flow out of the hose. 7. Quickly place the hose back on the neck of the thermostat housing. Re--tighten the hose clamp. 8. Start the machine and run it to operating temperature. Shut off the engine. 9. Let the machine cool down for and carefully re--check the level of the radiator coolant. There should be enough room to poor another 1/2 gallon of coolant in. If not----repeat steps 4 thru 8. 10. If the machine overheats----repeat steps 4 thru 8. NOTE: There may be air trapped in one of the radiator hoses. It might take one or two tries to completely purge all of the air from the cooling system. 6-40 7400 MM428 (12--98) ENGINE--DIESEL CONTENTS Page LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 7-3 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . 7-3 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 7-3 ENGINE FAN BELT . . . . . . . . . . . . . . . . . 7-4 AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . 7-4 AIR FILTER INDICATOR . . . . . . . . . . . . 7-4 AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . 7-4 TO REPLACE AIR FILTER ELEMENT 7-5 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7-6 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . 7-6 TO REPLACE THE FUEL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . 7-6 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . 7-7 TO PRIME FUEL SYSTEM . . . . . . . . . . 7-7 TO REPLACE ENGINE ALTERNATOR . . 7-8 TO REPLACE ENGINE STARTER . . . . . 7-10 TO REMOVE ENGINE . . . . . . . . . . . . . . . . 7-12 TO INSTALL ENGINE . . . . . . . . . . . . . . . . 7-14 TO PURGE AIR FROM RADIATOR . . . . 7-16 7400 MM428 (9--01) DIESEL ENGINE SERVICE MANUAL KUBOTA V1505 B (E) TENNANT Part Number 84660 7-1 ENGINE--DIESEL 7-2 7400 MM428 (12--98) ENGINE--DIESEL INTRODUCTION This section includes repair information on the engine and related systems, such as fuel, electrical, and drive belts. 7400 MM428 (12--98) 7-3 ENGINE--DIESEL LUBRICATION ENGINE OIL Check the engine oil level daily. Change the engine oil and oil filter every 100 hours of machine operation. Use 10W30 SAE--CC/CD rated engine oil. Fill the engine with oil to the level indicated on the oil dipstick. The engine oil capacity is 6 L (6.3 qt) with out the oil filter. COOLING SYSTEM Check the radiator coolant level every 100 hours of operation. Use clean water mixed with a permanent-type, ethylene glycol antifreeze to a --34_ C (--30_ F) rating. FOR SAFETY: When Servicing Machine, Avoid Contact With Hot Engine Coolant. ATTENTION! Never pour cold water or cold antifreeze into the radiator of an overheated engine. Allow the engine to cool down to avoid cracking the cylinder head or block. Keep the engine running while adding water. Check the radiator hoses and clamps every 200 hours of operation. Tighten the clamps if they are loose. Replace the hoses and clamps if the hoses are cracked, harden, or swollen. Check the radiator core exterior and hydraulic cooler fins for debris every 100 hours of operation. Blow or rinse all dust, which may have collected on the radiator, in through the grille and radiator fins, opposite the direction of normal air flow. The grille and hydraulic cooler open for easier cleaning. Be careful not to bend the cooling fins when cleaning. Clean thoroughly to prevent the fins becoming encrusted with dust. Clean the radiator and cooler only after the radiator has cooled to avoid cracking. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. Flush the radiator and the cooling system every 400 hours of operation, using a dependable cleaning compound. 7-4 7400 MM428 (12--98) ENGINE--DIESEL ENGINE FAN BELT The engine fan belt is driven by the engine crankshaft pulley and drives the alternator pulley. Proper belt tension is obtained when the belt deflects 7 to 9 mm (0.28 to 0.35 in) from a force of 10 kg (22 lb) applied at the mid-point of the longest span. Check and adjust the belt tension every 100 hours of operation. WARNING: Moving belt and fan. Keep away. AIR INTAKE SYSTEM AIR FILTER INDICATOR The air filter indicator shows when to clean or replace the air filter element. Check the indicator daily. The indicator’s red line will move as the air filter element fills with dirt. Do not clean or replace the air filter element until the red line reaches 5 kPa (20 in H2O) and the ”SERVICE WHEN RED” window is filled with red. The indicator’s red line may return to a lower reading on the scale when the engine shuts off. The red line will return to a correct reading after the engine runs for a while. Reset the air filter indicator by pushing the reset button on the end of the indicator after cleaning or replacing the air filter element. AIR FILTER The engine air filter housing has a dust cap and a dry cartridge-type air filter element. Empty the dust cap daily. The air filter must be replaced whenever the filter element is damaged or has been cleaned three times. Machines with the heavy duty air filter option have a safety element. It is inside the standard element. Replace, do not clean this element after the regular element has been damaged or cleaned three times. Service the air filter element only when the air filter indicator shows restriction in the air intake system. Do not remove the air filter element unless it is restricting air flow. 7400 MM428 (12--98) 7-5 ENGINE--DIESEL TO REPLACE AIR FILTER ELEMENT FOR SAFETY: Before Leaving Or Servicing Machine: Stop On Level Surface, Set The Parking Brake, Turn Off Machine And Remove Key. 1. Open the engine cover and side door. 2. Unscrew the clamp ring on the filter. 3. Remove the dust cap. 4. Empty the dust cap. 5. Remove the filter wing nut. 6. Pull the filter element out of the filter housing. 7. Clean the interior of the air cleaner housing with a camp cloth. Clean the element housing sealing surfaces. 8. Using an air hose, direct dry, clean air maximum 205 kPa (30 psi) up and down pleats on the inside of the filter. Do not rap, tap, or pound dust out of the element. FOR SAFETY: When Servicing Machine, Wear Eye And Ear Protection When Using Pressurized Air Or Water. 9. After cleaning the air filter element, inspect it for damage by placing a bright light inside. The slightest rupture requires replacement of the filter. Clean and inspect the seals on the ends of the element. They should be unbroken and flexible. Remember to replace the element after cleaning it three times. 10. Install the new or cleaned filter element so the fins on the element are at the intake end of the air cleaner. Be careful not to damage the fins. Make sure the element is seating evenly. Tighten the element wing nut. 11. Install the dust cap with the arrows pointing up. Tighten the clamp ring to hold it in place. Check all intake hose connections for leaks or abrasions. 12. Reset the air filter restriction indicator. 13. Close the access doors. 7-6 7400 MM428 (12--98) ENGINE--DIESEL FUEL SYSTEM -- DIESEL The diesel fuel system is made up of five basic components which are: fuel tank, fuel filter/water trap, fuel pump, injection pump, and injectors. Fuel flows from the fuel tank through the fuel filter/ water trap. The water trap-filter separates water and impurities from the fuel. From the fuel water trap-filter, fuel is drawn through the electric fuel pump and pumped to the injection pump. The injection pump pressurizes and sends fuel to the injectors. The injectors atomize and inject proper amounts of fuel into the combustion chamber at the proper times. Excess fuel is returned to the fuel tank through an overflow pipe. FUEL FILTER The fuel filter cartridge filters impurities from the fuel. It is located low on the left side of the engine block TO REPLACE THE FUEL FILTER CARTRIDGE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, And Turn Off Machine. 1. Loosen the unit vent plug and open the water trap drain to drain diesel fuel. 2. Remove the filter cartridge from the filter head. 3. Lubricate the o-ring of the new filter cartridge and spin it onto the filter head. 4. Bleed the fuel lines of air as described in TO PRIME FUEL SYSTEM instructions. 7400 MM428 (12--98) 7-7 ENGINE--DIESEL FUEL LINES Check the fuel lines every 50 hours of operation. If the clamp band is loose, apply oil to the screw of the band, and securely tighten the band. The rubber fuel lines can become worn-out whether the engine has been used much or not. Replace the fuel lines and clamp bands every two years. If the fuel lines and clamp bands are found worn or damaged before two years’ time, replace or repair them at once. Bleed the fuel system after replacement of any of the fuel lines, see TO PRIME THE FUEL SYSTEM. When the fuel lines are not installed, plug both ends with clean cloth or paper to prevent dirt from entering the lines. Dirt in the lines can cause fuel injection pump malfunction. PRIMING FUEL SYSTEM Typical diesel fuel systems require priming to remove pockets of air in the fuel lines and fuel components. This is usually required after running out of fuel, changing fuel filter elements or repairing a fuel system component. Air in the fuel system prevents smooth engine operation. This fuel system however is self-priming. The return line comes from the top of the injector that causes all air to escape through the return line. TO PRIME FUEL SYSTEM FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, And Turn Off Machine. 1. Make sure the fuel tank is full. 2. Open the air vent on top of the fuel filter. 3. Start the engine, operate it for one minute, then stop it; or operate the starter motor in ten-second intervals until a steady stream of fuel flows from the vent. 4. Close the air vent and shut off the engine. 5. Clean up any fuel that was spilled during the bleeding process. 7-8 7400 MM428 (12--98) ENGINE--DIESEL TO REPLACE ALTERNATOR ON DIESEL ENGINE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine engine cover and side door. Remove the side door from the machine. 3. Remove the two hex screws holding the fan belt cover to the front of the engine. Remove the cover. 4. Disconnect the wires from the back of the alternator. 5. Remove the hex screw from the top of the alternator. 6. Loosen the lower hex screw and nyloc nut and push the alternator in toward the engine. Remove the V--belt from the alternator drive pulley. 7. Remove the hex screw and nyloc nut from the bottom of the alternator. Retain the spacer. Remove the alternator. 8. If the new alternator does not have a drive pulley----remove the hex nut and washer holding the drive pulley to the old alternator. Install the drive pulley on the new alternator and tighten tight. 9. Install the new alternator back in the machine. Reinstall the lower hex screw, spacer, and nyloc nut. Leave loose for now. 10. Reinstall the hex screw in the upper arm and the top of the alternator. Leave loose for now. 7400 MM428 (12--98) 7-9 ENGINE--DIESEL 11. Reinstall the V--belt on the alternator drive pulley. 12. Pull the alternator away from the engine to tighten the V--belt. Tighten the upper hex screw tight. 13. Reconnect the wires to the back of the new alternator. See schematic in the ELECTRICAL section. 14. Reinstall the belt cover to the front of the engine. Hand tighten the hex screws tight. 15. Reconnect the battery cables, close the operators seat and start the machine. 16. Check the new alternator for proper operation. 7-10 7400 MM428 (12--98) ENGINE--DIESEL TO REPLACE STARTER ON DIESEL ENGINE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake, Turn Off Machine And Remove Key. 1. Raise the operators seat, engage the prop rod, and disconnect the battery cables from the battery. 2. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 3. The vacuum fan assembly can be removed for better access to the starter. See TO REMOVE VACUUM FAN instructions in the SCRUBBING section. 4. Remove the air cleaner intake tube from the air cleaner and machine frame. 5. Reach in through the left side of the engine and disconnect the battery cable and electrical wires leading to the starter. 6. Reach in through the left side of the engine and remove the two hex screws holding the starter to the bellhousing. 7. Remove the starter out through the area of the vacuum fan and engine oil filter. 8. Position the new starter in the machine. 9. Reinstall the two hex screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 10. Reconnect the battery cable and electrical wires to the starter. See schematic in the ELECTRICAL section. 7400 MM428 (12--98) 7-11 ENGINE--DIESEL 11. Reinstall the air cleaner intake tube to the air cleaner and machine frame. 12. If the vacuum fan was removed----reinstall. See TO INSTALL VACUUM FAN instructions in the SCRUBBING section. 13. Reconnect the battery cables to the battery and close the operators seat. 14. Reinstall the engine side door and close the covers. 15. Start the machine. 7-12 7400 MM428 (12--98) ENGINE--DIESEL TO REMOVE DIESEL ENGINE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Pivot the operators seat to the open position and engage the prop rod. 2. Disconnect the battery cables and remove the battery. NOTE: The battery tray can also be removed for better access to the propel pump 3. Remove the detergent tank and the rubber sound flap from the machine. 4. Remove the two hex screws holding the propel pump to the engine bellhousing NOTE: The main suction line to the accessory pump is held, by plastic ties, in a bundle of hoses near the main valve. Remove the plastic ties to gain slack in the suction line to ease pump removal. 5. Remove the two hex screws holding the hydraulic flow valve to back, left of the engine mount. Do not disconnect any hydraulic hoses. 6. Pull the propel pump out of the bellhousing and drive coupler. Do not disconnect any hydraulic hoses. 7. Open the machine front cover, engine cover, and side door. Remove the side door from the machine. 8. Remove the vacuum hose from the vacuum fan and the recovery tank. 9. The vacuum fan assembly can be removed for better access to the engine. See TO REMOVE VACUUM FAN instructions in the SCRUBBING section. NOTE: The engine hood must be supported in the open position before the next step can be completed. 10. Remove the clips on the bottom of the engine hood gas springs. Remove the gas springs from the ball studs on the support channel. 7400 MM428 (12--98) 7-13 ENGINE--DIESEL 11. Remove the hex screws holding the support channel to the tank lintel and hood lintel. Remove the support channel from the machine. 12. Drain the radiator coolant. 13. Remove the radiator hoses where they connect to the engine. 14. Drain the engine oil. NOTE: Disconnect the engine oil drain hose from the oil pan before lifting the engine completely out of the machine. 15. Disconnect the exhaust pipe at the engine manifold. 16. Disconnect the wire harness from all of the engine components and place it out of the way. 17. Disconnect the engine ground strap from frame. 18. Disconnect the battery cable and electric wires from the engine starter. 19. Disconnect the fuel line at the fuel filter/water separator on the left side of the engine. Disconnect the small fuel return line. 20. Using an overhead hoist, hook a chain through two pick--up points on the engine. Put a slight amount of tension on the chain. 21. Remove the three M12 hex screws and nyloc nuts holding the motor mounts to the rubber isolators on the machine frame. 22. Engine can now be carefully lifted out. 7-14 7400 MM428 (12--98) ENGINE--DIESEL TO INSTALL DIESEL ENGINE FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Using a overhead hoist, hook a chain through the two pick--up points on top of the engine. Carefully position the engine back in the engine compartment. 2. Carefully Lower the engine assembly down on the the motor mounts. NOTE: Make sure the hoses, wire harness, exhaust pipe, and propel pump are pulled back out of the way when lowering the engine assembly in place. 3. Reinstall the three M12 hex screws in the three motor mount isolators. Tighten to 64 -- 83 Nm (50 -- 60 ft lb) 4. Reconnect the ground cable from the bellhousing to the machine frame. 5. Reinstall the flow valve on the back, left of the bellhousing. 6. Reconnect the battery cable and electrical wires to the starter. See schematic in the ELECTRICAL section. 7. Reconnect the wire harness to engine components, alternator, governor actuator, oil switch, and temperature sender. See schematic in the ELECTRICAL section. 8. Reinstall the propel pump back in the bellhousing. Use a small amount of blue loctite 242 on the threads. Reinstall the two hex screws. Tighten to 64 -- 83 Nm (50 -- 60 ft lb). NOTE: Make sure the splines on pump line up with splines in coupler when installing pump. 9. Reinstall the detergent tank in the seat support area. 10. Reinstall the battery tray and battery. 11. Reinstall the exhaust pipe back on the manifold. Reinstall the muffler clamp and tighten tight. 7400 MM428 (12--98) 7-15 ENGINE--DIESEL 12. Reconnect the fuel line at the fuel filter/water separator on the left side of the engine. 13. Fill the engine with the proper grade of oil. 14. Reinstall the radiator hoses to the engine and fill the radiator with coolant. See TO PURGE AIR FROM RADIATOR instructions. 15. If the vacuum fan was removed----reinstall. See TO INSTALL VACUUM FAN instructions in the SCRUBBING section. 16. Reinstall the vacuum hose on the recovery tank and vacuum housing. 17. Reinstall the support channel to the tank lintel and hood lintel. Reinstall the four hex screws and tighten to 18 -- 24 Nm (15 -- 20 ft lb). 18. Reinstall the engine hood gas springs on the ball studs on the support channel. Reinstall the two clips. 19. Reconnect the battery cables. 20. Disengage the prop rod and lower the seat. 21. Jack up the front of the machine and place jack stands under the frame. FOR SAFETY: Block machine tires before jacking machine up. Jack machine up at designated locations only. Block machine up with jack stands 22. Start the machine. Check the engine, hydraulic motors, and pumps for leaks. 23. Reinstall the engine side door and close the covers. 7-16 7400 MM428 (12--98) ENGINE--DIESEL TO PURGE AIR FROM RADIATOR FOR SAFETY: Before Leaving Or Servicing Machine; Stop On Level Surface, Set Parking Brake., Turn Off Machine And Remove Key. 1. Make sure that both radiator hoses are connected to the engine. 2. Remove the radiator cap and pour in approximately 1--1/2 gallons of coolant. 3. Open the engine cover and side door. 4. Loosen the hose clamp on the upper radiator hose. This is the hose on the thermostat housing. 5. Break the hose loose from the neck of the thermostat housing and slowly pull the hose off the neck. 6. Keep the hose off the neck until coolant starts to flow out of the hose. 7. Quickly place the hose back on the neck of the thermostat housing. Re--tighten the hose clamp. 8. Start the machine and run it to operating temperature. Shut off the engine. 9. Let the machine cool down for and carefully re--check the level of the radiator coolant. There should be enough room to poor another 1/2 gallon of coolant in. If not----repeat steps 4 thru 8. 10. If the machine over heats----repeat steps 4 thru 8. NOTE: There may be air trapped in one of the radiator hoses. It might take one or two tries to completely purge all of the air from the cooling system. 7400 MM428 (12--98) 7-17 ENGINE--DIESEL 7-18 7400 MM428 (12--98)
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