8410 Service Manual Tennant Rider Floor Sweeper Scrubber

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8410

Service Manual

MM392

Rev. 03 (5--02)

*mm392*

This service manual is intended to be an aid for the disassembly and reassembly of your TENNANT

Model 8410.

The set is organized into eight major groups: General Information, Chassis, Sweeping, 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, and cover/door adjustment.

Sweeping: Hopper repair/replacement, brush repair/replacement. skirt/seal repair/replacement, and

sweeping troubling shooting.

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 -- MM392

Revision: 03

Published: 5--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.

GENERAL INFORMATION

1-1

8410 MM392 (8--01)

CONTENTS

Page

SAFETY PRECAUTIONS 1--3..............

PUSHING OR TOWING MACHINE 1--7......

TIEING DOWN MACHINE 1--7..............

MACHINE JACKING 1--8...................

STORING MACHINE 1--8..................

SPECIFICATIONS 1--9....................

GENERAL MACHINE PERFORMANCE 1--9..

POWER TYPE 1--10.......................

STEERING 1--11..........................

HYDRAULIC SYSTEM 1--11................

MAINTENANCE 1--12.....................

MAINTENANCE CHART/GLP 1--12.......

MAINTENANCE CHART/D 1--14.........

HARDWARE INFORMATION 1--16..........

STANDARD BOLT TORQUE CHART 1--16

METRIC BOLT TORQUE CHART 1--16...

BOLT IDENTIFICATION 1--16............

THREAD SEALANT AND LOCKING

COMPOUNDS 1--16.................

HYDRAULIC FITTING INFORMATION 1--17..

HYDRAULIC TAPERED PIPE

FITTING (NPT) TORQUE CHART 1--17

HYDRAULIC TAPERED SEAT

FITTING (JIC) TORQUE CHART 1--17.

HYDRAULIC O--RING FITTING

TORQUE CHART 1--17....................

GENERAL INFORMATION

1-2 8410 MM392 (8--01)

GENERAL INFORMATION

1-3

8410 MM392 (5--02)

SAFETY PRECAUTIONS

The following precautions are used throughout

this manual as indicated in their description:

WARNING: To warn of hazards or

unsafe practices that could result in

severe personal injury or death.

FOR SAFETY: To identify actions that

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.

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: Raised hopper may fall.

Engage hopper support bar.

WARNING: Lift arm pinch point. Stay

clear of hopper lift arms.

WARNING: Moving belt and fan. Keep

away.

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: Strong vacuum. Keep away

from fan inlet when fan is running.

WARNING: Hot bumper. Keep away.

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.

-- Move machine with care when hopper

is raised.

-- Make sure adequate clearance is

available before raising hopper.

-- Do not carry passengers on machine.

-- Always follow safety and traffic rules.

-- Report machine damage or faulty

operation immediately.

-- Follow mixing and handling

instructions on chemical containers.

5. Before leaving or servicing machine:

-- Stop on level surface.

-- Set parking brake.

-- Turn off machine and remove key.

GENERAL INFORMATION

1-4 8410 MM392 (5--02)

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 that will support the

wieght of the 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.

7. When loading/unloading machine

onto/off truck or trailer:

-- Turn off machine.

-- Use truck or trailer that will support

the weight of the machine.

-- Use winch. Do not drive the machine

onto/off the truck or trailer unless the

load height is 380 mm (15 in) or less

from the ground.

-- Set parking brake after machine is

loaded.

-- Block machine tires.

-- Tie machine down to truck or trailer.

GENERAL INFORMATION

1-5

8410 MM392 (8--01)

The following safety labels are mounted on the

machine in the locations indicated. If these or any

label becomes damaged or illegible, install a new

label in its place.

HOPPER SUPPORT BAR LABEL -- LOCATED

ON THE HOPPER SUPPORT BAR AND ON

BOTH HOPPER LIFT ARMS.

ENGINE FAN AND BELT LABEL -- LOCATED

ON THE RADIATOR SHROUD.

EMISSIONS LABEL -- LOCATED ON THE SIDE

PANEL OF THE OPERATOR COMPARTMENT.

11047

FOR SAFETY LABEL -- LOCATED ON THE

SIDE PANEL OF THE OPERATOR

COMPARTMENT.

FLAMMABLE SPILLS LABEL -- LOCATED ON

THE SIDE PANEL OF THE OPERATOR

COMPARTMENT.

GENERAL INFORMATION

1-6 8410 MM392 (8--01)

STRONG VACUUM LABEL -- LOCATED ON

THE VACUUM FAN HOUSING.

HOPPER LIFT ARMS LABEL -- LOCATED ON

BOTH HOPPER LIFT ARMS.

09078

FLAMMABLE MATERIALS LABEL -- LOCATED

ON THE SOLUTION TANK COVER.

HOT BUMPER LABEL -- LOCATED ON THE

REAR LEFT PANEL.

GENERAL INFORMATION

1-7

8410 MM392 (8--01)

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.

GENERAL INFORMATION

1-8 8410 MM392 (8--01)

TRANSPORTING THE MACHINE

1. Position the rear of the machine at the

loading edge of the truck or trailer.

FOR SAFETY: Use truck or trailer that

will support the weight of the machine.

NOTE: Empty the hopper, recovery tank, and

solution tank before transporting the machine.

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.

WARNING: Hot bumper. Keep away.

If the machine has the optional rear tie down

brackets, attach the winching chains to

them.

WARNING: Hot bumper. Keep away.

GENERAL INFORMATION

1-9

8410 MM392 (8--01)

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.

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, lower the scrub head

and block the machine tires. Tie down the

machine to the truck or trailer before

transporting.

The front tie-down locations are the holes in

the wheel pockets at the front of the

machine frame.

If the machine has the optional front tie

down brackets above the front tires, attach

the winching chains to them.

08152

GENERAL INFORMATION

1-10 8410 MM392 (8--01)

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.

WARNING: Hot bumper. Keep away.

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.

STORING MACHINE

Before storing the machine for an extended period

of time, the machine needs to be prepped to

lessen the chance of rust, sludge, and other

undesirable deposits from forming. Contact

TENNANT service personnel.

GENERAL INFORMATION

1-11

8410 MM392 (8--01)

SPECIFICATIONS

GENERAL MACHINE DIMENSIONS/CAPACITIES

Item Dimension/capacity

Length, Gasoline 2970 mm (117 in)

Length, LPG 15 kg (33 lb) tank 3070 mm (121 in)

Length, LPG 19.5 kg (43 lb) tank 3175 mm (125 in)

Length, Diesel 2970 mm (117 in)

Width with side brush 1610 mm (63.5 in)

Height 1625 mm (64 in)

Height with overhead guard 2125 mm (83.7 in)

Track 1330 mm (52.38 in)

Wheelbase 1625 mm (63.88 in)

Main sweeping brush diameter 355 mm (14 in)

Main sweeping brush length 1145 mm (45 in)

Scrub brush diameter 405 mm (16 in)

Side brush diameter 585 mm (23 in)

Sweeping path width 1145 mm (45 in)

Sweeping path width with side brush 1525 mm (60 in)

Squeegee width 1490 mm (58.7 in)

Scrubbing path width 1220 mm (48 in)

Main sweeping brush pattern width 50 to 65 mm (2 to 2.5 in)

Hopper weight capacity 545 kg (1200 lb)

Hopper volume capacity 400 L (14 ft3)

Dust filter area 6.9 m2(74 ft2)

Solution tank 227 L (60 gal)

Recovery tank 227 L (60 gal)

Detergent tank (option) 18.9 L (5 gal)

Total capacity with ESt(option) 379 L (100 gal)

GVWR 3133 kg (6900 lb)

Ceiling height minimum dumping clearance 2490 mm (98 in)

GENERAL MACHINE PERFORMANCE

Item Measure

Maximum forward speed 12.9km/h(8mph)

Maximum reverse speed 4.8km/h(3mph)

Minimum aisle turn width, left 3530 mm (139 in)

Minimum turning radius, right 3235 mm (128 in)

Minimum turning radius, left 2270 mm (90 in)

Maximum rated incline for transport of machine 8_/14.1%

Maximum rated incline for scrubbing/sweeping 6_/10.5%

GENERAL INFORMATION

1-12 8410 MM392 (8--01)

POWER TYPE

Engine Type Ignition Cycle Aspiration Cylinders Bore Stroke

Kubota V2203--B Piston Diesel 4Natural 487 mm

(3.34 in)

92.4 mm

(3.64 in)

Displacement Net power, governed Net power, maximum

2200 cc (134.08 cu in) 32.8 kw (44 hp) @ 2400 rpm 36.6 kw (49 hp) @

2800 rpm

Fuel Cooling system Electrical system

Diesel

Fuel tank: 37.9 L (10 gal)

Water/ethylene glycol

antifreeze

12 V nominal

(

)

Total: 17 L (4.5 gal) 50 A alternator

Radiator: 6 L (1.6 gal)

Idle speed, no load (Fast) governed speed, under

load

Engine lubricating oil

without filter

1500 +25 rpm 2400 +25 rpm 6.15 L (6.5 qt)

SAE--CC/CD rated

engine oil

Engine Displacement Net power, governed Net power, maximum

Ford LRG 2.3 2300 cc (140 cu in) 37.3 kw (50 hp) @ 2400 rpm 47 kw (63 hp) @

2800 rpm

Ford LRG 2.5 2500 cc (152 cu in) 40.3 kw (54 hp) @ 2400 rpm 59 kw (79 hp) @

3000 rpm

Ford LRG 2.3

and LRG 2.5

Type Ignition Cycle Aspirat-

ion

Cyl Bore LRG 2.3

Stroke

LRG 2.5

Stroke

Piston Distributerless-

type spark

4Natural 496 mm

(3.78 in)

80 mm

(3.126 in)

96 mm

(3.78 in)

Fuel Cooling system Electrical system

Gasoline, 87 octane

minimum, unleaded. Fuel

tank: 45.5 L (12 gal)

Water/ethylene glycol

antifreeze

12 V nominal

LPG,

(

)

Total: 16.7 L (4.4 gal) 50 A alternator

(

)

Fuel tank: 19.5 kg (43 lb) Radiator: 6.2 L (1.6 gal)

(Start) governed speed (Low) governed speed (High) governed speed

1475 + 50 rpm 2000 + 50 rpm 2400 + 50 rpm

Spark plug gap Firing order

1to1.1mm

(0.042 to 0.046 in)

1--3--4--2

Engine lubricating oil with filter (10W30 SAE--SG/SH)

Ford LRG 2.5 -- 4.26 L (4.5 qt) FordLRG2.3--4.7L(5qt)

GENERAL INFORMATION

1-13

8410 MM392 (8--01)

STEERING

Type Power source Emergency steering

Rear wheel, hydraulic cylinder

and rotary valve controlled

Hydraulic accessory pump Manual

HYDRAULIC SYSTEM

System Capacity Fluid Type

Hydraulic reservoir 37.8 L (10 gal) TENNANT part no. 65869 -- above 7_C(45_F)

Hydraulic total 53 L (14 gal)

(

)

TENNANT part no. 65870 -- below 7_C(45_F)

BRAKING SYSTEM

Type Operation

Service brakes Mechanical drum brakes (2), one per front wheel,

cable actuated

Parking brake Utilize service brakes, cable actuated

TIRES

Location Type Size Pressure

Front (2) Solid 5x18in --

Rear (1) Solid 6x18in --

GENERAL INFORMATION

1-14 8410 MM392 (8--01)

MAINTENANCE

4567

810

MAINTENANCE CHART G/LP

Interval Key Description Procedure

Lubricant/

Fluid

No. of

Service

Points

Daily 2Engine air filter Check indicator -- 1

Empty dust cap -- 1

2Engine crankcase Check oil level EO 1

11 Brush compartment skirts Check for damage, wear and ad-

justment

-- 5

9Hopper lip skirts Check for damage, wear and ad-

justment

-- 3

11 Main sweep brush Check for damage, wear, and ad-

justment

-- 1

Check brush pattern -- 1

10 Side brush Check for damage, wear, and ad-

justment

-- 1

Check brush pattern -- 1

9Hopper dust filter Shake -- 2

15 Rear Squeegee Check for damage and wear -- 1

Check deflection -- 1

4Side Squeegees Check for damage and wear -- 2

4Scrub brushes Check for damage and wear -- 1

5Recovery tank Clean -- 1

12 Recovery tank, EStmode Clean EStfilter -- 1

6Solution tank, EStmode Clean -- 1

50 Hours 11 Main sweep brush Rotate end-for-end -- 1

17 Rear squeegee casters Lubricate SPL 2

100 Hours 1Radiator Clean core exterior -- 1

Check coolant level WG 1

2Engine crankcase Change oil and filter element EO 1

GENERAL INFORMATION

1-15

8410 MM392 (8--01)

Interval Key Description Procedure

Lubricant/

Fluid

No. of

Service

Points

100 Hours 2Engine Check belt tension -- 1

Check and adjust idle speed -- 1

Check and adjust idle mixture -- 1

9Hopper dust filter Check for damage, clean or re-

place

-- 1

3Hydraulic fluid reservoir Check fluid level HYDO 1

8Tires Check for damage -- 3

11 Main sweep brush and

hopper seals

Check for damage or wear -- 8

15 Rear squeegee Check leveling -- 1

200 Hours 1Radiator hoses and clamps Check for tightness and wear -- 2

14 Parking brake Check adjustment -- 1

14 Brake pedal Check and adjust travel -- 1

16 Rear wheel support bear-

ings

Lubricate SPL 2

10 Side brush guard Rotate 90_-- 1

7Lift arm pivots Lubricate SPL 4

9Hopper door pivots Lubricate SPL 2

400 Hours 8Front wheel bearings Check, lubricate, and adjust SPL 2

1 Cooling system Flush WG 1

2Engine Clean or replace and adjust

spark plugs

-- 4

Replace PCV valve -- 1

Fuel filter, gasoline -- 2

Replace suction strainer -- 1

Change hydraulic fluid HYDO 1

3Hydraulic fluid filter Change filter element -- 1

-- Hydraulic hoses Check for wear and damage -- All

16 Propelling motor HTorque shaft nut -- 1

16 Rear wheel HTorque wheel nuts -- 1

13 Battery HClean and tighten battery cable

connections

-- 1

Check electrolyte DW 1

2Engine Clean PCV hoses, tubes, and fit-

tings

-- 1

Torque intake manifold bolts -- 8

Check timing belt -- 1

1600

Hours

2Engine Replace timing belt -- 1

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 number 01433--1)...

DW Distilled water....

NOTE: Also check procedures indicted (H) after

the first 50-hours of operation.

NOTE: More frequent intervals may be required

in extremely dusty conditions.

GENERAL INFORMATION

1-16 8410 MM392 (8--01)

4567

810

1516

MAINTENANCE CHART Diesel

Interval Key Description Procedure

Lubricant/

Fluid

No. of

Service

Points

Daily 2Engine air filter Check indicator -- 1

Empty dust cap -- 1

2Engine crankcase Check oil level EO 1

11 Brush compartment skirts Check for damage, wear and ad-

justment

-- 5

9Hopper lip skirts Check for damage, wear and ad-

justment

-- 3

11 Main sweep brush Check for damage, wear, and ad-

justment

-- 1

Check brush pattern -- 1

10 Side brush Check for damage, wear, and ad-

justment

-- 1

Check brush pattern -- 1

9Hopper dust filter Shake -- 2

16 Rear Squeegee Check for damage and wear -- 1

Check deflection -- 1

4Side Squeegees Check for damage and wear -- 2

4Scrub brushes Check for damage and wear -- 1

5Recovery tank Clean -- 1

12 Recovery tank, EStmode Clean EStfilter -- 1

6Solution tank, EStmode Clean -- 1

50 Hours 11 Main sweep brush Rotate end-for-end -- 1

2Fuel pipes and clamps Check for tightness and wear -- 1

2Engine crankcase Change oil and filter EO 1

18 Rear squeegee casters Lubricate SPL 2

GENERAL INFORMATION

1-17

8410 MM392 (8--01)

Interval Key Description Procedure

Lubricant/

Fluid

No. of

Service

Points

100 Hours 1Radiator Clean core exterior -- 1

Check coolant level WG 1

2Engine belt Check tension -- 1

9Hopper dust filter Check for damage, clean or re-

place

-- 1

3Hydraulic fluid reservoir Check fluid level HYDO 1

8Tires Check for damage -- 3

11 Main sweep brush and

hopper seals

Check for damage or wear -- 8

16 Rear squeegee Check leveling -- 1

200 Hours 1Radiator hoses and clamps Check for tightness and wear -- 2

14 Parking brake Check adjustment -- 1

14 Brake pedal Check and adjust travel -- 1

17 Rear wheel support bear-

ings

Lubricate SPL 2

10 Side brush guard Rotate 90_-- 1

7Lift arm pivots Lubricate SPL 4

9Hopper door pivots Lubricate SPL 2

400 Hours 8Front wheel bearings Check, lubricate, and adjust SPL 2

2Fuel filter Replace cartridge -- 1

15 Fuel tank Remove sediment -- 1

1 Cooling system Flush WG 1

800 Hours 3Hydraulic reservoir Replace filler cap -- 1

Replace suction strainer -- 1

Change hydraulic fluid HYDO 1

3Hydraulic fluid filter Change filter element -- 1

-- Hydraulic hoses Check for wear and damage -- All

17 Propelling motor HTorque shaft nut -- 1

17 Rear wheel HTorque wheel nuts -- 1

13 Battery HClean and tighten battery cable

connections

-- 1

Check electrolyte DW 1

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 number 01433--1)...

DW Distilled water....

NOTE: Also check procedures indicted (H) after

the first 50-hours of operation.

NOTE: More frequent intervals may be required

in extremely dusty conditions.

GENERAL INFORMATION

1-18 8410 MM392 (8--01)

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

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)

0.62 in 130--170

(176--231)

117--265

(159--359)

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)

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

ISO--Grade 8.8

ISO--Grade 10.9

01395

THREAD SEALANT AND LOCKING

COMPOUNDS

Thread sealants and locking compounds may be

used on this machine. They include the following:

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.

GENERAL INFORMATION

1-19

8410 MM392 (8--01)

HYDRAULIC FITTING INFORMATION

HYDRAULIC TAPERED PIPE FITTING (NPT)

TORQUE CHART

NOTE: Ratings listed are when using teflon

thread seal.

Size Minimum

Torque

Maximum

Torque

1/4 NPT 10 ft lb (14 Nm) 30 ft lb (41 Nm)

1/2 NPT 25 ft lb (34 Nm) 50 ft lb (68 Nm)

3/4 NPT 50 ft lb (68 Nm) 100 ft lb (136

Nm)

HYDRAULIC TAPERED SEAT FITTING (JIC)

TORQUE CHART

Tube O.D.

(in)

Thread Size Maximum

Torque

0.25 0.44--20 9ftlb(12Nm)

0.38 0.56--18 20 ft lb (27 Nm)

0.50 0.75--16 30 ft lb (41 Nm)

0.62 0.88--14 40 ft lb (54 Nm)

0.75 1.12--12 70 ft lb (95 Nm)

1.0 1.31--12 90 ft lb (122 Nm)

HYDRAULIC O--RING FITTING TORQUE

CHART

Tube

O.D.

(in)

Thread

Size

Minimum

Torque

Maximum

Torque

0.25 0.44--20 6ftlb(8Nm) 9ftlb

(12 Nm)

0.38 0.56--18 13 ft lb

(18 Nm)

20 ft lb

(27 Nm)

*10 ft lb

(14 Nm)

12 ft lb

(16 Nm)

0.50 0.75--16 20 ft lb

(27 Nm)

30 ft lb

(41 Nm)

*21 ft lb

(28 Nm)

24 ft lb

(33 Nm)

0.62 0.88--14 25 ft lb

(34 Nm)

40 ft lb

(54 Nm)

0.75 1.12--12 45 ft lb

(61 Nm)

70 ft lb

(95 Nm)

1.0 1.31--12 60 ft lb

(81 Nm)

90 ft lb

(122 Nm)

NOTE: Do not use sealant on o--ring threads.

*Aluminum bodied components

GENERAL INFORMATION

1-20 8410 MM392 (8--01)

CHASSIS

2-1

8410 MM392 (5--02)

CONTENTS

Page

INTRODUCTION 2-3......................

SEAT 2-4.............................

TO REMOVE SEAT ASSEMBLY 2-4..

TO REPLACE SEAT ASSEMBLY 2-4..

TO ADJUST SEAT POSITION 2-5....

STATIC DRAG CHAIN 2-5..............

BRAKES AND TIRES 2-6...............

SERVICE BRAKES 2-6..............

TO REPLACE BRAKE SHOES 2-6....

PARKING BRAKE LEVER 2-8........

FRONT TIRES AND WHEELS 2-9.......

TO REPACK FRONT WHEEL

BEARINGS 2-9..................

REAR WHEEL AND WHEEL

SUPPORT 2-11.....................

TO REPLACE REAR WHEEL

HOUSING PIVOT BEARINGS 2-12.

CHASSIS

2-2 8410 MM392 (8--01)

CHASSIS

2-3

8410 MM392 (8--01)

INTRODUCTION

This section includes information on the main

chassis related components for example the seat,

steering, brakes and tires.

CHASSIS

2-4 8410 MM392 (8--01)

SEAT

The seat assembly is removable and adjustable

on the 8400.

The operator seat is a fixed back style with a

forward-backward adjustment.

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.

2. Slide the seat prop rod up and out of the rod

slot.

3. Pull the hair cotter pin out of the pivot shaft.

4. Lift and slide the seat sideways off 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. Slide the seat assembly pins in the pivot

holes on the seat support.

2. Slide the hair cotter pin in the hole on the

pivot shaft to secure the seat.

3. Slide the seat rod through the large hole in

the slot.

4. Lower the seat.

CHASSIS

2-5

8410 MM392 (8--01)

TO ADJUST SEAT POSITION

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Pull the lever out, slide the seat backward or

forward to the desired position and release

the lever.

STATIC DRAG CHAIN

A static drag chain prevents the buildup of static

electricity in the machine. The chain is attached to

the machine by a rear main brush skirt retaining

bolt.

Make sure the chain is touching the floor at all

times.

CHASSIS

2-6 8410 MM392 (5--02)

BRAKES AND TIRES

SERVICE BRAKES

The mechanical service brakes are located on the

front wheels. The brakes are operated by the foot

brake pedal and connecting cables.

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. Empty the debris hopper.

2. Turn the parking brake knurled knob

counterclockwise until it stops.

(early version machines only)

3. Disconnect the battery cables and remove

the battery to access the floor plate

hardware.

4. Remove floor plate from the machine.

5. Thread the brake cable clevis yoke toward

the threaded rod to reduce brake cable

tension.

CHASSIS

2-7

8410 MM392 (8--01)

6. Jack up one front corner of the machine.

Place jack stands under machine.

7. Remove the hub cap.

8. Remove the cotter pin, slotted nut, flat

washer, and bearing cone.

9. Remove the front tire and wheel assembly

from the machine.

10. Remove the two springs holding the brake

shoes together. Remove the old brake

shoes from the machine.

11. Position the new brake shoes on the

machine.

NOTE: Always replace brake shoes in sets.

12. Reattach brake springs to the new brake

shoes.

13. Pack the wheel bearings with Lubriplate

EMB grease.

14. Slide the wheel on the axle.

15. Slide the outer bearing, flat washer and nut

on the shaft.

16. Tighten nut with hand wrench until wheel

binds, then back the nut off to nearest hole.

17. Insert a new cotter pin through nut and hole.

18. After making sure the wheel spins freely,

carefully install the hub cap.

19. Remove the jack stand and lower the

machine. Repeat this procedure on the

opposite side.

NOTE: Always replace brake shoes in sets.

20. Thread the brake cable clevis yoke away

from the threaded rod until the brake pedal

travels 25--50 mm (1--2 in) before engaging

brakes.

CHASSIS

2-8 8410 MM392 (8--01)

21. Tighten the brake clevis jam nuts.

22. Reinstall the floor plate.

23. Install the battery and battery cables.

24. Lower the seat support.

25. Adjust the parking brake by turning the

knurled knob clockwise until the parking

brake properly holds the machine in place.

(early version machines only).

26. Drive the machine and check the brakes for

proper operation.

PARKING BRAKE LEVER

The parking brake lever sets and releases the

front wheel brakes.

Set: Move the brake lever from the short to the

long slot with your foot. Step on the brake pedal to

lock the pedal in place.

Release: Step on the brake pedal to release it,

and move the brake lever to the left with your foot

at the same time. Lock the lever in place in the

short slot.

CHASSIS

2-9

8410 MM392 (8--01)

FRONT TIRES AND WHEELS

The machines front tires are semi--pneumatic.

Inspect the front 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 FRONT WHEEL BEARINGS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Empty the debris hopper.

2. Turn the parking brake knurled knob

counterclockwise until it stops. (early version

machines only)

3. Disconnect the battery cables and remove

the battery to access the floor plate

hardware.

4. Remove floor plate from the machine.

5. Thread the brake cable clevis yoke toward

the threaded rod to reduce brake cable

tension.

6. Jack up one front corner of the machine.

Place jack stands under machine.

7. Remove the hub cap.

8. Remove the cotter pin, slotted nut, flat

washer, and bearing cone.

9. Remove the front tire and wheel assembly

from the machine.

10. Pack the wheel bearings with Lubriplate

EMB grease.

11. Slide the wheel assembly back on the axle.

12. Slide the outer bearing, flat washer and nut

onto the shaft.

13. Tighten the nut with hand wrench until the

wheel binds, then back the nut off to the

nearest hole.

CHASSIS

2-10 8410 MM392 (8--01)

14. Insert a new cotter pin through nut and hole.

15. After making sure the wheel spins freely,

carefully install the hub cap. Repeat this

procedure on the opposite side of the

machine.

16. Remove the jack stand and lower the

machine.

17. Thread the brake cable clevis yoke away

from the threaded rod until the brake pedal

travels 25--50 mm (1--2 in) before engaging

brakes.

18. Tighten the brake clevis jam nuts.

19. Reinstall the floor plate.

20. Install the battery and battery cables.

21. Lower the seat support.

22. Adjust the parking brake by turning the

knurled knob clockwise until the parking

brake properly holds the machine in place.

(early version machines only)

23. Drive the machine and check for proper

operation.

CHASSIS

2-11

8410 MM392 (5--02)

REAR WHEEL AND WHEEL SUPPORT

The rear wheel support pivots the rear wheel. The

support has one grease fitting for the bearings.

The rear wheel support bearings must be

lubricated every 200 hours of operation. Use

Lubriplate EMB grease (TENNANT part no.

01433--1).

Torque the rear wheel nuts twice in the pattern

shown to 142 -- 156 Nm (105 -- 115 ft lb) after the

first 50-hours of operation, and every 800 hours

thereafter. Torque the rear wheel hub nut to

(375 ft lb).

CHASSIS

2-12 8410 MM392 (8--01)

TO REPLACE REAR WHEEL HOUSING

PIVOT BEARINGS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Engage the parking brake and block the

front tires.

2. Jack up the rear of the 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 rear tire and wheel assembly.

4. Remove the slotted nut from drive wheel

motor hub shaft.

5. Use a large puller to remove the drive hub

from the motor shaft.

6. Remove the hose support plate from the

rear wheel housing.

NOTE: The hydraulic hoses can remain

connected to the drive motor

7. Remove the four drive motor mounting bolts.

NOTE: The orientation of the motor in the rear

wheel housing.

8. Slide the motor out of the rear wheel

housing.

9. The hydraulic motor can moved out of the

way to ease rear wheel housing removal.

CHASSIS

2-13

8410 MM392 (8--01)

10. Remove .750 inch hex screw attaching rod

end of steering cylinder to rear wheel

housing.

11. Remove the cotter pin and large slotted nut

from the top of the pivot pin.

12. Loosen the two M10 socket head bolts that

are pinching the pivot pin in the frame.

13. Remove the pivot pin from the machine.

NOTE: The rear drive housing is heavy and will

drop out of the machine frame when the pivot pin

is removed.

14. Slide the wheel housing out of the main

frame. Retain the thrust washer that is in

place on top of the upper bearing cone.

15. Remove and discard both bearing cones.

16. Remove and discard the pressed in bearing

cups by tapping them out with a hammer

and drift punch.

17. Press the new bearing cups in by using a

hydraulic press.

18. Pack the new bearing cones with Lubriplate

EMB grease. Coat the new bearing cups

with grease also.

19. Position the new bearings in the wheel

housing.

20. Position the thrust washer on top of top

bearing cone.

21. Position the wheel housing back in the

machine frame.

22. Slide the pivot pin up through the hole in the

frame and through the two bearings. Thread

the castle nut on the pin. Tighten to

34 -- 40 Nm (25 -- 30 ft lb). Check for play. If

pin is not seated, tap with rubber mallet and

re--torque castle nut.

23. Torque the top socket screw with hand

torque wrench to 100 -- 115 Nm

(73--85 ft lb).

CHASSIS

2-14 8410 MM392 (8--01)

24. Tighten the castle nut to the next slot and

insert the cotter pin. Torque not to exceed

100 Nm (75 ft lb).

25. Check the casting to see if it rocks or binds.

If it does, loosen the top socket screw, move

the casting to seat bearing, and re--tighten

the socket screw to 100 -- 115 Nm

(73--85 ft lb).

26. Tighten the lower socket screw to

100 -- 115 Nm (73--85 ft lb).

27. Reconnect the rod end of the steering

cylinder to wheel casting using the

.750x3.25 hex screw, nyloc nut, and four

washers. Tighten to 270 -- 300 Nm

(200 -- 220 ft lb).

28. Slide the rear drive motor in the wheel

housing.

NOTE: The orientation of the motor in the rear

wheel housing.

29. Install the four socket screws. Torque to

90 -- 117 Nm (70 -- 85 ft lb).

30. Reinstall the hose clamp to the drive

housing. Tighten M8 hex screws to

18.5 -- 24Nm (15 -- 20 ft lb).

31. Install the drive hub to the tapered motor

shaft. Tighten slotted nut to 500 Nm

(375 ft lb). Install the cotter pin.

NOTE: Make sure the square key is in place on

the tapered shaft before installing the drive hub.

32. Install rear tire and wheel assembly. Torque

the rear wheel nuts to 142 -- 156 Nm

(105 -- 115 ft lb).

33. Re--connect battery cables, start engine, run

propelling in both directions, check for leaks.

34. Remove the jack stands and lower the

machine.

35. Drive the machine and check for proper

operation.

SWEEPING

3-1

8410 MM392 (5--02)

CONTENTS

Page

INTRODUCTION 3-3......................

DEBRIS HOPPER 3-4..................

TO REMOVE HOPPER 3-4..........

TO INSTALL HOPPER 3-5...........

TO ADJUST HOPPER 3-6...........

TO ADJUST HOPPER BUMPER 3-7..

HOPPER DUMP DOOR 3-8.............

TO REMOVE HOPPER DUMP

DOOR 3-8......................

TO INSTALL HOPPER DUMP

DOOR 3-9......................

TO ADJUST HOPPER DUMP

DOOR 3-10.....................

HOPPER DUST FILTER 3-11...........

TO REMOVE OR REPLACE HOPPER

DUST FILTER 3-12...............

THERMO SENTRYt3-14..............

TO REPLACE THERMO SENTRYt3-14

BRUSHES 3-15.

MAIN SWEEP BRUSH 3-15..........

REPLACING MAIN SWEEP

BRUSH 3-16..................

CHECKING AND ADJUSTING

MAIN SWEEP BRUSH

PATTERN 3-17.............

TO REPLACE MAIN BRUSH

IDLER PLUG BEARING 3-19...

TO REPLACE BRUSH SHAFT

BEARINGS 3-20..............

SIDE BRUSH 3-22..................

REPLACING SIDE BRUSH 3-23...

SIDE BRUSH GUARD 3-24.............

TO ROTATE OR REPLACE SIDE

BRUSH GUARD 3-24.............

SKIRTS AND SEALS 3-25..............

HOPPER LIP SKIRTS 3-25...........

TO REPLACE HOPPER LIP

SKIRTS 3-25.................

BRUSH DOOR SKIRTS 3-26.........

TO REPLACE AND ADJUST

BRUSH DOOR SKIRTS 3-26...

REAR SKIRT AND DEFLECTOR

BLADE 3-27.....................

TO REPLACE AND ADJUST

THE REAR SKIRT AND

DEFLECTOR BLADE 3-28...

BRUSH DOOR SEALS 3-29..........

HOPPER SEALS 3-29...............

TO REPLACE HOPPER

SEALS 3-29..................

HOPPER INSPECTION DOOR

SEAL 3-31......................

Page

HOPPER DOOR SEALS 3-31........

TO REPLACE HOPPER DOOR

SEALS 3-32..................

HOPPER COVER SEAL 3-33.........

TO REPLACE HOPPER

COVER SEAL 3-33............

HOPPER DUST SEAL 3-34..........

TO REPLACE HOPPER

DUST SEAL 3-34.............

HOPPER VACUUM FAN SEAL 3-35...

TO REPLACE HOPPER VACUUM

FAN SEAL 3-35...............

HOPPER LIFT ARMS 3-36..............

TO REMOVE HOPPER LIFT

ARMS 3-36......................

TO INSTALL HOPPER LIFT

ARMS 3-37......................

SWEEPING VACUUM FAN 3-38.........

TO REMOVE SWEEPING

VACUUM FAN 3-38..............

TO INSTALL SWEEPING

VACUUM FAN 3-39..............

TO REPLACE SWEEPING

VACUUM FAN IMPELLER 3-40....

MACHINE TROUBLESHOOTING 3-41...

SWEEPING

3-2 8410 MM392 (8--01)

SWEEPING

3-3

8410 MM392 (8--01)

INTRODUCTION

The side brush sweeps debris into the path of the

main brush. The main brush sweeps debris from

the floor into the hopper. The vacuum system

pulls dust and air through the hopper and the

hopper dust filter.

SWEEPING

3-4 8410 MM392 (8--01)

DEBRIS HOPPER

The debris hopper collects the debris swept up by

the machine. The hopper includes the following

main components: hopper dust filters, hopper

dump door, and dust skirts. All adjustment have

been made at the factory and require no regular

maintenance. If the hopper components are

repaired or replaced, some components may

need to be readjusted for best performance. The

hopper may need to be removed from the

machine some repair or service work.

TO REMOVE HOPPER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Engage the parking brake.

2. Start the engine and raise the hopper high

enough to position two 4” tall blocks on the

floor under the hopper. Lower the hopper

down on these blocks. Shut off the engine.

3. Open the hopper cover, unplug the wires

from the filter shaker and Thermo Sentryt.

4. Remove the filter carrier tray from the

machine.

5. Remove the six M12 hex screws and nyloc

nuts holding the lift arms to hopper sides.

6. Start the machine and carefully back it away

from the hopper a few feet. Watch the right

hand lift arm when backing up, it needs to

clear the hopper solenoid valve on the way

out.

7. After the machine is clear of the hopper,

shut off engine and disconnect and plug

hydraulic hoses leading from hopper to the

machine.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

8. Disconnect the hopper wire harness from

the main harness. Unplug the vacuum fan

solenoid from the main harness.

9. The hopper can now be removed from the

machine.

NOTE: Do not start engine with hydraulic hoses

disconnected.

SWEEPING

3-5

8410 MM392 (8--01)

TO INSTALL HOPPER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Position the hopper in front of the machine.

Move the hopper in close enough to

reconnect the hydraulic hoses and the wire

harness.

NOTE: Make sure the hopper cover is in the

raised position.

2. See the schematic in the HYDRAULICS

section of this manual for proper hose

connections.

3. See the schematic in the ELECTRICAL

section of this manual for proper harness

connections.

4. The machine can now be started and

carefully inched forward. The right hand lift

arm must clear the hopper solenoid valve

when positioning hopper back in the

machine.

NOTE: Be careful not to pinch hydraulic hoses or

electrical wires during this procedure.

5. The hopper must go in until the rubber pads

on the bumper hit the machine frame.

6. Remove the filter tray from the hopper.

7. Align the holes in lift arms with the holes in

hopper sides. It may be necessary to use a

pry bar for the final alignment.

NOTE: Hopper must be on 4”tall blocks for proper

adjustment before installing hardware.

8. Install six M12 hex screws, nyloc nuts and

Belleville washers along with the two hopper

plates. Tighten to 90 -- 117 Nm

(65 -- 85 ft lb).

9. Install the hydraulic hose clamps to the

hopper lift arm.

10. Reinstall the filter tray back in the hopper

and reconnect the wires to the filter shaker

and Thermo Sentryt.

11. Start the engine and check for proper

operation of the hopper vacuum fan, dump

door, side brush rotation and side brush up

and down.

SWEEPING

3-6 8410 MM392 (8--01)

TO ADJUST HOPPER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Engage the parking brake.

2. Start the engine and raise the hopper high

enough to position two 4” tall blocks on the

floor under the hopper. Lower the hopper

down on these blocks. Shut off the engine.

3. Open the hopper cover, unplug the wires

from the filter shaker and Thermo Sentryt.

4. Remove the filter carrier tray from the

machine.

5. Loosen the six M12 hex screws and nyloc

nuts holding lift arms to hopper. Make sure

hopper arms drop down to the lowest

position, and the hopper is all the way back

against the main frame.

6. Tighten the six M12 hex screws and nyloc

nuts to Tighten to 90 -- 117 Nm

(65 -- 85 ft lb).

7. Reinstall the filter tray back in the hopper

and reconnect the wires to the filter shaker

and Thermo Sentryt.

8. Start the engine, raise the hopper high

enough to remove the two 4” tall blocks.

Lower the hopper and check for proper

hopper to floor clearance.

SWEEPING

3-7

8410 MM392 (8--01)

TO ADJUST HOPPER BUMPER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Using a long straight edge, check the

levelness of the hopper bumper to the

machine frame. If there is more than an

1/8 in. difference; the bumper needs to be

adjusted.

2. Use a hoist or a floor jack to hold up the

bumper while loosening the six M10 hex

screws holding it to the hopper.

3. Using the straight edge and hoist, re--align

the bumper to the frame. Tighten the M10

hex screws to 52 -- 67 Nm (39 -- 51 ft lb).

4. Remove the hoist, shut the hopper cover,

check the hood and bumper for proper

alignment.

SWEEPING

3-8 8410 MM392 (8--01)

HOPPER DUMP DOOR

The hopper dump door is used to control the

debris when dumping.

TO REMOVE HOPPER DUMP DOOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Make sure the hopper is emptied of all

debris. Engage the parking brake.

2. Open the dump door and hopper cover.

3. Remove the clevis pin holding the rod end of

dump door cylinder and dust door pivot link

to the dump door pivot yoke.

4. Using a hammer and punch; drive the roll

pins out of the pivot yokes. Remove the

pivot yokes from the machine.

5. Remove the four M8 hex screws and flange

nuts holding the bearing pivot hubs to the

hopper. Remove both hubs.

6. Close the hopper cover.

7. Raise the hopper and engage the safety

arm.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

8. Completely loosen the two adjustment bolts

on the dump door pivot rod.

9. Using a vice grip and a pry bar, remove the

three springs from the dump door.

10. Slide the dump door all the way in either

direction, drop one side down, remove the

dump door from the machine.

SWEEPING

3-9

8410 MM392 (8--01)

TO INSTALL HOPPER DUMP DOOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Make sure the hopper is emptied of all

debris. Engage the parking brake.

2. Raise the hopper and engage safety arm.

3. Slide the pivot rod weldment in the holes on

hopper dump door.

NOTE: Both of the bearing pivot blocks must be

removed before the next step can be completed.

4. Place one end of dump door assembly in

one of the holes in rear of hopper. Slide it all

the way to one side, bring up the other end

and place it in the other hole. Center the

door in machine.

5. Reconnect the three tension springs from

eye bolts in hopper to holes in brackets on

dump door. Use a vice grips and a pry bar to

hook the springs in the holes.

6. Set the adjustment bolts on the dump door

to 3/4 in. from the head of the bolt to edge of

the bracket.

7. Disengage the safety arm, lower the hopper

and open hopper cover.

8. Reinstall both bearing pivot blocks using four

M8 hex head screws and flange nuts.

Tighten to 18 -- 24 Nm (13 -- 18 ft lb).

9. Install pivot yokes on the dump door rod with

the smooth side towards the hopper.

10. Align the holes in the rod with holes in the

pivot yoke. Use a hammer to drive the roll

pins in flush.

11. Reconnect the rod end of dump door

cylinder and the dust door pivot link to dump

door pivot yoke using the clevis pins and

hair pins.

12. Start the machine and open and close the

hopper door a few times checking for proper

operation.

SWEEPING

3-10 8410 MM392 (8--01)

TO ADJUST HOPPER DUMP DOOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Make sure the hopper is emptied of all

debris. Engage the parking brake.

2. Open the dump door.

3. Raise the hopper and engage the safety

arm.

4. Measure the opening between the inside of

the dump door to the inside lower corner of

the hopper. This dimension should be 10.5”.

5. Use the two adjustment screws on the dump

door to achieve this dimension.

SWEEPING

3-11

8410 MM392 (5--02)

HOPPER DUST FILTER

The dust filters filter the air pulled up from the

hopper. The dust filters are equipped with a

shaker to remove the accumulated dust particles.

The dust filters shaker is operated by the filter

shaker switch.

Shake the dust filters before dumping the hopper

and at the end of every work shift. Check and

clean the dust filters every 50 hours of operation.

Extremely dusty conditions may require more

frequent cleaning of dust filters.

To clean the dust filters, use one of the following

methods:

DSHAKING -- Press the filter shaker switch.

DTAPPING -- Tap the filter gently on a flat

surface with the dirty side down. Do not

damage the edges of the filter element or

the filter will not seat properly in the filter

frame.

DAIR -- Always wear eye protection when

using compressed air. Blow air through the

dust filter opposite the direction of the

arrows. Never use more than 690 kPa

(100 psi) of air pressure and never closer

than 50 mm (2 in) away from the filter.

FOR SAFETY: When Servicing Machine,

Wear Eye And Ear Protection When

Using Pressurized Air Or Water.

DWATER -- The dust filter can be rinsed with

water, but the filter will degrade with each

rinsing. Replaced the filter after rinsing five

times. Rinse with a low pressure garden

hose through the dust filter opposite the

direction of the arrows.

NOTE: Be sure the dust filter is dry before

reinstalling it in the machine.

SWEEPING

3-12 8410 MM392 (8--01)

TO REMOVE OR REPLACE HOPPER

DUST FILTER

1. Stop 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.

2. Open the hopper cover.

3. Disconnect the shaker motor wire

connectors.

4. Remove the four retaining screws from the

filter shaker frame.

5. Pull the filter shaker frame out of the hopper.

6. Lift the dust filter element out of the hopper

insert.

SWEEPING

3-13

8410 MM392 (8--01)

7. Clean or discard the dust filter as required.

8. Put the cleaned or new dust filter in the

hopper insert with the arrows pointing up.

9. Install the four retaining screws and tighten.

10. Connect the shaker motor wire connectors.

SWEEPING

3-14 8410 MM392 (8--01)

THERMO SENTRYt

The Thermo Sentrytsenses the temperature of

the air pulled up from the hopper. If there is a fire

in the hopper, the Thermo Sentrytstops the

vacuum fan and cuts off the air flow.

Reset the Thermo Sentrytby pushing in its reset

button.

TO REPLACE THERMO SENTRYt

1. Open the hopper cover.

2. Disconnect the Thermo Sentrytfrom the

hopper harness.

3. Remove the two screws holding the

Thermo Sentrytto the stiffener plate.

Remove the Thermo Sentryt.

4. Mount the new Thermo Sentrytto the

stiffener plate with existing hardware.

5. Connect the new Thermo Sentrytto the

hopper wire harness.

6. Close the hopper cover.

SWEEPING

3-15

8410 MM392 (5--02)

BRUSHES

MAIN SWEEP BRUSH

The main sweep brush is cylindrical and spans

the width of the machine, sweeping debris into the

hopper.

Check the brush daily for wear or damage.

Remove any string or wire tangled on the main

brush, main brush drive hub, or main brush idler

hub.

Check the main sweep brush pattern daily. The

pattern should be 50 to 65 mm (2.0 to 2.5 in) wide

with the main sweep brush in the lowered

position. Adjust the main sweep brush pattern by

turning the main brush pressure knob located next

to the brush position lever.

Rotate the main brush end-for-end every 50 hours

of operation for maximum brush life and best

sweeping performance.

Replace the main sweep brush when the

remaining bristles measure 25 mm (1 in) in length.

SWEEPING

3-16 8410 MM392 (5--02)

REPLACING MAIN SWEEP BRUSH

1. Stop 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.

2. Raise the main sweep brush.

3. Open the right side brush access door.

4. Unlatch and remove the brush idler plate.

5. Grasp the main sweep brush; pull it off the

brush drive plug and out of the main brush

compartment.

6. Put the new or rotated end-for-end main

sweep brush on the floor next to the access

door.

7. Slide the main sweep brush onto the drive

plug. Rotate the brush until it engages the

drive plug, and push it all the way onto the

plug.

8. Slide the brush idler plate plug onto the main

sweep brush.

9. Latch the idler plate onto the machine frame.

10. Close the right side brush access door.

08016

08017

08018

SWEEPING

3-17

8410 MM392 (5--02)

CHECKING AND ADJUSTING MAIN SWEEP

BRUSH PATTERN

1. Apply chalk, or some other material that will

not blow away easily, to a smooth, level

floor.

2. Raise the side brush and main sweep brush

and position the main sweep brush over the

chalked area.

3. Start the main sweep brush.

4. Lower the main sweep brush for 15 to 20

seconds while keeping a foot on the brakes

to keep the machine from moving. This will

lower the rotating main sweep brush.

NOTE: If chalk or other material is not available,

allow the sweep brush to spin on the floor for two

minutes. A polish mark will remain on the floor.

5. Raise the main sweep brush.

6. Stop the main sweep brush.

7. Drive the machine off the test area.

8. Observe the width of the brush pattern. The

proper brush pattern width is 50 to 65 mm

(2.0 to 2.5 in).

9. To increase the width of the main sweep

brush pattern, turn the main sweep brush

down pressure knob counter-clockwise.

To decrease the width of the main sweep

brush pattern, turn the main sweep brush

down pressure knob clockwise.

00582

SWEEPING

3-18 8410 MM392 (5--02)

If the main sweep brush pattern is tapered,

more than 15 mm (0.5 in) on one end than

the other, adjust the taper with the taper

adjustment bracket at the idler end of the

brush.

A. Loosen the bracket mounting bolts.

B. Turn the taper adjustment nut

counter-clockwise to increase the

pattern width at the brush idler end, and

clockwise to decrease the pattern width

at the brush idler end. Tighten the

mounting bolts.

C. Check the main sweep brush pattern

and readjust as necessary. Then adjust

the width of the main brush pattern.

00601

09183

09184

SWEEPING

3-19

8410 MM392 (8--01)

TO REPLACE MAIN BRUSH IDLER PLUG

BEARING

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Open the right side brush door and remove

the main brush idler arm from machine.

2. Remove the plastic cap from the idler plug.

3. Remove the M12 hex screw, nyloc hex nut,

and washer holding the idler plug to the

brush idler arm. Save the hardware.

4. Remove the four M6 hex screws holding the

idler shaft in the idler plug. Remove the

shaft. Save the hardware.

5. Remove the bearing seal plate, retainer and

bearing.

6. Clean the inside of the idler plug.

7. Place a new bearing, the seal plate and the

retainer in the idler.

8. Reinstall the four screws and flat washers.

9. Install the idler shaft and tighten the four M6

hex screws to 8--10 Nm (6--8 ft lb).

10. Position the idler plug and shaft on the brush

idler arm. Reinstall the hardware removed

earlier. Tighten to 68--81 Nm (50--60 ft lb).

11. Apply RTV to the area where plastic cap will

fit in the end of idler plug. Snap plastic cap

into place.

NOTE: If you replace idler arm latch, use blue

locktite on hardware to hold in place.

SWEEPING

3-20 8410 MM392 (8--01)

TO REPLACE BRUSH SHAFT BEARINGS

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Remove the main brush and idler.

2. Remove the main brush motor mount plate

from the brush shaft.

NOTE: The hydraulic hoses can be left hooked up

to the motor when removing the mount plate.

3. Remove the brush lift cable clevis from the

brush shaft arm.

4. Loosen the main brush taper adjustment

screw.

5. Remove the hardware holding each of the

two brush shaft flange bearings.

6. Pull the brush shaft out of the machine.

7. Use a punch and a hammer to drive the

brush hub roll pins out of the brush hubs.

8. Slide the brush hubs off the end of the shaft.

9. Remove the remaining hardware holding the

bearing collars in place.

10. Loosen the bearing set screws and slide the

bearings off the shaft.

11. Slide the new bearings on the shaft with the

collar facing the ends of the shaft. Be sure

to have a bearing flange on each side of the

bearings.

12. Slide the brush hubs on each end of the

brush shaft.

13. Align the hole in the hub with the hole in the

shaft.

SWEEPING

3-21

8410 MM392 (8--01)

14. Use a hammer to pound the roll pin in flush.

15. Mount the main brush shaft plate to the right

side bearing flange. Tighten the hardware to

22--27 Nm (16--20 ft lb).

NOTE: If you are replacing the idler arm latch

bracket, use blue locktite to hold the bolts in

place. Tighten the bolts to 8--10 Nm(6--8 ft lb).

16. Center the brush shaft in the machine.

Tighten the bearing collar set screws.

17. Connect the main brush lift cable to the

brush shaft arm with the clevis pin removed

earlier.

18. Reinstall the main brush hydraulic motor

mount plate. Tighten the hex screw to

64 -- 83 Nm (47 -- 61 ft lb).

19. Reinstall the main brush and idler.

20. Check the main brush pattern for taper and

width.

SWEEPING

3-22 8410 MM392 (5--02)

SIDE BRUSH

The side brush sweeps debris along edges into

the path of the main brush.

Check the brush daily for wear or damage.

Remove any string or wire found tangled on the

side brush or side brush drive hub.

Check the side brush pattern daily. The side brush

bristles should contact the floor in a 10 o’clock to

3 o’clock pattern when the brush is in motion.

Adjustthesidebrushpatternbythesidebrush

down pressure knob. Turn the knob

counter-clockwise to increase the brush contact

with the sweeping surface, and clockwise to

decrease the brush contact with the sweeping

surface.

The side brush should be replaced when it no

longer sweeps effectively for your application. A

guideline length is when the remaining bristles

measure 50 mm (2 in) in length. You may change

the side brush sooner if you are sweeping light

litter, or wear the bristles shorter if you are

sweeping heavy debris.

350327

SWEEPING

3-23

8410 MM392 (5--02)

REPLACING SIDE BRUSH

1. Empty the debris hopper.

2. Set the machine parking brake.

3. Stop the engine.

FOR SAFETY: Before leaving or

servicing machine; stop on level

surface, set parking brake, turn off

machine and remove key.

4. Remove the side brush retaining pin from

the side brush drive shaft by pulling the pin

keeper off over the end of the pin.

5. Slide the side brush off the side brush drive

shaft.

NOTE: Remove the drive hub and put it on the

new brush if one is not installed.

6. Slide the new side brush onto the side brush

drive shaft.

7. Insert the side brush retaining pin through

the side brush hub and shaft.

8. Secure the pin by clipping the pin keeper

over the end of the pin.

9. Disengage the hopper support bar and lower

the hopper.

10. Adjust the side brush pattern with the side

brush down pressure knob.

08019

SWEEPING

3-24 8410 MM392 (8--01)

SIDE BRUSH GUARD

The side brush guard protects the side brush from

objects along path of the machine. It deflects the

side brush out of harms way.

Rotate the side brush guard 90_every 200 hours

of operation. Replace the brush guard after all

four sides have been used.

TO ROTATE OR REPLACE SIDE BRUSH

GUARD

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Remove the side brush.

2. Remove the four bolts holding the side brush

guard to the side brush motor. Use care not

to disturb the motor position.

3. Rotate or replace the side brush guard.

4. Reinstall the four .375 in. hex screws in the

side brush motor. Tighten to 22--27 Nm

(16--20 ft lb).

5. Install the side brush.

SWEEPING

3-25

8410 MM392 (8--01)

SKIRTS AND SEALS

HOPPER LIP SKIRTS

The hopper lip skirts are located on the bottom

rear of the hopper. The skirts float over debris and

help deflect that debris into the hopper. The

hopper lip skirts consist of five bottom lip

segments and two additional side lip segments.

Check the hopper lip skirts for wear or damage

daily.

Replace the hopper lip skirts when they no longer

touch the floor.

TO REPLACE HOPPER LIP SKIRTS

1. Dump the machine debris hopper.

2. Set the machine parking brake.

3. Raise the hopper and engage the hopper

support bar.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

4. Shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

5. Remove the hopper lip skirt retaining strip

mounting hardware.

6. Remove the hopper lip retaining strip, the

hopper lip, and the back-up strip.

7. Thread the retaining strip mounting bolts

through the retaining strip, the new hopper

lip skirt, the back-up strip, and in the hopper.

8. Tighten the mounting bolts to 8--14 Nm

(6--10 ft lb).

9. Start the engine.

10. Disengage the hopper support bar and lower

the hopper.

11. Check the skirt for proper adjustment. The

skirt should be evenly touching the floor.

SWEEPING

3-26 8410 MM392 (5--02)

BRUSH DOOR SKIRTS

The brush door skirts are located on the bottom of

each of the two main brush doors. The long skirt

should clear the floor by 3 to 6 mm

(0.12 to 0.25 in). The inner skirt should be angled

so that the rear corner touches the floor, and the

front corner is 6 mm (0.25 in) above the corner of

the long skirt.

Check the skirts for wear or damage and

adjustment daily.

NOTE: The brush door skirts have slotted holes

to allow for a ground clearance adjustment. The

door must be closed for proper adjustment.

TO REPLACE AND ADJUST BRUSH DOOR

SKIRTS

1. Park the machine on a smooth, level

surface.

2. Stop 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. Open the main brush doors.

4. Remove the brush door skirt retaining bolts.

5. Remove the skirt retaining strip and the door

skirt.

6. Position the new door skirt and skirt

retaining strip on the brush door with the flat

edge forward and angled toward the back of

the machine.

7. Place the new half-length skirt over the front

half of the long skirt. Place the retainer over

the skirts.

8. Thread the skirt retaining bolts through the

brush door, the door skirts, and into the skirt

retaining strip.

NOTE: The brush door skirts have slotted holes to

allow for a ground clearance adjustment. The door

must be closed for proper adjustment.

08001

SWEEPING

3-27

8410 MM392 (8--01)

9. Slide the long brush door skirt up or down so

it will clear the floor by 3--5 mm

(0.12 to 0.25 in). Secure the two bolts

holding only one skirt.

10. Adjust the inner half--length skirt so the front

edge of it is 5 mm (0.25 in) above the long

skirt and the back half just touches the floor.

tighten all four bolts to 6--8 ft lb (8--10 Nm).

11. Repeat for the other brush door.

REAR SKIRT AND DEFLECTOR BLADE

The rear skirt and the deflector blade are located

on the bottom rear of the main brush

compartment. The rear skirt should clear the floor

up to 5 mm (0.25 in) in dusty conditions, and

touch the floor otherwise. The deflector blade is

spring loaded.

Check the skirt and blade for wear or damage and

adjustment daily.

NOTE: Rear tire pressure will affect skirt

clearances.

5 mm (0.25 in) 3mmto5mm

(0.12 to 0.25 in)

SWEEPING

3-28 8410 MM392 (8--01)

TO REPLACE AND ADJUST THE REAR

SKIRT AND DEFLECTOR BLADE

1. Park the machine on a smooth, level

surface.

2. Stop 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. Open the main brush doors.

4. Remove the main brush.

5. Remove the retaining strip and floor skirt.

6. Thread the mounting bolts through the

machine frame, the rear floor skirt, and the

retaining strip toward the rear wheel.

7. Slide the rear floor skirt up or down so it

clears the floor up to a maximum of

5 mm (0.25 in).

8. Tighten the rear floor skirt mounting bolts to

8--14 Nm (6--10 ft lb).

9. Remove the brush contact blade retaining

strip and the brush contact blade.

10. Thread the mounting bolts through the

mounting bracket, the brush contact blade,

and the retaining strip.

11. Tighten the brush contact blade mounting

bolts to 8--14 Nm (6--10 ft lb).

12. Make sure the deflector spring moves the

blade into position freely.

13. Reinstall the main brush.

14. Close the main brush doors.

up to 5 mm

(up to 0.25 in)

SWEEPING

3-29

8410 MM392 (5--02)

BRUSH DOOR SEALS

The brush door seals are located on both main

brush doors and on corresponding portions of the

main frame.

Check the seals for wear or damage every

100 hours of operation.

HOPPER SEALS

The hopper seals are located on the top and side

portions of the machine frame that contact the

hopper. They seal the main brush compartment.

Tighten the seal hardware to 4--5 Nm (3--4 ft lb).

Check the seals for wear or damage every

100 hours of operation.

TO REPLACE HOPPER SEALS

1. Park the machine on a smooth, level

surface.

2. Stop 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. Raise hopper and engage hopper support

bar.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

4. Open the main brush doors.

5. Remove the main brush.

08022

08023

SWEEPING

3-30 8410 MM392 (8--01)

6. Remove the skirt retainer and skirt on each

side of the machine. Remove the plastic

rivets by prying under the head.

7. Position new skirt and existing retainer on

front of machine frame. Secure with plastic

push--in rivets.

8. Pull skirt around inside of frame. Push skirt

all of the way in its slots. Secure with

existing angle retainer and two M6 bolts, flat

washers, and Nyloc nuts. tighten bolts to

4--5 Nm (3--4 ft lb).

9. Pull skirt toward the brush door. Secure it in

place with the C-shaped retainer and bolts.

Tighten the bolts to 8--10 Nm (6--8 ft lb).

10. Repeat for the other side of the main frame.

SWEEPING

3-31

8410 MM392 (8--01)

HOPPER INSPECTION DOOR SEAL

The hopper inspection door seal is located on the

hopper and seals the front of the debris hopper.

Check the seal for wear or damage every

100 hours of operation.

HOPPER DOOR SEALS

The hopper door seals are located on the hopper

door. They seal the hopper when the hopper door

is closed. Use RTV between the sponge cord and

door seal. Make sure the seals are straight.

Tighten hardware to 3--4 Nm (2.5--3.5 ft lb).

Hardware should be oriented with the nyloc nuts

on the top side of the door.

Check the seals for wear or damage every

100 hours of operation.

SWEEPING

3-32 8410 MM392 (8--01)

TO REPLACE HOPPER DOOR SEALS

1. Park the machine on a smooth, level

surface.

2. Open the hopper dump door.

3. Stop 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.

4. Raise the hopper and engage the hopper

support bar.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

5. Remove the six M6 hex screws and nyloc

nuts holding dump door seal, retainer, and

sponge cord to dump door. Discard the seal.

6. Use black RTV to hold the sponge cord to

the new dump door seal.

7. Align the holes in the new seal with holes on

dump door and retainer. Reinstall the six M6

hex screws and nyloc nuts. Tighten to

3.3--4.4Nm(30--39Inlb).

8. Remove the four M6 hex screws and nyloc

nuts holding the dump door side seals and

retainers to each side of the dump door.

Note the direction of the hardware.

Discard the seals.

9. Align the holes in the seal with the holes on

the dump door and retainer. Reinstall the

four M6 hex screws and nyloc nuts. Tighten

to 3.3 -- 4.4 Nm (30 -- 39 In lb).

NOTE: Make sure the seals are lined up with the

inside edge of the hopper when tightening.

10. Start the machine and lower the hopper.

SWEEPING

3-33

8410 MM392 (8--01)

HOPPER COVER SEAL

The hopper cover seal is located on the top edges

of the hopper insert. It seals the hopper filter

compartment when the hopper cover is in the

down position.

Check the seal for wear or damage every

100 hours of operation.

TO REPLACE HOPPER COVER SEAL

1. Park the machine on a smooth, level

surface.

2. Stop 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. Raise the hopper cover, unplug the wires

from filter shaker and thermo--sentry,

remove the filter carrier tray from the hopper

and set it on the floor.

4. Remove the old rubber bubble seal from the

filter carrier tray. The seal is glued to the tray

so a putty knife or a razor blade knife is

needed for removal.

5. Make sure the new seal is cut to the same

length as the old seal.

6. Use super glue in the groove of the new seal

and install it, bubble side up, on the filter

tray.

7. Reinstall the filter carrier tray back in the

hopper. Reconnect the shaker motor and

thermo--sentry to the hopper harness.

8. Close the hopper cover and operate the

machine. Check the new seal for any air

leaks.

SWEEPING

3-34 8410 MM392 (8--01)

HOPPER DUST SEAL

The hopper dust seal is located under the hopper

insert along the top of the hopper.

Check the seal for wear or damage every

100 hours of operation. You can reach the seal by

removing the hopper insert.

TO REPLACE HOPPER DUST SEAL

1. Park the machine on a smooth, level

surface.

2. Stop 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. Raise the hopper cover, unplug the wires

from filter shaker and thermo--sentry,

remove the filter carrier tray from the hopper

and set it on the floor.

4. Using a scraper or a putty knife, remove the

old seal from the back of the hopper.

Discard the old seal.

5. Make sure that all of the old seal is removed

before attempting to glue the new one on.

6. Cut the new seal to length and use an

industrial strength contact cement to attach

it to the back of the hopper.

7. Reinstall the filter carrier tray back in the

hopper. Reconnect the shaker motor and

thermo--sentry to the hopper harness.

8. Close the hopper cover and operate the

machine. Check the new seal for any air

leaks.

SWEEPING

3-35

8410 MM392 (5--02)

HOPPER VACUUM FAN SEAL

The hopper vacuum fan seal is mounted on the

inside of the hopper around the vacuum fan inlet.

Check the seal for wear or damage every

100 hours of operation. You can reach the seal by

removing the hopper insert.

TO REPLACE HOPPER VACUUM FAN SEAL

1. Park the machine on a smooth, level

surface.

2. Stop 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. Raise the hopper cover, unplug the wires

from filter shaker and thermo--sentry,

remove the filter carrier tray from the hopper

and set it on the floor.

4. Using a scraper or a putty knife, remove the

old seal from the back of the hopper.

Discard the old seal.

5. Make sure that all of the old seal is removed

before attempting to glue the new one on.

6. Cut the new seal to length and use an

industrial strength contact cement to attach

it to the back of the hopper.

7. Reinstall the filter carrier tray back in the

hopper. Reconnect the shaker motor and

thermo--sentry to the hopper harness.

8. Close the hopper cover and operate the

machine. Check the new seal for any air

leaks.

SWEEPING

3-36 8410 MM392 (8--01)

HOPPER LIFT ARMS

The hopper lift arms lift and lower the hopper

assembly. They are held in place by two pins and

self-aligning bearings with retaining rings.

TO REMOVE HOPPER LIFT ARMS

1. Park the machine on a smooth, level

surface.

2. Stop 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 hopper. See TO REMOVE

HOPPER instructions in this section.

4. Remove the RH and LH tank panels.

5. Disconnect the speed limiter cable from RH

side lift arm. The cable can be removed from

the ball by pushing down on the sleeve

around the ball joint end and prying it off.

6. Remove the M6 hex screw holding the

cylinder pin plate to the cylinder clevis.

7. Raise up slightly on lift arm to take the

pressure off the lift cylinder pin. Remove pin.

8. Remove the M8 socket screw from the

upper lift arm pivot pin.

9. Raise up slightly on the lift arm to take

pressure off the pivot pin. Remove the pivot

pin and lift arm from the machine.

10. If the large self aligning bearing needs to be

changed, remove the retaining rings and

press the bearing out of the lift arm.

11. If the small self aligning bearing needs to be

changed, press the bearing out of the lift

arm.

12. Repeat this procedure on the LH side lift

arm if needed.

SWEEPING

3-37

8410 MM392 (8--01)

TO INSTALL HOPPER LIFT ARMS

1. Park the machine on a smooth, level

surface.

2. Stop 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. Position the lift arm in the machine. Align the

large bearing with the upper hole in the

machine frame tower.

4. Install the lift arm pivot pin through the large

bearing from the outside of machine.

5. Align the hole in lift arm pivot pin with the

hole in the pin boss on the machine frame

tower. Install the M8 socket head screw and

tighten to 18 -- 24 Nm (13 -- 18 ft lb).

6. Align the small bearing in the lift arm with

the hole in the lift cylinder clevis.

7. Install the lift cylinder pin plate through the

bearing. Reinstall the M6 hex screw and

tighten to 8 -- 10 Nm (6 -- 8 ft lb).

8. On the RH lift arm, reconnect the speed

limiter cable to the ball end.

9. Repeat steps 3 -- 7 on the opposite side.

10. Reinstall hopper. See TO INSTALL

HOPPER instructions in this section.

SWEEPING

3-38 8410 MM392 (8--01)

SWEEPING VACUUM FAN

The sweeping vacuum fan is located on the back

of the debris hopper. It is used during sweeping to

control dusting by pulling air through the filters.

TO REMOVE SWEEPING VACUUM FAN

1. Park the machine on a smooth, level

surface.

2. Stop 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. Raise the hopper cover, unplug the wires

from filter shaker and thermo--sentry,

remove the filter carrier tray from the hopper

and set it on the floor.

4. Leave the hopper cover open and raise the

hopper 1/3 of the way up or far enough to

access the three M10 hex screws holding

the vacuum fan to the back of the hopper.

NOTE: Hopper must be held in this position with a

hoist, jack stands or a prop rod between hopper

bumper and machine frame.

5. Disconnect and plug the three hydraulic

hoses on the vacuum fan motor.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

6. Disconnect the wire harness from the fan

motor solenoid.

7. Remove the three M10 hex screws holding

vacuum fan to rear of hopper. Reach in from

the left side of the hopper, under the hopper

cover, to access the hex screws.

8. Remove the vacuum fan assembly from the

machine and make the necessary repairs.

SWEEPING

3-39

8410 MM392 (8--01)

TO INSTALL SWEEPING VACUUM FAN

1. Park the machine on a smooth, level

surface.

2. Stop 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. Raise the hopper cover, unplug the wires

from filter shaker and thermo--sentry,

remove the filter carrier tray from the hopper

and set it on the floor.

4. Leave the hopper cover open and raise the

hopper 1/3 of the way up or far enough to

access the three M10 hex screws holding

the vacuum fan to the back of the hopper.

NOTE: Hopper must be held in this position with a

hoist, jack stands or a prop rod between hopper

bumper and machine frame.

5. Align the holes in fan isolators with the holes

in the back of the hopper.

6. Reinstall the three M10 hex screws,

washers and nyloc nuts with the nuts on the

outside of the hopper. Tighten to 18 -- 24 Nm

(13 -- 18 ft lb).

7. Reconnect hydraulic hoses. See schematic

in HYDRAULICS section.

8. Reconnect the wire harness to the vacuum

fan solenoid.

9. Make sure the wires and hoses are tied and

clamped up properly.

10. Remove the hoist, jack stands or prop rod

and lower the hopper.

11. Reinstall the filter carrier tray back in the

hopper. Reconnect the shaker motor and

thermo--sentry to the hopper harness.

12. Close the hopper cover and operate the

machine. Check the sweeping vacuum fan

for proper operation.

SWEEPING

3-40 8410 MM392 (8--01)

TO REPLACE SWEEPING VACUUM FAN

IMPELLER

1. Park the machine on a smooth, level

surface.

2. Stop 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 vacuum fan from the machine.

See TO REMOVE SWEEPING VACUUM

FAN instructions in this section.

4. Place the vacuum fan assembly in a vice.

5. Remove the four 0.25 in. hex screws and

fender washers holding the inlet plate to the

vacuum fan housing. Remove the plate.

6. Hold the impeller from turning and remove

the 0.31 in. hex nut from the vacuum fan

motor shaft.

7. Pull the impeller straight off the shaft. The

impeller may have to be lightly pried off. Be

careful not to loose the square key.

8. Put a small amount of grease on the motor

shaft before installing the new impeller.

Make sure the square key is in place.

9. Slide the impeller all the way on the shaft

and spin it slowly. If the impeller rubs on

housing pull it back off and place a 0.38 in.

flat washer on shaft under impeller and

re--assemble. Repeat this procedure until

the impeller spins freely.

10. Hold the new impeller from turning and firmly

tighten the 0.31 in. flex lock nut.

11. Reinstall the inlet plate using the four 0.25

in. hex screws and fender washers. Tighten

t o 11 -- 1 4 N m ( 7 -- 1 0 f t l b ) .

12. Reinstall vacuum fan assembly to the rear of

the hopper. See TO INSTALL SWEEPING

VACUUM FAN instructions in this section.

SWEEPING

3-41

8410 MM392 (8--01)

MACHINE TROUBLESHOOTING

Problem Cause Remedy

Excessive dusting Brush skirts and dust seals worn,

damaged, out of adjustment

Replace or adjust brush skirts or

dust seals

Hopper dust filter clogged Shake and/or clean or replace

dust filter

Vacuum hose damaged Replace vacuum hose

Vacuum fan failure Contact TENNANT service

personnel

Thermo Sentryttripped Reset Thermo Sentryt

Poor sweeping performance Brush bristles worn Replace brushes

Main and side brushes not

adjusted properly

Adjust main and side brushes

Debris caught in main brush drive

mechanism

Free drive mechanism of debris

Main brush drive failure Contact TENNANT service

personnel

Side brush drive failure Contact TENNANT service

personnel

Hopper full Empty hopper

Hopper lip skirts worn or damaged Replace lip skirts

Wrong sweeping brush Contact TENNANT representative

for recommendations

SWEEPING

3-42 8410 MM392 (8--01)

SCRUBBING

4-1

8410 MM392 (5--02)

CONTENTS

Page

INTRODUCTION 4-3......................

SOLUTION SYSTEM 4-4...............

RECOVERY TANK 4-4..............

TO REMOVE RECOVERY

TANK 4-4....................

TO INSTALL RECOVERY

TANK 4-7....................

SOLUTION TANK 4-8...............

TO REMOVE SOLUTION

TANK 4-9....................

TO INSTALL SOLUTION TANK 4-10

SCRUB HEAD 4-11....................

TO REMOVE SCRUB HEAD 4-11.....

TO INSTALL SCRUB HEAD 4-14.....

TO REPLACE SIDE SHIFT CABLE 4-16

SQUEEGEES 4-17.....................

TO REPLACE SQUEEGEE

PUSH--PULL CABLE 4-17.........

TO REPLACE SQUEEGEE LIFT

CABLE 4-19.....................

TO REMOVE REAR SQUEEGEE

FRAME 4-20....................

TO INSTALL REAR SQUEEGEE

FRAME 4-21....................

LEVELING THE REAR

SQUEEGEE 4-23................

ADJUSTING REAR SQUEEGEE

BLADE DEFLECTION 4-24........

SQUEEGEE BLADES 4-25.............

REAR SQUEEGEE 4-25.............

REPLACING OR ROTATING

REAR SQUEEGEE BLADES 4-25

SIDE SQUEEGEES 4-26............

REPLACING SIDE SQUEEGEE

BLADES 4-26.................

SCRUB VACUUM FAN 4-27.............

TO REMOVE SCRUB VACUUM

FAN 4-27........................

TO INSTALL SCRUB VACUUM

FAN 4-28........................

MACHINE TROUBLESHOOTING 4-29...

SCRUBBING

4-2 8410 MM392 (8--01)

SCRUBBING

4-3

8410 MM392 (8--01)

INTRODUCTION

When the scrubbing mode is used, water flows

from the solution tank through the solution valve

to the three disc 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.

SCRUBBING

4-4 8410 MM392 (5--02)

SOLUTION SYSTEM

RECOVERY TANK

The recovery tank stores recovered solution. The

recovery tank should be drained and cleaned

daily, or when the recovery tank full light comes

on.

EStoption: The EStfilter should be cleaned

daily. The EStfilter can be rinsed while in the

recovery tank through the right tank fill opening, or

by removing the EStpump from the recovery

tank.

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. Drain the recovery tank.

2. Open the engine cover and side door.

3. Loosen the four M8 hex screws holding the

lintel cover to the machine. Remove the

cover.

4. Start the engine, raise the hopper, and

engage the safety leg.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

5. Disconnect the vacuum hose and squeegee

hose from the back of the recovery tank.

SCRUBBING

4-5

8410 MM392 (8--01)

6. Remove the six M6 hex screws holding the

LH side panel to the machine. Remove the

panel.

7. Remove the three M6 hex screws holding

the plastic clean out cover to the machine.

Remove the drain hoses, caps and clean out

cover. If the machine is equipped with the

EStoption, remove the solution hose from

the brass fitting.

8. Remove the three M6 hex screws and one

M8 hex screw holding the RH side panel to

the machine. Remove the panel.

9. Remove the M8 hex screws holding the

recovery tank to the machine. This hardware

is located near tank drain opening and the

center of the machine.

10. Remove the four M8 hex screws holding the

engine side door mount bracket to the back

of the recovery tank. Remove the mount

bracket.

11. If the machine is equipped with the EStor

auto--fill option, remove the hoses connected

to the recovery tank.

SCRUBBING

4-6 8410 MM392 (8--01)

12. Remove black plastic check valve from the

top of the solution tank.

5. Reinstall the left hand side panel.

SCRUBBING

4-8 8410 MM392 (5--02)

6. Reinstall the door mount bracket to the back

of the recovery tank and frame using the

M8 hex screws and washers. Tighten to

18 -- 24 Nm (13 -- 15 ft lb).

7. Go back and tighten the three M8 hex

screws on recovery tank near the tank drain

area. Tighten to 18 -- 24 Nm (13 -- 15 ft lb).

8. If the machine is equipped with the ESt

option, Reinstall the hoses to the fittings on

the back of the solution tank.

9. If the machine is equipped with the ESt

option, reconnect the wires to the float

switch on the right side of the tank. See

schematic in the ELECTRICAL section.

10. Reinstall the right hand side panel on the

machine using the six M6 hex screws and

washers. Tighten to 8 -- 10 Nm (5 -- 7 ft lb).

11. Reinstall the plastic clean out cover using

the three M6 hex screws and washers.

Tighten to 8 -- 10 Nm (5 -- 7 ft lb). Reinstall

tank caps and hoses.

12. Start the engine, disengage the safety arm,

and lower the hopper.

13. Reinstall the lintel cover and lightly hand

tighten the four M8 hex screws.

14. Lower the engine cover and side door.

SOLUTION TANK

The solution tank contains the cleaning solution.

The solution tank does not require regular

maintenance. If deposits form on the bottom of

the tank, rinse the tank with a strong blast of

warm water. The right tank can be flushed through

the drain opening. Drain the tank with the solution

tank drain hose.

The solution tank on machines with the ESt

option should be drained and cleaned daily. Rinse

the solution outlet filters at the bottom of the tank

through the drain access.

SCRUBBING

4-9

8410 MM392 (8--01)

TO REMOVE SOLUTION TANK

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. The

recovery tank must be removed before

the solution tank can be removed.

See TO REMOVE RECOVERY TANK

instructions.

2. Remove the four M8 hex screws holding the

solution tank to the machine frame. Make

sure to retain the two plated clamps from the

front of the tank.

3. Lift the solution tank slightly and remove the

solution lines from the electric water

solenoids.

4. Remove the M8 nyloc nut and clamp holding

the hydraulic hoses to the front of the

solution tank.

5. The solution tank can now be removed.

Some careful maneuvering of the tank will

be needed to get it to come out easily

because of the tight fit. Lift the tank straight

up and out of machine. Leave the outer ring

of the tank cap on the threads to protect it

from damage during removal.

SCRUBBING

4-10 8410 MM392 (8--01)

TO INSTALL SOLUTION TANK

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Position solution tank in the machine. Be

careful not to damage the face of the drain

outlet hole when placing tank in the

machine. Do not install any hardware at this

time.

NOTE: Be careful not to pinch any hydraulic

hoses or electrical wires during this procedure.

2. Make sure the solution hoses are on the

fittings on the right side of the tank.

3. Align the holes in the left hand side of

machine, near the main valve area, with the

threaded inserts in the solution tank. Install

the M8 SS hex screws and washers, leave

loose for now.

4. Align the two holes in the front of the

solution tank with the holes in the machine

frame. Install the two M8 hex screws,

washers and two plated clamps.

Tighten to 18 -- 24 Nm (13 -- 15 ft lb).

5. Go back and tighten the M8 hex screws on

solution tank near the main valve area.

Tighten to 18 -- 24 Nm (13 -- 15 ft lb).

6. Reinstall hydraulic hoses, clamp and M8

nyloc nut to the front of the solution tank.

Tighten to 18 -- 24 Nm (13 -- 15 ft lb).

NOTE: Do not install the EStfitting in the top of

the solution tank until the recovery tank has been

installed.

7. The recovery tank can now be installed. See

TO INSTALL RECOVERY TANK

instructions.

SCRUBBING

4-11

8410 MM392 (5--02)

SCRUB HEAD

The scrub head encloses the scrub brushes and a

solution dispensing system. The scrub head is

located directly behind the sweeping brush

compartment.

The scrub head is factory adjusted and the

measurement should not be changed unless

scrub head parts are damaged or are replaced.

The scrub head contains three disc brushes,

hydraulic motors, lift cylinders and side

squeegees. Each brush has its own hydraulic

motor and lift cylinder. There is also a hydraulic

cylinder that can shift the scrub head over to the

right for superior edge cleaning. Water from the

solution tank flows to the center of each brush.

TO REMOVE SCRUB HEAD

1. Start the engine, lower and side shift the

scrub head, shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 cotter pin from the long

horizontal clevis pin holding each side

squeegee to the scrub head frame. Remove

the clevis pins and squeegee assemblies

from both sides.

4. Remove all three scrub brushes.

SCRUBBING

4-12 8410 MM392 (8--01)

5. Remove the hex nut holding the balljoint and

push--pull cable to the LH side squeegee

bracket.

6. Loosen the large hex nut holding the cable

to the cable bracket. Remove the cable from

the bracket and place it out of the way for

scrub head removal.

7. Locate the water flow manifold on the

machine frame. Remove the three solution

feed lines from the manifold. Some of the

plastic ties will have to be removed from the

water flow lines to do this.

8. Locate the side shift gas spring and return

cable on the top, front, center of the scrub

head frame. Remove the small clip holding

the gas spring ball end to the scrub head.

Pop the gas spring off the ball end.

9. Remove the cotter pin and clevis from the

return cable at the cylinder bracket.

NOTE: Mark the hoses for proper re--assembly.

10. Disconnect and plug the two #4 hydraulic

hoses leading from the control valve to the

center scrub brush lift cylinder.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

SCRUBBING

4-13

8410 MM392 (8--01)

11. Disconnect and plug the two #8 hydraulic

hoses leading from the control valve to the

RH and LH scrub brush motors.

NOTE:Place a floor jack under the scrubber head

to help hold it up when pins are removed.

12. Remove the M6 hex screw and washer

holding the cotter pin into the scrub head pin

on the scrub head frame. Remove both pins.

13. The scrub head can now be removed from

the machine.

SCRUBBING

4-14 8410 MM392 (8--01)

TO INSTALL SCRUB HEAD

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Raise the rear of machine using a hoist or

floor jack.

FOR SAFETY: Block machine tires

before jacking machine up. Jack

machine up at designated locations

only. Block machine up with jack

stands.

2. Position the scrub head under the machine

using a floor jack.

3. Raise the head up and align the holes in the

scrub head frame with holes in edge scrub

link. Install the scrub head pins in from the

bottom.

4. Align the hole in the pin with the cotter pin

and hole in scrub head frame. Reinstall the

M6 hex screw and washer through the hole

in cotter pin. Tighten to 8 -- 10 Nm

(5 -- 7 ft lb).

5. Reconnect the two #4 hydraulic hoses to the

center lift cylinder and the two #8 hoses to

the outside brush motors. See schematic in

HYDRAULICS section.

NOTE: Make sure the scrub head is pulled over

all the way to the right for the next operation.

6. Reconnect the side shift cable to the

cylinder pivot bracket.

7. Install the gas spring ball end back on the

ball on the scrub head. Make sure to

reinstall the locking clip.

8. Reconnect the main solution feed line to the

plastic, water manifold.

NOTE: Make sure to reinstall any clamps or

plastic ties that were removed during disassembly.

SCRUBBING

4-15

8410 MM392 (8--01)

9. Position push--pull cable back in the

mounting bracket and hand tighten large nut.

Do not change the adjustment.

10. Reinstall the ball joint end of the push--pull

cable back in the hole on side squeegee

bracket. Tighten 0.31 in. hex nut to

18 -- 24 Nm (13 -- 18 ft lb).

11. Reinstall the three disc brushes.

12. Reinstall the LH and RH side squeegees

with the long clevis pins and cotter pins.

13. Lower the machine. Start the engine and

check for any leaks and for proper operation

of the scrub brushes and side shift.

SCRUBBING

4-16 8410 MM392 (8--01)

TO REPLACE SIDE SHIFT CABLE

1. Start the engine, lower and side shift the

scrub head, shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 left side. Look

up above the left hand scrub brush motor

and to the right of the control valve. Locate

the clevis pin holding the side shift cable to

the pivot bracket. Remove the cotter and

clevis pin.

4. Go under the machine on the right side and

locate the M8 hex screw holding the other

end of the side shift cable to the scrub head

frame. Remove the M8 hex screw, nyloc nut,

and cable from the machine.

5. Position the new cable back in the machine.

Align the hole in the ring end of cable with

the hole in scrub head frame. Reinstall the

M8 hex screw and lightly tighten. The cable

must be able to swivel after tightening.

6. Go under the machine on the left side and

align the clevis end of the cable with the hole

in the pivot bracket. Reinstall the clevis and

cotter pin.

7. Lower the machine. Start the engine and

check for proper side shift function.

SCRUBBING

4-17

8410 MM392 (8--01)

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.

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 squeegee can be adjusted for leveling and

deflection. The deflection of the squeegee blades

should be checked daily, or when scrubbing a

different type of floor. The leveling of the

squeegee should be checked every 100 hours of

machine operation.

TO REPLACE SQUEEGEE PUSH--PULL

CABLE

1. Start the engine, lower and side shift the

scrub head, shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 0.31 in. nyloc nut holding the

balljoint and push--pull cable to the LH side

squeegee bracket.

4. Loosen the large hex nuts holding the cable

to the cable bracket. Remove the cable from

the bracket.

SCRUBBING

4-18 8410 MM392 (8--01)

5. Remove the 0.31 in. nyloc nut holding the

balljoint on the other end of the push--pull

cable to the left hand rear squeegee pivot

bracket.

6. Remove the M6 thread roller hex screw

holding the clamp to the machine frame.

7. Remove the balljoints and jam nuts from the

old cable and install on the new one. Run

the jam nut and balljoint all the way on the

threads.

8. Install the new cable in the machine. Make

sure the cable is routed between the tie rod

and scrub head frame.

9. Adjust the rear squeegee end of the cable at

8.25 inches from the center line of the

balljoint to the edge of bracket with the cable

in the retracted position.

10. Adjust the side squeegee end of cable at

8.25 inches from the center line of the

balljoint to the edge of bracket with the cable

in the retracted position. Firmly tighten all

four large hex nuts.

11. Reinstall the cable clamp and M6 thread

rolling hex screw to the bottom of the

machine frame.

12. Reinstall the balljoints in the holes in both

rear and side squeegee brackets. Tighten

the 0.31 in. hex screw to 18 -- 24 Nm

(13 -- 18 ft lb).

13. Lower machine and check for proper scrub

head side shift operation.

SCRUBBING

4-19

8410 MM392 (8--01)

TO REPLACE SQUEEGEE LIFT CABLE

1. Start the engine, lower the rear squeegee,

shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 M8 hex screw, nyloc nut, and

spacer tube from the rear squeegee lift

cable where it attaches at the center of the

rear squeegee frame.

NOTE: The squeegee frame will drop down when

the hex screw is removed.

4. Remove the clevis pin holding the lift cable

to the upper cable bracket.

NOTE: When installing the new cable, make sure

to route it around the plastic rollers in the same

manner as it was removed.

5. Align the hole in the upper end of the new

cable with the hole in the upper cable

bracket. Reinstall the clevis pin and cotter

pin.

6. Lift the squeegee assembly up until the hole

in the lower end of the lift cable lines up with

the hole in the squeegee frame. Reinstall the

clevis pin and cotter pin.

7. Lower machine and check for proper rear

squeegee lift cable operation.

SCRUBBING

4-20 8410 MM392 (8--01)

TO REMOVE REAR SQUEEGEE FRAME

1. Start the engine, lower the rear squeegee,

shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 M8 hex screw, nyloc nut, and

spacer tube from the rear squeegee lift

cable where it attaches at the center of the

rear squeegee frame.

NOTE: The squeegee frame will drop down when

the hex screw is removed.

4. Remove the vacuum hose from the

squeegee frame.

5. Remove the two tension springs connecting

the squeegee upper link rods to the

squeegee pivot brackets.

6. Remove the M10 hex screw, washers

sleeve, thrust washers, and nyloc nut

holding each of the four link rods to the

squeegee pivot brackets.

7. The squeegee assembly can now be

removed from the machine.

SCRUBBING

4-21

8410 MM392 (8--01)

TO INSTALL REAR SQUEEGEE FRAME

1. Start the engine, lower the rear squeegee,

shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

FOR SAFETY: Block machine tires

before jacking machine up. Jack

machine up at designated locations

only. Block machine up with jack

stands.

3. Position the squeegee assembly under the

rear of the machine.

4. Align the holes in the end of squeegee link

rods to the holes in the squeegee pivot

brackets. Install the M10 hex screws,

washers, sleeves, thrust washers, and nyloc

nuts. Tighten to 37 -- 48 Nm (25 -- 53 ft lb).

5. Reconnect the tension springs from the

lower link rod to the squeegee pivot bracket.

SCRUBBING

4-22 8410 MM392 (8--01)

6. Lift the squeegee assembly up until the hole

in the lower end of the lift cable lines up with

the hole in the squeegee frame. Reinstall the

M8 hex screw, nyloc nut, and spacer tube.

Tighten to 18 -- 24 Nm (13 -- 18 ft lb).

7. Lower machine and check for proper rear

squeegee operation.

SCRUBBING

4-23

8410 MM392 (5--02)

LEVELING THE REAR SQUEEGEE

Leveling of the squeegee assures even contact

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 of the squeegee blade

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 turnbuckle

jam nuts.

5. Turn the turnbuckle clockwise, from the rear

of the machine, to increase the deflection at

the ends of the squeegee. Turn the

turnbuckle counter-clockwise, from the rear

of the machine, to decrease the deflection at

the ends of the squeegee blade. Be sure to

turn both turnbuckles the same number of

turns.

6. Tighten the jam nuts.

NOTE: When tightening the turnbuckle jam nuts,

make sure the rod ends are square with the

squeegee frame, not tilted up.

7. Start the engine and drive the machine

forward again to check the squeegee blade

deflection.

8. Readjust the squeegee blade deflection if

necessary.

SCRUBBING

4-24 8410 MM392 (5--02)

ADJUSTING REAR SQUEEGEE BLADE

DEFLECTION

Deflection is the amount of curl the squeegee

blade has when the machine moves 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.

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 of the squeegee blade

over the full length of the squeegee blade.

The correct amount of deflection is 7 mm

(0.25 in).

4. To adjust the amount of deflection, loosen

the top knob on the two casters.

5. Turn the bottom knob clockwise to decrease

the blade deflection. Turn the bottom knob

counter-clockwise to increase the blade

deflection. Be sure to turn both knobs the

same number of turns. Tighten the top

knobs on the casters.

6. Start the engine and drive the machine

forward again to check the squeegee blade

deflection. Readjust the squeegee blade

deflection if necessary.

7. Raise the squeegee when finished.

SCRUBBING

4-25

8410 MM392 (5--02)

SQUEEGEE BLADES

REAR SQUEEGEE

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.

REPLACING OR ROTATING 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 as stated in LEVELING THE

REAR SQUEEGEE and ADJUSTING REAR

SQUEEGEE BLADE DEFLECTION.

SCRUBBING

4-26 8410 MM392 (8--01)

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.

REPLACING SIDE SQUEEGEE BLADES

1. Raise the scrub head.

2. Turn off the machine 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 off 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 for easier

squeegee installation.

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.

SCRUBBING

4-27

8410 MM392 (8--01)

SCRUB VACUUM FAN

The scrub vacuum fan, when activated, creates a

vacuum in the recovery tank. The recovery tank is

sealed to the demister tank/engine cover when it

is the down position. Water is pulled from the rear

squeegee to the demister tank through a vacuum

hose.

TO REMOVE SCRUB VACUUM FAN

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Raise the engine cover.

2. Open the engine side door.

3. Loosen the hose clamp and remove the

vacuum hose leading from recovery tank to

the inlet tube of the scrub vacuum fan.

4. Loosen the hose clamp and remove the

vacuum hose from the exhaust outlet of

scrub vacuum fan.

NOTE: Mark the hoses for proper re--assembly.

5. Remove and plug the hydraulic hoses

connected to the scrub vacuum fan motor.

Access to these hoses is between air

cleaner and vacuum fan housing.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

6. Remove the three M10 hex screws,

washers, and nyloc nuts holding the vacuum

fan to mounting brackets.

7. Remove the vacuum fan assembly from the

machine.

SCRUBBING

4-28 8410 MM392 (8--01)

TO INSTALL SCRUB VACUUM FAN

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Raise the engine cover.

2. Open the engine side door.

3. Position the vacuum fan assembly in the

machine.

4. 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).

5. Reconnect the hydraulic hoses to the

vacuum fan motor. See the hydraulic

schematic in the HYDRAULIC section.

Access to these hoses is between air

cleaner and vacuum fan housing.

6. Reinstall the vacuum hose on the exhaust

outlet of vacuum fan housing. Firmly tighten

the hose clamp.

7. Reinstall the vacuum hose from recovery

tank to the inlet tube on the vacuum fan

housing. Firmly tighten the hose clamps.

8. Start engine and turn on the vacuum fan.

Check for leaks and proper operation.

SCRUBBING

4-29

8410 MM392 (5--02)

MACHINE TROUBLESHOOTING

Problem Cause Remedy

Trailing water -- poor or no

water pickup.

Worn rear squeegee blades. Rotate or replace squeegee

blades.

Rear squeegee out of adjustment. Adjust rear squeegee.

Side squeegees raised. Lower side squeegees.

Worn side squeegee blades. Replace side squeegee blades.

Side squeegees out of

adjustment.

Adjust side squeegees.

Tank cover not seated. Reseat tank cover.

Tank cover seals worn. Replace seals.

Too much solution flow to floor. Reduce solution flow to floor.

Vacuum hose clogged. Flush vacuum hoses.

Recovery tank full. Drain recovery tank.

Check EStpump and filter

Float stuck shutting off vacuum. Clean float.

Debris caught on rear squeegee. Remove debris.

Foam filling recovery tank. Empty recovery tank; use less or

change detergent.

Vacuum hose to rear squeegee

disconnected or damaged.

Reconnect or replace vacuum

hose.

Vacuum fan to recovery tank hose

damaged.

Replace hose.

Littleornosolutionflowtothe

Solution tank empty. Fill solution tank.

floor. Solution flow switch turned off. Turn solution flow switch on.

Solution supply lines plugged. Flush solution supply lines.

EStswitch off. Turn EStswitch on.

Poor scrubbing performance. Debris caught on scrub brushes. Remove debris.

Improper detergent or brushes

used.

Check with TENNANT

representative for advice.

Worn scrub brushes. Replace scrub brushes.

EStsystem does not fill

Clogged solution pump or lines. Flush EStsystem.

solution tank. EStfloat stuck. Clean floats of debris.

Clogged EStpump filter. Clean filter.

Water levels too low in tanks. Add water.

SCRUBBING

4-30 8410 MM392 (5--02)

ELECTRICAL

5-1

8410 MM392 (8--01)

CONTENTS

Page

INTRODUCTION 5--4......................

BATTERY 5--4.........................

TO REPLACE BATTERY 5--5............

INSTRUMENT PANEL 5--6.................

TO REPLACE MAIN INSTRUMENT

PANEL 5--6......................

TO REPLACE AUXILIARY INSTRUMENT

PANEL 5--7.........................

TO DISASSEMBLE MAIN INSTRUMENT

PANEL 5--8.........................

TO REASSEMBLE MAIN INSTRUMENT

PANEL 5--9.........................

TO DISASSEMBLE AUXILIARY

INSTRUMENT PANEL 5--10..........

TO REASSEMBLE AUXILIARY

INSTRUMENT PANEL 5--11..........

TO REPLACE MACHINE RELAY 5--12.......

CIRCUIT BREAKERS 5--13................

TO REPLACE MACHINE CIRCUIT

BREAKER 5--14.....................

TO REPLACE GOVERNOR

CONTROL BOX 5--15................

GAS/LP ELECTRICAL SCHEMATIC 5-17....

GAS/LP WIRE HARNESS GROUP 5-20.....

DIESEL ELECTRICAL SCHEMATIC 5-30....

DIESEL WIRE HARNESS GROUP 5-34.....

DIAGNOSTICS 5--44......................

FRONT PANEL OPERATING

MODES 5--45.......................

NORMAL MODE 5--46............

EDGE SCRUB: 5--46..............

SQUEEGEE: 5--46................

ENGINE SPEED: 5--46............

SCRUB: 5--47....................

DETERGENT: 5--48...............

ES: 5--48........................

OVER FLOW: 5--48...............

MANUAL MODE: 5--49............

ES: 5--49........................

EDGE SCRUB BUTTON: 5--49.....

SQUEEGEE BUTTON: 5--49.......

ENGINE BUTTON: 5--49..........

SCRUB BUTTON: 5--49...........

DETERGENT BUTTON: 5--49......

INPUT DISPLAY MODE: 5--50.....

ERROR DISPLAY MODE 5--51.....

ES LED 5--51....................

EDGE SCRUB LED 5--52..........

SQUEEGEE LED 5--52............

SCRUB LED 5--53................

DETERGENT LED 5--53...........

PRESSURE ADJUST MODE 5--54..

SCRUB BUTTON 5--54............

RESET SCRUB PRESSURES 5--55

Page

SIDE PANEL OPERATING MODES 5--56.

NORMAL MODE 5--57...............

HAZARD LIGHTS: 5--57..............

HEAD LIGHTS: 5--57................

FILTER SHAKER: 5--57..............

HOPPER LIFT: 5--57.................

HOPPER LOWER: 5--58.............

HOPPER DOOR: 5--58...............

SIDE BRUSH: 5--58..................

VACUUM FAN: 5--58.................

SWEEP 1 (NORMAL SWEEP): 5--59...

SWEEP 2 (LITTER SWEEP): 5--60....

MANUAL MODE 5--61...............

HAZARD LIGHT: 5--61...............

HEAD LIGHT: 5--61..................

FILTER SHAKER: 5--61..............

HOPPER UP: 5--61..................

HOPPER DOWN: 5--61..............

HOPPER DOOR: 5--61...............

SIDE BRUSH: 5--62..................

SWEEP FAN: 5--62..................

SWEEP 1: 5--62.....................

SWEEP 2: 5--62.....................

INPUT DISPLAY MODE: 5--63........

BLINKING HAZARD LED: 5--63.......

BLINKING SHAKER LED: 5--63.......

BLINKING HOPPER DOOR LED: 5--63

BLINKING SIDE BRUSH LED: 5--63...

BLINKING HEAD LIGHT LED: 5--63...

ERROR DISPLAY MODE 5--64........

BLINKING SHAKER LED: 5--64.......

BLINKING HAZARD LED: 5--64.......

BLINKING HEADLIGHT LED: 5--64....

BLINKING SIDE BRUSH LED: 5--64...

BLINKING HOPPER DOOR LED: 5--64

BLINKING HOPPER UP LED: 5--64....

BLINKING HOPPER DOWN LED: 5--64

BLINKING SWEEP FAN LED: 5--64....

BLINKING SWEEP 1 LED: 5--64......

BLINKING SWEEP 2 LED: 5--64......

TROUBLESHOOTING 5--66................

INSTRUMENT PANEL DOES NOT

POWER UP (SCHEMATIC) 5--67......

INSTRUMENT PANEL DOES NOT

POWER UP(FLOW CHART) 5--68.....

SCRUB BRUSH WILL NOT TURN ON

AND/OR DOWN (SCHEMATIC) 5--69..

SCRUB BRUSH WILL NOT TURN ON

AND/OR DOWN (FLOW CHART) 5--70.

SCRUB HEAD WILL NOT EXTEND

(SCHEMATIC) 5--73.................

SCRUB HEAD WILL NOT EXTEND

(FLOW CHART) 5--74................

ELECTRICAL

5-2 8410 MM392 (8--01)

Page

SQUEEGEE AND VACUUM FAN NOT

TURNING ON AND GOING DOWN

(SCHEMATIC) 5--75..............

SQUEEGEE AND VACUUM FAN NOT

TURNING ON AND GOING DOWN

(FLOW CHART) 5--76.............

WATER VALVES NOT OPERATING

(SCHEMATIC) 5--79.................

WATER VALVES NOT OPERATING

(FLOW CHART) 5--80................

RECOVERY TANK FULL LIGHT

WILL NOT TURN ON OR

OFF (SCHEMATIC) 5--81..........

RECOVERY TANK FULL LIGHT WILL NOT

TURN OFF(FLOW CHART) 5--82......

RECOVERY TANK FULL LIGHTWILL NOT

TURN ON (FLOW CHART) 5--82......

DETERGENT METERING PUMP IS NOT

OPERATING (SCHEMATIC) 5--83.....

DETERGENT METERING PUMP IS NOT

OPERATING (FLOW CHART) 5--84....

ES PUMP NOT WORKING

(SCHEMATIC) 5--85.................

ES PUMP NOT WORKING

(FLOW CHART) 5--86................

SWEEP BRUSH WILL NOT TURN ON

AND LOWER WITH SWEEP 1

SELECTED (SCHEMATIC) 5--87...

SWEEP BRUSH WILL NOT TURN ON

AND LOWER WITH SWEEP 1

SELECTED (FLOW CHART) 5--88..

SWEEP BRUSH WILL NOT TURN ON AND

LOWER WITH SWEEP 2 SELECTED

SWEEP 1 WORKS

(SCHEMATIC) 5--89............

SWEEP BRUSH WILL NOT TURN ON

AND LOWER WITH SWEEP 2

SELECTED (FLOW CHART) 5--90..

SWEEP SIDE BRUSH WILL NOT TURN

ON AND LOWER (SCHEMATIC) 5--91.

SWEEP SIDE BRUSH WILL NOT TURN

ON AND LOWER (FLOW CHART) 5--92

SWEEP VACUUM FAN WILL NOT

TURN ON (SCHEMATIC) 5--93........

SWEEP VACUUM FAN WILL NOT TURN

ON (FLOW CHART) 5--94............

SHAKER SYSTEM WILL NOT TURN

ON (SCHEMATIC) 5--95..............

SHAKER SYSTEM WILL NOT TURN

ON (FLOW CHART) 5--96............

HOPPER DIFFERENTIAL PRESSURE

LIGHT ALWAYS ON

(SCHEMATIC) 5--97..............

HOPPER DIFFERENTIAL PRESSURE

SWITCH ALWAYS ON

(FLOW CHART) 5--98.............

HOPPER DIFFERENTIAL PRESSURE

SWITCH ALWAYS OFF

(SCHEMATIC) 5--99..............

Page

HOPPER DIFFERENTIAL PRESSURE

LIGHT ALWAYS OFF

(FLOW CHART) 5--100............

HOPPER THERMAL SENTRY LIGHT

ALWAYS ON (SCHEMATIC) 5--101....

HOPPER THERMAL SENTRY LIGHT

ALWAYS ON (FLOW CHART) 5--102..

HOPPER THERMAL SENTRY LIGHT

ALWAYS OFF (SCHEMATIC) 5--103...

HOPPER THERMAL SENTRY LIGHT

ALWAYS OFF

(FLOW CHART) 5--104............

HOPPER WILL NOT LIFT

(SCHEMATIC) 5--105................

HOPPER WILL NOT LIFT

(FLOW CHART) 5--106...............

HOPPER WILL NOT LOWER

(SCHEMATIC) 5--107................

HOPPER WILL NOT LOWER

(FLOW CHART) 5--108...............

HOPPER DOOR WILL NOT CLOSE

(SCHEMATIC) 5--109................

HOPPER DOOR WILL NOT CLOSE

(FLOW CHART) 5--110...............

HOPPER DOOR WILL NOT OPEN

(SCHEMATIC) 5--111................

HOPPER DOOR WILL NOT OPEN

(FLOW CHART) 5--112...............

ENGINE COOLING FAN NOT

OPERATING (SCHEMATIC) 5--113....

ENGINE COOLING FAN NOT

OPERATING (FLOW CHART) 5--114...

ENGINE OIL PRESSURE WARNING

LIGHT WILL NOT TURN ON OR

OFF (SCHEMATIC) 5--115.........

ENGINE OIL PRESSURE WARNING

LIGHT WILL NOT TURN OFF

(FLOW CHART) 5--116............

ENGINE OIL PRESSURE WARNING

LIGHT WILL NOT TURN ON

(FLOW CHART) 5--116............

ENGINE TEMPERATURE LIGHT

WILL NOT TURN ON OR OFF

(SCHEMATIC) 5--117.............

ENGINE TEMPERATURE LIGHT

WILL NOT TURN ON

(FLOW CHART) 5--118............

ENGINE TEMPERATURE LIGHT

WILL NOT TURN OFF

(FLOW CHART) 5--118............

ALTERNATOR / BATTERY WARNING

LIGHT WILL NOT TURN ON

(SCHEMATIC) 5--119.............

ALTERNATOR / BATTERY WARNING

LIGHT WILL NOT TURN ON

(FLOW CHART) 5--120............

ALTERNATOR / BATTERY WARNING

LIGHT STAYS ON WHEN ENGINE IS

RUNNING (SCHEMATIC) 5--121...

ELECTRICAL

5-3

8410 MM392 (8--01)

Page

ALTERNATOR / BATTERY WARNING

LIGHT STAYS ON WHEN ENGINE IS

RUNNING (FLOW CHART) 5--122.

FUEL GAUGE NOT OPERATING

(GAS AND DIESEL)

(SCHEMATIC) 5--123.............

FUEL GAUGE NOT OPERATING

(GAS AND DIESEL)

(FLOW CHART) 5--124............

FUEL GAUGE (LPG) (SCHEMATIC) 5--125

FUEL GAUGE (LPG) (FLOW CHART)5--126

HEAD LIGHTS WILL NOT

TURN ON (SCHEMATIC) 5--127.......

HEAD LIGHTS WILL NOT TURN ON

(FLOW CHART) 5--128...............

HAZARD LIGHT WILL NOT TURN

ON (SCHEMATIC) 5--129.............

HAZARD LIGHT WILL NOT TURN

ON (FLOW CHART) 5--130...........

REVERSE LIGHT OR ALARMDO NOT

TURN ON (SCHEMATIC) 5--131.......

REVERSE LIGHT OR ALARM

DO NOT TURN ON

(FLOW CHART) 5--132............

ELECTRICAL

5-4 8410 MM392 (8--01)

INTRODUCTION

The machines electrical system consists of the

batteries, instrument panel, relays, and circuit

breakers.

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.

ELECTRICAL

5-5

8410 MM392 (8--01)

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 BATTERY

at 27_C(80_F) CHARGE

1.260 -- 1.280 100% Charged

1.230 -- 1.250 75% Charged

1.200 -- 1.220 50% Charged

1.170 -- 1.190 25% Charged

1.110 -- 1.160 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. Open the battery cover on the floor of the

operators compartment.

2. Disconnect the negative cable first and then

the positive battery cable.

3. Remove the battery hold down bracket from

the machine.

4. Tilt the battery back and lift it out of the

machine.

5. Clean the old cables and the posts on the

new battery and install it in the machines

battery tray.

6. Reinstall the battery hold down bracket.

7. Reconnect the positive cable and then the

negative battery cable. Close the battery

cover.

ELECTRICAL

5-6 8410 MM392 (8--01)

INSTRUMENT PANEL

The instrument panel consists of a circuit board, a

touch panel, and a water/dust resistant plastic

enclosure. The touch panel controls various

machine functions, while its indicator lights keep

the operator informed on machine performance.

TO REPLACE MAIN INSTRUMENT PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from the

machine.

2. Put the steering wheel in the lowest position.

3. Remove the four M8 hex head screws

holding the dash panel to the machine.

4. Pull the dash panel back away from the

machine.

5. Remove the four M5 pan head screws

holding the instrument panel to the dash

panel.

6. Loosen the allen head screw in center of

wire harness plug. Unplug the harness.

7. Remove the instrument panel from the

machine.

8. Install the new instrument panel back on the

dash panel using the four M5 pan head

screws and washers. Lightly hand tighten.

9. Push the harness plug back in the

instrument panel plug.

NOTE: The slot in the panel plug must line up

with the notch on the harness plug. Firmly hand

tighten the allen head screw.

10. Position the dash panel back on the

machine using the four M8 hex screws and

washers. Tighten to 18 -- 24 Nm

(13 -- 18 ft lb).

11. Reconnect the battery cables.

12. Start the machine and check for proper

instrument panel operation.

ELECTRICAL

5-7

8410 MM392 (8--01)

TO REPLACE AUXILIARY INSTRUMENT

PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from the

machine.

2. Put the steering wheel in the lowest position.

3. Remove the four M8 hex head screws

holding the dash panel to the machine.

4. Pull the dash panel back away from the

machine.

5. Remove the two M4 pan head screws and

bracket holding the top of the auxiliary

instrument panel to the dash panel. Loosen

the screws on the bottom of the panel.

6. Install the new auxiliary instrument panel

back on the dash panel using the four M5

pan head screws and washers. Lightly hand

tighten.

7. Push the harness plug back in the auxiliary

instrument panel plug.

NOTE: The slot in the panel plug must line up

with the notch on the harness plug. Firmly hand

tighten the allen head screw.

8. Position the dash panel back on the

machine using the four M8 hex screws and

washers. Tighten to 18 -- 24 Nm

(13 -- 18 ft lb).

9. Reconnect the battery cables.

10. Start the machine and check for proper

auxiliary instrument panel operation.

ELECTRICAL

5-8 8410 MM392 (8--01)

TO DISASSEMBLE MAIN INSTRUMENT

PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Remove the main instrument panel from the

machine. See TO REPLACE MAIN

INSTRUMENT PANEL instructions.

2. Place the main instrument panel face down

and remove the twelve larger pan head

screws holding it together.

3. The main instrument panel cases can now

be separated.

4. Remove the four smaller pan head screws

to completely disassemble touch panel case.

5. Remove the case box from the circuit board

and 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 and

unplug the flat connector and ground strap

to 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 them out.

9. To replace the hour meter, unplug the two

wires and remove the two pan head screws.

ELECTRICAL

5-9

8410 MM392 (8--01)

TO REASSEMBLE MAIN INSTRUMENT

PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Position the circuit board over the touch

panel. Feed the flat connector from the

panel through the slot in the board. Plug the

flat connector 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 the center of the case box.

5. Reinstall the touch panel case to the outer

case.

6. Reinstall the twelve pan head screws and

lightly hand tighten.

7. The instrument panel is now ready to

reinstall on the machine. See TO REPLACE

MAIN INSTRUMENT PANEL instructions.

ELECTRICAL

5-10 8410 MM392 (8--01)

TO DISASSEMBLE AUXILIARY INSTRUMENT

PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Remove the auxiliary instrument panel from

the machine. See TO REPLACE

AUXILIARY INSTRUMENT PANEL

instructions.

2. Place the auxiliary instrument panel face

down and remove the eight pan head

screws holding it together.

3. The auxiliary instrument panel cases can

now be separated.

4. Remove the four smaller pan head screws

to completely disassemble touch panel case.

5. Remove the case box from the circuit board

and touch panel assembly.

6. The o--ring and connector gaskets can now

be replaced in the case box if necessary.

7. Remove the four pan head screws and

unplug the flat connector and ground strap

to 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 them out.

9. To replace the hour meter, unplug the two

wires and remove the two pan head screws.

ELECTRICAL

5-11

8410 MM392 (8--01)

TO REASSEMBLE AUXILIARY INSTRUMENT

PANEL

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Position the circuit board over the touch

panel. Feed the flat connector from the

panel through the slot in the board. Plug the

flat connector in and reconnect the ground

strap.

2. Reinstall the four 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 the center of the case box.

5. Reinstall the touch panel case to the outer

case.

6. Reinstall the eight pan head screws and

lightly hand tighten.

7. The instrument panel is now ready to

reinstall on the machine. See TO REPLACE

AUXILIARY INSTRUMENT PANEL

instructions.

ELECTRICAL

5-12 8410 MM392 (8--01)

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. Disconnect the battery cables from the

machine.

2. Open the engine cover and side door.

3. Locate the problem relay on the back side of

the operators compartment.

4. Remove the M6 nyloc nut from the top of the

problem relay. Pull the relay off the stud.

5. Disconnect the relay from the main electrical

harness. Discard the relay.

6. Plug the new relay in the electrical harness.

7. Position the new relay on the stud. Reinstall

the M6 nyloc nut and firmly hand tighten.

8. Plug the new relay into the main harness.

See schematic in the ELECTRICAL section.

9. Reconnect the battery cables and operate

the machine. Check for proper operation.

ELECTRICAL

5-13

8410 MM392 (8--01)

CIRCUIT BREAKERS

The circuit breakers are resettable electrical

circuit protection devices. Their design stops the

flow of current in the event of a circuit overload.

Once a circuit breaker is tripped, it must be reset

manually. Press the reset button after the breaker

has cooled down.

If the overload that caused the circuit breaker to

trip is still there, the circuit breaker will continue to

stop current flow until the problem is corrected.

The circuit breakers are located in the operator

compartment.

The chart lists the circuit breakers and the

electrical components they protect.

Circuit

Breaker Rating Circuit Protected

CB-1 15 A Horn

CB-2 15 A Ignition

CB-3 10 A Instrument panel

CB-4 15 A Scrubbing

CB-5 15 A Filter shaker, vacuum fan

CB-6 15 A Operating lights

CB-7 15 A ESt

CB-8 15 A Sweeping

CB-9 15 A Solenoid valve

ELECTRICAL

5-14 8410 MM392 (8--01)

TO REPLACE MACHINE CIRCUIT BREAKER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from the

machine.

2. Go in the operators compartment and

remove the four black plastic rivets holding

the circuit breaker mount bracket to the dash

panel. Retain the rivets.

3. Pull the circuit breaker mount bracket back

to expose the circuit breakers.

4. Locate the problem circuit breaker and

disconnect it from the main electrical

harness.

5. Remove and retain the rubber boot from the

front of the circuit breaker.

6. Remove and discard the metal retaining ring

from the back of the circuit breaker.

7. Push the old circuit breaker out of the mount

panel. Discard the circuit breaker.

8. Position the new circuit breaker in the mount

panel.

NOTE: The hole in the mount panel is ”D” shaped.

Make sure to install the new circuit breaker in the

correct orientation.

9. Install the new retaining ring on the new

circuit breaker. Push the retaining ring all the

way down the circuit breaker.

10. Reconnect the circuit breaker to the main

electrical harness. See schematic in the

ELECTRICAL section.

11. Reinstall the rubber boot on the front of the

new circuit breaker.

12. Position the circuit breaker mount panel to

the dash panel. Reinstall the four plastic

rivets.

13. Reconnect the battery cables and operate

the machine. Check for proper operation.

ELECTRICAL

5-15

8410 MM392 (8--01)

TO REPLACE GOVERNOR CONTROL BOX

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from the

machine.

2. Open the engine cover and side door.

3. Locate the governor control box on the back

side of the operators compartment.

4. Remove the two nuts holding the control box

to the control panel.

5. Pull the control box off the studs and

disconnect it from the main electrical

harness. Remove the control box from the

machine.

NOTE: You may have to cut a few plastic ties

holding the control box harness to the main

harness.

6. Position the new control box in the engine

compartment.

7. Connect the new control box to the main

electrical harness. See schematic in the

ELECTRICAL section.

8. Position the control box on the studs and

reinstall the two nuts. Lightly hand tighten.

NOTE: Reinstall any plastic ties that were

removed earlier.

9. Reconnect the battery cables and operate

the machine. Check for proper operation.

ELECTRICAL

5-16 8410 MM392 (8--01)

ELECTRICAL

5-17

8410 MM392 (5--02)

GAS/LP ELECTRICAL SCHEMATIC

16E/GRN

CLOSES BELOW

70 PSI

1H/RED

CLOSED = RUN

S--5 CLOSED =

S--3&4 CLOSED=

96 OHM = FULL

OPEN AT 155F

REVERSE

CLOSES IN

13CD/BLK

13AY/BLK

13AQ/BLK

13BH/BLK

13AM/BLK

13AL/BLK

13AM/BLK

13AX/BLK

13BA/BLK

13BJ/BLK

13CF/BLK

16E/GRN

16F/

GRN 19C/BLU

19B/BLU

19A/BLU

83/BRN

83B/BRN

36B/GRN

36A/GRN

16H/

GRN

24B/PUR

50/ORA

1F/RED 21/ORA

21A/ORA

1G/RED

73/WHT

72/ORA

5A/BLU

8685

3087

87A

50A/ORA

50B/ORA

COOLANT SENSOR

CRANK

POSITION

SENSOR

SV--14

24A/PUR

BLU

GRY

GRY/RED

YEL/BLK

BLK

TAN/ORA

BLK

TAN/WHT

16C/

GRN

16D/

GRN

16/GRN

16G/GRN

RED/GRN

15A

CB--7

MTR

23A/GRY

30 87

BLK

IGN. COIL

15B/BLU

15A/BLU S--2 OIL SWITCH

16A/GRN

16B/GRN

3/ORA

CB--1

1A/RED

1D/RED

1B/RED

1A/RED

1C/RED

20A/BLU

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A 22/

YEL

CB--3

19/BLU

23/GRY

S--5

S--4 N.C.H.O.

S--3 N.O.H.C.

SWITCH

HOPPER THERMAL

S--8

S--7

24/PUR

36/GRN REVERSE

M5 86

START

STARTRUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

5 SEC. DELAY

ES PUMP RUNS

30 SEC.

5 SEC. DELAY

1MIN.TOVAC

FAN SHUT--OFF

42A/YEL

42B/YEL42/YEL

56/ORA

27/PUR

26/BRN

FRONT

RECOVERY

TANK

SOLUTION

TANK

ELEC.

SPARK

CONT. PLUGS

FLOW SWITCH

10/GRY

15A

15A15A

14/GRN

N.C.H.O.

GAS--DIESEL

FUEL PUMP

STARTER RELAY

S--6

8730

15/

BLU

M4 8685

28/YEL

57/GRN

ES PUMP

MTR

DETERGENT

METERING

RECOVERY TANK

S--1

8685 M3

ORA

43/BLU

55A MAX.

CHARGE

2/ORA

5/BLU

12V

540 C.C.A.

4/YEL

84/GRN

86/PUR

FEDC

CLOSES AT

225°F

ELECTRONIC

INSTRUMENT

PANEL

COOLANT TEMP

SENDER

FUEL SENDER

SE--1

SE--2

HORN BUTTON

15A

HORN

SENSE

GOV

CONTROL THROTTLE

ACTUATOR

13A/BLK

STARTER MOTOR

13/BLK

BATTERY

ALTERNATOR

GND

OUT

STARTER RELAY

M1 MTR

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-18

GAS/LP ELECTRICAL SCHEMATIC

OFF

C N.O.

62H/YEL

62B/YEL

R.H.

RUNNING

LIGHT

L.H.

RUNNING

LIGHT

R.H.

HEADLIGHT

13BF/BLK

13BG/BLK

62C/YEL 62F/YEL

62G/YEL

62E/YEL

4A/YEL

SV--19 SCRUB BR. DN. FORCE

PROP. VALVE

H2OCLOSED =

>20 INCHES

25J

25B

/GRY

WATER CONTROL

S--9

OFF

65/ORA

65A/ORA

65B/ORA

13CB/BLK

13CG/BLK

13CA/BLK

13AS/BLK

13AR/BLK

13CE/BLK

13EE/BLK

13FF/BLK

13GG/BLK

13AD/BLK

13AC/BLK

13AB/BLK

13AU/BLK

17/ORA7/BLU

31H/GRY

31L/GRY

25D/GRY

25H/GRY

25G/GRY

25F/GRY

46C/BRN

46B/BRN

46E/BRN

46/BRN

46D/BRN

25A

/GRY

25/GRY

21/

ORA

89A/BRN

90A/GRY

88A/GRN

87A/PUR

S--4

S--3

62D/YEL

77/GRY

45/GRN

48/BLU

SV--1 VAC FAN

SCRUB VALVE

LIGHTS ON

SWEEP SENSE

SV--4 SCRUB BR.

DOWN VALVE

SV--3 SCRUB BR.

ON VALVE

SV--22 HIGH

WATER VALVE

SV--21 LOW

WATER VALVE

96/YEL

GROUND

LINE

6/YEL

HOPPER DIFFERENTIAL PRESSURE

SV--10

EDJE SCRUB

SV--12

SQEEGEE DOWN

51/PUR

47/ORA 11

59B/

BRN

FRONT

SIDE BRUSH LIGHT

HEADLIGHT L.H.

87/PUR

88/GRN

89/BRN

90/GRY

80/BLU

79/YEL

RED

GRN

BLK

GRY

BLU

YEL

FLASHER

DIRECTIONAL

SWITCH

BRAKE

SWITCH

S--12

MTR--3

SHAKER MOTOR

11 /GRN

30A/GRY30/GRY

20A/

BLU

CB--5

59A/BRN

59/

BRN

95/BLU

20B/

BLU

ELECTRONIC

INSTRUMENT

PANEL

CB--6

62/YEL

15 AMP

TAIL LHT L.H.

TAIL LHT R.H.

AUTO FILL

RECOVERY TANK

SOLUTION TANK

N.O.H.C.

8730

15 AMP

MTR

FUSE

LEGEND

NORMALLY CLOSED

NORMALLY OPEN

COMMON

GROUND CHASSIS

ACCESSORY

SWITCH

SOLENOID VALVE

HOURMETER

N.C.

N.O.

GND

ACC

VOLTMETER

PUSHBUTTON

PLUG--MALE PIN

JACK--FEM. SOCKET

PERMANENT MAGNET

CIRCUIT BREAKER

MOTOR

POWER RELAY

MTR

GROUND

LINE

15 AMP

CB--4

9/BLU

SV--23

SV--24

11077--8410 G, LP

ELECTRICAL

5-19

8410 MM392 (5--02)

GAS/LP ELECTRICAL SCHEMATIC

53/BRN

WARNING LIGHT L.R.C.

WARNING LIGHT O.H.G.

BACKUPLIGHT

BACK UP ALARM

FLASHER

76/GRN

94/YEL

93/ORA

8730

8730 M9

50F/ORA

50E/ORA

50C/ORA

50D/ORA

50A/ORA

17B/ORA

17A/ORA

18/GRN

12/YEL

M--9

M--8

REVERSE RELAY

WARNING LIGHT RELAY

AUXILIARY

HOPPER

THERMAL

SENSE

ENG. SPEED SENSE

SCRUB SENSE

HOPPER LOCATION

SV--15 SIDE BR.

DOWN VALVE

SV--13 SIDE BR.

ON VALVE

44/YEL

SV--18 VAC FAN

SWEEP VALVE

41/PUR

SV--16 HOPPER

CLOSE VALVE

40/BRN

SV--17 HOPPER

OPEN VALVE

39/ORA

38/GRN

37/YEL

SV--9 HOPPER

DOWN VALVE

SV--8 HOPPER UP

VALVE

35/PUR

34/BRN

M--6

HEADLIGHT RELAY

85 M--7

SHAKER RELAY

SV--2 ENG. FAN

VALVE 49/GRN 17

UNSWITCHED POWER

15 AMP

CB--8

15 AMP

ELECTRONIC

INSTRUMENT

PANEL

GROUND

LINE

7C/BLU

7B/BLU

LOW = SCRUB

LOW = REVERSE

LOW = SW.FAN ENABLE

LOW = SWEEP ENABLE

HOPPER DN

N.O.H.C.

SV--5 MAIN SWEEP BRUSH

NORMAL SPEED VALVE

SV--6 MAIN SWEEP BRUSH

LITTER SPEED VALVE

SV--11 MAIN SWEEP BRUSH

DN. VALVE

13LL/BLK

13VV/BLK

13QQ/BLK

13NN/BLK

CLOSED =

13BE/BLK

13BD/BLK

13AH/BLK

13AG/BLK

13AF/BLK

13AT/BLK

46A/BRN

31D/GRY

31C/GRY

31M/GRY

31G/GRY

31F/GRY

31N/GRY

31K/GRY

31A/GRY

33D/ORA

33C/ORA

33E/ORA

33F/ORA

33/ORA

33A/ORA

25E/GRY

CB--9

97/BLU

76/GRN

93/ORA

44A/BRN

41A/PUR

40A/BRN

31/GRY

7A/BLU

7D/BLU

7E/BLU

33B/ORA

32/BLU

32A/BLU

8730

1G/RED

36A/GRN

REVERSE SENSE

83A/BRN

24A/PUR

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-20

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

5-21

8410 MM392 (5--02)

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-22

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

5-23

8410 MM392 (5--02)

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-24

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

5-25

8410 MM392 (5--02)

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-26

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

5-27

8410 MM392 (5--02)

GAS/LP WIRE HARNESS GROUP

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-28

GAS/LP WIRE HARNESS GROUP

OPTIONS

11077--8410 G, LP

ELECTRICAL

5-29

8410 MM392 (5--02)

GAS/LP WIRE HARNESS GROUP

OPTIONS

11077--8410 G, LP

ELECTRICAL

8410 MM392 (5--02)

5-30

DIESEL ELECTRICAL SCHEMATIC

16E/GRN

13BF/BLK

13AX/BLK

13AY/BLK

13BG/BLK

13AQ/BLK

1H/RED

3A/PUR

3/PUR

SHOWN

LOW SPEED

16G/GRN 49/PUR

ENG.FAN VALVE

SV--2

THROTTLE SWITCH

S--6

S--5 CLOSED =

S--3&4 CLOSED=

CLOSED=RUN

8/GRN

GLOW PLUGS

FU--1

40A

10A/GRY

96 OHM = FULL

OPEN AT 155F

REVERSE

CLOSES IN

13CD/BLK

13AM/BLK

13AL/BLK

13AM/BLK

13CF/BLK

16F/

GRN 19C/BLU

19B/BLU 19A/BLU

36B/GRN

36A/GRN

24B/PUR

50/ORA

1F/RED 21/ORA

21A/ORA

1G/RED

5A/BLU

8685

3087

87A

50A/ORA

50B/ORA

SV--14

24A/PUR

16C/

GRN

16D/

GRN

16/GRN

15A

CB--7

MTR

23A/GRY

30 87

15B/BLU

15A/BLU S--2 OIL SWITCH

16A/GRN

16B/GRN

CB--1

1A/RED

1D/RED

1B/RED

1A/RED

1C/RED

20A/BLU

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/

YEL

CB--3

19/BLU

23/GRY

S--5

S--4 N.C.H.O.

S--3 N.O.H.C.

SWITCH

HOPPER THERMAL

S--8

S--7

24/PUR

36/GRN

REVERSE

M5 86

START

STARTRUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

5SEC.DELAY

ES PUMP RUNS

30 SEC.

5SEC.DELAY

1MIN.TOVAC

FAN SHUT--OFF

42/YEL

56/ORA

27/PUR

26/BRN

FRONT

RECOVERY

TANK

SOLUTION

TANK

FLOW SWITCH

10/GRY

15A

14/GRN

N.C.H.O.

GAS--DIESEL

FUEL PUMP

STARTER RELAY

8730

15/

BLU

M4 8685

28/YEL

57/GRN

ES PUMP

MTR

DETERGENT

METERING

RECOVERY TANK

S--1

8685 M3

ORA

43/BLU

55A MAX.

CHARGE

2/ORA

5/BLU

12V

540 C.C.A.

4/YEL

CLOSES AT

225°F

ELECTRONIC

INSTRUMENT

PANEL

COOLANT TEMP

SENDER

FUEL SENDER

SE--1

SE--2

HORN BUTTON

HORN

SENSE

13A/BLK

STARTER MOTOR

13/BLK

BATTERY

ALTERNATOR

GND

OUT

STARTER RELAY

M1 MTR

11093--8410 D

ELECTRICAL

5-31

8410 MM392 (5--02)

DIESEL ELECTRICAL SCHEMATIC

ELECTRONIC

INSTRUMENT

PANEL

8730

CB--6 62/YEL

15 AMP

TAIL LHT L.H.

TAIL LHT R.H.

AUTO FILL

RECOVERY TANK

SOLUTION TANK

N.O.H.C.

8730

15 AMP

MTR

GROUND

LINE

FUSE

LEGEND

NORMALLY CLOSED

NORMALLY OPEN

COMMON

GROUND CHASSIS

ACCESSORY

SWITCH

SOLENOID VALVE

HOURMETER

N.C.

N.O.

GND

ACC

VOLTMETER

PUSHBUTTON

PLUG--MALE PIN

JACK--FEM. SOCKET

PERMANENT MAGNET

CIRCUIT BREAKER

MOTOR

POWER RELAY

MTR

C N.O.

R.H.

RUNNING

LIGHT

L.H.

RUNNING

LIGHT

R.H.

HEADLIGHT

62C/YEL

13GG/BLK

62D/YEL

62F/YEL

62G/YEL

62E/YEL

13BE/BLK

13BD/BLK

4A/YEL

25H

25E/GRY

25F/GRY

25G/GRY

SV--24

SV--23

SV--19 SCRUB BR. DN. FORCE

PROP. VALVE

H2OCLOSED =>20 INCHES

25B

/GRY

WATER CONTROL

S--9

OFF

65/ORA

65A/ORA

65B/ORA

13CB/BLK

13CG/BLK

13CA/BLK

13AS/BLK

13AR/BLK

13CE/BLK

13EE/BLK

13FF/BLK

13AD/BLK

13AC/BLK

13AB/BLK

13AU/BLK

17/ORA7/BLU

31H/GRY

31L/GRY

25D/GRY

46F/BRN

46E/BRN

46C/BRN

46/BRN46B/BRN

25A

/GRY

25/GRY

21/

ORA

89A/BRN

90A/GRY

88A/GRN

87A/PUR

S--4

S--3

77/GRY

45/GRN

48/BLU

SV--1 VAC FAN

SCRUB VALVE

LIGHTS ON

SWEEP SENSE

SV--4 SCRUB BR.

DOWN VALVE

SV--3 SCRUB BR.

ON VALVE

SV--22 HIGH

WATER VALVE

SV--21 LOW

WATER VALVE

96/YEL

CB--4

GROUND

LINE

6/YEL

HOPPER DIFFERENTIAL PRESSURE

SV--10

EDJE SCRUB

SV--12

SQEEGEE DOWN

51/PUR

47/ORA 11

59B/

BRN

FRONT

62B/YEL

62H/YEL

SIDE BRUSH LIGHT

HEADLIGHT L.H.

87/PUR

88/GRN

89/BRN

90/GRY

80/BLU

79/YEL

RED

GRN

BLK

GRY

BLU

YEL

XFLASHER

DIRECTIONAL

SWITCH

BRAKE

SWITCH

S--12

MTR--3

SHAKER MOTOR

11 /GRN

9/BLU

30A/GRY30/GRY

20A/

BLU CB--5

59A/BRN

59/

BRN

95/BLU

20B/

BLU

15 AMP

11093--8410 D

ELECTRICAL

8410 MM392 (5--02)

5-32

DIESEL ELECTRICAL SCHEMATIC

7C/BLU

7B/BLU

LOW = REVERSE

LOW = SCRUB

LOW = SW.FAN ENABLE

LOW = SWEEP ENABLE

13BA/BLK

13BC/BLK

N.C.H.O.

13LL/BLK

13VV/BLK

13QQ/BLK

13NN/BLK

HOPPER DN

CLOSED =

13AH/BLK

13AG/BLK

13AF/BLK

13AT/BLK

46A/BRN

31D/GRY

31C/GRY

31M/GRY

31G/GRY

31F/GRY

31N/GRY

31K/GRY

31A/GRY

33D/ORA

33C/ORA

33E/ORA

33F/ORA

33/ORA 33A/ORA

CB--9

97/BLU

76/GRN

93/ORA

44A/BRN

41A/PUR

40A/BRN

31/GRY

7A/BLU

7D/BLU

7E/BLU

33B/ORA

32A/BLU

8730

1G/RED

36A/GRN

REVERSE SENSE

24A/PUR

53/BRN

WARNING LIGHT L.R.C.

WARNING LIGHT O.H.G.

BACKUPLIGHT

BACK UP ALARM

FLASHER

76/GRN

94/YEL

93/ORA

8730

8730 M9

50F/ORA

50E/ORA

50C/ORA

50D/ORA

50A/ORA

17B/ORA17A/ORA

18/GRN

12/YEL

M--9

M--8

REVERSE RELAY

WARNING LIGHT RELAY

AUXILIARY

HOPPER

THERMAL

SENSE

SCRUB SENSE

HOPPER LOCATION

SV--15 SIDE BR.

DOWN VALVE

SV--13 SIDE BR.

ON VALVE

44/YEL

SV--18 VAC FAN

SWEEP VALVE

41/PUR

SV--16 HOPPER

CLOSE VALVE

40/BRN

SV--17 HOPPER

OPEN VALVE

39/ORA

SV--5 MAIN BRUSH

NORMAL SPEED VALVE

38/GRN

37/YEL

SV--9 HOPPER

DOWN VALVE

SV--8 HOPPER UP

VALVE

35/PUR

SV--6 MAIN BRUSH

LITTER SPEED VALVE

SV--11 MAIN BRUSH

DN. VALVE

34/BRN

M--6

HEADLIGHT RELAY

85 M--7

SHAKER RELAY

UNSWITCHED POWER

15 AMP

CB--8

15 AMP

ELECTRONIC

INSTRUMENT

PANEL

GROUND

LINE

32/BLU

11093--8410 D

ELECTRICAL

5-33

8410 MM392 (8--01)

ELECTRICAL

8410 MM392 (5--02)

5-34

DIESEL WIRE HARNESS GROUP

11093--8410 D

ELECTRICAL

5-35

8410 MM392 (5--02)

DIESEL WIRE HARNESS GROUP

11093--8410 D

ELECTRICAL

8410 MM392 (5--02)

5-36

DIESEL WIRE HARNESS GROUP

87A

VIEW J--J

VIEW H--H

MAIN

HARNESS

85 COIL+

86 COIL --

30 COMMON CONTACT

87 N.O. CONTACT

87A N.C. CONTACT

FUEL

PUMP

AUX.

SHAKER

MOTOR

HEAD

LIGHTS

HAZARD

LIGHTS

ROTATE

LIGHT

M2 M3 M4 M5 M6 M7 M8 M9

10A/GRY

12/YEL17B/ORA97/BLU

31C/GRY59/BRN65B/ORA

93/ORA62/YEL30/GRY32A/BLU21A/ORA

14/YEL

19C/BLU

19B/BLU

1G/RED

16B/GRN

16F/GRN16D/GRN

16C/GRN16A/GRN 50E/ORA50D/ORA50C/ORA

50B/ORA 76/GRN

50F/ORA

18/GRN

31D/GRY

15A/BLU

22/YEL

19/BLU

1F/RED

11093--8410 D

ELECTRICAL

5-37

8410 MM392 (5--02)

DIESEL WIRE HARNESS GROUP

11093--8410 D

ELECTRICAL

8410 MM392 (5--02)

5-38

DIESEL WIRE HARNESS GROUP

11093--8410 D

ELECTRICAL

5-39

8410 MM392 (5--02)

DIESEL WIRE HARNESS GROUP

11093--8410 D

ELECTRICAL

8410 MM392 (5--02)

5-40

DIESEL WIRE HARNESS GROUP

11093--8410 D

ELECTRICAL

5-41

8410 MM392 (8--01)

ELECTRICAL

8410 MM392 (5--02)

5-42

DIESEL WIRE HARNESS GROUP

OPTIONS

11093--8410 D

ELECTRICAL

5-43

8410 MM392 (5--02)

DIESEL WIRE HARNESS GROUP

OPTIONS

11093--8410 D

ELECTRICAL

5-44 8410 MM392 (8--01)

DIAGNOSTICS

The Model 8410 sweeper scrubber has a

on--board diagnostic system.

When the operator turns on the ignition key on the

8410, the front and side panels will each perform

an independent self test. If the self test for the

front panel passes, the OK light will begin to blink.

If the side panel passes its self test, it will blink

the headlight. When the main panel sees the

headlights blink, it assumes the side panel has

passed its self test. When both boards have

passed the self test, the OK light will go to a

steady on condition.

The 8410 front panel has 6 operating modes. The

side panel has 4 operating modes. The user can

access each mode by depressing various control

buttons, holding them, and turning on the key. The

common operating modes are as follows:

The first part of the diagnostics section describes

the different operating modes that can be

activated by using an entry sequence on the front

and side panels. There is also a chart describing

the normal mode messages that may appear on

the dash panel.

The second part of the diagnostics section

includes a chart that details the error messages

that may appear on the dash panel during the self

test mode and the cause/corrective action

description.

The third part of the diagnostics is a trouble

shooting section that includes a flow chart

detailing the flow of the electrical circuits.

ELECTRICAL

5-45

8410 MM392 (8--01)

FRONT PANEL OPERATING MODES

The 8410 front panel has a total of six operating

modes. When the operator starts the machine,

the panel will run its self test, then return to the

normal operating mode. The operator can access

five maintenance modes by turning the machine

off, pressing and holding the appropriate button,

turning the machine on, and holding the button

until the maintenance light comes on.

The following chart will detail each mode and the

entry sequence.

Operating Modes Entry Sequence

(how to activate)

Normal Mode;Normal operation.

More info pages 5--35 thru 5--37

Default (when key is turned on)

Manual Mode; Manually operate discrete

functions without interlocks.

More info page 5--38

1. Push and hold the EStbutton

2. Turn on the key

3. Hold the EStbutton until the maintenance light

comes on.

4. Release the EStbutton

5. To exit----turn off key

Input Display Mode; Display the state of floats,

limit switches, and sensors.

More info page 5--39

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

5. To exit----turn off key

Error Display Mode; Display the cause of a

self test failure.

More info pages 5--40 thru 5--42

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

5. To exit----turn off key

Pressure Adjust Mode; Adjust pressure levels for

the three down pressure settings.

More info page 5--43

1. Push and hold the Edge Scrub button

2. Turn on the key

3. Hold the Edge Scrub button until the

maintenance light comes on.

4. Release the Edge Scrub button

5. To exit----turn off key

Reset Scrub Pressures; Return the down

pressure settings to the factory defaults.

More info page 5--44

1. Push and hold the Scrub button

2. Turn on the key

3. Continue to hold the Scrub button

4. Wait for the maintenance light.

5. While holding the Scrub button, press and hold

the Edge Scrub button.

6. Wait for the maintenance light to go out.

7. Release the Scrub and Edge scrub buttons.

8. Turn the key off.

9. Restart the machine.

ELECTRICAL

5-46 8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Normal Mode;Normal operation. 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 buttons operation in the

normal mode.

EDGE SCRUB:

1. Pressing the Edge scrub button will toggle the

Edge scrub LED.

2. If the machine is in the scrub mode, the Edge

scrub LED is on, no reverse condition is

being sensed, and the machine is running at

high engine speed, the scrub head will shift

into the edge scrub position.

3. If the machine is in the scrub mode and the

Edge scrub LED is off, the scrub head will

be in the retracted position.

SQUEEGEE:

1. If the squeegee LED is off, pressing the

squeegee button will drop the squeegee,

turn on the vacuum fan, and select high

engine speed.

2. If the squeegee LED is on, pressing the

squeegee button will raise the squeegee,

initiate a delay, and turn off the vacuum fan.

3. The squeegee operation is inhibited in

reverse.

4. Squeegee LED will turn off automatically if

scrub system is turned off, low engine speed

is selected or recovery tank full condition is

sensed.

ENGINE SPEED:

1. If the engine is at idle speed, pressing this

button will bring it to operating speed.

2. If the scrub mode is active, pressing the

engine button will cancel all scrubbing

activities.

3. High speed is selected automatically if Scrub,

Squeegee, or Sweep 1 or 2 are turned on.

ELECTRICAL

5-47

8410 MM392 (8--01)

SCRUB:

DIf the scrub function is currently inactive,

pressing the scrub button will initiate the following

actions:

1. The engine speed is set to high.

2. The main brushes will turn on and go down.

The down pressure setting will be the same

used during the last scrub cycle. The

squeegee will lower and the scrub vacuum

will turn on. The solution will flow at the high

or low rate according to the water position

switch. The EStsystem, detergent

metering system, and the edge scrub will

operate if selected by the operator.

3. If the machine is in reverse, the brushes will

retract, lift , and turn off.

4. The squeegee will lift and the scrub vacuum

fan will turn off.

5. If the low engine speed is selected or an

overflow condition is sensed the scrub

system is turned off automatically.

DIf the operator pushes and holds the scrub

button, the pressure settings will begin to scroll.

The pressure setting displayed after releasing the

scrub button will become the new default down

pressure setting.

DIf 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 retract, raise and turn

off.

2. The solution flow will turn off.

3. The detergent pump will turn off.

4. A seven second delay will pass, and then

the rear squeegee will rise.

5. A four second delay will pass and the

vacuum fan will turn off.

ELECTRICAL

5-48 8410 MM392 (8--01)

DETERGENT:

DPressing the detergent button will cause the

detergent display to scroll through its three

modes. The detergent pump will run if the main

scrub brushes are active, the solution switch is

on, and the machine is not in reverse.

1. OFF (all LED’s off)----Detergent pump

OFF

2. LOW (left LED’s on)----Detergent pump

LOW.

3. HIGH (both LED’s on)----Detergent pump

HIGH.

ESt:

DPressing the EStbutton will enable or

disable the EStfunction. In order for the ESt

float to become active, it must be consistently in

the up position for ar least 10 seconds. If the ESt

function is enabled and the EStfloat becomes

active, the following actions will occur:

1. The EStpump will begin to run.

2. The EStpump will continue to run for 40

seconds after the EStfloat becomes

uncovered.

OVER FLOW:

DIn order for the recovery tank float to become

active, it must be consistently in the up position

for 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 50 second delay will pass.

3. The overflow light will stop blinking and stay

on.

4. The scrub and squeegee functions will be

cancelled.

ELECTRICAL

5-49

8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Manual Mode; Manually operate discrete

functions without interlocks.

1. Push and hold the EStbutton

2. Turn on the key

3. Hold the EStbutton until the maintenance light

comes on.

4. Release the EStbutton

5. To exit----turn off key

MANUAL MODE:

In this mode, the operator can turn on and off

accessories individually and manually. In the

manual mode, the operator can turn on

accessories without regard to inputs or interlocks.

If, for instance, the operator enables the ESt

pump in the manual mode, it will run regardless of

whether or not the EStfloat is in the water. What

follows is a brief description of each buttons

operation in the manual mode.

ESt:

DPressing the EStbutton in the manual mode

turns on and off the EStpump.

EDGE SCRUB BUTTON:

DPressing the Edge scrub button will extend or

retract the scrub head.

SQUEEGEE BUTTON:

DPressing the Squeegee button will turn on the

vacuum fan and lower the squeegee. Reverse is

ignored.

ENGINE BUTTON:

DPressing the Engine button will toggle the

engine between high and low speed.

SCRUB BUTTON:

DPressing the Scrub button will turn on and

lower the main scrub head. Holding the Scrub

button while scrub is active will cause the down

pressures to scroll.

DETERGENT BUTTON:

DPressing and holding 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 at high speed.

ELECTRICAL

5-50 8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Input Display Mode; Display the state of floats,

limit switches, and sensors.

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

5. To exit----turn off key

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:

DSEGMENT 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.

DSEGMENT 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.

DSEGMENT 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.

DSEGMENT 3 -- Forth segment from the

right of the gas gauge. This segment

displays the state of the sweep sense input.

This segment will be illuminated when this

input is shorted to ground.

DENGINE TEMPERATURE LIGHT -- In the

Input Display Mode, the engine temperature

light will blink until the engine reaches

operating temperature.

ELECTRICAL

5-51

8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Error Display Mode; Display the cause of a

self--test failure.

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:

EStLED

Problem with the EStoutput. If the operator

pushes the headlight button in this mode, the

panel will display one of the following codes:

DSEGMENT 0 -- Rightmost segment of the

gas gauge. This segment would indicate that

the EStoutput was shorted to ground when

the controller was expecting it to be open.

DSEGMENT 0, 1 -- First and second

segments from the right of the gas gauge.

These segments would indicate that the

EStoutput was open when the controller

was trying to short it to ground.

ELECTRICAL

5-52 8410 MM392 (8--01)

EDGE SCRUB LED

Problem with the edge scrub outputs. If the

operator pushes the edge scrub button in this

mode the panel would display one of the following

codes:

DSEGMENT 0 -- Rightmost segment of the

gas gauge. This segment would indicate that

the edge scrub output was shorted to

ground when the controller was expecting it

to be open.

DSEGMENT 0, 1 -- First and second

segments from the right of the gas gauge.

These segments would indicate that the

edge scrub 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:

DSEGMENT 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.

DSEGMENT 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.

DSEGMENT 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.

DSEGMENT 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.

ELECTRICAL

5-53

8410 MM392 (8--01)

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:

DSEGMENT 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.

DSEGMENT 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.

DSEGMENT 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.

DSEGMENT 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:

DSEGMENT 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.

DSEGMENT 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.

ELECTRICAL

5-54 8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Pressure Adjust Mode; Adjust the pressure

levels for the three down pressure settings.

1. Push and hold the Edge Scrub button

2. Turn on the key

3. Hold the Edge Scrub button until the

maintenance light comes on.

4. Release the Edge Scrub 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.

After each adjustment, the new pressure setting is

stored in a non--volatile (retained even after power

down) memory.

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.

DGAS 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

thesidebrushisactive).

DSQUEEGEE BUTTON -- Holding the

squeegee button will decrease the down

pressure.

DDETERGENT BUTTON -- Holding the

detergent button will increase the down

pressure.

ELECTRICAL

5-55

8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Reset Scrub Pressures; Return the down

pressure settings to the factory defaults.

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 Edge Scrub button

6. Wait for the maintenance light to go out

7. Release the Scrub and Edge Scrub 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.

ELECTRICAL

5-56 8410 MM392 (8--01)

SIDE PANEL OPERATING MODES

The 8410 side panel has a total of four operating

modes. When the operator starts the machine the

panel will run its self test. If the self test fails, an

LED which is associated with the failing system

will blink (error display mode). If the operator

engages any sweeping functions, the error display

mode will cancel and the side panel will run in the

normal mode. If the test passes, the side panel

will blink the headlights. The main panel will

detect the headlight flash, and display a

non--blinking OK signal.

Note; The hopper lift LED will blink if Sweep 1 or

2 is selected and the hopper is up.

The following chart will detail each mode and the

entry sequence.

Operating Modes Entry Sequence

(how to activate)

Normal Mode;Normal operation.

More info pages 5--46 thru 5--49

Default (when key is turned on)

Manual Mode; Manually operate discrete

functions without interlocks.

More info pages 5--50 and 5--51

1. Push and hold the Hazard light button.

2. Turn on the key

3. Hold the Hazard light button for 10 seconds.

comes on.

4. Release the Hazard light button. The Hazard

light should begin to blink.

5. To exit----turn off key

Input Display Mode; Display the state of floats,

limit switches, and sensors.

More info page 5--52

1. Push and hold the Headlight button.

2. Turn on the key

3. Hold the Headlight button for 10 seconds.

4. Release the Headlight button. The sweep

1 and sweep 2 lights will be on.

5. To exit----turn off key

Error Display Mode; Display the cause of a

self test failure.

More info page 5--53

If an error is detected, the side panel will

automatically go into the error display mode.

When a function from the side panel is selected,

the panel will go into the normal mode.

ELECTRICAL

5-57

8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Normal Mode;Normal operation. 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 buttons operation in the

normal mode.

HAZARD LIGHTS:

DPressing the Hazard light button will toggle on

and off the Hazard lights.

HEAD LIGHTS:

DPressing the Head light button will toggle on

and off the Head lights.

FILTER SHAKER:

DThe Filter shaker button controls the

operation of the filter shaker and timer system.

DIf the Filter shaker LED is OFF, pressing the

shaker button will initiate a shake sequence.

A shake sequence is defined as follows:

1. The Shaker LED will turn on.

2. The filter shaker will start.

3. The filter shaker and LED will remain on for

approximately 40 seconds.

4. The filter shaker and LED will turn off.

DIf the Filter shaker LED is ON, pressing the

shaker button will turn off the shaker motor

and LED.

DA 15 second shake sequence will also be

initiated each time the sweep system is

turned off.

DA shake sequence will be cancelled if active

while the sweep, or sweep vacuum fan is

turned on.

HOPPER LIFT:

DPressing and holding the Hopper lift button

will engage the hopper lift mechanism. The

Hopper will continue to lift as long as the operator

holds his finger on the Hopper lift button.

Note; The hopper lift LED will blink if Sweep 1 or

2 are selected and the hopper is up.

ELECTRICAL

5-58 8410 MM392 (8--01)

HOPPER LOWER:

DPressing and holding the Hopper lower button

will engage the hopper lower mechanism. The

Hopper will continue to drop as long as the

operator holds his finger on the Hopper lower

button.

HOPPER DOOR:

DPressing the Hopper door button will toggle

the hopper door open or closed.

DIf the Hopper door LED is lit, the hopper

door is closed. Pressing the Hopper door

button will turn off the LED and open the

door for 3 seconds.

DIf the Hopper door LED is not lit,the

hopper door is open. Pressing the Hopper

door button will turn on the LED and close

the door for 3 seconds.

DThe Hopper door will automatically open

each time the sweep function is engaged.

DThe Hopper door will automatically close

each time the machine is started, or the

sweep function is turned off.

SIDE BRUSH:

DPressing the Side Brush button will enable or

disable the side brush operation while sweeping.

DThe Side brush will only operate if the

Sweep function is engaged.

DEach time the Sweep function is engaged,

the side brush will be enabled.

DEach time the Sweep function is turned off,

the Side brush will be canceled.

VACUUM FAN:

DPressing the Sweep Vacuum Fan button will

enable or disable the fan operation while

sweeping.

DThe Sweep fan will only operate if the

Sweep function is engaged.

DEach time the Sweep function is engaged,

the fan will be enabled.

DEach time the Sweep function is turned off,

the fan will be canceled.

ELECTRICAL

5-59

8410 MM392 (8--01)

SWEEP 1 (NORMAL SWEEP):

DThe Sweep 1 button is used to engage and

disengage the normal sweep functions. Sweep 1

can only be engaged if the hopper is in the down

position. If the hopper is not in the down position

and the Sweep 1 button is pushed, the Sweep

system will not be engaged, and the hopper up

light will begin to blink.

DIftheSweep1and2LED’sarenotlit

(Sweep not currently active), pressing the

Sweep 1 button will engage the following

sweep sequence:

1. The controller will check the hopper down

switch. If the hopper down switch is not

engaged, the sweep function will be

canceled. If the hopper down switch is

engaged, the following sequence will

continue:

2. The hopper door will begin to open.

3. After the hopper door opens, the sweep fan

will turn on.

4. The side brush will turn on.

5. The engine will be set to its high operating

speed.

6. The main broom will turn on in normal

speed.

DIf the Sweep 1 LED is lit (Sweep currently

active), pressing the Sweep 1 button will

disengage the sweep system with the

following sequence:

1. The main broom, side brush, and sweep fan

will turn off.

2. The hopper door will close.

3. A filter shake sequence will begin.

ELECTRICAL

5-60 8410 MM392 (8--01)

SWEEP 2 (LITTER SWEEP):

DThe Sweep 2 button is used to engage and

disengage the litter sweep functions. The litter

sweep function can only be engaged if the scrub

system is turned off. Pressing the Sweep 2 button

while the scrub function is enabled will engage the

Sweep 1 system. Sweep 1 can only be engaged

if the hopper is in the down position. If the hopper

is not in the down position and the Sweep 1

button is pushed, the Sweep system will not be

engaged, and the hopper up light will begin to

blink.

DIftheSweep1and2LED’sarenotlit

(Sweep not currently active), pressing the

Sweep 2 button will engage the following

sweep sequence:

1. The controller will check the hopper down

switch. If the hopper down switch is not

engaged, the sweep function will be

canceled. If the hopper down switch is

engaged, the following sequence will

continue:

2. The hopper door will begin to open.

3. After the hopper door opens, the sweep fan

will turn on.

4. The side brush will turn on.

5. The engine will be set to its high operating

speed.

6. The main broom will turn on in litter speed.

DIf the Sweep 2 LED is lit (Sweep currently

active), pressing the Sweep 2 button will

disengage the sweep system with the

following sequence:

1. The main broom, side brush, and sweep fan

will turn off.

2. The hopper door will close.

3. A filter shake sequence will begin.

ELECTRICAL

5-61

8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Manual Mode; Manually operate discrete

functions without interlocks.

1. Push and hold the Hazard light button.

2. Turn on the key

3. Hold the Hazard light button for 10 seconds.

comes on.

4. Release the Hazard light button. The Hazard

light should begin to blink.

5. To exit----turn off key

MANUAL MODE

In this mode, the operator can turn on and off

accessories individually and manually. In the

manual mode, the operator can turn on

accessories without regard to inputs or interlocks.

If, for instance, the operator enables the sweep

vacuum fan in the manual mode, it will run

regardless of whether or not the sweep function is

engaged or the hopper down switch is closed.

What follows is a brief description of each buttons

operation in the manual mode.

HAZARD LIGHT:

DSame as normal operation.

HEAD LIGHT:

DSame as normal operation.

FILTER SHAKER:

DToggles on and off the filter shaker motor.

Timer is disabled.

HOPPER UP:

DSame as normal operation.

HOPPER DOWN:

DSame as normal operation.

HOPPER DOOR:

DSame as normal operation.

ELECTRICAL

5-62 8410 MM392 (8--01)

SIDE BRUSH:

DToggles on and off the side brush. Side brush

will run regardless of whether or not sweeping is

engaged.

SWEEP FAN:

DToggles on or off the sweep fan. Fan will run

regardless of the state of sweep or hopper down

switch. Sweep 1 or Sweep 2 must be engaged.

SWEEP 1:

DToggles on or off main broom in normal

speed. Broom will run regardless of the state of

the hopper down switch.

SWEEP 2:

DToggles on or off main broom in litter speed.

Broom will run regardless of the state of the

hopper down switch.

ELECTRICAL

5-63

8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Input Display Mode; Display the state of floats,

limit switches, and sensors.

1. Push and hold the Headlight button.

2. Turn on the key

3. Hold the Headlight button for 10 seconds.

4. Release the Headlight button. The sweep

1 and sweep 2 lights will be on simultaneously.

5. To exit----turn off key

INPUT DISPLAY MODE:

In this mode, the side panel will display the state

of the external switches (i.e. hopper down switch)

or functions which are used as interlocks. In this

mode, the function of the switch LED‘s changes

from indicating the state of an operation (like the

hopper door is closed), to indicating the state of a

sensor (like the hopper down switch). The

technician can use this mode to check the state of

various sensors on the machine.

The operation of the Input Display Mode is as

follows:

BLINKING HAZARD LED:

DHopper thermal switch is open.

BLINKING SHAKER LED:

DReverse switch is closed.

BLINKING HOPPER DOOR LED:

DHopper down switch is open.

BLINKING SIDE BRUSH LED:

DScrub signal is low (active).

BLINKING HEAD LIGHT LED:

DEngine is in high speed.

ELECTRICAL

5-64 8410 MM392 (8--01)

Operating Mode Entry Sequence

(how to activate)

Error Display Mode; Display the cause of a

self test failure.

If an error is detected, the side panel will

automatically go into the error display mode.

When a function from the side panel is selected,

the panel will go into the normal mode.

ERROR DISPLAY MODE

If the 8410 side panel fails its initial self test, this

mode is designed to give the service person a

clue as to the cause of the failure. The 8410 side

panel will automatically go into this mode when a

failure is detected. To cancel the error display

mode, the operator can press any button on the

side panel. Once a button has been pushed,

normal operation will resume.

The operator can identify errors detected during

self test using blinking LED’s on the side panel.

The assignments between LED’s and failures are

as follows:

BLINKING SHAKER LED:

DFailure on shaker output.

BLINKING HAZARD LED:

DFailure on hazard light or reverse output.

BLINKING HEADLIGHT LED:

DFailure on headlight output.

BLINKING SIDE BRUSH LED:

DFailure on side brush output.

BLINKING HOPPER DOOR LED:

DFailure on hopper door open or close output.

BLINKING HOPPER UP LED:

DFailure on hopper raise output.

BLINKING HOPPER DOWN LED:

DFailure on hopper lower output.

BLINKING SWEEP FAN LED:

DFailure on sweep fan or engine fan output.

BLINKING SWEEP 1 LED:

DFailure on Sweep 1 or brush down output.

BLINKING SWEEP 2 LED:

DFailure on Sweep 2 or output.

ELECTRICAL

5-65

8410 MM392 (8--01)

ELECTRICAL

5-66 8410 MM392 (8--01)

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.

ELECTRICAL

5-67

8410 MM392 (8--01)

16E/GRN

1H/RED 13AM/BLK

16E/GRN

16F/

GRN

19C/BLU

19B/BLU

19A/BLU

1F/RED 21A/ORA

1G/RED

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M5 86

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

50A/ORA

AUXILIARY

CB--8

15 AMP

ELECTRONIC

INSTRUMENT

PANEL

13AG/BLK

13AF/BLK

31A/GRY 31/GRY

32A/BLU

1G/RED M5

INSTRUMENT PANEL

DOES NOT POWER UP

(SCHEMATIC)

OPERATION:

--KEY SWITCH ACTIVATES M3, M4, AND M5

--M3, M4, AND M5 CONTACTS SUPPLY B+

TO INSTRUMENT PANEL (PIN 1 AND 2)

ELECTRICAL

5-68 8410 MM392 (8--01)

CHECK FOR VOLTAGE

AT PINS 22 AND 23 OF

EACH PANEL TO BATTERY

POSITIVE

KEY ON AND RELAYS

BACK IN

PANELS REMOVED

CHECK VOLTAGE AT PIN 1

AND PIN 2 OF BOTH PANELS

TO GROUND

REMOVE M3, M4, AND

M5 RELAYS

TURN KEY ON AND

CHECK VOLTAGE

FROM 16/GRN, PIN 85

TO 19/BLU, PIN 86 ON

EACH RELAY

KEY ON AND M3, M4,

AND M5 STILL REMOVED

CHECK VOLTAGE AT

--22/YEL, PIN 30, M3

--1F/RED, PIN 30, M4

--1G/RED, PIN 30, M5

TO MACHINE GROUND

SWEEP PANEL IS FAILING

SELF--TEST

POWER UP SYSTEM OK

FAILED OUTPUT LED,

SHOULD BE BLINKING

POWER UP AND

SELF--TEST ARE

SUCCESSFUL

DO FAULT LIGHTS ON

SCRUB PANEL TURN ON

FOR 4 SECONDS ? AND CAN

ANY OF THE SWEEP PANEL

LED’SBEACTIVATED?

INSTRUMENT PANEL

DOES NOT POWER UP

(FLOW CHART)

TURN KEY ON

ENGINE NEED NOT BE RUNNING

OPERATION:

--KEY SWITCH ACTIVATES M3,

M4, AND M5

--M3, M4, AND M5 CONTACTS

SUPPLY B+ TO INSTRUMENT

PANEL (PIN 1 AND 2)

YES TO BOTH CONDITIONS

NO TO EITHER CONDITION

TURN KEY OFF/ON

DOES SCRUB PANEL OK

LIGHT COME ON AFTER THE

4 SECOND POWER UP ?

ALL = B+

0 VOLTAGE

YES

IS THE LIGHT

BLINKING ?

SCRUB PANEL IS FAILING

SELF--TEST

POWER UP SYSTEM IS OK

YES

GO TO THE TROUBLESHOOTING

FLOW CHART OF THE MACHINE

FUNCTION INDICATING A FAILURE

IF MACHINE FUNCTION

PASSES TROUBLESHOOTING

TEST THE HEADLIGHT SYSTEM

FAILURE

REPAIR HEADLIGHT

SYSTEM AND RE--TEST

PASS

SYSTEM IS WORKING

RUN ERROR DISPLAY

SOFTWARE TO DETERMINE

WHICH FUNCTION IS FAILING

GO TO THE TROUBLESHOOTING

FLOW CHART OF THE MACHINE

FUNCTION INDICATING A FAILURE

KEY SWITCH, CB--2, 16/GRN

19/BLU, D--1, 13AM/BLK, OR

1A/RED ARE OPEN

1G/RED, 1F/RED, 1H/RED

CB--3, OR 22/YEL ARE OPEN

B+

ANY 0 VOLTAGE

0VOLTAGE

M3, M4, OR M5

ARE BAD OR 50/ORA, 21/ORA,

CB--4, 25/GRY, 32/BLU, CB--8,

OR 31/GRY ARE OPEN

B+

0 VOLTAGE

B+

REPLACE PANEL

NOT POWERING UP

13/BLK WIRES ON PINS

22 AND 23 ARE OPEN

TO MACHINE GROUND

ELECTRICAL

5-69

8410 MM392 (8--01)

OPERATION:

--SCRUB IS SELECTED ON TOUCH PANEL

--MACHINE IS NOT IN REVERSE

--RECOVERY TANK IS NOT FULL

--ENGINE SPEED IS SELECTED TO HIGH

--SCRUB SOLENOIDS WILL TURN ON,

HEAD WILL LOWER, BRUSHES WILL SPIN

SCRUB BRUSH WILL NOT

TURN ON AND/OR DOWN

(SCHEMATIC)

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN

19C/BLU

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M48685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

13AM/BLK

S--5

N.C.H.O.

28/YEL RECOVERY TANK

REVERSE

CLOSES IN

13AY/BLK

36B/GRN

S--7

36/GRN

REVERSE

FLOW SWITCH

SV--19 SCRUB BR. DN. FORCE

PROP. VALVE

25H/GRY

25G/GRY

25F/GRY

46C/BRN

46B/BRN

46/BRN

48/BLU

SV--4 SCRUB BR.

DOWN VALVE

SV--3 SCRUB BR.

ON VALVE

CLOSED =

REC TANK

FULL

ELECTRICAL

5-70 8410 MM392 (8--01)

S--7 IS NOT WORKING

(REVERSE SWITCH)

OR 36/GRN OR 13AY/

BLK IS OPEN OR ANY

36/GRN IS SHORTED

TO GROUND

IS THE REC TANK

FULL LIGHT ON ?

STILL NOT TURNING

ON/OFF

OPERATION:

--SCRUB IS SELECTED ON

TOUCH PANEL

--MACHINE IS NOT IN REVERSE

--RECOVERY TANK IS NOT

FULL

--ENGINE SPEED IS SELECTED

TO HIGH

--SCRUB SOLENOIDS WILL

TURN ON

--HEAD WILL LOWER

-- BRUSHES WILL SPIN

46/BRN IS OPEN

FROM PANEL PIN TO

SOLENOID WITHOUT

VOLTAGE

SCRUB BRUSH WILL NOT

TURN ON AND/OR DOWN

(FLOW CHART)

BOTH PANELS ARE

POWERED UP

KEY IS ON

ENGINE IS OFF

CAN THE SCRUB BUTTON

BE TURNED ON AND OFF ? NO

REPLACE TOUCH

PANEL FACE

REPLACE INSTRUMENT

PANEL

YES

ENGINE IS ON

ACTIVATE SQ. / VAC BUTTON

DOES THE SQUEEGEE GO DOWN

AND VAC FAN TURN ON ?

YES

DRAIN THE TANK

ENGINE IS OFF

KEY IS ON

SCRUB SELECTED

DISCONNECT SOLENOIDS

CHECK VOLTAGE AT SV--3,

SV--4, AND SV--19

FROM 25/GRY TO GROUND

VOLTAGE

WIRE 25/GRY

FROM CB--4 TO

SOLENOIDS SV--3,

SV--4, OR SV--19 IS

OPEN

VOLTAGE

ENGINE IS OFF

KEY IS ON

SCRUB SELECTED

DISCONNECT SOLENOIDS

CHECK VOLTAGE AT SV--3,

AND SV--4 FROM 25/GRY TO

46/BRN

VOLTAGE ON ONLY

ONE SOLENOID

NO VOLTAGE

AT EITHER

SOLENOID

SOLENOID STILL DISCONNECTED

TURN KEY SW. OFF THEN ON

DOES THE ” OK” LIGHT COME ON ?

YES

WIRE 46/BRN IS OPEN

FROM PANEL (PIN 19)

TO SV--3 AND SV--4

DISCONNECT INST. PANEL

CHECK CONTINUITY OF

WIRE 46/BRN FROM INST.

PANEL HARNESS (PIN 19)

TO GROUND

OPEN

REPLACE INST.

PANEL

CONTINUED ON

CONTINUITY

WIRE 46/BRN IS

SHORTED TO

GROUND

RUN INPUT DISPLAY

SOFTWARE MODE

DETERMINE IF REVERSE

SWITCH IS WORKING

SWITCH SIGNAL OK

VOLTAGE ACROSS

BOTH SOLENOIDS

GO TO SQUEEGEE/VAC FAN

TROUBLESHOOTING FLOW

CHART

ELECTRICAL

5-71

8410 MM392 (8--01)

CONTINUED FROM

KEY ON

ENGINE OFF

SCRUB SELECTED

SV--19 DISCONNECTED

CHECK VOLTAGE AT SV--19

FROM 25H/GRY TO 48/BLU

NO VOLTAGE

SOLENOID STILL

DISCONNECTED

TURN KEY OFF, THEN ON

DOES THE ”OK” LIGHT COME ON ?

NO YES

WIRE 48/BLU IS OPEN

FROM SV--19 TO INST.

PANEL (PIN 16)

KEY IS OFF

DISCONNECT INSTRUMENT PANEL

CHECK CONTINUITY FROM 48/BLU

TO GROUND

OPEN CONTINUITY

REPLACE PANEL WIRE 48/BLU IS

SHORTED TO GROUND

VOLTAGE

CHECK TO SEE IF ALL

THREE SOLENOIDS ARE

O N -- -- U S E M A G N E T I S M

TEST ON SV--3, SV--4,

AND SV--19

ALL ON ONE OR

MORE NOT

ACTIVATED

REPLACE BAD SOLENOID

AND RETEST

HYDRAULIC

PROBLEM

>2VOLTS

ELECTRICAL

5-72 8410 MM392 (8--01)

ELECTRICAL

5-73

8410 MM392 (8--01)

SCRUB HEAD WILL NOT EXTEND

(SCHEMATIC)

OPERATION:

--MACHINE MUST BE IN SCRUB MODE

--EDGE SCRUB BUTTON IS ACTIVATED

--MACHINE NOT IN REVERSE

--ENGINE SPEED ON HIGH

--SV--10 IS TURNED ON

--THE SCRUB HEAD WILL EXTEND

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M586

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M48685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

REVERSE

CLOSES IN

13AY/BLK

36B/GRN

S--7

36/GRN

REVERSE

FLOW SWITCH

1G/RED

CB--8

15 AMP

32A/BLU

1G/RED M5

31H/GRY

SV--10

EDJE SCRUB

51/PUR 12

31A/GRY

31/GRY

UNSWITCHED

POWER

ELECTRICAL

5-74 8410 MM392 (8--01)

--ENGINE OFF

--KEY ON

--SCRUB SELECTED

--EDGE SCRUB SELECTED

--SOLENOID DISCONNECTED,

CHECK VOLTAGE ACROSS

SOLENOID FROM 31H/GRY TO

51 PUR

--SOLENOIDS STILL DISCONNECTED

--TURN KEY OFF, THEN ON

DOES THE ”OK” LIGHT COME ON ?

31H/GRY, 31A/GRY, CB--8

32/BLU, OR M5 CONTACTS

ARE OPEN

REPLACE TOUCH

PANEL FACE

CAN THE EDGE SCRUB BUTTON

BE TURNED ON AND OFF?

SCRUB HEAD WILL NOT EXTEND

(FLOW CHART)

PANEL IS POWERED UP

KEY IS ON

ENGINE IS RUNNING

SCRUB SYSTEM ON

STILL DOES

NOT WORK

REPLACE INST.

PANEL

YES

--ENGINE OFF

--KEY ON

--SCRUB SELECTED

--EDGE SCRUB SELECTED

CHECK VOLTAGE AT SV--10 FROM

31H/GRY TO GROUND

VOLTAGE

NO VOLTAGE

VOLTAGE ACROSS

SOLENOID SV--10

NO VOLTAGE

YES

NO 51/PUR IS OPEN

FROM PANEL TO

SOLENOID SV--10

--DISCONNECT

INSTRUMENT PANEL

CHECK CONTINUITY

OF 51/PUR TO

GROUND

OPEN

CONTINUITY

REPLACE INST.

PANEL

WIRE 51/PUR IS

SHORTED TO

GROUND

OPERATION:

--MACHINE MUST BE IN SCRUB MODE

--EDGE SCRUB BUTTON IS ACTIVATED

--MACHINE NOT IN REVERSE

--ENGINE SPEED ON HIGH

--SV--10 IS TURNED ON

--THE SCRUB HEAD WILL EXTEND

CHECK TO SEE IF S--10 IS

TURNING ON

USE THE MAGNETIC TEST

OFF

REPLACE BAD

SOLENOID

HYDRAULIC PROBLEM

SEE TROUBLESHOOTING

ELECTRICAL

5-75

8410 MM392 (8--01)

SQUEEGEE AND VACUUM FAN NOT

TURNING ON AND GOING DOWN

(SCHEMATIC)

OPERATION:

--SQ/VAC IS SELECTED ON TOUCH PANEL

--MACHINE NOT IN REVERSE

--ENGINE SPEED HIGH

--NO OVERFLOW CONDITION SENSED

--THE SQUEEGEE LOWERS AND SCRUB VACUUM FAN TURNS ON

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M48685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

13AM/BLK

S--5

N.C.H.O.

28/YEL RECOVERY TANK

REVERSE

CLOSES IN

13AY/BLK

36B/GRN

S--7

36/GRN

REVERSE

FLOW SWITCH

1G/RED

CB--8

15 AMP

32A/BLU87

1G/RED M5

31A/GRY 31/GRY

UNSWITCHED

POWER

31L/GRY

SV--12

SQEEGEE DOWN

47/ORA 11

25D/GRY 45/GRN

SV--1 VAC FAN

SCRUB VALVE

ELECTRICAL

5-76 8410 MM392 (8--01)

START THE ENGINE

DOES THE THIRD FUEL

GAUGE SEGMENT

FROM RIGHT LIGHT UP

IN REVERSE AND TURN

OFF IN NEUTRAL?

VOLTAGE

YES

25/GRY, 21/ORA,

CB--4, M--4, 31/GRY,

CB--8, 32/BLU, OR

M5 CONTACTS

ARE OPEN

DISCONNECT SV--1 AND SV--12

CHECK VOLTAGE AT SV--1

FROM 25D/GRY TO GND. AND

SV--12 FROM 31L/GRY TO GND.

ELECTRONICS OK

SEE HYDRAULIC

TROUBLESHOOTING

DOES THE SQ. AND/OR

VAC TURN ON/OFF WITH THE

SQ/VAC BUTTON NOW ?

CAN THE SQ/VAC TOUCH

PANEL BUTTON

BE TURNED ON AND OFF?

SQUEEGEE AND VACUUM FAN NOT

TURNING ON AND GOING DOWN

(FLOW CHART)

PANEL IS POWERED UP

KEY IS ON

ENGINE IS RUNNING

YES

REPLACE TOUCH

PANEL FACE

STILL DOES

NOT WORK

REPLACE INST.

PANEL

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” BUT-

TON UNTIL THE MAINTE-

NANCE LIGHT COMES ON

--RELEASE ”ES” BUTTON

VOLTAGE

--MANUAL MODE

-- E N G I N E O F F

--KEY ON

--SQ/VAC SELECTED

”ON”

ARE SV--1 AND SV--12

TURNED ON ? (USE

MAGNETIZED TEST)

YES

DISCONNECT HYD.

COILS AGAIN

CHECK VOLTAGE

ACROSS BOTH COILS,

SV--1 FROM 25D/GRY TO

45/GRN AND SV--12 FROM

31L/GRY TO 47/ORA

VOLTAGE

CONTINUED ON

REPLACE HYD. COIL

THAT WILL NOT TURN

ON-- --RE--TEST SYSTEM

YES

IS THE REC TANK

FULL LIGHT ON ?

DRAIN TANK AND

RE--TEST

IF LIGHT IS STILL

ON--GO TO RE-

COVERY TANK

FULL LIGHT WILL

NOT TURN OFF

FLOW CHART

OPERATION:

--SQ/VAC IS SELECTED ON

TOUCH PANEL

--MACHINE NOT IN REVERSE

--ENGINE SPEED HIGH

--NO OVERFLOW CONDITION

SENSED

--THE SQUEEGEE LOWERS

AND SCRUB VACUUM FAN

TURNS ON

RECONNECT

SV--1 AND

SV--12

GO INTO ”INPUT DISPLAY MODE”

THE INPUT CONDITIONS WILL BE

DISPLAYED ON FUEL GAUGE

--TURN OFF THE KEY

--PUSH AND HOLD SQ/VAC BUTTON

HOLD UNTIL MAINTENANCE LIGHT

COMES ON

YES

PANEL TESTS

GOOD

LIGHT ALWAYS ON

LIGHT ALWAYS OFF

CHECK CONTINUITY OF

36/GRN AT PIN 8 TO GROUND

--ENGINE ON AND IN NEUTRAL

REPLACE INST.

PANEL

OPEN 36/GRN IS SHORTED

TO GROUND OR S--7

IS ALWAYS CLOSED

CONTINUITY

CHECK CONTINUITY

OF 36/GRN, 36B/GRN

AND S--7 (S--7 IS

CLOSED IN REVERSE

CONTINUITY

REPLACE INST.

PANEL

OPEN

REPAIR 36/GRN,

36B/GRN, OR

REPLACE S--7

TURN KEY OFF,

THEN ON

ELECTRICAL

5-77

8410 MM392 (8--01)

REMOVE THE SHORT

TO GROUND ON

47/ORA AND/OR

45/GRN

COILS STILL

DISCONNECTED

CONTINUED FROM

--TURN KEY OFF THEN ON

IS THE ”OK” LIGHT ON ?

YES

WIRE 47/ORA

OR WIRE 45/GRN

ARE OPEN

KEY OFF

PANEL

DISCONNECTED

CHECK CONTINUITY OF

47/ORA AND 45/GRN TO

GROUND

OPEN

CONTINUITY

--RECONNECT PANEL

--KEY OFF THEN ON

DOES THE ”OK” PANEL

LIGHT COME ON ?

YESNO

RE--TEST

SYSTEM

REPLACE

INSTRUMENT PANEL

ELECTRICAL

5-78 8410 MM392 (8--01)

ELECTRICAL

5-79

8410 MM392 (8--01)

WATER VALVES NOT OPERATING

(SCHEMATIC) OPERATION:

--SCRUB FUNCTIONS MUST

BE ON

--WATER SWITCH IN POSITION #1 TURNS ON

SV--21 LOW WATER VALVE

--WATER SWITCH IN POSITION #2 TURNS ON

SV--21 AND SV--22 (HIGH WATER VALVE)

16E/GRN

1H/RED

13AM/BLK

16E/GRN

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

OFF

25J

/GRY

WATER CONTROL

S--9

OFF

46E/BRN

46D/BRN

SV--22 HIGH

WATER VALVE

SV--21 LOW

WATER VALVE

96/YEL

95/BLU

25B

/GRY

ELECTRICAL

5-80 8410 MM392 (8--01)

TROUBLESHOOT THE

SCRUB FUNCTION FIRST

ACTIVATE THE SCRUB

DOES THE SCRUB BRUSH

TURN ON AND COME DOWN ?

WATER VALVES NOT OPERATING

(FLOW CHART)

PANEL IS POWERED UP

KEY IS ON

ENGINE IS RUNNING

YES

--ENGINE RUNNING

--SCRUB SYSTEM ON

--WATERSWITCHONPOSITION#2

--SV--21, AND SV--22 DISCONNECTED

CHECK FOR VOLTAGE AT SV--21 FROM

96/YEL TO GROUND

CHECK FOR VOLTAGE AT SV--22 FROM

95/BLU TO GROUND

NO VOLTAGE ON ANY

VOLTAGE ON

BOTH SOLENOIDS

--KEY ON, ENGINE OFF

--SOLENOIDS STILL DISCONNECTED

--SCRUB ON

CHECK VOLTAGE AT SV--21 FROM

96/YEL TO 46D/BRN

CHECK VOLTAGE AT SV--22 FROM

95/BLU TO 46E/BRN

NO VOLTAGE ACROSS

EITHER VALVE

VOLTAGE ON

SOLENOIDS

REPLACE ANY VALVE

NOT OPERATING

OPERATION:

--SCRUB FUNCTIONS MUST

BE ON

--WATERSWITCHINPOSITION#1

TURNS ON SV--21 LOW WATER

VALVE

--WATERSWITCHINPOSITION#2

TURNS ON SV--21 AND SV--22

(HIGH WATER VALVE)

96/YEL, 95/BLU, S--9,

25B/GRY, OR 25H/

GRY ARE OPEN

46D/BRN, 46E/BRN, OR

46/BRN IS OPEN

FROM SV--21 AND

SV--22 TO PIN 19

ELECTRICAL

5-81

8410 MM392 (8--01)

RECOVERY TANK FULL LIGHT

WILL NOT TURN ON OR OFF

(SCHEMATIC)

OPERATION:

--IF S--5 CLOSES, THE RECOVERY TANK

IS FULL

--THE RECOVERY TANK LIGHT COMES ON

--SCRUB , SQUEEGEE, AND VACUUM FAN

TURNS OFF

16E/GRN

1H/RED

13AM/BLK

16E/GRN

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

S--5 CLOSED =

13AM/BLK

S--5

5 SEC. DELAY

1 MIN. TO VAC FAN SHUT--OFF

N.C.H.O.

28/YEL

RECOVERY TANK

ELECTRICAL

5-82 8410 MM392 (8--01)

REPLACE INSTR.

PANEL

--DRAIN REC TANK

--TURN ON SCRUB

DOES THE LIGHT TURN OFF ?

DOES THE REC TANK FULL

LIGHT TURN ON

MOMENTARILY AT POWER UP ?

RECOVERY TANK FULL LIGHT

WILL NOT TURN OFF

(FLOW CHART)

RECOVERY TANK FULL LIGHT

WILL NOT TURN ON

(FLOW CHART)

-- P O W E R O F F

--DISCONNECT INSTR. PANEL

DISCONNECT S--5

CHECK CONTINUITY FROM WIRE

28/YEL TO GROUND

IF THE LIGHT IS STILL

NOT TURNING ON MO-

MENTARILY AT POWER

UP----REPLACE THE PANEL

OPERATION:

--IF S--5 CLOSES, THE RECOVERY TANK

IS FULL

--THE RECOVERY TANK LIGHT COMES ON

--SCRUB , SQUEEGEE, AND VACUUM FAN

TURN OFF

YES

REPLACE LAMP L3

INSIDE THE PANEL

DISCONNECT S--5 AND GROUND WIRE

28/YEL DOES THE LIGHT TURN ON ?

YES NO

WIRE 28/YEL IS OPEN

FROM S--5 TO PANEL

(PIN 10)

WHEN RECOVERY TANK

IS FULL, S--5 IS NOT CLOSING

OR 13J/BLK IS OPEN

OPERATION:

--IF S--5 CLOSES, THE RECOVERY TANK

IS FULL

--THE RECOVERY TANK LIGHT COMES ON

--SCRUB , SQUEEGEE, AND VACUUM FAN

TURNS OFF

--SELECTING SQUEEGEE/VAC FAN OR

TURNING KEY OFF, THEN ON WILL TURN

LIGHT OFF IF REC TANK IS NO LONGER

FULL

DISCONNECT S--5

DOES THE LIGHT TURN OFF ?

YES NO

RECOVERYTANKISFULL

SYSTEM OK, OR

S--5 IS SHORTED

OPEN CONTINUITY

WIRE 28/YEL IS

GROUNDED

YES

SYSTEM IS

WORKING

ELECTRICAL

5-83

8410 MM392 (8--01)

DETERGENT METERING

PUMP IS NOT OPERATING

(SCHEMATIC)

OPERATION:

--PANEL DETERGENT BUTTON IS

ACTIVE IN LOW OR HIGH POSITION

--MACHINE IS IN SCRUB MODE

--MACHINE IS NOT IN REVERSE

--DETERGENT PUMP WILL BE TURNED ON

WITH A PULSE WIDTH MODULATED SIGNAL

16E/GRN

1H/RED

13AM/BLK

16E/GRN

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M48685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

REVERSE

CLOSES IN

13AY/BLK

36B/GRN

S--7

36/GRN

REVERSE

FLOW SWITCH

15A

CB--7 23A/GRY 56/ORA 9

MTR

DETERGENT

METERING

ELECTRICAL

5-84 8410 MM392 (8--01)

--TURN KEY OFF, THEN ON

--START THE ENGINE

VERIFY THAT THE SCRUBBING

SYSTEM IS FUNCTIONING

SELECT SCRUB--DOES THE HEAD

LOWER AND BRUSHES TURN ON ?

DISCONNECT DETERGENT

PUMP

--IN MANUAL MODE

--KEY ON, ENGINE OFF

CHECK VOLTAGE AT

PUMP FROM WIRE 23A/

GRY TO 56/ORA

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

DETERGENT METERING

PUMP IS NOT OPERATING

(FLOW CHART)

PANEL IS POWERED UP

KEY IS ON

REPLACE TOUCH

PANEL FACE

STILL DOES

NOT WORK

REPLACE INST.

PANEL

CAN THE DETERGENT

METERING AND TOUCH

PANEL SWITCHES BE

TURNED ON AND OFF ?

YES

DOES THE DETERGENT METERING

PUMP TURN ON AND OFF WITH

THE TOUCH PANEL SWITCH ?

YES

TEST

SCRUB

INPUTS

CHECK VOLTAGE AT DETERGENT

PUMP FROM 23A/GRY TO GROUND

VOLTAGE

NO VOLTAGE

YESNO

TROUBLESHOOT

SCRUB BRUSH

SYSTEM FIRST

NO VOLTAGE

VOLTAGE

(LESS THAN 5 VOLTS)

REPLACE

PUMP

-- P O W E R O F F

--PANEL DISCONNECTED

CHECK CONTINUITY OF 56/ORA

REPLACE INST.

PANEL

OPERATION:

--PANEL DETERGENT BUTTON IS

ACTIVE IN LOW OR HIGH POSITION

--MACHINE IS IN SCRUB MODE

--MACHINE IS NOT IN REVERSE

--DETERGENT PUMP WILL BE TURNED

ON WITH A PULSE WIDTH MODULATED

SIGNAL

23A/GRY, CB--7,

21A/ORA, OR

M4 CONTACTS

ARE OPEN

SYSTEM TESTS GOOD

OPEN TO

GROUND

56/ORA SHORTED

TO GROUND

CONTINUITY

--COILS DISCONNECTED

--TURN KEY OFF, THEN

IS ”OK” LIGHT ON ?

YES

WIRE56/ORAISOPEN

ELECTRICAL

5-85

8410 MM392 (8--01)

EStPUMP NOT WORKING

(SCHEMATIC) OPERATION:

--IF ES IS SELECTED ON PANEL AND

--S--3 AND S--4 CLOSE FOR 10 SECONDS

--THE ES PUMP WILL RUN UNTIL S--3 OR

S--4 OPENS PLUS 40 SECONDS

16E/GRN

1H/RED

13AM/BLK

16E/GRN

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/

ORA

GROUND

LINE

15 AMP

CB--4

S--3&4 CLOSED=

13AL/BLK

S--4 N.C.H.O.

S--3 N.O.H.C.

5 SEC. DELAY

ES PUMP RUNS30 SEC.

327/PUR

26/BRN

RECOVERY

TANK

SOLUTION

TANK

15A

CB--7

MTR

23/GRY 4

57/GRN

ES PUMP

ELECTRICAL

5-86 8410 MM392 (8--01)

26/BRN, 27/PUR, 13AL/BLK,

S--3, OR S--4 ARE OPEN

GO INTO ”INPUT DISPLAY MODE”

THE INPUT CONDITIONS WILL BE DISPLAYED

ON FUEL GAUGE

--TURN OFF THE KEY

--PUSH AND HOLD SQ/VAC BUTTON----HOLD

UNTIL MAINTENANCE LIGHT COMES ON

DISCONNECT INSTRUMENT

PANEL AND CHECK CONTINUITY

OF 57/GRN TO GROUND

23/GRY, CB--7, 21A/ORA,

M4 CONTACT, OR

1F/RED ARE OPEN

GO INTO ”MANUAL MODE”

THE OUTPUTS WILL TURN ON

REGARDLESS OF THE INPUTS

--TURN KEY OFF

--PUSH AND HOLD ”ES” BUTTON

--TURN KEY ON, ENGINE NOT

RUNNING

--KEEP HOLDING ”ES” BUTTON

UNTIL THE MAINTENANCE LIGHT

COMES ON

--RELEASE ”ES” BUTTON

CAN THE ES PUMP TOUCH

PANEL BUTTON BE

TURNED ON/OFF

EStPUMP NOT WORKING

(FLOW CHART)

PANEL IS POWERED UP

KEY IS ON

ENGINE NOT RUNNING

YES REPLACE TOUCH

PANEL FACE

STILL DOES

NOT WORK

REPLACE INST.

PANEL

YES DOES THE ES PUMP TURN

ON AND OFF WITH THE ES

BUTTON IN MANUAL MODE ?

TEST INPUT

TEST OUTPUT

DISCONNECT ES PUMP

CHECK VOLTAGE FROM

23/GRY TO GROUND

NO VOLTAGE

VOLTAGE

OPERATION:

--IF ES IS SELECTED ON PANEL AND

--S--3 AND S--4 CLOSE FOR 10 SECONDS

--THE ES PUMP WILL RUN UNTIL S--3 OR

S--4 OPENS PLUS 40 SECONDS

WITH ES ON AND

MACHINE IN

MANUAL MODE

ES PUMP

DISCONNECTED

CHECK VOLTAGE FROM

23/GRY TO 57/GRN

VOLTAGE

REPLACE MOTOR

NO VOLTAGE

--ES PUMP STILL

DISCONNECTED

--TURN KEY OFF,

THEN ON

-- D O E S T H E ” O K

LIGHT” COME ON ?

YES

57/GRN IS OPEN

REPLACE INST.

PANEL

OPEN

CONTINUITY

WIRE 57/GRN IS

SHORTED TO

GROUND

WITH SOLUTION TANK LOW

(S--3=CLOSED)

AND RECOVERY TANK >1/2 FULL

(S--4 =CLOSED)

DOES THE FAR RIGHT SEGMENT OF

FUEL GAUGE LIGHT ?

YES

SYSTEM TESTS

GOOD

ELECTRICAL

5-87

8410 MM392 (8--01)

OPERATION:

--SWEEP 1 SELECTED ON PANEL

--HOPPER IN DOWN POSITION

--ENGINE SPEED SET ON HIGH

--SV--11 AND SV--5 ARE TURNED ON,

BRUSHES TURN ON AND LOWER

--HOPPER DOOR OPEN WILL SELECT

AUTOMATICALLY

UNSWITCHED

POWER

SWEEP BRUSH WILL NOT TURN ON AND

LOWER WITH SWEEP 1 SELECTED

(SCHEMATIC)

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

CB--8

15 AMP

32A/BLU

1G/RED M5

31A/GRY

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

53/BRN

HOPPER LOCATION

LOW = SWEEP ENABLE

HOPPER DN

N.O.H.C.

CLOSED =

13AT/BLK

39/ORA

35/PUR

34/BRN

SV--5 MAIN SWEEP BRUSH

NORMAL SPEED VALVE

SV--6 MAIN SWEEP BRUSH

LITTER SPEED VALVE

SV--11 MAIN SWEEP BRUSH

DN. VALVE

31M/GRY

31N/GRY

31K/GRY

31/GRY

22/YEL

ELECTRICAL

5-88 8410 MM392 (8--01)

SWEEP BRUSH WILL NOT

TURN ON AND LOWER

WITH SWEEP 1 SELECTED

(FLOW CHART)

WIRE 34/BRN OR

39/ORAISSHORTED

TO GROUND

GO TO HYDRAULIC

TROUBLESHOOTING

FLOW CHART

OPERATION:

--SWEEP 1 SELECTED ON PANEL

--HOPPER IN DOWN POSITION

--ENGINE SPEED SET ON HIGH

--SV--11 AND SV--5 ARE TURNED ON,

BRUSHES TURN ON AND LOWER

--HOPPER DOOR SELECTED AUTOMATICALLY

--KEY OFF

--DISCONNECT PANEL

CHECK CONTINUITY OF 34/BRN

AND 39/ORA TO GROUND

--TURN KEY OFF, THEN ON

DOES OK LIGHT COME

ONANDSTAYON?

REPLACE SV--11 IF HEAD

NOT LOWERING

REPLACE SV--5 IF BRUSHES NOT

SPINNING

-- S V -- 5 A N D S V -- 1 1 S T I L L

DISCONNECTED

CHECK VOLTAGE ACROSS

SV--11 WIRES 31K/GRY AND

34/BRN

CHECK VOLTAGE ACROSS

SV--5 WIRES 31M/GRY AND

39/ORA

--DISCONNECT SV--11 AND

SV--5

CHECK VOLTAGE AT SV--11 WIRE

31K/GRY AND SV--5 WIRE 31M/GRY

53/BRN, HOPPER

LOCATION SWITCH, OR

13AT/BLK ARE OPEN

LOWER HOPPER

RE--TEST

IS HOPPER LIFT LED

BLINKING ON

SWEEP PANEL ?

YES

--PANELS PASS POWER--UP

TESTING

--KEY ON AND ENGINE OFF

CAN SWEEP 1 BE

SELECTED ?

YES

REPLACE PANEL

STILL BLINKING ?

B+

0 VOLTAGE

31K/GRY, 31M/GRY,

31A/GRY, CB--8,

32/BLU, 32A/BLU,

M5 CONTACTS, OR

1G/RED ARE OPEN

B+ ON

BOTH

0 VOLTAGE ONE OR BOTH

YES

WIRE 34/BRN OR

39/ORAISOPEN OPENCONTINUITY

REPLACE PANEL

STILL

DISCONNECTED

ELECTRICAL

5-89

8410 MM392 (8--01)

SWEEP BRUSH WILL NOT

TURN ON AND LOWER

WITH SWEEP 2 SELECTED

SWEEP 1 WORKS

(SCHEMATIC)

OPERATION:

--SCRUB FUNCTION OFF

--SWEEP 2 SELECTED ON PANEL

--HOPPER IN DOWN POSITION

--ENGINE SPEED SET ON HIGH

--SV--11 AND SV--5 ARE TURNED ON, BRUSHES

TURN ON AND LOWER

--HOPPER DOOR SELECTED AUTOMATICALLY

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

CB--8

15 AMP

32A/BLU

1G/RED M5

31A/GRY

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

53/BRN

HOPPER LOCATION

LOW = SWEEP ENABLE

HOPPER DN

N.O.H.C.

CLOSED =

13AT/BLK

39/ORA

35/PUR

34/BRN

SV--5 MAIN SWEEP BRUSH

NORMAL SPEED VALVE

SV--6 MAIN SWEEP BRUSH

LITTER SPEED VALVE

SV--11 MAIN SWEEP BRUSH

DN. VALVE

31M/GRY

31N/GRY

31K/GRY

31/GRY

22/YEL

ELECTRICAL

5-90 8410 MM392 (8--01)

SWEEP BRUSH WILL NOT

TURN ON AND LOWER

WITH SWEEP 2 SELECTED

(FLOW CHART)

--KEY OFF

--DISCONNECT PANEL

CHECK CONTINUITY OF 34/BRN

AND 35/PUR TO GROUND

--TURN KEY OFF, THEN ON

DOES OK LIGHT COME

ONANDSTAYON?

REPLACE SV--11 IF HEAD

NOT LOWERING

REPLACE SV--6 IF BRUSHES NOT

SPINNING

-- S V -- 6 A N D S V -- 1 1 S T I L L

DISCONNECTED

CHECK VOLTAGE ACROSS

SV--11 WIRES 31K/GRY AND

34/BRN

CHECK VOLTAGE ACROSS

SV--6 WIRES 31N/GRY AND

35/PUR

--DISCONNECT SV--11 AND

SV--6

CHECK VOLTAGE AT SV--11 WIRE

31K/GRY AND SV--6 WIRE 31N/GRY

53/BRN, HOPPER

LOCATION SWITCH, OR

13AT/BLK ARE OPEN

LOWER HOPPER

RE--TEST

IS HOPPER LIFT LED

BLINKING ON

SWEEP PANEL ?

YES

--PANELS PASS POWER--UP

TESTING

--KEY ON AND ENGINE OFF

--SCRUB OFF

CAN SWEEP 2

BE SELECTED ?

YES

REPLACE PANEL

STILL BLINKING ?

B+

0 VOLTAGE

31K/GRY, 31N/GRY,

31A/GRY, CB--8,

32/BLU, 32A/BLU,

M5 CONTACTS, OR

1G/RED ARE OPEN

B+ ON

BOTH

0 VOLTAGE ONE OR BOTH

YES

WIRE 34/BRN OR

35/PUR IS OPEN OPENCONTINUITY

REPLACE PANEL

WIRE 34/BRN OR

35/PUR IS SHORTED

OPERATION:

--SCRUB FUNCTION OFF

--SWEEP 2 SELECTED ON PANEL

--HOPPER IN DOWN POSITION

--ENGINE SPEED SET ON HIGH

--SV--11 AND SV--5 ARE TURNED ON, BRUSHES

TURN ON AND LOWER

--HOPPER DOOR SELECTED AUTOMATICALLY

ELECTRICAL

5-91

8410 MM392 (8--01)

SWEEP SIDE BRUSH WILL

NOT TURN ON AND LOWER

(SCHEMATIC)

OPERATION:

--SIDE BRUSH IS SELECTED ON PANEL

--SWEEP 1 OR 2 ARE ON AND WORKING

--PIN 11 OF SWEEP PANEL = GROUND

-- S V -- 1 3 A N D S V -- 1 5 T U R N O N

--SIDE BRUSH TURNS ON AND LOWERS

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M5 86

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

32A/BLU

1G/RED M5

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

53/BRN

HOPPER LOCATION

LOW = SWEEP ENABLE

HOPPER DN

N.O.H.C.

CLOSED =

13AT/BLK

SV--15 SIDE BR.

DOWN VALVE

SV--13 SIDE BR.

ON VALVE

15 AMP

7C/BLU

7B/BLU

33D/ORA

33C/ORA

33/ORA

33A/ORA

CB--9

7D/BLU

7E/BLU

22/YEL

ELECTRICAL

5-92 8410 MM392 (8--01)

CHECK VOLTAGE ACROSS

SV--13 WIRE 33C/ORA

TO 7D/BLU

CHECK VOLTAGE ACROSS

SV--15 WIRE 33D/ORA TO 7E/BLU

REPLACE TOUCH

PANEL FACE--DISCONNECT SV--13 AND

SV--15

CHECK VOLTAGE AT SV--13 WIRE

33C/ORA AND SV--15 WIRE 33D/ORA

TO GROUND

SWEEP SIDE BRUSH WILL

NOT TURN ON AND LOWER

(FLOW CHART)

YES

OPERATION:

--SIDE BRUSH IS SELECTED ON PANEL

--SWEEP 1 OR 2 ARE ON AND WORKING

--PIN 11 OF SWEEP PANEL = GROUND

-- S V -- 1 3 A N D S V -- 1 5 T U R N O N

--SIDE BRUSH TURNS ON AND LOWERS

--BOTH PANELS PASS POWER--UP

TESTING

--SWEEP SYSTEM IS WORKING

--KEY ON AND ENGINE OFF

--SWEEP 1 OR 2 SELECTED ON

CAN SIDE BRUSH

BE SELECTED ON

PANEL?

B+

0 VOLTAGE

33C/ORA, 33D/ORA, 33A/

ORA, 33/ORA, CB--9, 32A/

BLU, M--5 CONTACTS, OR

1G/RED ARE OPEN

B+

0VOLTAGE

REPLACE VALVE SV--13

IF BRUSH NOT TURNING

REPLACE SV--15 IF NOT

LOWERING

STILL NOT WORKING

GO TO HYDRAULIC

TROUBLESHOOTING

FLOW--CHARTS

--TURN KEY OFF, THEN ON

DOES SIDE SWEEP BRUSH

PANEL LED BLINK ?

WIRE 7A/BLU OR

7D/BLU IS OPEN

YES

--KEY OFF

--DISCONNECT PANEL

CHECK CONTINUITY OF 7A/BLU

AND 7D/BLU TO GROUND

REPLACE PANEL

OPEN

CONTINUITY

WIRE 7A/BLU OR 7D/BLU ARE

SHORTED TO GROUND

STILL NOT

WORKING

REPLACE PANEL

ELECTRICAL

5-93

8410 MM392 (8--01)

OPERATION:

--SWEEP 1 OR 2 SELECTED

--SWEEP VACUUM FAN SELECTED

(TURNS ON AUTOMATICALLY WHEN

SWEEP 1 OR 2 SELECTED AND NO

HOPPER THERMAL CONDITION)

--SV--18 IS TURNED ON

SWEEP VACUUM FAN WILL

NOT TURN ON

(SCHEMATIC)

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

CB--8

15 AMP

32A/BLU

1G/RED M5

31A/GRY

50A/ORA

AUXILIARY

ELECTRONIC

INSTR.

PANEL

31/GRY

44/YEL

15 AMP

33/ORA

33A/ORA

CB--9

44A/BRN

33B/ORA

SV--18 VAC FAN

SWEEP VALVE

22/YEL

OPEN AT 155F

13CD/BLK

24B/PUR

24A/PUR

SWITCH

HOPPER THERMAL

S--8

24/PUR

ELECTRICAL

5-94 8410 MM392 (8--01)

--DISCONNECT S--8

--SHORT WIRE 24A/PUR

AT S--8 TO GROUND

DOES HAZARD LIGHT

STOP BLINKING ?

OPERATION:

--SWEEP 1 OR 2 SELECTED

--SWEEP VACUUM FAN SELECTED

(TURNS ON AUTOMATICALLY WHEN

SWEEP 1 OR 2 SELECTED AND NO

HOPPER THERMAL CONDITION)

--SV--18 IS TURNED ON

--KEY OFF

--DISCONNECT PANEL

CHECK CONTINUITY OF 44A/

BRN AND 44/YEL TO GROUND

STILL NOT WORKING

GO TO HYDRAULIC

TROUBLESHOOTING

FLOW--CHARTS

--SELECT SWEEP 1

DOES SWEEP VACUUM FAN

TOUCH PANEL LED LIGHT UP ?

--DISCONNECT SV--18

CHECK VOLTAGE AT SV--18 WIRE

33B/ORA TO GROUND

SWEEP VACUUM FAN WILL

NOT TURN ON

(FLOW CHART)

YES

--SWEEP 1 WORKS (BRUSHES SPIN

AND HEAD LOWERS)

--KEY ON AND ENGINE OFF

B+

0 VOLTAGE

33B/ORA, 33A/ORA,

32A/BLU, CB--9, M5

CONTACTS, OR

1G/RED ARE OPEN

CHECK VOLTAGE AT

SV--18 WIRE 33B/ORA

TO WIRE 44A/BRN

0VOLTAGE

B+

REPLACE SV--18

--SV--18 STILL DISCONNECTED

--TURN KEY OFF, THEN ON

IS THE SWEEP VACUUM LED

BLINKING ?

YES

44A/BRN OR 44/YEL

IS OPEN

REPLACE PANEL

OPEN

CONTINUITY

WIRE 44A/BRN OR

44/YEL IS SHORTED TO GROUND

--PUT SWEEP PANEL IN

”INPUT DISPLAY MODE”

--KEY OFF, HOLD HEADLIGHT

SWITCH, KEY ON

--HOLD HEADLIGHT SWITCH FOR

10 SEC, THEN RELEASE

--SWEEP 1 AND 2 LED’S SHOULD

TURN ON

IS HAZARD LED

BLINKING ?

YES

REPLACE PANEL

YES

S--8 IS OPEN

CHECK CONTINUITY

OF 24/PUR FROM

SWEEP PANEL PIN 3

TO S--8

OPEN

REPAIR 24/PUR

REPLACE PANEL

CONT.

ELECTRICAL

5-95

8410 MM392 (8--01)

SHAKER SYSTEM WILL

NOT TURN ON

(SCHEMATIC)

OPERATION:

--SWEEP AND SWEEP FAN MUST BE OFF

--SHAKE SYSTEM SELECTED ON PANEL

--ONCE ACTIVATED M6 IS TURNED ON FOR 40

SECONDS

--RUNS FOR 15 SECONDS EVERY TIME SWEEP

SYSTEM IS TURNED OFF

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M5 86

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

50A/ORA

AUXILIARY

ELECTRONIC

INSTR.

PANEL

22/YEL

20A/BLU

50C/ORA

M--6

SHAKER RELAY

8685

97/BLU

65B/ORA 13CE/BLK

MTR--3

SHAKER MOTOR

30A/GRY

30/GRY

20A/ BLU

CB--5 87

15 AMP

ELECTRICAL

5-96 8410 MM392 (8--01)

REPLACE TOUCH

PANEL FACE

97/BLU IS

SHORTED TO GROUND

--DISCONNECT PANEL

--KEY OFF

CHECK CONTINUITY OF

97/BLU TO GROUND

SHAKER SYSTEM WILL

NOT TURN ON

(FLOW CHART)

OPERATION:

--SWEEP AND SWEEP FAN MUST BE

OFF

--SHAKE SYSTEM SELECTED ON

PANEL

--ONCE ACTIVATED M6 IS TURNED

ON FOR 40 SECONDS

--RUNS FOR 15 SECONDS EVERY

TIME SWEEP SYSTEM IS TURNED

OFF

--DISCONNECT M--6

CHECK VOLTAGE AT M6 AT PIN 85

WIRE 50C/ORA TO GROUND

YES

--KEY ON AND ENGINE OFF

-- P A N E L S P O W E R U P

--SWEEP AND SWEEP FAN OFF

B+

0 VOLTAGE

CAN SHAKER SYSTEM

BE SELECTED ON PANEL ?

B+

0 VOLTAGE

REPLACE M6 WITH A KNOWN

GOOD RELAY

WORKS

PROBLEM

SOLVED

NOT

WORKING

WIRES 50C/ORA, 50A/ORA,

50B/ORA, M3 CONTACTOR,

22/YEL,CB--3,OR1H/RED

ARE OPEN

CHECK VOLTAGE AT M6

PIN 30 WIRE 65B/ORA

65B/ORA, CB--5,

20A/BLU, OR 20/BLU

ARE OPEN

--RECONNECT M6

CHECK VOLTAGE AT M6

PIN 87 TO GROUND

B+

0 VOLTAGE

CHECK VOLTAGE ACROSS

SHAKER MOTOR

REPLACE MOTOR

B+

0 VOLTAGE

30/GRY, 30A/GRY, OR

13CE/BLK IS OPEN

--DISCONNECT M6

--TURN KEY OFF THEN ON

DOES SHAKER LIGHT BLINK ?

97/BLU IS OPEN

YES

REPLACE PANEL

OPEN

CONTINUITY

STILL NOT

WORKING

REPLACE PANEL

ELECTRICAL

5-97

8410 MM392 (8--01)

HOPPER DIFFERENTIAL

PRESSURE LIGHT ALWAYS ON

(SCHEMATIC)

OPERATION;

--IF THE DIFFERENCE IN AIR PRESSURE ON

BOTH SIDES OF THE SWEEP FILTER EXCEED

20 INCHES OF H20 THE PRESSURE SWITCH

CLOSES

--THE PRESSURE SWITCH CLOSING WILL

SUPPLY A GROUND AT PIN 6 TURNING ON

THE LIGHT

--THIS LIGHT TELLS THE OPERATOR TO RUN

THE SHAKER SYSTEM

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M5 8685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

22/YEL

CN.O.

H2OCLOSED = >20 INCHES

13AU/BLK

6/YEL

HOPPER DIFFERENTIAL PRESSURE

ELECTRICAL

5-98 8410 MM392 (8--01)

RUN THE SHAKER SYSTEM

TWICE

IS THE LIGHT ALWAYS ON ?

HOPPER DIFFERENTIAL

PRESSURE SWITCH ALWAYS ON

(FLOW CHART)

YES

OPERATION;

--IF THE DIFFERENCE IN AIR PRESSURE ON

BOTH SIDES OF THE SWEEP FILTER EXCEED

20 INCHES OF H20 THE PRESSURE SWITCH

CLOSES

--THE PRESSURE SWITCH CLOSING WILL

SUPPLY A GROUND AT PIN 6 TURNING ON

THE LIGHT

--THIS LIGHT TELLS THE OPERATOR TO RUN

THE SHAKER SYSTEM

--KEY ON

--ENGINE OFF

FILTER MAY NEED TO

BE REPLACED SOON

DISCONNECT DIFFERENTIAL

PRESSURE SWITCH

IS THE LIGHT STILL ON ?

YES

MACHINE OFF

TAKE AN OHM READING

AT PRESSURE SWITCH

IS IT OPEN ?

YES

REPLACE DIFFERENTIAL

PRESSURE SWITCH

REPLACE THE FILTER

IS THE LIGHT STILL

ALWAYS ON ?

YESNO

REPLACE DIFFERENTIAL

PRESSURE SWITCH

FILTER WAS CLOGGED

--KEY OFF

--PANEL DISCONNECTED

CHECK CONTINUITY OF

6/YEL TO GROUND

OPEN

REPLACE THE PANEL

CONTINUITY

6/YEL IS SHORTED

TO GROUND

ELECTRICAL

5-99

8410 MM392 (8--01)

HOPPER DIFFERENTIAL

PRESSURE SWITCH ALWAYS OFF

(SCHEMATIC)

OPERATION;

--IF THE DIFFERENCE IN AIR PRESSURE ON

BOTH SIDES OF THE SWEEP FILTER EXCEED

20 INCHES OF H20 THE PRESSURE SWITCH

CLOSES

--THE PRESSURE SWITCH CLOSING WILL

SUPPLY A GROUND AT PIN 6 TURNING ON

THE LIGHT

--THIS LIGHT TELLS THE OPERATOR TO RUN

THE SHAKER SYSTEM

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

22/YEL

CN.O.

H2OCLOSED = >20 INCHES

13AU/BLK

6/YEL

HOPPER DIFFERENTIAL PRESSURE

ELECTRICAL

5-100 8410 MM392 (8--01)

REPLACE DIFF. PRESSURE

SWITCH IF AIR PRESSURE

DIFFERENCE EXCEEDS 20

INCH. 0F H2O

HOPPER DIFFERENTIAL

PRESSURE LIGHT ALWAYS OFF

(FLOW CHART)

YES

OPERATION;

--IF THE DIFFERENCE IN AIR PRESSURE ON

BOTH SIDES OF THE SWEEP FILTER EXCEED

20 INCHES OF H20 THE PRESSURE SWITCH

CLOSES

--THE PRESSURE SWITCH CLOSING WILL

SUPPLY A GROUND AT PIN 6 TURNING ON

THE LIGHT

--THIS LIGHT TELLS THE OPERATOR TO RUN

THE SHAKER SYSTEM

--KEY ON

--ENGINE OFF

DISCONNECT DIFFERENTIAL

PRESSURE SWITCH AND

GROUND WIRE 6/YEL

DOES THE LIGHT TURN ON ?

REPLACE THE PANEL

DOES THE LIGHT COME ON

MOMENTARILY AT POWER UP ?

WIRE 6/YEL

IS OPEN

REPLACE LAMP L5

INSIDE THE PANEL

THEN RE--TEST

DOES THE LIGHT

TURN ON MOMENTARILY

AT POWER UP ?

LIGHT STILL OFF

ELECTRICAL

5-101

8410 MM392 (8--01)

HOPPER THERMAL SENTRY

LIGHT ALWAYS ON

(SCHEMATIC)

OPERATION:

--HOPPER TEMPERATURE EXCEEDS 155_F

--S--8 OPENS

--HOPPER THERMAL SENTRY LIGHT TURNS

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

50A/ORA

AUXILIARY

ELECTRONIC

INSTR.

PANEL

22/YEL

OPEN AT 155F 13CD/BLK

24B/PUR

24A/PUR SWITCH

HOPPER THERMAL

S--8

24/PUR

13AC/BLK

13AB/BLK

HOPPER

THERMAL

SENSE

3LOW = SW.FAN ENABLE

24A/PUR

ELECTRICAL

5-102 8410 MM392 (8--01)

REPAIR 24/PUR

AND 24B/PUR

RE--TEST

--KEY OFF

--DISCONNECT PANEL

CHECK CONTINUITY OF

24/PUR AND 24B/PUR

HOPPER THERMAL SENTRY

LIGHT ALWAYS ON

(FLOW CHART)

YES

--KEY ON

--ENGINE OFF

OPERATION:

--HOPPER TEMPERATURE EXCEEDS 155_F

--S--8 OPENS

--HOPPER THERMAL SENTRY LIGHT TURNS

--DISCONNECT S--8

--GROUND 24B/PUR

DOES LIGHT TURN OFF ?

CHECK CONTINUITY

OF S--8

OPEN

CONTINUITY

REPLACE S--8

WIRE 13CD/BLK IS

OPEN TO MACHINE

GROUND

OPEN

CONTINUITY

REPLACE THE PANEL

ELECTRICAL

5-103

8410 MM392 (8--01)

HOPPER THERMAL SENTRY

LIGHT ALWAYS OFF

(SCHEMATIC)

OPERATION:

--HOPPER TEMPERATURE EXCEEDS 155_F

--S--8 OPENS

--HOPPER THERMAL SENTRY LIGHT TURNS

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/ GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M5 8685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

1FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

50A/ORA

AUXILIARY

ELECTRONIC

INSTR.

PANEL

22/YEL

OPEN AT 155F 13CD/BLK

24B/PUR

24A/PUR SWITCH

HOPPER THERMAL

S--8

24/PUR

13AC/BLK

13AB/BLK

HOPPER

THERMAL

SENSE

3LOW = SW.FAN ENABLE

24A/PUR

ELECTRICAL

5-104 8410 MM392 (8--01)

CHECK CONTINUITY OF

24/PUR AND 24A/PUR

TO GROUND

HOPPER THERMAL SENTRY

LIGHT ALWAYS OFF

(FLOW CHART)

OPERATION:

--HOPPER TEMPERATURE EXCEEDS 155_F

--S--8 OPENS

--HOPPER THERMAL SENTRY LIGHT TURNS

YES

--KEY ON

--ENGINE OFF

DISCONNECT S--8

DOES THE PANEL LIGHT

TURN ON ?

YES

REPLACE THE PANEL

DOES THE LIGHT COME ON

MOMENTARILY AT POWER UP ?

REPLACE LAMP L4

INSIDE THE PANEL

THEN RE--TEST

DOES THE LIGHT

TURN ON MOMENTARILY

AT POWER UP ?

REPLACE SWITCH

S--8

CONTINUITY

OPEN

REPLACE THE PANEL

24/PUR AND 24A/PUR

ARE SHORTED TO

GROUND

ELECTRICAL

5-105

8410 MM392 (8--01)

HOPPER WILL NOT LIFT

(SCHEMATIC)

OPERATION:

--HOLDING MOMENTARY HOPPER

LIFT SWITCH ON TOUCH PANEL

WILL:

-- T U R N O N S V -- 8

NOTE: IF SWEEP IS SELECTED

WHEN HOPPER IS UP, THE LIFT

LIGHT WILL BLINK AND SWEEP WILL

BE TURNED OFF AUTOMATICALLY

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M5 86

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

CB--8

15 AMP

32A/BLU

1G/RED M5

31A/GRY

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

22/YEL

37/YEL 18

SV--8 HOPPER UP

VALVE

31F/GRY

ELECTRICAL

5-106 8410 MM392 (8--01)

--DISCONNECT PANEL

CHECK CONTINUITY OF

37/YEL TO GROUND

HOPPER WILL NOT LIFT

(FLOW CHART)

OPERATION:

--HOLDING MOMENTARY HOPPER

LIFT SWITCH ON TOUCH PANEL

WILL:

-- T U R N O N S V -- 8

NOTE: IF SWEEP IS SELECTED

WHEN HOPPER IS UP, THE LIFT

LIGHT WILL BLINK AND SWEEP WILL

BE TURNED OFF AUTOMATICALLY

YES

--KEY ON AND ENGINE OFF

-- P A N E L S P O W E R U P

B+

0 VOLTAGE

REPLACE PANEL

CAN THE HOPPER LIFT

LEDONTHEPANELBE

TURNED ON ?

--DISCONNECT SV--8

CHECK VOLTAGE ON 31F/

GRY AT SV--8 TO GROUND

31F/GRY, 31A/GRY, CB--8,

32/BLU, M5 CONTACT,

OR 1G/RED ARE OPEN

WITH SV--8 DISCONNECTED

CHECK VOLTAGE ON 31F/GRY

TO 37/YEL WHILE HOLDING

HOPPER LIFT BUTTON

0 VOLTAGE

--TURN KEY OFF, THEN ON

IS HOPPER LIFT LIGHT

BLINKING ?

37/YEL IS OPEN

YES

OPEN

CONTINUITY

REPLACE PANEL

WIRE 37/YEL IS

SHORTED TO

GROUND

B+

REPLACE SV--8

STILL NOT WORKING

SEE HYDRAULIC

TROUBLESHOOTING

FLOW CHART

ELECTRICAL

5-107

8410 MM392 (8--01)

HOPPER WILL NOT LOWER

(SCHEMATIC)

OPERATION:

--HOLDING MOMENTARY HOPPER

LOWERSWITCHONTOUCHPANEL

WILL:

-- T U R N O N S V -- 9

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M58685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

CB--8

15 AMP

32A/BLU

1G/RED M5

31A/GRY

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

22/YEL

SV--9 HOPPER

31G/GRY 38/GRN

DOWN VALVE

ELECTRICAL

5-108 8410 MM392 (8--01)

--DISCONNECT PANEL

CHECK CONTINUITY OF

38/GRN TO GROUND

HOPPER WILL NOT LOWER

(FLOW CHART)

OPERATION:

--HOLDING MOMENTARY HOPPER

LOWERSWITCHONTOUCHPANEL

WILL:

-- T U R N O N S V -- 9

YES

--KEY ON AND ENGINE OFF

-- P A N E L S P O W E R U P

B+

0 VOLTAGE

REPLACE PANEL

CAN THE HOPPER LOWER

LEDONTHEPANELBE

TURNED ON ?

--DISCONNECT SV--9

CHECK VOLTAGE ON 31G/

GRY AT SV--9 TO GROUND

31G/GRY, 31A/GRY, CB--8,

32/BLU, M5 CONTACT, OR

1G/RED ARE OPEN

WITH SV--9 DISCONNECTED

CHECK VOLTAGE ON 31G/GRY

TO 38/GRN WHILE HOLDING

HOPPER LOWER BUTTON

0 VOLTAGE

--TURN KEY OFF, THEN ON

IS HOPPER LOWER LIGHT

BLINKING ?

38/GRN IS OPEN

YES

OPEN

CONTINUITY

REPLACE PANEL

WIRE 38/GRN IS

SHORTED TO

GROUND

B+

REPLACE SV--9

STILL NOT WORKING

SEE HYDRAULIC

TROUBLESHOOTING

FLOW CHART

ELECTRICAL

5-109

8410 MM392 (8--01)

HOPPER DOOR WILL NOT

(SCHEMATIC)

OPERATION:

--HOPPER DOOR CLOSE IS SELECTED ON PANEL

--SV--16 IS TURNED ON MOMENTARILY

--HOPPER DOOR IS CLOSED

NOTE: HOPPER DOOR CLOSED IS SELECTED AUTOMATI-

CALLY AT POWER UP AND WHEN SWEEP IS TURNED OFF

--DOOR CLOSES FOR 8 SECONDS IN LOW ENGINE SPEED

--DOOR CLOSES FOR 3 SECONDS IN HIGH ENGINE SPEED

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M586

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

32A/BLU

1G/RED M5

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

15 AMP 33/ORA

33A/ORA

CB--9

22/YEL

41/PUR

33E/ORA 41A/PUR

SV--16 HOPPER

CLOSE VALVE

ELECTRICAL

5-110 8410 MM392 (8--01)

WITH SV--16 DISCONNECTED

CHECK VOLTAGE ACROSS

SV--16 CONNECTOR WIRES

33E/ORA TO 41A/PUR

--TURN HOPPER DOOR CLOSE

OFF, THEN ON

33E/ORA, 33A/ORA, 33/ORA

CB--9, 32A/BLU, M5 CONTACTS,

OR 1G/RED IS OPEN

STILL NOT WORKING

SEE HYDRAULIC

TROUBLESHOOTING

FLOW CHART

--DISCONNECT PANEL

CHECK CONTINUITY OF

41/PUR TO GROUND

HOPPER DOOR WILL NOT

(FLOW CHART)

OPERATION:

--HOPPER DOOR CLOSE IS SELECTED

ON PANEL

--SV--16 IS TURNED ON MOMENTARILY

--HOPPER DOOR IS CLOSED

NOTE: HOPPER DOOR CLOSED IS SE-

LECTED AUTOMATICALLY AT POWER

UP AND WHEN SWEEP IS TURNED

OFF

--DOOR CLOSES FOR 8 SECONDS IN

LOW ENGINE SPEED

--DOOR CLOSES FOR 3 SECONDS IN

HIGH ENGINE SPEED

YES

--KEY ON AND ENGINE OFF

-- P A N E L S P O W E R U P

B+

0 VOLTAGE

REPLACE PANEL

CAN THE HOPPER DOOR

CLOSED BE SELECTED

ON THE PANEL ?

--DISCONNECT SV--16

CHECK VOLTAGE ON 33E/ORA

AT SV--16 TO GROUND

0 VOLTAGE

--TURN KEY OFF, THEN ON

IS HOPPER DOOR CLOSE

LIGHT BLINKING ?

41/PUR IS OPEN

YES

OPEN

CONTINUITY

REPLACE PANEL

WIRE 41/PUR IS

SHORTED TO

GROUND

B+

REPLACE SV--16

ELECTRICAL

5-111

8410 MM392 (8--01)

HOPPER DOOR WILL NOT

OPEN

(SCHEMATIC)

OPERATION:

--HOPPER DOOR CLOSE IS TURNED OFF ON PANEL

--SV--17 IS TURNED ON MOMENTARILY

--HOPPER DOOR IS OPENED

NOTE: HOPPER DOOR OPEN IS SELECTED AUTOMATI-

CALLY WHEN SWEEP IS TURNED ON

--DOOR OPENS FOR 8 SECONDS IN LOW ENGINE SPEED

--DOOR OPENS FOR 3 SECONDS IN HIGH ENGINE SPEED

UNSWITCHED

POWER

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19A/BLU

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

M586

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730M3

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1G/RED

32A/BLU

1G/RED M5

50A/ORA AUXILIARY

ELECTRONIC

INSTR.

PANEL

15 AMP 33/ORA

33A/ORA

CB--9

22/YEL

40/BRN

SV--17 HOPPER

OPEN VALVE

33F/ORA 40A/BRN

ELECTRICAL

5-112 8410 MM392 (8--01)

WITH SV--17 DISCONNECTED

CHECK VOLTAGE ACROSS

SV--17 CONNECTOR WIRES

33F/ORA TO 40A/BRN

--TURN HOPPER DOOR CLOSE

ON, THEN OFF

33F/ORA, 33A/ORA, 33/ORA

CB--9, 32A/BLU, M5 CONTACTS,

OR 1G/RED IS OPEN

STILL NOT WORKING

SEE HYDRAULIC

TROUBLESHOOTING

FLOW CHART

--DISCONNECT PANEL

CHECK CONTINUITY OF

40/BRN TO GROUND

HOPPER DOOR WILL NOT

OPEN

(FLOW CHART)

OPERATION:

--HOPPER DOOR CLOSE IS TURNED OFF

ON PANEL

--SV--17 IS TURNED ON MOMENTARILY

--HOPPER DOOR IS OPENED

NOTE: HOPPER DOOR OPEN IS SELECTED

AUTOMATICALLY WHEN SWEEP IS

TURNED ON

--DOOR OPENS FOR 8 SECONDS IN LOW

ENGINE SPEED

--DOOR OPENS FOR 3 SECONDS IN HIGH

ENGINE SPEED

YES

--KEY ON AND ENGINE OFF

-- P A N E L S P O W E R U P

B+

0 VOLTAGE

REPLACE PANEL

CAN THE HOPPER DOOR

CLOSED BE TURNED OFF

ON THE TOUCH PANEL ?

--DISCONNECT SV--17

CHECK VOLTAGE ON 33F/ORA

AT SV--17 TO GROUND

0 VOLTAGE

--TURN KEY OFF, THEN ON

IS HOPPER DOOR CLOSE

LIGHT BLINKING ?

40/BRN IS OPEN

YES

OPEN

CONTINUITY

REPLACE PANEL

WIRE 40/BRN IS

SHORTED TO

GROUND

B+

REPLACE SV--17

ELECTRICAL

5-113

8410 MM392 (8--01)

OPERATION:

--HIGH ENGINE SPEED SELECTED

--ENGINE SPEED IS SENSED ON SWEEP

PANEL WHEN PIN 15 IS LESS THEN 1 VDC

--PIN17ISPULLEDLOW

--SV--2 TURNS ON

ENGINE COOLING FAN NOT

OPERATING

(SCHEMATIC)

16E/GRN

1H/RED 13AM/BLK

16E/GRN

16F/

GRN

19C/BLU

19B/BLU

19A/BLU

1F/RED 21A/ORA

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

30 87

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M5 86

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

25A/GRY

25/GRY

21/ ORA

GROUND

LINE

15 AMP

CB--4

50A/ORA

AUXILIARY

ELECTRONIC

INSTRUMENT

PANEL

13AG/BLK

13AF/BLK

SV--2 ENG. FAN

VALVE 49/GRN 17

25E/GRY

83B/BRN

FEDC

GOVERNOR CONTROL

ENG. SPEED SENSE

15 83A/BRN

ELECTRICAL

5-114 8410 MM392 (8--01)

REPLACE SWEEP

PANEL

--KEY OFF

--PANEL DISCONNECTED

CHECK CONTINUITY FROM

49/GRN TO GROUND

--TURN KEY OFF, THEN ON

DOES THE SWEEP VAC

FAN LIGHT BLINK ?

(NOT BLINKING)

STILL NO FAN ?

GO TO HYDRAULIC

TROUBLESHOOTING

FLOW--CHARTS

--SELECT ”HIGH” ENGINE

SPEED

CHECK VOLTAGE ACROSS

SV--2 WIRES 25E/GRY AND

49/GRN

OPERATION:

--HIGH ENGINE SPEED SELECTED

--ENGINE SPEED IS SENSED ON

SWEEP PANEL WHEN PIN 15 IS LESS

THEN 1 VDC

--PIN17ISPULLEDLOW

--SV--2 TURNS ON

--DISCONNECT SV--2

CHECK VOLTAGE AT SV--2 WIRE

25E/GRY TO GROUND

ENGINE COOLING FAN NOT

OPERATING

(FLOW CHART)

YES

--KEY ON AND ENGINE OFF

-- P A N E L S P O W E R U P

REPLACE PANEL

B+

0 VOLTAGE

CAN ENGINE SPEED ”HIGH”

BE SELECTED ON PANEL ?

25E/GRY, 25A/GRY, CB--4,

21/ORA, 21A/ORA, M4

CONTACTS, OR IF/RED

ARE OPEN

B+

0VOLTAGE

REPLACE SV--2

YES

OPEN

CONTINUITY

WIRE 49/GRN IS

SHORTED TO GROUND

REPLACE PANEL

SV--2 STILL

DISCONNECTED

PUT SWEEP PANEL INTO

”INPUT DISPLAY MODE”

--TURN KEY OFF, HOLD HEADLIGHT BUTTON,

TURN KEY ON

--HOLD HEADLIGHT BUTTON FOR 10 SECONDS

THEN RELEASE

--SWEEP 1 AND 2 LED’S WILL BE ON

IS HEADLIGHT LED BLINKING

WHEN HIGH ENGINE SPEED

IS SELECTED

YES

49/GRN IS OPEN

--DISCONNECT PANELS

CHECK CONTINUITY OF 83/BRN

FROM SCRUB PANEL PIN 17 TO

SWEEP PANEL PIN 15

OPEN

REPAIR 83/BRN

CONTINUITY

IS ENGINE SPEED CHANGING

WHEN SELECTED ON SCRUB

PANEL ?

GO TO GOVERNOR

TROUBLESHOOTING

YES

ELECTRICAL

5-115

8410 MM392 (8--01)

ENGINE OIL PRESSURE WARNING

LIGHT WILL NOT TURN ON OR OFF

(SCHEMATIC)

OPERATION:

--(PIN 15) IS PULLED TO GROUND THROUGH

S--2 WHEN OIL PRESSURE IS HIGH ENOUGH

--OIL LIGHT TURNS OFF

16E/GRN

1H/RED

13AM/BLK

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M48685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

CLOSED = RUN

13BA/BLK

13BJ/BLK

8685

87A

SV--14

16/GRN

15B/BLU

15A/BLU S--2 OIL SWITCH

16A/GRN

16B/GRN

3/ORA

14/GRN

FUEL PUMP

15 15/ BLU

ELECTRICAL

5-116 8410 MM392 (8--01)

ENGINE OIL PRESSURE WARNING

LIGHT WILL NOT TURN OFF

(FLOW CHART)

ENGINE OIL PRESSURE WARNING

LIGHT WILL NOT TURN ON

(FLOW CHART)

(PIN 15) IS GROUNDED

CHECK OIL PRESSURE

SWITCH OPERATION

DOES OIL LIGHT TURN

ON MOMENTARILY AT

POWER UP ?

YES

REPLACE LAMP L1

INSIDE PANEL

STILL NOT TURNING

ON AT POWER UP

REPLACE INSTR. PANEL

DISCONNECT OIL PRESSURE

SWITCH S--4

GROUND WIRE 15/BLU

DOES LIGHT SHUT OFF ?

YES

KEY ON

ENGINE OFF

REPLACE OIL PRESSURE LIGHT

WIRE 15/BLU IS OPEN

FROM OIL PRES-

SURE SWITCH TO

(PIN 15)

OPERATION:

--(PIN 15) IS PULLED TO GROUND THROUGH

S--2 WHEN OIL PRESSURE IS HIGH ENOUGH

--OIL LIGHT TURNS OFF

OPERATION:

--(PIN 15) IS PULLED TO GROUND THROUGH

S--2 WHEN OIL PRESSURE IS HIGH ENOUGH

--OIL LIGHT TURNS OFF

ELECTRICAL

5-117

8410 MM392 (8--01)

ENGINE TEMPERATURE LIGHT

WILL NOT TURN ON OR OFF

(SCHEMATIC)

OPERATION:

--WHEN ENGINE COOLANT EXCEEDS

225 DEGREE F. SE--2 =<80 OHMS

--COOLANT LIGHT TURNS ON

16E/GRN

1H/RED

13AM/BLK

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

5N.C.H.O.

43/BLU

CLOSES AT225°F

COOLANT TEMP

SENDER

SE--2

ELECTRICAL

5-118 8410 MM392 (8--01)

ENGINE TEMPERATURE LIGHT

WILL NOT TURN ON

(FLOW CHART)

OPERATION:

--WHEN ENGINE COOLANT EXCEEDS

225 DEGREE F. SE--2 =<80 OHMS

--COOLANT LIGHT TURNS ON

DOES THE LIGHT TURN

ON MOMENTARILY AT POWER UP ?

YES

REPLACE LAMP L2

INSIDE PANEL

RETEST

REPLACE INSTR. PANEL

STILL NOT

TURNING ON AT

POWER UP

DISCONNECT SE--2 AND GROUND

WIRE 43/BLU

DOES LIGHT TURN ON ?

YES

WIRE 43/BLU IS

OPEN FROM (PIN 5) TO SE--2

IF ENGINE TEMP IS GREATER

THAN 225 DEGREES

REPLACE SE--2

SYSTEM IS OK

ENGINE TEMPERATURE LIGHT

WILL NOT TURN OFF

(FLOW CHART)

KEY ON

ENGINE OFF

DISCONNECT SE--2

LIGHT STILL ON

LIGHT TURNS OFF

POWER OFF

DISCONNECT PANEL

DISCONNECT SE--2

CHECK CONTINUITY

43/BLU TO GROUND

OPEN

CONTINUITY

REPLACE INSTR. PANEL

WIRE 43/BLU IS

GROUNDED

IF ENGINE TEMP IS LESS

THAN 225 DEGREES

REPLACE SE--2

SYSTEM IS OK

OPERATION:

--WHEN ENGINE COOLANT EXCEEDS

225 DEGREE F. SE--2 =<80 OHMS

--COOLANT LIGHT TURNS ON

ELECTRICAL

5-119

8410 MM392 (8--01)

ALTERNATOR / BATTERY WARNING

LIGHT WILL NOT TURN ON

(SCHEMATIC)

OPERATION:

--CONNECTION L2 ON ALTERNATOR

GOES TO BATTERY POSITIVE WHEN ALTER-

NATOR IS TURNED ON

--BATTERY POSITIVE AT (PIN 14) TURNS OFF

THE ALTERNATOR / BATTERY INDICATOR

16E/GRN

1H/RED

13AM/BLK

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/

YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

8685

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

2/ ORA

1B/RED

1A/RED

55A MAX.

CHARGE

2/ORA

SENSE

13A/BLK

ALTERNATOR

GNDOUT

ELECTRICAL

5-120 8410 MM392 (8--01)

ALTERNATOR IS SHORTED

L2 TO BATTERY POSITIVE

OR WIRE 2/ORA IS SHORTED

TO BATTERY POSITIVE

ALTERNATOR / BATTERY WARNING

LIGHT WILL NOT TURN ON

(FLOW CHART)

OPERATION:

--CONNECTION L2 ON ALTERNATOR

GOES TO BATTERY POSITIVE WHEN ALTER-

NATOR 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

OPEN

REPAIR AND REPLACE

2/ORA

CONTINUITY

REPLACE LAMP L8

INSIDE THE PANEL

CHECK CONTINUITY 2/ORA

FROM ALTERNATOR TO

(PIN 14)

ELECTRICAL

5-121

8410 MM392 (8--01)

ALTERNATOR / BATTERY WARNING LIGHT

STAYS ON WHEN ENGINE IS RUNNING

(SCHEMATIC)

OPERATION:

--CONNECTION L2 ON ALTERNATOR

GOES TO BATTERY POSITIVE WHEN ALTER-

NATOR IS TURNED ON

--BATTERY POSITIVE AT (PIN 14) TURNS OFF

THE ALTERNATOR / BATTERY INDICATOR

16E/GRN

1H/RED

13AM/BLK

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/

YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

2/ ORA

1B/RED

1A/RED

55A MAX.

CHARGE

2/ORA

SENSE

13A/BLK

ALTERNATOR

GNDOUT

ELECTRICAL

5-122 8410 MM392 (8--01)

DISCONNECT INSTR.

PANEL, THEN RECONNECT

IF LIGHT STILL ON----REPLACE

INSTR. PANEL

WIRE 2/ORA IS

SHORTED TO BATTERY

POSITIVE

--ENGINE RUNNING

--PANEL DISCONNECTED

CHECK VOLTAGE OF WIRE

2/ORA AT (PIN 14) OF INSTR.

PANEL

DISCONNECT WIRE 2/ORA

AT THE ALTERNATOR

TOUCH WIRE 2/ORA TO WIRE 1B/RED

AT THE ALTERNATOR

DOES THE ALTERNATOR LIGHT TURN

OFF ?

ALTERNATOR / BATTERY WARNING LIGHT

STAYS ON WHEN ENGINE IS RUNNING

(FLOW CHART)

OPERATION:

--CONNECTION L2 ON ALTERNATOR

GOES TO BATTERY POSITIVE WHEN ALTER-

NATOR 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

KEY ON

ENGINE OFF

YES

TIGHTEN ALTERNATOR BELT

IF NECESSARY

REPLACE ALTERNATOR

DOES LIGHT TURN OFF ?

VOLTAGE

NO VOLTAGE

WIRE2/ORAISOPEN

ELECTRICAL

5-123

8410 MM392 (8--01)

FUEL GAUGE NOT OPERATING

(GAS AND DIESEL)

(SCHEMATIC)

OPERATION:

--SE--1 GREATER THE 90 OHMS=FULL TANK

--SE--1 LESS THAN 10 OHMS=EMPTY TANK

-- N O T E ; I F S E -- 1 >500OHMS OR <10 OHMS AT

POWERUPTHEPANELGOESTOLPMODE

(NO LIGHTS FOR FULL, 2 LIGHTS FOR EMPTY)

16E/GRN

1H/RED

13AM/BLK

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

85M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1A/RED

96 OHM = FULL

13BH/BLK

42B/YEL42/YEL

GAS--DIESEL

FUEL SENDER

SE--1

ELECTRICAL

5-124 8410 MM392 (8--01)

--SE--1 STILL DISCONNECTED

--DISCONNECT THE PANEL

--TURN KEY OFF

CHECK THE CONTINUITY OF

42/YEL TO GROUND AND B+

--KEY OFF

--DISCONNECT 42B/YEL AT SE--1

--CHECK OHMS AT SE--1,

90 OHMS = TANK FULL

50 OHMS = 1/2 FULL

10 OHMS = EMPTY

FUEL GAUGE NOT OPERATING

(GAS AND DIESEL)

(FLOW CHART)

OPERATION:

--SE--1 GREATER THE 90 OHMS=FULL TANK

--SE--1 LESS THAN 10 OHMS=EMPTY TANK

-- N O T E ; I F S E -- 1 >500OHMS OR <10 OHMS AT

POWERUPTHEPANELGOESTOLPMODE

(NO LIGHTS FOR FULL, 2 LIGHTS FOR EMPTY)

YES

KEY ON

ENGINE OFF

FUEL TANK >

1/2 FULL

DO ANY OF THE FUEL

LIGHTS TURN ON ?

ARE THE LEFT 2

SEGMENTS FLASHING ?

MORE THAN

2LIGHTS

YES

IF THE GAUGE IS WORKING

BUT INACCURATE

--REPLACE THE FLOAT

--NOTE; 90 OHMS = FULL

10 OHMS = EMPTY

STILL

INACCURATE

REPLACE PANEL

BAD OHM

READINGS

REPLACE FUEL

TANK FLOAT

GOOD OHM

READINGS

OPEN

REPLACE PANEL

CONTINUITY

42/YEL IS SHORTED

TO GROUND

ELECTRICAL

5-125

8410 MM392 (8--01)

OPERATION:

--S--6ISOPEN=GAUGEISOFF

--S--6 IS CLOSED = LEFT 2 SEGMENTS OF

GAUGE FLASH

--SE--1 IS NOT ON MACHINE

-- N O T E ; I F S E -- 1 >500OHMS OR <10 OHMS AT

POWERUPTHEPANELGOESTOLPMODE

(NO LIGHTS FOR FULL, 2 LIGHTS FOR EMPTY)

FUEL GAUGE (LPG)

(SCHEMATIC)

16E/GRN

1H/RED

13AM/BLK

19B/BLU

19A/BLU

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCHS--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

85 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

1A/RED

CLOSES BELOW

70 PSI

13AQ/BLK

42A/YEL

42/YEL

N.C.H.O.

S--6 C

ELECTRICAL

5-126 8410 MM392 (8--01)

REPAIR 42 /YEL

AND 42A/YEL

FUEL GAUGE (LPG)

(FLOW CHART)

42/YEL AND 42A/YEL

ARE SHORTED

TO GROUND

-- P O W E R O F F

--DISCONNECT PANEL

--DISCONNECT S--6

CHECK CONTINUITY OF 42/YEL

AND 42A/YEL TO GROUND

-- P O W E R O F F

CHECK CONTINUITY OF 42/YEL

AND 42A/YEL FROM S--6 TO PANEL

(PIN 13)

IF SYSTEM IS NOT

WORKING PROPERLY----

REPLACE S--6

GROUND 42A/YEL AT S--6

IS GAUGE FLASHING ?

YES

KEY ON

ENGINE OFF

DISCONNECT S--6

IS GAUGE OFF ?

YES

OPEN CONTINUITY

REPLACE INSTR.

PANEL

CONTINUITY

OPEN

REPLACE INSTR.

PANEL

OPERATION:

--S--6ISOPEN=GAUGEISOFF

--S--6 IS CLOSED = LEFT 2 SEGMENTS OF

GAUGE FLASH

--SE--1 IS NOT ON MACHINE

-- N O T E ; I F S E -- 1 >500OHMS OR <10 OHMS AT

POWERUPTHEPANELGOESTOLPMODE

(NO LIGHTS FOR FULL, 2 LIGHTS FOR EMPTY)

2 SEGMENTS ON

ELECTRICAL

5-127

8410 MM392 (8--01)

OPERATION:

--HEADLIGHT SWITCH IS SELECTED

ON PANEL

--M7 IS TURNED ON

--CONTACT OF M7 SUPPLIES VOLTAGE

TO HEADLIGHTS

HEAD LIGHTS WILL NOT TURN ON

(SCHEMATIC)

16E/GRN

1H/RED 13AM/BLK

50A/ORA

50B/ORA

16C/GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

CB--3

19/BLU

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U RUN/ACC

1/RED

FRONT

15A

8730

8685M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

AUXILIARY

ELECTRONIC

INSTR.

PANEL

22/YEL

17/ORA

LIGHTS ON

20A/BLU

50D/ORA

50A/ORA

17B/ORA

HEADLIGHT RELAY

85 M--7

R.H.HEADLIGHT

62C/YEL 62F/YEL

62G/YEL

13CB/BLK

13CG/BLK

62D/YEL

HEADLIGHT L.H.

87/PUR

59/BRN

20B/BLU

8730 62/YEL

CB--6

15 AMP

17A

ORA

ELECTRICAL

5-128 8410 MM392 (8--01)

--DISCONNECT INSTRUMENT

PANEL

CHECK CONTINUITY OF

17/ORA TO GROUND

--REMOVE M7

--SELECT HEADLIGHTS

--TURN KEY OFF THEN ON

IS THE HEADLIGHT LED

FLASHING ?

--REPLACE M7

--KEY ON

--ENGINE OFF

--HEADLIGHTS SELECTED

CHECK VOLTAGE ON PIN 87 OF

M7, WIRE 62/YEL TO GROUND

-- R E M O V E M -- 7

--KEY ON

--ENGINE OFF

--HEADLIGHTS SELECTED

CHECK FOR VOLTAGE ON PIN 85 OF

M--7 (WIRE 50D/ORA) TO GROUND

REPLACE M--7 WITH A

GOOD RELAY

DO THE HEADLIGHTS COME ON ?

HEAD LIGHTS WILL NOT TURN ON

(FLOW CHART)

BOTH PANELS ARE

POWERED UP

KEY IS ON

VOLTAGE

NO VOLTAGE

OPERATION:

--HEADLIGHT SWITCH IS SELECTED

ON PANEL

--M7 IS TURNED ON

--CONTACT OF M7 SUPPLIES VOLTAGE

TO HEADLIGHTS

YES

PROBLEM SOLVED

50D/ORA, 50A/ORA, OR

50B/ORA ARE OPEN

--M--7 STILL REMOVED

CHECK THE VOLTAGE AT

PIN 30 OF M--7, WIRE

59/BRN TO GROUND

NO VOLTAGE

B+

59/BRN, CB--6, 20B/BLU,

OR 20/BLU ARE OPEN

B+

NO VOLTAGE

CHECK VOLTAGE

ACROSS LIGHTS

B+

REPLACE LIGHT

NO VOLTAGE

ALL 62/YEL WIRES OR

13/BLK WIRES GOING

TO THE HEADLIGHTS

ARE OPEN

YES

17A/ORA OR 17B/ORA

WIRES ARE OPEN

CONTINUITY

WIRE 17/ORA IS

SHORTED TO GROUND

REPLACE PANEL

ELECTRICAL

5-129

8410 MM392 (8--01)

HAZARD LIGHT WILL NOT TURN ON

(SCHEMATIC)

OPERATION:

--HAZARD LIGHT SWITCH IS SELECTED

ON PANEL

--M9 IS TURNED ON

--CONTACT OF M9 SUPPLIES VOLTAGE TO HAZARD LIGHT

16E/GRN

1H/RED

13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19B/BLU

19A/BLU

1G/RED

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M5 8685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

85 M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

GROUND

LINE

50A/ORA

AUXILIARY

CB--8

15 AMP

ELECTRONIC

INSTRUMENT

PANEL

13AG/BLK

13AF/BLK

31A/GRY

32A/BLU

1G/RED M5

50F/ORA 13

18/GRN

M--9

WARNING LIGHT RELAY

WARNING LIGHT L.R.C.

WARNING LIGHT O.H.G.

76/GRN

8730 M9

13LL/BLK

13VV/BLK 13BE/BLK

31D/GRY

76/GRN

ELECTRICAL

5-130 8410 MM392 (8--01)

31C/GRY, 31A/GRY, CB--8,

32/BLU, 32A/BLU, M5 CONTACTS,

OR 1G/RED ARE OPEN

--DISCONNECT INSTRUMENT

PANEL

CHECK CONTINUITY OF

18/GRN TO GROUND

--REMOVE M9

--TURN KEY OFF THEN ON

IS THE HAZARD LED

FLASHING ?

--REPLACE M9

--KEY ON

--ENGINE OFF

--HAZARD LIGHT SELECTED

CHECK VOLTAGE ON PIN 87 OF

M7, WIRE 76/GRN TO GROUND

-- R E M O V E M -- 9

--KEY ON

--ENGINE OFF

--HAZARD LIGHT SELECTED

CHECK FOR VOLTAGE ON PIN 85 OF

M--9 (WIRE 50F/ORA) TO GROUND

REPLACE M--9 WITH A

GOOD RELAY

DOES THE HAZARD LIGHT COME ON ?

HAZARD LIGHT WILL NOT TURN ON

(FLOW CHART)

BOTH PANELS ARE

POWERED UP

KEY IS ON

VOLTAGE

NO VOLTAGE

YES

PROBLEM SOLVED

50F/ORA, 50A/ORA, OR

50B/ORA ARE OPEN

--M--9 STILL REMOVED

CHECK THE VOLTAGE AT

PIN 30 OF M--9, WIRE

31C/GRY TO GROUND

NO VOLTAGE

B+

NO VOLTAGE

CHECK VOLTAGE

ACROSS HAZARD

LIGHT

B+

REPLACE LIGHT

NO VOLTAGE

ALL 76/GRN WIRES OR

13/BLK WIRES GOING

TO THE HEADLIGHTS

ARE OPEN

YES

18/GRN IS OPEN

CONTINUITY

WIRE 18/GRN IS

SHORTED TO GROUND

REPLACE PANEL

OPERATION:

--HAZARD LIGHT SWITCH IS SELECTED

ON PANEL

--M9 IS TURNED ON

--CONTACT OF M9 SUPPLIES VOLTAGE

TO HAZARD LIGHT

ELECTRICAL

5-131

8410 MM392 (8--01)

REVERSE LIGHT OR ALARM

DO NOT TURN ON

(SCHEMATIC)

OPERATION:

--S--7 CLOSES IN REVERSE

--M--8 WILL TURN ON

--M--8 CONTACTS SUPPLY VOLTAGE

TO ALARM AND LIGHT

16E/GRN

1H/RED 13AM/BLK

16E/GRN

16F/

GRN 19C/BLU

19B/BLU

19A/BLU

1G/RED

50A/ORA

50B/ORA

16C/

GRN

16D/

GRN

1A/RED

20/BLU

CB--2

IGNITION SWITCH

S--15

( X INDICATES A

CLOSED CONTACT )

D--1

10A

22/YEL

CB--3

19/BLU

M5 8685

START

RUN

OFF

PREHEAT

XXX

IGN.

BATT.

N/U

RUN/

ACC

1/RED

FRONT

15A

8730

M4 8685

85M3

ELECTRONIC

INSTRUMENT

PANEL

13/BLK

BATTERY

13AC/BLK

13AB/BLK

50A/ORA

AUXILIARY

CB--8

15 AMP

ELECTRONIC

INSTRUMENT

PANEL

13AG/BLK

13AF/BLK

31A/GRY

32A/BLU

1G/RED

50E/ORA 19

12/YEL

M--8

REVERSE RELAY

BACK UP LIGHT

BACK UP ALARM

FLASHER 94/YEL

93/ORA

8730 M8

13QQ/BLK

13NN/BLK 13BD/BLK

31C/GRY 93/ORA

93/ORA

LOW = REVERSE

36A/GRN

REVERSE SENSE

REVERSE

CLOSES IN

13AY/BLK

36B/GRN

S--7

36/GRN

REVERSE

FLOW SWITCH

ELECTRICAL

5-132 8410 MM392 (8--01)

--DISCONNECT INSTRUMENT

PANEL

CHECK CONTINUITY OF 12/YEL

TO GROUND

GO INTO ”INPUT DISPLAY MODE”

THE INPUT CONDITIONS WILL BE

DISPLAYED ON FUEL GAUGE

--TURN OFF THE KEY

--PUSH AND HOLD HEADLIGHT BUT-

TON, HOLD FOR 10 SEC. SWEEP 1

AND 2 LED’S SHOULD TURN ON

START THE ENGINE

DOES THE SHAKER LED

BLINK IN REVERSE AND

TURN OFF IN NEUTRAL

OR FWD?

YES

PANEL TEST

GOOD

CHECK CONTINUITY OF

12/YEL FROM M8 PIN 86

TO PIN 19 OF PANEL

-- R E M O V E M -- 8

--TURN KEY OFF, THEN ON

DOES THE HAZARD LIGHT BLINK ?

50E/ORA, 50A/ORA,

OR 50B/ORA ARE OPEN

-- R E M O V E M -- 8

--KEY ON, ENGINE OFF

CHECK VOLTAGE ON PIN 85 OF

M8 WIRE 50E/ORA TO GROUND

REVERSE LIGHT OR ALARM

DO NOT TURN ON

(FLOW CHART)

OPERATION:

--S--7 CLOSES IN REVERSE

--M--8 WILL TURN ON

--M--8 CONTACTS SUPPLY VOLTAGE

TO ALARM AND LIGHT

BOTH PANELS POWERED UP

REPLACE M--8

CHECK OPERATION OF

REVERSE LIGHT AND

ALARM

WORKS

PROBLEM SOLVED

STILL DOES

NOT WORK

0VOLTS

B+

CHECK VOLTAGE ON PIN

30 OF M8 WIRE 31C/GRY

TO GROUND

0VOLTS

31C/GRY, 31A/GRY, CB--8,

32/BLU, OR M5 CONTACT

OR 16/RED IS OPEN

B+

-- R E -- I N S T A L L M -- 8

--KEY AND ENGINE ON

--MACHINE SLIGHTLY IN

REVERSE

CHECK VOLTAGE ON PIN

87 OF M8 WIRE 93/ORA TO

GROUND

B+

CHECK VOLTAGE ACROSS

HAZARD LIGHT IN REVERSE

0VOLTS

B+

REPLACE LIGHT

93/ORA OR 13/BLK

IS OPEN

YES

OPEN

REPAIR 12/YEL

CONTINUITY

CONTINUED ON

CONTINUITY OPEN

REPLACE PANEL

WIRE 12/YEL

IS SHORTED

TO GROUND

ELECTRICAL

5-133

8410 MM392 (8--01)

S--7 NOT CLOSING

IN REVERSE

REPLACE S--7

AND RETEST

--DISCONNECT S--7

--GROUND WIRE 36/GRN

AT S -- 7

DOES THE SHAKER LED

BLINK ?

CONTINUED FROM

CHECK CONTINUITY

OF 36/GRN

CONTINUITY

REPAIR 36/GRN

REPLACE SWEEP

PANEL

OPEN

SHAKER LED

ALWAYS BLINKS

SHAKER LED

NEVER BLINKS

YES

--DISCONNECT S--7

DOES SHAKER

LED TURN OFF ?

YES

S--7 IS SHORTED

REPLACE S--7

--DISCONNECT PANEL

CHECK CONTINUITY

OF 36/GRN TO

GROUND

REPLACE SWEEP

PANEL

OPEN

CONTINUITY

36/GRN IS SHORTED

TO GROUND

ELECTRICAL

5-134 8410 MM392 (8--01)

HYDRAULICS

6-1

8410 MM392 (5--02)

CONTENTS

Page

INTRODUCTION 6-3.........................

HYDRAULIC FLUID RESERVOIR 6-4.......

HYDRAULIC FLUID 6-5................

HYDRAULIC HOSES 6-5...............

TO REPLACE DIRECTIONAL PEDAL

CENTERING SPRING 6-6...........

TO REPLACE DIRECTIONAL

CONTROL CABLE 6-8...............

TO ADJUST DIRECTIONAL

CONTROL 6-11....................

TO REPLACE PROPEL PUMP 6-12.....

TO REPLACE LOAD SENSING

PUMP 6-15........................

TO REPLACE HYDRAULIC

STEERING VALVE 6-18............

TO REPLACE MAIN HYDRAULIC

VALVE 6-19.......................

TO REPLACE SCRUB VALVE 6-21.....

TO REPLACE SOLENOID VALVE

CARTRIDGE 6-23..................

TO REPLACE REAR DRIVE MOTOR 6-24

TO REPLACE SWEEPING VACUUM

FAN HYDRAULIC MOTOR 6-26.....

TO REPLACE ENGINE COOLING

FAN HYDRAULIC MOTOR 6-28.....

TO REPLACE SCRUB VACUUM

FAN HYDRAULIC MOTOR 6-30.....

TO REPLACE SCRUB BRUSH

HYDRAULIC MOTOR 6-32..........

TO REPLACE MAIN BRUSH

HYDRAULIC MOTOR 6-34..........

TO REPLACE SIDE BRUSH MOTOR 6-36

TO REPLACE STEERING

CYLINDER 6-38...................

TO REPLACE HOPPER LIFT

CYLINDER 6-41...................

TO REPLACE HOPPER DUMP

DOOR CYLINDER 6-42.............

TO REPLACE MAIN BRUSH LIFT

CYLINDER 6-43...................

TO REPLACE SIDE BRUSH LIFT

CYLINDER 6-45...................

TO REPLACE SQUEEGEE LIFT

CYLINDER 6-46...................

TO REPLACE SCRUB BRUSH LIFT

CYLINDER 6-48...................

TO REPLACE SCRUB HEAD SIDE

SHIFT HYDRAULIC CYLINDER 6-50.

HYDRAULIC SCHEMATIC 6-52.........

HYDRAULIC HOSE GROUP 6-56.......

CLAMP LOCATION AND HOSE

ORIENTATION 6-58................

Page

TROUBLESHOOTING 6-61...............

8410 HYDRAULIC PUMP

OPERATION 6-62..................

8410 HYDRAULIC PUMP LOW

PRESSURE FLOW 6-63............

8410 HYDRAULIC PUMP INCREASE

FLOW DEMAND 6-64..............

8410 HYDRAULIC PUMP HIGH

PRESSURE 6-65..................

ENGINE FAN CIRCUIT

(HIGH SPEED) 6-66................

ENGINE FAN CIRCUIT

(IDLE SPEED) 6-67................

ENGINE FAN DOES NOT RUN 6-68....

ENGINE FAN ALWAYS RUNS FAST 6-69

ENGINE FAN ALWAYS RUNS SLOW 6-70

SCRUB FAN CIRCUIT 6-72............

SCRUB FAN DOES NOT TURN OFF 6-73

SCRUB FAN DOES NOT TURN ON 6-74

HOPPER DOOR CLOSE CIRCUIT 6-76.

HOPPER DOOR DOES NOT OPEN 6-77

HOPPER DOOR DOES NOT CLOSE 6-78

HOPPER DOOR DOES NOT

STAY CLOSED 6-79................

HOPPER LIFT CIRCUIT 6-80..........

HOPPER DOES NOT RAISE 6-81......

HOPPER DRIFTS DOWN

TOO QUICKLY 6-82................

HOPPER LOWER CIRCUIT 6-84.......

HOPPER DOES NOT LOWER 6-85.....

MAIN BRUSH CIRCUIT -- SPD 1

(MAIN BRUSH DOWN AND ON,

VAC FAN ON) 6-86..............

MAIN BRUSH CIRCUIT -- SPD 2

(MAIN BRUSH DOWN AND ON,

VAC FAN ON) 6-87..............

MAIN BRUSH DOES NOT RAISE 6-88..

MAIN BRUSH DOES NOT LOWER 6-89.

MAIN BRUSH DOES NOT

TURN OFF 6-90...................

MAIN BRUSH DOES NOT TURN ON 6-91

SWEEPER FAN DOES NOT

TURN OFF 6-92...................

SWEEPER FAN DOES NOT

TURN ON 6-93....................

SIDE BRUSH CIRCUIT -- SPD 1

(MAIN BRUSH ON, VAC FAN ON,

SIDE BRUSH DOWN AND

ON) 6-94....................

SIDE BRUSH CIRCUIT -- SPD 2

(MAIN BRUSH ON, VAC FAN ON,

SIDE BRUSH DOWN AND

ON) 6-95....................

HYDRAULICS

6-2 8410 MM392 (5--02)

Page

SIDE BRUSH DOES NOT RAISE 6-96..

SIDE BRUSH DOES NOT LOWER 6-97.

SIDE BRUSH DOES NOT

TURN OFF 6-98...................

SIDE BRUSH DOES NOT TURN ON 6-99

EDGE SCRUB CIRCUIT 6-100.........

SCRUB HEAD DOES NOT GO IN 6-101.

SCRUB HEAD DOES NOT GO OUT 6-102

SCRUB HEAD LOWER CIRCUIT 6-104..

SCRUB BRUSHES DO NOT

LOWER 6-105.....................

SCRUB HEAD RAISE CIRCUIT 6-106...

SCRUB BRUSHES DO NOT RAISE 6-107

SCRUB BRUSH CIRCUIT 6-108........

SCRUB BRUSHES DO NOT

TURN OFF 6-109..................

SCRUB BRUSHES DO NOT

TURN ON 6-110...................

SQUEEGEE LIFT CIRCUIT 6-112.......

SQUEEGEE DOES NOT RAISE 6-113..

SQUEEGEE DRIFTS DOWN TOO

QUICKLY 6-114....................

SQUEEGEE LOWER CIRCUIT 6-116...

SQUEEGEE DOES NOT LOWER 6-117.

LEFT TURN CIRCUIT 6-118............

RIGHT TURN CIRCUIT 6-119..........

HYDRAULICS

6-3

8410 MM392 (8--01)

INTRODUCTION

The hydraulic system consists of the propel pump,

accessory pump, control valve, drive motors,

steering cylinder, and vacuum fan motor.

HYDRAULICS

6-4 8410 MM392 (8--01)

HYDRAULIC FLUID RESERVOIR

The reservoir is located in the engine

compartment next to the radiator.

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.

HYDRAULICS

6-5

8410 MM392 (8--01)

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)

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.

HYDRAULICS

6-6 8410 MM392 (8--01)

TO REPLACE DIRECTIONAL PEDAL

CENTERING SPRING

1. Shut off the engine and engage the parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Remove the two M8 hex screws holding the

rear radiator grill to the machine. Disconnect

the taillight and remove the grill from the

machine.

3. Remove the nyloc nut holding the centering

spring balljoint to the directional control arm.

4. Loosen the large jam nut holding the

directional cable to the propel bracket.

5. Remove the spring assembly from the

propel bracket and place it outside the back

of the machine.

6. Remove the ball joint and jam nuts.

7. Unscrew the directional spring assembly

from the directional control cable.

NOTE: The directional cable will have to be held

to keep it from turning.

8. Thread a new directional spring assembly all

the way on the directional control cable.

Leave 0.25 in of threads showing on the

0.62 in diameter threads.

9. Install two 0.25 in. jam nuts on the end of

the directional cable. Tighten one to the

housing and the other one to the balljoint,

leaving 0.06 in. between them.

10. Use the large jam nut to lock directional

spring assembly in place.

HYDRAULICS

6-7

8410 MM392 (8--01)

11. Reinstall the balljoint to the directional

control arm. Tighten the 0.25 in. nyloc nut to

11 -- 14 Nm (7 -- 10 ft lb).

12. Jack up the rear 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.

13. Check the neutral centering of the propel

pump by starting the machine and observing

the rear tire for any rotation. If tire is rotating;

See TO ADJUST DIRECTIONAL

CONTROL instructions.

14. Once the neutral centering has been set;

reinstall the rear grill panel. Tighten the four

M8 hex screws to 18 -- 24 Nm (15 -- 20 ft lb).

Lower the machine and test drive.

HYDRAULICS

6-8 8410 MM392 (8--01)

TO REPLACE DIRECTIONAL

CONTROL CABLE

1. Shut off the engine and engage the parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Lift the battery cover and disconnect the

battery cables.

3. Remove the battery hold down bracket and

remove the battery.

4. Remove the 0.25 nyloc nut holding the

control cable balljoint to the directional pedal

assembly.

5. Remove the cotter pin and clevis pin from

the directional control pedal. Remove the

pedal from the machine.

6. Loosen the two large hex nuts holding the

control cable to the mount bracket on the

floor plate.

7. Go under machine on operators side and

locate the two M5 hex screws holding the

clamp on the speed limiter cable. Remove

screws and clamp.

8. Go under machine and remove any clamps

or plastic ties holding control cable to the

machine frame.

HYDRAULICS

6-9

8410 MM392 (8--01)

9. Remove the two hex screws holding the rear

radiator grill to the machine. Unplug the

taillight and remove the grill from the

machine.

10. Remove the 0.25 in. nyloc nut holding the

centering spring balljoint to the directional

control arm on the propel pump.

11. Loosen the large jam nuts holding the

directional cable to mount bracket on the

propel pump.

12. Remove the cable from the bracket and

position it outside the back of the machine.

13. Unscrew the directional spring assembly

from the directional control cable.

NOTE: Control cable will have to be held to keep

it from turning.

14. The old control cable can now be removed

from the machine and a new one installed.

Remove one of the jam nuts and thread the

other one all the way on.

NOTE: The end of the cable with 1.5 in of thread

goes to the directional spring.

15. Make sure to route the cable between the

square tube of the frame and the scrub

head.

16. Thread the directional spring assembly all

the way back on the directional control

cable. Leave 0.25 in of threads showing on

the 0.62 in diameter threads.

HYDRAULICS

6-10 8410 MM392 (8--01)

17. Install two 0.25 in jam nuts on the end of the

cable. Tighten one to the housing and the

other one to the balljoint, leaving 0.06

(1/16 in.) between them.

18. Reconnect the balljoint to the propel pump

control arm using the 0.25 nyloc nut. Tighten

t o 11 -- 1 4 N m ( 7 -- 1 0 f t l b ) .

19. Position the control cable back in the cable

mount bracket on the propel pump. Firmly

hand tighten large jam nut.

20. Install the control cable back in the mount

bracket on the bottom of the floor plate.

Firmly hand tighten large jam nuts so there

is an equal amount of threads showing on

both sides of bracket.

21. Reinstall the foot pedal with the clevis pin

and cotter pin.

22. Reinstall the 0.25 in. jam nut and balljoint on

the pedal end of control cable. Adjust it so

there is 1.5 in. of movement between jam

nut and rubber seal.

23. Reconnect the directional control cable

balljoint to foot pedal with 0.25 nyloc nut.

Tighten to 11 -- 14 Nm (7 -- 10 ft lb).

24. Jack up the rear 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.

25. Check the neutral centering of the propel

pump by starting the machine and observing

the rear tire for any sign of rotation. If the tire

is rotating See TO ADJUST DIRECTIONAL

CONTROL instructions.

26. Once the neutral centering has been set,

reinstall the rear grill panel. Tighten the four

M8 hex screws to 18 -- 24 Nm (15 -- 20 ft lb).

Lower the machine.

HYDRAULICS

6-11

8410 MM392 (8--01)

TO ADJUST DIRECTIONAL CONTROL

1. Set the emergency brake and start the

engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Jack up the rear of machine.

FOR SAFETY: Block machine tires

before jacking machine up. Jack

machine up at designated locations

only. Block machine up with jack

stands.

3. Check the neutral centering of the pump by

observing the rear tire for any rotation.

4. If the rear tire is rotating, shut off the engine

and go under the machine by the engine

muffler.

5. Look up at the propel pump and locate the

long threaded adjustment bolt on the

movable cable bracket. Loosen the jam

nuts.

6. Loosen the two hex screws holding the

movable cable bracket to the fixed pump

bracket.

7. Start the machine and observe the rear tire

for any rotation. If the tire is rotating in either

direction, turn the long threaded adjustment

bolt until the rotation stops. Tighten the jam

nuts and hex screws.

8. For fine adjustments the balljoint on the end

of the propel cable can be rotated in or out a

few turns.

9. Lower the machine to the ground and

operate. Check to see if the machine creeps

in either direction.

HYDRAULICS

6-12 8410 MM392 (8--01)

TO REPLACE PROPEL PUMP

1. Start the engine and lower the squeegee.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Disconnect the battery cables from the

battery.

3. Jack up the rear 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.

4. Remove two M8 hex screws holding the rear

radiator grill to the machine. Unplug the

taillight and remove the grill from the

machine.

5. Open the engine cover and side door.

6. Remove the muffler and exhaust pipe.

7. Remove hex screws holding directional

control cable mount bracket to the back of

propel pump.

8. Remove the hex screw holding the propel

pump arm to the pump hub.

9. Unplug the pump switch from main harness.

10. Move the pump arm, cable mount bracket,

and control cable back out of the way.

11. Remove and plug the four hydraulic hoses

leading to the propel pump.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

HYDRAULICS

6-13

8410 MM392 (8--01)

12. Remove the two 0.38 in. hex screws holding

the propel pump to the load sensing pump.

13. Move the flow switch and mounting bracket

out of the way.

14. The propel pump can now be pulled back

and out of the load sensing pump.

NOTE: Be careful not to loose or damage the

o--ring or the pump coupler.

15. Remove the propel pump from the machine.

16. Remove the hydraulic fittings from the old

pump and install them in the new one. Make

sure the fittings are installed in the same

orientation as they were removed.

17. Remove hub from the pump shaft on the old

propel pump. A puller may needed to break

the hub loose.

18. Install the hub on the new pump shaft. Use

the new key already on the pump shaft.

Lightly tap the hub on the taper shaft with a

hammer so it will stay in place until the

hardware is installed.

19. Position pump back in the machine. Make

sure the o--ring and coupler are in place.

Reinstall the 0.38 in. hex screws with blue

loctite 242. Place the flow switch bracket

under the bolt heads. Tighten to 31 -- 40 Nm

(27 -- 35 ft lb).

NOTE: Be careful not to loose or damage the

o--ring or the pump coupler.

20. Reconnect the hydraulic hoses. See the

schematic in this section.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

HYDRAULICS

6-14 8410 MM392 (8--01)

21. Place the control cable, cable mount plate,

and the pump arm back in position.

22. Align the mount holes in the cable plate with

the holes in the back of the propel pump.

Reinstall the 0.38 in. hex screws and

washers. Make sure to put one washer

between the plate and pump under each hex

screw. Use blue loctite 242 and tighten to

31 -- 40 Nm (27 -- 35 ft lb).

23. Reinstall the pump arm to the pump hub

using the two M8 hex screws on the outside

and one 0.31 in. hex screw in the center.

Tighten to 18 -- 24 Nm (15 -- 20 ft lb).

24. Reconnect the pump switch to the main

electrical harness.

25. Reinstall the muffler and exhaust pipe.

26. Reconnect the battery cables.

27. Check the neutral centering of the new

propel pump by starting the machine and

observing the rear tire for any rotation. If tire

is rotating See TO ADJUST DIRECTIONAL

CONTROL instructions in this section.

28. Once the neutral centering has been set,

reinstall rear grill panel. Tighten four M8 hex

screws to 18 -- 24 Nm (15 -- 20 ft lb). Lower

the machine.

HYDRAULICS

6-15

8410 MM392 (8--01)

TO REPLACE LOAD SENSING PUMP

1. Start the engine and lower the squeegee.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake., Turn Off

Machine And Remove Key.

2. Jack up the rear 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.

3. Open the engine cover and side door.

4. Lift the engine side door off the hinges and

put it aside.

5. Remove two M8 hex screws holding the rear

radiator grill to the machine. Unplug the

taillight and remove the grill from the

machine.

6. Remove the muffler and exhaust pipe.

7. Drain the hydraulic tank.

8. Remove the radiator overflow tank.

9. Remove the left hand corner channel.

10. Drain the radiator and disconnect the

radiator hoses from the radiator.

11. Remove and plug hydraulic hoses going to

the hydraulic oil cooler that sits behind

engine radiator.

12. Remove and plug the hydraulic hoses going

to the engine cooling fan hydraulic motor.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

13. Remove the two nyloc nuts holding the

bottom of the radiator to the mounting

channel.

14. The radiator assembly can now be carefully

lifted out and set aside.

15. Remove the six M8 hex screws holding the

mounting channel to the frame. Remove the

channel.

HYDRAULICS

6-16 8410 MM392 (8--01)

16. Remove the hex screws holding the propel

pump to the load sensing pump.

17. Move the flow switch and mounting bracket

out of the way.

18. The propel pump can now be pulled back

out of the load sensing pump.

NOTE: Be careful not to loose or damage the

o--ring or the pump coupler.

19. Remove and plug the hydraulic hoses going

to the load sensing pump.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

20. Remove the two M12 hex screws holding

the load sensing pump to the bellhousing.

21. The load sensing pump can now be pulled

back out of the flywheel coupler and

removed from the machine.

22. Remove the fittings from the old pump and

install in the new pump in the same

orientation they were removed.

23. Place a small amount of grease on the

splines of the new pump and install it back in

the machine.

24. Align the holes in pump flange with holes in

bellhousing. Install the two M12 hex screws

with blue loctite 242 and tighten to 31 -- 40

Nm (27 -- 35 ft lb).

25. Reconnect the hydraulic hoses to the load

sensing pump. See the schematic in this

section.

26. Position the propel pump back in the load

sensing pump. Make sure o--ring and

coupler are in place. Reinstall the 0.38 in.

hex screws with blue loctite 242. Place the

flow switch bracket back under the bolt

heads. Tighten to 31 -- 40 Nm (27 -- 35 ft lb).

27. Reinstall the radiator mounting channel

using six M8 hex screws. Tighten to

18 -- 24 Nm (15 -- 20 ft lb).

HYDRAULICS

6-17

8410 MM392 (8--01)

28. Place the radiator assembly back on the

mount channel. Reinstall the two M10 nyloc

nuts and washers and tighten to

18 -- 24 Nm (15 -- 20 ft lb).

29. Reconnect the hydraulic hoses to the engine

cooling fan motor. See the schematic in this

section.

30. Reconnect the hydraulic hoses to the

hydraulic oil cooler. See the schematic in

this section.

31. Reconnect the radiator hoses to the

radiator.

32. Position the LH tower back on the machine.

33. Tighten the M8 hex screws to 18 -- 24 Nm

(15 -- 20 ft lb). Tighten the M10 hex screw

to 52 -- 67 Nm (39 -- 51 ft lb).

34. Reinstall the muffler and exhaust pipe.

35. Refill the engine radiator with coolant.

36. Refill the hydraulic fluid reservoir with the

proper grade of hydraulic fluid.

37. Reinstall the engine side door.

38. Start the engine and check for proper

operation and leaks.

39. Once the neutral centering has been set,

reinstall rear grill panel. Tighten four M8 hex

screws to 18 -- 24 Nm (15 -- 20 ft lb). Lower

the machine.

HYDRAULICS

6-18 8410 MM392 (8--01)

TO REPLACE HYDRAULIC STEERING

VALVE

1. Turn off the engine and engage the parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Remove the battery cables from the battery.

3. Remove the recovery tank. See TO

REMOVE RECOVERY TANK instructions in

the SCRUBBING section.

4. Remove and plug the five hydraulic hoses

leading to the steering control motor.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

5. Remove the four M6 hex screws holding the

hydraulic steering valve to the steering

column.

6. The hydraulic steering valve can now be

removed from machine.

7. Remove the hydraulic fittings from the old

control motor. Install in the new or rebuilt

control motor in the same orientation as they

were removed.

NOTE: Remember to orientate the fittings as

close as possible to the way they came out.

8. Install the new hydraulic steering valve

assembly back in the machine. Position the

ports in the same orientation as it was

removed. Reinstall the four M6 hex screws

and tighten to 8 -- 10 Nm (5 -- 7 ft lb).

9. Reconnect the five hydraulic hoses to the

hydraulic steering valve. See the schematic

in this section.

10. Reconnect battery cables. Start engine and

move the steering wheel back and forth,

checking for leaks and proper operation.

11. Reinstall the recovery tank. See TO

INSTALL RECOVERY TANK instructions in

the SCRUBBING section.

HYDRAULICS

6-19

8410 MM392 (8--01)

TO REPLACE MAIN HYDRAULIC VALVE

NOTE: Do Not replace complete valve unless the

manifold block has cracked, otherwise replace

individual component cartridge.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake., Turn Off

Machine And Remove Key.

1. Jack up the rear 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. Remove the battery cables from the battery.

3. Go under the machine on left side and

locate the main hydraulic valve. Disconnect

the electrical solenoids from the main

harness.

4. Remove and cap the hydraulic hoses on the

main hydraulic valve. Start with the hoses

nearest the outside of the machine and work

toward the center.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

5. Remove the three M8 hex screws holding

the main valve to the mount bracket.

6. The main valve can now be dropped down

and out of the machine.

7. Carefully place the valve in a vice. Note the

orientation of fittings.

HYDRAULICS

6-20 8410 MM392 (8--01)

8. Remove the hydraulic fittings from old valve

and install in the new valve in the same

orientation.

NOTE: Install the fittings in the new valve in the

same orientation as they were removed.

9. Position the new valve back under machine.

Reinstall the three M8 hex screws and

washers. Tighten to 18 -- 24 Nm

(15 -- 20 ft lb).

10. Reconnect the hydraulic hoses to the new

valve. See the hydraulic schematic in this

section. Start from the side of the valve

nearest the center of the machine and work

toward the outside.

11. Reconnect the electric solenoids to the main

harness. See the schematic in the

ELECTRICAL section of this manual.

12. Reinstall the brush guard using the two M12

hex screws. Tighten to 64 -- 83 Nm

(50 -- 60 ft lb).

13. Remove the jack stands and lower the

machine.

14. Reconnect the battery cables to the battery.

15. Start the machine and check the hydraulic

components for proper operation.

HYDRAULICS

6-21

8410 MM392 (8--01)

TO REPLACE SCRUB VALVE

NOTE: Do Not replace complete valve unless the

manifold block has cracked, otherwise replace

individual component cartridge.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake., Turn Off

Machine And Remove Key.

1. The solution and recovery tanks must be

removed in order to service the scrubber

valve. See TO REMOVE SOLUTION TANK

instructions in the SCRUBBING section of

this manual.

2. Remove the battery cables from the battery.

3. Remove the main brush from the machine.

4. Locate the scrub valve on top of the

machine frame near the front left tower.

5. Disconnect the electrical solenoids from

main harness.

6. Remove and cap the hydraulic hoses on the

scrub valve.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

7. Open the the brush door on the left side of

the machine.

8. Remove the three M10 hex screws,

washers, and nyloc nuts holding the

scrubber valve assembly to the machine

frame.

9. Remove the scrubber valve from machine

and place it in a vice upside down.

10. Remove the three M8 hex screws holding

the two mounting plates to the valve.

11. Turn the valve over in the vice and remove

the hydraulic fittings.

12. Install fittings in the new valve in the same

orientation.

NOTE: Install the fittings in the new valve in the

same orientation as they were removed.

HYDRAULICS

6-22 8410 MM392 (8--01)

13. Reinstall the two mounting plates to the new

scrubber valve. Reinstall the three M8 hex

screws and tighten to 18 -- 24 Nm

(15 -- 20 ft lb).

14. Position the new scrubber valve assembly

back in the machine. Reinstall the three M10

hex screws, washers, and nyloc nuts.

Tighten to 37 -- 48 Nm (26 -- 34 ft lb).

NOTE: Remember to put hex screws in from

under the machine so the nyloc nuts are on valve

side.

15. Reconnect the hydraulic hoses to scrubber

valve. See the hydraulic schematic in this

section.

16. Reconnect the electric solenoids to the main

harness. See the schematic in the

ELECTRICAL section of this manual.

17. Reconnect the battery cables to the battery.

18. Start the machine and operate the hydraulic

scrubbing functions. Check the scrubber

valve for any leaks and for proper operation.

19. Reinstall solution and recovery tanks. See

TO INSTALL SOLUTION TANK instructions

in the SCRUBBING section of this manual.

HYDRAULICS

6-23

8410 MM392 (8--01)

TO REPLACE SOLENOID VALVE

CARTRIDGE

1. Shut off the engine and engage the parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Remove the battery cables from the battery.

3. Locate and identify the cartridge to be

replaced. Unplug the solenoid from the main

harness.

4. Remove the hex nut and rubber o--ring from

the cartridge stem.

5. Slide electrical coil and rubber o--ring off the

valve stem.

NOTE: Oil will run out of the valve when the

cartridge is removed.

6. Remove the cartridge stem from the valve

body.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

7. Install a new cartridge stem back in the

valve port. Firmly hand tighten.

NOTE: Make sure the new cartridge had an

o--ring installed and oiled.

8. Slip the o--ring and coil back over the new

stem.

9. Install the o--ring and hex nut on the new

stem. Lightly hand tighten.

NOTE: Do not over tighten----snug only.

10. Plug the solenoid coil back in the main

harness. See schematic in ELECTRICAL

section.

11. Reconnect the battery cables to the battery.

12. Start the machine and check the new

cartridge for leaks.

HYDRAULICS

6-24 8410 MM392 (8--01)

TO REPLACE REAR DRIVE MOTOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Engage the parking brake and block the

front tires.

2. Jack up the rear of the 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 rear tire and wheel assembly.

4. Remove the slotted nut from drive wheel

motor hub shaft.

5. Use a large puller to remove the drive hub

from the motor shaft.

NOTE: Mark the hoses to make sure they are

returned to the correct fitting when reassembled.

6. Remove and plug the hydraulic hoses

leading to the 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 the rear wheel

housing.

NOTE: The orientation of the motor in the rear

wheel housing.

9. Rebuild or replace drive motor. If you

replace the drive motor, install the fittings on

the new motor oriented the same as they

were removed.

10. Slide the rebuilt or new motor in the rear

wheel housing.

NOTE: The orientation of the motor in the rear

wheel housing.

HYDRAULICS

6-25

8410 MM392 (8--01)

11. Install the four socket screws. Torque to

90 -- 117 Nm (70 -- 85 ft lb).

12. Reconnect the hydraulic hoses to the drive

motor.

NOTE: Make sure the hoses are returned to the

correct fitting when reassembled. See schematic

in the HYDRAULICS section.

13. Install the drive hub to the tapered motor

shaft. Tighten slotted nut to 500 Nm

(375 ft lb). Install the cotter pin.

NOTE: Make sure the square key is in place on

the tapered shaft before installing the drive hub.

14. Install rear tire and wheel assembly. Torque

the rear wheel nuts to 142 -- 156 Nm

(105 -- 115 ft lb).

15. Remove the jack stands and the lower

machine.

16. Drive the machine and check for proper

operation.

HYDRAULICS

6-26 8410 MM392 (8--01)

TO REPLACE SWEEPING VACUUM FAN

HYDRAULIC MOTOR

1. Park the machine on a smooth, level

surface.

2. Stop 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 vacuum fan from the machine.

See TO REMOVE SWEEPING VACUUM

FAN instructions in this section.

4. Place the vacuum fan assembly in a vice.

5. Remove the four 0.25 in. hex screws and

fender washers holding the inlet plate to the

vacuum fan housing. Remove the plate.

6. Hold the impeller from turning and remove

the 0.31 in. hex nut from the vacuum fan

motor shaft.

7. Pull the impeller straight off the shaft. The

impeller may have to be lightly pried off. Be

careful not to loose the square key.

8. Remove the four M10 nyloc nuts holding the

hydraulic motor plate to vacuum fan

housing.

9. Remove the hydraulic motor and plate

assembly from the vacuum fan housing.

10. Remove the four M8 flat head screws and

nyloc nuts holding hydraulic fan motor to the

motor plate.

11. Remove the hydraulic fittings and install in

the new or rebuilt fan motor. Keep the same

orientation.

12. Install the new motor on the motor plate

using the four M8 flat head screws and nyloc

nuts. Tighten to 18 -- 24 Nm (13 -- 18 ft lb).

HYDRAULICS

6-27

8410 MM392 (8--01)

13. Reinstall the hydraulic motor and plate

assembly back on the fan housing using four

M10 nyloc nuts and flat washers. Tighten to

18 -- 24 Nm (13 -- 18 ft lb).The motor should

be oriented with case drain fitting pointing

toward the fan exhaust outlet.

14. Put a small amount of grease on the motor

shaft before installing the new impeller.

Make sure the square key is in place.

15. Slide the impeller all the way on the shaft

and spin it slowly. If the impeller rubs on

housing, remove and place a 0.38 in. flat

washer on shaft under impeller and

re--assemble. Repeat this procedure until

the impeller spins freely.

16. Hold the new impeller from turning and firmly

tighten the 0.31 in. flex lock nut.

17. Reinstall the inlet plate using the four 0.25

in. hex screws and fender washers. Tighten

t o 11 -- 1 4 N m ( 7 -- 1 0 f t l b ) .

18. Reinstall vacuum fan assembly to the rear of

the hopper. See TO INSTALL SWEEPING

VACUUM FAN instructions in this section.

HYDRAULICS

6-28 8410 MM392 (8--01)

TO REPLACE ENGINE COOLING FAN

HYDRAULIC MOTOR

1. Shut off the engine and engage the parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Open the engine cover and side door.

3. Remove and plug the hoses connected to

thecoolingfanmotor.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

4. Remove the four M6 hex screws and nyloc

nuts holding the fan motor mount channel to

the fan housing. Remove the cooling fan

assembly from the machine.

5. Remove the hex nut from the fan motor

shaft in center of fan blade.

6. Remove the fan blade from the motor shaft.

NOTE: A puller must be used to remove fan blade

from tapered motor shaft.

7. Remove the four M8 hex screws holding the

fan motor to mount channel. Remove the

motor.

8. Remove the fittings from the old fan motor

and install in the new motor in the same

orientation.

HYDRAULICS

6-29

8410 MM392 (8--01)

9. Install a new cooling fan motor on the mount

channel. Reinstall the four M8 hex screws.

Tighten to 18.5 -- 24 Nm (16 -- 21 ft lb).

10. Reinstall the fan blade on the new fan motor

shaft.

NOTE: Make sure key is in place on motor shaft.

11. Reinstall the hex nut and tighten to

18.5 -- 24 Nm (16 -- 21 ft lb).

12. Reinstall the fan motor assembly on the fan

housing. Reinstall the four M6 hex screws

and nyloc nuts. Tighten to 7.6 -- 9.9 Nm

(5 -- 7 ft lb).

13. Reconnect the hydraulic hoses to the new

cooling fan motor. See the hydraulic

schematic in this section.

14. Start the machine and check the new

cooling fan motor for leaks.

HYDRAULICS

6-30 8410 MM392 (8--01)

TO REPLACE SCRUB 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 scrub vacuum fan from the

machine. See TO REMOVE SCRUB

VACUUM FAN instructions in this section.

2. Place the vacuum fan assembly in a vice or

other holding device.

3. Remove the six hex screws holding the front

housing to the rear housing. Remove the

front housing.

NOTE: The orientation of front housing to rear

housing is very important. Mark both the front and

rear housing for proper reassembly.

4. Remove the crown nut on the impeller shaft.

Slide the impeller off the shaft.

NOTE: Remove and save the square key and any

shims on the shaft under the impeller.

5. Turn the bottom housing over and remove

the four nyloc nuts and washers from the

motor mount plate. Remove the plate from

the housing.

NOTE: Mark the orientation of hydraulic motor

and fittings.

6. Remove the four flat head screws and nyloc

nuts holding the hydraulic fan motor to the

mounting plate.

7. Install a new motor on the mounting plate.

Tighten the four flat head screws to

9--13Nm(7--10ftlb).

8. Remove the hydraulic fittings from the old

motor. Install these fittings in the new motor

in the same orientation as they were

removed.

9. Reinstall the new motor and mounting plate

on the rear housing. Tighten the four nyloc

nuts to 16 -- 22 Nm (12 -- 16 ft lb).

NOTE: Make sure the motor is installed on the

rear housing with the hydraulic motor in the

correct orientation.

HYDRAULICS

6-31

8410 MM392 (8--01)

10. Turn the rear housing over and reinstall the

shims, key, fan impeller, and crown nut.

Tighten nut to 34 -- 47 Nm (25 -- 35 ft lb).

NOTE: Be sure the key is on the shaft. Super

gluing the key helps keep it in place.

NOTE: Use blue loctite 242 on shaft threads.

11. Reinstall the front housing to 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 has been

tightened.

12. Reinstall the vacuum fan assembly back in

the machine. See TO INSTALL SCRUB

VACUUM FAN instructions in this section.

HYDRAULICS

6-32 8410 MM392 (8--01)

TO REPLACE SCRUB BRUSH HYDRAULIC

MOTOR

1. Start the engine, lower and side shift the

scrub head, shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 cotter pin from the long

horizontal clevis pin holding each side

squeegee to the scrub head frame. Remove

the clevis pins and squeegee assemblies

from both sides.

4. Remove all three scrub brushes.

NOTE: Mark the hoses for proper re--assembly.

5. Remove and plug the hydraulic hoses

connected to brush motor.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

6. Remove the 0.25 in. hex screw and spacer

washer holding the brush drive hub to the

brush hydraulic motor. Remove hub, spacer,

and key.

7. Remove the four 0.38 in. hex screws holding

the brush motor to the bracket. Note the

orientation of the motor in the bracket and

remove.

8. Remove the hydraulic fittings from the old

motor and install in the same orientation in

the new or rebuilt motor.

9. Install the new motor in the bracket in the

same orientation it came out. Reinstall the

four 0.38 in. hex screws and tighten to

31 -- 40 Nm (27 -- 35 ft lb).

HYDRAULICS

6-33

8410 MM392 (8--01)

10. Reinstall the spacer, key, hub, washer, and

0.25 in. hex screw in the new brush motor

shaft. Use blue loctite 242 in threads of the

hex screw. Tighten to 11 -- 14 Nm

(7 -- 10 ft lb).

11. Reconnect hydraulic hoses to brush motor.

See schematic in HYDRAULICS section.

12. Reinstall the three disc brushes.

13. Reinstall the LH and RH side squeegees

with the long clevis pins and cotter pins.

14. Lower the machine. Start the engine and

check for any leaks and for proper operation

of the scrub brushes.

HYDRAULICS

6-34 8410 MM392 (8--01)

TO REPLACE MAIN BRUSH HYDRAULIC

MOTOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Raise the hopper and engage the hopper

support bar.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

2. Remove the main brush.

3. Remove and plug the hydraulic hoses

leading to the main brush motor.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

4. Remove the cotter pin from castle nut at the

end of brush drive plug.

5. Hold the brush drive plug from turning and

remove the castle nut.

6. A puller must be used to remove brush drive

plug from the tapered shaft on the brush

motor.

7. Remove the four .375 in. hex screws holding

the main brush motor to the main brush

motor arm. The brush motor can now be

removed from the machine.

NOTE: Mark the orientation of the brush motor

before removal for proper reassembly.

8. Remove the hydraulic fittings from the old

motor.

9. Install a new or rebuilt main brush motor in

the main brush arm. Reinstall the four .375

in. hex screws and tighten to (27 -- 53 ft lb).

HYDRAULICS

6-35

8410 MM392 (8--01)

NOTE: Make sure the corners of brush motor line

up with the slots in brush arm.

10. Reinstall the hydraulic fittings in the new

motor.

NOTE: Make sure to orientate the fittings they

way they were removed.

11. Reconnect the hydraulic hoses to the motor.

See schematic in HYDRAULIC section.

12. Reinstall the brush drive plug on the tapered

motor shaft. Make sure the square key is in

place.

13. Reinstall the castle nut and tighten to

40 -- 54 Nm (30 -- 40 ft lb). Continue to

tighten the castle nut until it lines up with the

hole in brush motor shaft. Install a new

cotter pin.

14. Reinstall the main brush.

15. Start the machine and run the main brush.

Check for proper operation and leaks.

HYDRAULICS

6-36 8410 MM392 (8--01)

TO REPLACE SIDE BRUSH MOTOR

1. Empty the debris hopper.

2. Set the machine parking brake.

3. Raise the hopper and engage the hopper

support bar.

WARNING: Raised Hopper May Fall.

Engage Hopper Support Bar.

4. Stop the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

5. Remove the side brush retaining pin from

the side brush drive shaft by pulling the pin

keeper off and over the end of the pin.

6. Slide the side brush off the side brush drive

shaft.

7. Remove and plug hydraulic hoses from side

brush motor.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

8. Remove the four .375 in. hex screws from

bottom of side brush motor. Remove the

side brush guard and side brush motor from

machine.

9. Remove hydraulic fittings from the old motor.

10. Install a new or rebuilt side brush motor and

side brush guard with the four .375 in. hex

screws. Tighten to 31 -- 40 Nm

(27 -- 35 ft lb).

HYDRAULICS

6-37

8410 MM392 (8--01)

11. Reinstall the hydraulic fittings in the new

motor.

NOTE: Make sure to orientate the fittings they

way they were removed.

12. Reconnect the hydraulic hoses to the motor.

See schematic in HYDRAULIC section.

13. Slide the side brush on the side brush drive

shaft.

14. Insert the side brush retaining pin through

the side brush hub and shaft.

15. Disengage the hopper support bar and lower

the hopper.

16. Start the machine and run the side brush

motor. Check for proper operation and leaks.

HYDRAULICS

6-38 8410 MM392 (8--01)

TO REPLACE STEERING CYLINDER

1. Start the engine and lower the scrub head.

Shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Jack up the rear 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.

3. Disconnect the battery cables and remove

the battery from machine.

4. LPG machines; Disconnect the LP tank and

remove from the machine.

5. Gas and Diesel machines; Remove the

four hex screws holding the right rear panel.

Unplug the tail light and remove the panel.

Disconnect the fuel lines at the tank.

Remove the two tank straps and the fuel

tank.

6. Turn the steering wheel half way to the left

so the rear drive casting can be accessed

from the fuel tank area of the machine.

7. Remove the clamp holding the drive motor

hoses to rear casting. Move the hoses for

access to steering cylinder attachment bolt.

8. Using a torque multiplier wrench; remove the

.750IΧ3.25Ihex screw and nyloc nut

holding the rod end of steering cylinder to

the drive casting. Discard the hardware.

9. Using the access through the battery tray

area; remove and plug the hydraulic hose

near the rod end of the steering cylinder.

NOTE: Always observe hydraulic cleanliness

requirements when opening hydraulic lines.

HYDRAULICS

6-39

8410 MM392 (8--01)

10. Go under the machine from the operators

compartment side. Remove and plug the

hydraulic hose near the piston end of the

steering cylinder.

NOTE: Always observe hydraulic cleanliness

requirements when opening hydraulic lines.

11. Go under the machine from the engine side

and locate the .750“ X 3.25” hex screw and

nyloc nut holding the piston end of the

steering cylinder to machine frame.

12. Using the torque multiplier wrench, a

16Iextension, and a long breaker bar,

loosen and remove the .750” X 3.25“ hex

screw. Access to the nyloc nut is through the

battery tray area. Discard the hardware.

NOTE: An extension should be added to the

handle of the torque multiplier so it can be rested

against the rear tire for leverage.

13. Remove the steering cylinder from the

machine.

14. Remove the fittings from the old cylinder and

install in the new cylinder. Install in the same

orientation.

15. Position the new cylinder and balljoint

assembly in the machine with the rod end

toward the rear drive casting.

16. Install one new .750” X 3.25” hex screw

and nyloc nut along with three washers

between the balljoint and frame and one

washer between the balljoint and nyloc nut

in the piston end of the new steering

cylinder.

NOTE: Washers must be installed for proper

cylinder to frame clearance

17. Using the torque multiplier wrench, a

16Iextension, and a long ft lb torque

wrench; tighten the .750“ X 3.25” hex

screw to 200--220 ft lb. Access to the nyloc

nut is through the battery tray area.

NOTE: An extension should be added to the

handle of the torque multiplier so it can be rested

against the rear tire for leverage.

HYDRAULICS

6-40 8410 MM392 (8--01)

18. Go to the rear of the machine and install a

new .750” X 3.25” hex screw and nyloc nut

along with three washer between balljoint

and casting and one washer between

balljoint and hex screw in the rod end of the

new steering cylinder.

NOTE: Washers must be installed for proper

cylinder to frame clearance

19. Using the torque multiplier and a long ft lb

torque wrench; tighten the .750” X 3.25”

hex screw to 200--220 ft lb.

20. Use the access in the battery tray area and

reconnect the hydraulic hose near the rod

end of steering cylinder.

NOTE: Always observe hydraulic cleanliness

requirements when opening hydraulic lines.

21. Go under the machine from the operators

compartment side and reconnect the

hydraulic hose near the piston end of

steering cylinder.

22. Reinstall the clamp holding the drive motor

hoses to the rear casting.

23. LPG machines; Reinstall the LP tank.

24. Gas and Diesel machines; Reinstall the

fuel tank and straps. Reconnect the fuel

lines. Reinstall the rear panel and hardware.

Reconnect the tail light wires.

25. Reinstall the battery and reconnect the

cables.

26. Remove the jack stands and lower the

machine.

27. With the seat in the raised position, start the

machine and turn steering wheel in both

directions. Observe steering cylinder for any

leaks.

HYDRAULICS

6-41

8410 MM392 (8--01)

TO REPLACE HOPPER LIFT CYLINDER

1. Set the machine parking brake.

2. Raise the hopper and engage the prop arm.

Drop the hopper down on the prop rod to

relieve pressure on the cylinders.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

3. Disconnect and cap the two hydraulic hoses

leading to the hopper lift cylinder.

NOTE: Always observe hydraulic cleanliness

requirements when opening hydraulic lines.

4. Remove the M6 hex screw holding the

cylinder pin plate to the cylinder clevis.

5. Remove and retain one of the ”C” clips from

the grooved pin in the upper clevis of the lift

cylinder. Remove the grooved pin.

6. Remove and retain one of the ”C” clips from

the grooved pin in the lower clevis of the lift

cylinder. Remove the grooved pin. Remove

the old lift cylinder from the machine.

7. Remove the fittings from the old cylinder and

install in the new cylinder in the same

orientation.

8. Position the new cylinder in the machine

with the rod end pointing up.

9. Align the bottom of the lift cylinder with the

hole in the frame mount lug. Reinstall the

grooved pin and ”C” clip.

10. Align the small bearing in the lift arm with

the hole in the lift cylinder clevis.

11. Reconnect the hydraulic hoses to the new

lift cylinder. See schematic in this section.

12. Start the machine and raise the hopper.

Check for any leaks and proper operation.

HYDRAULICS

6-42 8410 MM392 (8--01)

TO REPLACE HOPPER DUMP DOOR

CYLINDER

1. 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.

2. Open the hopper cover.

3. Disconnect and plug the two hoses leading

to the hopper dump door cylinder.

4. Remove the retaining ring from the front

cylinder mount pin.

5. Remove the cotter pin and clevis pin from

the rear of the dump door cylinder were it

attaches to the pivot yoke.

6. Remove the old cylinder from the hopper.

7. Remove the fittings from the old cylinder and

install in the new cylinder in the same

orientation.

8. Position the new cylinder in the machine

with the rod end pointing to the rear of the

machine hopper.

9. Slip the piston end of the new cylinder over

the pin on the hopper. Reinstall the retaining

ring.

10. Reinstall the clevis pin and cotter pin in the

rod end of the dump door cylinder and the

door pivot yoke.

11. Reconnect the hydraulic hoses to the dump

door cylinder. See the schematic in this

section.

12. Start the machine and open and close the

hopper dump door. Check for any leaks and

proper operation.

HYDRAULICS

6-43

8410 MM392 (8--01)

TO REPLACE MAIN BRUSH LIFT CYLINDER

1. Start the engine and lower the main brush.

Shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Remove the solution and recovery tanks.

See TO REMOVE SOLUTION TANK

instructions in the SCRUBBING section.

3. Locate the clevis pin holding the main brush

lift cable to the main brush lift arm. Remove

the cotter pin and clevis pin.

4. Start the engine and raise the main brush.

Shut off the engine.

5. Locate the two M10 hex nuts holding the two

plastic tubes to the rod end of the main

brush lift cylinder.

NOTE: Make sure cylinder is all the way

retracted before removing springs.

6. Remove the hex nuts, tension springs,

plastic tubes, main brush lift cable and

threaded rod.

7. Disconnect and plug the two hydraulic hoses

leading to the main brush lift cylinder.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

8. Remove the cotter pin and clevis pin holding

the piston end of the main brush lift cylinder

to the machine frame.

9. Remove the lift cylinder from the machine.

NOTE: Remember to orientate the fittings as

close as possible to the way they came out.

10. Remove the hydraulic fittings from old main

brush lift cylinder and install in the new

cylinder in the same orientation.

HYDRAULICS

6-44 8410 MM392 (8--01)

11. Position the new main brush lift cylinder in

the machine. Align the mount hole in piston

end of the lift cylinder with hole in the mount

bracket on the machine frame.

12. Reinstall the clevis pin and cotter pin.

NOTE: Make sure cylinder is all the way retracted

before installing springs.

13. Reinstall the threaded rod, plastic tubes,

main brush lift cable, M10 hex nuts, and

tension springs to the rod end of the lift

cylinder. Hand tighten hex nuts.

14. Reconnect the hydraulic hoses to the main

brush lift cylinder. See the schematic in this

section.

15. Start engine and lower the main brush. Shut

off the engine.

16. Reconnect the main brush lift cable to the

main brush lift arm using the clevis pin and

cotter pin.

17. Start the engine and run the main brush up

and down. Check for leaks and proper

operation.

18. Reinstall solution and recovery tanks. See

TO INSTALL RECOVERY TANK instructions

in the SCRUBBING section.

HYDRAULICS

6-45

8410 MM392 (8--01)

TO REPLACE SIDE BRUSH LIFT CYLINDER

1. Start the engine and raise the side brush.

Shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Open the hopper cover.

3. Disconnect the tension spring from the

bracket on the side brush lift cylinder and

cable.

4. Start the machine and lower the side brush.

5. Disconnect and plug the two hydraulic hoses

leading to the side brush lift cylinder.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

6. Remove the two hex screws holding the lift

cylinder to the hopper bumper and side

brush lift cable. Remove the lift cylinder 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 on the machine

and reinstall the two hex screws and nyloc

nuts. Make sure the side brush lift cable is

attached to the rod end of the lift cylinder.

9. Reconnect the two hydraulic hoses. See

schematic in the HYDRAULICS section.

10. Start the machine and raise the side brush.

11. Reconnect the tension spring to the

brackets. Close the hopper cover.

HYDRAULICS

6-46 8410 MM392 (8--01)

TO REPLACE SQUEEGEE LIFT CYLINDER

1. Start the engine, lower the rear squeegee,

shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 M8 hex screw, nyloc nut, and

spacer tube from the rear squeegee lift

cable where it attaches at the center of the

rear squeegee frame.

NOTE: The squeegee frame will drop down when

the hex screw is removed.

NOTE: Mark the hoses for proper re--assembly.

4. Remove and plug the hydraulic hoses

connected to the rear squeegee lift cylinder.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

5. Remove the snap retaining ring from the

grooved pin on the pivot plate on the piston

end of the squeegee lift cylinder.

6. Remove the cotter pin and clevis pin from

the rod end of the lift cylinder and squeegee

lift bellcrank.

7. The squeegee lift cylinder can now be pulled

off the mount pin and removed from the

machine.

8. Remove the hydraulic fittings and install in

the new cylinder in the same orientation.

HYDRAULICS

6-47

8410 MM392 (8--01)

9. Position the new cylinder back in the

machine. Place the hole in the piston end of

the squeegee lift cylinder on the grooved

mount pin on frame. Reinstall the snap ring

retainer.

10. Align the hole in the rod end of the new

squeegee lift cylinder with hole in the

squeegee lift bellcrank. Reinstall the clevis

and cotter pin.

11. Reconnect the hydraulic hoses to squeegee

lift cylinder. See the schematic in the

HYDRAULICS section.

12. Lift the squeegee assembly up until the hole

in the lower end of the lift cable lines up with

the hole in the squeegee frame. Reinstall the

M8 hex screw, nyloc nut, and spacer tube.

Tighten to 18 -- 24 Nm (13 -- 18 ft lb).

13. Lower machine and check for proper rear

squeegee lift cylinder operation.

HYDRAULICS

6-48 8410 MM392 (8--01)

TO REPLACE SCRUB BRUSH LIFT CYLINDER

1. Start the engine, lower and side shift the

scrub head, shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 cotter pin from the long

horizontal clevis pin holding each side

squeegee to the scrub head frame. Remove

the clevis pins and squeegee assemblies

from both sides.

4. Remove all three scrub brushes.

5. Remove the 0.25 in. eye bolt holding the

tension spring to the scrub brush motor

bracket.

NOTE: Mark the hoses for proper re--assembly.

6. Remove and plug the hydraulic hoses

connected to the scrub brush lift cylinder.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

7. Remove the cotter pin from the clevis pin

holding the rod end of cylinder to the lower

link. Remove the clevis pin.

8. Remove the 0.38 in. nyloc nut, washer, and

hex screw holding the piston end of the lift

cylinder to the top of the squeegee frame.

The lift cylinder can now be removed from

the scrub frame.

9. Remove the hydraulic fittings from the old

cylinder and install in the same orientation in

the new or rebuilt lift cylinder.

HYDRAULICS

6-49

8410 MM392 (8--01)

10. Position the new lift cylinder back in the

scrub head frame. Align the hole in the

piston end of the cylinder with the hole in the

top of the frame. Reinstall the 0.38 in. hex

screw, washers, and nyloc nut. Firmly

tighten the hardware.

11. Raise the lower link up until the hole in the

rod end of the lift cylinder lines up with the

hole in the bracket. Reinstall the clevis pin

and cotter pin.

12. Reconnect the hydraulic hoses to the lift

cylinder. See the schematic in HYDRAULIC

section.

13. Reinstall the eye bolt and tension spring.

Firmly tighten the nyloc nut.

14. Reinstall the three disc brushes.

15. Reinstall the LH and RH side squeegees

with the long clevis pins and cotter pins.

16. Lower the machine. Start the engine and

check for any leaks and for proper operation

of the scrub brush lift cylinder.

HYDRAULICS

6-50 8410 MM392 (8--01)

TO REPLACE SCRUB HEAD SIDE SHIFT

HYDRAULIC CYLINDER

1. Start the engine, lower and side shift the

scrub head, shut off the engine.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

2. Raise the rear of machine using a hoist or

floor jack.

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 solution and recovery tanks

from the machine. See TO REMOVE

SOLUTION TANK FROM MACHINE

instructions in this section.

4. Once the tanks are removed, locate the side

shift cylinder on the left side of machine,

behind the hydraulic control valve.

NOTE: Mark the hoses for proper re--assembly.

5. Remove and plug the hydraulic hoses

connected to side shift cylinder.

NOTE:Observe hydraulic cleanliness

requirements when opening hydraulic lines.

6. Remove the retaining ring that is holding the

piston end of side shift cylinder to the mount

pinonthemachineframe.

7. Remove the cotter pin and clevis pin holding

the rod end of side shift cylinder to edge

scrub pivot lever.

HYDRAULICS

6-51

8410 MM392 (8--01)

8. The side shift cylinder can now be pulled up

and off the mount pin and removed from the

machine.

9. Remove the hydraulic fittings and install in

the new cylinder in the same orientation.

10. Position the new cylinder back in the

machine. Place the hole in the piston end of

the side shift cylinder on the mount pin on

the machine frame. Reinstall the snap ring

retainer.

11. Align the hole in the rod end of the side shift

cylinder with hole in edge scrub pivot lever.

Reinstall the clevis and cotter pin.

12. Reconnect the hydraulic hoses to the side

shift cylinder. See the schematic in the

HYDRAULICS section.

13. Reinstall the solution and recovery tanks.

See TO INSTALL SOLUTION TANK

instructions in this section.

14. Lower the machine. Start the engine and

check for any leaks and for proper operation

of the side shift function.

HYDRAULICS

8410 MM392 (8--01)

6-52

HYDRAULIC SCHEMATIC

11176 -- 8410, ALL

HYDRAULICS

6-53

8410 MM392 (8--01)

HYDRAULIC SCHEMATIC

11176 -- 8410, ALL

HYDRAULICS

8410 MM392 (8--01)

6-54

HYDRAULIC SCHEMATIC

11177 -- 8410, ALL

HYDRAULICS

6-55

8410 MM392 (8--01)

HYDRAULIC SCHEMATIC

11177 -- 8410, ALL

HYDRAULICS

8410 MM392 (8--01)

6-56

HYDRAULIC HOSE GROUP

Brush

Lift Cylinder LH

Control Valve

Lift Cylinder RH

Manifold

Steering

Control

Steering

Valve

Reservoir

Propelling

Motor

Squeegee

Lift Cylinder

Steering

Cylinder

Cooler

Propel

Pump

Auxilary Pump

Flow Sensor Switch

Filter Main

Motor

Edge In/Out

Cylinder Main Brush

Cylinder

11089

HYDRAULICS

6-57

8410 MM392 (8--01)

HYDRAULIC HOSE GROUP

Scrub Fan

Motor

Manifold

Hopper Control

Valve

Hopper Door

Cylinder

Engine

Motor

Left Scrub Brush Motor Left Scrub Head

Right Scrub Head

Right Scrub

Scrub

Head

Motor

Scrub Head

Lift Cylinder

Side Brush

Lift Cylinder

Hopper Door

Cylinder

Scrub Head

Motor Side Brush

Lift Cylinder

Brush Motor

Center Control Valve

Center

Lift Cylinder

Sweeping

Fan Motor

Fan

11091

HYDRAULICS

8410 MM392 (8--01)

6-58

CLAMP LOCATION AND HOSE ORIENTATION

78820 REF

57160 REF

50121 SLEEVE

87677 SLEEVE

77307 REF

82832 SLEEVE

82815 REF

77308 REF

31602 REF 53466 CLAMP

78776 REF

58366 CLAMP

78810 REF

77337 REF

31568 REF

77338 REF

82815 REF

77297 BRKT W/77298 INSOLATOR

82817 REF 34355 REF

63516 BRKT W/09900--1 SLEEVE

HOSE MOUNTING TO

HOPPER RH CORNER

MAIN BRUSH HOSE MOUNTING

TO BRUSH ARM

HOSE MOUNTING TO MAIN VALVE

BRACKET ON THE FRAME

HOSE MOUNTING TO SEAT SUPPORT

HOSE MOUNTING TO UNDERSIDE OF FRAME

HYDRAULICS

6-59

8410 MM392 (8--01)

CLAMP LOCATION AND HOSE ORIENTATION

50121 SLEEVE (2)

57966 REF

78821 REF

01988 REF

87652 REF

53466 CLAMP

57966 REF

78821 REF

31646 SLEEVE

53468 CLAMP

78887 BRKT W/78886

THREADED ROD

57193 REF

57160 REF

53466 CLAMP

01988 REF

87652 REF

78820 REF

57160 REF

53466 CLAMP

77316 REF

53466 CLAMP

57219 REF

77315 REF

19644 REF

77314 REF

82832 SLEEVE

58842 BRKT

SIDE BRUSH HOSE MOUNTING

(1) CLAMP TO HOPPER LIFT ARM

(1) CLAMP TO HOPPER SIDE

HOSE MOUNTING BY VAC FAN

ON HOPPER BACKSIDE

HOSE MOUNTING FROM SCRUB

VALVE TO MAIN PUMP

HOSE MOUNTING TO

SOLUTION TANK

HOSE MOUNTING ON

HOPPER BACKSIDE

HOSE MOUNTING TO FRAME

BETWEEN FILTER AND HYD TANK

HOSE MOUNTING TO FRAME

FROM MAIN DRIVE MOTOR

HYDRAULICS

8410 MM392 (8--01)

6-60

HYDRAULICS

6-61

8410 MM392 (8--01)

TROUBLESHOOTING

The troubleshooting charts that follow are

organized so they lead you through the circuits.

They include flow charts and instructions for you

as to where to insert your test instruments.

HYDRAULICS

6-62 8410 MM392 (8--01)

2400

RPM

8410 HYDRAULIC PUMP

OPERATION

FLOW

COMPENSATOR

HIGH PRESSURE

COMPENSATOR

SENSE

LINE

PRESSURE

LINE

2500 PSI

250 PSI

PRESSURE LINE

SENSE LINE

= 250 PSI

PURPOSE: 1. Reduce the total number of gear pumps.

2. Reduce the amount of horsepower required.

GENERAL: The pump will deliver only the amount of oil which is demanded by

the system.

OPERATION OF PISTON PUMP:

The piston pump contains nine piston assemblies which will move in and out of

the piston block bores depending on the position of the cam plate. With the cam

plate in the neutral position, there is no displacement of oil from the input to the

output of the pump.

When the cam plate moves, the pistons will move in and out of the bores. Now the

pump will pump oil. The pistons which are pulled, suck oil into the pump and then

pushes the oil out the pressure port.

HYDRAULICS

6-63

8410 MM392 (8--01)

2400

RPM

8410 HYDRAULIC PUMP

LOW PRESSURE FLOW

FLOW

COMPENSATOR

HIGH PRESSURE

COMPENSATOR

SENSE

LINE

PRESSURE

LINE

No demand for oil, so also no pressure fed back to the pump compensator

through the sensor line. The pump will go into the low--pressure standby

position. On the other ends of the flow compensator spool and high--

pressure compensator spool, there will be a pressure of about 250 PSI

(internal working of the pump). The flow spool will move and the oil will

flow into the control piston. The pressure will move the cam plate back to

neutral position causing the pump to destroke. Pump will only pump

enough oil to make up for internal oil leakage and maintain 250 PSI in the

pressure line.

PRESSURE--FLOW LOW--PRESSURE STANDBY:

HYDRAULICS

6-64 8410 MM392 (8--01)

2400

RPM

8410 HYDRAULIC PUMP

INCREASE FLOW DEMAND

FLOW

COMPENSATOR

HIGH PRESSURE

COMPENSATOR

SENSE

LINE

PRESSURE

LINE

PRESSURE--FLOW INCREASED FLOW DEMAND:

Demand for increased oil flow. The flow spool moves because of the pressure

on the sensor line. Now the oil will flow from the control piston via the spool

to the drain suction port. The cam plate will move to a greater angle and the

pump will provide more oil until the demand of oil is met.

PRESSURE--FLOW LOAD SENSING WORKING PRESSURE:

When there is a demand of oil, this is controlled by the difference in pressure

applied to the ends of the flow compensating spool. When the pressure in

the sensor line increases or decreases, the spool will move up and down.

This means that the control piston for the cam plate will be filled with oil or

decharged. This will move the cam plate to another position. When moving

the cam plate, the nine piston assemblies will move in and out of the bores

and provide more or less oil to the output port.

HYDRAULICS

6-65

8410 MM392 (8--01)

2400

RPM

8410 HYDRAULIC PUMP

HIGH PRESSURE

FLOW

COMPENSATOR

HIGH PRESSURE

COMPENSATOR

SENSE

LINE

PRESSURE

LINE

HIGH--PRESSURE STANDBY:

When the hydraulic system is overloaded, the pump will go into the high--

pressure standby position. The pressure on both ends of the flow spool

will be equal and does not function in this case. Now the high--pressure

spool is working. The pressure from the pump will move the spool and

will enter oil inside the control piston which will move the cam plate in

the position compared to the normal working condition. This means the

amount of oil is reduced.

HYDRAULICS

6-66 8410 MM392 (8--01)

ENGINE

FAN

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

SV02

LS1

RPM

ENGINE FAN CIRCUIT (HIGH SPEED)

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

1100 PSI

2.3 GPM (HIGH SPEED)

PRESSURE READINGS BASED

ON 150 F

HYDRAULICS

6-67

8410 MM392 (8--01)

ENGINE

FAN

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

SV02

LS1

RPM

ENGINE FAN CIRCUIT (IDLE SPEED)

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

.8 GPM (IDLE SPEED)

PRESSURE READINGS BASED

ON 150 F

HYDRAULICS

6-68 8410 MM392 (8--01)

ENGINE FAN DOES NOT RUN

NO YES

FLOW COMPENSATOR

CS2 STUCK?

CLEAN OR REPLACE

CS2

ORIFICE PLUGGED? NO

CHECK FAN

MOTOR

HYDRAULICS

6-69

8410 MM392 (8--01)

ENGINE FAN ALWAYS RUNS FAST

YESNO

NO YES

IS SV--2 CARTRIDGE

STEM STUCK?

FLOW COMPENSATOR

CS2 STUCK?

CLEAN OR REPLACE

CS2

ORIFICE PLUGGED?

CLEAN OR REPLACE

SV--2

HYDRAULICS

6-70 8410 MM392 (8--01)

ENGINE FAN ALWAYS RUNS SLOW

YESNO

NO YES

IS SV--2 CARTRIDGE

STEM STUCK?

FLOW COMPENSATOR

CS2 STUCK?

CLEAN OR REPLACE

CS2

ORIFICE PLUGGED?

CLEAN OR REPLACE

SV--2

CHECK FAN

MOTOR

HYDRAULICS

6-71

8410 MM392 (8--01)

HYDRAULICS

6-72 8410 MM392 (8--01)

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

SV01

SV02

5 PSI

LS1

RPM

SCRUB FAN CIRCUIT

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

SCRUB

FAN

1250 PSI

6.5 GPM

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

SQUEEGEE DOWN - CLEAN

MODE

HYDRAULICS

6-73

8410 MM392 (8--01)

SCRUB FAN DOES NOT TURN OFF

YESNO

NO YES

REPAIR OR REPLACE

SV--1

IS SC1 SENSE YES

DOES SV--1 COIL HAVE

MAGNETISM AFTER

TURNING THE

SCRUBBER FAN OFF?

CHECK

ELECTRICAL

SYSTEM

IS SV--1 CARTRIDGE

STEM STUCK OPEN?

REPAIR OR REPLACE

SC1

CHECK STUCK OPEN?

HYDRAULICS

6-74 8410 MM392 (8--01)

SCRUB FAN DOES NOT TURN ON

YES NO

NO YES

REPAIR OR REPLACE

SV--1

IS COMPENSATOR

YES

DOES SV--1 COIL HAVE

MAGNETISM AFTER

TURNING THE

SCRUBBER ON?

CHECK

ELECTRICAL

SYSTEM

IS SV--1 CARTRIDGE

STEM STUCK CLOSED?

REPAIR OR REPLACE

CS1

CS1 STUCK CLOSED?

IS ORIFICE OR1

PLUGGED?

REPAIR OR REPLACE

OR1

YES

HYDRAULICS

6-75

8410 MM392 (8--01)

HYDRAULICS

6-76 8410 MM392 (8--01)

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

C10

C11

C12

C13

DR5

SV16

SV15

SV17

HOPPER DOOR CLOSE CIRCUIT

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

LINE

PRESSURE

HYDRAULICS

6-77

8410 MM392 (8--01)

HOPPER DOOR DOES NOT OPEN

YES NO

NO YES

DOES SV--17 COIL HAVE

MAGNETISM FOR TIMED

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--17

CARTRIDGE STEM

PERIOD AFTER

TOUCHING THE DOOR

OPEN/CLOSE BUTTON?

ARE THE DOOR

CYLINDERS

RETRACTING?

CHECK DOOR

SEALS FOR BINDING

HYDRAULICS

6-78 8410 MM392 (8--01)

HOPPER DOOR DOES NOT CLOSE

YES NO

DOES SV--16 COIL HAVE

MAGNETISM FOR TIMED

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--16

CARTRIDGE STEM

PERIOD AFTER

TOUCHING THE DOOR

OPEN/CLOSE BUTTON?

HYDRAULICS

6-79

8410 MM392 (8--01)

HOPPER DOOR DOES NOT

STAY CLOSED

YESNO

DOES SV--17 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

ALL THE TIME?

DOOR CYLINDER

PISTON SEAL

LEAKING?

YES NO

REPLACE LEAKY

DOOR CYLINDER

REPLACE SV--17

CARTRIDGE STEM

SEALS

DOES DOOR

STAY CLOSED?

REPLACE SV--17

CARTRIDGE STEM

HYDRAULICS

6-80 8410 MM392 (8--01)

SV10

SV08 SV09

SV12

OR4

5 PSI

SV11

DR4

LS4

P4 PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

HOPPER LIFT CIRCUIT

1300 PSI -- EMPTY

2400 PSI -- FULL

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-81

8410 MM392 (8--01)

HOPPER DOES NOT RAISE

YES NO

DOES SV--8 & SV--9 HAVE

MAGNETISM AFTER

CHECK

ELECTRICAL

SYSTEM

TOUCHING THE HOPPER

LIFT CYLINDER

PISTON SEAL

LEAKING?

YES NO

REPLACE LEAKY

LIFT CYLINDER

DOES HOPPER

REPLACE SV--8

CARTRIDGE STEM &

RAISE BUTTON?

PUT #10 O--RING

PLUG IN PLACE OF

SV--9 CARTRIDGE

STEM

RAISE AND NOT

STAY UP?

YES

PUT SV--9 CARTRIDGE

BACK IN PLACE

REPLACE SV--9

CARTRIDGE STEM

WITH NEW STEM

HYDRAULICS

6-82 8410 MM392 (8--01)

HOPPER DRIFTS DOWN TOO QUICKLY

YESNO

DOES SV--9 COIL HAVE

MAGNETISM AFTER

CHECK

ELECTRICAL

SYSTEM

RAISING HOPPER?

LIFT CYLINDER

PISTON SEAL

LEAKING?

YES NO

REPLACE LEAKY

LIFT CYLINDER

REPLACE SV--9

CARTRIDGE STEM

SEALS

DOES HOPPER

STAY IN UP

REPLACE SV--9

CARTRIDGE STEM

POSITION?

HYDRAULICS

6-83

8410 MM392 (8--01)

HYDRAULICS

6-84 8410 MM392 (8--01)

SV10

SV08

SV09

SV12

OR4

5 PSI

SV11

DR4

LS4

P4 PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

HOPPER LOWER CIRCUIT

HYDRAULICS

6-85

8410 MM392 (8--01)

HOPPER DOES NOT LOWER

YES NO

DOES SV--9 COIL HAVE

MAGNETISM AFTER

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--9

CARTRIDGE STEM

TOUCHING THE HOPPER

LOWER BUTTON?

HYDRAULICS

6-86 8410 MM392 (8--01)

SWEEP FAN

MAIN BROOM

LIFT

SV06 3

OR6

SV05

5 PSI

CS4

OR5

SV11

DR4PB1

PB2

SV13

SV18

RV5

1800

MAIN BROOM

PSI

5.4 GPM

6.7 GPM

LS3 P4

DOWN

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

MAIN BRUSH CIRCUIT -- SPD 1

(MAIN BRUSH DOWN AND ON, VAC FAN ON)

1100 PSI

750 PSI

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-87

8410 MM392 (8--01)

SWEEP FAN

MAIN BROOM

LIFT

SV06

OR6

SV05

5 PSI

CS4

OR5

SV11

DR4PB1

PB2

SV13

SV18

RV5

1800

MAIN BROOM

PSI

5.4 GPM

6.7 GPM

LS3 P4

DOWN

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

MAIN BRUSH CIRCUIT -- SPD 2

(MAIN BRUSH DOWN AND ON, VAC FAN ON)

1400 PSI

1050 PSI

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-88 8410 MM392 (8--01)

MAIN BRUSH DOES NOT RAISE

YESNO

DOES SV--11 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

YES NO

REPLACE SV--11

AFTER TURNING THE

MAIN BRUSH OFF?

IS THE LIFT

CYLINDER

RETRACTING?

CHECK

MECHANICAL

LINKAGE STEM

HYDRAULICS

6-89

8410 MM392 (8--01)

MAIN BRUSH DOES NOT LOWER

YES NO

DOES SV--11 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

YES NO

REPLACE SV--11

AFTER TURNING THE

MAIN BRUSH ON?

IS THE LIFT

CYLINDER

EXTENDING?

CHECK

MECHANICAL

LINKAGE STEM

HYDRAULICS

6-90 8410 MM392 (8--01)

MAIN BRUSH DOES NOT

TURN OFF

YES

CHECK

ELECTRICAL

SYSTEM

YES NO

IS MAIN BRUSH

STUCK IN SPEED 1?

CHECK VOLTAGE

AT SV--5 & SV--6

AFTER TURNING OFF

REPLACE STEM

CARTRIDGE FOR

SV--5

REPLACE STEM

CARTRIDGE FOR

SV--6

HYDRAULICS

6-91

8410 MM392 (8--01)

MAIN BRUSH DOES NOT

TURN ON

YES NO

CHECK

ELECTRICAL

SYSTEM

YES

CHECK VOLTAGE

AT SV--5 IN LOW SPEED

REPLACE STEM

CARTRIDGE FOR

SV--5 OR SV--6

(SV--6 IN HIGH SPEED)

CHECK STEM

(IS IT SHIFTING?)

CHECK FLOW

COMPENSATOR

CS4 FOR STICKING

YESNO

REPLACE FLOW

COMPENSATOR

CS4

CHECK LOAD

SENSE CHECKS

FOR LEAKING

YES

RESEAT CHECK

VALVE OR REPLACE

VALVEBLOCK

OVER--RUNNING

CHECK VALVE AT

3 PSI STUCK OPEN?

NO YES

REPLACE

CHECK VALVE

CHECK LOAD--

SENSE PUMP FOR

FLOW

CHECK MAIN

BRUSH MOTOR

CHECK

PLUMBING

HYDRAULICS

6-92 8410 MM392 (8--01)

SWEEPER FAN DOES NOT TURN OFF

YES NO

DOES SV--18 COIL ON

MAGNETISM AFTER

TURNING FAN OFF?

FAN MOTOR HAVE

REPLACE SV--18

STEM

CHECK

ELECTRICAL

SYSTEM

HYDRAULICS

6-93

8410 MM392 (8--01)

SWEEPER FAN DOES NOT TURN ON

YES NO

NO YES

DOES SV--18 COIL ON

MAGNETISM AFTER

TURNING FAN ON?

CHECK

ELECTRICAL

SYSTEM

FAN MOTOR HAVE

IS THE MAIN

BRUSH MOTOR AT

SWEEP SPEED?

CHECK MAIN

BRUSH MOTOR

FUNCTIONS

REPLACE SV--18

STEM AT FAN MOTOR

DOES FAN MOTOR

TURN ON?

REPLACE THE

FAN MOTOR

HYDRAULICS

6-94 8410 MM392 (8--01)

SIDE BROOM

SWEEP FAN

SIDE BROOM

LIFT

SV06 3

OR6

SV05

5 PSI

CS4

OR5

PB1

C10

C11

C12

C13

PB2

DR5

SV16

SV15

SV13

SV17

SV18

RV5

1800

MAIN BROOM

PSI

5.4 GPM

6.7 GPM

LS3 P4

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

SIDE BRUSH CIRCUIT -- SPD 1

(MAIN BRUSH ON, VAC FAN ON, SIDE BRUSH DOWN AND ON)

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

750 PSI

850 PSI

1200 PSI

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-95

8410 MM392 (8--01)

SIDE BROOM

SWEEP FAN

SIDE BROOM

LIFT

SV06 3

OR6

SV05

5 PSI

CS4

OR5

PB1

C10

C11

C12

C13

PB2

DR5

SV16

SV15

SV13

SV17

SV18

RV5

1800

MAIN BROOM

PSI

5.4 GPM

6.7 GPM

LS3 P4

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

SIDE BRUSH CIRCUIT -- SPD 2

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

(MAIN BRUSH ON, VAC FAN ON, SIDE BRUSH DOWN AND ON)

1600 PSI

1150 PSI

1050 PSI

1600 PSI

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-96 8410 MM392 (8--01)

SIDE BRUSH DOES NOT RAISE

YESNO

DOES SV--15 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

YES NO

REPLACE SV--15

AFTER TURNING THE

SIDE BRUSH OFF?

IS THE LIFT

CYLINDER

RETRACTING?

CHECK

MECHANICAL

LINKAGE STEM

HYDRAULICS

6-97

8410 MM392 (8--01)

SIDE BRUSH DOES NOT LOWER

YES NO

DOES SV--15 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

YES NO

REPLACE SV--15

AFTER TURNING THE

SIDE BRUSH ON?

IS THE LIFT

CYLINDER

EXTENDING?

CHECK

MECHANICAL

LINKAGE STEM

HYDRAULICS

6-98 8410 MM392 (8--01)

SIDE BRUSH DOES NOT

TURN OFF

YES

DOES SV--13 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--13

AFTER TURNING THE

SIDE BRUSH OFF?

STEM

HYDRAULICS

6-99

8410 MM392 (8--01)

SIDE BRUSH DOES NOT

TURN ON

YES NO

DOES SV--13 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--13

AFTER TURNING THE

SIDE BRUSH ON?

STEM

NO YES

IS THE MAIN

BRUSH MOTOR AT

SWEEP SPEED?

CHECK MAIN

BRUSH MOTOR

FUNCTIONS

DOES SIDE BRUSH

MOTOR TURN ON?

REPLACE THE

SIDE BRUSH

MOTOR

HYDRAULICS

6-100 8410 MM392 (8--01)

SV10

SV08 SV09

SV12

OR4

5 PSI

SV11

DR4PB1

LS4

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

EDGE SCRUB CIRCUIT

OUT

LINE

PRESSURE

HYDRAULICS

6-101

8410 MM392 (8--01)

SCRUB HEAD DOES NOT GO IN

YES

DOES SV--10 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--10

AFTER TURNING THE

EDGER OFF?

STEM

NOYES IS THE EDGER

CYLINDER

RETRACTING?

CHECK

MECHANICAL

LINKAGE

HYDRAULICS

6-102 8410 MM392 (8--01)

SCRUB HEAD DOES NOT GO OUT

YES NO

DOES SV--10 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

REPLACE SV--10

AFTER TURNING THE

EDGER ON?

STEM

NOYES IS THE EDGER

CYLINDER

EXTENDING?

CHECK

MECHANICAL

LINKAGE

HYDRAULICS

6-103

8410 MM392 (8--01)

HYDRAULICS

6-104 8410 MM392 (8--01)

A150--400 PSI

SV19

300 PSI

84010

.018

.040 DIA

OR12

SCRUB HEAD LOWER CIRCUIT

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

DOWN

PRESSURE

DOWN FORCE PRESSURE

PSI

LEVEL #

150 LBS

300 LBS

450 LBS

260

330

380

HYDRAULICS

6-105

8410 MM392 (8--01)

SV4 AND SV19 STEMS

MAGNETIZED?

CHECK

ELECTRICAL SYSTEM

REPAIR OR REPLACE

PR1 STEM

CARTRIDGE

C2 PORT

PRESSURE OK?

(>400 PSI)

YES

SCRUB BRUSHES DO NOT LOWER

YES NO

C1 PORT

PRESSURE OK?

250--300 PSI

REPAIR OR REPLACE

SV4 STEM

CARTRIDGE

HYDRAULICS

6-106 8410 MM392 (8--01)

A150--400 PSI

SV19

300 PSI

84010

.018

.040 DIA

OR12

SCRUB HEAD RAISE CIRCUIT

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

PRESSURE

290 -- 310 PSI

HYDRAULICS

6-107

8410 MM392 (8--01)

C1 PORT PRESSURE

OK ? (300 PSI)

C2 PORT PRESSURE

OK ? (<25 PSI)

REPAIR OR REPLACE

PR1 CARTRIDGE

YES NO

SCRUB BRUSHES DO NOT RAISE

DR1 PORT PRESSURE

OK ? (<25 PSI)

YES

SV4 STEM

MAGNETIZED ?

REPAIR OR REPLACE

PLUMBING

REPAIR OR REPLACE

LINKAGE OR CYLINDER

YES

SV4 STEM CARTRIDGE

SHIFTING OK ?

REPAIR OR REPLACE

SV4 STEM CARTRIDGE

YES

CHECK

ELECTRICAL SYSTEM

HYDRAULICS

6-108 8410 MM392 (8--01)

SCRUB

BRUSHES

S--21

RV7

PSI

FILTER

STRAINER

RESERVOIR

RV1

3 PSI

2400

SV01

SV02

SV03

5 PSI

LS1

RPM

SCRUB BRUSH CIRCUIT

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-109

8410 MM392 (8--01)

SCRUB BRUSHES DO NOT

TURN OFF

YESNO

DOES SV--3 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

AFTER TURNING THE

SCRUBBER OFF?

YES

REPAIR OR REPLACE

IS SV--3 CARTRIDGE

STEM STUCK OPEN?

SV--3

IS SC3 STUCK

OPEN?

REPAIR OR REPLACE

SC3

HYDRAULICS

6-110 8410 MM392 (8--01)

SCRUB BRUSHES DO NOT TURN ON

YES NO

DOES SV--3 COIL

HAVE MAGNETISM

CHECK

ELECTRICAL

SYSTEM

AFTER TURNING THE

SCRUBBER ON?

YES

REPAIR OR REPLACE

IS SV--3 CARTRIDGE

STEM STUCK CLOSED?

SV--3

IS COMPENSATOR

CS3 STUCK

CLOSED?

REPAIR OR REPLACE

CS3

IS ORIFICE OR3

PLUGGED?

YES

REPAIR OR REPLACE

OR3

HYDRAULICS

6-111

8410 MM392 (8--01)

HYDRAULICS

6-112 8410 MM392 (8--01)

SV10

SV08 SV09

SV12

OR4

SV11

DR4PB1

LS4

SQUEEGEE LIFT CIRCUIT

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

LINE

PRESSURE

HYDRAULICS

6-113

8410 MM392 (5--02)

SQUEEGEE DOES NOT RAISE

YES NO

CHECK

ELECTRICAL

SYSTEM

NO YES

YES

IS ORIFICE TV16

PLUGGED?

YES

CLEAN OR REPLACE

ORIFICE

CHECK VOLTAGE

AT SV -- 12

CHECK STEM

(IS IT SHIFTING?)

REPLACE STEM

CARTRIDGE FOR

SV--12

PILOT CHECK

VALVE PC1 STUCK?

REPLACE CHECK

VALVE PC1

CHECK SQUEEGEE

LIFT CYLINDER

HYDRAULICS

6-114 8410 MM392 (8--01)

SQUEEGEE DRIFTS DOWN TOO QUICKLY

YESNO

NO YES REPLACE CHECK

VALVE PC1

PILOT CHECK VALVE

PC1 LEAKING?

SQUEEGEE LIFT

CYLINDER

LEAKING?

CHECK PLUMBING

FOR LEAKS

REPLACE

CYLINDER

HYDRAULICS

6-115

8410 MM392 (8--01)

HYDRAULICS

6-116 8410 MM392 (8--01)

SV10

SV08 SV09

SV12

OR4

SV11

DR4PB1

LS4

SQUEEGEE LOWER CIRCUIT

STRAINER

RESERVOIR

RV1

3 PSI

2400

RPM

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

LINE

PRESSURE

HYDRAULICS

6-117

8410 MM392 (8--01)

SQUEEGEE DOES NOT LOWER

YES NO

CHECK

ELECTRICAL

SYSTEM

NO YES

YES

IS ORIFICE TV16

PLUGGED?

YES

CLEAN OR REPLACE

ORIFICE

CHECK VOLTAGE

AT SV -- 12

CHECK STEM

(IS IT SHIFTING?)

REPLACE STEM

CARTRIDGE FOR

SV--12

PILOT CHECK

VALVE PC1 STUCK?

REPLACE CHECK

VALVE PC1

CHECK SQUEEGEE

LIFT CYLINDER

HYDRAULICS

6-118 8410 MM392 (8--01)

STRAINER

RESERVOIR

RV1

3 PSI

2400

RV6

1000 PSI

TEP

RPM

LEFT TURN CIRCUIT

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

400 PSI

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-119

8410 MM392 (8--01)

STRAINER

RESERVOIR

RV1

3 PSI

2400

RV6

1000 PSI

TEP

RPM

RIGHT TURN CIRCUIT

PRESSURE

RETURN

SUCTION

CASE DRAIN

SENSE LINE

400 PSI

PRESSURE READINGS BASED

ON 150 F - SMOOTH FLOORS

HYDRAULICS

6-120 8410 MM392 (8--01)

ENGINE--GAS/LP

7-1

8410 MM392 (5--02)

CONTENTS

Page

INTRODUCTION 7-3......................

LUBRICATION 7-4.....................

ENGINE OIL 7-4....................

COOLING SYSTEM 7-5................

RADIATOR 7-5.....................

ENGINE FAN BELT 7-5..............

AIR INTAKE SYSTEM 7-6..............

AIR FILTER INDICATOR 7-6.........

AIR FILTER 7-7.....................

TO REPLACE AIR FILTER

ELEMENT 7-7................

FUEL SYSTEM -- GASOLINE 7-9........

FUEL FILTERS 7-9..................

CARBURETOR 7-9.................

FUEL SYSTEM -- LPG 7-10.............

FUEL TANKS 7-12..................

TO CHANGE LPG FUEL TANK 7-14..

FUEL FILTER LOCK 7-15............

VAPORIZER-REGULATOR 7-15......

CARBURETOR 7-15................

OIL PRESSURE SWITCH 7-15.......

LPG FUEL TROUBLESHOOTING 7-16...

GOVERNOR 7-17.....................

TO ADJUST GOVERNOR

CONTROL BOX 7-17.............

DIGITAL CONTROLLER SET--UP 7-18

GOVERNOR

TROUBLESHOOTING 7-19.......

IGNITION SYSTEM 7-22...............

SPARK PLUGS 7-22................

TO REPLACE SPARK PLUGS 7-22...

ENGINE IGNITION TIMING 7-22.....

TIMING BELT 7-22..................

CYLINDER HEAD 7-23..............

VALVE TAPPET CLEARANCE 7-23...

CRANKCASE VENTILATION

SYSTEM 7-23...................

INTAKE MANIFOLD 7-23............

TO CHANGE ENGINE TIMING BELT 7-24

TO REPLACE ALTERNATOR 7-26....

TO REPLACE STARTER 7-28........

TO REMOVE ENGINE 7-30..........

TO INSTALL ENGINE 7-32...........

GAS ENGINE SERVICE MANUALS

FORD LRG--423 (2.3 Litre)

TENNANT Part Number 21791

FORD LRG--425 (2.5 Litre)

TENNANT Part Number 385439

ENGINE--GAS/LP

7-2 8410 MM392 (8--01)

ENGINE--GAS/LP

7-3

8410 MM392 (8--01)

INTRODUCTION

This section includes repair information on the

engine and related systems, such as fuel,

electrical, and drive belts.

ENGINE--GAS/LP

7-4 8410 MM392 (8--01)

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 4.7 L

(5 qt) including the oil filter.

ENGINE--GAS/LP

7-5

8410 MM392 (8--01)

COOLING SYSTEM

RADIATOR

Check the radiator coolant every 100 hours of

operation. Use clean water mixed with a

permanent-type, ethylene glycol antifreeze to a

-- 3 4 _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.

ENGINE FAN BELT

The engine fan belt is driven by the engine

crankshaft pulley and drives the alternator pulley.

Proper belt tension is 9 to 10 mm (0.35 to 0.39

in) for a new belt and 10 to 11 mm (0.3 to 0.43 in)

for a used belt with a force of 10 kg (22 lb).

Check and adjust the belt tension every 100 hours

of operation.

ENGINE--GAS/LP

7-6 8410 MM392 (5--02)

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.

ENGINE--GAS/LP

7-7

8410 MM392 (5--02)

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 when

the air filter indicator shows a restriction. The air

filters cannot be cleaned.

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.

Replace 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.

TO REPLACE AIR FILTER ELEMENT

1. Stop 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.

2. Open the left side and top engine access

doors.

3. Unscrew the clamp ring on the filter

assembly.

4. Remove the dust cap.

5. Empty the dust cap.

6. Remove the filter wing nut.

7. Gently pull the filter element out of the filter

housing.

8. Clean the interior of the air cleaner housing

with a damp cloth. Clean the element

housing sealing surfaces.

9. 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.

ENGINE--GAS/LP

7-8 8410 MM392 (5--02)

10. 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.

11. 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.

12. Install the dust cap on the air filter housing

with the arrows pointing up. Tighten the

clampringtoholditinplace.Checkall

intake hose connections for leaks or

abrasions.

13. Reset the air filter restriction indicator.

14. Close the access doors.

ENGINE--GAS/LP

7-9

8410 MM392 (8--01)

FUEL SYSTEM -- GASOLINE

FUEL FILTERS

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. Proper idle

speed is 950 + 50 rpm with all accessories off.

ENGINE--GAS/LP

7-10 8410 MM392 (8--01)

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.

ENGINE--GAS/LP

7-11

8410 MM392 (8--01)

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.

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.

ENGINE--GAS/LP

7-12 8410 MM392 (8--01)

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.

03485

ENGINE--GAS/LP

7-13

8410 MM392 (8--01)

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.

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.

03485

ENGINE--GAS/LP

7-14 8410 MM392 (8--01)

TO CHANGE 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).

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.

03485

ENGINE--GAS/LP

7-15

8410 MM392 (8--01)

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

The 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

The 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.

ENGINE--GAS/LP

7-16 8410 MM392 (8--01)

LPG FUEL TROUBLESHOOTING

Problem Cause Remedy

Engine will not start Outoffuel 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

Engine runs unevenly or lacks

power

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--GAS/LP

7-17

8410 MM392 (5--02)

GOVERNOR

The electronic governor controls the engine

speed. The governor consists of an ignition

control assembly, a control box, and an actuator

mounted to the carburetor. 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 CONTROL BOX

FOR SAFETY: Before Leaving Or

Servicing Machine: Stop On Level

Surface, Set The Parking Brake.

1. Raise the rear of the machine until the drive

wheel is off the floor.

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 speed switch to 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 engine surges do not occur.

Replace the hole plug if removed for

adjustment.

6. FOR DIGITAL CONTROLLER:

Follow the instructions on the Digital

Controller SetUp diagram.

ENGINE--GAS/LP

7-18 8410 MM392 (5--02)

rocker down

Set DIP switches according to

controller label, before installing

controller.

123 45 6 78

DIGITAL CONTROLLER SET -- UP

ENGINE--GAS/LP

7-19

8410 MM392 (8--01)

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 two.

If the problem continues, it is not with the

governor, it is with the ignition signal, fuel

systems or the engine itself.

2. The idle speed is the governor position. This

is 1100 -- 1500 RPM and is controlled by the

governor, NOT THE IDLE STOP SCREW

ON THE CARBURETOR! In order to adjust

the idle mixture and (SHUTOFF SPEED) on

the carburetor,either of the wires on the

actuator box must be disconnected. After

warming up the engine, adjust the shutoff

speed to 850 ¦25 RPM and adjust the idle

mixture for optimum idle quality. After doing

this, shut off the engine and reattach the

wires to the actuator. It is important that the

shutoff speed not be set any higher than 900

RPM or the engine will (diesel) when it is

shut off. Again, the idle speed screw on the

carburetor does not control the start/idle

speed of a correctly setup engine.

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.

ENGINE--GAS/LP

7-20 8410 MM392 (8--01)

4. System Grounds

The wire harness grounds 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.

The actuator is internally isolated and does

not require that the cable be grounded.

5. 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.

6. 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.

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.

a. Hunts at running speed with the

accessories off.

ENGINE--GAS/LP

7-21

8410 MM392 (5--02)

b. Responds very sluggishly to switch

changes, an adjustment change in the

control box may be necessary.

FOR ANALOG CONTROLLER:

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.

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.

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 CONTROLLER:

See To Adjust Governor Control Box section

of this manual.

ENGINE--GAS/LP

7-22 8410 MM392 (8--01)

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.

1. Open the engine cover and side door.

2. Pull the plug wires off the spark plugs.

NOTE: Before spark plugs are removed; clean

any dirt or grease that has accumulated around

the base of the spark plug.

3. Remove the spark plugs from the engine

cylinder head.

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.

ENGINE IGNITION TIMING

The engine timing should be set at 10_BTDC with

the throttle set in the idle position.

TIMING BELT

Check the engine timing belt every 800 hours of

operation, and replace the engine timing belt

every 1600 hours of operation.

ENGINE--GAS/LP

7-23

8410 MM392 (8--01)

CYLINDER HEAD

A three-stage torque procedure should be used

when reassembling the cylinder head. Tighten the

cylinder head bolts seasonally. See Ford LRG 2.5

Engine Service Manual at the end of this section.

VALVE TAPPET CLEARANCE

The valve tappet clearance must be checked and

adjusted if necessary every 400 hours of

operation. See Ford LRG 2.5 Engine Service

Manual.

Clean the crankcase ventilation hoses, tubes, and

fittings and replace the PCV valve every

400 hours of operation.

CRANKCASE VENTILATION SYSTEM

Replace the PCV valve every 400 hours of

operation. Clean the crankcase ventilation hoses,

tubes, and fittings every 800 hours of operation.

INTAKE MANIFOLD

Tighten the intake manifold bolts or nuts every

800 hours of operation. They are tighten in a two

step sequence. Torque the M8 bolts or nuts to

7to9.5Nm(5to7ftlb)inthefirststep,and

19 to 28.5 Nm (14 to 21 ft lb) in the second step

of torquing.

ENGINE--GAS/LP

7-24 8410 MM392 (8--01)

TO CHANGE ENGINE TIMING BELT

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from machine.

2. Open the engine cover and side door.

3. Remove the engine spark plugs.

NOTE: Make sure the timing pointer on the timing

belt cover is lined up with the ”O” mark on the

crank shaft damper before removing the timing

belt.

4. Loosen the engine alternator and remove

the V--belt.

NOTE: If the engine is equipped with a smaller

top timing belt cover; it needs to be removed

before the larger timing belt cover can be

removed.

5. Remove the three M6 hex screws and nyloc

nuts holding the smaller top cover to the

engine. Remove and retain the smaller

cover.

6. Remove the crankshaft damper pulley.

7. Pull the belt guide off the end of the

crankshaft where the damper was removed.

8. Remove the five hex screws holding the

large timing belt cover to the engine.

Remove and retain the large cover.

NOTE: The tension on the timing belt needs to be

released before the belt can be removed.

9. Loosen the belt tensioner adjustment screw

and release the tension on the timing belt.

Once the tension is released, re--tighten the

tensioner adjustment screw.

NOTE: A special tension release tool is available

from FORD. The part number is T74P--6254--A. A

small pry bar may be used in place of this tool.

ENGINE--GAS/LP

7-25

8410 MM392 (8--01)

10. Remove the old timing belt from the engine.

11. Before installing a new timing belt, make

sure the camshaft sprocket timing mark lines

up with the timing pointer on the engine.

12. Remove the distributor cap and set the

distributor rotor to number 1 firing position

by turning the auxiliary shaft sprocket.

Reinstall the distributor cap.

13. Install the new timing belt over the

crankshaft sprocket and then

counterclockwise over the the auxiliary and

camshaft sprockets. Align the belt fore and

aft on each sprocket.

14. Loosen the tensioner adjustment bolt to

allow the tensioner to move against the belt.

15. Rotate the crankshaft two complete turns in

normal rotation to remove the slack from the

belt.

16. Re--check the alignment of the timing marks.

17. Reinstall the belt guide and damper to the

crankshaft.

18. Reinstall the timing belt cover and the five

hex screws.

19. Reinstall the small, top cover on the timing

belt cover. Hand tighten the three M6 hex

screws and nyloc nuts.

20. Reinstall the spark plugs.

21. Reinstall the alternator V--belt, pull the

alternator to tension the belt, tighten the

alternator mount bolts.

22. Reconnect the battery cables. Start the

engine and check the timing. The timing

should be set at 10 degrees BTDC with the

engine at idle speed.

ENGINE--GAS/LP

7-26 8410 MM392 (8--01)

TO REPLACE ALTERNATOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. The solution and recovery tanks must be

removed from machine to replace the

alternator. See TO REMOVE SOLUTION

TANK FROM MACHINE instructions in the

SCRUBBING section of this manual.

2. Disconnect the battery cables from the

battery.

3. Open the engine cover and side door.

4. Disconnect the wires on the back of the

alternator.

5. Remove the 0.31 in. hex screw holding the

top of the alternator to the upper mount

bracket. Push the alternator toward the

engine and remove the v--belt.

6. Remove the 0.38 in. hex screw and nyloc

nut holding the bottom of the alternator to

the lower mount bracket.

7. The alternator can now be removed. Bring

the alternator forward and out through the

area of the solution tanks.

8. If the new or rebuilt alternator needs a drive

pulley; remove the pulley from the old

alternator by holding pulley from turning and

using an impact wrench to remove hex nut.

9. Install pulley, washer, and hex nut on the

new alternator. Hand tighten the nut with an

impact wrench.

10. Install the new alternator back in the

machine. Align the bottom hole in the

alternator with hole in the lower mount

bracket. Reinstall the 0.38 in. hex bolt,

washer, and sleeve. Leave loose for now.

11. Place the v--belt back on the alternator

pulley.

ENGINE--GAS/LP

7-27

8410 MM392 (8--01)

12. Reinstall the 0.31 in. hex screw in the top

hole of the alternator through the upper

mounting bracket. Pull alternator toward the

outside of machine to tighten belt. Tighten

the hex screw to 18 -- 24 Nm (13 -- 18 ft lb).

13. The engine fan belt is driven by the engine

crankshaft pulley and drives the alternator

pulley. Proper belt tension is 9 to 10 mm

(0.35 to 0.39 in) for a new belt and

10 to 11 mm (0.39 to 0.43 in) for a used

belt with a force of 10 kg (22 lb).

14. Tighten the bottom 0.38 in. hex screw to

31 -- 40 Nm (27 -- 35 ft lb).

15. Reconnect the wires to the back of

alternator. See the schematic in the

ELECTRICAL section.

16. Reconnect the battery, start the engine, and

check for proper operation of the alternator.

ENGINE--GAS/LP

7-28 8410 MM392 (8--01)

TO REPLACE STARTER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Remove all three scrub brushes.

2. If the machine will start, activate the scrub

mode to lower the scrub head. Shut off the

engine. If the machine will not start, place a

drain pan under the middle and left hand

scrub brush motors. Loosen the hydraulic

hoses at the cylinder rod end fittings. Push

the two scrub heads all the way down and

block them in this position using a piece of

wood. Re--tighten the two hydraulic hoses.

3. Disconnect the battery cables from the

battery.

4. Remove the side brush so it will not get

damaged when the rear of the machine is

raised.

5. Raise the rear of machine using a hoist or

floor jack.

FOR SAFETY: Block machine tires

before jacking machine up. Jack

machine up at designated locations

only. Block machine up with jack

stands.

6. The starter must be accessed from under

the machine. Go under from the engine side.

7. The hardware holding the positive battery

cable and starter wires to the starter is

difficult to reach when its bolted in the

engine. Remove the three M10 hex screws

holding the starter to the engine. Use a 17

MM thin wall socket and swivel on the top

screw. Tip the starter down and remove the

hardware holding the cable and wires to

starter.

ENGINE--GAS/LP

7-29

8410 MM392 (8--01)

8. Swing the rear squeegee all the way to the

left and slide the starter out through the

space between the oil pan and the

squeegee link plate.

9. Bring the new starter under machine and

reconnect positive battery cable and starter

wires to it. See the schematic in the

ELECTRICAL section. Hand tighten the

hardware.

10. Position the new starter, with wires

connected, back in the bellhousing. Align the

holes and reinstall the three M10 hex

screws. Tighten to 37 -- 40 Nm

(26--34ftlb).Usea17MMthinwallsocket

and swivel on the top screw.

11. Remove the wood blocks from the middle

and left hand scrub heads. Remove the jack

stands, lower the machine, and reinstall the

side brush.

12. Reconnect battery cables to battery, start

the engine, raise the scrub head and

reinstall the three scrub brushes.

ENGINE--GAS/LP

7-30 8410 MM392 (8--01)

TO REMOVE ENGINE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Remove the battery cables from the battery.

2. Remove the engine cover and side door.

3. Drain the radiator.

4. Drain the engine oil.

5. Remove the vacuum fan hose, squeegee

hose, and the air cleaner tube.

6. Remove the air cleaner assembly from the

mounting bracket.

7. Disconnect and plug the hydraulic hoses on

the scrubber vacuum fan motor.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

8. Remove the scrubber vacuum fan assembly.

9. Remove the vacuum fan/air cleaner mount

bracket from the engine.

10. Remove the radiator hoses from the engine.

11. Disconnect the exhaust pipe at the engine

manifold.

12. Disconnect the main electrical wire harness

from all engine components and remove the

clamps holding it to the engine. Place the

harness out of the way.

13. Disconnect the engine ground strap from the

right rear of the bellhousing.

14. On a GAS machine; disconnect the fuel line

at the fuel pump. On an LPG machine;

disconnect line from the lpg tank at the fuel

lockoff / vaporizer assembly.

ENGINE--GAS/LP

7-31

8410 MM392 (8--01)

15. On an LPG machine; remove the two

coolant and two fuel lines connected to the

lockoff / vaporizer assembly.

16. Remove the lockoff/vaporizer assembly from

the machine.

17. Remove the left rear grill panel for access to

the hydraulic pump assemblies.

18. Remove the two M12 hex screws holding

the load sensing / propel pump assembly to

the flywheel housing.

19. Pull the load sensing / propel pump

assembly back and out of flywheel housing.

20. Using an overhead hoist; hook a chain

through the two pick--up points on engine.

Put a slight amount of tension on the chain.

21. Remove the four M12 hex screws holding

the motor mounts to the rubber isolators.

22. The engine can now be carefully lifted out.

ENGINE--GAS/LP

7-32 8410 MM392 (8--01)

TO INSTALL ENGINE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Hook a chain through the two pick--up points

on the engine. Use an over head hoist to lift

the engine in the engine compartment.

2. Carefully lower the engine assembly down

on the motor mounts.

NOTE: Make sure the hoses, wire harness,

exhaust pipe, and load sensing pump are pulled

back out of the way when lowering the engine

assembly in place.

3. Reinstall the M12 hex screws in the four

engine motor mounts. Tighten to 64 -- 83 Nm

(50 -- 60 ft lb).

4. Reconnect the ground cable from the

bellhousing to the machine frame.

5. Reinstall load sensing pump back in the

bellhousing. Reinstall the M12 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.

6. Reinstall exhaust pipe back on the engine

manifold. Reinstall the four M10 hex screws.

Tighten to 52 -- 67Nm (39 -- 51 ft lb).

NOTE: Make sure the steel gasket is in place

when installing exhaust pipe.

7. Reconnect the fuel lines.

8. On an LPG machine; reinstall the

lockoff/vaporizer assembly on the machine.

9. On an LPG machine; reconnect the two

coolant and two fuel lines to the

lockoff/vaporizer assembly.

ENGINE--GAS/LP

7-33

8410 MM392 (8--01)

10. Fill the engine with proper grade of motor oil.

11. Reconnect wire harness to the engine

components: alternator, starter, governor

actuator, oil switch, temperature sender,

distributor, and ignition module.

12. Reinstall the radiator hoses to engine and fill

the radiator with coolant.

13. Reinstall the vacuum fan/air cleaner mount

bracket to bellhousing. Reinstall the two M10

hex screws and tighten to 37 -- 48 Nm

(26 -- 34 ft lb).

14. Reinstall the vacuum fan assembly to the

mount bracket. Reinstall the three M10 hex

screws, six washers, and three nyloc nuts.

Tighten to 34 -- 44 Nm (24 -- 28 ft lb).

15. Reconnect the hydraulic hoses to the

scrubbing vacuum fan motor. See the

schematic in the HYDRAULICS section.

16. Reinstall the air cleaner assembly.

17. Reinstall the air cleaner tube, squeegee

vacuum hose, and scrubber vacuum fan

hose.

18. Reinstall the left rear grill panel to the

machine. Reinstall the two M8 hex screws

and washers. Tighten to 18 -- 24 Nm

(15 -- 20 ft lb).

19. Reinstall the engine cover and side door.

20. Reconnect the battery cables to the battery.

21. Jack up the rear 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.

22. Start the engine and check for any leaks.

ENGINE--GAS/LP

7-34 8410 MM392 (8--01)

ENGINE--DIESEL

8-1

8410 MM392 (5--02)

CONTENTS

Page

INTRODUCTION 8-3......................

LUBRICATION 8-4.....................

ENGINE OIL 8-4....................

COOLING SYSTEM 8-4................

RADIATOR 8-4.....................

ENGINE FAN BELT 8-5..............

AIR INTAKE SYSTEM 8-6..............

AIR FILTER INDICATOR 8-6.........

AIR FILTER 8-7.....................

TO REPLACE AIR FILTER

ELEMENT 8-7................

FUEL SYSTEM -- DIESEL 8-9...........

DIESEL FUEL SYSTEM 8-9..........

FUEL FILTER 8-9...................

TO REPLACE THE FUEL FILTER

CARTRIDGE 8-9.................

FUEL LINES 8-10...................

PRIMING THE FUEL SYSTEM 8-10...

TO REPLACE ALTERNATOR 8-12....

TO REPLACE STARTER 8-14........

TO REMOVE ENGINE 8-15..........

TO INSTALL ENGINE 8-17...........

DIESEL ENGINE SERVICE MANUAL

Kubota V2203--B

TENNANT Part Number 73032.

ENGINE--DIESEL

8-2 8410 MM392 (8--01)

ENGINE--DIESEL

8-3

8410 MM392 (8--01)

INTRODUCTION

This section includes repair information on the

engine and related systems, such as fuel,

electrical, and drive belts.

ENGINE--DIESEL

8-4 8410 MM392 (5--02)

LUBRICATION

ENGINE OIL

Check the engine oil level daily. Change the

engine oil and oil filter every 50 hours of machine

operation. Use 10W30 SAE--CC/CD/CE rated

engine oil.

Fill the engine with oil to the level indicated on the

oil dipstick. Low oil level is indicated by the mark

closest to the end of the dipstick. Full level is

indicated by the mark closest to the top of the

dipstick. The engine oil capacity is 6.15 L (6.5 qt)

without the oil filter.

The engine oil filter is mounted on the right side of

the machine frame above the scrub brushes.

COOLING SYSTEM

RADIATOR

Check the radiator coolant level every 100 hours

of operation. Use clean water mixed with a

permanent-type, ethylene glycol antifreeze to a

-- 3 4 _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.

ENGINE--DIESEL

8-5

8410 MM392 (5--02)

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.

ENGINE FAN BELT

The engine fan belt is driven by the engine

crankshaft pulley and drives the engine water

pump and alternator pulleys. 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.

08935

ENGINE--DIESEL

8-6 8410 MM392 (5--02)

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.

ENGINE--DIESEL

8-7

8410 MM392 (5--02)

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 when

the air filter indicator shows a restriction. The air

filters cannot be cleaned.

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.

Replace 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.

TO REPLACE AIR FILTER ELEMENT

1. Stop 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.

2. Open the left side and top engine access

doors.

3. Unscrew the clamp ring on the filter

assembly.

4. Remove the dust cap.

5. Empty the dust cap.

6. Remove the filter wing nut.

7. Gently pull the filter element out of the filter

housing.

8. Clean the interior of the air cleaner housing

with a damp cloth. Clean the element

housing sealing surfaces.

9. 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.

ENGINE--DIESEL

8-8 8410 MM392 (5--02)

10. 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.

11. 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.

12. Install the dust cap on the air filter housing

with the arrows pointing up. Tighten the

clampringtoholditinplace.Checkall

intake hose connections for leaks or

abrasion.

13. Reset the air filter restriction indicator.

14. Close the access doors.

ENGINE--DIESEL

8-9

8410 MM392 (5--02)

FUEL SYSTEM -- DIESEL

DIESEL FUEL SYSTEM

The diesel fuel system is made up of five basic

components which are: fuel tank, fuel filter, fuel

water trap filter, fuel pump, injection pump, and

injectors.

Fuel flows from the fuel tank through the fuel

water trap-filter. 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. The filter is located by the fuel tank.

Replace the fuel filter element every 400 hours of

operation.

TO REPLACE THE FUEL FILTER

CARTRIDGE

1. Stop the engine and set the machine parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, And Turn

Off Machine.

2. Loosen the unit vent plug and open the

water trap drain to drain diesel fuel.

3. Remove the filter cartridge from the filter

head.

4. Lubricate the o-ring of the new filter

cartridge and spin it onto the filter head.

5. Bleed the fuel lines of air as described in TO

PRIME FUEL SYSTEM instructions.

ENGINE--DIESEL

8-10 8410 MM392 (5--02)

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.

Made of rubber, the fuel lines 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

PRIMING THE FUEL SYSTEM instructions.

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 THE FUEL SYSTEM

Priming the fuel system removes pockets of air in

the fuel lines and fuel components. Air in the fuel

system will prevent smooth engine operation.

Prime the fuel system after running out of fuel,

changing fuel filter elements or repairing a fuel

system component.

1. Stop the engine and set the machine parking

brake.

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, And Turn

Off Machine.

2. Make sure the fuel tank is full.

3. Raise the seat up.

4. Unplug the RH tail light from the main

harness.

ENGINE--DIESEL

8-11

8410 MM392 (8--01)

5. Loosen the two M8 hex screws holding the

RH rear panel to the center tower.

6. Go to the back of the machine and remove

the two M8 hex screws holding the rear

panel to the RH corner tower.

7. Remove the rear panel for access to the fuel

filter.

8. Open the air vent on top of the fuel filter.

9. 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.

10. Close the air vent and shut off the engine.

11. Position the RH rear access panel back on

the machine, Reinstall the two M8 hex

screws and tighten to 18 -- 24 Nm

(15 -- 20 ft lb).

12. Go under the seat and tighten the two M8

hex screws to 18 -- 24 Nm (15 -- 20 ft lb).

13. Reconnect the tail light to the main harness.

14. Lower the seat.

ENGINE--DIESEL

8-12 8410 MM392 (8--01)

TO REPLACE ALTERNATOR

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from the

battery.

2. Open the engine cover and side door.

3. Disconnect the wires on the back of the

alternator.

4. Remove the hex screw holding the top of the

alternator to the upper mount bracket. Push

the alternator toward the engine and remove

the v--belt.

5. Remove the hex screw and nyloc nut

holding the bottom of the alternator to the

lower mount bracket.

6. The alternator can now be removed. Bring

the alternator up and out of the machine.

7. If the new or rebuilt alternator needs a drive

pulley; remove the pulley from the old

alternator by holding pulley from turning and

using an impact wrench to remove hex nut.

8. Install pulley, washer, and hex nut on the

new alternator. Hand tighten the nut with an

impact wrench.

ENGINE--DIESEL

8-13

8410 MM392 (8--01)

9. Install the new alternator back in the

machine. Align the bottom hole in the

alternator with hole in the lower mount

bracket. Reinstall the hex bolt, washer, and

sleeve. Leave loose for now.

10. Place the v--belt back on the alternator

pulley.

11. Reinstall the hex screw in the top hole of the

alternator through the upper mounting

bracket. Pull alternator toward the outside of

machine to tighten belt. Tighten the hex

screw to 18 -- 24 Nm (13 -- 18 ft lb).

12. Tighten the bottom hex screw to

31 -- 40 Nm (27 -- 35 ft lb).

13. Reconnect the wires to the back of

alternator. See the schematic in the

ELECTRICAL section.

14. Reconnect the battery, start the engine, and

check for proper operation of the new

alternator.

ENGINE--DIESEL

8-14 8410 MM392 (8--01)

TO REPLACE STARTER

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake, Turn Off

Machine And Remove Key.

1. Disconnect the battery cables from the

battery.

2. Open the engine cover and side door.

3. Remove the vacuum hose from the exhaust

side of scrubbing vacuum fan.

4. Remove the M8 hex nut holding positive

battery cable to the starter. Remove the

cable and unplug the starter wires.

5. Remove one hex nut and one hex screw

holding the starter to the bellhousing.

Remove the starter from machine.

6. Position the new starter back in the

machine. Align the top hole in the starter

with the stud on bellhousing.

7. Reinstall one hex nut and one hex screw.

Firmly hand tighten.

8. Reconnect the battery cable and starter

wires to starter. See the schematic in the

ELECTRICAL section.

9. Reinstall the vacuum hose to the exhaust

side of scrubbing vacuum fan.

10. Reconnect the battery cables to the battery.

Start the engine to check the new starter for

proper operation.

ENGINE--DIESEL

8-15

8410 MM392 (8--01)

TO REMOVE ENGINE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake., Turn Off

Machine And Remove Key.

1. Remove the engine cover and side door.

2. Remove the battery cables from the battery.

3. Drain the radiator.

4. Drain the engine oil.

5. Remove the air cleaner assembly from the

mounting bracket.

6. Disconnect and plug the hydraulic hoses on

the scrubber vacuum fan motor.

NOTE: Observe hydraulic cleanliness

requirements when opening hydraulic lines.

7. Remove the scrubber vacuum fan assembly

and vacuum hose.

8. Remove the vacuum fan/air cleaner mount

bracket from the engine.

9. Remove the radiator hoses from the engine.

10. Disconnect the exhaust pipe at the engine

manifold.

11. Disconnect the main electrical wire harness

from all engine components and place it out

of the way.

12. Disconnect the engine ground strap from the

machine frame.

13. Disconnect both the fuel line and the return

line leading from the fuel tank to the engine.

14. Disconnect the throttle cable from the

engine.

ENGINE--DIESEL

8-16 8410 MM392 (8--01)

15. Disconnect and plug the two engine oil lines,

coming from the remote oil filter, at the

engine oil filter adaptor.

NOTE: Observe engine oil cleanliness

requirements when opening remote filter lines.

16. Remove the LH side panel.

17. Remove the side door mounting bracket

from the machine.

18. Remove the left rear grill panel for access to

the hydraulic pump assemblies.

19. Remove the two M12 hex screws holding

the load sensing / propel pump assembly to

the flywheel housing.

20. Pull the load sensing / propel pump

assembly back and out of flywheel housing.

21. Using an overhead hoist; hook a chain

through the two pick--up points on engine.

Put a slight amount of tension on the chain.

22. Remove the four M12 hex screws holding

the motor mounts to the rubber isolators.

23. The engine can now be carefully lifted out.

NOTE: Be sure to disconnect engine oil drain

hose from oil pan before lifting engine completely

out of the machine.

ENGINE--DIESEL

8-17

8410 MM392 (8--01)

TO INSTALL ENGINE

FOR SAFETY: Before Leaving Or

Servicing Machine; Stop On Level

Surface, Set Parking Brake., Turn Off

Machine And Remove Key.

1. Hook a chain through the two pick--up points

on the engine. Use an over head hoist to lift

the engine in the engine compartment.

2. Carefully lower the engine assembly down

on the motor mounts.

NOTE: Make sure the hoses, wire harness,

exhaust pipe, and load sensing pump are pulled

back out of the way when lowering the engine

assembly in place.

3. Reinstall the M12 hex screws in the four

engine motor mounts. Tighten to 64 -- 83 Nm

(50 -- 60 ft lb).

4. Reconnect the ground cable from the

bellhousing to the machine frame.

5. Reinstall load sensing pump back in the

bellhousing. Reinstall the M12 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.

6. Reinstall exhaust pipe back on the engine

manifold. Reinstall the four M10 hex screws.

Tighten to 52 -- 67Nm (39 -- 51 ft lb).

NOTE: Make sure the steel gasket is in place

when installing exhaust pipe.

7. Reconnect the fuel lines.

8. Reconnect the two engine oil lines to the

remote oil filter adaptor on the engine.

NOTE: Observe engine oil cleanliness

requirements when opening remote filter lines.

9. Reconnect the throttle cable to the engine.

ENGINE--DIESEL

8-18 8410 MM392 (8--01)

10. Fill the engine with proper grade of motor oil.

11. Reconnect wire harness to the engine

components: alternator, starter, oil switch,

temperature sender.

12. Reinstall the radiator hoses to engine and fill

the radiator with coolant.

13. Reinstall the vacuum fan/air cleaner mount

bracket to bellhousing. Reinstall the two M10

hex screws and tighten to 37 -- 48 Nm

(26 -- 34 ft lb).

14. Reinstall the vacuum fan assembly to the

mount bracket. Reinstall the three M10 hex

screws, six washers, and three nyloc nuts.

Tighten to 34 -- 44 Nm (24 -- 28 ft lb).

15. Reconnect the hydraulic hoses to the

scrubbing vacuum fan motor. See the

schematic in the HYDRAULICS section of

this manual.

16. Reinstall the air cleaner assembly.

17. Reinstall the LH side panel using the three

M6 hex screws and washers and two M8

hex screws and washers. Tighten the M6

hex screws to 11 -- 14 Nm (7 -- 10 ft lb).

Tighten the M8 hex screws to 18 -- 24 Nm

(15 -- 20 ft lb).

18. Reinstall the left rear grill panel to the

machine. Reinstall the two M8 hex screws

and washers. Tighten to 18 -- 24 Nm

(15 -- 20 ft lb).

19. Reinstall the engine cover and side door.

20. Reconnect the battery cables to the battery.

21. Jack up the rear 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

22. Start the engine and check for any leaks.

We Need Your Help...

As part of Tennant’s Zero Defects Program, we want to know about errors you have

found or suggestions you may have regarding our machine manuals. If you find an

error or have a suggestion, please complete this postage-paid form and mail it to us.

Thank you for helping us make zero defects a way of life at Tennant.

Manual No. Rev. No. Publish Date Page

Machine -Report Error -Suggestion

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Customer Number

Company

Address

City/State/Zip Code

Tape hereFold along dotted lines

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED SATES

BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 94 MINNEAPOLIS, MN

POSTAGE WILL BE PAID BY ADDRESSEE

Technical Publications #15

701 North Lilac Drive

P.O. Box 1452

Minneapolis, MN 55440--9947

TENNANT COMPANY

We Need Your Help...

As part of Tennant’s Zero Defects Program, we want to know about errors you have

found or suggestions you may have regarding our machine manuals. If you find an

error or have a suggestion, please complete this postage-paid form and mail it to us.

Thank you for helping us make zero defects a way of life at Tennant.

Manual No. Rev. No. Publish Date Page

Machine -Report Error -Suggestion

Name Date

Customer Number

Company

Address

City/State/Zip Code

Tape hereFold along dotted lines

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED SATES

BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 94 MINNEAPOLIS, MN

POSTAGE WILL BE PAID BY ADDRESSEE

Technical Publications #15

701 North Lilac Drive

P.O. Box 1452

Minneapolis, MN 55440--9947

TENNANT COMPANY

8410 Service Manual Tennant Rider Floor Sweeper Scrubber

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