Sentinel Service Manual Tennant Rider Floor Sweeper

2018-06-19

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SENTINEL
Service Information Manual

(Paper Manual)

331019
Rev. 00

*331019*
331005 (CD-- ROM)

This manual provides service information for the TENNANT Model SENTINEL.
This machine will provide excellent service. However, the best results will be obtained at minimum
costs if:
D The machine is operated with reasonable care.
D The machine is maintained regularly -- per the maintenance instructions provided.
D The machine is maintained with TENNANT supplied or approved parts.

Paper Manual Number -- 331019
CD--ROM Manual Number -- 331005
Revision: 00
Published: 12--03

CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
Copyright E 2003 TENNANT, Printed in U.S.A.

Electrical Troubleshooting .........................................................................................................
Wiring Diagram ...................................................................................................................
Wiring Harness Detail .........................................................................................................
Main Wire Harness .......................................................................................................
Cab Wire Harness ........................................................................................................
Hopper Wire Harness ...................................................................................................
Key Switch ..........................................................................................................................
Starting System ...................................................................................................................
Glow Plugs System .............................................................................................................
Charging System .................................................................................................................
Power-Up & Fuel System ....................................................................................................
Engine Oil Pressure & Temperature Sensors .....................................................................
Engine Air Filter, Speed & Fuel Level Sensors ...................................................................
Right & Left Brush Systems ................................................................................................
Main Brush & Conveyor Systems .......................................................................................
Hopper System ...................................................................................................................
Vacuum Fan & Filter Shaker Systems ................................................................................
Hopper Full Sensing System...............................................................................................
Hopper Door & Vacuum Wand Door Sensing Systems ......................................................
Machine Speed Sensing System ........................................................................................
Level & Hopper Tilt Sensing Systems .................................................................................
Blocked Conveyor & Hopper Temp. Sensing Systems .......................................................
Wet Dust Control System ....................................................................................................
Pressure Washer System ...................................................................................................
Forward Propel & Brake Systems .......................................................................................
Reverse Propel & Brake Systems .......................................................................................
Vario Brush Tilt System .......................................................................................................
Vario Brush Arm Swing / Slide System ...............................................................................
Vario Brush Raise / Lower & Rotate Systems .....................................................................
Operating Modes.................................................................................................................
Operational Matrix ...............................................................................................................
Connector Pin Designations ................................................................................................
Fuse Chart ..........................................................................................................................
Component Locator.............................................................................................................
Hydraulic Troubleshooting .........................................................................................................
Hydraulic Diagram ...............................................................................................................
Hydraulic Hose Diagram .....................................................................................................
Low Dump Hydraulic Hose Group ................................................................................
High Dump Hopper Hydraulic Hose Group...................................................................
Cab Hydraulic Hose Group ...........................................................................................
Conveyor and Main Brush Hydraulic Hose Group ........................................................
Hydraulic Reservoir Hose Group ..................................................................................
Steer, Brakes, Side Brush Hydraulic Hose Group ........................................................
Left Side Brush Hydraulic Hose Group .........................................................................
Propel Hydraulic Hose Group .......................................................................................
High Pressure Sprayer Hydraulic Hose Group .............................................................
Vario Brush Hydraulic Hose Group ...............................................................................
Cab Tilt Group ..............................................................................................................
Hydraulic Pumps & Valves ..................................................................................................
Hydraulic Pumps Group ...............................................................................................
Hydraulic Main Brush / Conveyor Lift Valve Group ......................................................
Hydraulic Hopper Control Valve Group ........................................................................
Hydraulic Side Brush Valve Group ...............................................................................
Hydraulic Manifold and Priority Valve Group ................................................................
Hopper Functions & Vacuum Fans Valve Block ...........................................................
Pressure Washer Valve Block ......................................................................................
Explanation of Abbreviations...............................................................................................
Conveyor & Main Brush Forward ........................................................................................
Conveyor & Main Brush Reverse ........................................................................................
Main Brush Lower ...............................................................................................................
Conveyor Lower ..................................................................................................................
Main Brush Lift, Conveyor Lift, & Conveyor Chain Tension ................................................
Right Side Brush Rotate & Lower .......................................................................................
Left Side Brush Rotate & Lower ..........................................................................................

1
2
8
8
23
25
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
53
54
55
63
64
69
69
70
71
72
73
74
75
76
77
78
79
80
80
81
82
83
84
85
87
88
89
90
91
92
93
94
95

Right & Left Side Brush Rotate & Lower .............................................................................
Right & Left Side Brush Lift .................................................................................................
Vacuum Fans Run ..............................................................................................................
Shaker Run .........................................................................................................................
Vacuum Fans & Shaker Off ................................................................................................
Hopper Tilt Back (Dump) .....................................................................................................
Hopper Tilt Forward (Normal Sweep Position)....................................................................
Hopper Lift (High Dump) .....................................................................................................
Hopper Lower (High Dump) ................................................................................................
Hopper Door Lock (Latch Closed) .......................................................................................
Hopper Door Unlock (Latch Open)......................................................................................
Vario Brush Rotate Clockwise .............................................................................................
Vario Brush Rotate Counter-Clockwise ...............................................................................
Vario Brush Swing Right (Clockwise) ..................................................................................
Vario Brush Swing Left (Counter-Clockwise) ......................................................................
Vario Brush Slide Right .......................................................................................................
Vario Brush Slide Left .........................................................................................................
Vario Brush Tilt Rear Edge Down .......................................................................................
Vario Brush Tilt Front Edge Down .......................................................................................
Vario Brush Tilt Left.............................................................................................................
Vario Brush Tilt Right ..........................................................................................................
Vario Brush Lift ....................................................................................................................
Vario Brush Lower ...............................................................................................................
Right Turn ...........................................................................................................................
Left Turn ..............................................................................................................................
Brake Pedal (Push) .............................................................................................................
Brake Pedal (Release) ........................................................................................................
Propel System .....................................................................................................................
Operational Matrix ...............................................................................................................
Solenoid Valve Details ........................................................................................................
Component Locator.............................................................................................................
Traffic Advisor Control ...............................................................................................................
Installation and Operating Guide: Sirens/Switches .............................................................
Installation for Traffic Advisor ..............................................................................................
Parts List for Traffic Advisor ................................................................................................
Operation Matrix ........................................................................................................................
Troubleshooting Matrix ..............................................................................................................
Interlocks ...................................................................................................................................
Pin Chart ....................................................................................................................................
Engine Specifications (Standard Engine) ..................................................................................
Engine Specifications (Turbo Engine) .......................................................................................
Torque Standard ........................................................................................................................
Inch Fasteners ....................................................................................................................
METRIC Fasteners .............................................................................................................
Nylon Insert Lock Nuts ........................................................................................................
Wheel Bolt and Nuts ...........................................................................................................
Tightening Nuts on Tapered Shafts ....................................................................................
Shoulder Bolts .....................................................................................................................
Taper Lockr Bushings .........................................................................................................
Sequence Tightening ..........................................................................................................
Auto Lube - Grease Jockey Installation and Maintenance ........................................................
Table of Content ..................................................................................................................
System Components ...........................................................................................................
Electric systems ..................................................................................................................
Installation Steps .................................................................................................................
Troublshooting the Grease Jockey .....................................................................................
Parts List .............................................................................................................................

96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
125
127
128
133
133
137
138
139
141
143
144
146
148
150
150
152
154
155
156
157
158
159
161
162
164
167
170
178
180

SENTINEL
ELECTRICAL
Troubleshooting Manual
BEFORE CONDUCTING TESTS:
* Read and Follow ALL Safety Warnings and Precautions in
Operator's Manual

DURING TESTS:
* Call Technical Services if Diagnostic Time Exceeds One
Hour With Unknown Cause or Course of Action

NOTE:Troubleshooting charts are shown with optional equipment. The optional equipment is not
specified in these charts. Some machines may not be equipped with all components shown.

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Diagram (page 1 of 6)

2
3

4
5

6
7
8
Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Diagram (page 2 of 6)

10
11
12

2
3

4
5
13
14
15
6
7
8

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Diagram (page 3 of 6)

10
11
12

13
14
15
Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Diagram (page 4 of 6)
16

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Diagram (page 5 of 6)
18
16

19
17

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Diagram (page 6 of 6)
18

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 1 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 2 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 3 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 4 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 5 of 19)

Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 6 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 7 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 8 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 9 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 10 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 11 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 12 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 13 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 14 of 19)
Main Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 15 of 19)
Main Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 16 of 19)
Cab Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 17 of 19)

Cab Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 18 of 19)
Hopper Wire Harness

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Wiring Harness Detail (page 19 of 19)
Hopper Wire Harness

Sentinel 331000 (6--03)
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Key Switch

15/54

30/1

GLOW PLUG POSITION
Spring loaded- Returns
to "OFF" unless held

OFF

Glow
Plug

START

RUN

Glow
Plug

START

KEY SWITCH

OFF

OFF
RUN
START

RUN

Glow
Plug

START
KEY SWITCH

KEY SWITCH

15/54

OFF POSITION

OFF
RUN

KEY SWITCH

Glow
Plug

30/1

15/54

30/1

START POSITION

RUN POSITION

Spring loaded- Returns to “RUN" unless held

SWITCH TERMINAL MARKING
KEY SWITCH POSITION

30, 30/1

15/54

GLOW PLUG
OFF

NO CONNECTIONS

RUN
START

“.

“ Indicates a common connection

NOTE: Common connections in various switch positions should be less than 1Ω
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Starting System

1/RED

13/BLK
STARTER MOTOR

1/RED

CHASSIS GROUND
M13
TO MACHINE CONTROL BOARD PIN P1-Y2
NEUTRAL
START
RELAY

KEY SWITCH
1/RED

30
7/YEL

1/RED

28/PUR

30/1

F27

6/ORA
87a

CHASSIS GROUND

M13
SW1

31/GRN

SEAT SWITCH
RELAY

27/GRY
16/YEL
30
87
15 AMP
M11

13/BLK

NEUTRAL
START RELAY
SEE “SENTINEL FORWARD PROPEL
& BRAKE SYSTEMS “ PAGE

Note: Ignition Switch is illustrated in the “OFF” position. Please
see Key Switch illustrations page for various operating positions

16/YEL

FORWARD / REVERSE
SWITCH

SET
TO MACHINE CONTROL
BOARD PIN P1-W2

37/PUR 85

PROPEL DISABLE
RELAY

21/PUR

PARKING BRAKE ENGAGED LAMP

D27

27/GRY
RELEASE
PARKING BRAKE
SWITCH

SEE “SENTINEL FORWARD PROPEL & BRAKE SYSTEMS “ PAGE
OR “SENTINEL REVERSE PROPEL & BRAKE SYSTEMS” PAGE

2003.10.14 Sentinel Electrical Troubleshooting Manual

SEE “SENTINEL REVERSE PROPEL
& BRAKE SYSTEMS “ PAGE

22/GRY

13/BLK
13/BLK

TO MACHINE CONTROL
BOARD PIN P1-M2

15/GRN
13/BLK
2/BLU
M11
87a SEAT SWITCH 86
85
SW8
PROPEL DISABLE

22/GRY
30

RELAY

SEAT SWITCH RELAY

Sentinel Glow Plugs System

1/RED

13/BLK

F29

1/RED

80/BRN

80 AMP

PRE-HEAT LAMP

8/BLU

10/BRN 6

OUT

GP3

46/PUR

GP2
GLOW PLUGS

TMR1

LAMP

GROUND

PREHEAT

START

GP1

CH ASS IS GRO UNDS

GP4

ENGINE PREHEAT TIMER

13/BLK

KEY SWITCH
1/RED

8/BLU

1/RED

7/YEL

30/1

Note: Ignition Switch is illustrated in the “OFF” position. Please
see Key Switch illustrations page for various operating positions

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Charging System

1/RED

13/BLK

1/RED
1/RED
2

Note: Ignition Switch is illustrated in the “OFF” position. Please
see Key Switch illustrations page for various operating positions

CHASSIS GROUND

+ ALT -

13/BLK

KEY SWITCH
1/RED
F1
87 30 AMP
30 66/BRN
M4 ACCESSORY

POWER RELAY

14/ORA

D30

1/RED
30/1

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

F27
28/PUR

15 AMP

27/GRY

F18

95/ORA

10 AMP

F16

10 AMP
F17

F19

15 AMP

PIN P1-X1 13/BLK

PIN P1-L2

PIN P1-E1 13/BLK

PIN P1-B1

PIN P1-E2 13/BLK

PIN P1-A2

PIN P1-F1 13/BLK

PIN P1-X2

34/ORA

15 AMP

PIN P1-Y1

91/PUR

CONTROL
BOARD

92/BRN
93/GRN

10 AMP

GAUGE
PANEL

VOLT
METER

Approximate values for Volt Meter Gauge

2003.10.14 Sentinel Electrical Troubleshooting Manual

# of LED's

status

voltage

8
7
6
5
4
3

flashing
on
on
on
on
on

15.45 V or higher
14.95 V
14.35 V
13.75 V
13.3 V
12.8V

12.2V

flashing

12.15 V or lower

Sentinel Power-Up & Fuel System

1/RED

13/BLK

27/GRY 86

27/GRY

Note: Ignition Switch is illustrated in the “OFF” position. Please
see Key Switch illustrations page for various operating positions

1/RED

27/GRY

3/BRN

M12

ENGINE SHUTDOWN RELAY

27/GRY
87a

KEY SWITCH

ACCESSORY
POWER RELAY

66/BRN

30 AMP

F27
28/PUR 15 AMP

27/GRY 86

ENGINE SHUTDOWN RELAY

30
87

M4
90/GRY
90/GRY
90/GRY
90/GRY

ACCESSSORY
POWER RELAY # 2

30
87
M12

90/GRY

F18

95/ORA

10 AMP

F16

10 AMP

15 AMP

F17

F19

15 AMP

34/ORA

13/BLK

FUEL LIFT PUMP

FUEL SOLENOID

3/BRN

COLD START
TEMP SWITCH

S10

1/RED
30/1

ACCESSORY
POWER RELAY

ACCESSSORY
POWER RELAY # 2

SOL1

SHUTDOWN
SW2ENGINE
OVERIDE SWITCH

13/BLK

85 11/YEL

MTR2

13/BLK

SOL4
COLD START
ADVANCE SOLENOID

PIN P1-W3

PIN P1-X1 13/BLK

PIN P1-Y1

PIN P1-E1 13/BLK

PIN P1-L2

PIN P1-E2 13/BLK

PIN P1-B1

PIN P1-F1 13/BLK

PIN P1-A2
PIN P1-X2

CONTROL
BOARD

91/PUR
92/BRN
93/GRN

GAUGE
PANEL

TOUCH
PANEL

10 AMP
TO FUSE PANEL FOR OPTIONS / ACCESSORIES

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Engine Oil Pressure & Temperature Sensors

1/RED

13/BLK
13/BLK
13/BLK

ACCESSORY 85
POWER RELAY

Note: Ignition Switch is illustrated in the “OFF”
position. Please see Key Switch illustrations
page for various operating positions
KEY SWITCH
1/RED

ENGINE OIL PRESSURE
SENSOR

SNSR4

27/GRY

F27
15 AMP

30/1

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

28/PUR
F18

95/ORA

10 AMP

F16

10 AMP

15 AMP

F17

F19

15 AMP

8
8
7
6
5
4
3
2
1
0

flashing /
engine shutdown
flashing
on
on
on
on
on
on
on
all LED's off

2003.10.14 Sentinel Electrical Troubleshooting Manual

PIN P1-Y1

PIN P1-X1 13/BLK

PIN P1-L2

PIN P1-E1 13/BLK

PIN P1-B1

PIN P1-E2 13/BLK

PIN P1-A2

PIN P1-F1 13/BLK

91/PUR

CONTROL
BOARD

92/BRN
H

93/GRN
L

Approximate values for Temperature Gauge & Sensor
status

PIN P1-R1

PIN P1-X2

34/ORA

10 AMP

# of LED's

139/ORA

ENGINE TEMPERATURE
SENSOR

1/RED

30 66/BRN
M4 ACCESSORY
POWER RELAY
87

P1-N1

SNSR3

F1
30 AMP

137/BRN PIN

ENGINE
TEMP

GAUGE
PANEL

H
L

OIL
PRESSURE

Approximate values for Oil Pressure Gauge

voltage @ sensor engine tem p.
o

< 0.88 V

above 240

0.88 V
1.04 V
1.19 V
1.35 V
1.51 V
1.82 V
2.31 V
3.35 V
> 3.35 V

240o
225o
215o
205o
195o
180o
160o
140o
below 140o

# of LED's

status

e ngine oil press ure

8
7
6
5
4
3
2

on
on
on
on
on
on
flashing
flashing /
engine shutdown

107 psi
82 psi
52 psi
41 psi
28 psi
16 psi
below 16 psi

below 5 psi

Sentinel Engine Air Filter, Speed & Fuel Level Sensors

1/RED

13/BLK
13/BLK
13/BLK

ACCESSORY 85
POWER RELAY

FUEL LEVEL
SENSOR (180 Ohm)

Note: Ignition Switch is illustrated in the “OFF”
position. Please see Key Switch illustrations
page for various operating positions
KEY SWITCH
1/RED
F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

SNSR5 138/GRN

ENGINE SPEED
SENSOR

27/GRY

SNSR2
B

1/RED
28/PUR
F18

90/GRY

95/ORA

10 AMP

F16

10 AMP

90/GRY
90/GRY

148/YEL
A

F27
15 AMP

30/1

90/GRY

PIN P1-P1

15 AMP

F17

F19

PIN P1-Y1

PIN P1-X1 13/BLK

PIN P1-L2

PIN P1-E1 13/BLK

PIN P1-B1

PIN P1-E2 13/BLK

PIN P1-A2

PIN P1-F1 13/BLK

PIN P1-X2

34/ORA

CONTROL
BOARD

PIN P1-N3

91/PUR
92/BRN

15 AMP

90/GRY

PIN P1-W1

93/GRN

147/GRY

10 AMP
CLOGGED ENGINE
AIR FILTER LAMP

RPM

S17

GAUGE
PANEL

FUEL
LEVEL

13/BLK

CLOGGED ENGINE AIR FILTER SENSOR
(CLOSED WITH CLOGGED AIR FILTER)

Approximate values for Fuel Level Gauge & Sensor
# of LED's

8
7
6
5
4
3
2
1

2003.10.14 Sentinel Electrical Troubleshooting Manual

status

resistance

on
180 ohms
100 ohms to
on
180 ohms
on
80 ohms to
on
100 ohms
on
0 ohms to
on
80 ohms
on
flashing
0 ohms

fuel level

full
between
half & full
half
between
empty & half
empty

Sentinel Right & Left Brush Systems

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
85
M4

ACCESSORY
POWER RELAY

86
KEY SWITCH
1/RED

13/BLK

SV5
RIGHT SIDE BRUSH DOWN

27/GRY

97/YEL

PIN P1-G2

96/GRY

PIN P1-F2

SV9
RIGHT SIDE BRUSH ON

SV7

30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

LEFT SIDE BRUSH DOWN

91/PUR

1/RED

F27
15 AMP
28/PUR

SV10

90/GRY
90/GRY
90/GRY
90/GRY

F16

91/PUR

15 AMP

F18

10 AMP

F17

F19

PIN P1-E1 13/BLK

SV8
ENABLE LIFT CIRCUITS # 1

90/GRY

PIN P1-X1 13/BLK

LEFT SIDE BRUSH ON

15 AMP

34/ORA

98/BRN

PIN P1-G3

PIN P1-E2 13/BLK
PIN P1-F1 13/BLK

PIN P1-B1
PIN P1-L2

95/ORA
92/BRN

PIN P1-Y1
PIN P1-A2

93/GRN

PIN P1-X2

CONTROL
BOARD

10 AMP

NOTE: Touch panel buttons shown activate their component when
they are pushed and released. To deactivate, push and release again

LEFT SIDE
BRUSH

TOUCH
PANEL

RIGHT SIDE
BRUSH

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Main Brush & Conveyor Systems

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
85
M4

ACCESSORY
POWER RELAY

86
KEY SWITCH
1/RED

13/BLK

SV3
MAIN BRUSH DOWN

27/GRY

126/BRN

PIN P1-J2

125/YEL

PIN P1-J3

SV4
ENABLE LIFT CIRCUITS # 2

SV12

30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

F27
15 AMP
28/PUR

SV13
MAIN BRUSH & CONV REV

SV31
CONVEYOR DOWN

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

F17

92/BRN

15 AMP

F18

10 AMP

F16

F19
10 AMP

128/BLU PIN

P1-B3

129/GRY PIN

P1-B2

MAIN BRUSH & CONV FWD

92/BRN

1/RED

15 AMP

34/ORA

154/PUR

PIN P1-X1 13/BLK
PIN P1-E1 13/BLK

PIN P1-A3

PIN P1-E2 13/BLK
PIN P1-F1 13/BLK

PIN P1-A2
PIN P1-L2

95/ORA
91/PUR

PIN P1-Y1
PIN P1-B1

93/GRN

PIN P1-X2

NOTE: Touch panel buttons shown activate their component when
they are pushed and released. To deactivate, push and release again

CONV
REVERSE

CONTROL
BOARD

TOUCH
PANEL

SWEEP

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hopper System

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
85
M4

ACCESSORY
POWER RELAY

KEY SWITCH

SV1
HOPPER LOWER

HOPPER LIFT

27/GRY

SV17

30
HOPPER DOOR RELEASE

30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

PIN P1-K3

127/GRN

PIN P1-J1

132/GRN

PIN P1-D3

133/ORA

PIN P1-E3

PIN P1-X1 13/BLK

134/BLU

PIN P1-F3

PIN P1-E1 13/BLK

162/YEL

PIN P1-D1

PIN P1-E2 13/BLK

SV18

F27
15 AMP

HOPPER TILT BACK

92/BRN

1/RED

150/ORA

SV2

86
1/RED

13/BLK

28/PUR

SV19
HOPPER TILT FORWARD

SV32
HOPPER ENABLE

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

F17

92/BRN

15 AMP

F18

10 AMP

F16

F19

34/ORA

PIN P1-L2
95/ORA

PIN P1-Y1

91/PUR

15 AMP

PIN P1-F1 13/BLK

PIN P1-A2

PIN P1-B1
93/GRN

PIN P1-X2

10 AMP

HOPPER
TILT BACK

HOPPER
TILT FWD

HOPPER
LIFT

CONTROL
BOARD

TOUCH
PANEL

HOPPER
LOWER

HOPPER
DR OPEN

HOPPER
DR CLOSE

NOTE: Indicated touch panel buttons activate their component when
they are pushed and held. To deactivate component, release button

NOTE: Indicated touch panel buttons activate their component when
they are pushed and held for 2 to 3 seconds.

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Vacuum Fan & Filter Shaker Systems

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

86
KEY SWITCH
1/RED

SV14

30
VACUUM FANS

30/1

F1
30 AMP

F27
15 AMP

92/BRN

1/RED

30 66/BRN
M4 ACCESSORY
POWER RELAY
87

27/GRY

28/PUR

130/YEL

PIN P1-C3
PIN P1-X1 13/BLK

SV16
FILTER SHAKER

131/BRN

PIN P1-D2

PIN P1-E1 13/BLK
PIN P1-E2 13/BLK

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

F17

92/BRN

15 AMP

F18

10 AMP

F16

F19
10 AMP

15 AMP

34/ORA

PIN P1-A2

PIN P1-F1 13/BLK

PIN P1-L2
95/ORA

91/PUR

PIN P1-Y1
PIN P1-B1

93/GRN

PIN P1-X2

FILTER
SHAKER

CONTROL
BOARD

TOUCH
PANEL

VACUUM
FANS

NOTE: Indicated touch panel button activates component for 30 seconds when
pushed and released. To deactivate, wait 30 seconds OR push and release again

NOTE: Indicated touch panel button activates component when
pushed and released. To deactivate, push and release again

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hopper Full Sensing System

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

13/BLK

86
KEY SWITCH
1/RED

1/RED

HOPPER
LOAD LIMIT
LAMP

F19

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

PIN P1-N2
PIN P1-X1 13/BLK

28/PUR

F1
30 AMP

145/ORA

S25

F27
15 AMP

30/1

30 66/BRN
M4 ACCESSORY
POWER RELAY
87

HOPPER LOAD LIMIT
SWITCH (CLOSED
WITH FULL HOPPER)

27/GRY

F17

10 AMP

15 AMP

F18

10 AMP

F16

136/YEL

PIN P1-E1 13/BLK

PIN P1-M3

PIN P1-E2 13/BLK
PIN P1-F1 13/BLK

PIN P1-X2

93/GRN
92/BRN

PIN P1-A2
PIN P1-L2

34/ORA
95/ORA
91/PUR

15 AMP

PIN P1-Y1
PIN P1-B1

CONTROL
BOARD

TO ADJUST HOPPER LOAD LIMIT SWITCH:
LOW DUMP
Set hopper load limit switch to 1/2" (12.5 mm) from roller to stop plate

HIGH DUMP
Set hopper load limit switch to 7/16" (11 mm) from roller to stop plate

Stop Plate

Hopper Load Limit
Switch Roller

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hopper Door & Vacuum Wand Door Sensing Systems

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

13/BLK

86
KEY SWITCH
1/RED

27/GRY

HOPPER DOOR OPEN SWITCH
(OPEN WITH DOOR OPEN)

S24
1/RED
30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

F27
15 AMP

S18

F19

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

146/BLU

VACUUM WAND DOOR
CLOSED SWITCH
(CLOSED WITH
DOOR CLOSED)

28/PUR

F17

10 AMP

15 AMP

F18

10 AMP

F16

P1-P2

PIN P1-T3

PIN P1-E2 13/BLK
PIN P1-X2

92/BRN

PIN P1-F1 13/BLK

PIN P1-A2
PIN P1-L2

34/ORA
95/ORA

PIN P1-Y1
PIN P1-B1

15 AMP

NOTE: Touch panel buttons shown activate their component when
they are pushed and released. To deactivate, push and release again

2003.10.14 Sentinel Electrical Troubleshooting Manual

PIN P1-X1 13/BLK
PIN P1-E1 13/BLK

VACUUM
WAND DOOR
CLOSED LAMP

93/GRN

91/PUR

143/BRN PIN

HOPPER
DR OPEN

CONTROL
BOARD

TOUCH
PANEL

HOPPER
DR CLOSE

Sentinel Machine Speed Sensing System

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

13/BLK

86
KEY SWITCH
1/RED

1/RED
30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

27/GRY

MACHINE
SPEED
SENSOR

F27
15 AMP

HALL
EFFECT

149/BRN
C

PIN P1-T1
PIN P1-X1 13/BLK

A
SW6

28/PUR

PIN P1-E1 13/BLK
PIN P1-E2 13/BLK

F19

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

F17

10 AMP

15 AMP

F18

10 AMP

F16

PIN P1-X2

93/GRN
92/BRN

PIN P1-A2
PIN P1-L2

34/ORA
95/ORA
91/PUR

PIN P1-Y1
PIN P1-B1

15 AMP

MPH or Km/h

2003.10.14 Sentinel Electrical Troubleshooting Manual

PIN P1-F1 13/BLK

CONTROL
BOARD

GAUGE
PANEL

Sentinel Level & Hopper Tilt Sensing Systems

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

13/BLK

86
KEY SWITCH
1/RED

1/RED
30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

HOPPER TILTED
SWITCH (CLOSED
WITH HOPPER TILTED)

27/GRY

13/BLK

S27

F27
15 AMP
28/PUR

PIN P1-X1 13/BLK

F19

90/GRY

90/GRY
90/GRY

PIN P1-E1 13/BLK

LEVEL SENSOR

94/GRY
C

90/GRY

P1-R2

94/GRY
MACHINE NOT
LEVEL LAMP

90/GRY

141/GRY PIN

F17

10 AMP

15 AMP

F18

10 AMP

F16

93/GRN

B
SNSR1

92/BRN

PIN P1-K2
PIN P1-X2

PIN P1-F1 13/BLK

PIN P1-A2
PIN P1-L2

34/ORA
95/ORA
91/PUR

PIN P1-Y1
PIN P1-B1

15 AMP

NOTE: Indicated touch panel buttons activate their component when
they are pushed and held. To deactivate component, release button

2003.10.14 Sentinel Electrical Troubleshooting Manual

PIN P1-E2 13/BLK

HOPPER
TILT BACK

CONTROL
BOARD

TOUCH
PANEL

HOPPER
TILT FWD

Sentinel Blocked Conveyor & Hopper Temp. Sensing Systems

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

13/BLK

86
KEY SWITCH
1/RED

BLOCKED CONVEYOR
SWITCH (CLOSED WITH
BLOCKED CONVEYOR) 140/BLU

27/GRY

PIN P1-T2

S16
1/RED
30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

F27
15 AMP

S26

144/GRN

28/PUR

PIN P1-P3

PIN P1-E1 13/BLK

HOPPER TEMPERATURE SWITCH
(OPEN WITH HIGH TEMPERATURE)

F19

90/GRY
90/GRY
90/GRY
90/GRY
90/GRY

F17

10 AMP

15 AMP

F18

10 AMP

F16
15 AMP

2003.10.14 Sentinel Electrical Troubleshooting Manual

92/BRN

PIN P1-F1 13/BLK

PIN P1-A2
PIN P1-L2

34/ORA
95/ORA
91/PUR

PIN P1-E2 13/BLK
PIN P1-X2

93/GRN

PIN P1-X1 13/BLK

PIN P1-Y1
PIN P1-B1

CONTROL
BOARD

Sentinel Wet Dust Control System

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
85
M4
86

KEY SWITCH
1/RED

30/1

F1
30 AMP
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

27/GRY

1/RED

ACCESSORY
POWER RELAY

13/BLK

LOW WATER
LEVEL SENSOR
(CLOSED WITH LOW WATER)

S28

F27
15 AMP

LOW WATER
LEVEL LAMP

28/PUR

93/GRN

90/GRY
90/GRY
90/GRY

151/BLU

MTR1

F17

F18

15 AMP

10 AMP

F16

39/PUR

93/GRN

PIN P1-L1

PIN P1-E2 13/BLK
PIN P1-X2

PIN P1-F1 13/BLK

PIN P1-A2
95/ORA

PIN P1-Y1
PIN P1-B1

15 AMP

NOTE: Touch panel button shown activates component when
pushed and released. To deactivate, push and release again

2003.10.14 Sentinel Electrical Troubleshooting Manual

PIN P1-E1 13/BLK

PIN P1-L2

92/BRN

91/PUR

PIN P1-X1 13/BLK

34/ORA

10 AMP 34/ORA

10 AMP

PIN P1-L3

WET DUST
CONTROL
WATER PUMP

F19

90/GRY
90/GRY

13/BLK

WATER
PUMP

CONTROL
BOARD

TOUCH
PANEL

Sentinel Pressure Washer System

1/RED

Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK

PRESSURE WASHER SWITCH
(SHOWN IN “ON” POSITION)

S12

21/PUR
100/BLU

28/PUR

90/GRY
90/GRY
90/GRY
90/GRY

98/BRN

PIN P1-G3

PRESSURE
WASHER SOLENOID

F19

90/GRY

PIN P1-X1 13/BLK

SV33

SEE “SENTINEL FORWARD PROPEL &
22/GRY
BRAKE SYSTEMS “ PAGE OR “SENTINEL
REVERSE PROPEL & BRAKE SYSTEMS” PAGE

30 66/BRN
M4 ACCESSORY
POWER RELAY
87

PIN P1-K1

153/YEL

RELEASE

F27
15 AMP

30/1

152/GRY

SET

27/GRY

F1
30 AMP

13/BLK

PARKING
BRAKE
SWITCH

M4
27/GRY

1/RED

13/BLK

ACCESSORY
POWER
RELAY 85

KEY SWITCH
1/RED

93/GRN

10 AMP 34/ORA

10 AMP

F17

F18

15 AMP

10 AMP

F16

PIN P1-E2 13/BLK
PIN P1-F1 13/BLK

PIN P1-L2

92/BRN

PIN P1-A2
95/ORA

91/PUR

PIN P1-X2

PIN P1-E1 13/BLK

PIN P1-Y1
PIN P1-B1

15 AMP

CONTROL
BOARD

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Forward Propel & Brake Systems

KEY SWITCH

30/1

M4 ACCESSORY
POWER RELAY

SET

27/GRY

RELEASE

27/GRY
30

28/PUR

90/GRY
90/GRY

M11

FWD / REV
SWITCH

16/YEL
87

SEAT SWITCH RELAY
(SHOWN CLOSED WITH
OPERATOR ON SEAT)

SEE “SENTINEL
REVERSE PROPEL
SYSTEM” PAGE

F17

10 AMP

15 AMP

F18

10 AMP

F16

102/PUR

15 AMP

93/GRN
92/BRN
34/ORA

13/BLK

SEAT SWITCH RELAY

SW8 15/GRN
13/BLK
2/BLU
M11
86
85
87a
SEAT SWITCH

31/GRN

(SHOWN CLOSED WITH
OPERATOR ON SEAT)

SEE “SENTINEL STARTING SYSTEM” PAGE

SOL3
FORWARD SOLENOID

13/BLK
13/BLK

PIN P1-Y3

PIN P1-X1 13/BLK

PIN P1-W2

PIN P1-E1 13/BLK

PIN P1-X2

PIN P1-E2 13/BLK

PIN P1-A2
PIN P1-L2

95/ORA
91/PUR

13/BLK

PROPEL
DISABLE RELAY

19/BRN
SW1

SV30B

19/BRN

37/PUR
F19

90/GRY

22/GRY

BRAKE RELEASE SOLENOID

30
F27
15 AMP

PROPEL
DISABLE
RELAY

90/GRY

SEE “SENTINEL
STARTING
SYSTEM” PAGE

19/BRN

66/BRN
30

27/GRY

F1
30 AMP

SV30A

PARKING BRAKE
SWITCH

1/RED

13/BLK

ACCESSORY
POWER
RELAY 85

27/GRY

13/BLK

22/GRY

Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
1/RED

1/RED

PIN P1-Y1
PIN P1-B1

PIN P1-F1 13/BLK
CONTROL
BOARD

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Reverse Propel & Brake Systems

KEY SWITCH

30/1

SET

27/GRY

RELEASE

27/GRY
30

28/PUR

90/GRY
90/GRY

M11

FWD / REV
SWITCH

16/YEL
87

37/PUR

F17

10 AMP

15 AMP

F18

10 AMP

F16
15 AMP

93/GRN
92/BRN
34/ORA

31/GRN

(SHOWN CLOSED WITH
OPERATOR ON SEAT)

SEE “SENTINEL STARTING SYSTEM” PAGE

D3
SOL2

13/BLK
13/BLK

REVERSE SOLENOID

PIN P1-X3

PIN P1-X1 13/BLK

PIN P1-W2

PIN P1-E1 13/BLK

PIN P1-X2

PIN P1-E2 13/BLK

PIN P1-A2
PIN P1-L2

95/ORA
91/PUR

SEAT SWITCH RELAY

SW8 15/GRN
13/BLK
2/BLU
M11
86
85
87a
SEAT SWITCH

102/PUR

TO BACK-UP LIGHTS
& BACK-UP ALARM

F19

13/BLK
13/BLK

PROPEL
DISABLE RELAY

102/PUR

SW1

SV30B

13/BLK

SEE “SENTINEL FORWARD PROPEL SYSTEM” PAGE

SEAT SWITCH RELAY
(SHOWN CLOSED WITH
OPERATOR ON SEAT)

90/GRY

22/GRY

BRAKE RELEASE SOLENOID

30
F27
15 AMP

PROPEL
DISABLE
RELAY

90/GRY

SEE “SENTINEL
STARTING
SYSTEM” PAGE

102/PUR

66/BRN
30 66/BRN
M4 ACCESSORY
POWER RELAY
87

27/GRY

F1
30 AMP

SV30A

PARKING BRAKE
SWITCH

1/RED

13/BLK

ACCESSORY
POWER
RELAY 85

27/GRY

13/BLK

22/GRY

Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
1/RED

1/RED

PIN P1-Y1
PIN P1-B1

PIN P1-F1 13/BLK
CONTROL
BOARD

NOTE: Refer to Operational Matrix Charts and Hydraulic Troubleshooting Charts
to successfully troubleshoot electrically operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Vario Brush Tilt System

Switch
Vario Brush Tilt Function

Joystick

Joystick
Joystick

Tilt Brush
Front Edge Down

Tilt Brush
Rear Edge Down

Joystick Switch
Contacts Closed: 11 & 12

Joystick Switch
Contacts Closed: 5 & 6

Tilt Brush Right

Tilt Brush Left

Joystick Switch
Contacts Closed: 2 & 3

Joystick Switch
Contacts Closed: 8 & 9

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

Joystick

13/BLK
13/BLK

85
M4

SV11

ACCESSORY
POWER RELAY

110/YEL

86
KEY SWITCH
1/RED

TILT BRUSH FRONT
EDGE DOWN SOLENOID

27/GRY

JOYSTICK

116/BLU

11
1/RED

F27
15 AMP

30/1

PIN 23

110/YEL

28/PUR

F1
30 AMP

117/BRN
66/BRN
30
87

118/GRY

ACCESSORY
POWER RELAY

SV6
121/PNK

PIN 11

PIN 3

PIN 15
PIN 19
PIN 12
PIN 21

13/BLK

TILT BRUSH RIGHT SOLENOID

109/ORA

109/ORA
SV23

109/ORA

120/TAN

PIN 18
PIN 13
PIN 20

TILT BRUSH LEFT SOLENOID

90/GRY

F24

103/BRN

118/GRY

PIN 10

119/WHT

PIN 22

SV22

10 AMP

TILT BRUSH REAR EDGE DOWN SOLENOID

103/BRN

PIN 14

SV26
111/PNK
SEE “SENTINEL VARIO BRUSH
ARM SWING / SLIDE SYSTEM” PAGE

S1
2

NOTE: Refer to Operational Matrix Charts
and Hydraulic Troubleshooting Charts to
successfully troubleshoot electrically
operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

PIN 9

VARIO BRUSH ENABLE SOLENOID

1
108/PUR
4

X
X

VARIO BRUSH ARM
MOVE/TILT MODE SWITCH

PIN 2
VARIO BRUSH
CONTROL
BOARD
13/BLK

Sentinel Vario Brush Arm Swing / Slide System

Switch
Vario Brush Swing / Slide Function

Joystick

Joystick
Joystick

Swing Brush
Arm Left

Joystick Switch
Contacts Closed: 11 & 12

Joystick

Slide Brush Arm Right

Slide Brush Arm Left

Joystick Switch
Contacts Closed: 2 & 3

Joystick Switch
Contacts Closed: 8 & 9

Swing Brush
Arm Right

Joystick Switch
Contacts Closed: 5 & 6

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

SV25

ACCESSORY
POWER RELAY

110/YEL

86
KEY SWITCH
1/RED

SWING BRUSH ARM
LEFT SOLENOID

27/GRY

JOYSTICK

114/YEL

11
1/RED

F27
15 AMP

30/1

PIN 16

110/YEL

28/PUR

F1
30 AMP

117/BRN
66/BRN
30
87

118/GRY

ACCESSORY
POWER RELAY

SV21
113/ORA

SLIDE BRUSH ARM RIGHT SOLENOID

109/ORA

109/ORA
SV20

109/ORA

112/BRN
SLIDE BRUSH ARM LEFT SOLENOID

90/GRY

F24

103/BRN

PIN 11

PIN 3

PIN 15
PIN 19
PIN 12
PIN 18
PIN 13

13/BLK

PIN 18
PIN 13
PIN 19
PIN 12

118/GRY

PIN 10

115/GRN

PIN 17

SV15

10 AMP

SWING BRUSH ARM RIGHT SOLENOID

103/BRN

PIN 14

SV26
111/PNK

PIN 9

VARIO BRUSH ENABLE SOLENOID

S1
2

NOTE: Refer to Operational Matrix Charts
and Hydraulic Troubleshooting Charts to
successfully troubleshoot electrically
operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

107/YEL

SEE “SENTINEL VARIO
BRUSH TILT SYSTEM” PAGE

4
X

X
X

VARIO BRUSH ARM
MOVE/TILT MODE SWITCH

PIN 1
VARIO BRUSH
CONTROL
BOARD
13/BLK

Sentinel Vario Brush Raise / Lower & Rotate Systems
LOWER
BRUSH

RAISE
BRUSH

OFF

ROTATE BRUSH
CLOCKWISE

OFF

ROTATE BRUSH
COUNTER-CLOCKWISE

Switch S3

Switch S2

Switch Contacts
Closed: 2 & 4

Switch Contacts
Closed: NONE

Switch Contacts
Closed: 1 & 2

Switch Contacts
Closed: NONE

Switch Contacts
Closed: 2 & 4

1/RED
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions

13/BLK
13/BLK

85
M4

ACCESSORY
POWER RELAY

86
KEY SWITCH
1/RED

27/GRY

1/RED

F27
15 AMP

30/1

103/BRN

28/PUR

F1
30 AMP

VARIO BRUSH ENABLE SOLENOID

66/BRN
30
87

S2
M4 ACCESSORY
POWER RELAY

SV27

2
4
X

F24

103/BRN

10 AMP

PIN 9

101/PNK

PIN 4
PIN 3

VARIO BRUSH ROTATE
CLOCKWISE SOLENOID

PIN 15

X
VARIO BRUSH ROTATE
ON / OFF SWITCH

111/PNK

13/BLK

90/GRY

PIN 14

SV26

104/BLU

PIN 5

105/GRY

PIN 7

106/GRN

PIN 6

13/BLK

SV28
13/BLK
VARIO BRUSH ROTATE
COUNTER-CLOCKWISE SOLENOID

SV29

2
4

13/BLK

VARIO BRUSH RAISE SOLENOID
X
X
X

NOTE: Refer to Operational Matrix Charts
and Hydraulic Troubleshooting Charts to
successfully troubleshoot electrically
operated hydraulic solenoid valves

2003.10.14 Sentinel Electrical Troubleshooting Manual

VARIO BRUSH RAISE /
LOWER SWITCH

SV24
13/BLK
VARIO BRUSH LOWER SOLENOID

VARIO BRUSH
CONTROL
BOARD
13/BLK

Sentinel Operating Modes

Operating Modes
Normal Mode;
Normal operation.

Entry Sequence
(how to activate)
Default (when key is turned on)
To exit turn off key

Indicator
D None

Manual Mode; Manually operate 1. Push and hold the Vac fan
D “Manual” appears in the hour
discrete functions without
button
meter window.
interlocks.
2. Turn on the key
3. Hold the button for 15 seconds
4. Release the Vac fan button
5. To exit turn off key
Input Display Mode; Display the 1. Push and hold the Left side
state of floats, limit switches, and
brush button
sensors.
2. Turn on the key
3. Hold the Left side brush
button for 15 seconds
4. Release the Left side brush
button
5. To exit turn off key

D Pin numbers and signal levels
at the pin are displayed on the
tach, speedo, hour meter, and
odometer displays. The pins
are displayed as alpha
characters (a z), numeric
(1 3), and signal level (0 1).
0 represents 0 volts,
1 represents 5 volts.

Toggle Units Mode; Toggle
between miles and kilometers for
speedometer and odometer.

D Tach, speedo, hour meter, and
odometer windows will display
the numbers for controller pins
that have failed self test.

1. Push and hold the Hopper
door open button
2. Turn on the key
3. Hold the Hopper door open
button for 15 seconds
4. Release the Hopper door
open button
5. To exit turn off key

Display Error Mode; Display pin 1. Push and hold the Right
numbers that failed self test.
Side Brush button
2. Turn on the key
3. Hold the Right Side Brush
button for 15 seconds
4. Release the Right Side
Brush button
5. To exit turn off key

2003.10.14 Sentinel Electrical Troubleshooting Manual

D Self test will re--run. If all out
puts pass self test, the “OK”
symbol will appear on the dis-play. If any output pins fail self
test, the failing pins will be
scrolled on the display.
NOTE: The water pump output
will only be tested in this mode.
Because of water that may drip
during self test, this output is not
tested during normal start--up.

Sentinel Operational Matrix (page 1 of 2)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Operational Matrix (page 2 of 2)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Connector Pin Designations

MACHINE CONTROL BOARD CONNECTOR PIN DESIGNATIONS

VARIO BRUSH CONTROL BOARD CONNECTOR PIN DESIGNATIONS

NOTE: View shown from wire harness side of connector

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Fuse Chart

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Component Locator (page 1 of 7)
Vario Brush Tilt &
Lift Valve Block
(Top of Vario Arm)

Vario Brush Swing,
Slide & Rotate Valve Block
(Behind Front Bumper)

Brake Pressure Switch (S13)
(Underside of Cab)

Machine Speed
Sensor (SW6)
(Differential Housing)
Side Brush & Brake
Release Valve Block
(Center Frame under Cab)

Hopper Tilted Switch (S27)
(Side of Hopper Stop Post)
Wet Dust Control
Water Pump (MTR1)
(Center Frame under Cab)
Main Brush & Conveyor
Valve Block (Top of Frame
under Hopper)

Blocked Conveyor Pressure
Switch (S16) (Mounted on Main
Brush / Conveyor Valve Block)

Hopper Load Limit Switch
(S25) (Frame Rail beside
Right Spring Shackle)

Hopper & Vacuum Fan Valve
Block (Underside of Hopper)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Component Locator (page 2 of 7)

Hopper Tilted Switch (S27)
(Side of Hopper Stop Post)
Vacuum Wand Door Switch (S18)
(Top Left Side of Conveyor)

Hopper & Vacuum Fan Valve
Block (Underside of Hopper)

Engine Assembly
(Behind Cab)

Forward / Reverse Switch
(SW1) (In Cab, Dash Panel)

Main Brush & Conveyor
Valve Block (Top of Frame
under Hopper)

Touch & Gauge Panels
(In Cab, Front & Center)

Blocked Conveyor Pressure
Switch (S16) (Mounted on Main
Brush / Conveyor Valve Block)
Low Water Level Switch for
Wet Dust Control (S28)
(Lower Left Corner of Water Tank)

Fuse / Relay Panel
(In Cab, Rear of
Center Console)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Component Locator (page 3 of 7)
Fuse / Relay Panel
(In Cab, Rear of
Center Console)
Propel Forward &
Reverse Solenoids
(SOL2 & SOL3)
(Top of Propel Pump)

Center Console Panel
(In Cab Center, beside Operator)

Air Filter Clogged
Switch (S17)
(Air Filter Housing)

Lights & Pressure Washer
Overhead Switch Panel
(In Cab, Above Windshield)
Engine Pre-Heat
Timer, Signal Flasher,
Warning Alarm, &
Wiper Motor (Under
Dash, forward of
Steering Column)

Vacuum Wand Door Switch (S18)
(Top Left Side of Conveyor)
Hopper Temperature Switch
(S26) (Rear Top Left Hopper)

Brake Lights Pressure
Switch (S13)
(Underside of Cab)
Fuel Level Sender
(SNSR5) (Frame Top,
forward of Conveyor)
Hopper Door Switch (S24)
(Left Rear Hopper Pivot)

Windshield Washer Motor (MTR3)
(Back of Cab, above Battery )

12 Volt Battery (Frame
Top, Behind Cab)
Hopper Load Limit Switch
(S25) (Frame Rail beside
Right Spring Shackle)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Component Locator (page 4 of 7)
Injector Timing Temperature Switch (S10)
(Engine, Conveyor Side, Near Water Neck)

Glow Plugs Connector (Engine,
Conveyor Side, Above Injector Pump)

Fuel Lift Pump (MTR2)
(Engine, Conveyor Side,
Top of Fuel Filter Assembly)
Fuel & Injector Pump Timing
Solenoids (SOL1 & SOL4)
(Engine, Conveyor Side,
Below Fuel Injector Pump)

NOTE: Optional Engine Starter
Motor Location – Not
Used on Sentinel

Oil Pressure Sensor (SNSR3)
(Engine, Conveyor Side on
Remote Oil Filter Adapter)

Engine Temperature
Sender (SNSR4)
(Engine, Cab Side)

Engine Speed Sensor (SNSR2)
(Engine, Lower Flywheel Housing)

Alternator & Diode (D30)
(Engine, Cab Side)

Engine Starter Motor
& Starter Solenoid (M13)
(Engine, Cab Side)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Component Locator (page 5 of 7)
SWITCHES
com ponent # page #(s)

description

location

Vario brush arm move/tilt mode
Vario brush rotate CW or CCW
Vario brush raise/lower
Front sweeping lights
Parking brake
Pressure, brake system low
Head lights,turn,horn,wiper,washer
Beacon light
Key switch (ignition)
Temperature, injector pump timing
4-way warning lights
Pressure washer
Brake lights
A/C thermostat
Rear sweeping lights
Pressure, blocked conveyor
Restriction, air filter
Vacuum wand door
Side brush lights
Pressure, A/C charge
Hopper door
Hopper load limit
Temperature, hopper
Hopper tilt
Low water level (for wet dust control)

In cab, mounted to operator's door
In cab, mounted to operator's door
In cab, mounted to operator's door
In cab, mounted in overhead switch panel
In cab, center console
On Side Brush & Brake Release hydraulic valve block
In cab, mounted to steering column
In cab, mounted in overhead switch panel
In cab, mounted to steering column
Engine, conveyor side, near water neck
In cab, mounted in overhead switch panel
In cab, mounted in overhead switch panel
Underside of cab, below brake pedal
In cab, center console
In cab, mounted in overhead switch panel
Left frame under front of hopper
Air filter housing on engine, cab side
Left side conveyor, top
In cab, mounted in overhead switch panel
On A/C dryer near A/C condenser
Left rear hopper pivot
Right rear leaf spring
Left rear hopper, top
Left hopper stop post
Water tank, left front bottom

2
3
3
1
x

Forward / reverse
Engine shut-down override
Fan speed
Machine speed sensor
Operator seat switch

In cab, dash panel
In cab, center console
In cab, center console
Left differential housing
In cab, under operator's seat

Vario brush arm move/tilt

In cab, mounted to operator's door

S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
S18
S20
S23
S24
S25
S26
S27
S28

x
x
x
3
3
1
x
3
x
4
3
3
1&
3
3
1&
3
2&
3
x
3
1&
3
1&
2

SW1
SW2
SW3
SW6
SW8
JOYSTICK

2
3

3
2

SENSORS
com ponent # page #(s)

SNSR1
SNSR2
SNSR3
SNSR4
SNSR5

x
4
4
4
3

description

location

Machine level (inclinometer)
Engine speed
Pressure, engine oil
Temperature, engine coolant
Fuel level

In cab, under fuse/relay panel
Engine, lower flywheel housing
Engine, conveyor side, on remote oil filter adapter
Engine, cab side, near water neck
Frame top, right side, forward of conveyor

ELECTRIC MOTORS
com ponent # page #(s)

MTR1
MTR2
MTR3
MTR4
HCU1
STARTER

1
4
3
3
x
4

2003.10.14 Sentinel Electrical Troubleshooting Manual

description

location

Water pump (wet dust control)
Fuel lift pump
Washer pump
Wiper motor
Heating & cooling unit
Engine starter motor

Frame mount, center, under cab
Engine, conveyor side, top of fuel filter assembly
Back side of cab, above battery
In Cab, under dash, forward of steering column
In cab, center console, forward of fuse/relay panel
Engine, cab side

Sentinel Component Locator (page 6 of 7)
FUSES, RELAYS, & DIODES
com ponent # page #(s)

F1 to F29

2&3

M1
M2
M3
M4
M5
M6
M7
M8
M9
M10
M11
M12
M13

2&
2&
2&
2&
2&
2&
2&
2&
2&
2&
2&
2&
4

3
3
3
3
3
3
3
3
3
3
3
3

D1
D2
D3
D4
D5A
D6
D7
D8
D26B
D27
D29
D30

2&
2&
2&
2&
2&
2&
2&
2&
2&
2&
2&
4

3
3
3
3
3
3
3
3
3
3
3

description

location

Electrical fuses

In cab, rear center console fuse panel (see Fuse Chart)

Horn relay
Neutral start relay
Propel disable relay
Accessory power relay # 1
Engine shut-down relay
High beam relay (headlights)
Low beam relay (headlights)
Medium speed relay (heater & A/C fan)
High speed relay (heater & A/C fan)
Hopper moving alarm relay
Seat switch relay
Accessory power relay # 2
Starter motor solenoid
Suppression diode, horn
Suppression diode, forward propel solenoid
Suppression diode, reverse propel solenoid
Suppression diode, fuel solenoids & lift pump
Blocking bridge rectifier, warning lights
Suppression diode, brake release solenoids
Suppression diode, A/C clutch
Blocking diode, pressure washer
Blocking bridge rectifier, heater & A/C fan
Blocking diode, parking brake input
Blocking diode, service brake input
Blocking diode, alternator

In cab, rear center console fuse panel

Engine, cab side, mounted to starter top

In cab, rear center console, below fuse panel

Engine, cab side, near alternator

MISCELLANEOUS COMPONENTS
com ponent # page #(s)

ALT
FL1
GP1 to GP4
L1
LS3
PWRSPLY1
TMR1
VARIO

4
3
4
x
3
2
3
2&3

2003.10.14 Sentinel Electrical Troubleshooting Manual

description

location

Alternator
Turn & warning lights flasher
Engine glow plugs
A/C clutch
Warning alarm
Panel backlight power supply
Engine glow plugs timer
Vario brush control board

Engine, cab side
In cab, under dash, forward of steering column
Engine, top
Near engine cooling fan, belt driven
In cab, under dash, forward of steering column
In cab, mounted behind touch & gauge panels
In cab, under dash, forward of steering column
In cab, rear center console, below fuse panel

Sentinel Component Locator (page 7 of 7)
HYDRAULIC VALVE BLOCKS
com ponent # page #(s)

767009
767212
768899
771010
771011
771012
771019

x
1&3
1&2
1
1
1
1&2

description

location

Pressure Washer
Front & rear brakes
Hopper & Vacuum Fan
Side Brush & Brake Release
Vario Swing, Slide, & Rotate
Vario Arm
Main Brush & Conveyor

Frame top, right side, forward of fuel filler neck
Underside of cab, below brake pedal
Left rear, underside of hopper
Frame mount, center, under cab
Behind front bumper
Top of Vario arm
Left frame under front of hopper

SOLENOID VALVE COILS
com ponent # page #(s)

SV1
SV2
SV3
SV4
SV5
SV6
SV7
SV8
SV9
SV10
SV11
SV12
SV13
SV14
SV15
SV16
SV17
SV18
SV19
SV20
SV21
SV22
SV23
SV24
SV25
SV26
SV27
SV28
SV29
SV30A
SV30B
SV31
SV32
SV33

1&
1&
1&
1&
1
1
1
1
1
1
1
1&
1&
1&
1
1&
1&
1&
1&
1
1
1
1
1
1
1
1
1
1
1
1
1&
1&
x

SOL1
SOL2
SOL3
SOL4

4
3
3
4

2
2
2
2

2
2
2
2
2
2
2

2
2

description

Hopper lower
Hopper lift
Main brush down
Enable
Right side brush down
Tilt Vario brush right
Left side brush down
Enable
Right side brush rotate
Left side brush rotate
Tilt Vario brush front edge down
Main brush & conveyor forward
Main brush & conveyor reverse
Vacuum fans
Swing Vario brush arm right
Shaker, panel filter
Hopper door release
Hopper tilt back
Hopper tilt forward
Slide Vario brush arm left
Slide Vario brush arm right
Tilt Vario brush rear edge down
Tilt Vario brush left
Vario brush lower
Swing Vario brush arm left
Enable Vario brush
Vario brush rotate clockwise
Vario brush rotate counter-clockwise
Vario brush raise
Brake release
Brake release
Conveyor down
Enable hopper
Pressure washer

2003.10.14 Sentinel Electrical Troubleshooting Manual

Engine fuel
Reverse propel
Forward propel
Injector pump timing

location

On Hopper & Vacuum Fan hydraulic valve block
On Main Brush & Conveyor hydraulic valve block
On Side Brush & Brake Release hydraulic valve block
On Vario Arm hydraulic valve block
On Side Brush & Brake Release hydraulic valve block
On Vario Arm hydraulic valve block
On Main Brush & Conveyor hydraulic valve block
On Hopper & Vacuum Fan hydraulic valve block
On Vario Swing, Slide, & Rotate hydraulic valve block
On Hopper & Vacuum Fan hydraulic valve block

On Vario Swing, Slide, & Rotate hydraulic valve block
On Vario Arm hydraulic valve block

On Vario Swing, Slide, & Rotate hydraulic valve block
On Vario Arm hydraulic valve block
On Side Brush & Brake Release hydraulic valve block
On Main Brush & Conveyor hydraulic valve block
On Hopper & Vacuum Fan hydraulic valve block
On Pressure Washer hydraulic valve block
Engine, conveyor side, below fuel injector pump
Top of propel pump
Top of propel pump
Engine, conveyor side, below fuel injector pump

SENTINEL
HYDRAULIC
Troubleshooting Manual
BEFORE CONDUCTING TESTS:
* Read and Follow ALL Safety Warnings and Precautions in
Operator's Manual
* Engine & Hydraulic Oil Must Be At Normal Operating
Temperatures after Running Machine and Hydraulics a
Minimum of 5 Minutes
•Examine Machine For Any Linkage Binding or Mechanical
Problems

DURING TESTS:
* Maintain Normal Main Brush Pressure as Listed in
Operator's Manual
* Call Technical Services if Diagnostic Time Exceeds One
Hour With Unknown Cause or Course of Action
NOTE:Troubleshooting charts are shown with optional equipment. The optional equipment is not
specified in these charts. Some machines may not be equipped with all components shown.

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Diagram (page 1 of 5)
1
2
3

4
5

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Diagram (page 2 of 5)
7

5
11
12

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Diagram (page 3 of 5)

8
9

11
12

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Diagram (page 4 of 5)

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Diagram (page 5 of 5)

2003.10.14 Sentinel Electrical Troubleshooting Manual

DOOR

HOPPER

CYL HYD

C12C11

C10 C2

MOTOR
VAC FAN
IN

OUT

SHAKER

MOTOR

SHAKER
IN

OUT
MOTOR

M5 M6 M10 M9

HOPPER CNTL

HOPPER TILT CYL

CONVEYOR/MAIN BRUSH
T8

TO PRIORITY VALVE (EF)

TO HYD RESERVOIR

Sentinel Hydraulic Hose Diagram (page 1 of 11)
Low Dump Hydraulic Hose Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

MOTOR, HYD
VAC FAN

OUT

C12 C11

C10C2
M5M6

HOPPER CNTL

M10M9

CYLINDER
LIFT

CYLINDER
TILT

SAFETY LEG

CONVEYOR/MAIN BRUSH

TO PRIORITY VALVE (EF)

TO HYD RESERVOIR

Sentinel Hydraulic Hose Diagram (page 2 of 11)
High Dump Hopper Hydraulic Hose Group

Sentinel Hydraulic Hose Diagram (page 3 of 11)

Front Axle

Rear Axle

Brake
Valve

B2
P2

Steering
Valve

Manifold

Cab Hydraulic Hose Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

Turbo Cooler

Gear
Pump

Hydraulic
Reservoir

Turbo Cooler

NA Cooler

Right
Lift

Right
Tension

Left
Lift

Left
Tension

T10
C3

Conveyor/Main Brush Valve

C22

Main Brush
Motor

Conveyor
Motor
Main
Brush
Lift

Sentinel Hydraulic Hose Diagram (page 4 of 11)
Conveyor and Main Brush Hydraulic Hose Group

Sentinel Hydraulic Hose Diagram (page 5 of 11)

2003.10.14 Sentinel Electrical Troubleshooting Manual

NA Cooler

Gear
Pump

Turbo Cooler

Piston
Pump

Hydraulic
Filter

Hydraulic
Reservoir

Piston
Motor

Aux. Gear
Pump

Hydraulic Reservoir Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

Brake
Valve

LS1

Steering
Valve

Front Axle

To P7 on
Hopper
Valve

R.H.
Side
Brush
Motor

Priority
Valve

Manifold
Gear
Pump

NA Cooler

P4 T7

T13

Rear Axle

C21

Side
Brush
Valve

Aux.
Gear
Pump

Turbo
Cooler

Hydraulic
Reservoir

Sentinel Hydraulic Hose Diagram (page 6 of 11)
Steer, Brakes, Side Brush hydraulic Hose Group

Sentinel Hydraulic Hose Diagram (page 7 of 11)

L.H. Side
Brush

R.H. Side
Brush

Manifold

Side Brush
Valve

Left Side Brush Hydraulic Hose Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Hose Diagram (page 8 of 11)

Speed
Control
Valve

Piston
Pump

Piston
Motor

Propel Hydraulic Hose Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Hose Diagram (page 9 of 11)
High Pressure Sprayer Hydraulic Hose Group

DUAL GEAR PUMP/PROPEL

HIGH PRESSURE
SPRAYER
MOTOR

P9
M16

T12

PRESSURE
WASH
CONTROL
VALVE

M15

2003.10.14 Sentinel Electrical Troubleshooting Manual

C15

2003.10.14 Sentinel Electrical Troubleshooting Manual

C16

C17

C18

C19

T16

Vario Brush
Hydraulic Lift
Valve

Vario Brush
Motor

Hydraulic
Filter

M11

M12

C14

Hydraulic
Solenoid
Valve

Hydraulic
Gear
Motor

C13

T16

T11

M13

M14
G9

Manifold

Aux. Gear
Pump

Sentinel Hydraulic Hose Diagram (page 10 of 11)
Vario Brush Hydraulic Hose Group

Sentinel Hydraulic Hose Diagram (page 11 of 11)
Cab Tilt Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 1 of 8)
Hydraulic Pumps Group

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 2 of 8)
Hydraulic Main Brush/Conveyor Lift Valve Group

T10

3
4

C22

T2
SW
C6

T8
M7
M8
T3

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 3 of 8)
Hydraulic Hopper Control Valve Group

C12

P7
C11

C10
C9

M1O

M9
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 4 of 8)
Hydraulic Side Brush Valve Group

G1
C7

G7
P3

T7
C21

T13

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 5 of 8)
Hydraulic Manifold and Priority Group

A2
LS1
EF

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 6 of 8)
Hopper Functions & Vacuum Fans Valve Block
Hyraulic Solenoid Valve Breakdown, 768899

CV5

SV17

RV7

SV19

SV32

SV2

RV4
SV18 SV1
SV16

CV4

SV14

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Hydraulic Pumps & Valves (page 7 of 8)
Hopper Functions & Vacuum Fans Valve Block
Hydraulic Solenoid Valve Breakdown, 768899
(For High Dump Hopper Lift Option)

SV17

CV5
RV7

SV19

SV32

SV2
SV14

2003.10.14 Sentinel Electrical Troubleshooting Manual

RV4

SV18
SV16

SV1

CV4

Sentinel Hydraulic Pumps & Valves (page 8 of 8)
Pressure Washer Valve Block
Hydraulic Solenoid Valve Breakdown, 767009

PF1

SV33

2003.10.14 Sentinel Electrical Troubleshooting Manual

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

Indicates Energized Solenoid Valve Coil

EXAMPLES
Circled envelope is
valve position for indicated
hydraulic circuit

SV32

SV12

SV8
Energized
Coils

SV3
Non-Energized
Coils

SV13
2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Conveyor & Main Brush Forward
SV12
SV4

S16
2400 PSI

SV12

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV4
SV13

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Conveyor & Main Brush Reverse

SV4

S16
2400 PSI

REVERSE

SV13

SV12

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV4
SV13

2003.10.14 Sentinel Electrical Troubleshooting Manual

Sentinel Main Brush Lower
SV3
SV4

S16
2400 PSI

LOWER

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV3

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV4

Sentinel Conveyor Lower
SV31
SV4
S16
2400 PSI

LOWER

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV4

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV31

Sentinel Main Brush Lift, Conveyor Lift, & Conveyor Chain Tension
SV31
SV3

SV4
S16
2400 PSI

LIFT

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV3

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV4

SV31

Sentinel Right Side Brush Rotate & Lower
SV8

SV9

SV10

2200 PSI

LOWER

SV5

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV5

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV8

SV9

SV10

Sentinel Left Side Brush Rotate & Lower
SV8

SV9

SV10

2200 PSI

LOWER

SV7

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV7

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV8

SV9

SV10

Sentinel Right & Left Side Brush Rotate & Lower
SV8

SV9

SV10

2200 PSI

LOWER

SV7
LOWER

SV5

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV5

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV7

SV8

SV9

SV10

Sentinel Right & Left Side Brush Lift

SV8

2200 PSI

LIFT

SV7
LIFT

SV5

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV5

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV7

SV8

Sentinel Vacuum Fans Run
SV14

SV32

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV14

SV32
98

Sentinel Shaker Run
SV32

SV16

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV16

SV32
99

Sentinel Vacuum Fans & Shaker Off
SV14

SV32

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV14

SV32
100

Sentinel Hopper Tilt Back (Dump)
SV32

SV18
TILT BACK

SV19

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV18
2003.10.14 Sentinel Electrical Troubleshooting Manual

SV19

SV32
101

Sentinel Hopper Tilt Forward (Normal Sweep Position)
SV32

SV18
TILT FORWARD

SV19

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV18
2003.10.14 Sentinel Electrical Troubleshooting Manual

SV19

SV32
102

Sentinel Hopper Lift (High Dump)
SV32

SV2
LIFT

SV1

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV1
2003.10.14 Sentinel Electrical Troubleshooting Manual

SV2

SV32
103

Sentinel Hopper Lower (High Dump)
SV32

SV14

SV2
SV1

LOWER

Note: Lowering of
hopper is due to gravity
(weight of hopper)

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE
2003.10.14 Sentinel Electrical Troubleshooting Manual

SV1

SV2

SV14

SV32
104

Sentinel Hopper Door Lock (Latch Closed)
NOTE: SV 32 Energized for
4 seconds when Hopper
Door Close button is pressed

SV32

SV17
LOCK

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV17
2003.10.14 Sentinel Electrical Troubleshooting Manual

SV32
105

Sentinel Hopper Door Unlock (Latch Open)
NOTE: SV 32 Energized for
4 seconds when Hopper
Door Open button is pressed

SV32

SV17
UNLOCK

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

SV17
2003.10.14 Sentinel Electrical Troubleshooting Manual

SV32
106

Sentinel Vario Brush Rotate Clockwise

ROTATE CLOCKWISE

SV27

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV28

SV26
SV27
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107

Sentinel Vario Brush Rotate Counter-Clockwise

SV28

ROTATE
COUNTER-CLOCKWISE

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV28

SV26
SV27
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108

Sentinel Vario Brush Swing Right (Clockwise)

SWING RIGHT
(CLOCKWISE)

SV15

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV25

SV26
SV15
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109

Sentinel Vario Brush Swing Left (Counter-Clockwise)

SV25

SWING LEFT
(COUNTER-CLOCKWISE)

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV25

SV26
SV15
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110

Sentinel Vario Brush Slide Right

SV21

SLIDE RIGHT

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV21

SV26
SV20
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111

Sentinel Vario Brush Slide Left

SLIDE LEFT

SV20

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV21

SV26
SV20
2003.10.14 Sentinel Electrical Troubleshooting Manual

112

Sentinel Vario Brush Tilt Rear Edge Down
TILT REAR
EDGE DOWN

SV22

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV22

SV26
SV11
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113

Sentinel Vario Brush Tilt Front Edge Down
TILT FRONT
EDGE DOWN

SV11

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV22

SV26
SV11
2003.10.14 Sentinel Electrical Troubleshooting Manual

114

Sentinel Vario Brush Tilt Left
TILT LEFT

SV23

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV23

SV26
SV6
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115

Sentinel Vario Brush Tilt Right
TILT RIGHT

SV6

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV23

SV26
SV6
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116

Sentinel Vario Brush Lift
LIFT

SV29

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV29

SV26
SV24
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117

Sentinel Vario Brush Lower
LOWER
Note: Lowering of
brush is due to gravity
(weight of brush & arm)

SV24

SUCTION LINE
PRESSURE / FLOW LINE

SV26

RETURN LINE

SV29

SV26
SV24
2003.10.14 Sentinel Electrical Troubleshooting Manual

118

Sentinel Right Turn
STEERING / BRAKE
PRIORITY VALVE

TO COOLER
INLET

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

STEERING VALVE ASSY.

STEERING VALVE

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119

Sentinel Left Turn
STEERING / BRAKE
PRIORITY VALVE

TO COOLER
INLET

SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

STEERING VALVE ASSY.

STEERING VALVE

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120

Sentinel Brake Pedal (Push)
STEERING / BRAKE
PRIORITY VALVE
SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

BRAKE
PEDAL

TO
FRONT
BRAKES

TO
REAR
BRAKES

BRAKE VALVE

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121

Sentinel Brake Pedal (Release)
STEERING / BRAKE
PRIORITY VALVE
SUCTION LINE
PRESSURE / FLOW LINE
RETURN LINE

BRAKE
PEDAL

TO
FRONT
BRAKES

TO
REAR
BRAKES

BRAKE VALVE

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122

2003.10.14 Sentinel Electrical Troubleshooting Manual

Propel Pump Assembly

Forward Propel Solenoid (SOL3)

Reverse Propel Solenoid (SOL2)

Speed Control Valve Assembly
(Foot Pedal)

Propel Motor Assembly

Sentinel Propel System (page 1 of 2)

123

2003.10.14 Sentinel Electrical Troubleshooting Manual

6150 psi

380 psi +/- 20 psi

Always consider safety
when performing tests.

All tests are performed at full engine RPM, with
the propel pedal fully depressed.

Propel Troubleshooting Tip Sheet

Sentinel Propel System (page 2 of 2)

124

Sentinel Operational Matrix (page 1 of 2)

2003.10.14 Sentinel Electrical Troubleshooting Manual

125

Sentinel Operational Matrix (page 2 of 2)

2003.10.14 Sentinel Electrical Troubleshooting Manual

126

Sentinel Solenoid Valve Details
SV23

SV1

SV2

SV3

SV4

SV5

SV7

SV8

SV6
SV22

SV9

SV10

SV18

SV19

SV28

SV29

SV27

SV12

SV24

2003.10.14 Sentinel Electrical Troubleshooting Manual

SV25

SV14
SV11

SV13

SV21

SV22

SV16

SV17

SV15
SV23

SV29

SV25

SV26
SV20

SV11

SV6

SV24

SV15

SV30A

SV30B

SV31

SV32

SV33

SOL3

SOL2 127

Sentinel Component Locator (page 1 of 5)
771012
Vario Brush Tilt & Lift Valve Block
(Top of Vario Arm)
SV6, SV11, SV22, SV23, SV24, SV29

771011
Vario Brush Swing, Slide & Rotate Valve Block
(Behind Front Bumper)
SV15, SV20, SV21, SV25, SV26, SV27, SV28

Propel Motor
(Center Frame under Cab)

771019
Main Brush & Conveyor Valve Block
(Top of Frame under Hopper)
SV3, SV4, SV12, SV13, SV31

Power Steering Valve
(Underside of Cab, below Steering Column)

Speed Control Valve
(Underside of Cab,
below Propel foot pedal)
767212
Front & Rear Brake Valve
(Underside of Cab, below Brake Pedal)

771010
Side Brush & Brake Release Valve Block
(Center Frame under Cab)
SV5, SV7, SV8, SV9, SV10, SV30A, SV30B

Steering / Brake Priority Valve
(Center Frame under Cab)

768899
Hopper & Vacuum Fan Valve Block
(Underside of Hopper)
SV1, SV2, SV14, SV16, SV17, SV18, SV19, SV32
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128

Sentinel Component Locator (page 2 of 5)

768899
Hopper & Vacuum Fan Valve Block
(Underside of Hopper)
SV1, SV2, SV14, SV16, SV17, SV18, SV19, SV32

771019
Main Brush & Conveyor Valve Block
(Top of Frame under Hopper)
SV3, SV4, SV12, SV13, SV31

2003.10.14 Sentinel Electrical Troubleshooting Manual

129

Sentinel Component Locator (page 3 of 5)

767200
Propel Pump
(Mounted to Engine)

Propel Forward &
Reverse Solenoids
(SOL2 & SOL3)
(Top of Propel Pump)

Power Steering Valve
(Underside of Cab,
below Steering Column)

Speed Control Valve
(Underside of Cab,
below Propel foot pedal)

767009
Pressure Washer Valve Block
(Frame Top, forward of Fuel Filler Neck)
SV33

2003.10.14 Sentinel Electrical Troubleshooting Manual

767212
Front & Rear Brake Valve
(Underside of Cab, below Brake Pedal)

130

Sentinel Component Locator (page 4 of 5)

PUMP(S)

Side Brush Functions & Brake Release
Solenoids Pump, Vario Brush Pump
(Mounted to Engine)

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131

Sentinel Component Locator (page 5 of 5)
HYDRAULIC VALVE BLOCKS
com ponent # page #(s)

767009
767212
768899
771010
771011
771012
771019

3
1&3
1&2
1
1
1
1&2

description

location

Pressure Washer
Front & rear brakes
Hopper & Vacuum Fan
Side Brush & Brake Release
Vario Swing, Slide, & Rotate
Vario Arm
Main Brush & Conveyor

SOLENOID VALVE COILS
com ponent # page #(s)

SV1
SV2
SV3
SV4
SV5
SV6
SV7
SV8
SV9
SV10
SV11
SV12
SV13
SV14
SV15
SV16
SV17
SV18
SV19
SV20
SV21
SV22
SV23
SV24
SV25
SV26
SV27
SV28
SV29
SV30A
SV30B
SV31
SV32
SV33

1&
1&
1&
1&
1
1
1
1
1
1
1
1&
1&
1&
1
1&
1&
1&
1&
1
1
1
1
1
1
1
1
1
1
1
1
1&
1&
x

SOL2
SOL3

3
3

2
2
2
2

2
2
2
2
2
2
2

2
2

description

2003.10.14 Sentinel Electrical Troubleshooting Manual

Reverse propel
Forward propel

location

On Vario Swing, Slide, & Rotate hydraulic valve block
On Vario Arm hydraulic valve block

132

Automotive: Sirens/Switches

ENGINEERING COMPANY INC.
Route 145, Winthrop Road,
Chester, Connecticut 06412
Phone: (860) 526-9504
Fax: (860) 526-4078
Internet: www.whelen.com
Sales e-mail: autosale@whelen.com
Canadian Sales e-mail: autocan@whelen.com
Customer Service e-mail: custserv@whelen.com

Installation and Operating Guide:
Traffic Advisor Control Head Models
TACTL1A, TACTL3A & TACTL4A

Safety First
This document provides all the necessary information to allow your Whelen product to be properly and safely installed.
Before beginning the installation and/or operation of your new product, the installation technician and operator must
read this manual completely. Important information is contained herein that could prevent serious injury or damage.
•

Proper installation of this product requires the installer to have a good understanding of automotive
electronics, systems and procedures.

•

If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or
other vital parts could be damaged by the drilling process. Check both sides of the mounting surface
before drilling begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets
into all wire passage holes.

•

If this product is mounted with tape or Velcro™, clean the mounting surface with a 50/50 mix of isopropyl
alcohol and water and dry thoroughly.

•

Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted
or located in the air bag deployment area will damage or reduce the effectiveness of the air bag, or
become a projectile that could cause serious personal injury or death. Refer to your vehicle owners
manual for the air bag deployment area. The User/Installer assumes full responsibility to determine proper
mounting location, based on providing ultimate safety to all passengers inside the vehicle.

•

For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be
made. The recommended procedure requires the product ground wire to be connected directly to the
NEGATIVE (-) battery post.

•

If this product uses a remote device to activate or control this product, make sure that this control is
located in an area that allows both the vehicle and the control to be operated safely in any driving
condition.

•

Do not attempt to activate or control this device in a hazardous driving situation.

•

It is recommended that these instructions be stored in a safe place and referred to when performing
maintenance and/or reinstallation of this product.

•

FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE
TO THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Page 1

133

damaged in the process. Check both sides of the
mounting surface before starting. If damage is
likely, select a different mounting location.

Important Note: This manual is used for both 12-volt
(TACTL*A) and 24-volt (TACTL2*A) versions of TACTLseries control switch. All 24-volt versions are identical to
their 12-volt counterparts in both fuction & operation.
However, any fusing and wiring differences will be
documented in the appropriate sections (example: The
TACTL1A (12V) & TACTL21A (24V) require different fuse
ratings).

Drill the mounting holes in the areas scribed in step 1.
The size of the drill bit should be determined by the size
of the mounting hardware (customer supplied) and
thickness of the mounting surface.

The TACTL-series Control Head features a four-function
rotary switch that allows the user to select from left arrow,
right arrow, split arrow, or flash pattern. Dip switches on the
rear panel determine which of the following patterns will be
displayed when “flash” is selected (see “Dip Switch
Programming” on page 3).

Using your mounting hardware, secure the bail strap to
the mounting location.

•
•
•
•
•
•
•
•
•

With the bail strap in place, insert the carriage bolt along
with the external tooth lockwasher (supplied) into the
assembly hole from the inner side of the Bail Strap as
shown.

Place the split lockwasher and the acorn nut on the
protruding bolt on the outer side of the bail strap. Loosely
secure the acorn nut to the carriage bolt.

Now slide the control head onto the carriage bolts. Once
it is in the position that the customer has chosen, tighten
the acorn nuts until the unit is firmly secured.

Note: There are 2 sets of holes on the Bail Strap
for positioning the control head at 2 different
heights (see Page 3).

One Lamp Sequence to Triple Flash
One Lamp Sequence to Double Flash
Sequence to Solid
Solid Arrow
Two Lamp Sequences
Three Lamp Sequences
Four Lamp Sequences
Sequence On / Sequence Off
Remote Flash Control (TACTL1A Only)

Remote Flash Control is the new feature on the TACTL1A.
This allows for the remote activation of the flash function
when the T/A head is off. Turning on the control head
overrides the auxiliary control. This is ideal for activation with

Wiring the Traffic Advisor System

FRONT VIEW
HIGH / LOW / OFF
SWITCH

PATTERN SELECTION
ROTARY KNOB

RIGHT

OFF

SPLIT

LOW

FLASH

POWER

LEFT

HIGH

FUNCTION

TRAFFIC ADVISOR

DIRECTION INDICATOR

LED STATUS DISPLAY

Plug the connector into the back of the control head unit
(See “Rear View” next page).

Extend the RED and BLACK wires to the battery.

Connect the RED wire to one end of a user supplied fuse
block. Do not connect this unit to the battery yet.

Connect the BLACK wire to the vehicle’s chassis ground

Extend and connect the WHITE wire to the accessory
switch for the back light controls (TACTL1A only).

Route the cable from the TA to the control head.

Following the pin charts for your model on page 3, insert
the contact wires into their positions. Check that the
wires are fully inserted by pulling back on them firmly.

Plug the connector(s) into the back of the control head.

a slide switch control.
A Center-Off Rocker Switch is used to turn the unit On and
Off, in either High or Low power mode. The TACTL has an
LED status display that provides a visual indication of the
current light pattern.

WARNING! All customer supplied wires that connect to the
positive terminal of the battery must be sized to supply at
least 125% of the maximum operating current and fused at
the battery to carry the load (see “Wire Chart” on page 3).

Installation: Mounting Control Head
1.

The installation of your Traffic Advisor System will be
complete after the fuse block wire is connected to the
POSITIVE (+) terminal of the battery. After this connection
has been made, inspect the fuses at the control head and at
the battery. If either of these fuses are blown, carefully
inspect all of the circuit wires and make sure they are wired
correctly. Replace blown fuses with one of an identical amp
rating as the original. If these fuses blow after installation or
activation, contact Whelen Engineering Technical Support.

Position the bail strap in the selected mounting location.
Using an awl or other suitable tool, scribe the surface
where the mounting hole are to be drilled.

Caution: As mounting the TACTL will require
drilling, it is absolutely necessary to make sure
that no other vehicle components could be

Page 2

134

Chassis BLK (Pos.2)
Ground

Rear View
TACTL1A

WHT (Pos.3)

Backlight
Control (to
Acc. Switch)

Rear View
TACTL3A & TACTL4A

Customer Supplied Fuse:
15 AMP (12V)
10 AMP (24V)

RED (Pos.1)

To POS.
(+) Battery

Customer Supplied
3 Amp Fuse

To Chassis Ground

BLACK

RED

To Chassis Ground

BLACK

RED

Customer Supplied Fuse:
30 AMP (12V)
15 AMP (24V)
To POS.
(+) Battery
Splice RED
wires together

Pos. 1

Dip
Switches

12 3 4 5

Pos. 12

FUSE

Power Input

RIGHT SIDE CONNECTOR
PIN

TO:

WIRE

TO:

WIRE

Lamp 1

BRN

Lamp 7

VIO

Lamp 2

RED

Lamp 8

GRY

Lamp 3

ORN

+BAT

WHT

Lamp 4

YEL

N/C

Lamp 5

GRN

N/C

Lamp 6

BLU

TO:

WIRE

TO:

WIRE

LAMP 5

GRN

LAMP 1

BRN

+ BATTERY

WHT

+ BATTERY

WHT

LAMP 6

BLU

LAMP 2

RED

7 8 9

+ BATTERY

WHT

+ BATTERY

WHT

10 11 12

LAMP 7

VIO

LAMP 3

ORG

+ BATTERY

WHT

+ BATTERY

WHT

LAMP 8

GRY

LAMP 4

YEL

+ BATTERY

WHT

+ BATTERY

WHT

N/C

1 2 3

4 5 6

Aux Input* WHT/BLU

* Requires a SP/ST switch
and a 3 Amp fuse.
(Customer Supplied)

Reference Point

CUSTOMER SUPPLIED
SHEET METAL SCREWS

BAIL STRAP
#10 SPLIT
LOCKWASHER
QTY. (2)

#10 EXT. TOOTH
LOCKWASHER
10-24
ACORN NUT
QTY. (2)
(4)
ASSEMBLY
HOLES

DIP SWITCH PROGRAMMING:
(TACTL1A & TACTL4A)

REAR VIEW OF
PIN HOUSING
1 2 3

4 5 6
7 8 9

Reference Point

RECOMMENDED WIRE SIZE
AUXILIARY
CONTROL WIRES
POWER WIRES
18 AWG
13 FT.
14 AWG 26 FT.
16 AWG
21 FT.
12 AWG 42 FT.
33 FT.
10 AWG

10-24 x ½"
CARRIAGE BOLT
QTY. (2)

DIP SWITCH SETTING
1
2
3
4
5

LEFT SIDE CONNECTOR

REAR VIEW OF
PIN HOUSING

DIP SWITCH PROGRAMMING:
(TACTL3A)

LEFT

RIGHT

SPLIT

FLASH

Sequence
Triple Flash
Sequence
Double Flash
Sequence
to Solid
Solid
Half Arrow
Sequence
Two Lamps
Sequence
Three Lamps
Sequence
Four Lamps
Sequence On
Sequence Off

Sequence
Triple Flash
Sequence
Double Flash
Sequence
to Solid

Single
Flash
Double
Flash
Double
Flash
Double
Flash
Double
Flash
Double
Flash
Double
Flash
Double
Flash

AlternatingSolid
Half Arrow

Sequence
Two Lamps
Sequence
Three Lamps
Sequence
Four Lamps
Sequence On
Sequence Off

UP = 6 LIGHT ARRAY DOWN = 8 LIGHT ARRAY

U = UP

DIP SWITCH SETTING
1
2
3
4
5

LEFT

RIGHT

SPLIT

FLASH

Sequence
Triple Flash

Alt Arrow Tips/
Solid Bar

Sequence
to Solid

Alt Arrow Tips/
Solid Bar

Sequence On/
Sequence Off

Alt Arrow Tips/
Solid Bar

Solid
Full Arrow

Alt Arrow Tips/
Solid Bar

Solid
Full Arrow

Arrow
Tips

Solid
Full Arrow

Solid
Bar

Solid
Half Arrow

Solid
Full Arrow

Arrow
Tips

Solid
Half Arrow

Solid
Full Arrow

Solid
Bar

UP = Normal DOWN = Reversed (Swap Left & Right) U = UP D = DOWN

D = DOWN

UP = New Array Patterns DOWN = Old Array Patterns

UP = ENABLE END LAMPS DOWN = DISABLE END LAMPS
To shut end-cap arrows off on T/A bars for a non-directional warning.

Page 3

135

136

Installation Manual for
TA836A Traffic Advisor

ENGINEERING COMPANY INC.
ROUTE 145, WINTHROP ROAD
CHESTER, CONNECTICUT 06412-0684
TELEPHONE: (860) 526-9504
FAX: (860) 526-4078
Installation: Mounting the Traffic Advisor

Servicing the Traffic Advisor Assembly:

The Traffic Advisor (T/A) mounting feet can be adjusted so that
no matter what the angle of the selected mounting surface, the
Traffic Advisor can deliver optimum visibility. See page 2.

The Traffic Advisor can be field serviced without difficulty. If you
need to replace the reflector, remove the end cap, disconnect
the reflector from the internal wire harness and slide the reflector out of the extrusion. Use the same procedure in reverse
order for reassembly. (Pg. 2)

CAUTION: Do not connect the T/A System to power until the
installation is completed. When servicing or trouble shooting
always disconnect it from the power source.
1. Remove the two lower brackets of the mounting feet from
the mounting kit and secure them to the upper brackets with
the supplied hardware. (Pg. 2)
2. Slide the mounting feet to their desired position inside the
groove, and secure them with the hardware supplied (Pg. 2).
3. Slightly loosen the hex nuts holding the upper and lower
brackets together and place the T/A in the desired position
on the proposed mounting surface. Adjust the lower brackets of the mounting feet to rest firmly on the mounting surface. Trace the outline of these brackets on that surface. If
the T/A’s power cable is to pass through the mounting surface, be sure to mark the area for this passage hole.

Halogen Lamp Replacement:
WARNING: Replacing any bulb requires the use of safety
glasses to prevent injury. To avoid injury, do not attempt to
replace the lamp with your fingers. Use a lamp replacement tool
or other suitable tool.

To Replace a Snap-In Bulb:
1. Be sure the power to the lamp is off. Remove the
two screws holding the lens to the reflector
housing, and
remove the
lens.

4. Remove the T/A from the mounting surface and separate the
lower brackets of the mounting feet from the upper brackets.
Align these brackets with the outlines traced in the previous
step. Trace mounting hole locations onto mounting surface.
NOTE: Make sure that the lower bracket is facing in the same
direction as it was facing, when it was outlined on the mounting
surface as indicated in step 3.
5. Examine the back side of the mounting surface to insure that
no damage will occur when drilling the mounting holes. Drill
mounting holes with a 7/32” drill. If a wire passage hole has
been marked, drill the hole using a drill bit sized for the cable
and for an appropriately sized grommet (customer supplied).

INSERT TOOL
INSIDE OR
OUTSIDE OF
LAMP BASE

USE TOOL TO
PULL LAMP OUT
OF BASE

6. Secure lower brackets to mounting surface. (Pg. 2)
7. Lower the T/A assembly onto the two lower brackets
secured to the mounting surface. Secure both brackets
together with the supplied hex head screw, internal tooth
lock washer, split lock washer and hex nut, in the same order
as indicated on page 2. Before tightening the upper and
lower brackets together, adjust the T/A to an angle best
suited to its mounting location.
NOTE: There are two holes that can be used when assembling
lower and upper brackets together, to position the T/A assembly
at two different heights (Pg. 2).

2. Locate the removal tool included with your new bulb. Use
the small end of the tool on either the outside (A) or inside
(B) of the base to lift the base of the bulb assembly away
from the socket as shown. Continue to lift until bulb is free.
3. Insert the alignment tab of the new bulb into the bulb holder
and press downwards to lock the new bulb into place.

8. Slide the cable through the wire passage hole and route the
cable to the control head mounting location. Refer to diagram on page 2, and your control head manual for wiring.

137

ITEM QTY.

1
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16

2
6/8
8
8
8
16
8
1
2
2
2
2
4
2
2
2
2

TA836A PARTS LIST

SPECIFICATIONS

PART NUMBER

DESCRIPTION

ENDCAP
#6-32 X 1/2" PPH SELF TAP MACH. SCREW
52 HALOGEN REFLECTOR HOUSING
SNAP-IN HALOGEN LAMP - 12V / 20W
SNAP-IN HALOGEN LAMP - 28V / 35W
#6 X 1/2" PPH THREAD FORMING SCREW
POLYCARBONATE OPTIC LENS / AMBER
HOUSING BASE / ALUMINUM
#10-24 X 1-1/4" PPH MACHINE SCREW
1/4-20 X 7/16" HEX NUT
1/4" SPLIT LOCK WASHER
#10-24 WHIZ NUT
MOUNTING BRACKET
1/4" EXTERNAL TOOTH LOCK WASHER
#14 X 1/2" PPH "A" PT. SHEET MTL SCREW
1/4" INTERNAL TOOTH LOCK WASHER
1/4-20 X 3/4" HEX HEAD SCREW

Input Voltage
12.8 VDC ±20% (25.6 VDC ±20%)
Back Light Voltage 12.8 VDC ±20% (25.6 VDC ±20%)
Power Per Lamp
20W(12V) / 35W(28V)
Input Current
1.5 AMPS / LAMP (12V & 24V)
Back Light Current
100MA(12V) / 50MA(24V)
Candel Power High
770 CANDELA (AMBER)
Candel Power Low
300 CANDELA (AMBER)
Sweep Rate
40 CYCLES PER. (MIN.)

11 - 2 6 1 3 2 6 - 0 0 0
14-062216-083
02-0283375-00
34-0041987-04
34-0041987-02
15-065419-080
6 8 - 11 6 1 3 1 3 - 1 0
11 - 3 1 4 1 2 6 - 0 0 0

14-104216-200
13-130120-070
16-1331520-65
1 3 - 0 1 4 111 - 0 6 3
07-261325-000
16-1310820-02
1 5 - 2 11 4 1 6 - 0 8 2
16-1321560-02
14-130436-120

NOTE: The outer surfaces of this product may be cleaned
with mild soap and water. Use of any other chemicals may void
product warranty. Do not use a pressure washer.

Reflector modules slide
side-ways, into grooves
located inside housing.

4
3

1
2

MOUNTING SURFACE

7
Upper bracket of mounting foot slides
inside groove, and may be positioned
to fit requirements.

NOTE: The mounting brackets have two holes that can
be used when assembling the lower and upper brackets
together, to position the T//A at two different heights.

16
15

14
9

MOUNTING SURFACE

13
10

12
11

138

SV17 & SV32
(SV32 for 4
seconds, see
notes)

SV17 & SV32

SV18

SV19

SV2

SV1

Hopper Door Latch,
Close

Hopper Door Latch,
Open

Hopper Tilt Down
(rest)

Hopper Tilt Forward

High Dump (Option)
Lift

High Dump (Option)
Down

Hopper System

Enable Lift Circuit #
1
Enable Lift Circuit #
2

SV16

On or Activated

Shaker Motor

SV4

SV8

SV14

On or Activated

Vacuum Fan Motor

Energized Coils

Function

Component

139

Must hold button to operate

Hopper
Control

Shaker LED On = Shaker Running
(30 second run cycle)

Hopper
Control

Feed
Port

Hopper
Control

Valve Block Test Port

Vac Fan LED On = Vac Fan Running
(see notes)

Notes

C10

C11

C12

C11

C12

C11

M10

RV4

RV7

RV4

Interlock/Indicator

SV32 stays on for four (4) seconds to allow
maximum pressure and fuild flow to Hopper Door
Cylinder. Door is held closed by hydraulic pressure
on piston end (always). To open door CV4 Check
Valve is "unchecked" by fluid pressure,
RV4@2750psi, OR5 @0.063 in Hopper Control
Block.
SV32 stays on until Hopper Close button, os
Hopper lift/lower/forward/back is pushed. SV17
stays on until hopper closed button is pushed.
RV4@2750psi, OR5 @0.063 in Hopper Control
Block.

CV5 Check Valve in circuit, OR3@0.063 located in
Parking or Service Brake must be applied Hopper Control Block, before Tilt Cylinders
RV4@2750psi, OR5 @0.063 in Hopper Control
for this system to operate.
Block. Check valves in cylinders on piston ends.

Shaker motor cannot be operated with the Vac Fan
operating. If Shaker Motor is turned on with Vac
Fan operating, the Vac Fan is shut off and the Vac
Fan LED will stay on until the Shaker Motor stops
running (Shaker Motor LED will be on when
shaking). There is a five (5) second delay before
the Shaker motor starts if the Vac Fan was on.

Notes

Gravity lowers the hopper. Hydraulic fluid moves to
return side of system via SV1. Cylinders have
Parking or Service Brake must be applied "velocity valves" in line connection on piston end of
for this system to operate.
cylinder. Velocity valves prevent sudden falling of
hopper if hose breaks. OR5 @0.063 in Hopper
Control Block. OR4 @0.120 in Hopper Block.

Cylinders have "velocity valves" in line connection
Parking or Service Brake must be applied on piston end of cylinder. Velocity valves prevent
2750 psi for this system to operate. Machine level sudden falling of hopper if hose breaks. OR5
sensor must indicate machine is level.
@0.063 in Hopper Control Block. OR4 @0.120 in
Hopper Block.

CV5 Pilot Check Valve in circuit is unseated by fluid
pressure via SV19, OR3@0.063 located in Hopper
Parking or Service Brake must be applied
Control Block, before Tilt Cylinders. OR5 @0.063
1250 psi for this system to operate. Machine level
in Hopper Control Block. Pilot Check valves on
sensor must indicate machine is level.
cylinder piston end is unseated by pressure via
SV19 to allow cylinders to tilt forward (rest position).

2750 psi

Hopper Thermal Sentry Close at 150
degrees F, (self resetting) --If this
2750 psi
happens the Vac Fan LED will flash
(blink) and Vac Fan will turn off.

Relief
Relief
Valve
Exit Retur
Valve in
Pressure
Port n Port
circuit
Setting

Lift

Lower

Conveyor System

Main Brush

Side Brushes

Conveyor System

SV3

Lift

Down/Lower

SV5 & SV9

SV7 & SV10

Operate left brush
motor and down
(Option)

Operate right brush
motor and dwon

SV13

SV12

SV31

Energized Coils

Operate motor
reverse

Operate main brush
Conveyor System motor and conveyor
forward

Function

Component

140

This is a press and release to operate
button.

Notes

Main Brush
Control

Side Brush
Valve

Main Brush
Control

Main Brush
Control
Main Brush
Control

Feed
Port

Main Brush
Control

Valve Block Test Port

T10

C7 & T1 &
M1
T13

C8 & T1 &
M3
T13

RV3

RV2

2750 psi

2200 psi

SV4 stays on for four (4)??? seconds to allow
maximum pressure and fuild flow to Main Broom
Cylinder. Pilot Check PC3 in Main Brush Control
block. Restrictor 0.031 at C6
Pressure unseats Pilot Check PC3 in Main Brush
Control block. Restrictor 0.031 at C6

SV8 stays on for four (4)??? seconds to allow
maximum pressure and fuild flow to Right Side
Brush Lift Cylinder through SV5. Pilot operated
check vlave at PC2. SV9 controls Right Side Brush

SV8 stays on for four (4)??? seconds to allow
maximum pressure and fuild flow to Right Side
Brush Lift Cylinder through SV7. Pilot operated
check vlave at PC1. SV10 controls Right Side
Brush

RV3
(see
note)

Restrictor 0.040 at C4

SV4 stays on for four (4)??? seconds to allow
maximum pressure and fuild flow to Conveyor Lift
Cylinder. Restrictor 0.040 at C4

If "jammed" RV3 will relaese pressure. If
conveyor is down, brush motor/conveyor will run in
RPM must be under 2000 for Main Brush reverse when down, if up brush motor/conveyor will
and Conveyor to operate. Hopper up or run in reverse when up. If system in sweep and
2750 psi
tilted or Up/Tilt buttons pressed. (LED's reverse is pressed wil cause to run in reverse,
blinking)
pressing again will cause sweep rotation. If in up
positoin, pressing will cause to run in reverse,
pressing again will cause motion to stop.

Notes

RV3
(see
note)

2750 psi

Interlock/Indicator

RPM must be under 2000 for Main Brush
and Conveyor to operate. Hopper up or Overlaod switch is set at 2400 psi, Overload LED
2750 psi
tilted or Up/Tilt buttons pressed. (LED's will turn on. If "jammed" RV3 will relaese pressure.
blinking)

RV3

Relief
Relief
Valve
Exit Retur
Valve in
Pressure
Port n Port
circuit
Setting

SV1, SV25B

SV1, SV25A

Lift

Lower

Side Brushes

Conveyor
System

Hopper System

SV37, SV6

Operate

Shaker Motor

SV1, SV19A

SV2 (PWM)

SV2 (PWM), SV4

SV11 (PWM)

SV1, SV38

SV38

SV1, SV16

SV9 (PWM)

SV1, SV39

Operate motor
forward

Operate motor
reverse

Operate left brush
motor

Lower left brush

Maintain left brush
on the ground

Lift left brush

Operate right brush
motor

Lower right brush

SV1, SV20B

Tilt out

Lower

SV1, SV20A

Tilt in

SV1, SV19B

SV37, SV23A

Return hopper home
and close chute

Lift

SV37, SV23B

Dump hopper and
open chute

SV7 (PWM)

Operate

Vacuum Fan
Motor

Energized Coils

Function

Component

Notes

Valve Block

Location

System max pressure is 3000 psi.

Motor speed and system max pressure
vary with current to coil SV9.

System max pressure is 3000 psi.

Motor speed and system max pressure
vary with current to coil SV11.

Motor speed and system max pressure
vary with current to coil SV2.

System max pressure is 3000 psi.

G11 max pressure is 3000 psi.

System max pressure is 3000 psi.

Above
Main
Broom

Right Side

Side Brush
Valve

M10,
M11

C17,
C18
C19,
C20
C19,
C20

C17,
C18

C1,
C2,
C3,
C4
C1,
C2,
C3,
C4

C12

PR1/SV
35

RV1

Sent Troubleshooting matrix 2003_01_16.xls

Right Side

Side Brush
Valve
Side Brush
Valve

Right Side

Side Brush
Valve

Right Side

Side Brush
Valve

Side Brush
Valve
Side Brush
Valve
Side Brush
Valve

Side Brush
Valve

Hopper Valve On Hopper

200

2700

Relief
Relief
Feed Exit
Valve
Valve in
Port Port
Pressure
circuit
Setting

Above
Main
Broom

Hopper Valve On Hopper

Main Valve

Hopper Valve On Hopper

Motor speed and system max pressure
Hopper Valve On Hopper
vary with current to coil SV7.

The following assumes that the PTOs are engaged and operating.

141

Stall Switch SW24. Reverse operation is
momentary

Stall Switch SW24. Speed varies with engine
speed and sweep mode.

Conveyor will lift when sweep is disengaged

Conveyor will not tilt in until hopper down switch
(S11)is closed. Conveyor will tilt forward when the
hopper down switch is made, and the hopper
down button is released (after lowering the
hopper) Converyor will tilt in when sweep
engergized
Conveyor will tilt out when hopper lift or tilt are
engaged

Velocity fuses prevent hopper from tilting at fast
speed.

Power to SV23A and SV25B supplied through
conveyor back switch (S12). These valveds
cannnot be energised when the conveyor back
switch is not made.

Velocity fuses prevent hopper from lowering at
fast speed.

Power to SV23A and SV25B supplied through
conveyor back switch (S12). These valveds
cannnot be energised when the conveyor back
switch is not made.

60 second timer in controller

Speed varies with engine speed.

Notes

Operation inhibited when reverse gear is
selected. Operation inhibited when
hopper down switch is open / Display msg

Page 1 of 2

Operation inhibited when reverse gear is
Varies with engine speed and touch-panel
selected. Operation inhibited when
adjustment.
hopper down switch is open / Display msg

Operation inhibited when reverse gear is
selected. Operation inhibited when
hopper down switch is open / Display msg

Operation inhibited when reverse gear is
Varies with engine speed and touch-panel
selected. Operation inhibited when
adjustment.
hopper down switch is open / Display msg

Operation inhibited when reverse gear is
selected

Hopper Down Switch / Display msg

Parking Brake / Display msg, conveyor
back switch / Display msg

Hopper Thermal Sentry (S16) / Display
msg, Shaker motor

Interlock/Indicator

Drag Shoes

Main Brush

Side Skirts

Component

SV13 (PWM),
SV14

SV1, SV17

Operate motor

Lift

SV1, SV43

Motor speed and system max pressure
vary with current to coil SV1.

SV29 (PWM)

Adjust brush pattern
lift pressure

Lower

max pressure varies with current to coil.

SV28

Maintain brush on
ground

System max pressure is 3000 psi.

Drag shoes must be lowered also.

System max pressure is 3000 psi.

SV28

System max pressure is 3000 psi.

Lower

SV1, SV31B

Lift

PR1 is manual valve, SV35 is PWM
valve (option)

SV1, SV27

SV35 (PWM) or
PR1

Adjust brush pattern
lift pressure

System max pressure is 3000 psi.

Lift

SV1, SV15

Lift right brush

SV1, SV31A

SV39

Maintain right brush
on the ground

Notes

Lower

Energized Coils

Function

The following assumes that the PTOs are engaged and operating.

142

Above
Main
Broom
Above
Main
Broom
Above
Main
Broom
Above
Main
Broom

Above
Main
Broom

C15,
C16

C22

C9,
C10

PR1/SV
35

Sent Troubleshooting matrix 2003_01_16.xls

Main Valve

200

Relief
Relief
Feed Exit
Valve
Valve in
Port Port
Pressure
circuit
Setting

Right Side

Side Brush
Valve
Side Brush
Valve

Right Side

Side Brush
Valve
Side Brush
Valve

Right Side

Location

Side Brush
Valve

Valve Block

Notes

Varies with engine speed and sweep mode.
Measure at G2.

Operation inhibited when reverse gear is
selected. Operation inhibited when
hopper down switch is open / Display msg

Page 2 of 2

Operation inhibited when reverse gear is
selected. Operation inhibited when
Varies with engine speed and sweep mode.
hopper down switch is open / Display msg

Operation inhibited when reverse gear is
selected. Operation inhibited when
hopper down switch is open / Display msg

Fixed valve (PR1) is option; set at 250 psi.
Operation inhibited when reverse gear is
Adjustable option (SV35) varies with touch-panel
selected. Operation inhibited when
adjustment. Stems share common cavity.
hopper down switch is open / Display msg
Measure at G1 with right brush on.

Operation inhibited when reverse gear is
selected. Operation inhibited when
hopper down switch is open / Display msg

Interlock/Indicator

"ON"
"OFF"

"ON"
"OFF"
"ON"

"ON"
"OFF"

Conveyor
Forward
LED

"ON"

Conveyor
Reverse
LED

"ON"

Conveyor
Tilt LED

"ON"

Hopper
Lift LED

Hopper
Lower
LED

Shaker Operation
Shaker button Pressed "ON" (60 second shake cycle)
after 15 second delay

Hopper Dump Operation
Hopper "Dump" button Pressed "ON" to dump hopper

Notes:
*
**
***
****

****

Sent Interlocks 2002_06_14.xls

Sweep button will start this operation if it was on when sweep last cancelled
Canceling sweep will turn this function off
Sweep button will automatically tilt conveyor in when sweep operation started
Active for 60 seconds

"ON"

"ON"
"OFF"

Conveyor
Water LED

Hopper Home Operation
Hopper "Home" button Pressed "ON" to move hopper to home position

"ON"
"OFF"

Water
LED

"ON"

***

*
**

"ON"
"ON"
"ON"
"ON"
"ON"
"OFF"
"OFF"

Sweep Gutter Broom Vac Fan
PTO LED
LED
LED
LED

Centurion Switch and LED Operation

Hopper Lift
Hopper "Lift" button Pressed ON to lift hopper
Hopper "Lower" button Pressed "ON" to lower hopper

Conveyor Tilt Operation
Conveyor Tilt button Pressed "ON" for tilt in

Conveyor Reverse Operation
Conveyor Reverse button "Pressed and Held ON"

Conveyor Forward Operation
Conveyor "Forward" button Pressed ON
Conveyor "Forward" button Pressed OFF

*
**

Vacuum Fan Operation
Vac Fan button Pressed ON
Vac Fan button Pressed OFF

Water Pump Operation
(front, conveyor, left/right gutter brooms)
Water Valve(s) button(s) Pressed ON
Water Valve(s) button(s) Pressed OFF
Thermal Sentry -- Fire in Hopper -- Thermal Sentry "Tripped"

*
**

Notes

Gutter Broom Operation
Gutter Broom button Pressed ON
Gutter Broom button Pressed OFF

Sweep Operation
SWEEP button Pressed ON
SWEEP button Pressed OFF

PTO Operation
PTO button Pressed ON
SWEEP button Pressed ON
Hopper Lift, Lower, Dump or Home buttons pressed ON
Side Brush button pressed ON
Conveyor button pressed ON
PTO button Pressed OFF
SWEEP button Pressed OFF

143

"ON"

Hopper
Dump
LED

Page 1 of 1

"ON"

Shaker
LED

144

Output
Ground, Power
Key On, Power Input

Key On, Power Input
Ground

Not Used
Output

B+
0vDC

Not used
0 vDC

B+
0vDC

B+

0 vDC

8
9
10
11
12
13
14
15
16
17
18
19
20

B+

0 vDC

F18
-

F24

B+

Output
Connects #4 Arm Up/Hold Switch
Output
Connects #1 Arm Up/Hold Switch
Output

5
6
6
7
7

Note
Note
Note
Note
Note

0vDC

0 vDC

Connects #1 Vario Mode Switch
Connects #4 Vario Mode Switch
0vDC
Ground
Connects #1 Brush Rotation Switch
Output
0 vDC
Connects #4 Brush Rotation Switch

15
-

Fuse Fuse
Active Inactive Num Amp
Voltage Voltage ber Rating

Read
Pin
Notes: Number
1
2
3
Note
4
Note
4
Note
5
SV27

103J/Brown
110J/Yellow

111J/Pink

SV26

6-8 ohms 1.5-2.0 amps Fuse is through

Vario Brush Float

Key On, Power
Power Ground

Enable Solenoid

6-8 ohms 1.5-2.0 amps

6-8 ohms 1.5-2.0 amps Fuse is through

Fuse is through
6-8 ohms 1.5-2.0 amps Brush Rotation

Vario Brush Rotate
Counter ClockWise

Vario Brush Up

6-8 ohms 1.5-2.0 amps Fuse is through

Amp Draw
per
Typ Solenoid
Solenoid
Resistance Notes

Vario Brush Rotate

Power Ground

Solenoid Solenoid
Number Location Description

104J/Blue
SV28
106J/Green
106J/Green SV24
105J/Gray
105J/Gray
SV29

N/A
101K/Pink
101K/Pink
104J/Blue

Wire
Number

145

Connects to #19
Connects to #18
Key On, Power Input
Ground

Connects #1 Vario Mode Switch
Connects #4 Vario Mode Switch
Ground
Connects #1 Brush Rotation Switch
Connects #4 Brush Rotation Switch
Connects #4 Arm Up/Hold Switch
Connects #1 Arm Up/Hold Switch

Sent Pin Chart 2003_10_02.xls

Connector Pin
Number Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
B+
0vDC
B+
B+

B+

0 vDC

B+
0vDC
0 vDC
0 vDC

0vDC

F18
-

F24

N/A
101K/Pink
104J/Blue
108K/Green
105J/Gray

Wire
Number

SV26

Solenoid
Number

103J/Brown
110J/Yellow
114J/Yellow SV25
115J/Green

10 111J/Pink

15
-

Fuse Fuse
Active Inactive Num Amp
Voltage Voltage ber Rating
Solenoid
Location

Page 1 of 1

Solenoid
Amp Draw per Resistan
Solenoid
ce
Notes

Power Ground
Vario Brush Arm Pivot Counter Clockwise
Vario Brush Arm Pivot Clockwise

Enable Solenoid

Power Ground

Description

Sentinel Vario Brush Control Board Pin Voltage Chart

Industrial
Diesel
Engine

3054C
3054E
Naturally Aspirated
50-64 bkW/67-86 bhp

CATERPILLAR® ENGINE SPECIFICATIONS
In-Line 4 Cylinder, Four-Stroke-Cycle Diesel
Bore — mm (in) . . . . . . . . . . . . . . . . . . . . . 105 (4.13)
Stroke — mm (in). . . . . . . . . . . . . . . . . . . . 127 (5.00)
Displacement — liter (cu in) . . . . . . . . . . 4.41 (269)
Combustion System . . . . . . . . . . . . Direct injection
Rotation (from flywheel end) . . Counterclockwise
Capacity for Liquids — L (U.S. qts)
Cooling System (engine only) . . . . . . . . . . 7 (7.4)
Lube Oil System (refill) typical. . . . . . . . 6.9 (7.3)
Weight, Net Dry (approximate) —
kg (lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 (641)

Engine Pictured with
Optional Equipment

BENEFITS
■

HIGH PERFORMANCE
Horsepower and torque capabilities
optimized.

■

QUALITY BY DESIGN FOR DURABILITY
Product design and process improvements
have been used from early stages to enhance
engine reliability and durability.

■

CLEAN AND QUIET POWER
Cleaner, meeting EPA Tier 2 emissions
standards and free from visible smoke
throughout operational speed range. Quieter,
with up to 3 dBA reduction in bare engine
noise.

■

EASY LOW-COST MAINTENANCE
Convenient positioning of service points for
easy accessibility. Service intervals at 500
hours as standard.

■

WEB SITE
For additional information on all your power
requirements, visit www.cat.com.

LEHH2492-01

STANDARD EQUIPMENT
Cast iron engine block
Flywheel and flywheel housing
Ecoplus oil and fuel filters
Electronic control module (on 3054E)
Glow plug starting aid
Integral inlet manifold
Cast iron exhaust manifold — center side outlet
Gear-driven coolant pump
Alternator — 12V and 24V; 55, 65, 85, 100 amp
Provision for PTOs
Choice of cooling fans
Starter motor — 12V and 24V
Plastic J2044 fuel system standard
Choice of lube oil sump
Choice of dipstick positions
Choice of filter positions
Choice of water outlet
Optional balancer

Page 1 of 2

146

3054C/3054E

INDUSTRIAL ENGINE

PERFORMANCE DATA
Naturally Aspirated
3054C

3054E
300
290

200

260

200

250

180

1600

1800

2000

2200

80
55

2400

1400

Engine Speed rpm

Power
bhp

bkW

65
80

Power
bhp

bkW

280
270
260

250

1400

220

Torque
lb-ft

280
270

N•m

220

Torque
lb-ft

N•m

300
290

1600

1800

2000

2200

2400

Engine Speed rpm

Gross Intermittent Power = SAE J1995
Other ratings are available.
Lower power ratings should not be read from these curves.

DIMENSIONS
Length

mm (in)

663 (26.1)

Width

mm (in)

563 (22.2)

Height

mm (in)

775 (30.5)

Weight

kg (lb)

291 (641)

Note: Dimensions and weight depend on final specifications.

RATING DEFINITIONS AND CONDITIONS
Intermittent is the horsepower and speed
capability of the engine which can be used for
about one hour, followed by an hour of
operation at or below the continuous rating.
Continuous is the horsepower and speed
capability of the engine which can be used
without interruption or load cycling.
Additional ratings are available for specific
customer requirements. Consult your Caterpillar
dealer.

Ratings are based on SAE J1995 standard
conditions of 100 kPa (29.61 in Hg) and 25° C
(77° F). These ratings also apply at ISO/TR14396,
standard conditions and to DIN6271 and BS5514
standard conditions of 100 kPa (29.61 in Hg),
27° C (81° F) and 30% relative humidity.
Fuel consumption is based on fuel oil having an
LHV of 42 780 kJ/kg (18 390 Btu/lb) and weighing
845-850 g/liter (7.052-7.094 lb/U.S. gal). Power
ratings are based on engine equipped with fuel,
lube oil, and jacket water pumps but without fan.

Materials and specifications are subject to change without notice.
LEHH2492-01 (2-03)

Printed in U.S.A.

147

Industrial
Diesel
Engine

3054C
3054E
Turbocharged
60-86 bkW/80-115 bhp

CATERPILLAR® ENGINE SPECIFICATIONS
In-Line 4 Cylinder, Four-Stroke-Cycle Diesel
Bore — mm (in) . . . . . . . . . . . . . . . . . . . . . 105 (4.13)
Stroke — mm (in). . . . . . . . . . . . . . . . . . . . 127 (5.00)
Displacement — liter (cu in) . . . . . . . . . . 4.41 (269)
Combustion System . . . . . . . . . . . . Direct injection
Rotation (from flywheel end) . . Counterclockwise
Capacity for Liquids — L (U.S. gal)
Cooling System (engine only) . . . . . . . . . . 7 (7.4)
Lube Oil System (refill) typical. . . . . . . . 6.9 (7.3)
Weight, Net Dry (approximate) —
kg (lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 (674)

Engine Pictured with
Optional Equipment

BENEFITS
■

HIGH PERFORMANCE
Horsepower and torque capabilities
optimized.

■

QUALITY BY DESIGN FOR DURABILITY
Product design and process improvements
have been used from early stages to enhance
engine reliability and durability.

■

CLEAN AND QUIET POWER
Cleaner, meeting EPA Tier 2 emissions
standards and free from visible smoke
throughout operational speed range. Quieter,
with up to 3 dBA reduction in bare engine
noise.

■

EASY LOW-COST MAINTENANCE
Convenient positioning of service points for
easy accessibility. Service intervals at 500
hours as standard.

■

WEB SITE
For additional information on all your power
requirements, visit www.cat.com.

LEHH2493-01

STANDARD EQUIPMENT
Cast iron engine block
Flywheel and flywheel housing
Ecoplus oil and fuel filters
Electronic control module (on 3054E)
Glow plug starting aid
Integral inlet manifold
Cast iron exhaust manifold — center side outlet
Gear-driven coolant pump
Alternator — 12V and 24V; 55, 65, 85, 100 amp
Provision for PTOs
Choice of cooling fans
Starter motor — 12V and 24V
Plastic J2044 fuel system standard
Choice of turbo outlet orientation
Choice of lube oil sump
Choice of dipstick positions
Choice of filter positions
Choice of water outlet
Optional balancer

Page 1 of 2

148

3054C/3054E

INDUSTRIAL ENGINE

PERFORMANCE DATA
Turbocharged
3054C

3054E

100

1400

1800

2000

2200

300

225

100

1600

250

2400

1400

Engine Speed rpm

Torque
lb-ft

275
350

Power
bhp

300

225

N•m

250

bkW

350

Torque
lb-ft

400
275

Power
bhp

bkW

N•m

400

1600

1800

2000

2200

2400

Engine Speed rpm

Gross Intermittent Power = SAE J1995
Other ratings are available.
Lower power ratings should not be read from these curves.

DIMENSIONS
Length

mm (in)

663 (26.1)

Width

mm (in)

597 (23.5)

Height

mm (in)

810 (31.9)

Weight

kg (lb)

306 (674)

Note: Dimensions and weight depend on final specifications.

Materials and specifications are subject to change without notice.
LEHH2493-01 (2-03)

Printed in U.S.A.

149

Torque Standard
Inch Fasteners

Thread
Size

SAE
Grade 2
Carriage
Bolts

SAE
Grade 1

Thread
Cutting
Thread
Rolling

SAE
Grade 5
Socket
and
Stainless
Steel

SAE
Grade 8

Headless
Socket
Set
Screws

Square
Head Set
Screws

4 (.112)

(5) -- (6.5)

(4) -- (6)

5 (.125)

(6) -- (8)

(9) -- (11)

6 (.138)

(7) -- (9)

(20) -- (24)

(9) -- (11)

8 (.164)

(12) -- (16)

(40) -- (47)

(17) -- (23)

10 (.190)

(20) -- (26)

(50) -- (60)

(31) -- (41)

1/4 (.250)

4-- 5

5-- 6

7-- 10

10-- 13

6-- 8

17-- 19

5/16 (.312)

7-- 9

9-- 12

15-- 20

20-- 26

13-- 15

32-- 38

3/8 (.375)

13-- 17

16-- 21

27-- 35

36-- 47

22-- 26

65-- 75

7/16 (.438)

20-- 26

26-- 34

43-- 56

53-- 76

33-- 39

106-- 124

1/2 (.500)

27-- 35

39-- 51

65-- 85

89-- 116

48-- 56

162-- 188

5/8 (.625)

80-- 104

130-- 170

171-- 265

228-- 383

3/4 (.750)

129-- 168

215-- 280

313-- 407

592-- 688

1 (1.000)

258-- 335

500-- 650

757-- 984

1281-- 1489

I
N
C
H
P
O
N
U
D
S

F
O
O
T
P
O
U
N
D
S

Torque Foot Pounds (Inch Pounds) Zinc Plated

Fasteners and Torque Control (10---90)

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150

Torque Standard
Inch Fasteners
Mechanical Properties
Fastener
Identification

Type

Material

SAE
Grade 1
Machine
Screws

Low or
Medium
Carbon
Steel

SAE
Grade 2
Carriage
Bolts

Low or
Medium
Carbon
Steel

Stainless
Steel

18-- 8
Austenitic
Stainless
Steel

Medium
Carbon
Steel
Quenched
Tempered

SAE
Grade 5

Socket
Screws

Nominal
Size

Medium
Carbon Alloy
Quenched
Tempered

Yield
Strength
Min (PSI)

#2 Thru
#10

Tensile
Strength
Min (PSI)
55,000

1/4 Thru
1 1/2

33,000

36,000

60,000

1/4 Thru
3/4

55,000

57,000

74,000

Over 3/4
Thru 1 1/2

33,000

36,000

60,000

50,000

90,000

1/4 Thru 1

85,000

92,000

120,000

Over 1 to
1 1/2

74,000

81,000

105,000

High Carbon
Alloy Steel
Quenched
Tempered

SAE
Grade 8

Proof Load
(PSI)

136,000

1/4 Thru
1 1/2

120,000

160,000

130,000

150,000

Fasteners and Torque Control (10---90)

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151

Torque Standard
METRIC Fasteners
Thread
Size
M3
M4
M5

4.8/5.6

8.8
Stainless
Steel

10.9

Set
Screws

12.9

N
43-- 56 Ncm
99-- 128 Ncm 139-- 180 Ncm 166-- 215 Ncm 61-- 79 Ncm E
W
T
99-- 128 Ncm 223-- 290 Ncm 316-- 410 Ncm 381-- 495 Ncm 219-- 285 Ncm O
N
193-- 250 Ncm 443-- 575 Ncm 624-- 810 Ncm 747-- 970 Ncm 427-- 554 Ncm

3.3-- 4.3 Nm

7.6-- 9.9 Nm

10.8-- 14 Nm 12.7-- 16.5 Nm 7.5-- 9.8 Nm

8.1-- 10.5 Nm

18.5-- 24 Nm

26.2-- 34 Nm

31-- 40 Nm

M10

16-- 21 Nm

37-- 48 Nm

52-- 67 Nm

63-- 81 Nm

M12

28-- 36 Nm

64-- 83 Nm

90-- 117 Nm

108-- 140 Nm

M14

45-- 58 Nm

102-- 132 Nm 142-- 185 Nm

169-- 220 Nm

M16

68-- 88 Nm

154-- 200 Nm 219-- 285 Nm

262-- 340 Nm

M20

132-- 171 Nm

300-- 390 Nm 424-- 550 Nm

508-- 660 Nm

M22

177-- 230 Nm

409-- 530 Nm 574-- 745 Nm

686-- 890 Nm

M24

227-- 295 Nm

520-- 675 Nm 732-- 950 Nm 879-- 1140 Nm

18.3-- 23.7 Nm

C
E
N
T
I
M
E
T
E
R
S

N
E
W
T
O
N
M
E
T
E
R
S

Zinc Plated
Conversion Tables
Ncm to Inch Pound x 0.08851
Nm to Foot Pound x 0.7376

Inch Pound to Ncm x 11.2982
Foot Pound to Nm x 1.3558

Fasteners and Torque Control (10---90)

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152

Torque Standard
METRIC Fasteners

Mechanical Properties
Fastener
Identification

Type

8.8

10.9

Tensile
Strength
(Min) MPa

Class

Material

3.6/4.6
Carriage
Bolts

Low or
Medium
Carbon
Steel

190
(27,550 PSI)
240
(34,800 PSI)

330
(47,850 PSI)
400
(58,000 PSI)

4.8 Pan
Head
Machine
Screws

Low or
Medium
Carbon
Steel

340
(49,300 PSI)

420
(60,900 PSI)

Austenitic
Stainless
Steel

450
(65,300 PSI)

700
(101,000 PSI)

A2-- 70
A2--- 70

Yield Point
.2% Elongati
(Min) MPa

Nominal Yield Stress
Size
(Min) MPa

Stainless
Steel

8.8 Hex
Head
(Grade 5)

Medium
Carbon
Steel
Quenched
Tempered

10.9
Hex Head
Flat Head
(Grade 8)

Medium
Carbon
Steel
Quenched
Tempered

12.9
Socket Head

Alloy
Steel

< M16

640
800
(92,800 PSI) (116,000 PSI)

> M16

660
830
(95,700 PSI) (120,350 PSI)

940
1040
(136,300 PSI) (150,800 PSI)

1100
1220
(159,500 PSI) (176,900 PSI)

12.9

Conversion Table
Mega Pascals to Pounds per Square Inch x 145.138
Fasteners and Torque Control (1---01)

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153

Torque Standard
Nylon Insert Lock Nuts
Nut-Hex Light THIN
(Cad or Zinc Plated)
Size

Grade 2 Bolt

Grade 5 Bolt

1/4---20

5---8

7---8

1/4---28

4---6

5---6

5/16---18

8---14

13---14

5/16---24

9---14

13---14

3/8---16

12---18

15---18

3/8---24

12---18

16---18

1/2---13

26---40

37---40

1/2---20

27---42

41---42

5/8---11

58---89

73---89

5/8---18

60---92

82---92

Torque in Foot Pounds

Fasteners and Torque Control (10---90)

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154

Torque Standard
Wheel Bolt and Nuts
Stud or Bolt Size
and Thread

Recommended Torque in
Foot Pounds

7/16---20

75---85

1/2---20

75---85

9/16---18

80---90

5/8---18

140---170

Wheel Bearing Adjustment
1. Tighten the spindle nut to 12 ft lbs while turning the wheel assembly forward by hand to
fully seat the bearings.
2. Back off the nut to the “just loose” position.
3. Hand tighten the spindle nut. Loosen the spindle nut until either hole in the spindle lines
up with a slot in the nut. (Not more than 1/2 flat.)
4. Install the cotter pin. Bend the ends of the cotter pin against the nut, cut off extra length
to ensure ends will not interfere with the dust cap.

Fasteners and Torque Control (10---90)

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155

Tightening Nuts on Tapered Shafts

Example of
recommended
torque.

+.0010
+0,025
.3730 -- .00000 /9,474 -- 0
1”-- 20 UNEF-- 2B SLOTTED
KEY WIDTH
HEX LOCKNUT PER SAE
J-- 501 (EXCEPT 1.50/38,1
ACROSS FLATS).
RECOMMENDED TOQUE TO
175 FT LB PLUS TORQUE
REQUIRED TO ALIGN
SLOTTED NUT TO SHAFT
HOLE

2.27/57,7
CLEARANCE
DIA.

.156
3,96

P
SHAFT
DIA.

DIA. THRU

1.500 + .002 TAPER PER
FOOT/125 + 0,17 MM TAPER
PER METER
.750 + .010
19,05 + 0,25

1.890
48,01
3.00
76,2

Check with the manufacturer to see what the recommended maximum torque is.
Tighten the slotted nut to a lower torque, and then tighten the nut to align the cotter pin
hole with the slot on the nut. Do not exceed the recommended torque. Do not back off
the nut to align the holes.
Motor

Tapered Shaft

Nut Info.

Torque Specification Recommendations

A&H Series

1.00 dia.

.75--16 UNF
1.107 Hex

150 ft lb dry
125 ft lb lubricated
Plus torque to align for pin

2000 Series

1.25 dia.

1--20 UNEF
1.44 Hex

225 ft lb dry
225 ft lb lubricated
PLUS torque to align for pin

4000 Series

1.625 dia.

1.25--18 UNEF
2.187 Hex

475 ft lb dry
375 ft lb lubricated
PLUS torque to align for pin

6000 Series

1.75 dia.

1.25--18 UNEF
2.187 Hex

475 ft lb dry
375 ft lb lubricated
PLUS torque to align for pin
Fasteners and Torque Control (10---90)

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156

Torque Standard
Shoulder Bolts

Nominal Diameter

Thread Size

Recommended Seating
Torque

.250

10 -- 24

45 In Lbs

.312

1/4-- 20

9 Ft Lbs

.375

5/16-- 18

19 Ft lbs

.500

3/8-- 16

32 Ft Lbs

.625

1/2-- 13

82 Ft Lbs

.750

5/8 -- 11

164 Ft Lbs

Metric
Nominal Diameter

Thread Size

Recommended Seating
Torque

M5x0.8

7 Nm

M6x1.0

12 Nm

M8x1.25

29 Nm

M10x1.5

57 Nm

M12x1.75

100 Nm

Fasteners and Torque Control (10---90)

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157

Taper Lockr Bushings
IMPORTANT: Follow all these instructions carefully. This is necessary to insure
satisfactory performance.
C

1008 to 3030

To Install
1. Clean shaft, bore and outside of bushing, and hub bore of all oil, lacquer, and dirt.
2. Insert bushing in hub. Match the hole pattern, not threaded holes (each hole will be
threaded on one side only).
3. Oil setscrews and thread into those half threaded holes indicated by C on above
diagram.
4. Alternately torque setscrews to recommended torque setting in chart below.
5. Using a block, sleeve, or drift, hammer large end of bushing (do not hammer bushing
directly).
6. Repeat steps 4 and 5 until torque wrench reading after hammering is the same as
before hammering.
7. Fill all unoccupied holes with grease.

To Remove
1. Remove all setscrews.
2. Insert setscrews in holes indicated by D on the diagram. Loosen bushing by alternately
tightening setscrews.
3. To reinstall, complete all seven (7) steps installation steps.
Recommended Wrench Torque
Wrench Torque
Bushing No.
Screws
(Pound-Inch)
1008, 1108
1210, 1215, 1310
1610, 1615
2012
2517, 2525
3020, 3030

1/4” Setscrews
3/8” Setscrews
3/8” Setscrews
7/16” Setscrews
1/2” Setscrews
5/8” Setscrews

55
175
175
280
430
800

Hammer
Size
6 lb
6 lb
6 lb
6 lb
6 lb
6 lb

If two bushings are used on same component and shaft, fully tighten one bushing before
working on the other.
Fasteners and Torque Control (10---90)

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158

Sequence Tightening
On some assemblies, it is advisable to use a crisscross pattern. Always avoid starting in
one spot and tightening one after another in a row. Remember that the object is to tighten
the parts in such a manner that even stress is set up throughout, at the same time allowing
the parts to be drawn together so that their mating surfaces will contact.

1
4

2
6

Torque in Steps
1. Run each fastener, in proper sequence, up to the recommended torque.
2. Repeat the process of running up each fastener, in proper sequence, up to the
recommended torque.
3. If necessary, repeat step two until all the fasteners are tightened to the recommended
torque.

Fasteners and Torque Control (10---90)

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159

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160

Bulletin GJ-30050

Centralized On-Board
Chassis Lubrication
System
Installation & Maintenance
Instructions

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161

Table of Content

SUBJECT

PAGE

System Description .............................................. 1
Component Description
Timer ........................................................... 2
Solenoid ...................................................... 2
Air Pumps .................................................... 3
Modules ....................................................... 3
Meters & Tubing .......................................... 4
Grease & Kits .............................................. 4
Electric Pumps ............................................ 4
Typical System Layout ......................................... 6
Typical Bill of Materials ........................................ 7
Installation Steps
1) Pump Mounting ....................................... 8
2) Solenoid .................................................. 8
3) Timer & Wiring ........................................ 9
4) Modules .............................................. 9-11
5) Tubing ................................................... 11
6) System Fill/Start .................................... 12
7) Air Purge Lines ...................................... 12
8) Warranty Registration ........................... 13
PM Procedure .................................................... 15
Troubleshooting ............................................ 16-17
Parts List ....................................................... 18-21

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162

SYSTEM DESCRIPTION
The Grease Jockey ® system is controlled by a timer, which activates
either an air solenoid valve or an electric motor to drive a pump. The
pump supplies grease into the main supply line for delivery to localized distribution modules.
These modules are made up of manifolds with metering valves and
distribution lines for each lube point in that localized area. The
meters are designed to dispense a precise amount of grease at each
lube cycle. Meter size is chosen by a ratio of the smallest to largest
lube point requirements in the system.
The pump must pressurize the system, then vent it to allow the
metering valves to reset for the next cycle. The use of a fluid grease
to achieve proper flow characteristics is required.

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163

SYSTEM COMPONENTS
TIMER
The timer on an air operated pump system is a compact solid state device housed in a high impact resistant plastic enclosure. It has seven lube cycle interval
settings from 1/2 to 6 hours, plus a test position and a
manual run button.
The timer operates the system only while the vehicle's
ignition is turned on. A memory function keeps track of
elapsed-cycle-time even if the ignition switch is turned
off. When the predetermined cycle time has elapsed,
the timer signals the pump to initiate a lubrication cycle.
If the vehicle's ignition is turned off before the interval
is complete, the timer's memory "holds" the time count
until the vehicle is restarted.

Fig. 1

When the cycle-time dial is switched from one range to
another, the manual run button should be pressed to
initiate the new cycle time setting (otherwise, the new
time is added to any time that remains from the previous lube cycle).

SOLENOID
The air valve used with the air operated pump threads
into the port on the bottom of the pump. It is a 3-way,
normally closed, free venting valve available with either
a 12 or 24 VDC 9 watt continuous duty rated coil. The
coil is molded and potted with a 6" lead of 16 AWG
wire and a weather tight (male) connector. The air
valve has a 1/8" NPT inlet port and a 1/4" NPT male
thread outlet port. The maximum operating pressure is
150 psi. A 22' wire harness with a weather tight
(female) connector to mate with the solenoid is available (included with kits).

When rapid repetitive cycles are needed, set the cycletime dial to the "test" position and press the manual run
button. In this mode the timer signals the pump to
cycle approximately once every minute. (45 seconds
on and 15 seconds off). This rapid cycling continues
as long as the timer remains in the "test" position.
Always reset the timer dial to it's proper setting.

Fig. 3

Recommended Timer Setting:
Fig. 2
Timer Setting
1/2 or 1 hr.
1.5 or 2 hr.

Driving Conditions
Off Highway
Start + stop city, heavy salt,
snow and ice, rough pavement,
wet climate, heavy loads, dusty
roads.
Normal city or highway driving,
normal climate, moderate loads.

3 hr.

These are recommended settings only. Experience
with individual applications will determine timer setting.

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164

AIR OPERATED PUMP
The air pump (Ref. Fig. 4) operates when the 3-way air
solenoid valve is actuated by the timer and air pressure
is applied to the air chamber port (1) and diaphragm (2).
This forces the spring-loaded pump piston (3) upward
compressing the grease in chamber (4). This pressure
seats the flapper valve (5) against the reservoir opening
(6) and grease flows toward port (9).
Simultaneously, pressure is applied behind the springloaded check valve poppet (8) through port (9) sealing
off passage way (7). Grease flows into the main lines
through outlet (11).
After completion of an on-time cycle, the 3-way air valve
exhausts the air in the pump. The pump piston spring
forces the pump piston (3) down allowing the flapper
valve (5) to unseat from the reservoir opening (6).
Grease from the reservoir is drawn into chamber (4) just
vacated by the pump piston (3). System pressure is
relieved through port (9) to port (7) back to the reservoir
as check valve (8) is returned by spring (10).

11
4
3

(15 to 22 ft/lb.
Torque)

MODULES
A module is an assembly that distributes the grease
from the main line to a group of lube points. It is made
up of a manifold, mounting stem, meters (metering
valves), 3/16" OD tubing, and fittings. One manifold
can hold as many as 12 meters. Plugs are available to
close off any manifold port that is not required. The
manifold mounts with the ported stud through a 5/8"
hole. Main lines may be connected at either end of the
manifold or at the end of the mounting stud.

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165

METERS
Fig. 5

Meters are positive displacement, spring-reloaded,
dispensing devices designed for use in Grease Jockey
systems operating at 900 to 1200 psi. These meters
are available in 9 sizes (based on output volume) to
meet various lube requirements. These 9 sizes provide
adequate choices to supply every lube point on a truck
chassis, including the fifth wheel. (See Fig. 5)
"O"
RING

1/2-24 THD.
INLET HEAD

HIGH OUTPUT
METER BODY

"O"
RING

SLEEVE
METER VALVE
ASSEMBLY

5/8 HEX

OUTPUT
SPACER
WASHER

CUP

"O"
RING

NUT
OUTPUT
END

SPRING

METER BODY
5/8 HEX

Meters can be identified by the following characteristics:
Meter
Size
0
1
2
3
4
5
6
7
8

No. of Washers
in Meter Body
Grove on Hex
0
no
1
no
2
no
3
no
4
no
1
2 For special applications only
3
4
yes

Output
(Cu.in.)
.001
.003
.006
.009
.012
.015
.018
.021
.024

TUBING
Only Grease Jockey heavy wall nylon tubing should be
used in the system. Use 3/16" OD lines for lube point
distribution and 5/16" OD for main lines with brass
fittings. (Tube inserts are required on ALL 5/16" line
connections). Other adapters, fittings, connectors, and
mounting hardware are available form Lubriquip. DO
NOT substitute air brake tubing for lube lines, the
pressure rating is NOT adequate for lubrication
system use.

INSTALLATION KITS
There are standard "automatic" Grease Jockey kits for
single axle tractors and for tandem axle tractors. Also
available are custom kits for other applications and
trailer systems. See page 18 for kits part numbers.

GREASE
A fluid lithium grease of NLGI grade "0" or "00" with an
"EP" additive is standard for this type system.
Lubriquip 550-400-020 is available from your Grease
Jockey distributor.

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166

ELECTRIC SYSTEMS
ELECTRIC MOTOR
DRIVEN PUMP

Fig. 6

The motor (1) is energized. The gear pump (2) begins
to turn, causing grease to flow into chamber (3). As
pressure builds, the shuttle valve assembly (4) moves
outward, sealing the fill tube opening (5). As pressure
continues to build, the spring-loaded ball check (6)
inside the shuttle valve moves outward. The grease
flows through the shuttle valve and out passage (7) into
the main line through outlet (8).
2

After completion of the on-time cycle, the motor shuts
off. The gear pump stops turning and pressure inside
the shuttle valve is released. The shuttle valve is
forced back inward by the spring (9). System pressure
is vented through the fill tube and port (10) back to
reservoir.
3
The timer is mounted under the pump motor cover. It
is a potted "ice cube" style device with settings for lube
cycle intervals from 6 to 480 minutes and settings for
cycle on-time intervals of 10 to 1,000 seconds. A
1
manual run button is located on the outside of the
pump housing.

10
7

4, 6

The lube cycle clock (settings in minutes) runs continuously regardless of the status of the vehicle. Only
when the vehicle switch is in the "ON" position will a
lubrication cycle be initiated.

b) Connect the WHITE lead to the battery positive
terminal circuit. Install a 5 Amp fuse at this
connection.

The cycle on-time determines the motor run time
(settings in seconds). Typically this setting is short in
length (approx. 40 sec.). Longer run times would only
be needed for systems with large numbers of lube
points and long lengths of main line.

c) Connect the BLACK lead to an environmentally
protected battery negative terminal.
d) The GREEN lead is not used and may be clipped
or grounded.

There is a pressure relief built inside the pump to guard
against dead head flow situations.

ELECTRIC PUMP WIRING

Fig. 7

The timer for an electric pump is an integral part of the
pump assembly. (Ref. Fig. 7)

BLK
GROUND
RED
IGN.
WHITE
BATT.

a) Connect the RED lead to the positive side of
the vehicle ignition switch. Install a fuse at
this connection. 10 Amp for a 12 VDC system
5 Amp for a 24 VDC system

MOTOR

TIMER

BLUE WIRE
MOTOR

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167

LUBRIQUIP, INC. CLEVELAND OH
TYPICAL LUBRICATION LAYOUT FOR A TANDEM AXLE TRACTOR & 5TH WHEEL
CUSTOMER:

VEH#:

KIT#:

DATE:

END USER:
3
MANIFOLD
PLUG 1/4 NPT
550-050-210

8
12

ELBOW
435-440-060

RH FRONT
MODULE

LH FRONT
MODULE

7
TEE
435-410-040

12
8
11

6
4

TIMER
550-200-081

3
10

PUMP
550-000-040

SOLENOID
550-250-090

MAIN LINE 5/16 OD
550-450-230 INSERTS FOR MAIN
LINE 550-402-330
PUMP
ELBOW
435-440-070

10
10

9
11

CONN
435-460-060

TANDEM AXLE
MODULE

AIR
TANK

AIR
LINE

5TH WHEEL
MODULE

OUTLET PLUG
550-350-040

4
4

ELBOW
435-440-070
MANIFOLD PLUG
1/8 NPT 412-130-130

SNAP ON ELBOW 550-402-380

1/8 ST ELBOW 509-110-000 + 1/8 CONN 435-460-030

1/8 ELBOW 435-440-030

1/4 SAE ELBOW 550-400-800 + 435-460-030

1/8 CONN 435-460-030

ELBOW 435-440-030 + EXTENSION 509-027-000

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168

CUSTOMER NAME:

LOCATION:
TYPE: TYPICAL LUBRICATION LAYOUT FOR
A TANDEM AXLE TRACTOR & 5TH WHEEL

VEHICLE# :
KIT#:

POINT#

DESCRIPTION

INJ#

COLOR

3
2
3
2
2
3
0
0
1
0
3
3

ORANGE
BLACK
BLUE
ORANGE
BLACK
ORANGE
BLACK
BLACK
ORANGE
BLACK
BLACK
ORANGE

3
3

BUNDLE#

MILEAGE:
DATE:

FITTING

LEFT HAND FRONT MODULE:
1
2
3
4
5
6
7
8
9
10
11
12

KING PIN UPPER
TIE ROD
KING PIN LOWER
DRAG LINK
DRAG LINK
SPRING PIN
CLUTCH LINKAGE
STEERING BOX
SLACK ADJUSTER
"S" CAM
SPRING SHACKLE
SPRING SHACKLE

1/8 ELBOW
1/4 ELBOW
1/8 ELBOW
1/4 ELBOW
1/4 ELBOW
1/8 ELBOW
1/4 ELBOW
SNAP ON ELBOW
1/8 ELBOW
1/8 ELBOW
1/8 ELBOW
1/8 ELBOW

ORANGE
BLACK

1/8 ELBOW
1/8 ELBOW

0
0
3
1
0
3
2
3

BLACK
ORANGE
BLACK
ORANGE
BLACK
BLUE
BLACK
ORANGE

} UNMARKED
UNMARKED
}2

0
1
0
1
1
0
1
0

BLACK
ORANGE
BLACK
ORANGE
ORANGE
BLACK
ORANGE
BLACK

ORANGE
BLACK
BLUE
BLUE
BLACK
ORANGE

}

UNMARKED

} UNMARKED
UNMARKED
UNMARKED
UNMARKED

RIGHT HAND FRONT MODULE:
1
2
3
4
5
6
7
8
9
10
11
12

SPRING SHACKLE
SPRING SHACKLE
PLUG
PLUG
CLUTH C/SHAFT LH
CLUTH C/SHAFT RH
SPRING PIN
SLACK ADJUSTER
"S" CAM
KING PIN LOWER
TIE ROD
KING PIN UPPER

1/8
1/8
1/8
1/8
1/8
1/8
1/4
1/8

ST ELBOW + 1/8 CONN
ELBOW
ELBOW
ELBOW
ELBOW
ELBOW
ELBOW
ELBOW

} UNMARKED
} UNMARKED
} UNMARKED
} UNMARKED

1/8
1/8
1/8
1/8
1/8
1/8
1/8
1/8

ELBOW
ELBOW
ELBOW
ELBOW
ELBOW
ELBOW
ELBOW
ELBOW

}
}

1/8
1/8
1/8
1/8
1/8
1/8

ELBOW + EXTENSION
ELBOW
CONN
CONN
ELBOW
CONN

}

UNMARKED

TANDEM AXLE MODULE:
1
2
3
4
5
6
7
8
9
10
11
12

PLUG
PLUG
"S" CAM
SLACK ADJUSTER
"S" CAM
SLACK ADJUSTER
SLACK ADJUSTER
"S" CAM
SLACK ADJUSTER
"S" CAM
PLUG
PLUG

OR 1/4 ELBOW
OR 1/4 ELBOW
OR 1/4 ELBOW
OR 1/4 ELBOW

5TH WHEEL MODULE:
1
2
3
4
5
6
7

FACE PLATE
8
FIFTH WHEELL PIVOT
1
FACE PLATE
8
FACE PLATE
8
FIFTH WHEEL PIVOT
1
FACE PLATE
8
THROUGH POINT #12 ARE PLUGGED

UNMARKED
UNMARKED

LUBE POINT FITTING; DESCRIPTION AND PART NUMBER:
1/8 ST ELBOW = 509-110-000
1/8 ELBOW = 435-440-030
1/8 CONN = 435-460-030

EXTENSION = 509-027-000
1/4 SAE ELBOW = 550-400-800 + 435-460-030
SNAP ON ELBOW = 550-402-380

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169

INSTALLATION STEPS
All lube points should be properly filled with grease
before removal of zerk fittings to change to tube
connector fittings.

Fig. 8

Step 1- PUMP
Pump mounting is the same for either an air or electric
pump. Select a location that is visible, accessible for
filling the reservoir, and protected. The mounting holes
and dimensions are the same on both styles of pump.
(See Fig. 8) A bracket is available to assist in mounting
the pump. The pump inlet is gravity fed; therefore the
pump must set vertically.

1.750

Use all four bolts in mounting.
Note:

2.281
4.562

When using an electric pump omit step 2.
For step 3 refer to page 9.

5.062

Fig. 9

Step 2 - SOLENOID
On air driven pumps the solenoid valve threads into the
air chamber at the bottom of the pump. (See Fig. 9)
Be sure you have the correct voltage (12 or 24 VDC) to
match your vehicles electrical system. Use a thread
sealant on all air supply fittings. The air supply line
should run from the aux. air tank only. Connect the air
supply line to the "in" port of the solenoid valve.
A 22' harness wire to supply the signal from the timer is
available (included in standard kits). This harness
comes with a weather tight connector to mate with the
solenoid connector. (see Step 3).
SOLENOID VALVE ASS'Y

IMPORTANT - ALL connections between the timer and
solenoid (blue and yellow leads) MUST be moistureproof and safe from grounding.

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170

Step 3 - TIMER

NEGATIVE GROUND SYSTEM

The timer for an air operated system should be mounted in
a protected but readily accessible location inside the cab.
The timer housing has four 7/32" dia. holes for No. 10
mounting screws. The timer leads are a 5-strand, 18 gauge
8" wire harness with a Packard connector. A wiring harness
with a mating connector is available (supplied with kits)
which simplifies installation of the timer and provides
excellent connection integrity. (See part list).
BLACK (-)
GROUND

LOAD
WIRES
BLUE &
YELLOW

LOAD WIRES
BLACK &
WHITE

ORANGE (+)
BATTERY TERMINAL
(MEMORY)
RED (+)
(IGNITION ON)
FROM KEYSWITCH

SOL.
VALVE

CONNECTOR

Fig. 10

5-AMP
FUSES

BLUE

BLACK

VALVE
YELLOW

WHITE

NOTE: Timer must be installed horizontally as shown
in picture with cable leads pointing down.

Step 4 - MODULES

After mounting the timer;

The modules are mounted with a ported stud through a
5/8" hole. Mount all modules on the frame rail or a cross
member close to the points they will be lubricating.
Grease Jockey kits come with module assemblies for
each strategic area of the chassis to be lubricated. Refer
to the typical system layout on page (6).

Modules

a) Connect the BLUE and YELLOW leads to the
wires from the pump mounted solenoid. (See
Fig. 10).

IMPORTANT - CAUTION, DO NOT ground the blue
and yellow wires to the solenoid. This could cause
damage to the timer.
b) Connect the RED lead to the positive side of
the vehicle ignition switch. Install a 5 amp
fuse at this connection.
c) Connect the ORANGE lead to the battery
positive terminal circuit. Install a 5 amp fuse at
this connection.
d) Connect the BLACK lead to the chassis
ground.
Fig. 11

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171

The unused ports in the manifolds should have plugs in
them. If additional lube points are needed these plugs
can be replaced with appropriate sized meters and
lines.

LEFT FRONT -

Fig. 12

FRONT

LEFT FRONT METER BLOCK ASSEMBLY
(LOCATED AS NEAR TO AXLE AS POSSIBLE)
FRONT SPRING
PIN METER

SLACK
ADJUSTER
TUBE

TWO 2-TUBE
BUNDLES

TWO-TUBE BUNDLE

DUST COVER
MOUNTING
BRACKET
AND CLAMP

SPRING SHACKLES
BRAKE SHAFT
TUBE

FRONT BRAKE
TUBE ROUTING
& FITTINGS

DRAG
LINK
ALLOW SLACK FOR DRAG
LINK MOVEMENT

TIE ROD

Step 4a - Left Front Module
This assembly contains the meters, hardware, and
tubing for 2 king pin, 1 spring pin, 2 spring shackle
pins, 1 tie rod, 2 drag link, 1 S-cam, and 1 slack
adjuster lube points. Optional points from this module
typically are linkage and steering box points.
(Ref. Fig. 12)

RIGHT FRONT -

Fig. 13
FRONT

TWO-TUBE BUNDLE
TO TRANSMISSION CROSS
SHAFT LUBE POINTS
FRONT SPRING
PIN METER

Step 4b - Right Front Module
THREE-TUBE BUNDLE

This assembly contains the meters, hardware, and
tubing for 2 king pin, 1 spring pin, 2 spring shackles, 1
tie rod, 2 clutch cross shaft, 1 S-cam, and 1 slack
adjuster lube points. Optional points from this module
typically may be body pivot pins. (Ref. Fig. 13).

ALLOW SLACK FOR
WHEEL MOVEMENT

ALLOW AMPLE SLACK FOR TIE
ROD MOVEMENT

REAR AXLE(S) Fig. 14
5/16" TUBING ( MAIN LINE)

MODULE ASSEMBLY

FRONT

Step 4c - Rear Axle(s)

REAR AXLE METER BLOCK ASSEMBLY
(LOCATE AS NEAR TO AXLE AS POSSIBLE
TWO 2-TUBE BUNDLES
ALLOW SLACK FOR AXLE MOVEMENT
BRAKE SHAFT

SLACK ADJUSTER

This assembly contains the meters, hardware, and
tubing for (2 or 4) S-cam and (2 or 4) slack adjuster
lube points. The number of points is determined by the
application (single or tandem axle). Optional points for
this module may be spring pin points or trailer system
meters. (Ref. Fig. 14).

SECURE ALL LINES WITH NYLON
STRAPS TO AVOID TUBING ABRASION

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172

FIFTH WHEEL Step 4d - Fifth Wheel

Fig. 15

This assembly contains the meters, hardware, and
tubing for 4 face plate and 2 pivot pin lube points (Ref.
Fig. 15).

3/16" TUBING
PLATE

3/16" TUBING
PIVOT

NOTE: Most 5th wheel plates do not have grease
fittings in the plate. This requires four holes to be
drilled and tapped (1/8" NPT) through the plate. These
meters should be #8.

MODULE ASSEMBLY

TWO 3/16" 2-TUBE BUNDLES
ALLOW SLACK FOR 5TH WHEEL MOVEMENT

5/16" TUBING

SECURE ALL LINES WITH NYLON
STRAPS TO AVOID TUBING ABRASION

TRUNK LINE

Step 5 - TUBING
When installing the tubing, AVOID routing any tubing
close to a heat source such as an exhaust manifold,
muffler, turbocharger, etc.

AIL
ER

Route tubes where they can be tied down securely with
plastic tie straps or tube clamps and yet flex or move
with moving parts.
Always use approved 3/16" and 5/16" OD Lubriquip
tubing. Non-approved nylon or air brake tubing should
NOT be used. (Ref. page 4).
3) Peel back the outside sheath and cut off the
excess. Be careful not to sever the remaining
sheath or tubes.

The 3/16" tubing comes in three configurations. Single
tubes are black or orange, 2 tube bundles have a black
and an orange tube inside a sheath. A 3 tube bundle
has a black, blue and orange tube inside a sheath.
The orange tube is connected to the highest output
meter. The blue tube is connected to a lesser or equal
output meter. The black tube is connected to the
lowest or equal output meter of the bundle group.

4) Align tubing with fitting and make cuts square
and clean with an anvil type cutter. NOTE:
Allow ample slack for tube movement and ease
of installation.

TUBING

For example, on the front chassis module, either left or
right, a 3 tube bundle is connected to two #3 meters
and a #2 meter (orange and blue tubes go to the upper
and lower king pin lube points and the black tube goes
to the tie rod end lube point).

A self aligned ferrule is supplied with all 3/16" and 5/16"
fittings. It is not necessary to remove the nut and
ferrule to seat the tube into the fitting. Care should be
taken to make sure the tube is well seated into each
fitting. Brass inserts are supplied with kits for use with
the 5/16" tubing. These inserts MUST be used at
every 5/16" connection.
The 5/16" tube is the main line tubing routed from the
pump to the manifolds. It may also be used as the air
supply line to the solenoid. It should be routed inside
the frame and secured well for protection.

TUBING PREPARATION;
1) Measure approximate lengths of tube bundles,
leaving extra length for trimming at the lube
points.
2) Cut the outside sheath on tube bundles back to
the point where this bundle meets it's first lube
point. Be careful not to puncture or cut the
tubes inside. Use a stripper to help prevent
damage to the tubes.

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173

Step 6 - System Fill + Start Up

Step 7 - Purging air from the main line:

Use lubricant part number 550-400-020 from
Lubriquip, or a quality NLGI "0" or "00" lithium base
with an "EP" additive grease.

Note: Check the vehicle air supply. At least 100 PSI
gauge pressure is required.

When using a flexible style reservoir be sure the top
of the bag is depressed inside the stiffener as far as
possible to purge the air from the reservoir.

All the air must be removed from the main lines and
manifolds. Follow the next 5 steps carefully.
1) All of the 1/4" NPT end port and 1/8" NPT stud
plugs on the module manifolds should be removed.

Fill the reservoir through the fill stud until it takes the
original shape (top of reservoir slightly domed). DO
NOT OVER FILL.

2) With the vehicle ignition switch turned ON. Set
timer at the test position and press the manual
run button.
3) As the pump cycles , check the open module
ports for flow of grease with no air.
4) When the flow of grease from a port is free of air
close the port and continue this process until all
ports have been checked. Check the open port
closest to the pump first proceeding to the port
furthermost from the pump last. This will push
out the air in the main line(s).

RESERVOIR

STIFFENER

Note: The 3/16" distribution lines are pre-filled. They
should not require purging of air.
5) Let the system run in the test position for a few
minutes. Check all line connections to be sure
they are holding pressure. Check at lube points
to be sure lubricant is moving to this point in the
system.

CLAMP

At this point the system should be running correctly
and you should reset the timer to the desired setting for
your application.
Timer settings are dependent upon your application.
As a starting point refer to Fig. 2.

DEPRESS RESERVOIR
INSIDE STIFFENER TO
PURGE AIR

If any part of the system has not functioned as it should
please refer to the troubleshooting section of this
bulletin.
This would be a good time to complete the GREASE
JOCKEY in service PM procedure and warranty card.
(See page 13).
Note: The Grease Jockey PM procedure shown on
page 15 is a simplified procedure for regular preventative maintenance intervals.

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174

GREASE JOCKEY IN SERVICE PM PROCEDURE
& WARRANTY REGISTRATION
PLEASE PRINT

Name:

In Service Date:

Company:

Tel #:

Address:

State:

Vehicle #:

Vehicle Make:

Zip:
Mileage:

REFER TO GREASE JOCKEY SCHEMATIC FOR LUBE POINT LOCATION
1. Fill the Grease Jockey reservoir with grease (use fluid grease NLGI 00 Lithium EP). Connect grease filler pump
quick disconnect to the mating quick disconnect at the base of the Grease Jockey lube system pump.
CAUTION: Do not over fill the reservoir. Full reservoir: YES
NO
2. RECORD THE SETTING OF THE GREASE JOCKEY TIMER (it should not be on TEST)
Air operated system (timer usually mounted in Cab); 0.5
Electric operated system; 8
15
30
60

1
90

1.5
120

2
180

3
240

4
360

hours.
Minutes

3. Set the Grease Jockey timer to the TEST position (at the test position a Grease Jockey air operated system will
cycle approx. every minute, 45 seconds on 15 seconds off; an electrically operated system will cycle approx.
every 2 minutes, 45 seconds on 75 seconds off).
4. Turn the ignition switch to the on position (engine not running). The Grease Jockey system will begin to cycle in
the TEST mode (for air operated systems the vehicle air pressure must be at least 100 psi).
5A. AIR OPERATED PUMP & SOLENOID VALVE (Air operated system):
Check the operation of the pump and solenoid (Listen for the solenoid to click on. Approx. 45 seconds later air
will exhaust from the bottom of the solenoid as the pump piston moves back);
Pump Working: YES
NO
Solenoid Working: YES
NO
5B. ELECTRICALLY OPERATED PUMP (Electrically operated system):
Check the operation of the pump (listen to the pump motor running during the 45 second on time).
Pump Working; YES
NO
6. Check main lines and secondary lines for damage (Look for; accumulation of grease where there should be none;
broken lines; lines not connected to, or leaking around, the fitting);
Condition of main lines (5/16" OD)
Condition of distribution lines (3/16" OD)

Okay:
Okay:

Line problem:
Line problem:

7. Check chassis lube points for signs of FRESH grease;
Signs of fresh grease at lube points; YES:
NO:
8. IMPORTANT: RESET THE GREASE JOCKEY TIMER TO THE SETTING RECORDED AT STEP 2.
CAUTION; The timer should never be left at the TEST position
Timer Reset to:
Hours/Minutes
9. Detail any problems: (refer to the troubleshooting sheet for corrective action or call Lubriquip for technical
assistance at the number shown below:

Inspected by:

Tear out this page at the perforation and
RETURN A COPY OF THIS COMPLETED FORM FOR WARRANTY REGISTRATION:
By Fax: (216) 581-8945
By Mail: Fold on lines, tape edge and mail it, postage paid.
13

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175

NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES

BUSINESS REPLY MAIL
FIRST CLASS MAIL PERMIT NO 15866 CLEVELAND OH
POSTAGE WILL BE PAID BY ADDRESSEE

LUBRIQUIP INC
A UNIT OF IDEX CORPORATION
18901 CRANWOOD PARKWAY
CLEVLAND OH 44128-4085

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176

GREASE JOCKEY PM Procedure
PM/Inspection by:

Date:

PM Type:

Location:

Vehicle #

Mileage:

REFER TO GREASE JOCKEY LUBE SYSTEM SCHEMATIC FOR LUBE POINT LOCATION/PARTS.
1. Check chassis lube points for signs of FRESH grease;
a) grease at lube points adequate:
b) too much grease at lube points:

ALL

One

ALL

Some

c) not enough grease at all lube points:
d) no sign of fresh grease at lube points:
2.

One

Check main lines and secondary lines for damage. (Look for accumulation of grease where there should
be none.) Check lines for wear or chafing.
a) Condition of main lines:

Okay

Line Problem

b) Condition of distribution lines;

Okay

Line Problem

3. Check that the air pressure is at least 100 psi. If not build up the pressure (air operated pump only). Turn the
ignition switch to on (the engine does not have to be running).
4a. AIR OPERATED PUMP:
Press the manual override button on the timer (located in the cab). Check operation of the pump and solenoid
(Listen for the solenoid to click on. 45 seconds later air will exhaust from the bottom of the solenoid as the
pump piston moves back);
Pump OK
Pump not working
Solenoid OK
Solenoid not working
4b. ELECTRICALLY OPERATED PUMP:
Press the manual override button located on the pump body. Listen to motor operating.
Pump OK

Pump not working

5. Check level of reservoir;
Full

Half

Less than half

6. Fill reservoir with grease. (Use fluid grease NLGI "00" Lithium EP).
Connect grease filler pump quick disconnect to the mating quick disconnect at the base of the automatic lube
system pump. CAUTION do not over fill reservoir.
YES
NO
7.

Detail all problems and corrective action. (Refer to troubleshooting section for corrective actions.)

LUBRIQUIP, INC., A UNIT of IDEX Corporation, 18901 Cranwood Pkwy., Cleveland, Ohio 44128
Telephone: 1-800-USA-LUBE

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177

TROUBLESHOOTING THE GREASE JOCKEY
PROBLEM

CAUSE

CORRECTIVE ACTION

Too much grease at all lube
points.

Timer cycle too frequent

Adjust the timer one click to a
higher time cycle. (example from 2 to
3 hours).

Too much grease at one lube
point.

Meter leaking

Remove and replace meter

(1c)

Not enough grease at all
lube points.

Timer cycle is too infrequent

Adjust the timer one click to a lower time
cycle. (example from 3 to 2 hours).

(1d)

No sign of fresh grease at
all points.

Lubricant reservoir empty

Fill lubicant reservoir

Lubricant reservoir filled with
heavy grease which will not
work in system.

Remove and clean reservoir, refill with
proper lubricant. Remove main line plugs
from meter blocks, and cycle pump until old
lubricant is removed from lines, replace
main line plugs.

Blown fuse, or break in wiring circuit

Check for electrical short circuit or
broken wire, & Repair.

Broken air line (air pump only)

Repair or replace line

Inoperative solenoid air valve (Air
pump only)

Check electrical circuit to make sure voltage
is reaching the solenoid coil from the timer.
Connect a meter from the supply "black" wire
to the return "white" wire at the connector of
the solenoid. Do not connect direct to grouond!
Repair or replace wiring as required:
Check coil resistance for approx. 20
ohms. Check valve opertion; repair or
replace if necessary.

(1b)

Inoperative air pump

See 4a page 17

Inoperative electric pump

See 4b page 17

Inoperative timer

With the ignition switch on, check the input
voltage of both the memory (orange) and
the (red) switch wires; If there is not 12
VDC (or greater) repair electric supply.
Set the timer to TEST. Check the output
signal to the solenoid. Connect a meter
from the timer supply to the return, NOT to
a ground. (At the timer connector the
supply is the blue wire and yellow is the
return), (At the solenoid connector the
supply may be a black wire and return a
white wire). It should show 12 VDC during
the On cycle (approx. 45 sec.) and 2 VDC
or less during the off period (approx. 15
sec.) If there is no signal or a constant 12
VDC output, check lines from the timer to
the solenoid for grounding or breakage;
replace timer if necessary.

Main line broken
R

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See 2a page 17

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178

TROUBLESHOOTING THE GREASE JOCKEY
CAUSE

PROBLEM
No sign of fresh grease at
some lube points.

No sign of fresh grease at one
lube point

(2a)

(2b)

(4a)

(4b)

Main lube line damaged

Secondary line damaged

Air-operated pump not working

Electrically operated pump not
working

CORRECTIVE ACTION

Main line broken

See 2a below

Air lock in main line

Purge main line of air; See page 12,
Step 7.

Secondary line damaged

See 2b below

Meter inoperative

Replace meter

Lube point fitting has broken off

Remove broken fitting and replace

Trapped and broken, rubbed through

Replace or repair (re-route or protect
the line to prevent the damage from
happening again). Purge with grease to
expel air before connecting new main
line into system. Be sure to use a tube
insert at all main line connections.

Main line has popped out of fitting

Refit line to the fitting using a new
compression sleeve and a tube insert.

Trapped and broken, rubbed through

Replace or repair (re-route or protect
the line to prevent the damage from
happening again).

Secondary line has popped out of fitting.

Refit line to the fitting using a new
compression sleeve.

Lube point fitting has broken off.

Remove broken fitting and replace.

Solenoid valve not working

See 1d. "Inoperative solenoid air valve" page 16

Air line damaged

Repair or replace if necessary.

Low air pressure

Build up air pressure in truck system.

Electrical circuit to timer or solenoid is
damaged

Check connections; repair or replace if
necessary.

Timer is not working

Repair or replace timer.

Electrical circuit is damaged

Check electrical circuit to make sure
voltage is reaching motor.

Inoperative motor

Repair or replace motor if necessary.

( ) Refer to Grease Jockey PM Procedure on Page 15

For more information call: 1-800-USA-LUBE

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179

PARTS LIST
Description

Part Number

Installation kit:

AIR PUMP ASSY.
W/FLEX RESER.
550-000-040

30 pt single axle tractor,
air pump, and
flexible reservoir

550-500-105

34 pt tandem axle tractor,
air pump, and
flexible reservoir

550-500-155

30 pt single axle tractor,
electric drive pump,
flexible reservoir

550-501-445

34 pt tandem axle tractor,
electric drive pump,
flexible reservoir

550-501-435

Air pump repair/rebuild kit

550-400-792

Flexible reservoir replacement kit

550-400-780

6lb. rigid reservoir replacement kit

550-402-530

AIR PUMP ASSY.
W/RIGID RESER.
550-001-050

E-Z Luber Installation kit:
6 pt manual trailer system

550-502-051

12 pt manual trailer system

550-502-061

Trailer add on kit to attach an
"E-Z Luber system to a tractor
with a GJ system

550-502-320

TIMER FOR AIR SYSTEM
(12-32) VDC
550-200-081

FILLER PUMP
ASSEMBLY
550-000-020

WIRE LEAD
for air pump timer
550-250-120

SOLENOIL AIR VALVE
12 VDC - 550-250-090
24 VDC - 550-250-010

35 LB. CAN GREASE
550-400-020
NLGI "00"
Non-Moly

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WIRE LEAD (22 ft.)
for air solenoid valve
550-250-140

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180

PARTS LIST Con't

UNIVERSAL PUMP
MOUNTING BRACKET
550-402-690

MAIN LINE TUBING
5/16" OD (60 FT.)
550-450-230
3/16" OD (60 FT.)
550-450-190

METER OUTPUT
PORT PLUG
550-150-130

METER VALVES
#
=
550-100-000
=
550-100-010
=
550-100-020
=
550-100-030
=
550-100-040
=
550-100-080
=

METER OUTPUT
SIZING SPACER
550-150-020

12 PORT MANIFOLD
WITH STUD, MODULE
550-350-145

DISTRIBUTION LINES
3/16" OD TUBING
BUNDLES(10FT.) Prefilled

FLEX. RESERV.
10LB CAPACITY
560-002-630
(CLAMP NOT INCLUDED)
(461-300-859)

550-450-100 = 3 Tube bundle
550-450-020 = 2 Tube bundle
550-450-210 = 1 Tube black
550-450-810 = 1 Tube orange

MANIFOLD METER
PORT PLUG
550-350-040

5/16" TUBING
INSERT (PKG. 20)
550-402-330

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Size
0
1
2
3
4
8

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181

ELBOW, STREET
(1/8"NPT to 1/8" NPT)
509-110-000
(3/8"NPT to 3/8" NPT)
509-117-000

PARTS LIST con't

NUT, TUBE
3/16" Tube - 435-702-340
5/16" Tube - 435-702-503

ADAPTER, STRAIGHT
1/8"NPT to 1/4"-28 SAE
MALE
550-400-880

MALE CONNECTOR
(3/16" tube, 1/8" NPT)
435-460-030
5/16" tube, 1/8"NPT
435-460-060
5/16" tube, 1/4"NPT
435-460-070

NYLON TIE STRAPS
(11.5")
550-400-230 - 36 pcs
550-402-340 - 100 pcs

MALE 900 ELBOW
CONNECTOR
(3/16 tube, 1/8 NPT)
435-440-030
(5/16" tube, 1/8"NPT)
435-440-060
(5/16" tube, 1/4" NPT)
435-440-070

TUBE UNION
for 3/16" tube 435-470-020
for 5/16" tube 435-470-040

FITTING ADAPTER STRAIGHT
1/4"-28 SAE X 3/16"T
435-702-367

1/8"NPT MALE
BRANCH TEE
5/16" tube run 435-410-040

ELBOW, STREET
1/8" NPT to
1/4" - 28 SAE MALE
550-400-800

TEE, TUBE UNION
for 5/16" tube 435-420-030

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182

PARTS LIST con't

ELECTRIC PUMP
Assy, Flex. Reservoir with
timer for
12 VDC - 550-002-095
24 VDC - 550-002-105

WIRING LEAD
for electric pump
492-240-244

BULKHEAD FITTING
550-400-450

RESERVOIR FILL
CONNECTOR (QD)
FEMALE,
1/4" NPT (FEMALE)
550-050-230

ZERK ADAPTORS,
PRESS ON:
(3/16" TUBE CONNECTION)
ELBOW - 550-402-860

RESERVOIR FILL
CONNECTOR (QD) MALE
3/8" NPT (MALE)
550-050-300

ZERK ADAPTORS,
PRESS ON:
(3/16" TUBE CONNECTION)
STRAIGHT - 550-402-870

SERVICE START-UP KIT

1/8"NPT
EXTENSION (.75") 509-027-000

550-402-800
CONSISTS OF:SOLENOID VALVE, TUBE AND
TUBE BUNDLES, INJECTORS,
FITTINGS, TUBE INSERTS, AND AN
AIR PUMP REPAIR KIT

EXTENSION (1.25")
509-028-000

CLAMPS
(932 dia. hole)
550-400-040 = 5/16"
550-400-070 = 3/8"
550-400-050 = 7/16"
550-400-080 = 1/2"
550-400-060 = 5/8"

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183

Bulletin GJ-30050

B-GJ30050-0701

® Registered trademark of LUBRIQUIP, INC.,
A Unit of IDEX Corporation, Printed in U.S.A.

LUBRIQUIP, INC., A Unit of IDEX Corporation ❑ 18901 Cranwood Pkwy ❑ Cleveland, Ohio 44128
Phone: 216-581-2000 ❑ FAX : 216-581-8945 ❑ www.lubriquip.com

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IDEX CORPORATION

184

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Format                          : application/pdf
Site Brand                      : tennant
Is Purchasable                  : true
Doc Status                      : Active
Modified                        : 2017:10:19 14:04:46.000-05:00
Category                        : manual
Share With Recon Machines       : true
Security                        : Secure
Creator                         : Steve Floyd
Marketing Channel               : DST, SLS, SRV, EMP, DIR, KSA, SSP
Language                        : en, all
Title                           : Sentinel Service Manual
Num Pages                       : 190
Extracted                       : 2017:10:19 14:03:35.186-05:00
Author                          : Steve Floyd
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Page Layout                     : SinglePage
Page Mode                       : UseOutlines
Page Count                      : 190

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Sentinel Service Manual Tennant Rider Floor Sweeper

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