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SR 1900 - IPS CLEAN

1. HOPPER SY STEM me DUMP DOOR CYLINDER a cc ciet tees Pa rir tire Peeters ua amana asa SOLUTION SYSTEM iactata tedeschi tede damian can fts aha data t e eade ENGINE SYSTEM Q O sassa is ENGINE SPECIFICATIONS P ENGINE MAINTENANCE CHECK ENGINE LIGHT TROUBLESHOOTING 77 MISCELLANEOUS ENGINE SYSTEM INFORMATION insasi aaia GM 16L GASOLINE FUEL SYSTEM DESCRIPTION is cinis tuti et coc ten trier rette rcc HYDRAULIC SYSTEM HYDRAULIC SYSTEM TROUBLESHOOTING aa aa i ked GENERAL HYDRAULIC SPECIFICATIONS TABLE I HYDRAULIC TRUTH TABLE 2 PRESSURE RELIEF VALVE itinere cita ite rt ttt en Let trt t ber attt ic ene ae HYDRAULIC DIAGRAM i HYDRAULIC SYSTEM LAYOUT FOR OPTIONAL LEFT SIDE BROOM I a HYDRAULIC COMPONENT LOCATION tii iiri tridente cnt HYDRAULIC SCHEMATIC ELECTRICAL SYSTEM a iiiter ttt triente tet ert ert t a HE A ta b ha dd hd ELECTRICAL C
2. Needs Cleaning Hydraulic Reservoir Level 104 30 engine oll only BotomofSewen 55 ste Spindle amp Drive Wheel motor open operator s sea Grease Spindle Zen Dr ae Rear Tire check lug nut torque 100 FTLB 135Nn Tire Pressure 90psi Mw Far GasolineDiesel tink Fiter Lins 22 L L er T LP Tank Hoses amp Fitings _ L L r T 49 LP Fuel Filter SVR Life 1500 Hrs L Replace 50 LP Fuel Regulator Lock Off Valve amp Hoses L Diesel Glow Plug indicator Ligt DedFue _ re 53 Engine Airintake Hose Assembly air inlett engine clamp fins CL 54 Dust Guard Water Tank Misting Pump amp StorageTank L T NOTE For additional service information see service manual form number 56043129 and operator manuals form numbers 56041661 56041666 Defect Codes A needs adjustment C dirty or contaminated M missing B binding D damaged bent or torn W worn out L leaks WORK COMPLETED BY ACKNOWLEDGED BY Service Technician Signature Date Customer Signature Date Dann Eon FORM NO 56043129 SR 1900 15 KNOW YOUR MACHINE As you read this manual you will occasionally run across a bold number in parentheses and underlined example 2 These numbers refer to an item on
3. uum ER ret En GE D rune aid stor READER his Hopper dump door will not open Part A Hopper dump door will not close Part 140 sese tenen Hopper dump door will not open or close Part B Solution Systemioa t MSN LE Dust control misting pump will not operate Optional Note To aid in machine system troubleshooting see the electrical and hydraulic manual sections for additional drawings of part component locations and diagrams to support wiring and hydraulic circuits 22 FORM NO 56043129 SR 1900 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom GM 1 6L 4 cylinder engine will not crank Part A Electrical Control and Load Circuit Note 1 To test the key switch must be in Start position and the foot pedal in neutral Note 2 Before T S check the CB1 60 Amp circuit breaker amp 12V s key switch Bat terminal Note 3 Before T S check Battery voltage starter main load red wire GM 1 6L 4 cylinder engine will not crank With the key in the start mode check for 12V Wht wire located on starter solenoid If yes repair or replace starter motor With starter relay removed test for 12V a the relay terminals 85 amp 86 wire colors Blue Pink amp Pink Black w key in the start mode Replace the defective starter rela amp the K4 relay do you have 12V the Blue Pink wire w key in the start mode
4. 1 LS UNUSED B FUEL PUMP Fri TWIST WIRES 19 TURNS 360 DEG FOOT FULL LENGTH pure TE T ma INJ4 LS PINK 18 VSW INJS 15 PED 12162859 CONNECTOR 6 LS PED_ 12124075 TERMINAL 15 YELLOW RED 18 INJ8 LS lt 10MM RING 69 BLACK 16 YELLOW 18 GND TEMP lt 78 16 BLACK 12 ARTE Z1 WHITEALT BLUE 18 PINKZDK GREEN 16 10 EGOH 12 75 BLACKAYELLOW 18 EGON 74 IGNITION COIL PINK DK GREEN 18 DIAGNOSTIC ale Z5 WHITE BLACK 18 4 BLACK LT GREEN 18 1_ ANA RTN CONNECTOR BUZZER 76 i LT GREEN RED 18 2_ REF 9 77 BROWN WHITE 16 STARTER DK GREEN 18 3 PC TX PWMS RECIRC lt 78 WHITE BROWN 16 ORANGE 18 4 PC RX 1FIT 144624 AA 004 CONN T 79 RED TAN 16 PINK DK GREEN 16 i SOLENOID 5 UNUSED GTS 0330930009 TERM 18 20 gt 80 GREEN YELLOW 18 16 UNUSED IS y of 16 GND TEMP lt 81 BLACK 16 r 16 0 6MM RING BLUE PINK 18 7 F5AB 14A666 AA DEW lt gt 82 PINK WHITE 18 BLUE WHITE 18 8_ CAN DEW F2 84 PED 12110539 CONN FPUMP PED_ 12110540 LOCK RED TAN 14 RED 14 AUX PMS RECIR lt 6 PURPLE WHITE 18 m CRANK SENSOR PED 12129409 TERM 14 16 AWG T AUX 2 444072 1 CONN PED 12015323 SEAL 20A AUX Pwu gt 89 PI KZELACK TE MHTEZPURPLE 18 AMP_927770 1 TERM 12010300 CAVITY PLUG IF NEEDED ECM STARTER AUX E AUX PWM4 RECIR 99 BLACK 16 m _8289
5. ENGINE HARNESS FOR 1 6L LPG Tier 3 ELECTRICAL SYSTE EGO1 SHO EGO 2 PED 12160825 CONNECTOR PED 712177158 TERM GOLD PED 12089678 WIRE SEAL PED 12169826 LOCK PED 12180825 CONNECTOR PED 712177150 TERM GOLD PED 12089678 WIRE SEAL PED 12176368 LOCK DK GREEN ORANGE 18 PINK DK GREEN 18 BLACK WHITE 18 PED 12162197 CONNECTOR GRAY PED 12052641 CONNECTOR DK GREEN WHITE 18 PED_ 12124075 TERMINAL 12048074 TERMINAL PINK DK GREEN 18 PED_ 12452634 LOCK BLACK YELLOW 18 PED 12048486 SEAL WHITE BLACK 18 PINK TAN 18 90 WAY CONNECTOR WHITE RED 18 A GREEN ORANGE 18 DK GREEN WHITE 18 EGO ei EGO2 211 s 25 agag connector EGOS 211 LOCKING 04 211 A 9a COVER TPS1 211 CC 25 1460 TERMINAL GOLD TPS2 MAP AUX ANA PD1 FPP2 NS AUX ANA PUD2 AUX ANA PUDS CAN TERM 2 CAN2 CAN2 TERM EXT 1 SV RTN CRANK CRANK CAM BLACK LT GREEN 18 B LOCKOFF LPG TEMPERATURE PURPLE LT 1 LT BLUEZDK BLUE 18 LT GREEN 18 GREEN 18 DK BLUE ORANGE 18 12 PURPLE YELLOW 18 WHITE ORANGE 18 14 BLUE PINK 18 PED 12182193 CONNECTOR PED 12103881 TERMINAL TAN WHITE 18 BOSCH KOMPAKT 1 928 403 736 CONN
6. the K4 relay do you have 12V Q coil relay wires Gra Wht amp Pink Replace the defective K4 neutral relay Remove the starter relay location engine fuse box and test for 12V the Red Tan terminal 87 to Grd w key in the start mode Test for 12V Blue Pink wire 86 to Bat Grd w key in the start mode amp the starter relay do you have 12V from Pink Black wire 85 to Bat w key in the start mode Test for 12V Pink K4 coil wire to Battery Grd w key on Test for 12V input Red wire F6 15A fuse If NO repair or replace the Red Bat feed wire from its Source Test F6 fuse replace if defective Repair Red Tan wire to starter relay terminal 87 Repair the Pink Black wire circuit If good replace the engine ECM Troubleshooting continued on next page part B Note A Any time the machines hydrostat mounted neutral position sensor is replaced or the hydrostat linkage adjusted its neutral position must be re programmed Also any time the A2 control box is replaced it must be re programmed See the programming options section in this manual for instructions FORM NO 56043129 SR 1900 23 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom reference Note A below Test for 12V the pink K4 coil wire to Grd With the key on Yes amp the K4 relay coil test for 12 from the Gra Wht wire to Bat with key on Before testing the dri
7. x WHITE 16 6MM RING 14A666 AA DOW SS B3 AN ORANGE 18 Pu e S TANZBLACK TB PED 12110539 CONN SERERE 12110540 Lock AUX pwys REGIRG BLACK RED TS PURPLE WHITE 18 CRANK SENSOR PED 12 129409 TERM 14 18 AWG AUX PWM1 444072 CONN PED 12015325 SEAL AUX WHITE PURPLE 18 AMP 927776 TERM PED 12010300 CAVITY PLUG IF NEEDED STARTER AUX 5 BLACK 16 AMP 82890471 SEAL NOTES AUX_PWM4_RECIRC WHTE 16 30 9 F6 1 ALL WIRE MUST BE SAE J1128 TXL TYPE 87 2 HARNESS TO BE LABELED WITH PART AND REVISION LEVEL 3 ALL CONVOLUTE MUST BE FLAME RETARDANT POLYPROPYLENE 4 PUSH TO SEAT CONNECTORS MAY BE USED FOR THE ECT AND ALT CONNECTORS AS FOLLOWS PED 15449028 CONN PED 15305351 SEAL PED 15326267 TERM PED 15305024 LOCK 5 ALTERNATE INJECTOR CONNECTORS MAY USED AS FOLLOWS TYCO 282189 1 CONN TYCO 929939 1 TERM TYCO 828904 1 SEAL STARTER RELAY LT BLUE PINK 18 15A STARTER PINK BLACK 18 85 F4 PINK DK GREEN 16 PINK DK GREEN 16 15A PINK 18 IGNITION PINKZTAN 18 PINK DK GREEN 16 M1 MT CONNECTOR MASTER TRACK 7 CONNECTOR WHITE LT BLUE 18 RED 18 30 MAXI FUSE NS _ _SLUE PINK 18 PINK DK GREEN 16 87 vsw PURPLE EE 8 RED TAN 1886 GROUND D
8. High speed 5 10 V Is there a voltage increase from idle to HS with a load Yes Substitute a good known working actuator if engine runs properly both idle amp HS replace actuator Ribbon connector see Electrical System Figure 1 for detail pin call outs Press on amp off the engine speed switch check for continuity ribbon connector pins J3 1 amp J3 2 on the A2 control box assembly Substitute a good known working governor if engine runs properly both idle amp HS replace governor Repair or replace the defective Gra Blu wire Ribbon pin s test open Replace the touch pad switch panel Check for 12V s the A2 control box output pin J1 17 Gra Blu to Bat Grd Replace the A2 control box assembly 30 FORM NO 56043129 SR 1900 WHEEL DRIVE SYSTEM Hydraulic Wheel Drive System Troubleshooting Check List Symptom Possible Cause Wheel drive functions sluggish or slow Engine not operating in high speed setting or engine speed is too slow 2400 RPM Air in hydraulic fluid loose fittings Propulsion pump inlet restriction cavitation of hydraulic fluid Worn drive wheel motor test working pressure amp wheel drive speed Wheel drive in one direction only Inspect propulsion pump relief valves for A Debris that allows valve seat to be held open B Damaged or weak valve spring C Valve unloading pressure setti
9. BLACK 18 LT BLUE DK BLUE 18 874 POWERRELAY RING cA RED TAN 18 18MM RING MUS sp OSCH THROTTLE TANZ Ri ALTERNATOR 1 PED 12 52848 CONNECTOR PED 12124107 CONNECTOR PED 12059168 CAVITY PLUG PED 15324973 CABLE SEAL PED 12059168 CAVITY PLUG PED 12045773 TERMINAL PED 12852850 TPA LOCK PED 12020833 CPA LOCK N PINK YELLOW 16 1 967616 1 CONNECTOR 9859 6 5 TERMINAL 967 67 1 SEAL PED 12162193 CONNECTOR PED 12103881 TERMINAL ALTERNATOR 6MM RING FUEL PUMP RELAY RED 16 R3 B TAN BLACK 18 PINKZYELLOW 16 ALTERNATOR RED 16 BROWN LT BLUE 18 PINKZTAN 18 FS BROWN LT BLUE 18 PINK Y 1 PINK Y 1 BLACK 8 GREEN AS BROWN LT GREEN 18 BROWN ZLT GREEN 18 GREEN 18 m INK YELLOW 16 INK YELLOW 16 10MM RING PINK DK GREEN 18 PINK DK GREEN 16 PINKZDK GREEN 18 10A GROUND FUEL PUMP 6 Faze 144464 MA CONN Faza CONN Faze tanagta CONN 6 1474 TERM 7349 14474 28 TERM 144468 03 SPACER E338 142468 0 SPACER INJECTOR 4 INJECTOR 3 INJECTOR 42 INJECTOR 1 14271 44 TERN TAMER DA SPACER AU E 1 6L GSLN W GCP 2010 Rev E2322120 A C P _ __ 76 FORM NO 56043129 SR 1900
10. A DANGER 15 used to warn of immediate hazards that will cause severe personal injury or death A WARNING 15 used to call attention to a situation that could cause severe personal injury A CAUTION Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property Read all instructions before using GENERAL SAFETY INSTRUCTIONS Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm A DANGER This machine emits exhaust gases carbon monoxide that can cause serious injury or death always provide adequate ventilation when using machine A WARNING This machine shall be used only by properly trained and authorized persons While on ramps or inclines avoid sudden stops when loaded Avoid abrupt sharp turns Use low speed down hills Clean only while ascending driving up the ramp hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near hydraulic system Turn the key switch off O and disconnect the batteries before servicing electrical components Never work under a machine without safety blocks or stands to support the machine Do not dispense flammable cleaning agents operate the machine on or near these agents or operate in areas where flammable liquids exist Only use the brooms provided with the appliance
11. CA Brakes check both service amp parking o Hopper Up Down aso check operation ofthe safety hopper suppor J Fw meperbumpDowOpmCme I I E Dust Control Filter Shaker amp Vacuum Impeller Tilt Steering Mechanism and Seat Adjustment lever 18 Dust Guard Water Pump Operation On Off HER VISUAL INSPECTION ITEMS ef Comments OK SideBroomMowr 171 Hopper Cover Gasket 2 Hopper Dust Fiter amp Gasket 1 2 Dust Vacuum Moor SY MEM NEN EE 19 20 21 23 s 6 4cm length pattern 9 Main Broom Motor open side access door to inspec 0 BromHowing amp DooSkms 1 2 3 Front tires check lug nut torque 80FT LB 108 Nm Tire Pressure 90 psi Clean amp Water Engine Air Cleaner Element inner amp outer Check SVR Indicator 2 2 2 2 2 3 3 3 3 Copyright 2007 Nilfisk Advance Page 1 of 2 2 21 2007 14 FORM NO 56043129 SR 1900 VISUAL INSPECTION ITEMS continued Defect Codes Comments OK circle Ls Ryde Damp Va mas s 36 Hopper Up Transport Speed contol as T Tm _ 39 Propulsion Pump Hydro Back Cable amp Clevis suw 40 Engine Oil Level Hoses amp Belts Add or Change L W Hi eec S ttes FT Radiator amp Oil Cooler Cove Blockage
12. CF 4 or CG 4 oil meeting specifications and suited temperatures important reference the oil fuel type note below for further diesel oil recommendations Refer to the Engine System section for oil capacities and additional engine specifications Replace the oil filter with every oil change TEMPERATURE RANGE OIL WEIGHT Above 77 25 SAE 30 or 10W 30 32 F to 77 F 0 C to 25 SAE 20 or 10W 30 Below 32 F 0 C SAE 10W or 10W 30 Diesel Lubricating Oil Note With the emission control now in effect the CF 4 and CG 4 lubricating oils have been developed for use of a low sulfur fuel on road vehicle engines When an off road vehicle engine runs on a high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter intervals Lubricating oil recommended when a low sulfur or high sulfur fuel is employed Fuel m Low sulfur Lubricating High sulfur Remarks Oil class 0 5 gt 0 0 gt 10 4 0 X CG 4 0 X O Recommendable X Not recommendable FORM NO 56043129 SR 1900 11 MAINTENANCE ENGINE AIR FILTER The engine Air Filter 24 is located in the engine compartment Check the air mechanical vacuum filter Service Indicator 27 before each use of the machine Do not service the air filter unless the indic
13. signal lights option Circuit Breaker 10 Amp misting pump option Circuit Breaker 40 Amp for cab option Flasher optional Fuse 1 Amp Horn Relay Horn Relay Lights Relay Shaker Relay Neutral Relay Signal Lights optional Relay Misting Pump optional Head Light Right Head Light Left Lamp Right Front optional Lamp Right Rear Signal optional Lamp Right Rear Tail Brake optional Lamp Left Front Signal optional Lamp Left Rear Signal optional Lamp Left Rear Tail Brake optional Lamp Curb optional Lamp Trouble optional Lamp Rear Work optional Light Strobe optional Motor Shaker Pump Fuel Pump Misting optional Gauge Combination Sender Oil Pressure Sender Fuel not used on LPG models Switch Ignition Switch Brake Switch part of LP10 Switch Hazard optional Switch Turn Signal optional 68 FORM NO 56043129 SR 1900 56507376 l Sheet 1 of 3 RED 81 BLK BATTERY 12
14. 09 FORM NO 56043129 SR 1900 73 ELECTRICAL SYSTEM ENGINE HARNESS FOR GM 1 6L GAS _ 184140 1 TERM 18 90 WAY CONNECTOR eal EGO 2 1 PC 90 25 9 CONNECTOR 9 1 211 A 90 0007 LOCKING wi 1 PED 12160825 CONNECTOR BLACK WHITE 18 1 A 90 0008 COVER 1T GREEN RED 18 GASOLINE SENSOR INTERFACE DK GREEN WHITE 18 PED 12177150 TERM GOLD 174257 2 CONN 1 2S 1460 TERMINAL GOLD WHITE LT GREEN 18 5 PINK DK GREEN 18 PED 12089678 WIRE SEAL BLACK LT GREEN 18 171662 1 SEAL 12160826 LOCK 184141 1 TERM 16 GAUGI _ 174258 7 LOCK PED 12160482 CONNECTOR PINK DK GREEN 18 PED 12048074 TERMINAL PED_ 12160480 LOCK EGO 1 Eco 2 EGO 3 EGO 4 TPS 1 TPS 2 DK GREEN ORANGE 18 WHITE 1 GREEN ORANGE 18 PURPLE LT BLUE 18 MAP AUX ANA PD1 FPP1 FPP2 5 AUX ANA PD2 AUX ANA PD3 CAN TERM CANT CAN2 CAN2 CAN2 TERM SV EXT 1 PURPLE YELI BLUE PINK 18 PED 12162193 CONNECTOR PED_ 12103881 TERMINAL 18 BLACK LT GREEN 18 BOSCH KOMPAKT 1 928 403 736 CONN 1 928 498 060 TERMINAL 1 928 500 599 SEAL ECT SV CRANK TOREM RES 1 CONNECTO
15. 18 B ECT ELECTRICAL SYSTEM i gt N 18 LT GREEN 18 CRANK 21 PURPLEAWHITE 18 J TT GREEN RED 18 C CONNECTOR 2 CRANK 22 WHITE PURPLE 18 YELOW GRAY18 PEDA ESZO CONI 23 TWIST WIRES 16 369 DEG FOOT FULL LENGTH BIACK LT GREEN 18 15 2 BOSCH TWIST WIRES 10 TURNS 36 DEG FOOT FULL LENGTH PINK DK GREEN 16 12V RELAYED POWER 5284787 TM SPEED e 22 RED WHITE 18 TAN DK GREEN 18 R AUX ANA SPEED e gt 26 RED BLACK 18 BLACK 18
16. 2 lel 4 BLK1847 B B 18 36 B B VALVE 59 HOPPER LOWER a 01817 A KA B 255 LAMP REAR WORK gt d GRN BRN 18 18 B 33 ydg g 1 122 2 YEL GRN 18 1 2 2 38 1542 61558 3 BACK UP ALARM 88 T 1 1 OPTIONAL 20 z LAMP LEFT REAR SIGNAL X50 33 ais A lt A REDIBLK 18 1 S2 RED 1 amp 2 FI A RED 184 i 29 2 22 5 1 2 8 B BERG ooo 56 FUSE 1 A xx aa RI X72 X74 ren gt gt gt 5 1 8 Gs a gg 18 3 A GRN 18 4 1 m BLK 1 1 gt I 1 LBLK11 1 E BLK 18 15 BLK 18 35 SWITCH HOPPER INTERLOCK 4 P Me SRG 1 12 8 B B SP20 2 X165 12 YEL BLK 18 3 YELIBLK 1812 2 amp gi lt WHT SP3 x167 SENDER OIL PRESSURE GRA 18 2 D GRA 18 5 2 1 RED lt OPTIONAL SP21 LP13 LAMP LEFT REAR TAIL BRAKE OPTIONAL BLK ORN 18 2 FORM NO 56043129 SR 1900 71 ELECTRICAL SYSTEM WIRING SCH EMATIC 2 of 3 REFERENCE E CONTROLS INC DRAWING NO E
17. B BLK1834 Topy C BLK1848 TROUBLE LAMP 5 N x x 381 ve GRAVEL 181 1 2 C YEUBLK 1811 a axi VIO 16 2 BLK STROBE BLK 18 21 1B GRA1 amp 3 D D GRA 18 4 1 2 RED x z a ooo 8 5 92 955 f as VIOIBRN 18 1 EL OPTIONAL SWITCH LOW LP PRESSURE MISTING SP18 X29 2 _ 87a E LAMP RIGHT REAR TAIL BRAKE VIO 16 6 amp lt X76 gt S V ju 1 2 Dwi0 gr WHT YEL 18 s a OPTIONAL E VIO 18 4 m BLK 18 21 AERE CIR BKR 15 20 AMP BKR 70 AMP RELAY MORN vig qus ag h 4 STARTER X211 VIO 16 3 X128 X127 C VIO 187 GRN YELTS4 1 VIO 16 3 J 4h p ORAORN18 1A gt gt B VIO 18 8 KZ 59 BLK18 87 B VIO 18 9 N x88 85 YEL WHT 18 1 5 o I 87a _ YELIBLK 16 2 8 30 Tr g7 3 u CB 14 1 E VIO18 10 1X2 RELAY LIGHTS 0164 D 18 11 CIR 20AMP CIR BKR 10 CIR BKR 20 K3 VIO 18 1 C VIO 18 12 E IGNITION ACGESSORY X204 Ss B VIO 18 13 vio18 20 A a VIO 18 15 r 30 87 BLU GRN 14 1 L7 a RELAY SHAKER VALVE 87 HOPPER DOOR L5 E 3 cai A X101 VALVE S5 HOPPER UP DOWN 8 2 117122 2 BLK WHT 18 1 amp 2120 t qaa 92 aenema 18 2 a5 PINK 16 2 T 1 1 VIO 18 5 CIR BKR 10 CIR BKR 20 AMP 0 J VALVE S3 SIDE BROOM 2 MISTING PU
18. GUIDE Auxillary pump output 4 92 on 4 cylinder models CIR Auxillary pump output as on 3 cylinder models CIR Problem Possible cause Slow steering hard steering or loss of Power assist Priority flow divider not providing 2 0 GPM 1100 PSI relief valve open or malfunctioning Steering wandering Loose or leaking cylinder piston packing Steering control unit worn Steering wheel turns freely without moving wheel Problem with steering column Shaft or spline Steering binding Steer cylinder loose 32 FORM NO 56043129 SR 1900 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Main broom motor will not run Part A Electrical Control Circuit Note 1 Do all testing with the engine running at high speed the main broom lowered sweep position and the drive pedal activated machine moving Note 2 The main broom magnetic switch S2 must be open and also the hopper interlock switch S4 closed for the main broom system motors to run Main broom motor will not Run Complete the above operator inputs to turn on main broom motor Back probe the S2 L2 main broom solenoid coil wires Vio 8 Grn BIK should read 12V s Yes Check S2 solenoid coil resistance Spec 9 Ohms See hydraulic side broom motor will not turn troubleshooting section B No Yes No Yes No Check S2 coil wiring continuity repair if
19. Replace defective fuses Engine still will not start Yes Ignition coil testing Using a spark plug tester check for spark each cylinder T S continued next page see additional system checks Repair B coil wire s to ECM Still no voltage signal substitute a good ECM Engine still will not start Replace the ignition coil pack Yes Troubleshooting continued on next page see additional system checks FORM NO 56043129 SR 1900 25 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom GM 1 6L 4 cylinder engine will crank but not start Part B Note 1 Check for 12V s at the CB5 ignition circuit breaker 10A If no input voltage the Orn Grn wire repair or replace wiring or key switch Note 2 Check the fuel supply empty tank Note 3 Check the condition of the spark plugs replace if needed Troubleshooting continued from previous page Follow the preliminary system checks listed below for engine cranks but does not start Fuel System Checks LP Check for air intake system leakage between the mixer and throttle body Verify proper operation of the low pressure lock off solenoid valve Check the fuel system pressure Refer to the LPG fuel system diagnosis for instructions amp Specification Check for proper mixer air valve operation Note the air valve must vibrate back amp forth when cranking No vibration look for an intake system leak Example The block off injector plugs loo
20. SIGNAL MOTOR ASM WIPER OPTIONAL GHN Wt T INCLUDES 2 SPEED SWITCH OPTIONAL LAMP LEFT REAR SIGNAL 128 YEL BLK WHT BLK 7 GRA RED uar LAMP LEFT REAR TAIL BRAKE GRN YEL Y M LeS 1 YEL BLK 1 2 BLK MOTOR DEFROST R FAN OPTIONAL CAB OPTION CURB LAMP YEL BLK 1 1 BLK OPTIONAL GRN YEL 1 1 2 BLK LAMP REAR WORK CAB OPTION 27 LP10 RED 1 RED 1 1 21 QE BLK BLK OPTIONAL FUSE 1A SW SPST CB8 M4 ris K6 1 52 BLU 30 87 GRA ORN BLK CIRCUIT BREAKER 10 A 2 R D OPTIONAL RELAY MISTING PUMP MISTING PUMP OPTIONAL OPTIONAL COMBINATION GAUGE OPTION VIO o 6 WHT BLK1 GAUGE COMBINATION SENDER OIL PRESSURE TAN vo 56507376 Sheet 2 of 3 VIO L1 VIO 4 12 BLU WHT VALVE 1 HOPPER CLOSE OPEN L2 VIO 312 GRN GRA VALVE S2 MAIN BROOM L3 VIO 1 2 BRN BLK VALVE 53 SIDE BROOM S26 K6 vio 2 I 3 BLK ORN BLU ORN BRN BLK SWITCH MISTING PUMP VIO L4 RELAY MISTING PUMP OPTIONAL 2 BRN YEL VIO K10 VALVE 84 DUST CONTROL RED GRA VIO L5 RELAY COMPRESSOR OPTIONAL 2 RED GRA VIO L6 2 VALVE 5 HOPPER UP DOWN BLU GRA VIO L7 2 VALVE S6 HOPPER UP BYPASS BLK WHT VIO L8 VALVE S7 HOPPER OPE
21. STARTER AUX PWM4 AUX PWM4 RECIR i ooo Nion DK GREEN ORANGE 18 DK GREEN ORANGE 18 PURPLE LT BLUE 18 LT BLUE DK BLUE 18 LT GREEN 18 TAN DK GREEN 18 DK BLUE ORANGE 18 PURPLE YELLOW 18 WHITE ORANGE 18 BLUE PINK 18 BLUE WHITE 18 LT GREEN RED 18 BLK LT GREEN 18 PURPLE WHITE 18 WHITE PURPLE 18 RED WHITE 18 RED BLACK 18 YELLOW 18 YELLOW RED 18 YELLOW GRAY 18 TAN WHITE 18 TAN RED 18 TAN BLACK 18 PINK TAN 18 DK BLUE YELLOW 18 YELLOW DK BLUE 18 LT GREEN WHITE 18 LT GREEN PURPLE 18 LT GREEN BLACK 18 GRAY DK BLUE 18 GRAY ORANGE 18 LT BLUE 18 WHITE LT GREEN 18 DK GREEN 18 ORANGE 18 GRAY 18 RED TAN 16 BROWN LT BLUE 18 BROWN LT GREEN 18 BLACK 16 WHITE LT BLUE 18 BLACK WHITE 18 BLACK YELLOW 18 BROWN WHITE 16 WHITE BROWN 16 RED TAN 16 GREEN YELLOW 18 BLACK 16 PINK WHITE 18 TAN ORANGE 18 TAN BLACK 18 PINK YELLOW 16 BLACK RED 16 TAN 16 DK BLUE 16 PINK BLACK 18 ECM ECM Detail Harness Connectors CONNECTOR 2 Machine Harness Connectors PINK DK GREEN 16 12V RELAYED POWER TAN DK GREEN 18 AUX ANA PD1 RED BLACK 18 VS RED WHITE 18 VS TAN BLACK 18 AUX DIG 3 TAN RED 18 AUX DIG 2 GRAY DK BLUE 18 GOV SELECT 1 THROTTLE INPUT GRA BLU 18 1 GRAY ORANGE 18 GOV SELECT 2 12V FOR HIGH SPEED DK BLUE YELLOW 18 AUX ANA PU1 YELLOW DK BLUE 18 AUX ANA PU2 TAN 18 AUX PWM 2 COOLANT TEMP OUTPUT TAN 18 1 BLACK 16 GROUND GRAY
22. a long period as this may cause damage excessive heat build up Observe the pressure gauge reading in the overloaded dead headed position and adjust accordingly The hydraulic systems relief setting is 2500 PSI for all models See Figure 3 Loosen lock nut turn adjustment screw CCW to decrease amp CW to increase FORM NO 56043129 SR 1900 61 1 O 400 See Radiator Assembly HYDRAULIC SYSTEM Hydraulic System 4 Cylinder models Item Description Steering Control Unit Reservoir Assembly Drive Motor Assembly Side Broom Motor Assembly Side Broom Cylinder Assembly Right Main Broom Motor Assembly Dust Control Motor Assembly Sleeve 23 In Nylon Manifold Assembly Steering Cylinder Assembly Hopper Door Cylinder Assembly Hopper Lift Cylinder Assembly Pump Assembly Filter Assembly Elbow 90 O Ring Sleeve Hydraulic Hose Sleeve 26 In Nylon Sleeve 24 In Nylon Decal Oil Fill Test Port 62 FORM NO 56043129 SR 1900 HYDRAULIC SYSTEM Left Hand Side Broom Option Item Description Item Description Instruction Sheet 10 Hose Hydraulic 1 Left Hand Side Broom Option 11 Hose Hydraulic 2 Side Broom Cylinder Assy Left 12 Hose Hydraulic 3 Side Broom Motor Assembly 13 Hose Hydraulic 4 Valve Assembly 14 Hose Hydraulic 5 Tee Union 15 Wire Tie not shown 6 Hose Hydraulic 16 Hose Clamp 1 4 Quadruple 7 Tee Run O Ring 17 Scr Hex 1 4 2
23. assy Does the dust control motor run Ribbon connector see Electrical System Figure 1 for detail pin call outs 38 FORM NO 56043129 SR 1900 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Dust control impellor motor will not run in the wand state Part B Hydraulic Load Circuit Note Do all testing with the engine running at high speed and the dust control switch pressed activated Dust control motor will not run Remove and disassemble L4 dust control motor valve cartridge Inspect clean and reinstall Does the motor run Substitute or replace the defective L4 dust control valve cartridge Does the motor run Replace the dust control impellor motor Substitute valve cartridge numbers 1 2 amp 4 they are the same and can be swapped to help troubleshoot the system FORM NO 56043129 SR 1900 39 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Shaker motor will not run Part A Electrical Control Circuit Shaker motor will not run Test for 12V s Check K3 relay Test for Neg the K3 shaker coil wiring 12V s motor relay coil continuity Vio amp the K3 wires Vio amp Yel Red repair Yel red wire Yel Red if faulty to Bat Is there 12V s at the K3 coil Replace the A2 control box assy Does the shaker motor run See hydraulic shaker motor troubleshooting section B Ribbon connector see Ele
24. faulty Is there 12V s at the S2 coil Replace the S2 solenoid coil Substitute a new A2 control box assy Does motor run Check the adjustment amp operation of the S2 magnetic broom SW Check SW continuity it must test open w broom lever lowered Clean metal from SW or replace shorted SW Does motor run FORM NO 56043129 SR 1900 33 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Main broom motor will not run Part B Hydraulic Load Circuit Note 1 Do all testing with the engine running at high speed the main broom lowered sweep position and the drive pedal activated machine moving Note 2 The main broom magnetic switch S2 must be open and also the hopper interlock switch S4 closed for the main broom system motors to run Main broom motor will not run Inspect the main broom motor drive lug and sweeping broom inserts for mechanical damage Make repairs to Remove and disassemble Replace the damaged parts L2 main broom motor valve L2 main broom control valve Inspect clean and reinstall cartridge Does the motor run Does the main cartridge broom motor run turn Does the motor run Replace the main broom motor 34 FORM NO 56043129 SR 1900 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Side broom motor s will not run Part A Electrical Control Circuit Note 1 Do all testing with the engine running at high speed th
25. manifold has a return or bleed circuit that is comprised of a 020 orifice and a 6 psi check valve that connects back to the equipment fuel tank This circuit is used to bleed off any vapor that develops in the line and returns a small amount of fuel to the tank The fuel comes from the fuel tank and passes through the inline fuel pump Fuel exits the fuel pump passes through the filter and then enters the fuel pressure and temperature manifold assembly Fuel flows through the feed circuit and is delivered to the fuel injector rail Fuel that enters the bleed circuits through the by pass valve in the manifold is returned to the fuel tank FORM NO 56043129 SR 1900 55 ENGINE SYSTEM FIGURE 3 Firing Order FIGURE 4 Cylinders 1 Engine Fuse Box A F2 20 Amp Fuse for ECM input B F4 15 Fuse for ignition C F6 15 Amp Fuse for starter relay coil D 10 Amp Fuse for EPR F5 15 Fuse for Fuel Pump relay coil F F15Amp e VSW G 60 Amp Maxi Fuse alternator power relay coil H Power Relay Alternator J Fuel Pump Relay K Engine Starter Relay 56 FORM NO 56043129 SR 1900 HYDRAULIC SYSTEM HYDRAULIC SYSTEM TROUBLESHOOTING Accurate measurements are the key to troubleshooting a hydraulic system Once measurements are obtained they can be compared with specifications to analyze a problem To
26. ow Plug RELAY NEUTRAL E4 Glow Plug Lee CLOSED INNEUTRAC GRABLU GRABLU GRABLU CONTROL BOX H CIRCUIT BREAKER 15 AMP ASSEMBLY 61 Alternator STARTER zi 2 j RED BH K4 Relay Neutral E RED s 8 Relay Acc Diesel only PINK BYB PINK ES E a S ALTERNATOR M2 Starter Pigg R7 Sender Temperature 1 527 PINK A S A PINK REDMEL 1 RED HENTER S7 Switch Ignition 4 mou esee ORN GRN 1 2 PINK 112 4 0 RED YEL L9 SAT eS Sule SWITCH IGN CIRCUIT BREAKER 10 AMP 5 I LPG LPG LOCK OFF X111 SoL GASOLINE Y VALVE 501 PINK Y VALVE BLK ae BOX POWER FUELPUMP CARBURETOR GRNYEL 1 GRN YEL An x2 S8 VIO BLU EXE VIO BLU 1 2 70 FORM NO 56043129 SR 1900 SWITCH COOLANT TEMP YEL BLK 16 2 YEL BLK 18 9 YEL BLK 18 10 1 1 SP2 2 LP1 X4 18 23 B 250 YEL BLK 18 9 A A HEAD LIGHT RIGHT SP11 BLK 1842 2 1 LP3 VIO YEL 18 3 2 1BLK 2 WHT SP12 LAMP RIGHT FRONT SIGNAL OPTIONAL M5 4 MOTOR ASM WIPER INCLUDES 2 SPEED SWITCH BLK 18 13 2251 SP13 S GRN 18 1 B K X WH SP14 lt gt LAMP LEFT FRONT SIGNAL OPTIONAL 3 LP2 lt B 20H IA HEAD LIGHT LEFT X4 BLK 18 11 B YEL BLK 18 10 A revised 8 09 24 S
27. position Raise the brooms Place the Engine Speed Switch GG in IDLE and let the engine idle for 25 30 seconds Turn the Ignition Key Switch TT OFF and remove the key Apply the Parking Brake F O SHUT DOWN THE PROPANE ENGINE T 1 Turn all controls to the OFF position 2 Raise the brooms 3 4 5 RC Turn the service valve on PROPANE Tank 21 OFF Run the engine until all the PROPANE is dispelled from the line the engine will stall Turn the Ignition Key Switch TT OFF and remove the key NOTE The 4 cylinder LPG engine will continue to run for a few seconds after switching the key to off This is part of the proper operation of the closed loop electronic control system 6 Apply the Parking Brake F 10 FORM NO 56043129 SR 1900 MAINTENANCE IMPORTANT MACHINE LUBRICATION Rear Steering Yoke Bearing Assembly Once every 150 hours attach a grease gun to the yoke bearing pivot zert location under operator s seat and pump a small amount of grease into bearing assembly Also every 150 hours apply light machine oil to maintain free movement of all general pivot points Example the seat and broom door hinges etc Broom and hopper pivots use composite bearings lubrication is not required A WARNING For the protection of the environment when servicing any of the machine s lubrication fluids they must be disposed of safely in accordance with your local environmental regulations recycling Ex
28. the next four pages Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text 1 Engine Compartment Cover 2 LeftSide Main Broom Access Panel 3 Battery 4 Center Cover Assembly 5 Hopper Safety Support 6 Hopper Cover Latch 7 HeadLight 8 Jacking Locations rear location is large weight below radiator 9 Side Broom 10 Side Broom Height Adjustment Knob 11 DustFilter Shaker Assembly 12 Hopper Dust Control Filter 13 Shaker Assembly Retainer Knobs 14 Hydraulic Oil Filter 15 Coolant Recovery Tank GM location 16 FORM NO 56043129 SR 1900 pd YOUR MACHINE CONTINUED Hopper Cover Hopper Cover Prop Rod 18 Right Side Main Broom Access Panel 19 Oil Reservoir 20 Oil Reservoir Fuel Tank Cover 21 Fuel Tank LPG tank shown Gasoline tank is in same location 22 Coolant Recovery Tank diesel location 23 Radiator Cap 24 Engine AirFilter diesel location 25 Fuel Tank Cover Release Latch 26 Tie Down Locations 5 27 Air Filter Service Indicator 28 Engine Air Filter GM location 27 24 23 2 0 N SS NSS SSSS 5552 53 5555555 M SS 82 255 gt gt 2 Sessss NW N 8 22 25 21 19 16 17 18 FORM NO 56043129 SR 1900 17 KNOW YOUR MACHINE OPERATOR S COMPARTMENT erator s Sea 18 FORM NO 56043129 SR 1900 KNOW YOUR MAC
29. the sweep system components and sends its hydraulic oil flow to tank when S6 is de energized 0 volts HYDRAULIC MANIFOLD ASSEMBLY COMPONENT LOCATION KEY Note the combined electrical solenoid and hydraulic valve cartridge assembly can be serviced separately Item Component Description amp Hydraulic Circuit Function 1 Solenoid coil amp valve cartridge hopper dump door open coil 8 Ohms S2 Solenoid coil amp valve cartridge main broom System coil 8 Ohms S3 Solenoid coil amp valve cartridge side broom system coil 8 Ohms 54 Solenoid coil amp valve cartridge dust control wand state coil 8 Ohms 55 Solenoid coil amp valve cartridge hopper lift system raise coil 8 Ohms S6 Solenoid coil amp valve cartridge hydraulic circuit on off by pass 8 Ohms 57 Solenoid coil amp valve cartridge hopper Dump door close coil 8 Ohms 58 Solenoid coil amp valve cartridge dust control fan off by pass coil 6 Ohms S9 Solenoid coil amp valve cartridge hopper lift close coil 8 Ohms Notes The solenoid coils w connector 1 S7 amp S9 are identical and can be swapped for T S troubleshooting B The solenoid coil w connector 58 is different only one is used C The valve cartridges for 1 2 amp 4 are identical 53 amp S7 the same and 5 amp S9 the same and can be swapped for T S D The S6 amp S8 valve cartridges are different configurations one of each are only use
30. thoroughly check the engine cooling system Check coolant level in overflow tank and radiator Inspect and clean radiator and hydraulic oil cooler Check for proper operations of the belt driven engine cooling fan slippage Check to see that the engine thermostat opens Check for proper operation of water pump Check engine crankcase oil level Over Temperature Protection The GM 1 6L engine will set a diagnostic test code DTC 116 after 5 sec at temperatures over 215 F and a power derate level one will be enforced This engine fault will limit the maximum throttle position to 50 With further overheating the engine will set a code DTC 217 after 10 15 sec at temperatures over 225 F and the engine will then shut down Loss of Oil Pressure Protection Engine shutdown if oil pressure is only 3 7 PSI 4 Cylinder Engine G P D Speed Settings Fast Engine Speed 2400 RPM Idle Engine Speed 1200 RPM GM 1 6L GASOLINE FUEL SYSTEM DESCRIPTION This engine is equipped with a fuel injector rail that does not have a pressure regulator Fuel pressure for this engine is regulated by the engine s ECM controlling the fuel pump via pulse width modulation The ECM receives fuel pressure and temperature feedback from the gasoline fuel sensor manifold and uses this information to control the ground side of the fuel pump Fuel pressure is regulated by the ECM pulse width modulating PWM the fuel pump The fuel pressure and temperature sensor
31. with an adjustable tow valve This valve prevents damage to the hydraulic system when the machine is being towed pushed short distances without use of the engine To access the valve unlatch and open the Oil Reservoir Fuel Tank Cover 20 and then open the Engine Compartment Cover 1 and locate the hydrostatic pump at the rear of the engine Turn the valve 90 degrees this disengages the hydrostatic lock between the motor and pump WARNING The hydraulic propelling pump can be damaged if the machine is towed with the valve in the normal working position A Reference the illustration on the following page for the normal working setting A vertical and the free wheeling towing setting B horizontal Note If the tow valve is left in free wheeling B horizontal position the propelling pump can t drive the machine FWD or REV No damage will result just re set valve to the normal working setting A vertical NOTE Tow or push machine no faster than a normal walking pace 2 3 miles per hour and for short distances only If the machine is to be moved long distances the drive wheel needs to be raised off the floor and placed on a suitable transport dolly 4 FORM NO 56043129 SR 1900 P Z gos 6 AY 127 x g e 22 7 3 2 6 A UM 2 NC Z JU av 27 FORM NO 56043129 SR 1900 5 OTHER MANUALS AVAILABLE The following manuals are available from the N
32. with code 1654 Code 1654 confirms the system has entered the blink code mode The ECM will flash code 1654 3 times before displaying the actual DTC code that may be set Example One short blink pause six short blinks pause five short blinks pause four short blinks If no DTC codes are found the ECM will continue to flash 1654 only This means no stored DTC codes were found FIGURE 2 Jumper across top row at outside pins ORN amp BLK GRN Pin 1 Communication Port Protective Cap FORM NO 56043129 SR 1900 53 ENGINE SYSTEM 1 6L DTC Code to SPN FMI Code Cross Reference FMI 16 535 8 91 Fuel Pump Low Voltage 94 4 127 IAT Higher Than Expected2 105 0 171 Adaptive Learn High Gasoline 520200 0 217 ECTHigherThanExpected2 110 0 221 TPS2SignalVotagelow 51 0 606 69 31 1112 SparkRevlimt 515 0 1151 Closed Loop Multiplier High LPG 520206 0 1155 Closed Loop Multiplier High Gasoline 520204 0 1161 Adaptive Learn High LPG 520202 o 1171 LPG Pressure Higher Than Expected 520260 0 2220 7 BPPressueHigh 108 0 54 FORM NO 56043129 SR 1900 ENGINE SYSTEM MISCELLANEOUS ENGINE SYSTEM INFORMATION Additional Engine Troubleshooting Symptom Engine Overheating Use the checklist below as a guide to
33. 0 x 1 75 8 Hose Hydraulic 18 Wsh Fit SAE 1 4 9 Hose Hydraulic 19 Elbow 90 W Nut 56507609 REF 56507537 REF 56507604 REF FORM NO 56043129 SR 1900 63 THIS PAGE IS INTENTIONALLY BLANK 64 FORM NO 56043129 SR 1900 HYDRAULIC SYSTEM COMPONENT LOCATION Item Description 1 Drive Motor Assembly 2 Dust Control Motor Assembly 3 Filter Assembly 4 Hopper Door Cylinder 5 Hopper Lift Cylinder 6 Oil Cooler 7 Main Broom Motor Assembly 8 Manifold Assembly 9 Pump Assembly 10 Reservoir Assembly 11 Side Broom Cylinder Assembly Right 12 Side Broom Motor Assembly 13 Steering Control Unit 14 Steering Cylinder N BN j D aN Sa Ds eS Z T gt QJ se N SET N q a L lt W Sk Q 1 N lt Ez at e FORM NO 56043129 SR 1900 65 X HYDRAULIC SYSTEM HYDRAULIC SCHEMATIC 66 FORM NO 56043129 SR 1900 DUAL SIDE BROOM OPTION SIDE BROOM LIFT 25 PSI 9 SIDE BROOM SIDEBROOMLIFT 1 00 1 18550 MAIN BROOM z7 gt Optional Dust Control On Wand State 67 z o a 2 0 6 3 gt 5 5 oa a g D I d gt 9 x 3 lt 58 282 e O B26 sak e c a 2 S o c mn 3 LO 5 l raw E ss o S
34. 1 928 498 060 TERMINAL 1928 3 LT GREEN 18 TT GREEN RED 18 YELLOW GRAY 18 GREEN 1 LI GREEN RED 18 20 BIK LT GREEN 18 21 PURPLE WHITE 18 22 WHITE PURPLE 18 BLACK LT GREEN 18 B TWIST WIRES 19 TURNS 36 DEG FOOT FULL LENGTH CONNECTOR 2 PINK DK GREEN 16 12V RELAYED POWER AAA A A A AA SPEED 1 AUX PD1 PED 15326868 CONN SPEED Vs PED_ 15304707 TERM KNOCK1 RED WHITE VS PED_ 12191153 SEAL KNOCK AUX DIG 2 KNOCKQ PED 12065287 CONNECTOR GRECE SEDE 8 cov SELECT 1 SPARK COIL 1A PED 12103881 L TERMINAL OIL PRESSURE GRAY ORANGE 18 J GOV SELECT 2 SPARK COIL 18 DK BLUE YELLOW 18 TH AUX ANA PUT SPARK COIL 2A I5 33 YELLOWZRED 18 LT GREEN RED 18 YELLOW OK BLUE 18 GT AUX ANA PUZ SPARK COIL 28 gt 34 TAN 18 F AUX PWM 1 SPARK COIL 32 LT BLUE 18 c 18 E GROUND SPARK COIL 38 35 SPARK COIL 4A BLACK LT GREEN 18 BROWN WHITE 16 C AUX PWM 5 SPARK COIL 48 AUX PWM 5 RECIRC UNUSED AUX DIG 1 AUX DIG 2 TAN WHITE 18 41 WHITE RED 18 2 TAN RED 18 4 TANZBLACK 18 AUX DIG ALCUN Em VEHICLE INTERFACE CONNECTORS 5 AUX ANA 3 AX ANA 47 YELLOW DK BLUE 18 CONNECTOR 1 FRT AUX ANA PUS FPP2
35. 150hrs 300 hrs 1000 hrs Rotate main broom X Inspect adjust brooms X Check Clean Hopper Dust Control Filter Using Method X Inspect broom housing skirts X nspect hopper seals X Clean radiator and oil cooler X Perform engine maintenance X Inspect and grease steering spindle X Check Clean Hopper Dust Control Filter Using Method X Check Clean Hopper Dust Control Filter Using Method X Change the hydraulic charge oil filter X Change reservoir hydraulic oil X Flush the radiator X All engine fuel filter s See the Mechanical Repair section and Operator Manual for detailed maintenance information of systems listed Sweeping Hopper Steering amp Dust Control Fuel filters replacement 400 hrs or yearly Reference the Parts List for engine type and filter part number AFTER USE 1 Shake the Hopper Dust Control Filter LL and empty the hopper 2 Check the maintenance schedule and perform all required maintenance before storage 3 Move the machine to an indoor storage area 4 Shutdown the engine according to the shut down procedures 5 Make sure the Ignition Switch TT is OFF and the Parking Brake is engaged NOTE It is safe to clean this machine with a pressure washer as long as you do not spray directly at or into electrical components The machine should always be allowed to dry completely before each use TO SHUT DOWN THE DIESEL GASOLINE ENGINE 1 Turn all controls to the OFF
36. 1737100 AND E1737200 5 STARTER 2 z X10 1 um uc 5 5 ar ENGINE GROUND 953 cil g 20 12522 3355 E GASOLINE lt zc 25 gana 52 SENSOR BC zz uas ak ou lt SUZ OE T gt o9 i20 88 ER X78 22222222222022224 o6oYYYCCOCCCYYYYXYYYYY 2224 g ag moouulorox azzacceo xz 223 iz 555 A x Wb ome ud 5 43 age 5821 8008 FEE aa E 8 gt x x 2 2 B Sl 9 253 2522 a Aoa zio o m GRN BLK 16 1 T KUBOTA DIESEL ENGINE SYSTEM SWITCH IGNITION RED 10 1 GRN BLU 14 1 ORN GRN 18 1 A4 AC 50 J2 X83 WHT GRA 18 1 8 1 YEL GRA 18 1 INSERT GRN RED WIRE INTO TERMINAL 6 WAY GRN RED 10 1 RED BLK 18 1 9 2 ORN GRA 18 1 POSITION 6 ON CONNECTOR J2 AT X154 WHT GRN RED 18 2 YEL VIO 18 1 10 3 BHN WHT 18 1 THE CONTROL BOX ASSEMBLY BED162 A A RED ACTUATOR f 6 PINK 18 1 11 4 GRANEL 18 1 B ACTUATOR WHTBLK 1 ORNjBLK 183 12 5 GHN YEL 18 1 D2 BLK 16 13 B B BK gt 13 6 18
37. 18 ENGINE HARNESS FOR 1 6L LPG PED 12162197 CONNECTOR GRAY PED_ 12124075 TERMINAL WHITE RED 18 LACK LT GREEN 18 B PED 12052641 CONNECTOR PED_ 12048074 TERMINAL PED_ 12052634 LOCK PED_ 12048086 SEAL PED 12160825 CONNECTOR PED 12177150 TERM GOLD 12089678 WIRE SEAL PED 12160826 LOCK BLACK WHITE 18 BLACK LT GREEN 18 PINK DK GREEN 18 gt EGO 1 AMP_ 174257 2 CONN _171662 1 SEAL 184140 1 TERM 18 SUGE 184141 1 TERM 16 GAUGE Eco abe 3 DK GREEN WHITE 18 eee 18 ty GREEN ORANGE 18 AMP 1742887 LOCK EGO 3 lt 8 2 3 50 Ale 5 PURPLE LT BLUE 18 LPG TEMPERATURE TES lt 5 LT BLUE OK BLUE 18 GREEN TE AUX ANA 9 BLUE ORANGE 18 EPPA VS FE 16 PURPLE YELLOW 18 AUX ANA PD2 lt 1 AUX ANA PD3 lt CAN TERM CANT E gt 2 2 2 TERM EXT 12 13 WHITE ORANGE 18 14 BLUE PINK 18 1 15 BLUE WHITE 18 23 16 17 18 19 LT GREEN RED 18 I BOSCH KOMPAKT 1 928 403 736 CONN 1 928 498 060 TERMINAL 1 928 300 599 SEAL 18 PED 12162193 CONNECTOR PED_ 12103881 TERMINAL BLACK LT GREEN
38. 18 TACH BROWN WHITE 16 AUX PWM 5 WHITE BROWN 16 AUX PWM 5 RECIRC S R P N M L K J H G F E D C B A UNUSED CONNECTOR 1 LT GREEN PURPLE 18 S 5V EXT 2 FPP2 ONLY LT GREEN BLACK 18 R 5VRTN2 BLUE WHITE 18 B PINK 18 CAN1 LT GREEN RED 18 5VEXT 1 BLACK LT GREEN 18 1 5VRTN 1 DK BLUE ORANGE 18 K FPP1 PURPLE YELLOW 18 4 FPP2 IVS UNUSED H FUEL SELECT AUX DIG 1 FUEL SELECT TAN BRN 16 1 GREEN YELLOW 18 G MIL MIL OUTPUT GRN YEL 18 1 LT BLUE PINK 16 E START COMMAND START COMMAND BLU PINK 16 1 DK BLUE 18 E AUXPWM 1 PINK YELLOW 16 D FUEL PUMP FUEL PUMP PINK YEL 16 1 BLACK RED 16 C FUELPUMP FUEL PUMP BLK RED 16 1 PURPLE 16 ALT EXCITE ALT EXCITE PINK 16 7 PINK 18 A VSW IGN SWITCH INPUT PINK 16 4 GASOLINE SENSOR INTERFACE X78 BLACK LT GREEN 18 WHT GRN 18 1 GASOLINE LT GREEN WHITE 18 GRN RED 18 1 LT GREEN RED 18 GRN WHT 18 1 2 MODELS ONLY WHITE LT GREEN 18 BLK GRN 18 1 DIAGNOSTIC CONNECTOR BLACK LT GREEN 18 ANA RTN LT GREEN RED 18 5V REF DK GREEN 18 PC TX ORANGE 18 PC RX UNUSED UNUSED BLUE PINK 18 CAN1 1 2 3 4 5 6 7 8 BLUE WHITE 18 CANT ELECTRICAL SYSTEM FIGURE 1 Access windows
39. 2 P vodas 6 G AOL MAGNETIC PICKUP BLK 18 3 14 7 2 SPEED SELECT 4 MAGNETIC PICKUP SEN 3 R7 SPeS P Mc RATES D D GR SPEED SELECT 2 Ove S9 57 SERVICE TOOL Tx t LORN 1 2 2 1 TAN 18 3 SP24 SP26 SERVICE TOOL Rx SWITCH COOLANT TEMP SENDER TEMP 1 5 APECS 3000 GOVERNOR BLK 18 5 ele a3 GRN YEL 18 3 8 95 6 1 S 5859 3 3 E 3 S RED 12 2 TT 825 ME ua 2 T ddd Zz g 54 VF 22 CIR BKR 70 in ENP L L 142 5889 3 g MAIN P 9 gt ALTERNATOR M M o S28 x Y a 38 GRA BRN 18 1 208 2 2 NOL B RED163 3 5 45 525 3 amp SOME RED YEL187 a 56 5 825 i 5 2 s 85 28 amp X151 1 2 88 Sad daa 9 gt CIR BKR 20 AMP X150 SWITCH OIL PRESS RE M7 ACCESSORY D 113 Z Z z O ulu cQ O m lt CONNECT VIO 14 1 2 2 3B UB 2 x140 TO VIO 16 1 VIO TERT E x K7 16 6 AND VIO 14 2 eU pee STARTER a gi ed T X ET EI EI 86 85 8 1 oxra Z Z x gt do u o o mwmoonuuor x Jazzazco 30 87a 9 1 1 4 201212 1 lt uh d BLK 1 1 1 3 e RELAY ACCESSORY 1 me DIESEL ONLY BLK 6 1 5 8 39 x E X10 2 27 8 59 225 2 2 gt
40. 2177158 TERM GOLD PED 12089678 WIRE SEAL PED 12160826 LOCK GCP 9 WAY CONNECTOR GASOLINE SENSOR INTERFACE LT GREEN RED 18 WHITE LT GREEN 18 GREEN WHITE 18 PINK DK GREEN 18 BLACK YELLOW 18 BLACK LT GREEN 18 DK GREEN ORANGE 18 PINK DK GREEN 18 BLACK WHITE 18 PED 12160825 CONNECTOR PED 12177150 TERM GOLD PED 12089678 WIRE SEAL PED 12160826 LOCK 0 PED 12160482 CONNECTOR PED 12048074 TERMINAL PED_ 12160480 LOCK DK GREEN ORANGE 18 DK 18 LI GREEN RED 18 EGO EGO2 Fa LT BLUE 18 1 s 25 comecror EGOS 211 A 92 9282 car 4 m 211 9o COR 21 Ce 2e 1468 TERMINAL COLD TPS2 LT BLUE 18 LT GREEN 18 18 BLUE ORANGE 18 12 PURPLE YELLOW 18 MAP AUX ANA PD1 1 2 NS AUX PUD2 AUX ANA PUDS TERM CANT MHITE ORANGE 18 14 BLUE PINK 18 PED 12162193 CONNECTOR PED 12103881 TERMINAL AN2 BOSCH KOMPAKT 1 928 403 736 CONN CAN2 1 928 498 6 TERMINAL 2 VEHICLE INTERFACE CONNECTORS CE LT GREEN RED 18 BLACK LT GREEN 18 B V EXT 28 Bra GREEN GREEN 18 21 PURPLE WHITE 18 22 WHITE PURPLE 18 GREEN RED 18 CRANK YELLOW GRA
41. 35 c GS oo 2 oO saegC St S x gt 5 224 2 55 55 55 o A 20204005555 lt co co Ci co gt a r X 9 0 9 TE 5 2 BR T Zeg 2 s 5 9 gt S lt G O lt e oz 5 z Sote 5268 lt CO iO CO CO CO iO C C No 2 ME S 252 C G G G 00 G OC D o o o o o o 22 D IT D Pp 2 2 Sees 2555555555 6565 8 oh S S S G ooooco CO xt NOOR OO x Item Description Kubota diesel fuel tank shown ELECTRICAL SYSTEM WIRING DIAGRAM 1 of 3 Item Qty Description A3 5 1 2 CB3 CB4 CBS CB6 CB7 CB8 CB9 E13 F1 H1 K1 K2 K3 K4 K5 K6 1 2 LP3 LP4 LP5 LP6 LP8 LP9 LP10 LP11 LP12 M2 M3 M4 P3 R1 R3 1 922 S24 525 526 Controller Manifold Fuel GM Engine only Battery 12Vdc Circuit Breaker 70 Amp Main Circuit Breaker 20 Amp Headlights Circuit Breaker 15 Amp Starter Circuit Breaker 20 Amp Accessories Circuit Breaker 10 Amp Ignition Circuit Breaker 20 Amp Shaker Circuit Breaker 15 Amp
42. 4 1 SEAL WHITE 16 3 ol 7 RED TAN 16 F6 RED 1 LTBLUE PINK 18 86 STARTER RELAY 15 PINK BLACK 18 STARTER NOTES F4 1 ALL WIRE MUST BE SAE J1128 TXL TYPE PINK DK GREEN 16 PINK DK GREEN 16 Fi 2 HARNESS TO BE LABELED WITH PART AND REVISION LEVEL 15A PINK TAN 18 VA PINK 18 3 ALL CONVOLUTE MUST BE FLAME RETARDANT POLYPROPYLENE IGNITION 5A VSW PINK DK GREEN 16 60A WHITE LT BLUE 18 85 F3 m ed PINK DK GREEN 16 RED LT BLUE 16 MAXI FUSE sepa 18 77 QA 7 POWERRELAY EPR DENN RING OR EHE PURPLE LT BLUE 18 RED 1 5 RED 1 N RED 12 ALTERNATOR 2 BLK LT GREEN 18 H BOSCH THROTTLE EPR CONNECTOR BATT PED 12162193 CONNECTOR 1 TANZORANGE 18 1 967616 1 CONNECTOR 965906 5 TERMINAL 967067 1 SEAL CAN CAN TERM CAN BLUE PINK 18 UNUSED UNUSED BLACK 16 GROUND VBAT UNUSED RED LT BLUE 16 776286 1 CONN 770520 1 TERM RED 16 PED 12103881 TERMINAL A PURPLE 16 B ALTERNATOR 10MM RING BLACK 10 6MM RING ALTERNATOR GROUND FORM NO 56043129 SR 1900 75 LECTRICAL SYSTEM ENGINE HARNESS FOR GM 1 6L GAS Petrol Tier 3 EGO 2 EGO 1 OIL PRESSURE SWITCH PED 12065287 CONNECTOR 12103881 L TERMINAL PED 12160825 CONNECTOR PED 71
43. 5 1900 Quick Start Troubleshooting Manual Models 56507009 4 cyl LPG 56507010 4 cyl Petrol 56507011 4 cyl Diesel 2 09 Revised 8 12 FORM NO 56043129 trusted since 1906 ONilfisk Printed in USA TABLE OF CONTENTS GENERAL INFORMATIONS m 3 6 SAFETY INSTRUCTIONS TECHNICAL SPECIFICATIONS L ar NE A cta tart te cha cerae iced 8 9 MAINTENANCE PM CHECKLIST is KNOW YOUR MACHINE rn citri teint dete P e nk HR HEY e E Ee OPERATOR S 2 hates inttr strict ct eire trice caca dba entr tr na c E CONTROL CONTROL PANEL DIAGNOSTICS GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF 22 20 2 2 000000 22 ENGINE TROUBLESHOOTING FLOW CHARTS WHEELIDRIVE SYSTEM s iiti ti ii rire er Eee aS Hn eR EAD aus Gala ds TROUBLESHOOTING CHECK LIST nitate tutte STEERING SYSTEM citi ne e ae t e o KE Ene ad en ER STEERING SYSTEM TROUBLESHOOTING ee necessities TROUBLESHOOTING uds rk SWEEPING SYSTEM tetti eere titanic askai aayqa rct feng ann de tn s de p SIDE BROOMS EUM DUST CONTROL IMPELLER irn te u u A upas Sua usha Sai oed SHAKER MOTOR m
44. 5K Ohm 2 Switch Main Broom S3 Switch Low LP Pressure 54 Switch Hopper Interlock S5 Switch Dust Control Filter optional S6 Switch Hopper Temp optional 26 Switch Misting Pump optional TPS1 Touch Pad Switch Engine Speed TPS2 Touch Pad Switch Horn TPS3 Touch Pad Switch Lights TPS4 Touch Pad Switch Shaker TPS5 Touch Pad Switch Dust Control TPS6 Touch Pad Switch Side Brooms TPS7 Touch Pad Switch Hopper Door Open TPS8 Touch Pad Switch Hopper Up TPS9 Touch Pad Switch Hopper Down TPS10 Touch Pad Switch Hopper Door Close FORM NO 56043129 SR 1900 69 ELECTRICAL SYSTEM WIRING DIAGRAM 3 of 3 Kubota Diesel Engine System Ref No Qty Description 56507376 Sheet 3 of 3 KUBOTA 972 ENGINE SYSTEM A4 ACPECS 3000 Governor BT Battery 12 Vdc BT DAN RED BIK CB1 Circuit Breaker 70 Amp uu CB3 Circuit Breaker 15 Amp CB4 Circuit Breaker 20 Amp 9 x ra CB5 Circuit Breaker 10 Amp F2 D2 Diode i O e 03 Diode RED Q o o 1 Glow Plug 5 THROTTLE INPUT E2 Glow Plug CIRCUIT BREAKER 0 AME K BLU PINK E SE BLU PINK 12V FOR HIGH E3 Glow 1 RED GRN 30 87 ed THROTTLE CONTROL MODULE
45. ALT EXCITE TACH L START COMMAND RED TAN 1 K 1 AUX PWM 1 INI LS PINK YELLOW 1 FUEL PUMP FUEL PUMP 2 15 TWIST WIRES 10 TURNS 360 DEG FOOT FULL LENGTH Weg INJ4 LS vw INJS LS INJ6 LS PED 12162859 CONNECTOR PED 12124275 TERMINAL g YELLOW RED 18 10MM RING O GROUND BLACK 12 c D IGNITION COIL PINK DK GREEN 1i DIAGNOSTIC CONNECTOR EPC_ 1FIT 14A624 AA 004 CONN GTS 0330 930009 TERM 18 20 GTS 0350 940001 TERM 14 16 EPC_E6DB 144468 DA LOCK EPCL FBAB 14 666 STARTER SOLENOID PWMS PWMS RECIRC VBAT PINK7DK GREEN 16 RED TAN 16 IREEN YI K 1 W 1 MILI GND TEMP DBW TAN ORANGE 18 DBW FPUMP PED 12110539 CONN INK YI T 12110548 LOCK RED TAN 14 AUX PWNS S BLACK RED 1 CRANK SENSOR BED 12129409 TERM 14 18 AWG AX AMP 4442721 CONN 12010300 CAVITY PLUG IF NEEDED AMP 927772 1 TERM 828904 1 SEAL STARTER AUX PWM4 PINK BLACK 18 AUX PWM4 RECIR F6 RED TAN 1 STARTER RELAY LT BLUE PINK 18 15A STARTER PINK BLACK 18 NOTES 1 ALL WIRE MUST BE SAE J1128 TXL TYPE 2 HARNESS TO BE LABELED WITH PART AND REVISION LEVEL 3 ALL CONVOLUTE MUST BE FLAME RETARDANT POLYPROPYLENE F4
46. AY DK BLUE 18 BLUE WHITE 18 CANI PED 12191819 TERM 52 GRAYZRED 18 BLUE PINK 18 CANI PED_ 12191153 SEAL it Pee IUE T IRE RTI REI NOI PED_ 15358785 LOCK AUX ANA PUD1 K NGE 1 p 55 GREEN 18 DK BLUE ORANGE 18 FPP1 ERE ORANGE 18 PURPLE YELLOW 18 FPP2 NS RAY 1 PROT d 60 RED TAN 16 amp AUX PWM 2 u ti 61 BROWN LT BLUE 18 PINK YELLOW 16 D FUEL PUMP Bus Ls 62 BROWN LT GREEN 18 BLACK RED 16 FUEL PUMP _ ing Le BLUE PINK 18 BLUE PINK 18 ALT EXCITE rdr PINK 18 VSW a PED_ 12162859 CONNECTOR BLUE WHITE 18 BLUE WHITE 18 INJ6 LS TWIST WIRES 10 TURNS 360 DEG FOOT FULL LENGTH INJ7 LS INJB LS GROUND STARTER RELAY EGOH 1 EGOH 2 3 LOCKOFF 4 BUZZER PED_ 12124475 TERMINAL Sun YELLOW RED 18 Y 1 16 1 10MM RING O GROUND wer 1 PINKZDK GR 7 D 73 BLACK YELLOW 18 IGNITION COIL PINK DK GREEN 18 BLACK LT GREEN 18 LT GREEN RED 18 DIAGNOSTIC CONNECTOR 77 BROWN WHITE 16 lt DK GREEN 18 PWNS EPC_ 1F1T 14A624 AA 004 CONN 7 5 RECIRC L SOLENOID ORANGE 18 GTS 0330 930009 TERM 18 20 VBAT PINK DK GREEN 16 015 330 940001 TERM 14 16 4 MILS EPC E6DB 14A468 DA LOCK 4 BLUE PINK 18
47. Below 32 F 0 C SAE 10W or SAE 10W 30 SAE 10W 40 Oil Filter Use Nilfisk 56482659 200 HRS Change oil and replace oil filter ENGINE FUEL FILTER DIESEL 400 HRS Replace fuel filter cartridge location before injector pump Use Nilfisk P N 56419086 400 HRS Replace fuel filter at electronic fuel pump FORM NO 56043129 SR 1900 51 ENGINE SYSTEM 1 6 liter GM Engine Specifications Engine type Displacement Fuel Gasoline Fuel LP Spark Plugs Spark Plug wiring Engine Firing Order Ignition Timing Engine Rotation Valve lifters Oil Capacity Oil Pressure Cooling System Liquid Cooled 4 Cylinder Single Overhead cam Distributor less 98 Cubic inches 1600 cc 87 Octane Unleaded Gasoline with no more than 10 Ethanol by volume 33 Lbs Tank Size liquid withdrawal system AC DELCO PN 93206675 Gap 032 035 8 mm 9 mm Match Numbered Coil Position to Spark Plug Number front to rear 1 2 3 amp 4 1 3 4 2 Fixed controlled by engine ECM CCW flywheel end Hydraulic 3 7 qts 3 5L with Oil Filter 21 PSI minimum with engine hot at idle 3 5 qts Engine Only ROUTINE ENGINE MAINTENANCE Keep the fuel tank filled This helps to reduce condensation and moisture entering the fuel system gasoline Make daily checks of the engine oil and coolant levels Repair any oil or coolant leaks immediately Check condition of battery water level and cables weekly Keep the eng
48. FORM NO 56043129 SR 1900 77 ELECTRICAL SYSTEM PROGRAMMABLE CONTROL OPTIONS Foot Pedal Neutral Position and Dead band Adjustment FACTORY DEFAULT 2 RANGE 1 3 The various scrub and sweep functions on the Falcon are activated when the foot pedal is moved from the neutral position The engine neutral start relay is also activated when the foot pedal is moved from the neutral position These functions are triggered via a position sensor mounted on the hydrostat Whenever adjustments are made to the hydrostat unit the neutral position will need to be programmed Also the neutral dead band sensitivity can be adjusted if necessary To set the neutral position and adjust the neutral dead band perform the following steps Turn the main power key switch to the off position Depress the foot pedal to the full reverse position Allow the foot pedal to slowly return to the neutral position and do not move the pedal during the remainder of this procedure Press and hold the engine speed switch While holding the engine speed switch turn the main power key switch to the on position Continue to hold the engine speed switch until all indicators turn off approximately two seconds Release the engine speed switch The service indicator will now be lit Pressing and releasing the engine speed switch will increase the deadband to the middle range Pressing and releasing the engine speed switch again will increase the deadband to the maximum
49. HIGH SPEED BRN WHT ORN GRA mf YELIGRA 1 3 DRIVE PEDAL SENSOR 5K OHM CLOSES WITH HIGH HOPPER 86 YELNIO TEMPERATURE 2 t 3 140 DEG SWITCH HOPPER TEMP OPTIONAL CLOSED WHEN HOPPER IS RED BLK DOWN 1 2 BLK SWITCH HOPPER INTERLOCK CHECK ENGINE OUTPUT FROM ENGINE SYSTEM CLOSES WHEN FILTER IS 55 WHT GRA PLUGGED 1 22 BLK IB SWITCH DUST CONTROL FILTER OPTIONAL CLOSES WHEN TANK 83 GRA YEL IS EMPTY 17 2 BLK SWITCH LOW LP PRESSURE OPEN WHEN 2 RUR BROOMISDOWN S2 SWITCH MAIN BROOM BLK BLK BLK COMMON ANODE D1 LED SERVICE INDICATOR LED DUST CONTROL FILTER D3 K LED GLOW PLUG D4 TOUCH PAD DISPLAY LED SERVICE ENG MIL D5 LED LOW FUEL D6 LED HOPPER TEMP D7 LED DUST CONTROL D8 LED HOPPER NOT DOWN ELECTRICAL SYSTEM WIRING DIAGRAM 2 of 3 Ref No Qty Description A2 Control Box Assembly H2 Back Up Alarm optional K1 Relay Horn K2 Relay Lights K3 Relay Shaker K4 Relay Neutral K6 Relay Misting Pump optional L1 Valve S1 Hopper Close Open L2 Valve S2 Main Broom L3 Valve S3 Side Broom L4 Valve 54 Dust Control L5 Valve S5 Hopper Up Down L6 Valve S6 Hopper Up Bypass L7 Valve S7 Hopper Open L8 Valve S8 Dust Control Bypass L9 Valve S9 Hopper Lower R2 Drive Pedal Sensor
50. HINE CONTROL PANEL Fuel Gauge Gasoline and Diesel Only Horn Switch PROPANE Low Indicator Light Headlight Switch Check Engine Light MIL GM 1 6L Only Glow Plug Indicator Light Diesel Only Engine Speed Switch Side Broom ON Down OFF Up Switch Dust Control Indicator Dust Control Switch Plugged Filter Indicator optional Shaker Switch MM Hopper UP Indicator NN Open Dump Door Switch Hopper Over temp Indicator optional Close Dump Door Switch Lower Hopper Switch Raise Hopper Switch Hour Meter Ignition Switch Main Controller Fault Code Light Voltmeter Engine Coolant Temperature Engine Oil Pressure ms 100 2 i S 2 09 FORM NO 56043129 SR 1900 19 SR 1900 CONTROL PANEL DIAGNOSTICS Function of the main controller s service indicator fault blink code display light The A2 main controller will out put a flashing fault code to the operator display panel when or if there is a problem current overloads associated with specific electrical low current circuit controller output functions Examples of circuits hydraulic solenoid coils used to turn on amp off hydraulic loads and numerous relays used for activating machine function such as the headlights horn shaker motor back up alar
51. Hopper lift linkage amp bushings No Remove the main broom then empty the hopper by shoveling debris out of the dump door opening Does the hopper raise Remove and disassemble L9 hopper lower valve cartridge Inspect clean and reinstall Replace the defective L5 hopper cylinder valve cartridge Does the hopper raise Replace the hydraulic hopper cylinder FORM NO 56043129 SR 1900 43 HOPPER SYSTEM TROUBLESHOOTING GUIDE Symptom Hopper will not lower Part A Electrical Control Circuit Note Do all testing with the engine running at high speed and the hopper lower DN switch pressed and held Hopper will not lower Check S9 coil wiring continuity repair if faulty Press amp hold hopper lower switch Back probe the S9 hopper solenoid coil wires Vio amp Yel Grn should read 12V s Is there 12V s at the S9 coil Press amp hold hopper lower SW Yes lt Yes Check for continuity the ribbon connector for pins Check S9 coil resistance Replace the S9 Spec 9 Ohms solenoid coil 43 1 amp 43 8 on the A2 control i Y box See hydraulic hopper raise Replace the A2 troubleshooting section B control box assy Does the hopper Ribbon pins test lower open replace the touch pad switch panel Ribbon connector see Electrical System Figure 1 for detail pin call outs 44 FORM NO 56043129 SR 1900 HOPPER SY
52. M 18 20 4 LE ERO 4 GROUND BLACK 16 w 36 RING BLUEPINK 18 CY EPCL 144666 CAP DBW DBW FPUMP AUX PWM3 RECIRC AUX PWM3 PED 12118539 CONN PED 12110542 LOCK PED_ 12129409 TERM 14 16 AWG PED_ 12015323 SEAL PED 12010300 CAVITY PLUG IF NEEDED RED TAN 14 CRANK SENSOR 444272 1 CONN 927770 1 TERM 828904 1 SEAL PURPLE WHITE 18 B TAN 18 Pray BB DK BLUE 18 AUX STARTER AUX pwm4j gt B2 PINK GLACK 18 AUX_PWM4_RECIRC WHITE PURPLE 18 BLACK 16 87A 16 30 87 F6 STARTER RELAY LT BLUE PINK 18 15A STARTER PINK BLACK 18 85 NOTE 1 ALL WIRE MUST BE SAE J1128 TXL TYPE 2 HARNESS BE LABELED WITH PART AND REVISION LEVEL 3 ALL CONVOLUTE MUST BE FLAME RETARDANT POLYPROPYLENE F4 PINK DK GREEN 16 PINK DK GREEN 16 15A PINK 18 IGNITION PINK TAN 18 PURPLE LT BLUE 18 LT BLUE DK BLUE 18 PINK WHITE 18 LT GREEN RED 18 GREEN 18 1 5 THROTTLE 1 967616 1 CONNECTOR PINK DK GREEN 16 965906 5 TERMINAL 987067 1 SEAL 7 WHITE LT BLUE 18 885 RED 16 30 PINK DK GREEN 14 87 RED TAN 1B 86 7 MAXI FUSE ALTERNATOR PINK DK GREE
53. M GM Woodward gine Sp PU a i governor diesel or A1 throttle control module Kubota 15 4 3 Note the Gra Blu wire is 0 Vs when J1 17 engine is idle is 12 for high speed Check Gra Blu wire for a short to ground 2 Substitute a new A2 control box 16 44 Spare overload 1 12 NA Not used at this time FORM NO 56043129 SR 1900 21 GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE OF CONTENTS Engng SyStelilu cn creto iHa docui 1 6L GM 4 cylinder engine will not crank 1 6L GM 4 cylinder engine will crank but not start 1 6L GM engine will not run at high speed sssssssssseeete nnns Diesel engine will crank but not start Diesel engine will not run at high speed l U l eene Wheel Drive System Troubleshooting check list sssssssseeeneet etn Steering System Troubleshooting guide sse tette tente tentent nM nid ade DET RID HIER n SS Cs EU Main broom will not run Side brooms will not run Side brooms will not ralSeIOWr tert ree rte Dust control impeller will not Shaker motor will not run Hopper 2 Hopper will riot r lSe cette t eri trice Hopper will Mot
54. MP SIGNAL LIGHTS RELAY NEUTRAL RED GAN 16 1 97 VALVE S2 MAIN BROOM M 3 i 22 2 BRN BLK 18 2 X96 86 85 E T 1 22 GRN GRA 18 1 NOTE VIO 18 20 IS USED WITH E VIO 18 2 d ENGINE SYS me MISTING PUMP OPTION 0 5 8 RELAY MISTING PUMP 185 n NOTE FOR DIESEL WIRE CB4 OPTIONAL zo 30 1 974 gRN YEL 16 3 x10 VALVE S4 DUST CONTROL AS SHOWN ON SHEET 2 52 7 188 0 X98 2 lt gt GRN YEL 16 4 P i 122 2 BRN YEL 18 x FLASHER 1 55 8 ion oor 53 58 X186 X187 GRN YEL 16 1 OPTIONAL inu pe RELAY SIGNAL LIGHTS 2 OPTIONAL ORN 16 1 i YU 1 YY Y TY YY YY y Y Y ANE SB HORPERDOOR X69 LP10 c C YEL GRA 18 1 oraozzsavrozouucdgoax moouuoroxazzamro lt 16 22 2 BLU WHT 18 14 BED 18 2 A 9 58 2 BIS B ORN GRA 18 1 BEDS 355 s 2 5 3 E VALVE S6 HOPPER UP BYPASS 1 BLK 18 18 B B 1 3 AISS A BRN WHT 18 1 431 i 3 FE z 1 22 2 BLU GRA 18 1 DRIVE PEDAL SENSOR 5 BLK 6 1 mia qo 2 lt OPTIONAL 5 X82 CHASSIS GROUND 223 5 2 E E Z Z gt 1 1 VIO 18 11 x 4 1 BLK 6 1 2444 2594 L8 S 6 VALVE 88 DUST CONTORL BYPASS Hi as a aem X102 x X 9 i 22 C 2 BRBN18 4 17 Se PINK 16 32 1 PINK 16 7 TE Sus dl 523 1 1 VIO 18 13 F s Ha 5 E a YELBLK 18 1 A YELBLK1849 A A 1 2 2 1622 L9 3 HORN X46 X45
55. N 12 BRN VIO L9 12 VALVE 8 DUST CONTROL BYPASS YEL GRN VIO H2 d VALVE 9 HOPPER LOWER 2 GRN BRN VIO BACKUP ALARM OPTIONAL K1 VIO BRN VIO K2 RELAY HORN YEL WHT VIO RELAY LIGHTS YEL RED RELAY SHAKER TOUCH PAD SWITCHES 1 TPS1 m 2 ENGINE SPEED 52 m 1 2 1 TPS3 HORN 2 TPS4 12 2 LIGHTS 1 TPS5 SHAKER 2 1 6 DUST CONTROL 2 TPS7 1 SIDE BROOMS 2 1 TPS8 HOPPER DOOR OPEN 2 TPS9 1 HOPPER UP 2 HOPPER DOWN 10 m 1 2 COMMON GROUND HOPPER DOOR CLOSE J1 11 J1 5 J1 8 J1 9 J1 15 J1 19 J1 16 J1 44 J3 4 J3 2 J3 3 J3 11 J3 10 J3 9 J3 5 J3 6 J3 8 J3 7 4341 ACC INPUT J2 6 IGN INPUT 42 11 41 18 41 17 4241 42 2 42 3 42 10 42 9 MIL INPUT J2 5 J2 8 A2 CONTROL BOX ASSEMBLY J2 4 J2 12 J1 10 J1 20 J2 14 J4 8 J4 10 J4 6 J4 5 J4 3 J4 2 J4 9 24 4 4 7 GRN RED I GLOW PLUG SIGNAL GRN RED DIESEL ENGINE ONLY PINK FROM IGNITION PINK CIRCUIT 4 GRA WHT RELAY NEUTRAL GRA BLU TROTTLE OUTPUT TO ENGINE SYSTEM GRA BLU 12 V FOR
56. N 16 RED LT BLUE 16 OWERRELAY 10MM RING O MASTERTRACK_ CONN BLUE PINK 18 Be BLUE WHITE 18 PED_ 12162193 CONNECTOR __ PED 12052848 CONNECTOR PINK TAN 18 EPR CONNECTOR PED 12103881 TERMINAL PED 12056198 CAVITY PLUG B BLACK 18 BLUE WHITE 18 CAN AUS ashi PED 12052858 Lock PC RED TAN 18 WHITE 18 CAN TERM gp afl UNUSED BIUE PINK 18 CAN x T UNUSED puree e ALTERNATOR 0 RING PED 12124107 CONNECTOR UNUSED waster TRACK_cap PED 12124107 CONN ALTERNATOR PED_ 12059168 CAVITY PLUG PED 12045773 TERMINAL as PED 12052850 10MM RING PED 12020833 GROUND CAN TERMINATION CONNECTOR 6 6 1 6L LD EPR B Rev PED 12015792 CONNECTOR PED 12010973 CONNECTOR 12124588 TERM FEMALE 14 16 ANG 12009305 TERM MALE 14 18 AWC E2322130 PED_ 12089188 TERM FEMALE 18 20 AWG PED 12089040 TERM MALE 18 20 PED 12015323 SEAL FORM NO 56043129 SR 1900 77 ELECTRICAL SYSTEM Wiring Harness Wiring Harness Component Description Item A ECM Wiring Connector 90 Pins B Gasoline Petrol Fuel Sensor Interface Connector fuel pressure regulation and temperature sensor manifold assembly C Engine Diagno
57. OMPONENT LOGATION du ttes st tts apr eire endo WIRING DIAGRAM i WIRING SCHEMAT C L I A A A ENGINE HARNESS GM LOL GAS n aasan isa ctia tire i cei teo n rt e i n nta ENGINE HARNESS GM VOL rd cad ENGINE WIRING HARNESS GM DETAIL PROGRAMMABLE CONTROL OPTIONS essentia aasan tts ttti tts tte ia Note All references to right left front or rear in this manual are as seen from the operator s stand point 2 FORM NO 56043129 SR 1900 GENERAL INFORMATION INTRODUCTION This manual will help you get the most from your Nilfisk rider Scrubber Sweeper Read it thoroughly before servicing the machine Note Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 14 17 i e B This product is intended for commercial use only PARTS AND SERVICE Repairs when required should be performed by your Authorized Nilfisk Service Center who employs factory trained service personnel and maintains an inventory of Nilfisk original replacement parts and accessories Call the NILFISK DEALER named below for repair parts or service Please specify the Model and Serial Number when discussing your machine Dealer affix service sticker here NAME PLATE The Model Number a
58. ONLY BV EXT 2 5V EXT 2 FPP2 ONLY SV RIN 2 RTN PED 15326863 CONN BLUE WHITE 18 CANI PED 12191819 TERM GOV2 32 GRAY ORANGE 18 BLUE PINK 18 CAN PED 12191153 SEAL LT BUE 18 TTGREENZRED IB M SVEXT FRP AUX ANA PUD T GREEN SV RTN 1 pe Tx 55 OK GREEN 18 DK BLUE ORANGE 18 K FPP PC ORANGE 18 PURPLEAXELLOW 18 FPP2 NS UNUS H_ FUEL SELECT AUX DIG 1 ALT EXCITE RAY 1 REEN YELLOW 1 ML BLUEZPINK 1 START COMMAND 60 RED TAN 16 DK BLUE 18 E AUX PWM 2 INIT LS UNUSED D FUEL PUMP INI2 LS UNUSED _ FUEL PUMP INI LS PURPLE 18 8 ALT EXCITE INu4 LS 18 VSW PED 12162859 CONNECTOR PED_ 12124975 TERMINAL YELLOW RED 18 INJ5 LS INJ6 LS INI7 15 TWIST WIRES 19 TURNS 360 DEG FOOT FULL LENGTH INJB LS z 10MM RING GROUND SETA STARTER O ATE 1 GREEN d GROUND 74 73 BLACK YELLOW 18 EGOH 2 IGNITION COIL PINK DK GREEN 18 1 B3 TAN ORANGE 18 CAN EGOH 3 WHITE BLACK 18 BLACK LT GREEN 18 1 ANA RTN LT GREENZRED 18 2 SV REF DIAGNOSTIC CONNECTOR 78 WHITE BROWN 16 STARTER ORANGE 18 PC RX _ 1 14 624 004 CONN PWNS RECIRC REDAN 16 ERE OK GREEN 16 SOLENOID UUSED GTS e330 950009 TER
59. ONNECT TO GRN YEL 2nd WIRE 188 FROM GRNVYEL 16 3 VIO GRA 12 1 X194 BLK 18 20 CONNECT TO X204 ON SHEET 1 SD zx x z VEL gt zi a 8 X184 18 20 Om _ lt E amp 8 CONNECT BLK WIRE AT X185 FROM K5 d X172 A 5 a X170 T 2 m I CB9 2 2 RED Y RED WITH A C SYSTEM 3 ORN ic 1 M6 IS NOT USED 2 X170 PLUGS INTO X174 CIR BKR 20 AMP MOTOR BLOWER 3 X172 PLUSG INTO X175 HVAC S85 X174 2 l 1 X175 SYSTEM 3 e co 3 al 3 BLK 14 5 2 1 BLK 18 31 33 SEE 32 E BLK 161 PNE t aS lt 9 E 3332 gore SEERE z BP GQ d 25 zx 52597 oo oqa zd m aay X zz m al s 5 a sl al gt gt d u lt L10 x105 a dz O m lt o O q xt K10 1 2 2 2 59 X197 2108 wed 1 L1 2 8 m lt lt L 90 bene VALVE COMPRESSOR E z E RELAY COMPRESSOR x z amp X tc C 2 _ 5 o X207 X208 iiie B um di CONNECT TO L5 CONNECT TO X99 AT L5 534 UM RED RED M 12 87 ME UNPLUG X99 FROM L5 S5 HOPPER 1 2 J ORN ORN T 30 87 BLU MV BLK UP DOWN VALVE AND CONNECT IT THERMOSTAT TO X208 CONNECT X207 TO L5 MOTOR BLOWER MOTOR BLOWER SWITCH PRESSURE RELAY CONDENSER FAN V MOTOR CONDENSER FAN revised 8
60. P vS KNOCK1 e 27 RED WHTE 18 N VS KNOCK 28 TAN BLACK 18 M AUX DIG 3 KNOCK2 29 TAN RED 18 L AUX DIG 2 KNOCK2 e gt 39 GRAY DK BLUE 18 K GOV SELECT 1 spk COL als YELLOW 18 E3 OIL PRESSURE SENSOR DREWENELOW 18 AX ANA PUL COIL 18 gt SPK COIL 2A gt 33 YELLOW RED 18 PED 12176800 CONNECTOR YELLOW DK BLUE 18 6_ AUX ANA SPK 2852 35 LT BLUE TS PED_ 12048074 TERMINAL 8 18 GROUND 2 SPK COIL 3B 9 36 rre ern FROME AX PWM 5 COIL 4A _ COIL 482 358 WHITE BROWN 16 B AUX PWM 5 RECIRC AT 32 YELLOW GRAY_18 TA UNUSED ECTS HM WEARS 18 EGT e AUX DIG 12 42 raN RED 1 AUX DIG 2 4 ipis VEHICLE INTERFACE CONNECTORS AUX DIG 3 gt 44TANZBLAGK 18 d 45 PINK TAN 18 AUX ANA PU1 peti DK BLUE YELLON 18 CONNECTOR 1 AUX ANA 2 lt 47 YELLOW DK BLUE 18 AUX PU3 lt 45 PED_ 15326863 CONN ro ED LI GREEN PURPLE 18 LTGREEN PURPLE 18 S_ EXT 2 FPP2 ONLY 12191819 TERM NLY 5V EXT 2 gt 50 LT GREEN BLACK 18 LT GREEN BLACK 1B R SV RTN 2 12191153 SEAL Con GRAY DK BLUE 18 BLUE WHITE 18 P GOV2 2 P CANI OIL PRESE LT BLUE 18 ITGREEN RED 18 SV EXT 1 AUX AND PUD1 lt 54 BLACK LT GREEN 18 L 5V RTN 1 DK GREEN 18 DK BLUE ORANGE 18 K FPP1 FPPZ NS ALT ED TH FUEL SELECT AUX DIG 1 TACH E gt G ML VBAT PROT F_ START COMMAND VBAT AUX
61. PINK DK GREEN 16 PINK DK GREEN 16 PINK TAN 1 PINK 18 15A IGNITION PINK DK GREEN 16 60A 1 RED 16 PINK DK GREEN 14 87 5 RED TAN 18 POWERRELAY MAXI FUSE 10MM RING O BATT RING ALTERNATOR I 1 LT BLUE DK BLUE 18 RED 12 PINK WHITE 18 RED 16 PINK YELLOW 16 BOSCH THROTTLE PED 12162193 CONNECTOR PED_ 12103881 TERMINAL RED18 PURPLE 16 8 10MM RING BLACK 10 GROUND T FUEL PUMP RELAY 1 967616 1 CONNECTOR 965906 5 TERMINAL AMP 967067 1 SEAL ALTERNATOR 0 RING ALTERNATOR PINK YELLOW 16 RED 16 PINK TAN 18 F5 BROWN LT BLUE 18 BROWN LT BLUE 18 BROWN LT GREEN 18 PINK DK GREEN 18 BROWN LT GREEN 18 PINK DK GREEN 18 15A FUEL PUMP F amp ZB 144464 MA CONN 14474 TERM F3V8 14474 TERM F3V8 14474 TERM 14474 TERM E938 144468 DA SPACER 144468 DA SPACER E938 144468 DA SPACER ED39 1 44468 DA SPACER INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1 FAZB 140464 MA CONN FAZB 140464 MA CONN FAZB 14M64 MA CONN 74 FORM NO 56043129 SR 1900 90 WAY CONNECTOR Fel 211 PC 9 25 9 CONNECTOR 211 A 90 0007 LOCKING CAM 211 90 0008 C OVER 211 CC 2S 1460 TERMINAL GOLD 1 GREEN ORANGE
62. R 2 CRANK TWIST WIRES 10 TURNS 36 DEG FOOT FULL LENGTH BLACK LT GREEN 18 CAN BOSCH TMAP TWIST WIRES 10 TURNS 36 DEG FOOT FULL LENGTH PINK DK GREEN 16 12V RELAYED POWER PED 15244065 m SPEED QAM Pot PED_ 12191153 SEAL 27 WHI VS KNOCK1 28 TANZI K M AUXDG3 29 TAN RED 18 l AUX DIG 2 GRAY DK BLUE 18 K GOV SELECT 1 i COL AI YELLOW 18 Ej OIL PRESSURE SENSOR GOV SELECT 2 32 AUX PU1 Poem YELLOW RED 18 EETA PED_ 12176800 CONNECTOR AUX ANA PU2 SPK COL 2B 9 PED 12048074 TERMINAL AUX 2 SPK COIL 3A 38 PED 12048086 SEAL 16 GROUND SK 38 37 PED 12176801 LOCK BROWN WHITE 16 C AUX 5 38 AUX PWM 5 RECIRC COL 48 UNUSED TAN WHITE 18 AUX DIG 1 AUX DIG 2 AUX DIG 3 VSw AUX ANA PU1 AUX ANA PU2 AUX PU3 FPP 2 ONLY SV EXT 2 SV RTN GOVI 602 TAN RED 18 18 VEHICLE INTERFACE CONNECTORS CONNECTOR 1 PED_ 15326863 CONN PED_ 12191819 TERM 12191153 SEAL Yi IZ DK I N WHITE 1 LT GREEN PURPLE 18 LT GREEN PURPLE 18 SV EXT 2 FPP2 ONLY SV RIN2 CANI CANI SV EXT 1 1 1 LT BLUE 18 WHITE LT DK GREEN 18 LT GREEN RED 18 K LT GREEN 1 DK BLUE ORANGE 18 OIL PRI FRP AUX PUD1 PC Tx FPP2 NS UNUSI FUEL SELECT AUX DIG 1 MI PC RX
63. R SYSTEM TROUBLESHOOTING GUIDE Symptom Hopper will not raise Part A Electrical Control Circuit Note Do all testing with the engine running at high speed and the hopper raise UP switch pressed and held Hopper will not raise Press amp hold hopper Check S5 coil wiring raise switch continuity repair if faulty Back probe the S5 Is there 12V s at the S5 coil hopper solenoid coil wires Vio amp Red Gry should read 12V s Replace the S5 Check S5 coil resistance solenoid Does Spec 9 Ohms the hopper raise Yes No Press amp hold hopper raise SW Check for continuity the ribbon connector for pins J3 1 amp J3 6 on the A2 control box See hydraulic hopper raise Replace the A2 troubleshooting section B control box assy Does the hopper Ribbon pins test raise open replace the touch pad switch panel Ribbon connector see Electrical System Figure 1 for detail pin call outs 42 FORM NO 56043129 SR 1900 HOPPER SYSTEM TROUBLESHOOTING GUIDE Symptom Hopper will not raise Part B Hydraulic Load Circuit Note Do all testing with the engine running at high speed and the hopper raise UP switch pressed and held Hopper will not raise Inspect for possible Repair or mechanical binding of replace damaged parts Does the hopper raise Is the hopper over loaded Weight Capacity is 1000 Lbs Hopper body amp machine frame interference
64. STEM TROUBLESHOOTING GUIDE Symptom Hopper will not lower Part B Hydraulic Load Circuit Note Do all testing with the engine running at high speed and the hopper lower DN switch pressed and held Hopper will not lower Inspect for possible mechanical binding of Hopper linkage Hopper Cylinder Repair or replace damaged parts Does the hopper lower Remove and disassemble Replace the defective L9 hopper cylinder valve cartridge Does the hopper lower L9 hopper lower valve cartridge Inspect clean and reinstall Does the hopper lower A WARNING Support the hopper securely with stands or an overhead supported lifting strap to prevent the hopper from lowering when removing either of the L5 amp L9 hopper system valve cartridges Replace the hydraulic hopper cylinder Note The hopper can be lowered with the engine turned off just by pressing and holding the hopper lower switch FORM NO 56043129 SR 1900 45 HOPPER SYSTEM TROUBLESHOOTING GUIDE Symptom Hopper dump door will not open Part A Electrical Control Circuit Note Do all testing with the engine running at high speed and the hopper dump door open switch pressed and held Hopper dump door will not open Press amp hold hopper Check S1 coil wiring open dump door continuity repair if faulty Switeh Is there 12V s at the S1 coil Back probe the S1 dump door solenoid coil wires Vio amp Blu Wht shoul
65. T GRN D Z ID WHT GRN4 1221 1 SENSOR GASOLINE PURPLE _ ALT EXCITE COOLANT TEMPERATURE san x2 GM ENGINE 1 OUTPUT FE TAN PINK TO CONTROL BOX fee ASSEMBLY 1 GRN BLU 4 2 11 12 BLK 4 h vo CIRCUIT BREAKER 20 AMP HOURMETER YELIBLK NOTE AND ARE NOT USED ON L P MODEL vio GRA BLK 1 cs SENDER FUEL GAUGE FUEL Bk LP12 E 1 BLK LIGHT STROBE id OPTIONAL MOTOR SHAKER 87 RED 15 BLU BLK BLUIGRN WHT 4 u gt BLK CIRCUIT BREAKER 20 AMP RELAY SHAKER 7a 87 WHT YEL 1 2 BLK RELAY HORN D Ks HORN vio BLK RELAY SIGNAL LIGHTS S OPTIONAL Brie CB2 OPTIONAL Ar K2 87a LP1 RED 1252 GRA RED 87 YELIBLK YEL BLK 1 BLK CIRCUIT BREAKER 20 RELAY LIGHTS LP2 HEAD LIGHT RIGHT 522 YEL BLK 1 2 BLK GRN YEL 14 2 GRA HEAD LIGHT LEFT SWITCH BRAKE LP3 VIOINEL BLK WHT BLK KOPTIONAL E13 LAMP RIGHT FRONT c Sir K5 87a S25 VIO YEL BLES WHT BLK RED 1122 ORN 0 L 87 GRN YEL GRN YEL oj YEL 2 1 3 VIO YEL OPTIONAL YEL 567 6 GRN LAMP RIGHT REAR SIGNAL CIRCUIT BREAKER 20 A RELAY SIGNAL LIGHTS LP5 OPTIONAL SWITCH HAZARD OPTIONAL FLASHER OPTIONAL YEL BLK WT B OPTIONAL GRA RED 09 NAE 526 LAMP RIGHT REAR TAIL BRAKE T 1 VIO YEL 126 5 YEL D GRN GRN WHT BLK GRN YEL M 7 Colon SWITCH TURN SIGNAL p AMP LEFT FRONT
66. Then soak the filter in warm water for 15 minutes then rinse it under a gentle stream of water maximum pressure 40 psi Let the filter dry completely before putting it back into the machine 6 Follow the instructions in reverse order to install the filter If the gasket on the filter is torn or missing it must be replaced NOTE Before replacing filter clear debris from dust plate located under filter Verify that the debris flap at the rear of the dust plate swings freely HOPPER DUST CONTROL FILTER OPTIONAL NILFISK POCKET FILTER SYSTEM The optional Nilfisk pocket filter system is basically maintenance free The only periodic maintenance required by the machine operator is to run the Shaker LL on a daily basis NOTE The shaker should only be run with the hopper in the down position FORM NO 56043129 SR 1900 13 SR 1900 PM Checklist Defect Codes Customer A needs adjustment B binding Address C dirty or contaminated D damaged bent or torn City St Zip L leaks M missing Model Serial Hours W worn out 5 OPERATIONAL INSPECTION ITEMS 1 Check Neutral Safety Sense Switch operation To test depress drive pedal and start the engine it should not start Engine Starting with pedal in neutral if it will not start check sensor switch starts hard programming noisy sluggish Engine Speeds 4 cyl G P 1200 2400 RPM Engine Speeds Diesel note electrical actuator linkage 1200 2400 RPM
67. Vdc oe K8 _ 87 1 42 RED VIO 87 VIO GRA CONTROL BLK CIRCUIT BREAKER 20 A RELAY HVAC S30 ME VEL VIO GRA B M RED RED BLK E REDT DH 1 BLOWER MOTOR FOR Swine FAN ndi MOTOR BIPER MOTOR PRESSURIZED AND HEATED CAB L2 T 1 WHT YEL TN 2 BLOWER MOTORS FOR A C SW SPST RI M j BLK HVAC OPTION K9 RELAY CONDENSOR FAN MOTOR BLOWER MOTOR 998 S34 Kt 110 BLKWHT 1 2___ 417 2 GRNWHT30 87 BLU IBRN 1 2 BLK k 87a 8 THERMOSTAT RELAY COMPRESSOR VALVE COMPRESSOR RED 30 87 BLU BLK SWITCH PRESSURE RELAY CONDENSOR FAN MOTOR CONDENSER FAN 2 9 M3 RED STARTER Bt PINKYEL DSS D PINKYEL MN FUEL PUMP OUTPUT xi BUMP BLK RED _ BLKRED CIRCUIT BREAKER 70 T 1 SER BLU PINK BLUPPINK STARTER COMMAND GROUND RELAY NEUTRAL A3 MIL OUTPUT 1 CHECK ENGINE LIGHT CLOSED IN NEUTRAL SWITCHED GRNYEL GRN YEL OUTPUT TO CONTROL GM ENGINE GRN YEL CIRCUIT BREAKER 15 AMP SYSTEM GROUND BOX ASSEMBLY CONTROLS INC CONNECT TO s INC THROTTLE INPUT DRAWING NO E1737100 12V FOR HIGH GRABLU K lt lt K GRAIBLU PGRAIBEU ASSEMBLY AND E1737200 x3 AS g xi BLK GRN A BLK GRN 1 4 IGN ORN GRN 41 1 PINK PINK A A PINK IGN SW INPUT GRN WHT B id B GRNWHT2 2014 SWITCH IGN CIRCUIT BREAKER 10 1 GRN RED C 4 GRN RED 3 e 5 WH
68. WITCH TURN SIGNAL ELECTRICAL SYSTEM zm YEL 16 3 adj X57 X58 S22 zz GANVEL162 A 12 2 ees 7 1 i aea a WIRING SCHEMATIC 1 of 3 ee ener VIO YEL 18 2 VIO 18 18 3 S25 SWITCH HAZARD GRA BLK 4841 ORN GRN 16 1 is S26 SWITCH MISTING PUMP P3 GRN BLK 16 1 ST YEL 16 3 I GAUGE lt GOMINATION BLK 18 24 YEL 16 2 x 2 3 OPTION YEL 16 2 3 6 REPLACES P1 AND P2 RED 10 1 5 E GRN 18 2 51 GRN 18 3 9 5 LP9 X33 SWITCH IGNITION VIO YEL 18 2 o 2 1 18 1 1692 B B BLK 18 19 ME VIO YEL 18 3 S a ETE Bt A YEL BLK 18 8 YEL BLK 16 5 GENVER 188 YEUIBLK 16 lt YELIBLK 18 11 18 1 SWITCH DUST CONTROL FILTER OPTIONAL YELBLK 851 1 dj OPTIONAL 52 CONTROL BOX ASSEMBLY Y I BLK 14 2
69. Y 18 BOSCH TMAP 4 3 2 1 CRANK TWIST WIRES 1 fURNS 360 D G FOOT FULL LENGTH KZL GREEN 1 CONNECTOR 2 CAM PINK DK GREEN 16 12V RELAYED POWER SPEED 1 AUX PED 15326868 CONN SPEED Vs PED_ 15304707 TERM KNOCK1 RED WHITE VS PED_ 12191153 SEAL KNOCK IAN AUX DIG 3 0 15358785 LOCK KNOCK2 TAN RED 18 L AUX DIG 2 KNOCK2 GRAY DK BLUE 18 _ GOV SELECT 1 SPARK COIL 1 gt I YELLOW 18 GRAY RED 18 3 GOV SELECT 2 SPARK COIL 18 DKBLUE YELLOW 18 TH AUX ANA PU1 SPARK COIL 2A 33 YELLOW RED 18 YELLOW DK BLUE 18 TE AUX ANA PU2 SPARK COIL 28 TAN 18 F AUX PWM 1 SPARK COIL 3A gt 35 BLACK 16 E GROUND SPARK COIL 38 gt 38 TACH SPARK COIL 4A 5 37 BROWN WHTE18 C AUX PWM 5 SPARK COIL 48 gt 38 2 AUX 3 RECIRC UNUSED TAN WHITE 18 DK GREEN PURPLE 18 AUX Dig 43 IANZRED 18 AUX DIG 3 24 18 SK 45 PINK TAN 18 AU ARA DUN 46 DK BLUE YELLOW 18 47 YELLOW DK BLUE 18 m Wer GREEN WHITE 18 FPP2 ONLY BV EXT 2 SV RTN CONNECTOR 1 PED 15326863 CONN V EXT 2 FPP2 ONLY SV RTN 2 GREEN PURP REEN YI E 1 1 ZPINK 1 FUEL SELECT AUX DIG 1 ML START COMMAND ALT EXCITE 51 GR
70. a 252 2 lt irae F oO m a maa v E m z 72 FORM NO 56043129 SR 1900 revised 8 09 Ex ELECTRICAL SYSTEM FL STROBE RED OPTIONAL WIRING SCHEMATIC 1 of 3 4 gi 191 WIRING 190 MOTOR ASM WIPER s INCLUDES 2 SPEED SWITCH X gt m y g _ X178 X203 gi i3 am amp 88 VIO GRA 12 3 y 2 Sele D a ae aa 22 lt lt lt 2533 gt gt mammam enm Jaz zs lt m 2 E BIS oC X189 x82 VIO GRA 122 1 5 GONNSETTOXT FOR CONNECT TO TERMINAL 1 ON CB1 SP27 9 LP14 M7 STROBE LIGHT OPTION VIO GRA 12 1 5 L 1 21 2 R9 ON TOP OF CAB B M 0 OPTION e 2 M H LAMP DOME JN 4 1 K8 MOTOR DEFROSTER FAN 13 ls T Y SWITCH FAN 2 3 e 1 1 amp RED VIO 12 1 3 lem lt 81 X195 CONNECT TO X83 ON SHEET 1 VIO GRA 12 5 RED HEATER TEME BLK 9 OPTIONAL GRN YEL 16 5 C
71. amples of machine lubrication products Engine crankcase oil Engine crankcase oil filter Hydraulic system oil Hydraulic system oil filters ENGINE COOLANT A CAUTION Do not remove the radiator cap when the engine is hot To check the engine coolant level first unlatch and open the Oil Reservoir Fuel Tank Cover 20 then lift the Engine Compartment Cover 1 and observe the coolant level on the Coolant Recovery Tank 15 or 22 If the level is low add a mixture of half water and automotive type anti freeze Clean the radiator and oil cooler exteriors by washing with low pressure water or using compressed air every 30 hours Service Note The oil cooler tips out for easy cleaning ENGINE OIL GASOLINE PETROL amp LPG Check the engine oil level when the machine is parked on a level surface and the engine is cool Change the engine oil after the first 35 hours of operation and every 150 hours after that Use any SF or SG rated oil meeting API specifications and suited to seasonal temperatures Refer to the Engine System section for oil capacities and additional engine specifications Replace the oil filter with every oil change TEMPERATURE RANGE OIL WEIGHT Above 60 F 15 C SAE 10W 30 Below 60 F 15 C SAE 5W 30 ENGINE OIL DIESEL Check the engine oil level when the machine is parked on a level surface and the engine is cool Change the engine oil after the first 35 hours of operation and every 150 hours after that Use CF
72. art 2 Diesel engine will crank but not start Note Always use activate the glow plugs circuit to start an engine that is not up to its operating temperature Note 1 Before troubleshooting inspect the 10A CB5 circuit breaker replace if defective Note 2 The engine uses a low oil pressure shut down feature Check to see that the engine oil fill level is correct As oil will prevent the engine from starting for its own protection 5PSI is min pressure to open switch S28 for engine to start Diesel engine will crank but not start Governor Actuator T S W engine cranking test for 12V s the governor speed select 2 terminal 15 there 12V s Yes Replace oil pressure SW amp reconnect all wiring does engine run If yes the oil pressure switch was defective Re test w engine cranking Is there 12V s speed select 2 terminal If the S28 oil pressure Switch does not receive its min oil pressure to open 5psi investigate further engine oil pressure problems amp make repairs Note Test engine oil pressure if below min spec investigate its cause and make needed repairs Substitute a good known working governor Does engine run Test for 12V the Apec Test the key Sw accessory 3000 governor battery output amp circuit wiring to input Pos amp Neg governor Repair or replace terminals defective parts Yes 1 Remove the 2 screws that fasten the fuel control actuator then rem
73. ator is shown red A CAUTION When servicing the engine air filter elements use extreme caution to prevent dust and dirt from entering the engine The engine air filter contains a primary outer and a safety inner filter element The primary element may be cleaned twice before being replaced Replace the safety element every third time that the primary element is serviced Never try to clean the safety element To clean the primary filter element remove the cover from the dust cup end of the canister and pull out the primary element Clean the element with compressed air maximum pressure 100 PSI or wash it with water maximum pressure 40 PSI Do not put the element back into the canister until it is completely dry Special Service Note Inspect the complete air intake system for proper routing kinks amp restrictions and sound tight connections The mechanic should run their hand around the air intake hoses to check for any cracks and holes that will allow non filtered air to enter the engine that will severely shorten the engine s useful life ENGINE MAINTENANCE 150 HOURS At 150 hour intervals it is recommended that the following service be performed Change oil and filter clean and inspect spark plugs check all engine belts condition and adjustment check battery charge and level check cooling system hoses and clamps and check general condition and performance of engine Note Reference the separately supplied PSI GM Power Trai
74. attery ground Do you have 12V s Yes On the Gra Orn amp BIk M4 pump wires check for an open circuit Repair or replace the defective wire Test continuity of the CB7 10A circuit breaker amp its wiring Repair or replace defective parts Replace the defective K6 misting pump relay 50 FORM NO 56043129 SR 1900 ENGINE SYSTEM ENGINE SPECIFICATIONS Kubota V1505 B 1 Engine Type Vertical water cooled 4 cycle diesel engine Displacement 91 41 cubic inches 1498cc Fuel Diesel fuel No 2 D ASTM D975 Injection Pump Bosch MD type mini pump Engine firing order 1 3 4 2 Injection Timing before TDC 19 deg Oil Capacity 5 5 5 2L Oil Pan depth 4 9 12 4 cm Cooling Capacity 8 Qts 7 5L Horsepower 46 gross 2800 41 Int 2400 RPM Idle Speeds Low idle 1200 RPM High idle 2400 RPM NOTE Reference the following engine manufacturer s Service and Operators manuals for more detailed engine specifications and service data e Kubota Operator s Manual 16622 8916 3 e Kubota Workshop Manual P N 97897 01640 ENGINE OIL DIESEL ENGINE Engine oil should be MIL L 2104C or have properties of API classification CD grades or higher Use the information below to choose the proper engine oil for the temperature where the machine is operated most of the time e Above 77 F 25 C SAE 30 or SAE 10W 30 SAE 10W 40 e 32 77 F 0 25 C SAE 20 or SAE 10W 30 SAE 10W 40
75. bove steps are completed the side broom s will lower automatically and turn ON rotate Note 2 By pressing the control panel side broom ON OFF switch during sweeping the side broom will be raised and turned OFF Side broom motor will not run Remove the side broom L3 Substitute or valve cartridge replace the Replace the nspect clean and reinstall failed side broom valve broom motor Does the motor run cartridge Does the motor run Substitute valve cartridge numbers 3 amp 7 they are the same and can be swapped to help troubleshoot the system 36 FORM NO 56043129 SR 1900 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Side broom s will not raise or lower Mechanical and Hydraulic functions Note 1 Do all testing with the engine running at high speed the main broom lowered sweep position and the drive pedal activated machine moving Note 2 The main broom magnetic switch S2 must be open and also the hopper interlock switch S4 closed for the main broom system motors to run Operating the main broom will automatically lower the side brooms Press the side broom off button or raise the main broom lever to raise the side brooms Side Broom s will not Raise or Lower Mechanical amp Visual Checks Inspect for possible mechanical binding of Side broom motor mount amp lift arm linkage damaged Side broom lift cylinder rod bent rod oil sea
76. call outs FORM NO 56043129 SR 1900 47 HOPPER SYSTEM TROUBLESHOOTING GUIDE Symptom Hopper dump door will not operate open or close Part B Hydraulic Load Circuit Note To test the engine must be running at high speed and the hopper door open close Switches pressed and held Dump door will not operate open or close Inspect for possible Remove amp Replace the mechanical binding at disassemble the defective Dump door amp hopper L1 dump 1 frame Opening L7 dump door close L7 door close Dump door cylinder amp Cartridge valve cartridge valve linkage Inspect clean and Does the door reinstall function Does the door Yes function Replace the hydraulic hopper door cylinder Repair or replace damaged parts Does the door function Note The engine must be shut off to remove and disassemble any valve cartridge 48 FORM NO 56043129 SR 1900 SOLUTION SYSTEM TROUBLESHOOTING GUIDE Symptom Misting Pump will not Work Part A Electrical Control Circuit Note 1 Do all testing with the key switch ON misting solution tank not empty main broom lever lowered drive pedal activated in Fwd or Rev and the M4 misting pump s control switch S26 turned ON Note 2 Before T S check the continuity of the pump s circuit breaker CB 7 10A reset or replace if defective Misting Pump will not work Test for 12V s the misting pump coil r
77. ccurs Change the Hydraulic Charge Oil Filter once a year or every 1000 hours HOPPER DUST CONTROL FILTER PANEL FILTER The hopper dust control filter must be cleaned regularly to maintain the efficiency of the vacuum system Follow the recommended filter service intervals for the longest filter life A CAUTION Wear safety glasses when cleaning the filter Do not puncture the paper filter Clean the filter in a well ventilated area Wear appropriate dust mask to avoid breathing in dust To remove the hopper dust control filter 1 Unlatch and open the Hopper Cover 16 Make sure that the Hopper Cover Prop Rod 17 is in place 2 Inspect the top of the Hopper Dust Control Filter 12 for damage A large amount of dust on top of the filter is usually caused by a hole in the filter or a damaged filter gasket 3 Unthread and remove the four Shaker Assembly Retainer Knobs 13 Lift off the Dust Filter Shaker Assembly 11 to access the panel filter 4 Liftthe Hopper Dust Control Filter 12 out of the machine 5 Clean the filter using one of the methods below Method A Vacuum loose dust from the filter Then gently tap the filter against a flat surface with the dirty side down to remove loose dust and dirt Method B Vacuum loose dust from the filter Then blow compressed air maximum pressure 100 psi into the clean side of the filter in the opposite direction of the airflow Method C Vacuum loose dust from the filter
78. cling it On amp Off test for 12V the engine ECM pin 51 wire Gra Blu to Battery Grnd 0 volts engine will only run idle 12 volts engine will run high speed 15 there 12V the ECM throttle input but no H S engine operation Yes Substitute a good known working ECM if engine runs properly amp both idle amp high speed replace ECM Ribbon connector see Electrical System Figure 1 for detail pin call outs Test the continuity of the throttle input wire Gra Blu from the ECM to the A2 control box Repair if faulty Does engine run high speed Test the speed SW input to the A2 control box by cycling it On amp Off checking the ribbon connector ground input continuity pins J3 1 amp J3 4 If speed switch checks open or closed all the time replace the membrane switch panel assembly Does speed SW test ok Yes Substitute a good known working A2 control box if engine runs properly both idle amp high speed replace A2 control box FORM NO 56043129 SR 1900 27 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom Part1 Diesel engine will crank but not start Note1 Always use activate the glow plugs circuit to start an engine that is not up to its operating temperature Note 2 Before troubleshooting inspect the 10A CB5 circuit breaker Glow plug circuit T S Check voltage each glow plug terminal to Battery ground Is the
79. ctrical System Figure 1 for detail pin call outs Note Do all testing with the key switch ON then press the control panel shaker switch to activate turn on the shaker motor shaker runs for approximately 15 seconds Press amp hold shaker motor switch and check for continuity the ribbon connector for pins J3 1 amp J3 11 on the A2 control box Yes Yes 21 Ribbon pins test open replace the touch pad switch panel 40 FORM NO 56043129 SR 1900 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Shaker motor will not run Shaker motor will not run Test for 12V s the M2 shaker motor wires Blu Grn amp Yes Repair or replace the M2 shaker motor Part B Electrical Load Circuit Note 1 Do all testing with the key switch ON then press the control panel shaker switch to activate turn on the shaker motor shaker runs for approximately 15 seconds Test for 12V s the K3 Vio wire to battery ground Do you have 12V s Yes Test for 12V s the K3 Blu Grn wire to battery ground Do you have 12V s Yes On the Blu Grn amp Wht pigtail amp M2 shaker wires check for an open circuit Repair or replace the defective wire Test continuity of the CB4 20 circuit breaker amp its wiring Repair or replace defective parts Replace the defective K3 shaker motor relay FORM NO 56043129 SR 1900 41 HOPPE
80. d Item 2 Additional Hydraulic Manifold Components Descriptions X1 Cartridge side broom lift cylinder piloted 3 2 directional valve X2 Cartridge side broom piloted check valve X3 Orifice 038 Dia hopper raise control X4 Orifice 086 Dia hopper dump door control X5 Orifice 078 Dia hopper lower control X6 Cartridge broom system flow divider XT Cartridge steering system flow divider X8 Check valve side broom s X9 Cartridge hopper lift free check X10 Pressure relief valve 2500 PSI manifold block FORM NO 56043129 SR 1900 59 HYDRAULIC SYSTEM FIGURE 3 Hydraulic Manifold top and bottom views shown i di 72 lt Lock nut 10 System Relief Valve 2500 PSI Shown with dashed lines behind S5 Bottom view Top view 60 FORM NO 56043129 SR 1900 HYDRAULIC SYSTEM PRESSURE RELIEF VALVE Instructions for testing and adjusting the main pressure relief valve that is built into the machines hydraulic manifold assembly Insert hydraulic test gauge 3000 psi to the XT1 test port location between pump amp solenoid manifold To check pressure the hydraulic oil must be warm amp engine at high speed 2400 RPM Activate the hopper lift raise or lower to dead head its cylinder to place the pump circuit into an overloaded condition A CAUTION Do not test in the overloaded condition for
81. d read Press amp hold hopper door open 12V s SW Check for continuity the ribbon connector for pins J3 1 Check 1 coil resistance Replace the S1 Spec 9 Ohms solenoid coil amp J3 5 on the A2 control box See hydraulic hopper raise Replace the A2 troubleshooting section B control box assy Ribbon pins test open replace the touch pad switch panel Ribbon connector see Electrical System Figure 1 for detail pin call outs 46 FORM NO 56043129 SR 1900 HOPPER SYSTEM TROUBLESHOOTING GUIDE Symptom Hopper dump door will not close Part A Electrical Control Circuit Note Do all testing with the engine running at high speed and the hopper dump door close switch pressed and held Hopper dump door will not close Press amp hold hopper Check S7 coil wiring dump door close continuity repair if faulty switch Is there 12V s at the S7 coil Back probe the S7 dump door solenoid coil wires Vio amp should read Press amp hold hopper door open 12V s SW Check for continuity the ribbon connector for pins J3 1 amp J3 7 on the A2 control box Check S7 coil resistance Replace the S7 solenoid coil Does SPEC ms the dump door close No Y Yes gee y O Replace the A2 Ribbon pins test See hydraulic hopper raise control box assy open replace the troubleshooting section B touch pad switch panel Ribbon connector see Electrical System Figure 1 for detail pin
82. de brooms Gross Weight Standard machine without options with 175 lbs operator with standard sweeping brooms and full tank of fuel 8 FORM NO 56043129 SR 1900 TECHNICAL SPECIFICATIONS Specifications common to Engine Size Sound Level At operators ear Speed and Gradeability Maximum grade angle transport Maximum grade angle sweeping Maximum trailer loading angle all models Travel speed Maximum Maximum reverse speed all models English Metric 83 dBA 25 14 25 14 19 4 9 mph 14 5km h 5 5 mph 8 8km h 7 mcr d 1 m qm lio FRONT VIEW Width Height w overhead guard Height Co SIDE VIEW Length FORM NO 56043129 SR 1900 9 MAINTENANCE MAINTENANCE SCHEDULE Maintenance intervals given are for average operating conditions Machines used in severe operational environments may require service more often MAINTENANCE ITEM PERFORM DAILY Perform the After Use maintenance steps X Check parking brake 0 X 2 Clean main and side broom s gt lt pp Check engine air filter indicator X Check engine coolant level X Check hydraulic oil level X MAINTENANCE ITEM 15 hrs 30hrs
83. e a problem in the control valve or circuit If the operational pressure is within range but the motor speed is too slow the problem could be in the motor If the broom motor Operational PSI reading is above the Bypass PSI but is below the Operational PSI check the broom adjustment and wear Check individual system troubleshooting sections of this manual for additional information FIGURE 2 Gauge 3 000 PSI 207 bar Hose 2 61 6 000 PSI 414 bar Fitting Parker Diagnostics PD222 FORM NO 56043129 SR 1900 57 HYDRAULIC SYSTEM GENERAL HYDRAULIC SPECIFICATIONS TABLE RPM RPM Relief Pump amp Motor Circuits for all models DISPL in GPM in out PSI PSI Main Broom sweep position Std Broom with a 2 0 pattern Wet sweep Bypass dust control off amp side 2 45 5 7 2800 405 1275 2500 broom s off eroi Impeller On machine high all systems 461 57 2800 8900 1800 2500 Dust control Impeller On machine high all systems off 161 5 7 2800 8900 1650 2500 1 Side Broom right machine high all systems running 6 1 2 9 2800 130 425 2500 2 Side Brooms machine high all systems running 6 1 29 2800 105 360 2500 open close time 2 3 sec nothing else 2800 Open20Close 50 Hopper Lift raise time 10 11 sec Empty 2800 2875 Hopper Lift lower time 7 sec Empty 380 Steering System 4 88 2 0 2800 150 1100 Auxillary Pu
84. e main broom lowered sweep position and the drive pedal activated machine moving When the above steps are completed the side broom s will lower automatically and turn ON rotate Note 2 By pressing the control panel side broom ON OFF switch during sweeping the side broom will be raised and turned OFF Side broom motor s will not Run Complete the above operator inputs to turn Check 3 coil wiring continuity repair if faulty on side brom No Is there 12V s at the S3 coil motor s Back probe the S3 side broom solenoid coil wires Vio amp should read 12V s Press amp hold side broom on Lower amp off raise SW Check for continuity the ribbon connector for pins Yes J3 1 amp J3 9 on the A2 control Yes box Check 53 coil resistance Spec 9 Ohms See hydraulic side broom Replace the S3 No solenoid coil Yes Ribbon pins test open replace the touch pad switch panel Replace the A2 N control box assy Do motor s runs motor will not turn troubleshooting section B Ribbon connector see Electrical System Figure 1 for detail pin call outs FORM NO 56043129 SR 1900 35 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Side broom motor s will not run Part B Hydraulic Load Circuit Note 1 Do all testing with the engine running at high speed the main broom lowered sweep position and the drive pedal activated machine moving When the a
85. elay wires Blu Orn amp Brn BIk Test for 12V s Neg the 6 Brn BIk wire to battery Pos Do you have 12V s See section B electrical load circuit for misting pump Testfor 12V s the K6 Blu org wire to battery ground Do you have 12V s Test continuity of the Brn BIk wire Replace the A2 control box Assy Test continuity of the 26 misting pump relay switch Does switch test good Test for 12V s the 26 SW Vio feed wire to battery GRD Repair or replace Vio wire No Repair or replace the defective Brn blk wire Replace the 26 misting pump relay switch FORM NO 56043129 SR 1900 49 SOLUTION SYSTEM TROUBLESHOOTING GUIDE Symptom Misting pump will not work Part B Electrical Load Circuit Note 1 Do all testing with the key switch ON misting solution tank not empty main broom lever lowered drive pedal activated in Fwd or Rev and the M4 misting pump s control switch 26 turned ON Note 2 Before T S check the continuity of the pump s circuit breaker CB 7 10 reset or replace if defective Note 3 Check for plugged misting nozzles clean if needed Misting pump will not Work Test for 12V s the 4 misting pump wires Gra Orn amp Yes Repair or replace the M4 misting pump Test for 12V s the Blu wire to battery ground Do you have 12V s Yes Test for 12V s the K6 Gra Orn wire to b
86. ilfisk Literature Service Department for your Rider Scrubber Sweeper General Information Nilfisk website nilfisk advance com Parts List Form Number 56042514 all systems w optional kits amp accessories Operation Manual Form Number 56041661 Danish Norway Swedish Finnish 56041662 German French Dutch Russian 56041663 Spanish Portuguese Italy Greek 56041664 Estonian Latvian Lithuanian Slovenian 56041665 Slovakian Czech Polish Hungarian 56041666 Turkish English Quick Start Troubleshooting Manual 56043129 Cab Manuals Cab Addendum Operator Manual 56041789 Cab Addendum Parts List 56042515 Cab Addendum Service Manual 56043123 Engine Manuals 1 6L Industrial Engine Operator Manual excerpt from 16LECSS 56041564 1 6L Industrial Engine Service Manual 36100009 PSI Tier 2 1 6L PFI Certified Engine Service Manual G LP PSI1P6LPFI A V1505 Kubota Diesel Engine Service Manual WSM English 97897 02432 V1505 Kubota Diesel Engine Service Manual WSM English French German 97897 01640 V1505 Kubota Diesel Engine Operator Manual English French German Italian Spanish 16622 8916 3 Available in electronic format only 6 FORM NO 56043129 SR 1900 CAUTIONS AND WARNINGS SYMBOLS Nilfisk uses the symbols below to signal potentially dangerous conditions Always read this information carefully and take the necessary steps to protect personnel and property
87. ine air filter clean Observe the engine coolant temperature gauge frequently Observe the engine oil pressure gauge frequently Check the voltmeter and charging system 52 FORM NO 56043129 SR 1900 ENGINE SYSTEM CHECK ENGINE LIGHT TROUBLESHOOTING FOR 1 6L GM ENGINE The engine ECM will light turn on the dash panel UU check engine light if there is a problem associated with the computerized engine control system The following steps explain how to correctly access the engine controller s fault code outputs 1 Onthe operator display panel the engine check light MIL 9 comes on steady will not shut off 2 Locate the 8 way ECM communication test port which is a part of the engine wiring harness 3 Next remove the test port protective cap See Figure 2 Insert a suitable jumper wire across pin 1 black green wire amp pin 4 orange wire Blink Code Function Although the DST Diagnostic Service Tool software is considered a required tool to access the DTC codes codes may be retrieved without a laptop computer using the blink code function To enable this function follow the steps below 4 Turn the ignition key to the on position 5 system will now enter the self diagnostic blink code mode Be ready with pen and paper to write down any codes that may be stored 6 The ECM will flash the MIL indicator with a pause between represented numbers that represent DTC codes The sequence starts
88. l box Solenoid broom overload 1 Check S2 coil wiring for a short circuit Vio amp Grn Gra 2 1 2 J1 2 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 control box 1 Check 53 coil wiring for a short circuit Vio amp Brn BIk 3 1 3 KD Mu OMO Col J1 3 2 Check coil resistance if below 6 Ohms replace 3 Substitute a new A2 control box 1 Check S4 coil wiring for a short circuit Vio amp Brn Yel 4 14 gust consol gvenoad J1 4 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 control box Solenoid 85 hopneru overload 1 Check S5 coil wiring for a short circuit Vio amp Red Gra 5 24 J1 5 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 control box Solenoid 86 overload 1 Check S6 coil wiring for a short circuit Vio amp Blu Gra 6 2 2 pper up 9yp J1 6 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 control box Solenoid ST hoouerdsoranenuuatiaad 1 Check S7 coil wiring for a short circuit Vio amp Blk Wht 7 2 3 PP J1 7 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 control box Solenoid 58 dust control bypass 1 Check S8 coil wiring for a short circuit Vio amp Brn 8 2 4 overload J1 8 2 Check coil re
89. l leakage Hydraulic Checks Possible internal blockage of the side broom hydraulic circuit oil path Remove Inspect amp clean manifold circuit components amp hoses Q port D the pilot check valve and the pilot valve cartridge port F the L3 valve cartridge oil return to tank circuit Blockage Side broom cylinder hose inlet amp outlet fittings Note See hydraulic system manual section for system specifications and troubleshooting information FORM NO 56043129 SR 1900 37 SWEEPING SYSTEM TROUBLESHOOTING GUIDE Symptom Dust control impellor motor will not run in the wand state Part A Electrical Control Circuit Note Do all testing with the engine running at high speed and the dust control switch pressed activated Dust control motor will not run Press activate the dust Press amp hold dust control SW control switch Check for continuity the ribbon connector for pins J3 1 amp J3 10 on the A2 control box Does it s indicator light come ON Back probe the S4 Check 54 coil wiring impellor motor solenoid continuity repair if coil wires Vio amp faulty Brn Yel should read Is there 12V s at the 12V s S4 coil Check S9 coil resistance No Spec 9 Ohms Yes Replace the S9 solenoid coil Ribbon pins test open replace the touch pad switch panel See hydraulic dust control motor troubleshooting section B Replace the A2 control box
90. m etc See Figure 1 When an A2 controller fault occurs the service indicator light LED UU will blink flash a special fault error code sequence until the fault is corrected See Table A for a description of the fault indications Service Note Instructions on how to read the fault code service indicator light The service indicator LED blink code should operate as follows e First part of code 250mS period per flash 125mS ON 125mS OFF the 700mS LED OFF period e Second part of the code 250mS period per flash 125mS 125mS OFF the 700mS LED OFF period e 2 second LED off period e Repeat sequence If multiple faults are present the codes should appear in order until all are displayed and then the entire sequence will repeat Example Code1 2 000 000 one light blink a short pause two blinks long pause and the code will be repeated LED on for 125mS LED off for 700mS LED on for 125mS LED off for 125mS LED on for 125mS LED off for 2000mS Repeat FIGURE 1 20 FORM NO 56043129 SR 1900 Fault Service Fault Description Output Troubleshooting Action Number LED Pin Blink Code Solenoid homer dbesosen oferioad 1 Check S1 coil wiring for a short circuit Vio amp Blu Wht I 1 1 d J1 4 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 contro
91. mp Circuit Engine 0 2400rpms No 1 02 10 6 2400 380 2500 systems running XT1 Propulsion Pump Circuit Hydrostatic pump 2 48 25 7 2400 3000 Wheel 6 7mph level ground smooth concrete 228 16 7 Fwd170 600 700 no systems running full speed forward Rev 90 Hydrostat Charge 100 The bypass pressure is the pressure reading with no motor or cylinder operating flow through Test conditions 70 degrees F empty hopper pedal 72 depressed amp fully depressed Note Pressure measurements taken at test Port XT1 location output of the accessory pump 58 FORM NO 56043129 SR 1900 HYDRAULIC SYSTEM Hydraulic Truth Table ectrical 5 S energize atus Solenoid Functions 1 2 3 4 5 6 7 8 9 Hopper Raise UP X X Hopper Lower DN X Dump Door Open X Dump Door Closed X Main Broom State ON X X Main Side Broom State ON X X X Dust Control ON Wand State Dust Control OFF Bypass Side Broom Lower X Side Broom Raise amp turn OFF side broom motor OV No Hydraulic Manifold System S6 not overloaded energized Functions nds rgi in relief Notes Operator sweeping wet debris with the dust control fan impeller turned off Operator using vacuum wand option The dust control fan operates with the machines drive stationary To vacuum attach the suction hose wand to the special hopper inlet fitting The S6 solenoid valve assembly bypasses
92. n Products Operation and Maintenance manual for more detailed service data See the Other Manuals Available section for a complete list of the engine manuals that are available SPECIAL LIQUID PROPANE FUEL SYSTEM MAINTENANCE ON THE GM 1 6L ENGINE Every 150 hours inspect and drain any oil build up from the LP fuel system electronic pressure regulator EPR During the course of normal operation oils or heavy ends may build inside the chambers of the propane regulator These oils and heavy ends may be a result of poor fuel quality contamination of the fuel supply chain or regional variation in the make up of the fuel If the build up of the oil is significant this can affect the function of the fuel control system Note Reference the Tier 2 PSI 1 61 PFI certified engine service manual form PSI1P6LPFI A and follow the procedure to drain the EPR regulator 12 FORM NO 56043129 SR 1900 MAINTENANCE HYDRAULIC OIL A WARNING To avoid hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near hydraulic System Check the Hydraulic Oil Level Unlatch and swing open the Oil Reservoir Fuel tank Cover 20 Remove the reservoir cap to check the oil level The hydraulic oil level should be half way up the screen filter inside the filler neck of the reservoir Add SAE 10W30 motor oil if it is below this level Change the oil if major contamination from a mechanical failure o
93. n the main power key switch to the off position 78 FORM NO 56043129 SR 1900 ELECTRICAL SYSTEM PROGRAMMABLE CONTROL OPTIONS Automatic Shaker Operation FACTORY DEFAULT ON RANGE ON OFF The dust control filter shaker can be programmed to automatically activate each time the main broom is turned off to automatically clean the filter To turn this feature on or off perform the following steps oor N T Turn the main power key switch to the off position Press and hold the shaker switch While holding the shaker switch turn the main power key switch to the on position Continue to hold the shaker switch until all indicators turn off approximately two seconds Release the shaker switch Pressing and releasing the shaker switch will alternately turn the automatic shaker feature on or off If the feature is on the indicator on the shaker switch will be lit If the feature is off the indicator will be off To save the new setting turn the main power key switch to the off position The new setting will be saved and will remain in effect until 15 changed again FORM NO 56043129 SR 1900 79 Nilfisk Advance A S Sognevej 25 DK 2605 Br ndby N s Denmark Tel 45 43 23 81 00 setting standards Fax 45 43 43 77 00 www nilfisk advance com
94. nd Serial Number of your machine are shown on the Nameplate on the machine This information is needed when ordering repair parts for the machine Use the space below to note the Model Number and Serial Number of your machine for future reference MODEL NUMBER SERIAL NUMBER HOPPER SAFETY SUPPORT A WARNING Make sure the Hopper Safety Support 5 is in place by using the Hopper Safety Support Handle 1 whenever attempting to do any maintenance work under or near the raised hopper The Hopper Safety Support 5 holds the hopper in the raised position to allow work to be performed under the hopper NEVER rely on the machine s hydraulic components to safely support the hopper I JACKING THE MACHINE A CAUTION Never work under a machine without safety stands or blocks to support the machine When jacking the machine do so at designated locations Do Not jack on the hopper see jacking locations 8 FORM NO 56043129 SR 1900 3 GENERAL INFORMATION TRANSPORTING THE MACHINE A CAUTION Before transporting the machine on an open truck or trailer make sure that All access doors are latched securely The machine is tied down securely see tie down locations 26 The machine parking brake is set TOWING OR PUSHING A DISABLED MACHINE A CAUTION The machine s drive propelling pump is manufactured
95. ng too low for application No wheel drive in either direction Check that pump bypass valve tow valve is in correct position Check connection of foot pedal linkage cable assembly to propulsion pump arm Worn propulsion pump test output oil volume with a flow meter Defective propulsion pump charge circuit Test its relief valve pressure setting 65 100 psi Worn or damaged wheel drive motor No hydraulic system functions drive or accessory Check for a damaged coupling connection from the engine to the pump shaft input Note See in the hydraulic specification manual section tables that list all the individual system component values pressures flows RPMs etc FORM NO 56043129 SR 1900 31 STEERING SYSTEM STEERING SYSTEM TROUBLESHOOTING OVERVIEW See Figure 1 A hydraulic steering unit with the steering wheel mounted to it controls the steer cylinder The steering unit runs off the auxiliary pump assembly The oil flows through a priority divider built into the manifold block assembly that divides the pump output and reduces the oil flow to 2 0 GPM for the steering system There is a check valve built into the steering unit that allows for manual steering if there is no hydraulic oil flow to the unit The relief valve for the steering system is located in the steering unit and is set to open at 1100 PSI FIGURE 1 Steering System Hydraulic Diagram TROUBLESHOOTING
96. om diameter Main broom bristle length Sweeping path w single side broom Sweeping path w dual side brooms Side broom diameter STD Side broom bristle length Hopper System Capacity Lifting capacity Dump height variable Dump height with door open Dust Control System Filter media area Filter dimension Dust Guard Water Misting Tank Capacity Steering System Turn radius left Turn radius right Minimum aisle turn width left Hydraulic System Oil type SAE 10W 30 fill to bottom of screen System fill capacity Engine System Diesel amp Petrol gasoline fuel tank capacity Tires Tire pressure all 3 General Specifications common to All Models Filter type Pleated paper panel STD optional poly filter available Type Full power steering unit and hydraulic cylinder English Metric Gas amp Propane 93 75 inches 238cm 64 5 164cm 58 5 inches 149cm 81 25 inches 206cm 79 inches 201cm 3 1 inches 7 8cm 101 4 inches 257 5cm 3000 Ibs 1360kg 3300 Ibs 1496kg 50 inches 127cm 14 inches 35 5cm 3 25 inches 8 26cm 65 inches 165cm 77 inches 196cm 24 inches 61cm 6 inches 15 2cm 14 ft 396L 1000 Ibs 454kg Max 60 inches 152cm 52 75 inches 134cm 88 f 8 1717 3 19 x 18 x 30 8 1 x 45 7cm x 76 2cm 14 gal 53L 95 242cm 63 160cm 109 in 277cm 11 gal 41 6L 12 5 gal 47 3L 90 100 PSI Width minimum Width of machine body at the hopper no si
97. or those specified in the instructions for use manual The use of other brooms may impair safety A CAUTION This machine is not approved for use on public paths or roads This machine is only approved for hard surface use This machine is not suitable for picking up hazardous dust When operating this machine ensure that third parties particularly children are not endangered Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without first turning the key switch O removing the key and applying the parking brake Turn the key switch off and remove the key before changing the brooms and before opening any access panels Take precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts Before use all doors and hoods should be properly latched Do notuse on surfaces having a gradient exceeding that marked on the machine All doors and covers are to be positioned as indicated in the instruction manual before using the machine SAVE THESE INSTRUCTIONS FORM NO 56043129 SR 1900 7 TECHNICAL SPECIFICATIONS Dimensions Length Width minimum Height Height w overhead guard Height w cab Ground clearance Minimum ceiling height dumping clearance Weights Gross weight 4 Cylinder Diesel Gross weight GM 1 6L Sweep System Main broom length Main bro
98. ove from injector pump 2 Try starting the engine it should start with actuator removed Important operator note When engine starts it could run full speed To stop engine pull DN on the engine stop lever to prevent over revving damage to engine Does engine start No Test the fuel control actuator for an open spec is 3 5 Ohms If defective replace Reinstall the actuator Does engine start Remove the governor magnetic pickup sensor inspect for damage amp also that the pickup is installed with the correct clearance Thread sensor in until it makes contact with the flywheel then back it out a 72 turn Does engine start Check the governor magnetic pickup voltage signal w engine cranking approx 1 2 3 7 VAC If no signal substitute a good known magnetic pickup sensor Does engine run 1 See fuel system T S part 1 2 See engine service manual no start fuel injector pump system FORM NO 56043129 SR 1900 29 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom Diesel engine will not run at high speed Note With the engine running at idle press the engine speed switch to activate the high speed engine function Diesel engine will not run at high speed Test for 12V s atthe Apec 3000 governor speed select 1 input terminal Gra Blu to No battery Grd Yes Test the governor controller actuator output voltage wire colors Wht amp Wht BIk Q idle approx 4 35 V No
99. range The next press will return the deadband to the minimum range The service indicator will be on steady if the minimum range is selected it will flash at a slow rate if the middle range is selected and it will flash at a fast rate if the maximum range is selected 9 To save the new setting turn the main power key switch to the off position 10 The new setting will be saved and will remain in effect until it is changed again SO D Recall Of Stored Fault Codes Whenever an electrical system fault is detected by the main control unit one or more fault codes are displayed and stored by the control unit If it is desired the fault code if any from the previous operation of the machine can be recalled for troubleshooting purposes To recall the last stored fault codes perform the following steps 1 Turm the main power key switch to the off position 2 Press and hold the horn switch 3 While holding the horn switch turn the main power key switch to the on position 4 Continue to hold the horn switch until all indicators turn off approximately two seconds 5 Release the horn switch 6 If there were previously no error codes stored the service indicator will be lit continuously If error codes were stored the service indicator will now flash the stored code s T To clear the stored codes press and release the horn switch The service indicator will light continuously 8 To exit the error code recall mode tur
100. reading close to battery Test for open circuits in the Pos feed wire and glow plug key switch circuit Repair or replace defective voltage parts Yes Test each glow plug for an open circuit The resistance spec is 9 Ohms Do any of the glow plugs test open Fuel System T S Is the fuel tank empty Yes Replace the open defective glow plug s With the engine cranking test for 12V oil pressure SW S28 Gra Brn wire to Bat Grd No With the engine cranking test for 12V the fuel pump Does fuel pump run Remove fuel line to injector pump crank Test fuel pump B Ground wiring amp repair Replace defective fuel pump Add fuel amp air bleed the fuel system Loosen air vent on fuel filter then next the fuel injection pump w engine cranking but bleed separately engine is fuel pumping Test the key SW accessory output amp Yes circuit wiring to the Com Does engine start terminal S28 If no voltage repair or replace bad parts If voltage input is OK replace the oil pressure switch S28 See part 2 Loosen injector line Governor fuel control injector crank actuator engine check for troubleshooting fuel See Kubota engine Service manual check engine compression injector pump fuel quality etc as further causes 28 FORM NO 56043129 SR 1900 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom P
101. rt Part A Note 1 Check for 12V s at the CB5 ignition circuit breaker 10A If no input voltage the Orn Grn wire repair or replace wiring or key switch Note 2 Check the fuel supply empty tank Note 3 Check the condition of the spark plugs replace if needed Engine will crank but not start Check the engine s ECM for any DTC diagnostic test codes two methods Mo e Check for any active codes with a computer using the GCP diagnostic software Using a short piece of wire jump the engines diagnostic connector pins 1 amp 4 See the engine section in this manual for instructions No Yes See the 1 6L Tier 2 Engine Service Manual form PSIP6LPFI A amp look up the specific DTC and use the T S chart for it to fix the problem No spark all cylinders W key in the on position test probe for 12V the B pink Grn wire the coil pack to Grd If 0 V s repair wire to its power source F4 fuse Still no start With the engine cranking test for 1 5V Aprox each B coil pack wires Yel amp Yel Red to B Test resistance of both primary coil pack windings Specification is 108K Ohms plus or minus 15 Test resistance of both secondary coil pack windings Specification is 5K Ohms plus or minus 15 Do both test ok Yes Check the continuity of all the fuses listed below location engine fuse box 1 VSW F2 20A ECM F4 15A Ignition F5 15A fuel pump gasoline only
102. se or missing Reference the 1 6L tier 2 engine service manual and follow the LPG system diagnosis Fuel System Checks for Gasoline Check fuel pump electrical circuit fuel pump pressure and fuel rail pressure Check electrical connections at the fuel injection solenoids Check for air intake system leakage between the throttle body amp intake manifold sealing surfaces Also any vacuum hoses for splits kinks and proper connections Reference the 1 6L tier 2 engine service manual and follow the gasoline system diagnosis Sensor Checks Check the TMAP sensor Check the magnetic pickup sensor RPM Miscellaneous Electrical and Visual Checks Check engine harness wiring for proper connections pinches or cuts Check the ECM amp engine ground for tight clean connection size and proper location Check spark plug wires for cracking hardness tight connections proper routing amp firing order Check thoroughly for any type of a leak or restriction Examples Intake filter blocked exhaust restriction muffler Cat a leaking exhaust manifold etc 26 FORM NO 56043129 SR 1900 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom 4 cylinder 1 6 GM engine will not run at high speed Note With the engine running at idle press the engine speed switch to activate the high speed engine function 1 6 GM engine will not run at high speed Press the speed select switch on the operator panel Cy
103. sistance if below 4 Ohms replace 3 Coil spec is 6 Ohms Substitute a new A2 control box Solenoid SO hopper lowerovedead 1 Check S9 coil wiring for a short circuit Vio amp Yel Grn 9 3 1 J1 9 2 Check coil resistance if below 6 Ohms replace 3 Coil spec is 8 Ohms Substitute a new A2 control box ausraad 1 Check K3 coil wiring for a short circuit Vio amp Yel Red 10 3 2 ay J1 14 2 Check coil resistance if below 70 Ohms replace 3 Coil spec is 85 Ohms Substitute a new A2 control box 1 Check the alarm wiring for a short circuit Vio amp Grn 11 3 3 Back up alarm overload J1 15 Brn 2 Disconnect alarm wiring if overload goes away replace the alarm if not substitute a new A2 control box chi relav K2 overload 1 Check K2 coil wiring for a short circuit Vio amp Yel Wht 12 34 bid J1 16 2 Check coil resistance if below 70 Ohms replace 3 Coil spec is 85 Ohms Substitute a new A2 control box Neutral start relay 1 Check K4 coil wiring for a short circuit Vio amp Gry Wht 13 4 1 J1 18 2 Check coil resistance if below 70 Ohms replace 3 Coil spec is 85 Ohms Substitute a new A2 control box Bain Telav 1 Check K1 coil wiring for a short circuit Vio amp Vio Brn 14 4 2 J1 19 2 Check coil resistance if below 70 Ohms replace 3 Coil spec is 85 Ohms Substitute a new A2 control box Endine speed outbutoreroad 1 Throttle input to engine A3 EC
104. stic Communication Port 8 Pin MIL shorting location D Ignition Coil Pack Wiring Connector E Engine Oil Pressure Switch F Crankshaft Position Sensor Connector G Throttle Fly Actuator Motor Connector Bosch H EGO 1 Sensor Wiring Connector Combined TMAP Engine Air Temperature and MAP Sensor Wiring Connector J Engine Coolant Temperature ECT Sensor Connector K Engine Starter Solenoid Wire Connector L EGO 322 Sensor Wiring Connector M LPG Fuel Lockoff Wiring Connector N LPG Temp Sensor Wiring Connector P EPR Connector LPG Fuel Regulator Q Gasoline Fuel Injectors Definition of Terms for Computerized Engine Controllers ANA RTN ECM Engine Control Module EGO Exhaust Gas Oxygen Sensor O2 EPR Electronic Pressure Regulator IAT Intake Manifold Air Temperature MAP Intake Manifold Absolute Pressure MIL Malfunction Indicator Light VSW Switched Battery Voltage VBAT Battery Voltage 78 FORM NO 56043129 SR 1900 AUX ANA PD1 FPP1 FPP2 IVS AUX ANA PD2 AUX ANA PD3 5V EXT 1 5V RTN CRANK CRANK CAM CAM SPEED SPEED KNOCK1 KNOCK1 KNOCK2 KNOCK2 SPK COIL SPK COIL SPK COIL SPK COIL SPK COIL SPK COIL SPK COIL SPK COIL AUX DIG 1 AUX DIG 2 AUX DIG 3 VSW AUX ANA PU1 AUX ANA PU2 FRT AUX FPP 2 ONLY 5V EXT 2 ALT EXCIT TACH VBAT PROT VBAT INJ1 INJ2 INJ3 INJ4 INJS INJ6 INJ7 AUX PWM3 RECIR AUX PWM3 AUX PWM2 AUX PWM1
105. troubleshoot the hydraulic system it is possible to use digital tachometers flow gauges or pressure gauges The pressure gauge should have a range of 0 3000 PSI see Figure 2 and have a Parker Diagnostics connector number PD222 The most convenient way to check for oil flow is to check the RPM of the motor that is performing poorly Use the chart on the next page to determine the motor RPM if the motor speed is correct the pump is producing the correct amount of oil flow However this does not mean that if a motor is running too slow the problem is in the pump The following information should be used to check for proper motor RPM system pressure and relief valve settings The readings are nominal figures and there will be variations due to manufacturer tolerances and system oil temperature If any reading varies greater than 2096 there will be a noticeable loss of performance and should be corrected TEST PORT NOMINAL PRESSURE READINGS see Figure 1 Insert pressure gauge see Figure 1 into the test port Run engine in high throttle position Allow oil to warm up The bypass pressure is the pressure reading with no motor or cylinder operating The operational pressure is the pressure range the motor or cylinders will operate in ENGINE FIGURE 1 Note 100 PSI 6 9 bar A much lower than normal bypass pressure could indicate a gear pump problem If the bypass pressure remains the same after turning the function on there could b
106. ve pedal sensor R2 follow the instructions located in the programmable control options section to synchronize the pedal s neutral dead band adjustment Test the drive pedal sensor R2 5K Ohms and wiring harness circuit Does the sensor test good Yes Substitute a new A2 control box assembly See Note A manual for instructions GM 1 6L 4 cylinder engine will not crank Part B Electrical Control and Load Circuit Continued from previous page Note 1 To test the key switch must be in start position and the foot pedal in neutral Also Note 2 Before T S check the CB1 60 Amp circuit breaker amp 12V s key switch Bat Terminal Note 3 Before T S check battery voltage starter main load red wire input Test electrical items below CB5 10A breaker Pink amp Org Grn ignition wiring continuity 12V power to ignition switch amp circuit functions of start amp ignition terminals Repair and replace as needed Repair or replace the defective R2 drive pedal sensor See Note A Note A Any time the machines hydrostat mounted neutral position sensor is replaced or the hydrostat linkage adjusted its neutral position must be re programmed Also any time the A2 control box is replaced it must be re programmed See the programming options section in this 24 FORM NO 56043129 SR 1900 ENGINE SYSTEM TROUBLESHOOTING GUIDE Symptom GM 1 6L 4 cylinder engine will crank but not sta
107. x VIO 18 2 i a VIO 18 18 O VIO 18 3 11 1 BLUWHT 18 1 S6 12 2 GRN GRA 18 1 p BLK 18 9 GAUGE FUEL 13 BRNIBLK 18 1 xis m 1 2 _ YELNIO 18 1 BLK 18 8 YEL RED 18 1 14 4 18 1 T GRN BRN 18 1 15 5 RED GRA 18 1 4 4 YEL WHT 18 1 16 6 BLU GRA 18 1 GRN RED 18 1 312 eee TEMPS X59 GRA BLU 18 1 17 7 BLK WHT 18 1 GENAMMT ES 21 IDE YEL BLK 18 8 CURB LIGHT GRA WHT 18 1 18 8 18 1 2 OPTIONAL REAR WORK LIGHT 1 HOURMETER VIO BRN 18 1 19 9 YEL GRN 18 1 BLK GRN 18 1 11221 E YEHBUK 18H VIO 18 18 5 BLK 18 2 20 1110 BLK 18 1 SENCOR EXSUDINE M2 X40 D 18 19 4 h 3 ja GM ENGINE B BLK 14 1 C YEL BLK 18 2 LIGHT OPTIONS vig 18 19 WHT GRA18 1 8 1 YEL GRA 18 1 n3 S aye GRN YEL 18 2 PINK 181 11 4 GRAJYEL 18 1 GRA BLK 18 1 2 X209 ORN BLK 18 1 12 5 GRN YEL 18 1 2 L GRN YEL 18 2 2 13 8 M8 54 x53 X55 neg GRN YEL 18 4 SE SENDER FUEL LP4 E LAMP RIGHT REAR SIGNAL B 5x4 P 1 BLK 18 9 X52 X37 X38 OPTIONAL BLUGRN 14 2 A BLK 18 7 B B SP16 CX6 BLK 18 7 BLK RED 16 1 B B 3 MOTOR SHAKER ORN BLK 18 1 1 2 PINK VEL 161 AI A 2 BLK WHT POCKET FILTER X125 X12 J SWITCH MAIN BROOM xn X73 N BLK gt e i SP15 PERS FEET BRN BLK 18 3 CHER VIO YEL 184 A A VIO YEL 18 6 EMT BLESS gt amp NOTE BRN BLK 18 3 IS FROM MISTING PUMP HARNESS 1P12 3 NUN

SR 1900 - IPS CLEAN

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