6600/6650 *330915* Service Information Manual. (Paper Manual) Rev (CD -ROM)

Transcription

1 6600/6650 Service Information Manual (Paper Manual) Rev. 00 *330915* (CD -ROM)

2 This manual provides service information for the TENNANT Model 6600/6650. This machine will provide excellent service. However, the best results will be obtained at minimum costs if: D D D The machine is operated with reasonable care. The machine is maintained regularly -- per the maintenance instructions provided. The machine is maintained with TENNANT supplied or approved parts. Paper Manual Number CD--ROM Manual Number Revision: 00 Published: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Copyright E 2003 TENNANT, Printed in U.S.A.

3 6600 Electrical Troubleshooting Charts GAS & L.P. OVERALL ELECTRICAL DIAGRAM DIESEL OVERALL ELECTRICAL DIAGRAM Key Switch Charging System Gas/L.P. Start Circuit Diesel Start Circuit Gas/L.P. Power-Up Circuit Diesel Power-Up Circuit Gas/L.P. Check Engine Lamp Circuit Gas/L.P. Oil Pressure & Hour Meter Circuit Diesel Oil Pressure & Hour Meter Circuit Vacuum Fan Circuit Vacuum Restriction Warning Circuit Gas/Diesel Fuel Sender Circuit Low L.P. Fuel Sender Circuit Shaker Motor Circuit Thermo-Sentry Circuit Hopper Door Switch Circuit with ZEEMS Gas/L.P. ZEEMS Check Engine Fault Codes Hydraulic Troubleshooting Charts OVERALL HYDRAULIC DIAGRAM HYDRAULIC HOSE ROUTING MAIN BRUSH MAIN & SIDE BRUSH VACUUM FAN RAISE HOPPER LOWER HOPPER OPEN HOPPER DOOR CLOSE HOPPER DOOR RIGHT TURN LEFT TURN PROPEL SYSTEM Electrical Troubleshooting Charts GAS & L.P. OVERALL ELECTRICAL DIAGRAM DIESEL OVERALL ELECTRICAL DIAGRAM Key Switch Charging System Gas/L.P. Start Circuit Diesel Start Circuit Gas/L.P. Power-Up Circuit Diesel Power-Up Circuit Gas/L.P. Check Engine Circuit Gas/L.P. High Engine Temperature Circuit Diesel High Engine Temperature Circuit Gas/L.P. Oil Pressure Circuit Diesel Oil Pressure Circuit Vacuum Fan Circuit Vacuum Restriction Warning Circuit Gas/Diesel Fuel Sender Circuit Low L.P. Fuel Sender Circuit Shaker Motor Circuit Thermo-Sentry Circuit Hopper Door Circuit Hopper Up/Down Circuit Main Brush Stall Circuit Main Brush On & Down Circuit Main & Side Brush On & Down Circuit Interlocks Operational/Diagnostic/Maintenance Modes... 77

4 Six Operational Modes with ZEEMS ZEEMS Check Engine Fault Codes Machine Control Board Pin Functions Hydraulic Troubleshooting Charts OVERALL HYDRAULIC DIAGRAM HYDRAULIC HOSE ROUTING MAIN BRUSH MAIN & SIDE BRUSH VACUUM FAN RAISE HOPPER LOWER HOPPER OPEN HOPPER DOOR CLOSE HOPPER DOOR LOWER MAIN BRUSH RAISE MAIN BRUSH LOWER SIDE BRUSH RAISE SIDE BRUSH RIGHT TURN LEFT TURN MAIN BRUSH STALL TRIGGERING PRESSURE SWITCH PROPEL SYSTEM ECU - Black Connector ECU - White Connector ECU - Pin Descriptions Engine Maintenance Schedule Engine General Specifications ZEEMS - Zenith Electronic Engine Management System Overview Block Diagram ECU Inputs Inputs, RPM Inputs, ECT & IAT Inputs, MAP Inputs, EGO Inputs Review Output Control Governor Fuel Injector Ignition Timing Open/Closed Loop Open & Closed Loop Closed Loop to Open Loop Closed Loop Operation Review Questions and Answers System Operation Key On Cranking Running Diagnostics Failures ECU Quick Tests Output Control Frequency Test Processor Quick Tests Input Sensor Quick Tests IAT and ECT Testing

5 MAP Testing EGO Testing Output Sensors Quick Test Failures Fuel Injector Testing Governor Actuator Testing Ignition Timing Testing Diagnostic Review Specifications Block Diagram Review Operation Review ZEEMS Troubleshooting Test Kit Gas Injector - Noid Light Tennant Part # LPG Injector - Noid Light Tennant Part # Engine Controls AIR AND COOLANT SENSOR RESISTANCE DIAGSTIC PROCEDURES Engine Idle Speed High Engine Speed Spikes Intermittentl Engine Runs Erratically, Poor Governor Performance Engine Runs, But Will Not Accelerate Engine Wont Start - Gasoline Gasoline Fuel Pump Diagnosis Engine Wont Start - LPG Engine Wont Start Dual Fuel Engine Runs, Low Power, Lean or Misfires Gasoline LPG Lock-Off Diagnosis Engine Runs Rich Gasoline Engine Runs, Low Power, Lean or Misfires LPG Engine Runs Rich LPG PSI - Operation and Maintenance Table of Contents Introduction How to Use this Manual Engine Identification Parts and Service Service Literature Operating Instructions Controls Ignition Switch Safety Gauges Fuel Systems Governors Instruments Oil Pressure Gaug Voltmeter Tachometer/Hourmeter Starting the Engine Carbureted, Mechanical Governor, Manual Choke Carbureted, Electric Choke, Electronic Governor LPG or NG Fuel Systems, Velocity Governors PSI Fuel Injection (Gasoline) PSI Fuel Injection (Gasoline/LPG)(Dual Fuel) Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor Stopping the Engine Fuel Recommendations Power Loss at Higher Elevations Carbureted Engines Fuel Injected Engines MAINTENANCE INSTRUCTIONS Initial Start Up Maintenance

6 Routine Maintenance Scheduled Preventive Maintenance Engine Oil Level Check Adding Engine Oil Changing Engine Oil and Filter Engine Oil Quality Oil Filter Engine Air Cleaner Cooling System Coolant Level Radiator Fan Belts Serpentine Belt V-Type Belt Fuel Filter Carbureted Engines TBI Engines Ignition Systems Ignition Timing Spark Plugs Storage One to Six Months For Extended Periods Removing the Engine From Extended Storage GM Engine Timing Procedures Maintenance Schedule Filter Chart Fuel System Chart GENERAL SPECIFICATIONS L Engine Spark Plug Wire Routing Torque Standards Inch Fasteners METRIC Fasteners Nylon Insert Lock Nuts Wheel Bolt and Nuts Tightening Nuts on Tapered Shafts Shoulder Bolts Taper Lockr Bushings Sequence Tightening

7 MODEL 6600 ELECTRICAL Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual DURING TESTS: * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action

8 OUTPUT+ 1D GROUND 13W -ALT 52 A 8C ENGINE BLOCK STARTER MOTOR ASSEMBLY POSITIVE BATTERY CABLE ENGINE BLOCK STARTER SOLEID COIL 83EB ENGINE HARNESS 83EC 1EA M-3 ENGINE HARNESS 28 1A 82EA 3EA J7--B 3A 2 83E 82E M-3 KEY:START 13F - START RUN X X X X X X 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 1 of 4 12 VDC LP5 EX. STARTER MOTOR STARTER SOLEID CONTACTS ALTERNATOR LIGHT MTR S--2 NEUTRAL START S F--5 30A FUSE 50 N.O./ CLOSED = DOWN 17 A A 13F D J 15A FUSE M-1 86 ACC 8L F-11 x=closed CONTACT 51A KEYSW 85 M K D 8EE J7--A 68EA B C 02 SENSOR 13EH 13EA 53EA ENGINE HARNESS O2-B J2--10 A J2--7 SL J1--14 ST J EF O2A J2--12 KEY1 13ED 13EC J EG 8C GD1 J1--20 KEY2 A 1C 1B J1--16 GD2 J1--21 RST LOW CURRENT GROUNDTHROUGHTHECONTROLLER 13EJ GND J2--11 GND. WITHENGINERUNNING WILLCLEAR FAULTCODES. A 55EA MAG1 J2--21 SOL3 L.P.INJECTOR MAG.PICK UP B 56EA J1--2 MAG2 J2--19 LP 54EA 69EC 70EA 69EA 57EA M B AUX. 2 RELAY M AUX. 1 RELAY C J1--15 MG-3 J2--20 INJ 6 13EL 58EA J1--3 SOL4 GASINJECTOR MP-C J EB MAP SENSOR C A GAS B 59EA MAP-B J2--17 D 60EA COIL-D J EE ZENITH ENGINE CONTROL 5EA 5 B + 8D COIL PACK B C 61EA COIL-B J1--18 J7--C HOUR METER A 63EA COIL-A J V REF. 148EA S-3 A B AIR TEMP SENSOR 13EM A S-4 B COOLANT TEMP SENSOR 1 13EK A MTR2 B GOVERR ACTUATOR 13EF A B 13M FUEl PUMP SOL4 A B 13L SOL5 L.P. LOCKOUT VALVE A B 13EG C OIL PRESSURE SWITCH 38B 64EA OXY J2--9 J9--F 65EA J EA T USED H20 J V J7--E 66EA J2--5 GOV J1--5 EX SPEED BIT B S--7 ENGINE SPEED SWITCH 38A 31A A 31EA J9--E J7--D J J2--16 FUEL SD2 67B J2--2 SPD1 29EA SPEED BIT A 29A 38B J9--D 5EA B LP5 27EB OIL J2--8 ENG 26EA J1--12 ENGINE TEMP/CHECK 26A 8B 27EC J9--C ENGINE SPEED SELECTION BITS A AND B BIT--A BIT--B 1350 RPM LOW: HIGH 0V 2000 RPM MED: 0V 2400 RPM HI GH : 0V H I G H 0V AUX #2 AUX #1 5 6 S-5 P1= WHITECONNECTOR P2 =BLACKCONNECTOR ENG. TEMP/CHECK LP5 27EA LOW OILPRESS. 27C 8A J9--A LOW OIL PRESS. S--6 13EB COOLANT TEMP SENSOR 2 B A 28EA ANALOG HIGH ENGINE TEMP T USED J9--B 1 T USED J9--G

9 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 2 of 4 87A/PUR 88A/GRN 62C/YEL 62B/YEL 62BB/YEL 62BA/YEL 62BC/YEL 93/ORA 93/ORA 34A 93B/ORA 94/YEL 76/ORA /YEL 4A/YEL 76A/ORA 76B/ORA 87/PUR 33A 13V 93A/ORA 79/YEL 88/GRN 4B/YEL 13NN 13QQ LAMP_HEADLIGHT 33A 4C/YEL 4D/YEL 33B LP7 SIDEBRUSH LIGHT 80/BLU D-3 S-9 HORN N.O. / CLOSED = HORN FLASHER LP10 DIRECTIONALSWITCH 7 RED YEL 1 4 GRN BLU 6 89/BRN 8 BLK 77/GRY 90/GRY BLK/ GRY 3 LP1 LP8 RUN LIGHT,R.H. REVOLVING LIGHT, OHG F-12 15A FUSE LP3 TAILLIGHT, R.H. LP5 HEADLIGHT,R.H. S-8 N.O. / CLOSED = REVERSE REVERSE SWITCH F-4 9 S-10 GRY LP4 TAIL LIGHT, L.H. HORN LP2 LP6 LP9 RUN LIGHT,L.H. HEADLIGHT, L.H. LOW MOUNTED BEACON F-3 15A FUSE 13KK FLASHER 13LL 3 REVERSEALARM 13Q 13U 13GG 13FF 13T 13S 13BE 13BD 13BF 13P 81A/YEL 15A FUSE 81/YEL S-11 N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH 62A/YEL LIGHT SWITCH S-12 62/YEL 62BA/YEL F-20 15A FUSE 95A 95A 95...WIRING COLOR CODE... RIGHT MOST DIGIT COLOR OF WIRE OF WIRE NUMBER IN HARNESS 2 0 TAN 1 PINK 2 BRN 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE 7 PURPLE 8 GRAY 9 WHITE 1A P 1 X 2 L 3 1D AUX #

10 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 AUX #1 6 F-19 13E 13BA S-13 HOPPER DOOR 7D 15A FUSE 14BA 7A N.O. / CLOSED = DOWN 14 HOPPER DOOR CLOSED S-14 FUEL SENDER 13L 15 FUEL GAUGE IN SEN 7C 13D GND S -14A LOW L.P. LOWL.P. 13R 16 7B N.O. / CLOSED = LOW L.P. THERMAL SENTRY SWITCH HIGH HOPPER TEMP 11BA 11 7A 13E 13BB COM S--15 SOL5 VAC.FAN SOLEID NC 19B B A 18B 19BA 19A D--2 18A 18A 13A GROUND FOR LAMP INSIDE SWITCH 13A LAMP(-) LAMP(+) A N.O./ CLOSED = HOPPER DN. S-16 HOPPER DOWN 6 7F SHAKER TIMER MODULE 7L 7L 7K B S-17 INIT 6 13B 2 LOAD GND VAC/SHAKER SWITCH M.O.M. 7J M-4 86 HOPPER STATIC GROUND 105 SHAKER PULSE MODULE 13C A 47BB 48BB H (-) OUT M-4 47 SHAKER SOLEID SOL1 (+) 3 CLOGGED VAC FAN 13U S-18 CLOGGED VACUUM FAN 22 7 N.O./ CLOSED=CLOGGED S-19 7E STALLED BRUSH 24 STALLED BRUSH 13H N.O./ CLOSED=STALLED

11 6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 4 of 4 4 DEFROST FAN 13DDD/BLK O PTIONAL AC AND CAB HARNESSES AUX #2 YEL BRN 111/ORA DOME LIGHT S C/ORA DOMELIGHT 116/BLU 13CCC/BLK WINDSHIELD WIPER BLK AC1 115/GRN GND BLU 13AAA/BLK YEL YEL 119/YEL BLK ORG/GRN 120/ORA 86 AC2 85 BLK YEL LOW GND BRN ORG ORG HIGH BLK GND BLK YEL ORG RED 118/GRY OFF 111B/ORA YEL RED S /PUR 113/YEL 13EEE/BLK 13AAA/BLK BLK AC COMPRESSOR GND CLUTCH SOL. BLK/WHT GRN GND BATTERY, B+ BLU AUX #2 111D/ORA WHT WHT WHT 111F/ORA 111E/ORA LOW MEDIUM HIGH COM WIPER SWITCH 50A 50 AC CONDENSERPRESS. A B AC EVAP. TEMP A B S-12 AC [ON -OFF] AC CONDENSERFANS D-6 CAB/PRESS. FAN SWITCH...WIRING COLOR CODE... RIGHT MOST DIGIT COLOR OF WIRE OF WIRE NUMBER IN HARNESS 0 TAN 1 PINK 2 BRN 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE 7 PURPLE 8 GRAY 9 WHITE UNLESS SPEC IFIED DIFFERENTLY ON SC HEMATIC F-8 15A FUSE BATTERY, B+ 15A FUSE 20A FUSE F-21 SWITCH BLK/WHT F S-15 OFF LOW HIGH COM 1 2 SWITCH 20A FUSE F LOW HIGH AC EVAP./CAB PRESS.FANS

12 13W OUTPUT+ GROUND ALT LP5 52 1D 8C A ENGINE BLOCK STARTER MOTOR ASSEMBLY ALTERNATOR LIGHT POSITIVE BATTERY CABLE ENGINE BLOCK STARTER SOLEID COIL ENGINE HARNESS 83 M7B 1K ENGINE HARNESS 42B ENGINE BLOCK 28 ENGINE HARNESS 13BD 1A ENGINE START TIMER MODULE 13BD LP1 OPTIONAL GLOW PLUG LAMP 42A 13BB 1 LOAD GND 3A J7 -B 3C KEY:START DIESEL OVERALL ELECTRICAL DIAGRAM Part 1 of VDC STARTER MOTOR STARTERSOLEID CONTACTS - EX. MTR1 GP--1 GP--2 GP--3 GP--4 GLOW PLUG 3A S-2 NEUTRAL START S-1 30 F-5 30A FUSE 2 RUN GLOW PLUG CREATES DELAY BETWEEN ENGINE START ATTEMPTS. 82 8BB 56 M7A B+ N.O./CLOSED = DOWN START X X IN IT 8BA 8BE 42A 34 X KEYSW M8B 87 15A FUSE ACC X X X 56 J7-A M8C 30 87a D-3 F-11 X=CLOSED CONTACT 3B A 13BC TO ALTERNATOR 13BG 55 55A T USED M8A J7 -E D C 1B 13M 67C T USED B 67A M6B 87 8BD J9 -G FUEL PUMP J7 -D 13L B 67B 30 M6C 87a 3D T USED L.P. LOCK OUT VALVE J9 -B SOL5 M B AUX. 2 RELAY M M6A BC 6 AUX. 1 RELAY 13BF OILPRESS. SWITCH 5A 5B A B N.O.OIL PRESSURE 27 C S D J7 -C HOUR METER 8A LP5 27C N.C. OIL PRESSURE J9-A LOW OIL PRESS. GOVERR 59 E D 61A F C 61 G B 13BA H A 8BF THROTTLE ACTUATOR + - ENG. SPEED/MAG. PICK -UP BA 29 J9 -D S-7 29A B 38A J9 -F 8BG 31 SPEED BIT A J9 -E 31A B ENGINE BLOCK ENGINE SPEED SWITCH 8BF EN G I N ESPEEDSELECTION BIT A BIT B 1350RPM LOW: HIGH 0V 2000RPM MED: 0V HI GH 2400RPM HI G H : 0 V 0 V AUX #2 AUX #1 SPEED BIT B S-16 HIGH ENGINE TEMP. 26 LP5 8B 26A N.O../CLOGGED = HIGH TEMP J9 -C ENG. TEMP/CHECK 13F 13F D J M A 85 8K M

13 DIESEL OVERALL ELECTRICAL DIAGRAM Part 2 of /YEL 4A/YEL 87/PUR 79/YEL 87A/PUR 88A/GRN 62C/YEL 62B/YEL 62BB/YEL 62BA/YEL 62BC/YEL 76/ORA 76A/ORA 76B/ORA 93/ORA 93/ORA 34A 93B/ORA 94/YEL 13Q 92 88/GRN 4B/YEL 80/BLU 89/BRN 77/GRY 13U 90/GRY 33A 13V 93A/ORA 81A/YEL 81/YEL S-11 13NN 13QQ LAMP_HEADLIGHT 33A 4C/YEL 4D/YEL 62A/YEL 62BA/YEL 33B LP7 SIDEBRUSH LIGHT 62/YEL D-3 S-9 HORN N.O. / CLOSED = HORN FLASHER LP10 DIRECTIONALSWITCH RED 7 YEL 1 GRN 4 BLU 6 BLK 8 BLK/ GRY 3 GRY 9 LIGHT SWITCH S-12 F-20 15A FUSE 2 95A LP1 LP8 RUN LIGHT, R.H. REVOLVING LIGHT, OHG F-12 15A FUSE LP3 TAILLIGHT, R.H. LP5 HEADLIGHT,R.H. S-8 N.O. / CLOSED = REVERSE REVERSE SWITCH F-4 S-10 15A FUSE N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH LP4 TAIL LIGHT, L.H. HORN LP2 LP6 LP9 RUN LIGHT,L.H. HEADLIGHT, L.H. LOW MOUNTED BEACON F-3 15A FUSE FLASHER 13GG 3 REVERSEALARM 13FF 13T 13S 13BE 13BD 13BF 13KK 13P 13LL 95A WIRING COLOR CODE RIGHT MOST DIGIT COLOR OF WIRE OF WIRE NUMBER IN HARNESS 0 TAN 1 PINK 2 BRN 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE 7 PURPLE 8 GRAY 9 WHITE P L X A 1D AUX #

14 6600 DIESEL OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 13E 13L 13D 13R 13E 13A 13B 13C 13U 13H AUX #1 6 F-19 7D 15A FUSE S BA HOPPER DOOR 13BA N.O./ CLOSED = DOWN 7A HOPPER DOOR CLOSED S-14 FUEL SENDER 15 FUEL GAUGE IN SEN 7C GND S -14A LOWL.P. LOWL.P. 16 7B N.O. / CLOSED=LOW L.P. THERMAL SENTRY SWITCH 11BA HIGH HOPPER TEMP 11 7A 13BB COM S-15 SOL5 VAC. FAN SOLEID NC 19B B A 18B 19BA 19A D-2 18A 18A N.O./CLOSED = HOPPER DN. GROUND FOR LAMP INSIDE SWITCH 13A LAMP(-) LAMP(+) A S-16 HOPPER DOWN 7F TIMER MODULE 7K M-4 7L S-17 M.O.M. VAC/SHAKER SWITCH 7L B+ INIT GND LOAD J 105 HOPPER STATIC GROUND PULSE MODULE A 47BB 48BB H (-) OUT M (+) SHAKER SOLEID SOL1 S-18 CLOGGED VACUUM FAN CLOGGED VAC FAN 22 7 N.O./ CLOSED=CLOGGED S-19 STALLED BRUSH STALLED BRUSH 7E 24 N.O./ CLOSED=STALLED

15 DIESEL OVERALL ELECTRICAL DIAGRAM DEFROST FAN 13DDD/BLK 111/ORA 15A FUSE 50A AUX #2 111F/ORA F-7 116/BLU DOME LIGHT 13CCC/BLK DOME LIGHT S C/ORA WINDSHIELD WIPER OFF S /PUR O P TIONAL AC AND CAB HARNESSES 113/YEL 13EEE/BLK 111E/ORA 111D/ORA 13AAA/BLK LOW MEDIUM HIGH COM BLK WIPER SWITCH AC COMPRESSOR GND CLUTCH SOL. GND AC CONDENSER PRESS. A B BLK/WHT SWITCH AC EVAP. TEMP A B BLK/WHT GRN BLK AC1 S-12 SWITCH 115/GRN 111B/ORA BLU AC [ON -OFF] WHT WHT YEL YEL 20A FUSE AC CONDENSOR FANS RED BATTERY, B+ GND BLU F-21 Part 4 of 4 13AAA/BLK D-6 YEL YEL WHT 119/YEL S-15 OFF ORG/GRN 86 AC2 85 BLK BLK YEL LOW GND BRN ORG ORG HIGH BLK 118/GRY F-10 15A FUSE 120/ORA LOW HIGH COM 50 AUX #2 1 2 CAB/PRESS. FAN SWITCH BRN 20A FUSE RED BATTERY, B+ LOW GND BLK YEL ORG F-22 HIGH AC EVAP./CAB PRESS. FANS...WIRING COLOR CODE... RIGHT MOST DIGIT COLOR OF WIRE OF WIRE NUMBER IN HARNESS 0 TAN 1 PINK 2 BRN 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE 7 PURPLE 8 GRAY 9 WHITE UNLESS SPECIFIED DIFFERENTLY ON SCHEMATIC

16 Key Switch ACC GLOW PLUG POSITION (Diesel Only) Spring loaded- Returns to "OFF" unless held Glow Plug OFF RUN KEY SWITCH START Glow Plug OFF RUN KEY SWITCH START OFF POSITION ACC OFF OFF 30 Glow Plug RUN START Glow Plug RUN START 30 KEY SWITCH KEY SWITCH ACC ACC RUN POSITION START POSITION Spring loaded-returns to RUN" unless held SWITCH TERMINAL MARKING KEY SWITCH POSITION GLOW PLUG OFF RUN START CONNECTIONS ACC. Indicates a common connection TE: Common connections in various switch positions should be less than

17 6600 Charging System Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11, turn key to RUN position (KOEO-Key On, Engine Off) Start engine (KOER-Key On, Engine Running), run engine at high governed RPM Is Alternator light lit? Test ALTERNATOR LIGHT; Re-test battery, re-check battery terminals, connections, wiring, and fuses F-5 & F-11; Restart diagnostic steps With lights on, check voltage at battery terminals- Is it 13.5 to 16.5 Volts? Is Alternator light lit? System operating correctly Re-test battery, re-check battery terminals, connections, wiring, and fuses F-5 & F-11; Suspect faulty alternator PLEASE TE: When finished, please reconnect all wires disconnected during testing

18 6600 Gas/L.P. Start Circuit POSITIVE BATTERY CABLE EA 83EC x x Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions x x xx 8 8L Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position 82EA 8EF 8EG 83EA PIN 7 BLACK CONNECTOR PIN 14 WHITE CONNECTOR PIN 22 PIN 20 PIN 23 PIN 21 ZENITH ENGINE CONTROLLER 13ED 13EC Does STARTER MOTOR click or make any other noises? Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Repair or replace STARTER MOTOR CAUTION! Disconnect wire harness plug from DIS ignition coil and turn key to OFF position for next test. With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLEID studs (the STARTER SOLEID is an integral part of the STARTER MOTOR) 12 Re-check all connections, wiring and fuses F-5 & F- 11; Test relay M-3; Test Key Switch; Test for proper power & ground connections at ZENITH ENGINE CONTROLLER (refer to ZEEMS troubleshooting) Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Repair or replace STARTER MOTOR As the remote start switch is engaged, does the STARTER MOTOR crank the engine? PLEASE TE: When finished, please reconnect all wires disconnected during testing

19 6600 Diesel Start Circuit POSITIVE BATTERY CABLE ACC A 34 13BB Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8BC 42B 8BE 3C 13M 5A 8D Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position 8A Does STARTER MOTOR click or make any other noises? Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR CAUTION! Turn key to OFF position for next test. With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLEID studs (the STARTER SOLEID is an integral part of the STARTER MOTOR) Re-check all connections, wiring and fuses F-5 & F-11; Test relays M-6, M- 7, & M8; Test ENGINE START TIMER MODULE; Test Key Switch Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR As the remote start switch is engaged, does the STARTER MOTOR crank the engine? PLEASE TE: When finished, please reconnect all wires disconnected during testing

20 6600 Gas/L.P. Power-Up Circuit x x x x xx 8 8L 8EF 8EG PIN 22 WHITE PIN 20 CONNECTOR PIN 23 PIN 21 ZENITH ENGINE CONTROLLER 13ED 13EC Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions Check all connections, wiring, and fuses F-5 & F-11, turn key to ON position (KOEO-Key On, Engine Off) Is battery voltage measured across all power and ground connections at ZENITH ENGINE CONTROLLER? Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch 14 PLEASE TE: When finished, please reconnect all wires disconnected during testing

21 Diesel Power-Up Circuit 1D 28 GOVERR CONTROLLER 40A FUSE PIN A PIN B 2 3A 3C 34 8BF 13BA Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 13BG 13M 13BF 8A 5A Check all connections, wiring, and fuses F-5 & F-11; Turn key to ON position (KOEO-Key On, Engine Off) Is battery voltage measured across all power and ground connections at GOVERR CONTROLLER? Refer to PRECISION GOVERR troubleshooting to test GOVERR CONTROLLER Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing 15

22 6600 Gas/L.P. Check Engine Lamp Circuit x x x x xx 8L 8EF 8EG 26EA PIN 22 PIN 23 PIN 20 WHITE CONNECTOR PIN 12 PIN 21 13ED 13EC Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8B 26A ZENITH ENGINE CONTROLLER ENGINE TEMP / CHECK ENGINE LAMP Note: Lamp will light if engine overheats or if an engine system fault is detected Check all connections, wiring, and fuses F-5 & F-11, turn key to ON position (KOEO-Key On, Engine Off) Is CHECK ENGINE LAMP flashing? Refer to ZENITH ENGINE FAULT CODES to diagnose engine or sensor faults Test CHECK ENGINE LAMP; Re-check all connections, wiring, and fuses F-5, & F-11; Test for proper power and ground connections at ZENITH ENGINE CONTROLLER; Test Key Switch; Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER 16 PLEASE TE: When finished, please reconnect all wires disconnected during testing

23 6600 Gas/L.P. Oil Pressure & Hour Meter Circuit x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8D ZENITH ENGINE CONTROLLER OIL PRESSURE SWITCH 6 PSI 27EC 13EG 8A BLACK CONNECTOR PIN 8 27C 27EB 27EA Check all connections, wiring, and fuses F-5 & F-11, turn key to ON position (KOEO-Key On, Engine Off) Is LOW OIL PRESSURE lamp lit? With engine running, does lamp go out? Remove harness plug at OIL PRESSURE SWITCH and place a jumper wire across harness plug wires B & C With engine running, is battery voltage measured across HOUR METER terminals? Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH Is LOW OIL PRESSURE lamp lit? Replace OIL PRESSURE SWITCH Re-check HOUR METER connections and wiring; Suspect faulty OIL PRESSURE SWITCH Test or replace HOUR METER Test LOW OIL PRESSURE lamp; Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing 17

24 6600 Diesel Oil Pressure & Hour Meter Circuit + - 1D 40A FUSE 28 Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8D OIL PRESSURE SWITCH A B 13BF A C Check all connections, wiring, and fuses F-5 & F-11, turn key to ON position (KOEO-Key On, Engine Off) Is LOW OIL PRESSURE LED lit? With engine running, does lamp go out? Remove harness plug at OIL PRESSURE SWITCH and place a jumper wire across harness plug wires B & C With engine running, does HOUR METER run? Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH Is LOW OIL PRESSURE lamp lit? Verify proper oil pressure in engine; Suspect faulty HOUR METER; Suspect faulty OIL PRESSURE SWITCH Verify proper oil pressure in engine; System operating correctly Replace OIL PRESSURE SWITCH Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing

25 Vacuum Fan Circuit 28 x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions LED INSIDE SWITCH 3 POSITION VAC FAN & FILTER SHAKER SWITCH S W I T C H POS.1 VAC FAN ON POS.2 ALL FUNCTIONS OFF POS.3 RUN SHAKER (MOMENTARY) 13A HOPPER SWITCH (RMALLY OPEN) SHOWN CLOSED (HOPPER DOWN) TO HIGH HOPPER TEMP LAMP SHOWN WITH SWITCH IN VAC FAN ON POSITION 13BB 13E Check all connections, wiring, and fuses F-5, F-11 & F-19, have hopper in full DOWN position, turn key to ON position (KOEO-Key On, Engine Off) With switch in VAC FAN ON (position 1), is battery voltage measured across wires at VAC FAN SOLEID (SOL5) plug? Repair or replace faulty hydraulic or mechanical components; Suspect faulty VAC FAN SOLEID coil Re-check all power & ground connections and fuses F-5, F-11 & F-19; Test HOPPER SWITCH; Test THERMO-SENTRY SWITCH (see circuit chart); Test 3-POSITION VAC FAN/SHAKER SWITCH; Test relay M-1; Test diodes D-1 & D-2; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing

26 6600 Vacuum Restriction Warning Circuit x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 7D VACUUM SWITCH (RMALLY OPEN) SEE TE BELOW U Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) VACUUM SWITCH TE Vacuum switch closes if vacuum fan is running with any one of these conditions: - a blocked (dirty) vacuum panel filter - a blocked Perma-Filter - a closed hopper door Remove wire plug from VACUUM SWITCH and place a jumper wire across harness plug wires Is CLOGGED VAC FAN lamp lit? Suspect faulty VACUUM SWITCH Test CLOGGED VAC FAN lamp; Re-check power & ground connections and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch 20 PLEASE TE: When finished, please reconnect all wires disconnected during testing

27 6600 Gas/Diesel Fuel Sender Circuit x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 7D 7C S14 FUEL SENDER 0 to 90 13L 90 = FULL TANK 13D Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wires from FUEL SENDER at tank and watch FUEL GAUGE; Place jumper wire across FUEL SENDER wires and watch FUEL GAUGE again Does FUEL GAUGE needle deflect from FULL to EMPTY? Suspect faulty FUEL SENDER Is battery voltage measured between wires IN & GND at FUEL GAUGE? Re-check wiring to FUEL SENDER ; Suspect faulty FUEL GAUGE Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing

28 6600 Low L.P. Fuel Sender Circuit x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 7D 7B LOW L.P. 13R With a full L.P. tank properly connected to machine, with L.P. supply valve fully open, turn key to ON position (KOEO-Key On, Engine Off) Check all connections and wiring; Suspect faulty LOW L.P. SWITCH Is LOW L.P. lamp lit? Fully close L.P. supply valve on L.P. tank and run machine until engine runs out of fuel Is LOW L.P. lamp lit? System operating properly Remove plug at LOW L.P. SWITCH and place a jumper wire across harness wires Is LOW L.P. lamp lit? Suspect faulty LOW L.P. SWITCH Test LOW L.P. LAMP; Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch 22 PLEASE TE: When finished, please reconnect all wires disconnected during testing

29 Shaker Motor Circuit 28 x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions HOPPER DOWN SWITCH RMALLY OPEN- CLOSED WITH HOPPER DOWN 3 POSITION VAC FAN & FILTER SHAKER SWITCH S W I T C H POS.1 VAC FAN ON POS.2 ALL FUNCTIONS OFF (CENTER) POS.3 RUN SHAKER (MOMENTARY) 13B SHOWN WITH SWITCH IN RUN SHAKER POSITION 13C Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wire from #2 post of SHAKER PULSE MODULE; Momentarily push SHAKER SWITCH (position 3) Momentarily push SHAKER SWITCH (position 3)- Is battery voltage measured across terminals #3 & #1 at SHAKER PULSE MODULE? Does SHAKER SOLEID pulse as wire is tapped to ground? Disconnect SHAKER SOLEID plug; Connect one SHAKER SOLEID wire to ground and the other to battery (+) Suspect faulty SHAKER PULSE MODULE Repair power or ground circuits leading to SHAKER PULSE MODULE Go to A Next Page PLEASE TE: When finished, please reconnect all wires disconnected during testing

30 6600 Shaker Motor Circuit (continued) A Does SHAKER SOLEID pulse as ground side wire is tapped to ground? Suspect faulty SHAKER SOLEID Reconnect SHAKER SOLEID to circuit Push & hold SHAKER SWITCH (position 3) - Is battery voltage measured across posts #6 & #1 at SHAKER TIMER MODULE? Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test 3- POSITION VAC FAN/SHAKER SWITCH; Test relay M-1; Test diode D-1; Test Key Switch; Replace components as needed Momentarily push SHAKER SWITCH (position 3) - Is battery voltage measured across posts #85 & 86 at relay M-4? Re-check connections & power feed on post #30 at relay M-4; Suspect faulty relay M-4 Re-check power & ground circuits to SHAKER TIMER MODULE; Suspect faulty SHAKER TIMER MODULE 24 PLEASE TE: When finished, please reconnect all wires disconnected during testing

31 Thermo-Sentry Circuit 28 x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 7D TO VAC. FAN SWITCH SOL 5 VAC. FAN SOLEID 13E Check all connections, wiring, and fuses F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wires from & COM terminals at THERMO-SENTRY SWITCH and connect wires with a jumper wire Is HIGH HOPPER TEMP LAMP lit? Reset or suspect faulty THERMO-SENTRY switch Test HIGH HOPPER TEMP LAMP; Recheck all power and ground circuits and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing

32 6600 Hopper Door Switch Circuit x x x x xx Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 7D 7C7A 14 Close Hopper Door; Turn key to ON position (KOEO-Key On, Engine Off) HOPPER DOOR SWITCH (RMALLY OPEN) CLOSED WITH HOPPER DOOR CLOSED 13E Is HOPPER DOOR CLOSED LAMP lit? Open Hopper Door; Turn key to ON position (KOEO-Key On, Engine Off) Is HOPPER DOOR CLOSED LAMP lit? Remove wire harness plug from HOPPER DOOR SWITCH and place a jumper wire across harness wires Check all connections and wiring; Suspect faulty HOPPER DOOR SWITCH System operating properly Is HOPPER DOOR CLOSED LAMP lit? Suspect faulty HOPPER DOOR SWITCH Test HOPPER DOOR CLOSED LAMP; Re-check all connections, wiring, and fuses F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch 26 PLEASE TE: When finished, please reconnect all wires disconnected during testing

33 6600 with ZEEMS (Zenith) Engine Management System Check Engine Light illumination for "12" will be as follows: on, medium off, on, short off, on; longer pause; on, medium off, on, short off, on; longer pause. on, medium off, on, short off, on. (other code readouts are similar) 2-3 Seconds running then off Blinks Continuously (either 0.5 seconds on then 1 second off or 1 second on then 1 second off) Low Oil Pressure automatic shutdown sequence activated Start and Run Engine Does engine "shut off" after 2-3 seconds or 40 seconds of running? 40 Seconds running then off Turn Key Off, Turn Key On, Engine Off (KOEO) Does Check Engine Light Blink Continuously, Blinks Another Sequence or Blink 12, 12, 12? (3 times only) Blinks another sequence (3 times only) Blinks 12,12,12 Tennant Engine Trouble Codes are: 14-ECT Sensor Open (Engine Coolant Sensor) 15-ECT Sensor Shorted (Engine Coolant Sensor) 23-ACT Sensor Open (Air Temperature Sensor) 24-ACT Sensor Shorted (Air Temperature Sensor) 33-MAP Sensor Open (Manifold Absolute Pressure) 34-MAP Sensor Shorted (Manifold Absolute Pressure) 44-O2 Sensor Lean (Oxygen Sensor) 45-O2 Sensor Rich (Oxygen Sensor) High Temperature automatic shutdown sequence activated No Engine Fault Codes Detected during KOEO and KOER STOP No Engine Fault Codes Detected during KOEO Start and Run Engine Is Check Engine Light On during Key On, Engine Run? (KOER) Service and Repair as Required Clear Codes by momentarily grounding 49/White "pigtail" while engine is running RETEST

34 6600 Gas/L.P. ZEEMS Check Engine Fault Codes MACHINE STATUS Key On, Engine Off (KOEO) No engine faults detected Key On, Engine Running (KOER) No engine faults detected Key On, Engine Running (KOER) Engine fault(s) detected Key On, Engine Off (KOEO) Engine fault(s) detected Key On, Engine Running (KOER) High engine temperature sensed AUTOMATIC ENGINE SHUTDOWN OCCURS TE: If key switch is turned off and machine restarted, engine will run 40 seconds until another automatic shutdown Key On, Engine Running (KOER) Low engine oil pressure sensed AUTOMATIC ENGINE SHUTDOWN OCCURS TE: If key switch is turned off and machine restarted, engine will run 2 to 3 seconds until another automatic shutdown CHECK ENGINE LAMP Blinks 12,12,12 continuously OFF ON Blinks engine fault code (see chart below) Blinks ON/OFF continuously (0.5 sec. ON, 1 sec. OFF) (Note: There is no separate high engine temp lamp for gas or L.P. engines) Blinks ON/OFF continuously (1 sec. ON, 1 sec. OFF) and LOW OIL PRESSURE lamp turns on CONDITION with Key On, Engine Off (KOEO) Beginning of fault codes, or OK if no other codes displayed Engine coolant sensor OPEN Engine coolant sensor SHORTED Air temp sensor OPEN Air temp sensor SHORTED MAP sensor OPEN, circuit voltage >4.98V MAP sensor SHORTED FAULT CODE DISPLAYED (ON CHECK ENGINE LAMP) 12, 12, 12 14, 14, 14 15, 15, 15 23, 23, 23 24, 24, 24 33, 33, 33 34, 34, 34 TO CLEAR FAULT CODES AND TURN OFF CHECK ENGINE LAMP Ground PIN # 16 of the WHITE CONNECTOR at the ZENITH ENGINE CONTROLLER while engine is running (Note: Some controllers have a wire pigtail that is connected to PIN #

35 MODEL 6600 HYDRAULIC Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual * Engine & Hydraulic Oil Must Be At Normal Operating Temperatures after Running Machine and Hydraulics a Minimum of 5 Minutes * Examine Machine For Any Linkage Binding or Mechanical Problems DURING TESTS: * Maintain Normal Main Brush Pressure as Listed in Operator's Manual * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action

36 6600 OVERALL HYDRAULIC DIAGRAM (Part 1 of 2) T CK5 CV3 R STEERING SYSTEM VACUUM FAN 12V DC CV2 RV6 P L CYL4 2,0 x 08,0 in, 600 psi 6.1 cu.in. PMP3 RV psi,194 cu,in, MTR4 OUT BYD CV1 LIFT CV1C F E TV1,047 dia, CYL1 LIFT CK4 2,50 x 15,0 in, DOOR CV1B D C MTR2 CYL2 CLOSE 2,0 x 04,0 in, BROOMS CV1A B A 17,9 cu,in, SIDE BROOM MAIN BROOM RV psi IN MTR RPM RPM RPM RPM RPM RPM 2,8 cu,in, PLEASE TE: All specifications listed are for normal operating conditions

37 6600 OVERALL HYDRAULIC DIAGRAM (Part 2of 2) PMP1 PMP2C,40 cu,in, PMP2B,66 cu,in, PMP2A,66 cu,in, PMP2 RV psi 4000 psi RV3 CK1 CK2 RV1 CV4 PMP1A 120 psi 1,44 cu,in, PMP1B PROPEL SYSTEM M SPEED 1 = 2000 RPM SPEED 2 = 2400 RPM ORnn ORnn CV5 MTR1 STRN1 25 psi RV4 3psi FLTR RV7 HTX RES AUX...Auxiliary CK...Check Valve CM...Centimeters CU...Cubic CV...Control Valve CYL...Cylinder DC...Disconnect Coupler (Hydraulic) DC...Direct Current (Electrical) FLTR...Filter GPM...Gallons per Minute EXPLANATION OF ABBREVIATIONS HTX...Heat Exchanger IN...Inches LH...Left Hand LPM...Liters per Minute M...Motor (Combustion) MTR...Motor (Hydraulic) OR...Orifice PC...Pilot Port Check Valve PMP...Pump PSI...Pounds per Square Inch PSWITCH...Pressure Switch RES...Reservoir RH...Right Hand RPM...Revolutions per Minute RV...Relief Valve STRN...Strainer SV...Solenoid Valve TV...Throttle Valve V...Volts PLEASE TE: All specifications listed are for normal operating conditions

38 P Side Brush Motor T Steering Valve R L Hopper Dump Door Cylinder Hopper Lift Cylinder Aux Pump Propel Pump Reservoir OUT Control Valve BYD E C B A Vac Fan Motor Main Brush Motor 9 6 IN 8 23 Steer Cylinder Wheel Drive Motor Cooler Filter HYDRAULIC HOSE ROUTING

39 6600 MAIN BRUSH BYD BROOMS VALVE BROOMS CV1A A HYDRAULIC FLOW METER 5.4 GPM ( RPM 6.5 GPM ( RPM (Flow readings +/- 5%) RV PSI (166 BAR) IN 600 PSI (41 BAR) MAIN BRUSH 600 PSI (41 BAR) 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR MAIN BRUSH RPM 460 RPM +/ RPM 550 RPM +/ RPM Note: Specs. shown are for main brush down with 2" (5 cm) brush pattern PLEASE TE: All specifications listed are for normal operating conditions

40 6600 MAIN & SIDE BRUSH BYD RV PSI (166 BAR) BROOMS CV1A IN B A 800 PSI (55 BAR) SIDE BRUSH 200 PSI (14 BAR) HYDRAULIC FLOW METER 5.4 GPM ( RPM 6.5 GPM ( RPM (Flow readings +/- 5%) 600 PSI (41 BAR) MAIN BRUSH 600 PSI (41 BAR) 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR MAIN BRUSH RPM 460 RPM +/ RPM 550 RPM +/ RPM SIDE BRUSH RPM 75 RPM +/ RPM 90 RPM +/ RPM Note: Specs. shown are for main & side brushes down, with 2" (5 cm) main brush pattern PLEASE TE: All specifications listed are for normal operating conditions

41 6600 VACUUM FAN CV2 HYDRAULIC FLOW METER 5.4 GPM ( RPM 6.5 GPM ( RPM (Flow readings +/- 5%) 1000 PSI (69 BAR) RV PSI (124 BAR) 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION VACUUM FAN 1000 PSI (69 BAR) ACCESSORY PUMP STRAINER RV4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

42 6600 RAISE HOPPER BYD CV1C E LIFT CYLINDER RESTRICTOR RV PSI (166 BAR) CK4 LIFT VALVE LIFT PRESSURE RETURN SUCTION ACCESSORY PUMP 5.4 GPM ( RPM 6.5 GPM ( RPM STRAINER RV 4 3 PSI (0.2 BAR) RV7 25PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

43 6600 LOWER HOPPER BYD CV1C E LIFT CYLINDER RESTRICTOR LOWER RV PSI (166 BAR) LIFT VALVE Note: Lowering of hopper is due to gravity (weight of hopper) PRESSURE RETURN SUCTION 5.4 GPM ( RPM ACCESSORY PUMP 6.5 GPM ( RPM ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

44 6600 OPEN HOPPER DOOR OUT BYD DOOR CV1B C HOPPER DOOR CYLINDER OPEN RV PSI (166 BAR) 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI RV 7 25 PSI (0.2 BAR) (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

45 6600 CLOSE HOPPER DOOR OUT BYD DOOR CV1B C HOPPER DOOR CYLINDER CLOSE RV PSI (166 BAR) IN Note: Arrows show direction of Fluid Flow, T Pressure (PSI) 5.4 GPM ( RPM 6.5 GPM ( RPM ACCESSORY PUMP PRESSURE RETURN SUCTION STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

46 6600 RIGHT TURN RV PSI (41 BAR) T CK5 P MTR/PMP3 CV3 R L STEERING SYSTEM CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) 3.3 GPM ( RPM 3.9 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

47 6600 LEFT TURN CV3 RV PSI (41 BAR) T CK5 R L STEERING SYSTEM P MTR/PMP3 CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) PRESSURE 3.3 GPM ( RPM 3.9 GPM ( RPM RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

48 6600 PROPEL SYSTEM Propel Pump Assembly Tow Valve Charge Pump (to keep propel system full of oil) Propel Motor Assembly Propel Motor Propel Pump Engine Pick-up To Reservoir (Case drains) PLEASE TE: All specifications listed are for normal operating conditions

49 MODEL 6650 ELECTRICAL Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual DURING TESTS: * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action

50 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 1 of 4 12 VDC AC GROUND - ALT + OUTPUT B 8A KEY SWITCH R EX. 20 OHM/40W A ENGINE BLOCK STARTERMOTOR STARTERSOLEIDCONTACTS INST. PANEL 52A STARTERMOTORASSEMBLY POSITIVEBATTERYCABLE MTR1 ENGINE BLOCK STARTER SOLEID COIL 1EA EC 83EB M3B ENGINE HARNESS ENGINEHARNESS 5 1D RELAY S--1 S EA 3EA KEY:START J7--B 3A 2 START RUN GLOW PLUG F--5 30A FUSE M3A NEUTRAL START 50 X 13G 83EA N.O./ CLOSED = DOWN 17 X 13G D C 8 15A FUSE 19 X M1A ACC 8H 51A 8D XX x=closed CONTACT KEYSW X F-11 M2A J7--A 8A D 8EE 13EA 13EH ENGINE HARNESS 02 SENSOR B C 68EA J2--10 O2-B A 53EA J2--12 J2--7 SL J1--14 ST J ED 13EC O2A KEY1 J1--20 J1--23 GD1 KEY2 8EF 8EG B ALTERNATOR 1C 1B 1A J1--21 J1--16 GD2 RST LOW CURRENT GROUNDTHROUGH CONTROLLER. 13EJ J2--11 GND GND. WITHENGINERUNNING WILLCLEAR FAULTCODES. A 55EA J2--21 MAG1 56EA J2--19 J1--2 MAG2 LP 54EA 69EC 70EA 69EA M2B AUX. 2 RELAY 57EA J2--20 J1--15 M1B AUX. 1 RELAY F-1 15AFUSE MAG.PICK UP B SOL3 L.P.INJECTOR C MG-3 INJ 50B 6 13EL 58EA 69EB 34A 85 C J2--4 J1--3 SOL4 GASINJECTOR MAP SENSOR A MP-C GAS B 59EA J2--17 MAP-B D 60EA J EE COIL-D COIL PACK B C 61EA J1--18 COIL-B A 63EA J1--10 S1 AIR TEMP SENSOR 13EM A B A S2 B COOLANT TEMP SENSOR 13EK A MTR2 B 13EF COIL-A 64EA J2--9 OXY ZENITH ENGINE CONTROL 65EA J1--1 J2--3 H20 +5V 148EA 72EA 13M GOVERR ACTUATOR A B FUEL PUMP SOL 4 A B SOL 5 L.P. LOCKOUT VALVE A B 13EG C OIL PRESSURE SWITCH 66EA 67EA 67A J2--5 GOV J1--5 EX J2--16 FUEL J1--4 SP2 13L 67B J7--D J EA 29EA SPD1 WIRING COLOR CODE 5EA 27EC J EA J EB OIL ENG RIGHTMOSTDIGIT COLOR OFWIRE OF WIRE NUMBER IN HARNESS 0 TAN 1 PINK 2 BRN 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE 7 PURPLE 8 GRAY 9 WHITE AUX #2 AUX #1 13EB COOLANT TEMP SENSOR 2 S3 S16 J9-B T USED 28E A N.C. OIL PRESSURE 27EA J9--A 27C C 5EA J7-C T USED N.O.OIL PRESSURE J1 =WHITECONNECTOR J2 = BLACK CONNECTOR B A J9-C 26A D ENGINE TEMP/CHECK J9-G T USED T USED 29EA J9-D 29A F SPEED BIT A 31EA J9-E 31A G SPEED BIT B 72EA J7-E T USED CONFIG PIN 148EA J9-F T USED ENGINE SPEED SELECTION BITS A AND B BIT--A BIT--B LOW: HIGH 0V MED: 0V HIGH HIGH: 0V 0V 1350RPM 2000RPM 2400RPM SWITCHED, B+ UNSWITCHED, B

51 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM 1 Part 2 of 4 2 F-12 34A 15A FUSE 92 S A 13NN 13R REVERSE ALARM LP10 FLASHER 13QQ LAMP_HEADLIGHT N.O. / CLOSED = REVERSE REVERSE SWITCH 93B 94 HOPPER STATIC GND. 105AA 105AA SOL1 SHAKER MODULE 46 M5B 47 47BB 48BB F 13V OUT (-) SHAKER RELAY SHAKER SOLEID 47A F--6 15A FUSE 1D 3 (+) 13H D--2 13J 33 33A 33 4C/YEL F--3 15A FUSE 1D HORN S--8 HORN N.O./ CLOSED = HORN 4/YEL LP1 13GG 87A/PUR 87/PUR DIRECTIONAL SWITCH 7 FLASHER RED RUN LIGHT, R.H. 79/YEL 13FF 13T LP2 88A/GRN 88/GRN YEL 1 3 P 4 4B/YEL GRN RUN LIGHT, L.H. LP3 62C/YEL 80/BLU X 1 89/BRN BLU 6 2 L TAILLIGHT, R.H. 8 13S LP4 BLK 62B/YEL 77/GRY 90/GRY BLK/ GRY 3 TAIL LIGHT, L.H. 9 GRY S--20 S--9 81A/YEL F--2 15A FUSE 1D N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH 81/YEL 62A/YEL 13BE LP5 62BB/YEL SWITCHED,B+ HEADLIGHT, R.H. 13BD LP6 62BA/YEL 62BA/YEL 62/YEL S A 95A F-14 15A FUSE 34A HEADLIGHT, L.H. 13BF LP7 62BC/YEL Q SIDE BRUSH LIGHT 13KK REVOLVING LIGHT, OHG 13LL LOW MOUNTED BEACON LP8 LIGHT SWITCH 76/ORA 76A/ORA LP9 76B/ORA

52 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 ENG TEMP/CHECK P1--26 D 26A C P1--25 ENG OIL 27C PRESS. SPEED BIT A F P A G P A SPEED BIT B 13A INPUT8 INPUT7 OUTPUT12 OUTPUT13 13D 13C 13B 13Y 13N 105 CHASSIS GROUND 9 S--18 HOPPER DOWN N.O./ CLOSED = DOWN S--4 FUEL SENDER 10 POWER GND1 P1--22 POWER GND3 P1--35 POWER GND4 P1--34 P1--33 CONTROL GND. P1--1 STATIC GND. INPUT1 P1--27 INPUT9 UNSWITHCED, B+ 12 VOLTS POWER2 12 VOLTS CONTROL P1--16 P1--32 P1--2 P1--3 P1--4 OUTPUT1 P1--5 INPUT2 P1--28 TOUCH PANEL INCORPORATED INTO CONTROL BOARD INCLUDES LCD SIGNLE IN DISPLAY A 14A 14B 14E 14C 14D 15D 15E 15F 15G 14 15A OUTPUT2 13BB S-4A 10A LOWL.P. 13K N.O. / CLOSED= LOW L.P. S--5 THERMAL SENTRY 11 COM N.O. 11BA 12 T USED S-19 STALLED BROOM 13AA N.O./ CLOSED=STALLEDED CONTROL BOARD P1--23 OUTPUT3 P1--6 INPUT3 P1--13 OUTPUT4 N.O./ CLOSED=FIRE S--6 CLOGGED VACUUM FAN 13X N.O./ CLOSED=CLOGGED P1--31 INPUT4 P1--14 OUTPUT5 INPUT5 P1--15 P1--7 INPUT9 P1--29 OUTPUT6 P1--8 OUTPUT7 P1--9 OUTPUT8 P1--10 OUTPUT9 P1--11 OUTPUT10 P1--24 OUTPUT18 P1--17 OUTPUT15 P1--18 OUTPUT16 P1--19 OUTPUT17 P1--12 OUTPUT11 P1--30 OUTPUT14 UNSWITCHED, B+ 52A 85 ALTERNATOR LAMP PAGE A 16 SV--1 ENABLE VALVE 17 SV--2 MAIN BROOM ONLY ON MAIN BROOM ONLY DOWN 73 SV SV--3 SIDE BROOM AND MAIN BROOM ON 53 SV--8 SIDE BROOM DOWN HOPPER DOOR OPEN 19 SV SV--6B HOPPER UP 21 SV--6A HOPPER DOWN 22 SV--9 VACUUM FAN 15B SHAKER RELAY M5A 85 OPTIONAL WARNING ALARM 24 15G WARNING ALARM WIRING COLOR CODE T USED RIGHTMOSTDIGIT COLOROFWIRE OF WIRENUMBER INHARNESS 1 TAN PINK 2 BRN 3 ORANGE 4 YELLOW 5 GREEN 6 BLUE 8 PURPLE GRAY WHITE 0 T USED T USED HOPPER TILT IN 7 9 HOPPER TILT OUT AUX #1 F-19 15A FUSE F-20 15A FUSE F-17 15A FUSE

53 6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM 4 13DDD/BLK DEFROST FAN 111/ORA 15A FUSE 50A 111F/ORA F--7 13CCC/BLK DOME LIGHT S /BLU DOME LIGHT 111C/ORA OPTIONAL AC AND CAB HARNESSES 112/PUR 113/YEL 13EEE/BLK 111E/ORA BLK 13AAA/BLK WINDSHIELD WIPER OFF S--14 LOW MEDIUM HIGH COM 111D/ORA WIPER SWITCH AC COMPRESSOR AC CONDENSER PRESS. AC EVAP. TEMP GND A B A B CLUTCH SOL. BLK/WHT SWITC H BLK/WHT SWITC H GRN BLK 86 AC /GRN S B/ORA Part 4 of 4 GND BLU AC [ON--OFF] WHT WHT YEL YEL 20A FUSE AC CONDENSER FANS RED GND BLU F-21 13AAA/BLK D--6 WHT YEL YEL 119/YEL S--15 OFF ORG/GRN 86 BLK AC 2 85 BLK YEL LOW GND BRN ORG ORG HIGH BLK 120/ORA 118/GRY F-10 15A FUSE LOW HIGH COM CAB FAN/PR ESS. SWITCH BRN 20A FUSE RED LOW YEL F-22 GND BLK HIGH ORG AC EVAP./CAB PRESS.FANS 109/BRN 109A/BRN S B/GRY 110/YEL 110A/YEL 110B/YEL 2 13WW/BLK RIGHT AUX. SIDE BRUSH 109B/BRN AUX. SIDE BRUSH, D.P.D.T., ON--OFF--ON 106/ORA 106A/ORA S C/GRY 107B/YEL 2 107A/YEL 107/YEL 106B/ORA 108/GRY XX/BLK LEFT AUX. SIDE BRUSH 8 AUX. SIDE BRUSH, D.P.S.T., ON--OFF--ON FROM PAGE 1 AUX #2 BATTERY, B+ FROM PAGE 1 AUX #2 BATTERY, B+ SWITCHE D,B+ F-13 15A FUSE 34A

54 13AC GROUND B 52 OUTPUT KEY SWITCH R--1 8A 20 OHM/ 40W A 52A INST. PANEL ENGINE BLOCK STARTER MOTOR ASSEMBLY POSITIVE BATTERY CABLE STARTER SOILEID COIL ENGINE BLOCK 83 1K ENGINE HARNESS ENGINE HARNESS 42B ENGINE BLOCK GP--3 ENGINE HARNESS 13BD LP1 42A 13BD 5 1D 13BB 82 8BB 3C J7--B 3A 3A KEY:START CREATES DELAY BETWEEN ENGINE STARTATTEMPTS A START RUN GLOW PLUG 56 8A J7 -A 8BA X 8BE X X X 6650 DIESEL OVERALL ELECTRICAL DIAGRAM Part 1 of 4 12 VDC ALT EX. + STARTER MOTOR STARTER SOLEID CONTACTS MTR M7B GLOW PLUGS GP--1 OW GP--2 GP--4 OPTIONAL GLOW PLUG LAMP ENGINE START TIMER MODULE S--2 NEUTRAL START S F--5 40A FUSE 1 LOAD GND M7A B+ N.O. / CLOSED = DOWN IN IT ACC M8B 87 X X x=closedcontact 56 M8C 30 87a D--3 3B F-11 15A FUSE KEYSW 13BC 13BG M8A 85 D A 13M FUELPUMP B 67 67C 67A A 30 M6B 87 8BD J7--D 67 M6C 3D 8A 30 87a B ALTERNATOR OILPRESS. SWITCH 13BF B A 5B 5 M6A BC N.C.OIL PRESSURE J9--A 27C C 27 1C S3 1B 1A C THROTTLEACTUATOR J7--C T USED N.O.OILPRESSURE 5A GOVERR BE 59 E D 61A ENG.SPEED/MAG. PICK--UP BA 61 13BA 8BF 34A 50B 6 85 F G 26A 26 ENGINE BLOCK J9--C N.O./CLOSED HIGH TEMP 8BF 60 SPEED BIT A 29A 29 J9--D 31A 31 J9--E SPEED BIT B D 8BG ENGINE SPEED SELECTION BIT A BIT B 1350RPM LOW: HIGH 0V 2000RPM MED: 0V HI GH 2400RPM HI G H : 0 V 0 V 30 M2B 87 AUX. 2 RELAY M1B AUX.1 RELAY F-1 15A FUSE F C G B A H S-16HIGH ENGINE TEMP. J9-B J9-G J7-E J9-F T USED T USED T USED T USED SWITCHED, B+ AUX. #2 AUX. # UNSWITCHED, B

55 DIESEL OVERALL ELECTRICAL DIAGRAM 8C M1A 85 D--1 8D 86 51A M2A 85 OUT (-) 13G F-12 34A 15A FUSE 92 S A 13NN 13R REVERSE ALARM N.O. / CLOSED = REVERSE REVERSE SWITCH FLASHER LP2 93B 94 13QQ LAMP_HEADLIGHT 105AA 46 SOL1 HOPPER STATIC GND. M5B SHAKER PULSE MODULE 47 47BB 48BB F 13V SHAKER RELAY SHAKER SOLEID 47A F--6 15A FUSE (+) 3 13H D--2 13J 33 33A S HORN 4C/YEL F--3 15A FUSE HORN N.O. / CLOSED = HORN 4/YEL Part 2 of 4 LP3 DIRECTIONAL SWITCH 13GG 87A/PUR 87/PUR 7 FLASHER RUN LIGHT, R.H. RED 79/YEL LP4 13FF 13T 88A/GRN 88/GRN YEL 1 3 P 4 4B/YEL RUN LIGHT, L.H. LP5 GRN 62C/YEL 80/BLU X 1 89/BRN BLU 6 2 TAILLIGHT, R.H. L 8 BLK 13S LP6 62B/YEL 77/GRY 90/GRY BLK/ GRY 3 TAIL LIGHT, L.H. 9 S--9 81A/YEL F--2 15A FUSE 13BE GRY S--20 N.O. / CLOSED = BRAKING BRAKE PEDAL SWITCH 81/YEL LP7 62BB/YEL HEADLIGHT, R.H. 13BD LP8 62BA/YEL 62A/YEL S A 1 62/YEL 62BA/YEL 2 95A F-14 15A FUSE HEADLIGHT, L.H. 34A LP9 13BF 62BC/YEL Q SIDE BRUSH LIGHT 13KK REVOLVING LIGHT, OHG 13LL LOW MOUNTED BEACON LP10 LIGHT SWITCH 76/ORA 76A/ORA LP11 76B/ORA 1D 1D 1D SWITCHED,B

56 6650 DIESEL OVERALL ELECTRICAL DIAGRAM Part 3 of 4 GROUND 4 13A 13A 13D 13C 13D 13C 13B 13B 105 CHASSIS GROUND 13Y S-18 HOPPER DOWN 9 N.O./ CLOSED = DOWN S--4 FUEL SENDER 13N 10 13BB 13X 10A 13K N.O./CLOSED = LOW L.P. 11 S--5 THERMAL SENTRY 11BA S--6 CLOGGED VACUUM FAN 12 S-4A LOW L.P. N.O./ CLOSED=FIRE N.O./ CLOSED=CLOGGED T USED S-19 STALLED BROOM 96 13AA N.O./ CLOSED=STALLEDED S-1,LED1: ONE STEP S--2,LED2: VACUUM S-3,LED3: SHAKER S-4,LED4: SIDE BRUSH S-5,LED5: HOPPER UP S-6,LED6: HOPPER DOWN S-7,LED7: HOPPER DOOR CLOSE S-8,LED8: HOPPER DOOR OPEN S-9,LED9: HOPPER TILT OUT (800) S-10,LED10: HOPPER TILT IN (800) S--11,LED11: ENGINE SPEED LOW S-11,LED12: ENGINE SPEED MED. S-11,LED13: ENGINE SPEED HIGH TE: SEVEN WARNINGCONDITION LEDS LED--14: THERMAL SENTRY LED--15: HO PPER DIFFERENTIALPRESSURE LED--16: LOW FUEL LED--17: HIGH ENGINETEMP. LED--18: LOW ENGINE OIL PRESSURE LED--19: ALTERNATOR LED-- 20: STALLED BROOM TOUCH PANEL INCORPORATED INTO CONTROL BOARD INCLUDES LCD SINGLE LINE DISPLAY. ENG TEMP/CHECK P1-26 D INPUT8 E1 26A P1-25 C INPUT7 E1 27C ENG OIL PRESSURE SPEED BIT A P1-21 OUTPUT12 F E1 29A OUTPUT13 P1-20 G E1 31A SPEED BIT B POWER GND1 P1--22 INPUT9 POWER GND3 P1--35 UNSWITHCED, B+ P VOLTS POWER2 POWER GND4 P VOLTS CONTROL CONTROL GND. P1--1 STATIC GND. P1--27 OUTPUT1 INPUT1 P1--16 P1--32 P1--2 P1--3 P1--4 P1--5 P1--28 OUTPUT2 INPUT CONTROL BOARD P1--23 OUTPUT3 P1--13 INPUT3 P1--6 OUTPUT4 P1--14 INPUT4 P1--31 OUTPUT5 P1--15 INPUT5 P1--29 INPUT9 P1--7 OUTPUT6 P1--8 OUTPUT7 P1--9 OUTPUT8 P1--10 OUTPUT9 P1--11 OUTPUT10 P1--24 OUTPUT18 P1--17 OUTPUT15 P1--18 OUTPUT16 P1--19 OUTPUT17 OUTPUT11 P1--12 OUTPUT14 P1--30 UNSWITCHED, B+ AUX #1 52A 85 ALTERNATOR LAMP PAGE 1 A A F-19 15A FUSE A 14 F-20 15A FUSE 17 14B 73 14E 18 14C 53 SV--1 ENABLE VALVE 1.7 AMPS SV--2 MAIN BROOM ONLY ON 1.7 AMPS SV--7 MAIN BROOM DOWN 1.7 AMPS SV--3 SIDE BROOM AND MAIN BROOM ON 1.7 AMPS SV--8 SIDE BROOM DOWN 1.7 AMPS 14D 15D 15A F-17 15A FUSE SV--5 HOPPER DOOR OPEN AMPS SV--6B HOPPER UP AMPS SV--6A HOPPER DOWN AMPS SV--9 VACUUM FAN AMPS 86 SHAKER RELAY M5A E 15F 15G 15B OPTIONAL WARNING ALARM 24 15G WARNING ALARM WIRING COLOR CODE T USED RIGHT MOSTDIGIT COLOR OF WIRENUMBER IN HARNESS T USED T USED HOPPER TILT IN (800 ONLY) 0 TAN PINK BRN ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE (800 ONLY) HOPPER TILT OUT

57 DIESEL OVERALL ELECTRICAL DIAGRAM 13DDD/BLK DEFROST FAN 111/ORA 15A FUSE 111F/ORA F--7 DOME LIGHT 116/BLU 13CCC/BLK S--11 DOME LIGHT 111C/ORA OPTIONAL AC AND CAB HARNESS WINDSHIELD WIPER 112/PUR OFF S /YEL 13EEE/BLK 111E/ORA 13AAA/BLK LOW MEDIUM HIGH COM 111D/ORA BLK WIPER SWITC H AC COMPRESSOR AC CONDENSERPRESS. AC EVAP. TEMP GND A B A B Part 4 of 4 CLUTCH SOL. BLK/WHT BLK/WHT 85 GRN BLK 86 AC 1 S--12 SWITCH SWITC H 115/GRN 111B/ORA GND BLU AC [ON--OFF] AC CONDENSER FANS WHT WHT YEL YEL 20A FUSE GND BLU F-21 13AAA/BLK D--6 WHT YEL YEL 119/YEL S--15 OFF ORG/GRN 86 AC 2 85 BLK BLK YEL LOW GND BRN ORG ORG HIGH BLK 120/ORA 118/GRY F-10 15A FUSE LOW HIGH COM 1 2 CAB/PR ESS. FAN SWITC H BRN 20A FUSE LOW GND HIGH BLK AC EVAP./CAB PRESS.FANS YEL F-22 ORG 109/BRN 109A/BRN S A/YEL 110B/YEL 2 108B/GRY 110/YEL 13WW/BLK RIGHT AUX. SIDE BRUSH 109B/BRN AUX. SIDE BRUSH, D.P.D.T., ON--OFF--ON 106/ORA 106A/ORA S B/YEL 2 108C/GRY 13XX/BLK LEFT AUX. SIDE BRUSH 107A/YEL 107/YEL 106B/ORA AUX. SIDE BRUSH, D.P.S.T., ON--OFF--ON 50A AUX #2 RED BATTERY, B+ 50 AUX #2 RED BATTERY, B+ F-13 15A FUSE SWITCHE D,B+ 34A 108/GRY

58 Key Switch ACC GLOW PLUG POSITION (Diesel Only) Spring loaded- Returns to "OFF" unless held Glow Plug OFF RUN KEY SWITCH START Glow Plug OFF RUN KEY SWITCH START OFF POSITION ACC OFF OFF 30 Glow Plug RUN START Glow Plug RUN START 30 KEY SWITCH KEY SWITCH ACC ACC RUN POSITION START POSITION Spring loaded-returns to RUN" unless held SWITCH TERMINAL MARKING KEY SWITCH POSITION GLOW PLUG OFF RUN START CONNECTIONS ACC. Indicates a common connection TE: Common connections in various switch positions should be less than

59 Charging System Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 52A PIN 16 PIN 22 13A 8A 8A PIN 33 13B 1D 1A B 6 15A FUSE 7 Test battery, clean battery terminals, check all connections, wiring, Resistor R-1, and fuses F-1, F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) M1 F-1 15A FUSE F C 7A PIN 32 PIN 2 PIN CONTROL BOARD PIN 34 PIN 35 PIN 1 ALTERNATOR LED 51 M1 13C 13D 105 CHASSIS GROUND Start engine (KOER-Key On, Engine Running), run engine at high governed RPM Is ALTERNATOR LED lit? Re-test battery, re-check battery terminals, connections, wiring, Resistor R-1, and fuses F-1, F-5, F-11 & F-19; Suspect faulty 6650 Control Board; Restart diagnostic steps With lights on, check voltage at battery terminals- Is it 13.5 to 16.5 Volts? Is ALTERNATOR LED lit? System operating correctly Re-test battery, re-check battery terminals, connections, wiring, Resistor R-1, and fuses F-1, F-5, F-11 & F-19; Suspect faulty alternator PLEASE TE: When finished, please reconnect all wires disconnected during testing

60 6650 Gas/L.P. Start Circuit POSITIVE BATTERY CABLE + - 1D 28 1EA 83EC 83EA 8 PIN 7 BLACK CONNECTOR Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8H Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position 82EA 8EF 8EG PIN 14 WHITE CONNECTOR PIN 22 PIN 20 PIN 23 PIN 21 ZENITH ENGINE CONTROLLER 13ED 13EC Does STARTER MOTOR click or make any other noises? 54 Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR Re-check all connections, wiring and fuses F-5 & F- 11; Test relay M-3; Test Key Switch; Test for proper power & ground connections at ZENITH ENGINE CONTROLLER (refer to ZEEMS troubleshooting) Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR CAUTION! Disconnect wire harness plug from DIS ignition coil and turn key to OFF position for next test. With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLEID studs (the STARTER SOLEID is an integral part of the STARTER MOTOR) As the remote start switch is engaged, does the STARTER MOTOR crank the engine? PLEASE TE: When finished, please reconnect all wires disconnected during testing

61 6650 Diesel Start Circuit POSITIVE BATTERY CABLE ACC A 34 13BB Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8A 42B 8BE 3C 13M TO 6650 CONTROL BOARD Test battery, clean battery terminals, check all connections, wiring, and fuses F-5 & F-11; Turn key to START position Does STARTER MOTOR click or make any other noises? Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR Re-check all connections, wiring and fuses F-5 & F-11; Test relays M-6, M- 7, & M8; Test ENGINE START TIMER MODULE; Test Key Switch CAUTION! Turn key to OFF position for next test. With a remote start switch tool or equivalent, connect leads to the two large STARTER SOLEID studs (the STARTER SOLEID is an integral part of the STARTER MOTOR) Re-test battery & battery terminals; Re-check all connections & wiring; Examine engine for excessive internal resistance (due to lack of lubrication, mechanical failure, etc.); Suspect faulty STARTER MOTOR As the remote start switch is engaged, does the STARTER MOTOR crank the engine? PLEASE TE: When finished, please reconnect all wires disconnected during testing

62 Gas/L.P. Power-Up Circuit 1A F D A FUSE 1B 6 M1 F-19 15A FUSE 7 PIN 22 13A Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8EF 8H 8EG 8 8C PIN 22 PIN 23 M1 WHITE CONNECTOR ZENITH ENGINE CONTROLLER 51 PIN 20 PIN 21 13ED 13EC A PIN 32 PIN 2 PIN 3 PIN 33 PIN 34 PIN CONTROL BOARD 13B 13C PIN 35 13D 105 CHASSIS GROUND 13G Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to ON position (KOEO-Key On, Engine Off) Is battery voltage measured across all power and ground connections at ZENITH ENGINE CONTROLLER and 6650 CONTROL BOARD? Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER or suspect faulty 6650 CONTROL BOARD Re-check all connections, wiring, and fuses F-1, F-5, F- 11 & F-19; Test Key Switch 56 PLEASE TE: When finished, please reconnect all wires disconnected during testing

63 1D 40A FUSE Diesel Power-Up Circuit 1A 15A FUSE 1B 6 M1 F-1 2 3A 34 3C 85 F-19 15A FUSE 8BF 7 GOVERR CONTROLLER PIN A PIN B A 6650 CONTROL BOARD PIN 32 PIN 2 PIN 3 PIN 22 PIN 33 PIN 34 PIN 35 13D PIN 1 13A 13B 13C 105 Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions CHASSIS GROUND 13BA 13BG 8A 13M 13BF 8C M1 TO 6650 CONTROL BOARD 51 13G Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to ON position (KOEO-Key On, Engine Off) Is battery voltage measured across all power and ground connections at GOVERR CONTROLLER and 6650 CONTROL BOARD? Refer to PRECISION GOVERR troubleshooting to test GOVERR CONTROLLER or suspect faulty 6650 CONTROL BOARD Re-check all connections, wiring, and fuses F-1, F-5, F- 11 & F-19; Test Key Switch PLEASE TE: When finished, please reconnect all wires disconnected during testing

64 6650 Gas/L.P. Check Engine Circuit + - 1D A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 LCD DISPLAY PANEL CHECK ENGINE PIN 22 13A Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8EF 8H 8EG 8 8C PIN 22 PIN 20 WHITE CONNECTOR PIN 21 PIN 23 M1 ZENITH ENGINE CONTROLLER 51 PIN 12 13ED 13EC 26A A PIN 32 PIN 2 PIN 3 PIN 26 PIN 33 PIN 34 PIN CONTROL BOARD 13B 13C PIN 35 13D 105 CHASSIS GROUND Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to ON position (KOEO-Key On, Engine Off) Is CHECK ENGINE displayed on LCD panel? Refer to ZENITH ENGINE FAULT CODES to diagnose engine or sensor faults No faults detected by ZENITH ENGINE CONTROLLER; Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER 58 PLEASE TE: When finished, please reconnect all wires disconnected during testing

65 1D 6650 Gas/L.P. High Engine Temperature Circuit A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 LCD DISPLAY PANEL CHECK ENGINE PIN 22 13A Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8EF 8H 8EG 8 8C PIN 22 PIN 23 WHITE CONNECTOR M1 ZENITH ENGINE CONTROLLER 51 PIN 20 PIN 21 PIN 12 13ED 13EC 26A A HIGH ENGINE TEMP LED PIN 32 PIN 2 PIN 3 PIN 26 PIN 33 PIN 34 PIN CONTROL BOARD 13B 13C PIN 35 13D 105 CHASSIS GROUND Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Turn key to ON position (KOEO-Key On, Engine Off) Is CHECK ENGINE displayed on LCD panel? Refer to ZENITH ENGINE FAULT CODES to diagnose engine or sensor faults No faults detected by ZENITH ENGINE CONTROLLER; Refer to ZEEMS troubleshooting to test ZENITH ENGINE CONTROLLER PLEASE TE: When finished, please reconnect all wires disconnected during testing

66 1D 6650 Diesel High Engine Temperature Circuit A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 LCD DISPLAY PANEL CHECK ENGINE PIN 22 13A 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions S-16 HIGH ENGINE TEMP 26 N.O./CLOSED=HIGH TEMP 7A 26A HIGH ENGINE TEMP LED PIN 3 PIN 26 PIN CONTROL BOARD PIN 35 13D 105 CHASSIS GROUND Check all connections, wiring, and fuses F-1, F-5, & F- 19; Turn key to ON position (KOEO-Key On, Engine Off), and place jumper wire from wire 26A at HIGH ENGINE TEMP switch to chassis or frame ground Is CHECK ENGINE displayed on LCD panel? System operating correctly; Suspect faulty HIGH ENGINE TEMP switch High engine temp. not detected by 6650 CONTROL BOARD; Recheck all connections, wiring, and fuses F-1, F-5, & F-19; Suspect faulty 6650 CONTROL BOARD 60 PLEASE TE: When finished, please reconnect all wires disconnected during testing

67 6650 Gas/L.P. Oil Pressure Circuit 1D A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 LCD DISPLAY PANEL CHECK ENGINE PIN 22 13A Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) 8EF 8H 8EG 8 8C PIN 22 PIN 23 PIN 21 WHITE CONNECTOR M1 BLACK CONNECTOR 51 PIN 20 ZENITH ENGINE CONTROLLER 13ED 13EC A PIN 32 PIN 2 PIN 3 27EB 27EA 27C PIN 8 PIN 25 27EC A C OIL PRESSURE SWITCH B 13EG PIN 33 PIN 34 PIN CONTROL BOARD 13B 13C PIN 35 13D 105 CHASSIS GROUND LOW ENGINE OIL PRESSURE LED Is LOW OIL PRESSURE LED lit? With engine running, does lamp go out? Remove harness plug at OIL PRESSURE SWITCH and place a jumper wire across harness plug wires B & C Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH Is LOW OIL PRESSURE lamp lit? Verify proper oil pressure in engine; System operating correctly Replace OIL PRESSURE SWITCH Re-check all connections, wiring, and fuses F-5 & F-11; Test Key Switch; Suspect faulty 6650 Control Board PLEASE TE: When finished, please reconnect all wires disconnected during testing

68 6650 Diesel Oil Pressure Circuit 1D A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 LCD DISPLAY PANEL CHECK ENGINE PIN 22 13A 85 PIN 32 PIN 33 13B 7 PIN 2 PIN 34 13C 7A PIN 3 PIN 35 13D Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 27 A C S-3 B 27C LOW ENGINE OIL PRESSURE LED PIN 25 ENGINE OIL PRESSURE SWITCH N.C./OPEN=OIL PRESSURE SENSED PIN CONTROL BOARD 105 CHASSIS GROUND 13BF Check all connections, wiring, and fuses F-1, F-5, & F- 19; Turn key to ON position (KOEO-Key On, Engine Off), and place jumper wire from wire 27 at ENGINE OIL PRESSURE SWITCH to chassis or frame ground Is LOW OIL PRESSURE LED lit? With engine running, does lamp go out? Re-check all connections, wiring, and fuses F-1, F-5 & F-19; Test Key Switch; Suspect faulty 6650 Control Board Verify proper oil pressure in engine; Suspect faulty OIL PRESSURE SWITCH Verify proper oil pressure in engine; System operating correctly 62 PLEASE TE: When finished, please reconnect all wires disconnected during testing

69 1D A 6650 Vacuum Fan Circuit F-1 15A FUSE 1B 6 M1 85 F-19 15A FUSE 7 85 PIN 32 VACUUM FAN SWITCH PIN 22 13A 7 PIN 2 PIN 33 13B Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C 6 F-17 15A FUSE M1 51 SV-9 7A 15A 15G 22 VACUUM FAN SOLEID VACUUM FAN LED PIN 3 PIN 10 PIN 34 PIN CONTROL BOARD 13C PIN 35 13D 105 CHASSIS GROUND Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, have hopper in full DOWN position, turn key to ON position (KOEO-Key On, Engine Off) TE: DO T UNPLUG connector at VACUUM FAN SOLEID (SV-9) when doing voltage tests. Unplugging connector will give false readings. Turn VACUUM FAN ON (VAC FAN LED should be lit); Is battery voltage measured across wires at VAC FAN SOLEID (SV-9) plug? Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty VAC FAN SOLEID coil Re-check all power & ground connections and fuses F-1, F-5, F-11 & F-19; Test HOPPER SWITCH; Test THERMO-SENTRY SWITCH (see circuit chart); Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board PLEASE TE: When finished, please reconnect all wires disconnected during testing

70 6650 Vacuum Restriction Warning Circuit + - 1A F D A FUSE 1B 6 M1 F-19 15A FUSE 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C VACUUM RESTRICTION LED 12 VACUUM SWITCH (RMALLY OPEN) SEE TE BELOW PIN 14 PIN CONTROL BOARD PIN 35 13D 105 CHASSIS GROUND 13X M1 51 Check all connections, wiring, and fuses F-1, F-5, & F-11, turn key to ON position (KOEO-Key On, Engine Off) VACUUM SWITCH TE Vacuum switch closes if vacuum fan is running with any one of these conditions: - a blocked (dirty) vacuum panel filter - a blocked Perma-Filter - a closed hopper door Remove wire plug from VACUUM SWITCH and place a jumper wire across harness plug wires Is CLOGGED DUST FILTER LED lit? Suspect faulty VACUUM SWITCH Re-check power & ground connections and fuses F-1, F-5, & F-11; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 64 PLEASE TE: When finished, please reconnect all wires disconnected during testing

71 1D Gas/Diesel Fuel Sender Circuit 5 1A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 85 LCD DISPLAY PANEL FUEL LEVEL PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C 10 LOW FUEL LED S-4 FUEL SENDER 10 PIN 28 PIN CONTROL BOARD PIN 35 13D 105 CHASSIS GROUND 13N M1 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wires from FUEL SENDER at tank and watch FUEL GAUGE; Place jumper wire across FUEL SENDER wires and watch FUEL GAUGE again Does LOW FUEL LED light and FUEL GAUGE on LCD panel deflect from FULL to EMPTY? Suspect faulty FUEL SENDER Re-check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Suspect faulty 6650 Control Board PLEASE TE: When finished, please reconnect all wires disconnected during testing

72 1D Low L.P. Fuel Sender Circuit 5 1A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE 7 85 LCD DISPLAY PANEL FUEL LEVEL PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C LOW FUEL LED 10 PIN 28 PIN CONTROL BOARD PIN 35 13D 105 S-4A LOW FUEL PRESSURE SWITCH 10A 13K 13N RMALLY OPEN / CLOSED WITH LOW L.P. FUEL PRESSURE CHASSIS GROUND M1 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; With a full L.P. tank properly connected to machine, with L.P. supply valve fully open, turn key to ON position (KOEO-Key On, Engine Off) Check all connections and wiring; Suspect faulty LOW L.P. SWITCH Is LOW FUEL LED lit? Fully close L.P. supply valve on L.P. tank and run machine until engine runs out of fuel Is LOW FUEL LED lit? System operating properly Remove plug at LOW L.P. PRESSURE SWITCH and place a jumper wire across harness wires Is LOW FUEL LED lit? Suspect faulty LOW L.P. SWITCH Re-check all connections, wiring, and fuses F-1, F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test power and ground circuits; Test Key Switch; Suspect faulty 6650 Control Board 66 PLEASE TE: When finished, please reconnect all wires disconnected during testing

73 1D Shaker Motor Circuit 1A F-1 15A FUSE 1B 6 M1 85 F-19 15A FUSE 7 85 PIN 32 SHAKER SWITCH PIN 22 13A 7 PIN 2 PIN 33 13B 6 SHAKER RELAY 7A PIN 3 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C F-17 15A 15B 23 M5 15A FUSE M1 51 SHAKER LED PIN 11 PIN CONTROL BOARD PIN 35 13D 105 CHASSIS GROUND 1D F SHAKER MODULE 15A FUSE M5 47A Check all connections, wiring, and fuses F-1, F-5, F-6, F-11, F-17 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wire from #2 post of SHAKER PULSE MODULE; Momentarily push SHAKER button Momentarily push SHAKER SWITCH - Is battery voltage measured across terminals #3 & #1 at SHAKER PULSE MODULE? Repair power or ground circuits leading to SHAKER MODULE Replace SHAKER MODULE Does SHAKER SOLEID pulse as wire is tapped to ground? Disconnect SHAKER SOLEID plug; Connect one SHAKER SOLEID wire to ground and the other to battery (+) Go to A Next Page PLEASE TE: When finished, please reconnect all wires disconnected during testing

74 6650 Shaker Motor Circuit (continued) A Does SHAKER SOLEID pulse as ground side wire is tapped to ground? Replace SHAKER SOLEID Momentarily push SHAKER SWITCH - Is battery voltage measured across posts #85 & 86 at SHAKER RELAY M-5? Re-check all connections, wiring, and fuses F-1, F-5, F-6, F-11, F-17 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board Re-check connections & power feed on post #30 at SHAKER RELAY M-5; Suspect faulty relay M-5 68 PLEASE TE: When finished, please reconnect all wires disconnected during testing

75 Thermo-Sentry Circuit 1A F D A FUSE 1B 6 M1 F-19 15A FUSE 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C M1 HIGH HOPPER TEMP LED 51 S-5 11 PIN 13 PIN CONTROL BOARD RMALLY OPEN / CLOSED WITH HIGH HOPPER TEMPERATURE PIN 35 13D 105 CHASSIS GROUND 13BB Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wires from & COM terminals at THERMO-SENTRY SWITCH and connect wires with a jumper wire Is HIGH HOPPER TEMP LED lit? Reset or suspect faulty THERMO-SENTRY switch Re-check all power and ground circuits and fuses F-1, F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board PLEASE TE: When finished, please reconnect all wires disconnected during testing

76 1D Hopper Door Circuit F-1 1A 15A FUSE 1B 6 M F A FUSE HOPPER DOOR F-17 15A SOLEID 15D SV-5 15A FUSE A 19 PIN 32 PIN 2 PIN 3 PIN 7 PIN 22 PIN 33 PIN 34 13A 13B 13C PIN 35 13D Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C F A SV-1 15A FUSE ENABLE SOLEID HOPPER DOOR OPEN LED HOPPER DOOR CLOSED LED 16 PIN 4 PIN CONTROL BOARD OPEN CLOSE 105 CHASSIS GROUND M1 51 HOPPER DOOR OPEN/CLOSE SWITCHES (ON TOUCH PANEL) TE: DO T UNPLUG connector at ENABLE SOLEID (SV-1) or HOPPER DOOR SOLEID (SV-5) when doing voltage tests. Unplugging connector will give false readings. Check all connections, wiring, and fuses F-1, F-5, F-11, F-17 & F-19; Start engine and push HOPPER DOOR CLOSED button until HOPPER DOOR CLOSED LED is lit; Shut off engine; Turn key to ON position (KOEO-Key On, Engine Off) Push HOPPER DOOR OPEN button - Is battery voltage measured across wires at ENABLE SOLEID (SV-1) plug and HOPPER DOOR OPEN SOLEID (SV-5) plug? Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty HOPPER DOOR OPEN SOLEID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-17 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 70 PLEASE TE: When finished, please reconnect all wires disconnected during testing

77 1D A Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 6650 Hopper Up/Down Circuit F-1 15A FUSE 1B 6 M1 F A FUSE 8 8C 85 F-17 15A 15A FUSE F-19 15A FUSE 15E 15F F A 15A FUSE 7 SV-6B HOPPER UP SOLEID HOPPER DOWN SOLEID SV-1 ENABLE SOLEID HOPPER UP LED HOPPER DOWN LED SV-6A 85 PIN 32 7 PIN 2 7A PIN 3 20 PIN 8 21 PIN 9 16 PIN 4 9 PIN 27 PIN 22 PIN 33 PIN 34 PIN 35 PIN CONTROL BOARD 13A 13B 13C 13D UP DOWN S-18 HOPPER POSITION HOPPER UP/DOWN SWITCH 9 SWITCHES(ON TOUCH PANEL) 13Y RMALLY OPEN / CLOSED WITH HOPPER IN FULL DOWN POSITION 105 CHASSIS GROUND M1 51 TE: DO T UNPLUG connectors at ENABLE SOLEID (SV-1) or HOPPER UP and DOWN SOLEIDS (SV-6B & SV-6A) when doing voltage tests. Unplugging connector will give false readings. Check all connections, wiring, and fuses F-1, F-5, F-11, F-17 & F-19; Turn key to ON position (KOEO-Key On, Engine Off); Push and hold HOPPER UP button and measure voltage across wires at ENABLE SOLEID (SV-1) plug, then HOPPER UP SOLEID (SV-6B) plug. Push and hold HOPPER DOWN button and measure voltage across wires at ENABLE SOLEID (SV-1) plug, then HOPPER DOWN SOLEID (SV-6A). Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Is battery voltage measured across wires at HOPPER UP and DOWN SOLEIDS (SV-6B & SV-6A)? Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty HOPPER UP or DOWN SOLEID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-17 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board PLEASE TE: When finished, please reconnect all wires disconnected during testing

78 Main Brush Stall Circuit 1A F D A FUSE 1B 6 M1 F-19 15A FUSE 7 85 PIN 32 PIN 22 13A 7 PIN 2 PIN 33 13B 7A PIN 3 PIN 34 13C Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8 8C STALLED MAIN BRUSH LED S-19 STALLED MAIN BRUSH 96 PIN 29 PIN CONTROL BOARD RMALLY OPEN / CLOSED WITH MAIN BRUSH STALL 96 PIN 35 13D 105 CHASSIS GROUND 13AA M1 51 Check all connections, wiring, and fuses F-1, F-5, F-11 & F-19, turn key to ON position (KOEO-Key On, Engine Off) Remove wires from terminals at STALLED MAIN BRUSH SWITCH and connect wires with a jumper wire Is STALLED MAIN BRUSH LED lit? Suspect faulty STALLED MAIN BRUSH SWITCH Re-check all power and ground circuits and fuses F-1, F-5, F-11 & F-19; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 72 PLEASE TE: When finished, please reconnect all wires disconnected during testing

79 1D Main Brush On & Down Circuit A 15A FUSE 1B 6 M1 F-1 85 F-19 15A FUSE PIN 32 PIN 2 PIN 22 PIN 33 13A 13B 6 F A 15A FUSE SV-1 ENABLE SOLEID 7A 16 PIN 3 PIN 4 PIN 34 13C PIN 35 13D 8 14B MAIN BRUSH ON SOLEID SV-2 17 PIN 5 PIN Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 8C M1 14E 51 SV-7 MAIN BRUSH 73 DOWN SOLEID PIN CONTROL BOARD ON/OFF ONE STEP ON/OFF SWITCH CHASSIS GROUND ONE STEP LED TE: DO T UNPLUG connectors at ENABLE SOLEID (SV-1), MAIN BRUSH ON SOLEID (SV-2), or MAIN BRUSH DOWN SOLEID (SV-7) when doing voltage tests. Unplugging connector will give false readings. Check all connections, wiring, and fuses F-1, F-5, F-11, F-19 & F-20; Turn key to ON position (KOEO-Key On, Engine Off); Push ONE-STEP button and measure voltage across wires at ENABLE SOLEID (SV-1), MAIN BRUSH ON SOLEID (SV-2), and MAIN BRUSH DOWN SOLEID (SV-7) Is battery voltage measured across wires at ENABLE SOLEID (SV-1), MAIN BRUSH ON SOLEID (SV-2), and MAIN BRUSH DOWN SOLEID (SV-7)? Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty SOLEID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-19 & F-20; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board PLEASE TE: When finished, please reconnect all wires disconnected during testing

80 1D Main & Side Brush On & Down Circuit A Note: Ignition Switch is illustrated in the OFF position. Please see Key Switch illustrations page for various operating positions 15A FUSE 1B 6 M1 F-1 8 8C 6 85 M1 F-19 15A FUSE F A 15A FUSE 51 7 ENABLE SOLEID 14C SIDE & MAIN BRUSH ON SOLEID 14E SV-1 SV-7 SV A 16 MAIN BRUSH 73 DOWN SOLEID SV-8 18 PIN 32 PIN 2 PIN 3 PIN 4 PIN 6 PIN 23 14D SIDE BRUSH 53 PIN 31 DOWN SOLEID ONE STEP ON/OFF SWITCH SIDE BRUSH ON/OFF SWITCH PIN 22 PIN 33 PIN 34 PIN 35 13D PIN CONTROL BOARD ONE STEP LED 13A 13B 13C 105 CHASSIS GROUND SIDE BRUSH ON LED TE: DO T UNPLUG connectors at ENABLE SOLEID (SV-1), SIDE & MAIN BRUSH ON SOLEID (SV-3), MAIN BRUSH DOWN SOLEID (SV-7), or SIDE BRUSH DOWN SOLEID (SV-8) when doing voltage tests. Unplugging connectors will give false readings. Check all connections, wiring, and fuses F-1, F-5, F-11, F-19 & F-20; Turn key to ON position (KOEO-Key On, Engine Off); Push ONE-STEP button (be sure that the SIDE BRUSH is also turned on) and measure voltage across wires at ENABLE SOLEID (SV-1), SIDE & MAIN BRUSH ON SOLEID (SV-3), MAIN BRUSH DOWN SOLEID (SV-7), and SIDE BRUSH DOWN SOLEID (SV-8) Is battery voltage measured across wires at ENABLE SOLEID (SV-1), SIDE & MAIN BRUSH ON SOLEID (SV-3), MAIN BRUSH DOWN SOLEID (SV-7), and SIDE BRUSH DOWN SOLEID (SV-8)? Note: Typical Solenoid Valve Coil Resistance is 6 to 8 Ohms Repair or replace faulty hydraulic or mechanical components (refer to 6650 HYDRAULIC TROUBLESHOOTING); Suspect faulty SOLEID coil Re-check all power & ground connections and fuses F-1, F-5, F-11, F-19 & F-20; Test relay M-1; Test diode D-1; Test Key Switch; Suspect faulty 6650 Control Board 74 PLEASE TE: When finished, please reconnect all wires disconnected during testing

81 6650 Interlocks Condition Turn off ONE-STEP button (causes the following:) Main & side brush off & up Vacuum fan off Shaker system on Hopper door closed Select LOW ENGINE SPEED To START Main & side brushes (ON & DOWN) Turn on ONE-STEP button (causes the following:) Main & side brush on & down (Note: Main brush must be on for the side brush to operate) Vacuum fan on Shaker system off Hopper door open Close the hopper door Excessive hopper temperature Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 To STOP Main & side brushes (OFF & UP) Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1(6 to 8 seconds), then NE Indication ONE-STEP LED ON SIDE BRUSH LED ON VACUUM FAN LED ON ENG.SPEED #2 or #3 LED ON HOPPER OPEN LED ON HOPPER CLOSED LED ON SHAKE FILTER LED ON (10 seconds) ENG.SPEED #1 LED ON HOPPER CLOSED LED ON THERMO SENTRY LED ON HOPPER CLOSED LED ON Lift the hopper Solenoid Valves Energized: SV-1, SV-6A or SV-6B HOPPER UP LED ON Turn on ONE-STEP button Condition To START Vacuum Fan (ON) Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 Indication ONE-STEP LED ON SIDE BRUSH LED ON VACUUM FAN LED ON ENG.SPEED #2 or #3 LED ON HOPPER OPEN LED ON Turn on VACUUM FAN button Solenoid Valves Energized: SV-9 with ONE-STEP system OFF Note: This is the Vacuum Wand Mode High engine speed is automatically selected To STOP Vacuum Fan (OFF) Note: Any one of the following will cause this to happen VACUUM FAN LED ON Turn off ONE-STEP button Turn off VACUUM FAN button Turn on SHAKER button Solenoid Valves Energized: SV-1(6 to 8 seconds), then NE Solenoid Valves Energized: NE (W/ ONE-STEP SYSTEM OFF) HOPPER CLOSED LED ON SHAKE FILTER LED ON (10 seconds) VACUUM FAN LED OFF VACUUM FAN LED OFF SHAKER LED ON

82 6650 Interlocks (continued) Condition To START Shaker System (ON) Note: Any one of the following will cause this to happen Indication Turn on SHAKER button Turn off VACUUM FAN button (Note: Triggers an automatic 10 second shake cycle) Turn off ONE-STEP button (Note: Triggers an automatic 10 second shake cycle) Turn on ONE-STEP button Turn on VACUUM FAN button Turn off SHAKER button SHAKER system times out PUSH and HOLD HOPPER UP or DOWN button Release HOPPER UP or DOWN button Solenoid Valves Energized: NE (W/ ONE-STEP SYSTEM OFF) To STOP Shaker System (OFF) Note: Any one of the following will cause this to happen Condition Solenoid Valves Energized: SV-1(6 to 8 seconds), then NE Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 Solenoid Valves Energized: SV-9 (W/ ONE-STEP SYSTEM OFF) Solenoid Valves Energized: NE (W/ ONE-STEP SYSTEM OFF) To START Hopper Lift or Lower Solenoid Valves Energized: SV-1, SV-6A or SV-6B To STOP Hopper Lift or Lower Solenoid Valves Energized: NE SHAKE FILTER LED ON (10 seconds) SHAKE FILTER LED ON (10 seconds) HOPPER CLOSED LED ON SHAKE FILTER LED ON (10 seconds) ONE-STEP LED ON (See prev. page) SHAKE FILTER LED OFF VACUUM FAN LED ON SHAKE FILTER LED OFF SHAKE FILTER LED OFF SHAKE FILTER LED OFF Indication HOPPER UP or DOWN LED ON HOPPER UP or DOWN LED OFF Note: The hopper will lift or lower only while the button is held or until the end of travel. Either operation will automatically cancel the One- Step operation. If engine is at low speed, it will automatically increase to medium. The hopper door is automatically closed when hopper is fully lowered and hopper down switch is closed. 76 Turn on HOPPER OPEN button Turn on ONE-STEP button Turn on HOPPER CLOSE button Turn off ONE-STEP button Fully lower hopper Excessive hopper temperature Condition To OPEN Hopper Door Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1(6 to 8 seconds), then NE Solenoid Valves Energized: SV-1, SV-3, SV-5, SV-7, SV-8, SV-9 To CLOSE Hopper Door Note: Any one of the following will cause this to happen Solenoid Valves Energized: SV-1(6 to 8 seconds), then NE Indication HOPPER OPEN LED ON ONE-STEP LED ON (See prev. page) HOPPER OPEN LED ON HOPPER UP or DOWN LED ON HOPPER UP or DOWN LED ON HOPPER UP or DOWN LED ON THERMO-SENTRY LED ON

83 6650 Operational/Diagnostic/Maintenance Modes Six Operational Modes MODE & DESCRIPTION 1) RMAL MODE Use this mode to perform normal sweeping functions with machine 2) MANUAL MODE Use this mode to turn on any system without regard to the state of inputs, sensors or interlocks 3) INPUT DISPLAY MODE Use this mode to observe if the inputs to the machine control board are operating correctly - the LED s on instrument panel will show the state of each input 4) SELF TEST / DISPLAY ERROR / DISPLAY SOFTWARE REVISION MODE Use this mode to run a self-test on all of the machine control board outputs when test is complete, the software revision is displayed if panel passes test, OK will also be displayed - if panel fails test, the pin number of the failed output(s) is also displayed 5) DISPLAY CHECK ENGINE FAULTS MODE Use this mode to decode any ZENITH ENGINE CONTROLLER (ZEEMS) faults when the words CHECK ENGINE are displayed on the LCD panel 6) CONTRAST ADJUST MODE Use this mode to adjust the contrast of the LCD panel display Turn OFF machine START and RUN Machine TO INITIATE Turn OFF machine Press and hold SHAKER and ENGINE SPEED buttons START and RUN Machine Hold buttons for 5 seconds and release The word MANUAL should be displayed on the LCD panel display Turn OFF machine Press and hold HOPPER OPEN and HOPPER CLOSED buttons START and RUN Machine Hold buttons for 5 seconds and release The word INPUT should be displayed on the LCD panel display Turn OFF machine Press and hold VACUUM FAN and ENGINE SPEED buttons START and RUN Machine Hold buttons for 5 seconds and release The software revision and any self-test faults should be displayed on the LCD panel display TE: If OPEN LOAD or SHORT LOAD is displayed after pin number, then the self-test found a load that is electrically open or shorted to BATTERY + (check output wires or replace load as needed) Turn OFF machine Press and hold SIDE BRUSH and ENGINE SPEED buttons Turn key switch to ON, but DO T START the engine Hold buttons for 5 seconds and release The ZEEMS engine control faults will now be displayed by blinking the SHAKER LED (see 6650 ZEEMS ENGINE FAULT CODES ) Turn OFF machine Press and hold HOPPER UP and HOPPER DOWN buttons Turn key switch to ON, but DO T START the engine Hold buttons for 5 seconds and release The word CONTRAST should be displayed on the LCD panel TE: Hold the HOPPER DOWN button to darken the LCD display Hold the HOPPER UP button to lighten the LCD display TO EXIT FROM ANY MODE, THE KEY SWITCH MUST BE CYCLED OFF

84 6650 with ZEEMS (Zenith) Engine Management System Is "Oil Pressure Light" or "High Temperature Light" also on? Yes Turn Key Off, Turn Key On, Engine Off (KOEO) Is "Check Engine" displayed on LCD panel? No No Engine Fault Codes Detected during KOEO Yes No Shaker LED Light illumination for "14" will be as follows: on, medium off, on, short off, on, short off, on, short off, on; longer pause; on, medium off, on, short off, on, short off, on, short off, on; longer pause. on, medium off, on, short off, on, short off, on, short off, on; (other code readouts are similar) Start and Run Engine Does engine "shut off" after 2-3 seconds or 40 seconds of running? READ ENGINE TROUBLE CODES - Turn Engine Off - Press and Hold Side Brush & Engine Speed Buttons - Turn Key on, do not start - Hold buttons for 5 seconds - Watch blinking Shaker LED for engine trouble codes Is "Check Engine" displayed on LCD panel with engine running? (KOER) 2-3 Seconds running then off 40 Seconds running then off Tennant Engine Trouble Codes are: 14-ECT Sensor Open (Engine Coolant Sensor) 15-ECT Sensor Shorted (Engine Coolant Sensor) 23-ACT Sensor Open (Air Temperature Sensor) 24-ACT Sensor Shorted (Air Temperature Sensor) 33-MAP Sensor Open (Manifold Absolute Pressure) 34-MAP Sensor Shorted (Manifold Absolute Pressure) 44-O2 Sensor Lean (Oxygen Sensor) 45-O2 Sensor Rich (Oxygen Sensor) Low Oil Pressure automatic shutdown sequence activated High Temperature automatic shutdown sequence activated No Engine Fault Codes Detected during KOEO and KOER STOP 78 Service and Repair as Required Clear Codes by momentarily grounding 49/White "pigtail" while engine is running RETEST

85 6650 ZEEMS Check Engine Fault Codes MACHINE STATUS Key On, Engine Off (KOEO) No engine faults detected Key On, Engine Running (KOER) No engine faults detected Key On, Engine Running (KOER) Engine fault(s) detected Key On, Engine Off (KOEO) Engine fault(s) detected Key On, Engine Running (KOER) High engine temperature sensed AUTOMATIC ENGINE SHUTDOWN OCCURS TE: If key switch is turned off and machine restarted, engine will run 40 seconds until another automatic shutdown Key On, Engine Running (KOER) Low engine oil pressure sensed AUTOMATIC ENGINE SHUTDOWN OCCURS TE: If key switch is turned off and machine restarted, engine will run 2 to 3 seconds until another automatic shutdown LCD PANEL Fuel level & hour meter reading displayed Fuel level & hour meter reading displayed CHECK ENGINE displayed (see MODE 5 on previous page) CHECK ENGINE displayed (see MODE 5 on previous page) CHECK ENGINE displayed (see MODE 5 on previous page) CHECK ENGINE displayed (see MODE 5 on previous page) CONDITION TE: See MODE 5 on previous page Beginning of fault codes, or OK if no other codes displayed Engine coolant sensor OPEN Engine coolant sensor SHORTED Air temp sensor OPEN Air temp sensor SHORTED MAP sensor OPEN, circuit voltage >4.98V MAP sensor SHORTED FAULT CODE DISPLAYED (ON SHAKER LED) 12, 12, 12 14, 14, 14 15, 15, 15 23, 23, 23 24, 24, 24 33, 33, 33 34, 34, 34 TO CLEAR FAULT CODES AND TURN OFF CHECK ENGINE WARNING Ground PIN # 16 of the WHITE CONNECTOR at the ZENITH ENGINE CONTROLLER while engine is running (Note: Some controllers have a wire pigtail that is connected to PIN # 16)

86 6650 Machine Control Board Pin Functions PIN # 1 2,3 4,5,6,7,8,9, 10, ,14,15,16 17,18,19 20, ,24 25,26, ,34,35 INPUT or OUTPUT INPUT INPUT OUTPUT INPUT OUTPUT INPUT OUTPUT INPUT INPUT INPUT OUTPUT INPUT INPUT FUNCTION Chassis ground Battery positive (B+) Low side drivers DIGITAL - Activates when grounded Governor speed control Battery ground (B-) Low side drivers DIGITAL - Activates when grounded Fuel gauge input DIGITAL - Activates when grounded Low side driver Memory storage Battery ground (B-) ACTIVE VOLTAGE Battery ground (B-) Battery positive (B+) 0 VDC T PRESENTLY USED 0 VDC T PRESENTLY USED OPEN Battery ground (B-) 0 VDC 0 VDC >100 ohms = full tank <5 ohms = empty tank 0 VDC T PRESENTLY USED 0 VDC Battery positive (B+) Battery ground (B-) INACTIVE VOLTAGE Battery ground (B-) 0 VDC Battery positive (B+) 5 VDC Battery positive (B+) Battery ground (B-) Battery positive (B+) 5 VDC 5 VDC Battery positive (B+) Battery positive (B+) Battery ground (B-)

87 MODEL 6650 HYDRAULIC Troubleshooting Charts BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnings and Precautions in Operator's Manual * Engine & Hydraulic Oil Must Be At Normal Operating Temperatures after Running Machine and Hydraulics a Minimum of 5 Minutes * Examine Machine For Any Linkage Binding or Mechanical Problems DURING TESTS: * Maintain Normal Main Brush Pressure as Listed in Operator's Manual * Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown Cause or Course of Action

88 6650 OVERALL HYDRAULIC DIAGRAM (Part 1 of 2) SIDE BRUSH LIFT/LOWER MAIN BRUSH LIFT/LOWER HOPPER LIFT/LOWER HOPPER DOOR OPEN/CLOSE MAIN BRUSH SIDE BRUSH (OPTIONAL) PLEASE TE: All specifications listed are for normal operating conditions

89 6650 OVERALL HYDRAULIC DIAGRAM (Part 2 of 2) AUX...Auxiliary CK...Check Valve CM...Centimeters CU...Cubic CV...Control Valve CYL...Cylinder DC...Disconnect Coupler (Hydraulic) DC...Direct Current (Electrical) FLTR...Filter GPM...Gallons per Minute EXPLANATION OF ABBREVIATIONS HTX...Heat Exchanger IN...Inches LH...Left Hand LPM...Liters per Minute M...Motor (Combustion) MTR...Motor (Hydraulic) OR...Orifice PC...Pilot Port Check Valve PMP...Pump PSI...Pounds per Square Inch PSWITCH...Pressure Switch RES...Reservoir RH...Right Hand RPM...Revolutions per Minute RV...Relief Valve STRN...Strainer SV...Solenoid Valve TV...Throttle Valve V...Volts PLEASE TE: All specifications listed are for normal operating conditions

90 T 26 Side Brush Lift Cylinder Side Brush Motor P Steering Valve R L 30 Hopper Dump Door Cylinder 24 Hopper Lift Cylinder Main Brush Lift Cylinder Aux Pump 4 Reservoir 1 12 Propel Pump Vac Fan Motor Main Brush Motor 8 Steer Cylinder 5 2 Wheel Drive Motor 3 16 Control Valve T3 T1 M1 P C8 M C7 C1 Cooler 17 T2 C5 C3 C6 C2 Filter T HYDRAULIC HOSE ROUTING

91 CV MAIN BRUSH SV2 M2 HYDRAULIC FLOW METER 5.4 GPM ( RPM 6.5 GPM ( RPM (Flow readings +/- 5%) SV1 600 PSI (41 BAR) MAIN BRUSH 600 PSI (41 BAR) RV PSI (166 BAR) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR MAIN BRUSH RPM 460 RPM +/ RPM 550 RPM +/ RPM Note: Specs. shown are for main brush down with 2 inch (5 cm) brush pattern PLEASE TE: All specifications listed are for normal operating conditions

92 CV1 SV3 M MAIN & SIDE BRUSH 600 PSI (41 BAR) P SV1 RV PSI (165 BAR) SIDE BRUSH MAIN BRUSH 200 PSI 600 PSI 800 PSI (14 BAR) (41 BAR) (55 BAR) HYDRAULIC FLOW METER 5.4 GPM ( RPM 6.5 GPM ( RPM (Flow readings +/- 5%) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR MAIN BRUSH RPM 460 RPM +/ RPM 550 RPM +/ RPM SIDE BRUSH RPM 75 RPM +/ RPM 90 RPM +/ RPM Note: Specs. shown are for main & side brushes down, with 2 inch (5 cm) main brush pattern PLEASE TE: All specifications listed are for normal operating conditions

93 6650 VACUUM FAN HYDRAULIC FLOW METER 5.4 GPM ( RPM 6.5 GPM ( RPM (Flow readings +/- 5%) 1000 PSI (68 BAR) SV9 RV PSI (124 BAR) 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN VACUUM FAN 1000 PSI (69 BAR) SUCTION ACCESSORY PUMP STRAINER RV7 25 PSI (1.7 BAR) RV4 3 PSI (0.2 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

94 6650 RAISE HOPPER T2 SV6B CV1 PC2 C4 C3 RESTRICTOR SV6A SV1 RAISE P RV PSI (166 BAR) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

95 6650 LOWER HOPPER T2 SV6B CV1 PC2 C4 C3 Note: Lowering of hopper is due to PILOT CHECK VALVE 2 (PC2) being unseated, and gravity (weight of hopper) RESTRICTOR SV6A SV1 LOWER P RV PSI (166 BAR) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV4 3 PSI (0.2 BAR) RV7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

96 6650 OPEN HOPPER DOOR T2 OUT CV1 C2 DOOR SV5 PC1 CV1B C C1 SV1 HOPPER DOOR CYLINDER OPEN P RV PSI (166 BAR) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

97 6650 CLOSE HOPPER DOOR T2 OUT CV1 C2 DOOR SV5 CV1B C PC1 C1 Note: Arrows show direction of Fluid Flow, T Pressure (PSI) SV1 HOPPER DOOR CYLINDER CLOSE RV PSI (166 BAR) T1 P 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI RV 7 25 PSI (0.2 BAR) (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

98 6650 LOWER MAIN BRUSH T2 OUT CV1 DOOR SV7 CV1B C C6 C5 SV1 MAIN BRUSH LIFT CYLINDER OPEN LOWER P RV PSI (166 BAR) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

99 6650 RAISE MAIN BRUSH T2 OUT CV1 DOOR SV7 CV1B C C6 SV1 C5 MAIN BRUSH LIFT CYLINDER RAISE RV PSI (166 BAR) T1 P 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

100 6650 LOWER SIDE BRUSH T2 OUT CV1 DOOR SV8 CV1B C C8 C7 SV1 SIDE BRUSH LIFT CYLINDER OPEN LOWER P RV PSI (166 BAR) T1 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

101 6650 RAISE SIDE BRUSH T2 OUT CV1 DOOR SV8 CV1B C C8 SV1 C7 SIDE BRUSH LIFT CYLINDER RAISE RV PSI (166 BAR) T1 P 5.4 GPM ( RPM 6.5 GPM ( RPM PRESSURE RETURN ACCESSORY PUMP SUCTION STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) FILTER HEAT EXCHANGER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

102 6650 RIGHT TURN RV PSI (41 BAR) T CK5 P MTR/PMP3 CV3 R L STEERING SYSTEM CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) 3.3 GPM ( RPM 3.9 GPM ( RPM PRESSURE RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

103 6650 LEFT TURN CV3 RV PSI (41 BAR) T CK5 R L STEERING SYSTEM P MTR/PMP3 CYLINDER Note: MTR/PMP3 operates as a motor with engine running (to reduce operator effort to steer) and as a pump with engine not running (for ability to steer machine) PRESSURE 3.3 GPM ( RPM 3.9 GPM ( RPM RETURN SUCTION ACCESSORY PUMP STRAINER RV 4 3 PSI (0.2 BAR) RV 7 25 PSI (1.7 BAR) HEAT EXCHANGER FILTER RESERVOIR PLEASE TE: All specifications listed are for normal operating conditions

104 6650 MAIN BRUSH STALL TRIGGERING PRESSURE SWITCH CV1 SV PSI (166 BAR) 0 GPM/LPM BRUSH STALLED 2400 PSI (166 BAR) 0 GPM/LPM PRESSURE SWITCH 2400 PSI (166 BAR) MAIN BRUSH SV3 TO BRUSH STALL WARNING LAMP SV1 CK2 5PSI (0.3 BAR) 2400 PSI (166 BAR) 0 GPM/LPM SIDE BRUSH 2400 PSI (166 BAR) 0 GPM/LPM FROM PUMP RV PSI (166 BAR) 2400 PSI (166 BAR) Full Hydraulic Oil Flow 0.0 PSI (0.0 BAR) Full Hydraulic Oil Flow TO RESERVOIR TE: THESE CONDITIONS WILL OCCUR IF MAIN BRUSH STALLS WHEN SWEEPING WITH MAIN BRUSH ONLY OR WHEN SWEEPING WITH MAIN AND SIDE BRUSH

105 6650 PROPEL SYSTEM Propel Pump Assembly Tow Valve Charge Pump (to keep propel system full of oil) Propel Motor Assembly Propel Motor Propel Pump Engine Pick-up To Reservoir (Case drains)

106 100

107 ECU - Black Connector LOW LEVEL INPUT TCX LOW LEVEL IMPUT HIGH LEVEL INPUT RCX N/A PROGRAMING PORT SHIELD GROUND LOW LEVEL INPUT LOW LEVEL INPUT CRANK SENSOR GROUND SENSOR GROUND +5V SENSOR REFERENCE CRANK SENSOR INPUT SENSOR GROUND +5V SENSOR REFERENCE N/A 02 SENSOR INPUT POTENTIOMETER INPUT (0-5V) MAP SENSOR INPUT AIR TEMP SIGNAL COOLANT TEMP SIGNAL 0-5V ATOO INPUT

108 ECU - White Connector ECU +12V OUT IGNITION POWER (+12V) ECU +12V OUT COIL DRIVER 1 IGNITION POWER (+12V) LOW LEVEL DRIVER (.2A) COIL DRIVER 2 ENGI00 GROUND HIGH LEVEL OUTPUT (1A) GOVER OUTPUT (HIGH SIDE) ENGI00 GROUND CHECK ENGINE LAMP DRIVER (.2A) FUEL PUMP/LOCKOFF OUPUT (+12V) TACHOMETER INPUT (-)COIL DIGITAL INPUT GASOLINE INJECTOR DRIVER DIGITAL OUTPUT DIGITAL OUT LP INJECTOR DRIVER HIGH LEVEL/12V A to D INPUT HIGH LEVEL INPUT ALTERNATE FUEL REQUEST (+12V) OEM LOW LEVEL INPUT

109 White Connector Active Circuit Voltage Notes Key On, Engine Off Voltage Key Off, engine Off, Voltage Voltage Range, Nominal Voltage Acronym Used Pin Number Description 1 Alternative Fuel Request 0-12 vdc 0 vdc 0 vdc 12 vdc Use only with dual fuel applications 2 High Level Input 0-12 vdc 0 vdc 0 vdc 12 vdc 3 LP Injector Driver 0-12 vdc 0 vdc 12 vdc 0 vdc Grounds circuit to "turn on" 4 Fuel pump/lock off control 0-12 vdc 0 vdc 0 vdc 12 vdc Sends 12 vdc to fuel pump or lock off 5 Governor Output 0-12 vdc 0 vdc 0 vdc, pulsed voltage 12 vdc Sends 12 vdc to hz, duty cycles varies 6 Coil Driver # vdc 0 vdc 0 vdc 12 vdc Sends 12 vdc to coil 7 Coil Driver # vdc 0 vdc 0 vdc 12 vdc Sends 12 vdc to coil 8 ECU 12 vdc out 0-12 vdc 0 vdc 12 vdc 12 vdc Sends 12 vdc to???? 9 High level input 0-12 vdc 0 vdc 0 vdc 12 vdc 10 Digital Out Signal 0-12 vdc 0 vdc 0 vdc Pulsed On or off signal 11 Digital Input 0-12 vdc 0 vdc 0 vdc 12 vdc Square wave 12 Check Engine Lamp Driver (0.2a) 0-12 vdc 0 vdc 0 vdc 12 vdc On or off signal 13 High level output 0-12 vdc 0 vdc 0 vdc 12 vdc On or off signal 14 Low Level Driver (0.2a) 0-12 vdc 0 vdc 0 vdc 12 vdc On or off signal 15 ECU 12 vdc out to fuel injector 0-12 vdc 0 vdc 0 vdc 12 vdc Sends 12 vdc to fuel injector 16 OEM Low Level Input 0-5 vdc 0 vdc 0 vdc 5 vdc 17 High level / 12 A to D Input 0-12 vdc 0 vdc 0 vdc 12 vdc 18 Digital Output 0-12 vdc 0 vdc 0 vdc Pulsed On or off signal 19 Tachometer Input from Ignition Coil vdc 0 vdc 12 vdc vdc Engine Ground for governor, lockoff, fuel pump, distrubutor ground 0 vdc 0 vdc 0 vdc 0 vdc Ground Engine Ground for governor, lockoff, fuel pump, distrubutor ground 0 vdc 0 vdc 0 vdc 0 vdc Ground 22 Ignition Power 0-12 vdc 0 vdc 12 vdc 12 vdc Power into ECU 23 Ignition Power 0-12 vdc 0 vdc 12 vdc 12 vdc Power into ECU Active Circuit Voltage Notes Key On, Engine Off Voltage Key Off, engine Off, Voltage Voltage Range, Nominal Voltage Acronym Used Black Connector Description 1 Coolant Temperature Sensor Signal CTS 0-5 vdc 0 vdc 0-5 vdc 0-5 vdc 2 Potentiometer Input 0-5 vdc 0 vdc 0-5 vdc 0-5 vdc 3 Sensor Reference 5 vdc 0 vdc 5 vdc 5 vdc Signal from ECU to input sensors 4 Sensor Reference to MAP sensor 5 vdc 0 vdc 5 vdc 5 vdc Signal from ECU to input sensors 5 Low Level Input 5 vdc 0 vdc 0 vdc 0-5 vdc 6 Programming Port 0-5 vdc 0 vdc 0 vdc 0-5 vdc Signal into ECU, to reprogram memory 7 High Level Input 0-12 vdc 0 vdc 0 vdc 0-5 vdc 8 Low Level Input 5 vdc 0 vdc 0 vdc 0-5 vdc 9 Intake Air Temperature Sensor Signal IAT 0-5 vdc 0 vdc 0-5 vdc 0-5 vdc 10 O2 Sensor Input 0-1 vdc 0 vdc 0.45 vdc 0-1 vdc 11 Sensor Ground, MAP, CTS and IAT 0 vdc 0 vdc 0 vdc 0 vdc 12 Sensor Ground 0 vdc 0 vdc 0 vdc 0 vdc 13 Low Level Input 0-5 vdc 0 vdc 0 vdc 5 vdc 14 N/A N/A N/A N/A N/A 15 Low Level Input 0-5 vdc 0 vdc 0 vdc 5 vdc 16 Input, from dash panel low, med, high RPM 0-12 vdc 0 vdc 0 vdc 5 vdc 17 MAP Sensor Signal Input MAP 0-5 vdc 0 vdc 4.70 vdc 0-5 vdc Measure BARO with Key on engine off 18 N/A N/A N/A N/A N/A N/A 19 Crank Sensor Input 0-5 vdc 0 vdc 0 vdc 0-5 vdc Square wave 20 Crank Sensor Ground 0 vdc 0 vdc 0 vdc 0 vdc 21 Shield Ground 0 vdc 0 vdc 0 vdc 0 vdc Protected ground circuit 22 Receive Signal from data recording device 0-5 vdc 0 vdc 0 vdc 0-5 vdc Square wave 23 Transmit Signal to data recording device 0-5 vdc 0 vdc 0 vdc 0-5 vdc Square wave 103

110 Maintenance Schedule Power Solutions, Inc GM Powertrain L, 2.2L, 3.0L, 4.3L, 5.71L, 7.4L, and 8.1L Engines Initial Start- Up Sequence Checks Operation Daily Weekly Every 50 Hrs Every 100 Hrs Every 200 Hrs Every 400 Hrs Every 800 Hrs As Req'd 1 Check Engine Oil Level x 2 Check Coolant Level (4) x 3 Check Fluid Leaks x 4 Governor, Mechanical (Check oil level)(2) x Change Engine Oil & Filter (1) x 5 Battery, Check Charge & Fluid Level (3) x Inspect & Clean Radiator Exterior (3) x Clean Battery Cables (3) x 6 Check Belts and Belt Tension x Lubricate Throttle, Governor & Choke Linkage (Carbureted Engines Only) x Check & Adjust Idle Speed (Carbureted Engines Only) x Inspect and Clean Air Cleaner Element x Replace Primary Air Cleaner Element (1) x Replace Safety Air cleaner Element x Replace Engine Coolant (3)(4) x Replace Fuel Filter (5) x Spark Plugs, Clean, Adjust & Test or Replace (3) x Replace PCV Valve (If equipped)(3) x Check PCV Hoses, Tubes, Fittings (3) x Replace Spark Plugs (3) x Adjust Throttle & Governor (3) x 7 Check All Bolts & Nuts for Tightness (3) x (1) More frequent intervals may be required in dusty or dirty operating conditions. (2) Mechanical governor (belt driven). (3) Seasonal or as required. (4) Check engine coolant condition & protection, hoses & clamps annually (prior to cold weather). (5) More frequent intervals may be required with dirt in fuel system.

111 Engine 2.0L 2.2L 3.0L 4.3L 5.7L 7.4L 8.1L Oil Capacity Without Filter 5 qt. 4.5 qt. 5 qt. 8 qt. 8 qt. Coolant Capacity Without Radiator 4 qt. 7 qt. 7.8 qt qt qt Coolant Capacity With Radiator 12 qt. 17 qt qt 28 qt 31 qt (Turbo 105

112 General Specifications Power Solutions, Inc GM Powertrain Industrial Engines Engine 3.0L Type 3.0L L4 Displacement cc (c.i.d) 2966 (181) Compression Ratio 9.2:1 Push Rod Actuated Valve Configuration Overhead Valve Valve Lifters Flat Follower Bore x Stroke mm(inches) x91.44(4.00x3.60) Main Bearing Caps 2 Bolt Balance method External Intake Manifold TBI, Carburetor, Mixer Firing Order Oil Capacity With 5 qts. (4.7L) Oil Filter 5.5 qts. (5.2L) Oil Filter PF-25 or Equivalent Coolant Capacity (Engine) 4 qts. (3.78L) Fuel Type Gasoline, LPG, NG Engine Rotation (Flywheel End) CCW Ignition System Solid State Distributor Ignition Timing (Degrees BTDC) Gasoline (Carb) 0 Gasoline (TBI) 0 LPG 10 (4 Europe) NG 10 Dual Fuel 0 Spark Plugs AC Delco R46TS Spark Plug Gap Gasoline (Carb) 0.04 TBI LPG NG Dual Fuel Valve Clearance (Lash) Intake Exhaust 1/2 to 1 Turn Down From 0 Lash Manufactured Toluca, Mexico 106

113 107 ZEEMS ZEEMS Zenith Electronic Engine Management System Propane and Gasoline Electronic Fuel Injection

114 108 Home Page ZEEMS ZEEMS System Advantages Block Diagram ECU, Electronic Control Unit Inputs Output Controls System Operation Diagnostics No Start Diagnostics Specifications

115 109 Overview page 1 ZEEMS The ZEEMS Advantages Precise fuel control throughout all operating temperatures and conditions Precise ignition timing control throughout all operating temperatures and conditions Virtually eliminates flat spots and engine run-on (dieseling) Achieves maximum power with lowest emissions

116 110 Overview page 2 ZEEMS The ZEEMS Control system electrically controls the following: Fuel Delivery via fuel injector (gas, propane or both) Ignition timing via ECU and High Energy Ignition (HEI) system Engine RPM via throttle shaft actuator control Speed-Density Discussion

117 111 Overview page 2a ZEEMS The ZEEMS System The ZEEMS system is a Speed-Density design. This system measures the engine RPM (speed of the engine) and calculates the Density of the Air (from atmospheric pressure and temperature of the air) to determine the optimum fuel and timing settings for the altitude and climatic conditions.

118 112 Block Diagram ZEEMS ZEEMS Block Diagram Electrical fuel shut off/on, propane (LPG) Electric fuel pump, gasoline Input Sensors Fuel Tank, propane or gasoline Fuel Return, gasoline only Fuel Pressure Regulator, gasoline only Distributor Throttle Actuator Fuel Injector RPM Timing Advance ECU Electronic Control Unit

119 113 ECU page 1 ZEEMS The ECU is the control center of the ZEEMS, sometimes called the processor or brain box (logic device) The ECU monitors the input sensors, compares to programmed look up tables ECU Electronic Control Unit and then controls the output devices.

120 114 The Black Connector is used for low level current devices, such as input signals, transmit and receive signals, and other low voltage signals. ECU page 2 ECU Electronic Control Unit ZEEMS The White Connector is used for high current loads, such as battery power and ground and controlling the out put devices. Battery Ground Feed Pins 20 & 21 on White Connector Battery Power Feed Pins 22 & 23 on White Connector

121 115 The ECU monitors most input sensors once every distributor pulse or engine event, depending on engine RPM and operating conditions. One engine event is an ignition pulse (spark plug firing). ZEEMS ECU Page 3 Engine Event Discussion ECU Electronic Control Unit There are two distributor pulses (events) per engine revolution on a 4 cylinder, 4 cycle engine Therefore: 500 RPM = 1000 events 1000 RPM = 2000 events 2000 RPM = 4000 events

122 116 Inputs Introduction ZEEMS The ZEEMS systems uses several input devices to monitor the engine and atmospheric conditions. ECU Inputs Engine RPM Engine Coolant Temperature (ECT) Intake Air Temperature (IAT) Manifold Absolute Pressure (MAP) Exhaust Gas Oxygen Sensor (EGO) (if equipped) ECU Electronic Control Unit Lets examine each input sensor in depth

123 117 ECU Inputs Engine RPM Inputs, RPM page 1 ZEEMS RPM Engine RPM ECU Electronic Control Unit Engine RPM is determined from the distributor pulses generated by the magnetic pick up and converted to a digital pattern by the HEI (High Energy Ignition) module.

124 118 ECU Inputs Engine RPM Ignition Module (Analog to Digital Converter A/D) Magnetic Pick Up (AC Sine Wave) Inputs, RPM page 1a ZEEMS RPM Engine RPM ECU Electronic Control Unit For every ignition pulse, a signal is received at the ECU. The ECU then signals fuel injector to turn on and spray fuel. One fuel injector pulse per event.

125 119 Inputs, ECT & IAT page 1 ECT & IAT ZEEMS ECT & IAT Engine Coolant Temp Sensor (ECT), Intake Air Temp Sensor (IAT) ECU Inputs ECT IAT ECU Electronic Control Unit The ECT is located in or near the water outlet from the engine block to the radiator. The IAT is located in the throttle body assembly. Both sensors are two (2) wire sensors.

126 120 Inputs, ECT & IAT page 2 ECT & IAT ZEEMS ECT & IAT Engine Coolant Temp Sensor (ECT), Intake Air Temp Sensor (IAT) ECU Inputs ECT IAT ECU Electronic Control Unit The ZEEMS system uses a Negative Temperature Coefficient (NTC) thermistors for the ECT and IAT sensors. A thermistor changes its internal resistance as the temperature changes. A NTC thermistor resistance increases as the temperature decreases, and the resistance decreases as the temperature increases.

127 121 Inputs, ECT & IAT page 3 ECT & IAT ZEEMS ECT & IAT Engine Coolant Temp Sensor (ECT), Intake Air Temp Sensor (IAT) ECU Inputs ECT IAT ECU The ECU monitors the ECT and IAT wires to determine the temperature changes. ECU monitors here

128 122 Inputs, MAP page 1 MAP ZEEMS MAP ECU Inputs Manifold Absolute Pressure Sensor Manifold Absolute Pressure Sensor The MAP is located between the throttle body assembly and the ECU. ECU Electronic Control Unit This MAP sensor is a three (3) wire sensor similar in operation to a potentiometer. Routing to the intake manifold source is accomplished by a passage way drilled from the throttle bore directly into the MAP.

129 123 ECU Inputs Manifold Absolute Pressure Sensor Inputs, MAP page 2 ZEEMS MAP MAP The MAP changes its internal resistance as the atmospheric or intake manifold pressure changes. ECU Electronic Control Unit The MAP sensor with the ECU calculates the barometric pressure when the key is turned on. (KOEO=Key On Engine Off). As the engine starts/runs, the MAP s internal resistance changes causing the signal wire voltage to change. (KOER = Key On Engine Run).

130 124 ECU Inputs Manifold Absolute Pressure Sensor Inputs, MAP page 3 ZEEMS MAP MAP ECU Electronic Control Unit This sensor has two chambers internally. These chambers are isolated by a silicone diaphragm.

131 125 ECU Inputs Manifold Absolute Sensor 5 volt DC Reference Voltage Inputs, MAP page 3 ZEEMS MAP MAP ECU Electronic Control Unit The ECU sends a fixed 5 vdc +/- 10% voltage to the MAP. The ECU monitors the signal wire to determine the barometric pressure and/or engine load changes. (intake manifold pressure). ECU monitors here

132 126 ECU Inputs Manifold Absolute Sensor 5 volt DC Reference Voltage Inputs, MAP page 4a Discussion MAP ECU Electronic Control Unit ECU monitors here ZEEMS MAP Manifold Absolute Pressure Sensor The ECU sends a fixed 5 vdc +/- 10% voltage to the MAP. This is a must! If voltage is not 5vDC +/-10%, suspect the ECU is faulty Question What voltage will be seen with the key on, KOEO? Answer This is the baro voltage at this location. This number is constant depending on actual barometric pressure.

133 127 ECU Inputs Exhaust Gas Oxygen Sensor Click here for a detailed explanation on Oxygen sensors Inputs, EGO page 1 EGO ZEEMS EGO Exhaust Gas Oxygen Sensor (if equipped) ECU Electronic Control Unit The EGO is located on the exhaust pipe within six (6) inches of the exhaust manifold. (15 cm) This sensor is a four (4) wire sensor. The ZEEMS system uses a heated EGO sensor.

134 128 ECU Inputs Exhaust Gas Oxygen Sensor Click here for a detailed explanation on Oxygen sensors Inputs, EGO page 1a EGO (if equipped) ZEEMS EGO Exhaust Gas Oxygen Sensor The EGO sensor generates a DC voltage (0-1vDC) that is proportional to the Oxygen content of the exhaust stream and ambient oxygen. ECU Electronic Control Unit When the Oxygen (O2) content in the exhaust stream goes up the voltage goes down. Question If the engine is running with too much fuel and no misfires, will the EGO voltage be high or low?

135 129 ECU Inputs Exhaust Gas Oxygen Sensor Click here for a detailed explanation on Oxygen sensors Inputs, EGO page 2 EGO (if equipped) ZEEMS EGO Exhaust Gas Oxygen Sensor When the EGO sensor approaches 600 degrees F / 300 degrees C it starts to operate properly. ECU Electronic Control Unit An internal heater brings the EGO to its operating temp and maintains this temp if the exhaust gases temp decreases. The EGO heater is a 12v heater controlled by the ignition switch. This is not controlled by the ECU. These are the white wires going to sensor harness.

136 130 ECU Inputs EGO Heater EGO Key Switch On Inputs, EGO page 3 EGO ZEEMS EGO Exhaust Gas Oxygen Sensor (if equipped) The EGO generates voltages between 0-1vDC. ECU Electronic Control Unit The ECU monitors the signal wire to determine the O2 content of the exhaust stream. ECU monitors here

137 131 Inputs, EGO page 3a EGO ZEEMS EGO Exhaust Gas Oxygen Sensor ECU Inputs The ECU internally sends a bias voltage to the EGO signal wire. This bias voltage is in the EGO Heater EGO Key Switch On Bias voltage vdc (if equipped) ECU Electronic Control Unit ECU monitors here vdc range. If the EGO generates a voltage higher than the bias voltage the ECU determines less fuel is required, if under the bias voltage, more fuel is required.

138 132 Inputs Review ZEEMS The ZEEMS systems uses several input devices to monitor the engine and atmospheric conditions. ECU Inputs Engine RPM Engine Coolant Temperature (ECT) Intake Air Temperature (IAT) Manifold Absolute Pressure (MAP) Exhaust Gas Oxygen Sensor (EGO) (if equipped) ECU Electronic Control Unit Input Sensor Review

139 133 Output Control Introduction ZEEMS The ZEEMS systems uses three output devices. Commands to the outputs are determined from input conditions. ECU Outputs Output Controls Lets examine each output device in depth ECU Electronic Control Unit Governor Actuator Fuel Injector Ignition Timing

140 134 Outputs Governor page 1 ZEEMS Governor Governor The Governor is an electric actuator which controls (turns) the throttle plate. ECU Outputs Governor Actuator The governor actuator motor is the only connection to the throttle plate. The governor uses two wires to control the actuator. ECU Electronic Control Unit A ground wire and the control circuit from the ECU.

141 135 Outputs Governor page 2 ZEEMS Governor Governor The governor is located on the throttle body assembly and is the only part that is not field replaceable. The throttle plate has a mechanical stop and must be tested/reset at hour intervals. The proper RPM for the mechanical stop is 750 RPM. ECU Electronic Control Unit ECU Outputs Governor Actuator

142 136 Outputs Governor page 3 ZEEMS Governor Governor To control the governor, the ECU uses two inputs: dash switch (2 or 3 speed) engine RPM From the RPM input (condition), the ECU commands the governor to increase or decrease the RPM depending on the engine load and other operating conditions to match the dash switch desired RPM. ECU Electronic Control Unit ECU Outputs Governor Actuator

143 137 Outputs Governor page 4 ZEEMS Governor Governor The ECU controls the power side to the Governor with the ground coming from ECU. Dash Switch Command Engine RPM ECU Electronic Control Unit ECU controls here ECU Outputs Governor Actuator Coil High Side Switch Circuit This circuit controls the power side of the Governor Actuator Coil

144 138 Outputs Governor page 4a ZEEMS Governor Governor The ECU controls the governor by changing the on-time or pulse width modulation (PWM) (duty cycle change) during fixed frequency pulses. ECU Outputs Governor Actuator Coil 50% On 50% Off One Cycle 25% On XX% Off One Cycle 6 vdc Average 3 vdc Average ECU Electronic Control Unit ECU controls here High Side Switch Circuit XX% On xx vdc Average XX% Off One Cycle

145 139 Outputs Governor page 4b ZEEMS Governor Governor The frequency of the governor control circuit is 240 hertz +/-2%. ECU Outputs Governor Actuator Coil The duty cycle will vary according to the engine load, based on the throttle plate setting, ignition timing, quality of fuel and many other factors. The duty cycle must change as the demand for engine RPM is commanded. ECU Electronic Control Unit ECU controls here High Side Switch Circuit

146 140 Outputs Governor page 5 ZEEMS Governor Governor If the ECU or throttle body/governor assembly is replaced or the base idle setting is altered, the ECU must relearn the base throttle setting. This procedure takes 2-4 minutes during normal operation. This idle setting relearn procedure is a self-programming operation of the ECU ECU Electronic Control Unit ECU Outputs Governor

147 141 ZEEMS Outputs Governor page 1 Adjustments Governor Governor The proper RPM for the mechanical stop is 750 RPM. ECU Outputs Governor To adjust: (engine must be over 171 degrees F) unplug the actuator (governor) remove sealant over stop screw start engine and monitor RPM turn stop screw to desired RPM turn engine off connect actuator (gov) restart engine, run for 2 minutes re-run base RPM test (readjust) reseal stop screw ECU Electronic Control Unit

148 142 Outputs Fuel Injector page 1 ZEEMS Fuel Injector Fuel Injector The Fuel Injector is an electric actuator which controls the fuel flow to the engine. ECU Output Fuel Injector The gasoline fuel injector is calibrated at 10 psi w/o EGO (0.69 bar) 15 psi with EGO (1.0 bar) and the propane fuel injector is calibrated at 24 psi. w/o EGO (1.65 bar) calibrated at 14 psi. with EGO (0.96 bar) No normal servicing is required. ECU Electronic Control Unit

149 Home Find... Go To Fuel Injector Insert a narrow piece of thin cardboard under the fuel injector nozzle. Wait for 5-10 minutes, the cardboard should remain stain free, if the cardboard is stained, the injector is leaking. With the engine not running and the key in the off position. Electronic Control Unit ECU Fuel Injector page 1a Gasoline Fuel Injector Leak Test Fuel Injector Outputs ZEEMS

150 144 Outputs Fuel Injector page 2 ZEEMS Fuel Injector Fuel Injector To control the fuel injector, the ECU provides the power and controls the ground side of the circuit. ECU Output Fuel Injector The injector fires once per engine event and varies the pulse width (on-time) according to the engine conditions. The engine conditions are monitored by the input sensors and the the ECU commands the fuel injector with a longer or shorter pulse width (on time). ECU Electronic Control Unit

151 145 Outputs Fuel Injector page 3 ZEEMS Fuel Injector Fuel Injector ECU Output 12 vdc Fuel Injector The injector triggers once for every distributor references pulse going into the ECU. Engine RPM ECU Electronic Control Unit HEI Module Operation Review ECU controls here Low Side Switch Circuit

152 146 Outputs Fuel Injector page 4 ZEEMS Fuel Injector Fuel Injector The ECU varies the amount of on-time of the injector by looking at the various input sensors of the engine. IAT EGO Engine RPM ECT MAP 12 vdc ECU Electronic Control Unit ECU Output Fuel Injector The ECU varies the injector pulse width Off ECU controls here Low Side Switch Circuit On

153 147 Outputs Timing Control page 1 ZEEMS Timing Ignition Timing The ECU controls the ignition timing based on the MAP, ECT, IAT and RPM inputs. Base Ignition Timing needs to be checked/reset at hour intervals. Gas RPM 17 degrees BTDC +/- 2 deg LPG RPM 25 degrees BTDC +/- 2 deg IAT EGO ECT MAP RPM ECU Electronic Control Unit ECU Output Ignition Timing Timing Advance Discussion

154 148 Outputs Timing Control page 2a ZEEMS Timing Ignition Module Engine RPM Analog to Digital Converter A/D Magnetic Pick Up (AC Sine Wave) Ignition Timing Cranking, up to RPM Advance Relay Control Ignition Coil ECU Electronic Control Unit

155 149 Outputs Timing Control page 2b ZEEMS Timing Ignition Timing Running, over RPM Engine RPM Ignition Module (Analog to Digital Converter A/D) Advance Relay Control Ignition Coil ECU Electronic Control Unit Magnetic Pick Up (AC Sine Wave)

156 150 Open/Closed Loop page 1 ZEEMS Open & Closed Loop Open & Closed Loop Open Loop During warm-up the ECU controls in open loop. The ECU controls the outputs based on the MAP, ECT, IAT and RPM inputs. Open Loop is defined as no EGO control. ECT IAT MAP EGO RPM ECU Electronic Control Unit Closed Loop

157 151 Open/Closed Loop page 2 ZEEMS Open & Closed Loop Open & Closed Loop Open Loop IAT EGO ECT MAP RPM ECU Electronic Control Unit Closed Loop To achieve closed loop these conditions must be meet: engine fully warm EGO hot and operating engine running for seconds Closed Loop is defined as the EGO is monitoring the the O2 content of the exhaust stream and the ECU is adjusting the fuel injector pulse width based on the EGO values.

158 152 Open/Closed Loop page 3 ZEEMS Open & Closed Loop Closed Loop to Open Loop Open Loop The ECU will move from Closed Loop to Open Loop if sudden changes in MAP, ECT, or RPM values occur. MAP sensor changes are load dependent. ECT changes are coolant related. RPM changes are engine running conditions. ECT IAT MAP EGO RPM ECU Electronic Control Unit Closed Loop

159 153 Open/Closed Loop page 4 ZEEMS Open & Closed Loop Closed Loop Operation ECU Electronic Control Unit EGO Fuel Injector ENGINE Rich Lean Out Lean ` Richen Rich Lean Out Condition Command Move to Review Page

160 154 Review Questions and Answers Open/Closed Loop Discussion Review Questions and Answers ZEEMS

161 155 Review Questions and Answers ZEEMS Review Questions and Answers Name the five (5) input sensors (input sensor review) Name the three (3) output actuators (actuator review) If the engine coolant temperature is high, will the ECT resistance be high or low? (ECT review) How does the EGO sensor produce voltage? (EGO review) If the MAP sensor signal voltage 2.8vDC, (KOEO) at what altitude is the machine located at? (MAP review)

162 156 Operation page 1 ZEEMS System Operation Key On Calculates or measures: Altitude, barometric pressure Coolant temperature Ambient temperature ECU Electronic Control Unit ECU Turns on Fuel Pump (gasoline) or MAP Opens Fuel Lock Off (propane) ECT IAT This will be on for 2 seconds if a RPM signal is not received. Listen and feel the pump run or the lock off to turn on.

163 157 MAP ECT IAT Operation page 2 ZEEMS System Operation Cranking ECU Electronic Control Unit Fuel is flowing (pump pumping or lock off open ) Injector Firing RPM Governor is starting to control Ignition Timing is at base timing setting

164 158 Dash Switch Command MAP ECT IAT Operation page 3 without EGO Running ZEEMS System Operation without EGO Sensor ECU Electronic Control Unit Fuel is flowing (pump pumping or lock off open ) Injector Firing RPM Governor is at specified controlled RPM Ignition Timing advancing

165 159 EGO Dash Switch Command MAP ECT IAT Operation page 4 with EGO Running with EGO Sensor ZEEMS System Operation EGO Heater Key On Not ECU Controlled ECU Electronic Control Unit Fuel is flowing (pump pumping or lock off open ) Injector Firing RPM Governor is at specified controlled RPM Ignition Timing advancing

166 160 Operation Review ZEEMS System Operation Review Questions and Answers

167 161 ZEEMS Diagnostics

168 162 Diagnostics ZEEMS Failures 30% Wiring 40% Input sensors 25% Actuator outputs 5% ECU Failures 30% Wiring 40% Input Sensors 25% Actuator Outputs 5% ECU Failures

169 163 ZEEMS Diagnostics, ECU Quick Tests Diagnostics ECU Quick Tests (These quick tests can determine whether the ECU can control correctly. These test/s have a high accuracy rating to determine a defective ECU.) MAP Reference Voltage Test (KOEO, Black Connector Pin 4) Measure Reference voltage to MAP Sensor Turn Key Off Remove wire harness to MAP Turn key on (KOEO) Voltmeter red lead to Terminal C on the MAP Sensor, black lead to Terminal A Results should be 5.0 vdc +/- 10% ( vdc) MAP Sensor Review

170 164 Diagnostics Output Control Frequency Test (KOER, White Connector Pin 5) Measure Frequency to Governor Actuator Turn Key Off Diagnostics, ECU Quick Tests ZEEMS Connect frequency meter red lead to Terminal A on Governor Actuator, black lead to Terminal B Leave governor actuator connected in circuit Start Engine (KOER) Results should be 240 Hertz +/- 2% at stable RPM Governor Actuator Review

171 165 Diagnostics, ECU Quick Tests ZEEMS Diagnostics Processor Quick Tests EGO Bias Voltage Test (KOEO, Black Connector Pin 10) (if equipped) Measure Bias voltage to EGO Sensor Turn Key Off Remove wire harness to EGO Turn key on Voltmeter red lead to Terminal?? on EGO Sensor, black lead to Terminal?? Results should be vdc EGO Sensor Review

172 166 Diagnostics Processor Quick Tests Diagnostics, ECU Quick Tests ZEEMS Conclusion If all of these tests fail, suspect a faulty power or ground circuit/s to the ECU. If one or two of these tests fail, suspect a faulty ECU.

173 167 ZEEMS Diagnostics, Input Sensors Quick Test Input Sensor Quick Tests IAT Testing ECT Testing MAP Testing EGO Testing Distributor Reference 40% Input Sensors

174 168 ZEEMS Diagnostics, Input Sensors Quick Test IAT and ECT Testing Remove wiring harness from sensor/s Install test harness to IAT or ECT sensor Measure the resistance values in Ohms and compare to chart below Temp F Temp C Nominal Resistance Minimum Resistance Maximum Resistance

175 169 ZEEMS Diagnostics, Input Sensors Quick Test IAT and ECT Testing Remove wiring harness from sensor/s Turn Key On (KOEO) Measure voltage between terminals A & B of the wiring harness going to the IAT or ECT Black Voltmeter lead to B, red lead to A Voltage should be 5 vdc +/- 10% (KOEO)

176 170 ZEEMS Diagnostics, Input Sensors Quick Test MAP Testing Complete ECU reference voltage test at MAP With the MAP connected in-circuit Connect a voltmeter as follows, key on (KOEO) Red lead to terminal B, black lead to ground Measure the Voltage values and compare to chart These voltages will vary according the current weather conditions at your location Altitude above Sea Level Nominal Voltage DC

177 171 ZEEMS Diagnostics, Input Sensors Quick Test EGO Testing (if equipped) Complete EGO Bias voltage test With the EGO connected in-circuit Connect a voltmeter as follows, key on (KOEO) Red lead to terminal XX, black lead to ground Complete EGO test in machine per EGO testing sequence Richen Mixture EGO voltage 0.8 vdc or higher Lean Mixture EGO voltage 0.3 vdc or lower (EGO Sensor Review)

178 172 ZEEMS Diagnostics, Output Sensors Quick Test Failures 30% Wiring 40% Input sensors 25% Actuator outputs 5% ECU Failures 25% Actuator Outputs

179 173 ZEEMS Diagnostics, Output Sensors Quick Test Fuel Injector Testing Disconnect wire/s to fuel injector Measure the resistance of the fuel injector Ohms is specification Turn Key on and measure voltage on the harness Volt meter red lead to terminal A, black lead to terminal B, turn key on (KOEO) Voltage should be 9-14 vdc Complete fuel injector tap test

180 174 ZEEMS Diagnostics, Output Sensors Quick Test Governor Actuator Testing Disconnect wire/s to Governor Actuator Measure the resistance of the actuator Ohms is specification Turn Key on and measure voltage on the harness Volt meter red lead to terminal A, black lead to terminal B, turn key on (KOEO) Voltage should be battery voltage (+/-0.4vDC)

181 175 ZEEMS Diagnostics, Output Sensors Quick Test Governor Actuator Testing Connect ammeter to one wire going to governor actuator Turn key on (KOEO) Measure governor actuator amperage draw Specification is amp when Governor actuator is activated (3 amps maximum draw) If higher than three amp draw, suspect sticking throttle plates or other mechanical binding

182 176 ZEEMS Diagnostics, Output Sensors Quick Test Ignition Timing Testing Set to lowest governed RPM (1350) Start engine and monitor ignition timing Gas RPM 17 degrees BTDC +/- 2 deg LPG RPM 25 degrees BTDC +/- 2 deg

183 177 Diagnostics ZEEMS Diagnostic Review 30% Wiring 40% Input sensors 25% Actuator outputs 5% ECU Failures 30% Wiring 40% Input Sensors 25% Actuator Outputs 5% ECU Failures

184 178 Temp F Temp C IAT and ECT Nominal Resistance Specifications Minimum Resistance Maximum Resistance MAP Altitude above Sea Level Nominal Voltage DC Governor Actuator Ohms 3 amp max current draw Fuel Injector Ohms ZEEMS Fuel Pressure Gasoline 10 psi (0.69 bar) w/o EGO 15 psi (1.0 bar) w/ego Propane 14 psi. (0.96 bar) w/ego 24 psi. (1.65 bar) w/o EGO RPM Gas 17 deg BTDC +/- 2 deg LPG 25 deg BTDC +/- 2 deg

185 179 Operation Review ZEEMS System Operation Review Questions and Answers

186 180 Block Diagram Review ZEEMS ZEEMS Block Diagram Electrical fuel shut off/on, propane (LPG) Electric fuel pump, gasoline Input Sensors Fuel Tank, propane or gasoline Fuel Return, gasoline only Fuel Pressure Regulator, gasoline only Distributor Throttle Actuator Fuel Injector RPM Timing Advance ECU Electronic Control Unit

187 181 EGO Dash Switch Command MAP ECT IAT Operation Review Running with EGO Sensor ZEEMS System Operation EGO Heater Key On Not ECU Controlled ECU Electronic Control Unit Fuel is flowing (pump pumping or lock off open ) Injector Firing RPM Governor is at specified controlled RPM Ignition Timing advancing

188 182 ZEEMS ZEEMS 550/1550 Engine Replacement Kit Numbers Perkins Diesel GM 3.0 L LPG GM 3.0 L Gas

189 183 ZEEMS ZEEMS Zenith Electronic Engine Management System Propane and Gasoline Electronic Fuel Injection END

190 184

191 ZEEMS Troubleshooting Test Kit Complete Test Kit Tennant Part # Zenith Part # C Pressure Gauge Tennant Part # Zenith Part # C Male Connector 45 Flare Tennant Part # Zenith Part # T Assly Street TEE w/fittings Tennant Part # Zenith Part # C210-7 Male Connector SAE 45 Flare Tennant Part # Zenith Part # T Connector Fitting Tennant Part # Zenith Part # T220-5 Male Pipe X Female Pipe Tee Tennant Part # Zenith Part # T

192 Service Connector Air Temp Sensor Tennant Part # Zenith Part # C Service Connector Coolant Temp Sensor Tennant Part # Zenith Part # C Service Connector MAP Sensor Tennant Part # Zenith Part # C Service Connector Governor Tennant Part # Zenith Part # C

193 Service Connector Gasoline Injector Tennant Part # Zenith Part # C Service Connector LPG Injector Tennant Part # Zenith Part # C GM Micropak Coil Adapter Tennant Part # Zenith Part # C

194 Gas Injector - Noid Light Tennant Part # Zenith Part # C LPG Injector - Noid Light Tennant Part # Zenith Part # C Actuator Power Tool Tennant Part # Zenith Part # C

195 Engine Controls AIR AND COOLANT SENSOR RESISTANCE Temp deg F Temp deg F Nominal Resistance ohms Minimum Resistance ohms Maximum Resistance ohms Table 7:1 WIRING DIAGRAMS Refer to Section 3, Engine Electrical, for wiring diagrams. Note: The wiring diagrams are specific to the engine and machine application. If the following wiring diagrams do not match the machine being repaired contact Power Solutions, Inc., or the machine manufacturer for a copy of the diagram. 189

196 Engine Controls DIAGSTIC PROCEDURES Diagnostic procedures are listed separately for each fuel but, unlike mechanical fuel systems that require different thinking processes for gasoline and LPG, the diagnostic procedures for both the gasoline and LPG ZEEMS system follow the same thinking pattern. Diagnostic Procedure Pg. No. Engine Idle Speed High 4-36 Engine Speed Spikes Intermittently 4-37 Engine Runs Erratically, Poor Governor Performance 4-38 Engine Runs but will not Accelerate 4-39 Engine Won t Start - Gasoline 4-40 Gasoline Fuel Pump Diagnosis 4-41 Engine Won t Start - LPG 4-42 Engine Won t Start - Dual Fuel 4-44 Engine Runs, Low Power, Lean or Misfire - Gasoline 4-45 Engine Runs Rich - Gasoline 4-46 Engine Runs, Low Power, Lean or Misfires - LPG 4-47 Engine Runs Rich - LPG 4-48 Below is a brief list of items to check BEFORE entering the ZEEMS diagnostic charts that follow. Too often the tendency is to blame the most unfamiliar part of a new system and we forget to get back to the basics. The following is a quick check list of items to check. Ignition System Operation Ignition Timing Fuel pressures Fuel level Electrical Connections Alternator charging voltages Battery condition 190

197 Engine Controls Diagnostic Procedures - Continued Engine Idle Speed High Check vacuum leaks: Intake manifold Throttle body Throttle adapter PCV valve TE: disconnect battery when servicing electrical components Does engine idle at RPM with actuator unplugged? Back out idle stop screw one turn Does idle speed drop? Binding or stuck throttle Engine idle above RPM with actuator connected Adjust idle stop to specifications SEE: Operating Spec. With ECT above 161 deg. F allow engine to idle for 2-5 1/2 min. to self learn idle speed SEE: Operating Spec. 191

198 Engine Controls Diagnostic Procedures - Continued Engine Speed Spikes Intermittently Disconnect Governor Actuator. Engine idle speed RPM? < 650 RPM > 650 RPM Adjust base idle screw to lower engine RPM Is idle speed reduced? Repair faulty connection Verify ECU ignition supply is constant and uninterrupted. Constant? Remove Throttle body and inspect for binding/obstruction Repair faulty connection Verify ECU ground is constant and uninterrupted. Constant? Clean and Tight? Adjust base idle screw to specifications Allow unit to reach operating temperature (>160 F) and allow unit to Self Learn Repair fault in Speed Select wiring. 192 REV 3

199 Engine Controls Diagnostic Procedures - Continued Engine Runs Erratically, Poor Governor Performance Engine speed surges Correct charging system fault Charging voltage system surges? Repair ground ECU ground? SEE engine diagnostics System fuel pressures low? Correct CKP sensor polarity Ignition timing incorrect? Voltage reversed on CKP sensor? SEE engine diagnostics Vacuum Leaks? Set timing to manufacturers specifications SEE engine idle speed high Throttle plate sticking? Replace throttle body 193

200 Engine Controls Diagnostic Procedures - Continued Engine Runs, But Will Not Accelerate Fuel Level SEE: Engine runs low power, lean or misfires diagnosis Map Sensor Replace *APP sensor or speed select output OK? Repair or replace accelerator pedal position sensor or speed select switch *Refer to the applicable schematic in Section 3 to check the speed switch operation. Governor actuator input OK? Repair wiring or replace ECU Governor actuator continuity (3-5 Ω)? Replace throttle body Check throttle plate rotation 194

201 Engine Controls Diagnostic Procedures - Continued Engine Won t Start - Gasoline Spark Present at Spark Plugs? Refer to Section 3, Engine Electrical Fuel Level? Add fuel See pump diagnosis Momentary fuel pressure when key is on? Correct ignition system. Repair or replace ECU Repair wiring or voltage souce Fuel pressure w/crank? Tach. signal to ECU? Repair wiring or CKP sensor 12V at injector? Injector light flashes? Replace fuel press regulator. Adjust Fuel press psi. Check ground or replace ECU Injector sprays? Fuel press psi? Restrict fuel return line. Fuel press. 16 psi? Replace injector or o-rings Injector leaks? Disconnect inj. Crank engine 15 sec. Replace fuel filter and/or pump Clean or replace plugs Are plugs fouled? Is engine flooded? 195

202 Engine Control Diagnostic Procedures - Continued Gasoline Fuel Pump Diagnosis Momentary 12v at pump when key is turned on? Ground continuity to frame? Repair or replace pump Repair wire to pump Momentary 12v from ECU when key is turned on? 12v to ECU? Repair 12v source to ECU Repair ground wire Ground continuity? Replace ECU 196

203 Engine Controls Diagnostic Procedures - Continued Engine Won t Start - LPG Spark Present at Spark Plugs? Refer to Section 3, Engine Electrical Repair Open Circuit Does LP tank have fuel? Add Fuel Repair open circuit With key on, does ignition coil have power? Ignition ON. Does ECU have both ignition and ground? Turn ignition on and immediately observe LP lock-off voltage. Is voltage present for 2 seconds and turns off? Disconnect 4-pin connector from Distributor. Do spark plugs fire while cranking? Consult Engine Electrical Section Replace ECU and perform Self-learning Repair incorrect wiring Repair wiring/loose connection Crank engine for 5 seconds and observe LP lock-off voltage. Does voltage remain constant for the 5 second crank? Check ignition system. Do spark plugs fire while cranking? Verify injector wires have continuity between ECU and injector CONTINUITY Using an injector ID light. Does light flash during cranking? Repair open circuit in distributor reference wiring to ECU CONTINUED ON NEXT PAGE OK Replace ECU REV A 197

204 Engine Controls Diagnostic Procedures - Continued Engine Won t Start - LPG (Continued) Using a digital multimeter, measure injector coil resistance. Resistance ( ohms) OPEN CIRCUIT Replace faulty injector CHECKS OK CAUTION: Extreme care should be taken when disconnecting fuel lines. Lines may be under pressure. Gasoline is highly flammable an should not be exposed to ignition sources or areas of high heat. Install fuel pressure gauge at Throttle Body fuel inlet. Fuel pressure OK when key is turned on? SEE LP REFER TO FUEL PUMP REGULATOR DIAGSIS DIAGSIS Turn Restrict ignition fuel return on momentarily line and turn to ignition charge on fuel momentarily pressure. Disconnect to charge LP fuel lock-off pressure. power Disconnect and crank fuel engine. pump power Observe and fuel crank engine. Observe fuel pressure gauge. pressure gauge. Does fuel pressure drop rapidly while cranking? Replace defective injector REV A System operating properly 198

205 Engine Controls Diagnostic Procedures - Continued Engine Won t Start Dual Fuel Spark Present at Spark Plugs? Refer to Section 3, Engine Electrical Check fuel in both tanks Check fuel selector switch position Go to gasoline no start diagnostic GAS LPG Starts in alternate fuel? LPG GAS Go to LPG no start diagnostic NEITHER FUEL STARTS Momentary 12v at lock-off or gas pump when key is on Go to no start diagnostic Momentary 12v from ECU when key is turned on? Go to no start diagnostic Repair ground wire Ground continuity? 12v to ECU? Repair 12v source to ECU Replace ECU 199

206 Engine Controls Diagnostic Procedures - Continued Engine Runs, Low Power, Lean or Misfires Gasoline START HERE Check vacuum leaks: Intake manifold Throttle body Throttle adapter PCV valve System voltage 13.5/14.7v? Repair charging system Replace fuel pressure regulator Fuel pressure 9-11 psi? 16 psi restricted fuel line Replace fuel pump and/ or filter Replace map sensor Map sensor ok? Set ignition timing SEE engine service manual Ignition timing ok? Replace module or ECU DIS ignition module in ECU Ignition module ok? Tune engine Repair wiring or CKP sensor Tach. signal input to ECU? Check restrictions: Air Filter Exhaust 200

207 Engine Controls Diagnostic Procedures - Continued LPG Lock-Off Diagnosis Momentary 12v at lock-off when key is turned on? Ground continuity to frame? Repair or replace lock-off Repair wire to lock-off Momentary 12v from ECU when key is turned on? 12v to ECU? Repair 12v source to ECU Repair ground wire Ground continuity? Replace ECU 201

208 Engine Controls Diagnostic Procedures - Continued Engine Runs Rich Gasoline START HERE Check MAP sensor connections OK Check MAP sensor with alternate sensor OK Check coolant and air temperature sensor connection OK Check for leaky injector OK Check air/coolant sensors resistance as per chart OK Repair/replace fuel return line Fuel press. greater than 11 psi? Restriction in fuel return line? Adjust timing or repair harness/ module. Refer to Section 3, Engine Electrical. Ign. timing retarded? Adjust press. reg psi Runs okay Replace fuel pressure regulator 202

209 Engine Controls Diagnostic Procedures - Continued Engine Runs, Low Power, Lean or Misfires LPG START HERE Fuel level? Tank oriented in correct position? Orientate tank for liquid withdrawal. Replace or fill tank. Replace injector. Service valve on liquid withdrawal side of tank? Change tanks. Secondary Regulator Pressure See Page 4-22 Regulator freeze-up? Engine coolant level and circulation? Primary Regulator Pressure See Page 4-22 Fuel pressure ok? Check restriction filter or lock-off. Adjust pressure or replace regulator. System voltage V? Repair charging system. Check vacuum leaks: Intake manifold Throttle adapter Throttle body PCV valve OK continued 203

210 Engine Controls Diagnostic Procedures - Continued Engine Runs, Low power, Lean or Misfires LPG (Continued) Map sensor okay? Replace map sensor. Ignition timing okay? Set ignition timing. Refer to Section 3 Engine Electrical. Ignition Module okay? Replace module or ECU DIS ignition module in ECU Tune engine. OK Tach. signal input to ECU? Repair wiring or CKP sensor. Check restrictions: Exhaust Air Filter OK Check Valve clearances. 204

211 Engine Controls Diagnostic Procedures - Continued Engine Runs Rich LPG START HERE Check MAP sensor connections OK Check MAP sensor with alternate sensor OK Check coolant and air temperature sensor connection OK Replace fuel injectors. Leaky injector? OK Check air/coolant sensors resistance as per chart. Adjust/replace primary regulator Fuel press. primary reg. See Page 4-22 Adjust secondary reg. See Page 4-22 Adjust/replace secondary regulator. Adjust timing or repair harness/module Refer to Section 3, Engine Electrical Ignition timing ok? Runs ok. 205

212 206

213 Operation and Maintenance Manual PSI s 4.3L OPU Industrial Gasoline and Alternate Fueled Engines 1.6L, 3.0L, 4.3L, 5.7L, 7.4L and 8.1L Engines /REV A GM Powertrain Product by Power Solutions, Inc. Wood Dale, IL

214 Table of Contents Page Introduction 1 How to Use This Manual 1 Engine Identification 2 Parts and Service 2 Service Literature 2 Operating Instructions 3 Controls 3 Ignition Switch 3 Safety Gauges 3 Fuel Systems 3 Governors 4 Instruments 4 Oil Pressure Gauge 4 Temperature Gauge 4 Voltmeter 5 Tachometer/Hourmeter 5 Starting the Engine 5 Carbureted, Mechanical Governor, Manual Choke 5 Carbureted, Electric Choke, Electronic Governor 6 LPG or NG Fuel Systems, Velocity Governors 6 PSI, Inc. Fuel Injection (Gasoline) Integral Governor 6 PSI, Inc. Fuel Injection (Dual Fuel) Integral Governor 6 Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor 6 Stopping the Engine 7 Normal Conditions 7 Abnormal Conditions (Carbureted) 7 Abnormal Conditions (Fuel Injected) 7 Fuel Recommendations 7 Fuel Quality 7 Anti-Knock Index (Octane Rating) 8 Gasohol and Alcohol/Gasoline Fuels 8 Spark Plugs 8 Power Loss at Higher Elevations 9 Carbureted Engines 9 Fuel Injected Engines 9 Maintenance Instructions 10 Initial Start Up Maintenance 10 Routine Maintenance

215 Table of Contents (cont.) Scheduled Preventive Maintenance 10 Engine Oil Level Check 10 Adding Engine Oil 10 Changing Engine Oil and Filter 11 Engine Oil Quality 11 Engine Oil Recommendation 11 Oil Filter 11 Engine Air Cleaner 12 Safety Element 12 Cooling System 12 Coolant Level 12 Radiator 13 Fan Belts 13 Sepentine Belt 14 V-Type Belt 14 Fuel Filter 14 Carbureted Engines 14 Fuel Injected Engines 14 Ignition Systems 15 Types of Ignition Systems 15 Ignition Timing 15 Spark Plugs 15 Storage 16 One to Six Months 16 Extended Periods 16 Removing the Engine From Storage 16 Appendix Timing Procedures Maintenance Schedule Capacities Filter Chart Fuel System Chart Governor Chart General Specifications I II II III IV IV V 209

216 Table of Contents (cont.) Spark Plug Wire Routing 3.0L 210

217 Introduction Power Solutions, Inc. is pleased that you have selected a GM Powertrain engine for your requirements. Power Solutions, Inc. takes great pride in our tradition of quality products produced from the GM Powertrain line of industrial gasoline and alternative fuel engines. Power Solutions engines are inspected and tested before leaving the factory. However, certain checks should be made before placing the engine into regular service. Please read the Initial Start-Up inspection requirements in the Maintenance Section of this manual. How to Use this Manual This manual contains instructions on the safe operation and preventive maintenance of your GM Powertrain industrial engine. We urge you to read this manual prior to start up or operation of the engine. The Table of Contents permits you to quickly open the manual to any section. Power Solutions, Inc., engines are built with a variety of standard and/or optional components to suit a broad range of customer requirements. This manual does not identify equipment as standard or optional. All the equipment described in this manual may not be found on your engine or power unit. Please pay special attention to the TES, CAUTIONS, and WARNINGS. WARNINGS remind you to be careful in areas where carelessness can cause personal injury. CAUTIONS are given to prevent you from error that could cause damage to the equipment. TES give you added information designed to help you. The descriptions and specifications contained in this manual were in effect at the time of publication. Power Solutions, Inc. reserves the right to discontinue models at any time, or to change specifications or design without notice and without incurring obligation. 1 Power Solutions, Inc. 655 Wheat Lane Wood Dale, IL

218 Engine Identification An identification label is affixed to the right side of the engine on the rocker cover when looking at the engine from the flywheel end.. (The engine serial number is also stamped into the left side of the cylinder block near the engine flywheel.) The label contains the engine model number (i.e. 4.3L, 5.7L, etc.) and a serial number which identifies the engine from other GM Powertrain engines provided by Power Solutions, Inc. The engine model and serial number are required when seeking information concerning the engine and/or ordering replacement service parts. Insert Picture of the Label Parts and Service Replacement parts can be obtained from Power Solutions, Inc. by calling the Service Parts Department at The engine model and serial number will be required when seeking information and/or ordering parts. Service and technical support for GM Powertrain engines supplied by Power Solutions, Inc. can be obtained by contacting the Service Department at Service Literature Additional operator manuals and service manuals for specific GM Powertrain engines provided by Power Solutions, Inc. can be obtained by contacting the Parts or Service Department at

219 Operating Instructions Controls Ignition Switch The ignition switch is located on the control panel. The switch is a 3 position switch, OFF, RUN and START. The OFF position disconnects the electrical system from the battery. The key can be removed from the switch when it is in this position. In the RUN position, the electrical system is activated. Engage the starter by turning the key to the START position. Release the key when the engine starts and it will return to the ON position. Safety Gauges Power Solutions, Inc., industrial power units are equipped with instrument panels which contain shut down gauges for High Engine Water Temperature and Low Engine Oil Pressure. A push button Tattletale relay is utilized with this system. When starting the engine it is necessary to depress the safety switch override button, until the engine starts and engine oil pressure is obtained (usually 2 to 5 seconds). The engine will continue to run when the button is released. CAUTION: If the engine does not continue to run when the button is released, it will be necessary to check the instrument panel fuse and/or the engine lubrication system (i.e. oil level, etc.) before restarting the engine. TE: Power Solutions, Inc. provides engines to many different original equipment manufacturers. Not all manufacturers use the PSI instrument panel. Please refer to the equipment Operators Manual for instructions on engine starting. Fuel Systems Several different fuel systems have been used on Power Solutions, Inc. GM Powertrain engines. A chart identifiying the different types of fuel systems used by engine model can be found in the back of this manual. TE: Some fuel systems are installed by the original equipment manufacturer. Therefore it may be necessary to contact the equipment manufacturer for information pertaining to your specific fuel system if it cannot be found in the chart

220 Governors As with fuel systems, several different governor controls have also been used with the Power Solutions, Inc. GM Powertrain engines. A chart identifying the different types of governor systems used is included at the back of this manual. TE: Some governors are installed by the original equipment manufacturer. If your governor is not included in the chart, it will be necessary to contact the equipment manufacturer. Instruments Insert Photo of the Instrument Panel Oil Pressure Gauge The oil pressure gauge show the engine lubrication system pressure in pounds per square inch (psi) and should be checked frequently to ensure that the system is functioning correctly. Should the pressure fluctuate or drop, stop the engine and find the cause. Do not operate the engine at lower than normal oil pressure (see maintenance schedule for minimum engine oil pressure). CAUTION: Do not continue to operate your engine below the normal operating range. Severe engine damage could occur. Temperature Gauge The temperature gauge registers the coolant temperature and will indicate overheating which may arise from low coolant level, plugged radiator, loose fan belt or faulty thermostat. Coolant level should be checked daily. CAUTION: If the engine continues to overheat, have the cooling system checked and serviced