56110004
Nilfisk-Advance 56110004, 56110000, 56110005, 56110006, 56110007 Service Manual
...
Condor XL
™
Service Manual
Advance Models:
56110000(LPG/48”), 56110001(Petrol/48”), 56110002(Diesel/48”), 56110003(LPG/60”),
56110004(Petrol/60”), 56110005(Diesel/60”), 56110006(LPG/62”), 56110007(Petrol/62”),
56110008(Diesel/62”), 56110009(LPG/67”), 56110010(Petrol/67”), 56110015(Diesel/67”)
56111035(LPG-AXP/48”), 56111036(Petrol-AXP/48”), 56111037(Diesel-AXP/48”)
56111038(LPG-AXP/60”), 56111039(Petrol-AXP/60”), 56111040(Diesel-AXP/60”)
56111041(LPG-AXP/62”), 56111042(Petrol-AXP/62”), 56111043(Diesel-AXP/62”)
56111044(LPG-AXP/67”), 56111045(Petrol-AXP/67”), 56111046(Diesel-AXP/67”)
7/09 FORM NO. 56043124
TABLE OF CONTENTS
SAFETY INSTRUCTIONS ....................................................................................................................................................4
GENERAL INFORMATION ...............................................................................................................................................5-7
DIAGNOSTIC AND SERVICE TOOLS ..............................................................................................................................8-9
TECHNICAL SPECIFICATIONS ...................................................................................................................................10-13
MAINTENANCE ............................................................................................................................................................14-19
PM CHECKLIST ............................................................................................................................................................20-21
KNOW YOUR MACHINE...............................................................................................................................................22-24
CONTROL PANEL ............................................................................................................................................................24
CONTROL PANEL DIAGNOSTICS ..............................................................................................................................25-26
ELECTRICAL SYSTEM.................................................................................................................................................27-40
FAULT CODE SYSTEM DIAGNOSTICS ..........................................................................................................................27
MAIN CONTROL BOARD FAULT CODES ..................................................................................................................28-31
ENGINE ELECTRICAL COMPONENT LOCATIONS – GM 1.6 GASOLINE ....................................................................32
ENGINE ELECTRICAL COMPONENT LOCATIONS – GM 1.6 LPG ...............................................................................33
ENGINE ELECTRICAL COMPONENT LOCATIONS – KUBOTA DIESEL .......................................................................34
ELECTRICAL COMPONENT LOCATIONS .................................................................................................................35-37
CONTROL BOARD CONNECTORS ...........................................................................................................................38-40
ADJUSTMENTS/REPAIRS ...........................................................................................................................................41-46
SIDE BROOM LIFT ACTUATOR MOTOR ADJUSTMENT ...............................................................................................41
BRAKE TENSION ADJUSTMENT .................................................................................................................................... 42
FOOT PEDAL/HYDROBACK OVERVIEW & NEUTRAL ADJUSTMENT ....................................................................42-43
PUSH/PULL CONTROL CABLE REPLACEMENT ........................................................................................................... 44
HYDROBACK REPLACEMENT .......................................................................................................................................45
FOOT PEDAL NEUTRAL DEADBAND ADJUSTMENT .................................................................................................... 45
SIDE BRUSH TILT ADJUSTMENT ...................................................................................................................................46
TRACTION DRIVE MOTOR HOSE ROUTING ................................................................................................................. 46
GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ...............................................................47
TROUBLESHOOTING GUIDES ..................................................................................................................................48-61
CONTROL BOARD PROGRAMMING OPTIONS ......................................................................................................... 62-66
ENGINE SYSTEM .........................................................................................................................................................67-72
ENGINE SPECIFICATIONS..............................................................................................................................................67
MISCELLANEOUS ENGINE INFORMATION ...................................................................................................................68
GM 1.6L GASOLINE FUEL SYSTEM DESCRIPTION......................................................................................................68
ENGINE DIAGNOSTICS .............................................................................................................................................69-70
1.6L DTC CODES .............................................................................................................................................................71
GM 1.6L ENGINE FUSE BOX & WIRING .........................................................................................................................72
HYDRAULIC SYSTEM ..................................................................................................................................................73-83
HYDRAULIC SYSTEM COMPONENTS ........................................................................................................................... 73
HYDRAULIC COMPONENT LOCATION
HYDRAULIC CYLINDERS ............................................................................................................................................. 74
HYDRAULIC MOTORS..................................................................................................................................................75
HYDRAULIC PUMPS ....................................................................................................................................................76
HYDRAULIC VALVE BLOCK/MANIFOLD .....................................................................................................................77
HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................................................................77
TEST PORT NOMINAL PRESSURE READINGS .......................................................................................................78-79
SCRUB LIFT CYLINDER OVERVIEW ..............................................................................................................................80
HYDRAULIC TRUTH TABLE ............................................................................................................................................81
HYDRAULIC MANIFOLD ASSEMBLY COMPONENT LOCATION KEY .....................................................................81-82
APPENDIX .....................................................................................................................................................................84-98
ELECTRICAL INPUT/OUTPUT TABLE .......................................................................................................................84-87
FAULTS ............................................................................................................................................................................. 88
SOLUTION FLOW DIAGRAM – STANDARD WITH RIGHT FRONT SCRUB .................................................................. 89
SOLUTION FLOW DIAGRAM – ACCESSORIES .............................................................................................................90
SOLUTION FLOW DIAGRAM – AXP................................................................................................................................91
SOLUTION FLOW DIAGRAM – EXTENDED SCRUB .....................................................................................................92
HYDRAULIC SCHEMATIC .........................................................................................................
WIRING DIAGRAM ......................................................................................................................................................94-95
WIRING SCHEMATIC ..................................................................................................................................................96-97
ENGINE HARNESS GM 1.6L GAS ...................................................................................................................................98
ENGINE HARNESS GM 1.6L LPG ...................................................................................................................................99
WIRING HARNESS COMPONENT DESCRIPTION ......................................................................................................100
SWITCH SEQUENCES FOR MAIN CONTROLLER PROGRAMMING OPTIONS ........................................................101
......................................93
FORM NO. 56043124 - Condor XL™ - 3
CAUTIONS AND WARNINGS
SYMBOLS
Advance uses the symbols below to signal potentially dangerous conditions. Always read this information carefully and take the necessary steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property.
Read all instructions before using.
GENERAL SAFETY INSTRUCTIONS
Specifi c Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.
DANGER!
* This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide adequate ventilation
when using machine.
WARNING!
* This machine shall be used only by properly trained and authorized persons.
* While on ramps or inclines, avoid sudden stops when loaded. Avoid abrupt sharp turns. Use low speed down hills. Clean only
while ascending (driving up) the ramp.
* To avoid hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near hydraulic
system.
* Turn the key switch (50) off (O) and disconnect the batteries before servicing electrical components.
* Never work under a machine without safety blocks or stands to support the machine.
* Do not dispense fl ammable cleaning agents, operate the machine on or near these agents, or operate in areas where fl ammable
liquids exist.
* Do not clean this machine with a pressure washer.
CAUTION!
* This machine is not approved for use on public paths or roads.
* This machine is not suitable for picking up hazardous dust.
* Use care when using scarifi er discs and grinding stones. Advance will not be held responsible for any damage to fl oor surfaces
caused by scarifi ers or grinding stones.
* When operating this machine, ensure that third parties, particularly children, are not endangered.
* Before performing any service function, carefully read all instructions pertaining to that function.
* Do not leave the machine unattended without fi rst turning the key switch (50) off (O), removing the key and applying the parking
brake.
* Turn the key switch (50) off (O) before changing the brushes and before opening any access panels.
* Take precautions to prevent hair, jewelry or loose clothing from becoming caught in moving parts.
* Use caution when moving this machine in below-freezing temperature conditions. Any water in the solution or recovery tanks or
in the hose lines could freeze.
* Before use, close and latch all doors and hoods.
SAVE THESE INSTRUCTIONS
4 - FORM NO. 56043124 - Condor XL
™
INTRODUCTION
Service Manual Purpose
This manual is a technical resource that Nilfi sk-Advance expects to be utilized when servicing a Condor XL. It contains information deemed neces-
sary to provide basic troubleshooting, maintenance and repairs within a reasonable timeframe (example - 2-3 hours). If your repair involves multiple
visits to repair the same problem, or the repair cannot be completed within 3-4 hours, a call to Nilfi sk-Advance Technical Support is needed to alert
the factory to potential issues and/or provide the customer with an acceptable level of service. Refer to the website
ditional information not contained herein as well updates or expanded instructions to procedures noted here.
Note: Bold numbers in parentheses in text indicate an illustrated item.
Note: All references to right, left, front and rear in this manual are as seen from the operator’s position (seat).
General Machine Description
The Condor XL machines are industrial automatic rider sweeper/scrubbers with multiple sweep/scrub single pass coverages. All models use dual
cylindrical scrub brooms with variable scrub pressure and solution fl ow rates. Different models are available with front mounted side brooms (single
and dual) and right side disc scrub.
Parts and Service
Repair should be performed by an Authorized Nilfi sk-Advance Service Center that employs factory-trained service personnel and maintains an
inventory of Nilfi sk-Advance original replacement parts and accessories.
Nameplate
See Figure 1. The Model Number and Serial Number of the machine are shown on the nameplate (A) located on the steering column support, and
on a second nameplate (B) beneath the fl oor plate attached to steering spindle support.
www.advance-us.com for ad-
MODEL NUMBER ________________________________________________
SERIAL NUMBER ________________________________________________
This information is required when ordering repair parts for the machine or contacting Nilfi sk-Advance Technical Support.
FIGURE 1
FORM NO. 56043124 - Condor XL™ - 5
JACKING THE MACHINE
CAUTION!
Never work under a machine without safety stands or blocks to support the machine.
When jacking the machine, do so at designated locations. See Tie Down/Jacking Locations (C) in Figure 2.
TRANSPORTING THE MACHINE
CAUTION!
Before transporting the machine on an open truck or trailer, make sure that:
All access doors are latched securely.
The machine is tied down securely. See Tie Down/Jacking Locations (C) in Figure 2.
The machine Parking Brake (28) is set.
TOWING OR PUSHING A DISABLED MACHINE
CAUTION!
The machine’s drive propelling pump is manufactured with an adjustable tow valve. This valve prevents damage to the hydraulic
system when the machine is being towed/pushed short distances without the use of the engine.
See Figure 3. The tow valve is controlled by the Tow Valve Lever (34) which is accessed by opening and propping up the Engine Cover (3). Pull
the Tow Valve Lever out to disengage the hydrostatic lock between the motor and pump.
The hydrostatic pump can be damaged if the machine is towed with the valve in the normal working position (Tow Valve Lever pushed IN). Note: If
the tow valve is left in free-wheeling position (Tow Valve Lever pulled OUT) the hydrostatic pump can’t drive the machine FWD or REV. No damage
will result, just reset the valve to the normal working position by pushing the lever IN. Tow or push the machine no faster than a normal walking pace
(2-3 miles per hour) and for short distances only. If the machine is to be moved long distances, the front drive wheel needs to be raised off the fl oor
and placed on a suitable transport dolly.
FIGURE 2
6 - FORM NO. 56043124 - Condor XL
™
FIGURE 3
OTHER MANUALS AVAILABLE
The manuals listed below can be found via Nilfi sk-Advance’s two electronic supported databases. They are:
Nilfi sk-Advance website (www.advance.us.com) and EzParts service/parts CD-ROM.
Parts List - Form Number .................................... 56042484 (all systems w/optional kits and accessories)
Instructions for Use - For m Number .................. 56041705 (English, Spanish)
Engine Manuals
PSI Tier II 1.6L PFI Certifi ed Engine Service Manual G/LP ......................................................... PSI1P6LPFI-A
Kubota V1505TE Diesel Engine Operator Manual
(English, French, German, Italian, Spanish) ................................................................................ 16622-8916-3
Kubota V1505TE Diesel Engine Service Manual (English, French, German) ............................. 97897-01640
Kubota V1505TE Diesel Engine Service Manual (English) ......................................................... 97897-02432
FORM NO. 56043124 - Condor XL™ - 7
DIAGNOSTIC AND SERVICE TOOLS
In addition to a full set of metric and standard tools, the following items are required in order to successfully and quickly perform troubleshooting and
repair of Nilfi sk-Advance Industrial fl oor cleaning equipment.
Laptop computer loaded with current version of EzParts, Adobe Reader and (preferably cellular) internet access
Digital voltmeter (DVM) with DC current clamp
Hydrometer
Battery load tester for checking 6V and 12V batteries
Automotive fuel pressure test gauge (used on gasoline engines)
Static control wrist strap
Set of torque wrenches
Hard (printed) copies of service manuals for regularly serviced machines (available at
sites)
These tools are also available from Nilfi sk-Advance, Inc.:
56407502 Actuator power cord adapter
56205281 Vacuum water lift gauge
www.advance-us.com and other Nilfi sk-Advance web-
56109084 PSI engine service kit (see photo)
8 - FORM NO. 56043124 - Condor XL
™
56504450 PSI LP test kit (see photo)
56305647 PSI diagnostic communication
cable and software (see photo)
PSI diagnostics cable, 4-pin – 8-pin
(Gen1 old style) (see photo)
56504516 Hydraulic test gauge w/con-
nector 3000 psi range (see photo)
FORM NO. 56043124 - Condor XL™ - 9
TECHNICAL SPECIFICATIONS
General Machine Dimensions and Capacities
Length 100 in (254 cm)
Height 58 in (147 cm)
Height (with overhead guard) 84 in (213 cm)
Width/frame (roller to roller) 56 in (142 cm)
Width (with rear squeegee) 57 in (144.7 cm)
Width (with right side scrub brush) 66 in (167.6 cm)
Cleaning path width (main brush only) 48 in (121.9 cm) deck size all models
Cleaning path width (with right side scrub brush ) 60 in (152.4 cm)
Cleaning path width (dual sweep) 62 in (157.4 cm)
Cleaning path width (left sweep/right scrub) 67 in (170 cm)
Main brush diameter and length 11 in x 48 in (27.9 cm x 121.9 cm)
Side scrub brush (right) 16 in (40.6 cm)
Side broom sweep 20 in (50.8 cm)
Solution tank capacity (3 in from top) 100 gal. (378L)
Recovery tank (shutoff) 100 gal. (378L)
Scrub brush pressure (in lbs) three settings (1) 150 (2) 250 (3) 400
Main brush RPM 400 RPM @2200 engine RPM
3
Debris hopper volume capacity 1.5 ft
Debris hopper weight capacity 150 lbs (68 Kg)
Weight empty 2975 lbs (1349 Kg)
Weight GVWR 4135 lbs (1875 Kg)
Minimum aisle turn 119 in (302 cm)
Transport ground clearance 3 inches (7.62 cm) when in transport
Operator sound level @ operator ear 82.4 dBA @ 2200 RPM
Vibration level @ steering wheel does not exceed .80 m/s
Certifi cation ETL
(.04 m3)
10 - FORM NO. 56043124 - Condor XL
™
FIGURE 4
FORM NO. 56043124 - Condor XL™ - 11
Fastener Torque Specifi cations
Standard Torque Specifi cations (unless otherwise speci-
fi ed)
Drive Wheel System Torque Specifi cations
See Figure 5
Size Plated Steel Stainless Steel
#10 42 in.-lb. 28 in.-lb.
1/4“ 100 in.-lb. 67 in.-lb.
5/16” 17 ft.-lb. 11 ft.-lb.
3/8” 31 ft.-lb. 20 ft.-lb.
1/2” 75 ft.-lb. 50 ft.-lb.
3/4” 270 ft.-lb. 180 ft.-lb.
M5 61 in.-lb. 36 in.-lb.
M6 9 ft.-lb. 62 in.-lb.
M8 22 ft.-lb. 13 ft.-lb.
M10 44 ft.-lb. 25 ft.-lb.
M12 70 ft.-lb. 40 ft.-lb.
FIGURE 5
Item
No.
1
2 ¾”-16 Hex Jam Nut Torque to 150 ft.-lb.
3 ½”-20 x 1.25 Hex Screw
4 ½”-13 Nyloc Hex Nut Torque to 100 ft.-lb.
5
6 Wheel Studs Torque to 100 ft.-lb.
Description
Steering Castle (Spindle)
Nut
Drive Wheel Motor
Spindle Nut
Torque
Specifi cation
Torque to 40 ft.-lb.,
then loosen to align
cotter pin.
Use Loctite 242,
torque to 90 ft.-lb.
Torque to 375 ft.-lb.
(lubed) or 475 ft.-lb.
(dry), then tighten to
align cross hole.
12 - FORM NO. 56043124 - Condor XL
™
TECHNICAL SPECIFICATIONS
Power System Performance
Engine
4-cylinder 1.6L GM (gasoline and LP)
Engine speeds
4-cylinder 1505 Kubota Diesel
Transport speed forward 8 mph (12.8 kph)
Transport speed reverse 3 mph (4.8 kph)
Grade ability – Cleaning 6° / 10.5% - all models
Grade ability – Transporting 9° / 16% - all models
Hydraulic
Hydraulic reservoir 10 gal. (37.8 L), fl uid type: 10W-30 engine oil
Hydraulic system components See hydraulic manual section
Steering Brakes and Tires
Steering Front wheel, hydraulic cylinder and rotary valve controlled
Brakes (service)
Tire (front 1) drive/steer Size 18 in x 6 in (457 mm x 152 mm) P7 solid
Tire (rear 2) load bearing Size 16 in x 4 in (406 mm x 101 mm) solid
Solution and Chemical System Delivery Rates
Solution system fl ow rates (fi ve settings)
AXP detergent dispensing system
Extended Scrub System
Dust Guard system (side broom dust control )
See the ENGINE SYSTEM/ENGINE SPECIFICATIONS
section
Idle - 1200 RPM
Normal Run - 2200 RPM
High Output Turbo - 2400 RPM
Idle - 1300 RPM
Normal Run - 2200 RPM
High Output Turbo - 2400 RPM
Mechanical drum brakes, one on each rear wheel, cable
actuated
Setting 1 – 1.6 gal/min (6 L/min)
Setting 2 – 1.9 gal/min (7.2 L/min)
Setting 3 – 2.3 gal/min (8.7 L/min)
Setting 4 – 2.7 gal/min (10.2 L/min)
Setting 5 – 3.1 gal/min (11.7L/min)
Refi llable cartridge, Qty (2) 2.5 gal (9.5L)
Available dilution rates: 300:1, 256:1, 200:1, 150:1, 128:1,
100:1, 64:1, 50:1, 32:1, 26:1
Standard nozzle size .015” dia. Flow volume – .033 gal/min
(0.125 L/min) @ 40 psi.
Optional nozzle size .026 Dia. Flow volume – .1 gal/min
(.379 L/min) @ 40 psi.
FORM NO. 56043124 - Condor XL™ - 13
MAINTENANCE
MAINTENANCE SCHEDULE
Keep the machine in top condition by following the maintenance schedule closely. Maintenance intervals given are for average operating
conditions. Machines used in severe environments may require service more often. In general:
• Keep the fuel tank filled (gasoline and diesel). This helps to reduce condensation and moisture entering the fuel system.
• Be aware of the red Warning Indicator Light (62), the yellow Attention Indicator Light (66) and the LCD Display (64) on the operator
panel for icons and fault codes that indicate a critical or non-critical fault condition. Note: Refer to the MAIN CONTROL BOARD
WARNING AND ATTENTION INDICATOR LIGHTS section for a listing and explanation of the LCD display icons and fault codes.
• Reference the engine service manual for recommended engine service intervals and procedures.
Recommended Service Materials
• Engine Oil (5W-30)
• Hydraulic Oil (10W-30)
• Manufacturer-recommended Coolant (antifreeze) 50/50 mix
• Lithium-base Grease
• Loctite
• Never-Seez
Daily Maintenance
Perform “After Use” maintenance steps
Engine
Operator panel Check for a hydraulic filter plugged indicator light (66) on the operator panel display (64)
Hydraulic system
Recovery tank
Squeegee pick up tool Clean the tool, check the blades for damage/wear and deflection
Scrub housing side skirts Check for damage/wear on both the main and right side
Scrub brushes, main and right side scrub Check for debris wrapped around the brushes and for damage/wear
Wet debris hopper Clean the hopper, debris screen and hose
Parking brake and foot pedal brake Check for proper operation of brakes, make adjustments as needed
Maintenance Every 15-20 Hours
Battery
Solution tank filter Inspect and clean the debris filter on the solution filter system
Solution delivery trough Clean the drain holes
AXP detergent system Purge the chemical delivery lines
Scrub deck skid plates Inspect for wear (replace if worn to ǩ inch
Scrub brushes Rotate and flip the main scrub brushes
Dust Guard Clean the dust control system spray nozzles
®
(or equivalent) thread sealant in the appropriate grades
®
(or equivalent) anti-seize compound
Maintenance Item Procedure
“After use” maintenance is normally the responsibility of the machine operator. See “AFTER
USE” maintenance steps in the operator manual.
Check the engine oil level
Check the engine coolant level in the reservoir
Check for engine and coolant leaks
Check the air cleaner service indicator and service the air filter when the indictor is shown red
Check the oil level in the hydraulic oil reservoir (level should be to bottom of screen)
Check for any hydraulic leaks
Check the cover gasket for damage/wear
Check that the drain hose cap is sealed
Drain and clean the inside of the tank, flush with clean water
Maintenance Item Procedure
Check the electrolyte level in the battery
Check the battery cables and connections
14 - FORM NO. 56043124 - Condor XL
™
MAINTENANCE
MAINTENANCE SCHEDULE
Maintenance Every Month (see Figure 6)
Maintenance Item Procedure
Squeegee Caster Wheel Axle and
Pivot (A)
Steering Rack (A)
Angle adjustment knob threads on
the squeegee mount (A)
Squeegee tool end wheels (B)
Fuel Tank Cover Latch (B)
Pump a small amount of grease into each grease fi tting on the machine until grease seeps
out around the bearings.
Apply grease to lubricate
Recovery Tank Latch (B)
AXP Cover Latch (B)
Brake Pedal (parking brake) linkage
(B)
Apply light machine oil to lubricate
Maintenance Every 150 Hours
Maintenance Item Procedure
Engine maintenance
Radiator and oil cooler Inspect and clean the exterior core cooling fi ns
Steering Inspect and apply grease to the spur gear and rack
LP fuel system electronic pressure regulator (EPR) – LP engines only
Change the engine oil and oil fi lter. *Also review the engine manufacturer’s additional maintenance
requirements
Inspect and drain any oil buildup from the LP fuel system EPR
Maintenance Every 400 Hours
Maintenance Item Procedure
Air intake housing and hoses
Hydraulic hoses Inspect for leaks, wear
Battery Check electrolyte level; check terminals for corrosion, loose connections
Fuel Filter
Inspect the complete air intake system for correct routing, kinks, restrictions, sound tight connections, holes and cracks in hoses
Replace fuel fi lter cartridge (located before injector pump). Use Nilfi sk-Advance p/n 56419086
Replace the fuel fi lter at the electronic fuel pump
Maintenance Every 800-1000 Hours
Maintenance Item Procedure
Engine maintenance Change the spark plugs
Hydraulic oil reservoir Change the reservoir oil and fi lter
Radiator Flush and refi ll radiator with 50/50 mix of water and anti freeze
Maintenance Every 2000 Hours
Maintenance Item Procedure
Engine maintenance * Review the engine manufacturer’s additional maintenance requirements
Note: The engine maintenance schedule shown lists the recommended engine service intervals. Refer to the OTHER MANUALS AVAILABLE/Engine Manuals section for list of available engine manufacturers’ service manuals. Refer to these manuals for more complete maintenance and service information and instructions.
FORM NO. 56043124 - Condor XL™ - 15
FIGURE 6
16 - FORM NO. 56043124 - Condor XL
™
LUBRICATION
POINTS
MAINTENANCE
HYDRAULIC OIL
Open and prop the Engine Cover (3) to access the hydraulic oil reservoir. Remove the Fill Cap (44) from the tank and look to the bottom of the fi ller
screen. If the oil level is below the bottom of the fi ller screen, add 10W-30 motor oil until the bo ttom of the fi ller screen is covered. (The oil level
should not be higher than 1/2” (12.7mm) above the bottom of the fi ller screen.) Change and fl ush the oil if major contamination from a mechanical
failure occurs.
ENGINE MAINTENANCE
ENGINE OIL – GASOLINE / PETROL AND LPG
Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the fi rst 35 hours
of operation and every 150 hours after that. Use any SF or SG rated oil meeting API specifi cations and suited to seasonal temperatures. Refer
to the engine manufacturers’ service manuals for oil capacities and additional engine specifi cations. Replace the oil fi lter with every oil change.
TEMPERATURE RANGE OIL WEIGHT
Above 60° F (15° C) SAE 10W-30
Below 60° F (15° C) SAE 5W-30
ENGINE OIL – DIESEL
Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil after the fi rst 35 hours of
operation and every 150 hours after that. Use CF, CF-4 or CG-4 oil meeting API specifi cations and suited temperatures.
*Important: Reference the oil/fuel type note below for further diesel oil recommendations. Refer to the engine manufacturers’ service manuals for
oil capacities and additional engine specifi cations. Replace the oil fi lter with every oil change.
TEMPERATURE RANGE OIL WEIGHT
Above 77 °F (25 °C) SAE 30 or 10W-30
32 °F to 77 °F (0 °C to 25 °C) SAE 20 or 10W-30
Below 32 °F (0 °C) SAE 10W or 10W-30
* Diesel Lubricating Oil Note:
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use with a low-sulfur fuel used in on-road vehicle
engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total
base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.
Recommended lubricating oil when low-sulfur or high-sulfur fuel is employed
Fuel
Lubricating
Oil class
CF
CF-4
CG-4
O : Recommended X : Not recommended
Low sulfur
(0.5 % ≥)
OO
OX
OX
High sulfur Remarks
TBN ≥ 10
SPECIAL LIQUID PROPANE FUEL SYSTEM MAINTENANCE ON THE GM 1.6L ENGINE
Every 150 hours inspect and drain any oil buildup from the LP fuel system electronic pressure regulator (EPR). During the course of normal operation, oils or “heavy ends” may build inside the chambers of the propane regulator. These oils and heavy ends may be a result of poor fuel quality,
contamination of the fuel supply chain, or regional variation in the makeup of the fuel. If the oil buildup is signifi cant it can affect the function of the
fuel control system. Note: Reference the Tier 2 PSI 1.6l PFI certifi ed engine service manual, form # PSI1P6LPFI-A, and follow the procedure to
drain the EPR regulator.
FORM NO. 56043124 - Condor XL™ - 17
MAINTENANCE
ENGINE COOLANT
CAUTION!
Do not remove the radiator cap when the engine is hot.
To check the engine coolant level, open and prop the Engine Cover (3) and observe the coolant level in the Coolant Overfl ow Tank (6). If the level is
low, add a 50/50 mix of water and the recommended type antifreeze. Clean the radiator and oil cooler exteriors by washing with low-pressure water
or using compressed air every 150 hours. Service Note: The oil cooler tips out for easy cleaning.
ENGINE AIR FILTER MAINTENANCE
Check the Engine Air Filter Service Indicator (5) before each use of the machine. Do not service the air fi lter unless the red fl ag is visible in the
service indicator.
CAUTION!
When servicing the engine air fi lter elements, use extreme care to prevent loose dust from entering the engine. Dust can severely
damage the engine.
The engine air fi lter contains a Primary (outer) and a Safety (inner) fi lter element. The Primary Element can be cleaned twice before being replaced.
The Safety Element should be replaced every third time that the Primary Filter Element is replaced. Never attempt to clean the Inner Safety Element.
To clean the Primary Filter Element, unsnap the two clips at the end of the air fi lter and remove the end housing. Pull the primary element out. Clean
the element with compressed air (maximum pressure 100 psi) or wash it with water (maximum pressure 40 psi). DO NOT put the element back into
the canister until it is completely dry.
18 - FORM NO. 56043124 - Condor XL
™
MAINTENANCE
AXP SYSTEM
You will need to purge the system of the previous detergent when switching to a different detergent. SERVICE NOTE: Move machine over fl oor
drain before purging because a small amount of detergent will be dispensed in the process.
To Purge When Changing Chemicals (the scrub system
must be off):
1 Disconnect and remove the detergent cartridge.
2 Turn the key switch (50) on and wait a few seconds for
the start-up sequence to fi nish.
3 Press and hold the detergent switch (61) for approxi-
mately two seconds.
4 Release the switch when the chemical purge icon (E) ap-
pears on the display and the indicator on the detergent
switch (61) starts fl ashing.
Note: Once activated, the purge process takes at least 10
seconds. See the illustration on this page for Detergent
System indicators. Normally one purge cycle is adequate to
purge the system.
To Purge Weekly (the scrub system must be off):
1 Disconnect and remove the detergent cartridge.
2 Install and connect a Cartridge fi lled with clean hot water.
3 Turn the key switch (50) on and wait a few seconds for
the start-up sequence to fi nish.
4 Press and hold the detergent switch (61) for approxi-
mately two seconds.
5 Release the switch when the chemical purge icon (E) ap-
pears on the display and the indicator on the detergent
switch (61) starts fl ashing.
Note: Once activated, the purge process takes at least 10
seconds. See the illustration on this page for Detergent
System indicators. Normally one purge cycle is adequate to
purge the system.
Note: The Detergent Box (C) has Detergent Level Viewing
Slots (D) for referencing the amount of detergent remaining
in the cartridge(s). When the detergent level is nearing the
bottom of this slot, refi ll or replace the cartridge(s).
To Change the Detergent Mix Ratio (the scrub system
must be on):
1 Press and hold the detergent switch (61) for two seconds.
2 Release the switch once the detergent switch light begins fl ashing.
3 While the light is fl ashing, press and release the detergent switch to select the next detergent mixture ratio. Once the desired ratio is selected,
the detergent system will return to normal operation within three seconds.
Note: The detergent mixture (F) will be displayed for approximately 10 seconds each time the scrub mode changes, or each time the detergent
switch is pressed. Once set, the detergent fl ow rate automatically increases and decreases with the solution fl ow rate, but the detergent mix ratio
will remain the same. If an operator would prefer the fl exibility of setting different detergent dilutions ratios for different solution
specifi c programming option can be found in the Appendix.
Note: During scrubbing, the detergent system can be turned off at any time by pressing the Detergent ON/OFF Switch (61) to allow scrubbing with
water only. No detergent is dispensed until the scrub system is activated and the Drive Pedal (29) is pushed forward.
Service Note: Follow the “To Purge Weekly” instructions above if the machine is going to be stored for an extended period of time, or if you plan
to discontinue use of the detergent (AXP) system.
fl ow rates, this
FORM NO. 56043124 - Condor XL™ - 19
Advance Condor XL 48/60/62/67 G/P/D
PM Checklist
Defect Codes
Customer A needs adjustment
B binding
Address C dirty or contaminated
D damaged, bent or torn
City St Zip L leaks
M missing
Model Serial Hours W worn out
Ref
1 Check drive pedal sensor operation (to test depress drive pedal and start the engine, it
should not start.)
2 Engine starting with pedal in neutral (if it will not start check pedal calibration
programming)
3 Engine idle speed, GM/1200 RPM & Kubota/1300 RPM A rough
4 Normal operational speed (run switch setting) 2200 RPM A low power
Turbo high speed (hold 2200 RPM switch setting for 2 sec. to enter ) 2400 RPM
5 Drive pedal linkage (check for FWD/REV drive and any neutral creep) A B
6 Drive system performance (max Fwd 8 mph) Noisy sluggish
7 Brakes (check both service & parking)
8 Steering excessive play
9 Right side scrub brush raise/lower (model option if equipped) B D L
10 Right side scrub brush on/off (must have main scrub turned on) B L
11 Side sweep broom(s) raise/lower (model option if equipped) A B
12 Side broom(s) on/off B L
13 Dust guard (sweep dust control) On/Off (model option if equipped)
14 Scrub system (Raise/Lower and auto scrubbing functions) <----->
15 Main scrub brushes On/Off (will drift) <----->
16 Scrub Brush (pressure settings 1,2 &3) A B
17 Solution control (On/Off and flow volume min/max) C D
18 Test & purge the detergent AXP system (model option if equipped)
19 Squeegee system (raise/lower and auto lift in reverse) <----->
20 Vacuum Performance (Sealed water lift 34" @ 2200 RPM) C L
21 Headlights, gauges and (optional) accessories rotating beacon, backup alarm <----->
22 Tilt steering mechanism and seat adjustment lever <----->
23
Ref
24 Side sweep broom(s) bristles min wear 3 inches A B D W
25 Side broom motor(s) B L
26 Scrub brush motor(s) Also RT scrub brush B L
27 Main scrub brushes, check for wear and rotate (1.75” length) Min wear .875 D W
28 Scrub deck housing & door skirts
29 Solution system pumps and solenoid valves as many as 4 pumps
30 Solution tank, delivery hoses & filter clean filter screen
31 Vacuum impellor motor & hose C L D
32 Recovery tank screen & float clean screen
33 Recovery tank cover gasket
34 Recovery tank drain hose & cap C D L M
35 Squeegee pick-up hose back flush C L
OPERATIONAL INSPECTION ITEMS
VISUAL INSPECTION ITEMS
Comments
OK
A B C
A
A B W
A C L
C L W
OK
C D W
C L W
C L M
D L W
Defect Codes
(circle)
Defect Codes
(circle)
B C
Does
Not
Work
Does
Not
Work
Copyright 2009 Nilfisk-Advance Page 1 of 2 6/29/2009
20 - FORM NO. 56043124 - Condor XL
™
Ref
36 Squeegee tool & blades clean & rotate
37 Squeegee casters, leveler adjustment knob & linkage grease C W
38 Hydraulic lift cylinders (squeegee, RT side & main scrub
39 Battery clean & water C
40 Engine, oil level, hoses & belts C D L
41 Engine air cleaner element (inner & outer) check SVR indicator C L
42 Engine coolant level fill at reservoir C L
43 Radiator & oil cooler core blockage clean
44 Hydraulic oil reservoir level (10W-30 engine oil only) to bottom of screen C L
45 Hydraulic system hoses & fittings L
46 Propulsion (drive) pump dump valve (tow valve) B D
47 Propulsion drive & accessory pump L
48 Propulsion pump hydro back cable & clevis connections A B D
49 Propulsion pump hydraulic filter C L
50 Gasoline/Diesel fuel tank , filter & lines Xx hours
51 LP tank, hoses & fittings L W
52 LP fuel filter SVR life 1500 Hrs C
53 LP fuel regulator, lock off valve & hoses L
54 Diesel glow plug function light hard starting <----->
55 Gasoline & Diesel fuel tank strainer yearly C
56 Brake cable and parking brake pedal A B
57 Circuit breaker panel
58 Front tire (check lug nut torque 100 FT LB, 135Nm)
59 Front drive wheel motor, steer spindle, rack & cylinder grease pinion & rack
60 Front & rear tires tread wear C W
61 Scrub housing debris hopper (tray) clean C
62 Scrub housing recovery hose & pick-up screen back flush/clean C
63 Dust guard spray nozzles & strainers clean C L W
64
65
66
67
68
69
70
71
VISUAL INSPECTION ITEMS (continued)
deck)
Comments
B L
OK
Defect Codes
(circle)
C D W
C D L
C L W
D M W
A
D L W
Does
Not
Work
NOTE: For additional service information see service manual form number 56043124 and
operators manual form number 56041705.
Defect Codes A needs adjustment C dirty or contaminated M missing
B binding D damaged, bent or torn W worn out
L leaks
WORK COMPLETED BY: ACKNOWLEDGED BY:
Service Technician Signature Date Customer Signature Date
Copyright 2009 Nilfisk-Advance Page 2 of 2 6/29/2009
FORM NO. 56043124 - Condor XL™ - 21
KNOW YOUR MACHINE
As you read this manual you will occasionally run across a bold number in parentheses; for example: (2). These numbers refer to items on the next
four pages. Refer to these pages whenever necessary to locate an item mentioned in the text.
1 Operator’s Seat
2 Solution Tank Fill Cover
3 Engine Cover
4 Recovery Tank Cover
5 Engine Air Filter Service Indicator
6 Coolant Overfl ow Tank
7 Engine Air Filter
8 Engine Cover Latch
9 Recovery Tank Drain Hose
10 Recovery Tank Tilt Out Latch
11 Recovery Tank Tilt Out Grip
12 Left Side Skirt Latch
13 Left Side Skirt
14 Fuel Tank (petrol tank shown)
15 Fuel Tank Cover Latch
16 Headlight
17 Fuel Tank Cover
18 Operator Seat Adjustment Lever
19 Steering Wheel
20 Double Scrub Skirt Holder
22 - FORM NO. 56043124 - Condor XL
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KNOW YOUR MACHINE (CONTINUED)
25 Control Panel
26 Circuit Breaker Panel (see Troubleshooting)
27 Steering Wheel Tilt Adjust Lever
28 Brake Pedal / Parking Brake
29 Drive Pedal, Directional/Speed
30 AXP Cartridge Compartment
31 Right Side Skirt
32 Right Side Skirt Latch
33 Hopper
34 Tow Valve Lever
35 Battery
36 Solution Filter
37 Solution Tank Drain Hose
38 Squeegee Assembly
39 Squeegee Height Adjust Knob
40 Squeegee Mount Wrench
41 Squeegee Tilt Adjust Knob
42 Engine Oil Filter
43 Engine Cover Prop Rod
44 Hydraulic Oil Reservoir Filler Cap
45 Oil Cooler Tilt Out Latch
46 Engine Oil Dipstick
47 Right Scrub Skirt Retainer Knobs
48 Right Scrub Skirt Assembly
49 Engine Oil Drain (under radiator)
FORM NO. 56043124 - Condor XL™ - 23
KNOW YOUR MACHINE
CONTROL PANEL
50 Key Switch
51 Engine Speed Switch
52 Dust Guard
53 Side Broom/Scrub ON / OFF Switch
53a Side Broom DOWN adjust Switch
53b Side Broom UP adjust Switch
54 Scrub ON / Scrub Mode Select
55 Scrub OFF
56 Solution Switch
56a Solution Flow Decrease Switch
56b Solution Flow Increase Switch
57 Vacuum Switch
58 Wand Switch (optional)
59 Horn Switch
60 Extended Scrub Switch (optional)
61 Detergent System (AXP models only)
62 Warning Indicator Light (RED) (see page 25)
63 Left Turn Signal (optional)
64 Display
64a Scrub Pressure Indicator
64b Hour Meter
64c AXP Indicator (optional)
64d Fuel Gauge
64e Solution Flow Indicator
64f Extended Scrub Indicator (optional)
65 Right Turn Signal (optional)
66 Attention Indicator Light (YELLOW) (see page 26)
67 Emergency Flashers (optional)
68 Headlights
(scrub 1) (scrub 2) (scrub 3)
press 1 time press 2 times press 3 times
Flow Flow Flow
Rate 1 Rate 2 Rate 3
(scrub 1) (scrub 2) (scrub 3)
press 1 time press 2 times press 3 times
24 - FORM NO. 56043124 - Condor XL
™
MAIN CONTROL BOARD WARNING AND ATTENTION INDICATOR LIGHTS
The main control board uses a red warning indicator light (62) and a yellow warning indicator light (66) and special dash panel icons to communicate
specifi c monitored operational (modes) activities to the machine operator. When an operational activity or electrical circuit operational problem is
sensed, the red warning and/or yellow attention lights and appropriate icon are displayed. See short explanation for each icon for the two light
groups below.
Red Warning Indicator Light (62)
62A - Parking brake icon;
Displayed icon shows the operator that the parking brake is set. Operator
needs to release the brake pedal, then the icon and light will disappear.
62B - Diesel oil pressure icon;
Active when low engine oil pressure in the diesel engine is sensed.
Check for possible causes for low oil pressure such as engine crankcase
level is low, improper oil viscosity, fault in oil pressure switch S28, excessive engine wear or defective internal oil pump (relief valve). Note: This
icon display is for the Kubota diesel engine only. The GM 1.6L has a
low oil pressure monitor that is activated through the 62C engine service
display icon.
62C - Engine service icon;
Sets when the GM 1.6L engines ECM (electronic control module) activates an engine fault code. See the ENGINE SYSTEM/ENGINE DIAGNOSTICS section for more detailed diagnostic help.
62a
62b
62c
62D - Battery low icon;
Indicates low battery voltage. Check alternator output, test the battery,
clean and tighten cables.
62E - Controller critical fault icon;
The main control board has sensed a specifi c system component
failure(s) and displays a two-digit number with a wrench icon. See the
controller fault (error) code description table for troubleshooting actions.
Note: Some critical faults will prevent the operation of certain machine
functions.
62F - Hydraulic temperature icon;
Icon sets when the hydraulic oil temperature exceeds an average operating temp greater than 220 degrees F for longer than 15 seconds. Possible causes include low oil level in reservoir, debris blocking airfl ow at the
oil cooler, hydraulic component overloads.
62G Low fuel icon;
Icon sets when the fuel sensors read low fuel levels from the liquid fuel
tank (gasoline /diesel) or low pressure from the LP storage cylinder. Refi ll
the gasoline/diesel tank 10 gal capacity. Replace the 33 lbs liquid capacity LP cylinder.
62H Engine coolant temperature icon;
High coolant temperature sensed causes and engine fault. Check for low
coolant level in radiator, debris blocking airfl ow through the radiator, fan
damage, loose fan belt, leaks, bad engine water pump, engine overload
at high ambient temperature.
62d
62e
62f
62g
62h
FORM NO. 56043124 - Condor XL™ - 25
Yellow Attention Indicator Light (66)
66A Solution low icon;
Comes on when the solution level in the tank is low (xx gallons remaining). Fill above the xx gallon level to clear the light and display.
66B Hydraulic fi lter plugged;
Comes on to indicate that the fi lter needs to be replaced (serviced). Note
the oil temperature must be above 100 degrees F for a plugged fi lter to
activate the icon (this prevents a false indication with cold oil start-ups).
66C Controller non critical fault icon;
The main control board has sensed specifi c system component failure(s)
and displays a two-digit number and the wrench symbol. See the controller fault (error) codes description table for troubleshooting actions.
Note: When non-critical faults exist, hour meter will be displayed in rotation with faults.
66D Diesel start glow plug icon;
Comes onto indicates that the key switch is in the run position and the
glow plugs are activated (heating up) for their timed 10 seconds. The
engine can be cranked to start when the yellow attention light and display
icon go out.
66a
66b
66c
66d
300:1
66E Recovery tank full icon;
The tank fl oat has sensed a high water level. The operator needs to
empty the waste water from the tank. If tank is empty and icon is displayed, service (clean) the tank fl oat (could be stuck). Also check the
fl oat circuit wiring for an open.
66e
EXAMPLES:
The main controller board shows the engine service 62C icon with a two-digit
fault code (38) and wrench symbol. This is a critical engine fault code that indicates the main control board received a run-inhibit signal from the ECM (gasoline
and LP) or governor (diesel) that will shut down the engine.
The main controller board shows the non-critical controller fault code 66C icon
with a two-digit code (08) and wrench symbol. This is a non-critical fault code
that indicates the right side scrub solution solenoid valve is over its current limit.
The right side scrub system will shut off but the rest of the machine systems will
continue to operate.
62
66
300:1
26 - FORM NO. 56043124 - Condor XL
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ELECTRICAL SYSTEM
pg y ( )
FAULT CODE SYSTEM DIAGNOSTICS
The following table describes the systems that are disabled for each fault code. This is included to assist the technician in understanding the machine response to a specifi c fault code status.
Note: “X” means the corresponding machine system is disabled (turned off).
Recovery
Display
Code
System
System
Scrub
Solution
System
Chemical
System
Side Scrub
System
Side Sweep
System
Side Mist
System
Recycle
System
Fault Description
00 Solution pump(s) M4 and M6 over current x x x
01 Scrub brush pressure valve solenoids over current
x x x
(L5andL7)
02 Main power relay K1 over current x x x x x x x x
03 Wash hose pump M8 over current
04 Dust guard mist pump M5 over current x
05 No speed input 2200 RPM @ ECM
06 No speed input 2400 RPM @ ECM
07 Main solution solenoid valve L10 over current x x
08 RT side scrub solution solenoid L11 over current x
09 Vacuum fan solenoid L1 over current x x x x
10 Not used
11 Squeegee UP solenoid L3 over current x x x x
12 Squeegee DN solenoid L2 over current x x x x
13 Scrub motor solenoid L4 over current x x x
14 Glow plug relay K4 coil over current
15 Scrub cylinder lock solenoid L6 over current x x x
16 RT side scrub/sweep motor solenoid L8 over
x x
current
17 Back Up alarm over current
18 RT side scrub lift cylinder solenoid L9 over current x
19 Horn over current
20 Left turn signal lamp over current
21 Right turn signal lamp over current
22 Head and tail lamp over current
23 Left stop lamp over current
24 Right stop lamp over current
25 20A circuit breaker CB1 over current
26 20A circuit breaker CB2over current
27 15A circuit breaker CB3 over current
28 20A circuit breaker CB4 over current
29 10A circuit breaker CB5 over current
30 Side sweep lift M7 actuator over current x
31 #1 Chemical pump M10 over current (AXP) x
32 #2 Chemical pump M11 over current (AXP) x
33 Engine hot fault (diesel) x x x x x x x x
34 Hydraulic oil temperature fault
35 Low voltage fault (battery)
36 Service engine fault GM (non critical)
37 Low oil pressure (diesel engine) x x x x x x x x
38 Engine fault (critical) x x x x x x x x
39 Hydraulic filter fault (plugged)
FORM NO. 56043124 - Condor XL™ - 27
ELECTRICAL SYSTEM
MAIN CONTROL BOARD FAULT CODES
Fault codes are organized by machine systems (functions). The RED warning light (62) or the Yellow attention light (66) will display on the operators’
control dash panel showing a two-digit number and wrench icon. Listed below is a description and brief comment for each fault code.
Note: C = Critical NC = Non-Critical
Recovery System
Code# Fault Description by System Family Troubleshooting Actions and Comments
09 C Vacuum fan solenoid over current Check L1 solenoid coil wiring for problems (+ GRN/BRN and - BRN/YEL).
Check coil resistance; less than 6 ohms - replace. Also see vacuum fan
on and squeegee down electrical ladder detail.
11 C Squeegee UP solenoid over current Check L3 solenoid coil wiring for problems (+ GRN/BRN and - BRN/
GRN). Check coil resistance; less than 6 ohms - replace. Also see vacuum fan off and squeegee up electrical ladder detail.
12 C Squeegee DN solenoid over current Check L2 solenoid coil wiring for problems (+ GRN/BRN and - RED/
GRA). Check coil resistance; less than 6 ohms - replace. Also see vacuum fan on and squeegee down electrical ladder detail.
Scrub System
Code# Fault Description by System Family Troubleshooting Actions and Comments
13 C Scrub brush motor solenoid over current Check L4 solenoid coil wiring for problems (+ ORN and - ORN/BLU).
Check coil resistance; less than 6 ohms - replace. Also see main scrub
on and side sweep/RT scrub electrical ladder detail.
15 C Scrub cylinder lock solenoid over current Check L6 solenoid coil wiring for problems (+ ORN and - YEL/BLU).
Check coil resistance; less than 6 ohms - replace. Also see main scrub
on and RT scrub brushes deck pressure electrical ladder detail.
01 C Scrub brush pressure valve solenoids over current Check L5 down and L7 up pressure valve solenoid coils (on same fault
line) for wiring problems, L5 wire colors (+ ORN and - WHT/VIO) and L7
( + ORN and ORN/RED). Check coil resistance; less than 1.8 ohms replace. Also see main scrub on and right scrub brushes deck pressure
electrical ladder detail and further specs.
Solution System
Code# Fault Description by System Family Troubleshooting Actions and Comments
00 C Solution pump(s) over current Check M4 main solution pump and M6 optional recycle pump wiring for
problems (on same fault line), M4 wire colors (+GRN/BRN and - GRN/
BLU) and M6 (+GRN/BRN and - GRA/ORN). Check pump motors for
short circuits replace as needed.
07 NC Main solution solenoid valve over current Check L10 solenoid coil wiring for problems (+ ORN and - YEL/GRN).
Check coil resistance; less than 6 ohms - replace. Also see main scrub
and RT side scrub solution valves and pump electrical ladder detail.
Chemical System AXP
Code# Fault Description by System Family Troubleshooting Actions and Comments
31 NC Chemical pump #1 over current Check #1 chemical pump M10 and #2 chemical pump M11 wiring for
problems, #1 pump wire colors (+RED/WHT and - RED/BLU), #2 (+ BLK/
YEL and - BLK/RED). Check pump motors for short circuit replace as
needed.
32 NC Chemical pump #2 over current See pump #1
28 - FORM NO. 56043124 - Condor XL
™
ELECTRICAL SYSTEM
MAIN CONTROL BOARD FAULT CODES
Side Scrub System
Code# Fault Description by System Family Troubleshooting Actions and Comments
18 NC RT Side scrub lift solenoid over current Check L9 solenoid coil wiring for problems (+ ORN and - GRN/VIO).
Check coil resistance; less than 6 ohms - replace. Also see main scrub
and right side scrub lift electrical ladder detail.
16 NC RT side scrub/sweep motor solenoid valve over
current
08 NC RT side scrub solution solenoid valve over current Check L11 solenoid coil wiring for problems (+ ORN and - BLU/YEL).
Side Sweep System
Code# Fault Description by System Family Troubleshooting Actions and Comments
30 Side sweep lift actuator over current Three wires supply power to the M7 side broom lift actuator motor check
16 NC RT side scrub/sweep motor solenoid valve over
current
Side Mist System
Check L8 solenoid coil wiring for problems (+ ORN and - BLK/WHT).
Check coil resistance; less than 6 ohms - replace. Also see main scrub
on and side sweep/right scrub electrical ladder detail.
Check coil resistance; less than 10 ohms - replace. Also see main scrub
and right side scrub solution valves and pump electrical ladder detail.
wiring for problems. Wire colors J3-4 BLU/RED (+) DN otherwise open,
J3-5 WHT/RED (-) UP otherwise open, J3-7 GRA/VIO common wire +
UP and - DN. Test current draw full load 20A +/-2A max. Check for frozen
or binding lift linkage, repair/replace as needed.
Check L8 solenoid coil wiring for problems (+ ORN and - BLK/WHT).
Check coil resistance; less than 6 ohms - replace. Also see main scrub
on and side sweep/right scrub electrical ladder detail.
Code# Fault Description by System Family Troubleshooting Actions and Comments
04 NC Side sweep mist pump over current Check Pump motor M5 wiring for problems (+ BLU and - YEL/BLK). Test
current draw 3.9A full load max. Note: 24V pump operating @ 12V
Recycle System
Code# Fault Description by System Family Troubleshooting Actions and Comments
00 C Extend scrub pump over current Check Pump motor M6 wiring for problems (+ GRN/BLU and - GRA/
ORN). Same fault line used for main solution pump M4 and M6.
Engine Speed System
Code# Fault Description by System Family Troubleshooting Actions and Comments
05 C 2200 RPM no input @ ECM Check for 12V (+) from controller wire J2-29 (GRA/ORN) to battery
ground (-) with the engine speed switch 51 active. Should read 12V if 0V
T.S the throttle wire, then if still OV substitute a good know controller and
dashboard panel. If 12V and no 2200 RPM throttle response test engine
controller out put to specifi c throttle control G/LP/D. See engine wiring
diagram for additional help.
06 NC 2400 RPM no input @ECM Check for 12V (+) from controller wire J2-30 (GRA/BLU) to battery
ground (-) with the engine speed switch 51 active. Should read 12V if 0V
T.S the throttle wire, then if still OV substitute a good know controller and
dashboard panel. If 12V and no 2400 RPM throttle response test engine
controller out put to specifi c throttle control G/LP/D.
10 Not used
FORM NO. 56043124 - Condor XL™ - 29
ELECTRICAL SYSTEM
MAIN CONTROL BOARD FAULT CODES
Faults Non-Board
Code# Fault Description by System Family Troubleshooting Actions and Comments
03 NC Wash hose pump over current Check Pump motor M8 wiring for problems (+ BLU and - BLU/RED).
Check pump motor for short circuit (spec XA) replace as needed. Test
current draw 12.5A full load max @12V.
19 NC Horn over current Check H4 horn wiring for problems (+ ORN/GRN and - WHT/YEL). Check
horn for short circuit (spec 4A@12V) replace as needed.
17 NC Back Up Alarm over current Check optional back up alarm wiring for problems (+ ORN/GRN and
- BLU/BLK). Check horn for short circuit (spec .25A at 12V, electronic
alarm) replace as needed.
02 C Main power relay K1 coil over current Check K1 relay coil wiring for problems (+ ORN/GRN and - BLU/GRN).
Check coil resistance; less than 36 ohms - replace. Also see main power
distribution electrical ladder detail. (Spec .29A@12V) replace as needed.
25 C 20A Circuit breaker CB1 over current Control board has sensed open circuit fault for CB1 power for head/tail
and turn signal lamps. Check for GRA/RED wire shorted to ground.
26 C 20A Circuit breaker CB2 over current Control board has sensed open circuit fault for CB2 power for mist pump
(M5) and (M8) wash hose pump. Check for Blue wire shorted to ground.
27 C 15A Circuit breaker CB3 over current Control board has sensed open circuit fault for CB3 power for side broom
actuator motor (M7). Check for Violet wire shorted to ground.
28 C 20A Circuit breaker CB4 over current Control board has sensed open circuit fault for CB4 power for hydrau-
lic solenoid manifold coils (L4-L 11). Check for Orange wire shorted to
ground.
29 C 10A Circuit breaker CB5 over current Control board has sensed open circuit fault for CB5 power for hydraulic
solenoid manifold coils (L1, L2 and L3) also PumpsM4 and M6. Check for
GRN/BRN wire shorted to ground.
20 NC Left turn signal lamp over current Check left turn signal wiring for problems (+ YEL and - BLK). Check lamp
for short (see the I/O table for circuit spec).
21 NC Right turn signal lamp over current Check right turn signal wiring for problems (+ GRN and - BLK). Check
lamp for short (see the I/O table for circuit spec).
22 NC Head and tail lamp over current Check head and tail lamp wiring for problems (+ BRN, YEL/RED, ORN/
BLU and - BLK). Check lamps for short (see the I/O table for circuit spec).
23 NC Left stop lamp over current Check left stop lamp wiring for problems (+ ORN/BRN and - BLK). Check
lamps for short (see the I/O table for circuit spec).
24 NC Right stop lamp over current Same as left stop lamp just different wire color (+ YEL/RED and - BLK).
14 NC Glow plug relay K4 coil over current Check K4 relay coil wiring for problems (+ ORN/GRN and - WHT/ORN).
Check coil resistance; less than 36 ohms - replace. Also see diesel glow
plug starting circuit electrical ladder detail.
30 - FORM NO. 56043124 - Condor XL
™
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