Nilfisk-Advance 56110004, 56110005, 56110006, 56110007, 56110008 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

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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

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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

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 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

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

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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.

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.

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

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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

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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

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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-4

CG-4

O : Recommended X : Not recommended

Low sulfur

(0.5 % ≥)

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.

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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

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 <----->

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

A B C

A B W

A C L

C L W

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

20 - FORM NO. 56043124 - Condor XL

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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

VISUAL INSPECTION ITEMS (continued)

deck)

Comments

B L

Defect Codes

(circle)

C D W

C D L

C L W

D M W

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

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

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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.

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

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

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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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ELECTRICAL SYSTEM MAIN CONTROL BOARD FAULT CODES

Other Faults Non-board

Code# Fault Description by System Family Troubleshooting Actions and Comments

35 C Low voltage fault (battery) One of the red display panel warning indicator lights see the explanation

for icon 62D

37 C Low oil pressure fault Diesel only - causes engine fault to set. One of the red display panel

warning indicator lights see the explanation for icon 62I

33 C Engine hot fault Coolant temperature high –causes engine fault, sets on diesel machine

only.

38 C Engine fault Occurs if engine temperature too high (diesel), oil pressure low (diesel),

or engine run has change to ignition inhibit and key is on (gas and propane). Note: Engines will shut down. See engine section for the list of engine codes and process for reading (extracting) codes.

36 NC Service engine fault Gasoline, LP engine (GM 1.6) only, sets when ECM activates MIL output-

could be for mf++-any different reasons. See engine section for the list of engine codes and process for reading (extracting) codes.

34 C Hydraulic temperature fault Sets when hydraulic oil temperature exceeds 220 F for 15 seconds.

39 NC Hydraulic ﬁ lter fault Sets to warn operator that oil ﬁ lter is plugged and needs to be replaced.

Note: Only activates when oil temperature is above 100 degrees F (this prevents false signal upon cold engine start up).

FORM NO. 56043124 - Condor XL™ - 31

ELECTRICAL SYSTEM ENGINE ELECTRICAL COMPONENT LOCATIONS – GM 1.6 GASOLINE

O2 Sensor (in exhaust manifold)

(pre CATCON)

TMAP Sensor ETC (Electronic Throttle Control)

ECT (Engine Coolant Temperature)

Sensor

Fuel Pump and Manifold

(mounted on fuel tank)

32 - FORM NO. 56043124 - Condor XL

™

Fuel Injectors and Connectors

ECM and Oil Pressure Switch Crank Position Sensor

ELECTRICAL SYSTEM ENGINE ELECTRICAL COMPONENT LOCATIONS – GM 1.6 LPG

Fuel Temperature Sensor

(mounted on EPR – LPG only)

TMAP Sensor

ETC (Electronic Throttle Control)

O2 Sensor (in exhaust manifold)

ECT (Engine Coolant

Temperature) Sensor

EPR and Fuel Lockout and Filter ECM and Oil Pressure Switch Crank Position Sensor

FORM NO. 56043124 - Condor XL™ - 33

ELECTRICAL SYSTEM ENGINE ELECTRICAL COMPONENT LOCATIONS – KUBOTA DIESEL

Oil Pressure Sensor

(above oil ﬁ lter)

Coolant Temperature Sensor

(above alternator)

34 - FORM NO. 56043124 - Condor XL

™

Governor Engine Speed

Magnetic Pickup

Woodward Governor and

Throttle Actuator

ELECTRICAL SYSTEM ELECTRICAL COMPONENT LOCATIONS

Extended Scrub Pump Extended Scrub Float Switch

Recovery Tank Full Switch

Drive Pedal Sensor

FORM NO. 56043124 - Condor XL™ - 35

ELECTRICAL SYSTEM ELECTRICAL COMPONENT LOCATIONS

Mist Pump (if so equipped) Solution Pump (top) and

36 - FORM NO. 56043124 - Condor XL

™

Wash Pump (bottom)

AXP Pumps

(behind cover panel)

ELECTRICAL SYSTEM CONTROL BOARD ASSEMBLY

Board Relay

Start/Run

Inhibit

Power Relay

FORM NO. 56043124 - Condor XL™ - 37

TABLE 1 – CONTROL BOARD CONNECTORS

Note: Also refer to the I/O Tables in the Appendix

Condor XL J1 Main Control Board Connectors

Pin# Wire# Color Type Goes to

J1-1 18-1 GRA input Engine control module output (run signal)

J1-2 20-1 BLK/YEL -CANbus User interface panel (membrane switches)

J1-3 20-1 ORN/BLK +CANbus User interface panel (membrane switches)

J1-4 Open

J1-5 Open

J1-6 Open

J1-7 18-1 GRA/BLK input Fuel level sensor for either petrol/diesel,/LP

J1-8 Open

J1-9 Open

J1-10 18-1 BRN/WHT output Foot pedal position potentiometer (sensor high)

J1-11 18-1 YEL/GRA output Foot pedal position potentiometer (sensor low)

J1-12 18-1 ORN/GRN input Key switch ignition switch (run)

J1-13 Open

J1-14 Open

J1-15 Open

J1-16 18-1 RED/BLK input S29 Horn switch

J1-17 Open

J1-18 16-1 BLK ground Chassis ground X-49

J1-19 18-1 GRN/ORN input Sender hydraulic oil temperature

J1-20 18-1 VIO/WHT input S6 Brake switch

J1-21 18-1 VIO/YEL input S3 Solution empty switch

J1-22 18-1 WHT/BRN output Relay PCB (start inhibit pin #J7-3)

J1-23 Open

J1-24 18-2 VIO/BRN input Ignition switch start position

J1-25 18-1 GRN/YEL input Engine control module (MIL output signal)

J1-26 Open

J1-27 18-1 GRA/YEL input S2 Recovery tank full switch

J1-28 Open

J1-29 Open

J1-30 18-1 VIO/BLU input Engine control module (engine coolant temperature out-

put)

J1-31 18-1 ORN/GRA input Foot pedal position potentiometer (sensor wiper)

J1-32 18-1 RED/YEL input S4 Hydraulic ﬁ lter switch

J1-33 18-1 BRN/BLU input S7 Extend scrub level switch

J1-34 18-1 YEL/WHT output Relay PCB (ignition inhibit pin #J7-7)

J1-35 Open

38 - FORM NO. 56043124 - Condor XL

™

Condor XL J2 Main Control Board Connectors

Pin# Wire# Color Type Goes to

J2-1 18-1 BLU/GRN - output K1 power relay coil

J2-2 18-1 BLK/WHT - output S8 side sweep scrub solenoid coil

J2-3 18-1 GRN/VIO - output S9 side scrub lift solenoid coil

J2-4 18-1 YEL/BLU - output S6 scrub cylinder lock solenoid coil

J2-5 18-1 RED/GRA - output S2 squeegee down solenoid coil

J2-6 18-1 BRN/GRN - output S3 squeegee up solenoid coil

J2-7 18-1 ORN/BLU - output S4 scrub brush solenoid coil

J2-8 18-1 BRN/YEL - output S1 vacuum fan solenoid coil

J2-9 Open

J2-10 18-1 BLU/YEL - output L11 solenoid valve, right solution

J2-11 18-1 BLU/BLK - output H3 back-up alarm (optional)

J2-12 16-1 ORN + input CB4 circuit breaker 20A

J2-13 18-1 WHT/ORN - output K4 glow plug relay coil

J2-14 Open

J2-15 Open

J2-16 Open

J2-17 16-2 BLK - input X49 control box ground

J2-18 16-3 BLK - input X49 control box ground

J2-19 Open

J2-20 Open

J2-21 Open

J2-22 18-1 YEL/GRN - output L10 solenoid valve, main solution

J2-23 18-3 GRN/BRN + input CB5 circuit breaker 10A

J2-24 18-1 ORN/RED - output S7 scrub pressure proportional solenoid (up)

J2-25 Open

J2-26 18-1 WHT/VIO - output S5 scrub pressure proportional solenoid (down)

J2-27 Open

J2-28 Open

J2-29 18-1 GRA/ORN + output X2 throttle input (12V 2200 RPM)

J2-30 18-1 GRA/BLU + output X2 throttle input (12V 2400 RPM)

J2-31 18-1 YEL + output LP6 left front turn lamp

J2-32 18-1 GRN + output LP5 right front turn lamp

J2-33 18-1 ORN/BRN + output LP4 left rear stop/turn lamp

J2-34 18-1 YEL/RED + output LP3 right rear stop/turn lamp

J2-35 18-2 GRA/ORN + output M6 extended scrub pump

FORM NO. 56043124 - Condor XL™ - 39

Condor XL J3 Main Control Board Connectors

Pin# Wire# Color Type Goes to

J3-1 16-2 GRA/RED + input CB1 Circuit Breaker, 20A

J3-2 16-1 GRN/BLU - output M4 solution pump

J3-3 Open

J3-4 16-1 BLU/BRN output M7 side broom actuator extend (red wire)

J3-5 16-1 WHT/RED output M7 side broom actuator retract (black wire)

J3-6 Open

J3-7 16-1 GRA/VIO M7 side broom actuator common (white wire)

J3-8 16-6 BRN + output LP2 left and right headlights and taillights

J3-9 16-1 GRA/RED + input CB1 Circuit Breaker, 20A

J3-10 Open

J3-11 16-4 BLK - input X49 control box ground

J3-12 16-5 BLK - input X49 control box ground

J3-13 16-6 BLK - input X49 control box ground

J3-14 16-3 BLU + input CB2 Circuit Breaker, 20A

J3-15 16-2 BLU + input CB2 Circuit Breaker, 20A

J3-16 18-1 VIO + input CB3 Circuit Breaker, 15A

J3-17 18-1 WHT/YEL + output horn

J3-18 16-1 YEL/BLK - output M5 mist pump

J3-19 18-1 BLK/RED - output M11 chemical pump 2 (AXP)

J3-20 18-1 BLK/YEL + output M11 chemical pump 2 (AXP)

J3-21 18-1 RED/BLU - output M10 chemical pump 1 (AXP)

J3-22 18-1 RED/WHT + output M10 chemical pump 1 (AXP)

J3-23 16-1 BLU/RED - output M8 wand pump

40 - FORM NO. 56043124 - Condor XL

™

ADJUSTMENTS/REPAIRS SIDE BROOM LIFT ACTUATOR MOTOR ADJUSTMENT

1 See Figure 7. This shows the jumper wiring needed to connect the machine battery to the three-wire connector on the actuator. Note: Reference the bill of materials for building the two jumper wires. Important Service Note: The power cord adapter (p/n 56407502)

normally used on all other two-wire actuator motors should not be used.

2 See Figures 7-A and 7-B. The wiring diagram illustrates the correct battery polarity (+ and -) power inputs to operate the actuator motor for both

extending and retracting the drive nut.

3 See Figure 7-A. Connect the jumper wiring as shown to run the actuator motor in the retracted (IN) mode. 4 Hold the drive nut tube (AE) and press the switch to run the drive nut toward the motor housing (it’s IN limit). 5 Measure the position of the drive nut on the actuator shaft, then compare it to the retracted dimension speciﬁ cation shown in Figure 7. Manually

turn the steel drive nut tube to match the IN position shown.

6 See Figure 7-B. Connect the jumper wiring to run the actuator motor in the extended (OUT) mode. 7 Hold the drive nut tube (AE) and press the switch to run the drive motor to the out position waiting for the motor to stop (reaching its Out limit). 8 Measure the position of the drive nut on the actuator shaft and compare the measurement with the OUT position shown in Figure 7. 9 If the measurement doesn’t match the dimension shown, it will be necessary to remove the large rubber Adjuster Cover (AF). Note: Use a 1/2”

(13mm) socket to turn the outside hex adjuster. Each click of the top adjuster (cam) will change the nut travel 1/16” (1.6mm). To extend the travel of the drive nut, turn the adjuster clockwise. To retract the travel of the nut, turn the adjuster counterclockwise.

10 After each adjustment, hold the drive nut tube, run the actuator IN and OUT and check both dimensions. Note: When checking the directional

travel dimensions remember to change the connections (battery polarity) of the jumper wires.

11 Check that the drive nut limits are set correctly, then reinstall the Adjuster Cover (AF). Service Tip: Leave the correctly-adjusted actuator motor in the out (extended) position when you reinstall the motor.

FIGURE 7

RED

BLK

12 volt

battery

Jumper WireAssembly

Bill of Material

Item Qty Description

1 Wire 16 gauge (red) 60" length 1 Wire 16 gauge (black) 60" length

A 2 Medium size insulated alligator clips (60 series) B 2 Small size insulated alligator clips (30 series) C 1 Normally Open snap switch part # 56385615 D 2 .250 (1/4) insulated female connectors

part # 56244138

RED

BLK

RED

BLK

Retract (IN)

Extend (OUT)

6-A

BLK

RED

WHT

6-B

BLK

RED

WHT

A B C D

6-7/8"

(175mm)

9-9/16"

OUT

(243mm)

FORM NO. 56043124 - Condor XL™ - 41

ADJUSTMENTS/REPAIRS BRAKE TENSION ADJUSTMENT

1 See Figure 8. Remove the Floor Weldment to access the Rod End (A). 2 Remove the Nyloc Nut (B) and remove the Rod End (A) from the Brake

Pedal Assembly.

3 Loosen the Jam Nut (C) and rotate the Rod End (A) in the appropriate

direction to adjust the brake tension.

4 When the brake tension has been adjusted, tighten the Jam Nut (C).

5 Reinstall the Rod End (A) into the Brake Pedal Assembly, then reinstall



and tighten the Nyloc

Nut (B).

6 Check the brake tension as follows:

a. Jack up the rear of the machine to get the rear wheels off of the

ground.

CAUTION!

Make sure to follow the instructions in the JACKING THE MACHINE

7 When the brake tension is adjusted correctly, lower the machine and reinstall the Floor Weldment.

section. Jack the machine at the designated locations only.

b. Manually rotate the rear wheels to check the brake tension. The

tension is set correctly when the wheels cannot be rotated with the parking brake applied to three “clicks”, but will rotate freely when the parking brake is off.

c. Readjust the brake tension as necessary following steps 2 through 5

above.

FIGURE 8

FOOT PEDAL/HYDROBACK SYSTEM OVERVIEW

See Figure 9. A Hydroback centering unit (D), installed between the Push/Pull Control Cable (A) and the drive Piston Pump Lever Weldment (E), returns the pedal and Piston Pump (G) to the neutral position when the pedal is released. A rotary potentiometer, called the Rotary Sensor (F), is attached to the Piston Pump, and the resistance through the Rotary Sensor will vary with the position of the Piston Pump Lever Weldment. When the engine is started, the Control Board (Driver Box) checks the Rotary Sensor resistance to conﬁ rm that the drive pedal and Piston Pump are in the neutral position before the engine can be started. This is to prevent the machine from moving forward or backward when the engine is ﬁ rst started, or unless the drive pedal is depressed.

The resistance that the Control Board must see through the Rotary Sensor in order to allow the engine to be started is deﬁ ned as a nominal resis- tance, plus or minus a percentage of the nominal resistance. This resistance range is referred to as the neutral “deadband.” If the Control Board fails to see the Rotary Sensor resistance in the deadband, it will send a “start-inhibit” signal to the Relay PCB which will prevent the engine from starting.

Once the engine is started with the machine in neutral, the Control Board will enable the solution, scrub and vacuum systems once it sees that the resistance through the Rotary Sensor is out of the deadband due to the drive pedal being depressed.

Dependable starting and responsive operation depends on the drive pedal and Piston Pump returning to a repeatable neutral position when the pedal is released.

42 - FORM NO. 56043124 - Condor XL

™

ADJUSTMENTS/REPAIRS FOOT PEDAL/HYDROBACK NEUTRAL ADJUSTMENT

Note: When servicing the hydrostatic drive system, always check for any machine creeping (movement) when the machine is in neutral with the

engine running. The machine must not move either forward or reverse after the drive pedal is released. If machine creeps in neutral, or if you replace the Hydroback, pedal cable or Rotary Sensor, you will need to set the hydrostatic drive neutral position, then recalibrate the neutral deadband setting.

1 Empty and remove the recovery tank to access the Hydroback Adjuster Plate (I).

CAUTION!

Make sure to follow the instructions in the JACKING THE MACHINE section. Jack the machine at the designated locations only.

2 Block the rear wheels. 3 Jack up the front of the machine until the front drive wheel is off the ﬂ oor. 4 Place supports at the front corners of the machine. 5 Start the engine and observe the direction of the drive wheel rotation. 6 Loosen the two 5/16”-18 hex head screws (C) holding the Adjuster Plate to the chassis. 7 See Figure 9. Loosen the jam nut and turn the Adjustment Screw (B) clockwise or counterclockwise to move the Adjuster Plate and Hydroback

unit (D) as required to stop any wheel movement. The Piston Pump Lever Weldment (E) on the Piston Pump (G) is now in the neutral position. 8 Tighten the two 5/16”-18 hex head screws to secure the Adjuster Plate to the chassis. 9 Tighten the jam nut on the Adjustment Screw. 10 Test the neutral adjustment by activating the drive pedal in both forward and reverse, then letting the drive pedal return to the neutral position.

Readjust the Adjuster Plate neutral position if the neutral setting is not repeatable. If you can’t get a repeatable neutral position, replace the

Hydroback unit and/or Push/Pull Control Cable (A) as necessary. 11 Check the maximum forward and reverse wheel speeds and adjust the pedal stops as necessary. Refer to the GENERAL HYDRAULIC SPECI-

FICATIONS TABLE in the HYDRAULIC SYSTEM section for nominal wheel speeds. 12 Turn the engine off, then see if it will restart. If engine will not start, the Rotary Sensor (F) is probably out of its neutral (deadband) range and

needs to be recalibrated. See the FOOT PEDAL NEUTRAL/DEADBAND ADJUSTMENT section for programming instructions.

13 Lower the machine and reinstall the recovery tank.

FIGURE 9

FORM NO. 56043124 - Condor XL™ - 43

ADJUSTMENTS/REPAIRS PUSH/PULL CONTROL CABLE REPLACEMENT

1 Lower the side broom(s). 2 Empty and remove the recovery tank.

CAUTION!

Make sure to follow the instructions in the JACKING THE MACHINE section. Jack the machine at the designated locations only.

3 Block the rear wheels. 4 Jack up the front of the machine. This will make it easier to access the Push/Pull Control Cable (A) and mounting hardware by the foot pedal

assembly.

5 From underneath the machine, note the position and spacing of the two jam nuts and star washer holding the old Push/Pull Control Cable in

the mounting fork by the drive pedal. Loosen the jam nuts and remove the Cable from the mounting fork.

6 Disconnect the rod end on the old Cable from the foot pedal assembly. 7 Loosen the locknut, then remove the rod end and locknut from the Cable. 8 Remove the two jam nuts and star washer from the old Push/Pull Control Cable. (This will make it easier to remove the old Cable from the

machine.)

9 See Figure 9. Loosen the jam nut holding the old Push/Pull Control Cable and Hydroback in the mounting fork by the Piston Pump (G). 10 Disconnect the Rod End (H) from the Piston Pump Lever Weldment (E). 11 Loosen the locknut, then remove the Rod End and locknut from the old Push/Pull Control Cable. 12 Remove the four jam nuts and two star washers from the new Push/Pull Control Cable. (This will make it easier to pull the new Cable through

the machine.)

Service Note: To thread the new Push/Pull Control Cable from the foot pedal assembly to the Hydroback, we recommend that you SECURELY attach the new Cable to the old Cable, then carefully pull the new Cable through the old Cable routing path in the machine. This will eliminate a lot of disassembly and reassembly work.

13 Once the new Push/Pull Control Cable has been threaded through the machine, disconnect it from the old Cable. 14 Reinstall the two jam nuts and star washer onto the pedal end of the Push/Pull Control Cable. Position the jam nuts and star washer in the

same location as noted in step 5 above. 15 Remove the red plastic thread protector sleeve from the new Push/Pull Control Cable, then install the locknut and rod end onto the new Cable. 16 Reinstall the rod end into the foot pedal assembly. 17 Position the new Push/Pull Control Cable into the mounting fork by the drive pedal. Make sure the star washer is located on the rear side of

the mounting fork, then tighten the two jam nuts. 18 Reinstall one jam nut and a star washer onto the Hydroback end of the new Push/Pull Control Cable. (Only one jam nut is needed to fasten the

Cable and Hydroback to the rear mounting fork.) 19 Remove the red plastic thread protector sleeve from the new Push/Pull Control Cable, then install the Cable into the Hydroback. Note that the

smaller end of the Cable will thread through the rear of the Hydroback, and the larger threads on the outside of the Cable will thread directly

into the front of the Hydroback.

20 Install the locknut and Rod End onto the new Push/Pull Control Cable. 21 Reinstall the Rod End into the Piston Pump Lever Weldment. 22 Position the Push/Pull Control Cable and attached Hydroback into the mounting fork by the Piston Pump. Make sure the star washer is located

on the rear side of the mounting fork and contacts the front of the Hydroback, then tighten the jam nut. 23 After installing a new Push/Pull Control Cable, set the foot pedal/Hydroback neutral position according to the instructions in the FOOT PEDAL/

HYDROBACK NEUTRAL ADJUSTMENT section.

44 - FORM NO. 56043124 - Condor XL

™

ADJUSTMENTS/REPAIRS HYDROBACK REPLACEMENT

1 Empty and remove the recovery tank. 2 See Figure 9. Loosen the jam nut holding the Push/Pull Control Cable (A) and Hydroback (D) in the mounting fork by the Piston Pump (G). 3 Disconnect the Rod End (H) from the Piston Pump Lever Weldment (E). 4 Loosen the locknut and remove the Rod End and locknut from the Push/Pull Control Cable. 5 Remove (unscrew) the old Hydroback from the Push/Pull Control Cable. 6 Install the new Hydroback unit onto the Cable. Note that the smaller end of the Cable will thread through the rear of the Hydroback and the

larger threads on the outside of the Cable will thread directly into the front of the Hydroback.

7 Reinstall the locknut and Rod End onto the Push/Pull Control Cable. 8 Reinstall the Rod End into the Piston Pump Lever Weldment. 9 Position the Push/Pull Control Cable and attached Hydroback into the mounting fork by the Piston Pump. Make sure the star washer is located

on the rear side of the mounting fork and contacts the front of the Hydroback, then tighten the jam nut.

10 After installing a new Hydroback unit, set the foot pedal/Hydroback neutral position according to the instructions in the FOOT PEDAL/HYDRO-

BACK NEUTRAL ADJUSTMENT section.

FOOT PEDAL NEUTRAL DEADBAND ADJUSTMENT

The resistance through the Rotary Sensor (rotary potentiometer) attached to the hydrostatic Piston Pump linkage will vary with the position of the linkage. The Control Board must see the resistance through the Rotary Sensor within a particular range, called the neutral “deadband”, to conﬁ rm the Piston Pump is in neutral before the Board will allow the engine to start.

Once the engine is started, depressing the drive pedal moves the Rotary Sensor out of the deadband range. When the Control Board sees the resistance from the Rotary Sensor out of the deadband range, it activates the various scrub/sweep functions.

Whenever you change or repair the drive pedal linkage components or the hydrostatic unit, or if you replace the Rotary Sensor or Control Board, you will have to recalibrate the neutral deadband position and set the sensitivity.

1 Depress the foot pedal to full reverse position, then allow the pedal to slowly return to its neutral position. Do not move the pedal during the

remainder of this procedure.

2 Press and hold the Engine Speed Switch (51), then turn the ignition Key Switch (50) to the run (on) position. Continue to hold the Engine Speed

Switch until all the display panel lights turn off (approximately three seconds), then release the Switch.

• The ﬁ rst line of the LCD display will read “PEDAL CALIBRATION”.

• The second line of the display will read “Place Pedal in Neutral” with an arrow to the left of the line.

• The third line of the display will read “Neutral Deadband”. 3 Press the green Scrub ON Switch (54).

• The ﬁ rst line of the LCD display will read “Neutral Set”.

• The second line of the display will show the resistance value, in ohms, that the Control Board is reading through the Rotary Sensor. Note

that it’s normal for this value to drift a little.

4 Press the green Scrub ON Switch to set the nominal deadband resistance value. The display will return to the previous menu. 5 Press the Side Broom Down Switch (53a) to move the arrow to the left of the “Neutral Deadband” line. 6 Press the green Scrub ON Switch to display the “Neutral Deadband” range menu. The percentages shown are the limits the resistance from

the Rotary Sensor can vary from the “Neutral Set” resistance and still be in the deadband range and allow the engine to start.

7 Press the Side Broom Up and Down Switches (53) to scroll through the available percentages. Note that 3% is the factory default value. Note: The ideal neutral deadband percentage range is one that allows reliable starting, yet still actuates the scrub functions with minimal pedal

travel. 8 When the arrow is to the left of the desired percentage value:

• Press the green Scrub ON Switch. The display will return to the previous menu and the new percentage value will be saved.

• Press the red Scrub Off Switch to return to the previous menu without changing the percentage value. 9 Turn the ignition key switch to the off position. The new settings will be saved and remain in effect until they are changed again.

FORM NO. 56043124 - Condor XL™ - 45

ADJUSTMENTS/REPAIRS SIDE BRUSH TILT ADJUSTMENT

1 See Figure 10. Disconnect one of the two Rod Ends from its mounting tab. 2 Loosen the Jam Nut. 3 Rotate either Rod End to lengthen or shorten the Rod/Rod End assembly as neces-

sary to get the correct brush angle to the ﬂ oor. Note: The nominal factory dimension between the Rod End stud centers is 7.5” ±.06” (190.5 mm ±1.5 mm). 4 Make sure the threaded stud on the Rod End will align with the matching hole in the

mounting tab, then tighten the Jam Nut.

5 Reinstall the Rod End into the mounting tab. 6 Run the brush up and down to check for correct brush angle with the ﬂ oor. 7 Repeat steps 1 through 5 above as necessary.

TRACTION DRIVE MOTOR HOSE ROUTING

If the traction drive motor or the Hydraulic Hoses to the motor are replaced or repaired, it’s important to route the Hoses correctly when reinstalled to prevent wear or damage to the Hoses and surrounding components.

When reinstalling the traction drive motor Hydraulic Hoses:

1 Tighten the hoses at the bulkhead ﬁ ttings on the frame. 2 Turn the steering wheel all the way toward the left. 3 Make sure the Hoses are routed up and inside the channel in the Drive Wheel Weld-

ment as shown in Figure 11, and ﬂ at against the bottom of the Frame as shown in

Figure 12 below. 4 Twist the Hoses as necessary so they lie ﬂ at against the top of the Frame as shown in

Figure 12, then tighten the ﬁ ttings at the traction drive motor. 5 Turn the steering wheel all the way toward the left and right several times to make sure

the Hoses are not rubbing against the surrounding components.

Rod End (2)

Jam Nut

FIGURE 10

Hydraulic

Hoses

Hydraulic

Hoses

Bottom of

Frame

FIGURE 12

46 - FORM NO. 56043124 - Condor XL

™

Drive Wheel

Weldment

FIGURE 11

GENERAL MACHINE SYMPTOM TROUBLESHOOTING GUIDE TABLE OF CONTENTS

K1 POWER RELAY ON ...................................................................................................................................................48

CONNECTOR CALLOUT – ENGINE START RELAY MODULE .....................................................................................49

ENGINE START/RUN RELAY GM ................................................................................................................................... 50

ENGINE START/RUN RELAY KUBOTA ..........................................................................................................................51

ENGINE SPEED MAGNETIC PICKUP (WOODWARD GOVERNOR) ............................................................................ 52

MAIN SCRUB DECK RIGHT SCRUB DOWN .................................................................................................................53

MAIN SCRUB AND SIDE SWEEP/SCRUB ON ............................................................................................................... 54

VACUUM FAN ON AND SQUEEGEE DOWN ................................................................................................................. 55

VACUUM FAN OFF AND SQUEEGEE UP ...................................................................................................................... 56

MAIN AND RIGHT SIDE SCRUB BRUSH SOLUTION VALVES AND PUMP ................................................................. 57

MAIN AND RIGHT SIDE SCRUB BRUSH(ES) DECK PRESSURE ................................................................................ 58

AXP PCB ASSEMBLY ...................................................................................................................................................... 59

FORM NO. 56043124 - Condor XL™ - 47

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

K1 POWER RELAY ON

Conditions;  S1 Key turned on

B+ SUPPLY

BOUTPUT

PIN J2-1

CB1 CB2 CB3

++++++++ +++ +++ +++

RED/VIO

CB4 CB5

KEY SWITCH

BLU/GRN ORN/GRN

--- +++

RELAY COIL

POWER RELAY

CB6

VIO/GRA

+++ ++++ +

+ +

15A

IGN RUN (ON)

+ + + +

RED

+ + +

FUSE

100A

- - - - -

12V DC

BATTERY

DRIVER

BOX

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Component Current Amps Coil Ohms

K1 Relay Coil .29 Amps @ 12V 46 ± 5 ohms

48 - FORM NO. 56043124 - Condor XL

™

- - - - - - - - - - - - - - - - - - - - - - - - -

BAT (-)

ELECTRICAL SYSTEM CONNECTOR CALLOUT – ENGINE START RELAY MODULE

Pin# Color Type Voltage Pin Description and Function

J7-1

J7-2

J7-3

J7-4 BLK Input B- Module relays coil ground supply

J7-5 PINK Output B+ Engine ECU ignition run relay command

J7-6

J7-7

J7-8

* Note: The normal condition for the start inhibit is in its non-inhibited state. A ﬂ oat voltage of approximately 8V (when referenced to B-) is measured when the key is in the start position. When inhibited, the signal is pulled to ground, will read 0V and will prevent the engine from cranking. This prevents the starter relay from being energized.

VIO/

GRA

BLU/ PINK

WHT/

BRN

VIO/

BRN

YEL/ WHT

ORN/

GRN

Input B+ Module relays load power supply

Output B+ Engine ECU starter relay command

Input

Input B+ Module starter relay Bat +coil signal

Input

Input B+ Module ignition relay Bat+ coil signal

0V Floats

Engine start inhibit signal *

Engine run inhibit signal **

** Note: The normal condition for the run inhibit is its non-inhibited state. A ﬂ oat voltage of approximately 10V (when referenced to B-) is measured when the key is in the start/run and run positions. When inhibited, the signal is pulled to ground, will read 0V and will prevent the engine ECU from receiving its needed input switch command. This prevents the ignition system from ﬁ ring, and if the engine is running will cause it to shut down. Important: See the list for possible reasons the inhibit functions (start and run) could be active or inhibited.

Possible causes for start inhibit to be active causing the engine not to crank.

 Drive pedal sensor switch R1 not calibrated; follow programming instructions to calibrate foot pedal sensor.  Drive pedal activated out off neutral (out of the calibrated deadband range):

 Remove foot from drive pedal.  Adjust or repair the Hydroback/cable and/or drive Piston Pump linkage.

 The control panel displays the critical fault icon 62E showing code #38. See the main control board fault code table code 38 TS explanation

and the engine section for engine code diagnostics.

Possible causes for run inhibit to be active causing the engine to shut down (stop running).

 Loss of the engine run signal input to the main control board Pin # J1-1 (GRA):

 A good LP/G (GM 1.6L) engine run signal will test 0V when measured (referenced) to B- ground. The run signal is lost when the voltage

reads 12V.

 A good diesel (Kubota) engine run signal will test 12V when measured (referenced) to B- ground. The run signal is lost when the voltage

reads 0V.

 The operator control panel displays the critical fault icon 62E showing code #38. See main control board fault code table code 38 TS explana-

tion and the engine section for engine code diagnostics.

FORM NO. 56043124 - Condor XL™ - 49

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

ENGINE START/RUN RELAY 1.6L GM

Conditions;

• First turn the S1 Key Switch to Start position, then release to its run position.

• Foot pedal in Neutral.

Battery (+) From F1 Fuse 100A & CB6 15A

++++++

DRIVE BOX

+ +

++++++

START

+ + + +

+ + + + + + + + + + + + + + + +

++++++ + + + + + + +

J7-8

+++++++++

J7-6

++++++++++

B1 IGN

---

+ + + + + + + + + +

J7-1

+ + + + + + +

++ ++++++ +

++++++

+ + + +

++ +++++++

J7-5

J7-2

+++

+ + + + +

+ + + +

START COMMAND TO STARTER RELAY

IGN. SW INPUT

+ + +

ALT.EXCITE

+ +

STARTINHIBIT

PIN J1-22

PIN J1-34

RUN INHIBIT

PIN J1-10

PIN J1-31

PIN J1-11

J7-3

J7-7

J7-4

BA T-

DRIVE PEDAL SENSOR

BAT -

Note: See connector callout page for engine run/start relay module for more details on circuit functions.

50 - FORM NO. 56043124 - Condor XL

™

RELAY PCB

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

ENGINE START/RUN RELAY KUBOTA DIESEL

Conditions;

• First turn the key S1 to the run position, the glow plug icon will appear on the operator display panel. Next wait until the glow icon goes out then turn the key to the start position and release to the run position.

• Foot pedal in Neutral

Battery (+) From F1 Fuse 100A & CB6 15A

DRIVE BOX

PIN J1-22

++++++

START

+ + + +

+ + + + + + + + + + + + + + + +

STARTINHIBIT

++++++ + + + + + + +

J7-8

+++++++++

J7-6

++++++++++

J7-3

++++++

+ +

B1 IGN

---

+ + + + + + + + + +

J7-1

+ + + + + + +

+ + + +

RUN

++ +++++ +

++++++

++ ++++++

J7-5

J7-2

START

BLU/PINK

++++++ + + + + + + + + + + + + + + + +

+ + + +

PINK

+++

+ + + + + + + + +

STARTER

ALTERNATOR

RED

B(+)

I/F

GOVERNOR

PIN J1-34

RUN INHIBIT

PIN J1-10

PIN J1-31

PIN J1-11

J7-7

DRIVE PEDAL SENSOR

BA T-

Note: See connector callout page for engine run/start relay module for more details on circuit functions.

RELAY PCB

J7-4

BA T-

FORM NO. 56043124 - Condor XL™ - 51

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

DIESEL ENGINE WILL NOT RUN @ HIGH SPEED OR TURBO SPEED (KUBOTA)

Conditions;

• With engine started and running press the engine speed switch. Note: When speed switch indicator light is not on the engine will run at low idle. Press once and indicator will turn green (high speed 2200 rpm), hold switch for more than 2 seconds engine will run at its highest (turbo speed 2400 rpm) speed. Press again the engine will revert back to high speed then again to idle. See additional troubleshooting notes for control circuit details.

++++++++++++++ ++++

RELAY PCB

PIN J7-1

PIN J7-5

Run Relay Out J7-5 Ref: Engine Start/Run Relay for more detail

+ + + + + +

DRIVER BOX

+ + + + + +

PIN J1-1

PIN J2-30 PIN J2-29

+12V (Engine Run Signal)

VIO

RED

++++++++++++++

S28

GRA

OILPRESSURE

SWITCH

(SHOWN IN LOW

PRESSURE STATE)

WOODWARD

B+

SPEED 1 (2400) SPEED 2 (2200)

GOVERNOR

- - - -

B-

DIAGNOSTIC SERVICE TOOL CONNECTOR

- - - - - - - - - - - - - - -

FUEL RAIL & SHUT DOWNACTUATOR

- - - - - - - - - - - - - -

Mounts to Engine Injector Pump

TO ENGINE FLYWHEEL MAGNETIC PICKUP

Component Current Amps Coil Ohms

Actuator 1-1.5 Amps 3.2 ohms

Pin#

J2-30 on Driver

Box

J2-29 on Driver

Box

52 - FORM NO. 56043124 - Condor XL

Wire

Color

VIO Input from Driver Box 0 0 +12 VDC

GRA Input from Driver Box 0 +12 VDC 0

™

Function

Voltage at 1300 RPM

Voltage at 2200 RPM

Voltage at 2400 RPM

ELECTRICAL SYSTEM TROUBLESHOOTING NOTES FOR KUBOTA ENGINE SPEED GOVERNING SYSTEM

Problem: Engine will not run @ high speed 2200rpm or turbo speed 2400 rpm settings Model of governor used: APECS 3000 Mfg. by Woodward (manual # SE-4049). Additional information can be found on their website. Possible causes Things to check

Electrical control circuit

• With key switch ON check for battery voltage at the governor control box (B+ & B-) inputs, correct value 12 VDC.

• Press the engine speed selection button (located on the operator control panel) with engine cranking/running and test for 12VDC @ the governor speed select inputs 1 & 2. See ladder diagram for speed selection voltage relationships.

• If 0 volts check continuity of speed select input wiring from governor to the main controller.

• If wiring check is ok substitute a new main controller (driver box) & dash board panel.

• Check status lamp on governor for fault codes, reference ﬂ ash code table found on APEC S 3000 website.

• Test governor controller actuator out put voltage at different speed selection modes (approx value 3.9 VDC).

• Check continuity of fuel control actuator wiring.

• Test the fuel control actuator for an open circuit (speciﬁ cation is 3.2 Ohms).

• With the engine cranking or running, check the governor magnetic pickup (RPM speed sensor) voltage signal (approx. x VAC).

• Remove and inspect the magnetic speed pickup sensor for damage. When reinstalling, thread sensor in until it makes contact with the ﬂ y wheel then back out a ½ turn.

FORM NO. 56043124 - Condor XL™ - 53

ELEC TRICAL SYSTEM TROUBLESHOOTING GUIDE

MAIN SCRUB DECK and RIGHT SIDE SCRUB DOWN

Conditions;

• Key ON.

• Engine running.

• Scrub ON mode selected

CB4

ORN

RED/VIO

20A

B+ from K1 Power Relay (12V DC)

KEY SWITCH

12VDC

WHT/VIO

MAIN SCRUB LIFT

CYLINDER DOWN

12VDC

YEL/BLU

SCRUB CYLINDER

LOCK

DRIVER BOX

PIN J2-26

B- OUTPUT

PIN J2-4

B- OUTPUT

Component Current Amps Coil Ohms

L5 2.1 Amps 2.2 ohms

L6 1.5 Amps 8 ohms

L9 1.5 Amps 8 ohms

B-

B+ B-

TOUCH PAD

DASHBOARD PANEL

54 - FORM NO. 56043124 - Condor XL

™

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

MAIN SCRUB and SIDE SWEEP/SCRUB ON

Conditions;

• Key ON.

• Engine running.

• Scrub ON mode selected.

• Foot pedal activated (out of neutral).

CB4

ORN

20A

12VDC

MAIN SCRUB

BRUSH

12VDC

SIDE SWEEP/

RIGHT SCRUB

ORN/BLU

BLK/WHT

B+ from K1 Power Relay

DRIVER BOX

PIN J2-7

B- OUTPUT

PIN J2-2

B- OUTPUT

KEY SWITCH

B-

B+ B-

TOUCH PAD

DASHBOARD PANEL

Component Current Amps Coil Ohms

L4 1.5 Amps 8 ohms

L8 1.5 Amps 8 ohms

FORM NO. 56043124 - Condor XL™ - 55

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

VACUUM FAN ON and SQUEEGEE DOWN

Conditions;

• Key ON

• Engine running

• Scrub On Mode selected or vacuum switch selected

• Foot Pedal activated (out of neutral)

B+ from K1 Power Relay

CB5

GRN/BRN

10A

12VDC

SQUEEGEE

DOWN

12VDC

VACUUMFAN

SOLENOID

RED/GRA

BRN/YEL

DRIVER BOX

PIN J2-5

B- OUTPUT

PIN J2-8

B- OUTPUT

KEY SWITCH

B+

TOUCH PAD

DASHBOARD PANEL

B-

Component Current Amps Coil Ohms

L1 1.5 Amps 8 ohms

L2 1.5 Amps 8 ohms

56 - FORM NO. 56043124 - Condor XL

™

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

VACUUM FAN OFF and SQUEEGEE UP

Conditions;

• Key ON

• Engine running

• Scrub Off Mode selected or vacuum switch turned off

• Foot Pedal placed in reverse squeegee will raise (up)

B+ from K1 Power Rel ay

CB5

GRN/BRN

10A

12VDC

SQUEEGEE

UP SOLENOID

SQUEEGEE

DOWN

VACUUMFAN

RED/VIO

BRN/GRN

DRIVER BOX

PIN J2-6

B- OUTPUT

KEY SWITCH

B+

TOUCH PAD

DASHBOARD PANEL

B-

Component Current Amps Coil Ohms

L3 1.5 Amps 8 ohms

FORM NO. 56043124 - Condor XL™ - 57

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

MAIN and RIGHT SIDE SCRUB BRUSH SOLUTION VALVES and PUMP

Conditions;

• Key ON.

• Engine running

• Scrub System ON.

• Foot Pedal Activated (out of neutral in forward direction)

CB4

ORN

20A

CB5

GRN/BRN

10A

MAIN SOLUTION

PUMP

12VDC

L10

MAIN SOLUTION

VALVE

RED/VIO

GRN/BLU

YEL/GRN

B+ from K1 Power Relay

DRIVER BOX

PIN J3-2

B- OUTPUT

PIN J2-22

B- OUTPUT

KEY SWITCH

B+

TOUCH PAD

DASHBOARD PANEL

B-

12VDC

L11

BLU/YEL

PIN J2-10

B- OUTPUT

RIGHT SIDE

SOLUTION VALVE

Component Current Amps Coil Ohms

L10 1.5 Amps 8 ohms

L11 1.0 Amps 12 ohms

M4* 11.5 Amps @ FLA -

*FLA = Full Load Amps

58 - FORM NO. 56043124 - Condor XL

™

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

MAIN and RIGHT SIDE SCRUB BRUSH(ES) DECK PRESSURE

Conditions;

• Key ON.

• Engine running.

• Scrub System ON.

• Foot pedal activated (out of neutral).

CB4

ORN

RED/VIO

20A

Variable 12VDC PWM

WHT/VIO

SCRUB PRESSURE

PROPORTIONALDN

12VDC

YEL/BLU

SCRUB CYLINDER

LOCK

Variable 12VDC PWM

ORN/RED

SCRUB PRESSURE

PROPORTIONALUP

B+ from K1 Power Relay

DRIVER BOX

PIN J2-26

B- OUTPUT

PWM*

PIN J2-4

B- OUTPUT

PIN J2-24

B- OUTPUT

PWM*

Component Current Amps Coil Ohms

L5 2.1 Amps 2.2 ohms

L6 1.5 Amps 8 ohms

L7 2.1 Amps 2.2 ohms

DASHBOARD PANEL

KEY SWITCH

B-

B+ B-

TOUCH PAD

*PWM = Pulse Width Modulated

Pressure Setting L5 Coil Amp draw readings (± 10%)

1 1.38 - 1.75 amps

Pressure Setting L7 Coil Amp draw readings (± 10%)

1 1.45 to 1.75 amps

(varies with scrub setting selected)

(all three scrub pressure settings)

FORM NO. 56043124 - Condor XL™ - 59

ELECTRICAL SYSTEM TROUBLESHOOTING NOTES FOR SCRUB LIFT CYLINDER OVERVIEW

Problem: Scrub deck pressures will not change inoperative in its three settings

Possible causes Things to check

Electrical control circuit

• Check coil resistance on both L5 & L7 solenoids (spec 2.2 Ohms).

• Check solenoid wiring continuity from main controller for both L5 & L7

• Using an AMP clamp check both solenoids current draw (Ref. chart for speciﬁ cation).

• Substitute a new main controller (driver box) if solenoid coils and wiring check good but no current is found when activating scrub deck pressure circuit function.

• If electrical control circuits test OK see possible causes for the Hydraulic load circuit problems.

Hydraulic load circuit

• Inspect for binding and any possible mechanical damage to the deck lift cylinder and deck lift linkage.

• Remove the S5 & S7 scrub lift cylinder valve cartridges from its manifold.

• Inspect, clean and operate the cartridges out side of the manifold if functional reinstall.

• Connect a hydraulic pressure gauge at the test ports TP4 & TP5 and check system operating pressures (see chart for speciﬁ cations).

• If after replacement of a valve cartridge(s) and the deck pressures still do not function correctly, replace the hydraulic lift cylinder.

60 - FORM NO. 56043124 - Condor XL

™

ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE

AXP PCB ASSEMBLY

• The signal controlling the chemical pump is extremely complex and ﬁ eld troubleshooting should take a functional approach. Substitute with a known good chemical pump to check operation. If the known good pump does not operate, and the wiring and control inputs to the AXP system are correct, the main controller Driver Box is probably defective. Check the resistance of the chemical pump before replacing the main controller Driver Box so as not to damage it if the pump is defective.

• The Solution Pump (-) line provides a switched ground return for the pump. When the solution pump is “ON” a 7.8KHz signal with a varying duty cycle and average voltage will appear between this pin and B+. Measuring with a DC voltmeter will give a signal in the range of 0 to 12 volts. Changing the ﬂ ow rate solution bars on the LCD should produce a relative increase or decrease of the meter reading.

FORM NO. 56043124 - Condor XL™ - 61

ELECTRICAL SYSTEM CONTROL BOARD PROGRAMMING OPTIONS

Foot Pedal Neutral Position and Deadband Adjustment

FACTORY DEFAULT: 3% RANGE: 2% - 15%

1 Depress the foot pedal to full reverse position, then allow the pedal to slowly return to its neutral position. Do not move the pedal during the

remainder of this procedure.

2 Press and hold the Engine Speed switch (51), then turn the ignition Key Switch (50) to the run (on) position. Continue to hold the Engine Speed

switch until all the display panel lights turn off (approximately three seconds), then release the switch.

 The ﬁ rst line of the LCD display will read “PEDAL CALIBRATION”.  The second line of the display will read “Place Pedal in Neutral” with an arrow to the left of the line.  The third line of the display will read “Neutral Deadband”.

3 Press the green Scrub ON Switch (54).

 The ﬁ rst line of the LCD display will read “Neutral Set”.  The second line of the display will show the resistance value, in ohms, that the Control Board is reading through the Rotary

Sensor. Note that it’s normal for this value to drift a little.

the Rotary Sensor can vary from the “Neutral Set” (nominal) resistance and still be in the deadband range and allow the engine to start.

7 Press the Side Broom Up and Down Switches (53) to scroll through the available percentages. Note: The ideal neutral deadband percentage range is one that allows reliable starting, yet still actuates the scrub functions with minimal pedal

travel. The factory default value is 3%. 8 When the arrow is to the left of the desired percentage value:

 Press the green Scrub ON Switch to save the new percentage value. The display will return to the previous menu.  Press the red Scrub Off Switch to return to the previous menu without changing the percentage value.

9 Turn the ignition key switch to the off position. The new settings will be saved and remain in effect until they are changed again.

PEDAL CALIBRATION

PLACE PEDAL IN NEUTRAL

NEUTRAL DEADBAND

2%, 3%, 4% ... 15% (2-15%, 1% increment)

62 - FORM NO. 56043124 - Condor XL

™

Entered by pressing and holding ENGINE SPEED button during 3 second power on sequence.

NEUTRAL SET

Indicates that neutral position has been set.

NEUTRAL_ DEADBAND:

2, 3

,4,...15

ELECTRICAL SYSTEM CONTROL BOARD PROGRAMMING OPTIONS

Conﬁ guration Display Menu

Note: The Conﬁ guration Display will only display the active conﬁ gured settings and fault codes. You cannot make any changes to the machine

conﬁ guration from the Conﬁ guration Display other than clearing the fault codes. See the Conﬁ guration Menu section for instructions on how to change the machine conﬁ guration.

1 Press and hold the Emergency Flashers switch (67). 2 Turn the ignition Key Switch (50) to the run (on) position. 3 Continue to hold the Emergency Flashers switch until all the display panel lights turn off (approximately three seconds), then release the switch.

The ﬁ rst line of the LCD display will read “CONFIGURATION DISPLAY”.

4 Press the Side Broom Up (53b) and Side Broom Down (53a) switches to scroll through the display menu items as shown in the chart below. 5 When the arrow is pointing to a menu item:

a. Press the green Scrub On switch (54) to display the next level of menu items. b. Press the red Scrub Off switch (55) to return to the previous menu level.

6 To exit the Conﬁ guration Display, turn the ignition Key Switch to the off position.

CONFIGURATION DISPLAY

FAUL T CODES

VIEW FAULT C ODES

CLEAR FAULT C ODES

ENGINE TYPE

UNDEFINED, PROPANE, GASOLINE, DIESEL

DETERGENT SYSTEM

DISPLAYFORMAT

SIDE SCRUB SYSTEM

NOT INSTALLED,INSTALLED

SIDE SWEEP SYSTEM

Entered by pressing and holding HAZARD button during 3 second power on sequence. ALLOWS DISPLAY OF CONFIGURATION ONLY - NO CHANGES TO PARAMETERS ALLOWED.

Fault codes are displayed in a list. Display format: xx - brief description (xx = two digit error code)

ARE YOU SURE ?

ENGINE_TYPE: 0 = undefined, 1 = propane, 2 = gasoline, 3 = diesel

INSTALLED ?

NOT INSTALLED, INSTALLED

RATIO, PERCENTAGE

SIDE_SCRUB_INSTALLED_FLG: 0 = not installed, 1 = installed

CHEMICAL_SYSTEM_INSTALLED_FLG: 0 = not installed, 1 = installed

CHEMICAL_DISPLAY_TYPE: 0 = ratio, 1 = percentage

NOT INSTALLED,INSTALLED

EXTENDED SCRUB SYSTEM

NOT INSTALLED, INSTALLED

BACK-UP ALARM

NOT INSTALLED,INSTALLED

LIGHTS

NOT INSTALLED,INSTALLED

SIDE_SWEEP_INSTALLED_FLG: 0 = not installed, 1 = installed

RECYCLE_INSTALLED_FLG: 0 = not installed, 1 = installed

BACKUP_ALARM_INSTALLED_FLG: 0 = not installed, 1 = installed

Refers to all lights EXCEPT headlights. Headlights are standard on all models.

LIGHTS_INSTALLED_FLG: 0 = not installed, 1 = installed

FORM NO. 56043124 - Condor XL™ - 63

ELECTRICAL SYSTEM CONTROL BOARD PROGRAMMING OPTIONS

User Options Menu

1 Press and hold in the red Scrub Off switch (55) and the green Scrub On switch (54). 2 Turn the ignition Key Switch (50) to the run (on) position. 3 Continue to hold the Scrub Off and the Scrub On switches until all the display panel lights turn off (approximately three seconds), then release

the switches. The ﬁ rst line of the LCD display will read “USER OPTIONS MENU”.

4 Press the Side Broom Up (53b) and Side Broom Down (53a) switches to scroll through the options menu items as shown in the chart below. 5 When the arrow is pointing to the desired menu item, press the green Scrub On switch (54) to display the next level of menu options. 6 Press the Side Broom Up (53b) and Side Broom Down (53a) switches to select the desired option. 7 When the arrow is pointing to an option:

 Press the green Scrub On switch (54) to select the option. The display will then return to the previous menu level.  Press the red Scrub Off switch (55) to return to the previous menu level without selecting the option.

8 To save the new setting(s), turn the ignition Key Switch to the off position. The new setting(s) will be saved and remain in effect until changed

again.

USER OPTIONS MENU

MENU OPTIONS ONLY APPEAR WHEN SCRUB_FUNCTION = 1 (manual - pressure)

MENU OPTIONS ONLY APPEAR WHEN SCRUB_FUNCTION = 0 (automatic - modes)

SCRUBSYSTEM

SCRUB MODE START UP

DETERGENT START UP

SCRUB MODE OPERATION

SOLUTION FLOW START

Entered by pressing and holding SCRUB OFF and SCRUB ON buttons during 3 second power on sequence.

MODE # 1,LASTUSED

OFF, ON ,LASTSTATE

AUTOMATIC, MANUAL

MAXIMUM PRESSURE

1,2,3

LAST USED,1,2,3,4,5

SCRUB MODE 1

SCRUBPRESSURE

1,2,3

SOLUTION FLOW

1,2,3 ,4,5

DETERGENT MIX

0,1,2,3,4,5,6,7, 8,9,LAST USED

SCRUB MODE 2

SCRUBPRESSURE

1,2,3

SOLUTION FLOW

1,2,3 ,4,5

DETERGENT MIX

0,1,2,3,4,5,6,7, 8,9,LAST USED

SCRUB MODE 3

SCRUBPRESSURE

1,2,3

SOLUTION FLOW

1,2,3,4,5

DETERGENT MIX

0,1,2,3,4,5,6,7, 8,9,LAST USED

NEUTRAL OFF DELAY

0.5 SECON DS (0-3 SEC, IN CREMENT=0.5 SEC)

SCRUB_RESUME_LAST_FLG: 0 = scrub mode 1,1=lastused LAST_SCRUB_MODE = 1

CHEMICAL_START_MODE: 0 = off, 1=on

SCRUB_FUNCTION: 0=automatic(modes)

SCRUB_PRESSURE_LIMIT: 1, 2, OR 3

DEFAULT_SOLUTION_FLOW: 0=lastused, 1,2,3,4 or 5

SCRUB_OFF_DELAY: 0-30, default = 5

,2,OR3

,2=laststate

, 1= manual (pressure)

SCRUB_PRESSURE_MODE1 (SCRUB_PRESSURE_REGS[1]): 1

SOLUTION_FLOW_MODE1 (SOLUTION_FLOW_REGS[1]): 1

CHEMICAL_RATIO_MODE1(CHEMICAL_RATIO_REGS[1]): 0,1,2,3,4,5,6,7,8,9, or 10 = last used display actual ratio or percentage based on CHEMICAL_DISPLAY_TYPE: 0 = ratio, 1 = percentage (from configuration menu)

SCRUB_PRESSURE_MODE2 (SCRUB_PRESSURE_REGS[2]): 1, 2

SOLUTION_FLOW_MODE2 (SOLUTION_FLOW_REGS[2]): 1, 2

CHEMICAL_RATIO_MODE2 (CHEMICAL_RATIO_REGS[2]):

0,1,2,3,4,5,6,7,8,9, or 10 = last used

display actual ratio or percentage based on CHEMICAL_DISPLAY_TYPE: 0 = ratio, 1 = percentage (from configuration menu)

SCRUB_PRESSURE_MODE3 (SCRUB_PRESSURE_REGS[3]): 1, 2, OR 3

SOLUTION_FLOW_MODE3 (SOLUTION_FLOW_REGS[3]): 1, 2, 3,4,or 5

CHEMICAL_RATIO_MODE3(CHEMICAL_RATIO_REGS[3]): 0,1,2,3,4,5,6,7,8,9, or 10 = last used display actual ratio or percentage based on CHEMICAL_DISPLAY_TYPE: 0 = ratio, 1 = percentage (from configuration menu)

Chemical Mix Display

(CHEMICAL_DISPLAY_TYPE = 0):

0 - 300:1 1 - 256:1 2 - 200:1 3 - 150:1 4 - 128:1 5 - 100:1

6 - 64:1 7 - 50:1 8 - 32:1 9 - 26:1

10 - LAST USED

Chemical Mix Display

(CHEMICAL_DISPLAY_TYPE = 1):

0 - 0.3% 1 - 0.4% 2 - 0.5% 3 - 0.7% 4 - 0.8% 5 - 1.0% 6 - 1.5% 7 - 2.0% 8 - 3.0% 9 - 3.8%

10 - LAST USED

,2,OR3

,2,3,4,or5

,OR3

, 3,4,or 5

64 - FORM NO. 56043124 - Condor XL

™

USER OPTIONS MENU (continued)

SOLUTION IN REVERSE

Entered by pressing and holding SCRUB OFF and SCRUB ON buttons during 3 second power on sequence.

OFF,ON

RECOVERY SYSTEM

SQUEEGEE UP DELAY

15 SECOND S (5-30 SEC, INCREMENT=1 SEC)

VACUUM OFF DELAY

10 SECOND S (10-30 SEC, INCREMENT=1 SEC)

TIMEOUT MOD E

CONTROL LOCKS

UNLOCK, DETER GENT, DETERGENT & SOLUTION

SIDE SCRUB SYSTEM

START UP STATE

SIDE SWEEP SYSTEM

BROOM START UP

SOLUTION_IN_REVERSE_FLG: 0=OFF(false),1=ON(true)

NORMAL, IN NEUTRA L

Only appears when SIDE_SCRUB_INSTALLED_FLG = 1 (from configuration menu)

OFF, ON, LASTSTATE

Only appears when SIDE_SWEEP_INSTALLED_FLG = 1 (from configuration menu)

SQUEEGEE_OFF_DELAY: 50-300, default = 150

VACUUM_OFF_DELAY: 100-300, default = 100

RECOVERY_TIMEOUT_MODE: 0=normal, 1 = in neutral

CONTROL_LOCK: 0=unlock

SIDE_SCRUB_START_MODE: 0 = off, 1 = on, 2=laststate

, 1 = detergent mix only, 2 = detergent mix and solution flow

OFF, ON, LASTSTATE

DUST GUARD START UP

OFF, ON, LASTSTATE

EXTENDED SCRUB SYSTEM

START UP STATE

OFF, ON, LASTSTATE

OPERAT ING MODE

USE AN YTIME, USE CLEAN FIRST

ENGINE IDLE DELAY

20 SECOND S (10-250 SEC, INCREMENT = 1 SEC)

BACK-UPALARM

OFF, REVERSE,FORWARD&REVERSE

LIGHTS

NORMAL,ALWAYSON

SIDE_SWEEP_START_MODE: 0 = off, 1 = on, 2 = last state

SIDE_MIST_START_MODE: 0 = off, 1 = on, 2 = last state

Only appears when RECYCLE_INSTALLED_FLG = 1 (from configuration menu)

RECYCLE_START_MODE: 0 = off, 1 = on, 2=laststate

RECYCLE_OP_MODE: 0 = use anytime, 1=usecleanfirst

IDLE_TIME_OUT: 100-2500, default = 200

Only appears when BACKUP_ALARM_INSTALLED_FLG = 1 (from configuration menu)

BACKUP_ALARM_OP_MODE: 0 = off, 1= reverse only

LIGHTS_OP_MODE: 0 = normal

,1=alwayson

, 2 = forward and reverse

FORM NO. 56043124 - Condor XL™ - 65

ELECTRICAL SYSTEM CONTROL BOARD PROGRAMMING OPTIONS

Conﬁ guration Menu

1 Press and hold the Emergency Flashers (67) and Headlight (68) switches. 2 Turn the ignition Key Switch (50) to the run (on) position. 3 Continue to hold the Emergency Flashers and Headlight switches until all the display panel lights turn off (approximately three seconds), then

release the switches. The ﬁ rst line of the LCD display will read “CONFIGURATION MENU”.

4 Press the Side Broom Up (53b) and Side Broom Down (53a) switches to scroll through the conﬁ guration menu items as shown in the chart

below.

5 When the arrow is pointing to the desired menu item, press the green Scrub On switch (54) to display the next level of conﬁ guration options. 6 Press the Side Broom Up (53b) and Side Broom Down (53a) switches to select the desired option. 7 When the arrow is pointing to the conﬁ guration option:

8 To save the new setting(s), turn the ignition Key Switch to the off position. The new setting(s) will be saved and remain in effect until changed

again.

CONFIGURATION MENU

ENGINE TYPE

UNDEFINED,PROPANE, GASOLINE, DIESEL

DETERGENT SYSTEM

SIDE SCRUB SYSTEM

NOT INSTALLED, INSTALLED

SIDE SWEEP SYSTEM

NOT INSTALLED, INSTALLED

EXTENDED SCRUB SYSTEM

NOT INSTALLED, INSTALLED

Entered by pressing and holding HAZARD and LIGHT buttons during 3 second power on sequence.

INSTALLED ?

NOT INSTALLED,INSTALLED

DISPLAYFORMAT

RATIO, PERCENTAGE

ENGINE_TYPE: 0= undefined

CHEMICAL_SYSTEM_INSTALLED_FLG: 0 = not installed

CHEMICAL_DISPLAY_TYPE: 0=ratio

SIDE_SCRUB_INSTALLED_FLG: 0 = not installed

SIDE_SWEEP_INSTALLED_FLG: 0 = notinstalled

RECYCLE_INSTALLED_FLG: 0 = not installed

, 1 = propane, 2 = gasoline, 3 = diesel

, 1 = installed

, 1 = percentage

, 1 = installed

,1=installed

BACK-UP ALARM

NOT INSTALLED, INSTALLED

LIGHTS NOT INSTALLED, INSTALLED

RESTORE DEFAULTS

ARE YOU SURE ?

66 - FORM NO. 56043124 - Condor XL

™

BACKUP_ALARM_INSTALLED_FLG: 0 = notinstalled

Refers to all lights EXCEPT headlights. Headlights are standard on all models.

LIGHTS_INSTALLED_FLG: 0 = not installed

Restores all configuration and option values to their factory default state.

, 1 = installed

ENGINE SYSTEM ENGINE SPECIFICATIONS

1.6 liter GM

Engine type

Displacement 98 Cubic inches (1600 cc)

Fuel

Gasoline

LP 33-lb. Tank Size (liquid withdrawal system)

Spark Plugs AC Delco p/n 93206675, Gap .032 -.035 (.8 mm-.9 mm)

Spark Plug Wiring

Engine Firing Order 1-3-4-2

Ignition Timing Fixed (controlled by engine ECM)

Engine Rotation CCW (ﬂ ywheel end)

Valve lifters Hydraulic

Oil Capacity 3.7 qt. (3.5L) with Oil Filter

Oil Pressure 21 psi (minimum with engine hot at idle)

Cooling System 3.5 qt. (Engine Only)

Kubota V1505-B-1

Engine Type Vertical, liquid cooled, 4 cylinder, 4-cycle diesel engine

Displacement 91.41 cubic inches (1498cc)

Fuel Diesel fuel No. 2-D (ASTM D975)

Injection Pump Bosch MD type mini pump

Engine ﬁ ring order 1-3-4-2

Injection Timing (before TDC)

Oil Capacity 5.5 qt. (5.2L) / Oil Pan depth 4.9” (12.4 cm)

Cooling Capacity 8 qt. (7.5L)

Horsepower 46 gross @2800 RPM,41 Int @2400 RPM

Idle Speeds Low idle 1300 RPM, High idle 2400 RPM

Note: Refer to the engine manufacturer’s Operator and Service manuals for more detailed engine speciﬁ cations and service data.

Vertical, liquid Cooled, 4 Cylinder, Single Overhead cam Distributor-less

87 Octane Unleaded Gasoline with no more than 10% Ethanol by volume

Match numbered coil position to spark plug number (front to rear 1, 2, 3 and 4)

19 degrees

FORM NO. 56043124 - Condor XL™ - 67

ENGINE SYSTEM MISCELLANEOUS ENGINE SYSTEM INFORMATION

Engine Overheating Problems

Use the checklist below as a guide to thoroughly check the engine cooling system.

 Check the coolant level in the overﬂ ow tank and radiator.  Inspect and clean the radiator and hydraulic oil cooler.  Check for correct operation of the belt-driven engine cooling fan (slippage).  Check to see that the engine thermostat opens.  Check for correct water pump operation.  Check the engine crankcase oil level.

Over-temperature Protection

The GM 1.6L engine will set a diagnostic test code (DTC 116) after ﬁ ve seconds at temperatures over 215 °F, and the ECM will derate the engine power to level one (maximum throttle position of 50%). If the engine continues to overheat, it will set a code (DTC 217) after 10-15 seconds at temperatures over 225 °F, then the engine will shut down.

Loss of Oil Pressure Protection

The engine will shut down if the oil pressure drops to 3-7 psi.

GM 1.6L GASOLINE FUEL SYSTEM DESCRIPTION

This engine is equipped with a fuel injector rail that does not have a pressure regulator. Fuel pressure for this engine is regulated by the engine’s ECM controlling the fuel pump via pulse width modulation. The ECM receives fuel pressure and temperature feedback from the gasoline fuel sensor manifold and uses this information to control the ground side of the fuel pump. Fuel pressure is regulated by the ECM pulse width modulating (PWM) the fuel pump. The fuel pressure and temperature sensor manifold has a return or “bleed” circuit that is comprised of a .020” oriﬁ ce and a 6 psi check valve that connects back to the equipment fuel tank. This circuit is used to bleed off any vapor that develops in the line and returns a small amount of fuel to the tank. The fuel comes from the fuel tank and passes through the in-line fuel pump. Fuel exits the fuel pump, passes through the ﬁ lter and then enters the fuel pressure and temperature manifold assembly. Fuel ﬂ ows through the feed circuit and is delivered to the fuel injector rail. Fuel that enters the bleed circuits through the bypass valve in the manifold is returned to the fuel tank.

68 - FORM NO. 56043124 - Condor XL

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ENGINE SYSTEM ENGINE DIAGNOSTICS

Accessing Engine Diagnostic Information Using the Con-

troller Interface Kit and a PC

The Controller Interface Kit (p/n 56305647 shown on page 9) al-

lows you to connect a laptop PC to the engine to view the various engine parameters, conﬁ guration settings and error codes, and displays the engine software and hardware information. Note that this is the preferred way to view the engine diagnostic information. To use the Controller Interface Kit:

1 Install the software from the provided CD onto your PC. 2 Connect the USB connector on the kit cable to a USB port in your PC.

Communication Port

TIER II

Protective Cap

FIGURE 13

3 See Figure 13. Remove the Protective Cap, then connect the kit cable to the Communication Port on the engine.

Note: The minimum system requirements for the software in the Controller Interface Kit are as follows:

 Windows XP, 2000 or 98SE (Second Edition) operating system  Minimum processor speed – Pentium II 450 MHz  Minimum RAM requirements:

 Windows XP – 256 MB  Windows 2000 – 128 MB  Windows 98SE – 128 MB

 At least one available RS232 serial or USB port. Note that the USB driver does not support Windows 98 SE.

FORM NO. 56043124 - Condor XL™ - 69

ENGINE SYSTEM ENGINE DIAGNOSTICS

Accessing Engine DTC Error Codes Manually

You can access the engine DTC (diagnostic test code)

error codes manually without using a Controller Interface Kit and PC. The codes will be shown through a sequence of blinks on the Warning Indicator Light (62). To access the codes:

1 See Figure 14. Remove the Protective Cap from

the Communication Port on the engine.

2 Use a wire to jumper pin #1 to pin #4 as shown in

Figure 14.

3 Turn the key switch (50) to the on position. You

can now read the error codes by observing the blinks on the Warning Indicator Light (62). Be ready to write down any codes that may be stored.

Protective Cap

Communication Port

TIER II

Jumper across top row at

outside pins ORN & BLK/GRN

Pin #1

Empty

Pin #4

FIGURE 14

Note: The light will always blink “1-6-5-4” three times at

the beginning and at the end of the error code number display series.

For example, error code “118”, indicating an ECT (engine coolant temperature) High Voltage condition, would be indicated as follows:

a The light will show one blink, a short pause, six blinks, a short pause, ﬁ ve blinks, a short pause, then one blink. Note that this 1-6-5-4

sequence is not an error code, but will repeated three times to indicate the beginning of the error code number display series.

b The light will show the ﬁ rst actual error code (118 in this example) with one blink, a short pause, one blink, a short pause, then eight blinks.

This 1-1-8 sequence will be repeated three times, then the light will blink the next error code number sequence in the series (if present).

c When all of the error code number sequences have been displayed, the light will blink the 1-6-5-4 sequence three times again to indicate

the end of the error code number series.

d The light will then repeat steps a through c above.

70 - FORM NO. 56043124 - Condor XL

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ENGINE DIAGNOSTICS

1.6L DTC CODE TO SPN:FMI CODE CROSS REFERENCE

DTC

Description

Code

16 Crank Never Synced at Start 636 8 604 RAM Failure 630 12

91 Fuel Pump Low Voltage 94 4 606 COP Failure 629 31

92 Fuel Pump High Voltage 94 3 642 External 5V Reference Low 1079 4

107 MAP Low Voltage 106 4 643 External 5V Reference High 1079 3

108 MAP High Pressure 106 16 685 Power Relay Open 1485 5

111 IAT Higher Than Expected 1 105 15 686 Power Relay Shorted 1485 4

112 IAT Low Voltage 105 4 687 Power Relay Short to Power 1485 3

113 IAT High Voltage 105 3 1111 Fuel Rev Limit 515 16

116 ECT Higher Than Expected 1 110 15 1112 Spark Rev Limit 515 0

117 ECT Low Voltage 110 4 1151 Closed Loop Multiplier High LPG 520206 0

118 ECT High Voltage 110 3 1152 Closed Loop Multiplier Low LPG 520206 1

121 TPS 1 Lower Than TPS 2 51 1 1155 Closed Loop Multiplier High Gasoline 520204 0

122 TPS 1 Signal Voltage Low 51 4 1156 Closed Loop Multiplier Low Gasoline 520204 1

123 TPS 1 Signal Voltage High 51 3 1161 Adaptive Learn High LPG 520202 0

127 IAT Higher Than Expected 2 105 0 1162 Adaptive Learn Low LPG 520202 1

129 BP Low Pressure 108 1 1165 LPG Cat Monitor 520213 10

134 EGO 1 Open/Inactive 724 10 1171 LPG Pressure Higher Than Expected 520260 0

154 EGO 2 Open/Inactive 520208 10 1172 LPG Pressure Lower Than Expected 520260 1

171 Adaptive Learn High Gasoline 520200 0 1173 EPR Comm Lost 520260 31

172 Adaptive Learn Low Gasoline 520200 1 1174 EPR Voltage Supply High 520260 3

182 Fuel Temp Gasoline Low Voltage 174 4 1175 EPR Voltage Supply Low 520260 4

183 Fuel Temp Gasoline High Voltage 174 3 1176 EPR Internal Actuator Fault 520260 12

187 Fuel Temp LPG Low Voltage 520240 4 1177 EPR Internal Circuitry Fault 520260 12

188 Fuel Temp LPG High Voltage 520240 3 1178 EPR Internal Comm Fault 520260 12

217 ECT Higher Than Expected 2 110 0 1612 RTI 1 Loss 629 31

219 Max Govern Speed Override 515 15 1613 RTI 2 Loss 629 31

221 TPS 2 Signal Voltage Low 51 0 1614 RTI 3 Loss 629 31

222 TPS 2 Signal Low Voltage 520251 4 1615 A/D Loss 629 31

223 TPS 2 Signal High Voltage 520251 3 1616 Invalid Interrupt 629 31

336 Crank Sync Noise 636 2 1626 CAN Tx Failure 639 12

337 Crank Loss 636 4 1627 CAN Rx Failure 639 12

420 Gasoline Cat Monitor 520211 10 1628 CAN Address Conﬂ ict Failure 639 13

524 Oil Pressure Low 100 1 2111 Unable to Reach Lower TPS 51 7

562 System Voltage Low 168 17 2112 Unable to Reach Higher TPS 51 7

563 System Voltage High 168 15 2229 BP Pressure High 108 0

601 Flash Checksum Invalid 628 13

SPN

Code

FMI

Code

DTC

Code

Description

SPN

Code

FMI

Code

FORM NO. 56043124 - Condor XL™ - 71

ENGINE SYSTEM

72 - FORM NO. 56043124 - Condor XL

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HYDRAULIC SYSTEM HYDRAULIC SYSTEM COMPONENTS

Item Description

50 Fan Motor Assembly 51 Res

52 Steering Pump Ass’y 53 Squeegee Cylinder Ass’y 54 Hydraulic Motor Ass’y 55 Drive Motor Ass’y 56 Pump Assembly, Low Speed 57 Valve Block Ass’y 58 Cylinder Assembly, Steer 59 Scrub Lift Cyl. Ass’y 60 Oil Cooler Ass’y

ervoir Ass’y

Item Description

62 Pump Assembly 63 Union Cross 64 End Cap, Flare Tube 65 Locknut, Bulkhead 66 Locknut, Bulkhead 68 Sleeve, Nylon 69 Clamp, P 70 Elbow, 90 Bulkhead Union 71 Nipple, Test 72 TEE, BULKHEAD RUN

FORM NO. 56043124 - Condor XL™ - 73

HYDRAULIC SYSTEM HYDRAULIC CYLINDERS

Item Ref. No. Qty Description A 56110261 1 Squeegee Cylinder Ass’y B 56110412 1 Cylinder Assembly, Steer C 56110425 1 Scrub Lift Cylinder Ass’y

74 - FORM NO. 56043124 - Condor XL

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HYDRAULIC SYSTEM HYDRAULIC MOTORS

Item Ref. No. Qty Description

A 56110062 1 Vacuum Fan Motor Assembly B 56111517 1 Steering Pump Assembly C 56110369 1 Drive Motor Assembly D 56110339 1 Main Broom Motor Assembly

FORM NO. 56043124 - Condor XL™ - 75

HYDRAULIC SYSTEM HYDRAULIC PUMPS

Item Ref. No. Qty Description

A 56111085 1 Propulsion (transport) Pump Assembly B 56110372 1 Accessory Pump Assembly

76 - FORM NO. 56043124 - Condor XL

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HYDRAULIC SYSTEM HYDRAULIC VALVE BLOCK/MANIFOLD

HYDRAULIC SYSTEM TROUBLESHOOTING

Accurate measurements are the key to troubleshooting a hydraulic system. Once measurements are obtained, they can be compared with speciﬁ cations to analyze a problem. You can use digital tachometers, ﬂ ow gauges or pressure gauges to troubleshoot the hydraulic system. The pressure gauge should have a range of 0 to 3000 psi (see the DIAGNOSTIC AND SERVICE TOOLS section) and have a Parker Diagnostics connector number PD222. The most convenient way to check for oil ﬂ ow is to check the RPM of the motor that is performing poorly. Refer to the GENERAL HYDRAULIC SPECIFICATIONS TABLE to determine the motor RPM. If the motor speed is correct, the pump is producing the correct amount of oil ﬂ ow. However, this does not mean that if a motor is running too slow the problem is in the pump.

The following information should be used to check for correct motor RPM, system pressure and relief valve settings. The readings are nominal ﬁ gures and there will be variations due to manufacturing tolerances and system oil temperature. If any reading varies greater than 20 percent, there will be a noticeable loss of performance and the problem should be corrected.

FORM NO. 56043124 - Condor XL™ - 77

HYDRAULIC SYSTEM

TEST PORT NOMINAL PRESSURE READINGS

Note: See Figure 15 and the GENERAL HYDRAULIC SPECIFICATIONS TABLE.

Note: 100 psi = 6.9 bar

1 Insert the pressure gauge into the test port. Note: The Lower Test Port (TP 4) on the Scrub Lift Cylinder is easier to access if you lower the scrub deck. 2 Run the engine in high throttle position and allow the hydraulic oil to warm up.

 The bypass pressure is the pressure reading with no motor or cylinder operating.  The operational pressure is the pressure range in which the motor or cylinders will operate.

 A much lower than normal bypass pressure could indicate a gear pump problem.  If the bypass pressure remains the same after turning the function on, there could be a problem in the control valve or circuit.  If the operational pressure is within range but the motor speed is too slow, the problem could be in the motor.  If the broom motor operational PSI reading is above the bypass psi but is below the operational psi, check the broom adjust-

ment and wear.

 Check individual system troubleshooting sections of this manual for additional information.

FIGURE 15

TP 3

Scrub Lift Cylinder

Test Ports

TP 1

TP 5

Accessory Pump

Test Ports

Upper Test Port (TP 5) on the Scrub Lift Cylinder Lower Test Port (TP 4) on the Scrub Lift Cylinder

TP 2

TP 4

TP 5

78 - FORM NO. 56043124 - Condor XL

™

TP 4

HYDRAULIC SYSTEM GENERAL HYDRAULIC SPECIFICATIONS TABLE

Accessory Pump 1 Circuits

Accessory pump 1, engine @ 2200 RPM no systems running (test port TP1)

Displacement

Cu. In.

GPM

.58 5.52 2200 * 120 2700

Vacuum Fan motor (open fan) .129 5.52 8600 2040 2700 Vacuum water lift sealed @ 2200 RPM, 33.7 in/H2O

Accessory Pump 2a Circuits

Accessory Pump 2a non-priority branch, engine @ 2200 RPM, no systems running (test port TP2) Main scrub brush motors (only) setting (A) no load broom off floor and ** scrub setting #3 pressure

Displacement

Cu. In.

GPM

1.20 8.42 2200 *370 2700

4.5 2200

Main scrub and RT side scrub motors #3 pressure 2200 1880 Right side brush motor speed 11.3 160 Main scrub and dual sweep 2200 1780 Side sweep broom motor speed 17.9 100 Main scrub, RT scrub and LT sweep 2200 1950 Squeegee cylinder 1.50 x 5.00 2200 315

Accessory Pump 2b Circuits

Accessory Pump 2b priority branch, engine @ 2200 RPM no systems running (test port TP3) Steering unit (driving and turning) 4.5 500

Test Port

TP4

Scrub lift cylinder 1.50 x 5.00, engine at 2200 RPM

TP5

Propulsion Pump Circuits

Displacement

Cu. In.

GPM

1.20 3.0 2200 * 296 1500

Pressure

Controlled

Type

Lift

Pressure

Down

Pressure

Displacement

Cu. In.

Proportioning

Valve S7

Proportioning

Relief Valve

GPM

Hydrostat pump charge pressure 250 Hydrostatic pump 1.44 13.7 2200

Forward drive wheel motor speed test @ 8 mph level ground, smooth concrete, no accessory systems running, foot at full speed forward,

18.3

set 153 RPM @ 2400 RPM

Reverse same as above @ 4 mph, set 78 RPM @2400 RPM

Hydraulic Reservoir Capacity

Hydraulic reservoir capacity: 10 gallons Oil Type: 10W-30

* The bypass pressure is the pressure reading with no motor or cylinder operating (flow through). ** Scrub brush system hydraulic pressure under load setting #3

RPM

RPM OUT

415 400

RPM OUT

PSI

A 850

1700**

PSI

Pressure

Setting

1 750 - 774 2 750 - 767 3 745 - 779

1 333 - 346 2 393 - 412 3 458 - 499

RPM OUT

PSI

1060@

2200

FWD

153

RPM

1200@

2400 RPM

REV

PSI

Relief

PSI

Relief

PSI

Relief

PSI

Relief

PSI

3500

2500

FORM NO. 56043124 - Condor XL™ - 79

HYDRAULIC SYSTEM SCRUB LIFT CYLINDER OVERVIEW

The scrub lift cylinder is controlled by two proportioning hydraulic valves that work together, on opposite ends of the lift cylinder, to produce the desired main scrub deck pressure. (Reference Hydraulic Schematic in Appendix).

 The lift pressure (scrub pressure up) is controlled by Proportioning Valve S7 which gets its signal from pin J2-24 on the Driver Box.  The down pressure (scrub pressure down) is controlled by Proportioning Valve S5 which gets its signal from pin J2-26 on the Driver Box.

The Driver Box signals are pulse width modulated (PWM) signals (voltages) which open the valves proportionally to produce the appropriate hydraulic pressures on both the piston and rod ends of the scrub lift cylinder. This combination of up and down forces on the lift cylinder applies the correct amount of downward force to the main scrub deck to produce the desired scrub pressure.

Note that the signals to the valves allow the valves to “dither” (oscillate in a slight back-and-forth motion) (high frequency) to prevent the valves from sticking.

The table below shows the hydraulic pressures to the Valves and the solenoid coil current draws at the three scrub pressures.

Proportioning

Valve

Proportioning

Valve

Pressure

Type

Scrub

Pressure

Type

Scrub

Pressure

Down

Scrub

Pressure

Setting

1 750 to 774 psi

2 750 to 767 psi

3 745 to 779 psi

Scrub

Pressure

Setting

1 333 to 346 psi

2 393 to 412 psi

3 458 to 499 psi

Hydraulic Pres-

sure at Test Port

Hydraulic Pres-

sure at Test Port

TP4

TP5

Valve Solenoid Coil

Current Draw

1.45 to 1.75 amps

(all three scrub pres-

sure settings)

Valve Solenoid Coil

Current Draw

1.38 - 1.75 amps

(varies with scrub set-

ting selected)

80 - FORM NO. 56043124 - Condor XL

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HYDRAULIC SYSTEM

HYDRAULIC TRUTH TABLE

Electrical Solenoid’s Energized Status – Component to Operate

Solenoid Functions S1 S2 S3 S4 S5 S6 S7 S8 S9

Recovery Tank Fan

Squeegee Down

Squeegee UP

Scrub Brushes ON

Scrub Brush Pressure Setting Regular #1

Scrub Brush Pressure Setting Heavy #2

Scrub Brush Pressure Setting Extreme #3

Right Side Scrub Brush Pressure Settings 1, 2 and 3

Scrub Brushes OFF

Right Scrub ON

Dual Side Broom Sweep ON

XXX

XXX X

HYDRAULIC MANIFOLD ASSEMBLY COMPONENT LOCATION KEY

Note: the combined electrical solenoid and hydraulic valve cartridge assembly can be serviced separately.

Notes: (A) The S1, S2, S3, S4 and S6 solenoid coils w/connectors are the same, and the S5 and S7 solenoid coils w/connectors are the same,

and can be swapped for troubleshooting purposes. (B) The S8 and S9 solenoid coils w/connectors are both different and only one of each is used. (C) The S1 and S4 valve cartridges are the same, the S2 and S3 valve cartridges are the same, and can be swapped for troubleshoot-

ing purposes. (D) The S5, S6, S7, S8 and S9 valve cartridges are all different and only one of each is used.

Item# Component Description and Hydraulic Circuit Function

LI/S1 Solenoid coil and valve cartridge, vacuum fan motor, coil 8 ohms

L2/S2 Solenoid coil and valve cartridge, squeegee lift cylinder DOWN (top), coil 8 ohms

L3/S3 Solenoid coil and valve cartridge, squeegee lift cylinder UP (bottom), coil 8 ohms

L4/S4 Solenoid coil and valve cartridge, scrub/sweep system motors, coil 8 ohms

L5/S5 Solenoid coil and valve cartridge, scrub pressure DN, proportional relief, coil 2.2 ohms

L6/S6 Solenoid coil and valve cartridge, scrub lift cylinder lock, coil 8 ohms

L7/S7 Solenoid coil and valve cartridge, scrub pressure UP, proportional relief coil 2.2 ohms

R1 Solenoid coil and valve cartridge, pressure relief, vacuum fan, 2700 psi

R2 Solenoid coil and valve cartridge, pressure relief, scrub brush(s), 2700 psi

L8/S8 Solenoid coil and valve cartridge, right scrub/sweep system, coil 8 ohms

L9/S9 Solenoid coil and valve cartridge, right scrub lift cylinder, coil 8 ohms

FORM NO. 56043124 - Condor XL™ - 81

HYDRAULIC SYSTEM

82 - FORM NO. 56043124 - Condor XL

™

HYDRAULIC SYSTEM

FORM NO. 56043124 - Condor XL™ - 83

APPENDIX TABLE 2 – ELECTRICAL INPUT/OUTPUT TABLE MAIN CONTROL BOARD

Ladder Diagram: 56111804 Main PCB Assembly: 56111781 Main (Control) PCB: 56111782 Main PCB Schematic: 56111783

Pin ID

* = no connec-

tion on Rev C

Board

J1-1 Input Engine Run

J1-2 CANbus CANL Canbus (-) 0-5V J1-3

J1-3 CANbus CANH Canbus (+) 0-5V J1-2

J1-7 Input

J1-10 5V output

J1-11

J1-12 Input

J1-16 Input

J1-18 Ground Ground Ground 0V B- Ground

J1-19 Input

J1-20 Input

J1-21 Input

J1-22 Output Start Inhibit

J1-24 Input

J1-25 Input

Designa-

tion

Ground

Output

Pin As-

signment

Fuel Level

Sensor

(gas and

diesel)

Throttle Position (3.3V-A)

Throttle Position

Ground

Ignition

Input Volt-

age

Horn

Switch

Hydraulic

Fluid Temp

Brake

Pedal

Switch

Solution

Empty Switch

Start KEY-

POS Switch

Check

Engine

Switch

Signal Char-

acteristic

Digital Volt-

age

Variable

Resistance

3.3v-A +3.3V B-

Ground 0V B-

Analog Volt-

age

Digital Volt-

age

Variable

Resistance

Digital Volt-

age

Digital Volt-

age

Low Side

Driver

Digital Volt-

age

Digital Volt-

age

Nominal

Voltage at

Connec-

tor (when

activated)

0V (for Gas/

Propane);

B+ (for Diesel)

0.40-1.66V B-

B+ B-

0V B-

0.16-2.24V B-

0V B-

B+ B-

0V B-

Refer-

ence

To:

B-

Load Or Sup-

ply Charac-

teristics

Engine Control Module Output

Differential

Serial Data

Differential

Serial Data

Variable

Resistance to

Ground, 33-

240 ohms

Pedal Position Potentiometer

End 5K ohm

Pedal Position Potentiometer

End 5K ohm

System Volt-

age

Switch to

Ground

Variable

Resistance to

Ground, 12-

500 ohms

Switch to

Ground

Switch to

Ground

MOSFET Gate

On Relay

PCB Assy. - 3

Ma@12V

System Volt-

age

Engine Control

Module Low Side Output

Comments

Switch to ground, ground = run, ﬂ oat = not running (for Gas/ Propane); Switch to Vbat (for Propane)

User interface panel serial communication

Nominal voltage provided is subject to change if additional resolution is required

Drive pedal sensor High side

Drive pedal sensor Low side

From key switch Ignition position

Push button switch - ground or open - closed to activate horn

Closes when brake pedal released

Ground or open, closes when tank is empty

Ground or ﬂ oat

From key switch

Switch to ground,

84 - FORM NO. 56043124 - Condor XL

™

Pin ID

* = no connec-

tion on Rev C

Board

J1-27 Input

J1-30 Input

J1-31 Input

J1-32 Input

J1-33 Input

J1-34 Output

J2-1 Output

J2-2 Output

J2-3 Output

J2-4 Output

J2-5 Output

J2-6 Output

J2-7 Output

J2-8

J2-10

J2-11 Output

Designa-

tion

Pin As-

signment

Recovery

Full Switch

Engine

Coolant

Temp

Throttle

Position

Sensor

Hydraulic Filter

Switch

Extend

Scrub Lvl

Switch

Ignition

Inhibit

Main Power

Relay

Side

Sweep/

Scrub

Solenoid

Side Scrub

Lift Sole-

noid

Scrub Lock

Solenoid

Squeegee

Down

Solenoid

Squeegee

Up Sole-

noid

Scrub Brush

Solenoid

Vacuum

Motor

Solenoid

Side Scrub

Solution

Solenoid

Backup Audible

Alarm

Signal Char-

acteristic

Digital Volt-

age

Analog Volt-

age

Analog Volt-

age

Digital Volt-

age

Digital Volt-

age

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Low Side

Driver

Nominal

Voltage at

Connec-

tor (when

activated)

0V B-

0.34-2.93 B-

0-5V B-

0V B-

Refer-

ence

To:

Load Or Sup-

ply Charac-

teristics

Switch to

Ground

Engine Control

Module Low Side Output

Pedal Position

Potentiometer

Wiper 5K ohm

Switch to

Ground

Switch to

Ground

MOSFET Gate

On Relay

PCB Assy. - 3

Ma@12V

Relay Coil -

0.29A@12V

Hydraulic Coil

- 1.5A@12V

Hydraulic Coil

- 1.5A@12V

Hydraulic Coil

- 1.5A@12V

Hydraulic Coil

- 1.5A@12V

Hydraulic Coil

- 1.5A@12V

Hydraulic Coil

- 1.5A@12V

Hydraulic Coil

- 1.5A@12V

Solution

Solenoid -

1.0A@12V

Elec-

tronic Alarm

0.25A@12V

Comments

Level switch, ground or open, opens when tank is full

Drive Pedal sensor wiper (0-5K ohm)

Ground or open, closed when ﬁ lter plugged

Ground or open, closed when tank is empty

Ground or ﬂ oat

46 ± 5 ohms

8 ohms @ 20°C

11W

FORM NO. 56043124 - Condor XL™ - 85

Pin ID

* = no connec-

tion on Rev C

Board

J2-12 Power (B+)

Designa-

tion

Pin As-

signment

Circuit

Breaker 4

Signal Char-

acteristic

Power 12-15VDC B-

Nominal

Voltage at

Connector (when activated)

Refer-

ence

To:

Load Or Sup-

ply Charac-

teristics

System Volt-

(VACC4)

J2-13 Output

Glow Plug

Relay

Low Side

Driver

0V B-

Relay Coil -

0.29A@12V

J2-17 Ground Ground Ground 0V B- Ground

J2-18 Ground Ground Ground 0V B- Ground

J2-22 Output

J2-23 Power (B+)

Main

Solution

Solenoid

Circuit

Breaker 5

Low Side

Driver

0V B-

Power 12-15VDC B-

Solution

Solenoid -

1.5A@12V

System Volt-

(VACC5)

J2-24 Output

J2-26 Output

J2-29 Output

J2-30 Output

J2-31 Output

J2-32 Output

J2-33 Output

J2-34 Output

J2-35 Output

J3-1 Power (B+)

Scrub Pres-

sure Up

Scrub Pres-

sure Down

ECM En-

gine 2200

RPM

ECM En-

gine 2400

RPM

Left Front

Turn Lamp

Right Front Turn Lamp

Left Rear

Stop/Turn

Right Rear

Stop/Turn

Extended

Scrub Pump

Circuit

Breaker 1

Low Side

PWM Driver

Low Side

PWM Driver

High Side

Driver

High Side

Driver

High Side

Driver

High Side

Driver

High Side

Driver

High Side

Driver

Low Side

PWM Driver

PWM 0-12V B-

12V B-

PWM 0 -

12V

Power 12-15VDC B-

B-

Hydraulic Coil

- 2.1A@12V

Hydraulic Coil

- 2.1A@12V

Engine Control

Module Input

Engine Control

Module Input

Incandescent

Lamp -

0.33A@12V

Incandescent

Lamp -

0.33A@12V

Incandescent

Lamp -

2.2A@12V

Incandescent

Lamp -

2.2A@12V

Pump Motor

11.5FLA @

12V, 46 LRA

System Volt-

(VACC1)

Pump Motor

11.5FLA @

12V, 46 LRA

Actuator Motor

20 ± 2FLA,

80LRA (Est.)

J3-2 Output

J3-4 Output

Main Solu-

tion Pump

Side Sweep

Actuator

- HI

(Red Lead)

Low Side

PWM Driver

H-Bridge

Driver

PWM 0 -

12V

12V B-

B-

age

Comments

Power from circuit breaker 4 (20A)

46 ± 5 ohms

17W

Power from circuit breaker 5 (10A)

2.2 ohms @ 20°C

12V for 2400 RPM, ﬂ oat other- wise

12V for 2200 RPM, ﬂ oat other- wise

0.4A@14.5V (4W turn lamp)

2.7A@14.5V (26W stop and turn lamp)

5KHz variable duty cycle

Power from circuit breaker 1 (20A)

5KHz variable duty cycle

Bridge (switching power/ground) (+) for Down, otherwise open

86 - FORM NO. 56043124 - Condor XL

™

Pin ID

* = no connec-

tion on Rev C

Board

Designa-

tion

Pin As-

signment

Signal Char-

acteristic

Nominal

Voltage at

Connec-

tor (when

activated)

Refer-

ence

To:

Load Or Sup-

ply Charac-

Side Sweep

J3-5 Output

Actuator

- LO

(Black

H-Bridge

Driver

0V B-

Actuator Motor

20 ± 2FLA,

80LRA (Est.)

Lead)

Side Sweep

J3-7 Output

Actuator -

MID

(White,

Common

H-Bridge

Driver

B+ or 0V B-

Actuator Motor

20 ± 2FLA,

80LRA (Est.)

Lead)

Incandescent

9.3@12V

System Volt-

J3-8 Output

J3-9 Output

Head / Tail

Lamps

Circuit

Breaker 1

High Side

Driver

12V B-

Power 12-15VDC B-

(VACC1)

J3-11 Ground Ground Ground 0V B- Ground

J3-12 Ground Ground Ground 0V B- Ground

J3-13 Ground Ground Ground 0V B- Ground

J3-14 Power (B+)

Circuit

Breaker2

Power 12-15VDC B-

System Volt-

(VACC2)

J3-15 Power (B+)

Circuit

Breaker 2

Power 12-15VDC B-

System Volt-

(VACC2)

J3-16 Power (B+)

Circuit

Breaker 3

Power 12-15VDC B-

System Volt-

(VACC3)

Electromag-

netic Horn

4A@12V

Pump Motor

3.9 FLA @

24V, 16 LRA

Pump Motor

12.5FLA@12V,

J3-17 Output Horn

J3-18 Output

J3-19 Output

J3-20 Output

J3-21 Output

J3-22 Output

J3-23 Output

Side Sweep

Mist Pump

AXP Chem

Pump 2 (-)

AXP Chem Pump 2 (+)

AXP Chem

Pump 1 (-)

AXP Chem

Pump 1(+)

Wand Solu-

tion Pump

Low Side

Driver

Low Side

Driver

H-Bridge

Driver

H-Bridge

Driver

H-Bridge

Driver

H-Bridge

Driver

Low Side

Driver

0V B-

0 to B+ B- 0.65a @ 12v

0V B-

Note: B- = Ground = 0V, B+ = system voltage = 12-15VDC

teristics

Lamp -

age

50 LRA

Comments

Bridge (switching power/ground) (-) for Up, otherwise open

Bridge (switching power/ground) (+) for Up, (-) for Down

11.3A@14.5V (2x 50W headlamp, 2x 5.6W tail lamp)

Power from circuit breaker 1 (20A)

Power from circuit breaker 2 (20A)

Power from circuit breaker 3 (15A)

24V pump operated at 12V

Pulsed on and off at a rate less than 10 Hz

FORM NO. 56043124 - Condor XL™ - 87

xxx

xxxxxxx

)

APPENDIX FAULTS

Inputs

[Name used in program code] Comments

same fault line used for clean and recycle

up and down pressure valves on same fault

line

same fault line used for clean and recycle

FAULT_RECYCLE_SOLUTION_SOLENOID not used

different reasons

ane

diesel only - causes ENGINE_FAULT_FLG

to be set

coolant temperature high - causes

ENGINE_FAULT_FLG to be set on diesel

machines

occurs if engine temp too high (diesel), oil

pressure low (diesel), or if engine run has

changed to false and key is on (gas &

set when ECM activates MIL output - could

be for man

Set if hydraulic temperature exceeds 220°F

for 15 seconds

Set if hydraulic temperature greater than or

equal to 100°F AND hydraulic filter input is

active.

Inputs (logic ORed unless specified)

[Name used in flow charts]

09 VACUUM_FAULT_FLG FAULT_VACUUM_MOTOR_SOLENOID

11 SQUEEGEE_UP_FAULT_FLG FAULT_SQUEEGEE_UP_SOLENOID

12 SQUEEGEE_DOWN_FAULT_FLG FAULT_SQUEEGEE_DOWN_SOLENOID

13 SCRUB_MOTOR_FAULT_FLG FAULT_SCRUB_BRUSH_SOLENOID

Fault

Code

System Fault Name

RECOVERY_SYSTEM_FAULT_FLG set if any of the following are set

other fault

control board fault

non-critical fault

critical fault

recycle system

Inhibits:

side mist system

side sweep system

side scrub system

chemical system

solution system

scrub system

recovery system

sort

15 SCRUB_LOCK_FAULT_FLG FAULT_SCRUB_CYLINDER_LOCK_SOLENOID

SCRUB_SYSTEM_FAULT_FLG set if any of the following are set

x x 01 SCRUB_PRESSURE_FAULT_FLG FAULT_SCRUB_PRESSURE

07 SOLUTION_VALVE_FAULT_FLG FAULT_MAIN_SOLUTION_SOLENOI

31 CHEMICAL_PUMP1_FAULT_FLG

32 CHEMICAL_PUMP2_FAULT_FLG

18 SIDE_SCRUB_LIFT_FAULT_FLG FAULT_SIDE_SCRUB_LIFT_SOLENOID

SOLUTION_SYSTEM_FAULT_FLG set if any of the following are set

CHEMICAL_SYSTEM_FAULT_FLG set if any of the following are set

SIDE_SCRUB_SYSTEM_FAULT_FLG set if any of the following are set

x x 00 SOLUTION_PUMP_FAULT_FLG FAULT_SOLUTION_PUMP

16 SIDE_CLEAN_MOTOR_FAULT_FLG FAULT_SIDE_SWEEP_SCRUB_SOLENOID

08 SIDE_SOLUTION_FAULT_FLG FAULT_SIDE_SCRUB_SOLUTION_SOLENOID

30 SIDE_SWEEP_LIFT_FAULT_FLG FAULT_ACTUATOR

16 SIDE_CLEAN_MOTOR_FAULT_FLG FAULT_SIDE_SWEEP_SCRUB_SOLENOID

04 SIDE_MIST_PUMP_FAULT_FLG FAULT_SIDE_SWEEP_MIST_PUMP

SIDE_SWEEP_SYSTEM_FAULT_FLG set if any of the following are set

SIDE_MIST_SYSTEM_FAULT_FLG set if any of the following are set

RECYCLE_SYSTEM_FAULT_FLG set if any of the following are set

05 2200RPM_OUT_FAULT_FLG FAULT_ECM_2200

ENGINE_SPEED_FAULT_FLG set if any of the following are set

x x 00 SOLUTION_PUMP_FAULT_FLG FAULT_SOLUTION_PUMP

06 2400RPM_OUT_FAULT_FLG FAULT_ECM_2400

10 RECYCLE_SOLUTION_VALVE_FAULT_FL

03 SPRAY_HOSE_FAULT_FLG FAULT_WAND_SOLUTION_PUMP

19 HORN_FAULT_FLG FAULT_HORN

17 BACKUP_ALARM_FAULT_FLG FAULT_BACKUP_ALARM

02 MAIN_RELAY_FAULT_FLG FAULT_MAIN_POWER_RELAY inhibits ALL functions

25 VACC1_FAULT_FLG FAULT_VACC1

26 VACC2_FAULT_FLG FAULT_VACC2

27 VACC3_FAULT_FLG FAULT_VACC3

28 VACC4_FAULT_FLG FAULT_VACC4

29 VACC5_FAULT_FLG FAULT_VACC5

20 LEFT_TURN_FAULT_FLG FAULT_LEFT_TURN_LAMP

21 RIGHT_TURN_FAULT_FLG FAULT_RIGHT_TURN_LAMP

23 LEFT_STOP_FAULT_FLG FAULT_LEFT_STOP_LAMP

24 RIGHT_STOP_FAULT_FLG FAULT_RIGHT_STOP_LAMP

22 HEAD_TAIL_LAMP_FAULT_FLG FAULT_HEAD_LAMPS

14 GLOW_PLUG_OUT_FAULT_FLG FAULT_GLOW_PLUG_RELAY diesel model only

35 LOW_VOLTAGE_FAULT_FLG low voltage when engine is running

xxxxxxxx x x 33 ENGINE_HOT_FLG

xxxxxxxx x x 37 LOW_OIL_PRESSURE_FLG

x x 36 SERVICE_ENGINE_FLG

xxxxxxxx x x 38 ENGINE_FAULT_FLG

x 39 HYDRAULIC_FILTER_FAULT_FLG

x 34 HYDRAULIC_TEMP_FAULT_FLG

88 - FORM NO. 56043124 - Condor XL

™

FORM NO. 56043124 - Condor XL - 89

Item Description

1 Solution Tank 2 Solution Flow Control Valve 3 Solution Filter 4 Main Solution Pump (M4) 5 Main Solution Valve (L10) 6 *Right Solution Valve (L11) 7 Solution Tank Drain Hose

* = Only if equipped with Right Front Scrub.

APPENDIX

SOLUTION FLOW DIAGRAM - STANDARD WITH RIGHT FRONT SCRUB

90 - FORM NO. 56043124 - Condor XL

Item Description

1 Solution Tank 2 Solution Flow Control Valve 3 Solution Filter 4 Main Solution Pump (M4) 7 Solution Tank Drain Hose 8 Mist Pump (M5) 9 Wand Pump (M8) 10 Mist Spray Nozzles 11 Wash Hose Spray Gun

A = Solution ﬂ ow to the scrub deck see “Solution Flow Diagram – Standard with Right Front Scrub” for more details.

SOLUTION FLOW DIAGRAM - ACCESSORIES

APPENDIX

FORM NO. 56043124 - Condor XL - 91

Item Description

1 Solution Tank 2 Solution Flow Control Valve 3 Solution Filter 4 Main Solution Pump (M4) 5 Main Solution Valve (L10) 7 Solution Tank Drain Hose 12 Reducer Tee 13 Y Barb Fitting 14 Detergent Pumps (M10 & M11) 15 Detergent Tank

B = Location for the Right Front Scrub Tee if equipped.

C = Location for the Extended Scrub Tee if equipped.

APPENDIX

SOLUTION FLOW DIAGRAM - AXP

92 - FORM NO. 56043124 - Condor XL

Item Description

1 Solution Tank 2 Solution Flow Control Valve 3 Solution Filter 4 Main Solution Pump (M4) 5 Main Solution Valve (L10) 7 Solution Tank Drain Hose 16 Extended Scrub Pump (M6) 17 Solution Coupler Quick Disconnect 18 Strainer 19 Float Switch 20 Float Wiring Quick Disconnect 21 Recovery Tank

B = Location for the Right Front Scrub Tee if equipped.

D = Location for the AXP Tee if equipped.

SOLUTION FLOW DIAGRAM - EXTENDED SCRUB

APPENDIX

FORM NO. 56043124 - Condor XL - 93

APPENDIX

HYDRAULIC SCHEMATIC

94 - FORM NO. 56043124 - Condor XL

APPENDIX

WIRING DIAGRAM - W/GM ENGINE

Item Description

A2 Gasoline Sensor, Assy BT Battery 12V CB1 Circuit Breaker, 20 Amp (lights) CB2 Circuit Breaker, 20 Amp CB3 Circuit Breaker, 15 Amp (actuator) CB4 Circuit Breaker, 20 Amp CB5 Circuit Breaker, 10 Amp CB6 Circuit Breaker, 15 Amp

F1 Fuse, 100 Amp

H3 Back-Up Alarm (optional) H4 Horn

K1 Relay, Power K2 Relay, Run K3 Relay, Start K4 Relay, Glow Plugs

L1 Vacuum Fan Valve, S1 L2 Squeegee Down Valve, S2 L3 Squeegee Up Valve, S3 L4 Scrub Brush Valve, S4 L5 Scrub Pressure Proportional Down Valve, S5 L6 Scrub Cylinder Lock Valve, S6 L7 Scrub Pressure Proportional Up Valve, S7 L8 Side Sweep/Scrub Valve, S8 L9 Side Scrub Lift Valve, S9 L10 Main Solution Valve L11 Right Solution Valve

LP1 Headlight, Right LP2 Headlight, Left LP3 Lamp, Right Rear S/T/T LP4 Lamp, Left Rear S/T/T LP5 Lamp, Right Front Turn LP6 Lamp, Left Front Turn LP7 Beacon

Item Description

M2 Fuel Pump (Gasoline/Petrol) M4 Pump, Solution M5

Pump, Mist (optional)

Pump, Ext. Scrub (optional)

M7 Actuator, Side Broom M8 Pump, Wand (optional) M10 Pump, Chemical 1 M11 Pump, Chemical 2

R1 Drive Pedal Sensor, 5K Ohm R2 Sender, Hydraulic Oil Temp R3 Sender, Fuel (Petrol and Diesel models only) S1 Switch, Ignition S2 Switch, Recovery Full S3 Switch, Solution Empty S4 Switch, Hydraulic Filter S5 Switch, Low LP Pressure (LPG only) S6 Switch, Brake S7 Switch, Extended Scrub S29 Switch, Push Button, Horn

BLK

RED/VIO

RED

BLU

ORN

ORN/RED

YEL/BLUORN

ORN

BLK/WHT

PINK/YEL

GRN/VIO

ORN

RED

RED/VIO

PINK/YEL

RED

BLK

ORN YEL/GRN

BLU/YEL

ORN WHT/VIO

ORN REDRED/VIO

RED/VIOVIO

GRN/YELGRN/YEL

PINK

RED/YEL

VIO/YEL

GRA/YEL BLK

BLK

VIO/WHT BLK

BLK BLK BLK BLK

BLK

GRA/ORNGRA/ORN

RED

BLU/PINK BLU/PINK

PINKPINK

VIO/GRA

VIO/BRN

WHT/BRN

VIO

RED/VIOGRN/BRN

BLU

GRN/BRN

ORN

YEL/BLKBLU

GRN/ORN

VIO/BLUVIO/BLU

BLK

BLK/GRN

GRN/WHT

GRN/RED

WHT/GRN

BLK/GRN

GRN/WHT

GRN/RED

WHT/GRN

WHT/ORN

PURPLEPINK

BLK/RED BLK/REDGRA/RED

RED/VIO

GRA/RED

BLKORN/GRN

YEL/WHT

BRN/WHTGRA

VIO/GRA

BLKBRN/BLU

GRA/BLK

YEL/RED

GRA/VIO

YEL/GRA

ORN/GRA

WHT/RED

BLU/BRN

BRN/WHT

YEL

BRN

ORN/BRN

ORN/BRN GRN

YEL/RED

YEL BLK

BRN

GRN

BLK

BRN

BLK

BRN

BLKBRN

BLK

VIO/BRN

ORN/GRN

PINK

BLU/PINK

VIO/GRA

BLK

BLK/YEL

ORN/BLK

BLU/GRN

ORN/GRN

GRA/BLUGRA/BLU

GRN/BRN GRA/ORN

BLU/REDBLU

GRN/BLU

BLKRED/BLK

ORN/GRN

BLU/BLK

WHT/YEL

GRN/BRN

RED/BLU

RED/WHT

BLK/RED

BLK/YEL

BLU

ORN/BLU

BRN/YEL

RED/GRA

BRN/GRN

NOTES UNLESS OTHERWISE

SPECIFIED

1. ALL DIMENSIONS IN INCHES.

2. DO NOT SCALE DRAWING.

3. ALL DIMENSIONS APPLY AFTER PLATING AND HEAT TREATING, BUT BEFORE PAINTING.

4. REMOVE ALL BURRS AND SHARP EDGES.

J3-22

J3-19

J2-4

STARTER B+

MIL OUTPUT (SWITCHED GROUND)

FUEL PUMP (+)

THROTTLE INPUT (12V FOR 2200 RPM)

GROUND

J3-18

J2-3

J2-2

DRIVER BOX

J3-21

(REFERENCE: E-CONTROLS, INC. DRAWING NO. 33000701 AND 33000702)

COOLANT TEMPERATURE OUTPUT

ENGINE SYSTEM

J2-35

J1-21

J1-32

J1-33

J1-20

J1-27

J1-25

(OPENS WHEN TANK IS FULL)

(CLOSES WHEN TANK IS EMPTY)

(CLOSES WHEN FILTER IS PLUGGED)

(CLOSES WHEN BRAKE PEDAL RELEASED)

J2-29

IGN. SW INPUT

START COMAND

START_KEYPOS

J1-22

START_INHIBIT

J1-34

J3-16

J3-14 J3-15

J2-23

J2-12

J1-30

NOTE: R3 IS USED ON PETRO AND DIESEL ONLY

J1-7

J2-13

ALT. EXCITE

J1-3 (CAN+) J1-2 (CAN-)

DASHBOARD PANEL

J6-3 (CAN+) J6-4 (CAN-)

J6-1 (B+) J6-2 (B-)

IGNITION INHIBIT

J3-1 J3-9

J1-19

J1-18 J2-17 J2-18 J3-11 J3-12 J3-13

J1-1 RUN SIGNAL (GROUND)

FUEL PUMP (-)

(CLOSES WHEN TANK IS EMPTY)

NOTE: S5 IS USED ON LPG ONLY

J3-4

M7 ACTUATOR MOTOR WIRING: (-) WHITE & (+) RED = CW (EXTEND) (+) WHITE & (-) BLACK = CCW( RETRACT) WHITE = COMMON

J1-31

J3-5

J3-7

J1-10

J1-11

J2-34 J2-33 J2-32 J2-31

J3-8

J7-6

J7-3

IGNITION_KEYPOS

J1-12

J7-8

J7-5

J7-7

J7-2

ENGINE START

ENGINE RUN

IGNITION_KEYPOS

J7-1

GROUND

J7-4

B+

RELAY PCB

(VACC1)

(VACC3)

(VACC2)

(VACC5)

(VACC4)

J2-1

J1-24

TWISTED PAIR TWISTED PAIR

THROTTLE INPUT (12V FOR 2400 RPM)

J2-30

J3-2

J3-23

J1-16

J3-20

J2-11

J3-17

J2-22

J2-10

J2-24

J2-26

J2-7

J2-8

J2-5

J2-6

CHEMICAL PUMP REAR VIEW

CONDOR XL W/GM ENGINE SYSTEM

LP4

LAMP, LEFT REAR S/T/T

LP4

LAMP, LEFT REAR S/T/T

BLK RED

WHT

CB4

CIRCUIT BREAKER, 20A.

CB4

CIRCUIT BREAKER, 20A.

PUMP, SOLUTION

1 2

VAC FAN S1L1VAC FAN S1

1 2

M10

PUMP, CHEMICAL 1

M10

PUMP, CHEMICAL 1

FUEL PUMP

SENSOR, GASOLINE

(GM ENGINE)

SENSOR, GASOLINE

(GM ENGINE)

L10

VALVE, MAIN SOLUTION

L10

VALVE, MAIN SOLUTION

1 2

L11

VALVE, RIGHT SOLUTION

L11

VALVE, RIGHT SOLUTION

1 2

SCRUB PRESSURE PROPORTIONAL DOWN (S5)

1 2

HORNH4HORN

1 2

X2X2

LP1

HEAD LIGHT, RIGHT

LP1

HEAD LIGHT, RIGHT

1 2

SWITCH, SOLUTION EMPTY

START RELAYK3START RELAY

SWITCH, RECOVERY FULL

X1X1 A A

SIDE SCRUB LIFT (S9)

1 2

SENDER, HYDRAULIC OIL TEMP

1 2

SQUEEGEE UP S3L3SQUEEGEE UP S3

1 2

SENDER, FUELR3SENDER, FUEL

1 2

CB3

CIRCUIT BREAKER, 15 A. (ACTUATOR)

CB3

CIRCUIT BREAKER, 15 A. (ACTUATOR)

LP2

HEAD LIGHT, LEFT

LP2

HEAD LIGHT, LEFT

1 2

X2X2

X1X1

X2X2

LP6

LAMP,LEFT FRONT TURN

LP6

LAMP,LEFT FRONT TURN

1 2

SWITCH, HYDRAULIC FILTER

1 2

SCRUB CYLINDER LOCK (S6)

1 2

CB1

CIRCUIT BREAKER, 20 A. (LIGHTS)

CB1

CIRCUIT BREAKER, 20 A. (LIGHTS)

SWITCH, IGN.S1SWITCH, IGN.

SWITCH, BRAKES6SWITCH, BRAKE

1 2

LP3

LAMP, RIGHT REAR S/T/T

LP3

LAMP, RIGHT REAR S/T/T

BLK RED

WHT

CB5

CIRCUIT BREAKER, 10A.

CB5

CIRCUIT BREAKER, 10A.

X2X2

RELAY, GLOWPLUGS

PUMP, MIST (OPTIONAL)

X1X1 F F

CB6

CIRCUIT BREAKER, 15 A. CB6

CIRCUIT BREAKER, 15 A.

LP7

BEACON

LP7

BEACON

1 2

SCUB BRUSH S4L4SCUB BRUSH S4

1 2

X1X1

CB2

CIRCUIT BREAKER, 20 A.

CB2

CIRCUIT BREAKER, 20 A.

12 VDCBT12 VDC

+ -

LP5

LAMP, RIGHT FRONT TURN

LP5

LAMP, RIGHT FRONT TURN

1 2

SIDE SWEEP/SCRUB (S8)

1 2

SWITCH, LOW LP PRESSURE

1 2

PUMP, WAND (OPTIONAL)

S29

SWITCH, PUSH BUTTON, HORN

S29

SWITCH, PUSH BUTTON, HORN

1 2

RELAY, POWERK1RELAY, POWER

DRIVE PEDAL SENSOR, 5K OHM

123

FUSE, 100 A.F1FUSE, 100 A.

1 2

RUN RELAYK2RUN RELAY

X78X78 A

RELAY, POWERK1RELAY, POWER

3087

SQUEEGEE DOWN S2

1 2

X1X1 B B

1 2

ACTUATOR, SIDE BROOM

BLK

RED

WHT

PUMP, EXT. SCRUB (OPTIONAL)

SCRUB PRESSURE PROPORTIONAL UP (S7)

1 2

M11

PUMP, CHEMICAL 2

M11

PUMP, CHEMICAL 2

SWITCH, EXTENDED SCRUB

BLKWHT

X1X1

G G

BACK UP ALARM

(OPTIONAL)

BACK UP ALARM

(OPTIONAL)

1 2

FORM NO. 56043124 - Condor XL - 95

APPENDIX

BLK

RED/VIO

RED

BLU

ORN

ORN/RED

YEL/BLUORN

ORN

BLK/WHT

GRN/VIO

ORN

RED

RED/VIO

BLK

ORN YEL/GRN

BLU/YEL

ORN WHT/VIO

ORN REDRED/VIO

RED/VIOVIO GRN/YEL

PINK

RED/YEL

VIO/YEL

GRA/YEL BLK

BLK

VIO/WHT BLK

BLK BLK BLK BLK

BLK

GRA/ORN

VIO/GRA

VIO/BRN

WHT/BRN

VIO

RED/VIOGRN/BRN

BLU

GRN/BRN

ORN

YEL/BLKBLU

GRN/ORN

BLK

WHT/ORN

GRA/RED

RED/VIO

GRA/RED

BLKORN/GRN

YEL/WHT

GRA

VIO/GRA

BLKBRN/BLU

GRA/BLK

YEL/RED

GRA/VIO

YEL/GRA

ORN/GRA

WHT/RED

BLU/BRN

BRN/WHT

YEL

BRN

ORN/BRN

ORN/BRN GRN

YEL/RED

YEL BLK

BRN

GRN

BLK

BRN

BLK

BRN

BLK

VIO/BRN

ORN/GRN

PINK

BLU/PINK

VIO/GRA

BLK

BLK/YEL

ORN/BLK

BLU/GRN

ORN/GRN

GRA/BLU

GRN/BRN GRA/ORN

BLU/REDBLU

GRN/BLU

BLKRED/BLK

ORN/GRN

BLU/BLK

WHT/YEL

GRN/BRN

RED/BLU

RED/WHT

BLK/RED

BLK/YEL

BLU

ORN/BLU

BRN/YEL

RED/GRA

BRN/GRN

RED/YEL

BLK

GRA

VIO

GRA

RED

BLK

BLU/PINK

BLK

RED

GRA/BRN BLK/RED

GRA/BRN

PINK/YEL

BLK

RED

GRA/BRN

RED

BLK

GRN/RED

BLK

RED RED

PINK

BLU/PINK

VIO/BLU BLU/PINK

REDRED

PINKPINK

GRN/YEL

GRA

RED

DWG. NO. SHEET

AGREES TO RETURN IT UPON REQUEST.

PLYMOUTH, MINNESOTA AND IT HAS BEEN ISS

DUCED NOR COPIED NOR USED FOR ANY PUR

THIS

DRAWING AND THE DESIGN REPRESENTE

REV

NOTES UNLESS OTHERWISE

SPECIFIED

1. ALL DIMENSIONS IN INCHES.

2. DO NOT SCALE DRAWING.

3. ALL DIMENSIONS APPLY AFTER PLATING AND HEAT TREATING, BUT BEFORE PAINTING.

4. REMOVE ALL BURRS AND SHARP EDGES.

APPROVED

CHECKED

TITLE

DRAWN

PROJ ENG

BILL OF MATERIAL

J3-22

J3-19

J2-4

J3-18

J2-3

J2-2

DRIVER BOX

J3-21

J2-35

J1-21

J1-32

J1-33

J1-20

J1-27

J1-25

(OPENS WHEN TANK IS FULL)

(CLOSES WHEN TANK IS EMPTY)

(CLOSES WHEN FILTER IS PLUGGED)

(CLOSES WHEN BRAKE PEDAL RELEASED)

J2-29

START_KEYPOS

J1-22

START_INHIBIT

J1-34

PMO

J3-16

J3-14 J3-15

J2-23

J2-12

2 OF 2

J1-30

NOTE: R3 IS USED ON PETRO AND DIESEL ONLY

J1-7

J2-13

J1-3 (CAN+) J1-2 (CAN-)

DASHBOARD PANEL

J6-3 (CAN+) J6-4 (CAN-)

J6-1 (B+) J6-2 (B-)

IGNITION INHIBIT

J3-1 J3-9

J1-19

J1-18 J2-17 J2-18 J3-11 J3-12 J3-13

J1-1

56110921

8-18-08

(CLOSES WHEN TANK IS EMPTY)

NOTE: S5 IS USED ON LPG ONLY

J3-4

M7 ACTUATOR MOTOR WIRING: (-) WHITE & (+) RED = CW (EXTEND) (+) WHITE & (-) BLACK = CCW( RETRACT) WHITE = COMMON

J1-31

J3-5

J3-7

J1-10

J1-11

J2-34 J2-33 J2-32 J2-31

J3-8

J7-6

J7-3

IGNITION_KEYPOS

J1-12

J7-8

J7-5

J7-7

J7-2

ENGINE START

ENGINE RUN

IGNITION_KEYPOS

J7-1

GROUND

J7-4

B+

RELAY PCB

(VACC1)

(VACC3)

(VACC2)

(VACC5)

(VACC4)

J2-1

J1-24

TWISTED PAIR TWISTED PAIR

J2-30

J3-2

J3-23

J1-16

WGL8-18-08

J3-20

J2-11

J3-17

J2-22

J2-10

J2-24

J2-26

J2-7

J2-8

J2-5

J2-6

ENGINE RUN SIGNAL

(2400 RPM)

(2200 RPM)

CONDOR XL W/KUBOTA DIESEL ENGINE SYSTEM

GLOW PLUGS

CHEMICAL PUMP REAR VIEW

(SHOWN IN LOW PRESSURE STATE)

RELAY, GLOW PLUG

30 87

SWITCH, EXTENDED SCRUB

BLKWHT

SCRUB PRESSURE PROPORTIONAL UP (S7)

1 2

X1X1 F

PUMP, WAND (OPTIONAL)

RUN RELAYK2RUN RELAY

X2X2

SWITCH, HYDRAULIC FILTER

1 2

SENDER, HYDRAULIC OIL TEMP

1 2

FUSE, 100 A.F1FUSE, 100 A.

1 2

ACTUATOR, SIDE BROOM

BLK

RED

WHT

SWITCH, LOW LP PRESSURE

1 2

DRIVE PEDAL SENSOR, 5K OHM

123

X1X1 G

RELAY, GLOWPLUGS

APECS 3000 GOVERNOR

B (+)

RED

B (-)

BLK

ACTUATOR (+)

WHT

ACTUATOR (-)

WHT/BLK

MAGNETIC PICKUP (+)

BLU

MAGNETIC PICKUP (-)

GRN

SPEED SELECT 1

VIO

SPEED SELECT 2

GRA

SERVICE TOOL (Tx)

YEL

SERVICE TOOL (Rx)

ORN

X113X113

X1X1 A

E1E1

PUMP, SOLUTION

X113X113

LP4

LAMP, LEFT REAR S/T/T

LP4

LAMP, LEFT REAR S/T/T

BLK RED

WHT

DIODED2DIODE

PUMP, EXT. SCRUB (OPTIONAL)

M11

PUMP, CHEMICAL 2

M11

PUMP, CHEMICAL 2

L10

VALVE, MAIN SOLUTION

L10

VALVE, MAIN SOLUTION

1 2

VAC FAN S1L1VAC FAN S1

1 2

BACK UP ALARM

(OPTIONAL)

BACK UP ALARM

(OPTIONAL)

1 2

CB4

CIRCUIT BREAKER, 20A.

CB4

CIRCUIT BREAKER, 20A.

1 2

STARTERM3STARTER

START RELAYK3START RELAY

SWITCH, IGN.S1SWITCH, IGN.

X1X1 B

X2X2

HORNH4HORN

1 2

L11

VALVE, RIGHT SOLUTION

L11

VALVE, RIGHT SOLUTION

1 2

SWITCH, BRAKES6SWITCH, BRAKE

1 2

LP2

HEAD LIGHT, LEFT

LP2

HEAD LIGHT, LEFT

1 2

X113X113

SQUEEGEE UP S3L3SQUEEGEE UP S3

1 2

SCRUB CYLINDER LOCK (S6)

1 2

M14

FUEL PUMP

M14

FUEL PUMP

S28

SWITCH, OIL PRESSURE

S28

SWITCH, OIL PRESSURE

NO NC

PUMP, MIST (OPTIONAL)

CB2

CIRCUIT BREAKER, 20 A.

CB2

CIRCUIT BREAKER, 20 A.

E2E2

CB6

CIRCUIT BREAKER, 15 A. CB6

CIRCUIT BREAKER, 15 A.

X140X140

E4E4

SWITCH, RECOVERY FULL

LP1

HEAD LIGHT, RIGHT

LP1

HEAD LIGHT, RIGHT

1 2

X140X140

X2X2

LP5

LAMP, RIGHT FRONT TURN

LP5

LAMP, RIGHT FRONT TURN

1 2

X113X113

CB3

CIRCUIT BREAKER, 15 A. (ACTUATOR)

CB3

CIRCUIT BREAKER, 15 A. (ACTUATOR)

LP6

LAMP,LEFT FRONT TURN

LP6

LAMP,LEFT FRONT TURN

1 2

SIDE SCRUB LIFT (S9)

1 2

CB1

CIRCUIT BREAKER, 20 A. (LIGHTS)

CB1

CIRCUIT BREAKER, 20 A. (LIGHTS)

SENDER, FUELR3SENDER, FUEL

1 2

X113X113

X140X140

I/F

ALTERNATOR

I/F

ALTERNATOR

LP7

BEACON

LP7

BEACON

1 2

LP3

LAMP, RIGHT REAR S/T/T

LP3

LAMP, RIGHT REAR S/T/T

BLK RED

WHT

SIDE SWEEP/SCRUB (S8)

1 2

DIODED3DIODE

CB5

CIRCUIT BREAKER, 10A.

CB5

CIRCUIT BREAKER, 10A.

RELAY, POWERK1RELAY, POWER

3087

S29

SWITCH, PUSH BUTTON, HORN

S29

SWITCH, PUSH BUTTON, HORN

1 2

RELAY, POWERK1RELAY, POWER

12 VDCBT12 VDC

+ -

X1X1

E3E3

SCUB BRUSH S4L4SCUB BRUSH S4

1 2

SWITCH, COOLANT TEMP.

1 2

SQUEEGEE DOWN S2

1 2

SCRUB PRESSURE PROPORTIONAL DOWN (S5)

1 2

M10

PUMP, CHEMICAL 1

M10

PUMP, CHEMICAL 1

SWITCH, SOLUTION EMPTY

Item Description

A5 APECS 3000 Governor BT Battery 12V CB1 Circuit Breaker, 20 Amp (lights) CB2 Circuit Breaker, 20 Amp CB3 Circuit Breaker, 15 Amp (actuator) CB4 Circuit Breaker, 20 Amp CB5 Circuit Breaker, 10 Amp CB6 Circuit Breaker, 15 Amp

D2 Diode D3 Diode

E1 Glow Plug E2 Glow Plug E3 Glow Plug E4 Glow Plug

F1 Fuse, 100 Amp

G2 Alternator

H3 Back-Up Alarm (optional) H4 Horn

K1 Relay, Power K2 Relay, Run K3 Relay, Start K4

Relay, Glow Plugs

LP1 Headlight, Right LP2 Headlight, Left LP3 Lamp, Right Rear S/T/T LP4 Lamp, Left Rear S/T/T LP5 Lamp, Right Front Turn LP6 Lamp, Left Front Turn LP7 Beacon

Item Description

M3 Starter M4 Pump, Solution M5 Pump, Mist (optional) M6 Pump, Ext. Scrub (optional) M7 Actuator, Side Broom M8 Pump, Wand (optional) M10 Pump, Chemical 1 M11 Pump, Chemical 2 M14 Fuel Pump

R1 Drive Pedal Sensor, 5K Ohm R2 Sender, Hydraulic Oil Temp R3 Sender, Fuel S1 Switch, Ignition S2 Switch, Recovery Full S3 Switch, Solution Empty S4 Switch, Hydraulic Filter S6 Switch, Brake S7 Switch, Extended Scrub S9 Switch, Coolant Temp. S28 Switch, Oil Pressure S29 Switch, Push Button, Horn

WIRING DIAGRAM - W/KUBOTA DIESEL ENGINE

96 - FORM NO. 56043124 - Condor XL

GRN/ORN 18-1

RED/YEL 18-1

RED 6-3

RED/VIO 12-4

RED/VIO 12-3

RED/VIO 12-2

RED/VIO 12-1

ORN 18-3

BLU/YEL 18-2

WHT/RED 16-2

BLU/BRN 16-2

GRA/VIO 16-2

ORN 18-2

BLU/YEL 18-1

WHT/RED 16-1

BLU/BRN 16-1

GRA/VIO 16-1

ORN 18-3

ORN 18-4

GRN 18-1

BLK 18-3

YEL 18-1

BLK 18-8 BLK 18-9

GRN 18-2

BLK 18-9

YEL 18-2

GRN/BRN 18-7

BRN/YEL 18-1

GRN/BRN 18-5

RED/GRA 18-1

GRN/BRN 18-6

BRN/GRN 18-1

ORN 18-13

YEL/BLU 18-1

ORN 18-8 ORN/BLU 18-1

ORN 18-12 ORN/RED 18-1

ORN 18-14

WHT/VIO 18-1

ORN 16-5

ORN 18-8

ORN 16-5

ORN 18-12

ORN 18-13

ORN 18-14

ORN 16-4

BLU 14-1

YEL/BLK 16-1

ORN/GRN 16-1

WHT/ORN 18-1

BLU/GRN 18-1

ORN/GRN 18-5

BLU/BLK 18-1

BLK 18-15

GRA/YEL 18-1

GRA/BLK 18-1

PINK/YEL 16-1

WHT/GRN 18-1

GRN/RED 18-1

GRN/WHT 18-1

BLK/GRN 18-1

GRN/WHT 18-1

GRN/RED 18-1

WHT/GRN 18-1

BRN 16-2

BRN 16-1

BRN 16-3

ORN/BRN 18-1

YEL/RED 18-1

BLK 16-8

ORN/BRN 18-2

YEL/RED 18-2

BRN 16-5

BLK 16-9

BRN 16-5 BRN 16-4 ORN/BRN 18-2

BRN 16-4 YEL/RED 18-2

WHT/YEL 18-1

WHT/RED 16-2

BLU/BRN 16-2

GRA/VIO 16-2

VIO/BRN 18-1

VIO/BRN 18-2

ORN/GRN 18-1

ORN/GRN 18-2

RED 8-1

GRN/RED 8-1

VIO/WHT 18-1

BLK 1-1

BLK 4-1

ORN 16-3

ORN 16-2

BRN 16-3

BRN 16-1

BRN 16-2

BLK 18-5

BLK 18-6

BLK 18-7

BLK 18-5

BLK 6-2

BLK 18-7

BLK 18-11

BLU 12-1

BLU 14-1

RED 1-1

BLK 1-1

GRN/BRN 18-8

GRN/BLU 16-1

BLK 4-1

BLK 18-14

BLK 18-13

BLK 18-14

BLK 18-15

BLK 16-8

BLK 16-10

BLK 16-9

BLK 16-10

BLK/RED 16-1

PINK 16-8

PINK 16-7

PINK 16-6

YEL/GRA 18-1

BRN/WHT 18-1

ORN/GRA 18-1

RED/VIO 12-5

BRN 16-6

VIO/GRA 16-2

RED 14-2

ORN/GRN 16-2

BLK 20-1

ORN/GRN 20-1

PINK 16-4

VIO/BRN 18-1

VIO/GRA 16-1

BLK 18-1

VIO/YEL 18-1

VIO/WHT 18-1

BLK 16-2 BLK 16-3

BLK 16-4

BLK 16-6

ORN/RED 18-1

BLK 16-1

YEL/WHT 18-1

ORN/GRN 18-3

BLU/PINK 16-1

WHT/BRN 18-1

PINK 16-7

PINK 16-8

BLK/RED 16-1

PINK/YEL 16-1

BLU/PINK 16-1

GRN/YEL 18-1

GRA 18-1

VIO/BLU 18-1

YEL 18-2

BLK 18-8

GRN 18-2

ORN 18-17

BLK/WHT 18-2

GRN/VIO 18-1GRN/VIO 18-2

BLK/WHT 18-1BLK/WHT 18-2

ORN 18-18

ORN 18-17

ORN 18-2

BLK 18-17

ORN 18-4

BLU/YEL 18-2

GRN/VIO 18-2

ORN 18-18

RED 14-2

VIO/GRA 16-1

VIO/GRA 16-2

ORN/GRA 18-1

BLK 18-6

BLK 18-3

BLK 18-11 BLK 18-10

BLK 18-17

BLK 18-1

BLK 16-3 BLK 16-4

BLK 16-2

BLK 16-1

BLK 16-5 BLK 16-6

BLK 6-2

BLK 20-1

BLK 18-12

BRN/BLU 18-1

GRN/BRN 18-2

GRA/ORN 18-2

BLK 18-12

PINK 16-5

BLK 18-10

ORN 16-4

ORN 18-6

BLK/YEL 20-1

ORN/BLK 20-1

BLK 16-5

BLU/BLK 18-1

ORN/BLK 20-1

GRN/YEL 18-1

BLK/WHT 18-1

VIO/BRN 18-2

ORN/GRN 18-1

WHT/BRN 18-1

YEL/WHT 18-1

BLK/YEL 20-1

BRN 16-6

YEL/RED 18-1

ORN/BRN 18-1

GRN 18-1

YEL 18-1

VIO/BLU 18-1

BRN/WHT 18-1 YEL/GRA 18-1

GRA/BLK 18-1

GRN/ORN 18-1

GRA/YEL 18-1

RED/YEL 18-1 BRN/BLU 18-1

ORN/GRN 16-2

GRA/BLU 18-1

GRA/ORN 18-1

GRA 18-1

GRA/ORN 18-2

ORN/GRN 18-4

ORN 16-3

BLU/GRN 18-1

VIO/YEL 18-1

BLK 18-13

BLU 14-3

BLU/RED 16-1

BLK 18-4

RED/BLK 18-1

BLU 14-3

ORN/GRN 16-1

GRN/VIO 18-1 YEL/BLU 18-1 RED/GRA 18-1 BRN/GRN 18-1 ORN/BLU 18-1

BLU/YEL 18-1

BRN/YEL 18-1

ORN 16-1

YEL/GRN 18-1 GRN/BRN 18-3

WHT/VIO 18-1

GRA/ORN 18-1 GRA/BLU 18-1

GRN/BLU 16-1

BLU/BRN 16-1

WHT/RED 16-1

GRA/VIO 16-1

GRA/RED 16-1

GRA/RED 16-2

BLU 16-3

WHT/YEL 18-1

YEL/BLK 16-1

BLU/RED 16-1

ORN 18-6

YEL/GRN 18-1

PINK 16-5 PINK 16-6

PINK 16-4

BLK/RED 18-1

BLK/YEL 18-1

RED/BLU 18-1

RED/WHT 18-1

BLK/RED 18-1

BLK/YEL 18-1

RED/BLU 18-1

RED/WHT 18-1

RED/VIO 12-3

BLU 12-1

BLU 16-1

GRA/RED 16-1

GRA/RED 16-2

RED/VIO 12-5

RED/VIO 12-4

VIO 18-1

RED/VIO 12-1

ORN 16-2

ORN 16-1

GRN/BRN 18-2

RED/VIO 12-2

GRN/BRN 18-1

VIO 18-1 BLU 16-2

ORN/GRN 18-2

ORN/GRN 18-4

ORN/GRN 18-5

ORN/GRN 18-3

BLU 16-1

BLU 16-2

BLU 16-3

WHT/ORN 18-1

GRN/BRN 18-1

GRN/BRN 18-3

GRN/BRN 18-4

GRN/BRN 18-5

GRN/BRN 18-6

GRN/BRN 18-7

GRN/BRN 18-8

RED 1-1

RED 6-2

GRN/RED 8-1

UNITS IN [ ] ARE ISO METRIC

DIM. IN [ ] ARE MM.

NOTES UNLESS OTHERWISE

SPECIFIED

1. ALL DIMENSIONS IN INCHES.

2. DO NOT SCALE DRAWING.

3. ALL DIMENSIONS APPLY AFTER PLATING AND HEAT TREATING, BUT BEFORE PAINTING.

4. REMOVE ALL BURRS AND SHARP EDGES.

APPROVED

CHECKED

DRAWN

PROJ ENG

DASHBOARD PANEL ASSY

ENGINE SYSTEM SEE SHEET 2

TO GLOW PLUGS

TO STARTER

NOTE: S5 IS USED IN PLACE OF R3 ON LPG MODELS

8-18

E: EF. LADDER DIAGRAM 56111804

8-18

SP16SP16

S29 SWITCH, PUSH BUTTON, HORN

X15X15

X2X2

NPR

LP6

LAMP, RIGHT FRONT TURN

LP6

LAMP, RIGHT FRONT TURN

WHT BLK

CB5

CIR. BREAKER, 10 AMP VACC5

CB5

CIR. BREAKER, 10 AMP VACC5

1 2

ACTUATOR, SIDE BROOM

BLK

RED

WHT

CB3

CIR. BREAKER, 15 AMP VACC3

CB3

CIR. BREAKER, 15 AMP VACC3

1 2

GROUND, CONTROL BOX

X49 GROUND, CONTROL BOX

X49

234

VALVE, VAC FAN (S1)

X165X165

ABCDEF

X36X36

SP4SP4

1 2

BACK UP ALARMH2BACK UP ALARM

+ -

LP5

LAMP, RIGHT FRONT TURN

LP5

LAMP, RIGHT FRONT TURN

WHT BLK

SWITCH, EXT. SCRUB

(OPTIONAL)

SWITCH, EXT. SCRUB

(OPTIONAL)

BLK WHT

RELAY, GLOW PLUG

86 85

8730

X21X21

X68X68 A

L10

VALVE, MAIN SOLUTION

L10

VALVE, MAIN SOLUTION

SP13SP13

SENDER, FUELR3SENDER, FUEL

1 2

X73X73

X20X20

CB2

CIR. BREAKER, 20 AMP VACC2

CB2

CIR. BREAKER, 20 AMP VACC2

1 2

X81X81 A

1 2

X57X57

SENSOR, GASOLINE (GM ENGINE)

X32X32

FUSE, 100 A.F1FUSE, 100 A.

1 2

X79X79

X40X40

ABC

VALVE, SCRUB LIFT (S9)

CB4

CIR. BREAKER., 20 AMP VACC4

CB4

CIR. BREAKER., 20 AMP VACC4

1 2

X47X47

PUMP, FUEL

X71X71 A

X64X64

BATTERY, 12 VdcBTBATTERY, 12 Vdc

+ -

X72X72 A

SP14SP14

PUMP, SOLUTION

SP7SP7

X33X33

X39X39

X38X38

SP3SP3

X1X1

NPR

X12X12

X60X60

SWITCH, LOW LPGS5SWITCH, LOW LPG

1 2

HORNH1HORN

1 2

SWITCH, KEY'S1SWITCH, KEY'

VALVE, SCRUB PRESSURE UP (S7)

PUMP, MIST

SP12SP12

122

SWITCH, BRAKES6SWITCH, BRAKE

1 2

X171X171

1 2

CB1

CIR. BREAKER, 20 AMP VACC1

CB1

CIR. BREAKER, 20 AMP VACC1

1 2

J6J6

123

BLACKJ1BLACK

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

PUMP, EXT. SCRUB

(OPTIONAL)

PUMP, EXT. SCRUB

(OPTIONAL)

LP4

LAMP, LEFT REAR S/T/T

LP4

LAMP, LEFT REAR S/T/T

BLK RED

WHT

SP19SP19

212

X78X78

X37X37

X46X46

CB6

CIR. BREAKER, 15 AMP IGNITION

CB6

CIR. BREAKER, 15 AMP IGNITION

1 2

X22X22

VALVE, SQUEEGEE DOWN (S2)

L11

VALVE, RIGHT SOLUTION

L11

VALVE, RIGHT SOLUTION

X53X53

SP10SP10

1 1

SP1SP1

2 2

DRIVE PEDAL SENSOR, 5K OHM

123

SWITCH, RECOVERY FULL

X173X173

SP9SP9

M10

PUMP, CHEMICAL 1

M10

PUMP, CHEMICAL 1

LP2

LAMP, LEFT HEAD

LP2

LAMP, LEFT HEAD

1 2

X7X7

SP2SP2

VALVE, SCRUBB PRESSURE DOWN (S5)

SWITCH, SOLUTION EMPTY

VALVE, SIDE SWEEP/SCRUB (S8)

SENDER, HYDRAULIC OIL TEMP

1 2

X43X43 A

X35X35

X74X74

START/ENGINE RELAY MODULE

1 2 3 4

5 6 7 8

X54X54

VALVE, SQUEEGEE UP (S3)

NATURALJ2NATURAL

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

X174X174

SP15SP15

1 2

SP5SP5

LP7

BEACON

LP7

BEACON

X34X34

GROUND, CHASSIS

X50 GROUND, CHASSIS

X50

123

SP18SP18

DASHBOARD GROUND

X166

DASHBOARD GROUND

X166

X77X77

ABCDEFGH

SP20SP20

X172X172

X10 GROUND, ENGINE

123

M11

PUMP, CHEMICAL 2

M11

PUMP, CHEMICAL 2

SP8SP8

SP6SP6

LP3

LAMP, RIGHT REAR S/T/T

LP3

LAMP, RIGHT REAR S/T/T

BLK RED

WHT

SP17SP17

LP1

LAMP, RIGHT HEAD

LP1

LAMP, RIGHT HEAD

1 2

GROUND, HYD. TANK

X11X11

VALVE, SCRUB BRUSH (S4)

X19X19

SWITCH, HYDRAULIC FILTER

1 2

X75X75

ABCDEFGH

GROUND, CHASSIS

X48

GROUND, CHASSIS

X48

X41X41 A

X42X42

BLACKJ3BLACK

RELAY, POWERK1RELAY, POWER

86 85

8730

PUMP, WAND

VALVE, SCRUB CYLINDER LOCK (S6)

APPENDIX

WIRING SCHEMATIC 1 of 2

FORM NO. 56043124 - Condor XL - 97

WIRING SCHEMATIC 2 of 2

APPENDIX

GRA/BRN 18-1

GRA/BRN 18-2

GRA/BRN 18-3

RED 16-3

VIO 18-21

GRA/BRN 18-3

TAN 18-3

GRA/BRN 18-1

RED 16-1

PINK 16-8

GRN/YEL 18-3

BLU/PINK 16-4

RED/YEL 18-7

RED 16-3

RED/YEL 18-7

BLK 16-12

GRA/BRN 18-2

GRN/YEL 18-3

RED 12-2

BLK 16-13

RED 16-2

RED/YEL 18-8

RED 16-1

RED 16-2

VIO 18-22

GRA 18-6

VIO 18-21

BLK 16-13

RED/YEL 18-9

RED/YEL 18-8

RED 6-1

RED/YEL 18-9

PINK 16-8

BLK 16-12

RED 6-1

TAN 18-3

BLU/PINK 16-4

GRA 18-7

KUBOTA DIESEL ENGINE SYSTEM

BLK/GRN 18-1

GRN/WHT 18-1

GRN/RED 18-1

WHT/GRN 18-1

COOLANT TEMPERATURE

OUTPUT

GM ENGINE SYSTEM

THROTTLE INPUT

(12V FOR 2400 RPM)

(REFERENCE: E-CONTROLS, INC. DRAWING NO. 33000701 AND 33000702)

GASOLINE SENSOR

GRN/YEL 18-1

BLU/PINK 16-1

PINK/YEL 16-1

BLK/RED 16-1

PINK 16-8

PINK 16-7

RED 1-1 RED 6-2

BLK 1-1

BLK 4-1

ALT. EXCITE

MIL OUTPUT

FUEL PUMP (+)

IGN. SWITCH INPUT

FUEL PUMP (-)

CAN (-)

CAN (+)

START COMMAND

GRA/BLU 18-1

VIO/BLU 18-1

RUN SIGNAL

GRA 18-1

ORN/BLK 18-1

BLK/YEL 18-1

RED 1-1

RED 6-2

BLK 1-1 BLK 4-1

GRN/YEL 18-1

BLU/PINK 16-1

PINK/YEL 16-1

BLK/RED 16-1

PINK 16-8

PINK 16-7

GRA/BLU 18-1

GRA 18-1

VIO/BLU 18-1

GRN/RED 8-1

BLK/YEL 18-1

ORN/BLK 18-1

GRA/ORN 18-1

THROTTLE INPUT

(12V FOR 2200 RPM)

GRA/ORN 18-1

SPEED SELECT 1 = 2400 RPM SPEED SELECT 2 = 2200 RPM

X1_X1_

NPR

M13

STARTER

M13

STARTER

D3D3

E4E4

X2_X2_

NPR

SP28SP28

X2.X2.

NPR

SP26SP26

2 2

X154X154 A

SWITCH, COOLANT TEMP.

1 2

X1.X1.

NPR

E2E2

M1.

STARTER

M1.

STARTER

BAT

GND

X113X113

ABCDEFGHJKLMNPR

SP22SP22

X10.1 ENGINE GROUND

123

APECS 3000 GOVERNOR

B (+)

RED

B (-)

BLK

ACTUATOR (+)

WHT

ACTUATOR (-)

WHT/BLK

MAGNETIC PICKUP (+)

BLU

MAGNETIC PICKUP (-)

GRN

SPEED SELECT 1

VIO

SPEED SELECT 2

GRA

SERVICE TOOL (Tx)

YEL

SERVICE TOOL (Rx)

ORN

SENDER, TEMP.

E1E1

SP23SP23

X140X140

ABCDEFGHJKLMNPR

SP24SP24

X78.X78.

X10..X10..

123

D2D2

E3E3

X158X158

X142X142

S28

SWITCH, OIL PRESSURE

S28

SWITCH, OIL PRESSURE

NO NC

I/F

ALTERNATOR

I/F

ALTERNATOR

98 - FORM NO. 56043124 - Condor XL

ENGINE HARNESS FOR GM 1.6L GAS

APPENDIX

GASOLINE SENSOR INTERFACE

BOSCH THROTTLE

INJECTOR #1

INJECTOR #2

INJECTOR #3

INJECTOR #4

FUEL PUMPRELAY

FUEL PUMP

BATT +

GROUND

ALTERNATOR

ALTERNATOR+

ALTERNATOR -

DIAGNOSTIC CONNECTOR

CONNECTOR 1

VEHICLE INTERFACECONNECTORS

CONNECTOR 2

EGO 2

EGO 1

ECT

BOSCH_TMAP

OIL PRESSURESENSOR

IGNITION COIL

CRANK SENSOR

GROUND

POWERRELAY

IGNITION

STARTERRELAY

STARTER

SOLENOID

ECM

STARTER

VSW

GCP 90WAY CONNECTOR

FORM NO. 56043124 - Condor XL - 99

APPENDIX

ENGINE HARNESS FOR GM 1.6L LPG

POWERRELAY

EPR CONNECTOR

LPG TEMPERATURE

GCP 90WAY CONNECTOR

BOSCH THROTTLE

BATT +

GROUND

ALTERNATOR

ALTERNATOR+

ALTERNATOR -

DIAGNOSTIC CONNECTOR

CONNECTOR 1

VEHICLE INTERFACECONNECTORS

CONNECTOR 2

EGO 2

EGO 1

ECT

BOSCH_TMAP

OIL PRESSURESENSOR

IGNITION COIL

CRANK SENSOR

GROUND

EPR

IGNITION

STARTERRELAY

STARTER

SOLENOID

ECM

STARTER

VSW

LOCKOFF

100 - FORM NO. 56043124 - Condor XL

APPENDIX

LTGREEN/PURPLE 18

LTGREEN/BLACK 18

BLUE/WHITE 18

BLUE/PINK 18

LTGREEN/RED 18

BLACK/LTGREEN 18

DK BLUE/ORANGE 18

PURPLE/YELLOW 18

UNUSED

GREEN/YELLOW 18

LTBLUE/PINK 16

DK BLUE 18

PINK/YELLOW 16

BLACK/RED 16

PURPLE 16

PINK 18

S 5V EXT2 (FPP2 ONLY) R5VRTN2 PCAN1NCAN1+ M5VEXT1 L5VRTN1 K FPP1 J FPP2/IVS H FUEL SELECT (AUX DIG 1) GMIL FSTARTCOMMAND EAUXPWM2 D F UELPUMP + C F UELPUMP BALTEXCITE A VSW

PINK/DK GREEN 16

TAN/DK GREEN 18

RED/BLACK 18 RED/WHITE 18

TAN/BLACK 18

TAN/RED 18 GRAY/DK BLUE 18 GRAY/ORANGE 18

DK BLUE/YELLOW 18 YELLOW/DK BLUE 18

TAN 18

BLACK 16

GRAY 18 BROWN/WHITE 16 WHITE/BROWN 16

S12VRELAYEDPOWER RAUXANAPD1 PVSNVS+ MAUXDIG3 LAUXDIG2 K GOV SELECT 1 J GOV SELECT 2 HAUXANAPU1 GAUXANAPU2 FAUXPWM1 E GROUND DTACH CAUXPWM5 B AUX PWM 5RE CIRC A UNUSED

ECM Detail

CONNECTOR 1

CONNECTOR 2

BLACK/LTGREEN 18

LTGREEN/RED 18

DK GREEN 18

ORANGE 18

BLUE/PINK 18

BLUE/WHITE 18

1ANARTN 25VREF 3PCTX 4PCRX 5 UNUSED 6 UNUSED 7CAN1+ 8CAN1-

GASOLINE SENSOR INTERFACE

GRN/YEL 18-1 BLU/PINK 16-1

PINK/YEL 16-1 BLK/RED 16-1 PINK 16-7 PINK 16-4

S R

CAN1 (-) P

CAN1 (+) N

MIL OUTPUT G

STARTCOMMAND F

FUEL PUMP (+) D

FUEL PUMP (-) C

ALT.EXCITE B

IGN. SWITCH INPUT A

GRA/BLU J2-30 GRA/ORN J2-29

VIO/BLU J1-30

GRA J1-1

S R P N M

J H G

COOLANT TEMP. OUTPUT F

E D

RUN SIGNAL (GROUND) C

B A

WHT/GRN 18-1 GRN/RED 18-1 GRN/WHT 18-1 BLK/GRN 18-1

D C B A

X78

(GASOLINE

MODELS ONLY)

DIAGNOSTIC CONNECTOR

Machine

Harness Connectors

ECM

Harness Connectors

WHITE/LT GREEN 18

LTGREEN/RED 18 LTGREEN/W HITE 18 BLACK/LTGREEN 18

D C B A

Wiring

Harness Wiring Harness Component Description

Item

A ECM Wiring Connector (90 Pins) B Gasoline/Petrol Fuel Sensor Interface Connector (fuel pressure

regulation and temperature sensor manifold assembly)

C Engine Diagnostic Communication Port (8 Pin)

(MIL shorting location)

D Ignition Coil Pack Wiring Connector E EngineOil Pressure Switch F Crankshaft Position Sensor Connector G Throttle Fly Actuator Motor Connector (Bosch) H EGO #1 Sensor Wiring Connector

I Combined TMAP Engine Air Temperature and MAP Sensor Wiring

Connector

J Engine Coolant Temperature (ECT) Sensor Connector K Engine Starter Solenoid Wire Connector L EGO #2 Sensor Wiring Connector M LPG Fuel Lockoff Wiring Connector N LPG Temp Sensor Wiring Connector P EPRConnector (LPG) Fuel Regulator Q Gasoline Fuel Injectors

Definition of Terms for Computerized Engine Controllers

•ANA-RTN:

• ECM: Engine Control Module

• EGO: Exhaust Gas Oxygen Sensor (O2)

• EPR: Electronic Pressure Regulator

• IAT: Intake Manifold Air Temperature

• MAP: Intake Manifold Absolute Pressure

• MIL: Malfunction Indicator Light

• VSW: Switched Battery Voltage

• VBAT: Battery Voltage

THROTTLE INPUT

(12V FOR 2400RPM)

THROTTLE INPUT

(12V FOR 2200RPM)

Nilfisk-Advance 56110004, 56110005, 56110006, 56110007, 56110008 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual