Nilfisk-Advance SR 1900, 56507009, 56507010, 56507011 Troubleshooting Manual

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SR 1900

Quick Start Troubleshooting Manual

Models: 56507009 (4 cyl LPG), 56507010 (4 cyl Petrol), 56507011 (4 cyl Diesel)

2/09 Revised 8/12 FORM NO. 56043129

Printed in USA

TABLE OF CONTENTS

GENERAL INFORMATION ................................................................................................................................................ 3-6

SAFETY INSTRUCTIONS .................................................................................................................................................... 7

TECHNICAL SPECIFICATIONS ........................................................................................................................................ 8-9

MAINTENANCE .............................................................................................................................................................10-13

PM CHECKLIST ............................................................................................................................................................14-15

KNOW YOUR MACHINE ............................................................................................................................................... 16-21

OPERATOR’S COMPARTMENT ......................................................................................................................................18

CONTROL PANEL ............................................................................................................................................................ 19

CONTROL PANEL DIAGNOSTICS .............................................................................................................................20-21

GENERAL MACHINE TROUBLESHOOTING GUIDE TABLE OF CONTENTS ................................................................. 22

ENGINE TROUBLESHOOTING FLOW CHARTS .........................................................................................................23-30

WHEEL DRIVE SYSTEM ....................................................................................................................................................31

TROUBLESHOOTING CHECK LIST ................................................................................................................................ 31

STEERING SYSTEM .......................................................................................................................................................... 32

STEERING SYSTEM TROUBLESHOOTING OVERVIEW ..............................................................................................32

TROUBLESHOOTING GUIDE..........................................................................................................................................32

SWEEPING SYSTEM ....................................................................................................................................................33-41

MAIN BROOM .............................................................................................................................................................33-34

SIDE BROOMS ............................................................................................................................................................35-37

DUST CONTROL IMPELLER ......................................................................................................................................38-39

SHAKER MOTOR ........................................................................................................................................................40-41

HOPPER SYSTEM ........................................................................................................................................................42-48

LIFT CYLINDER ..........................................................................................................................................................42-45

DUMP DOOR CYLINDER............................................................................................................................................46-48

SOLUTION SYSTEM .....................................................................................................................................................49-50

MISTING PUMP ...........................................................................................................................................................49-50

ENGINE SYSTEM .........................................................................................................................................................51-56

ENGINE SPECIFICATIONS.........................................................................................................................................51-52

ENGINE MAINTENANCE ................................................................................................................................................. 52

CHECK ENGINE LIGHT TROUBLESHOOTING .............................................................................................................. 53

MISCELLANEOUS ENGINE SYSTEM INFORMATION ...................................................................................................55

GM 1.6L GASOLINE FUEL SYSTEM DESCRIPTION......................................................................................................55

HYDRAULIC SYSTEM ..................................................................................................................................................57-66

HYDRAULIC SYSTEM TROUBLESHOOTING ................................................................................................................57

GENERAL HYDRAULIC SPECIFICATIONS TABLE ........................................................................................................58

HYDRAULIC TRUTH TABLE ............................................................................................................................................ 59

MANIFOLD ASSEMBLY COMPONENTS ....................................................................................................................59-60

PRESSURE RELIEF VALVE .............................................................................................................................................61

HYDRAULIC DIAGRAM ...................................................................................................................................................62

HYDRAULIC SYSTEM LAYOUT FOR OPTIONAL LEFT SIDE BROOM ......................................................................... 63

HYDRAULIC COMPONENT LOCATION .......................................................................................................................... 65

HYDRAULIC SCHEMATIC ...............................................................................................................................................66

ELECTRICAL SYSTEM .................................................................................................................................................67-79

ELECTRICAL COMPONENT LOCATION.........................................................................................................................67

WIRING DIAGRAM ......................................................................................................................................................69-70

WIRING SCHEMATIC ..................................................................................................................................................71-73

ENGINE HARNESS GM 1.6L GAS ...................................................................................................................................74

ENGINE HARNESS GM 1.6L LPG ................................................................................................................................... 75

ENGINE WIRING HARNESS GM DETAIL ....................................................................................................................... 76

PROGRAMMABLE CONTROL OPTIONS .....................................................................................................................77-79

Note: All references to right, left, front, or rear in this manual are as seen from the operator’s stand-point.

2 - FORM NO. 56043129 - SR 1900

GENERAL INFORMATION INTRODUCTION

This manual will help you get the most from your Nilsk rider Scrubber-Sweeper. Read it thoroughly before servicing the machine.

Note: Bold numbers and letters in parentheses and underlined indicate an item illustrated on pages 14-17 i.e. (B).

This product is intended for commercial use only.

PARTS AND SERVICE

Repairs, when required, should be performed by your Authorized Nilsk Service Center, who employs factory trained service personnel, and maintains an inventory of Nilsk original replacement parts and accessories.

Call the NILFISK DEALER named below for repair parts or service. Please specify the Model and Serial Number when discussing your machine.

(Dealer, afx service sticker here.)

NAME PLATE

The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. This information is needed when ordering repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference.

MODEL NUMBER ________________________________________

SERIAL NUMBER ________________________________________

HOPPER SAFETY SUPPORT

WARNING!

Make sure the Hopper Safety Support (5) is in place, by using the Hopper Safety Support Handle (I) whenever attempting to do any maintenance work

under or near the raised hopper. The Hopper Safety Support (5) holds the hopper in the raised position

to allow work to be performed under the hopper.

NEVER rely on the machine’s hydraulic components to safely support the hopper.

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 (Do Not jack on the hopper) – see jacking locations (8).

FORM NO. 56043129 - SR 1900 - 3

GENERAL INFORMATION 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 locations (26).

• The machine parking brake 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 use of the engine.

To access the valve; unlatch and open the Oil Reservoir / Fuel Tank Cover (20) and then open the Engine Compartment Cover (1) and locate the hydrostatic pump at the rear of the engine. Turn the valve 90 degrees, this disengages the hydrostatic lock between the motor and pump.

WARNING: The hydraulic propelling pump can be damaged if the machine is towed with the valve in the normal working position (A). Reference the illustration on the following page for the normal working setting (A) (vertical) and the free wheeling towing setting (B) (horizontal). Note: If the tow valve is left in free wheeling (B) (horizontal) position the propelling pump can’t drive the machine FWD or REV. No damage will result, just re-set valve to the normal working setting (A) (vertical). NOTE: Tow or push machine no faster than a normal walking pace (2-3 miles per hour) and for short distances only. If the machine is to be moved long distances the drive wheel needs to be raised off the oor and placed on a suitable

transport dolly.

4 - FORM NO. 56043129 - SR 1900

FORM NO. 56043129 - SR 1900 - 5

OTHER MANUALS AVAILABLE

The following manuals are available from the Nilsk Literature Service Department, for your Rider Scrubber/Sweeper:

• GeneralInformation

- Nilsk website (www.nilsk-advance.com)

• Parts List - Form Number 56042514 (all systems w/optional kits & accessories)

• Operation Manual - Form Number 56041661 (Danish, Norway, Swedish, Finnish)

56041662 (German, French, Dutch, Russian) 56041663 (Spanish, Portuguese, Italy, Greek) 56041664 (Estonian, Latvian, Lithuanian, Slovenian) 56041665 (Slovakian, Czech, Polish, Hungarian) 56041666 (Turkish, English)

• Quick Start Troubleshooting Manual 56043129

• Cab Manuals

- Cab Addendum (Operator Manual) 56041789

- Cab Addendum (Parts List) 56042515

- Cab Addendum (Service Manual) 56043123

• Engine Manuals

- 1.6L Industrial Engine Operator Manual (excerpt from 16LECSS) 56041564

- 1.6L Industrial Engine Service Manual 36100009*

- PSI Tier 2 1.6L PFI Certied Engine Service Manual G/LP PSI1P6LPFI-A*

- V1505 Kubota Diesel Engine Service Manual (WSM English) 97897-02432

- V1505 Kubota Diesel Engine Service Manual (WSM English, French, German) 97897-01640

- V1505 Kubota Diesel Engine Operator Manual (English, French, German, Italian, Spanish) 16622-8916-3

*Available in electronic format only

6 - FORM NO. 56043129 - SR 1900

CAUTIONS AND WARNINGS SYMBOLS

Nilsk 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

Speci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 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 ammable cleaning agents, operate the machine on or near these agents, or operate in areas where ammable

liquids exist.

• Only use the brooms provided with the appliance or those specied in the instructions for use manual. The use of other brooms

may impair safety.

CAUTION!

• This machine is not approved for use on public paths or roads.

• This machine is only approved for hard surface use.

• This machine is not suitable for picking up hazardous dust.

• When operating this machine, ensure that third parties, particularly children, are not endangered.

• Before performing any service function, carefully read all instructions pertaining to that function.

• Do not leave the machine unattended without rst turning the key switch off (O), removing the key and applying the parking

brake.

• Turn the key switch off (O) and remove the key, before changing the brooms, and before opening any access panels.

• Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.

• Before use, all doors and hoods should be properly latched.

• Do not use on surfaces having a gradient exceeding that marked on the machine.

• All doors and covers are to be positioned as indicated in the instruction manual before using the machine.

SAVE THESE INSTRUCTIONS

FORM NO. 56043129 - SR 1900 - 7

TECHNICAL SPECIFICATIONS

GeneralSpecicationscommontoAll Models English (Metric)

Dimensions Gas & Propane

Length 93.75 inches (238cm) Width (minimum)* 64.5 (164cm) Height 58.5 inches (149cm) Height w/overhead guard 81.25 inches (206cm) Height w/cab 79 inches (201cm) Ground clearance 3.1 inches (7.8cm) Minimum ceiling height dumping clearance 101.4 inches (257.5cm)

Weights

Gross weight** 4 Cylinder Diesel 3000 lbs. (1360kg) Gross weight** GM 1.6L 3300 lbs. (1496kg)

Sweep System

Main broom length 50 inches (127cm) Main broom diameter 14 inches (35.5cm) Main broom bristle length 3.25 inches (8.26cm) Sweeping path w/single side broom 65 inches (165cm) Sweeping path w/dual side brooms 77 inches (196cm) Side broom diameter (STD) 24 inches (61cm) Side broom bristle length 6 inches (15.2cm)

Hopper System

Capacity 14 ft3 (396L) Lifting capacity 1000 lbs. (454kg) Dump height (variable) Max. 60 inches (152cm) Dump height with door open 52.75 inches (134cm)

Dust Control System

Filter type: Pleated paper panel STD (optional poly lter available)

Filter media area 88 ft2 (8.17m2)

Filter dimension 3.19” x 18” x 30” (8.1cm x 45.7cm x 76.2cm) Dust Guard Water Misting Tank Capacity 14 gal. (53L)

Steering System

Type: Full power steering unit and hydraulic cylinder

Turn radius left 95” (242cm) Turn radius right 63” (160cm) Minimum aisle turn width (left) 109 in. (277cm)

Hydraulic System

Oil type: SAE 10W-30 (ll to bottom of screen) System ll capacity 11 gal. (41.6L)

Engine System

Diesel & Petrol (gasoline) fuel tank capacity 12.5 gal. (47.3L)

Tires

Tire pressure (all 3) 90-100 PSI

*Width (minimum): Width of machine body at the hopper, no side brooms. **Gross Weight: Standard machine without options, with 175 lbs. operator, with standard sweeping brooms and full tank of fuel.

8 - FORM NO. 56043129 - SR 1900

TECHNICAL SPECIFICATIONS

SpecicationscommontoEngine Size English (Metric)

Sound Level

At operators ear 83 dBA

Speed and Gradeability

Maximum grade angle (transport) 25% / 14° Maximum grade angle (sweeping) 25% / 14° Maximum trailer loading angle (all models) 19.4° Travel speed (Maximum) 9 mph (14.5km/h) Maximum reverse speed (all models) 5.5 mph (8.8km/h)

FRONT VIEW

Width

Height

w/overhead

guard

Height

SIDE VIEW

Length

FORM NO. 56043129 - SR 1900 - 9

MAINTENANCE MAINTENANCE SCHEDULE

Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often.

MAINTENANCE ITEM PERFORM DAILY

Perform the “After Use” maintenance steps X

Check parking brake X Check engine oil X *Clean main and side broom(s) X Check engine air lter indicator X Check engine coolant level X Check hydraulic oil level X

MAINTENANCE ITEM 15 hrs. 30 hrs. 150 hrs. 300 hrs. 1000 hrs.

*Rotate main broom X *Inspect/adjust brooms X * Check / Clean Hopper Dust Control Filter Using Method “A” X *Inspect broom housing skirts X *Inspect hopper seals X

Clean radiator and oil cooler X Perform engine maintenance X

*Inspect and grease steering spindle X * Check / Clean Hopper Dust Control Filter Using Method “B” X * Check / Clean Hopper Dust Control Filter Using Method “C” X Change the hydraulic “charge” oil lter X Change reservoir hydraulic oil X

Flush the radiator X

All engine fuel lter(s) X**

*See the Mechanical Repair section and Operator Manual for detailed maintenance information of systems listed. (Sweeping, Hopper,

Steering & Dust Control)

**Fuel lters replacement: 400 hrs or yearly. Reference the Parts List for engine type and lter part number.

AFTER USE

1 Shake the Hopper Dust Control Filter (LL) and empty the hopper. 2 Check the maintenance schedule and perform all required maintenance before storage. 3 Move the machine to an indoor storage area. 4 Shut down the engine according to the shut down procedures. 5 Make sure the Ignition Switch (TT) is OFF and the Parking Brake (F) is engaged. NOTE: It is safe to clean this machine with a pressure washer as long as you do not spray directly at or into electrical components. The machine should always

be allowed to dry completely before each use.

TO SHUT DOWN THE DIESEL / GASOLINE ENGINE

1 Turn all controls to the OFF position. 2 Raise the brooms. 3 Place the Engine Speed Switch (GG) in IDLE and let the engine idle for 25 - 30 seconds. 4 Turn the Ignition Key Switch (TT) OFF and remove the key. 5 Apply the Parking Brake (F).

TO SHUT DOWN THE PROPANE ENGINE

1 Turn all controls to the OFF position. 2 Raise the brooms. 3 Turn the service valve on PROPANE Tank (21) OFF. 4 Run the engine until all the PROPANE is dispelled from the line (the engine will stall). 5 Turn the Ignition Key Switch (TT) OFF and remove the key. NOTE: The 4 cylinder LPG engine will continue to run for a few seconds after switching the key

to off. This is part of the proper operation of the closed loop electronic control system.

6 Apply the Parking Brake (F).

10 - FORM NO. 56043129 - SR 1900

MAINTENANCE IMPORTANT MACHINE LUBRICATION

Rear Steering Yoke Bearing Assembly

Once every 150 hours attach a grease gun to the yoke bearing pivot zert (location under operator’s seat) and pump a small amount of grease into bearing assembly.

Also every 150 hours apply light machine oil to maintain free movement of all general pivot points. Example the seat, and broom door hinges etc. Broom and hopper pivots use composite bearings lubrication is not required.

WARNING

For the protection of the environment; when servicing any of the machine’s lubrication uids they must be disposed of safely in accordance with your local environmental regulations (recycling). Examples of machine lubrication products: (Enginecrankcaseoil,Enginecrankcaseoillter,

Hydraulicsystemoil,Hydraulicsystemoillters).

ENGINE COOLANT

CAUTION!

Do not remove the radiator cap when the engine is hot.

To check the engine coolant level, rst unlatch and open the Oil Reservoir / Fuel Tank Cover (20) then lift the Engine Compartment Cover (1) and observe the coolant level on the Coolant Recovery Tank (15) or (22). If the level is low add a mixture of half water and automotive type anti-freeze. Clean the radiator and oil cooler exteriors by washing with low-pressure water or using compressed air every 30 hours. Service Note: The oil cooler

tips out for easy cleaning.

ENGINE OIL – GASOLINE (PETROL) & 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 rst 35 hours of operation and every 150 hours after that. Use any SF or SG rated oil meeting API specications and suited to seasonal temperatures. Refer to the Engine System section for oil capacities and additional engine specications. Replace the oil 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 rst 35 hours of operation and every 150 hours after that. Use CF, CF-4 or CG-4 oil meeting API specications and suited temperatures (*important reference the oil/fuel type note below for further diesel oil recommendations). Refer to the Engine System section for oil capacities and additional engine specications. Replace the oil 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 of a low-sulfur fuel on-road vehicle

engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.

• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.

Fuel

Lubricating

Oil class

CF-4

CG-4

O : Recommendable X : Not recommendable

Low sulfur

(0.5 % ≥)

O O O X O X

High sulfur Remarks

TBN ≥ 10

FORM NO. 56043129 - SR 1900 - 11

MAINTENANCE ENGINE AIR FILTER

The engine Air Filter (24) is located in the engine compartment. Check the air mechanical vacuum lter Service Indicator (27) before each use of the machine. Do not service the air lter unless the indicator is shown (red).

CAUTION!

When servicing the engine air lter elements, use extreme caution to prevent dust and dirt from entering the engine.

The engine air lter contains a primary (outer) and a safety (inner) lter element. The primary element may be cleaned twice before being replaced. Replace the safety element every third time that the primary element is serviced. Never try to clean the safety element. To clean the primary lter element, remove the cover from the dust cup end of the canister and pull out the primary element. Clean the element with compressed air (maximum pressure 100 PSI) or wash it with water (maximum pressure 40 PSI). Do not put the element back into the canister until it is completely dry.

Special Service Note: Inspect the complete air intake system for proper routing (kinks & restrictions) and sound tight connections. The mechanic

should run their hand around the air intake hoses to check for any cracks and holes that will allow non-ltered air to enter the engine that will severely shorten the engine’s useful life.

ENGINE MAINTENANCE (150 HOURS)

At 150 hour intervals it is recommended that the following service be performed: Change oil and lter, clean and inspect spark plugs, check all engine belts condition and adjustment, check battery charge and level, check cooling system hoses and clamps and check general condition and

performance of engine.

Note: Reference the separately supplied PSI GM Power Train Products Operation and Maintenance manual for more detailed service data. See the “Other Manuals Available” section for a complete list of the engine manuals that are available.

SPECIAL LIQUID PROPANE FUEL SYSTEM MAINTENANCE ON THE GM 1.6L ENGINE

Every 150 hours inspect and drain any oil build up from the LP fuel system electronic pressure regulator (EPR). During the course of normal operation oils or “heavy ends” may build inside the chambers of the propane regulator. These oils and heavy ends may be a result of poor fuel quality, contamination of the fuel supply chain, or regional variation in the make up of the fuel. If the build up of the oil is signicant this can affect the function of the fuel control system. Note: Reference the Tier 2 PSI 1.6l PFI certied engine service manual form # PSI1P6LPFI-A, and follow

the procedure to drain the EPR regulator.

12 - FORM NO. 56043129 - SR 1900

MAINTENANCE HYDRAULIC OIL

WARNING!

To avoid hydraulic oil injection or injury, always wear appropriate clothing and eye protection when working with or near hydraulic

system.

Check the Hydraulic Oil Level. Unlatch and swing open the Oil Reservoir / Fuel tank Cover (20). Remove the reservoir cap to check

the oil level. The hydraulic oil level should be half way up the screen lter inside the ller neck of the reservoir. Add SAE 10W30 motor oil if it is below this level. Change the oil if major contamination from a mechanical failure occurs.

Change the Hydraulic “Charge” Oil Filter once a year or every 1000 hours.

HOPPER DUST CONTROL FILTER (PANEL FILTER)

The hopper dust control lter must be cleaned regularly to maintain the efciency of the vacuum system. Follow the recommended lter service intervals for the longest lter life.

CAUTION!

Wear safety glasses when cleaning the lter. Do not puncture the paper lter. Clean the lter in a well-ventilated area. Wear appropriate dust mask to avoid breathing in dust.

Toremovethehopperdustcontrollter...

1 Unlatch and open the Hopper Cover (16). Make sure that the Hopper Cover Prop Rod (17) is in place. 2 Inspect the top of the Hopper Dust Control Filter (12) for damage. A large amount of dust on top of the lter is usually caused by a hole in the

lter or a damaged lter gasket.

3 Unthread and remove the four Shaker Assembly Retainer Knobs (13). Lift off the Dust Filter Shaker Assembly (11) to access the panel lter. 4 Lift the Hopper Dust Control Filter (12) out of the machine.

5 Cleanthelterusingoneofthemethodsbelow:

Method “A” Vacuum loose dust from the lter. Then gently tap the lter against a at surface (with the dirty side down) to remove loose dust and dirt. Method “B”

Vacuum loose dust from the lter. Then blow compressed air (maximum pressure 100 psi) into the clean side of the lter (in the opposite

direction of the airow).

Method “C”

Vacuum loose dust from the lter. Then soak the lter in warm water for 15 minutes, then rinse it under a gentle stream of water (maximum

pressure 40 psi). Let the lter dry completely before putting it back into the machine.

6 Follow the instructions in reverse order to install the lter. If the gasket on the lter is torn or missing, it must be replaced. NOTE: Before

replacing lter clear debris from dust plate located under lter. Verify that the debris ap at the rear of the dust plate swings freely

HOPPER DUST CONTROL FILTER (OPTIONAL NILFISK POCKET FILTER SYSTEM)

The optional Nilsk pocket lter system is basically maintenance free. The only periodic maintenance required by the machine operator is to run the Shaker (LL) on a daily basis. NOTE: The shaker should only be run with the hopper in the down position.

FORM NO. 56043129 - SR 1900 - 13

SR 1900

PM Checklist

Defect Codes

Customer A needs adjustment

B binding

Address C dirty or contaminated

D damaged, bent or torn

City St Zip L leaks

M missing

Model Serial Hours W worn out

Ref

1 Check Neutral Safety/Sense Switch 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 sensor switch

programming)

3 Engine Speeds 4 cyl G/P (1200 - 2400 RPM) A low power

4 Engine Speeds Diesel (note electrical actuator linkage 1200 - 2400 RPM)

5 Drive Pedal Linkage (check for FWD/REV drive and any neutral creep) A B

6 Drive System Performance noisy sluggish

7 Brakes (check both service & parking) A B W

8 Steering excessive play

9 Hopper Up/Down (also check operation of the safety hopper support) A B

10 Hopper Dump Door Open/Close A B

11 Main Broom Raise /Lower <----->

12 Side Broom Raise /Lower <----->

13 Main Broom On/Off <----->

14 Side Broom On/Off <----->

15 Headlights, Gauges and Optional Accessories (example rotating beacon, backup alarm)

16 Dust Control Filter Shaker & Vacuum Impeller <----->

17 Tilt Steering Mechanism and Seat Adjustment lever A B

18 Dust Guard (OPT) Water Pump Operation On/Off

OPERATIONAL INSPECTION ITEMS

Defect Codes

(circle)

A B C

starts hard

Does

Not

Work

Does

Ref

19 Side Broom Pattern & Height Adj. (min bristle wear 3 inches) 3 O'clock to 11 A B D W

20 Side Broom Motor B L

21 Hopper Cover Gasket D W

22 Hopper Dust Filter & Gasket D W

23 Dust Control Vacuum Impeller Motor L

24 Hopper Dump Door Cylinder A B L

25 Hopper Skirting & Seals (raise hopper to inspect) D M W

26 Hopper Dump Door & Seal (raise hopper to inspect) A B D W

27 Hopper Lift Cylinder & Hopper Interlock Switch Magnetic Switch A B L

28 Main Broom Pattern Adjustment (min bristle wear 2-1/2"

6.4cm length)

29 Main Broom Motor (open left side access door to inspect) B L

30 Broom Housing & Door Skirts D M W

31 Front tires (check lug nut torque 80FT LB, 108 Nm) Tire Pressure 90 psi L W

32 Battery Clean & Water C W

33 Engine Air Cleaner Element (inner & outer) Check SVR Indicator C W

Comments

2-3" (5-7 cm) wide

pattern

VISUAL INSPECTION ITEMS

Defect Codes

(circle)

A B D W

Not

Work

14 - FORM NO. 56043129 - SR 1900

Ref

34 Circuit Breaker/Relay panel (inspect electrical connections) C D

35 Hydrostatic Dump Valve Tow Valve B

36 Hopper Up Transport Speed control Cam/Cable Linkage A B

37 Propulsion drive & Accessory Pumps L

38 Hydraulic Reservoir, System Hoses & fittings L

39 Propulsion Pump Hydro Back Cable & Clevis Connections B M W

40 Engine, Oil Level, Hoses & Belts Add or Change L W

41 Engine Coolant Level L Add Coolant

42 Radiator & Oil Cooler Core Blockage L Needs Cleaning

43 Hydraulic Oil Reservoir Level (10W-30 engine oil only) Bottom of Screen L Add Oil

44 Hydraulic Oil Filter SVR Life 1000 Hrs L Replace

45 Steer Spindle & Drive Wheel motor (open operator’s seat) Grease Spindle Zert D L

46 Rear Tire (check lug nut torque 100 FT LB, 135Nm) Tire Pressure 90 psi L M W

47 Gasoline/Diesel tank , Filter & Lines C L

48 LP Tank, Hoses & Fittings L

49 LP Fuel Filter SVR Life 1500 Hrs L Replace

50 LP Fuel Regulator, Lock Off Valve & Hoses L

51 Diesel Glow Plug Indicator Light Hard Starting Replace

52 Diesel Fuel Filter L Replace

53 Engine Air-Intake Hose Assembly (air inlet to engine) clamp fittings / Holes C L

54 Dust Guard Water Tank, Misting Pump & Storage Tank

Comments

VISUAL INSPECTION ITEMS (continued)

Defect Codes

(circle)

NOTE: For additional service information see service manual form number 56043129 and operator manuals form numbers 56041661-56041666.

Defect Codes A needs adjustment C dirty or contaminated M missing B binding D damaged, bent or torn W worn out L leaks

Does

Not

Work

WORK COMPLETED BY: ACKNOWLEDGED BY:

Service Technician Signature Date Customer Signature Date

FORM NO. 56043129 - SR 1900 - 15

KNOW YOUR MACHINE

As you read this manual, you will occasionally run across a bold number in parentheses and underlined - example: (2). These numbers refer to an item on the next four pages. Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text.

1 Engine Compartment Cover

2 LeftSideMainBroomAccessPanel

3 Battery 4 Center Cover Assembly

5 HopperSafetySupport

6 Hopper Cover Latch 7 Head Light 8 Jacking Locations (rear location is large weight below radiator) 9 Side Broom 10 Side Broom Height Adjustment Knob 11 Dust Filter Shaker Assembly 12 Hopper Dust Control Filter 13 Shaker Assembly Retainer Knobs 14 Hydraulic Oil Filter 15 Coolant Recovery Tank (GM location)

16 - FORM NO. 56043129 - SR 1900

KNOW YOUR MACHINE (CONTINUED)

16 Hopper Cover 17 Hopper Cover Prop Rod 18 Right Side Main Broom Access Panel 19 Oil Reservoir 20 Oil Reservoir / Fuel Tank Cover 21 Fuel Tank (LPG tank shown / Gasoline tank is in same location) 22 Coolant Recovery Tank (diesel location) 23 Radiator Cap 24 Engine Air Filter (diesel location) 25 Fuel Tank Cover Release Latch 26 Tie-Down Locations (5) 27 Air Filter Service Indicator 28 Engine Air Filter (GM location)

FORM NO. 56043129 - SR 1900 - 17

KNOW YOUR MACHINE OPERATOR’S COMPARTMENT

A Operator’s Seat B Main Broom Lever C Main Broom Adjust Knob D Control Panel (See Associated Pages) E Steering Wheel F Brake Pedal / Parking Brake G FWD / REV Drive Pedal H Circuit Breaker Panel

I HopperSafetySupportHandle

J Operator Seat Adjustment Lever

18 - FORM NO. 56043129 - SR 1900

KNOW YOUR MACHINE CONTROL PANEL

AA Fuel Gauge (Gasoline and Diesel Only) BB Horn Switch CC PROPANE Low Indicator Light DD Headlight Switch EE Check Engine Light MIL (GM 1.6L Only) FF Glow Plug Indicator Light (Diesel Only) GG Engine Speed Switch HH Side Broom ON-Down / OFF-Up Switch II Dust Control Indicator JJ Dust Control Switch KK Plugged Filter Indicator (optional) LL Shaker Switch

MM Hopper UP Indicator NN Open Dump Door Switch OO Hopper Over-temp Indicator (optional) PP Close Dump Door Switch QQ Lower Hopper Switch RR Raise Hopper Switch SS Hour Meter TT Ignition Switch UU Main Controller Fault Code Light VV Voltmeter XX Engine Coolant Temperature YY Engine Oil Pressure

FORM NO. 56043129 - SR 1900 - 19

SR 1900 CONTROL PANEL DIAGNOSTICS

Functionofthemaincontroller’sserviceindicatorfaultblinkcodedisplaylight

The A2 main controller will out put a ashing fault code to the operator display panel when or if there is a problem (current overloads) associated with specic electrical low current circuit controller output functions. Examples of circuits; hydraulic solenoid coils used to turn on & off hydraulic loads and numerous relays used for activating machine function such as the headlights, horn, shaker motor, back-up alarm etc.

See Figure 1. When an A2 controller fault occurs the service indicator light (LED) (UU) will blink (ash) a special fault (error) code sequence until

the fault is corrected. See “Table A” for a description of the fault indications.

Service Note: Instructions on how to read the fault code service indicator light. The service indicator LED blink code should operate as follows:

• First part of code (250mS period per ash – 125mS ON, 125mS OFF the 700mS LED OFF period.

• Second part of the code (250mS period per ash – 125mS ON, 125mS OFF the 700mS LED OFF period.

• 2 second LED off period

• Repeat sequence

If multiple faults are present, the codes should appear in order until all are displayed and then the entire sequence will repeat.

Example: Code1, 2 0 00 0 00 one light blink, a short pause two blinks, long pause and the code will be repeated.

LED on for 125mS LED off for 700mS LED on for 125mS LED off for 125mS LED on for 125mS LED off for 2000mS Repeat

FIGURE 1

20 - FORM NO. 56043129 - SR 1900

TABLE A

Fault

Number

1 1,1

2 1,2

3 1,3

4 1,4

5 2,1

6 2,2

7 2,3

8 2,4

9 3,1

10 3,2

Service

LED Blink Code

Fault Description Output

Pin #

Solenoid S1 hopper close/open overload

Coil spec is 8 Ohms

Solenoid S2 main broom overload

Coil spec is 8 Ohms

Solenoid S3 side broom overload Coil

spec is 8 Ohms

Solenoid S4 dust control overload

Coil spec is 8 Ohms

Solenoid S5 hopper up/down overload

Coil spec is 8 Ohms

Solenoid S6 hopper up/bypass overload

Coil spec is 8 Ohms

Solenoid S7 hopper door/open overload

Coil spec is 8 Ohms

Solenoid S8 dust control bypass overload

Coil spec is 6 Ohms

Solenoid S9 hopper lower overload

Coil spec is 8 Ohms

Shaker relay K3 overload

Coil spec is 85 Ohms

J1-1

J1-2

J1-3

J1-4

J1-5

J1-6

J1-7

J1-8

J1-9

J1-14

Troubleshooting Action

1. Check S1 coil wiring for a short circuit Vio + & Blu/Wht