6600 / 6650 Service Manuald2z4qs2e3spnc1.cloudfront.net/product_file/file/2774/tennant-6600... ·...

6600/6650Service Information Manual

(Paper Manual)

330915Rev. 00

*330915*

330935 (CD--ROM)

This manual provides service information for the TENNANT Model 6600/6650.

This machine will provide excellent service. However, the best results will be obtained at minimumcosts if:

D The machine is operated with reasonable care.D The machine is maintained regularly -- per the maintenance instructions provided.D The machine is maintained with TENNANT supplied or approved parts.

Paper Manual Number -- 330915

CD--ROM Manual Number -- 330935

Revision: 00

Published: 9--03

CALIFORNIA PROPOSITION 65 WARNING:Engine exhaust from this product contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproductive harm.

Copyright E 2003 TENNANT, Printed in U.S.A.

6600 Electrical Troubleshooting Charts 1.......................................................................................6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM 2.............................................................6600 DIESEL OVERALL ELECTRICAL DIAGRAM 6...................................................................6600 Key Switch 10........................................................................................................................6600 Charging System 11..............................................................................................................6600 Gas/L.P. Start Circuit 12........................................................................................................6600 Diesel Start Circuit 13............................................................................................................6600 Gas/L.P. Power-Up Circuit 14................................................................................................6600 Diesel Power-Up Circuit 15....................................................................................................6600 Gas/L.P. Check Engine Lamp Circuit 16...............................................................................6600 Gas/L.P. Oil Pressure & Hour Meter Circuit 17......................................................................6600 Diesel Oil Pressure & Hour Meter Circuit 18..........................................................................6600 Vacuum Fan Circuit 19..........................................................................................................6600 Vacuum Restriction Warning Circuit 20.................................................................................6600 Gas/Diesel Fuel Sender Circuit 21.........................................................................................6600 Low L.P. Fuel Sender Circuit 22............................................................................................6600 Shaker Motor Circuit 23.........................................................................................................6600 Thermo-Sentry Circuit 25......................................................................................................6600 Hopper Door Switch Circuit 26...............................................................................................6600 with ZEEMS 27......................................................................................................................

6600 Gas/L.P. ZEEMS Check Engine Fault Codes 28............................................................

6600 Hydraulic Troubleshooting Charts 29......................................................................................6600 OVERALL HYDRAULIC DIAGRAM 30..................................................................................6600 HYDRAULIC HOSE ROUTING 32........................................................................................6600 MAIN BRUSH 33...................................................................................................................6600 MAIN & SIDE BRUSH 34.......................................................................................................6600 VACUUM FAN 35..................................................................................................................6600 RAISE HOPPER 36...............................................................................................................6600 LOWER HOPPER 37.............................................................................................................6600 OPEN HOPPER DOOR 38....................................................................................................6600 CLOSE HOPPER DOOR 39..................................................................................................6600 RIGHT TURN 40....................................................................................................................6600 LEFT TURN 41......................................................................................................................6600 PROPEL SYSTEM 42............................................................................................................

6650 Electrical Troubleshooting Charts 43.......................................................................................6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM 44.............................................................6650 DIESEL OVERALL ELECTRICAL DIAGRAM 48...................................................................6650 Key Switch 52........................................................................................................................6650 Charging System 53..............................................................................................................6650 Gas/L.P. Start Circuit 54........................................................................................................6650 Diesel Start Circuit 55............................................................................................................6650 Gas/L.P. Power-Up Circuit 56................................................................................................6650 Diesel Power-Up Circuit 57....................................................................................................6650 Gas/L.P. Check Engine Circuit 58.........................................................................................6650 Gas/L.P. High Engine Temperature Circuit 59.......................................................................6650 Diesel High Engine Temperature Circuit 60...........................................................................6650 Gas/L.P. Oil Pressure Circuit 61............................................................................................6650 Diesel Oil Pressure Circuit 62................................................................................................6650 Vacuum Fan Circuit 63..........................................................................................................6650 Vacuum Restriction Warning Circuit 64.................................................................................6650 Gas/Diesel Fuel Sender Circuit 65.........................................................................................6650 Low L.P. Fuel Sender Circuit 66............................................................................................6650 Shaker Motor Circuit 67.........................................................................................................6650 Thermo-Sentry Circuit 69......................................................................................................6650 Hopper Door Circuit 70..........................................................................................................6650 Hopper Up/Down Circuit 71...................................................................................................6650 Main Brush Stall Circuit 72.....................................................................................................6650 Main Brush On & Down Circuit 73.........................................................................................6650 Main & Side Brush On & Down Circuit 74..............................................................................6650 Interlocks 75...........................................................................................................................6650 Operational/Diagnostic/Maintenance Modes 77....................................................................

Six Operational Modes 77........................................................................................................6650 with ZEEMS 78......................................................................................................................

6650 ZEEMS Check Engine Fault Codes 79...........................................................................6650 Machine Control Board Pin Functions 80........................................................................

6650 Hydraulic Troubleshooting Charts 81......................................................................................6650 OVERALL HYDRAULIC DIAGRAM 82..................................................................................6650 HYDRAULIC HOSE ROUTING 84........................................................................................6650 MAIN BRUSH 85...................................................................................................................6650 MAIN & SIDE BRUSH 86.......................................................................................................6650 VACUUM FAN 87..................................................................................................................6650 RAISE HOPPER 88...............................................................................................................6650 LOWER HOPPER 89.............................................................................................................6650 OPEN HOPPER DOOR 90....................................................................................................6650 CLOSE HOPPER DOOR 91..................................................................................................6650 LOWER MAIN BRUSH 92.....................................................................................................6650 RAISE MAIN BRUSH 93........................................................................................................6650 LOWER SIDE BRUSH 94......................................................................................................6650 RAISE SIDE BRUSH 95........................................................................................................6650 RIGHT TURN 96....................................................................................................................6650 LEFT TURN 97......................................................................................................................6650 MAIN BRUSH STALL TRIGGERING PRESSURE SWITCH 98............................................6650 PROPEL SYSTEM 99............................................................................................................

ECU - Black Connector 101..................................................................................................................

ECU - White Connector 102..................................................................................................................

ECU - Pin Descriptions 103..................................................................................................................

Engine Maintenance Schedule 104......................................................................................................

Engine General Specifications 106......................................................................................................

ZEEMS - Zenith Electronic Engine Management System 107...........................................................Overview 109....................................................................................................................................Block Diagram 112............................................................................................................................ECU 113...........................................................................................................................................Inputs 116.........................................................................................................................................

Inputs, RPM 117.........................................................................................................................Inputs, ECT & IAT 119................................................................................................................Inputs, MAP 122.........................................................................................................................Inputs, EGO 127.........................................................................................................................Inputs Review 132......................................................................................................................

Output Control 133............................................................................................................................Governor 134..............................................................................................................................Fuel Injector 142.........................................................................................................................Ignition Timing 147.....................................................................................................................

Open/Closed Loop 150.....................................................................................................................Open & Closed Loop 150...........................................................................................................Closed Loop to Open Loop 152..................................................................................................Closed Loop Operation 153........................................................................................................Review Questions and Answers 155..........................................................................................

System Operation 156......................................................................................................................Key On 156.................................................................................................................................Cranking 157..............................................................................................................................Running 158...............................................................................................................................

Diagnostics 162................................................................................................................................Failures 162................................................................................................................................ECU Quick Tests 163.................................................................................................................

Output Control Frequency Test 164.....................................................................................Processor Quick Tests 165..................................................................................................

Input Sensor Quick Tests 167....................................................................................................IAT and ECT Testing 168....................................................................................................

MAP Testing 170.................................................................................................................EGO Testing 171.................................................................................................................

Output Sensors Quick Test 172.................................................................................................Failures 172.........................................................................................................................Fuel Injector Testing 173.....................................................................................................Governor Actuator Testing 174............................................................................................Ignition Timing Testing 176..................................................................................................Diagnostic Review 177........................................................................................................

Specifications 178.............................................................................................................................Block Diagram Review 180...............................................................................................................Operation Review 181......................................................................................................................

ZEEMS Troubleshooting Test Kit 185.................................................................................................Gas Injector - Noid Light Tennant Part # 371780 188....................................................................LPG Injector - Noid Light Tennant Part # 371781 188....................................................................

Engine Controls 189..............................................................................................................................AIR AND COOLANT SENSOR RESISTANCE 189..........................................................................DIAGNOSTIC PROCEDURES 190..................................................................................................

Engine Idle Speed High 191.......................................................................................................Engine Speed Spikes Intermittentl 192...................................................................................Engine Runs Erratically, Poor Governor Performance 193........................................................Engine Runs, But Will Not Accelerate 194.................................................................................Engine Wont Start - Gasoline 195.............................................................................................Gasoline Fuel Pump Diagnosis 196...........................................................................................Engine Wont Start - LPG 197....................................................................................................Engine Wont Start Dual Fueel 199............................................................................................Engine Runs, Low Power, Lean or Misfires Gasoline 200.......................................................LPG Lock-Off Diagnosis 201......................................................................................................Engine Runs Rich Gasoline 202...............................................................................................Engine Runs, Low Power, Lean or Misfires LPG 203..............................................................Engine Runs Rich LPG 205......................................................................................................

PSI - Operation and Maintenance 207.................................................................................................Table of Contents 208.......................................................................................................................Introduction 211................................................................................................................................How to Use this Manual 211.............................................................................................................Engine Identification 212...................................................................................................................Parts and Service 212.......................................................................................................................Service Literature 212.......................................................................................................................Operating Instructions 213................................................................................................................

Controls 213...............................................................................................................................Ignition Switch 213...............................................................................................................Safety Gauges 213..............................................................................................................Fuel Systems 213................................................................................................................Governors 214.....................................................................................................................

Instruments 214..........................................................................................................................Oil Pressure Gaug 214........................................................................................................Voltmeter 215.......................................................................................................................Tachometer/Hourmeter 215.................................................................................................

Starting the Engine 215..............................................................................................................Carbureted, Mechanical Governor, Manual Choke 215.......................................................Carbureted, Electric Choke, Electronic Governor 216.........................................................LPG or NG Fuel Systems, Velocity Governors 216.............................................................PSI Fuel Injection (Gasoline) 216........................................................................................PSI Fuel Injection (Gasoline/LPG)(Dual Fuel) 216..............................................................Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor 216...............................

Stopping the Engine 217............................................................................................................Fuel Recommendations 217.......................................................................................................Power Loss at Higher Elevations 219.........................................................................................

Carbureted Engines 219......................................................................................................Fuel Injected Engines 219...................................................................................................

MAINTENANCE INSTRUCTIONS 220.............................................................................................Initial Start Up Maintenance 220................................................................................................

Routine Maintenance 220...........................................................................................................Scheduled Preventive Maintenance 220....................................................................................Engine Oil Level Check 220.......................................................................................................Adding Engine Oil 220................................................................................................................Changing Engine Oil and Filter 221............................................................................................Engine Oil Quality 221................................................................................................................Oil Filter 221...............................................................................................................................Engine Air Cleaner 222..............................................................................................................Cooling System 222...................................................................................................................

Coolant Level 222................................................................................................................Radiator 223........................................................................................................................Fan Belts 223.......................................................................................................................Serpentine Belt 224.............................................................................................................V-Type Belt 224...................................................................................................................

Fuel Filter 224.............................................................................................................................Carbureted Engines 224......................................................................................................TBI Engines 224..................................................................................................................

Ignition Systems 225..................................................................................................................Ignition Timing 225...............................................................................................................Spark Plugs 225...................................................................................................................

Storage 226................................................................................................................................One to Six Months 226........................................................................................................For Extended Periods 226...................................................................................................Removing the Engine From Extended Storage 226............................................................

GM Engine Timing Procedures 228...........................................................................................Maintenance Schedule 229........................................................................................................Filter Chart 230...........................................................................................................................Fuel System Chart 231...............................................................................................................

GENERAL SPECIFICATIONS 232...................................................................................................3.0L Engine Spark Plug Wire Routing 233.......................................................................................

Torque Standards 244...........................................................................................................................Inch Fasteners 235...........................................................................................................................METRIC Fasteners 237....................................................................................................................Nylon Insert Lock Nuts 239...............................................................................................................Wheel Bolt and Nuts 240..................................................................................................................Tightening Nuts on Tapered Shafts 241...........................................................................................Shoulder Bolts 242............................................................................................................................Taper Lockr Bushings 243................................................................................................................Sequence Tightening 244.................................................................................................................

BEFORE CONDUCTING TESTS:

* Read and Follow ALL Safety Warnings and

Precautions in Operator's Manual

MODEL

Troubleshooting Charts

6600

ELECTRICAL

DURING TESTS:* Call Technical Services if Diagnostic Time Exceeds One

Hour With Unknown Cause or Course of Action

6600 07-2003 1

B

B

A

A

61B

STARTERSOLENOID

COIL

STARTERMOTORASSEMBLY

31EA

29EA

26EA

1A

3EA

34

2

KEY:START

POSITIVEBATTERYCABLE

ENGINEBLOCK

ENGINEBLOCK

8J

8K

13F

13F

51

51A

50B1C

52

OUTPUT+

GROUND

ENGINEHARNESS

ENGINEHARNESS

ENGINEHARNESS

J7--A

J7--B

8L

ZENITH ENGINE CONTROL

27EA

27EBJ7--D

8EF

8EG

54EA

69EC

70EA

69EA

69EB

8EE

5EA

67B

67A

67

66EA

65EA

64EA

63EA

61EA

60EA

59EA

58EA

57EA

56EA

55EA

53EA

68EA

13EA

13EH

13ED

13EC

13EL

13EE

13EM

13EK

13EF

13M

13EG

13L

J7--C

5EA

72EA

13EB

28

82EA

83EC

82E A

83E A

1D

LOWOILPRESS.

ANALOGHIGHENGINETEMP

NOTUSED

SPEED

BIT”B”

SPEED

BIT”A”

ENGINETEMP/CHECK

J9--B

J9--E

J9--D

J9--A

J9--C

J7--E

ENGINESPEEDSWITCH

8C

8C

58D

8B

8A

NOTUSED

31A

29A

26A

27C

28EA

LOWCURRENTGROUNDTHROUGHTHECONTROLLER

13EJ

J9--F

+5VREF.148EA

38A

38B

3A

27EC

M--2

M--1

M--3

M--3

M--2

M--1

83EB

1EA

13W

38B

NOTUSED

J9--G

P1=WHITECONNECTOR

P2=BLACKCONNECTOR

GND.W

ITHENGINERUNNING

WILLCLEARFAULTCODES.

BIT--A BIT--B

LOW: HIGH 0VMED: 0V HIGHHI GH: 0V 0V

ENGINE SPEED SELECTION BITS ’A’ AND ’B’

1350 RPM2000 RPM2400 RPM

MTR2

GOVERNORACTUATOR

AB

D--1

02SENSOR

ABC

D

S--4

COOLANTTEMPSENSOR1

BA

HOURMETER--

+

LP5

ENG.TEMP/CHECK

x=CLOSEDCONTACT

START

RUN X

X

X

X X

X

S--1

KEYSW

50

17

19

ACC

30

O2--BJ2--10

O2A

J2--12

GD1J1--20

GD2J1--21

GND

J2--11

MAG1

J2--21

MAG2

J2--19

MG--3

J2--20

MP--C

J2--4

MAP--B

J2--17

COIL--D

J1--8

COIL--B

J1--18

COIL--A

J1--10

OXY

J2--9

H20

J1--1

GOV

J1--5

FUEL

J1--4

OIL

J2--8

__SLJ2--7

STJ1--14

KEY1

J1--22

KEY2

J1--23

LP

J1--2

INJ

J1--15

GAS

J1--3

ENG

J1--12

+5V

J2--3

SPD1

J2--2

SD2

J2--16

EX

J2--5

RST

J1--16

30

87

85

86

STARTERSOLENOID

CONTACTS

ALT

--

EX.

COILPACK

ABC

D

30 87

S--6

BA

AUX #1

S--7

3

56

2

MTR1

STARTERMOTOR

F--11

15AFUSE8

AUX. 2 RELAY

30 87

85

86

MAPSENSOR

B

AC

12VDC

+----

SOL4

GASINJECTOR

85

86

LP5

ALTERNATOR

LIGHT

S--5

OILPRESSURESWITCH

B

CA

S--3

AIR

TEMPSENSOR

BA

S--2

NEUTRALSTART

N.O./CLOSED=DOWN

SOL5

L.P.LOCKOUTVALVE

BA

LP5

LOW

OILPRESS.

SOL3

L.P.INJECTOR

MAG.PICKUP

CBA

AUX #2

SOL4

FUElPUMP

AB

F--5

30AFUSE

COOLANTTEMPSENSOR2

AUX. 1 RELAY

1

2

3

6600 GAS & L.P. OVERALL ELECTRICAL DIAGRAM

Part 1 of 4

6600 07-2003

2

4A/YEL

4B/YEL

81A/YEL

87A/PUR

88A/GRN

62BB/YEL

62BA/YEL

62BC/YEL

76/ORA

76A/ORA

76B/ORA

1A

1D

13U

4/YEL 81/YEL

33

79/YEL

80/BLU

77/GRY

62/YEL

87/PUR

88/GRN

89/BRN

90/GRY

62C/YEL

62B/YEL

13GG

13FF

13T

13S

13BE

13BD

13BF

13LL

93/ORA

93/ORA

34A

13Q

93B/ORA

94/YEL

92

95A

S--11

S--12

62A/YEL

95

13KK

13P

6

13V

33A

...........W

IRING

COLOR

CODE

.............

0TAN

1PINK

2BRN

3ORANGE

4YELLOW

5GREEN

6BLUE

7PURPLE

8GRAY

9WHITE

RIGHTMOSTDIGIT

COLOR

OFWIRE

OF

WIRENUMBER

INHARNESS

93A/ORA

13QQ

13NN

4C/YEL

4D/YEL

95A

62BA/YEL

33A

33B

LP7

SIDEBRUSHLIGHT

AUX #1

D--3

S--9 HORN

N.O./CLOSED=HORN

LP10

LAMP_HEADLIGHT

FLASHER

GRY

BLK

GRN

RED

BLK/

GRY

BLU

YEL

DIRECTIONALSWITCH

3

9847

61

LIGHTSWITCH 1

24 5

68

F--20

15AFUSE

LP1

RUNLIGHT,R

.H.

LP8

REVOLVINGLIGHT,OHG

F--12

15AFUSE

LP3

TAILLIGHT,R.H.

LP5

HEADLIGHT,R.H.

S--10

BRAKEPEDAL

SWITCH

N.O./CLOSED=BRAKING

F--4

15AFUSE

S--8 REVERSESWITCH

N.O./CLOSED=REVERSE

LP9

LOW

MOUNTEDBEACON

HORN

LP6

HEADLIGHT,

L.H.

LP2

RUNLIGHT,L.H.

LP4

TAILLIGHT,L.H.

F--3

15AFUSE

P

XFLASHER

1

23

REVERSEALARM

L

1

2

3

Part 2 of 4


6600 07-2003

3

6

7A

7C

7B

7A 7F 7

18

14BA

15

16

11BA

19B 2

2

13E

13L

13D

13R

13E

13U

7E

24

13H

19A

18A

18B

47A

47BB

48

47

13C

13B

S--17

7J

7H

82

7K 32

13A

GROUNDFORLAMPINSIDE

SWITCH

30A

18A

M.O.M.

LAMP(--)

LAMP(+)

M--4

M--4

7D

14

13BA

19BA

11

13BB

32

13A

48BB

105

HOPPERSTATIC

GROUND

7L

7L

S--19

STALLEDBRUSH

N.O./CLOSED=STALLED

S--14A

LOWL.P.

N.O./CLOSED=LOW

L.P.

LOWL.P.

AUX #1

30

87

S--16

HOPPERDOWN

N.O./CLOSED=HOPPERDN.

FUELGAUGE

INSEN

GND

SOL5

VAC. FANSOLENOID

BA

STALLEDBRUSH

CLOGGEDVACFAN

SOL1

SHAKERSOLENOID

D--2

S--15

THERMALSENTRY

SWITCH

COM

NC

NO

VAC/SHAKERSWITCH

214

658

9

10

HOPPERDOORCLOSED

LOAD

GND

B+

INIT

SHAKERTIMERMODULE

21

3 6

F--19

15A FUSE

HIGHHOPPERTEMP

(+)

(--)

OUT

SHAKERPULSEMODULE

12 3

GROUND

S--18

CLOGGEDVACUUMFAN

N.O./CLOSED=CLOGGED

85

86

S--14

FUELSENDER

S--13

HOPPERDOOR

N.O./CLOSED=DOWN4

Part 3 of 4


6600 07-2003

4

OPTIONAL AC AND CAB HARNESSES

YEL

BRN

GND

BLU

BLK

ORG

BLK

YEL

YEL

AC2

13AAA/BLK

13DDD/BLK

111/ORA

AC1

115/GRN

YEL

ORG

119/YEL

120/ORA

BLK

YEL

ORG/GRN

ORG

BRN

BLK

BLK

118/GRY

RED

111B/ORA

111C/ORA

YEL

RED

116/BLU

13CCC/BLK

GRN

BLK

13AAA/BLK

WHT

WHT

GND

WHT

BLK/W

HT

GND

BLU

111F/ORA

111D/ORA

111E/ORA

112/PUR

113/YEL

13EEE/BLK

5050A

...........W

IRING

COLOR

CODE

.............

0TAN

1PINK

2BRN

3ORANGE

4YELLOW

5GREEN

6BLUE

7PURPLE

8GRAY

9WHITE

UNLESSSPEC

IFIED

DIFFERENTLY

ON

SCHEMATIC

RIGHTMOSTDIGIT

COLOR

OFWIRE

OF

WIRENUMBER

INHARNESS

WIPERSWITCH

CAB/PRESS.FANSWITCH

DEFROSTFAN

S--12

AC[ON--OFF]

GND

HIGH

LOW

85

86

AUX#2

F--8

15AFUSE

CLUTCHSOL.

AC

COMPRESSOR

ACCONDENSERFANS

D--6

WINDSHIELDWIPER

30

87

DOMELIGHT

AUX#2

F--21

20AFUSE

OFF

LOW

HIGH

MEDIUM

S--14

COM

1 32

OFF

LOW

HIGH

S--15

COM

1 2

SWITCHBLK/W

HT

ACCONDENSERPRESS.

AB

30

87

F--22

20AFUSE

F--7

15AFUSE

BATTERY,

B+

S--11DOMELIGHT

ACEVAP./CABPRESS.FANS

GND

HIGH

LOW

SWITCH

ACEVAP.TEMP

AB

BATTERY,

B+

85

86

4

Part 4 of 4


6600 07-2003

5

ENGINESTARTTIM

ERMODULE

A

A

TOALTERNATOR

61B

STARTERSOLENOID

COIL


1A

34

2


ENGINEBLOCK

ENGINEBLOCK

50B1C

52

OUTPUT+

GROUND

ENGINEHARNESS

J7--A

J7--B

28

1D

8C

3A

M--2

M--1

83

13W

M--2

M--1

8J

8K

13F

13F

51

51A

ENGINEBLOCK

ENGINEHARNESS

13BD

KEY:START

56

5

26

ENGINE BLOCK

N.C.OILPRESSURE

N.O.OILPRESSURE

13BG

67

67C

67A

J7--D

8BE

CREATESDELAYBETWEEN

ENGINESTARTATTEMPTS.

3C

31

29

GOVERNOR

3A

3B

8BD

8BA

3D

8BC

8BB

82

56

55 55A

6059

61A

61

13BA

8BF

67

5B

5A 27

OILPRESS.SWITCH

13BF

13M

13BC

13BB

13BD

1K

ENGINEHARNESS

58D

J7--C

8A

27C

J9--A

29A

31A

J9--F38B

38A

38B

J9--D

J9--E

ENGINESPEEDSWITCH

8B

26A

J9--C

67B

13L

42

42A

42B

42A

8BG

8BF

NOTUSED

J7--E

J9--G

J9--B

13BA

BIT A BIT BLOW: HIGH 0VMED: 0V HIGHHI GH: 0V 0V

ENGINESPEEDSELECTION

1350RPM2000RPM2400RPM

SPEEDBIT

”A”

D--1

M6B

30

87

LOAD

GND

INIT

B+

6

12 3

HOURMETER--

+

M8C

30

87a

LP5

LOW

OILPRESS.

M6C

30

87a

X=CLOSEDCONTACT

START

RUN

GLOW

PLUG

X

X

X

X X

X

S--1

KEYSW

50

17

19

ACC

30

S--16

HIGHENGINETEMP.

N.O../CLOGGED=HIGHTEMP

D--5

STARTERSOLENOID

CONTACTS

ALT

--

EX.

GP--1

SOL5

L.P.LOCKOUTVALVE

B

LP1

OPTIONALGLOW

PLUGLAMP

THROTTLEACTUATOR

+

--

LP5

ENG.TEMP/CHECK

D--3

AUX. 2 RELAY

30 87

S--76

53

2

FUELPUMP

B

M7A

85

86

AUX #1

HGB

E FCD A

MTR1

STARTERMOTOR

M8A

85

86

GLOW PLUG

F--11

15AFUSE

30 87

12VDC

+----

85

86

LP5

ALTERNATORLIGHT

M6A

85

86

S3

B

CA

S--2

NEUTRALSTART

N.O./CLOSED=DOWN

M7B

30

87

M8B

30

87

AUX #2

ENG.SPEED/MAG.PICK--UP

--+

85

86

F--5

30AFUSE

SPEEDBIT

”B”

GP -- 2

GP--3

GP--4

NOTUSED

NOTUSED

AUX. 1 RELAY

1

2

3

Part 1 of 4

6600 DIESEL OVERALL ELECTRICAL DIAGRAM

6600 07-2003

6

4A/YEL

4B/YEL

81A/YEL

87A/PUR

88A/GRN

62BB/YEL

62BA/YEL

62BC/YEL

76/ORA

76A/ORA

76B/ORA

1A

1D

13U

4/YEL

81/YEL

33

79/YEL

80/BLU

77/GRY

62/YEL

87/PUR

88/GRN

89/BRN

90/GRY

62C/YEL

62B/YEL

13GG

13FF

13T

13S

13BE

13BD

13BF

13LL

93/ORA

93/ORA

34A

13Q

93B/ORA

94/YEL

92

95A

S--11

S--12

62A/YEL

95

13KK

13P

6

13V

33A

...........W

IRING

COLOR

CODE

.............

0TAN

1PINK

2BRN

3ORANGE

4YELLOW

5GREEN

6BLUE

7PURPLE

8GRAY

9WHITE

RIGHTMOSTDIGIT

COLOR

OFWIRE

OF

WIRENUMBER

INHARNESS

93A/ORA

13QQ

13NN

4C/YEL

4D/YEL

95A

62BA/YEL

33A

33B

LP7

SIDEBRUSHLIGHT

AUX #1

D--3

S--9 HORN

N.O./CLOSED=HORN

LP10

LAMP_HEADLIGHT

FLASHER

GRY

BLK

GRN

RED

BLK/

GRY

BLU

YEL

DIRECTIONALSWITCH

3

9847

61

LIGHTSWITCH 1

24 5

68

F--20

15AFUSE

LP1

RUNLIGHT,R.H.

LP8

REVOLVINGLIGHT,OHG

F--12

15AFUSE

LP3

TAILLIGHT,R.H.

LP5

HEADLIGHT,R.H.

S--10

BRAKEPEDAL

SWITCH

N.O./CLOSED=BRAKING

F--4

15AFUSE

S--8 REVERSESWITCH

N.O./CLOSED=REVERSE

LP9

LOW

MOUNTEDBEACON

HORN

LP6

HEADLIGHT,

L.H.

LP2

RUNLIGHT,L.H.

LP4

TAILLIGHT,L.H.

F--3

15AFUSE

P L

X

FLASHER

1

23

REVERSEALARM

1

2

3

6600 DIESEL OVERALL ELECTRICAL DIAGRAMPart 2 of 4

6600 07-2003

7

6

7A

7C

7B

7A 7F 7

18

14BA

15

16

11BA

19B

22

13E

13L

13D

13R

13E

13U

7E

24

13H

19A

18A

18B

47A

47BB

48

473

13C

13B

S--17

7J

7H

82

7K 32

13A

GROUNDFORLAMPINSIDESWITCH

30A

7L

18A

M.O.M.

LAMP(--)

LAMP(+)

M--4

M--4

7D

14

13BA

19BA

11

13BB

32

13A

48BB

105

HOPPER

STATIC

GROUND

7L

S--19

STALLEDBRUSH

N.O./CLOSED=STALLED

S--14A

LOWL.P.

N.O./CLOSED=LOW

L.P.

LOWL.P.

AUX #1

30

87

S--16

HOPPERDOWN

N.O./CLOSED=HOPPERDN.

FUELGAUGE

INSEN

GND

SOL5

VAC.FANSOLENOID B

A

STALLEDBRUSH

CLOGGEDVACFAN

F--19

15A FUSE

SOL1

SHAKERSOLENOID

D--2

S--15

THERMALSENTRY

SWITCH

COM

NC

NO

VAC/SHAKERSWITCH

214

658

9

10

HOPPERDOORCLOSED

LOAD

GND

B+

INIT

TIM

ERMODULE

21

3 6

HIGHHOPPERTEMP

(+)

(--)

OUT

PULSEMODULE

12

GROUND

S--18

CLOGGEDVACUUMFAN

N.O./CLOSED=CLOGGED

85

86

S--14

FUELSENDER

S--13

HOPPERDOOR

N.O./CLOSED=DOWN4


Part 3 of 4

6600 07-2003

8

O P TIONAL AC AND CAB HARNESSES

...........W

IRING

COLOR

CODE

.............

0TAN

1PINK

2BRN

3ORANGE

4YELLOW

5GREEN

6BLUE

7PURPLE

8GRAY

9WHITE

UNLESSSPECIFIEDDIFFERENTLY

ONSCHEMATIC

RIGHTMOSTDIGIT

COLOR

OFWIRE

OF

WIRENUMBER

INHARNESS

YEL

BRN

GND

BLU

BLK

BLK

ORG

YEL

YEL

AC2

13AAA/BLK

13DDD/BLK

111/ORA

115/GRN

YEL

ORG

119/YEL

120/ORA

YEL

BLK

ORG/GRN

ORG

BRN

BLK

BLK

118/GRY

RED

111C/ORA

111B/ORA

YEL

RED

116/BLU

13CCC/BLK

GRN

BLK

13AAA/BLK

WHT

WHT

GND

WHT

BLK/W

HT

GND

BLK/W

HT

BLU

111F/ORA

111D/ORA

112/PUR

111E/ORA

113/YEL

13EEE/BLK

5050A

WIPERSWITCH

CAB/PRESS.FANSWITCH

AUX

#2

F--21

20AFUSE

OFF

LOW

HIGH

MEDIUM

S--14

COM

1 32

OFF

LOW

HIGH

S--15

COM

1 2

SWITCH

ACCONDENSERPRESS.

AB

30

87

85

86

F--22

20AFUSE

S--11

DOMELIGHT


GND

HIGH

LOW

BATTERY,

B+

SWITCH

ACEVAP.TEMP

AB

BATTERY,

B+

F--7

15AFUSE

85

86

S--12

AC[ON--OFF]

GND

HIGH

LOW

DEFROSTFAN

AUX

#2

F--10

15AFUSE

CLUTCHSOL.

ACCOMPRESSOR

ACCONDENSORFANS

D--6

WINDSHIELDWIPER

30

87

DOMELIGHT

AC1

4


Part 4 of 4

6600 07-20036600 07-2003

9

6600 Key Switch

30

17

19

ACC

50

RUN POSITION

30

17

19

ACC

50

START POSITIONSpring loaded-Returns to “RUN" unless held

Glow

Plug

START

RUN

OFF

KEY SWITCH

Glow

PlugSTART

RUN

OFF

KEY SWITCH

30

17

19

ACC

50

OFF POSITIONGlow

PlugSTART

RUN

OFF

KEY SWITCH

30

17

19

ACC

50

GLOW PLUG POSITION (Diesel Only)

Spring loaded- Returns

to "OFF" unless held

Glow

PlugSTART

RUN

OFF

KEY SWITCH

ACC

START

RUN

NO CONNECTIONSOFF

GLOW PLUG

19175030

“ . “ Indicates a common connection

SWITCH TERMINAL MARKING

KE

Y S

WIT

CH

PO

SIT

ION

NOTE: Common connections in various switch positions should be less than 1

6600 07-200310

6600 Charging System

28

+ -

Test battery, clean battery terminals, check all

connections, wiring, and fuses F-5 & F-11, turn key

to “RUN” position (KOEO-Key On, Engine Off)

Is

Alternator

light lit?

Start engine

(KOER-Key On,

Engine Running),

run engine at high

governed RPM

Is

Alternator

light lit?

System operating

correctly

With lights on,

check voltage at

battery terminals-

Is it 13.5 to 16.5

Volts?

NO

Re-test battery, re-check battery

terminals, connections, wiring, and fuses

F-5 & F-11; Suspect faulty alternator

Test ALTERNATOR LIGHT;Re-test battery, re-check battery

terminals, connections, wiring,

and fuses F-5 & F-11; Restart

diagnostic steps

YES NO

YES NO

YES

Note: Ignition Switch is illustrated

in the “OFF” position. Please see

Key Switch illustrations page for

various operating positions

PLEASE NOTE: When finished, please reconnect all wires disconnected during testing6600 07-2003 11

6600 Gas/L.P. Start Circuit

28

ZENITH

ENGINE

CONTROLLER

82EA

PIN 7

PIN 14 WHITECONNECTOR

POSITIVE BATTERY CABLE

BLACKCONNECTOR

83EA

83EC

+ -

8EG

8EFPIN 22

PIN 23 PIN 21

PIN 20

13EC

13ED

xxxx

xx

1EA

8

8L

Test battery, clean battery terminals,

check all connections, wiring, and fuses

F-5 & F-11; Turn key to START position

Does STARTER

MOTOR “click” or

make any other

noises?

YES NO

CAUTION!

Disconnect wire harness plug from

DIS ignition coil and turn key to

OFF position for next test.

Re-test battery & battery terminals; Re-check

all connections & wiring; Examine engine for

excessive internal resistance (due to lack of

lubrication, mechanical failure, etc.); Repair

or replace STARTER MOTOR

With a remote start switch tool or equivalent,

connect leads to the two large STARTER

SOLENOID studs (the STARTER SOLENOID

is an integral part of the STARTER MOTOR)

As the remote start

switch is engaged,

does the STARTER

MOTOR crank the

engine?

Re-check all connections, wiring and fuses F-5 & F-

11; Test relay M-3; Test Key Switch; Test for proper

power & ground connections at ZENITH ENGINE

CONTROLLER (refer to ZEEMS troubleshooting)

YES NO




lubrication, mechanical failure, etc.); Repair

or replace STARTER MOTOR





PLEASE NOTE: When finished, please reconnect all wires disconnected during testing

6600 07-200312

6600 Diesel Start Circuit

2


83

+ -

50

17

19

ACC

42

42A

34

8

8BC

42B

3C

13M

13BB

5A

8D

8A

8B

E








Does STARTER


make any other

noises?

YES NO

CAUTION!

Turn key to OFF position for next test.Re-test battery & battery terminals; Re-check



lubrication, mechanical failure, etc.); Suspect

faulty STARTER MOTOR With a remote start switch tool or equivalent,



is an integral part of the STARTER MOTOR)

Re-check all connections, wiring and

fuses F-5 & F-11; Test relays M-6, M-

7, & M8; Test ENGINE START TIMER

MODULE; Test Key Switch

YESAs the remote start

switch is engaged,

does the STARTER

MOTOR crank the

engine? NORe-test battery & battery terminals; Re-check




faulty STARTER MOTOR


6600 07-2003 13

6600 Gas/L.P. Power-Up Circuit

28

ZENITH

ENGINE

CONTROLLER8

8L

8EG

8EF 13ED

13EC

PIN 22

PIN 23

PIN 20

PIN 21

WHITECONNECTOR

+ -

xxxx

xx

Is battery voltage

measured across all

power and ground

connections at

ZENITH ENGINE

CONTROLLER?

YES

Re-check all connections,

wiring, and fuses F-5 &

F-11; Test Key Switch

Refer to ZEEMS troubleshooting to

test ZENITH ENGINE CONTROLLER

Check all connections, wiring, and

fuses F-5 & F-11, turn key to “ON”

position (KOEO-Key On, Engine Off)

NO






6600 07-200314

6600 Diesel Power-Up Circuit

28

+ -

1D





40A FUSE

2 3A

34

13BG

13BA

GOVERNOR

CONTROLLER

PIN A PIN B

5A

3C

8BF

13M

13BF

8A

Is battery voltage measured

across all power and

ground connections at

GOVERNOR

CONTROLLER?

YES


wiring, and fuses F-5 & F-11;

Test Key Switch

Refer to PRECISION

GOVERNOR troubleshooting to

test GOVERNOR

CONTROLLER

Check all connections, wiring, and fuses

F-5 & F-11; Turn key to “ON” position

(KOEO-Key On, Engine Off)

NO


6600 07-2003

15

6600 Gas/L.P. Check Engine Lamp Circuit

28

8B

ZENITH

ENGINE

CONTROLLER

8L

8EG

8EF 13ED

13EC

PIN 22

PIN 23

PIN 20

PIN 21

WHITE

CONNECTOR

8

26A

PIN 122

6E

A

+ -

x

xx

xxx


F-5 & F-11, turn key to “ON” position


Is CHECK

ENGINE

LAMP

flashing?

YES NO

Test CHECK ENGINE LAMP; Re-check all

connections, wiring, and fuses F-5, & F-11;

Test for proper power and ground connections

at ZENITH ENGINE CONTROLLER; Test Key

Switch; Refer to ZEEMS troubleshooting to test

ZENITH ENGINE CONTROLLER

Refer to “ZENITH ENGINE

FAULT CODES” to diagnose

engine or sensor faults





ENGINE TEMP / CHECK ENGINE LAMP

Note: Lamp will light if engine overheats

or if an engine system fault is detected


6600 07-200316

6600 Gas/L.P. Oil Pressure & Hour Meter Circuit

OIL PRESSURE SWITCH

6 PSI

13EG8D

28

27EC

27EB

27EA

8A 27C

ZENITH

ENGINE

CONTROLLER

BLACKCONNECTOR

PIN 8

+ -

xxxx

xx




Is LOW OIL

PRESSURE

lamp lit?

Replace OIL

PRESSURE SWITCH

Test LOW OIL PRESSURE lamp;

Re-check all connections, wiring, and

fuses F-5 & F-11; Test Key Switch

With engine

running, does

lamp go out?

Verify proper oil pressure in

engine; Suspect faulty OIL

PRESSURE SWITCH

Re-check HOUR METER connections and

wiring; Suspect faulty OIL PRESSURE SWITCH

Is LOW OIL

PRESSURE

lamp lit?

YES NO

Remove harness plug at OIL PRESSURE

SWITCH and place a jumper wire across

harness plug wires B & CYES NO

YES NO

With engine

running, is battery

voltage measured

across HOUR

METER terminals?

YES NO

Test or replace

HOUR METER






6600 07-200317

6600 Diesel Oil Pressure & Hour Meter Circuit

28

+ -

1D

40A FUSE

34

AB

C

34 8

8D

8A

OIL PRESSURE SWITCH

13BF




With engine

running, does

lamp go out?



PRESSURE SWITCH

Is LOW OIL

PRESSURE

LED lit?

YES NO



harness plug wires B & CYES NO

Is LOW OIL

PRESSURE

lamp lit?

YES NO

Replace OIL

PRESSURE SWITCH


wiring, and fuses F-5 & F-11;

Test Key Switch

With engine

running, does

HOUR METER run?

NO

Verify proper oil pressure

in engine; System

operating correctly

YES


engine; Suspect faulty HOUR

METER; Suspect faulty OIL

PRESSURE SWITCH






6600 07-200318

6600 Vacuum Fan Circuit

28

+ -

HOPPER SWITCH

(NORMALLY OPEN)

SHOWN CLOSED

(HOPPER DOWN)

3 POSITION VAC

FAN & FILTER

SHAKER SWITCHLED

INSIDE

SWITCH

TO

HIG

H

HO

PP

ER

TE

MP

LA

MP

13BB

13E

POS.1 – VAC FAN ONPOS.2 – ALL FUNCTIONS OFF

POS.3 – RUN SHAKER (MOMENTARY)

S

W

I

T

C

H

SHOWN WITH SWITCH IN

“VAC FAN ON” POSITION

xxxx

xx

13A

With switch in “VAC FAN

ON” (position 1), is battery

voltage measured across

wires at VAC FAN

SOLENOID (SOL5) plug?


F-5, F-11 & F-19, have hopper in full

“DOWN” position, turn key to “ON”


NOYES

Repair or replace faulty hydraulic or

mechanical components; Suspect

faulty VAC FAN SOLENOID coil

Re-check all power & ground connections and

fuses F-5, F-11 & F-19; Test HOPPER

SWITCH; Test THERMO-SENTRY SWITCH

(see circuit chart); Test “3-POSITION” VAC

FAN/SHAKER SWITCH; Test relay M-1; Test

diodes D-1 & D-2; Test Key Switch






6600 07-200319

6600 Vacuum Restriction Warning Circuit

7 13U7D

28

22

xxxx

xx

+ -

Is CLOGGED

VAC FAN

lamp lit?

Test CLOGGED VAC FAN lamp;

Re-check power & ground

connections and fuses F-5, F-11 &

F-19; Test relay M-1; Test diode

D-1; Test Key Switch

YES


F-5, F-11 & F-19, turn key to “ON”


Remove wire plug from VACUUM

SWITCH and place a jumper wire

across harness plug wires

NO

Suspect faulty

VACUUM SWITCH





VACUUM SWITCH

(NORMALLY OPEN)

SEE NOTE BELOW

Vacuum switch closes if vacuum fan is

running with any one of these conditions:

- a blocked (dirty) vacuum panel filter

- a blocked Perma-Filter

- a closed hopper door

VACUUM SWITCH NOTE


6600 07-200320

6600 Gas/Diesel Fuel Sender Circuit

7C

13D

7D

28

S14

FUEL SENDER

0 to 90

90 = FULL TANK

x

xx

xxx

+ -

13L

Does FUEL

GAUGE needle

deflect from FULL

to EMPTY?

YES NO




Remove wires from FUEL SENDER at tank and watch

FUEL GAUGE; Place jumper wire across FUEL

SENDER wires and watch FUEL GAUGE again

Suspect faulty

FUEL SENDER

YES NO

Re-check wiring to FUEL

SENDER ; Suspect faulty

FUEL GAUGE


fuses F-5, F-11 & F-19; Test relay

M-1; Test diode D-1; Test power and

ground circuits; Test Key Switch

Is battery voltage

measured between

wires “IN” & “GND”

at FUEL GAUGE?






6600 07-2003 21

6600 Low L.P. Fuel Sender Circuit

7D 7B

28

x

xx

xxx

LOW L.P.

+ -

13R

With a full L.P. tank properly connected to

machine, with L.P. supply valve fully open, turn

key to “ON” position (KOEO-Key On, Engine Off)

Is LOW L.P.

lamp lit?YES NO

Is LOW L.P.

lamp lit?YES NO

Fully close L.P. supply valve

on L.P. tank and run machine

until engine runs out of fuel

Remove plug at LOW L.P.

SWITCH and place a jumper

wire across harness wires

Suspect faulty

LOW L.P. SWITCH

Test LOW L.P. LAMP; Re-check all

connections, wiring, and fuses F-5, F-11 &

F-19; Test relay M-1; Test diode D-1; Test

power and ground circuits; Test Key Switch

Check all connections

and wiring; Suspect faulty

LOW L.P. SWITCH

Is LOW L.P.

lamp lit?YES NO

System operating

properly






6600 07-200322

6600 Shaker Motor Circuit

28

HOPPER DOWN

SWITCH

NORMALLY OPEN-

CLOSED WITH

HOPPER DOWN

3 POSITION VAC

FAN & FILTER

SHAKER SWITCH

13B

13C

POS.1 – VAC FAN ON

POS.2 – ALL FUNCTIONS OFF (CENTER)

POS.3 – RUN SHAKER (MOMENTARY)

S

W

I

T

C

H

SHOWN WITH SWITCH IN

“RUN SHAKER” POSITION

xxxx

xx

+ -

Does SHAKER

SOLENOID pulse

as wire is tapped

to ground?

NO




Remove wire from #2 post of SHAKER PULSE

MODULE; Momentarily push SHAKER

SWITCH (position 3)

Momentarily push

SHAKER SWITCH

(position 3)- Is battery


terminals #3 & #1 at

SHAKER PULSE

MODULE?YES NO

YES

Disconnect SHAKER SOLENOID

plug; Connect one SHAKER

SOLENOID wire to ground and

the other to battery (+)

Go to

ANext Page

Repair power or ground

circuits leading to SHAKER

PULSE MODULE

Suspect faulty SHAKER

PULSE MODULE






6600 07-200323

6600 Shaker Motor Circuit (continued)

A

Reconnect SHAKER

SOLENOID to circuit – Push

& hold SHAKER SWITCH

(position 3) - Is battery


posts #6 & #1 at SHAKER

TIMER MODULE?


fuses F-5, F-11 & F-19; Test “3-

POSITION” VAC FAN/SHAKER

SWITCH; Test relay M-1; Test diode

D-1; Test Key Switch; Replace

components as needed

NO

NO

NO

YES

YES

Does SHAKER

SOLENOID pulse as

ground side wire is

tapped to ground?

Suspect faulty

SHAKER SOLENOID

Momentarily push

SHAKER SWITCH

(position 3) - Is battery

voltage measured

across posts #85 & 86

at relay M-4?

YES

Re-check connections &

power feed on post #30 at relay

M-4; Suspect faulty relay M-4


circuits to SHAKER TIMER

MODULE; Suspect faulty

SHAKER TIMER MODULE


6600 07-200324

6600 Thermo-Sentry™ Circuit

7D

28

SOL 5

VAC. FAN SOLENOID

TO VAC. FAN SWITCH

13E

xxxx

xx

+ -

Is HIGH

HOPPER

TEMP LAMP

lit?

Test HIGH HOPPER TEMP LAMP; Re-

check all power and ground circuits and

fuses F-5, F-11 & F-19; Test relay

M-1; Test diode D-1; Test Key Switch

Reset or suspect faulty

THERMO-SENTRY switch

YES




Remove wires from “NO” & “COM”

terminals at THERMO-SENTRY SWITCH

and connect wires with a jumper wire

NO






6600 07-2003 25

6600 Hopper Door Switch Circuit

7C 13E7D

28

HOPPER DOOR

SWITCH

(NORMALLY OPEN)

CLOSED WITH

HOPPER DOOR

CLOSED

7A 14

x

xx

xxx

Close Hopper Door; Turn

key to “ON” position


+ -

Is HOPPER

DOOR

CLOSED

LAMP lit?

YES NO

Test HOPPER DOOR CLOSED LAMP;


fuses F-5, F-11 & F-19; Test relay M-1;

Test diode D-1; Test power and ground

circuits; Test Key Switch

Is HOPPER

DOOR

CLOSED

LAMP lit?

YES NO

Remove wire harness plug from

HOPPER DOOR SWITCH and place a

jumper wire across harness wires

Suspect faulty HOPPER

DOOR SWITCH

Open Hopper Door; Turn key

to “ON” position (KOEO-Key

On, Engine Off)

Is HOPPER

DOOR

CLOSED

LAMP lit?

YES NO

Check all connections and

wiring; Suspect faulty HOPPER

DOOR SWITCH

System operating

properly






6600 07-200326

No Engine

Fault Codes

Detectedduring KOEO and KOER

STOP

Does Check Engine Light

Blink Continuously,

Blinks Another Sequence

or Blink 12, 12, 12 ?

(3 times only)

6600 with ZEEMS

(Zenith) Engine Management System

Blinks

12,12,12

No Engine

Fault Codes

Detectedduring KOEO

Start and Run

Engine

Is

Check Engine Light

On during

Key On, Engine Run?(KOER)

Turn Key Off,

Turn Key On,

Engine Off

(KOEO)

Blinks

another

sequence

(3 times only)

NO

YES

Check Engine Light illumination for "12" will be as follows:

on, medium off, on, short off, on;

longer pause;

on, medium off, on, short off, on;

longer pause.on, medium off, on, short off, on.

(other code readouts are similar)

Tennant Engine Trouble Codes are:

14-ECT Sensor Open (Engine Coolant Sensor)

15-ECT Sensor Shorted (Engine Coolant Sensor)23-ACT Sensor Open (Air Temperature Sensor)

24-ACT Sensor Shorted (Air Temperature Sensor)

33-MAP Sensor Open (Manifold Absolute Pressure)

34-MAP Sensor Shorted (Manifold Absolute Pressure)

44-O2 Sensor Lean (Oxygen Sensor)45-O2 Sensor Rich (Oxygen Sensor)

RETEST

Does engine

"shut off" after

2-3 seconds or

40 seconds

of running?

40

Secondsrunning

then off

2-3

Secondsrunning

then off

Service and Repair

as Required

Clear Codes by

momentarily

grounding 49/White

"pigtail"

while engine is running

Blinks Continuously(either 0.5 seconds on

then 1 second off

or

1 second onthen 1 second off)

Start and Run

Engine

High Temperature

automatic shut-

down sequence

activated

Low Oil Pressure

automatic shut-

down sequence

activated

6600 07-2003 27

6600 Gas/L.P. ZEEMS Check Engine Fault Codes

Blinks engine fault code (see chart below)Key On, Engine Off (KOEO)

Engine fault(s) detected

Blinks ON/OFF continuously (0.5 sec. ON,

1 sec. OFF) (Note: There is no separate high

engine temp lamp for gas or L.P. engines)

Key On, Engine Running (KOER)

High engine temperature sensed

AUTOMATIC ENGINE SHUTDOWN OCCURS

NOTE: If key switch is turned off and machine restarted,

engine will run 40 seconds until another automatic shutdown

Blinks “12,12,12” continuouslyKey On, Engine Off (KOEO)

No engine faults detected

Blinks ON/OFF continuously (1 sec. ON,

1 sec. OFF) and LOW OIL PRESSURE lamp

turns on


Low engine oil pressure sensed



engine will run 2 to 3 seconds until another automatic shutdown

ONKey On, Engine Running (KOER)


OFFKey On, Engine Running (KOER)


CHECK ENGINE LAMPMACHINE STATUS

33, 33, 33MAP sensor OPEN, circuit voltage >4.98V

14, 14, 14Engine coolant sensor OPEN

23, 23, 23Air temp sensor OPEN

15, 15, 15Engine coolant sensor SHORTED

34, 34, 34MAP sensor SHORTED

24, 24, 24Air temp sensor SHORTED

12, 12, 12Beginning of fault codes, or OK if no other

codes displayed

FAULT CODE DISPLAYED (ON CHECK

ENGINE LAMP)

CONDITION with Key On, Engine

Off (KOEO)

Ground PIN # 16 of the WHITE CONNECTOR at the ZENITH ENGINE CONTROLLER

while engine is running (Note: Some controllers have a wire pigtail that is connected to PIN # 16

TO CLEAR FAULT CODES AND TURN OFF CHECK ENGINE LAMP

6600 07-200328

BEFORE CONDUCTING TESTS:* Read and Follow ALL Safety Warnings and Precautions in Operator's Manual

* Engine & Hydraulic Oil Must Be At Normal Operating Temperatures after

Running Machine and Hydraulics a Minimum of 5 Minutes

* Examine Machine For Any Linkage Binding or Mechanical Problems

* Maintain Normal Main Brush Pressure as Listed in Operator's Manual

* Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown

Cause or Course of Action

MODEL


6600

HYDRAULIC

DURING TESTS:

6600 07-2003

29

1 2 3 4 5

STEERING SYSTEM

2,0 x 08,0 in,

CYL4

TV1 ,047 dia,

2,8 cu,in,

MTR3

MAIN BROOM

379607

17,9 cu,in,

MTR2

CLOSE

2,0 x 04,0 in,

CYL2

SIDE BROOM

2,50 x 15,0 in,

CYL1

LIFT

6.5 GPM @ 2400 RPM

5.4 GPM @ 2000 RPM

IN

C

OUT BYD CV1

E

F

D

B

A

CK4

CV1B

CV1C

CV1A

RV52400 psi

BROOMS

DOOR

LIFT

6.1 cu.in.

PMP3

CV3

L

R

T

P

600 psi

RV6

CK5

3.9 GPM @ 2400 RPM

3.3 GPM @ 2000 RPM

6.5 GPM @ 2400 RPM

5.4 GPM @ 2000 RPM

VACUUM FAN

CV212V DC

1800 psiRV8

,194 cu,in,

MTR4

6600 OVERALL HYDRAULIC DIAGRAM

(Part 1 of 2)

6600 07-2003

PLEASE NOTE: All specifications listed are for normal operating conditions

30

1 2 3 4 5

FLTR

RV7

25 psi

HTX

PMP2

,40cu,in,

PMP2C

,66cu,in,

PMP2B

,66cu,in,

PMP2A CK1RV2

4000 psi

CK2RV34000 psi

CV4

RV1

120 psi

1,44 cu,in,PMP1B

M

PMP1A

PMP1

CV5

ORnn

ORnn

MTR1PROPEL SYSTEM

RES1

SPEED 2 = 2400 RPMSPEED 1 = 2000 RPM

3 psiRV4

STRN1

6600


(Part 2of 2)

EXPLANATION OF ABBREVIATIONS

PSWITCH.........Pressure Switch

RES..................Reservoir

RH....................Right Hand

RPM.................Revolutions per Minute

RV....................Relief Valve

STRN...............Strainer

SV....................Solenoid Valve

TV....................Throttle Valve

V......................Volts

HTX..............Heat Exchanger

IN..................Inches

LH.................Left Hand

LPM..............Liters per Minute

M..................Motor (Combustion)

MTR.............Motor (Hydraulic)

OR................Orifice

PC.................Pilot Port Check Valve

PMP..............Pump

PSI................Pounds per Square Inch

AUX..........Auxiliary

CK............Check Valve

CM............Centimeters

CU............Cubic

CV............Control Valve

CYL..........Cylinder

DC............Disconnect Coupler (Hydraulic)

DC............Direct Current (Electrical)

FLTR........Filter

GPM.........Gallons per Minute

6600 07-2003


31

4

1

23

20

24

21

AB

C

E

BYD

IN

OUT

T

R

L

P

Reservoir

Cylinder

Aux

Pump

Hopper

Lift

Cylinder

DumpDoor

Hopper

SideBrush

Motor

Steering

Valve

Steer

WheelDrive

Motor

Cylinder

MainBrush

Motor

Filter

Control

Valve Vac

Fan

Propel

Pump

Motor

16

5

6

7

89

10

11

12

13

14

15

18

17

23

19

22

Cooler

6600 HYDRAULIC HOSE ROUTING

6600 07-2003

32

6600 MAIN BRUSH

PRESSURE

RETURN

BROOMS

ACCESSORY PUMP

RESERVOIR

STRAINER

RV4

3 PSI

FILTER

HEAT

EXCHANGER

A

IN

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

SUCTION

RV5

2400 PSI

BYD

MAIN BRUSH

600 PSI

(0.2 BAR)

(166 BAR)

(1.7 BAR)

(41 BAR)

RV7

25 PSI

MAIN BRUSH RPM

460 RPM +/- 25 RPM @ 2000 RPM

550 RPM +/- 25 RPM @ 2400 RPM

CV1A

BROOMS VALVE

Note: Specs. shown are

for main brush down with

2" (5 cm) brush pattern

600 PSI(41 BAR)

HYDRAULIC FLOW METER

5.4 GPM (20 LPM) @ 2000 RPM

6.5 GPM (25 LPM) @ 2400 RPM

(Flow readings +/- 5%)

6600 07-20036600 07-2003


33

HEAT

EXCHANGER

FILTER

RESERVOIR

STRAINER

ACCESSORY PUMP

BROOMS

CV1A

RV 4

3 PSI

IN

PRESSURE

RETURN

SUCTION

6600 MAIN & SIDE BRUSH

A

B

BYD

MAIN BRUSH

600 PSI

SIDE BRUSH

200 PSI

800 PSI

(166 BAR)

RV5

2400 PSI

(0.2 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

RV7

25 PSI(1.7 BAR)

(41 BAR)

(41 BAR)600 PSI

(55 BAR)

(14 BAR)

MAIN BRUSH RPM

460 RPM +/- 25 RPM @ 2000 RPM

550 RPM +/- 25 RPM @ 2400 RPM

SIDE BRUSH RPM

75 RPM +/- 10 RPM @ 2000 RPM

90 RPM +/- 10 RPM @ 2400 RPM

Note: Specs. shown are for

main & side brushes down, with

2" (5 cm) main brush pattern


5.4 GPM (20 LPM) @ 2000 RPM

6.5 GPM (25 LPM) @ 2400 RPM


6600 07-2003


34

ACCESSORY PUMP

RESERVOIR

STRAINER

RV4

3 PSI

FILTER

HEAT

EXCHANGER

PRESSURE

RETURN

SUCTION

6600 VACUUM FAN

VACUUM FAN

1000 PSI

CV2

RV81800 PSI

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)

RV7

25 PSI(1.7 BAR)

(69 BAR)

1000 PSI

(69 BAR)

(124 BAR)HYDRAULIC FLOW METER

5.4 GPM (20 LPM) @ 2000 RPM

6.5 GPM (25 LPM) @ 2400 RPM


6600 07-20036600 07-2003


35

CYLINDER

ACCESSORY PUMP

STRAINER

RESERVOIR

CV1C E

LIFT

RESTRICTOR

RV 4

3 PSI

PRESSURE

RETURN

SUCTION

6600 RAISE HOPPER

BYD

RV7

25PSI

FILTER

HEAT

EXCHANGER

RV5

2400 PSI

LIFT VALVE

CK4

LIFT

(166 BAR)

(0.2 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(1.7 BAR)

6600 07-20036600 07-2003


36

RESERVOIR

STRAINER

ACCESSORY PUMP

FILTER

RV 4

3 PSI

RV 7

25 PSI

ECV1C CYLINDER

LIFT

LIFT VALVE

HEAT

EXCHANGER

RESTRICTOR

PRESSURE

RETURN

SUCTION

ACCESSORY PUMP

6600 LOWER HOPPER

LOWER

RV5

2400 PSI

BYD

(166 BAR)

(0.2 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(1.7 BAR)

Note: Lowering of hopper is due

to gravity (weight of hopper)

6600 07-20036600 07-2003


37

FILTER

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

OPEN

HOPPER DOOR CYLINDER

6600 OPEN HOPPER DOOR

RV5

2400 PSI

BYD

(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR) (1.7 BAR)

6600 07-20036600 07-2003


38

DOOR

ACCESSORY PUMP

OUT

CV1B

IN

HEAT

EXCHANGER

FILTER

RV 7

25 PSI

RV 4

3 PSI

RESERVOIR

STRAINER

PRESSURE

RETURN

SUCTION

RV5

2400 PSI

BYD

CLOSE

C

6600 CLOSE HOPPER DOOR


(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)

(1.7 BAR)

Note: Arrows show direction of

Fluid Flow, NOT Pressure (PSI)

6600 07-20036600 07-2003


39

HEAT

EXCHANGER

FILTER

RV 7

25 PSI

ACCESSORY PUMP

STRAINER

RESERVOIR

RV 4

3 PSI

CV3

R

L

600 PSI

CK5T

P

RV 6

STEERING SYSTEM

CYLINDER

PRESSURE

RETURN

SUCTION

6600 RIGHT TURN

3.3 GPM (12.5 LPM) @ 2000 RPM

3.9 GPM (14.8 LPM) @ 2400 RPM

PMP3

(0.2 BAR)

(1.7 BAR)

(41 BAR)

Note: MTR/PMP3 operates as a motor with engine running (to reduce operator

effort to steer) and as a pump with engine not running (for ability to steer machine)

MTR/PMP3

6600 07-20036600 07-2003


40

CYLINDER

STEERING SYSTEM

HEAT

EXCHANGER

FILTER

RV 7

25 PSI

RESERVOIR

STRAINER

ACCESSORY PUMP

RV 4

3 PSI

R

L

RV 6

600 PSI

P

T CK5

CV3

PRESSURE

RETURN

SUCTION

6600 LEFT TURN

PMP3

(0.2 BAR)

(1.7 BAR)

3.3 GPM (12.5 LPM) @ 2000 RPM

3.9 GPM (14.8 LPM) @ 2400 RPM

(41 BAR)

MTR/PMP3



6600 07-20036600 07-2003


41

To Reservoir

(Case drains)Pick-up

Engine

Propel Motor Assembly

Tow Valve

Charge Pump (to keep

propel system full of oil)

Propel Pump Assembly

Propel Pump

Propel Motor

6600 PROPEL SYSTEM


6600 07-2003

42

sfd

Text Box

TO ADJUST DIRECTIONAL CONTROL LINKAGE 1. Engage the parking brake. 2. Jack up the rear of the machine. Place jack stands under the frame and lower the machine down. 3. Open engine hood and side door. 4. Locate the centering spring cam arms and cam on the propel pump, near the center frame tube. Loosen the M8 cam bolt. 5. Start the engine. 6. Adjust the cams so the rear wheel does not turn. Turning the cams toward the front of the machine will make the wheel go forward. Turning the cams toward the rear of the machine will make the wheel go backward. 7. Stop the engine. 8. Hold the cams in position and tighten the cam bolts. 9. Start the engine and test to verify adjustment. Repeat if necessary. 10. Lower the machine. 11. Start the engine. Move the directional control pedal forward and backward to make sure machine will not move when the directional control pedal is in neutral. Readjust as necessary. 12. Raise the hopper and engage hopper support bar. 13. The machine should travel 1.6 kmh (1 mph) maximum forward speed. To adjust, turn the speed control rod (directional control rod with a balljoint and a vibration isolator.) Turning the rod clockwise, as viewed from above, will slow machine. Turning it counterclockwise will speed machine. 14. Lower the hopper and stop the engine. 15. Check the gap between the speed limiter bracket and the contact surface as the drive linkage rod assembly is 1.5--3 mm (0.06 -- 0.12 in). 16. Adjust the balljoint on the end of the speed control rod to get the correct gap. Tighten all jam nuts.


* Read and Follow ALL Safety Warnings and

Precautions in Operator's Manual

MODEL


6650

ELECTRICAL

DURING TESTS:* Call Technical Services if Diagnostic Time Exceeds One

Hour With Unknown Cause or Course of Action

6650 07-2003 43

C

D

B

F

G

A

INST.PANEL

BALTERNATOR

61B

STARTERSOLENOID

COIL


31EA

29EA 26EA

27C

1D

3EA

34

2

8

SPEED BIT ”A”

ENGINE TEMP/CHECK

N.C. OIL PRESSURE

KEY:START


ENGINEBLOCK

ENGINEBLOCK

8C

8D

13G

13G

51 51A

50B1C

52

OUTPUT

GROUND

ENGINEHARNESS

ENGINEHARNESS

ENGINEHARNESS

J9--E

J9--D

J9--C

J9--A

J7--A

J7--B

26A

29A

31A

8H

ZENITH ENGINE CONTROL

27EA

27EBJ7--D

8EF

8EG

54EA

69EC

70EA

69EA

69EB

8EE

67B

67A

67EA66EA

65EA

64EA

63EA

61EA

60EA

59EA

58EA

57EA

56EA

55EA

53EA

68EA

13EA

13EH

13ED

13EC

13EL

13EE

13EM 13EK

13EF

13M

13EG

J7--E

CONFIG PIN

72EA

J9--B

13EB

5

1A

34A

85

82EA

83EC

83EA

J9--G

J9--F

LOWCURRENTGROUNDTHROUGH

CONTROLLER.13EJ

8A

NOT USED28E A

3A

148EA

N.O.OIL PRESSURE

5EA J7--C

27EC

52A

8A

1EA

83EB

13AC 13L

5EA

29EA

31EA

72EA

148EA

GND.W

ITHENGINERUNNING

WILLCLEARFAULTCODES.

J1=WHITECONNECTOR

J2=BLACKCONNECTOR

WIRING COLOR CODE

0 TAN1 PINK2 BRN3 ORANGE4 YELLOW5 GREEN6 BLUE7 PURPLE8 GRAY9 WHITE

RIGHT MOST DIGIT COLOR OF WIREOF WIRENUMBER IN HARNESS

BIT--A

BIT--B

LOW:HIGH

0V

MED:0V

HIGH

HIGH:0V

0V

ENGINESPEEDSELECTIONBITS

”A”AND”B”

1350RPM

2000RPM

2400RPM

MTR2

GOVERNORACTUATOR

AB

D--1

02SENSOR

ABC

D

SWITCHED, B+

S2

COOLANTTEMPSENSOR

BA

S3

OILPRESSURESWITCH

BCA

x=CLOSEDCONTACT

START

RUN

GLOW

PLUG

X X

XX

XX

S--1

KEYSW

50

17

19

ACC

30

O2--BJ2--10

O2A

J2--12

GD1J1--20

GD2J1--21

GND

J2--11

MAG1

J2--21

MAG2

J2--19

MG--3

J2--20

MP--C

J2--4

MAP--B

J2--17

COIL--D

J1--8

COIL--B

J1--18

COIL--A

J1--10

OXYJ2--9

H20

J1--1

GOVJ1--5

FUELJ1--4

OIL

J2--8

__SLJ2--7

STJ1--14

KEY1

J1--22

KEY2

J1--23

LP

J1--2

INJ

J1--15

GAS

J1--3

ENG

J1--12

+5V

J2--3

SPD1

J2--2

SP2

J2--16

EX

J2--5

RST

J1--16

M3B

RELAY

30

87

M3A

85

86

STARTERSOLENOIDCONTACTS

ALT

+

--

EX.

COILPACK

ABC

D

M1B30 87

S16

COOLANT

TEMPSENSOR

2B

A

R--1

20OHM/40W

MTR1

STARTERMOTOR

F--11

15AFUSE

M2B

AUX. 2 RELAY

30 87

M2A

85

86

F--1

15AFUSE

MAPSENSOR

BA

C

12VDC

+----

SOL4

GASINJECTOR

M1A

85

86

S1

AIR

TEMPSENSOR

BA

S--2

NEUTRALSTART

N.O./CLOSED=DOWN

SOL5

L.P. LOCKOUTVALVE

BA

SOL3

L.P.INJECTOR

MAG.PICKUP

CBA

AUX #2

SOL4

FUELPUMP

AB

F--5

30AFUSE

SPEED BIT ”B”

KEYSWITCH

AUX #1

UNSWITCHED, B+

NOT USED

NOT USED

NOT USED

NOT USED

NOT USED

AUX. 1 RELAY

1

2

3

Part 1 of 4


6650 07-200344

4C/YEL

4B/YEL

81A/YEL

87A/PUR

88A/GRN

62BB/YEL

62BA/YEL

62BC/YEL

76/ORA

76A/ORA

76B/ORA

1D

1D

13J

1D

4/YEL 81/YEL

33

79/YEL

80/BLU

77/GRY

62A/YEL

87/PUR

88/GRN

89/BRN

90/GRY

62C/YEL

62B/YEL

13GG

13FF

13T

13S

13BE

13BD

13BF

13Q

93

93A

34A

13R

93B

94

46

47

48

13V

92

S--20

62/YEL

S--26

13KK

13LL

95A

34A

47A

13H

33

13NN

13QQ

13F

48BB

47BB

33A

95A

95

62BA/YEL

105AA

HOPPER

STATIC

GND.

105AA

LP7

SIDEBRUSHLIGHT

M5B

SHAKER

RELAY

30

87

S--8

HORN

N.O./CLOSED=HORN

LP10

LAMP_HEADLIGHT

FLASHER

GRY

BLK

GRN

RED

BLK/

GRY

BLU

YEL

DIRECTIONALSWITCH

3

9847

61

LIGHTSWITCH1

24 5

68

SOL1

SHAKER

SOLENOID

LP1

RUNLIGHT,R.H.

LP8

REVOLVINGLIGHT,OHG

F--12

15AFUSE

LP3

TAILLIGHT,R.H.

LP5

HEADLIGHT,R.H.

S--9

BRAKEPEDAL

SWITCH

N.O./CLOSED=BRAKING

F--14

15AFUSE

F--2

15AFUSE

D--2

S--10

REVERSESWITCH

N.O./CLOSED=REVERSE

LP9

LOW

MOUNTED

BEACON

HORN

LP6

HEADLIGHT,

L.H.

LP2

RUNLIGHT,L.H.

LP4

TAILLIGHT,L.H.

F--3

15AFUSE

P L

X

FLASHER

1

23

(+)

(--)

OUT

SHAKERMODULE

12 3

F--6

15AFUSE

SWITCHED,B+

REVERSEALARM

1

2

3

Part 2 of 4


6650 07-2003 45

15B

15G

15F

15E

15D

14C

14D

14B

14E

14A

14

15A

15G

D

C

F

G

A

PAGE1

TOUCH PANEL INCORPORATED INTO CONTROL BOARD

13X

12

13BB

11

13N

10

13Y

9

13B

10A

13K

52A

ALTERNATOR

LAMP

SHAKERRELAY

23

22

21

20

13A

19

18

177

7A

16

66 6

53

73

SPEED BIT ”B”

ENG TEMP/CHECK

ENG OIL

26A

27C

29A

31A

13D

13C

85

RIGHTMOSTDIGIT

COLOROFWIRE

OFWIRENUMBER

INHARNESS

85

WIRINGCOLORCODE

0TAN

1PINK

2BRN

3ORANGE

4YELLOW

5GREEN

6BLUE

7PURPLE

8GRAY

9WHITE

13AA

96

OPTIONALWARNINGALARM

24

105

CHASSIS

GROUND

N.O.

COM

11BA

NOTUSED

NOTUSED

NOTUSED

NOTUSED

SV--7

S--4A

LOWL.P.

N.O./CLOSED=LOW

L.P.

F--17

15AFUSE

AUX #1

S--19

STALLEDBROOM

N.O./

CLOSED=STALLEDED

6650 CONTROL BOARD

OUTPUT11

P1--12

OUTPUT7

P1--8

OUTPUT3

P1--23

OUTPUT12P1--21

OUTPUT5

P1--31

OUTPUT2

P1--5

OUTPUT8

P1--9

OUTPUT10

P1--11

OUTPUT13P1--20

OUTPUT9

P1--10

OUTPUT4

P1--6

12VOLTS

POWER2

P1--2

STATIC

GND.P1--1

POWERGND3P1--35

POWERGND4P1--34

INPUT1P1--27

INPUT2

P1--28

INPUT3P1--13

INPUT4P1--14

INPUT5P1--15

CONTROLGND.P1--33

OUTPUT1

P1--4

OUTPUT6

P1--7

12VOLTS

CONTROL

P1--3

INPUT7P1--25

INPUT8

P1--26

POWERGND1P1--22

INPUT9

P1--16

OUTPUT14

P1--30

OUTPUT15

P1--17

OUTPUT16

P1--18

OUTPUT17

P1--19

UNSWITHCED,

B+

P1--32

INPUT9P1--29

OUTPUT18

P1--24

SV--9

VACUUM

FAN

S--5THERMALSENTRY

N.O./CLOSED=FIRE

UNSWITCHED, B+

SV--1

ENABLEVALVE

SV--5

HOPPERDOOROPEN

SV--6B

HOPPERUP

SV--3

SIDEBROOMANDMAIN

BROOMON

WARNINGALARM

S--6

CLOGGEDVACUUMFAN

N.O./CLOSED=CLOGGED

F--19

15AFUSE

SV--2

MAIN

BROOMONLY

ON

GROUND

F--20

15AFUSE

S--4FUELSENDER

SV--6A

HOPPERDOWN

M5A

85

86

SV--8

SIDEBROOMDOWN

S--18HOPPERDOWN

N.O./CLOSED=DOWN

INCLUDES LCD SIGNLE IN DISPLAY

HOPPERTILTIN

NOTUSED

HOPPERTILTOUT

MAIN

BROOMONLY

DOWN

SPEED BIT ”A”PRESS.

4

Part 3 of 4


6650 07-200346

110B/YEL

106B/ORA

107A/YEL

107/YEL

111C/ORA

111B/ORA

108/GRY108B/GRY

108C/GRY

116/BLU

13WW/BLK

13CCC/BLK

13XX/BLK

109/BRN

106/ORA

109A/BRN

106A/ORA

110/YEL

110A/YEL

107B/YEL

109B/BRN

34A

111D/ORA

112/PUR

111E/ORA

113/YEL

13EEE/BLK

AC1

115/GRN

YEL

OPTIONALAC AND CAB HARNESSES

111F/ORA

AC2

13AAA/BLK

ORG

119/YEL

120/ORA

YEL

BLK

ORG/GRN

ORG

BRN

BLK

BLK

118/GRY

FROM

PAGE1

RED

YEL

RED

GRN

BLK

13AAA/BLK

WHT

WHT

GND

WHT

BLK/W

HT

GND

BLK/W

HT

BLU

50

FROM

PAGE1

50A

YEL

BRN

GND

BLU

BLK

BLK

ORG

YEL

YEL

13DDD/BLK

111/ORA

CABFAN/PR

ESS.SWITCH

WIPER

SWITCH

85

86

F--13

15AFUSE

LEFT

AUX.

SIDE

BRUSH

S--17

AUX.

SIDE

BRUSH,D.P.S.T.,ON--OFF--ON

12

4 56

8

S--12

AC[ON--OFF]

SWITCHE D,B+

CLUTCHSOL.

AC

COMPRESSOR

DEFROSTFAN

F--10

15AFUSE

30

87

D--6

AC

CONDENSER

FANS

F--21

20AFUSE

OFF

LOW

HIGH

S--15

COM

1 2

RIGHT

AUX.

SIDE

BRUSH

85

86

OFF

LOW

HIGH

MEDIUM

S--14

COM

1 32

BATTERY,

B+

SWITC

H

AC

EVAP.TEMP

AB

BATTERY,

B+

30

87

DOMELIGHT

F--22

20AFUSE

AUX#2

S--11

DOME

LIGHT

SWITC

H

AC

CONDENSER

PRESS.

AB

AUX#2

S--16

AUX.SIDE

BRUSH,

D.P.D.T.,ON--OFF--ON

12

4 56

8

WINDSHIELDWIPER

GND

HIGH

LOW

F--7

15AFUSE


GND

HIGH

LOW

4

Part 4 of 4


6650 07-2003 47

B

KEYSWITCH

A

INST.PANEL

B

ALTERNATOR

C

D

GF

61B

STARTERSOILENOID

COIL


1D

3C

34

8

KEY:START


ENGINEBLOCK

ENGINEBLOCK

50B1C

52

OUTPUT

GROUND

ENGINEHARNESS

ENGINEHARNESS

J7--B

5

1A

34A

85

83

8A

3A

52A

J7--A

8A

J7--E

J9--F

N.C.OILPRESSURE

J9--A

27C

N.O.OILPRESSURE

NOTUSED

J7--C

J9--G

J9--BNOT USED

26A

J9--C

GOVERNOR

2 42

42A

42B

3A

3B

8BD

8A

8BA

3D

8BC

8BB

82

56

55 55A

8BF

60

59

61A

61

13BA

8BF

67

5B

5A

27

OILPRESS.SWITCH

13BA

13BE

13BF

13M

13BC

13BB

CREATESDELAYBETWEEN

ENGINESTARTATTEMPTS.

J9--E

31A

31

29A

J9--D

29

1K

13AC

42A

13BD

ENGINEBLOCK

ENGINEHARNESS

13BD

56

5

26

ENGINEBLOCK

13BG

67

67C67A

J7--D

8BE

8BG

BIT A BIT BLOW: HIGH 0VMED: 0V HIGHHI GH: 0V 0V

ENGINE SPEED SELECTION

1350RPM2000RPM2400RPM

SPEEDBIT”B”

SWITCHED, B+

D--5

GP--3

D--3

x=CLOSEDCONTACT

START

RUN

GLOW

PLUG

X X

XX

XX

S--1

KEYSW

50 17

19

ACC

30

M6B

30

87

M8C

30

87a

M7B

30

87

STARTERSOLENOID

CONTACTS

M7A

85

86

ALT

+

--

EX.

LOAD

GND

INIT

B+

ENGINESTARTTIMERMODULE

6

12 3

M6C

30

87a

S3

BCA

GP--2

LP1

OPTIONALGLOW

PLUGLAMP

THROTTLEACTUATOR

+

--

M1B30 87

M8A

85

86 HG

B

E FCD A

GP--4

R--1

20OHM/40W

MTR1

STARTERMOTOR

M2B

AUX. 2 RELAY

30 87

F--11

15AFUSE

12VDC

+----

S--16HIGHENGINETEMP.

GP--1

GLOW PLUGS

OW

S--2

NEUTRALSTART

N.O./CLOSED=DOWN

ENG.SPEED/MAG.PICK--UP

--+

M8B

30

87

M6A

85

86

FUELPUMP

BA

F--5

40AFUSE

N.O./CLOSEDHIGHTEMP

NOT USED

NOT USED

NOT USED

SPEEDBIT”A”

AUX.1 RELAY

F--1

15A FUSE

UNSWITCHED, B+

AUX. #1

AUX. #2

1

2

4

3

Part 1 of 4


6650 07-200348

8D

4C/YEL

4B/YEL

81A/YEL

87A/PUR

88A/GRN

62BB/YEL

62BA/YEL

62BC/YEL

76/ORA

76A/ORA

76B/ORA

1D

1D

13J

1D

4/YEL 81/YEL

33

79/YEL

80/BLU

77/GRY

62A/YEL

87/PUR

88/GRN

89/BRN

90/GRY

62C/YEL

62B/YEL

13GG

13FF

13T

13S

13BE

13BD

13BF

13Q

93

93A

34A

13NN

93B

94

13QQ

46

47

48

13V

92

S--20

62/YEL

S--26

95

13KK

13LL

95A

34A

47A

13H

33

8C

51

51A

13R

13G

47BB

48BB

13F

33A

95A

62BA/YEL

105AA

HOPPERSTATIC

GND.

LP9

SIDEBRUSHLIGHT

D--1

M5B

SHAKER

RELAY

30

87

S--8

HORN

N.O./CLOSED=HORN

LP2

LAMP_HEADLIGHT

FLASHER

GRY

BLK

GRN

RED

BLK/

GRY

BLU

YEL

DIRECTIONALSWITCH

3

9847

61

LIGHTSWITCH1

24 5

68

SOL1

SHAKERSOLENOID

LP10

REVOLVINGLIGHT,OHG

LP3

RUNLIGHT,R.H.

F--12

15AFUSE

LP5

TAILLIGHT,R.H.

LP7

HEADLIGHT,R.H.

S--9

BRAKEPEDAL

SWITCH

N.O./CLOSED=BRAKING

F--14

15AFUSE

F--2

15AFUSE

D--2

S--10

REVERSESWITCH

N.O./CLOSED=REVERSE

M2A

85

86

LP11

LOW

MOUNTED

BEACON

HORN

LP4

RUNLIGHT,L.H.

LP8

HEADLIGHT,

L.H.

M1A

85

86

LP6

TAILLIGHT,L.H.

F--3

15AFUSE

P L

X

FLASHER

1

23

(+)

(--)

OUT

SHAKERPULSE

MODULE 1

2 3

F--6

15AFUSE

SWITCHED,B+

REVERSEALARM

1

2

4

3


Part 2 of 4

6650 07-2003 49

15B

15G

15F

15E

15D

14C

14D

14B

14E

14A

14

15A

15G

DE1

CE1

FE1

GE1

A

PAGE1

TOUCH PANEL INCORPORATED INTO CONTROL BOARD

S--1,LED1: ONE STEPS--2,LED2: VACUUMS--3,LED3: SHAKERS--4,LED4: SIDE BRUSHS--5,LED5: HOPPER UPS--6,LED6: HOPPER DOWNS--7,LED7: HOPPER DOOR CLOSES--8,LED8: HOPPER DOOR OPENS--9,LED9: HOPPER TILT OUT (800)S--10,LED10: HOPPER TILT IN (800)S--11,LED11: ENGINE SPEED LOWS--11,LED12: ENGINE SPEED MED.S--11,LED13: ENGINE SPEED HIGH

NOTE: SEVENWARNINGCONDITION LEDSLED--14: THERMAL SENTRYLED--15: HOPPERDIFFERENTIALPRESSURELED--16: LOW FUELLED--17: HIGH ENGINETEMP.LED--18: LOW ENGINE OIL PRESSURELED--19: ALTERNATORLED--20: STALLED BROOM

NOTUSED

13X

12

13BB

11

13N

10

13Y

913B

13B

10A

13K

52A

ALTERNATORLAMP

SHAKERRELAY

23

22

21

20

13A

13A

19

13D

13C

18

177

7A 16

66 6

HOPPERTILTIN

(800ONLY)

53

73

SPEED BIT ”B”

ENG OIL PRESSURE

26A

27C

29A

31A

13D

13C

(800ONLY)

78

85

RIGHTMOSTDIGIT

COLOR

OFWIRENUMBER

INHARNESS

85

WIRINGCOLORCODE

0TAN

1PINK

2BRN

3ORANGE

4YELLOW

5GREEN

6BLUE

7PURPLE

8GRAY

9WHITE

13AA

96

OPTIONALWARNINGALARM

24

105

CHASSIS

GROUND

11BA

NOTUSED

NOTUSED

NOTUSED

SV--7

MAIN

BROOMDOWN

1.7AMPS

S--4A

LOWL.P.

N.O./ CLOSED=

LOW

L.P.

F--17

15AFUSE

AUX #1

S--19STALLEDBROOM

N.O. /CLOSED=STALLEDED

6650 CONTROL BOARD

OUTPUT11

P1--12

OUTPUT7

P1--8

OUTPUT3

P1--23

OUTPUT12P1--21

OUTPUT5

P1--31

OUTPUT2

P1--5

OUTPUT8

P1--9

OUTPUT10

P1--11

OUTPUT13P1--20

OUTPUT9

P1--10

OUTPUT4

P1--6

12VOLTSPOWER2

P1--2

STATIC

GND.P1--1

POWERGND3

P1--35

POWERGND4

P1--34

INPUT1

P1--27

INPUT2

P1--28

INPUT3

P1--13

INPUT4

P1--14

INPUT5

P1--15

CONTROLGND.P1--33

OUTPUT1

P1--4

OUTPUT6

P1--7

12VOLTSCONTROL

P1--3

INPUT7P1--25

INPUT8P1--26

POWERGND1

P1--22

INPUT9

P1--16

OUTPUT14

P1--30

OUTPUT15

P1--17

OUTPUT16

P1--18

OUTPUT17

P1--19

UNSWITHCED,B+

P1--32

INPUT9

P1--29

OUTPUT18

P1--24

SV--9

VACUUM

FAN

1.7AMPS

S--5

THERMALSENTRY

N.O./CLOSED=FIRE

UNSWITCHED, B+

SV--1

ENABLEVALVE

1.7AMPS

SV--5

HOPPERDOOR

OPEN

1.7AMPS

SV--6B

HOPPERUP

1.7AMPS

SV--3

SIDEBROOMANDMAIN

BROOMON

1.7AMPS

WARNING

ALARM

S--6

CLOGGEDVACUUMFAN

N.O./CLOSED=CLOGGED

F--19

15AFUSE

SV--2

MAIN

BROOMONLY

ON

1.7AMPS

GROUND

F--20

15AFUSE

S--4

FUELSENDER

SV--6A

HOPPERDOWN

1.7AMPS

M5A

85

86

SV--8

SIDEBROOMDOWN

1.7AMPS

S--18

HOPPERDOWN

N.O./CLOSED=DOWN

ENG TEMP/CHECK

HOPPERTILTOUT

SPEED BIT ”A”

INCLUDES LCD SINGLE LINE DISPLAY.

4


Part 3 of 4

6650 07-200350

110B/YEL

106B/ORA

107A/YEL

107/YEL

108B/GRY

108/GRY

13WW/BLK

13XX/BLK

109/BRN

106/ORA

109A/BRN

106A/ORA

110/YEL

110A/YEL

107B/YEL

109B/BRN

34A

108C/GRY

YEL

BRN

GND

BLU

BLK

BLK

ORG

YEL

YEL

AC2

13AAA/BLK

13DDD/BLK

111/ORA

AC1

115/GRN

YEL

ORG

119/YEL

120/ORA

YEL BLK

ORG/GRN

ORG

BRN

BLK

BLK

118/GRY

RED

111C/ORA

111B/ORA

YEL

RED

116/BLU

13CCC/BLK

GRN

BLK

13AAA/BLK

WHT

WHT

GND

WHT

BLK/W

HT

GND

BLK/W

HT

BLU

111F/ORA

111D/ORA

112/PUR

111E/ORA

113/YEL

13EEE/BLK

5050A

OPTIONALAC AND CAB HARNESS

WIPER

SWITC

H

CAB/PR

ESS.FANSWITC

H

BATTERY,

B+

AUX#2

85

86

CLUTCHSOL.

AC

COMPRESSOR

AC

CONDENSER

FANS

F--13

15AFUSE

LEFT

AUX.

SIDE

BRUSH

S--17

AUX.SIDE

BRUSH,D.P.S.T.,ON--OFF--ON

12

4 56

8

WINDSHIELDWIPER

S--12

AC

[ON--OFF]

SWITCHE D,B+

GND

HIGH

LOW

DEFROSTFAN

F--10

15AFUSE

RIGHT

AUX.

SIDE

BRUSH

D--6

30

87

OFF

LOW

HIGH

MEDIUM

S--14

COM

1 32

DOMELIGHT SWITCH

AC

CONDENSERPRESS.

AB

30

87

85

86

AUX#2

F--21

20AFUSE

SWITC

H

AC

EVAP.TEMP

AB

OFF

LOW

HIGH

S--15

COM

1 2

F--7

15AFUSE

S--16

AUX.SIDE

BRUSH,

D.P.D.T.,ON--OFF--ON

12

4 56

8

F--22

20AFUSE

S--11

DOME

LIGHT


GND

HIGH

LOW

BATTERY,

B+

4


Part 4 of 4

6650 07-2003 51

6650 Key Switch

30

17

19

ACC

50

RUN POSITION

30

17

19

ACC

50

START POSITIONSpring loaded-Returns to “RUN" unless held

Glow

Plug

START

RUN

OFF

KEY SWITCH

Glow

PlugSTART

RUN

OFF

KEY SWITCH

30

17

19

ACC

50

OFF POSITIONGlow

PlugSTART

RUN

OFF

KEY SWITCH

30

17

19

ACC

50

GLOW PLUG POSITION (Diesel Only)

Spring loaded- Returns

to "OFF" unless held

Glow

PlugSTART

RUN

OFF

KEY SWITCH

ACC

START

RUN

NO CONNECTIONSOFF

GLOW PLUG

19175030

“ . “ Indicates a common connection

SWITCH TERMINAL MARKING

KE

Y S

WIT

CH

PO

SIT

ION

NOTE: Common connections in various switch positions should be less than 1

6650 07-2003

52

5

+ -

8

8A

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 16

PIN 1

PIN 33

PIN 34

PIN 3513D

13C

13B

13A

1D 85

52A

15A FUSE

1A

M1

15A FUSE1B 6 7

7A

PIN 2

PIN 3

ALTERNATOR LED

M151

Note: Ignition Switch is illustrated in the “OFF” position. Please

see Key Switch illustrations page for various operating positions

F-19

F-1

6650 Charging System

8A

CHASSIS

GROUND

8CTest battery, clean battery terminals, check all

connections, wiring, Resistor R-1, and fuses F-1,

F-5, F-11 & F-19, turn key to “ON” position


Start engine

(KOER-Key On,

Engine Running),

run engine at high

governed RPM

Is

ALTERNATOR

LED lit?

YES NO

Re-test battery, re-check battery

terminals, connections, wiring,

Resistor R-1, and fuses F-1, F-5, F-11

& F-19; Suspect faulty 6650 Control

Board; Restart diagnostic steps

Re-test battery, re-check battery terminals,

connections, wiring, Resistor R-1, and fuses

F-1, F-5, F-11 & F-19; Suspect faulty alternator

Is

ALTERNATOR

LED lit?

System operating

correctly

With lights on,

check voltage at

battery terminals-

Is it 13.5 to 16.5

Volts?

YES NO

YES NO

6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing53

6650 Gas/L.P. Start Circuit

28

ZENITH

ENGINE

CONTROLLER

82EA

PIN 7

PIN 14 WHITECONNECTOR


BLACKCONNECTOR

83EA

83EC

+ -

8EG

8EFPIN 22

PIN 23 PIN 21

PIN 20

13EC

13ED

1D

Note: Ignition Switch is illustrated in the “OFF”

position. Please see Key Switch illustrations

page for various operating positions

1EA

8

8H




Does STARTER


make any other

noises?

YES NO

CAUTION!

Disconnect wire harness plug from

DIS ignition coil and turn key to

OFF position for next test.Re-test battery & battery terminals; Re-check




faulty STARTER MOTORWith a remote start switch tool or equivalent,



is an integral part of the STARTER MOTOR)Re-check all connections, wiring and fuses F-5 & F-

11; Test relay M-3; Test Key Switch; Test for proper

power & ground connections at ZENITH ENGINE

CONTROLLER (refer to ZEEMS troubleshooting)

As the remote start

switch is engaged,

does the STARTER

MOTOR crank the

engine?

YES NO







6650 Diesel Start Circuit

2


83

+ -

50

TO 6650

CONTROL

BOARD

17

19

ACC

42

42A

34

8

8A

42B

3C

13M

13BB

8B

E








Does STARTER


make any other

noises?

YES NO

CAUTION!

Turn key to OFF position for next test.Re-test battery & battery terminals; Re-check




faulty STARTER MOTORWith a remote start switch tool or equivalent,



is an integral part of the STARTER MOTOR)Re-check all connections, wiring and

fuses F-5 & F-11; Test relays M-6, M-

7, & M8; Test ENGINE START TIMER

MODULE; Test Key Switch

YES

As the remote start

switch is engaged,

does the STARTER

MOTOR crank the

engine?






NO


M151

28

6650 Gas/L.P. Power-Up Circuit

ZENITH

ENGINE

CONTROLLER

8

8H

8EG

8EF 13ED

13EC

PIN 22

PIN 23

PIN 20

PIN 21

WHITECONNECTOR

+ -

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

15A FUSE

F-19

F-1

7

M1

13G





Is battery voltage

measured across all

power and ground

connections at ZENITH

ENGINE CONTROLLER

and 6650 CONTROL

BOARD?

YES


wiring, and fuses F-1, F-5, F-

11 & F-19; Test Key Switch

Refer to ZEEMS troubleshooting to test

ZENITH ENGINE CONTROLLER or

suspect faulty 6650 CONTROL BOARD


F-1, F-5, F-11 & F-19; Turn key to “ON”


NO


6650 Diesel Power-Up Circuit

28

+ -6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

15A FUSE

F-19

F-1

7

M1





40A FUSE

M151 13G

GOVERNOR

CONTROLLERPIN A

PIN B

TO 6650

CONTROL

BOARD

2 3A

8BF

34

8C

13BF

13BG

13BA

3C

13M

8A


across all power and

ground connections at

GOVERNOR

CONTROLLER and 6650

CONTROL BOARD?

YES


wiring, and fuses F-1, F-5, F-

11 & F-19; Test Key Switch

Refer to PRECISION GOVERNOR

troubleshooting to test GOVERNOR

CONTROLLER or suspect faulty 6650

CONTROL BOARD




NO


6650 Gas/L.P. Check Engine Circuit

M151

28

ZENITH

ENGINE

CONTROLLER

8

8H

8EG

8EF 13ED

13EC

PIN 22

PIN 23

PIN 20

PIN 21

WHITECONNECTOR

+ -

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

15A FUSE

F-19

F-1

7

CHECK ENGINELCD DISPLAY PANEL

PIN 12

PIN 2626A

M1








Is CHECK

ENGINE

displayed on

LCD panel?

YES NO

No faults detected by ZENITH

ENGINE CONTROLLER; Refer

to ZEEMS troubleshooting to test






6650 Gas/L.P. High Engine Temperature Circuit

M151

28

ZENITH

ENGINE

CONTROLLER

8

8H

8EG

8EF 13ED

13EC

PIN 22

PIN 23

PIN 20

PIN 21

WHITECONNECTOR

+ -

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

15A FUSE

F-19

F-1

7


PIN 12

PIN 2626A

HIGH ENGINE

TEMP LED

M1








Is CHECK

ENGINE

displayed on

LCD panel?

YES NO

No faults detected by ZENITH

ENGINE CONTROLLER; Refer

to ZEEMS troubleshooting to test






6650 Diesel High Engine Temperature Circuit

28

+ -

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

15A FUSE

F-19

F-1

7


PIN 2626A

M1





S-16

HIGH ENGINE TEMP

N.O./CLOSED=HIGH TEMP

26

HIGH ENGINE

TEMP LED

Check all connections, wiring, and fuses F-1, F-5, & F-

19; Turn key to “ON” position (KOEO-Key On, Engine

Off), and place jumper wire from wire 26A at HIGH

ENGINE TEMP switch to chassis or frame ground

Is CHECK

ENGINE

displayed on

LCD panel?

YES NO

High engine temp. not detected by

6650 CONTROL BOARD; Recheck all

connections, wiring, and fuses F-1, F-5,

& F-19; Suspect faulty 6650

CONTROL BOARD

System operating correctly;

Suspect faulty HIGH

ENGINE TEMP switch


6650 Gas/L.P. Oil Pressure Circuit

M151

28

8

8H

8EG

8EF 13ED

13EC

PIN 22

PIN 23

PIN 20

PIN 21

WHITECONNECTOR

+ -

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

15A FUSE

F-19

F-1

7


PIN 8 PIN 2527EB 27EA

LOW ENGINE OIL

PRESSURE LED

ZENITH

ENGINE

CONTROLLER

BLACKCONNECTOR

27C

13EG

OIL

PRESSURE

SWITCHA

B

C

27EC

M1






F-1, F-5, F-11 & F-19, turn key to “ON”


Is LOW OIL

PRESSURE

LED lit?

YES NO



harness plug wires B & C

Is LOW OIL

PRESSURE

lamp lit?

YES NO

Replace OIL

PRESSURE SWITCH


fuses F-5 & F-11; Test Key Switch;

Suspect faulty 6650 Control Board

With engine

running, does

lamp go out?

NOYES



PRESSURE SWITCH


in engine; System

operating correctly


6650 Diesel Oil Pressure Circuit

28

+ -

6650

CONTROL

BOARD

105

PIN 22

PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

15A FUSE

F-19

F-1

7


PIN 2527C

M1





27

13BF

ENGINE OIL PRESSURE SWITCH

N.C./OPEN=OIL PRESSURE SENSED

S-3A

C

B LOW ENGINE OIL

PRESSURE LED

Is LOW OIL

PRESSURE

LED lit?

YES NO


fuses F-1, F-5 & F-19; Test Key

Switch; Suspect faulty 6650 Control

Board

With engine

running, does

lamp go out?

YES

NO



PRESSURE SWITCH

Check all connections, wiring, and fuses F-1, F-5, & F-

19; Turn key to “ON” position (KOEO-Key On, Engine

Off), and place jumper wire from wire 27 at ENGINE OIL

PRESSURE SWITCH to chassis or frame ground


in engine; System

operating correctly


M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSE

15A FUSE

F-17PIN 10

15A 15G 22

SV-9

VACUUM FAN SOLENOID

VACUUM

FAN LED

M1

VACUUM

FAN

SWITCH





6650 Vacuum Fan Circuit

6

Turn VACUUM FAN ON

(VAC FAN LED should be

lit); Is battery voltage

measured across wires at

VAC FAN SOLENOID

(SV-9) plug?


F-1, F-5, F-11 & F-19, have hopper in full

“DOWN” position, turn key to “ON”


YES


mechanical components (refer to 6650

HYDRAULIC TROUBLESHOOTING);

Suspect faulty VAC FAN SOLENOID coil

Re-check all power & ground connections and fuses

F-1, F-5, F-11 & F-19; Test HOPPER SWITCH;

Test THERMO-SENTRY SWITCH (see circuit

chart); Test relay M-1; Test diode D-1; Test Key

Switch; Suspect faulty 6650 Control Board

NOTE: DO NOT UNPLUG connector

at VACUUM FAN SOLENOID (SV-9)

when doing voltage tests. Unplugging

connector will give false readings.

Note: Typical Solenoid

Valve Coil Resistance

is 6 to 8 Ohms

NO


6650 Vacuum Restriction Warning Circuit


F-1, F-5, & F-11, turn key to “ON”


M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSE

VACUUM

RESTRICTION

LED

M1

VACUUM SWITCH

(NORMALLY OPEN)

SEE NOTE BELOW

PIN 14

13X





VACUUM SWITCH NOTE

Vacuum switch closes if vacuum fan is

running with any one of these conditions:

- a blocked (dirty) vacuum panel filter

- a blocked Perma-Filter

- a closed hopper door

12

Is CLOGGED

DUST FILTER

LED lit?


connections and fuses F-1, F-5, &

F-11; Test relay M-1; Test diode

D-1; Test Key Switch; Suspect

faulty 6650 Control Board

YES

Remove wire plug from VACUUM

SWITCH and place a jumper wire

across harness plug wires

NO

Suspect faulty

VACUUM SWITCH


6650 Gas/Diesel Fuel Sender Circuit

S-4

FUEL SENDER

M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 28

13N

FUEL LEVEL

LCD DISPLAY PANEL

10

10

LOW

FUEL

LEDNote: Ignition Switch is illustrated




Does LOW FUEL

LED light and FUEL

GAUGE on LCD

panel deflect from

FULL to EMPTY?

YES


wiring, and fuses F-1, F-5,

F-11 & F-19; Suspect faulty

6650 Control Board

Suspect faulty

FUEL SENDER




Remove wires from FUEL SENDER at tank and watch

FUEL GAUGE; Place jumper wire across FUEL

SENDER wires and watch FUEL GAUGE again

NO


6650 Low L.P. Fuel Sender Circuit

M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 28

13N

FUEL LEVEL

LCD DISPLAY PANEL

10

10A

S-4A

LOW FUEL

PRESSURE SWITCH

13K

NORMALLY OPEN / CLOSED WITH LOW L.P. FUEL PRESSURE

LOW

FUEL





Check all connections, wiring, and fuses F-1, F-5, F-11

& F-19; With a full L.P. tank properly connected to

machine, with L.P. supply valve fully open, turn key to

“ON” position (KOEO-Key On, Engine Off)

Is LOW FUEL

LED lit?YES NO

Is LOW FUEL

LED lit?YES NO

Fully close L.P. supply valve

on L.P. tank and run machine

until engine runs out of fuel

Remove plug at LOW L.P.

PRESSURE SWITCH and place a

jumper wire across harness wires

Suspect faulty

LOW L.P. SWITCH

Re-check all connections, wiring, and fuses F-1,

F-5, F-11 & F-19; Test relay M-1; Test diode

D-1; Test power and ground circuits; Test Key


Check all connections and

wiring; Suspect faulty

LOW L.P. SWITCH

Is LOW FUEL

LED lit?YES NO

System operating

properly


M5

M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSE

15A FUSE

F-17PIN 11

15A 23

SHAKER

LED

M1

15B

F-6

15A FUSE M5

1D 46 47

47A

SHAKER MODULE

SHAKER

RELAY





6650 Shaker Motor Circuit

SHAKER

SWITCH

6


F-1, F-5, F-6, F-11, F-17 & F-19, turn key

to “ON” position (KOEO-Key On, Engine

Off)

Remove wire from #2 post of SHAKER PULSE

MODULE; Momentarily push SHAKER button

Disconnect SHAKER SOLENOID

plug; Connect one SHAKER

SOLENOID wire to ground and

the other to battery (+)

Does SHAKER

SOLENOID pulse

as wire is tapped

to ground?

NO

Momentarily push

SHAKER SWITCH - Is

battery voltage measured

across terminals #3 & #1

at SHAKER PULSE

MODULE?

YES

YES NO

Repair power or ground

circuits leading to SHAKER

MODULE

Go to

ANext Page

Replace SHAKER

MODULE


6650 Shaker Motor Circuit (continued)

A

NO

NOYES

Does SHAKER

SOLENOID pulse as

ground side wire is

tapped to ground?

Replace SHAKER

SOLENOID

Momentarily push

SHAKER SWITCH - Is

battery voltage

measured across posts

#85 & 86 at SHAKER

RELAY M-5?

YES

Re-check all connections, wiring,

and fuses F-1, F-5, F-6, F-11, F-17

& F-19; Test relay M-1; Test diode

D-1; Test Key Switch; Suspect

faulty 6650 Control Board

Re-check connections &

power feed on post #30 at

SHAKER RELAY M-5;

Suspect faulty relay M-5


M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 13

13BBS-5

11

NORMALLY OPEN / CLOSED WITH

HIGH HOPPER TEMPERATURE

HIGH

HOPPER

TEMP LED

M1





6650 Thermo-Sentry™ Circuit

Is HIGH

HOPPER

TEMP LED

lit?

Re-check all power and ground circuits

and fuses F-1, F-5, F-11 & F-19; Test

relay M-1; Test diode D-1; Test Key


Reset or suspect faulty

THERMO-SENTRY switch

YES




Remove wires from “NO” & “COM”

terminals at THERMO-SENTRY SWITCH

and connect wires with a jumper wire

NO


M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 719

15A FUSE

F-1715A 15D SV-5

HOPPER DOOR

SOLENOID

HOPPER DOOR OPEN/CLOSE

SWITCHES (ON TOUCH PANEL)

OPEN CLOSE





PIN 416

15A FUSE

F-20 14 14A

ENABLE SOLENOID

SV-1

6650 Hopper Door Circuit

6

HOPPER DOOR

OPEN LED

HOPPER DOOR

CLOSED LED

Push HOPPER DOOR

OPEN button - Is battery


wires at ENABLE

SOLENOID (SV-1) plug and

HOPPER DOOR OPEN

SOLENOID (SV-5) plug?

Check all connections, wiring, and fuses F-1,

F-5, F-11, F-17 & F-19; Start engine and

push HOPPER DOOR CLOSED button until

HOPPER DOOR CLOSED LED is lit; Shut off

engine; Turn key to “ON” position


YES



HYDRAULIC TROUBLESHOOTING); Suspect

faulty HOPPER DOOR OPEN SOLENOID coil

Re-check all power & ground connections

and fuses F-1, F-5, F-11, F-17 & F-19;

Test relay M-1; Test diode D-1; Test Key


NOTE: DO NOT UNPLUG connector

at ENABLE SOLENOID (SV-1) or

HOPPER DOOR SOLENOID (SV-5)


connector will give false readings.Note: Typical Solenoid


is 6 to 8 Ohms

NO


M151

28

8

+ -

105

13D

13C

13B

13A85

7

7A

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

13Y

9

9

S-18

HOPPER POSITION

SWITCH

NORMALLY OPEN / CLOSED WITH HOPPER IN FULL DOWN POSITION

HOPPER

DOWN LED

6650 Hopper Up/Down Circuit

6650

CONTROL

BOARD

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35

PIN 2

PIN 3

PIN 27

HOPPER UP/DOWN

SWITCHES(ON TOUCH PANEL)

UP DOWN

6

15F

15ESV-6B

HOPPER

UP SOLENOID

SV-6A

HOPPER DOWN

SOLENOID

20

21

PIN 8

PIN 9

15A FUSE

F-1715A





PIN 416

15A FUSE

F-20 14 14A

ENABLE SOLENOID

SV-1

15A FUSE

F-11

CHASSIS

GROUNDHOPPER

UP LED

Is battery voltage

measured across wires at

HOPPER UP and DOWN

SOLENOIDS (SV-6B &

SV-6A)?

NO

Check all connections, wiring, and fuses F-1, F-5, F-11,

F-17 & F-19; Turn key to “ON” position (KOEO-Key On,

Engine Off); Push and hold HOPPER UP button and

measure voltage across wires at ENABLE SOLENOID

(SV-1) plug, then HOPPER UP SOLENOID (SV-6B) plug.

Push and hold HOPPER DOWN button and measure

voltage across wires at ENABLE SOLENOID (SV-1) plug,

then HOPPER DOWN SOLENOID (SV-6A).




faulty HOPPER UP or DOWN SOLENOID coil

Note: Typical Solenoid


is 6 to 8 Ohms

NOTE: DO NOT UNPLUGconnectors at ENABLE SOLENOID

(SV-1) or HOPPER UP and DOWN

SOLENOIDS (SV-6B & SV-6A) when

doing voltage tests. Unplugging

connector will give false readings.

YES


and fuses F-1, F-5, F-11, F-17 & F-19;




M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 29

13AA

96

96

S-19STALLED

MAIN BRUSH

NORMALLY OPEN / CLOSED WITH MAIN BRUSH STALL

STALLED

MAIN

BRUSH





6650 Main Brush Stall Circuit

Is STALLED

MAIN BRUSH

LED lit?

Re-check all power and ground circuits

and fuses F-1, F-5, F-11 & F-19; Test

relay M-1; Test diode D-1; Test Key


Suspect faulty STALLED

MAIN BRUSH SWITCH

YES




Remove wires from terminals at STALLED

MAIN BRUSH SWITCH and connect wires

with a jumper wire

NO


M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 416

15A FUSE

F-20 14 14A

ONE STEP

ON/OFF SWITCH

ON/OFF

6650 Main Brush On & Down Circuit

ONE

STEP

LED

ENABLE

SOLENOID

SV-2

SV-7MAIN BRUSH

DOWN SOLENOID

14B

14E

17

73

PIN 5

PIN 23

SV-1





6

MAIN BRUSH

ON SOLENOID


across wires at ENABLE

SOLENOID (SV-1), MAIN

BRUSH ON SOLENOID (SV-2),

and MAIN BRUSH DOWN

SOLENOID (SV-7)?



position (KOEO-Key On, Engine Off); Push

ONE-STEP button and measure voltage across

wires at ENABLE SOLENOID (SV-1), MAIN

BRUSH ON SOLENOID (SV-2), and MAIN

BRUSH DOWN SOLENOID (SV-7)

YES




faulty SOLENOID coil


and fuses F-1, F-5, F-11, F-19 & F-20;



NOTE: DO NOT UNPLUG connectors

at ENABLE SOLENOID (SV-1), MAIN

BRUSH ON SOLENOID (SV-2), or MAIN

BRUSH DOWN SOLENOID (SV-7) when

doing voltage tests. Unplugging

connector will give false readings. Note: Typical Solenoid


is 6 to 8 Ohms

NO


M151

28

8

+ -

6650

CONTROL

BOARD

105

PIN 22PIN 32

PIN 1

PIN 33

PIN 34

PIN 35 13D

13C

13B

13A

CHASSIS

GROUND

85

7

7A

PIN 2

PIN 3

51D

85

15A FUSE

1A

1B 6

8C

F-19

F-1

7

15A FUSEM1

PIN 416

15A FUSE

F-20 14 14A

6650 Main & Side Brush On & Down Circuit

ONE

STEP

LED

ENABLE

SOLENOID

SIDE & MAIN

BRUSH ON SOLENOID

MAIN BRUSH

DOWN SOLENOID

14C

14E

18

73

PIN 6

PIN 23

SIDE BRUSH

DOWN SOLENOID

14D 53 PIN 31

ONE STEP ON/OFF SWITCH

SIDE

BRUSH

ON LED

SIDE BRUSH ON/OFF SWITCH

SV-1

SV-3

SV-7

SV-8





6

Is battery voltage measured across

wires at ENABLE SOLENOID (SV-1),

SIDE & MAIN BRUSH ON SOLENOID

(SV-3), MAIN BRUSH DOWN

SOLENOID (SV-7), and SIDE BRUSH

DOWN SOLENOID (SV-8)?



position (KOEO-Key On, Engine Off); Push

ONE-STEP button (be sure that the SIDE

BRUSH is also turned on) and measure voltage

across wires at ENABLE SOLENOID (SV-1),

SIDE & MAIN BRUSH ON SOLENOID (SV-3),

MAIN BRUSH DOWN SOLENOID (SV-7), and

SIDE BRUSH DOWN SOLENOID (SV-8)




faulty SOLENOID coil


and fuses F-1, F-5, F-11, F-19 & F-20;



NOTE: DO NOT UNPLUG connectors at

ENABLE SOLENOID (SV-1), SIDE & MAIN

BRUSH ON SOLENOID (SV-3), MAIN

BRUSH DOWN SOLENOID (SV-7), or

SIDE BRUSH DOWN SOLENOID (SV-8)


connectors will give false readings.Note: Typical Solenoid


is 6 to 8 Ohms

YES NO


6650 Interlocks

IndicationCondition

To STOP Main & side brushes (OFF & UP)Note: Any one of the following will cause this to happen

HOPPER CLOSED LED ON

SHAKE FILTER LED ON (10

seconds)

Turn off ONE-STEP button (causes the following:)

• Main & side brush off & up

• Vacuum fan off

• Shaker system on

• Hopper door closed

ENG.SPEED #1 LED ONSelect LOW ENGINE SPEED

To START Main & side brushes (ON & DOWN)

ONE-STEP LED ON

SIDE BRUSH LED ON

VACUUM FAN LED ON

ENG.SPEED #2 or #3 LED ON

HOPPER OPEN LED ON

Turn on ONE-STEP button (causes the following:)

• Main & side brush on & down (Note: Main brush must be on for the side brush to operate)

• Vacuum fan on

• Shaker system off

• Hopper door open

HOPPER UP LED ONLift the hopper

THERMO SENTRY LED ON

HOPPER CLOSED LED ONExcessive hopper temperature

HOPPER CLOSED LED ONClose the hopper door

VACUUM FAN LED ONTurn on VACUUM FAN button

with ONE-STEP system OFF

IndicationCondition

To STOP Vacuum Fan (OFF)Note: Any one of the following will cause this to happen


SHAKE FILTER LED ON (10

seconds)

Turn off ONE-STEP button

VACUUM FAN LED OFFTurn off VACUUM FAN button

To START Vacuum Fan (ON)Note: Any one of the following will cause this to happen

ONE-STEP LED ON

SIDE BRUSH LED ON

VACUUM FAN LED ON

ENG.SPEED #2 or #3 LED ON

HOPPER OPEN LED ON

Turn on ONE-STEP button

VACUUM FAN LED OFF

SHAKER LED ONTurn on SHAKER button

Solenoid Valves Energized:

SV-1, SV-3, SV-5, SV-7, SV-8, SV-9


SV-1(6 to 8 seconds), then NONE


SV-1, SV-6A or SV-6B


SV-1, SV-3, SV-5, SV-7, SV-8, SV-9

Note: This is the Vacuum Wand Mode – High engine speed is automatically selected


SV-9




NONE (W/ ONE-STEP SYSTEM OFF)

6650 07-2003

75

6650 Interlocks (continued)

SHAKE FILTER LED OFFTurn off SHAKER button

SHAKE FILTER LED ON (10 seconds)

Turn off VACUUM FAN button

(Note: Triggers an automatic

10 second shake cycle)


SHAKE FILTER LED ON (10 seconds)

Turn off ONE-STEP button

(Note: Triggers an automatic

10 second shake cycle)

IndicationCondition

To STOP Shaker System (OFF)Note: Any one of the following will cause this to happen

ONE-STEP LED ON (See prev. page)

SHAKE FILTER LED OFFTurn on ONE-STEP button

VACUUM FAN LED ON

SHAKE FILTER LED OFFTurn on VACUUM FAN button

To START Shaker System (ON)Note: Any one of the following will cause this to happen

SHAKE FILTER LED ON (10 seconds)Turn on SHAKER button

SHAKE FILTER LED OFFSHAKER system times out



IndicationCondition

To STOP Hopper Lift or Lower

HOPPER UP or DOWN LED OFFRelease HOPPER UP

or DOWN button

To START Hopper Lift or Lower

HOPPER UP or DOWN LED ONPUSH and HOLD HOPPER UP

or DOWN button

Note: The hopper will lift or lower only while the button is held or until the end of travel. Either operation will automatically cancel the One-

Step operation. If engine is at low speed, it will automatically increase to medium. The hopper door is automatically closed when hopper

is fully lowered and hopper down switch is closed.

HOPPER UP or DOWN LED ONFully lower hopper

THERMO-SENTRY LED ON

ONE-STEP LED ON (See prev. page)

HOPPER OPEN LED ONTurn on ONE-STEP button

HOPPER UP or DOWN LED ONTurn off ONE-STEP button

IndicationCondition

To CLOSE Hopper DoorNote: Any one of the following will cause this to happen

HOPPER UP or DOWN LED ONTurn on HOPPER CLOSE button

To OPEN Hopper DoorNote: Any one of the following will cause this to happen

HOPPER OPEN LED ONTurn on HOPPER OPEN button

Excessive hopper temperature




SV-1, SV-3, SV-5, SV-7, SV-8, SV-9


SV-9 (W/ ONE-STEP SYSTEM OFF)




SV-1, SV-6A or SV-6B


NONE




SV-1, SV-3, SV-5, SV-7, SV-8, SV-9



6650 07-2003

76

6650 Operational/Diagnostic/Maintenance Modes

Six Operational Modes

• Turn OFF machine

• Press and hold SHAKER and ENGINE SPEED buttons

• START and RUN Machine

• Hold buttons for 5 seconds and release

• The word “MANUAL” should be displayed on the LCD panel display

2) MANUAL MODEUse this mode to turn on any system without

regard to the state of inputs, sensors or

interlocks


• Press and hold HOPPER OPEN and HOPPER CLOSED buttons



• The word “INPUT” should be displayed on the LCD panel display

3) INPUT DISPLAY MODEUse this mode to observe if the inputs to the

machine control board are operating correctly

- the LED’s on instrument panel will show the

state of each input


• Press and hold VACUUM FAN and ENGINE SPEED buttons



• The software revision and any self-test faults should be displayed on

the LCD panel display

NOTE: If “OPEN LOAD” or “SHORT LOAD” is displayed after pin

number, then the self-test found a load that is electrically open or

shorted to BATTERY + (check output wires or replace load as needed)

4) SELF TEST / DISPLAY

ERROR / DISPLAY SOFTWARE

REVISION MODEUse this mode to run a self-test on all of the

machine control board outputs – when test is

complete, the software revision is displayed –

if panel passes test, “OK” will also be

displayed - if panel fails test, the pin number

of the failed output(s) is also displayed


• Press and hold HOPPER UP and HOPPER DOWN buttons

• Turn key switch to “ON”, but DO NOT START the engine


• The word “CONTRAST” should be displayed on the LCD panel

NOTE: Hold the HOPPER DOWN button to darken the LCD display

Hold the HOPPER UP button to lighten the LCD display

6) CONTRAST ADJUST MODEUse this mode to adjust the contrast of the

LCD panel display


• Press and hold SIDE BRUSH and ENGINE SPEED buttons

• Turn key switch to “ON”, but DO NOT START the engine


• The ZEEMS engine control faults will now be displayed by blinking the

SHAKER LED (see “6650 ZEEMS ENGINE FAULT CODES”)

5) DISPLAY “CHECK ENGINE

FAULTS” MODEUse this mode to decode any ZENITH

ENGINE CONTROLLER (ZEEMS) faults

when the words “CHECK ENGINE” are

displayed on the LCD panel



1) NORMAL MODEUse this mode to perform normal sweeping

functions with machine

TO INITIATEMODE & DESCRIPTION

TO EXIT FROM ANY MODE, THE KEY SWITCH MUST BE CYCLED “OFF”

6650 07-2003

77

No Engine

Fault Codes

Detectedduring KOEO and KOER

STOP

Is

"Check Engine"

displayed

on LCD panel?

6650 with ZEEMS

(Zenith) Engine Management System

No

No Engine

Fault Codes

Detectedduring KOEO

Start and Run

Engine

Is

"Check Engine" displayed

on LCD panel with

engine running?

(KOER)

Turn Key Off,

Turn Key On,

Engine Off

(KOEO)

NO

YES

Tennant Engine Trouble Codes are:

14-ECT Sensor Open (Engine Coolant Sensor)

15-ECT Sensor Shorted (Engine Coolant Sensor)23-ACT Sensor Open (Air Temperature Sensor)

24-ACT Sensor Shorted (Air Temperature Sensor)

33-MAP Sensor Open (Manifold Absolute Pressure)

34-MAP Sensor Shorted (Manifold Absolute Pressure)

44-O2 Sensor Lean (Oxygen Sensor)45-O2 Sensor Rich (Oxygen Sensor)

RETEST

Does engine

"shut off" after

2-3 seconds or

40 seconds

of running?

40

Secondsrunning

then off

2-3

Secondsrunning

then off

Service and Repair

as Required

Clear Codes by

momentarily

grounding 49/White

"pigtail"

while engine is running

High Temperature

automatic shut-

down sequence

activated

Low Oil Pressure

automatic shut-

down sequence

activated

Is

"Oil Pressure

Light"

or

"High Temperature

Light"

also on?

Yes

Yes

No

READ ENGINE TROUBLE CODES

- Turn Engine Off

- Press and Hold Side Brush & Engine

Speed Buttons

- Turn Key on, do not start

- Hold buttons for 5 seconds

- Watch blinking Shaker LED for

engine trouble codes

Shaker LED Light illumination for "14" will be as follows:

on, medium off, on, short off, on, short off, on, short off, on;

longer pause;

on, medium off, on, short off, on, short off, on, short off, on;

longer pause.on, medium off, on, short off, on, short off, on, short off, on;

(other code readouts are similar)

6650 07-2003

78

6650 ZEEMS Check Engine Fault Codes

“CHECK ENGINE” displayed

(see MODE 5 on previous page)

Key On, Engine Off (KOEO)





High engine temperature sensed



engine will run 40 seconds until another automatic shutdown

Fuel level & hour meter reading displayedKey On, Engine Off (KOEO)





Low engine oil pressure sensed



engine will run 2 to 3 seconds until another automatic shutdown





Fuel level & hour meter reading displayedKey On, Engine Running (KOER)


LCD PANELMACHINE STATUS

33, 33, 33MAP sensor OPEN, circuit voltage >4.98V

14, 14, 14Engine coolant sensor OPEN

23, 23, 23Air temp sensor OPEN

15, 15, 15Engine coolant sensor SHORTED

34, 34, 34MAP sensor SHORTED

24, 24, 24Air temp sensor SHORTED

12, 12, 12Beginning of fault codes, or OK if no other

codes displayed

FAULT CODE DISPLAYED

(ON SHAKER LED)

CONDITION

NOTE: See MODE 5 on previous page

Ground PIN # 16 of the WHITE CONNECTOR at the ZENITH ENGINE CONTROLLER

while engine is running (Note: Some controllers have a wire pigtail that is connected to PIN # 16)

TO CLEAR FAULT CODES AND TURN OFF “CHECK ENGINE” WARNING

6650 07-2003

79

6650 Machine Control Board Pin Functions

Battery ground

(B-)

Battery positive

(B+)

0 VDC

0 VDC

>100 ohms = full tank

<5 ohms = empty tank

0 VDC

0 VDC

Battery ground

(B-)

OPEN

0 VDC

0 VDC

Battery positive

(B+)

Battery ground

(B-)

ACTIVE

VOLTAGE

0 VDCBattery positive (B+)INPUT2,3

Battery positive

(B+)Low side driversOUTPUT

4,5,6,7,8,9,

10,11

NOT PRESENTLY USED12

5 VDCDIGITAL - Activates

when groundedINPUT13,14,15,16

Battery positive

(B+)

Governor speed

controlOUTPUT20,21

Battery ground

(B-)Battery ground (B-)INPUT22

Battery positive

(B+)Low side driversOUTPUT23,24


when groundedINPUT25,26,27


when groundedINPUT29

NOT PRESENTLY USED30

Battery positive

(B+)Low side driverOUTPUT31

Battery positive

(B+)Memory storageINPUT32

NOT PRESENTLY USED17,18,19

Battery ground

(B-)Battery ground (B-) INPUT33,34,35

Fuel gauge inputINPUT28

Battery ground

(B-)Chassis groundINPUT1

INACTIVE

VOLTAGEFUNCTION

INPUT or

OUTPUTPIN #

6650 07-2003

80

MODEL


6650

HYDRAULIC

* Read and Follow ALL Safety Warnings and Precautions in Operator's Manual

* Engine & Hydraulic Oil Must Be At Normal Operating Temperatures after

Running Machine and Hydraulics a Minimum of 5 Minutes

* Examine Machine For Any Linkage Binding or Mechanical Problems

* Maintain Normal Main Brush Pressure as Listed in Operator's Manual

* Call Technical Services if Diagnostic Time Exceeds One Hour With Unknown

Cause or Course of Action


DURING TESTS:

6650 07-2003

81

1 2 3 4 5 6


(Part 1 of 2)

SIDE BRUSH LIFT/LOWER

MAIN BRUSH LIFT/LOWER

HOPPER LIFT/LOWER

HOPPER DOOR OPEN/CLOSE

MAIN BRUSH

SIDE BRUSH

(OPTIONAL)


6650 07-200382

1 2 3 4 5 6


(Part 2 of 2)

EXPLANATION OF ABBREVIATIONS

HTX..............Heat Exchanger

IN..................Inches

LH.................Left Hand

LPM..............Liters per Minute

M..................Motor (Combustion)

MTR.............Motor (Hydraulic)

OR................Orifice

PC.................Pilot Port Check Valve

PMP..............Pump

PSI................Pounds per Square Inch

AUX..........Auxiliary

CK............Check Valve

CM............Centimeters

CU............Cubic

CV............Control Valve

CYL..........Cylinder

DC............Disconnect Coupler (Hydraulic)

DC............Direct Current (Electrical)

FLTR........Filter

GPM.........Gallons per Minute

PSWITCH.........Pressure Switch

RES..................Reservoir

RH....................Right Hand

RPM.................Revolutions per Minute

RV....................Relief Valve

STRN...............Strainer

SV....................Solenoid Valve

TV....................Throttle Valve

V......................Volts

PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions

6650 07-2003

83

T1

4

T1

T3

M1

T2

C1

M2

C2

T

R

LP

Reservoir

Cylinder

Aux

Pump

Hopper

Lift

Cylinder

DumpDoor

Hopper

SideBrush

Motor

Steering

Valve

Steer

WheelDrive

MotorCylinder

MainBrush

Motor

Filter

Control

Valve

Vac

Fan

Propel

Pump

Motor

6

7

89

10

14

19

Cooler

C3

C5

C6

C7

C8

P

13

203

16

17

1

5

11

12

15

18

21

22

23

25

24

26

27

28

29

30

LiftCylinder

MainBrush

SideBrush

LiftCylinder

2

6650 HYDRAULIC HOSE ROUTING

6650 07-200384

6650 MAIN BRUSH

PRESSURE

RETURN

ACCESSORY PUMP

RESERVOIR

STRAINER

RV4

3 PSI

FILTER

HEAT

EXCHANGER

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

SUCTION

RV1

2400 PSI

MAIN BRUSH

600 PSI

(0.2 BAR)

(166 BAR)

(1.7 BAR)

(41 BAR)

RV7

25 PSI

MAIN BRUSH RPM

460 RPM +/- 25 RPM @ 2000 RPM

550 RPM +/- 25 RPM @ 2400 RPM

SV2

SV1

CV1

T1

M2

Note: Specs. shown are for

main brush down with 2 inch

(5 cm) brush pattern


5.4 GPM (20 LPM) @ 2000 RPM

6.5 GPM (25 LPM) @ 2400 RPM


600 PSI(41 BAR)


6650 07-2003

85

6650 MAIN & SIDE BRUSH

PRESSURE

RETURN

ACCESSORY PUMP

RESERVOIR

STRAINER

RV4

3 PSI

FILTER

HEAT

EXCHANGER

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

SUCTION

RV1

2400 PSI

MAIN BRUSH

600 PSI800 PSI

(0.2 BAR)

(165 BAR)

(1.7 BAR)

(14 BAR)

RV7

25 PSI

MAIN BRUSH RPM

460 RPM +/- 25 RPM @ 2000 RPM

550 RPM +/- 25 RPM @ 2400 RPM

SV3

SV1

CV1

T1

M1

(55 BAR)800 PSI

SIDE BRUSH

200 PSI

(41 BAR)

SIDE BRUSH RPM

75 RPM +/- 10 RPM @ 2000 RPM

90 RPM +/- 10 RPM @ 2400 RPM

P

Note: Specs. shown are for main

& side brushes down, with 2 inch

(5 cm) main brush pattern

(41 BAR)600 PSI


5.4 GPM (20 LPM) @ 2000 RPM

6.5 GPM (25 LPM) @ 2400 RPM



6650 07-2003

86

ACCESSORY PUMP

RESERVOIR

STRAINER

RV4

3 PSI

FILTER

HEAT

EXCHANGER

PRESSURE

RETURN

SUCTION

6650 VACUUM FAN

VACUUM FAN

1000 PSI

RV8

1800 PSI

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)

RV7

25 PSI(1.7 BAR)

(68 BAR)

1000 PSI

(69 BAR)

(124 BAR)

SV9


5.4 GPM (20 LPM) @ 2000 RPM

6.5 GPM (25 LPM) @ 2400 RPM



6650 07-2003

87

ACCESSORY PUMP

6650 RAISE HOPPER

RAISE

RV1

2400 PSI(166 BAR)

(0.2 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

CV1

T2

SV6A

SV6BPC2

C3

C4

T1

RV4

3 PSI

RESERVOIR

STRAINER

RESTRICTOR

PRESSURE

RETURN

SUCTION

HEAT

EXCHANGER

RV7

25 PSI(1.7 BAR)

FILTER

P

SV1


6650 07-2003

88

ACCESSORY PUMP

6650 LOWER HOPPER

LOWER

RV1

2400 PSI(166 BAR)

(0.2 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

PRESSURE

SUCTION

RETURN

CV1

T2

SV1

SV6B

PC2C3

C4

T1

RV4

3 PSI

RESERVOIR

STRAINER

RESTRICTOR

SV6A

HEAT

EXCHANGER

FILTER

RV7

25 PSI(1.7 BAR)

P

Note: Lowering of hopper is

due to PILOT CHECK VALVE 2

(PC2) being unseated, and

gravity (weight of hopper)


6650 07-2003

89

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

OPEN


6650 OPEN HOPPER DOOR

RV1

2400 PSI(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)(1.7 BAR)

FILTER

SV5

SV1

T1

C1

T2

C2

P

CV1

PC1


6650 07-2003

90

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

CLOSE


6650 CLOSE HOPPER DOOR

RV1

2400 PSI(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR) (1.7 BAR)

FILTER

SV5

SV1

T1

C1

T2

C2

P

CV1

PC1

Note: Arrows show direction of

Fluid Flow, NOT Pressure (PSI)


6650 07-2003

91

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

OPEN

MAIN BRUSH LIFT CYLINDER

6650 LOWER MAIN BRUSH

RV1

2400 PSI(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)(1.7 BAR)

FILTER

SV7

SV1

T1

C6

T2

P

CV1

LOWER

C5


6650 07-2003

92

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

RAISE

MAIN BRUSH LIFT CYLINDER

6650 RAISE MAIN BRUSH

RV1

2400 PSI(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)(1.7 BAR)

FILTER

SV7

SV1

T1

C5

T2

C6

P

CV1


6650 07-2003

93

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

OPEN

SIDE BRUSH LIFT CYLINDER

6650 LOWER SIDE BRUSH

RV1

2400 PSI(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)(1.7 BAR)

FILTER

SV8

SV1

T1

C8

T2

P

CV1

LOWER

C7


6650 07-2003

94

HEAT

EXCHANGER

RV 7

25 PSI

RESERVOIR

STRAINER

RV 4

3 PSI

OUT

CCV1B

DOOR

ACCESSORY PUMP

PRESSURE

RETURN

SUCTION

RAISE

SIDE BRUSH LIFT CYLINDER

6650 RAISE SIDE BRUSH

RV1

2400 PSI(166 BAR)

5.4 GPM (20.4 LPM) @ 2000 RPM

6.5 GPM (24.6 LPM) @ 2400 RPM

(0.2 BAR)(1.7 BAR)

FILTER

SV8

SV1

T1

C7

T2

C8

P

CV1


6650 07-2003

95

HEAT

EXCHANGER

FILTER

RV 7

25 PSI

ACCESSORY PUMP

STRAINER

RESERVOIR

RV 4

3 PSI

CV3

R

L

600 PSI

CK5T

P

RV 6

STEERING SYSTEM

CYLINDER

PRESSURE

RETURN

SUCTION

6650 RIGHT TURN

3.3 GPM (12.5 LPM) @ 2000 RPM

3.9 GPM (14.8 LPM) @ 2400 RPM

MTR/PMP3

(0.2 BAR)

(1.7 BAR)

(41 BAR)




6650 07-2003

96

CYLINDER

STEERING SYSTEM

HEAT

EXCHANGER

FILTER

RV 7

25 PSI

RESERVOIR

STRAINER

ACCESSORY PUMP

RV 4

3 PSI

R

L

RV 6

600 PSI

P

T CK5

CV3

PRESSURE

RETURN

SUCTION

6650 LEFT TURN

(0.2 BAR)

(1.7 BAR)

3.3 GPM (12.5 LPM) @ 2000 RPM

3.9 GPM (14.8 LPM) @ 2400 RPM

(41 BAR)

MTR/PMP3




6650 07-2003

97

PRESSURE

SWITCH

2400 PSI (166 BAR)

CK2

5 PSI

RV1

2400 PSI

(166 BAR)

SV1

SV3

SV2

CV1

MAIN

BRUSH

BRUSH

STALLED

2400 PSI

(166 BAR)

0 GPM/LPM

2400 PSI

(166 BAR)

0 GPM/LPM

2400 PSI

(166 BAR)

0 GPM/LPM

2400 PSI

(166 BAR)

0 GPM/LPM

TO BRUSH STALL

WARNING LAMP

SIDE

BRUSH

TO RESERVOIR

NOTE:

THESE CONDITIONS WILL OCCUR

IF MAIN BRUSH STALLS WHEN

SWEEPING WITH MAIN BRUSH

ONLY OR WHEN SWEEPING WITH

MAIN AND SIDE BRUSH

2400 PSI(166 BAR)

Full Hydraulic

Oil Flow

FROM PUMP

6650 MAIN BRUSH STALL TRIGGERING PRESSURE SWITCH

0.0 PSI

(0.0 BAR)

Full Hydraulic

Oil Flow

(0.3 BAR)

6650 07-2003

98

To Reservoir

(Case drains)Pick-up

Engine

Propel Motor Assembly

Tow Valve

Charge Pump (to keep

propel system full of oil)

Propel Pump Assembly

Propel Pump

Propel Motor

6650 PROPEL SYSTEM

6650 07-2003

99

sfd

Text Box

TO ADJUST DIRECTIONAL CONTROL LINKAGE 1. Engage the parking brake. 2. Jack up the rear of the machine. Place jack stands under the frame and lower the machine down. 3. Open engine hood and side door. 4. Locate the centering spring cam arms and cam on the propel pump, near the center frame tube. Loosen the M8 cam bolt. 5. Start the engine. 6. Adjust the cams so the rear wheel does not turn. Turning the cams toward the front of the machine will make the wheel go forward. Turning the cams toward the rear of the machine will make the wheel go backward. 7. Stop the engine. 8. Hold the cams in position and tighten the cam bolts. 9. Start the engine and test to verify adjustment. Repeat if necessary. 10. Lower the machine. 11. Start the engine. Move the directional control pedal forward and backward to make sure machine will not move when the directional control pedal is in neutral. Readjust as necessary. 12. Raise the hopper and engage hopper support bar. 13. The machine should travel 1.6 kmh (1 mph) maximum forward speed. To adjust, turn the speed control rod (directional control rod with a balljoint and a vibration isolator.) Turning the rod clockwise, as viewed from above, will slow machine. Turning it counterclockwise will speed machine. 14. Lower the hopper and stop the engine. 15. Check the gap between the speed limiter bracket and the contact surface as the drive linkage rod assembly is 1.5--3 mm (0.06 -- 0.12 in). 16. Adjust the balljoint on the end of the speed control rod to get the correct gap. Tighten all jam nuts.

100

ECU

- B

lack

Con

nect

or8

15

2

3LO

W L

EVEL

INPU

T

TC

XLO

W L

EVEL

IMPU

TH

IGH

LEV

EL IN

PUT

RC

X N

/APR

OG

RA

MIN

G P

OR

T

SH

IELD

GR

OU

ND

L

OW

LEV

EL IN

PUT

LOW

LEV

EL IN

PUT

C

RA

NK

SEN

SOR

GR

OU

ND

S

ENSO

R G

RO

UN

D+5

V S

ENSO

R R

EFER

ENC

E

CR

AN

K S

ENSO

R IN

PUT

S

ENSO

R G

RO

UN

D+5

V S

ENSO

R R

EFER

ENC

E

N

/A02

SEN

SOR

INPU

TPO

TEN

TIO

MET

ER IN

PUT

(0-5

V)

M

AP

SEN

SOR

INPU

TA

IR T

EMP

SIG

NA

LC

OO

LAN

T TE

MP

SIG

NA

L

0-5

V A

TOO

INPU

T1

9

1

6

101

ECU

- W

hite

Con

nect

or8

15

2

3EC

U +

12V

OU

T

IG

NIT

ION

PO

WER

(+12

V)

EC

U +

12V

OU

T C

OIL

DR

IVER

1

IG

NIT

ION

PO

WER

(+12

V)

LO

W L

EVEL

DR

IVER

(.2A

)C

OIL

DR

IVER

2

EN

GI0

0 G

RO

UN

D

HIG

H L

EVEL

OU

TPU

T (1

A)

GO

VEN

OR

OU

TPU

T (H

IGH

SID

E)

EN

GI0

0 G

RO

UN

D

CH

ECK

EN

GIN

E LA

MP

DR

IVER

(.2A

)FU

EL P

UM

P/LO

CK

OFF

OU

PUT

(+12

V)

T

AC

HO

MET

ER IN

PUT

(-)C

OIL

DIG

ITA

L IN

PUT

GA

SOLI

NE

INJE

CTO

R D

RIV

ER

DIG

ITA

L O

UTP

UT

DIG

ITA

L O

UT

LP IN

JEC

TOR

DR

IVER

H

IGH

LEV

EL/1

2V A

to D

INPU

TH

IGH

LEV

EL IN

PUT

ALT

ERN

ATE

FU

EL R

EQU

EST

(+12

V)

O

EM L

OW

LEV

EL IN

PUT

1

9

16

102

Whi

te

Con

nect

or

Pin

Num

ber

Des

crip

tion

Acro

nym

U

sed

Volta

ge R

ange

, N

omin

al V

olta

geKe

y O

ff, e

ngin

e O

ff, V

olta

geKe

y O

n, E

ngin

e O

ff Vo

ltage

Activ

e C

ircui

t Vo

ltage

Not

es1

Alte

rnat

ive

Fuel

Req

uest

0-12

vD

C0

vDC

0 vD

C12

vD

CU

se o

nly

with

dua

l fue

l app

licat

ions

2H

igh

Leve

l Inp

ut0-

12 v

DC

0 vD

C0

vDC

12 v

DC

3LP

Inje

ctor

Driv

er0-

12 v

DC

0 vD

C12

vD

C0

vDC

Gro

unds

circ

uit t

o "tu

rn o

n"4

Fuel

pum

p/lo

ck o

ff co

ntro

l0-

12 v

DC

0 vD

C0

vDC

12 v

DC

Send

s 12

vD

C to

fuel

pum

p or

lock

off

5G

over

nor O

utpu

t0-

12 v

DC

0 vD

C0

vDC

, pul

sed

volta

ge12

vD

CSe

nds

12 v

DC

to g

over

nor,

@21

0 hz

, dut

y cy

cles

var

ies

6C

oil D

river

# 2

0-12

vD

C0

vDC

0 vD

C12

vD

CSe

nds

12 v

DC

to c

oil

7C

oil D

river

# 1

0-12

vD

C0

vDC

0 vD

C12

vD

CSe

nds

12 v

DC

to c

oil

8EC

U 1

2 vD

C o

ut0-

12 v

DC

0 vD

C12

vD

C12

vD

CSe

nds

12 v

DC

to ?

???

9H

igh

leve

l inp

ut0-

12 v

DC

0 vD

C0

vDC

12 v

DC

10D

igita

l Out

Sig

nal

0-12

vD

C0

vDC

0 vD

CPu

lsed

On

or o

ff si

gnal

11D

igita

l Inp

ut0-

12 v

DC

0 vD

C0

vDC

12 v

DC

Squa

re w

ave

12C

heck

Eng

ine

Lam

p D

river

(0.2

a)0-

12 v

DC

0 vD

C0

vDC

12 v

DC

On

or o

ff si

gnal

13H

igh

leve

l out

put

0-12

vD

C0

vDC

0 vD

C12

vD

CO

n or

off

sign

al14

Low

Lev

el D

river

(0.2

a)0-

12 v

DC

0 vD

C0

vDC

12 v

DC

On

or o

ff si

gnal

15EC

U 1

2 vD

C o

ut to

fuel

inje

ctor

0-12

vD

C0

vDC

0 vD

C12

vD

CSe

nds

12 v

DC

to fu

el in

ject

or16

OEM

Low

Lev

el In

put

0-5

vDC

0 vD

C0

vDC

5 vD

C17

Hig

h le

vel /

12

A to

D In

put

0-12

vD

C0

vDC

0 vD

C12

vD

C18

Dig

ital O

utpu

t0-

12 v

DC

0 vD

C0

vDC

Puls

edO

n or

off

sign

al19

Tach

omet

er In

put f

rom

Igni

tion

Coi

l0-

250

vDC

0 vD

C12

vD

C0-

250

vDC

20En

gine

Gro

und

for g

over

nor,

lock

off,

fuel

pu

mp,

dis

trubu

tor g

roun

d0

vDC

0 vD

C0

vDC

0 vD

CG

roun

d

21En

gine

Gro

und

for g

over

nor,

lock

off,

fuel

pu

mp,

dis

trubu

tor g

roun

d0

vDC

0 vD

C0

vDC

0 vD

CG

roun

d22

Igni

tion

Pow

er0-

12 v

DC

0 vD

C12

vD

C12

vD

CPo

wer

into

EC

U23

Igni

tion

Pow

er0-

12 v

DC

0 vD

C12

vD

C12

vD

CPo

wer

into

EC

U

Bla

ck

Con

nect

orD

escr

iptio

nAc

rony

m

Use

dVo

ltage

Ran

ge,

Nom

inal

Vol

tage

Key

Off,

eng

ine

Off,

Vol

tage

Key

On,

Eng

ine

Off

Volta

geAc

tive

Circ

uit

Volta

geN

otes

1C

oola

nt T

empe

ratu

re S

enso

r Sig

nal

CTS

0-5

vDC

0 vD

C0-

5 vD

C0-

5 vD

C2

Pote

ntio

met

er In

put

0-5

vDC

0 vD

C0-

5 vD

C0-

5 vD

C3

Sens

or R

efer

ence

5 vD

C0

vDC

5 vD

C5

vDC

Sign

al fr

om E

CU

to in

put s

enso

rs4

Sens

or R

efer

ence

to M

AP s

enso

r5

vDC

0 vD

C5

vDC

5 vD

CSi

gnal

from

EC

U to

inpu

t sen

sors

5Lo

w L

evel

Inpu

t5

vDC

0 vD

C0

vDC

0-5

vDC

6Pr

ogra

mm

ing

Port

0-5

vDC

0 vD

C0

vDC

0-5

vDC

Sign

al in

to E

CU

, to

repr

ogra

m m

emor

y7

Hig

h Le

vel I

nput

0-12

vD

C0

vDC

0 vD

C0-

5 vD

C8

Low

Lev

el In

put

5 vD

C0

vDC

0 vD

C0-

5 vD

C9

Inta

ke A

ir Te

mpe

ratu

re S

enso

r Sig

nal

IAT

0-5

vDC

0 vD

C0-

5 vD

C0-

5 vD

C10

O2

Sens

or In

put

0-1

vDC

0 vD

C0.

45 v

DC

0-1

vDC

11Se

nsor

Gro

und,

MAP

, CTS

and

IAT

0 vD

C0

vDC

0 vD

C0

vDC

12Se

nsor

Gro

und

0 vD

C0

vDC

0 vD

C0

vDC

13Lo

w L

evel

Inpu

t0-

5 vD

C0

vDC

0 vD

C5

vDC

14N

/AN

/AN

/AN

/AN

/A15

Low

Lev

el In

put

0-5

vDC

0 vD

C0

vDC

5 vD

C16

Inpu

t, fro

m d

ash

pane

l low

, med

, hig

h R

PM0-

12 v

DC

0 vD

C0

vDC

5 vD

C17

MAP

Sen

sor S

igna

l Inp

utM

AP0-

5 vD

C0

vDC

4.70

vD

C0-

5 vD

CM

easu

re B

ARO

with

Key

on

engi

ne o

ff18

N/A

N/A

N/A

N/A

N/A

N/A

19C

rank

Sen

sor I

nput

0-5

vDC

0 vD

C0

vDC

0-5

vDC

Squa

re w

ave

20C

rank

Sen

sor G

roun

d0

vDC

0 vD

C0

vDC

0 vD

C21

Shie

ld G

roun

d0

vDC

0 vD

C0

vDC

0 vD

CPr

otec

ted

grou

nd c

ircui

t22

Rec

eive

Sig

nal f

rom

dat

a re

cord

ing

devi

ce0-

5 vD

C0

vDC

0 vD

C0-

5 vD

CSq

uare

wav

e23

Tran

smit

Sign

al to

dat

a re

cord

ing

devi

ce0-

5 vD

C0

vDC

0 vD

C0-

5 vD

CSq

uare

wav

e

103

Initi

al S

tart-

Up

Sequ

ence

C

heck

sO

pera

tion

Dai

lyW

eekl

yEv

ery

50 H

rsEv

ery

100

Hrs

Ever

y 20

0 H

rs

Ever

y 40

0 H

rsEv

ery

800

Hrs

As R

eq'd

1C

heck

Eng

ine

Oil

Leve

lx

2C

heck

Coo

lant

Lev

el (4

)x

3C

heck

Flu

id L

eaks

x4

Gov

erno

r, M

echa

nica

l (C

heck

oil

leve

l)(2)

xC

hang

e En

gine

Oil

& Fi

lter (

1)x

5Ba

ttery

, Che

ck C

harg

e &

Flui

d Le

vel (

3)x

Insp

ect &

Cle

an R

adia

tor E

xter

ior (

3)x

Cle

an B

atte

ry C

able

s (3

)x

6C

heck

Bel

ts a

nd B

elt T

ensi

onx

Lubr

icat

e Th

rottl

e, G

over

nor &

Cho

ke

Link

age

(Car

bure

ted

Engi

nes

Onl

y)x

Che

ck &

Adj

ust I

dle

Spee

d (C

arbu

rete

d En

gine

s O

nly)

xIn

spec

t and

Cle

an A

ir C

lean

er E

lem

ent

xR

epla

ce P

rimar

y Ai

r Cle

aner

Ele

men

t (1)

xR

epla

ce S

afet

y Ai

r cle

aner

Ele

men

tx

Rep

lace

Eng

ine

Coo

lant

(3)(4

)x

Rep

lace

Fue

l Filt

er (5

)x

Spar

k Pl

ugs,

Cle

an, A

djus

t & T

est o

r R

epla

ce (3

)x

Rep

lace

PC

V Va

lve

(If e

quip

ped)

(3)

xC

heck

PC

V H

oses

, Tub

es, F

ittin

gs (3

)x

Rep

lace

Spa

rk P

lugs

(3)

xAd

just

Thr

ottle

& G

over

nor (

3)x

7C

heck

All

Bolts

& N

uts

for T

ight

ness

(3)

x(1

) M

ore

freq

uent

inte

rval

s m

ay b

e re

quire

d in

dus

ty o

r dirt

y op

erat

ing

cond

ition

s .(2

) M

echa

nica

l gov

erno

r (be

lt dr

iven

).(3

) Se

ason

al o

r as

requ

ired.

(4)

Che

ck e

ngin

e co

olan

t con

ditio

n &

pro

tect

ion,

hos

es &

cla

mps

ann

ually

(prio

r to

cold

wea

ther

).(5

) M

ore

freq

uent

inte

rval

s m

ay b

e re

quire

d w

ith d

irt in

fuel

sys

tem

.

Mai

nten

ance

Sch

edul

ePo

wer

Sol

utio

ns, I

ncG

M P

ower

trai

n

2.0L

, 2.2

L, 3

.0L,

4.3

L, 5

.71L

, 7.4

L, a

nd 8

.1L

Engi

nes

104

Engi

ne2.

0L2.

2L3.

0L4.

3L5.

7L7.

4L8.

1LO

il C

apac

ity W

ithou

t Filt

er5

qt.

4.5

qt.

5 qt

.8

qt.

8 qt

.C

oola

nt C

apac

ity W

ithou

t Rad

iato

r4

qt.

7 qt

.7.

8 qt

.14

.5 q

t.14

.5 q

t

Coo

lant

Cap

acity

With

Rad

iato

r12

qt.

17 q

t.17

.5 q

t28

qt 3

1 qt

(T

urbo

105

Engine 3.0LType 3.0L L4Displacement cc (c.i.d) 2966 (181)Compression Ratio 9.2:1

Valve ConfigurationPush Rod Actuated

Overhead ValveValve Lifters Flat FollowerBore x Stroke mm(inches) 101.60x91.44(4.00x3.60)Main Bearing Caps 2 BoltBalance method ExternalIntake Manifold TBI, Carburetor, MixerFiring Order 1-3-4-2Oil Capacity With Oil Filter

5 qts. (4.7L) 5.5 qts. (5.2L)

Oil Filter PF-25 or EquivalentCoolant Capacity (Engine) 4 qts. (3.78L)Fuel Type Gasoline, LPG, NGEngine Rotation (Flywheel End) CCWIgnition System Solid State DistributorIgnition Timing (Degrees BTDC)Gasoline (Carb) 0Gasoline (TBI) 0LPG 10 (4 Europe)NG 10Dual Fuel 0Spark Plugs AC Delco R46TSSpark Plug GapGasoline (Carb) 0.04TBILPGNGDual FuelValve Clearance (Lash)Intake Exhaust

1/2 to 1 Turn Down From 0 Lash

Manufactured Toluca, Mexico

General SpecificationsPower Solutions, Inc

GM Powertrain Industrial Engines

106

ZEEM

S

ZEEM

SZe

nith

Ele

ctro

nic

Engi

ne M

anag

emen

t Sys

tem

Prop

ane

and

Gas

olin

e El

ectr

onic

Fue

l Inj

ectio

n

107

ZEEM

S

• ZEE

MS

Syst

em A

dvan

tage

s

• EC

U, E

lect

roni

c C

ontro

l Uni

t• I

nput

s• O

utpu

t Con

trols

• Dia

gnos

tics

• Sys

tem

Ope

ratio

n

• Blo

ck D

iagr

am

Hom

ePa

ge

• Spe

cific

atio

ns• N

o St

art D

iagn

ostic

s

108

ZEEM

SO

verv

iew

pa

ge 1

The

ZEEM

S A

dvan

tage

sPr

ecis

e fu

el c

ontr

ol

thro

ugho

ut a

ll op

erat

ing

tem

pera

ture

s an

d co

nditi

ons

Prec

ise

igni

tion

timin

g co

ntro

l th

roug

hout

all

oper

atin

g te

mpe

ratu

res

and

cond

ition

s

Virtu

ally

elim

inat

es “

flat s

pots

” an

d en

gine

run-

on (d

iese

ling)

Achi

eves

max

imum

pow

er w

ith lo

wes

t em

issi

ons

109

ZEEM

SO

verv

iew

p

age

2

The

ZEEM

S C

ontr

ol s

yste

m e

lect

rical

ly

cont

rols

the

follo

win

g:

Igni

tion

timin

g vi

a EC

U a

nd H

igh

Ener

gy Ig

nitio

n (H

EI) s

yste

m

Fuel

Del

iver

y vi

a fu

el in

ject

or (g

as, p

ropa

ne o

r bot

h)

Engi

ne R

PM v

ia th

rottl

e sh

aft a

ctua

tor c

ontro

l

Spee

d-D

ensi

ty D

iscu

ssio

n

110

ZEEM

SO

verv

iew

p

age

2a

The

ZEEM

S sy

stem

is a

“Spe

ed-D

ensi

ty”

desi

gn.

This

sys

tem

mea

sure

s th

e en

gine

RPM

(spe

ed o

f the

eng

ine)

and

cal

cula

tes

the

Den

sity

of t

he A

ir(fr

om a

tmos

pher

ic p

ress

ure

and

tem

pera

ture

of t

he a

ir)

to d

eter

min

e th

e op

timum

fuel

and

tim

ing

setti

ngs

for t

he a

ltitu

de a

nd c

limat

ic c

ondi

tions

.

The

ZEEM

S Sy

stem

111

ZEEM

SB

lock

Dia

gram

ZEEM

S B

lock

Dia

gram

Elec

trica

l fue

l shu

t off/

on, p

ropa

ne (L

PG)

Elec

tric

fuel

pum

p, g

asol

ine

ECU

Elec

troni

cC

ontro

lU

nit

Fuel

Inje

ctor

Thro

ttle

Actu

ator

Dis

tribu

tor

Fuel

Ret

urn,

ga

solin

e on

ly

Fuel

Tan

k,

prop

ane

or

gaso

line

Tim

ing

Adva

nce

RPM

Inpu

t Sen

sors

Fuel

Pre

ssur

e R

egul

ator

, ga

solin

e on

ly

112

ZEEM

SEC

U p

age

1

The

ECU

is th

e ‘c

ontr

ol c

ente

r’ of

the

ZEEM

S,so

met

imes

cal

led

the

proc

esso

r or “

brai

n bo

x”(lo

gic

devi

ce)

ECU

Elec

troni

cC

ontro

lU

nit

and

then

con

trols

the

outp

ut d

evic

es.

The

ECU

mon

itors

the

inpu

t sen

sors

,co

mpa

res

topr

ogra

mm

ed“lo

ok u

p ta

bles

”

113

ZEEM

SEC

U

page

2

ECU

Elec

troni

cC

ontro

lU

nit

The

Whi

te C

onne

ctor

is u

sed

for h

igh

curre

ntlo

ads,

suc

h as

bat

tery

pow

er a

nd g

roun

d an

dco

ntro

lling

the

out p

utde

vice

s.

The

Bla

ck C

onne

ctor

is u

sed

for l

ow le

vel

curre

nt d

evic

es, s

uch

asin

put s

igna

ls, t

rans

mit

and

rece

ive

sign

als,

and

othe

r low

vol

tage

sign

als.

Batte

ry P

ower

Fee

dPi

ns 2

2 &

23 o

n W

hite

Con

nect

or

Batte

ry G

roun

d Fe

edPi

ns 2

0 &

21 o

n W

hite

Con

nect

or

114

ZEEM

SEC

U

Page

3

Engi

ne E

vent

Dis

cuss

ion

ECU

Elec

troni

cC

ontro

lU

nit

The

ECU

mon

itors

mos

t inp

ut s

enso

rson

ce e

very

dis

tribu

tor

puls

e or

eng

ine

“eve

nt”,

depe

ndin

g on

engi

ne R

PM a

ndop

erat

ing

cond

ition

s.

One

eng

ine

“eve

nt”

isan

igni

tion

puls

e(s

park

plu

g fir

ing)

.

Ther

e ar

etw

o di

strib

utor

pul

ses

(eve

nts)

per e

ngin

e re

volu

tion

on a

4 c

ylin

der,

4 cy

cle

engi

ne

Ther

efor

e: 5

00 R

PM =

100

0 ev

ents

1000

RPM

= 2

000

even

ts20

00 R

PM =

400

0 ev

ents

115

ZEEM

SIn

puts

In

trodu

ctio

n

ECU

Elec

troni

cC

ontro

lU

nit

The

ZEEM

S sy

stem

s us

es s

ever

al in

put d

evic

es

to m

onito

r the

eng

ine

and

atm

osph

eric

con

ditio

ns.

Engi

ne R

PM

Engi

ne C

oola

ntTe

mpe

ratu

re (E

CT)

Inta

ke A

irTe

mpe

ratu

re (I

AT)

Man

ifold

Abs

olut

ePr

essu

re (M

AP)

Exha

ust G

as O

xyge

nSe

nsor

(EG

O)

(if e

quip

ped)

ECU

Inpu

ts

Lets

exa

min

eea

ch in

put

sens

or in

dep

th

116

ZEEM

SIn

puts

, RPM

pa

ge 1

ECU

Elec

troni

cC

ontro

lU

nit

RPM

Engi

ne R

PM

ECU

Inpu

tsEn

gine

RPM

Engi

ne R

PM is

det

erm

ined

from

the

dist

ribut

or p

ulse

sge

nera

ted

by th

e m

agne

ticpi

ck u

p an

d co

nver

ted

to a

digi

tal p

atte

rn b

y th

e H

EI(H

igh

Ener

gy Ig

nitio

n)m

odul

e.

117

ZEEM

SIn

puts

, RPM

pa

ge 1

a

ECU

Elec

troni

cC

ontro

lU

nit

Engi

ne R

PM

ECU

Inpu

tsEn

gine

RPM

For e

very

igni

tion

puls

e, a

sign

al is

rece

ived

at t

heEC

U.

The

ECU

then

sig

nals

fuel

inje

ctor

to “t

urn

on” a

ndsp

ray

fuel

.

One

fuel

inje

ctor

pul

se p

er“e

vent

”.M

agne

tic P

ick

Up

(AC

Sin

e W

ave)

Igni

tion

Mod

ule

(Ana

log

to D

igita

l Con

verte

r A/D

)

RPM

118

ZEEM

SIn

puts

, EC

T &

IAT

pag

e 1

ECU

Elec

troni

cC

ontro

lU

nit

ECT

ECU

Inpu

ts

The

ECT

is lo

cate

d in

or

near

the

wat

er o

utle

t fro

mth

e en

gine

blo

ck to

the

radi

ator

.

The

IAT

is lo

cate

d in

the

thro

ttle

body

ass

embl

y.

Both

sen

sors

are

two

(2)

wire

sen

sors

.

ECT

& IA

TEn

gine

Coo

lant

Tem

p Se

nsor

(EC

T) ,

Inta

ke A

ir Te

mp

Sens

or (I

AT)

ECT

& IA

T

IAT

119

ZEEM

SIn

puts

, EC

T &

IAT

pag

e 2

ECU

Elec

troni

cC

ontro

lU

nit

ECT

ECU

Inpu

ts

ECT

& IA

TEn

gine

Coo

lant

Tem

p Se

nsor

(EC

T) ,

Inta

ke A

ir Te

mp

Sens

or (I

AT)

ECT

& IA

T

IAT

The

ZEEM

S sy

stem

use

s a

Neg

ativ

e Te

mpe

ratu

reC

oeffi

cien

t (N

TC) t

herm

isto

rsfo

r the

EC

T an

d IA

T se

nsor

s.

A th

erm

isto

r cha

nges

its

inte

rnal

resi

stan

ce a

s th

ete

mpe

ratu

re c

hang

es.

A “N

TC” t

herm

isto

r res

ista

nce

incr

ease

s as

the

tem

pera

ture

decr

ease

s, a

nd th

e re

sist

ance

decr

ease

s as

the

tem

pera

ture

incr

ease

s.

120

ZEEM

SIn

puts

, EC

T &

IAT

pag

e 3

ECU

ECU

Inpu

ts

ECT

& IA

TEn

gine

Coo

lant

Tem

p Se

nsor

(EC

T) ,

Inta

ke A

ir Te

mp

Sens

or (I

AT)

ECT

& IA

T

The

ECU

“mon

itors

” the

ECT

and

IAT

wire

s to

dete

rmin

e th

e te

mpe

ratu

rech

ange

s.

ECT

ECU

Inpu

ts

ECU

m

onito

rs h

ere

IAT

121

ZEEM

SIn

puts

, MA

P p

age

1

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Inpu

ts

MA

P

The

MAP

is lo

cate

d be

twee

nth

e th

rottl

e bo

dy a

ssem

bly

and

the

ECU

.

This

MAP

sen

sor i

s a

thre

e(3

) wire

sen

sor s

imila

r in

oper

atio

n to

a p

oten

tiom

eter

.

Rou

ting

to th

e in

take

man

ifold

sou

rce

isac

com

plis

hed

by a

pas

sage

way

dril

led

from

the

thro

ttle

bore

dire

ctly

into

the

MAP

.

MA

PM

anifo

ld A

bsol

ute

Pres

sure

Sen

sor

Man

ifold

Abs

olut

ePr

essu

re S

enso

r

122

ZEEM

SIn

puts

, MA

P p

age

2

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Inpu

tsTh

e M

AP c

hang

es it

sin

tern

al re

sist

ance

as

the

atm

osph

eric

or i

ntak

em

anifo

ld p

ress

ure

chan

ges.

The

MAP

sen

sor w

ith th

eEC

U c

alcu

late

s th

eba

rom

etric

pre

ssur

e w

hen

the

key

is tu

rned

on.

(KO

EO=K

ey O

n En

gine

Off)

.

As th

e en

gine

sta

rts/ru

ns, t

heM

AP’s

inte

rnal

resi

stan

cech

ange

s ca

usin

g th

e si

gnal

wire

vol

tage

to c

hang

e.(K

OER

= K

ey O

n En

gine

Run

).

Man

ifold

Abs

olut

ePr

essu

re S

enso

r

MA

P

MA

P

123

ZEEM

SIn

puts

, MA

P p

age

3

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Inpu

tsM

AP

Man

ifold

Abs

olut

ePr

essu

re S

enso

r

MA

P

This

sen

sor h

as tw

och

ambe

rs in

tern

ally

. Th

ese

cham

bers

are

isol

ated

by

asi

licon

e di

aphr

agm

.

124

ZEEM

SIn

puts

, MA

P p

age

3

ECU

Elec

troni

cC

ontro

lU

nit

Man

ifold

Abs

olut

eSe

nsor

ECU

Inpu

ts

The

ECU

sen

ds a

fixed

5 v

DC

+/-

10%

vol

tage

to th

e M

AP.

The

ECU

“mon

itors

” the

sign

al w

ire to

det

erm

ine

the

baro

met

ric p

ress

ure

and/

oren

gine

load

cha

nges

.(in

take

man

ifold

pre

ssur

e).

5 vo

lt D

C

Ref

eren

ce V

olta

geEC

U m

onito

rs h

ere

MA

P M

AP

125

ZEEM

SIn

puts

, MA

P p

age

4a D

iscu

ssio

n

ECU

Elec

troni

cC

ontro

lU

nit

Man

ifold

Abs

olut

eSe

nsor

ECU

Inpu

tsTh

e EC

U s

ends

afix

ed 5

vD

C +

/- 10

% v

olta

geto

the

MAP

.Th

is is

a m

ust

!If

vo

ltag

e is

no

t 5v

DC

+/-

10%

,su

spec

t th

e E

CU

is f

ault

y

Que

stio

nW

hat v

olta

ge w

ill be

“see

n”w

ith th

e ke

y on

, KO

EO?

Ans

wer

This

is th

e “b

aro”

vol

tage

at t

his

loca

tion.

Thi

s nu

mbe

r is

con

stan

tde

pend

ing

on a

ctua

l bar

omet

ricpr

essu

re.

5 vo

lt D

C

Ref

eren

ce V

olta

geEC

U m

onito

rs h

ere

MA

P M

AP

Man

ifold

Abs

olut

e Pr

essu

re S

enso

r

126

ZEEM

SIn

puts

, EG

O

page

1

ECU

Elec

troni

cC

ontro

lU

nit

Exha

ust G

as O

xyge

nSe

nsor

ECU

Inpu

ts

EGO

Exha

ust G

as

Oxy

gen

Sens

or

The

EGO

is lo

cate

d on

the

exha

ust p

ipe

with

in s

ix (6

)in

ches

of t

he e

xhau

stm

anifo

ld.

(15

cm)

This

sen

sor i

s a

four

(4)

wire

sen

sor.

The

ZEEM

S sy

stem

use

s a

heat

ed E

GO

sen

sor.

EGO

(if e

quip

ped)

Clic

k he

re fo

r a d

etai

led

expl

anat

ion

on O

xyge

nse

nsor

s

127

ZEEM

SIn

puts

, EG

O

page

1a

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Inpu

ts

The

EGO

sen

sor g

ener

ates

a D

C v

olta

ge (0

-1vD

C) t

hat

is p

ropo

rtion

al to

the

Oxy

gen

cont

ent o

f the

exha

ust s

tream

and

ambi

ent o

xyge

n.

Whe

n th

e O

xyge

n (O

2)co

nten

t in

the

exha

ust

stre

am g

oes

up th

e vo

ltage

goes

dow

n. Que

stio

nIf

the

engi

ne is

runn

ing

with

too

muc

h fu

el a

nd n

om

isfir

es, w

ill th

e EG

Ovo

ltage

be

high

or l

ow?

EGO

Exha

ust G

as

Oxy

gen

Sens

or

Exha

ust G

as O

xyge

nSe

nsor

Clic

k he

re fo

r a d

etai

led

expl

anat

ion

on O

xyge

nse

nsor

s

EGO

(if e

quip

ped)

128

ZEEM

SIn

puts

, EG

O

page

2

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Inpu

tsW

hen

the

EGO

sen

sor

appr

oach

es 6

00 d

egre

es“F

”/ 30

0 de

gree

s “C

” it

star

ts to

ope

rate

pro

perly

.

An in

tern

al h

eate

r brin

gsth

e EG

O to

its

oper

atin

gte

mp

and

mai

ntai

ns th

iste

mp

if th

e ex

haus

t gas

este

mp

decr

ease

s.

The

EGO

hea

ter i

s a

12v

heat

er c

ontro

lled

by th

eig

nitio

n sw

itch.

Th

is is

not

cont

rolle

d by

the

ECU

.Th

ese

are

the

whi

te w

ires

goin

g to

sen

sor h

arne

ss.

EGO

Exha

ust G

as

Oxy

gen

Sens

or

Exha

ust G

as O

xyge

nSe

nsor

Clic

k he

re fo

r a d

etai

led

expl

anat

ion

on O

xyge

nse

nsor

s

EGO

(if e

quip

ped)

129

ZEEM

SIn

puts

, EG

O

page

3

ECU

Elec

troni

cC

ontro

lU

nit

EGO

ECU

Inpu

ts

The

EGO

gen

erat

esvo

ltage

s b

etw

een

0-1v

DC

.

The

ECU

“mon

itors

” the

sign

al w

ire to

det

erm

ine

the

O2

cont

ent o

f the

exh

aust

stre

am.

ECU

mon

itors

her

e

EGO

Exha

ust G

as

Oxy

gen

Sens

or

Key

Switc

h O

n

EGO

Hea

ter

EGO

(if e

quip

ped)

130

ZEEM

SIn

puts

, EG

O

page

3a

ECU

Elec

troni

cC

ontro

lU

nit

EGO

ECU

Inpu

tsTh

e EC

U in

tern

ally

sen

ds a

‘bia

s’ v

olta

ge to

the

EGO

sign

al w

ire. T

his

‘bia

s’vo

ltage

is in

the

0.4

- 0.5

vD

C ra

nge.

If th

e EG

O g

ener

ates

avo

ltage

hig

her t

han

the

bias

volta

ge th

e EC

U d

eter

min

esle

ss fu

el is

requ

ired,

if u

nder

the

bias

vol

tage

, mor

e fu

el is

requ

ired.

ECU

mon

itors

her

e

EGO

Exha

ust G

as

Oxy

gen

Sens

or

Key

Switc

h O

n

EGO

Hea

ter

Bias

vol

tage

0.44

0-0.

460

vDC

EGO

(if e

quip

ped)

131

ZEEM

SIn

puts

R

evie

w

ECU

Elec

troni

cC

ontro

lU

nit

The

ZEEM

S sy

stem

s us

es s

ever

al in

put d

evic

es

to m

onito

r the

eng

ine

and

atm

osph

eric

con

ditio

ns.

Engi

ne R

PM

Engi

ne C

oola

ntTe

mpe

ratu

re (E

CT)

Inta

ke A

irTe

mpe

ratu

re (I

AT)

Man

ifold

Abs

olut

ePr

essu

re (M

AP)

Exha

ust G

as O

xyge

nSe

nsor

(EG

O)

(if e

quip

ped)

ECU

Inpu

ts

Inpu

t Sen

sor

Rev

iew

132

ZEEM

SO

utpu

t Con

trol

In

trodu

ctio

n

ECU

Elec

troni

cC

ontro

lU

nit

The

ZEEM

S sy

stem

s us

es th

ree

outp

ut d

evic

es.

Com

man

ds to

the

outp

uts

are

dete

rmin

ed fr

om in

put c

ondi

tions

. EC

U O

utpu

ts

Out

put C

ontro

ls

Fuel

Inje

ctor

Lets

exa

min

eea

ch o

utpu

tde

vice

in d

epth

Igni

tion

Tim

ing

Gov

erno

r Act

uato

r

133

ZEEM

SO

utpu

ts

Gov

erno

r p

age

1

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

puts

Gov

erno

r Act

uato

r

Gov

erno

r

Gov

erno

r Th

e G

over

nor i

s an

ele

ctric

actu

ator

whi

ch c

ontro

ls(tu

rns)

the

thro

ttle

plat

e.

The

gove

rnor

act

uato

r mot

oris

the

only

con

nect

ion

to th

eth

rottl

e pl

ate.

The

gove

rnor

use

s tw

ow

ires

to c

ontro

l the

act

uato

r.

A gr

ound

wire

and

the

cont

rol c

ircui

t fro

m th

e EC

U.

134

ZEEM

SO

utpu

ts

Gov

erno

r p

age

2

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

putsGov

erno

r

Gov

erno

r Th

e go

vern

or is

loca

ted

onth

e th

rottl

e bo

dy a

ssem

bly

and

is th

e on

ly p

art t

hat i

sno

t fie

ld re

plac

eabl

e.

The

thro

ttle

plat

e ha

s a

mec

hani

cal s

top

and

mus

tbe

test

ed/re

set a

t10

00-1

200

hour

inte

rval

s.

The

pro

per R

PM fo

r the

mec

hani

cal s

top

is75

0 R

PM.

Gov

erno

r Act

uato

r

135

ZEEM

SO

utpu

ts

Gov

erno

r p

age

3

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

putsGov

erno

r

Gov

erno

r To

con

trol t

he g

over

nor,

the

ECU

use

s tw

o in

puts

:•d

ash

switc

h (2

or 3

spe

ed)

•eng

ine

RPM

From

the

RPM

inpu

t(c

ondi

tion)

, the

EC

Uco

mm

ands

the

gove

rnor

toin

crea

se o

r dec

reas

e th

eR

PM d

epen

ding

on

the

engi

ne lo

ad a

nd o

ther

oper

atin

g co

nditi

ons

tom

atch

the

dash

sw

itch

desi

red

RPM

.

Gov

erno

r Act

uato

r

136

ZEEM

SO

utpu

ts

Gov

erno

r p

age

4

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

putsGov

erno

r

Gov

erno

r Th

e EC

U c

ontro

ls th

e po

wer

side

to th

e G

over

nor w

ithth

e gr

ound

com

ing

from

ECU

.

Engi

ne R

PM

Das

h Sw

itch

Com

man

d

Gov

erno

r Act

uato

r Coi

l

This

circ

uit c

ontro

ls th

e ‘p

ower

sid

e’

of th

e G

over

nor A

ctua

tor C

oil

ECU

con

trols

her

e

“Hig

h Si

de”

Switc

h C

ircui

t

137

ZEEM

SO

utpu

ts

Gov

erno

r p

age

4a

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

putsGov

erno

r

Gov

erno

r Th

e EC

U c

ontro

ls th

e go

vern

orby

cha

ngin

g th

e ‘o

n-tim

e’ o

rpu

lse

wid

th m

odul

atio

n (P

WM

)(d

uty

cycl

e ch

ange

)du

ring

fixed

freq

uenc

y pu

lses

.

One

Cyc

le

Off

On

50%

On

25% O

ne C

ycle

XX%

Off

50%

One

Cyc

le

6 vD

CAv

erag

e

xx v

DC

Aver

age

XX%

On

XX%

Off

3 vD

CAv

erag

e

“Hig

h Si

de”

Switc

h C

ircui

t

Gov

erno

r Act

uato

r Coi

l

ECU

con

trols

her

e

138

ZEEM

SO

utpu

ts

Gov

erno

r p

age

4b

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

puts

Gov

erno

r Act

uato

r Coi

l

Gov

erno

r

Gov

erno

r Th

e fre

quen

cy o

f the

gov

erno

rco

ntro

l circ

uit i

s24

0 he

rtz +

/-2%

.

The

duty

cyc

le w

ill va

ryac

cord

ing

to th

e en

gine

load

,ba

sed

on th

e th

rottl

e pl

ate

setti

ng, i

gniti

on ti

min

g, q

ualit

yof

fuel

and

man

y ot

her f

acto

rs.

The

duty

cyc

le m

ust c

hang

e as

the

dem

and

for e

ngin

e R

PM is

com

man

ded.

ECU

con

trols

her

e

“Hig

h Si

de”

Switc

h C

ircui

t

139

ZEEM

SO

utpu

ts

Gov

erno

r p

age

5

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

puts

Gov

erno

rGov

erno

r

Gov

erno

r If

the

ECU

or t

hrot

tlebo

dy/g

over

nor a

ssem

bly

is re

plac

ed o

r the

bas

eid

le s

ettin

g is

alte

red,

the

ECU

mus

t rel

earn

the

base

thro

ttle

setti

ng.

This

pro

cedu

re ta

kes

2-4

min

utes

dur

ing

norm

alop

erat

ion.

This

‘idl

e se

tting

rele

arn’

pr

oced

ure

is a

‘sel

f-pro

gram

min

g’

oper

atio

n of

the

ECU

140

ZEEM

SO

utpu

ts

Gov

erno

r p

age

1 Ad

just

men

ts

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

puts

Gov

erno

rGov

erno

r

Gov

erno

r T

he p

rope

r RPM

for t

hem

echa

nica

l sto

p is

750

RPM

.

To a

djus

t:(e

ngin

e m

ust b

e ov

er 1

71 d

egre

es F

)•u

nplu

g th

e ac

tuat

or (g

over

nor)

•rem

ove

seal

ant o

ver s

top

scre

w•s

tart

engi

ne a

nd m

onito

r RPM

•turn

sto

p sc

rew

to d

esire

d R

PM•tu

rn e

ngin

e of

f•c

onne

ct a

ctua

tor (

gov)

•res

tart

engi

ne, r

un fo

r 2 m

inut

es•r

e-ru

n ba

se R

PM te

st (r

eadj

ust)

•res

eal s

top

scre

w

141

ZEEM

SO

utpu

ts

Fuel

Inje

ctor

p

age

1

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

put

Fuel

Inje

ctor

Fuel

Inje

ctor

Fuel

Inje

ctor

The

Fuel

Inje

ctor

is a

n el

ectri

cac

tuat

or w

hich

con

trols

the

fuel

flow

to th

e en

gine

.

The

gaso

line

fuel

inje

ctor

isca

libra

ted

at10

psi

w/o

EG

O (0

.69

bar)

15 p

si w

ith E

GO

(1.0

bar

)an

d th

epr

opan

e fu

el in

ject

or is

calib

rate

d at

24 p

si. w

/o E

GO

(1.

65 b

ar)

calib

rate

d at

14 p

si. w

ith E

GO

(0.

96 b

ar)

No

norm

al s

ervi

cing

is re

quire

d.

142

ZEEM

SO

utpu

ts

Fuel

Inje

ctor

p

age

1a

ECU

Elec

troni

cC

ontro

lU

nit

Gas

olin

eFu

el In

ject

or L

eak

Test

Fuel

Inje

ctor

Fuel

Inje

ctor

With

the

engi

ne n

ot ru

nnin

gan

d th

e ke

y in

the

off p

ositi

on.

Inse

rt a

narro

w p

iece

of t

hin

card

boar

d un

der t

he fu

elin

ject

or n

ozzl

e.W

ait f

or 5

-10

min

utes

, the

card

boar

d sh

ould

rem

ain

“sta

in fr

ee”,

if th

e ca

rdbo

ard

is s

tain

ed,

the

inje

ctor

is le

akin

g.

143

ZEEM

SO

utpu

ts

Fuel

Inje

ctor

p

age

2

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

put

Fuel

Inje

ctor

Fuel

Inje

ctor

Fuel

Inje

ctor

To c

ontro

l the

fuel

inje

ctor

, the

ECU

pro

vide

s th

e po

wer

and

cont

rols

the

“gro

und

side

” of t

heci

rcui

t.

The

inje

ctor

fire

s on

ce p

eren

gine

eve

nt a

nd v

arie

s th

epu

lse

wid

th (o

n-tim

e) a

ccor

ding

to th

e en

gine

con

ditio

ns.

The

engi

ne c

ondi

tions

are

mon

itore

d by

the

inpu

t sen

sors

and

the

the

ECU

com

man

dsth

e fu

el in

ject

or w

ith a

long

er o

rsh

orte

r pul

se w

idth

(on

time)

.

144

ZEEM

SO

utpu

ts

Fuel

Inje

ctor

p

age

3

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

put

Fuel

Inje

ctor

Fuel

Inje

ctor

Fuel

Inje

ctor

ECU

con

trols

her

e

12 v

DC

Engi

ne R

PM

The

inje

ctor

“trig

gers

” onc

e fo

rev

ery

dist

ribut

or re

fere

nces

puls

e go

ing

into

the

ECU

.

“Low

Sid

e” S

witc

h C

ircui

t

HEI

Mod

ule

Ope

ratio

n R

evie

w

145

ZEEM

SO

utpu

ts

Fuel

Inje

ctor

p

age

4

ECU

Elec

troni

cC

ontro

lU

nit

ECU

Out

put

Fuel

Inje

ctor

Fuel

Inje

ctor

Fuel

Inje

ctor

ECU

con

trols

her

e

12 v

DC

Engi

ne R

PM

The

ECU

var

ies

the

amou

nt o

fon

-tim

e of

the

inje

ctor

by

look

ing

at th

e va

rious

inpu

tse

nsor

s of

the

engi

ne.

ECT

IAT

MAP

EGO

The

ECU

var

ies

the

inje

ctor

pul

se w

idth

Off

On

“Low

Sid

e”

Switc

h C

ircui

t

146

ZEEM

S

ECU

Elec

troni

cC

ontro

lU

nit

ECT

IAT

MAP

EGO

The

ECU

con

trols

the

igni

tion

timin

gba

sed

on th

e M

AP, E

CT,

IAT

and

RPM

inpu

ts.

Base

Igni

tion

Tim

ing

need

s to

be

chec

ked/

rese

t at

1000

-120

0 ho

ur in

terv

als.

Gas

Eng

ine

@13

50 R

PM17

deg

rees

BTD

C +

/- 2

deg

LPG

Eng

ine

@13

50 R

PM25

deg

rees

BTD

C +

/- 2

deg

RPM

Tim

ing

Out

puts

Ti

min

g C

ontro

l p

age

1

Igni

tion

Tim

ing EC

U O

utpu

t

Igni

tion

Tim

ing

Tim

ing

Adva

nce

Dis

cuss

ion

147

ZEEM

S

ECU

Elec

troni

cC

ontro

lU

nit

Tim

ing

Out

puts

Ti

min

g C

ontro

l p

age

2a

Igni

tion

Tim

ing C

rank

ing,

up

to 2

50-4

00 R

PM

Igni

tion

Coi

l

Engi

neR

PM

Mag

netic

Pic

k U

p(A

C S

ine

Wav

e)

Anal

og to

Dig

ital C

onve

rter A

/D

Adva

nce

Rel

ayC

ontro

l

Igni

tion

Mod

ule

148

ZEEM

S

ECU

Elec

troni

cC

ontro

lU

nit

Tim

ing

Out

puts

Ti

min

g C

ontro

l p

age

2b

Igni

tion

Tim

ing R

unni

ng,

over

250

-400

RPM

Igni

tion

Coi

l

Engi

neR

PM

Mag

netic

Pic

k U

p(A

C S

ine

Wav

e)

Igni

tion

Mod

ule

(Ana

log

to D

igita

l Con

verte

r A/D

)

Adva

nce

Rel

ayC

ontro

l

149

ZEEM

SO

pen/

Clo

sed

Loop

page

1

ECU

Elec

troni

cC

ontro

lU

nit

Clo

sed

Loop

Ope

n &

C

lose

d Lo

op

Ope

n &

Clo

sed

Loop

ECT

IAT

MAP

EGO

Ope

n Lo

opD

urin

g w

arm

-up

the

ECU

cont

rols

in “o

pen

loop

”.Th

e EC

U c

ontro

ls th

eou

tput

s ba

sed

on th

e M

AP,

ECT,

IAT

and

RPM

inpu

ts.

Ope

n Lo

op is

def

ined

as

“no

EGO

con

trol”.

RPM

150

ZEEM

SO

pen/

Clo

sed

Loop

page

2

ECU

Elec

troni

cC

ontro

lU

nit

Clo

sed

Loop

Ope

n &

C

lose

d Lo

op

Ope

n &

Clo

sed

Loop

ECT

IAT

MAP

EGO

Ope

n Lo

op RPM

To a

chie

ve ‘c

lose

d lo

op’ t

hese

cond

ition

s m

ust b

e m

eet:

•eng

ine

fully

war

m•E

GO

hot

and

ope

ratin

g•e

ngin

e ru

nnin

g fo

r 15-

120

seco

nds

Clo

sed

Loop

is d

efin

ed a

s th

eEG

O is

mon

itorin

g th

eth

e O

2 co

nten

t of t

he e

xhau

stst

ream

and

the

ECU

isad

just

ing

the

fuel

inje

ctor

pul

sew

idth

bas

ed o

n th

e EG

Ova

lues

.

151

ZEEM

SO

pen/

Clo

sed

Loop

page

3

ECU

Elec

troni

cC

ontro

lU

nit

Clo

sed

Loop

Ope

n &

C

lose

d Lo

op

Clo

sed

Loop

to O

pen

Loop

ECT

IAT

MAP

EGO

Ope

n Lo

op RPM

The

ECU

will

mov

e fro

mC

lose

d Lo

op to

Ope

n Lo

op if

sudd

en c

hang

es in

MAP

, EC

T,or

RPM

val

ues

occu

r.

MAP

sen

sor c

hang

es a

re lo

adde

pend

ent.

ECT

chan

ges

are

cool

ant r

elat

ed. R

PM c

hang

esar

e en

gine

runn

ing

cond

ition

s.

152

ZEEM

SO

pen/

Clo

sed

Loop

page

4

ECU

Elec

troni

cC

ontro

lU

nit

Ope

n &

C

lose

d Lo

op

Clo

sed

Loop

Ope

ratio

n

EGO

Fuel

Inje

ctor

“Rich”

Lean

Out

ENG

INE

“Lean

”`Rich

en

“Rich”

Lean

Out

“Com

man

d”“C

ondi

tion”

Mov

e to

R

evie

w P

age

153

ZEEM

S

Rev

iew

Que

stio

nsan

dAn

swer

s

Rev

iew

Que

stio

ns a

nd A

nsw

ers

Ope

n/C

lose

d Lo

op

Dis

cuss

ion

154

ZEEM

S

Rev

iew

Que

stio

nsan

d An

swer

s

Nam

e th

e fiv

e (5

) inp

ut s

enso

rs

(inpu

t sen

sor r

evie

w)

Nam

e th

e th

ree

(3) o

utpu

t act

uato

rs(a

ctua

tor r

evie

w)

If th

e en

gine

coo

lant

tem

pera

ture

is h

igh,

w

ill th

e EC

T re

sist

ance

be

high

or l

ow?

(EC

T re

view

)

How

doe

s th

e EG

O s

enso

r pro

duce

vol

tage

? (E

GO

revi

ew)

If th

e M

AP s

enso

r sig

nal v

olta

ge 2

.8vD

C, (

KOEO

)at

wha

t alti

tude

is th

e m

achi

ne lo

cate

d at

? (M

AP re

view

)

Rev

iew

Que

stio

ns a

nd A

nsw

ers

155

ZEEM

SO

pera

tion

page

1

ECU

Elec

troni

cC

ontro

lU

nit

Syst

em O

pera

tion

Key

On

IAT

MA

P

ECT

ECU

Tur

ns o

n Fu

el P

ump

(gas

olin

e)

or

Ope

ns F

uel L

ock

Off

(pro

pane

)

This

will

be

“on”

for

2 se

cond

s if

a R

PM s

igna

l is

not

rece

ived

.Li

sten

and

“fe

el”

the

pum

p ru

n or

the

lock

off

to “

turn

on”

.

Cal

cula

tes

or m

easu

res:

•Alti

tude

, bar

omet

ric p

ress

ure

•Coo

lant

tem

pera

ture

•Am

bien

t tem

pera

ture

156

ZEEM

SO

pera

tion

page

2

ECU

Elec

troni

cC

ontro

lU

nit

Syst

em O

pera

tion

Cra

nkin

g

IAT

MA

P

ECT

Fuel

is fl

owin

g(p

ump

“pum

ping

” or

lock

off

“ope

n”)

Inje

ctor

Firi

ng

Gov

erno

r is

star

ting

to

cont

rol

Igni

tion

Tim

ing

is a

t ba

se ti

min

g se

tting

RPM

157

ZEEM

SO

pera

tion

page

3 w

ithou

t EG

O

ECU

Elec

troni

cC

ontro

lU

nit

Syst

em O

pera

tion

Run

ning

w

ithou

t EG

O S

enso

r

IAT

MA

P

ECT

Fuel

is fl

owin

g(p

ump

“pum

ping

” or

lock

off

“ope

n”)

Inje

ctor

Firi

ng

Gov

erno

r is

at s

peci

fied

cont

rolle

d R

PM

Igni

tion

Tim

ing

adva

ncin

g

RPM

Das

h Sw

itch

Com

man

d

158

ZEEM

SO

pera

tion

page

4 w

ith E

GO

ECU

Elec

troni

cC

ontro

lU

nit

Syst

em O

pera

tion

IAT

MA

P

ECT

Fuel

is fl

owin

g(p

ump

“pum

ping

” or

lock

off

“ope

n”)

Inje

ctor

Firi

ng

Gov

erno

r is

at s

peci

fied

cont

rolle

d R

PM

Igni

tion

Tim

ing

adva

ncin

g

RPM

EGO

Hea

ter

Key

On

Not

EC

U

Con

trol

led

Das

h Sw

itch

Com

man

d

EGO

Run

ning

w

ith E

GO

Sen

sor

159

ZEEM

SO

pera

tion

Rev

iew

Syst

em O

pera

tion

Rev

iew

Que

stio

ns a

nd A

nsw

ers

160

ZEEM

S

Dia

gnos

tics

161

ZEEM

SD

iagn

ostic

s

•Fai

lure

s•

30%

Wiri

ng•

40%

Inpu

t sen

sors

•25

% A

ctua

tor o

utpu

ts•

5% E

CU

Fai

lure

s30

%

Wiri

ng

40%

In

put S

enso

rs

25%

Ac

tuat

or

Out

puts

5% E

CU

Fai

lure

s

162

ZEEM

SD

iagn

ostic

s, E

CU

Qui

ck T

ests

Dia

gnos

tics

•EC

U Q

uick

Tes

ts

(The

se q

uick

test

s ca

n de

term

ine

whe

ther

the

ECU

can

con

trol c

orre

ctly

.

The

se te

st/s

hav

e a

high

acc

urac

y ra

ting

to d

eter

min

e a

defe

ctiv

e EC

U.)

•M

AP R

efer

ence

Vol

tage

Tes

t•

(KO

EO, B

lack

Con

nect

or P

in 4

)

•M

easu

re R

efer

ence

vol

tage

to M

AP S

enso

r•

Turn

Key

Off

•R

emov

e w

ire h

arne

ss to

MAP

•Tu

rn k

ey o

n (K

OEO

)•

Voltm

eter

red

lead

to T

erm

inal

“C” o

n th

e M

APSe

nsor

, bla

ck le

ad to

Ter

min

al “A

”•

Res

ults

sho

uld

be 5

.0 v

DC

+/-

10%

(4.5

- 5.

5 vD

C)

•M

AP S

enso

r Rev

iew

163

ZEEM

S

Dia

gnos

tics

•Out

put C

ontro

l Fre

quen

cy T

est

•(K

OER

, Whi

te C

onne

ctor

Pin

5)

•M

easu

re F

requ

ency

to G

over

nor A

ctua

tor

•Tu

rn K

ey O

ff•

Con

nect

freq

uenc

y m

eter

red

lead

to T

erm

inal

“A” o

nG

over

nor A

ctua

tor,

blac

k le

ad to

Ter

min

al “B

”•

Leav

e go

vern

or a

ctua

tor c

onne

cted

in c

ircui

t•

Star

t Eng

ine

(KO

ER)

•R

esul

ts s

houl

d be

240

Her

tz +

/- 2%

at s

tabl

e R

PM•

Gov

erno

r Act

uato

r Rev

iew

Dia

gnos

tics,

EC

U Q

uick

Tes

ts

164

ZEEM

S

Dia

gnos

tics

•Pro

cess

or Q

uick

Tes

ts•

EGO

Bia

s Vo

ltage

Tes

t (KO

EO, B

lack

Con

nect

or P

in 1

0)•

(if e

quip

ped)

•M

easu

re “B

ias”

vol

tage

to E

GO

Sen

sor

•Tu

rn K

ey O

ff•

Rem

ove

wire

har

ness

to E

GO

•Tu

rn k

ey o

n•

Voltm

eter

red

lead

to T

erm

inal

“??”

on

EGO

Sen

sor,

blac

k le

ad to

Ter

min

al “?

?”•

Res

ults

sho

uld

be 0

.4 -

0.5

vDC

•EG

O S

enso

r Rev

iew

Dia

gnos

tics,

EC

U Q

uick

Tes

ts

165

ZEEM

S

Dia

gnos

tics

•Pro

cess

or Q

uick

Tes

ts

•Con

clus

ion

•If

all o

f the

se te

sts

fail,

sus

pect

a fa

ulty

pow

er o

r gro

und

circ

uit/s

to th

e EC

U.

•If

one

or tw

o of

thes

e te

sts

fail,

sus

pect

a fa

ulty

EC

U.

Dia

gnos

tics,

EC

U Q

uick

Tes

ts

166

ZEEM

SD

iagn

ostic

s, In

put S

enso

rs Q

uick

Tes

t

•Inp

ut S

enso

r Qui

ck T

ests

•IA

T Te

stin

g•

ECT

Test

ing

•M

AP T

estin

g•

EGO

Tes

ting

•D

istri

buto

r Ref

eren

ce

40%

In

put S

enso

rs

167

ZEEM

S

•IAT

and

EC

T Te

stin

g•

Rem

ove

wiri

ng h

arne

ss fr

om s

enso

r/s•

Inst

all “

test

har

ness

” to

IAT

or E

CT

sens

or•

Mea

sure

the

resi

stan

ce v

alue

s in

Ohm

san

d co

mpa

re to

cha

rt be

low

Tem

p F

Tem

p C

Nom

inal

Re

sist

ance

Min

imum

Re

sist

ance

Max

imum

Re

sist

ance

266

130

8480

8823

011

014

413

915

121

210

018

918

219

917

680

349

334

369

140

6069

365

773

410

440

1484

1398

1579

6820

3481

3254

3719

320

9099

8442

9767

-4-2

027

050

2491

029

10-4

0-4

093

630

8557

010

1400

Dia

gnos

tics,

Inpu

t Sen

sors

Qui

ck T

est

168

ZEEM

S

•IAT

and

EC

T Te

stin

g•

Rem

ove

wiri

ng h

arne

ss fr

om s

enso

r/s•

Turn

Key

On

(KO

EO)

•M

easu

re v

olta

ge b

etw

een

term

inal

s “A

” & “B

”of

the

wiri

ng h

arne

ss g

oing

to th

e IA

T or

EC

T•

Blac

k Vo

ltmet

er le

ad to

“B”,

red

lead

to “A

”•

Volta

ge s

houl

d be

5 v

DC

+/-

10%

(KO

EO)

Dia

gnos

tics,

Inpu

t Sen

sors

Qui

ck T

est

169

ZEEM

S

•MAP

Tes

ting

•C

ompl

ete

ECU

refe

renc

e vo

ltage

test

at M

AP•

With

the

MAP

con

nect

ed “i

n-ci

rcui

t”•

Con

nect

a v

oltm

eter

as

follo

ws,

key

on

(KO

EO)

•R

ed le

ad to

term

inal

“B”,

blac

k le

ad to

gro

und

•M

easu

re th

e Vo

ltage

val

ues

and

com

pare

to c

hart

•Th

ese

volta

ges

will

vary

acc

ordi

ng th

e cu

rrent

wea

ther

cond

ition

s at

you

r loc

atio

n

Dia

gnos

tics,

Inpu

t Sen

sors

Qui

ck T

est

Altit

ude

abov

e Se

a Le

vel

Nom

inal

Vo

ltage

DC

0-10

005.

00-4

.60

1000

-200

04.

60-4

.10

2000

-300

04.

10-3

.60

3000

-400

03.

60-3

.20

170

ZEEM

S

•EG

O T

estin

g (if

equ

ippe

d)

•C

ompl

ete

EGO

Bia

s vo

ltage

test

•W

ith th

e EG

O c

onne

cted

“in-

circ

uit”

•C

onne

ct a

vol

tmet

er a

s fo

llow

s, k

ey o

n (K

OEO

)

•R

ed le

ad to

term

inal

“XX”

, bla

ck le

ad to

gro

und

•C

ompl

ete

EGO

test

in m

achi

ne p

er E

GO

test

ing

sequ

ence

•‘R

iche

n M

ixtu

re’ E

GO

vol

tage

0.8

vD

C o

r hig

her

•‘L

ean

Mix

ture

’ EG

O v

olta

ge 0

.3 v

DC

or l

ower

•(E

GO

Sen

sor R

evie

w)

Dia

gnos

tics,

Inpu

t Sen

sors

Qui

ck T

est

171

ZEEM

S

•Fai

lure

s•

30%

Wiri

ng•

40%

Inpu

t sen

sors

•25

% A

ctua

tor o

utpu

ts•

5% E

CU

Fai

lure

s25

%

Actu

ator

O

utpu

ts

Dia

gnos

tics,

Out

put S

enso

rs Q

uick

Tes

t

172

ZEEM

S

•Fue

l Inj

ecto

r Te

stin

g•

Dis

conn

ect w

ire/s

to fu

el in

ject

or•

Mea

sure

the

resi

stan

ce o

f the

fuel

inje

ctor

•1.

2 - 1

.4 O

hms

is s

peci

ficat

ion

•Tu

rn K

ey o

n an

d m

easu

re v

olta

ge o

n th

eha

rnes

s•

Volt

met

er re

d le

ad to

term

inal

“A”,

blac

k le

ad to

term

inal

“B”,

turn

key

on

(KO

EO)

•Vo

ltage

sho

uld

be 9

-14

vDC

•C

ompl

ete

fuel

inje

ctor

“tap

test

”

Dia

gnos

tics,

Out

put S

enso

rs Q

uick

Tes

t

173

ZEEM

S

•Gov

erno

r Act

uato

r Te

stin

g•

Dis

conn

ect w

ire/s

to G

over

nor A

ctua

tor

•M

easu

re th

e re

sist

ance

of t

he a

ctua

tor

•3.

0-4.

5 O

hms

is s

peci

ficat

ion

•Tu

rn K

ey o

n an

d m

easu

re v

olta

ge o

n th

eha

rnes

s•

Volt

met

er re

d le

ad to

term

inal

“A”,

blac

k le

ad to

term

inal

“B”,

turn

key

on

(KO

EO)

•Vo

ltage

sho

uld

be b

atte

ry v

olta

ge (+

/-0.4

vDC

)

Dia

gnos

tics,

Out

put S

enso

rs Q

uick

Tes

t

174

ZEEM

S

•Gov

erno

r Act

uato

r Te

stin

g•

Con

nect

am

met

er to

one

wire

goi

ng to

gove

rnor

act

uato

r•

Turn

key

on

(KO

EO)

•M

easu

re g

over

nor a

ctua

tor a

mpe

rage

dra

w•

Spec

ifica

tion

is 0

.5 -

2.5

amp

whe

n G

over

nor

actu

ator

is “a

ctiv

ated

” (3

amps

max

imum

dra

w)

•If

high

er th

an th

ree

amp

draw

, sus

pect

stic

king

thro

ttle

plat

es o

r oth

er m

echa

nica

l bin

ding

Dia

gnos

tics,

Out

put S

enso

rs Q

uick

Tes

t

175

ZEEM

S

•Ign

ition

Tim

ing

Tes

ting

•Se

t to

low

est g

over

ned

RPM

(135

0)•

Star

t eng

ine

and

mon

itor i

gniti

on ti

min

g

•Gas

Eng

ine

@13

50 R

PM17

deg

rees

BTD

C +

/- 2

deg

•LPG

Eng

ine

@13

50 R

PM25

deg

rees

BTD

C +

/- 2

deg

Dia

gnos

tics,

Out

put S

enso

rs Q

uick

Tes

t

176

ZEEM

SD

iagn

ostic

s

•Dia

gnos

tic R

evie

w•

30%

Wiri

ng•

40%

Inpu

t sen

sors

•25

% A

ctua

tor o

utpu

ts•

5% E

CU

Fai

lure

s30

%

Wiri

ng

40%

In

put S

enso

rs

25%

Ac

tuat

or

Out

puts

5% E

CU

Fai

lure

s

177

ZEEM

SSp

ecifi

catio

ns

IAT

and

ECT

Tem

p F

Tem

p C

Nom

inal

Re

sist

ance

Min

imum

Re

sist

ance

Max

imum

Re

sist

ance

266

130

8480

8823

011

014

413

915

121

210

018

918

219

917

680

349

334

369

140

6069

365

773

410

440

1484

1398

1579

6820

3481

3254

3719

320

9099

8442

9767

-4-2

027

050

2491

029

10-4

0-4

093

630

8557

010

1400

MA

PAl

titud

e ab

ove

Sea

Leve

lN

omin

al

Volta

ge D

C0-

1000

5.0

- 4.7

1000

-200

04.

7 - 4

.320

00-3

000

4.3

- 4.1

3000

-400

04.

1 - 3

.940

00-5

000

3.9

- 3.8

Fuel

Inje

ctor

1.2

- 1.4

Ohm

s

Fuel

Pre

ssur

eG

asol

ine

10 p

si (0

.69

bar)

w/o

EG

O15

psi

(1.0

bar

) w/E

GO

Pro

pane

14 p

si. (

0.96

bar

) w/E

GO

24 p

si. (

1.65

bar

) w/o

EG

O

Gov

erno

rA

ctua

tor

3.0-

4.5

Ohm

s3

amp

max

cur

rent

dra

wTim

ing

@13

50 R

PMG

as 1

7 de

g BT

DC

+/-

2 de

gLP

G 2

5 de

g BT

DC

+/-

2 de

g

178

r1l

Line

r1l

Line

r1l

Line

r1l

Text Box

14 psi (0.96 bar)

ZEEM

SO

pera

tion

Rev

iew

Syst

em O

pera

tion

Rev

iew

Que

stio

ns a

nd A

nsw

ers

179

ZEEM

SB

lock

Dia

gram

Rev

iew

ZEEM

S B

lock

Dia

gram

Elec

trica

l fue

l shu

t off/

on, p

ropa

ne (L

PG)

Elec

tric

fuel

pum

p, g

asol

ine

ECU

Elec

troni

cC

ontro

lU

nit

Fuel

Inje

ctor

Thro

ttle

Actu

ator

Dis

tribu

tor

Fuel

Ret

urn,

ga

solin

e on

ly

Fuel

Tan

k,

prop

ane

or

gaso

line

Tim

ing

Adva

nce

RPM

Inpu

t Sen

sors

Fuel

Pre

ssur

e R

egul

ator

, ga

solin

e on

ly

180

ZEEM

SO

pera

tion

Rev

iew

ECU

Elec

troni

cC

ontro

lU

nit

Syst

em O

pera

tion

IAT

MA

P

ECT

Fuel

is fl

owin

g(p

ump

“pum

ping

” or

lock

off

“ope

n”)

Inje

ctor

Firi

ng

Gov

erno

r is

at s

peci

fied

cont

rolle

d R

PM

Igni

tion

Tim

ing

adva

ncin

g

RPM

EGO

Hea

ter

Key

On

Not

EC

U

Con

trol

led

Das

h Sw

itch

Com

man

d

EGO

Run

ning

w

ith E

GO

Sen

sor

181

ZEEM

S

ZEEM

S55

0/15

50 E

ngin

e R

epla

cem

ent K

it N

umbe

rs39

2556

Per

kins

Die

sel

3925

57 G

M 3

.0 L

LPG

3925

58 G

M 3

.0 L

Gas

182

ZEEM

S

ZEEM

SZe

nith

Ele

ctro

nic

Engi

ne M

anag

emen

t Sys

tem

Prop

ane

and

Gas

olin

e El

ectr

onic

Fue

l Inj

ectio

n

END

183

184

ZEEMS Troubleshooting Test Kit

Complete Test Kit – Tennant Part # 371772 – Zenith Part # C282-311

Pressure Gauge – Tennant Part # 371784 – Zenith Part # C190-181

Male Connector 45 Flare – Tennant Part # 371783 – Zenith Part # T220-17 Assly Street TEE w/fittings – Tennant Part # 371785 – Zenith Part # C210-7

Male Connector SAE 45 Flare – Tennant Part # 371786 – Zenith Part # T220-16 Connector Fitting – Tennant Part # 371787 – Zenith Part # T220-5

Male Pipe X Female Pipe Tee – Tennant Part # 371788 – Zenith Part # T270-7

185

Service Connector – Air Temp Sensor – Tennant Part # 371773 – Zenith Part # C282-305

Service Connector – Coolant Temp Sensor – Tennant Part # 371774 – Zenith Part # C282-306

Service Connector – MAP Sensor – Tennant Part # 371775 – Zenith Part # C282-307

Service Connector – Governor – Tennant Part # 371776 – Zenith Part # C282-308

186

Service Connector – Gasoline Injector – Tennant Part # 371777 – Zenith Part # C282-309

Service Connector – LPG Injector – Tennant Part # 371778 – Zenith Part # C282-310

GM Micropak Coil Adapter – Tennant Part # 371779 – Zenith Part # C201-33

187

Gas Injector - Noid Light – Tennant Part # 371780 – Zenith Part # C282-110

LPG Injector - Noid Light – Tennant Part # 371781 – Zenith Part # C282-109

Actuator Power Tool – Tennant Part # 371782 – Zenith Part # C282-113

188

Engine Controls

Te m pdeg F

-40

-30

-20

-10

0

10

20

25

30

40

50

60

70

80

90

100

110

120

130

Te m pdeg F

-40

-22

-4

14

32

50

68

77

86

104

122

140

158

176

194

212

230

248

266

N o m i n a lRes is tance

o h m s

93630

49320

27050

15420

9099

5546

3481

2787

2245

1484

1004

693

488

349

255

189

144

109

84

M i n i m u mRes is tance

o h m s

85570

45250

24910

14250

8442

5165

3254

2609

2106

1398

949

657

465

334

244

182

139

105

80

M a x i m u mRes is tance

o h m s

101400

53310

29160

16580

9767

5939

3719

2974

2393

1579

1065

734

516

369

268

199

151

114

88

AIR AND COOLANT SENSOR RESISTANCE

Table 7:1

WIRING DIAGRAMSRefer to Section 3, Engine Electrical, for wiring diagrams.

Note: The wiring diagrams are specific to the engine and machine application. If the following wiring diagrams do notmatch the machine being repaired contact Power Solutions, Inc., or the machine manufacturer for a copy of thediagram.

189

Engine Controls

Below is a brief list of items to check BEFORE entering the ZEEMS diagnostic charts that follow. Too often thetendency is to blame the most unfamiliar part of a new system and we forget to ‘get back to the basics’.

The following is a quick check list of items to check.

Ignition System Operation

Ignition Timing

Fuel pressures

Fuel level

Electrical Connections

Alternator charging voltages

Battery condition

DIAGNOSTIC PROCEDURES

Diagnostic procedures are listed separately for each fuel but, unlike mechanical fuel systems that require differentthinking processes for gasoline and LPG, the diagnostic procedures for both the gasoline and LPG ZEEMS systemfollow the same thinking pattern.

Diagnostic Procedure Pg. No. Engine Idle Speed High 4-36 Engine Speed “Spikes” Intermittently 4-37 Engine Runs Erratically, Poor Governor Performance 4-38 Engine Runs but will not Accelerate 4-39 Engine Won’t Start - Gasoline 4-40 Gasoline Fuel Pump Diagnosis 4-41 Engine Won’t Start - LPG 4-42 Engine Won’t Start - Dual Fuel 4-44 Engine Runs, Low Power, Lean or Misfire - Gasoline 4-45 Engine Runs Rich - Gasoline 4-46 Engine Runs, Low Power, Lean or Misfires - LPG 4-47 Engine Runs Rich - LPG 4-48

190

Engine Controls

Engine Idle Speed High

Check vacuum leaks:Intake manifold

Throttle bodyThrottle adapter

PCV valve

Y E S

N O Back out idlestop screw

one turn

Does idlespeed drop?

Y E S

Binding orstuck throttle

Y E S

N O

Y E S

Y E S

NOTE:disconnect batterywhen servicingelectrical components

With ECT above 161 deg. Fallow engine to idle

for 2-5 1/2 min.to self learn idle speed

SEE: Operating Spec.

Does engine idleat 500 – 650 RPM

with actuatoru n p l u g g e d ?

Adjust idle stop tospec i f i ca t ions

SEE: OperatingS p e c .

Engine idle above500-650 RPM with

ac tua to rc o n n e c t e d

Diagnostic Procedures - Continued

191

Engine Controls


Engine Speed “Spikes” Intermittently

Disconnect GovernorActuator. Engine idlespeed 500-650 RPM?

Verify ECU ignitionsupply is constantand uninterrupted.

Constant?

< 650 RPM

> 650 RPM

Adjust baseidle screw tolower engine

RPM

Is idlespeed

reduced?

Remove Throttle bodyand inspect for

binding/obstruction

Adjust baseidle screw tospecifications

YES

NO

Repair faultyconnection

NO

YES

Verify ECU groundis constant anduninterrupted.

Constant? Cleanand Tight?

Repair faultyconnection

NO

Allow unit to reachoperating temperature(>160°F) and allowunit to “Self Learn”YES

Repair fault in SpeedSelect wiring.

3

REV

192

Engine Controls

Engine Runs Erratically, Poor Governor Performance

SEE engine idlespeed high

Engine speed surges

Repair ground

SEE engine diagnostics

SEE engine diagnostics

Correct chargingsystem fault

Voltage reversedon CKP sensor?

Correct CKPsensor polarity

Set timing tomanu fac tu re rsspec i f i ca t ions

R e p l a c ethrottle body

Y E S

N O

Y E S

N O

N O

Y E S

Y E S

Throttle plates t i ck ing?

Ignition timingincor rec t?

Charging systemvoltage surges?

E C Ug r o u n d ?

System fuelpressures low?

Va c u u mL e a k s ?

N O

Y E S

N O

N O

N O

Y E S


193

Engine Controls

Engine Runs, But Will Not Accelerate

SEE: Engine runs low power, lean ormisfires diagnosis

Replace

Repair or replace accelerator pedalposition sensor or speed select switch

Repair wiringor replace ECU

Replace throttle body

NO

NO

NO

NO

NO

YES

YES

YES

YES

FuelLevel

MapSensor

*APP sensoror speed select

output OK?

Governoractuator

input OK?

Governoractuator

continuity (3-5 Ω) ?

YES

Check throttleplate rotation


*Refer to the applicable schematic in Section 3 to check the speed switch operation.

194

Engine Controls

NO

Momentaryfuel pressure when

key is on?

Injectorsprays?

Injectorleaks?

Are plugsfouled?

See pump diagnosis

Checkground or

replace ECU

Repair wiringor

voltage souce

Replaceinjector or

o-rings

Injectorlight flashes?

12V atinjector?

Clean orreplaceplugs

Addfuel

Correct ignition system.Repair or replace ECU

Tach. signalto ECU?

Replace fuelpress regulator.

Disconnect inj.Crank engine

15 sec.

Fuel press.9-11 psi?

Is engineflooded?

AdjustFuel press.

9-11 psi.

Restrictfuel return line.

Fuel press.16 psi?

Replace fuelfilter and/or pump

Fuel pressurew/crank?

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO Repair wiringor

CKP sensor

Engine Won’t Start - GasolineDiagnostic Procedures - Continued

FuelLevel?

SparkPresent at Spark

Plugs?

NO Refer to Section 3,Engine Electrical

YES

195

Engine Control

Gasoline Fuel Pump Diagnosis

G r o u n dcont inu i tyto frame?

Repair orreplace pump

Repair wireto pump

Momentary 12vfrom ECU when

key is turned on?

Repair 12v sourceto ECU

12v toE C U ?

R e p l a c eE C U

R e p a i rground wire

G r o u n dcont inu i ty?

Momentary 12vat pump when

key is turned on?

Y E S

Y E S

Y E S

Y E S

Y E S

N O

N O

N O

N O


196

Engine Controls

NOCONTINUITY

YES

NOYES

NO

Does LP tankhave fuel?

YES

NO

Add Fuel

Turn ignition on andimmediately observe LP

lock-off voltage.Is voltage present for2 seconds and turns

off?

Ignition ON.Does ECU haveboth ignition and

ground?

Repair OpenCircuit

YES

NO

Replace ECUand perform

“Self-learning”

Crank engine for 5seconds and observeLP lock-off voltage.

Does voltage remainconstant for the 5second crank?

YES

NO Check ignitionsystem. Do sparkplugs fire while

cranking?

NO

Disconnect 4-pinconnector fromDistributor. Dospark plugs firewhile cranking?

With key on,does ignition

coil havepower?

NO

Repair opencircuit

Consult EngineElectricalSection

Repair incorrectwiring

YES

Repair open circuit indistributor

“reference” wiring toECU

Using an injectorNOID light. Doeslight flash during

cranking?

YES

NOVerify injectorwires havecontinuity

between ECUand injector

Repairwiring/looseconnection

Replace ECU

OKYES

CONTINUED ON NEXT PAGE

REV A

Engine Won’t Start - LPGDiagnostic Procedures - Continued


Plugs?


YES

197

Engine Controls

CHECKS OK

OPENCIRCUIT

Install fuel pressuregauge at Throttle Body

fuel inlet. Fuelpressure OK when key

is turned on?

NOREFER TO FUEL

PUMP DIAGNOSIS

YES

Restrict fuel return line and turn ignition onmomentarily to “charge” fuel pressure.Disconnect fuel pump power and crankengine. Observe fuel pressure gauge.

Does fuel pressuredrop rapidly while

cranking?

YES

Systemoperatingproperly

NOReplace defective

injector

CAUTION: Extremecare should be takenwhen disconnectingfuel lines. Lines maybe under pressure.Gasoline is highlyflammable an shouldnot be exposed toignition sources orareas of high heat.

Replace faultyinjector

REV A

Engine Won’t Start - LPG (Continued)


Using a digital multimeter,measure injector coil

resistance.Resistance (1.2 - 1.6 ohms)

Turn ignition on momentarily to “charge”fuel pressure. Disconnect LP lock-offpower and crank engine. Observe fuelpressure gauge.

SEE LPREGULATORDIAGNOSIS

198

Engine Controls

Engine Won’t Start — Dual Fuel

Check fuelselector switch

position

Check fuelin both tanks

Starts inalternate

fuel?

Go to gasolineno start

diagnostic

Go to LPGno start

diagnostic

Momentary 12vat lock-off

or gas pumpwhen key is on

Momentary 12vfrom ECU

when key isturned on?

Repair 12vsource to

ECU

12v toECU?

Groundcontinuity?

Repairground wire

ReplaceECU

N O

Y E S

Y E S

N ON O

N O

NEITHER FUELS TA RT S

Y E S

NO GAS

LPG YES

NO LPG

GAS YES

Go to no startdiagnostic

YES

Go to no startdiagnostic

YES


Y E S


Plugs?


YES

199

Engine Controls

Engine Runs, Low Power, Lean or Misfires — Gasoline


Check restrictions:Air FilterExhaust

Check vacuum leaks:Intake manifoldThrottle body

Throttle adapterPCV valve

Systemvoltage

13.5/14.7v?

Repaircharging system

Tune engine

Fuel pressure9-11 psi?

Replace fuel pressureregulator

Replace fuel pump and/or filter

Map sensorok?

Replace map sensor

Set ignition timingSEE engine service manual Ignition

timing ok?

Replace module orECU DIS ignitionmodule in ECU

Ignitionmodule ok?

Repair wiringor CKP sensor

Tach. signalinput to ECU?

STAR

T HE

RE

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO 16 psi restrictedfuel line

NO

YES

NO

NO

NO

NO

200

Engine Controls

G r o u n dcont inu i tyto frame?

Repair orreplace lock-off

Repair wireto lock-off

Momentary 12vfrom ECU when

key is turned on?

Repair 12v sourceto ECU

12v toE C U ?

R e p l a c eE C U

R e p a i rground wire

G r o u n dcont inu i ty?

Momentary 12vat lock-off when

key is turned on?

Y E S

Y E S

Y E S

Y E S

Y E S

N O

N O

N O

N O


LPG Lock-Off Diagnosis

201

Engine Controls

Engine Runs Rich — Gasoline

Check MAPsensor with

alternate sensor

Check coolant andair temperature

sensor connection

Repa i r / r ep lacefuel return line

Ign. timingre ta rded?

Ad jus tpress. reg.

9-11 psi

Adjust timing orrepair harness/

module. Refer toSection 3, Engine

Electr ica l .

Runs okayReplace fuel

p r e s s u r eregu la to r

Rest r ic t ionin fuel return

l i n e ?

Fuel press.greater than

11 psi?

Check for leakyin jec to r

Check air/coolants e n s o r s

res is tanceas per chart

Check MAPs e n s o r

connec t i ons

O KO K

O K

O K

O K

Y E S

Y E S

Y E S

N O

N O N O

N O

STAR

T HE

RE


202

Engine Controls

Engine Runs, Low Power, Lean or Misfires — LPG

F u e ll e v e l ?

R e g u l a t o rf r eeze -up?

START HERE

S e c o n d a r yRegulator Pressure

See Page 4-22

Pr ima ryRegulator Pressure

See Page 4-22

E n g i n ecoolant level

and circulation?

Orientate tank forliquid withdrawal.

Change tanks.

Se rv i cevalve on liquid

withdrawal sideof tank?

F u e lp r e s s u r e

o k ?Check restrictionfilter or lock-off.

Adjust pressure or replaceregula tor.

R e p l a c einjector.

System voltage13.5 - 14.7 V?

Replace or fill tank.

con t inued

Check vacuum leaks:Intake manifoldThrottle adapter

Throttle bodyPCV valve

Tank oriented incorrect position?

Repair charging system.

Y E S

Y E S

Y E S Y E S

Y E S

Y E S

Y E S

Y E S

Y E S

O K

N O

N O

N O

N O

N O

N O

N O


203

Engine Controls

Engine Runs, Low power, Lean or Misfires — LPG (Continued)

M a ps e n s o ro k a y ?

Ign i t ionM o d u l eo k a y ?

Ign i t iont im ingo k a y ?

Tune engine.

Tach.signal input

to ECU?

Check restrictions:E x h a u s tAir Filter

Replace map sensor.

Set ignition timing.Refer to Section 3 Engine

Electr ica l .

Replace module or ECUDIS ignition

module in ECU

R e p a i rwiring or

CKP sensor.

N O

N O

N O

N O

O K

O K

Y E S

Y E S

Y E S

Y E S

C h e c kValve clearances.


204

Engine Controls

Engine Runs Rich — LPG

L e a k yin jec to r?

Fuel press.primary reg.

See Page 4-22

Ad jus tsecondary reg.See Page 4-22

Ign i t iont im ing

o k ?

Runs ok.

Replace fuelin jectors.

Ad jus t / rep laceprimary regulator

Ad jus t / rep lacesecondary regulator.

C h e c kMAP sensorconnec t i ons

C h e c kMAP sensor

with alternate sensor

Check coolant andair temperature

sensor connection

Check air/coolantsensors resistance

as per chart.

Adjust timing or repairh a r n e s s / m o d u l e

Refer to Section 3,Engine Electrical

STAR

T HE

RE

O K O K

O K

O KY E S

Y E S

Y E S

Y E S

N O

N O

N O

N O


205

206

Operation and Maintenance

Manual

PSI’s 4.3L OPU

Industrial Gasoline and

Alternate Fueled Engines

1.6L, 3.0L, 4.3L, 5.7L, 7.4L and 8.1L Engines

A GM Powertrain Product by Power Solutions, Inc.

Wood Dale, IL 60191 36100007/REV030101

207

Table of Contents

Page Introduction 1

How to Use This Manual 1 Engine Identification 2 Parts and Service 2 Service Literature 2

Operating Instructions 3

Controls 3 Ignition Switch 3 Safety Gauges 3 Fuel Systems 3 Governors 4

Instruments 4 Oil Pressure Gauge 4 Temperature Gauge 4 Voltmeter 5 Tachometer/Hourmeter 5 Starting the Engine 5 Carbureted, Mechanical Governor, Manual Choke 5 Carbureted, Electric Choke, Electronic Governor 6 LPG or NG Fuel Systems, Velocity Governors 6 PSI, Inc. Fuel Injection (Gasoline) Integral Governor 6 PSI, Inc. Fuel Injection (Dual Fuel) Integral Governor 6 Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor 6 Stopping the Engine 7 Normal Conditions 7 Abnormal Conditions (Carbureted) 7 Abnormal Conditions (Fuel Injected) 7 Fuel Recommendations 7 Fuel Quality 7 Anti-Knock Index (Octane Rating) 8 Gasohol and Alcohol/Gasoline Fuels 8 Spark Plugs 8 Power Loss at Higher Elevations 9 Carbureted Engines 9 Fuel Injected Engines 9

Maintenance Instructions 10

Initial Start Up Maintenance 10 Routine Maintenance 10

208

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

209

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

210

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

Power Solutions, Inc. 655 Wheat Lane

Wood Dale, IL 60191 1

211

Engine Identification An identification label is affixed to the right side of the engine on the rocker cover when looking at the engine from the flywheel end.. (The engine serial number is also stamped into the left side of the cylinder block near the engine flywheel.) The label contains the engine model number (i.e. 4.3L, 5.7L, etc.) and a serial number which identifies the engine from other GM Powertrain engines provided by Power Solutions, Inc. The engine model and serial number are required when seeking information concerning the engine and/or ordering replacement service parts.

Insert Picture of the Label

Parts and Service Replacement parts can be obtained from Power Solutions, Inc. by calling the Service Parts Department at 800-551-2938. The engine model and serial number will be required when seeking information and/or ordering parts. Service and technical support for GM Powertrain engines supplied by Power Solutions, Inc. can be obtained by contacting the Service Department at 800-551-2938. Service Literature Additional operator manuals and service manuals for specific GM Powertrain engines provided by Power Solutions, Inc. can be obtained by contacting the Parts or Service Department at 800-551-2938

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

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Governors As with fuel systems, several different governor controls have also been used with the Power Solutions, Inc. GM Powertrain engines. A chart identifying the different types of governor systems used is included at the back of this manual. NOTE: Some governors are installed by the original equipment manufacturer. If your governor is not included in the chart, it will be necessary to contact the equipment manufacturer. Instruments

Insert Photo of the Instrument Panel

Oil Pressure Gauge The oil pressure gauge show the engine lubrication system pressure in pounds per square inch (psi) and should be checked frequently to ensure that the system is functioning correctly. Should the pressure fluctuate or drop, stop the engine and find the cause. Do not operate the engine at lower than normal oil pressure (see maintenance schedule for minimum engine oil pressure). CAUTION: Do not continue to operate your engine below the normal operating range. Severe engine damage could occur. Temperature Gauge The temperature gauge registers the coolant temperature and will indicate overheating which may arise from low coolant level, plugged radiator, loose fan belt or faulty thermostat. Coolant level should be checked daily. CAUTION: If the engine continues to overheat, have the cooling system checked and serviced.

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Instruments (cont.) Voltmeter The voltmeter indicates the battery charging voltage. If the meter consistently indicates less than 13 volts or more than 15.7 volts under normal operating conditions, you should have the engine electrical system checked by a qualified service technician. Tachometer/Hourmeter The tachometer indicates the engine speed in hundreds of revolutions per minute (rpm). It serves, as a guide to insure that engine speed is set correctly. The hourmeter records the hours of operation and is used to determine when periodic maintenance is required. Starting the Engine Warning: All internal combustion engines give off various fumes and gases while running. Do no start or run the engine in a closed or poorly ventilated building where exhaust gases can accumulate. Avoid breathing these gases as they may contain poisonous carbon monoxide, which can endanger your health or life if inhaled steadily for even a few minutes. If the engine is equipped with a manual clutch it must be disengaged prior to starting the engine. Starting the engine with the clutch engaged imposes unnecessary strain on the battery, starter, and driven components. CAUTION: If the engine stalls or falters during starting, wait 3 to 4 seconds before re-engaging the starter. This will prevent possible damage to the starter or the engine. DO NOT operate the starter for periods longer than 30 seconds at a time. An interval of at least 1-minute should be observed between cranking periods to protect the starter from overheating. Carbureted, Mechanical Governor, Manual Choke Pull the throttle cable out approximately ½ inch, and the choke out full. Turn the ignition key to the START position. After the engine starts, release the key, decrease the throttle setting and adjust the choke cable for fast idle warm-up. When the engine is at operating temperature, push the choke in all the way. When the engine is warm, it may not be necessary to use the choke for starting.

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Carbureted, Electric Choke, Electronic Governor Turn the On/Off switch on the instrument panel to the ON position. Turn the ignition key to the ON position. This allows the electric choke to pre-set prior to starting. Turn the ignition key to the START position. After the engine starts release the key to the ON position. Allow a few minutes for the engine to warm up. Move the governor control switch to the LOW position. Engage the clutch, then move the governor control switch to the HI position. LPG or NG Fuel Systems, Velocity Governors Turn on the gas supply to the engine. Turn the ignition key to the START position. After the engine starts release the key to the ON position. PSI Fuel Injection (Gasoline) Turn the ignition key to the ON position, this energizes the electric fuel pump to charge the fuel system with fuel. Turn the ignition key to the START position. After the engine starts release the key to the ON position. PSI Fuel Injection (Gasoline/LPG)(Dual Fuel) Select the desired fuel switch position for starting the engine (Gasoline/LPG). Turn the ignition key switch ON, then move ignition key to the START position. After the engine starts release the key to the ON position. Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor Turn the ignition key to the ON position to energize the fuel pump. Ensure that the Hi/Lo switch on the instrument is in the Lo position. Turn the ignition key to the START position. After the engine starts release the key to the ON position. Allowing a few minutes for engine warm-up, move the Hi/Lo switch to the Hi position.

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Stopping the Engine Normal Conditions: Following normal operating conditions, lower the engine speed to idle, pushing the throttle cable in on mechanical systems or with electronic systems placing the Hi/Lo switch in the Lo position. If the machine is equipped with a clutch, move the clutch lever to the disengaged position. Run engine for a few minutes at idle to allow the coolant system to cool down before turning the ignition switch to the OFF position. Abnormal Conditions (Carbureted): Under abnormally overheated conditions, the engine may continue to run after the switch is turned OFF. If this is encountered, turn the ignition switch to the ON position immediately and allow the engine to run at idle until it has cooled down enough to stop. (Fuel Injected) Fuel injected engines generally will not after run, even if hot. These systems require that the fuel delivery be shut off completely when turning the ignition switch to the OFF position. WARNING: Avoid injury when checking a Hot Engine. Allow the engine to cool down before removing the radiator cap. CAUTION: Before restarting the engine ensure that both the coolant system and the engine oil level have been checked and re-filled if necessary. Fuel Recommendations Fuel Quality Using a high quality unleaded gasoline will help maintain the power, fuel economy and emissions performance of your engine. A properly formulated gasoline will be comprised of well refined hydrocarbons and chemical additives and will perform the following functions: Minimize varnish, lacquer, and other induction system deposits. Prevent gum formation or other deterioration during storage. Protect fuel tank and other fuel system components from corrosion or degradation.

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Fuel Recommendations (cont.) Provide the correct seasonally and geographically adjusted volatility which

should provide easy starting in the winter and summer. Avoid fuel system icing. In addition, the fuel must be free of water, debris, and other impurities. It is recommended that the fuel supply be kept fresh when the engine is in storage (especially in hot weather). The fuel tank should be kept at least ¾ full. Fuel stored for more than two months should be drained, properly discarded, and the fuel tank re-filled. Anti-Knock Index (Octane Rating) This engine is designed to operate on unleaded 87 or 89 octane gasoline with an (R + M)/2”minimum anti-knock index. Federal regulations require that each retail gasoline dispensing pump must display a label bearing the minimum index rating. Use of unleaded gasoline with anti-knock index rating lower than 87 can cause persistent, heavy spark knock, which can lead to engine damage. If your engine knocks heavily when you use gasoline with an anti-knock index rating of 87 or higher, or if you hear continuous spark knock while maintaining constant operating speeds, consult a dealer or qualified technician. Gasohol and Alcohol/Gasoline Fuels Gasohol, a mixture of gasoline and ethanol (grain alcohol), is available in some areas. PSI, GM Powertrain engines should operate satisfactorily on gasohol blends containing no more than 10% ethanol by volume and having and anti-knock index of 87 or 89. CAUTION: In some cases, methanol (wood alcohol) or other alcohol’s may be added to gasoline. PSI GM Powertrain engines should operate satisfactorily on blends containing up to 5% methanol by volume when cosolvents and other necessary additives are used. DO NOT USE blends containing more than 5% methanol by volume or blends that do not contain cosolvents and corrosion inhibitors. CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if fuel system problems occur. Do not use such fuels unless they are UNLEADED. Spark plugs Always use the recommended spark plugs for your engine. Hotter or colder plugs, or similar plugs that are not exact equivalents to the recommended plugs, can cause permanent engine damage, reduce the engines useful life, and cause many other problems such as hard starting, spark knock and run-on. Installing new spark plugs regularly is one of the best ways to keep your engine at peak performance.

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Power Loss at Higher Elevations All engines will experience power loss when operated at elevations above sea level, unless they are turbocharged or supercharged. Turbochargers and superchargers are mechanical pumps that put extra air into the engine to make up for the lower air density at higher elevations. Carbureted Engines Carbureted engines will loose power for two reasons. First, power is reduced 3.5% for each 1000 feet it is operated above sea level due to the decreased air density. With less dense air, the engine receives less oxygen to burn the fuel. The engine power is decreased in direct proportion to the reduction of available oxygen. Second, the reduced oxygen causes the fuel mixture to have too much fuel for the available oxygen. This is a rich mixture (rich with fuel) and not only causes the engine to produce sooty black exhaust, but causes additional loss of power and premature spark plug fouling. Engines that are operated over 3000 feet of elevation, that exhibit black smoke or produce less than optimum power should have the fuel system re-calibrated. For additional information on optimizing your engine for higher elevations contact your dealer or Power Solutions, Inc. at 800-551-2938. Caution: Engines re-calibrated for high elevations will run lean at lower elevations. Lean running can burn valves, will reduce valve and valve seat life and can cause engine overheating. Failures caused by these problems are not covered by warranty. Fuel Injected Engines Fuel injected engines will loose 3.5% power for every 1000 feet the engine is operated above sea level. All fuel injection systems installed by Power Solutions, Inc. are equipped with a “manifold absolute pressure sensor” (MAP Sensor). The MAP sensor senses barometric pressure and automatically corrects the fuel system calibration for changes in altitude. This means the air/fuel mixture will always be optimized, regardless of elevation (or barometric pressure), however, the engine will still loose 3.5% power for every 1000 feet increase in elevation.

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MAINTENANCE INSTRUCTIONS Initial Start Up Maintenance The initial start-up checks must be made before putting the engine into service. Please refer to the Maintenance Schedule on page II and perform the initial start-up operations in the sequence shown in column 1. Routine Maintenance Routine maintenance provides the best solution for making sure that the engine is ready when you are. The following are some routine service points: Keep the fuel tank filled. A full tank of fuel reduces the possibility of condensation forming in the fuel tank and moisture entering the fuel system Make frequent checks of the engine oil and coolant levels Repair any oil or coolant leaks immediately Check battery condition and cables frequently Keep the engine air filter clean Monitor engine coolant temperature Monitor engine oil pressure Check voltmeter and charging system Scheduled Preventive Maintenance Refer to the Maintenance Schedule on page II to ensure that all of the maintenance items listed are checked and replaced as recommended at the hours shown. Engine Oil Level Check The engine oil level should be checked daily. It is recommended that the oil be checked just before the engine is started for the first time for that day. The oil level should be between the ‘Add’ and the ‘Full’ marks on the dipstick. CAUTION: Do not operate the engine with the oil level below the bottom or ‘Add’ mark on the dipstick, or above the top or ‘Full’ mark on the dipstick. Adding Engine Oil It is normal to add some oil in the period of time between oil changes. The amount will vary with the severity of operation. When adding or replacing engine oil, be sure the oil meets or exceeds the recommended specification.

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Changing Engine Oil and Filter The engine oil and filter must be changed every 200 hours or every 3 months whichever occurs first. Under normal operating conditions, you do not need to change them more often if you use oil and filters of the recommended quality. The oil and filter should be changed more often if the engine is operating in dusty or extremely dirty areas, or during cold weather. No oil additives or break-in oil change is required. Engine Oil Quality To achieve proper engine performance and durability, it is important that you use only engine lubricating oils of the correct quality in your engine. Proper quality oils also provide maximum efficiency for crankcase ventilation systems, which reduces pollution. Important: use only engine oils displaying the American Petroleum Institute (API) “Starburst” Certification Mark ‘FOR GASOLINE ENGINES’ on the container. Gasoline engines that are converted for LPG or NG fuels MUST use oils labeled ‘FOR GASOLINE ENGINES’. Do not use oils that are specifically formulated for Diesel Engines only. CC or CD classification oils, even when labeled Heavy Duty or for Natural Gas Engines, ARE NOT ACCEPTABLE. Engine Oil Recommendation Multi-viscosity oils are recommended. SAE 10W-30 is recommended for your engine from 0 degrees F (-18 degrees C) or above. If ambient temperatures are consistently below 0 degrees F, SAE 5W-30 oil can be used. Synthetic oils are not recommended for industrial or stationary engines. Oil Filter The PSI GM Powertrain engines use an AC Delco oil filter as original equipment. An equivalent oil filter must be used when servicing the engine (see Engine Specifications for the recommended oil filter for your engine). The filter protects your engine from harmful, abrasive, or sludgy particles without blocking the flow of oil to vital engine parts. To replace the filter, use a proper filter wrench to remove the filter. Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil. Hand tighten the filter until the gasket contacts the base, then tighten another ½ turn. Fill the engine with the correct amount of oil, run the engine and check for oil leaks at the drain plug and oil filter gasket. Tighten as necessary to stop any oil leakage noted.

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Engine Air Cleaner The engine air cleaner filters air entering the engine intake system and acts as a silencer and flame arrester when assembled to the intake system. Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe damage to the cylinder walls and piston rings. Damage to the cylinder walls and piston rings will cause high oil consumption and shorten engine life. A restricted or dirty air cleaner will also cause a rich fuel mixture. Thus, it is extremely important that the air cleaner be serviced properly at the recommended intervals. CAUTION: Service the air cleaner more frequently under severe dusty or dirty conditions. Remove the primary air cleaner element from the air cleaner assembly and inspect the element for foreign material restrictions or signs of excessive wear or damage. Replace the element if necessary. Remove all dust and foreign matter from the air cleaner housing. Reinstall the air cleaner element. Reinstall the air cleaner cup, and securely fasten the retaining clips. Safety Element If your engine is equipped with an air cleaner which utilizes a safety element, ensure that the element is properly in place before installing the primary element. Change the safety element annually. Cooling System Coolant Level Check the coolant level of the radiator daily and only when the engine is cool. Generally a good time to do this is just prior to starting the engine for the first time each day. Maintain the coolant level at ¾ to 1½ inches below the filler neck seat of the radiator when the coolant is cold. When ever coolant level checks are made inspect the condition of the radiator cap rubber seal. Make sure it is clean and free of any dirt particles which would keep it from seating on the filler neck seat. Rinse off with clean water if necessary. Also make sure that the filler neck seat is free of any dirt particles.

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WARNING Never remove the radiator cap under any conditions while the engine is operating. Failure to follow these instruction could result in damage to the cooling system, engine, or cause personal injury. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme caution when removing the radiator cap from a hot radiator. If possible, wait until the engine has cooled, then wrap a thick cloth around the radiator cap and turn slowly to the first stop. Step back while the pressure is released from the cooling system. When all the pressure has been released, press down on the cap and remove it slowly. DO NOT add coolant to any engine that has become overheated until the engine cools. Adding coolant to an extremely hot engine can result in a cracked block or cylinder head. Use only a permanent-type coolant when refilling or flushing the coolant system. Recommended ethylene glycol mix 52/48 is normal up to a maximum of 60% glycol, 40% water. Refer to the mixture chart on the container for additional antifreeze protection information. DO NOT use alcohol or methanol antifreeze, or mix them with the specified coolant. Plain water may be used in an emergency (except in freezing temperatures), but replace it with the specified coolant as quickly as possible to avoid damage to the system. Radiator Inspect the exterior of the radiator for obstructions. Remove all bugs, dirt or foreign material with a soft brush or cloth. Use care to avoid damaging the core fins. If available, use low pressure compressed air or a stream of water in the opposite direction of the normal air flow. Check all hoses and connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they must be replaced. Fan Belts The water pump is usually belt driven. The same belt may also drive the fan and/or the alternator. The drive belts should be properly adjusted at all times. A loose belt can cause improper alternator, fan and water pump operation, in addition to overheating.

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Serpentine Belt Some GM Powertrain engines utilize serpentine belts on the front of the engine. This type of belt system incorporates a belt tensioning device which keeps the belt at the proper tension. This belt should be checked routinely for cracks or ‘checking’ on the groove side of the belt. If cracks or ‘checking’ are apparent the belt must be changed. V-Type Belt V-Type belts are generally tensioned by adjusting the alternator, or through a mechanical belt tensioner. The belt is generally correctly tensioned when there is an ½ inch of depression on the belt between the water pump and the crankshaft pulley. Fuel Filter Carbureted Engines On carbureted engines, an in-line fuel filter is incorporated into the fuel supply line. It is recommended that this filter be changed every 250 hours or every 6 months which ever occurs first. TBI Engines On PSI Fuel Injection or Fuel Injection/Dual Fuel two fuel filters are used in the gasoline fuel supply line to the engine TBI unit. A coarse fuel filter is located in the supply line between the fuel tank and the electric fuel pump. This filter protects the fuel pump from debris in the fuel tank. This filter must be changed every 200 hours or every 6 months which ever occurs first. A primary fuel filter is located between the fuel pump and the TBI unit on the engine. This filter protects the injectors from microscopic particles in the fuel which can cause plugging of the injectors. This filter MUST be changed every 500 hours or annually which ever occurs first. Zenith Z.E.E.M.S. TBI Fuel Injection requires an in-line fuel filter in the fuel supply line from the fuel tank to the TBI unit, ahead of the electric fuel supply pump. This filter must be changed every 200 hours or every 6 months which ever occurs first. CAUTION: Failure to change the fuel system filters as recommended can result in premature failure of the TBI fuel system components. NOTE: Some original equipment manufacturers install their own fuel systems. Please refer to the manufacturers manual if the gasoline fuel system is different than described here.

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WARNING Use extreme care when changing the fuel filters on gasoline engines. Gasoline is highly flammable and should not be exposed to open flame, sparks, or hot engine components. Allow the engine to cool to ambient temperatures prior to changing fuel filters. Ignition Systems Types of Ignition Systems Three types of ignition systems are used on PSI GM Powertrain engines. Solid state electronic distributor, solid state electronic distributor with ECU (Electronic Control Unit) and distributor-less electronic ignition with ECU. Please refer to the General Specification chart to determine the ignition system used on your particular engine. Ignition Timing Proper adjustment of the ignition timing must be obtained to provide the optimum engine power output and economy. To properly adjust timing refer to the timing procedure section of this manual. Spark Plugs Spark plugs should be replaced at the recommended intervals described in the Maintenance Schedule. Use only the recommended spark plug or an equivalent as described in the General Specifications. Spark plug gap, should be adjusted as recommended in the General Specifications. When removing spark plugs, always note which cylinder each plug came out of. Look at the porcelain around the center electrode of each plug. You can detect many engine problems from the color and type of deposits that have built up on the white porcelain. For example, if the deposits are a glossy brown, that cylinder is burning excess oil. If the deposits are a very dark gray or sooty black color, your engine is running rich, and you are burning excess fuel. The optimum color of the deposits on the porcelain is light tan or light brown. This shows optimum fuel mixture and proper engine running conditions. If the deposits are almost white, the engine may be running excessively lean. Lean running is very detrimental to your engine life, and should be corrected immediately. If one or more cylinders are burning oil, the smoke from the engine will be a blue-gray color. Most common causes are piston rings (worn out or not broken in) and valve stem seals (cut, nicked, or worn out). If the engine is running rich the exhaust smoke will be a sooty black color and it will smell like gasoline (on gasoline engines).

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Storage One to Six Months If the engine or machine is to be placed in storage for a period of one to six months it is recommended that the following steps be followed: Add ‘Stabil’ or equivalent fuel conditioner to the fuel tank as recommended

on the bottle. Run the engine for approximately 10 to 15 minutes to insure that the treated fuel is completely through the fuel system.

Fill the fuel tank with fuel Protect the air cleaner inlet from water entry Protect the exhaust outlet or muffler outlet from water entry Check the coolant protection and top off radiator Store indoors if possible For Extended Periods Follow the above recommended procedures, plus do the following: Drain the engine crankcase and refill with recommended oil Change the oil filter Disconnect and remove the battery Clean exterior surface of the engine If the engine is equipped with an automotive type clutch or PTO clutch,

make sure that the clutch is disengaged Removing the Engine From Extended Storage When removing the engine from extended storage: Install a fully charged battery Remove all protective coverings from the air inlet, air cleaner, exhaust,

and muffler openings Check the coolant level in the radiator and verify the protection level

of the coolant 16

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Removing the Engine From Extended Storage (cont.) Start the engine and allow it to run at slow idle. Verify engine oil pressure Run the engine at idle until the coolant temperature approaches 120 degrees F

(49 degrees C) Run the engine a various speeds for approximately 15 minutes Shut the engine down, drain the oil, change the oil filter, and re-fill with

the recommended grade of oil

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GM Engine Timing Procedures Carbureted, LPG an NG 3.0L, 4.3L, 5.7L, 7.4L PSI/GM Engines PSI Timing Connector Part Number 33000036 MUST be used when checking and adjusting the engine timing.

1. With the engine shut-off, plug the 33000036 Timing Connector into the distributor. DO NOT connect the alligator clip to any positive or negative terminal. (Connecting this wire to any battery terminal prior to starting the engine will cause the distributor module to fail when starting the engine.)

2. Start the engine and run at slow idle. 800 to 1000 rpm. 3. Connect the alligator clip to a B+ terminal. (This connection cancels the programmed

timing advance from the distributor module. You will notice a change in engine sound and rpm when making this connection.)

4. Connect an electronic timing light to the No.1 spark plug wire. (The front cylinder on the 3.0L engine and the front cylinder on the left bank of the 4.3L, 5.7L and 7.4L engines.)

5. Check and adjust the distributor as necessary viewing the timing mark on the crankshaft pulley in relation to the pointer on the engine timing case. (On some engines there may be a timing port in the flywheel housing also.)

6. Refer to the General Specifications chart in this manual, for the initial timing specification for your engine and type of fuel being used.

PSI Fuel Injected and Dual Fuel engines For engines equipped with this type of fuel system, the engine timing is controlled by the ECM (Engine Control Module). Checking the initial timing on engines equipped with PSI fuel injected and dual fuel engines incorporating and ECM can only be accomplished when using a laptop computer or a hand

held diagnostic meter. It will be necessary to contact the OEM or PSI for the necessary equipment and instructions for checking and adjusting the engine timing. (CAUTION:

Failure to follow the correct specified procedures when checking and adjusting the engine timing, can cause severe damage to the engine.)

Zenith Z.E.E.M.S. Throttle Body Fuel Injected Engines

Engine timing for Zenith TBI fuel injected engines is checked and adjusted following the

procedures noted under Carbureted engines. Check the General Specifications chart for the correct engine timing.

Generator Timing

PSI/GM engines operating on generators are timed at 1800 RPM. Timing procedures are

the same as for Carbureted engines. Check the General Specifications chart for the correct engine timing for the type of fuel being used.

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Maintenance Schedule Power Solutions, Inc.

GM Powertrain

1.6L, 3.0L, 4.3L, 5.7L, 7.4L, and 8.1L Engines

Initial Start-Up Sequence Checks

Operation

Daily

Weekly

Every

50 hrs

Every 100 hrs

Every 200 hrs

Every 400 hrs

Every 800 hrs

As

Req.

1 Check Engine Oil Level x 2 Check Coolant Level x 3 Check for Fluid Leaks x 4 Governor, Mechanical (Check oil level)(2) x Change Engine Oil & Filter (1) x

5 Battery, Check Charge & Fluid Level x Inspect & Clean Radiator Exterior x Clean Battery Cables x

6 Check Belts and Belt Tension x Lubricate Throttle, Governor & Choke

Linkage (Carbureted Engines Only) x

Check & Adjust Idle Speed (Carbureted Engines Only)

x

Inspect and Clean Air Cleaner Element x Replace Primary Air Cleaner Element (1) x Replace Safety Air Cleaner Element x Check Coolant Protection & Tighten Hose

Clamps x

Replace Engine Coolant (3) x Replace Gasoline Fuel Filter (4) x Replace LPG Filter – Zenith EFI (4) x Replace PCV Valve (If Equipped) x Check PCV Hoses, Tubes, and Fittings x Replace Spark Plugs (3) x Distributor Cap & Rotor (5) x Secondary Ignition Wires x Adjust Throttle & Governor (3) x

7 Check All Engine Bolts & Nuts for Tightness

x

(1) More frequent intervals may be required in dusty or dirty operating conditions. (2) Mechanical governor (belt driven). (3) To be performed at specified interval or annually, whichever occurs first. (4) More frequent intervals may be required with dirt in the fuel system. (5) Does not apply to engines with DIS ignition.

Capacities Engine 1.6L 3.0L 4.3L 5.7L 7.4L 8.1L

Oil Capacity Without Filter 3.4 qts. 4 qts. 4.5 qts. 5 qts. 8 qts. 8 qts. Oil Capacity With Filter 3.7 qts. 4.5 qts. 5 qts. 5.5 qts. 9 qts. 9 qts. Coolant Capacity Without Radiator 3.5 qts. 4 qts. 7.75 qts. 8.1 qts. 14.5 qts. 14.5 qts. Coolant Capacity With Radiator 10 qts. 12 qts. 17 qts. 17.5 qts. 28 qts.

31 qt (Turbo) 28.5 qts.

Revised 12/27/01

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4.5

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5 qt

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8 qt

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9

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Min

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18

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6

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18

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18

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7.75

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. (7.

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7.8L

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17

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tion

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ing

(Deg

rees

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DC

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ener

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s 180

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PM

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26

36

26

36

26

36

26

36

26

30

Spar

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ugs

AC

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3206

675

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A

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all

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35

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to 1

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evis

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3.

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ark

Plug

Wire

Rou

ting

233

234

Fasteners and Torque Control (10---90)

Torque Standard

Inch Fasteners

(5)-- (6.5)

ThreadSize

SAEGrade 1

SAEGrade 2CarriageBolts

ThreadCuttingThreadRolling

SAEGrade 5Socketand

StainlessSteel

SAEGrade 8

HeadlessSocketSet

Screws

SquareHead SetScrews

4 (.112) (4)-- (6)

5 (.125) (6)-- (8) (9)-- (11)

6 (.138) (7)-- (9) (20)-- (24) (9)-- (11)

8 (.164) (12)-- (16) (40)-- (47) (17)-- (23)

10 (.190) (20)-- (26) (50)-- (60) (31)-- (41)

1/4 (.250) 4--5 5--6 7--10 7--10 10--13 6--8 17--19

5/16 (.312) 7--9 9--12 15--20 15--20 20--26 13--15 32--38

3/8 (.375) 13--17 16--21 27--35 36--47 22--26 65--75

7/16 (.438) 20--26 26--34 43--56 53--76 33--39 106--124

1/2 (.500) 27--35 39--51 65--85 89--116 48--56 162--188

5/8 (.625) 80--104 130--170 171--265 228--383

3/4 (.750) 129--168 215--280 313--407 592--688

1 (1.000) 258--335 500--650 757--984 1281--1489

INCHPONUDS

FOOTPOUNDS

Torque Foot Pounds (Inch Pounds) Zinc Plated

235


Torque Standard

Inch Fasteners

FastenerIdentification Type Material

NominalSize

Proof Load(PSI)

TensileStrengthMin (PSI)

YieldStrengthMin (PSI)

Mechanical Properties

SAEGrade 1MachineScrews

Low orMediumCarbonSteel

#2 Thru#10

1/4 Thru1 1/2 33,000 36,000

55,000

60,000

SAEGrade 2CarriageBolts


1/4 Thru3/4

Over 3/4Thru 1 1/2

55,000

33,000

57,000 74,000

36,000 60,000

StainlessSteel

18--8AusteniticStainlessSteel

50,000 90,000

SAEGrade 5

MediumCarbonSteel

QuenchedTempered

1/4 Thru 1

Over 1 to1 1/2

85,000

74,000

92,000

81,000

120,000

105,000

SocketScrews

High CarbonAlloy SteelQuenchedTempered

136,000 160,000

SAEGrade 8

MediumCarbon Al-

loyQuenchedTempered

1/4 Thru1 1/2 120,000 130,000 150,000

236


Torque Standard

METRIC Fasteners

747--970 Ncm

18.3--23.7 Nm

ThreadSize 4.8/5.6

8.8StainlessSteel 10.9 12.9

SetScrews

M3 43--56 Ncm 99--128 Ncm 139--180 Ncm 166--215 Ncm 61--79 Ncm

M4 99--128 Ncm 223--290 Ncm 316--410 Ncm 381--495 Ncm 219--285 Ncm

M5 193--250 Ncm 443--575 Ncm 624--810 Ncm 427--554 Ncm

M6 3.3--4.3 Nm 7.6--9.9 Nm 10.8--14 Nm 12.7--16.5 Nm 7.5--9.8 Nm

M8 8.1--10.5 Nm 18.5--24 Nm 26.2--34 Nm 31--40 Nm

M10 16--21 Nm 37--48 Nm 52--67 Nm 63--81 Nm

M12 28--36 Nm 64--83 Nm 90--117 Nm 108--140 Nm

M14 45--58 Nm 102--132 Nm 142--185 Nm 169--220 Nm

M16 68--88 Nm 154--200 Nm 219--285 Nm 262--340 Nm

M20 132--171 Nm 300--390 Nm 424--550 Nm 508--660 Nm

NEWTON

CENTIMETERS

NEWTONMETERS

M22 177--230 Nm 409--530 Nm 574--745 Nm 686--890 Nm

M24 227--295 Nm 520--675 Nm 732--950 Nm 879--1140 Nm

Zinc Plated

Conversion Tables

Ncm to Inch Pound x 0.08851 Inch Pound to Ncm x 11.2982Nm to Foot Pound x 0.7376 Foot Pound to Nm x 1.3558

237


Torque Standard

METRIC Fasteners

FastenerIdentification

Type

MaterialNominalSize

Yield Stress(Min) MPa

Yield Point.2% Elongati(Min) MPa

TensileStrength(Min) MPa

Mechanical Properties

3.6/4.6CarriageBolts


4.8 PanHead

MachineScrews


A2--70

StainlessSteel

AusteniticStainlessSteel

8.8 HexHead

(Grade 5)

MediumCarbonSteel

QuenchedTempered

10.9Hex HeadFlat Head(Grade 8)

12.9Socket Head

Class

190(27,550 PSI)

240(34,800 PSI)

330(47,850 PSI)

400(58,000 PSI)

340(49,300 PSI)

420(60,900 PSI)

450(65,300 PSI)

700(101,000 PSI)

< M16

> M16

640(92,800 PSI)

800(116,000 PSI)

660(95,700 PSI)

830(120,350 PSI)

MediumCarbonSteel

QuenchedTempered

940(136,300 PSI)

1040(150,800 PSI)

AlloySteel

A2---70

8.8

A

10.9

12.9

1100(159,500 PSI)

1220(176,900 PSI)

Conversion Table

Mega Pascals to Pounds per Square Inch x 145.138

238


Size Grade 2 Bolt Grade 5 Bolt

1/4---20 5---8 7---8

1/4---28 4---6 5---6

5/16---18 8---14 13---14

5/16---24 9---14 13---14

3/8---16 12---18 15---18

3/8---24 12---18 16---18

1/2---13 26---40 37---40

1/2---20 27---42 41---42

5/8---11 58---89 73---89

5/8---18 60---92 82---92

Torque Standard

Nylon Insert Lock Nuts

Nut-Hex Light THIN

(Cad or Zinc Plated)

Torque in Foot Pounds

239


Stud or Bolt Sizeand Thread

Recommended Torque inFoot Pounds

7/16---20 75---85

1/2---20 75---85

9/16---18 80---90

5/8---18 140---170

Torque Standard

Wheel Bolt and Nuts

Wheel Bearing Adjustment

1. Tighten the spindle nut to 12 ft lbs while turning the wheel assembly forward by hand tofully seat the bearings.

2. Back off the nut to the “just loose” position.

3. Hand tighten the spindle nut. Loosen the spindle nut until either hole in the spindle linesup with a slot in the nut. (Not more than 1/2 flat.)

4. Install the cotter pin. Bend the ends of the cotter pin against the nut, cut off extra lengthto ensure ends will not interfere with the dust cap.

240


Tightening Nuts on Tapered Shafts

.37301”--20 UNEF--2B SLOTTEDHEX LOCKNUT PER SAEJ--501 (EXCEPT 1.50/38,1ACROSS FLATS).RECOMMENDED TOQUE TO175 FT LB PLUS TORQUEREQUIRED TO ALIGNSLOTTED NUT TO SHAFTHOLE

2.27/57,7CLEARANCE

DIA. PSHAFTDIA.

1.500 + .002 TAPER PERFOOT/125 + 0,17 MM TAPERPER METER

.750 + .01019,05 + 0,25

1.89048,01

+.0010-- .00000 /9,474

+0,025--0

3.0076,2

KEY WIDTH

.1563,96 DIA. THRU

Example ofrecommendedtorque.

Check with the manufacturer to see what the recommended maximum torque is.Tighten the slotted nut to a lower torque, and then tighten the nut to align the cotter pinhole with the slot on the nut. Do not exceed the recommended torque. Do not back offthe nut to align the holes.Motor Tapered Shaft Nut Info. Torque Specification Recommendations

A&H Series 1.00 dia. .75--16 UNF 150 ft lb dry1.107 Hex 125 ft lb lubricated

Plus torque to align for pin

2000 Series 1.25 dia. 1--20 UNEF 225 ft lb dry1.44 Hex 225 ft lb lubricated

PLUS torque to align for pin

4000 Series 1.625 dia. 1.25--18 UNEF 475 ft lb dry2.187 Hex 375 ft lb lubricated


6000 Series 1.75 dia. 1.25--18 UNEF 475 ft lb dry2.187 Hex 375 ft lb lubricated


241


Nominal Diameter

Torque Standard

Shoulder Bolts

Thread Size Recommended SeatingTorque

.250 10--24

.312

45 In Lbs

1/4--20 9 Ft Lbs

.375 5/16--18 19 Ft lbs

.500 3/8--16 32 Ft Lbs

.625 1/2--13 82 Ft Lbs

.750 5/8--11 164 Ft Lbs

Nominal Diameter Thread Size Recommended SeatingTorque

6

8

7 Nm

M6x1.0 12 Nm

10 M8x1.25 29 Nm

12 M10x1.5 57 Nm

16 M12x1.75 100 Nm

M5x0.8

Metric

242


Taper Lockr BushingsIMPORTANT: Follow all these instructions carefully. This is necessary to insuresatisfactory performance.

C C

1008 to 3030

To Install1. Clean shaft, bore and outside of bushing, and hub bore of all oil, lacquer, and dirt.

2. Insert bushing in hub. Match the hole pattern, not threaded holes (each hole will bethreaded on one side only).

3. Oil setscrews and thread into those half threaded holes indicated by C on abovediagram.

4. Alternately torque setscrews to recommended torque setting in chart below.

5. Using a block, sleeve, or drift, hammer large end of bushing (do not hammer bushingdirectly).

6. Repeat steps 4 and 5 until torque wrench reading after hammering is the same asbefore hammering.

7. Fill all unoccupied holes with grease.

To Remove1. Remove all setscrews.

2. Insert setscrews in holes indicated byD on the diagram. Loosenbushing by alternatelytightening setscrews.

3. To reinstall, complete all seven (7) steps installation steps.Recommended Wrench Torque

Bushing No. ScrewsWrench Torque(Pound-Inch)

HammerSize

1008, 11081210, 1215, 1310

1610, 1615

1/4” Setscrews3/8” Setscrews3/8” Setscrews

55175175

6 lb6 lb6 lb

20122517, 25253020, 3030

7/16” Setscrews1/2” Setscrews5/8” Setscrews

280430800

6 lb6 lb6 lb

If two bushings are used on same component and shaft, fully tighten one bushing beforeworking on the other.

243


Sequence Tightening

On some assemblies, it is advisable to use a crisscross pattern. Always avoid starting inone spot and tightening one after another in a row. Remember that the object is to tightenthe parts in such amanner that even stress is set up throughout, at the same time allowingthe parts to be drawn together so that their mating surfaces will contact.

5 1 3

4 2 6

1 2

53

6 4

1 23 45 6

Torque in Steps

1. Run each fastener, in proper sequence, up to the recommended torque.

2. Repeat the process of running up each fastener, in proper sequence, up to therecommended torque.

3. If necessary, repeat step two until all the fasteners are tightened to the recommendedtorque.

244

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