Nilfisk-Advance Condor XL User manual

Advance Condor™;/1LO¿VN(5DOOPRGHOV

11/11 Form No. 56043157

English

Service Manual

Advance Condor XL, Condor XL AXP™ and Condor XL EcoFlex™ Models:

 /3*´

 3HWURO´

 'LHVHO´

 /3*´

 3HWURO´

 'LHVHO´

 /3*´

 3HWURO´

 'LHVHO´

 /3*´

 3HWURO´

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 /3*$;3´

 3HWURO$;3´

 'LHVHO$;3´

 /3*$;3´

 3HWURO$;3´

 'LHVHO$;3´

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 3HWURO$;3´

 'LHVHO$;3´

 /3*$;3´

 3HWURO$;3´

 'LHVHO$;3´

 /3*;

 3HWURO;

 'LHVHO;

 /3*;

 3HWURO;

 'LHVHO;

 /3*;

 3HWURO;

 'LHVHO;

 /3*;

 3HWURO;

 'LHVHO;

1LO¿VN(5DQG(50RGHOV

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 'LHVHO

 /3*

 3HWURO

 'LHVHO

ii6HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

&RQWHQWV

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Service Manual Purpose and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Other Reference Manuals and Information Sources . . . . . . . . . . . . . . . . . . . . . 5

Diagnostic and Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Parts and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cautions and Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Jacking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Towing or Pushing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7HFKQLFDO6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Liquid Crystal Display (LCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Major Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Control Board (Driver Box) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Control Board (Driver Box) Programming Options . . . . . . . . . . . . . . . . . . . . . . 43

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Wiring Diagram - GM Engine, Drawing #56111804-D . . . . . . . . . . . . . . . . . . . . 79

Wiring Diagram - Kubota Diesel, Drawing #56111804-D . . . . . . . . . . . . . . . . . . 80

Wiring Schematic - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Wiring Schematic - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Engine Harness for Tier II GM 1.6L Gas (Petrol) . . . . . . . . . . . . . . . . . . . . . . 83

Engine Harness for Tier II GM 1.6L LPG. . . . . . . . . . . . . . . . . . . . . . . . . . .84

Engine Harness for Tier III GM 1.6L Gas (Petrol) . . . . . . . . . . . . . . . . . . . . . .85

Engine Harness for Tier III GM 1.6L LPG . . . . . . . . . . . . . . . . . . . . . . . . . .86

Engine System, Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

&RQWHQWV iii6HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

Engine System, Gasoline/LPG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Scrub System, Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Scrub System, Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

&RQWHQWV iv6HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Sweep System, Side Broom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Wheel System, Non-traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

6SHFLÀFDWLRQV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

56HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

General Information

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Form

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Advance LPG/48” 56110000 56091002 - English

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56042484

Advance Petrol/48” 56110001

Advance Diesel/48” 56110002

Advance LPG/60” 56110003

Advance Petrol/60” 56110004

Advance Diesel/60” 56110005

Advance LPG/62” 56110006

Advance Petrol/62” 56110007

Advance Diesel/62” 56110008

Advance LPG/67” 56110009

Advance Petrol/67” 56110010

Advance Diesel/67” 56110015

Advance LPG X48 56381131

Advance Petrol X48 56381133

Advance Diesel X48 56381134

Advance LPG X60 56381135

Advance Petrol X60 56381137

Advance Diesel X60 56381138

Advance LPG X62 56381139

Advance Petrol X62 56381140

Advance Diesel X62 56381141

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Model Name Model

Number

Instructions for Use

Form Number

Parts List

Form

Number

Advance LPG X67 56381142 56091002 - English

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56042484

Advance Petrol X67 56381143

Advance Diesel X67 56381145

1LO¿VN/3* 56111025 56091008 - English

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PSI LPG test kit, p/n 56504450

Diagnostic Communication Cable and software,

p/n 56305647

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Hydraulic test gauge w/connector

3000 psi range, p/n 56504516

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&DXWLRQ 'RQRWSUHVVXUHZDVKWKHRSHUDWRUFRQWUROSDQHOHOHFWULFDOFRPSRQHQWVRUHQJLQH

FRPSDUWPHQWDUHD

Maintenance Item Procedure

3HUIRUP³$IWHU8VH´PDLQWHQDQFHVWHSV ³$IWHUXVH´PDLQWHQDQFHLVQRUPDOO\WKHUHVSRQVLELOLW\RIWKH

PDFKLQH2SHUDWRU5HIHUWRWKH,QVWUXFWLRQVIRU8VH

Engine

&KHFNWKHHQJLQHRLOOHYHO

&KHFNWKHHQJLQHFRRODQWOHYHOLQWKHUHVHUYRLU

&KHFNIRUHQJLQHDQGFRRODQWOHDNV

&KHFNWKHDLUFOHDQHUVHUYLFHLQGLFDWRUDQGVHUYLFHWKHDLU¿OWHU

ZKHQWKHLQGLFWRULVVKRZQUHG

2SHUDWRUFRQWUROSDQHO &KHFNIRUDK\GUDXOLF¿OWHUSOXJJHGLFRQRQWKHRSHUDWRUSDQHO

GLVSOD\

+\GUDXOLFV\VWHP

&KHFNWKHRLOOHYHOLQWKHK\GUDXOLFRLOUHVHUYRLUOHYHOVKRXOGEHWR

ERWWRPRIVFUHHQ

&KHFNIRUDQ\K\GUDXOLFOHDNV

5HFRYHU\WDQN

&KHFNWKDWWKHGUDLQKRVHFDSLVVHDOHG

'UDLQDQGFOHDQWKHLQVLGHRIWKHWDQNÀXVKZLWKFOHDQZDWHU

&KHFNWKHFRYHUJDVNHWIRUGDPDJHZHDU

6TXHHJHHSLFNXSWRRO &OHDQWKHVTXHHJHHWRROFKHFNWKHEODGHVIRUGDPDJHZHDUDQG

GHÀHFWLRQ

6FUXEKRXVLQJVLGHVNLUWV &KHFNIRUGDPDJHZHDU

6FUXEEUXVKHVPDLQDQGULJKWVLGH &KHFNIRUGHEULVZUDSSHGDURXQGWKHEUXVKHVEURRPVDQGIRU

GDPDJHZHDU

0DLQDQGVLGHEURRPV

:HWGHEULVKRSSHU &OHDQWKHKRSSHUGHEULVVFUHHQDQGKRVH

3DUNLQJEUDNHDQGIRRWSHGDOEUDNH &KHFNIRUFRUUHFWRSHUDWLRQRIEUDNHVDGMXVWDVQHHGHG

General Information 6HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

0DLQWHQDQFH(YHU\WR+RXUV

Maintenance Item Procedure

%DWWHU\ &KHFNWKHHOHFWURO\WHOHYHOLQWKHEDWWHU\

&KHFNWKHEDWWHU\FDEOHVDQGFRQQHFWLRQV

6ROXWLRQWDQN¿OWHU ,QVSHFWDQGFOHDQWKHGHEULV¿OWHURQWKHVROXWLRQ¿OWHUV\VWHP

EcoFlex™ and AXP™ GHWHUJHQWV\VWHPV 3XUJHWKHGHWHUJHQWGHOLYHU\OLQHV

6FUXEGHFNVNLGSODWHV ,QVSHFWIRUZHDUUHSODFHLIZRUQWRóLQFK

6FUXEEUXVKHV 5RWDWHDQGÀLSWKHPDLQVFUXEEUXVKHV

'XVW*XDUG™&OHDQWKHGXVWFRQWUROV\VWHPVSUD\QR]]OHV

0RQWKO\0DLQWHQDQFH

Maintenance Item Procedure

6TXHHJHHFDVWHUZKHHOD[OHDQGSLYRW 3XPSDVPDOODPRXQWRIJUHDVHLQWRHDFKJUHDVH¿WWLQJRQWKH

PDFKLQHXQWLOJUHDVHVHHSVRXWDURXQGWKHEHDULQJV

6WHHULQJ5DFN

$SSO\JUHDVHWROXEULFDWH

$QJOHDGMXVWPHQWNQREWKUHDGVRQWKH

VTXHHJHHPRXQW

6TXHHJHHWRROHQGZKHHOV

$SSO\OLJKWPDFKLQHRLOWROXEULFDWH

)XHO7DQN&RYHU/DWFK

EcoFlex™ / AXP™ Cover Latch

5HFRYHU\WDQNODWFK

%UDNH3HGDOSDUNLQJEUDNHOLQNDJH

0DLQWHQDQFH(YHU\+RXUV

Maintenance Item Procedure

(QJLQHPDLQWHQDQFH &KDQJHWKHHQJLQHRLODQGRLO¿OWHU$OVRUHYLHZWKHHQJLQH

PDQXIDFWXUHU¶VDGGLWLRQDOPDLQWHQDQFHUHTXLUHPHQWV

Radiator and oil cooler ,QVSHFWDQGFOHDQWKHH[WHULRUFRUHFRROLQJ¿QV

Steering ,QVSHFWDQGDSSO\JUHDVHWRWKHVSXUJHDUDQGUDFN

/3IXHOV\VWHPHOHFWURQLFSUHVVXUH

UHJXODWRU(35±/3HQJLQHVRQO\ ,QVSHFWDQGGUDLQDQ\RLOEXLOGXSIURPWKH/3IXHOV\VWHP(35

General Information 6HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

0DLQWHQDQFH(YHU\+RXUV

Maintenance Item Procedure

$LULQWDNHKRXVLQJDQGKRVHV ,QVSHFWWKHFRPSOHWHDLULQWDNHV\VWHPIRUFRUUHFWURXWLQJNLQNV

UHVWULFWLRQVVRXQGWLJKWFRQQHFWLRQVKROHVDQGFUDFNVLQKRVHV

+\GUDXOLFKRVHV ,QVSHFWIRUOHDNVZHDUFUDFNLQJDQGNLQNV

%DWWHU\ &KHFNHOHFWURO\WHOHYHOFKHFNWHUPLQDOVIRUFRUURVLRQORRVH

connections.

)XHO)LOWHU 5HSODFHIXHO¿OWHUFDUWULGJHORFDWHGEHIRUHLQMHFWRUSXPS

5HSODFHWKHIXHO¿OWHUDWWKHHOHFWURQLFIXHOSXPS

0DLQWHQDQFH(YHU\WR+RXUV

Maintenance Item Procedure

(QJLQHPDLQWHQDQFH*DVROLQHDQG/3*

RQO\

&KDQJHWKHVSDUNSOXJV

Radiator )OXVKDQGUH¿OOUDGLDWRUZLWKPL[RIZDWHUDQGDQWLIUHH]H

+\GUDXOLFRLOUHVHUYRLU &KDQJHWKHUHVHUYRLURLODQG¿OWHU

0DLQWHQDQFH(YHU\+RXUV

Maintenance Item Procedure

(QJLQHPDLQWHQDQFH/3*DQGGLHVHORQO\ 5HYLHZWKHHQJLQHPDQXIDFWXUHU¶VDGGLWLRQDOPDLQWHQDQFH

UHTXLUHPHQWV

*Note: The engine maintenance schedule shown lists the recommended engine service intervals.

Refer to the 2WKHU5HIHUHQFH0DQXDOVDQG,QIRUPDWLRQ6RXUFHV/(QJLQH0DQXIDFWXUHUV¶

7HFKQLFDO0DQXDOV section for list of available engine manufacturers’ service manuals. Refer

to these manuals for more complete maintenance and service information and instructions.

General Information 6HUYLFH0DQXDO±$GYDQFH&RQGRU;/1LO¿VN(5

/XEULFDWLRQ3RLQWV

Angle

Adjustment

Knob Threads

on Squeegee

Mount (grease)

Steering

Rack (grease)

Squeegee

End Tool

Wheel (oil)

Squeegee

End Tool

Wheel (oil)

Recovery

Tank Latch

(oil)

Fuel Tank

Cover

Latch (oil)

Brake Pedal

(parking brake)

Linkage (oil)

Detergent

Cover Latch

(oil)

Squeegee

Caster Wheel

Pivot (grease)

Squeegee

Caster

Wheel Axle

(grease)

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