Exterra. SERVICE MANUAL - CAB ADDENDUM Advance Models: (4 cyl LPG), (4 cyl Petrol), (4 cyl Diesel) 11/08 FORM NO.

Transcription

1 Exterra SERVICE MANUAL - CAB ADDENDUM Advance Models: (4 cyl LPG), (4 cyl Petrol), (4 cyl Diesel) /08 FORM NO

2 CONTENTS Contents... iii Figures...iv Section Introduction Exterra Deluxe Cab Options... Other Manuals Available... General tes... Cautions and Warnings... Symbols... General Safety Instructions... Technical Specifications...3 Section Know Your Machine Cab Controls...4 Heating System Components...5 Air Conditioning System Components...6 Section 3 Maintenance...7 Maintenance Schedule...7 To Clean and Replace the Cab Filter...7 Section 4 Heating System General System Overview...8 Electrical Circuit Overview...8 Heater Blower Motor...8 Heater Temperature Control...8 Electrical Troubleshooting...9- Symptom: The heater Blower Motor will not run....9 Symptom: There is no cab heat, or the cab heat cannot be controlled To Eliminate Air Locks from the Cooling System... Cooling System Vacuum Filler... Purge the Heater Circuit... Section 5 Air Conditioning System General System Overview...3 Electrical Circuit Overview...3 Blower Motors...3 Condenser Fan, Thermostat, Pressure Switch and Compressor Motor...4 Electrical Troubleshooting...5 Symptom: One or both of the Blower Motors will not run....5 Symptom: The Blower Motors run but there is no cold air coming out of the Evaporator-Heater Unit....6 Component Troubleshooting...7 Compressor Motor Hydraulic Valve (L0)...7 Accessory (Gear) Hydraulic Pump...7 Compressor Relay (K0)...8 Binary Pressure Switch (S34)...9 Thermostat (S33)...0 Section 6 Appendix... Cab Electrical Wiring Diagram... Cab Electrical Ladder Diagram... Heating and A/C System Plumbing and Hydraulic Schematic...3 FIGURES Figure - Exterra Cab Height...3 Figure - Cab Controls...4 Figure - Heating System Components...5 Figure -3 Air Conditioning System Components...6 Figure 3- Cab Filter...7 Figure 4- Valve Assembly Connector Pins...0 Figure 4- Valve Assembly Hose Functions... Figure 5- Compressor Motor Hydraulic Valve...7 Figure 5- Compressor Relay...8 Figure 5-3 Checking Continuity through the Binary Pressure Switch...9 Figure 5-4 Checking Continuity through the Thermostat...0

3 SECTION INTRODUCTION EXTERRA DELUXE CAB OPTIONS The Exterra Deluxe Cab is available with two levels of environmental control that provide additional comfort and convenience for the Operator, and add additional functionality to the machine. An optional cab heater is available which includes a pressurized cab with an external air filter. An optional heating and air conditioning system is available that provides Operator comfort throughout a wide range of ambient temperatures. OTHER MANUALS AVAILABLE This service manual includes instructions and information to help you to maintain, troubleshoot and repair the cab heating and air conditioning systems. This manual is meant to be used in conjunction with the following manuals and information sources for the Exterra Rider Sweeper and Cab. The manuals listed below can be found via Advance s two electronic-supported databases. General Information Nilfisk-Advance website ( EzParts service/parts CD-Rom Exterra Cab Manuals Form Number Cab Addendum Parts List Cab Addendum Exterra Manuals Form Number Parts List (all systems w/optional kits & accessories) Operation Manual (English, Spanish) Quick Start Troubleshooting Manual Engine Manuals.6L Industrial Engine Operator Manual (excerpt from 6LECSS), Advance form number L Industrial Engine Service Manual * PSI.6L PFI Tier II Certified Engine Service Manual, publication number PSIP6LPFI-A (available in electronic format only) V505 Kubota Diesel Engine Service Manual (WSM English) V505 Kubota Diesel Engine Service Manual (WSM English, French, German) V505 Kubota Diesel Engine Operator Manual (English, French, German, Italian, Spanish) GENERAL NOTES As you read this manual you will occasionally run across a bold number or letter in parentheses, for example (). These numbers refer to items shown on the following pages. Refer to Section Know Your Machine for the location of items highlighted in bold in the text. te: All references to right, left, front, or rear in this manual are as seen from the operator s position. FORM NO Exterra -

4 CAUTIONS AND WARNINGS SYMBOLS Advance uses the symbols below to signal potentially dangerous conditions. Read this information carefully and take the necessary steps to protect personnel and property. DANGER! Is used to warn of immediate hazards that will cause severe personal injury or death. WARNING! Is used to call attention to a situation that could cause severe personal injury. CAUTION! Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property. Read all instructions before using. GENERAL SAFETY INSTRUCTIONS Specific Dangers, Warnings and Cautions are included to warn you of potential danger of machine damage or bodily harm. DANGER! This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death. Always provide adequate ventilation when using machine. WARNING! Remove all jewelry when working near electrical components. Turn the key switch off (O) and disconnect the battery before servicing electrical components. Never work under a machine without safety blocks or stands to support the machine. Do not dispense flammable cleaning agents, operate the machine on or near these agents, or operate in areas where flammable liquids exist. CAUTION! Before performing any service function, carefully read all instructions pertaining to that function. Do not leave the machine unattended without first turning the key switch off (O), removing the key and securing the machine. Turn the key switch off (O) and remove the key before changing the brooms and before opening any access panels. Take precautions to prevent hair, jewelry or loose clothing from becoming caught in moving parts. Close and secure all doors, covers and access panels as shown in the Instructions For Use before using the machine. Do not clean the cab with a pressure washer. We recommend hand-washing the cab using normal garden hose water pressure. Do not spray water directly at or into the cab filter or any electrical components. Allow the machine to dry completely before use. SAVE THESE INSTRUCTIONS - FORM NO Exterra

5 TECHNICAL SPECIFICATIONS Total Machine Height with Cab (Refer to Figure - below.) System Voltage Heater Temperature Control Blower Motors Refrigerant Condenser Fan Motor Compressor Compressor Motor Heating System Capacity Air Conditioning System Capacity Heating System A/C System 79.5 in (0 cm) without Amber Strobe Kit 84.5 in (5 cm) with Amber Strobe Kit installed VDC Electronic Water Valve w/bypass () Fasco OEM p/n , Fasco p/n DC36, /8 HP, 400 RPM, three-speed, 4.5 Amp () SPAL type 008-A37/C-4D, 4.5 Amp R-34a,.3 lbs. SPAL, type VA3-AP9/C-35S, 6.9 Amp ICE TM-08-HD, 5 cu. in. (8.0 cc) per revolution, RPM Sauer-Danfoss p/n ,.0 cu. in. (6.7 cc) displacement 0,000 BTUs/hr. 3,000 BTUs/hr. FIGURE - Exterra Cab Height FORM NO Exterra - 3

6 SECTION KNOW YOUR MACHINE CAB CONTROLS Refer to Figure -. Cooling Fan Switch Dome Light 3 Heater A/C Fan Switch 4 Heater Temperature Control 5 A/C On/Off Switch 6 Windshield Wiper Switch FIGURE - Cab Controls 4 - FORM NO Exterra

7 HEATING SYSTEM COMPONENTS Refer to Figure - 7 Blower Motor 8 Blower Assembly 9 Heater Core 0 Heater Air Box Assembly Filter Coolant Tube (From Engine Radiator) 3 Cab Filter Cover 4 Heater Hoses 5 Heater Control Assembly 6 HVAC Relay FIGURE - Heating System Components FORM NO Exterra - 5

8 AIR CONDITIONING SYSTEM COMPONENTS Refer to Figure -3 7 Evaporator-Heater Unit 8 A/C Condenser 9 Binary Pressure Switch 0 A/C Receiver/Dryer A/C Compressor Hydraulic Compressor Motor 3 Air Filter 4 Cab Filter Cover 5 Coolant Tube (From Engine Radiator) 6 Heater Hoses 7 Heater Control Assembly 8 Accessory (Gear) Hydraulic Pump 9 Compressor Motor Hydraulic Valve 30 Compressor Relay 3 HVAC Relay FIGURE -3 Air Conditioning System Components 6 - FORM NO Exterra

9 SECTION 3 MAINTENANCE WARNING! Turn the key switch off and remove the key from the ignition switch before performing any machine maintenance. MAINTENANCE SCHEDULE Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often. Maintenance Item Daily Weekly Monthly Hours Check for any coolant, hydraulic or refrigerant leaks. te: Refrigerant leaks can appear as dirty, oily areas around A/C X 8- components and fittings. Check the cab filter and clean or replace as necessary. te: The cab filter may need to be cleaned or replaced more often if the X 40 machine is operated in dusty environments. Clean the heater core fins and air box (heater only). X 60 Clean the evaporator and heater core fins inside the evaporator-heater unit X 60 (A/C only). Clean the condenser fins (A/C only). X 40 TO CLEAN AND REPLACE THE CAB FILTER Refer to Figure 3-.. Remove the four screws holding the Cab Filter Cover, then remove the Cab Filter Cover and Filter from the machine.. Clean the Filter using any of the following methods: Tap the Filter gently on a flat surface (dirty side down). Clean the Filter with compressed air (00 psi max.) blown from the inside (cab side) of the Filter. Soak the Filter in warm water for 5 minutes, rinse with clean water (40 psi max. water pressure), then air-dry (don t use compressed air). Make sure the Filter is completely dry before reinstalling. 3. Reinstall the Filter and Cab Filter Cover, then reinstall and tighten the four screws. FIGURE 3- Cab Filter FORM NO Exterra - 7

10 SECTION 4 HEATING SYSTEM te: Refer to Section Know Your Machine and the schematics in Section 6 Appendix. GENERAL SYSTEM OVERVIEW The Exterra cab heating system uses an electronic Heater Control Assembly (5) to direct the appropriate amount of engine coolant to the Heater Core (9) in the Heater Air Box Assembly (0). The Blower Assembly (8) in the Heater Air Box Assembly blows filtered air through the Heater Core to provide warm air to the cab. A four-port bypass butterfly valve in the Heater Control Assembly, run by a small electric motor, controls the coolant flow to the Heater Core. The Heater Temperature Control (4) in the cab controls the voltage to the valve motor, and uses a feedback potentiometer to sense the position of the butterfly valve. ELECTRICAL CIRCUIT OVERVIEW Heater Blower Motor The following conditions must be met for the blower motor to function: Positive (+) Voltage The key switch (S)must be in either the accessory or ignition position to provide + VDC (GRN/BLU wire) to the 0A circuit breaker CB4. Circuit breaker CB4 must be closed to provide + VDC ( wire) to the control side (coil) of the HVAC Relay K8. The 0A circuit breaker CB9 must be closed to provide voltage (RED/ wire) to the input load side of the HVAC Relay K8. HVAC Relay K8 must be closed to provide + VDC (/GRAY wire) to the positive terminal on the Fan Switch S30. The Fan Switch S30 must be set to the Low (YEL wire), Medium (RED wire) or High (ORN wire) position to provide + VDC to the corresponding terminal on the Blower Motor M6. Negative ( ) Voltage The Blower Motor M6 must be connected to battery negative (BLK wire). The control side (coil) of the HVAC Relay K8 must be connected to battery negative (BLK wire). Heater Temperature Control The following conditions must be met for the heater temperature control to function: Positive (+) Voltage The key switch must be in either the accessory or ignition position to provide + VDC (GRN/BLU wire) to the 0A circuit breaker Circuit breaker CB4 must be closed to provide + VDC ( wire) to the control side (coil) of the HVAC Relay K8. The 0A circuit breaker CB9 must be closed to provide voltage (RED/ wire) to the input load side of the HVAC Relay K8. HVAC Relay K8 must be closed to provide + VDC (/GRAY to RED wire) to the Heater Temperature Control E. Negative ( ) Voltage The Heater Temperature Control E (BLK wire) must be connected to battery ground. The control side (coil) of the HVAC Relay K8 must be connected to battery negative (BLK wire). CB FORM NO Exterra

11 ELECTRICAL TROUBLESHOOTING te: Refer to the Electrical Wiring and Ladder Diagrams in Section 6 Appendix. Symptom: The heater Blower Motor will not run. The Blower Motor is not working. Is there V at the /GRA wire on the Fan Switch S30? (ref. to bat. neg. w/key switch on) Is there voltage at each of the three positive terminals on Fan Switch S30 when the Switch is set to the corresponding fan speed? (YEL, RED and ORN wires ref. to bat. neg.) Replace the Fan Switch S30. Reset or replace circuit breaker CB4. Is there continuity through 0A circuit breaker CB4? Is there continuity in the YEL, RED and ORN wires from Fan Switch S30 to the positive terminals on the Blower Motor M6? Repair the wires. Reset or replace circuit breaker CB9. Is there continuity through 0A circuit breaker CB9? Replace the Relay. Does the resistance of Relay coil K8 measure 85 ±0%? Is there V in the BLK wire from the negative terminal on the Blower Motor M6 ref. to bat. pos.? Repair the wire. Replace the relay. Is there continuity through the load contacts on K8 (terminals 30 and 87) when the coil is energized? Replace the Blower Motor M6. Check the connectors and wiring and repair as necessary. FORM NO Exterra - 9

12 Symptom: There is no cab heat, or the cab heat cannot be controlled. te: Before troubleshooting the heating system, make sure the engine is up to normal operating temperature, the engine coolant is at the recommended level and there are no air locks in the cooling system. (Refer to the To Eliminate Air Locks from the Cooling System subsection.) To Troubleshoot the Valve Assembly Refer to Figure 4-.. Disconnect the electrical connector from the Valve Assembly.. Carefully connect a VDC source to the Motor (-) and Motor (+) pins (directly or via the BLK/WHT and ORN wires in the connector) to run the butterfly valve motor independently without input from the heater temperature control. 3. Check for the heated coolant being switched on and off to the heater core. te that it will take approximately 5-0 seconds for the valve motor to run between its full-off and full-on positions. 4. If the valve motor isn t running, replace the Valve Assembly. If the valve motor appears to be running correctly, continue on to step 5 below. 5. Check the resistance through the Feedback Pins to determine if the feedback potentiometer in the Valve Assembly is working correctly. The resistance values should be close to those shown in the table below. Motor (-) Pin Motor (+) Pin Feedback (-) Pin Valve Assembly Feedback Pot Pin Feedback (+) Pin FIGURE 4- Valve Assembly Connector Pins Valve Open to Heater Core, Heater Temperature Control set to Hot (full clockwise) Ohmmeter Connections Feedback (+) Pin and Feedback (-) Pin Feedback (+) Pin and Feedback Pot Pin Feedback Pot Pin and Feedback (-) Pin Resistance (Approximate) 5.7 k 5.55 k 0.88 k Valve Closed to Heater Core, Heater Temperature Control set to Cold (full counterclockwise) Feedback (+) Pin and Feedback (-) Pin Feedback (+) Pin and Feedback Pot Pin Feedback Pot Pin and Feedback (-) Pin 5.7 k 0.48 k 5.63 k Valve Halfway Open, Heater Temperature Control set to approximate midpoint Feedback (+) Pin and Feedback (-) Pin Feedback (+) Pin and Feedback Pot Pin Feedback Pot Pin and Feedback (-) Pin 5.7 k 3.4 k 3.5 k 6. If the Feedback Pin resistance values are not close to those shown in the above table, it indicates that the feedback potentiometer in the Valve Assembly is not working correctly. Replace the Valve Assembly. 0 - FORM NO Exterra

13 TO TROUBLESHOOT THE HEATER TEMPERATURE CONTROL There is no Cab heat/the Cab heat cannot be controlled. Is there V to the Heater Temperature Control (BLK and RED wires)? Check the wiring to the Heater Temperature Control and repair as necessary. Is there approximately +/- 9.75V at the Valve Assembly Connector (BLK/WHT and ORN wires) when the Heater Temperature Control E is rotated between cold and hot? Is there continuity in all five wires from the Heater Temperature Control to the Valve Assembly Connector? Repair the wiring as necessary. Replace the Heater Temperature Control. Is there continuity in the three feedback pot wires (WHT, and GRN) from the Heater Temperature Control to the Valve Assembly Connector? Repair the wiring as necessary. Replace the Heater Temperature Control. Service Tip: If you have to replace the Heater Temperature Control in the cab, we recommend that you do so as follows:. Remove the Overhead Control Plate from the cab.. Disassemble the Heater Temperature Control from the Overhead Control Plate. 3. Cut the seven wires going to the Heater Temperature Control at the point where they enter the sealed back of the module. 4. Check the continuity of the five wires going to the Valve Assembly (, WHT, GRN, GRA/BLK WHT, and ORN). If there is continuity in all five wires from the cab to the Valve Assembly, continue to step 5. If there is no continuity in any of the five wires from the cab to the Valve Assembly, you will need to either repair the wires or run new wires to the Valve Assembly. 5. Install the replacement Heater Temperature Control on the Overhead Control Plate. 6. Splice the original wires from the Valve Assembly to the replacement Heater Temperature Control using butt connectors and heat-shrink insulation. 7. Reinstall the Overhead Control Plate in the cab. FORM NO Exterra -

14 TO ELIMINATE AIR LOCKS FROM THE COOLING SYSTEM Air locks (air bubbles) in the cooling system can prevent normal coolant flow to the heater core. One factor that can contribute to the formation of air locks is the fact that the heater cores in the Exterra cabs are the highest point in the machine s cooling system. This can make it difficult to purge the air from the system using traditional methods more common to the automotive industry. Cooling System Vacuum Filler One recommended method for removing air locks is to drain the cooling system completely, then refill the system using a cooling system vacuum filler tool. This type of tool uses a Venturi vacuum generator to remove the air from the radiator as it fills the radiator with coolant. Purge the Heater Circuit Refer to Figure 4-. Another method is to remove the hoses that run from the Valve Assembly to the heater core, purge the hoses with coolant to remove as much air as possible from the heater circuit, reinstall the hoses, then run the machine with the heater on to purge any remaining air from the system. Figure 4- shows the heater hose functions for reference. WARNING! Before attempting to remove the heater hoses, make sure: The engine is switched off. The machine coolant has cooled to a low enough temperature so as not to cause burns or injury to persons contacting the hoses or coolant. The cooling system temperature and pressure have decreased enough to allow you to remove the radiator cap to relieve the system pressure before removing the hoses. FIGURE 4- Valve Assembly Hose Functions Coolant Supply from Engine Coolant Return to Engine Coolant Supply to Heater Core Coolant Return from Heater Core - FORM NO Exterra

15 SECTION 5 AIR CONDITIONING SYSTEM te: Refer to Section Know Your Machine and the schematics in Section 6 Appendix. General System Overview The Exterra cab air conditioning system uses a Hydraulic Compressor Motor (), powered by the Gear (Accessory) Hydraulic Pump (8), to run the A/C Compressor (). The A/C Compressor compresses the refrigerant and transfers the hot, high-pressure refrigerant gas to the A/C Condenser (8) at the rear of the machine which condenses the refrigerant gas into a liquid. The condensed high-pressure liquid refrigerant travels from the A/C Condenser to the A/C Receiver/Dryer (0), then to the expansion valve and evaporator inside the Evaporator-Heater Unit (7) inside the cab. The cold, low-pressure refrigerant gas then returns to the A/C Compressor to complete the refrigeration cycle. The Operator moderates the cab cooling by mixing in heated air from the heater core in the Evaporator-Heater Unit by adjusting the Heater Temperature Control (4). The Thermostat (S33) (normally closed) has a temperature probe that is inserted into the evaporator coil in the Evaporator-Heater Unit. When the temperature of the evaporator coil reaches 39.5 F, the Thermostat closes to enable the A/C system. When the temperature of the evaporator coil drops to 3 F, the Thermostat opens to switch off the A/C system. The Binary Pressure Switch (S34) (9) (normally closed), located on top of the A/C Receiver/Dryer, will interrupt the + VDC to the Compressor Motor Hydraulic Valve (L0) (9) to switch off the Hydraulic Compressor Motor and A/C Compressor under the following two conditions: The refrigerant line pressure drops below 30 psig, indicating an insufficient amount of refrigerant in the system. The refrigerant line pressure rises above 70 psig, indicating an overheated or unsafe condition. The Compressor Relay (K0) (30) will interrupt the + VDC to the Compressor Motor Hydraulic Valve (L0) to switch off the Hydraulic Compressor Motor and A/C Compressor whenever the hopper is raised. Electrical Circuit Overview Blower Motors The following conditions must be met for the blower motors to function: Positive (+) Voltage The key switch must be in either the accessory or ignition position to provide + VDC (GRN/BLU wire) to the 0A circuit breaker CB4. Circuit breaker CB4 must be closed to provide + VDC ( wire) to the control side (coil) of the HVAC Relay K8. The 0A circuit breaker CB9 must be closed to provide voltage (RED/ wire) to the load side of the HVAC Relay K8. The HVAC Relay K8 must be closed to provide + VDC (/GRAY wire) to the positive terminal on the Fan Switch S30. The Fan Switch S30 must be set to the Low (YEL wire), Medium (RED wire) or High (ORN wire) position to provide + VDC to the corresponding terminals on the Blower Motors M9 and M0. Negative ( ) Voltage The Blower Motors M9 and M0 must be connected to battery negative (BLK wires). The control side (coil) of the HVAC Relay K8 must be connected to battery negative (BLK wire). FORM NO Exterra - 3

16 CONDENSER FAN, THERMOSTAT, PRESSURE SWITCH AND COMPRESSOR MOTOR The following conditions must be met for the air conditioning system to function: Positive (+) Voltage The key switch must be in either the accessory or ignition position to provide + VDC (GRN/BLU wire) to the 0A circuit breaker CB4. Circuit breaker CB4 must be closed to provide + VDC ( wire) to the control side (coil) of the HVAC Relay K8. The 0A circuit breaker CB9 must be closed to provide voltage (RED/ wire) to the load side of the HVAC Relay K8. HVAC Relay K8 must be closed to provide + VDC (/GRA wire) to the positive terminal on the Fan Switch S30. The Fan Switch S30 must be set to the Low, Medium or High position to provide + VDC (RED/WHT wire) to the AC Switch S35. The AC Switch S35 must be closed to provide + VDC to: o The control side (coil) of the Condenser Fan Relay K9 (WHT wire). o The input terminal on the Thermostat S33 (BLK/WHT wire). The Thermostat S33 (normally closed) must be closed to provide + VDC (GRN wire) to the input terminal on the Pressure Switch S34. The Binary Pressure Switch S34 (normally closed) must be closed to provide + VDC (GRN/WHT wire) to the load side of the Compressor Relay K0 (terminal 30). The load side of the Compressor Relay K0 (normally closed) must be closed to provide + VDC (BLU/BRN wire from terminal 87a) to the Compressor Hydraulic Valve L0. te: The Compressor Relay K0 coil (control side) is wired in parallel with the Hopper Up/Down Hydraulic Valve L5. When the Raise Hopper switch is pressed, it actuates the Hopper Up/Down Hydraulic Valve L5 to raise the hopper, and actuates the Compressor Relay K0 coil to open the circuit to the Compressor Hydraulic Valve L0 and switch off the A/C compressor motor. This feature allows the machine to use the maximum available hydraulic force to raise the hopper. Negative ( ) Voltage The control side (coil) of the Condenser Fan Relay K9 must be connected to battery negative (BLK wire). The control side (coil) of the Compressor Hydraulic Valve L0 must be connected to battery negative (BLK wire). The control side (coil) of the HVAC Relay K8 must be connected to battery negative (BLK wire). 4 - FORM NO Exterra

17 ELECTRICAL TROUBLESHOOTING te: Refer to the Cab Electrical Wiring and Ladder Diagrams in Section 6 Appendix. Symptom: One or both of the Blower Motors will not run. One or both of the Blower Motors will not run. Is there V at /GRA wire on Fan Switch S30? (ref. to bat. neg. w/key switch on) Is there voltage at each of the three positive terminals on Fan Switch S30 when the Switch is set to the corresponding fan speed? (YEL, RED and ORN wires ref. to bat. neg.) Replace the Fan Switch. Reset or replace circuit breaker CB4. Is there continuity through 0A circuit breaker CB4? Is there continuity in the YEL, RED and ORN wires from Fan Switch S30 to positive terminals on Blower Motors M9 and M0? Repair the wires. Reset or replace circuit breaker CB9. Is there continuity through 0A circuit breaker CB9? Replace the Relay. Does the resistance of Relay coil K8 measure 85 ±0%? Is there V in the BLK wire from negative terminal on Blower Motors M9 and M0 ref. to bat. pos.? Repair the wire(s). Replace the Relay. Is there continuity through the load contacts on K8 (terminals 30 and 87) when the coil is energized? Replace Blower Motor M9 and/or M0. Check the connectors and wiring and repair as necessary. FORM NO Exterra - 5

18 Symptom: The Blower Motors run but there is no cold air coming out of the Evaporator-Heater Unit. te: Before troubleshooting the air conditioning system, make sure the system is filled with the recommended amount of refrigerant. We recommend that you have this checked by a qualified technician or an EPA-certified air conditioning repair shop. te: Refer to the Cab Electrical Wiring and Ladder Diagrams in Section 6 Appendix, and the Component Troubleshooting subsections on the following pages. There is no cold air from the Evaporator-Heater Unit. Check the cartridge on Hydraulic Valve L0 and clean/replace as necessary. Is there V across the coil on the Compressor Hydraulic Valve L0 (hopper down, A/C switched on)? Check/replace A/C Switch S35. Is there V at the WHT wire on A/C Switch S35 (ref. to bat. neg. w/a/c Switch S35 on)? Check/replace Thermostat S33. Is there V at the GRN wire on the Thermostat S33 (ref. to bat. neg.)? The A/C system is overheated. Check the Condenser Fan Relay K9, Condenser Fan and associated wiring and replace/repair as necessary. Is there V at the GRN/WHT wire on the Pressure Switch S34 (ref. to bat. neg.)? Check the function of the Compressor Relay K0 and wiring and repair/replace as necessary. Is there V at the BLU/BRN wire on the Compressor Relay K0 (ref. to bat. neg. with the Hopper down)? Check the auxiliary pump, compressor motor and related hydraulics. Is the hydraulic pressure at the auxiliary pump test port within specs? Check the compressor and air conditioning system components. 6 - FORM NO Exterra

19 COMPONENT TROUBLESHOOTING Compressor Motor Hydraulic Valve (L0) Refer to Figure 5-. te: The Compressor Motor Hydraulic Valve and Hydraulic Pressure Test Port are attached to the tee-fitting off of the Accessory Hydraulic Pump.. Disconnect the Electrical Connector from the Hydraulic Valve.. Switch on the A/C and check for VDC at the Electrical Connector. 3. Check the coil resistance of the Hydraulic Valve. It should be approximately 7 ±0%. 4. If there is VDC at the Electrical Connector and the coil resistance is within spec, disassemble the Hydraulic Valve and clean or replace the cartridge as necessary. FIGURE 5- Compressor Motor Hydraulic Valve Hydraulic Valve (L0) Hydraulic Pressure Test Port Electrical Connector Accessory Hydraulic Pump Accessory (Gear) Hydraulic Pump Refer to Figure 5-.. Connect a hydraulic pressure gauge to the Hydraulic Pressure Test Port off of the Accessory Hydraulic Pump.. Start the engine, then switch the A/C on and off at the two engine speeds and note the hydraulic pressures at the Hydraulic Pressure Test Port. The following chart shows pressure values that are representative of what you should be reading at normal operating temperature if the Accessory Hydraulic Pump, Hydraulic Valve and compressor motor are working correctly. te that pressures tend to be higher if the hydraulic system is below normal operating temperature. Engine at idle, A/C off Engine at idle, A/C on Engine at high speed, A/C off Engine at high speed, A/C on Hydraulic Pressure at Test Port (typical) 500 psi 880 psi 675 psi 00 psi Difference in Hydraulic Pressure between A/C off and A/C on 380 psi 45 psi If you don t observe differences in the hydraulic pressures similar to those in the above chart when switching the A/C on and off, it could indicate a problem with the Hydraulic Valve (L0), the Accessory Hydraulic Pump or the A/C compressor motor. FORM NO Exterra - 7

20 COMPRESSOR RELAY (K0) Refer to Figure 5-. te: The Compressor Relay is located in the engine compartment below the main broom lever.. Make sure the hopper is down, then switch on the A/C.. Back-probe the BLU/BRN wire connected to the Compressor Relay. If you see VDC at the BLU/BRN wire referenced to battery negative, the Compressor Relay is working correctly. If you don t see VDC at the BLU/BRN wire, proceed to step 3 below. 3. Remove the electrical connector from the Compressor Relay and check for continuity across the load terminals (30 and 87a). te: The Compressor Relay is a normally-closed relay and should have continuity across the load terminals with the electrical connector removed. If there is continuity across load terminals 30 and 87a, the Compressor Relay is working correctly. Check the connections and wiring upstream of the Compressor Relay and repair/replace as necessary. If there is very high resistance or no continuity across terminals 30 and 87a, replace the Compressor Relay. FIGURE 5- Compressor Relay Compressor Relay (K0) 8 - FORM NO Exterra

21 WARNING! High-pressure side air conditioning components, fittings, lines and hoses can be extremely hot after operation and can cause severe burns. Always use the appropriate precautions when working around the Binary Pressure Switch, Receiver/Dryer or other A/C components. BINARY PRESSURE SWITCH (S34) Refer to Figure 5-3. te: The Binary Pressure Switch is mounted to the top of the A/C Receiver/Dryer at the rear of the machine.. Open the rear Cover Assembly.. Remove the electrical connector from the Binary Pressure Switch and check for continuity across the two terminals. te: The Binary Pressure Switch is normally closed and should have continuity across the terminals if the A/C system is charged adequately and is at normal ambient temperature. If there is continuity across the terminals, the Binary Pressure Switch is working correctly. If there is very high resistance or no continuity across the terminals, replace the Binary Pressure Switch. FIGURE 5-3 Checking Continuity through the Binary Pressure Switch Binary Pressure Switch (S34) A/C Receiver/Dryer FORM NO Exterra - 9

22 THERMOSTAT (S33) Refer to Figure 5-4. te: The Thermostat is located inside the Evaporator-Heater Unit in the cab.. Remove the top cover/nozzle assembly from the Evaporator-Heater Unit.. Remove the front panel from the Evaporator-Heater Unit. 3. Remove the two electrical connectors (BLK/WHT and GRN wires) from the Thermostat and check the continuity across the two terminals. te: The Thermostat is normally closed and should have continuity across the terminals at ambient temperatures above 3 F. If there is continuity across the terminals, the Thermostat is working correctly. If there is very high resistance or no continuity across the terminals, replace the Thermostat. Service Tip: To verify that the thermostat is operating correctly, spray electronic component cooler or canned air dusting spray onto the probe embedded in the evaporator coils to cool the probe to below 3 F. The Thermostat should open and you should read an open circuit through the terminals with the probe below 3 F. Once the probe warms up to 39.5 F, there should again be continuity through the Thermostat terminals. FIGURE 5-4 Checking Continuity through the Thermostat Thermostat (S33) 0 - FORM NO Exterra

23 SECTION 6 APPENDIX Cab Electrical Wiring Diagram YEL 4- RED 4-6 ORN 4- BLK 4-4 GRN/YEL 6-4 BLK 8-9 RED - RED/ - RED.. YEL 4- RED 4-6 ORN 4- GRN/YEL 6-3 GRN/YEL 6-4 BLK 8-9 BLK 8-8 GRN/YEL 6-5 BLK 8-30 RED - GRN/YEL 6-5 GRN/YEL 6-3 /GRA - /GRA - 8- RED/ BLK 8-3 /GRA - BLK 8-0 /GRA -4 /GRA - 8- BLK 8-3 BLK 8-30 BLK 8-8 BLK 4-4 /GRA -5 BLK/WHT WHT GRN YEL.. RED.. ORN.. BLK.. GRN/WHT. GRN. BLK/WHT. RED. BLK. HEATER TEMP. RED... BLK... CONTROL YEL 4- X75 RED 4-7 ORN 4- BLU BLK. BLK/WHT 8- WHT 8- GRN 8-5 WHT 8- RED/WHT 8- YEL 4- RED 4-7 ORN 4- BLK 6- BLK 4-5 GRN/WHT 8- GRN 8-5 BLK/WHT 8- /GRA 4- BLK 4-7 /GRA 4- YEL.. BLU.. BLK 4-5 BLK 6- BLK 4-7 BLK 8-3 CAB WIRING /GRA -3 CONNECT TO X76 FOR STROBE LIGHT OPTION ON TOP OF CAB CONNECT TO X83 ON SHEET CONNECT TO GRN/YEL WIRE (AT X88) FROM K5 RED/GRA RED/GRA 8-3 GRN/WHT RED/GRA 8-3 RED/GRA 8- BLU/BRN 8- BLK 8-3 BLU/BRN 8- E WITH A/C SYSTEM:. M6 IS NOT USED. X70 PLUGS INTO X74 3. X7 PLUSG INTO X75 A B X90 + M5 M X95 SP8 X89 X8 CONNECT TO TERMINAL ON CB X83 CONNECT TO X04 ON SHEET K a RELAY, HVAC (OPTIONAL) A/C SYSTEM K a 87 L0 VALVE, COMPRESSOR RELAY, COMPRESSOR UNPLUG X99 FROM L5 (S5 HOPPER UP/DOWN VALVE) AND CONNECT IT TO X08. CONNECT X07 TO L5. MOTOR ASM, WIPER INCLUDES SPEED SWITCH - A B C D M9 M YEL RED ORN MOTOR, BLOWER X05 - A B C S33 t o THERMOSTAT LP. STROBE (OPTIONAL) X9 RED BLK LP4 (CAB OPTION) LAMP, DOME + M7 M MOTOR, DEFROSTER FAN X74 3 X98 X84 BLK 8-0 CONNECT TO BLK WIRE (AT X85) FROM K5 X07 CONNECT TO L5 - A B C D R9 X7 S34 SWITCH, PRESSURE X03 B S30 L M H C SWITCH, FAN X97 3 X70 YEL RED ORN M0 M MOTOR, BLOWER SP7 - A B C X94 CB9 CIR. BKR., 0 AMP HVAC X99 A B C D E F A B C D E F S35 SWITCH, A/C YEL RED ORN M6 MOTOR, BLOWER M X X83. X79 K a 87 RELAY, CONDENSER FAN + M8 M MOTOR, CONDENSER FAN X08 CONNECT TO X99 AT L FORM NO Exterra -

24 CAB ELECTRICAL LADDER DIAGRAM RED RED/ HVAC OPTION /GRA BT RED + - BLK BATTERY, Vdc B S30 SWITCH, FAN /GRA YEL RED ORN RED/WHT K9 87a RED BLU RELAY, CONDENSOR FAN L M H C E S35 SW SPST HEATER TEMP. CONTROL WHT WHT YEL RED ORN M6/M9 M MOTOR, BLOWER MOTOR M0 BLK BLK S33 S34 K0 87a L0 t o BLK/WHT GRN GRN/WHT BLU/BRN BLK THERMOSTAT RELAY, COMPRESSOR VALVE, COMPRESSOR BLK SWITCH, PRESSURE BLK BLOWER MOTOR FOR PRESSURIZED AND HEATED CAB, BLOWER MOTORS FOR A/C G BLK RED/GRN ORN/GRN PINK RED RELAY, NEUTRAL (CLOSED IN NEUTRAL) BLU/PINK PINK BLU/PINK PINK PINK/YEL GRN/YEL GRA/BLU TAN PINK/YEL GRN/YEL GRA/BLU GRN/BLU BLK YEL/BLK P S GRA/BLK RED GRN/BLU BLK BLU/GRN WHT M BLK WHT/YEL BLK BLK RED RED GRN/BLK CB9 CIRCUIT BREAKER, 0 A. K8 87a RELAY, HVAC + M8 M MOTOR, CONDENSER FAN YEL RED ORN M MOTOR, BLOWER MOTOR K9 RELAY, CONDENSOR FAN CB CIRCUIT BREAKER, 70 AMP S BAT ST CB3 CIRCUIT BREAKER, 5 AMP ACC IGN SWITCH, IGN. CB5 CIRCUIT BREAKER, 0 AMP K4 87a PINK TAN/BRN X F F X A A X H H X PINK B B PURPLE STARTER B+ STARTER COMMAND A3 GM ENGINE SYSTEM (REFERENCE: E-CONTROLS, INC. DRAWING NO. E73700 AND E73700) IGN. SW INPUT ALT. EXCITE FUEL PUMP OUTPUT GROUND MIL OUTPUT (SWITCHED GROUND) THROTTLE INPUT (V FOR HIGH) COOLANT TEMPERATURE OUTPUT BLK/RED BLK/GRN GRN/WHT GRN/RED WHT/GRN G F D C X G X K K X F X D X C X3 A B C D BLK/RED A B C D BLK/GRN GRN/WHT GRN/RED WHT/GRN TAN + M3 M FUEL PUMP GRN/YEL GRA/BLU 3 4 CHECK ENGINE LIGHT OUTPUT TO CONTROL BOX ASSEMBLY CONNECT TO CONTROL BOX ASSEMBLY SENSOR, GASOLINE (GM ENGINE) 4 3 A5 CB4 CIRCUIT BREAKER, 0 AMP TO CONTROL BOX ASSEMBLY P 4 h 3 HOURMETER NOTE: P3 AND R3 ARE NOT USED ON L.P. MODEL R3 SENDER, FUEL GAUGE, FUEL 3 BLK LP RED CB6 CIRCUIT BREAKER, 0 AMP BLU/BLK K3 87a RELAY, SHAKER K 87a RELAY, HORN K5 LIGHT, STROBE (OPTIONAL) H M MOTOR, SHAKER HORN K8 RELAY, SIGNAL LIGHTS (OPTIONAL) BLK CB K 87a RELAY, HVAC (OPTIONAL) LP I - I I (OPTIONAL) L4 VALVE S4, DUST CONTROL K0 RED/GRA BRN/YEL J-4 J-0 RELAY, COMPRESSOR L5 (OPTIONAL) VALVE S5, HOPPER UP/DOWN L6 RED/GRA BLU/GRA J-5 J-6 J-9 VALVE S6, HOPPER UP/BYPASS L7 BLK/WHT J-7 (MIL INPUT) J-5 VALVE S7, HOPPER OPEN L8 BRN J-8 J-8 L9 H VALVE S8, DUST CONTROL BYPASS VALVE S9, HOPPER LOWER YEL/GRN J-9 A CONTROL BOX ASSEMBLY - FORM NO Exterra

25 HEATING AND A/C SYSTEM PLUMBING AND HYDRAULIC FLOW SCHEMATIC Heater Core AC Evaporator Radiator Coolant Tube Feed Hot Water Return Flow Heater Control Valve Hydraulic Test Port Low Pressure Refrigerant (Gas) High Pressure Gas High Pressure Liquid FORM NO Exterra - 3

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