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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 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
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 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
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 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
6600 07-2003
5
ENGINESTARTTIM
ERMODULE
A
A
TOALTERNATOR
61B
STARTERSOLENOID
COIL
STARTERMOTORASSEMBLY
1A
34
2
POSITIVEBATTERYCABLE
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
6600 DIESEL OVERALL ELECTRICAL DIAGRAM
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
ACEVAP./CABPRESS.FANS
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
6600 DIESEL OVERALL ELECTRICAL DIAGRAM
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
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
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 testing
6600 07-200312
6600 Diesel Start Circuit
2
POSITIVE BATTERY CABLE
83
+ -
50
17
19
ACC
42
42A
34
8
8BC
42B
3C
13M
13BB
5A
8D
8A
8B
E
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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!
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.); Suspect
faulty 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)
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
all connections & wiring; Examine engine for
excessive internal resistance (due to lack of
lubrication, mechanical failure, etc.); Suspect
faulty STARTER MOTOR
PLEASE NOTE: When finished, please reconnect all wires disconnected during testing
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
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 testing
6600 07-200314
6600 Diesel Power-Up Circuit
28
+ -
1D
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
Re-check all connections,
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
PLEASE NOTE: When finished, please reconnect all wires disconnected during testing
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
Check all connections, wiring, and fuses
F-5 & F-11, turn key to “ON” position
(KOEO-Key On, Engine Off)
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
ENGINE TEMP / CHECK ENGINE LAMP
Note: Lamp will light if engine overheats
or if an engine system fault is detected
PLEASE NOTE: When finished, please reconnect all wires disconnected during testing
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
Check all connections, wiring, and fuses
F-5 & F-11, turn key to “ON” position
(KOEO-Key On, Engine Off)
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
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 testing
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
Check all connections, wiring, and fuses
F-5 & F-11, turn key to “ON” position
(KOEO-Key On, Engine Off)
With engine
running, does
lamp go out?
Verify proper oil pressure in
engine; Suspect faulty OIL
PRESSURE SWITCH
Is LOW OIL
PRESSURE
LED lit?
YES NO
Remove harness plug at OIL PRESSURE
SWITCH and place a jumper wire across
harness plug wires B & CYES NO
Is LOW OIL
PRESSURE
lamp lit?
YES NO
Replace OIL
PRESSURE SWITCH
Re-check all connections,
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
Verify proper oil pressure in
engine; Suspect faulty HOUR
METER; Suspect faulty OIL
PRESSURE SWITCH
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 testing
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?
Check all connections, wiring, and fuses
F-5, F-11 & F-19, have hopper in full
“DOWN” position, turn key to “ON”
position (KOEO-Key On, Engine Off)
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
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 testing
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
Check all connections, wiring, and fuses
F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
Remove wire plug from VACUUM
SWITCH and place a jumper wire
across harness plug wires
NO
Suspect faulty
VACUUM SWITCH
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
PLEASE NOTE: When finished, please reconnect all wires disconnected during testing
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
Check all connections, wiring, and fuses
F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
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
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
Is battery voltage
measured between
wires “IN” & “GND”
at FUEL GAUGE?
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 testing
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
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 testing
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
Check all connections, wiring, and fuses
F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
Remove wire from #2 post of SHAKER PULSE
MODULE; Momentarily push SHAKER
SWITCH (position 3)
Momentarily push
SHAKER SWITCH
(position 3)- Is battery
voltage measured across
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
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 testing
6600 07-200323
6600 Shaker Motor Circuit (continued)
A
Reconnect SHAKER
SOLENOID to circuit – Push
& hold SHAKER SWITCH
(position 3) - Is battery
voltage measured across
posts #6 & #1 at SHAKER
TIMER MODULE?
Re-check all connections, wiring, and
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
Re-check power & ground
circuits to SHAKER TIMER
MODULE; Suspect faulty
SHAKER TIMER MODULE
PLEASE NOTE: When finished, please reconnect all wires disconnected during testing
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
Check all connections, wiring, and fuses
F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
Remove wires from “NO” & “COM”
terminals at THERMO-SENTRY SWITCH
and connect wires with a jumper wire
NO
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 testing
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
(KOEO-Key On, Engine Off)
+ -
Is HOPPER
DOOR
CLOSED
LAMP lit?
YES NO
Test HOPPER DOOR CLOSED 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
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
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 testing
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
Key On, Engine Running (KOER)
Low engine oil pressure sensed
AUTOMATIC ENGINE SHUTDOWN OCCURS
NOTE: If key switch is turned off and machine restarted,
engine will run 2 to 3 seconds until another automatic shutdown
ONKey On, Engine Running (KOER)
Engine fault(s) detected
OFFKey On, Engine Running (KOER)
No engine faults detected
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
Troubleshooting Charts
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
6600 OVERALL HYDRAULIC DIAGRAM
(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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
HYDRAULIC FLOW METER
5.4 GPM (20 LPM) @ 2000 RPM
6.5 GPM (25 LPM) @ 2400 RPM
(Flow readings +/- 5%)
6600 07-2003
PLEASE NOTE: All specifications listed are for normal operating conditions
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
(Flow readings +/- 5%)
6600 07-20036600 07-2003
PLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
HOPPER DOOR CYLINDER
(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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditions
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
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)
6600 07-20036600 07-2003
PLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditions
6600 07-2003
42
BEFORE CONDUCTING TESTS:
* Read and Follow ALL Safety Warnings and
Precautions in Operator's Manual
MODEL
Troubleshooting Charts
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
STARTERMOTORASSEMBLY
31EA
29EA 26EA
27C
1D
3EA
34
2
8
SPEED BIT ”A”
ENGINE TEMP/CHECK
N.C. OIL PRESSURE
KEY:START
POSITIVEBATTERYCABLE
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 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
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 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
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 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
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
ACEVAP./CABPRESS.FANS
GND
HIGH
LOW
4
Part 4 of 4
6650 GAS & L.P. OVERALL ELECTRICAL DIAGRAM
6650 07-2003 47
B
KEYSWITCH
A
INST.PANEL
B
ALTERNATOR
C
D
GF
61B
STARTERSOILENOID
COIL
STARTERMOTORASSEMBLY
1D
3C
34
8
KEY:START
POSITIVEBATTERYCABLE
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 DIESEL OVERALL ELECTRICAL DIAGRAM
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
6650 DIESEL OVERALL ELECTRICAL DIAGRAM
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
6650 DIESEL OVERALL ELECTRICAL DIAGRAM
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
ACEVAP./CABPRESS.FANS
GND
HIGH
LOW
BATTERY,
B+
4
6650 DIESEL OVERALL ELECTRICAL DIAGRAM
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
(KOEO-Key On, Engine Off)
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
POSITIVE BATTERY CABLE
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
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.); Suspect
faulty STARTER MOTORWith 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)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
Re-test battery & battery terminals; Re-check
all connections & wiring; Examine engine for
excessive internal resistance (due to lack of
lubrication, mechanical failure, etc.); Suspect
faulty STARTER MOTOR
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing54
6650 Diesel Start Circuit
2
POSITIVE BATTERY CABLE
83
+ -
50
TO 6650
CONTROL
BOARD
17
19
ACC
42
42A
34
8
8A
42B
3C
13M
13BB
8B
E
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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!
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.); Suspect
faulty STARTER MOTORWith 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)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?
Re-test battery & battery terminals; Re-check
all connections & wiring; Examine engine for
excessive internal resistance (due to lack of
lubrication, mechanical failure, etc.); Suspect
faulty STARTER MOTOR
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing55
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
Is battery voltage
measured across all
power and ground
connections at ZENITH
ENGINE CONTROLLER
and 6650 CONTROL
BOARD?
YES
Re-check all connections,
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
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19; Turn key to “ON”
position (KOEO-Key On, Engine Off)
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing56
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
40A FUSE
M151 13G
GOVERNOR
CONTROLLERPIN A
PIN B
TO 6650
CONTROL
BOARD
2 3A
8BF
34
8C
13BF
13BG
13BA
3C
13M
8A
Is battery voltage measured
across all power and
ground connections at
GOVERNOR
CONTROLLER and 6650
CONTROL BOARD?
YES
Re-check all connections,
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
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19; Turn key to “ON”
position (KOEO-Key On, Engine Off)
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing57
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19; Turn key to “ON”
position (KOEO-Key On, Engine Off)
Is CHECK
ENGINE
displayed on
LCD panel?
YES NO
No faults detected by ZENITH
ENGINE CONTROLLER; Refer
to ZEEMS troubleshooting to test
ZENITH ENGINE CONTROLLER
Refer to “ZENITH ENGINE
FAULT CODES” to diagnose
engine or sensor faults
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing58
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
CHECK ENGINELCD DISPLAY PANEL
PIN 12
PIN 2626A
HIGH ENGINE
TEMP LED
M1
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19; Turn key to “ON”
position (KOEO-Key On, Engine Off)
Is CHECK
ENGINE
displayed on
LCD panel?
YES NO
No faults detected by ZENITH
ENGINE CONTROLLER; Refer
to ZEEMS troubleshooting to test
ZENITH ENGINE CONTROLLER
Refer to “ZENITH ENGINE
FAULT CODES” to diagnose
engine or sensor faults
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing59
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
CHECK ENGINELCD DISPLAY PANEL
PIN 2626A
M1
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing60
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
CHECK ENGINELCD DISPLAY PANEL
PIN 8 PIN 2527EB 27EA
LOW ENGINE OIL
PRESSURE LED
ZENITH
ENGINE
CONTROLLER
BLACKCONNECTOR
27C
13EG
OIL
PRESSURE
SWITCHA
B
C
27EC
M1
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
Is LOW OIL
PRESSURE
LED lit?
YES NO
Remove harness plug at OIL PRESSURE
SWITCH and place a jumper wire across
harness plug wires B & C
Is LOW OIL
PRESSURE
lamp lit?
YES NO
Replace OIL
PRESSURE SWITCH
Re-check all connections, wiring, and
fuses F-5 & F-11; Test Key Switch;
Suspect faulty 6650 Control Board
With engine
running, does
lamp go out?
NOYES
Verify proper oil pressure in
engine; Suspect faulty OIL
PRESSURE SWITCH
Verify proper oil pressure
in engine; System
operating correctly
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing61
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
CHECK ENGINELCD DISPLAY PANEL
PIN 2527C
M1
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
Re-check all connections, wiring, and
fuses F-1, F-5 & F-19; Test Key
Switch; Suspect faulty 6650 Control
Board
With engine
running, does
lamp go out?
YES
NO
Verify proper oil pressure in
engine; Suspect faulty OIL
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
Verify proper oil pressure
in engine; System
operating correctly
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing62
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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?
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19, have hopper in full
“DOWN” position, turn key to “ON”
position (KOEO-Key On, Engine Off)
YES
Repair or replace faulty hydraulic or
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 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing63
6650 Vacuum Restriction Warning Circuit
Check all connections, wiring, and fuses
F-1, F-5, & F-11, turn key to “ON”
position (KOEO-Key On, Engine Off)
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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?
Re-check power & ground
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 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing64
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
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
Does LOW FUEL
LED light and FUEL
GAUGE on LCD
panel deflect from
FULL to EMPTY?
YES
Re-check all connections,
wiring, and fuses F-1, F-5,
F-11 & F-19; Suspect faulty
6650 Control Board
Suspect faulty
FUEL SENDER
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
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 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing65
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
LEDNote: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
Switch; Suspect faulty 6650 Control Board
Check all connections and
wiring; Suspect faulty
LOW L.P. SWITCH
Is LOW FUEL
LED lit?YES NO
System operating
properly
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing66
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
6650 Shaker Motor Circuit
SHAKER
SWITCH
6
Check all connections, wiring, and fuses
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 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing67
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
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing68
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
Switch; Suspect faulty 6650 Control Board
Reset or suspect faulty
THERMO-SENTRY switch
YES
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
Remove wires from “NO” & “COM”
terminals at THERMO-SENTRY SWITCH
and connect wires with a jumper wire
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing69
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
voltage measured across
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
(KOEO-Key On, Engine Off)
YES
Repair or replace faulty hydraulic or
mechanical components (refer to 6650
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
Switch; Suspect faulty 6650 Control Board
NOTE: DO NOT UNPLUG connector
at ENABLE SOLENOID (SV-1) or
HOPPER DOOR SOLENOID (SV-5)
when doing voltage tests. Unplugging
connector will give false readings.Note: Typical Solenoid
Valve Coil Resistance
is 6 to 8 Ohms
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing70
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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).
Repair or replace faulty hydraulic or
mechanical components (refer to 6650
HYDRAULIC TROUBLESHOOTING); Suspect
faulty HOPPER UP or DOWN SOLENOID coil
Note: Typical Solenoid
Valve Coil Resistance
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
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
Switch; Suspect faulty 6650 Control Board
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing71
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
LEDNote: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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
Switch; Suspect faulty 6650 Control Board
Suspect faulty STALLED
MAIN BRUSH SWITCH
YES
Check all connections, wiring, and fuses
F-1, F-5, F-11 & F-19, turn key to “ON”
position (KOEO-Key On, Engine Off)
Remove wires from terminals at STALLED
MAIN BRUSH SWITCH and connect wires
with a jumper wire
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing72
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
6
MAIN BRUSH
ON SOLENOID
Is battery voltage measured
across wires at ENABLE
SOLENOID (SV-1), MAIN
BRUSH ON SOLENOID (SV-2),
and MAIN BRUSH DOWN
SOLENOID (SV-7)?
Check all connections, wiring, and fuses F-1,
F-5, F-11, F-19 & F-20; Turn key to “ON”
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
Repair or replace faulty hydraulic or
mechanical components (refer to 6650
HYDRAULIC TROUBLESHOOTING); Suspect
faulty SOLENOID coil
Re-check all power & ground connections
and fuses F-1, F-5, F-11, F-19 & F-20;
Test relay M-1; Test diode D-1; Test Key
Switch; Suspect faulty 6650 Control Board
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
Valve Coil Resistance
is 6 to 8 Ohms
NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing73
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
Note: Ignition Switch is illustrated
in the “OFF” position. Please see
Key Switch illustrations page for
various operating positions
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)?
Check all connections, wiring, and fuses F-1,
F-5, F-11, F-19 & F-20; Turn key to “ON”
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)
Repair or replace faulty hydraulic or
mechanical components (refer to 6650
HYDRAULIC TROUBLESHOOTING); Suspect
faulty SOLENOID coil
Re-check all power & ground connections
and fuses F-1, F-5, F-11, F-19 & F-20;
Test relay M-1; Test diode D-1; Test Key
Switch; Suspect faulty 6650 Control Board
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)
when doing voltage tests. Unplugging
connectors will give false readings.Note: Typical Solenoid
Valve Coil Resistance
is 6 to 8 Ohms
YES NO
6650 07-2003PLEASE NOTE: When finished, please reconnect all wires disconnected during testing74
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
HOPPER CLOSED LED ON
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
Solenoid Valves Energized:
SV-1(6 to 8 seconds), then NONE
Solenoid Valves Energized:
SV-1, SV-6A or SV-6B
Solenoid Valves Energized:
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
Solenoid Valves Energized:
SV-9
Solenoid Valves Energized:
SV-1(6 to 8 seconds), then NONE
Solenoid Valves Energized:
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)
HOPPER CLOSED LED ON
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
Solenoid Valves Energized:
NONE (W/ ONE-STEP SYSTEM OFF)
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
Solenoid Valves Energized:
SV-1(6 to 8 seconds), then NONE
Solenoid Valves Energized:
SV-1, SV-3, SV-5, SV-7, SV-8, SV-9
Solenoid Valves Energized:
SV-9 (W/ ONE-STEP SYSTEM OFF)
Solenoid Valves Energized:
NONE (W/ ONE-STEP SYSTEM OFF)
Solenoid Valves Energized:
SV-1, SV-6A or SV-6B
Solenoid Valves Energized:
NONE
Solenoid Valves Energized:
SV-1(6 to 8 seconds), then NONE
Solenoid Valves Energized:
SV-1, SV-3, SV-5, SV-7, SV-8, SV-9
Solenoid Valves Energized:
SV-1(6 to 8 seconds), then NONE
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
• Turn OFF machine
• Press and hold HOPPER OPEN and HOPPER CLOSED buttons
• START and RUN Machine
• Hold buttons for 5 seconds and release
• 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
• Turn OFF machine
• Press and hold VACUUM FAN and ENGINE SPEED buttons
• START and RUN Machine
• Hold buttons for 5 seconds and release
• 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
• Turn OFF machine
• Press and hold HOPPER UP and HOPPER DOWN buttons
• Turn key switch to “ON”, but DO NOT START the engine
• Hold buttons for 5 seconds and release
• 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
• Turn OFF machine
• Press and hold SIDE BRUSH and ENGINE SPEED buttons
• Turn key switch to “ON”, but DO NOT START the engine
• Hold buttons for 5 seconds and release
• 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
• Turn OFF machine
• START and RUN Machine
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)
Engine fault(s) detected
“CHECK ENGINE” displayed
(see MODE 5 on previous page)
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
Fuel level & hour meter reading displayedKey On, Engine Off (KOEO)
No engine faults detected
“CHECK ENGINE” displayed
(see MODE 5 on previous page)
Key On, Engine Running (KOER)
Low engine oil pressure sensed
AUTOMATIC ENGINE SHUTDOWN OCCURS
NOTE: If key switch is turned off and machine restarted,
engine will run 2 to 3 seconds until another automatic shutdown
“CHECK ENGINE” displayed
(see MODE 5 on previous page)
Key On, Engine Running (KOER)
Engine fault(s) detected
Fuel level & hour meter reading displayedKey On, Engine Running (KOER)
No engine faults detected
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
5 VDCDIGITAL - Activates
when groundedINPUT25,26,27
5 VDCDIGITAL - Activates
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
Troubleshooting Charts
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
BEFORE CONDUCTING TESTS:
DURING TESTS:
6650 07-2003
81
1 2 3 4 5 6
6650 OVERALL HYDRAULIC DIAGRAM
(Part 1 of 2)
SIDE BRUSH LIFT/LOWER
MAIN BRUSH LIFT/LOWER
HOPPER LIFT/LOWER
HOPPER DOOR OPEN/CLOSE
MAIN BRUSH
SIDE BRUSH
(OPTIONAL)
PLEASE NOTE: All specifications listed are for normal operating conditions
6650 07-200382
1 2 3 4 5 6
6650 OVERALL HYDRAULIC DIAGRAM
(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
HYDRAULIC FLOW METER
5.4 GPM (20 LPM) @ 2000 RPM
6.5 GPM (25 LPM) @ 2400 RPM
(Flow readings +/- 5%)
600 PSI(41 BAR)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
HYDRAULIC FLOW METER
5.4 GPM (20 LPM) @ 2000 RPM
6.5 GPM (25 LPM) @ 2400 RPM
(Flow readings +/- 5%)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
HYDRAULIC FLOW METER
5.4 GPM (20 LPM) @ 2000 RPM
6.5 GPM (25 LPM) @ 2400 RPM
(Flow readings +/- 5%)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
HOPPER DOOR CYLINDER
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
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
HOPPER DOOR CYLINDER
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)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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)
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)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
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)
PLEASE NOTE: All specifications listed are for normal operating conditionsPLEASE NOTE: All specifications listed are for normal operating conditions
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
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
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
Diagnostic Procedures - Continued
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
Diagnostic Procedures - Continued
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
Diagnostic Procedures - Continued
*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
Diagnostic Procedures - Continued
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
SparkPresent at Spark
Plugs?
NO Refer to Section 3,Engine Electrical
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)
Diagnostic Procedures - 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
Diagnostic Procedures - Continued
Y E S
SparkPresent at Spark
Plugs?
NO Refer to Section 3,Engine Electrical
YES
199
Engine Controls
Engine Runs, Low Power, Lean or Misfires — Gasoline
Diagnostic Procedures - Continued
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
Diagnostic Procedures - Continued
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
Diagnostic Procedures - Continued
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
Diagnostic Procedures - Continued
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.
Diagnostic Procedures - Continued
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
Diagnostic Procedures - Continued
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
2
212
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.
3
213
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.
4
214
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.
5
215
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.
6
216
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.
7
217
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.
8
218
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.
9
219
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.
10
220
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.
11
221
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.
12
222
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.
13
223
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.
14
224
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).
15
225
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
226
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
17
227
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.
228
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
229
Pow
er S
olut
ions
, Inc
. G
M P
ower
train
Indu
stri
al E
ngin
es
Fi
lter
Cha
rt
E
ngin
e
1.
6L3.
0L4.
3L5.
7L7.
4L/7
.4L
T8.
1LO
il Fi
lter
9463
2619
P-
25 o
r Eq
uiva
lent
PF
-47/
PF-5
2 or
Eq
uiva
lent
PF
-121
8 Eq
uiva
lent
PF
-121
8 or
Eq
uiva
lent
PF
-454
or
Equi
vale
nt
Fuel
Filt
er
(Car
bure
ted)
3250
0020
(101
021)
32
5000
20
(101
021)
Fu
el F
ilter
(P
SI T
BI
Coa
rse)
3250
0111
3250
0111
Fuel
Filt
er
(PSI
TB
I Fi
ne)
3250
0058
3250
0058
Fuel
Filt
er
Zeni
th
Z.E
.E.M
.S
Gas
olin
e C
282-
224
LPG
C
282-
5
3250
0292
32
5002
92
Air
Filt
er
Prim
ary
(PSI
Pow
er
Uni
t)
P822
768
P822
8889
Air
Filt
er
Safe
ty
(PSI
Pow
er
Uni
t)
P822
769
P829
333
Rev
ised
05/
31/0
0
230
Pow
er S
olut
ions
, Inc
. G
M P
ower
train
Indu
stri
al E
ngin
es
Fu
el S
yste
m C
hart
Eng
ine
1.
6L
3.
0L
4.3L
5.
7L
7.4L
/T
8.1L
Zeni
th C
arbu
reto
r (01
3448
) Man
ual C
hoke
x
Ze
nith
Car
bure
tor (
0150
17) E
lect
ric C
hoke
x
Ze
nith
Car
bure
tor (
0150
52) u
sed
w/D
ual F
uel S
yste
m
x
x
Hol
ley
Car
bure
tor (
0-74
48) E
lect
ric C
hoke
x
H
olle
y C
arbu
reto
r(0-
8201
0) E
lect
ric C
hoke
x
Im
pco
LPG
Fue
l Sys
tem
x x
x
xN
olff
LPG
Fue
l Sys
tem
x
x x
x
xx
PSI F
uel I
njec
tion
(Gas
olin
e)
x x
x
PSI F
uel I
njec
tion/
LPG
Mix
er (D
ual F
uel)
x x
x
Impc
o N
atur
al G
as M
ixer
x x
x
xN
olff
Nat
ural
Gas
Mix
er
x x
x
xx
xZe
nith
Z.E
.E.M
.S F
uel I
njec
tion
x x
x
G
over
nor
Cha
rt
E
ngin
e 1.
6L
3.
0L4.
3L5.
7L7.
4L/T
8.1L
Hoo
f Mec
hani
cal (
Bel
t Driv
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No
Long
er A
vaila
ble)
x
H
oof V
eloc
ity G
over
nor
x(
NLA
) x(
NLA
) x
x
Ais
an V
eloc
ity G
over
nor
x
x
Bar
ber C
olm
an E
lect
roni
c
x x
G
over
nors
Am
eric
a
x
xx
xB
arbe
r Col
man
Pow
er F
low
, PSI
EC
U
x
x x
x
Zeni
th Z
.E.E
.M.S
. Fu
el In
ject
ion
Inte
gral
In
tegr
al
Inte
gral
Woo
dwar
d
xR
evis
ed 0
6/05
/01
231
GE
NE
RA
L S
PEC
IFIC
AT
ION
S Po
wer
Sol
utio
ns, I
nc.
GM
Pow
ertra
in In
dust
rial
Eng
ines
E
ngin
e 1.
6L
3.0L
4.
3L
5.7L
7.
4L/7
.4L
Tur
bo
8.1L
/8.1
L T
urbo
T
ype
1.6-
2V
3.0L
L4
4.3L
V-6
5.
7L V
-8 G
EN-1
E 7.
4L V
-8
8.1L
V-8
D
ispl
acem
ent
cc
(c.i.
d.)
1600
(98)
29
66 (1
81)
4294
(26
2)
5735
(35
0)
7441
(45
4)
8127
(49
6)
Com
pres
sion
Rat
io
9.4:
1
9.2:
19.
4:1
9.4:
18.
9:1
9.1:
1V
alve
Con
figur
atio
n O
verh
ead
Cam
Pu
sh R
od A
ctua
ted
Ove
rhea
d V
alve
Pu
sh R
od A
ctua
ted
Ove
rhea
d V
alve
Pu
sh R
od A
ctua
ted
Ove
rhea
d V
alve
Pu
sh R
od A
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ted
Ove
rhea
d C
ante
d V
alve
Pu
sh R
od A
ctua
ted
Ove
rhea
d V
alve
V
alve
Lift
ers
Hyd
raul
ic
Flat
Fol
low
er
Hyd
raul
ic R
olle
r H
ydra
ulic
Rol
ler
Hyd
raul
ic R
olle
r
Hyd
raul
ic R
olle
rB
ore
x St
roke
mm
(inc
hes)
79
.0x8
1.5
(3.1
1x3.
21)
101.
60x9
1.44
(4.0
0x3.
60)
101.
60x8
8.39
(4.0
0x3.
48)
101.
60x8
8.39
(4.0
0x3.
48)
107.
95x1
01.6
0 (4
.25x
4.00
) 10
7.95
x111
(4.2
5x4.
37)
Mai
n B
eari
ng C
aps
2 B
olt
2 B
olt
2 B
olt
2 B
olt
4 B
olt
4 B
olt
Bal
ance
Met
hod
Exte
rnal
Ex
tern
alIn
tern
al B
alan
ce S
haft
Exte
rnal
Exte
rnal
Exte
rnal
Inta
ke M
anifo
ld
TBI
TBI,
Car
bure
tor,
Mix
er
TBI,
Car
bure
tor,
Mix
er
Mix
er
Mix
er
Mix
er
Firi
ng O
rder
1-
3-4-
2
1-3-
4-2
1-6-
5-4-
3-2
1-8-
4-3-
6-5-
7-2
1-8-
4-3-
6-5-
7-2
1-8-
7-2-
6-5-
4-3
Oil
Cap
acity
W
ith O
il Fi
lter
3.4
qts.
(3.2
L)
3.7
qts.
(3.5
L)
4 qt
s. (3
.8L)
5
qts.
(4.7
L)
4.5
qts.
(4.3
L)
5 qt
s. (4
.7L)
4.
5 qt
s. (4
.3L)
5
qts.
(4.7
L)
8 qt
s. (7
.6L)
9
qts.
(8.5
L)
8 qt
s. (7
.6L)
9
qts (
8.5L
) O
il Fi
lter
PF
-25
or E
quiv
alen
t PF
-47/
PF-5
2 or
Equ
ival
ent
PF-1
218
or E
quiv
alen
t PF
-121
8 or
Equ
ival
ent
PF-4
54 o
r Equ
ival
ent
Min
imum
Oil
Pres
sure
(Hot
) 21
psi
@ id
le
6 ps
i @ 1
000
rpm
18
psi
@ 2
000
rpm
6
psi @
1000
rpm
18
psi
@ 2
000
rpm
6
psi @
100
0 rp
m
18 p
si @
200
0 rp
m
6 ps
i @ 1
000
rpm
18
psi
@ 2
000
rpm
5
psi @
100
0 rp
m
15 p
si @
200
0 rp
m
Coo
lant
Cap
acity
(Eng
ine)
3.
5 qt
s. 4
qts.
(3.7
8L)
7.75
qts
. (7.
3L)
8.1
qts (
7.8L
) 14
.5 q
ts (1
3.7L
) 14
.5 q
ts (1
3.7L
) C
oola
nt C
apac
ity (W
/PSI
Rad
) 10
qts
12
qts
. (11
.4L)
17
qts
. (16
L)
17.5
qts
. (16
.6L)
28
(26.
5L)
28 q
ts (2
6.5L
) Fu
el T
ype
Gas
olin
e, L
PG
Gas
olin
e, L
PG, N
G
Gas
olin
e, L
PG, N
G
LPG
, NG
LP
G, N
G
LPG
, NG
E
ngin
e R
otat
ion
(Fly
whe
el E
nd)
CC
W
C
CW
CC
WC
CW
CC
WC
CW
Igni
tion
Syst
em
Dis
tribu
tor-
less
El
ectro
nic
(EC
U)
Solid
Sta
te
Dis
tribu
tor
Solid
Sta
te
Dis
tribu
tor
Solid
Sta
te
Dis
tribu
tor
Solid
Sta
te
Dis
tribu
tor
Dis
tribu
tor-
less
El
ectro
nic
ECU
Ig
nitio
n T
imin
g (D
egre
es B
TD
C)
Gas
olin
e (C
arb)
G
asol
ine
(TB
I)
LPG
N
G
Dua
l Fue
l
D
IS
No
Adj
ustm
ent
0 0 10
(4
Euro
pe)
10
0
0 0 10
(4
Eur
ope)
10
0
0 0 10
(4
Eur
ope)
10
0
0 0 10
10
0
D
IS
No
Adj
ustm
ent
Igni
tion
Tim
ing
(Deg
rees
BT
DC
) G
ener
ator
s 180
0 R
PM
LPG
N
G
D
IS
No
Adj
ustm
ent
26
36
26
36
26
36
26
36
26
30
Spar
k Pl
ugs
AC
Del
co 9
3206
675
AC
Del
co R
45TS
A
C D
elco
R42
LTS
AC
Del
co R
42LT
S A
C D
elco
R42
LTS
AC
Del
co R
42LT
S Sp
ark
Plug
Gap
TBI
LPG
N
G
Dua
l Fue
l
.8
mm
-.9m
m
all
.0
45
all
.0
35
.035
.0
35
.035
.0
35
.035
.0
35
.035
.0
35
.035
.0
35
.0
30/.0
25T
.030
/.025
T .0
30/.0
25T
Val
ve C
lear
ance
(Las
h)
Inta
ke
Exha
ust
N
o A
djus
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t O
HC
Eng
ine
½
to 1
Tur
n D
own
From
0
Lash
N
et L
ash
No
Adj
ustm
ent
1
Turn
Dow
n Fr
om
0 La
sh
N
et L
ash
No
Adj
ustm
ent
N
et L
ash
No
Adj
ustm
ent
Man
ufac
ture
d B
razi
l To
luca
, Mex
ico
Tona
wan
da, N
Y
Tolu
ca, M
exic
o To
naw
anda
, NY
To
naw
anda
, NY
R
evis
ed 0
2/09
/02
232
3.
0L E
ngin
e Sp
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
Fasteners and Torque Control (10---90)
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
Low orMediumCarbonSteel
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
Fasteners and Torque Control (10---90)
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
Fasteners and Torque Control (1---01)
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
Low orMediumCarbonSteel
4.8 PanHead
MachineScrews
Low orMediumCarbonSteel
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
Fasteners and Torque Control (10---90)
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
Fasteners and Torque Control (10---90)
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
Fasteners and Torque Control (10---90)
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
PLUS torque to align for pin
6000 Series 1.75 dia. 1.25--18 UNEF 475 ft lb dry2.187 Hex 375 ft lb lubricated
PLUS torque to align for pin
241
Fasteners and Torque Control (10---90)
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
Fasteners and Torque Control (10---90)
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
Fasteners and Torque Control (10---90)
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