Zamboni 525 - Engine Wire Harness Repair

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Engine Wire Harness Repair

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Manufacturer's Warranty3
Tank Capacities17
Operation19
Recommended Maintenance Schedule50
Malfunction Indicator Light (MIL)58
Troubleshooting Guide93
Parts List98
Table of Contents191
General Information192
Maintenance195
Cooling System196
LPG Fuel System203
Air Fuel Mixer206
Three Way Catalytic Converter207
Engine Control Module207
Coolant Temperature Sensor209
Oil Pressure Sender209
Tmap Sensor209
GASOLINE Fuel System210
Fuel Injector Rail213
Fuel Injectors215
Fuel System Diagnosis216
Test Description218
Hesitation, Sag, Stumble227
Electrical Section232
Diagnostic Scan Tool239
Password Login244
Malfunction Indicator Lamp (Mil)257
Diagnostic Trouble Codes (Dtc)257
Intermittent Problems260
Engine Wire Harness Repair261
Connectors and Terminals262
Diagnostic Trouble Codes (Dtcs)265
Circuit Description286
Diagnostic Aids385
Overview550
Warranty550
Safety Precautions550
Unintended Machine Movement550
Flammable Cleaning Solvents550
Fluid under Pressure550
Personal Safety550
Hazardous Material550
Symbols Used in Sauer-Danfoss Literature551
General Description552
The System Circuit552
Design553
Fluid Specifications554
Pressure555
Temperature and Viscosity556
Hydraulic Fluid556
Pressure Measurements557
Port Locations and Gauge Installation557
Fan Speed Not Controlled by Current to Coil560
Fan Does Not Turn561
Fan too Slow at High Engine Rpm562
Improper Modulation of Control Module562
System Noise563
Hydraulic System Operating Hot563
Leaking Motor Shaft Seal563
Overview578
Warranty578
General Instructions578
Remove the Unit578
Keep It Clean578
Replace All O-Rings and Gaskets578
Safety Precautions579
Unintended Machine Movement579
Flammable Cleaning Solvents579
Fluid under Pressure579
Personal Safety579
Hazardous Material579
Symbols Used in Danfoss Literature580
Design580
The System Circuit581
The Basic Closed Circuit581
Case Drain and Heat Exchanger581
Pump Schematic582
Fluid and Filter Maintenance583
Fluid and Filter Recommendations583
Hazardous Material583
Initial Startup Procedures584
General584
Start-Up Procedure584
Required Tools and Pressure Measurements585
Required Tools585
Port Locations and Gauge Installation585
Troubleshooting587
Overview587
Safety Precautions587
System Noise or Vibration587
System Operating Hot587
System will Not Operate in One Direction588
System will Not Operate in Either Direction588
Neutral Difficult or Impossible to Find589
System Response Is Sluggish589
Electrical Troubleshooting590
Adjustments591
Standard Procedures, Inspections, and Adjustments591
Warranty591
Pump Adjustment591
Charge Pressure Relief Valve591
Engaging the Bypass Function592
System Check/Relief (SCR) Valves593
Displacement Limiter Adjustment594
Swashplate Neutral Adjustment595
Measured Data595
Pump Setup595
Manual Displacement Control Neutral-Return Bracket Adjustment596
Measured Data596
Procedure596
Electric Displacement Control/Hydraulic Displacement Control Neutral Adjustment597
Measured Data597
Procedure597
HC EDC Control598
Control Neutral Adjustment598
Minor Repair601
Standard Procedures, Removing the Pump601
Displacement Limiter601
Pressure Filtration Adapter602
Charge Pump603
Shaft Seal, Roller Bearing and Shaft Replacement605
SCR Valves606
Charge Pressure Relief Valve607
Bypass Valve608
Manual Displacement Control609
Electronic Displacement Control/Hydraulic Displacement Control610
MDC Orifice Repair611
EDC/HDC Orifice Repair612
HC EDC Control Repair613
Torque Chart616
Fastener Size and Torque Chart616
Plug Size and Torque Chart616
Technical Information622
Specifications626
Design Specifications626
Technical Specifications626
Operating Parameters626
Options627
Fluid Specifications627
General Information628
M46 Pumps628
M46 Variable Pumps628
System Circuit Diagram629
Schematic Diagram629
Features and Options630
Features630
Options630
Operating Parameters631
Fluids631
Viscosity631
Temperature631
Charge Pressure631
Control Pressure632
Case Pressure632
System Pressure632
Speed Ratings632
Inlet Pressure633
System Design Parameters634
Sizing Equations634
Filtration634
Suction Filtration635
Charge Pressure Filtration635
Redundant Braking System Requirement636
Loop Flushing636
Reservoir636
Case Drain Usage for Tandem Pumps637
Bearing Life and External Shaft Loading637
Hydraulic Unit Life638
Mounting Flange Loads638
Shaft Torques640
Shaft Selection640
Shaft Torque and Spline Lubrication640
Shaft Torque for Tapered Shafts640
Model Code - Single Pumps641
Single Pumps641
Model Code - Tandem Pumps645
Tandem Pumps645
Options649
Shaft Options649
Single Pumps649
Tandem Pumps651
Charge Pump652
Charge Pump Output Flow653
Charge Pump Power Requirements653
Charge Relief Valve653
High Pressure Relief Valve (HPRV) and Charge Check654
Bypass Function655
Displacement Limiters655
Auxiliary Mounting Pads and Auxiliary Pumps656
Manual Displacement Control (MDC) - Options AB, AC, AK, AW, and GB657
Hydraulic Displacement - Options BA, BB and BC660
Electrical Displacement Control- Options CE, CG, CM, and CN662
High Current Electric Displacement Control - Options HA (12Vdc) and HB (24Vdc)665
Control Signal Requirements667
Connector667
Response Times668
Manual Override (MOR)668
Three-Position Electrical Control - Options da and DB669
Port Locations672
Single Pump672
Tandem Pump673
Installation Drawings - Single Pump Dimensions674
Auxiliary Mounting Flanges674
Pump, Filtration/Charge Pump Options, MDC, Displacement Limiter675
Installation Drawings - Tandem Pump Dimensions676
Auxiliary Mounting Flange676
Rear Mounting Boss677
Pumps, Filtration/Charge Pump Options, MDC, Displacement Limiters678
Control Options - Installation Drawings679
Control Options, AC, AK679
Option GB679
Options AB, AW680
HC EDC Control681
Hydraulic Displacement Control (HDC)682
Option CE683
Options CG, CN683
Options DA, DB684
Reference Literature685
Literature685
Specifications694
Design Specifications694
Technical Specifications694
Operating Parameters694
Options695
Fluid Specifications695
General Information696
M46 Pumps696
M46 Variable Pumps696
System Circuit Diagram697
Schematic Diagram697
Features and Options698
Features698
Options698
Operating Parameters699
Fluids699
Viscosity699
Temperature699
Charge Pressure699
Control Pressure700
Case Pressure700
System Pressure700
Speed Ratings700
Inlet Pressure701
System Design Parameters702
Sizing Equations702
Filtration702
Suction Filtration703
Charge Pressure Filtration703
Redundant Braking System Requirement704
Loop Flushing704
Reservoir704
Case Drain Usage for Tandem Pumps705
Bearing Life and External Shaft Loading705
Hydraulic Unit Life706
Mounting Flange Loads706
Shaft Torques708
Shaft Selection708
Shaft Torque and Spline Lubrication708
Shaft Torque for Tapered Shafts708
Model Code - Single Pumps709
Single Pumps709
Model Code - Tandem Pumps713
Tandem Pumps713
Options717
Shaft Options717
Single Pumps717
Tandem Pumps719
Charge Pump720
Charge Pump Output Flow721
Charge Pump Power Requirements721
Charge Relief Valve721
High Pressure Relief Valve (HPRV) and Charge Check722
Bypass Function723
Displacement Limiters723
Auxiliary Mounting Pads and Auxiliary Pumps724
Manual Displacement Control (MDC) - Options AB, AC, AK, AW, and GB725
Hydraulic Displacement - Options BA, BB and BC728
Electrical Displacement Control- Options CE, CG, CM, and CN730
High Current Electric Displacement Control - Options HA (12Vdc) and HB (24Vdc)733
Control Signal Requirements735
Connector735
Response Times736
Manual Override (MOR)736
Three-Position Electrical Control - Options da and DB737
Port Locations740
Single Pump740
Tandem Pump741
Installation Drawings - Single Pump Dimensions742
Auxiliary Mounting Flanges742
Pump, Filtration/Charge Pump Options, MDC, Displacement Limiter743
Installation Drawings - Tandem Pump Dimensions744
Auxiliary Mounting Flange744
Rear Mounting Boss745
Pumps, Filtration/Charge Pump Options, MDC, Displacement Limiters746
Control Options - Installation Drawings747
Control Options, AC, AK747
Option GB747
Options AB, AW748
HC EDC Control749
Hydraulic Displacement Control (HDC)750
Option CE751
Options CG, CN751
Options DA, DB752
Reference Literature753
Literature753
Water Pump758
Important Reminders762
Building Ventilation765
General Safety Practices768
Important Safety Notice768
Warning Signs and Labels769
Fire or Explosion Prevention771
Safe Operation775
Mounting and Dismounting775

Zamboni 525 - Engine Wire Harness Repair

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