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Advance acoustic Warrior AXP Service Manual Download Page 49

FORM NO. 56043103 - Warrior

™

 ST, Warrior

™

 AXP - 

47

WHEEL DRIVE SYSTEM
DRIVE WHEEL REMOVAL

 WARNING!

Disconnect the battery pack connector before servicing machine.

 WARNING!

Never work under machine without safety stands or blocking to support the machine.

Remove the squeegee and place wood blocking in front and rear of the opposite drive wheel that you are removing to prevent the machine from rolling.

1 

Using a scissors jack, raise the machine until the wheel is off the ground. 

2 

See Figure 6

 for jack placement.

Remove the (3) Locknuts 

3 

(E)

 and Drive Wheel 

(F)

.

Reinstall in reverse order.

4 

FIGURE 6

Summary of Contents for Warrior AXP

Page 1: ...56043103 Warrior ST Warrior AXP Service Manual Advance Models 56315036 28D 56315037 32D 56315038 28C 56315039 32C C 56315040 X28D C 56315041 X32D C 56315538 28D C 56315539 32D C 56315540 28C C 563155...

Page 2: ......

Page 3: ...MAINTENANCE OF VACUUM MOTOR INLET SCREEN 34 VACUUM MOTOR REMOVAL 35 RECOVERY TANK REMOVAL 36 SQUEEGEE SYSTEM 37 40 SQUEEGEE LIFT LINKAGE ADJUSTMENT 37 SERVICING THE SQUEEGEE 38 ADJUSTING THE SQUEEGEE...

Page 4: ...the space below to note the Model Number and Serial Number of your machine for future reference MODEL NUMBER ______________________________________________ SERIAL NUMBER _____________________________...

Page 5: ...t Do not clean this machine with a pressure washer Do not operate this machine on ramps or inclines of more than a 2 percent gradient Only use the brushes provided with the appliance or those specifie...

Page 6: ...hr 21 120 ft hr 1 717 m hr 1 962 m hr 1 717 m hr 1 962 m hr Scrub Head Size Type 2 14 in 36 cm brushes or pad holders 2 16 in 41 cm brushes or pad holders 2 27 in 69 cm brushes 2 31 in 79 cm brushes S...

Page 7: ...FORM NO 56043103 Warrior ST Warrior AXP 5 TECHNICAL SPECIFICATIONS...

Page 8: ...rbon brushes check every 500 hours or once a year WARNING Turn the key switch off and disconnect the batteries before servicing the machine Check vacuum motor carbon brushes Qty 2 once a year or after...

Page 9: ...t Work 10 Scrub Brushes check for wear and rotate D M W 11 Scrub Brush Motor s check for carbon brush wear 500 Hours B C W 12 Scrub Brush Motor s check gearboxes disc deck B D L 13 Brush Drive Plate R...

Page 10: ...xt Note Refer to the service manual for detailed explanations of each item illustrated on the next 4 pages 9 Scrub Deck Bumper 10 Drive Wheel 11 Solution Filter 12 Solution Shutoff Valve 13 Squeegee A...

Page 11: ...Circuit Circuit Breaker 22 Squeegee Blade Tension Strap 23 Squeegee Blade Latch 24 Squeegee Blade Alignment Pins 25 Squeegee Mount Thumb Nut 26 Squeegee Adjustment Knob 27 Recovery Tank Drain Hose 28...

Page 12: ...Meter D4 AXP Indicator D5 Battery Indicator D6 Scrub Pressure Indicator D7 Recovery Tank FULL Indicator D8 Battery Low Indicator E Wand Switch Dealer Installed Option F Detergent System AXP models on...

Page 13: ...tch Dealer Installed Option G Extended Scrub System Dealer Installed Option H Scrub OFF I Scrub ON Extreme Scrub Heavy Scrub Regular Scrub Extreme Scrub Heavy Scrub Regular Scrub D Display Panel D1 So...

Page 14: ...ime the panel display will show the correct changed scrub pressure setting Wand Switch E This switch is used when an external vacuum scrub wand is used Pressing this switch will turn the vacuum on con...

Page 15: ...e is moving in either direction This indicator will be off if the scrub system has been turned OFF Extreme Scrub ON Indicators K L Both of these indicators will be yellow if the scrub system is enable...

Page 16: ...volume demand to the scrub brushes AXP only See Electrical Diagram Figure 2 The electrical circuit that turns on energizes the solenoid coil and water pump is activated through the A1 control panel s...

Page 17: ...pin 6 Red Blk wire to the A1 control board Red Blk wire terminal J1 5 Note The A2 speed controls brake output pin 6 occurs whenever the R1 direction throttle pot is moved off its neutral setting A neg...

Page 18: ...m 6 sec 0 sec Note Refer to the Appendix Main Controller I O Tables for electrical test values SOLUTION SYSTEM MAINTENANCE Solution Tank See Figure 1 Empty the solution tank weekly remove the solutio...

Page 19: ...LECTRICAL Possible Symptoms 1 No solution flow while in the scrub auto solution mode 2 Solution Pump will not operate SYMPTOM ONE Note Activate the Service Test Mode Program See optional program secti...

Page 20: ...rrior AXP SOLUTION SYSTEM TROUBLESHOOTING GUIDE ELECTRICAL CONTINUED SYMPTOM TWO Note Activate the Service Test Mode Program See optional program section for instructions All testing will be performed...

Page 21: ...amps 5 D that secure the hoses to the valve body Separate pry the solution outlet hose off from its valve body barbed fitting 6 Remove the 2 Hex Screws 7 E that secure the valve to the Mount Bracket F...

Page 22: ...Separate pry the solution outlet hose L off from its valve body barbed fitting 6 Remove the 2 Hex Screws M that secure the valve to the underside of the chassis then pull the valve body to the front s...

Page 23: ...URE 5 SOLUTION PUMP REMOVAL AXP Drain the solution tank or turn the solution filter ball valve to the off position to prevent solution loss 1 See Figure 5 2 Loosen the 2 Hose Clamps V and pry off inle...

Page 24: ...the A1 board s terminal J1 14 Vio Blk wire completes the K1 solenoid coil circuit Pos Neg and pulls in the load contact making the brush motors run The Neg M2 and M3 load voltage is supplied from the...

Page 25: ...s de energized the neg voltage from the K3 relay is connected to the Brush Motors Positive Wht wires through a Red Wht jumper wire connected to the K1 N C With two battery ground inputs at the brush m...

Page 26: ...uator motor is not run while it is disconnected from the deck or chassis mounts This precaution will prevent the actuator drive nut from being misadjusted moved out of its set specification 9 To reins...

Page 27: ...FORM NO 56043103 Warrior ST Warrior AXP 25 FIGURE 2 SCRUB SYSTEM...

Page 28: ...3 J Hex Screws from the flexible coupler that attaches the brush holder to the drive Hub K of the Motor Gearbox Assembly you want to remove Remove the 1 Hex Screw 5 L that secures the Hub K to the out...

Page 29: ...FORM NO 56043103 Warrior ST Warrior AXP 27 NOTES...

Page 30: ...s match up Aligned SCRUB BRUSH SYSTEM MAINTENANCE CYLINDRICAL The scrubbing system must be serviced at regular intervals to maintain good scrubbing performance Follow the maintenance steps listed belo...

Page 31: ...FORM NO 56043103 Warrior ST Warrior AXP 29 FIGURE 4 SCRUB SYSTEM...

Page 32: ...to lift the wastewater off of the floor The air and wastewater move through the squeegee hose at high speed until it reaches the recovery tank There the air slows down because of the increased volume...

Page 33: ...board s terminal J1 12 Blk Yel wire to complete the K2 solenoid coil circuit Pos Neg and pulls in the solenoid load contact making the vacuum motor run Note Earlier machines used a normally closed re...

Page 34: ...ealing and not damaged Make sure that the recovery tank drain hose cap seals airtight TROUBLESHOOTING GUIDE If water flows around the ends of the squeegee tool instead of being pulled into the tool th...

Page 35: ...full Dirty extended scrub system switches can prevent the optional extended scrub system from functioning properly If daily rinsing of the recovery tank does not suffice to keep the switches clean yo...

Page 36: ...INLET SCREEN The Vacuum Motor Inlet Screen 4 should be cleaned on a daily basis DO NOT run water down the screen in an attempt to clean it If you do this you will be running water directly into the v...

Page 37: ...igure 5 4 Remove the vacuum motor Shroud Cover A secured to the bottom of the recovery tank qty 4 screws Loosen the exhaust hose clamp and remove Hose 5 B from the vacuum motor discharge tube and comp...

Page 38: ...onnect any other options installed on the tank 3 See Figure 6 Remove the Screw F and Tank Cable G and allow the tank to swing down to the side of the battery compartment box 4 Remove the Recovery Tank...

Page 39: ...able To adjust Lower the squeegee assembly to the floor 1 See Figure 1 2 The Squeegee Mount Bracket has 3 Mount Holes A for changing the lift cable length Remove the Hardware Items 3 B from the Squeeg...

Page 40: ...Replace the Front Squeegee Blade 1 Raise the squeegee tool off the floor loosen the 2 Thumb Nuts 25 disconnect the Recovery Hose 19 and remove the Squeegee Assembly 15 from the mount 2 Remove both rea...

Page 41: ...L 1 See Figure 3 Disconnect Squeegee Hose 19 and remove the Squeegee Assembly 13 from the machine 2 Lower the Squeegee Lever 17 and disconnect the Squeegee Lift Cable C from the squeegee mount bracket...

Page 42: ...squeegee assembly and have the scrub deck in the up stored position with the scrub brushes installed 2 See Figure 4 Place Wood Blocking F in front of the drive wheels to prevent the machine from rolli...

Page 43: ...ts operational powering it up The F3 circuit breaker 30 Amp supplies the positive load circuit voltage input to the B controller terminal Wht Yel wire The black wire from the battery negative standoff...

Page 44: ...BLU BLK BRN WHT BLK FOR REV REVERSE J1 5 A2 B B SPEED CONTROLLER M1 M2 PIN 3 POT HI PIN 4 POT WIPER PIN 13 POT LO PIN 5 KSI PIN 16 REV PIN 6 BRAKE 1228 FOR 36V STATUS PIN 9 STATUS PIN 18 SPEED LIMIT P...

Page 45: ...ry output to main controller E1 to turn on activate all auto scrub functions 7 Open not used 8 Open not used 9 Orn Blu Status Fault Speed controller fault output to main control panel fault indicator...

Page 46: ...e Potentiometer R1 replace Wheel drive in one direction only loss of either forward or reverse Test the Fwd Rev R1 wiring outputs pins 3 4 13 at the speed control for an open circuit Repair wiring or...

Page 47: ...under machine without safety stands or blocking to support the machine Drain both the solution and recovery tanks and remove the squeegee 1 Remove the Scrub deck by following the Scrub Deck Removal in...

Page 48: ...om this location until the drive wheels are approximately 1 off the ground Remove the 6 Locknuts 5 A and then remove the 2 Drive Wheels B from the transaxle Disconnect the drive motor wiring connector...

Page 49: ...ut safety stands or blocking to support the machine Remove the squeegee and place wood blocking in front and rear of the opposite drive wheel that you are removing to prevent the machine from rolling...

Page 50: ...nd outside rear 1 low Fwd reading 2 420 ohms to 4 700 ohms Rev 2 420 ohms to 230 ohms 5 Testing Summary The above tests are to show the increase and decrease of the pot through its working range If yo...

Page 51: ...ote The potentiometer pot doesn t have to be removed from the drive paddle cover to test Test Procedure FIGURE 8 FIGURE 9 1 See Figure 7 Remove the front drive paddle Cover G from the rear housing H h...

Page 52: ...en gas from overcharging must be allowed to escape When Servicing Batteries Remove all jewelry Do not smoke Wear safety glasses rubber gloves and a rubber apron Work in a well ventilated area Do not a...

Page 53: ...y pack must increase to a 38 6 volt minimum DESCRIPTION OF THE BATTERY CONDITION INDICATORS The Battery Condition Indicator will give an indication of the state of charge of the batteries 5 vertical b...

Page 54: ...ten the vent caps Wash the tops of the batteries with a solution of baking soda and water 2 tablespoons of baking soda to 1 liter of water CHARGING GEL VRLA BATTERIES AXP Charge the batteries each tim...

Page 55: ...all battery caps are vented so there s no need to loosen or remove them for charging Keep the Batteries Clean Monthly Use a damp cloth to wipe dirt from the top of the batteries Battery terminals mus...

Page 56: ...B as shown with the nut pin pocket away from the motor Then finish assembly of remaining parts long compression spring Spring Housing D and mounting hardware 2 Hold onto the spring housing assembly a...

Page 57: ...FORM NO 56043103 Warrior ST Warrior AXP 55 FIGURE 4...

Page 58: ...bvious problems such as broken wires or loose connections 2 Connect the programmer put it in diagnostic mode and read the displayed fault information In this example the display shows No Faults Presen...

Page 59: ...FORM NO 56043103 Warrior ST Warrior AXP 57 FIGURE 5 ELECTRICAL SYSTEM revised 5 08 AXP MODELS...

Page 60: ...h Pedal Disable fault 1 Improper sequence of throttle and KSI push or inhibit inputs 2 Misadjusted throttle pot 4 1 0000 O current sense fault 1 Short in motor or in motor wiring 2 Controller failure...

Page 61: ...ycle the key switch to clear the fault code 4 Move the drive paddle to operate the throttle The motor should begin to turn in the selected direction If it does not verify the wiring to the controller...

Page 62: ...ay an error code on the display panel or store it in the main control board s recall memory mode The error code s are used to help the serviceperson determine the fault and to quickly guide in repairi...

Page 63: ...motor bearings 4 Check for short circuit in vacuum motor or wiring Repair or replace 5 Check for an open in the small ORG current sense wire 08 E 0 8 Solenoid Bank Coil Circuit Overload Brush Motor S...

Page 64: ...speed control fault code with a sequence of blinks If SCS Green Light does not display follow the troubleshooting procedure below Disconnect the Orn Blu wire from the speed controller and main control...

Page 65: ...FORM NO 56043103 Warrior ST Warrior AXP 63 FIGURE 6 ELECTRICAL SYSTEM revised 5 08 AXP Models...

Page 66: ...current sensed Brief On Green Flash Brush motor output is off and brush motor current is being sensed abnormal condition Check for voltage at the Wht wire on K1 contactor to battery ground If any volt...

Page 67: ...Note the actuator can only move in this situation if it is not at its down limit When the output is in state 4 the actuator output is turned on The scrub pressure decrease indicator should be green or...

Page 68: ...ution solenoid contactor coil overload has occurred Extended Scrub Switch G This switch is used to toggle the state of the recycle pump and recycle valve if the machine is so equipped Pressing and rel...

Page 69: ...andard cutout level factory default select S or 30 96V For the alternate cutout level select A or 32 58V 7 To save the new setting press the scrub off switch The scrub off indicator will turn green On...

Page 70: ...d with a 28 disc deck Select cylindrical icon with 28 if the machine is equipped with a 28 cylindrical deck Select disc icon with 32 if the machine is equipped with a 32 disc deck Select cylindrical i...

Page 71: ...itches until scrub off and chemical indicators turn green 4 Release both switches 5 The display will display the revision level letter of the control unit Chemical indicator will blink in revision dis...

Page 72: ...will save the new setting and display key switch icon on display 9 Turn the main power key switch to the off position 10 The new settings will be saved and will remain in effect until they are change...

Page 73: ...crub pressure setting 1 3 the scrub off indicator will turn red and the heavy scrub on indicator will turn yellow 6 Press the scrub on switch to select new heavy scrub pressure 7 Press the scrub off s...

Page 74: ...e of Recovery Tank Float Switches In the normally closed configuration the float remains horizontal when the tank is empty then floats up when the tank is full All current machines use the normally op...

Page 75: ...power key switch to the off position 2 Press and hold the recycle switch 3 While holding the recycle switch turn the main key switch to the on position 4 Continue to hold the recycle switch until the...

Page 76: ...74 FORM NO 56043103 Warrior ST Warrior AXP THIS PAGE IS INTENTIONALLY BLANK...

Page 77: ...5 Motor Brush Actuator M7 Pump Solution AXP M8 Pump Recycle Optional M9 Detergent Pump Optional AXP M10 Side Broom Motor Left Not Shown Optional Cylindrical models only M11 Side Broom Motor Right Not...

Page 78: ...TUATOR 1 BRUSH ACTUATOR 2 B 3 B 4 B 2 A1 CONTROL BOARD J1 5 J2 5 J2 10 J1 6 J1 2 J1 1 J2 4 J1 7 J1 8 J2 12 J2 8 J2 1 J2 6 J1 9 J2 9 OPTIONAL RECOVERY TANK FULL SENSE RELAY COMMON RELAY N O BRUSH REMOV...

Page 79: ...18 2 YEL BLU 18 1 BLK 18 3 WHT BLK 18 1 RED 16 2 RED 18 1 RED 18 2 RED 18 1 GRN BLK 18 1 ORN RED 18 1 RED 18 2 ORN 18 1 BLK 12 1 BLU 12 1 BLK 12 1 BRN 16 4 RED GRN 18 2 BRN 16 5 YEL GRN 18 1 BRN 16 5...

Page 80: ...Shut Off Valve 3 Inline Solution Filter 4 Solution Pump 5 Check Valve 6 Detergent Pump 7 Reducer Tee 8 Reducer Coupler 9 Solution Solenoid Valve 10 Detergent Tank 11 Reducer Coupler 12 Solution Manifo...

Page 81: ...ended Scrub Solenoid Valve 16 Solution Manifold Cylindrical Models 17 Tee EXTENDED SCRUB SYSTEM PLUMBING SCHEMATIC APPENDIX Service Note 1 After each use drain and rinse the recovery tank thoroughly a...

Page 82: ...g Detergents 1 Disconnect and remove the detergent cartridge 2 Turn the Key Switch A ON and press the Detergent Switch F and the Solution Switch B down for at least 3 seconds NOTE Once activated the p...

Page 83: ...Software Revision Level Scrub OFF Switch H Chemical Switch F Scrub OFF Switch H Wand Switch E Scrub Deck Down Time Scrub ON Switch I Solution Switch B Scrub ON Switch I Solution Switch B Regular Scru...

Page 84: ...nput J1 4 ORN BLU Speed Control Status VDC 36V B 37 6 30 6V Pulsed signal equal to the fault code fl ashed by the speed control built in status led Input J1 5 RED BLK Forward Reverse VDC 36V B 37 6 30...

Page 85: ...Gnd 5 0 1 0V Controlled by chemical ratio sensor Input J2 4 GRA WHT Recovery Tank Full Switch VDC 36V B 37 6 30 6V Recovery tank is not full fl oat switch normally closed 31V B 31 6 25 6V Recovery ta...

Page 86: ......

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