Nilfisk-Advance 34 RST EcoFlex Service Manual Download Page 4

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- FORM NO. 56043115 - 34 RST

Table of Contents

Palm Drive Button Replacement 67

Testing the Reverse Button 68

Reverse Button Replacement 69

Testing the Speed Limit Control Potentiometer 70

Speed Limit Control Potentiometer Replacement 70

Electrical System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Schematic

Batteries

Description of the Low Voltage Cut-Out Feature 73

Description Of The Battery Condition Indicators

Specific Wet Cell Battery Information 73

Battery Maintenance

Charging Batteries 74

Extending Battery Life 74

Removal and Installation 75

Battery Testing 75

Maintenance and Adjustment 76

Lift Actuator Limit Adjustment 76

Curtis Controller Diagnostics

Function of the Speed Controller Status Light and Display 78

Diagnostics Using the Curtis Handheld Programmer 78

Fault History 78

Drive Status LED Fault Codes 79

Speed Control Programming Options

Installation Checkout for the Curtis Speed Controller 80

Programming Vehicle Speed Changes 80

Maintenance 80

Summary of Contents for 34 RST EcoFlex

Page 1: ...115 34 RST 34 RST EcoFlex Service Manual Advance Models 56315900 34RST D 56315901 34RST D C 56315902 34RST D C W Strainer 56315903 34RST D C W Battery Watering 56381029 34 RST X34D 56381031 34 RST X34D C 56381809 34RST D C Strainer HD ...

Page 2: ...21 Displaying the Control Board Revision Level 22 Recall of Stored Error Codes 22 Turning Fault Detection On or Off 23 Low voltage Cutout Threshold 23 Selecting Machine Type EcoFlex version only 24 Chemical Option EcoFlex Models 24 Scrub Deck Down Time Period Adjustment 25 Scrub Deck Pressure Solution Flow Rate and Chemical Flow Rate Adjustments 26 Restoring the Scrub Pressures to Factory Default ...

Page 3: ...stem 48 Functional Overview 48 Vacuum Motor Control Circuit Overview Auto Mode 49 Maintenance 50 Service Maintenance Checklist 50 Troubleshooting Guide 50 Maintenance of the Recovery Tank Float Switch 51 Maintenance of Vacuum Motor Inlet Screen 52 Removal and Installation 53 Vacuum Motor Removal 53 Recovery Tank Removal 54 Squeegee System 55 Maintenance 55 Squeegee Lift Linkage Adjustment 55 Servi...

Page 4: ...icators 73 Specific Wet Cell Battery Information 73 Battery Maintenance 74 Charging Batteries 74 Extending Battery Life 74 Removal and Installation 75 Battery Testing 75 Maintenance and Adjustment 76 Lift Actuator Limit Adjustment 76 Curtis Controller Diagnostics 78 Function of the Speed Controller Status Light and Display 78 Diagnostics Using the Curtis Handheld Programmer 78 Fault History 78 Dri...

Page 5: ...ISK ADVANCE DEALER named below for repair parts or service Please specify the Model and Serial Number when discussing your machine Dealer affix service sticker here Nameplate The Model Number and Serial Number of your machine are shown on the Nameplate on the machine This information is needed when ordering repair parts for the machine Use the space below to note the Model Number and Serial Number...

Page 6: ...es only Note Disconnecting the wheel drive motor wiring connector will make a disabled machine easier to push Cautions and Warnings Symbols It is important for you to read and understand this manual The information it contains relates to protecting your safety and preventing problems The symbols below are used to help you recognize this information Danger Indicates a potentially hazardous situatio...

Page 7: ...ascending driving up the ramp Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without first turning the key switch off O removing the key and securing the machine Take precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts Only use the brushes provided with the appliance or th...

Page 8: ...nches 86 cm Gradeability Transport 2 1 15º Cleaning 2 1 15º Max Productivity 3 0 mph 44 880 ft2 hr 4 169 m2 hr Max Productivity 1 5 mph 22 440 ft2 hr 2 085 m2 hr Scrub Head Size and Type 2 17 in 43 cm Brushes or Pad Holders Scrub Pressure 1 Regular Scrub Max 90 lbs 40 8 kg 2 Heavy Scrub Max 175 lbs 79 4 kg 3 Extreme Scrub Max 250 lbs 113 4 kg Scrub Head Speed 220 RPM Solution Flow Rate 1 Regular S...

Page 9: ...9 FORM NO 56043115 34 RST Introduction Technical Specifications continued ...

Page 10: ...Check the vacuum motor carbon brushes two per motor once a year or after 300 operating hours Check the carbon brushes on the brush and wheel drive motors four per motor once a year or after 500 operating hours The original new length of each carbon brush is 1 25 4mm on all 36 volt machine models brush and wheel drive motors All motors Replace carbon brushes when shorter than 3 8 9 5mm to obtain th...

Page 11: ...Codes circle Does Not 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 B D L 13 Brush Drive Motor Gimbals C D M 14 Scrub Deck Lift Motor Brush Housings and Side Wheel D M W 15 Solution Solenoid Valve C L W 16 Solution Tank Delivery Hoses and Filter clean filter screen C L 17 Vacuum Motor ...

Page 12: ...xt 1 Solution Tank Fill 2 Operator Control Handle 3 Bottle Holders 4 Vacuum Motor Inlet Screen 5 Recovery Tank Cover 6 Nose Cone 6a Detergent chemical cover EcoFlex models 6b Detergent chemical cartridge EcoFlex models 7 Scrub Deck 8 Brush Housings includes Bristle Skirt 9 Scrub Deck Bumper Wheel 10 Drive Wheel 11 Solution Filter 12 Solution Shutoff Valve 13 Squeegee Assembly 14 Battery Pack Conne...

Page 13: ... Recovery Hose 20 Wheel Drive Circuit Breaker 21 Circuit Breaker for the Control Circuit 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 Reverse Button 29 Palm Drive Buttons 30 Speed Limit Control Knob 31 Control Panel 32 Vacuum Shutoff Switch ...

Page 14: ...0 Amp K1 Contactor Brush Motor K2 Contactor Vac Motor L1 Solenoid Solution M1 Motor Wheel Drive M2 Motor Left Brush M3 Motor Right Brush M4 Motor Vac M5 Motor Brush Actuator R1 Potentiometer 100K Ohm Speed Limit S3 Switch Key S4 Switch Float Recovery Tank Full S5 Switch Reverse S6 Switch Palm Assy S7 Switch Palm Assy X9 Battery Disconnect X10 Battery Disconnect ...

Page 15: ...crub OFF Indicator I Scrub ON Switch I1 Regular Scrub ON Indicator I2 Heavy Scrub ON Indicator I1 and I2 Extreme Scrub ON Indicators J Display J1 Battery Indicator J2 Hour Meter Scrub Pressure Indicator Fault Code Display Recovery Tank FULL Indicator A B C H I J J1 J2 1 2 3 D1 H1 I1 I2 I1 I2 I2 I1 C1 B1 Extreme Scrub Pressure Heavy Scrub Pressure Regular Scrub Pressure High Solution Flow Low Solut...

Page 16: ...ur Meter D4 Detergent 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 EcoFlex models only G EcoFlex Switch H Scrub OFF I Scrub ON Ø 4 A E C G F B H I D D1 D2 D3 D4 D5 D6 D7 D8 D Regular Heavy Extreme Regular Heavy Extreme Scrub Scrub Scrub Scrub Scrub Scrub ...

Page 17: ...or if the machine is stopped after the scrub system has been turned off the vacuum will shut off after a 10 second delay Scrub ON Switch I If the scrub system is off pressing this switch once will cause the following to occur The scrub system will be enabled with the scrub pressure set to the Regular Normal mode 1 and the scrub deck will be lowered Note that pressing the Scrub ON switch twice will...

Page 18: ...g off after the delay period A steady yellow indicator means that the particular function has been enabled and in a ready state but is not currently on For example if a scrub mode is selected and the throttle is in neutral the scrub system vacuum and solution indicators will all be yellow indicating that the systems are enabled and ready to turn on when the throttle is moved to forward and or reve...

Page 19: ... if the EcoFlex system is in a temporary override state This indicator will be off if the EcoFlex system is disabled and turned off Scrub Mode Indicators The Solution system and Scrub system have three scrub modes regular heavy and extreme These scrub modes are jointly controlled when the Scrub On Switch I is pressed but the Solution system can be controlled separately by pressing the Solution Swi...

Page 20: ...els when in Service Mode the actual battery voltage will be displayed numerically in the lower left corner of the main display Hour Meter For standard models the J2 display will flash through the total number of run hours on the machine The run hours will be displayed sequentially when the key switch is first turned on provided the recovery tank is not full and there is no fault condition to gener...

Page 21: ...n Control Board Programing section in this chapter for further information Main Control Board Programming The Main controller is programmable for machine specific functions and parameters This is a required task when replacing the controller with a new controller The table below and following sections describe the parameters to be programmed Programming Option Button s to Hold While Turning Key Sw...

Page 22: ...ntroller maintains a list of past error codes To recall and or clear the stored error codes perform the following steps 1 Turn the key switch to the off position 2 While holding the Solution Switch B depressed turn the key switch to the on position 3 Continue to hold the solution switch until the solution indicator turns green On EcoFlex models If there are no error codes stored the display will s...

Page 23: ...t is changed again Low voltage Cutout Threshold The 34 RST is equipped with a low voltage cutout feature to prevent over discharging the batteries This feature will automatically shut down the scrub system when the battery voltage falls to the selected threshold The cutout threshold has two levels Standard and Alternate The Standard setting is 30 96 volts 5 16 volts per battery and is for standard...

Page 24: ...switch E to save this setting The display will show the key switch icon 7 Turn the key switch to the off position to commit the setting Chemical Option EcoFlex Models EcoFlex models are equipped with the chemical detergent system To enable or disable this option do the following 1 Turn the key switch to the off position 2 While holding the Scrub Off H and Scrub On I switches depressed turn the key...

Page 25: ...tinue to hold both switches until the indicators for both switches turn green 5 Release both switches The Regular and Heavy Scrub On indicators will turn yellow and the Scrub Off indicator will turn red On EcoFlex models the display will show the scrub deck icon on right top corner and clock icon with number On standard models the LED display will show the number corresponding to the deck down tim...

Page 26: ...0 less than normal chemical setting Two bar gauge 2 0 6 g m 10 more than normal chemical setting Three bar gauge 3 0 9 g m Restoring the Scrub Pressures to Factory Default Settings Use this procedure to restore all of the scrub deck pressure settings to their factory default values 1 Turn the key switch to the off position 2 While holding the Scrub On switch I depressed turn the key switch to the ...

Page 27: ... On switch I will scroll through the 3 scrub pressure settings 7 Pressing Scrub Off switch H will save the pressure setting and move to solution rate setting 8 Solution Rate Setting The Regular Scrub indicator I1 will turn from yellow to green and the Solution indicator will turn yellow For EcoFlex models the display will show the solution icon with gauge 9 Press the Solution switch B to scroll th...

Page 28: ...show the level number of the current scrub pressure setting 5 Press the Scrub On switch I to scroll through the 3 scrub pressure settings 6 Press the Scrub Off switch H to save the pressure setting and move to solution rate setting 7 Solution Rate Setting The Heavy Scrub indicator I2 will turn from yellow to green and the Solution indicator will turn yellow For EcoFlex the display will show the so...

Page 29: ...l show the level number of the current scrub pressure setting 5 Press the Scrub On switch I to scroll through the 3 scrub pressure settings 6 Press the Scrub Off switch H to save the pressure setting and move to solution rate setting 7 Solution Rate Setting The Heavy Scrub indicator I2 will turn from yellow to green and the Solution indicator will turn yellow For EcoFlex the display will show the ...

Page 30: ...flash out a specific Curtis Drive controller error code See the Wheel System Traction chapter troubleshooting section for a list of error codes E04 Scrub deck lift actuator overload Inspect the scrub deck for obstruction Measure the actuator amperage with and without the scrub deck connected No load current 1 4 amps Normal current 1 0 2 5 Amps Maximum current 6 Amps If the no load current remains ...

Page 31: ...s a switched ground PWM so one terminal will be 36 volts B 2 bus to Battery Negative and the other should be non zero PWM of B 2 to Battery Negative If both remain near 36 volts it indicates a controller failure E018 Scrub deck lift actuator short The controller s internal circuitry is seeing maximum voltage in the current sensing circuit Inspect the B 2 bus J1 9 for connection to ground Inspect t...

Page 32: ... spec 102Ω 20 PWM Voltage B Gnd 7V depending on battery voltage 5000 Hz freq 80 duty cycle Vacuum Motor is Active 6 9V 0 duty cycle Vacuum Motor is off 36V Power J1 13 BRN Power Supply VDC 36V B Gnd 37 6 30 6V Key is switched On Output J1 14 VIO BLK Brush Contactor Note Coil resistance spec 98 5Ω 20 PWM Voltage 7 2V B Gnd 7V depending on battery voltage 5000 Hz freq 80 duty cycle Brush Motor is Ac...

Page 33: ...r without interpretation and represents the error code from the Drive controller On Standard models the green light in the battery indicator j5 will light whenever the key is on If there is a speed control fault the indicator will flash the fault code produced by the speed controller On EcoFlex models the SCS will be displayed whenever the key is on If there is a speed control fault this indicator...

Page 34: ...tion Check for voltage at the Wht wire on K1 contactor to battery ground If any voltage is present replace K1 contactor NO voltage replace the Main control board Brief Off Green Flash Brush motor output is on and brush motor current is not being sensed abnormal condition Check brush motor wiring plugs Check one of the Blk wires of the main harness connector at the brush motor to battery Positive I...

Page 35: ...en this indicates that the control is sensing current flow through the actuator shorted output driver control error If the scrub pressure decrease switch was the last switch pressed it is possible to momentarily activate the actuator output using the wand switch This can be used to jog the actuator to allow precise positioning of the actuator Note the actuator can only move in this situation if it...

Page 36: ...ebris in the vacuum motor Worn carbon brushes Defective motor bearings Check for short circuit in vacuum motor or wiring Repair or replace Solution Switch B This switch is used to toggle the state of the solution solenoid Pressing and releasing this switch will alternately turn the solution solenoid L1 on and off The indicator provides the following status information Off Solution output is off St...

Page 37: ...See the Know Your Machine section in this manual for a complete explanation of the solution operation modes During normal machine scrubbing the solution system s Auto Mode is selected and works in conjunction with the wheel drive speed controller and the A1 main controller s scrub system outputs to turn the L1 solenoid valve on and off The solution will flow to the scrub brushes when the scrub dec...

Page 38: ...Three bar gauge 0 9 g m 6 sec 0 sec The positive terminal of the chemical pump is connected to battery positive through the 5 amp circuit breaker F2 The main control board activates the pump by pulling the J2 11 terminal to ground battery negative The chemical pump is a simple DC motor so to control the speed of the motor the signal is PWM controlled Electrical Diagram Note For a complete descript...

Page 39: ...scrub auto solution mode Note Activate the Service Test Mode Program See the Electrical System Service Test Mode section in this manual for instructions All testing will be performed in the Service Test Mode Program Symptom No solution flow when scrubbing in the auto solution mode Note Activate the Service Test Mode Program See optional program section for instructions While in the Service Test Mo...

Page 40: ...tie Note You may want to place a pan underneath the Solenoid Valve H to catch any water remaining in the Inlet and Outlet hoses when you disconnect the hoses 4 Loosen the Hose Clamps K holding the Inlet Hose N and Outlet Hose L to the Solenoid Valve H 5 Carefully remove pry off the Outlet Hose L from barbed fitting on the Solenoid Valve H 6 Remove the 2 Phillips Pan Head Screws M and Washers J hol...

Page 41: ...k using the solution drain hose B 2 Loosen the 2 Hose Clamps R and carefully remove pry off the solution Inlet Hose S and Outlet Hose T from the Filter Valve Assembly F 3 Remove the 2 Hose Clamps U that secure the Filter Valve Assembly F to the chassis and remove the Filter Valve Assembly F from the machine ...

Page 42: ...ve to motors M2 and M3 M5 Scrub Brush Actuator Lift Motor Function The A1 control board outputs a controlled motor voltage polarity change wires J2 1 and J2 8 that raises and lowers the scrub deck for installing removing and controlling the scrub brushes selected current load The large Blk negative scrub brush motor wire is specially designed so that it has a known specified resistance value As br...

Page 43: ... J1 12 J1 11 REVERSE B 1 BRUSHACTUATOR1 BRUSHACTUATOR2 B 3 B 4 B 2 A1 CONTROLBOARD J1 5 J2 5 J2 10 J1 6 J2 4 J1 7 J2 8 J2 1 J2 6 J1 9 J2 9 RECOVERYTANKFULL STATUS J1 4 CHEMICAL PUMP J2 11 M4 M4 M M5 MOTOR BRUSHACTUATOR M M5 MOTOR BRUSHACTUATOR K1 COIL BRUSHMOTORCONTACTOR K1 COIL BRUSHMOTORCONTACTOR BT1 BATTERY BT1 BATTERY F1 FUSE 150A F1 FUSE 150A 1 2 M M2 MOTOR LEFTBRUSH M M2 MOTOR LEFTBRUSH S3 S...

Page 44: ... Remove the 5 16 18 Socket Head Screw D using a hex wrench then remove the Motor Gimbal C Brush Driver Collar E and Key F from the scrub motor shaft Special Service Note If the 5 16 18 Socket Head Screw D is frozen in the scrub motor shaft it may be easier to remove the scrub deck from the machine before you remove the screw Refer to the Scrub Brush Deck Removal section in this manual 5 To reinsta...

Page 45: ...h deck to take pressure off the Pin K Service Note It is important not to run the actuator motor or the rotate the spring housing assembly on the lead screw while the Lift Actuator Assembly T is disconnected from the scrub brush deck or chassis mounts This precaution will prevent the actuator drive nut from getting out of adjustment moved out of its set specification and will maintain the correct ...

Page 46: ...e either of the Cotter Hair Pins L and remove the Pin K to detach the Lift Actuator Assembly T from the lower mount on the Deck Weldment N Note Lift up on the scrub brush deck to take pressure off the Pin K 5 See Figure 3 Remove the Cotter Hair Pin V from the Ring Pin W 6 Hold the Lift Actuator Assembly T securely remove the Ring Pin W from the Actuator Mount Weldment X then remove the Lift Actuat...

Page 47: ...he motor output shaft then remove the Motor Gimbal C Brush Driver Collar E and Key F Make sure to save the Key F 5 Remove the 4 3 8 16 Hex Head Locking Screws Y holding the Motor Gear Unit Assembly J to the Deck Weldment N and remove the Motor Gear Unit Assembly J 6 Reinstall the Motor Gear Unit Assembly J by following the above steps in reverse order then test for correct operation Note Apply a s...

Page 48: ...astewater off of the floor The air and wastewater move through the squeegee hose at high speed until the wastewater reaches the recovery tank There the air slows down because of the increased volume large size of the tank With the decreased air speed the heavier water falls to the bottom of the recovery tank The airflow continues through the tank vacuum fan inlet screen and vacuum motor and is exh...

Page 49: ...a palm drive button is pressed to run the wheel drive motor The recovery tank full float switch S4 must be open in its lowered position in order for a negative voltage output from the A1 board s terminal J1 12 Blk Yel wire to complete the K2 solenoid coil circuit Pos and Neg and pulls in the solenoid load contact K2 making the vacuum motor run The Neg M4 load voltage is supplied from the battery N...

Page 50: ...pect and clean the vacuum motor inlet filter screen Troubleshooting Guide If water flows around the ends of the squeegee tool instead of being pulled into the tool the vacuum system is not working correctly When a vacuum system performs poorly it is usually because of one of the following problems Vacuum Leaks Air flowing into the vacuum system past a bad gasket or leaky hose damaged tank or a lea...

Page 51: ...to not function at all or fail to shut off when the tank is full If daily rinsing of the recovery tank is not sufficient to keep the switch clean you may need to remove the float arm for cleaning The float arm can be removed easily by grasping it as shown below and twisting to remove It is very important that the float switch be reassembled correctly in order to function See Figure 3 for the corre...

Page 52: ...r 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 vacuum motor To remove the Vacuum Motor Inlet Screen 4 from the recovery tank grip twist and pull up on the Vacuum Motor Inlet Screen 4 FIGURE 4 ...

Page 53: ...very Tank A 5 Remove the 4 Phillips Pan Head Screws D and Flat Washers E holding the Vacuum Motor Shroud F to the bottom of the Recovery Tank A then remove the Vacuum Motor Shroud F 6 Carefully remove the Vacuum Motor Assembly G and attached Acoustical Foam vacuum exhaust hose B from the Recovery Tank A Note Take care not to lose the three Vibration Mounts H 7 Inspect the condition of the vacuum m...

Page 54: ...embly N from the Recovery Tank A Caution The Recovery Tank is relatively heavy You may choose to get some assistance when swinging the Recovery Tank down after disconnecting the Cable Assembly and when removing it from the machine 5 See Figure 6 Remove the Phillips Pan Head Screw P and tank Cable Assembly O and allow the Recovery Tank A to swing down to the side of the battery compartment box 6 Su...

Page 55: ...hanging the up down squeegee positions 3 Remove the Nyloc Nut B from the Hex Head Screw C then remove the Hex Head Screw C flat Washer D Cable Bushing E and attached cable assembly from the squeegee mount weldment 4 Reinstall in the Hex Head Screw C flat Washer D Cable Bushing E and attached cable assembly into the appropriate hole to raise or lower the squeegee positions as needed then reinstall ...

Page 56: ...ront 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 13 from the mount 2 First remove both rear Tension Straps 22 3 Remove all the wing nuts that hold the front blade in place and then remove the front tension strap and front blade 4 The squeegee blade has four working edges Turn the blade so a clean...

Page 57: ...chine make sure you support the machine with safety stands or blocking to prevent the machine from dropping and possibly causing personal injury or machine damage Warning Never work under machine without safety stands or blocking to support the machine 4 Remove the Screw D through the access hole in the bottom of the chassis and slide the Squeegee Mount Assembly E away from the chassis 5 Reinstall...

Page 58: ...squeegee assembly and have the scrub brush deck in the up stored position with the scrub brushes installed 3 See Figure 4 Place Wood Blocking H in front of the drive wheels to prevent the machine from rolling 4 Jack the machine in the location shown until the caster wheel is approximately 1 off the ground 5 Place Blocking I under the chassis tab as shown 6 Remove the 4 Screws Nuts and Washers J th...

Page 59: ...5 KSI to make its internal control circuits 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 supplies the NEG input to the B controller terminal Pressing either palm drive switch S6 or S7 activates the operator input to the speed control which generat...

Page 60: ...SE VACUUM MOTOR SENSE J2 7 J1 13 J1 14 J1 12 J1 11 REVERSE B 1 BRUSHACTUATOR1 BRUSHACTUATOR2 B 3 B 4 B 2 A1 CONTROLBOARD J1 5 J2 5 J2 10 J1 6 J2 4 J1 7 J2 8 J2 1 J2 6 J1 9 J2 9 RECOVERYTANKFULL A2 B B 1228SPEEDCONTROLLER M1 M2 PIN3 POT HI PIN4 POT WIPER PIN13 POT LO PIN5 KSI PIN16 REV PIN6 BRAKE STATUS PIN9 STATUS PIN18 SPEEDLIMITPOT J1 4 PIN17 REV CHEMICAL PUMP J2 11 M M1 MOTOR WHEELDRIVE M M1 MO...

Page 61: ...gh input 5V ref 4 Blu Vio Throttle Pot R1 pot wiper input 5 Brn Red Vio KSI key switch input Battery powers up controller logic circuits 6 Red Blk Brake Auxiliary Driver Battery output to main controller A1 to turn on activate all auto scrub functions its open when in neutral 7 Open not used 8 Open not used 9 Orn Blu Status Fault Speed controller fault output to main control panel fault indicator ...

Page 62: ...y Defective R1 speed limit potentiometer test for an open in both the pot and circuit wiring repair or replace Operator control panel displays error 03 fault code Speed controller has sensed an operational error code fault See Drive Status LED fault codes table 1 in the Electrical System section Additional wheel drive circuit information Control circuit pin connection test specification data Circu...

Page 63: ...ack before servicing machine Warning Never work under machine without safety stands or blocking to support the machine 2 Drain both the solution and recovery tanks and remove the squeegee 3 Remove the Scrub deck by following the instructions in the Scrub Brush Deck Removal section in this manual 4 Block the rear of the machine See Figure 4 for correct placement of the wood blocking FIGURE 4 ...

Page 64: ...ntil the drive wheels are approximately 1 off the ground 6 Remove the 6 wheel Nuts A and remove the 2 Drive Wheels B from the Motor Transaxle D 7 Disconnect the drive motor wiring connector 8 Remove the 4 Motor Mount Bolts and Nuts C and the two Transaxle Mount Plates E and carefully slide the Motor Transaxle D away from the machine 9 Reinstall the Motor Transaxle D by following the above steps in...

Page 65: ... Wheel F opposite of the one that you are removing to prevent the machine from rolling Service Note You may find it easier to loosen the wheel Nuts G slightly when the wheel is still on the ground and before you jack up the machine 4 Using a scissors jack raise the machine until the Drive Wheel F is off the ground See Figure 6 for jack placement 5 Remove the 3 wheel Nuts G and Drive Wheel F 6 Rein...

Page 66: ...en the palm drive buttons are working correctly The circuit through pins 4 and 6 should be open when both palm drive buttons are released The circuit through pins 4 and 6 should be closed approximately zero ohms when either of the palm drive buttons is pressed 3 See Figure 7 When you re done checking the palm drive buttons reconnect the Handle Harness H to the connector on the machine FIGURE 7 FIG...

Page 67: ...tached Access Panel Gasket X from the Handle K 9 Note the wire colors and connector locations then disconnect the SPST Momentary Switch leads from the connectors in the access area and remove the old SPST Momentary Switch S Note that you may need to cut a cable tie to access the wires and connectors 10 Thread the leads from the replacement SPST Momentary Switch S into the side of the Handle K and ...

Page 68: ...hmmeter to check the continuity between pins 3 and 5 on the Handle Harness H When the reverse button is working correctly The circuit through pins 3 and 5 should be open when the reverse button is released The circuit through pins 3 and 5 should be closed approximately zero ohms when the reverse button is pressed 3 See Figure 9 When you re done checking the reverse button reconnect the Handle Harn...

Page 69: ...ndle K 7 Note the wire colors and connector locations then disconnect the leads on the reverse button SPST Momentary Switch Y from the connectors in the access area Note that you may need to cut a cable tie to access the wires and connectors 8 Remove the old reverse button through the top of the Handle K 9 Insert the leads from the replacement reverse button SPST Momentary Switch Y through the hol...

Page 70: ...dle Harness H from the mating connector located to the left of the squeegee raise lower handle This will prevent excessive pulling or stress on the Handle Harness H and connector when the Handle K is swung down to remove the Access Plate V 5 Loosen the bottom left and right hand 5 16 18 Hex Head Screws Z holding the Handle K to the machine 6 Remove the top left and right hand 5 16 18 Hex Head Scre...

Page 71: ...rclockwise slow positions Readjust the rotational position of the Knob AA on the Potentiometer AB shaft as necessary to center the indicator to the Handle K 16 Reconnect the Handle Harness H to the connector on the machine 17 Snap the Drain Hose back into the brackets 18 Check the machine drive functions forward reverse speed control to make sure the controls are working correctly ...

Page 72: ...REV PIN6 BRAKE STATUS PIN9 STATUS PIN18 SPEEDLIMITPOT ONBOARDBATTERY CHARGER OPTIONAL B B INTERLOCK NOTE CONNECTGRNWIRETOF2ANDDISCONNECT REDWIREFROMF2FORCHARGEROPTION J1 4 PIN17 REV CHEMICAL PUMP J2 11 M M4 MOTOR VAC M M4 MOTOR VAC 1 2 F2 CIRCUITBREAKER 5AMP F2 CIRCUITBREAKER 5AMP 1 2 M M1 MOTOR WHEELDRIVE M M1 MOTOR WHEELDRIVE R3 100OHM R3 100OHM M M5 MOTOR BRUSHACTUATOR M M5 MOTOR BRUSHACTUATOR ...

Page 73: ...isplay has 5 vertical bars D5 showing 6 levels of voltage When the low voltage cutout is active the charge symbol D8 will be shown or the red LED will flash These levels are summarized in the tables below EcoFlex Display Standard Display Display Standard Alternate Display Standard Alternate 5 bars 36 1 36 1 Grn 34 0 34 5 4 bars 35 5 36 1 35 5 36 1 Grn Yel 33 0 34 0 34 0 34 5 3 bars 34 4 35 5 34 4 ...

Page 74: ... to follow proper charging instructions Make sure you have an appropriate charger for the type of battery Use only voltage regulated or voltage limited chargers Standard constant current or taper current chargers must not be used A temperature sensing charger is recommended Important Do not attempt to open sealed gel batteries or add water Doing so will damage the battery and void the warranty For...

Page 75: ...ll cables are connected positive to negative for a series connection between all 6 batteries Position the cables so the battery caps can be easily removed for battery service Take care to not over torque the cable connector as this may damage the battery post 6 Coat the terminals with spray on battery terminal coating available at most auto parts stores 7 Put one of the black rubber boots over eac...

Page 76: ... pin 3 that secures the spring housing 4 to the scrub deck to permit the actuator to swing freely 6 While holding the spring housing 4 from turning press the For Rev switch on the Adapter 1 to raise the spring housing 4 toward the actuator gear housing 5 until the motor stops minimum limit switch engaged 7 Rotate the spring housing 4 until the distance between the spring housing and gear housing 5...

Page 77: ...Distance turn the nut clockwise To decrease the Housing Distance turn the nut counterclockwise If you need to make large adjustments it is recommended to move the actuator away from its limit position first 12 To check your adjustments you must first raise the actuator away from the limit position before lowering it back to the limit position and re measuring the Housing Distance for the Lower Lim...

Page 78: ...e programmer 3 test the circuitry with the programmer and 4 correct the problem Repeat the last three steps as necessary until the vehicle is operational Example A vehicle that does not operate in forward is brought in for repair 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections 2 Connect the programmer navigate to the Faults screen then read t...

Page 79: ...en speed limiting pot 3 2 000 00 brake On fault 1 Electromagnetic brake driver shorted 2 Electromagnetic brake coil open 3 3 000 000 pre charge fault 1 Low battery voltage 2 KSI and palm drive switch turned on at same time 3 4 000 0000 brake Off fault 1 Electromagnetic brake driver open 2 Electromagnetic brake coil shorted 3 5 000 00000 HPD High Pedal Disable fault 1 Incorrect sequence of palm dri...

Page 80: ... a diagnostic code and the programmer will display a diagnostic message If you are conducting the checkout without a programmer look up the LED fault code in Table 1 in the Electrical System section When the problem has been corrected it may be necessary to cycle the key switch to clear the fault code 4 Press one of the palm drive switches The motor should begin to turn in the selected direction I...

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