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Service Manual-

AS1050R

24 Electrical System 68

Harness to Harness Connector Locations

This chapter mainly marks the locations of harness to harness connectors that are not easy to find for the convenience
of technicians.

•

Harness to Harness Connectors C15 (Left Brush Motor), C18 (Brush Deck Actuator).

•

Harness to Harness Connectors C11 (Water Pump).

•

Harness to Harness Connectors C10 (Seat Signal).

Summary of Contents for 50000593

Page 1: ...English 04 2021 Rev 02 Form No VR41020 AS1050R 50000593 50000594 50000595 50000596 AS1050R Service Manual ...

Page 2: ... Instructions 7 Lifting Machine 8 Transporting Machine 8 Technical Data 9 Maintenance Schedule 10 Machine Structure 11 Machine Structure continues 12 Control Panel 13 Service and Diagnostic Equipment 14 Dimensions continues 15 04 Control System 16 Functional Description 16 Component Locations 18 Removal and Installation 19 Troubleshooting 21 Specifications 32 10 Chassis System 46 Chassis main part...

Page 3: ...tion 61 Troubleshooting 63 Specifications 63 Electrical Wiring Diagram 71 30 Solution System 72 Functional Description 72 Wiring Diagram 72 Component Locations 73 Maintenance and Adjustment 74 Solution Filter Cleaning 74 Removal and Installation 75 Troubleshooting 76 Specifications 77 34 Scrub System 78 Functional Description 78 Wiring Diagram 79 Brush Deck Actuator System 80 Component Locations 8...

Page 4: ...d Adjustment 92 Removal and Installation 96 Troubleshooting 98 Specifications 98 40 Recovery System 99 Functional Description 99 Wiring Diagram 99 Component Locations 100 Removal and Installation 101 Maintenance and Adjustment 104 Recovery Tank and Seals 104 Cleaning the Recovery Tank 105 Troubleshooting 106 Specifications 107 ...

Page 5: ... This Service Manual is a technical resource intended to aid service personnel in maintaining and repairing the AS1050R to ensure optimum performance and long service life Please read this manual carefully before performing any maintenance and repair procedure on machine Other Reference Manuals Document name Document number Document type AS1050R Instructions for Use VR41002 Instructions for Use AS...

Page 6: ...ly by the manufacturer and use original spare parts and accessories Customers can find the Model No indicated on the label to order spare parts Retailer label here Serial Number Label The Model No and Serial No are shown on the back of control housing This information is needed when ordering repair parts Use the following table to write down machine identification data MODEL NUMBER SERIAL NUMBER F...

Page 7: ... only by properly trained and authorized persons Do not operate the machine near toxic dangerous flammable and or explosive materials This machine is not suitable for collecting dangerous or hazardous materials In case of fire use a powder fire extinguisher not a water based extinguisher Do not use on surfaces having a gradient exceeding what is marked on the machine While on ramps avoid sudden st...

Page 8: ...e is not approved for use on public paths or roads This machine is only approved for use on hard surface Use brushes and pads supplied with the machine or those specified in the User Manual Using other brushes or pads could reduce safety Do not wash the machine with direct or pressurized water jets or with corrosive substances Do not allow the brush pad to operate while the machine is stationary t...

Page 9: ...ing speed 0 8 Km 0 5 Miles per hour Forward speed 0 8 Km 0 5 Miles per hour Reverse speed 0 5 Km 0 3 1 Miles per hour Drive motor power input 1600 W 2 1 HP Min aisle turn 2650mm 104 Inches Climbing capacity max transport 20 Climbing capacity max working 16 Driving wheel diameter 340mm 13 4 Inches Driving wheel specific pressure on floor 0 68 N mm2 Front wheel diameter 250 mm 10 Inches Front wheel ...

Page 10: ...arging Squeegee cleaning Brush Pad holder cleaning Tank cleaning Tank gasket strip inspection Debris collection box cleaning Brush Pad cleaning Splash guard cleaning Squeegee blade check and replacement Solution filter cleaning Vacuum intake filter cleaning WET battery fluid level check Screw and nut tightness inspection 1 Add lubricating oil for rotating parts like brake oil 1 Brush motor carbon ...

Page 11: ...Service Manual AS1050R 03 General Information 11 Machine Structure Figure 2 ...

Page 12: ...Service Manual AS1050R 03 General Information 12 Machine Structure continues Figure 3 ...

Page 13: ...Service Manual AS1050R 03 General Information 13 Control Panel Figure 4 ...

Page 14: ...t Besides a complete set of standard meters the following instruments are necessary to perform quick check and repairs on machines Digital Voltmeter DVM Amp clamp with possibility of making DC measurements A copy of the User Manual and Spare Parts List of the machine to be serviced ...

Page 15: ...Service Manual AS1050R 03 General Information 15 Dimensions continues ...

Page 16: ...tion protocol between Dash Board EB1 and Main Controller EB2 is CAN protocol Block Diagram 2 2 3 3 4 4 5 5 6 6 7 7 TIGER 3 Control System Traction EB2 Main Controller B B B B M M1 Traction Motor CAN H Battery 36V USB Charger KSI EB1 Dash Board Brush Motor M2 M3 Vacuum Motor M4 M5 Optional Brush Deck Actuator M6 CAN H VR1 POT High POT Low Speed Limit POT One button start Vacuum system adjustment bu...

Page 17: ...age wise To send a data bit the module pulls the high and low wires apart voltage wise Both modules monitor this to detect a communication message which is a string of low and high binary pulses However the binary logic states are reverse of typical in that a logic 1 is recessive and the difference between CANH and CANL is low near zero A logic 0 is the dominant bit and the difference between CANH...

Page 18: ...cations Dash Board EB1 Main Controller EB2 USB charger EB3 Main contactor K1 Warning lamp Main ground lug Figure 2 Figure 3 Figure 4 Figure 5 Dash Board EB1 Main Controller EB2 Main contactor K1 USB charger EB3 Warning lamp Figure 6 Main ground lug Figure 7 ...

Page 19: ...cket spanner 2 Remove 7 screws on Dash Board detach Dash Board Figure 8 3 Disconnect all harnesses and terminals which are used for connecting Dash Board then take out Dash Board Figure 9 and 10 4 Use sleeve to take out 9 screws which are used for fastening PCBA Figure 11 5 Assemble components in reverse order of disassembly Figure 8 Figure 9 Figure 10 Figure 11 Remove 7 screws on Dash Board Disco...

Page 20: ...r of electric control box then take off cover Figure 12 3 Disconnect all harnesses connected to Main Controller Figure 13 4 Remove 2 screws that are used for fixing Main Controller and take out Main Controller Figure 14 5 Assemble components in reverse order of disassembly to assemble Main Controller EB2 Figure 14 Figure 13 Figure 12 ...

Page 21: ...pressure and scrub pressure buttons at the same time LCD will display the input status of the second digit Figure 4 5 Input the second digit by pressing scrub pressure button and confirm it Input the third digit and confirm it LCD will display Figure 5 6 Confirm the password by pressing brush release button LCD will display system setting menu Figure 6 7 Confirm selection by pressing brush release...

Page 22: ...Service Manual AS1050R 04 Control System 22 Confirm the password by pressing the button Figure 5 Figure 6 Press the button Figure 7 ...

Page 23: ...eplace vacuum motor carbon brush Error 14 C EEPROM Err Controller EEPROM error or parameter setting error Error 15 P EEPROM Err Panel EEPROM error or parameter setting error Error 16 Comm Err Communication wiring broken 1 Wrong wiring Controller power off Error 17 C Self Test Err 1 Accelerator fault 2 Internal relay fault 3 Mosfet or other hardware fault Error 18 Overheat 1 Controller overheat 2 M...

Page 24: ...t or overload Possible causes 1 Brush motor or Main Controller EB2 or wiring short circuit 2 Physical resistance to motor rotation such as debris wrapped around brush motor shaft 3 Error 3 Vacuum motor short circuit or overload Possible causes Vacuum motor or Main Controller EB2 or wiring short circuit Solenoid valve Main Controller EB2 Brush motor disc Main Controller EB2 Vacuum motor Main Contro...

Page 25: ...or 5 Brush actuator motor short circuit or overload Possible causes 1 Brush actuator motor or Main Controller EB2 or wiring short circuit 2 Physical resistance to deck raising or lowering 6 Error 6 Low battery voltage Check battery voltage Charge battery 7 Error 7 Brush motor wiring open circuit Check wire harness in brush motor and Main Controller EB2 Check circuit breaker F3 F4 Check brush motor...

Page 26: ...ng open circuit Check wire harness in solution valve and Main Controller EB2 Check solution valve 10 Error 10 When key switch is turned on accelerator pedal is being pressed Release accelerator pedal before turning on key switch Brush motor wires Circuit breaker 30A F3 F4 Brush motor wires Brush motor Circuit Breaker 30A F5 F6 Vacuum motor wires Vacuum motor wires Solution valve Solution valve wir...

Page 27: ...econds to 0000 Hr Figure 2 12 Error 12 Need to replace brush motor carbon brush Replace brush motor carbon brush or brush motor Reset brush motor runtime 1 Refer to steps in Access to Panel Parameter Setting Page 21 2 Press scrub pressure button to select NO 12 parameter Figure 1 3 Press the 4 buttons solution solution scrub pressure and scrub pressure simultaneously the present runtime will be re...

Page 28: ...0 Hr Figure 2 14 Error 14 Controller EEPROM Error or parameter setting error Replace Main Controller EB2 Or contact after sale technical support 15 Error 15 Panel EEPROM Error or parameter setting error Load the parameters of the panel 1 Refer to steps in Access to Panel Parameter Setting Page 21 2 LCD will show the first parameter The default value is 0 Modify the value to 1 by pressing solution ...

Page 29: ...heat Stop using the machine to cool down Main Controller EB2 Replace Main Controller EB2 19 Error 19 Battery voltage 44V Check battery voltage 20 Error 23 Clean water empty Solution tank is empty fill it up with clean water Check solution sensor switch wiring Replace solution sensor 21 Error 24 Dirty water full Recovery tank is full drain the dirty water Check recovery sensor switch wiring Replace...

Page 30: ...rnal contactor K1 internal resistance is short circuit Replace external contactor K1 27 Error 31 Speed potentiometer resistance value is out of range 100 20K Check if speed potentiometer is out of range 100 20K and its wiring Replace speed potentiometer 28 Error 32 Warning lamp short circuit or overload Check if warning lamp wiring is short circuit Check if warning lamp internal circuit is short c...

Page 31: ...k if electromagnetic brake wiring is broken Check if electromagnetic brake handle is opened manually Check if electromagnetic brake internal resistance is short circuit Replace electromagnetic brake 33 Error 39 USB overload Check if USB charging wiring is short circuit Check if USB charging current 2 8A ...

Page 32: ...in numbers are listed out of sequence when measurements require pin to pin voltage references instead of the main ground lug Values of 36V represent full battery voltage regardless of the circuit path Please refer to Figure 1 and Figure 2 for connectors location on Dash Board EB1 and Main Controller EB2 Figure 1 Connectors on Dash Board EB1 Dash Board EB1 P1 P5 Connector Pin Color Function Conditi...

Page 33: ... 12V 2 BLK Headlight power output Headlight On 0 01V Headlight Off 11V Dash Board EB1 P4 Connector Pin Color Function Condition Value 1 BRN Buzzer power output Buzzer On 12V Buzzer Off 12V 2 BLU Buzzer power output Buzzer On 0V Buzzer Off 12V Dash Board EB1 P6 Connector Pin Color Function Condition Value 1 RED USB 5V Key switch on 5V Key switch off 0V 2 WHI USB DM 2 6V 3 GRN USB DP 2 6V 4 BLK USB ...

Page 34: ...eleased 36V 2 WHI Electromagnetic Brake Inactive Brake set 36V Active Brake released 2V Main Controller EB2 P2 Connector Pin Color Function Condition Value 1 GRN 36V Output Key switch on 36V Key switch off 0V 2 BLK Water pump PWM output Pump Active High flow output test 12V Pump Inactive 36V 3 RED Brush deck actuator out1 Brush deck actuator out2 Raise Ref 3 to 10 36v Lower Ref 3 to 10 30V 10 YEL ...

Page 35: ...grees 0V Turn 30 degrees or straight ahead 12V 14 N A N A N A N A Main Controller EB2 P3 Connector Pin Color Function Condition Value 1 GR BK Recovery tank sensor input Recovery tank is full 0V Recovery tank is not full 18V 2 BN BK Solution sensor input Solution tank is empty 0V Solution tank is not empty 20V 3 N A N A N A N A 4 BU BK Mechanical brake sensor input Pressed 0V Released 18V 5 N A N A...

Page 36: ...ollowing steps to set the parameters Dash Board EB1 Parameter Setting NO Parameter Name Value Unit Comment 1 Load Fac Set 0 1 N A Restore factory settings 2 Contrast 15 N A LCD display contrast 3 Language 0 N A 0 English 1 Chinese 4 Display Mode 1 N A Reserved 5 Password 1st 6 N A First digit of password 6 Password 2nd 6 N A Second digit of password 7 Password 3rd 1 N A Third digit of password 8 P...

Page 37: ... voltage at level 3 36 DIS EV 4 VOLT 36 9 V DIS EV battery voltage at level 4 37 DIS EV 5 VOLT 37 8 V DIS EV battery voltage at level 5 38 ENE 0 VOLT 32 7 V ENE battery voltage at level 0 39 ENE 1 VOLT 34 V ENE battery voltage at level 1 40 ENE 2 VOLT 35 5 V ENE battery voltage at level 2 41 ENE 3 VOLT 36 1 V ENE battery voltage at level 3 42 ENE 4 VOLT 36 6 V ENE battery voltage at level 4 43 ENE...

Page 38: ... ENE Main Controller EB2 Parameter Setting The password to parameter setting of Main Controller EB2 is 661 The parameters whose serial numbers with in the parameter setting tables can be modified Do not change any of the other parameters unless specifically directed by an authorized factory representative Please refer to following steps to set the parameters 1 Refer to steps 1 6 of Access to Panel...

Page 39: ...peed input function 19 Brush Spd In Typ 0 N A Brush speed input switch type 20 Tra Spd In Fun 0 N A Traction motor speed input function 21 Tra Spd In Fun 0 N A Traction motor speed input switch type 22 BruD SW In Fun 3 N A Brush disc lifting switch input function 3 Second level turning deceleration 23 BruD SW In Typ 0 N A Brush disc lifting switch input type 24 Sque Sw In Fun 2 N A Squeegee liftin...

Page 40: ... reverse deceleration rate 58 Tra PowOff DEC 0 7 Seconds Traction motor power off deceleration rate 59 Tra NoStSW DEC 2 Seconds Accelerator releasing deceleration rate 1 60 ACC R Dec Rate 2 Seconds Accelerator releasing deceleration rate 2 61 Tra I limit 170 A Traction motor current limiting value 62 Tra Stall Time 15 Seconds Traction motor overcurrent protection time 63 Tra Reg Port T 0 2 Seconds...

Page 41: ...reverse 0 Not off 1 Off A0 Vac Accel Rate 1 8 Seconds Vacuum motor acceleration rate A1 Vac Decel Rate 1 8 Seconds Vacuum motor deceleration rate A2 Vac PowOff Dec 1 2 Seconds Vacuum motor power off deceleration rate A3 Vac I Limit 50 A Vacuum motor current limiting value A4 Vac Stall Time 3 0 1S Vacuum motor overcurrent protection time A5 Vac SW control 0 N A Reserved A6 Vac Off DelayT 0 Seconds ...

Page 42: ...Stop Tim 4 7 Seconds Brush disc down stop time D6 BrD Up Stop I 2 A Brush disc up stop current D7 BrD DW Stop I 2 A Brush disc down stop current D8 Aux1 Out Func 8 N A Auxiliary 1 output function D9 Aux1 Off Dly T 0 Seconds Auxiliary 1 output off delay time E0 Aux1 Out Volt 31 V Auxiliary 1 output voltage E1 Aux2 Out Func 7 N A Auxiliary 2 output function E2 Aux2 Off Dly T 0 Seconds Auxiliary 2 ou...

Page 43: ... mode Turning deceleration rate 2 H3 Turn Spd Perc 2 45 Transport mode Turning deceleration percentage 2 H4 Pressure L1 L2 1 2 Seconds Brush down time from brush pressure level 1 to level 2 H5 Pressure L2 L3 1 3 Seconds Brush down time from brush pressure level 2 to level 3 H6 Pressure L2 L1 1 Seconds Brush up time from brush pressure level 2 to level 1 H7 Pressure L3 L2 1 2 Seconds Brush up time ...

Page 44: ...A Battery type WET AGM GEL Discover EV ENE 2 Load Unit Def 0 N A Restore factory settings 3 LCD Contrast 15 N A Range 0 40 4 Vac OFF Delay 10 Seconds Vacuum motor off delay time 5 Working Max Spd 100 Work mode maximum speed of transport speed 6 ECO Max Spd 75 ECO mode maximum speed of transport speed 7 Tra Fwd H Spd 90 Traction motor maximum forward speed battery volt 8 Tra Rvs H Spd 45 Traction m...

Page 45: ... Turning deceleration percentage 2 19 Scr TrdSpd Dec 1 2 Seconds Work mode Turning deceleration rate 1 20 Scr TrdSpd Red 1 65 Work mode Turning deceleration percentage 1 21 Scr TrdSpd Dec 2 2 Seconds Work mode Turning deceleration rate 2 22 Scr TrdSpd Red 2 40 Work mode Turning deceleration percentage 2 23 ECO TrdSpd Dec 1 2 Seconds ECO mode Turning deceleration rate 1 24 ECO TrdSpd Red 1 65 ECO m...

Page 46: ...Service Manual AS1050R 10 Chassis System 46 10 Chassis System Chassis main parts The chassis is attached to the bottom of solution tank Figure 1 ...

Page 47: ...f traction motor will be reversed thus achieving reverse operation of traction motor There are 2 proximity sensors SQ1 SQ2 which monitor a steel plate attached to front wheel assembly and pivots with it See SQ1 SQ2 assembly diagram below The purpose of these inputs is to slow machine transport speed when turning for safety When machine is moving straight ahead the steel plate is near each sensor a...

Page 48: ... CAN L CAN H CAN L F2 FUSE 200A C6 2 C6 1 Fe SQ1 Proximity Sensor Fe SQ2 Proximity Sensor HALL VO Pedal C7 2 C7 1 C6 3 C7 3 K1 RED BLK SW6 KA1 C13 1 C13 2 C12 2 C12 3 C12 4 C12 5 C12 1 RED BRN WHI BU BK GR BK WHI P7 1 P7 4 P7 5 RED RED BLK BLK BRN BRN BLU BLU BLK BRN BLK WHI Slow Down Sensor 1 BU BK P3 4 BLK Brake Brake P1 1 P1 2 WHI WHI WHI WHI P3 10 P2 7 Accel Wiper Move Enable ORG GRY GRN BLK B...

Page 49: ...Locations Speed limit potentiometer VR1 Throttle pedal Brake sensor switch SW6 Seat switch SW7 Main Controller EB2 Figure 2 Figure 3 Figure 4 Figure 5 Speed limit potentiometer VR1 Throttle pedal Seat switch SW7 Main Controller EB2 Brake sensor switch SW6 ...

Page 50: ... 14 Wheels System 50 Component Locations continues Electromagnetic brake KA1 Traction motor M1 Proximity sensor SQ1 SQ2 Figure 6 Figure 7 Electromagnetic brake KA1 Traction motor M1 Proximity sensor SQ2 Proximity sensor SQ1 ...

Page 51: ... blocking Figure 8 7 Remove screw B then remove plain washer C and spring washer D remove mechanical brake E 8 Cut off nylon cable tie and unplug connector F 9 Remove hex screw G then remove plain washer I and spring washer H then remove screw K 10 Remove traction motor J NOTE Do Not press brake pedal during removal and installation Installation Assemble components in reverse order of disassembly ...

Page 52: ...Use supporting tool jack A and adequate blocking B to support machine 5 Remove bolt D then remove plain washer F and spring washer E 6 Take out shaft I then remove bushing G and H 7 Take off front wheels C Installation Assemble components in reverse order of disassembly Please pay attention to installation position of bushing G and H Figure 12 Figure 13 A B C C D E F G I H Figure 14 Figure 15 ...

Page 53: ...turn freely 4 Use supporting tool jack F and adequate blocking to support machine 5 Remove rear wheel cover A 6 Remove hex screw B then remove plain washer D and spring washer C 7 Take off rear wheel E NOTE Do Not press brake pedal during removal and installation Installation Assemble components in reverse order of disassembly Figure 16 Figure 17 A E D C B F Figure 18 E ...

Page 54: ...fault Check coil resistance replace brake Mechanical brake is pressed or mechanical brake sensor switch is stuck Release mechanical brake or check mechanical brake sensor switch Throttle pedal fault Replace throttle pedal The machine moves slowly Check wiring of sensor SQ1 and SQ2 Power supply of SQ1 and SQ2 is 12V When machine is not turning output is 12V If output voltage is wrong replace SQ1 or...

Page 55: ...tor wiring harness 2 Turn on machine and activate forward drive at its maximum speed via throttle pedal Check whether current draw is between 3A and 8A when voltage is at 36V 3 Release throttle pedal 4 If amperage is higher than 8A perform following procedures to determine cause and correct abnormal amperage Check and make sure electromagnetic brake KA1 can function properly Disassemble motor and ...

Page 56: ...Voltage V 36 Traction Motor Rated Input Current A 45 Traction Motor Allowed Over Current less than 1 minute A 150 Traction Motor Normal Current traction motor lifted A 3 8 Traction Motor Coil Resistance 25 Ω 0 5 Electromagnetic Brake Coil Resistance 25 Ω 30 Speed Limit Potentiometer VR1 Coil Resistance 25 Ω 100K Vehicle Forward Maximum Speed Km h 8 ...

Page 57: ... EB1 and Main Controller EB2 When one of the switches is opened all machine functions will be disabled Only when both the key switch SW2 and emergency switch SW1 are switched on can USB charger EB3 charge the phone To prolong battery lifespan the machine has low voltage cut off function When battery voltage is low the battery power icon on LCD flashes to remind operator to charge Brush motor and v...

Page 58: ...6V Input RED RED F1 Circuit Breaker 5A SW1 Emergency Stop K1 SW3 Charger SW RD BK RD BK BLU GRN P2 5 P2 6 GRN BLU P1 1 VCC GND MCU VDD Charger Input P1 4 RED BAT BAT BLK BLK B EB1 Main Controller Dash Board P6 1 RED EB3 USB Charger P6 2 P6 3 P6 4 GRN BLK WHI 5V GND D D C4 1 C4 2 External Charger Connector C5 K1 Main Contactor 24V YEL YEL P3 8 P3 17 36V Out B BLK BLK RED Figure 1 ...

Page 59: ...t breaker 5A F1 External charger connector C5 Key switch SW2 Emergency switch SW1 Charger sensor switch SW3 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Dash Board EB1 Battery BAT Battery connector Dash Board circuit breaker 5A F1 Key switch SW2 Emergency switch SW1 External charger connector C5 Figure 7 Charger sensor switch SW3 ...

Page 60: ... battery type is GEL Battery Installation 1 Open recovery tank cover and check if recovery tank is empty if not empty it with the drain hose 2 Close the recovery tank cover 3 Open the latch then tip back recovery tank B Figure 9 carefully 4 The machine comes with cables suitable for installation of 6X6V batteries Put the batteries into the compartment carefully then position them correctly 5 Route...

Page 61: ...ove warning lamp assembly Installation Assemble components in reverse order of disassembly Headlight Removal 1 Raise machine off the ground with gantry and make sure the machine is placed securely and safely 2 Remove screws A then remove plain washer B 3 Remove the right LED lamp holder C and left LED lamp holder D 4 Remove self tapping screws E 5 Then remove LED lamp F Figure 10 ...

Page 62: ...Service Manual AS1050R 24 Electrical System 62 Installation Assemble components in reverse order of disassembly Figure 11 Machine Gantry ...

Page 63: ...Warning lamp doesn t work Warning lamp is damaged Repair replace Wiring loose Repair replace Headlight doesn t work Headlight is damaged Repair replace Wiring loose Repair replace LCD display still on when charging Charger sensor switch SW3 is damaged Repair replace Wiring loose Repair replace Specifications Electrical Parameters Description Unit Value Battery Voltage V 36 External Battery Charger...

Page 64: ...1 P5 Connector Pin Name Color 1 Ground BLK 2 CAN H BRN 3 CAN L WHI 4 Power Input 36V RED Dash Board EB1 P2 Connector Pin Name Color 1 Speed limit pot in WHI 2 Speed limit pot high BLU BLK 3 Speed limit pot low GRN BLK 4 N A N A 5 Power for MCU GRN 6 External charger sensor Input BLU ...

Page 65: ...nector Pin Name Color 1 Buzzer power output BRN 2 Buzzer power output BLU Dash Board EB1 P6 Connector Pin Name Color 1 USB 5V RED 2 USB DM WHI 3 USB DP GRN 4 USB GND BLK Dash Board EB1 P3 Connector Pin Name Color 1 Headlight power output BRN 2 Headlight power output BLK ...

Page 66: ...r Power RED 2 SQ1 Proximity sensor Power RED 3 N A N A 4 SQ1 Proximity sensor GND BLK 5 SQ2 Proximity sensor GND BLK Main Controller EB2 P4 Connector Pin Name Color 1 N A N A 2 CAN H BRN 3 CAN L WHI 4 N A N A Main Controller EB2 P1 Connector Pin Name Color 1 Electromagnetic Brake WHI 2 Electromagnetic Brake WHI ...

Page 67: ... deck actuator out2 YEL 11 Squeegee actuator out2 BLU 12 N A N A 13 Slow down sensor 2 Input BRN 14 N A N A Main Controller EB2 P3 Connector Pin Name Wire Color 1 Recovery tank sensor input GRN BLK 2 Solution sensor input BRN BLK 3 N A N A 4 Mechanical brake sensor input BLU BLK 5 N A N A 6 N A N A 7 Warning lamp output BLU 8 36V Output YEL 9 N A N A 10 Accelerator wiper GRY 11 N A N A 12 N A N A ...

Page 68: ...hapter mainly marks the locations of harness to harness connectors that are not easy to find for the convenience of technicians Harness to Harness Connectors C15 Left Brush Motor C18 Brush Deck Actuator Harness to Harness Connectors C11 Water Pump Harness to Harness Connectors C10 Seat Signal ...

Page 69: ...ice Manual AS1050R 24 Electrical System 69 Harness to Harness Connectors C12 Pedal Harness to Harness Connectors C8 Solution sensor Harness to Harness Connectors C6 Slow Down Sensor 2 C7 Slow Down Sensor 1 ...

Page 70: ...Service Manual AS1050R 24 Electrical System 70 Harness to Harness Connectors C9 Recovery Sensor Power for Warning Light Harness to Harness Connectors C13 Electromagnetic Brake C19 Squeegee Actuator ...

Page 71: ...ircuit Breaker 3A P2 4 P2 11 BRN BRN RED BLU BLK Warning Lamp C9 1 C9 2 C11 1 C11 2 RED BLK ORG BLU PUR PUR P2 8 P2 9 P3 7 P2 1 P2 2 BLK BLK GRN RED SW4 SW6 BLK WHI P2 6 C6 3 BLK BLU P2 13 C7 1 C7 2 BRN C6 1 C6 2 BRN BLU P7 2 P7 4 BLK RED P7 5 P7 1 RED BLK K1 F2 FUSE 200A F1 Circuit Breaker 5A SW3 SW1 Emergency Stop VR1 TO 1D4 36V RD BK RED RD BK RED BAT RED Main Contactor 24V GND BLK BLK YEL YEL ...

Page 72: ...ump M8 and solution valve EV1 can only operate when all following inputs conditions are met Brush function is enabled The throttle pedal is pressed Battery capacity 10 Solution sensor SW4 is not activated Wiring Diagram 3 4 5 6 TIGER3 Solution System EB2 BLK BAT BAT 36V Input B RED PUR EB1 P3 18 P4 2 P4 3 P1 1 P1 4 P1 2 P1 3 CAN H CAN L CAN H CAN L EV1 Solution Valve P2 8 P2 9 RED BRN WHI Main Con...

Page 73: ...Service Manual AS1050R 30 Solution System 73 Component Locations Solution valve EV1 Water pump M8 Solution sensor SW4 Figure 2 Figure 3 Solution valve EV1 Water pump M7 Figure 4 Solution sensor SW4 ...

Page 74: ...und 2 Ensure that machine is off and ignition key has been removed 3 Turn the valve A Figure 5 to off 0 4 Remove filter cover D Figure 5 then clean filter E Figure 5 Afterwards replace them to the filter body F Figure 5 5 Turn the valve to on 1 NOTE The filter screen E must be correctly positioned to the housing of filter support H Figure 5 ...

Page 75: ...ve EV1 Removal 5 Disconnect hoses A B from solenoid valve C 6 Disconnect electrical connectors D on solenoid valve C 7 Remove hex screw E then remove plain washer F and spring washer G 8 Remove solenoid valve C Installation Assemble components in reverse order of disassembly Figure 7 ...

Page 76: ...e or repair electrical connector There is dust debris in the tank or in the detergent hoses obstructing solution flow Clean tank hoses Solution tank is empty Fill up solution tank with water Solenoid valve electrical connector is broken Repair Main Controller EB2 fault Replace Dash Board EB1 fault Replace Solution still flows to brush when machine is off There is dirt or calcium deposit on solenoi...

Page 77: ...n System 77 Specifications Description Unit Value Solution tank capacity L 200 Solution flow values Liters Min 1 6 2 3 3 3 4 6 Solution solenoid coil resistance 25 Ω 50 Water pump maximum input current A 5 Water pump rated voltage V 24 ...

Page 78: ...art up and then stop immediately After brush motors start up for several seconds the wires on both sides of brush motors will be connected to positive terminal of power supply at the same time generating reverse current to stop the motor abruptly The brush s inertia thus causes it to disengage from the hub Brush Install Function First put the brush under the brush disc and make sure they are basic...

Page 79: ... CAN H CAN L Brush RED BRN WHI Main Controller M M3 Brush Left C15 1 C15 2 Dash Board VCC GND Key Switch BLK P2 3 P2 10 RED M M2 Brush Right M Brush Deck Actuator M6 F3 Circuit Breaker 30A Brush C14 1 C14 2 F4 Circuit Breaker 30A C18 1 C18 2 F7 Circuit Breaker 3A BLK RED BLK RED BLK BLK B B B B YEL RED RED BRN BRN BRN RED BLK BAT BAT B B 120 Ohm 120 Ohm 36V Out Figure 1 ...

Page 80: ...ator has reached this position which is also defined as the home position When brush pressure function is enabled brush deck actuator M6 will descend to the position of the selected brush pressure level There are 3 brush pressure levels in total Operators can select them via Dash Board EB1 Different levels of brush pressure are achieved by controlling the electrifying time for the brush deck actua...

Page 81: ...ors M2 M3 Brush deck Brush circuit breakers 30A F3 F4 Brush deck actuator circuit breaker 3A F7 Brush deck actuator M6 Brush deck actuator M6 Figure 2 Figure 3 Figure 4 Brush motors M2 M3 Brush deck Brush circuit breakers 30A F3 F4 Brush deck actuator circuit breaker 3A F7 ...

Page 82: ... J 7 Take actuator F and deck lifting arm N out of the brush deck C 8 Remove bolt K and spacer L then take out shaft M 9 Then the actuator can be taken out Installation Assemble components in reverse order of disassembly When assemble shaft E and H turn on power switch and press brush pressure button then actuator will extend When it extends to the lowest position the rest parts can be assembled T...

Page 83: ...from its seat then detach the carbon brush by disengaging its electrical connection F 4 Check condition of the four carbon brushes E Replace carbon brushes if their contact with motor armature is insufficient or carbon brush contact surface is not intact due to wear or thrust spring is broken etc If residual length of carbon brushes reaches the minimum 7mm they must be replaced in any case All mot...

Page 84: ...nd C 3 Remove bolts D 4 Cut off nylon cable tie E and F unplug connector H and G 5 Turn on power switch then press brush pressure button Remove motor I when brush system extends to the lowest position Installation Assemble components in reverse order of disassembly Pay attention to the installation direction of connection plate B and C Figure 7 ...

Page 85: ...reversed to a new edge for up to 3 times before replacement is required During replacement it is important that the blades be installed flat without waves and adjusted to be laid flat against the floor 1 First lift the side squeegee assembly B off the ground 2 Loosen the two thumbscrews A and slide the side squeegee assembly B out of the mounting slots and then remove the squeegee Figure 8 A B ...

Page 86: ...r side blade can be rotated and or flipped for 3 times to expose a new edge 4 edges in total to the lower front When all 4 edges are worn replace it 6 Lay the rubber side blade F on the bracket G and make sure the assembly holes are aligned 7 Use the side blade strap E to compress rubber side blade F Then use the butterfly nut C and carriage screw D to fix them 8 Before fixing the side blade strap...

Page 87: ...otor damaged Repair replace Wiring damaged Repair Circuit breaker F3 or F4 is opened Reset circuit breaker Can t raise lower the brush Brush deck actuator overloaded Check if brush deck actuator is stuck Brush deck actuator M5 damaged Replace Wiring damaged Repair replace Main Controller EB2 damaged Repair replace Circuit breaker F7 is opened Reset circuit breaker The brush disengagement system do...

Page 88: ...tivate brush by pressing throttle pedal and check if current draw of each motor is between 10A and 18A at 36V 7 If amperage is higher than 18A perform following procedures to determine cause and correct abnormal amperage Check and clean it if there are debris wrapped around the shaft Check and replace motor carbon brushes if necessary On page 76 Remove motor and check t condition of all components...

Page 89: ... 2 1000 2 Brush rotation speed normal mode RPM 240 Brush rotation speed ECO mode RPM 175 Brush motors insulation class F Brush motors current no brushes A 4 8 Brush motors protection class IP20 Actuator technical data Max load N 2000 Stroke in mm 2 8 70 Rated voltage V 36 Protection class N A IP54 Insulation class N A F Normal current A 2 ...

Page 90: ...ically When the machine moves backward if the squeegee is not in the status of being elevated it will raise immediately to ensure it won t get damaged The angle of the squeegee and the pressure of the blades against the floor can be adjusted by a knob The front blade has some slots in the bottom but the rear blade doesn t have any so the squeegee can collect water on the floor when the machine is ...

Page 91: ...50R 38 Squeegee System 91 Component Locations Squeegee actuator M7 Mounting handwheel Impact deflection wheel Squeegee blade Squeegee blade Squeegee actuator M7 Mounting handwheel Impact deflection wheel Figure 2 Figure 3 ...

Page 92: ...lipped or reversed to a new edge for up to 3 times before replacement is required During replacement it is important that the blades be installed flat without waves and adjusted to be laid flat against the floor 1 Remove squeegee suction hose C from squeegee assembly A 2 Loosen two thumbscrews B and slide squeegee assembly out of mounting slots and remove squeegee Figure 4 C A B B ...

Page 93: ...de The squeegee blade can be rotated and or flipped for 3 times to expose a new edge 4 edges total to the lower front When all 4 edges are worn replace it 7 Lay rear squeegee blade H on frame K and make sure the tabs and slots J are aligned 8 Close latch D and tighten rear strap G 9 Before closing latch D make sure rear squeegee blade H is straight without waves Figure 5 D E G F J K H D M ...

Page 94: ... 14 Lay squeegee assembly flat on the floor and examine the edges N of the front and rear blades to make sure they are flat without any waves Make this examination with the squeegee assembly still removed from machine and there should be no downward force on squeegee blades If there are waves loosen the strap and straighten the blade again 15 Examine both the front and rear squeegee blades to make...

Page 95: ...ne to level ground lower the squeegee to the floor 3 Examine the contact area between the squeegee blades and the floor The squeegee blades should be in full contact with the floor A small bubble level B may be used to adjust the frame of the squeegee to be level with the floor 4 If squeegee is tilted up there will be a gap at the center and the bubble in the bubble level will be toward the rear o...

Page 96: ...tank 2 Drain solution tank 3 Remove brushes 4 Remove squeegees 5 Remove machine s batteries 6 Raise machine 7 First pull out spring A and B 8 Pull out pin C then take out shaft D 9 Unplug connector E then take out squeegee bracket Installation Assemble components in reverse order of disassembly Figure 8 E A B C D ...

Page 97: ...Squeegee Actuator Removal 1 Pull out spring F and G 2 Take out shaft I then remove brass bushing H 3 Pull out pin J then take out shaft K 4 Take out actuator L Installation Assemble components in reverse order of disassembly Figure 9 F G I H J K L ...

Page 98: ...edges are torn or worn Replace Performance of the squeegee springs fails Replace Squeegee is not correctly adjusted Adjust Can t raise lower squeegee Wiring damaged Repair replace Main Controller EB2 fault Replace Circuit breaker F8 is opened Reset the circuit breaker Squeegee actuator fault Repair replace Specifications Description Unit Value Squeegee width in mm 43 3 1100 Actuator technical data...

Page 99: ...tem is activated automatically by the one touch button and it can then be managed via the vacuum button independently If recovery tank is full it can be emptied through drain hose To work properly the vacuum motor M4 needs the following conditions to be met Vacuum motor function is enabled Battery capacity 10 Recovery tank is not full Recovery sensor SW5 is open Wiring Diagram 3 4 5 6 7 TIGER3 Rec...

Page 100: ... circuit breaker 3A F8 Vacuum motor circuit breaker 30A F5 F6 Recovery sensor SW5 Vacuum motor connecting terminals Figure 2 Figure 3 Figure 4 Figure 5 Squeegee actuator M7 Vacuum motor circuit breaker 30A F5 F6 Squeegee actuator circuit breaker 3A F8 Recovery sensor SW5 Vacuum motor connecting terminals ...

Page 101: ...battery connector 5 Cut off nylon cable tie A disconnect vacuum motor connector B 6 Remove screws C and remove vacuum motor retention plate D 7 Remove bolt E then remove plain washer F and spring washer G 8 Cut off nylon cable tie H remove suction hose I 9 Unscrew lock nut J take out hex screw K then remove plain washer L 10 Remove vacuum motor M Installation Assemble components in reverse order o...

Page 102: ...weight in the tanks can throw off the balance of machine when scrubbing deck is removed from machine 2 Remove vacuum motor according to procedures described on previous page 3 Remove two screws B that fix the brush cover A 4 Remove screws C that fix the brush holder D to the motor 5 Tilt brush holder D out of its pocket and slide it away from the motor 6 Examine commutator bars E if any are damage...

Page 103: ...nstalled before the brush holder is replaced in the motor 11 Align the tip of the carbon brush H against the commutator E 12 Slide the brush holder inward compressing the spring 13 Lower the brush holder into the pocket in the motor housing 14 Reinstall the two retaining screws C 15 Repeat the above mentioned process for the other brush 16 Before replacing the brush cover examine the cooling fan i...

Page 104: ...ched properly Take care that the tank lid should not be opened too far and you won t bump into the support while working under it The tank lid may close suddenly NOTE The tank gasket strip G is critical to creating suction inside the tank when the vacuum motor is working The tank must be sealed so that the vacuum motor can effectively remove the water from the ground to the recovery tank 6 Check w...

Page 105: ...ain hose clamp E open drain hose cover G and then place it in drainage area NOTE When flushing recovery tank B prevent water from getting into battery 6 Use high pressure water gun to flush out garbage and debris from recovery tank B 7 Flush the tank in appointed disposal area 8 Close drain hose cover G and put recovery drain hose F back into drain hose clamp E 9 Close recovery tank lid C then clo...

Page 106: ...personnel only 1 Apply amp clamp A Figure 10 to one of the vacuum motor cables B Figure 10 2 Insert ignition key to switch on machine 3 Start vacuum motor by pressing vacuum button 4 Check if current draw of motor is between 16A and 20A at 36V for one vacuum motor system 5 If amperage is higher than 20A perform following procedures to determine cause and correct abnormal amperage Check and replace...

Page 107: ... Value Recovery tank capacity 200L Vacuum motor technical data 600W DC 36V Maximum vacuum circuit capacity normal mode single motor 62 in H2O 1575 mm H2O Vacuum circuit capacity ECO mode single motor 50 in H2O 1270 mm H2O Vacuum motor normal current single motor 16 20A 36V ...

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Nilfisk-Advance 50000593, Service Manual

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