Nilfisk-Advance 56104000 Service Manual Download Page 62

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Electrical System

Service Manual – SC1500

J4 (39012185)

Pin#

Conductor

Wire Color

–

W060

YEL

W272

GRA

W293

BRN

W276

RED/WHT

–

W067

ORN/BLU

–

W302

RED/YEL

W064

VIO

W278

ORN

–

W066

BLU/BLK

W166

RED/BRN

W217

GRN/ORN

X2 (Ducon 12147067)

Pin#

Conductor

Wire Color

W199

BLK

W167

RED

Summary of Contents for 56104000

Page 1: ...SC1500 5 2013 Revised 11 2017 Form No 56043166 English Service Manual Advance SC1500 Models 56104000 X20D 56104001 X20R Nilfisk SC1500 Models 56104002 SC1500 51D...

Page 2: ...Schedule 13 Lubrication Locations 14 Major Machine Components 15 Machine Controls 16 Key Switch Emergency Stop and Horn Switch 16 Circuit Breakers 17 Speed and Direction Controls and Indicators 18 Sc...

Page 3: ...43 A1 Control Board Shop Measurements 45 Electrical System 47 Functional Description 47 Overview 47 On board Battery Charger 47 Interlock Circuit 48 S P E Charging Profiles and Charging Progress 49 D...

Page 4: ...n 88 Scrub Deck 88 Scrub Deck Actuator Assembly 92 Scrub Deck Actuator Adjustment 93 Specifications 94 Solution System 95 Functional Description 95 Solution Tank Water Filter and Valves 95 Solution So...

Page 5: ...eral Troubleshooting 120 E1 Curtis Speed Controller Diagnostics 120 Diagnostics Method A Graphic Display and Detergent On Off Indicator 120 Diagnostics Method B Curtis Programmer 121 Diagnostic Histor...

Page 6: ...fe Please read it thoroughly before servicing your machine Revision History Date Revisions 6 13 Initial publication 7 13 Revised Scrub Deck Actuator adjustment Added manual Revision History table to G...

Page 7: ...be performed by an Authorized Advance Service Center that employs factory trained service personnel and maintains an inventory of Advance original replacement parts and accessories Call the Advance De...

Page 8: ...ly trained and authorized personnel This machine is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge Avoid su...

Page 9: ...y Switch off O removing the key and applying the parking brake Turn the Key Switch off O and remove the key before changing the brushes and before opening any access panels Take precautions to prevent...

Page 10: ...etic brake that engages whenever the Key Switch is Off or the Go Pedal is released You can manually override this brake if necessary by reaching up around the back of the front drive wheel and rotatin...

Page 11: ...A Gross Vehicle Weight w full solution tank empty recovery tank heaviest batteries no Operator 718 lbs 326 kg Net Weight w empty solution and recovery tanks no batteries or brushes 354 lbs 161 kg Maxi...

Page 12: ...lb 23 05 N m 11 ft lb 14 91 N m 3 8 31 ft lb 42 03 N m 20 ft lb 27 12 N m 1 2 75 ft lb 101 69 N m 50 ft lb 67 79 N m 3 4 270 ft lb 366 07 N m 180 ft lb 244 05 N m M5 61 in lb 6 89 N m 36 in lb 4 07 N...

Page 13: ...ean the Brushes Pads X Check Clean the Squeegee X Check Clean Vacuum Shutoff Float X Empty Clean Debris Catch Tray in Recovery Tank X Check Each Battery Cell s Water Level X Inspect Scrub Housing Skir...

Page 14: ...ing too much grease Hex Shaft Steering Tube Assembly Drive Wheel Chain Drive Chain Idler Sprocket grease fitting Steering Chain Once a month apply light machine oil to the Upper and Lower Steering Sha...

Page 15: ...eneral Information 15 Service Manual SC1500 Major Machine Components Electrical System Recovery System Solution System Chassis System Squeegee Assembly Scrub System 20D Scrub System REV Control System...

Page 16: ...ry power to the machine Note that you must turn the Key Switch to the on I position before stepping onto the machine platform Emergency Stop shuts off all battery power to the machine when pressed To...

Page 17: ...e positive voltage to the key switch and to the battery positive inputs J3 1 and J3 8 on the A1 Control Board 20 amp Circuit Breaker labeled CB3 in the Ladder Diagram controls the positive voltage to...

Page 18: ...Indicator lights to indicate that the Forward Drive Switch has been selected Note that this indicator is lighted in the adjacent drawing Reverse Drive Switch selects the reverse direction Reverse Dri...

Page 19: ...ressure Bar Graph displays the scrub pressure on the graphic display as follows Bottom box filled standard scrub pressure as shown Top and bottom boxes filled extra scrub pressure Solution Controls an...

Page 20: ...three seconds The Detergent On Off Indicator will flash and the purge cycle will last for approximately 10 seconds Burst of Power Switch and Indicator Burst of Power Switch temporarily overrides the c...

Page 21: ...the vacuum mode from low quiet bottom box filled as shown to high standard both top and bottom boxes filled then to off no boxes filled Note that the vacuum motor will switch on when the machine is d...

Page 22: ...of filled bars in the battery icon Five solid bars indicates a full battery charge No solid bars empty battery icon indicates that the batteries are discharged Battery Status and Charger Screens Batt...

Page 23: ...Pedal The Battery Charger is mounted to the bottom of the Chassis Weldment The non traction Wheels are held by flat washers and M8 x 20 screws that thread into the axle in the Chassis Weldment The Dri...

Page 24: ...uates the Operator Presence Switch called the Deadman Switch S2 in the Wiring Diagram The Operator Presence Switch must be actuated before the Go Pedal will drive the machine forward or reverse When t...

Page 25: ...Test Mode The Programming Mode is used primarily for telling the A1 Control Board how the machine is equipped so that it can operate accordingly The Service Test Mode allows you to operate various ma...

Page 26: ...ximately 1 amp 10 Brush Contactor K2 coil overload The Brush Contactor has drawn more than approximately 1 amp 11 Detergent Pump overload The Detergent Pump has drawn more than approximately 1 amp 21...

Page 27: ...the Detergent Pump driver should have been off 70 On board Battery charger fault An error has been generated via the serial communications between the charger and the A1 Control Board due to an incorr...

Page 28: ...g the machine systems Service Test Mode is accessed through the hidden menu system which is described in Programming Options on page 31 Note Service Test Mode is not available if the machine is being...

Page 29: ...ation Switch see below SPD indicates the drive controller state In this case it would display R for reverse The three digits display the battery voltage 26 5 volts in this example REV indicates that t...

Page 30: ...Pressing the Solution Flow Adjustment Switch toggles the solution solenoid ON and OFF When the solenoid is ON it will operate at 50 duty cycle 1 cycle 3 seconds ON 3 seconds OFF SOL indicates the sta...

Page 31: ...submenu press the forward reverse switches to scroll through the options 9 Press the Scrub switch to save and exit the submenu The main menu contains the following links to the corresponding programmi...

Page 32: ...pump automatically when the batteries discharge to the selected cutout level The 2 LOW VOLT CUTOUT submenus allow you to select the voltage cutout level for the type of battery installed in your machi...

Page 33: ...to enable or disable the burst of power function When the burst of power function is enabled YES pressing the Burst Of Power Switch while scrubbing will attempt to make a temporary increase in the sol...

Page 34: ...hat the 6 CHEMICAL RATE BIAS submenus only have an effect if the ECOFLEX INSTALLED YES option is selected see above The default setting is NONE Open Fault Detect Normally the A1 Control Board will per...

Page 35: ...settings The Operator will not be able to select flow rate s that are locked out during normal operation The default setting is NONE PROGRAM OPTIONS LOCKOUT BRUSH NONE PROGRAM OPTIONS 9 LOCKOUT BRUSH...

Page 36: ...horn volume The default setting is HIGH PROGRAM OPTIONS BACKUP ALARM VOL MEDIUM PROGRAM OPTIONS BACKUP ALARM VOL HIGH PROGRAM OPTIONS BACKUP ALARM VOL LOW PROGRAM OPTIONS BACKUP ALARM VOL OFF PROGRAM...

Page 37: ...ing the machine Any logged fault codes will be shown on the display Fault codes 3 32 and 52 are shown here in this example If no fault code is present the display will show a Pressing the Burst Of Pow...

Page 38: ...e but the selected information can be changed at will via the 17 EXTRA INFO ON LCD submenus Descriptions of the letter codes are as follows BV Battery Voltage LOK Battery Lock Level ACT Deck Actuator...

Page 39: ...the time on the hour meter when the error code occurred 12 15 in this example The other nine first level submenus are links to the next second layer of submenus that display the 128 data points corre...

Page 40: ...he Reverse Drive Switch will step you from data record 128 to 127 127 to 126 etc In the fast scrolling mode the increment decrement value is 10 one second Pressing the Forward Drive Switch will step y...

Page 41: ...cators are used as described in the table below Membrane Switch Resulting LED Indicators Legacy Machines Resulting LED Indicators Newer Control Boards Horn Switch Burst Of Power Amber LED Burst Of Pow...

Page 42: ...to discharge any electrical charge that may have built up in your body Do not walk around with a Control Board in your hands 1 Disconnect the batteries 2 Remove the four Phillips Screws and Flat Washe...

Page 43: ...Assembly 6 Reinstall the A1 Control Board by following the above steps in reverse order E1 Curtis 1210 Speed Controller 1 Disconnect the batteries 2 Remove the four Phillips Screws and Flat Washers ho...

Page 44: ...e E1 Curtis 1210 Speed Controller 5 Remove the two Socket Head Screws and remove the E1 Curtis 1210 Speed Controller from the Control Panel 6 Reinstall the E1 Curtis 1210 Speed Controller by following...

Page 45: ...9v retracting J1 10 ORN BLK Brush Act B 2 1v or 3 8v at rest 0 2v retracting 22 9v extending J2 1 BLK B B 0 09v Vacuum On J2 2 BLK B B 0 09v Vacuum On J2 3 ORN Batt Chg Comm B 0 8v key off Plug in Cha...

Page 46: ...24 4v key off or on J3 9 GRN BLK Horn B 14 9v horn off 0 004v horn on J3 10 ORN RED Horn B 14 9v horn off or on J3 11 VIO BLK Solution Solenoid B 24 4v solenoid off 0 12v solenoid on J3 12 GRA BLK Vac...

Page 47: ...for connecting the batteries to a shelf battery charger unit The control system will turn off the scrub system and recovery systems if the battery voltage drops too low to prevent damage to the batter...

Page 48: ...voltage to be present in the Keyswitch E Stop and Deadman circuit When all switches are closed positive voltage is applied to the enabling inputs of the A1 Control Board and the Speed Controller When...

Page 49: ...he charging progress The S P E battery charger and A1 Control Board communicate with one another on the YEL ORN wire that runs between them Each time the battery charger is plugged in the charger cont...

Page 50: ...Profile Table Battery Manufacturer Volts Battery Model 20 Hour Rating N A P N Use Profile DISCOVER 6 EV250A AGM 260 40953A P 0 4 3 DISCOVER 6 EV305A A 312 56112546 P 0 4 3 DISCOVER 6 EV305A A 312 563...

Page 51: ...1 56317154 P 0 7 2 US BATTERY 6 US1800 201 56206117 P 0 1 1 US BATTERY 6 US250HC 275 56026200 P 0 1 1 US BATTERY 6 US 305 305 891384 P 0 7 2 US BATTERY 6 US 305 305 891385 P 0 7 2 US BATTERY 6 US 305...

Page 52: ...Contactors Relays 150 amp Fuse The Batteries sit in the Battery Tray To access the Batteries lift up the Control Panel Housing Recovery Tank Cover engage the Prop Rod then tilt the Recovery Tank back...

Page 53: ...S1 are all mounted on the back of the Control Panel The Solid State Relay K1 Brush Motor Contactor K2 Fly back Diode D2 and 150 amp Fuse are located inside the control panel assembly 25 amp Circuit Br...

Page 54: ...es Measure the voltage across each individual battery while operating the machine Write down the values and compare them A battery that has a dead cell will typically be 1 2 volts lower than the other...

Page 55: ...OPTIONAL SEE PAGE 2 A B 1 2 3 X001 X003 X004 X002 X006 TRACKCLEAN CONNECTIONS X001 B RED X002 B BLU X003 SCRUB WHT X004 KEY SW BRN X005 VACUUM GRA X006 DRIVE PNK X007 BYPASS BRN X008 MACHINE SUPPLY OR...

Page 56: ...R POWER MODULE SOLID STATE RELAY 1 2 3 INLINE FUSE 3A P N 56383587 X005 C YEL ORN RED BLK BRN YEL YEL BLK RED VIO BLK WHT RED BLK BLU ORN WHT GRA BLK BRN BLU ORN BLK B B M M4 MOTOR VAC 1 2 M M3 MOTOR...

Page 57: ...Electrical System 57 Service Manual SC1500 Wiring Harness Diagram Current Drawing 56104447 Rev B for machines with Serial Numbers above 3510143206293...

Page 58: ...Electrical System 58 Service Manual SC1500 Wiring Harness Diagram Legacy Drawing 56104082 Rev C for machines with Serial Numbers below 3510143206293...

Page 59: ...ntify a Connector For example if you need to find out which connector is on the L1 solution Solenoid Valve and what it looks like refer to the Wiring Harness Diagram The Wiring Harness Diagram shows t...

Page 60: ...Fit Jr 39012105 Pin Conductor Wire Color 1 W279 RED YEL 2 3 W280 BLU GRA 4 5 6 7 W302 RED YEL 8 W165 YEL BLK 9 W054 BLU 10 W055 ORN BLK J2 Molex Mini Fit Jr 39012125 Pin Conductor Wire Color 1 W162 BL...

Page 61: ...Molex Mini Fit Jr 39012145 Pin Conductor Wire Color 1 W181 BRN VIO 2 3 W166 RED BRN 4 W294 BRN 5 W066 BLU BLK 6 W277 RED WHT 7 W067 ORN BLU 8 W182 BRN VIO 9 W281 GRN BLK 10 W282 ORN RED 11 W283 VIO BL...

Page 62: ...in Conductor Wire Color 1 2 3 W060 YEL 4 W272 GRA 5 W293 BRN 6 W276 RED WHT 7 8 9 W067 ORN BLU 10 11 12 W302 RED YEL 13 W064 VIO 14 W278 ORN 15 16 W066 BLU BLK 17 W166 RED BRN 18 W217 GRN ORN X2 Ducon...

Page 63: ...nual SC1500 X6 Delphi 12052613 Pin Conductor Wire Color A W191 WHT B W194 BLK X7 Delphi 12015792 Pin Conductor Wire Color A W284 BRN B W283 VIO BLK X126 AMP 282087 1 Pin Conductor Wire Color 1 W172 BR...

Page 64: ...hi 15363990 Pin Conductor Wire Color A W170 RED B W171 BLK X139 Delphi 12020786 Pin Conductor Wire Color A W055 ORN BLK B W054 BLU C W204 RED VIO D W165 YEL BLK E F W218 BLK WHT X143 Ducon 12147067 Pi...

Page 65: ...System 65 Service Manual SC1500 X144 Delphi 12015792 Pin Conductor Wire Color A W278 ORN B W275 RED WHT X161 Delphi 12020926 Pin Conductor Wire Color A W272 GRA B W271 YEL C W289 WHT BRN D W293 BRN E...

Page 66: ...age and Recovery Tank The Vacuum Motor creates a vacuum inside of the Recovery Tank to pull the wastewater from the squeegee into the Recovery Tank The Float Cage Assembly contains two internal plasti...

Page 67: ...wer handing capabilities Also refer to Squeegee System on page 106 for more information on the squeegee components and operation Circuit Descriptions Vacuum Motor Off S1 2 1 Bat Pin 6 J3 6 24v Bat J3...

Page 68: ...t loses the drive signal from the E1 Curtis Speed Controller When the Operator selects a drive direction and presses the go pedal The Brake switch on Pin 6 in the E1 Curtis Speed Controller closes to...

Page 69: ...back Diode D2 The Recovery Tank is located underneath the control panel The Vacuum Motor is mounted below the Recovery Tank The Debris Cage filters any debris out of the wastewater before it can enter...

Page 70: ...Drain Hose allows you to drain the wastewater from the Recovery Tank The Solid State Relay K1 and Fly back Diode D2 rectifier bridge are located inside the control panel assembly Drain Hose Control P...

Page 71: ...cuum Motor M4 and repair as necessary The Vacuum Motor M4 is not connected to battery ground Check the ground connection to the Vacuum Motor M4 and repair as necessary Relay SSR1 is faulty Replace rel...

Page 72: ...onnect the negative test lead to the negative terminal on the rectifier 3 One at a time touch the positive test lead to the remaining 3 terminals If the meter beeps or reads continuity for any of the...

Page 73: ...in the upper left position as shown then fasten the Fly back Diode to the electrical panel with the Screw and Nut 9 Connect the White Wire to the Positive Tab and the Black Wire to the opposite tab a...

Page 74: ...e Vacuum Motor from the Recovery Tank 6 Reinstall the Vacuum Motor by following the above steps in reverse order Note Make sure you install the Acoustic Insulation correctly around the Vacuum Motor wh...

Page 75: ...nent Specifications Vacuum Motor Current Draw Low Speed 11 12 Amps High Speed 16 17 Amps Vacuum Water Lift Sealed 40 44 Inches of Water 1 open hole 9 5 Inches of Water Vacuum Motor Mounting Screws 3 N...

Page 76: ...m the floor with no scrubbing The normal scrub pressure position lowers the scrub deck so the brush pad contacts the floor with normal scrub pressure The extra scrub pressure position lowers the scrub...

Page 77: ...r which is bolted to the Deck Lift Plate Weldment Brush Housing and Lower Deck Plate The Solution Solenoid Valve Assembly controls the solution flow to the Brush The squeegee assembly snaps onto the S...

Page 78: ...Plate Weldment and Rev Housing The Solution Solenoid Valve Assembly controls the solution flow to the Pad The squeegee assembly snaps onto the Squeegee Link Weldment Note that the 20R REV Scrub Decks...

Page 79: ...ent positions The fully retracted up position is the Scrub Deck transport position and is used when the Scrub and Recovery Systems are not active Scrub Deck position 1 is the vacuum only position In t...

Page 80: ...ated by rotating Cams provide actuator position feedback to the A1 Control Board Two internal Limit Switches top and bottom also actuated by rotating Cams switch off the actuator Motor at the fully re...

Page 81: ...h Motor Brake K2 Brush Contactor A1 Control Board E1 Curtis 1210 Speed Controller Motion Input 24v When the machine is stationary The Brake switch on Pin 6 in the E1 Curtis Speed Controller is open an...

Page 82: ...scrub deck is below the vacuum only position The A1 Control Board must receive a motion signal from the E1 Curtis Speed Controller When the Operator selects a drive direction and presses the go pedal...

Page 83: ...Board switches on the power to the Brush Lift Actuator Motor M3 The Deck Actuator Assembly lowers the scrub deck to POS position 1 When the deck reaches POS 1 the Cam closes the S7 POS 1 switch which...

Page 84: ...urst of Power switch is pressed the Gang Switch in the A1 Control Board switches on the power to the Brush Lift Actuator Motor The Deck Actuator Assembly lowers the scrub deck to the extra scrub press...

Page 85: ...rub Deck Motor Brush Motor Contactor K2 Scrub Deck Actuator Assembly The Scrub Deck is suspended underneath the machine and pivots up and down on a mechanical mount The Scrub Deck Motor is mounted on...

Page 86: ...2 controls the power to the scrub deck motor and is located inside the control panel assembly The Scrub Deck Actuator Assembly is attached to the Scrub Deck and machine frame and lowers and raises the...

Page 87: ...ng from the K2 Brush Contactor to the Brush Motor and repair as necessary 6 Check the Brush Motor ground connection and repair as necessary Scrub Deck Actuator not running No voltage to the Deck Actua...

Page 88: ...wire tie to do this 3 Turn the key switch off 4 Make sure the Ball Valve from the solution tank to the Filter is set to the off position 5 Loosen the Clamp and remove the Solution Hose from the Soluti...

Page 89: ...and the two Linkage Bars Note that you ll need to hold the M10 Nyloc nuts with a 17mm wrench while you remove the Shoulder Screws 11 Remove the Shoulder Screw and nut that connect the scrub deck actu...

Page 90: ...ub Deck Actuator is disconnected from the scrub deck This can cause the Scrub Deck Actuator to get out of adjustment 12 Lift up the link bar and rotate the scrub deck slightly counterclockwise as view...

Page 91: ...to remove the deck from the machine 16 Reinstall the deck by following the above steps in reverse order Caution Note that the scrub deck actuator will automatically raise the scrub deck when you recon...

Page 92: ...f 4 Disconnect and remove the battery closest to the scrub deck actuator to get enough clearance to remove the actuator 5 Remove the Shoulder Screw and nut that connect the scrub deck actuator to the...

Page 93: ...ect the Actuator Electrical Connector and battery Scrub Deck Actuator Adjustment The Scrub Deck Actuator adjustment consists of setting the Tube position with the retracted travel limit switch actuate...

Page 94: ...Voltage 24 VDC RPM 2200 Current Draw No load 8A Normal Operation 12 19 Amps depending on floor surface solution flow rate and scrub pressure Output Power 560 Watts 3 4 HP K2 Brush Contactor Nominal C...

Page 95: ...that opens and closes the Valve to regulate the solution flow according to the flow rate selected with the solution flow adjustment switch The Solution System includes the Solution Tank Water Filter S...

Page 96: ...through Pin J3 11 to switch the L1 Solution Solenoid Valve to ground and open the L1 Solution Solenoid Valve for a period of time corresponding to the selected solution flow rate The period of time du...

Page 97: ...upstream of the scrub deck The A1 Control Board sends voltage pulses to the Detergent Pump that alternate polarity to move the pump plunger and diaphragm in and out to control the Detergent Pump outp...

Page 98: ...n the machine is stationary The Brake switch on Pin 6 in the E1 Curtis Speed Controller is open and is not sending the drive signal to the Motion Input line on pin J3 6 on the A1 Control Board The Sol...

Page 99: ...l Board must receive a motion signal from the E1 Curtis Speed Controller When the Operator selects a drive direction and presses the go pedal The Brake switch on Pin 6 in the E1 Curtis Speed Controlle...

Page 100: ...peed Controller Motion Input 0 1v Bat Pin 6 J3 6 24v Pin 6 M2 M J1 3 J1 1 Bat Bat Bat RED YEL BLU GRA RED WHT Detergent Pump Detergent Pump Detergent Pump Brake A1 Control Board E1 Curtis 1210 Speed C...

Page 101: ...ller Motion Input 24v When the Detergent System is off the Detergent Pump switches on pins J1 1 and J1 3 do not provide power to the Detergent Pump Component Locations The following components are inc...

Page 102: ...rub brush pad The solution Ball Valve controls the solution flow from the solution tank to the Water Filter The Water Filter filters the solution upstream of the solution solenoid valve The 90 Ball Va...

Page 103: ...the Control Panel Housing Recovery Tank Cover and sits below the Prop Rod Mounting Bracket The Detergent Cartridge is located at the front of the machine underneath the Control Panel Housing Recovery...

Page 104: ...wiring from the Key Switch to the Solution Solenoid Valve and repair as necessary The Solution Solenoid Valve is not operating correctly 1 Check the Solution Solenoid Valve coil resistance If the resi...

Page 105: ...tance 38 5 Ohms Pulse Frequency 3 5 Hz Pulse Width 110 ms Pulse Current 0 7 A Pulse Power Consumption 15 W Detergent Cartridge Capacity 1 gallon 4 liters Nominal Solution Flow Rates The nominal soluti...

Page 106: ...Weldment The Squeegee Link Weldment attaches to a pivoting mount on the scrub deck that allows the Squeegee Assembly to rotate about the scrub deck This allows the Squeegee Assembly to pick up wastewa...

Page 107: ...Squeegee Link Weldment Knob Assemblies Squeegee Blades Squeegee Casting Caster Wheel Squeegee Mount Bracket Squeegee Cover Rear Squeegee Strap Vacuum Hose Assembly Squeegee Link Weldment Knob Assembly...

Page 108: ...hine on a flat even surface and lower the squeegee 2 Drive the machine forward enough to have the squeegee blades fold over to the rear 3 Adjust the squeegee tilt by adjusting the Caster Wheel height...

Page 109: ...e Assembly when the Control Panel Housing Recovery Tank Cover is opened and closed to maintain steering alignment The Steering Tube Assembly is connected to the Lower Universal Joint which drives the...

Page 110: ...Upper Universal Joint Hex Shaft and Steering Tube Assembly are located underneath the Control Panel Housing Recovery Tank Cover The Lower Universal Joint is connected to the Steering Tube Assembly and...

Page 111: ...rection The steering is binding or the machine steers hard The upper and lower universal joints are out of phase Realign the upper and lower universal joints Refer to the Wheel System Traction Removal...

Page 112: ...peed Controller provides pulse width modulated voltage to the Drive Wheel Motor to control the machine speed The Speed Controller will alternate the voltage polarity to control the machine direction T...

Page 113: ...s 1210 Speed Controller The contacts in the Internal Relay in Battery Charger must be closed charger unplugged The Emergency Stop S4 switch and Dead Man Switch S2 must be closed If all of these condit...

Page 114: ...ed Controller at Pin 18 Speed Limit The Speed Controller provides a power supply out Pin 14 24V Brake to the Y1 Brake solenoid Just before the Speed Controller provides power to the Wheel Drive Motor...

Page 115: ...When the switch on Pin 6 closes the voltage on the wire drops to 0 volts Inhibit Output J1 7 Pin 12 Inhibit Input The A1 Control Board uses the inhibit signal to tell the Speed Controller when it is...

Page 116: ...rcuit is identical to the Motion circuit When not in reverse the switch on Pin 16 Reverse Alarm in the Speed Controller is open leaving the signal at J3 5 high 24 volts When driving the wheel in rever...

Page 117: ...Speed Control Adjustment Knob 100k Speed Control Potentiometer Drive Wheel Brake The Drive Wheel Assembly is fastened to the machine frame underneath the front of the machine Note that the adjacent p...

Page 118: ...ntrols the machine speed in both forward and reverse The Drive Wheel Brake is built in to the Drive Wheel Motor and will engage to stop the machine whenever the key switch is Off or the Go Pedal is re...

Page 119: ...ter set at maximum Smaller numbers provide faster response Accel Min Speed 0 2 8 0 4 0 Sets the forward acceleration rate with the speed potentiometer set at minimum Smaller numbers provide faster res...

Page 120: ...voltage to the drive motor 1 Check the wiring from the Speed Controller to the drive motor and repair as necessary 2 If the wiring is OK replace the Speed Controller E1 Curtis Speed Controller Diagno...

Page 121: ...Test the circuitry with the programmer 1 Correct the problem 1 Repeat the last three steps as necessary until the vehicle is operational Refer to the Status LED Fault Code Table on page 122 for sugges...

Page 122: ...oken throttle pot or throttle mechanism 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...

Page 123: ...n and recovery tanks 4 Disconnect and remove the batteries 5 Remove the four M8 x 30 Screws and flat washers holding each of the two Tip Pads to the machine and remove the Tip Pads Caution Tipping the...

Page 124: ...ip Make sure the axes of the two Universal Joints are parallel when you reconnect the Steering Assembly Tube to the Lower Universal Joint If the two Universal Joints are out of phase the steering syst...

Page 125: ...the M8 x 55 Screw with a wrench and loosen the M8 x 55 Screw 4 Slide the Idler Adjust Weldment and Sprocket Assembly as necessary to get some slack in the Chain 5 Remove the Master Link and remove the...

Page 126: ...rame Weldment 8 To reinstall the Drive Motor into the Drive Wheel Frame Weldment follow the above steps in reverse order Service Tip When you set the chain tension with the M6 x 35 Idler Adjuster Scre...

Page 127: ...three M6 x 14 Screws and flat washers holding the Steering Shaft Weldment to the Spindle Mount Weldment 4 Remove the chain from the sprocket on the Steering Shaft Weldment then remove the Steering Sh...

Page 128: ...high quality lithium base grease before reassembly Bearing Cone Bearing Cup Shaft Seal Bearing Block Shaft Seal Bearing Cone Bearing Cup Bearing Block 8 Remove and replace the Ball Bearing as necessar...

Page 129: ...3 2 Remove the Drive Wheel Motor described on page 125 3 Remove the Cap holding the brush in the motor 4 Carefully pry out the old Brush from the motor 5 Install a new Brush then reinstall the Cap 6 R...

Page 130: ...rlock switches closed 6 RED WHT Brake B 22 2v off brake applied 0 1v on brake released 7 8 9 ORN BLU Status B Unstable voltage when there is a code If unplugged 23v from A1 control board 10 11 12 RED...

Page 131: ...FWD high speed 0 17v REV low speed 12v REV high speed 20v M1 M2 FWD low speed 1 5v FWD high speed 23 2v REV low speed 1 3v REV high speed 16v General Specifications Component Specifications Drive Whe...

Page 132: ...Wheel System Traction 132 Service Manual SC1500 Special Tools Curtis 1311 Handheld Programmer p n 56409441...

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