Nilfisk-Advance 9087350020 Service Manual Download Page 98

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Service Manual – SC500

05 - Control System, Magnetic Smart Key

J3 - 8 way ribbon connector

Figure 49:

PIN

Color

Circuit Description

Measured

Comments

Power supply - common

0.003v

SP / EXTRAPR function LED (red)(LD3R) 1.78v Red LED on

0.032v Red LED off

SP / EXTRAPR function LED (green)

(LD3V)

1.95v Grn LED on

0.032v Grn LED off

BRUSH RELEASE function LED (LD4)

0.07v LED off

Pulsing when flashing

BRUSH RELEASE switch (P6)

3.14v not pressed

0.03v pressed

INCREASE SPEED button (P7)

3.14v not pressed

0.02v pressed

DECREASE SPEED button (P8)

3.14v not pressed

0.02v pressed

ONETOUCH / EXTRAPR. button (P5)

3.16v not pressed

0.04v pressed

Summary of Contents for 9087350020

Page 1: ...C500 20D B 9087403020 SC500 X20 B V 9087405020 SC500 X20R B V 9087404020 SC500 20D B V Nilfisk Model Numbers 9087350020 SC500 53 B FULL PKG 9087351020 SC500 53 B 9087351020 SC500 53R B 9087400020 SC500 53 B FULL PKG V 9087401020 SC500 53 B V 9087402020 SC500 53R B V 01 2015 revised 07 2017 E Form No 9099984000 ...

Page 2: ...tic Equipment 20 Dimensions 21 SC500 Disc 21 SC500 REV 22 04 Control System 23 Model No 9087352020 9087354020 9087350020 9087351020 9087353020 9087355020 23 Functional Description 23 Wiring Diagram 24 Component Locations 25 Troubleshooting 26 Main machine controller EB1 Alarm Codes 26 Black box Recording of Alarms Parameters see pages 34 35 Partial Operating Time Counter 31 Display Main Screen 31 ...

Page 3: ...Connectors 80 Connectors of the Display Controller EB2 86 Shop Measurements 89 Shop Measurements Main machine controller EB1 89 Shop Measurements Display Controller EB2 96 10 Chassis System 100 Chassis main parts 100 20 Wheel System Traction 101 Functional Description 101 Wiring Diagram 102 Component Locations 103 Troubleshooting 105 Drive System Gear Motor Current Draw Test 106 Removal and Instal...

Page 4: ... Description 138 Brush Release System 138 Wiring Diagram 139 Brush Deck Actuator System 140 Component Locations 141 Maintenance and Adjustments 143 Brush Installation Removal 143 Troubleshooting 144 Brush Motor Current Draw Test 145 Removal and Installation 146 Brush Deck 146 Checking Replacing Brush Motor Carbon Brushes 149 Brush Motor Disassembly Assembly 150 Brush Deck Actuator 151 Specificatio...

Page 5: ...tion 172 Gas Spring on the Squeegee Support 172 Spring on the Squeegee Support 173 Specifications 174 40 Recovery System 175 Functional Description 175 Wiring Diagram 176 Component Locations 177 Maintenance and Adjustments 178 Recovery Tank Cleaning 178 Troubleshooting 179 Vacuum Motor Current Draw Test 180 Removal and Installation 181 Vacuum Motor Unit 181 Container and Vacuum Motor Disassembly A...

Page 6: ...ming any maintenance and repair procedure on the machine Other Reference Manuals Model Model No Instructions for use Spare Parts List Advance SC500 X20 B 9087352020 9099980000 9099981000 Advance SC500 X20R B 9087353020 Advance SC500 20D B 9087354020 Advance SC500 X20 B V 9087403020 Advance SC500 X20R B V 9087405020 Advance SC500 20D B V 9087404020 Nilfisk SC500 53 B FULL PKG 9087350020 9099974000 ...

Page 7: ...me are marked on the plate see the example to the side Product code and year of production Date code A17 as January 2017 are marked on the same plate Model Scrubber Dryer SC500 20 B Prod Nr 9087352020 GVW 207 kg 456 lb Battery 24 Vdc 21 A Charg 100 240Vac 50 60 Hz Type E Scrubber Dryer Serial No Date code LpA 63 dB A IPX4 2 Made in Hungary Nilfisk Advance Inc Plymouth MN USA www advance us com UL ...

Page 8: ...ets max 2 WARNING Do not use the machine on slopes with a gradient exceeding the specifications Symbols The following symbols are used to help you recognize the information concerning the safety and the prevention of problems DANGER Indicates a potentially hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if no...

Page 9: ... cards electronic keys phone cards near the key The built in magnet can damage or erase the data stored on the magnetic bands Before using the battery charger ensure that frequency and voltage values indicated on the machine serial number plate match the electrical mains voltage Do not pull or carry the machine by the battery charger cable and never use the battery charger cable as a handle Do not...

Page 10: ... While using this machine take care not to cause damage to people or objects Do not bump into shelves or scaffoldings especially where there is a risk of falling objects Do not lean liquid containers on the machine use the relevant can holder The machine operating temperature must be between 32 F and 104 F 0 C and 40 C The machine storage temperature must be between 32 F and 104 F 0 C and 40 C The...

Page 11: ...o lack of maintenance If necessary request assistance from the authorised personnel or from an authorised Service Center If parts must be replaced require ORIGINAL spare parts from an Authorised Dealer or Retailer To ensure machine proper and safe operation the scheduled maintenance shown in the relevant chapter of this Manual must be performed by the authorised personnel or by an authorised Servi...

Page 12: ... without supporting it with safety stands Transporting The Machine WARNING Before transporting the machine make sure that All covers are closed The recovery tank and the detergent tank are empty The batteries are disconnected The ignition key is removed The machine is securely fastened to the means of transport ...

Page 13: ...sure function turned on 66 lb 30 kg 66 lb 30 kg Solution flow values 0 75 cl m 1 5 cl m 3 0 cl m 2 8 l min 0 38 cl m 0 75 cl m 1 5 cl m 2 8 l min EcoFlex system detergent percentage Ratio 1 400 1 33 0 25 3 Sound pressure level at workstation ISO 11201 ISO 4871 EN 60335 2 72 LpA 63 3 dB A 65 3 dB A Sound pressure level at workstation in silent mode LpA 60 3 dB A 61 3 dB A Machine sound power level ...

Page 14: ... Weight without batteries and with empty tanks 187 lb 85 kg 194 lb 88 kg Gross vehicle weight GVW 456 lb 207 kg 463 lb 210 kg Shipping weight 256 lb 116 kg 262 lb 119 kg Machines have been tested under the following conditions Battery maximum size Maximum brush and squeegee size Full detergent tank Optional equipment installed Wheel weight checked Print on the floor checked on cement for each sing...

Page 15: ... pad cleaning Recovery tank and debris tray cleaning and cover gasket check EcoFlex system cleaning and draining Squeegee blade check Solution Filter Cleaning Battery WET fluid level check Squeegee blade replacement Brush motor carbon brush check or replacement Drive system motor carbon brush check or replacement Brush deck vibration damper replacement only for REV version ...

Page 16: ...button Machine speed adjustment push buttons Machine start stop push button Machine ignition key Operator key grey Super user key yellow Figure 2 Control panel REV deck Prod Nr 9087353020 9087355020 max 2 1s EcoFlex system push button Display Vacuum system adjustment deactivation push button One Touch Scrub ON OFF push button Detergent flow adjustment push button REV function push button Detergent...

Page 17: ...ine speed adjustment push buttons Machine start stop push button Smart key reader Magnetic smart key Blue User Yellow Supevisor Figure 4 Control panel REV deck Prod Nr 9087405020 9087402020 max 2 1s EcoFlex system push button Display Vacuum system adjustment deactivation push button One Touch Scrub ON OFF push button Detergent flow adjustment push button REV function push button Detergent percenta...

Page 18: ...cable Battery charger cable housing and document holder Recovery water drain hose Battery connector red Squeegee vacuum hose Squeegee lifting lowering pedal Squeegee adjusting knob Squeegee mounting handwheels Solution drain and level check hose Tank lifting handle Serial number plate technical data conformity certification Solution filter Solution tap Rear pivoting wheels Figure 6 ...

Page 19: ...k cover Vacuum grid with automatic shut off float Vacuum system motor Solution tank Recovery tank Detergent solution tank front filler Batteries Water removable filler hose Squeegee EcoFlex detergent tank Disc brush deck REV deck Front driving wheels Machine straight forward movement adjusting knob Brush REV brush Figure 7 ...

Page 20: ...ble Internet connection Digital Volt Meter DVM Amp clamp with possibility of making DC measurements Hydrometer Battery charge tester to check 12V batteries Static control wrist strap Dynamometric wrench set A copy of the Instructions for Use Manual and Spare Parts List of the machine to be serviced provided with the machine or available at www advance us com or other Nilfisk websites The following...

Page 21: ...21 Service Manual SC500 03 General Information Dimensions SC500 Disc 50 3 in 1277 mm 28 3 in 720 mm 41 8 in 1063 mm 21 in 532 mm Figure 9 ...

Page 22: ...22 Service Manual SC500 03 General Information SC500 REV 51 2 in 1302 mm 28 3 in 720 mm 41 8 in 1063 mm 21 2 in 538 mm Figure 10 ...

Page 23: ...eck actuator M5 Brush motor M6 Solution flow solenoid valve EV1 Detergent pump M4 The Display controller EB2 serves mainly as an aggregator for all input signals buttons and outputs LEDs from the User interface controller EB3 which it is connected to via 2 flat cables Mounted on the Display controller EB2 is also the LCD display and the 2 sensors which detect the presence and type of magnetic key ...

Page 24: ...y Return from key FCI DUFLEX 2 54 pitch 8 way male pins FCI DUFLEX 2 54 pitch 9 way male pins User interface controller power supply User interface controller serial User interface controller serial User interface controller power supply Return from key B B DISPLAY CONTROLLER EB2 BATT BATT Microprocessor Microprocessor SIGNAL CIRCUITS FUSE F2 MAIN MACHINE CONTROLLER EB1 USER INTERFACE CONTROLLER E...

Page 25: ...25 Service Manual SC500 04 Control System Component Locations Figure 2 Main machine controller EB1 Figure 3 Flat calbes from EB2 to EB3 User interface controller EB3 Display controller EB2 ...

Page 26: ...agnostic LEDs Figure 5 on the Main machine controller EB1 as indicated in the following tables Figure 5 General alarms Alarm on Main machine controller FLASHING YELLOW RED LEDS Alarm code Description No Flashes Meaning Condition Effect Service Suggestions G2 EEPROM ERROR 2 EEPROM error EEPROM error Function block Default setting reset If the machine continues to function after G2 has been displaye...

Page 27: ...is broken Check the battery voltage under load G4 BATTERY LOW VOLTAGE 4 Undervoltage The battery voltage remains below 18 4V for over 10 seconds for WET CELL batteries 19 6V for GEL AGM batteries Function block 1 Check the battery voltage under no load conditions and under load Replace the faulty battery batteries if necessary 2 Recharge the batteries by performing a complete charging cycle G5 BAT...

Page 28: ... than 1 second Brush function block 1 Check that there is no friction on the brush deck linkage lubricate if necessary 2 Check that the actuator and deck travel is not blocked by mechanical obstructions 3 If the problem persists replace the actuator F5 HARDWARE FAILURE 5 Short circuit on the vacuum or brush motor drive MOSFET MOSFET short circuit Function block 1 Check that there are no short circ...

Page 29: ... pedal 1 If the alarm persist replace the controller 2 If not check the cables of the gear motor and motor itself for a short circuit T6 DRIVE MOTOR FAILURE 6 Overcurrent motor D C Drive motor current draw greater than 1 5 times the value of the parameter see page 35 IMAX Drive blocked 1 Check that the gear motor cables are not short circuited 2 Check that the motor of the gear motor unit is not s...

Page 30: ...LTAGE Battery overvoltage Battery voltage over 32V Battery charger block 1 Check the connections of the batteries and the voltage of the installed batteries 2 Disconnect and reconnect the battery charger C4 CHARGING TIME I EXPIRED Charging phase I expired Battery excessively discharged or at end of life cycle Battery charger block If the problem persists replace the batteries C5 CHARGING TIME II E...

Page 31: ...in place of the operator grey key Figure 6 to access the main screen Figure 7 of the display Figure 6 2 Press One Touch push button to change the machine settings see Machine Settings Screen section 3 Press the brush release button or REV button to check for any stored machine alarms see Alarms Log Screen section 4 Press the hare button to check the machine s hours of operation see Operating Time ...

Page 32: ...o recorded as in the following table On board Battery Charger Alarms Alarm code Description Meaning Condition Effect GB N CONTINUOUS LOW BATTERY VOLTAGE Time of continuous use with discharged batteries N is the number of hours from key on to off when the battery level is below 20 4V for WET CELL 21 6 for AGM batteries This event is not recorded if the usage time is below 10 minutes Incorrect use b...

Page 33: ...as Function of Speed 0 25 100 P2 P3 Level 2 solution flow rate in relation to level 3 see section System for Flow Rate Regulation as Function of Speed 0 50 100 P3 Level 3 solution flow rate DISC 1 0 cl m 3 0 cl m 5 0 cl m REV 1 0 cl m 1 5 cl m 5 0 cl m P4 Level 4 solution flow enabling 2 8 l min regardless of speed OFF OFF ON SPT EcoFlex function timer 0 disabled 60 sec 300 sec XPRES Brush deck ex...

Page 34: ...ing this value increases the risk of the motors overheating VS1 Brush 1 motor protection threshold 20A 30A 50A This is the maximum current which can be supplied to the disc brush deck WARNING increasing this value increases the risk of the motors overheating VS2 Brush 2 motor protection threshold 20A 40A 50A This is the maximum current which can be supplied to the cylindrical brush deck WARNING in...

Page 35: ...DRIVE counter drive system usage time C BRUSH counter brush rotation system usage time D VACUUM counter vacuum system usage time Figure 10 A B C D Time Counter Reset To reset the time counter see the table below for the procedure PUSH BUTTON 10 SEC TIME COUNTER RESET A TOTAL counter B DRIVE counter C BRUSH counter D VACUUM counter When the TOTAL counter is reset it is automatically reset also all ...

Page 36: ...uare metre of floor treated Levels 1 and 2 are defined via the corresponding parameters P1 and P2 as a of level 3 For example for P1 25 and P2 50 P1 and P2 are respectively 25 and 50 of the reference flow rate P3 The default values the same as in the example above are summarized in the table with the corresponding flow rate values in liters per minute dependent on machine speed given as a referenc...

Page 37: ...e 7 screws and remove the electronic component compartment cover 4 Disconnect the following connections sequentially Figure 11 A and B Main machine controller power supply connection B and B C and D Brush motor connection BR and BR Figure 11 B D B D A C A C 5 Disconnect the following connections sequentially Figure 12 E and F Drive system motor connection M1 and M2 G and H Vacuum motor connection ...

Page 38: ...olenoid valve connection J2 K Display controller connection J3 L Battery charger connection J4 M Detergent level sensor connection J5 N Connection J6 Figure 13 I I K K L L N N M M J J 7 Unscrew the 4 retaining screws O and carefully remove the Main machine controller Figure 14 Figure 14 O O O O 8 Assemble the components in the reverse order of disassembly ...

Page 39: ...or 4 Unscrew the 2 screws A Figure 15 5 Release the retaining tab B then lift up and remove the Main machine controller cover C Figure 15 A A C B 6 Disconnect the following connections sequentially Figure 16 A Speed potentiometer connection J4 B Display controller power supply connection J1 C Flat connection J2 D Flat connection J3 7 Unscrew the 4 screws E then remove the display controller F Figu...

Page 40: ...2 B Flat connection J3 10 Carefully raise the User interface controller C detaching it from the cover D Assembly 11 Assemble the components in the reverse order of disassembly and note the following Before fastening the User interface controller C ensure that the flat connections A and B are correctly run through the slots in the cover D then glue the User interface controller to the cover itself ...

Page 41: ...ription Controller in out V ref I max Connected to B Main machine controller power supply in 24V 125A BAT B Main machine controller power supply in 24V 125A BAT Figure 18 Figure 19 Drive connections Ø3 6mm male RADSOK terminals AMPHENOL P N N01 036 6501 001 or equivalent Ref Description Controller in out V ref I max Connected to BR Brush motor out 24V 50A M1 BR Brush motor out 24V 50A M1 Figure 19...

Page 42: ...ref I max Connected to M1 Drive system motor out 0 24V 45A M3 M2 Drive system motor out 0 24V 45A M3 Figure 20 Figure 21 Vacuum connections 2 way male parallel faston connectors 6 3x0 8 spacing 6 5mm Ref Description Controller in out V ref I max Connected to VA Vacuum system power supply out 10 24V 30A M2 VA Vacuum system power supply out 0V 30A M2 Figure 21 ...

Page 43: ...24V 8A M5 4 Deck actuator power supply out 0 24V 8A M5 5 Power supply for ADV versions configurator out 0V 1A J1 6 6 ADV versions configurator return in 0V 1A J1 5 7 Power supply for deck configurator out 0V 1A J1 8 8 Deck configurator return in 0V 1A J1 7 Figure 22 Figure 23 J2 MOLEX MINIFIT type 2 ways vertical PIN Description Controller in out V ref I max Connected to 1 Solenoid valve power sup...

Page 44: ...erial in out 0V 1A EB2 3 4 User interface controller power supply out 0V 1A EB2 4 5 Return from key in 24V 1A EB2 5 6 Return from key repetition out 24V 1A Figure 24 Figure 25 J4 MOLEX MINIFIT type 4 ways vertical PIN Description Controller in out V ref I max Connected to 1 Enabling from battery charger in 24V 1A CH 1 2 Power supply from battery charger in 24V 1A CH 2 3 Battery charger enabling po...

Page 45: ...cal 3 way PIN Description Controller in out V ref I max Connected to 1 Power supply for water level sensor out 24V 1A S1 1 2 Water level sensor return in 0V 1A S1 2 3 Power supply for water level sensor out 0V 1A S1 3 Figure 26 Figure 27 J6 JUMPER 2 ways vertical Figure 27 ...

Page 46: ...r in out V ref I max Connected to 1 24V power supply out 24V 1A TRK RD 2 5V power supply out 5V 1A 3 iButton input CAN H channel In Out 0V 0 5V 1A TRK YE 4 Ext operating time counter enable CAN L channel In Out 0V 0 24V 1A TRK WH 5 Power supply out 0V 1A TRK BU 6 Machine on signal out 24V 1A TRK BN Figure 28 ...

Page 47: ...1A CFD12 J3 3 4 Power supply out 0V 1A CFD12 J3 4 5 Key signal return KEY0 out 24V 1A CFD12 J3 5 6 Key signal return KEY0 in 24V 1A Figure 29 Figure 30 J2 FCI DUFLEX 2 54 pitch 9 way male pins Ref Description Controller in out V ref I max 1 Power supply common out 0V 1A 2 ON OFF button P0 in 0V 1A 3 DETERGENT MIX button P4 in 0V 1A 4 EDS button P3 in 0V 1A 5 VACUUM button P2 in 0V 1A 6 VACUUM func...

Page 48: ... 5V 1A 4 BRUSH RELEASE function LED LD4 out 5V 1A 5 BRUSH RELEASE switch P6 in 0V 1A 6 INCREASE SPEED button P7 in 0V 1A 7 DECREASE SPEED button P8 in 0V 1A 8 ONETOUCH EXTRAPR button P5 in 0V 1A Figure 31 Figure 32 J4 JST VH vertical 3 way B 3P VH PIN Description Controller in out V ref I max Connected to 1 VR1 potentiometer power supply Out 3V 1A VR1 1 2 VR1 potentiometer return In 0 3V 1A VR1 2 ...

Page 49: ...ues were measured with the black Negative voltmeter lead connected to the main battery negative unless otherwise specified Shop Measurements Main machine controller EB1 Battery volts at battery key on 25 03V Power Supply Figure 33 PIN Color Description Measured Comments B Red Main machine controller power supply 24 5v Vacuum on B Black Main machine controller power supply 0 035vV Vacuum on ...

Page 50: ...or 24 4V off 0 15v on without RPM control activated 5 8v on with RPM Control Active set at 20 PWM Battery Negative Drive System Motor Figure 35 PIN Color Circuit Description Measured Neutral Fwd Initial Reverse Initial FWD Max REV Max M1 Red Drive system motor 5 62v 12 7v 10 9v 21 8v 8 7v M2 Gray Drive system motor 5 61 1 95 16 00 8 9v 13 5v M1 to M2 0 001v 6 1v 2 5v 22 6 7 4 ...

Page 51: ...Motor Figure 36 PIN Color Description Measured Comments VA Red Vacuum system power supply 24 8v off 24 4v on Constant Positive VA Blue Vacuum system power supply 24 56 off 1 36v on High 9 69v on Quiet mode VRID parameter 1 1 02 Running 9 56 Quiet Mode ...

Page 52: ... 6v Reset Up Stationary 0v Transport to Scrub 24 8v Scurb to Ex Press 24 8v then 12v near end of travel Ex Press to Scrub 24 8v Scrub to Transport 24 8v then 12v near end of travel Reset to transport 12 5v entire range Reference to J1 3 4 Blue Deck actuator power supply 24 8v stationary 0 03v Transport to scrub Scrub to EX Press Initial 0 03v then 12v near bottom 24 8v Ex press to scrub Scrub to T...

Page 53: ...e just momentarily changes J3 6 Ways Figure 39 PIN Color Circuit Description Measured Comments 1 Red Main machine controller power supply 24 9v On or Off 2 White Main machine controller serial 4 62v key on 0v key off 3 Blk Wh Main machine controller serial 4 13v key on 0v key off 4 Black Main machine controller power supply 0 001v key on 5 Orange Return from key 24 3v key inserted and power on Eit...

Page 54: ...0 136v Not charging 26 1v Charging 3 Brown Battery charger enabling power supply 24 8v key on or off Constant power whether charging or not Key on or off 4 Green Battery charger data communication 4 98v when charger is first plugged in Then dropped to 4 6 J5 3 Ways Figure 41 PIN Color Circuit Description Measured Comments 1 Brown Power supply for water level sensor 24 7v Key on 2 Black Water level...

Page 55: ...oller is set for EcoFlex Is there a measurable voltage on either of the pins when not jumped Yes 4 98v on pin near the LEDS on the Main machine controller J7 6 Ways Measured machine did not have a wiring connector Measurements were taken at each pin on the Main machine controller Figure 43 PIN Color Circuit Description Measured Comments 1 24V power supply 24 6 2 5V power supply 5 00 3 iButton inpu...

Page 56: ...ontroller pins Always use battery negative as your reference point for your black voltmeter lead J1 6 Ways Figure 44 PIN Color Circuit Description Measured Comments 1 Red Power supply 24 6 2 White Main machine controller serial 4 62 3 Blk Wh Main machine controller serial 4 12 4 Black Power supply 0 003 5 Orange Key signal return KEY0 24 23 6 ...

Page 57: ...2v Key off or key on 3 DETERGENT MIX button P4 3 14v Not pressed 0 02v pressed 4 EDS button P3 Solution Button 3 14v Not pressed 0 02v pressed 5 VACUUM button P2 3 14v not pressed 0 05v pressed 6 VACUUM function LED LD2 0 007v LED off 7 SPOT function LED LD1 0 007v LED off 8 SPOT button P1 EcoFlex Burst of power 3 14v Not pressed 0 02v pressed 9 DS versions configurator 3 14v ...

Page 58: ...ED on 0 032v Red LED off 3 SP EXTRAPR function LED green LD3V 1 95v Grn LED on 0 032v Grn LED off 4 BRUSH RELEASE function LED LD4 0 07v LED off Pulsing when flashing 5 BRUSH RELEASE switch P6 3 14v not pressed 0 03v pressed 6 INCREASE SPEED button P7 3 14v not pressed 0 02v pressed 7 DECREASE SPEED button P8 3 14v not pressed 0 02v pressed 8 ONETOUCH EXTRAPR button P5 3 16v not pressed 0 04v pres...

Page 59: ...ntiometer Connector Figure 47 PIN Color Circuit Description Measured Comments 1 Red VR1 potentiometer power supply 2 675 2 White VR1 potentiometer return 1 45 Neutral 2 48 Full Fwd Pin 2 0 44 Full Rev Pin 2 3 Black VR1 potentiometer power supply 0 41 Ground ...

Page 60: ...gregator for all input signals buttons and outputs LEDs from the User interface controller EB3 which it is connected to via 2 flat cables The Magnetic key reader IB is connected to the Display controller EB2 The display controller EB2 check the presence of the Magnetic smart key and drive the switch on off of the system accordingly The Display controller EB2 sends all the input and output signals ...

Page 61: ... contr power supply Return from key FCI DUFLEX 2 54 pitch 8 way male pins FCI DUFLEX 2 54 pitch 9 way male pins cpower supply User interface contr serial User interface contr serial User interface contr power supply Return from key B B DISPLAY CONTROLLER EB2 BATT BATT Microprocessor Microprocessor SIGNAL CIRCUITS FUSE F2 MAIN MACHINE CONTROLLER EB1 Power supply Power supply J5 1 J5 2 SMART KEY IB ...

Page 62: ...nual SC500 05 Control System Magnetic Smart Key Component Locations Figure 2 Main machine controller EB1 Figure 3 Flat calbes from EB2 to EB3 User interface controller EB3 Display controller EB2 Smart key reader IB ...

Page 63: ... and red diagnostic LEDs Figure 5 on the Main machine controller EB1 as indicated in the following tables Figure 5 General alarms Alarm on Main machine controller FLASHING YELLOW RED LEDS Alarm code Description No Flashes Meaning Condition Effect Service Suggestions G2 EEPROM ERROR 2 EEPROM error EEPROM error Function block Default setting reset If the machine continues to function after G2 has be...

Page 64: ...f a battery is broken Check the battery voltage under load G4 BATTERY LOW VOLTAGE 4 Undervoltage The battery voltage remains below 18 4V for over 10 seconds for WET CELL batteries 19 6V for GEL AGM batteries Function block 1 Check the battery voltage under no load conditions and under load Replace the faulty battery batteries if necessary 2 Recharge the batteries by performing a complete charging ...

Page 65: ...d for more than 1 second Brush function block 1 Check that there is no friction on the brush deck linkage lubricate if necessary 2 Check that the actuator and deck travel is not blocked by mechanical obstructions 3 If the problem persists replace the actuator F5 HARDWARE FAILURE 5 Short circuit on the vacuum or brush motor drive MOSFET MOSFET short circuit Function block 1 Check that there are no ...

Page 66: ...ess the pedal 1 if the alarm persist replace the controller 2 if not check the cables of the gear motor and motor itself for a short circuit T6 DRIVE MOTOR FAILURE 6 Overcurrent motor D C Drive motor current draw greater than 1 5 times the value of the parameter see page 72 IMAX Drive blocked 1 Check that the gear motor cables are not short circuited 2 Check that the motor of the gear motor unit i...

Page 67: ...TERY OVERVOLTAGE Battery overvoltage Battery voltage over 32V Battery charger block 1 Check the connections of the batteries and the voltage of the installed batteries 2 Disconnect and reconnect the battery charger C4 CHARGING TIME I EXPIRED Charging phase I expired Battery excessively discharged or at end of life cycle Battery charger block If the problem persists replace the batteries C5 CHARGIN...

Page 68: ...upevisor key yellow Figure 6 then press the the button to access the main screen Figure 7 of the display Figure 6 2 Press One Touch push button to change the machine settings see Machine Settings Screen section 3 Press the brush release button or REV button to check for any stored machine alarms see Alarms Log Screen section 4 Press the hare button to check the machine s hours of operation see Ope...

Page 69: ...er are also recorded as in the following table On board Battery Charger Alarms Alarm code Description Meaning Condition Effect GB N CONTINUOUS LOW BATTERY VOLTAGE Time of continuous use with discharged batteries N is the number of hours from key on to off when the battery level is below 20 4V for WET CELL 21 6 for AGM batteries This event is not recorded if the usage time is below 10 minutes Incor...

Page 70: ...egulation as Function of Speed 0 25 100 P2 P3 Level 2 solution flow rate in relation to level 3 see section System for Flow Rate Regulation as Function of Speed 0 50 100 P3 Level 3 solution flow rate DISC 1 0 cl m 3 0 cl m 5 0 cl m REV 1 0 cl m 1 5 cl m 5 0 cl m P4 Level 4 solution flow enabling 2 8 l min regardless of speed OFF OFF ON SPT EcoFlex function timer 0 disabled 60 sec 300 sec XPRES Bru...

Page 71: ...ating and vice versa DR Maximum deceleration ramp sec DISC 0 5 sec 1 5 sec 8 sec Increase to obtain a less abrupt response when decelerating and vice versa WARNING increasing this value increases the braking distance REV 0 5 sec 2 5 sec 8 sec IR Maximum deceleration ramp in reverse sec 0 5 sec 0 5 sec 5 sec This is the maximum current which can be supplied to the disc brush deck WARNING increasing...

Page 72: ...value increases the risk of the motor overheating TMAX Protection trip time for IMAX 0 sec 12 sec 60 sec This is the reaction time of the electric wheel drive unit protection device when overloaded this parameter is used in conjunction with IMAX to obtain the most appropriate response curve for the overload protection motor actuation system WARNING increasing this value increases the risk of the m...

Page 73: ...machine B DRIVE counter drive system usage time C BRUSH counter brush rotation system usage time D VACUUM counter vacuum system usage time Figure 10 A B C D Time Counter Reset To reset the time counter see the table below for the procedure PUSH BUTTON 10 SEC TIME COUNTER RESET A TOTAL counter B DRIVE counter C BRUSH counter D VACUUM counter When the TOTAL counter is reset it is automatically reset...

Page 74: ...rvisor key if present from the key reader 2 Place the user key on the key reader then press the One Touch button Remove a specific user key from the list of the keys to be used for the machine 1 Remove the supervisor key if present from the key reader 2 Place the user key on the key reader then press the brush release button Replace the factory setting whatever user key can be used for the machine...

Page 75: ...rs per square metre of floor treated Levels 1 and 2 are defined via the corresponding parameters P1 and P2 as a of level 3 For example for P1 25 and P2 50 P1 and P2 are respectively 25 and 50 of the reference flow rate P3 The default values the same as in the example above are summarized in the table with the corresponding flow rate values in liters per minute dependent on machine speed given as a...

Page 76: ...y tank 3 Remove the 7 screws and remove the electronic component compartment cover 4 Disconnect the following connections sequentially Figure 12 A and B Board power supply connection B and B C and D Brush motor connection BR and BR Figure 12 B D B D A C A C 5 Disconnect the following connections sequentially Figure 13 E and F Drive system motor connection M1 and M2 G and H Vacuum motor connection ...

Page 77: ...ion J1 J Solenoid valve connection J2 K Display controller connection J3 L Battery charger connection J4 M Detergent level sensor connection J5 N Connection J6 Figure 14 I I K K L L N N M M J J 7 Unscrew the 4 retaining screws O and carefully remove the Main machine controller Figure 15 Figure 15 O O O O 8 Assemble the components in the reverse order of disassembly ...

Page 78: ...he red battery connector 4 Unscrew the 2 screws A Figure 16 5 Lift up and remove the User interface controller cover B Figure 16 A A B 6 Disconnect the following connections sequentially Figure 17 A Speed potentiometer connection J4 B Display controller power supply connection J1 C Smart key connection J6 D Flat connection J2 E Flat connection J3 7 Unscrew the 4 screws F then remove the Display co...

Page 79: ...m the cover D Smart Key Reader IB 11 Perform points 1 to 5 for removal of the Display controller 12 Disconnect the Smart key reader connection J6 E 13 Loosen the exagon F then remove the Smart key reader G Assembly 14 Assemble the components in the reverse order of disassembly and note the following Before fastening the User interface controller C ensure that the flat connections A and B are corre...

Page 80: ...t Ref Description Controller in out V ref I max Connected to B Main machine controller power supply in 24V 125A BAT B Main machine controller power supply in 24V 125A BAT Figure 19 Figure 19 Drive connections Ø3 6mm male RADSOK terminals AMPHENOL P N N01 036 6501 001 or equivalent Ref Description Controller in out V ref I max Connected to BR Brush motor out 24V 50A M1 BR Brush motor out 24V 50A M1...

Page 81: ... in out V ref I max Connected to M1 Drive system motor out 0 24V 45A M3 M2 Drive system motor out 0 24V 45A M3 Figure 21 Figure 21 Vacuum connections 2 way male parallel faston connectors 6 3x0 8 spacing 6 5mm Ref Description Controller in out V ref I max Connected to VA Vacuum system power supply out 10 24V 30A M2 VA Vacuum system power supply out 0V 30A M2 Figure 22 ...

Page 82: ...ply out 0 24V 8A M5 4 Deck actuator power supply out 0 24V 8A M5 5 Power supply for ADV versions configurator out 0V 1A J1 6 6 ADV versions configurator return in 0V 1A J1 5 7 Power supply for deck configurator out 0V 1A J1 8 8 Deck configurator return in 0V 1A J1 7 Figure 23 Figure 23 J2 MOLEX MINIFIT type 2 ways vertical PIN Description Controller in out V ref I max Connected to 1 Solenoid valve...

Page 83: ...ntroller serial in out 0V 1A EB2 3 4 User interface controller power supply out 0V 1A EB2 4 5 Return from key in 24V 1A EB2 5 6 Return from key repetition out 24V 1A Figure 25 Figure 25 J4 MOLEX MINIFIT type 4 ways vertical PIN Description Controller in out V ref I max Connected to 1 Enabling from battery charger in 24V 1A CH 1 2 Power supply from battery charger in 24V 1A CH 2 3 Battery charger e...

Page 84: ... 3N vertical 3 way PIN Description Controller in out V ref I max Connected to 1 Power supply for water level sensor out 24V 1A S1 1 2 Water level sensor return in 0V 1A S1 2 3 Power supply for water level sensor out 0V 1A S1 3 Figure 27 Figure 27 J6 JUMPER 2 ways vertical Figure 28 ...

Page 85: ... Controller in out V ref I max Connected to 1 24V power supply out 24V 1A TRK RD 2 5V power supply out 5V 1A 3 iButton input CAN H channel In Out 0V 0 5V 1A TRK YE 4 Ext operating time counter enable CAN L channel In Out 0V 0 24V 1A TRK WH 5 Power supply out 0V 1A TRK BU 6 Machine on signal out 24V 1A TRK BN Figure 29 ...

Page 86: ...al in 0V 1A CFD12 J3 3 4 Power supply out 0V 1A CFD12 J3 4 5 Key signal return KEY0 out 24V 1A CFD12 J3 5 6 Key signal return KEY0 in 24V 1A Figure 30 Figure 30 J2 FCI DUFLEX 2 54 pitch 9 way male pins Ref Description Controller in out V ref I max 1 Power supply common out 0V 1A 2 ON OFF button P0 in 0V 1A 3 DETERGENT MIX button P4 in 0V 1A 4 EDS button P3 in 0V 1A 5 VACUUM button P2 in 0V 1A 6 VA...

Page 87: ... LD3V out 5V 1A 4 BRUSH RELEASE function LED LD4 out 5V 1A 5 BRUSH RELEASE switch P6 in 0V 1A 6 INCREASE SPEED button P7 in 0V 1A 7 DECREASE SPEED button P8 in 0V 1A 8 ONETOUCH EXTRAPR button P5 in 0V 1A Figure 32 Figure 32 J4 JST VH vertical 3 way B 3P VH PIN Description Controller in out V ref I max Connected to 1 VR1 potentiometer power supply Out 3V 1A VR1 1 2 VR1 potentiometer return In 0 3V ...

Page 88: ...roller in out V ref I max Connected to 1 Smart Key reader signal GND In Out 0V 1A KEY 1 2 Smart key reader signal IN OUT In Out 0 3V 1A KEY 2 Figure 34 Figure 35 J6 MOLEX MINIFIT vertical 2 ways PIN Description Controller in out V ref I max Connected to 1 CAN H In Out 0 5V 1A TRACK WH 2 CAN L In Out 0 5V 1A TRACK PK Figure 35 ...

Page 89: ...oltage values were measured with the black Negative voltmeter lead connected to the main battery negative unless otherwise specified Shop Measurements Main machine controller EB1 Battery volts at battery key on 25 03V Power Supply Figure 36 PIN Color Description Measured Comments B Red Main machine controller power supply 24 5v Vacuum on B Black Main machine controller power supply 0 035vV Vacuum ...

Page 90: ... Brush motor 24 4V off 0 15v on without RPM control activated 5 8v on with RPM Control Active set at 20 PWM Battery Negative Drive System Motor Figure 38 PIN Color Circuit Description Measured Neutral Fwd Initial Reverse Initial FWD Max REV Max M1 Red Drive system motor 5 62v 12 7v 10 9v 21 8v 8 7v M2 Gray Drive system motor 5 61 1 95 16 00 8 9v 13 5v M1 to M2 0 001v 6 1v 2 5v 22 6 7 4 ...

Page 91: ...y Vacuum Motor Figure 39 PIN Color Description Measured Comments VA Red Vacuum system power supply 24 8v off 24 4v on Constant Positive VA Blue Vacuum system power supply 24 56 off 1 36v on High 9 69v on Quiet mode VRID parameter 1 1 02 Running 9 56 Quiet Mode ...

Page 92: ... press 12 6v Reset Up Stationary 0v Transport to Scrub 24 8v Scurb to Ex Press 24 8v then 12v near end of travel Ex Press to Scrub 24 8v Scrub to Transport 24 8v then 12v near end of travel Reset to transport 12 5v entire range Reference to J1 3 4 Blue Deck actuator power supply 24 8v stationary 0 03v Transport to scrub Scrub to EX Press Initial 0 03v then 12v near bottom 24 8v Ex press to scrub S...

Page 93: ... The value just momentarily changes J3 6 Ways Figure 42 PIN Color Circuit Description Measured Comments 1 Red Main machine controller power supply 24 9v On or Off 2 White Main machine controller serial 4 62v key on 0v key off 3 Blk Wh Main machine controller serial 4 13v key on 0v key off 4 Black Main machine controller power supply 0 001v key on 5 Orange Return from key 24 3v key inserted and pow...

Page 94: ... charger 0 136v Not charging 26 1v Charging 3 Brown Battery charger enabling power supply 24 8v key on or off Constant power whether charging or not Key on or off 4 Green Battery charger data communication 4 98v when charger is first plugged in Then dropped to 4 6 J5 3 Ways Figure 44 PIN Color Circuit Description Measured Comments 1 Brown Power supply for water level sensor 24 7v Key on 2 Black Wa...

Page 95: ...ine controller is set for EcoFlex Is there a measurable voltage on either of the pins when not jumped Yes 4 98v on pin near the LEDS on the Main machine controller J7 6 Ways Measured machine did not have a wiring connector Measurements were taken at each pin on the Main machine controller Figure 46 PIN Color Circuit Description Measured Comments 1 24V power supply 24 6 2 5V power supply 5 00 3 iBu...

Page 96: ... machine controller pins Always use battery negative as your reference point for your black voltmeter lead J1 6 Ways Figure 47 PIN Color Circuit Description Measured Comments 1 Red Power supply 24 6 2 White Main machine controller serial 4 62 3 Blk Wh Main machine controller serial 4 12 4 Black Power supply 0 003 5 Orange Key signal return KEY0 24 23 6 ...

Page 97: ...ton P0 24 2v Key off or key on 3 DETERGENT MIX button P4 3 14v Not pressed 0 02v pressed 4 EDS button P3 Solution Button 3 14v Not pressed 0 02v pressed 5 VACUUM button P2 3 14v not pressed 0 05v pressed 6 VACUUM function LED LD2 0 007v LED off 7 SPOT function LED LD1 0 007v LED off 8 SPOT button P1 EcoFlex Burst of power 3 14v Not pressed 0 02v pressed 9 DS versions configurator 3 14v ...

Page 98: ...78v Red LED on 0 032v Red LED off 3 SP EXTRAPR function LED green LD3V 1 95v Grn LED on 0 032v Grn LED off 4 BRUSH RELEASE function LED LD4 0 07v LED off Pulsing when flashing 5 BRUSH RELEASE switch P6 3 14v not pressed 0 03v pressed 6 INCREASE SPEED button P7 3 14v not pressed 0 02v pressed 7 DECREASE SPEED button P8 3 14v not pressed 0 02v pressed 8 ONETOUCH EXTRAPR button P5 3 16v not pressed 0...

Page 99: ... Ways Potentiometer Connector Figure 50 PIN Color Circuit Description Measured Comments 1 Red VR1 potentiometer power supply 2 675 2 White VR1 potentiometer return 1 45 Neutral 2 48 Full Fwd Pin 2 0 44 Full Rev Pin 2 3 Black VR1 potentiometer power supply 0 41 Ground ...

Page 100: ...nit and the rear frame Reference to Figure 1 Deck raising levers see also Brush System Disc and Brush System REV Frame integrated in the drive motor see also Wheels System Drive Rear pivoting wheels support frame with squeegee raising lowering system see also Squeegee System Figure 1 Drive gear motor with integrated frame Rear pivoting wheels support frame with squeegee raising lowering system Bru...

Page 101: ...not pressed when the machine is started if they are an alarm is generated see section Main machine controller Alarm Codes in the Control System chapter and the drive system is inhibited Once the paddles are returned to the rest position the alarm will stop automatically without the need to turn the machine on and off When the paddles are pressed the Main machine controller EB1 supplies a voltage t...

Page 102: ...J3 2 J3 3 J3 4 J3 5 B B DRIVE SYSTEM MOTOR M3 Main control board power supply Power supply Power supply Main control board serial Main control board serial Main control board power supply Return from key Main control board power supply Main control board serial Main control board serial Main control board power supply Return from key SPEED POTENTIOMETER RV1 MAIN MACHINE CONTROLLER EB1 DISPLAY CONT...

Page 103: ...C500 20 Wheel System Traction Component Locations Figure 2 Maximum speed regulation buttons Speed Potentiometer RV1 Forward reverse gear and activation paddle Figure 3 Driving wheels Rear pivoting wheel Gear motor unit M3 ...

Page 104: ...104 Service Manual SC500 20 Wheel System Traction Figure 4 Drive system motor fuse F5 Main machine controller EB1 ...

Page 105: ... Drive system motor fuse F5 broken Replace Speed potentiometer RV1 incorrectly regulated or broken Replace Main machine controller EB1 faulty Replace Wiring damaged Check all connections inside the electrical component compartment included those of the Main machine controller EB1 Drive system motor M3 carbon brushes worn Replace Drive system motor M3 faulty Replace ...

Page 106: ... battery wiring harness 5 Turn on the machine and activate forward drive at maximum speed via the paddle checking that the current draw falls within the following values Between 3 and 7A at 24V for AMER gear motor Between 4 and 8A at 24V for TEKNO gear motor 6 Release the paddle 7 Switch off the machine and remove the amperometric clamp 8 If the amperage is higher perform the following procedures ...

Page 107: ...ctor 2 Unscrew the 2 screws A Figure 4 3 Release the retaining tab B then lift up and remove the User interface controller cover C 4 Disconnect the following connections D Speed potentiometer connection J4 E Display controller power supply connection J1 5 Unscrew the two hex screws F then remove the potentiometer G 6 Remove and retain the connecting rod H Figure 5 A B A C D E F E G ...

Page 108: ...on ratio 13 1 Protection class IP44 Insulation class F TEKNO electric wheel drive unit technical data Power 0 27 hp 200 W Voltage 24V Transmission ratio 11 4 Protection class IP44 Insulation class F Drive speed variable 0 3 1 mi h 0 5 km h Maximum gradient when working 2 1 14 Machines have been tested under the following conditions Battery maximum size Maximum brush and squeegee size Full detergen...

Page 109: ...idge must be used on connector C3 The bridge is installed at the Main machine controller J4 location as shown in a photo below J4 bridge connector The green cable terminal 4 of connector C3 is the data cable between the Main machine controller EB1 and battery charger CH This connection allows the battery charger charging curve to the be set directly from the User interface controller and to view t...

Page 110: ...atteries from damage caused by over discharging The voltage threshold where loads are turned off depends on the battery type See table below Significant levels for machine operation INDICATION TRANSITION THRESHOLD VOLT CONSEQUENCE WET GEL 1 22V 22 2V Little remaining run time no block 2 20 4V 21 6V Brush OFF 3 19 4V 20 6V Vacuum system OFF 4 18 4V 19 6V Drive system OFF ...

Page 111: ...ry charger enabling power supply Battery charger data communication B B C1 C1 C2 A 24V BATTERIES BAT SIGNAL CIRCUITS FUSE F2 BATTERY CONNECTOR MAIN BATTERY CONNECTOR BATTERY CONNECTOR BATTERY CHARGER CH MAIN MACHINE CONTROLLER FUSE F1 MAIN MACHINE CONTROLLER EB1 Power supply Power supply Figure 1 Optional for BASIC version Version without on board battery charger ...

Page 112: ...ystem Component Locations Figure 2 Main machine controller EB1 Brush motor fuse F4 Battery charger CH Main machine controller fuse F1 Signal circuits fuse F2 Drive system motor fuse F5 Figure 3 Batteries BAT Batteries BAT Battery connections ...

Page 113: ... Figure 5 3 Press the One Touch button until you reach the BAT parameter MODIFIABLE PARAMETERS Code Description Min Value Factory Setting Max Value BAT Installed battery type 0 1 5 4 Press the hare or tortoise button to modify the value of the BAT parameter as per the following table Code BAT Value Installed battery type 0 WET Wet cell batteries 1 GEL AGM Generic GEL or AGM batteries 2 GEL DISCOVE...

Page 114: ...lly lift the recovery tank 4 The machine is supplied with cables suitable to install 2 12V batteries 5 Carefully lift the batteries until the relevant compartment then place them properly 6 Route and install the battery cable as shown in the diagram Figure 6 then carefully tighten the nut on each battery terminal 7 Place the protection cap on each terminal then connect the red battery connector 8 ...

Page 115: ...ger is suitable by referring to the relevant Manual The battery charger voltage rating must be 24V 4 Disconnect the red battery connector with handle and connect it to the external battery charger 5 Connect the battery charger to the electrical mains 6 After charging disconnect the battery charger from the electrical mains and from the battery red connector 7 Connect the battery connector to the m...

Page 116: ...ft the recovery tank 4 Remove the 7 screws and remove the electronic component compartment cover 5 Check replace the following fuses Figure 7 F1 100A midi fuse Main machine controller A F2 3A blade fuse Signal circuits B 6 Place the Main machine controller assembly in its housing tighten the mounting screws and install the electronic component compartment cover Figure 7 A B A B ...

Page 117: ... fuseholder then check replace the following fuses Figure 8 F4 50A midi fuse brush motor C F5 30A midi fuse Drive system motor D 8 Place the Main machine controller assembly in its housing tighten the mounting screws and install the electronic component compartment cover Figure 8 D C ...

Page 118: ...medy The machine is not working Batteries BAT flat or connections faulty Charge the batteries or clean the connections The batteries BAT are broken Check the battery no load voltage The battery charger CH is broken Replace The wiring harness is cut or pressed or short circuited Repair Note A damage to the battery charger or its connections can prevent the machine from operating properly ...

Page 119: ...sensor return Power supply for water level sensor Drive system motor J3 1 J3 2 J3 3 J3 4 J3 5 J4 1 J4 2 J4 3 J4 1 J4 3 J4 4 J7 1 J7 4 J7 3 J7 5 J7 6 24V power supply External operating time counter enable CAN L channel iButton input CAN H channel Power supply Machine on signal B B C1 C1 C2 A 24V BATTERIES BAT MAIN MACHINE CONTROLLER FUSE F1 WATER LEVEL SENSOR SW1 BATTERY CONNECTOR MAIN BATTERY CON...

Page 120: ...pply for water level sensor Water level sensor return Power supply for water level sensor Drive system motor J3 1 J3 2 J3 3 J3 4 J3 5 J4 1 J4 2 J4 3 J4 1 J4 3 J4 4 B B C1 C1 C2 A 24V BATTERIES BAT MAIN MACHINE CONTROLLER FUSE F1 WATER LEVEL SENSOR SW1 BATTERY CONNECTOR MAIN BATTERY CONNECTOR BATTERY CONNECTOR J7 1 J7 5 J7 6 24V power supply Power supply Machine on signal TRACKUNIT TCU BATTERY CHAR...

Page 121: ... compartment size length x width x height 13 7x13 7x10 2 in 350x350x260 mm Standard batteries 2 12V 105 AhC5 Standard battery run time capacity 3 5 h Battery charger Model 24V 13A Input voltage 85Vac 264Vac 50Hz 60Hz Charging procedure by microprocessor Efficiency 85 Environmental protection class IP30 ...

Page 122: ...ace controller EB3 The quantity of detergent is defined by the operator via the buttons on the User interface controller EB3 Solution flow levels 1 2 and 3 regulate the flow of detergent solution on the basis of the machine speed so as to keep the quantity of solution dispensed per square metre of floor treated constant for further details and modifications see the corresponding section in the cha...

Page 123: ...ss than half Through this information the times of opening of the solenoid valve EV1 and the detergent pump M4 are adjusted to maintain this flow more constant Figure 1 The water level sensor is capacitive with NPN output output 0 Volt with water floating without water Full Empty Solution tank With sensor Without sensor Solution flow to the brush Litre min Figure 1 J5 1 J5 2 J5 3 MAIN MACHINE CONT...

Page 124: ...J2 2 J2 1 J1 2 J1 1 Detergent pump power supply Detergent pump power supply Solenoid valve power supply Solenoid valve power supply Power supply for water level sensor Water level sensor return Power supply for water level sensor B B WATER LEVEL SENSOR SW1 Power supply Power supply MAIN MACHINE CONTROLLER EB1 Figure 3 ...

Page 125: ...l SC500 30 Solution System Component Locations Figure 4 Detergent solution tank front filler Water removable filler hose Solution tank Detergent solution tank side filler cap Figure 5 Solution drain and level check hose ...

Page 126: ...Figure 6 Solution filter Solenoid valve EV1 Battery compartment liquid drain hole Solution tap Figure 7 Cap with detergent supply hose Detergent pump M4 piston pump Detergent pump M4 peristaltic pump EcoFlex detergent tank Water level sensor SW1 ...

Page 127: ...in the detergent solution tank with the level hose Then rinse the tank with clean water 4 Close the detergent solution valve A Figure 8 The valve A is closed when it is in position B and it is open when it is in position C 5 Remove the transparent cover D and the gasket E then remove the filter strainer F Wash and rinse them then refit them carefully onto the filter support G 6 Open the valve A D ...

Page 128: ...ty if not empty it using the drain hose 4 Close the recovery tank cover until the handle clicks 5 Grasp the handle and carefully lift the recovery tank 6 Unscrew the cap A Figure 9 from the detergent tank B 7 Remove the tank 8 Rinse and wash out the tank in the appointed disposal area 9 Replace the detergent tank B as shown in the figure then refit the cap A 10 When the detergent tank has been dra...

Page 129: ...the display to finish and the vacuum to be activated 15 Collect the detergent remained on the floor 16 Remove the ignition key 17 Lift the recovery tank then check that the detergent tank hose is empty otherwise perform steps 3 to 7 again Note The draining cycle lasts about 30 seconds then the vacuum function automatically turns on which allows to remove the detergent remained The draining cycle c...

Page 130: ...ent is not reaching the brush or is not arriving in sufficient quantity On the brush comes only water The detergent flow percentage is too low Check change the percentage The hydraulic circuit upstream of the detergent pump is not triggered Check if the hose is filled and if necessary perform one or more draining cycles The detergent pump M4 is broken or there is an open in the electrical connecti...

Page 131: ...solution tank is empty Humid fouling inside the solution tank Washing the solution tank with clean water Presence of water between the water level sensor and the outer wall of the solution tank Dry the area Water level sensor broken Replace the sensor The symbol is displayed when the solution tank is full Excessive distance between the water level sensor and the wall of the solution tank Check the...

Page 132: ...on 3 Lower the brush deck by pressing the One Touch button 4 Switch off the machine and disconnect the battery connector 5 Unscrew and disconnect the connection A Figure 11 on the solenoid valve B 6 Disconnect the detergent supply hose C from the solenoid valve 7 Unscrew the two screws D disconnect the hose E then remove the solenoid valve B Installation 8 Assemble the components in the reverse or...

Page 133: ...t the battery connector 3 Lift the recovery tank 4 Unscrew the two screws A Figure 12 and remove the cover B 5 Disconnect the connectors C and the tank hose D and brush hose E 6 Unscrew the two screws F and remove the detergent pump G Installation 7 Assemble the components in the opposite order to that they were removed in ensuring the supply hoses D and E are correctly fitted on the detergent pum...

Page 134: ...cover B 5 For remove only the head of the detergent pump a Disconnect the tank hose C and brush hose D b Remove the head of the detergent pump E to the detergent pump motor 6 For remove the detergent pump a Disconnect the connectors F and the tank hose C and brush hose D b Unscrew the two screws G and remove the detergent pump H Installation Assemble the components in the opposite order to that th...

Page 135: ...nsert the Supervisor key yellow in place of the User key grey or blue to access the main screen Figure 14 of the multifunction display 2 With the solution tank more than half full the symbol displayed is A 3 With the solution tank less than half full the symbol displayed is B Figure 14 A B ...

Page 136: ...isconnect the battery connector 3 Lift the recovery tank 4 Unscrew the two screws A Figure 15 and remove the cover B 5 Unscrew the two screws C and lift the tank D 6 Disconnect the connector E 7 Disassemble and remove the water level sensor F Assembly 8 Assemble the components in the reverse order of disassembly Figure 15 A B A E D C F D ...

Page 137: ...on Model SC500 DISC REV Solution tank capacity 12 US gal 45 liters Solution flow values 0 75 cl m 1 5 cl m 3 0 cl m 2 8 l min 0 38 cl m 0 75 cl m 1 5 cl m 2 8 l min EcoFlex kit tank capacity 1 3 US gal 5 L EcoFlex kit detergent percentage setting Ratio 1 400 1 33 0 25 3 ...

Page 138: ...roller EB1 following activation of the paddle The brush system uses the solution to wash the floor In case of brush motor overload a safety system stops the brush to prevent continuous overload If the overload takes place when the extra pressure function is on the system automatically turns the extra pressure function off If the overload persists the brush stops The overload is detected by monitor...

Page 139: ...5 J1 4 J1 3 Deck actuator power supply Deck actuator power supply BRUSH DECK ACTUATOR MOTOR M5 M1 BR BR Brush motor Brush motor B B BRUSH MOTOR M1 Electronic board power supply Electronic board power supply MAIN MACHINE CONTROLLER EB1 BRUSH MOTOR FUSE F4 Figure 1 ...

Page 140: ...n pressing the actuator integrated spring The actuator is powered at 50 PWM about 12Vdc near the end of strokes or during the machine switch on reset feature otherwise at 100 PWM 24Vdc The machine switch on reset feature moves the actuator from the position where it was the last time the machine was switched off to the RETRACTED position The quotes of the actuator strokes with a tolerance of 2mm a...

Page 141: ...Scrub System Disc Component Locations Figure 2 Brush deck support Brush Deck raising levers Machine straight forward movement adjusting knob Disc brush deck Brush motor M1 Figure 3 Drive hub Brush deck lifting lowering actuator M5 ...

Page 142: ...142 Service Manual SC500 34 Scrub System Disc Figure 4 Brush motor fuse F4 Main machine controller EB1 Actuator system wiring connection ...

Page 143: ...ed adjustment button 4 With the brush deck raised position the brush A or pad holder B under the deck 5 Press the One Touch button to lower the deck onto the brush 6 To engage the brush press the paddle 2 then release it If necessary repeat the procedure until the brush is engaged CAUTION Turn the machine speed to idle and slightly press the paddle otherwise the machine starts to move 7 To remove ...

Page 144: ...nd the brush or between the brush and attachment flange Remove the brush and clean it Faulty brush motor Repair or replace Wiring damaged Repair It is not possible to raise lower the brush See the chapter Control System Main machine controller EB1 Error Codes Deck raising lowering actuator M5 broken Replace Break in actuator wiring Check the connections according to the instructions in the Electri...

Page 145: ...pressing the paddle then check that the brush motor current draw is between 3 and 4A at 20V 8 Deactivate the brush by releasing the paddle and raise the brush deck by pressing the One Touch button 9 Remove the Amp clamp C 10 If the amperage is higher perform the following procedures to detect and correct the abnormal amperage Check the brush motor carbon brushes Remove the brush motor then check t...

Page 146: ...key and the button 4 Lower the brush deck by pressing the One Touch button 5 Switch off the machine and disconnect the battery connector 6 Undo the screw A Figure 7 on the pin of the actuator B retain the bushing 7 Unscrew and disconnect the connection C on the solenoid valve D 8 Disconnect the detergent supply hose E from the solenoid valve 9 Remove the cover F Figure 8 then disconnect the hose G...

Page 147: ...he 4 screws I Figure 9 fastening the deck raising levers J retaining the bushings and washers 11 Unscrew the 2 retaining nuts K and disconnect the brush motor power supply cables L Figure 9 I I J I I J L K 12 Extract the brush deck M Figure 10 from beneath the solution tank ...

Page 148: ...48 Service Manual SC500 34 Scrub System Disc Figure 10 M Assembly 13 Assemble the components in the opposite order they were removed in ensuring the brush motor power supply cable polarities are correct ...

Page 149: ...h the lead in wires 5 Disengage the tabs C and remove the carbon brushes D 6 Check the carbon brushes D for wear The carbon brushes are worn out when They do not make sufficient contact with the armature of the brush motor due to their wear When their contact surface is not intact When the residual stroke is below 0 12 in 3 mm When the thrust spring etc is broken 7 Replace the carbon brushes as an...

Page 150: ...he bench remove the screw A Figure 12 of the brush motor 3 Use a puller to remove the brush hub B 4 Remove the screws C 5 Remove the brush motor D 6 Recover the key E Assembly 7 Assemble the components in the reverse order of disassembly Note For further information on deck components see the Spare Parts List Figure 12 D A E B C ...

Page 151: ...onnect the battery connector 3 Remove the cover and disconnect the actuator connector A Figure 13 4 Unscrew the screw B of the lower pin retaining the bushings 5 Remove the screws C retaining the plates D 6 Remove the actuator E installation 7 Assemble the components in the reverse order of disassembly Figure 13 C D C C D C B E A ...

Page 152: ...e controller EB1 following activation of the paddle Transmission of motion from the gear motor to the brush occurs via an eccentric system which provides the orbital movement The system once activated uses the solution coming form the solution system to wash the floor In case of REV motor overload a safety system stops the brush to prevent continuous overload If the overload takes place when the e...

Page 153: ...5 J1 4 J1 3 Deck actuator power supply Deck actuator power supply BRUSH DECK ACTUATOR MOTOR M5 M1 BR BR Brush motor Brush motor B B BRUSH MOTOR M1 Electronic board power supply Electronic board power supply MAIN MACHINE CONTROLLER EB1 BRUSH MOTOR FUSE F4 Figure 1 ...

Page 154: ...n pressing the actuator integrated spring The actuator is powered at 50 PWM about 12Vdc near the end of strokes or during the machine switch on reset feature otherwise at 100 PWM 24Vdc The machine switch on reset feature moves the actuator from the position where it was the last time the machine was switched off to the RETRACTED position The quotes of the actuator strokes with a tolerance of 2mm a...

Page 155: ...55 Service Manual SC500 34 Scrub System REV Component Locations Figure 2 Brush deck support REV pad Deck raising levers Brush deck REV Motor M1 Figure 3 Drive disc Brush deck lifting lowering actuator M5 ...

Page 156: ...156 Service Manual SC500 34 Scrub System REV Figure 4 Brush motor fuse F4 Main machine controller EB1 Actuator system wiring connection ...

Page 157: ... the pad A Figure 5 or the brush C depending on the type of treatment to be performed Place the pad A under the deck and press it until it is fastened with the Velcro of the drive disc B Place the brush C optional under the deck and then match the centering pins D to the respective holes of the drive disc B and then engage the brush with the mounting screws E 2 To remove the pad or brush proceed i...

Page 158: ...ushes worn Replace Faulty REV motor Repair or replace Wiring damaged Repair It is not possible to raise lower the brush See the chapter Control System Main machine controller EB1 Error Codes Deck raising lowering actuator M5 broken Replace Break in actuator wiring Check the connections according to the instructions in the Electrical System chapter Troubleshooting paragraph Main machine controller ...

Page 159: ... lower the brush deck 7 Apply the amperometric clamps C to an electrical wire D of the motor 8 Activate the brush by pressing the paddle then check that the REV motor current draw is between 3 and 4A at 24V 9 Deactivate the brush by releasing the paddle and raise the brush deck by pressing the One Touch button 10 Remove the Amp clamp C 11 If the amperage is higher perform the following procedures ...

Page 160: ... 3 Lower the brush deck by pressing the One Touch button 4 Switch off the machine and disconnect the battery connector 5 Undo the screw A Figure 7 on the pin of the actuator B retain the bushing 6 Unscrew and disconnect the connection C on the solenoid valve D 7 Disconnect the detergent supply hose E from the solenoid valve 8 Remove the cover F Figure 8 then disconnect the hose G from the detergen...

Page 161: ...ng the bushings and washers 10 Disconnect the REV motor power supply connections K Figure 9 J I I K 11 Extract the REV deck L Figure 10 from beneath the solution tank Figure 10 M Assembly 12 Assemble the components in the opposite order they were removed in ensuring the REV motor power supply cable polarities are correct ...

Page 162: ...REV deck 2 Place the deck on a workbench Note The motor cannot be removed with the REV deck fitted to the machine 3 Remove the connector holder 4 Remove the wire mounting nut and the rubber gasket Figure 11 Remove the wire mounting nut and the rubber gasket 5 Remove both nuts Figure 12 Remove both nuts ...

Page 163: ...ing Route the wire through the carbon brush housing Place the rear end of the carbon brush in the spring cup so that the spring unrolls with the carbon brush pushed back once installed Figure 14 Spring cup side Spring unroll side opening Push the carbon brush back against the spring and insert a paper clip through the access hole in the deck Remove the silicone sealant from the holes The wire must...

Page 164: ... washer 9 Install the top cover Install it far enough so that the carbon brushes make contact with the collector when the temporary support wires are removed Then remove the temporary wires Figure 16 Commutator Carbon brush Install the top cover Install the nuts Seal the wire mounting holes with silicone sealant ...

Page 165: ...nnect the battery connector 3 Remove the cover and disconnect the actuator connector A Figure 17 4 Unscrew the screw B of the lower pin retaining the bushings 5 Remove the screws C retaining the plates D 6 Remove the actuator E installation 7 Assemble the components in the reverse order of disassembly Figure 17 C D C C D C B E A ...

Page 166: ...function turned on 66 lb 30 kg Brush deck right left offset 100 25 mm 3 9 1 in Brush distance from the floor when lifted 1 9 in 48 mm REV motor power 0 9 HP 670 W Rotation speed 2200 RPM Insulation class H Insulation class F Actuator technical data Strength 300 N Maximum load 600 N Regulated travel 2 5 in 63 mm Total travel 3 8 in 98 mm Maximum speed 24V Voltage IP 44 Protection class B Insulation...

Page 167: ... allows for squeegee immediate removal The squeegee can be raised and lowered by the operator using just their foot on the squeegee support footrest thanks to a mechanism consisting of two levers and a gas spring The angle of the squeegee and the correct adherence of the blades on the floor can be adjusted with a knob The front blade has an opening in the bottom edge so the squeegee can collect th...

Page 168: ... support Mounting handwheels Squeegee lifting lowering pedal Gas spring Squeegee blades Impact deflection wheel Upper squeegee support Model No 9087403020 9087404020 9087400020 9087401020 9087405020 9087402020 Figure 2 Squeegee adjusting knob Lower squeegee support Mounting handwheels Squeegee lifting lowering pedal Spring Squeegee blades Impact deflection wheel Upper squeegee support ...

Page 169: ...e may be sharp debris 1 Drive the machine on a level floor 2 Ensure that the machine is off and the ignition key has been removed 3 Loosen the handwheels and remove the squeegee 4 Wash and clean the squeegee In particular clean the compartments A Figure 2 and the vacuum hole B Check that the front blade C and the rear blade D are integral and free from cuts and lacerations if necessary replace the...

Page 170: ...following procedure Using the tab F release and remove the elastic strap G from the fasteners H then turn or replace the rear blade D Install the blade in the reverse order of removal Fix the elastic strap G to the fasteners H starting from one side Constrain to the fastener one by one with the hand M blocking the elastic strap before the fastener and pulling with the other hand N for fixing Unscr...

Page 171: ...on existent Squeegee or vacuum hose blocked or damaged Clean or repair replace The squeegee leaves lining on the floor or does not collect water There is debris under the blade Remove Squeegee blade lips damaged or worn Replace Squeegee not balanced Adjust with the relevant handwheel Squeegee will not raise Gas spring worn out Replace ...

Page 172: ...oisting system to facilitate the disassembly procedures 2 Lower the squeegee and remove it from the support 3 Unscrew the nut A Figure 4 retaining the bushings washers and spacers B 4 Unscrew the screw C retaining the nut washers and spacers D 5 Unscrew the screw E retaining the nut and washers 6 Remove and replace the gas spring F Assembly 7 Assemble the components in the reverse order of disasse...

Page 173: ...ystem to facilitate the disassembly procedures 2 Remove the squeege from the squeegee support A then lower the squeegee support by slowly to the floor 3 Press lighly the spring B then remove it with its pair of terminals Assembly 4 Assemble the components in the reverse order of disassembly and note the following Mount the spring with its pair of terminals as shown of the picture C Figure 6 A C C ...

Page 174: ...174 Service Manual SC500 38 Squeegee System Specifications Description Model SC500 DISC REV Squeegee width 28 3 in 720 mm Gas spring 300 N ...

Page 175: ...rough the recovery tank hose The automatic float in the vacuum grid stops vacuum system motor M2 from collecting any liquids When the automatic float closes and shuts down the vacuum system the vacuum system motor noise will increase and the floor will not be dried The vacuum system is activated automatically with the One Touch button It can then be managed independently via the vacuum button The ...

Page 176: ...176 Service Manual SC500 40 Recovery System Wiring Diagram M2 VA VA B B VACUUM SYSTEM MOTOR M2 Vacuum system power supply Vacuum system power supply MAIN MACHINE CONTROLLER EB1 Figure 1 ...

Page 177: ...mponent Locations Figure 2 Recovery tank cover Recovery tank Vacuum grid with automatic shut off float Container with debris collection grid Cover gasket Figure 3 Motor protection case Squeegee vacuum hose Recovery water drain hose Vacuum motor M2 ...

Page 178: ...en clean it carefully 6 Reinstall it on the vacuum hose 7 Reinstall the debris collection tank on the rigid tube in the tank 8 Check the condition of the tank cover gasket E Note The gasket E creates the vacuum in the tank that is necessary to vacuum up the recovery water 9 If necessary replace the gasket E by removing it from its housing F When fitting the new gasket position the joint G in the a...

Page 179: ...uum motor faulty Check the amperage Suction of dirty water is insufficient or non existent Activation of automatic float shut off Drain the recovery tank Debris collection filter dirty Clean Vacuum grid with automatic float shut off dirty Clean Tank cover not correctly positioned Adjust Tank cover seal damaged or not working correctly Clean or replace Vacuum motor container dirty Clean Vacuum seal...

Page 180: ...acuum and check that the current draw of the vacuum motor is between 13 and 17A at 24V Stop the vacuum Remove the amp clamp A If the amperage is higher perform the following procedures to detect and correct the abnormal amperage Remove the vacuum motor see the procedure in the Vacuum Motor paragraph and check the condition of all its components If the above mentioned procedures do not produce the ...

Page 181: ...the recovery tank then lift it 4 Remove the cover A Figure 6 then disconnect the connector B Figure 6 A B 5 Unscrew the 4 screws C Figure 7 and remove the case D 6 Unscrew the screw E holding the vacuum motor wiring 7 Unscrew the 4 screws F and remove the vacuum motor unit G Installation 8 Assemble the components in the reverse order of disassembly Figure 7 C D C C E C F F F G F ...

Page 182: ...ove the ignition key 2 Disconnect the red battery connector 3 If present drain the recovery tank then lift it 4 Unscrew the 4 screws A Figure 8 and remove the case B 5 Unscrew the screw C holding the vacuum motor wiring 6 Unscrew the 4 screws D and remove the vacuum motor unit E Figure 8 A B A A C A D D D E D ...

Page 183: ...t H from the internal soundproofing support I 9 Clean any dirt from the space between the two containers 10 Remove the seal J and the internal support K 11 Clean any dirt from the space between the container and the motor Figure 9 F H F F G F H I K J 12 Cut the strap L and disconnect the power supply M Figure 10 13 Remove the motor N Figure 10 N L M ...

Page 184: ...an and check the condition of all seals O Figure 11 replace them if necessary Figure 11 O O O Assembly 15 Check that all components are reassembled with the correct polarity and orientation 16 Assemble the components in the reverse order of disassembly ...

Page 185: ...ual SC500 40 Recovery System Specifications Description Model SC500 DISC REV Recovery tank capacity 12 US gal 45 L Vacuum motor technical data 0 37 hp 280 W 20 8A VDC 24V Vacuum circuit capacity 29 9 in H2O 760 mm H2O ...

Page 186: ...nsert dry brake Cap Refill cap Hose Pump detergent mix piston pump for the old models Pump detergent mix peristaltic pump for the new models Sensor water level Support sensor Hardware BATTERY CHARGER KIT EU model only Charger extention UK EU Cable tie plug Charger battery Support battery charger Hardware ...

Page 187: ...187 Service Manual SC500 90 Options Description Illustration VACUUM SYSTEM MOTOR KIT All version Vacuum motor group Tie cable USB KIT Model No 9087412020 9087411020 9087410020 USB cable Plate Hardware ...

Page 188: ...188 Service Manual SC500 90 Options Description Illustration TRACKCLEAN KIT US Advance Kit US with reader Kit US without reader TRACKCLEAN KIT EU Nilfisk Kit EU with reader Kit EU without reader ...

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Nilfisk-Advance 9087350020, Service Manual

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