Nilfisk-ALTO 56114004 Service Manual Download Page 1

Page: 1 / 93

08/12 Updated 08/14 Form No. 56043159

Service Manual

Clarke

model numbers:

56114000

Focus II Rider 28 D Base

56114001

Focus II Rider 34 D OBC Base

56114002

Focus II Rider 34 D Base

56114003

Focus II Rider 28 B Base

56114009

Focus II Rider 28 B OBC Base

56114010

Focus II Rider 28 D OBC Base

Nilfisk-Alto model numbers:

56114004

Scrubtec R 6-71 28D

56114005

Scrubtec R 6-71C 28C

56114006

Scrubtec R 6-86 34D

56114008

Scrubtec R 6-100 40D

English

Clarke Focus II Rider Autoscrubber

Nilfisk-Alto Scrubtec R6 Rider Autoscrubber

Summary of Contents for 56114004

Page 1: ...II Rider 34 D Base 56114003 Focus II Rider 28 B Base 56114009 Focus II Rider 28 B OBC Base 56114010 Focus II Rider 28 D OBC Base Nilfisk Alto model numbers 56114004 Scrubtec R 6 71 28D 56114005 Scrubt...

Page 2: ...l Description 15 Control System 16 Functional Description 16 Control Panel 16 Main Machine Controller 17 Component Locations 18 Main Machine Controller Programming 19 Programming Menu Outline 19 Quick...

Page 3: ...esting 36 Removal and Installation 36 Batteries 36 Electrical Panel Cover 37 Specifications 37 Wet Cell Battery Specifications 37 Wet Cell Battery Charger Specifications 37 Wiring Diagrams 37 Wiring L...

Page 4: ...cations 66 Special Tools 66 Solution System 67 Functional Description 67 Solution Solenoid 67 Detergent Models 67 Circuit Overview 68 Solenoid Valve Circuit 68 Detergent Pump 68 Solution System Schema...

Page 5: ...unction 79 Wheel Drive Controller J10 Pinout Functions 80 Troubleshooting 81 Wheel Drive Controller Error Codes 82 Removal and Installation 83 Drive Controller 83 Drive Wheel Assembly 84 Drive Motor B...

Page 6: ...arger VS Delta Q Electrical System Added information for Delta Q IC650 onboard battery charger and added wiring diagrams Other Reference Manuals and Information Sources The following documents contain...

Page 7: ...low speed down hills Clean only while ascending driving up the ramp Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unatten...

Page 8: ...the machine page 74 This is required to access the rear hold down points and also protects the squeegee during loading unloading and transport If the loading unloading or transport operations pose a r...

Page 9: ...information which will be needed when ordering parts Model Name Part No Part number of the machine which is often referred to as the Model Number and Serial Number Know Your Machine Major components...

Page 10: ...A Gross Weight 1 341 lbs 608 kg 1 371 lbs 622 kg 1 359 lbs 616 kg 1 350 lbs 613 kg 1 603 lbs 727 kg Maximum Wheel Floor Loading front 152 psi 1 05 N mm2 Maximum Wheel Floor Loading right rear 193 psi...

Page 11: ...ean Rotate the Brushes Pads Check Clean the Squeegee Clean Hopper on Cylindrical System Check Battery Cell Water Level does not apply to gel cell batteries Inspect Scrub Housing Skirts If so equipped...

Page 12: ...sfully and quickly perform troubleshooting and repair of Nilfisk Advance Industrial floor cleaning equipment Laptop computer loaded with current version of EzParts Adobe Reader and preferably cellular...

Page 13: ...ormance refer to Curtis Programmer Manual SM56043101 for speed control changes Noisy Sluggish 6 Scrub System Raise Lower auto scrubbing functions A B 7 Scrub Brush pressure settings Normal Heavy Extre...

Page 14: ...W 26 Vacuum Motor Gaskets Filters L W 27 Vacuum Float Ball Cage Assembly Clean Float C M 28 Recovery Lid Gasket C D L 29 Recovery Tank Drain Hose Cap Flush C L 30 Recovery Tank Strainer Basket Clean...

Page 15: ...make it more rigid The forward drive wheel is connect to the frame through a thrust bearing block for rotational movement An integral welded rear axle through the frame transfers the load of the machi...

Page 16: ...ller then sends a reverse command to the Wheel controller by pulling the J3 3 output high When the Indicator B is lit pressing down on the foot pedal will cause the machine to move in reverse Speed In...

Page 17: ...ion system is an optional accessory The detergent pump is active only when the solution pump is active Pressing this switch will cycle through the detergent ratios Main Machine Controller The Main Mac...

Page 18: ...Rider Autoscrubber Component Locations Vacuum Contactor Brush Contactor Wheel Drive Controller 150 Amp Fuse Battery Pos Terminal Battery Neg Terminal 70 Amp Breaker 10 Amp Breaker E Stop Seat Switch...

Page 19: ...emical 4 Detergent Mode 1 Off 5 Vacuum Selection 2 Vacuum Motors 1 Vacuum Motor 6 Low Voltage Cutout Main Free Battery 70 LVC 21 75V Wet Battery 80 LVC 20 55V 7 Max Scrub Speed 100 of Transport 8 Lock...

Page 20: ...know what type of deck is installed on the machine The options are 28 Boost 40 Disk 34 Disc 28 Cyl 28 Disc This parameter must be set when replacing the Main Machine Controller Battery Charger If no...

Page 21: ...ures can be locked out so they are not selectable during normal operation If two pressures are locked out then the machine will operate with only the single remaining pressure available 1 None Lockout...

Page 22: ...machine is moving in the reverse direction the backup alarm can sound to notify bystanders that the machine is backing up There are 4 options for the volume including disabling the function off low me...

Page 23: ...ellow violet for continuity Make sure the correct scrub deck is specified in the control board settings 06 Squeegee Lift Actuator Overload The actuator amperage was detected above 6 amps for more than...

Page 24: ...for more than 5 seconds Check for wiring problems on the coil circuit and repair wiring Check resistance on the solenoid coil If the value is less than 45 replace the contactor 11 Chemical Pump Overlo...

Page 25: ...rvice Test Mode submenu 4 To exit Service Test Mode turn the key switch to the off position O Test Mode Display In Service Test Mode the display will present basic information about the machine The ba...

Page 26: ...equivalent voltage somewhere in between 24 and 0 volts The symbol means approximately To aid in taking voltage measurements from the cable connectors without removing the connector a T shaped push pin...

Page 27: ...volts when deck lowers to each position Open 5 volts when raised J2 12 Deck Pos 1 0 4 94 Main Machine Controller Sample Voltage Measurements at the J3 Connector Pin Name V On V Off Ref Comments J3 1...

Page 28: ...urrent J2 9 Voltage Drop 1 88 mV 2 176 mV B Voltage drop 4 1mV per amp Single vac tank full 74 mV Dual vac tank full 148mV Brush Current J2 10 Voltage Drop 130 mV B Voltage drop 1 74 mV per amp Positi...

Page 29: ...he control board to the steering column 4 Lift the control board away from the steering column taking care not to stress the wiring harness 5 Remove the two screws 2 that secure the two wires 3 4 to t...

Page 30: ...no operator on seat then control power is removed from the Wheel Drive controller The Main Machine controller still has power but the software is notified that the seat circuit or E stop is open The...

Page 31: ...n the charger is plugged into an AC power outlet This prevents the machine from being propelled while the batteries are charging S P E Charging Profiles and Charging Progress When the S P E battery ch...

Page 32: ...Battery Charging 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...

Page 33: ...Y 6 US 14 5XC 251 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 B...

Page 34: ...6 Rider Autoscrubber Component Locations Vacuum Contactor Brush Contactor Wheel Drive Controller 150 Amp Fuse Battery Pos Terminal Battery Neg Terminal 70 Amp Breaker 10 Amp Breaker E Stop Seat Switch...

Page 35: ...r voltage limited chargers Standard constant current or taper current chargers must not be used A temperature sensing charger is recommended Important Do not attempt to open sealed gel batteries or ad...

Page 36: ...rking with batteries Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes Explosive hydrogen gas is vented from the batteries through openings in the battery caps...

Page 37: ...e battery system Note The battery pack must fit the battery compartment size listed in Specifications Wet Cell Battery Charger Specifications Use a 24 Volt DC output charger matching the DC battery pa...

Page 38: ...HIGH J2 6 POT LOW J2 5 OPTIONAL PIN 17 REVERSE REVERSE J3 3 3 1 2 2 WHEN NO CHARGER IS PRESENT INSTALL JUMPER BETWEEN PIN 1 AND PIN 2 J2 3 BAT CHARGER ON BOARD COMMUNICATION 1 REFERENCE WIRING DIAGRAM...

Page 39: ...POSITION_1_ J2 12 POSITION_2_ J2 11 A B C C WHT WHT RED RED RED BLK WHT GRN BLK YEL BLU ORN BLK YEL VIO BLK BRN RED RED RED BLK RED RED RED BLK BLK ORN RED GRN BLK RED YEL BLU GRY BLK BLK BLK BLK BLK...

Page 40: ...14 BRAKE PIN 5 KSI B B M1 M2 A2 WHEEL DRIVE CONTROLLER J3 1 B J3 8 B J3 14 KEY SWITCH J3 12 VACUUM CONTACTOR J3 13 BRUSH CONTACTOR J3 11 SOLUTION SOLENOID SEAT SWITCH J3 4 MOTION J3 6 STATUS J3 7 REV...

Page 41: ...INNES DRAWN PROJ ENG NILFISK ADVA A1 MAIN MACHINE CONTROLLER SQUEEGEE ACT J1 9 SQUEEGEE ACT J1 10 DECK ACT J1 4 DECK ACT J1 5 BRUSH MOTOR 1 SENSE J2 10 VACUUM MOTOR SENSE J2 9 2 OF 2 DIAGRAM LADDE 561...

Page 42: ...Electrical System 42 Service Manual Focus II Scrubtec R6 Rider Autoscrubber Wiring Harness Diagram 56114062 Rev B Early before machine SN 3000167142...

Page 43: ...Electrical System 43 Service Manual Focus II Scrubtec R6 Rider Autoscrubber Wiring Harness Diagram 56114405 Rev A Late beginning with machine SN 3000167142...

Page 44: ...B WHT BRN W221 M4 Brush Lift Motor A BLU W054 B ORN BLK W055 M4 Brush Lift Sensor A RED VIO W225 B YEL BLK W165 C BLK WHT W224 WP3 A M5 Vac Motor 1 A WHT W202 B BLK W191 MP2 A M6 Vac Motor 2 A WHT W20...

Page 45: ...k W165 J1 9 Squeegee Lift Blk Yel W205 J1 10 Squeegee Lift Wht Grn W206 Main Machine Controller J2 Connector Pin Name Wire Color ID J2 1 B Blk W162 1 12 J2 2 B Blk W161 J2 3 Charger Comm Yel Orn W174...

Page 46: ...RED BRN W166 J3 4 Seat Switch BRN W178 J3 5 Reverse Signal BLU BLK W066 J3 6 Fwd Rev Signal RED WHT W058 J3 7 Drive Status ORN BLU W068 J3 8 Power BRN VIO W182 J3 9 Horn GRN BLK W049 J3 10 Horn ORN RE...

Page 47: ...r more information The warning beacon may be added for increased visibility of the machine when it is operated in high traffic environments The light operates whenever the machine is in a ready state...

Page 48: ...acuum motor generates airflow through the recovery tank and suction hose to the squeegee The high velocity air at the squeegee pulls the wastewater off the floor and up through the suction hose As the...

Page 49: ...This PWM signal does not impact the actual vacuum motor voltage only the coil s voltage The PWM signal begins high to pull the contacts together and then reduces power to just enough to hold the conta...

Page 50: ...k the vacuum motor power connector Check the vacuum motor contactor for proper operation Poor suction Unknown Leak versus Clog To determine whether the problem is a leak versus a clog remove the sucti...

Page 51: ...the middle of the PVC tube and clean off the burs 7 As necessary wrap duct tape 8B around the tube so it fits snugly in the end of the end of the suction hose 3A with no leaks 8 Turn the vacuum on and...

Page 52: ...switch 2 Remove the drain hose cap 2 and drain the recovery tank You may also wish to rinse and flush the tank before removing it 3 Lift the operator s seat and disconnect the power connector 5 for t...

Page 53: ...hose 6G Take care not to lose the three vibration mounts 6D 4 If necessary remove the cable tie that secures the discharge hose to the motor outlet 5 Inspect the main vacuum gasket 6E for damage and c...

Page 54: ...n H2 O 2 kPa Vacuum Lift Dual Motor Sealed water lift 59 in H2 O 15 kPa 1 inch open hole aperture 21 in H2 O 5 kPa Contactor Coil Resistance 58 3 Motor Amperage Single Motor with squeegee off floor 19...

Page 55: ...on or full off The primary on off function is controlled with the brush motor contactor K1 located in the main electrical panel under the operator s seat The output of this contactor is all on or all...

Page 56: ...deck pressure For this reason current sensing is not used for deck pressure control The lift actuator contains two extra position switches to tell the controller what the physical position is of the...

Page 57: ...n described on page 79 for more information on PWM control The deck lift actuator contains two additional position switches S5 S6 not found in other actuators on the machine These switches provide pos...

Page 58: ...g press the For Rev switch on the Adapter 99 to move the spring housing 2C until the actuator reaches its limit switch and the motor stops For Boost and Disk decks move the actuator to its extended po...

Page 59: ...pper retaining pin 2A and a better view you may wish to remove the Electrical Panel Cover described on page 37 Note For machines equipped with the onboard detergent system this access is behind the de...

Page 60: ...b deck to the lift arms Take care not to loose the spacers 1D 7 Slide the scrub deck out from the right side of the machine Make sure no wires or hoses get hung up on the deck as you remove it 8 Insta...

Page 61: ...reaching in from below the machine while looking through the opening behind the electrical panel or detergent cartridge 10 If the actuator is going to be reinstalled without modification take care no...

Page 62: ...and slide the pin brackets 2J out of the lead nut 2 Remove the four screws 2L that secure the end cap 2F and slide the spring housing 2C off the leadscrew 3 Unscrew the lead nut and replace the upper...

Page 63: ...rt circuit can damage the components or your tools and equipment 1 Turn off the key and disconnect the main battery connector 2 Remove the Electrical Panel Cover described on page 37 3 Remove the inco...

Page 64: ...may be present and securing the solution line 6 When replacing the motor take care to match whether it is a right hand or left hand gearbox Cylindrical Deck Motor 1 Lower the deck to a neutral positio...

Page 65: ...ates 5S Take care to not lose the 4 spacers 5P 8 Remove the 8 nuts 5N that secure the isolation mounts to the mid plate 5T and remove the 2 flex plates 5S from the mid plate 5T 9 Remove the retaining...

Page 66: ...or Amperage Raising 1 4 2 8 A Lowering 0 8 1 3 A Scrub Pressure Amperage Specifications Chart Scrub Mode Default Pressure Indicator Deck Type Disc 28 Cyl 28 Disc 34 Disk 40 Regular Scrub 1 LED 24 AMPS...

Page 67: ...floor when the machine is stationary the solenoid output from the controller is disabled when the wheel drive is not active The rate of solution flow is controlled by cycling the solution solenoid on...

Page 68: ...put is inhibited unless the machine is in motion or pre wetting is called for Detergent Pump The detergent pump is a small reversible diaphragm pump The polarity of the pump is reversed to cycle the p...

Page 69: ...flex hose 5 and remove the flex hose c Remove the solenoid mounting screw 6 and remove the solenoid To replace the filter body 2A or the outlet valve 1 do the following a Loosen the hose clamp 7 on th...

Page 70: ...cted to each terminal of the pump 5 Disconnect the hoses 10 11 and wires 12 13 from the pump 9 6 Raise the operator s seat and remove the two screws that secure the pump to the detergent bulkhead and...

Page 71: ...squeegee within the scrubbing path while turning the machine Squeegee Lift Actuator The squeegee lift actuator operates on a cable that raises the squeegee assembly When the actuator is not pulling on...

Page 72: ...nd tight Squeegee Trim Adjustment The squeegee trim needs to be checked or adjusted whenever the squeegee blades are replaced or if the squeegee is not fully wiping the floor Misadjustment symptoms in...

Page 73: ...to the gear housing a drill bit is shown in the photo for clarity Important After the limit is adjusted and until the actuator is back in the machine make sure not to rotate the nut housing relative t...

Page 74: ...d remove the retaining strap 4 4 Lift the rear squeegee blade 5 off the squeegee body 1 The squeegee can be rotated and or flipped 3 times to expose a new edge 4 edges total to the lower front If all...

Page 75: ...4 edges total to the lower front If all 4 edges are worn replace the squeegee blade 5 with a new one 6 To replace the blade 8 align the slots in the blade with the tabs 1C on the squeegee body 1 7 Re...

Page 76: ...and remove the pin and lift cable 13 6 Disconnect the motor cable connector 14 7 Remove the cotter key 15 from the front guide pin 16 and remove the pin 8 Slide the lift actuator 17 out toward the fro...

Page 77: ...ed directly to the machine s subframe Removal and Installation Warning Never work under machine without safety stands or blocking to support the machine 1 To reduce the weight of the machine drain bot...

Page 78: ...a single potentiometer Instead the forward reverse function is independently controlled by a separate control line between the Main Machine Controller and the Wheel Drive controller Moreover the spee...

Page 79: ...ery charger is present its interlock signal is also in series with these switches The two potentiometers throttle position and speed limit control the internal clock of the controller which determines...

Page 80: ...6 Red Wht Brake Off Signifies when the drive system is in motion 7 Open not used 8 Open not used 9 Orn Blu Status Fault Speed controller output to main controller 10 Open not used 11 Open not used 12...

Page 81: ...heck for broken or disconnected brake wires Measure the resistance of the brake It should be approximately 25 ohms Wheel drive motor will run in only one direction but not the other Reverse control pr...

Page 82: ...THROTTLE FAULT 1 Throttle fault Throttle input wire open or shorted Throttle pot defective Wrong throttle type selected 1 3 SPEED LIMIT POT FAULT Speed limit pot fault Speed limit pot wire s broken or...

Page 83: ...in motor wiring Controller failure The keyswitch must be cycled before this fault can clear Removal and Installation Drive Controller Warning Disconnect the battery connector before servicing machine...

Page 84: ...anks To lower the center of gravity of the machine you may even choose to remove the recovery tank from the machine 3 Block both sides of the machine at the rear lifting points 15 to keep the machine...

Page 85: ...machine back down to the floor 13 Remove the plastic cap from the solution tank above the spindle nut 8 14 The drive wheel assembly is heavy Make sure the machine is lowered back to the floor first an...

Page 86: ...he seal 2 Remove the thrust bearing cone 25 and clean the old grease from the cone and also from the upper bearing 27 which is not removable 3 Inspect the bearings and cup 26 for wear and replace if n...

Page 87: ...sing flange However the brake disks can be inspected without removing the drive assembly from the machine 1 Remove the Drive Wheel Assembly described on page 84 2 Remove the two screws 29 that secure...

Page 88: ...ing and remove the brake 12 During replacement use a screw driver 37 to hold the brake release lever 36 raised This will allow the spline gear to float while you realign the mounting screws 34 Reassem...

Page 89: ...in the machine down at the rear lifting points 3 Raise the front of the machine by jacking at the center front flat surface of the solution tank 4 Using a 5mm hex key remove the four screws 38 that se...

Page 90: ...isk 43 4 Slide the drive hub with the new wheel tire over the alignment pins 5 Gently tap on the upper portion of the drive hub 40 to get the wheel started over the main bearing 42 until the mounting...

Page 91: ...prevent tipping it is also a good idea to chain the machine down at the rear lifting points 4 Raise the front of the machine by jacking at the center front flat surface of the solution tank 5 Block t...

Page 92: ...e 4 Pot Wiper 4 18 0 04 B Speed potentiometer wiper 5 KSI 25 1 0 B Safety circuit to enable drive controller 6 Brake Out 0 25 23 1 B Drive wheel brake 7 Not Used B 8 Not Used B 9 Status Data 1 2 B Sta...

Page 93: ...te diagnostic information in plain language without codes to decipher Faults are displayed in the Diagnostic Menu and the status of the controller inputs outputs is displayed in the Test Menu The hand...

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