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ELECTRICAL

4-11

5400 330735 (3–01)

INSTRUMENT PANEL

The instrument panel contains the electrical
controls needed to operate the machine. The
battery meter, brush pressure gauge, rocker
switches, relays, contactor, and fuses are located
on the panel. By removing the attachment
hardware, the panel can be pulled back to access
these components.

TO ACCESS INSTRUMENT PANEL

FOR SAFETY: Before Leaving Or Servicing
Machine; Stop On Level Surface, Turn Off
Machine.

1. Open the recovery tank.

2. Disconnect the positive battery cable from

the front, left machine battery.

FOR SAFETY: Disconnect the battery
connections before working on the machine.

Machine Front

5

RED

BLACK

4

3

1

2

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Summary of Contents for 5400

Page 1: ...330735 Rev 00 3 01 Service Manual 5400 ...

Page 2: ...d Transaxle drive motor replacement Scrubbing Squeegee assembly replace and adjust Scrubber head replace and adjust Scrubber brush motor replacement Vacuum fan replacement Solution recovery tank replacement Power wand pump replacement and Scrubbing troubleshooting chart Electrical Battery maintenance and replacement Charging instructions Circuit breaker relay replacement Instrument panel replaceme...

Page 3: ...LS 1 6 MACHINE DIMENSIONS 610mm 24 in CYLINDRICAL BRUSH MODEL 1 7 TROUBLESHOOTING 1 8 MACHINE JACKING 1 10 MACHINE TRANSPORTING 1 10 STORING MACHINE 1 11 TO STORE MACHINE 1 11 STORAGE INFORMATION 1 11 HARDWARE INFORMATION 1 12 STANDARD BOLT TORQUE CHART 1 12 METRIC BOLT TORQUE CHART 1 12 BOLT IDENTIFICATION 1 12 THREAD SEALANT AND LOCKING COMPOUNDS 1 12 ...

Page 4: ...GENERAL INFORMATION 1 2 5400 330735 3 01 ...

Page 5: ...g machine Do not carry riders on machine Always follow safety and traffic rules Report machine damage or faulty operation immediately 4 Before leaving or servicing machine Stop on level surface Turn off machine Set parking brake if equipped 5 When servicing machine Avoid moving parts Do not wear loose jackets shirts or sleeves Block machine tires before jacking machine up Jack machine up at design...

Page 6: ...ng on machine FLAMMABLE MATERIALS LABEL LOCATED ON THE RECOVERY TANK COVER WARNING Flammable materials can cause an explosion or fire Do not use flammable materials in tank s Flammable materials or reactive metals can cause explosion or fire Do not pick up BATTERY CHARGE LABEL LOCATED ON THE RECOVERY TANK COVER AND BOTTOM SIDE OF RECOVERY TANK WARNING Batteries emit hydrogen gas Explosion or fire ...

Page 7: ...w 25 hp Transaxle 24 V 19 kw 25 hp Transaxle 24 V 19 kw 25 hp CLEANING RATE 2415 m2 per hour 26 000 sq ft 2601 m2 per hour 28 000 sq ft 2415 m2 per hour 26 000 sq ft CLEANING PATH WIDTH 610mm 24 in 660mm 26 in 610mm 24 in PAD PRESSURE Variable 0 54 kg 0 120 lb Variable 0 54 kg 0 120 lb Variable 0 41 kg 0 90 lb SQUEEGEE WIDTH 839mm 33 in 839mm 33 in 839mm 33 in TOTAL POWER CONSUMPTION 60 Amp nomina...

Page 8: ... 6 5400 330735 3 01 MACHINE DIMENSIONS 610mm 24 in and 660mm 26 in DISK MODELS 641mm 25 25 in 559mm 22 in 1041mm 41 in 839mm 33 in 699mm 27 5 in Dimensions apply to 660 mm 26 in disk models only 1270mm 50 in 1289mm 50 75 in ...

Page 9: ...GENERAL INFORMATION 1 7 5400 330735 3 01 MACHINE DIMENSIONS 610mm 24 in CYLINDRICAL BRUSH MODEL 667 mm 26 25 in 559 mm 22 in 1359 mm 53 5 in 1041 mm 41 in 839 mm 33 in ...

Page 10: ...tripped Determine cause and reset circuit breaker button Faulty vacuum motor or wiring Contact Service Center Worn carbon brushes Contact Service Center Little or no solution Solution switch is not activated Turn on solution switch flow Clogged solution line or solution tank filter Remove hose and blow compressed air through it Flush solution tank after each use Clogged solution valve or solenoid ...

Page 11: ...d tilt tank side ways to access inlet hole remove ob struction Worn tank lid gasket Replace gasket Loose drain hose plug Tighten plug Recovery tank lid not in place Properly position lid Loose vacuum motor Contact Service Center Battery charge level is low Charge batteries Do not run machine when battery meter is in the red zone ES option not ES filter is clogged Remove and clean ES filter operati...

Page 12: ...achine up with jack stands MACHINE TRANSPORTING FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key FOR SAFETY When using machine go slow on inclines and slippery surfaces When transporting machine by use of trailer or truck be certain to follow tie down procedures below 1 Raise squeegee and scrub head 2 Load machine using a recomm...

Page 13: ...E FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Make sure the tanks are drained and rinsed out 2 Un plug the batteries and charge them properly STORAGE INFORMATION The following steps should be taken when storing the machine for extended periods of time 1 Drain and clean the solution and recovery tanks 2 Park the machine in...

Page 14: ...291 380 313 407 424 552 1 00 in 500 650 678 881 757 984 1026 1334 NOTE Decrease torque by 20 when using a thread lubricant METRIC BOLT TORQUE CHART Thread Size Class 8 8 Torque ft lb _Nm Class 10 9 Torque ft lb Nm M4 2 3 3 4 M5 4 5 6 8 M6 7 9 10 14 M8 18 24 25 34 M10 32 43 47 64 M12 58 79 83 112 M14 94 127 133 180 M16 144 195 196 265 M20 260 352 336 455 M24 470 637 664 900 NOTE Decrease torque by ...

Page 15: ...1 5400 330735 3 01 CONTENTS Page INTRODUCTION 2 3 DRIVE TRANSAXLE 2 4 TO REMOVE DRIVE TRANSAXLE 2 4 TO INSTALL THE TRANSAXLE 2 6 TO REPLACE DRIVE WHEEL TIRE ASSEMBLY 2 7 REAR CASTER 2 9 TO REPLACE REAR CASTER 2 9 ...

Page 16: ...CHASSIS 2 2 5400 330735 3 01 ...

Page 17: ...400 330735 3 01 INTRODUCTION This section includes information on the main chassis related components for example the transaxle casters and tires The transaxle drive motor and transaxle must be replaced as one unit ...

Page 18: ...hine The drive transaxle is powered by a 24V electric motor TO REMOVE DRIVE TRANSAXLE 1 Lower the scrub head all the way to the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 2 Turn the machine power off 3 Lift the rear of the machine until the transaxle drive wheels are off the ground ...

Page 19: ...and washers holding each drive wheel to the transaxle Remove the drive wheels from the machine 6 Un plug the transaxle drive motor from the main harness 7 Remove the four M8 hex screws and washers holding the two transaxle mount brackets to the machine frame 8 The transaxle can now be removed from the machine ...

Page 20: ...nt brackets and M8 hex screws can be reinstalled Tighten to 18 24 Nm 15 20 ft lb 3 Plug the drive motor into the main harness See schematic in the ELECTRICAL section of this manual 4 Reinstall the drive wheels onto the transaxle using the four 0 250 in hex nuts and washers Tighten to 11 14 Nm 7 10 ft lb 5 Remove the jack stands and lower the machine to the ground 6 Raise the scrubber head 7 Operat...

Page 21: ... scrub head all the way to the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 2 Turn the machine power off 3 Lift the rear of the machine until the transaxle drive wheels are off the ground 4 Place a jackstand under the machine frame ...

Page 22: ...move the drive wheels from the machine 6 Position the new drive wheel onto the transaxle using the four 0 250 in hex nuts and washers Tighten to 11 14 Nm 7 10 ft lb 7 Remove the jack stands and lower the machine to the ground 8 Raise the scrubber head 9 Operate the machine checking for proper operation of the drive wheels ...

Page 23: ... off 2 Lift the rear of the machine with an over head hoist or other lifting device until the rear caster is off the ground Place a jackstand under the machine frame 3 Remove the four M8 hex screws and washers holding the caster to the machine frame Remove the caster from the machine 4 Position the new caster under the machine and reinstall the four M8 hex screws and washers Tighten to 18 24 Nm 15...

Page 24: ...CHASSIS 2 10 5400 330735 3 01 ...

Page 25: ...7 TO ADJUST TAPERED BRUSH PATTERN 3 20 TO ADJUST UNEVEN BRUSH PATTERN 3 22 TO ADJUST CYLINDRICAL SCRUB HEAD SKIRTS 3 23 TO REPLACE CYLINDRICAL SCRUB HEAD SKIRT 3 25 TO REPLACE CYLINDRICAL SCRUB BRUSH DRIVE BELT 3 26 TO REPLACE CYLINDRICAL SCRUB BRUSH IDLER PLUG AND BEARING ASSEMBLY 3 29 TO REPLACE CYLINDRICAL SCRUB BRUSH DRIVE PLUG BEARINGS 3 31 SQUEEGEE 3 37 TO REMOVE SQUEEGEE 3 37 TO REPLACE OR ...

Page 26: ...SCRUBBING 3 2 5400 330735 3 01 ...

Page 27: ...and down to the scrub head The brush scrubs the floor As the machine moves forward the squeegee wipes the dirty solution off the floor which is then picked up and drawn into the recovery tank by the vacuum fan This section includes information on the scrub head scrub brush squeegee lift actuator vacuum fan float switches and solution tanks ...

Page 28: ...quire regular maintenance except daily rinsing of any sludge or deposits If any deposits do form on the bottom of the tank rinse with a strong blast of warm water NOTE The water must not be hotter than 60 C 140 F or tank damage may occur Do not use steam to clean the tank ES Option The recovery tank should be partially filled with clean water after using the ES Option and clean water should be run...

Page 29: ...the squeegee and scrubbing vacuum fan The recovery tank is the top tank on the machine It can be opened for battery vacuum fan head lift actuator and water valve access The recovery tank should be drained and cleaned daily NOTE The water must not be hotter than 60 C 140 F or tank damage may occur Do not use steam to clean the tank ...

Page 30: ... brush should be replaced if large amounts of bristles are missing or if the remaining bristles length is less than 10 mm 0 38 in NOTE Be sure to replace brushes in sets Otherwise one brush will be more aggressive than the other Cleaning pads must be placed on pad drives before they are ready to use The cleaning pad is held in place by a pad holder Cleaning pads need to be cleaned with soap and wa...

Page 31: ...ed position FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 2 Turn the machine off 3 Push the brush release knobs downward 4 Remove the brush from the drive plug Pull the brush out from under the scrub head 5 Reverse this order for installing the disc scrub brush ...

Page 32: ...Or Servicing Machine Stop On Level Surface Turn Off Machine 2 Turn the machine off 3 The cylindrical scrub brush must be removed from the end of the scrub head opposite the brush drive motor 4 The brush idler plate is held in place with a spring clip To remove the idler plate the spring clip must be pressed down flat to the top of the scrub head ...

Page 33: ... 8 Place the brush on the motor drive end first 9 Partially engage the idler plug into the other end of the scrub brush 10 Position the idler plate on the scrub head making sure that the notches on the idler plate engage the lip of the scrub head 11 Push the spring clip down until the slot is positioned under the clip on the idler plate Release the spring 12 Start the brushes and check for proper ...

Page 34: ... a solution dispensing system The scrub head skirt controls over spray from the scrub brush Make sure the scrub head skirt touches the floor all the way around when the scrub head is lowered Check the disk brush scrub head skirt for damage or wear daily Check the cylindrical brush scrub head side skirt for damage daily ...

Page 35: ... Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Remove the scrub head shroud 3 Disconnect the solution hose running from the solution tank to the scrub head 4 Unplug the electrical connectors attaching the scrub head motor to the main harness ...

Page 36: ...to the scrub head lift arms 7 Pull the disc scrub head away from the front of the machine 8 Reverse these steps to install a disc scrub head NOTE When reinstalling a scrub head loosen the two mounting screws on the switch box Align the corresponding arrow printed on the switchbox label with the notch in the spring bracket Roller Bracket Switch Box Notch Disk Cylindrical Spring Bracket DETAIL ...

Page 37: ... to 345 kPa 45 to 50 psi 2 Fill the solution tank 3 Lower the scrub head to the floor Apply maximum down pressure FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 4 The scrub head levelness is checked by measuring from the top of the scrub head to the floor at the center front and center back ...

Page 38: ...the angle of the scrub head Make sure to re tighten the jam nut Re check the scrub head levelness NOTE Make sure the scrub head skirt touches the floor all the way around when the scrub head is lowered Check the skirt for damage or wear daily TO REPLACE DISK SCRUB HEAD SKIRT 1 If the disc scrub head skirt is torn or worn it needs to be replaced Remove the skirt retaining band and skid strip holdin...

Page 39: ...ETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Remove the scrub head shroud 3 Disconnect the solution hose running from the solution tank to the scrub head 4 Unplug the electrical connectors attaching the scrub head motors to the main harness ...

Page 40: ...disc scrub head away from the front of the machine 8 Reverse these steps to install a cylindrical scrub head After installing scrub head see TO CHECK CYLINDRICAL BRUSH PATTERN instructions NOTE When reinstalling a scrub head loosen the two mounting screws on the switch box Align the corresponding arrow printed on the switchbox label with the notch in the spring bracket Roller Bracket Switch Box No...

Page 41: ...n the drive tires Proper air pressure for standard pneumatic tire is 315 to 345 kPa 45 to 50 psi 2 Fill the solution tank 3 Position the machine with the scrub head located over the top of the chalk area Lower the scrub head to the floor Apply minimal down pressure FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key ...

Page 42: ...d and brushes up off the floor when checking the brush pattern You may have to adjust them up or pull them to the side 6 Slightly rotate the control grips forward for 2 seconds while holding the machine in one spot Lower the scrub head allowing the brushes to spin on the floor in one spot for 15 to 20 seconds NOTE If no chalk or other material is available allow the brushes to spin for 30 seconds ...

Page 43: ...dth from side to side If both brush patterns look good the adjustment procedure is complete If either brush shows a tapered pattern see TO ADJUST TAPERED BRUSH PATTERN instructions If either brush shows an uneven pattern see TO ADJUST UNEVEN BRUSH PATTERN instructions Good pattern Tapered pattern Uneven pattern Good pattern Tapered pattern Uneven pattern ...

Page 44: ...Turn the machine off 3 Remove the brush idler plate from the end of the brush that has a taper The brush idler plate is held in place with a spring clip To remove the idler plate the spring clip must be pressed down flat to the top of the scrub head 4 With the spring clip pressed down flat to the top of the scrub head pull the bottom of the idler plate out of the end of the brush and off the sprin...

Page 45: ...len wrench 9 Turn eccentric shaft to raise or lower that end of the brush Re tighten the flat head screw while holding the flat of eccentric shaft 10 Reinstall the idler plate and re check the brush pattern Re adjust if necessary NOTE Make sure to install the idler plate on the side it was removed from to avoid having to re adjust the brush taper ...

Page 46: ... Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 The scrub head levelness is checked by measuring from the edge of the scrub head to the floor at all four corners of the scrub head 3 If the scrub head is not level loosen the scrub head adjustment screw jam nut Use a 1 inch open end wrench on the adjustment hex screw located at the front of the pivot bracket to adjust the ...

Page 47: ...head is the lowered position Check the skirts for damage or wear daily 1 Lower the scrub head on a level floor until the brushes make contact 2 Turn the machine power off FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 3 Check to see if the scrub head skirts touch the floor on both sides of the scrub head ...

Page 48: ...e four M8 flat head screws holding the skirt and retainer to the scrub head 5 Adjust the skirt down so it lightly contacts the floor Hand tighten the M8 flat head screws 6 Operate the machine and check the scrub head skirts for proper operation ...

Page 49: ... Turn Off Machine 3 Remove the four M8 flat head screws holding the skirt retainer and skirt to the side of the scrub head Remove the skirt 4 Position a new skirt under the skirt retainer and reinstall the four M8 flat head screws 5 Adjust the skirt down so it lightly contacts the floor Hand tighten the M8 flat head screws Do not over tighten 6 Operate the machine and check the scrub head skirts f...

Page 50: ... Off Machine And Remove Key 1 Remove the scrub brush from the motor that the belt needs to be changed See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 2 Loosen the front and rear pivot bolts on the brush motor 3 Remove the two M6 hex screws holding the belt guard onto the motor that the belt needs changing Remove the belt cover from the scrub head ...

Page 51: ...TE Make sure the scrub head is in the raised position before attempting to remove the drive plug rubber seal 5 Using a needle nose pliers pull the rubber seal off the brush drive plug Remove the belt cover from the bottom of the scrub head Take care not to damage the cover gasket 6 Pull the drive belt off the bottom drive pulley 7 Slip the new drive belt over the drive plug Push the rest of the be...

Page 52: ...plying 2 5 2 7 lbs of force per belt at the middle of the span that is opposite the belt travel with a deflection of 0 10 inch 10 Tighten the two pivot bolts to 18 24 Nm 15 20 ft lb Re check the belt tension 11 Reinstall the belt cover Install the two M6 hex screws and washers Tighten to 11 14 Nm 7 10 ft lb 12 Reinstall the scrub brush See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this ...

Page 53: ... Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Remove the scrub brush idler door See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 2 Remove the M10 flat screw holding the idler plug to the brush door 3 Remove the snap ring holding the plastic idler plug and bearing assembly to the idler plug shaft ...

Page 54: ...lat screw holding the idler plug shaft and hub assembly to the brush door Make sure to align the small pin on the shaft base with the hole in the brush door Leave the flat screw loose for now the brush hub will need to be adjusted later 7 Reinstall the cylindrical scrub brush idler door See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 8 Operate the machine Check the cylindrica...

Page 55: ...Set Parking Brake Turn Off Machine And Remove Key 1 Remove the scrub brush See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 2 Loosen the front and rear pivot bolts on the brush motor 3 Remove the two M6 hex screws holding the belt guard and belt shield on the motor that the belt needs changing Remove the belt cover from the scrub head ...

Page 56: ... drive plug in the brush area NOTE Make sure the scrub head is in the raised position before attempting to remove the drive plug rubber seal 5 Using a needle nose pliers pull the rubber seal off the brush drive plug Remove the belt cover from the bottom of the scrub head Take care not to damage the cover gasket 6 Pull the drive belt off the bottom drive pulley 7 Unscrew the drive plug assembly fro...

Page 57: ...ing holding the hub and bearing to the hub shaft 10 Use an arbor press to remove the two bearings from the brush drive plug 11 Use the arbor press to first press the inner bearing onto the hub shaft 12 Secondly press the drive hub onto the inner bearing ...

Page 58: ...ress the outer bearing into the drive hub 14 Reinstall the snap ring onto the hub shaft 15 Place a small amount of Loctite blue 242 on the threads of the drive hub shaft 16 Reinstall the drive hub shaft onto the scrub head casting Tighten firmly ...

Page 59: ... a bead of silicone sealant part 08317 around the seal to bond it in place Reinstall the lower cover and gasket 10 Using the M8 hex screw located under the brush motor tension the belt by applying 2 5 2 7 lbs of force per belt at the middle of the span that is opposite the belt travel with a deflection of 0 10 inch 11 Tighten the two pivot bolts to 18 24 Nm 15 20 ft lb Re check the belt tension ...

Page 60: ...einstall the belt cover two M6 hex screws and washers Tighten to 11 14 Nm 7 10 ft lb 13 Reinstall the scrub brush See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 14 Operate the machine and check for proper operation ...

Page 61: ...ate or replace either of the squeegee blades if the leading edge is torn or worn half way through the thickness of the blade The squeegee can be removed from the squeegee pivot so the squeegee will not be damaged during transport of the machine TO REMOVE SQUEEGEE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 1 Raise the squeegee 2 Remove the squeegee suction...

Page 62: ... 38 5400 330735 3 01 3 Loosen the two mounting thumbscrews 4 Pull the squeegee off the machine NOTE Reverse this order to install the squeegee assembly 5 Operate the machine Check the squeegee for proper operation ...

Page 63: ...cing Machine Stop On Level Surface Turn Off Machine 1 Raise the squeegee 2 Un snap the squeegee rear retainer clamp 3 Remove the retainer and squeegee blade from the squeegee frame NOTE Reverse this order to install the squeegee blade and retainer 4 Operate the machine Check the squeegee for proper operation ...

Page 64: ...p On Level Surface Turn Off Machine 1 Raise the squeegee 2 Remove the six thumbscrews holding the retainer and squeegee blade to the squeegee frame 3 Pull the squeegee blade off the squeegee frame NOTE Reverse this order to install the squeegee blade and retainer 4 Operate the machine Check the squeegee for proper operation ...

Page 65: ...FETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 1 Lower the squeegee 2 Disconnect the tension spring from the squeegee lift cable 3 Remove the cotter pin and clevis pin from the end of the lift cable where it attaches to the lower bracket ...

Page 66: ...t holding the squeegee lift cable to the ball joint Un screw the cable from the ball joint 6 Pull the cable end through the cable bushing Remove the cable from the machine Remove the balljoint end and jam nut from the existing cable Install the jam nut and balljoint in the same location on the new lift cable NOTE Reverse this order to install the squeegee lift cable 7 Operate the machine Check the...

Page 67: ...chine 1 Use a 5 64 inch allen wrench to loosen the set screw holding the solution flow control cable to the end of the valve Pull the cable off the valve 2 Remove the four pan screws holding the solution flow bracket assembly to the back of the solution tank 3 Use a small flat screw driver to remove the solution control knob from the top of the cable ...

Page 68: ... Use a 1 2 inch nut driver to remove the cable jam nut Remove the solution cable from the bracket NOTE Reverse this order to install the new solution control cable 5 Operate the machine Check the new solution cable for proper operation ...

Page 69: ...n flow to the Solution tank empty Fill solution tank floor Solution switch off Turn switch on Solution control cable broken or out of adjustment Replace and or adjust cable Solution flow knob turn off Turn solution flow knob on Solution supply lines plugged Flush solution supply lines Solution solenoid clogged or stuck Clean or replace ES mode ES switch off Turn ES switch on Poor scrubbing perform...

Page 70: ...SCRUBBING 3 46 5400 330735 3 01 ...

Page 71: ...NAL EXTENDED SCRUB 4 51 TO REPLACE THE ES PUMP 4 51 OPTIONAL POWER WAND 4 53 TO REPLACE POWER WAND PUMP 4 53 Page ELECTRIC MOTORS 4 55 TO REPLACE VACUUM FAN MOTOR BRUSHES 4 55 TO REPLACE DISC SCRUB BRUSH MOTOR BRUSHES 4 57 ELECTRICAL SCHEMATIC 4 59 WIRING DIAGRAM 4 60 WIRING DIAGRAM OPTIONS 4 61 TROUBLESHOOTING 4 63 POWER UP CIRCUIT 4 64 NO POWER KEY ON AND BATTERY CHARGER DISCONNECTED 4 65 PROPEL...

Page 72: ...ELECTRICAL 4 2 5400 330735 3 01 ...

Page 73: ...L SYSTEM The 5400 electrical system consists of the batteries electrical drive motor scrub brush motors vacuum fan motor power control panel and related components This section includes information on these components and their troubleshooting ...

Page 74: ...rong solution of baking soda and water Brush the solution sparingly over the battery tops terminals and cable clamps Do not allow any baking soda solution to enter the batteries Use a wire brush to clean the terminal posts and the cable connectors After cleaning apply a coating of clear battery post protectant to the terminals and the cable connectors Keep the tops of the batteries clean and dry K...

Page 75: ...the water and acid are not thoroughly mixed the readings may not be accurate Check the hydrometer readings against the following chart to determine the remaining battery charge level SPECIFIC GRAVITY BATTERY at 27 C 80 F CHARGE 1 265 100 Charged 1 223 75 Charged 1 185 50 Charged 1 148 25 Charged 1 110 Discharged NOTE If the readings are taken when the battery electrolyte is any temperature other t...

Page 76: ...very tank for access to the batteries NOTE The recovery tank must be empty 4 Check fluid level A in each battery cell before charging If battery plates B are exposed add just enough distilled water to cover plates by approximately 3 mm 0 13 in DO NOT OVERFILL Overfilled batteries can overflow during charging due to fluid expansion Replace cell caps before charging NOTE Make sure the battery caps a...

Page 77: ... turn off 8 After the charger has turned off unplug the charger from the wall outlet 9 Unplug the charger connector from the battery connector on the machine FOR SAFETY When Maintaining or Servicing Machine Avoid Contact With Battery Acid 10 Check the electrolyte level in each battery cell Add just enough distilled water to bring the electrolyte level up to the fill rings 11 Lower the recovery tan...

Page 78: ...evel Surface Set Parking Brake Turn Off Machine And Remove Key NOTE Drain the recovery tank 1 Open the recovery tank 2 Disconnect the positive battery cable from the front left machine battery FOR SAFETY Disconnect the battery connections before working on the machine 3 Lower the squeegee Machine Front 5 RED BLACK 4 3 1 2 ...

Page 79: ...lding the charger safety switch to the bracket Remove the switch 7 Install the new switch onto the bracket Reinstall the hex screws and nuts Position the switch so it is activated when the connector from the battery charger is plugged into the machine connector Tighten the hardware 8 Reconnect the wires to the new switch See electrical schematic in this section 9 Position the squeegee lever bracke...

Page 80: ...o the battery 12 Operate the machine Check the charger safety switch for proper operation The machine MUST NOT turn on with the key when the charger is plugged into the machine connector If the machine starts with the charger plugged in readjust the safety switch Machine Front 5 RED BLACK 4 3 1 2 ...

Page 81: ... on the panel By removing the attachment hardware the panel can be pulled back to access these components TO ACCESS INSTRUMENT PANEL FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 1 Open the recovery tank 2 Disconnect the positive battery cable from the front left machine battery FOR SAFETY Disconnect the battery connections before working on the machine Mach...

Page 82: ...sing 4 Pull the instrument panel back for access to the electrical components 5 When reinstalling the panel reconnect all wires that were disconnected Install the eight phillips head mounting screws DO NOT over tighten the screws or damage to the female brass insert could occur Reconnect the positive battery cable ...

Page 83: ...O ACCESS INSTRUMENT PANEL instructions FOR SAFETY Disconnect the battery connections before working on the machine 2 Remove the right handle grip 3 Use a screwdriver to loosen the set screw on the handle bar lock collar The collar should now move freely on the handle bar Make sure the rounded side of the lock collar is facing OUT towards the handle grip when reassembling handle bar ...

Page 84: ... off the bar Remove the gear hub from the machine 6 To reassemble with a new gear hub reverse the above steps When reinstalling the handle grips onto the handlebar use a light film of alcohol to ease assembly 7 Reinstall the instrument panel See TO ACCESS INSTRUMENT PANEL instructions 8 Operate the machine Check the propelling for proper operation Make sure the machine stops propelling when the ha...

Page 85: ...ACCESS INSTRUMENT PANEL instructions FOR SAFETY Disconnect the battery connections before working on the machine 2 Mark the location of the plastic gear on the shaft of the existing potentiometer Loosen the small set screw and remove the gear from the shaft 3 Remove the jam nut holding the potentiometer to the mount bracket Note the orientation of the potentiometer on the mount bracket ...

Page 86: ...tion on the shaft as the old one 7 See TO ADJUST POTENTIOMETER instructions in this section 8 Adjust the new potentiometer so that the teeth on the gear fully engage the teeth on the hub and gear assembly Make sure not to push the gears too tightly together so they bind Tighten the potentiometer jam nut DO NOT over tighten the jam nut or damage to the switch may occur 9 Reinstall the instrument pa...

Page 87: ...S 5 While measuring from the black wire to the red wire adjust the potentiometer to the midpoint 6 Without moving the potentiometer shaft measure from the white wire to the red wire This reading should be the same as the midpoint in step 4 If not repeat steps 4 and 5 until the readings are within 100 OHMS 7 Tighten the set screw of the small plastic gear onto the potentiometer shaft Re check steps...

Page 88: ...Off Machine 1 Open the instrument panel See TO ACCESS INSTRUMENT PANEL instructions FOR SAFETY Disconnect the battery connections before working on the machine 2 Locate the speed control board at the back of the instrument panel box 3 Mark and disconnect the wires leading to the speed control board See electrical schematic in this section ...

Page 89: ...el Make sure to retain the two steel spacers 6 Install the new board onto the heat sink plate Reinstall the two nuts Lightly tighten the nuts 7 Reconnect the wires and connectors to the new board See electrical schematic in this section 8 Reinstall the instrument panel See TO ACCESS INSTRUMENT PANEL instructions 9 Operate the machine Check the propelling for proper operation ...

Page 90: ...ion of the line side of diode Make sure the line side is connected to wire 22YEL Failure to do so will result in a short circuit 4 Remove the two hex nuts holding the contactor to the panel Remove the contactor from the instrument panel 5 Install the new contactor onto the instrument panel Install the two nuts and hand tighten tight 6 Reconnect the wires to the contactor See electrical schematic i...

Page 91: ...enter of the instrument panel box 3 Mark and disconnect the wires leading to the circuit breaker that needs to be changed 4 Loosen and remove the breakers mounting nut located on the front side of the switch panel 5 Connect the wires to the new circuit breaker See electrical schematic in this section 6 Install the new breaker into the panel DO NOT over tighten the mounting nut or damage may occur ...

Page 92: ... recovery tank 1 Open the recovery tank 2 Disconnect the positive battery cable from the front left machine battery FOR SAFETY Disconnect the battery connections before working on the machine 3 Remove the two pan screws holding the hour meter mount plate to the solution tank Pull the hour meter mount plate up and out of the way Machine Front 5 RED BLACK 4 3 1 2 ...

Page 93: ...Failure to do so will result in a short circuit 6 Remove the two hex nuts holding the solenoid to the mount plate Remove the solenoid from the plate 7 Install the new solenoid onto the plate using the two hex nuts Tighten to 7 9 Nm 5 6 ft lb 8 Reconnect the wires leading to the new solenoid See electrical schematic in this section 9 Position the solenoid mount bracket down onto the solution tank R...

Page 94: ...ELECTRICAL 4 24 5400 330735 3 01 11 Reconnect the positive battery cable to the battery 12 Operate the machine checking for proper operation Machine Front 5 RED BLACK 4 3 1 2 ...

Page 95: ... FAN FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key NOTE Drain the recovery tank 1 Open the recovery tank 2 Disconnect the positive battery cable from the front left machine battery FOR SAFETY Disconnect the battery connections before working on the machine 3 Disconnect the vacuum fan from the main harness Machine Front 5 RED ...

Page 96: ...the fan Remove the fan from the recovery tank Make sure to retain the three spacers 5 Remove the exhaust muffler from the existing fan and install on the new fan using a plastic tie 6 Install a gasket on the new vacuum fan motor 7 Install the new vacuum fan onto the recovery tank Reinstall the three hex screws and spacers Tighten to 5 6 Nm 50 60 in lb ...

Page 97: ... 5400 330735 3 01 8 Reconnect the vacuum fan to the main harness 9 Reconnect the positive battery cable to the battery 10 Operate the machine Check the vacuum fan for proper operation Machine Front 5 RED BLACK 4 3 1 2 ...

Page 98: ...el Surface Set Parking Brake Turn Off Machine And Remove Key NOTE Drain the recovery tank 1 Open the recovery tank 2 Disconnect the positive battery cable from the front left machine battery FOR SAFETY Disconnect the battery connections before working on the machine 3 Lower the squeegee Machine Front 5 RED BLACK 4 3 1 2 ...

Page 99: ...leading to the switch 6 Remove the two pan screws and nuts holding the vacuum fan switch to the bracket Remove the switch 7 Install the new switch onto the bracket Reinstall the pan screws and nuts Tighten the hardware 8 Reconnect the wires to the new switch See electrical schematic in this section 9 Position the squeegee lever bracket assembly to the left side of the solution tank Reinstall the t...

Page 100: ...queegee 11 Reconnect the positive battery cable to the battery 12 Operate the machine Check the vacuum fan switch for proper operation Make sure the vacuum fan turns on when the key is on and the squeegee is lowered Machine Front 5 RED BLACK 4 3 1 2 ...

Page 101: ...rush The disc scrub brush motor is direct drive The cylindrical scrub brush motor uses a drive belt from the motor to the brush TO REPLACE DISC SCRUB BRUSH MOTOR 1 Make sure the scrub head is in the raised position Shut off the key 2 Remove the scrub head shroud 3 Remove the disc scrub brush ...

Page 102: ...f the brush motor shaft Retain the square key and two washers 7 Remove the four 3 8 inch hex screws and washers holding the disc brush motor to the scrub head frame NOTE Make sure to mark the location of the existing scrub brush motor on the scrub head The new brush motor needs to be positioned in the same location The right hand motor has slots for motor adjustment S The distance between the moto...

Page 103: ...move the disc scrub brush motor from the machine 10 Remove the clamp holding the water shroud to the brush motor Remove the water shroud 11 Install the water shroud onto the new disc brush motor in the same orientation The shroud opening should face the center of the scrub head Tighten the clamp ...

Page 104: ...26 inch head 13 Raise the scrub head and turn off the key 14 Reinstall the four 3 8 inch hex screws and washers holding the disc brush motor to the scrub head frame Make sure the motor is installed in the same location The motor spacing is important for proper brush performance Tighten the hardware to 31 40Nm 27 35 ft lb 15 Place a small amount of water proof grease on the shaft of the brush motor...

Page 105: ...rs holding the brush drive hub to the motor shaft Tighten to 18 24Nm 15 20 ft lb 17 Reconnect the scrub brush motor to the main harness 18 Reinstall the disc scrub brush 19 Reinstall the scrub head shroud 20 Operate the machine Check the new scrub brush motor for proper operation ...

Page 106: ... 4 36 5400 330735 3 01 TO REPLACE CYLINDRICAL HEAD SCRUB BRUSH MOTOR 1 Start the machine and lower the scrub head to the floor Shut off the key 2 Remove the scrub head shroud 3 Remove the cylindrical scrub brush ...

Page 107: ... holding the belt guard and shield onto the motor that the belt needs changing Remove the belt cover from the scrub head 5 Loosen the front and rear pivot bolts on the brush motor 6 Loosen the belt tension bolt 7 Remove the brush drive belt from the motor sprocket ...

Page 108: ...from the end of the scrub brush motor 9 Remove the front and rear pivot bolts from the brush motor 10 Remove the scrub brush motor from the scrub head mounting bracket 11 Loosen the set screws holding the belt sprocket onto the existing motor shaft Remove the sprocket ...

Page 109: ...w 13 Apply grease to the new motor shaft Position the belt cover shield on the motor before installing the sprocket 14 Install the belt drive sprocket onto the shaft of the new motor Leave the set screws loose for now Make sure the square key is in place in the motor shaft 15 Position the cogged brush drive belt over the motor sprocket ...

Page 110: ...lug to align the motor sprocket with the lower drive sprocket Tighten the motor sprocket set screws Make sure to apply blue loctite 242 to the set screws before installing 18 Tighten the two pivot bolts to 18 24 Nm 15 20 ft lb Re check the belt tension 19 Reconnect the brush motor wires to the new brush motor See schematic in this section Make sure to reinstall the washers on the terminal studs on...

Page 111: ... belt cover Install the two M6 hex screws and washers Tighten to 11 14 Nm 7 10 ft lb 21 Reinstall the scrub brush See TO REPLACE A CYLINDRICAL SCRUB BRUSH instructions in this section 22 Operate the machine and check the new motor for proper operation ...

Page 112: ...ATOR FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Turn Off Machine 1 Lower the scrub head until it just touches the floor FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 2 Open the recovery tank 3 Disconnect the positive battery cable from the front left machine battery Machine Front 5 RE D BLAC K 4 3 1 ...

Page 113: ... clevis pin holding the bottom of the scrub head lift actuator to the scrub head roller assembly 6 Disconnect the lift actuator wire from the main harness 7 Remove the two pan screws holding the hour meter mount plate to the solution tank Pull the hour meter mount plate up and out of the way ...

Page 114: ...t of the way Lift the actuator and mount bracket out of the machine 9 Remove the hair pin and clevis pin holding the top of the actuator to the mount bracket 10 Remove the mount bracket from the actuator 11 Set the length of the new lift actuator to 13 inches from hole to hole 12 Reinstall the actuator mount bracket onto the top of the new actuator using the clevis pin and hair pin ...

Page 115: ...ws and tighten to 18 20 Nm 15 18 ft lb 14 Align the hole in the bottom of the new actuator lift tube with the mount hole in the roller assembly Reinstall the clevis pin and cotter pin 15 Remove the two pan screws holding the hour meter mount plate to the solution tank Pull the hour meter mount plate up and out of the way 16 Connect the new lift actuator to the main electrical harness ...

Page 116: ...1 17 Reconnect the positive battery cable to the battery 18 Reinstall the scrub head shroud 19 Close the recovery tank and operate the machine Check the scrub head lift actuator for proper operation Machine Front 5 RED BLACK 4 3 1 2 ...

Page 117: ...E SOLUTION SOLENOID VALVE FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key NOTE Drain the solution and recovery tanks 1 Open the recovery tank 2 Disconnect the positive battery cable from the front left machine battery FOR SAFETY Disconnect the battery connections before working on the machine 3 Lower the squeegee Machine Front ...

Page 118: ...h wires leading to the existing valve Remove the valve from the machine Reconnect the two wires to the new solution valve See the schematic in this section Note the direction of the diode connected to the coil terminals Make sure the line side of the diode is connected to wire 24 grey Failure to do so will result in a short circuit 8 Install the new solution valve onto the mount bracket Reinstall ...

Page 119: ...nes to the new valve 10 Turn the knob on the water control at the top of the machine fully clockwise water off position 11 Reconnect the water control cable to the shaft on the valve Make sure the set screw seats in the hole on the valve shaft 12 Raise the squeegee ...

Page 120: ... the battery 14 Operate the machine Check the solution flow system for proper operation 15 If more or less flow is required adjust the location of the knob on top of the machine Loosen the flexible shaft set screw adjust knob tighten set screw Machine Front 5 RED BLACK 4 3 1 2 ...

Page 121: ... used This greatly extends the amount of scrubbing that can be done on one fill up The ES system is activated by a switch on the instrument panel TO REPLACE THE ES PUMP FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key NOTE Drain the recovery tank 1 Open the recovery tank 2 Un plug the ES pump from the main harness ...

Page 122: ...t on the threads of the new ES pump 6 Screw the new pump clockwise into the recovery tank Tighten until the outlet tube points towards the back of the machine 7 Re connect the small water line and worm drive clamp to the ES pump 8 Re connect the main wire harness to the new pump See schematic in the ELECTRICAL section of this manual 9 Close the recovery tank operate the machine and check the ES pu...

Page 123: ... FOR SAFETY Before Leaving Or Servicing Machine Stop On Level Surface Set Parking Brake Turn Off Machine And Remove Key 1 Drain the solution tank 2 Locate the power wand pump at the bottom of the machine frame just in front the transaxle 3 Disconnect the pump from the main electrical harness 4 Loosen the worm drive clamps holding the two hoses leading to the solution pump Remove the hoses from the...

Page 124: ...to the mount bracket Remove the pump from the bracket Note the orientation of the pump to the bracket 7 Remove the brass elbow from the existing pump Install the elbow into the new pump in the same orientation Use a small amount of thread sealant on the threads of the elbow fitting 8 Reverse these steps to install a new wand solution pump 9 Fill the solution tank and check the power wand pump for ...

Page 125: ...ng Machine Stop On Level Surface Turn Off Machine 1 Remove the vacuum fan from the machine See TO REMOVE VACUUM FAN instructions in this section 2 Pry back the locking tabs and remove the fan motor cover NOTE DO NOT operate vacuum fan with the top cover removed 3 Remove the two pan head screws holding the clamp and motor brushes in place Remove the brushes and measure NOTE If the motor brushes mea...

Page 126: ...tions into each one of the two replacement motor brush mechanisms 6 Remount both motor brushes into position using the pan head screws and brush clamps 7 Reinstall the fan motor cover by pushing down and locking into place 8 Reinstall the vacuum fan motor assembly See TO INSTALL VACUUM FAN instructions in this section 9 Plug the vacuum fan in and start the machine checking for proper fan operation...

Page 127: ...face Turn Off Machine 1 Remove the disc scrub brush motor See TO REPLACE DISC SCRUB BRUSH MOTOR instructions in this section 2 Mark the location of the motor cover on the motor body 3 Remove the two long bolts holding the top of the motor and motor body together 4 Using a hammer and straight screwdriver gently tap and pry the motor top off ...

Page 128: ...brushes from hitting the commutator during motor re assembly After the top of the motor is properly assembled push the motor brushes completely into the brush holder using a small screwdriver The brush springs should snap into position behind the brush Line up the marks on the motor and cover to reassemble 6 Reinstall the disc scrub brush motor See TO REPLACE DISC SCRUB BRUSH MOTOR instructions in...

Page 129: ... 20K BLK WHT BLK R E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 5...

Page 130: ...1 BLK 4 RED 64 ORG 36 RED 42 WHT 22 YEL 52 GRN 4 RED 8 RED RED B L K 16 B L U E 24 G R A Y 40 RED WHT RED BLK B L K R E D 13 B L K 15 B L K 50 T A N 38 R E D 52 G R N 4 R E D 9 B L K 13 BLK 40 R E D 22 Y E L 36 R E D 35 B L K 42 W H T 25 BLK 60 GRN 33 BLK 38 R E D 44 R E D 34 R E D 46 O R G 50 T A N 19 B L K 9 BLK 2 RED 64 O R G 34 RED 28 TAN 13 BLK 91 BLK 15 B L K 64 ORG 58 RED 30 BLUE 5 BLK 58 R...

Page 131: ...0 PUR 31 BLK 31 B L K 31 B L K 31 BLK 72 ORG 75 BLK 78 BLUE 73 BLK 70 P U R 82 G R N 71 B L K 76 B L U E 76 BLUE 80 G R N 80 GRN 77 BLK 86 GRN 84 G R N 79 B L K 56 B R N 74 ORG OPTIONAL WAND PUMP SWITCH EMERGENCY STOP SWITCH FLOAT SWITCH ES SWITCH TANK FULL LIGHT ES TIMER RELAY POSITIVE STANDOFF NEGATIVE STANDOFF 31 BLK 32 GRN 20 GRN 31 BLK ...

Page 132: ...ELECTRICAL 4 62 5400 330735 3 01 ...

Page 133: ...ELECTRICAL 4 63 5400 330735 3 01 TROUBLESHOOTING The troubleshooting flow charts and high lighted electrical schematics are used to diagnose and repair electrical problems ...

Page 134: ...E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 BLK...

Page 135: ...HECK VOLTAGE AT 10 AMP CIRCUIT BREAKER 4 RED TO BATTERY NEGATIVE CHECK VOLTAGE AT 10 AMP CIRCUIT BREAKER 6 RED TO BATT NEG REPAIR OR REPLACE 4 RED CHECK VOLTAGE AT KEYSWITCH 6 RED TO BATT NEG REPAIR OR REPLACE 6 RED RESET OR REPLACE 10 AMP CIRCUIT BREAKER CHECK VOLTAGE AT KEYSWITCH 32 GRN TO BATT NEG REPAIR OR REPLACE KEYSWITCH CONTINUED ON NEXT PAGE YES YES NO NO NO NO YES YES BATTERY VOLTAGE 2 R...

Page 136: ...K VOLTAGE AT EMERGENCY STOP SWITCH 80 GRN TO BATT NEG MACHINE HAS OPTIONAL EMERGENCY STOP BUTTON CHECK VOLTAGE AT 32 80 GRN CONNECTION 32 GRN TO BATT NEG REPAIR OR REPLACE 80 GRN REPAIR OR REPLACE 32 GRN CHECK VOLTAGE AT HARNESS WIRE SPLICE 10 18 20 26 52 GRN 20 GRN TO 3 BLK AT VACUUM CONTACTOR REPAIR OR REPLACE 3 BLACK REPAIR OR REPLACE NEGATIVE BATTERY CABLE REPAIR OR REPLACE 7 BLACK YES YES YES...

Page 137: ...ELECTRICAL 4 67 5400 330735 3 01 ...

Page 138: ... E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 BL...

Page 139: ... AND CHECK VOLTAGE AT SPEED CONTROL BOARD M1 TO M2 1 VOLT REPAIR OR REPLACE TRANSAXLE CHECK VOLTAGE AT SPEED CONTROL BOARD 64 ORG TO 5 BLK CHECK VOLTAGE AT SPEED CONTROL BOARD M1 TO BATT NEG 1 VOLT 1 VOLT REPAIR OR REPLACE 48 RED REPAIR OR REPLACE 17 BLK YES NO GO TO CONTROL BOARD TROUBLESHOOTING NO YES NO YES REPAIR OR REPLACE 3 BLK YES NO CHECK VOLTAGE AT SPEED CONTROL BOARD 64 ORG TO 3 BLK AT V...

Page 140: ...LACE NEGATIVE BATTERY CABLE NO YES CHECK VOLTAGE AT 15 AMP CIRCUIT BREAKER 58 RED TO BATT NEG REPAIR OR REPLACE 64 ORG CHECK VOLTAGE AT BATTERY PACK BATTERY POSITIVE TO BATTERY NEGATIVE RESET OR REPLACE 15 AMP CIRCUIT BREAKER YES YES NO NO RECHARGE OR SERVICE BATTERY PACK REPAIR OR REPLACE POSITIVE BATTERY CABLE YES NO SAFETY NOTE LEAVE TRANSAXLE DISCONNECTED DURING TESTS CONTINUE ...

Page 141: ... WIRE TO BATTERY NEGATIVE REPLACE SPEED CONTROL BOARD CHECK RESISTANCE OF 20K DASH POTENTIOMETER DISCONNECT BOTH 5 BLK AND 75 BLK FROM THE RED WIRES ON THE CONTROL BOARD HARNESS MEASURE RESISTANCE FROM 5 BLK TO 75 BLK WHILE ROTATING POTENTIOMETER READING SHOULD VARY BETWEEN 0 20K OHMS 0 VOLTS 0 20K OHMS DEFECTIVE DISCONNECT 6 PIN CONNECTOR FROM SPEED CONTROL BOARD LEAVE 20K DASH POTENTIOMETER DISC...

Page 142: ...R E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 B...

Page 143: ...ED TO NEGATIVE STAND OFF TWIST ROLL GRIPS DURING TEST RESET CIRCUIT BREAKERS 1 AND 2 BRUSHES WORK NO YES REPAIR OR REPLACE POSITIVE BATTERY CABLE GO TO NEXT PAGE CHECK VOLTAGE AT BRUSH CONTACTOR CR2 36 38 RED TO 23 BLK TWIST ROLL GRIPS DURING TEST NO YES NO YES NO YES REPAIR OR REPLACE 23 BLK CHECK VOLTAGE AT BRUSH CONTACTOR CR2 36 38 RED TO 27 BLK TWIST ROLL GRIPS DURING TEST REPAIR OR REPLACE 27...

Page 144: ... YES REPAIR OR REPLACE 30 BLU CHECK VOLTAGE AT BRUSH MOTOR CONTROL SWITCH GRN WIRE IN ACTUATOR CONNECTOR 26 GRN TO BATT NEG NO YES CHECK VOLTAGE AT BRUSH CONTACTOR 30 BLU TO 91 BLK AT FUSE HOLDER TWIST ROLL GRIPS DURING TEST NO CHECK VOLTAGE AT WIRE SPLICE 10 18 20 26 52 GRN TO BATT NEG REPAIR OR REPLACE BRUSH DECK ACTUATOR YES NO GO TO NO POWER TROUBLESHOOTING REPAIR OR REPLACE 26 GRN NO YES REPA...

Page 145: ...LTAGE AT CIRCUIT BREAKER 1 40 RED TO BATT NEG REPAIR OR REPLACE 44 RED CHECK VOLTAGE AT BRUSH PRESSURE METER 40 RED TO BATT NEG RESET OR REPLACE CIRCUIT BREAKER 1 YES NO REPAIR OR REPLACE 40 RED CHECK VOLTAGE AT BRUSH PRESSURE METER 38 RED TO BATT NEG CHECK VOLTAGE AT BRUSH CONTACTOR CR2 38 RED TO BATT NEG REPLACE BRUSH PRESSURE METER NOTE THE TWIST GRIPS MUST BE ROLLED FORWARD OR BACKWARD DURING ...

Page 146: ... CIRCUIT BREAKER 2 42 WHT TO BATT NEG YES BRUSH MOTOR 2 DOES NOT OPERATE YES NO NO CHECK VOLTAGE AT CIRCUIT BREAKER 2 36 RED TO BATT NEG REPAIR OR REPLACE 42 WHT CHECK VOLTAGE AT BRUSH CONTACTOR CR2 36 RED TO BATT NEG RESET OR REPLACE CIRCUIT BREAKER 2 YES NO REPAIR OR REPLACE 36 RED CHECK VOLTAGE AT BRUSH CONTACTOR CR2 POSITIVE BATTERY CABLE TO BATT NEG REPAIR OR REPLACE POSITIVE BATTERY CABLE GO...

Page 147: ...ELECTRICAL 4 77 5400 330735 3 01 ...

Page 148: ...E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 BLK...

Page 149: ...PAIR OR REPLACE 7 BLK CHECK VOLTAGE AT LOWER LIMIT SWITCH 54 RED TO BATT NEG REPAIR OR REPLACE 54 RED CHECK VOLTAGE AT LOWER LIMIT SWITCH 46 ORG TO BATT NEG CHECK VOLTAGE AT BRUSH HEIGHT ADJUSTMENT SWITCH 46 ORG TO BATT NEG ADJUST OR REPLACE LOWER LIMIT SWITCH REPAIR OR REPLACE 46 ORG CHECK VOLTAGE AT BRUSH HEIGHT ADJUSTMENT SWITCH 12 GRN TO BATT NEG CHECK VOLTAGE AT BATTERY METER 10 GRN TO BATT N...

Page 150: ...TCH REPLACE BRUSH PRESSURE ADJUSTMENT SWITCH CHECK VOLTAGE AT BRUSH HEIGHT ADJUSTMENT SWITCH 15 BLK TO 46 ORG AT LOWER LIMIT SWITCH REPAIR OR REPLACE 46 ORG CHECK VOLTAGE AT BRUSH HEIGHT ADJUSTMENT SWITCH 15 BLK TO 54 RED AT LOWER LIMIT SWITCH CHECK VOLTAGE AT BRUSH HEIGHT ADJUSTMENT SWITCH 15 BLK TO 54 RED IN HARNESS ACTUATOR CONNECTOR TEST DIODE AND WIRES 68 ORG AND 66 RED REPAIR OR REPLACE AS R...

Page 151: ...ELECTRICAL 4 81 5400 330735 3 01 ...

Page 152: ... D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 BLK ...

Page 153: ...YES NO CHECK VOLTAGE AT VACUUM CONTACTOR CR1 50 TAN TO BATT NEG CHECK VOLTAGE AT VACUUM CONTACTOR CR1 28 TAN TO BATT NEG REPAIR OR REPLACE 50 TAN NO YES CHECK VOLTAGE AT 25 AMP CIRCUIT BREAKER 28 TAN TO BATT NEG GO TO NEXT PAGE YES NO CHECK VOLTAGE AT 25 AMP CIRCUIT BREAKER 34 RED TO BATT NEG REPAIR OR REPLACE 28 TAN NO YES VACUUM FAN DOES NOT OPERATE YES RESET OR REPLACE 25 AMP CIRCUIT BREAKER CH...

Page 154: ...UM CONTACTOR CR1 CHECK VOLTAGE AT VACUUM CONTACTOR CR1 22 YEL TO NEG STANDOFF YES NO NO YES REPAIR OR REPLACE 22 YEL CHECK VOLTAGE AT SQUEEGEE HANDLE VACUUM SWITCH 52 GRN TO BATT NEG YES NO GO TO NO POWER TROUBLESHOOTING VERIFY SWITCH CONNECTIONS OR REPLACE SWITCH YES NO REPAIR OR REPLACE NEGATIVE BATTERY CABLE REPAIR OR REPLACE 3 BLK VACUUM FAN DOES NOT OPERATE CONTINUED YES NO CONTINUE NOTE PERF...

Page 155: ...ELECTRICAL 4 85 5400 330735 3 01 ...

Page 156: ...CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 BLK 86 ...

Page 157: ...O REPLACE FUSE GO TO BOTH BRUSHES DO NOT OPERATE YES NO CHECK VOLTAGE AT SOLUTION SOLENOID 24 GRY TO 21 BLK TWIST ROLL GRIPS DURING TEST CHECK FOR WATER SUPPLY PROBLEM REPAIR OR REPLACE SOLUTION SOLENOID YES NO CHECK VOLTAGE AT BRUSH CONTACTOR CR2 16 BLU TO 19 BLK TWIST ROLL GRIPS DURING TEST CHECK VOLTAGE AT SOLUTION SOLENOID 24 GRY TO 19 BLK TWIST ROLL GRIPS DURING TEST CHECK VOLTAGE AT SOLUTION...

Page 158: ... R E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 ...

Page 159: ...EPLACE 70 PUR CHECK VOLTAGE AT TIMER RELAY 78 BLU TO 73 BLK GO TO NEXT PAGE CHECK VOLTAGE AT TIMER RELAY 78 BLU TO BATT NEG START NOTE WATER LEVEL IN RECOVERY TANK MUST BE ABOVE FLOAT SWITCH FOR TESTING Yes No Yes No Yes No Yes No Yes No CHECK VOLTAGE AT ES SWITCH 86 GRN TO BATT NEG CHECK VOLTAGE AT TIMER RELAY 76 BLU TO BATT NEG CHECK VOLTAGE AT ES SWITCH 76 BLU TO BATT NEG REPAIR OR REPLACE 73 B...

Page 160: ...TO BATT NEG CHECK VOLTAGE AT FLOAT SWITCH 74 ORG TO BATT NEG REPLACE FLOAT SWITCH CHECK VOLTAGE AT POSITIVE STAND OFF IN ACCESSORY BOX 82 GRN TO BATT NEG GO TO NO POWER TROUBLESHOOTING REPAIR OR REPLACE 82 GRN CONTINUED FROM PREVIOUS PAGE Yes No Yes No Yes No Yes No NOTE WATER LEVEL IN RECOVERY TANK MUST BE ABOVE FLOAT SWITCH FOR TESTING ES PUMP DOES NOT OPERATE CONTINUED ...

Page 161: ...ELECTRICAL 4 91 5400 330735 3 01 ...

Page 162: ...E D CR 2 BRUSH PRESSURE METER 1 30A CIRCUIT BREAKER 2 30A CIRCUIT BREAKER 25A CIRCUIT BREAKER CR 1 38 RED 40 RED 44 RED 27 BLK 36 RED 42 WHT 23 BLK 25 BLK 50 TAN 28 TAN DRIVE MOTOR CR2 HOUR METER 60 22 YEL 15A DRIVE CIRCUIT BREAKER RED BRUSH CONTACTOR VACUUM CONTACTOR LOWER LIMIT 66 68 POWER INDICATOR 20 32 20 32 20 GRN EMERGENCY STOP SWITCH 80 GRN EXTENDED SCRUB SWITCH 77 BLK 56 BRN 79 BLK 29 BLK...

Page 163: ...AT WAND PUMP SWITCH 56 BRN TO BATT NEG Yes No REPAIR OR REPLACE 56 BRN CHECK VOLTAGE AT WAND PUMP SWITCH 84 GRN TO BATT NEG No Yes CHECK VOLTAGE AT ACCESSORY BOX POSITIVE STAND OFF 84 GRN TO BATT NEG REPAIR OR REPLACE WAND PUMP SWITCH Yes No REPAIR OR REPLACE 84 GRN GO TO NO POWER TROUBLESHOOTING Yes No WAND PUMP DOES NOT OPERATE NOTE WAND PUMP SWITCH MUST BE ON DURING TESTS START HERE ...

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