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Service Manual – SC901

24 - Electrical System

Understanding the Features of the Main Wiring Diagram

The main wiring diagram is sometimes referred to as a ladder diagram because it is historically rooted

in a type of schematic that resembled the rungs of a ladder Over time it has evolved into a hybrid ladder

diagram, specifically to accommodate the presence

of intelligent control modules that drive the system

components (Such as a main controller and power module,

for example ) Even as a hybrid diagram, it still maintains

some of the features of a true ladder diagram

Positive voltage source(s) are represented by vertical

“Rails” on the left side of the diagram, and the negative

voltages source (typically only 1, being battery negative)

is represented by a vertical Rail on the right side of the

diagram Devices are drawn between the two rails, and

current flows from the positive rail, through the load, and to

the negative rail

Unique to the hybrid ladder diagram are the intelligent

controllers that control if and when devices are connected

to either positive or negative power Even though not

technically accurate, circuit symbols have been drawn

inside the controller outlines to represent the electrical

function that takes place inside These represent the

function, but not an actual device For example, even though a symbol may look like a switch, it cannot be

tested as though it was a real switch

Some of the common controller internal symbols are described below:

B-

Output, Switch to positive or negative power.

The controller serves to complete the circuit to the respective power source, most

commonly battery negative.

B-

B+

Output, Bi-directional switch to power

These outputs are always in pairs, and are for reversible loads.

•

For forward direction, one output is positive and the other is negative.

•

For reverse direction, one output is negative and the other is positive.

•

For no movement, both outputs are the same, which may be positive, negative,

or zero, depending on the controller.

PWM

B-

Pulse Width Modulation (PWM) Switch

This is an electronic (transistor) switch that completes the circuit to either battery

positive or battery negative power. The duty cycle between on and off states

determines how much power the load receives.

SCLK

Digital Data Out

This symbol indicates that the output is a digital stream of data pulses.

+3.3V

Digital Data In, with Pullup

This symbol represents a digital data stream input signal that is active-low, and the

pullup resistor represents the open-circuit (inactive) signal voltage.

+5V

Discrete Input with Pullup

This symbol represents a binary (On/Off) input with a 5-volt pullup resistor. When

the switch or sensor is off (open circuit) the pullup resistor makes the input equal 5

volts. When the switch or sensor is closed, the input typically goes to 0 volts.

B-

J4-10

B+

J4-19

CURTIS 1229

DRIVE WHEEL CONTROLLER

J4-14

J4-1

J4-2

J4-17

J4-16

J4-4

J4-3

J4-20

KSI

J4-13

J4-11

J4-18

J4-6

J4-9

J4-12

ORN

BLU/VIO

RED/GRN

YEL/BLK

YEL/WHT

GRN/ORN

VIO/BLK

BLK/WHT

BLU/BLK

GRN/GRY

BLK

YEL

GRN

POT 1

POT 2

J4-8

(V) TO 2A1

(W) TO 4A3

(B) TO 2A1

(AA) TO 1B2

(AB) TO 1B2

(AC) TO 4B3

(AD) TO 5B4

(AF) TO 2E1

(AG) TO 4E4

ANALOG GND

DRIVER 1

DRIVER 2

SWITCH 1

SWITCH 2

SWITCH 3

SWITCH 4

BLU/RED

RED

YEL/BLU

BLK

GRN/BLU

GRY

ORN/GRN

GRY

GRN

YEL

B+

STEERING READY

AUTO OK

KSI

B-

OPERATOR PRESENCE SW

E-STOP MAIN CONTROL BOARD

CAN1 L, (R) TO 2D2

CAN1 H, (Q) TO 2D3

CAN1 L, (T) TO 4A2

CAN1 H, (S) TO 4A2

B+

KSI

B-

+5V

FUSE, 40 A.

B-

B+

+17V

SW14

B-

B+

B-

EM BRAKE

Sample

Содержание 56115530

Страница 1: ...SC901 04 2019 Form No 56043178 Service Manual Advance Model Numbers 56115530 SC901 ST 28D 56115531 SC901 ST 34D 56115532 SC901 ST 32C English ...

Страница 2: ...onal Description 13 Removal and Installation 13 20 Wheel System Traction 14 Functional Description 14 Speed Limiting Potentiometer 14 Wigwag Throttle Potentiometer 14 Drive Motor PWM Function 15 Drive Controller 15 Circuit Description 16 Drive Power 16 Throttle and Speed Limit 16 Troubleshooting 17 Error Codes 17 Removal and Installation 25 Drive Controller 25 Follow up Testing 25 Wheels 26 Drive ...

Страница 3: ...Breakers and TrackClean 53 Sheet 5 TrackClean Adapter Harnesses 54 Specifications 55 Connector Pinouts 55 TrackClean Connector 55 EcoFlex Connector 55 Operator s Handle Connector 55 Drive Controller Connector 56 30 Solution System 57 Functional Description 57 Non Detergent Models 57 Detergent Models 58 Detergent Pump 58 Troubleshooting 59 Scrub System General 59 No Solution Flow 60 No EcoFlex Dete...

Страница 4: ... 38 Squeegee System 82 Functional Description 82 Squeegee 82 Maintenance and Adjustment 83 Squeegee Blade Cleaning and Inspection 83 Squeegee Tilt Adjustment 83 Removal and Installation 84 Squeegee Blade Replacement 84 40 Recovery System 85 Functional Description 85 Vacuum Motor and Recovery Tank 85 Circuit Overview 86 Troubleshooting 86 No Vacuum Motor 86 Poor Suction 86 Vacuum Suction Test 87 Re...

Страница 5: ...ervice Manual Purpose and Application This Service Manual is a resource for professional service technicians It provides information for understanding how the machine operates where components are located basic troubleshooting maintenance and mechanical service operations Other Reference Manuals and Information Sources Document Name Document Number Document Type Instructions for Use 56091217 Opera...

Страница 6: ... Conventions All references to right left front and rear in this manual are as seen from the Operator s position Modifications Modifications and additions to the cleaning machine which affect capacity and safe operation shall not be performed by the customer or user without prior written approval from Nilfisk Inc Unapproved modifications will void the machine warranty and make the customer liable ...

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

Страница 8: ...achine is only approved for hard surface use Use brushes and pads supplied with the machine or those specified in the User Manual Using other brushes or pads could reduce safety Do not wash the machine with direct or pressurised water jets or with corrosive substances Do not allow the brush pad to operate while the machine is stationary to avoid damaging the floor Use only factory authorized parts...

Страница 9: ...ansporting the machine will vary depending on the mode of transport Follow these general guidelines as applicable to the situation Remove the squeegee from the machine This is required to access the rear hold down points and also protects the squeegee during loading unloading and transport If transport will occur below freezing temperatures place a small amount of environmentally friendly antifree...

Страница 10: ...th 65 4 166 cm 67 4 171 cm 63 1 160 3 cm Solution Tank Capacity 30 Gal 113 6 L Recovery Tank Capacity 32 Gal 121 L Battery Compartment Size approximate Height maximum Width maximum Length maximum 15 in 38 cm 26 in 66 cm 27 5 in 70 cm Scrub brush size 2 per machine Ø 14 inch 35 5 cm Ø 17 inch 43 1 cm 5 5 x 31 Inch 13 9 x 78 7 cm Scrub Brush Speed 250 RPM 250 RPM 900 RPM Cleaning Path Width scrubbin...

Страница 11: ...11 Service Manual SC901 03 General Information Know Your Machine Major components Recovery Cover Solution Tank Recovery Tank Chassis Drive Disk Deck Cylindrical Deck Squeegee Control Handle ...

Страница 12: ...lution Manifolds on Cylindrical System Purge Detergent System AXP and EcoFlex Lubricate the Machine Check Vacuum Motor Carbon Brushes 300 hours Check Brush Motor Carbon Brushes 500 hours Check Drive Motor Carbon Brushes 500 hours Note See the individual machine system sections for maintenance information Carbon Brush Notes The original new length of each carbon brush is 1 25 4mm on brush and wheel...

Страница 13: ...emoval 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 both the recovery and solution tanks 2 Raise the rear of the machine and place blocking under the rear lifting points 3 Remove the four screws and washers that secure the caster to the chassis and remove the caster Caster Wheels ...

Страница 14: ...he maximum speed is set very low The drive controller itself provides the 5 volt bias voltage to both the speed limit and throttle potentiometers Wigwag Throttle Potentiometer The throttle potentiometer R2 pot is controlled by the drive paddles When the drive paddles are pushed forward the output voltage from the potentiometer increases toward 5 volts and when the paddles are pulled back the outpu...

Страница 15: ...chine which will be discussed in greater detail in the applicable chapters As a motor controller it delivers PWM varying power to the drive motor in both positive and negative polarities for forward and reverse motor operation Even though the machine does not utilize an electromechanical brake system the drive controller possesses the output control for one Instead this is used for ancillary machi...

Страница 16: ...ontroller will issue a precharge error code Throttle and Speed Limit Both the speed limit and throttle potentiometers receive a 5 volt bias voltage from the Curtis 1228 drive controller This results in the wiper voltages from both potentiometers to have a 0 to 5 volt range The Curtis drive controller interprets these voltages as the machine drive commands Brake Output Scrub Enable When the drive c...

Страница 17: ...if the brake output isn t active it will cause the scrub system to not function Error Codes Because most drive system failures will be accompanied by a drive controller error code troubleshooting is generally error code driven Those few exceptions that would not be error code drive are covered in the electrical chapter 1 1 Thermal Cutback Description Drive Controller Over Temperature or Under Temp...

Страница 18: ...ce between contacts 1 and 2 1 and 3 and 2 and 3 respectively of the X105 connector of the control handle If any measurement is open circuit greater than 5K ohms repair or replace the throttle potentiometer and or wiring If any measurement to contact 3 results in a reading of at or near 0 ohms move the drive paddle position and confirm the measurement If the result does not change replace the poten...

Страница 19: ...handle operator s controls b Check the resistance between contacts 1 and 2 1 and 4 and 2 and 4 respectively of the X105 connector of the control handle If any measurement is open circuit greater than 100K ohms repair or replace the speed limit potentiometer and or wiring If any measurement to contact 4 results in a reading of at or near 0 ohms replace the potentiometer If all 3 measurements are no...

Страница 20: ...minal 3 Check the positive power circuit a Place the negative voltage probe at either the battery terminal or main ground lug whichever is more convenient Both were tested above b Place the positive voltage probe at the B contact of the drive controller If the voltage is 36 volts and the error persists confirm the voltage directly at the drive controller and if persistent replace the drive control...

Страница 21: ... drive controller If the battery charger is delivering 48 volts to the batteries at any time replace the charger 2 1 Main Off Fault 2 4 Main On Fault Description The main internal relay for the DC Bus failed in the open or closed condition Setting Conditions When Monitored Always Possible Causes Failed drive controller Initial Action Replace the drive controller Troubleshooting Steps 2 3 Main Cont...

Страница 22: ...he machine Troubleshooting Steps 3 2 Brake On Fault 3 4 Brake Off Fault Description The internal driver transistor for the brake output has failed in the closed condition shorted Brake On Fault or the open condition open circuit Brake Off Fault Note that the On and Off refer to the driver not the output of the brake circuit which is inverted Setting Conditions The drive controller has detected an ...

Страница 23: ...r to the KSI input of the drive controller J10 5 If the error is not reported trace the KSI circuit back toward the keyswitch to locate a loose connection If the error persists continue 2 Eliminate the Brake circuit as the cause a Disconnect the J10 connector from the drive controller b Use a jumper to provide battery positive power to the KSI input of the drive controller J10 5 If the error persi...

Страница 24: ...damaged as a result of uncontrolled amperage Initial Action Clear any cause for a motor short circuit If the error persists replace the drive controller Troubleshooting Steps 4 3 EEPROM Fault 4 4 Power Section Fault Description Internal drive controller fault Setting Conditions When Monitored Always Possible Causes Initial Action Disconnect the battery to perform a full power cycle of the machine ...

Страница 25: ...verse the steps to install a new module Follow up Testing 1 Before reconnecting the battery either block the wheels off the ground or move the machine to an open area without obstructions 2 Turn the speed dial all the way to its lowest speed 3 Reconnect the battery connector and turn on the key switch 4 With the drive paddle in neutral slowly increase the speed limit dial up and back down to verif...

Страница 26: ...ight of the machine is not on the caster wheels which can pivot unexpectedly 1 Drain both the recovery and solution tanks to reduce the weight of the machine 2 Turn off the key and disconnect the batteries 3 Slightly raise the rear of the machine and place rigid blocking below the frame so the caster wheels are slightly off the ground 4 Raise the front of the machine and place rigid blocks under t...

Страница 27: ... wheel removed from the machine Raise the right side of the machine and remove the drive wheel 4 Disconnect the motor connector A and the ground wire B 5 Using a 3 16 hex key remove the two screws C that secure the motor to the transaxle Due to the tight quarters you may find it easier to remove the upper screw first Support the motor before completely removing the last screw Replacement Notes App...

Страница 28: ...achine block the rear caster wheels so that the weight of the machine is not on the caster wheels which can pivot unexpectedly 1 Drain the recovery tank and disconnect the main battery connector 2 Optional but recommended Raise the left side of the machine and remove the left wheel for easier access to the brush motor 3 Unscrew the brush cap A and remove the spring loaded brush For the upper 2 bru...

Страница 29: ...he weight of the machine 2 Turn off the key and disconnect the batteries 3 Slightly raise the rear of the machine and place rigid blocking below the rear lifting points so the caster wheels are slightly off the ground Make sure these blocks are stable and cannot tip over 4 Remove the Scrub Skirt described on page 69 5 Remove the brush skirt or hopper depending on whether it is a disk or cylindrica...

Страница 30: ... transaxle from falling to the floor place supports or cushioning under the transaxle 12 Remove the 4 bolts C and nuts D securing the right and left retaining plates E to the frame It s best to first loosen all 4 bolts and then remove them when you are prepared for the transaxle to be lowered 13 With the retaining plates removed lower the transaxle to the floor Note the orientation with the motor ...

Страница 31: ...osition 2 48 V Full Forward 4 46 V Full Reverse 0 53 V 5 KSI Violet Key Switch Input 36 5 V On 6 Brake Pink Blue Scrub Enable Deck Down Drive Neutral 34 7 V Deck Down Travelling 0 104 V 7 N A 8 N A 9 Status None Unused Status LED Rapid Pulse 10 N A 11 N A 12 N A 13 Pot Lo Yellow 0 Volt bias to the potentiometers 0 43 V 14 Brake Pink Positive power to the scrub functions 36 5 V 15 N A 16 N A 17 N A...

Страница 32: ... to decipher Faults are displayed in the Diagnostic Menu and the status of the controller inputs outputs is displayed in the Test Menu The handheld programmer can also be used to access the drive controller s diagnostic history file This file contains the history of cleared error codes which may be helpful in determining the functional status of the machine between service intervals Refer to the C...

Страница 33: ...amp fuse located on the positive battery terminal There are 5 circuit breakers that protect the electronics A 25A circuit breaker protects each of the two brush motors a 20A circuit breaker protects the vacuum motor a 30A circuit breaker protects the drive controller and therefore the scrub system controls and a 2 5A circuit breaker protects all logic circuits downstream from the key switch If the...

Страница 34: ...ch is on and the vacuum switch squeegee lower handle is closed When the optional TrackClean module is not present a jumper is installed at the TrackClean electrical connector This jumper is required for machine operation and is a series connection of the key switch The purpose of the circuit is so that a TrackClean module with a SmartKey reader can disable the operation of the machine if no author...

Страница 35: ...dentified by number The table to the right lists those profiles that are applicable to SC901 battery system options The Delta Q instruction manual explains how to set these profiles There are two options for programming this information into the charger One option uses a laptop QuiQ software and a special USB interface connector kit This method is the easiest but it does require obtaining the QuiQ...

Страница 36: ...ach discrete wire in the system Every wire in the machine s harness is given a unique wire number identifier The significance of this is that even though the schematic shows a continuous circuit from one electrical connector to another that circuit may be made up from one or more individual wire segments spliced together Each of those segments has its own unique number and those numbers are even p...

Страница 37: ...h to power These outputs are always in pairs and are for reversible loads For forward direction one output is positive and the other is negative For reverse direction one output is negative and the other is positive For no movement both outputs are the same which may be positive negative or zero depending on the controller PWM B Pulse Width Modulation PWM Switch This is an electronic transistor sw...

Страница 38: ...ipe on the wire For the connector identifier example shown J4 6 the first part J4 represents the connector number and the last part 6 represents the pin number within that connector This information along with the Connector Pinouts on page 55 is used locate the physical wires on the machine Navigation In some cases it is necessary to have references across different areas of a drawing These refere...

Страница 39: ...iate connector such as shown to the right but each wire has only 2 connection points To trace a complete circuit you would need to search for both ends of any wire number and see where they connect to the next wire segment And then repeat this for each wire segment in the circuit Service Tip We use the Ladder Diagram to trace a circuit but use the harness diagram to trace the wires that make up th...

Страница 40: ...cation for accessing a circuit is from the back side of an electrical connector However many of the connectors used in the machine are moisture resistant and have seals where the insulated wire enters the connector body It is important that the seal not be damaged as the connector may then corrode over time Standard voltmeter probes are too large to slip past the seal without damaging it The best ...

Страница 41: ...s at both connectors that the circuit in question passes through Ohmmeter probes are placed on the two appropriate contacts and continuity at or near 0 ohms is tested for Service Tip If the two connectors are too far apart for ohmmeter test leads to be connected you can install a shorting jumper on the contacts at one connector This creates a return path back to the first connector where you can p...

Страница 42: ...TrackClean module is not installed make sure the shunt connector is in place Check for 36 Volts at pin 5 of the Curtis controller If not present work back upstream to locate the break Limited System Function No Drive No Scrub But Vacuum Runs Drive Controller Fault Because the vacuum runs this is most likely related to a drive controller fault There can be many causes to a drive controller fault Re...

Страница 43: ... If any other systems are running then you know the KSI circuit is functional This leaves solely the vacuum circuit itself as the cause Check the vacuum switch at the squeegee lever Check the vacuum relay K3 Check the vacuum breaker CB4 Check the motor Battery Testing A battery problem is usually recognized by the machine operator as a decrease in the machine s running time This condition is usual...

Страница 44: ...et with a long extension remove the 4 screws that secure it to the body of the solution tank Squeegee and Brush Switches 1 With the deck fully raised place blocking under the scrub brushes to prevent the deck from lowering 2 Move the deck lift lever D out of the raised position and allow the blocking to support the deck 3 Lower the squeegee C 4 Using a 10mm socket remove the 4 screws B that secure...

Страница 45: ... 14mm socket and extension unscrew the 5 screws A that secure the drive handle to the machine Make sure to support the handle as you loosen the last screw It is best to leave the screws and washers in place versus removing them This reduces the likelihood of dropping any of them in the cavity below the solution control 2 Move the handle away and disconnect the harness connector B 3 Remove the 2 sc...

Страница 46: ...s outward on the latch tabs G while pressing downward on the main body of the hour meter E The hour meter is held in place with a ratcheting retaining ring Make sure to firmly press the two together when reinstalling the meter After you have completed the reassembly continued below verify the function of the hour meter with the following observations Key on Battery LEDs on hourglass steady Scrub o...

Страница 47: ...ing boot B and disconnect the main battery connector s positive terminal at E Do not disconnect at lug F because that secures the 150 amp fuse 3 In a similar manner remove the main battery connector s negative terminal C However there is no fuse at the negative terminal 4 Taking care to not short across the battery terminals remove each of the interconnecting cables H from the batteries 5 Make sur...

Страница 48: ... 4 HM1 7 B 8 HM2 6 K1 COIL LOW VOLTAGE CUTOUT RELAY P3 DETERGENT MODULE OPTIONAL B 1 B 5 SOL IN 2 SOL OUT 3 DET OUT 4 BRAKE 6 S5 SW VAC X119A 1 2 3 4 X44 8 3 7 2 1 6 5 4 L2 PUMP DETERGENT 1 2 P1 CURTIS 1228 POT HI 3 THR POT 4 KSI 5 POT LO 13 6 REV 17 B B M1 M2 M1 M2 SPD POT 18 BRAKE 36v 14 CB2 30A K3 COIL VAC RELAY M M1 MOTOR DRIVE WHEEL X5b3 X87A 1 2 3 4 5 6 CB4 20A B CB1 30A L1 SOLUTION SOLENOID...

Страница 49: ... RED 16 W042 PNK WHT 18 W044 PNK WHT 18 W044 BLK 18 W053 BLK 18 W053 YEL 18 W058 YEL 18 W058 BLU 18 W059 BLU 18 W059 VIO WHT 18 W060 VIO WHT 18 W060 VIO GRN 18 W061 VIO GRN 18 W061 VIO RED 18 W062 VIO RED 18 W062 X62 BLK 18 W063 BLK 18 W063 X63 SPL 10 WHT RED 10 W064 WHT RED 12 W065 WHT RED 12 W065 WHT RED 12 W066 WHT RED 12 W066 X64 GRY RED 12 W067 GRY RED 12 W067 BRN 18 W069 BRN 18 W069 RED GRN ...

Страница 50: ... GRN 18 W061 VIO RED 18 W062 BLK 18 W063 BRN 18 W069 RED GRN 10 W077 RED GRN 10 W078 YEL BLK 10 W080 YEL BLK 10 W081 RED YEL 18 W084 RED YEL 18 W084 BLK 18 W085 RED 4 W089 5 9 0 W 8 1 O I V VIO 18 W096 VIO 18 W096 X87 1 2 3 4 5 6 GRN YEL 16 W105 X87A 1 2 3 4 5 6 BLK 18 W134 PNK 18 W138 PNK 18 W141 SW8 KEY P2 BATTERY GUAGE HOURMETER X105 1 2 3 4 5 6 7 8 9 10 11 12 SPL 30 X108 X109 BRN 18 W157 BRN V...

Страница 51: ...18 W024 PNK BLU 18 W024 BLK 18 W030 VIO WHT 18 W032 GRY 18 W037 BLK 4 W038 RED 4 W039 RED 18 W040 RED 10 W041 RED 16 W042 PNK WHT 18 W044 BLK 18 W053 YEL 18 W058 BLU 18 W059 VIO GRN 18 W061 VIO RED 18 W062 X62 BLK 18 W063 X63 SPL 10 WHT RED 10 W064 WHT RED 12 W065 WHT RED 12 W066 X64 GRY RED 12 W067 X65 BLK 12 W072 BLK 12 W073 BLK 12 W075 X68 X69 X70 X71 X72 X73 RED GRN 10 W077 RED GRN 10 W077 RED...

Страница 52: ...O WHT 18 W033 VIO WHT 18 W034 GRY 18 W036 PNK WHT 18 W044 BLK 18 W053 BLK 18 W063 RED GRN 12 W070 RED BRN 12 W071 BLK 12 W072 BLK 12 W073 ORN VIO 12 W074 BLK 12 W075 SPL 12 SPL 13 RED GRN 12 W076 RED GRN 10 W077 RED GRN 10 W078 BLU YEL 12 W079 YEL BLK 10 W080 YEL BLK 10 W081 RED YEL 18 W084 BLK 18 W085 BLK 18 W085 X84 1 2 X85 1 2 VIO 18 W096 DECK GND CHASSIS GND TRANSAXLE GND X89 X90 GRN YEL 16 W1...

Страница 53: ...K BLU 18 W023 BRN VIO 18 W026 SPL 6 BRN 18 W028 BRN 18 W029 BLK 18 W030 BLK 18 W030 SPL 7 VIO WHT 18 W031 VIO WHT 18 W032 VIO WHT 18 W033 VIO WHT 18 W034 SPL 8 GRY 18 W035 GRY 18 W036 GRY 18 W037 BLK 4 W038 RED 18 W040 RED 10 W041 RED 16 W042 VIO WHT 18 W060 VIO RED 18 W062 WHT RED 12 W065 WHT RED 12 W066 GRY RED 12 W067 BRN 18 W069 RED GRN 12 W070 RED BRN 12 W071 BLK 12 W072 BLK 12 W073 ORN VIO 1...

Страница 54: ... 4 5 6 7 8 PNK BLU 18 W023 BRN VIO 18 W026 SPL 6 BRN 18 W028 BRN 18 W029 BLK 18 W030 SPL 7 VIO WHT 18 W031 VIO WHT 18 W032 VIO WHT 18 W033 VIO WHT 18 W034 SPL 8 GRY 18 W035 GRY 18 W036 GRY 18 W037 RED 18 W040 VIO WHT 18 W060 VIO 18 W093 SMARTKEY KSI RELAY K4 X92 1 2 3 4 5 6 7 8 X93 1 2 3 4 5 6 7 8 9 10 11 12 BLK 16 W106 GRY 18 W109 WHT 18 W110 PNK 18 W111 BRN 18 W112 BLU 18 W113 X94 1 2 3 4 5 6 7 ...

Страница 55: ... Name Wire Color ID 1 Batt VIO W095 1 6 2 Solution In VIO WHT W060 3 Solution Out VIO RED W062 4 Detergent Out VIO GRN W061 5 Batt BLK W063 6 Brake PINK W138 Operator s Handle Connector Pin Name Wire Color ID 1 Pot High WHT W019 12 1 2 Go In YEL W058 3 Go Out Pot Low BLU W059 4 Speed Limit ORN W020 5 Reverse Out GRY VIO W018 6 Key Switch In BRN W069 7 Key Switch Out BRN VIO W026 8 Batt BLK W053 9 ...

Страница 56: ...m Drive Controller Connector Pin Name Wire Color ID 1 18 1 2 3 Pot High WHT W019 4 Throttle Pot BLU W059 5 KSI VIO W011 6 Brake PNK BLU W023 7 8 9 10 11 12 13 Pot Low YEL W058 14 Brake PNK W137 15 16 17 Reverse GRY VIO W018 18 Speed Pot ORN W020 ...

Страница 57: ...off valve The solution solenoid is either all on or all off and is controlled by the same circuit that activates the brush motors A circuit jumper replaces the connector where the optional EcoFlex control board connects in the solution panel For the solution circuit to be active the machine must be in motion and the scrub brushes be active When the machine is in motion the Curtis drive controller ...

Страница 58: ...alves As the solenoid oscillates in and out it drives a flexible diaphragm that draws fluid in during the retraction stroke and drives fluid out during the compression stroke The check valves allow fluid to enter only though the inlet port and exit only through the outlet port Unlike an AC solenoid that moves its plunger the same direction regardless of the electrical polarity a DC solenoid change...

Страница 59: ...djacent tab E This should permit the switch F to close without lowering the scrub deck CAUTION Always be prepared for the scrub deck to unexpectedly drop Keep hands and feet away from the scrub deck when it is raised in this manner 5 If the machine is equipped with the EcoFlex system set both detergent and solution flow rates to maximum 6 Turn the key switch to the on position 7 Press one of the G...

Страница 60: ...ive controller is not the cause For non EcoFlex machines make sure the jumper is present on the electrical connector under the solution panel Test the solenoid itself by applying battery voltage to the terminals For EcoFlex machines if the solenoid itself is functional and the brush motor runs then the detergent module is likely at fault No EcoFlex Detergent Flow Inspect the function of the deterg...

Страница 61: ...tank Solution Solenoid If the solution solenoid is being serviced for the purposes of inspection and cleaning you can rotate the upper solenoid body B counterclockwise and remove it from the valve body C 1 Disconnect the solenoid electrical connector A 2 Loosen the hose clamp E and remove the supply hose from the solenoid 3 Using a 2 5mm hex key remove the two screws D that secure the solenoid bra...

Страница 62: ...Solution Filter 1 Shutoff the solution valve B 2 Unscrew the solution filter A There will likely still be some liquid in the line that will spill out 3 Clean the filter bowl and screen C Note that the screen is not removable from the bowl B A C ...

Страница 63: ...olution shutoff valve 1 Remove the cable clamp A 2 Remove the screw nut and washer B that secures the cable to the solution shutoff valve 3 Remove the 4 screws C that secure the control panel to the solution tank and lift the control panel upward and free up the cable through the machine While you have the solution control panel off it is a good idea to check that the solution jumper D is in place...

Страница 64: ...ntrol panel is replaced with the EcoFlex control panel 1 Remove the 4 screws that secure the control panel to the solution tank and lift the panel away from the tank 2 Disconnect the electrical connector and remove the control panel Specifications Parameter Range Solution Solenoid Coil Resistance 105 Ω Detergent Pump Coil Resistance 37 Ω A B ...

Страница 65: ...ng brushes are driven by independent motors with integral speed reduction gear boxes The scrub deck is supported by a parallelogram linkage to maintain level with the floor at any height The deck lift lever can be set in a raised position float medium or heavy scrub The brush motors are counter rotating DC motors with integral gear reduction They are relay controlled without variable speed or soft...

Страница 66: ...Brush Switch and K1 relay along with the Drive Controller s Brake output provides the fundamental control of the brush motor This circuit is active only when all 4 of the prerequisite conditions mentioned above have been met The control coil for the K1 relay is in series with the hour meter This aspect of the circuit provides the low voltage cutout feature to disable the scrub system when the batt...

Страница 67: ...adjacent tab E This should permit the switch F to close without lowering the scrub deck CAUTION Always be prepared for the scrub deck to unexpectedly drop Keep hands and feet away from the scrub deck when it is raised in this manner 5 If the machine is equipped with the EcoFlex system set both detergent and solution flow rates to maximum 6 Turn the key switch to the on position 7 Press one of the ...

Страница 68: ...problem lies between the relay and the circuit breakers or a broken ground at the Batt lug Check the voltage across the coil from B to C If the voltage is 36V then the relay is defective If the voltage is zero trace the Pink and Violet wires to locate a break If neither solution nor optional detergent flows check the following Check the continuity of the brush deck lower switch Check the function ...

Страница 69: ...sings 3 With the scrub deck fully raised remove both scrub brushes even if only one motor is being removed 4 Using a 1 4 hex key remove the socket head cap screw A that secures the brush plate B to the motor shaft 5 Slide the brush plate off the motor shaft If you need to pry it off try to pry evenly Lubricant may help if it is corroded Take care not to lose the motor shaft key 6 Using a 9 16 sock...

Страница 70: ... that secure the top cap C through the motor housing D and down to the bottom cap The screws are very long 8 Carefully pry up the top cap C away from the motor housing D Note the following The rotor s bearing is a light press into the top cap It will come free fairly easily but care must be taken to not skew the cap in the process A very light tap on the side of the cap with a plastic deadblow ham...

Страница 71: ...the brush This will hold the brush retracted but can easily be pushed forward later 15 Before replacing the end cap inspect the interior of the motor Inspect the commutator for missing or damaged bars Replace the motor if any of the bars are missing Inspect the rotor bearing for wear Replace the motor if worn Inspect the permanent magnets for metallic debris and clean off as needed 16 Place the wa...

Страница 72: ...72 Service Manual SC901 34 Scrub System Disc Specifications Parameter Range K2 Brush Relay Coil Resistance 118 Ω Sample Left Brush Amps 2 44A No Load Sample Right Brush Amps 2 65A No Load ...

Страница 73: ...e The two counter rotating cylindrical brushes are driven by independent motors and belt drives The scrub deck is supported by a parallelogram linkage to maintain level with the floor at any height The deck lift lever can be set in a raised position float medium or heavy scrub The brush motors are counter rotating DC motors They are relay controlled without variable speed or soft start ...

Страница 74: ...il Brush Switch and K1 relay along with the Drive Controller s Brake output provides the fundamental control of the brush motor This circuit is active only when all 4 of the prerequisite conditions mentioned above have been met The control coil for the K1 relay is in series with the hour meter This aspect of the circuit provides the low voltage cutout feature to disable the scrub system when the b...

Страница 75: ...the adjacent tab E This should permit the switch F to close without lowering the scrub deck CAUTION Always be prepared for the scrub deck to unexpectedly drop Keep hands and feet away from the scrub deck when it is raised in this manner 5 If the machine is equipped with the EcoFlex system set both detergent and solution flow rates to maximum 6 Turn the key switch to the on position 7 Press one of ...

Страница 76: ...he problem lies between the relay and the circuit breakers or a broken ground at the Batt lug Check the voltage across the coil from B to C If the voltage is 36V then the relay is defective If the voltage is zero trace the Pink and Violet wires to locate a break If neither solution nor optional detergent flows check the following Check the continuity of the brush deck lower switch Check the functi...

Страница 77: ...r tab from the solution tank Scrub Brush Motor 1 Lower the scrub deck and remove the Scrub skirt as described above 2 Using a 3 8 socket remove the screw A that secures the belt cover B to the scrub deck and remove the cover 3 Walk the stretch belt D off the pulleys 4 Remove the three screws C that secure the motor to the scrub deck 5 Disconnect the motor connector and remove the motor from the sc...

Страница 78: ...using D Note the following The rotor s bearing is a light press into the top cap It will come free fairly easily but care must be taken to not skew the cap in the process A very light tap on the side of the cap with a plastic deadblow hammer should be enough to loosen the cap enough to begin prying with a small screw driver Taking care not to damage the aluminum cap work the small screw driver aro...

Страница 79: ...sh holder 11 Insert the brush and coil spring into the brush holder The brush wire should be toward the top away from the brush cap 12 Compress the brush all the way in to the brush holder and insert the temporary retaining pin Insert the pin from the opposite side of the end cap through the bottom of the brush holder in front of the brush and up through the top of the brush holder Make sure the p...

Страница 80: ...owerful magnet can be used but a Rare Earth magnet is powerful enough to hold itself in place 14 Place the end cap over the top of the motor and lower it until the coil springs prevent you from lowering it any farther Make sure to realign the marks A that you made on the motor before disassembly When the brushes are compressed in this manner they are too wide to fit the cap all the way into the mo...

Страница 81: ... Service Manual SC901 34 Scrub System Cylindrical Specifications Parameter Range K2 Brush Relay Coil Resistance 118 Ω Sample Left Brush Motor Amps 2 84A No Load Sample Right Brush Motor Amps 2 48A No Load ...

Страница 82: ...to ensure collection of all wastewater from the perimeter of the scrubbing area The squeegee also pivots to the side to permit operation near walls and to keep the squeegee within the scrubbing path while turning the machine Squeegee The squeegee tool has a front and rear squeegee blade creating a vacuum area in between where water can be drawn up from the fast moving airflow The squeegee tool att...

Страница 83: ...ld be adjusted when the squeegee blades are replaced or if the squeegee is not fully wiping the floor Misadjustment symptoms include water streaks at the center or edges of the squeegee path 1 Park the machine on a flat even surface and lower the squeegee 2 Without moving the machine which will cause the rear squeegee blade to bend backward inspect the interface between the edge of the rear squeeg...

Страница 84: ...n undamaged edge points toward the front of the machine Replace the blade if all 4 edges are nicked torn or worn to a large radius 5 Reinstall the rear squeegee blade and tension strap and tighten the latch 6 To replace the front squeegee blade loosen both thumbscrews E that hold the retaining strap F remove the strap and remove the squeegee blade G 7 After replacing both blades rest the squeegee ...

Страница 85: ...he suction hose As the mixture of air and water enters the recovery tank the airflow slows down due to the larger space and the water drops out of the airflow and into the tank The airflow passes through an inlet screen to prevent debris from entering the impeller of the vacuum motor The exhaust air is expelled inside the machine so it can be dispersed without blowing directly on the operator or t...

Страница 86: ...elf Check for 36 volts at both terminals of the circuit breaker Check for 36 volts at the vacuum motor connector If 36 volts is reaching the motor then inspect replace the motor brushes described on page 89 If 36 volts was not present at A then check the voltage between B and C If 36 volts is present then the relay is defective If 36 volts is not present between B and C then the vacuum switch is l...

Страница 87: ...ly in the middle of the PVC tube and clean off the burs 7 As necessary wrap duct tape around the tube so it fits snugly in the end of the end of the suction hose with no leaks 8 Turn the vacuum on and place the vacuum gauge on the restricter tube 9 Record the vacuum pressure reading from the gauge This is the restricted flow pressure Results Summary The first part of this procedure determined the ...

Страница 88: ...nd remove the hose 4 Remove the three screws and washers B that secure the vacuum retaining plate D and remove the plate and motor Take care not to lose the three vibration mounts E 5 Inspect the main vacuum gasket F for damage and compressibility and replace if necessary Leaks in this gasket will reduce recovery system suction 6 During replacement make sure the three vibration mounts E are in pla...

Страница 89: ...rews C that secure the contact strap D and remove the strap Take care to not bend the wire any more than necessary 4 Lift the outer end of the brush E up and slide the brush out of the motor housing 5 Repeat for the second brush E 6 When installing a new brush tilt the brush assembly downward at the front so the carbon bar contacts the commutator bars and then compress the spring to fully insert t...

Страница 90: ... K3 Vac Relay Coil Resistance 105 Ω Sample Vacuum Motor Amps 17 5 to 18 3 Amps Open hose no squeegee Note that the less restricted the air flow the higher the amps should be Special Tools Vacuum Pressure Gauge 1 inch open hole adapter part number 56205281 Fabricated from PVC ...

Страница 91: ...ged in this wire has no power and therefore the machine is inoperable Refer to the 24 Electrical System on page 33 for additional information on the charger TrackClean The TrackClean module adds a telemetry module at the front left of the battery bay This module receives discrete inputs from various circuits in the machine and reports them via cellular network to the machine s administrator The mo...

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