PowerBoss ADMIRAL 30 Service Manual
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PowerBoss ADMIRAL 30 Service Manual

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ADMIRAL 30 & 32

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Summary of Contents for PowerBoss ADMIRAL 30

  • Page 1 SERVICE MANUAL ADMIRAL 30 & 32...

  • Page 2: Table Of Contents

    CONTENTS • 1 Remarks • 2 General – 2.1 Setting – 2.2 Brief description – 2.2.1 Vacuuming OFF/soiled water tank full – 2.2.2 Initial position of machine • 3 Check and set machine type, LDS and options, view and • delete last error –...
  • Page 3 CONTENTS • Particular settings according to customer’s requirements (last error display and water stage selection) • • Display of last error • Water stage when start scrubbing • Water stage when start cleaning with green ADMIRAL key • Water stage when start cleaning with green bordered key •...

  • Page 4: Remarks

    1. REMARKS • Caution: • Before working at the machine make sure that no voltage applies (disconnect battery plug); except for cases of current and voltage measurement. • When replacing the stripe fuses only loosen the screws. Do not remove them completely to avoid short-circuit hazard.

  • Page 5: General

    2. GENERAL •The ADMIRAL 30/32 uses a service display integrated in the hourmeter display. When turning the key switch ON, a 4-digit display will appear for about 3 seconds, describing the software version (e.g. 3.017), then another 4-digit display may appear which repeats the last error, followed by the hourmeter display.

  • Page 6: Setting

    2.1 SETTINGS The following settings on the control unit (A1)/control panel of each machine must be defined and checked: • machine type • LDS (low discharge signal sender) • options • delete last error display after elimination • program variants with a given drive rheostat position Settings via control panel which may be defined by the customer: •...

  • Page 7: Brief Description

    2.2 BRIEF DESCRIPTION The following electronic modules control the machine: • control unit (A1) • power electronic (A2), referred to as ”module 1” in the diagrams • drive control unit (A4) • control panel (A3) The control unit (A1) ensures all control and monitoring functions in the machine except for the drive control unit.

  • Page 8: Vacuuming Off/Soiled Water Tank Full

    2.2.1 VACUUMING OFF/ soiled water tank full The vacuuming function is turned OFF either by operator’s key action or automatically when the signal “Soiled water tank full” applies. Operator turns vacuuming OFF: • squeegee is lifted • suction motor turned OFF with a delay of 15 seconds Turned OFF when tank full: •...

  • Page 9: Initial Position Of Machine

    2.2 INITIAL POSITION OF THE MACHINE •After turning ON the machine, all components are set to “initial position” after the seat contact switch has closed. •The lifting elements will lift if they have not been turned OFF in top final position by the micro switch integrated in the lifting element.

  • Page 10: Check And Set Machine Type, Lds And Options, View And Delete Last Error

    3. CHECK AND SET MACHINE Check and set machine type, LDS and options, view and delete last error The settings described in this paragraph must by all means be checked and modified if required and in particular after replacing the electronic module.

  • Page 11: Check And Set Machine Type

    3. CHECK AND SET MACHINE TYPE • Check and set machine type, LDS and options, view and delete last error • Figure 2 shows the control panel of B750R with cylinder brush (7090.20/40). For Internal Office Use Only...
  • Page 12 3. CHECK AND SET MACHINE TYPE Entry in the programming step 1. Turn OFF machine with the key switch. 2. Depress "G" and "H" keys the same time and hold, turn ON with the key switch. 3. Hold both keys until a number (software version) appears in the display, then release both keys.
  • Page 13 3. CHECK AND SET MACHINE TYPE “N” Software version, next display appears automatically Machine type setting: 9 stands for B750R Option settings LDS setting (in relation to the battery type) Display of last error and reset “L” For Internal Office Use Only...
  • Page 14 3.1 CHECK AND SET MACHINE TYPE 1. Setting the correct machine type is absolutely necessary. To do so use DIP-switch A on the control unit (A1). 2. For the B750R type the first and the last bar have to be positioned in the top line and the second and third bar in the bottom line.

  • Page 15: Check And Set Options

    3.2 CHECK AND SET OPTIONS 1. The setting of all options on the DIP-Switch B of the control unit (A1) is absolutely necessary. 2. The DIP-switches are assigned as follows: 1 - 3: unassigned, i.e. “OFF” plate brush or cylinder brush unit (ON = cylinder brush;...
  • Page 16 3.2 CHECK AND SET OPTIONS Control unit (A1) For Internal Office Use Only...
  • Page 17 3.3 CHECK AND SET LDS The LDS Must set to the correct battery type. The LDS is set following this chart. Display Code ® PowerBoss Lead PowerBoss Lead PowerBoss PowerBoss European Acid Deep Cycle Acid Deep Cycle Industrial – Industrial –...

  • Page 18: Check And Set Lsd

    3.3 CHECK AND SET LDS “1” means ON; “0” means OFF “Foreign” means all batteries not delivered by Hako. Reset voltage: approx. 25.5V. •Caution: The maintenance-free Gel batteries are no longer differentiated by the manufacturer (Sonnenschein or Deta). The setting is related to the type of battery used e.g.

  • Page 19: View And Delete Last Error In Display

    3.4 VIEW AND DELETE LAST ERROR IN DISPLAY •Viewing 1. Depress “N” key three times, the 4-digit error code with flashing dots will appear (last and eliminated error). 2. Quit the session by turning the key switch OFF (must not be executed when passing to “deleting”).

  • Page 20: Setting (Check And Set)

    4. PROGRAM VARIOUS Program various cleaning cycles as a function of drive rheostat setting (check and set) For Internal Office Use Only...
  • Page 21 4. PROGRAM VARIOUS Checking 1. Turn machine OFF with key switch. 2. Depress "N" and "O" key the same time and hold, turn key switch ON 3. Hold both keys until a number (software version) appears in the display, thereafter release both keys. 4.

  • Page 22: Program Functions

    5. PROGRAMS FUNCTIONS The description of program functions requires the “brushing” and/or “vacuuming” function being turned ON. All programs allow normal cleaning or vacuuming in the ‘forward’ drive rheostat position. The following chart shows the differences for ‘neutral’ and ‘reverse’ drive rheostat position. ( up to software version 3.017).
  • Page 23 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes and water ON Squeegee OFF + lifted Reverse Brushes and water ON Squeegee OFF + lifted Neutral Brushes and water OFF Vacuuming remains ON Reverse Brushes and water ON...
  • Page 24 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes and water OFF Squeegee OFF + lifted brush head lifted (3 seconds delay for brushes to prevent brushes from being turned OFF when switching from forward to reverse mode)
  • Page 25 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes and water OFF Squeegee OFF + lifted (3 Sec. delay) Reverse Brushes and water ON Squeegee OFF + lifted and lowered Neutral Brushes and water OFF, Vacuuming remains ON...
  • Page 26 5. PROGRAMS FUNCTIONS On from software version 3.018 additional program functions are implemented to the machine control. This allows to work on sensitive floor without leaving marks on the floor. Remark: as a result of this short switch off times, the life time of brush motor and lifting element will decrease.
  • Page 27 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes ON, water OFF Vacuuming remains ON Reverse Brushes and water ON Squeegee OFF + lifted Neutral Brushes and water OFF Vacuuming remains ON Reverse Brushes and water ON...
  • Page 28 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes and water OFF Squeegee OFF + lifted brush head lifted (3 seconds delay for brushes to prevent brushes from being turned OFF when (long switching from forward...
  • Page 29 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes and water OFF Vacuuming remaines ON (3 Sec. delay) (long brush head lifted switch OFF Reverse Brushes and water ON Squeegee OFF + lifted time) and lowered...
  • Page 30 5. PROGRAMS FUNCTIONS • Program Drive Function with a given drive rheostat code rheostat setting Brush head Squeegee Neutral Brushes and water OFF Vacuuming remaines ON (less than 1 sec) (short switch OFF Reverse Brushes ON Squeegee OFF + lifted time) water OFF Neutral...
  • Page 31 5. PROGRAMS FUNCTIONS The water supply, brush or vacuuming function LED or the Hakomatic key (green key) is flashing if the selected function is turned OFF due to the drive rheostat setting. *The brush motors switch off with a delay of 3 seconds. This delay precludes switching off in case of direction alteration but allows it in neutral rheostat position.

  • Page 32: Particular Settings According To Customer's Requirements (Last Error Display And Water Stage Selection)

    6. PARTICULAR SETTINGS Particular settings according to customer’s requirements (last error display and water stage selection) The settings described in this paragraph may be modified following the customer’s requirements. The settings made in the factory may be altered. For Internal Office Use Only...
  • Page 33 6. PARTICULAR SETTINGS Entry in the programming step 1. Turn machine OFF with key switch. 2. Depress “G” and “O” key the same time and hold, turn key switch ON. 3. Hold both keys until a number (software version) appears in the display, then release both keys.
  • Page 34 6. PARTICULAR SETTINGS • • currently programmed setting water stage setting error display For Internal Office Use Only...

  • Page 35: Display Of Last Error

    6.1. DISPLAY OF LAST ERROR 1. Select required setting with “L” and “N” keys. 2. The bar of the setting to be modified is flashing. 3. Move the bar up or down with “M” key. = ON = error code (of eliminated error) will appear for approx.
  • Page 36 6.2. WATER STAGE WHEN STARTING TO SCRUB 1. Select required setting with “L” and “N” keys. 2. The bar of settings to be modified is flashing. 3. Move the bar up or down with “M” key. Up = = last selected stage is set Down = OFF = middle stage is always set 4.
  • Page 37 6.3 WATER STAGE Water stage when start cleaning with green Hakomatic key Select required setting with “L” and “N” keys. The bar of settings to be modified is flashing. Move the bar up or down with “M” key. Up = = last selected stage is set Down = OFF = 2nd stage is always set...

  • Page 38: Water Stage When Start Cleaning With Green Bordered Key

    6.4 WATER STAGE WHEN STARING TO CLEAN Water stage when start cleaning with green bordered key (increased brush pressure) 1. Select required setting with “L” and “N” keys. 2. The bar of settings to be modified is flashing. 3. Move the bar up or down with “M” key. Up = = last selected stage is set Down =...

  • Page 39: Settings On Power Electronic (A2)

    7. SETTINGS ON POWER ELECTRONICS (A2) The correct DIP-switch settings on the power electronic (A2) are necessary since they have an influence on the electronic circuit breaker values for the lifting elements (brush head and squeegee). DIP-switch settings: 1: OFF 2: ON Circuit breaker values: Brush head:...

  • Page 40: Water Pump

    8.0 WATER PUMP For check purpose of the water pump function, the voltage of the different stages be measured on power electronic module (A2:X2:6+7). In case of measurement with measuring device Fluke 87, water in tank but suction turbine turned OFF, the result is: plate brush cylindrical brush stage 1: xxx V...
  • Page 41 8. WATER PUMP •A good basis is measuring the water quantities. •Let the pump run and measure the delivered quantity of water per minute. •The quantities are indicated in the operating instructions as follows: • Stage • • plate • brush •...

  • Page 42: Water Pump Standstill Recognition

    8.1 WATER PUMP STAND STILL RECOGNITION If the pump does not deliver water to the brushes due to clogging of the hoses the so-called standstill recognition is activated. Automatic standstill recognition for water pump: The electronic module allows protection of the water pump if the pump does not deliver correctly.

  • Page 43: Diagnosis Led For Drive Module

    9. DIAGNOSIS LED for DRIVE MODULE The LED is located on the drive module LED shows Malfunction Remarks Drive module is Voltage supply interrupted inoperable Check fuses and wiring; No release signal at A4:X51:2 Drive module is Drive module function OK serviceable 2 signals Wrong start sequence...
  • Page 44 9. DIAGNOSIS LED for DRIVE MODULE LED shows Malfunction Remarks 3 signals “M” and “B-” Check cable to drive motor; short-circuited check carbon brushes; Check chassis of the machine for potential, if OK but error code displayed, replace the drive module For Internal Office Use Only...
  • Page 45 9. DIAGNOSIS LED for DRIVE MODULE LED shows Malfunction Remarks 4 signals Direction contactor Do contactors switch and do stuck the correct direction selection signals apply at the drive control unit? Check motor connections for short circuit or contact to chassis and remedy if required since chassis has to be free of potential;...
  • Page 46 9. DIAGNOSIS LED for DRIVE MODULE LED shows Malfunction Remarks 5 signals Direction contactors do Do contactors switch and do not close or no the correct direction selection connection to drive signals apply at the drive motor control unit? Check cable to drive motor; check carbon brushes;...
  • Page 47 9. DIAGNOSIS LED for DRIVE MODULE LED shows Malfunction Remarks 7 signals Battery low, Measure battery voltage less than 13 Volts under load (measure at input of the drive control unit as well), Check connections and fuses For Internal Office Use Only...
  • Page 48 9. DIAGNOSIS LED for DRIVE MODULE LED shows Malfunction Remarks 8 signals Excessive temperature Is travel drive smooth? of drive module Correct position of parking (70 °C or more) brake? Excessive uphill riding? Measure operating voltage of the motor line “A2” at full throttle on level ground using a clip-on current transformer (approx.

  • Page 49: Signal Measuring At The Drive Control Unit

    9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT Check the following items when testing the drive control unit. If the respective signals do not apply, the drive control unit does not work sufficiently. In the circuit diagram the drive control unit is designated with A4. When testing the drive control unit, be supported by the circuit diagram and check connections there since the complete procedure became more complex by releasing via A1, closing the drive rheostat switch, the direction switch and the K4 relay.
  • Page 50 9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT 1. Self-test Before the drive control unit is operable, it executes a self-test. This self-test starts automatically after switching on the machine with key switch. If, during this self-test, the drive control unit detects an error, the LED on the unit flashes to signal non-operability.
  • Page 51 9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT 2. Drive direction The drive direction is set via the direction selector switch S7 but closing of this switch alone is not sufficient for signalling the selection to the drive control unit. Simultaneous releasing of A1, closing of the drive rheostat switch S8 and the K4 relay switching contact is required.
  • Page 52 9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT Drive rheostat switch S8: This switch is located at the accelerator and is closed after pedal actuation. Then the battery plus signal is transferred to the coil of the K4 relay and the relay closes the switching contact.
  • Page 53 9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT Speed The speed attained directly depends on the drive rheostat which is actuated via the accelerator pedal. The max. speed with full throttle is: Forward ride: approx. 7.1km/h Reverse ride: approx. 3.8 km/h. With a free-wheeling drive wheel (jacked machine and cold drive motor), the parameters are as follows: Forward ride:...
  • Page 54 9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT Forward ride: attaining 100% of the final speed: In order to attain 100% of the final speed in forward ride, the battery minus signal has to be transferred from the A1:X3:3 contact of the control unit to the drive control unit contact A4:X51:11.
  • Page 55 9.1 SIGNAL MEASURING AT THE DRIVER CONTROL UNIT 50% of the speed apply if: Driving in reverse mode The LDS displays low battery status (red LED of LDS lights) The thermal switch of the drive motor has opened, i.e. the motor is overheated (error code 3.4.5.1.
  • Page 56 9.2 SETTING THE ACCELERATOR PETAL Setting the drive rheostat switch S8 and the drive rheostat ‘R1‘ at the accelerator pedal is required. Caution: Before proceeding to settings at the drive control unit make sure that the drive wheel rotates freely and has no contact with the ground. The setting work has to be executed with the greatest precaution possible to preclude injuries of persons or a...
  • Page 57 9.2 SETTING THE ACCELERATOR PETAL The ‘S8’ drive rheostat switch has to be set such that it is not activated in neutral pedal position, i.e. a small gap between the actuation roller of the switch and the eccentric disk of the accelerator is required. If the accelerator pedal is pressed down, the switch should be actuated (clicking sound) but without bending the actuation lever.
  • Page 58 9.2 SETTING THE ACCELERATOR PETAL Before further setting of the drive rheostat use a voltmeter to measure at the drive control unit between X51 Pin 3 and Pin 9. When the accelerator pedal is not pressed down, the voltage has to amount to U ≈...

  • Page 59: A4:X51 Plug Assignment

    9.3 A4:X51 PLUG ASSIGNMENT Plug assignment (measured to battery minus) (X51) not connected Drive control unit release; U = 24V or battery voltage if key switch has closed Drive rheostat; U = 0V Forward drive direction; U = 0V after forward mode has been selected and ‘S8’...
  • Page 60 9.3 A4:X51 PLUG ASSIGNMENT • Plug assignment (measured to battery minus) (X51) • • not connected • • not connected • • not connected • For Internal Office Use Only...
  • Page 61 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 1.2.5.2. Thermal protector of Brush motor fan ok? brush motor Wire broken (break contact circuit)? Measure operating current (approx. 36.5A max; to preclude motor overload due to uneven ground conditions 32A max.
  • Page 62 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 1.2.6.3. Block protection of Jammed? brush head lifting Measure operating current element (5.0A max.) Correct Dip switch setting on power electronic module (A2)? 1.4.6.1 Block protection of Jammed? squeegee lifting Measure operating current...
  • Page 63 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 1.2.5.2. Thermal protector of Brush motor fan ok? brush motor Wire broken (break contact circuit)? Measure operating current (approx. 36.5A max; to preclude motor overload due to uneven ground conditions, 32A max.
  • Page 64 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 1.2.6.3. Block protection of Jammed? brush head lifting Measure operating current element (5.0A max.) Correct Dip switch setting on power electronic module (A2)? 1.4.6.1 Block protection of Jammed? squeegee lifting Measure operating current...
  • Page 65 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 3.1.6.1. Fuse of power Check all fuses, electronic module (A2) If the code for blocking protection of lifting element for brushes or squeegee appears, check these; Check water pump and water valve if 10A/80V fuse was defective...
  • Page 66 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 3.2.1.1. LDS defective Measure approx. battery voltage on control unit A1.X2 PIN 1 and 4 , if voltage is not ok check plug contacts for corrosion etc. and cable connection up to battery plug;...
  • Page 67 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 3.4.5.1. Thermal protector of Is drive motor fan OK? Does drive motor travel drive respond smoothly? Parking brake setting ok? Did you perform an extended uphill ride? Wire broken (wiring to thermal switch or connectors badly plugged?
  • Page 68 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 4.1.2.1. Power electronic Check connection between module (A2) not control unit (A1) and power recognised electronic module (A2) control unit A1:X10:PIN 1 and PIN 2 and power electronic module (A2:X22:PIN 1 and 2);...
  • Page 69 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 4.1.3.1. Power electronic Check connection between module (A2) no control unit (A1) and power response (timeout) electronic module (A2) control unit A1:X10:PIN 1 and PIN 2 and power electronic module (A2:X22:PIN 1 and 2);...
  • Page 70 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display CAN bus error Check 2 A / 32 V circuit 4.6.2.1. (no response - timeout) breaker of control unit (A1), check wiring between A1:X10:PIN 1 and PIN 2 and power electronic module (A2:X22:PIN 1 and 2) as well as the contacts and plugs, check voltage supply of power...
  • Page 71 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 4.6.3.1. CAN bus error Check wiring between (bus error) A1:X10:PIN 1 and PIN 2 and power electronic module (A2:X22:PIN 1 and 2) as well as the contacts and plugs, check voltage supply of power electronic module (A2) and control unit (A1);...
  • Page 72 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 4.6.3.2. CAN bus error Check wiring between (overrun) A1:X10:PIN 1 and PIN 2 and power electronic module (A2:X22:PIN 1 and 2) as well as the contacts and plugs, check voltage supply of power electronic module (A2) and control unit (A1);...
  • Page 73 10. ERROR REFERENCE CHART WITH INFORMATION ON SERVICE DISPLAY Error code Malfunction Remarks in display 4.6.5.1. Incorrect machine Check machine type setting of type setting Dip switch A on control unit A1 4.6.5.2. Set option impossible Too many options set at Dip switch B on control unit A1? 4.6.5.3.
  • Page 74 11. ADJUSTMENT OF DISC BRAKE For Internal Office Use Only...

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Admiral 32

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